Thermal Care NQ Series User manual

Installation & Operation Manual
NQ Series Portable and Remote Condenser Chillers

Page Intentionally Blank

Table of Contents
Foreword ...........................................................................................................................................................................1
Safety Guidelines .............................................................................................................................................................2
General Data .....................................................................................................................................................................3
Table 1 –Air Cooled Chiller General Data (60 Hz) ......................................................................................................................... 3
Table 2 –Water Cooled Chiller General Data (60 Hz)................................................................................................................... 3
Table 3 –Remote Air Cooled Condenser Chiller General Data (60 Hz) .................................................................................4
Table 4 –Remote Air-Cooled Condenser General Data (60 Hz)............................................................................................... 4
Pre-Installation.................................................................................................................................................................5
Receiving Inspection ....................................................................................................................................................................................... 5
Unit Storage........................................................................................................................................................................................................ 5
Installation –Chiller Mechanical ...................................................................................................................................6
Foundation..........................................................................................................................................................................................................6
Unit Location......................................................................................................................................................................................................6
Rigging ................................................................................................................................................................................................................. 6
Chilled Water Piping ....................................................................................................................................................................................... 6
Figure 1 –Recommended Overhead Piping.....................................................................................................................................7
Figure 2 –4 Ton Chiller Net Pump Performances (60 Hz) ..........................................................................................................7
Figure 3 –4 Ton High Flow Chiller Net Pump Performances (60 Hz).....................................................................................8
Figure 4 - 5 Ton Chiller Net Pump Performances (60 Hz) ........................................................................................................... 8
Figure 5 –5 Ton High Flow Chiller Net Pump Performances (60 Hz).....................................................................................9
Figure 6 –7½ Ton Chiller Net Pump Performances (60 Hz) ...................................................................................................... 9
Figure 7 –7½ Ton High Flow Chiller Net Pump Performances (60 Hz) ..............................................................................10
Figure 8 - 10 Ton Chiller Net Pump Performances (60 Hz) ......................................................................................................10
Figure 9 –10 Ton High Flow Chiller Net Pump Performances (60 Hz) ................................................................................11
Figure 10 - 13 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................11
Figure 11 –13 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................12
Figure 12 - 15 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................12
Figure 13 –15 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................13
Figure 14 - 20 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................13
Figure 15 –20 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................14
Figure 16 - 25 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................14
Figure 17 –25 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................15
Figure 18 - 30 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................15
Figure 19 –30 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................16
Figure 20 - 35 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................16
Figure 21 –35 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................17
Figure 22 - 40 Ton Chiller Net Pump Performances (60 Hz)....................................................................................................17
Figure 23 –40 Ton High Flow Chiller Net Pump Performances (60 Hz)..............................................................................18
Figure 24 –Chiller Coolant Circuit Pressure Drop (4-Ton and 5-Ton) .................................................................................18
Figure 25 –Chiller Coolant Circuit Pressure Drop (7½-Ton and 10-Ton)...........................................................................19
Figure 26 –Chiller Coolant Circuit Pressure Drop (13-Ton and 15-Ton) ............................................................................19
Figure 27 –Chiller Coolant Circuit Pressure Drop (20-Ton and 25-Ton) ............................................................................20
Figure 28 –Chiller Coolant Circuit Pressure Drop (30-Ton and 35-Ton) ............................................................................20
Figure 29 –Chiller Coolant Circuit Pressure Drop (40-Ton) .....................................................................................................21
Condenser Water Piping..............................................................................................................................................................................21
Figure 30 –Water Cooled Condenser Pressure Drop Curve (5-Ton to 15-Ton) ..............................................................22

