Sterling Refrigerator A0554831 User Manual

2–40 hp Portable Chillers  
Part Number: A0554831  
Bulletin Number: SC2-610C.10  
Effective: 4/3/2008  
Write Down Your Serial Numbers Here For Future Reference:  
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We are committed to a continuing program of product improvement.  
Specifications, appearance, and dimensions described in this manual are subject to change without notice.  
DCN No. ____________  
© Copyright 2008  
All rights reserved.  
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Table of Contents  
CHAPTER 1: SAFETY .................................................................6  
1-1  
How to Use This Manual .............................................................................................6  
Safety Symbols Used in this Manual.....................................................................6  
Warnings and Precautions ..........................................................................................7  
Responsibility ..............................................................................................................7  
1-2  
1-3  
CHAPTER 2: FUNCTIONAL DESCRIPTION...............................8  
2-1  
2-2  
Models Covered in This Manual..................................................................................8  
General Description.....................................................................................................9  
Chilled Water Circuit..............................................................................................9  
Refrigeration Circuit...............................................................................................9  
Standard Features.....................................................................................................10  
Mechanical Features...........................................................................................10  
Electrical Features...............................................................................................11  
Refrigeration Features.........................................................................................11  
Controller Features..............................................................................................11  
Other Features ....................................................................................................11  
Safety Devices and Interlocks...................................................................................12  
High/Low Thermostat Control..............................................................................12  
Crankcase Heater ...............................................................................................12  
High Pressure Cutout..........................................................................................12  
Low Pressure Cutout...........................................................................................13  
Oil Pressure Safety Switch……………………………………………………………13  
Fan Cycling Switch..............................................................................................13  
Pressure Switch ..................................................................................................13  
Flow Switch .........................................................................................................13  
Remote Start/Stop Interlock ................................................................................13  
Optional Features......................................................................................................14  
2-3  
2-4  
2-5  
CHAPTER 3: INSTALLATION ...................................................17  
3-1  
3-2  
3-3  
3-4  
3-5  
3-6  
3-7  
Uncrating...................................................................................................................17  
Electrical Connections...............................................................................................17  
Process Water Connections......................................................................................18  
Bypass Valve Considerations....................................................................................18  
Galvanic Corrosion Considerations...........................................................................18  
Water Treatment Considerations ..............................................................................18  
Condenser Considerations........................................................................................19  
Water-Cooled Chiller Condensers.......................................................................19  
Air-Cooled Chiller Condensers............................................................................19  
Remote Air-Cooled Chiller Condensers ..............................................................20  
Checking Motor Direction..........................................................................................24  
Three-Phase Compressors .................................................................................24  
Water Pumps.......................................................................................................24  
Condenser Fan....................................................................................................24  
Water Reservoir ........................................................................................................25  
3-8  
3-9  
3-10 Automatic Water Make-Up Option.............................................................................27  
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3-11 Initial Start-Up............................................................................................................28  
CHAPTER 4: OPERATION ........................................................29  
4-1  
Panel Buttons, Indicator Lights, and Switches ..........................................................29  
Microprocessor Controllers..................................................................................29  
Graphic Panel......................................................................................................32  
Start-up......................................................................................................................35  
Setting the Process Water Temperatures .................................................................35  
Auto-Tuning...............................................................................................................35  
Optional Communications .........................................................................................35  
Programming the Electronic High/Low Thermostat...................................................36  
4-2  
4-3  
4-4  
4-5  
4-6  
CHAPTER 5: MAINTENANCE...................................................38  
5-1  
5-2  
5-3  
Lubrication.................................................................................................................38  
Filter Cleaning ...........................................................................................................38  
Maintaining the Condenser .......................................................................................39  
Air- and Remote Air-Cooled Chillers ...................................................................39  
Water-Cooled Chillers .........................................................................................39  
Maintaining the Evaporator .......................................................................................39  
Evaporator Process Piping Y-Strainer.......................................................................39  
Preventative Maintenance Service............................................................................40  
5-4  
5-5  
5-6  
CHAPTER 6: TROUBLESHOOTING.........................................41  
CHAPTER 7: APPENDIX ...........................................................43  
7-1  
7-2  
Returned Material Policy ...........................................................................................43  
Technical Assistance.................................................................................................44  
Parts Department ................................................................................................44  
Service Department.............................................................................................44  
Sales Department................................................................................................44  
Contract Department...........................................................................................44  
Drawings and Specifications .....................................................................................45  
2 hp and 3 1/2 hp Air-Cooled Portable Chillers ...................................................45  
5 hp and 7.5 hp Air-Cooled Portable Chillers ......................................................46  
10 hp and 15 hp Air-Cooled Portable Chillers .....................................................47  
20 hp, 25 hp, and 30 hp Air-Cooled Portable Chillers .........................................48  
2 hp and 3.5 hp Water-Cooled Portable Chillers.................................................49  
5 hp and 7.5 hp Water-Cooled Portable Chillers.................................................50  
10 hp and 15 hp Water-Cooled Portable Chillers................................................51  
20 hp, 25 hp, and 30 hp Water-Cooled Portable Chillers....................................52  
35 hp and 40 hp Water-Cooled Portable Chillers................................................53  
5 hp and 7.5 hp Remote Air-Cooled Portable Chillers.........................................54  
10 hp and 15 hp Remote Air-Cooled Portable Chillers........................................55  
20 hp through 40 hp Remote Air-Cooled Portable Chillers .................................56  
Remote Condenser Assembly Models ................................................................57  
Pump Curves, Flow, and Pressure Considerations...................................................58  
60 Hertz Pump Curves........................................................................................59  
50 Hertz Pump Curves........................................................................................60  
Water Pressure Drop Tables...............................................................................61  
7-3  
7-4  
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Flow and Pressure Considerations......................................................................61  
Recirculation Pump Specifications......................................................................61  
Remote Air-Cooled Chiller Configurations ................................................................62  
Typical Ductwork for Air-Cooled Chillers...................................................................63  
Piping Diagrams........................................................................................................64  
Central and Gravity Return Piping with Standpipe Diagram................................64  
Typical Piping Schematic, 2 and 3 1/2 hp Models...............................................65  
Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models ....................66  
Typical Piping Schematic, 5 hp through 40 hp, Two-Pump Models ....................67  
Typical Piping Schematic, 5 hp through 40 hp, No-Pump Models ......................68  
Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models ....................69  
Electrical Schematics ................................................................................................70  
7-5  
7-6  
7-7  
7-8  
2-40 HP Portable Chillers  
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Chapter 1: Safety  
1-1 How to Use This Manual  
Use this manual as a guide and reference for installing, operating, and maintaining your  
equipment. The purpose is to assist you in applying efficient, proven techniques that enhance  
equipment productivity.  
This manual covers only light corrective maintenance. No other maintenance should be  
undertaken without first contacting a service engineer.  
The Functional Description section outlines models covered, standard features, and optional  
features. Additional sections within the manual provide instructions for installation, pre-  
operational procedures, operation, preventive maintenance, and corrective maintenance.  
The Installation chapter includes required data for receiving, unpacking, inspecting, and setup  
of the equipment. We can also provide the assistance of a factory-trained technician to help  
train your operator(s) for a nominal charge. This section includes instructions, checks, and  
adjustments that should be followed before commencing with operation of the equipment.  
These instructions are intended to supplement standard shop procedures performed at shift,  
daily, and weekly intervals.  
The Operation chapter includes a description of electrical and mechanical controls, in  
addition to information for operating the equipment safely and efficiently.  
The Maintenance chapter is intended to serve as a source of detailed assembly and  
disassembly instructions for those areas of the equipment requiring service. Preventive  
maintenance sections are included to ensure that your equipment provides excellent, long  
service.  
The Troubleshooting chapter serves as a guide for identification of most common problems.  
Potential problems are listed, along with possible causes and related solutions.  
The Appendix contains technical specifications, drawings, schematics, and parts lists. A  
spare parts list with part numbers specific to your machine is provided with your shipping  
paperwork package. Refer to this section for a listing of spare parts for purchase. Have your  
serial number and model number ready when ordering.  
Safety Symbols Used in this Manual  
The following safety alert symbols are used to alert you to potential personal injury hazards.  
Obey all safety messages that follow these symbols to avoid possible injury or death.  
DANGER indicates an imminently hazardous situation which, if not avoided, will result in  
death or serious injury.  
WARNING indicates a potentially hazardous situation or practice which, if not avoided,  
could result in death or serious injury.  
CAUTION indicates a potentially hazardous situation or practice which, if not avoided,  
may result in minor or moderate injury or in property damage.  
2-40 HP Portable Chillers  
Chapter 1: Safety  
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1-2 Warnings and Precautions  
Our equipment is designed to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety codes.  
To avoid possible personal injury or equipment damage when installing, operating, or  
maintaining this equipment, use good judgment and follow these safe practices:  
9 Follow all SAFETY CODES.  
9 Wear SAFETY GLASSES and WORK GLOVES.  
9 Disconnect and/or lock out power before servicing or maintaining the equipment.  
9 Use care when LOADING, UNLOADING, RIGGING, or MOVING this  
equipment.  
9 Operate this equipment within design specifications.  
9 OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment.  
You should remove the fuses and carry them with you.  
9 Make sure the equipment and components are properly GROUNDED before you  
switch on power.  
9 When welding or brazing in or around this equipment, make 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.  
9 Refrigeration systems can develop refrigerant pressures in excess of 500 psi  
(3,447.5 kPa/ 34.47 bars). DO NOT CUT INTO THE REFRIGERATION  
SYSTEM. This must be performed by a qualified service technician only.  
9 Do not restore power until you remove all tools, test equipment, etc., and the  
equipment and related components are fully reassembled.  
9 Only PROPERLY TRAINED personnel familiar with the information in this  
manual should work on this equipment.  
We have long recognized the importance of safety and have designed and manufactured our  
equipment with operator safety as a prime consideration. We expect you, as a user, to abide  
by the foregoing recommendations in order to make operator safety a reality.  
1-3 Responsibility  
These machines are constructed for maximum operator safety when used under standard  
operating conditions and when recommended instructions are followed in the maintenance  
and operation of the machine.  
All personnel engaged in the use of the machine should become familiar with its operation as  
described in this manual.  
Proper operation of the machine promotes safety for the operator and all workers in its  
vicinity.  
Each individual must take responsibility for observing the prescribed safety rules as outlined.  
All warning and danger signs must be observed and obeyed. All actual or potential danger  
areas must be reported to your immediate supervisor.  
2-40 HP Portable Chillers  
Chapter 1: Safety  
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Chapter 2: Functional Description  
2-1 Models Covered in This Manual  
This manual provides operation, installation, and maintenance instructions for air- and water-  
cooled portable chillers. Model numbers are listed on the serial tag. Make sure you know the  
model and serial number of your equipment before contacting the manufacturer for parts or  
service.  
Our portable chiller models are designated by approximate compressor horsepower (2, 3 1/2,  
5, 7 1/2, 10, etc) and the cooling method used: -A for air-cooled, -W for water-cooled, and –R  
for remote-air cooled.  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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2-2 General Description  
Our portable chillers are reliable, accurate, and easy to use process cooling units. They are  
available in air-, water-, and remote air-cooled designs in a range of sizes from 2 to 40 tons.  
All are self-contained, fully portable and shipped ready to use. (Remote air-cooled chillers  
require field installation by qualified technicians.)  
Standard range of operation is 30ºF to 65ºF (-1ºC to 18ºC) for applications using a  
water/glycol mix and 45ºF to 65ºF (7º to 18ºC) for water only applications.  
A factory installed crankcase pressure regulating valve option is available for processes  
requiring a leaving water temperature of up to 75ºF (24ºC).  
Chilled Water Circuit  
Cooling water “To Process” and “From Process” connections are made at the gate valves  
provided outside the unit. Warm coolant (water and glycol mixture) returns from the process  
and goes into the reservoir tank. The coolant is then pumped through the evaporator where it  
is cooled. The coolant flows to the process and returns to repeat the cycle.  
A pressure actuated process water bypass valve located between the supply line and reservoir  
tank (single pump models only) allows minimal flow through the unit during the intermittent  
fluctuating flow conditions. It is not intended to provide continuous full bypass flow.  
This minimal flow allows the temperature sensor to signal the controller to shut down the  
compressor because of the drop in process water temperature. Typically the flow switch shuts  
down the chiller in this low flow condition.  
The 2 hp and 3 1/2 hp models have a 1/4” poly-tubing constant bypass to provide additional  
process water bypass to prevent system freeze-up.  
Refrigeration Circuit  
Air-, water-, and remote air-cooled refrigerant condensing differs only in the way the  
compressed gas is condensed to a liquid.  
