Sterling Saw 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  
 
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  
1-2  
1-3  
1-4  
1-5  
1-6  
1-7  
1-8  
1-9  
Introduction  
Necessary Documents  
Models Covered  
Available Options  
Uncrating Your New Chiller  
In the Event of Shipping Damages  
If the Shipment is Not Complete  
If the Shipment is Incorrect  
Returns  
2 Chiller Installation.................................................. 13  
2-1  
2-2  
2-3  
2-4  
2-5  
Electrical Connections  
Process Water Connections  
SMC Condenser Air Supply  
Water Reservoir  
Overhead Process Considerations  
3 Sequence of Operation.......................................... 17  
3-1  
3-2  
3-3  
3-4  
3-5  
Chilled Water Circuit  
Refrigeration Circuit  
High Pressure Cutout  
Low Pressure Cutout  
Remote Start/Stop Interlock  
Page 4  
SMC Series Chillers  
 
Table of Contents  
4 Startup Checklists.................................................. 23  
4-1  
4-2  
4-3  
Introduction  
SMC Pre-Startup Checklist  
SMC Startup Checklist  
5 Microprocessor Control ........................................ 25  
5-1  
5-2  
5-3  
Introduction  
Setting the Process Water Temperature  
Setting the Alarm Value  
6 Optional Graphic Panel ......................................... 27  
6-1  
6-2  
Indicator Lights  
Switches  
7 Routine Maintenance............................................. 29  
7-1  
7-2  
Lubrication  
Condenser Maintenance  
8 Troubleshooting Guide.......................................... 33  
SMC Series Chillers  
Page 5  
 
Charts and Figures  
1
2
3
4
5
6
7
8
SMC050A Process Pump Curves  
10  
10  
11  
12  
15  
16  
19  
20  
21  
22  
24  
26  
28  
29  
30  
31  
35  
SMC100A Process Pump Curves  
SMC150A Process Pump Curves  
SMC Series Chiller Specifications  
Ethylene Glycol Curve  
Overhead Piping  
SMC Component Identification  
Piping Schematic — 1 Pump with Reservoir  
9
Piping Schematic — 1 Pump without Reservoir  
10  
11  
12  
13  
14  
15  
16  
17  
Piping Schematic — No Pump, No Reservoir  
SMC Water Circuit Pressure Drop Table  
SMC Control  
Optional Graphic Panel  
Typical SMC Subpanel  
Typical SMC Wiring Schematic  
SMC Wiring Schematic for Chillers with No Pump or Reservoir  
SMC Spare Parts List  
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  
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  
60 HERTZ PUMP CURVE  
TOTAL HEAD  
MTRS PSI FEET  
49 69 160  
37 52 120  
24 35 80  
12 18 40  
BZ050C  
BZ050A  
BZ050B  
U. S. GALLONS  
PER MINUTE  
LITRES  
0.4  
1.5  
0.8  
3.0  
1.2  
4.5  
1.6  
6.1  
2.0  
7.6  
2.4  
9.1  
2.8  
3.2  
3.6  
4.0  
4.4  
4.8  
10.6  
12.1  
13.6  
15.1  
16.7  
18.2  
PER MINUTE  
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS  
Do not extrapolate pump curves.  
Figure 2  
SMC100A Process Pump Curves  
SMC100A- PROCESS PUMPS SELECTIONS  
60 HERTZ PUMP CURVE  
TOTAL HEAD  
PSI  
MTRS  
FEET  
49 69 160  
37 52 120  
24 35 80  
12 18 40  
BZ100C  
BZ100B  
BZ100A  
U. S. GALLONS  
PER MINUTE  
LITRES  
1.6  
2.0  
7.6  
2.4  
9.1  
2.8  
3.2  
3.6  
4.0  
4.4  
4.8  
5.2  
5.6  
6.0  
6.4  
6.1  
10.6  
12.1  
13.6  
15.1  
16.7  
18.2  
19.7  
21.2  
22.8  
24.2  
PER MINUTE  
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS  
Do not extrapolate pump curves.  
Page 10  
SMC Series Chillers  
 
