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Service Manual Portable Chiller

1. 075 11 05 INSTRUCTION MANUAL INSTALLATION OPERATION MAINTENANCE PORTABLE CHILLER with CF 1 Instrument EMPIEK 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 com e mail sales Temptek com Page 2 PORTABLE CHILLER INSTRUCTION MANUAL CF Series Portable Chiller 5 40 Tons Air Cooled amp Water Cooled COVERING INSTALLATION OPERATION MAINTENANCE EMPIEK TEMPTEK INC 525 East ae 18 Road Greenwood IN 46142 7 887 0729 fax 317 881 1277 e Department fax 317 885 8683 www TempTek com e mail sales O TempTek com Series Portable Chillers with CF 1 Instrument TABLE OF CONTENTS 1 0 2 0 3 0 4 0 5 0 6 0 GENERAL 1 1 Introduction 1 2 Unit location 1 3 Efficiency 1 4 Safety 1 5 Clean air act 1 6 Miscellaneous INSTALLATION 2 1 General 2 2 To and From process connections 2 3 Water supply connection 2 4 Air cooled condenser 2 5 Water cooled condenser 2 6 Electrical connection OPERATIONS 3 1 General 3 2 Start up operations procedure 3 3 Instrument operation 3 4 Shut down procedure TROUBLESHOOTING 4 1 Unit Will Not Start 4 2 Compressor Hums But Will Not Start 4 3 Shuts Off On High Pressure 4 4 Shuts Off On Low Pressure 4 5 Compressor Shuts Off On Internal Overload 4 6 Low Or No Process Pressure Or Water Flow 4 7 Cooling Capacity Inadequ
2. Series Portable Chillers with CF 1 Instrument 6 0 COMPONENTS 6 1 WATER SYSTEM 6 2 REFRIGERATION SYSTEM jf 525 East Stop 18 Road Greenwood Indiana 46142 Page 47 EMI I E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument 6 1 WATER SYSTEM MOTOR PUMP ASSEMBLY the motor pump assembly circulates chilled fluid to the process loop The pump assembly is built of total stainless steel to maintain water quality figure 6 1A 6 2 REFRIGERATION SYSTEM COMPRESSOR hermetic or semi hermetic compressors take low pressure low temperature refrigerant gas and compress the gas into high pressure high temperature gas figure 6 2A Pump Motor Assembly Figure 6 1A Semi hermetic compressor B AIR COOLED CONDENSER the air cooled condenser removes BTU s from the compressed refrigerant gas The action causes the gas to condense into a liquid state still under high pressure Air flow across the condenser is achieved via a motor driven fan assembly or centrifugal blower figure 6 2B Hermetic compressor Figure 6 24 FILTER DRIER the filter drier removes contaminants and moisture from the liquid refrigerant figure 6 2C D LIQUID LINE SOLENOID VALVE controlled by the instrument this valve closes when the compressor cycles off to prevent refrigerant liquid from mig
3. Refrigerant Low Pressure Limit protects from low suction pressures Motor Overload Relay protects motor from excessive amperage D GENERAL 1 Make certain all ground connections to the unit are properly affixed Make certain power conductor disconnecting means and fusing are properly sized according to the unit s power supply requirements INFORMATION REGARDING PHASING OF SCROLL COMPRESSORS All portable chillers that have pumps the compressor s will be set in phase with the pump during the testing process at the factory After installation the phase status must be checked by observing the pump motor shaft on the end of the pump and comparing its rotation to the directional arrow on the motor In either case if the phase needs to be altered it should be done at the main power entry 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 Motor Contractor supplies voltage to coolant pump motor Figure 2 5A Typical electrical panel 525 East Stop 18 Road Greenwood Indiana 46142 Page 19 EMI E 317 887 6352 Fax 317 881 1277 y Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com THIS PAGE INTENTIONALLY BLANK Page 20 Series Portable Chillers with CF 1 Instrument 3 0 OPERATIONS 3 1 GEN
4. dWNd LNVIOOD Es E gt ANTWA GIONT10S ann ainon 043114 H SSV19 LHOIS NV Bd INVA pe y D O U NUNG um SVD amp NOLLOHNNOO JHOd NAVIA ANTWA GIONT10S Sana nD D rT HOLIMS C 1O1VdOdVA3 _ p NOLLOHNNOO 1HOd 5542 WOtH WAY ANTWA y ainon dpay 10 1019S je 1HOd 2 LEE HOLIMS A133VS 3ufisS3dd MOT ue Bus sesn SNV4 M YSNA NOD 310098 39nv5 1 NOLLONS HOSSTdWOI HOLIMS 134 5 dd 1SSddd HOIH AONVS JANSSIAA GVSH Page 54 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Ek CF Series Portable Chillers with CF 1 Instrument MECHANICAL SCHEMATIC AIR COOLED 15 30 TON MODELS 7 4 AONVS 3ufisSdud 5542 OL NOLLOANNOD 1HOd US HOS 5 SSdD Oud OL y dWNd LNVIOOD ANVL 53 n NOLLDANNOD 1HOd dN AYN RS ANTWA GION31OS 52 U HOLIMS ATI A TU YO WHO VA gt Ww NOLLOANNOD 1H4Od 553
5. PRECAUTIONS The chiller control is programmed from the factory with a setpoint range of 48 to 90 F To operate below 48 F the addition of inhibited propylene glycol and modification of the safety control settings are required Diligent monitoring of the water glycol solution is mandatory to prevent freezing of the evaporator Freezing may cause the evaporator to rupture allowing water and freon to mix which will cause major damage to the refrigeration system On R22 R134A and R407C models operating above 70 F and R404A models operating above 60 F requires the addition of a refrigerant crankcase pressure regulating CPR valve The CPR valve is necessary to prevent overloading of the compressor which can cause premature failure R410A models may be operated up to 80 F without a CPR valve Contact your local refrigeration contractor or the factory for further information The operating range of the chiller control may be changed to 10 F 90 F by adjusting the Setpoint Lockout SPL jumper Refer to the technical section of this manual for more information B INSTRUMENT OPERATION 1 To start the unit toggle on the illuminated ON OFF SWITCH The chiller control will begin temperature control operations 2 To select setpoint temperature press and hold the UP ARROW or DOWN ARROW keys until the desired set point temperature is displayed in the TEMPERATURE WINDOW The default range for the setpoint temperature is 48 90 F
6. when the switch is illuminated 2 UP ARROW and DOWN ARROW KEYS depress and hold this push button to increase UP ARROW or decrease DOWN ARROW the setpoint temperature If the push button is pressed momentarily the setpoint value is incremented or decremented by one degree If the push button is held down the setpoint will increase or decrease continously 3 SETPOINT LOCK OUT JUMPER this jumper controls whether the user is allowed to reduce the setpoint below 48 F or 9 C If the jumper is in position 1 farthest from the SPL label the user IS NOT ALLOWED to reduce the setpoint below 48 F or 9 C If the jumper is in position 2 closest to the SPL label the user is allowed to reduce the setpoint to 10 F or 11 C 4 TEMPERATURE DISPLAY JUMPER if this jumper is in the F position the To Process and Setpoint temperatures are displayed in Fahrenheit If the jumper is in the position the To Process and Setpoint temperatures are displayed in Celsius 5 Probe Calibration this pot CALPOT 1 is used to calibrate the probe circuit Setpoint Lock Out Jumper Temperature Display Jumper Probe Calibration 525 East Stop 18 Road Greenwood Indiana 46142 Page 28 ee IN A 317 887 6352 Fax 317 881 1277 E E Le Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument D STATUS LIGHTS 1 2 COMPRESSOR illu
7. 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Page 5 THIS PAGE INTENTIONALLY BLANK Page 6 Series Portable Chillers with CF 1 Instrument 10 GENERAL 1 1 INTRODUCTION 1 2 UNIT LOCATION 1 3 EFFICIENCY 1 4 SAFETY 1 5 CLEAN AIR ACT 1 6 MISCELLANEOUS lt soe ass jf 525 East Stop 18 Road Greenwood Indiana 46142 Page 7 E E 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument 1 1 INTRODUCTION This manual covers portable chillers from 5 to 40 tons When calling for assistance from the Manufacturer s Service Department it is important to know the model and serial number of the particular unit The model number encodes critical unit information which is helpful in any attempt to troubleshoot operating difficulties The serial number allows the service team to locate manufacturing and testing records which can have additional information relating to a particular unit 1 2 UNIT LOCATION 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 dry and well ventilated environment For air cooled models 1 The unit has an air cooled refrigerant condenser For air cooled condensers a motor driven fan on mo
