INTRODUCTION

TERMS & CONDITIONS

1
_

Chiller Manual SAFETY 2

Installation, Operation
& Maintenance

INSTALLATION
3
OPERATING INSTRUCTIONS
4

TROUBLE-SHOOTING 5

MAINTENANCE
-CLEANING 6
OPTIONAL FEATURES &
ACCESSORIES 7
APPEDIXES & NOTES
8
 Read Safety Section before installing or using equipment

Chiller Manual Installation, Operation & Maintenance

INTRODUCTION
Turbo Refrigerating is a will help avoid injury to falling over vertical
supplier of fluid chillers, personnel and/or damage to stainless steel plates in a
icemaking, and ice storage the equipment. Both are thin falling film. Because of
equipment. TURBO® does valuable assets to your method of chilling the
not engineer or design fluid operation. Take the time to liquid heat exchangers are
chilling systems, ice protect them. often referred to as falling
systems, ice plants, or film chillers.
processing lines. TURBO Read the manual contents
can provide assistance in before you start your HTD Series
locating qualified installation or operation. HTD stands for High
companies familiar with the This will save time by Temperature Difference.
installation and operation of ensuring that all necessary Fluids are chilled or heated
TURBO chillers. Contact materials and tools are over large temperature
the factory at the address or available when the differences, ranging from
telephone numbers listed at equipment arrives. 5°F to 60°F in a single pass
the end of this section. using R-22, ammonia or
History glycol as the refrigerant
Information on safety, inside the plate. Systems are
installation, operation, TURBO has been available in direct
maintenance and trouble- producing a line of fluid expansion (DX), flooded
shooting is contained in this chillers since 1984 and recirculated models.
manual. If you have equipment as well as Flow rates are available
questions concerning any of icemakers and ice over a wide range but are
these phases, contact generators for the ice typical considered relatively
TURBO or one of its industry since 1960. The low. Higher flow rates can
distributors to ensure that chillers described in this be obtained with HF
you fully understand the manual are part of a family chillers.
instructions and guidelines. of products designed
specifically for the HF Chillers
You must read all of the industrial market for a HF stands for High Flow.
information carefully and variety of cooling needs. Fluids are chilled over
make sure that all personnel narrow temperature
involved in the installation Fluid Heat Exchangers differences, ranging from
have also read and HTD and HF series heat 1°F to 2°F. The plate’s long
understood the information exchangers are designed to narrow geometry enables
and safety instructions. This instantaneously chill fluids high fluid flow over the

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 Read Safety Section before installing or using equipment

plate. Ammonia, R-22 and and uniform fragmented the field (trailer mounted
glycol are all available for nuggets. TURBO has units) or in the processing
use in direct expansion, produced the C-line area
flooded and recirculated icemaker since 1964. This • Concrete icing
systems. product line uses a water • Ingredient icing
defrost to produce ice in (bakeries)
Applications capacities ranging from 1 • Fish icing
HTD/HF chillers are ton per dry to 200 tons per • Poultry icing
suitable for a variety of day in CAR and CAR-LR • Chemical and dye
applications including: (ammonia) and CF (R-22) processes
• Food models. • Emergency cooling
• Beverage loads
• Chemical TURBO® TIG/TIGAR • Ice slurries
• Manufacturing Ice Generators • Catering trucks
In industrial applications • Salad bars or display ice
Models where ice is being used for • Food processing
A number of standard and processing or for top icing,
special chiller plates are TURBO produces a series Ice Storage Systems
available in a variety of of wet ice generators called TURBO® rakes and storage
configurations to meet the TIG (R-22) and TIGAR bins were introduced in
many applications. Standard (NH3) series. These hot gas 1967. There are three basic
plate sizes include: defrost icemakers are built sizes in the hydraulic
• 48” x 60” with the same high quality version as well as two
• 72’ x 60” standards and engineering larger versions known as
as the TURBO® icemakers automatic ice rakes
• 96” x 60”
of the sixties. The only (described in this manual).
• 144” x 24”
difference is that the The smaller hydraulic
icemaking process produces models range in capacity
Refrigerants/Refrigerant
slightly wetter ices due to from 20 to 87 tons while the
Feed
the hot gas defrost, and the larger automatic ice rakes
Chillers are available in R-
standard system used to range from 100 to 300 tons
22, ammonia, and glycol
produce dry, uniform ice of ice storage.
with direct expansion (DX),
nuggets is eliminated. As a TURBO rakes have been
flooded, and recirculated
result, a random shaped used in USDA inspected
refrigerant feed. Chillers
piece of fragmented ice is installations.
can be furnished with their
produced at a lower cost per
own high side and
ton. USDA Design
condensing unit or
All TURBO® ice storage
connected to existing
In applications where systems are designed to
refrigeration systems.
totally dry, uniform ice is meet USDA guidelines and
not required; the meet rugged industrial
Associated Equipment
TIG/TIGAR series offers a standards which make them
low cost alternative. the most reliable in the
Icemakers/Ice Generators
industry. Each system is
TURBO® C-Line
Typical Applications designed to make the
Icemakers
• Produce (broccoli, loading and unloading of
Packaged ice applications
carrots, etc.) – top icing in the ice storage system as
require a dry sub-cooled ice