Figure 31 –Water Cooled Condenser Pressure Drop Curve (20-Ton to 40-Ton)............................................................22
Installation –Remote Air-Cooled Condenser ............................................................................................................23
Location..............................................................................................................................................................................................................23
Mounted Legs and Lifting (5 - 10 ton Units).......................................................................................................................................23
Mounted Legs and Lifting (15 –40 ton Units)....................................................................................................................................24
Interconnecting Refrigerant Piping.........................................................................................................................................................24
Refrigeration Piping Design .......................................................................................................................................................................24
Figure 32 –Condenser Located with No Elevation Difference................................................................................................25
Figure 33 –Condenser Located above Chiller Unit .....................................................................................................................25
Figure 34 - Condenser Located Below Chiller Unit ......................................................................................................................26
Determining Equivalent Line Length ......................................................................................................................................................26
Table 5 –Equivalent Lengths of Fittings ..........................................................................................................................................27
Liquid Line Sizing............................................................................................................................................................................................27
Table 6 –Liquid Line Sizes for R410A................................................................................................................................................28
Discharge (Hot Gas) Line Sizing................................................................................................................................................................30
Figure 35 –Vertical Riser Traps............................................................................................................................................................30
Figure 36 - Double Discharge Riser ...................................................................................................................................................31
Table 7 - Horizontal or Downflow Discharge Line Sizes for R410A (inches OD)..............................................................31
Table 8 - Upflow Discharge Line Sizes for R410A (inches OD)................................................................................................31
Calculating System Refrigerant and Oil Charge.................................................................................................................................32
Table 9 –Combined Chiller and Remote Condenser Summer Refrigerant Charge........................................................32
Table 10 - Field Piping R-410A Refrigerant Charge per 100 Feet of Run (Lbs.) ...............................................................32
Oil Charge Determination...........................................................................................................................................................................32
Setting Condenser Fan Controls...............................................................................................................................................................32
Table 11 - Condenser Fan Pressure Settings (psig) .....................................................................................................................32
Installation - Electrical ..................................................................................................................................................33
Table 12 –Air Cooled Chiller Electrical Data (60 Hz)...................................................................................................................34
Table 13 –Water Cooled & Remote Air Cooled Condenser Chiller Electrical Data (60 Hz) ........................................38
Table 14 –Remote Air Cooled Condenser Electrical Data (60 Hz) ........................................................................................42
Standard Controller Operation....................................................................................................................................43
Start Button.......................................................................................................................................................................................................43
Stop Button.......................................................................................................................................................................................................43
Alarm Silence / Alarm Reset Button........................................................................................................................................................43
Compressor Running Hours Button........................................................................................................................................................43
Pump Running Hours Button ....................................................................................................................................................................44
Pump Test Button...........................................................................................................................................................................................44
Display/Program Button ..............................................................................................................................................................................44
Up Button ..........................................................................................................................................................................................................44
Down Button ....................................................................................................................................................................................................44
Control Power On LED..................................................................................................................................................................................44
Autostart Signal LED......................................................................................................................................................................................44
Pump LED ..........................................................................................................................................................................................................45
Hot Gas Bypass LED.......................................................................................................................................................................................45
Compressor #1 LED .......................................................................................................................................................................................45
Compressor #2 LED .......................................................................................................................................................................................45
Temperature Limit LED.................................................................................................................................................................................45
Electrical Phase Error LED............................................................................................................................................................................45
Low Flow LED ...................................................................................................................................................................................................45
Freezestat LED .................................................................................................................................................................................................46
Low Reservoir Level LED ..............................................................................................................................................................................46

Compressor Recycle LED .............................................................................................................................................................................46
High Refrigerant Pressure LED..................................................................................................................................................................46
Low Refrigerant Pressure LED....................................................................................................................................................................46
Program Mode LED .......................................................................................................................................................................................46
Set Point Temperature Display .................................................................................................................................................................46
Process Temperature Display ....................................................................................................................................................................46
Program Menu.................................................................................................................................................................................................46
Table 15 - Controller Program Menu ................................................................................................................................................48
Table 16 –Controller Control Fault Logic........................................................................................................................................49
SPI Communications (Optional) ...............................................................................................................................................................50
Table 17 - SPI Parameters ......................................................................................................................................................................50
Modbus RTU (Optional)...............................................................................................................................................................................51
Table 18 –ModBus RTU Option Parameters (Integer Values).................................................................................................51
Table 19 –ModBus RTU Option Parameters (Floating Point Values) ...................................................................................52
Optional Controller Operation.....................................................................................................................................54
Start-Up Screen & Thermal Care Contact Information ...................................................................................................................54
Main Screen......................................................................................................................................................................................................54
Local/ Remote Button (Press to Toggle) ..........................................................................................................................................54
Start Button..................................................................................................................................................................................................54
Stop Button..................................................................................................................................................................................................54
Set Point Temperature Display & Entry............................................................................................................................................54
Actual Supply Water Temperature Display .....................................................................................................................................54
Alarms Button .............................................................................................................................................................................................54
Setup Button ...............................................................................................................................................................................................54
Process Diagnostic Button.....................................................................................................................................................................54
Refrigereration Diagnostic Button......................................................................................................................................................54
Active Alarms Screen.....................................................................................................................................................................................55
Alarm Reset Button...................................................................................................................................................................................55
Alarm History Button ...............................................................................................................................................................................55
Main Button.................................................................................................................................................................................................55
Alarm History Screen ....................................................................................................................................................................................55
Up and Down Buttons .............................................................................................................................................................................55
Acknowledge Button................................................................................................................................................................................55
Alarms Button .............................................................................................................................................................................................55
Process Diagnostic Button.....................................................................................................................................................................55
Main Button.................................................................................................................................................................................................55
Compressor Setup Screen...........................................................................................................................................................................56
Process Setup Button...............................................................................................................................................................................56
PID Setup ......................................................................................................................................................................................................56
FreezeStat Setup Button .........................................................................................................................................................................56
Main Button.................................................................................................................................................................................................56
Process Setup Screen....................................................................................................................................................................................56
HGBP PID Button .......................................................................................................................................................................................56
Compressor Setup Button......................................................................................................................................................................56
Main................................................................................................................................................................................................................56
Hot Gas Bypass Screen PID Tuning Screen ..........................................................................................................................................57
Refrigeration Diagnostic Button..........................................................................................................................................................57
Compressor Setup Button......................................................................................................................................................................57
Main Button.................................................................................................................................................................................................57
Freezestat Setup Screen...............................................................................................................................................................................57