8. 5 PUMP SEAL SERVICE The coolant pump seal is a carbon niresist shaft seal assembly including a stationary member rotating member and tension spring figure 5 5A B The operator can determine the pump Rotating Member Tension Spring Stationary member Figure 5 5A seal is leaking when fluid is identified leaking from the pump case adapter Generally a pump seal will leak due to inadequate unit pressure excessive flow and poor fluid quality The operator should follow this procedure to replace the pump seal 1 Disengage process operations according to the procedure outlined in section 3 4 The operator must be certain process fluid temperature is under 100 F and pressure is relieved COOLANT pressure gauge reads 0 and water make up flow is shut off and all pressure relieved Disengage main power supply The operator must verify the proper lockout procedures are followed Access the pump motor by opening or removing any cover panels as necessary figure 5 5B Drain machine The machine can be drained by using the drain valve located on the pump case Drain fluid into a suitable container for reuse or disposal according to manufacturer s instructions if a glycol solution is used Locate and remove the three motor wire leads from the motor wiring terminals The operator should map the wire terminal locations to ensure correct rewiring Pump motor Figure 5 5C The power c
9. E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 7 6 TYPICAL ELECTRICAL SCHEMATIC WATER COOLED MODELS FO lu u o compress on wer u mro concer wc MICROPROCESSOR 22 2 525 East Stop 18 Road Greenwood Indiana 46142 Page 57 EMI I 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 7 7 PHYSICAL SCHEMATIC AIR COOLED 7 5 10 TONS 525 East Stop 18 Road Greenwood Indiana 46142 Page 58 4 317 887 6352 Fax 317 881 1277 E MUR Elk Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com CF Series Portable Chillers with CF 1 Instrument 7 8 PHYSICAL SCHEMATIC AIR COOLED 5 TONS 525 East Stop 18 Road Greenwood Indiana 46142 Page 59 lt 317 887 6352 Fax 317 881 1277 f 4 Service Department Fax 317 885 8683 4
10. F 255 00 10 260 57 20 266 14 271 71 40 277 27 50 282 84 60 288 41 70 293 98 80 299 55 90 305 12 100 310 69 110 316 26 Formula 120 F 321 82 130 F 327 39 140 F 332 96 150 F 338 53 160 F 344 10 170 F 349 67 180 F 355 24 190 F 360 80 200 F 366 37 210 F 371 64 220 F 377 51 230 F 383 08 240 F 388 65 250 F 394 22 1uA 556 8627 x 10 x F 255 x 10 e F 1uA 255x 10 556 8627 x 10 lt 2 gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt White wire Black wire 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Page 65 Series Portable Chillers with CF 1 Instrument 8 5 REFRIGERANT PRESSURE TEMPERATURE CHART Refrigerant Pressure Temperature Chart a Italics indicates vacuum inches of mercury Standard font indicates pressure pounds per inch gauge 525 East Stop 18 Road Greenwood Indiana 46142 Page 66 SSS 317 887 6352 317 881 1277 E MUR El Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 8 6 CHILLER CAPACITY AND DERATE CHA
11. OL Ss3DOYd OL C gt di x SSV 19 LHOIS LNAI INIVA n lo L HIO AHAS T4 ANTWA GIONTI10S and day Jo 3ATVA SSVAAd Sv9 LOH 4 NOLLO3NNOO 3 5 dNDIV IN JAVA GIONTIOS YOLVYOdv d ge E V U HOLIMS EAT A t 2neuueH 10205 0553 HOLIMS 1355 J4NSSTHA H9IH gt x AONVS 34NSSIAd NOLLO3NNOO 1HOd er So ANTWA JOIAS 39nv9 34055384 INM NOLLINS HOLIMS ALHYS 34055 44 MOT Ss3DOYd WO NOLLDINNO IMOd es ANO ESNIONO a gt NOLLDANNOD MN NI YALVM YAS NON OO S 2 0 3ATVA 1 H11VM YISNJA NOD 5 2 Page 53 a Yo 9 c do BRO ET OE 588 5 Sens 2 su 8 x D x D Sate cuz D Ga Ont 99 Roo Best G N W ite a ts TEMPIEK Email service Temptek com Series Portable Chillers with CF 1 Instrument MECHANICAL SCHEMATIC AIR COOLED 2 10 TON MODELS 7 3 AONVS dufisSdud 5542 OL NOLLO3NNOO INOd 38 Odd YOS 5 ne 5542 OL
12. Road Greenwood Indiana 46142 Page 44 A r s o WQ 317 887 6352 317 881 1277 E MUR elk Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument 5 6 CHECKING THE REFRIGERANT CHARGE 5 7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATORS All standard chillers are manufactured with thermostatic expansion valves as the metering device to the evaporator All standard chillers have a refrigerant sight glass figure 5 6A with a moisture indicator To check the refrigerant charge under normal operating conditions 1 Remove the plastic cap me covering the sight glass 2 Start the chiller and allow system pressures and temperatures to stabilize 3 With the unit operating at 100 capacity not in the capacity control mode the sight glass should appear clear with no foam or bubbles evident If foam or bubbles evident the chiller has suffered from a loss of refrigerant and should be checked by a qualified refrigeration technician 4 The dot in the middle of the sight glass is the moisture indicator It should appear green at all times A white or yellow color indicates moisture has invaded the refrigeration system which is detrimental to the life of the compressor The filter drier should be replaced by a qualified refrigeration technician The brazed plate evaporator is
13. according to the procedure outlined in section 3 4 The operator must be certain process fluid temperature is under 100 F and pressure is relieved pressure gauge reads 0 and water system flow is shut off and all pressure relieved Disengage main power supply The operator must verify the proper lockout procedures are followed Remove or open any access cover panel and set aside to gain access to the cooling solenoid valve The operator must be certain all water system pressure is relieved Retaining screw Identify the retaining screw figure 5 4B on the solenoid valve coil Remove the screw Keeping all electrical connections intact lift the coil off of the enclosure tube and set aside Use a pair of channel lock pliers or a pipe wrench to separate the bonnet assembly from the valve body The plunger is loose inside the enclosing tube Be certain it is retained in the enclosure tube as the bonnet is removed figure 5 4C Coil Figure 5 4B Identify the diaphragm assembly Gently remove the assembly from the valve body figure 5 4D 525 East Stop 18 Road Greenwood Indiana 46142 Page 40 jl oO IN A pl 317 887 6352 Fax 317 881 1277 E E Le Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 10 11 12 13 14 15 TErriek Identify the mesh screen Gently removed the mesh screen a
14. illuminate Adjust the gt 525 East Stop 18 Road Greenwood Indiana 46142 Page 23 EM 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument setpoint to 70 F to prevent the compressor from activating during this procedure Remove all necessary cover panels to access the pump motor Note that the electrical power is engaged at this point and caution must be observed while the electrical supply is engaged and cabinet panels are removed and opened Locate the electric motor figure 3 2C The electric motor can be identified when the electrical panel cover is open The operator must identify the motor shaft inside the electric motor housing The motor shaft can be seen through the vent slots in the motor housing or by removing the shaft cover Electric motor Figure 3 2C Toggle the illuminated ON OFF SWITCH figure 3 2D This will quickly cycle the pump motor on and then off Observe the motor shaft When the ON OFF SWITCH is Illuminated On Off switch Figure 3 2D on the motor shaft will rotate When switched off the shaft will slowly coast to a stop As the shaft slows the operator can identify the rotation of the motor shaft Correct rotation correct phase is clockwise when viewed from the rear of the motor Incorrect rot
15. made of stamped stainless steel plates furnace brazed together with copper based joints The complex geometry of the flow passages promotes turbulent flow which gives high efficiency and reduces fouling by mineral Evaporator Figure 5 6A deposits Large solids such as plastic pellets or chunks of mineral deposits will collect at the water inlet port at the evaporator and restrict flow through some of the passages If this possibility exists the Manufacturer recommends filters or strainers be added to the from process line If the evaporator becomes fouled there are a couple of methods for cleaning je 525 East Stop 18 Road Greenwood Indiana 46142 Page 45 EMI I 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 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 flush the evaporator to remove any solids that may be trapped between the plates see back flush procedure below If there are mineral deposits adhered to the plates the evaporator must be back flushed with a mild acid solution 5 phosphoric or 5 oxalic acid is recommended After cleaning rinse with clear water before returning to service Continue with step C on the next page Back flushing procedure 1 Turn off all power to the
