MODELS CP2-10 AND CP2-20 - paulmueller.com Safety Statement ... (Also Refer to Refrigeration Unit...

COMPACT CHILLERMODELS CP2-10 AND CP2-20INSTALLATION AND OPERATION MANUAL

Part No. 8826880Effective December 21, 2011

Original English Version

®

THE MILK COOLING SYSTEMS SPECIALISTS™

COMPACT CHILLERMODELS CP2-10 AND CP2-20

INSTALLATION AND OPERATION MANUAL

®

Table of Contents

Section 1.0 - Introduction1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.3 Authorized Mueller Installation and Service Representative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.4 Safety Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.5 Intended Use of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.6 Misuse of Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Section 2.0 - Description of the Equipment2.1 Equipment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Figure 1—Compact Chiller Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Figure 2—Compact Chiller Cooling System Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2 Refrigeration Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.3 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.4 Liquid Solution Flow Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.5 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2.6 Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Section 3.0 - Installation3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.2 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Figure 3—Fork Lift Crated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Figure 4—Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Figure 5—CP2 Anchor Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.3 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.4 Chilled Solution Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.5 Refrigeration Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.6 Refrigeration Unit Expansion Valve Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Section 4.0 - Cleaning the System4.1 First Time Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.2 Leak Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.3 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.4 Filling the Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.5 Liquid Solution for Instant Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Table 1—Typical Freezing Points of Aqueous Solution of Dowfrost™ . . . . . . . . . . . . . . . . . . . . . . . . . .10

Section 5.0 - Evacuation, Charging, and Start-Up of System5.1 System Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.2 System Charging (Also Refer to Refrigeration Unit Method) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.3 System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.4 Temperature Control Calibration Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Original English Version

Table of Contents

Section 6.0 - Equipment Sound Level6.1 Sound Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6.2 Sound Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Section 7.0 - Multi-Stage Chiller Control Installation7.1 Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7.2 Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7.3 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7.4 Instructions for Mounting the Multi-Stage Chiller Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Section 8.0 - Multi-Stage Chiller Control Electrical Wiring8.1 Multi-Stage Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8.2 Digital Temperature Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8.3 Digital Temperature Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8.4 Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 6—Sensor/Remote Start/Flow Switch Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Figure 7—Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 8—24-VAC Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Figure 9—Dry Switch Closure Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

8.5 Flow Switch and Remote Switch Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Section 9.0 - Multi-Stage Chiller Control Programming9.1 Programming Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

9.2 Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Table 2—Programming Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Section 10.0 - Multi-Stage Chiller Control Operation10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

10.2 Off/Pump/Chiller Rotary Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

10.3 Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

10.4 Alarm Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Section 11.0 - Chiller Maintenance11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Section 12.0 - Disposal12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

12.2 Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

12.3 Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

12.4 Metal Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24



® Original English Version

Table of Contents

Section 13.0 - Safety13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

13.2 Refrigerant Health Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

13.3 First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

13.4 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Section 14.0 - Equipment Markings14.1 Label No. 8820454, Dry Nitrogen Holding Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

14.2 Label No. 30890, Data Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

14.3 Label No. 8826701, Data Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

14.4 Label No. 8826705, Warning Symbol: Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

14.5 Label No. 8820623, Warning Symbol: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

14.6 Label No. 8826707, Solution Flow Arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

14.7 Label No. 8820677, Ground Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

14.8 Label, Primary Earth Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

14.9 Label, Lift Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

14.10 Label, Water/Solution In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

14.11 Label, Chilled Water/Solution Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Section 15.0 - Manual Parameters Selection Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Section 16.0 - Declarations16.1 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

16.2 Declaration of Incorporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Section 17.0 - Wiring Schematics (Attached) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32



® Original English Version

Mueller Compact Chiller CP2-10 and CP2-20 Effective December 21, 2011Installation and Operation Manual, Part No. 8826880 Original English Version

SECTION 1.0 - INTRODUCTION

1.1 General

The Mueller® compact chiller is designed to provide your cooling system with the efficient productionof a chilled liquid cooling solution while providing a minimum amount of installation time andmaintenance. This manual provides the basic information necessary to install, start-up, and operate thisMueller compact chiller. The information supplied in this manual must be followed closely to preventdamage to the equipment.

1.2 Technical Support

This manual provides the basic installation and operating information for a Mueller compact chiller.

Please contact your local Mueller Sales and Service Representative if you require additional technicalassistance pertaining to installation or operating procedures.

1.3 Authorized Mueller Installation and Service Representative

Meko Services B.V.Raaterweg 508124 AE WesepePhone: +31 (0) 570 538 310Fax: +31 (0) 570 538 349E-mail: [email protected]

1.4 Safety Statement

Electrical and refrigeration installation and service must be performed by an authorized servicetechnician who has the proper training to install and service refrigeration and electrical equipment.Local, state, and/or country electrical and refrigeration regulations must be followed during installation,service, and/or operation of this equipment.

1.5 Intended Use of Equipment

The Mueller compact chiller is designed to be incorporated with a Mueller plate heat exchanger andrefrigeration unit of sufficient size to complete a complex assembly for cooling milk.

1.6 Misuse of Equipment

Any misuse of the Mueller compact chiller may result in damage to the unit and/or personnel.

IMPORTANT: Do not allow objects to be placed on the chiller or around the chiller to block access.

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SECTION 2.0 - DESCRIPTION OF THE EQUIPMENT

2.1 Equipment Components

A. System Features:• (1) 90 gallon (340 liter) insulated reservoir• (1) 3 hp circulator pump• (2) Flow switches• (2) Evaporator heat exchangers for (2) 5 hp or (2) 10 hp• (1) Control cabinet with temperature controls, circulator pump contactor, and on/off switch

B. System Component Requirements:• (1) Mueller CP2 compact chiller• (2) 5 hp or 3.5 hp Mueller “OESE” E-Star® refrigeration units

– or –• (2) 10 hp Mueller “OESE” E-Star refrigeration units • Refrigerant piping• (1) Mueller Accu-Therm® plate heat exchanger

Figure 1 - Compact Chiller Cooling System

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1

1 - Refrigeration units for chiller2 - Cold chiller water to the plate heat exchanger3 - Return water to the chiller4 - Warm milk to be cooled5 - Cooled milk to the storage tank

Mueller® Compact Chiller Mueller Accu-Therm®

Plate Heat Exchanger

Mueller Milk Cooler

4

3

5

2


Figure 2 - Compact Chiller Cooling System Dimensions

2.2 Refrigeration Components

The Mueller CP2-10 is designed to operate with two (2) Mueller 5 hp “OESE” refrigeration units formaximum performance and efficiency. The Mueller CP2-20 is designed to operate with two (2) Mueller10 hp “OESE” refrigeration units for maximum performance and efficiency. (Refer to the “OESE”refrigeration unit manuals for technical information.)

