TURBO Refrigerating Chiller-Manual

INTRODUCTION
TERMS & CONDITIONS

1
_
Chiller Manual SAFETY 2

Installation, Operation
& Maintenance
INSTALLATION
3
OPERATING INSTRUCTIONS
4
TROUBLE-SHOOTING 5
MAINTENANCE
-CLEANING 6
OPTIONAL FEATURES &
ACCESSORIES 7
APPEDIXES & NOTES
8
Read Safety Section before installing or using equipment
Chiller Manual Installation, Operation & Maintenance
INTRODUCTION
Turbo Refrigerating is a will help avoid injury to falling over vertical
supplier of fluid chillers, personnel and/or damage to stainless steel plates in a
icemaking, and ice storage the equipment. Both are thin falling film. Because of
equipment. TURBO® does valuable assets to your method of chilling the
not engineer or design fluid operation. Take the time to liquid heat exchangers are
chilling systems, ice protect them. often referred to as falling
systems, ice plants, or film chillers.
processing lines. TURBO Read the manual contents
can provide assistance in before you start your HTD Series
locating qualified installation or operation. HTD stands for High
companies familiar with the This will save time by Temperature Difference.
installation and operation of ensuring that all necessary Fluids are chilled or heated
TURBO chillers. Contact materials and tools are over large temperature
the factory at the address or available when the differences, ranging from
telephone numbers listed at equipment arrives. 5°F to 60°F in a single pass
the end of this section. using R-22, ammonia or
History glycol as the refrigerant
Information on safety, inside the plate. Systems are
installation, operation, TURBO has been available in direct
maintenance and trouble- producing a line of fluid expansion (DX), flooded
shooting is contained in this chillers since 1984 and recirculated models.
manual. If you have equipment as well as Flow rates are available
questions concerning any of icemakers and ice over a wide range but are
these phases, contact generators for the ice typical considered relatively
TURBO or one of its industry since 1960. The low. Higher flow rates can
distributors to ensure that chillers described in this be obtained with HF
you fully understand the manual are part of a family chillers.
instructions and guidelines. of products designed
specifically for the HF Chillers
You must read all of the industrial market for a HF stands for High Flow.
information carefully and variety of cooling needs. Fluids are chilled over
make sure that all personnel narrow temperature
involved in the installation Fluid Heat Exchangers differences, ranging from
have also read and HTD and HF series heat 1°F to 2°F. The plate’s long
understood the information exchangers are designed to narrow geometry enables
and safety instructions. This instantaneously chill fluids high fluid flow over the
Introduction 2/01 Turbo Refrigerating 1-1

plate. Ammonia, R-22 and and uniform fragmented the field (trailer mounted
glycol are all available for nuggets. TURBO has units) or in the processing
use in direct expansion, produced the C-line area
flooded and recirculated icemaker since 1964. This • Concrete icing
systems. product line uses a water • Ingredient icing
defrost to produce ice in (bakeries)
Applications capacities ranging from 1 • Fish icing
HTD/HF chillers are ton per dry to 200 tons per • Poultry icing
suitable for a variety of day in CAR and CAR-LR • Chemical and dye
applications including: (ammonia) and CF (R-22) processes
• Food models. • Emergency cooling
• Beverage loads
• Chemical TURBO® TIG/TIGAR • Ice slurries
• Manufacturing Ice Generators • Catering trucks
In industrial applications • Salad bars or display ice
Models where ice is being used for • Food processing
A number of standard and processing or for top icing,
special chiller plates are TURBO produces a series Ice Storage Systems
available in a variety of of wet ice generators called TURBO® rakes and storage
configurations to meet the TIG (R-22) and TIGAR bins were introduced in
many applications. Standard (NH3) series. These hot gas 1967. There are three basic
plate sizes include: defrost icemakers are built sizes in the hydraulic
• 48” x 60” with the same high quality version as well as two
• 72’ x 60” standards and engineering larger versions known as
as the TURBO® icemakers automatic ice rakes
• 96” x 60”
of the sixties. The only (described in this manual).
• 144” x 24”
difference is that the The smaller hydraulic
icemaking process produces models range in capacity
Refrigerants/Refrigerant
slightly wetter ices due to from 20 to 87 tons while the
Feed
the hot gas defrost, and the larger automatic ice rakes
Chillers are available in R-
standard system used to range from 100 to 300 tons
22, ammonia, and glycol
produce dry, uniform ice of ice storage.
with direct expansion (DX),
nuggets is eliminated. As a TURBO rakes have been
flooded, and recirculated
result, a random shaped used in USDA inspected
refrigerant feed. Chillers
piece of fragmented ice is installations.
can be furnished with their
produced at a lower cost per
own high side and
ton. USDA Design
condensing unit or
All TURBO® ice storage
connected to existing
In applications where systems are designed to
refrigeration systems.
totally dry, uniform ice is meet USDA guidelines and
not required; the meet rugged industrial
Associated Equipment
TIG/TIGAR series offers a standards which make them
low cost alternative. the most reliable in the
Icemakers/Ice Generators
industry. Each system is
TURBO® C-Line
Typical Applications designed to make the
Icemakers
• Produce (broccoli, loading and unloading of
Packaged ice applications
carrots, etc.) – top icing in the ice storage system as
require a dry sub-cooled ice
1-2 Turbo Refrigerating 2/01 Introduction

safe and simple as possible. Optional Rake Features TURBO® block press the
Regardless of size, all of the most reliable on the market.
ice storage systems operate Although TURBO designs
in basically the same simple and builds the ice storage Special Applications
yet reliable manner. system to be as flexible as
possible, the standard TURBO is in the business
system may not meet a of supplying equipment to
The entire load and unload particular application. meet the needs of the
sequence is automatic and TURBO can design a customer. If you have an
does not require the storage system to meet application or a need that is
operator to be in contact almost any need. not discussed here, contact:
with the ice or any moving
parts in the ice storage TURBO® Block Press Turbo Refrigerating, LLC
system. TURBO offers another Sales Department
feature to make optimum P.O. Box 396
The continuous presence of profits from your ice Denton, Texas 76202-0396
an operator is not required production. Instead of Phone: 940-387-4301
although it is recommended. throwing away the snow Fax: 940-382-0364
At the end of the day, the produced by the breaker Web Site:
bin is empty (on a design bar, ice sizer, screw WWW.vogtice.com
day). The bin refills conveyors, or other
overnight and is full when handling devices, install a Customer Service
personnel return to work. TURBO® block press. This
block press converts the The TURBO service
NOTE: All controls are snow into ten or fifty-five department provides
adjustable to allow the pound blocks of ice. assistance for all customer
load or unload rate to needs. TURBO conducts
match the customer’s Introduced in 1977, the training schools at the
production and/or block press is a completely factory and at various
delivery requirements. automatic, hydraulic locations throughout the
powered unit capable of world.
Rake Variations producing from 120 to an
CB and Automatic rakes are excess of 400 ten pound NOTE: The model and
available in a number of blocks per hour. serial number of your
standard sizes to The block press is available TURBO equipment is
accommodate bulk storage with a block bagger located on the data
capacities ranging from 20 attachment, which means: nameplate attached to the
tons to 400 tons. Models are electrical control panel.
available in standard 10’, • Eliminates handling Please refer to the model
12’-6”, 15’ and 20’ widths; until the block is in the bag and serial number when
20’ to 55’ length; heights • A better product making inquiries about
from 9’ to 25’ making it • Higher profits the equipment. This will
possible to produce a enable our personnel to
variety of standard Rugged industrial handle your questions
capacities. construction and stainless quickly and accurately.
steel or UHMW in all areas
of ice contact make the

High Values
TURBO highly values its friends and customers in the industry. Please remember to:
T hink safely – act safely.

U nderstand operating procedures and dangers of the equipment.
R emember to think before you act.
B efore you act, understand the consequences of your actions.
O bserve equipment warnings and labels.

TERMS &
CONDITIONS
Turbo Refrigerating, LLC Company may be required upon delivery to
(the “Company”) agrees to to pay arising from the sale transporting carrier.
sell the Equipment or delivery of the
described herein upon the Equipment or the use 3. Delivery
following terms and thereof. Prepaid freight, if
conditions of sale which, applicable, will be added to (a) The Company will
accordingly, supersede any the purchase price and endeavor to make shipment
of Buyer’s additional or invoiced separately. Where of orders as scheduled.
inconsistent terms and price includes transportation However, all shipment dates
conditions of purchase. or other shipping charges, are approximate only, and
any increases in the Company reserves the
1. Terms and Prices transportation rates or other right to readjust shipment
shipping charges from date schedules.
(a) All orders are to be of quotation or purchase
accompanied by a twenty order shall be for the (b) Under no circumstances
percent (20%) down account of and paid by will the Company be
payment or an acceptable Buyer. responsible or incur any
irrevocable letter of credit liability for costs or
confirmed on a U.S. Bank (d) Contract prices are damages of any nature
acceptable to Turbo. No subject to adjustment to the (whether general,
orders are to be entered Company’s prices in effect consequential, as a penalty
without payment or L/C in at time of shipment unless or liquidated damages or
hand. otherwise specified in a otherwise) arising out of or
separate Price Adjustment owing to (i) any delays in
(b) All orders are subject to Policy attached to the delivery or (ii) failure to
the approval of the proposal or other contract make delivery at agreed or
Company’s home office. document of the Company. specified times due to
Unless otherwise stated, circumstances beyond its
standard terms of payment (e) If Buyer requests reasonable control.
are thirty (30) days net from changes in the Equipment
the earlier of date of or delays progress of the (c) If shipment is delayed or
shipment or readiness of the manufacture or shipment of suspended by Buyer, Buyer
Equipment for shipment. If the Equipment, the contract shall pay (i) Company’s
partial shipments are made, price shall be adjusted to invoice for the Equipment
payment shall become due reflect increases in selling as per payment terms, (ii)
and payable to the partial price caused thereby. Company’s handling and
shipment. storage charges then in
2. Shipment effect, and (iii) demurrage
(c) In addition to the charges if loaded on rail
purchase price, Buyer shall Shipment is F.O.B. cars.
pay any excise, sales, Company’s plant or place of
privilege, use or any other manufacture, unless 4. Limited Warranty:
taxes, Local, State or otherwise specified. Risk of Warranty Adjustment:
Federal, which the loss shall pass to Buyer

Exclusions: Limitation of (i) THE FOREGOING IS loading, or by erosive or

Liability IN LIEU OF ALL OTHER corrosive substances or by
WARRANTIES, ORAL the alien presence of oil,
(a) LIMITED OR EXPRESS OR grease, scale, deposits or
WARRANTY IMPLIED, INCLUDING other contaminants in the
ANY WARRANTIES Equipment.
The Company warrants that THAT EXTEND BEYOND
at the time of shipment the THE DESCRIPTION OF (c) WARRANTY
Equipment manufactured by THE EQUIPMENT. ADJUSTMENT
it shall be merchantable, THERE ARE NO
free from defects in material EXPRESS WARRANTIES Buyer must make claim of
and workmanship and shall OTHER THAN THOSE any breach of any warranty
possess the characteristics CONTAINED IN THIS by written notice to the
represented in writing by PARAGRAPH 4 AND TO Company’s home office
the Company. The THE EXTENT within thirty (30) days of
Company’s warranty is PERMITTED BY LAW the discovery of any defect.
conditioned upon the THERE ARE NO The Company agrees at its
Equipment being properly IMPLIED WARRANTIES option to repair or replace,
installed and maintained OF FITNESS FOR A BUT NOT INSTALL,
and operated within the PARTICULAR PURPOSE. F.O.B. Company’s plant,
Equipment’s capacity under THE PROVISIONS OF any part or parts of the
normal load conditions with THIS PARAGRAPH 4 AS Equipment which within
competent supervised TO DURATION, twelve (12) months from
operators and, if the WARRANTY the date of initial operation
Equipment uses water, with ADJUSTMENT AND but no more than eighteen
proper water conditioning. LIMITATION OF (18) months from date of
Equipment, accessories and LIABILITY SHALL BE shipment shall prove to the
other parts and components THE SAME FOR BOTH Company’s satisfaction
not manufactured by the IMPLIED WARRANTIES (including return to the
Company are warranted (IF ANY) AND EXPRESS Company’s plant,
only to the extent of and by WARRANTIES. transportation prepaid, for
the original manufacturer’s inspection, if required by
warranty to the Company, (ii) The Company’s the Company) to be
in no event shall such other warranty is solely as stated defective within the above
manufacturer’s warranty in (a) above and does not Warranty. Any warranty
create any more extensive apply or extend, for adjustments made by the
warranty obligations of the example, to expendable Company shall not extend
Company to the Buyer than items, ordinary wear and the initial warranty period
the Company’s warranty tear, altered units; units set forth above. The
covering Equipment repaired by persons not warranty period for
manufactured by the expressly approved by the replacements made by the
Company. Company, materials not of Company shall terminate
the Company’s upon the termination of the
(b) EXCLUSIONS FROM manufacture, or damage initial warranty period set
WARRANTY caused by accident, the forth above. Expenses
elements, abuse, misuse, incurred by Buyer in
temporary heat, over- replacing or repairing or

returning the Equipment or the Warranty and Warranty ANY OTHER CAUSE
any part or parts will not be Adjustment extended to the WHETHER BASED ON
reimbursed by the Company by the original WARRANTY (EXPRESS
Company. manufacturer of such parts, OR IMPLIED) OR TORT
in no event shall such other OR CONTRACT, and
(d) SPARE AND manufacturer’s warranty regardless of any advices or
REPLACEMENT PARTS create any more extensive recommendations that may
WARRANTY warranty obligation of the have been rendered
ADJUSTMENT Company to the Buyer for concerning the purchase,
such parts than the installation or use of the
The Company sells spare Company’s Warranty Equipment.
and replacement parts. This Adjustment covering parts
subparagraph (d) is the manufactured by the 5. Patents
Warranty Adjustment for Company as set forth in this
such parts. Buyer must subparagraph (d). Expenses (a) PATENT INDEMNITY
make claim of any breach incurred by the Buyer in AND CONDITIONS
of any spare or replacement replacing, repairing, or
parts warranty by written returning the spare or The Company agrees at its
notice to the Company’s replacements parts will not own expense to defend and
home office within thirty be reimbursed by the hold Buyer harmless in the
(30) days of the discovery Company. event of any suits instituted
of any alleged defect for all against Buyer for an alleged
such parts manufactured by (e) LIMITATION OF infringement of any claim
the Company. The LIABILITY of any United States Patent
Company agrees at its covering solely to the
option to repair or replace, The above Warranty structure of the Equipment
BUT NOT INSTALL, Adjustment sets forth as originally manufactured
F.O.B. Company’s plant, Buyer’s exclusive remedy by the Company per the
any part or parts of material and the extent of the Company’s specifications,
it manufactures which, Company’s liability for and without modification by
within one (1) year from the breach of implied (if any) the Buyer, provided buyer
date of shipment shall prove and express warranties, shall (i) have given the
to the Company’s representations, instructions Company immediate notice
satisfactory (including or defects from any cause in in writing of any such claim
return to the Company’s connection with the sale or or institution or threat of
plant, transportation use of the Equipment. THE such suit, and (ii) have
prepaid, for inspection, if COMPANY SHALL NOT permitted the Company to
required by the Company) BE LIABLE FOR ANY defend or settle the same,
to be defective within this SPECIAL, INDIRECT OR and have given all needed
Parts Warranty. The CONSEQUENTIAL information assistance and
Warranty and warranty DAMAGES OR FOR authority to enable the
period for spare and LOSS, DAMAGE OR Company to do so. Buyer
replacement parts not EXPENSE, DIRECTLY shall defend and indemnify
manufactured by the OR INDIRECTLY the Company against all
Company (purchased by the ARISING FROM THE expenses, costs and loss by
Company, from third party USE OF THE reason of any real or alleged
suppliers) shall be limited to EQUIPMENT OR FROM infringement by the

Company’s incorporating a included in the purchase fails to comply with any

design or modification price, then Buyer shall and all provisions of this
requested by Buyer. indemnify and hold the contract, the Company shall
Company harmless from all have the remedies available
(b) LIMITATION OF liability, costs and expenses under the Uniform
LIABILITY for all such damage or Commercial Code.
injury.
The Company’s total (b) So long as the purchase
liability hereunder is 7. Equipment Changes price is unpaid, Buyer at its
expressly limited to an cost shall obtain insurance
amount no greater than the The Company may, but against loss or damage from
sales price of the Equipment shall not be obligated to, all external causes, naming
and may be satisfied by the incorporate in the the Company as an insured,
Company’s refunding to Equipment any changes in in an amount and form
Buyer, at the Company’s specifications, design, sufficient to protect the
option, the sales price of the material, construction, Company’s interest in the
Equipment in the event the arrangement, or Equipment.
Company elects to defend components.
any such suit and the 9. Cancellation
structure of the said 8. Security Interest
Equipment is held to Insurance Buyer cannot cancel orders
infringe any such United placed with the Company,
States Patent and if the (a) To secure payment of except with the Company’s
Buyer’s use thereof is the purchase price, Buyer express written consent and
enjoined, the Company agrees that the Company upon terms and payment to
shall, at its expense and at shall retain a security the Company indemnifying
its option (i) obtain for the interest in the Equipment the Company against loss,
Buyer the right to continue until Buyer shall have paid including but not limited to
using the Equipment, or (ii) in cash the full purchase expenses incurred and
supply non-infringing price when due, interest at commitments made by the
Equipment for installation the highest lawful contract Company.
by Buyer, or (iii) modify the rate until so paid and the
Equipment so that it costs of collection, 10. Loss, Damage or Delay
becomes non-infringing, or including reasonable
(iv) refund the then market attorney’s fees. The The Company shall not be
value of the Equipment. Equipment shall at times be liable for loss, damage or
considered and remain delay resulting from causes
6. Prior Use personal property and beyond its reasonable
Buyer shall perform all acts control or caused by strikes
If damage to the Equipment necessary to assure and or labor difficulties,
or other property or injury perfect retention of the lockouts, acts or omissions
to persons is caused by use Company’s security interest of any governmental
or operation of the against the rights or authority or the Buyer,
Equipment prior to being interests of third persons. In insurrection or riot, war,
placed in initial operation the event Buyer defaults in fires, floods, Acts of God,
(“Start up”) by the payment of any part of the breakdown of essential
Company where start up is purchase price when due, or machinery, accidents,

priorities or embargoes, car desired by it and/or required condition or any of the

and material shortages, by law or OSHA standards Company’s rights.
delays in transportation or respecting Buyer’s use of
inability to obtain labor, the Equipment. Buyer shall
materials or parts from be responsible for
usual sources. In the event ascertaining that the
of any delay from such Equipment is installed and
sources, performance will operated in accordance with
be postponed by such length all code requirements and
of time as may be other applicable laws, rules,
reasonably necessary to regulations and ordinances.
compensate for the delay. In
the event performance by 12. Complete Agreement
the Company of this
agreement cannot be THE COMPLETE
accomplished by the AGREEMENT BETWEEN
Company due to any action THE COMPANY AND
of governmental agencies, BUYER IS CONTAINED
or any laws, rules or HEREIN AND NO
regulations of the United ADDITIONAL OR
States Government, the DIFFERENT TERM OR
Company (at its option) CONDITION STATED BY
may cancel this agreement BUYER SHALL BE
without liability. In no BINDING UNLESS
event shall the Company be AGREED TO BY THE
liable for any loss or COMPANY IN WRITING.
damage of any kind, No course of prior dealings
including consequential or and no usage of the trade
special damages of any shall be relevant to
nature. supplement or explain any
terms used in this
11. Work By Others: Agreement. This
Accessory and Safety Agreement may be
Devices modified only by a writing
signed by both the
The Company, being only a Company and Buyer and
supplier of the Equipment, shall be governed by the
shall have no responsibility Uniform Commercial Code
for labor or work of any as enacted the State of
nature relating to the Texas. The failure of the
installation or operation or Company to insist upon
use of the Equipment, all of strict performance of any of
which shall be performed the terms and conditions
by Buyer or others. It is the stated herein shall not be
responsibility of Buyer to considered a continuing
furnish such accessory and waiver of any such term or
safety devices as may be

WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.
Chiller Generator Operation & Maintenance Manual
Section 2: SAFETY
Here are some safety points to Important • Follow directions and
keep in mind when creating an Indicates hazards or unsafe illustrations.
efficient yet safe working practices which could cause • Check to see that all
environment. minor personal injury or equipment meets
product or property damage. applicable installation
Safety Definitions codes for your area as well
Note as state and federal
Statements or labels in this Gives helpful information. requirements.
manual or on the product • Have sufficient safety
preceded by the following Machinery Is Dangerous warnings on all equipment.
words are of special • Make sure all safety
significance: Machinery can hurt you if you devices and guards are in
are not careful. Use caution place.
Warning during assembly and operation
Indicates severe personal of equipment. Note:
injury or death will result if Warning labels attached to the
instructions are not followed. ALWAYS: chiller, equipment installed
• Read the entire manual with the chiller, and on access
Caution first. panels should be followed.
Indicates a strong possibility of • Use common sense and be They are shown in Figures 2-1,
severe personal injury or death careful. and 2-2.
if instructions are not followed. • Have enough manpower.
• Have the proper tools.
Safety 2/04 Turbo Refrigerating, LLC 2-1

Figure 2-1 Warning Labels on Control Panels
Figure 2-2 Warning Label on Access Panels
If all labels are not attached Turbo Refrigerating Phone:940-387-4301

and visible or labels start to Service Department Fax: 940-382-0364
become illegible, contact: P.O. Box 396
Denton, Texas 76202-0396
2-2 Turbo Refrigerating, LLC 2/04 Safety

Involve Your People area and notify qualified through the relief system.
personnel. Consideration should be given
Before operating equipment, to prevailing winds to ensure
have the people involved in the Use only recommended ice that refrigerant releases are not
operating or maintenance of machine cleaners suitable for carried to or trapped in
the equipment meet to discuss stainless steel. Follow occupied areas. The contractor
the dangers and safety aspects instructions and warnings should verify that the method
of the chiller. supplied by the manufacturer used meets local, state, and
of the cleaning agents. federal codes.
• Warn them of the danger of
miscommunication. Never open the control panel Note:
• Turn electricity off and (by others unless otherwise Field piping is required by
lock it out when working specified) without others from all safety relief
on the chiller. disconnecting and locking out devices supplied with the
• Have a person trained and electrical service. All electrical various components.
qualified in the operation work should be performed by a
of the equipment on duty to qualified electrician. A written evacuation plan
ensure that the electricity should be available to all
stays locked out to protect When servicing the chiller employees and the local fire
personnel working on the TURBO recommends that at department should be provided
equipment. least two (2) people be present with a copy. The written plan
at all times. should be developed jointly
Pull disconnect and lock out all between the fire department
electrical service before If an outside contractor is and operators or other
removing any guards, access required to install or service designated personnel familiar
panels, and/or covers. your chiller, require him to with the refrigeration system.
furnish you with a certificate Fire department personnel
Never operate the unit without of insurance before performing should be familiarized with the
all guards, access panels, and any work on your equipment. refrigeration system, including
covers in place and securely TURBO recommends that the the location of isolation valves
fastened. person hiring a contractor to and controls for terminating
perform work be satisfied with operation of the system and/or
If leaks in the refrigerant their experience and isolating leaks. Emergency
piping require welding, be sure competence. phone numbers should be
refrigerant is bled off and the posted in a visible manner near
system is open before All refrigerant field piping all areas in which the
attempting to repair. Protect should be done in compliance equipment is located.
eyes with the proper eye with section 5 of Standard
protection. ANSI/IIAR 74-2-1984 (or the IMPORTANT
latest edition, if available). A copy of the evacuation
Always wear proper eye Field piping is not supplied by plan should be available in
protection when cleaning the TURBO. each area in which
system. equipment is located. The
All refrigerant relief valve location should be clearly
Do not expose insulation vent lines must be routed to a marked, easily accessible,
(polyurethane) to open flame. safe discharge location having and away from piping or
If ignited, it will give off adequate ventilation to components from which
highly toxic fumes. Leave the dissipate refrigerant discharged
escaping refrigerant would Refrigerating, and Air- 2. The safety lockout

prevent access. Conditioning Engineers, Inc. procedure is on pages 2-9
(ASHRAE) bulletin through 2-11.
All leaks should be reported ANSI/ASHRAE 15-1994 –
and repaired immediately. “Safety code for Mechanical Checklist for Lock Out Of
Refrigeration”. Controls-By others unless
Each pressure vessel (if otherwise specified
supplied) is equipped with a To request information contact
safety relief valve to prevent RETA at: To lock out the chiller
operation over design limits. Refrigerating Engineers and controls:
Smaller models use a single Technicians Association
relief valve. Larger models use 4700 West Lake Avenue 1. Pull disconnects and lock
dual safety relief type valves Glenview, Ill.60025-1485 out all electrical service –
with a three-way manifold. If a Phone: 847-375-4738 single-phase and three-
safety relief valve discharges, Fax: 847-375-6338 phase power. Refer to the
the three-way valve position E-mail: info@reta.com “Safety Lockout
should be changed to the Procedure” on page 2-9.
“good" relief valve and the Contact IIAR at:
“discharged” relief valve International Institute of 2. Turn the master control
immediately replaced. Ammonia Refrigeration selector switch (provided)
1100 North Glebe Road to the “off” position.
WARNING Arlington, VA 22201
Never install a second relief Phone: 703-312-4200 Emergency Stop Button-By
valve in the outlet of the Fax: 703-312-0065 others unless otherwise
original valve. All relief E-mail: http://www.iiar.org specified
valves used in this system are
atmospheric relief devices. Contact ASHRAE at: A red push/pull mushroom
Installation of any restriction American Society of head emergency switch is on
in the valve outlet, including Heating, Refrigerating, and the control panel door for
a second relief valve, will Air-Conditioning Engineers, emergency cut-off of the
prevent proper operation of Inc. control circuit power. This
the safety relief valve. 1791 Tullie Circle, N.E. button is not to be used for
Failure to carefully follow Atlanta, GA 30329 service or lock out. This is an
these instructions could Phone: 404-636-8400 emergency button only.
result in permanent injury or Web: http://www.ashrae.org
loss of life. If you have any questions, call
Notes: Turbo Refrigerating Service
Additional information on Department at:
refrigeration system safety 1. Per the OSHA Hazard
may be obtained through Communication Standard, Telephone: 940-387-4301
International Institute of material safety data sheets Fax: 940-382-0364
Ammonia Refrigeration (IIAR) for refrigerants and
for ammonia systems, refrigerant oils are on
Refrigerating Engineers and pages 2-9 through 2-16.
Technicians Association
(RETA) for Freon systems, or
American Society of Heating,