HGBP PID Button .......................................................................................................................................................................................57
Compressor Setup Button......................................................................................................................................................................57
Main................................................................................................................................................................................................................57
Process Diagnostic Screen..........................................................................................................................................................................58
I/O Status Button.......................................................................................................................................................................................58
Alarms Button .............................................................................................................................................................................................58
Setup Button ...............................................................................................................................................................................................58
Main................................................................................................................................................................................................................58
I/O Status Screen............................................................................................................................................................................................58
Output Designation Button...................................................................................................................................................................58
Input Status Button...................................................................................................................................................................................58
Refrigeration Diagnostic Screen...............................................................................................................................................................59
I/O Status Button.......................................................................................................................................................................................59
Setup Button ...............................................................................................................................................................................................59
Process Diagnostic Button.....................................................................................................................................................................59
Main................................................................................................................................................................................................................59
Start-Up...........................................................................................................................................................................59
Step 1 - Connect Main Power ...................................................................................................................................................................60
Step 2 - Fill Coolant Circuit.........................................................................................................................................................................60
System Fill Water Chemistry Requirements....................................................................................................................................60
Table 20 –Fill Water Chemistry Requirements..............................................................................................................................61
Table 21 - Recommended Glycol Solutions....................................................................................................................................61
Step 3 - Check Condenser ..........................................................................................................................................................................61
Intergral Air-Cooled Condenser Check.............................................................................................................................................61
Water-Cooled Condenser Check.........................................................................................................................................................61
Remote Air-Cooled Condenser Check ..............................................................................................................................................61
Step 4 –Check Refrigerant Valves...........................................................................................................................................................62
Step 5 –Verify Freezestat Setting ............................................................................................................................................................62
Step 6 –Turn On Control Power ..............................................................................................................................................................62
Step 7 –Establish Coolant Flow................................................................................................................................................................62
Step 8 –Intial Unit Operation....................................................................................................................................................................62
Preventive Maintenance ...............................................................................................................................................63
Once a Week ....................................................................................................................................................................................................63
Once a Month..................................................................................................................................................................................................63
Every Three Months.......................................................................................................................................................................................63
Preventive Maintenance Checklist ..............................................................................................................................64
General Troubleshooting..............................................................................................................................................65
Drawings .........................................................................................................................................................................66
Warranty .........................................................................................................................................................................67
Extended 5 Year Compressor Warranty –(Optional)...............................................................................................68

