Sterling Power Products 30F User's Manual
Contents
1. OPERATION AND INSTALLATION MANUAL SMC SERIES AIR COOLED PORTABLE WATER CHILLERS IMPORTANT PLEASE READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OR OPERATE EQUIPMENT Sterling Inc is committed to a continuous program of product improvement Specifications are subject to change without notice Sterling Inc 2003 All Rights Reserved Effective 10 1 2007 Part Number 882 00740 00 Bulletin SC2 615A 4 Page 2 SMC Series Chillers Safety Considerations Sterling Inc SMC Series Chillers are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices M Follow SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment It is a good idea to remove the fuses and carry them with you Make sure the chiller is properly GROUNDED before switching power on When welding or brazing in or around this equipment be sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be cl2. Discharge line Liguid line Refrigeration evacuation valve Reliet valve lt Refrigeration evacuation valve l s Suction Filter Filter Line Drier Expansion Sight valve glass Evaporator i P Th N Legend Equalizing line j Refrigeration lines Chilled water piping Refrigerati Power element Condenser water piping gt gt efrigeration MEE access valve End of unit piping Temperature Optional probe pressure High n TC 7 gauge pressure 5 To control Low Process o pressure control Bypass N lt Optional CPR valve Compressor Refrigeration Y access valve Vent Fill compressor mounted O Sight glass Tank Pum Drain L From Process SMC Series Chillers Page 21 Figure 10 Piping Schematic 1 Pump Without Reservoir Discharge line Air cooled condenser Liquid line a Lo Refrigeration 7 evacuation valve Failt valve Refrigeration i evacuation valve Suction Filter Filter line drier Legend Expansion Sight Refrigeration lines Evaporator valve glass Chilled water piping Y P C 71 Condenser water piping Equalizing line End of unit piping H Power element Refrigeration access valve lt Temperature Optional
3. Chillers Page 15 M A corrosion inhibitor suitable for the materials in the system should be added to the glycol water solution MI If straight water use is desired contact the Sterling Inc Engineering Department M The six gallon 23 liter reservoir is not designed to withstand water pressure above 5 psi 34 kPa M The fill opening and vent line must be vented to the atmosphere for proper operation Figure 6 Ethylene Glycol Curve Ethylene Glycol Required for Evaporator Freeze Protection 30 Ethylene Glycol 20 Percent by Volume 10 0 25 35 45 55 65 Chilled Water Operating Temperature F Set Point Normal Operating Range between 30 F 70 F Page 16 SMC Series Chillers 2 5 Overhead Process Considerations If your application has chilled water or process piping above the reservoir fill and vent level install a standpipe to a point 1 30 cm above the highest point in the system In applications where the process or its piping is 15 feet 4 6 m or more above the reservoir you must take steps to prevent over pressurization of the reservoir This condition can occur on system shutdown when the water in the system drains into the reservoir To prevent this install a check valve in the unit TO PROCESS line and a vacuum breaker at the high point of the return FROM PROCESS line See Figure 7 below for more information Note The reserve capacity of the reservoir can hold a volume equal to
4. conditions of the Carrier the responsibility of the shipper ends at the time and place of shipment The Carrier then assumes full responsibility of the shipment M Notify the transportation company s local agent Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterling Inc before the transportation company inspection and authorization M File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill M Advise Sterling Inc regarding your wish for replacement 1 7 Ifthe Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have M SMC Series Chiller Bill of Lading M Packing List M Operating and Installation Packet Re inspect the container and packing material to see if smaller items have been missed during unpacking Determine that the item was not taken from the area before the shipment was checked in Notify the Sterling Inc parts and service department immediately of the shortage at 262 641 8610 1 8 If the Shipment is Incorrect I If the shipment is not what you ordered contact Sterling Inc immediately Include the
