Temptek CF Series Instruction Manual

I.O.M. #075 11/05

INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE

TEMPTEK, INC.

525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: [phone]

Service Department fax: [phone]

www.Temptek.com

e-mail: [e-mail]

with CF-1 Instrument

Page: 2

INSTRUCTION MANUAL

CF Series Portable Chiller

5 - 40 Tons

Air-Cooled & Water-Cooled

COVERING

INSTALLATION

OPERATION

MAINTENANCE

TEMPTEK, INC.

525 East Stop 18 Road Greenwood, IN 46142

317-887-0729 fax: [phone]

Service Department fax: [phone]

www.TempTek.com

e-mail: [e-mail]

CF Series Portable Chillers with CF-1 Instrument

Page: 4

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

Email: [e-mail]

TABLE OF CONTENTS

1.0 GENERAL 7

1.1 Introduction 8

1.2 Unit location 8

1.3 Efficiency 8

1.4 Safety 9

1.5 Clean air act 9

1.6 Miscellaneous 9

2.0 INSTALLATION 13

2.1 General 14

2.2 To and From process connections 14

2.3 Water supply connection 15

2.4 Air-cooled condenser 15

2.5 Water-cooled condenser 17

2.6 Electrical connection 18

3.0 OPERATIONS 21

3.1 General 22

3.2 Start up/operations procedure 23

3.3 Instrument/operation 26

3.4 Shut down procedure 30

4.0 TROUBLESHOOTING 31

4.1 Unit Will Not Start 32

4.2 Compressor Hums But Will Not Start 32

4.3 Shuts Off On High Pressure 32

4.4 Shuts Off On Low Pressure 33

4.5 Compressor Shuts Off On Internal Overload 34

4.6 Low Or No Process Pressure Or Water Flow 34

4.7 Cooling Capacity Inadequate 34

4.8 Sensor 35

4.9 Coolant Pump 35

4.10 Crankcase Heater 35

4.11 Chiller Controller 35

5.0 MAINTENANCE 37

5.1 Warranty service procedure 38

5.2 Periodic preventative maintenance 38

5.3 Special maintenance 39

5.4 Solenoid valve service 40

5.5 Pump seal service 42

5.6 Checking the refrigerant charge 45

5.7 Proper cleaning procedure for brazed plate evaporators 45

6.0 COMPONENTS 47

6.1 Water system 48

6.2 Refrigeration system 48

CF Series Portable Chillers with CF-1 Instrument

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7.0 RELATED DRAWINGS 51

7.1 Mechanical Schematic : Water-Cooled : 5 - 10 Tons 52

7.2 Mechanical Schematic : Water-Cooled : 15 - 40 Tons 53

7.3 Mechanical Schematic : Air-Cooled : 5 - 10 Tons 54

7.4 Mechanical Schematic : Air-Cooled : 15 - 30 Tons 55

7.5 Typical Electrical : Air-Cooled 56

7.6 Typical Electrical : Water-Cooled 57

7.7 Physical Schematic : Air-Cooled : 7.5 - 10 Tons 58

7.8 Physical Schematic : Air-Cooled : 5 Tons 59

7.9 Physical Schematic : Water-Cooled 60

7.10 Duct Schematic for Air-Cooled Chillers 61

8.0 APPENDIX 63

8.1 Operations below 48°F 64

8.2 Water quality control 65

8.3 Inhibited propylene glycol 65

8.4 Sensor current vs temperature 65

8.5 Refrigerant pressure-temperature chart 66

8.6 Chiller capacity and derate chart 67

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CF Series Portable Chillers with CF-1 Instrument

1.0 GENERAL

1.1 INTRODUCTION

1.2 UNIT LOCATION

1.3 EFFICIENCY

1.4 SAFETY

1.5 CLEAN AIR ACT

1.6 MISCELLANEOUS

Page: 7

525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

Email: [e-mail]

CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

Email: [e-mail]

1.1 INTRODUCTION

A. This manual covers portable chillers from 5 to 40 tons.

B. When calling for assistance from the Manufacturer’s Service

Department, it is important to know the model and serial number of
the particular unit. The model number encodes critical unit
information which is helpful in any attempt to troubleshoot operating
difficulties. The serial number allows the service team to locate
manufacturing and testing records which can have additional
information relating to a particular unit.