16. of installation as outline in section 2 of this manual If the operator has any questions concerning the location and operation of the unit contact the The Manufacturer s Service Department jf 525 East Stop 18 Road Greenwood Indiana 46142 Page 9 EM I 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument Cover Panel Pressure Gauges Instrument Enclosure Panel Electrical Panel Enclosure Air Cooled Casters Water Cooled Air Discharge Fan Motor Hot Gas Bypass Valve Refrigerant Site Glass Expansion Valve Liquid Line Solenoid Compressor Insulated Reservoir Tank Liquid Receiver Pump Caster 525 East Stop 18 Road Greenwood Indiana 46142 Page 10 a u O I O LL I 317 887 6352 317 881 1277 E MUR El Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument To Process Connection From Process Connection Reservoir Optional Reservoir Sight Glass Refrigerant Sight Glass Condenser Water Out Expansion Valve Connection Reservoir Make Up Compressor Connection Electrical Panel Condenser Water In Connection optional Condenser Condenser Water Regulator Valve Make Up Valve Pump Water Cooled Model 525 East Stop 18 Roa
17. 2 WO IDINSS HOLIMS 1345 5539 MOT MOIQ M tHSN3QNOO 431009 s Mi NOLLONS SSV19 LHOIS INVESORII4 ANTWA I Vv 3ATVA SSVdAd SVO LOH JAVA GION31OS ann ainon U W3ABOHd JATVA Pw anon IIS U Ll day 10 3n uu H 1019S WOSSdud NOD HOLIMS AT33VS dd 1SSddd HOIH AONVS J4NSSJAd Page 55 a E Yo 9 c do sho ET OE 2598 d Sens su 8 x D x D Sate cuz D Ga OT 2G Roo Best ore d 19 e ite a ts Email service Series Portable Chillers with CF 1 Instrument 75 TYPICAL ELECTRICAL SCHEMATIC AIR COOLED MODELS 3 20 El ne aa _ x i EM _ 5 Ae ANTLORAN BACK SOLENOID OPTIONAL a 1159 ee tate e 525 East Stop 18 Road Greenwood Indiana 46142 Page 56 ER 317 887 6352 317 881 1277 E MUR
18. 81 1277 Service Department Fax 317 885 8683 Website www Temptek com Typical pump casing bolt Figure 5 5D Motor shaft Figure 5 5F Typical impeller Figure 5 5G Page 43 Email service Temptek com Series Portable Chillers with CF 1 Instrument 12 Install new stationary seal member in pump casing cavity figure 5 51 The operator must be certain the stationary seal member is fully squared and seated in cavity 13 Slide the rotating member onto lubricated pump shaft figure 5 5J The operator Seal components Figure 5 5H must be certain not to damage or tear rubber bellows assembly 14 Place the spring onto the rotating member 15 Align the impeller spring and rotating member before reinstalling the impeller figure 5 5K The operator must be certain the spring and rotating member are aligned before the impeller is fully tighten and the impeller retaining screw is reinstalled Stationary member Figure 5 51 16 Clean pump casing cavities impeller and O ring before reassembly 17 Mate the motor and motor adapter to the pump casing Reinstall the pump casing bolts Stationary member Figure 5 5J 18 Reconnect the motor power cord and leads 19 Restore all cover panels as were removed E When the pump seal replacement procedure is complete the operator may restart the unit according the section 3 Seal members Figure 5 5K 525 East Stop 18
19. ERAL 3 2 START UP OPERATIONS PROCEDURE 3 3 INSTRUMENT 3 4 SHUT DOWN lt soe ass jf 525 East Stop 18 Road Greenwood Indiana 46142 Page 21 E E 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument 3 1 GENERAL Failure to follow the factory required operations procedure adversely affect the unit s ability to adequately control process temperature and may create a hazardous operating condition which may result in serious operator injury and or unit damage IMPORTANT if this unit contains a hermetic or semi hermetic reciprocating compressor it is equipped with a crankcase heater on the compressor While the compressor is idle the crankcase heater prevents freon vapor from migrating to and condensing in the compressor crankcase If freon is allowed to condense in the crankcase it can be drawn into the cylinders upon start up This can cause catastrophic damage to the connecting rods pistons and valve plates To avoid this BEFORE THE UNIT IS STARTED THE POWER SUPPLY SHOULD BE APPLIED TO THE UNIT FOR AT LEAST 12 HOURS OR UNTIL THE BOTTOM OF THE COMPRESSOR IS WARM TO THE TOUCH If the power has been disconnected more than two hours the power should be applied for six hours before restarting Power should be applied to the unit continuously except for service purposes The crankca
20. Have compressor windings and internal solid state safety control checked by a refrigeration serviceman Have it repaired or replace if defective LOW OR NO PROCESS PRESSURE OR WATER FLOW Valves Check if water valves are open Pump Check pump for correct rotation Check pump suction for restriction Replace motor if defective Filters Check filter in the chilled water circuit and clean if necessary Pressure switch or flow switch Readjust or replace if defective Fuses and wiring Have electrician check the fuses and wiring COOLING CAPACITY INADEQUATE 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 refrigeration serviceman Hot gas bypass valve stuck open Have repaired or replace if defective by a refrigeration serviceman 525 East Stop 18 Road Greenwood Indiana 46142 Page 34 St 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 4 8 4 9 4 10 4 11 C Expansion valve plugged or inoperative Check thermal bulb and capillary tube for damage Have repaired or replaced if defective by a refrigeration serviceman D Plugged filter Check filter in chilled water circuit and clean E Air in system Purge air SENSOR The sensor is
21. OUT SETTING WITHOUT ADDING GLYCOL TO THE CIRCULATING SYSTEM EVAPORATOR DAMAGE WILL RESULT AND WILL NOT BE COVERED BY THE WARRANTY Refrigerant Low Pressure Switch Cut Out amp Cut In Settings R134A R410A Point Temp Temp Cut Out Cut In Cut Out Cut In Cut Out Cut In 48 70 F 25 47 F 10 24 F Operating Glycol Freeze Cut Out Cut In 0 32 F 30 10 F 40 5 32 F 36 F 39 F 58 63 28 33 102 111 10 F 15 F 18 F 334 38 12 17 63 72 5 09 79 20 25 4 9 43 52 R404A R407C Temperature Point Temp Temp Cut Out Cut In Cut Out Cut In 48 70 F 0 32 F 32 F 36 F 3 9F 72 79 52 58 25 47 F 30 10 F 10 F 15 F 1 8F 44 49 28 34 10 24 F 40 5 F 5 F O F 7 F 29 34 16 22 High Pressure Cut Out maximum Refrigerant Air Cooled Water Cooled R22 380 360 R134A 260 260 407 4054 360 R410A 610 550 R404A 405 360 Figure 8 3A amp Figure 8 3B Page 64 TEMPIEK 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 8 2 WATER QUALITY CONTROL Lack of proper water treatment can damage the chilling unit The services of a competent water treatment specialist should be obtained and their recommendations followed It is the equipment owner s respons
22. Page 38 a 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument l Refrigerant sight glass check for bubbles when compressor is operating at 100 Check the moisture indicator for a color other than green J Clean unit 5 3 SPECIAL MAINTENANCE A Any service of the refrigeration system must be accomplished by a certified 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 j 525 East Stop 18 Road Greenwood Indiana 46142 Page 39 EMI E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 5 4 SOLENOID VALVE SERVICE Units with the optional water make up system use a solenoid valve figure 5 4A to regulate flow into the reservoir tank The solenoid valve is controlled by the float switch Generally solenoid valves fail due to poor water quality low water flow or defective valve elements 1 Typical water make up Figure 5 4A The operator should follow this valve procedure to service the make up solenoid valve Disengage process operations
23. RE GAUGE indicates refrigerant pressure on the discharge side of the compressor This is the condensing pressure which is f 525 East Stop 18 Road Greenwood Indiana 46142 Page 29 EM I E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument critical to equipment efficiency Head pressure on water condensed units will vary with ambient temperatures between 190 290 psig 3 LOW PRESSURE GAUGE indicates refrigerant pressure on the suction side of the compressor This pressure will fluctuate with the process temperature 3 4 SHUT DOWN DISCONNECT SEQUENCE A PRECAUTIONS WARNINGS 1 The operator must precisely follow all shut down procedures outlined in this manual If the operator fails to follow precisely all procedures outlined in this manual an unsafe condition can develop resulting in damage to the unit or personal injury B UNIT SHUT DOWN 1 To shut down the unit without disconnecting from the process a Move the ON OFF switch to the off position b Maintain electrical power to the unit at all times except for service purposes 2 To shut down the unit and disconnect from the process a Move the ON OFF switch to the off position b Disengage the electrical supply to the chiller at the disconnecting device Disconnect all process lines 525 East Stop 18 Road Greenwood I
