Manuale d’uso / di manutenzione del prodotto A0554832 del fabbricante HP
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2–40 hp Portable Chillers Part N u m b er: A055483 2 Bulletin Number: SC2-610C.8 Effective: 11/01/03 Write Down Your Serial Numbers Here For Future Reference: _________________________ _____________.
2-40 HP Portable Chillers ii Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check the equipment for any damage that might have occu rred in transit, such as broken or loose wiring and components, loose hardware and mounting screws, etc.
2-40 HP Portable Chillers iii Table of Contents CHAPTER 1: SAFETY ................................................................. 6 1-1 How to Use This Manual ..........................................................................................
2-40 HP Portable Chillers iv 3-11 Initial Start-Up........................................................................................................... .2 8 CHAPTER 4: OPERATION ........................................................ 29 4-1 Panel Buttons, Indicator Lights, and Switches .
2-40 HP Portable Chillers v Flow and Pressure Considerations ..................................................................... 61 Recirculation Pump Specifications ...................................................................... 61 7-5 Remote Air-Cooled Chiller Configurations .
2-40 HP Portable Chillers Chapter 1: Safety 6 of 78 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference fo r installing, operating, and maintaining your equipment. The purpose is to assist you in appl ying efficient, pr oven techniques that enhance equipment productivity.
2-40 HP Portable Chillers Chapter 1: Safety 7 of 78 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operated within design specifications, followi ng national and local safety codes.
2-40 HP Portable Chillers Chapter 2: Functional Description 8 of 78 Chapter 2: Functional Description 2-1 Models Covered in This Manual This manual provides operation, installation, an d maintenance instructions for air- and water- cooled portable chillers.
2-40 HP Portable Chillers Chapter 2: Functional Description 9 of 78 2-2 General Description Our portable chillers are reliable, accurate, a nd 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.
2-40 HP Portable Chillers Chapter 2: Functional Description 10 of 78 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.
2-40 HP Portable Chillers Chapter 2: Functional Description 11 of 78 Electrical Features • Fully accessible NEMA 12-style electrical control enclosure • Single-point power and ground connection .
2-40 HP Portable Chillers Chapter 2: Functional Description 12 of 78 • Three year limited controller warranty 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.
2-40 HP Portable Chillers Chapter 2: Functional Description 13 of 78 Low Pressure Cutout This electro-mechanical cutout device opens th e compressor control circuit if refrigeration system compressor suction pressure drops below 15 psi. It automatically resets when refrigerant suction pressure reaches 30 psi.
2-40 HP Portable Chillers Chapter 2: Functional Description 14 of 78 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.
2-40 HP Portable Chillers Chapter 2: Functional Description 15 of 78 Stainless Steel Reservoir. 5 hp to 30 hp models only (Standard on 35 hp and 4 0 hp models).
2-40 HP Portable Chillers Chapter 2: Functional Description 16 of 78 Figure 1: Optional Pump Amperages Voltage Construction HP Full Load Amps Bronze Turbine .75 5.4 16 . 4 1.5 7.5 29 . 6 208-230/1/60 SS 3 12.7 Bronze Turbine .75 1.5 11 . 8 1.5 2.3 23 .
2-40 HP Portable Chillers Chapter 3: Installation 17 of 78 Chapter 3: Inst allation 3-1 Uncrating 2 hp to 5 hp models are shipped m ounted on a skid, enclosed in a plastic wrapper, and contained in a cardboard box. 7.5 to 40 hp m odels are shipped mounted on a skid, enclosed in a plastic wrapper, and open-crated on all four sides and top.
2-40 HP Portable Chillers Chapter 3: Installation 18 of 78 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.
2-40 HP Portable Chillers Chapter 3: Installation 19 of 78 3-7 Condenser Considerations Water-Cooled Chiller Condensers Water-cooled portable chillers can use city wate r or tower water as a cooling medium. Make sure that all external piping and connections supplying an d discharging water to and from the condenser are full size.