SAFETY LOCKOUT PROCEDURE

Effective November 1, 1989
I. Purpose III. Supervisory It is the responsibility of the

Responsibility Safety Coordinator to inspect
The purpose of this procedure the plant on a periodic basis to
is to prevent injury and/or It is the responsibility of all ensure compliance with this
death to personnel by requiring supervisors having contact procedure. If it is determined
that certain precautions be with such operations to: that this procedure is not being
taken before servicing or complied with, immediate
repairing equipment. It has A. Instruct all affected corrective action will be
been developed and employees as to the content of initiated. Wherever possible,
implemented so as to comply this program. such action will be taken in
with 29 CFR 1910.147, of the B. Ensure compliance with conjunction with the first-line
Occupational Safety and this procedure. supervisor; however, higher
Health Act, as amended. level management personnel
IV. Safety Locks will be involved if the
These precautions include: violation is of a serious or
Safety locks and keys will be repetitive nature.
1. Shutting off and locking issued to designated
out electrical power. employees. Locks and keys VI. Rules and Regulations
2. Releasing pressure in must be returned to the plant
pneumatic and hydraulic manager when an employee The following rules and
systems. transfers to another assignment regulations have been
3. Effectively isolating those or terminates his employment. established and are mandated:
portions of equipment and Safety and supervisory
machinery that are energy personnel shall have access to A. Any electrician or
intensive and are being master keys for protective maintenance person whose
serviced or maintained. locks, and under certain duties require that he or
controlled conditions, be others be exposed to the
II. Scope available to assist in the hazards of electrical shock
removal of safety locks. or moving equipment must
This procedure includes those perform those duties in a
employees whose duties Safety locks are painted yellow safe and uncompromising
require them to do for electricians and red for manner. The following
maintenance work on power- maintenance personnel. These steps outline such
driven equipment. It covers the locks are to be used only for precautions:
servicing or maintenance of locking out machinery, tooling,
machines or equipment in and equipment described in 1. The employee must
which the unexpected this procedure. understand the equipment
energization, start-up or with which he is working
release of stored energy could V. Safety Department and its hazards.
cause injury. Responsibility

2. When working with completed his own task, when it has actually been
electrical equipment and remove his own lock. turned back on.
where the accidental
starting of such C. If the equipment controls F. If a machine is locked out
equipment or release of are so located that only one and it is necessary to leave
stored energy would lock can be the area, recheck the lock
create a hazard, the accommodated, a special upon returning to make
employee must turn off attachment that sure that the machine is
all power to the unit or accommodates several still locked out. While
use energy isolating locks must be used. This supervision will make
devices and apply his attachment will be issued every attempt to avoid the
personal lock, and have to all designated removal of locks, there
the supervisor of that employees. may be situations when it
area apply his personal must be done. This recheck
lock. At all times when D. Should an employee be is for your protection.
maintenance is being required to work on
performed on our another piece of equipment G. It is sometimes necessary
equipment, that and need to leave his lock to operate equipment for
equipment will have 2 on the present equipment, purposes of testing or
locks on it, one by the another lock must be making adjustments prior
person performing the obtained from the plant to the actual completion of
maintenance plus the manager. the work. It is recognized
one of the supervisor. that electricians must work
E. Should it be necessary to on live circuits from time
3. In instances where operate a piece of to time, particularly when
multiple circuits are in equipment which is locked trouble-shooting, but
a circuit breaker box, out, every effort should be extreme caution must be
an attaching made by supervision to used under these
mechanism will be locate the employee whose circumstances. Never work
placed on the outside of lock is on the equipment. If alone when changing live
the box to allow that that employee cannot be wiring.
box to be locked out located, the supervisor may
and prevent the door obtain a master key for the VII. Outside Contractors
from being opened. lock. The supervisor must
personally assure himself Whenever outside servicing
B. Each employee who that it is safe to remove the personnel are to be engaged in
performs the duties lock. The lock should than activities covered by the scope
prescribed above will be be returned to the proper and application of this lockout
provided with an individual employee. and tag procedure, such
safety lock and one key. If personnel are to be informed of
more that one employee is This procedure must be used this procedure by the person
assigned to a task, each with extreme caution and good responsible for their work
employee is required to judgement. There is danger activity and are to direct them
place his own lock and tag that the employee involved to follow its requirements.
so the controls cannot be will return thinking that the Failure to do so shall require
operated, even though machine is still locked out, that they do not be permitted to
another person may have continue working in the plant.

VIII. Failure to Follow

Procedures
These procedures have been

developed to protect
employees from serious injury.
It is necessary that all
employees follow them. Those
employees not complying with
the provisions in this
procedure will be subject to
disciplinary action, up to and
including discharge.

Material Safety Data Sheets (MSDS)
Material Safety Data Sheets (MSDS) are provided for all refrigerants (ammonia, Freon, glycol, refrigerant
oils) typically used in chiller applications.
See MSDS sheets attached for details.





Material Safety Data Sheet for Anhydrous Ammonia

I. Product Identification
Trade Name: Anhydrous Ammonia

Synonyms: Ammonia
Manufacturer's Name: USS Agri-Chemicals, Division, United States Steel Corporation
Regular Telephone: 404/572-4000
Emergency Telephone: 800/424-9300 (Chemtrec)
Address: P.O. Box 1685, Atlanta, GA 30301
Chemical Name: Ammonia
Formula: NH3
CAS No.: 7664-41-7
Chemical Family: Nitrogen Hydride
EPA Reg. No.: Code A100-6259
II. Hazardous Ingredients
Material or Component: Ammonia

%: 100
Hazard Data (TLV): 50 PPM in air by volume, 8 hour time weighted average in any 8-hour work shift of a
40-hour work week (OSHA).
III. Physical Data
Boiling Point, 760 MM Hg: –33.3°C (–28.0°F)

Melting Point: @ 1 atm.: –77.8°C (–107.9°F)
Specific Gravity (H20=1): @ –33.3°C, 1 atm.: 0.682
Vapor Pressure: Sat. Liq. @ 32°F: 47.6 psig
Vapor Density (Air=1): @ 0.0°C (32°F), 1 atm.: 0.597
Solubility in H20 % By Wt.: @ 32°F, 1 atm.: 47.3
% Volatiles by Vol.: 100
Evaporation Rate (Butyl Acetate=1): not applicable
Appearance And Odor: Colorless liquid or vapor with characteristic pungent odor.
IV. Fire and Explosion Data
Flash Point (Test Method): Not applicable.

Autoignition Temperature: 671°C (1204°F) (iron bomb)
Flammable Limits in Air, % by Volume: 16 – 25
Extinguishing Media: Water spray or fog, dry chemicals, carbon dioxide.
Special Fire Fighting Procedures: Stop flow of gas; move containers from fire zone if possible; stay clear
of tank heads; use water to keep fire exposed containers cool and to protect personnel. Fire fighting
personnel must be equipped with appropriate protective clothing and respiratory equipment.
Unusual Fire and Explosion Hazard: Presence of oil or other combustibles will increase fire hazard.

V. Health Hazard Information
Toxicity Data
Inhalation: Moderately toxic. LCLo: 1,000 PPM/3 hrs. (Humans)

Skin Contact: Corrosive: 1st and 2nd degree burns. Burns may be fatal if extensive.
Skin Absorption: Not listed as potentially contributing to overall exposure by the cutaneous route.
Eye Contact: Corrosive: Blindness may follow serious eye burns caused by liquid ammonia.
Ingestion: Highly Toxic: Five ml of ammonia solution (28% NH3) has been recorded a fatal oral dose.
Effects of Exposure
Acute Overexposure: Concentrations of ammonia in air of 5,000 to 10,000 PPM are reportedly fatal.
Chronic Overexposure: Concentrations of ammonia in air of 2,500 to 6,000 PPM during 30 minute
exposure are considered dangerous to life.
Emergency and First Aid Procedures
Eyes: Flood immediately with copious quantities of clean water. Irrigation must continue for at least
15 minutes. Patient must receive prompt attention from a physician.
Skin: Flood with water for 15 minutes and remove any contaminated clothing. Do not use salves or
ointments during 24 hour period after injury. Subsequent treatment is as for thermal burns.
Inhalation: Remove to uncontaminated area and begin artificial respiration immediately if necessary. If
available, administer oxygen when breathing restored. Call physician.
Ingestion: If patient is conscious and able, have him drink large quantities of water. If vomiting begins,
place patient face down with head lower than hips.
Notes to Physician: If respiratory embarrassment is the result of pulmonary edema, provide appropriate
supportive treatment and drug therapy.
VI. Reactivity Data
Conditions Contributing To Instability: Dissociation begins to occur at 429° – 498°C (804° – 930°F)
Incompatibility: Store separately from oxidizers, halogens and acids.
Hazardous Decomposition Products: Hydrogen and nitrogen.
Conditions Contributing To Hazardous Polymerization: Not applicable.
VII. Spill or Leak Procedures
Steps To Be Taken If Material Is Released Or Spilled:

Stop leak if no risk involved. Avoid breathing vapor or liquid. Evacuate personnel not equipped with
protective clothing and equipment. Use copious amounts of water spray or fog to reduce concentration and
lower vapor pressure. Do NOT put water on liquid ammonia spill unless more than 100 volumes of water are
available for each volume of liquid ammonia.
Neutralizing Chemicals: Do NOT neutralize with chemicals. Use water only.

Waste Disposal Method:
Contain run-off of liquid ammonia or ammonia in water from getting into a stream, lake, sewer, or ditch by
building a dam. Let ammonia evaporate or soak into the ground. Notify local, state, and federal authorities.
Release of 100# or more of ammonia within 24 hours must be reported to the National Response Center,
telephone: 800/424-8802.
VIII. Special Protection Information

Ventilation Requirements: Under normal operating conditions, sufficient ventilation is required to avoid
vapor concentrations exceeding a threshold limit value of 50 PPM in air by
volume based upon an 8-hour time weighted average. See 29 CFR 1910.1000.
Specific Personal Safety Equipment

Respiratory (Specify in Detail): Gas masks with canisters approved for ammonia by NIOSH/MSHA may
be used in concentrations in air of up to 30,000 PPM. Over this limit or in
unknown concentrations, approved air supplied respiratory equipment in
pressure demand mode must be used.
Eye: Tight fitting chemical splash goggles with hooded ventilation. A full face shield may be worn over
the goggles for additional protection, but not as a substitute for the goggles.
Gloves: Gauntlet type rubber or plastic impervious to ammonia.
Other Clothing and Equipment: For emergency and rescue purposes, protective slicker or protective pants
and jacket; protective boots; hard hat; life line; safety shower and eye
wash.
IX. Dot Information

Shipping Name: Anhydrous Ammonia, Nonflammable Gas, UN1005, RQ
Classification: Nonflammable Gas
Label: Nonflammable Gas
Placard: Nonflammable Gas
USSAC Hazard Class Code: C2
X. Special Precautions
Precautionary Statements:
WARNING! HAZARDOUS LIQUID AND VAPOR UNDER PRESSURE. LIQUID CAUSES
BURNS. VAPOR EXTREMELY IRRITATING. Do not breathe vapor. Do not get in eyes, on skin, or
clothing.
Other Handling and Storage Requirements:

Store and use with adequate ventilation, protect containers from excessive heat or physical damage. Zinc,
copper, and copper base alloys such as brass are subject to rapid destruction by moist ammonia. Refer to
ANSI K61.1.
The information and recommendations contained herein are based upon data believed to be correct.
However, no guaranty or warranty of any kind expressed or implied is made by TURBO with respect
to the information contained herein. This data is provided solely for your consideration and
investigation.

Material Safety Data Sheet for Suniso 3 GS & 4 GS

Product: Refrigeration Oil Suniso 3GS and 4GS
Section I.
Manufacturing Division or Subsidiary: Sonneborn Division

Address (Number, Street, City, State, Zip Code): P.O. Box 308 Gretna, Louisiana 70053
Emergency Telephone (Manufacturer): 1-504-366-7281
Chemical Name or Family: Refined Mineral Oil
Formula: A mixture of liquid hydrocarbons refined from petroleum.
Section II. Chemical and Physical Properties
Hazardous Decomposition Products: Upon combustion, CO2 and CO are generated.

Incompatibility (Keep Away From): Strong oxidizing agents such as chromic acid, hydrogen peroxide and
bromine.
List All Toxic and Hazardous Ingredients: None
Form: Viscous liquid Odor: Petroleum
Appearance: Clear liquid
Color: Amber
Specific Gravity (water = 1): 0.91 @ 15.6° C
Boiling Point: >500° F (>260° C)
Melting Point: NA
Solubility in Water: Insoluble
% Volatile (by weight %): Negligible
Evap. Rate: Negligible
Vapor Pressure (mm Hg at 20° C): <0.0001 Vapor Density (air = 1): >10
pH As Is: NA
Strong Acid q
Strong Base q
Stable n
Unstable q
Viscosity SUS at 100° F: <100 q 100 or > n
Section III. Fire and Explosion Data
Special Fire Fighting Procedures: Wear self-contained breathing apparatus. Water spray is an unsuitable
extinguishing agent.
Unusual Fire and Explosion Hazards: None
Flash Point (Method Used): ASTM D-92 >300° F (>150° C)
Flammable Limits %: NA
Extinguishing Agents: n Dry Chemical n CO2 n Water fog
q Water spray n Foam n Sand/Earth
q Other:

Section IV. Health Hazard Data
Permissible Concentrations (air): 5 mg/m3 mineral oil mist (OSHA).

Effects of Overexpose: Prolonged contact may cause minor skin irritation.
Toxicological Properties: NDA
Emergency First Aid Procedures:

Eyes: Flush with large amounts of water for at least 15 minutes. If redness or irritation persists,
contact a physician.
Skin Contact: Wash with soap and water. Wash clothing before reuse.
Inhalation: None normally required.
If Swallowed: Call a physician.
Section V. Special Protection Information
Ventilation Type Required (Local, Mechanical, Special): NA

Respiratory Protection (Specify Type): NA
Protective Gloves: Oil resistant rubber
Eye Protection: Chemical splash goggles
Other Protective Equipment: Rubber apron
Section VI. Handling Of Spills or Leaks
Procedures for Clean-up:

Stop leak, dike up large spills. Use inert absorbent material such as earth, sand, or vermiculite for clean-up.
Waste Disposal:
Dispose of in accordance with Local, State, and Federal government regulations.
Section VII. Special Precautions
Precautions to be taken in Handling and Storage:

Avoid exposure to heat and flame. Protect against eye and skin contact. Wash thoroughly after handling.
Section VIII. Transportation Data
Unregulated by D.O.T. n
Regulated by D.O.T. q
Transportation Emergency Information: CHEM TREC 1-800-424-9300
U.S. D.O.T. Proper Shipping Name: NA
U.S. D.O.T. Hazard Class: NA
I.D. Number: NA
RQ: NA
Label(s) Required: NA
Freight Classification: Petroleum Oil NOIBN
Special Transportation Notes: NA

Section IX. Comments
CAS #64742-52-5
Signature: ____________________________________
Title: ________________________________________
Telephone:____________________________________
Date: ________________________________________
Revision Date:_________________________________
Sent To:______________________________________
Supersedes: ___________________________________
TURBO believes the statements, technical information and recommendations contained herein are
reliable, but they are given without warranty or guarantee of any kind, express or implied, and
TURBO assumes no responsibility for any loss, damage, or expense, direct or consequential, arising
out of their use.

Material Safety Data Sheet for Suniso 3 GS & 4 GS
Product: Refrigeration Oil Suniso 3GS and 4GS
Section I.
Manufacturing Division or Subsidiary: Sonneborn Division

Address (Number, Street, City, State, Zip Code): P.O. Box 308 Gretna, Louisiana 70053
Emergency Telephone (Manufacturer): 1-504-366-7281
Chemical Name or Family: Refined Mineral Oil
Formula: A mixture of liquid hydrocarbons refined from petroleum.
Section II. Chemical and Physical Properties
Hazardous Decomposition Products: Upon combustion, CO2 and CO are generated.

Incompatibility (Keep Away From): Strong oxidizing agents such as chromic acid, hydrogen peroxide and
bromine.
List All Toxic and Hazardous Ingredients: None
Form: Viscous liquid Odor: Petroleum
Appearance: Clear liquid
Color: Amber
Specific Gravity (water = 1): 0.91 @ 15.6° C
Boiling Point: >500° F (>260° C)
Melting Point: NA
Solubility in Water: Insoluble
% Volatile (by weight %): Negligible
Evap. Rate: Negligible
Vapor Pressure (mm Hg at 20° C): <0.0001 Vapor Density (air = 1): >10
pH As Is: NA
Strong Acid q
Strong Base q
Stable n
Unstable q
Viscosity SUS at 100° F: <100 q 100 or > n
Section III. Fire and Explosion Data
Special Fire Fighting Procedures: Wear self-contained breathing apparatus. Water spray is an unsuitable
extinguishing agent.
Unusual Fire and Explosion Hazards: None
Flash Point (Method Used): ASTM D-92 >300° F (>150° C)
Flammable Limits %: NA
Extinguishing Agents: n Dry Chemical n CO2 n Water fog
q Water spray n Foam n Sand/Earth
q Other:

Section IV. Health Hazard Data
Permissible Concentrations (air): 5 mg/m3 mineral oil mist (OSHA).

Effects of Overexpose: Prolonged contact may cause minor skin irritation.
Toxicological Properties: NDA
Emergency First Aid Procedures:

Eyes: Flush with large amounts of water for at least 15 minutes. If redness or irritation persists,
contact a physician.
Skin Contact: Wash with soap and water. Wash clothing before reuse.
Inhalation: None normally required.
If Swallowed: Call a physician.
Section V. Special Protection Information
Ventilation Type Required (Local, Mechanical, Special): NA

Respiratory Protection (Specify Type): NA
Protective Gloves: Oil resistant rubber
Eye Protection: Chemical splash goggles
Other Protective Equipment: Rubber apron
Section VI. Handling Of Spills or Leaks
Procedures for Clean-up:

Stop leak, dike up large spills. Use inert absorbent material such as earth, sand, or vermiculite for clean-up.
Waste Disposal:
Dispose of in accordance with Local, State, and Federal government regulations.
Section VII. Special Precautions
Precautions to be taken in Handling and Storage:

Avoid exposure to heat and flame. Protect against eye and skin contact. Wash thoroughly after handling.
Section VIII. Transportation Data
Unregulated by D.O.T. n
Regulated by D.O.T. q
Transportation Emergency Information: CHEM TREC 1-800-424-9300
U.S. D.O.T. Proper Shipping Name: NA
U.S. D.O.T. Hazard Class: NA
I.D. Number: NA
RQ: NA
Label(s) Required: NA
Freight Classification: Petroleum Oil NOIBN
Special Transportation Notes: NA

Section IX. Comments
CAS #64742-52-5
Signature: ____________________________________
Title: ________________________________________
Telephone: ___________________________________
Date: ________________________________________
Revision Date: ________________________________
Sent To: _____________________________________
Supersedes:___________________________________
TURBO believes the statements, technical information and recommendations contained herein are
reliable, but they are given without warranty or guarantee of any kind, express or implied, and
TURBO assumes no responsibility for any loss, damage, or expense, direct or consequential, arising
out of their use.

Material Safety Data Sheet for Propylene Glycol

1 - PRODUCT IDENTIFICATION
PRODUCT NAME: PROPYLENE GLYCOL

FORMULA: CH3CHOHCH2OH
COMMON SYNONYMS: 1,2-PROPANEDIOL; 1,2-DIHYDROXYPROPANE;

METHYLETHYLENE GLYCOL;
PROPANE-1,2-DIOL
PRECAUTIONARY LABELLING
FLAMMABILITY - 1 SLIGHT
REACTIVITY - 1 SLIGHT
CONTACT - 2 MODERATE
HAZARD RATINGS ARE 0 TO 4 (0 = NO HAZARD; 4 = EXTREME HAZARD).
LABORATORY PROTECTIVE EQUIPMENT

SAFETY GLASSES; LAB COAT
PRECAUTIONARY LABEL STATEMENTS:
WARNING CAUSES IRRITATION

AVOID CONTACT WITH EYES, SKIN, CLOTHING. KEEP IN TIGHTLY CLOSED
CONTAINER. WASH THOROUGHLY AFTER HANDLING.
APPEARANCE & ODOR: COLORLESS, ODORLESS VISCOUS LIQUID.
UNUSUAL FIRE & EXPLOSION HAZARDS

CLOSED CONTAINERS EXPOSED TO HEAT MAY EXPLODE.
5 - HEALTH HAZARD DATA
EMERGENCY AND FIRST AID PROCEDURES

IN CASE OF CONTACT, IMMEDIATELY FLUSH EYES WITH PLENTY OF WATER
FOR AT LEAST 15 MINUTES. FLUSH SKIN WITH WATER.
7 - SPILL AND DISPOSAL PROCEDURES
STEPS TO BE TAKEN IN THE EVENT OF A SPILL OR DISCHARGE.

WEAR SELF-CONTAINED BREATHING APPARATUS AND FULL PROTECTIVE
CLOTHING.
STOP LEAK IF YOU CAN DO SO WITHOUT RISK. USE WATER SPRAY TO
REDUCE VAPORS.
TAKE UP WITH SAND OR OTHER NON-COMBUSTIBLE ABSORBENT MATERIAL AND
PLACE INTO CONTAINER FOR LATER DISPOSAL. FLUSH SPILL AREA WITH
WATER.
DISPOSAL PROCEDURE
DISPOSE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE, AND
LOCAL ENVIRONMENTAL REGULATIONS.
8 - PROTECTIVE EQUIPMENT
VENTILATION:
USE ADEQUATE GENERAL OR LOCAL EXHAUST VENTILATION TO KEEP VAPOR
AND MIST LEVELS AS LOW AS POSSIBLE.IF AIRBORNE CONCENTRATION IS
HIGH, USE AN APPROPRIATE RESPIRATOR OR DUST MASK.
EYE/SKIN PROTECTION:
SAFETY GOGGLES, UNIFORM, APRON, PROPER GLOVES ARE RECOMMENDED.