24. RT Standard chiller rating is at 50 F For all other temperature settings output tonnage is altered as follows OUTPUT FULL TEMPERATURE AVAILABLE F CAPACITY 60 105 50 100 45 90 40 80 35 70 30 60 25 50 20 40 15 30 10 22 5 15 0 9 5 5 NOTES If operation of the chiller at less than 48 F is required an inhibited propylene glycol solution is required Consult factory for chiller operation below 20 F Ambient conditions affect air cooled chiller operation and capacity Standard rating is at 95 F entering air temperature For ambient air conditions greater than 95 F chiller derating will occur For ambients of 95 105 F select the next larger capacity chiller For ambients over 105 F consult factory These ranges require special options 525 East Stop 18 Road Greenwood Indiana 46142 Page 67 EM I E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com THIS PAGE INTENTIONALLY BLANK Page 68 2009 TEMPTEK INC RE 2 09 09
25. Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 79 PHYSICAL SCHEMATIC WATER COOLED 525 East Stop 18 Road Greenwood Indiana 46142 Page 60 e d U 4 317 887 6352 Fax 317 881 1277 E MUR Elk Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument 7 10 E JOOOOOOO0000000000000000009 il DUCT SCHEMATIC FOR AIR COOLED CHILLERS NOTE THIS DRAWING IS FOR EXPLANATION PURPOSES ONLY 6 Te 2 8 ee 9 12 13 For models equiped with centrifugal blower Models with equipped with fans can not be ducted NOT FOR CONSTRUCTION PURPOSES pm 10 Item Description 1 Weather cap 2 Screen 3 Flashing to suit 4 Roof curb 5 Plant roof 6 Butterfly with counterbalance 7 Separate duct support from roof 8 Gate control for exhaust air flow 9 Manual chain control 10 Duct to plant heating system 11 Mating collar 12 Chiller air exhaust port 13 Air cooled chiller with blower 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Service D
26. a solid state temperature transducer which converts temperature input to proportional current output To quickly test for a defective probe switch connections between the defective probe and a probe known to be working properly A defective sensor will display a in the display window on the instrument control COOLANT PUMP The centrifugal pump is designed to operate at a specific flow and pressure at the maximum run load amp draw of the motor Too much flow can overload the motor and cause the overload circuit to open and stop the pump If the overload trips check for electrical shorts loose wires or blown fuses If these check OK reset the overload circuit and restart the chiller Check the amp draw and if overloaded partially close the from process line valve until the amp draw drops to the proper level CRANKCASE HEATER A B If the crankcase heater is not drawing current during the compressor off cycle check for a defective crankcase heater defective fuses or defective interlock on the compressor starter Scroll compressors do not have crankcase heaters CHILLER CONTROLLER A The display is used for all normal set ups diagnostics temperature readout and operational information Note the display is not field repairable lt can be easily removed and replaced if required The CPU contains the software and various electronic components which make the instrument work Note the CPU 15 not a fiel
27. ata plate Determine the plant s voltage supply is the same as the unit s voltage requirements WARNING Do not connect the unit to a voltage supply source not equal to the unit s voltage requirements as specified on the unit s data plate Use of incorrect voltage will void the unit s warranty and cause a significant hazard that may result in serious personal injury and unit damage Appropriate conduit and fittings should be selected which will maintain the integrity of the cabinet Supply a power conductor sized according to the unit s power supply requirements Connect the power conductor to the unit s power supply entry terminal block or the fused disconnect switch Some Nema 12 models may be supplied with an optional disconnect switch The owner supplied fused disconnecting means shall be sized and installed according to the unit s power supply requirements and local electrical codes CONTROL CIRCUIT WIRING 1 The unit s supplied control circuit is 110 volt 1 phase 60 cycle The control circuit is supplied by the factory installed transformer An inline control circuit fuse is provided 525 East Stop 18 Road Greenwood Indiana 46142 Page 18 A o 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument Refrigerant High Pressure Limit protects from excessive condensing pressures
28. ate 4 8 Sensor 4 9 Coolant Pump 4 10 Crankcase Heater 4 11 Chiller Controller MAINTENANCE 5 1 Warranty service procedure 5 2 Periodic preventative maintenance 5 3 Special maintenance 5 4 Solenoid valve service 5 5 Pump seal service 5 6 Checking the refrigerant charge 5 7 Proper cleaning procedure for brazed plate evaporators COMPONENTS 6 1 Water system 6 2 Refrigeration system 525 East Stop 18 Road Greenwood Indiana 46142 a m u 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Page 4 Series Portable Chillers with CF 1 Instrument 7 0 RELATED DRAWINGS 7 1 Mechanical Schematic Water Cooled 5 10 Tons 7 2 Mechanical Schematic Water Cooled 15 40 Tons 7 3 Mechanical Schematic Air Cooled 5 10 Tons 7 4 Mechanical Schematic Air Cooled 15 30 Tons 7 5 Typical Electrical Air Cooled 7 6 Typical Electrical Water Cooled 77 Physical Schematic Air Cooled 7 5 10 Tons 7 8 Physical Schematic Air Cooled 5 Tons 79 Physical Schematic Water Cooled 7 10 Duct Schematic for Air Cooled Chillers 8 0 APPENDIX 81 Operations below 48 F 8 2 Water quality control 8 3 Inhibited propylene glycol 8 4 Sensor current vs temperature 8 5 Refrigerant pressure temperature chart 8 6 Chiller capacity and derate chart 525 East Stop 18 Road Greenwood Indiana 46142 EMI E E 4 317 887 6352 Fax 317 881
29. ater flow Check condenser water pumping system 3 Condenser water temperature too high Check cooling tower or proper operation city water temperature 4 Condenser water tubes scaled Clean with brushes and chemicals approved by the Advantage Service Department Improperly set high pressure control Have refrigeration serviceman reset or replace the control if defective 4 4 SHUTS OFF ON LOW PRESSURE CONTROL Note See Temperature Pressure chart in Section 8 5 for refrigerant pressure See Temperature Pressure chart in Section 8 5 for refrigerant pressure The low pressure switch will automatically resets when the pressure rises above the cut in pressure If this does not occur contact the the Manufacturer s service department for instructions The low pressure switch is set to cut out at 32 F and cut in at 36 F 39 F If a low pressure condition exists for more than five seconds the compressor will stop and a L P fault will appear in the display window After the refrigerant pressure rises above the cut in pressure a three minute time delay will occur before the compressor restarts This will protect the evaporator and compressor from damage should a problem occur in the refrigeration system or if the chiller is operated under circumstances which could cause damage to the refrigeration system Air cooled units Head pressure too low Check that entering air temperature is above 60 F If below 60 F find o
30. ation is counter clockwise incorrect phase when viewed from the rear of the motor If the shaft does not rotate when the ON OFF SWITCH is on the operator must identify the cause as outlined in the troubleshooting and repair section of this manual If the motor shaft is phased correctly shaft turns in a clockwise direction continue with step C If the motor shaft is NOT phased correctly shaft turns in a counter clockwise direction correct as outlined in step 2 525 East Stop 18 Road Greenwood Indiana 46142 Page 24 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 2 If the unit is phased incorrectly the operator must a Disengage the electrical power supply to the unit at the unit s disconnect switch Follow proper lockout procedures before proceeding b Once the electrical power supply is disengaged reverse any two power leads of the power cord at the disconnect terminals Note reversing any two power leads of the power cord will correctly phase the power supply to the unit The operator must reverse the power leads at the disconnect switch only and not at the power entry terminals on the unit s electrical panel The unit s internal electrical system wiring is phased correctly at the factory and must not be altered in the field C PROCESS FLOW ADJUSTMENTS 1 The operator mus