5. for service LOW REFRIGERANT PRESSURE red This indicator lights if the refrigerant pressure drops below a safe level The compressor will stop and remain off until the pressure reaches a safe level The light will go out and the chiller will then resume operation automatically LOW WATER FLOW red PCA units without pump only This indicator lights if the flow switch senses chilled water glycol flow through the evaporator dropping to an unacceptable level The compressor will stop until the flow switch senses adequate flow and restarts the chiller 6 2 Switches POWER This switch energizes the control circuit and also turns off the chiller ED SMC Series Chillers Page 31 Figure 13 Optional Graphic Panel Portable Chiller LOW HIGH REFRIGERANT REFRIGERANT PRESSURE PRESSURE Page 32 SMC Series Chillers 7 Routine Maintenance 7 1 Lubrication Every three months grease all fan motors and pump motors that do not have permanently sealed bearings Remove grease relief plug motors only before adding grease Failure to do so may result in dislodging the bearing grease retainer eventually causing bearing failure Compressors are hermetically sealed no oiling is required 7 2 Condenser Maintenance Dirty condenser heat exchange surfaces reduce system capacity Brush or vacuum light dirt a
6. probe pressure High 1 22 gauge pressure s P control T Process 7 pressure N Optional 4 CPR valve i Bypass Compressor Refrigeration access valve compressor mounted Pump a a From Process Page 22 SMC Series Chillers Figure 11 Piping Schematic No Pump No Reservoir Discharge line Air cooled condenser C EX Liquid line var N y Refrigeration SI evacuation valve Relief valve Refrigeration evacuation valve Suction Filter Filter drier line Expansion Sight Legend 2 valve glass Refrigeration lines Evaporator 9 Y za d B Chilled water piping Equalizing line Condenser water piping End of unit piping H Power element Refrigeration U access valve Temperature Optional Probe pressure High TC A gauge pressure S P To control 15 id Process k pressure control 04 Bypass J Optional N CPR valve Compressor Refrigeration access valve compressor mounted Flow switch T From I Process SMC Series Chillers Page 23 Startup Checklists 4 2 Introduction Follow the check lists below for the startup of your new chiller These lists assume the installation information elsewhere in this manual h
7. take up to 45 minutes and is best done before any product is being run Important Factory default settings are 3 1 7 and D 1 To auto tune the controller Press and hold down the AT AT key for several seconds until the AT indicator flashes m The AT LED flashes to indicate that the control is tuning itself When the AT LED light stops flashing the controller is tuned and ready for operation SMC Series Chillers Page 29 5 6 Optional Communications Standard Omron Protocol The communications function allows you to monitor and set ESCK parameters by a program prepared and running on a host computer connected to the ESCK controller When using the communications function you must add on the unit for RS 232C or RS 485 communications The ESCK communications function allows you to read write parameters do operating instructions and select the setting level Page 30 I SMC Series Chillers 6 Optional Graphic Panel 6 1 Indicator Lights PUMP green This indicator lights when the pump is running O COMPRESSOR ON green This indicator lights when the compressor is operating HIGH REFRIGERANT PRESSURE red This indicator lights if the condensing pressure exceeds a safe level The chiller goes to Idle mode until the high refrigerant pressure cutout resets The light then goes out and the chiller automatically restarts Call a gualified refrigeration service technician
