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Sterling Power Products 30F to 65F manual

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Table of contents for the manual

  • Page 1

    OPERATION AND INSTALLATION MANUAL SMC SERIES AIR COOLED PORTABLE WATER CHILLERS IMPORTANT: PLEASE READ CAREFULL Y BEFORE ATTEMPTING TO I N S T A L L OR OPERATE EQUIPMENT[...]

  • Page 2

    Page 2 SMC Series Chillers Sterling, Inc. is committed to a continuous program of product improvement. Specifications are subject to change without notice. © Sterling, Inc. 2003 All Rights Reserved Effective 10-1-2007 Part Number 882.00740.00 Bulletin: SC2-615A.4[...]

  • Page 3

    SMC Series Chillers Page 3 Safety Considerations Sterling, Inc. SMC Series Chillers are designe d to provide safe and reliable operation when installed and operated within design sp ecifications, following natio nal and local safety codes. To avoid possible personnel injury or equi pment damage when installing, operating or maintaining this equipme[...]

  • Page 4

    Page 4 SMC Series Chillers Table of Contents 1 General Information ................................................. 7 1-1 Introduction 1-2 Necessary Documents 1-3 Models Covered 1-4 Available Options 1-5 Uncrating Your New Chiller 1-6 In the Event of Shipping Damages 1-7 If the Shipment is Not Complete 1-8 If the Shipment is Incorrect 1-9 Returns [...]

  • Page 5

    SMC Series Chillers Page 5 Table of Contents 4 Startup Checklists .................................................. 23 4-1 Introduction 4-2 SMC Pre-Startup Checklist 4-3 SMC Startup Checklist 4-4 SMC Water Circuit Pressure Drop Table 5 Microprocessor Control ......................................... 25 5-1 Introduction 5-2 Setting the Process Wate[...]

  • Page 6

    Page 6 SMC Series Chillers Charts and Figures Figure 1: SMC050 Process Pump Curves..................................................................................... 11 Figure 2: SMC100 Process Pump Curves..................................................................................... 11 Figure 3: PCA150 Process Pump Curves .................[...]

  • Page 7

    SMC Series Chillers Page 7 1 General Information 1-1 Introduction Sterling, Inc.'s SMC Series Water Chillers ar e reliable, accurate, and easy-to-use air cooled chillers designed for use with water/ glycol. Standard range of operation is 30 ° F (-1°C) to 65 ° F (18°C) for applications using glycol and 45ºF (7ºC) to 65 ° F (18°C) for wa[...]

  • Page 8

    Page 8 SMC Series Chillers 1-4 Available Options SMC Series Chillers are available with options th at tailor the unit to your requirem ents. Some are factory installed, some can be re trofitted in the f iel d. Consult your local Sterling, Inc. Sales Representative. Some of these options are: Special Pumps Special pump options are available for grea[...]

  • Page 9

    SMC Series Chillers Page 9 1-6 In the Event of Shipping Damages IMPORTANT! According to the contract terms and conditions of the Carrier, the responsibility of the shipper ends at the time and place of shipment. The Carrier then assumes full responsibility of the shipment. ; Notify the transportation com pany's local agent. ; Hold the damaged [...]

  • Page 10

    Page 10 SMC Series Chillers 1-9 Returns IMPORTANT! Do not return any damaged or incorrect items until you receive shipping instructions from STERLING, Inc.[...]

  • Page 11

    SMC Series Chillers Page 11 Figure 1: SMC050 Process Pump Curves Figure 2: SMC100 Process Pump Curves Figure 3: SMC150 Process Pump Curves[...]

  • Page 12

    Page 12 SMC Series Chillers Figure 4: SMC Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW)[...]

  • Page 13

    SMC Series Chillers Page 13 Figure 5: SMC Series Chiller Specifications POWER A0537868 OFF ON REFRIGERANT Mini Chiller PUMP ON COMPRESSOR ON Portable Chiller HIGH PRESSURE REFRIGERANT LOW PRESSURE PC Series Application Engineering PUMP PRESSURE O ptional gauge package Side cover handle Sight glass To Process (3/4" NPT) From Process (3/4" [...]

  • Page 14

    Page 14 SMC Series Chillers 2 Chiller Installation 2-1 Electrical Connections Check serial tag voltage and amperage re quirements and make sure your electrical service conforms. See Figure 5 on page 13 for total running amps. Bring properly sized power l eads and ground from a fused di sconnect (installed by your electrician) to the main power term[...]

  • Page 15

    SMC Series Chillers Page 15 Process Water Bypass All SMC chillers have an in ternal bypass device (patent pending). If the process flow becomes blocked during chille r operation, this com ponent allows water to flow through the chiller. This protects the chiller from freeze-up, excessiv e pressu res, and pump damage, and allows other safety feature[...]