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 Read Safety Section before installing or using equipment

safe and simple as possible. Optional Rake Features TURBO® block press the
Regardless of size, all of the most reliable on the market.
ice storage systems operate Although TURBO designs
in basically the same simple and builds the ice storage Special Applications
yet reliable manner. system to be as flexible as
possible, the standard TURBO is in the business
system may not meet a of supplying equipment to
The entire load and unload particular application. meet the needs of the
sequence is automatic and TURBO can design a customer. If you have an
does not require the storage system to meet application or a need that is
operator to be in contact almost any need. not discussed here, contact:
with the ice or any moving
parts in the ice storage TURBO® Block Press Turbo Refrigerating, LLC
system. TURBO offers another Sales Department
feature to make optimum P.O. Box 396
The continuous presence of profits from your ice Denton, Texas 76202-0396
an operator is not required production. Instead of Phone: 940-387-4301
although it is recommended. throwing away the snow Fax: 940-382-0364
At the end of the day, the produced by the breaker Web Site:
bin is empty (on a design bar, ice sizer, screw WWW.vogtice.com
day). The bin refills conveyors, or other
overnight and is full when handling devices, install a Customer Service
personnel return to work. TURBO® block press. This
block press converts the The TURBO service
NOTE: All controls are snow into ten or fifty-five department provides
adjustable to allow the pound blocks of ice. assistance for all customer
load or unload rate to needs. TURBO conducts
match the customer’s Introduced in 1977, the training schools at the
production and/or block press is a completely factory and at various
delivery requirements. automatic, hydraulic locations throughout the
powered unit capable of world.
Rake Variations producing from 120 to an
CB and Automatic rakes are excess of 400 ten pound NOTE: The model and
available in a number of blocks per hour. serial number of your
standard sizes to The block press is available TURBO equipment is
accommodate bulk storage with a block bagger located on the data
capacities ranging from 20 attachment, which means: nameplate attached to the
tons to 400 tons. Models are electrical control panel.
available in standard 10’, • Eliminates handling Please refer to the model
12’-6”, 15’ and 20’ widths; until the block is in the bag and serial number when
20’ to 55’ length; heights • A better product making inquiries about
from 9’ to 25’ making it • Higher profits the equipment. This will
possible to produce a enable our personnel to
variety of standard Rugged industrial handle your questions
capacities. construction and stainless quickly and accurately.
steel or UHMW in all areas
of ice contact make the

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 Read Safety Section before installing or using equipment

High Values

TURBO highly values its friends and customers in the industry. Please remember to:

T hink safely – act safely.

U nderstand operating procedures and dangers of the equipment.
R emember to think before you act.
B efore you act, understand the consequences of your actions.
O bserve equipment warnings and labels.