31. ature Pressure chart in Section 8 5 for refrigerant pressure 525 East Stop 18 Road Greenwood Indiana 46142 Page 17 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 2 5 ELECTRICAL CONNECTION 1 MODELS 1 Electrical power supply requirements for Nema 1 units are identified on the equipment data plate Determine the plant s voltage supply is the same as the unit s voltage requirements WARNING Do not connect the unit to a voltage supply not equal to the unit s voltage requirements as specified on the unit s data plate Use of incorrect voltage will void the unit s warranty and cause a significant hazard that may result in serious personal injury and unit damage A customer supplied four conductor cable is required for connection to a customer supplied fused disconnecting means The fused disconnecting means shall be sized and installed according to the unit s power supply requirements and local electrical codes Connect the four conductor power cable to power entry terminal block on the unit s electrical panel Then connect the power cable to the fused disconnect switch B NEMA 12 MODELS 1 NEMA 12 units are constructed with a dust tight electrical enclosure and branch circuit fusing Electrical power supply requirements are identified on the equipment d
32. d repairable part It can be easily removed and replaced if a problem arises 525 East Stop 18 Road Greenwood Indiana 46142 Page 35 EM I E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com THIS PAGE INTENTIONALLY BLANK Page 36 Series Portable Chillers with CF 1 Instrument 5 0 MAINTENANCE 5 1 WARRANTY SERVICE PROCEDURE 5 2 PERIODIC PREVENTATIVE MAINTENANCE 5 3 SPECIAL MAINTENANCE 5 4 SOLENOID VALVE SERVICE 5 5 PUMP SEAL SERVICE 5 6 CHECKING THE REFRIGERANT CHARGE 5 7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATOR lt soe ass j 525 East Stop 18 Road Greenwood Indiana 46142 Page 37 ES 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 5 1 WARRANTY SERVICE PROCEDURE In the event of a problem with chiller that can not be resolved by normal troubleshooting procedures the customer is invited to consult the Service Department for assistance The correct model number and serial number of the chiller must be available The service department will attempt to isolate the problem and advise repair procedures Often times with the customer s input and with the machine diagnostics problems can be determined with over the phone consultation If the problem is beyond the scope
33. d Greenwood Indiana 46142 Page 11 E E J 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com THIS PAGE INTENTIONALLY BLANK Page 12 Series Portable Chillers with CF 1 Instrument 2 0 INSTALLATION 2 1 GENERAL 2 2 TO AND FROM PROCESS CONNECTIONS 2 3 WATER SUPPLY CONNECTION 2 4 AIR COOLED CONDENSER INSTALLATION 2 5 WATER COOL CONDENSER INSTALLATION 2 6 ELECTRICAL CONNECTION 525 East Stop 18 Road Greenwood Indiana 46142 Page 13 EMI E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 2 1 GENERAL All process piping materials such as hose rigid piping valves or filters used in process water piping circuitry must be rated for 100 F minimum temperature and 100 PSI minimum pressure All such materials must have the equivalent or larger diameter of the particular process connection that length of process water piping is connected to 2 2 TO AND FROM PROCESS CONNECTIONS A From Process Connect to Water Out port on process manifold To Process Connect to Water In port on process manifold Air cooled model shown Connect the TO PROCESS to the water in manifold on the mold or process Connect the FROM PROCESS port to the water out port on
34. dels from 5 to 15 tons or a centrifugal blower on models from 15 to 30 tons generates air flow through the condenser to remove heat from the refrigerant system The air cooled condenser on the unit will discharge a maximum of 15 000 BTU s per hour per ton of cooling 2 The unit must have a minimum entering air temperature of 60 and a maximum entering air temperature of 95 F for efficient operation 3 The unit must have a minimum of two feet clearance at the air intake and six feet at the vertical exhaust air discharge 4 The unit must have all enclosure panels in place before operating compressor Air will not be drawn through the condenser coil if they are not in place This will cause the compressor to lockout on the high pressure safety fault 1 3 EFFICIENCY A Long term efficiency of operation is largely determined by proper maintenance of the mechanical parts of the unit and the water quality The Manufacturer recommends filtering where required to prevent solids from plugging critical parts pumps heaters seals for example The Manufacturer highly recommends the services of a competent water treatment specialist be obtained and his 525 East Stop 18 Road Greenwood Indiana 46142 Page 8 Ve m 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 1 4 1 5 1 6 rec
35. ed with a back flow prevention device to prevent contamination of potable water 2 4 AIR COOLED CONDENSER A Air cooled condensers require ambient air temperatures between 60 F and 95 F for efficient operation Operating above 95 F may result in elevated condensing pressures and eventual shut down on the high pressure safety switch In such cases a water assist unit may be necessary for operations Air temperatures below 60 F may result in below normal condensing pressures and poor condensing In such cases a low ambient damper assembly is required Check with the Manufacturer s service department for more information on operating with ambients air temperatures above 95 F or below 60 F gt 525 East Stop 18 Road Greenwood Indiana 46142 Page 15 EM I 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument B Air flow is generated by the motor mounted fans figure 2 4A or centrifugal blowers figure 2 4B Air flow is from the outside of the chiller through the condenser and exhausted through the top of the unit On centrifugal blowers models exhaust air can be ducted outside of the plant s interior environment Special duct work is required and a 2 contractor should be Typical fan assembly Figure 2 4A consulted for sizing and material specifications Exhaust air can not be ducted
36. emptek com Series Portable Chillers with CF 1 Instrument process circuitry This will allow a portion of the flow to bypass the process and return directly to the chiller This keeps the total flow above the cutoff point Figure 3 2E illustrates a typical bypass loop Figure 3 2E low flow by pass loop b Some models may have a factory installed bypass Adjust the valve accordingly 3 3 INSTRUMENT OPERATION MENTE DIGITAL CONTROL TEMPERATURE ADJUST SETPOINT v For Service call Phone 317 887 6353 ice Temptek com For information on Temptek system products Y www Temptek cor 1 Chiller Control Figure 3 3A INSTRUMENT START UP 1 When the correct electrical power and adequate water supply pressure are supplied to the unit it is possible to start the unit 2 Upon power up the instrument displays ChF indicating that the unit is in Fahrenheit temperature mode or ChC indicating that it is in Celsius mode The control then shows the current setpoint for approximately 2 seconds before reverting to the To Process temperature When power is supplied to the unit the ON OFF switch will illuminate 525 East Stop 18 Road Greenwood Indiana 46142 Page 26 Fa ng 4 317 887 6352 Fax 317 881 1277 F MUR 4 Service Department Fax 317 885 8683 4 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 3
37. epartment Fax 317 885 8683 Website www Temptek com Email service O Temptek com Page 61 THIS PAGE INTENTIONALLY BLANK Page 62 Series Portable Chillers with CF 1 Instrument 8 0 APPENDIX 8 1 OPERATIONS BELOW 48 F 8 2 WATER QUALITY CONTROL 8 3 INHIBITED PROPYLENE GLYCOL 8 4 SENSOR CURRENT VS TEMPERATURE CHART 8 5 REFRIGERANT PRESSURE TEMPERATURE CHART 8 6 CHILLER CAPACITY AND DERATE CHART lt soe ass j 525 East Stop 18 Road Greenwood Indiana 46142 Page 63 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 8 1 OPERATIONS BELOW 48 F Operating Glycol Freeze Cut Out Cut In R22 Temperature Chillers supplied with the automatic water supply system the water supply connection must be plugged when operating below 48 F or anytime the system utilizes a water inhibited propylene glycol solution The system must be manually filled and the mix shall be checked for the proper ratio on a regular basis Addition of an inhibited propylene glycol solution is required ration shall be according to figure 8 3A Too much glycol can cause capacity and control problems Under no circumstances shall an automotive type antifreeze be used in the chilling unit The freezestat and low pressurestat settings must be field adjusted according to figure 8 3B NEVER LOWER THE CUT
