OPTI TEMP OTC Series Specification sheet

OTC Series Air Cooled Chiller
Operation and Installation Manual
Manual # O002639AC
Date Effective: 08/01/2013

1
OTC Series Air Cooled Chiller
Operation and Installation Manual
Page
Section 1 – Preface ......................................................................................................................... 2
Section 2 – About this Manual......................................................................................................... 2
2.1 General.................................................................................................................................. 2
2.2 Warnings and Safety Symbols.............................................................................................. 2
Section 3 – General Information...................................................................................................... 3
3.1 Safety Precautions................................................................................................................ 3
3.2 Compliance ........................................................................................................................... 4
3.3 Service and Support.............................................................................................................. 4
Section 4 – Unpacking..................................................................................................................... 5
4.1 Receiving / Inspection........................................................................................................... 5
4.2 Handling, Transporting and Storage..................................................................................... 5
4.3 Package Contents................................................................................................................. 5
Section 5 – Description.................................................................................................................... 6
5.1 Overview of Liquid Chillers.................................................................................................... 6
5.2 Specifications and Available Options.................................................................................... 7
5.4 System Construction Standards.......................................................................................... 15
Section 6 – Installation .................................................................................................................. 15
6.1 Chiller Location.................................................................................................................... 15
6.2 Process Fluid Connection ................................................................................................... 15
6.3 Chilled Water Lines............................................................................................................. 16
6.4 Overhead Piping and Drain Back Prevention .................................................................... 17
6.5 Electrical Connection .......................................................................................................... 17
Section 7 – Operation and Start Up............................................................................................... 18
7.1 General Start Up Information.............................................................................................. 18
7.2 Operating Temperature Range Limits................................................................................. 19
7.3 Fluid Selection, Water Quality and Corrosion Protection.................................................... 19
7.4 Control Interface Layout...................................................................................................... 19
7.5 Fluid Fill............................................................................................................................... 20
7.6 Starting the Unit................................................................................................................... 20
7.7 Temperature Setting and Adjustment ................................................................................. 20
7.8 Fluid Bypass Valve Setting and Adjustment....................................................................... 23
7.9 System Fluid Drainage........................................................................................................ 23
Section 8 – Maintenance............................................................................................................... 24
Section 9 – Troubleshooting.......................................................................................................... 25
9.1 Low Refrigerant Check........................................................................................................ 26
Section 10 – Replacement Parts................................................................................................... 28
Section 11 – Warranty and Service............................................................................................... 29
Section 12 – Appendix................................................................................................................... 33
12.1 Dew Point / Temperature Chart ........................................................................................ 33
12.2 Description of Optional System Components................................................................... 34
12.3 Electrical Schematic.......................................................................................................... 35
12.5 Refrigeration Diagram....................................................................................................... 37
12.7 Water Quality Guidelines .................................................................................................. 39
12.8 Pump Curves..................................................................................................................... 40
12.9 RoHS Material Table......................................................................................................... 42
12.10 Electrical Interfacing........................................................................................................ 43
12.11 Dimensional Drawings .................................................................................................... 44
12.12 Temperature Control Parameters ................................................................................... 45
12.13 Glycol Tables................................................................................................................... 46
12.14 Notes............................................................................................................................... 47

2
Section 1 – Preface
Thank you for choosing OPTI TEMP for your heat transfer equipment needs. We
encourage your comments about our products and operation manual. Please feel free to
contact us with questions or concerns at 231-946-2931 or [e-mail].
We appreciate your business!
Section 2 – About this Manual
2.1 General
This manual is intended to serve as a guide for placing your portable chiller in service,
operating it safely, and maintaining it properly. This manual will be supplemented as
required to accommodate any special equipment which may have been provided for a
specific application.
NOTE: The written information contained in this manual, as well as various drawings, are
intended to be general in nature.
OPTI TEMP strives to maintain an accurate record of all equipment produced for the
course of its useful life. While every effort is made to standardize the design features of
these chillers, the various options may make it necessary to re-arrange some of the
components; therefore, some of the general drawings in this manual may differ from your
specific unit.
We encourage all personnel to familiarize themselves with this manual’s contents. Failure
to do so may unnecessarily prolong equipment down time.
2.2 Warnings and Safety Symbols
This symbol marks chapters and sections of this instruction manual which
are particularly relevant to safety
When attached to the unit, this symbol draws attention to the relevant
section of the instruction manual.
This manual assumes the OPERATOR is non-technical with limited
training and the RESPONSIBLE BODY is technical and fully trained.
This symbol indicates that hazardous voltages may be present.

3
Section 3 – General Information
3.1 Safety Precautions
Make sure you read and understand all instructions and safety precautions listed in this
manual before installing or operating your unit. If you have any questions concerning the
operation of your unit or the information in this manual, please contact our Sales
Department at 231-946-2931 or [e-mail].
•For safety reasons power supplies must be properly grounded. All federal, state, and
local codes should be followed.
•Never use flammable or corrosive fluids with this unit.
•Do not use automobile anti-freeze. Automotive anti-freeze often contains silicates or
other components that can damage your system. Only an un-inhibited glycol should
be used. Use of automobile anti-freeze will void the manufacturer’s warranty.
•Never place the unit in a location where excessive heat, moisture, or corrosive
materials are present.
•Do not modify or seal reservoir in any way.
•Performance of installation, operation, or maintenance procedures other than
described in this manual may result in a hazardous situation and may void the
manufacturer’s warranty.
•Transport the unit with care. Sudden jolts or drops can damage internal components.
•Observe all warning labels.
•Never remove warning labels.
•Never operate damaged or leaking equipment.
•Never operate the unit without heat transfer fluid in the reservoir.
•Always disconnect power to the unit before opening the control box.
•Always empty the reservoir before moving the unit.
•Never operate equipment with damaged power cords.
•Refer service and repairs to a qualified technician.
CAUTION: Our refrigerated chilling equipment uses chemical refrigerants for heat
transfer purposes. This chemical is sealed and tested in a pressurized system containing
ASME coded vessels; however, refrigerant gas can be released if there is a system
failure. Refrigerant gas can cause toxic fumes if it is exposed to flame. These units must
be placed in a well ventilated area, especially if open flames are present. Failure to follow
these instructions could result in a hazardous condition. Models OTC-.25A through OTC-
3.0A utilize a Hydro-fluorocarbon refrigerant (HFC) trade name R-134A. Models OTC-
5.0A through OTC-10A utilize a refrigerant trade named R-407c. The EPA has enacted
laws regarding the handling of refrigerants and has phased out the use of HCFC
refrigerants, such as R-22. HCFC refrigerant production will be available until January 1,
2020 for service purposes only. Customers are advised to immediately implement a
refrigerant management program including a survey of all equipment to document the
type and quantity of refrigerant in each machine. All refrigeration service technicians
must be certified by an EPA approved organization.

