Conair ESEW-020D, ESEW-060D, ESEW-030D, ESEW-040D, ESEW-080D User Manual

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USER GUIDE
UGH050-0816

ESE Series Central Chillers

ESE Series Scroll Central Chillers

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

DISCLAIMER: Conair shall not be liable for errors contained in this User Guide or for incidental, consequential

Copyright 2016 l Conair l All rights reserved

Please record your equipment’s

model and serial number(s) and
the date you received it in the
spaces provided.

It’s a good idea to record the model and serial number(s) of your equi pment and the date you
received it in the User Guide. Our service department uses this information, along with the manual
number, to provide help for the specific equipment you installed.

Please keep this User Guide and all manuals, engine ering prints and parts lists together for
documentation of your equipment.

Date:

Manual Number: UGH050-0816

Serial Number(s):

Model Number(s)

damages in connection with the furnishing, performance or use of this information. Conair makes no warranty
of any kind with regard to this information, including, but not limited to the implied warranties of
merchantability and fitness for a particular purpose.

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Table of Contents

Foreword ............................................................................................................................................................................. 1

Safety Guidelines ............................................................................................................................................................... 2

General Data ....................................................................................................................................................................... 3

Table 1 – ESEW Series Single-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ............................................ 3

Table 2 – ESEW Series Dual-Circuit Water-Cooled Condenser Chiller General Data (60 Hz) ................................................ 4

Table 3 – ESER Series Single-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz) ................................... 5

Table 4 – ESER Series Dual-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz) ....................................... 6

Table 5 – Remote Air-Cooled Condenser General Data (60 Hz) ....................................................................................................... 7

Pre-Installation ................................................................................................................................................................... 8

Receiving Inspection ............................................................................................................................................................................................... 8

Unit Storage ............................................................................................................................................................................................................... 8

Installation - Chiller Mechanical ...................................................................................................................................... 9

Unit Location ............................................................................................................................................................................................................. 9

Rigging ......................................................................................................................................................................................................................... 9

Chilled Water Piping ............................................................................................................................................................................................... 9

Condenser Water Piping ....................................................................................................................................................................................... 9

Water Pressure Gauges ......................................................................................................................................................................................... 10

Master Temperature Sensor ................................................................................................................................................................................ 10

Figure 1 – Standard Flow Chiller Coolant Circuit Pressure Drop (10 through 30 Ton Single-Circuit Chillers) ............... 11

Figure 2 – Standard Flow Chiller Coolant Circuit Pressure Drop (40 through 80 Ton Single-Circuit Chillers) ............... 12

Figure 3 – Standard Flow Chiller Coolant Circuit Pressure Drop (20 through 160 ton Dual-Circuit Chillers) ................. 13

Figure 4 – Standard Flow Chiller Coolant Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers) ................. 14

Figure 5 – High Flow Chiller Coolant Circuit Pressure Drop (10 through 25 ton Single-Circuit Chillers) ......................... 15

Figure 6 – High Flow Chiller Coolant Pressure Drop (30 through 50 ton Single-Circuit Chillers) ....................................... 16

Figure 7 – High Flow Chiller Coolant Pressure Drop (20 through 50 ton Dual-Circuit Chillers) .......................................... 17

Figure 8 – High Flow Chiller Coolant Pressure Drop (60 through 100 ton Dual-Circuit Chillers) ........................................ 18

Figure 9 – Condenser Water Circuit Pressure Drop (10 through 30 ton Single-Circuit Chillers) ......................................... 19

Figure 10 – Condenser Water Circuit Pressure Drop (40 through 80 ton Single-Circuit Chillers) ....................................... 20

Figure 11 – Condenser Water Circuit Pressure Drop (20 through 60 ton Dual-Circuit Chillers) .......................................... 21

Figure 12 – Condenser Water Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers) ....................................... 22

Installation - Remote Air-Cooled Condenser ................................................................................................................ 23

Location ....................................................................................................................................................................................................................... 23

Mounted Legs and Lifting (10 ton Single-Circuit and 20-ton Dual-Circuit Units) ......................................................................... 24

Mounted Legs and Lifting (all except 10 ton Single-Circuit and 20-ton Dual-Circuit Units)..................................................... 25

Interconnecting Refrigerant Piping .................................................................................................................................................................. 26

Refrigeration Piping Design ................................................................................................................................................................................ 26

Figure 13 – Condenser Located with No Elevation Difference .......................................................................................................... 27

Figure 14 – Condenser Located above Chiller Unit................................................................................................................................ 27

Figure 15 - Condenser Located Below Chiller Unit ................................................................................................................................ 28

Determining Equivalent Line Length ................................................................................................................................................................ 28

Table 6 – Equivalent Lengths of Fittings ..................................................................................................................................................... 29

Liquid Line Sizing ..................................................................................................................................................................................................... 29

Table 7 – Liquid Line Sizes for R410A .......................................................................................................................................................... 30

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Discharge (Hot Gas) Line Sizing ......................................................................................................................................................................... 32

Figure 16 – Vertical Riser Traps ...................................................................................................................................................................... 32

Figure 17 - Double Discharge Riser.............................................................................................................................................................. 33

Table 8 – Discharge Line Sizes for Chiller (inches OD) ......................................................................................................................... 33

Table 9 - Upflow Discharge Line Sizes for R410A (inches OD) .......................................................................................................... 34

Calculating System Refrigerant and Oil Charge .......................................................................................................................................... 34

Table 10 – Combined Chiller and Remote Condenser Summer Refrigerant Charge ............................................................... 34

Table 11 - Field Piping R-410A Refrigerant Charge per 100 Feet of Run (Lbs.) ......................................................................... 34

Oil Charge Determination .................................................................................................................................................................................... 35

Setting Condenser Fan Controls ........................................................................................................................................................................ 35

Table 12 - Condenser Fan Pressure Settings (psig) ............................................................................................................................... 35

Installation - Electrical ...................................................................................................................................................... 36

Table 13 – ESEW & ESER Single-Circuit Chiller Electrical Data (60 Hz) .......................................................................................... 37

Table 14 – ESEW & ESER Single-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz) ............................. 38

Table 15 – ESEW & ESER Single-Circuit Chiller with High Flow Pump Set 1 Electrical Data (60 Hz) .................................. 39

Table 16 – ESEW & ESER Single-Circuit Chiller with High Flow Pump Set 2 Electrical Data (60 Hz) .................................. Error! Book

Table 17 – ESEW & ESER Dual-Circuit Chiller Electrical Data (60 Hz) ............................................................................................. 40

Table 18 – ESEW & ESER Dual-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz) ................................ 41

Table 19 – ESEW & ESER Dual-Circuit Chiller with High Flow Pump Set 1 Electrical Data (60 Hz) ..................................... 42

Table 20 – ESEW & ESER Dual-Circuit Chiller with High Flow Pump Set 2 Electrical Data (60 Hz) ..................................... Error! Book

Table 21 – Single-Circuit Remote Condenser Electrical Data (60 Hz) ............................................................................................. 43

Table 22 – Dual-Circuit Remote Condenser Electrical Data (60 Hz) ................................................................................................ 44

General Control Operation ............................................................................................................................................... 45

System Initialization ................................................................................................................................................................................................ 45

Figure 18 – Start-Up Splash Screen .............................................................................................................................................................. 45

Home - System Overview ................................................................................................................................................. 46

System Overview ...................................................................................................................................................................................................... 46

Figure 19 – ESEW System Overview ............................................................................................................................................................. 46

Figure 20 – ESER System Overview ............................................................................................................................................................... 46

Table 23 – System Overview Functions ....................................................................................................................................................... 46

Home – Full Screen ............................................................................................................................................................ 47

Figure 21 – Full Screen ...................................................................................................................................................................................... 47

Warnings ..................................................................................................................................................................................................................... 47

Figure 22 – Warning Screen ............................................................................................................................................................................ 47

Home – Pump Control (Optional) ................................................................................................................................... 48

Pump Control Screen (Optional) ....................................................................................................................................................................... 48

Figure 23 – Pump Control Screen ................................................................................................................................................................. 48

Pump VFD Control Screen (Optional) .............................................................................................................................................................. 48

Figure 24 – Pump VFD Control Screen ....................................................................................................................................................... 48

Menu 1 - Overview ............................................................................................................................................................ 49

Figure 25 – Menu 1 Screen .............................................................................................................................................................................. 49

Table 24 – Menu 1 Functions .......................................................................................................................................................................... 50

Menu 1 - Alarms................................................................................................................................................................. 51

Alarms Active ............................................................................................................................................................................................................. 51

Figure 26 – HMI Alarm Handler ..................................................................................................................................................................... 51

Alarm History ............................................................................................................................................................................................................. 51

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Figure 27 – Alarm History ................................................................................................................................................................................. 51

Alarm Setup ............................................................................................................................................................................................................... 52

Figure 28 – Alarm Setup ................................................................................................................................................................................... 52

Alarm Glycol ............................................................................................................................................................................................................... 52

Figure 29 – Alarm Setup ................................................................................................................................................................................... 52

Menu 1 – Metric Units/Imperial Units ............................................................................................................................ 53

Menu 1 - Compressor Data .............................................................................................................................................. 53

Compressor Data Screen ...................................................................................................................................................................................... 53

Figure 30 – Circuit Data Screen (Water-Cooled Condenser Chiller) ................................................................................................ 53

Figure 31 – Circuit Data Screen (Remote Air-Cooled Condenser Chiller) ..................................................................................... 54

Compressor Data Screen – Interlocks .............................................................................................................................................................. 54

Figure 32 – Interlocks ......................................................................................................................................................................................... 54

Figure 33 – Critical Interlocks .......................................................................................................................................................................... 55

Figure 34 – Refrigeration Interlocks ............................................................................................................................................................. 55

Menu 1 – Modbus/BAS ..................................................................................................................................................... 56

Modbus RTU/BAS Setup Screen ........................................................................................................................................................................ 56

Figure 35 – Modbus Setup Screen ................................................................................................................................................................ 56

Figure 36 – Modbus Word Data Screen ..................................................................................................................................................... 56

Figure 37 – Modbus Bit Data Screen ........................................................................................................................................................... 56

Menu 1 – EXV1 Expansion Valve Setup .......................................................................................................................... 57

EXV1 Expansion Valve Setup Screen ................................................................................................................................................................ 57

Figure 38 – EXV1 Expansion Valve Setup Screen .................................................................................................................................... 57

Table 25 – EXV1 Setup Parameters............................................................................................................................................................... 57

Menu 1 – EXV2 Hot Gas Bypass Setup ............................................................................................................................ 58

EXV2 Hot Gas Bypass Setup Screen (Optional)............................................................................................................................................ 58

Figure 39 – EXV2 Hot Gas Bypass Screen .................................................................................................................................................. 58

Table 26 – EXV2 Setup Parameters............................................................................................................................................................... 58

Menu 1 – Water Regulating Valve (WRV) Setup .......................................................................................................... 59

WRV Water Regulating Valve Setup Screen ................................................................................................................................................. 59

Figure 40 – WRV Setup Screen....................................................................................................................................................................... 59

Table 27 – WRV Setup Parameters ............................................................................................................................................................... 59

Menu 1 – Compressor Staging/PID ................................................................................................................................. 60

Compressor Staging Setup Screen ................................................................................................................................................................... 60

Figure 41 – Compressor Staging Setup Screen ....................................................................................................................................... 60

Table 28 – Compressor Staging Setup Parameters ................................................................................................................................ 60

Compressor Staging Graph Screen .................................................................................................................................................................. 61

Figure 42 – Compressor Staging Graph Screen ...................................................................................................................................... 61

Table 29 – Compressor Staging Graph Parameters ............................................................................................................................... 61

Compressor Staging Local Screen .................................................................................................................................................................... 62

Figure 43 – Compressor Staging Local Screen ........................................................................................................................................ 62

Table 30 – Compressor Staging Local Parameters ................................................................................................................................. 62

Menu 1 – Inputs/Outputs ................................................................................................................................................. 63

Inputs / Outputs Screens ...................................................................................................................................................................................... 63

Figure 44 – Digital Inputs Screen .................................................................................................................................................................. 63

Figure 45 – Digital Outputs Screen .............................................................................................................................................................. 63

Figure 46 – Analog Inputs Screen ................................................................................................................................................................. 63

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Figure 47 – Analog Outputs Screen ............................................................................................................................................................. 63

Menu 1 – Temperature Offsets ........................................................................................................................................ 64

RTD Temperature Offset Adjustment .............................................................................................................................................................. 64

Figure 48 – RTD Temperature Offsets Screen .......................................................................................................................................... 64

Menu 1 – Process Control ................................................................................................................................................. 65

Leaving/Entering Sensor Selection ................................................................................................................................................................... 65

Figure 49 – Process Control Screen .............................................................................................................................................................. 65

Menu 1 – Pumps Setup ..................................................................................................................................................... 66

Pump Setup Screen ................................................................................................................................................................................................. 66

Figure 50 – Pump Setup Screen ..................................................................................................................................................................... 66

Table 31 – Pump Setup Parameters ............................................................................................................................................................. 66

Menu 1 – Tank Setup ......................................................................................................................................................... 67

Tank Setup Screen ................................................................................................................................................................................................... 67

Figure 51 – Tank Setup Screen ....................................................................................................................................................................... 67

Menu 1 – Counters ............................................................................................................................................................. 68

Counters Screens ..................................................................................................................................................................................................... 68

Figure 52 – Counters 1 Screen ....................................................................................................................................................................... 68

Figure 53 – Counters 2 Screen ....................................................................................................................................................................... 68

Figure 54 – Counters 3 Screen ....................................................................................................................................................................... 68

Menu 2 - Overview ............................................................................................................................................................ 69

Figure 55 – Menu 2 ............................................................................................................................................................................................. 69

Table 32 – Menu 2 Functions .......................................................................................................................................................................... 69

Menu 2 – Hardware Options Selected ............................................................................................................................ 70

Hardware Options Screen .................................................................................................................................................................................... 70

Figure 56 – Hardware Options Screen ........................................................................................................................................................ 70

Menu 2 - Date/Time .......................................................................................................................................................... 71

Menu 2 – System Menu .................................................................................................................................................... 71

Menu 2 – Defaults .............................................................................................................................................................. 71

Figure 57 – Restore Factory Settings ........................................................................................................................................................... 71

Figure 58 – Factory Settings Restored ........................................................................................................................................................ 72

Menu 2 – Remote Setpoint Setup ................................................................................................................................... 72

Figure 59 – Remote Setpoint Setup Screen .............................................................................................................................................. 72

Menu 2 – Remove SD Storage ......................................................................................................................................... 73

Menu 2 – Trending ............................................................................................................................................................ 73

Figure 60 – Trending Screen ........................................................................................................................................................................... 73

Menu 2 – Remote Mode ................................................................................................................................................... 73

Menu 2 – PLC Link Setup .................................................................................................................................................. 74

PLC Link (Master/Slave) Setup Screen ............................................................................................................................................................. 74

Figure 61 – PLC Link Setup Screen ............................................................................................................................................................... 74

Figure 62 – PLC Link Word Data Screen ..................................................................................................................................................... 74

Figure 63 – PLC Link Bit Data Screen ........................................................................................................................................................... 74

Menu 2 – Touch Calibration ............................................................................................................................................. 75

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Start-Up ............................................................................................................................................................................... 75

Step 1 - Connect Main Power ............................................................................................................................................................................. 75

Step 2 - Fill Coolant Circuit .................................................................................................................................................................................. 76

System Fill Water Chemistry Requirements .............................................................................................................................................. 76

Table 33 – Fill Water Chemistry Requirements ........................................................................................................................................ 77

Table 34 - Recommended Glycol Solutions .............................................................................................................................................. 77

Step 3 - Check Condenser .................................................................................................................................................................................... 77

Water-Cooled Condenser Check ................................................................................................................................................................... 77

Remote Air-Cooled Condenser Check ........................................................................................................................................................ 77

Step 4 – Check Refrigerant Valves .................................................................................................................................................................... 77

Step 5 – Verify Freezestat Setting ..................................................................................................................................................................... 78

Step 6 – Turn On Control Power ........................................................................................................................................................................ 78

Step 7 – Establish Coolant Flow ......................................................................................................................................................................... 78

Step 8 – Intial Unit Operation ............................................................................................................................................................................. 78

Low-Ambient Start-Up (Remote Condensers) ......................................................................................................................................... 78

Preventive Maintenance ................................................................................................................................................... 79

Once a Week ............................................................................................................................................................................................................. 79

Once a Month ........................................................................................................................................................................................................... 80

Once Every Three Months .................................................................................................................................................................................... 80

Once a Year ................................................................................................................................................................................................................ 80

Cleaning the Operator Interface ...................................................................................................................................... 81

General Troubleshooting .................................................................................................................................................. 82

Preventive Maintenance Checklist .................................................................................................................................. 83

Drawings ............................................................................................................................................................................. 83

Warranty Information ....................................................................................................................................................... 84

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Foreword

The central chiller contains on or more refrigeration
circuits intended to chiller or cool a process fluid. As
an option, a process fluid reservoir and pumping
system is available to create a complete packaged
chiller system.

The intent of this manual is to serve as a guide for
placing our central chiller in service and operating
and maintaining it properly. Improper installation
can lead to poor equipment performance or severe
equipment damage. Failure to follow the installation
instructions may result in damage not covered by
your warranty. It is extremely important that a
qualified refrigeration installation contractor perform
all installation line sizing and piping. Please supply
these instructions to your authorized refrigeration
contractor. This manual is for our standard product
line with supplements as required to accommodate
any special items provided for a specific application.
The written information contained in this manual, as
well as various drawings, are intended to be general
in nature. Unit specific drawings are included with
the equipment for troubleshooting and servicing of
the unit. Additional copies of drawings are available
upon request. We strive to maintain an accurate
record of all equipment during the course of its
useful life.

Due to the ever-changing nature of applicable
codes, ordinances, and other local laws pertaining to
the use and operation of this equipment we do not
reference them in this manual. There is no substitute
for common sense and good operating practices
when placing any mechanical equipment into
operation. We encourage all personnel to familiarize
themselves with this manual's contents. Failure to do
so may unnecessarily prolong equipment down time.

The chiller uses chemical refrigerants for heat
transfer purposes. This chemical is sealed and tested
in a pressurized system containing ASME coded
vessels; however, a system failure will release it.
Refrigerant gas can cause toxic fumes if exposed to
fire. Place these units in a well-ventilated area,
especially if open flames are present.

Failure to follow these instructions could result in a
hazardous condition. The standard refrigerant used
in these units is a hydro fluorocarbon (HFC) trade
named R-410A. We strongly recommend a
refrigerant management program be implemented
which includes a survey of all equipment to
document the type and quantity of refrigerant in
each machine. In addition, we recommend only
licensed and EPA certified service technicians work
on our refrigeration circuits. Follow good piping
practices and the information in this manual to
ensure successful installation and operation of this
equipment. We are not responsible for liabilities
created by substandard piping methods and
installation practices external to the chiller.

We trust your equipment will have a long and useful
life. If you should have any questions, please contact
the Conair Service Department specifying the serial
number and model number of the unit as indicated
on the nameplate.

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1

General Warning

High Voltage Warning

Sharp Element Warning

Hot Surface Warning

Flammable Material Warning

Explosive Material Warning

General Mandatory Action

Wear Eye Protection

Wear Protection Gloves

Wear Ear Protection

Disconnect Before Carrying Out Maintenance or

Connect an Earth Terminal to Ground

WARNING: Any use or misuse of this equipment

harm.

WARNING: Vent all refrigerant relief valves in

displace oxygen and cause suffocation.

WARNING: This equipment contains hazardous

WARNING: This equipment contains refrigerant

property damage.

WARNING: This equipment may contain fan

in place.

WARNING: The exposed surfaces of motors,

CAUTION: Disconnect and lock out incoming

opening access panels for repair or maintenance.

CAUTION: Wear eye protection when installing,

protect against any sparks, debris, or fluid leaks.

CAUTION: The chiller will exceed 70 dBA sound

chiller.

CAUTION: Wear protective gloves when

or fluid leaks.