8. 20 feet 6 1 m of 1 inch 2 5 cm pipe Figure 7 Overhead Piping The reservoir vent amp fill line Vent Vacuum Breaker to be piped 12 above the highest Assembly point of the system The vent line Cap must remain open to the atmosphere Process Return Strainer Process Supply Ls Ad Add check valve if system piping extends 15 feet above reservoir J Indicates end of Sterling piping ED SMC Series Chillers Page 17 3 Sequence of Operation IMPORTANT SMC unit has a leaving water temperature range of 30 F 1 to 65 F 18 C Do not attempt to run the SMC unit outside this temperature range or damage to the unit may occur When operating the SMC unit between 30 F 1 C and 40 F 5 C you must use a solution of 75 water and 25 industrial grade ethylene glycol with a suitable corrosion inhibitor to protect the SMC unit from freeze up See Figure 6 on page 16 for more information Such damage is not covered by the Sterling Inc warranty 3 1 Chilled Water Circuit Figure 9 Figure 10 and Figure 11 Process cooling water supply and return connections are made at the pipe stubs at the rear of the chiller Warm water returns from the process and enters the reservoir tank The process water is pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle E NNN A chilled water bypass assembly patent pe
9. 55 AEC has a qualified service department ready to help Service contracts are available for most AEC products WWW acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST AEC products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 262 641 8610 Monday Friday 8am 5pm CST Let AEC install your system The Contract Department offers any or all of these services project planning system packages including as built drawings equipment labor and construction materials union or non union installations and field supervision Sterling Inc 2900 S 160 Street New Berlin WI 53151 262 641 8610 Fax 262 641 8653 SMC Series Chillers Page 43
10. Drain plug i I 1 oa 3 4 NPT N No Flow indicator To Process for pumpless 3 4 NPT units only 34 18 S 6 From Process 3 4 NPT mu 0 N Ri T 20 2 Optional Casters Rear View Front View Right Side View Capacity Capacity 65 F O 50 F Nominal Amp LWT 75 F LWT 90 F Chilled Process Draw Dimensions Operating Shipping Model Ambient Ambient Compressor Connection 230 1 60 i i Weight Number Btuh gpm hp inches NPT 1 3 hp SMC 050 8 100 4 800 1 2 gpm 24 psig 1 3 hp SMC 100 14 000 9 550 2 4 gpm 34 psig 1 3 hp SMC 150 25 400 16 000 3 6 gpm 24 psig Capacity Capacity 18 C 10 C Nominal LWT 24 C LWT 32 C Chilled Process Draw Model Ambient Ambient Water Compressor Connection 230 1 60 Number watts pm watts inches NPT i 224 watts SMC 050 2 374 4 5 Ipm 207 kPa 224 watts SMC 100 4 103 9 0 234 kPa 224 watts SMC 150 7 444 13 6 lpm 207 kPa SMC Series Chillers Page 13 2 Chiller Installation 2 1 Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms See Figure 5 on page 13 for total running amps Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the main power terminal in the chiller s electrical enclosure Electrical connections must comply with all applicab
11. Reservoir 23 Figure 12 Typical SMC Series ESCK Microprocessor Controller 27 Figure 13 Optional Graphic es ace taa aed usa QU a 32 Figure 14 Typical SMe SUBpanel ue odi disini aeo 33 Figure 15 Typical SMC Wiring Schematic ie se 34 Figure 16 SMC Wiring Schematic for Chillers with No Pump or Reservolir 35 Page 6 SMC Series Chillers 1 General Information 1 1 Introduction Sterling Inc s SMC Series Water Chillers are reliable accurate and easy to use air cooled chillers designed for use with water glycol Standard range of operation is 30 F 1 C to 65 F 18 C for applications using glycol and 45 F 7 C to 65 F 18 C for water only applications A crankcase pressure regulating valve option is available for processes requiring a leaving water temperature of up to 75 F 24 C PCA models are available in 1 2 hp 373 W 1 hp 746 W and 1 1 2 hp 1 118 W models and have an internal six gallon 23 liter reservoir All models are self contained fully assembled and shipped ready to use A properly installed operated and maintained SMC Series Chiller will provide many years of reliable operation To get the most satisfaction from your new chiller read and follow the instructions in thi
