Enviroheat OMNI OWC-5 Series Installation manual

By
INSTALLATIONSTARTUPADJUSTMENTMAINTENANCE
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier,
call the fire department.
Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
USED OIL or
GAS/PROPANE
FIRED AIR COOLED
ABSORPTION
WATER CHILLER
OWC-5 Series
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
IF UNIT OVERHEATS OR UNIT’S
GAS VALVE FAILS TO SHUT OFF:
DO NOT SHUT OFF ELECTRICAL
SUPPLY TO UNIT. INSTEAD, SHUT “OFF” GAS
SUPPLY TO UNIT.
CALL SERVICE COMPANY.
Enviro Heat  5714 1st Avenue  Spokane Washington 99212.  [phone] - Rev 4/2013
WARNING:
Never burn chlorinated solvents mixed
with oils or otherwise rapid corrosion to
internal metals will occur. An optional
chlorine test kit is available from the
factory upon request.
NOTE:
The power supply line must not be used
to turn the unit “ON” or “OFF”. The
dedicated control switch in the R-Y line is
for this purpose.
EnviroHeat

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2
The OWC-5 Chiller can operate using either used oil or gas/propane. Normal
operation of the Chiller will attempt to run on used oil first then automatically switch
over to gas or propane if used oil burner is turned off or not operating due to lack of
fuel or flame.

Installation, Start-Up, Adjustment and Maintenance Manual
3
INDEX
SECTION 1 GENERAL WARNINGS 4
SECTION 2 OVERVIEW AND TECHNICAL DATA 5
2.1 OVERVIEW 6
2.2 USED OIL AND GAS FIRED CHILLER OPERATION CYCLE 7
2.3 TECHNICAL DATA 13
SECTION 3 INSTALLATION 16
3.1 GENERAL RULES 16
3.2 INSTALLATION OF THE UNIT 17
SECTION 4 HYDRONIC, USED OIL AND GAS INSTALLATION 20
4.1 WATER PIPING DESIGN AND INSTALLATION 20
4.2 SIZING A SYSTEM PUMP 21
4.3 EXPANSION TANK SIZING 26
4.4 GAS SUPPLY PIPING 29
SECTION 5 ELECTRICAL CONNECTION 31
5.1 POWER SUPPLY 31
5.2 PUMP WIRING 32
5.3 CONTROL SWITCH WIRING 33
5.4 CHILLER WIRING 37
SECTION 6 START-UP AND ADJUSTMENT 38
6.1 DETERMING VOLUMES OF HYDRONIC SYSTEM AND ANTIFREEZE 38
6.2 FILLING THE WATER PIPING 39
6.3 GAS PRESSURE ADJUSTMENT 41
6.4 USED OIL BURNER ADJUSTMENTS 42
6.5 CHILLED WATER TEMPERATURE REGULATION 43
SECTION 7 USED OIL BURNER 43
7.1 OIL BURNER TECHNOLOGY 44
SECTION 8 OIL PUMP 47
SECTION 9 SERVICING AND MAINTENANCE 48
SECTION 10 TROUBLE-SHOOTING INSTRUCTIONS 56
SECTION 11 ADAPTING TO ANOTHER TYPE OF GAS 64
SECTION 12 APPENDIX 65
SECTION 13 WARRANTY 68