Safety Guidelines

Observe all safety precautions during installation,
start-up, and service of this equipment. The
following is a list of symbols used in this manual and
their meaning.

outside of the design intent may cause injury or

accordance to ANSI/ASHRAE Standard 15, Safety
Code for Mechanical Refrigeration. This
equipment should be located within a well­ventilated area. Inhalation of refrigerant can be
hazardous to your health and the accumulation
of refrigerant within an enclosed space can

voltages that can cause severe injury or death.

under pressure. Accidental release of refrigerant
under pressure can cause personal injury and or

blades or other sharp edges. Make sure all fan
guards and other protective shields are securely

Repair

Only qualified personnel should install, start-up, and
service this equipment. When working on this
equipment, observe precautions in literature, and on
tags, stickers, and labels located on the equipment.

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2

refrigerant piping, and other fluid circuit
components can be very hot and can cause burns
if touched with unprotected hands.

power before installing, servicing, or
maintaining the equipment. Connecting power to
the main terminal block energizes the entire
electric circuitry of the unit. A power supply
provides 24 VDC control power. Electric power at
the main disconnect should be shut off before

maintaining, or repairing the equipment to

pressure at 1 meter distance and 1 meter
elevation when operating. Wear ear protection
as required for personnel comfort when
operating or working in close proximity to the

installing, maintaining, or repairing the
equipment to protect against any sparks, debris,

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

010S

015S

020S

025S

030S

040S

050S

060S

080S

General

Cooling Capacity tons

1

Set Point Range °F

Process In/Out (in.)-Standard

3 3 4

Process In/Out (in.)-High Flow

4 4

Condenser Water In/Out (in.)

3 4 4

Refrigerant Charge (lbs of
R410A)

70 80

Min Unloaded Capacity ton

with HGBP Option ton

A - Length inches {mm}

68 {1727}

68 {1727}

68 {1727}

68 {1727}

72 {1829}

100 {2540}

100 {2540}

100 {2540}

105 {2667}

B - Width inches {mm}

24 {610}

24 {610}

24 {610}

24 {610}

24 {610}

24 {610}

30 {762}

30 {762}

30 {762}

C- Height inches {mm}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

Ship Weight lbs {kg}

1200 {544}

1300 {590}

1400 {635}

1500 {680}

1600 {726}

1800 {816}

2000 {907}

2200 {998}

2400 {1089}

Operating Weight lbs {kg}

1400 {635}

1500 {680}

1600 {726}

1700 {771}

1800 {816}

2000 {907}

2200 {998}

2400 {1089}

2600 {1179}

MCA @ 460/3/60 amps

2

22

34

42

53

62

71

86

124

165

Reservoir Capacity gal {l}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

450 {1703}

450 {1703}

(Process/Chiller)

5D/1.5A

5D/1.5A

5D/1.5A

5D/1.5A

7.5D/2A

10D/2A

10D/3A

10D/3A

15D/3A

Process Connection Size inch

1½

1½ 2 2

2½

2½ 3 3

4

D - Length inches {mm}

84 {2134}

84 {2134}

84 {2134}

96 {2438}

96 {2438}

96 {2438}

96 {2438}

108 {2743}

108 {2743}

E - Width inches {mm}

72 {1829}

72 {1829}

76 {1930}

76 {1930}

76 {1930}

92 {2337}

92 {2337}

95 {2413}

100 {2540}

F - Height inches {mm}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

Ship Weight lbs {kg}

Operating Weight lbs {kg}

MCA @ 460/3/60 amps

2

Reservoir Capacity gal {l}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

650 {2461}

650 {2461}

Pump Models
(Process/Chiller)

5D/1.5A

7.5D/1.5A

10D/1.5A

10D/1.5A

10D/2A

15D/2A

15D/3A

20D/3A

25D/3A

Process Connection Size
inches

2

2½

2½ 3 3 4 4 4 6

D - Length inches {mm}

84 {2134}

84 {2134}

84 {2134}

84 {2134}

120 {3048}

132 {3353}

132 {3353}

132 {3353}

132 {3353}

E - Width inches {mm}

72 {1829}

72 {1829}

72 {1829}

76 {1930}

76 {1930}

92 {2337}

92 {2337}

92 {2337}

92 {2337}

F - Height inches {mm}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

Operating Weight lbs {kg}

MCA @ 460/3/60 amps

2

General Data

Table 1 – ESEW Series Single-Circuit Water-Cooled Condenser Chiller General Data (60 Hz)

Model

10.9 16.1 22.1 27.3 32.6 42.2

20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80

1½ 1½ 2 2 2½ 2½

2 2½ 2½ 3 3 4

1½ 2 2 2½ 2½ 3

10 30 30 35 40 50

5.5 8.1 11.1 13.7 16.2 21.0

2.7 4.0 5.5 6.8 8.1 10.5

53.3

20 to 80

25.9

13.0

Dimensions, Weights, Amps (Chiller Only)

Dimensions, Weights, Amps (Chiller with Standard Flow Reservoir Option , 10°F ∆T Process, 10°F ∆T Chiller)

Pump Models

68.4

20 to 80

33.9

17.0

86.2

20 to 80

N/A

100

42.6

21.3

2600 {1179} 2700 {1225} 2900 {1315} 3200 {1451} 3900 {1769} 4100 {1860} 4700 {2132} 5100 {2313} 5400 {2449}

4900 {2223} 5000 {2268} 5100 {2313} 5500 {2495} 6200 {2812} 6400 {2903} 7000 {3175} 7400 {3357} 7800 {3538}

32 43 50 62 75 86

104

Dimensions, Weights, Amps (Chiller with High Flow Reservoir Option 1, 5°F ∆T Process, 10°F ∆T Chiller)

Ship Weight lbs {kg}

1

Cooling capacity when cooling water with 50°F {10°C} set point, 60°F {16°C} return, 85°F {29°C} condenser water, R-410A

refrigerant.

2

MCA is Minimum Circuit Amps (for wire sizing), complie with NEC, Section 430-24.

2800 {1270} 2900 {1315} 3100 {1406} 3400 {1542} 4100 {1860} 4300 {1950} 4900 {2223} 5350 {2427} 5650 {2563}

5960 {2699} 6050 {2744} 6150 {2790} 6550 {2971} 7250 {3289} 7450 {3379} 8050 {3651} 9050 {4105} 9450 {4286}

32 46 57 68 78 91

109

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

3

141

153

188

201

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

ESEW-

020D

030D

040D

050D

060D

080D

0100D

0120D

0160D

General

Cooling Capacity tons

1

Set Point Range °F

Process In/Out (in.)-Standard

Process In/Out (in.)-High Flow

Condenser Water In/Out
inches

Refrig Charge/Cir (lbs of R410A)

Mini Unloaded Capacity ton

Dimensions, Weights, Amps (Chiller Only)

A - Length inches {mm}

75 {1905}

75 {1905}

80 {2032}

80 {2032}

85 {2159}

115 {2921}

115 {2921}

118 {2997}

125 {3175}

B - Width inches {mm}

56 {1422}

56 {1422}

56 {1422}

56 {1422}

56 {1422}

56 {1422}

56 {1422}

56 {1422}

56 {1422}

C- Height inches {mm}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

Ship Weight lbs {kg}

2500 {1134}

2600 {1179}

2800 {1270}

3000 {1361}

3200 {1451}

3600 {1633}

4000 {1814}

4400 {1996}

4800 {2177}

Operating Weight lbs {kg}

2700 {1225}

2800 {1270}

3000 {1361}

3200 {1451}

3400 {1542}

3800 {1724}

4200 {1905}

4600 {2087}

5000 {2268}

MCA @ 460/3/60 amps

2

42

63

76

99

115

131

161

232

311

Dimensions, Weights, Amps (Chiller with Standard Flow Reservoir Option , 10°F ∆T Process, 10°F ∆T Chiller)

Reservoir Size gal {l}

Pump Models (Process/Chiller)

Process Connection Size inch

78 {1981}

78 {1981}

78 {1981}

90 {2286}

90 {2286}

1053

1103

1103

1103

F - Height inches {mm}

Ship Weight lbs {kg}

10450
{4740}

MCA @ 460/3/60 amps

2

Dimensions, Weights, Amps (Chiller with High Flow Reservoir Option 1, 5°F ∆T Process, 10°F ∆T Chiller)

Reservoir Size gal {l}

Pump Models (Process/Chiller)

10D/1.5A

Process Connection Size inch

78 {1981}

78 {1981}

78 {1981}

90 {2286}

90 {2286}

1053

{26746}

1103

{28016}

1103

{28016}

1103

{28016}

F - Height inches {mm}

76 {1930}

76 {1930}

76 {1930}}

76 {1930}

76 {1930}

90 {2286}

90 {2286}

90 {2286}

Operating Weight lbs {kg}

7450 {3379}

7650 {3470}

7750 {3515}

8050 {3651}

9350 {4241}

9500 {4332}

11000

11400

11800

MCA @ 460/3/60 amps

2

Table 2 – ESEW Series Dual-Circuit Water-Cooled Condenser Chiller General Data (60 Hz)

21.7 32.1 44.3 54.7 65.2 84.5 106.7 136.9 172.5

20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80

2 2½ 2½ 3 3 4 4 4 6

2½ 3 4 4 4 6 6 6 N/A

2 2½ 3 3 4 4 4 6 6

10 30 30 35 40 50 70 80 100

5.5 8.0 11.1 13.7 16.2 20.9 25.9 33.9 42.6

with HGBP Option ton

2.7 4.0 5.5 6.8 8.1 10.5 13.0 16.9 21.3

275 {1041} 275 {1041} 275 {1041} 275 {1041} 450 {1703} 450 {1703} 700 {2650} 700 {2650} 1000 {3785}

5D/1.5A 7.5D/2A 10D/2A 10D/3A 10D/3A 15D/3A 15D/5A 20D/7.5F 25D/10E

2 2½ 2½ 3 3 4 4 4 6

D - Length inches {mm}

E - Width inches {mm}

108 {2743} 108 {2743} 108 {2743} 120 {3048} 132 {3353} 132 {3353} 132 {3353} 144 {3658} 144 {3658}

{26746}

{28016}

{28016}

75 {1905} 75 {1905} 75 {1905} 75 {1905} 75 {1905}} 75 {1905} 75 {1905} 75 {1905} 90 {2286}

4100 {1860} 4300 {1950} 4400 {1996} 4700 {2132} 5400 {2449} 5600 {2540} 6200 {2812} 6600 {2994} 7000 {3175}

Operating Weight lbs {kg}

6400 {2903} 6600 {2994} 6700 {3039} 7000 {3175} 7700 {3493} 7900 {3583} 8500 {3856} 8900 {4037}

51 76 93 117 133 154 187 269 356

400 {1514} 400 {1514} 400 {1514} 400 {1514} 650 {2461} 650 {2461} 1000 {3785} 1000 {3785} 1000 {3785}

10D/2A 15D/2A 15D/3A 20D/3A 25D/3A 30D/5A 40D/7.5F 40D/10E

2½ 3 4 4 4 6 6 6 6

D - Length inches {mm}

108 {2743} 108 {2743} 108 {2743} 120 {3048} 132 {3353} 132 {3353} 144 {3658} 144 {3658} 144 {3658}

E - Width inches {mm}

Ship Weight lbs {kg}

1

Cooling capacity when cooling water with 50°F {10°C} set point, 60°F {16°C} return, 85°F {29°C} condenser water, R-410A

refrigerant.

2

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24

3

To keep the shipping dimensions within a 102” width for standard flatbed shipping, the condenser inlet manifold is removed

for shipment.

4300 {1950} 4500 {2041} 4600 {2087} 4900 {2223} 5650 {2563} 5850 {2654} 6500 {2948} 6900 {3130} 7300 {3311}

{4990}

{5171}

59 79 98 122 145 168 207 294 375

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

4

{28016}

90 {2286}

{5352}

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

010S

015S

020S

025S

030S

040S

050S

060S

080S

General

Cooling Capacity tons

1

Set Point Range °F

Process In/Out (in.)-Standard

Process In/Out (in.)-High Flow

Refrigerant Discharge Line inch

Refrigerant Liquid Line inch

Refrigerant Charge (lbs of
R410A)

with HGBP Option ton

A - Length inches {mm}

68 {1727}

68 {1727}

68 {1727}

68 {1727}

72 {1829}

102 {2591}

102 {2591}

102 {2591}

105 {2667}

B - Width inches {mm}

24 {610}

24 {610}

24 {610}

24 {610}

24 {610}

24 {610}

30 {762}

30 {762}

30 {762}

C- Height inches {mm}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

Ship Weight lbs {kg}

1200 {544}

1300 {590}

1400 {635}

1500 {680}

1600 {726}

1800 {816}

2000 {907}

2200 {998}

2400 {1089}

Operating Weight lbs {kg}

1300 {590}

1400 {635}

1500 {680}

1600 {726}

1700 {771}

1900 {862}

2100 {953}

2300 {1043}

2500 {1134}

MCA @ 460/3/60 amps

2

22

34

42

53

62

71

86

124

165

Reservoir Capacity gal {l}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

275 {1041}

450 {1703}

450 {1703}

Pump Models (Process/Chiller)

5D/1.5A

5D/1.5A

5D/1.5A

5D/1.5A

7.5D/2A

10D/2A

10D/3A

10D/3A

15D/3A

Process Connection Size inch

1½

1½ 2 2

2½

2½ 3 3

4

D - Length inches {mm}

84 {2134}

84 {2134}

84 {2134}

96 {2438}

96 {2438}

96 {2438}

96 {2438}

108 {2743}

108 {2743}

E - Width inches {mm}

64 {1626}

64 {1626}

64 {1626}

76 {1930}

76 {1930}

92 {2337}

92 {2337}

96 {2438}

98 {2489}

F - Height inches {mm}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

Ship Weight lbs {kg}

Operating Weight lbs {kg}

MCA @ 460/3/60 amps

2

Reservoir Capacity gal {l}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

400 {1514}

650 {2460}

650 {2460}

Pump Models (Process/Chiller)

5D/1.5A

7.5D/1.5A

10D/1.5A

10D/1.5A

10D/2A

15D/2A

15D/3A

20D/3A

25D/3A

Process Connection Size inch

2

2½

2½ 3 3 4 4 4 6

D - Length inches {mm}

84 {2134}

84 {2134}

84 {2134}

96 {2438}

96 {2438}

96 {2438}

96 {2438}

108 {2743}

108 {2743}

E - Width inches {mm}

64 {1626}

64 {1626}

64 {1626}

76 {1930}

92 {2337}

92 {2337}

92 {2337}

96 {2438}

98 {2489}

F - Height inches {mm}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

Ship Weight lbs {kg}

Operating Weight lbs {kg}

MCA @ 460/3/60 amps

2

Table 3 – ESER Series Single-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz)

10 14.9 20.4 25.2

20 to 80 20 to 80 20 to 80 20 to 80

1½ 1½ 2 2

2 2½ 2½ 3

⅞ 1⅛ 1⅛ 1⅜

⅝ ⅞ ⅞ 1⅛

30.1 38.9 48.9 63.6 78.7

20 to 80 20 to 80 20 to 80 20 to 80 20 to 80

2½ 2½ 3 3 4

3 4 4 4 N/A

1⅜ 1⅝ 1⅝ 1⅝ 2⅛

1⅛ 1⅛ 1⅛ 1⅜ 1⅝

Varies based on refrigerant system piping

Min Unloaded Capacity ton

5.0 7.4 10.0 12.5

2.5 3.7 5.0 6.2

14.8 19.1 23.6 30.9 38.5

7.4 9.6 11.8 15.5 19.3

Dimensions, Weights, Amps (Chiller Only)

Dimensions, Weights, Amps (Chiller with Standard Flow Reservoir Option , 10°F ∆T Process, 10°F ∆T Chiller)

2600 {1179} 2700 {1225} 2900 {1315} 3200 {1451} 3900 {1769}

4900 {2223} 5000 {2268} 5100 {2313} 5500 {2495} 6200 {2812} 6400 {2903} 7000 {3175} 7400 {3357} 7800 {3538}

32 43 50 62

4100 {1860} 4700 {2132} 5100 {2313} 5400 {2449}

75 86 104 141 188

Dimensions, Weights, Amps (Chiller with High Flow Reservoir Option 1, 5°F ∆T Process, 10°F ∆T Chiller)

2800 {1270} 2900 {1315} 3100 {1406} 3400 {1542} 4100 {1860} 4300 {1950} 4900 {2223} 5350 {2427} 5650 {2563}

5950 {2699} 6050 {2744} 6150 {2790} 6550 {2971} 7250 {3289} 7450 {3379} 8050 {3651} 9050 {4105} 9450 {4286}

1

Cooling capacity when cooling water with 50°F {10°C} set point, 60°F {16°C} return, 95°F {35°C} condenser air, R-410A

refrigerant.

2

MCA is Minimum Circuit Amps (for wire sizing).

32 46 57 68

78 91 109 153 201

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

5

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

ESER-

020D

030D

040D

050D

060D

080D

0100D

0120D

0160D

General

Cooling Capacity tons

1

Set Point Range °F

Process In/Out (in.)-Standard

Process In/Out (in.)-High Flow

Refrig Discharge Line/Circuit
inches

Refrig Liquid Line/Circuit
inches

R410A)

Min Unloaded Capacity ton

with HGBP Option ton

A - Length inches {mm}

75 {1905}

75 {1905}

80 {2032}

80 {2032}

89 {2261}

105 {2667}

105 {2667}

110 {2794}

125 {3175}

B - Width inches {mm}

48 {1219}

48 {1219}

48 {1219}

48 {1219}

48 {1219}

48 {1219}

48 {1219}

48 {1219}

52 {1321}

C- Height inches {mm}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

69 {1753}

Ship Weight lbs {kg}

2500 {1134}

2600 {1179}

2800 {1270}

3000 {1361}

3200 {1451}

3600 {1633}

4000 {1814}

4400 {1996}

4800 {2177}

Operating Weight lbs {kg}

2700 {1225}

2800 {1270}

3000 {1361}

3200 {1451}

3400 {1542}

3800 {1724}

4200 {1905}

4600 {2087}

5000 {2268}

MCA @ 460/3/60 amps

2

42

63

76

99

115

131

161

232

311

Reservoir Size gal {l}

275 [1041}

275 {1041}

275 {1041}

275 {1041}

450 {1703}

450 {1703}

700 {2650}

700 {2650}

1000 {3785}

Pump Models
(Process/Chiller)

5D/1.5A

7.5D/2A

10D/2A

10D/3A

10D/3A

15D/3A

15D/5A

20D/7.5F

20D/10E

Process Connection Size inch

6

D - Length inches {mm}

108 {2743}

108 {2743}

108 {2743}

120 {3048}

132 {3353}

132 {3353}

132 {3353}

144 {3658}

144 {3658}

E - Width inches {mm}

74 {1880}

74 {1880}

74 {1880}

74 {1880}

74 {1880}

92 {2337}

102 {2591}

102 {2591}

102 {2591}

F - Height inches {mm}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

75 {1905}

Ship Weight lbs {kg}

6800 {3084}

Operating Weight lbs {kg}

9100 {4128}

MCA @ 460/3/60 amps

2

356

400 {1514}

400 {1514}

400 {1514}

400 {1514}

650 {2461}

650 {2461}

1000 {3785}

1000 {3785}

1000 {3785}

Pump Models
(Process/Chiller)

10D/1.5A

10D/2A

15D/2A

15D/3A

20D/3A

25D/3A

30D/5A

40D/7.5F

40D/10E

D - Length inches {mm}

108 {2743}

108 {2743}

108 {2743}

120 {3048}

132 {3353}

132 {3353}

132 {3353}

144 {3658}

144 {3658}

E - Width inches {mm}

74 {1880}

74 {1880}

74 {1880}

74 {1880}

74 {1880}

92 {2337}

102 {2591}

102 {2591}

102 {2591}

F - Height inches {mm}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

76 {1930}

90 {2286}

90 {2286}

90 {2286}

90 {2286}

Operating Weight lbs {kg}

7250 {3289}

7350 {3334}

7450 {3379}

7850 {3561}

9150 {4150}

9350 {4241}

10800

11200

11160

MCA @ 460/3/60 amps

2

Table 4 – ESER Series Dual-Circuit Remote Air-Cooled Condenser Chiller General Data (60 Hz)

20.4 29.9 40.7 50.5 60.2 77.8 97.7 127.2 157.5

20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80 20 to 80

2 2½ 2½ 3 3 4 4 4 6

2½ 3 4 4 4 6 6 6 N/A

⅞ 1⅛ 1⅛ 1⅜ 1⅜ 1⅝ 1⅝ 1⅝ 2⅛

⅝ ⅞ ⅞ 1⅛ 1⅛ 1⅛ 1⅛ 1⅜ 1⅝

Refrig Charge/Cir (lbs of

Varies based on refrigeration system piping

5.0 7.3 10.0 12.5 14.7 19.1 23.6 30.9 38.5

2.5 3.7 5.0 6.2 7.4 9.6 11.8 15.5 19.3

Dimensions, Weights, Amps (Chiller Only)

Dimensions, Weights, Amps (Chiller with Standard Flow Reservoir Option , 10°F ∆T Process, 10°F ∆T Chiller)

2 2½ 2½ 3 3 4 4 4

3900 {1769} 4000 {1814} 4200 {1905} 4500 {2041} 5200 {2359} 5400 {2449} 6000 {2722} 6400 {2903}

6200 {2812} 6300 {2858} 6400 {2903} 6800 {3084} 7500 {3402} 7700 {3493} 8300 {3765} 8700 {3946}

51 76 93 117 133 154 187 269

Dimensions, Weights, Amps (Chiller with High Flow Reservoir Option 1, 5°F ∆T Process, 10°F ∆T Chiller)

Reservoir Size gal {l}

Process Connection Size inch

Ship Weight lbs {kg}

1

Cooling capacity when cooling water with 50°F{10°C} set point, 60°F {16°C} return, 95°F {35°C} condenser air, R-410A

refrigerant.

