Mueller Falling Film Chiller User manual

Part No. 9843514
Effective February 12, 2003
Revised March 17, 2020
Falling Film Chiller
INSTALLATION AND OPERATION MANUAL

Section 1.0 – Introduction
1.1 General Information ........................................................................................................1
1.2 Model 3 x 5 Standard Features..............................................................................................1
1.3 Model 3 x 5 Dimensions .................................................................................................... 2
1.4 Model 4 x 8 Standard Features............................................................................................. 3
1.5 Model 4 x 8 Dimensions .................................................................................................... 4
1.6 Plate Design..................................................................................................................5
Figure 1: Plate Design for Direct Expansion or Recirculated Refrigeration Systems ...................................5
Figure 2: Plate Design for Flooded Refrigeration Systems................................................................5
1.7 Falling Film Chiller Refrigerant Volumes ................................................................................ 6
1.8 Model Number Breakdown ................................................................................................ 7
Section 2.0 – Installation
2.1 Inspection................................................................................................................... 8
2.2 Locating and Leveling the Chiller ......................................................................................... 8
2.3 Obtaining Parts ............................................................................................................ 8
2.4 Locating Refrigeration Units .............................................................................................. 9
2.5 Connecting the Refrigerant Lines ......................................................................................... 9
2.6 Liquid Line Solenoid Valve................................................................................................10
2.7 Water Line Connections ..................................................................................................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
Figure 3: Temperature Sensors ........................................................................................... 11
2.11 Setting Chiller Recirculation Flow and Water Makeup Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.12 Distribution Pan Water Flow Rates ......................................................................................12
2.13 Recommended Chilled Water Line Size..................................................................................12
2.14 Cleaning the System ......................................................................................................13
2.15 Test Running ..............................................................................................................13
2.16 Chlorine Gas Rusting .....................................................................................................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 March 17, 2020

Section 3.0 – Condensing Unit Setup/Startup Procedures
3.1 Head Pressure Control Valve Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Plate Superheat Adjustment .............................................................................................. 15
3.3 Hot Gas Adjustment ....................................................................................................... 15
3.4 Liquid Injection Adjustment.............................................................................................. 15
3.5 Ambient Fan Cycling Control Adjustment............................................................................... 16
Figure 4: Condensing Unit Schematic.................................................................................... 16
Figure 5: Wiring Schematic............................................................................................... 17
Table of Contents
Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised March 17, 2020

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised March 17, 2020
1.1 GENERAL INFORMATION
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 STANDARD FEATURES
• Constructed of Type 304 or 316L stainless steel.
• Designed for use with R-22, R-134A, R-404A, R-507, or R-717.
• An electronic makeup water solenoid assembly is optional.
• Hinged and gasketed top doors are available as an option.
• A clamp-type ferrule and male pipe-thread adapter are included for the inlet.
• 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. Using a high-flow distribution pan:
Minimum flow rate: 14.7 gpm per plate
Maximum flow rate: 29.0 gpm per plate
2. Using a low-flow distribution pan:
Minimum flow rate: 9.1 gpm per plate
Maximum flow rate: 14.3 gpm per plate
3. Using a extra-low-flow distribution pan:
Minimum flow rate: 5.8 gpm per plate
Maximum flow rate: 8.95 gpm per plate
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.
1
Section 1.0 – Introduction

1.2 MODEL 3 X 5 STANDARD FEATURES (CONTINUED)
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.
1.3 MODEL 3 X 5 DIMENSIONS
Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised March 17, 2020
2
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 March 17, 2020
1.4 MODEL 4 X 8 STANDARD FEATURES
• Constructed of Type 304 or 316L stainless steel.
• Designed for use with R-22, R-134A, R-404A, R-507, or R-717.
• An electronic makeup water solenoid assembly is optional.
• Hinged and gasketed top doors are available as an option.
• A clamp-type ferrule and male pipe-thread adapter are included for the inlet.
• 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. Using high-flow distribution pan:
Minimum flow rate: 31.0 gpm per plate
Maximum flow rate: 50.2 gpm per plate
2. Using low-flow distribution pan:
Minimum flow rate: 17.9 gpm per plate
Maximum flow rate: 28.7 gpm per plate
3. Using 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
3

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised March 17, 2020
1.4 MODEL 4 X 8 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.
1.5 MODEL 4 X 8 DIMENSIONS
4
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 March 17, 2020
1.6 PLATE DESIGN
Paul Mueller Company manufactures plates for the falling film chiller in two basic styles. Figure 1 shows the
plate used for direct expansion or recirculated refrigeration systems. Figure 2 shows the plate used for flooded
refrigeration systems.
FIGURE 1: PLATE DESIGN FOR DIRECT EXPANSION
OR RECIRCULATED REFRIGERATION SYSTEMS
FIGURE 2: PLATE DESIGN FOR FLOODED REFRIGERATION SYSTEMS
5
DX or Recirculated
Flooded
DX or Recirculated
Flooded

Mueller Falling Film Chiller Effective February 12, 2003
Installation and Operation Manual, Part No. 9843514 Revised March 17, 2020
1.7 FALLING FILM CHILLER REFRIGERANT VOLUMES
IMPORTANT: The capacities listed above are for the plates ONLY, and do not include manifolds or piping.
6
MODEL 3 X 5
No. of Plates 1 2 3 4 5 6 7 8 9 10 11 12
Lbs. of R-22 @ 25°F 12 24 36 48 60 72 84 96 108 120 132 144
Lbs. of R-717 @ 25°F 6 12 18 24 30 36 42 48 54 60 66 72
Lbs. of R-507 @ 25°F 11 22 33 44 55 66 77 88 99 110 121 132
MODEL 4 X 8
No. of Plates 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Lbs. of R-22 @ 25°F 34 68 102 136 170 204 238 272 306 340 374 408 442 476 510 544
Lbs. of R-717 @ 25°F 17 34 51 68 85 102 119 136 153 170 187 204 221 238 255 272
Lbs. of R-507 @ 25°F 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450 480
MODEL 4 X 8
No. of Plates 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Lbs. of R-22 @ 25°F 578 612 646 680 714 748 782 816 850 884 918 952 986 1,020 1,054 1,088
Lbs. of R-717 @ 25°F 289 306 323 340 357 374 391 408 425 442 459 476 493 510 527 544
Lbs. of R-507 @ 25°F 510 540 570 600 630 660 690 720 750 780 810 840 870 900 930 960