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Carefully read the information contained in this manual. It contains important instructions regarding installation,
use and maintenance safety. Save this manual for any future needs. The manufacturer cannot be held
responsible for any damages from improper, erroneous or irrational use.
With the aim of continuously improving of quality of our products, manufacturer reserves the right to change
reported instructions and drawings without any prior notice.
1 GENERAL WARNINGS
This manual is an integral and essential part of the product and must be given to the owner.
Only qualified technicians, strictly complying with the manufacturer’s instructions and the local
standards, should install this product. The manufacturer will not accept responsibility for personal
injuries or property damage resulting from improper installation.
Qualified technicians are those having specific technical competence in air conditioning and gas
appliances according to international and national standards.
This appliance must be used exclusively for its intended purpose. All chilling applications must be in
accordance with the operating specifications of the unit. Any other use is considered improper and,
therefore, dangerous. Steps must be taken to avoid improper use and potential dangers.
The fluids used in the sealed refrigerant circuit may cause health problems if inhaled, ingested or
when allowed to come into contact with the skin. It is recommended that no work be performed on the
sealed refrigerant circuit except by a qualified service technician or engineer. Care should also be
taken not to disturb or handle the valves of the chiller’s sealed refrigerant circuit.
The manufacturer will not accept contractual or non-contractual liability for damages resulting from
improper installation or misuse of the unit or intentional disregard of any of the manufacturer’s
instructions.
After unpacking the unit, check the unit for integrity. Due to the potential danger, keep all packaging
materials (plastic bags, polystyrene foam, nails, etc.) away from children.
Before installation, it is recommended that all chilled water and oil/gas supply piping be flushed. If not
flushed prior to installation, residual materials may be left in the piping that could cause improper
functioning of the chiller.
The installation of the appliance must conform to the requirements of the authority having jurisdiction
or in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI
Z223.1. If the unit is installed in Canada, the installation must conform to the Canadian Gas
Association Standard CAN1 B149.1 and .2.
The chiller’s electrical connections and grounding must be in accordance with the latest edition of the
National Electrical Codes, ANSI/NFPA No. 70 (CSA Standard C22.1 when installed in Canada) and
with any local codes. To ensure the electrical safety of this appliance, it must be correctly connected
to an efficient grounding system. The manufacturer is not responsible for any damages caused by the
failure of the grounding system.
In the case of failure and/or poor unit performance, shut the unit down in the proper manner,
disconnect the unit’s power supply and close the gas valve. Do not attempt any repair and call a
qualified technician for service. The chiller should also be disconnected when not in use for a
prolonged period of time.
The manufacturer’s authorized service technicians, using only original replacement parts, must
perform repairs to the product. Failure to adhere to this guideline may compromise the safety of the
unit. To ensure the correct operation and efficiency of the unit, it is essential that qualified service
technicians perform annual maintenance in accordance with the manufacturer’s instructions.
Should the unit be sold or transferred to another owner, it is imperative that this manual be provided
for use to the new owner and/or installer.
NOTE

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Under no circumstances should the unit be operated with any safety or electrical component
by-passed or defective.
Do not use this appliance if any part has been under water. Immediately call a qualified service
technician to inspect the appliance and to replace any part of the control system and any gas
control, which has been under water.
Before starting the appliance:
A qualified service technician must verify that:
- The electric and oil/gas supplies are the same as indicated on the rating plate
- The fuel supply and water distribution systems are water tight
- The appliance is supplied with the type of fuel for which it is preset
- The oil and gas supply gallons per hour and pressure conform to the oil flow rate and gas
pressure indicated on the rating plate.
- The oil/gas supply system is appropriately designed for the BTU and gas rate needed by the unit,
and equipped with all safety and control devices prescribed by standards in force.
To guarantee the correct operation of the unit and avoid possible failures, ALWAYS turn off the unit
by means of the thermostat or any switch that controls the operation of the unit.
NEVER turn off the unit by shutting off the power supply.
WARNING