2-40 HP Portable Chillers Chapter 3: Installation 20 of 78 Remote Air-Cooled Chiller Condensers Remote air-cooled portable chillers are shippe d with nitrogen holding charge and a full charge of oil (excluding the amount needed for field piping). The rem ote air condenser is shipped with a dry air charge.
2-40 HP Portable Chillers Chapter 3: Installation 21 of 78 System Configuration. The system can be configured in any of the arrangements shown on page 62 of the Appendix. The configuratio n and distance between the chiller and the condenser affects pipe size, refrigerant charge, oil return, and oil charge.
2-40 HP Portable Chillers Chapter 3: Installation 22 of 78 Figure 2: Equivalent Length in Feet for Valves and Fittings Line Size Inches OD Globe Valve Equivalent Ft Angle Valve Equivalent Ft Short Radius Elbow Equivalent Ft Long Radius Elbow Equivalent Ft 1/2” 43 15 1.
2-40 HP Portable Chillers Chapter 3: Installation 23 of 78 Refrigerant Charge Determination. The approximate amount of re frigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller.
2-40 HP Portable Chillers Chapter 3: Installation 24 of 78 3-8 Checking Motor Direction All of our portable chillers have their moto r 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.
2-40 HP Portable Chillers Chapter 3: Installation 25 of 78 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 fre ezing.
2-40 HP Portable Chillers Chapter 3: Installation 26 of 78 Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe r ce n t G ly c ol C u r v e s f or Fr e e ze P r ot e c tio n -60.0 -50.0 -40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 0.0 10.0 20.
2-40 HP Portable Chillers Chapter 3: Installation 27 of 78 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, sole noid valve and 1/2” NPT city water make-up connection) is factory installed.
2-40 HP Portable Chillers Chapter 3: Installation 28 of 78 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 cont rolled. Portable chillers are built with a voltage specific compressor and cannot be re-wired for an alternate voltage.
2-40 HP Portable Chillers Chapter 4: Operation 29 of 78 Chapter 4: Operation 4-1 Panel Buttons, Indicator Lights, and Switches Microprocessor Controllers Standard chillers use a microprocessor-based PI D controller. These controllers are modular, self-contained units that can slide from their mounting housing.
2-40 HP Portable Chillers Chapter 4: Operation 30 of 78 Indicator Name Description SUB1 SUB 1 LED The orange SUB1 LED lights when the process temperature is two degrees or more below the “To Process” setpoint.
2-40 HP Portable Chillers Chapter 4: Operation 31 of 78 Figure 7: Typical Portable Ch iller Microprocessor Controllers PV SV OUT1 OUT2 MANU STOP RMT AT SUB1 AT E5CK OMRON SP T MADE I N U .
2-40 HP Portable Chillers Chapter 4: Operation 32 of 78 Graphic Panel (See Figure 8 on Page 32. ) Indicator Name Description Compressor On Light The Compressor On light turns on whenever the compressor is operating.
2-40 HP Portable Chillers Chapter 4: Operation 33 of 78 Indicator Name Description Low Water Flow/Pressure Light 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.
2-40 HP Portable Chillers Chapter 4: Operation 34 of 78 Figure 8: Typical Graphic Panels (With E5CK Controller) (With Sterlco 2000 Controller) ON OFF CONTROL POWER A0554705 SILENCE ALARM COMPRE SSOR O.
2-40 HP Portable Chillers Chapter 4: Operation 35 of 78 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.
2-40 HP Portable Chillers Chapter 4: Operation 36 of 78 4-6 Programming the Electronic High/Low Thermostat The thermostat control is located in the chiller enclosure. The control has three control ke ys and a one-line, four-character LCD display. The thermostat control has a lockout slide switch to prevent tampering by unauthorized personnel.
2-40 HP Portable Chillers Chapter 4: Operation 37 of 78 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 Use the Up Arrow and Down Arrow keys to toggle between Fahrenheit and Celsius.
2-40 HP Portable Chillers Chapter 5: Maintenance 38 of 78 Chapter 5: Maintenance 5-1 Lubrication Grease all blower bearings, fan and blower motors, and pump m otors that do not have permanently sealed bearings.
