HT Chillers Recirculating 36000 Plus User Manual & Installation Guide

Hensley Thermodynamics
1.830.370.2362
1.800.259.2720
HT Chillers
Recirculating 36000 Plus
User Manual & Installation Guide
www.HTChillers.com
UM-R36000 Rev 1
Manufacturer Information
About Hensley Thermodynamics
Hensley Thermodynamics, Inc. is chiller manufacturer focused on the design and manufacture
of affordable, efficient, easy to use and easy to maintain chiller units for everyone from major
industry to the individual hobbyist that have machines that require chilled coolant less than
65°F for optimal operation.
Hensley Thermodynamics
1.830.370.2362
1.800.259.2720
Hours: 8:00 a.m. to 5:00 p.m. Central Time, Monday - Friday
Email anytime: info@HTChillers.com
Shipping Address: Hensley Thermodynamics
454 Cade Loop
Ingram, TX 78025
Mailing Address:
Hensley Thermodynamics
P.O. Box 318
Ingram, TX 78025
Visit us Online:
www.HTChillers.com
This document contains subject matter protected by United States copyright law and to which
Hensley Thermodynamics Corporation has proprietary rights. Recipients of this document
shall not reproduce, distribute, transmit, display, publish, broadcast or use information
contained herein, in whole or in part, for any use other than the purpose for which this manual
was provided.
The following are trademarks of Hensley Thermodynamics, Inc.: Hensley Thermodynamics™
and the Hensley Thermodynamics logo.
HT is used herein as shorthand notation to refer to Hensley Thermodynamics.
HT Chiller is used herein as shorthand notation to refer to the Hensley Thermodynamics
Chiller.
All other products and brand names mentioned in this document are trademarks of their
respective companies.
Instructions in English
© 2013-2014 Hensley Thermodynamics Corporation
Doc #: UM-R36000
All Rights Reserved
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Recirculating Chiller
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
This User Manual & Installation Guide
applies to the following units:
Recirculating Chiller
Model R32301
Model R32303
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Table of Contents
1. Manufacturer Information ----------------------------------------------------------------------------- i
About Hensley Thermodynamics ...........................................................................i
2. Important Information ---------------------------------------------------------------------------------- 1
Abbreviations and Definitions .................................................................................1
3. Safety ------------------------------------------------------------------------------------------------------ 1
Recognizing Safety Information in this Manual........................................................1
Equipment Labels, Symbols and Meanings............................................................2
Access by Qualified Personnel Only .......................................................................2
Electrical Precautions .............................................................................................2
Emergency Shutdown ............................................................................................3
Structural Support ..................................................................................................3
Mechanical Strength...............................................................................................3
4. Product Description------------------------------------------------------------------------------------- 4
Purpose .................................................................................................................4
Recirculating 36000 Model Configurations .............................................................4
Equipment Usage...................................................................................................4
Approved Recirculating Coolants .....................................................................4
Decibel Levels........................................................................................................4
Dimensions and Weight .........................................................................................5
Product Components .............................................................................................6
Condensing Unit...............................................................................................6
Recirculating Coolant Reservoir .......................................................................6
Pressure Regulating Valve ...............................................................................6
Inline Strainer ...................................................................................................6
Make-up Coolant Float Valve ...........................................................................6
Chiller Barrel Energy Storage Tank ..................................................................6
Relief Valve ......................................................................................................6
Chiller Functions ....................................................................................................7
Refrigeration ....................................................................................................7
Recirculation ....................................................................................................7
5. Installation Instructions -------------------------------------------------------------------------------- 8
Location Checklist ..................................................................................................8
How to Access the Chiller Barrel Energy Storage Tank ..........................................9
How to Fill the Chiller Barrel Energy Storage Tank .................................................11
Attaching Coolant Make-up, Coolant In and Coolant Out Lines....................................12
Wiring Electrical Power to the HT Chiller .................................................................13
Wiring Instructions ............................................................................................13
6. HT Chiller Operation ----------------------------------------------------------------------------------- 14
How to Turn On the HT Chiller ...............................................................................14
How to Turn Off the HT Chiller ...............................................................................14
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7. Maintenance, Repairs and Storage ----------------------------------------------------------------- 15
General Maintenance .............................................................................................15
Repairing Components ............................................................................................15
Draining Coolant Reservoir Tank ...........................................................................16
Unscrew Brass Disconnect ....................................................................................16
Attach Hose ...........................................................................................................16
Cleaning Pump Strainer and Reservoir Tank .........................................................17
Replacing Make-up Coolant Float Valve ................................................................17
Storing the HT Chiller while Not in Service .............................................................19
How to Remove Water from the Chiller Barrel Energy Storage Tank ................19
How to Remove Coolant from Recirculating Coolant Reservoir Tank ...............20
How to Remove Coolant from the Recirculating Lines ......................................20
Freeze Thermostat .................................................................................................20
8. Field Splitting the HT Chiller -------------------------------------------------------------------------- 21
How to Field Split the HT Chiller .............................................................................21
9. Refrigeration Technician Section: Installing the Condensing Unit ---------------------------- 24
10. Trouble Shooting ---------------------------------------------------------------------------------------- 30
Wiring Diagram (3-Phase Units Only) ....................................................................31
11. Receiving and Unpacking Instructions ------------------------------------------------------------- 32
12. Repair Authorization ------------------------------------------------------------------------------------ 32
13. Limited Warranty ---------------------------------------------------------------------------------------- 32
Purchase and Installation Records .........................................................................34
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Important Information
Read this User Manual & Installation Guide carefully before you begin chiller
installation, operation, or service. This manual contains important information.
Failure to read this manual can result in personal injury or damage to your chiller.
Abbreviations and Definitions
Abbreviation
CBEST
gpm
HT
HT Chiller
psi
Definition
Chiller Barrel Energy Storage Tank.
gallons per minute
Hensley Thermodynamics
Hensley Thermodynamics Chiller
pounds per square inch
Safety
Safety instructions must be followed when you install, operate, inspect, or perform maintenance
or service on this equipment. If ignored, physical injury or death may follow, or damage may
occur to the equipment. Always observe applicable safety precautions when using this
equipment.
Recognizing Safety Information in this Manual
This is the safety-alert symbol
When you see this symbol on the unit and in this manual, be
alert to the potential for personal injury or equipment damage. Understand these signal words;
DANGER, WARNING, and CAUTION. These words are used with the safety-alert symbol.
DANGER
Identifies the most serious hazards that will result in severe personal injury
or death.
WARNING Identifies hazards that could result in personal injury or death.
CAUTION Identifies unsafe practices, which would result in minor personal injury or
product and property damage.
NOTE, TIP and IMPORTANT Used to highlight suggestions, which will result in enhanced
installation, reliability, or operation.
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Equipment Labels, Symbols and Meanings
The following labels and symbols are used in/on the Hensley Thermodynamics Chiller.
Symbol / Label
Purpose / Meaning
Location
Hazardous voltage may
cause severe injury or
death. Only Qualified and
Authorized Personnel may
access areas marked with
this label.
Condensing Unit
Hazardous voltage may
cause severe injury or
death. Only Qualified and
Authorized Personnel may
access areas marked with
this label.
Recirculating Pump
Indicates the Make-up
Coolant valve.
Front panel to the
right of the Make-up
Coolant Valve.
Indicates the Coolant Out
valve.
Front panel to the
right of the Coolant
Out valve.
Indicates the Coolant
Return valve.
Front panel to the
right of the Coolant
Return valve.
Access by Qualified Personnel Only
Access to the HT Chiller shall be restricted to properly trained and qualified personnel who are
familiar with the potential hazards of equipment that uses high voltages, high temperatures, low
temperature, refrigerant and components under pressure.
Electrical Precautions
Only properly trained and qualified personnel are authorized to perform work on an energized
system.
WARNING To prevent electrical shock:
•
The HT Chiller must be grounded through your electrical power source.
•
The HT Chiller must be powered off and disconnected from the main power supply
prior to installation, maintenance, moving, and decommissioning.
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Emergency Shutdown
In case of emergency, disconnect power to the HT Chiller at your electrical power source.
Structural Support
The HT Chiller is mounted on steel legs; however, underlying, level and structurally sound
support must be provided.
WARNING Failure to provide proper support may result in personal injury and / or damage
to the Chiller Unit.
Mechanical Strength
Do not stack, mount or lean anything on the HT Chiller.
WARNING External loads or stresses placed on or against the chiller unit may result in
personal injury and / or damage to the HT Chiller.
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Product Description
Purpose
The Hensley Thermodynamics Chiller (HT Chiller) provides chilled recirculating coolant to
equipment that requires coolant below 65 degrees with a flow rate of up to 5 gallons per minute
at 50 psi.
Recirculating 36000 Model Configurations
HT Recirculating Chillers are available in the following configurations:
Model R32301 – 3 Ton, 230 Volt, Single-Phase
Model R32303 – 3 Ton, 230 Volt, Three-Phase
Equipment Usage
The HT Chiller is designed to chill recirculating coolant, as specified in this manual, for
equipment requiring:

Up to 5 gallons per minute

50 psi or less, and

Temperatures below 65 degrees Fahrenheit
Note: The HT Chiller is not intended for use other than described in this manual.
To prevent damage to the HT Chiller and voiding the warranty, call the Hensley
Thermodynamics Engineering Department at 1-830-370-2362 or 1-800-259-2720 before
using the HT Chiller beyond the scope of this manual.
Approved Recirculating Coolants
The HT Recirculating Chiller is currently designed to use the following recirculating coolants:

Water

Glycol
CAUTION
To prevent damage to the chiller and voiding the warranty, only use the
approved coolants.
For questions about using other coolants, call the Hensley Thermodynamics
Engineering Department at 1-830-370-2362 or 1-800-259-2720.
Decibel Levels
The HT Chiller is quiet with a maximum decibel level of 74. This low decibel level does not
overwhelm normal conversation so the unit can be placed in the work environment.
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Dimensions and Weight
Recirculating HT Chiller
Empty
Barrel filled with water
Weight
525 Pounds
985 Pounds
Width
31 ½ inches
HT Chiller Side View
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Length
31 ½ inches
Height
73 ¼ inches
HT Chiller Front View
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Product Components
The HT Recirculating Chiller is comprised of the following major components:
Condensing Unit
A 13 SEER unit manufactured by Ruud and contains the environmentally friendly 410A
refrigerant.
Recirculating Coolant Reservoir
Holds 7.3 gallons of coolant for the recirculating coolant circuit.
Pressure Regulating Valve
Maintains the recirculating coolant circuit at 50 psi and 0-5 gpm flow.
Inline Strainer
Protects recirculating pump from debris.
Make-up Coolant Float Valve
Maintains the correct level in the recirculating coolant reservoir tank.
Chiller Barrel Energy Storage Tank
The Chiller Barrel Energy Storage Tank (CBEST) located within the Chiller Barrel Compartment,
holds approximately 55 gallons of water that is utilized for two specific purposes:
1. The thermo-conductive property of water enables efficient heat transfer, and
2. The water stores excess energy to be used when the refrigeration system cycles off.
The recirculating flow-through coolant lines are submerged within this R-10 insulated Chiller Barrel
Energy Storage Tank and the recirculating coolant is efficiently chilled on the way to the
equipment. Fill the Chiller Barrel with clean water upon installation and secure the lid. The water
in the barrel stays in the barrel and you will only need to check the water level during periodic
inspections.
Relief Valve
Relieves excessive water or pressure CBEST should there ever be a leak in the CBEST.
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Chiller Functions
The HT Recirculating Chiller performs 2 essential functions:

Refrigeration of coolant

Recirculation of chilled coolant
Refrigeration
The HT Chiller uses coil technology to chill your equipment recirculating coolant. Immersed
inside the 55 gallon CBEST are separate copper lines containing recirculating coolant and
refrigerant.
As the refrigerant system runs, heat is removed from the recirculating coolant lines and the
water contained within the CBEST. When the water within the CBEST reaches approximately
45 degrees, the refrigerant system cycles off. At this time, there is approximately 11,000 BTUs
of energy stored within the 55 gallons of water in the CBEST. When the water in the CBEST
reaches 52 degrees, the refrigeration unit cycles on to again start cooling the recirculating
coolant and the water in the CBEST; thus completing the refrigeration cycle.
Thermostats
Within the CBEST, a thermostat ensures that the 55 gallons of water is maintained within the
range of 45-52°F.
Within the recirculating coolant reservoir tank, another thermostat ensures that the recirculating
coolant is also maintained between 45-52°F degrees.
A freezestat located in the recirculating coolant reservoir tank protects the recirculating coolant
from freezing in case of thermostat failure.
Recirculation
The recirculating coolant pump draws suction from the make-up coolant reservoir tank,
pressurizes it to 50 psi, and sends it to the recirculating coolant lines. The recirculating coolant
flows through a pressure regulating valve that maintains 50 psi at 0-5 gpm flow. The
recirculating coolant flows to the equipment requiring chilled coolant, and then returns to the
coolant reservoir tank; thus completing the coolant recirculating system.
The recirculating coolant system consists of 5 parts:
1.
2.
3.
4.
5.
Coolant reservoir tank located in the base of the HT Chiller
Refrigerant and recirculating coolant lines submerged in water within the CBEST
Coolant recirculation pump
Strainer that protects the recirculation pump from debris
Equipment requiring the chilled coolant
A low coolant level switch located in the recirculating coolant reservoir tank will interrupt power
to the recirculation pump in the event of low coolant conditions.
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Installation Instructions
The HT Chiller is typically delivered on a pallet.
1.
2.
3.
4.
Review the Location Checklist below before installing the HT Chiller.
Use a pallet jack or forklift to safely move the HT Chiller to the selected location.
Carefully remove any protectant wrapping or crating material.
Use a pallet jack to lift the HT Chiller off of the pallet and set into position.
Location Checklist
Review the following items to help determine the best location for the HT Chiller:
 The HT Chiller must be installed on a level surface and indoors.
 The HT Chiller can be separated (field split) with the condensing unit located in one area
and the Chiller Barrel Compartment (lower half of the HT Chiller) located in another
area. To separate the unit, refer to the section “How to Field Split the HT Chiller”.
 The Chiller Barrel Compartment (lower half of the HT Chiller) is designed for indoor
installation only where ambient temperatures do not fall below 32F.
 The Condensing Unit is designed for use with ambient temperatures of 55°F or more.
If you are field splitting the HT Chiller and the condensing unit will be required to operate
in conditions below 55°F, contact us or your authorized Ruud representative to install low
ambient controls and/or accessories.
 The maximum ambient temperature for the Condensing Unit is 125°F.
 Allow sufficient airflow around and vertical discharge above the Condensing Unit for
proper operation.
Proper Clearance
Measurement
Around all sides of chiller
18 inches
Above top of condensing unit
4 feet
 Access to required electrical source as follows:
Model
Number
Phase
Freq.
(Hz)
Voltage
(Volts)
Rated
Load
Amperes
(RLA)
R32301
1
60
230
16.7
R34303
3
60
230
10.4
Minimum
Circuit
Amperes
Fuse/HACR
Breaker
Min
Amps
Max
Amps
15
30
35
15
20
20
Contact a licensed electrician and your local power company to ensure that installation
wiring complies with local fire, safety and electrical codes.
 Access to a clean water source if water is your recirculating coolant of choice.
 To prevent heat gain to the Coolant Out line, place the HT Chiller near your equipment
and insulate the coolant line. (Insulating the line also protects surrounding surfaces from
condensation or sweating from the chilled coolant.)
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How to Access the Chiller Barrel Energy Storage Tank
1. If the HT Chiller is powered on, press the ON/OFF push button power switch to turn the
HT Chiller off. The light will extinguish to indicate that the chiller is powered off.
Push Button Power Switch
ON
OFF
2. Disconnect electrical power from the HT Chiller.
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3. Remove the left side panel of the Chiller Barrel Energy Storage Tank Compartment by
unscrewing the 7 screws around the perimeter.
4. Loosen and remove the clamp ring on the Chiller Barrel Energy Storage Tank.
5. Lift off and remove the Chiller Barrel Energy Storage Tank lid.
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How to Fill the Chiller Barrel Energy Storage Tank
CAUTION Do not add any chemicals to the Chiller Barrel Energy Storage Tank; possible
damage to the HT Chiller may occur. Adding chemicals to the Chiller Barrel
Energy Storage Tank will void the warranty.
1. If necessary, follow the instructions to “How to Access the Chiller Barrel Energy Storage
Tank”.
2. Fill the Chiller Barrel with clean water to the water line indicator located on the inside of
the tank. (Approximately 55 gallons.)
3. Replace the Chiller Barrel lid securely.
4. Replace and fasten the Chiller Barrel ring onto the Chiller Barrel.
5. Replace the side panel by securing all 7 screws.
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Attaching Coolant Make-up, Coolant In and Coolant Out Lines
Note: The Coolant Make-up, Coolant In, and Coolant Out valves are all ½” NPT valves.
Note: Use a backup wrench to secure coolant valves while installing connections to prevent
damage to the lines.
1. Attach the coolant return line from your equipment to the bottom valve.
2. Attach the coolant out line going to your equipment, to the middle valve.
3. Attach the line from your make-up coolant source (coolant tank or water hose) to the top
valve.
Valves Shown in Closed Position
TIP:
To maintain the chilled coolant temperature and to prevent heat gain of the chilled
coolant line, the HT Chiller either needs to be close to the equipment or the coolant out
line needs to be properly insulated. This is especially important if the coolant line is
exposed to high temperatures or hot surfaces.
TIP:
The chilled coolant leaving the HT Chiller will be typically below the dew point so
condensation may occur. Properly insulate the coolant out line to prevent nearby
surfaces from condensation damage.
Reminder about the Water in the Chiller Barrel
This HT Chiller is a recirculating system with recirculating coolant flowing through a pipe that is
submerged in the Chiller Barrel Energy Storage Tank. This recirculating coolant pipe is chilled
by refrigerant lines and the cold water within the Chiller Barrel Energy Storage Tank. The
purpose of the water in the Chiller Barrel is to store cooling energy only, in other words, the
water in the barrel stays in the barrel.
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Wiring Electrical Power to the HT Chiller
DANGER ELECTRICAL SHOCK HAZARD – Disconnect Main Power!
Before installing, modifying, or servicing the HT Chiller, your main electrical
disconnect switch must be in the OFF position. Your setup may have more than
1 (one) disconnect switch. Lock out and tag switch(es) with a suitable warning
label(s).
All Electrical Work Must Be Completed By a Qualified Person
Wire according to all national, state and city electrical codes.
Failure to follow this warning could result in personal injury or death.
CAUTION Prevent Reverse Wiring of 3-Phase
As with all typical 3-phase systems, you can accidentally wire the HT Chiller
incorrectly to cause the compressor motor to run backwards. This is evident by
excessive compressor noise, no heat being exhausted by the condenser fan
within 1 minute, and recirculating coolant not cooling. Reverse any two leads to
change the phase for proper rotation. Not correcting the wiring will cause the
compressor to overheat, turn off, and stay off until the compressor protector has
sufficiently cooled.
CAUTION Prevent Breakage of Lines - Fill Chiller Barrel Before Applying Power
To prevent freezing and breakage of recirculating coolant lines, the Chiller
Barrel Energy Storage Tank MUST be filled with water before power is applied
to the HT Chiller.
CAUTION Prevent Skin Damage – Do not Touch Refrigerant Lines in Chiller Barrel
Refrigerant lines in the Chiller Barrel Energy Storage Tank can operate at
temperatures below freezing. Touching these lines can freeze skin.
Note: Operating the HT Chiller on improper line voltage will void the warranty.
Note: Do not connect the HT Chiller to an electrical source that has power fluctuations beyond
approved limits.
Wiring Instructions
1. Connect proper voltage to condensing unit.
See applicable data plate on condensing unit.
2. Install proper size wire to the “Line In” connections in the condensing unit electrical
compartment.
3. Attach proper ground.
4. Reinstall cover on condensing unit.
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HT Chiller Operation
Your HT Chiller arrives pre-set and ready to use as soon as:

Proper electrical connections are made,

Chiller Barrel Energy Storage Tank is filled with water, and

Coolant line connections attached.
TIP: If the condensing unit does not come on upon initial installation, the freezestat may have
tripped due to unit being exposed to below 35°F during shipping or storage. See section
“Freeze Thermostat” for instructions on how to reset the freezestat.
CAUTION Prevent damage to your equipment and/or the HT Chiller by confirming the
following:
1. Chiller Barrel Energy Storage Tank has been properly filled.
2. Your equipment recirculating pump is turned on.
3. Your make-up coolant source is turned on.
How to Turn On the HT Chiller
1. Press the HT Chiller ON/OFF push button power switch located on the front panel.
2. Verify the power indicator light in the switch is illuminated.
Power Light Illuminated
How to Turn Off the HT Chiller
1. Press the HT Chiller ON/OFF push button power switch.
2. Verify the indicator light in the switch goes out.
Power Light Off
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Maintenance, Repairs and Storage
WARNING To prevent electrical shock, the HT Chiller (condenser and Chiller Barrel
Compartment) must be disconnected from all electrical sources during
maintenance and repair.
General Maintenance
The HT Chiller is designed to be virtually maintenance free when operated under normal
working conditions.
As long as the Chiller Barrel Energy Storage Tank is securely sealed, water will not escape.
If you move the HT Chiller after the tank has been filled, it is recommended that you visually
inspect the water level.
The condensing unit requires only routine maintenance as required with a standard air
conditioning condensing unit. If you have a yearly contract with an air conditioning service
company, ask them to inspect your HT Chiller condensing unit during your yearly inspection.
Repairing Components
Other than the general maintenance outlined in the sections below, do NOT attempt to repair
any HT Chiller components unless previously authorized in writing by
Hensley Thermodynamics. Unauthorized repairs will VOID warranty.
Contact Technical Support:
Telephone: 1-830-370-2362 or 1-800-259-2720 toll-free
8:00 a.m. to 5:00 p.m. Central Time, Monday - Friday
Email: Support@HTChillers.com
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Draining Coolant Reservoir Tank
Drain the Reservoir Tank when you want clean and inspect the pump strainer and reservoir
tank. Clean debris from the recirculating pump strainer and coolant reservoir tank as needed.
For example, if the flow is restricted or noisy, check to see if cleaning is necessary.
Tip: Some spilling of coolant will occur. A drain pan placed under the front of the HT Chiller is
recommended to catch the leakage of coolant while attaching a drain hose.
Note: The recirculating coolant reservoir tank holds approximately 7.3 gallons.
How to Drain the Coolant Reservoir Tank
1. Close the Make Up coolant valve
.
2. Remove both side panels of the HT Chiller.
3. Remove the lower section of the front panel.
4. Disconnect the strainer hose on the coolant reservoir side by unscrewing the brass
disconnect and then quickly attach a garden hose or appropriate drain hose to allow
draining of the reservoir tank into an appropriate container.
Unscrew Brass Disconnect
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Attach Hose
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Cleaning Pump Strainer and Reservoir Tank
1. Follow the instructions for “Draining Coolant Reservoir Tank”.
2. Unscrew and remove the clear bowl from the strainer body.
3. Remove mesh screen and rinse screen and clear bowl with clean water to remove all
debris.
4. Reinsert mesh filter into clear bowl; reattach bowl to strainer body and hand tighten.
5. Visually inspect bottom of the coolant reservoir tank and remove any debris by using an
appropriate wet/dry vacuum or clean cloth.
6. Disconnect garden/drain hose.
7. Reconnect strainer hose at brass disconnect.
8. Open the Make-up coolant valve to refill the coolant reservoir and check for leaks
around the pump strainer.
9. Attach front panel of HT Chiller, and then attach side panels.
Replacing Make-up Coolant Float Valve
Over time, age and exposure to coolant liquid will naturally degrade the rubber washer on the
float valve. If the rubber washer fails, the coolant tank will overflow.
To Replace the Float Valve Rubber Washer
1. Close Make-up Coolant valve
.
2. Remove both side panels of the HT Chiller.
3. Remove lower section of front panel.
4. Remove recirculating coolant reservoir tank lid.
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5. Disconnect float valve assembly from coolant line brass connection.
6. Remove brass ¼” 20 screw from front of the coolant reservoir tank and remove float
valve assembly.
7. Remove cotter pin.
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8. Remove float.
9. Replace rubber washer.
10. Reassemble in reverse order.
11. Attach front panel of HT Chiller, and then attach side panels.
Storing the HT Chiller while Not in Service
To prolong the life of the HT Chiller when taking the unit out of service, it is recommended that
all water is removed from the Chiller Barrel Energy Storage Tank, coolant removed from the
coolant reservoir tank, the pump strainer, and purged from all associated piping; especially if
the HT Chiller will be stored in a location that could potentially freeze.
CAUTION Prevent component damage/rupture by removing/purging all water and coolant
from the HT Chiller if the unit is taken out of service.
How to Remove Water from the Chiller Barrel Energy Storage Tank
1. Turn off the HT Chiller by pushing the ON/OFF push button switch located on the front
panel. The light in the switch will go out.
2. Disconnect the HT Chiller from your electrical power source.
3. Access the Chiller Barrel Energy Storage Tank by removing the left side panel.
4. Remove the tank ring and the tank lid.
5. Either siphon or pump the water out of the tank.
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Recirculating Chiller
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
How to Remove Coolant from Recirculating Coolant Reservoir Tank
1. Remove left side panel of HT Chiller, and then remove front panel.
2. Drain coolant reservoir tank by following instructions in section “Draining Coolant
Reservoir Tank”.
3. Remove excess coolant in the bottom of the reservoir by using a clean rag or wet-dry
vac.
How to Remove Coolant from the Recirculating Lines
1. Turn off your equipment that requires the recirculating coolant.
2. Turn off the HT Chiller by pressing the ON/OFF push button power switch located on the
front panel.
3. Close Make-up, Coolant In and Coolant Out valves.
4. Disconnect Make-up line, Coolant In and Coolant Out lines being sure to drain coolant in
an appropriate container.
5. Open Coolant In and Coolant Out valves.
6. Apply no more than 60 psi of pressure to one of the valves so that when under pressure
the coolant escapes from the other valve. (Alternatively, a wet-dry vac can be used if
you seal off the vacuum head to create sufficient suction. There isn’t that much coolant
in the line but it must be removed.
Freeze Thermostat
If the HT Chiller has been stored or shipped in temperatures less than 35° F, the freeze
thermostat (freezestat) will trip. This thermostat, by design, requires a manual reset.
Indications of a tripped freezestat are the recirculating pump is running, but the condensing unit
on top is not running and the chiller is not cooling.
Note: If the freezestat trips during operation, turn the chiller off and troubleshoot the Chiller
Barrel and recirculating tank thermostats.
How to Reset the Freezestat
1. Remove the right side panel of the Chiller Barrel Energy Storage Tank compartment by
unscrewing the 7 screws around the perimeter.
2. Remove the 2 screws that hold the control box cover.
3. Press (push down) the reset button. (The freezestat is the larger of the 3 thermostats.)
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Recirculating Chiller