Figure 3  
SMC150A Process Pump Curves  
SMC150A - PROCESS PUMPS SELECTIONS  
60 HERTZ PUMP CURVE  
TOTAL HEAD  
MTRS PSI FEET  
49 69 160  
37 52 120  
24 35 80  
12 18 40  
BZ150B  
BZ150C  
BZ150A  
U. S. GALLONS  
PER MINUTE  
LITRES  
2.0  
2.4  
9.1  
2.8  
3.2  
12.1  
3.6  
4.0  
4.4  
16.7  
4.8  
5.2  
5.6  
6.0  
6.4  
6.8  
7.6  
10.6  
13.6  
15.1  
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  
 
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  
PRESSURE  
(3/4" NPT)  
Mini Chiller  
PC Series  
Portable Chiller  
ON  
LOW  
HIGH  
PUMP  
ON  
COMPRESSOR  
ON  
REFRIGERANT  
PRESSURE  
REFRIGERANT  
PRESSURE  
POWER  
To Process  
(3/4" NPT)  
No Flow indicator  
(for pumpless  
units only)  
OFF  
A0537868  
NO FLOW  
34"  
18 7/16"  
From Process  
(3/4" NPT)  
13 7/16"  
Rear View  
Optional Casters  
26"  
Right Side View  
20"  
Front View  
Capacity  
@ 65°F  
LWT 75°F LWT 90°F  
Capacity  
@ 50°F  
Nominal  
Chilled  
Water  
Amp  
Draw  
Process  
Dimensions  
(inches)  
Operating Shipping  
Model  
Ambient  
Ambient  
Compressor  
Pump  
Connection 230/1/60  
Weight  
Weight  
Number  
(Btuh)  
(Btuh)  
(gpm)  
(hp)  
(inches NPT) Running  
L
W
H
(lbs)  
(lbs)  
1/3 hp,  
1.2 gpm @  
24 psig  
1/3 hp,  
2.4 gpm @  
34 psig  
1/3 hp,  
3.6 gpm @  
24 psig  
SMC-050  
8,100  
4,800  
9,550  
1.2  
2.4  
3.6  
8A  
20 26 34  
20 26 34  
20 26 34  
265  
325  
345  
265  
325  
345  
½
¾
SMC-100 14,000  
SMC-150 25,400  
10A  
1
¾
1½  
16,000  
12A  
¾
Capacity  
@ 18°C  
Capacity  
@ 10°C  
Nominal  
Amp  
LWT, 24°C LWT, 32°C Chilled  
Process  
Connection 230/1/60  
(inches NPT) Running  
Draw  
Dimensions  
(cm)  
Operating Shipping  
Model  
Number  
Ambient  
Ambient  
Water  
Compressor  
(watts)  
Pump  
Weight  
Weight  
(watts)  
(watts)  
(lpm)  
L
W
H
(kg)  
(kg)  
224 watts,  
4.5 lpm  
@ 207 kPa  
SMC-050  
SMC-100  
SMC-150  
2,374  
4,103  
7,444  
1,407  
2,800  
4,690  
4.5  
9.0  
373  
746  
8A  
51 66 86  
51 66 86  
51 66 86  
120  
147  
156  
120  
147  
156  
¾
224 watts,  
9.0 lpm  
@ 234 kPa  
10A  
¾
224 watts,  
13.6 lpm  
@ 207 kPa  
13.6  
1,118  
12A  
¾
Page 12  
SMC Series Chillers  
 
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 250.  
; Voltage must be within 10% of the chiller’s nameplate rating.  
2-2 Process Water Connections  
; All external chilled water connections to the process must be of adequate size.  
; See Figure 6 on Page 18 for sizing recommendations.  
; The largest possible openings and passages should be provided for the flow of chilled water  
through platens, dies, molds or other pieces of equipment.  
Important!  
Keep any pressure drop in external process piping  
to an absolute minimum for optimum unit operation.  
To Process  
Connect the TO PROCESS chilled water supply outlet to the process being cooled.  
From Process  
Connect the FROM PROCESS chilled water return inlet to the return from the process back into  
the chiller for cooling and recirculation.  
; Sterlco recommends a strainer on the FROM PROCESS return line.  
SMC Series Chillers  
Page 13  
 