2.3 Evaporator

The Mueller compact chiller utilizes two totally enclosed, heavy-duty stainless steel evaporators that willprovide years of trouble-free operation when properly installed and controlled. However, like any low-temperature chiller evaporator, they are susceptible to non-warranted damage if the chilled liquidsolution is allowed to freeze.

The unit is not designed to operate at chilled solution temperatures below 1.11°C without properlyprotecting the system with a 20% (–7.5°C) to 25% (–10°C) mixture of Dowfrost propylene glycol. If apropylene glycol other than Dowfrost is used, the mix ratio must achieve a –9°C freeze point.

IMPORTANT: The circulation of a controlled warm water or a completely drained evaporator ismandatory during pump down or refrigerant recovery to eliminate evaporator damage due to freezing.

3

H

LW

Length 132 cm 52 in

Width 79 cm 31 in

Height 138 cm 54 in

Approx. CP2-10 352 kg 775 lb

Weight CP2-20 383 kg 845 lb

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2.4 Liquid Solution Flow Components

A 3 hp centrifugal pump circulates the chilled solution from the reservoir through the evaporator heatexchangers and remote Accu-Therm plate heat exchanger and back to the reservoir.

The chilled-liquid circulation system incorporates a threaded suction screen located internally in thereservoir at the suction connection. This will prevent particulate matter from entering the circulationpump, evaporator heat exchanger, and Accu-Therm plate heat exchanger. It should be removed andcleaned as necessary.

Isolation valves are provided in the liquid solution lines for servicing the pump.

The system has two liquid solution flow switches that utilize normally open (N.O.) contacts connectedin series to the chiller control. In the event of a pump failure, flow blockage, or loss of liquid solution,the paddle in one of the flow switches will open and de-energize both refrigeration units. In the eventthat one of the flow switches breaks the control circuit and de-energizes the refrigeration units, theunits will re-energize when the switch is closed again, indicating adequate fluid flow.

This condition indicates that there was a flow restriction and a service technician should be contactedto troubleshoot and repair the cause prior to multiple restarts.

NOTE: The above condition could be caused by improper temperature settings of the electronictemperature control. Multiple restarts prior to repair or adjustment could cause a non-warranted failureof an evaporator due to expansion from freezing.

The 90 gallon (340 liter) insulated reservoir is constructed of polyethylene. The cover should remain onthe reservoir at all times to prevent particulate and contaminants from entering the liquid solution.

2.5 Electrical Components

The Mueller compact chiller comes with a complete electrical control system. The electronictemperature control is housed in a separate enclosure. The multi-stage chiller control must be mountedand wired to the flow switches, refrigeration units, temperature sensors, and pump.

NOTE: The electrical control enclosure should not be exposed to ambients above 60°C or below 0°C.

All wiring must be performed in accordance with the regulatory agency for the installation locality.

2.6 Control Operation

See Section 7 for control operation.

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SECTION 3.0 - INSTALLATION

3.1 Inspection

Because it is possible for equipment to be damaged during shipment, we recommend that you make athorough inspection of all equipment before it is unloaded from the freight truck. Carefully inspectequipment for hidden damage. It may be difficult to collect for damage if it is not found prior tounloading. It is very important to note any damage on the bill of lading and have the driver sign it.

3.2 Handling

IMPORTANT: Equipment used to move or lift this equipment must be rated for the weight of theequipment. See Figure 2 for equipment weight.

A. Unloading

1. Utilize qualified personnel and equipment. See Figure 3 for lifting the crated chiller.

2. Spread the forks to the maximum width to fit under the skid for equal balance.

3. Insert the forks fully under the skid and raise the unit from the carrier. Slightly tips forks towardforklift to prevent the unit from sliding off.

4. Move the unit near the installation area and place on floor.

NOTE: If moving the unit to a warehouse for storage, do not stack more than one unit highand do not stack any objects on the crate.

5. Remove the upper wood shipping crate and inspect the unit for damage. Report any damage tothe carrier immediately.

B. Skid Removal

1. Remove the wood cross braces securing the unit to the skid.

2. Utilizing qualified personnel and equipment, locate the lift points from the side of the unit. SeeFigure 4.

3. Spread the forks to match lift points and insert the forks between the wood skid and the baseof the unit. Fully insert the forks to engage both sides of the base.

4. Carefully lift the unit out of the skid and place the unit in the final installation location andremove forks.

C. Anchoring the Chiller

1. The chiller must be secured in place utilizing the anchor points marked on the chiller. SeeFigure 5.

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Figure 3 - Fork Lift Crated

Figure 4 - Skid Removal

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Figure 5 - CP2 Anchor Points

3.3 Location

When choosing a location for the Mueller Compact Chiller, consider these items:

• Environment: An indoor location will be necessary where the chiller is protected from freezingtemperatures.

• Serviceability: The chiller should be located with the circulating pump and the electronictemperature control accessible for service. Keep in mind the chiller will require field connections tothe main electrical supply and the liquid solution reservoir may require a drain for maintenance.

• Refrigeration Units: The refrigeration units must be located where they are protected from theenvironment and have adequate air flow for the condensers. Be especially cautious for conditionsthat would allow dust or oil to enter the condenser.

• Efficiency: Locate the chiller as close to the Mueller Accu-Therm plate heat exchanger as possible.This will improve efficiency by reducing heat gain and flow restrictions in the chilled liquidsolution piping.

3.4 Chilled Solution Piping

The piping between the Mueller compact chiller and the Mueller Accu-Therm plate heat exchangershould be a minimum of 3" Schedule-40 or -80 PVC, stainless steel, or copper pipe. Make any reducerconnections at the Accu-Therm and install a union and shut-off valve in each line for service.