WARNING! Read safety section before this section. Failure to carefully follow these instructions could
result in permanent injury or loss of life.
Chiller Operation & Maintenance Manual
Section 3: INSTALLATION & PRE-START-UP

REQUIREMENTS
To install and prepare the b. Evaporative-Cooled • Inlet and Outlet refrigerant
TURBO® HTD, HF or uHTD Condensers connections are on the front
chiller, you will need two to c. Water-Cooled Condensers of the evaporator section.
three people whose skills 14. Optional Refrigerant Connections can be made
include mechanical, welding, Recirculation System from either side.
and plumbing capabilities, and a 15. Optional Flooded System • Hinged access doors are
qualified electrician. Components located on both ends for
cleaning access.
This section includes step-by- IMPORTANT • Hinged roof panel(s) with a
step instructions on installing Pay special attention to any mechanism to hold roof
and connecting your chiller. bold print or boxed in panel open are provided on
Your chiller has been tested and paragraphs. Following this top.
inspected at the factory prior to information is essential for a • All doors and hinged roof
packing and shipping. safe, efficient installation. panels have slip hinge pins
for easy removal.
Installation Sequence To Help You Get Started • Reference Figure 3-1 for
typical chiller configuration.
1. Delivery Inspection • Read instructions
2. Hoisting or Moving completely before NOTE: The refrigerant and
3. Site Preparation installation. water connections on the
4. Mounting and Leveling • Gather all required tools. chiller can be reversed by
5. Electrical Connections • Standard water and rotating the chiller (upper
6. Water Connections refrigerant connections are section) on the reservoir
7. Refrigerant Piping located on the front of the during installation. Unless
9. Testing Refrigeration System Chiller as you face the inlet otherwise specified the
for Leaks water connection on the connections will be as shown
10. Evacuating the System Chiller. The water in Figure 3-1.
11. Refrigerant Charging connections for the reservoir
12. Post Installation Clean Up (sump) are located on the
13. Optional High Side right side of the Chiller
a. Air-Cooled Condensers /reservoir assembly.
Installation & Assembly Requirements 3/04 Turbo Refrigerating, LLC 3-1

Figure 3-1 Typical Chiller Orientation (Typical HTDA9612XX Shown)
Recommended Service and rotate the upper chiller • Wrenches and sockets (a full
Cleaning Clearances section 180° when placing it set up to 1 1/8")
on the chiller sump. • Phillips (not cross-point) and
Minimum recommended standard (slotted) screw
clearances for service and Tools Required for drivers
cleaning: Installation • Level (four feet long)
• 48" on all sides • Tape measure (thirty feet
• 36" above the chiller for To install the Chiller, you will long)
access to the water need two to three people whose • Pry bar
distribution pan(s) and skills include mechanical, • Lifting straps (2000#)
header(s) for cleaning. welding, and plumbing • Welder suitable for carbon-to-
capabilities as well as a stainless steel
Access doors are provided on qualified electrician. The • Framing square
the front, rear, and top of the following is a list of tools • Forklift or crane
chiller. required for safe erection and
assembly of the Chiller: Always remember –SAFETY
Note: To locate the FIRST!!!
connections on the opposite
3-2 Turbo Refrigerating, LLC 3/04 Installation & Assembly Requirements

1. DELIVERY INSPECTION
All Chillers and reservoirs (if Delivery Inspection Checklist
supplied) are inspected at the
factory to assure shipment of a 1. Inspect panels.
mechanically sound piece of
equipment. If provided 2. Open and inspect loose
electrical controls and options equipment and crate(s).
are also factory tested
3. Inspect evaporator plates.
TURBO® Chillers are shipped
on “air-ride” trailers to ensure 4. Inspect valves (if
that the equipment arrives in the applicable) and piping.
best possible condition.
5. Damage and missing parts
Inspect the Chiller and reservoir must be noted on bill of
thoroughly upon arrival at the lading at the time of receipt.
installation site to check for any
shipment damage. Report any
damage to the transportation
company immediately so that an
authorized agent can:
• Using the Packing List

provided with the shipment
examine the Chiller and/or
loose parts shipped with the
unit to ensure everything on
the list has been received.
• Determine the extent of the
damage.
• Take the necessary steps to
rectify the claim without
costly delays.
Since most equipment is

shipped FOB Factory title to the
equipment transfers to the
owner when it is loaded on the
truck and leaves the factory.
Therefore any claims must be
filed by the owner. Notify
TURBO of any claims made.

2. HOISTING OR MOVING
Equipment Rigging A spreader bar and blocks may
Instructions be required to protect the plates. Figure 3-2 shows the
The hinged roof panels and configuration with lifting slings
The Chiller should be lifted by front and rear doors should be around the plate bank and
the lifting straps (slings) around removed during the rigging reservoir (sump).
the plate bank inside the frame. operation.
Figure 3-2 Chiller Lifting Configuration

Hoisting or Moving available a large forklift WARNING

on both ends should be Hoisting or moving
If a Chiller is installed in a used. The unit can also be heavy equipment should
location that requires the moved by a large forklift only be done by
unit to be lifted by means from one end with heavy competent rigging and
of a crane, TURBO duty dollies under each hoisting contractors.
requires that the lifting corner of the other end. Never allow personnel to
and/or slinging be done go under the unit while
from the bottom of the IMPORTANT it is in the air. Failure to
unit. Use a spreader at the Never lift or sling the carefully follow these
top of the unit to prevent Chiller with devices instructions could result
the plates from being fastened to the top frame in permanent injury or
damaged. A competent structure. Lift the loss of life.
rigging and hoisting Chiller only from the
contractor can handle the bottom of the plate bank. The following tables list
job without danger or the shipping weights of all
damage to the Chiller. Before hoisting, the rigger standard chillers and
must ensure that the load reservoirs. Consult the
If a Chiller has to be is properly balanced to factory for shipping
moved along a floor, road, prevent tilting or tipping weights of special or self-
driveway, etc., use either of the Chiller. Test the contained chiller that
pipes as rollers or dollies load before lifting it off include the high side or
(of sufficient capacity) the truck or ground. other options.
under the unit or if
Table 3-1. Standard HTD Chiller Models Shipping Weights

48" Plate Chiller Models
MODEL SHIP OPERATING MODEL SHIP OPERATING
WT WT WT WT
(LBS) (LBS) (LBS) (LBS)
HTD "X" -48-06-01 1,482 2,466 HTD "X" -48-12-07 2,540 4,634
HTD "X" -48-06-02 1,587 2,637 HTD "X" -48-12-08 2,645 4,805
HTD "X" -48-06-03 1,692 2,809 HTD "X" -48-12-09 2,750 4,977
HTD "X" -48-06-04 1,797 2,981 HTD "X" -48-12-10 2,855 5,149
HTD "X" -48-06-05 1,902 3,153 HTD "X" -48-12-11 2,960 5,320
HTD "X" -48-06-06 2,007 3,324 HTD "X" -48-12-12 3,065 5,492
HTD "X" -48-06-07 2,112 3,496 HTD "X" -48-12-13 3,170 5,664
DIMENSIONS (IN) L W DIMENSIONS (IN) L W
68 36 68 60

72" Plate Chiller Models

WT WT WT WT
HTD "X" -72-06-01 1,856 3,227 HTD "X" -72-12-07 3,347 6,296
HTD "X" -72-06-02 2,014 3,488 HTD "X" -72-12-08 3,505 6,557
HTD "X" -72-06-03 2,172 3,749 HTD "X" -72-12-09 3,663 6,818
HTD "X" -72-06-04 2,330 4,011 HTD "X" -72-12-10 3,821 7,079
HTD "X" -72-06-05 2,488 4,272 HTD "X" -72-12-11 3,979 7,340
HTD "X" -72-06-06 2,646 4,533 HTD "X" -72-12-12 4,137 7,601
HTD "X" -72-06-07 2,804 4,794 HTD "X" -72-12-13 4,295 7,862
92 36 92 60
96" Plate Chiller

WT WT WEIGHT WEIGHT
HTD 'X'-96-06-01 2,321 4,087 HTD 'X'-96-12-07 4,147 7,959

HTD 'X'-96-06-02 2,531 4,436 HTD 'X'-96-12-08 4,357 8,308
HTD 'X'-96-06-03 2,741 4,786 HTD 'X'-96-12-09 4,567 8657
HTD 'X'-96-06-04 2,951 5,135 HTD 'X'-96-12-10 4,777 9,007
HTD 'X'-96-06-05 3,161 5,485 HTD 'X'-96-12-11 4,987 9,357
HTD 'X'-96-06-06 3,371 5,834 HTD 'X'-96-12-12 5,197 9,706
HTD 'X'-96-06-07 3,581 6,184 HTD 'X'-96-12-13 5,407 10,056
116 36 116 60

96" Plate Chiller

WT WT WT WT
HTD 'X'-96-18-14 6,195 12,192 HTD 'X'-96-30-20 8,055 14,623

HTD 'X'-96-18-15 6,405 12,542 HTD 'X'-96-30-21 8,265 14959
HTD 'X'-96-18-16 6,615 12,891 HTD 'X'-96-30-22 8,475 15,296
HTD 'X'-96-18-17 6,825 13,241 HTD 'X'-96-30-23 8,685 15,632
HTD 'X-'96-18-18 7,035 13,590 HTD 'X'-96-30-24 8,895 15,968
HTD 'X'-96-18-19 7,245 13,939 HTD 'X'-96-30-25 9,105 16,304
HTD 'X'-96-18-20 7,455 14,289 HTD 'X'-96-30-26 9,315 16,640
HTD 'X'-96-30-27 9,525 16,976
HTD 'X'-96-30-28 9,735 17,313
HTD 'X'-96-30-29 9,945 17,649
HTD 'X'-96-30-30 10,155 17,985
116 83½ 116 83½
Consists of standard insulated reservoir with 3" legs, evaporator section, water distribution pan,
PVC water distribution header, splash curtains and insulated panels. Door configuration is top
and end. Chillers are shipped in two pieces with a charge of inert gas.
DESIGN NOTE: HTD 'X' 96-30-XX is not suitable for flooded applications. Consult
Factory.

Table 3-2. Un-insulated (uHTD)Chiller Shipping Weights
uChiller
MODEL SHIP OPERATING
WT. WEIGHT
(LBS) (LBS)
UHTD "X" -48-06-01 1,395 2,370

UHTD "X" -48-06-02 1,500 2,485
UHTD "X" -48-06-03 1,620 2,610
UHTD "X" -48-06-04 1,725 2,740
UHTD "X" -48-06-05 1,840 2,780
UHTD "X" -48-06-06 1,965 3,025
UHTD "X" -48-06-07 2,085 3,026
DIMENSIONS (IN) L W
68 36
Consists of standard insulated reservoir with 3" legs, un-insulated evaporator section panels,
water distribution pan, all constructed of stainless steel, and PVC water distribution header.
Door configuration is top and end. Chillers are shipped in two pieces with a charge of inert gas.

Table 3-3. High Flow(HF) Chiller Shipping Weights
144" Plate Hi Flow Chiller

MODEL SHIP WT. OPERATING MODEL SHIP OPERATING
(LBS) WEIGHT WT. WEIGHT
(LBS) (LBS) (LBS)
HF 'X'-144-06-01 1,935 4,355 HF 'X'-144-12-07 3,325 7,700

HF 'X'-144-06-02 2,065 4,495 HF 'X'-144-12-08 3,460 7,895
HF 'X'-144-06-03 2,195 4,635 HF 'X'-144-12-09 3,585 8,080
HF 'X'-144-06-04 2,340 4,840 HF 'X'-144-12-10 3,715 8,275
HF 'X'-144-06-05 2,485 5,045 HF 'X'-144-12-11 3,885 8,510
HF 'X'-144-06-06 2,625 5,250 HF 'X'-144-12-12 3,995 8,680
HF 'X'-144-06-07 2,765 5,450 HF 'X'-144-12-13 4,105 8,920
163 36 163 60
144" Plate Hi Flow Chiller

MODEL SHIP OPERATING
WT. WEIGHT
(LBS) (LBS)
HF 'X'-144-12-07 3,325 7,700

HF 'X'-144-12-08 3,460 7,895
HF 'X'-144-12-09 3,585 8,080
HF 'X'-144-12-10 3,715 8,275
HF 'X'-144-12-11 3,885 8,510
HF 'X'-144-12-12 3,995 8,680
HF 'X'-144-12-13 4,105 8,920
DIMENSIONS (IN) L W
163 60

WARNING! Read safety section before this section. Failure to carefully follow these instructions could result in permanent injury or loss of
life.
Table 3-4. Reservoir Shipping Weights and Capacities.

OVERALL TANK SUMP WEIGHT
DIMENSION WATER (SEE NOTE) ACTUAL
# OF CHILLER GAL / # OF
Size LEVEL CAPACITY
PLATES MODEL IN SHIP OP LEGS
L W H (IN) (GAL)
WT WT
HTD-48-06 68 8.875 271 1,188 6 110
1 THRU 6 HTD-72-06 92 36 12.2 346 1,614 152
HTD-96-06 116 422 2,048 195

15.53
STD HTD-48-12 68 17½ 12½ 380 2,006 195
7 THRU
12 HTD-72-12 92 60 21.35 482 2,709 267
HTD-96-12 27.18 583 3,419 340

116
14 THRU
30
HTD-96-XX 83½ 38 1/2 741 4,786 482
HTD-48-06 68 37½ 32 1/2" 8.875 185 288

1,669
1 THRU 6 HTD-72-06 92 36 12.2 228 397
2,271
HTD-96-06 116 270 505
2,856
15.53
MEDIUM HTD-48-12 68 228 505
2,813
7 THRU
12 HTD-72-12 92 60 21.35 270 694
3,831
HTD-96-12 27.18 313 883
4,842
116
14 THRU
30
HTD-96-XX 83½ 38 1/2 355 1,252
6,751

WARNING! Read safety section before this section. Failure to carefully follow these instructions could result in permanent injury or loss of
life.
HTD-48-06 68 15.53 410 505
3,704
1 THRU 6 HTD-72-06 92 60 21.35 504 694
5,024
HTD-96-06 116 27.18 598 883
6,336
HIGH
HTD-48-12 68 24.4 528 793
5,515
7 THRU
12 HTD-72-12 92 92 33.56 639 8 1,091
7,511
HTD-96-12 116 42.71 750 1,388
9,490
HTD-48-XX 68 24.4 988
824 8,146
EXTRA
HIGH
1 THRU 30 HTD-72-XX 92 92 45½ 40 1/2" 33.56 8 1,359
1,003 11,069
HTD-96-XX 116 42.71 1,730
1,182 13,984

3. SITE PREPARATION
Install the Chiller in an area outdoor installations are the data sheet provided with the
where the ambient temperature not recommended. chiller.
does not fall below 40°F or rise • A cover over the roof
above 100°F. The chiller and panels to prevent debris, Raised Curbing
reservoir (sump) on all HTD/HF rain, snow, and other
chillers are insulated against outdoor contaminates A raised curbing around the
excessive heat infiltration. Most from collecting on the outside of the Chiller is
Reservoirs are optional on HF roof and preventing recommended to contain any
series chillers are provided normal opening of the condensate, leakage, or cleaning
without reservoirs. uHTD roof panel for cleaning fluid during maintenance from
chiller cabinets are not without contaminating the unit. A curbing height of
insulated. the interior of the two (2) to three (3) inches is
chiller. Optional roof typically sufficient. Refer to
Provide adequate working space vinyl covers are Figure 3-6.
on all sides and the top of the available.
Chiller for easy access to Elevated Installation
service and clean. IMPORTANT
Normal freeze-up precautions Some installations require
Outdoor Installation should be taken when pump mounting the Chiller at an
or drain lines must be exposed elevation above grade. In these
Insulated chillers are suitable to freezing temperatures. cases, a structural steel platform
for outdoor installation. For (capable of supporting the
ease of maintenance and Concrete Slab dynamic and static load) must
cleaning as well as access under be provided.
all weather conditions indoor If the Chiller is to be mounted
installations are preferred. on a concrete slab, the surface Due to variations in local and
Outside installation typically of the slab must be level or state codes, a local firm
require additional installation shimming must be provided specializing in structural steel
considerations including but not under the unit to ensure that it is should be consulted to
limited to: level to ensure proper water determine the requirements of
flow over the evaporator plates. the steel to be erected. Contact
• Provisions for chiller Leveling legs are provided on TURBO for information
operation in conditions all chiller reservoirs for final required by the firm that is
where the ambient is leveling after the providing the steel platform
below 40°F to prevent chiller/reservoir are set in place. including weight, dimensions,
freeze up. Operation for connection locations, and access
short intervals (less than IMPORTANT requirements for service. The
8 hours per day) is Failure to follow these steel supporting the unit must
possible without guidelines could result in be level or shimmed to obtain a
problems. For uneven water distribution satisfactory level. The same
operations requiring over the evaporator plates. guidelines for supported and
24/7 (24 hours per day; unsupported sections apply as
seven days a week) Location of all leveling feet on for concrete slabs. Refer to
the chiller reservoir is shown on Figure 3-4.

Figure 3-4 Elevated Installation

Access, Service, Air Space Water Pressure Lines dispose of this water and for the
unit overflow drain.
When laying out the unit Properly size the water piping
installation, allow adequate to the make-up water Water Treatment
space around the unit for access connection and cooling tower Optional make-up water
and service. Give particular (if equipped) to deliver the strainers are available to remove
attention to the location of the specified flow and pressure. solids and material large enough
Chiller, optional evaporator Standard design parameters for to plug openings in the water
high side equipment, and Chillers use minimum 5 PSIG distribution system. Consult a
optional refrigerant city water pressure or water local water treatment company
recirculation unit. Removal or pumped from storage at the to determine if additional water
service of larger, heavier inlet to the chiller. If available treatment or filtration is
components (condensers, water pressure is below 5 PSIG required to produce the desired
compressors, etc.) may require at the inlet water connection, water quality and reduce
access by a forklift or other consult TURBO to determine if maintenance of the water
lifting devices which require a booster pump is required. The distribution system.
additional space. maximum water pressure is 100
PSIG. Systems with water
On air cooled condensers, pressures over 100 PSIG should
evaporative condensers, and be equipped with pressure
cooling towers (supplied as an reducing valves in the lines to
option or by others), adequate the Chiller. Expansion tanks
space must be allowed for air may be required on some
intake and air discharges to systems with high water
prevent insufficient air supply pressure to prevent water
or recirculation of discharge air. hammer.
Allow space for electrical Floor Drain

disconnects and load centers (by
others) near the equipment and The Chiller reservoir requires
for conduit runs from the load periodic cleaning. Make
center to the equipment. provisions for a floor drain to

4. MOUNTING AND LEVELING

Set the Chiller on a solid, level and width. Failure to level Use a level with a minimum
base or floor. Refer to step 3. the Chiller in both directions length of forty-eight (48) inches
Reference "Site Preparation" on will disturb the water flow to insure a good installation.
page 3-6 for additional details. patterns and may cause
incomplete coverage of the As indicated in step 3 leveling
IMPORTANT chilling surfaces. legs are provided on all
It is imperative that the reservoirs for leveling the
Chiller be level in both length Chiller/reservoir assembly.

5. WATER SYSTEM
General Chiller Requirements temperature can not be Water Temperature
obtained. Refer to the
Water temperature and flow are maintenance section for Entering water temperatures on
used to determine the number of cleaning procedures. typical chiller installations can
evaporator plates required for range from 90°F down to 35°F.
the chilling service to be Free chlorine is released from For entering water temperatures
provided. All chiller capacities the water as it is discharged over 90°F consult the factory.
are based on the entering water from the distribution header. As Leaving water temperatures to
temperature, leaving water the chlorine level of the water within 0.5°F of the fluid freeze
temperature, specific heat of the increases or if the water is super point are obtainable.
fluid, and the flow rate over the chlorinated, the free chlorine
chiller plates. The number of level can concentrate and cause The fluid to be cooled is
plates is determined by the load corrosion of even stainless steel brought into the chiller through
calculated from the data above surfaces that are not wetted the water inlets located at the
and the saturated evaporator during operation. These top of the chiller. Entering fluid
temperature which is typically surfaces include the chiller is discharged from the PVC
between 26°F and 30°F for frame, parts of the water fluid distribution system located
applications using water as the distribution pan, exterior panel inside the chiller into the
fluid being chilled. surfaces, and refrigerant stainless steel water distribution
headers. The free chlorine must pan to ensure optimum
The holes sizes in the water be vented to reduce the distribution to all plates in the
distribution pan and the water concentration level. Venting can system. From the water
distribution header are also be obtained by installing distribution pan, the fluid flows
based on the water flow over optional vents or typically by over the exterior of the chiller
the plates. To minimize fouling weekly cleaning procedures to plates and is discharged into the
of the holes in the header and remove the stagnant water that reservoir located below the
pan, the maximum diameter collects on the non-wetted chiller. Pump, drain, and
size allowable without surfaces and vent free chlorine. overflow connections are
impacting water distribution is Cleaning procedures are located in the reservoir.
used. described in the maintenance
section. Opening the cabinet High flow (HF) chillers for
Water Quality doors releases trapped chlorine. some application do not use a
If followed by a fresh water reservoir below the chiller
When the fluid to be cooled is wash down of all the surfaces plates. For these applications
water, the water quality can on a weekly basis the system the chilled fluid is discharged
affect the performance and will typically remain in a directly into the process, over a
corrosion resistance of the passive state and corrosion free. processing conveyor carrying
system if proper corrective Weekly cleaning also eliminates the product, or directly into a
action is not taken. scale build that requires more chilled fluid tank.
aggressive cleaning methods to
Minerals in the water can cause remove. Reference the Maintenance
a scale build up on the surface Section for additional
of the heat transfer surface. If information on cleaning, and
this fouling is not removed from the “Handling and Post
the plates the leaving water Installation” section of the
Installation Instructions for Water Distribution Pan in the water distribution pan.
additional steps to follow to For USDA applications a
ensure the long term integrity of A stainless steel water perforated PVC sheet is used in
the chiller. If you are uncertain distribution pan is located on the bottom of the water
about the quality of the water or top of the chiller plates to distribution pan to filter the
fluid to be used in the chiller uniformly distribute the fluid water before it plugs the holes
consult the factory for over all the plates. The size and in the water distribution pan.
assistance. number of holes in the pans are The PVC filter requires more
Water Distribution Header selected to match the flow frequent cleaning to ensure
requirements specified by the proper water distribution at all
A PVC water distribution customer. At design rate rates times.
header is located inside the unit. the water level in the pans is at
This is designed for easy approximately the 50% full Insulation
disassembly for cleaning. The level. All pans are designed to
laterals that branch off of the maintain proper flow over a 2:1 Fluid lines connected to the
main lines can be removed from flow range that covers a water chiller should be insulated to
the fittings into which they are level from approximately 1” reduce heat infiltration and
inserted for cleaning. Plastic minimum to 4” maximum in the condensation. Insulation of
caps are located on the end of pan. these lines is by others.
the laterals to permit full access
to the lateral interior from both NOTE: Water levels below 1”
ends. These parts are not glued in the water distribution pan
together to allow for will result in water wicking
disassembly for cleaning. (separation of the fluid flow
over the plates) and will result
Holes in the water distribution in freeze ups due to erratic
header are sized for even fluid flow to t he plates.
distribution of the fluid into the
pan and large enough to pass Water levels above 4” can
solids in the fluid stream. result in excessive splashing
Reference “Water Distribution and also result in freeze-ups
Pan Filter” below for removal due to the splashing freezing
of solids and debris from the on the refrigerant headers or
fluid stream. other surfaces that are
normally not wetted.
Larger chillers normally use
multiple water distribution Larger chillers normally use
headers to make them easier to multiple water distribution pans
remove for cleaning. to make them easier to remove
for cleaning.
Stainless steel water distribution
headers with sanitary fittings for Water Distribution Pan Filter
easy disconnect and removal of
the complete water distribution A filter pad is located in the
system are available as an bottom of the water distribution
option. pan for all non-USDA
applications to filter debris that
is large enough to plug the holes
6. ELECTRICAL CONNECTIONS
Standard chillers consist of the and are furnished with each disconnects/circuit breakers to
upper evaporator section and operating manual. Consult the terminal blocks in the
lower reservoir. No electrical these diagrams before making chiller. All field wiring is
components are required for electrical service connections. provided by others.
these components. Control of
the chiller and/or water system Electrical Service Connections Checking Pump Rotation
is an option or typically
supplied by others and Chillers can be furnished with The water pump (by other
integrated into the control optional features factory wired. unless otherwise specified)
systems for other parts of the Electrical service connections to rotation is typically indicated on
processing plant. the following is required by the pump housing. Pump
others: rotation can be verified by
The options section can be observing the fan rotation on
referenced for optional kits • L1, L2, L3 motor starter the pump motor or by
required for a complete system connectors (three phase) measuring the amp draw of the
and the electrical requirements motor. The correct motor amp
for each. • L1, L2 control circuit draw will be higher than the
connections (single phase) amp draw in the reverse
WARNING rotation. Rotation can be
All electrical work should be All of these connections are changed by reversing two of the
done only by a qualified made on the terminal blocks phases on the motor starter; i.e.
electrician. Do NOT turn located inside the optional reverse the wiring connections
power on at this time. Failure Chiller control panel if to L2 and L3 if the rotation is
to carefully follow these supplied. Installation of not correct.
instructions could result in disconnect switches or circuit
permanent injury or loss of breakers is by others in the Note:
life. incoming power lines ahead of When checking rotation, only
the control panel on the chiller. the power to the pump should
IMPORTANT Field wiring is required from be on. Turn the three phase
Electrical wiring diagrams for the electrical source to power to the other
optional control systems are disconnects and/or circuit components in the system off.
located in each control panel breakers, and from

