HT Chillers Flow-Through Chiller 36000 Plus
Contents
1. Length shown is as measured one way along wire path between unit and service panel for voltage drop not to exceed 2 Time Delay fuse FLA Full Load Amps LRA Locked Rotor Amps MCA Minimum Circuit Amps RLA Rated Load Amps NOTE Control circuit is 24 V on all units and requires external power source Copper wire must be used from service disconnect to unit All motors compressors contain internal overload protection Complies with 2007 requirements of ASHRAE Standards 90 1 CHARGING SUBCOOLING TX V TYPE EXPANSION DEVICE UNIT SIZE VOLTAGE SERIES REQUIRED SUBCOOLING F 36 000 9 www HTChillers com Flow Through Chiller Page 24 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Trouble Shooting In diagnosing common faults with the HT Chiller it is useful to present the logical pattern of thought that is used by experienced technicians The charts on the following pages are not intended to be an answer to all problems but only to guide your thinking as you attempt to decide on your course of action Through a series of yes and no answers you will follow the logical path to a likely conclusion TIP For assistance with any questions please feel free to call Technical Support at 1 830 370 2362 or 1 800 259 2720 toll free www HTChillers com Flow Through Chiller Page 25 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Electrical Checks Flow Chart2. Unit Running NO YES Voltage on compressor Unit Noisy side of contactor Go to Mechanical Flow Chart 3 phase compressor running backwards switch any 2 incoming electrical leads YES NO 24 Volts present Voltage on line terminal board side of contactor NO YES NO YES Need to reset overload Freeze Stat Tripped Circuit Breakers Hi Pressure Control safety on transformer Fuses Open Lo Pressure Control NO NO YES Compressor Thermal Overload Replace Cold Control Open Faulty Cold Control Unit Wiring and Connections Transformer or Replace Cold Control Unit Wiring and Connections and reset freeze stat Run Capacitor Start Capacitor Compressor Internal Overload Open Compressor Winding Open Unit Wiring and Connections www HTChillers com Flow Through Chiller Page 26 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Mechanical Checks Flow Chart Unit Running YES NO 3 phase compressor Go to Electrical running backwards Checks Flow Chart ee YES Switch any 2 leads on incoming power NO Pressure problems ne High Head Pressure Dirty Condenser Coil Inoperative Outdoor Fan Overcharge Recirculation of Condenser Air Non condensibles Higher than Ambient Air Entering Condenser Wrong Condenser Fan Rotation Expansion Valve Stuck Open Low Head Pressure Low sucuq Pressure Low on Charge No Water in Tank Open IPR Valve Low
3. including but not limited to the specific exclusions set forth below of this Limited Warranty and subject to the Manufacturer s right to inspect and validate the warranty claim as set forth below If an exact replacement is not available an equivalent unit or credit will be provided The replacement will be warranted for only the unexpired portion of the original Applicable Warranty Period If government regulations industry certification or similar standards require the replacement unit to have features not found in the defective unit you will be charged for the difference for those required features If you pay the difference you will also receive a completely new Limited Warranty for the new replacement unit The Manufacturer does not authorize or warranty any online Internet sale of equipment through auction or any other method of unapproved online sales direct to the consumer nor the sale of equipment by liquidators The ONLY approved online sales are through the Manufacture s websites www HTChillers com and www HensleyThermodynamics com Errective DATE AND APPLICABLE WARRANTY PERIODS The Effective Date of warranty coverage is the date of sale plus 2 years Exctusions In addition to the specific exclusions set forth in the other sections of this Limited Warranty document THIS Limited Warranty WILL NOT APPLY TO A damages malfunctions or failures resulting from failure to properly install operate or maintain Covered Equipment in a
4. 8 3 8 250 250 250 250 250 250 250 250 250 410A Maximum actual length not to exceed 200 ft 61 m t Total equivalent length accounts for losses due to elbows or fitting Maximum Total Equivalent Length Outdoor Unit ABOVE Indoor Unit AC with 410A Refrigerant Maximum Total Equivalent Lengtht Outdoor unit BELOW Indoor Liquid imate tine ao Vertical Separation ft m Size 1am 25 26 50 51 75 76 100 101 125 126 150 151 175 176 200 Connection wTxy 7 6 7 9 15 2 15 5 22 9 23 2 30 5 30 8 38 1 38 4 45 7 46 0 53 3 53 6 61 0 036 3 8 3 8 250 250 250 250 250 250 250 250 410A Maximum actual length not to exceed 200 ft 61 m Total equivalent length accounts for losses due to elbows or fitting REFRIGERANT CHARGE ADJUSTMENTS Liquid Line 3 8 0 5 oz ft Factory charge for lineset 3 oz 85 05 g Charging Formula Lineset oz ft x total length factory charge for lineset charge adjustment Example System has 20 ft of line set Formula 50 oz ft x 20ft 3 0z 7 oz Net result is to add 7 oz of refrigerant to the system www HTChillers com Flow Through Chiller Page 23 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 LONG LINE APPLICATIONS An application is considered Long Line when the refrigerant level in the system requires the use of accessories
5. Length Height Empty 525 Pounds 31 inches 31 inches 73 1 4 inches Barrel Filled with water 985 Pounds Chiller Barral Compartment Chiller Barral Compartment da h iata PE T HT Chiller Side View HT Chiller Front View www HTChillers com Flow Through Chiller Page 5 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Product Components The HT Flow Through Chiller is comprised of the following major components Condensing Unit The condensing unit is a 13 SEER unit manufactured by Ruud and contains the environmentally friendly 410A refrigerant Chiller Barrel Energy Storage Tank The R 10 insulated Chiller Barrel Energy Storage Tank is located within the Chiller Barrel Compartment The Chiller Barrel holds approximately 55 gallons of water that is utilized for two specific purposes 1 The thermo conductive property of water enables efficient heat transfer and 2 The water stores excess energy to be used when the refrigeration system cycles off Copper flow through water lines are submerged within this R 10 insulated Chiller Barrel where they are cooled both by the accompanying refrigerant lines and the chilled water within the Chiller Barrel Fill the Chiller Barrel with clean water upon installation and secure the lid The water in the barrel stays in the barrel and you will only need to check the water level during periodic inspections www HTChillers com F