If PVC plastic pipe is used with solutions containing propylene glycol, the manufacturers’ of PVC orCPVC pipe recommend that Schedule-80 purple primer and Schedule-80 gray adhesive be used. Thefollowing procedure should be used to assemble PVC or CPVC:

1. Scour primer with a hard bristle brush. It should be alternately applied to the surface of the pipeonce and to the fitting socket twice.

2. Solvent cement should be applied with a stiff bristle brush while the primer is wet. It should bealternately applied to the surface of the pipe twice and to the fitting socket once.

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AnchorPoints


3.4 Chilled Solution Piping (Continued)

IMPORTANT: Galvanized pipe should not be used for applications with propylene glycol, aspropylene glycol can strip the zinc coating from galvanized pipe.

To provide efficient, chilled liquid solution flow to the Accu-Therm plate heat exchanger, utilize long-radius fittings and 45° elbows where possible. A non-absorbent pipe insulation should be installed onboth pipes to reduce sweating and heat gain of the chilled liquid solution piping.

3.5 Refrigeration Unit Installation

Refer to the “OESE” manual for installation of refrigeration units.

The refrigeration units, pre-assembled line sets, and compact chiller refrigeration circuit will require arefrigeration system evacuation to 500 microns prior to refrigerant charging. The system must holdbelow 1,000 microns in a standing vacuum test, insuring that it is leak free.

IMPORTANT: The circulation of controlled warm water or a completely drained evaporator ismandatory during pump down or refrigerant recovery to eliminate evaporator damage due to freezing.

3.6 Refrigeration Unit Expansion Valve Sizing

8

Unit Size Part No. R-507

5 hp 9843711 Y573-SPE-4-PC

10 hp 8825850 EBSPE-7.5-PC

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SECTION 4.0 - CLEANING THE SYSTEM

4.1 First Time Start-Up

It is very important that the system be cleaned before the reservoir is filled. This will retard the growthof algae and bacteria in the chilled liquid solution.

4.2 Leak Testing Procedure

1. Remove all dirt, paper, and other debris that accumulated during shipment and installation.

2. Fill the reservoir with 30–50 gallons (114–190 liters) of cold water and operate the circulating pumpwith the refrigeration units turned off. Check all liquid solution piping and components for leaks.

3. After confirming the system has no leaks, drain the reservoir and proceed with the outlinedcleaning procedure.

4.3 Cleaning Procedure

1. Fill the reservoir with a mixture of approximately 45 gallons (170 liters) of 160°F (71°C) water and8 pounds (3.6 kg) of trisodium phosphate.

2. Operate the circulating pump for 15 minutes with the refrigeration units off. During this time, brushthe inside of the reservoir to clean the areas that are not submerged.

3. Drain the wash solution and fill with 30–50 gallons (114–190 liters) of lukewarm rinse water.

4. Operate the circulating pump for 10 minutes while manually rinsing the reservoir walls that are notsubmerged. Drain the rinse water completely.

4.4 Filling the Reservoir

Fill the reservoir to within three inches of the top with deionized water. Do not use softened waterfrom a standard water softener as there is an increased possibility of chloride corrosion to the stainlesssteel evaporator or Accu-Therm plate heat exchanger.

Never use chlorine as a bacteria inhibitor or cleaning agent as it will cause premature failure of theevaporator and plates within the Accu-Therm plate heat exchanger. A food-grade inhibitor, methyl-paraben, Part No. 9841027, is available through Paul Mueller Company.

The water quality must meet the following standards:

• Chlorides: 25 ppm max.• Sulfates: 25 ppm max.• Calcium: 50 ppm max.• Magnesium: 50 ppm max.• Total Hardness: 100 ppm max.

PROHIBITION: Never use chlorine as a bacteria inhibitor or cleaning agent, as it will cause prematurefailure of the evaporator and plates within the remote, secondary plate heat exchanger.

9


4.5 Liquid Solution for Instant Cooling

If the system is to be used for instant cooling and operated at a liquid solution temperature at or below34°F (1.11°C), the liquid solution must be protected with an approved propylene glycol to preventfailure of the evaporator by freezing. The propylene glycol liquid solution must be concentrated toobtain a minimum of 17°F (–8.3°C) freeze point.

Paul Mueller Company recommends Dowfrost™ propylene glycol, manufactured by Dow ChemicalCompany. Table 1 provides freeze points of Dowfrost solutions at specific concentration percentages.Please contact the Mueller Service Department for assistance in locating a local Dow Chemical dealer.

Table 1 - Typical Freezing Points of Aqueous Solution of Dowfrost

IMPORTANT: A refractometer designed for testing the freeze point of propylene glycol solutionsshould be used to determine the actual freeze point of the solution. Please contact the Mueller ServiceDepartment for assistance in locating a supplier of propylene glycol refractometers.

10

Volume % Dowfrost Freezing Point °F (°C)

0.0 32.0 (0.0)

5.0 29.1 (–1.6)

10.0 26.1 (–3.3)

15.1 22.9 (–5.1)

20.3 19.2 (–7.1)

21.3 18.3 (–7.6)

22.4 17.6 (–8.0)

23.4 16.6 (–8.6)

24.5 15.6 (–9.1)

25.5 14.7 (–9.6)

26.5 13.7 (–10.2)

27.6 12.6 (–10.8)

28.6 11.5 (–11.4)

29.7 10.4 (–12.0)

30.7 9.2 (–12.7)

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SECTION 5.0 - EVACUATION, CHARGING, AND START-UP OF SYSTEM

5.1 System Evacuation

With refrigerant piping completed and leak tested, equipment is ready to evacuate. A quality vacuumpump capable of 500 micron vacuum is necessary for adequate and dependable system evacuation.Moisture in a refrigeration system can cause corrosion, expansion valve freeze-up, and oil sludge.

Attach vacuum pump to both high and low side of system through compressor service valves andevacuate to 500 microns. (All service valves, hand valves, and solenoids must be open duringevacuation.)

NOTE: Service valves are back seating valves and must be in mid-position to open both sides of thesystem to the evacuation pump.

SERVICE NOTE: As a final leak test, close the valve to the vacuum pump and make sure vacuum ismaintained below 1,000 microns for five minutes.

