Mueller 9843514 User manual

Part No. 9843514
Effective February 12, 2003
Revised April 17, 2023
Falling Film Chiller
INSTALLATION AND OPERATION MANUAL

Section 1.0 – Introduction
1.1 General Information.........................................................................................................1
1.2 Model 3 x 5 Falling Film Chiller Standard Features ........................................................................1
Table 1: Model 3 x 5 Falling Film Chiller Dimensions ..................................................................... 2
1.3 Model 4 x 8 Falling Film Chiller Standard Features ....................................................................... 3
Table 2: Model 4 x 8 Falling Film Chiller Dimensions ..................................................................... 4
1.4 Plate Design ..................................................................................................................5
Figure 1: Plate Design for Direct Expansion or Recirculated Refrigeration Systems......................................5
Figure 2: Plate Design for Flooded Refrigeration Systems .................................................................5
1.5 Model Number Breakdown................................................................................................. 6
Section 2.0 – Installation
2.1 Inspection ................................................................................................................... 7
2.2 Locating and Leveling the Chiller .......................................................................................... 7
2.3 Obtaining Parts ............................................................................................................. 7
Table 3: Recommended Chilled Water Line Size .......................................................................... 8
2.4 Locating Condensing Units ................................................................................................ 8
2.5 Connecting the Refrigerant Lines.......................................................................................... 9
2.6 Liquid Line Solenoid Valve ................................................................................................. 9
2.7 Water Line Connections.................................................................................................... 9
Figure 3: Component Locations ...........................................................................................10
2.8 Makeup Water Valve.......................................................................................................10
2.9 Connecting the Overflow Line .............................................................................................11
2.10 Mueller Multi-Stage Chiller Cooling and Pump Control..................................................................11
2.11 Optional Chiller Cabinet Venting ..........................................................................................11
2.12 Glycol Solution..............................................................................................................11
2.13 Setting Chiller Water Flows ................................................................................................11
Table 4: Distribution Pan Water Flow Rates .............................................................................. 12
2.14 Cleaning the System ....................................................................................................... 13
2.15 Test Running............................................................................................................... 13
Table of Contents
Falling Film Chiller
INSTALLATION AND OPERATION MANUAL
Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023

Section 3.0 – Condensing Unit Setup/Startup Procedures
3.1 Refrigerant Charging ......................................................................................................14
Table 5: Condensing Unit Refrigerant Charge ............................................................................ 15
3.2 Pressure Switch Adjustments ............................................................................................. 15
Table 6: Pressure Switch Settings ......................................................................................... 15
3.3 Head Pressure Control Valve Adjustment ................................................................................ 15
3.4 Plate Superheat Adjustment .............................................................................................. 16
3.5 Hot Gas Adjustment ....................................................................................................... 16
Table 7: Hot Gas Bypass Settings .......................................................................................... 16
3.6 Liquid Injection Adjustment ..............................................................................................17
3.7 Ambient Fan Cycling Control Adjustment................................................................................ 17
Figure 4: Condensing Unit Schematic ....................................................................................17
Figure 5: General Wiring Schematic ...................................................................................... 18
Section 4.0 – Cleaning the System
4.1 General Information....................................................................................................... 19
4.2 Chemical and Cleaning Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.3 Cleaning the System: Startup..............................................................................................20
4.4 Cleaning the System: Periodic Inspections and Cleaning Procedures...................................................20
Figure 6: Chiller Components .............................................................................................21
4.5 General Inspection Procedures ........................................................................................... 21
4.6 General Distribution Pan Cleaning Procedures ..........................................................................21
4.7 General Chiller Cleaning Procedures .....................................................................................22
4.8 Cleaning the System: Rust and Hard Water Stain Removal ..............................................................23
4.9 Rust and Hard Water Stain Removal Procedures.........................................................................23
Table of Contents
Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
1
1.1 GENERAL INFORMATION
Paul Mueller Company falling film chillers are designed to quickly and efficiently cool water or a liquid solution of
water and glycol for many different processes. Mueller® falling film chillers use gravity to flow the medium over
the refrigerated vertical evaporators for instant cooling. The medium is then either recirculated back into the
distribution pan above the Mueller Temp-Plate® evaporators to be cooled again or flowed out of the reservoir into
the process piping.
This manual provides the basic information necessary to install, startup, and operate a Mueller falling film chiller.
Please contact Paul Mueller Company for additional technical assistance.
Paul Mueller Company
1600 West Phelps Street
Springfield, Missouri 65802
Direct Telephone: [phone]
Facsimile: 1-800-436-2466
Email: [e-mail]
1.2 MODEL 3 X 5 FALLING FILM CHILLER STANDARD FEATURES
• Constructed of Type 304 or 316L stainless steel.
• Designed for use with R-22, R-404A, R-507, R-134a, R-448A, or R-717.
• Electronic makeup water solenoid assembly (optional).
• Hinged and gasketed cabinet top doors (optional).
• Clamp-type ferrule and male pipe-thread adapter for the inlet (included).
• Falling film chiller expansion valves for each refrigeration plate are available.
• Refrigeration capacity and refrigerant type must be specified at the time of order.
A. Required Water Flow Rates
1. High-flow distribution pan:
Minimum flow rate: 14.7 gpm per plate
Maximum flow rate: 29.0 gpm per plate
2. Low-flow distribution pan:
Minimum flow rate: 9.1 gpm per plate
Maximum flow rate: 14.3 gpm per plate
3. Extra-low-flow distribution pan:
Minimum flow rate: 5.8 gpm per plate
Maximum flow rate: 8.95 gpm per plate
Section 1.0 – Introduction

