Sterling A0544325 User Manual
SMC-050 to SMC-150 Series
0.5 to 1.5 hp Portable Chillers
Operation and Installation Manual
Sterling, Inc./Sterlco
P. O. Box 245018
5200 West Clinton Avenue
Milwaukee, WI 53224-9518
Tel (414) 354-0970
Fax (414) 354-6421
Part No. A0544325 Bulletin No. SC2-615.1
Sterling/Sterlco is committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
are subject to change without notice.
© Copyright Sterling/Sterlco and Sterling, Inc. 2003
All rights reserved. Effective 7/30/2003
Part No. A0544325 Bulletin No. SC2-615.1
Page 2
SMC Series Chillers
Safety Considerations
SMC Series Chillers are designed to provide safe and reliable operation when installed and
operated within design specifications, following national and local safety codes.
To avoid possible personnel injury or equipment damage when installing, operating or
maintaining this equipment, use good judgment and follow these safe practices:
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. It is a good
idea to remove the fuses and carry them with you.
; Make sure the chiller is properly GROUNDED before switching power on.
; When welding or brazing in or around this equipment, be sure VENTILATION is
ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet
metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if
needed.
; The refrigeration system can develop refrigerant pressures in excess of 500 psi (3,450 kPa).
DO NOT CUT into the system without first relieving pressure.
; Do not jump or bypass any electrical safety control.
; Do not restore power until all tools, test equipment etc. have been removed and the panels
replaced.
; Only PROPERLY TRAINED personnel familiar with the information within this manual
should work on this equipment.
SMC Series Chillers Page 3
Table of Contents
1 General Information ................................................. 7
1-1 Introduction
1-2 Necessary Documents
1-3 Models Covered
1-4 Available Options
1-5 Uncrating Your New Chiller
1-6 In the Event of Shipping Damages
1-7 If the Shipment is Not Complete
1-8 If the Shipment is Incorrect
1-9 Returns
2 Chiller Installation .................................................. 13
2-1 Electrical Connections
2-2 Process Water Connections
2-3 SMC Condenser Air Supply
2-4 Water Reservoir
2-5 Overhead Process Considerations
3 Sequence of Operation.......................................... 17
3-1 Chilled Water Circuit
3-2 Refrigeration Circuit
3-3 High Pressure Cutout
3-4 Low Pressure Cutout
3-5 Remote Start/Stop Interlock
Page 4
SMC Series Chillers
Table of Contents
4 Startup Checklists.................................................. 23
4-1 Introduction
4-2 SMC Pre-Startup Checklist
4-3 SMC Startup Checklist
5 Microprocessor Control ........................................ 25
5-1 Introduction
5-2 Setting the Process Water Temperature
5-3 Setting the Alarm Value
6 Optional Graphic Panel ......................................... 27
6-1 Indicator Lights
6-2 Switches
7 Routine Maintenance ............................................. 29
7-1 Lubrication
7-2 Condenser Maintenance
8 Troubleshooting Guide.......................................... 33
SMC Series Chillers Page 5
Charts and Figures
1
SMC050A Process Pump Curves 10
2
SMC100A Process Pump Curves 10
3
SMC150A Process Pump Curves 11
4
SMC Series Chiller Specifications 12
5
Ethylene Glycol Curve 15
6
Overhead Piping 16
7
SMC Component Identification 19
8
Piping Schematic — 1 Pump with Reservoir 20
9
10
11
12
13
14
15
16
17
Piping Schematic — 1 Pump without Reservoir 21
Piping Schematic — No Pump, No Reservoir 22
SMC Water Circuit Pressure Drop Table 24
SMC Control 26
Optional Graphic Panel 28
Typical SMC Subpanel 29
Typical SMC Wiring Schematic 30
SMC Wiring Schematic for Chillers with No Pump or Reservoir 31
SMC Spare Parts List 35
Page 6
SMC Series Chillers
1 General Information
1-1 Introduction
SMC Series Water Chillers are reliable, accurate, and easy-to-use air cooled chillers designed for
use with water/glycol. Standard range of operation is 30°F (-1°C) to 65°F (18°C). A crankcase
pressure regulating valve option is available for processes requiring a leaving water temperature
of up to 75°F (24°C). SMC models are available in ½ hp (373 W), 1 hp (746 W), and 1½ hp
(1,118 W) models and have an internal six gallon (23 liter) reservoir. All models are self
contained, fully assembled, and shipped ready to use.
