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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
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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 Piping Schematic — 1 Pump without Reservoir 21 10 Piping Schematic — No Pump, No Reservoir 22 11 SMC Water Circuit Pressure Drop Table 24 12 SMC Control 26 13 Optional Graphic Panel 28 14 Typical SMC Subpanel 29 1
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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
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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 ar
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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
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1-9 Returns Important! Do not return any damaged or incorrect items until you receive shipping instructions from STERLCO. Figure 1 SMC050A Process Pump Curves SMC050A - PROCESS PUMPS SELECTIONS TOTAL HEAD 60 HERTZ PUMP CURVE MTRS PSI FEET 49 69 160 BZ050A BZ050B BZ050C 37 52 120 24 35 80 12 18 40 U. S. GALLONS 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 PER MINUTE LITRES 1.5 3.0 4.5 6.1 7.6 9.1 10.6 12.1 13.6 15.1 16.7 18.2 PER MINUTE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-
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Figure 3 SMC150A Process Pump Curves SMC150A - PROCESS PUMPS SELECTIONS TOTAL HEAD 60 HERTZ PUMP CURVE MTRS PSI FEET 49 69 160 BZ150B BZ150C 37 52 120 BZ150A 24 35 80 12 18 40 U. S. GALLONS 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 5.2 5.6 6.0 6.4 6.8 PER MINUTE LITRES 7.6 9.1 10.6 12.1 13.6 15.1 16.7 18.2 19.7 21.2 22.7 24.3 25.8 PER MINUTE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS Do not extrapolate pump curves. SMC Series Chillers Page 11
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Figure 4 SMC Series Chiller Specifications Optional gauge package Optional gauge package Power cable entrance, either side Side cover handle Sight glass Drain plug PUMP (3/4" NPT) PRESSURE Mini Chiller PC Series Portable Chiller ON LOW HIGH PUMP ON COMPRESSOR ON REFRIGERANT PRESSURE REFRIGERANT PRESSURE POWER No Flow indicator To Process OFF A0537868 (for pumpless (3/4" NPT) NO FLOW units only) 34" 18 7/16" From Process 13 7/16" (3/4" NPT) Rear View Optional Casters 20" 26" Front View Right Side
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2 Chiller Installation 2-1 Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms. See Figure 4 on Page 12 for total running amps. Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the main power terminal in the chiller’s electrical enclosure. Electrical connections must comply with all applicable electrical codes. The chiller must be grounded in accordance with NEC Article 25
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Process Water Bypass All SMC chillers have an internal bypass device (patent pending). If the process flow becomes blocked during chiller operation, this component allows water to flow through the chiller. This protects the chiller from freeze-up, excessive pressures, and pump damage, and allows other safety features to remain effective. 2-3 SMC Condenser Air Supply SMC chillers use the surrounding air to cool the condenser. Condenser air entering the SMC unit should be at least 65°F (18°C). Op
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A corrosion inhibitor suitable for the materials in the system should be added to the glycol/water solution. If straight water use is desired, contact the Sterlco Engineering Department. The six gallon (23 liter) reservoir is not designed to withstand water pressure above 5 psi (34 kPa). The fill opening and vent line must be vented to the atmosphere for proper operation. Figure 5 Ethylene Glycol Curve Ethylene glycol required for evaporator freeze protection 30% 20% Ethylene glycol percent
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2-5 Overhead Process Considerations If your application has chilled water or process 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 piping is 15 feet (4.6 m) or more above the reservoir, you must take steps to prevent over-pressurization of the reservoir. This condition can occur on system shutdown when the water in the system drains into the reservoir. To prevent this, inst
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3 Sequence of Operation Important! • The SMC unit has a leaving water temperature 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. • When operating the SMC unit between 30°F (-1°C) and 40°F (5°C), you must use a solution of 75% water and 25% industrial-grade ethylene glycol with a suitable corrosion inhibitor to protect the SMC unit from freeze-up. See Figure 5 on Page 17 for more information. Such damage is
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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
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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
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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. Operat
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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 Reserv
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3-3 High Pressure Cutout The high pressure cutout is an electro-mechanical safety feature that opens the control circuit if the system condensing pressure exceeds a safe level. The chiller will automatically restart when the pressure drops back to an acceptable level. Model Cuts out if condensing pressure exceeds: SMC050A 275 psi (1,897 kPa) SMC100A 275 psi (1,897 kPa) SMC150A 400 psi (2,759 kPa) Important! Call a refrigeration service technician to analyze the problem if high pressure recurs. 3
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Figure 7 SMC Component Identification SMC Series Chillers Page 19
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Figure 8 Piping Schematic — 1 Pump with Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Filter Suction Drier Line Expansion Sight valve glass Evaporator Legend Refrigeration lines Equalizing line Chilled water piping Power element Condenser water piping Refrigeration End of unit piping access valve Optional Temperature pressure probe gauge TC High S pressure P To control Process Low pressure control