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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1.2 MODEL 3 X 5 FALLING FILM CHILLER STANDARD FEATURES (CONTINUED)
B. Nominal Operating Capacity of Insulated Tank*
• 2–8 plates: 173 U.S. gallons
• 2–8 plates, oversized reservoir: 365 U.S. gallons
*Tankless cabinets are also available.
C. Circulation Water Connection Size
• 2–8 plates: Inlet: Single, extra-low-flow pan, 2" MPT Outlet**: 4" MPT
Inlet: Single, low-flow pan, 2" MPT Outlet**: 4" MPT
Inlet: Single, high-flow pan, 3" MPT Outlet**: 4" MPT
*Optional 6", 8", and 10" RFSO pipe flanges are also available.
TABLE 1: MODEL 3 X 5 FALLING FILM CHILLER DIMENSIONS
3 x 5 Tankless Length (in) Width (in) Height (in)
Height with
Top Door (in) Weight (lb)
Weight with
Top Door (in)
2–8 plate cabinet 70 40.75 46.75 49.25 436 420
Refrigerant plate 64
Glycol plate 48
Pan 49
3 x 5 Tankless Length (in) Width (in) Height (in)
Height with
Top Door (in) Weight (lb)
Weight with
Top Door (in)
2–4 plate cabinet 68 24.75 46.75 49.25 354 348
Refrigerant plate 64
Glycol plate 48
Pan 33
3 x 5 with Tank Length (in) Width (in) Height (in)
Height with
Top Door (in) Weight (lb)
Weight with
Top Door (in)
2–8 plate cabinet 68.5 39.13 77.13 79.63 770 754
Refrigerant plate 64
Glycol plate 48
Pan 49
3 x 5 Oversized Length (in) Width (in) Height (in)
Height with
Top Door (in) Weight (lb)
Weight with
Top Door (in)
2–8 plate cabinet 68.5 39.13 97.13 99.63 837 821
Refrigerant plate 64
Glycol plate 48
Pan 49

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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1.3 MODEL 4 X 8 FALLING FILM CHILLER STANDARD FEATURES
• Constructed of Type 304 or 316L stainless steel.
• Designed for use with R-22, R-404A, R-507, R-134a, R-448A, or R-717.
• Electronic makeup water solenoid assembly (optional).
• Hinged and gasketed cabinet top doors (optional).
• Clamp-type ferrule and male pipe-thread adapter for the inlet (included).
• Falling film chiller expansion valves for each refrigeration plate are available.
• Refrigeration capacity and refrigerant type must be specified at the time of order.
A. Required Water Flow Rates
1. High-flow distribution pan:
Minimum flow rate: 31.0 gpm per plate
Maximum flow rate: 50.2 gpm per plate
2. Low-flow distribution pan:
Minimum flow rate: 17.9 gpm per plate
Maximum flow rate: 28.7 gpm per plate
3. Extra-low-flow distribution pan:
Minimum flow rate: 8.3 gpm per plate
Maximum flow rate: 15.5 gpm per plate
B. Nominal Operating Capacity of Insulated Tank*
• 2–8 plates: 293 U.S. gallons • 17–24 plates: 750 U.S. gallons
• 9–16 plates: 525 U.S. gallons • 25–32 plates: 1,113 U.S. gallons
*Tankless cabinets with 2–8, 9–16, and 17–24 plates are also available.
C. Circulation Water Connection Size
• 2–8 plates: Inlet: Single, extra-low-flow pan, 2" MPT Outlet**: 4" MPT
• 2–8 plates: Inlet: Single, extra-low-flow pan, 4" MPT Outlet**: 4" MPT
Inlet: Single, low-flow pan, 4" MPT Outlet**: 4" MPT
Inlet: Single, high-flow pan, 6" MPT Outlet**: 4" MPT
• 9–16 plates: Inlet: Dual, extra-low-flow pan, 4" MPT Outlet**: 6" RFSO pipe flange
Inlet: Dual, low-flow pan, 4" MPT Outlet**: 6" RFSO pipe flange
Inlet: Dual, high-flow pan, 6" MPT Outlet**: 6" RFSO pipe flange