7. WATER CONNECTIONS
Water Pump Connection cleaning. The shut off valve on 3 GPM/ton of refrigeration.*
should be closed during normal The actual flow rate is wholly
A MPT connection is provided operation. Installation of the contingent on the water
at the bottom of the reservoir valve and piping are by others. temperature and evaporator load
for connection to a water pump but will not exceed the design
to be used to pump the chilled IMPORTANT flow.
water to the process or final Normal freeze-up precautions
distribution point. should be taken when pump * Tons of refrigeration = Total
or drain lines must be exposed Heat Rejection @ 10°F
This connection is typically to freezing temperatures. SET/105°F SDT ÷ 15,000
located at the same end as the BTU/ton
overflow and drain connection. Connection Size and Location
Optional Water Regulating
Multiple pump connections or Refer to the Data Sheet supplied Valve (SC Models Only)
connections in different with the manual for connection
locations including the bottom sizes and locations. The A water regulating valve can be
of the reservoir are available as locations shown in Figure 3-1 furnished in the Chiller high
options. are typical. Locations for side and must be field installed
special chillers may vary. external of the unit in the outlet
Water Overflow Connection water line. A 1/4" SAE flare
Optional Components type valve is provided on the
A connection for water Water Requirements water cooled condenser for the
overflow is located on the front (Optional Condensing Unit) water regulator high pressure
of the chiller above the pump Water Cooled Condensers gas connection. The regulator
connection. This is piped to an modulates in response to
overflow drain for disposal if Water-cooled condensers increases and decreases in the
the pump fail, water flow to the supplied on chiller high sides discharge pressure to maintain a
chiller exceeds design flow, or are the conventional constant pressure under all
the lines become plugged. condenser/receiver combination operating conditions.
Piping to a safe discharge type. They feature shell and
location is by others. tube type construction, Evaporative-Cooled
cleanable with removable Condensers
Drain Connection heads. The water in and out
connections are sized to permit Evaporative-cooled condensers
A female coupling is factory maximum water flow at peak can also be supplied with
installed in the bottom of the requirements. optional high side system to be
pump connection. The reservoir used with TURBO chillers.
is shipped from the factory with Condenser water requirements
a plug installed in the are based on 85°F water to the The same basic requirements
connection. The plug may be condenser, 95°F water off the for water quality and
removed and replaced by a shut condenser, and 105°F temperature apply to
off (isolation) valve for draining condensing. The condenser’s evaporative-cooled systems
the reservoir for service or design water flow rate is based except evaporative-cooled
condensers like cooling towers other devices used to feed liquid Optional Features &
sizing is based on the design to the recirculation vessel or Accessories for Winterizing.
wet bulb temperature for the surge drum.
installation location. Standard Optional evaporative-cooled
selections are based on a design When contemplating the use of condensers also require
wet bulb temperature of 78°F city or well water for discharge pressure controls to
and a saturated condensing condensing, a careful check maintain the discharge under all
temperature of 95°F. For other should be made of the seasonal operating conditions. Discharge
design conditions consult the variation in the water pressure controls include a
factory. temperatures and the quality of variety of methods. Air
the water. discharge dampers that
Discharge Pressure Controls modulate in response to the
Water flow lines should be discharge pressure are the most
When optional cooling towers sized large enough for the economical. Flood back
are used and no other positive required flow at the maximum controls and variable frequency
means of regulating head water temperature to be drives (VFD) may be required
pressure are provided (i.e., fan encountered. for applications that operate in a
and pump pressure switches), a wide range of ambient
water regulating valve will be For applications requiring conditions including low
required. Adequate head condenser water above 85°F, ambient conditions where
pressure is important to provide consult TURBO. When Chillers dampers alone may not be
proper refrigerant flow to are installed in an area where sufficient. Consult factory for
refrigerant control valves such the ambient falls below additional information.
as hand expansion valves or freezing, refer to section 8 –

8. REFRIGERANT PIPING
All piping in the chiller is 304L Steel Pipe Joints compound may be used. Use
stainless steel. Optional 316L thread filling compound
piping is also available. As indicated all piping inside sparingly and on the pipe only.
Refrigerant connections are the chiller is stainless steel. It is; Do not put any thread filling
stubbed out on the right side of however, acceptable to connect compound on the first two
the chiller for standard carbon steel pipe to the inlet and threads, this prevents any of the
installation. These connections outlet connections. compound from entering the
can be easily reversed by system.
rotating the chiller on the IMPORTANT: When welding
reservoir during installation. carbon steel to stainless steel, Refer to the Data Sheet in the
the chiller should be covered manual for the refrigerant
NOTE: Although the during all grinding, welding connection sizes and location.
connections can be reversed in and deburring operations to The locations shown in Figure
the field please specify the avoid contamination of the 3-1 are typical. Locations for
side the refrigerant headers stainless steel surfaces. special chillers may vary.
should exit when the chiller is Failures to follow these
ordered to ensure the package instructions could result in
along with any options pitting or corrosion of the Steel Pipe
provided can be properly stainless steel. Reference
assembled in the field. additional information on Carbon steel or stainless steel
post-installation clean up in pipe can be used for refrigerant
Piping in a refrigerant system this section. lines but must be either
has two functions: sandblasted or pickled to ensure
Clean threads on the pipe and complete removal of wax, oil,
1. To carry the refrigerant fittings to remove all traces of or other processing films.
through the system as a grease or oil. Wipe the threads
liquid, a gas, or a liquid/gas dry with a lintless wiping cloth. Pipe Line Hangers
mixture with a minimum
pressure drop. Threaded Joints Hangers and supports for coils
and pipe lines should receive
2. To return any oil entrained Standard refrigerant careful attention. Hangers must
in the refrigerant to the connections are butt weld. have ample strength and be
compressor. Threaded connections are not securely anchored to withstand
recommended but can be any vibration from the
Avoid trapping the lines except supplied if specified. For compressor and adequately
for specific purposes. If traps threaded connections on piping support the pipe lines.
are used, the horizontal for refrigerants, use Teflon
dimension should be as short as thread sealing tape. Wrap the Storage / Inactive Systems
possible to avoid excessive tape around the threaded male
trapping of oil. Suction mains portion of the joint about two If the equipment is not installed
should be pitched toward the full turns, thread into the female upon receipt or is installed but
compressor. portion, and tighten. If thread not put in service, the interior
sealing tape is not available, must be maintained in a clean
conventional thread filling dry environment. All units are
evacuated and charged with installation, the system should water and air dried or wiped off
nitrogen or an ammonia holding be properly evacuated and an with clean dry cloth. The
charge to protect the system. ammonia holding charge integrity of the system should
During installation the dry established. All external be checked on a regular basis to
holding charge will be lost. If surfaced should also be avoid damage during the
the system is not started after thoroughly washed with clean extended off period.

9. TESTING REFRIGERATION SYSTEM FOR LEAKS – FIELD

PIPING
Testing for leaks assures a tight plug the connection during system is under pressure.
system that operates without the test. Welded joints should be
loss of refrigerant. 2. Open all valves except those ground and re-welded. Do
leading to the atmosphere. not simply add more weld
In order to test field piping for 3. Open all solenoids by lifting to a leaking joint.
leaks, the system pressure must their stems manually.
be built up. Test pressures for 4. Open all bypass 4. After all the joints have
the system’s low side and high arrangements. been repaired and the
side are defined in the following system is considered “tight”,
standards: Oil free dry nitrogen may be test the chiller with
used to raise the pressure to the refrigerant.
• ANSI/ASHRAE 15 Safety proper level for testing. 5. Attach a drum of the
Code For Mechanical proper refrigerant to the
Refrigeration Testing system and allow the gas to
• ANSI B9.1 Safety Code for enter until a pressure of 5
Mechanical Refrigeration When the proper pressure is PSIG is reached.
• ASME/ANSI B31.5 attained: 6. Remove the refrigerant
Refrigeration Piping drum and bring the pressure
1. Test for leaks with a to the recommended test
These standards should be mixture of four parts water level with oil free dry
referenced for field test and one part liquid soap nitrogen.
pressures and procedures. These applied to all flanges and 7. Check the entire system
pressures will usually suffice threaded or welded joints again for leaks, using a
but check local codes as they with a one inch round brush. sulfur stick or electronic
may differ. A small amount of glycerin leak detector. Check all
added to the test solution will flanged, welded, screwed,
IMPORTANT strengthen the bubbles and and gasket joints, all valve
Do not use the compressor to improve the solution. stem packings, and all
build up the pressure; it is not 2. Observe the entire joint. parting lines on castings. If
designed to pump air. Serious If a leak is present, the any leaks are found, they
overheating and damage may escaping gas will cause the must be repaired and
result. test solution to bubble. rechecked before the system
3. After all leaks are found can be considered tight.
Prior to Testing and marked, relieve the
system pressure and repair Test Pressure
1. If test pressures exceed the leaks. The evaporator plates when
settings of system relief ASME coded are rated for 202
valves or safety devices, psig. However, during pressure
remove the system relief IMPORTANT testing, the maximum
valves or safety devices and Never attempt to repair recommended test pressure is
welded joints while the 150 psig.

10. EVACUATING THE SYSTEM

Reasons to Evacuate temperature is 60° or higher (to off pressure of 10 microns or
allow for proper moisture boil less.
Refrigeration systems operate off).
best when only refrigerant is Attach this pump to the system
present in the system. Steps If free moisture is in the system and allow it to operate until the
must be taken to remove all air, before evacuation (such as pressure in the system has been
water vapor, and all other non- water collected in traps or low reduced somewhere below 500
condensables from the Chiller places in the piping), this can microns.
unit before charging it with easily be detected by feeling of
refrigerant. If air, water vapor, these traps and low places. If Connect the high vacuum pump
or non-condensables are left in moisture is present, it will into the refrigeration system
the system, various operating condense in the low places and following the manufacturer’s
difficulties can be encountered, freeze. It can be removed by instructions.
including: gently heating the trap the
farthest away from the vacuum Note:
1. Water will decrease the pump. This causes the water to For best results, connect the
capacity of the evaporator boil, the ice to melt, and the pump to the high side and the
and cause formation of ice vapor to collect in the next trap low side of the system so that
in orifice openings causing towards the vacuum pump. the entire system is
restriction or complete shut- Repeat this process until all thoroughly evacuated.
off of refrigerant flow. pockets of water have been
boiled off and the vacuum Connect the vacuum indicator
2. Air and non-condensables pump has had a chance to or gauge into the system in
will lodge in the condenser; remove all of the water vapor accordance with the
decrease the space for from the system. manufacturer’s instructions.
condensing liquid and cause
the head pressures to rise, Proper Measuring Instrument First Evacuation
thus reducing capacity.
It is not possible to read high A single evacuation of the
Helpful Hints vacuums or low absolute system is not satisfactory to
pressures with a pressure gauge remove all of the air, water, and
If properly evacuated as or mercury monometer. non-condensables present. To
outlined below, the system will do a complete job, the triple
be oxygen free, dry, and there Use the proper gauge evacuation method is
will be no non-condensables to manufactured by McLeod, recommended:
cause problems later. Stokes, and Airserco. These
gauges usually read in the range 1. When the pump is first
If at all possible, the piping from 20 to 20,000 microns. turned on, reduce the system
should not be insulated before pressure as low as the pump
the evacuation process is High Vacuum Pump is able to bring it.
started.
Use a high vacuum pump 2. Allow the pump to operate
The evacuation should not be capable of attaining a blanked for five (5) or six (6) hours.
done unless the room
3. Stop the pump and isolate 2. Allow the pump to operate 2. Allow the pump to operate
the system. for two (2) or three (3) an additional six (6) hours.
hours.
4. Allow it to stand at this 3. Stop the system and allow it
vacuum for another five (5) 3. Stop the pump and allow the to stand for approximately
to six (6) hours. system to stand with this twelve (12) hours at the low
vacuum for a minimum of pressure.
5. Break the vacuum. three (3) hours.
4. Break the vacuum with the
6. Raise the system pressure 4. Break the vacuum with the oil free dry nitrogen.
up to zero (0) with oil free oil pumped dry nitrogen.
dry nitrogen. 5. Allow the pressure in the
5. Raise the pressure in the system to come up to
Second Evacuation system to zero (0). slightly above zero (0)
pounds (drier cartridges and
1. Start the second evacuation, Third Evacuation moisture indicators may be
again allowing the pump to installed in the system).
operate, and reduce the 1. Operate the pump until the
pressure to less than 500 system pressure is reduced 6. Evacuate the system below
microns. below the 500 micron the 500 micron figure and
figure. charge with the refrigerant
being used for the system.

11. CHARGING THE SYSTEM WITH REFRIGERANT OIL

After the complete system When properly charged, the oil Refrigerant Oil
consisting of the Chiller level in the compressor should
(evaporator), high side, and be visible in the compressor Unless otherwise specified, the
refrigerant recirculation unit is sight glass. An oil reservoir may following refrigeration oil
started, it may be necessary to also be used on these units. should be used:
add oil to maintain the proper
level in the compressor (by Other equipment such as the oil • Sun Oil Suniso 3GS
others). filter or oil coolers (when used) • DuPont synthetic oil, 150
also require an oil charge. SSU only
IMPORTANT: Refer to the Therefore, the oil level in the • Texaco Capella B1
manual and specifications compressor and oil reservoir
provided by the supply of all should be rechecked after the Consult the equipment supplier
accessories equipment. The compressor has been operated. specifications.
information provided in this If additional oil is required, add
section applies to optional only the oil specified by the IMPORTANT
equipment supplied by compressor manufacturer. Use Do not mix different types or
TURBO. only dehydrated, wax-free, grades of oil. Do not overfill
refrigerant grade oil of suitable with oil; this is especially true
Note: viscosity. on the hermetic type
Production capacity of the compressors. Make sure the
Chiller is based on an oil free Periodic Checks & Records oil is fresh and not
NH3 refrigerant supply for contaminated.
ammonia systems. Optional The above oil check should be
equipment supplied for the done at start-up or after any Oil Quality
refrigeration system must service work is performed.
provide for proper oil Periodic checks should be done Periodic analysis of oil samples
management. Consult the on a regular basis. Keep by local testing laboratories can
high side and/or refrigerant complete records of any detect unusual build-up of
recirculation package supplier additions to or removal of oil to metals or other contaminants
for additional information on the system. (which result from wear or
oil management. other debris in the oil) before
they become a problem.

12. REFRIGERANT CHARGING

Chillers step 8 – Testing Refrigeration The unit data nameplate lists the
System for Leaks. unit model, refrigerant type, and
All Chiller models are furnished refrigerant charge of the
without refrigerant charge. The Adding Refrigerant evaporator only. Always
entire refrigerant system must monitor and record how much
be evacuated (refer to step 9 – IMPORTANT refrigerant is added. Additional
Evacuating the System) and Before adding refrigerant or refrigerant will be required for
then charged by following the placing the unit in operation, field piping and/or other
procedure set forth under evacuate the entire system to components added to the
“Adding Refrigerant” on this ensure a completely dry systems by others. Never
page. Each unit is shipped with system. Refer to step 9 – exceed the refrigerant charge
a holding charge to keep the Evacuating the System. specified by the “system”
system dry during shipment or supplier.
storage. If the holding charge is Whenever refrigerant is added
not in the system at the time of to any Chiller system, extreme IMPORTANT
receipt or installation notify the care should be taken in charging Do not overcharge the
factory before proceeding. refrigerant into the system. refrigerant circuit because
this induces high discharge
NOTE: Freon Chillers sold The Chiller unit should be pressures. Be sure the correct
with the optional high side as placed in operation and the type of refrigerant is being
self-contained models and liquid level observed during the added to the systems.
shipped within the United first five minutes of operation Ammonia (NH3) and Freon™
States may be shipped with and every hour after that until (R-22) are standard
the operating charge factory the oil level is stable refrigerants for all Chillers.
installed. Ammonia models Refrigerant 404A is available
regardless of options included With the head pressure between as an option.
are shipped only with a 180 PSIG and 213 PSIG,
holding charge for both additional refrigerant, if
domestic and international required, should be slowly
orders. charged into the suction of the
compressor as a gas only (never
Possible Leaks as a liquid). Be sure that all
charging lines are clean and
Chiller units are furnished with properly purged of air. Air is
a nitrogen holding charge to purged from the charging line
keep the system dry during by allowing some refrigerant to
shipping. A leak in the escape while attaching the hose
refrigerant circuit might occur to the charging port.
during shipping or handling. If a
leak is detected, immediate When the liquid level in the
corrective action should be refrigerant recirculation drum
taken before refrigerant gas is and/or receiver (depending the
added to the system. Refer to configuration of the system) is
stable, the unit is fully charged.
TABLE 3-3 Evaporator Operating Charge per Plate

Plate Size Ammonia, pounds Freon R-22, pounds 20% Propylene Glycol,
pounds
48” x 60” 8.1 14.5 19.7
72” x 60” 12.5 22.0 30.0
96” x 60” 17.0 30.0 40.8
24” x 144” 9.1 16.4 22.3
Note: To determine the total evaporator charge, multiply the number of plates in the chiller by the weights
shown per plate in the table. For example a HTDA480606 chiller is an ammonia chiller with six (6) 48” x 60”
plates. The total operating charge of the chiller only would be 48.6 pounds of ammonia (6 plates x 8.1 pounds
per plate).Additional charge will be required for piping and other components in the system.
Remote Air or Evaporative the system dry during shipment (condensers, receivers, etc.) to
Cooled Units (Optional) or storage. prevent excessive pressure
build-up in the system. These
Optional condensing units Refrigerant Recirculation safety relief valves should be
furnished for use with remote Systems (Optional) vented to a safe discharge point.
air cooled condensers (SCAR) Field piping will be required to
or remote evaporative cooled Optional refrigerant vent the valve outside for
condensers (SCER) are shipped recirculation vessels are shipped indoor installations or to a
without the operating charge without a refrigerant charge. location away from exposure to
and will require refrigerant gas. personnel for indoor or outdoor
Follow the procedure set forth Relief Devices installations. Refer to Figure 3-
under “Adding Refrigerant” on 9, Figure 3-10, and Figure 3-11.
this page. Each unit is shipped Relief valves should be installed
with a holding charge to keep on all pressure vessels
Figure 3-9 Typical Optional Air Cooled Condenser Relief Valve Field Piping

Figure 3-10 Typical Indoor Installation Relief Valve Piping of Optional Condensing
Unit
Figure 3-11 Correct and Incorrect Relief Valve Discharge Piping

TURBO provides a relief valve Failure to carefully follow

on all pressure vessels supplied these instructions could result ANSI/ASHRAE 15-1987 code
with optional kits and in permanent injury or loss of permits a maximum back
accessories for are supplied to life. pressure through the relief valve
assist in the proper sizing of discharge piping of 25% of the
relief devices used on the All relief valves are tagged with inlet pressure while the device
Chiller “system” including the above warning or a similar is discharging at rated capacity.
components not supplied by warning.
TURBO. Based on the set pressure and
Do not attempt to add capacity of the relief device, the
WARNING refrigerant to the system before maximum length of discharge
All relief valves must be piped piping all relief valve piping can be calculated using
to a safe discharge location. connections. the formula:
L = [0.2146(d5)(Po2 – P22)/fCr2] – [(d)Ln Po / P2) / 6f] ASHRAE Addendum 15c-2000
where:
L = maximum length of relief valve discharge piping (ft)
P2 = Absolute pressure at relief valve outlet (PSIA)
Po = Absolute back pressure at relief valve outlet (PSIA)
d = Internal diameter of discharge piping (inches)
Cr = Rated capacity of relief valve (lbs. of air per minute)
f = Moody friction factor in full turbulent flow (see list below for factors)
Ln = Natural logarithm
Po = 0.15 P + 14.7 for conventional relief valves

Where P = Set pressure of the relief valve used
Friction factors for typical pipe sizes are:
Table 3-10 Relief Valve Piping Friction Factors
Pipe size Internal Diameter, inches Friction factor, f

½” 0.622 0.0259
¾” 0.824 0.0240
1” 1.049 0.0225
1-1/4” 1.038 0.0209
1-1/2” 1.610 0.0202
2” 2.067 0.0190
2-1/2” 2.469 0.0173
For larger sizes consult ASHRAE, the relief valve or TURBO
For selection of relief valve, the calculated discharge rate is:
C = f DL1

Where:
C = minimum required discharge capacity of relief valve (lbs. of air per minute)
f = 0.5 for NH3
D = outside diameter of vessel (ft)
L1 = length of vessel (ft)
Example:
A Chiller with a water cooled condensing unit using a 12-3/4" diameter x 48" receiver.
Design relief pressure is 300 PSIG.
Refrigerant is NH3 (ammonia) – refrigerant grade.
Minimum required discharge capacity of the relief valve:
C = f DL1 =(0.5)*(12-3/4/12)*(48/12)= 2.1 pounds of air per minute required
And maximum discharge piping length:
L = [0.2146(d5)(Po2 – P22)/fCr2] – [(d)Ln Po / P2) / 6f]
Where:
P2 = 14.7 PSIA
Therefore P22 = 216.09
Po = (0.15*300) +14.7 = 59.7 PSIA
Therefore Po2 = 3,564.09
d = 1.049" (1-1/4" SCH40 pipe)
d5 = 1.2702
Cr = 20.5 pounds of air per minute

Hansen H5600R pressure relief valve 1/2" x 3/4" (inlet x outlet) or equivalent
Cr2 = 420.25
Ln Po / P2 = Ln(59.7/14.7) = 1.401
Then:
L =[(0.2146*1.2702*(3,564.09-216.09)/(0.0225*420.25)] – [1.049*1.401/(6*0.0225)] = 85.6 feet
Therefore, a 1" SCH40 pipe is adequate for installations with relief valve discharge piping less than 86 feet
long. If longer piping is required, a larger pipe size may be required. In the example above a 1-1/4” line could
be used for relief discharge lines up to 394 feet.
For other applications the tables and formulas above should be used to calculate the relief valve size and the
maximum piping distance. For convenience Table 3-11 below shows typical valve selections and piping
distances for the relief valves used on standard TURBO models.
Table 3-11 Maximum Equivalent Relief Valve discharge Piping

Maximum Equivalent Length of Outlet Piping
Relief Pressure, Relief Valve Capacity, lbs/min Schedule 40 Pipe Size
PSIG Size,inches of air ¾” 1” 1-1/4” 1-1/2” 2” 2-1/2”
150 ½” x ¾” 10.6 30 119 524
½” x ¾” 31.3 7 51 125 456
½” x 1” 35.8 4 37 92 344
250 ½” x ¾” 17.2 22 93 422

½” x ¾” 50.5 25 70 298
½” x 1” 57.7 25 70 298
¾” x 1” 17.2 93 422
¾” x 1” 57.7 25 70 298
1” x 1-1/4” 85.4 4 23 124 344
300 ½” x ¾” 20.5 19 86 394

½” x ¾” 60.1 32 88 370
½” x 1” 68.6 21 63 278
¾” x 1” 20.5 86 394
¾” x 1” 68.6 21 63 278
1” x 1-1/4” 101.6 19 113 319
350 ½” x ¾” 24.1 27 113 510