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 Read Safety Section before installing or using equipment

TERMS &
CONDITIONS
Turbo Refrigerating, LLC Company may be required upon delivery to
(the “Company”) agrees to to pay arising from the sale transporting carrier.
sell the Equipment or delivery of the
described herein upon the Equipment or the use 3. Delivery
following terms and thereof. Prepaid freight, if
conditions of sale which, applicable, will be added to (a) The Company will
accordingly, supersede any the purchase price and endeavor to make shipment
of Buyer’s additional or invoiced separately. Where of orders as scheduled.
inconsistent terms and price includes transportation However, all shipment dates
conditions of purchase. or other shipping charges, are approximate only, and
any increases in the Company reserves the
1. Terms and Prices transportation rates or other right to readjust shipment
shipping charges from date schedules.
(a) All orders are to be of quotation or purchase
accompanied by a twenty order shall be for the (b) Under no circumstances
percent (20%) down account of and paid by will the Company be
payment or an acceptable Buyer. responsible or incur any
irrevocable letter of credit liability for costs or
confirmed on a U.S. Bank (d) Contract prices are damages of any nature
acceptable to Turbo. No subject to adjustment to the (whether general,
orders are to be entered Company’s prices in effect consequential, as a penalty
without payment or L/C in at time of shipment unless or liquidated damages or
hand. otherwise specified in a otherwise) arising out of or
separate Price Adjustment owing to (i) any delays in
(b) All orders are subject to Policy attached to the delivery or (ii) failure to
the approval of the proposal or other contract make delivery at agreed or
Company’s home office. document of the Company. specified times due to
Unless otherwise stated, circumstances beyond its
standard terms of payment (e) If Buyer requests reasonable control.
are thirty (30) days net from changes in the Equipment
the earlier of date of or delays progress of the (c) If shipment is delayed or
shipment or readiness of the manufacture or shipment of suspended by Buyer, Buyer
Equipment for shipment. If the Equipment, the contract shall pay (i) Company’s
partial shipments are made, price shall be adjusted to invoice for the Equipment
payment shall become due reflect increases in selling as per payment terms, (ii)
and payable to the partial price caused thereby. Company’s handling and
shipment. storage charges then in
2. Shipment effect, and (iii) demurrage
(c) In addition to the charges if loaded on rail
purchase price, Buyer shall Shipment is F.O.B. cars.
pay any excise, sales, Company’s plant or place of
privilege, use or any other manufacture, unless 4. Limited Warranty:
taxes, Local, State or otherwise specified. Risk of Warranty Adjustment:
Federal, which the loss shall pass to Buyer

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 Read Safety Section before installing or using equipment

Exclusions: Limitation of (i) THE FOREGOING IS loading, or by erosive or

Liability IN LIEU OF ALL OTHER corrosive substances or by
WARRANTIES, ORAL the alien presence of oil,
(a) LIMITED OR EXPRESS OR grease, scale, deposits or
WARRANTY IMPLIED, INCLUDING other contaminants in the
ANY WARRANTIES Equipment.
The Company warrants that THAT EXTEND BEYOND
at the time of shipment the THE DESCRIPTION OF (c) WARRANTY
Equipment manufactured by THE EQUIPMENT. ADJUSTMENT
it shall be merchantable, THERE ARE NO
free from defects in material EXPRESS WARRANTIES Buyer must make claim of
and workmanship and shall OTHER THAN THOSE any breach of any warranty
possess the characteristics CONTAINED IN THIS by written notice to the
represented in writing by PARAGRAPH 4 AND TO Company’s home office
the Company. The THE EXTENT within thirty (30) days of
Company’s warranty is PERMITTED BY LAW the discovery of any defect.
conditioned upon the THERE ARE NO The Company agrees at its
Equipment being properly IMPLIED WARRANTIES option to repair or replace,
installed and maintained OF FITNESS FOR A BUT NOT INSTALL,
and operated within the PARTICULAR PURPOSE. F.O.B. Company’s plant,
Equipment’s capacity under THE PROVISIONS OF any part or parts of the
normal load conditions with THIS PARAGRAPH 4 AS Equipment which within
competent supervised TO DURATION, twelve (12) months from
operators and, if the WARRANTY the date of initial operation
Equipment uses water, with ADJUSTMENT AND but no more than eighteen
proper water conditioning. LIMITATION OF (18) months from date of
Equipment, accessories and LIABILITY SHALL BE shipment shall prove to the
other parts and components THE SAME FOR BOTH Company’s satisfaction
not manufactured by the IMPLIED WARRANTIES (including return to the
Company are warranted (IF ANY) AND EXPRESS Company’s plant,
only to the extent of and by WARRANTIES. transportation prepaid, for
the original manufacturer’s inspection, if required by
warranty to the Company, (ii) The Company’s the Company) to be
in no event shall such other warranty is solely as stated defective within the above
manufacturer’s warranty in (a) above and does not Warranty. Any warranty
create any more extensive apply or extend, for adjustments made by the
warranty obligations of the example, to expendable Company shall not extend
Company to the Buyer than items, ordinary wear and the initial warranty period
the Company’s warranty tear, altered units; units set forth above. The
covering Equipment repaired by persons not warranty period for
manufactured by the expressly approved by the replacements made by the
Company. Company, materials not of Company shall terminate
the Company’s upon the termination of the
(b) EXCLUSIONS FROM manufacture, or damage initial warranty period set
WARRANTY caused by accident, the forth above. Expenses
elements, abuse, misuse, incurred by Buyer in
temporary heat, over- replacing or repairing or