2-40 HP Portable Chillers Chapter 5: Maintenance 39 of 78 5-3 Maintaining the Condenser Dirty condenser heat exchange surfaces reduce syste m capacity and efficiency. Air- and Remote Air-Cooled Chillers Brush or vacuum light dirt accumulations off the alum inum condenser fins.
2-40 HP Portable Chillers Chapter 5: Maintenance 40 of 78 5-6 Preventative Maintenance Service Follow a systematic preventive maintenance pr ogram 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.
2-40 HP Portable Chillers Chapter 6: Troubleshooting 41 of 78 Chapter 6: T r oubleshooting Problem Possible cause Solution No power. Check main disconnect, fuses, wi ring, and power lead to unit. Wrong voltage supp lied to unit. Voltage m ust be within plus or m inus 10% of nameplat e rating.
2-40 HP Portable Chillers Chapter 6: Troubleshooting 42 of 78 Problem Possible cause Solution Water/glycol mixture i nadequate for process. Make sure t hat the wate r/glycol m ixture protection is right for the process. Defective or improperly set High/Low thermostat.
2-40 HP Portable Chillers Chapter 7: Appendix 43 of 78 Chapter 7: Appendix 7-1 Warranty We warrant all of our equipment to be free fro m defects in workmanship and material when used under recommended conditions.
2-40 HP Portable Chillers Chapter 7: Appendix 44 of 78 7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3183 or call [414] 354-0970 , Fax [414] 354-6421 The ACS Custo.
2-40 HP Portable Chillers Chapter 7: Appendix 45 of 78 7-3 Drawings and Specifications 2 hp and 3 1/2 hp Air-Cooled Portable Chillers Nominal operating parameters for air-coo led models are 50 ºF (10ºC) leaving water temperatur e at 2.4 gpm per ton (9.
2-40 HP Portable Chillers Chapter 7: Appendix 46 of 78 5 hp and 7.5 hp Air-Cooled Portable Chillers Nominal operating parameters for ai r-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35º C) ambient air.
2-40 HP Portable Chillers Chapter 7: Appendix 47 of 78 10 hp and 15 hp Air-Cooled Portable Chillers Nominal operating parameters for air-coo led models are 50 ºF (10ºC) leaving water temper ature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air.
2-40 HP Portable Chillers Chapter 7: Appendix 48 of 78 20 hp, 25 hp, and 30 hp Air-Cooled Portable Chillers Nominal operating parameters for air-coo led models are 50 ºF (10ºC) leaving water temperatur e at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air.
2-40 HP Portable Chillers Chapter 7: Appendix 49 of 78 2 hp and 3.5 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50 ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water.
2-40 HP Portable Chillers Chapter 7: Appendix 50 of 78 5 hp and 7.5 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50 ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water.
2-40 HP Portable Chillers Chapter 7: Appendix 51 of 78 10 hp and 15 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50 ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water.
2-40 HP Portable Chillers Chapter 7: Appendix 52 of 78 20 hp, 25 hp, and 30 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50 ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water.
2-40 HP Portable Chillers Chapter 7: Appendix 53 of 78 35 hp and 40 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50 ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water.
2-40 HP Portable Chillers Chapter 7: Appendix 54 of 78 5 hp and 7.5 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remote air-coo led model s are 50ºF (10ºC) leavi ng wa ter temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air.
2-40 HP Portable Chillers Chapter 7: Appendix 55 of 78 10 hp and 15 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remote air-coo led model s are 50ºF (10ºC) leaving wa ter temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air.
2-40 HP Portable Chillers Chapter 7: Appendix 56 of 78 20 hp through 40 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remote air-coo led model s are 50ºF (10ºC) leavi ng wa ter temperature at 2.4 gpm per ton (9.1 lpm per 3.
2-40 HP Portable Chillers Chapter 7: Appendix 57 of 78 Remote Condenser Assembly Models To convert inches to cm , multiply dimension by 2.54. Fan(s) d e f Remote Condenser Refrigeration g Each To tals e f Overall Dimens ions Connections Charge HP Dia.