5.2 System Charging (Also Refer to Refrigeration Unit Manual)

With the system wired, plumbed, and evacuated, the unit is ready to charge with the appropriaterefrigerant. All charging lines and manifolds must be evacuated prior to admitting refrigerant into thesystem to prevent contaminating the system with non-condensable.

1. Place the rotary switch in the pump position and ensure liquid solution circulation through thebrazed plate evaporators. Admit liquid refrigerant into the evacuated system until low and high sidepressure is above the freeze point of the liquid solution or 32°F (0°C).

2. With the charging line connected to the receiver service valve, admit liquid refrigerant into the highside of the system until the flow stops due to pressure equalization between high side and therefrigerant drum. Back seat service valve, close manifold valve, and disconnect charging line.

3. Energize equipment and continue to admit liquid into the low side of system until the liquid linesight glass clears, indicating a fully charged system (it may be necessary to bypass the low pressurecontrol on initial start to prevent nuisance trips until low side pressure is above cut-out point ofcontrol).

NOTE: If utilizing a Mueller E-Star refrigeration unit, liquid may be charged upstream of theaccumulator/heat exchanger. Refer to E-Star manual for more detailed charging instructions.

5.3 System Start-Up

This is a continuation of system charging and must be performed before equipment can be leftoperating and unattended. This will involve checking and adjusting all safety and operating controls.Do not attempt to function safety controls without some means of stopping compressor in the event ofextreme high or low pressure conditions that could damage the equipment. If controls fail to functionat setpoints, determine the cause and correct. Jumping any safety control other than for testingpurposes is dangerous to personnel and equipment, and nullifies equipment warranty.

NOTE: Energize crankcase heaters and allow a minimum of 4 hours of operation before a compressorstart-up.

11


5.3 System Start-Up (Continued)

• High Pressure Control: To test the high pressure control, connect a gauge to the compressordischarge service valve and disable condenser fan(s) or water regulating valve(s). Control shouldopen immediately when discharge pressure reaches control setpoint. Enable condenser fans orwater regulating valve(s) and reset pressure control. (Refer to specific refrigeration unit manual.)

• Low Pressure Control: Ensure solution temperature is above 50°F (10°C) to prevent damage toevaporator by freezing. To test the low pressure control, connect a gauge to the compressor suctionservice valve. Throttle receiver outlet valve to lower suction pressure at compressor. The systemshould pump down and the compressor de-energize when suction pressure reaches “cut-out”setting of control. Open receiver outlet valve and observe rise in pressure at compressor suctionconnections. Reset the low pressure control and the compressor should re-energize when pressurereaches “cut-in” setting of control. (Refer to specific refrigeration unit manual.)

IMPORTANT: Controlled warm water circulation must be maintained through the evaporator toprevent damage caused by freezing when testing the low pressure switch.

• Thermal Expansion Valve: Adjust superheat setting to 10–12°F (5.6–6.7°C).

How to determine superheat correctly:

1. With an accurate set of manifold gauges, measure the suction pressure at the evaporator outlet.

2. Convert the suction pressure to a saturation temperature using a refrigerant pressure-temperature table.

3. With an accurate thermometer, measure the temperature of the suction gas at expansion valveremote bulb location.

4. Subtract the saturation temperature read from the tables in Step 2 from the temperaturemeasured in Step 3. The difference is the superheat of suction gas.

5.4 Temperature Control Calibration Accuracy

Once the installation wiring is completed for the chiller control box, check the calibration accuracy ofthe temperature control as outlined below:

1. Allow the product temperature to stabilize for a minimum of 15 minutes.

2. Using an accurate electronic thermometer, determine the actual temperature of the solution.

3. If the known product temperature does not correspond with the temperature display, thetemperature control will require a calibration correction. Refer to Section 9 for sensor calibration.

12

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SECTION 6.0 - EQUIPMENT SOUND LEVEL

6.1 Sound Testing Equipment

The CP2-10 and CP2-20 chiller sound level test was performed under normal operating conditions withthe circulation pump operating. Measurements were taken with a sound meter, model Slim-1352A, andperformed by a third party.

6.2 Sound Measurement

All sound measurements were recorded at a distance of 1 meter (3.28 feet) from the operatingequipment. The highest recorded measurement was 73dbA.

13


SECTION 7.0 - MULTI-STAGE CHILLER CONTROL INSTALLATION

7.1 Box Removal

1. Remove all packaged parts.

2. Inspect all contents and report any damage to the transportation carrier.

3. Ensure all parts are present. Contact Paul Mueller Company with any questions.

7.2 Site Requirements

It is the responsibility of the installer and/or purchaser to provide adequate electrical service and toensure the control is compatible with all refrigeration units and the chiller system. Please contact PaulMueller Company prior to installation if any questions or concerns exist.

7.3 Electrical Requirements

The multi-stage chiller control requires a 208V/240V/277V power supply, fused at 20 amps maximum;or a 380V/480V power supply, fused at 10 amps maximum. A lockable disconnect is provided inaccordance with CE Standard EN60947-3. See Section 16 for detailed wiring schematics.

Electrical installation requirements for the refrigeration units should be obtained from the installationand operation manual specific to the refrigeration unit(s) being installed.

NOTE: All wiring to be performed in accordance with the National Electric Code and/or regulatoryagency for the installation locality. All wiring that enters the multi-stage chiller control enclosure mustbe sealed with cord grips or liquid-tight conduit connectors.

7.4 Instructions for Mounting the Multi-Stage Chiller Control Enclosure

Mount the Mueller multi-stage chiller control where it is easily accessible by the operator and protectedfrom excessive wash down.

14


SECTION 8.0 - MULTI-STAGE CHILLER CONTROL ELECTRICAL WIRING

8.1 Multi-Stage Temperature Control

The Mueller multi-stage chiller control uses an electronic temperature control and one or two digitalsensor(s). The following installation and calibration procedures are very important to ensure accuratesensing of the chilled water temperature. Failure to properly follow these instructions could lead tonon-warranted damage to the chiller or other system components.