4
3.2 Compliance
CE: OPTI TEMP products are conformant per EN55011A, EN61326,
EN61010-1. NRTL certification to UL 61010-1 part 1 is also available.
European RoHS: OPTI TEMP products do not fall under the scope of
the RoHS directive per categories 8 (medical devices) and 9
(monitoring & control instruments).
WEEE: OPTI TEMP products with the WEEE mark should be
collected, treated, recovered and environmentally disposed of directly
through the OPTI TEMP collection scheme. Contact OPTI TEMP to
determine the collection scheme for that particular location. As of
August 13, 2005, all cooling system products introduced to the EU
will be labeled with the "Crossed Wheelie Bin" symbol.
China RoHS: OPTI TEMP products are compliant per China RoHS
guidelines. A RoHS material table, detailing the unit’s contents and
respective toxic or hazardous substances or element levels is
displayed in Section 12.8 Specification of this manual.
3.3 Service and Support
OPTI TEMP is committed to customer service both during and after the sale. If you have
questions concerning the unit operation, please contact our Service Department at
231.946.2931.
OPTI TEMP systems are built to provide years of trouble free service. All systems are
tested prior to shipping to insure you receive the highest quality product. In the unlikely
event you experience problems, rest assured our technical service staff will be available
to assist you resolve any problems quickly. If your unit fails to operate properly, or if you
have questions concerning spare parts or service, contact our customer service
department at 231-946-2931 or [e-mail].
Before calling, please refer to the serial number tag to obtain the serial number:
Unit Serial Number ___________________________________

5
Section 4 – Unpacking
4.1 Receiving / Inspection
Each unit is skid mounted and either boxed or crated prior to shipment depending on size
and/or shipping destination.Before accepting delivery, check the overall equipment
condition for any visible damage. If damage is evident the unit should be thoroughly
inspected in front of the delivery driver. Any and all damage should be properly
documented on the delivery receipt. Shipping damage is the responsibility of the carrier.
In order to expedite payment for damages it is important that proper procedures be
followed and records kept. Photographs provide an excellent means of documenting
damaged equipment. Once the unit is removed from the box or crate, it should be
inspected for hidden damage. Refrigerant lines can be susceptible to damage in transit.
Check for broken lines, oil leaks, damaged controls, or any other major component torn
loose from its mounting point.
NOTE: Any sign of damage should be recorded and a claim filed immediately with the
shipping company. OPTITEMP will provide assistance in preparation and filing of your
claims, including arranging for an estimate and quotation on repairs; however,
filing the claim is the responsibility of the receiving party.
NOTE: You may notice a small amount of fluid in your chiller system when it arrives.
During the winter months (between October 1st and April 30th) a small amount of non-
hazardous Propylene Glycol solution may be added to protect critical components from
freeze damage. This solution can be flushed from the system prior to connecting to your
process. Contact OPTI TEMP at 231-946-2931 or [e-mail] with any
questions or disposal concerns.
4.2 Handling, Transporting and Storage
Smaller units are normally equipped with casters (two fixed and two swivel) to provide in-
plant mobility. Proper rigging methods must be followed to prevent damage to
components when removing units from pallets and/or placing into the desired service
location. Avoid impact loading caused by sudden jerking when lifting or lowering the
chiller. Use pads where abrasive surface contact is anticipated. The skid supporting the
chiller can be used for positioning the unit with a fork lift.
•Storage temperature: -10 to 55oC (14 to 131oF)
•Operating ambient humidity conditions: 0 to 90 % relative humidity up to 40oC (non-
condensing), 10 to 50% relative humidity from 40 to 55oC (non-condensing)
4.3 Package Contents
•OTC Series Water Chiller
•Operation and installation manual
•Rubber vibration pads (optional)
•Filters and spare cartridges (optional)
•Hose Kits and/or other accessories (optional)

6
Section 5 – Description
5.1 Overview of Liquid Chillers
The OPTI TEMP refrigerated heat exchanger (chiller) is a re-circulating system designed
to provide a continuous supply of heat transfer fluid (usually water) at a constant
temperature and flow rate. The system consists of a refrigeration system, fluid pump,
fluid reservoir, and is controlled by a Proportional Integral Derivative (PID) controller.
The OPTI TEMP OTC Series chillers feature our patented refrigeration circuitry. This
innovative circuitry allows the unit to provide excellent temperature control whether
operating at “Zero load or Full Load”. It also allows the chiller to provide very tight
temperature stability over the industries widest (actively cooled) operating temperature
range. See operating temperature range limits in section “5.2 Specifications” for more
information about available operating ranges of OPTI TEMP systems.
A wide range of pumps, flow controls, monitoring devices, and filtration options are
provided making the OTC Series chillers a flexible solution for a range of applications.
*Standard OTC-.25A, .33A and .50A Chiller