Liquid refrigerant from the condenser heat exchanger flowing in the liquid line passes  
through a shut-off valve (5 hp to 40 hp chillers only) into a filter/dryer that removes moisture  
and other contaminants. A refrigerant sight glass is provided. The refrigerant then passes  
through the thermal expansion valve, which allows the refrigerant to expand (boil off) and  
cool the fluid inside of the evaporator. The refrigerant gas flows through the suction linen  
back into the compressor.  
The refrigerant is compressed in the compressor and flows through the discharge line as a gas  
to the condenser. There it gives up its heat as it condenses to a liquid in the condenser.  
A hot gas bypass valve is used to control cooling capacity during intermittent or partial load  
conditions. This feature contributes substantially to chiller longevity by eliminating excessive  
cycling of the compressor and providing close temperature control.  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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2-3 Standard Features  
Mechanical Features  
Compressor. Hermetic scroll compressors are used on 2 hp through 30 hp (1.49 through  
23.37 kW) models. Semi-hermetic discus compressors are used on the 35 hp and 40 hp (26.20  
and 29.83 kW) models.  
Evaporator. Stainless steel copper brazed plate evaporators are used on 2 hp through 30 hp  
models. Shell and tube evaporators are used on the 35 hp and 40 hp models.  
Air-Cooled Condenser. Aluminum fin/copper tube with washable filters, package unit only.  
Water-Cooled Condenser. 2 hp to 7.5 hp models use tube-in-tube condensers. 10 hp to 40  
hp use cleanable shell and tube condensers. All come with cooling water regulating valves  
for cooling tower water or city water.  
Remote Air-Cooled Condenser. 5 hp to 40 hp only. Aluminum fin/copper tube with low  
ambient control down to –20ºF (-29ºC) via pressure-actuated fan staging and a variable-speed  
primary fan.  
Reservoir. 2 hp and 3 1/2 hp models use a 6 gallon polyethylene tank. 5 hp and 7.5 hp  
models use a 20 gallon polyethylene tank. 10 hp and 15 hp models use a 40 gallon  
polyethylene tank. 20 hp to 30 hp models use an 80 gallon polyethylene tank, and 40 hp  
models use a 65 gallon stainless steel tank.  
Piping. Non-ferrous piping for 2 hp through 30 hp models. 40 hp models have non-ferrous  
piping.  
Pump. ODP motors—horizontally mounted stamped stainless steel or cast bronze  
construction.  
Other Mechanical Features  
External fill/drain sight glass  
Low process water pressure switch on 2 hp and 3 1/2 hp models  
Low process water flow switch on 5 hp to 40 hp models  
Galvanized steel mounting rails for remote air-cooled models  
NEMA-rated fan motor(s) on air-cooled models  
Galvanized structural steel frame, painted cabinetry, with 2 1/2” swivel casters on 2 hp  
and 3 1/2 hp models. 4” swivel casters on 5 hp to 15 hp models, and 5” swivel casters  
with brake on 20 hp to 40 hp models.  
Valved process water connections  
Pressure-actuated process water bypass valve for system protection only; on single  
pump models only  
To process 2 1/2” dual scale liquid-filled water pressure gauge  
Fully insulated refrigeration and process water piping  
Isolated fan section on air-cooled models, allowing chiller to run during maintenance  
20 mesh Y strainer on process water piping into the evaporator  
2-40 HP Portable Chillers  
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Electrical Features  
Fully accessible NEMA 12-style electrical control enclosure  
Single-point power and ground connection  
Non-fused disconnect switch, lockable  
Branch circuit fusing  
208-230/3/60 and 460/3/60 volt (consult factory for other voltages)  
208-230/1/60 volt on 2 and 3 1/2 hp models  
Refrigeration Features  
R-22 refrigerant  
Hot gas bypass capacity control  
High discharge temperature cutout on 2 hp to 10 hp models  
High and low refrigerant pressure cutout switches  
Fan cycling switch (5 hp to 30 hp air-cooled models only)  
High pressure spring actuated relief valve  
Multiple refrigeration access ports  
Hot gas bypass and liquid line shut-off ball valves on 5 hp to 40 hp models  
Filter-dryer  
Sight glass  
Balanced port thermal expansion valve  
Controller Features  
Off-the-shelf microprocessor-based PID auto-tuning controller with To Process and  
Set Point LED readout  
Microprocessor temperature switch with LCD display for process water freeze  
protection compressor cutout, and high process water temperature pump cutout  
Electronic time delay for proof of water flow/pressure (models w/pump only)  
Off-delay water flow timer to prevent short cycling (models w/pump only)  
Low refrigerant pressure switch, override timer for low ambient start-up on remote air-  
cooled and air-cooled chillers with the variable-speed fan option.  
Graphic control panel with indicating and warning status lights  
Other Features  
One year labor warranty and one year compressor warranty  
Two year parts warranty  
Three year limited controller warranty  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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2-4 Safety Devices and Interlocks  
High/Low Thermostat Control  
The high/low thermostat is a cutout device that protects the chiller system in two ways. Stage  
one of the thermostat shuts down the compressor if the chilled process water/glycol  
temperature approaches the particular mixture’s freezing point. The chilled process  
water/glycol pump will continue to run.  
The low thermostat stage one cutout temperature is factory-set at 42ºF (5.5ºC). This is correct  
for a supply water temperature of 50ºF (10ºC), the rated capacity operating temperature. If  
you want lower chilled water temperatures, mix process water with glycol to provide  
protection down to 20ºF (11ºC) below the operating “To Process” temperature you want.  
You can then reset the high/low thermostat cutout temperature to a temperature 8ºF (4.4ºC)  
below the operating temperature you want.  
Stage two of the high thermostat shuts down the pumps, therefore shutting off the chiller, if  
the chilled process water/glycol temperature rises above the selected cutout point. This  
prevents possible damage to the complete process piping system due to overheating of the  
components by the process water/glycol. The thermostat stage two cutout temperature is  
factory set at 100ºF (38ºC). See Section 4-6 on page 36 for information about changing the  
thermostat settings.  
Caution! Protect the system from freezing with glycol 20ºF below the leaving water  
temperature set point. Condensation may form inside the pump tank and dilute  
the mixture, therefore the freezing point should be verified periodically. See  
Figure 6 on page 26 for the correct mixture.  
Caution! Set low thermostat cutout temperature 8ºF below the set point leaving water  
temperature.  
Crankcase Heater  
5 hp through 40 hp portable chillers have a crankcase heater. It is wired through the control  
transformer that operates continuously whenever power is applied to the chiller.  
Caution! Energize the crankcase heater for at least 24 hours before initial startup to  
drive dissolved refrigerant from the compressor oil. Failure to do so will  
damage the compressor.  
High Pressure Cutout  
This electro-mechanical cutout device opens the compressor control circuit if the refrigeration  
system compressor discharge pressure exceeds 360 psi for an air-cooled chiller and 290 psi  
for a water-cooled chiller.  
Note:  
The high-pressure cutout is a manual reset device typically mounted on the  
compressor discharge line inside the mechanical cabinet. Call a refrigeration  
service technician to analyze the problem and reset the control.  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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Low Pressure Cutout  
This electro-mechanical cutout device opens the compressor control circuit if refrigeration  
system compressor suction pressure drops below 15 psi. It automatically resets when  
refrigerant suction pressure reaches 30 psi.  
Note:  
The low pressure cutout is an automatic reset device typically mounted on the  
compressor suction line inside the mechanical cabinet. Call a refrigeration  
service technician to analyze the problem and reset the control.  
Fan Cycling Switch  
Air-cooled models only. 5 hp and 7.5 hp models have one fan. The fan cycling switch turns  
on the fan when the discharge pressure in the condenser reaches 300 psi and turns it off when  
the pressure drops below 190 psi.  
10 hp to 30 hp models have two fan blowers. One fan blower runs continuously every time  
the compressor operates. The second fan turns on when the discharge pressure in the  
condenser reaches 300 psi and turns off when the pressure drops below 190 psi.  
Pressure Switch  
2 hp and 3 1/2 hp models have a pressure switch cutout device mounted in the process piping.  
The switch shuts down the chiller if it senses that the water/glycol pressure through the  
evaporator has dropped below an acceptable level. The pressure switch opens the control  
circuit, shuts down the pumps, and shuts off the chiller.  
Flow Switch  
5 hp to 40 hp models only. The flow switch cutout device, mounted in the process piping,  
shuts down the chiller if senses that the water/glycol flow rate through the evaporator has  
dropped below an acceptable level. The flow switch opens the control circuit and shuts down  
the pumps and the chiller.  
Remote Start/Stop Interlock  
An additional contact is provided to allow the remote starting or stopping of the chiller. To  
use this feature, remove the jumper between terminals X1 and 1, and supply a switch or dry  
contact interlock connected in series between these two terminals. Refer to the schematic  
inside the control enclosure door.  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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2-5 Optional Features  
Options marked with “*” indicate options that can be factory installed or retrofitted in the  
field.  
Automatic Water Make-Up*. Not available on chillers less reservoir tank. Includes a  
pressure-regulating valve set at 3 to 5 psi, an electric water solenoid valve, a float switch  
mounted in the reservoir tank, and the necessary internal piping to connect the chiller to a  
make-up water source. See Appendix for typical piping diagrams.  
Caution! Customer piping must provide backflow protection and venting of tank to  
atmosphere to prevent over-pressurization of the reservoir tank. See Central  
and Gravity Return Piping with Standpipe Diagram on page 64.  
Process Water Sidestream Filter*. Not available on chillers less pump and reservoir tank.  
Includes a 50 micron filter, flow meter, ball valve for throttling water flow, and the necessary  
piping to provide constant filtering of the process water at about one gallon per minute (1  
gpm/3.8lpm).  
General Fault Indicator Audible/Visual Alarm*. Includes a 100 dB audible alarm horn/  
visual alarm strobe and silence button with provisions for customer wiring indication  
interlock. The alarm signals anytime that a fault is recognized during the operation of the  
chiller.  
Compressor Hour Meter*. Includes a DIN-mount hour meter that keeps track of the total  
time that the compressor runs.  
Communications Options. RS-232C and RS-485 serial communications and remote setpoint  
are available.  
Recirculation Pump. Necessary whenever process water flow is less than 2.2 gpm per ton  
(8.3 lpm per 3.517 kW) or greater than 4.8 gpm per ton (18.2 lpm per 3.517 kW).  
High Pressure Fans. Provides for an additional 0.30”WC (75 pa) of static pressure on fan  
discharge. High-pressure fans are necessary and must be included in chiller installations  
where exiting air exhausts through ductwork.  
The fans are available on 5 to 15 hp air-cooled chillers. They can be retrofitted without sheet  
metal modification, but will require changing out fan blades, and in some cases, fan motors  
and electrical components. 20 hp to 30 hp models come standard with squirrel cage blowers,  
which can be ducted.  
Variable Speed Fan. Available on 5 to 15 hp air-cooled chillers. Reduces the speed of the  
fan based on entering air temperature and system load, allowing the chiller to operate in  
ambient temperatures below 60ºF (15.5ºC). This option will also reduce fan noise in ambients  
below 95ºF (35ºC).  
Crankcase Pressure Regulating (CPR) Valve. Required on chillers operating at leaving  
water temperatures from 66ºF to 75ºF (10ºC to 24ºC). This valve prevents compressor motor  
overloading.  
Stainless Steel Reservoir. 5 hp to 30 hp models only (Standard on 40 hp models).  
Manufactured from 304 stainless steel.  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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Mounting Features.  
Locking 5” swivel casters with brake, optional on air- and water- cooled 5 hp to 15 hp  
models  
Mounting rails: standard on remote air-cooled models, optional on other models  
Mounting rails with feet  
Optional Operating Voltages. 380/3/50 volt available on 5 hp to 40 hp models only. Consult  
factory for other voltages  
UL Labeled Electrical Subpanel. Provides for the subpanel to be listed with Underwriters  
Laboratory, with UL-related benefits and features.  
Optional Pumps. Pump options are available for greater pressure and flow rates. A  
recirculation pump is required whenever process water flow is less than 2.2 gpm per ton or  
greater than 4.8 gpm per ton. See Figure 1 on page 16 for optional pump amperages.  
NEMA 12 Electrical Enclosure. 5 hp to 40 hp models only. Provides for NEMA 12-level  
electrical enclosure protection. Includes an accessible protective window kit over the graphic  
control panel.  
NEMA 12 Control Access Door. Includes an accessible protective window kit over the  
graphic control panel.  