2

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

2½ 3 4 4 4 6 6 6 6

4100 {1860} 4200 {1905} 4400 {1996} 4700 {2132} 5450 {2472} 5650 {2563} 6300 {2858} 6700 {3039} 7100 {3221}

{4899}

{5080}

{5262}

59 79 98 122 145 168 207 294 375

6

Chiller

Dimensions inches {mm}

Weights lbs {kg}

Total

Sound

MCA @

Refrig Lines

(in)

Inlet

Circuit

Outlet

Circuit

KCM014

Operating weight varies base on system refrigeration charge

and operating conditions

14,400

53

KCL023

24,000

63

KCL030

22,600

63

KCL037

20,600

63

KCL045

33,900

64

KCL056

30,900

64

KCL068

42,400

65

KCL095

51,800

66

KCL110

62,100

67

KCM034

28,400

55

KCL047

47,900

65

KCL060

45,200

65

KCL074

41,200

65

KCL090

67,800

67

KCL112

61,800

67

KCL137

84,800

68

KCL190

103,500

69

KCL224

124,200

70

Table 5 – Remote Air-Cooled Condenser General Data (60 Hz)

Model

Single-Circuit

Dual-Circuit

1

One condenser is required per chiller; dual-circuit chillers use one remote condenser that has two refrigeration circuits.

2

Sound pressure level at 30 feet.

3

MCA is Minimum Circuit Amps (for wire sizing) as provided by the remote condenser manufacturer.

Model

Used

1

With

ESER-010S 83 {2108} 43 {1092} 48 {1219} 415 {188}

ESER-015S 113 {2870} 45 {1143} 54 {1372} 670 {304}

ESER-020S 113 {2870} 45 {1143} 54 {1372} 720 {327}

ESER-025S 113 {2870} 45 {1143} 54 {1372} 800 {363}

ESER-030S 168 {4267} 45 {1143} 54 {1372} 1075 {488}

ESER-040S 168 {4267} 45 {1143} 54 {1372} 1200 {544}

ESER-050S 223 {5664} 45 {1143} 54 {1372} 1475 {669}

ESER-060S 278 {7061} 45 {1143} 54 {1372} 1950 {885}

ESER-080S 333 {8458} 45 {1143} 54 {1372} 2300 {1043}

ESER-020D 83 {2108} 83 {2108} 48 {1219} 830 {376}

ESER-030D 113 {2870} 87 {2210} 54 {1372} 1275 {578}

ESER-040D 113 {2870} 87 {2210} 54 {1372} 1350 {612}

ESER-050D 113 {2870} 87 {2210} 54 {1372} 1525 {692}

ESER-060D 168 {4267} 87 {2210} 54 {1372} 2050 {930}

ESER-080D 168 {4267} 87 {2210} 54 {1372} 2275 {1032}

ESER-0100D 223 {5664} 87 {2210} 54 {1372} 2800 {1270}

ESER-0120D 278 {7061} 87 {2210} 54 {1372} 3700 {1678}

ESER-0160D 333 {8458} 87 {2210} 54 {1372} 4400 {1996}

L W H Ship Oper

Air

Flow

(cfm)

Pressure

Level

(dBA)2

460/3/60

(amps)

2.6

7.0

7.0

7.0

10.1

10.1

16.0

16.0

21.0

4.9

16.0

16.0

16.0

21.0

21.0

24.8

36.0

46.0

3

Per

1⅜ 1⅛

2⅛ 1⅜

2⅛ 1⅝

2⅛ 1⅝

2⅝ 1⅝

2⅝ 2⅛

2⅝ 2⅛

3⅛ 2⅝

3⅛ 2⅝

1⅝ 1⅛

2⅛ 1⅜

2⅛ 1⅝

2⅛ 1⅝

2⅝ 1⅝

2⅝ 2⅛

2⅝ 2⅛

3⅛ 2⅝

3⅛ 2⅝

Per

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

7

Pre-Installation

Receiving Inspection

When the unit arrives, verify it is the correct unit by
comparing the information that appears on the unit
nameplate with that which appears on the order
acknowledgement and shipping papers. Inspect the
equipment condition for any visible damage and
verify all items shown on the bill of lading are
present. If damage is evident, properly document it
on the delivery receipt and clearly mark any item
with damage as “unit damage” and notify the carrier.
In addition, make note of the specific damage and
notify Conair’s Service Department.

Shipping damage is the responsibility of the carrier.
To protect against possible loss due to damage
incurred during shipping and to expedite payment
for damages, it is important to follow proper
procedures and keep records. Photographs of
damaged equipment are excellent documentation
for your records.

Start unpacking the unit, inspect for concealed
damages, and take photos of any damages found.
Once received, equipment owners have the
responsibility to provide reasonable evidence that
the damage did not occur after delivery. Photos of
the equipment damage while the equipment is still
partially packed will help in this regard. Refrigerant
lines can be susceptible to damage in transit. Check
for broken lines, oil leaks, damaged controls, or any
other major component torn loose from its
mounting point.

Record any signs of concealed damage and file a
shipping damage claim immediately with the
shipping company. Most carriers require concealed
damages be reported within 15 days of receipt of
the equipment. In addition to notifying the carrier,
notify Conair’s Service Department.

Water-cooled chillers ship with a full refrigerant
charge while remote condenser chillers ship with a
nitrogen holding charge. Remote air-cooled
condensers ship separately with a 350-psi dry
nitrogen gas charge. Check the remote condenser
for signs of leaks prior to rigging. This will ensure no
coil damage has occurred after the unit left the

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factory. The condenser ships with the legs removed.
Mount the legs to the condenser using the provided
nuts, bolts, and washers.

Unit Storage

If the chiller is stored prior to installation, it is
important to protect it from damage. Blow out any
water or fluid from the evaporator and water-cooled
condenser circuits to protect the unit from damage
from freezing. Close any open refrigerant valves.
Cover the equipment to keep dirt and debris from
accumulating on it. Units charged with refrigerant
should not be stored in areas warmer than
145°F (62.8°C).

8

Installation - Chiller Mechanical

Unit Location

The chiller is available in many different
configurations to meet various environments. Please
refer to the proposal and order acknowledgement
for this equipment to verify the specific
environmental design conditions for your chiller.

Allow a minimum of 48 inches (1219mm) of
clearance between the remote condenser and any
walls or obstructions. For installations with multiple
condensers, allow a minimum of 96 inches (2438mm)
between condensers placed side-by-side or 48
inches (1219mm) for condensers placed end-to-end.
In all cases, install the equipment on a rigid surface
suitable to support the full operating weight of the
unit. Level all equipment to ensure proper operation.
When installed the equipment must be level within
¼ inch over its length and width.

Serviceability is an important factor to consider when
deciding on the location of the chiller. Do not
compromise this feature by locating it in an
inaccessible area. When locating the chiller it is
important to consider accessibility to the
components to allow for proper maintenance and
servicing of the unit. In general, allow a minimum of
36 inches (914mm) of clearance around all sides and
above the unit. There should be no piping or conduit
located over the unit. This will ensure easy access
with an overhead crane or lift for heavier
components should they need to be replaced or
serviced.

Proper ventilation is another important
consideration when locating the unit. Locate the unit
is an area that will not rise above 110°F (43.3°C).
In addition, ensure the condenser and evaporator
refrigerant pressure relief valves can vent in
accordance with all local and national codes.

Rigging

The chiller has a structural steel frame with forklift
slots to facilitate easy movement and positioning.
Follow proper rigging methods to prevent damage
to components. Avoid impact loading caused by

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sudden jerking when lifting or lowering the chiller.
Use pads where abrasive surface contact may occur.
Use the frame supporting the unit for positioning it
with a crane or a forklift.

Chilled Water Piping

Proper insulation of chilled water piping is crucial to
prevent condensation. The formation of
condensation on chiller water piping, the state
change of the water from gas to liquid, adds a
substantial heat load to the system and becomes an
additional burden for the chiller.

The importance of properly sized piping between
the chiller and process cannot be overemphasized.
Reference the current edition of the ASHRAE
Fundamentals Handbook or other suitable design
guide for proper pipe sizing. In general, run full size
piping out to the process and then reduce the pipe
size to match the connections on the process
equipment. One of the most common causes of
unsatisfactory chiller performance is poor piping
system design. Avoid long lengths of hoses, quick
disconnect fittings, and manifolds wherever possible
as they offer high resistance to water flow. When
manifolds are required, install them as close to the
use point as possible. Provide flow-balancing valves
at each machine to assure adequate water
distribution in the entire system.

Condenser Water Piping

(Water-Cooled Condenser Chillers Only)
The performance of a condenser is dependent on
maintaining the proper flow and temperature of
water through the heat exchanger. Insufficient water
flow or high condenser water supply temperature
will result in the reduction of cooling capacity of the
chiller. Extreme conditions will eventually result in
the chiller shutting down due to high refrigerant
pressure. Allowing the condenser to plug up from
contaminants in the condenser water stream
adversely affects performance. In order to reduce
maintenance costs and chiller downtime, a water
treatment program is highly recommended for the
condenser cooling water. Contact our Customer
Service Department for assistance in the proper
procedure for cleaning out any plugged condenser.

9

The nominal chiller design is for 85°F (38.6°C)
condenser cooling water supply. Under normal
operation under full load there will be about a 10°F
(4.5°C) rise through the condenser resulting in 95°F
(43.1°C) exiting water temperature from the
condenser. To ensure proper water flow through the
condenser, the condenser water pump should
provide at least 25 psi (1.7 bar).

Each condenser has a two-way condenser water­regulating valve. Under varying loads and condenser
inlet water temperatures the amount of cooling
water needed varies. The condenser water­regulating valve controls the amount of water
allowed to pass through the condenser in order to
maintain proper refrigeration pressures in the circuit.

To prevent damage to the condenser or regulating
valve, the condenser water pressure should not
exceed 150 psig (10.3 bar). The condenser water-

Mount the sensor in a ½” NPT coupling in a
minimum pipe size of 3”. The probe sheath is ¼” OD
x 3” in length and is equipped with a ½” NPT male
fitting for direct mounting in a coupling. The sensor
is to be direct immersion for the most accurate
reading and quickest response time. If direct
immersion mounting is not possible, mount the
sensor inside a thermowell to aid in maintenance
and or repair of the sensor if opening of the process
piping is not possible. Use a suitable heat transfer
compound with a thermowell. The sensor is
equipped with a NEMA-4 sensor head with an
integral temperature transmitter. Wiring must be
field provided from the sensor head to the chiller
electrical enclosure and landed at the designated
terminal blocks within the enclosure. Please see the
chiller electrical schematic provided for further
detail.

regulating valve controls the condenser water flow in
order to maintain the pressure set point. The chiller
load, condenser-water inlet temperature, and
pressure set point determine the actual flow.

Water Pressure Gauges

It is highly recommended to install pressure gauges
or taps in the inlet and outlet of both the condenser
and evaporator chilled water piping. The ability to
read the pressure drop across the chiller is important
and will aid in preventive maintenance and in
troubleshooting the chiller performance.

Master Temperature Sensor

This section only applies to installations where
multiple chillers are in a common system where one
chiller will be the master with the other chillers
serving as slaves. In those situations, a field-installed
master fluid-temperature sensor is required to be
field installed in the common chilled water supply
and return piping. The sensor ships loose from the
factory. The supply sensor should be installed
downstream of all individual chilled water supply
streams. Position the sensor to read the mixed
supply temperature. The supply sensor will normally
be the control sensor for the chilled water set point
and will determine the loading/unloading of the
compressors of the system.

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10

0

5

10

15

20

25

30

35

40

0 20 40 60 80 100 120 140 160

Pressure Loss (psi)

Flow (gpm)

Standard Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW15S

& T SER15S

TSEW20S

& T SER20S

TSEW25S

& T SER25S

TSEW30S

& T SER30S

TSEW10S

& T SER10S

Figure 1 – Standard Flow Chiller Coolant Circuit Pressure Drop (10 through 30 Ton Single-Circuit Chillers)

ESEW-015S

ESER-015S

ESEW-025S

ESER-025S

ESEW-020S

ESER-020S

ESEW-010S

ESER-010S

ESEW-030S

ESER-030S

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11

0

5

10

15

20

25

30

35

40

0 50 100 150 200 250 300 350 400

Pressure Loss (psi)

Flow (gpm)

Standard Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW50S

& T SER50S

TSEW60S

& T SER60S

TSEW80S

& T SER80S

TSEW40S

& T SER40S

ESEW-060S

ESER-060S

Figure 2 – Standard Flow Chiller Coolant Circuit Pressure Drop (40 through 80 Ton Single-Circuit Chillers)

ESEW-040S

ESER-040S

ESEW-050S

ESER-050S

ESEW-080S

ESER-080S

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12

0

5

10

15

20

25

30

35

40

0 40 80 120 160 200 240 280 320

Pressure Loss (psi)

Flow (gpm)

Standard Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW30D

& T SER30D

TSEW40D

& T SER40D

TSEW50D

& T SER50D

TSEW60D

& T SER60D

TSEW20D

& T SER20D

ESEW-060D

Figure 3 – Standard Flow Chiller Coolant Circuit Pressure Drop (20 through 160 ton Dual-Circuit Chillers)

ESEW-040D

ESER-040D

ESEW-030D

ESER-030D

ESEW-020D

ESER-020D

ESEW-050D

ESER-050D

ESER-060D

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13

0

5

10

15

20

25

30

35

40

0 100 200 300 400 500 600 700 800

Pressure Loss (psi)

Flow (gpm)

Standard Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW100D

& T SER100D

TSEW120D

& T SER120D

TSEW160D

& T SER160D

TSEW80D &

TSER80D

Figure 4 – Standard Flow Chiller Coolant Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers)

ESEW-080D

ESER-080D

ESEW-0100D

ESER-0100D

ESEW-0120D

ESER-0120D

ESEW-0160D

ESER-0160D

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14

0

5

10

15

20

25

30

35

40

0 20 40 60 80 100 120 140 160 180 200 220 240

Pressure Loss (psi)

Flow (gpm)

High Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW15S &

TSER15S

TSEW20S &

TSER20S

TSEW25S &

TSER25S

TSEW10S &

TSER10S

Figure 5 – High Flow Chiller Coolant Circuit Pressure Drop (10 through 25 ton Single-Circuit Chillers)

ESEW-010S

ESER-010S

ESEW-015S

ESER-015S

ESEW-020S

ESER-020S

ESEW-025S

ESER-025S

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15

0

5

10

15

20

25

30

35

40

0 50 100 150 200 250 300 350 400 450

Pressure Loss (psi)

Flow (gpm)

High Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW50S

& T SER50S

TSEW40S

& T SER40S

TSEW30S

& T SER30S

Figure 6 – High Flow Chiller Coolant Pressure Drop (30 through 50 ton Single-Circuit Chillers)

ESEW-030S

ESER-030S

ESEW-040S

ESEW-050S

ESER-050S

ESER-040S

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16

0

5

10

15

20

25

30

35

40

0 50 100 150 200 250 300 350 400 450 500

Pressure Loss (psi)

Flow (gpm)

High Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW30D

& T SER30D

TSEW40D

& T SER40D

TSEW50D

& T SER50D

TSEW20D

& T SER20D

Figure 7 – High Flow Chiller Coolant Pressure Drop (20 through 50 ton Dual-Circuit Chillers)

ESEW-020D

ESER-020D

ESEW-030D

ESER-030D

ESEW-040D

ESER-040D

ESEW-050D

ESER-050D

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17

0

5

10

15

20

25

30

35

40

0 100 200 300 400 500 600 700 800 900

Pressure Loss (psi)

Flow (gpm)

High Flow Chiller Coolant Circuit Pressure Drop

(Water at 50°F)

TSEW100D

& T SER100D

TSEW80D

& T SER80D

TSEW60D

& T SER60D

ESER-060D

ESER-080D

Figure 8 – High Flow Chiller Coolant Pressure Drop (60 through 100 ton Dual-Circuit Chillers)

ESEW-060D

ESEW-080D

ESEW-0100D

ESER-0100D

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18

0

3

6

9

12

15

18

21

24

0 25 50 75 100 125 150 175 200

Pressure Loss (psi)

Flow (gpm)

Condenser Water Circuit Pressure Drop

(Water at 85°F with Condenser Water Regulating Valve 100% Open)

TSEW10S

TSEW15S

TSEW20S

TSEW25S

TSEW30S

Figure 9 – Condenser Water Circuit Pressure Drop (10 through 30 ton Single-Circuit Chillers)

ESEW-010S

ESEW-015S

ESEW-020S

ESEW-025S

ESEW-030S

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19

0

3

6

9

12

15

18

21

24

0 50 100 150 200 250 300 350 400 450 500

Pressure Loss (psi)

Flow (gpm)

Condenser Water Cicuit Pressure Drop

(Water at 85°F with Condenser Water Regulating Valve 100% Open)

TSEW40S

TSEW50S

TSEW60S

TSEW80S

Figure 10 – Condenser Water Circuit Pressure Drop (40 through 80 ton Single-Circuit Chillers)

ESEW-050S

ESEW-040S

ESEW-060S

ESEW-080S

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20

0

3

6

9

12

15

18

21

24

0 50 100 150 200 250 300 350 400

Pressure Loss (psi)

Flow (gpm)

Condenser Water Circuit Pressure Drop

(Water at 85°F with Condenser Water Regulating Valve 100% Open)

TSEW20D

TSEW30D

TSEW40D

TSEW50D

TSEW60D

Figure 11 – Condenser Water Circuit Pressure Drop (20 through 60 ton Dual-Circuit Chillers)

ESEW-030D

ESEW-020D

ESEW-040D

ESEW-050D

ESEW-060D

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21

0

3

6

9

12

15

18

21

24

0 100 200 300 400 500 600 700 800 900 1000

Pressure Loss (psi)

Flow (gpm)

Condenser Water Circuit Pressure Drop

(Water at 85°F with Condenser Water Regulating valve 100% Open)

TSEW80D

TSEW100D

TSEW120D

TSEW160D

Figure 12 – Condenser Water Circuit Pressure Drop (80 through 160 ton Dual-Circuit Chillers)

ESEW-080D

ESEW-0100D

ESEW-0120D

ESEW-0160D

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22

Installation - Remote Air­Cooled Condenser

The remote condenser usually ships separately and
from a different location than the chiller.

Location

Chillers with a remote air-cooled condenser use a
separate remote air-cooled condenser. The
condenser is for outdoor use. A primary concern
when designing your unit was serviceability;
therefore, the condenser should be located in an
accessible area. Install the unit on a firm, level base
no closer than their width from walls or other
condensers. Avoid locations near exhaust fans,
plumbing vents, flues, or chimneys. Fasten the
mounting legs at their base to the steel or concrete
of the supporting structure. For units mounted on a
roof structure, the steel support base holding the
condenser should be elevated above the roof and
attached to the building.