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 Read Safety Section before installing or using equipment

returning the Equipment or the Warranty and Warranty ANY OTHER CAUSE
any part or parts will not be Adjustment extended to the WHETHER BASED ON
reimbursed by the Company by the original WARRANTY (EXPRESS
Company. manufacturer of such parts, OR IMPLIED) OR TORT
in no event shall such other OR CONTRACT, and
(d) SPARE AND manufacturer’s warranty regardless of any advices or
REPLACEMENT PARTS create any more extensive recommendations that may
WARRANTY warranty obligation of the have been rendered
ADJUSTMENT Company to the Buyer for concerning the purchase,
such parts than the installation or use of the
The Company sells spare Company’s Warranty Equipment.
and replacement parts. This Adjustment covering parts
subparagraph (d) is the manufactured by the 5. Patents
Warranty Adjustment for Company as set forth in this
such parts. Buyer must subparagraph (d). Expenses (a) PATENT INDEMNITY
make claim of any breach incurred by the Buyer in AND CONDITIONS
of any spare or replacement replacing, repairing, or
parts warranty by written returning the spare or The Company agrees at its
notice to the Company’s replacements parts will not own expense to defend and
home office within thirty be reimbursed by the hold Buyer harmless in the
(30) days of the discovery Company. event of any suits instituted
of any alleged defect for all against Buyer for an alleged
such parts manufactured by (e) LIMITATION OF infringement of any claim
the Company. The LIABILITY of any United States Patent
Company agrees at its covering solely to the
option to repair or replace, The above Warranty structure of the Equipment
BUT NOT INSTALL, Adjustment sets forth as originally manufactured
F.O.B. Company’s plant, Buyer’s exclusive remedy by the Company per the
any part or parts of material and the extent of the Company’s specifications,
it manufactures which, Company’s liability for and without modification by
within one (1) year from the breach of implied (if any) the Buyer, provided buyer
date of shipment shall prove and express warranties, shall (i) have given the
to the Company’s representations, instructions Company immediate notice
satisfactory (including or defects from any cause in in writing of any such claim
return to the Company’s connection with the sale or or institution or threat of
plant, transportation use of the Equipment. THE such suit, and (ii) have
prepaid, for inspection, if COMPANY SHALL NOT permitted the Company to
required by the Company) BE LIABLE FOR ANY defend or settle the same,
to be defective within this SPECIAL, INDIRECT OR and have given all needed
Parts Warranty. The CONSEQUENTIAL information assistance and
Warranty and warranty DAMAGES OR FOR authority to enable the
period for spare and LOSS, DAMAGE OR Company to do so. Buyer
replacement parts not EXPENSE, DIRECTLY shall defend and indemnify
manufactured by the OR INDIRECTLY the Company against all
Company (purchased by the ARISING FROM THE expenses, costs and loss by
Company, from third party USE OF THE reason of any real or alleged
suppliers) shall be limited to EQUIPMENT OR FROM infringement by the

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 Read Safety Section before installing or using equipment