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2 OVERVIEW AND TECHNICAL DATA
2.1 OVERVIEW
The High Efficiency ACF series chiller is a single-block water-chilling unit equipped with an air-cooled
condenser and designed for outdoor installation. The absorption cooling cycle is based upon a
solution of water and ammonia for the production of chilled water at a temperature as low as 37oF.
The chilling system is fed by thermal energy provided by used oil burner or gas burner; therefore, the
required electric energy is limited to driving the fan, pump motors and oil burner components. The
removal of combustion gases is handled by the appliance's condenser fan and oil burners internal
blower, which creates a forced draft.
The combustion fuel is Fuel Oil or Used Oil, Natural Gas or Propane Gas.
Required electric supply is 208 / 230V –60Hz single phase.
CHILLER’S CONTROL AND SAFETY DEVICES
Electronic Control Board with integrated microprocessor controls the operation of the chiller.
High Temperature Limit Switch (manual reset) is located at the generator wall above the
combustion chamber; the switch opens if the generator's sidewall temperature exceeds 330°F; the
switch is manual reset. The switch can be reset when the generator sidewall temperature drops below
280°F.
Safety Relief Valve on the sealed circuit is set to release ammonia vapor if internal pressure exceeds
450 psig; the valve closes automatically when pressure is under 450 PSIg
Differential Air Pressure Switch on the combustion circuit stops the burner ignition due to
insufficient combustion air flow.
Ignition Control Box controls the burner ignition. Checks the differential air pressure switch and
starts the pre-mixer blower. After 30 seconds of purging, the ignition control box opens the gas valve
and starts the ignition transformer sparking at the burner for 8 seconds. If no flame is detected, the
ignition control box will close the gas valve and retry lighting after an inter-purge period of 30 seconds.
The ignition control box will try a total of three times to light. The unit will stop if no flame has been
established or detected after the 3 tries.
Dual Gas Valve: two gas valves in the same housing, electrically controlled, which positively stops
gas flow when either closes.
Flow Switch monitors the chilled water flow and shuts down the unit when the water flow stops or
drops to an insufficient level.
Pre-Heater Control Board located at the oil burner automatically prevents the burner from energizing
if the oil is less than 150°F.
Oil Primary Control located on the oil burner locks out the burner operation if flame is not detected
within a 45 second time period. Requires manual reset.
Over Temperature Snap Switch located on the oil pre-heater block prevents energizing of the pre-
heater block if the temperature exceeds 175°F and will automatically reset when temperature drops
below 145°F.

Installation, Start-Up, Adjustment and Maintenance Manual
7
2.2 USED OIL AND GAS FIRED CHILLER OPERATION CYCLE
DESCRIPTION OF THE ABSORPTION REFRIGERANT CYCLE
The fluid used in the cooling cycle is a solution of water and ammonia (see Figure 1). Ammonia is the
refrigerant and water is the absorbing fluid. In the chiller’s generator, the ammonia-water solution is
heated to boiling producing both a vapor with a strong concentration of ammonia and a liquid solution
with a low concentration of ammonia. Liquid solution with a low concentration of ammonia is called a
"weak solution".
The ammonia vapor passes into the rectifier, which separates the water from the vapor. The hot and
pressurized ammonia vapor exiting the rectifier enters the condenser where it is cooled and changed
to a liquid.
The liquid ammonia is then brought to a lower pressure by means of a restricter and further cooled in
a “tube-in-tube” refrigerant heat exchanger. Finally, the liquid ammonia is reduced to a pressure of 39
to 60 psig and a temperature lower than 37°F by a second restricter.
Under this low pressure and temperature condition, liquid ammonia enters the evaporator where the
ammonia evaporates due to heat being removed from water returning from the user's required cooling
application (thermal blowers, fan-coils, etc.) within the chilled water system.
The cold, low-pressure ammonia vapor exiting the evaporator exchanges heat with the liquid ammonia
coming from the condenser in the refrigerant heat exchanger. The ammonia vapor then enters the
“solution cooled absorber” where it comes into contact with "weak solution" from the generator that
has been brought to a low pressure by means of a restricter.
Inside the “solution cooled absorber” the absorption process starts, i.e. the dilution of ammonia vapor
into the "weak solution". The absorption of ammonia vapor is an exothermic process. (i.e. heat is
produced) To have the vapor completely absorbed by the solution, the solution exiting the “solution
cooled absorber” must be further cooled in a portion of the condenser/absorber coils.
Once the absorption process is complete, the liquid solution contains a high concentration of
ammonia, also called "strong solution". A hydraulically driven, diaphragm pump pumps the “strong
solution” to the generator at high pressure.
As the “strong solution” is pumped to the generator, it passes through the coil of the rectifier and the
solution cooled absorber (the GAX section) where it is preheated before entering the generator. The
cycle then starts over.

