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I.O.M. #075 11/05

INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE

TEMPTEK, INC.525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277 Service Department fax: 317-885-8683

www.Temptek.come-mail: [email protected]

with CF-1 Instrument

Page: 2

INSTRUCTION MANUALCF Series Portable Chiller

5 - 40 TonsAir-Cooled & Water-Cooled

COVERING

INSTALLATIONOPERATION

MAINTENANCE

TEMPTEK, INC.525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: 317-881-1277 Service Department fax: 317-885-8683

www.TempTek.come-mail: [email protected]

CF Series Portable Chillers with CF-1 Instrument

Page: 4525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277

Service Department Fax: 317-885-8683Website: www.Temptek.com

Email: [email protected]

TABLE OF CONTENTS

1.0 GENERAL 71.1 Introduction 81.2 Unit location 81.3 Efficiency 81.4 Safety 91.5 Clean air act 91.6 Miscellaneous 9

2.0 INSTALLATION 13 2.1 General 142.2 To and From process connections 142.3 Water supply connection 152.4 Air-cooled condenser 152.5 Water-cooled condenser 172.6 Electrical connection 18

3.0 OPERATIONS 213.1 General 223.2 Start up/operations procedure 233.3 Instrument/operation 263.4 Shut down procedure 30

4.0 TROUBLESHOOTING 314.1 Unit Will Not Start 324.2 Compressor Hums But Will Not Start 324.3 Shuts Off On High Pressure 324.4 Shuts Off On Low Pressure 334.5 Compressor Shuts Off On Internal Overload 344.6 Low Or No Process Pressure Or Water Flow 344.7 Cooling Capacity Inadequate 344.8 Sensor 354.9 Coolant Pump 354.10 Crankcase Heater 354.11 Chiller Controller 35

5.0 MAINTENANCE 375.1 Warranty service procedure 385.2 Periodic preventative maintenance 385.3 Special maintenance 395.4 Solenoid valve service 405.5 Pump seal service 425.6 Checking the refrigerant charge 455.7 Proper cleaning procedure for brazed plate evaporators 45

6.0 COMPONENTS 476.1 Water system 486.2 Refrigeration system 48





7.0 RELATED DRAWINGS 517.1 Mechanical Schematic : Water-Cooled : 5 - 10 Tons 527.2 Mechanical Schematic : Water-Cooled : 15 - 40 Tons 537.3 Mechanical Schematic : Air-Cooled : 5 - 10 Tons 547.4 Mechanical Schematic : Air-Cooled : 15 - 30 Tons 557.5 Typical Electrical : Air-Cooled 567.6 Typical Electrical : Water-Cooled 577.7 Physical Schematic : Air-Cooled : 7.5 - 10 Tons 587.8 Physical Schematic : Air-Cooled : 5 Tons 597.9 Physical Schematic : Water-Cooled 607.10 Duct Schematic for Air-Cooled Chillers 61

8.0 APPENDIX 638.1 Operations below 48°F 648.2 Water quality control 658.3 Inhibited propylene glycol 658.4 Sensor current vs temperature 658.5 Refrigerant pressure-temperature chart 668.6 Chiller capacity and derate chart 67

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THIS PAGE INTENTIONALLY BLANK


1.0 GENERAL1.1 INTRODUCTION1.2 UNIT LOCATION1.3 EFFICIENCY1.4 SAFETY1.5 CLEAN AIR ACT1.6 MISCELLANEOUS








1.1 INTRODUCTION

A. This manual covers portable chillers from 5 to 40 tons.

B. When calling for assistance from the Manufacturer’s ServiceDepartment, it is important to know the model and serial number ofthe particular unit. The model number encodes critical unitinformation which is helpful in any attempt to troubleshoot operatingdifficulties. The serial number allows the service team to locatemanufacturing and testing records which can have additionalinformation relating to a particular unit.

1.2 UNIT LOCATION

A. For air-cooled and water-cooled models:

1. These units are designed for indoor use only.

2. For most efficient operation, locate the chiller in a clean, dryand well ventilated environment.

B. For air-cooled models:

1. The unit has an air-cooled refrigerant condenser. For air-cooled condensers, a motor driven fan (on models from 5 to15 tons) or a centrifugal blower (on models from 15 to 30tons) generates air flow through the condenser to removeheat from the refrigerant system. The air cooled condenseron the unit will discharge a maximum of 15,000 BTU’s perhour per ton of cooling.

2. The unit must have a minimum entering air temperature of60°F and a maximum entering air temperature of 95°F forefficient operation.

3. The unit must have a minimum of two feet clearance at theair intake and six feet at the vertical exhaust air discharge.

4. The unit must have all enclosure panels in place beforeoperating compressor. Air will not be drawn through thecondenser coil if they are not in place. This will cause thecompressor to lockout on the high pressure safety fault.

1.3 EFFICIENCY

A. Long term efficiency of operation is largely determined by propermaintenance of the mechanical parts of the unit and the waterquality. The Manufacturer recommends filtering where required toprevent solids from plugging critical parts (pumps, heaters, seals forexample). The Manufacturer highly recommends the services of acompetent water treatment specialist be obtained and his





recommendations followed. The Manufacturer accepts noresponsibility for inefficient operation, or damage caused by foreignmaterials or failure to use adequate water treatment.

1.4 SAFETY

A. It is important to become thoroughly familiar with this manual andthe operating characteristics of the unit.

B. It is the owner’s responsibility to assure proper operator training,installation, operation, and maintenance of the unit.

C. Observe all warning and safety placards applied to the chiller.Failure to observe all warnings can result in serious injury or deathto the operator and severe mechanical damage to the unit.

1.5 CLEAN AIR ACT

A. The unit contains HCFC-22 (chlorodifloromethane). This is a class2 substance.

B. Effective July 1, 1992, it is unlawful for any person in the course ofmaintaining, servicing, repairing, or disposing of refrigerationequipment to knowingly vent or otherwise dispose of any class 2substance used as a refrigerant in the manner which permits suchsubstance to enter the atmosphere.

C. De minimis releases associated with good faith attempts torecapture, reclaim or recycle such substance shall not be subject tothe prohibition set forth in the preceding paragraph.

1.6 MISCELLANEOUS

A. The unit is designed to circulate temperature stabilized fluid throughthe process resulting in process temperature control.

B. The ability of the unit to maintain process temperature control issignificantly affected by the method of installation as outline insection 2 of this manual.

C. If the operator has any questions concerning the location andoperation of the unit, contact the The Manufacturer’s ServiceDepartment.





Air-Cooled.

Water-Cooled.

Air-Cooled Model.

Pressure Gauges

Cover Panel

Enclosure Panel

Electrical PanelEnclosure

Casters

Instrument

Caster

Liquid Receiver

Compressor

Liquid Line Solenoid

Refrigerant Site Glass

Fan Motor

Protective Fan Shroud

Air Discharge

Hot Gas Bypass Valve

Pump

Expansion Valve

Insulated Reservoir Tank





Condenser Water-Out Connection

Reservoir Make-UpConnection

Condenser Water-In Connection(optional)

Condenser WaterRegulator Valve

From Process Connection

Reservoir

Optional Reservoir Sight Glass

To Process Connection

Pump

Caster

Condenser

Electrical Panel

Compressor

Refrigerant Sight Glass

Expansion Valve

Make-Up Valve

Water-Cooled Model.

Page: 12






2.0 INSTALLATION2.1 GENERAL2.2 TO AND FROM PROCESS CONNECTIONS2.3 WATER SUPPLY CONNECTION2.4 AIR COOLED CONDENSER INSTALLATION2.5 WATER-COOL CONDENSER INSTALLATION2.6 ELECTRICAL CONNECTION





2.1 GENERAL

A. All process piping materials (such as hose, rigid piping, valves orfilters) used in process water piping circuitry must be rated for100°F minimum temperature and 100 PSI minimum pressure.

B. All such materials must have the equivalent or larger diameter ofthe particular process connection that length of process waterpiping is connected to.

2.2 TO AND FROM PROCESS CONNECTIONS

A. Connect the ‘TO PROCESS’ to the ‘water in’ manifold on the moldor process.

B. Connect the ‘FROM PROCESS’ port to the ‘water out’ port on theprocess manifold.

C. Process water piping circuitry should be designed to avoid anexcessive use of elbows and/or lengths of pipe or hose. If hose isthe material of choice, avoid tight twists or curls and excessivelengths.