Avoid areas that can create a “micro-climate” such as
an alcove with east, north, and west walls that can be
significantly warmer than surrounding areas. The
condenser needs to have unrestricted airways so it
can easily move cool air in and heated air away.
Consider locating the condenser where fan noise
and vibration transmission into nearby workspaces is
unlikely.

Allow a minimum of the width of the remote
condenser in clearance between the remote
condenser and any walls or obstructions. For
installations with multiple condensers, allow a
minimum of the width of the largest remote
condenser between condensers.

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23

Mounted Legs and Lifting (10 ton Single-Circuit and 20-ton Dual-Circuit Units)

The unit ships on its side with the legs removed to reduce shipping dimensions and provide more protection to
the coil from possible damaged caused by impact loading over rough roads and transit conditions. Follow the
below for mounting of the legs and lifting into position.

Use only qualified persons using the proper equipment when lifting and positioning the condenser. Lifting
brackets or holes are at the corners for attaching lifting slings. Use spreader bars when lifting to apply the lifting
force vertically.

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24

Mounted Legs and Lifting (all except 10 ton Single-Circuit and 20-ton Dual-Circuit Units)

The unit ships on its side with the legs removed to reduce shipping dimensions and provide more protection to
the coil from possible damaged caused by impact loading over rough roads and transit conditions. Follow the
below for mounting of the legs and lifting into position.

Use only qualified persons using the proper equipment when lifting and positioning the condenser. Lifting
brackets or holes are at the corners for attaching lifting slings. Use spreader bars when lifting to apply the lifting
force vertically.

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25

Note: Use refrigerant grade copper tubing ASTM

ODS or smaller.

Note: Do not use soft solders. For copper-to-

WARNING: The POE oil contained within the

tubing.

Interconnecting Refrigerant Piping

The chiller and remote condenser ship with a
nitrogen holding charge. Evacuation of this charge is
required before charging with refrigerant. The chiller
is for use only with the air-cooled condenser
provided with the unit. The following section covers
the required piping between the chiller and the
provided air-cooled condenser.

The chiller may consist of multiple evaporators,
compressors, liquid line solenoid valves, expansion
valves, sight glasses, filter driers, and receivers. The
discharge and liquid lines leaving the chiller have
caps. These line sizes do not necessarily reflect the
actual line sizes required for the piping between the
chiller and the air-cooled condenser. The installing
contractor need only provide the interconnecting
piping between the chiller and the air-cooled
condenser.

Refrigerant piping size and piping design have a
significant effect on system performance and
reliability. Refer to the Refrigeration Line Sizing
section of this manual to ensure the refrigerant
piping and runs are proper. All piping should
conform to the applicable local and state codes.

B280 only and isolate the refrigeration lines
from building structures to prevent transfer of
vibration. All copper tubing must have a pressure
rating suitable for R-410A: tubing that is ¾” OD
or larger must be Type K rigid tubing. ACR
annealed tubing coil may be used for sizes ⅝”

Do not use a saw to remove end caps. This might
allow copper chips to contaminate the system. Use a
tube cutter or heat to remove the caps. When
sweating copper joints it is important to evacuate all
refrigerant present if any and flow dry nitrogen
through the system. This prevents the formation of
toxic gases, corrosive acids, and the formation of
scale within the copper tube.

copper joints use a copper-phosphorus braze
alloy (BCuP per the American Welding Society)
with 5% (BCuP-3) to 15% (BCuP-5) silver
content. Only use a high silver content brazing
alloy (BAg per AWS) for copper-to-brass or
copper-to-steel joints such as a 45% (BAg-5)
silver content. Only use oxy-acetylene brazing.

compressor is hygroscopic and has the ability to
absorb water vapor from the atmosphere. Take
necessary steps to prevent an open system from
exposure to the atmosphere for extended periods
while installing the interconnecting refrigerant

Refrigeration Piping Design

The system is configurable in any of the
arrangements as shown in Figure 13, Figure 14, and
Figure 15. The configuration and its associated
elevation, along with the total distance between the
chiller and the air-cooled condenser are important
factors in determining the liquid line and discharge
line sizes. This will also affect the field refrigerant
charges. Consequently, it is important to adhere to
certain physical limitations to ensure the system
operates as designed.

General design considerations are:

1. The total distance between the chiller and the

air-cooled condenser must not exceed 200
actual feet (70.0 m) or 300 equivalent feet
(91.4 m). Keep the distance as short as possible.

2. Liquid line risers must not exceed 15 feet (4.6 m)

in height from the condenser liquid line
connection.

3. Discharge line risers cannot exceed an elevation

difference greater than 100 actual feet (30.5 m)
without a minimum of 2% efficiency decrease.

4. To form a proper liquid seal at the condenser,

immediately drop at least 15 inches (38.1 cm)
down from the liquid outlet before routing the
piping to the chiller. Make the drop leg before
any bends or angles connecting to the
remainder of the liquid connection piping.

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26

Condenser Width

To be same as

condenser width

Chiller

15" minimum at liquid

exit from condenser.

W W

Chiller

Locate condenser so

condenser liquid turns

down right away.

Figure 13 – Condenser Located with No Elevation Difference

Figure 14 – Condenser Located above Chiller Unit

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27

Note: Liquid line sizing for each chiller capacity is in Table 7. These line sizes are listed per circuit and apply where

ASHRAE Refrigeration Handbook or other suitable design guide.

Note: When calculating the equivalent length, do

piping must be considered.

Chiller

10' MAX

Figure 15 - Condenser Located Below Chiller Unit

leaving water temperature (LWT) is 40°F or higher. For applications where the LWT is below 40°F, size lines using the

Determining Equivalent Line Length

To determine the appropriate size for field installed
liquid and discharge lines, it is first necessary to
establish the equivalent length of pipe for each line.
The equivalent length is the approximate friction loss
from the combined linear run of pipe and the
equivalent feet of elbows, valves, and other
components in the refrigeration piping. The sum
total is the equivalent length of pipe that would have
the same pressure loss. See the ASHRAE
Refrigeration Handbook for more information.

Follow these steps when calculating line size:

1. Start with an initial approximation of equivalent

length by assuming that the equivalent length of
pipe is 1.5 times the actual pipe length.

2. Determine approximate line sizes by referring to

Table 7 for liquid lines, Table 8 and Table 9 for
the discharge lines.

3. Check the line size by calculating the actual

equivalent length using the equivalent lengths
as shown in Table 6.

not include piping of the chiller unit. Only field

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28

Elbow

Standard

Elbow 90°

Radius

⅞

2.0

1.4

3.2

0.9

1.6

1⅛

2.6

1.7

4.1

1.3

2.1

1⅝

2⅛

5.0

3.3

8.2

2.6

4.5

2⅝

6.0

4.1

10.0

3.2

5.2

3⅛

7.5

5.0

12.0

4.0

6.4

4⅛

10.0

6.7

17.0

5.2

8.5

Table 6 – Equivalent Lengths of Fittings

Line
Size

OD

inches

1⅜ 3.3 2.3 5.6 1.7 3.0

3⅝ 9.0 5.9 15.0 4.7 7.3

Equivalent Lengths of Refrigerant Pipe (feet)

90°

4.0 2.6 6.3 2.1 3.4

Long

Elbow 90°

Street

Elbow 45°

Standard

Elbow 45°

Street

Liquid Line Sizing

The liquid line diameter should be as small as
possible while maintaining acceptable pressure drop.
This is necessary to minimize refrigerant charge. The
total length between the chiller unit and the air­cooled condenser must not exceed 200 actual feet
(70.0 m) or 300 equivalent feet (91.4 m).

Liquid line risers in the system will require an
additional 0.5 psig pressure drop per foot of vertical
rise. When it is necessary to have a liquid line riser,
make the vertical run immediately after the
condenser before any additional restrictions. The
liquid line risers must not exceed 10 feet (3.0 m) in
height from the condenser liquid line connection
(see Figure 15). The liquid line does not require
pitching. Install a pressure tap valve at the condenser
to facilitate measuring pressure for service.

Liquid lines do not typically require insulation.
However, if exposing the lines to solar heat gain or
temperatures exceeding 110 °F (43.3°C), there is a
negative effect on sub-cooling. In these situations,
insulate the liquid lines.

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29

10 Ton Circuit (R410A)

15 Ton Circuit (R410A)

Liquid Line Size (Inch OD)

Liquid Line Size (Inch OD)

Horizontal

Downflow

Horizontal

Downflow

25 ⅝ ⅝ ⅝ ¾

25 ⅞ ⅞ ⅞ ⅞

50 ⅝ ⅝ ¾ ¾

50 ⅞ ⅞ ⅞ ⅞

75 ⅝ ⅝ ¾ ¾

75 ⅞ ⅞ ⅞ ⅞

100 ⅝ ¾ ¾ ¾

100 ⅞ ⅞ ⅞ 1⅛

125 ¾ ¾ ¾ ⅞

125 ⅞ ⅞ ⅞ 1⅛

150 ¾ ¾ ¾ ⅞

150 ⅞ ⅞ ⅞ 1⅛

175 ¾ ¾ ¾ ⅞

175 ⅞ ⅞ ⅞ 1⅛

200 ¾ ¾ ¾ ⅞

200 ⅞ ⅞ ⅞ 1⅛

225 ¾ ¾ ¾ ⅞

225 ⅞ ⅞ ⅞ 1⅜

250 ¾ ¾ ¾ ⅞

250 ⅞ ⅞ ⅞ 1⅜

275 ¾ ¾ ¾ 1⅛

275 ⅞ ⅞ ⅞ 1⅜

300 ⅞ ⅞ ⅞ 1⅛

300 ⅞ ⅞ ⅞ 1⅜

20 Ton Circuit (R410A)

25 Ton Circuit (R410A)

Liquid Line Size (Inch OD)

Liquid Line Size (Inch OD)

Horizontal

Downflow

Horizontal

Downflow

25

25

50 ⅞ ⅞ ⅞ 1⅛

50

1⅛

1⅛

1⅛

1⅛

75 ⅞ ⅞ ⅞ 1⅛

75

1⅛

1⅛

1⅛

1⅛

100 ⅞ ⅞

1⅛

1⅛

100

1⅛

1⅛

1⅛

1⅜

125 ⅞ ⅞

1⅛

1⅛

125

1⅛

1⅛

1⅛

1⅜

150 ⅞ 1⅛

1⅛

1⅜

150

1⅛

1⅛

1⅛

1⅜

175 ⅞ 1⅛

1⅛

1⅜

175

1⅛

1⅛

1⅛

1⅜

200

1⅛

1⅛

1⅛

1⅜

200

1⅛

1⅛

1⅛

1⅜

225

1⅛

1⅛

1⅛

1⅜

225

1⅛

1⅛

1⅜

1⅜

250

1⅛

1⅛

1⅛

1⅜

250

1⅛

1⅛

1⅜

1⅜

275

1⅛

1⅛

1⅛

1⅜

275

1⅛

1⅛

1⅜

1⅜

300

1⅛

1⅛

1⅛

1⅜

300

1⅛

1⅛

1⅜

1⅜

Table 7 – Liquid Line Sizes for R410A

Total
Equivalent
Length (ft)

Total
Equivalent
Length (ft)

or

or

⅞ ⅞ ⅞ 1⅛

Upflow

1 to 5 ft

Upflow

1 to 5 ft

Upflow

6 to 10 ft

Upflow

6 to 10 ft

Upflow

11 to 15 ft

Upflow

11 to 15 ft

Total
Equivalent
Length (ft)

Total
Equivalent
Length (ft)

or

or

1⅛ 1⅛ 1⅛ 1⅛

Upflow

1 to 5 ft

Upflow

1 to 5 ft

Upflow

6 to 10 ft

Upflow

6 to 10 ft

Upflow

11 to 15 ft

Upflow

11 to 15 ft

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

30

30 Ton Circuit (R410A)

40 Ton Circuit (R410A)

Liquid Line Size (Inch OD)

Liquid Line Size (Inch OD)

Horizontal

Downflow

Horizontal

Downflow

25

1⅛

1⅛

1⅛

1⅛

25

1⅛

1⅛

1⅛

1⅛

50

1⅛

1⅛

1⅛

1⅛

50

1⅛

1⅛

1⅛

1⅜

75

1⅛

1⅛

1⅛

1⅛

75

1⅛

1⅛

1⅛

1⅜

100

1⅛

1⅛

1⅛

1⅛

100

1⅛

1⅛

1⅜

1⅜

125

1⅛

1⅛

1⅛

1⅛

125

1⅛

1⅛

1⅜

1⅜

150

1⅛

1⅛

1⅛

1⅛

150

1⅛

1⅜

1⅜

1⅝

175

1⅛

1⅛

1⅛

1⅛

175

1⅛

1⅜

1⅜

1⅝

200

1⅛

1⅛

1⅛

1⅛

200

1⅜

1⅜

1⅜

1⅝

225

1⅛

1⅛

1⅛

1⅛

225

1⅜

1⅜

1⅜

1⅝

250

1⅛

1⅛

1⅛

1⅛

250

1⅜

1⅜

1⅝

2⅛

275

1⅛

1⅛

1⅛

1⅛

275

1⅜

1⅜

1⅝

2⅛

300

1⅛

1⅛

1⅛

1⅜

300

1⅜

1⅜

1⅝

2⅛

50 Ton Circuit (R410A)

60 Ton Circuit (R410A)

Liquid Line Size (Inch OD)

Liquid Line Size (Inch OD)

Horizontal

Downflow

Horizontal

Downflow

25

25

50

1⅛

1⅛

1⅛

1⅜

50

1⅛

1⅛

1⅜

1⅝

75

1⅛

1⅛

1⅜

1⅝

75

1⅛

1⅜

1⅜

1⅝

100

1⅛

1⅛

1⅜

1⅝

100

1⅜

1⅜

1⅜

1⅝

125

1⅛

1⅜

1⅜

1⅝

125

1⅜

1⅜

1⅝

2⅛

150

1⅜

1⅜

1⅜

1⅝

150

1⅜

1⅜

1⅝

2⅛

175

1⅜

1⅜

1⅝

2⅛

175

1⅜

1⅜

1⅝

2⅛

200

1⅜

1⅜

1⅝

2⅛

200

1⅜

1⅝

1⅝

2⅛

225

1⅜

1⅜

1⅝

2⅛

225

1⅜

1⅝

1⅝

2⅛

250

1⅜

1⅜

1⅝

2⅛

250

1⅜

1⅝

1⅝

2⅛

275

1⅜

1⅝

1⅝

2⅛

275

1⅝

1⅝

2⅛

2⅛

300

1⅜

1⅝

1⅝

2⅛

300

1⅝

1⅝

2⅛

2⅛

Table 7 – Liquid Line Sizes for R410A (continued)

Total
Equivalent
Length (ft)

Total
Equivalent
Length (ft)

or

or

1⅛ 1⅛ 1⅛ 1⅜

Upflow

1 to 5 ft

Upflow

1 to 5 ft

Upflow

6 to 10 ft

Upflow

6 to 10 ft

Upflow

11 to 15 ft

Upflow

11 to 15 ft

Total
Equivalent
Length (ft)

Total
Equivalent
Length (ft)

or

or

1⅛ 1⅛ 1⅜ 1⅝

Upflow

1 to 5 ft

Upflow

1 to 5 ft

Upflow

6 to 10 ft

Upflow

6 to 10 ft

Upflow

11 to 15 ft

Upflow

11 to 15 ft

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

31

80 Ton Circuit (R410A)

Liquid Line Size (Inch OD)

Horizontal

Downflow

Upflow

ft

25

1⅛

1⅜

1⅜

1⅝

50

1⅛

1⅜

1⅜

1⅝

75

1⅜

1⅜

1⅝

2⅛

100

1⅜

1⅜

1⅝

2⅛

125

1⅜

1⅝

1⅝

2⅛

150

1⅜

1⅝

1⅝

2⅛

175

1⅝

1⅝

2⅛

2⅛

200

1⅝

1⅝

2⅛

2⅛

225

1⅝

1⅝

2⅛

2⅝

250

1⅝

1⅝

2⅛

2⅝

275

1⅝

2⅛

2⅛

2⅝

300

1⅝

2⅛

2⅛

2⅝

FROM

CHILLER

15'

TO

CONDENSER

TRAP &

REVERSE

TRAP

(4 LR STREET ELS)

REVERSE

TRAP

(3 LR STREET ELS)

REVERSE

TRAP

(3 LR STREET ELS)

VERTICLE UPFLOW

DISCHARGE RISER

Table 7 – Liquid Line Sizes for R410A (continued)

Total

Equivalent

Length

(ft)

or

Upflow

1 to 5 ft

Upflow

6 to 10 ft

11 to 15

Figure 16 – Vertical Riser Traps

Discharge (Hot Gas) Line Sizing

The discharge line sizes depend on the velocity
needed to obtain sufficient oil return. It is very
important to minimize line length and restrictions to
reduce pressure drop and maximize capacity.

Upflow hot gas risers need to have a trap at the
bottom and reverse trap at the top. In addition, a
trap and reverse trap arrangement needs to be
spaced every 15 feet (4.6 m) in the rise for oil
management (see Figure 16).

The discharge lines should pitch downward, in the
direction of the hot gas flow, at the rate of ½ inch
per each 10 foot (1.27 cm per 3.05 m) of horizontal
run. If the chiller unit is below the condenser, loop
the discharge line to at least 1 inch (2.54 cm) above
the top of the condenser. Install a pressure tap valve
at the condenser to facilitate measuring pressure for
service. Take careful consideration in the design of
the discharge gas riser.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

All chillers have unloading capabilities. The chiller
uses tandem compressors with one circuit per
tandem set. Unloading will cycle off one of the
compressors. This is not enough to cause problems
with oil return from the remote condenser. Check
the oil-level sight glass in the compressor if there is
a concern there may be oil in the piping.

On chillers equipment with the optional hot gas
bypass capacity control the gas in the upflow
discharge lines may have problems moving the oil
against gravity when completely unloaded. For those
systems only, see Figure 17 and Table 9 for double
riser constructions.

32

Note: Discharge line sizing shown in Table 8 and Table 9 are listed per circuit and applies where leaving water

Handbook or other suitable design guide.