38. g main plant fuse and wiring If the problem is with the main power supply coming into the plant call the local power company Loose terminals Tighten terminals with POWER OFF 4 3 SHUTS OFF ON HIGH PRESSURE CONTROL Note Refrigerant high pressure will vary with ambient temperature from minimum of 190 psi to as high as 280 psi The high pressure switch manually reset when discharge pressure falls to a safe level The switch is located inside the electrical panel Air cooled units 1 Insufficient condenser air flow Check condenser filter for dirt 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 fuses and wiring motor starter and overloads and motor Repair or replace motor if defective Water cooled units 1 Water regulator valve Adjust condenser water regulator valve to maintain 100 F to 105 F refrigerant condensing 525 East Stop 18 Road Greenwood Indiana 46142 Page 32 Ve m 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument See Temperature Pressure chart in Section 8 5 for refrigerant pressure temperature If valve is defective have valve repaired replaced by a refrigeration serviceman 2 Insufficient condenser w
39. ibility to prevent damage from foreign material or inadequate water treatment The two main things to consider for water treatment in chillers are corrosion and organism growth Proper chemical treatment can control PH levels and algae growth An alternative to chemical treatment is the addition of 30 inhibited propylene glycol to the water This will help prevent organism growth and coat the heat transfer surfaces with corrosion inhibitor 8 3 INHIBITED PROPYLENE GLYCOL A To operate liquid chillers below 48 F it is necessary to add inhibited propylene glycol to the circulating system to lower the freeze point and prevent damage to the cooling system Inhibited propylene glycol contains corrosion inhibitors which are compatible with most industrial heat transfer surfaces Inhibited propylene glycol is manufactured by e Dow Chemical DowFrost 1 800 258 2436 e Monsanto Therminol FS 1 800 459 2665 Advantage Engineering Thermofluid 1 317 887 0729 Automotive anti freeze must never be used in industrial heat transfer applications Automotive anti freeze contains silicate type corrosion inhibitors designed to be compatible with automotive components In an industrial application the silicates will form a gel on the heat transfer surface which will result in substantial reduction in cooling capacity and is virtually impossible to remove 8 4 SENSOR CURRENT VS TEMPERATURE 20 243 86 10 249 43 0
40. ith CF 1 Instrument MECHANICAL SCHEMATIC WATER COOLED 2 10 TONS 7 1 34NSSJAd Ss390td OL NOILO3NNOO 1HOd 38 Odd HOS 5 5542 OL ia b dWNd LNVIOOI ANVL 5 NOLLDANNOD JHOd dN DIVIN ANTWA GIONTIOS W HOLINS BAT D eJ NOLLO3NNOO 1HOd SS1904d CI JHOd 39 1435 AONVS dunssdud INN NOLLINS INVA INVAN 3ATVA SSvdAg Sv9 LOH SES HOLIMS A134VS 34NSSIHA MOT n ANTWA GIO N31OS 10 2neuueH 1005 aq dOSSdud NOD HOLIMS 1355 3ufiSSddd H9IH CS AONVS 34NSSIAd No NOLLO3NNOO 1HOd 1NO HIVM HISNIGNOD Sem ud NOLLOHNNOO 1HOd NI SSIVM YAS NAG NOD gt p gt JAVA H11VM E gt ISNIGNOI 441009 mc Page 52 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com CF Series Portable Chillers with CF 1 Instrument MECHANICAL SCHEMATIC WATER COOLED 15 40 TONS 72 AONVS 34NSSJdd Ss390td OL NOILA NNOD INOd 390dd HOS 5 dWNd LNVIOOI 55420
41. machine For chillers with a reservoir 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 acid pump to the evaporator outlet port 3 Connect a hose to the evaporator water supply port and to an appropriate containment vessel If acid cleaning connect the evaporator water inlet port to an acid solution reservoir tank Dispose of all back flush fluid according to local codes 4 The cleaning fluid source should have at least 20 psi available If acid cleaning follow the instructions supplied with the acid solution carefully 5 When the procedure is complete reinstall all water lines to original factory orientation Restart the unit and check for proper operation 6 Note this procedure is not normal maintenance Maintaining proper water quality and filtration will minimize the need to back flush the evaporator ORIGINAL WATER IN PORT RAZED EVAPORATOR ANGER BACKFLUSH WATER OUT PORT ROUTE WATER TO PROPER SEWER OR DRAIN CONTAINER FREON OUT ORIGINAL WATER OUT PORT BACKFLUSH WATER IN PORT SUPPLY BACKFLUSHING WATER FLOW TO THIS PORT FREON IN 525 East Stop 18 Road Greenwood Indiana 46142 Page 46 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com
42. minates when compressor is turned on CAPACITY CONTROL illuminates when capacity control system is turned on REFRIGERANT FAULT illuminates when there is a high pressure or low pressure alarm Check troubleshooting section of this manual for more details High Pressure Alarm If the chiller control detects a high pressure condition it will immediately turn off the compressor and hot gas bypass Low Pressure Alarm After the compressor is turned on the control has a 15 second buffer for the low pressure alarm lf a low pressure condition occurs within the first 15 seconds the control waits the amount of time specified by the LP TIME potentiometer before indicating an alarm and Low Pressure Potentiometer Figure 3 3C turning off the compressor If the condition is corrected before the time expires no alarm occurs If a low pressure condition occurs 15 seconds after the compressor turns on the instrument waits 20 seconds before indicating an alarm and turning off the compressor E TEMPERATURE DISPLAY 1 A three digit display window indicates the appropriate temperature The window also displays the numeric value for the setpoint temperature 2 The To Process temperature is always displayed unless a button has been pressed If there is a probe error the display will show three dashes F PRESSURE GAUGES OPTIONAL 1 PROCESS PRESSURE GAUGE indicates process pump Pressure 2 REFRIGERANT HEAD PRESSU
43. nd clean or replace as necessary Clean the valve body Reset the mesh screen into the valve body If anew diaphragm assembly was obtained continue with step 12 If not disassemble the diaphragm assembly and note component order figure 5 4E Clean the valve port plate collar and O ring Once cleaned reassemble the diaphragm Set the reassembled diaphragm assembly or the new assembly back into the valve body The stem should be facing out of the valve body Inset the plunger with spring first into the enclosing tube of the top bonnet figure 5 4F Holding the plunger in the enclosure tube set the top bonnet onto the valve body and tighten Place the coil onto the top bonnet and replace the retaining screw Open the water supply and drain valves if installed to circulate water through the supply and drain manifolds Check the solenoid valve for leakage Restart the unit as outlined in section 3 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Plunger Diaphragm assembly Top bonnet Enclosure tube Figure 5 4C Mesh screen Diaphragm assembly O Ring Figure 5 40 Collar Plate Diaphragm and stem O Ring Figure 5 4E Enclosure tube Top bonnet Spring Plunger Figure 5 4F Page 41 Email service Temptek com Series Portable Chillers with CF 1 Instrument 5
44. ndiana 46142 Page 30 AA u 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 40 TROUBLESHOOTING 4 1 UNIT WILL NOT START 4 2 COMPRESSOR HUMS BUT WILL NOT START 4 3 SHUTS OFF ON HIGH PRESSURE 4 4 SHUTS OFF ON LOW PRESSURE 4 5 COMPRESSOR SHUTS OFF ON INTERNAL OVERLOAD 4 6 LOW OR NO PROCESS PRESSURE OR WATER FLOW 4 7 COOLING CAPACITY INADEQUATE 4 8 SENSOR 4 9 PUMPS 4 10 CRANKCASE HEATER 4 11 CHILLER CONTROLLER 525 East Stop 18 Road Greenwood Indiana 46142 EMI E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Page 31 Series Portable Chillers with CF 1 Instrument 4 1 UNIT WILL NOT START Power off Check main disconnect Main line open Check fuses Loose terminals Tighten terminals with POWER OFF Control circuit open check control voltage fuses and transformer 4 2 COMPRESSOR HUMS BUT WILL NOT START Contactor Check contacts and contactor operation Low voltage Check voltage at main and at the unit If voltage is OK at 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 No power on one phase of a three phase unit Check fuses in control panel and main disconnect Also check unit wirin
45. of over the phone consultation and if the warranty status of the machine is valid the Manufacturer will contact the nearest authorized service contractor and provide authorization to conduct an on site inspection of the unit in order to determine the course of repair If the chiller is not covered by the warranty the Manufacturer will advise on the repair and recommend available service contractors It is of the utmost importance that you provide the correct model number and serial number of the machine in question This will allow the Service Department to obtain the correct manufacturing records which will help to properly troubleshoot the problem and obtain the proper replacement parts when they are required This information is stamped on the data tag that is attached to the electrical enclosure of each machine The Service Department must be notified prior to any repair or service of a warranty nature Warranty claims will not be honored without prior authorization 5 2 PERIODIC PREVENTATIVE MAINTENANCE A Lubricate all motors Note that some motors are supplied with sealed bearings Tighten all wire terminals Clean and check motor starter and contactor contacts Check safety switch settings Clean condenser fins of dust and dirt air cooled models only Back flush evaporator Check glycol water solution ratio for operating temperature Check system for leaks 525 East Stop 18 Road Greenwood Indiana 46142