2-40 HP Portable Chillers  
Chapter 2: Functional Description  
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Figure 1: Optional Pump Amperages  
Voltage Construction  
HP  
.75  
1
Full Load Amps  
208-230/1/60 Bronze Turbine  
SS  
5.4  
6.4  
7.5  
9.6  
12.7  
1.5  
1.8  
2.3  
3.1  
4.2  
6.2  
9.8  
13.2  
19.0  
2.7  
4.5  
6.6  
9.0  
1.5  
2
3
460/3/60  
Bronze Turbine  
SS  
.75  
1
1.5  
2
3
5
7.5  
10  
15  
2
Dual SS  
3
5
7.5  
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Chapter 3: Installation  
3-1 Uncrating  
2 hp to 5 hp models are shipped mounted on a skid, enclosed in a plastic wrapper, and  
contained in a cardboard box. 7.5 to 40 hp models are shipped mounted on a skid, enclosed in  
a plastic wrapper, and open-crated on all four sides and top.  
1. Pry the crating away from the skid.  
Note:  
2 to 5 hp models: remove the nails holding the box to the skid and lift the  
box off carefully, avoiding staples in the 1’ x 4’ wood supports. Cut the  
steel banding.  
2. Use a pry bar to remove the blocks securing the unit to the skid.  
3. Lift unit from sides, inserting forklift under the base. The forks must be equidistant  
from the centerline of the unit and the unit must be balanced on the forks. (20 hp to  
40 hp units feature special lifting openings.) Lift slowly and only high enough to  
clear the skid. Use a pry bar if necessary to carefully remove the skid from the unit.  
4. Lower slowly. The unit should land on its casters or rails and can then be moved into  
position.  
5. Temporary hardware has been installed to prevent side panels from shifting in transit.  
Remove hardware.  
6. Retain the crating material for reshipping the chiller in case hidden shipping damage  
is found.  
Never remove the unit from the front (electrical control end) or the rear (pipe connection  
end). Damage may result.  
3-2 Electrical Connections  
Supply electricity of the voltage, phase, and cycle listed on the serial tag. Total running amps  
are also found in the specification tables on pages 45-57 in the Appendix.  
Bring properly sized power leads and ground from a fused disconnect (installed by your  
electrician) to the unit. Use dual-element fuses in the disconnect switch, sized according to  
the National Electrical Code recommendations. Note the outline drawings for egress into the  
cabinet. Make sure all electrical connections are tight.  
Important!  
Refer to National Electric Code (NEC) Article 430-24 through 430-26, Table  
310.15(B)(2)(a) for proper feeder conductor and supply disconnect sizing.  
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3-3 Process Water Connections  
All of our portable chillers have two chilled water connections. The chilled water supply,  
labeled “To Process” is the outlet for the chilled water leading to the process being cooled.  
The chilled water return, labeled “From Process” is the inlet leading from the process back  
into the chiller to be cooled and re-circulated.  
All external chilled water connections should be run full size to the process. Flow and  
pressure information is available on pages 58-61 in the Appendix. The largest possible  
openings and passages should be provided for the flow of chilled water through platens, dies,  
molds, or other pieces of equipment.  
Note:  
Be sure to reduce external pressure drop as much as possible by generously  
sizing piping and tooling water passageways.  
3-4 Bypass Valve Considerations  
Our portable chillers have a spring-loaded bypass valve. If the chilled water shut-off valves  
are inadvertently closed while the chiller is running, the factory-set bypass valve opens and  
allows a small amount of water to flow through the chiller. This action protects the chiller  
from freeze-up and allows the other cutout devices to shut down the chiller. The bypass valve  
is not intended to provide continuous full bypass flow.  
Caution! Do not attempt to adjust or otherwise tamper with the bypass valve. Your  
warranty will be voided.  
3-5 Galvanic Corrosion Considerations  
The materials used in the water circuit piping of these chillers are non-ferrous and react  
electro-chemically with ferrous metallic materials. Some water has dissolved minerals that  
greatly accelerate the reaction between dissimilar metals.  
PVC or non-ferrous piping is recommended to reduce galvanic action. If iron piping must be  
used, use dielectric unions at the chiller.  
3-6 Water Treatment Considerations  
Water treatment is an integral part of the system. In some locations, water may cause large  
deposits of scale, erosion, algae, and/or corrosion.  
Note:  
The use of poor quality water may result in inefficient operation, heat  
exchanger damage, and pump seal damage. Consult a qualified water  
treatment specialist to determine whether treatment is needed.  
We offer a complete line of water treatment equipment. Contact your sales representative for  
water testing and treatment options.  
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3-7 Condenser Considerations  
Water-Cooled Chiller Condensers  
Water-cooled portable chillers can use city water or tower water as a cooling medium. Make  
sure that all external piping and connections supplying and discharging water to and from the  
condenser are full size.  
You’ll make two connections to the water-cooled condenser:  
Condenser Water In. The condenser water supply, labeled “Condenser Water In”, is located  
at the rear of the chiller. It is the inlet for city or tower water.  
Make sure that water is supplied at a maximum temperature of 85ºF (29ºC) and a minimum  
pressure of 25 psi.  
The water-regulating valve is set at the factory. Only a qualified refrigeration technician  
should adjust it.  
Normal R-22 refrigerant condensing pressure is 210 psi, with 85ºF (27ºC) water at 25 psi  
entering condenser water pressure  
Condenser Water Out. Condenser water return, labeled “Condenser Water Out”, is located  
at the rear of the chiller. It is the outlet for water after it has passed through the condenser.  
It is connected to the tower water return line or to a sewer or other approved discharge  
receiver. A water-regulating valve is a standard feature in the condenser water return line.  
Air-Cooled Chiller Condensers  
Air-cooled chillers use the surrounding air to cool the condenser. Install the chiller in an area  
where there is free passage of air for condensing and provisions for removal of heated air  
from the area. Do not locate air-cooled chillers in locations where steam, hot air, or fume  
exhausts can be drawn into the chiller. A typical ductwork diagram is located on page 63 in  
the Appendix of this manual.  
Caution! Clean air-cooled condensers and filters frequently. Failure to do so results in  
reduced capacity, increased operating costs, and possible failure of the  
equipment. Cleaning instructions can be found on page 38 in the Maintenance  
chapter of this manual  
Normal maximum refrigerant condensing pressure with 95ºF (35ºC) air entering the  
condenser is 260 psi.  
Condensing Air Temperature. Our air-cooled portable chillers are designed to operate at a  
minimum condenser entering air temperature of approximately 60ºF (15.5ºC). Operation of  
the equipment at a lower condenser entering air temperature can cause the chiller to lose  
capacity. For entering air temperatures below 60ºF, an optional fan motor speed control is  
available. We recommend maintaining a minimum 60ºF ambient temperature.  
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Remote Air-Cooled Chiller Condensers  
Remote air-cooled portable chillers are shipped with nitrogen holding charge and a full  
charge of oil (excluding the amount needed for field piping). The remote air condenser is  
shipped with a dry nitrogen charge. Verify that the holding charge has not been lost prior to  
installation. If there is no pressure, leak test the unit and repair before installing the  
interconnecting refrigerant piping. Read this entire section before installation.  
Note:  
Piping should be type “L” or type “K” refrigerant grade copper tubing only.  
Proper sizing and installation has a significant effect on system performance,  
reliability, and safety.  
Interconnecting Refrigerant Piping. The chiller and condenser refrigerant lines are  
terminated with a cap and brazed closed. Use a tube cutter to remove caps.  
Caution! Do not use a saw to remove the end caps because this will allow copper chips to  
contaminate the system.  
A certified refrigeration contractor need only to install the interconnecting refrigerant piping  
between the chiller and the outdoor air-cooled condenser. This piping must be properly sized,  
type “L” or type “K” refrigerant grade tubing, high temperature brazed, Install a customer  
supplied 400 psi approved refrigerant relief valve in the discharge line at the condenser,  
following all codes.  
When brazing copper joints, flow dry nitrogen through the system to prevent carbon/scale  
formation, which causes contamination. Isolate the refrigerant lines from the building,  
preventing transfer of line vibration to the structure. Do not secure the lines rigidly.  
Leak check and evacuate the system down to 400 microns. A decay of 50 microns after one  
hour is acceptable.  
Warning! To prevent injury or death due to explosion and/or inhalation of phosgene gas,  
purge system thoroughly while brazing refrigerant piping connections. Use a  
pressure regulator in the line between the unit and the high-pressure nitrogen  
cylinder to avoid over-pressurization and possible explosion.  
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System Configuration. The system can be configured in any of the arrangements shown on  
page 62 of the Appendix. The configuration and distance between the chiller and the  
condenser affects pipe size, refrigerant charge, oil return, and oil charge. Therefore there are  
limitations that must be adhered to for reliable and optimal operation.  
Leaving water temperature affects discharge line size. Be sure to inform the installing  
contractor of the leaving water temperature range in which the chiller will be operating  
The total distance between the chiller and condenser must not exceed 200 feet or 300  
equivalent pipe feet  
Discharge line risers cannot exceed an elevation difference greater than 100 feet  
without a 2% efficiency decrease.  
Refer to page 62 of the Appendix for the location of traps.  
Refrigeration lines must not be crossed, i.e., chiller liquid lines are to be piped to  
condenser liquid lines.  
Sizing Refrigerant Lines. To determine field installed liquid and discharge line sizes, first  
establish the equivalent length of pipe for each line, valve, and elbow. Chiller capacity and  
leaving water temperature range is also required. See Figure 2 on page 22 for lengths of  
refrigerant valves and fittings.  
Liquid Line Sizing. The liquid line should be sized as small as possible while maintaining  
acceptable pressure drop to minimize the refrigerant charge. Liquid line risers must not  
exceed 15 feet from the base of the air-cooled condenser. Horizontal runs do not require a  
pitch. Insulation is not required unless the line is installed in a high ambient area, i.e., boiler  
room. Install a liquid line-charging valve to facilitate refrigerant charging. See Figure 3 on  
page 22 for sizing information. See Figure 5 on page 23 for charge determination.  
Discharge Line Sizing. For horizontal runs, the discharge line should be pitched downward,  
in the direction of flow, at a rate of 1/2” for every 10 feet. This will allow oil to flow towards  
the condenser. Discharge line sizing is based on the velocity required for sufficient oil return  
back to the compressor. See Figure 4 on page 22 for discharge line sizing.  
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Figure 2: Equivalent Length in Feet for Valves and Fittings  
Line Size  
Inches OD  
1/2”  
Globe Valve  
Equivalent Ft  
Angle Valve  
Equivalent Ft  
Short Radius Elbow  
Long Radius Elbow  
Equivalent Ft  
Equivalent Ft  
43  
55  
69  
15  
18  
24  
29  
33  
34  
39  
44  
1.4  
1.6  
2.0  
2.7  
3.2  
3.8  
5.2  
6.5  
0.9  
1.0  
1.4  
1.9  
2.2  
2.6  
3.4  
4.2  
5/8”  
7/8”  
1 1/8”  
1 3/8”  
1 5/8’  
2 1/8”  
2 5/8”  
87  
102  
115  
141  
159  
Figure 3: Liquid Line Sizing  
30 – 65°F Leaving Water Temperature  
Liquid Line Size (O.D.”)  
Eqiv. FT  
5 hp  
7.5 hp  
10 hp  
15 hp  
20 hp  
25 hp  
30 hp  
35 hp  
40 hp  
25  
50  
75  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
5/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
7/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
7/8  
7/8  
7/8  
7/8  
7/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
7/8  
7/8  
7/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 3/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
100  
125  
150  
175  
200  
225  
250  
275  
300  
7/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
Figure 4: Discharge Line Sizing  
30 – 65°F Leaving Water Temperature  
Discharge Line Size (O.D.”)  
Eqiv. FT  
25  
5 hp  
7/8  
7/8  
7/8  
7/8  
7.5 hp  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
10 hp  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
15 hp  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
20 hp  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 3/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
25 hp  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
30 hp  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
35 hp  
1 5/8  
1 5/8  
1 5/8  
1 5/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
40 hp  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
2 1/8  
50  
75  
100  
125  
150  
175  
200  
225  
250  
275  
300  
7/8  
7/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
1 1/8  
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Refrigerant Charge Determination. The approximate amount of refrigerant charge required  
by the system varies based on the total length of the refrigerant lines and the size of the  
chiller. Referring to Figure 5, determine the amount of charge based on the horsepower of the  
chiller and the amount of charge based on discharge and liquid line sizes and lengths. Add  
these three numbers together to find the final operating charge. The final operating charge  
must be verified by running the system and checking the liquid line sight glass.  
Figure 5: Refrigerant Charge Determination  
Chiller Condenser Charge  
Field Installed Piping Charge  
Horsepower  
Pipe O.D.  
Inches  
Discharge Line  
c R-22(Lbs.)  
Liquid Line  
c R-22(Lbs.)  