6. o Charge Low Ambient Temperature Faulty Metering Device Inoperative Compressor Restriction in System Valves Restricted Filter drier Restricted Filter drier Restriction in System Expansion Valve Stuck Closed www HTChillers com Flow Through Chiller Page 27 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Wiring Diagram 3 Phase Units Only www HTChillers com Flow Through Chiller Page 28 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Receiving and Unpacking Instructions IMPORTANT Inspect the shipping crate immediately upon receipt and file a claim with the delivery driver if any obvious damage is present Upon delivery carefully remove the crating and inspect the HT Chiller for damage Call HT Chiller Support at 1 830 370 2362 or 1 800 259 2720 toll free within 72 hours of receipt if you have any questions or concerns Repair Authorization All HT Chiller warranty repairs must be first authorized by calling Hensley Thermodynamics technical support 1 830 370 2362 or 1 800 259 2720 Any repairs performed without prior authorization will be at owner s expense and may void the warranty Proof of purchase and delivery date are required before service can be authorized Only qualified personnel shall be allowed to unpack install use and perform maintenance on this unit Only a qualified HVAC technician is authorized to repair the condensing unit under warranty This
7. switch will go out Turn off your flow through water source Disconnect the HT Chiller from your electrical power source Access the Chiller Barrel Energy Storage Tank by removing the left side panel Remove the tank ring and the tank lid Either siphon or pump the water out of the tank With both the incoming and outgoing water valves in the open position apply no more than 60 psi of pressure to one of the valves so that when under pressure the water escapes from the other valve Alternatively a wet dry vac can be used if you seal off the vacuum head to create sufficient suction There isn t that much water in the line but it must be removed www HTChillers com Flow Through Chiller Page 15 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Field Splitting the HT Chiller Note Field Splitting the HT Chiller is optional and not required The HT Chiller is Field Splitable allowing you to place the condensing unit away from the Chiller Barrel Compartment For example split the Chiller Unit if you prefer that the condensing unit be located away from the waterjet work area to eliminate noise and heat exhaust How to Field Split the HT Chiller IMPORTANT These instructions are a general guide to be used in conjunction with the Refrigeration Technician Section Installing the Condensing Unit located near the end of this manual Step 1 Empty the Chiller Barrel Water Storage Tank Optional A WARNI
8. the Canadian electrical code CSA 22 1 Recognize safety information This is the safety alert symbol When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand these signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol DANGER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing and gloves when handling parts A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label The condensing unit contains system refrigerant charge for operation with the HT Chiller Barrel For proper unit operation check refrigerant charge using c
9. to Fig 3 FEE Fig 3 Refrigerant tubes and Chiller Barrel heat exchanger should be evacuated using the recommended deep vacuum method of 500 microns The alternate triple Liquid Line Dryer A CAUTION UNIT DAMAGE HAZARD improper operation Never use the system compressor as a vacuum pump Failure to follow this caution may result in equipment damage or www HTChillers com Flow Through Chiller Page 20 evacuation method may be used see triple evacuation procedure in service manual Always break a vacuum with dry nitrogen Deep Vacuum Method The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and liquid water A tight dry system will hold a vacuum of 1000 microns after approximately 7 minutes See Fig 4 5000 4500 4000 9000 ps g 2900 2000 1500 1000 500 LEAK IN SYSTEM TOO WET TIGHT GITZ S424 aG F MINUTES A95424 Fig 4 Deep Vacuum Graph Final Tubing Check IMPORTANT Check to be certain factory tubing on both Chiller Barrel heat exchanger and outdoor unit has not shifted during shipment Ensure tubes are not rubbing against each other or any sheet metal or wires Pay close attention to feeder tubes making sure wire ties on feeder tubes are secure and tight Make Ele
10. Chiller User Manual amp Installation Guide UM F36000 Rev 1 exist when the outdoor temperature is between 70 F and100 F 21 11 C and 37 78 C and the Chiller water is between 70 F and 90 F 7 22 C and 26 67 C Follow the procedure below Unit is factory charged for 15ft of lineset Adjust charge by adding or removing 0 6 oz ft of 3 8 liquid line above or below 8ft 2 44 m respectively For standard refrigerant line lengths 50 ft 24 38 m or less allow system to operate in cooling mode at least 15 minutes If conditions are favorable check system charge by subcooling method If any adjustment is necessary adjust charge slowly and allow system to operate for 15 minutes to stabilize before declaring a properly charged system If the Chiller water temperature is above 80 F 26 67 C and the outdoor temperature is in the favorable range adjust system charge by weight based on line length and allow the Chiller water temperature to drop to 80 F 26 67 C before attempting to check system charge by subcooling method as described above NOTE If line length is beyond 50 ft 24 38 m or greater than 20 ft 6 10 m vertical separation See Long Line Guideline for special charging requirements Final Checks IMPORTANT Before leaving job be sure to do the following 1 Ensure that all wiring is routed away from tubing and sheet metal edges to prevent rub through or wire pinching 2 Ensure that all wiring and tubing
11. HT Chillers Flow Through Chiller 36000 Plus User Manual amp Installation Guide THERMODYNAMICS Hensley Thermodynamics 1 830 370 2362 1 800 259 2720 www HTChillers com UM F36000 Rev 1 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Manufacturer Information About Hensley Thermodynamics Hensley Thermodynamics Inc is chiller manufacturer focused on the design and manufacture of affordable efficient easy to use and easy to maintain chiller units for everyone from major industry to the individual hobbyist that have machines that require chilled coolant less than 65 F for optimal operation Hensley Thermodynamics 1 830 370 2362 Hours 8 00 a m to 5 00 p m Central Time Monday Friday 1 800 259 2720 Email anytime info HTChillers com Shipping Address Hensley Thermodynamics 454 Cade Loop Ingram TX 78025 Mailing Address Hensley Thermodynamics P O Box 318 Ingram TX 78025 Visit us Online www HTChillers com This document contains subject matter protected by United States copyright law and to which Hensley Thermodynamics Corporation has proprietary rights Recipients of this document shall not reproduce distribute transmit display publish broadcast or use information contained herein in whole or in part for any use other than the purpose for which this manual was provided The following are trademarks of Hensley Thermodynamics Inc Hensley Thermodynamics and the Hensley Ther
