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Sterling A0554831 manual

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Table of contents for the manual

  • Page 1

    2–40 hp Portable Chillers Part Number: A0554831 Bulletin Number: SC2-610C.10 Effective: 4/3/2008 Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing prog[...]

  • Page 2

    2-40 HP Portable Chillers ii Shipping Information Unpacking and Inspection You should inspect your equipm ent for possible shipping damage. Thoroughly check the equipment for any damage that m ight have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc. In the Event of Shipping Damage Accor[...]

  • Page 3

    2-40 HP Portable Chillers iii Table of Contents CHAPTER 1: SAFETY ................................................................. 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ..........................................................[...]

  • Page 4

    2-40 HP Portable Chillers iv 3-11 Initial Start-Up.......................................................................................................... .. 28 CHAPTER 4: OPERATION ........................................................ 29 4-1 Panel Buttons, Indicator Lights, and Switches ........................................................[...]

  • Page 5

    2-40 HP Portable Chillers v Flow and Pressure Considerations...................................................................... 61 Recirculation Pump Specifications ...................................................................... 61 7-5 Remote Air-Cooled Chiller Configurations ...............................................................[...]

  • Page 6

    2-40 HP Portable Chillers Chapter 1: Safety 6 of 70 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in a pplying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective main[...]

  • Page 7

    2-40 HP Portable Chillers Chapter 1: Safety 7 of 70 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personal injury or equi pm ent damage when installing, operating, or maintaining this[...]

  • Page 8

    2-40 HP Portable Chillers Chapter 2: Functional Description 8 of 70 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for air- and water- cooled portable chillers. Model numbers are liste d on the serial tag. Make sure you know the model and serial number [...]

  • Page 9

    2-40 HP Portable Chillers Chapter 2: Functional Description 9 of 70 2-2 General Description Our portable chillers are reliable, accurate, a nd easy to use process cooling units. They are available in air-, water-, and remote air-cooled designs in a range of sizes from 2 to 40 tons. All are self-contained, fully portable and shi pped ready to use. ([...]

  • Page 10

    2-40 HP Portable Chillers Chapter 2: Functional Description 10 of 70 2-3 Standard Features Mechanical Features Compressor. Hermetic scroll compressors are used on 2 hp through 30 hp (1.49 through 23.37 kW) models. Semi-hermetic discus compress ors are used on the 35 hp and 40 hp (26.20 and 29.83 kW) models. Evaporator. Stainless steel copper brazed[...]

  • Page 11

    2-40 HP Portable Chillers Chapter 2: Functional Description 11 of 70 Electrical Features • Fully accessible NEMA 12-styl e electrical control enclosure • Single-point power and ground connection • Non-fused disconnect switch, lockable • Branch circuit fusing • 208-230/3/60 and 460/3/60 volt (consult factory for other voltages) • 208-230[...]

  • Page 12

    2-40 HP Portable Chillers Chapter 2: Functional Description 12 of 70 2-4 Safety Device s and Interlocks High/Low Thermostat Control The high/low thermostat is a cutout device that protects the chiller system in two ways. Stage one of the thermostat shuts down the compressor if the chilled process water/glycol temperature approaches the particular m[...]

  • Page 13

    2-40 HP Portable Chillers Chapter 2: Functional Description 13 of 70 Low Pressure Cutout This electro-mechanical cutout device opens th e compressor control circuit if refrigeration system compressor suction pressure drops below 15 psi. It automatically resets when refrigerant suction pressure reaches 30 psi. Note: The low pressure cutout is an aut[...]

  • Page 14

    2-40 HP Portable Chillers Chapter 2: Functional Description 14 of 70 2-5 Optional Features Options marked with “ * ” indicate options that can be factory installed or retrofitted in the field. Automatic Water Make-Up*. Not available on chillers less reservoir tank. Includes a pressure-regulating valve set at 3 to 5 psi, an electric water soleno[...]

  • Page 15

    2-40 HP Portable Chillers Chapter 2: Functional Description 15 of 70 Mounting Features. • Locking 5” swivel casters with brake, opti onal on air- and water- cooled 5 hp to 15 hp models • Mounting rails: standard on remote air-c ooled models, optional on other m odels • Mounting rails with feet Optional Operating Voltages. 380/3/50 volt avai[...]