Lbs. of  
R-22  
5.9  
5
1/2”  
5/8”  
7/8”  
1 1/8”  
1 3/8”  
1 5/8’  
2 1/8”  
2 5/8”  
-
-
7.2  
11.5  
24.0  
40.9  
62.2  
88.1  
153.0  
236.0  
7.5  
10  
15  
20  
25  
30  
35  
40  
6.1  
10.8  
12.6  
21.2  
24.2  
40.2  
41.2  
50.2  
1.6  
2.7  
4.0  
5.7  
10.0  
15.0  
c Based on 100 feet of pipe, 100 ºF Liquid, 100 ºF Discharge  
Oil Charge Determination. The remote air-cooled portable chillers are factory charged with  
the amount of oil required without field-installed piping. Additional oil required is dependent  
on the amount of additional refrigerant added.  
Calculate the amount of additional oil required by using the following formula:  
Pints of oil (Sunisco 3GS) = lbs. of R-22 added for field installed piping / 100.  
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3-8 Checking Motor Direction  
All of our portable chillers have their motor rotations properly phased at the factory. If  
compressors, pumps, or fans are running in reverse rotation, disconnect and lock out the  
power source and reverse any two power leads into the chiller disconnect switch.  
Caution! Do not switch leads at the motors, motor starters, or contactors.  
Three-Phase Compressors  
Scroll compressors are directionally-dependent and compress in one rotational direction.  
Reversing rotation direction results in an elevated sound level and a substantially-reduced  
current draw.  
Water Pumps  
Correct pump rotation is indicated by a positive pressure of 20 to 40 psi on the pump pressure  
gauge. Pump rotation should be clockwise when viewed from the motor end. For chillers with  
optional pumps, check the appropriate pump curve in the Appendix.  
Caution! Do not run pump dry. Doing so will result in seal damage.  
Condenser Fan  
Air should be drawn through the condenser and discharged vertically from the chiller.  
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3-9 Water Reservoir  
All portable chillers shipped during the fall, winter, or spring, or those units that are shipped  
from stock are flushed at the factory with a water/ethylene glycol solution to prevent piping  
components prone to retaining water from freezing. During startup and when additional  
solution is required, refer to the ethylene glycol and propylene glycol curves in Figure 6 on  
page 26. Add a pre-mixed solution of industrial quality (not automotive) ethylene glycol or  
propylene glycol and water to provide freeze protection to a temperature 20ºF (11ºC) below  
the normal chiller operating temperature set point.  
Glycol and/or water, with an inhibitor, should be used to protect the materials (copper, steel,  
stainless steel, and bronze) in the system from corrosion. If you intend to use straight water,  
we strongly advise a minimum leaving water temperature of 50ºF (10ºC) or contact the  
service department.  
The following glycol products are available:  
Part Number Description  
A0541358  
A0539637  
A0542990  
A0542991  
Ethylene glycol, 5 gallons (18.9 liters)  
Ethylene glycol, 55 gallons (208.2 liters)  
Propylene glycol, 5 gallons (18.9 liters)  
Propylene glycol, 55 gallons (208.2 liters)  
Caution! Do not connect make-up water directly to the chilled water reservoir unless you  
have an approved automatic water make-up system installed.  
Note:  
The reservoir is not designed to withstand water pressure. The fill opening and  
vent line must be vented to the atmosphere for proper operation. The optional  
automatic make-up system is described in section 3-10 on page 27.  
Caution! Do not pressurize tank. Fill and vent lines must be open to atmosphere. Supply  
and return connections must be trapped and vented to allow vertical risers to  
drain into tank. Do not overfill system. Allow enough free space in tank for  
vertical piping to drain.  
If your application has chilled water or process piping above the reservoir fill and vent level,  
trap and vent the supply and return lines to allow vertical piping to drain into tank.  
Note:  
In applications where the process or process piping is above the reservoir, 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, a vacuum breaker should be installed at the high point of the “To  
Process” and “From Process” lines.  
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Figure 6: Ethylene Glycol and Propylene Glycol Curves  
Pe rce nt G lyc ol Cu rves for Free ze Protec tion  
40.0  
30.0  
20.0  
Eth ylene G lycol  
Prop ylene Glycol  
10.0  
0.0  
-10.0  
-20.0  
-30.0  
-40.0  
-50.0  
-60.0  
0.0  
10.0  
20.0  
30.0  
40.0  
50.0  
60.0  
% Gl ycol by Vol um e  
Example: 45°F set point minus 20°F = 25°F.  
From Figure 28, 25°F equates to 10% by volume of glycol required.  
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3-10 Automatic Water Make-Up Option  
The chiller may be connected to an automatic make-up system if the optional package (float  
switch, pressure regulating, pipe fittings, solenoid valve and 1/2” NPT city water make-up  
connection) is factory installed.  
Refer to the typical piping schematics on pages 64-69 in the Appendix for additional  
components necessary for this installation.  
Note:  
Prevent reservoir over-pressurization by setting the required pressure-  
regulating valve to limit make-up water pressure to less than 5 psi. The  
reservoir must remain vented to the atmosphere.  
If the automatic make-up system is connected to a city water system, make provisions to  
prevent backflow contamination. Install an approved backflow preventer in accordance with  
local codes.  
Caution! Adding straight city water into a glycol/water mixture dilutes the solution and  
eventually leads to system freeze-up. Damage from freeze-up is not covered by  
the warranty.  
To prevent system freeze-up in automatic make-up applications, we recommend using either  
a chemical feeder or make-up reservoir to replenish glycol. Contact the sales department for  
more information about these configurations.  
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3-11 Initial Start-Up  
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. Portable chillers are built with a  
voltage specific compressor and cannot be re-wired for an alternate voltage.  
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 plus or minus ten percent (±10%) of the voltage listed on the serial tag.  
Electrical connections must conform to all applicable codes.  
Complete chilled water To Process and From Process connections.  
Make sure the chilled water To and From process valves on the chiller are open.  
Be sure the reservoir tank and chilled water circuit piping are filled to the full mark  
with a water/glycol mixture. The water/glycol mixture should provide for freeze  
protection to at least 20°F (11ºC) below the leaving water temperature you want.  
The air-cooled condenser should have an adequate supply of 60º to 95ºF (16º to 35ºC)  
air for proper operation.  
The tower or city water condenser cooling in and out connections should be completed  
and an adequate supply of 85ºF (30ºC) tower or 70ºF (21ºC) city water, at 25 psi  
pressure, for proper operation.  
Connect the main 3 phase incoming power to the unit making certain that line one (1)  
L1 is connected to the A phase, line two (2) L2 is connected to the B phase, and line  
three (3) L3 is connected to the C phase. Check for proper rotation direction of fan(s)  
and pump(s). 2 hp and 3 hp models are single phase.  
For 5-40 hp units, the crankcase heater is automatically energized when the main power  
is applied. It should be on for at least 24 hours before startup to force dissolved  
refrigerant from the compressor oil.  
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Chapter 4: Operation  
4-1 Panel Buttons, Indicator Lights, and Switches  
Microprocessor Controllers  
Standard chillers use a microprocessor-based PID controller. These controllers are modular,  
self-contained units that can slide from their mounting housing. They are factory set and  
adjusted; no field adjustment to the internal controls are necessary. Their standard operation  
range is 30ºF to 65ºF (-1ºC to 18ºC). See Figure 7: Typical Portable Chiller Microprocessor  
Controller.  
E5CK Controller  
Indicator  
Name  
Description  
PV  
Process Value  
LED  
During normal operation, the top LED display on  
the controller displays the actual process  
temperature. It also lists parameter symbols during  
setup and error messages if an error occurs.  
8.8.8.8  
SV  
Set Value LED During normal operation, the green bottom LED  
display on the controller displays the process set  
point you want the chiller to maintain. It also  
displays parameter and pre-set function values  
during set up.  
8.8.8.8  
Out 1 LED  
The orange OUT1 LED lights when the control  
output energizes the hot-gas bypass solenoid  
valve.  
OUT1  
OUT2  
Out 2 LED  
The orange OUT2 LED lights whenever the  
process temperature is four degrees or more above  
the “To Process” setpoint. The compressor then  
comes on and runs until the temperature at the “To  
Process” thermocouple is three degrees below the  
setpoint.  
MANU LED  
The orange MANU LED is not used and does not  
light.  
MANU  
STOP  
Stop LED  
RMT LED  
The orange STOP LED is not used.  
The orange RMT LED is lit during remote  
communication operation.  
RMT  
AT LED  
The orange AT LED flashes during auto-tuning.  
AT  
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Indicator  
Name  
Description  
SUB 1 LED  
The orange SUB1 LED lights when the process  
temperature is three degrees or more below the  
“To Process” setpoint. The compressor then shuts  
down by means of a latching circuit, and it does  
not run again until the temperature at the “To  
Process” thermocouple is four degrees above the  
setpoint.  
SUB1  
AutoTune Key Press and hold the AT key for two seconds to  
initiate or stop the auto-tune function  
AT  
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.  
Down Arrow  
Key  
Each press of the Down Arrow key decrements or  
reduces values or settings on the SV display  
Up Arrow Key Each press of the Up Arrow key increments or  
advances the values or settings on the SV display.  
Sterlco 2000 Controller  
Indicator  
Name  
Description  
T
Process Value LED During normal operation, the large red T LED on  
the controller displays the actual process  
8.8.8.8  
temperature at the “To Process” thermocouple. It  
also lists parameter symbols during setup and  
error messages if an error occurs  
SP  
Set Value LED  
During normal operation, the green SP LED on  
the controller displays the process set point you  
want the chiller to maintain. It also displays  
parameter and pre-set function values during set  
up.  
8.8.8.8  
Index Key  
Press the Index key for less than (1) second to  
scroll through parameters within the mode.  
Up Arrow Key  
Down Arrow Key  
Enter Key  
Each press of the Up Arrow key increments or  
advances the values or settings on the SP display.  
Each press of the Down Arrow key decrements or  
reduces the values or settings on the SP display.  
Press the Enter key to verify or confirm an entry.  
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Figure 7: Typical Portable Chiller Microprocessor Controllers  
PV  
SV  
OUT1  
OUT2 MANU STOP RMT  
AT  
SUB1  
AT  
OMRON  
E5CK  
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Graphic Panel  
(See Figure 8)  
Indicator Name  
Description  
Compressor On  
Light  
The Compressor On light turns on whenever the  
compressor is operating.  
Low Temperature  
Light  
The Low Temperature light comes on if the process  
water/glycol temperature drops below the High/Low  
thermostat set point. The Low thermostat stage one  
switch opens the control circuit shutting down the  
compressor, but the process water/glycol pump(s)  
continue to operate. This action prevents possible  
chiller evaporator freeze-up.  
Hot Gas Bypass  
Light  
The Hot Gas By-Pass light turns on when the hot  
gas bypass valve is in operation. The OUT1 LED on  
the controller also lights when the hot gas bypass  
valve is in operation.  
High Temperature  
Light  
The High Temperature light comes on if the process  
water/glycol temperature rises above the High/Low  
thermostat stage two set point. The High thermostat  
stage two switch opens the control circuit shutting  
down the process water/glycol pump(s), and the  
chiller shuts off. This action prevents possible  
system failure from overheating of the process  
water/glycol.  
Pump On Light  
High Discharge  
The Pump On light, installed on chillers with a  
pump, lights whenever the pump(s) operates.  
The High Discharge Temperature light comes on if  
Temperature Light the compressor discharge line temperature switch  
opens. This switch prevents possible compressor  
failure due to over loading, the compressor stops,  
but the pump(s) continue to run. This occurs when  
the discharge line temperature rises above 260ºF  
(127ºC). Call a qualified refrigeration service  
technician or contact the Service Department.  
Pump Overload  
Light  
The Pump Overload light, installed on chillers with  
a pump(s), lights whenever a pump motor(s) has  
shut down from a motor overload condition.  
High Refrigerant  
Pressure Light  
The High Refrigerant Pressure light comes on if the  
compressor discharge pressure exceeds the limit of  
the high pressure cutout switch. The compressor  
stops but the pump(s) continue to run until you  
manually reset the high-pressure cutout switch. Call  
a qualified refrigeration service technician or  
contact the Service Department.  
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Indicator Name  
Low Water  
Description  
The Low Water Flow/Pressure light comes on when  
the flow switch (pressure switch on 2 & 3 hp  
models) senses that the water/glycol flow rate  
through the evaporator has dropped below an  
acceptable level. The flow switch opens shutting  
down the pump(s) and the chiller.  
Flow/Pressure  
Light  
Low Refrigerant  
Pressure Light  
The Low Refrigerant Pressure light come on if the  
compressor suction pressure drops below the limit  
of the low pressure cutout switch. The compressor  
shuts off, but the pump(s) continues to run.  
The indicator turns off and compressor restarts  
automatically when the refrigerant pressure rises to  
the limit of the low-pressure cutout switch. Call a  
qualified refrigeration service technician or contact  
the Service Department.  