12. Manual amp Installation Guide UM F36000 Rev 1 3 Remove the left side panel of the Chiller Barrel Energy Storage Tank Compartment by unscrewing the 7 screws around the perimeter ae gt PS SEAS 4 Loosen and remove the clamp ring on the Chiller Barrel Energy Storage Tank 5 Lift off and remove the Chiller Barrel Energy Storage Tank lid www HTChillers com Flow Through Chiller Page 9 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 How to Fill the Chiller Barrel Energy Storage Tank A CAUTION Do not add any chemical to the Chiller Barrel Energy Storage Tank possible damage to the Chiller Unit may occur Adding chemicals to the Chiller Barrel water tank will void the warranty 1 If necessary follow the instructions to How to Access the Chiller Barrel Energy Storage Tank 2 Fill the Chiller Barrel with clean water to the water line indicator located on the inside of the tank Approximately 55 gallons Replace the Chiller Barrel lid securely Replace and fasten the Chiller Barrel ring onto the Chiller Barrel Replace the side panel securing all 7 screws www HTChillers com Flow Through Chiller Page 10 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Attaching Water In Water Out Lines 1 The Water In and the Water Out lines are NPT valves 2 Use a backup wrench to secure the water valve while installing connections to prevent damage to th
13. NG The weight of the Chiller Unit when filled with water is 985 pounds If you are moving the Chiller Unit for the splitting process it is highly recommended that you drain the Chiller Barrel water tank 1 Gain access to the internal Chiller Barrel by following the instructions How to Access the Chiller Barrel Energy Storage Tank 2 Empty the Chiller Barrel by following the instructions How to Remove Water from Chiller Barrel and Flow Through Lines Step 2 Pump Down Refrigerant A WARNING To prevent personal injury and or damage to equipment only qualified refrigeration technicians are authorized to make the modifications outlined below The condensing unit uses 410A refrigerant 1 Using the proper High Pressure gauges for 410A connect the High and Low side hoses to the appropriate pump down valves at condensing unit 2 On Chiller Barrel Cabinet front panel press the ON OFF push button power switch to apply power to the condenser 3 Close the High side pump down valve and pump refrigerant into the condenser until suction pressure reaches approximately 5 psi 4 Turn off the condenser by pushing ON OFF push button power switch The light in the switch will go out Disconnect the electrical power from the HT Chiller Close the Low side pump down valve Step 3 Remove Internal Wiring A DANGER To prevent electrical shock only qualified electricians are authorized to make the modifications outlined
14. NG To prevent electrical shock e The HT Chiller must be grounded through your electrical power source e The HT Chiller must be powered off and disconnected from the main power supply prior to installation maintenance moving and decommissioning www HTChillers com Flow Through Chiller Page 2 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Emergency Shutdown In case of emergency disconnect power to the HT Chiller at your electrical power source Structural Support The HT Chiller is mounted on steel legs however underlying level and structurally sound support must be provided A WARNING Failure to provide proper support may result in personal injury and or damage to the Chiller Unit Mechanical Strength Do not stack mount or lean anything on the HT Chiller A WARNING External loads or stresses placed on or against the chiller unit may result in personal injury and or damage to the HT Chiller www HTChillers com Flow Through Chiller Page 3 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Product Description Purpose The Hensley Thermodynamics Chiller HT Chiller is designed specifically for waterjet cutting machines with the goal of helping to reduce waterjet machine downtime due to pump failure To extend the life of your waterjet pump and to protect your pump manufacturer warranty it is critical to keep the pump water temperature between 45 F
15. air that has been authorized by the Manufacturer How TO OBTAIN WARRANTY CLAIMS ASSISTANCE You must promptly report any failure covered by this Warranty to the Manufacturer Normally your local HVAC air conditioning contractor will be able to take the necessary corrective action by obtaining replacement parts through the Manufacturer The name and location of local HVAC contractors can be usually found in your telephone directory in the HVAC contractor section HOWEVER ANY PART REPLACEMENTS ARE MADE SUBJECT TO VALIDATION BY THE MANUFACTURER OF IN WARRANTY COVERAGE Any part to be replaced must be made available in exchange for the replacement Ecwusive WARRANTY LIMITATION OF LIABILITY This Limited Warranty is the ONLY warranty given by the Manufacturer This warranty is non transferable No one is authorized to make any warranties on behalf of the Manufacturer ANY IMPLIED WARRANTIES INCLUDING MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS SPECIFIED IN THIS LIMITED WARRANTY THE MANUFACTURER S SOLE LIABILITY WITH RESPECT TO DEFECTIVE PARTS OR FAILURE SHALL BE AS SET FORTH IN THIS LIMITED WARRANTY AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARE EXPRESSLY EXCLUDED Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential damages so the above limitation or exclusion may not apply to you This Limited Warran
16. and 65 F Water temperatures above the recommended values cause the pump seals to wear and fail sooner Extend the life of your equipment by cooling the water Flow Through 36000 Model Configurations HT Flow Through Chillers are available in the following configurations Model F32301 3 Ton 230 Volt Single Phase Model F32303 3 Ton 230 Volt Three Phase Model F34603 3 Ton 460 Volt Three Phase Description This HT Chiller is a flow through system that efficiently provides chilled water to waterjet cutting machines Our HT Chiller is designed specifically for the water usage requirements of a waterjet machine 1 to 2 gallons minute and is a true waterjet chiller that can handle 95 F incoming water temperatures dropping the temperature of the water going to the waterjet to below 65 F without having to oversize its capacity The internal Chiller Barrel Energy Storage Tank holds approximately 55 gallons of water used to store refrigeration energy The storage tank has a capacity of storing 11 000 BTUs of energy and the HT Chiller produces a nominal 36 000 BTUs The HT Chiller can efficiently handle constant cutting even when the incoming water is above 90 F Refrigerant lines submerged in the Chiller Barrel Energy Storage Tank first remove heat from water traveling through the flow through water lines going to the waterjet Then any unused refrigeration capacity not used by the flow through water lines is stored in the Chill
17. below www HTChillers com Flow Through Chiller Page 16 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 1 Completely remove all electrical power from the HT Chiller by using the breaker on your fuse box or pulling the fuse in your electrical panel as is appropriate for your electrical connections Remove the HT Chiller side panel right side when facing front of chiller Disconnect the 24 Volt control wiring from the Control Box Step 4 Cut Refrigeration Lines 1 With all electrical lines removed proceed to unsweat copper connection at the base of the condensing unit after following proper refrigeration techniques for removing remaining refrigerant Be sure that the brass pump down valves stay cool while unsweating the connections 2 Seal refrigerant lines to prevent contamination Step 5 Separate Chiller Barrel Compartment from Condensing Unit The condensing unit is attached to the Chiller Barrel Compartment top by 2 bolts accessible from the inside of the condensing unit under the fan housing 1 Separate the condensing unit from the Chiller Barrel Compartment top by removing these 2 bolts 2 Provide a pad for the condensing unit at its new location Step 6 Connect New Refrigerant Lines and Electrical Wires 1 Install the condensing unit at the new location according to all city and state codes 2 Install new refrigerant lines in accordance to the instructions by following section Refrigera
