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
2
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
3
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
4
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
5
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
6
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