A properly installed, operated, and maintained SMC Series Chiller will provide many years of
reliable operation. To get the most satisfaction from your new chiller, read and follow the
instructions in this manual.
1-2 Necessary Documents
The following documents are necessary for the operation, installation and maintenance SMC
Series Chillers. Additional copies are available from Sterlco. Familiarize the appropriate
personnel with these documents:
; This manual.
; The electrical schematic and connection diagram mounted inside the control enclosure.
Typical schematics for general reference are provided in Figures 14 and 15 on Pages 32 and
33.
; The operation and installation manuals for installed accessories and options.
; The Customer Parts List included in the information packet.
1-3 Models Covered
This manual provides operation, installation, and maintenance instructions for SMC Series
Chillers. Model numbers are on the serial tag. Please know the model number, serial number and
operating voltage of your chiller if you need to contact Sterlco.
SMC Series Chiller models are designated by approximate compressor horsepower. A SMC050
chiller has a ½ hp (373 W) compressor, a SMC100 chiller has a 1 hp (746 W) compressor, and a
SMC150 chiller has a 1½ hp (1,118 W) compressor.
SMC Series Chillers Page 7
1-4 Available Options
SMC Series Chillers are available with options that tailor the unit to your requirements. Some are
factory installed, some can be retrofitted in the field. Consult your local Sterlco Sales
Representative. Some of these options are:
Special Pumps
Special pump options are available for greater pressure and flow rates. Bronze and stainless steel
wetted surface standard flow pumps ranging from 30 psi (207 kPa) to 60 psi (414 kPa) are
available.
Reservoirs
SMC Series Chillers are available without a reservoir for processes that use their own reservoir.
Power Cord
A 10 foot (3 meter) power cord is available to speed SMC installation.
Casters
Four 2-inch (5 cm) swivel casters add mobility to the SMC unit.
CPR Valve
A crankcase pressure regulating (CPR) valve is available for leaving water temperatures up to
75°F (24°C).
1-5 Uncrating Your New Chiller
SMC Series Chillers are shipped mounted on a skid, enclosed in a plastic wrapper, and open
crated on all four sides and top.
; Pry the crating away from the skid and remove. Use a pry bar to remove the blocks securing
the unit to the skid.
; Lift the unit off the skid with a fork truck. Insert forks between skid and chiller from the side
until they protrude beyond the opposite side of the unit. The forks must be equidistant from
the center line of the unit and the unit must be balanced on the forks.
; Lift slowly and only high enough to clear the skid. Use a pry bar if necessary to remove the
skid from the unit.
; Lower slowly. The unit will land on its feet or casters and can be moved into position.
Page 8
SMC Series Chillers
1-6 In the Event of Shipping Damages
Important!
According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of shipment.
The Carrier then assumes full responsibility of the shipment.
; Notify the transportation company’s local agent.
; Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods to Sterlco before the transportation company inspection and authorization.
; File a claim against the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
; Advise Sterlco regarding your wish for replacement.
1-7 If the Shipment is Not Complete
Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted
on the packing list. You should have:
; SMC Series Chiller
; Bill of Lading
; Packing List
; Operating and Installation Packet
Re-inspect the container and packing material to see if smaller items have been missed during
unpacking. Determine that the item was not taken from the area before the shipment was checked
in. Notify Sterlco immediately of the shortage.
1-8 If the Shipment is Incorrect
; If the shipment is not what you ordered, contact Sterlco immediately. Include the order
number and item.
; Hold the items until shipping instructions are received.
SMC Series Chillers Page 9
1-9 Returns
Do not return any damaged or incorrect items until
you receive shipping instructions from STERLCO.
Important!
Figure 1
SMC050A Process Pump Curves
TOTAL HEAD
MTRS
PSI FEET
49
69 160
37 52 120
24
35 80
12 18 40
U. S. GALLONS
PER MINUTE
LITRES
PER MINUTE
TOTAL HEAD
PSI
MTRS
49
69 160
37 52 120
24
35 80
FEET
BZ050A BZ050B
0.4
1.5
0.8
3.0
1.2
4.5
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
BZ100B
BZ100A
SMC050A - PROCESS PUMPS SELECTIONS
60 HERTZ PUMP CURVE
BZ050C
1.6
6.1
2.0
7.6
2.4
9.1
2.8 3.2
10.6
12.1
Do not extrapolate pump curves.