18. ccordance with the Manufacturer s instructions B damages malfunctions or failures caused by misuse accident contaminated or corrosive atmosphere vandalism freight damage fire flood freeze lightning acts of war acts of God and the like C Covered Equipment which is not installed by qualified trained personnel in accordance with applicable codes ordinance and good trade practices or D damages malfunctions or failures caused by the use of any attachment accessory or component not authorized by the Manufacture E Covered equipment when operated with system components or accessories which do not match or meet the specifications recommended by the Manufacturer F any Covered Equipment manufactured by the Manufacturer that has been sold to the consumer via the Internet from an unapproved website or auction website Online sales are only authorized through www HTChillers com and www HensleyThermodynamics com Shipping COSTS This Limited Warranty does NOT cover shipping costs You are responsible for the cost of shipping warranty replacement parts from our factory to the location of your Covered Equipment You also are responsible for the cost of shipping failed parts and for incidental costs incurred locally including handling charges You also must pay the shipping costs of returning the failed part to the port of entry into the continental United States Lasor COSTS This Limited Warranty covers any labor costs or expenses for rep
19. charge above the Condensing Unit for proper operation Proper Clearance Measurement Around all sides of chiller 18 inches Above top of condensing unit 4 feet Access to required electrical source as follows eae Fra Voltad Rated Load Minimum Fuse HACR Breaker Number Phase Hz Volts Amperes Circuit Min Max RLA Amperes Amps Amps F32301 1 60 230 16 7 15 30 35 F34303 3 60 230 10 4 15 20 20 F34603 3 60 460 5 8 15 15 15 Contact a licensed electrician and your local power company to ensure that installation wiring complies with local fire safety and electrical codes Access to a clean water source To prevent heat gain to the Chiller Unit Water Out line place the Chiller Unit near the waterjet machine and insulate the water line Insulating the waterline also protects surrounding surfaces from condensation or sweating from the chilled waterline www HTChillers com Flow Through Chiller Page 7 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 How to Access the Chiller Barrel Energy Storage Tank 1 If the HT Chiller is powered on press the ON OFF push button power switch to turn the HT Chiller off The light will extinguish to indicate that the chiller is powered off Push Button Power Switch ON OFF 2 Disconnect electrical power from the HT Chiller TE www HTChillers com Flow Through Chiller Page 8 HT Chiller User
20. ctrical Connections Be sure field wiring complies with local and national fire safety and electrical codes and voltage to system is within limits shown on unit rating plate Contact local power company for correction of improper voltage See unit rating plate for recommended circuit protection device NOTE Operation of unit on improper line voltage constitutes abuse and could affect unit reliability See unit rating plate Do not install unit in system where voltage may fluctuate above or below permissible limits NOTE Use copper wire only between disconnect switch and unit HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 NOTE Install branch circuit disconnect of adequate size per NEC to handle unit starting current Locate disconnect within sight from and readily accessible from unit per Section 440 14 of NEC Route Ground and Power Wires Remove access panel to gain access to unit wiring Extend wires from disconnect through power wiring hole provided and into unit control box A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes VACUUM TIGHT DRY SYSTEM Connect Ground and Pow
21. e construction NOTE Unit must be level to within 2 43 8 in ft 9 5 mm m per compressor manufacturer specifications www HTChillers com Flow Through Chiller Page 19 Clearance Requirements When installing allow sufficient space for airflow clearance wiring refrigerant piping and service Allow 24 in 609 6 mm clearance to service end of unit and 60 in 1219 2 mm above unit For proper airflow a 6 in 152 4 mm clearance on 1 side of unit and 12 in 304 8 mm on all remaining sides must be maintained Maintain a distance of 24 in 609 6 mm between units or 18 in 457 2 mm if no overhang within 12 ft 3 66 m Position so water snow or ice from roof or eaves cannot fall directly on unit NOTE 18 457 2 mm clearance option described above is approved for outdoor units with wire grille coil guard only Units with louver panels require 24 609 6 mm between units On rooftop applications locate unit at least 6 in 152 4 mm above roof surface Operating Ambient The minimum outdoor operating ambient in cooling mode without accessory is 55 F 12 78 C and the maximum outdoor operating ambient in cooling mode is 125 F 51 67 C Sweat Connection A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Service valves must be wrapped in a heat sinking material such as a wet cloth while brazing Use re
22. e water lines 3 Purge air from the flow through line before applying power to the HT Chiller Valves Open TIP The chilled water leaving the HT Chiller will be typically below the dew point so condensation may occur Properly insulate the water out line chilled water to prevent nearby surfaces from condensation damage TIP To maintain the chilled water temperature and to prevent heat gain of the chilled water line the HT Chiller either needs to be close to the waterjet machine or the water out chilled water line needs to be properly insulated This is especially important if the water out chilled water line is exposed to high temperatures or hot surfaces Reminder about the Water in the Chiller Barrel This HT Chiller is a flow through system with water flowing through a water pipe that is submerged in the Chiller Barrel Energy Storage Tank This water pipe is chilled by refrigerant lines and the cold water within the Chiller Barrel Energy Storage Tank The purpose of the water in the Chiller Barrel is to store cooling energy only in other words the water in the barrel stays in the barrel www HTChillers com Flow Through Chiller Page 11 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Wiring Electrical Power to the HT Chiller A DANGER A CAUTION CAUTION CAUTION ELECTRICAL SHOCK HAZARD Disconnect Main Power Before installing modifying or servicing the HT Chiller your main el