Page 20
HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Field Splitting the HT Chiller
Note: Field Splitting the HT Chiller is optional and not required.
The HT Chiller is “Field Splitable” allowing you to place the condensing unit away from the
Chiller Barrel Compartment. For example, split the HT Chiller if you prefer that the condensing
unit be located away from the work area to eliminate noise and heat exhaust.
How to Field Split the HT Chiller
IMPORTANT: These instructions are a general guide to be used in conjunction with the
“Refrigeration Technician Section: Installing the Condensing Unit” located near
the end of this manual.
Step 1: Empty the Chiller Barrel Energy Storage Tank (Optional)
WARNING The weight of the HT Chiller when filled with water is 985 pounds. If you are
moving the HT Chiller for the splitting process, it is highly recommended that
you drain the Chiller Barrel Energy Storage Tank.
1. Gain access to the internal Chiller Barrel by following the instructions “How to
Access the Chiller Barrel Energy Storage Tank”.
2. Empty the Chiller Barrel by following the instructions “How to Remove Water from
the Chiller Barrel Energy Storage Tank”.
Step 2: Pump Down Refrigerant
WARNING To prevent personal injury and/or damage to equipment,
only qualified refrigeration technicians are authorized to make the
modifications outlined below. The condensing unit uses 410A
refrigerant.
1. Using the proper high pressure gauges for 410A, connect the High and Low side
hoses to the appropriate pump-down valves at condensing unit.
2. On Chiller Barrel Cabinet front panel, press the ON/OFF push button power switch
to apply power to the condenser.
3. Close the High side pump-down valve and pump refrigerant into the condenser until
suction pressure reaches approximately 5 psi.
4. Turn off the condenser by pushing ON/OFF push button power switch.
The light in the switch will go out.
5. Disconnect the electrical power from the HT Chiller.
6. Close the Low side pump-down valve.
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Recirculating Chiller
Page 21
HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Step 3: Remove Internal Wiring
DANGER To prevent electrical shock, only qualified electricians are authorized to make
the modifications outlined below.
1. Completely remove all electrical power from the HT Chiller by using the breaker on
your fuse box, or pulling the fuse in your electrical panel, as is appropriate for your
electrical connections.
2. Remove the HT Chiller right side panel.
3. Disconnect the 24 Volt control wiring from the Control Box.
Step 4: Cut Refrigeration Lines
1. With all electrical lines removed, proceed to unsweat copper connection at the base
of the condensing unit after following proper refrigeration techniques for removing
remaining refrigerant. Be sure that the brass pump-down valves stay cool while
unsweating the connections.
2. Seal refrigerant lines to prevent contamination.
Step 5: Separate Chiller Barrel Compartment from Condensing Unit
The condensing unit is attached to the Chiller Barrel Compartment top by 2 bolts accessible
from the inside of the condensing unit under the fan housing.
1. Separate the condensing unit from the Chiller Barrel Compartment top by removing
these 2 bolts.
2. Provide a pad for the condensing unit at its new location.
Step 6: Connect New Refrigerant Lines and Electrical Wires
1. Install the condensing unit at the new location according to all city and state codes.
2. Install new refrigerant lines in accordance to the instructions by following section
“Refrigeration Technician Section: Installing the Condensing Unit” following proper
refrigeration techniques and referring to the long line application chart.
3. Install new liquid line filter dryer.
4. Run new 24-volt control wiring from the condensing unit to the Control Panel in the
Chiller Barrel Compartment.
5. Replace the Control Box cover in the Chiller Barrel Compartment.
6. Replace the electrical panel on the condensing unit.
CAUTION The Chiller Barrel Energy Storage Tank MUST be filled with water
before power is applied. Follow the instructions below.
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Recirculating Chiller
Page 22
HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Step 7: Position the Chiller Barrel Compartment in the new location.
Step 8: Refill the Chiller Barrel Energy Storage Tank
1. Fill the Chiller Barrel Energy Storage Tank to the waterline indicated on the inside of
the tank. Refer to the instructions “How to Fill the Chiller Barrel Energy Storage
Tank”.
2. Replace the Chiller Barrel Energy Storage Tank cover and secure the ring.
3. Replace the Chiller Barrel Compartment front panel, and then the side panels.
Step 9: Evacuate Refrigerant System
CAUTION The Chiller Barrel Energy Storage Tank must be filled with water
BEFORE powering on the condensing unit to prevent damage to the
HT Chiller.
1. Pull proper evacuation of the condensing unit system and release refrigerant
accordingly.
2. Deliver power to the HT Chiller by energizing the breakers or fuses depending on
your electrical setup.
3. Power up the system by pressing the ON/OFF push button power switch located on
the Chiller Barrel Cabinet front panel. The system will begin cooling the water in the
Chiller Barrel if the water is above 58°F.
4. Adjust refrigerant to 9° subcooling.
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Recirculating Chiller
Page 23
HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Refrigeration Technician Section: Installing the Condensing Unit
WARNING The following steps must be performed by a qualified refrigerant technician.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock, or other conditions, which may cause death,
personal injury, or property damage. The qualified
installer or agency must use factory-authorized kits or
accessories when modifying this product. Refer to the
individual instructions packaged with the kits or
accessories when installing. Follow all safety codes. Wear
safety glasses, protective clothing, and work gloves. Use
quenching cloth for brazing operations. Have fire
extinguisher available. Read these instructions thoroughly
and follow all warnings or cautions included in literature
and attached to the unit. Consult local building codes and
current editions of the National Electrical Code (NEC)
NFPA 70. In Canada, refer to current editions of the
Canadian electrical code CSA 22.1.
Recognize safety information. This is the safety-alert
symbol
When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for
personal injury. Understand these signal words;
DANGER, WARNING, and CAUTION. These words are
used with the safety-alert symbol. DANGER identifies the
most serious hazards, which will result in severe personal
injury or death. WARNING signifies hazards, which
could result in personal injury or death. CAUTION is
used to identify unsafe practices, which would result in
minor personal injury or product and property damage.
NOTE is used to highlight suggestions, which will result
in enhanced installation, reliability, or operation.
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch. Lock out
and tag switch with a suitable warning label.
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CAUTION
CUT HAZARD
Failure to follow this caution may result in
personal injury.
Sheet metal parts may have sharp edges or burrs. Use
care and wear appropriate protective clothing and gloves
when handling parts.
The condensing unit contains system refrigerant charge
for operation with the HT Chiller. For proper unit
operation, check refrigerant charge using charging
information located inside condenser electrical cover
and/or in the Check Charge section of this instruction.
IMPORTANT: Maximum liquid-line size is 3/8-in. OD
for all applications including long line. Refer to Piping
and Longline Guideline for further information.
IMPORTANT: Always install the factory-supplied
liquid-line filter drier. If replacing the filter drier, refer to
Product Data Digest for appropriate part number. Obtain