½” x ¾” 70.1 46 118 480
½” x 1” 80.0 32 86 364
¾” x 1” 24.1 27 113 510
¾” x 1” 80.0 32 86 364
1” x 1-1/4” 118.5 29 152 419

13. POST INSTALLATION CLEAN UP

Three critical steps are contaminates that could should be opened at least on a
required to ensure the cause corrosion. weekly basis and the entire
Chiller operates reliably interior and exterior surfaces
and is corrosion free for During shipment the flushed with fresh water. Areas
the life of the chiller and reservoir (if such as the frame and sides of
installation. The three supplied) are stretch the water distribution pan
Golden Rules are: wrapped to eliminate should be watched closely.
a. Ship it clean contamination during These areas typically have
b. Install it clean transportation to the job stagnant water droplets that
c. Keep it clean site. draw free chlorine. If left long
enough the concentration will
Rule #1. Ship it Clean. Rule #2. Install it Clean. increase to the point that the
The equipment must Installation of the chiller passive layer is stripped and pit
leave the factory is a requires connection of carbon corrosion will result.
clean passive state. All steel piping to connections on
stainless steel has a the chiller as well as other The key to a long corrosion free
passive layer that normal grinding, and welding life for your investment is to
provides a protective processes that can contaminate keep it clean. Additional
barrier against the stainless surfaces of the information follows on how to
corrosion. To ensure this chiller. Every effort must be clean the chiller during
passive layer exists. made to eliminate the installation and the basic
TURBO passivates all possibility of this contamination weekly cleaning process.
chillers prior to including covering the chiller to
shipment. Passivation of avoid exposure of the surfaces Chiller Protection during
the entire chiller frame, during installation. To ensure Installation
plate bank, refrigerant the surfaces are clean. Upon A tarp or canvas cover should
headers and water completion of the installation be used during all piping and
distribution pan in a process the final step should be installation work done around
nitric acid passivation a complete cleaning of all thee chiller after it is set in
tank ensures surfaces using a citric acid place and leveled. The cover
contaminates from the cleaner followed by a fresh will protect contaminates from
manufacturing process water rinse and drying. welding, grinding or other
are completely removed installation steps that could
from the surface of the Rule #3. Keep it Clean. come in contact with the chiller
stainless steel After the chiller is put into surface. After the chiller is set
components and a service it must be cleaned on a and leveled the exterior panels
protective passive layer regular basis to ensure that it that were removed during that
exists. remains clean and the stainless step in the process should be
steel surfaces maintain their replaced and closed to protect
After passivation the passive layer. Cleaning and the interior of the cabinet and
exterior panels are sanitizing procedures may vary the reservoir.
installed and all areas of depending on the application
the chiller are again and plant guidelines. However, Weld Zone Clean Up
cleaned to removed as a minimum requirement for Installation of the chiller
any installation the chiller includes welding the refrigerant
connection to the chiller. After for proper use and safety chlorine content) rinse to
the welding has been completed precautions. remove the cleaning agent.
it is recommended that this be .
cleaned. Use a wire brush to Other Areas NOTE: Citric acid cleaning
remove loose scale. Next treat In addition to weld zones any agents are environmental
the area with a passivation area that has been in contact friendly and can be safely
agent such as DeRustit to with carbon steel (tools, pry drain to local drain
passivate the stainless steel next bars, moving devices, etc.) connections.
to the carbon-to-stainless steel should be examined for signs of
weld joint. Follow the discoloration or contamination After the interior surfaces are
instructions on the passivating and if necessary these areas cleaned and rinsed, the same
agent or contact TURBO for should also be passivated. procedure should be followed to
additional information on clean the exterior surfaces.
passivating agents. After If clean lifting straps were used
passivating the weld area should to hoist the chiller into place the If the chiller is to be put into
be rinsed with fresh water. plates should be free of service no additional action is
contamination in the area the required. If the chiller will not
IMPORTANT: The straps were in contact with the be put into immediate service it
passivating process described plates. It may be necessary to is recommended that it be
above is done with a treat the two outer plates that covered until the time it is
passivating gel applied with a the straps are in more contact activated.
brush to the area to be treated with during the lifting process.
and is not the same as the IMPORTANT: Reference
nitric acid passivation Final Cleaning Step 7- Refrigerant Piping for
described at the beginning of Once the installation process additional requirements for
this section. Nitric acid has been completed the securing idle or inactive
passivation is done in a tank complete chiller should be systems.
with the dilute nitric acid cleaned. Using a citric acid
solution at elevated cleaning agent in a spray bottle,
temperatures and the chiller wet all of the stainless steel
immersed in the solution. This surfaces starting on the inside of
process is followed by a the chiller. If necessary use a
neutralization and rinse Scotch-BriteTM Light Duty
process. Only specially Cleaning Pad No. 66 (white in
trained personnel should color) or equivalent. These pads
perform this type of are designed specifically for
treatment. It is not cleaning stainless steel.
recommended for local Abrasive pads of any type
personnel or job site should not be used on the
passivation. stainless steel surfaces.
Abrasive pads or heavy
When using the passivating scrubbing of the stainless steel
gel to do the localized surfaces strips the protective
passivation proper safety passive layer and leads to
equipment including eye corrosion. Contact TURBO for
protection and glove should additional information.
be used. Follow all
instructions on the product The final step in the citric acid
cleaning is a fresh water (low
13.PRE-START-UP CHECKLIST
A. AMMONIA (NH3) SYSTEMS
Customer ________________________________________
Date ____________________________________________
Serial No ________________________________________
Model __________________________________________
Check off the following items prior to start-up of the unit (recirculated or flooded):
□1. Verify that all loose components shipped for field installation are at the jobsite and have been installed
per the manufacturer’s instructions.
Note: The Chiller is a low side evaporator only. Field connection to a condensing unit and
refrigerant recirculation unit or surge vessel are required to complete the system. Field
connections may include water piping, refrigerant piping, electrical controls and power, and
insulation of vessels and piping. Refer to the wiring and piping diagrams provided with the unit
for field connection requirements.
□2. Familiarize yourself with the installation site: the location of safety equipment, eye wash and showers
for exposure to ammonia (NH3), and evacuation plans in the event of an NH3 release.
□3. Review the operating and maintenance manual provided with the equipment. Read the safety section
before starting the installation of the equipment.
□4. Complete the checklist provided with the condensing unit (if applicable).
□5. Complete the checklist provided with the refrigerant recirculation unit or surge drum (if applicable).
□6. Verify that all field electrical connections to the evaporator have been completed per the wiring diagram
provided with the equipment and per the instructions in the operating and maintenance manual. Circuit
breakers and/or electrical disconnects are not supplied by TURBO but are required by code in most
locations. Supply and proper installation of the circuit breakers and/or disconnects to meet all applicable
codes is the responsibility of others.
□7. Verify that all field refrigerant piping connections to the evaporator have been completed per the piping
diagram provided with the equipment and per the instructions in the operating and maintenance manual.
Supply and proper installation of field refrigerant piping to meet all applicable codes is the responsibility
of others.
□8. If the unit is to be connected to an existing central system, verify the interface requirements for the
evaporator to the central system.
□9. Verify that all relief valves have been piped to a safe discharge location (refer to the operating and
maintenance manual for guidelines).
□10. Verify that all field water piping connections to the evaporator have been completed per the piping
Supply and proper installation of field water piping to meet all applicable codes is the responsibility of
others. Flush and drain all water piping and water tanks.
Note: Water piping may include the make-up water to condensers, oil coolers, or components
supplied by others with the condensing unit and/or refrigerant recirculation unit, and the make-
up water connection to the evaporator. Water drain and overflow piping is required from the
evaporator to the proper disposal points (provided by others).
□11. Verify that the complete system has been properly evacuated, leak checked, and charged with the
proper refrigerant (refrigerant grade ammonia - NH3).
Note: Each of the above functions is the responsibility of others. Refrigerant is not supplied with
the equipment.
□12. Note all leaks found and repaired during step number 11.
Checklist Completed By __________________________________

Date __________________________________________________
If you have any questions concerning the above checklist or any other aspect of equipment installation in
preparation for start-up, contact:
Turbo Refrigerating, LLC

Service Department
P.O. Box 396
Phone:940-387-4301
Fax: 940-382-0364

B. DIRECT EXPANSION (DX) FREON SYSTEMS

Customer ________________________________________
Date ____________________________________________
Serial No ________________________________________
Model __________________________________________
Note: The Chiller is a low side evaporator only. Field connection to a condensing unit and
refrigerant recirculation unit or surge vessel are required to complete the system. Field
connections may include water piping, refrigerant piping, electrical controls and power, and
insulation of vessels and piping. Refer to the wiring and piping diagrams provided with the unit
for field connection requirements.
□2. Familiarize yourself with the installation site: the location of safety equipment, and evacuation plans in
the event of a fire or other hazardous situations.
□4. Complete the checklist provided with the condensing unit (if applicable).
□5. Complete the checklist provided with the high side and condenser (if applicable).
□7. Verify that all field refrigerant piping connections to the evaporator have been completed per the piping
Supply and proper installation of field refrigerant piping to meet all applicable codes is the responsibility
of others.
□8. Verify the interface requirements for the evaporator to the high side and condenser.
maintenance manual for guidelines).

Note: Water piping may include the make-up water to chiller, condensers, oil coolers, or other
components supplied by others with the condensing unit, and the make-up water connection to the
evaporator. Water drain and overflow piping is required from the evaporator to the proper
disposal points (provided by others).
□11. Verify that the complete system has been properly evacuated, leak checked, and charged with the
proper refrigerant.
Note: Each of the above functions is the responsibility of others. Refrigerant is not supplied with
the equipment.

Date __________________________________________________

Service Department
P.O. Box 396
Phone:940-387-4301
Fax: 940-382-0364

C. GLYCOL SYSTEMS
Customer ________________________________________
Date ____________________________________________
Serial No ________________________________________
Model __________________________________________
Note: The Chiller is a low side evaporator only. Field connection to a glycol system are required
to complete the system. Field connections may include water piping, glycol piping, electrical
controls and power, and insulation of vessels and piping. Refer to the wiring and piping diagrams
provided with the unit for field connection requirements.
□2. Familiarize yourself with the installation site: the location of safety equipment, and evacuation plans in
the event of a fire or other hazardous situations.
□4. Complete the checklist provided with the glycol unit (if applicable).
□7. Verify that all field glycol piping connections to the evaporator have been completed per the piping
Supply and proper installation of field glycol piping to meet all applicable codes is the responsibility of
others.
□8. Verify the interface requirements for the evaporator to the glycol system.
maintenance manual with equipment supplied by others for guidelines).

Note: Water piping may include the make-up water to chiller, condensers, oil coolers, or other
components supplied by others with the glycol system, and the make-up water connection to the
evaporator. Water drain and overflow piping is required from the evaporator to the proper
disposal points (provided by others).
□11. Verify that the complete system has been properly evacuated, and leak checked.
Note: Each of the above functions is the responsibility of others. Glycol is not supplied with the
equipment.

Date __________________________________________________

Service Department
P.O. Box 396
Phone:940-387-4301
Fax: 940-382-0364

14.START-UP CHECKLIST
The checklist below is a reduction of the actual checklist. Contact TURBO for a full sized checklist.

WARNING! Read the Safety Section before this section. Failure to carefully follow these
instructions could result in permanent injury or loss of life.
Section 4: OPERATING INSTRUCTIONS

This section describes the steel plates mounted in a
Chiller operating sequence and stainless steel frame. The Options for flooded chillers
the function of the Chiller cabinet is enclosed by two inch include a surge drum, water
insulated panels and doors on level controls, high pressure
components and control panel the sides and top. The bottom liquid line controls, a dry
components (if supplied). Hints of the unit is open and sits on suction line pressure regulator
are provided for safe, efficient, top of an insulated sump. and controls, a dual relief valve
and reliable operation of both Chillers can also be assembly for the surge drum, a
the Chiller and associated provided without a sump for surge drum, and oil drain drum.
equipment for operating R-22, mounting over raceways or
existing water collection Options for recirculating
ammonia and glycol systems systems. Optional door and systems include the liquid line
using direct expansion, panel arrangements are valve kit, a suction line kit,
recirculated, or flooded available. Standard Chillers which includes a pressure
systems. Information is also have doors are both ends and regulator, and refrigerant
provided on options including the top. recirculation systems.
recirculators and flooded Options for DX include the
A water distribution pan
system components. Only (stainless steel) and a PVC expansion valve group, the
standard features are discussed distribution header are installed liquid line valves, and a filter
in this section. For optional on top of the plates. drier.
features and accessories, refer
to section 8 – Optional Features Stainless steel refrigerant inlet High side systems are also
& Accessories. and outlet headers are provided available with water-cooled,
on the same side as the water
inlet connection. evaporative –cooled or air-
Operation Sequence of cooled condensers.
HTD Chiller Option kits are available for
the Chiller with either flooded Typical operation of flooded,
or recirculated ammonia or R- recirculated, direct expansion
General Information 22, or glycol. Chillers are also and glycol chillers is described
available in direct expansion
(DX) models. below.
The Turbo high TD chiller
consists of a bank of stainless
Operating Instructions 3/04 Turbo Refrigerating, LLC 4-1

WARNING! Read the Safety Section before this section. Failure to carefully follow these instructions
could result in permanent injury or loss of life.
FLOODED SYSTEM OPERATION

(N.O.) dry contact closes. The
Typical Start-Up Procedure control circuit of the remote The electronic probe has a
Operating Sequence high side should be connected probe column installed in the
to these dry contacts to initiate liquid column. This column has
Refer to the wiring diagram and the start and stop of the system two (2) sensors. One sensor is
ladder logic provided with the (i.e., for systems with dedicated for the high level cut-out. The
unit for complete information compressors, the evaporator second sensor is used to control
on CHILLER-FL model should be turned ON before the the high pressure liquid
controls. compressor operation is started, solenoid valve that supplies
and turned OFF upon refrigerant to the surge drum.
Field connections are required termination of the chilling When the liquid level drops
to the: process). For evaporators below the setting of the
connected to a central system, operating level sensor, the
• Optional operating level the dry contacts can be used to contacts of the sensor close to
refrigerant switch indicate the status of the Chiller energize the liquid solenoid.
• Solenoid coils on the (OFF/ON) at a remote control When the liquid level reaches
suction pressure regulators panel (central equipment the proper operating level, the
(SS‘X’) located above the room). sensor contacts open and the
evaporator high pressure liquid solenoid
• Optional high pressure Optional Refrigerant Level valve closes. The liquid level is
liquid solenoid valve Float Switches (FSHL) - continuously monitored by the
Electronic Level Probe electronic level controls during
Also refer to operating operation.
instructions for additional field Although the surge drum/liquid
connected devices. level assembly is supplied only On flooded models, a liquid
as an option from TURBO, it is level failure indicator light is
As indicated in Figure 4-2, required for the system to provided on the control panel.
typical wiring, the switches function properly. Inputs from This light is connected to a
must be connected to the the electronic level probe and signal from the optional surge
designated input module of the FSHL switch are required to drum/liquid level assembly. If
PLC for the evaporator to control the operating and high the operating level in the surge
operate properly. liquid level in the surge drum. drum is above 50%, the high
If the level reaches the high level refrigerant float switch
Controls (Reference Figure 4- refrigerant level sensor of the (FSHL) should close. Upon
1) electronic level indicator, closure of the switch contact,
operation of the surge drum, the input to the programmable
Compressor Relay (CR1) condensing unit, and evaporator controller (PLC) immediately
are terminated immediately. terminates operation of the
A control relay is provided in The FSHL is a mechanical float evaporator. Field connection of
the control panel to control the switch used as a maximum the FSHL switch is required to
operation of a remote high side liquid level control and is wired ensure adequate protection for
(by others). Through the logic in parallel to the electronic the high side equipment (by
of the PLC, the relay is level probe as a secondary others).
energized via an output of the switch to terminate operation if
PLC. When the relay is the electronic switch should
energized, a normally open fail.
4-2 Turbo Refrigerating, LLC 3/04 Operating Instructions
High Pressure Liquid of the HPLS should be terminal strip numbers in the
Solenoid Valve (HPLS) connected to the controls of the evaporator control panel to
evaporator. Field wiring (by which field connections are
The refrigerant make-up feed to others) is required between the required.
the optional surge drum is evaporator control panel and
controlled by the high pressure the remote surge drum. The coil The HPLS opens, feeding
liquid solenoid valve shown in of the HPLS is connected to the refrigerant to the surge drum
Figure 4-3. The surge output of a PLC module. Refer when the FSOL is closed,
drum/liquid level controls are to the wiring diagram provided indicating a low level.
optional. However, the control with the evaporator for the
Figure 4-5 Typical Optional Surge Drum/Liquid Level Controls

sequence, the surge drum inch differential of the

Flooded Ammonia refrigerant level should be float switch.
below the operating level.
Chiller When the refrigerant feed 8. In the event that the
The following is control circuit is energized, the refrigerant liquid solenoid
sequence typical for operating level and high fails to close or the load
Chillers provided with level refrigerant switches drops (causing the
optional TURBO should both be in their refrigerant level to raise
controls. The operating normal positions. OLFS- above the OLFS switch),
1 and NLFS-1 the high level float switch
sequence can be provided should be closed and contacts would reverse.
by others. OLFS-2 and NLFS-2 This would de-energize
Turn the master control should be open. CR2 the CR1 control relay
control relay would causing LS to close. At
switch (MCS) to the "on" then be de-energized. the same time, the CR2
position. control relay would
The following sequence 6. Under this condition, energize causing the
should occur (Reference CR1 control relay would CR2-1 contacts to open
Figure 4-1): be energized through (which shuts off the
NLFS-L OLFS-1, compressor circuit), and
CR1-1, and CR3-1 (water the CR2-2 contacts to
1. Time delay relay solenoid open) would all close (turning on the
(TDl) energizes. Contacts be closed, resulting in the red pilot light indicating
TD1-1 and TD1-2 refrigerant liquid high level).
instantaneously close. solenoid (LS) being open.
A green pilot light 9. A set of terminal
indicates that the switch is connections are wired
in the "on" position. 7. The refrigerant
level in the surge parallel with CR2 relay
drum rises until the for connection to a remote
2. When TD1-1 is alarm circuit.
closed, the compressor level reaches the
control circuit terminals operating level float
are energized, providing switch. As the float
CR2-1 (N.C. contact of rises up in the float
CR2) is closed. Under chamber, the contacts
normal circumstances, the of the switch reverse
CR2-1 contact should be (i.e., OLFS-1 opens
closed. Compressor and OLFS-2 closes).
controls are provided by When LS closes, a
others. green pilot light
indicates that the
3. At the same time, refrigerant level has
TD1-2 closes, energizing dropped
the refrigerant liquid feed approximately one
controls (i.e., the inch and that the
refrigerant float switches liquid solenoid
and liquid solenoid). will open to maintain
the surge drum
4. When MCS is refrigerant level.
switched to the "on"
position, the water — The hand expansion
solenoid (WS) (open) valve on the liquid feed
contact is energized, line to the surge drum can
operating the water be adjusted to obtain a
solenoid. steady modulation of the
5. During the start-up liquid level within the one
FIGURE 4-1. Typical Chiller Wiring for Flooded system
Operating Instructions 3/04 Turbo

Refrigerating, LLC 4-5
water circulating system

Shut Down Procedure Pump and Water and water distribution
(Flooded Ammonia Distributor Circuit pan(s) may cause the
Chiller) reservoir to overflow.
Turn the master control The chilled water is
switch (MCS) to the "off” drawn from the sump Typical Shutdown
position. (reservoir) and pumped to Sequence
The following sequence the process or other
should occur: distribution points. The The TURBO® Chiller
pump is typically supplied can be turned off without
1. Time delay relay TD1 is by others. pump down of the system
de-energized and the
power to the water during daily operation. If
solenoid switch relay If the water is recirculated the system is to be shut
LPR is removed. or returns to the chiller down for longer time
the return water should periods a pump down of
- The WS (closed) enter at the water the system including the
switch on the motor
actuated water solenoid is connection on the front of evaporator plates is
energized through a the chiller. recommended. For daily
contact block on the MCS operation the chiller
switch assembly, causing The water distribution operation is typically
the water solenoid to header evenly fills the terminated by turning the
close regardless of the water distribution pans. master control switch off.
sump float switch
position. It is also recommended
The water distribution that an emergency stop
2. TD1-2 should open pans allow a thin film of and the safety failure
instantaneously upon water to run over both switches be provided.
turning MCS "off". This sides of the evaporator
should terminate power to plates. This water runs Normal shutdown is
the refrigerant feed circuit
and close the refrigerant continuously while the initiated by turning the
liquid solenoid. machine is in operation. master control switch
(MCS) to the OFF
3. TD 1-1 should start to Overflow Drain Circuit position or by a remote
time open (0-3 minute off signal. Any normally
delay). With the An overflow drain box or closed (N.C.) contact in
refrigerant liquid solenoid
"off" and the compressor standpipe is provided in series with the MCS
circuit "on", the the reservoir to allow for contact blocks in the
refrigerant system should overflow in case of water control system wiring will
start to pump down until surges or interruption of initiate the shutdown
either the compressor flow to the process. sequence. This can
cycles "off” on suction include:
pressure through the
compressor low suction The overflow drain box is
pressure safety switch, or piped to the outside of the • Process controls
the TD1 time delay times unit for field connection • Time clocks
out and the TD1-1 to a drain line. • Remote safety
contacts open. interlocks
During shutdown, the
water that drains back to After a normal shutdown
the reservoir from the sequence is initiated, the
main liquid solenoid automatically restart and prior to use to ensure
valve (LS – by others) is run until the system is that any liquid
de-energized to stop the “pumped down” and the refrigerant that
flow of refrigerant to the compressor stops again. migrated to the
surge drum. The If this sequence continues compressor crankcase
compressors and water more than three (3) times, (by others) is eliminated
pump(s) stop. locate the source of the prior to start-up.
pressure (defective Failure to follow these
Note: solenoid valve, etc.) and instructions could result
The high side package repair. in failure or damage to
can be provided with an the compressor.
optional pump-down Shutting Equipment Off
cycle to keep the For an Extended Period Optional Features
refrigerant in a receiver of Time
or combination Condenser Discharge
condenser/receiver. An extended period of Pressure Control
time is more than forty-
WARNING eight (48) hours. Water Cooled
CHILLER models Optional pressure
equipped with a Close the isolation “king” actuated water regulating
continuous pump down valve on the outlet of the valve(s) are field
cycle can restart receiver or optional installed. Optional
automatically even if the combination cooling tower and cooling
master control switch is condenser/receiver. tower pumps are not
OFF. Never attempt supplied.
servicing the Turn off the three phase
compressor without electrical power to the Evaporative Cooled
locking out the electrical compressor, and water An upstream pressure
service. Failure to pump(s). Disconnect or regulator is in the
carefully follow these circuit breakers furnished discharge line entering the
instructions could result by others. condenser. A hot gas
in permanent injury or bypass through a
loss of life. Do not turn off the single downstream pressure
phase control circuit regulator is provided to
With the optional pump- power. This may turn off maintain receiver pressure
down feature, the unit will power to the compressor during “cold” start-up.
stay off as long as the crankcase heater in the Factory installed on SCE
evaporator pressure is optional high side models; supplied for field
below the setting of the package and optional installation on SCER
low pressure safety winterizing equipment. models.
switch.
IMPORTANT A variable speed fan
If the evaporator pressure If the control circuit motor control (optional)
rises, due to incomplete power has been turned can also be provided to
pump-down or liquid off, it should be turned adjust the RPM of the
bypass around the LS, the on for a minimum of condenser fan motor to
compressor will twenty-four (24) hours
maintain a desired sensor contacts open and of the high refrigerant

