SMC-050 to SMC-150 Series 0.5 to 1.5 hp Portable Chillers Operation and Installation Manual Sterling, Inc./Sterlco P. O. Box 245018 5200 West Clinton Avenue Milwaukee, WI 53224-9518 Tel (414) 354-0970 Fax (414) 354-6421 Part No. A0544325 Bulletin No. SC2-615.
Sterling/Sterlco is committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. © Copyright Sterling/Sterlco and Sterling, Inc. 2003 All rights reserved. Effective 7/30/2003 Part No. A0544325 Bulletin No. SC2-615.
Safety Considerations SMC Series Chillers are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating or maintaining this equipment, use good judgment and follow these safe practices: ; ; ; ; ; ; ; ; ; ; ; Follow all SAFETY CODES. Wear SAFETY GLASSES and WORK GLOVES.
Table of Contents 1 General Information ................................................. 7 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 2 Chiller Installation .................................................. 13 2-1 2-2 2-3 2-4 2-5 3 Electrical Connections Process Water Connections SMC Condenser Air Supply Water Reservoir Overhead Process Considerations Sequence of Operation..........................................
Table of Contents 4 Startup Checklists.................................................. 23 4-1 4-2 4-3 5 Microprocessor Control ........................................ 25 5-1 5-2 5-3 6 Indicator Lights Switches Routine Maintenance ............................................. 29 7-1 7-2 8 Introduction Setting the Process Water Temperature Setting the Alarm Value Optional Graphic Panel .........................................
Charts and Figures 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Page 6 SMC050A Process Pump Curves 10 SMC100A Process Pump Curves 10 SMC150A Process Pump Curves 11 SMC Series Chiller Specifications 12 Ethylene Glycol Curve 15 Overhead Piping 16 SMC Component Identification 19 Piping Schematic — 1 Pump with Reservoir 20 Piping Schematic — 1 Pump without Reservoir 21 Piping Schematic — No Pump, No Reservoir 22 SMC Water Circuit Pressure Drop Table 24 SMC Control 26 Optional Graphic Pane
1 1-1 General Information Introduction SMC Series Water Chillers are reliable, accurate, and easy-to-use air cooled chillers designed for use with water/glycol. Standard range of operation is 30°F (-1°C) to 65°F (18°C). A crankcase pressure regulating valve option is available for processes requiring a leaving water temperature of up to 75°F (24°C). SMC models are available in ½ hp (373 W), 1 hp (746 W), and 1½ hp (1,118 W) models and have an internal six gallon (23 liter) reservoir.
1-4 Available Options SMC Series Chillers are available with options that tailor the unit to your requirements. Some are factory installed, some can be retrofitted in the field. Consult your local Sterlco Sales Representative. Some of these options are: Special Pumps Special pump options are available for greater pressure and flow rates. Bronze and stainless steel wetted surface standard flow pumps ranging from 30 psi (207 kPa) to 60 psi (414 kPa) are available.
1-6 In the Event of Shipping Damages Important! According to the contract terms and conditions of the Carrier, the responsibility of the Shipper ends at the time and place of shipment. The Carrier then assumes full responsibility of the shipment. ; Notify the transportation company’s local agent. ; Hold the damaged goods and packing material for the examining agent’s inspection. Do not return any goods to Sterlco before the transportation company inspection and authorization.
1-9 Returns Important! Do not return any damaged or incorrect items until you receive shipping instructions from STERLCO. Figure 1 SMC050A Process Pump Curves SMC050A - PROCESS PUMPS SELECTIONS TOTAL HEAD MTRS PSI FEET 49 69 160 37 52 120 24 35 80 12 18 40 U. S. GALLONS PER MINUTE LITRES PER MINUTE 60 HERTZ PUMP CURVE BZ050A BZ050B BZ050C 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 1.5 3.0 4.5 6.1 7.6 9.1 10.6 12.1 13.6 15.1 16.7 18.
Figure 3 SMC150A Process Pump Curves SMC150A - PROCESS PUMPS SELECTIONS TOTAL HEAD MTRS PSI FEET 49 69 160 37 52 120 24 35 80 12 18 40 60 HERTZ PUMP CURVE BZ150B U. S. GALLONS 2.0 PER MINUTE LITRES 7.6 PER MINUTE BZ150C BZ150A 2.4 2.8 3.2 3.6 4.0 4.4 4.8 5.2 5.6 6.0 6.4 6.8 9.1 10.6 12.1 13.6 15.1 16.7 18.2 19.7 21.2 22.7 24.3 25.8 CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS Do not extrapolate pump curves.