  • Page 16

    Page 16 SMC Series Chillers ; A corrosion inhibitor suitable for the materials in the sy stem should be added to the glycol/water solution. ; If straight water use is desired, contac t the Sterling, Inc. Engineering Department. ; The six gallon (23 liter) reservoir is not designed to withstand water pressure above 5 psi (34 kPa). ; The fill opening[...]

  • Page 17

    SMC Series Chillers Page 17 2-5 Overhead Process Considerations If your application has chilled water or pro cess piping above the reservoir fill and vent level, install a standpipe to a point 1’ (30 cm) above the highest point in the system. In applications where the process or its pi ping is 15 feet (4.6 m) or more above the reservoir, you must[...]

  • Page 18

    Page 18 SMC Series Chillers 3 Sequence of Operation IMPORTANT! • The SMC unit has a leaving water temperat ure range of 30°F (-1°C) to 65°F (18°C). Do not attempt to run the SMC unit outside this temperature range or damage to the unit may occur. • When operating the SMC unit between 30°F (-1°C) and 40°F (5°C), you must use a solution o[...]

  • Page 19

    SMC Series Chillers Page 19 3-3 High Pressure Cutout The high pressure cutout is an electro-mechan ical safety feature that opens the control circuit if the system condensing pressure exceeds a safe leve l. The chiller will automatically restart when the pressure drops back to an acceptable level. Model Cuts out if condensing pressure exceeds: SMC0[...]

  • Page 20

    Page 20 SMC Series Chillers Figure 8: SMC Component Identification[...]

  • Page 21

    SMC Series Chillers Page 21 Figure 9: Piping Schematic - 1 Pump with Reservoir Expansion valve Filter Drier Sight glass Filter High pressure control Compressor Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Liquid line Suction Line Tank Vent Fill glass Sight Process From To P Evaporator Pump Power element [...]

  • Page 22

    Page 22 SMC Series Chillers Figure 10: Piping Schematic - 1 Pump Without Reservoir Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Temperature compressor-mounted access valve, Refrigeration Compressor Pump Optional CPR valve evacuation valve Refrigeration Low control pressure access valve Refrigeration cont[...]

  • Page 23

    SMC Series Chillers Page 23 Figure 11: Piping Schematic - No Pump, No Reservoir Flow switch Temperature compressor-mounted access valve, Refrigeration Compressor Optional CPR valve Low control pressure access valve Refrigeration control pressure High Discharge line Refrigeration evacuation valve Equalizing line Power element Evaporator Suction line[...]

  • Page 24

    Page 24 SMC Series Chillers 4 Startup Checklists 4-1 Introduction Follow the check lists below for the startup of your new chiller. These lists assume the installation inform ation elsewhere in this m anual has been read and followed. New chillers should be started up and checked by a qualified refrigeration servic e technician. 4-2 SMC Pre-Startup[...]

  • Page 25

    SMC Series Chillers Page 25 4-4 SMC Water Circuit Pressure Drop Table Model Gallons per minute Liters per minute Δ P (psig) Δ P (kPa) SMC050 2.0 7.5 2.5 17.3 2.4 9.0 4.0 27.6 3.6 13.6 7.5 51.8 4.8 18.1 12.5 86.2 SMC100 2.0 7.5 2.5 17.3 2.4 9.0 2.5 17.3 3.6 13.6 3.0 20.7 4.8 18.1 5.0 34.5 SMC150 2.0 7.5 2.5 17.3 2.4 9.0 2.5 17.3 3.6 13.6 3.0 20.7 [...]

  • Page 26

    Page 26 SMC Series Chillers 5 Microprocessor Control 5-1 Introduction Standard SMC Series chillers use a microproces sor-based PID controller. The controller is a modular, self-c ontained unit that can slide from its mounting housing. It is factory set and adjusted; no field adjustme nt to the interna l controls is necessary. SMC Control Operation [...]

  • Page 27

    SMC Series Chillers Page 27 Figure 12: Typical SMC Series E5CK Microprocessor Controller PV SV OUT1 OUT2 MANU STOP RMT AT SUB1 AT E5CK OMRON OUT2 LED The orange OUT2 energizes whenever the proces s temperature is two degrees (2 ° F/ºC) or more above the To Process set point. Th e compressor then comes on and runs until the temperature at the To P[...]

  • Page 28

    Page 28 SMC Series Chillers RMT LED The orange RMT LED is lit during remote operation. AT LED The orange AT LED flashes during auto-tuning. SUB1 LED The orange SUB1 LED energizes whenever the process temperatu re is two degrees (2 ° F/ºC) or more below the To Process set point. The com pressor then shuts down by means of a latching circu it, and [...]