OTC Series Air Cooled Water Chillers: Pricing Proprietary Information-Please Do Not Distribute
for Laser, Semiconductor, Medical & Laboratory applications
Ordering Information
Description
(1)
Code
Standard Flow Rating GPM
Standard Pressure Rating PSIG
(2)
Max Available Flow Range (See optional pumps below)
Connection (MNPT) Size
Capacity
(3)
KW
BTU/hr
tons
Compressor HP
Type
Full Load Amps
(4)
115/1/60 Hz
100/1/50 Hz
230/1/60 Hz
230/1/50 Hz
230/3/60 Hz
460/3/60 Hz
Dimensions
(5)
Height
Width
Depth
Weight lbs.
Internal Reservoir Gallon
Temp Stability °F
Refrigerant Type
Condensing Medium
Air Discharge Direction
Example: 
Select Model OTC-.5A
O=Optional S=Standard N/A=Not Available
CF=Consult Factory
Unit Base Prices
Wetted Construction/Temperature Range Options:
(by wetted construction/ Temperature range)
Standard Non-ferrous
(1)
Fluid Temperature Range (45 to 104°F)
Extended Range Non-ferrous
(2)
Fluid Temperature Range (45 to 190°F)
Stainless Steel/Plastic Contstruction (DI Compatible)
(3)
Fluid Temperature Range (45 to 104°F)
High Purity (DI Compatible)
(4)
Fluid Temperature Range (45 to 104°F)
Example: 
Select Wetted Construction OTC-.5AL
(1) Wetted materials include Br, Cu, 304 & 316 S.S., Ni, HDPE, Polypropylene, & Clearbraid® hose. (2) Wetted materials include Br, Cu, 304 & 316 S.S., Ni. High temperature hose
& stainless steel reservoir used on this model. High temperature stainless steel filter must be used when filtration is required on high temp models. (3) Wetted materials include 304
& 316 S.S., Ni, HDPE, Polypropylene, & Clearbraid® hose. (4) Wetted materials include 316 S.S., Ni, HDPE, Polypropylene, & Clearbraid® hose. Some pump options not available.
(5) Special construction for certain engineered heat transfer fluids may be available. Contact "applications engineering" for more information. Note: "Stainless Steel" (S) or "High
Purity" (D) wetted construction required with certain water quality options.
S
p
ecialt
y
Wetted Construction / Tem
p
.Ra
g
e
(5)
CCF CF CF CF CF CF CF CF CF CF CF
Contact applications engineering department.
SO O O O O O O O O O O
DCF CF CF CF CF CF CF CF CF CF CF
HO O O O O O O O O O O
OTC-.25A OTC-.33A OTC-.5A OTC-.75A OTC-1.0A OTC-1.5A OTC-2.0A OTC-3.0A OTC-5.0A OTC-7.5A OTC-10A
(1) As a result of continuous improvement efforts, specifications are subject to change without notice or liability. (2) Pump pressures at pump discharge. (3) Capacity based on 55 °F
LWT and 95 °F ambient air temperature. Capacities may be ± 5% as reserved by compressor manufacturer. (4) Full load amps for models with standard pumps. Consult
applications engineering for models with optional pumps. Full load amps must be used for sizing disconnects and supply wiring. Contact factory for 50 Hz applications engineering.
(5) Dimensions are approximate and do not include filters. * Upgraded pump required for 460/3/60.
LO O O O O O O O O O O
0.75 2.5 2.5 2.5 2.5 20
130
± 0.2 ± 0.2 ± 0.5
R-134A R-134A R407c
Air Air Air
Horizontal Horizontal VerticalHorizontal
22.5" 22.5" 27.5" 26.5" 34.5" 55"
46" 61"
15" 24" 28" 36" 31" 38"
155 205 215 350 455
23" 25.5" 25" 36"
505 800 850
236 12 16 17 31 36 57 60
436 6* 8* 10 15 14 23 35
216 6.9 9 13 15 22 29 46 48
215 6.5 8.4 12.2 14 20 26 42 44
Hermetic Scroll
116 12.8 14 19 23
115 12 13.1 17.8 20
0.25 0.33 0.4 0.7 0.8 1.4 1.7 3 4.5 6.8 10
0.25 0.33 0.5 0.75 1 1.5 2 3.5 5 7.5 10
1/2 1 1 1.25 1.5
0.6 0.8 1.3 2.3 2.8 5 6 10.5 16 24 35
2000 2800 4570 7940 9550 17000 20700 36100 54400 82000 120000
61
5.5 7 12 18
58
2.3 4
3.5 5 26
65 65 65 55
Pump HP (Standard)
Code
0.33
P1
0.33
P3
0.5
P5
1.5
C3
1.5
C3
2
C4
OTC-5.0A
Hermetic Scroll
38 48
Portable Water Chillers - Air Cooled
Compact Medium Capacity Large Capacity
OTC-.25A OTC-.33A OTC-.5A OTC-.75A OTC-1.0A OTC-1.5A OTC-2.0A OTC-3.0A OTC-7.5A OTC-10A
24
53
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Pumps: Price Adders
GPM
(1)
Construction
(2)
O=Optional S=Standard N/A=Not Available (for non-standard pumps)
NF P1
SS P2
NF R1
SS R2
RT SS RG
SS M1
SS M2
NF P3
(4)
SS P4
(4)
NF P5
(4)
SS P6
(4)
NF R3
SS R4
RA
SS C1
NF R5
SS R6
SS C2
SS C3
NF R7
SS R8
SS C4
NF R9
SS R0
SS C5
Example: 
Select Pump OTC-.5AL-P1
PD=Positive Displacement, RT=Regenerative Turbine, CF=Centrifugal, MD=Magnetic Drive
Electrical Configuration Price Adders
(for select voltage configurations)
Nominal Operating Range
100V, 1  95 -110V
115V, 1  109-126V
110V, 1  105 -121V
127V, 1  120-139V
200V, 1  190 -220V
208-230V, 1  198-253V
220V, 1  209 -264V
253V, 1  217-278V
200-220V, 3  180-242V
208-230V, 3  187-253V
380-420V, 3  361-462V
460V, 3  414-506V
Example: 
Select Voltage OTC-.5AL-P1-116

436

(2,3)