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Figure 1 –ABSORPTION REFRIGERANT CYCLE
STRONG
SOLUTION
WEAK
SOLUTION
VAPOR
REFRIGERANT
LIQUID
REFRIGERANT
CHILLED
WATER
SOLUTION PUMP
EVAPORATOR
LEVELING CHAMBER AND RECTIFIER
GENERATOR
RESTRICTOR
BURNER
SOLUTION
COOLED
ABSORBER
REFRIGERANT HEAT EXCHANGER
RESTRICTOR
RESTRICTOR
CONDENSER/
ABSORBER COLIS

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9
DESCRIPTION OF THE CHILLER OPERATIONS
All chiller functions and operations are monitored and controlled by the electronic control board.
The temperature probes, placed on the system in order to monitor the operation of the chiller, are
transferring the following operating temperatures to the electronic control board:
-outlet chilled water temperature
-inlet chilled water temperature
-ammonia outlet temperature from condenser
-external ambient temperature
-generator temperature
Further control of the chiller’s operation is carried out by:
-high temperature limit switch
-high pressure limit switch
-water flow switch
-differential air pressure switch
-chilled water thermostat
-hydraulic pump rotation probe
To control the startup of the chiller, it is necessary to install a control switch (not included with the
unit). The switch can be a programmable timer, room thermostat or any other type of on/off switch.
The installer must do installation of this switch. Approximately 1 second after the control switch is
closed, the electronic control board will start the hydraulic pump, condenser fan and water pump (if
controlled by the board). Simultaneously, the electronic control board will energize the oil burner if
using oil for fuel or the ignition control box if using LP or natural gas. Using LP or natural gas the
ignition control box will check the differential air pressure switch’s status and then start the ignition
sequence. The premixer motor will then start.
Used Oil (Primary): Assuming Oil Pre-heater has established set-point temperature, the Oil Primary
will energize the burner blower motor, fuel valve, igniter circuitry, and on-burner air compressor at
which time a flame is established. The chiller is then in normal operation.
Natural Gas (Secondary): After a 15-second purge period, the ignition control box will energize the
ignition transformer and dual gas valve simultaneously. The ignition transformer sends a high voltage
current through the igniter to generate a spark igniting the fuel-air mixture at the burner. When flame
is established, the flame sensor signals that fact to the ignition control and the ignition control stops
the spark. The chiller is then in normal operation.
After the burning device has established a flame, The Display of the electronic control board, during
the normal operation, shows in alternative mode the following information:
Water inlet temperature (after the symbol )
Water outlet temperature (after the symbol )
Temperature difference ΔT (after the symbol )
Used Oil: de-energize the transfer relay which will shut down the Oil Primary causing the oil burner to
shut off.
Natural Gas: shutdown the ignition system (i.e. the dual gas valve will close and the premixer motor
will stop). The gas burner shuts off.
And 215 seconds later the hydraulic pump, condenser fan and water circulator contacts on the
electronic control board open stopping the hydraulic, fan and water pump motors. These motors are
ran for the 215 seconds to assure that solution is returned to the generator, residual cooling in
evaporator is used and the unit is made ready for the next operating demand.