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). Operation with air  
below 65°F (18°C) can cause the low pressure cutout to shut down the chiller due to the low  
refrigerant pressure.  
; Install the chiller in an area where there is free passage of air for condensing.  
; Provide 18” (46 cm) or more clearance for the chiller’s air intake.  
; Make provisions to exhaust the heated air discharged from the chiller.  
; Do not put the SMC unit where steam, hot air or fume exhausts will be drawn into the  
condenser.  
; Air-cooled condensers must be cleaned frequently. Neglect reduces capacity, increases  
operating costs, and leads to possible chiller failure. See Chapter 7 on Page 31 for cleaning  
instructions.  
; Normal condensing pressure with 95°F (35°C) air is approximately 180 psi (1,241 kPa) for  
the SMC050A and SMC100A; 275 psi (1,897 kPa) for the SMC150A.  
SMC Ambient Temperature Ranges  
Ambient temperature range  
Operation  
Minimum temperature  
65°F (18°C)  
Maximum temperature  
100°F (38°C)  
Storage  
40°F (4°C)  
120°F (49°C)  
2-4 Water Reservoir  
During startup and when additional solution is required, see Figure 5 on Page 17 for the  
recommended ethylene glycol/water solution. This chart shows the proportions needed to  
provide freeze protection to 20°F/°C below the desired process setpoint.  
; Add a pre-mixed solution to provide freeze protection to a temperature 20°F/°C below the  
normal operating temperature of the chiller.  
; Use industrial quality (not automotive) ethylene glycol.  
Page 14  
SMC Series Chillers  
 
; 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  
by  
volume  
10%  
0%  
0º  
30º  
40º  
50º  
60º  
70º  
Chilled water  
operating temperature °F  
(set point)  
Normal operating range is between 30°F and 70°F  
SMC Series Chillers  
Page 15  
 
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, install a check valve in the unit TO PROCESS line and a vacuum breaker at the  
high point of the return FROM PROCESS line. See Figure 6 on Page 18 for more information.  
Note: The reserve capacity of the reservoir can hold a volume equal to 20 feet (6.1 m) of 1-inch  
(2.5 cm) pipe.  
Figure 6  
Overhead Piping  
Vent  
The reservoir vent & fill line  
to be piped 12" above the highest  
point of the system. The vent line  
Vacuum Breaker  
Assembly  
Cap  
must remain open to the atmosphere.  
12"  
Check  
Valve  
1/8"  
Hole  
1/4"  
6" Min.  
Process Return  
Process Supply  
Strainer  
Add check valve  
if system piping  
extends 15 feet  
above reservoir.  
Indicates end of STERLCO piping  
Page 16  
SMC Series Chillers  
 
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 not covered by  
the Sterlco warranty.  
3-1 Chilled Water Circuit  
Figures 8, 9, and 10  
; Process cooling water supply and return connections are made at the pipe stubs at the rear of  
the chiller.  
; Warm water returns from the process and enters the reservoir tank.  
; The process water is pumped through the evaporator where it is cooled.  
; The coolant flows to the process and returns to repeat the cycle.  
; A chilled water bypass assembly (patent pending) between the supply and return lines  
guarantees a constant flow through the evaporator during intermittent low or no-flow  
conditions.  
; A flow switch in units without pumps will prevent the compressor from running without  
adequate flow through the evaporator  
3-2 Refrigeration Circuit  
Liquid refrigerant from the condenser passes through a filter/dryer which removes moisture  
and other contaminants.  
The refrigerant then passes through the thermal expansion valve which allows the  
refrigerant to expand and cool the inside of the heat exchanger. The refrigerant flows  
through the suction line to the compressor.  
The refrigerant gives up its heat as it re-condenses to a liquid in the condenser and the cycle  
starts over again.  
SMC Series Chillers  
Page 17  
 