25

50

75

100

125

150

175

200

225

250

275

300

10 ⅞ ⅞ ⅞ ⅞ ⅞ ⅞ ⅞ 1⅛

1⅛

1⅛

1⅛

1⅛

15 ⅞ ⅞

1⅛

1⅛

1⅛

1⅛

1⅛

1⅛

1⅛

1⅛

1⅜

1⅜

20 ⅞ 1⅛

1⅛

1⅜

1⅜

1⅜

1⅜

1⅜

1⅜

1⅜

1⅝

1⅝

25

1⅛

1⅛

1⅛

1⅛

1⅜

1⅜

1⅜

1⅜

1⅜

1⅜

1⅝

1⅝

30

1⅛

1⅛

1⅛

1⅜

1⅜

1⅜

1⅜

1⅜

1⅜

1⅝

1⅝

1⅝

40

1⅝

1⅝

1⅝

1⅝

1⅝

1⅝

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

50

1⅝

1⅝

1⅝

1⅝

1⅝

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

60

1⅝

1⅝

1⅝

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

80

1⅝

1⅝

2⅛

2⅛

2⅛

2⅛

2⅛

2⅛

2⅝

2⅝

2⅝

2⅝

A

B

REDUCING

TEE

FROM

CHILLER

PITCH TO

CONDENSER

45 DEGREE

STREET ELBOWS

90 DEGREE

STREET ELBOWS

Figure 17 - Double Discharge Riser

temperature (LWT) is 40°F or higher. For applications where LWT is below 40°F, size lines using the ASHRAE Refrigeration

Table 8 – Discharge Line Sizes for Chiller (inches OD)

Circuit

Tons

Total Equivalent Length (ft)

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33

25

50

75

100

125

150

175

200

225

250

275

300

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

B - ¾

B - ¾

B - ¾

B - ¾

B - ¾

B - ¾

B - ¾

B - ⅞

B - ⅞

B - ⅞

B - ⅞

B - ⅞

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ⅜

A - ½

A - ½

B - ¾

B - ¾

B - ⅞

B - ⅞

B - ⅞

B - ⅞

B - ⅞

B - ⅞

B - ⅞

B - ⅞

B - 1⅛

B - 1⅛

A - ⅜

A - ⅜

A - ⅜

A - ½

A - ½

A - ½

A - ½

A - ½

A - ½

A - ½

A - ⅝

A - ⅝

B - ¾

B - ⅞

B - ⅞

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅜

B - 1⅜

A - ⅜

A - ⅜

A - ⅜

A - ½

A - ½

A - ½

A - ½

A - ½

A - ½

A - ½

A - ⅝

A - ⅝

B - ⅞

B - ⅞

B - ⅞

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅜

B - 1⅜

A - ½

A - ½

A - ½

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

B - ⅞

B - ⅞

B - ⅞

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅛

B - 1⅜

B - 1⅜

B - 1⅜

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

A - ¾

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅜

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

A - ¾

A - ¾

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

B - 1⅜

B - 1⅜

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

A - ¾

A - ¾

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

A - ⅞

B - 1⅜

B - 1⅜

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 1⅝

B - 2⅛

B - 2⅛

B - 2⅛

B - 2⅛

Refrigeration Circuit Capacity (tons)

10

15

20

25

30

40

50

60

80

Single-Circuit Chillers

15.3

22.2

30.2

37.2

44.3

59.4

79.6

109.0

136.1

Dual-Circuit Chillers

17.3

24.7

30.2

37.2

43.8

59.4

79.6

108.5

136.1

Line Size OD (inches)

⅜ ½ ⅝ ¾ ⅞

1⅛

1⅜

1⅝

2⅛

2⅝

Discharge Line

0.4

0.7

1.1

1.6

2.2

3.6

5.6

7.9

13.9

21.4

Liquid Line

3.7

6.8

11.0

16.4

22.8

36.7

57.4

81.2

142.1

219.5

Table 9 - Upflow Discharge Line Sizes for R410A (inches OD)

Circuit

Tons

10

15

20

25

30

40

50

60

80

Total Equivalent Length (ft)

Calculating System Refrigerant and Oil Charge

To determine the approximate charge, first refer to Table 10 and establish the required charge for the condenser
and chiller. Values given in Table 10 are per circuit. Then refer to Table 11 to determine the charge required for
the field-installed piping per circuit. The approximate charge per circuit is therefore the sum of the values from
Table 10 and Table 11.

Table 10 – Combined Chiller and Remote Condenser Summer Refrigerant Charge

Refrigerant Charge (Lbs. of R-410A)

Table 11 - Field Piping R-410A Refrigerant Charge per 100 Feet of Run (Lbs.)

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34

Stage

Number

Number of Fan Stages

1 2 3 4 5

6

Max Speed

410

410

410

410

410

410

Min Speed

320

320

320

320

320

320

Fan On

365

365

365

365

365

Fan Off

330

330

330

330

330

Fan On

375

375

375

375

Fan Off

340

340

340

340

Fan On

385

385

385

Fan Off

350

350

350

Fan On

395

395

Fan Off

360

360

405

370

Oil Charge Determination

The chiller is factory charged with the amount of oil
required by the chiller only and not the total system.
The amount of oil required is dependent upon the
amount of refrigerant added to the system for the
field-installed piping. Use the following to determine
the amount of oil needed for the system.

Pints of Oil = Pounds of refrigerant added to the
system / 100

Check the oil level after the chiller has run for 15
minutes.

Setting Condenser Fan Controls

Depending on the number of condenser fans
present there will be different fan cycling pressure
control setting requirements. It is important that
these settings be correct in order to maintain proper
capacity control and operation of the system. Each
refrigerant circuit has a separate head-pressure
control circuit. Refer to Table 12 for the proper
pressure settings.

Table 12 - Condenser Fan Pressure Settings (psig)

Setting

Stage 1

Stage 2

Stage 3

Stage 4

Stage 5

Stage 6

Note: Dual circuit condensers have two separate head-pressure
controls circuits.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

35

WARNING: This equipment contains hazardous

WARNING: This equipment contains refrigerant

property damage.

WARNING: This equipment may contain fan

in place.

WARNING: The exposed surfaces of motors,

if touched with unprotected hands.

CAUTION: Disconnect and lock out incoming

opening access panels for repair or maintenance.

CAUTION: Wear eye protection when installing,

CAUTION: Wear protective gloves when

or fluid leaks.

CAUTION: Ground the unit properly in

CAUTION: The unit requires the main power to

Installation - Electrical

All wiring must comply with local codes and the
National Electric Code. Minimum Circuit Amps (MCA)
and other unit electrical data are on the unit
nameplate. A unit specific electrical schematic ships
with the unit. Measure each leg of the main power
supply voltage at the main power source. Voltage
must be within the voltage utilization range given on
the drawings included with the unit. If the measured
voltage on any leg is not within the specified range,
notify the supplier and correct before operating the
unit. Voltage imbalance must not exceed 2%.
Excessive voltage imbalance between the phases of a
three-phase system can cause motors to overheat
and eventually fail. Voltage imbalance is determined
using the following calculations:

% Imbalance = (Vavg – Vx) x 100 / Vavg

Vavg = (V1 + V2 + V3) / 3
Vx = phase with greatest difference from Vavg

There is a terminal block for main power connection
to the main power source. The main power source
should be connected to the terminal block through
an appropriate disconnect switch. There is a separate
lug in the main control panel for grounding the unit.
Check the electrical phase sequence at installation
and prior to start-up. Operation of the compressor
with incorrect electrical phase sequencing will result
in mechanical damage to the compressors. Check
the phasing with a phase sequence meter prior to
applying power. The proper sequence should read
“ABC” on the meter. If the meter reads “CBA”, open
the main power disconnect and switch two line leads
on the line power terminal blocks (or the unit
mounted disconnect). Do not interchange any load
leads that are from the unit contactors or the motor
terminals.

voltages that can cause severe injury or death.

under pressure. Accidental release of refrigerant
under pressure can cause personal injury and or

blades or other sharp edges. Make sure all fan
guards and other protective shields are securely

refrigerant piping, and other fluid circuit
components can be very hot and can cause burns

power before installing, servicing, or
maintaining the equipment. Connecting power to
the main terminal block energizes the entire
electric circuitry of the unit. A power supply
provides 24 VDC control power. Electric power at
the main disconnect should be shut off before

maintaining, or repairing the equipment to
protect against any sparks, debris, or fluid leaks.

installing, maintaining, or repairing the
equipment to protect against any sparks, debris,

compliance with local and national codes.

remain connected during off-hours to energize
the compressor’s crankcase heater. Disconnect
main power only when servicing the chiller. The
crankcase heater should remain on when the
compressor is off to ensure liquid refrigerant
does not accumulate in the compressor
crankcase. Connect main power at least 24 hours
prior to initial start-up.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

36

Main Power (3-phase, 60 Hz)

Compressors

Chiller

Allowable

RLA1 LRA

2

Min

Max

(each)

(each)

208

187

253 2 19.0

123

43

60

230

187

253 2 19.0

123

43

70

460

414

508 2 9.7

62

22

35

575

518

632 2 7.4

50

18

25

208

187

253 2 29.5

195

67

110

230

187

253 2 29.5

195

67

110

460

414

508 2 14.7

95

34

50

575

518

632 2 12.2

80

29

45

208

187

253 2 33.3

239

76

125

230

187

253 2 33.3

239

76

125

460

414

508 2 17.9

125

42

60

575

518

632 2 12.8

80

30

45

208

187

253 2 51.3

300

117

175

230

187

253 2 51.3

300

117

175

460

414

508 2 23.1

150

53

80

575

518

632 2 19.9

109

46

70

208

187

253 2 55.8

340

127

200

230

187

253 2 55.8

340

127

200

460

414

508 2 26.9

173

62

100

575

518

632 2 23.7

132

55

80

208

187

253 2 72.4

538

164

250

230

187

253 2 72.4

538

164

250

460

414

508 2 30.8

229

71

110

575

518

632 2 25.0

180

58

90

208

187

253 2 85.3

605

193

300

230

187

253 2 85.3

605

193

300

460

414

508 2 37.8

320

86

125

575

518

632 2 34.6

250

79

125

208

187

253 2 109.6

599

248

400

230

187

253 2 109.6

599

248

400

460

414

508 2 54.5

310

124

200

575

518

632 2 49.4

239

112

175

208

187

253 2 N/A

N/A

N/A

N/A

230

187

253 2 N/A

N/A

N/A

N/A

460

414

508 2 73.0

368

165

250

575

518

632 2 N/A

N/A

N/A

N/A

Table 13 – ESEW & ESER Single-Circuit Chiller Electrical Data (60 Hz)

Model

ESEW-010S

& ESER-010S

ESEW-015S

& ESER-015S

ESEW-020S

& ESER-020S

ESEW-025S

& ESER-025S

ESEW-030S

& ESER-030S

ESEW-040S

& ESER-040S

Rated

Qty

MCA

3

MOPD

4

ESEW-050S

& ESER-050S

ESEW-060S

& ESER-060S

ESEW-080S

& ESER-080S

1

RLA is Rated Load Amps.

2

LRA is Locked Rotor Amps.

3

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

4

MOPD is Maximum Over-current Protection Device, complies with NEC, Section 430-53.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

37

Main Power

(3-phase, 60 Hz)

Process

Pump

Min

Max

(ea)

(ea)

Qty

FLA3 Qty

FLA

3

208

187

253 2 19.0

123 1 16.6 1 5.3

65

80

230

187

253 2 19.0

123 1 15.0 1 4.8

63

80

460

414

508 2 9.7

62 1 7.5 1 2.4

32

40

575

518

632 2 7.4

50 1 6.0 1 1.9

25

30

208

187

253 2 29.5

195 1 16.6 1 5.3

88

110

230

187

253 2 29.5

195 1 15.0 1 4.8

86

110

460

414

508 2 14.7

95 1 7.5 1 2.4

43

50

575

518

632 2 12.2

80 1 6.0 1 1.9

35

45

208

187

253 2 33.3

239 1 16.6 1 5.3

97

125

230

187

253 2 33.3

239 1 15.0 1 4.8

95

125

460

414

508 2 17.9

125 1 7.5 1 2.4

50

60

575

518

632 2 12.8

80 1 6.0 1 1.9

37

50

208

187

253 2 51.3

300 1 16.6 1 5.3

137

175

230

187

253 2 51.3

300 1 15.0 1 4.8

135

175

460

414

508 2 23.1

150 1 7.5 1 2.4

62

80

575

518

632 2 19.9

109 1 6.0 1 1.9

53

70

208

187

253 2 55.8

340 1 24.3 1 6.6

157

200

230

187

253 2 55.8

340 1 22.0 1 6.0

154

200

460

414

508 2 26.9

173 1 11.0 1 3.0

75

100

575

518

632 2 23.7

132 1 8.8 1 2.4

65

80

208

187

253 2 72.4

538 1 31.0 1 6.6

200

250

230

187

253 2 72.4

538 1 28.0 1 6.0

197

250

460

414

508 2 30.8

229 1 14.0 1 3.0

86

110

575

518

632 2 25.0

180 1 11.2 1 2.4

70

90

208

187

253 2 85.3

605 1 31.0 1 10.0

233

300

230

187

253 2 85.3

605 1 28.0 1 9.0

229

300

460

414

508 2 37.8

320 1 14.0 1 4.5

104

125

575

518

632 2 34.6

250 1 11.2 1 3.6

93

125

208

187

253 2 109.6

599 1 31.0 1 10.0

288

350

230

187

253 2 109.6

599 1 28.0 1 9.0

284

350

460

414

508 2 54.5

310 1 14.0 1 4.5

141

175

575

518

632 2 49.4

239 1 11.2 1 3.6

126

175

208

187

253 2 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

230

187

253 2 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

460

414

508 2 73.0

368 1 19.0 1 4.5

188

250

575

518

632 2 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Table 14 – ESEW & ESER Single-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz)

Compressors Pumps Chiller

Model

ESEW-010S

& ESER-010S

ESEW-015S

& ESER-015S

ESEW-020S

& ESER-020S

ESEW-025S

& ESER-025S

Rated

Allowable

Qty

RLA1 LRA

2

Chiller Pump

MCA

4

MOPD

5

ESEW-030S

& ESER-030S

ESEW-040S

& ESER-040S

ESEW-050S

& ESER-050S

ESEW-060S

& ESER-060S

ESEW-080S

& ESER-080S

1

RLA is Rated Load Amps.

2

LRA is Locked Rotor Amps.

3

FLA is Full Load Amps.

4

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

5

MOPD is Maximum Over-current Protection Device, complies with NEC, Section 430-53.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

38

Main Power

(3-phase, 60 Hz)

Process

Pump

Min

Max

(ea)

(ea)

Qty

FLA3 Qty

FLA

3

208

187

253 2 19.0

123 1 16.6 1 5.3

65

80

230

187

253 2 19.0

123 1 15.0 1 4.8

63

80

460

414

508 2 9.7

62 1 7.5 1 2.4

32

40

575

518

632 2 7.4

50 1 6.0 1 1.9

25

30

208

187

253 2 29.5

195 1 24.3 1 5.3

96

125

230

187

253 2 29.5

195 1 22.0 1 4.8

93

110

460

414

508 2 14.7

95 1 11.0 1 2.4

46

60

575

518

632 2 12.2

80 1 8.8 1 1.9

38

50

208

187

253 2 33.3

239 1 31.0 1 5.3

111

125

230

187

253 2 33.3

239 1 28.0 1 4.8

108

125

460

414

508 2 17.9

125 1 14.0 1 2.4

57

70

575

518

632 2 12.8

80 1 11.2 1 1.9

42

50

208

187

253 2 51.3

300 1 31.0 1 5.3

152

200

230

187

253 2 51.3

300 1 28.0 1 4.8

148

200

460

414

508 2 23.1

150 1 14.0 1 2.4

68

90

575

518

632 2 19.9

109 1 11.2 1 1.9

58

70

208

187

253 2 55.8

340 1 31.0 1 6.6

163

200

230

187

253 2 55.8

340 1 28.0 1 6.0

160

200

460

414

508 2 26.9

173 1 14.0 1 3.0

78

100

575

518

632 2 23.7

132 1 11.2 1 2.4

67

90

208

187

253 2 72.4

538 1 42.0 1 6.6

212

250

230

187

253 2 72.4

538 1 38.0 1 6.0

207

250

460

414

508 2 30.8

229 1 19.0 1 3.0

91

110

575

518

632 2 25.0

180 1 15.2 1 2.4

74

90

208

187

253 2 85.3

605 1 42.0 1 10.0

244

300

230

187

253 2 85.3

605 1 38.0 1 9.0

239

300

460

414

508 2 37.8

320 1 19.0 1 4.5

109

125

575

518

632 2 34.6

250 1 15.2 1 3.6

97

125

208

187

253 2 109.6

599 1 57.5 1 10.0

314

400

230

187

253 2 109.6

599 1 52.0 1 9.0

308

400

460

414

508 2 54.5

310 1 26.0 1 4.5

153

200

575

518

632 2 49.4

239 1 20.8 1 3.6

136

175

208

187

253 2 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

230

187

253 2 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

460

414

508 2 73.0

368 1 32.0 1 4.5

201

250

575

518

632 2 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Table 15 – ESEW & ESER Single-Circuit Chiller with High Flow Pump Set 1 Electrical Data (60 Hz)

Compressors Pumps Chiller

Model

ESEW-010S

& ESER-010S

ESEW-015S

& ESER-015S

ESEW-020S

& ESER-020S

ESEW-025S

& ESER-025S

ESEW-030S

& ESER-030S

Rated

Allowable

Qty

RLA1 LRA

2

Chiller Pump

MCA

4

MOPD

5

ESEW-040S

& ESER-040S

ESEW-050S

& ESER-050S

ESEW-060S

& ESER-060S

ESEW-080S

& ESER-080S

1

RLA is Rated Load Amps.

2

LRA is Locked Rotor Amps.

3

FLA is Full Load Amps.

4

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

5

MOPD is Maximum Over-current Protection Device, complies with NEC, Section 430-53.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

39

Main Power (3-phase, 60 Hz)

Compressors

Chiller

Allowable

RLA1 LRA

2

Min

Max

(each)

(each)

208

187

253 4 19.0

123

81

100

230

187

253 4 19.0

123

81

100

460

414

508 4 9.7

62

42

50

575

518

632 4 7.4

50

32

35

208

187

253 4 29.5

195

126

150

230

187

253 4 29.5

195

126

150

460

414

508 4 14.7

95

63

70

575

518

632 4 12.2

80

52

60

208

187

253 4 33.3

239

142

175

230

187

253 4 33.3

239

142

175

460

414

508 4 17.9

125

76

90

575

518

632 4 12.8

80

55

60

208

187

253 4 51.3

300

219

250

230

187

253 4 51.3

300

219

250

460

414

508 4 23.1

150

99

110

575

518

632 4 19.9

109

85

100

208

187

253 4 55.8

340

238

250

230

187

253 4 55.8

340

238

250

460

414

508 4 26.9

173

115

125

575

518

632 4 23.7

132

101

110

208

187

253 4 72.4

538

308

350

230

187

253 4 72.4

538

308

350

460

414

508 4 30.8

229

131

150

575

518

632 4 25.0

180

107

125

208

187

253 4 85.3

605

363

400

230

187

253 4 85.3

605

363

400

460

414

508 4 37.8

320

161

175

575

518

632 4 34.6

250

148

175

208

187

253 4 109.6

599

466

500

230

187

253 4 109.6

599

466

500

460

414

508 4 54.5

310

232

250

575

518

632 4 49.4

239

210

250

208

187

253 4 N/A

N/A

N/A

N/A

230

187

253 4 N/A

N/A

N/A

N/A

460

414

508 4 73.0

368

311

350

575

518

632 4 N/A

N/A

N/A

N/A

Table 17 – ESEW & ESER Dual-Circuit Chiller Electrical Data (60 Hz)

Model

ESEW-020D &

ESER-020D

ESEW-030D &

ESER-030D

ESEW-040D &

ESER-040D

ESEW-050D &

ESER-050D

ESEW-060D &

ESER-060D

ESEW-080D &

ESER-080D

Rated

Qty

MCA

3

MOPD

4

ESEW-0100D

& ESER-0100D

ESEW-0120D

& ESER-0120D

ESEW-0160D

& ESER-0160D

1

RLA is Rated Load Amps.

2

LRA is Locked Rotor Amps.

3

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

4

MOPD is Maximum Over-current Protection Device, complies with NEC, Section 430-53.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

40

Main Power

(3-phase, 60 Hz)

Process

Pump

Min

Max

(ea)

(ea)

Qty

FLA3 Qty

FLA

3

208

187

253 4 19.0

123 1 16.6 1 5.3

103

110

230

187

253 4 19.0

123 1 15.0 1 4.8

101

110

460

414

508 4 9.7

62 1 7.5 1 2.4

51

60

575

518

632 4 7.4

50 1 6.1 1 2.4

40

45

208

187

253 4 29.5

195 1 24.3 1 6.6

156

175

230

187

253 4 29.5

195 1 22.0 1 6.0

153

175

460

414

508 4 14.7

95 1 11.0 1 3.0

76

90

575

518

632 4 12.2

80 1 9.0 1 2.7

64

70

208

187

253 4 33.3

239 1 31.0 1 6.6

179

200

230

187

253 4 33.3

239 1 28.0 1 6.0

176

200

460

414

508 4 17.9

125 1 14.0 1 3.0

93

110

575

518

632 4 12.8

80 1 11.0 1 2.7

68

80

208

187

253 4 51.3

300 1 31.0 1 10.0

259

300

230

187

253 4 51.3

300 1 28.0 1 9.0

255

300

460

414

508 4 23.1

150 1 14.0 1 4.5

117

125

575

518

632 4 19.9

109 1 11.0 1 3.9

99

110

208

187

253 4 55.8

340 1 31.0 1 10.0

278

300

230

187

253 4 55.8

340 1 28.0 1 9.0

274

300

460

414

508 4 26.9

173 1 14.0 1 4.5

133

150

575

518

632 4 23.7

132 1 11.2 1 3.6

116

125

208

187

253 4 72.4

538 1 42.0 1 10.0

360

400

230

187

253 4 72.4

538 1 38.0 1 9.0

355

400

460

414

508 4 30.8

229 1 19.0 1 4.5

154

175

575

518

632 4 25.0

180 1 17.0 1 3.9

127

150

208

187

253 4 85.3

605 1 42.0 1 16.6

421

500

230

187

253 4 85.3

605 1 38.0 1 15.0

416

500

460

414

508 4 37.8

320 1 19.0 1 7.5

187

225

575

518

632 4 34.6

250 1 17.0 1 6.1

170

200

208

187

253 4 109.6

599 1 57.5 1 24.3

548

600

230

187

253 4 109.6

599 1 52.0 1 22.0

540

600

460

414

508 4 54.5

310 1 26.0 1 11.0

269

300

575

518

632 4 49.4

239 1 22.0 1 6.1

238

250

208

187

253 4 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

230

187

253 4 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

460

414

508 4 73.0

368 1 32.0 1 14.0

356

400

575

518

632 4 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Table 18 – ESEW & ESER Dual-Circuit Chiller with Standard Flow Pump Set Electrical Data (60 Hz)

Compressors Pumps Chiller

Model

ESEW-020D &

ESER-020D

ESEW-030D &

ESER-030D

ESEW-040D &

ESER-040D

ESEW-050D &

ESER-050D

ESEW-060D &

ESER-060D

Rated

Allowable

Qty

RLA1 LRA

2

Chiller Pump

MCA4 MOPD

5

ESEW-080D &

ESER-080D

ESEW-0100D

& ESER-0100D

ESEW-0120D

& ESER-0120D

ESEW-0160D

& ESER-0160D

1

RLA is Rated Load Amps.