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-Ammonia-water solution pump: The unit will stop if 15 seconds after start-up or during the
operation of the appliance, no signal is received from the hydraulic pump rotation probe. (fault code
E11 will appear on the electronic control board display)
-Condenser Fan: The fan’s speed depends on the external ambient and condenser outlet
temperatures. When ambient temperature is above 91°F, the fan is at full speed. Condenser and
external ambient temperatures are monitored continuously. Fault codes will appear on the
electronic control board display and the appliance will stop if any of the following occur: condenser
overheating - fault code E04; external ambient temperature above 131°F - fault code E05; external
ambient temperature below 10°F - fault code E06.
-Used Oil Burner Cooling Fan: The fan will be operative whenever the used oil burner is running.
It helps in cooling the combustion chamber and burner assembly.
-Water Pump (not supplied with the unit): A water pump is used for chilled water circulation. The
burner will turn off when the water flow rate is insufficient or stopped for more than 15 seconds and
a fault code of E10 will appear on the electronic control board. During a normal shut down, the
water pump will, if controlled by the electronic control board, continue to run for 215 seconds.
-Chilled Water Control: When the leaving chilled water temperature reaches the set point, the unit
will shut down. If the control switch is still calling for cooling, i.e. closed, the unit will restart when
the leaving water temperature reaches 1°F above the chilled water thermostat setting.
-Low Temperature Chilled Water Control: When the leaving water temperature is below the
chilled water thermostat set point, the appliance will be shut down. If the control switch is calling for
cooling, i.e. closed, and the water temperature falls below 33°F (fault E03 will appear on the
electronic control board display), the water pump will run continuously after the normal shut down
time of 215 seconds. The unit will automatically restart when the outlet water temperature reaches
1°F above the chilled water thermostat set point.
When chiller is running, the following operations are continuously monitored:
-Temperature probes; in the case of a short circuit or missing signal from the probes, the unit will
stop and the respective fault code will display on the electronic board.
-High temperature limit switch and high pressure limit switch, both are manual reset; The
intervention of any of these safeties causes the unit to stop and the respective fault code will
display on the electronic board.
-Oil burner photo eye; detects the absence of flame, If flame is not detected within 45 seconds
the Oil Primary will shutdown the oil burner.

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When the appliance is turned off from the control switch (thermostat, programmable timer or similar),
the hydraulic pump, fan and water pump (if controlled from electronic board) will continue to run for
the next 215 seconds.
Figure 2 - The S-60 Electronic Control Board
A = 4 digit display shows the operation data (example: chilled water temperature) and possible anomalies. It also
displays all relative available information (data, parameters, values, etc…)
B = Regulating Knob (Encoder) allows the scrolling and selection of the information on the display.
NOTE
A
B

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Figure 3 –USED OIL BURNER/COMBUSTION CHAMBER (door open for chamber viewing).
BURNER
ASSEMBLY
W/ON BURNER
COMPRESSOR
(for burneer gun
assembly only)
HINGED
COMBUSTION
CHAMBER
AIR BLAST
MANIFOLD
TUBE
AIR BLAST OR
GAS/PROPANE
MANIFOLDS
AIR STORAGE
TANK (air or
additional self
contained
compressor)
AIR OR
GAS/PROPANE
SELECTOR
MANIFOLD

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2.3 TECHNICAL DATA1
PERFORMANCE RATINGS
Nominal Cooling Capacity2
Btu/hr
60,500
Natural Gas/Used Oil Input
Btu/hr
94,900
Maximum Ambient Operating Temperature
F
120
Minimum Ambient Operating Temperature
F
32
Condenser Air Flow3, Nominal
Minimum
CFM
CFM
6,000
2,000
Chilled Water Entering Temperature, Maximum
F
113
Chilled Water Leaving Temperature, Minimum
F
37.4
Chilled Water Flow, Nominal
Minimum Allowable
Maximum Allowable
GPM
GPM
GPM
12.2
11
14.1
Internal Pressure Drop
Feet of Head (psig)
9.7 (4.2)
ELECTRICAL RATINGS
Required Voltage, 60 Hz, Single Phase4
-
208/230
Condenser Fan Motor HP (Variable Speed)
Full Load / Locked Rotor Amps, Nominal
-
-
1/2
3.1 / 6.2
Hydraulic Pump Motor HP
Full Load / Locked Rotor Amps, Nominal
-
-
1/2
3.1 / 24.2
Premix Blower Motor HP
Full Load / Locked Rotor Amps, Nominal
-
-
1/50
.55 / .75
Burner Cooling Fan HP
Full Load Amps /Watts
-
-
1/4
.85/186.5
Burner/Pump Electrical Requirements
Voltage 60Hz
Amperage
VAC
Amp
208/230
6.25
Total Electrical Operating Consumption5
kW
2.85
Minimum Circuit Ampacity (MCA)
-
20.4
Maximum Over Current Protection (MOCP)
Qty (2) - Field Supplied
Amp
30
PHYSICAL DATA
Refrigerant Type
-
R717
Unit Chilled Water Volume6
Gallons
0.79
Chilled Water Entering and Leaving Connections7
FPT
1
Gas Inlet Connection
FPT
1/2
Electrical Entrance Knockouts, Diameter
Inches
7/8
ShippingWeight
Pounds
1450
Operating Weight
Pounds
1350
Table 1 –OWC-5 TECHNICAL DATA
Notes:
1. All illustrations and specifications contained herein are based on the latest information available at the time of
publication approval. Enviro Heat reserves the right to make changes at any time without notice, in materials,
specifications, and models or to discontinue models.
2. Capacity at standard conditions of 95F ambient temperature. Chilled water Oulet temperature 45F, chilled water
Inlet temperature 55F. Actual capacity will vary with ambient (condenser) air temperature and leaving water
temperature. Capacity characteristics are shown in the table 2. Interpolations between tabled values are permissible,
but do not extrpolate.
3. Fan speed is reduced when external temperature is less than 91.4F.
4. Units are factory- wired for 208-230 volt operation.
5. May vary by ±10% as a function of both power supply and electrical motor input tolerance.
6. "Chilled Water" refers to a solution of quality tap water and 10% by volume of inhibited permanent antifreeze. Higher
antifreeze concentrations may be required in certain applications.
7. DO NOT USE FERROUS METAL PIPE OR TUBING in the chilled water circulating system.

