Sterling 30F to 65F, Operation And Installation Manual

Page 1: ...OPERATION AND INSTALLATION MANUAL SMC SERIES AIR COOLED PORTABLE WATER CHILLERS IMPORTANT PLEASEREADCAREFULLYBEFOREATTEMPTINGTO INSTALL OR OPERATE EQUIPMENT ...

Page 2: ... Sterling Inc is committed to a continuous program of product improvement Specifications are subject to change without notice Sterling Inc 2003 All Rights Reserved Effective 10 1 2007 Part Number 882 00740 00 Bulletin SC2 615A 4 ...

Page 3: ...ore 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 close at hand and ready for use if needed ...

Page 4: ...mages 1 7 If the Shipment is Not Complete 1 8 If the 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 Operation 17 3 1 Chilled Water Circuit 3 2 Refrigeration Circuit 3 3 High Pressure Cutout 3 4 Low Pressure Cutout 3 5 Remote Start ...

Page 5: ...re 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 Panel 30 6 1 Indicator Lights 6 2 Switches 7 Routine Maintenance 32 7 1 Lubrication 7 2 Condenser Maintenance 8 Troubleshooting Guide 36 ...

Page 6: ...e Glycol Curve 16 Figure 7 Overhead Piping 17 Figure 8 SMC Component Identification 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 Reservoir 23 Figure 12 Typical SMC Series E5CK Microprocessor Controller 27 Figure 13 Optional Graphic Panel 32 Figure 14 Typical SMc Subpanel 33 Figure 15 Typical SMc W...

Page 7: ...cessary 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 This manual The electrical schematic and connection diagram mounted inside the control enclosure Typical schematics for general reference are provided in F...

Page 8: ... 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 1 5 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 bloc...

Page 9: ... is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise Sterling Inc regarding your wish for replacement 1 7 If the 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 SMC Series Chiller Bill of Lading Packing List Operating and Installa...

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

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

Page 12: ...Page 12 SMC Series Chillers Figure 4 SMC Cast Iron Centrifugal Pump Curve 1 3 hp 0 249 kW ...

Page 13: ...Connection Amp Draw 230 1 60 Dimensions inches Operating Weight Shipping Weight Number Btuh Btuh gpm hp inches NPT Running L W H lbs lbs SMC 050 8 100 4 800 1 2 1 2 1 3 hp 1 2 gpm 24 psig 3 4 8A 20 26 34 265 265 SMC 100 14 000 9 550 2 4 1 1 3 hp 2 4 gpm 34 psig 3 4 10A 20 26 34 325 325 SMC 150 25 400 16 000 3 6 1 1 2 1 3 hp 3 6 gpm 24 psig 3 4 12A 20 26 34 345 345 Model Capacity 18 C LWT 24 C Ambi...

Page 14: ...e chiller s nameplate rating 2 2 Process Water Connections All external chilled water connections to the process must be of adequate size 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...

Page 15: ...om the chiller 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 frequently Neglect reduces capacity increases operating costs and leads to possible chiller failure See Chapter 7 on Page 29 for cleaning instructions Normal condensing pressure with 95 F 35 C air is approximately 180 psi 1 241 kPa for the SMC050 and SM...

Page 16: ...The six gallon 23 liter reservoir is not designed to withstand water pressure above 5 psi 34 kPa The fill opening and vent line must be vented to the atmosphere for proper operation Figure 6 Ethylene Glycol Curve Ethylene Glycol Required Normal Operating Range between 30 F 70 F for Evaporator Freeze Protection Chilled Water Operating Temperature F Set Point 10 20 30 35 25 45 55 0 65 Ethylene Perce...

Page 17: ...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 20 feet 6 1 m of 1 inch 2 5 cm pipe Figure 7 Overhead Piping Vent 6 Min Process Return Process Supply 1 8 Hole Vacuum Breaker Assembly Cap ...

Page 18: ... 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 A chilled water bypass assembly patent pending between the supply and return lines guarantees a constant flow through the evaporator during intermittent low or no flow conditions A flow switch in units without pumps will preve...

Page 19: ... electro mechanical safety feature that prevents compressor suction pressure from dropping below a preset point It 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 Cuts out if suction pressure falls below SMC050 15 psi 103 kPa SMC100 15 psi 103 kPa SMC150 35 psi 241 k...

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

Page 21: ...g End of unit piping Liquid line Suction Line Tank Vent Fill glass Sight Process From To P Evaporator Pump Power element Equalizing line Discharge line Bypass Refrigeration access valve Relief valve Air cooled condenser evacuation valve Refrigeration Temperature probe TC S Process Optional pressure gauge pressure control Low CPR valve Optional Refrigeration access valve Drain compressor mounted ev...

Page 22: ...e Refrigeration Compressor Pump Optional CPR valve evacuation valve Refrigeration Low control pressure access valve Refrigeration control pressure High Discharge line Equalizing line Power element Evaporator Suction line TC probe S Bypass Process From Process Air cooled condenser Liquid line Filter gauge pressure Optional valve P glass Expansion Sight valve Relief To Filter drier evacuation valve ...

