HP A0554832 manual Process Water Connections, Bypass Valve Considerations

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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.

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.

2-40 HP Portable Chillers

Chapter 3: Installation

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Contents Hp Portable Chillers Shipping Information Table of Contents Operation HP Portable Chillers Safety How to Use This ManualSafety Symbols Used in this Manual Wear Safety Glasses and Work Gloves ResponsibilityFunctional Description Models Covered in This ManualGeneral Description Chilled Water CircuitRefrigeration Circuit Standard Features Mechanical FeaturesOther Mechanical Features Controller Features Electrical FeaturesRefrigeration Features Other FeaturesCrankcase Heater Safety Devices and InterlocksHigh/Low Thermostat Control High Pressure CutoutPressure Switch Oil Pressure Safety SwitchFan Cycling Switch Flow SwitchOptional Features Mounting Features Optional Pump Amperages Voltage Construction Full Load Amps Installation UncratingElectrical Connections Galvanic Corrosion Considerations Process Water ConnectionsBypass Valve Considerations Water Treatment ConsiderationsCondenser Considerations Water-Cooled Chiller CondensersAir-Cooled Chiller Condensers Remote Air-Cooled Chiller Condensers Page Equivalent Length in Feet for Valves and Fittings Chiller Condenser Charge Field Installed Piping Charge Refrigerant Charge DeterminationWater Pumps Three-Phase CompressorsChecking Motor Direction Condenser FanWater Reservoir Part Number DescriptionEthylene Glycol and Propylene Glycol Curves Automatic Water Make-Up Option Initial Start-Up Operation Panel Buttons, Indicator Lights, and SwitchesE5CK Controller Indicator Name Description Microprocessor ControllersIndicator Name Description Sterlco 2000 Controller Indicator Name Description2000 See on Indicator Name Description Graphic PanelIndicator Name Description Typical Graphic Panels With E5CK Controller With Sterlco 2000 ControllerStart-up Setting the Process Water TemperaturesAuto-Tuning Optional CommunicationsThermostat Buttons Indicator Name Description Programming the Electronic High/Low ThermostatStage 2 High Temperature Protection Select Fahrenheit or CelsiusStage 1 Freeze Protection Maintenance Filter CleaningLubrication Evaporator Process Piping Y-Strainer Maintaining the CondenserMaintaining the Evaporator Air- and Remote Air-Cooled ChillersPreventative Maintenance Service Troubleshooting HP Portable Chillers TroubleshootingHP Portable Chillers Troubleshooting Warranty AppendixParts Department Service DepartmentTechnical Assistance Sales DepartmentDrawings and Specifications Hp and 3 1/2 hp Air-Cooled Portable ChillersHp and 7.5 hp Air-Cooled Portable Chillers Hp and 15 hp Air-Cooled Portable Chillers 20 hp, 25 hp, and 30 hp Air-Cooled Portable Chillers Hp and 3.5 hp Water-Cooled Portable Chillers Nominal Condenser water Nominal cooling Water ComIn. NPT Height Width Depth Lbs Hp and 7.5 hp Water-Cooled Portable Chillers Hp and 15 hp Water-Cooled Portable Chillers 20 hp, 25 hp, and 30 hp Water-Cooled Portable Chillers Hp and 40 hp Water-Cooled Portable Chillers 12.8 17.3 Nominal cooling Com Refrigeration Power in amps eHp and 7.5 hp Remote Air-Cooled Portable Chillers 748Pres Nom Connections Hp and 15 hp Remote Air-Cooled Portable ChillersNominal cooling Com Refrigeration 15.0 40.9 34.0 74.7Hp through 40 hp Remote Air-Cooled Portable Chillers To/from No tank Tank, to/from Height Width Depth LbsRemote Condenser Assembly Models ‘A’in ‘B’in ‘C’in ‘D’in ODSinPump Curves, Flow, and Pressure Considerations Hertz Pump CurvesDWG. No. S0554823 Water Pressure Drop Tables Calculating Chiller Nominal Flow and Pressure to ProcessRecirculation Pump Specifications Recirc. power Flow Rate ∆ pressure Gpm Lpm Psi KPaFlow and Pressure Considerations Remote Air-Cooled Chiller Configurations Configuration aConfiguration B Configuration C Typical Ductwork for Air-Cooled Chillers Piping Diagrams Central and Gravity Return Piping with Standpipe DiagramTypical Piping Schematic, 2 and 3 1/2 hp Models HP Portable Chillers Appendix HP Portable Chillers Appendix Typical Piping Schematic, 5 hp through 40 hp, No-Pump Models HP Portable Chillers Appendix Typical Electrical Subpanel Electrical SchematicsTime-delay Relays Disconnect Switch Optional Speed FusesTypical Electrical Schematic, 2 hp and 3 1/2 hp Models Typical Power Wiring Schematic, 5 hp through 40 hp Models A0554815HP Portable Chillers Appendix DWG A0554931 DWG A0562343 DWG A0562435 Typical Wiring Schematic, 35 hp and 40 hp Models with Pump DWG A0562434