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TYPICAL CAPACITY CHARACTERISTICS in Btu/hr
AMBIENT AIR
TEMPERATURE (F)
OUTLET CHILLED WATER (F)
37.4
41.0
44.6
48.2
32
59,307
59,912
61,123
62,323
41
59,307
59,912
61,123
62,333
50
59,307
59,912
61,123
62,323
59
59,307
59,912
61,123
62,333
68
59,307
59,912
61,123
62,323
77
58,701
59,912
61,123
62,333
86
54,465
59,307
61,123
62,333
95
40,546
52,650
60,517
61,727
104
-
-
53,255
56,281
113
-
-
40,546
47,203
120
-
-
-
39,336
Table 2 –OWC-5 COOLING CAPACITY
Figure 4 –UNIT’S DIMENSIONS
51”
(INCLUDES FAN GUARD)
33-1/2”
91”
SEE FIGURE 10
FOR DETAIL
SHIPPING CRATE DIMENSIONS
58”H x 94”D x 52”W

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Graph 1 –UNIT’S PRESSURE DROP AS A FUNCTION OF INLET WATER TEMPERATURE
10
11
12
13
14
15
16
17
18
19
11.5 12 12.5 13 13.5 14
PRESSURE DROP –FEET OF HEAD
WATER FLOW –GALLONS PER MINUTE
46F
52F
55F
63F

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3 INSTALLATION
3.1 GENERAL RULES
Only qualified technicians, in compliance with the manufacturer’s instructions, should carry out the
installation and maintenance of the OWC-5 unit. The installation of the appliance must conform to the
requirements of the authority having jurisdiction or in the absence of such requirements, to the latest
edition of the National Fuel Gas Code, ANSI Z223.1. If the unit is installed in Canada, the installation
must conform to the Canadian Gas Association Standard CAN1 B149.1 and .2.
All wiring should be installed in accordance with the latest edition of the National Electrical Codes,
ANSI/NFPA No. 70, CSA Standard C22.1 when installed in Canada, and with any local codes.
The manufacturer cannot be held responsible for any damages to persons, animals or goods
due to improper, erroneous or irrational installation of these appliances.
To ensure a correct installation and maximum unit performances are obtained, the following rules
have to be followed:
-Unpack the unit carefully, checking that it has not suffered damage during transport. Each unit is
factory tested before shipping, if damage is found report this immediately to the haulage
contractor.
-Each unit must be installed outdoors in an area of free natural air circulation and does not
require particular weather protection.
In no case must the unit be installed in a room.
-No overhead obstructions should block the outlet of air from the unit top.
-The unit should not be installed so that the fan discharge is in close proximity to the fresh
air intakes of a building or in such a manner that hot or contaminated air from flues, dryer
vents, chimney, etc., could be drawn into the unit by the condenser fan.
-The front and rear sides of the unit must have a minimum clearance of 36 inches and 24 inches,
respectively, (for maintenance or servicing) from walls or other stationary constructions. The left
and right sides require a minimum distance of 18 inches for proper airflow toward the condenser.
-Be sure that gas supply provided from the gas main meets the manufacturer’s specifications. Inlet
gas pressure to the unit must not exceed 14.0" W.C. on natural gas or propane gas. The minimum
inlet gas pressure at the unit is 5.0" W.C. on natural gas and 11.0" W.C. on propane gas.
The electrical safety of the unit is obtained only when it is correctly connected to an efficient grounding
system, which meets existing applicable safety standards. Never use gas supply piping to ground the
appliances. The ground wire should be longer than power supply wires for safety reasons. If the power
supply wires are accidentally stretched, the ground wire will be the last to break. By following this rule,
good ground continuity will be assured.
WARNING