2

LRA is Locked Rotor Amps.

3

FLA is Full Load Amps.

4

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

5

MOPD is Maximum Over-current Protection Device, complies with NEC, Section 430-53.

Corporate Office: 724.584.5500  Instant Access 24/7 (Parts and Service): 800.458.1960  Parts and Service: 814.437.6861

41

Main Power

(3-phase, 60 Hz)

Process

Pump

Min

Max

(ea)

(ea)

Qty

FLA3 Qty

FLA

3

208

187

253 4 19.0

123 1 31.0 1 5.3

120

125

230

187

253 4 19.0

123 1 28.0 1 4.8

116

125

460

414

508 4 9.7

62 1 14.0 1 2.4

59

60

575

518

632 4 7.4

50 1 6.1 1 2.4

40

45

208

187

253 4 29.5

195 1 31.0 1 6.6

163

175

230

187

253 4 29.5

195 1 28.0 1 6.0

159

175

460

414

508 4 14.7

95 1 14.0 1 3.0

79

90

575

518

632 4 12.2

80 1 9.0 1 2.7

64

70

208

187

253 4 33.3

239 1 42.0 1 6.6

192

200

230

187

253 4 33.3

239 1 38.0 1 6.0

187

200

460

414

508 4 17.9

125 1 19.0 1 3.0

98

110

575

518

632 4 12.8

80 1 11.0 1 2.7

68

80

208

187

253 4 51.3

300 1 42.0 1 10.0

270

300

230

187

253 4 51.3

300 1 38.0 1 9.0

265

300

460

414

508 4 23.1

150 1 19.0 1 4.5

122

125

575

518

632 4 19.9

109 1 11.0 1 3.9

99

110

208

187

253 4 55.8

340 1 57.5 1 10.0

305

350

230

187

253 4 55.8

340 1 52.0 1 9.0

298

300

460

414

508 4 26.9

173 1 26.0 1 4.5

145

150

575

518

632 4 23.7

132 1 11.0 1 4.5

116

125

208

187

253 4 72.4

538 1 70.8 1 10.0

388

450

230

187

253 4 72.4

538 1 64.0 1 9.0

381

450

460

414

508 4 30.8

229 1 32.0 1 4.5

168

175

575

518

632 4 25.0

180 1 17.0 1 3.9

127

150

208

187

253 4 85.3

605 1 86.3 1 16.6

466

500

230

187

253 4 85.3

605 1 78.0 1 15.0

456

500

460

414

508 4 37.8

320 1 39.0 1 7.5

207

225

575

518

632 4 34.6

250 1 17.0 1 6.1

170

200

208

187

253 4 109.6

599

1

112.8

1

24.3

604

600

230

187

253 4 109.6

599

1

102.0

1

22.0

590

600

460

414

508 4 54.5

310 1 51.0 1 11.0

294

300

575

518

632 4 49.4

239 1 22.0 1 6.1

238

250

208

187

253 4 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

230

187

253 4 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

460

414

508 4 73.0

368 1 51.0 1 14.0

375

400

575

518

632 4 N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Table 19 – ESEW & ESER Dual-Circuit Chiller with High Flow Pump Electrical Data (60 Hz)

Compressors Pumps Chiller

Model

ESEW-020D &

ESER-020D

ESEW-030D &

ESER-030D

ESEW-040D &

ESER-040D

ESEW-050D &

ESER-050D

ESEW-060D &

ESER-060D

Rated

Allowable

Qty

RLA1 LRA

2

Chiller Pump

MCA4 MOPD

5

ESEW-080D &

ESER-080D

ESEW-0100D

& ESER-0100D

ESEW-0120D

& ESER-0120D

ESEW-0160D

& ESER-0160D

1

RLA is Rated Load Amps.

2

LRA is Locked Rotor Amps.

3

FLA is Full Load Amps.

4

MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

5

MOPD is Maximum Over-current Protection Device, complies with NEC, Section 430-53.

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Main Power

(3-phase, 60 Hz)

Variable-Speed Fan

(1-phase)

Constant Speed Fans

(3-phase)

Allowable

Motor

FLA

1

Motor

FLA1 Min

Max

(hp)

Each

(hp)

Each

208

187

253 1 ½

3.6 1 ¾

2.3

4.6

5.2

15

230

187

253 1 ½

3.6 1 ¾

2.3

4.6

5.2

15

460

414

508 1 ½

1.7 1 ¾

1.2

2.3

2.6

15

1.8

2.0

15

13.2

16.0

20

230

187

253 1 ½

3.6 1 2

6.6

13.2

16.0

20

460

414

508 1 ½

1.7 1 2

3.1

6.2

7.0

15

5.0

5.6

15

13.2

16.0

20

230

187

253 1 ½

3.6 1 2

6.6

13.2

16.0

20

460

414

508 1 ½

1.7 1 2

3.1

6.2

7.0

15

575

518

632 1 ½

1.4 1 2

2.5

5.0

5.6

15

208

187

253 1 ½

3.6 1 2

6.6

13.2

16.0

20

230

187

253 1 ½

3.6 1 2

6.6

13.2

16.0

20

460

414

508 1 ½

1.7 1 2

3.1

6.2

7.0

15

5.0

5.6

15

19.8

21.5

25

230

187

253 1 ½

3.6 2 2

6.6

19.8

21.5

25

460

414

508 1 ½

1.7 2 2

3.1

9.3

10.1

15

7.5

8.1

15

19.8

21.5

25

230

187

253 1 ½

3.6 2 2

6.6

19.8

21.5

25

460

414

508 1 ½

1.7 2 2

3.1

9.3

10.1

15

575

518

632 1 ½

1.4 2 2

2.5

7.5

8.1

15

208

187

253 1 ½

3.6 3 2

6.6

26.4

31.0

35

230

187

253 1 ½

3.6 3 2

6.6

26.4

31.0

35

460

414

508 1 ½

1.7 3 2

3.1

12.4

16.0

20

10.0

10.6

15

33.0

41.0

45

230

187

253 1 ½

3.6 4 2

6.6

33.0

41.0

45

460

414

508 1 ½

1.7 4 2

3.1

15.5

16.0

20

12.5

16.0

20

39.6

46.0

50

230

187

253 1 ½

3.6 5 2

6.6

39.6

46.0

50

460

414

508 1 ½

1.7 5 2

3.1

18.6

21.0

25

575

518

632 1 ½

1.4 5 2

2.5

15.0

16.0

20

Table 21 – Single-Circuit Remote Condenser Electrical Data (60 Hz)

Model

KCM014

KCL023

KCL030

KCL037

KCL045

Rated

575 518 632 1 ½ 1.4 1 ¾ 0.9
208 187 253 1 ½ 3.6 1 2 6.6

575 518 632 1 ½ 1.4 1 2 2.5
208 187 253 1 ½ 3.6 1 2 6.6

575 518 632 1 ½ 1.4 1 2 2.5
208 187 253 1 ½ 3.6 2 2 6.6

575 518 632 1 ½ 1.4 2 2 2.5
208 187 253 1 ½ 3.6 2 2 6.6

Qty

Qty

Total

FLA

MCA3 MOP

2

4

KCL056

KCL068

575 518 632 1 ½ 1.4 3 2 2.5
208 187 253 1 ½ 3.6 4 2 6.6

KCL095

575 518 632 1 ½ 1.4 4 2 2.5
208 187 253 1 ½ 3.6 5 2 6.6

KCL110

1

FLA is Full Load Amps.

2

Total FLA as provided by the remote condenser manufacture.

3

MCA is Minimum Circuit Amps (for wire sizing) as provided by the remote condenser manufacturer.

4

MOP is Maximum Over-current Protection as provided by the remote condenser manufacturer.

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Main Power

(3-phase, 60 Hz)

Variable-Speed Fan

(1-phase)

Constant Speed Fans

(3-phase)

Allowable

Motor

FLA

1

Motor

FLA1 Min

Max

(hp)

Each

(hp)

Each

208

187

253 2 ½

3.6 2 ¾

2.3

9.2

9.8

15

230

187

253 2 ½

3.6 2 ¾

2.3

9.2

9.8

15

460

414

508 2 ½

1.7 2 ¾

1.2

4.6

4.9

15

3.6

3.8

15

26.4

31.0

35

230

187

253 2 ½

3.6 2 2

6.6

26.4

31.0

35

460

414

508 2 ½

1.7 2 2

3.1

12.4

16.0

20

10.0

10.6

15

26.4

31.0

35

230

187

253 2 ½

3.6 2 2

6.6

26.4

31.0

35

460

414

508 2 ½

1.7 2 2

3.1

12.4

16.0

20

575

518

632 2 ½

1.4 2 2

2.5

10.0

10.6

15

208

187

253 2 ½

3.6 2 2

6.6

26.4

31.0

35

230

187

253 2 ½

3.6 2 2

6.6

26.4

31.0

35

460

414

508 2 ½

1.7 2 2

3.1

12.4

16.0

20

10.0

10.6

15

39.6

46.0

50

230

187

253 2 ½

3.6 4 2

6.6

39.6

46.0

50

460

414

508 2 ½

1.7 4 2

3.1

18.6

21.0

25

15.0

16.0

20

39.6

46.0

50

230

187

253 2 ½

3.6 4 2

6.6

39.6

46.0

50

460

414

508 2 ½

1.7 4 2

3.1

18.6

21.0

25

575

518

632 2 ½

1.4 4 2

2.5

15.0

16.0

20

208

187

253 2 ½

3.6 6 2

6.6

52.8

61.0

70

230

187

253 2 ½

3.6 6 2

6.6

52.8

61.0

70

460

414

508 2 ½

1.7 6 2

3.1

24.8

31.0

35

20.0

21.0

25

66.0

81.0

90

230

187

253 2 ½

3.6 8 2

6.6

66.0

81.0

90

460

414

508 2 ½

1.7 8 2

3.1

31.0

36.0

40

25.0

31.0

35

79.2

91.0

100

230

187

253 2 ½

3.6

10 2 6.6

79.2

91.0

100

460

414

508 2 ½

1.7

10 2 3.1

37.2

46.0

50

575

518

632 2 ½

1.4

10 2 2.5

30.0

36.0

40

Table 22 – Dual-Circuit Remote Condenser Electrical Data (60 Hz)

Model

KCM034

KCL047

KCL060

KCL074

KCL090

Rated

575 518 632 2 ½ 1.4 2 ¾ 0.9
208 187 253 2 ½ 3.6 2 2 6.6

575 518 632 2 ½ 1.4 2 2 2.5
208 187 253 2 ½ 3.6 2 2 6.6

575 518 632 2 ½ 1.4 2 2 2.5
208 187 253 2 ½ 3.6 4 2 6.6

575 518 632 2 ½ 1.4 4 2 2.5
208 187 253 2 ½ 3.6 4 2 6.6

Qty

Qty

Total

FLA

MCA3 MOP

2

4

KCL112

KCL137

575 518 632 2 ½ 1.4 6 2 2.5
208 187 253 2 ½ 3.6 8 2 6.6

KCL190

575 518 632 2 ½ 1.4 8 2 2.5
208 187 253 2 ½ 3.6 10 2 6.6

KCL224

1

FLA is Full Load Amps.

2

Total FLA as provided by the remote condenser manufacture.

3

MCA is Minimum Circuit Amps (for wire sizing) as provided by the remote condenser manufacturer.

4

MOP is Maximum Over-current Protection as provided by the remote condenser manufacturer.

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General Control Operation

System Initialization

Upon power-up, the first screen to appear is the Start-Up Screen as shown in Figure 18. This screen will display
while the Programmable Logic Controller (PLC) and Human Machine Interface (HMI) establish communications.
The PLC/HMI version is located in the lower right hand corner of the screen.

Figure 18 – Start-Up Splash Screen

Once the control communication system has established, the HMI screen automatically switches to the Home
Screen as shown in Figure 19 for water-cooled condenser chillers and Figure 20 for remote air-cooled condenser
chillers.

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Figure 19 – ESEW System Overview

Figure 20 – ESER System Overview

Function

Description

Screen Reference

Circuit Status

Informs the operator of the chiller operation state as well as the status of the

None

Messaging

Touching the Alarm Messaging banner will display the currently active alarms.

Modify the Setpoint by touching the current Setpoint on the HMI. An authorized
security level password is required to enter a new Setpoint.

None

The chiller can be set to control entering or leaving water temperatures. A “(PV)”

mainly for systems with a smaller system fluid volume.

None

Menu Button

Changes to the Menu 1 screen

Figure 25

Full Screen
Display Mode

Will display only the Setpoint and process temperature in a large visible font

A listing of active and prior alarm history

Figure 26, Figure 27,

Detail

Additional circuit related information

Multiple

Pumps

Pump Control (Optional)

Figure 23, Figure 24

Warning

A listing of all active warnings

Figure 22

Pressing START will start this chiller as well as any other networked chillers

Pressing the STOP button will stop all chillers.

None

Home - System Overview

System Overview

The System Overview Screen (Home Screen) provides an overall synopsis of the chiller system. It also provides
quick links to other views as well as additional information.

Table 23 – System Overview Functions

Messaging

Alarm

Setpoint

Process Indicator
(PV)

Alarms

circuits(s)

Provides information about any warnings or alarms which may have occurred.

appears after the temperature used for temperature control. As standard the
systems is set for leaving water temperature control, which is suitable for systems
with a large system volume and a buffer tank. Return water temperature control is

None

Figure 21

Figure 28, Figure 29

Start / Stop

attached to this system if they exist. The Start button will disappear at this point.

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Home – Full Screen

The Full Screen (Figure 21) provides a simplified view of the ESE Chiller. The SETPOINT and PROCESS temperatures
appear in a large font easily seen from a distance, providing a “quick glance” look to validate proper operation.

Figure 21 – Full Screen

Warnings

The Warning Screen (Figure 22) provides a view of any warnings that currently exist within the system. Warnings
that are left unresolved will typically result in a fault after some time.

Figure 22 – Warning Screen

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Home – Pump Control (Optional)

Pump Control Screen (Optional)

The Pump Control Screen (Figure 23) displays pertinent pump status information for a system with integral pump
controls. The Pump Control Screen also provides the ability to change mode selection.

Figure 23 – Pump Control Screen

Pump VFD Control Screen (Optional)

The Pump VFD Screen (Figure 24) displays pertinent pump VFD status information for system with integral pump
controls with pump VFDs. The Pump VFD Screen also provides the ability to change mode selection.

Figure 24 – Pump VFD Control Screen

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Menu 1 - Overview

Menu 1 (Figure 25) provides a common location for most adjustments and settings. Descriptions of each section
are in detail within this manual. Access to some of the parameters is password protected. The main user-level
password is 9999 used for gaining access to changing the main system set point and various other warning and
alarm settings. A few higher-level areas require a high-level user password that is 7720. If you are attempting to
access an area where neither of these passwords is accepted you main require a technician level password. For
access to these areas of the program, you will need to contact our Customer Service Department for assistance.

Figure 25 – Menu 1 Screen

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Function

Description

Screen Reference

A listing of all active, history, and frequency of system alarms.

Figure 26, Figure 27,

Figure 28, Figure 29

Imperial or Metric units can be selected directly from this screen. Touch the
UNITS button to toggle the selection between Imperial or Metric units

N/A

Compressor Data

Additional compressor related information

Figure 30, Figure 31

Default Modbus Settings: Baud-19200, Data Length-8, Parity-Odd, Stop Bits-1

Figure 37

EXV1 Expansion
Valve Setup

Electric Expansion Valve Setup (Superheat Control)

Figure 38

EXV2 Hot Gas
Bypass Setup

Hot Gas Bypass Setup (Load Balance Valve) (Optional)

Figure 39

Water Regulating
Valve Setup

Water Regulating Valve Setup (Discharge Pressure Control) ESEW Only

Figure 40

Compressor
Staging

Compressor staging options and stage order setup

Figure 41, Figure 42

The Input / Output screens provide the status of all digital inputs, outputs, and

Figure 43, Figure 44,

Temperature Offset

RTD Temperature Sensor Offset Adjustment

Figure 48

Process Control

Process related setting options such as entering or leaving fluid temperature

Figure 49

Pump Setup

Pump Configuration and Setup

Figure 50

Tank Setup

Tank System Setup

Figure 51

System Counters

Figure 52, Figure 53,

Figure 54

Table 24 – Menu 1 Functions

Alarms

Units

Modbus Setup

Input / Output

Counters

Modbus RTU (Building Automation System) Setup

analog inputs.

Figure 35, Figure 36,

Figure 45, Figure 46,

Figure 47

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Menu 1 - Alarms

Alarms Active

When a critical system fault occurs, the controller activates the HMI alarm handler (Figure 26). This forces the
alarm screen to appear and will display the current faults. To silence this alarm, press the ALARM SILENT button. If
multiple alarms are active at once, use the DOWN and UP buttons to view all alarms. When no alarms are active,
the white portion of the display will be blank.

All alarms must be resolved and reset using the RESET ALARM button.

Figure 26 – HMI Alarm Handler

Alarm History

Alarm History (Figure 27) displays a history of previously active alarms.

Figure 27 – Alarm History

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Alarm Setup

Alarm set points and timers are modifiable on the Alarm Setup Screen (Figure 28).

Figure 28 – Alarm Setup

Alarm Glycol

If the Chiller Setpoint goes below 45°F {7°C}, the Glycol Warning Screen will appear as in Figure 29. The amount of
antifreeze will vary depending on the actual desired operating conditions and should be enough to provide freeze
protection to temperatures 15°F {-9°C} colder than the coldest temperature anticipated. Use only antifreeze
solutions designed for heat exchanger duty. Do not use automotive antifreeze due to the potential for fouling that
can occur once its relatively short-lived inhibitors break down. Verify the proper Glycol solution is used and
“Accept” the Warning.

Figure 29 – Alarm Setup

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Menu 1 – Metric Units/Imperial Units

All units of measures within all menus and screens can be changed from Metric to Imperial and back again using
this button. The units of measure indicated on this button are the active units.

Menu 1 - Compressor Data

Compressor Data Screen

The Compressor Data Screen (Figure 30 and Figure 31) is accessible directly from Menu 1 (Figure 25) or by
touching the requested circuit on the Home Screen (Figure 19 or Figure 20). This screen provides additional
information relative to the particular circuit.

Figure 30 – Circuit Data Screen (Water-Cooled Condenser Chiller)

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Figure 31 – Circuit Data Screen (Remote Air-Cooled Condenser Chiller)

Compressor Data Screen – Interlocks

Touching the INTERLOCK button on the bottom of the Compressor Data Screen (Figure 30 or Figure 31) will
display the Interlock Screen shown in Figure 32. If the compressor is not starting, the reason for the fault will
clearly be visible on this screen.