1
Foreword
The portable chiller is a packaged unit typically
consisting of a refrigeration circuit and a coolant
reservoir and pumping system in a compact
packaged cabinet for easy location in industrial
applications where chilled water is required.
The intent of this manual is to serve as a guide for
placing your portable chiller in service and operating
and maintaining it properly. Improper installation
can lead to poor equipment performance or severe
equipment damage. Failure to follow the installation
instructions may result in damage not covered by
your warranty. It is extremely important that a
qualified refrigeration installation contractor perform
all installation line sizing and piping. Please supply
these instructions to your authorized refrigeration
contractor.
This manual is for our standard product line with
supplements as required to accommodate any
special items provided for a specific application. The
written information contained in this manual, as well
as various drawings, are intended to be general in
nature. Unit specific drawings are included with the
equipment for troubleshooting and servicing of the
unit. Additional copies of drawings are available
upon request. We strive to maintain an accurate
record of all equipment during the course of its
useful life.
Due to the ever-changing nature of applicable
codes, ordinances, and other local laws pertaining to
the use and operation of this equipment we do not
reference them in this manual. There is no substitute
for common sense and good operating practices
when placing any mechanical equipment into
operation. We encourage all personnel to familiarize
themselves with this manual's contents. Failure to do
so may unnecessarily prolong equipment down time.
The chilling equipment uses chemical refrigerants for
heat transfer purposes. This chemical is sealed and
tested in a pressurized system containing ASME
coded vessels; however, a system failure will release
it. Refrigerant gas can cause toxic fumes if exposed
to fire. Place these units in a well-ventilated area,
especially if open flames are present.
Failure to follow these instructions could result in a
hazardous condition. The standard refrigerant used
in these units is a hydro fluorocarbon (HFC) trade
named R-410A. We strongly recommend a
refrigerant management program be implemented
which includes a survey of all equipment to
document the type and quantity of refrigerant in
each machine. In addition, we recommend only
licensed and EPA certified service technicians work
on our refrigeration circuits. Follow good piping
practices and the information in this manual to
ensure successful installation and operation of this
equipment. We are not responsible for liabilities
created by substandard piping methods and
installation practices external to the chiller.
We trust your equipment will have a long and useful
life. If you should have any questions, please contact
our Customer Service Department specifying the
serial number and model number of the unit as
indicated on the nameplate.

2
Safety Guidelines
Observe all safety precautions during installation,
start-up, and service of this equipment. The
following is a list of symbols used in this manual and
their meaning.
General Warning
Electricity Warning
Sharp Element Warning
Hot Surface Warning
Flammable Material Warning
Explosive Material Warning
General Mandatory Action
Wear Eye Protection
Wear Protective Gloves
Wear Ear Protection
Disconnect Before Carrying Out Maintenance or
Repair
Connect an Earth Terminal to Ground
Only qualified personnel should install, start-up, and
service this equipment. When working on this
equipment, observe precautions in literature, and on
tags, stickers, and labels located on the equipment.
WARNING: Any use or misused of this equipment
outside of the design intent may cause injury or
harm.
WARNING: Vent all refrigerant relief valves in
accordance to ANSI/ASHRAE Standard 15, Safety
Code for Mechanical Refrigeration. This
equipment should be located within a well-
ventilated area. Inhalation of refrigerant can be
hazardous to your health and the accumulation
of refrigerant within an enclosed space can
displace oxygen and cause suffocation.
WARNING: This equipment contains hazardous
voltages that can cause severe injury or death.
WARNING: This equipment contains refrigerant
under pressure. Accidental release of refrigerant
under pressure can cause personal injury and or
property damage.
WARNING: This equipment may contain fan
blades or other sharp edges. Make sure all fan
guards and other protective shields are securely
in place.
WARNING: The exposed surfaces of motors,
refrigerant piping, and other fluid circuit
components can be very hot and can cause burns
if touched with unprotected hands.
CAUTION: Disconnect and lock out incoming
power before installing, servicing, or
maintaining the equipment. Connecting power to
the main terminal block energizes the entire
electric circuitry of the unit. A power supply
provides 24 VDC control power. Electric power at
the main disconnect should be shut off before
opening access panels for repair or maintenance.
CAUTION: Wear eye protection when installing,
maintaining, or repairing the equipment to
protect against any sparks, debris, or fluid leaks.
CAUTION: The chiller will exceed 70 dBA sound
pressure at 1 meter distance and 1 meter
elevation when operating. Wear ear protection
as required for personnel comfort when
operating or working in close proximity to the
chiller.
CAUTION: Wear protective gloves when
installing, maintaining, or repairing the
equipment to protect against any sparks, debris,
or fluid leaks.