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:  
275 psi (1,897 kPa)  
SMC050A  
SMC100A  
SMC150A  
275 psi (1,897 kPa)  
400 psi (2,759 kPa)  
Important!  
Call a refrigeration service technician to analyze  
the problem if high pressure recurs.  
3-4 Low Pressure Cutout  
The low pressure cutout is an electro-mechanical safety feature that prevents compressor suction  
pressure from dropping below a preset point.  
It is factory set to open the control circuit when pressure drops below a safe level. The chiller  
will automatically restart when the suction pressure reaches an acceptable level.  
Model  
SMC050  
A
Cuts out if suction pressure falls below:  
15 psi (103 kPa)  
SMC100  
A
SMC150  
A
15 psi (103 kPa)  
35 psi (241 kPa)  
3-5 Remote Start/Stop Interlock  
A contact is provided to allow interlocking of the SMC Series Chiller with process controls. To  
use this feature, remove the jumper between Terminals X1 and 1 on Terminal Block 1. Supply a  
switch or dry contact interlock connected in series between these two terminals. See Figures 14  
and 15 on Pages 32 and 33 for more information.  
Page 18  
SMC Series Chillers  
 
Figure 7  
SMC Component Identification  
SMC Series Chillers  
Page 19  
 
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  
Line  
Drier  
Expansion Sight  
valve  
glass  
Evaporator  
Legend  
Refrigeration lines  
Equalizing line  
Power element  
Chilled water piping  
Condenser water piping  
Refrigeration  
access valve  
End of unit piping  
Optional  
pressure  
gauge  
Temperature  
probe  
TC  
High  
pressure  
control  
S
P
To  
Process  
Low  
pressure  
control  
Bypass  
Optional  
CPR valve  
Refrigeration  
access valve,  
compressor-mounted  
Compressor  
Vent  
Fill  
Sight  
glass  
Tank  
Drain  
Pump  
From  
Process  
Page 20  
SMC Series Chillers  
 
Figure 9  
Piping Schematic — 1 Pump without Reservoir  
Air-cooled condenser  
Discharge line  
Liquid line  
Refrigeration  
evacuation valve  
Relief  
valve  
Refrigeration  
evacuation valve  
Filter  
Filter  
Suction  
drier  
Legend  
line  
Refrigeration lines  
Chilled water piping  
Condenser water piping  
End of unit piping  
Expansion  
valve  
Sight  
glass  
Evaporator  
Equalizing line  
Power element  
Refrigeration  
access valve  
Optional  
pressure  
gauge  
Temperature  
probe  
TC  
High  
pressure  
control  
S
P
To  
Process  
Low  
pressure  
control  
Optional  
CPR valve  
Bypass  
Refrigeration  
access valve,  
Compressor  
compressor-mounted  
From  
Process  
Pump  
SMC Series Chillers  
Page 21  
 
Figure 10  
Piping Schematic — No Pump, No Reservoir  
Air-cooled condenser  
Discharge line  
Liquid line  
Refrigeration  
evacuation valve  
Relief  
valve  
Refrigeration  
evacuation valve  
Filter  
Filter  
drier  
Suction  
line  
Expansion  
valve  
Legend  
Sight  
glass  
Refrigeration lines  
Chilled water piping  
Condenser water piping  
End of unit piping  
Evaporator  
Equalizing line  
Power element  
Refrigeration  
access valve  
Optional  
pressure  
gauge  
Temperature  
Probe  
TC  
High  
pressure  
control  
P
S
To  
Process  
Low  
pressure  
control  
Bypass  
Optional  
CPR valve  
Refrigeration  
access valve,  
Compressor  
compressor-mounted  
Flow  
switch  
From  
Process  
Page 22  
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 information elsewhere in this manual has been read and followed. New chillers  
should be started up and checked by a qualified refrigeration service technician.  
4-2 SMC Pre-Startup Checklist  
1. Check the shipping papers against the serial tag to be sure chiller size, type and voltage is  
correct for the process that will be controlled.  
2. Check the transformer primary voltage connections to be sure they are configured for the  
electrical power you are using. The voltage at the main power connection must read  
within +/-10% of the voltage listed on the serial tag. Electrical connections must conform  
to all applicable codes.  
3. The chilled water TO PROCESS and FROM PROCESS connections should be completed.  
4. Be sure the reservoir tank and chilled water circuit piping are filled with water.  
5. The air-cooled condenser should have an adequate supply of air for proper operation.  
6. Connect main power to the chiller and run the chiller just long enough to see if the pump  
is generating normal pressure.  
7. Check your work and proceed to the SMC Startup Checklist section below.  
4-3 SMC Startup Checklist  
1. Turn ON the chiller. The SMC chiller should continue to run until the switch is turned  
OFF.  
2. Put the SMC chiller under a process load.  
3. Set the microprocessor control to the desired process temperature setpoint using the  
,
, and  
buttons. See Chapter 5 on Page 27 for more information.  
4. Check the pump amp draw and pump pressure. The amp draw reading must be within the  
running load and service factor amps.  
5. Operate the chiller, looking for leaks and listening for unusual noises or vibrations that  
could indicate improper operation.  
SMC Series Chillers  
Page 23  
 