12. as been read and followed New chillers should be started up and checked by a qualified refrigeration service technician SMC Pre Startup Checklist 1 Check the shipping papers against the serial tag to be sure chiller size type and voltage is correct for the process that will be controlled Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using The voltage at the main power connection must read within 10 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes The chilled water TO PROCESS and FROM PROCESS connections should be completed Be sure the reservoir tank and chilled water circuit piping are filled with water The air cooled condenser should have an adequate supply of air for proper operation Connect main power to the chiller and run the chiller just long enough to see if the pump is generating normal pressure Check your work and proceed to the SMC Startup Checklist section below 4 3 PCA Startup Checklist Page 24 1 Turn ON the chiller The SMC chiller should continue to run until the switch is turned OFF Put the SMC chiller under a process load Set the microprocessor control to the desired process temperature setpoint using the KA and buttons See Chapter Five on Page 25 for more information Check the pump amp draw and pump pressure The amp draw reading must be within the running l
13. ccumulations Avoid bending or damaging the fins Heavy soil accumulations on the coil require professional steam cleaning washing from the outside only makes matters worse Figure 14 Typical SMC Subpanel Distribution Block Grounding Lug Terminal Blocks Control Voltage Transformer Pump Condenser Contactor Contactor LD SMC Series Chillers Page 33 Figure 15 Typical SMC Wiring Schematic ILI 1 1 1MTR Pump N 112 1T2 l 1L1 20 2T1 2MTR Compressor 1L2 212 Earth 3T1 ground gt 3MTR Fan 3T2 Remote interlock 112 1L1 by others Control gt I 230 ON OFF Jumper 1T Subpanel 1S 1LT 1FU l 2 ground 1 XI 115V 2 t O Power On Pump 3 starter a Sus E eis le sS 20 Cm Low Refrig Hi Retrig Pres Pres 2 3LT R ALT TR Ma Were E Taa pane 1PS 2PS Condensing unit 4 5 6 contactor TAR Compressor ned 6 7 8 9 10 1CNTL Jumper Legend 1 2 3 4 5 Customer wiring Customer supplied compone
14. ecial Pumps Special pump options are available for greater pressure and flow rates Bronze and stainless steel wetted surface standard flow pumps ranging from 30 psi 207 kPa to 60 psi 414 kPa are available Reservoirs SMC Series Chillers are available without a reservoir for processes that use their own reservoir Power Cord A 10 foot 3 meter power cord is available to speed SMC installation Casters Four 2 inch 5 cm swivel casters add mobility to the SMC unit CPR Valve A crankcase pressure regulating CPR valve is available for leaving water temperatures up to 75 F 24 C Uncrating Your New Chiller SMC Series Chillers are shipped mounted on a skid enclosed in a plastic wrapper and open crated on all four sides and top Pry the crating away from the skid and remove Use a pry bar to remove the blocks securing the unit to the skid M Lift the unit off the skid with a fork truck Insert forks between skid and chiller from the side until they protrude beyond the opposite side of the unit The forks must be equidistant from the center line of the unit and the unit must be balanced on the forks MI Lift slowly and only high enough to clear the skid Use a pry bar if necessary to remove the skid from the unit Lower slowly The unit will land on its feet or casters and can be moved into position I SMC Series Chillers 1 6 Inthe Event of Shipping Damages IMPORTANT According to the contract terms and
15. he Stelring Service Department 5 4 Temperature Controller Keys AT Key Press and hold the AT AT key for two seconds to initiate or stop the auto tune function Display Key The functions of the Display key change based on how long you press it Press the Display key for less than one 1 second to scroll through parameters within the mode Press the Display key for at least one 1 second or more to display the menu this function also lets you select the mode you need to adjust Page 28 I SMC Series Chillers Important Do not change any of the control settings without consulting the Sterling Service Department The AEC Inc warranty does not cover chiller failures from tampering with controller settings Down Key Each press of the Down Arrow key decrements or reduces the values or settings on the SV display Up Key Each press of the Up Arrow key increments or advances the values or settings on the SV display 5 5 Auto Tuning SMC Series Chillers The Auto Tune function lets you fine tune the control PID to process requirements Activate the Auto Tune function whenever the process under control changes Don t be alarmed by control response It may take the process temperature above and below the set points as many as three 3 times It will then level off and control to the process set point Auto tuning can
