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Sterling A0544325 - page 1
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 A0544325 - page 2
Page 2 SMC Series Chillers 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 ...
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Sterling A0544325 - page 3
SMC Series Chillers Page 3 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 judgme ...
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Sterling A0544325 - page 4
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 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 ...
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Sterling A0544325 - page 5
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 5 Microprocessor Control ........................................ 25 5-1 Introduction 5-2 Setting the Process Water Temperature 5-3 Setting the Alarm Value 6 ...
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Sterling A0544325 - page 6
Page 6 SMC Series Chillers 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 withou ...
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Sterling A0544325 - page 7
SMC Series Chillers Page 7 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 wat ...
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Sterling A0544325 - page 8
Page 8 SMC Series Chillers 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 pre ssur ...
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Sterling A0544325 - page 9
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. ; Notify the transportation company’s local agent. ; Hold the damaged good ...
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Sterling A0544325 - page 10
Page 10 SMC Series Chillers 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 60 HERTZ PUMP CURVE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS SMC050A - PROCESS PUMPS SELECTIONS PER MINUTE LITRES PER MINUTE U. S. GALLONS 24 ...
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Sterling A0544325 - page 11
SMC Series Chillers Page 11 Figure 3 SMC150A Process Pump Curves 60 HERTZ PUMP CURVE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS SMC150A - PROCESS PUMPS SELECTIONS PER MINUTE LITRES PER MINUTE U. S. GALLONS 24 12 18 40 35 80 49 37 52 120 69 160 MTRS TOTAL HEAD PSI FEET 10.6 2.8 3.2 12.1 3.6 13.6 15.1 4.0 4.4 16.7 4.8 18.2 5.2 5.6 ...
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Sterling A0544325 - page 12
Page 12 SMC Series Chillers Figure 4 SMC Series Chiller Specifications POWER A0537868 OFF ON REFRIGERANT Mini Chiller PUMP ON COMPRESSOR ON Portable Chiller HIGH PRESSURE REFRIGERANT LOW PRESSURE PC Series PUMP PRESSURE O ptional gauge package Side cover handle Sight glass To Process (3/4" NPT) From Process (3/4" NPT) (3/4" NPT) Drai ...
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Sterling A0544325 - page 13
SMC Series Chillers Page 13 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 termina ...
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Sterling A0544325 - page 14
Page 14 SMC Series Chillers 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 ...
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Sterling A0544325 - page 15
SMC Series Chillers Page 15 ; 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 ...
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Sterling A0544325 - page 16
Page 16 SMC Series Chillers 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 t ...
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Sterling A0544325 - page 17
SMC Series Chillers Page 17 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 o ...
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Sterling A0544325 - page 18
Page 18 SMC Series Chillers 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: SMC050 ...
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Sterling A0544325 - page 19
SMC Series Chillers Page 19 Figure 7 SMC Component Identification ...
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Sterling A0544325 - page 20
Page 20 SMC Series Chillers Figure 8 Piping Schematic — 1 Pump with Reservoir Expansion valve Filter Drier Sight glass Filter High pressure control Compressor Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Liquid line Suction Line Tank Vent Fill glass Sight Process From To P Evaporator Pump Power element ...
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Sterling A0544325 - page 21
SMC Series Chillers Page 21 Figure 9 Piping Schematic — 1 Pump without Reservoir Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Temperature compressor-mounted access valve, Refrigeration Compressor Pump Optional CPR valve evacuation valve Refrigeration Low control pressure access valve Refrigeration cont ...
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Sterling A0544325 - page 22
Page 22 SMC Series Chillers Figure 10 Piping Schematic — No Pump, No Reservoir Flow switch Temperature compressor-mounted access valve, Refrigeration Compressor Optional CPR valve Low control pressure access valve Refrigeration control pressure High Discharge line Refrigeration evacuation valve Equalizing line Power element Evaporator Suction lin ...
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Sterling A0544325 - page 23
SMC Series Chillers Page 23 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 Ch ...
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Sterling A0544325 - page 24
Page 24 SMC Series Chillers Figure 11 SMC Water Circuit Pressure Drop Table Model Gallons per minute ∆ P (psig) 2.0 2.5 2.4 4.0 3.6 7.5 SMC050A 4.8 12.5 2.0 2.5 2.4 2.5 3.6 3.0 SMC100A 4.8 5.0 2.0 2.5 2.4 2.5 3.6 3.0 SMC150A 4.8 3.5 ...
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Sterling A0544325 - page 25
SMC Series Chillers Page 25 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 ...
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Sterling A0544325 - page 26
Page 26 SMC Series Chillers Figure 12 SMC Control SP AL AL ON C° OMRON E5CS Scroll -- Steps Through Process set point, actual temperature, and alarm value displays Lights when the display shows the process set point Lights if Process Temperature is below the set point Compressor On indicator Process temperature is 10° or more above the set point ...
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Sterling A0544325 - page 27
SMC Series Chillers Page 27 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 h ...
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Sterling A0544325 - page 28
Page 28 SMC Series Chillers Figure 13 Optional Graphic Panel OFF ON PRESSURE LOW REFRIGERANT POWER ON PUMP COMPRESSOR ON Portable Chiller REFRIGERANT PRESSURE HIGH A0537868 SMC Series ON AL O RO E5CS ...
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Sterling A0544325 - page 29
SMC Series Chillers Page 29 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 ...
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Sterling A0544325 - page 30
Page 30 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 G "Power On" ON/OFF 1L1 1L2 1L1 1L2 1L1 1L2 2 Control power 1PS 2PS 1 1 1CNTL RED (-) YEL (+) Type K Thermocouple Subpanel ground 1C 1T1 1T2 ...
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Sterling A0544325 - page 31
SMC Series Chillers Page 31 Figure 16 SMC Wiring Schematic for Chillers 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 G 1S-1LT G "Power On" ON/OFF 1L1 1L2 1L1 1L2 2 Control power 1PS 1PS 2PS 1 1CNTL RED (-) YEL (+) Type K thermocouple Subpanel ground 1C 1T1 1T ...
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Sterling A0544325 - page 32
Page 32 SMC Series Chillers - Notes - ...
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Sterling A0544325 - page 33
SMC Series Chillers Page 33 8 Troubleshooting Guide Problem Possible cause Solution 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. Defective on/off switch. Replace. Control circuit fuse blown. Replace, check the trans ...
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Sterling A0544325 - page 34
Page 34 SMC Series Chillers Problem Possible cause Solution 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. Check for dirty condenser. Check for condenser air obs ...
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Sterling A0544325 - page 35
SMC Series Chillers Page 35 Figure 17 SMC Spare Parts List Part number Description A0537868 SMC graphic A0537899 BZ pressure gauge A0534584 Red neon graphic light * A0534586 Green neon graphic light * A0500857 2” swivel casters A0534269 1/16 DIN digital temperature controller A0537955 Process water flow switch A0533873 Thermocouple, 8’ A0539409 ...
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Sterling A0544325 - page 36
Page 36 SMC Series Chillers Service Notes ...
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Sterling A0544325 - page 37
SMC Series Chillers Page 37 Service Notes ...
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Sterling A0544325 - page 38
Page 38 SMC Series Chillers 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 operat ion at design specifications. Please have the model and serial ...
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