Figure 4 SMC Series Chiller Specifications Optional gauge package Optional gauge package Power cable entrance, either side Side cover handle Drain plug (3/4" NPT) PUMP PRESSURE Mini Chiller No Flow indicator (for pumpless units only) Sight glass PC Series To Process (3/4" NPT) Portable Chiller ON PUMP ON COMPRESSOR ON LOW REFRIGERANT PRESSURE HIGH REFRIGERANT PRESSURE POWER OFF A0537868 NO FLOW 34" 18 7/16" From Process 13 7/16" (3/4" NPT) 20" 26" Front View Right Side View Model Number
2 2-1 Chiller Installation Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms. See Figure 4 on Page 12 for total running amps. Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the main power terminal in the chiller’s electrical enclosure. ; Electrical connections must comply with all applicable electrical codes. ; The chiller must be grounded in accordance with NEC Article 250.
Process Water Bypass All SMC chillers have an internal bypass device (patent pending). If the process flow becomes blocked during chiller operation, this component allows water to flow through the chiller. This protects the chiller from freeze-up, excessive pressures, and pump damage, and allows other safety features to remain effective. 2-3 SMC Condenser Air Supply SMC chillers use the surrounding air to cool the condenser. ; Condenser air entering the SMC unit should be at least 65°F (18°C).
; A corrosion inhibitor suitable for the materials in the system should be added to the glycol/water solution. ; If straight water use is desired, contact the Sterlco Engineering Department. ; The six gallon (23 liter) reservoir is not designed to withstand water pressure above 5 psi (34 kPa). ; The fill opening and vent line must be vented to the atmosphere for proper operation.
2-5 Overhead Process Considerations If your application has chilled water or process piping above the reservoir fill and vent level, install a standpipe to a point 1’ (30 cm) above the highest point in the system. In applications where the process or its piping is 15 feet (4.6 m) or more above the reservoir, you must take steps to prevent over-pressurization of the reservoir. This condition can occur on system shutdown when the water in the system drains into the reservoir.
3 Sequence of Operation Important! • The SMC unit has a leaving water temperature range of 30°F (-1°C) to 65°F (18°C). Do not attempt to run the SMC unit outside this temperature range or damage to the unit may occur. • When operating the SMC unit between 30°F (-1°C) and 40°F (5°C), you must use a solution of 75% water and 25% industrial-grade ethylene glycol with a suitable corrosion inhibitor to protect the SMC unit from freeze-up. See Figure 5 on Page 17 for more information.
3-3 High Pressure Cutout The high pressure cutout is an electro-mechanical safety feature that opens the control circuit if the system condensing pressure exceeds a safe level. The chiller will automatically restart when the pressure drops back to an acceptable level. Model SMC050A SMC100A SMC150A Cuts out if condensing pressure exceeds: 275 psi (1,897 kPa) 275 psi (1,897 kPa) 400 psi (2,759 kPa) Important! Call a refrigeration service technician to analyze the problem if high pressure recurs.
Figure 7 SMC Component Identification SMC Series Chillers Page 19
Figure 8 Piping Schematic — 1 Pump with Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Suction Line Expansion valve Evaporator Filter Drier Sight glass Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Equalizing line Power element Refrigeration access valve Temperature probe TC High pressure control S Optional pressure gauge P To Process Low pressure control By
Figure 9 Piping Schematic — 1 Pump without Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Suction line Expansion valve Evaporator Equalizing line Sight glass Filter drier Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Power element Refrigeration access valve Temperature probe High pressure control TC P S Low pressure control Optional CPR valve Compressor Refr
Figure 10 Piping Schematic — No Pump, No Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Suction line Expansion valve Evaporator Sight glass Filter drier Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Equalizing line Power element Refrigeration access valve Optional pressure gauge Temperature Probe High pressure control TC P S Low pressure control To Process B
4 Startup Checklists 4-1 Introduction Follow the check lists below for the startup of your new chiller. These lists assume the installation information elsewhere in this manual has been read and followed. New chillers should be started up and checked by a qualified refrigeration service technician. 4-2 SMC Pre-Startup Checklist 1. Check the shipping papers against the serial tag to be sure chiller size, type and voltage is correct for the process that will be controlled. 2.
Figure 11 SMC Water Circuit Pressure Drop Table Model SMC050A SMC100A SMC150A Page 24 Gallons per minute 2.0 2.4 3.6 4.8 2.0 2.4 3.6 4.8 2.0 2.4 3.6 4.8 ∆P (psig) 2.5 4.0 7.5 12.5 2.5 2.5 3.0 5.0 2.5 2.5 3.0 3.
5 5-1 Microprocessor Control Introduction Standard SMC Series chillers use a microprocessor based controller. The controller is a modular, self-contained unit that can slide from its mounting housing. It is factory set and adjusted; no field adjustment to the internal controls is necessary. 5-2 Setting the Process Water Temperature • Press • Press or temperature. until the SP indicator lights.