16. is factory set to open the control circuit when pressure drops below a safe level The chiller will automatically restart when the suction pressure reaches an acceptable level Model Cutsoutif suction pressure falls below SMC050 15 psi 103 kPa 15 SMC100 osi 103 kPa SMC150 35 psi 241 kPa 3 5 Remote Start Stop Interlock A contact is provided to allow interlocking of the SMC Series Chiller with process controls To use this feature remove the jumper between Terminals X1 and 1 on Terminal Block 1 Supply a switch or dry contact interlock connected in series between these two terminals See Figure 15 and Figure 16 on pages 34 and 35 for more information SMC Series Chillers Page 19 Figure 8 SMC Component Identification Seamless plastic reservoir Sight glass for easy water level indication NEMA 1 enclosure with dependable rated components 9 Insulated refrigerant lines Efficient insulated ja for increased efficiency pump and evaporator 2 Convenient chilled water zg supply and retum connections Process bypass protection Refrigerant sight glass Rugged dependable reciprocating compressor Filter dryer Optional casters Page 20 I SMC Series Chillers Figure 9 Piping Schematic 1 Pump with Reservoir Air cooled condenser
17. le electrical codes The chiller must be grounded in accordance with NEC Article 250 M Voltage must be within 10 of the chiller s nameplate rating 2 2 Process Water Connections MI All external chilled water connections to the process must be of adequate size M See Figure 7 on page See 17 for sizing recommendations The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment IMPORTANT Keep any pressure drop in external process piping to an absolute minimum for optimum unit operation To Process Connect the TO PROCESS chilled water supply outlet to the process being cooled From Process Connect the FROM PROCESS chilled water return inlet to the return from the process back into the chiller for cooling and recirculation M Sterling Inc recommends a strainer on the FROM PROCESS return line Page 14 SMC Series Chillers Process Water Bypass All SMC chillers have an internal bypass device patent pending If the process flow becomes blocked during chiller operation this component allows water to flow through the chiller This protects the chiller from freeze up excessive pressures and pump damage and allows other safety features to remain effective 2 3 PCA Condenser Air Supply SMC chillers use the surrounding air to cool the condenser M Condenser air entering the SMC unit should be at least 65 F 18 C Opera
18. minus 10 of the the chiller nameplate rating Defective on off switch X Replace check the Control circuit fuse blown transformer Pump runs compressor No process load on the cycles at short intervals Increase the process load Faftaeranble low Check the refrigerant 9 The leaving water Check the refrigerant Make sure that the coolant solution is right for the Improper water glycol process must be 75 solution water and 25 glycol See Figure 6 on page 16 for more information Pump pressure is low see pump curves Check for foreign matter Clean the system Pump pressure is too high Check for partially closed x Restricted water flow valves etc Be sure all lines are properly sized ED SMC Series Chillers Page 37 Problem Cause Solution Pump runs compressor Check the refrigerant Sight glass should be clear Pressure switch contacts while compressor runs are open Call for service if bubbling or foaming Refrigerant high pressure Check for dirty condenser cutout switch contacts Check for condenser air open obstruction Check for high low voltage Must be within plus or minus 10 of the nameplate rating Check for poor compressor electrical connections Broken wire in the NE Locate and repair compressor control circuit p Unit runs continuously but Restricted condenser y Clean the condenser not enough cooling power airflow Unit lo