  • Page 16

    2-40 HP Portable Chillers Chapter 2: Functional Description 16 of 70 Figure 1: Optional Pump Amperages Voltage Construction HP Full Load Amps Bronze Turbine .75 5.4 1 6.4 1.5 7.5 2 9.6 208-230/1/60 SS 3 12.7 Bronze Turbine .75 1.5 1 1.8 1.5 2.3 2 3.1 3 4.2 5 6.2 7.5 9.8 10 13.2 SS 15 19.0 2 2.7 3 4.5 5 6.6 460/3/60 Dual SS 7.5 9.0[...]

  • Page 17

    2-40 HP Portable Chillers Chapter 3: Installation 17 of 70 Chapter 3: Inst allation 3-1 Uncrating 2 hp to 5 hp m odels are shipped mounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 7.5 to 40 hp m odels are shipped mounted on a skid, enclosed in a plastic wrapper, and open-crated on all four sides and top. 1. Pry th[...]

  • Page 18

    2-40 HP Portable Chillers Chapter 3: Installation 18 of 70 3-3 Process Water Connections All of our portable chillers have two chille d water connections. The chilled water supply, labeled “To Process” is the outlet for the chille d water leading to the process being cooled. The chilled water return, labeled “From Process” is the inlet lead[...]

  • Page 19

    2-40 HP Portable Chillers Chapter 3: Installation 19 of 70 3-7 Condenser Considerations Water-Cooled Chiller Condensers Water-cooled portable chillers can use city wate r or tower water as a cooling medium. Make sure that all external piping and connections suppl ying and discharging water to and from the condenser are full size. You’ll make two [...]

  • Page 20

    2-40 HP Portable Chillers Chapter 3: Installation 20 of 70 Remote Air-Cooled Chiller Condensers Remote air-cooled portable chillers are shipped with nitrogen holding charge and a full charge of oil (excluding the am ount needed for field piping). The remote air condenser is shipped with a dry nitrogen charge. Verify that the holding charge has not [...]

  • Page 21

    2-40 HP Portable Chillers Chapter 3: Installation 21 of 70 System Configuration. The system can be configured in any of the arrangements shown on page 62 of the Appendix. The configurati on and distance between the chiller and the condenser affects pipe size, refrigerant charge, oil return, and oil charge. Therefore there are limitations that must [...]

  • Page 22

    2-40 HP Portable Chillers Chapter 3: Installation 22 of 70 Figure 2: Equivalent Length in Feet for Valves and Fittings Line Size Inches OD Globe Valve Equivalent Ft Angle Valve Equivalent Ft Short Radius Elbow Equivalent Ft Long Radius Elbow Equivalent Ft 1/2” 43 15 1.4 0.9 5/8” 55 18 1.6 1.0 7/8” 69 24 2.0 1.4 1 1/8” 87 29 2.7 1.9 1 3/8”[...]

  • Page 23

    2-40 HP Portable Chillers Chapter 3: Installation 23 of 70 Refrigerant Charge Determination. The approximate amount of re frigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller. Referring to Figure 5, determine the amount of charge based on the horsepower of the chiller and the [...]

  • Page 24

    2-40 HP Portable Chillers Chapter 3: Installation 24 of 70 3-8 Checking Motor Direction All of our portable chillers have their moto r rotations properly phased at the factory. If compressors, pumps, or fans are running in reverse rotation, disconnect and lock out the power source and reverse any two power lead s into the chiller disconnect switch.[...]

  • Page 25

    2-40 HP Portable Chillers Chapter 3: Installation 25 of 70 3-9 Water Reservoir All portable chillers shipped during the fall, winter , or spring, or those units that are shipped from stock are flushed at the factory with a water/ethylene glycol solution to prevent piping components prone to retaining water from fr eezing. During startup and when ad[...]

  • Page 26

    2-40 HP Portable Chillers Chapter 3: Installation 26 of 70 Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe r ce n t G ly c ol C u r v e s f or Fr e e ze P r ot e c tio n -60.0 -50.0 -40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 % Gl y col b y V ol um e Eth y le ne G ly c ol P r op ylene G l yc o l Exampl[...]

