Sterling A0554831 User Manual Download | Manualshive

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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:

_________________________   _________________________

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_________________________   _________________________

We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual are subject to change without notice.

DCN No. ____________
© Copyright 2008
All rights reserved.

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Summary of Contents for A0554831

Page 1: ...____________ _________________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product impro...

Page 2: ...ailable upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise customer service regarding your wis...

Page 3: ...rol 12 Crankcase Heater 12 High Pressure Cutout 12 Low Pressure Cutout 13 Oil Pressure Safety Switch 13 Fan Cycling Switch 13 Pressure Switch 13 Flow Switch 13 Remote Start Stop Interlock 13 2 5 Optio...

Page 4: ...istance 44 Parts Department 44 Service Department 44 Sales Department 44 Contract Department 44 7 3 Drawings and Specifications 45 2 hp and 3 1 2 hp Air Cooled Portable Chillers 45 5 hp and 7 5 hp Air...

Page 5: ...ng Diagrams 64 Central and Gravity Return Piping with Standpipe Diagram 64 Typical Piping Schematic 2 and 3 1 2 hp Models 65 Typical Piping Schematic 5 hp through 40 hp One Pump Models 66 Typical Pipi...

Page 6: ...anical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions...

Page 7: ...s can develop refrigerant pressures in excess of 500 psi 3 447 5 kPa 34 47 bars DO NOT CUT INTO THE REFRIGERATION SYSTEM This must be performed by a qualified service technician only 9 Do not restore...

Page 8: ...ns for air and water cooled portable chillers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts o...

Page 9: ...It is not intended to provide continuous full bypass flow This minimal flow allows the temperature sensor to signal the controller to shut down the compressor because of the drop in process water tem...

Page 10: ...polyethylene tank 10 hp and 15 hp models use a 40 gallon polyethylene tank 20 hp to 30 hp models use an 80 gallon polyethylene tank and 40 hp models use a 65 gallon stainless steel tank Piping Non fe...

Page 11: ...liquid line shut off ball valves on 5 hp to 40 hp models Filter dryer Sight glass Balanced port thermal expansion valve Controller Features Off the shelf microprocessor based PID auto tuning controlle...

Page 12: ...by the process water glycol The thermostat stage two cutout temperature is factory set at 100 F 38 C See Section 4 6 on page 36 for information about changing the thermostat settings Caution Protect t...

Page 13: ...on when the discharge pressure in the condenser reaches 300 psi and turns off when the pressure drops below 190 psi Pressure Switch 2 hp and 3 1 2 hp models have a pressure switch cutout device mounte...

Page 14: ...hiller Compressor Hour Meter Includes a DIN mount hour meter that keeps track of the total time that the compressor runs Communications Options RS 232C and RS 485 serial communications and remote setp...

Page 15: ...the subpanel to be listed with Underwriters Laboratory with UL related benefits and features Optional Pumps Pump options are available for greater pressure and flow rates A recirculation pump is requi...

Page 16: ...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...

Page 17: ...emove the skid from the unit 4 Lower slowly The unit should land on its casters or rails and can then be moved into position 5 Temporary hardware has been installed to prevent side panels from shiftin...

Page 18: ...s a small amount of water to flow through the chiller This action protects the chiller from freeze up and allows the other cutout devices to shut down the chiller The bypass valve is not intended to p...

Page 19: ...approved discharge receiver A water regulating valve is a standard feature in the condenser water return line Air Cooled Chiller Condensers Air cooled chillers use the surrounding air to cool the con...

Page 20: ...because this will allow copper chips to contaminate the system A certified refrigeration contractor need only to install the interconnecting refrigerant piping between the chiller and the outdoor air...

Page 21: ...ines To determine field installed liquid and discharge line sizes first establish the equivalent length of pipe for each line valve and elbow Chiller capacity and leaving water temperature range is al...

Page 22: ...5 8 5 8 7 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 225 5 8 5 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 250 5 8 5 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 275 5 8 5 8 7 8 7 8 1 1 8 1 1 8 1 1 8 1 1 8 1 3 8 300 5...

Page 23: ...5 Refrigerant Charge Determination Chiller Condenser Charge Field Installed Piping Charge Horsepower Lbs of R 22 Pipe O D Inches Discharge Line c R 22 Lbs Liquid Line c R 22 Lbs 5 5 9 1 2 7 2 7 5 6 1...

Page 24: ...ompressors Scroll compressors are directionally dependent and compress in one rotational direction Reversing rotation direction results in an elevated sound level and a substantially reduced current d...

Page 25: ...ycol 55 gallons 208 2 liters A0542990 Propylene glycol 5 gallons 18 9 liters A0542991 Propylene glycol 55 gallons 208 2 liters Caution Do not connect make up water directly to the chilled water reserv...

Page 26: ...Curves Pe rce nt Glyc ol Cu rves for Free ze Protec tion 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 ycol by Vol um e Eth ylene G lycol Prop ylene Glyco...

Page 27: ...egulating valve to limit make up water pressure to less than 5 psi The reservoir must remain vented to the atmosphere If the automatic make up system is connected to a city water system make provision...

Page 28: ...hilled water circuit piping are filled to the full mark with a water glycol mixture The water glycol mixture should provide for freeze protection to at least 20 F 11 C below the leaving water temperat...

Page 29: ...parameter symbols during setup and error messages if an error occurs SV 8 8 8 8 Set Value LED During normal operation the green bottom LED display on the controller displays the process set point you...

