Tmb PMC 40-RC, PMC50-RC Installation Manual
MUELLER
®
BAKERY CHILLER
MODELS PMC 40/50 AND PMC 70/120
INSTRUCTIONS FOR
INSTALLATION • OPERATION
Part No. 9842311
Effective February 23, 1999
Revised May 7, 2009
®
REFRIGERATION PRODUCTS
BAKERY CHILLER MODELS PMC 40/50 AND PMC 70/120
INSTRUCTIONS FOR INSTALLATION AND OPERATION
Section 1.0 - Bakery Chiller Introduction
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Mueller Bakery Chiller Evaporator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.3 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Description of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.5 Refrigeration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.6 Liquid Solution Flow Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.7 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Section 2.0 - Installation
2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.4 Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.5 Refrigeration Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Section 3.0 - First Time Start-Up and Cleaning the System
3.1 First Time Start-Up and Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2 Filling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 4.0 - Programming and Troubleshooting
4.1 Power On Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.2 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.3 Locking and Unlocking Temperature Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.4 Programming Temperature Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.5 Changing Calibration Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.6 Fahrenheit Celsius Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Section 5.0 - Diagrams
5.1 Wiring Diagram, Part No. 9842313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.2 Bakery Chiller PMC Model 70/120 Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.3 Bakery Chiller PMC Model 40/50 Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
®
Table of Contents
Table of Contents - Continued
Section 6.0 - Parts Illustrations
6.1 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.2 Control Box Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
6.3 Chiller Assembly Model PMC 40/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6.4 Chiller Assembly Parts List Model PMC 40/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
6.5 Chiller Assembly Model PMC 70/120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6.6 Chiller Assembly Parts List Model PMC 70/120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Section 7.0 - Refrigeration Units
7.1 Specifications/Electrical Data for Model PMC 40/50 with 2 HP Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .16
7.2 Specifications/Electrical Data for Model PMC 70/120 with 3.5 HP Unit . . . . . . . . . . . . . . . . . . . . . . . . .16
7.3 Refrigeration Cycle Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.4 EPA Refrigerant Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.5 Thermal Expansion Valve (TEV) Superheat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.6 Thermal Expansion Valve Superheat Adjustment Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Section 8.0 - Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section 9.0 - Installation and Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 1.0 - INTRODUCTION
1.1 Introduction
The Mueller®bakery chiller is designed to provide chilled water at a preset temperature for batch
applications. This manual provides the basic information necessary to install, start-up, and operate this
Mueller bakery chiller. The information supplied in this manual must be followed to prevent damage to
the equipment.
1.2 Mueller Bakery Chiller Evaporator Assembly
1.3 Dimensions and Weight
1
PMC 40/50 PMC 70/120
Length 32" 42"
Width 24" 34"
Height 72" 84"
Approx. Shipping Weight 310 lbs. 705 lbs.
Bakery Chiller Models PMC 40/50 and PMC 70/120 Effective February 23, 1999
Installation and Operation Instructions, Part No. 9842311 Revised May 7, 2009
Condensing Unit
Liquid Line
Suction Line
Make-Up
Water In
S
LS
1
S
Bakery Mixer
Process
Field Installed
Process Flow Switch
FS
1
Valve
Pump
Bakery Chiller
TE
1
Bakery Chiller Models PMC 40/50 and PMC 70/120 Effective February 23, 1999
Installation and Operation Instructions, Part No. 9842311 Revised May 7, 2009
1.4 Description of the Equipment
The Mueller bakery chiller evaporator assembly is available in two sizes and two model variations to
meet installation and application needs.
A. Sizes
1. PMC 40/50: Nominal 50-gallon storage capacity to be used with a 2 hp condensing unit.
2. PMC 70/120: Nominal 120-gallon storage capacity to be used with a 3.5 hp condensing unit.
B. Model Variations
1. RC: Evaporator assembly and remote condensing unit.
2. RS: Evaporator assembly and solenoid valve for a rack system.
Example: PMC 40/50 RC
1.5 Refrigeration Components
The refrigeration components of the evaporator assembly include a thermal expansion valve for
refrigerant control, a stainless steel evaporator that is outside of a baked, glass-lined water tank, and
inner-connect refrigerant piping. Single-point refrigeration piping connections are provided for ease of
installation that is described is Section 2.5.
1.6 Liquid Solution Flow Components
The liquid solution flow components include a baked, glass-lined, and insulated water storage tank,
water solenoid valve to control make-up water and recirculation, circulation pump, and inner-connect
piping. Single point 3/4" MPT connections are provided for water inlet and chilled water outlet. This
system is designed to maintain the water level in the storage tank after each batch of chilled water is
drawn. Make-up water will not enter the storage tank during the batch draw which eliminates
temperature blending of warmer make-up water and chilled water.
1.7 Electrical Components
All wiring must be performed in compliance with the National Electric Code and local codes and
regulations.
The control box contains fuses for system protection. Fuse failure requires troubleshooting to determine
the cause of failure and replacement with the same fuses as described in Section 5.0.
The electronic temperature control can be set for temperature control of chilled water and temperature
display in Fahrenheit or Celsius. Programming is described in Section 4.0.
2
Bakery Chiller Models PMC 40/50 and PMC 70/120 Effective February 23, 1999
Installation and Operation Instructions, Part No. 9842311 Revised May 7, 2009
SECTION 2.0 - INSTALLATION
2.1 Inspection
Because it is possible for equipment to be damaged during shipment, we recommend that you make a
thorough inspection of all equipment before it is unloaded from the freight truck. Carefully inspect
equipment for hidden damage. It may be difficult to collect for damage if it is not found prior to
unloading. It is very important to note any damage on the bill of lading and have the driver sign it.