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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1.3 MODEL 4 X 8 FALLING FILM CHILLER STANDARD FEATURES (CONTINUED)
C. Circulation Water Connection Size (Continued)
• 17–24 plates: Inlet: Triple, extra-low-flow pan, 4" MPT Outlet**: 8" RFSO pipe flange
Inlet: Triple, low-flow pan, 4" MPT Outlet**: 8" RFSO pipe flange
Inlet: Triple, high-flow pan, 6" MPT Outlet**: 8" RFSO pipe flange
• 25–32 plates: Inlet: Quad, extra-low-flow pan, 4" MPT Outlet**: 10" RFSO pipe flange
Inlet: Quad, low-flow pan, 4" MPT Outlet**: 10" RFSO pipe flange
Inlet: Quad, high-flow pan, 6" MPT Outlet**: 10" RFSO pipe flange
**Optional 6” , 8”, and 10” RFSO pipe flanges are also available.
TABLE 2: MODEL 4 X 8 FALLING FILM CHILLER DIMENSIONS
4 x 8 with Tank Length (in) Width (in) Height (in)
Height with
Top Door (in) Weight (lb)
Weight with
Top Door (in)
2–8 plate cabinet 104.38 39.13 90.63 92.88 1,169 1,164
9–16 plate cabinet 104.38 72.38 90.63 92.88 1,621 1,604
17–24 plate cabinet 104.38 105.63 90.63 92.88 2,060 2,035
25–32 plate cabinet 104.38 138.88 90.63 92.88 3,700 3,642
Refrigerant plate 130
Glycol plate 100
Pan 100
4 x 8 Tankless Length (in) Width (in) Height (in)
Height with
Top Door (in) Weight (lb)
Weight with
Top Door (in)
2–8 plate cabinet 108.75 41.75 61.44 63.59 787 782
9–16 plate cabinet 108.75 75.88 61.44 63.59 1,041 1,024
17–24 plate cabinet 108.75 109.13 61.44 63.59 1,444 1,419
Refrigerant plate 130
Glycol plate 100
Pan 100

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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1.4 PLATE DESIGN
Paul Mueller Company manufactures plates for the falling film chiller in two different styles. Figure 1 shows
the plate used for direct expansion or recirculated refrigeration systems. Figure 2 shows the plate used for
flooded refrigeration systems. Note the number of baffles in both designs. The direct expansion or recirculated
refrigeration plate has three baffles and the flooded refrigeration plate only has one.
FIGURE 1: PLATE DESIGN FOR DIRECT EXPANSION
OR RECIRCULATED REFRIGERATION SYSTEMS
FIGURE 2: PLATE DESIGN FOR FLOODED REFRIGERATION SYSTEMS
DX or Recirculated
Flooded

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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1.5 MODEL NUMBER BREAKDOWN
Cabinet Model
(If overflow is located
under front door)
A = Tankless
J = 293 (2–8 4 x 8)
K = 525 (9–16 4 x 8)
L = 750 (17–24 4 x 8)
M= 1,113 (25–32 4 x 8)
N = 173 (2–8 3 x 5)
O = 365 (2–8 3 x 5)
Cabinet Model
(If overflow is located
on the side of chiller)
I = Tankless
J = 361 (2–8 4 x 8)
K = 706 (9–16 4 x 8)
L = 1,084 (17–24 4 x 8)
M= 1430 (25–32 4 x 8)
N = 150 (2–8 3 x 5)
O = 345 (2–8 3 x 5)
Plate Size
N = 3 x 5
L = 4 x 8
Cabinet /
Plate Material
1 = 304 / 304
2 = 304 / 316L
3 = 316L / 316L
4 = 304 / 304 EP
5 = 304 / 316L EP
6 = 316L / 316L EP
7 = Other
ASME
A = ASME
N = Non-ASME
Manifolds
1 = Yes
2 = No
Pan Type
1 = High Flow
2 = Low Flow
3 = Extra-Low Flow
Sanitary /
Non-Sanitary
1 = Sealed Edge
2 = Non-Sealed Edge
No. of Plates
3 x 5 (2–12)
4 x 8 (2–36)
Refrigerant / Control Type
A = R-22 / DX
B = R-404A, R-507A / DX
C = R-134a / DX
D = R-717 / DX
E = R-22 / Flooded
F = R-404A, R-507 / Flooded
G = R-134a / Flooded
H = R-717 / Flooded
I = R-22 / Recirculated
J = R-404A, R-507 / Recirculated
K = R-134a / Recirculated
L = R-717 / Recirculated
M = Glycol
N = Other
P = R-448A