D. Valves and filters may be installed in the process water pipingcircuitry to facilitate service and maintenance provided that suchdevices maintain the full inside diameter of the process connection.If installed, all such devices must be open and clean during unitoperation.

Air-cooled model shown.

From Process :Connect to ‘Water Out’

port on process manifold Water Make-Up :Connect to plant’s citywater source.To Process :

Connect to ‘Water In’ porton process manifold





2.3 WATER SUPPLY CONNECTION

A. The automatic water supply make-up system continually monitorsthe reservoir tank and fills it when needed. Connect as follows:

1. Connect the chiller’s ‘WATER SUPPLY’ port to the plant’scity water source.

2. Minimum water supply pressure requirement is identified onthe equipment data plate. This is normally 20 psi.

3. Be certain to use a water supply line equipped with a backflow prevention device to prevent contamination of potablewater.

2.4 AIR COOLED CONDENSER

A. Air-cooled condensers require ambient air temperatures between60°F and 95°F for efficient operation. Operating above 95°F mayresult in elevated condensing pressures and eventual shut-down onthe high pressure safety switch. In such cases, a water assist unitmay be necessary for operations. Air temperatures below 60°F mayresult in below normal condensing pressures and poor condensing.In such cases, a low-ambient damper assembly is required. Checkwith the Manufacturer’s service department for more information onoperating with ambients air temperatures above 95°F or below 60°F.

Water-Cooled model shown.

To Process Connection

From Process Connection

Water Supply Connection

Condenser Water-Out Connection

Condenser Water-In Connection(with optional water regulator valve)





B. Air flow is generated by the motormounted fans (figure 2.4A) orcentrifugal blowers (figure 2.4B). Airflow is from the outside of the chiller,through the condenser andexhausted through the top of theunit. On centrifugal blowers models,exhaust air can be ducted outside ofthe plant’s interior environment.Special duct work is required and aHVAC contractor should beconsulted for sizing and materialspecifications. Exhaust air can notbe ducted on motor mounted fanmodels.

C. A free air space of at least two (2)feet is required at the condenserintake and six (6) feet at thecondenser discharge to allow forproper air flow.

D. At full load, the chiller will dischargeapproximately 15,000 BTU’s perhour per ton of cooling.

E. On blower units, air dischargeduct work should be sized by aqualified HVAC engineer.Sizing shall be according torated CFM at the staticpressure of .90 inches ofwater. See figure 2.4C at right.

F. On blower units, a dampercontrol assembly isrequired in lowambient temperatureareas or whenoutdoor air make-upis used. Theassembly works inconjunction withrefrigerant headpressure to regulateair flow to maintainproper refrigeranthead pressure whencondenser intake airtemperature will beless than 60°F. Seefigure 2.4D to theright.

Figure 2.4ATypical fan assembly

Figure 2.4BTypical blower assembly

Figure 2.4C

Figure 2.4D





G. All air cooled units must have all enclosure panels in place beforeoperating compressor. Air will not be drawn through the condensercoil if they are not in place. This will cause the compressor tolockout on the high pressure safety fault.

2.5 WATER-COOLED CONDENSER

A. Connect the ‘CONDENSER WATERIN’ port to the plant’s city watersupply or tower system supply.

1. Required consumption froma city water source is 1.5gpm at 65°F per ton of ratedcapacity.

2. Required consumption for atower water source is 3 gpmat 85°F per ton of ratedcapacity.

B. Connect the chiller’s ‘CONDENSER WATER OUT’ port to theplant’s drain or tower system return.

1. Note: if dumping to the plant’s open drain, drainage shallbe done according to local codes.

C. The pressure differential requirement between the condenser “waterin” and the condenser “water out” lines must be 30 psi for adequateefficiency.

D. The installation of a strainer in thecondenser “water in” line isrecommended. This removes solidsfrom the water supply and serves toprotect the water saver (regulator)valve.

E. The water saver (regulator) valve(figure 2.5B) is located in thecondenser “water in” line. Duringwinter months, or cold seasons, thevalve will throttle the water flowthrough the condenser. The amountof flow is based on the refrigerant head pressure and the regulatorwill modulate the valve orifice to maintain 100° - 105°F condensingtemperature for best efficiency*.

Figure 2.5ATypical condenser connections - 30 ton unit

Figure 2.5BOptional Regulator Valve

* See Temperature-Pressurechart in Section 8.5 forrefrigerant pressure.





2.5 ELECTRICAL CONNECTION

A. NEMA 1 MODELS

1. Electrical power supply requirements for Nema 1 units areidentified on the equipment data plate. Determine the plant’svoltage supply is the same as the unit’s voltagerequirements.

WARNING: Do not connect the unit to a voltage supplynot equal to the unit’s voltage requirements asspecified on the unit’s data plate. Use of incorrectvoltage will void the unit’s warranty and cause asignificant hazard that may result in serious personalinjury and unit damage.

2. A customer supplied, four conductor cable is required forconnection to a customer supplied fused disconnectingmeans. The fused disconnecting means shall be sized andinstalled according to the unit’s power supply requirementsand local electrical codes.

3. Connect the four conductor power cable to power entryterminal block on the unit’s electrical panel. Then connectthe power cable to the fused disconnect switch.

B. NEMA 12 MODELS

1. NEMA 12 units are constructed with a dust tight electricalenclosure and branch circuit fusing. Electrical power supplyrequirements are identified on the equipment data plate.Determine the plant’s voltage supply is the same as theunit’s voltage requirements.

WARNING: Do not connect the unit to a voltage supplysource not equal to the unit’s voltage requirements asspecified on the unit’s data plate. Use of incorrectvoltage will void the unit’s warranty and cause asignificant hazard that may result in serious personalinjury and unit damage.

2. Appropriate conduit and fittings should be selected whichwill maintain the integrity of the cabinet.

3. Supply a power conductor sized according to the unit’spower supply requirements. Connect the power conductor tothe unit’s power supply entry terminal block or the fuseddisconnect switch. Some Nema 12 models may be suppliedwith an optional disconnect switch. The owner suppliedfused disconnecting means shall be sized and installedaccording to the unit’s power supply requirements and localelectrical codes.

C. CONTROL CIRCUIT WIRING

1. The unit’s supplied control circuit is 110 volt, 1 phase, 60cycle. The control circuit is supplied by the factory installedtransformer. An inline control circuit fuse is provided.





D. GENERAL

1. Make certain all ground connections to the unit are properlyaffixed.

2. Make certain power conductor, disconnecting means, andfusing are properly sized according to the unit’s powersupply requirements.

E. INFORMATION REGARDING ‘PHASING’ OF SCROLLCOMPRESSORS

1. All portable chillers that have pumps, the compressor(s) willbe set in phase with the pump during the testing process atthe factory.

2. After installation the phase status must be checked byobserving the pump motor shaft on the end of the pumpand comparing its rotation to the directional arrow on themotor. In either case, if the phase needs to be altered, itshould be done at the main power entry.

Figure 2.5A Typical electrical panel

Refrigerant High Pressure Limit(protects from excessive condensing pressures)

Refrigerant Low Pressure Limit(protects from low suction pressures)

Motor Contractor(supplies voltage to coolant pump motor)

Motor Overload Relay(protects motor from excessive amperage)

Transformer(provides different voltages to instrument and other components)

Power Entry(connect to power cord - grounding lug on panel)

Compressor Contactor(supplies voltage to compressor)

Page: 20






3.0 OPERATIONS3.1 GENERAL3.2 START UP/OPERATIONS PROCEDURE3.3 INSTRUMENT 3.4 SHUT DOWN





3.1 GENERAL

A. Failure to follow the factory required operations procedure mayadversely affect the unit’s ability to adequately control processtemperature and may create a hazardous operating condition whichmay result in serious operator injury and/or unit damage.

B. IMPORTANT: if this unit contains a hermetic or semi-hermeticreciprocating compressor it is equipped with a crankcase heater onthe compressor. While the compressor is idle, the crankcase heaterprevents freon vapor from migrating to and condensing in thecompressor crankcase. If freon is allowed to condense in thecrankcase, it can be drawn into the cylinders upon start up. This cancause catastrophic damage to the connecting rods, pistons, andvalve plates.