Figure 32 – Interlocks

There are two active buttons on the Interlocks Screen (indicated by the “TOUCH” text) which presents an even
deeper view of the interlocks. The Critical Interlocks Screen (Figure 33) appears by touching the “critical status”
text on the Interlocks Screen (Figure 32). A critical interlock fault will shut down the entire system and must be
resolved prior to restarting the system. The Refrigeration Faults Screen (Figure 34) appears by touching the
“refrigeration status” text on the Interlocks Screen (Figure 32). A refrigeration fault will just shut down that
particular circuit and will not shut down any other circuits unless faults are present on those circuits as well.

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Figure 33 – Critical Interlocks

Figure 34 – Refrigeration Interlocks

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Figure 36 – Modbus Word Data Screen

Figure 37 – Modbus Bit Data Screen

Menu 1 – Modbus/BAS

Modbus RTU/BAS Setup Screen

This Modbus BAS Setup Screen (Figure 35) can enable or disable the Modbus RTU capability. It also displays the
current Modbus data and its associated Modbus registers as shown in the following figures.
Default Modbus Settings: Baud-19200, Data Length-8, Parity-Odd, Stop Bits-1. The display of the Modbus data
makes it quick and easy to verify data points between the chiller and the system to which it is connected.

Figure 35 – Modbus Setup Screen

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Default

Value

In Auto Mode, the control system adjusts the valve to maintain discharge pressure

the valve to a fixed position and holds it there for service diagnostic purposes.

AUTO MODE

Minimum Position

The minimum percent the expansion valve will go to.

5%

Maximum Position

The maximum percent the expansion valve will go to.

100%

Start Percent

This sets the valve to a pre-start position for a given period.

50%

percent open position.

The valve meters the amount of refrigerant into the evaporator in the precise

Only a trained refrigeration service technician should adjust this valve.

10.0

The EXV behaves as a high limit suction pressure regulator when the suction

below the maximum limit or if the superheat becomes dangerously low.

150 PSI

Kp

Proportional PID value

20

Ti

Integral PID value

1000

Td

Derivative PID value

0

Menu 1 – EXV1 Expansion Valve Setup

EXV1 Expansion Valve Setup Screen

Figure 38 – EXV1 Expansion Valve Setup Screen

Table 25 – EXV1 Setup Parameters

Menu Item Description

Mode Control

Startup Position Delay

Superheat Setpoint
(Superheat Mode)

MOP Mode Setpoint
(Suction Pressure
Mode)

(Super Heat Mode or Suction Pressure Mode). In manual mode, the system drives

This is the delay time from compressor startup to hold the valve at the startup

quantity in order to maintain superheat. The difference between the saturated
suction temperature and the suction line temperature is the superheat. The
superheat is factory set for 10°F and should never exceed 15°F or go below 4°F.

pressure rises above a preset suction pressure. The valve regulates to maintain
suction pressure instead of superheat. The suction pressure set point is factory set
to allow the compressor to run at the highest allowable suction pressure. The valve
control automatically reverts to superheat control if the suction pressure falls

30 sec.

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Default

Value

OFF: The valve will always be closed (zero output)

AUTO

Minimum Position

The minimum percent the valve will go to.

0%

Maximum Position

The maximum percent the valve will go to.

100%

Kp

Proportional PID value

1000

Ti

Integral PID value

500

Td

Derivative PID value

0

Menu 1 – EXV2 Hot Gas Bypass Setup

EXV2 Hot Gas Bypass Setup Screen (Optional)

Figure 39 – EXV2 Hot Gas Bypass Screen

Table 26 – EXV2 Setup Parameters

Menu Item Description

AUTO-LAST COMP ONLY: The valve will only respond relative to the demand PID

Mode Selection

when operating with the last compressor running.
AUTO-ALWAYS ON: The valve will always respond relative to the demand PID
regardless of how many compressors are running.
MANUAL MODE: The manual mode value percent will be the output to the valve.

ALWAYS ON

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58

Default

Value

manual mode, the manual mode value is the output to the valve at all times.

Discharge Setpoint

Discharge Setpoint Value

340 PSIG

Low Temp Setpoint

Low temp setpoint relating to low percent setpoint – (During the start sequence)

45°F {7°C}

High Temp Setpoint

High temp setpoint relating to high percent setpoint – (During the start sequence)

85°F {29°C}

The low percent value during startup if the condenser water temperature is at or
below the low temp setpoint

20%

The high percent value during startup if the condenser water temperature is at or
above the high temp setpoint

50%

Kp

Proportional PID value

20

Ti

Integral PID value

1000

Td

Derivative PID value

50

Menu 1 – Water Regulating Valve (WRV) Setup

WRV Water Regulating Valve Setup Screen

An electric condenser water-regulating valve is standard on all chillers with a water-cooled condenser. The valve is
a butterfly type valve with a modulating actuator and is located in the condenser water piping at the outlet of the
condenser. The chiller PLC controls the valve actuator using a high-side refrigerant pressure signal from a pressure
transducer. The valve regulates the flow of water through the condenser in order to maintain the discharge
pressure set point.

Figure 40 – WRV Setup Screen

Table 27 – WRV Setup Parameters

Menu Item Description

Mode

Low Percent Setpoint

High Percent Setpoint

In Auto Mode, the control system adjusts the valve for optimum performance. In

AUTOMATIC

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59

Default

Value

compressors.

This is the minimum delay duration between stages on multiple compressors. This

newly staged compressor to properly influence the system.

60

Kp

Proportional PID value

3

Ti

Integral PID value

1000

Td

Derivative PID value

0

This is the differential below set point the current process value is allowed to go to
before staging off all the compressors.

5°F {-15°C}

Menu 1 – Compressor Staging/PID

Compressor Staging Setup Screen

Figure 41 – Compressor Staging Setup Screen

Table 28 – Compressor Staging Setup Parameters

Menu Item Description

Staging Mode

Stage to Stage Delay

Destage ΔT

In Auto Mode, the control system adjusts the number of staged compressors
relative to the demand and available compressors. In manual mode, the number of
staged compressors depends on the Manual Mode Value relative to available

time delay temporarily halts the demand percent from calculating allowing the

AUTOMATIC

Touching the Graph button will display the Staging Graph Screen as shown in Figure 42. Touching the local
staging button will display the Compressor Staging Local Screen as shown in Figure 43.

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Default

staged compressor to properly influence the system.

Compressor Staging Graph Screen

The Staging Graph Screen (Figure 42) depicts the process value versus the process setpoint. As the process value
increases above the setpoint, the system demand will increase. This increase in system demand will stage
compressors on as needed to maintain setpoint. As the process value decreases, compressors will de-stage trying
to maintain process setpoint. If the process value reaches the stage off value, then all compressors will de-stage.
The system demand is calculated by dividing the number of active compressors by the total number of
compressors available.

Figure 42 – Compressor Staging Graph Screen

Table 29 – Compressor Staging Graph Parameters

Menu Item Description

The minimum delay duration between staging on multiple compressors. This time

Stage to Stage Delay

delay temporarily halts the demand percent from calculating allowing the newly

Value

60

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Default

Value

Manual Trigger will immediately recalculate the stage order instead of waiting for
the automatic trigger to occur.

None

Manual OFF/ON

Allows the ability to manually activate a compressor for testing purposes

OFF

Automatic: calculates the stage order by the AUTO STAGE HOURS parameter
Manual: Manually enter the stage order

AUTOMATIC

Auto Stage Hours

The number of run hours before recalculating the stage order

24 HOURS

stage

Local

Compressor Staging Local Screen

The Compressor Staging Local Screen (Figure 43) depicts the stage order of the local chiller. The stage order will
auto calculate based off of the hours entered in the auto stage hours parameter. The intent is to run the
compressors with the least amount of hours first to help equalize the run hours of all the compressors.

Figure 43 – Compressor Staging Local Screen

Table 30 – Compressor Staging Local Parameters

Menu Item Description

Manual Trigger

Stage Mode

Minutes Until Auto

Compressors requested

Minutes remaining until the stage calculation occurs None

The number of compressor requested by the master control from this chiller None

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Figure 44 – Digital Inputs Screen

Figure 45 – Digital Outputs Screen

Menu 1 – Inputs/Outputs

Inputs / Outputs Screens

The Inputs/Outputs screens provide the status of all digital inputs, digital outputs, analog inputs and outputs. X’s
are discrete inputs and Y’s are discrete outputs. When the PLC input LED is illuminated (ON), the corresponding
input or output is on. The inputs and outputs numbers are hex base numbering system. The following screens
show a full complement of inputs and outputs.

Note: Your screen may differ depending on machine type and options.

Figure 46 – Analog Inputs Screen

Figure 47 – Analog Outputs Screen

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Menu 1 – Temperature Offsets

RTD Temperature Offset Adjustment

The Entering Water RTD and LWT Manifold RTD (Dual Circuits or Master/Slave Systems only) are adjustable. To
change, enter a temperature offset into the RTD Temperature Offset Screen. Only change the offset if there is a
discrepancy between the sensor reading and the actual temperature.

Figure 48 – RTD Temperature Offsets Screen

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Menu 1 – Process Control

Leaving/Entering Sensor Selection

There are two selections for the temperature control mode, Leaving Water Control or Entering Water Control. To
make a change from the current selection, simply press the mode of operation button. This will toggle between
the two options (Master Only).

If an external leaving water temperature is used the RTD sensors must be enabled. Typically, a Manifold RTD
temperature sensor is used when a combination leaving water temperature is being controlled, i.e. Master/Slave
or Dual Circuits.

Figure 49 – Process Control Screen

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Default

Value

AUTOMATIC: Allows for automatic timer enable of the pumps.
MANUAL: Requires manual enable of the pumps.

AUTOMATIC

Recirc On Delay

Delay duration before the Recirc Pump starts.

3 sec

Recirc Off Delay

Delay duration before stopping the Recirc Pump after initiation of a system stop.

60 sec

Process On Delay

Delay duration before the Process Pump starts.

30 sec

Process Off Delay

Delay duration before stopping the Process Pump after initiation of a system stop.

120 sec

VFD Pressure Setpoint

P1 Pump Pressure Setpoint (VFD OPTION ONLY)

50 PSI

Kp

Proportional PID value

100

Ti

Integral PID value

50

Td

Derivative PID value

1

Menu 1 – Pumps Setup

Pump Setup Screen

Figure 50 – Pump Setup Screen

Table 31 – Pump Setup Parameters

Menu Item Description

Mode

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Menu 1 – Tank Setup

Tank Setup Screen

The Tank Setup Screen (Figure 51) displays tank options, inputs and outputs. The tank ENABLE/DISABLE option is
located in the lower right hand corner of the screen. Touch this button to toggle its state. If the tank mid/high
sensors are enabled their status will be indicated. If the mid level sensor has been off for over 10 seconds, that
tank water makeup valve will energize. Once the high-level water level sensor has activated, the water makeup
valve will de-energize.

Figure 51 – Tank Setup Screen

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Figure 52 – Counters 1 Screen

Figure 53 – Counters 2 Screen

Menu 1 – Counters

Counters Screens

Once powered up, the control system keeps track of certain inputs and outputs. Every time an input or output is
activated a counter will record this state change. This is useful in troubleshooting the system. Also recorded are
minimum and maximum pressure levels. Once the system is powered down, these counters will reset.

Figure 54 – Counters 3 Screen

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Function

Description

Screen Reference

Selected

Date/Time

Date and Time for the HMI (Used for logging alarms)

N/A

Display the HMI system menu. (To be used by an authorized service technician
only)

N/A

Provides the ability to restore the control system back to factory defaults in the

unexpectedly.

Figure 57, Figure

System Selection

Water or air cooled system selection

N/A

Single / Dual
System Selection

Single or dual circuit system selection

N/A

Remote Setpoint
Setup

Configuration of analog Input used for system setpoint

Figure 59

removing any SD card from the HMI.

Graphical display of critical process values

Figure 60

Remote Mode

Touch this button to enable or disable external digital remote START/STOP.

N/A

62, Figure 63

Touch Screen Calibration Settings
(To be used by an authorized service technician only)

N/A

Menu 2 - Overview

Figure 55 – Menu 2

Table 32 – Menu 2 Functions

Hardware Options

System Menu

Defaults

Remove SD Storage

Trending

PLC Link Setup

Touch Calibration

Displays the current Hardware configuration

case that an unknown setting occurred and the system now behaves

Used to properly close the trend file for SD removal. Press this button prior to

Master/Slave Setup

Figure 56

58

N/A

Figure 61, Figure

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Menu 2 – Hardware Options Selected

Hardware Options Screen

The Hardware Options Screen (Figure 56) shows an overall status view of the current hardware options enabled.
This is a read only screen. Make all adjustments on their appropriate screens.

Figure 56 – Hardware Options Screen

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Menu 2 - Date/Time

The Date/Time screen is where the system date and time is set. The system date and time stamps any alarms.

Menu 2 – System Menu

This menu is part of the HMI manufacturer’s firmware and is for high-level setup of the HMI hardware. This menu
is password protected to prevent unintended adjustments that may impair proper functioning of the system. This
menu is for use only by qualified service technicians. Please contact our Customer Service Department for
assistance as needed to access this area of the system program.

Menu 2 – Defaults

WARNING

The Default Settings screen provides the ability to restore the control system back to factory defaults in the case
that an unknown setting modification occurred and the system now behaves unexpectedly.

Touching “YES” on Figure 57 will restore all the system parameters to a factory stable state and indicate that the
process has finished as shown in Figure 58.

Figure 57 – Restore Factory Settings

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Figure 58 – Factory Settings Restored

Menu 2 – Remote Setpoint Setup

When the remote setpoint option is enabled, an incoming 4-20mA signal controls the setpoint of the master
chiller. The 4- 20mA signal will span from the MINIMUM SETPOINT to the MAXIMUM SETPOINT as defined in
Figure 59.

Figure 59 – Remote Setpoint Setup Screen

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Menu 2 – Remove SD Storage

This is an optional feature and is only active if programmed as such from the factory. This feature allows data
logging to an SD storage card. When activated data is automatically data logged to the SD storage card. When
the SD storage feature is active, this function stops writing data to the SD storage card to allow for safe removal.
Activating the ability to write to a removable SD storage device requires a new control program from the factory.
When active the controller requires a SD storage card be present at time of start-up and will not allow the chiller
to start if not present. If you need to activate this feature, please contact our Customer Service Department for
assistance.

Menu 2 – Trending

The trending screen (Figure 60) displays the setpoint temperature, process temperature, expansion valve, and
optional hot gas bypass valve (if present) resisters for easy analysis of the system operation. Trending is always
enabled and always running.

Figure 60 – Trending Screen

Menu 2 – Remote Mode

The Remote Mode toggle indicates if the chiller is set to use a remote contact closure for remote start/stop. When
active, the Remote Mode toggle will indicate Remote Mode Enabled and when not active it will indicate Remote
Mode Disabled.

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Menu 2 – PLC Link Setup

PLC Link (Master/Slave) Setup Screen

This screen can enable or disable the Master/Slave Capability. It also displays the current linked data. Each chiller is
capable of being a Master or a Slave. To do this, toggle the MASTER MODE to SLAVE MODE.

Figure 61 – PLC Link Setup Screen

Figure 62 – PLC Link Word Data Screen

Figure 63 – PLC Link Bit Data Screen

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WARNING: This equipment contains hazardous

WARNING: This equipment contains refrigerant

property damage.

WARNING: This equipment may contain fan

in place.

WARNING: The exposed surfaces of motors,

if touched with unprotected hands.

CAUTION: Disconnect and lock out incoming

opening access panels for repair or maintenance.

CAUTION: Wear eye protection when installing,

protect against any sparks, debris, or fluid leaks.

CAUTION: Wear protective gloves when

or fluid leaks.

CAUTION: Ground the unit properly in

CAUTION: The unit requires the main power to

prior to initial start-up.

Menu 2 – Touch Calibration

This is a firmware menu provided by the HMI
manufacturer to allow the touch sensitivity and
operation to be fine-tuned. HMI calibration occurs at
the factory prior to shipment. This menu is password
protected to prevent unintended adjustments that
may impair proper functioning of the system. This
menu is for use only by qualified service technicians.
Please contact our Customer Service Department for
assistance as needed to access this area of the
system program.

Start-Up

Every unit is factory set to deliver chilled water in
accordance with the standard operating
specifications for that particular chiller. Due to
variables involved with different applications and
different installations, minor adjustments may be
required during the initial start-up to ensure proper
operation.

We strongly recommend the following start-up
procedure be performed by a qualified experienced
refrigeration technician and must be followed in
sequence. If trouble is encountered the fault can
usually be traced to one of the control or safety
devices. This outline serves as a checklist for the
initial start-up and for subsequent start-ups if the
chiller is out of service for a prolonged time.

voltages that can cause severe injury or death.

under pressure. Accidental release of refrigerant
under pressure can cause personal injury and or

blades or other sharp edges. Make sure all fan
guards and other protective shields are securely

refrigerant piping, and other fluid circuit
components can be very hot and can cause burns

power before installing, servicing, or
maintaining the equipment. Connecting power to
the main terminal block energizes the entire
electric circuitry of the unit. A power supply
provides 24 VDC control power. Electric power at
the main disconnect should be shut off before

maintaining, or repairing the equipment to

installing, maintaining, or repairing the
equipment to protect against any sparks, debris,

compliance with local and national codes.

remain connected during off-hours to energize
the compressor’s crankcase heater. Disconnect
main power only when servicing the chiller. The
crankcase heater should remain on when the
compressor is off to ensure liquid refrigerant
does not accumulate in the compressor
crankcase. Connect main power at least 24 hours

Step 1 - Connect Main Power

Connect main power properly ensuring it matches
the voltage shown on the nameplate of the unit.
Check the electrical phase sequence prior to start­up. Operation of the compressor with incorrect
electrical phase sequencing will result in mechanical
damage to the compressors. Check the phasing with
a phase sequence meter prior to applying power.
The proper sequence should read “ABC” on the
meter. If the meter reads “CBA”, open the main
power disconnect and switch two line leads on the
line power terminal blocks (or the unit mounted
disconnect). All components requiring electric power
are in-phase at the factory. Do not interchange any
load leads that are from the unit contactors or the
motor terminals. After making proper power
connection and grounding, turn the main power on.

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Step 2 - Fill Coolant Circuit

Check to make sure all process chilled-water piping
connections are secure. Fill the chilled water
reservoir with the proper water or water/glycol
solution following the guidelines shown below.
When using a glycol solution only use glycol with a
corrosion inhibitor. See Table 34 for recommended
glycol solutions.

System Fill Water Chemistry Requirements

Water is a unique molecule whose properties make it
ideal for heat transfer applications. It is safe: non­flammable and non-poisonous. It is easy to handle,
widely available and inexpensive in most
industrialized areas. It is capable of absorbing more
heat per unit mass than almost any other material.

Water also has properties that need to be within
limits to avoid unwanted side effects. Water is a
“universal solvent” because it can dissolve many
solid substances to some extent and absorb gases.
As a result, water can cause the corrosion of metals
used in a cooling system. Often water is in an open
system (exposed to air) that concentrates the ions as
water evaporates as in a cooling tower. When the
concentration exceeds the solubility of some
minerals, scale forms. The life giving properties of
water can also encourage biological growth that can
foul heat transfer surfaces.

Sometimes the source of the water can be the cause
of some of the problems. Anyone living in an area
with extremely hard water that has caused scale
build up can attest to that. Source waters available
for make-up use have an almost unlimited chemistry
variation.

To avoid the unwanted side effects associated with
water cooling, proper chemical treatment and
preventive maintenance is required for continuous
plant productivity.

Unwanted Side Effects of Improper Water Quality

• Corrosion

• Scale

• Fouling

• Biological Contamination

• Electrical Conductivity

• pH

• Alkalinity

• Total Hardness

• Dissolved gases

Some of the water chemistry properties can combine
to cause the unwanted side effects. Some of the
levels are temperature dependent (i.e. dissolved
gases).

Our chiller construction minimizes the potential for
corrosion by using stainless steel brazed plate
evaporators. The stainless steel resists corrosion but
is not immune to it. All heat exchangers are
susceptible to fouling that may coat the heat transfer
surfaces. Coating of these surfaces reduces the heat
transfer surface, increases the fluid velocities and
pressure drops through the heat exchanger. All of
these effects reduce the heat transfer and affect the
productivity of the plant. This is just as true with shell
and tube heat exchangers.