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.1 INSPECTION
Paul Mueller Company requires thoroughly inspecting the equipment before it is unloaded from the freight truck.
Carefully examine the equipment for concealed damage. Note any damage on the bill of lading, and take photos of
the damage, crating, and how the unit is positioned on the truck. In the unlikely event of damage during shipment, it
may be considerably difficult to receive compensation for damage not found prior to unloading.
IMPORTANT: It is imperative to note any damage on the bill of lading and have the driver sign it.
Open all packages and check against the bill of lading for shortages of parts. This allows you to order them prior to
equipment installation.
2.2 LOCATION AND LEVELING THE CHILLER
A. Location
Locate the falling film chiller as close as practical to the process and to the condensing units. A drain should be
close by for draining the chiller.
Consider ease of disassembly for cleaning and the possible future addition of more vertical evaporator plates
when selecting a location for the falling film chiller. To take full advantage of the chiller’s easy-clean feature,
a 3-foot clearance on each side of the chiller and a clearance equal to the length of the evaporator plate should
remain at the end opposite the refrigeration connections.
B. Leveling
The falling film chiller is equipped with adjustable legs for leveling. The chiller must be level for proper
operation of the distribution pan and to maintain an even film flow over the vertical evaporator plates. Leveling
also allows for complete drainage of the holding tank.
It is recommended to use a carpenter’s level placed on the top edge of the distribution pan in both directions or
on the top edge of the water storage tank will place the chiller at the proper pitch.
2.3 OBTAINING PARTS
The parts quantity, size, and type will vary with each installation.
A. Refrigeration
• Liquid line tubing.
• Suction line tubing.
• Reducers.
• Elbows (if elbows are used, Paul Mueller Company recommends a long radius type).
• Refrigerant (i.e., R-22, R-404A, R-448A, R-507, etc.).
• Hangers and brackets to support refrigerant lines or water lines.
• Support stands (if compressors are to be stacked or wall-mounted).
• Insulation: Due to evaporator temperatures, condensation is likely.
Insulation will be required to cover the refrigerant lines.
• Liquid line solenoid valve (if necessary).
Section 2.0 – Installation

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.3 OBTAINING PARTS (CONTINUED)
B. Water Lines
• Chilled water line (see Table 3 for the recommended chilled water line size).
• Adapter, tri-clamp to pipe thread.
• Fittings (e.g., Elbows, tees, unions, valves, and adapters).
• Circulating pump, if not provided.
• Flow switch. Please call Paul Mueller Company for sizing assistance.
• Overflow line, 2.0" PVC.
• Propylene glycol will be required if the cooling water is to be operated below 34°F (1.1°C).
• Drain valve(s) for draining the reservoir during maintenance.
TABLE 3: RECOMMENDED CHILLED WATER LINE SIZE
IMPORTANT: The maximum velocity recommended on the suction line to the circulator pump is 2 to 3
feet per second (FPS). The maximum velocity recommended on the discharge line and through the plate
heat exchanger (if used) is 7 to 10 FPS (feet per second).
2.4 LOCATING CONDENSING UNITS
Air Flow (for air-cooled condensing units only): There are several factors to consider when locating the
refrigeration units; the most important is air flow. Whether located inside or outside, it is essential that the
condenser has a supply of unrestricted fresh air. When units are located inside, it is very important that the louvers
be at least the same dimension as the condensing unit face.
• An exhaust fan or opening large enough to prevent any increase in static pressure must be provided.
• The units must be located so that routine maintenance can be accomplished (e.g., cleaning the condensers and
replacing the compressors).
• Avoid areas with machines that would create dust or oil.
Recommended Suction Line Size Recommended Discharge Line Size
Line Size (in)
Maximum
Flow (gpm) Velocity (ft/sec) Line Size (in)
Maximum
Flow (gpm) Velocity (ft/sec)
370 3.04 1.5 60 10.5
4 120 3.02 2 100 10.1
6 260 2.89 3 220 10.1
8 450 2.89 4 400 10.5
10 700 2.85 6 850 10.0