1.2 UNIT LOCATION

A. For air-cooled and water-cooled models:

1. These units are designed for indoor use only.

2. For most efficient operation, locate the chiller in a clean, dry

and well ventilated environment.

B. For air-cooled models:

1. The unit has an air-cooled refrigerant condenser. For air-

cooled condensers, a motor driven fan (on models from 5 to
15 tons) or a centrifugal blower (on models from 15 to 30
tons) generates air flow through the condenser to remove
heat from the refrigerant system. The air cooled condenser
on the unit will discharge a maximum of 15,000 BTU’s per
hour per ton of cooling.

2. The unit must have a minimum entering air temperature of
60°F and a maximum entering air temperature of 95°F for
efficient operation.

3. The unit must have a minimum of two feet clearance at the
air intake and six feet at the vertical exhaust air discharge.

4. The unit must

have all enclosure panels in place before
operating compressor. Air will not be drawn through the
condenser coil if they are not in place. This will cause the
compressor to lockout on the high pressure safety fault.

1.3 EFFICIENCY

A. Long term efficiency of operation is largely determined by proper

maintenance of the mechanical parts of the unit and the water
quality. The Manufacturer recommends filtering where required to
prevent solids from plugging critical parts (pumps, heaters, seals for
example). The Manufacturer highly recommends the services of a
competent water treatment specialist be obtained and his

CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

Email: [e-mail]

recommendations followed. The Manufacturer accepts no
responsibility for inefficient operation, or damage caused by foreign
materials or failure to use adequate water treatment.

1.4 SAFETY

A. It is important to become thoroughly familiar with this manual and

the operating characteristics of the unit.

B. It is the owner’s responsibility to assure proper operator training,

installation, operation, and maintenance of the unit.

C. Observe all warning and safety placards applied to the chiller.

Failure to observe all warnings can result in serious injury or death
to the operator and severe mechanical damage to the unit.

1.5 CLEAN AIR ACT

A. The unit contains HCFC-22 (chlorodifloromethane). This is a class

2 substance.

B. Effective July 1, 1992, it is unlawful for any person in the course of

maintaining, servicing, repairing, or disposing of refrigeration
equipment to knowingly vent or otherwise dispose of any class 2
substance used as a refrigerant in the manner which permits such
substance to enter the atmosphere.

C. De minimis releases associated with good faith attempts to

recapture, reclaim or recycle such substance shall not be subject to
the prohibition set forth in the preceding paragraph.

1.6 MISCELLANEOUS

A. The unit is designed to circulate temperature stabilized fluid through

the process resulting in process temperature control.

B. The ability of the unit to maintain process temperature control is

significantly affected by the method of installation as outline in
section 2 of this manual.

C. If the operator has any questions concerning the location and

operation of the unit, contact the The Manufacturer’s Service
Department.

CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

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Air-Cooled.

Water-Cooled.

Air-Cooled Model.

Pressure Gauges

Cover Panel

Enclosure Panel

Electrical Panel

Enclosure

Casters

Instrument

Caster

Liquid Receiver

Compressor

Liquid Line Solenoid

Refrigerant Site Glass

Fan Motor

Protective Fan Shroud

Air Discharge

Hot Gas Bypass Valve

Pump

Expansion Valve

Insulated Reservoir Tank

CF Series Portable Chillers with CF-1 Instrument

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317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

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Condenser Water-Out

Connection

Reservoir Make-Up

Connection

Condenser Water-In Connection

(optional)

Condenser Water

Regulator Valve

From Process Connection

Reservoir

Optional Reservoir Sight Glass

To Process Connection

Pump

Caster

Condenser

Electrical Panel

Compressor

Refrigerant Sight Glass

Expansion Valve

Make-Up Valve

Water-Cooled Model.

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CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

Email: [e-mail]

2.0 INSTALLATION

2.1 GENERAL

2.2 TO AND FROM PROCESS CONNECTIONS

2.3 WATER SUPPLY CONNECTION

2.4 AIR COOLED CONDENSER INSTALLATION

2.5 WATER-COOL CONDENSER INSTALLATION

2.6 ELECTRICAL CONNECTION

CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

Email: [e-mail]

2.1 GENERAL

A. All process piping materials (such as hose, rigid piping, valves or

filters) used in process water piping circuitry must be rated for
100°F minimum temperature and 100 PSI minimum pressure.

B. All such materials must have the equivalent or larger diameter of

the particular process connection that length of process water
piping is connected to.