(2,3)
 
OPTI TEMP units are 50/60 Hz compatible. Some countires/destinations require compliance with established safety standards. Consult applications engineering for more
information. Consult applications engineering for lead time. (1) Equipped with transformer. (2) Extended lead time. (3) Brass Turbine pump R3 upgrade is required on these models in
460V configurations.
236
  
215
(1)  
216
 
(2)
115
(1) 
(1) Pump characterisitics shown represent a specific operating point on the pump curve. Actual flow characteristics will depend upon fluid circuiting and associated frictional losses.
Pump upgrades may result in reduced heat removal capacites and increased amp draws. Consult applications engineering for more information. (2) Stainless Steel pumps are
required with "Stainless steel" (S) or "High Purity" (D) wetted construction selections. (3) Brass Turbine pump R3 upgrade is required on these models in 460V configurations. (4)
Positive Displacment pumps P3,P4,P5 & P6 not available of 460 Volt models. Thus, P3, P4, P5, & P6 can only be used with 1 Phase electrical configurations 116, 115, 216, or 215.

= Available Voltages CF=Consult Factory
116

(2)
RT 5.00 38 65 N/A N/A N/A N/A N/A N/A N/A N/A O O O
CF 3.00 48 48 N/A N/A N/A N/A N/A N/A N/A N/A N/A O O
CF 2.00 30 55 N/A N/A N/A N/A N/A N/A N/A N/A O S S
RT 5.00 38 65 N/A N/A N/A N/A N/A N/A N/A N/A O O O
RT 1.50 16 69 N/A N/A N/A N/A N/A N/A O O O N/A N/A
RT 1.50 16 69 N/A N/A N/A N/A N/A N/A O O O N/A N/A
CF 1.00 18 43 N/A N/A N/A N/A N/A N/A O O O N/A N/A
CF 1.50 26 48 N/A N/A N/A N/A N/A N/A O S S N/A N/A
RT 1.00 7 70 N/A N/A N/A N/A N/A N/A O O N/A N/A N/A
RT 1.00 7 70 N/A N/A N/A N/A N/A N/A O O N/A N/A N/A
RT 0.75 5.2 80 NF N/AN/AN/AOOOOO N/A N/AN/A
CF 0.50 12 30 N/A N/A N/A N/A N/A N/A O O N/A N/A N/A
RT 0.50 5 65 N/A N/A N/A O O O N/A N/A N/A N/A N/A
RT 0.50 5 65 N/A N/A N/A O O O N/A N/A N/A N/A N/A
PD 0.50 5.5 65 N/A N/A N/A O O O S N/A N/A N/A N/A
PD 0.50 5.5 65 N/AN/AN/AOOOON/A N/A N/AN/A
PD 0.33 4 65 N/A N/A O S S
(3)
S
(3)
N/A N/A N/A N/A N/A
PD 0.33 4 65 N/AN/AOOOON/AN/A N/A N/AN/A
MD 1.47 3.5 43 N/A N/A N/A O O O N/A N/A N/A N/A N/A
MD 0.60 3.2 55 O O O N/A N/A N/A N/A N/A N/A N/A N/A
RT 0.33 3 70 OOOOOON/AN/A N/A N/AN/A
0.33 3.2 70 OOOOOON/AN/A N/A N/AN/A
PD 0.33 2.3 65 O O O N/A N/A N/A N/A N/A N/A N/A N/A
RT 0.33 3 70 OOOOOON/AN/A N/A N/AN/A
OTC-.25A OTC-.33A OTC-.5A OTC-.75A OTC-1.0A OTC-1.5A OTC-2.0A OTC-3.0A OTC-5.0A OTC-7.5A OTC-10A
Type HP PSI
PD 0.33 2.3 65 S S S N/A N/A N/A N/A N/A N/A N/A N/A
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Controller Packages Price Adders
Standard Contoller O=Optional S=Standard N/A=Not Available CF=Consult Factory
(for optional control packages)
Enhanced Controller
RS232 - Lovelink
RS232 - Modbus
RS485 - Lovelink
RS485 - Modbus
Ethernet Ready Controller
Programmable Logic Controller
Example: 
Select Controller OTC-.5AL-P1-116-SC1
Factory Installed Options: Option Pricing
O=Optional S=Standard CF=Consult Factory
Water Quality Options
Particle FIltration Particle Size Max Flow (gpm)
Model 5 Slim 30 µ
Model 10 Slim 30 µ
Model 10 30 µ
Model 12 30 µ
Model ST-1 30 µ
Model 20 30 µ
Model LC04 25 µ
Model LC04 50 µ
De-ionization Package
pH Control Package
UV Filtration
(1)
Resistivity Alarm Contacts
Resistivty Retransmission (0 - 10 VDC) RR2 OOOOOOOO O OO
(1) Certain options not available on OTC-.25A, .33A, & .5A when equipped with active DI Control System. Contact applications for details. (2) Deionization control options
D02 & D01 limit maximum operating temperature to 104 F (40C).
High Intensity UV lamp. Effective against disease causing
microbes. (Requires D01 or D02 De-ionization Package Unless
ordered with PH1 w/o DI). UVBOOOOOOOO O CFCF
RR1 OOOOOOOO O OO
Passive DI Control System
(1.,2)
includes resistivity indicator lamp,
resin cartridge, associated plumbing, and installation. Avail. with
200KOhm or 1 Mohm Indicator lamps. (Requires "S" or "D"
wetted construction/temperature range option.) D01OOOOOOOO O OO
Controls pH of De-ionized water. Includes monitor/controller,