23. ectrical disconnect switch must be in the OFF position Your setup may have more than 1 one disconnect switch Lock out and tag switch es with a suitable warning label s All Electrical Work Must Be Completed By a Qualified Person Wire according to all national state and city electrical codes Prevent Reverse Wiring of 3 Phase As with all typical 3 phase systems you can accidentally wire the HT Chiller incorrectly to cause the compressor motor to run backwards This is evident by excessive compressor noise no heat being exhausted by the condenser fan within 1 minute and flow through water not cooling Reverse any two leads to change the phase for proper rotation Not correcting the wiring will cause the compressor to overheat and turn off Prevent Breakage of Lines Fill Chiller Barrel Before Applying Power To prevent freezing and breakage of flow through water lines the Chiller Barrel Energy Storage Tank MUST be filled with water before power is applied to the HT Chiller Prevent Skin Damage Do not Touch Refrigerant Lines in Chiller Barrel Refrigerant lines in the Chiller Barrel Energy Storage Tank can operate at temperatures below freezing Touching these lines can freeze skin Note Operating the HT Chiller on improper line voltage will void the warranty Note Do not connect the HT Chiller to an electrical source that has power fluctuations beyond approved limits Wiring Instructions 1 Connect proper voltage t
24. eeeeeeeaaees 10 Attaching Water In Water Out LiIn S eeeecccccceee eee eeeeeenaeeeeeeeeeeeeenenaeaeeeeeees 11 Wiring Electrical Power to the HT Chiller eccccceeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeneeeeeeeees 12 Wiring INstructions ye etisenctcntntntsachneneccntnerts Retneneene ti Beem eee eis 12 6 HT Chiller Operation 13 How to Turn On the HT Chiller scecsiecertivincancebimeacdeutevenass meerdsulwescasbeetendietwuaredaiweiadehex 13 How to Turn Off the HT Chiller eeceeccccceceeeeeeeeeeenaeeeeeeeeeeeesaaaaaeaeeeeeeeeeeneenaaaaes 13 7 Maintenance Repairs and Storage 14 General MAINTE MANGE srira aner onen EEE KEE EE a NEEE aa an 14 Repairing Components sssssessessserrttesstrrttrrrntttstrtrtttnnttsstrtntrnnnnnseennnEnnnnnseeeenee 14 Freeze MNGi MNOS tA scsianctccenetsdediouiccanhaieutiorenieineisthiee se eens tame wieeseiiaaeeeeer 14 How to Reset the FreeZestal viiccssccsscsescseinearccstacastiatcnereseiwestivweencrsieearenaneessonte 14 Storing the HT Chiller while Not in Service 0 ccccceecteceeteeeeeeeeeeteeeeenneeeeeeeeeteees 15 How to Remove Water from Chiller Barrel and Flow Through Lines 00008 15 8 Field Splitting the HT Chiller 16 How to Field Split the HT Chiller w
25. eeeeeeeeeeeeeeeneeeeeeeeeeeeeeeaaees 2 Access by Qualified Personnel Only ccceceeecsccceeeeeeeeeeeeeneaeaeeeeeeetenenenaaaeeeeeees 2 Electrical PreCautlOns eireiisiisie sssrini nperi tinina eaire a Ea Eere EAE EEEE TEREE 2 Emergency Shutdown cic cecieeeszeccetcceactetacgesyecccectueaimasyestdentveiaeaWescdecbetaiaeaaveaedectutace 3 Structural Support oss 28 cee ats peice teste oes ees aoe ee 3 Mechanical Strength issena a E a OE NEE EE E Ea ER 3 4 Product Description 4 PU OS Eea eae ciate igs aha tedanet oe 4 Flow Through 36000 Model Configurations cccceeeeceeeeeeeeeeeeenneeeeeeeeeeeeneenaaees 4 EDS CIR cca es se eee aires nase cae eee eee escalate este a 4 Dimensions and Weight ccceeeeeeeeeseeceeeeeeeeeeeeenaaeeeeeeeeeeeeaaaaaaaeeeeeeeeeeeeenaaaaes 5 Product COmMpOneN S S 3s5 sees ast ciesits eves s Seay eran eee ees 6 Conde nsing UMN seisssesnetstenuaets i eeke a A E EE REEE 6 Chiller Barrel Energy Storage Tank ssssssessessnrrrnrrssererrrrnnnnsssrrrnrrnnnnnserrrnne 6 5 Installation Instructions 7 L cation ChetkliSt sser nera EEE EE EA EEEE EEA TERRIER 7 How to Access the Chiller Barrel Energy Storage Tank cccceeeeeeeeeeeeeeeeeeeeees 8 How to Fill the Chiller Barrel Energy Storage Tank ccceecceeseeteeeeeeeee
26. er Barrel Energy Storage Tank This ability to store energy saves energy because the HT Chiller is not running needlessly when you are working in light load conditions changing material and re setting up When the water in the Chiller Barrel reaches 45 F the condensing unit cycles off to save energy The cold water in the Chiller Barrel continues to absorb heat in the water traveling through the flow through water line When the water discharge temperature reaches approximately 58 F the condenser unit cycles on to once again lower the Chiller Barrel water temperature to 45 F The HT Chiller is mounted on 4 inch metal legs This design provides a means to easily transport the HT Chiller with a pallet jack or forklift As an optional installation feature the HT Chiller can be field split therefore allowing you to install the Chiller Barrel Energy Storage Tank Cabinet near the waterjet machine and install the condensing unit up to 200 feet away from the work area Note The HT Chiller is not intended for use other than described in this manual To prevent damage to the HT Chiller and voiding the warranty call the Hensley Thermodynamics Engineering Department at 1 830 370 2362 or 1 800 259 2720 before using the HT Chiller beyond the scope of this manual www HTChillers com Flow Through Chiller Page 4 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Dimensions and Weight Flow Through HT Chiller Weight Width
27. er Wires Connect ground wire to ground connection in control box for safety Connect power wiring to contactor as shown in Fig 5 DISCONNECT PER N E C AND OR LOCAL CODES CONTACTOR eee S i FIELD POWER m m m m am WIRING Vo O FIELD GROUND m C THREE PHASE _ only WIRING Te GROUND LUG A94025 Fig 5 Line Connections Connect Control Wiring Route 24 v control wires through control wiring grommet and connect leads to control wiring Refer to Chiller Unit Wiring Diagram Use No 18 AWG color coded insulated 35 C minimum wire If condensing unit is located more than 100 ft 30 48 m from Chiller Barrel Cabinet as measured along the control voltage wires use No 16 AWG color coded wire to avoid excessive voltage drop All wiring must be NEC Class 1 and must be separated from incoming power leads www HTChillers com Flow Through Chiller Page 21 Final Wiring Check IMPORTANT Check factory wiring and field wire connections to ensure terminations are secured properly Check wire routing to ensure wires are not in contact with tubing sheet metal etc Start Up A _ CAUTION UNIT OPERATION AND SAFETY HAZARD Failure to follow this caution may result in personal injury equipment damage or improper operation Do not overcharge system with refrigerant e Do not operate unit in a vacuum or at negative pressure Compressor dome temperatures may be