2.2 TO AND FROM PROCESS CONNECTIONS

A. Connect the ‘TO PROCESS’ to the ‘water in’ manifold on the mold

or process.

B. Connect the ‘FROM PROCESS’ port to the ‘water out’ port on the

process manifold.

C. Process water piping circuitry should be designed to avoid an

excessive use of elbows and/or lengths of pipe or hose. If hose is
the material of choice, avoid tight twists or curls and excessive
lengths.

D. Valves and filters may be installed in the process water piping

circuitry to facilitate service and maintenance provided that such
devices maintain the full inside diameter of the process connection.
If installed, all such devices must be open and clean during unit
operation.

Air-cooled model shown.

From Process :

Connect to ‘Water Out’

port on process manifold

Water Make-Up :
Connect to plant’s city
water source.

To Process :

Connect to ‘Water In’ port

on process manifold

CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

Website: www.Temptek.com

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2.3 WATER SUPPLY CONNECTION

A. The automatic water supply make-up system continually monitors

the reservoir tank and fills it when needed. Connect as follows:

1. Connect the chiller’s ‘WATER SUPPLY’ port to the plant’s
city water source.

2. Minimum water supply pressure requirement is identified on
the equipment data plate. This is normally 20 psi.

3. Be certain to use a water supply line equipped with a back
flow prevention device to prevent contamination of potable
water.

2.4 AIR COOLED CONDENSER

A. Air-cooled condensers require ambient air temperatures between

60°F and 95°F for efficient operation. Operating above 95°F may
result in elevated condensing pressures and eventual shut-down on
the high pressure safety switch. In such cases, a water assist unit
may be necessary for operations. Air temperatures below 60°F may
result in below normal condensing pressures and poor condensing.
In such cases, a low-ambient damper assembly is required. Check
with the Manufacturer’s service department for more information on
operating with ambients air temperatures above 95°F or below 60°F.

Water-Cooled model shown.

To Process Connection

From Process Connection

Water Supply Connection

Condenser Water-Out Connection

Condenser Water-In Connection
(with optional water regulator valve)

CF Series Portable Chillers with CF-1 Instrument

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B. Air flow is generated by the motor

mounted fans (figure 2.4A) or
centrifugal blowers (figure 2.4B). Air
flow is from the outside of the chiller,
through the condenser and
exhausted through the top of the
unit. On centrifugal blowers models,
exhaust air can be ducted outside of
the plant’s interior environment.
Special duct work is required and a
HVAC contractor should be
consulted for sizing and material
specifications. Exhaust air can not
be ducted on motor mounted fan
models.

C. A free air space of at least two (2)

feet is required at the condenser
intake and six (6) feet at the
condenser discharge to allow for
proper air flow.

D. At full load, the chiller will discharge

approximately 15,000 BTU’s per
hour per ton of cooling.

E. On blower units, air discharge

duct work should be sized by a
qualified HVAC engineer.
Sizing shall be according to
rated CFM at the static
pressure of .90 inches of
water. See figure 2.4C at right.

F. On blower units, a damper

control assembly is
required in low
ambient temperature
areas or when
outdoor air make-up
is used. The
assembly works in
conjunction with
refrigerant head
pressure to regulate
air flow to maintain
proper refrigerant
head pressure when
condenser intake air
temperature will be
less than 60°F. See
figure 2.4D to the
right.

Figure 2.4A

Typical fan assembly

Figure 2.4B

Typical blower assembly

Figure 2.4C

Figure 2.4D

CF Series Portable Chillers with CF-1 Instrument

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

Service Department Fax: [phone]

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G. All air cooled units must have all enclosure panels in place before

operating compressor. Air will not be drawn through the condenser
coil if they are not in place. This will cause the compressor to
lockout on the high pressure safety fault.

2.5 WATER-COOLED CONDENSER

A. Connect the ‘CONDENSER WATER

IN’ port to the plant’s city water

supply or tower system supply.

1. Required consumption from
a city water source is 1.5
gpm at 65°F per ton of rated
capacity.

2. Required consumption for a
tower water source is 3 gpm
at 85°F per ton of rated
capacity.

B. Connect the chiller’s ‘CONDENSER WATER OUT’ port to the

plant’s drain or tower system return.