46. of as well as improper water treatment can damage the chilling unit The services of competent water treatment specialist should be obtained and their recommendations followed It is the equipment owners responsibility to prevent damage from foreign material or inadequate water treatment See water treatment section in section 8 of this manual for more information FOR OPTIONAL AUTOMATIC FILL engage the water supply to unit The level switch will activate the make up solenoid figure 3 2A which will open and the water supply will fill the reservoir tank MANUAL FILL disconnect the electrical power supply and remove all necessary cover panels to access the reservoir Add fluid directly to the reservoir When the pump is first started as process lines are filled and air is purged additional fluid may be required to restore the reservoir to the correct level Verify reservoir level via the coolant sight glass figure 3 2B Figure 3 2A Make up solendid valve Typical reservoir sight glass Figure 3 2B B ELECTRIC MOTOR PHASING PUMP ROTATION 1 The operator must determine the unit is phased correctly by visually inspecting the rotation of the pump motor shaft The procedure is outlined below Incorrect phasing results in poor operation and eventual damage to the unit a Supply electrical power to the unit Once the correct voltage is supplied to the unit the POWER switch on the unit s control panel will
47. om the process fluid As the heat is absorbed the process fluid is chilled figure 6 2F Expansion Valve Figure 6 2E HOT GAS BY PASS SOLENOID the hot gas by pass solenoid prevents short cycling of the compressor by reducing the capacity by 50 when the process fluid temperature nears the setpoint HIGH LOW PRESSURESTATS the high low pressurestats protect the refrigeration system from unsafe operating levels The high pressure switch is factory set and protects the refrigeration components and personnel from potential damage of injury from excessive high pressure The high pressure safety must not be altered in the field for any reason See section 8 1 for factory settings The low pressure switch is factory set to open at 32 F and to close at 36 39 F The low pressure switch protects the chillers from possible damage due to low operating pressure The low pressure switch is field adjustable for setpoints below 48 F Typical hot gas bypass valve Figure 6 2H NEVER LOWER THE CUT OUT SETTING WITHOUT ADDING GLYCOL TO THE CIRCULATING SYSTEM EVAPORATOR DAMAGE WILL RESULT AND WILL NOT BE COVERED BY THE WARRANTY 1 525 East Stop 18 Road Greenwood Indiana 46142 Page 49 EM 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument J Liquid receiver located after the condenser thi
48. ommendations followed The Manufacturer accepts no responsibility for inefficient operation or damage caused by foreign materials or failure to use adequate water treatment SAFETY It is important to become thoroughly familiar with this manual and the operating characteristics of the unit B It is the owner s responsibility to assure proper operator training installation operation and maintenance of the unit Observe all warning and safety placards applied to the chiller Failure to observe all warnings can result in serious injury or death to the operator and severe mechanical damage to the unit CLEAN AIR ACT The unit contains 22 chlorodifloromethane This is a class 2 substance Effective July 1 1992 it is unlawful for any person in the course of maintaining servicing repairing or disposing of refrigeration equipment to knowingly vent or otherwise dispose of any class 2 substance used as a refrigerant in the manner which permits such substance to enter the atmosphere De minimis releases associated with good faith attempts to recapture reclaim or recycle such substance shall not be subject to the prohibition set forth in the preceding paragraph MISCELLANEOUS The unit is designed to circulate temperature stabilized fluid through the process resulting in process temperature control The ability of the unit to maintain process temperature control is significantly affected by the method
49. on motor mounted fan models C A free air space of at least two 2 feet is required at the condenser intake and six 6 feet at the condenser discharge to allow for proper air flow 25 a D At full load the chiller will discharge approximately 15 000 BTU s per hour per ton of cooling Typical blower assembly Figure 2 4B E On blower units air discharge duct work should be sized by a qualified HVAC engineer Sizing shall be according to rated CFM at the static pressure of 90 inches of water See figure 2 4C at right F On blower units a damper Figure 2 4C control assembly is required in low ambient temperature areas or when outdoor air make up is used The assembly works in conjunction with refrigerant head pressure to regulate air flow to maintain HH m proper refrigerant um m nl head pressure when condenser intake air TES temperature will be tamm im less than 60 F See cu figure 2 4D to the Figure 240 right 525 East Stop 18 Road Greenwood Indiana 46142 Page 16 Lo lI 317 887 6352 317 881 1277 E MUR El Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument G All air cooled units must have all enclosure panels in place before operating compressor Air will not be drawn through the condenser coil if they are n
50. or 9 32 C 3 The setpoint temperature can be displayed by pressing the UP ARROW or DOWN ARROW keys The setpoint temperature will be displayed for 5 seconds 4 When the compressor is turned off the instrument will wait 3 minutes before turning it back on regardless of the To Process temperature or setpoint If a fault has occurred the control will attempt to turn the compressor on after 3 minutes powered down If the fault condition remains the control will turn the compressor off and retry after 1 minute This sequence will repeat until the compressor turns on or instrument power is cycled 525 East Stop 18 Road Greenwood Indiana 46142 Page 27 EM I 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 5 Under normal conditions no fault conditions compressor has been off for three minutes the instrument will turn on the compressor when the To Process temperature is above the setpoint The instrument will turn on the hot gas bypass when the To Process temperature is below the setpoint by no more than 3 degrees The instrument will turn off the compressor and hot gas bypass when the To Process temperature is 4 degrees or more below the setpoint INSTRUMENT CONTROLS 1 ILLUMINATED ON OFF SWITCH this rocker switch starts or stops the unit Electrical power is supplied to the unit
51. ord should be 525 East Stop 18 Road Greenwood Indiana 46142 Page 42 eee IN A pl 317 887 6352 Fax 317 881 1277 E E Le Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 10 11 removed from the motor housing figure 5 50 Locate and remove the pump casing bolts These bolts secure the motor and motor adapter to the pump casing figure 5 5D Separate the motor and motor adapter from the pump casing to expose the pump impeller figure 5 5E Remove the motor and motor adapter from the unit and place on a workbench to continue the procedure Locate and remove the dust cap from motor end to expose slotted motor shaft The motor shaft is free to rotate but must be secured to remove the impeller To secure the motor shaft insert flat bladed screw driver in slot to hold the shaft stationary Figure 5 5F Locate and remove impeller locking screw Figure 5 5G Using a socket and ratchet the impeller retaining screw can be removed Once the retaining screw is removed the impeller can be unthreaded from the motor shaft to expose the pump seal assembly Remove all seal parts Figure 5 5H Note seal component arrangement to facilitate reassembly Clean motor shaft and lubricate with a mild soap solution 525 East Stop 18 Road Greenwood Indiana 46142 317 887 6352 Fax 317 8