replacement filter driers from your HVAC distributor or
branch.
INSTALLATION
Check Equipment and Job Site
Install on a Solid, Level Mounting Pad
If conditions or local codes require the unit be attached to
pad, tie down bolts should be used and fastened through
knockouts provided in unit base pan. Refer to unit
mounting pattern in Fig. 2 to determine base pan size and
knockout hole location. For hurricane tie downs, contact
local distributor for details and PE (Professional
Engineer) certification, if required by local authorities. On
rooftop applications, mount on level platform or frame.
Place unit above a load-bearing wall and isolate unit and
tubing set from structure. Arrange supporting members to
adequately support unit and minimize transmission of
vibration to building. Consult local codes governing
rooftop applications. Roof mounted units exposed to
winds may require wind baffles. Consult the Ruud
Application Guideline and Service Manual - Residential
Split System Air Conditioners for wind baffle
construction.
NOTE: Unit must be level to within ±2 ° (±3/8 in./ft.,
±9.5 mm/m) per compressor manufacturer specifications.
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Clearance Requirements
When installing, allow sufficient space for airflow
clearance, wiring, refrigerant piping, and service. Allow
24 in. (609.6 mm) clearance to service end of unit and 60
in. (1219.2 mm) (above unit. For proper airflow, a 6-in.
(152.4 mm) clearance on 1 side of unit and 12-in. (304.8
mm) on all remaining sides must be maintained. Maintain
a distance of 24 in. (609.6 mm) between units or 18 in.
(457.2 mm) if no overhang within 12 ft. (3.66 m) Position
so water, snow, or ice from roof or eaves cannot fall
directly on unit.
NOTE: 18” (457.2 mm) clearance option described
above is approved for outdoor units with wire grille
coil guard only. Units with louver panels require 24”
(609.6 mm) between units.
On rooftop applications, locate unit at least 6 in. (152.4
mm) above roof surface.
Operating Ambient
The minimum outdoor operating ambient in cooling
mode without accessory is 55 °F (12.78 °C), and the
maximum outdoor operating ambient in cooling mode is
125°F (51.67 °C).
Sweat Connection
Length), refer to the Ruud Residential Piping and
Longline Guide line - Air Conditioners and Heat
Pumps using 410 A refrigerant.
3. For alternate liquid line options on 18-42 size units, see
Product Data or Piping and Application Guideline.
Change Liquid-Line Filter Drier Inside Chiller Barrel
Compartment
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in
equipment damage or improper operation.
1. Installation of a new filter drier in liquid line
is required.
2. Filter drier must be wrapped in a heat-sinking
material such as a wet cloth while brazing.
3. Flow arrow must point towards Chiller Barrel
heat exchanger.
Refer to Fig. 3.
Liquid Line
Dryer
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in
equipment damage or improper operation.
Service valves must be wrapped in a heat-sinking
material such as a wet cloth while brazing.
Use refrigeration grade tubing. After wrapping service
valve with a wet cloth, braze sweat connections using
industry accepted methods and materials. Consult local
code requirements. Refrigerant tubing and Chiller
Barrel heat exchanger are now ready for leak testing.
This check should include all field and factory joints.
24ABB3
UNIT SIZE
LIQUID
Connection
& Max. Tube
Diameter
36
3/8
RATED VAPOR
Connection
Tube
Diameter
Diameter
3/4
3/4
Notes:
1. Do not apply capillary tube or fixed orifice coils to
these units.
2. For Tubing Set lengths between 50 and 200 ft. (24.38
and 60.96 m) horizontal or 35 ft. (10.7 m) vertical
differential 250 ft. (76.2 m) Total Equivalent
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Fig. 3
Refrigerant tubes and Chiller Barrel heat exchanger should be
evacuated using the recommended deep vacuum method of
500 microns. The alternate triple
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage or
improper operation.
Never use the system compressor as a vacuum pump.
Recirulating Chiller
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
evacuation method may be used (see triple evacuation
procedure in service manual). Always break a vacuum
with dry nitrogen.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump
capable of pulling a vacuum of 500 microns and a
vacuum gage capable of accurately measuring this
vacuum depth. The deep vacuum method is the most
positive way of assuring a system is free of air and
liquid water. A tight dry system will hold a vacuum of
1000 microns after approximately 7 minutes. See Fig. 4.
NOTE: Install branch circuit disconnect of adequate size
per NEC to handle unit starting current. Locate disconnect
within sight from and readily accessible from unit, per
Section 440-14 of NEC.
Route Ground and Power Wires
Remove access panel to gain access to unit wiring.
Extend wires from disconnect through power wiring hole
provided and into unit control box.
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in
personal injury or death.
The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault
should occur. The ground may consist of electrical wire or
metal conduit when installed in accordance with existing
electrical codes.
Connect Ground and Power Wires
Connect ground wire to ground connection in control box
for safety. Connect power wiring to contactor as shown in
Fig. 5.
Final Tubing Check
IMPORTANT: Check to be certain factory tubing on
both Chiller Barrel heat exchanger and outdoor unit has
not shifted during shipment. Ensure tubes are not
rubbing against each other or any sheet metal or wires.
Pay close attention to feeder tubes, making sure wire ties
on feeder tubes are secure and tight.
Make Electrical Connections
Be sure field wiring complies with local and national
fire, safety, and electrical codes, and voltage to system is
within limits shown on unit rating plate. Contact local
power company for correction of improper voltage. See
unit rating plate for recommended circuit protection
device.
NOTE: Operation of unit on improper line voltage
constitutes abuse and could affect unit reliability. See
unit rating plate. Do not install unit in system where
voltage may fluctuate above or below permissible limits.
NOTE: Use copper wire only between disconnect
switch and unit.
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Connect Control Wiring
Route 24-v control wires through control wiring grommet
and connect leads to control wiring. Refer to HT Chiller
Wiring Diagram.
Use No. 18 AWG color-coded, insulated (35°C
minimum) wire. If condensing unit is located more than
100 ft. (30.48 m) from Chiller Barrel Cabinet, as
measured along the control voltage wires, use No. 16
AWG color-coded wire to avoid excessive voltage drop.
All wiring must be NEC Class 1 and must be separated
from incoming power leads.
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Final Wiring Check
IMPORTANT: Check factory wiring and field wire
connections to ensure terminations are secured properly.
Check wire routing to ensure wires are not in contact with
tubing, sheet metal, etc.
Start-Up
CAUTION
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this caution may result in personal
injury, equipment damage or improper operation.
 Do not overcharge system with refrigerant.
 Do not operate unit in a vacuum or at negative
pressure.
 Compressor dome temperatures may be hot.
CAUTION
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal
injury. Wear safety glasses, protective clothing, and
gloves when handling refrigerant and observe the
following:
 Front seating service valves are equipped with
Schrader valves.
Follow these steps to properly start up system:
1. After system is evacuated, fully open liquid and vapor
service valves.
2. Replace stem caps after system is opened to refrigerant
flow. Replace caps finger-tight and tighten with wrench
an additional 1/12 turn.
3. Close electrical disconnects to energize system.
4. If the Chiller Barrel Energy Storage Tank was