8.2 Digital Temperature Sensor Installation

The temperature sensors utilized by the multi-stage chiller control are extremely accurate, fastresponding digital sensors. It is very important that the sensor(s) be installed in the provided wells inthe chilled solution piping. The sensors should be adequately protected from mechanical damage andinstalled into the piping to ensure complete coverage at all times by the chilled solution. When sensorsare installed in pipes discharging into a reservoir, Mueller recommends that the sensors be installed atthe six o’clock position. Care must be taken to never deform the sensor housing as damage to theenclosed circuit board could result. Mueller does not recommend the use of copper compressionfittings on the digital temperature sensor.

IMPORTANT: The digital sensors must be installed into chilled solution stream for propertemperature sensing. Failure to follow these instructions could cause inaccurate temperature indication,degraded milk quality, and non-warranted damage to the chiller or other system components.

8.3 Digital Temperature Sensor Wiring

If necessary, extension of the digital temperature sensor is possible by utilizing the appropriate lengthshielded extension wire (Part No. 8824887, sold by the foot) and three sealing splice connectors (Part No.8825009). Do not strip the insulation from the individual connectors. Fully insert two like-colors into thesplice and pinch closed with pliers. Splice green to green, red to red, black to black, and bare to bare.

NOTE: Cut the aluminum foil and shield/drain wire back to the cable jacket and insulate withelectrical tape inside the chiller cabinet. The foil and shield/drain wire must be insulated so that it doesnot make contact with any metallic surface inside the chiller cabinet. See Figure 6.

Install the sensor cables together in conduit separate from all other wiring. Do not route sensor cablewith other high-voltage cables or route sensor cable conduit parallel in close proximity with other high-voltage conduits.

Route the sensor cables into the multi-stage chiller control enclosure. If using the shielded extensioncable, cut the white wire and aluminum foil back to the cable jacket.

IMPORTANT: Do not cut off the shield/drain wires. The shield/drain wire must connect to the sensorterminal strip inside the chiller control cabinet. See Figure 6.

Connect the red, black, green, and bare drain wires to the appropriate terminal connections on thelogic board located on the back side of the door. Connect sensor A wires to the sensor A terminals andsensor B wires to the sensor B terminals.

NOTE: If either of the temperature displays show “??” (question mark and question mark) you have apoor electrical connection at the sensor splice, a miss-wire of the sensor circuit, or the chilled solutionis below 17°F (–8.33°C).

15

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8.4 Field Wiring

The Mueller multi-stage chiller control may be wired to provide 24-VAC output, dry switch closures, orany combination of the two. Please refer to the following diagrams for wiring procedures.

Figure 6 - Sensor/Remote Start/Flow Switch Wiring Diagram

16

N.O

. FLO

W S

WIT

CH

RE

MO

TE S

TAR

T S

WIT

CH

(INS

TALL

JU

MP

ER

IF N

OT

US

ING

)

LOG

IC B

OA

RDSW

ITC

H C

AB

LE

SE

NS

OR

A

SE

NS

OR

B

RE

D BLA

CK

GR

EE

N SH

IELD

RE

D

BLA

CK

GR

EE

N SH

IELD

PW

R

3

24

NC

NO

DA

TAG

ND

GN

DP

WR

DA

TAG

ND

GN

DS

W1

CO

MS

W2

CO

M

RE

DB

LKG

RN

RE

DB

LKS

HLD

GR

NS

HLD

SE

NS

OR

BS

EN

SO

R A

FLO

W S

WIT

CH

N.O

.R

EM

OTE

STA

RT

SW

ITC

H

IN 1

IN 2

DFE

0028

9


Figure 7 - Relay Board

Figure 8 - 24-VAC Output

For installations requiring 24-VAC output, the 24-VACsignal is available by connecting to the bottom twoterminals, terminals C and D.

17

RE

LAY

BO

AR

D

DFE

0303

PUMP

ALARM

STAGE 1

STAGE 2

STAGE 3

STAGE 4

STAGE 5

STAGE 6

STAGE 7

STAGE 8

STAGE 9

STAGE 10

N (Constant)A B

C D L (Switched)


Figure 9 - Dry Switch Closure Output

For installations requiring dry switch closure type output, connect toterminals A and B.

NOTE: For most wiring schemes, the dry switch closure is factorywired to use 24-vac. To use a voltage rating other than 24-vac, removethe two wires from terminals A and B. Install the field wiring toterminals A and B of appropriate control voltage.

8.5 Flow Switch and Remote Switch Wiring

The Mueller multi-stage chiller control is designed for operation with a normally open (NO) flow switchand a remote switch.

The NO flow switch is an optional programmable feature (although installation is highlyrecommended). See Section 9.2 for flow switch programming. The flow switch should be wiredbetween input SW2 and COM (see Figure 6 for field wiring) on the logic board (mounted to the door).

IMPORTANT: Check with your chiller manufacturer for specific flow switch requirements. Failure tofollow the manufacturer’s recommendations could lead to possible non-warranted damage to theequipment.

The remote switch input must be made for normal chiller operation to occur (units to stage on and off).If no remote switch is to be installed, a jumper must be installed between input SW1 and COM for thecontrol to operate (see Figure 6 for field wiring). If a remote switch is utilized, the switch must providea dry closure for the input SW1 and COM on the logic board (mounted to the door).

18

Dry Switch Closure

A B

C D

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SECTION 9.0 - MULTI-STAGE CHILLER CONTROL PROGRAMMING

9.1 Programming Overview

The Mueller multi-stage chiller control is field programmable to allow for installation on most chillersystems utilizing one to ten independent stages. Each stage has a programmable setpoint temperature,differential, operation mode, and anti-short cycle feature; as well as being able to monitor one of twosystem temperatures. These features allow for maximum possible flexibility.

Care should be taken while selecting parameters that system operation, compressor life, and systemlimitations are not compromised. It is recommended that only Mueller Authorized Service Techniciansadjust programming parameters.

IMPORTANT: The Mueller multi-stage chiller control ships from the factory with basic parameters.All stages are programmed “OFF.” It will be necessary for the technician installing the control to enterprogramming mode before system operation can begin.

9.2 Programming Parameters

Before programming, it is recommended that you complete the programming worksheet (see Section15) located at the end of the manual. Record your desired values in pencil on the worksheet and utilizethis as a reference as you step through all of the parameters available. This method will save valuabletime during the programming portion of the installation.