Low Oil Pressure  
Light  
The Low Oil Pressure light is installed on chillers  
with a semi-hermetic compressor that have an oil  
pump. A differential pressure switch monitors the  
difference between crankcase pressure and oil pump  
pressure.  
If the pressure drops to an unsafe level for more  
than two minutes the switch will open the control  
wiring circuit, shutting off the compressor, turning  
the light on, but allowing the pump(s) to continue  
running. This is a manual reset switch. Call a  
qualified refrigeration service technician or the  
Service Department.  
Control Power  
Lighted Switch  
The green, lighted, sustained-on Control Power  
Switch lights whenever the switch is in the ON  
position and the control circuit is energized.  
Alarm Silence  
Switch  
The red momentary-on Alarm Silence Switch is  
used to turn off the audible alarm on chillers that are  
built with the audible or audible/visual alarm option.  
This switch is always provided and requires no  
additional wiring if either alarm option is installed at  
a later time.  
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Figure 8: Typical Graphic Panels  
(With E5CK Controller)  
COMPRESSOR  
ON  
LOW  
TEMPERATURE  
HOT GAS  
BY-PASS  
HIGH  
TEMPERATURE  
PUMP ON  
HIGH DISCHARGE  
TEMPERATURE  
PV  
PUMP  
OVERLOAD  
HIGH REFRIGERANT  
PRESSURE  
SV  
OUT1  
OUT2 MANU STOP RMT  
AT  
SUB1  
LOW WATER  
FLOW/PRESSURE  
LOW REFRIGERANT  
PRESSURE  
AT  
OMRON  
E5CK  
LOW OIL  
PRESSURE  
ON  
CONTROL  
POWER  
ALARM  
SILENCE  
OFF  
A0554705  
(Eurotherm 3216 Controller)  
COMPRESSOR  
LOW  
TEMPERATURE  
ON  
HOT GAS  
BY-PASS  
HIGH  
TEMPERATURE  
PUMP ON  
HIGH DISCHARGE  
TEMPERATURE  
PUMP  
OVERLOAD  
HIGH REFRIGERANT  
PRESSURE  
LOW WATER  
FLOW/PRESSURE  
LOW REFRIGERANT  
PRESSURE  
LOW OIL  
PRESSURE  
ON  
CONTROL  
POWER  
ALARM  
SILENCE  
OFF  
A0554705  
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4-2 Start-up  
1. Turn on the chiller and put it under a process load.  
2. Set the controller for the To Process temperature you want, using the Up  
Arrow button or the Down Arrow button located on the face of the controller.  
3. Adjust the High/Low thermostat, located in the electrical enclosure, to 8°F  
(4.4ºC) below the To Process temperature you want. The High/Low  
thermostat is factory-set at 42ºF (6ºC). See page 36 for information on  
resetting the High/Low thermostat.  
4. Check the pump amp draw and pump pressure. Make sure that the amp draw  
reading is within the running load and service factor amps.  
5. Operate the chiller, looking for any leaks and listening for unusual noises or  
vibrations that could indicate improper operation.  
Note:  
Elevated sound level and substantially reduced current draw indicate reverse  
rotation. After several minutes of operation, the compressor internal protector  
trips.  
4-3 Setting the Process Water Temperatures  
Chiller Controller  
To change the process water temperature set point, press the Up Arrow button to raise the set  
point, and press the Down Arrow button to lower the set point.  
4-4 Auto-Tuning  
E5CK Controller Only  
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 times before leveling off and controlling the process set point. Auto-Tuning can take  
up to 45 minutes and is best done before any product is being run.  
1. Press and hold down the AT key for several seconds until the AT indicator  
flashes.  
2. When the AT LED light stops flashing, the controller is tuned and ready for  
operation.  
Eurotherm 3216 Controller  
1. Press the INDEX key once. “A. Tune” will be displayed.  
2. Press the UP arrow once to display “on”.  
3. Press the MODE key once to running condition. The top display will flash  
“tune”. The tune is complete when the display stops flashing.  
4-5 Optional Communications  
The communications function allows you to monitor and set controller parameters by a  
program prepared and running on a host computer connected to the controller.  
When using the communications function, you must add on the unit for RS-232C or RS-485  
serial communications. The controller communications function allows you to read/write  
parameters, do operating instructions, and select the setting level.  
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4-6 Programming the Electronic High/Low Thermostat  
The thermostat control is located in the chiller enclosure. The control has three control keys  
and a one-line, four-character LCD display.  
The thermostat control has a lockout slide switch to prevent tampering by unauthorized  
personnel. The switch is located on the inside cover of the thermostat. The keypad is disabled  
when the switch is moved to the left in the “Lock” position. The keypad functions normally  
when the switch is moved to the right in the “Unlock” position. All chillers are shipped with  
the switch in the “Lock” position.  
Thermostat Buttons  
Indicator Name  
Set Button  
Description  
The Set button is used to enter the programming  
mode for the thermostat.  
SET  
Up Arrow button  
Each press of the Down Arrow key decrements or  
reduces values or settings on the display  
Down Arrow  
button  
Each press of the Up Arrow key increments or  
advances the values or settings on the display.  
2-40 HP Portable Chillers  
Chapter 4: Operation  
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Perform the following procedures to program the electronic High/Low Thermostat control:  
Select Fahrenheit or Celsius  
1. Press the Set key once to access Fahrenheit/Celsius mode. Factory set to F.  
Use the Up Arrow and Down Arrow keys to toggle between Fahrenheit and Celsius.  
Stage 1: Freeze Protection  
2. Press the Set key again to access the low temperature set point. The screen displays  
the current set point and the S1 indicator blinks on and off to indicate that the control  
is in set point mode.  
Use the Up Arrow and Down Arrow keys to adjust the set point. At 50ºF (10ºC)  
leaving water temperature, the setting should be 42ºF (6ºC).  
3. Press the Set key again to access the Stage 1 differential. The screen displays the  
current differential and the DIF1 indicator blinks on and off to indicate that the  
control is in differential mode.  
Use the Up Arrow and Down Arrow keys to adjust the differential. The setting  
should be 12ºF (-11°C).  
4. Press the Set key again to access Stage 1 cooling or heating mode. The screen  
displays the current mode: C1 for cooling or H1 for Heating.  
Use the Up Arrow and Down Arrow keys to toggle between C1 or H1. The setting  
should be C1.  
Stage 2: High Temperature Protection  
5. Press the Set key again to access the high temperature set point. The screen displays  
the current set point and the S2 indicator blinks on and off to indicate that the control  
is in set point mode.  
Use the Up Arrow and Down Arrow keys to adjust the set point. The setting should  
be 100ºF (38ºC).  
6. Press the Set key again to access the Stage 2 differential. The screen displays the  
current differential and the DIF2 indicator blinks on and off to indicate that the  
control is in differential mode.  
Use the Up Arrow and Down Arrow keys to adjust the differential. The setting  
should be 2ºF (-17°C).  
7. Press the Set key again to access Stage 2 cooling or heating mode. The screen  
displays the current mode: C2 for cooling or H2 for Heating.  
Use the Up Arrow and Down Arrow keys to toggle between C2 and H2. The setting  
should be H2.  
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Chapter 5: Maintenance  
5-1 Lubrication  
Grease all blower bearings, fan and blower motors, and pump motors that do not have  
permanently sealed bearings. Remove the grease relief plug (motors only) before adding  
grease, add grease until a small amount pours out, and replace the plug when finished.  
Caution! Failure to remove the grease relief plug will result in dislodging the bearing  
grease seal, eventually causing bearing failure.  
Refrigeration compressors are hermetically sealed and no lubrication is required.  
5-2 Filter Cleaning  
Air filter cleaning is important to keep your air-cooled portable chiller operating at peak  
efficiency and capacity. Clean the filters whenever they appear dirty, or at regularly  
scheduled intervals.  
1. Turn the chiller off.  
2. Slide the filter up off of the retaining pins holding it in place along its bottom.  
3. Tip the bottom of the filter away from the chiller.  
4. Slide it down and out.  
5. Wash down the filter with clean water (preferably with a garden hose), directing the flow  
of water opposite the direction of airflow. If dirt is heavy, use a mild detergent and rinse  
well. Allow the filter to dry completely before replacing it on the chiller.  
Note:  
Keep a spare air filter set on hand. Install and use it while cleaning).  
Caution! Do not use compressed air to blow off a dirty filter. It will not clean very well,  
and the filter could be damaged. Never run the chiller without properly  
installed filters.  
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Chapter 5: Maintenance  
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5-3 Maintaining the Condenser  
Dirty condenser heat exchange surfaces reduce system capacity and efficiency.  
Air- and Remote Air-Cooled Chillers  
Brush or vacuum light dirt accumulations off the aluminum condenser fins. Avoid bending or  
damaging them. Heavy dirt accumulations on the fins may require professional cleaning.  
Water-Cooled Chillers  
Proper water treatment will greatly reduce cleaning intervals.  
Coaxial Condensers (2 to 7.5 hp chillers). Remove dirt and slime in the condenser tube  
water side by reverse-circulating with a mild detergent and water solution. Remove mineral  
deposits by reverse circulating Liquid Inhibited Acid De-Scaling Solution (Part No.  
A0502600) through the water side of the condenser. Follow the directions on the container.  
Shell & Tube Condensers (10 to 40 hp chillers). Remove dirt and slime in the condenser  
tube water side by cleaning with a nylon tube brush. Remove mineral deposits by reverse  
circulating Liquid Inhibited Acid De-Scaling Solution (Part No. A0502600) through the tube  
water side of the condenser. Follow the directions on the container.  
The refrigerant side is sealed and requires no routine maintenance.  
Caution! Do not use steam or water over 140ºF (60ºC) to clean a condenser unless you  
are monitoring the refrigeration circuit for excessive pressure with gauges.  
Only a trained technician should use this method.  
5-4 Maintaining the Evaporator  
Dirty evaporator heat exchange surfaces reduce system capacity and efficiency. Remove dirt  
and slime in the evaporator by reverse-circulating with a mild detergent and water solution.  
Remove mineral deposits by reverse-circulating Liquid Citric Acid De-Scaling Solution (Part  
No. A0536607). Follow the directions on the container.  
5-5 Evaporator Process Piping Y-Strainer  
The process piping Y-strainer requires periodic cleaning of its screen to insure the proper  
flow through the evaporator. To clean the strainer screen, remove the access plug and  
retaining cap, and pull out the screen.  
Wipe, brush, or vacuum out any dirt left in the strainer body. Clean the screen and replace it  
in the strainer taking care to fit it squarely into the machined seat provided.  
Caution! Do not forget to re-install the screen after cleaning it. Operating the chiller  
with no strainer screen can potentially plug the evaporator with dirt. The  
warranty does not cover chiller failures from a dirty evaporator.  
2-40 HP Portable Chillers  
Chapter 5: Maintenance  
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5-6 Preventative Maintenance Service  
Follow a systematic preventive maintenance program to help avoid costly down time. Call  
the Service Department to arrange a schedule of inspections. This service can be tailored to  
fit your maintenance requirements. These inspections include, but are not limited to:  
Checking refrigerant suction and discharge pressures  
Checking safety and operating conditions  
Checking voltage and amperage of all motors  
Checking all electrical connections  
Checking quantity of refrigerant  
Checking compressor oil level  
Checking lubrication of motor and pump bearings.  
Checking circulating pump operation  
Checking flow through heat exchangers  
Checking compressor efficiency  
Checking noise levels  
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Chapter 6: Troubleshooting  
Problem  
Possible cause  
No power.  
Solution  
Check main disconnect, fuses, wiring,  
and power lead to unit.  
Voltage must be within plus or minus  
10% of nameplate rating.  
Replace.  
Wrong voltage supplied to unit.  
Defective on/off switch.  
Replace control circuit fuse.  
Check transformer.  
Unit does not run.  
Control circuit fuse blown.  
Check for a short circuit.  
Replace.  
Add water or water/glycol solution as  
required.  
Defective control transformer.  
Piping flow switch circuit open.  
Pump motor off on overload.  
High/Low thermostat set higher  
than temperature of liquid in  
system.  
Reset and test.  
Lower thermostat stage 1 set to 10°F  
(6°C) below the leaving temperature  
you want.  
Defective High/Low thermostat.  
Low refrigerant indicator on.  
Replace.  
Check refrigerant charge.  
Sight glass should be clear and the  
moisture indicator should be green  
while compressor is running. Bubbles or  
foaming is normal when the hot-gas by-  
pass solenoid is energized. Call for  
service if bubbling is occurring and/or  
moisture indicator is yellow.  
Clean the air filters.  
Refrigerant low pressure switch  
contacts open.  
Check condenser fans for proper  
rotation.  
Check for dirty condenser.  
Reset and test.  
Refrigerant high-pressure indicator  
on.  