Page 30: ...ach press of the Up Arrow key increments or advances the values or settings on the SV display Sterlco 2000 Controller Indicator Name Description T 8 8 8 8 Process Value LED During normal operation the...

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

Page 32: ...rocess water glycol pump s and the chiller shuts off This action prevents possible system failure from overheating of the process water glycol Pump On Light The Pump On light installed on chillers wit...

Page 33: ...artment Low Oil Pressure Light The Low Oil Pressure light is installed on chillers with a semi hermetic compressor that have an oil pump A differential pressure switch monitors the difference between...

Page 34: ...LOW PRESSURE LOW TEMPERATURE HIGH TEMPERATURE HIGH DISCHARGE TEMPERATURE HIGH REFRIGERANT PRESSURE LOW REFRIGERANT PRESSURE LOW OIL PRESSURE ON OFF CONTROL POWER A0554705 SILENCE ALARM COMPRESSOR ON H...

Page 35: ...lower the set point 4 4 Auto Tuning E5CK Controller Only The Auto Tune function lets you fine tune the control PID to process requirements Activate the Auto Tune function whenever the process under c...

Page 36: ...ermostat The keypad is disabled when the switch is moved to the left in the Lock position The keypad functions normally when the switch is moved to the right in the Unlock position All chillers are sh...

Page 37: ...the differential The setting should be 12 F 11 C 4 Press the Set key again to access Stage 1 cooling or heating mode The screen displays the current mode C1 for cooling or H1 for Heating Use the Up Ar...

Page 38: ...d portable chiller operating at peak efficiency and capacity Clean the filters whenever they appear dirty or at regularly scheduled intervals 1 Turn the chiller off 2 Slide the filter up off of the re...

Page 39: ...tions on the container The refrigerant side is sealed and requires no routine maintenance Caution Do not use steam or water over 140 F 60 C to clean a condenser unless you are monitoring the refrigera...

Page 40: ...intenance requirements These inspections include but are not limited to Checking refrigerant suction and discharge pressures Checking safety and operating conditions Checking voltage and amperage of a...

Page 41: ...harge Refrigerant low pressure switch contacts open Sight glass should be clear and the moisture indicator should be green while compressor is running Bubbles or foaming is normal when the hot gas by...

Page 42: ...ol Water temperature is too high Refrigerant charge is low Call service to find and repair the leak then have refrigerant added Pump running in reverse Verify rotation if running in reverse rotation r...

Page 43: ...e supplied No credit will be issued for material that is not within the manufacturer s warranty period and or in new and unused condition suitable for resale Warranty Returns Prior to the return of an...

Page 44: ...dicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 5pm CST call 847 439 5655 We have a qualified service...

Page 45: ...cap per 0 746 kW pump power d Based on 2 4 gpm per ton 9 1 lpm per 3 517 kW nominal 1 pump e An optional oversized process pump adds to the total rated or running chiller amperage To find the new tota...

Page 46: ...twork requires optional high pressure fan for 5 hp to 15 hp 3 73 kW to 11 20 kW models f An optional oversized process pump adds to the total rated or running chiller amperage To find the new total ch...

Page 47: ...requires optional high pressure fan for 5 hp to 15 hp 3 73 kW to 11 20 kW models f An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller...

Page 48: ...er 3 517 kW nominal 1 pump e An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage f...

Page 49: ...3 517 kW nominal 1 pump e Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum f Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum g An...

Page 50: ...kW nominal 1 pump e Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum f Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum g An optio...

Page 51: ...nominal 1 pump e Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum f Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum g An optional...

Page 52: ...ominal 1 pump e Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum f Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum g An optional o...

Page 53: ...al 1 pump e Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum f Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum g An optional overs...

Page 54: ...m per ton 9 1 lpm per 3 517 kW nominal 1 pump e An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard proc...

Page 55: ...per ton 9 1 lpm per 3 517 kW nominal 1 pump e An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard proce...

Page 56: ...lpm per 3 517 kW nominal 1 pump e An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amper...

Page 57: ...15 26 1 3 hp 3 5 0 3 20 500 550 129 8 43 0 40 5 120 0 15 8 11 8 6 4 20 30 1 1 2 hp 3 5 9 2 23 000 840 125 0 45 5 50 0 108 0 15 8 15 8 10 0 25 30 1 1 2 hp 3 5 9 2 21 900 860 125 0 45 5 50 0 108 0 15 8...

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: ...kPa 22 0 83 3 4 7 32 6 30 0 113 6 4 5 31 3 40 0 151 4 4 0 27 6 55 0 208 2 5 5 37 9 30 0 113 6 8 28 57 1 40 0 151 4 7 5 51 7 45 0 170 3 4 0 27 6 58 0 219 5 5 8 40 0 38 0 143 8 12 91 89 0 50 0 189 3 12...

Page 61: ...3 W 3 5 hp 8 6 32 7 6 0 41 2 1 0 746 31 7 218 5 2 2 W 5 hp 12 6 47 7 2 3 16 00 1 0 746 34 3 236 2 2 4 W 7 5 hp 17 0 64 5 3 1 21 4 1 0 746 32 0 220 3 2 2 W 10 hp 25 7 97 4 6 3 43 3 2 1 492 41 4 285 3...

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

Page 63: ...on for models 5 through 15 hp Allow 30 77 cm minimum clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility Size the ductwork for maximum capacity S...

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...

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...

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: ...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 A...

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