probe, resin cartridges, plumbing, installation, and "Active DI
Control System" (D02). (Requires "S" or "D" wetted
construction/temperature range option.)
PH1OOOOOOOO O OO
50 LC04 OOOOO
Active DI Control System
(1,2)
includes monitor/control board,
digitial display, mixed bed resin cartridge, associated plumbing,
and installation. Adjustable range 0 - 2 Mohm-cm. (Requires
"S" or "D" wetted construction/temperature range option.) D02OOOOOOOO O OO
40 M20 OOO
50 LC04 OOOOO
20 M12 OO O
15 MS1OOOOOOOO O
5 M1LOOOOOO
10 M1T OOOO
Contact Factory for details.
PLC CF CF CF
5 M05OOOON/AN/A
EC3 O O O
SS
EC4 O O O
Veiw, read, & write capibility via
ethernet connection. ETC CF CF CF
SS
Includes microporocessor based PID
control with LED display, calibratiojn
offset, auto restart, C/F toggle, self
tune, and high/low alarm.
SC1 S S S
Same as the basic control plus RS-232
or RS-485 communication, via 9 Pin D-
sub (male).
EC1(16A) O O O
SSSS
EC2(16A) O O O
OTC-3.0A OTC-5.0AOTC-.25A OTC-.33A OTC-.5A OTC-.75A OTC-1.0A OTC-1.5A OTC-2.0A OTC-7.5A OTC-10A
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Factory Installed Options Cont.:
Fluid Monitoring & Control Options Accessory Pricing
Low Flow Indicator w/ indicator lamp & contacts
Flow Meter & Digital Display
Critcal Water Level Safety Switch
Low Water Indicator lamp
Temperature out-of-tolerance contacts
Pressure Gauge
(for "S" & "D" Wetted Const. options)
Pressure Gauge (for "L" & "H" Wetted Const. options)
Pressure Transducer & Digital Display
Anti Drain Back Valve Package
(S & D Wetted Const.)
Anti Drain Back Valve Package (L & H Wetted Const.)
Automatic Water Make-up Package
Audible Alarm w/Silence
Audible & Visual Alarm Beacon
Remote Start/Stop via 12-24V AC/DC
Remote Control Tether Package
Remote Temperature Sensing
Other Factory Options
Side Mounted Filter Housing
CPC Fittings CPC
Silicon Hose SBH
Phase Monitor
(3)
Resevoir Construction (Stainless Steel)
(4)
Outdoor Operation Package
OPTI TEMP Patented Control Circuitry
Reservoir Drain Plug 1/2"NPT
Sound Reduction Package
Fluid Circuit Insulation (internal)
(4)
Manifolds
25 Ft Power Cord
Casters
Compliance/NRTL Certifcations
CE
CSA
UL 61010
UL 1995
One Year Extended Warranty
Re-Usable International Rated Shipping Crate
Example: 
Select Options OTC-.5AL-P1-116-SC1-LW1
CTEOOOOOOOO O OO
(1) UV System option includes a circulation pump upgrade for the De-ionization package. (2) Contact factory for amp draws on units with heaters. (3) Available on three phase units
only. (4) Fluid circuit insulation standard for high temperature (Extended Range) package.
NR4 CF CF CF CF CF CF CF CF CF CF CF
W01CFCFCFCFCFCFCFCF CF CFCF
NR2 CF CF CF CF CF CF CF CF CF CF CF
NR3 CF CF CF CF CF CF CF CF CF CF CF
NR1 CF CF CF CF CF CF CF CF CF CF CF
PC1OOOOOOOO O OO
CA1SSSSSSSS S N/AN/A
FC1OOOOOOOO O OO
MA1CFCFCFCFCFCFCFCF CF CFCF
RDKSSSSSSSS S SS
SR1NANANANANANANANA NA NANA
OD1CFCFCFCF O O O O O O O
OTPSSSSSSSS S SS
PM1NANANANA O O O O O O O
RE1OOOOOOOO O OO
CF CF CF CF CF CF CF CF CF CF CF
CF CF CF CF CF CF CF CF CF CF CF
OOO
1.5kW 1.5kW 1.5kW 3kW 3kW 3kW 4kW 4kW 4kW 4kW 4kW
SF1 CF CF CF CF CF CF CF CF CF CF CF
Heater Package
(2)
(Requires Extended Range wetted
construction/temperature range option If still using "L" for fluid range under
104 F then add RE1) (Capacity-kW)
HT1 OOOOOOOO
Remote controls on tether (up to 100 ft. in length). Includes PID
control interface, start/stop, faults. RC1 $955 $955 $955 $955 $955 $955 $955 $955 $955 $955 $955
RT1CFCFCFCFCFCFCFCF CF CFCF
AV1OOOOOOOO O OO
RS1OOOOOOOO O OO
AWMCFCFCFCFCFCFCFCF CF CFCF
AA1OOOOOOOO O OO
AD1OOOOOOOO O CFCF
AD2OOOOOOOO O OO
PG2OOOOOOOO O S S
PT1OOOOOOOO O OO
TA1OOOOOOOO O OO
PG1OOOOOOOO O OO
CW1SSSSSSSS S SS
LW1OOOOOOOO O OO
LF1OOOOOOOO O OO
FS1OOOOOOOO O OO
OTC-.25A OTC-.33A OTC-.5A OTC-.75A OTC-1.0A OTC-1.5A OTC-2.0A OTC-3.0A OTC-5.0A OTC-7.5A OTC-10A
5/6/2013 \\OPTISERVER\Server\Opti Temp PRODUCTS\OTC\Air Cooled-Portable\D003680AK OTC Series Air Cooled Chiller Configuration, Option & Pricing Matrix