2.2 Safety
Installation and service should be performed by an authorized service technician who has the proper
training to install and service refrigeration equipment. Effective November 1994, the service technician
must be certified in refrigerant usage by an EPA-approved testing organization prior to installing or
servicing any refrigeration equipment.
All electrical connections must be performed by a qualified electrician in accordance with local and
NEC regulations.
2.3 Location
When choosing a location for the Mueller bakery chiller, consider these items:
• Environment: An indoor location will be necessary where the chiller section is protected from
freezing temperature.
• Serviceability: The chiller should be located with the circulating pump and the control panel
accessible for service. Keep in mind the chiller will require field connections to the main electrical
supply and water supply line. The chiller should be located close to a drain for service and
cleaning.
• Refrigeration Unit: The refrigeration unit (for PC and RC models) must be located where they are
protected from the environment and have adequate air-flow for the condenser. Be especially
cautious of conditions that would allow dust or oil to enter the condenser.
• Efficiency: Locate the chiller as close as possible to point of use for chilled water.
2.4 Chilled Water Piping
The bakery chiller supply water should be connected to the 3/4" inlet water solenoid valve located at
the top of the water tank (refer to Figure 3, “Flow Diagram”). The supply water line should be taken
from a source that provides adequate water flow and a minimum of 3/4" in size. It is recommended that
a full flow shut-off valve and union be installed just prior to the solenoid valve for service.
The chilled water supply should be connected to the 3/4" chilled water outlet located near the
circulation pump. Keep this line as short as possible to allow for chilled water of desired temperature
to be provided to point(s) of use. This line should be insulated to reduce external heat gain to the
chilled water.
Check all piping for leaks and repair if required. Clean and rinse lines and water storage tank prior to
usage.
3
Bakery Chiller Models PMC 40/50 and PMC 70/120 Effective February 23, 1999
Installation and Operation Instructions, Part No. 9842311 Revised May 7, 2009
2.5 Refrigeration Unit Installation
All refrigerant piping should be in accordance to acceptable refrigeration practices. Distance between
refrigeration unit and bakery chiller assembly should be as close as possible. Long distance piping and
risers may require attention to reduce restriction of refrigerant flow and to provide adequate oil return.
The liquid line should be
3
/8" OD copper pipe and the suction line 7/8" OD copper pipe. A liquid line
drier of adequate size should be installed on all PMC 40/50 RS and RC models. A liquid line drier is
provided on 3.5 hp. units for PMC 70/120 RS and RC models. A liquid line sight glass should be
installed just prior to the thermal expansion valve (TEV) on the bakery chiller evaporator assembly.
Attach the thermal expansion valve sensing bulb to the suction line and insulate after refrigerant lines
are installed as shown in Section 7.3 and Figure 7.
Evacuation to 500 microns prior to charging with refrigerant is required. The system must hold 1,000
microns in a standing vacuum test, ensuring that it is leak free.
Refrigerant charging should be through the suction service valve in vapor form only. Charge with an
adequate amount of refrigerant prior to starting the compressor and make sure that water storage tank
is filled with water. Refer to Section 3.0 for start-up procedures.
The initial refrigerant charge for PMC 40/50 model with a 2 hp unit is 6 lbs R-22 or 5 lbs. R-507
refrigerant. The initial refrigerant charge for PMC 70/120 models with a 3.5 hp unit is 13 lbs R-22 or 12
lbs. R-507 refrigerant.
4
Bakery Chiller Models PMC 40/50 and PMC 70/120 Effective February 23, 1999
Installation and Operation Instructions, Part No. 9842311 Revised May 7, 2009
SECTION 3.0 - FIRST TIME START-UP AND CLEANING THE SYSTEM
3.1 First Time Start-Up
1. Make sure that the water piping is complete as described in Sections 2.4 and 5.0, Figure 3, and
refrigeration piping is complete as described in Sections 2.5 and 7.0. Make sure that the wiring is
complete as described in Section 5.0.
2. The first step to start-up will be to open the supply water shut-off valve(s). Open the drain valve
located at the outlet of the water storage tank. A toggle switch that disables the circulation pump is
located inside the control box in the upper right hand corner of the back panel. The up position
will allow the pump to run and the down position will disable the pump. Any time the tank is
empty, or on initial start-up, the operator must disable the circulation pump. This will
allow the fill solenoid to fill the tank and prevent the pump from running dry. Turn the
toggle switch to the down position. Turn the power on to the control panel. Make sure the power
is off to the refrigeration unit during this part of start-up. Push the green push button switch on the
front of the control panel to energize the system. This will allow water to flow to the storage tank.
Allow water to flow until clean and clear water is flowing out of the drain. Close the drain valve
and allow the storage tank to fill.
3. Turn the toggle switch to the up position and allow the circulation pump to operate for 2 minutes
and turn the push button switch off. Open the drain valve again and drain the water from the
storage tank. If the water is not clean repeat the cleaning procedure.
3.2 Filling the System
1. Close the drain valve, turn the toggle switch to the down position, and turn the push button switch
on to fill the system with water again. Open the chilled water valve and allow water to flow until
clean. Close the chilled water valve and allow the storage tank to refill with make-up water. Turn
the toggle switch to the up position to operate the circulation pump.
2. Complete the initial refrigeration unit charging procedure. Final refrigerant charging is to be
completed in conjunction with the thermal expansion valve (TEV) superheat adjustment as
described in Section 7.0.
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