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17
3.2 INSTALLATION OF THE UNIT
HANDLING OF THE UNIT ON SITE
When arriving at the installation site, visually inspect the unit for any signs of damage to the package,
which may indicate possible unit damage.
Once on site, the units must remain in the factory packaging and only be unpacked at the moment
before installation.
Before locating and unpacking the unit, make a hole in the package to check for ammonia odor. If
ammonia odor is present, contact the factory.
LOCATION
The chillers must be installed outdoors in an area of free natural air circulation.
The installation inside a room or a building is not allowed.
There must be a minimum clearance of 4 feet horizontally from electric meters, gas meters,
regulators, and relief equipment and in no case located above or below these items unless a 4 feet
horizontal distance is maintained.
The unit can be installed at ground level, on a platform or on the roof (if it can withstand the weight).
The noise generated by the condenser fan during unit operation is not excessive. However, avoid
locating the unit in an area adjacent to bedrooms or neighboring buildings (see Figure 5).
Also, avoid installing the unit in building corners, where air turbulence can take place or the unit noise
(reverberation) can be amplified.
Figure 5 - LOCATION OF THE UNIT
CLEARANCES
A free space is to be provided around the unit to allow for proper unit operation and for servicing. The
minimum clearance from walls, obstructions and other units should be as follows (see Figure 6):
•right / left side: 18 inches
•rear side: 24 inches
•front side: 36 inches
BEDROOMS
LIVING
ROOM
GARAGE
GOOD
BETTER
IDEAL
AVOID
INSTALLATION IN
THIS AREA

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Figure 6 –CLEARANCES FOR CORRECT INSTALLATION OF THE UNIT
There MUST NOT be any obstructions or structural overhangs (roof edges, balconies) over the top of
the unit. The re-circulation of the air discharged from the condenser results in a poor unit performance.
When the unit is installed in close proximity to buildings, keep the unit away from the roof edge drip
line. In no case should the unit be placed within 6 feet of any external air intakes of the building. For
installations on balconies or roofs, the unit should not be located within 8 feet from chimney flues,
outlets and other such vents. It is important that the unit be located so that hot or contaminated air IS
NOT drawn into the air intakes of the unit (see Figure 7).
Figure 7 –CLEARANCES FROM VENT OUTLETS, CHIMNEY FLUES AND AIR INTAKE OPENINGS
GROUND INSTALLATION
Ground level units should be supported on a LEVEL concrete pad with a minimum thickness of 4" and
slightly larger than the unit base (see Figure 9 for typical slab dimensions). Local soil conditions will
actually dictate the slab thickness required to prevent shifting.
Do not allow the concrete slab touch the foundation of a structure. Unit operational noises can be
transmitted inside the structure if they are connected.
ROOF / TERRACE INSTALLATION
GROUND INSTALLATION
6 FT. MIN
6 FT. MIN.
8 FT. MIN.
8 FT. MIN.
18” 18” 18” 18” 18”
36” 24”
36” 24”
SINGLE UNIT
MULTIPLE UNITS