  • Page 27

    2-40 HP Portable Chillers Chapter 3: Installation 27 of 70 3-10 Automatic Water Make-Up Option The chiller may be connected to an automatic make-up sy stem if the optional package (float switch, pressure regulating, pipe fittings, sole noid valve and 1/2” NPT city water make-up connection) is factory installed. Refer to the typical piping schemat[...]

  • Page 28

    2-40 HP Portable Chillers Chapter 3: Installation 28 of 70 3-11 Initial Start-Up • Check the shipping papers against the serial tag to be sure chiller size, type and voltage is correct for the process that will be controlled. Portable chillers are built with a voltage specific compressor and cannot be re-wired for an alternate voltage. • Check [...]

  • Page 29

    2-40 HP Portable Chillers Chapter 4: Operation 29 of 70 Chapter 4: Operation 4-1 Panel Buttons, Indicator Lights, and Switches Microprocessor Controllers Standard chillers use a microprocessor-based PI D controller. These controllers are modular, self-contained units that can slide from their mounting ho using. They are factory set and adjusted; no[...]

  • Page 30

    2-40 HP Portable Chillers Chapter 4: Operation 30 of 70 Indicator Name Description SUB1 SUB 1 LED The orange SUB1 LED lights when the process temperature is three degrees or more below the “To Process” setpoint. The compressor then shuts down by means of a latching circuit, and it does not run again until the temperature at the “To Process”[...]

  • Page 31

    2-40 HP Portable Chillers Chapter 4: Operation 31 of 70 Figure 7: Typical Portable Ch iller Microprocessor Controllers PV SV OUT1 OUT2 MANU STOP RMT AT SUB1 AT E5CK OMRON[...]

  • Page 32

    2-40 HP Portable Chillers Chapter 4: Operation 32 of 70 Graphic Panel (See Figure 8 ) Indicator Name Description Compressor On Light The Compressor On light turns on whenever the compressor is operating. Low Temperature Light The Low Temperature light comes on if the process water/glycol temperature drops below the High/Low thermostat set point. Th[...]

  • Page 33

    2-40 HP Portable Chillers Chapter 4: Operation 33 of 70 Indicator Name Description Low Water Flow/Pressure Light The Low Water Flow/Pressure light comes on when the flow switch (pressure switch on 2 & 3 hp models) senses that the water/glycol flow rate through the evaporator has dropped below an acceptable level. The flow switch opens shutting [...]

  • Page 34

    2-40 HP Portable Chillers Chapter 4: Operation 34 of 70 Figure 8: Typical Graphic Panels (With E5CK Controller) (Eurotherm 3216 Controller) ON OFF CONTROL POWER A0554705 SILENCE ALARM COMPRE SSOR ON HOT GAS BY-PASS PUMP ON PUMP OVERLOAD LOW WATER FLOW/ PRESSURE LOW TEMPERATURE HIGH TEMPERATURE HIGH DISCHARGE TEMPERATURE HIGH REF RIGERAN T PRESSU RE[...]

  • Page 35

    2-40 HP Portable Chillers Chapter 4: Operation 35 of 70 4-2 Start-up 1. Turn on the chiller and put it under a process load. 2. Set the controller for the To Process temperature you want, using the Up Arrow button or the Down Arrow button located on the face of the controller. 3. Adjust the High/Low thermostat, located in the electrical enclosure, [...]

  • Page 36

    2-40 HP Portable Chillers Chapter 4: Operation 36 of 70 4-6 Programming the Electronic High/Low Thermostat The thermostat control is located in the chiller enclosure. The control has three control ke ys and a one-line, four-character LCD display. The thermostat control has a lockout slide switch to prevent tampering by unaut horized personnel. The [...]

  • Page 37

    2-40 HP Portable Chillers Chapter 4: Operation 37 of 70 Perform the following procedures to pro gram the electronic High/Low Thermostat control: Select Fahrenheit or Celsius 1. Press the Set key once to access Fahrenheit/Celsius mode. Factory set to F. Use the Up Arrow and Down Arrow keys to toggle between Fahrenheit and Celsius. Stage 1: Freeze Pr[...]

  • Page 38

    2-40 HP Portable Chillers Chapter 5: Maintenance 38 of 70 Chapter 5: Maintenance 5-1 Lubrication Grease all blower bearings, fan and blower m otors, and pump motors that do not have permanently sealed bearings. Remove the grease relief plug (motors only) before adding grease, add grease until a small amount pours out, and replace the plug when fini[...]