To enter programming mode, press and hold the “Mode” button for ten seconds. Once the temperaturedisplays change, release the button. Changes can be made to the displayed parameter. Use the “Mode”button to step between individual sections of the programming (i.e., Stage 1, Stage 2, Stage 3, …,Alarms, etc.). Use the Enter button ( ) to cycle to the individual parameters in each section.

To change a parameter, press the up (▲) or down (▼) arrow keys to step through the values. Pressingand holding the up (▲) or down (▼) arrow keys will cause the values to step quickly. See Table 2 fora list and description of all parameters available.

NOTE: Programming may be performed with the rotary switch in any position. Caution must be usedduring programming in the “Chiller” position as to not cycle compressors on and off rapidly.

19

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Table 2 - Programming Parameters

20

Parameter Parameter Code Parameter No. Section Code Description Option(s) Operational Description

1 Stages 1-10 on-off Stage Enable “on” or “off” Selects whether the particular stage should function.

2 SP Setpoint 29.0 – 99.5°F Setpoint temperature for the particular stage. (-1.8 – 37.4°C) Cool Mode - stage off temperature (opens output on fall). Heat Mode - load temperature (opens output on rise)

3 DIF Differential 1.0 – 9.5°F Setpoint differential for the particular stage. Cool Mode - stage on (0.4 – 5.4°C) temperature = SP+DIF. Heat Mode - Unload temperature = SP-DIF.

4 SEN Sensor Select “A” or “b” Selects which sensor the particular stage operates on.

5 H-C Mode Select “H” or “C” Selects whether the particular stage operates as a Cool (close on rise) or Heat (open on rise) application. Cool mode should be selected to operate compressor contactors. Heat mode should be selected to operate unloader coils.

6 ASC Anti-Short Cycle “0” to “10” Anti-short cycle restart feature for the particular stage. Indicates the length of time, in minutes, before a compressor can restart once it has been started.

7 Alarms HI High Alarm 28.0 – 99.5°F High temperature alarm setpoint. (-2.2 – 37.4°C)

8 SEN Sensor “A” or “b” Selects which sensor will trigger a high temperature alarm.

9 LO Low Alarm 28.0 – 99.5°F Low temperature alarm setpoint. (-2.2 – 37.4°C)

10 SEN Sensor “A” or “b” Selects which sensor will trigger a low temperature alarm.

11 Calibration A Sensor A Offset -9.5 – 9.5°F Calibration offset for temperature sensor A. (-5.4 – 5.2°C)

12 B Sensor B Offset -9.5 – 9.5°F Calibration offset for temperature sensor B. (-5.4 – 5.2°C)

13 Flow Flo Flow Switch “y” or “n” Selects whether a NO flow switch has been installed, yes or no.

14 Temperature T Degrees F/C “f” or “c” Selects Fahrenheit or Celsius temperature display.

15 Software SFT Software “_ _ _” Displays installed software version. Version

EXAMPLES OF HEAT/COOL MODE

Settings Compressor #1

Stage 1 On-Off (on-off) On

Setpoint (SP) 34 Off at 34

Differential (DIF) 2 On at 36

Sensor Select (SEN) A

Mode Select (H-C) Cool Energizes on temperature increase.

Anti-Short Cycle (ASC) 5 Min.

Settings Unloader Compressor #1

Stage 2 On-Off (on-off) On

Setpoint (SP) 35 On at 35 (Unloaded)

Differential (DIF) 2 Off at 37 (Loaded)

Sensor Select (SEN) B

Mode Select (H-C) Heat Energizes on temperature decrease.

Anti-Short Cycle (ASC) 0 Min.

Parameter Code: Sensor A, chilled water to PHE. Sensor B, chilled water from PHE.


SECTION 10.0 - MULTI-STAGE CHILLER CONTROL OPERATION

10.1 General

The multi-stage chiller control is designed for easy, touch-of-a-button operation and programming withsimple visual indication of each operation mode by way of bright LED indicators.

10.2 Off/Pump/Chiller Rotary Selector Switch

Select “Off” when the chiller is not in operation or will not be started remotely using the remote-startfeature (See Section 8.4 for remote-start wiring). The “Pump” position enables the circulation pump(s),but will not allow the refrigeration unit(s) to stage on. “Chiller” mode energizes the circulation pump(s)and allows the refrigeration unit(s) to stage on and off automatically. When utilizing the remote-Startfeature of the multi-stage chiller control, the selector switch should be placed in the “Chiller” positionand remain there for automatic operation via the optional remote-start switch.

10.3 Operational Overview

• Cool Mode Stages: “Cool” mode is typically selected to operate compressor contactor coils. Stagesprogrammed for “Cool” mode operate just as a thermostat would for any cooling application. Astemperature rises past the cut-in temperature (setpoint plus differential) the output relay will closeproviding either 24-VAC or a “made” switch closure (see Section 16 for wiring). Once thetemperature falls below the cut-out temperature (setpoint) the output will reopen.

• Heat Mode Stages: “Heat” mode is typically selected to operate compressor unloader coils. Stagesprogrammed for “Heat” mode operate just as a thermostat would for any heating application. Astemperature cools past the cut-in temperature (setpoint minus differential) the output relay willclose providing either 24-VAC or a “made” switch closure (see Section 16 for wiring). Once thetemperature rises above the cut-out temperature (setpoint) the output will reopen. If we look at theoperation of the unloader, the coil will be de-energized (compressor loaded) when the systemtemperature rises above the setpoint temperature. The coil will re-energize (compressor unloaded)when temperature falls below the setpoint temperature minus the differential.

NOTE: All programmed heat stages are energized at startup to start the compressors unloaded.The compressors are then loaded according to temperature requirements.

• Anti-Short Cycle Feature: The “Anti-Short Cycle” (ASC) parameter for each stage selects the time, inminutes, which a compressor coil must wait to restart once it has been started. More simply stated,if the ASC for a particular stage is set to 5 minutes, once the stage is started (for example, at 1:00p.m.) it cannot restart for another 5 minutes (at 1:05 pm). The “Anti-Short Cycle” parameter has noeffect if a stage is programmed for “Heat” mode operation.