28. frigeration grade tubing After wrapping service valve with a wet cloth braze sweat connections using industry accepted methods and materials Consult local code requirements Refrigerant tubing and Chiller Barrel heat exchanger are now ready for leak testing This check should include all field and factory joints 24ABB3 LIQUID RATED VAPOR Connection Connection Tube UNIT SIZE amp Max Tube Diameter Diameter Diameter 36 3 8 3 4 3 4 Notes 1 Do not apply capillary tube or fixed orifice coils to these units 2 For Tubing Set lengths between 50 and 200 ft 24 38 and 60 96 m horizontal or 35 ft 10 7 m vertical differential 250 ft 76 2 m Total Equivalent HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Length refer to the Ruud Residential Piping and Longline Guide line Air Conditioners and Heat Pumps using 410 A refrigerant 3 For alternate liquid line options on 18 42 size units see Product Data or Piping and Application Guideline Change Liquid Line Filter Drier Inside Chiller Barrel Compartment A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation 1 Installation of a new filter drier in liquid line is required 2 Filter drier must be wrapped in a heat sinking material such as a wet cloth while brazing 3 Flow arrow must point towards Chiller Barrel heat exchanger Refer
29. harging information located inside condenser electrical cover and or in the Check Charge section of this instruction IMPORTANT Maximum liquid line size is 3 8 in OD for all applications including long line Refer to Piping and Longline Guideline for further information IMPORTANT Always install the factory supplied liquid line filter drier If replacing the filter drier refer to Product Data Digest for appropriate part number Obtain replacement filter driers from your HVAC distributor or branch INSTALLATION Check Equipment and Job Site Install on a Solid Level Mounting Pad If conditions or local codes require the unit be attached to pad tie down bolts should be used and fastened through knockouts provided in unit base pan Refer to unit mounting pattern in Fig 2 to determine base pan size and knockout hole location For hurricane tie downs contact local distributor for details and PE Professional Engineer certification if required by local authorities On rooftop applications mount on level platform or frame Place unit above a load bearing wall and isolate unit and tubing set from structure Arrange supporting members to adequately support unit and minimize transmission of vibration to building Consult local codes governing rooftop applications Roof mounted units exposed to winds may require wind baffles Consult the Ruud Application Guideline and Service Manual Residential Split System Air Conditioners for wind baffl
30. hot A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant and observe the following e Front seating service valves are equipped with Schrader valves Follow these steps to properly start up system 1 After system is evacuated fully open liquid and vapor service valves 2 Replace stem caps after system is opened to refrigerant flow Replace caps finger tight and tighten with wrench an additional 1 12 turn 3 Close electrical disconnects to energize system 4 If the Chiller Unit Water Barrel was emptied confirm that it was refilled 5 If Water In Water Out lines were cut confirm that they were reconnected and purged of air 6 Confirm that Water In Water Out lines are open and flowing 5 Turn on the HT Chiller by pushing the on off push button switch located on the front panel Note If the unit is noisy and or cooling not be achieved the compressor is probably running in reverse direction Remedy is to change any 2 Incoming power leads 6 Operate unit for 15 minutes Check Charge Factory charge amount is 67 8 oz and desired subcooling is 7 F and is shown on unit rating plate Charging method is shown on information plate inside condensing unit To properly check or adjust charge conditions must be favorable for subcooling charging Favorable conditions HT
31. is secure in unit before adding panels and covers Securely fasten all panels and covers 3 Tighten service valve stem caps to 1 12 turn past finger tight 4 Leave this User Manual amp Installation Guide including Wiring Diagram with owner CARE AND MAINTENANCE For continuing high performance and to minimize possible equipment failure periodic maintenance must be performed on this equipment Frequency of maintenance may vary depending upon geographic areas such as coastal applications See Owner s Manual for information www HTChillers com Flow Through Chiller Page 22 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 REFRIGERANT PIPING LENGTH LIMITATIONS Liquid Line Sizing and Maximum Total Equivalent Lengths for Cooling Only Systems with Puron Refrigerant The maximum allowable length of a split system depends on the liquid line diameter and vertical separation between Chiller Barrel heat exchanger and condensing unit See Table below for liquid line sizing and maximum lengths Maximum Total Equivalent Length Outdoor Unit BELOW Indoor Unit Liquid AC with 410A Refrigerant Maximum Total Equivalent Lengtht Outdoor unit BELOW Indoor Size Liquid Line Line Vertical Separation ft m Connection Diam 0 5 6 10 11 20 21 30 31 40 41 50 51 60 61 70 71 80 w TXV 0 1 5 1 8 3 0 3 4 6 1 6 4 9 1 9 4 12 2 12 5 15 2 15 5 18 3 18 6 21 3 21 6 24 4 036 AC with 3
32. isiccisessscsuvedonesdenediatannlstcmnseainestniaaeounees tetueelaaeoans 16 www HTChillers com iii HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 9 Refrigeration Technician Section Installing the Condensing Unit 19 10 Trouble Shooting 25 Electrical Checks Flow Chart scacciciccesscarenavedeinesepeacaeaneletenuseeetnentadaaetunceeeeeweelaaeueseoets 26 Mechanical Checks Flow Chart ccccc cccccstecsseneentaacedsecessseseaneencssecteesesteereesncseenane 27 Wiring Diagram 3 Phase Units Only cece eeeceneeee tere eeeeeecaneeeeeeeeeeteneneeeeeeeeees 28 11 Receiving and Unpacking Instructions 29 12 Repair Authorization 29 13 Limited Warranty 29 Purchase and Installation FeCONdS cccc covsassoceetsi tdi elt adele ee teks 31 www HTChillers com iv HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Important Information Read this User Manual amp Installation Guide carefully before you begin chiller installation operation or service This manual contains important information Failure to read this manual can result in personal injury or damage to you
33. ler Page 13 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Maintenance Repairs and Storage A WARNING To prevent electrical shock the HT Chiller condensing unit and Chiller Barrel Compartment must be disconnected from all electrical sources during maintenance and repair General Maintenance The HT Chiller is designed to be virtually maintenance free when operated under normal working conditions As long as the Chiller Barrel Energy Storage Tank is securely sealed water will not escape If you move the HT Chiller after the tank has been filled it is recommended that you visually inspect the water level The condensing unit requires only routine maintenance as required with a standard air conditioning condensing unit If you have a yearly contract with an air conditioning service company ask them to inspect your HT Chiller condensing unit during your yearly inspection Repairing Components Other than the general maintenance outlined in the sections below do NOT attempt to repair any HT Chiller components unless previously authorized in writing by Hensley Thermodynamics Unauthorized repairs will VOID warranty Contact Technical Support Telephone 1 830 370 2362 or 1 800 259 2720 toll free 8 00 a m to 5 00 p m Central Time Monday Friday Email Support HTChillers com Freeze Thermostat If the HT Chiller has been stored or shipped in temperatures less than 35 F the freeze thermostat freezesta