  • Page 39

    2-40 HP Portable Chillers Chapter 5: Maintenance 39 of 70 5-3 Maintaining the Condenser Dirty condenser heat exchange surfaces reduce sy stem capa city and efficiency. Air- and Remote Air-Cooled Chillers Brush or vacuum light dirt accumulations off th e aluminum condenser fins. Avoid bending or damaging them. Heavy dirt accumulations on th e fins m[...]

  • Page 40

    2-40 HP Portable Chillers Chapter 5: Maintenance 40 of 70 5-6 Preventative Maintenance Service Follow a systematic preventive maintenance pr ogram to help avoid costly down time. Call the Service Department to arrange a schedule of inspections. This service can be tailored to fit your maintenance requirements. These inspections include, but are not[...]

  • Page 41

    2-40 HP Portable Chillers Chapter 6: Troubleshooting 41 of 70 Chapter 6: T roubleshooting Problem Possible cause Solution No power. Check main disconnect, fuses, wiring, and power lead to unit. Wrong voltage supplied to unit. Voltage m ust be withi n plus or m inus 10% of nameplat e rating. Defective on/off switch. Replace. Replace control circuit [...]

  • Page 42

    2-40 HP Portable Chillers Chapter 6: Troubleshooting 42 of 70 Problem Possible cause Solution Plugged Y-St r a i ner Clean Hot gas not comi ng on Replace relay board on control bed hot gas coil Pump runs, co mpressor cycles at short intervals. Low water flow Install bypass between to-a nd-from process line Water/glycol m ixture inadeq uat e for pro[...]

  • Page 43

    2-40 HP Portable Chillers Chapter 7: Appendix 43 of 70 Chapter 7: Appendix 7-1 Returned Material Policy Credit Returns Prior to the return of any material, authorization must be given by the manufacturer . A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned material purchased [...]

  • Page 44

    2-40 HP Portable Chillers Chapter 7: Appendix 44 of 70 7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423- 3813 or call [262] 641 -8610, Fax [262] 641-8653 The ACS Customer Service Group will provide your compan y with genuine OEM qualit y parts manufactured to engi neering desig n specifications, which will maximiz [...]

  • Page 45

    2-40 HP Portable Chillers Chapter 7: Appendix 45 of 70 7-3 Drawings and Specifications 2 hp and 3 1/2 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50º F (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. Fo r 50 Hz applications, multiply capacit y b[...]

  • Page 46

    2-40 HP Portable Chillers Chapter 7: Appendix 46 of 70 5 hp and 7.5 hp Air-Cooled Portable Chillers Nominal operating paramet ers for air-co oled models are 50ºF (10º C) le aving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35º C) a mbient air. For 50 Hz applications , multiply capacity by 0.83 . Nom i nal 60 Hz capaci[...]

  • Page 47

    2-40 HP Portable Chillers Chapter 7: Appendix 47 of 70 10 hp and 15 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50º F (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications , multiply capacity by 0.83 . Nominal 60 Hz capacity flo[...]

  • Page 48

    2-40 HP Portable Chillers Chapter 7: Appendix 48 of 70 20 hp, 25 hp, and 30 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50º F (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications , multiply capacity by 0.83 . Nominal 60 Hz capa[...]

  • Page 49

    2-40 HP Portable Chillers Chapter 7: Appendix 49 of 70 2 hp and 3.5 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applica tions , multiply capacity by 0.83 . Nominal 60 Hz capacity[...]

  • Page 50

    2-40 HP Portable Chillers Chapter 7: Appendix 50 of 70 5 hp and 7.5 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applica tions , multiply capacity by 0.83 . Nominal 6 0 Hz capacit[...]

  • Page 51

    2-40 HP Portable Chillers Chapter 7: Appendix 51 of 70 10 hp and 15 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applica tions , multiply capacity by 0.83 . Nominal 6 0 Hz capacit[...]

  • Page 52

    2-40 HP Portable Chillers Chapter 7: Appendix 52 of 70 20 hp, 25 hp, and 30 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applica tions , multiply capacity by 0.83 . Nominal 6 0 Hz[...]