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.5 CONNECTING THE REFRIGERANT LINES
• Do not use tubular fittings that are smaller in diameter than the connections on the condensing unit or a flow
restriction will result. Use practical refrigeration practices for refrigerant line sizes.
• Use long radius fittings and do not bend tubing in a manner that will cause it to flatten.
• Always clean and deburr all fitting and tubing ends before soldering and purge with nitrogen.
• After soldering is complete, pressurize the tubing and leak test before evacuating and insulating the lines.
IMPORTANT: United States Environmental Protection Agency (EPA) regulations require that any
technician performing refrigerant installation or service on a high-pressure appliance be certified
as a Type II or Universal Technician in accordance with Section 608 of the Clean Air Act. Clean Air
act regulations may change or differ, depending on locality. It is the responsibility of the technician
performing the refrigerant service and/or installation to abide by all regulatory requirements and
procedures for the locality, state, and country.
2.6 LIQUID LINE SOLENOID VALVE
The Mueller condensing unit is designed to start and stop based on water temperature. It is not designed as a
pump-down system. For proper operation of the falling film chiller it is necessary to install a liquid line solenoid
valve to prevent refrigerant migration during down time. The solenoid should be wired to close upon compressor
shut down and open when the compressor restarts. Contact points are provided on the condensing unit to connect
a customer-supplied solenoid valve. See the general wiring schematic in Figure 5 for solenoid wiring information.
2.7 WATER LINE CONNECTIONS
• The water connections on the falling film chiller will be male pipe thread or tri-clamp fittings with an adapter
to male pipe thread.
• A short length of flexible hose must be used between the pump and chiller outlet to prevent damage to the
outlet due to vibration.
• Mueller recommends mounting the pump reasonably close to the falling film chiller with a gate-type valve on
both the inlet and outlet of the pump, so it can be isolated for servicing.
• A flow switch can be installed in the pump discharge line. It should be wired to shut the refrigeration units off
and activate an alarm if the cooling solution flow should stop unexpectedly to prevent a freezeup.
• If the chilled water is to be routed to more than one piece of equipment, a balancing valve must be used to
regulate the flow of water to each piece of equipment. It may be more effective to use a second pump for the
additional equipment.
• It is recommended to insulate the chilled water lines to prevent condensation from dripping at lower operating
temperatures.
• It is recommended to install a drain valve in the reservoir outlet piping so the chiller may be drained for
cleaning or maintenance purposes.

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.7 WATER LINE CONNECTIONS (CONTINUED)
• If PVC plastic pipe is used with solutions containing propylene glycol, the manufacturers of PVC or CPVC
pipe recommend Schedule-80 purple primer and Schedule-80 gray adhesive be used. The following procedure
should be used to assemble PVC or CPVC:
a. Scour primer into the surface with a hard bristle brush. It should be alternately applied to the surface of
the pipe once and to the fitting socket twice.
b. Solvent cement should be applied with a hard bristle brush while the primer is wet. It should be
alternately applied to the surface of the pipe twice and to the fitting socket once.
IMPORTANT: Galvanized pipe should not be used for applications with propylene glycol, as propylene
glycol can strip the zinc coating from galvanized pipe.
FIGURE 3: COMPONENT LOCATIONS
2.8 MAKEUP WATER VALVE
An optional water makeup valve is available. Some installations require a makeup water valve to replenish the
water used in the process. See Part No. 8826498, “Falling Film Chiller Water Level Control Instructions” for more
information.
Water Makeup Valve
Part No. 9841357
Refrigerant
Outlet
Flow Control
Refrigerant Inlet
Sensor
Cord Grip
PN 8822084
Multi-Stage
Sensor
PN 8825485
Optional Tank
Connections
Flow Control
Optional
Building Loop
CR0058
Vent Fan
PN 9843544
Sensor
Cord Grip
PN 8822084
Multi-Stage
Sensor
PN 8825485
Replacement Filter
PN 9843847
The building loop
return tee should be
located within 24˝ of
the process valve.
Outlet to Process
SENSOR A
SENSOR B
Field-
Installed
Drain