Figure 11  
SMC Water Circuit Pressure Drop Table  
Model  
Gallons per minute  
P (psig)  
2.5  
2.0  
2.4  
3.6  
4.8  
2.0  
2.4  
3.6  
4.8  
2.0  
2.4  
3.6  
4.8  
4.0  
7.5  
12.5  
2.5  
2.5  
3.0  
5.0  
2.5  
2.5  
SMC050A  
SMC100A  
SMC150A  
3.0  
3.5  
Page 24  
SMC Series Chillers  
 
5
Microprocessor Control  
5-1 Introduction  
Standard SMC Series chillers use a microprocessor based controller. The controller is a modular,  
self-contained unit that can slide from its mounting housing. It is factory set and adjusted; no  
field adjustment to the internal controls is necessary.  
5-2 Setting the Process Water Temperature  
Press  
until the SP indicator lights.  
or to raise or lower the setpoint to the desired leaving water  
Press  
temperature.  
Note: SMC leaving water temperature range of operation is 30ºF (-1°C) to 65ºF (18°C).  
Press to display the current process temperature (SP and AL are off).  
5-3 Setting the Alarm Value  
Press  
until AL lights.  
or to raise or lower the alarm value. The factory setting is 10, and  
Press  
should be correct for most processes. Setting the alarm value to 10 creates an alarm if the  
process temperature rises or falls 10ºF/ºC or more from the chiller process setpoint.  
Press  
to display the current process temperature (SP and AL are off).  
SMC Series Chillers  
Page 25  
 
Figure 12  
SMC Control  
Lights when the display  
shows the alarm value  
Lights if Process Temperature  
is above the set point  
Compressor On indicator  
C°  
ON  
AL  
Process temperature is 10°  
or more above the set point  
Lights when Process Temp is  
within +/- 1% of the full scale  
Lights if Process Temperature  
is below the set point  
Increases the process set point  
or alarm value  
SP AL  
Lights when the display  
Lowers the process set point  
or alarm value  
shows the process set point  
OMRON E5CS  
Scroll -- Steps Through Process  
set point, actual temperature,  
and alarm value displays  
Page 26  
SMC Series Chillers  
 
6
Optional Graphic Panel  
6-1 Indicator Lights  
PUMP ON (green)  
This indicator is lit when the pump runs.  
COMPRESSOR ON (green)  
This indicator is lit when the compressor operates.  
HIGH REFRIGERANT PRESSURE (red)  
This indicator lights if the condensing pressure exceeds a safe level. The chiller goes to Idle  
mode until the high refrigerant pressure cutout resets. The light then goes out and the chiller  
automatically restarts. Call a qualified refrigeration service technician for service.  
LOW REFRIGERANT PRESSURE (red)  
This indicator lights if the refrigerant pressure drops below a safe level. The compressor will stop  
and remain off until the pressure reaches a safe level. The light will go out and the chiller will  
then resume operation automatically.  
LOW WATER FLOW (red), SMC units without pump only  
This indicator lights if the flow switch senses chilled water/glycol flow through the evaporator  
dropping to an unacceptable level. The compressor will stop until the flow switch senses  
adequate flow and restarts the chiller.  
6-2 Switches  
POWER  
This switch energizes the control circuit; it also turns off the chiller.  
SMC Series Chillers  
Page 27  
 