Installation, Start-Up, Adjustment and Maintenance Manual
19
Figure 8 –DIMENSIONS AND THE POSITION OF THE CONCRETE SUPPORTS
ROOF / TERRACE INSTALLATION
If the unit must be lifted by a hoist for installation, leave it on the crate base. Attach hoist lines to the
crate base and use spreader bars to prevent the hoist lines from damaging unit's cabinet panels.
Both the unit and the supporting base weight should be sufficiently supported by the roof joists.
Provide for a gangway all around the unit for maintenance purposes.
WARNING: IF ROOF MOUNTED A FIRE PROOF BARRIER IS NEEDED BETWEEN CHILLER AND
ROOF
Installation on roofs directly above sleeping quarters should be avoided if possible. If not possible,
special consideration must be given to the transmission characteristics of the building structure. The
use of vibration isolators under the equipment (acoustically insulated bases) and approved flexible
connections (vibration-dampening pipefittings) between the unit and the system piping is
recommended.
LEVELING
The unit should be level both front to back and side to side. Place a level on the top of the unit to
check for level. If the unit is not level, metal shims are recommended for use under proper corners to
obtain level. If the shim(s) thickness exceeds 1/2", support shims should be inserted under the center
of the unit.
4” CONCRETE
SLAB
92 1/2” TYPICAL
35” TYPICAL

Installation, Start-Up, Adjustment and Maintenance Manual
20
4 HYDRONIC AND OIL/GAS INSTALLATION
4.1 WATER PIPING DESIGN AND INSTALLATION
Piping for the chiller is to be designed and installed as a closed hydronic circuit.
The following items (not supplied) must be installed close to the unit (see the Figure 9):
-FLEXIBLE CONNECTIONS to avoid vibration transmission to the chiller water lines.
-PRESSURE / TEMPERATURE TAPS in the inlet and outlet chiller water lines to set and
measure proper water flow and water temperatures.
-CHILLED WATER FILTER mounted in the water inlet line to remove debris from the chiller
water lines.
-REGULATION VALVES for adjusting proper water flow rate.
-WATER PUMP properly sized for system.
-EXPANSION TANK must be properly sized based on the hydronic system size, maximum
thermal expansion, and maximum water pressure.
-FILL VALVE for filling, draining or flushing the hydronic system.
-AIR BLEED set at the highest point in the hydronic system for removal of air.
To ensure the correct operation of the unit and to avoid the water freezing, add 10% by volume
of mono-ethylene glycol (antifreeze) to the circulation water. Add more mono-ethylene glycol as
needed for the minimum external temperature of the installation zone (see Table 10).
When using an automatic water charge system, the glycol percentage must be checked once a year.
There must be correct chilled water flow when the unit is operating and during the shut down period
(215 seconds, between turning the burner off and complete shutdown of the appliance).
Piping (diameters of tubes etc.) must be sized appropriately in order to ensure the correct chilled
water flow necessary for the proper operation of the unit. The water lines should also be sized so the
maximum velocity of the water/glycol solution in the lines does not exceed 6 feet per second to avoid
excessive noise.
When rigid pipes are used, it is recommended to use flexible connections between the unit and piping
to avoid vibration transmission.
All piping must be properly insulated according to federal and local codes to avoid thermal losses and
condensate on the water lines. All seams and joints should be carefully made so as to be air and
watertight.
For size of water connections on the unit, refer to TECHNICAL DATA sheet in SECTION 2.
Connections at the coil or heat exchanger must be performed in accordance with the
recommendations of the coil or heat exchanger manufacturer. For best performance, the supply-
chilled water line must attach to the side of the coil or heat exchanger nearest the exit of the leaving
cooled medium.
If the heat exchanger is an air coil, the air coil must be installed downstream from the furnace to avoid
condensation in the furnace. Additionally if the heat exchanger is an air coil, a “P” trap must be
provided to drain condensate. The height of the “P” trap must be sufficient to ensure drainage of
condensate. Any horizontal run of the condensate drain line must slope ¼” for each running foot and
not be smaller than ¾” I.P.S. to assure the condensate will drain by gravity. The condensate drain line
must be insulated and ran to a suitable drain.
WARNING