User Installed Accsssories:
N/A=Not Available
Replacement Cartridges-Particle
Filter Code Particle Size
M5 30 µ
M10 Sl 30 µ
M10 St 30 µ
M12 30 µ
M20 30 µ
MS1 30 µ
LC04 25 µ
LC04 50 µ
DI1
Particle Filter Housings (See water quality options above)
Ball Valves (Isolation Valves)
External Pressure Reducer
Plumbing Packages
Condenser Air Filter (Cleanable)
(1) Contact factory for installation instructions.
Contains 50 ft. of Clearbraid® hose, 50 ft. of Armaflex®
insulation, Male NPT to barb fittings, & hose clamps. CF CF CF CF CF CF CF CF CF CF CF
HP1
AF1CFCFCFCFCFCFCFCF CF CFCF
For applications requiring reduced pressure. Kit contains
pressure relief valve, 2 Tees, Hose Clamps, and plumbing
instructions.
PR1CFCFCFCFCFCFCFCF CF CFCF
BV1 CF CF CF CF CF CF CF CF CF CF CF
PE25-G4-RPE ■■■
PE50-G4-RPE ■■■
Replacement Cartridges - Resin 155273-43 155273-43 155273-43 155273-43 155273-43
■■■■
155273-43 155273-43 155273-43 155281-03 155281-03 155281-03
■■■■ ■ ■■
500202 ■N/A N/A
500202 ■■N/A
500402 ■■■
500502 ■■■
500602 ■■ON/AN/A
■=Available
PN
500102 ■N/A N/A
OTC-.25A OTC-.33A OTC-.5A OTC-.75A OTC-1.0A OTC-1.5A OTC-2.0A OTC-3.0A OTC-5.0A OTC-7.5A OTC-10A
5/6/2013 \\OPTISERVER\Server\Opti Temp PRODUCTS\OTC\Air Cooled-Portable\D003680AK OTC Series Air Cooled Chiller Configuration, Option & Pricing Matrix

12
5.3 Description Standard System Components
Coolant Circuit
The pump draws coolant from the reservoir and circulates it to the process and returns it to
the evaporator. It is in the evaporator where the heat is transferred from the coolant to the
refrigerant. Adjusting the amount of heat transferred in the evaporator controls the
temperature of the coolant being delivered to the process. There is a freezestat sensor and
flow switch (optional) in the coolant circuit to serve as safety controls. There is also a
thermocouple to sense the temperature of the coolant being delivered to process and
communicates this temperature to the microprocessor based PID temperature controller.An
adjustable bypass valve allows the chiller to operate with sufficient flow through the
evaporator even if the flow is restricted or completely shut off through the process.
NOTE: Closing the bypass valve off too far may result in a situation that could damage
components in the chiller. The main purpose of the bypass line is to avoid deadheading of the
pump and reduce the possibility of an evaporator freeze-up. See Section 7.8 for more
information on adjusting the bypass valve.
Refrigerant Circuit -Advanced Refrigeration Control Circuitry (ARCC)
The OTC Series Chillers features our “Advanced Refrigeration Capacity Control” (ARCC)
circuitry. This patented circuitry allows the unit to operate from “zero load to full load”
(without cycling the compressor) while providing excellent temperature stability. Another
benefit is the ability to operate over a very wide temperature range.
The patented refrigeration control circuitry adjusts and controls the flow of refrigerant in
response to the process load. The circuitry provides only the needed cooling capacity.
Because of this innovative circuitry, the refrigeration system compressor will operate when
the unit is on regardless of whether or not the process calls for cooling. This is normal and is
not a cause for concern. Continuous compressor operation reduces wear and tear
associated with frequent cycling which can lead to premature compressor failure.
The heat that is transferred in the evaporator from the coolant to the refrigerant is used to
change the state of the refrigerant from a liquid to a gas. After leaving the evaporator, the
refrigerant passes to the compressor.
Compressor
The OTC Series Chillers are equipped with a hermetic reciprocating or hermetic scroll
compressor, depending on model. Both the compressor and the motor are encased together
and solidly mounted in the cabinet. The compressor is unidirectional and will only pump
refrigerant when properly phased. The cool refrigerant suction gas cools the motor windings,
and there is an internal thermal overload to protect the windings from overheating. The
compressor is lubricated with oil that travels throughout the system with the refrigerant.
NOTE: The compressor on OPTI TEMP OTC Series chillers runs continuously regardless of
load on the system. This is normal and not a cause for concern.
Air Cooled Condenser
This component is only used in the air cooled chillers. The condenser is constructed of heavy
gauge copper tubing and aluminum fins for maximum heat transfer capabilities. The
condenser has been generously sized so the chiller can operate with full cooling capacities in
ambient air temperatures of up to 95°F (35°C). When the ambient air temperatures are above
95°F (35°C) the chiller will lose approximately 1% of its cooling capacity per 1°F (0.5°C)
above 95°F (35°C). The chiller should be able to operate with ambient temperatures of up to
110°F (43°C). The fan(s) draw the air flow through the condenser and blows the warm
discharge air through the chiller cabinet and out the other side. The fan(s) are designed to
draw sufficient air flow through the chiller as long as there are no obstructions. The fan(s) are