  • Page 29

    SMC Series Chillers Page 29 Important! Do not change any of the cont rol settings without consulting the Sterling Service Department. The AEC, Inc. warranty does not cover chiller failures from tampering with controller settings ! Down Key Each press of the Down Arrow key decrements or reduces the values or settings on the SV display. Up Key Each p[...]

  • Page 30

    Page 30 SMC Series Chillers 5-6 Optional Communications Standard Omron Protocol The communications function allows you to monitor and set E5CK parameters by a program prepared and running on a host com puter connected to the E5CK controller. When using the communications function, you must add on the unit for R S-232C or RS-485 communications. The [...]

  • Page 31

    SMC Series Chillers Page 31 6 Optional Graphic Panel 6-1 Indicator Lights PUMP ON (green) This indicator lights when the pump is running. COMPRESSOR ON (green) This indicator lights when the compressor is operating. HIGH REFRIGERANT PRESSURE (red) This indicator lights if the condensing pressu re exceeds a safe level. The chiller goes to Idle mode [...]

  • Page 32

    Page 32 SMC Series Chillers Figure 13: Optional Graphic Panel OFF ON PRESSURE LOW REFRIGERANT POWER ON PUMP COMPRESSOR ON Portable Chiller REFRIGERANT PRESSURE HIGH A0537868 PC Series ON AL O RO E5CS[...]

  • Page 33

    SMC Series Chillers Page 33 7 Routine Maintenance 7-1 Lubrication Every three months, grease all fan moto rs and pump motors that do not have permanently sealed bearings. Rem ove greas e relief plug (motors only) before adding grease. Failure to do so may result in dislodgi ng the bearing grease retainer, eventually causing bearing failure. Compres[...]

  • Page 34

    Page 34 SMC Series Chillers Figure 15: Typical SMC Wiring Schematic 1T 1T 1FU 1FU 1 X1 1 1 Jumper Remote interlock by others 1S-1LT 1 3 1C 1 41 6 1 5 2C Pump starter Condensing unit contactor G 1S-1LT G "Power On" ON/OFF 1L1 1L2 1L1 1L2 1L1 1L2 2 Control power 1PS 2PS 1 1 1CNTL RED (-) YEL (+) Type K Thermocouple Subpanel ground 1C 1T1 1T[...]

  • Page 35

    SMC Series Chillers Page 35 Figure 16: SMC Wiring Schematic for Ch illers with No Pump or Reservoir 1T 1T 1FU 1FU X1 1 1 Jumper Remote interlock by others 1S 1S-1LT 5 7 6 1C Condensing unit contactor G 1S-1LT G "Power On" ON/OFF 1L1 1L2 1L1 1L2 2 Control power 1PS 1PS 2PS 1 1CNTL RED (-) YEL (+) Type K thermocouple Subpanel ground 1C 1T1 [...]

  • Page 36

    Page 36 SMC Series Chillers - Notes -[...]

  • Page 37

    SMC Series Chillers Page 37 8 Troubleshooting Guide Problem Cause Solution Chiller will not run. No power. Check main disconnect fuses, wiring, and power lead to the unit. Wrong voltage supplied to the chiller. Voltage must be within plus or minus 10% of the nameplate rating. Defective on/off switch. Replace. Control circuit fuse blown. Replace, ch[...]

  • Page 38

    Page 38 SMC Series Chillers Problem Cause Solution Pump runs, compressor will not. Refrigerant is low. Check the refrigerant charge. Pressure switch contacts are open. Sight glass should be clear while compressor runs. Call for service if bubbling or foaming Refrigerant high pressure cutout switch contacts are open. Check for dirty condenser. Check[...]

  • Page 39

    SMC Series Chillers Page 39 PCA Unit Parts List Part Number Part Description A0537868 SMC Graphic A0537899 BZ Pressure Gauge A0534584 Red Neon Graphic Light * A0534586 Green Neon Graphic Light * A0500857 2” Swivel Casters A0534269 1/16 DIN Digital Temperature Controller A0537955 Process Water Flow Switch A0533873 Thermocouple, 8’ A0539409 150 V[...]

  • Page 40

    Page 40 SMC Series Chillers - Notes -[...]

  • Page 41

    SMC Series Chillers Page 41 - Notes -[...]

  • Page 42

    Page 42 SMC Series Chillers -Notes - Technical Assistance[...]

  • Page 43

    SMC Series Chillers Page 43 Parts Department Call toll-free 7am - 5pm CST [800] 423-31 83 Or call [262] 641-8610, Fax [262] 641-8653 The Parts Department at AEC, Inc. is ready to provide th e parts to keep your system s up and running. AEC replacement parts ensure operation at design spec ifications. Please have th e mo del and serial number of you[...]