emptied, confirm that it was refilled.
5. If Water In / Water Out lines were cut, confirm that
they were reconnected and purged of air.
6. Confirm that Water In / Water Out lines are open and
flowing.
5. Turn on the HT Chiller by pushing the ON/OFF
switch located on the front of the chiller. Light in the
switch will illuminate.
Note: If the unit is noisy and/or cooling not be achieved,
the compressor is probably running in reverse direction.
Remedy is to change any 2 Incoming power leads.
6. Operate unit for 15 minutes.
Check Charge
Factory charge amount is 90.6 oz. and desired subcooling is
9 °F and is shown on unit rating plate. Charging method is
shown on information plate inside condensing unit. To
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properly check or adjust charge, conditions must be
favorable for subcooling charging. Favorable conditions
exist when the outdoor temperature is between 70°F
and100°F (21.11°C and 37.78°C), and the Chiller water is
between 70°F and 90°F (7.22°C and 26.67°C). Follow the
procedure below:
Unit is factory charged for 15ft of lineset. Adjust charge
by adding or removing 0.6 oz/ft of 3/8 liquid line above
or below 8ft (2.44 m) respectively.
For standard refrigerant line lengths (50 ft/24.38 m or
less), allow system to operate in cooling mode at least 15
minutes. If conditions are favorable, check system charge
by subcooling method. If any adjustment is necessary,
adjust charge slowly and allow system to operate for 15
minutes to stabilize before declaring a properly charged
system.
If the Chiller water temperature is above 80°F (26.67°C),
and the outdoor temperature is in the favorable range,
adjust system charge by weight based on line length and
allow the Chiller water temperature to drop to 80°F
(26.67°C) before attempting to check system charge by
subcooling method as described above.
NOTE: If line length is beyond 50 ft (24.38 m) or
greater than 20 ft (6.10 m) vertical separation, See Long
Line Guideline for special charging requirements.
Final Checks
IMPORTANT: Before leaving job, be sure to do the
following:
1. Ensure that all wiring is routed away from tubing and
sheet metal edges to prevent rub-through or wire
pinching.
2. Ensure that all wiring and tubing is secure in unit
before adding panels and covers. Securely fasten all
panels and covers.
3. Tighten service valve stem caps to 1/12-turn past
finger tight.
4. Leave this User Manual & Installation Guide
including Wiring Diagram with owner.
CARE AND MAINTENANCE
For continuing high performance and to minimize
possible equipment failure, periodic maintenance must
be performed on this equipment.
Frequency of maintenance may vary depending upon
geographic areas, such as coastal applications. See
Owner’s Manual for information.
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
REFRIGERANT PIPING LENGTH LIMITATIONS
Liquid Line Sizing and Maximum Total Equivalent Lengths† for Cooling Only Systems with Puron® Refrigerant:
The maximum allowable length of a split system depends on the liquid line diameter and vertical separation between
Chiller Barrel heat exchanger and condensing unit.
See Table below for liquid line sizing and maximum lengths:
Maximum Total Equivalent Length
Outdoor Unit BELOW Indoor Unit
Size
Liquid Line
Connection
Liquid
Line
Diam.
w/ TXV
036
AC
with
410A
3/8
3/8
AC with 410A Refrigerant Maximum Total Equivalent Length†: Outdoor unit BELOW Indoor
Vertical Separation ft (m)
0-5
6-10
11-20
21-30
31-40
41-50
51-60
61-70
71-80
(0-1.5) (1.8-3.0) (3.4-6.1) (6.4-9.1) (9.4-12.2) (12.5-15.2) (15.5-18.3) (18.6-21.3) (21.6-24.4)
250*
250*
250*
250*
250*
250*
250*
250*
250*
* Maximum actual length not to exceed 200 ft (61 m)
† Total equivalent length accounts for losses due to elbows or fitting.
Maximum Total Equivalent Length
Outdoor Unit ABOVE Indoor Unit
Size
036
AC
with
410A
Liquid Line
Connection
Liquid
Line
Diam.
w/ TXV
3/8
3/8
AC with 410A Refrigerant Maximum Total Equivalent Length†: Outdoor unit BELOW Indoor
Vertical Separation ft (m)
25
26-50
51-75
76-100
101-125
126-150
151-175
176-200
(7.6)
(7.9-15.2) (15.5-22.9) (23.2-30.5) (30.8-38.1) (38.4-45.7) (46.0-53.3) (53.6-61.0)
250*
250*
250*
250*
250*
250*
250*
250*
* Maximum actual length not to exceed 200 ft (61 m)
† Total equivalent length accounts for losses due to elbows or fitting.
REFRIGERANT CHARGE ADJUSTMENTS
Liquid
Line
3/8
0.5 oz./ft
(Factory charge for lineset = 3 oz / 85.05 g)
Charging Formula:
[(Lineset oz/ft x total length) – (factory charge for lineset)] = charge adjustment
Example: System has 20 ft of line set.
Formula: (.50 oz/ft x 20ft) – (3 oz.) = 7 oz.
Net result is to add 7 oz. of refrigerant to the system.
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Recirulating Chiller
Page 28
HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
LONG LINE APPLICATIONS
An application is considered Long Line, when the refrigerant level in the system requires the use of accessories to maintain acceptable
refrigerant management for systems reliability. See Accessory Usage Guideline table for required accessories. Defining a system as long
line depends on the liquid line diameter, actual length of the tubing, and vertical separation between the indoor and outdoor units.
For Air Conditioner systems, the chart below shows when an application is considered Long Line.
Liquid Line Size
AC WITH 410A REFRIGERANT LONG LINE DESCRIPTION ft
(m) Beyond these lengths, long line accessories are required
Units On Same Level
Outdoor Below Indoor
3/8
80 (24.4)
Outdoor Above Indoor
35 (10.7) vertical or 80 (24.4) total
80 (24.4)
ELECTRICAL DATA
UNIT SIZEVOLTAGE,
SERIES
V/PH
OPER
VOLTS*
MAX
MIN
COMPR
FAN
LRA
RLA
FLA
MCA
MAX
FUSE** or
CKT BRK
AMPS
036
230/1 Ø
79.0
16.7
0.8
35
036
230/3 Ø
73.0
10.4
0.8
20
* Permissible limits of the voltage range at which the unit will operate satisfactorily
† If wire is applied at ambient greater than 30°C, consult table 310-16 of the NEC (NFPA 70). The ampacity of non-metallic-sheathed cable (NM), trade name
ROMEX, shall be that of 60°C conditions, per the NEC (NFPA 70) Article 336-26. If other than uncoated (no-plated), 60 or 75°C insulation, copper wire (solid
wire for 10 AWG or smaller, stranded wire for larger than 10 AWG) is used, consult applicable tables of the NEC (NFPA 70).
‡ Length shown is as measured one way along wire path between unit and service panel for voltage drop not to exceed 2%.
** Time -Delay fuse.
FLA - Full Load Amps
LRA - Locked Rotor Amps
MCA - Minimum Circuit Amps
RLA - Rated Load Amps
NOTE: Control circuit is 24-V on all units and requires external power source. Copper wire must be used from service disconnect to unit.
All motors/compressors contain internal overload protection.
Complies with 2007 requirements of ASHRAE Standards 90.1
CHARGING SUBCOOLING (TXV-TYPE EXPANSION DEVICE)
REQUIRED SUBCOOLING °F
9°
UNIT SIZE-VOLTAGE, SERIES
36,000
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Trouble Shooting
The following chart is included to help guide you as you approach a troubleshooting course of
action. For assistance, please feel free to call Technical Support at 1-830-370-2362 or
1-800-259-2720 toll-free.
WARNING To prevent electrical shock, disconnect all power to unit before servicing.
Symptom
Possible Cause
Actions to Try
System not cooling
(Recirculating pump
running, condensing
unit off)
If upon initial startup from receipt of chiller, or
if unit coming out of storage, the freeze stat
may be tripped if unit was exposed to
temperatures below 35°
System not cooling
Freeze stat trips while unit operating
Replace both thermostats
Improper voltage to unit
Confirm supply voltage
Compressor running backwards as indicated
by noise in the compressor
3-phase only: Switch any 2 power leads
Faulty thermostat
Replace thermostat. Use ohm meter to
determine which thermostat is bad.
Dirty condenser coil
Clean coil
Condenser fan not operating
Improper charge
Circulating pump
noisy
Circulating pump
not running
Coolant leaking
from chiller
Water leaking from
check valve from
CBEST
Coolant leaking
from rotary seal on
pump