Page 23: ...rigeration control pressure High Discharge line Refrigeration evacuation valve Equalizing line Power element Evaporator Suction line TC Probe S Bypass Process Air cooled condenser Liquid line Filter gauge pressure Optional valve P glass Expansion Sight valve Relief To Filter drier From Process Refrigeration evacuation valve Legend Refrigeration lines Chilled water piping Condenser water piping End...

Page 24: ...lled water TO PROCESS and FROM PROCESS connections should be completed 4 Be sure the reservoir tank and chilled water circuit piping are filled with water 5 The air cooled condenser should have an adequate supply of air for proper operation 6 Connect main power to the chiller and run the chiller just long enough to see if the pump is generating normal pressure 7 Check your work and proceed to the ...

Page 25: ...lons per minute Liters per minute ΔP psig ΔP kPa SMC050 2 0 7 5 2 5 17 3 2 4 9 0 4 0 27 6 3 6 13 6 7 5 51 8 4 8 18 1 12 5 86 2 SMC100 2 0 7 5 2 5 17 3 2 4 9 0 2 5 17 3 3 6 13 6 3 0 20 7 4 8 18 1 5 0 34 5 SMC150 2 0 7 5 2 5 17 3 2 4 9 0 2 5 17 3 3 6 13 6 3 0 20 7 4 8 18 1 3 5 24 2 ...

Page 26: ...s the Up Arrow button to raise the set point Press the Down Arrow button to lower the set point 5 3 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 n...

Page 27: ...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 ºC below the set point This 2 F ºC 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 S...

Page 28: ... ºC above the set point This 2 F ºC control set point is factory set for proper compressor operation Changing it is not recommended without consulting the Stelring Service Department 5 4 Temperature Controller Keys AT 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 Pres...

Page 29: ... 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 take up to 45 minutes and is best done before any product is being run Importan...

Page 30: ...nd set E5CK parameters by a program prepared and running on a host computer connected to the E5CK controller When using the communications function you must add on the unit for RS 232C or RS 485 communications The E5CK communications function allows you to read write parameters do operating instructions and select the setting level ...

Page 31: ... refrigeration service technician 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 sen...

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

Page 33: ...ausing 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 accumulations 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 B...

Page 34: ...wer On ON OFF 1L1 1L2 1L1 1L2 1L1 1L2 2 Control power 1PS 2PS 1 1 1CNTL RED YEL Type K Thermocouple Subpanel ground 1C 1T1 1T2 1MTR Pump 2C 2T1 2T2 Compressor 230V 115V Jumper 1 6 1 2 1 7 1 3 1 8 1 4 1 9 1 5 1 10 Low Refrig Pres G 3LT R Hi Refrig Pres G 4LT R ground Earth Fan 3T2 3T1 2MTR 3MTR G 5LT G G 2LT G Pump On Compressor On Legend Customer wiring Customer supplied components Optional compon...

Page 35: ...ctor G 1S 1LT G Power On ON OFF 1L1 1L2 1L1 1L2 2 Control power 1PS 1PS 2PS 1 1CNTL RED YEL Type K thermocouple Subpanel ground 1C 1T1 1T2 1MTR Compressor 230V 115V Jumper 6 2 7 3 8 4 9 5 10 ground Earth Low Refrig Pres 3LT R 4LT R Pres High Refrig 2 4 5 1FLS 1FLS G 5LT G 2LT R No Flow Compressor On 1 3 2T2 2T1 2MTR Fan Legend Customer wiring Customer supplied components Optional components 2 ...

Page 36: ...Page 36 SMC Series Chillers Notes ...

Page 37: ...ns compressor cycles at short intervals No process load on the chiller Increase the process load Refrigerant is low Check the refrigerant charge The leaving water temperature is too high Refrigerant is low Check the refrigerant charge Improper water glycol solution Make sure that the coolant solution is right for the process must be 75 water and 25 glycol See Figure 6 on page 16 for more informati...

Page 38: ...enser air obstruction Defective fan motor Repair or replace Compressor internal overload is open Allow time to cool and reset 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 compressor control circuit Locate and repair Unit runs continuously but not enough cooling power Restricted condenser airfl...

Page 39: ...hermocouple 8 A0539409 150 VA Transformer A0103778 Rubber Feet A0537900 Tank Sight Glass Assembly A0537908 Handles A0537915 SMC050 100 Low Refrigerant Pressure Switch A0543063 SMC150 Low Refrigerant Pressure Switch A0537916 SMC050 100 High Refrigerant Pressure Switch A0537917 SMC150 High Refrigerant Pressure Switch A0501642 SMC050 100 High Refrigerant Pressure Safety Relief Valve A0104093 SMC150 H...

Page 40: ...Page 40 SMC Series Chillers Notes ...

Page 41: ...SMC Series Chillers Page 41 Notes ...

Page 42: ...Page 42 SMC Series Chillers Notes Technical Assistance ...

Page 43: ...847 439 5655 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 26...