19. nding between the supply and return lines guarantees a constant flow through the evaporator during intermittent low or no flow conditions M A flow switch in units without pumps will prevent the compressor from running without adeguate flow through the evaporator 3 2 Refrigeration Circuit M Liguid refrigerant from the condenser passes through a filter dryer which removes moisture and other contaminants The refrigerant then passes through the thermal expansion valve which allows the refrigerant to expand and cool the inside of the heat exchanger The refrigerant flows through the suction line to the compressor M The refrigerant gives up its heat as it re condenses to a liguid in the condenser and the cycle starts over again Page 18 SMC Series Chillers 3 3 High Pressure Cutout The high pressure cutout is an electro mechanical safety feature that opens the control circuit if the system condensing pressure exceeds a safe level The chiller will automatically restart when the pressure drops back to an acceptable level Model Cuts out if condensing pressure exceeds SMC050 275 psi 1 897 kPa SMC100 275 psi 1 897 kPa SMC150 400 psi 2 759 kPa IMPORTANT Call a refrigeration service technician to analyze the problem if high pressure recurs 3 4 Low Pressure Cutout The low pressure cutout is an electro mechanical safety feature that prevents compressor suction pressure from dropping below a preset point It
20. nts Optional components YEL Re RED Type K Thermocouple Page 34 I SMC Series Chillers Figure 16 SMC Wiring Schematic for Chillers with No Pump or Reservoir 1C 1L1 1T1 2 1 1 e Q1MTR Compressor ja 112 1 2 gt 1L2 111 211 iF 2MTR Fan Earth Remote 2T2 N ground interlock by others Control 14 230V power AAA ON OFF 1T s J AN ubpanel 1S 1LT d 1FU LEN 2 ground 1 115V 2 15 pem 4 O ISALT Power On LowRefrig HighRefig Low Refrig Hi efri 3 No Flow I Pres Pres E 4 R 2LT R 3LT R 4LT u en oak ssl 1FLS 1PS 2PS EN Condensing unit 40 45 5 6 7 1C 1 contactor pl s Td SC G SLT Compressor On 5 S 2 Legend 6 7 8 9 HO N N gt Customer wiring Customer supplied components Jumper 1CNTL Optional components o YEL RED Type K thermocouple SMC Series Chillers Page 35 Notes Page 36 I SMC Series Chillers 8 Troubleshooting Guide Chiller will not run Check main disconnect No power fuses wiring and power lead to the unit Voltage must be within plus Wrong voltage supplied to or
21. oad and service factor amps Operate the chiller looking for leaks and listening for unusual noises or vibrations that could indicate improper operation EGD SMC Series Chillers 4 4 SMC Water Circuit Pressure Drop Table Model Gallons per minute Liters per minute AP psig 5 050 24 19 14 26 SMC100 90 5 150 24 9 10 SMC Series Chillers Page 25 Microprocessor Control Page 26 Introduction Standard SMC Series chillers use a microprocessor based PID controller The controller is a modular self contained unit that can slide from its mounting housing It is factory set and adjusted no field adjustment to the internal controls is necessary SMC Control Operation Range Standard models 30 F to 65 F 1 C to 18 C Setting the Process Water Temperature To change the process water temperature set point e Press the Up Arrow button to raise the set point e Press the Down Arrow button to lower the set point LED Indicators PV or Process Value Numeric LED During normal operation the large red PV LED on the controller displays the actual process temperature at the To Process thermocouple It also lists parameter symbols during setup and error messages if an error occurs SV or Set Value Numeric LED During normal operation the green SV LED on the controller displays the process set point you want the chiller to maintain I