• Pump Operation and Flow Switch Monitoring: The pump output is energized any time that theremote switch is made and the selector switch is in the “Pump” or the “Chill” position. When normalchiller operation is stopped (either by rotating the selector switch to “Off” or by opening the remoteswitch) the pump will continue to run for an additional 20 seconds. After this time, there is anadditional 4-second delay to allow loop circulation to stop before the flow switch monitoring willresume. Once this delay expires, any making of the flow switch (with the pump de-energized) willcause the alarm light on the front panel to light and the alarm output relay to close.

21


10.3 Operational Overview (Continued)

• Pump Operation and Flow Switch Monitoring (Continued): When the normal chiller operation isresumed (either by rotating the selector switch to “Chill” or by closing the remote switch), thepump will restart and any required stages will begin to stage on. There is a 4-second delay fromthe time the pump starts until the flow switch monitoring begins. Once this delay expires, anybreaking of the flow switch for longer than 1 second will cause the alarm light on the front panelto light and the alarm output relay to close as well as all “Cool” mode stages to open.

10.4 Alarm Features

There are two separate alarm indications on the Mueller multi-stage chiller control. One is the red alarmLED on the control’s front panel and the other consists of an alarm output on the relay board forremote indication.

The alarm LED will light and provide an alarm output closure to indicate an alarm condition exists.Possible alarm conditions include: Temperature too high or too low, inadequate flow or flow switchmalfunction, or loss of communication with one or both temperature sensors. In the event an alarmcondition exists, the alarm output may be temporarily disabled to provide time to correct the condition.To utilize this function, press and release the enter key ( ). The alarm output will open and thealarm LED will begin to flash. If after 15 minutes the alarm condition has not been corrected, the alarmoutput will re-close and the alarm LED will once again be lit steady. Once all alarm conditions arecorrected, the alarm indications will clear and operation will resume as before.

The specific conditions necessary to cause an alarm are as follows:

• Temperature: Anytime the temperature of sensor “A” or “B” is below the programmed lowtemperature alarm setpoint or above the programmed high temperature alarm setpoint, an alarmcondition exists. Operation continues as before during a high temperature alarm condition with thealarm LED lit and the alarm output closed. In the case of a low temperature alarm, the control willimmediately unload all stages and de-energize all compressor contactors in order to protect theheat transfer surfaces from damage.

Also, any loss of communication with one or both temperature sensors will cause an alarmcondition to exist. This is indicated by a “??” symbol in the appropriate sensor display.

• Flow Switch (with “FLO” programmed for “YES”): Anytime the circulation pump is energized andthe flow switch is open, an alarm condition exists. This alarm is displayed in the sensor A windowas “Flo.” Conversely, anytime the circulation pump is de-energized and the flow switch is closed,and alarm condition exists.

NOTE: There is a 4-second delay when the pump is energized or de-energized before flow switchmonitoring is active to allow the flow of chilled solution to close the switch or open the switch.

22


SECTION 11.0 - CHILLER MAINTENANCE

11.1 General

The Mueller CP2 chiller requires minimal maintenance. It is recommended that a knowledgeable servicetechnician perform the following scheduled maintenance procedures on an annual basis:

1. Check glycol level to ensure adequate chilled water solution levels.

2. Check freeze point with refractometer to maintain a –8.3°C freeze point.

3. Check refrigerant charge and superheat settings of expansion valve. Refer to refrigeration unitmanual for superheat settings.

4. Check for proper incoming supply voltage.

5. Measure the amperage draw of the circulation pump and verify that it is within 10% of the pumpname plate.

6. Check all electrical connections, ensuring that they are clean and tight.

7. Check operation of chilled water circulation flow switches.

Safety Notes:

All maintenance and service must be performed by trained and knowledgeable service technicians.

Individuals who are not trained and certified in proper refrigeration and electrical procedures shouldnot attempt servicing this equipment.

All covers must be in place during operation to prevent mechanical and electrical hazards.

23


SECTION 12.0 - DISPOSAL

12.1 General

If the Mueller CP2 chiller is removed for resale or disposal, ensure the materials, refrigerant, and oilsare handled and/or disposed of according to applicable codes and regulations.

12.2 Refrigerant

This CP2 chiller contains R-507 hydrofluorocarbon, which has zero ozone depletion potential.

12.3 Refrigerant Oil

The CP2 chiller contains a lubricant consisting of polyol ester (P.O.E.). Dispose of in accordance withlocal regulations.

12.4 Metal Components

The CP2 chiller’s basic structure consists of steel, tin, aluminum, plastic, and copper, all of which maybe separated and recycled.

24


SECTION 13.0 - SAFETY

NOTE: See all safety, warning, and/or caution labels displayed in Section 14.

13.1 General

Improper handling or service of equipment containing refrigerant and/or powered by electricity cancreate a health hazard. All installation, service, and/or maintenance must be performed by servicetechnicians who are trained and knowledgeable in proper refrigeration and electrical procedures.

This equipment can start automatically. Use extreme caution when servicing.

All guards and covers must be in place during operation to prevent mechanical and electrical hazards.

13.2 Refrigerant Health Hazards

Although the toxicity and flammability of HFC refrigerants is low, the possibility of injury or deathexists in unusual situations or if they are deliberately misused. These refrigerant vapors are severaltimes heavier than air. Good ventilation must be provided in areas where high concentration ofrefrigerant vapors might accumulate and exclude oxygen.

Most halogenated compounds will decompose at high temperatures such as those associated with gasflames or electric heaters. The chemicals that result under these circumstances include hydrogenchloride and hydrogen fluoride.

These dangerous vapors have a sharp, stinging effect on the nose and can be detected by odor atconcentrations below their toxic level. These odors serve as a warning that decomposition hasoccurred. If detected, evacuate the area until ventilation has cleared the area of the decomposedvapors.

Skin or eye contact can result in irritation and frostbite.

13.3 First Aid

If refrigerant vapors are inhaled, remove victim to fresh air. If not breathing, give artificial respiration. Ifbreathing is difficult, give oxygen. Avoid stimulants. Do not give adrenaline (epinephrine), as this cancomplicate possible effects on the heart. Call a physician.