To avoid this, BEFORE THE UNIT IS STARTED, THE POWERSUPPLY SHOULD BE APPLIED TO THE UNIT FOR AT LEAST 12HOURS, OR UNTIL THE BOTTOM OF THE COMPRESSOR ISWARM TO THE TOUCH.

If the power has been disconnected more than two hours, the powershould be applied for six hours before restarting. Power should beapplied to the unit continuously, except for service purposes. Thecrankcase heater should be checked for proper operation on aregular basis.

UNITS WITH SCROLL COMPRESSORS DO NOT HAVE ACRANKCASE HEATER AND THIS PROCEDURE IS NOTNECESSARY.

C. The OPERATIONS segment of this manual is divided into thefollowing sections:

3.2 Start up/operations - follow this segment to start the unitafter the initial install to the process system or to restart theunit after reinstallation to the same or different processsystem. This section includes information on system fill,electric motor phasing (pump rotation) and process flowadjustments.

3.3 Chiller Control - follow this segment to start up andoperate the chiller control. This section includes informationon setpoint selection and adjustment, and featureexplanations.

3.4 Shut down procedure - follow this segment to shut downthe unit. This segment includes information on system shutdown, electrical power supply precautions, anddisconnection from system.





3.2 START UP / OPERATION PROCEDURE

A. SYSTEM FILL

1. The unit has an internal reservoir which must be filled andmaintained for proper operation. The unit has a level switchmounted at the proper water level in the reservoir.

2. WATER QUALITY CONTROL. Lack of, as well as, improperwater treatment can damage the chilling unit. The servicesof competent water treatment specialist should be obtainedand their recommendations followed. It is the equipmentowner’s responsibility to prevent damage from foreignmaterial or inadequate water treatment. See watertreatment section in section 8 of this manual for moreinformation.

3. FOR OPTIONALAUTOMATIC FILL: engagethe water supply to unit. Thelevel switch will activate themake-up solenoid (figure3.2A), which will open andthe water supply will fill thereservoir tank.

4. MANUAL FILL: disconnectthe electrical power supplyand remove all necessarycover panels to access thereservoir. Add fluid directly tothe reservoir. When thepump is first started, asprocess lines are filled andair is purged, additional fluidmay be required to restorethe reservoir to the correctlevel. Verify reservoir levelvia the coolant sight glass(figure 3.2B).

B. ELECTRIC MOTOR PHASING (PUMP ROTATION)

1. The operator must determine the unit is phased correctly byvisually inspecting the rotation of the pump motor shaft. Theprocedure is outlined below. Incorrect phasing results inpoor operation and eventual damage to the unit.

a. Supply electrical power to the unit. Once the correctvoltage is supplied to the unit, the POWER switchon the unit’s control panel will illuminate. Adjust the

Figure 3.2AMake-up solenoid valve

Figure 3.2BTypical reservoir sight glass





setpoint to 70°F to prevent the compressor fromactivating during this procedure.

b. Remove all necessary cover panels to access thepump motor. Note that the electrical power isengaged at this point and caution must beobserved while the electrical supply is engagedand cabinet panels are removed and opened.

c. Locate the electricmotor (figure 3.2C).The electric motorcan be identifiedwhen the electricalpanel cover is open.The operator mustidentify the motorshaft inside theelectric motorhousing. The motorshaft can be seenthrough the vent slots in the motor housing or byremoving the shaft cover.

d. Toggle theilluminated ON/OFFSWITCH (figure3.2D). This willquickly cycle thepump motor “on”and then “off”.

e. Observe the motorshaft. When theON/OFF SWITCH ison, the motor shaftwill rotate. Whenswitched off, the shaft will slowly “coast” to a stop.As the shaft slows, the operator can identify therotation of the motor shaft. Correct rotation (correctphase) is “clockwise”, when viewed from the rear ofthe motor. Incorrect rotation is “counter-clockwise”(incorrect phase) when viewed from the rear of themotor. If the shaft does not rotate when theON/OFF SWITCH is on, the operator must identifythe cause as outlined in the troubleshooting andrepair section of this manual.

f. If the motor shaft is phased correctly (shaft turns ina clockwise direction), continue with step C. If themotor shaft is NOT phased correctly (shaft turns ina counter-clockwise direction), correct as outlined instep 2.

Figure 3.2CElectric motor

Figure 3.2DIlluminated On/Off switch





2. If the unit is phased incorrectly, the operator must:

a. Disengage the electrical power supply to the unit atthe unit’s disconnect switch. Follow proper lockoutprocedures before proceeding.

b. Once the electrical power supply is disengaged,reverse any two power leads of the power cord atthe disconnect terminals.

c. Note: reversing any two power leads of the powercord will correctly phase the power supply to theunit. The operator must reverse the power leadsat the disconnect switch only and not at thepower entry terminals on the unit’s electricalpanel. The unit’s internal electrical system wiring isphased correctly at the factory and must not bealtered in the field.

C. PROCESS FLOW ADJUSTMENTS

1. The operator must determine and set proper water flow ratefor the most efficient and trouble free operation.

a. Water flow rate through the process is determinedby the pressure losses in the process loop.Generally, higher flow rates result in turbulent flowachieving maximum temperature control and lowermaintenance. Since the evaporator in most liquidchillers is flow sensitive, the efficiency of operationis directly related to the flow of liquid.

b. Maximum chiller efficiency is obtained atapproximately 2.4 gpm per ton of rated capacity.Low liquid flow can reduce efficiency and in somecases allow ice to develop in the evaporator whichcan damage the evaporator. Excessive liquid flowwill trip the motor overload protection circuit.

2. Switch on the illuminated ON/OFF SWITCH to activate theprocess pump. Wait a few moments to allow air to be purgefrom system. Observe the COOLANT pressure gauge forsteady readout. Two items the operator for look for are lowflow or excessive flow conditions.

3. LOW FLOW: If a low flow condition is present, be sure allprocess valves are open. If all process valves are open anda low flow conditions exists, consider the following:

a. To operate under a low flow condition, it isnecessary to install a flow bypass system in the





process circuitry. This will allow a portion of the flowto bypass the process and return directly to thechiller. This keeps the total flow above the cutoffpoint. Figure 3.2E illustrates a typical bypass loop.

b. Some models may have a factory installed bypass.Adjust the valve accordingly.

3.3 INSTRUMENT/OPERATION

A. INSTRUMENT START-UP

1. When the correct electrical power and adequate watersupply pressure are supplied to the unit, it is possible tostart the unit.

2. Upon power up, the instrument displays “ChF” indicatingthat the unit is in Fahrenheit temperature mode or “ChC”indicating that it is in Celsius mode. The control then showsthe current setpoint for approximately 2 seconds beforereverting to the To Process temperature. When power issupplied to the unit, the ON/OFF switch will illuminate.

Figure 3.2E Typical low flow by-pass loop

Figure 3.3ACF-1 Chiller Control.





3. PRECAUTIONS:

The chiller control is programmed from the factory with asetpoint range of 48° to 90°F. To operate below 48°F, theaddition of inhibited propylene glycol and modification of thesafety control settings are required. Diligent monitoring ofthe water/glycol solution is mandatory to prevent freezing ofthe evaporator. Freezing may cause the evaporator torupture allowing water and freon to mix which will causemajor damage to the refrigeration system.

On R22, R134A and R407C models operating above 70°Fand R404A models operating above 60°F requires theaddition of a refrigerant crankcase pressure regulating(CPR) valve. The CPR valve is necessary to preventoverloading of the compressor which can cause prematurefailure. R410A models may be operated up to 80°F withouta CPR valve.

Contact your local refrigeration contractor or the factory forfurther information. The operating range of the chiller controlmay be changed to 10°F - 90°F by adjusting the SetpointLockout (SPL) jumper. Refer to the technical section of thismanual for more information.

B. INSTRUMENT OPERATION

1. To start the unit, toggle on the illuminated ON/OFFSWITCH. The chiller control will begin temperature controloperations.

2. To select setpoint temperature, press and hold the UPARROW or DOWN ARROW keys until the desired set pointtemperature is displayed in the TEMPERATURE WINDOW.The default range for the setpoint temperature is 48° - 90°For 9° - 32°C.