13
not capable of drawing air in through ductwork on the intake or discharging air through
ductwork on the exhaust. The discharge air will be significantly warmer than the intake air.
Evaporator
The standard evaporator is constructed of stainless steel plates and copper brazing. (An
optional “nickel brazed” evaporator is available with the high purity construction option.)The
refrigerant passes between every other set of plates, while the coolant flows on the other side
of the plates in the opposite direction.
Thermostatic Expansion Valve
This valve (referred to as the TXV) separates the high pressure/high temperature side of the
refrigeration circuit (the condenser side) from the low pressure/low temperature side of the
refrigeration circuit (the evaporator side). The TXV maintains constant superheat at the
evaporator outlet, regardless of process load, by precisely metering the amount of refrigerant
into the evaporator. Superheat is the difference between the saturated evaporative
temperature and the actual measured temperature at the TXV sensor bulb. The superheat is
factory set for 10°F to 12°F (5°C to 6°C) and should never exceed 15°F (8°C). Only a trained
refrigeration technician should adjust refrigeration system valves.
Refrigerant Sight Glass
The refrigerant sight glass is located in the liquid line ahead of the expansion valve. It allows
the operator or service technician to observe the flow of liquid refrigerant. Prolonged periods
of foaming in the sight glass may indicate a low refrigerant condition or a restriction in the
liquid line. Occasional bubbling in the sight glass may occur at a time when load conditions
are changing and the thermostatic expansion valve is adjusting to the new conditions. This
momentary occurrence is a result of normal chiller operation. The sight glass can also be
used to check if there is moisture in the refrigeration system. If there is moisture in the
system, the green dot in the center of the sight glass will turn yellow. If this occurs, the chiller
should be serviced immediately.
Refrigerant Filter Drier
The filter drier is located in the liquid line between the condenser and the refrigerant sight
glass. It is designed to remove any moisture and/or foreign matter that may have gotten into
the refrigerant stream. Moisture and foreign matter can cause serious damage to the
components of a refrigeration system. For this reason, it is important that the chiller be
equipped with a clean filter drier. Replace the filter drier if any of the following conditions
occur:
1. The refrigeration system is opened to the atmosphere for repairs or maintenance.
2. Moisture is indicated in the sight glass (the green dot has changed to yellow).
3. An Excessive pressure drop develops across the filter drier. This is indicated by a
significant temperature difference between the filter inlet and outlet.
Pressure Relief Valve / Blow Out Plug
The pressure relief valve is located in the liquid line after the condenser. It is designed to
relieve refrigerant pressure under severe conditions in order to protect the refrigeration circuit
components from damage.
Hot Gas Bypass Valve
This valve is located in the refrigerant line that runs from the compressor discharge to the
evaporator inlet. It is designed to artificially load the chiller when the chiller is catering to a
partial load from the process. This is accomplished by directing some of the hot compressor
discharge gas directly back into the evaporator instead of going through the condenser. The
microprocessor based PID temperature controller controls the amount of hot gas used.

14
Solenoid Valve
The solenoid valve is controlled by the microprocessor based PID temperature controller and
supplies adequate amount of refrigerant necessary to cool the process fluid to the desired
temperature.
Reservoir
The reservoir material will vary depending upon the materials of construction option selected.
There is a removable cover on the top of the reservoir. During chiller operation the reservoir
should be at least half full. For most installations the reservoir has sufficient capacity to
handle coolant drain back from the process equipment which occurs during chiller shut down.
For installations with overhead piping special precautions will have to be made during
installation. Contact OPTI TEMP customer service department for details at 231-946-2931 or
[e-mail].
NOTE: The reservoir must not be pressurized. Modifications to the chiller that would result in
pressurization of the reservoir will void the warranty.
Coolant Pump
The standard close coupled pump is typically equipped with a mechanical seal. Material of
construction and seal type will vary by model and the options selected. The pump is factory
tested for the specified operating conditions and meets NEMA specifications / industry
standards.
High Refrigerant Pressure Switch
The High Refrigerant Pressure switch is designed to limit the compressor discharge pressure
within the design parameters of the compressor. The switch is located on the discharge side
of the compressor. All models feature automatic reset switches.
Low Refrigerant Pressure Switch
The Low Refrigerant Pressure switch is designed to limit the compressor suction pressure to
within the designed parameters of the compressor. The switch is located in the suction side
of the compressor. The low pressure refrigerant switch is an automatic reset switch.
Freezestat
The freezestat control is an electronic thermostat most commonly used that senses the
coolant temperature separately from the microprocessor based PID temperature controller.
The PID controller is sometimes used as the freezestat. This safety is designed to limit the
temperature of the coolant leaving the evaporator and prevent a possible freeze up situation.
This control should be set 10°F (5°C) below the minimum coolant supply temperature, and
there should be a sufficient glycol concentration for 10°F (5°C) below the freezestat setting.
NOTE: It is critical that the freezestat is set properly and that there is sufficient glycol in the
system to correspond with the freezestat setting. Freeze ups can cause extensive damage to
several components in the chiller, and the warranty does not cover repairs required due to a
freeze up.

M002359AB OTC-.25A-10A- Remote Condenser.doc
1
OPERATION AND INSTALLATION MANUAL
REMOTE CONDENSER # M002359AB
FOR OTC and OTM SERIES
ALL Models
CAUTION (REFER TO ACCOMPANYING DOCUMENTS)
CAUTION: RISK OF ELECTRICAL SHOCK. DISCONNECT SWITCH
REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICING.
THE CHILLER CONTAINS REFRIGERANT.
Be sure that all mechanical piping and wiring conform to federal, state and local codes.
Run the appropriate copper tubing discharge and liquid lines from the chiller (internal to building)
to the condenser (external to building in area where both intake and exhaust are not blocked).
See refrigeration schematic for details. After the tubing has been connected, test the lines for
leaks using nitrogen. Evacuate the lines by connecting a vacuum pump to the interconnecting
tubing. Once it is evacuated, open the Service Valves in the Chiller to “Charge” the lines.
The electrical contactor for the fan(s) is in the condenser cabinet. Connect a power cable
(provided by others) to a fused disconnect (provided by others) located within sight of the
condenser. Run the power cable from the disconnect to the correct terminals in the condenser
box.See electrical schematic for details. All wiring shall be run through appropriate seal-tite.
The unit is pre-charged with R-134a or R-407c refrigerant. The unit was tested with 2 feet of
lines. It may be necessary to add refrigerant for additional line lengths. Please contact the
factory to obtain the proper refrigerant charge.
The chiller system is designed such that the chiller’s compressor and pump run all of the time.
The condenser fan cycles as needed. The hot gas bypass valve and solenoid cycle in order to
provide part load control in the refrigeration system.
CONNECTING THE (OPTIONAL) REMOTE CONDENSER