34. low Through Chiller Page 6 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Installation Instructions Use a pallet jack or forklift to safely position the HT Chiller in the designated location The HT Chiller is mounted on metal legs for convenience The HT Chiller is quiet with a maximum decibel level of 74 This low decibel level does not overwhelm normal conversation so the unit can be placed in the work environment Location Checklist Review the following items to help determine the best location for the HT Chiller Q Q The HT Chiller must be installed on a level surface and indoors The HT Chiller can be separated field split with the condensing unit located in one area and the Chiller Barrel Compartment lower half of the HT Chiller located in another area To separate the unit refer to the section Field Splitting the HT Chiller The Chiller Barrel Compartment lower half of the HT Chiller is designed for indoor installation only where ambient temperatures do not fall below 32 F The Condensing Unit is designed for use with ambient temperatures of 55 F or more If you are field splitting the HT Chiller and the condensing unit will be required to operate in conditions below 55 F contact us or your authorized Ruud representative to install low ambient controls and or accessories The maximum ambient temperature for the Condensing Unit is 125 F Allow sufficient airflow around and vertical dis
35. modynamics logo HT is used herein as shorthand notation to refer to Hensley Thermodynamics HT Chiller is used herein as shorthand notation to refer to the Hensley Thermodynamics Chiller All other products and brand names mentioned in this document are trademarks of their respective companies Instructions in English 2013 2014 Hensley Thermodynamics Corporation Doc UM F36000 All Rights Reserved www HTChillers com i HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 This User Manual amp Installation Guide applies to the following units Flow Through Chiller Model F32301 Model F32303 Model F34603 www HTChillers com HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Table of Contents 1 Manufacturer Information i About Hensley Thermodynamics ccccceeeeeeecscccceeeeeeeeeeeesaaeeeeeeeeeeeseeesnaaaeeeeeees i 2 Important Information 1 Abbreviations and Definitions ccccccceeeeeeeeeeeeeneeeeeeeeeeeeeeccaaeeeeeeeeeeteesesiaaeeeeeees 1 3 Safety Information 1 Recognizing Safety Information in this Manual cccceeeeeeeeeetneeeeeeeeeeeeeeenaaees 1 Equipment Labels Symbols and MeaningS cceee
36. o condensing unit See applicable data plate on condensing unit 2 Install proper size wire to the Line In connections in the condensing unit electrical compartment 3 Attach proper ground Reinstall covers on condensing unit www HTChillers com Flow Through Chiller Page 12 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 HT Chiller Operation Your HT Chiller arrives pre set and ready to use as soon as e Proper electrical connections are made e Chiller Barrel Energy Storage Tank is filled with water and e Water line connections attached TIP If the condensing unit does not come on upon initial installation the freezestat may have tripped due to unit being exposed to below 35 F during shipping or storage See section Freeze Thermostat for instructions on how to reset the freezestat A CAUTION Prevent damage to your equipment and or the HT Chiller by confirming the following 1 Chiller Barrel Energy Storage Tank has been properly filled 2 Flow through water source is turned on How to Turn On the HT Chiller e Press the HT Chiller ON OFF push button power switch located on the front panel e Verify the power indicator light in the switch is illuminated Power Light Illuminated How to Turn Off the HT Chiller 1 Press the HT Chiller ON OFF push button power switch 2 Verify the indicator light in the switch goes out Power Light Off www HTChillers com Flow Through Chil
37. r chiller Abbreviations and Definitions Abbreviation Definition CBEST Chiller Barrel Energy Storage Tank gpm gallons per minute HT Hensley Thermodynamics HT Chiller Hensley Thermodynamics Chiller psi pounds per square inch Safety Information Safety instructions must be followed when you install operate inspect or perform maintenance or service on this equipment If ignored physical injury or death may follow or damage may occur to the equipment Always observe applicable safety precautions when using this equipment Recognizing Safety Information in this Manual This is the safety alert symbol A When you see this symbol on the unit and in this manual be alert to the potential for personal injury or equipment damage Understand these signal words DANGER WARNING and CAUTION These words are used with the safety alert symbol A DANGER Identifies the most serious hazards that will result in severe personal injury or death A WARNING Identifies hazards that could result in personal injury or death A CAUTION Identifies unsafe practices which would result in minor personal injury or product and property damage NOTE TIP and IMPORTANT Used to highlight suggestions which will result in enhanced installation reliability or operation www HTChillers com Flow Through Chiller Page 1 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Equipment Labels Symbols and Meaning
38. s The following labels and symbols are used in on the Hensley Thermodynamics Chiller Symbol Label Purpose Meaning Location HAZARDOUS VOLTAGE CAN CAUSE SEVERE PERSONA 2 uly INJURY OR DEATH TURN OFF ELECTRICAL POWER BEFORE REMOVING THI IS PANEL SERVICE MUST BE PERFORMED BY A QUALIFIED SERVICE PERSON Hazardous voltage may cause severe injury or death Only Qualified and Authorized Personnel may access areas marked with this label Condensing Unit ADANGER Hazardous voltages cause severe injury or death Disconnect all sources of powe icii before servicing Multiple and or remote sources of power may be present J5314 AF Hazardous voltage may cause severe injury or death Only Qualified and Authorized Personnel may access areas marked with this label Recirculating Pump Indicates the Water Out valve Front panel to the right of the Water Out valve Indicates the Water In valve Front panel to the right of the Water In valve Access by Qualified Personnel Only Access to the HT Chiller shall be restricted to properly trained and qualified personnel who are familiar with the potential hazards of equipment that uses high voltages high temperatures low temperatures refrigerant and components under pressure Electrical Precautions Only properly trained and qualified personnel are authorized to perform work on an energized system A WARNI