Figure 13  
Optional Graphic Panel  
SMC Series  
Portable Chiller  
ON  
LOW  
HIGH  
ON  
PUMP  
ON  
COMPRESSOR  
ON  
REFRIGERANT  
PRESSURE  
REFRIGERANT  
PRESSURE  
AL  
POWER  
O
RO E5CS  
OFF  
A0537868  
Page 28  
SMC Series Chillers  
 
7
Routine Maintenance  
7-1 Lubrication  
Every three months, grease all fan motors and pump motors that do not have permanently sealed  
bearings. Remove grease relief plug (motors only) before adding grease. Failure to do so may  
result in dislodging the bearing grease retainer, eventually causing bearing failure.  
Compressors are hermetically sealed; no oiling is required.  
7-2 Condenser Maintenance  
Dirty condenser heat exchange surfaces reduce system capacity.  
Brush or vacuum light dirt accumulations. Avoid bending or damaging the fins. Heavy soil  
accumulations on the coil require professional steam cleaning; washing from the outside only  
makes matters worse.  
Figure 14  
Typical SMC Subpanel  
Distribution  
Block  
Grounding  
Lug  
Terminal  
Blocks  
Control Voltage  
Transformer  
Pump  
Contactor  
Condenser  
Contactor  
SMC Series Chillers  
Page 29  
 
Figure 15  
Typical SMC Wiring Schematic  
1C  
1L1  
1T1  
Pump  
1MTR  
2MTR  
3MTR  
1L2  
1T2  
2T1  
2C  
1L1  
Compressor  
1L2  
2T2  
3T1  
Earth  
ground  
Fan  
3T2  
Remote  
interlock  
by others  
1L2  
1L1  
230V  
Control  
power  
ON/OFF  
1T  
Subpanel  
ground  
Jumper  
1FU  
1S-1LT  
2
1
X1  
115V  
2
1S-1LT  
"Power On"  
G
Pump  
starter  
3
1C  
"Low Refrig  
Pres"  
"Hi Refrig  
Pres"  
2LT  
G
"Pump On"  
3LT  
4LT  
R
R
1PS  
2PS  
Condensing unit  
contactor  
4
5
6
2C  
G
5LT  
"Compressor On"  
6
1
7
2
8
9
4
10  
5
1CNTL  
Jumper  
3
Legend  
Customer wiring/Customer-supplied components  
Optional components  
(+)  
YEL  
(-)  
RED  
Type K Thermocouple  
Page 30  
SMC Series Chillers  
 
Figure 16  
SMC Wiring Schematic for Chillers with No Pump or Reservoir  
1C  
1L1  
1T1  
Compressor  
1MTR  
2MTR  
1L2  
1T2  
2T1  
1L2  
1L1  
Fan  
Remote  
interlock  
by others  
Earth  
ground  
2T2  
230V  
115V  
Control  
power  
ON/OFF  
1T  
Subpanel  
ground  
Jumper  
1FU  
1S-1LT  
2
2
1
X1  
1S  
1S-1LT  
G
"Power On"  
"Low Refrig  
Pres"  
"High Refrig  
Pres"  
31  
"No Flow"  
2LT  
3LT  
4LT  
R
R
R
1FLS  
1PS  
2PS  
Condensing unit  
contactor  
4
5
5
6
7
1C  
G
5LT  
"Compressor On"  
2
Legend  
6
7
2
8
9
4
10  
5
Customer wiring/Customer-supplied components  
Optional components  
Jumper  
3
1CNTL  
1
(+)  
(-)  
YEL  
RED  
Type K thermocouple  
SMC Series Chillers  
Page 31  
 