3
General Data
Table 1 –Air Cooled Chiller General Data (60 Hz)
Model
NQA04
NQA05
NQA08
NQA10
NQA13
NQA15
NQA20
NQA25
NQA30
Cooling Capacity (tons)1
4.4
5.1
7.8
11.0
12.5
14.9
20.9
25.6
30.6
Set Point Range (°F)
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
Refrigerant
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
Condenser Air Flow (cfm)
4,000
4,000
8,000
8,000
8,000
10,450
18,000
20,000
24,000
Sound Pressure @ 1 meter (dBA)2
73.8
74.0
75.8
76.2
76.2
82.2
84.4
84.4
85.9
Minimum Unloaded Capacity (tons)
1.0
1.2
1.8
2.7
3.1
3.6
4.8
6.0
7.2
Pump Motor Size (hp)
1.5
1.5
1.5
1.5
1.5
3
3
5
5
Pump Flow (gpm)
11
12
19
27
30
36
48
60
72
Net Available Pump Pressure (psi)3
35
36
35
30
28
48
39
58
55
Unit MCA @ 460/3/60 (amps)4
15.6
18.1
26.1
30.9
36.5
44.3
55.5
70.0
83.1
Length (inches)
48
48
75
75
75
87
87
105
105
Width (inches)
35
35
35
35
35
41
41
41
41
Height w/standard fans (inches)
61
61
61
61
61
94
94
94
94
Height w/high pressure fans (inches)
n/a
n/a
63
63
63
96
96
96
96
Reservoir Holding Capacity (gal)
11
11
22
22
22
50
50
67
67
Process Connections (inches)
1.5
1.5
1.5
1.5
1.5
2
2
2
2
Shipping Weight (lbs)
720
720
1,195
1,195
1,215
3,200
3,300
3,800
4,150
1Cooling tons based on 12,000 BTU/Hr/ton with 50°F leaving coolant and 95°F ambient air.
2Sound power shown is for standard high-efficiency constant-speed AC motor fans. A high-pressure variable-speed EC motor
fan option is available for NQA08 and larger units that changes the sound pressure at 1 meter (dBA) to 75 for NQA08-10, 82
for NQA15, 84 for NQA20, 85 for NQA25, and 82 for NQA30.
3Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant-circuit pressure loss.
4MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.
Table 2 –Water Cooled Chiller General Data (60 Hz)
Model
NQW05
NQW08
NQW10
NQW15
NQW20
NQW25
NQW30
NQW35
NQW40
Cooling Capacity (tons)1
5.5
8.1
12.0
16.5
22.6
28.1
33.3
38.9
43.4
Set Point Range (°F)
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
Refrigerant
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
Condenser Water Flow (gpm)
17
24
36
48
65
82
96
111
124
Sound Pressure @ 1 meter (dBA)
69.8
70.3
71.3
73.3
73.7
73.7
74.7
76.6
78.1
Minimum Unloaded Capacity (tons)
1.3
1.9
2.9
3.9
5.2
6.6
7.8
8.9
9.9
Pump Motor Size (hp)
1.5
1.5
1.5
3
3
5
5
5
5
Pump Flow (gpm)
13
20
29
39
54
67
79
92
102
Net Available Pump Pressure (psi)2
35
34
28
45
32
54
51
48
44
Unit MCA @ 460/3/60 (amps)3
16.4
22.6
27.4
39.7
46.3
60.8
69.3
73.7
77.2
Length (inches)
48
75
75
75
87
87
105
105
105
Width (inches)
35
35
35
35
41
41
41
41
41
Height (inches)
54
54
54
54
47
47
47
47
47
Reservoir Holding Capacity (gal)
11
22
22
22
50
50
67
67
67
Process Connections (inches)
1.5
1.5
1.5
1.5
2
2
2
2.5
2.5
Condenser Connections (inches)
1.5
1.5
1.5
1.5
2.5
2.5
2.5
2.5
3
Shipping Weight (lbs)
720
1,195
1,195
1,315
1,900
2,100
2,250
3,400
3,900
1Cooling tons based on 12,000 BTU/Hr/ton with 50°F leaving coolant and 85°F condenser water.
2Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant-circuit pressure loss.
3MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.