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.9 CONNECTING THE OVERFLOW LINE
This line should be installed with PVC pipe and must have a continuous pitch to the drain, as any trapping may
prevent drainage of this line. See Figure 3 for component locations.
2.10 MUELLER MULTI-STAGE CHILLER COOLING AND PUMP CONTROL
If the Mueller multi-stage chiller cooling and pump control was purchased, please reference the multi-stage chiller
control manual for installation and setup procedures.
A crucial step in the installation of the multi-stage chiller control is the location of the temperature sensors. A rise
in water temperature inside the chiller’s distribution pan will turn on Stage 1 and the condensing unit. The most
efficient way to accomplish this is to sense the temperature entering the pan. Sensor A should be installed in the .5"
FPT port between the water makeup valve and the chiller distribution pan connection. See Figure 3, “Component
Locations.” Sensor B should be located in the .5" FPT port on the process pump connection under the chiller door.
Sensor B is only used for referencing the temperature inside the chiller reservoir.
2.11 OPTIONAL CHILLER CABINET VENTING
Chillers using chlorinated water must be constantly vented to prevent chlorine rusting. Venting is handled by an
optional chiller cabinet vent fan located on the top of the chiller (see Figure 3 for location and part number). This
fan requires a separate, field-installed 120/60/1 power supply with a fused disconnect for service.
The chiller cabinet brings in fresh air through the door on the front of the chiller cabinet through a replaceable
mesh filter (see Figure 3 for location and part number).
2.12 GLYCOL SOLUTION
If the system is to be operated at or below 34°F (1.1°C), the water must be protected with an approved propylene
glycol to prevent freezing. To prevent fowling of the liquid solution, deionized water must be used. Refer to the
glycol manufacturer’s ratios to obtain the proper freeze point.
2.13 SETTING CHILLER WATER FLOWS
Setting the water flows after the temperature and pump controls are installed is important for several reasons.
When the recirculation and makeup water flows meet in the chiller’s distribution pan, it creates the blended
temperature that was specified when the chiller was sized. If the blend temperature is not correct, the chiller will
not perform properly.
When the chiller calls for makeup water, the sensor sees the rise in temperature as the water enters the pan.
The refrigeration unit then turns on, cooling the water down to the designed temperature in one pass across the
evaporator plates.
The correct water flow rates across the plates are achieved by setting the water depth in the distribution pan. The
two flows can be regulated by flow control setters or a manual valve that can be set to maintain the set position.

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.13 SETTING CHILLER WATER FLOWS (CONTINUED)
In order to set the correct distribution pan water depth, follow these instructions:
1. First, gather the following sizing information for the chiller:
• Size (3 x 5 or 4 x 8) and number of evaporator plates.
• Style of distribution pan (high flow, low flow, or extra low flow).
• Recirculation water flow required.
• Total water depth required in the distribution pan.
2. Allow the bottom reservoir to fill up to near the top level probe. Once it is close to that point, shut off the
makeup water with the isolation valve. The only water going into the distribution pan should be from the
recirculation circuit.
3. Using the sizing information in step 1, divide the required recirculation flow by the number of plates in the
chiller to calculate the water flow rate (gpm) per plate. Then, refer to the appropriate line in Table 4 for the
chiller size and selected distribution pan to determine the proper water depth.
Example: Falling film chiller, extra low-flow distribution pan; (4) 3 x 5 plates, 27 gpm recirculation flow.
27 gpm ÷ 4 plates = 6.75 gpm per plate. Referring to Table 4, this shows 2" of water depth.
4. Using the water depth determined from step 3, adjust the recirculation water flow to obtain this water depth.
The water level will require a few minutes to stabilize with each adjustment.
5. Reopen the makeup water supply and begin draining water from the reservoir so the makeup water solenoid
will open. Continue draining water to adjust the makeup water flow.
6. Using the sizing information gathered for this chiller, obtain the total water depth required in the distribution
pan. Adjust the makeup water valve to obtain this final level including the recirculation water depth calculated
from above. The water level will require a few minutes to stabilize with each adjustment.
Contact Paul Mueller Company’s Service Department at 1-800-756-5991 or [e-mail]
for assistance with obtaining sizing data for the chiller.
TABLE 4: DISTRIBUTION PAN WATER FLOW RATES
Distribution Pan
Distribution
Plate
Size
Water Flow Rate (GPM) Per Plate vs. Height of Water in Pan
1" 1.25" 1.5" 1.75" 2" 2.25" 2.5" 2.75" 3" 3.25" 3.5" 3.75" 4" 4.25" 4.5" 4.75"
High Flow 3' x 5' 14.7 17.8 19.8 21.1 22.3 23.5 24.6 25.5 26.3 27.4 28.2 29
Low Flow 3' x 5' 9.1 9.9 10.7 11.3 11.9 12.5 12.9 13.5 13.9 14.3
Extra Low Flow 3' x 5' 5.8 6.4 6.75 7.2 7.45 7.8 8.15 8.4 8.65 8.95
High Flow 4' x 8' 31 33.3 35.8 37.6 39.3 40.5 42.4 43.5 44.8 46.5 47.8 48.8 50.2
Low Flow 4' x 8' 17.9 19.3 20.5 21.8 22.6 23.6 24.5 25.3 26.3 27.2 27.8 28.7
Extra Low Flow 4' x 8' 8.3 9.2 10 10.6 11.3 11.9 12.5 13 13.4 13.9 14.3 14.6 15.2 15.5