52. ot in place This will cause the compressor to lockout on the high pressure safety fault 2 5 WATER COOLED CONDENSER A Connect the CONDENSER WATER IN port to the plant s city water supply or tower system supply 1 Required consumption from a city water source is 1 5 gpm at 65 F per ton of rated capacity 2 Required consumption for a tower water source is 3 gpm Typical condenser connections Figure 2 5A at 85 F per ton of rated one capacity B Connect the chillers CONDENSER WATER OUT port to the plant s drain or tower system return 1 Note if dumping to the plant s open drain drainage shall be done according to local codes C The pressure differential requirement between the condenser water in and the condenser water out lines must be 30 psi for adequate efficiency D The installation of a strainer in the condenser water in line is recommended This removes solids from the water supply and serves to protect the water saver regulator valve E The water saver regulator valve figure 2 5B is located in the condenser water in line During winter months or cold seasons the valve will throttle the water flow through the condenser The amount of flow is based on the refrigerant head pressure and the regulator will modulate the valve orifice to maintain 100 105 F condensing temperature for best efficiency Optional Regulator Valve Figure 2 5B See Temper
53. rating to the evaporator The valve opens when the compressor cycles on E REFRIGERANT SIGHT GLASS the refrigerant sight glass indicates refrigerant charge and moisture content Refrigerant charge is determined by a clear liquid flow Bubbles indicate low refrigerant Moisture content is indicated by the color of the element Element color is normally green If the color of the Typical filter drier Figure 6 20 525 East Stop 18 Road Greenwood Indiana 46142 Page 48 AE _ IRA Al 317 887 6352 317 881 1277 E E Y Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument See Temperature Pressure chart in Section 8 5 for refrigerant pressure element is chartreuse or yellow the system has been contaminated with moisture In such case the filter drier must be replaced replacement of the filter drier must be completed by a qualified refrigerant service technician figure 6 2D EXPANSION VALVE the expansion valve throttles flow of Refrigerant sight glass Figure 6 2D refrigerant liquid into the evaporator and creates a pressure drop in the refrigerant system that allows the liquid refrigerant to boil off inside the evaporator figure 6 2E EVAPORATOR the evaporator is a brazed plate heat exchanger where the refrigerant liquid is allowed to evaporate boil off to absorb heat BTU fr
54. s component receives and stores liquid refrigerant leaving the condenser K Service valves have been provided throughout the system Only a qualified refrigeration service technician shall operate these valves L Crankcase heater insures that freon and compressor crankcase oil do not mix during the compressor s off cycles Power must be applied to the chiller previous to startup M Oil pressure safety switch protects the compressor from lubrication failure 525 East Stop 18 Road Greenwood Indiana 46142 Page 50 a m u 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 7 0 RELATED DRAWINGS 7 1 MECHANICAL SCHEMATIC WATER COOLED 2 10 TONS 72 MECHANICAL SCHEMATIC WATER COOLED 15 40 TONS 7 3 MECHANICAL SCHEMATIC AIR COOLED 5 10 TONS 7 4 MECHANICAL SCHEMATIC AIR COOLED 15 30 TONS 7 5 TYPICAL ELECTRICAL AIR COOLED 7 6 TYPICAL ELECTRICAL WATER COOLED 7 7 PHYSICAL SCHEMATIC AIR COOLED 7 5 10 TONS 7 8 PHYSICAL SCHEMATIC AIR COOLED 5 TONS 79 PHYSICAL SCHEMATIC WATER COOLED 7 10 DUCT SCHEMATIC FOR AIR COOLED CHILLERS 525 East Stop 18 Road Greenwood Indiana 46142 Page 51 EMI E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers w
55. se heater should be checked for proper operation on a regular basis UNITS WITH SCROLL COMPRESSORS DO NOT HAVE A CRANKCASE HEATER AND THIS PROCEDURE IS NOT NECESSARY The OPERATIONS segment of this manual is divided into the following sections 3 2 Start up operations follow this segment to start the unit after the initial install to the process system or to restart the unit after reinstallation to the same or different process system This section includes information on system fill electric motor phasing pump rotation and process flow adjustments 3 3 Chiller Control follow this segment to start up and operate the chiller control This section includes information on setpoint selection and adjustment and feature explanations 3 4 Shut down procedure follow this segment to shut down the unit This segment includes information on system shut down electrical power supply precautions and disconnection from system 525 East Stop 18 Road Greenwood Indiana 46142 Page 22 317 887 6352 317 881 1277 E MUR E Service Department Fax 317 885 8683 Website www Temptek com Email service O Temptek com Series Portable Chillers with CF 1 Instrument 3 2 START UP OPERATION PROCEDURE SYSTEM FILL 1 The unit has an internal reservoir which must be filled and maintained for proper operation The unit has a level switch mounted at the proper water level in the reservoir WATER QUALITY CONTROL Lack
56. t determine and set proper water flow rate for the most efficient and trouble free operation a Water flow rate through the process is determined by the pressure losses in the process loop Generally higher flow rates result in turbulent flow achieving maximum temperature control and lower maintenance Since the evaporator in most liquid chillers is flow sensitive the efficiency of operation is directly related to the flow of liquid b Maximum chiller efficiency is obtained at approximately 2 4 gpm per ton of rated capacity Low liquid flow can reduce efficiency and in some cases allow ice to develop in the evaporator which can damage the evaporator Excessive liquid flow will trip the motor overload protection circuit 2 Switch on the illuminated ON OFF SWITCH to activate the process pump Wait a few moments to allow air to be purge from system Observe the COOLANT pressure gauge for steady readout Two items the operator for look for are low flow or excessive flow conditions 3 LOW FLOW If a low flow condition is present be sure all process valves are open If all process valves are open and a low flow conditions exists consider the following a To operate under a low flow condition it is necessary to install a flow bypass system in the 525 East Stop 18 Road Greenwood Indiana 46142 Page 25 EM I 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service T
57. the process manifold Process water piping circuitry should be designed to avoid an excessive use of elbows and or lengths of pipe or hose If hose is the material of choice avoid tight twists or curls and excessive lengths Valves and filters may be installed in the process water piping circuitry to facilitate service and maintenance provided that such devices maintain the full inside diameter of the process connection If installed all such devices must be open and clean during unit operation Water Make Up Connect to plant s city water source 525 East Stop 18 Road Greenwood Indiana 46142 Page 14 Y 317 887 6352 317 881 1277 E MUR elk Service Department Fax 317 885 8683 Website www Temptek com Email service 9 Temptek com Series Portable Chillers with CF 1 Instrument To Process Connection From Process Connection Condenser Water Out Connection Water Supply Connection Condenser Water In Connection with optional water regulator valve zn vU Water Cooled model shown 2 3 WATER SUPPLY CONNECTION A The automatic water supply make up system continually monitors the reservoir tank and fills it when needed Connect as follows 1 Connect the 5 WATER SUPPLY port to the plant s city water source 2 Minimum water supply pressure requirement is identified on the equipment data plate This is normally 20 psi 3 Be certain to use a water supply line equipp
58. ut reason why Water cooled units Head pressure too low Adjust condenser water regulating valve to maintain 100 F 105 F refrigerant condensing temperature Have refrigeration serviceman repair valve or replace if defective 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 refrigeration serviceman 525 East Stop 18 Road Greenwood Indiana 46142 Page 33 EM I E E 4 317 887 6352 Fax 317 881 1277 Service Department Fax 317 885 8683 Website www Temptek com Email service Temptek com Series Portable Chillers with CF 1 Instrument 4 5 4 6 4 7 D Improperly set low pressure switch Have a refrigeration serviceman reset control or replace if defective Restriction in the liquid line 1 Clogged filter drier Check for pressure or temperature drop and have drier core replaced by a refrigeration serviceman 2 Liquid line valve or suction valve on compressor is partially closed Open fully 3 Liquid line solenoid not opening fully or leaking during off cycle have repaired or replaced if defective by a refrigeration serviceman 4 Expansion valve plugged or inoperative Check thermal bulb and capillary tube for damage Have repaired or replaced if defective by a refrigeration serviceman COMPRESSOR SHUTS OFF ON INTERNAL OVERLOAD Control does not reset

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