4
Table 3 –Remote Air Cooled Condenser Chiller General Data (60 Hz)
Model
NQR05
NQR08
NQR10
NQR15
NQR20
NQR25
NQR30
NQR35
NQR40
Cooling Capacity (tons)1
5.3
7.6
11.0
15.3
20.8
25.8
30.7
35.5
39.9
Set Point Range (°F)
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
20 to 80
Refrigerant
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
R410A
Sound Pressure @ 1 meter (dBA)2
69.8
70.3
71.3
73.3
73.7
73.7
74.7
76.6
78.1
Minimum Unloaded Capacity (tons)
1.2
1.8
2.7
3.6
4.8
6.0
7.2
8.4
9.6
Pump Motor Size (hp)
1.5
1.5
1.5
3
3
5
5
5
5
Pump Flow (gpm)
13
18
27
36
48
61
73
83
92
Net Available Pump Pressure (psi)3
35
36
30
48
39
57
54
53
50
Unit MCA @ 460/3/60 (amps)4
16.4
22.6
27.4
39.7
46.3
60.8
69.3
73.7
77.2
Length (inches)
48
75
75
75
87
87
105
105
105
Width (inches)
35
35
35
35
41
41
41
41
41
Height (inches)
54
54
54
54
47
47
47
47
47
Reservoir Holding Capacity (gal)
11
22
22
22
50
50
67
67
67
Process Connections (inches)
1.5
1.5
1.5
1.5
2
2
2
2.5
2.5
Refrigerant Liquid Line (inches)
0.625
0.625
0.875
0.875
0.875
1.125
1.125
1.375
1.375
Refrigerant Suction Line (inches)
0.625
0.625
0.875
0.875
0.875
1.125
1.125
1.375
1.375
Shipping Weight (lbs)
720
1,195
1,195
1,315
1,900
2,100
2,250
3,400
3,900
1Cooling tons based on 12,000 BTU/Hr/ton with 50°F leaving coolant and 95°F ambient air.
2Sound pressure is for chiller unit only; see the Remote Air-Cooled Condenser table for condenser sound pressures.
3Net available pressure at outlet of chiller is pump discharge pressure less the internal coolant-circuit pressure loss.
4MCA is Minimum Circuit Amps (for wire sizing), complies with NEC, Section 430-24.
Table 4 –Remote Air-Cooled Condenser General Data (60 Hz)
Condenser
Model
Chiller
Used
With
Dimensions (in)
Weights (Lbs)
Total Air
Flow
(cfm)
Sound
Pressure
(dBA)1
MCA @
460/3/60
(amps)2
Refrigerant
Connections (in)
L
W
H
Ship
Oper
Inlet
Outlet
KCM009
NQR05
53.625
43.625
48.125
245
Operating
weight
varies
based on
system
charge
and
operating
conditions
6,870
60
1.4
0.875
1.125
KCM011
NQR08
53.625
43.625
48.125
265
6,620
60
1.4
0.875
1.125
KCM014
NQR10
93.625
43.625
48.125
415
14,400
62
2.6
1.375
1.125
KCL023
NQR15
125.750
45.625
54.000
670
24,000
72
7.0
2.125
1.375
KCL030
NQR20
125.750
45.625
54.000
720
22,600
72
7.0
2.125
1.625
KCL037
NQR25
125.750
45.625
54.000
800
20,600
72
7.0
2.125
1.625
KCL045
NQR30
180.750
45.625
54.000
1,075
33,900
73
10.1
2.625
1.625
KCL054
NQR35
180.750
45.625
54.000
1,175
32,000
73
10.1
2.625
2.125
KCL056
NQR40
180.750
45.625
54.000
1,200
30,900
73
10.1
2.625
2.125
1Sound pressure at 3 meters.
2MCA is minimum circuit amps (for wire sizing) as provided by the remote condenser manufacturer.