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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2.14 CLEANING THE SYSTEM
The entire water circulation system must be cleaned prior to startup. See Section 4.3 for startup system cleaning.
2.15 TEST RUNNING
After the refrigeration and water piping is completed, the flows are set, all the electrical connections are made, both
water temperature sensors are installed, and the system has been cleaned, it is time to test run the system.
Start the circulating pump. After determining the chilled water system is operating properly, start the refrigeration
system(s) and check the setpoints of the refrigeration units, as described in Section 3.

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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3.1 REFRIGERANT CHARGING
IMPORTANT: EPA regulations require any technician performing refrigerant installation or service on a
high-pressure appliance be certified as a Type II or Universal Technician in accordance with Section 608
of the Clean Air Act.
The initial charge for the condensing unit is specified in Table 5. The charges indicated represent the volume
of refrigerant the condensing unit requires. This refrigerant volume does not account for refrigerant piping or
evaporator volume.
Extra refrigerant will be necessary in the winter for the head pressure control valve to function as designed. The
extra refrigerant must be sufficient enough in the receiver to flood the condenser and still maintain a “liquid seal”
at the receiver outlet. To assure the proper refrigerant charge for winter conditions and to avoid nuisance high
pressure trips in summer conditions, the extra refrigerant to flood the condenser should be weighed into the system
when the system is operating with its summer charge. Make sure that all fans are on when adding the extra winter
charge. Match the extra charge shown in Table 5 to the typical winter ambient temperature for the region the
condensing unit is installed in.
Once the total refrigerant charge has been determined follow these steps to charge the condensing unit properly:
1. Triple evacuate the entire refrigeration system to 500 microns. Break the first and second evacuation with dry
nitrogen. Make sure to leave all hoses connected through this process.
2. Following the third evacuation to 500 microns, keep the charging hoses connected to the low and high sides
of the system and connect the yellow hose to a cylinder of new or reclaimed ARI 700-88 specifications
refrigerant.
3. Weigh and record the gross weight of the refrigerant cylinder.
4. Purge any air from the manifold gauge hose, as specified by EPA Section 608, de-minimus release.
5. With the chiller circulation pump running, break the refrigeration system’s vacuum with liquid refrigerant,
charging into the liquid receiver on the high side of the system.
6. When the system pressure equalizes with the pressure of the refrigerant drum, energize the compressor.
7. While monitoring the gross weight of the refrigerant cylinder, weigh in the remaining charge in the liquid state
into the suction side of the system up-stream of the suction accumulator.
8. The final charge will be dependent on two factors; the volume of the evaporator plates and the equivalent
length of refrigeration piping. The sight glass must be clear with no bubbles for proper final operating charge.
Section 3.0 – Condensing Unit Setup/Startup Procedures