3. The setpoint temperature can be displayed by pressing theUP ARROW or DOWN ARROW keys. The setpointtemperature will be displayed for 5 seconds.

4. When the compressor is turned off, the instrument will wait3 minutes before turning it back on regardless of the ToProcess temperature or setpoint. If a fault has occurred, thecontrol will attempt to turn the compressor on after 3minutes powered down. If the fault condition remains, thecontrol will turn the compressor off and retry after 1 minute.This sequence will repeat until the compressor turns on orinstrument power is cycled.





5. Under normal conditions (no fault conditions, compressorhas been off for three minutes) the instrument will turn onthe compressor when the To Process temperature is abovethe setpoint.The instrument will turn on the hot gas bypass when the ToProcess temperature is below the setpoint by no more than3 degrees.

The instrument will turn off the compressor and hot gasbypass when the To Process temperature is 4 degrees ormore below the setpoint.

C. INSTRUMENT CONTROLS

1. ILLUMINATED ON/OFF SWITCH: this rocker switch startsor stops the unit. Electrical power is supplied to the unitwhen the switch is illuminated.

2. UP ARROW and DOWN ARROW KEYS: depress and holdthis push button to increase (UP ARROW) or decrease(DOWN ARROW) the setpoint temperature. If the pushbutton is pressed momentarily the setpoint value isincremented or decremented by one degree. If the pushbutton is held down the setpoint will increase or decreasecontinously.

3. SETPOINT LOCK OUT JUMPER: this jumper controlswhether the user is allowed to reduce the setpoint below48°F or 9°C. If the jumper is in position 1 (farthest from theSPL label) the user IS NOT ALLOWED to reduce thesetpoint below 48°F or 9°C. If the jumper is in position 2(closest to the SPL label) the user is allowed to reduce thesetpoint to 10°F or -11°C.

4. TEMPERATURE DISPLAY JUMPER: if this jumper is in the“F” position, the To Process and Setpoint temperatures aredisplayed in Fahrenheit. If the jumper is in the “C” position,the To Process and Setpoint temperatures are displayed inCelsius.

5. Probe Calibration: this pot (CALPOT 1) is used to calibratethe probe circuit.

Setpoint Lock Out Jumper Temperature Display Jumper Probe Calibration

Figure 3.3B





D. STATUS LIGHTS

1. COMPRESSOR: illuminates when compressor is turned on.

2. CAPACITY CONTROL: illuminates when capacity controlsystem is turned on.

3. REFRIGERANT FAULT: illuminates when there is a highpressure or low pressure alarm. Check troubleshootingsection of this manual for more details.

High Pressure Alarm. If the chiller control detects a highpressure condition it will immediately turn off thecompressor and hot gas bypass.

Low Pressure Alarm. Afterthe compressor is turned on,the control has a 15 secondbuffer for the low pressurealarm. If a low pressurecondition occurs within thefirst 15 seconds, the controlwaits the amount of timespecified by the “LP TIME”potentiometer beforeindicating an alarm andturning off the compressor. Ifthe condition is correctedbefore the time expires, no alarm occurs. If a low pressurecondition occurs 15 seconds after the compressor turns on,the instrument waits 20 seconds before indicating an alarmand turning off the compressor.

E. TEMPERATURE DISPLAY

1. A three digit display window indicates the appropriatetemperature. The window also displays the numeric valuefor the setpoint temperature.

2. The To Process temperature is always displayed unless abutton has been pressed. If there is a probe error, thedisplay will show three dashes “---”.

F. PRESSURE GAUGES (OPTIONAL)

1. PROCESS PRESSURE GAUGE: indicates process pumppressure.

2. REFRIGERANT HEAD PRESSURE GAUGE: indicatesrefrigerant pressure on the discharge side of thecompressor. This is the condensing pressure which is

Figure 3.3CLow Pressure Potentiometer.





critical to equipment efficiency. Head pressure on watercondensed units will vary with ambient temperaturesbetween 190-290 psig.

3. LOW PRESSURE GAUGE: indicates refrigerant pressureon the suction side of the compressor. This pressure willfluctuate with the process temperature.

3.4 SHUT DOWN/DISCONNECT SEQUENCE

A. PRECAUTIONS/WARNINGS

1. The operator must precisely follow all shut down proceduresoutlined in this manual. If the operator fails to followprecisely all procedures outlined in this manual, an unsafecondition can develop resulting in damage to the unit orpersonal injury.

B. UNIT SHUT DOWN

1. To shut down the unit without disconnecting from theprocess:

a. Move the ON / OFF switch to the off position.

b. Maintain electrical power to the unit at all timesexcept for service purposes.

2. To shut down the unit and disconnect from theprocess:

a. Move the ON / OFF switch to the off position.

b. Disengage the electrical supply to the chiller at thedisconnecting device.

c. Disconnect all process lines.





4.0 TROUBLESHOOTING4.1 UNIT WILL NOT START4.2 COMPRESSOR HUMS BUT WILL NOT START 4.3 SHUTS OFF ON HIGH PRESSURE4.4 SHUTS OFF ON LOW PRESSURE4.5 COMPRESSOR SHUTS OFF ON INTERNAL OVERLOAD 4.6 LOW OR NO PROCESS PRESSURE OR WATER FLOW4.7 COOLING CAPACITY INADEQUATE4.8 SENSOR4.9 PUMPS4.10 CRANKCASE HEATER 4.11 CHILLER CONTROLLER





4.1 UNIT WILL NOT START

A. Power off. Check main disconnect.

B. Main line open. Check fuses.

C. Loose terminals. Tighten terminals with POWER OFF.

D. Control circuit open. check control voltage fuses and transformer.

4.2 COMPRESSOR HUMS BUT WILL NOT START

A. Contactor. Check contacts and contactor operation.

B. Low voltage. Check voltage at main and at the unit. If voltage is OKat the main but low at the unit, increase wire size. If low at main,consult your local power company. Voltage must be +/- 10%nameplate rating.

C. No power on one phase of a three phase unit. Check fuses incontrol panel and main disconnect. Also check unit wiring, mainplant fuse and wiring. If the problem is with the main power supplycoming into the plant, call the local power company.

D. Loose terminals. Tighten terminals with POWER OFF.

4.3 SHUTS OFF ON HIGH PRESSURE CONTROL

Note. Refrigerant high pressure will vary with ambient temperaturefrom minimum of 190 psi to as high as 280 psi. The high pressureswitch manually reset when discharge pressure falls to a safe level.The switch is located inside the electrical panel.

A. Air-cooled units:

1. Insufficient condenser air flow. Check condenser filter fordirt, fins may be plugged with dirt or foreign material. Also,check for proper fan rotation.

Note: all enclosure panels must be attached.

2. Fan motor not operating. Have electrician check fusesand wiring, motor starter and overloads, and motor. Repairor replace motor if defective.

B. Water-cooled units:

1. Water regulator valve. Adjust condenser water regulatorvalve to maintain 100°F to 105°F refrigerant condensing





temperature*. If valve is defective, have valve repaired orreplaced by a refrigeration serviceman.

2. Insufficient condenser water flow. Check condenserwater pumping system.

3. Condenser water temperature too high. Check coolingtower or proper operation city water temperature.

4. Condenser water tubes scaled. Clean with brushes andchemicals approved by the Advantage Service Department.

C. Improperly set high pressure control. Have refrigerationserviceman reset or replace the control if defective.

4.4 SHUTS OFF ON LOW PRESSURE CONTROL

Note: The low pressure switch will automatically resets when the pressurerises above the cut-in pressure. If this does not occur contact thethe Manufacturer’s service department for instructions.

The low pressure switch is set to cut-out at 32°F and cut-in at36°F - 39°F*. If a low pressure condition exists for more than fiveseconds the compressor will stop and a “L-P” fault will appear inthe display window.

After the refrigerant pressure rises above the cut-in pressure, athree minute time delay will occur before the compressor restarts.This will protect the evaporator and compressor from damageshould a problem occur in the refrigeration system or if the chiller isoperated under circumstances which could cause damage to therefrigeration system.

A. Air-cooled units:

Head pressure too low. Check that entering airtemperature is above 60°F. If below 60°F, find out reasonwhy.

B. Water-cooled units:

Head pressure too low. Adjust condenser water regulatingvalve to maintain 100°F - 105°F refrigerant condensingtemperature*. Have refrigeration serviceman repair valveor replace if defective.