  • Page 53

    2-40 HP Portable Chillers Chapter 7: Appendix 53 of 70 40 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water tem perature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applica tions , multiply capacity by 0.83 . Nominal 6 0 Hz capacity flow rat[...]

  • Page 54

    2-40 HP Portable Chillers Chapter 7: Appendix 54 of 70 5 hp and 7.5 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remo te air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications , multiply capacity by 0.83 . Nominal 60 Hz[...]

  • Page 55

    2-40 HP Portable Chillers Chapter 7: Appendix 55 of 70 10 hp and 15 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remo te air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications , multiply capacity by 0.83 . Nominal 60 Hz[...]

  • Page 56

    2-40 HP Portable Chillers Chapter 7: Appendix 56 of 70 20 hp through 40 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remo te air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications , multiply capacity by 0.83 . Nominal 6[...]

  • Page 57

    2-40 HP Portable Chillers Chapter 7: Appendix 57 of 70 Remote Condenser Assembly Models To convert inches to cm , multiply dimension by 2.5 4. Fan(s) d e f Remote Condenser Re frigeration g Each Totals e f Overall Dimensions Connections Charge HP Dia. Motor Amps Air flow Net wt. Length W idth Height Mtg. Discharge Liquid R-22 in. hp c 460V Fans cfm[...]

  • Page 58

    2-40 HP Portable Chillers Chapter 7: Appendix 58 of 70 7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves DWG. No. A0554823[...]

  • Page 59

    2-40 HP Portable Chillers Chapter 7: Appendix 59 of 70 50 Hertz Pump Curves DWG. No. S0554823[...]

  • Page 60

    2-40 HP Portable Chillers Chapter 7: Appendix 60 of 70 Evaporator Water Pressure Drop Tables Note: A recirculation pump is required for flows greater than the maximum or less than the minimum indicated. Note: Process flow less than or greater than the flow rates shown below requires a recirculation pump. Pressure drops in Δ P, psig and kPa 2 HP 3.[...]

  • Page 61

    2-40 HP Portable Chillers Chapter 7: Appendix 61 of 70 Evaporator Flow and Pressure Considerations Model c Design flow Desig n Δ P Standard pump power To Process pressure gpm lpm psig kPa hp kW psi kPa bars -A, 2 hp 4.6 17.5 4.4 30.4 1 0.746 34.1 235.3 2.4 -A, 3.5 hp 7.9 29.9 4.9 33.7 1 0.746 33.0 227.5 2.3 -A, -R, 5 hp 11.6 43.8 2.0 13.7 1 0.746 [...]

  • Page 62

    2-40 HP Portable Chillers Chapter 7: Appendix 62 of 70 7-5 Remote Air-Cooled Chiller Configurations[...]

  • Page 63

    2-40 HP Portable Chillers Chapter 7: Appendix 63 of 70 7-6 Typical Ductwork for Air-Cooled Chillers *See specification tables on pages 45-48 for air flow and pressure capacities. When locating your air-cooled portable chiller a nd designing its ductwork, note any potential high temperature conditions when discharging into your bu ilding and any neg[...]

  • Page 64

    2-40 HP Portable Chillers Chapter 7: Appendix 64 of 70 7-7 Piping Diagrams Central and Gravity Return Piping with Standpipe Diagram[...]

  • Page 65

    2-40 HP Portable Chillers Chapter 7: Appendix 65 of 70 Typical Piping Schematic, 2 and 3 1/2 hp Models μ[...]

  • Page 66

    2-40 HP Portable Chillers Chapter 7: Appendix 66 of 70 Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models[...]

  • Page 67

    2-40 HP Portable Chillers Chapter 7: Appendix 67 of 70 Typical Piping Schematic, 5 hp through 40 hp, Two-Pump Models μ[...]

  • Page 68

    2-40 HP Portable Chillers Chapter 7: Appendix 68 of 70 Typical Piping Schematic, 5 hp through 40 hp, No-Pump Models[...]

  • Page 69

    2-40 HP Portable Chillers Chapter 7: Appendix 69 of 70 Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models[...]

  • Page 70

    2-40 HP Portable Chillers Chapter 7: Appendix 70 of 70 7-8 Electrical Schematics Typical Electrical Subpanel Please refer to your owner’s information packet for more details regarding your specific unit. DWG: A0562434[...]