Fan motor out on overload.  
Defective fan cycling control.  
Reset and test.  
Replace.  
Pump runs; compressor does not.  
Defective fan motor.  
Repair or replace.  
Allow time to cool and reset, then check  
for high/low volt-age. It must be within  
plus or minus 10% of the nameplate  
rating.  
Compressor internal overload or  
fuses are open.  
Check for open fuses and loose  
compressor electrical connections.  
Compressor contactor holding coil  
open.  
Repair or replace.  
Repair or replace.  
Locate and repair.  
Defective pump motor to  
compressor auxiliary contact.  
Broken wire in the compressor  
control circuit.  
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Chapter 6: Troubleshooting  
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Problem  
Possible cause  
Solution  
Clean  
Plugged Y-Strainer  
Pump runs, compressor cycles at  
short intervals.  
Replace relay board on control bed hot  
gas coil  
Install bypass between to-and-from  
process line  
Hot gas not coming on  
Low water flow  
Make sure that the water/glycol mixture  
protection is right for the process.  
Water/glycol mixture inadequate  
for process.  
Defective or improperly set  
High/Low thermostat.  
Adjust or replace.  
Water temperature is too high.  
Refrigerant low pressure switch is  
set too high.  
Call service to adjust pressure control.  
Call service to find and repair the leak,  
then have refrigerant added.  
Refrigerant charge is low.  
Verify rotation; if running in reverse  
rotation, reverse any two main power  
leads. Re-verify for correct pump  
rotation.  
Pump pressure low (refer to curves  
for normal pressure for various  
pumps).  
Pump running in reverse.  
Check for foreign matter.  
Restricted water flow.  
Clean the system.  
Check for partially closed valves etc.  
Make sure that all lines are properly  
sized.  
Pump pressure is too high.  
Clean filters.  
Clean condenser.  
Restricted condenser air.  
Unit low on refrigerant.  
Check the refrigerant charge.  
Unit runs continuously, but not  
enough cooling power.  
Compressor not operating  
efficiently.  
Call service.  
Unit under-sized for application.  
Call sales rep.  
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Chapter 6: Troubleshooting  
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Chapter 7: Appendix  
7-1 Returned Material Policy  
Credit Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMS number  
will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking  
charge.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
No credit will be issued for material that is not within the manufacturer’s warranty period and/or in new  
and unused condition, suitable for resale.  
Warranty Returns  
Prior to the return of any material, authorization must be given by the manufacturer. A RMS number  
will be assigned for the equipment to be returned.  
Reason for requesting the return must be given.  
All returns are to be shipped prepaid.  
The invoice number and date or purchase order number and date must be supplied.  
After inspecting the material, a replacement or credit will be given, at the manufacturer’s discretion, if  
the item is found to be defective in materials or workmanship. Purchased components are covered  
under their specific warranty items.  
2-40 HP Portable Chillers  
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7-2 Technical Assistance  
Parts Department  
[
]
Call toll-free 7am–5pm CST 800 423-3813 or call [262] 641-8610, Fax [262] 641-8653  
The ACS Customer Service Group will provide your company with genuine OEM quality parts  
manufactured to engineering design specifications, which will maximize your equipment’s performance  
and efficiency. To assist in expediting your phone or fax order, please have the model and serial  
number of your unit when you contact us. A customer replacement parts list is included in this manual  
for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing  
excellent customer service.  
Service Department  
[
]
Call toll-free 8am–5pm CST 800 423-3183 or call [262] 641-8610  
Emergencies after 5pm CST, call [847] 439-5655  
We have a qualified service department ready to help. Service contracts are available for most of our  
Sales Department  
[262]  
Call  
641-8610 Monday–Friday, 8am–5pm CST, fax [262] 641-8653  
Our 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  
[262]  
Call  
641-8610 Monday–Friday, 8am–5pm CST  
Let us install your system. The Contract Department offers any or all of these services: project planning;  
system packages including drawings; equipment, labor, and construction materials; and union or non-  
union installations.  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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7-3 Drawings and Specifications  
2 hp and 3 1/2 hp Air-Cooled Portable Chillers  
Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c in tons  
Water  
flow  
gpm d  
4.6  
7.9  
Com-  
pressor  
hp  
Nominal  
pump  
hp  
Power in amps e,  
HP  
Discharge air  
openings cfm g  
1 @ 18.5” 1,475  
1 @ 18.5” 2,350  
460/3/60 f  
no pump  
1.9  
1 pump  
1.7  
rated  
8.0  
running  
6.9  
2
3.5  
2.0  
3.5  
1.0  
1.0  
3.3  
3.1  
10.9  
8.8  
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp (kW) reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
f Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages.  
g To convert cfm to cmh, multiply by 1.699.  
2 and 3 1/2 hp portable chillers come standard with 2 1/2” (63 mm) swivel casters.  
Process  
Dimensions  
Weights  
Compressor  
hp  
connections  
inches c  
Dry d  
Ship. d Oper. d e  
in. NPT  
height  
width  
depth  
lbs.  
lbs.  
lbs.  
2.0  
3.5  
¾” or 1.0”  
1.0”  
49.7”  
49.7”  
22.0”  
22.0”  
41.7”  
41.7”  
387  
410  
417  
440  
437  
460  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply lbs. by 0.454 to calculate Kg.  
e Operating weight is with a full 6-gallon (22.7 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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5 hp and 7.5 hp Air-Cooled Portable Chillers  
Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4  
gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply  
capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c in tons  
Water Com- Nom.  
flow pressor pump Discharge air e  
Power in amps f, 460/3/60 g  
1 pump 2 pumps  
HP  
no pump 1 pump 2 pump gpm d  
hp  
5.0  
7.5  
hp  
1.0  
1.0  
openings cfm h rated running rated running  
5
7.5  
4.8  
6.6  
4.6  
6.4  
4.5  
6.3  
11.6  
15.7  
1 @ 27”  
1 @ 27”  
3,400 14.0  
5,100 18.2  
11.0 14.9 11.9  
14.6 19.1 15.5  
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Customer use of ductwork requires optional high-pressure fan for 5 hp to 15 hp (3.73 kW to 11.20 kW) models.  
f An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
g Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.  
h To convert cfm to cmh, multiply by 1.699.  
5 hp and 7.5 hp air-cooled chillers come standard with 4” (101 mm) swivel casters.  
Com-  
pressor  
hp  
Process connections, in. NPT  
no pump, 1 pump, no  
Dimensions  
in inches c  
height width depth  
Weights  
Dry d Ship. d Oper. d e  
1
2
pump Pumps no tank  
tank,  
lbs.  
lbs.  
lbs.  
to/from  
5.0  
7.5  
1.5/2.0  
1.5/2.0  
2.0  
2.0  
1.5”  
1.5”  
1.5” / 2.0”  
1.5” / 2.0”  
82.3”  
82.3”  
34.0”  
34.0”  
54.7”  
54.7”  
872  
922  
1,047  
1,097  
1,205  
1,255  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply lbs. by 0.454 to calculate Kg.  
e Operating weight is with a full 20-gallon (76 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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10 hp and 15 hp Air-Cooled Portable Chillers  
Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
Water Com- Nom.  
flow pressor pump Discharge air e  
Power in amps f, 460/3/60 g  
1 pump 2 pumps  
HP  
no pump 1 pump 2 pump gpm d  
hp  
10.0  
15.0  
hp  
2.0  
2.0  
openings cfm h rated running rated running  
10  
15  
9.9  
9.5  
9.4  
23.8  
34.9  
2 @ 27”  
5,800 26.1  
21.8 27.8 23.5  
27.5 35.0 29.2  
14.5  
14.1  
14.0  
2 @ 27” 10,000 33.3  
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Customer use of ductwork requires optional high-pressure fan for 5 hp to 15 hp (3.73 kW to 11.20 kW) models.  
f An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
g Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.  
h To convert cfm to cmh, multiply by 1.699.  
10 hp and 15 hp air-cooled chillers come standard with 4” (101 mm) swivel casters.  
Com-  
pressor  
hp  
Process connections, in. NPT  
no pump, 1 pump, no  
Dimensions  
in inches c  
height width depth  
Weights  
Dry d Ship. d Oper. d e  
1
2
Pump pumps no tank  
tank,  
lbs.  
lbs.  
lbs.  
to/from  
10.0  
15.0  
1.5”/3.0” 2.0”/3.0 1.5”  
2.0”/3.0” 2.5”/3.0 2.0”  
1.5” / 2.0”  
2.0” / 3.0”  
82.3”  
82.3”  
34.0”  
34.0”  
74.7” 1,305 1,570  
74.7” 1,388 1,653  
1,637  
1,720  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply lbs. by 0.454 to calculate Kg.  
e Operating weight is with a full 40-gallon (151 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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20 hp, 25 hp, and 30 hp Air-Cooled Portable Chillers  
Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
no pump 1 pump 2 pump gpm d  
Water Com- Nom.  
flow pressor pump  
Power in amps e, 460/3/60 f  
1 pump 2 pumps  
openings cfm g rated running rated running  
HP  
Discharge air  
hp  
hp  
5
20  
25  
30  
19.4  
23.9  
29.2  
18.4  
22.8  
28.2  
18.0  
22.4  
27.8  
46.5 2 @ 10  
57.2 2 @ 13  
70.2 2 @ 15  
25” x 18.5” 10,200 48.3 42.0 51.4  
25” x 18.5” 13,300 62.1 48.3 65.2  
25” x 18.5” 18,150 74.1 64.4 77.2  
45.1  
51.4  
67.5  
5
5
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
f Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.  
g To convert cfm to cmh, multiply by 1.699.  
20 hp, 25 hp, and 30 hp air-cooled portable chillers come standard with 4” (101 mm) swivel casters.  
Com-  
Process connections, in. NPT  
Dimensions  
in inches c  
Weights  
Dry d Ship. d Oper. d e  
HP pressor 1 Pump 2 Pump no pump, 1 pump, no  
hp  
to/from to/from no tank  
tank,  
height width depth  
lbs.  
lbs.  
lbs.  
to/from  
20  
25  
30  
2 @ 10 2” / 3” 2.5” / 3”  
2 @ 13 2” / 3” 2.5” / 3”  
2 @ 15 2” / 3” 2.5” / 3”  
2.0”  
2.0”  
2.0”  
2” / 3”  
2” / 3”  
2” / 3”  
91.4  
91.4  
91.4  
34.0  
34.0  
34.0  
100.7 2,305 2,605  
100.7 2,348 2,648  
100.7 2,610 2,910  
2,971  
3,014  
3,276  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply lbs. by 0.454 to calculate Kg.  
e Operating weight is with a full 80-gallon (303 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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2 hp and 3.5 hp Water-Cooled Portable Chillers  
Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal  
water  
flow  
gpm d  
5.1  
Condenser water  
Com- Nominal Water flow in gpm  
pressor pump conn. Tower City  
Nominal cooling  
capacity c in tons  
no pump 1 pump  
Amp draws g  
460/3/60 h  
HP  
hp  
2.0  
3.5  
hp  
1.0  
1.0  
in. NPT water e water f rated running  
2
3.5  
2.1  
3.6  
1.9  
3.4  
1.0”  
1.0”  
6.2  
10.5  
4.2  
7.2  
12.2  
16.4  
8.3  
11.8  
8.6  
c Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) tower water. Optional additional process  
pump hp (kW) reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Based on availability of 85ºF (29ºC) tower water at 25 psi (172.4 kPa/1.7 bars) minimum.  
f Based on availability of 70ºF (21ºC) city water at 25 psi (172.4 kPa/1.7 bars) minimum.  
g An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
h Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages.  
2 hp and 3.5 hp water-cooled portable chillers come standard with 2” (63 mm) swivel casters.  
Process  
Weights  
HP  
Compressor connections  
Dimensions in inches c  
Dry d  
lbs.  
333  
Shipping d Operating d e  
hp  
2.0  
3.5  
in. NPT  
1.0”  
1.0”  
height  
28.3”  
width  
22.0”  
22.0”  
depth  
41.7”  
41.7”  
lbs.  
363  
392  
lbs.  
383  
412  
2
3.5  
28.3”  
362  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply by 0.454 to calculate Kg.  
e Operating weight is with a full 6-gallon (22.7 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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5 hp and 7.5 hp Water-Cooled Portable Chillers  
Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
Nominal Com-  
water pres- Nom. Water flow in gpm  
flow sor pump conn. Tower City  
pump pump pump gpm d hp hp in. NPTwater ewater f rated running rated running  
Condenser water  
Power in amps g  
460/3/60 h  
HP  
no  
1
2
1 pump  
2 pumps  
5
7.5  
5.2  
7.1  
5.0  
6.9  
4.9  
6.8  
12.6  
17.0  
5.0  
7.5  
1.0  
1.0  
1.0”  
1.0”  
15.7  
21.3  
7.9  
10.7  
12.2  
16.4 11.8  
8.3  
13.1  
17.3 12.7  
9.2  
c Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) tower water. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Based on availability of 85ºF (29ºC) tower water at 25 psi (172.4 kPa/1.7 bars) minimum.  
f Based on availability of 70ºF (21ºC) city water at 25 psi (172.4 kPa/1.7 bars) minimum.  
g An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
h Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages.  