5
Pre-Installation
Receiving Inspection
When the unit arrives, verify it is the correct unit by
comparing the information that appears on the unit
nameplate with that which appears on the order
acknowledgement and shipping papers. Inspect the
equipment condition for any visible damage and
verify all items shown on the bill of lading are
present. If damage is evident, properly document it
on the delivery receipt and clearly mark any item
with damage as “unit damage” and notify the carrier.
In addition, make note of the specific damage and
notify our Customer Service Department and they
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. Do not install
damaged equipment without getting the equipment
repaired.
Shipping damage is the responsibility of the carrier.
To protect against possible loss due to damage
incurred during shipping and to expedite payment
for damages, it is important to follow proper
procedures and keep records. Photographs of
damaged equipment are excellent documentation
for your records.
Start unpacking the unit, inspect for concealed
damages, and take photos of any damages found.
Once received, equipment owners have the
responsibility to provide reasonable evidence that
the damage did not occur after delivery. Photos of
the equipment damage while the equipment is still
partially packed will help in this regard. 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.
Record any signs of concealed damage and file a
shipping damage claim immediately with the
shipping company. Most carriers require concealed
damages be reported within 15 days of receipt of
the equipment. In addition to notifying the carrier,
notify our Customer Service Department and they
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.
Water-cooled chillers ship with a full refrigerant
charge while remote condenser chillers ship with a
nitrogen holding charge. Remote air-cooled
condensers ship separately with a 350-psi dry
nitrogen gas charge. Check the remote condenser
for signs of leaks prior to rigging. This will ensure no
coil damage has occurred after the unit left the
factory. The condenser ships with the legs removed.
Mount the legs to the condenser using the provided
nuts, bolts, and washers.
Unit Storage
If the chiller is stored prior to installation, it is
important to protect it from damage. Blow out any
water from the evaporator and water-cooled
condenser circuits to protect the unit from damage
from freezing. Close any open refrigerant valves.
Cover the equipment to keep dirt and debris from
accumulating on it. Units charged with refrigerant
should not be stored in areas warmer than 145°F.

6
Installation –Chiller
Mechanical
Foundation
The chiller is for installation on a rigid, non-warping
mounting pads or a concrete foundation suitable to
support the full operating weight of the equipment.
When installed the equipment must be level within
¼ inch over its length and width.
Unit Location
The chiller is available in many different
configurations to allow each unit to meet the
environments in which they are used. Please refer to
the proposal and order acknowledgement for this
equipment to verify the specific design conditions in
which your chiller is to operate.
Allow a minimum of 48 inches of clearance between
the remote condenser and any walls or obstructions.
For installations with multiple condensers, allow a
minimum of 96 inches between condensers placed
side-by-side or 48 inches for condensers placed end-
to-end. In all cases, install the equipment on a rigid
surface suitable to support the full operating weight
of the unit. Level all equipment to ensure proper
operation.
Serviceability was an important factor in the design
of our equipment. Do not compromise this feature
by locating the chiller in an inaccessible area. When
locating the chiller it is important to consider
accessibility to the components to allow for proper
maintenance and servicing of the unit. In general,
allow a minimum of 36 inches of clearance around
all sides and above the unit. Avoid locating piping or
conduit over the unit. This ensures easy access with
an overhead crane or lift to lift out heavier
components during replacement or service.
Proper ventilation is another important
consideration when locating the unit. In general,
locate the unit in an area that will not rise above
110°F. In addition, ensure the condenser and
evaporator refrigerant pressure relief valves can vent
in accordance with all local and national codes.
Chillers with an integral air-cooled condenser require
a minimum of 36 inches of clearance at both the
condenser air inlet and condenser air discharge.
They are not designed to have the condenser air
discharge ducted. Improper clearance or poor
ventilation will reduce the cooling capacity of the
chiller and may cause high refrigerant pressure
problems. In order to avoid possible low refrigerant
pressure safety trips during start-up, maintain the
inlet air temperature above 50°F. If outside air is
ducted into an indoor chiller with integral air-cooled
condenser there is an option for low ambient heat
pressure controls which allow for incoming air
temperatures down to 0°F. Cooler temperatures than
this require custom modifications.
Rigging
The chiller has a structural steel frame with forklift
slots to facilitate easy movement and positioning.
Follow proper rigging methods to prevent damage
to components. Avoid impact loading caused by
sudden jerking when lifting or lowering the chiller.
Use pads where abrasive surface contact may occur.
Use the frame supporting the unit for positioning it
with a crane or a forklift.
Chilled Water Piping
Proper insulation of chilled water piping is crucial to
prevent condensation. The formation of
condensation on chiller water piping, the state
change of the water from gas to liquid, adds a
substantial heat load to the system and becomes an
additional burden for the chiller.
The importance of properly sized piping between
the chiller and process cannot be overemphasized.
See the ASHRAE Handbook or other suitable design
guide for proper pipe sizing. 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 poor piping
system design. Avoid long lengths of hoses, quick
disconnect fittings, and manifolds wherever possible
as they offer high resistance to water flow. When
manifolds are required, install them as close to the
use point as possible. Provide flow-balancing valves
at each machine to assure adequate water
distribution in the entire system.
The connection labeled “Chilled Water Supply”
delivers fluid to the process and the connection
labeled “Chilled Water Return” receives water back