C. Low refrigerant charge. Check for adequate refrigerant charge(bubbles or misty sight glass indicates low charge). If charge is low,have system checked for leaks and recharged by a refrigerationserviceman.








D. Improperly set low pressure switch. Have a refrigerationserviceman reset control or replace if defective.

E. Restriction in the liquid line.

1. Clogged filter drier. Check for pressure ortemperature drop and have drier core replaced by arefrigeration serviceman.

2. Liquid line valve or suction valve oncompressor is partially closed. Open fully.

3. Liquid line solenoid not opening fully or leakingduring off cycle. have repaired or replaced ifdefective by a refrigeration serviceman.

4. Expansion valve plugged or inoperative. Checkthermal bulb and capillary tube for damage. Haverepaired or replaced if defective by a refrigerationserviceman.

4.5 COMPRESSOR SHUTS OFF ON INTERNAL OVERLOAD

A. Control does not reset. Have compressor windings and internalsolid state safety control checked by a refrigeration serviceman.Have it repaired or replace if defective.

4.6 LOW OR NO PROCESS PRESSURE OR WATER FLOW

A. Valves. Check if water valves are open.

B. Pump. Check pump for correct rotation. Check pump suction forrestriction. Replace motor if defective.

C. Filters. Check filter in the chilled water circuit and clean ifnecessary.

D. Pressure switch (or flow switch). Readjust or replace if defective.

E. Fuses and wiring. Have electrician check the fuses and wiring.

4.7 COOLING CAPACITY INADEQUATE

A. Low refrigerant charge. Check for adequate refrigerant charge(bubbles or misty sight glass indicates low charge). If charge is low,have system checked for leaks and recharged by a refrigerationserviceman.

B. Hot-gas bypass valve stuck open. Have repaired or replace ifdefective by a refrigeration serviceman.





C. Expansion valve plugged or inoperative. Check thermal bulb andcapillary tube for damage. Have repaired or replaced if defective bya refrigeration serviceman.

D. Plugged filter. Check filter in chilled water circuit and clean.

E. Air in system. Purge air.

4.8 SENSOR

The sensor is a solid state temperature transducer which convertstemperature input to proportional current output. To quickly test for adefective probe, switch connections between the defective probeand a probe known to be working properly. A defective sensor willdisplay a “---” in the display window on the instrument control.

4.9 COOLANT PUMP

A. The centrifugal pump is designed to operate at a specific flow andpressure at the maximum run load amp draw of the motor. Toomuch flow can overload the motor and cause the overload circuit toopen and stop the pump.

B. If the overload trips, check for electrical shorts, loose wires, orblown fuses. If these check OK, reset the overload circuit andrestart the chiller.

C. Check the amp draw and if overloaded, partially close the fromprocess line valve until the amp draw drops to the proper level.

4.10 CRANKCASE HEATER

A. If the crankcase heater is not drawing current during thecompressor off cycle, check for a defective crankcase heater,defective fuses or defective interlock on the compressor starter.

B. Scroll compressors do not have crankcase heaters.

4.11 CHILLER CONTROLLER

A. The display is used for all normal set ups, diagnostics, temperaturereadout, and operational information. Note: the display is not fieldrepairable. It can be easily removed and replaced if required.

B. The CPU contains the software and various electronic componentswhich make the instrument work. Note: the CPU is not a fieldrepairable part. It can be easily removed and replaced if a problemarises.

Page: 36






5.0 MAINTENANCE5.1 WARRANTY SERVICE PROCEDURE5.2 PERIODIC PREVENTATIVE MAINTENANCE5.3 SPECIAL MAINTENANCE5.4 SOLENOID VALVE SERVICE5.5 PUMP SEAL SERVICE5.6 CHECKING THE REFRIGERANT CHARGE5.7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATOR





5.1 WARRANTY SERVICE PROCEDURE

A. In the event of a problem with a chiller that can not be resolved bynormal troubleshooting procedures, the customer is invited toconsult the Service Department for assistance. The correct modelnumber and serial number of the chiller must be available. Theservice department will attempt to isolate the problem and adviserepair procedures. Often times, with the customer’s input and withthe machine diagnostics, problems can be determined with “over-the-phone” consultation.

B. If the problem is beyond the scope of “over-the-phone” consultation,and if the warranty status of the machine is valid, the Manufacturerwill contact the nearest authorized service contractor and provideauthorization to conduct an “on-site” inspection of the unit in orderto determine the course of repair. If the chiller is not covered by thewarranty, the Manufacturer will advise on the repair and recommendavailable service contractors.

C. It is of the utmost importance that you provide the correct modelnumber and serial number of the machine in question. This willallow the Service Department to obtain the correct manufacturingrecords which will help to properly troubleshoot the problem andobtain the proper replacement parts when they are required. Thisinformation is stamped on the data tag that is attached to theelectrical enclosure of each machine.

D. The Service Department must be notified prior to any repair orservice of a warranty nature. Warranty claims will not be honoredwithout prior authorization.

5.2 PERIODIC PREVENTATIVE MAINTENANCE

A. Lubricate all motors. Note that some motors are supplied withsealed bearings.

B. Tighten all wire terminals.

C. Clean and check motor starter and contactor contacts.

D. Check safety switch settings.

E. Clean condenser fins of dust and dirt (air cooled models only).

F. Back flush evaporator.

G. Check glycol/water solution ratio for operating temperature.

H. Check system for leaks.





I. Refrigerant sight glass: check for bubbles when compressor isoperating at 100%. Check the moisture indicator for a color otherthan green.

J. Clean unit.

5.3 SPECIAL MAINTENANCE

A. Any service of the refrigeration system must be accomplished by acertified refrigeration technician.

1. Addition of compressor oil.

2. Addition of refrigerant.

3. Repair of a refrigerant leak.

4. Adjustment of super heat.

5. Changing of filter-drier or drier core.

6. Repair of a refrigeration solenoid.





5.4 SOLENOID VALVE SERVICE

A. Units with the optional water make-up system use a solenoidvalve (figure 5.4A) to regulate flowinto the reservoir tank. The solenoidvalve is controlled by the floatswitch.

B. Generally, solenoid valves fail dueto poor water quality, low waterflow, or defective valve elements.

C. The operator should follow thisprocedure to service the make-upsolenoid valve:

1. Disengage process operations according to the procedureoutlined in section 3.4. The operator must be certainprocess fluid temperature is under 100°F and pressure isrelieved (pressure gauge reads “0”) and water system flowis shut off and all pressure relieved.

2. Disengage main power supply. The operator must verify theproper lockout procedures are followed.

3. Remove or open any access cover panel and set aside togain access to the cooling solenoid valve.

4. The operator must be certain all water system pressure isrelieved.

5. Identify the retaining screw(figure 5.4B) on thesolenoid valve coil. Removethe screw. Keeping allelectrical connectionsintact, lift the coil off of theenclosure tube and setaside.

6. Use a pair of channel lockpliers or a pipe wrench toseparate the bonnetassembly from the valve body.The plunger is “loose” inside the enclosing tube. Be certainit is retained in the enclosure tube as the bonnet is removed(figure 5.4C).

7. Identify the diaphragm assembly. Gently remove theassembly from the valve body (figure 5.4D).

Coil Figure 5.4B

Retaining screw

Typical water make-upsolenoid valve

Figure 5.4A





8. Identify the mesh screen.Gently removed the meshscreen and clean orreplace as necessary.

9. Clean the valve body.

10. Reset the mesh screen intothe valve body.

11. If a new diaphragmassembly was obtained,continue with step 12. Ifnot, disassemble thediaphragm assembly andnote component order(figure 5.4E). Clean thevalve port, plate, collar andO-ring. Once cleaned,reassemble the diaphragm.

12. Set the reassembleddiaphragm assembly or thenew assembly back into thevalve body. The stemshould be facing out of thevalve body.

13. Inset the plunger withspring first into theenclosing tube of the topbonnet (figure 5.4F).Holding the plunger in theenclosure tube, set the topbonnet onto the valve bodyand tighten.

14. Place the coil onto the topbonnet and replace theretaining screw.

15. Open the water supply anddrain valves (if installed) tocirculate water through thesupply and drain manifolds.Check the solenoid valvefor leakage. Restart the unitas outlined in section 3.