5 hp and 7.5 hp water-cooled chillers come standard with 4” (101 mm) swivel casters.  
Com-  
pressor  
hp  
Process connections, in. NPT  
no pump, 1 pump, no  
pump pumps no tank tank, to/from height width depth  
Dimensions  
in inches c  
Weights  
Dry d Ship. d Oper. d e  
1
2
lbs.  
637  
727  
lbs.  
787  
877  
lbs.  
970  
1,060  
5.0 1.5”/2.0 2.0”  
7.5 1.5”/2.0 2.0”  
1.5”  
1.5”  
1.5” / 2.0”  
1.5” / 2.0”  
44.0”  
44.0”  
34.0”  
34.0”  
54.7”  
54.7”  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply by 0.454 to calculate Kg.  
e Operating weight is with a full 20-gallon (76 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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10 hp and 15 hp Water-Cooled Portable Chillers  
Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
Nominal Com-  
water pres- Nom. Water flow in gpm  
flow sor pump conn. Tower City  
pump pump pump gpm d hp hp in. NPTwater ewater f rated running rated running  
Condenser water  
Power in amps g  
460/3/60 h  
HP  
no  
1
2
1 pump  
2 pumps  
10  
15  
10.7  
15.9  
10.3  
15.5  
10.2  
15.3  
25.7 10.0 2.0  
38.1 15.0 2.0  
1.5”  
2.0”  
32.2  
47.6  
16.1 22.5  
23.8 29.7  
16.7  
21.6  
24.2  
31.4  
18.4  
23.3  
c Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) tower water. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Based on availability of 85ºF (29ºC) tower water at 25 psi (172.4 kPa/1.7 bars) minimum.  
f Based on availability of 70ºF (21ºC) city water at 25 psi (172.4 kPa/1.7 bars) minimum.  
g An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
h Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages.  
10 hp and 15 hp water-cooled chillers come standard with 4” (101 mm) swivel casters.  
Com-  
pressor  
hp  
Process connections, in. NPT  
no pump, 1 pump, no  
Dimensions  
in inches c  
height width Depth  
Weights  
Dry d Ship. d Oper. d e  
1
2
Pump pumps no tank  
tank,  
lbs.  
lbs.  
lbs.  
to/from  
10.0  
15.0  
1.5”/3.02.0”/3.0  
2.0”/3.02.5”/3.0  
1.5”  
2.0”  
1.5” / 2.0”  
2.0” / 3.0”  
44.0”  
44.0”  
34.0”  
34.0”  
74.7”  
950 1,175  
1,282  
1,365  
74.7” 1,024 1,249  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply by 0.454 to calculate Kg.  
e Operating weight is with a full 40-gallon (151 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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20 hp, 25 hp, and 30 hp Water-Cooled Portable Chillers  
Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
Nominal Com-  
Condenser water  
Power in amps g  
capacity c tons  
water  
flow  
pres- Nom. Water flow in gpm  
sor pump conn. Tower City  
460/3/60 h  
HP  
no  
1
2
1 pump  
2 pumps  
pump pump pump gpm d  
hp  
hp in. NPTwater ewater f rated running rated running  
20  
25  
30  
21.0  
25.7  
31.8  
20.0  
24.7  
30.8  
19.6  
24.3  
30.4  
50.4  
61.7  
76.2  
2 @ 10 5.0  
2 @ 13 5.0  
2 @ 15 5.0  
2.0”  
2.0”  
2.5”  
61.7  
75.9  
93.9  
31.5 43.9  
38.6 55.9  
47.6 60.1  
34.7  
38.2  
45.3  
47.0  
59.0  
63.2  
37.8  
41.3  
48.4  
c Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) tower water. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Based on availability of 85ºF (29ºC) tower water at 25 psi (172.4 kPa/1.7 bars) minimum.  
f Based on availability of 70ºF (21ºC) city water at 25 psi (172.4 kPa/1.7 bars) minimum.  
g An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
h Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages.  
20 hp, 25 hp, and 30 hp water-cooled chillers come standard with 4” (101 mm) swivel casters.  
Com-  
Process connections, in. NPT  
Dimensions  
in inches c  
Weights  
Dry d Ship. d Oper. d e  
HP pressor 1 pump 2 Pump no pump, 1 pump, no  
hp  
to/from to/from no tank  
tank,  
height width depth  
lbs.  
lbs.  
lbs.  
to/from  
20  
25  
30  
2 @ 10 2” / 3” 2.5” / 3”  
2 @ 13 2” / 3” 2.5” / 3”  
2 @ 15 2” / 3” 2.5” / 3”  
2.0”  
2.0”  
2.0”  
2” / 3”  
2” / 3”  
2” / 3”  
45.3”  
45.3”  
45.3”  
34.0”  
34.0”  
34.0”  
100.7” 1,495 1,745  
100.7” 1,680 1,930  
100.7” 1,885 2,135  
2,161  
2,346  
2,551  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply by 0.454 to calculate Kg.  
e Operating weight is with a full 80-gallon (303 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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40 hp Water-Cooled Portable Chillers  
Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton  
(9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60  
Hz capacity flow rate must be maintained.  
Nominal cooling  
Nominal Com-  
water pres- Nom. Water  
flow  
pump pump pump gpm d hp  
41.0 39.5 39.1 98.4 40  
Condenser water  
Power in amps g  
capacity c tons  
flow in gpm  
City  
460/3/60 h  
HP  
no  
1
2
sor pump conn. Tower  
1 pump  
2 pumps  
hp in. NPT water e water f rated running rated running  
7.5 2.5” 123.0 61.5 81.9 63.1 85.0 66.2  
40  
c Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) tower water. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e Based on availability of 85ºF (29ºC) tower water at 25 psi (172.4 kPa/1.7 bars) minimum.  
f Based on availability of 70ºF (21ºC) city water at 25 psi (172.4 kPa/1.7 bars) minimum.  
g An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
h Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages.  
40 hp water-cooled chillers come standard with 4” (101 mm) swivel casters.  
Com-  
Process connections, in. NPT  
Dimensions  
in inches c  
Weights  
Dry d Ship. d Oper. d e  
pressor 1 pump 2 Pump no pump, 1 pump, no  
hp  
to/from to/from no tank  
2.5” / 3” 2.5” / 3” 2.5”  
tank,  
to/from  
2.5” / 3”  
height width depth  
lbs.  
lbs.  
lbs.  
40  
59.9”  
34.0”  
100.7” 2,680 2,930  
3,369  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight. Multiply by 0.454 to calculate Kg.  
e Operating weight is with a full 80-gallon (303 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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5 hp and 7.5 hp Remote Air-Cooled Portable Chillers  
Nominal operating parameters for remote air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm  
per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83.  
Nominal 60 Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
Nom. Com-  
water pres- Nom.  
Refrigeration  
connections  
in. dia. ODS  
Power in amps e  
460/3/60 f  
HP  
no  
1
2
flow  
sor pump  
1 pump  
2 pumps  
pump pump pump gpm d hp  
hp  
Discharge Liquid rated running rated running  
5
4.8  
6.6  
4.6  
6.4  
4.5  
6.3  
11.6  
15.7  
5.0  
7.5  
1.0  
5
5
12.2  
9.2  
13.1  
10.1  
/8”  
/8”  
7.5  
1.0  
7
5
16.2  
12.8  
17.3  
13.7  
/8”  
/8”  
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
f Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.  
Remote air-cooled portable chillers come standard with mounting rails. Remote air-cooled portable  
chillers are charged with 25 psi (172.4 kPa/1.72 bars) nitrogen for shipping purposes.  
Com-  
pressor  
hp  
Process connections, in. NPT  
no pump, 1 pump, no  
Dimensions  
in inches c  
height width depth  
Weights  
Dry d Ship. d Oper. d e  
1
2
pump pumps no tank  
tank,  
lbs.  
lbs.  
lbs.  
to/from  
5.0  
7.5  
1.5”  
1.5”  
2.0”  
2.0”  
1.5”  
1.5”  
1.5” / 2.0”  
1.5” / 2.0”  
40.9”  
40.9”  
34.0”  
34.0”  
54.7”  
54.7”  
597  
644  
748  
794  
930  
977  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight.  
e Operating weight is with a full 20-gallon (76 liter) reservoir tank of water.  
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10 hp and 15 hp Remote Air-Cooled Portable Chillers  
Nominal operating parameters for remote air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm  
per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83.  
Nominal 60 Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
Nom. Com-  
water pres- Nom.  
Refrigeration  
connections  
in. dia. ODS  
Power in amps e  
460/3/60 f  
HP  
no  
1
2
flow  
sor pump  
1 pump  
2 pumps  
pump  
9.9  
pump  
9.5  
pump gpm d hp  
hp  
2.0  
Discharge Liquid rated running rated running  
10  
15  
9.4  
23.8 10.0  
34.9 15.0  
1
5
22.5 18.2  
24.2  
19.9  
1 /8”  
/8”  
14.5  
14.1  
14.0  
2.0  
1
5
29.7 23.9  
31.4  
25.6  
1 /8”  
/8”  
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
f Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.  
Remote air-cooled portable chillers come standard with mounting rails. Remote air-cooled portable  
chillers are charged with 25 psi (172.4 kPa/1.72 bars) nitrogen for shipping purposes.  
Com-  
pressor  
hp  
Process connections, in. NPT  
no pump, 1 pump, no  
pump pumps no tank tank, to/from height width Depth lbs.  
Dimensions  
in inches c  
Weights  
Dry d Ship. d Oper. d e  
1
2
lbs.  
lbs.  
10.0  
15.0  
1.5”  
2.0”  
2.0”  
2.5”  
1.5”  
2.0”  
1.5” / 2.0”  
2.0” / 3.0”  
40.9” 34.0” 74.7”  
40.9” 34.0” 74.7”  
827  
870  
1,052  
1,095  
1,159  
1,202  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight.  
e Operating weight is with a full 40-gallon (151 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
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20 hp through 40 hp Remote Air-Cooled Portable Chillers  
Nominal operating parameters for remote air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm  
per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83.  
Nominal 60 Hz capacity flow rate must be maintained.  
Nominal cooling  
capacity c tons  
Nom. Com-  
water pres- Nom.  
Refrigeration  
connections  
in. dia. ODS  
Power in amps e  
460/3/60 f  
no  
1
2
flow  
sor  
hp  
pump  
1 pump  
2 pumps  
HP  
pump pump pump gpm d  
hp Discharge Liquid rated running rated running  
20  
19.4  
23.8  
29.2  
36.9  
18.4  
22.8  
28.2  
35.4  
18.0  
22.4  
27.8  
35.0  
46.5 2 @ 10  
57.2 2 @ 13  
70.2 2 @ 15  
5
3
7
7
7
43.9  
55.9  
60.0  
81.9  
37.6  
42.1  
50.4  
68.8  
47.0  
59.0  
63.2  
85.0  
40.7  
45.2  
53.5  
58.0  
1 /8”  
/8”  
/8”  
/8”  
25  
30  
40  
5
3
1 /8”  
5
3
1 /8”  
88.6  
40  
7.5  
5
1
1 /8”  
1 /8”  
c Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) ambient air. Optional additional process  
pump hp reduces chiller capacity by 0.2 tons per hp (0.703 kW ref. cap. per 0.746 kW pump power).  
d Based on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.  
e An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total  
chiller amperage, subtract the standard process pump amperage from the optional pump amperage (see Figure 1  
on page 16), and add it to the chiller rated or running amperage.  
f Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.  
Remote air-cooled portable chillers come standard with mounting rails. Remote air-cooled portable  
chillers are charged with 25 psi (172.4 kPa/1.72 bars) nitrogen for shipping purposes.  
Com-  
HP pressor 1 pump 2 Pump no pump, 1 pump, no  
hp  
Process connections, in. NPT  
Dimensions  
in inches c  
Weights  
Dry d Ship. d Oper. d e  
to/from to/from no tank tank, to/from height width depth lbs.  
lbs.  
lbs.  