discharge pressure. the high pressure liquid level is determined and
solenoid valve closes. The corrected, the controls
Air Cooled liquid level is must be reset before
The fan cycling with continuously monitored normal operation can
flood-back controls by the electronic level resume.
consists of an upstream controls during operation.
regulator in the condenser IMPORTANT
drain line to the receiver. The refrigerant is dropped The system should be
The downstream regulator to evaporator pressure pumped down after a
is in the hot gas bypass through the hand high refrigerant level
line to the receiver inlet. expansion valve. For a trip before normal
26°F system, the pressure operation is resumed.
Refrigerant Float is reduced from a This will eliminate the
Switch condenser pressure of possibility of a liquid
150-250 PSIG to 40 PSIG slug or liquid carry-over
Operating Level for ammonia; 50 PSIG for from the surge drum.
(Electronic Probe R-22. A certain amount of
Sensor) the liquid refrigerant boils High Level (FSHL)
Inputs from the electronic off as a gas due to this A mechanical float switch
level probe are required to sudden reduction in is wired in parallel to the
control the operating pressure. The gas goes to electronic probe high
liquid level in the surge the top of the surge drum level sensor to provide
drum. The operating level and is removed through back-up to the primary
is typically 3" for a the dry suction. high refrigerant level
smaller system and up to controls. The FSHL
4"–6" for larger units. High Level (Electronic switch provides the same
This level is factory set. Probe Sensor) protection as the
The second probe in the electronic probe.
The electronic probe has a probe column is located at Although this should
probe column installed in the high refrigerant level. provide adequate surge
the liquid column This sensor is typically protection for the
attached to the surge located at the 50% level compressor, systems with
drum. This column has of the surge drum. If the multiple evaporators may
two (2) sensors. The refrigerant level reaches require an additional
lower sensor is used to the high refrigerant level “knock-out" drum at the
control the high pressure sensor of the electronic compressor.
liquid solenoid valve that level indicator, operation
supplies refrigerant to the of the surge drum, A set of electrical contacts
surge drum. When the condensing unit, and in the float switch opens
liquid level drops below evaporator are terminated or closes as the float in
the setting of the immediately. The contacts the float chamber rises or
operating level sensor, the of the sensor open to falls with the liquid level.
contacts of the sensor indicate a failure The normally open
close to energize the condition. If the liquid contacts are connected to
liquid solenoid. When the drops after operation is the PLC and remain open
liquid level reaches the terminated, the unit will during normal operation.
proper operating level, the not restart. After the cause If the liquid solenoid
sticks open or the system This set of valves consists solenoid valve without
surges, raising the liquid of two (2) isolating interrupting operation.
level in the surge drum, valves, a strainer, a liquid The isolation valve and
the float raises in the float solenoid valve, and a hand expansion valve are
chamber and the normally hand expansion valve. closed and the bypass
open contacts close to High pressure liquid valve opened for this
signal the PLC that a high refrigerant is metered into mode of operation.
level exists. the surge drum through
the hand expansion Dual Pressure Relief
The PLC immediately (pressure reducing) valve. Valve Assembly
shuts the unit off to A signal from the
prevent liquid carryover refrigerant float switch Two (2) relief valves are
to the compressor. A high energizes the liquid mounted on a three way
liquid level shut down solenoid valve when the manifold with the
requires resetting the liquid level in the surge common connection
controls before the unit drum is below the set going to the safety valve
can be restarted. point. connection located on the
top of the surge drum.
IMPORTANT When the liquid solenoid Each valve has an FPT
Determine the cause of opens, high pressure outlet connection which
the surge or high liquid liquid refrigerant enters should be piped to the
level before returning the hand expansion valve outside or other safe
the unit to normal and is dropped to venting area.
operation. evaporator pressure. The
hand expansion valve can In the event that a relief
The float valve be adjusted to maintain a valve does open, the
components include the steady flow of refrigerant cause of the excessive
float valve and two (2) to the surge drum. If the pressure should be
isolating valves. A hand expansion valve is immediately determined
connection is provided in overfeeding, there will be and corrected. The relief
the surge drum for the a tendency for the float valve in service at the
vent line from the top of switch and liquid solenoid time should be isolated
the float switch to a point to short cycle and cause and replaced.
always above the erratic pressure controls.
maximum liquid level. Closing the valve too Oil Accumulator Drum
The bottom connection much will cause the liquid
should be installed in the level to drop faster than To prevent oil from
liquid leg from the bottom the liquid being added, accumulating in the
of the surge drum. This thus starving the evaporator, an oil
line should be pitched evaporators. accumulator drum is
down to prevent trapping provided for installation
refrigerant oil in the A bypass hand expansion at the bottom of the liquid
bottom of the float switch. valve is provided to allow leg from the surge drum.
operation with the main Included with the oil
High Pressure Liquid liquid feed line closed. accumulator is a pressure
Line This allows service of the relief valve, isolating
strainer and liquid valves for the oil inlet, an
oil pot vent, and oil drain valve. The end of the hose Note:
connections. A pipe plug should be placed in a SET (saturated evaporator
is provided for the oil bucket of water to absorb temperature) for the
drain valve in case of the NH3 removed with the chilling mode is noted
leakage through the valve oil. above. For condenser
or accidental opening of selection use a SET 10°F
the oil drain valve. Once the oil is removed, above Chilling mode SET
close the oil drain valve for calculating the Total
During normal operation, and replace the plug. Heat of Rejection (THR)
the oil inlet valve and oil Open the oil vent line used for selecting the
pot vent valve will always first, then the oil drain condenser. This ensures
be open. The oil drain inlet valve. adequate sizing for start-
valve is closed. As the up and pull down loads.
liquid refrigerant and oil WARNING
flows down the liquid leg, Never leave the oil THR (total heat rejection)
the velocity is very low, accumulator isolated for is evaporator load plus
allowing the heavier oil to extended periods of compressor input for open
separate and go to the time. Excessive pressure compressor at selected
bottom of the liquid leg will develop in the SET. For example:
along with the liquid isolated drum. A relief Chiller SET is 26°F,
refrigerant where it is valve is provided as a therefore select condenser
drained into the oil safety device. Failure to based on 26°F + 10°F =
accumulator. Oil will carefully follow these 36°F
continue to displace the instructions could result THR = Evaporator load
liquid in the oil in permanent injury of (BTU/HR) @ 36°F +
accumulator until it loss of life. compressor BHP @ 36°F
reaches a level requiring it x 2,545
to be removed. Isolation of the drum for
extended periods of time Fluid Temperature
To drain the oil from the means that the small oil Water “on” chiller plates:
oil accumulator, isolate pot built into the bottom Specified by customer.
the oil accumulator by of the liquid leg may not For entering water
closing the oil inlet valve hold all of the oil temperatures above 90°F
and the oil pot vent valve. accumulated. The excess consult the factory
After the oil accumulator oil would then go to the
warms up, check the oil evaporator, resulting in Water “off” chiller plates:
drain valve to make sure poor or erratic operation Minimum 32.5°F for
it is tightly closed and including failure to water; consult factory for
then carefully remove the harvest properly. other fluids
pipe plug from the valve
outlet. Remove the plug Flooded System Fluid Flow Rates
slowly because gas or Operating Parameters Reference Table 4-1
small amounts of liquid
could be trapped in the Saturated Evaporator Surge Drum Location
valve outlet. Next, 26°F Minimum (40 PSIG Minimum 42" for
connect a hose or some for ammonia; 50 PSIG for ammonia; 72” for R-22
other means of draining R-22).
the oil to the outlet of the
This distance is from the
top of the evaporator plate Relief Valve Setting
to the bottom of the drum. 250 PSIG

Direct Expansion (DX) HTD Chillers

consists of the motor/ (on optional high side
Self-Contained DX compressor assembly and package)
Chillers condenser.
Note:
Direct expansion (DX) Various operating Controls necessary for
chillers are typically conditions are described in components used to
supplied with refrigerant this section as well as distribute the chilled
R-22 although direct options available for DX water to points of use
expansion ammonia systems. are not furnished by
systems are also available. TURBO. Such controls
DX chiller use a thermal Controls can be provided as an
expansion valve (TXV) option.
with a refrigerant All DX Chiller models
distributor, and distributor operate in the same basic Control Panel Door
tubes to meter the way and control panel
refrigerant to the components are the same The control panel door
evaporator plates. Since the except for size (larger contains the following
plates are not overfed in magnetic starters for items:
the same manner as pumps, compressors,
recirculated chiller, the gas condenser fan and pump • Master control
leaving the plates is motors, etc.). The control selector switch –
superheated and free of panel contains: ON/OFF
liquid. The dry suction gas • Two 10-amp fuses
leaving the plates is • Programmable logic • Reset buttons for the
returned to the suction of controller (PLC) magnetic starter
the compressor through a • Magnetic starter for overload relays
dry suction line. This line the: • Emergency stop
is connected to a suction – Water pump(s) button
accumulator/heat – Compressor(s) • Warning labels
exchanger before the – Condenser fan and • Data nameplate
compressor to boil off any pump(s) • Safety failure pilot
liquid refrigerant resulting • Magnetic motor light(s)
by momentary overfeed of starter for the optional
the TXV or improper evaporative condenser Refer to section 2 –
adjustment of the TXV fan and pump (where Safety for a list of all
superheat setting. applicable – SCE warning labels that should
Superheat setting is models) be on the control panel
covered later in this • Magnetic motor door. If any labels are
section. starter for the fan(s) missing, contact TURBO
on optional air cooled immediately to obtain the
Self-contained chillers condensers (where missing labels.
consist of the DX chiller applicable – SCA
mounted on a common models) Note:
skid with the condensing • Magnetic motor Refer to the serial
unit. The condensing unit starter for compressor number on the data
nameplate when Emergency Stop Push
inquiring about the Button If the system is off for
controls. A file is more than thirty (30)
maintained under this A large, red, mushroom minutes verify that the
serial number. This head push button with a compressor crankcase
ensures that all normally closed contact heaters on the optional
information required to block is located on the high side package have
assist you can be control panel door and is been on long enough to
accessed quickly and wired into the main boil off any liquid
accurately. control circuit wiring. If refrigerant in the
immediate termination of crankcase.
WARNING operation is required, the
The selector switch is push button is pushed in. Restart the high side
not a service disconnect. This cuts off the single package (compressor) and
Lock out electrical phase control circuit allow it to pump-down
power to controls before power and stops all the system to prevent
performing service. electrical devices located liquid slugging of the
Have a qualified within the unit, including compressor when the
electrician perform all any optional high side or system is restarted. The
service. Failure to liquid recirculation units compressor should shut-
carefully follow these and optional winterizing off on a low pressure
instructions could result controls that are field (suction) safety at the
in permanent injury or wired to the control panel completion of the pump-
loss of life. by others. down. Refer to the
compressor
Electrical Components WARNING manufacturer’s
Description Never use the specifications.
emergency stop button
Master Control Switch as a service disconnect. Return the isolation valve
(ON/OFF) Failure to carefully to the open position and
follow these instructions place the MDS switches
A two position, cam could result in in the AUTO position one
operated master control permanent injury or loss at a time as the unit is
switch (MCS) with a of life. restarted.
normally open (N.O.)
contact block is provided Resetting the To restart, pull out the
to input a signal to the Emergency Stop Push emergency stop push
programmable controller. Button button. Turn on the MCS.
This signal initiates the
logic required to start and Turn the keyed MCS If the emergency stop was
stop the chiller. Turning switch to the OFF used, determine why and
the selector switch to the position. Close the take action to correct the
OFF position initiates a isolation valve in the problem before returning
shutdown sequence. main liquid line to the to normal operation.
Actual termination of evaporator and the
operation occurs isolation valve in the high Control Devices
immediately. pressure liquid refrigerant
line to the optional
recirculation vessel.
Water Pump Selector S immediately be returned failure. The PLC requires

witch (MAN/AUTO)- to the AUTO position for a reset signal after such a
Option normal automatic failure. To reset, turn the
operation. MCS to the OFF position
During normal operation, and then back to the ON
the MANUAL/AUTO IMPORTANT position. Before resetting,
selector switch should The water system does determine the cause of the
always be in the AUTO not have a water level failure and correct.
position. In this position, switch to indicate if
the Chiller water water is in reservoir. If Reservoir Water Level
recirculating pump will the switch is placed in Controls
run to supply water to the the MAN position, the Refer to the chiller
chiller evaporator plates water pump will run manual Options Section
and /or other chilled water even if the reservoir is for the operation of the
distribution points when empty. Damage to the water level controls
the programmable water pump can result (Option #1) for the
controller logic (PLC) from such an operation. chillers. The operation of
output module is ON. At the water level controls is
the termination of the Water Pump Interlock the same for both the DX
chilling operation, the (WP-1) and flooded chillers.
water pump is turned OFF
through the PLC logic. An interlock is installed Safety Failure Relay
on the magnetic starter of (SFR) Dry Contact of
During service, the water recirculating SFR (SFR-1)
maintenance, or cleaning pump. The normally open
of the evaporator plates or (N.O.) WP-1 interlock is A control relay is
reservoir, the water pump used to input a signal to connected to an output of
can be turned ON the programmable the PLC to indicate that a
manually by placing the controller indicating safety failure has
selector switch in the water is being supplied to occurred. If any of the
MANUAL position. In the evaporator plates. If safeties trip, the logic of
this position, the logic of the interlock closure is the PLC will energize the
the PLC is bypassed and not obtained (i.e., the SFR relay. Although the
the water pump(s) will pump starter fails), the control panel does not
operate until the switch is PLC logic will terminate have a safety failure pilot
returned to the AUTO operation of the chiller light on the control panel
position. With the switch after a preset time delay door, the following pilot
in MANUAL, the water is (typically 2 seconds). lights should be ON if a
circulated over the failure does occur:
evaporator plates even if The WP-1 interlock is a
the Master Control Switch proof of water flow signal • Compressor failure –
(MCS) is in the OFF that must be input to the CM-1 interlock fails
position. PLC for normal to close or opens
evaporator operation. during operation
Upon completion of the • Water pump failure –
service or cleaning A red pilot light is located WP‘X’-1 interlock
operation, the selector on the control panel door fails to close or opens
switch should to indicate a water pump during operation (if
the unit has 3 pumps, draws air from the outside Overloads produce
then X = 3; for 4 through an inlet grill and electrical currents that
pumps, then X = 4; filter. exceed the rating of the
etc.) overload causing it to
Control Circuit Fuses produce enough heat to
A dry contact of the open a circuit in the
safety failure relay (SFR- A 10 amp fuse is located overload relay. The
1) is provided for in each leg of the single wiring of the starter coil is
interface to modems, auto phase control circuit connected in series with
dialers, or other remote power to the control the overload relay. As a
alarms to indicate that a panel. On panels using result, the starter will de-
failure has occurred. All control circuit step down energize when the
of the failures indicated transformers, the fuse(s) overload relay contact
will terminate operation are located on the opens.
of the unit. The cause of secondary side of the
the failure must be transformer. Separate A reset mechanism is
determined and corrected circuit breakers (by located on the overload
before the SFR is reset. If others) are required for relay and a push button is
the failure has been the transformer and on the control panel door
corrected, the SFR can be electrical panel service. to operate the “reset”
reset by turning the MCS mechanism on the starter
to OFF and then back to Control circuit overloads overload relay.
ON. or shorts can cause the
fuse(s) to blow. Before WARNINGS
Terminal strip replacing the fuse(s), have Have a qualified
connections are provided a qualified electrician electrician determine the
in the control panel for check all components in cause of the overload
field connections of the electrical panel and on before resetting. Never
remote alarms. Refer to the machine to determine bypass the overload
the wiring diagram the overload cause. relay. Never use an
provided with the unit for Correct all defects or overload size larger than
the terminal strip numbers problems immediately. the size specified by the
to which the connection is Never bypass fuse(s) factory. Failure to
made. protection. carefully follow these
instructions could result
Control Panel Fan Magnetic Starters with in permanent injury or
(CPF) Bimetallic Overload loss of life.
Relay
A ventilation fan is Three bimetallic heater
mounted on the control Each electrical motor elements are factory sized
panel to provide cooling used in the Chiller is and supplied to match the
to the electronics and provided with a magnetic motor horsepower and
electrical components in starter to start and stop voltage.
the panel. The each motor. Each starter
temperature in the control contains an overload relay All magnetic starters are
panel enclosure is (bimetallic type) to supplied with dual
maintained below 120°F protect the motor from voltage/dual frequency
to ensure proper operation overloads. coils (115 or 230 VAC;
of the controls. The fan 50/60 hertz).
• NH3 pump - motors are used for the

Auxiliary interlocks are recirculated units only compressor(s), water
mounted on the magnetic (by others) pump(s), and other
starters to control motors supplied by
auxiliary operations (i.e., Outputs TURBO.
the water pump interlock
is used to input a signal to • Electric motor starter Optional 208 or 575
the PLC, indicating that coils voltage motors are
the water pump starters – Water pumps available for 50 and 60
are energized). • Remote signal to hertz systems. Each motor
optional equipment is bottom wired to a
Additional auxiliary (high side, magnetic starter at the
interlocks can be recirculation unit, factory. Starter top wiring
provided. Consult etc.) (incoming power), motor
TURBO for information. • Solenoid valve coils disconnects, and/or circuit
on refrigerant control breakers should be
Programmable Logic valves (if applicable) furnished by others to
Controller (PLC) meet all local electrical
Additional I/Os can be codes.
Refer to Appendix A. provided for remote
equipment operation Start -Up Procedure
An Underwriter’s (optional). Turn the master control
Laboratory (UL) listed switch (MCS) to the "on"
programmable logic All chiller controls, and position.
controller is used to time delays are The following sequence
control the operating programmed into the should occur:
sequence of the unit. The PLC. Certain time and 1. Time delay relay
PLC consists of the: time-delay presets can be (TD1) energizes.
easily field adjusted Contacts TD1-1 and
• Power supply through the PLC TD1-2 instantaneously
• Central processing programmer pad supplied. close. A green pilot light
unit (CPU with indicates that the switch is
EEPROM) A keyed switch is located in the "on" position.
• Input/output modules on the PLC programmer 2. When TD1-1 closes,
(I/O) to prevent unauthorized the compressor control
access or changes to the circuit terminals are
Each electrical device or program. The PLC energized, providing
group of devices is programmer may be power to the compressor
connected to an I/O removed when not in use safety circuit and the
contact. or password protected to refrigerant liquid solenoid
prevent access to the valve through the TD2-1
Standard Inputs control logic. contacts. TD1-1 is already
closed; therefore, the
• Master control switch Electric Motors liquid solenoid opens and
• Safety circuit the increase in pressure
• Water pump interlock Standard, open, drip- causes the low pressure
(by others) proof 230/460/3/60 cut-out switch (LP) to

"make", starting the cut-out to "make" and start enters a liquid-to-suction
compressor. (If the LP the compressor.) gas heat exchanger where
switch does not close, the the liquid refrigerant
Refrigeration Systems
TD2-1 contact times open (Self-Contained R-22 is sub-cooled. The sub-
and closes the liquid Models: cooled liquid then enters
solenoid valve. To restart SC/SCA/SCE/SCAR and a thermostatic expansion
the chiller, MCS must be SCER) valve where it is
turned "off" and then back metered and fed to a
"on" to reset the time refrigerant distributor
delay relays). Self-contained R-22 and then delivered to the
3. The refrigerant liquid models are available in evaporators where the
solenoid valve is held four types: SC water- refrigerant load is applied
open through a cooled condenser, SCA via the water flowing
compressor interlock and air-cooled condenser, over the outside of the
remains open until the SCE evaporative-cooled, plates. The refrigerant
MCS switch is turned SCAR air-cooled remote, load applied to the plates
"off. and SCER evaporative- causes the liquid
Shut-Down Procedure cooled remote. SCER and refrigerant to evaporate
(DX Chillers) SCAR require installation into a gas. The refrigerant
of the condenser in the gas is drawn from the
The shut-down procedure field; i.e. the condenser is evaporators and flows by
for the DX chillers is the not mounted on a
same as for the flooded means of the suction line
common skid wit the through the
chillers. Refer to the compressor/motor
flooded chiller manual. liquid to suction gas heat
assembly and chiller. All exchanger.
In addition to the of the self-contained This heat exchanger
procedure described in the models have the same introduces a small amount
flooded chiller manual, the refrigeration system and
TD2-1 contact of TD2 of superheat into the
functionally are the same. suction gas that ensures
should close
instantaneously on the DX that no liquid droplets of
chiller. The refrigerant SC Models refrigerant will enter the
liquid solenoid will still The SC models have a compressor. The suction
remain closed, allowing complete refrigeration gas then enters
the system to "pump- system within the
down" since the TD1-2 the compressor where it
confines of the unit is then discharged to the
contact opens at the
same time TD2-1 closes. frame. The liquid water-cooled condenser.
refrigerant charge is The water-cooled
The system will now stored in the lower shell condenser removes the
pump-down and shut-off portion of the heat of rejection induced
on low pressure with combination
refrigerant stored in the by the refrigeration load
condenser/receiver. A at the evaporators
condenser or receiver, as
applicable. When MCS is king valve is provided in and the heat of
turned "on", the system the liquid line leaving the compression and thereby
will automatically restart condenser/receiver. condenses the hot gas
(i.e., TD1-2 contact closes Liquid refrigerant flows
and opens LS through back to liquid and stores
from the condenser / the
TD2-1. Opening the liquid receiver through a filter
solenoid raises the liquid in the lower half of
pressure in the system drier, sight glass and the condenser shell ready
causing the low pressure liquid solenoid valve and
for passage through the to a remote air-cooled

system again. condenser. The condenser
The thermostatic is also available as an
expansion valve is option.
controlled by a sensing
device, which is SCE/SCER Models
temperature actuated, The SCE unit has a
placed on the suction line receiver instead of a
coming from the suction combination
header, and regulates the condenser/receiver and
area of the expansion includes an evaporative-
valve orifice opening cooled condenser piped
through which the liquid into the refrigerant circuit
must flow. During the on the discharge side of
chiller operation, the the compressor. The hot
refrigerant liquid solenoid gas is condensed into a
remains open at all times. liquid in the air-cooled
condenser and then flows
A cooling tower and to the storage receiver.
cooling tower pump re also The SCER units operate
required for the high side the same as the SCE but
and can be provided as are furnished without the
options. The cooling tower evaporative-cooled
is typically not mounted on condenser. A receiver is
the skid with the high side furnished with the SCER
water-cooled condenser. model but must be
installed and connected to
SCA/SCAR Models a remote evaporative-
The SCA unit has a cooled condenser by
receiver instead of a others. The condenser is
combination also available as an option.
condenser/receiver and
includes an air-cooled
condenser piped into the
refrigerant circuit on the
discharge side of the
compressor. The hot gas is
condensed into a liquid in
the air-cooled condenser
and then flows to the
storage receiver.
The SCAR units operate
the same as the SCA but
are furnished without the
air-cooled condenser. A
receiver is furnished with
the SCAR model but must
be installed and connected
RECIRCULATED OPERATION
Recirculated chiller for the vertical evaporator plates.