22. order number and item Hold the items until shipping instructions are received SMC Series Chillers Page 9 1 9 Returns IMPORTANT Do not return any damaged or incorrect items until you receive shipping instructions from STERLING Inc Page 10 SMC Series Chillers Figure 1 SMC050 Process Pump Curves 050 PROCESS PUMPS SELECTIONS 60 HERTZ PUMP CURVE I I il VT TT EITIAJTITI 60 HERTZ PUMP CURVE Lg Lg LLL UI TTT TT TTT et TT S GALLONS PER MINUTE 2 0 Y E 4 0 LITRES T T T T T T T T PER MINUTE 7 6 12 4 13 6 15 1 CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS 44 48 5 2 T T T T T T T 16 7 18 2 19 7 21 2 ED SMC Series Chillers Page 11 Figure 4 SMC Cast Iron Centrifugal Pump Curve 1 3 hp 0 249 kW PROCESS PUMP CI CENTRIFUGAL 60 HERTZ PUMP CURVE LITRES PER MINUTE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS Page 12 I SMC Series Chillers Figure 5 SMC Series Chiller Specifications Optional gauge package Optional gauge package Power cable entrance either side Side cover handle Sight glass j
23. ose at hand and ready for use if needed The refrigeration system can develop refrigerant pressures in excess of 500 PSI 3 450 kPa DO NOT CUT into the system without first relieving pressure Do not jump or bypass any electrical safety control Do not restore power until all tools test equipment etc have been removed and the panels replaced Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment ED SMC Series Chillers Page 3 Table of Contents 1 General Information 7 1 1 Introduction 1 2 Necessary Documents 1 3 Models Covered 1 4 Available Options 1 5 Uncrating Your New Chiller 1 6 Event of Shipping Damages 1 7 Ifthe Shipment is Not Complete 1 8 Shipment is Incorrect 1 9 Returns 2 Chiller Installation 13 2 1 Electrical Connections 2 2 Process Water Connections 2 3 SMC Condenser Air Supply 2 4 Water Reservoir 2 5 Overhead Process Considerations 3 Sequence of 17 3 1 Chilled Water Circuit 3 2 Refrigeration Circuit 3 3 High Pressure Cutout 3 4 Low Pressure Cutout 3 5 Remote Start Stop Interlock Page 4 SMC Series Chillers Table of Contents 4 Startup Checklists ss ses ssesennennznnnzznznzznzzzznni 23 4 1 Introduction 4 2 SMC Pre Startup Checklist 4 3 SMC Startup Checklist 4 4 SMC Water Circuit Press
24. s manual 1 2 Necessary Documents The following documents are necessary for the operation installation and maintenance of Sterling Inc s SMC Series Chillers Additional copies are available from AEC Inc Familiarize the appropriate personnel with these documents M This manual M The electrical schematic and connection diagram mounted inside the control enclosure Typical schematics for general reference are provided in Figure 15 and Figure 16 on pages 34 and 35 M The operation and installation manuals for installed accessories and options The Customer Parts List included in the information packet 1 3 Models Covered This manual provides operation installation and maintenance instructions for Sterling Inc SMC Series Chillers Model numbers are on the serial tag Please know the model number serial number and operating voltage of your chiller if you need to contact Sterling Inc SMC Series Chiller models are designated by approximate compressor horsepower A SMC050 chiller has 1 2 hp 373 W compressor a SMC100 chiller has a 1 hp 746 W compressor and a SMC150 chiller has a 1 1 2 hp 1 118 W compressor SMC Series Chillers Page 7 Page 8 Available Options SMC Series Chillers are available with options that tailor the unit to your requirements Some are factory installed some can be retrofitted in the field Consult your local Sterling Inc Sales Representative Some of these options are Sp
25. t also displays parameter and pre set function values during setup OUT1 LED The orange OUT1 LED lights when the control output energizes the hot gas bypass solenoid valve SMC Series Chillers Figure 12 Typical SMC Series ESCK Microprocessor Controller OUT2 LED The orange OUT2 energizes whenever the process temperature is two degrees 2 F C or more above the To Process set point The compressor then comes on and runs until the temperature at the To Process thermocouple is two degrees 2 F C below the set point This 2 F C control set point is factory set for proper compressor operation Changing it is not recommended without consulting the AEC Service Department MANU LED The orange MANU LED does not light because it is not used