Instruction/ maintenance manual of the product 30F to 65F Sterling
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OPERATION AND INSTALLATION MANUAL SMC SERIES AIR COOLED PORTABLE WATER CHILLERS IMPORTANT: PLEASE READ CAREFULL Y BEFORE ATTEMPTING TO I N S T A L L OR OPERATE EQUIPMENT.
Page 2 SMC Series Chillers Sterling, Inc. is committed to a continuous program of product improvement. Specifications are subject to change without notice. © Sterling, Inc. 2003 All Rights Reserved Effective 10-1-2007 Part Number 882.00740.00 Bulletin: SC2-615A.
SMC Series Chillers Page 3 Safety Considerations Sterling, Inc. SMC Series Chillers are designe d to provide safe and reliable operation when installed and operated within design sp ecifications, following natio nal and local safety codes.
Page 4 SMC Series Chillers Table of Contents 1 General Information ................................................. 7 1-1 Introduction 1-2 Necessary Documents 1-3 Models Covered 1-4 Available Options.
SMC Series Chillers Page 5 Table of Contents 4 Startup Checklists .................................................. 23 4-1 Introduction 4-2 SMC Pre-Startup Checklist 4-3 SMC Startup Checklist 4-4 SMC Water Circuit Pressure Drop Table 5 Microprocessor Control .
Page 6 SMC Series Chillers Charts and Figures Figure 1: SMC050 Process Pump Curves..................................................................................... 11 Figure 2: SMC100 Process Pump Curves............................................
SMC Series Chillers Page 7 1 General Information 1-1 Introduction Sterling, Inc.'s SMC Series Water Chillers ar e reliable, accurate, and easy-to-use air cooled chillers designed for use with water/ glycol.
Page 8 SMC Series Chillers 1-4 Available Options SMC Series Chillers are available with options th at tailor the unit to your requirem ents. Some are factory installed, some can be re trofitted in the f iel d. Consult your local Sterling, Inc. Sales Representative.
SMC Series Chillers Page 9 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.
Page 10 SMC Series Chillers 1-9 Returns IMPORTANT! Do not return any damaged or incorrect items until you receive shipping instructions from STERLING, Inc.
SMC Series Chillers Page 11 Figure 1: SMC050 Process Pump Curves Figure 2: SMC100 Process Pump Curves Figure 3: SMC150 Process Pump Curves.
Page 12 SMC Series Chillers Figure 4: SMC Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW).
SMC Series Chillers Page 13 Figure 5: SMC Series Chiller Specifications POWER A0537868 OFF ON REFRIGERANT Mini Chiller PUMP ON COMPRESSOR ON Portable Chiller HIGH PRESSURE REFRIGERANT LOW PRESSURE PC .
Page 14 SMC Series Chillers 2 Chiller Installation 2-1 Electrical Connections Check serial tag voltage and amperage re quirements and make sure your electrical service conforms.
SMC Series Chillers Page 15 Process Water Bypass All SMC chillers have an in ternal bypass device (patent pending). If the process flow becomes blocked during chille r operation, this com ponent allows water to flow through the chiller.
Page 16 SMC Series Chillers ; A corrosion inhibitor suitable for the materials in the sy stem should be added to the glycol/water solution. ; If straight water use is desired, contac t the Sterling, Inc. Engineering Department. ; The six gallon (23 liter) reservoir is not designed to withstand water pressure above 5 psi (34 kPa).
SMC Series Chillers Page 17 2-5 Overhead Process Considerations If your application has chilled water or pro cess piping above the reservoir fill and vent level, install a standpipe to a point 1’ (30 cm) above the highest point in the system. In applications where the process or its pi ping is 15 feet (4.
Page 18 SMC Series Chillers 3 Sequence of Operation IMPORTANT! • The SMC unit has a leaving water temperat ure range of 30°F (-1°C) to 65°F (18°C). Do not attempt to run the SMC unit outside this temperature range or damage to the unit may occur.
SMC Series Chillers Page 19 3-3 High Pressure Cutout The high pressure cutout is an electro-mechan ical safety feature that opens the control circuit if the system condensing pressure exceeds a safe leve l. The chiller will automatically restart when the pressure drops back to an acceptable level.
Page 20 SMC Series Chillers Figure 8: SMC Component Identification.
SMC Series Chillers Page 21 Figure 9: Piping Schematic - 1 Pump with Reservoir Expansion valve Filter Drier Sight glass Filter High pressure control Compressor Legend Refrigeration lines Chilled water.
Page 22 SMC Series Chillers Figure 10: Piping Schematic - 1 Pump Without Reservoir Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Temperature compressor-moun.
SMC Series Chillers Page 23 Figure 11: Piping Schematic - No Pump, No Reservoir Flow switch Temperature compressor-mounted access valve, Refrigeration Compressor Optional CPR valve Low control pressur.
Page 24 SMC Series Chillers 4 Startup Checklists 4-1 Introduction Follow the check lists below for the startup of your new chiller. These lists assume the installation inform ation elsewhere in this m anual has been read and followed. New chillers should be started up and checked by a qualified refrigeration servic e technician.