15
5.4 System Construction Standards
OPTI TEMP standard chillers are designed with NEMA 1 construction suitable for indoor use.
Unless the unit was specifically ordered with NEMA 4 construction for outdoor duty, it should
not be installed or stored in an outdoor location.
Section 6 – Installation
6.1 Chiller Location
The OPTI TEMP units utilize air-cooled refrigeration systems and must be placed in well
ventilated areas only. Air is drawn and/or discharged through the front, rear, side and top
panels of the unit. The unit must be located so the intake and discharge air is not restricted.
A minimum clearance of “one width” of the unit is suggested on all vented sides. Failure to
provide adequate ventilation may cause a reduction in cooling capacity, excessively high
refrigeration pressures, and/or pre-mature failure.
Never place the unit in a location where excessive heat, moisture, airborne oils, or corrosive
materials are present. The unit should be periodically cleaned to insure optimum
performance. A regular maintenance schedule based on operating conditions is
recommended. Please reference Section 8 of this manual for more information. Please note
that oil, dust, and/or other airborne agents can build up on air-cooled condensers resulting in
a decrease in performance or system failure.
NOTE: Serviceability was a primary concern when designing your portable chiller.
Removable panels permit easy access for periodic maintenance or repair. Do not
compromise this feature by locating the chiller in an inaccessible area.
NOTE: The condenser air inlet temperature should be maintained above 60°F (15°C) in order
to avoid possible low refrigerant pressure safety trips during start-up. If it is necessary to
store the chiller in an unheated area when not in use, be sure that all water is drained or that
an adequate amount of antifreeze is added to prevent freeze-up of the unit.
6.2 Process Fluid Connection
Connect “TO PROCESS” and “FROM PROCESS” connections on rear of chiller to your
process lines. Standard process connections provided on OTC Series chillers are stainless
steel male pipe fittings. See specifications table in Section 5.2 for connection sizes on
specific chiller models. It is suggested that valves be installed on the “TO PROCESS” line
and “FROM PROCESS” line at the OPTI TEMP unit to be used as balancing valves and to
isolate the chiller should maintenance be required on the unit.

16
Recommended Hose Selection Table
CAUTION: Under-sizing the process hose will result in greater than typical pressure drop
and may cause inadequate process pressure to be delivered. This may harm your process
equipment and/or cause unnecessary wear on the chiller motor and pump.
CAUTION: The fittings are connected to a manifold plate attached to the unit. Do not over
tighten fittings or failure may occur.
CAUTION: Never connect the fittings to your building water supply or any pressurized water
source.
6.3 Chilled Water Lines
All chilled water piping should be adequately insulated to prevent condensation. If water is
allowed to condense on the piping, the state change of the water from gas to liquid will result
in a substantial heat load which becomes an additional burden for the chiller.
Standard portable chillers have been designed for a nominal flow of 2.4 GPM per ton at
nominal conditions. During normal full-load operation with 55°F (10°C) coolant supplied to the
process, this nominal flow rate will result in a 65°F (15°C) coolant returned from the
process. The nominal flow rate for each chiller is shown above in the Recommended Hose
Selection Table. This table also provides the maximum flow rate for each chiller. The
maximum flow rate should not be exceeded unless the chiller was specifically ordered to
handle high flow conditions. If the process cannot handle the full nominal flow from the
chiller, the excess water flow will simply bypass the process through the bypass line inside
the chiller.
The importance of properly sized piping between the chiller and process cannot be
overemphasized. In general, run full size piping out to the process and then reduce the pipe
size to match the connections on the process equipment. One of the most common causes of
unsatisfactory chiller performance is poorly designed piping. Avoid unnecessarily long lengths
of hoses or quick disconnect fittings which offer high resistance to water flow.
When manifolds are required for water distribution, they should be installed as close to the
use point as possible. Provide flow balancing valves at each machine to assure adequate
water distribution in the entire system.
Standard
Model OTC Standard Flow Rating Minimum Hose Size Hose Length from Machine
.25A, .33A,
.5A, .75A,
1.0A, 1.5A
2.3 GPM @ 65 PSI
4 GPM @ 65 PSI
≥ ¾” ID
≥ 1” ID < 10’ >10’
2.0A, 3.0A,
5.0A
5 to 7 GPM @ 55 PSI
12 GPM @ 53 PSI
≥ 1-1/4” ID
≥ 1-1/2” ID < 10’ > 10’
7.5A, 10A 18 to 30 GPM @ 56 PSI
≥ 1-1/2” ID
≥ 2” ID < 10’ > 10’

17
Suggested Overhead Pipe Sizing Table
Pipe Size Max. Flow Rate (GPM)
1/2" 2
3/4" 5
1" 10
1 1/4" 20
1 1/2" 30
2" 50
2 1/2" 90
3" 160
*Based on standard weight schedule 40 black iron or PVC
schedule 80 pipes.
NOTE: It is recommended that good piping practices are followed and that the information in
this manual is adhered to. We cannot be held responsible for liabilities created by
substandard piping methods and installation practices external to the chiller.
6.4 Overhead Piping and Drain Back Prevention
Depending on the length of hoses/piping and therefore the amount of fluid contained in the
system, fluid may drain back causing the reservoir to overflow when the unit is turned off
during shut down periods. This problem can be eliminated by locating the unit so the
reservoir is at the same level or above the system; or a check valve can be installed in the
process supply line and a solenoid valve installed in the process return line to prevent drain
back. Contact OPTI TEMP for further information at 231-946-2931 or
[e-mail].
CAUTION: The OPTI TEMP system is designed as an “open system” with the top of the
reservoir at atmospheric pressure. Do not connect any fittings to the cover of the reservoir or
pressurize the reservoir in any way or damage to the system and/or personal injury could
result. The reservoir is designed to be filled manually.
6.5 Electrical Connection
Refer to the serial number tag for the specific electrical requirements of your unit. Ensure the
voltage of the intended power source meets the specified voltage requirement. See
reference electrical requirement table below. Power must be provided through a circuit
breaker or a switch-able “fused disconnect” in close proximity to the unit and within easy
reach of the operator.
If the nominal supply voltage does not fall within the range specified in the table below a
transformer will be required. Transformers are provided in certain OPTI TEMP models
depending on voltage configuration selected. For more information contact OPTI TEMP
sales or engineering at 231-946-2931 or [e-mail].
NOTE: Check pump rotation on 3 phase units at this time. Follow the instructions on the tag
attached to the power cord.
NOTE: All electrical service installation should be performed by a qualified electrician in
accordance with all applicable code.