Figure 5.4FPlungerSpring

Top bonnet Enclosure tube

Top bonnet Figure 5.4CEnclosure tube

Plunger Diaphragm assembly

Figure 5.4DO-Ring

Diaphragm assembly Mesh screen

Figure 5.4EO-RingDiaphragm and stem

Collar Plate

5.5 PUMP SEAL SERVICE

A. The coolant pump sealis a carbon/niresistshaft seal assemblyincluding a stationarymember, rotatingmember and tensionspring (figure 5.5A).

B. The operator candetermine the pumpseal is leaking whenfluid is identified leaking from the pump case adapter.Generally, a pump seal will leak due to inadequate unitpressure, excessive flow and poor fluid quality.

C. The operator should follow this procedure to replace the pump seal:

1. Disengage process operations according to the procedureoutlined in section 3.4. The operator must be certainprocess fluid temperature is under 100°F and pressure isrelieved (COOLANT pressure gauge reads “0”) and watermake-up flow is shut off and all pressure relieved.

2. Disengage main power supply. The operator must verify theproper lockout proceduresare followed.

3. Access the pump motor byopening or removing anycover panels as necessary(figure 5.5B).

4. Drain machine. Themachine can be drained byusing the drain valvelocated on the pump case.Drain fluid into a suitablecontainer for reuse ordisposal according tomanufacturer’s instructions(if a glycol solution isused).

5. Locate and remove thethree motor wire leads fromthe motor wiring terminals.The operator should “map”the wire terminal locationsto ensure correct rewiring.The power cord should be





Stationary member

Rotating Member Tension Spring

Figure 5.5A

Pump motor Figure 5.5B

Pump motor Figure 5.5C

removed from the motorhousing (figure 5.5C).

6. Locate and remove thepump casing bolts. Thesebolts secure the motor andmotor adapter to the pumpcasing (figure 5.5D).

7. Separate the motor andmotor adapter from thepump casing to expose thepump impeller (figure5.5E). Remove the motorand motor adapter from theunit and place on aworkbench to continue theprocedure.

8. Locate and remove thedust cap from motor end toexpose slotted motor shaft.The motor shaft is free torotate, but must be securedto remove the impeller. Tosecure the motor shaft,insert a flat bladed screwdriver in slot to hold theshaft stationary (Figure5.5F).

9. Locate and remove impellerlocking screw (Figure5.5G). Using a socket andratchet, the impellerretaining screw can beremoved. Once theretaining screw is removed,the impeller can be“unthreaded” from themotor shaft to expose thepump seal assembly.

10. Remove all seal parts(Figure 5.5H). Note sealcomponent arrangement tofacilitate reassembly.

11. Clean motor shaft andlubricate with a mild soapsolution.





Typical pump casing bolt Figure 5.5D

Motor shaft Figure 5.5F

Typical impeller Figure 5.5G

Impeller Figure 5.5E





12. Install new stationary sealmember in pump casingcavity (figure 5.5I). Theoperator must be certainthe stationary seal memberis fully squared and seatedin cavity.

13. Slide the rotating memberonto lubricated pump shaft(figure 5.5J). The operatormust be certain not todamage or tear rubberbellows assembly.

14. Place the spring onto therotating member.

15. Align the impeller, springand rotating member beforereinstalling the impeller(figure 5.5K). The operatormust be certain the springand rotating member arealigned before the impelleris fully tighten and theimpeller retaining screw isreinstalled.

16. Clean pump casing,cavities, impeller and O-ring before reassembly.

17. Mate the motor and motoradapter to the pumpcasing. Reinstall the pumpcasing bolts.

18. Reconnect the motor powercord and leads.

19. Restore all cover panels aswere removed.

E. When the pump seal replacementprocedure is complete, the operatormay restart the unit according thesection 3.

Stationary member Figure 5.5I

Stationary member Figure 5.5J

Seal members Figure 5.5K

Seal components Figure 5.5H





5.6 CHECKING THE REFRIGERANT CHARGE

A. All standard chillers aremanufactured with thermostaticexpansion valves as the meteringdevice to the evaporator.

B. All standard chillers have arefrigerant sight glass (figure 5.6A)with a moisture indicator. To checkthe refrigerant charge under normaloperating conditions:

1. Remove the plastic capcovering the sight glass.

2. Start the chiller and allow system pressures andtemperatures to stabilize.

3. With the unit operating at 100% capacity (not in the“capacity control” mode) the sight glass should appear clearwith no foam or bubbles evident. If foam or bubbles areevident, the chiller has suffered from a loss of refrigerantand should be checked by a qualified refrigerationtechnician.

4. The “dot” in the middle of the sight glass is the moistureindicator. It should appear green at all times. A white oryellow color indicates moisture has invaded the refrigerationsystem, which is detrimental to the life of the compressor.The filter-drier should be replaced by a qualifiedrefrigeration technician.

5.7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATORS

A. The brazed plate evaporator ismade of stamped stainless steelplates, furnace brazed togetherwith copper based joints. Thecomplex geometry of the flowpassages promotes turbulentflow which gives high efficiencyand reduces fouling by mineraldeposits. Large solids such asplastic pellets or chunks of mineral deposits will collect at the waterinlet port at the evaporator and restrict flow through some of thepassages. If this possibility exists, the Manufacturer recommendsfilters or strainers be added to the “from process” line. If theevaporator becomes fouled there are a couple of methods forcleaning.

Sight Glass Figure 5.6A

Evaporator Figure 5.6A

B. To begin, remove the piping to the “water in” port at the evaporator.Remove any solids that have collected at this point. Then back flushthe evaporator to remove any solids that may be trapped betweenthe plates (see back flush procedure below). If there are mineraldeposits adhered to the plates, the evaporator must be back flushedwith a mild acid solution (5% phosphoric or 5% oxalic acid isrecommended.) After cleaning rinse with clear water beforereturning to service. Continue with step C on the next page.

C. Back flushing procedure:

1. Turn off all power to the machine. For chillers with areservoir tank, drain the tank to below the evaporator outlet.For chillers without a reservoir tank, drain total unit.

2. Connect a water supply hose to the evaporator water outlet.If acid cleaning, connect the discharge hose from the acidpump to the evaporator outlet port.

3. Connect a hose to the evaporator water supply port and toan appropriate containment vessel. If acid cleaning, connectthe evaporator water inlet port to an acid solution reservoirtank. Dispose of all back flush fluid according to localcodes.

4. The cleaning fluid source should have at least 20 psiavailable. If acid cleaning, follow the instructions suppliedwith the acid solution carefully.

5. When the procedure is complete, reinstall all water lines tooriginal factory orientation. Restart the unit and check forproper operation.

6. Note: this procedure is not normal maintenance.Maintaining proper water quality and filtration will minimizethe need to back flush the evaporator.





BRAZED PLATE HEAT EXCHANGER(EVAPORATOR)

FREON OUT

FREON IN

ORIGINAL WATER OUT PORTBACKFLUSH WATER IN PORT(SUPPLY BACKFLUSHING WATER

FLOW TO THIS PORT)

ORIGINAL WATER IN PORTBACKFLUSH WATER OUT PORT

(ROUTE WATER TO PROPERSEWER OR DRAIN CONTAINER)





6.0 COMPONENTS6.1 WATER SYSTEM6.2 REFRIGERATION SYSTEM

6.1 WATER SYSTEM

A. MOTOR/PUMP ASSEMBLY: themotor/pump assembly circulateschilled fluid to the process loop. Thepump assembly is built of totalstainless steel to maintain waterquality (figure 6.1A).

6.2 REFRIGERATION SYSTEM

A. COMPRESSOR: hermetic or semi-hermetic compressors take lowpressure/low temperaturerefrigerant gas and compress thegas into high pressure/hightemperature gas (figure 6.2A).

B. AIR COOLED CONDENSER: theair cooled condenser removesBTU’s from the compressedrefrigerant gas. The action causesthe gas to “condense” into a liquidstate still under high pressure. Airflow across the condenser isachieved via a motor driven fanassembly or centrifugal blower(figure 6.2B).

C. FILTER-DRIER: the filter-drierremoves contaminants andmoisture from the liquid refrigerant(figure 6.2C).

D. LIQUID LINE SOLENOID VALVE:controlled by the instrument, thisvalve closes when the compressorcycles off to prevent refrigerantliquid from migrating to theevaporator. The valve opens whenthe compressor cycles on.