ammonia and R-22 require a Typical Daily Start-Up The water is ON anytime the
refrigerant pumping system to Sequence unit is running.
supply refrigerant to the chiller.
The refrigerant recirculator The master control switch As the refrigerant leaves the
systems typically consists of a (MCS) is turned to the ON plates, the liquid-vapor mixture
pressure vessel (surge drum) position. is collected in the wet suction
with a wet suction connection, header. The wet suction branch
a dry suction connection, a Through the PLC, a signal line is connected to surge drum
liquid valve connection, a energizes the remote optional (by others). The vapor is
liquid feed assembly with hand high side and recirculation units separated from the liquid in the
expansion valve to reduce the required for operation of the surge drum and returned to the
high pressure line supply to system for a preset time refrigeration high side via the
evaporator pressure, relief interval. dry suction lines.
valve assembly, a primary
refrigerant and stand-by If all other safety switches are Liquid refrigerant is maintained
refrigerant (if specified, and a in a “non-trip” status, the water at a level of approximately 3"
refrigerant level control system pump(s), compressor motor, in the bottom of the surge drum
for the surge drum. The surge and NH3 pump motor energize to ensure an adequate liquid
drum separates the liquid and and the liquid solenoid remains supply to the recirculation
gas returned from the chiller in open. pump(s) at all times.
the wet suction line and return
dry gas to the compressor via With the recirculation unit and Oil Accumulator Drum
the dry suction line. Refrigerant high side (compressor) on, (Optional)
feed to the surge drum is refrigerant is pumped to the
controlled by the refrigerant evaporator plates and water To prevent oil from
level controls. As the chilling flows over both sides of each accumulating in the evaporator,
process evaporates a portion of evaporator plate. an oil accumulator drum is
the liquid flowing through the provided for installation at the
chiller and it is returned to the If the unit fails to start, refer to bottom of the liquid leg from
compressor, liquid to replace section 5 – Trouble-Shooting. the surge drum. Included with
this refrigerant is metered in to the oil accumulator is a
the surge drum through a hand Operation continues in this pressure relief valve, isolating
expansion valve. mode until the unit is turned off valves for the oil inlet, an oil
or a safety failure occurs. pot vent, and oil drain
Typically operating conditions connections. A pipe plug is
and sequence of operation are Typical Refrigerant Sequence provided for the oil drain valve
described below. The operating in case of leakage through the
sequence is typical for Liquid NH3 is pumped to the valve or accidental opening of
ammonia and R-22 chillers. top of each plate bank. Liquid the oil drain valve.
enters the evaporator plates
through orificed headers. Water During normal operation, the
is circulated over the outside of oil inlet valve and oil pot vent
valve will always be open. The A relief valve is provided as a the chiller operation). For
oil drain valve is closed. As the safety device. Failure to evaporators connected to a
liquid refrigerant and oil flows carefully follow these central system, the dry contacts
down the liquid leg, the instructions could result in can be used to indicate the
velocity is very low, allowing permanent injury of loss of status of the chiller (ON/OFF)
the heavier oil to separate and life. at a remote control panel such
go to the bottom of the liquid as the central equipment room.
leg along with the liquid Isolation of the drum for
refrigerant where it is drained extended periods of time means Additional relay contacts or an
into the oil accumulator. Oil that the small oil pot built into interlock of the NH3 pump
will continue to displace the the bottom of the liquid leg should be used to start the
liquid in the oil accumulator may not hold all of the oil compressor/condensing unit as
until it reaches a level requiring accumulated. The excess oil well as to open and close the
it to be removed. would then go to the high pressure liquid solenoid
evaporator, resulting in poor or supplying liquid refrigerant to
To drain the oil from the oil erratic operation. the recirculating unit.
accumulator, isolate the oil
accumulator by closing the oil Control Devices The following sequence may be
inlet valve and the oil pot vent used to control the compressor,
valve. After the oil accumulator Compressor/NH3 NH3 pump, and liquid solenoid:
warms up, check the oil drain Pump/Liquid Solenoid
valve to make sure it is tightly Control Relay 1. The Control Relay (-1)
closed and then carefully contact closes to turn the
remove the pipe plug from the A control relay is provided in NH3 pump on.
valve outlet. Remove the plug the control panel to control the
slowly because gas or small operation of remote 2. An interlock of the NH3
amounts of liquid could be components including the pump (by others) is used to
trapped in the valve outlet. compressor/condensing unit, input a signal to the
Next, connect a hose or some NH3 pump, and high pressure compressor (condensing
other means of draining the oil liquid solenoid. All of these unit) control circuit to
to the outlet of the valve. The components are supplied by initiate start-up of the
end of the hose should be others or as an option by compressor and to energize
placed in a bucket of water to TURBO. Through the logic of the high pressure liquid
absorb the NH3 removed with the PLC, the Control Relay is solenoid valve.
the oil. energized via an output of the
PLC. When the relay is 3. An interlock of the
Once the oil is removed, close energized, a normally open compressor starter is used
the oil drain valve and replace (N.O.) dry contact of the to input a signal to the
the plug. Open the oil vent line Control Relay (-1) closes. The chiller PLC indicating the
first, then the oil drain inlet control circuit of the compressor has started. The
valve. recirculation unit should be interlock of the compressor
connected to these dry contacts would be connected as a dry
WARNING to initiate the start and stop of contact in series with the
Never leave the oil the NH3 pump (i.e., the NH3 pump interlock (AP-1)
accumulator isolated for evaporator and NH3 pump and would provide the same
extended periods of time. should be turned on before the control as the AP-1
Excessive pressure will compressor is started and interlock.
develop in the isolated drum. turned off upon termination of
Note: energize the liquid solenoid
For central plant operations Field wiring by others is valve to feed liquid refrigerant
only, the NH3 pump interlock required for all installations. A to the vessel. When the liquid
input is required to the PLC. jumper is not installed between level reaches the proper
the terminal strip connections operating level, the sensor
NH3 Pump Interlock (AP-1) - when the evaporator is shipped. contacts open, and the high
Recirculating Units Only pressure liquid solenoid valve
Refrigerant Level Float closes.
An interlock of the NH3 Switches (FSHL) - Electronic
recirculating pump magnetic Level Probe The third sensor is used to
starter (AP-1) is required as an terminate operation of the NH3
input to the programmable Although the recirculation recirculating pump if the
controller. The normally open unit/liquid level assembly is refrigerant level in the
(N.O.) dry contact must be field supplied only as an option from recirculation vessel is not
installed by others. The chiller TURBO, it is required for the adequate (too low) to supply
will not operate without this system to function properly. liquid to the NH3 pump. The
input present. Refer to the Inputs from the electronic level liquid level is continuously
wiring diagram provided with probe and the FSHL switch are monitored by the electronic
the Chiller for the terminal strip required to control the level controls during operation.
numbers which the contacts are operating, low, and high liquid
connected to. The NH3 level in the recirculation drum. Pump and Water Distributor
recirculating pump can be If the level reaches the high Circuit
provided by TURBO as an refrigerant level sensor of the
option. electronic level indicator, The water is drawn from the
operation of the recirculator, reservoir and pumped to the
The AP interlock is a proof of condensing unit, and evaporator process or to the water
operation for the supply of NH3 are terminated immediately. distribution header in the
refrigerant to the evaporator The FSHL is a mechanical float Chiller.
plates by the remote switch used as a maximum
recirculating unit. This signal liquid level control and is wired Overflow Drain Circuit
must be received by the PLC in parallel to the electronic
logic for the evaporator to level probe as a secondary An overflow drain box is
operate. If the signal is not switch to terminate operation if provided in the reservoir to
received, the PLC logic will the electronic switch should allow for overflow incase of
terminate operation of the fail. surges in the water flow.
evaporator after a preset time
delay (typically 2 seconds). The electronic probe has a The overflow drain box is piped
probe column installed in the to the outside of the unit for
A red pilot light is located on liquid column. This column has field connection to a drain line.
the control panel door to three (3) sensors. One sensor is
indicate an NH3 pump failure. for the high level cut-out. The Shutting Equipment Off For
The PLC requires a reset signal second sensor is used to control an Extended Period of Time
after such a failure. Turn the the high pressure liquid
MCS to the OFF position and solenoid valve that supplies An extended period of time is
then back to the AUTO position refrigerant to the surge drum. more than forty-eight (48)
to reset. After resetting, When the liquid level drops hours.
operation should be monitored below the setting of the
to determine the cause of the operating level sensor, the Close the isolation “king” valve
failure. contacts of the sensor close to on the outlet of the optional
receiver or optional Do not turn off the single phase be turned on for a minimum
combination control circuit power. This may of twenty-four (24) hours
condenser/receiver. turn off power to the prior to use to ensure that
compressor crankcase heater in any liquid refrigerant that
Turn off the three phase the optional high side package migrated to the compressor
electrical power to the and optional winterizing crankcase (by others) is
compressor, NH3 pumps, water equipment and/or the PLC eliminated prior to start-up.
pump(s), and other motors power supply. Failure to follow these
(disconnect or circuit breakers instructions could result in
furnished by others). IMPORTANT failure or damage to the
If the control circuit power compressor.
has been turned off, it should

Specifications
Specifications Air Cooled compressor BHP @ 36°F x
Condensing 120°F 2,545
Refrigerant (260 PSIG for R-22; 272 PSIG
Refrigerant grade NH3 for ammonia) Refrigerant Feed
(ammonia) – do not use Design dry bulb 100°F Pumped liquid at a recirculation
agricultural grade NH3. rate of 4:1.
Note:
Evaporator Temperature SET (saturated evaporator Make-Up Water
26°F (40 PSIG for ammonia; 50 temperature) for the chilling Temperature
PSIG for R-22) Minimum for mode is noted above. For • Entering water
water; consult factory for other condenser selection use a SET temperature specified
fluids including glycols. 10°F above Chilling mode SET by customer. Above
for calculating the Total Heat of 90°F consult factory
Design Conditions Rejection (THR) used for • Leaving water
selecting the condenser. This temperature minimum
Water Cooled ensures adequate sizing for 32.5°F for water;
Condensing 105°F start-up and pull down loads. consult factory for other
(214 PSIG for R-22; 214 PSIG fluids.
for ammonia) THR (total heat rejection) is
Water in 85°F evaporator load plus Make-Up Water Pressure
Water out 95°F compressor input for open At inlet to water distribution
Design wet bulb: 78°F compressor at selected SET. header 8 PSIG
For example:
Evaporative Cooled Chiller SET is 26°F, therefore Make-Up Water Flow
Condensing 95°F select condenser based on 26°F Flow rates for standard chiller
(181 PSIG for R-22; 181 PSIG + 10°F = 36°F plates are shown in the table
for ammonia) THR = Evaporator load below.
Design wet bulb: 78°F (BTU/HR) @ 36°F +
Table 4-1 Plate Specifications (Per Plate)

Plate Overall Length, inches
48” 72” 96” 144”
Plate Overall Wetted Length, inches 44 68 92 140
Plate Overall Depth, inches 60 60 60 24
Maximum water flow, Gallons per minute 44 68 92 140
Maximum water flow, Gallons per minute 5.5 8.5 11.5 17.5
Internal volume, cubic feet 0.31 0.47 0.64 0.35
Weight, pounds 105 158 210 126
Note: 1. All plate sizes and data are standard for R-22 and ammonia applications.
2. Consult factory for other materials or flow conditions.
3. All data is per plate. To determine total flow for a plate bank multiply the data above by the number of
plates in t he system. For example a HTDA960606 chiller is a flooded chiller with six (6) 96” by 60”
plates. The maximum water flow for this system is:
Maximum Flow = 6 plates x 92 GPM per plate = 522 GPM

Make-Up Water Feed

Control
Reference TURBO option kit
#1 for “Water Level Controls”
Evaporator Plates
304 Stainless Steel
Hydraulically blown to inflate
to proper rise.
304L available as option.
Design Operating Pressure

200 PSIG
Burst Pressure
1,500 PSIG

Optional Features
Condenser Discharge maintain receiver pressure units are provided with flood-
Pressure Control during “cold” start-up. Factory back controls as standard.
installed on SCE models; Variable speed drives are also
Water Cooled supplied for field installation on available.
Optional pressure actuated SCER models.
water regulating valve(s) are Reservoir Water Level
field installed. Optional cooling A variable speed fan motor Controls
tower and cooling tower pumps control (optional) adjusts the
are available. RPM of the condenser fan Refer to the chiller manual
motor to maintain a desired Options Section for the
Evaporative Cooled discharge pressure. operation of the water level
An upstream pressure regulator controls (Option #1) for the
is in the discharge line entering Air Cooled chillers. The operation of the
the condenser. A hot gas bypass Fan cycling can be used in water level controls is the same
through a downstream pressure place of flood-back controls in for both the DX and flooded
regulator is provided to some installations. Air cooled chillers.

GLYCOL SYSTEM OPERATION
Glycol chillers use propylene or Shutting Equipment Off For

ethylene glycol as a secondary Operation continues in this an Extended Period of Time
refrigerant that is pumped mode until the unit is turned off
through the plates to chill the or a safety failure occurs. Glycol chillers should be
fluid flowing over the exterior drained and cleaned both
of the plates. A glycol Typical Refrigerant Sequence internally and external if they
pumping system to supply the are being stored or taken out of
glycol is required (by others). Glycol is pumped to the top of service for extended time
The system typically consists of each plate bank. Liquid enters periods. Extended period of
a pump, and a glycol chiller. the evaporator plates through time is more than 30 days.
glycol supply headers. Water is Refer to the cleaning and
Typical operating conditions circulated over the outside of maintenance sections of the
and sequence of operation are the vertical evaporator plates. manual for additional
described below. The water is ON anytime the information on cleaning.
unit is running.
Typical Start-Up The refrigeration system (by
As the refrigerant leaves the others) for the glycol chiller
The master control switch plates, the glycol is collected in may require a pump down to
(MCS) is turned to the ON the suction header or glycol isolation the refrigerant charge
position. return. The suction/glycol into the receiver or combination
return branch line is connected water-cooled
Through the PLC, a signal to main glycol return line (by condenser/receiver. This is
energizes the remote optional others). typically done by closing the
glycol system, glycol pump(s) isolation “king” valve on the
and the external water system. Pump and Water Distributor outlet of the optional receiver
Circuit or optional combination
If all other safety switches in condenser/receiver.
the glycol system and pumping The water is drawn from the
systems are in a “non-trip” reservoir and pumped to the Turn off the three phase
status, the water pump(s) for t process or to the water electrical power to the
he external flow over the plates, distribution header in the compressor, glycol pumps,
compressor motor and controls Chiller. water pump(s), and other
for the glycol system, and the motors (disconnect or circuit
glycol pump start to supply Overflow Drain Circuit breakers furnished by others).
glycol to the chiller. .
An overflow drain box is Do not turn off the single phase
With the glycol system on, provided in the reservoir to control circuit power. This may
refrigerant (glycol) is pumped allow for overflow incase of turn off power to the
to the evaporator plates and surges in the water flow. compressor crankcase heater in
water flows over both sides of the optional high side package
each evaporator plate. The overflow drain box is piped and optional winterizing
to the outside of the unit for equipment and/or the PLC
If the unit fails to start, refer to field connection to a drain line. power supply.
section 5 – Trouble-Shooting.
IMPORTANT of 10 PSIG or less (16 PSIG problems in chiller with longer
If the control circuit power Maximum). The number of plates (96” and 144” plates).
has been turned off, it should plates used can be adjusted to
be turned on for a minimum ensure the flow rates meet the Consult factory if inlet
of twenty-four (24) hours pressure drop criteria. pressures higher than 85 PSIG
prior to use to ensure that are to be provided to the chiller.
any liquid refrigerant that Glycol Pressure
migrated to the compressor Note: The pressure limit on
crankcase (by others) is As indicated above the glycol the glycol circuit is not to
eliminated prior to start-up. circuit is designed for 10 PSIG prevent plate failures or
Failure to follow these or less pressure drop through leaks. The plate burst
instructions could result in the plates. The maximum pressures are well beyond
failure or damage to the design pressure drop is 16 these pressures. However,
compressor. PSIG. Glycol pumps should be plate bowing that causes
sized for the pressure drop erratic flow over the plate
Specification specified above plus all piping exterior can result. Erratic
Glycol Temperature losses, elevation losses, and flow can affect the chiller
valves losses. For example, performance including high
The temperature of the glycol select a glycol pump for the leaving fluid temperatures
pumped through the evaporator following conditions; and freeze up in areas starved
plates is determined by the for adequate fluid flow.
application to obtain the desired • Glycol flow rate: 138
fluid temperature of the gallons per minute
external flow over the plates. If (GPM).
the external flow is water, the • Refrigerant: 42 %
glycol temperatures would propylene glycol
never be lower than 25°F. The • Pressure drop –
flow rate through the plate(s) as evaporator: 11 PSIG
well as the glycol temperature • Pressure drop –system
and concentration can be (piping, elevation, and
adjusted to obtain the desired valves): 15 PSIG
leaving temperature of the Solution:
external fluid. • Total pressure drop = 11
+15 = 26 PSI
The glycol entering and leaving or
temperatures are calculated for • For 42% propylene
each application to meet the glycol at 65.4 pounds
refrigeration load and external per cubic foot = 57.2
fluid temperature requirements. foot of head.
Pump selection:
Glycol Flow • 138 GPM at a 57.2 foot
The flow for the internal
head (26 PSI).
glycol flow is calculated for
each application to provide the
The maximum glycol pressure
maximum performance without
at the inlet to the glycol circuit
minimal pressure drop through is 85 PSIG. Above 85 PSIG,
t he plates. Flow rates are
the plates deflect enough to
typically selected for a pressure
cause water distribution
drop through the glycol circuit
WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.
Section 5: TROUBLE-SHOOTING
This section lists common problems and suggests solutions with various chillers and chiller systems. Some of the problems and solutions
apply to optional equipment o r equipment supplied by others and may vary. Many problems are easy to solve if you know what caused
them. If your problem is not covered in this section, contact Turbo Refrigerating at: 1-940-387-4301 Ask for the Service Department.
The following pages describe problems you might encounter and provide diagnostic instructions and solutions.
PROBLEMS AND SOLUTIONS

Problem Causes Solutions
Compressor will not start. No three phase or control circuit Check fuses and disconnect. Reset tripped circuit breakers.
Note: For optional power, tripped circuit breaker.
compressor supplied
by others or Blown fuse. Reset or replace manual reset.
separately, consult
supplier’s data for Refrigerant recirculation unit or Determine cause of low recirculator before restarting.
additional pump(s) “off” or “tripped”.
information.
Improper signal at the programmable The run and power lights must be on for unit to operate. Check
controller. for loose connection and control circuit power to controller.
Chiller MCS turned off. Turn switch to “ON” position. For dedicated system the
icemaker should be on before the compressor starts.
Trouble-Shooting 03/04 Turbo Refrigerating, LLC 5-1

or loss of life.
Emergency stop button depressed. Determine reason emergency stop button was used and correct
before resetting.
Overload relay on magnetic starter Determine cause of motor overload. Depress manual reset
tripped. button.
Unit drawing high amps Loose terminal connections. Tighten connections (qualified electrician).
(compressor or water pump
motors).
Defective motor bearings or motor. Replace. Check compressor/motor alignment and mounting
bolts before restarting.
Motor defective. Replace or rewind.
Debris or restriction preventing Clear obstruction and restart.

normal operation.

or loss of life.
Chiller evaporator temperature too High discharge pressure: Check pressure sensing connection to regulator. Replace if
high; leaving water temperature too - Defective water regulating valve necessary.
high (water cooled).
- Fouling at condenser (water cooled). Clean condenser by brushing and/or acid treatment. Consult
. manufacturer for water treatment recommendations.
- Faulty water pump (water or Replace pump. Check pump suction and discharge for
evaporative cooled). obstructions.
- Fouling at condenser (air cooled). Clean with air, water hose, or brushing. Remove debris from
condenser inlet.
- Flood back valves out of adjustment Adjust to maintain 180 PSIG.

(air or evaporative cooled).
- Belt worn or loose causing belts to Adjust, replace belts.

slip (air or evaporative cooled).
- Fan turning too slow (air cooled). Change sheave to increase speed up to FLA of motor. Consult
factory before restarting. Check for restrictions.
Ammonia Recirculated Models:

NH3 pump off or flow restricted Check pump overload. Check pump suction and discharge for
(recirculated system). obstructions. Check bypass pressure regulator. Rebuild pump.
Low on NH3. Search for leak and repair. Add refrigerant to maintain proper
. level in recirculator or surge drum (flooded) and high pressure
receiver

or loss of life.
Hand expansion valve improperly Balance all hand expansion valves to maintain adequate
adjusted. refrigerant to all sections. Open the valve(s) if necessary until
proper evaporator temperature is obtained. Note: It may be
necessary to close the hand TXV to other sections/chillers to
increase flow to chiller that is not operating properly. Adjust
hand expansion valve to maintain 40-45 PSIG in each chiller.
Reference chiller specifications for evaporator temperature.
Plugged or restricted strainer on Clean strainer. Restrictions can be observed by temperature

liquid or recirculation unit (by others). drop across the strainer resulting in lower temperature at outlet.
If temperature can not be measured isolate the strainer and
remove it for visual inspection.
Plugged or restricted liquid line Clean strainer. Restrictions can be observed by temperature
strainer. drop across the strainer resulting in lower temperature at outlet.
If temperature can not be measured isolate the strainer and
remove it for visual inspection.
Air or other non-condensable in Bleed air from condenser. Replace refrigerant charge if
refrigerant system. contamination can not be removed.
Restriction in piping. Check all isolation valves for proper position – open or closed.
Except for the hand expansion valves all other valves should be
fully open or closed and should not be used for throttling or
flow control.
Power off to condensing unit. Check power, circuit breaker, and disconnects to all motors,
starters, and control switches.

or loss of life.
Insufficient water flow to condenser Clean or replace.
(water cooled): Check adjustment. Replace if required.
- Strainer plugged. Check water pump impeller for wear – replace impeller or
-Float valve defective (make-up water pump if necessary.
line to cooling tower).
-Pump impeller worn
Condenser pump prime lost – low Add water to cooling tower. Determine cause of water loss.
water level in sump. - leak in sump or piping
. - water line broken
- isolation valve in water line closed
Condenser water make-up valve closed Clean, repair, open, or replace valve.
or restricted.
Recirculating water pump off: Check pump for restrictions. Reset starter overload relay.
-Motor overloads tripped. Locate water feed restriction. Add water to tank.
-Water recirculating pump prime lost. Remove and clean.
Low water level in reservoir. Remove and clean.
-Strainer plugged. Clean, repair, or replace valve. This check is installed and
-Check valve stuck closed. normally located outside the unit at the liquid line connection to
-water connection broken or water the ice generator
supply lost
-water level sensor switch defective Verify connection to the water solenoid valve and check the
upstream water piping and valves outside unit.
Verify the solenoid opening in response to the water level

sensor switch signal. Verify the water level assembly is
properly positioned – make sure assembly in firmly in place and
has not slipped down in the mounting bracket.
Note: Some older models were not equipped with a make-up

water header. Consult the factory for additional information.

or loss of life.

-water solenoid coil failed Verify the coil energizes when the output for the water solenoid
is on. It can also be tested by applying power from the control
circuit L1 to the water solenoid coil using a jumper to
temporarily pulse the coil
Evaporator plates oil logged. Drain oil from NH3 recirculation unit oil reservoir. Raise
evaporator plate temperature by placing manual defrost switch
(MDS) in manual position or by spraying plates with warm
water (not to exceed 90°F).
Orifice in liquid header to evaporator Consult factory.

plate plugged.
High suction pressure. Water temperature too high. Water temperature above 60°F (based on incoming city water).
Improperly adjusted hand expansion Check expansion valve adjustment (close to reduce refrigerant
valve (overfeeding refrigerant). flow). Set to maintain 15 PSIG in all sections.
High discharge pressure. Refrigerant system overcharged. Verify actual charge. Reduce charge as required.
Note: Optional condensing unit
supplied by others or Dirty condenser. Clean.
separately, consult supplier’s
data for additional information. Non-condensable in refrigerant. Air in system. Remove by purging.
Readjust to correct setting.
Head pressure controls improperly set. Normally 190–220 PSIG for water cooled; 170–190 PSIG for
evaporative cooled; 210–250 PSIG for air cooled.
Discharge line check valve inoperative Check and replace if required.

or partially open.
or loss of life.
Check position of all isolation valves Open all valves fully open or to correct position. Make sure all
and pressure controls. pressure controls are properly adjusted and in automatic
position.
Low oil pressure. Oil reservoir full indicating need for Drain oil reservoir and add new oil to compressor.
Note: Optional condensing unit maintenance.
supplied by others or
separately, consult supplier’s Plugged or stopped up oil strainer. Clean. Purge line.
data for additional information.
Low oil level in crankcase. Consult supplier’s data.
Defective compressor oil pump. Check rotation and wear. Replace as required.
Oil leak Check all areas around system for signs of oil leakage. Repair
leak and recharge system with oil.
Excessive vibration of motor Misalignment. Realign to within specifications.
and compressor.
Note: Optional condensing unit Loose motor/compressor hold down Tighten. Check alignment.
supplied by others or bolts.
separately, consult supplier’s
data for additional information. Flooding of compressor. Adjust high pressure liquid line hand expansion valve setting.
Check refrigerant level controls on NH3 recirculation unit to
Excessive motor temperature. Defective or worn bearing. ensure high refrigerant level switch is operative.
Note: Optional condensing unit
supplied by others or Structural support under unit Remove coupling and check bearing.
separately, consult supplier’s insufficient.
data for additional information. Reinforce structural support. Shim as required. Consult factory
for guidelines.