Figure 2
SMC100A Process Pump Curves
SMC100A- PROCESS PUMPS SELECTIONS
60 HERTZ PUMP CURVE
BZ100C
3.6
13.6 15.1
4.0 4.4
16.7
4.8
18.2
12 18 40
U. S. GALLONS
PER MINUTE
LITRES
PER MINUTE
Page 10
1.6
6.1
2.0
7.6
2.4
9.1
2.8
10.6
3.2
12.1
3.6
13.6 15.1
4.0 4.4
16.7
4.8
18.2
5.65.2 6.0 6.4
19.7 21.2 22.8 24.2
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
Do not extrapolate pump curves.
SMC Series Chillers
Figure 3
SMC150A Process Pump Curves
TOTAL HEAD
MTRS
PSI FEET
49
69 160
37 52 120
24
35 80
12 18 40
U. S. GALLONS
PER MINUTE
LITRES
PER MINUTE
SMC150A - PROCESS PUMPS SELECTIONS
60 HERTZ PUMP CURVE
BZ150B
BZ150C
BZ150A
2.42.0
9.17.6
2.8
10.6
3.2
12.1
3.6
13.6 15.1
4.0 4.4
16.7
4.8
18.2
5.2 5.6 6.0 6.4 6.8
19.7 21.2 22.7 24.3 25.8
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
Do not extrapolate pump curves.
SMC Series Chillers Page 11
O
No Flow indicator
(for pumpless
units only)
A0537868
NO FLOW
ptional gauge package
Optional gauge package
PUMP
PRESSURE
Mini Chiller
PC Series
Portable Chiller
ON
HIGH
LOW
REFRIGERANT
REFRIGERANT
PUMPONCOMPRESSOR
PRESSURE
PRESSURE
ON
POWER
OFF
Figure 4
SMC Series Chiller Specifications
Power cable entrance,
either side
Side cover
handle
Sight glass
Drain plug
(3/4" NPT)
To Process
(3/4" NPT)
34"
Model
Capacity
@ 65°F
LWT 75°F
Ambient
20"
Front View
Capacity
@ 50°F
LWT 90°F
Ambient
26"
Right Side View
Nominal
Chilled
Water Compressor Pump
18 7/16"
Process
Connection
13 7/16"
Optional Casters
Amp
Draw
230/1/60
From Process
(3/4" NPT)
Dimensions
(inches)
Rear View
Operating
Weight
Shipping
Weight
Number (Btuh) (Btuh) (gpm) (hp) (inches NPT) Running L W H (lbs) (lbs)
1
/
hp,
SMC-050 8,100 4,800 1.2
SMC-100 14,000 9,550 2.4
SMC-150 25,400 16,000 3.6
Model
Capacity
@ 18°C
LWT, 24°C
Ambient
Capacity
@ 10°C
LWT, 32°C
Ambient
Nominal
Chilled
Water Compressor Pump
½
1
1½
3
1.2 gpm @
24 psig
1
/
hp,
3
2.4 gpm @
34 psig
1
/
hp,
3
3.6 gpm @
24 psig
¾
¾
¾
Process
Connection
8A 20 26 34 265 265
10A 20 26 34 325 325
12A 20 26 34 345 345
Amp
Draw
230/1/60
Dimensions
(cm)
Operating
Weight
Shipping
Weight
Number (watts) (watts) (lpm) (watts) (inches NPT) Running L W H (kg) (kg)
224 watts,
SMC-050 2,374 1,407 4.5 373
4.5 lpm
@ 207 kPa
¾
8A 51 66 86 120 120
224 watts,
SMC-100 4,103 2,800 9.0 746
9.0 lpm
@ 234 kPa
¾
10A 51 66 86 147 147
224 watts,
SMC-150 7,444 4,690 13.6 1,118
13.6 lpm
@ 207 kPa
¾
12A 51 66 86 156 156
Page 12
SMC Series Chillers
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