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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TABLE 5: CONDENSING UNIT REFRIGERANT CHARGE*
*All table values are based on R-507, R-404A, and R-448A. To calculate for R-22 or R-134a, multiply the total by 1.12.
**50–80 horsepower (HP) units are dual circuit. The listed charge is the sum of both units.
3.2 PRESSURE SWITCH ADJUSTMENTS
The high- and low-pressure switches will need to be adjusted prior to startup of the condensing unit. Verify each
pressure switch is set according to Table 6, below. It is important to verify the correct cut-in and cut-out of each
pressure switch by using a manifold gauge. DO NOT rely on the pressure switch pressure ranges alone to
verify proper settings.
TABLE 6: PRESSURE SWITCH SETTINGS
3.3 HEAD PRESSURE CONTROL VALVE ADJUSTMENT
The head pressure control valve is required to maintain stable head pressure when the outdoor ambient
temperature falls. This condensing unit has an adjustable control, which is factory set at 180 psig for 8 HP
condensing units and 200 psig for condensing units 10 HP and up.
IMPORTANT: This valve should not be adjusted unless it has been replaced.
If adjustment is required, the setting is increased by turning the adjusting stem clockwise and decreased by turning
it counterclockwise. A 15 to 20 psi change in head pressure results from one complete turn of the adjusting stem.
This adjustment should be made during low-ambient conditions.
Condensing
Unit (HP)
Summer
Charge (lb)
Extra Charge (lb) vs. Ambient Temperature
40°F -20°F 0°F 20°F 40°F 60°F Max Extra (lb)
8 and 10 10.9 15.0 14.6 13.9 12.8 11.1 3.8 17.6
15 21.2 21.7 21.2 20.2 18.7 16.1 11.0 25.5
20 and 25 39.8 21.7 21.2 20.2 18.7 16.1 11.0 25.5
30 44.8 32.2 31.4 29.9 27.6 23.8 16.3 37.8
35 52.2 32.2 31.4 29.9 27.6 23.8 16.3 37.8
40 60.5 47.9 46.7 44.5 41.1 35.5 24.2 56.3
50** 63.6 44.2 43.1 41.0 38.0 32.7 22.4 63.6
60** 84.1 64.3 62.8 59.8 55.3 47.7 32.6 84.0
70** 104.4 64.4 62.8 59.8 55.3 47.7 32.6 75.6
80** 121.0 95.8 93.4 89.0 82.2 71.0 48.4 112.6
Refrigerant
High-Pressure Switch Low-Pressure Switch
Cut-In Cut-Out Cut-In Cut-Out
R-22 175 350 40 20
R-507 220 400 55 35
R-404A 220 400 55 35
R-448A 225 400 42 35

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised April 17, 2023
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3.4 PLATE SUPERHEAT ADJUSTMENT
IMPORTANT: Ensure the evaporator plates are receiving the proper water flows prior to making any
superheat adjustments. See Section 2.12 for setting the correct water flows.
De-energize the hot gas solenoid valve and the liquid injection solenoid valve so these valves do not interfere with
the plate superheat adjustment. Deactivation of these valves can be done by turning off the “PDS” toggle switch in
the condensing unit electrical cabinet.
The evaporator plate superheat should be adjusted with a product temperature higher than what the final design
product temperature requires to allow the condensing unit to operate while the adjustments are made. The
superheat should be adjusted at the expansion valves located on the liquid line of the evaporator plate. Begin
adjusting the superheat with a product temperature of 50°F. Take a pressure measurement at the suction Schrader
valve located on the suction header. Measure the temperature at the expansion valve suction bulb location. Set the
superheat at 12°F to 13°F, which is slightly high due to the 50°F product temperature. As the product temperature
pulls down to the setpoint, the superheat should settle to around 8°F to 10°F. Make the necessary adjustments
while the temperature continues to drop to ensure the correct superheat is achieved.
3.5 HOT GAS ADJUSTMENT
The hot gas valve’s purpose is to maintain a 27°F evaporator saturation temperature to prevent water from freezing
to the plates which could result in unwarranted equipment damage.
First, adjust the unload pressure switch (UPS) to operate the hot gas valve and liquid injection valve at the correct
pressures. The UPS needs to cut-in at a 25°F saturated suction temperature and cut-out at a 30°F saturated suction
temperature. See Table 7 for UPS pressure settings.
Next, unwire the liquid injection valve solenoid and energize the hot gas solenoid. As the product temperature
approaches 36°F, measure the suction pressure at the compressor. Adjust the hot gas valve to maintain a 27°F
evaporator. See Table 7 for hot gas valve pressure settings.
IMPORTANT: Observe the compressor superheat while making hot gas adjustments. The superheat of
the compressor will increase while hot gassing, as there is no liquid injection at that time. To prevent
the compressor from overheating, do not allow the compressor’s superheat to get above 40°F. Also, the
compressor’s discharge temperature should not be allowed to exceed 200°F. The compressor superheat
adjustment is discussed in Section 3.6.
TABLE 7: HOT GAS BYPASS SETTINGS
Refrigerant
Unload Pressure Switch (UPS) Settings Hot Gas Valve Setting
Cut-In Pressure Setting (psig) Cut-Out Pressure Setting (psig) Pressure Setting (psig)
R-22 48 55 51
R-507 65 73 68
R-448A 50 57 53
R-404A 62 69 65