20  
25  
30  
40  
2 @ 10 2” / 3” 2.5” / 3”  
2 @ 13 2” / 3” 2.5” / 3”  
2 @ 15 2” / 3” 2.5” / 3”  
2.0”  
2.0”  
2.0”  
2.5”  
2” / 3”  
2” / 3”  
2” / 3”  
43.3” 34.0” 100.7” 1,299  
43.3” 34.0” 100.7” 1,305  
43.3” 34.0” 100.7” 1,607  
43.3” 34.0” 100.7” 2,243  
1,549  
1,555  
1,857  
2,470  
1,965  
1,971  
2,273  
2,909  
40  
2.5” / 3” 2.5” / 3”  
2.5” / 3”  
c To convert to cm, multiply by 2.54. Add to height dimension based on mounting options.  
d Weight is for standard chiller. Some optional features will increase weight.  
e Operating weight is with a full 80-gallon (303 liter) reservoir tank of water.  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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Remote Condenser Assembly Models  
To convert inches to cm, multiply dimension by 2.54.  
Fan(s) d e f  
Remote Condenser  
Overall Dimensions  
Net Length Width Height Mtg. Discharge Liquid  
wt.  
Refrigeration g  
Connections Charge  
R-22  
Each  
Totals e f  
Air  
HP Dia.  
in.  
Motor  
Amps  
flow  
hp c  
460V Fans cfm h lbs.h ‘A’(in.) ‘B’(in) ‘C’(in.) ‘D’(in) ODS(in.) ODS(in.) lbs. g  
5
26 3/4 hp 1 ø  
2.4  
3.7  
3.7  
5.0  
1
2
2
3
2
2
3
4
6,450 260  
12,400 470  
13,700 510  
20,500 550  
23,000 840  
21,900 860  
49.8  
69.8  
43.0  
43.0  
43.0  
43.0  
45.5  
45.5  
45.5  
45.5  
40.5  
40.5  
40.5  
40.5  
50.0  
50.0  
50.0  
50.0  
40.0  
60.0  
80.0  
120.0  
108.0  
108.0  
i
1
7
7
3.6  
3.6  
1 /8  
/8  
7.5 26  
1
1
1
1
/3 hp 3 ø  
/3 hp 3 ø  
/3 hp 3 ø  
1 /8  
/8  
10  
15  
20  
25  
30  
40  
26  
26  
89.8  
3
1
4.6  
1 /8  
1 /8  
129.8  
125.0  
125.0  
5
1
6.4  
1 /8  
1 /8  
30 1 1/2 hp 3 ø 5.9  
30 1 1/2 hp 3 ø 5.9  
30 1 1/2 hp 3 ø 9.4  
30 1 1/2 hp 3 ø 12.9  
5
5
10.0  
16.0  
24.0  
29.0  
1 /8  
1 /8  
5
5
1 /8  
1 /8  
34,800 1,280 180.0  
46,400 1,690 235.0  
1
1
2 /8  
2 /8  
i
1
1
2 /8  
2 /8  
c ø represents electrical phase; all motors are 1,140 rpm. Multiply hp by 0.746 to convert to kW.  
d All first fan motors (Header Side) are ¾ hp (0.56 kW) single phase variable speed.  
e Multiply 460V amperages by 2.0 for 208-230V amperages.  
f Multiply 460 V amperages by 0.8 for 575 V amperages.  
g Refrigeration charge is for remote condenser only!  
h To convert cfm to cmh, multiply by 1.699. To convert lbs. to Kg, multiply by 0.454.  
i See drawing above.  
2-40 HP Portable Chillers  
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7-4 Pump Curves, Flow, and Pressure Considerations  
60 Hertz Pump Curves  
DWG. No. A0554823  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
58 of 70  
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50 Hertz Pump Curves  
DWG. No. S0554823  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
59 of 70  
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Evaporator Water Pressure Drop Tables  
Note:  
A recirculation pump is required for flows greater than the maximum or  
less than the minimum indicated.  
Note:  
Process flow less than or greater than the flow rates shown below requires  
a recirculation pump.  
Pressure drops in ΔP, psig and kPa  
2 HP  
3.5 HP  
5 HP  
7.5 HP  
Flow  
gpm lpm  
4.06 15.4  
6.01 22.8  
8.02 30.4 11.5  
Flow  
gpm lpm  
8.03 30.4  
Flow  
gpm lpm  
Flow  
gpm lpm  
Δ P  
Δ P  
Δ P  
Δ P  
psig  
3.5  
7.0  
kPa  
24.1  
psig  
4.0  
6.5  
kPa  
27.6  
44.8  
69.  
psig  
1.5  
2.2  
4.7  
7.3  
kPa  
10.5  
14.8  
32.1  
50.2  
psig  
2.3  
2.9  
5.0  
6.9  
9.6  
kPa  
16.1  
20.1  
34.5  
47.4  
65.9  
87.8  
10.0  
12.0  
18.0  
24.0  
37.9  
45.4  
68.1  
90.8  
12.0  
16.0  
20.0  
24.0  
45.4  
60.6  
75.7  
90.8  
48.3 10.00 37.9  
79.3 12.00 45.4 10.0  
10.00 37.9 18.0 124.1 14.00 53.0 13.0  
89.6  
16.00 60.6 18.0 124.1  
28.0 106.0  
33.0 124.9 12.7  
10 HP  
15 HP  
20 HP  
25 HP  
Flow  
Flow  
gpm lpm  
22.0  
83.3  
30.0 113.6  
Flow  
gpm lpm  
30.0 113.6  
Flow  
gpm  
Δ P  
Δ P  
Δ P  
Δ P  
psig  
4.7  
8.28 57.1  
kPa  
32.6  
psig  
4.5  
kPa  
31.3  
51.7  
85.2  
lpm  
psig  
4.0  
4.0  
5.0  
6.0  
6.5  
kPa  
27.6  
27.6  
34.5  
41.4  
44.8  
gpm  
lpm  
psig  
5.5  
5.8  
6.0  
8.5  
kPa  
37.9  
40.0  
41.4  
58.6  
40.0 151.4  
45.0 170.3  
50.0 189.3  
52.0 196.8  
55.0 208.2  
55.0 208.2  
58.0 219.5  
61.0 230.9  
70.0 264.9  
40.0 151.4  
7.5  
38.0 143.8 12.91 89.0  
46.0 174.1 16.77 115.6  
50.0 189.3 20.00 137.9  
30 HP  
50.0 189.3 12.4  
60.0 227.1 17.8 122.8  
70.0 264.9 24.2 166.6  
40 HP  
Flow  
gpm lpm  
72.0 272.5  
75.0 283.9  
80.0 302.8  
85.0 321.7  
Flow  
gpm lpm  
44.7 169.2  
58.5 221.4  
70.9 268.3  
81.6 308.8  
Δ P  
Δ P  
psig  
6.0  
6.5  
8.0  
9.5  
kPa  
41.1  
44.8  
55.2  
65.5  
psig  
2.0  
3.4  
4.9  
6.3  
kPa  
13.8  
23.4  
33.8  
43.5  
71.0  
105.7 400.0 10.3  
Note:  
These pressure drop values are valid for single- and no-pump portable  
chillers.  
Calculating Chiller Nominal Flow and Pressure to Process  
Flow rate: Obtain the flow reading from the appropriate pump curve.  
Pressure: Obtain a corresponding pressure reading from the pump curve you selected,  
then subtract the one-pump pressure drop listed in the above table using the  
appropriate chiller hp and flow rate.  
For two-pump (Process/Recirc) chillers, do not subtract pressure drop from table above  
for process pump.  
2-40 HP Portable Chillers  
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Evaporator Flow and Pressure Considerations  
Modelc  
-A, 2 hp  
Design flow  
Standard pump power  
To Process pressure  
Design Δ P  
psig  
gpm  
lpm  
17.5  
29.9  
kPa  
30.4  
33.7  
13.7  
19.0  
35.2  
41.8  
49.0  
55.9  
72.4  
56.5  
hp  
1
1
1
1
2
2
5
kW  
psi  
kPa  
bars  
4.6  
7.9  
4.4  
4.9  
2.0  
2.8  
5.1  
6.1  
7.1  
8.1  
10.5  
8.2  
0.746  
0.746  
0.746  
0.746  
1.492  
1.492  
3.73  
34.1  
33.0  
34.9  
32.7  
43.4  
38.0  
54.0  
52.0  
47.5  
55.0  
235.3  
227.5  
240.8  
225.7  
299.0  
262.1  
372.3  
358.5  
327.5  
379.2  
2.4  
2.3  
2.4  
2.3  
3.0  
2.6  
3.7  
3.6  
3.3  
3.8  
-A, 3.5 hp  
-A, -R, 5 hp  
-A, -R, 7.5 hp  
-A, -R, 10 hp  
-A, -R, 15 hp  
-A, -R, 20 hp  
-A, -R, 25 hp  
-A, -R, 30 hp  
-R 40 hp  
11.6  
15.7  
23.8  
34.9  
46.5  
57.2  
70.2  
88.6  
43.8  
59.6  
90.1  
132.1  
175.9  
216.4  
265.6  
335.4  
5
3.73  
5
3.73  
7.5  
5.59  
-W 2 hp  
-W 3.5 hp  
-W 5 hp  
-W 7.5 hp  
-W 10 hp  
-W 15 hp  
-W 20 hp  
-W 25 hp  
-W 30 hp  
-W 40 hp  
5.1  
8.6  
19.1  
32.7  
47.7  
64.5  
97.4  
144.1  
190.8  
233.7  
288.5  
372.4  
5.7  
6.0  
2.3  
3.1  
6.3  
7.0  
8.8  
9.0  
10.8  
8.2  
39.1  
41.2  
16.00  
21.4  
43.3  
48.1  
60.3  
62.1  
74.1  
56.5  
1
1
1
1
2
2
5
5
5
0.746  
0.746  
0.746  
0.746  
1.492  
1.492  
3.73  
3.73  
3.73  
5.59  
32.9  
31.7  
34.3  
32.0  
41.4  
35.5  
52.0  
49.0  
43.0  
55.0  
226.6  
218.5  
236.2  
220.3  
285.3  
244.4  
358.5  
337.9  
296.5  
379.2  
2.3  
2.2  
2.4  
2.2  
2.9  
2.4  
3.6  
3.4  
3.0  
3.8  
12.6  
17.0  
25.7  
38.1  
50.4  
61.7  
76.2  
98.4  
7.5  
c -A – Air-cooled; -W – Water-cooled; -R – Remote Air-cooled.  
Pressure is proportional to flow. Recirculation pump is required for values exceeding  
those listed.  
Recirculation Pump Specifications  
HP  
Recirc. power  
Flow Rate  
Δ pressure  
hp  
kW  
gpm  
13.0  
17.0  
26.0  
38.0  
50.0  
63.0  
76.0  
98.0  
lpm  
49.2  
psi  
2.3  
3.1  
6.3  
7.0  
8.8  
9.0  
10.8  
8.2  
kPa  
5
0.75  
0.75  
0.75  
0.75  
2.0  
2.0  
2.0  
0.373  
0.373  
0.595  
0.595  
1.492  
1.492  
1.492  
2.238  
16.0  
21.4  
43.3  
48.0  
60.3  
62.0  
74.1  
56.5  
7.5  
10  
15  
20  
25  
30  
40  
64.3  
98.4  
143.8  
189.2  
238.4  
287.6  
370.9  
3.0  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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7-5 Remote Air-Cooled Chiller Configurations  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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7-6 Typical Ductwork for Air-Cooled Chillers  
*See specification tables on pages 45-48 for air flow and pressure capacities.  
When locating your air-cooled portable chiller and designing its ductwork, note any potential high  
temperature conditions when discharging into your building and any negative pressures with the building  
when discharging air outside.  
Notes: Customer use of ductwork requires the high pressure fan option for models 5 through 15 hp. •  
Allow 30” (77 cm) minimum clearance around the chiller footprint to facilitate free passage of cooling air  
and service accessibility Size the ductwork for maximum capacity Support ductwork from the  
building structure, not off of the chiller Back draft damper to outside must be closed at all times when  
fan/blower is not operating Chillers with dual fans/blower must have a back draft damper on the cycling  
fan/blower to prevent recirculation of hot discharge air Chillers are designed to operate at a condensing  
entering air temperature of 60ºF (16ºC) minimum Maximum total static pressure drop external to the  
chiller must not exceed 0.30” WG (75 pa)  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
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7-7 Piping Diagrams  
Central and Gravity Return Piping with Standpipe Diagram  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
64 of 70  
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Typical Piping Schematic, 2 and 3 1/2 hp Models  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
65 of 70  
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Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
66 of 70  
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Typical Piping Schematic, 5 hp through 40 hp, Two-Pump Models  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
67 of 70  
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Typical Piping Schematic, 5 hp through 40 hp, No-Pump Models  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
68 of 70  
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Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
69 of 70  
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7-8 Electrical Schematics  
Typical Electrical Subpanel  
Please refer to your owner’s information packet for more details regarding your specific  
unit.  
2-40 HP Portable Chillers  
Chapter 7: Appendix  
70 of 70  
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DWG: A0562434  

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