- Notes -  
Page 32  
SMC Series Chillers  
 
8
Troubleshooting Guide  
Problem  
Possible cause  
No power.  
Solution  
Check main disconnect  
fuses, wiring, and power lead  
to the unit.  
Voltage must be within plus  
or minus 10% of the  
nameplate rating.  
Replace.  
Wrong voltage supplied to  
the chiller.  
Chiller will not run.  
Defective on/off switch.  
Replace, check the  
transformer.  
Control circuit fuse blown.  
Defective control transformer. Replace.  
No process load on the  
chiller.  
Refrigerant is low.  
Refrigerant is low.  
Increase the process load.  
Pump runs, compressor  
cycles at short intervals.  
Check the refrigerant charge.  
Check the refrigerant charge.  
Make sure that the coolant  
solution is right for the  
process — must be 75%  
water and 25% glycol.  
The leaving water  
temperature is too high.  
Improper water/glycol  
solution.  
See Figure 5 on Page 17 for  
more information.  
Pump pressure is low (see  
pump curves).  
Check for foreign matter.  
Restricted water flow.  
Clean the system.  
Check for partially closed  
valves, etc. Be sure all lines  
are properly sized.  
Pump pressure is too high.  
SMC Series Chillers  
Page 33  
 
Problem  
Possible cause  
Refrigerant is low.  
Solution  
Check the refrigerant charge.  
Sight glass should be clear  
Pressure switch contacts are while compressor runs. Call  
open.  
for service if bubbling or  
foaming.  
Refrigerant high pressure  
cutout switch contacts are  
open.  
Check for dirty condenser.  
Check for condenser air  
obstruction.  
Pump runs, compressor will  
not.  
Defective fan motor.  
Repair or replace.  
Check for high/low voltage.  
Compressor internal overload Must be within plus or minus  
is open. Allow time to cool  
and reset.  
10% of the nameplate rating.  
Check for poor compressor  
electrical connections.  
Broken wire in the  
compressor control circuit.  
Locate and repair.  
Restricted condenser airflow. Clean the condenser.  
Unit low on refrigerant.  
Inefficient compressor.  
Unit undersized for  
application.  
Call Service.  
Call Service.  
Unit runs continuously, but  
not enough cooling power.  
Call Sales Representative.  
Page 34  
SMC Series Chillers  
 
Figure 17  
SMC Spare Parts List  
Part number  
A0537868  
A0537899  
A0534584  
A0534586  
A0500857  
A0534269  
A0537955  
A0533873  
A0539409  
A0103778  
A0537900  
A0537908  
A0537915  
A0543063  
A0537916  
A0537917  
A0501642  
A0104093  
A0537974  
Description  
SMC graphic  
BZ pressure gauge  
Red neon graphic light *  
Green neon graphic light *  
2” swivel casters  
1/16 DIN digital temperature controller  
Process water flow switch  
Thermocouple, 8’  
150 VA transformer  
Rubber feet  
Tank sight glass assembly  
Handles  
SMC050A-SMC100A low refrigerant pressure switch  
SMC150A low refrigerant pressure switch  
SMC050A-SMC100A high refrigerant pressure switch  
SMC150A high refrigerant pressure switch  
SMC050A-SMC100A high refrigerant pressure safety relief valve  
SMC150A high refrigerant pressure safety relief valve  
Bronze Y strainer  
* Units with the optional SMC graphic panel.  
SMC Series Chillers  
Page 35  
 
Service Notes  
Page 36  
SMC Series Chillers  
 
Service Notes  
SMC Series Chillers  
Page 37  
 
Parts Department  
[
]
[
]
Call toll-free 7am–6pm CST 800 783-7835 or call 414 354-0970  
The Sterling/Sterlco Parts Department at Sterling, Inc. is ready to provide the parts to keep your systems up and  
running. Sterling/Sterlco replacement parts ensure operation at design specifications. Please have the model and  
serial number of your equipment when you call. Consult the Customer Parts List included in your information packet  
for replacement part numbers.  
Service Department  
[
]
[
[
]
]
Call toll-free 8am–5pm CST 800 783-7835 or call 414 354-0970  
Emergencies after 5pm CST, call 847 439-5655  
Sterling/Sterlco has a qualified service department ready to help. Service contracts are available for most Sterling/  
Sterlco products.  
Sales Department  
[
]
Call 414 354-0970Monday–Friday, 8am–5pm CST  
Sterling/Sterlco products are sold by a world-wide network of independent sales representatives. Contact our Sales  
Department for the name of the sales representative nearest you.  
Sterling/Sterlco  
5200 West Clinton Avenue  
Sterling  
Milwaukee, WI 53224-9518  
[
]
[
]
414 354-0970 Fax 414 354-6421  
Page 38  
SMC Series Chillers  
 

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