Chilled cooling water systems, at their simplest, have
two main heat exchangers: the evaporator that
absorbs the heat from the process and the
condenser that removes the heat from the chiller.
The chiller is only part of the entire cooling system.
The system requires proper design following sound
engineering practice and satisfying local and
industry standards. Improperly designed or installed
systems may cause unsatisfactory operation and/or
system failure.

The complex nature of water chemistry requires a
specialist to evaluate and implement appropriate
sensing, measurement and treatment needed for
satisfactory performance and life. The
recommendations of the specialist may include
filtration, monitoring, treatment and control devices.
With the ever-changing regulations on water usage
and treatment chemicals, the information is usually
up to date when a specialist in the industry is
involved. Table 33 – Fill Water Chemistry
Requirements shows the list of water characteristics
and quality limitations.

Cooling Water Chemistry Properties

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Water Characteristic

Quality Limitation

Alkalinity (HCO

3

-

)

70-300 ppm

Aluminum (Al)

Less than 0.2 ppm

Ammonium (NH3)

Less than 2 ppm

Chlorides (Cl-)

Less than 300 ppm

Electrical Conductivity

10-500µS/cm

Free (aggressive) Carbon
Dioxide (CO2)†

Free Chlorine(Cl2)

Less than 1 PPM

HCO

3

-

/SO

4

2-

Greater than 1.0

Hydrogen Sulfide (H2S)*

Iron (Fe)

Less than 0.2 ppm

Manganese (Mn)

Less than 0.1 ppm

Nitrate (NO3)

Less than 100 ppm

pH

7.5-9.0

Sulfate (SO

4

2-

)

Less than 70 ppm

Total Hardness (dH)k

4.0-8.5

Chilled Water

Temperature

Percent Glycol

By Volume

50°F (10°C)

Not required

45°F (7.2°C)

5 %

40°F (4.4°C)

10 %

35°F (1.7°C)

15 %

30°F (-1.1°C)

20 %

25°F (-3.9°C)

25 %

20°F (-6.7°C)

30 %

CAUTION: When your application requires the

leaks or premature pump failures.

WARNING: Ethylene Glycol is flammable at

flames or other possible ignition sources.

CAUTION: Do not operate the unit with the

cause serious compressor damage.

Table 33 – Fill Water Chemistry Requirements

* Sulfides in the water quickly oxidize when exposed to air;
therefore ensure agitation does not occur when taking a water
sample. Unless tested immediately at the site, the sample will
require stabilization with a few drops of one Molar zinc acetate
solution, allowing accurate sulfide determination up to 24 hours
after sampling. A low pH and high alkalinity cause system
problems, even when both values are within the range shown. The
term pH refers to the acidity, basicity, or neutrality of the water
supply. Below 7.0, water is acidic. Neutral water contains a pH of

7.0.
† Dissolved carbon dioxide calculation is from the pH and total
alkalinity values shown below or measured on the site using a test
kit.
Dissolved Carbon Dioxide, PPM = TA x 2
Total Alkalinity, PPM as CaCO

3

Table 34 - Recommended Glycol Solutions

Less than 5 ppm

Less than 0.05 ppm

[(6.3-pH)/0.3]

where TA =

use of glycol, use industrial grade glycol
specifically designed for heat transfer systems
and equipment. Never use glycol designed for
automotive applications. Automotive glycols
typically have additives engineered to benefit
the materials and conditions found in an
automotive engine; however, these additives can
gel and foul heat exchange surfaces and result in
loss of performance or even failure of the chiller.
In addition, these additives can react with the
materials of the pump shaft seals resulting in

higher temperatures in a vapor state. Carefully
handle this material and keep away from open

Step 3 - Check Condenser

There are two possible types of condensers present
in the chiller: water-cooled, and remote air-cooled. It
is important to verify the chiller will have adequate
condenser cooling for proper chiller operation.

Water-Cooled Condenser Check

Check the condenser water lines to make sure all
connections are secure. Make sure sufficient
condenser water flow and pressure are available, the
condenser water supply is turned on, and all shut-off
valves are opened. The electronic water regulating
valves ship in the closed position and open after
enabling the circuit.

Remote Air-Cooled Condenser Check

Check the refrigerant lines to make sure all
connections are secure and that a proper evacuation
of the chiller, the field piping, and the remote
condenser has occured. Verify the refrigeration
piping has been installed as descibed in the
installation section of this manual. Check the remote
condenser main power and control wiring to ensure
all connections are secure.

Step 4 – Check Refrigerant Valves

During shipment or installation it is possibe valves
where closed. Verify that all refrigerant valves are
open.

compressor, oil line, or liquid line service valves
“CLOSED”. Failure to have these “OPEN” may

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77

CAUTION: The manufacturer’s warranty does not

that the Freezestat is set properly.

WARNING: During normal operation, enable all

circuit’s evaporator.

WARNING: Under no circumstance should the

damage, severe personal injury or death.

Step 5 – Verify Freezestat Setting

Make sure the Freezestat is set appropriately for the
operating conditions of the chiller. The Freezestat is
in a password-protected menu of the chiller
controller. Refer to the controller operation section
for instruction on how to access this menu. It should
be set at 10°F

{-12°C} below the minimum chilled

water temperature setting that the chiller will
operate. Be sure the coolant solution has sufficient
freeze protection (glycol) to handle at least 5°F

{-15°C} below the Freezestat setting. All chillers ship

with the Freezestat set at 45°F
protect against a possible freeze-up if no glycol is
present in the coolant. Once the proper glycol
solution is present, adjust the Freezestat to the
appropriate setting.

cover the evaporator from freezing. It is vital

Step 6 – Turn On Control Power

Turn on the control power by touching the operator
interface. The panel displays should illuminate.

Due to extreme temperatures during shipment the
High Refrigerant Pressure switch may have tripped. If
this is the case, disconnect the main power and reset
the High Refrigerant Pressure by depressing the
manual reset button located on the switch.
Reconnect the main power and turn the control
power on by pressing the Power button. Clear the
alarm condition by pressing the Alarm Reset button.

Step 7 – Establish Coolant Flow

Establish flow through the evaporator(s). Set process
water flow through the evaporator(s). If a flow meter
is not available, run the chiller fully loaded and
balance the flow until a 10°F
established. A water temperature rise of 5°F
or less will result in a significant increase in flow
beyond the recommended rate and may damage the
evaporators and create excessive pressure drops that
influence the overall efficiency of the system.

Note: The compressors will not start as long as the flow switch
is open. There must be a positive flow through the
evaporator(s) before the compressor(s) can operate.

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{-12°C} rise is

{7.2°C}. This is to

{-15°C}

Step 8 – Intial Unit Operation

Enter the desired leaving fluid temperature on the
control panel. Unless otherwise specified, the chiller
is factory set to deliver coolant at 50°F
to the desired operating temperature. The chiller
should now be controlling to the selected
temperature. Please note that if there is insufficient
load the compressor may cycle on and off causing
swings in temperature.

circuits. Failure to heed this warning may lead to
evaporator freeze-up. When shutting down a
circuit for servicing, shut off water to that

High Refrigerant Pressure or the Low Compressor
Pressure switch be deactivated. Failure to heed
this warning can cause serious compressor

Starting a compressor is only possible if its cycle
time has expired, its liquid line solenoid valve is open
and meeting all of its safeties. The time to
completion displays on the screen. Once the
compressor starts, it will operate fully unloaded for
two minutes. If the demand requires additional
loading after the two minutes has expired, the
compressor will load accordingly. This sequence is to
improve the compressor’s liquid refrigerant handling
capability during start-up.

Low-Ambient Start-Up (Remote Condensers)

When a chiller system with an outdoor remote air­cooled condenser stops, the temperature of the
refrigerant in the condenser will cool to the ambient
temperatures. The cooler the refrigerant gets, the
lower the refrigerant pressure will be. The chiller has
a low refrigerant pressure safety to protect the chiller
from damage due to the refrigerant pressure being
too low for proper operation. When starting a chiller
that has been off for an extended period the
refrigerant pressure in the system will often times be
lower than the set point of the low refrigerant
pressure alarm.

To allow for cold weather start-up of a remote
condenser system there is a low-low refrigerant
pressure safety that is set below the normal low
refrigeration pressure alarm. This low-low pressure

78

{10°C}. Adjust

CAUTION: A clear sight glass alone does not

may result in overcharging the circuit.

safety is the absolute lowest pressure allowed for
operation. At start-up, the control system ignores
the low refrigerant pressure alarm for a period of 2
minutes to allow the system to build pressure. After
2 minutes, the control system returns to normal
operation and used the higher set point of the
standard low refrigerant pressure alarm.

In most cases, the 2-minute time delay for the low
refrigerant pressure will be sufficient to allow the
compressor(s) to build up the system refrigerant
pressure. In extreme conditions with -10°F

{-12°C} or

cooler ambient air and/or additional cooling effect
due to wind, the chiller may experience a low
refrigerant pressure alarm after the initial 2-minute
bypass time has expired. Under these conditions,
multiple starts may be required to build the
refrigerant pressure.

Operate the system for approximately 30 minutes.
Check the liquid line sight glasses. The refrigerant
flow past the sight glasses should be clear. Bubbles
in the refrigerant indicate either low refrigerant
charge or excessive pressure drop in the liquid line.
An indication of a shortage of refrigerant is if
operating pressures are low and sub-cooling is low.
Normal sub-cooling ranges from 10°F

{-6°C}. If the sub-cooling is not within this range,

{-12°C} to 20°F

check the superheat and adjust if required. The
superheat should be approximately 10°F

{-12°C}.

Since the unit is factory charged, adding or removing
refrigerant charge should not be necessary. If the
refrigerant pressure, sight glass, superheat, and sub­cooling readings indicate a refrigerant shortage, gas­charge refrigerant into each circuit, as required. With
the unit running, add refrigerant vapor by
connecting the charging line to the suction service
valve and slowly charging through the backseat port
until operating conditions become normal.

mean that the system is properly charged. Also,
check system superheat, sub-cooling, and unit
operating pressures. If both suction and
discharge pressures are low but sub-cooling is
normal, a problem other than refrigerant
shortage exists. Do not add refrigerant, as this

Once proper flow and temperature are achieved,
press the Stop button. The unit is now ready to be
placed into service.

Preventive Maintenance

Once your chiller is in service, follow the
maintenance procedures as closely as possible. The
importance of a properly established preventive
maintenance program cannot be overemphasized.
Taking the time to follow these simple procedures
will result in substantially reduced downtime,
reduced repair costs, and an extended useful lifetime
for the chiller. Any monetary costs of implementing
these procedures will usually more than pay for
itself.

To make this as simple as possible, we recommend
the use of a checklist of the recommended service
operations and the times performed. At the end of
this manual, you will find a checklist to use for this
purpose. Please notice that there are locations for
logging the voltage readings, amperages, etc. With
this information, maintenance personnel may be
able to correct a potential problem before it causes
any downtime. For best results, take all readings with
a full heat load from process, preferably with similar
operating conditions each time. The following is a
list of suggested periodic maintenance.

Once a Week

1. Check to make sure that the To Process

temperature is reasonably close to the Set Point
temperature. If the temperature stays more than
5°F away from the set point, there may be a
problem with the chiller. If this is the case, refer
to the Troubleshooting Chart or contact our
Customer Service Department.

2. Check the chiller and/or process pump discharge

pressures. Investigate further if the pressure
starts to stray away from the normal operating
pressure.

3. Check the suction and discharge refrigerant

pressure at the compressor.

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79

4. Check each refrigerant sight glass for air bubbles

or moisture indication. Bubbles in the refrigerant
indicate either low refrigerant charge or
excessive pressure drop in the liquid line. If the
sight glass indicates that there is a refrigeration
problem, have the unit serviced as soon as
possible.

Once a Month

Repeat items 1 through 4 listed above and continue
with the following.

5. With the main disconnect shut off and locked

out, check the condition of electrical connections
at all contactors, starters and controls. Check for
loose or frayed wires.

6. Check the incoming voltage to make sure it is

within 10% of the design voltage for the chiller.

7. Check the amp draws to each leg of the

compressor(s) to confirm that it is drawing the
proper current.

8. Check the system superheat and sub-cooling.

Normal superheat is approximately 10°F;
however, it may be high but not more than 15°F.
Normal sub-cooling ranges from 10°F to 20°F.

11. (Remote Air-Cooled Condenser Chillers Only)

Check the condition of the air coils of the
remote condensers for dirt and debris. If the
coils are dirty or clogged, use a compressed air
source to blow the contaminants out of the air
coil. To clean, rinse thoroughly with water. Mild
detergent can be used to remove smoke and or
grease stains.

12. Have a qualified refrigeration technician inspect

the operation of the entire unit to ensure
everything is operating properly.

Once Every Three Months

Repeat items 1 through 8 listed above and continue
with the following.

9. Check the evaporator Y-strainer and clean if

necessary. The Y-strainer is located between the
return connection and the evaporator. This may
require more frequent cleaning if contaminants
can easily get into the system.

Once a Year

Repeat items 1 through 9 listed above and continue
with the following.

10. (Water-Cooled Condenser Chillers Only) Check

the condition of the condenser water for algae,
scale, or other contamination. If needed, rod out
the tubes and back flush condensers before
reconnecting pipes.

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80

Problem

Possible Cause

Remedy

Three-phase power monitor tripped

Check correct phasing of incoming power

Compressor overload

Check supply voltage, amperage of each leg,
contactor and wiring, overload set point

Compressor contactor

Replace if faulty

PLC output card

Replace if faulty

Compressor failure

Contact Conair’s Service Department for
assistance

Low refrigerant charge

Contact refrigeration service technician

Refrigerant leak

Contact refrigeration service technician

closed

Low refrigerant pressure sensor

Replace if faulty

PLC input card

Replace if faulty

Fouled evaporator flow

Clean evaporator inlet strainer. If the

replace if necessary.

Low evaporator flow

Check evaporator pumping system

Plugged condenser

Clean condenser

Insufficient condenser water flow (ESEW only)

Make sure chiller is installed in accordance
with recommendations in this manual

High condenser water temperature (ESEW only)

Maximum temperature is 95°F

Condenser water regulating valve (ESEW only)

Replace if faulty

Compressor discharge service valve is fully or partially
closed

Open valve all the way
Refrigerant circuit overcharged

Contact refrigeration service technician

High refrigerant pressure sensor

Replace if faulty

PLC input card

Replace if faulty

Low flow through evaporator

Adjust flow to proper level

Temperature sensor

Replace if faulty

Cleaning the Operator Interface

Use of abrasive cleaners or solvents may damage the
window. Do not scrub or use brushes. To clean the
display window:

1. Disconnect power from the terminal at the

power source.

2. Using a clean sponge or a soft cloth, clean the

display with a mild soap or detergent. If paint or

General Troubleshooting

Compressor will not
start

grease splash is present, remove before drying
by rubbing lightly with isopropyl alcohol.
Afterward, provide a final wash using a mild
soap or detergent solution. Rinse with clean
water.

3. Dry the display with a chamois or moist cellulose

sponge to avoid water spots.

Compressor suction service valve partially or fully

Low refrigerant
pressure

High refrigerant
pressure

Freezestat

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Freezestat control Check for proper setting and replace if faulty

Open valve all the way

evaporator is plugged, clean if possible or

81

PLC input card

Replace if faulty

Evaporator Y-strainer clogged or dirty

Clean Y-strainer

process load

Coolant flow outside of normal operating range

Adjust flow to proper level

Insufficient condenser cooling

See high refrigerant pressure

Refrigeration circuit problem

Contact refrigeration service technician

Temperature sensor

Replace if faulty

PLC input card

Replace if faulty

Low coolant flow through evaporators

Adjust flow to proper level

process load

Temperature sensor

Replace if faulty

PLC input card

Replace if faulty

Insufficient cooling
(temperature
continues to rise
above set point)

Process load too high Check to make sure chiller is properly sized for

Erratic temperature
control

Overloading of chiller capacity Check to make sure chiller is properly sized for

Week Number

1 2 3 4 5 6 7 8 9

10

11

12

Date

Temperature Control

Pump Discharge Pressure

Refrigerant Suction Pressure #1

Refrigerant Suction Pressure #2

Refrigerant Discharge Pressure #1

Refrigerant Discharge Pressure #2

Refrigerant Sight Glass #1

Refrigerant Sight Glass #2

Check and clean evaporator Y-strainer

Electrical Connections

Incoming Voltage

Compressor #1 L1 Amps

Compressor #1 L2 Amps

Compressor #1 L3 Amps

Compressor #2 L1 Amps

Compressor #2 L2 Amps

Compressor #2 L3 Amps

Compressor #3 L1 Amps

Compressor #3 L2 Amps

Compressor #3 L3 Amps

Compressor #4 L1 Amps

Compressor #4 L2 Amps

Compressor #4 L3 Amps

Refrigerant Circuit #1 Superheat

Refrigerant Circuit #2 Superheat

Refrigerant Circuit #1 Sub-cooling

Refrigerant Circuit #2 Sub-cooling

*Oil Level Check #1

*Oil Level Check #2

*Oil Analysis #1

*Oil Analysis #2

Preventive Maintenance Checklist

The following is a sample of a typical dual-circuit chiller checklist.

Maintenance Activity

* Once a year

Drawings

We have prepared a custom set of drawings for your unit and placed them inside the control panel prior to
shipment. Please refer to these drawings when troubleshooting, servicing, and installing the unit. If you cannot
find these drawings or wish to have additional copies sent, please contact our Customer Service Department and
reference the serial number of your unit.

We’re Here to Help

Conair has made the largest investment in customer support in the plastics industry. Our service experts are
available to help with any problem you might have installing and operating your equipment. Your Conair sales
representative also can help analyze the nature of your problem, assuring that it did not result from
misapplication or improper use.

How to Contact Customer Service

To contact Customer Service personnel, call:

NOTE: Normal operating hours are 8:00 am - 5:00 pm (EST). After hours emergency

service is available at the same phone number.

From outside the United States, call: 814-437-6861
You can commission Conair service personnel to provide on-site service by contacting the Customer Service
Department. Standard rates include an on-site hourly rate, with a one-day minimum plus expenses.

Before You Call...

If you do have a problem, please complete the following checklist before calling Conair:

 Make sure you have all model, control type from the serial tag, and parts list numbers for your particular

equipment. Service personnel will need this information to assist you.

 Make sure power is supplied to the equipment.

 Make sure that all connectors and wires within and between control systems and related components

have been installed correctly.

 Check the troubleshooting guide of this manual for a solution.

 Thoroughly examine the instruction manual(s) for associated equipment, especially controls. Each manual

may have its own troubleshooting guide to help you.

 Check that the equipment has been operated as described in this manual.

 Check accompanying schematic drawings for information on special considerations.

Equipment Guarantee

Conair guarantees the machinery and equipment on this order, for a period as defined in the quotation from date
of shipment, against defects in material and workmanship under the normal use and service for which it was
recommended (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.).
Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after

examination. The customer assumes the cost of transportation of the part or parts to and from the factory.

Performance Warranty

Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the
equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and
maintained in the recommended manner as outlined in our quotation or specifications.

Should performance not meet warranted levels, Conair at its discretion will
exercise one of the following options:

• Inspect the equipment and perform alterations or adjustments to satisfy performance claims. (Charges for

such inspections and corrections will be waived unless failure to meet warranty is due to misapplication,
improper installation, poor maintenance practices or improper operation.)

• Replace the original equipment with other Conair equipment that will meet original performance claims at no

extra cost to the customer.

• Refund the invoiced cost to the customer. Credit is subject to prior notice by the customer at which time a

Return Goods Authorization Number (RGA) will be issued by Conair’s Service Department. Returned
equipment must be well crated and in proper operating condition, including all parts. Returns must be
prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a
claim is being made.

Warranty Limitations

Except for the Equipment Guarantee and Performance Warranty stated above, Conair disclaims all other
warranties with respect to the equipment, express or implied, arising by operation of law, course of
dealing, usage of trade or otherwise, including but not limited to the implied warranties of merchantability
and fitness for a particular purpose.