Figure 12 SMC Control Lights when the display shows the alarm value Lights if Process Temperature is above the set point C° ON Process temperature is 10° Lights when Process Temp is or more above the set point within +/- 1% of the full scale Lights if Process Temperature is below the set point Compressor On indicator SP AL Lights when the display AL Increases the process set point or alarm value Lowers the process set point or alarm value shows the process set point OMRON E5CS Scroll -- St
6 Optional Graphic Panel 6-1 Indicator Lights PUMP ON (green) This indicator is lit when the pump runs. COMPRESSOR ON (green) This indicator is lit when the compressor operates. HIGH REFRIGERANT PRESSURE (red) This indicator lights if the condensing pressure exceeds a safe level. The chiller goes to Idle mode until the high refrigerant pressure cutout resets. The light then goes out and the chiller automatically restarts. Call a qualified refrigeration service technician for service.
Figure 13 Optional Graphic Panel SMC Series ON ON PUMP ON AL O RO E5CS Portable Chiller COMPRESSOR ON LOW REFRIGERANT PRESSURE HIGH REFRIGERANT PRESSURE POWER OFF A0537868 Page 28 SMC Series Chillers
7 Routine Maintenance 7-1 Lubrication Every three months, grease all fan motors and pump motors that do not have permanently sealed bearings. Remove grease relief plug (motors only) before adding grease. Failure to do so may result in dislodging the bearing grease retainer, eventually causing bearing failure. Compressors are hermetically sealed; no oiling is required. 7-2 Condenser Maintenance Dirty condenser heat exchange surfaces reduce system capacity. Brush or vacuum light dirt accumulations.
Figure 15 Typical SMC Wiring Schematic 1C 1L1 1T1 1L2 1MTR Pump 2MTR Compressor 3MTR Fan 1T2 2C 1L1 2T1 1L2 2T2 3T1 Earth ground 3T2 Remote interlock by others 1L2 1L1 230V Control power ON/OFF 1S-1LT 1T Jumper 1 1FU X1 1 115V 2 G 3 1 1S-1LT R G 4 1 1PS "Hi Refrig Pres" 3LT R G 5 1 2PS G 1 7 1CNTL 1 8 1 9 1 10 4 1 5 1 Jumper 1 2 1 3 1 2LT "Pump On" 4LT 61 Condensing unit contactor 2C G 1 6 "Power On" Pump starter 1C "Low Refrig Pres" Subpanel ground
Figure 16 SMC Wiring Schematic for Chillers with No Pump or Reservoir 1C 1L1 1L1 Compressor 2MTR Fan 2T1 Remote interlock by others Earth ground 1MTR 1T2 1L2 1L2 1T1 2T2 230V Control power ON/OFF 1T Jumper 1S-1LT 1 1S 1FU 2 115V X1 2 G 1 3 "Low Refrig Pres" 3LT R "No Flow" R 4 1FLS 2LT 5 5 1PS 1S-1LT Subpanel ground "Power On" "High Refrig Pres" 4LT R 6 2PS 7 Condensing unit contactor 1C G 5LT "Compressor On" 2 6 7 8 9 Jumper 1 (+) YEL 2 3 Legend 10 Custo
- Notes - Page 32 SMC Series Chillers
8 Troubleshooting Guide Problem Possible cause No power. Chiller will not run. Wrong voltage supplied to the chiller. Defective on/off switch. Control circuit fuse blown. Pump runs, compressor cycles at short intervals. The leaving water temperature is too high. Defective control transformer. No process load on the chiller. Refrigerant is low. Refrigerant is low. Improper water/glycol solution. Solution Check main disconnect fuses, wiring, and power lead to the unit.
Problem Possible cause Refrigerant is low. Pressure switch contacts are open. Pump runs, compressor will not. Refrigerant high pressure cutout switch contacts are open. Defective fan motor. Compressor internal overload is open. Allow time to cool and reset. Unit runs continuously, but not enough cooling power. Page 34 Broken wire in the compressor control circuit. Restricted condenser airflow. Unit low on refrigerant. Inefficient compressor. Unit undersized for application.
Figure 17 SMC Spare Parts List Part number Description A0537868 SMC graphic A0537899 BZ pressure gauge A0534584 Red neon graphic light * A0534586 Green neon graphic light * A0500857 2” swivel casters A0534269 1/16 DIN digital temperature controller A0537955 Process water flow switch A0533873 Thermocouple, 8’ A0539409 150 VA transformer A0103778 Rubber feet A0537900 Tank sight glass assembly A0537908 Handles A0537915 SMC050A-SMC100A low refrigerant pressure switch A0543063 SMC150A low refrigerant pressure sw
Service Notes Page 36 SMC Series Chillers
Service Notes SMC Series Chillers Page 37
Parts Department Call toll-free 7am–6pm CST [800] 783-7835 or call [414] 354-0970 The Sterling/Sterlco Parts Department at Sterling, Inc. is ready to provide the parts to keep your systems up and running. Sterling/Sterlco replacement parts ensure operation at design specifications. Please have the model and serial number of your equipment when you call. Consult the Customer Parts List included in your information packet for replacement part numbers.