1. Note: if dumping to the plant’s open drain, drainage shall
be done according to local codes.

C. The pressure differential requirement between the condenser “water

in” and the condenser “water out” lines must be 30 psi for adequate
efficiency.

D. The installation of a strainer in the

condenser “water in” line is
recommended. This removes solids
from the water supply and serves to
protect the water saver (regulator)
valve.

E. The water saver (regulator) valve

(figure 2.5B) is located in the
condenser “water in” line. During
winter months, or cold seasons, the
valve will throttle the water flow
through the condenser. The amount
of flow is based on the refrigerant head pressure and the regulator
will modulate the valve orifice to maintain 100° - 105°F condensing
temperature for best efficiency*.

Figure 2.5A

Typical condenser connections ­30 ton unit

Figure 2.5B

Optional Regulator Valve

* See Temperature-Pressure

chart in Section 8.5 for

refrigerant pressure.

CF Series Portable Chillers with CF-1 Instrument

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Service Department Fax: [phone]

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2.5 ELECTRICAL CONNECTION

A. NEMA 1 MODELS

1. Electrical power supply requirements for Nema 1 units are

identified on the equipment data plate. Determine the plant’s
voltage supply is the same as the unit’s voltage
requirements.

WARNING: Do not connect the unit to a voltage supply
not equal to the unit’s voltage requirements as
specified on the unit’s data plate. Use of incorrect
voltage will void the unit’s warranty and cause a
significant hazard that may result in serious personal
injury and unit damage.

2. A customer supplied, four conductor cable is required for

connection to a customer supplied fused disconnecting
means. The fused disconnecting means shall be sized and
installed according to the unit’s power supply requirements
and local electrical codes.

3. Connect the four conductor power cable to power entry
terminal block on the unit’s electrical panel. Then connect
the power cable to the fused disconnect switch.

B. NEMA 12 MODELS

1. NEMA 12 units are constructed with a dust tight electrical

enclosure and branch circuit fusing. Electrical power supply
requirements are identified on the equipment data plate.
Determine the plant’s voltage supply is the same as the
unit’s voltage requirements.

WARNING: Do not connect the unit to a voltage supply
source not equal to the unit’s voltage requirements as
specified on the unit’s data plate. Use of incorrect
voltage will void the unit’s warranty and cause a
significant hazard that may result in serious personal
injury and unit damage.

2. Appropriate conduit and fittings should be selected which

will maintain the integrity of the cabinet.

3. Supply a power conductor sized according to the unit’s
power supply requirements. Connect the power conductor to
the unit’s power supply entry terminal block or the fused
disconnect switch. Some Nema 12 models may be supplied
with an optional disconnect switch. The owner supplied
fused disconnecting means shall be sized and installed
according to the unit’s power supply requirements and local
electrical codes.

C. CONTROL CIRCUIT WIRING

1. The unit’s supplied control circuit is 110 volt, 1 phase, 60

cycle. The control circuit is supplied by the factory installed
transformer. An inline control circuit fuse is provided.

CF Series Portable Chillers with CF-1 Instrument

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D. GENERAL

1. Make certain all ground connections to the unit are properly

affixed.

2. Make certain power conductor, disconnecting means, and
fusing are properly sized according to the unit’s power
supply requirements.

E. INFORMATION REGARDING ‘PHASING’ OF SCROLL

COMPRESSORS

1. All portable chillers that have pumps, the compressor(s) will

be set in phase with the pump during the testing process at
the factory.

2. After installation the phase status must be checked by
observing the pump motor shaft on the end of the pump
and comparing its rotation to the directional arrow on the
motor. In either case, if the phase needs to be altered, it
should be done at the main power entry.

Figure 2.5A Typical electrical panel

Refrigerant High Pressure Limit

(protects from excessive condensing pressures)

Refrigerant Low Pressure Limit

(protects from low suction pressures)

Motor Contractor

(supplies voltage to coolant pump motor)

Motor Overload Relay

(protects motor from excessive amperage)

Transformer

(provides different voltages
to instrument and other components)

Power Entry

(connect to power cord ­grounding lug on panel)

Compressor Contactor

(supplies voltage to compressor)

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525 East Stop 18 Road Greenwood, Indiana 46142

317-887-6352 Fax: [phone]

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Website: www.Temptek.com

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3.0 OPERATIONS

3.1 GENERAL

3.2 START UP/OPERATIONS PROCEDURE

3.3 INSTRUMENT

3.4 SHUT DOWN