39. t will trip This thermostat by design requires a manual reset Indications of a tripped freezestat are the pump is running but the condensing unit on top is not running and the chiller is not cooling Note If the freezestat trips during operation turn the chiller off and troubleshoot the Chiller Barrel thermostats How to Reset the Freezestat 1 Remove the right side panel of the Chiller Barrel Energy Storage Tank compartment by unscrewing the 7 screws around the perimeter 2 Remove the 2 screws that hold the control box cover www HTChillers com Flow Through Chiller Page 14 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 3 Press push down the reset button The freezestat is the larger of the 2 thermostats Storing the HT Chiller while Not in Service To prolong the life of the HT Chiller when taking the unit out of service it is recommended that all water be removed from the Chiller Barrel Energy Storage Tank and all water evacuated purged from the flow through water lines especially if the HT Chiller will be stored in a location that could potentially freeze A CAUTION Prevent component damage rupture by removing purging all water from the HT Chiller if the unit is taken out of service How to Remove Water from Chiller Barrel and Flow Through Lines 1 NO a F WO Turn off the HT Chiller by pushing the ON OFF push button power switch located on the front panel The light in the
40. the HT Chiller by energizing the breakers or fuses depending on your electrical setup Power up the system by pressing the ON OFF push button power switch located on the Chiller Barrel Cabinet front panel The system will begin cooling the water in the Chiller Barrel if the water is above 58 F Adjust refrigerant to 9 subcooling www HTChillers com Flow Through Chiller Page 18 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Refrigeration Technician Section Installing the Condensing Unit A WARNING The following steps must be performed by a qualified refrigerant technician SAFETY CONSIDERATIONS Improper installation adjustment alteration service i maintenance or use can cause explosion fire electrical shock or other conditions which may cause death personal injury or property damage The qualified installer or agency must use factory authorized kits or accessories when modifying this product Refer to the individual instructions packaged with the kits or accessories when installing Follow all safety codes Wear safety glasses protective clothing and work gloves Use quenching cloth for brazing operations Have fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit Consult local building codes and current editions of the National Electrical Code NEC NFPA 70 In Canada refer to current editions of
41. tion Technician Section Installing the Condensing Unit following proper refrigeration techniques and referring to the long line application chart 3 Install new liquid line filter dryer Run new 24 volt control wiring from the condensing unit to the Control Panel in the Chiller Barrel Compartment Replace the Control Box cover in the Chiller Barrel Compartment Replace the electrical panel on the condensing unit AX CAUTION The Chiller Barrel water tank MUST be filled before power is applied Follow the instructions below www HTChillers com Flow Through Chiller Page 17 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Step 7 Position the Chiller Barrel Compartment in the new location Step 8 Refill the Chiller Barrel Water Tank 1 Fill the Chiller Barrel Energy Storage Tank to the waterline indicated on the inside of the tank Refer to the instructions How to Fill the Chiller Barrel Energy Storage Tank Secure the water tank cover and ring Replace the Chiller Barrel Energy Storage Tank cover and secure the ring Replace the Chiller Barrel Compartment front panel and then the side panels Step 9 Evacuate Refrigerant System A CAUTION The Chiller Barrel Energy Storage Tank must be filled with water BEFORE powering on the condensing unit to prevent damage to the HT Chiller Pull proper evacuation of the condensing unit system and release refrigerant accordingly Deliver power to
42. to maintain acceptable refrigerant management for systems reliability See Accessory Usage Guideline table for required accessories Defining a system as long line depends on the liquid line diameter actual length of the tubing and vertical separation between the indoor and outdoor units For Air Conditioner systems the chart below shows when an application is considered Long Line AC WITH 410A REFRIGERANT LONG LINE DESCRIPTION ft m Beyond these lengths long line accessories are required Liquid Line Size Units On Same Level Outdoor Below Indoor Outdoor Above Indoor 3 8 80 24 4 35 10 7 vertical or 80 24 4 total 80 24 4 ELECTRICAL DATA UNIT SIZE V PH OPER COMPR FAN MCA MAX VOLTAGE VOLTS FUSE or SERIES CKT BRK MIN MAX LRA RLA FLA AMPS 036 460 3 414 508 38 5 8 0 35 8 6 15 036 230 1 79 0 16 7 0 8 35 036 230 3 73 0 10 4 0 8 20 Permissible limits of the voltage range at which the unit will operate satisfactorily T If wire is applied at ambient greater than 30 C consult table 310 16 of the NEC NFPA 70 The ampacity of non metallic sheathed cable NM trade name ROMEX shall be that of 60 C conditions per the NEC NFPA 70 Article 336 26 If other than uncoated no plated 60 or 75 C insulation copper wire solid wire for 10 AWG or smaller stranded wire for larger than 10 AWG is used consult applicable tables of the NEC NFPA 70
43. ty gives you specific legal rights and you may also have other rights which vary from state to state The Manufacture suggests that you immediately complete the Purchase and Installation Records section and retain this Limited Warranty Certificate in the event warranty service is needed and that you keep proper documentation www HTChillers com Flow Through Chiller Page 30 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Purchase and Installation Records COMPLETE THE FOLLOWING INFORMATION FOR YOUR RECORDS DO NOT MAIL Date of Purchase Date of Delivery Model Number Serial Number Date of Original Installation Installing Contractor Name Contractor s address phone Owner Name Address City State Zip Manufactured by Hensley Thermodynamics P O Box 318 Ingram Texas 78025 mailing address 454 Cade Loop Ingram Texas 78025 shipping address 1 830 370 2362 1 800 259 2720 www HTChillers com www HTChillers com Flow Through Chiller Page 31
44. warranty will be null and void if unauthorized personnel perform any modifications or repairs on this unit Misuse of the product will void the warranty Hensley Thermodynamics Corporation is not liable for any injury or damaged cause by incorrect installation maintenance or operation of this HT Chiller resulting from failure to follow instructions and guidelines outlined in this manual Replacement of parts or subassemblies will be provided under warranty when they have failed due to faulty manufacturing Misuse will void warranty Limited Warranty The Limited Warranty for the HT Chiller is 2 years parts and labor starting the date of delivery This warranty is non transferable You will need the chiller unit serial number for all correspondence The unit s serial number is located on the back of the condenser z s CERELTCOCO TYPE BREAKER F A a SCTE SIFFS TE EQIDSSS82E www HTChillers com Flow Through Chiller Page 29 HT Chiller User Manual amp Installation Guide UM F36000 Rev 1 Limited Warranty Parts and Labor 2 years SCOPE OF WARRANTY AND EQUIPMENT COVERED The products covered by this Limited Warranty Hensley Thermodynamics Manufacturer warrants the Covered Equipment to be free from defects in materials and workmanship and will repair or replace at its option ANY PART of Covered Equipment which fails in normal use and service within the Applicable Warranty Periods in accordance with the terms
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