2-40 HP Portable Chillers Chapter 7: Appendix 58 of 78 7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves DWG. No. A0554823.
2-40 HP Portable Chillers Chapter 7: Appendix 59 of 78 50 Hertz Pump Curves DWG. No. S0554823.
2-40 HP Portable Chillers Chapter 7: Appendix 60 of 78 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.
2-40 HP Portable Chillers Chapter 7: Appendix 61 of 78 Flow and Pressure Considerations Model c Design flow Design ∆ P Standard pump pow er To Process pressure gpm lpm psig kPa hp kW psi kPa bars -A, 2 hp 4.6 17.5 4.4 30.4 1 0.746 34.1 235.3 2.4 -A, 3.
2-40 HP Portable Chillers Chapter 7: Appendix 62 of 78 7-5 Remote Air-Cooled Chiller Configurations Configuration A: *Liquid line riser should not exceed 15 feet from base of air-cooled condenser.
2-40 HP Portable Chillers Chapter 7: Appendix 63 of 78 7-6 Typical Ductwork for Air-Cooled Chillers *See specification tables on pages 45-48 for air flow and pressure capacities.
2-40 HP Portable Chillers Chapter 7: Appendix 64 of 78 7-7 Piping Diagrams Central and Gravity Return Piping with Standpipe Diagram.
2-40 HP Portable Chillers Chapter 7: Appendix 65 of 78 Typical Piping Schematic, 2 and 3 1/2 hp Models µ.
2-40 HP Portable Chillers Chapter 7: Appendix 66 of 78 Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models.
2-40 HP Portable Chillers Chapter 7: Appendix 67 of 78 Typical Piping Schematic, 5 hp through 40 hp, Two-Pump Models µ.
2-40 HP Portable Chillers Chapter 7: Appendix 68 of 78 Typical Piping Schematic, 5 hp through 40 hp, No-Pump Models.
2-40 HP Portable Chillers Chapter 7: Appendix 69 of 78 Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models.
2-40 HP Portable Chillers Chapter 7: Appendix 70 of 78 7-8 Electrical Schematics Typical Electrical Subpanel Time-delay Relays Relays Optional Fan Motor Speed Control Control Transformer Fuses High/Lo.
2-40 HP Portable Chillers Chapter 7: Appendix 71 of 78 Typical Electrical Schematic, 2 hp and 3 1/2 hp Models.
2-40 HP Portable Chillers Chapter 7: Appendix 72 of 78 Typical Power Wiring Schematic, 5 hp through 40 hp Models FUSE SIZE ________ 2L3 BY OTHERS PROTECTED PER OVERCURRENT PROTEC TION N.
2-40 HP Portable Chillers Chapter 7: Appendix 73 of 78 Typical Wiring Schematic, 5 hp through 15 hp Models with Pump.
2-40 HP Portable Chillers Chapter 7: Appendix 74 of 78 Typical Wiring Schematic, 5 hp through 15 hp Models without Pump DWG: A0554931.
2-40 HP Portable Chillers Chapter 7: Appendix 75 of 78 Typical Wiring Schematic, 20 hp through 30 hp Models with Pump DWG: A0562343.
2-40 HP Portable Chillers Chapter 7: Appendix 76 of 78 Typical Wiring Schematic, 20 hp through 30 hp Models without Pump DWG: A0562435.
2-40 HP Portable Chillers Chapter 7: Appendix 77 of 78 Typical Wiring Schematic, 35 hp and 40 hp Models with Pump DWG: A0562344.
2-40 HP Portable Chillers Chapter 7: Appendix 78 of 78 Typical Wiring Schematic, 35 hp and 40 hp Models without Pump DWG: A0562434.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il HP A0554832 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del HP A0554832 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso HP A0554832 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul HP A0554832 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il HP A0554832, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del HP A0554832.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il HP A0554832. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo HP A0554832 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