In case of eye contact, flush eyes promptly with cool water for at least 15 minutes.Call a physician. Soak exposed skin in lukewarm water, not cold or hot. Do not use dressing orointments. Call a physician.

13.4 Safety Equipment

Technicians handling refrigerants should wear side-shielded safety glasses, impervious (preferablybutyl-lined) gloves, and other protective equipment or clothing as required by the situation.

25


SECTION 14.0 - EQUIPMENT MARKINGS

14.1 Label No. 8820454, Dry Nitrogen Holding Charge

14.2 Label No. 30890, Data Tag

14.3 Label No. 8826701, Data Tag

14.4 Label No. 8826705, Warning Symbol: Hot

14.5 Label No. 8820623, Warning Symbol: Electrical

26

IMPORTANT

(11/94) 8820454

THIS EQUIPMENT CONTAINS A HOLDING CHARGE OF DRY NITROGEN GAS. SLOWLY RELEASE PRESSURE THROUGH SERVICE PORTS OR SCHRADER VALVES BEFORE REMOVING FITTINGS.

EVACUATE THE SYSTEM TO 500 MICRONS BEFORE CHARGINGWITH REFRIGERANT. DISCARD THIS TAG UPON CHARGING SYSTEM WITH REFRIGERANT AND APPLY A SYSTEM REFRIGERANT SPECIFICATION DECAL.

NOTE: IT IS THE TECHNICIAN’S RESPONSIBILITY TO COMPLY WITH ALL CURRENT REFRIGERANT USAGE REGULATIONS.

PRODUCT

MODEL NUMBER PART NUMBER SERIAL NUMBER

VOLT S HERTZ PHASE LRG MTR AMPS FLA

DISCONNECT MAIN POWER SUPPLY BEFORE SERVICING.ROMPRE LE CABLE DE DISTRIBUTION AVANT DE REPARER.

0007 30890

Year of ConstructionAnnée de fabrication

Año de fabricación

Model NumberNuméro de modèleNúmero de modelo

Serial NumberNuméro de sérieNúmero de serie

Noise LevelNiveau de bruit

Nivel de ruido

WeightPoidsPeso

10762886001


14.6 Label No. 8826707, Solution Flow Arrow

14.7 Label No. 8820677, Ground Symbol

14.8 Label, Primary Earth Ground

14.9 Label, Lift Point

14.10 Label No. 9810092, Water/Solution In

14.11 Label No. 9810093, Chilled Water/Solution Out

27

PE

WATER / SOLUTIONIN

9810092

CHILLEDWATER / SOLUTION

OUT 9810093


SECTION 15.0 - MANUAL PARAMETERS SELECTION SHEET

28

Parameter Parameter Parameter No. Section Code Code Description Option(s) Selection

1 Stage 1 on - off Stage Enable “on” or “off”

2 SP Setpoint 29.0 to 99.5°F (-1.8 to 37.4°C)

3 DIF Differential 1.0 to 9.5°F (0.4 to 5.4°C)

4 SEN Sensor Select “A” or “b”

5 H-C Mode Select “H” or “C”

6 ASC Anti-Short Cycle “0” to “10”
































Manual Parameters Selection Sheet (Continued)

*Displays installed software version.

29

Parameter Parameter Parameter No. Section Code Code Description Option(s) Selection

























7 Alarms HI High Alarm 28.0 to 99.5°F (-1.8 to 37.4°C)

8 SEN Sensor “A” or “b”

9 LO Low Alarm 28.0 to 99.5°F (-2.2 to 37.4°C)

10 SEN Sensor “A” or “b”

11 Calibration A Sensor A Offset -9.5 to 9.5°F (-5.4 to 5.2°C)

12 B Sensor B Offset -9.5 to 9.5°F (-5.4 to 5.2°C)

13 Flow Flo Flow switch “y” or “n”

14 Temperature T Degrees F/C “f” or “c”

15 Software SFT Software “_ _ _”*


SECTION 16.0 - DECLARATIONS

16.1 Declaration of Conformity

30


16.2 Declaration of Incorporation

31


SECTION 17.0 - WIRING SCHEMATIC (ATTACHED)

32

RELAY BOARDLOGIC BOARD

PU

MP

ALA

RM

STA

GE

1

STA

GE

2

STA

GE

3

STA

GE

4

STA

GE

5

STA

GE

6

STA

GE

7

STA

GE

8

STA

GE

9

STA

GE

10

DFE_0349

TEMPERATURE PROBE(OUT FLOW — TS1)

TEMPERATURE PROBE(RETURN FLOW — TS2)

REMOTE START SWITCH(INSTALL JUMPER IF NOT USING)

N.O. FLOW SWITCH #1

N.O. FLOW SWITCH #2

CONNECT INSIDECONTROL BOX

CABLE FROMMULTI-STAGE LABEL SWITCH CABLE

DATA CABLE

POWER CABLEREDBLACKGRN OR WHTSHIELD

REDBLACKGRN OR WHTSHIELD

YELLOWYELLOW

CP2 FLOWSWITCH DETAIL

FLOW SWITCH#1

FLOW SWITCH#2

EMERGENCYSTOP(DISCONNECT)

CUSTOMER SUPPLIED:380/50/3

IP1 IP2

L1 L2 L3

Sto

p

On

L1 - BLACK

L2 - BLACK

L3 - BLACK

PE

L1 - BLACK

L2 - BLACK

T3 - BLACK

T2 - BLACKT1 - BLACK

REFRIG. CONTACT#1

REFRIG. CONTACT#2

4 - WHITE

3 - BLUE

1 - BLUE

1 -

BLU

E

2 -

WH

ITE

X2 F1 F2 X1

T3T2T1

CIRCULATIONPUMP

TRANSFORMER DETAIL

TRANSFORMER

H1 H2 H3 H4 H5 H6

H1 H2 H3 H4 H5 H6

480

380

277

240

208

1

2

3

4

NC NO


1600 West Phelps Street • Springfield, Missouri 65802, U.S.A.Phone: (417) 575-9000 • Fax: (417) 575-9887www.muel.com • E-mail: [email protected]

©2011 Paul Mueller Company (12/11) 8826880

®

MODELS CP2-10 AND CP2-20 - paulmueller.com Safety Statement ... (Also Refer to Refrigeration Unit...

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