Section 6: MAINTENANCE
To help you get the best Weekly Inspections (Includes • General neat
performance from your Chiller accessory equipment used housekeeping
system, follow the maintenance with the Chiller System)
instructions listed below. If you Clean the chiller weekly:
have questions concerning the Check the oil level in the • Clean the water
maintenance or upkeep of your compressor. distribution pan and
equipment, contact: header. The
Check for signs of oil leakage. distribution header
Turbo Refrigerating can be easily
Service Department Check the refrigerant liquid disassembled to
P.O. Box 396 level in the receiver (if remove debris inside
Denton, Texas 76202 applicable) or during pump- the header or clear
Phone: 940-387-4301 down to ensure that the level is plugged holes.
Fax: 940-382-0364 proper and has not changed • If necessary remove
the water distribution
Daily Inspections Check the receiver. Inspect header from the water
valve packings and relief valve distribution pan and
Inspect the chiller daily to for indications of refrigerant wipe out all loose
determine that the unit is loss. debris in the pans.
operating properly. Observe t he Unplug holes in the
fluid flow over the plates to Check for 20-30% refrigerant pans as required to
ensure the water distribution level in the receiver (or the ensure complete flow
system is free of debris. Check supplier’s recommendation) over the entire plate.
as required. while operating. • Check for indications
of discoloration on
When starting, observe that the Check unit at least once a week. the frame, water,
discharge and suction pressures A visual inspection includes and pans, panels, and
are correct on the gauges and is not limited to: headers. If necessary
are stable to ensure the proper • Leaks use citric acid to
refrigerant feed to the chiller. • Vibration of piping clean the areas using
on other components a non-abrasive
• Capillary tubes cleaning pad. Follow
rubbing the cleaning with a
• Unusual noises fresh water rinse.
• Tight bolts, nuts,
screws
Maintenance 03/04 Turbo Refrigerating, LLC 6-1
After Initial Ten Hours of • Solids build-up on the unit, contact a local reputable
Operation interior of water cooled supplier of chemical and
condenser (if so equipped) cleaning sanitizing products.
Check for indications of Based on the knowledge of the
discoloration on the frame, To avoid these problems, local water conditions, the
water, pans, panels, and consult a local water treatment material to be cleaned (304
headers. If necessary use consultant and follow these and/or 304L stainless steel), and
citric acid to clean the areas guidelines below. the operating conditions of the
using a non-abrasive equipment, they can
cleaning pad. Follow the Goldenrod water treatment recommend a cleaning and
cleaning with a fresh water systems are also available from sanitizing product to meet your
rinse. Vogt Ice. The Goldenrod can specific needs.
eliminate scaling problems in
After Initial Fifty Hours of most cases. Consult the factory Helpful Hints
Operation for additional information.
1. Chlorine will attack
Check for indications of Plates Forming Scale stainless steel. Most water
discoloration on the frame, supplies contain chlorine in
water, pans, panels, and Flush plates with an acceptable levels too low to cause
headers. If necessary use icemaker cleaner – typically concern. Some cleaning
citric acid to clean the areas citric acid. Have water agents contain high levels of
using a non-abrasive analyzed. chlorine and should be
cleaning pad. Follow the avoided unless the cleaning
cleaning with a fresh water Stainless Steel Surface process can be closely
rinse. Cleaning controlled and a thorough
rinsing of the plates and any
Have a qualified electrician Scale on the chiller plates other parts coming in
check the control panel for resulting from mineral deposits contact with the cleaning
loose connections or loose lugs in the water and other sources agent can be ensured every
on the magnetic starter. of contamination can reduce the time.
efficiency of the plate. If left
Every Six Weeks untreated, it may result in 2. Water scale can be removed
deterioration of the metal using dilute nitric acid under
Grease all greasable fittings on surface thus reducing the life of 1% or phosphoric acid
the shaft bearings. the plates. under 5% at temperatures no
higher than 105°F. These
Water Scale Build-Up The life and efficiency of the solutions must be free of
plates are dependent on proper salt and thoroughly flushed
One of the main concerns with care and cleaning of the surface. from all surfaces
any system using water is scale Since conditions and immediately after use with a
build-up resulting from: installation of equipment vary 1/4% caustic and plain
from location to location, it is water flush.
• Solids forming the plates difficult to provide a simple
• Solids build-up in the water solution to selecting a cleaning Citric acid cleaning agents
distribution pan and headers and sanitizing method. To are also recommended for
obtain the best care for your frequent cleaning. Regular
03/04 Turbo Refrigerating, LLC 6-2 Maintenance
use eliminates the need to Air cooled condensers can be

use stronger acids such as Dirty or scaled tubes in water washed out using a water hose
the nitric acid mixture to cooled condensers can cause and flushing out against the
remove built up scale. high discharge pressure. airflow. Prior to performing this
Periodically remove the service, ensure that the electric
3. Hydrochloric and sulphuric condenser head and use a circuit is disconnected and
acid should not be used. condenser tube cleaning brush locked out. Lubricate the fan
to remove scale. Acids or bearing and tighten belts where
Scale and Solids Forming In chemical additives can also be equipped according to the
Water Tank used. Care should be exercised manufacturer’s specification.
Drain and flush tank at least when using acid. Follow
once a week. Solids can stop up directions on the container Note:
the holes in distribution pans. (consult local chemical TURBO recommends that
Clean pan by using an air hose, treatment supplier). warnings and labels for any
a vacuum cleaner, or a brush. If additional equipment not
excessive or frequent cleaning Cooling towers should be supplied by TURBO need to
is required, consult the factory. treated for scale and algae when be added to the weekly
needed. inspection sheet.
Clean strainer in make-up water
line.

Table 6-2 Sample Weekly Maintenance Log Sheet

Date
Evaporator plates clean

First Shift Start First Shift End
Second Shift Start Second Shift End
Third Shift Start Third Shift End
Frame, panel interior, water distribution pan and headers clean

Water flow across all plates providing complete wetting of plate surface
Chiller High Side Head (discharge) Pressure within normal range (Reference
manual for various refrigerants and condensing types)
Chiller Suction Pressure within normal range (Reference chiller

specifications for proper pressure)
Compressor Oil Pressure

Chiller Entering Water Temperature within Normal Limits

03/04 Turbo Refrigerating, LLC 6-4 Maintenance

Chiller Leaving Water Temperature within Normal Limits

Chiller Inlet Water Pressure within Normal Limits

Ambient Temperature
Operators
First Shift
Second Shift
Third Shift
Remarks
First Shift
Second Shift
Third Shift

Section 7: OPTIONS AND ACCESSORIES
Option Kits kits for the chiller water and

components for the Figure 1 below shows the
A number of options are refrigeration systems as well basic option kits available
available with HTDA, HF as condensing units, for chillers.
AND UHTD chillers. A few refrigerant recirculation
of the options are described packages, complete skid
below and include the basic mounted systems and more.
Figure1. Chiller Option Kits – Flooded and Recirculated Models
Options & Accessories 03/04 Turbo Refrigerating, LLC 7-1

Starting with the sump the

Standard option kit empty and MCS "on", the N.C. FS contact to
descriptions: following sequence open. When FS
opens, the LPR
Option #1 would occur: relay de-energizes
Water Level Controls – causing the
1. The float switch (FS) N.C. contacts to
All Chiller Model should be on the close. The WS
bottom of the (closed) switch on
The water level controls "splash" enclosure. the water solenoid
consist of a motor The normally is energized
actuated water solenoid, closed contact of the and the water
water strainer, and a load-pack relay (LPR) solenoid valve
float switch assembly. should be open and closes.
the LPR relay should
The float switch assembly be — If the sump water
consists of a SPDT switch energized. level drops below
mounted in a "splash" FS and MCS is
enclosure on the 2. With the LPR "on", the FS and
end of a stainless steel energized, the the LPR relay
rod. This rod acts as the normally open contact contacts should
adjusting arm and wiring should be closed, reverse. The WS
conduit for the float energizing the WS (open) switch in
switch. A wiring junction (open) switch of the the water solenoid
box is mounted on top of water solenoid. The
valve should rotate a should be
the rod. emerged and the
1/4 turn and stop,
permit- valve should
A set of plastic blocks are rotate 1/4 turn to
attached to the fixed ting water to enter the
sump. the open
lower panel in the upper position.4. FS
frame of the chiller. and the LPR relay
The top block can be 3. Water will continue to
enter the sump until will continue to
removed and the rod maintain the
assembly installed either MCS is turned
"off" or the water desired water
between the two blocks. level until MCS is
Loosen the two (2) bolts level
holding the plastic blocks reaches FS. turned "off" (see
together and move the note 3).
assembly up or down as — If MCS is turned
required to obtain the "off", power to the Notes: If the sequence
desired water level in the common terminal of the water solenoid
sump. on the LPR is is opposite the
disconnected sequence described
The float switch contacts and switched to
are rated for pilot duty the WS (closed) above, it can
only. A solid state switch on the be reversed by
switching relay (LPR) is water solenoid changing the wires on
used with the float valve. the N.C. and the N.O.
switch to activate the contacts of the LPR
motor actuated solenoid. - If the water level
Refer to the wiring reaches FS, the relay or turning the
diagram for connections. float moves up float on FS.
the stem of the
switch causing 4. A CR3 control relay is
shown in parallel with the WS (open) switch of the

omitted, a pilot light, controlled in the water
water solenoid. Its surge suppressor, return connection or
function is to close the metal-oxide variator, make-up water
refrigerant liquid solenoid or some type of load connection.
valve when the water sup- must be wired parallel Flow control valves
ply is shut off. This is with WS (open) in may also be used on
done to prevent surging of order for the LPR relay the outlet connection
the low pressure surge to function properly. of the sump to
drum during maintain a steady
no load conditions 4. Water level controls sump water level.
are intended for use at
If a different method a high level control.
of control is used and Water flow to the
the CR3 relay is chiller can be
Figure 2. Water Level Controls Option

wet suction connection match the design

Option #2 on the end opposite the conditions for the
Surge Drum (Flooded liquid log connection, a application. Sufficient
Ammonia) dry suction connection to volume is allowed for
the high side, a high pull-down
A low pressure vessel pressure liquid and operation at higher
(surge drum) operating at connection, a relief valve loads for short periods.
evaporator pressure is connection and a gas Float switch assemblies
used to maintain a liquid (top) connection for the should be set to a
seal on the evaporator, refrigerant float switch seven inch high level
and provide separation of assembly. The bottom setting.
the liquid from the vapor float switch assembly is
in the wet re- installed in the liquid leg Insulation of the surge
turn line. by others. drum and all connections
The normal operating is field installed by
Each surge drum is others.
provided with a liquid level in the surge drum is
leg connection in the three inches. Each surge
bottom of the drum, a dram is sized to
Figure 3. Typical Surge Drum

Option #3
Oil Drum (Ammonia) exposure
to ammonia in the
In flooded ammonia event of an accident
systems, the refrigerant Failure to carefully
oil contained in the liquid follow these
ammonia must be re- instructions
moved from the system could result in
before it enters the chiller permanent injury or
plates. The liquid leg loss of life.
from the surge drum
to the chiller is not
provided with any of the
option kits. When the
liquid leg is field in-
stalled, it should be
provided with an oil pot
lower than the horizontal
portion of the liquid
leg. This allows the oil to
collect in the bottom of
the liquid leg before it
reaches the chiller
refrigerant inlet.
To remove the
refrigerant oil, an oil
drain drum with an
isolating valve is
provided. This
drum is also provided
with a 150 # relief
valve.
The isolating valve,
located between the oil
pot on the liquid leg and
the drum inlet, is
closed.
A drain valve is located
on the bottom of the oil
drum to remove the oil.
________________________________ WARNING __________________________

Only qualified service
personnel should
remove oil from the oil
drum. Such personnel
should have proper
knowledge of handling
ammonia as well as
treatment for
between the valves.

NEVER leave the
Option #4 isolating valve closed
Liquid Line Valve unless service is being
Package performed. When
operating the strainer
High pressure or solenoid valve, the
refrigerant is supplied refrigerant between
to the surge drum the isolating valve
through a refrigerant must be bled off
solenoid valve, slowly. Failure to
strainer, and hand carefully follow these
expansion valve to instructions could
drop the pressure to the result in permanent
lower system operating injury or loss of life.
pressure in the surge
drum.
A by-pass hand
expansion valve is
piped in parallel to the
refrigerant solenoid
valve, strainer, and
isolating valve. By
closing the main hand
expansion valve and
isolating valve, the
solenoid valve and
strainer may be serviced
without shutting the
system off (for service
or emergency use only).
The operation of the
refrigerant solenoid is
controlled by the float
switches OLFS and
NELS mounted on the
surge drum.
________________________________ WARNING __________________________

Only qualified service
personnel should
attempt to service the
refrigerant solenoid
valve or strainer.
When the isolating
valves are closed and
the line is exposed to
heat, excessive
pressure can develop
Isolating valves are

provided on both sides of
Option #5 the pressure regulator so
Suction Line Package that it can be serviced
with Pressure without affecting the rest
of the system.
Regulator
To prevent ice
formation on the chiller
plates due to variations
in system loading, a
suction pressure
regulator is installed in
the dry suction line
from the surge drum to
the system high
side.
During periods of low
load on the system,
resulting from reduced
water flow or lower
temperature water
entering the chiller, the
suction pressure
regulator senses the
lower upstream
pressure (surge drum
pressure) and modulates
to close the regulator.
As the regulator closes,
the upstream pressure
increases. As the
pressure increases, the
regulator modulates
open to reduce the surge
drum pressure. The
regulator continues to
modulate and control the
surge drum pressure to
the desired pressure
setting.
For a typical chiller
system using water as
the chilled media, a
suction temperature of
26°F can be used
without icing the chiller
plate(s).

and relief valve.

Option #6 Failure to carefully
Dual Relief Valve follow these
Assembly instructions could
result in permanent
Two pressure relief injury or loss of life.
valves mounted on a
three-way valve are
needed to protect the
surge drum from
excessive pressure.
For ammonia systems,
a 150 PSIG relief valve
is used. Only one relief
valve is in use at a
time. If the relief valve
in use should open, the
chiller should be shut
off immediately and
the cause of the
problem determined.
Before restarting the
chiller, the three-way
valve should be closed
to isolate the relief
valve in
use at the time of the
overpressure. When the
three-way valve closes
the 'Ar relief valve, it
opens the 'B' relief
valve thus providing
continuous protection.
After the first valve has
been isolated, it should
be replaced with a new
valve.
________________________________ WARNING __________________________

Only qualified
personnel should
attempt to replace the
relief valve. Caution
must be
used in removing the
valve to prevent
sudden exposure to
refrigerant between
the three-way valve

control circuit is OLFS.

energized.
Option #7 Each float switch is
Refrigerant Level 2. At start-up, the provided with two (2)
Control refrigerant is below isolating valves to
the level of the allow service of the
Two refrigerant floats are operating level float switches without
(OLFS) and high purging the entire surge
used to control the drum.
level (HLFS) float
refrigerant level in the switches, therefore,
surge drum. the refrigerant liquid
solenoid valve should _______________________________ W
The normal refrigerant energize to feed
operating level in the liquid to the surge Only qualified service
surge drum is three drum through the personnel should
inches and is controlled hand expansion perform service work
by the lower operating valve. or remove the float
level float switch switches. Caution
(OLFS). The refrigerant The solenoid valve must be used to
liquid solenoid will will remain open remove the refrigerant
remain open and feed until the liquid level contained in the float
refrigerant through the reaches the operating switch chamber and
hand expansion valve in level of the OLFS piping from the
the liquid line until the and then it closes. isolating valves to the
refrigerant level raises float switch. NEVER
the float in the float 3. As the liquid level in leave both isolating
switch. This causes the the surge drum drops valves closed except
switch contacts to below the differential when performing
reverse and shut off (approximately one service (i.e., when
refrigerant flow to the inch) of the float exposed to heat,
surge drum. switch, the liquid excessive pressure can
solenoid should open develop between the
If the OLFS switch and feed refrigerant two isolating valves
should fail to shut off the to the surge drum when closed. Purge the
refrigerant or if the until OLFS reaches refrigerant as soon as
system should surge, a its operating level possible after closing
high refrigerant level and shuts the liquid the valves.) Failure to
switch (HLFS) is also solenoid "off. carefully follow these
provided. The HLFS instructions could
switch shuts off the 4. If the refrigerant result in permanent
refrigerant liquid level does not reach injury or loss of life.
solenoid, as well as the the operating level,
compressor circuit. the hand expansion
Contacts are also valve should be
provided for connection opened SLOWLY to
to a remote alarm circuit. allow additional
refrigerant flow.
Adjust the hand
A typical operating expansion valve until
sequence is described there is a steady
below: modulation of the
1. The refrigerant level refrigerant solenoid
valve through
Aligning motor and Motor/Compressor Assembly equipment. The following

compressor assembly procedure is used:
Chiller models are furnished The motor/compressor
with direct coupled motors and assembly is doweled to the base 1. With the compressor at
compressors. The coupling after the factory alignment is operating temperature,
center section is shipped loose completed to help maintain verify the compressor
for field installation. The alignment and aid in alignment.
compressor and motor are repositioning the motor after 2. With the compressor still at
carefully aligned at the factory servicing. operating temperature, drill
before testing. and ream two (2) holes
Compressor Alignment diagonally opposite on both
Coupling Center the compressor and motor.
If, for any reason, the Do not ream the holes too
Check for alignment before compressor alignment is not deep. Part of the dowel pin
inserting the coupling center within tolerance after should protrude above the
section. reinstallation of the coupling, it compressor or motor foot
must be realigned (refer to (see step 4 below). See
Compressor Motor Table 3-1). Figure 3-12.
Inspect the compressor motor Doweling Procedure Tools Required:

alignment with a dial indicator - Drill motor
to check if it may have been Since doweling is performed - 9/32" diameter drill
disturbed during shipment or after the motor/compressor - #6 taper reamer
installation. See Table 3-1. alignment has been hot checked
(i.e. compressor has been run 3. Insert the #6 x 2 1/2"
Motor & Compressor Flanges and brought up to operating hardened taper dowel pins in
temperature after initial the holes.
Check the alignment of the alignment), some models are
motor and compressor flanges shipped from the factory 4. Using a rubber hammer or
with a dial indicator on the without doweling. mallet, tap the dowel lightly
motor flange. The procedure into position. Leave
for checking alignment and Note: 1/8" – 3/16" of the dowel pin
alignment tolerances follow. All self-contained SC, SCA, above the motor foot
Both angular and parallel must and SCE models are factory (required to tap and loosen
be checked. For the details on run and doweled. SCAR and the dowel for removal when
the compressor manufacturer SCER utilize remote required).
alignment procedure, refer to condensers and are not
the Installation, Start-Up and factory run. 5. Coat the dowels with white
Service Instructions located in lead or lubricant to prevent
the Appendix & Notes Section. In such cases, doweling is done rusting.
after the initial start-up of the

Figure 3-12 Doweling
Reference
Refer to the compressor manufacturer alignment procedure in the Installation, Start-Up and Service
Instructions in the Appendix & Notes Section
.
Table 3-1 Compressor Alignment Tolerances


Optional Condensing Controls evacuation and

Units Magnetic starters for the charging process.
compressor motor(s).
Condensing units Gauge and safety Structural Base Frame
supplied by TURBO console for high, low, Capable of supporting
consist of the following and oil pressure safety the basic components
basic components: circuit. ON/OFF master listed above during
control switch and transportation and
Motor/Compressor terminal switch operation.
Assembly connections for
Open drive or screw connection of the Field Piping
compressor. When control circuit power
required, water cooled and lugs for the three SC, SCA and SCE
heads and/or water phase power models are factory piped
cooled oil coolers are connections. Main and including the refrigerant
provided. Water piping branch circuit breakers piping between the
(if required) to the and disconnects are not evaporator section and
motor/compressor provided. the condensing unit – no
assembly is not refrigerant field piping
included. Refrigerant is required. Field piping
The refrigerant between the condensing
Condenser operating charge unit and all other
Water cooled is required is provided by components is required
standard. Evaporative others for all models for SCAR and SCER
cooled and air-cooled except SC, SCA and models with remote air-
are available. SCE. Models without cooled (SCAR) or
the refrigerant are evaporative -cooled
Condenser Head supplied with either a (SCER) condensers.
Pressure Controls nitrogen holding charge Field piping is by others.
Water regulating valve only. SC, SCA and SCE
is standard for water models are factory Electrical Service
cooled. charged prior to SC, SCA and SCE
shipment except for models are factory wired
High Pressure international shipments. including the wiring
Receiver International shipments between the evaporator
For storage of for all models are section and the
refrigerant charge during shipped with a nitrogen condensing unit – no
pump down for service holding charge only. field wiring is required.
or extended off periods. Field wiring between the
Includes inlet isolation NOTE: condensing unit and all
valve, outlet valve, and The nitrogen holding other components is
safety relief valves. charge is required for SCAR and
approximately 15PSIG SCER models with
and must be relieved remote air-cooled
before beginning the (SCAR) or evaporative -
WARNING! Read the Safety Section before this section. Failure to carefully follow
these instructions could result in permanent injury or loss of life.
cooled (SCER) connections are local, state and federal

condensers. Field wiring provided in the control codes.
is by others. panel. Main circuit
breakers and branch Cooling Tower and
Single-phase and three- circuits breakers and/or Cooling Tower
phase electrical service disconnects are not Pump(s)
to the evaporator section provided. Main and Not included with the
and all other branch protection must condensing unit -
components is field be provided by others in available as options.
installed by others. accordance with all Consult TURBO for
Terminal block additional information.
Options & Accessories 03/04 Turbo Refrigerating, LLC

7-14
WARNING! Read the Safety Section before this section. Failure to carefully follow
these instructions could result in permanent injury or loss of life.
Optional Flooded Unit level column, and pump

vent. Oil Recovery Vessel
TIG evaporators are Consists of an oil pot,
available for flooded High Pressure relief valve, vent line,
operation with Refrigerant Make-Up and isolation valves for
refrigerant R-22.For Line Assembly the removal of oil from
flooded models the Consists of a liquid the system. Oil is
evaporator is connected solenoid valve, hand removed manually from
to an optional surge expansion valve, and the oil pot connected to
drum. The surge drum isolation valves on the the drop leg of the surge
package supplied by inlet and outlet of the drum.
TURBO consists of: assembly. A second
hand expansion valve is Structural Base Frame
Surge Drum connected in parallel to Capable of supporting
Sized for the the solenoid valve and the components listed
refrigeration duty listed main hand expansion above during
above. This vessel valve. The manual transportation and
serves as the source of bypass permits operation operation.
liquid refrigerant for the while the solenoid valve
evaporator plates as well and/or hand expansion Surge Drum Insulation
as a surge vessel to are being serviced. Required for proper
separate the liquid and operation. Due to
gas returning from the Dual Safety Relief variations in
evaporator. Connections Valves requirements, insulation
are provided for the wet Provided. Field piping of the vessel and piping
suction return, dry by others is required is field installed and
suction to the from the discharge of provided by others.
compressor, relief valve, the relief valves to a safe Insulation and jacketing
oil drain, high pressure discharge location. can be supplied as an
liquid make-up, liquid Refer to section 2 – option.
Safety.
Options & Accessories 03/04 Turbo Refrigerating, LLC

7-15

TURBO Refrigerating Chiller-Manual

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TURBO Refrigerating Chiller-Manual

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INTRODUCTION

TERMS & CONDITIONS

Chiller Manual SAFETY 2

Chiller Manual Installation, Operation & Maintenance

Introduction 2/01 Turbo Refrigerating 1-1

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T hink safely – act safely.

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Exclusions: Limitation of (i) THE FOREGOING IS loading, or by erosive or

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Company’s incorporating a included in the purchase fails to comply with any

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priorities or embargoes, car desired by it and/or required condition or any of the

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Chiller Generator Operation & Maintenance Manual

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Figure 2-1 Warning Labels on Control Panels

Figure 2-2 Warning Label on Access Panels

If all labels are not attached Turbo Refrigerating Phone:940-387-4301

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escaping refrigerant would Refrigerating, and Air- 2. The safety lockout

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SAFETY LOCKOUT PROCEDURE

I. Purpose III. Supervisory It is the responsibility of the

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VIII. Failure to Follow

These procedures have been

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Material Safety Data Sheets (MSDS)

See MSDS sheets attached for details.

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Material Safety Data Sheet for Anhydrous Ammonia

Trade Name: Anhydrous Ammonia

II. Hazardous Ingredients

Material or Component: Ammonia

III. Physical Data

Boiling Point, 760 MM Hg: –33.3°C (–28.0°F)

IV. Fire and Explosion Data

Flash Point (Test Method): Not applicable.

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V. Health Hazard Information

Inhalation: Moderately toxic. LCLo: 1,000 PPM/3 hrs. (Humans)

Emergency and First Aid Procedures

VI. Reactivity Data

VII. Spill or Leak Procedures

Steps To Be Taken If Material Is Released Or Spilled:

Neutralizing Chemicals: Do NOT neutralize with chemicals. Use water only.

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VIII. Special Protection Information

Specific Personal Safety Equipment

IX. Dot Information

Other Handling and Storage Requirements:

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Material Safety Data Sheet for Suniso 3 GS & 4 GS

Manufacturing Division or Subsidiary: Sonneborn Division

Section II. Chemical and Physical Properties