E. REFRIGERANT SIGHT GLASS:the refrigerant sight glass indicatesrefrigerant charge and moisturecontent. Refrigerant charge isdetermined by a clear liquid flow.Bubbles indicate low refrigerant.Moisture content is indicated by thecolor of the element. Element coloris normally green. If the color of the





Hermetic compressor

Semi-hermetic compressor

Figure 6.2A

Pump Motor Assembly Figure 6.1A

Typical filter-drier Figure 6.2C

Fans

Blower

Figure 6.2B

element is chartreuse or yellow, thesystem has been contaminatedwith moisture. In such case, thefilter-drier must be replaced. Thereplacement of the filter-drier mustbe completed by a qualifiedrefrigerant service technician(figure 6.2D).

F. EXPANSION VALVE: theexpansion valve throttles flow ofrefrigerant liquid into the evaporatorand creates a pressure drop in therefrigerant system that allows theliquid refrigerant to “boil off” insidethe evaporator (figure 6.2E).

G. EVAPORATOR: the evaporator is abrazed plate heat exchanger wherethe refrigerant liquid is allowed toevaporate (boil off) to absorb heat(BTU) from the process fluid. As theheat is absorbed, the process fluidis chilled (figure 6.2F).

H. HOT GAS BY-PASS SOLENOID:the hot gas by-pass solenoidprevents short cycling of thecompressor by reducing thecapacity by 50% when the processfluid temperature nears thesetpoint.

I. HIGH/LOW PRESSURESTATS:the high/low pressurestats protectthe refrigeration system fromunsafe operating levels. The highpressure switch is factory set andprotects the refrigeration components and personnel from potentialdamage of injury from excessive high pressure. The high pressuresafety must not be altered in the field for any reason. (See section8.1 for factory settings.) The low pressure switch is factory set toopen at 32°F and to close at 36° - 39°F.* The low pressure switchprotects the chillers from possible damage due to low operatingpressure. The low pressure switch is field adjustable for setpointsbelow 48°F.

NEVER LOWER THE CUT OUT SETTING WITHOUT ADDINGGLYCOL TO THE CIRCULATING SYSTEM. EVAPORATORDAMAGE WILL RESULT AND WILL NOT BE COVERED BY THEWARRANTY.





Expansion Valve Figure 6.2E

Refrigerant sight glass Figure 6.2D

Typical hot gas bypass valve Figure 6.2H






J. Liquid receiver: located after the condenser, this componentreceives and stores liquid refrigerant leaving the condenser.

K. Service valves: have been provided throughout the system. Only aqualified refrigeration service technician shall operate these valves.

L. Crankcase heater: insures that freon and compressor crankcaseoil do not mix during the compressor’s “off ” cycles. Power must beapplied to the chiller previous to startup.

M. Oil pressure safety switch: protects the compressor fromlubrication failure.





7.0 RELATED DRAWINGS7.1 MECHANICAL SCHEMATIC : WATER-COOLED : 2 - 10 TONS7.2 MECHANICAL SCHEMATIC : WATER-COOLED : 15 - 40 TONS7.3 MECHANICAL SCHEMATIC : AIR-COOLED : 5 - 10 TONS7.4 MECHANICAL SCHEMATIC : AIR-COOLED : 15 - 30 TONS7.5 TYPICAL ELECTRICAL : AIR-COOLED7.6 TYPICAL ELECTRICAL : WATER-COOLED7.7 PHYSICAL SCHEMATIC : AIR-COOLED : 7.5 - 10 TONS7.8 PHYSICAL SCHEMATIC : AIR-COOLED : 5 TONS7.9 PHYSICAL SCHEMATIC : WATER - COOLED :7.10 DUCT SCHEMATIC FOR AIR-COOLED CHILLERS





7.1 MECHANICAL SCHEMATIC : WATER-COOLED : 2 - 10 TONS

TO P

ROC

ESS

PRES

SURE

GA

UG

E

WAT

ER R

EGU

LATO

R VA

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SEN

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SPO

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RTC

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R W

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VALV

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7.2 MECHANICAL SCHEMATIC : WATER-COOLED : 15 - 40 TONS

TO P

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PRES

SURE

GA

UG

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WAT

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LATO

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7.3 MECHANICAL SCHEMATIC : AIR-COOLED : 2 - 10 TON MODELS

TO P

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PRES

SURE

GA

UG

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AIR

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7.4 MECHANICAL SCHEMATIC : AIR-COOLED : 15 - 30 TON MODELS

TO P

ROC

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PRES

SURE

GA

UG

E

AIR

-CO

OLE

D C

ON

DEN

SER

w/b

low

er

CO

OLA

NT

PUM

P

TO P

ROC

ESS

SEN

SOR

PRO

BETO

PRO

CES

SPO

RT C

ON

NEC

TIO

N

MA

KE-U

P PO

RTC

ON

NEC

TIO

N

MA

KE-U

PSO

LEN

OID

VA

LVE

LEVE

L SW

ITC

H

FRO

M P

ROC

ESS

PORT

CO

NN

ECTI

ON

RESE

RVO

IR T

AN

K

EXPA

NSI

ON

VA

LVE

EVA

PORA

TOR

SERV

ICE

LID

AN

D F

ILL

PORT

REFR

IGER

AN

TSI

GH

T G

LASS

LIQ

UID

LIN

ESO

LEN

OID

VA

LVE

FILT

ER-D

RIER

SERV

ICE

VALV

ELI

QU

ID L

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REC

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RH

OT

GA

SBY

PASS

VA

LVE

CO

MPR

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R(m

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roll

Her

met

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r Re

cip

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GA

UG

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SA

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SW

ITC

H

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TIO

N L

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PRES

SURE

GA

UG

E

LOW

PRE

SSU

RESA

FETY

SW

ITC

H





7.5 TYPICAL ELECTRICAL SCHEMATIC : AIR-COOLED MODELS

UNIT

ON/OFF

22

BLK

WHT

PRIMARY

24 VAC

SECONDARY

120v

BLU/RED

BLU/WHT

RED/RED

RED/RED

5022

2325

2427

27

31

23

L1

L2

L3

L4

GROUND

POWER ENTRY

PUMP

M1

1 MOL

M1

COMPRESSOR

M2

M2

110VAC SEC.

TRANSFORMER

GROUNDFU1

1

2

3 3

2

1

3

1

161514 17

18 19

M3

19

17

FAN MOTOR

LEVEL SWITCH

50

50

M1

1 MOL

S50

50

23

2323PUMP MOTOR COIL

SNUBBER

5023ANTI-DRAIN BACK SOLENOID (OPTIONAL)

S5020

PRESSURESTAT

HIGH

M2

S

50

50

5030

30

30

COMPRESSOR MOTOR COIL

SNUBBER

LIQUID LINE SOLENOID

S

50

5031

31

SNUBBER

SNUBBER

20

20

20

50

22

22

22

50

HOT GAS SOLENOID

21

POWER ON

WATER MAKE-UP SOLENOID (OPTIONAL)

M4

19

17

FAN MOTOR

(OPTIONAL)

FLOW SWITCH

OPTIONALOPTIONAL

STAT

FREEZE-

29 30

JUMPER

28

TO PROCESS PROBEBLK

ADJUST SETPOINT

* PUSH ONCE TO VIEW SETPOINT* PUSH AND HOLD TO CHANGE SETPOINT

TEMPERATURECOMPRESSOR

CAPACITY

CONTROL

REFRIGERATION

FAULT

CHILLER CONTROL

MICROPROCESSOR

BLU/YELRED/YEL

RED/YEL PRESSURESTAT

LOW

5026

31

FAULT INDICATOR





7.6 TYPICAL ELECTRICAL SCHEMATIC : WATER-COOLED MODELS

UNIT

ON/OFF

22

BLK

WHT

PRIMARY

24 VAC

SECONDARY

120v

BLU/RED

BLU/WHT

RED/RED

RED/RED

5022

2325

2427

27

31

23

L1

L2

L3

L4

GROUND

POWER ENTRY

PUMP

M1

1 MOL

M1

COMPRESSOR

M2

M2

110VAC SEC.