SMC Series Chillers Page 25 4-4 SMC Water Circuit Pressure Drop Table Model Gallons per minute Liters per minute Δ P (psig) Δ P (kPa) SMC050 2.0 7.5 2.5 17.3 2.4 9.0 4.0 27.6 3.6 13.6 7.5 51.8 4.8 18.1 12.5 86.2 SMC100 2.0 7.5 2.5 17.3 2.4 9.0 2.5 17.
Page 26 SMC Series Chillers 5 Microprocessor Control 5-1 Introduction Standard SMC Series chillers use a microproces sor-based PID controller. The controller is a modular, self-c ontained unit that can slide from its mounting housing. It is factory set and adjusted; no field adjustme nt to the interna l controls is necessary.
SMC Series Chillers Page 27 Figure 12: Typical SMC Series E5CK Microprocessor Controller PV SV OUT1 OUT2 MANU STOP RMT AT SUB1 AT E5CK OMRON OUT2 LED The orange OUT2 energizes whenever the proces s temperature is two degrees (2 ° F/ºC) or more above the To Process set point.
Page 28 SMC Series Chillers RMT LED The orange RMT LED is lit during remote operation. AT LED The orange AT LED flashes during auto-tuning. SUB1 LED The orange SUB1 LED energizes whenever the process temperatu re is two degrees (2 ° F/ºC) or more below the To Process set point.
SMC Series Chillers Page 29 Important! Do not change any of the cont rol settings without consulting the Sterling Service Department. The AEC, Inc. warranty does not cover chiller failures from tampering with controller settings ! Down Key Each press of the Down Arrow key decrements or reduces the values or settings on the SV display.
Page 30 SMC Series Chillers 5-6 Optional Communications Standard Omron Protocol The communications function allows you to monitor and set E5CK parameters by a program prepared and running on a host com puter connected to the E5CK controller. When using the communications function, you must add on the unit for R S-232C or RS-485 communications.
SMC Series Chillers Page 31 6 Optional Graphic Panel 6-1 Indicator Lights PUMP ON (green) This indicator lights when the pump is running. COMPRESSOR ON (green) This indicator lights when the compressor is operating. HIGH REFRIGERANT PRESSURE (red) This indicator lights if the condensing pressu re exceeds a safe level.
Page 32 SMC Series Chillers Figure 13: Optional Graphic Panel OFF ON PRESSURE LOW REFRIGERANT POWER ON PUMP COMPRESSOR ON Portable Chiller REFRIGERANT PRESSURE HIGH A0537868 PC Series ON AL O RO E5CS.
SMC Series Chillers Page 33 7 Routine Maintenance 7-1 Lubrication Every three months, grease all fan moto rs and pump motors that do not have permanently sealed bearings. Rem ove greas e relief plug (motors only) before adding grease. Failure to do so may result in dislodgi ng the bearing grease retainer, eventually causing bearing failure.
Page 34 SMC Series Chillers Figure 15: Typical SMC Wiring Schematic 1T 1T 1FU 1FU 1 X1 1 1 Jumper Remote interlock by others 1S-1LT 1 3 1C 1 41 6 1 5 2C Pump starter Condensing unit contactor G 1S-1LT.
SMC Series Chillers Page 35 Figure 16: SMC Wiring Schematic for Ch illers with No Pump or Reservoir 1T 1T 1FU 1FU X1 1 1 Jumper Remote interlock by others 1S 1S-1LT 5 7 6 1C Condensing unit contactor .
Page 36 SMC Series Chillers - Notes -.
SMC Series Chillers Page 37 8 Troubleshooting Guide Problem Cause Solution Chiller will not run. No power. Check main disconnect fuses, wiring, and power lead to the unit. Wrong voltage supplied to the chiller. Voltage must be within plus or minus 10% of the nameplate rating.
Page 38 SMC Series Chillers Problem Cause Solution Pump runs, compressor will not. Refrigerant is low. Check the refrigerant charge. Pressure switch contacts are open. Sight glass should be clear while compressor runs. Call for service if bubbling or foaming Refrigerant high pressure cutout switch contacts are open.
SMC Series Chillers Page 39 PCA Unit Parts List Part Number Part Description A0537868 SMC Graphic A0537899 BZ Pressure Gauge A0534584 Red Neon Graphic Light * A0534586 Green Neon Graphic Light * A0500.
Page 40 SMC Series Chillers - Notes -.
SMC Series Chillers Page 41 - Notes -.
Page 42 SMC Series Chillers -Notes - Technical Assistance.
SMC Series Chillers Page 43 Parts Department Call toll-free 7am - 5pm CST [800] 423-31 83 Or call [262] 641-8610, Fax [262] 641-8653 The Parts Department at AEC, Inc. is ready to provide th e parts to keep your system s up and running. AEC replacement parts ensure operation at design spec ifications.
An important point after buying a device Sterling 30F to 65F (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Sterling 30F to 65F yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Sterling 30F to 65F - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Sterling 30F to 65F you will learn all the available features of the product, as well as information on its operation. The information that you get Sterling 30F to 65F will certainly help you make a decision on the purchase.
If you already are a holder of Sterling 30F to 65F, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Sterling 30F to 65F.
However, one of the most important roles played by the user manual is to help in solving problems with Sterling 30F to 65F. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Sterling 30F to 65F along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