STOP LED The orange STOP LED does not light because it is not used SMC Series Chillers Page 27 RMT LED The orange RMT LED is lit during remote operation AT LED The orange AT LED flashes during auto tuning SUB1 LED The orange SUB1 LED energizes whenever the process temperature is two degrees 2 F C or more below the To Process set point The compressor then shuts down by means of a latching circuit and does not run again until the temperature at the To Process thermocouple is two degrees 2 F C above the set point This 2 F C control set point is factory set for proper compressor operation Changing it is not recommended without consulting t
26. tion with air below 65 F 18 C can cause the low pressure cutout to shut down the chiller due to the low refrigerant pressure Install the chiller in an area where there is free passage of air for condensing Provide 18 46 cm or more clearance for the chiller s air intake Make provisions to exhaust the heated air discharged from the chiller E N A Do not put the SMC unit where steam hot air or fume exhausts will be drawn into the condenser Air cooled condensers must be cleaned freguently Neglect reduces capacity increases operating costs and leads to possible chiller failure See Chapter 7 on Page 29 for cleaning instructions M Normal condensing pressure with 95 F 35 C air is approximately 180 psi 1 241 kPa for the SMC050 and SMC100 275 psi 1 897 kPa for SMC150 PCA Ambient Temperature Ranges Ambient Temperature Range Minimum Temperature Maximum Temperature 65 F 18 C 100 F 38 C 40 F 4 C 120 49 C 2 4 Water Reservoir During startup and when additional solution is required see Figure 6 on page 16 for the recommended ethylene glycol water solution This chart shows the proportions needed to provide freeze protection to 20 F C below the desired process setpoint M Add a pre mixed solution to provide freeze protection to a temperature 20 F C below the normal operating temperature of the chiller M Use industrial quality not automotive ethylene glycol ED SMC Series
27. ure Drop Table 5 Microprocessor Control 25 5 1 Introduction 5 2 Setting the Process Water Temperature 5 3 LED Indicators 5 4 Temperature Controller Keys 5 5 Auto Tuning SMC Series Chillers 5 6 Optional Communications 6 Optional Graphic 30 6 1 Indicator Lights 6 2 Switches Z Routine Maintenance 32 7 1 Lubrication 7 2 Condenser Maintenance 8 Troubleshooting Guide 36 SMC Series Chillers Page 5 Charts and Figures Figure SMC050 Process Pump Cutrves 11 Figure 2 SMC100 Process Pump b etm 11 Figure 3 PUA 150 Pro ess Pump Cur yes iode E uxo pes RM E EM QE 11 Figure 4 SMC Cast Iron Centrifugal Pump Curve 1 3 hp 0 249 KW 12 Figure 5 SMC Series Chiller Specifications dU cna sui akuta a 13 Figure 6 Ethylen Glycol u aaa 16 Figure 1 Overhead PIPINS u steeds en die 17 Figure 8 SMC Component Identification n nasa 20 Figure 9 Piping Schematic 1 Pump with Reservoir 21 Figure 10 Piping Schematic 1 Pump Without Reservoir 22 Figure 11 Piping Schematic No Pump No
28. w on refrigerant Call Service Inefficient compressor Call Service Unit undersized for application Call Sales Representative Compressor internal overload is open Allow time to cool and reset Page 38 SMC Series Chillers PCA Unit Parts List Red Neon Graphic Light Green Neon Graphic Light 2 Swivel Casters 1 16 DIN Digital Temperature Controller A0103778 Rubber Feet A0537900 Tank Sight Glass Assembl A0537908 SMC050 100 Low Refrigerant Pressure Switch SMC150 Low Refrigerant Pressure Switch SMC050 100 High Refrigerant Pressure Switch SMC150 High Refrigerant Pressure Switch Units with the optional SMC graphic panel SMC Series Chillers Page 39 Notes Page 40 I SMC Series Chillers Notes SMC Series Chillers Page 41 Notes Technical Assistance Page 42 SMC Series Chillers Parts Department Call toll free 7am 5pm CST 800 423 3183 Or call 262 641 8610 Fax 262 641 8653 The Parts Department at AEC Inc is ready to provide the parts to keep your systems up and running AEC replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call toll free 8am 5pm CST 800 423 3183 Or call 262 641 8610 Emergencies after 5pm CST call 847 439 56
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