7
from the process. Typically, when piping is overhead
with a total run length over 90 feet there should be a
valve in the supply line and an inverted P trap with a
vacuum break valve installed as shown in Figure 1.
Figure 1 –Recommended Overhead Piping
All standard portable chillers include an internal
coolant pump and reservoir. Nominal coolant flow
rates assume a 10°F rise across the evaporator at
50°F set point and 85°F entering condenser water for
water-cooled chillers or 95°F entering air for integral
air-cooled or remote air-cooled condenser chillers.
For units with one of our internal coolant pumps
reference one of the following net pump pressure
drop curves to determine actual pumping
capabilities for your process. If you have ordered the
chiller less pump, use the following coolant circuit
pressure drop curves to select the proper pump for
your application.
Figure 2 –4 Ton Chiller Net Pump Performances (60 Hz)
NOTE:
If piping is above chiller and exceeds 90 feet in total
length, install an inverted P-trap and vacuum break
valve in return line and add a check valve to the
supply line.
Check valve
1/2 inch vacum break valve
12 inches above highest
point in piping system
0
10
20
30
40
50
60
70
80
90
0 5 10 15 20 25 30 35
Pressure (psi)
Flow (gpm)
4-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 3 hp
2-stage
5 hp
2-stage

8
Figure 3 –4 Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 4 - 5 Ton Chiller Net Pump Performances (60 Hz)
0
10
20
30
40
50
60
70
80
90
0 5 10 15 20 25 30 35 40 45 50
Pressure (psi)
Flow (gpm)
4-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 3 hp
2-stage
5 hp
2-stage
0
10
20
30
40
50
60
70
80
90
0 5 10 15 20 25 30 35
Pressure (psi)
Flow (gpm)
5-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 3 hp
2-stage
5 hp
2-stage

9
Figure 5 –5 Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 6 –7½ Ton Chiller Net Pump Performances (60 Hz)
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60
Pressure (psi)
Flow (gpm)
5-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp
3 hp 3 hp
2-stage 5 hp
2-stage
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60
Pressure (psi)
Flow (gpm)
7½-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp
7½ hp
5 hp

10
Figure 7 –7½ Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 8 - 10 Ton Chiller Net Pump Performances (60 Hz)
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60 70 80
Pressure (psi)
Flow (gpm)
7½-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 5 hp
7½ hp
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60 70
Pressure (psi)
Flow (gpm)
10-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 7½ hp5 hp

11
Figure 9 –10 Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 10 - 13 Ton Chiller Net Pump Performances (60 Hz)
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60 70 80 90 100
Pressure (psi)
Flow (gpm)
10-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 7½ hp5 hp
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60 70
Pressure (psi)
Flow (gpm)
13-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 7½ hp5 hp

12
Figure 11 –13 Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 12 - 15 Ton Chiller Net Pump Performances (60 Hz)
0
10
20
30
40
50
60
70
80
90
020 40 60 80 100 120
Pressure (psi)
Flow (gpm)
13-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
1½ hp 3 hp 7½ hp5 hp
0
10
20
30
40
50
60
70
80
90
010 20 30 40 50 60 70 80 90
Pressure (psi)
Flow (gpm)
15-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
3 hp
7½ hp
5 hp

13
Figure 13 –15 Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 14 - 20 Ton Chiller Net Pump Performances (60 Hz)
0
10
20
30
40
50
60
70
80
90
020 40 60 80 100 120
Pressure (psi)
Flow (gpm)
15-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
3 hp 7½ hp5 hp
0
20
40
60
80
100
120
020 40 60 80 100 120
Pressure (psi)
Flow (gpm)
20-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
3 hp 7½hp5 hp 10 hp

14
Figure 15 –20 Ton High Flow Chiller Net Pump Performances (60 Hz)
Figure 16 - 25 Ton Chiller Net Pump Performances (60 Hz)
0
20
40
60
80
100
120
020 40 60 80 100 120 140 160
Pressure (psi)
Flow (gpm)
20-Ton High Flow Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
3 hp
7½ hp
5 hp
10 hp
0
20
40
60
80
100
120
020 40 60 80 100 120 140
Pressure (psi)
Flow (gpm)
25-Ton Standard Chiller Net Pump Performance
Pump Discharge Pressure Less Coolant Circuit Pressure Loss
Based on Water at 50°F, 60 Hz
7½ hp5 hp 10 hp