TRANSFORMER

GROUNDFU1

1

2

3 3

2

1

3

1

161514 17

18 19

LEVEL SWITCH

50

50

M1

1 MOL

S50

50

23

2323PUMP MOTOR COIL

SNUBBER

5023ANTI-DRAIN BACK SOLENOID (OPTIONAL)

S5020

PRESSURESTAT

HIGH

M2

S

50

50

5030

30

30

COMPRESSOR MOTOR COIL

SNUBBER

LIQUID LINE SOLENOID

S

50

5031

31

SNUBBER

SNUBBER

20

20

20

50

22

22

22

50

HOT GAS SOLENOID

21

POWER ON

WATER MAKE-UP SOLENOID (OPTIONAL)

FLOW SWITCH

OPTIONALOPTIONAL

STAT

FREEZE-

29 30

JUMPER

28

TO PROCESS PROBEBLK

ADJUST SETPOINT

* PUSH ONCE TO VIEW SETPOINT* PUSH AND HOLD TO CHANGE SETPOINT

TEMPERATURECOMPRESSOR

CAPACITY

CONTROL

REFRIGERATION

FAULT

CHILLER CONTROL

MICROPROCESSOR

BLU/YELRED/YEL

RED/YEL PRESSURESTAT

LOW

5026

31

FAULT INDICATOR

23

26

30

27





7.7 PHYSICAL SCHEMATIC : AIR-COOLED : 7.5 - 10 TONS





7.8 PHYSICAL SCHEMATIC : AIR-COOLED : 5 TONS





7.9 PHYSICAL SCHEMATIC : WATER-COOLED





7.10 DUCT SCHEMATIC FOR AIR-COOLED CHILLERS

A. For models equiped with centrifugal blower. Models with equippedwith fans can not be ducted.

13

12 11

10

98

7

6 5

432

1

Item123456789

10111213

DescriptionWeather capScreenFlashing to suitRoof curbPlant roofButterfly with counterbalanceSeparate duct support from roofGate control for exhaust air flowManual chain controlDuct to plant heating systemMating collarChiller air exhaust portAir cooled chiller with blower

NOTE: THIS DRAWING IS FOR EXPLANATION PURPOSES ONLY, NOT FOR CONSTRUCTION PURPOSES

Page: 62






8.0 APPENDIX8.1 OPERATIONS BELOW 48°F8.2 WATER QUALITY CONTROL8.3 INHIBITED PROPYLENE GLYCOL8.4 SENSOR CURRENT VS TEMPERATURE CHART8.5 REFRIGERANT PRESSURE-TEMPERATURE CHART 8.6 CHILLER CAPACITY AND DERATE CHART





8.1 OPERATIONS BELOW 48°F

A. Chillers supplied with the automatic water supply system, the watersupply connection must be plugged when operating below 48°F oranytime the system utilizes a water/inhibited propylene glycolsolution. The system must be manually filled and the mix shall bechecked for the proper ratio on a regular basis.

B. Addition of an inhibited propylene glycol solution is required. Theration shall be according to figure 8.3A. Too much glycol can causecapacity and control problems. Under no circumstances shall anautomotive type antifreeze be used in the chilling unit.

C. The freezestat and low pressurestat settings must be field adjustedaccording to figure 8.3B.

NEVER LOWER THE CUT OUT SETTING WITHOUT ADDINGGLYCOL TO THE CIRCULATING SYSTEM. EVAPORATORDAMAGE WILL RESULT AND WILL NOT BE COVERED BY THEWARRANTY.

OperatingTemperature

48° - 70°F

25° - 47°F

10° - 24°F

Glycol

0%

30%

40%

FreezePoint

32°F

10°F

-5°F

Cut OutTemp

32°F

10°F

-5°F

Cut InTemp

36°F - 39°F

15°F - 18°F

0°F - 7°F

Cut-Out

58#

33#

20#

Cut-In

63#

38#

25#

Refrigerant

R22

R134A

R407C

R410A

R404A

Air-Cooled

380#

260#

405#

610#

405#

Water-Cooled

360#

260#

360#

550#

360#

R22Cut-Out

28#

12#

4#

Cut-In

33#

17#

9#

R134ACut-Out

102#

63#

43#

Cut-In

111#

72#

52#

R410A

OperatingTemperature

48° - 70°F

25° - 47°F

10° - 24°F

Glycol

0%

30%

40%

FreezePoint

32°F

10°F

-5°F

Cut OutTemp

32°F

10°F

-5°F

Cut InTemp

36°F - 3°9F

15°F - 1°8F

0°F - 7°F

Cut-Out

72#

44#

29#

Cut-In

79#

49#

34#

R404ACut-Out

52#

28#

16#

Cut-In

58#

34#

22#

R407C

Refrigerant Low Pressure Switch Cut-Out & Cut-In Settings

High Pressure Cut Out (maximum)

Figure 8.3A & Figure 8.3B





8.2 WATER QUALITY CONTROL

A. Lack of proper water treatment can damage the chilling unit. Theservices of a competent water treatment specialist should beobtained and their recommendations followed. It is the equipmentowner’s responsibility to prevent damage from foreign material orinadequate water treatment.

B. The two main things to consider for water treatment in chillers arecorrosion and organism growth. Proper chemical treatment cancontrol PH levels and algae growth. An alternative to chemicaltreatment is the addition of 30% inhibited propylene glycol to thewater. This will help prevent organism growth and coat the heattransfer surfaces with corrosion inhibitor.

8.3 INHIBITED PROPYLENE GLYCOL

A. To operate liquid chillers below 48°F, it is necessary to addinhibited propylene glycol to the circulating system to lower thefreeze point and prevent damage to the cooling system. Inhibitedpropylene glycol contains corrosion inhibitors which are compatiblewith most industrial heat transfer surfaces. Inhibited propylene glycolis manufactured by:

• Dow Chemical - “DowFrost” (1-800-258-2436)• Monsanto “Therminol FS” (1-800-459-2665)• Advantage Engineering “Thermofluid” (1-317-887-0729)

B. Automotive anti-freeze must never be used in industrial heat transferapplications. Automotive anti-freeze contains silicate type corrosioninhibitors designed to be compatible with automotive components. Inan industrial application, the silicates will form a gel on the heattransfer surface which will result in substantial reduction in coolingcapacity and is virtually impossible to remove.

8.4 SENSOR CURRENT VS TEMPERATURE

-20°F = 243.86 A-10°F = 249.43 A

0°F = 255.00 A10°F = 260.57 A20°F = 266.14 A30°F = 271.71 A40°F = 277.27 A50°F = 282.84 A60°F = 288.41 A70°F = 293.98 A80°F = 299.55 A90°F = 305.12 A

100°F = 310.69 A110°F = 316.26 A

120°F = 321.82 A130°F = 327.39 A140°F = 332.96 A150°F = 338.53 A160°F = 344.10 A170°F = 349.67 A180°F = 355.24 A190°F = 360.80 A200°F = 366.37 A210°F = 371.64 A220°F = 377.51 A230°F = 383.08 A240°F = 388.65 A250°F = 394.22 A

Formula:

• 1 u A = (556.8627 x 10 x °F) = (255 x 10)

• °F = (1 u A - 255 x 10) + (556.8627 x 10)

Microammeter

Black wireWhite wire

Battery9 volt

+ -+ -





8.5 REFRIGERANT PRESSURE-TEMPERATURE CHART





8.6 CHILLER CAPACITY AND DERATE CHART

60

50

45

40

35

30

25

20

15

10

5

0

-5

*

*

*

*

*

105%

100%

90%

80%

70%

60%

50%

40%

30%

22%

15%

9%

5%

OUTPUTTEMPERATURE

°F

FULLAVAILABLE %CAPACITY

NOTES:

If operation of the chiller at less than 48°F is required, an inhibited propylene glycol solutionis required.

Consult factory for chiller operation below 20°F.

Ambient conditions affect air cooled chiller operation and capacity. Standard rating is at 95°Fentering air temperature. For ambient air conditions greater than 95°F, chiller derating willoccur. For ambients of 95-105°F, select the next larger capacity chiller. For ambients over105°F, consult factory.

* These ranges require special options.

Standard chiller rating is at 50°F. For all other temperature settings, outputtonnage is altered as follows:

Page: 68


END© 2009 TEMPTEK, INC.

RE 2 09/09

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