Reset freeze thermostat
1. Check voltage to the fan
2. Check run capacitor
3. Replace fan motor
Check and adjust to 9 degrees subcooling




Coolant filter dirty
Restriction in coolant lines
Make up feed valve closed
Low coolant in tank




Check coolant filter
Check for restrictions in the lines
Open Make up feed valve
Fill coolant tank




Insufficient coolant in tank
Faulty coolant level switch
Faulty circulating pump contactor
Faulty pump




Fill coolant in tank
Replace coolant level switch
Replace circulating pump contactor
Replace pump

Faulty float valve in coolant tank

Line failure (connections or fittings)



Replace coolant tank float valve
Tighten or replace connections
Tighten or replace fittings
Ruptured heat exchanger
Replace heat exchanger, replace the two
thermostats, and replace the freeze
thermostat.
Faulty pump
Replace pump
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Recirulating Chiller
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Wiring Diagram (3-Phase Units Only)
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Recirulating Chiller
Page 31
HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Receiving and Unpacking Instructions
IMPORTANT: Inspect the shipping crate immediately upon receipt and file a claim with the delivery
driver if any obvious damage is present.
Upon delivery, carefully remove the crating and inspect the HT Chiller for damage.
Call HT Chiller Support at 1-830-370-2362 or 1-800-259-2720 toll-free within 72 hours of receipt if you
have any questions or concerns.
Repair Authorization
All HT Chiller warranty repairs must be first authorized by calling Hensley Thermodynamics technical
support: 1-830-370-2362 or 1-800-259-2720. Any repairs performed without prior authorization will
be at owner’s expense and may void the warranty.
Proof of purchase and delivery date are required before service can be authorized.
Only qualified personnel shall be allowed to unpack, install, use and perform maintenance on this unit.
Only a qualified HVAC technician is authorized to repair the condensing unit under warranty.
This warranty will be null and void if unauthorized personnel perform any modifications or repairs on
this unit. Misuse of the product will void the warranty.
Hensley Thermodynamics Corporation is not liable for any injury or damaged cause by incorrect
installation, maintenance, or operation of this HT Chiller resulting from failure to follow instructions and
guidelines outlined in this manual.
Replacement of parts or subassemblies will be provided under warranty when they have failed
due to faulty manufacturing. Misuse will void warranty.
Limited Warranty
The Limited Warranty for the HT Chiller is 2 years parts and labor starting the date of delivery.
This warranty is non-transferable.
You will need the chiller unit serial number for all correspondence.
The unit’s serial number is located on the back of the condenser.
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UM-R36000 Rev 1
Limited Warranty – Parts and Labor – 2 years
SCOPE OF WARRANTY AND EQUIPMENT COVERED: The products covered by this Limited Warranty. Hensley Thermodynamics
(Manufacturer) warrants the Covered Equipment to be free from defects in materials and workmanship, and will repair or replace, at its
option, ANY PART of Covered Equipment which fails in normal use and service within the Applicable Warranty Periods in accordance with
the terms, including, but not limited to, the specific exclusions set forth below, of this Limited Warranty and subject to the
Manufacturer’s right to inspect and validate the warranty claim as set forth below. If an exact replacement is not available, an equivalent
unit or credit will be provided. The replacement will be warranted for only the unexpired portion of the original Applicable Warranty
Period. If government regulations, industry certification or similar standards require the replacement unit to have features not found in
the defective unit, you will be charged for the difference for those required features. If you pay the difference, you will also receive a
completely new Limited Warranty for the new replacement unit. The Manufacturer does not authorize or warranty any online/Internet
sale of equipment through auction or any other method of unapproved online sales direct to the consumer, nor the sale of equipment by
liquidators. The ONLY approved online sales are through the Manufacture’s websites: www.HTChillers.com and
www.HensleyThermodynamics.com
EFFECTIVE DATE AND APPLICABLE WARRANTY PERIODS: The Effective Date of warranty coverage is the date of sale plus 2 years.
EXCLUSIONS – In addition to the specific exclusions set forth in the other sections of this Limited Warranty document, THIS Limited
Warranty WILL NOT APPLY TO: A) damages, malfunctions, or failures resulting from failure to properly install, operate or maintain
Covered Equipment in accordance with the Manufacturer’s instructions
B) damages, malfunctions, or failures caused by misuse, accident, contaminated or corrosive atmosphere, vandalism, freight damage,
fire, flood, freeze, lightning, acts of war, acts of God and the like
C) Covered Equipment which is not installed by qualified, trained personnel in accordance with applicable codes, ordinance, and good
trade practices; or
D) damages, malfunctions, or failures caused by the use of any attachment, accessory or component not authorized by the Manufacture:
E) Covered equipment when operated with system components or accessories which do not match or meet the specifications
recommended by the Manufacturer;
F) any Covered Equipment manufactured by the Manufacturer that has been sold to the consumer via the Internet from an unapproved
website or auction website. Online sales are only authorized through www.HTChillers.com and www.HensleyThermodynamics.com
SHIPPING COSTS: This Limited Warranty does NOT cover shipping costs. You are responsible for the cost of shipping warranty
replacement parts from our factory to the location of your Covered Equipment. You also are responsible for the cost of shipping failed
parts and for incidental costs incurred locally, including handling charges. (You also must pay the shipping costs of returning the failed
part to the port of entry into the continental United States.)
LABOR COSTS: This Limited Warranty covers any labor costs or expenses for repair that has been authorized by the Manufacturer.
HOW TO OBTAIN WARRANTY CLAIMS ASSISTANCE: You must promptly report any failure covered by this Warranty to the Manufacturer.
Normally, your local HVAC air conditioning contractor will be able to take the necessary corrective action by obtaining replacement parts
through the Manufacturer. The name and location of local HVAC contractors can be usually found in your telephone directory in the
HVAC contractor section. HOWEVER, ANY PART REPLACEMENTS ARE MADE SUBJECT TO VALIDATION BY THE MANUFACTURER OF
IN-WARRANTY COVERAGE. Any part to be replaced must be made available in exchange for the replacement.
ECLUSIVE WARRANTY- LIMITATION OF LIABILITY: This Limited Warranty is the ONLY warranty given by the Manufacturer. This warranty
is non-transferable. No one is authorized to make any warranties on behalf of the Manufacturer. ANY IMPLIED WARRANTIES, INCLUDING
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, SHALL NOT EXTEND BEYOND THE APPLICABLE WARRANTY PERIODS
SPECIFIED IN THIS LIMITED WARRANTY. THE MANUFACTURER’S SOLE LIABILITY WITH RESPECT TO DEFECTIVE PARTS OR FAILURE SHALL
BE AS SET FORTH IN THIS LIMITED WARRANTY, AND ANY CLAIMS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES ARE EXPRESSLY
EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts or for the exclusion of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This Limited Warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
The Manufacture suggests that you immediately complete the Purchase and Installation Records section and retain this Limited Warranty
Certificate in the event warranty service is needed and that you keep proper documentation.
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HT Chiller User Manual & Installation Guide
UM-R36000 Rev 1
Purchase and Installation Records
COMPLETE THE FOLLOWING INFORMATION FOR YOUR RECORDS – DO NOT MAIL
Date of Purchase:
Date of Delivery:
Model Number:
Serial Number:
Date of Original Installation:
Installing Contractor Name:
Contractor’s address/phone:
Owner Name:
Address:
City/State/Zip:
Manufactured by Hensley Thermodynamics
P.O. Box 318, Ingram, Texas 78025 (mailing address)
454 Cade Loop, Ingram, Texas 78025 (shipping address)
1-830-370-2362
1-800-259-2720
www.HTChillers.com
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