Company’s incorporating a included in the purchase fails to comply with any

design or modification price, then Buyer shall and all provisions of this
requested by Buyer. indemnify and hold the contract, the Company shall
Company harmless from all have the remedies available
(b) LIMITATION OF liability, costs and expenses under the Uniform
LIABILITY for all such damage or Commercial Code.
injury.
The Company’s total (b) So long as the purchase
liability hereunder is 7. Equipment Changes price is unpaid, Buyer at its
expressly limited to an cost shall obtain insurance
amount no greater than the The Company may, but against loss or damage from
sales price of the Equipment shall not be obligated to, all external causes, naming
and may be satisfied by the incorporate in the the Company as an insured,
Company’s refunding to Equipment any changes in in an amount and form
Buyer, at the Company’s specifications, design, sufficient to protect the
option, the sales price of the material, construction, Company’s interest in the
Equipment in the event the arrangement, or Equipment.
Company elects to defend components.
any such suit and the 9. Cancellation
structure of the said 8. Security Interest
Equipment is held to Insurance Buyer cannot cancel orders
infringe any such United placed with the Company,
States Patent and if the (a) To secure payment of except with the Company’s
Buyer’s use thereof is the purchase price, Buyer express written consent and
enjoined, the Company agrees that the Company upon terms and payment to
shall, at its expense and at shall retain a security the Company indemnifying
its option (i) obtain for the interest in the Equipment the Company against loss,
Buyer the right to continue until Buyer shall have paid including but not limited to
using the Equipment, or (ii) in cash the full purchase expenses incurred and
supply non-infringing price when due, interest at commitments made by the
Equipment for installation the highest lawful contract Company.
by Buyer, or (iii) modify the rate until so paid and the
Equipment so that it costs of collection, 10. Loss, Damage or Delay
becomes non-infringing, or including reasonable
(iv) refund the then market attorney’s fees. The The Company shall not be
value of the Equipment. Equipment shall at times be liable for loss, damage or
considered and remain delay resulting from causes
6. Prior Use personal property and beyond its reasonable
Buyer shall perform all acts control or caused by strikes
If damage to the Equipment necessary to assure and or labor difficulties,
or other property or injury perfect retention of the lockouts, acts or omissions
to persons is caused by use Company’s security interest of any governmental
or operation of the against the rights or authority or the Buyer,
Equipment prior to being interests of third persons. In insurrection or riot, war,
placed in initial operation the event Buyer defaults in fires, floods, Acts of God,
(“Start up”) by the payment of any part of the breakdown of essential
Company where start up is purchase price when due, or machinery, accidents,

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 Read Safety Section before installing or using equipment

priorities or embargoes, car desired by it and/or required condition or any of the

and material shortages, by law or OSHA standards Company’s rights.
delays in transportation or respecting Buyer’s use of
inability to obtain labor, the Equipment. Buyer shall
materials or parts from be responsible for
usual sources. In the event ascertaining that the
of any delay from such Equipment is installed and
sources, performance will operated in accordance with
be postponed by such length all code requirements and
of time as may be other applicable laws, rules,
reasonably necessary to regulations and ordinances.
compensate for the delay. In
the event performance by 12. Complete Agreement
the Company of this
agreement cannot be THE COMPLETE
accomplished by the AGREEMENT BETWEEN
Company due to any action THE COMPANY AND
of governmental agencies, BUYER IS CONTAINED
or any laws, rules or HEREIN AND NO
regulations of the United ADDITIONAL OR
States Government, the DIFFERENT TERM OR
Company (at its option) CONDITION STATED BY
may cancel this agreement BUYER SHALL BE
without liability. In no BINDING UNLESS
event shall the Company be AGREED TO BY THE
liable for any loss or COMPANY IN WRITING.
damage of any kind, No course of prior dealings
including consequential or and no usage of the trade
special damages of any shall be relevant to
nature. supplement or explain any
terms used in this
11. Work By Others: Agreement. This
Accessory and Safety Agreement may be
Devices modified only by a writing
signed by both the
The Company, being only a Company and Buyer and
supplier of the Equipment, shall be governed by the
shall have no responsibility Uniform Commercial Code
for labor or work of any as enacted the State of
nature relating to the Texas. The failure of the
installation or operation or Company to insist upon
use of the Equipment, all of strict performance of any of
which shall be performed the terms and conditions
by Buyer or others. It is the stated herein shall not be
responsibility of Buyer to considered a continuing
furnish such accessory and waiver of any such term or
safety devices as may be

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 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

Chiller Generator Operation & Maintenance Manual

Section 2: SAFETY
Here are some safety points to Important • Follow directions and
keep in mind when creating an Indicates hazards or unsafe illustrations.
efficient yet safe working practices which could cause • Check to see that all
environment. minor personal injury or equipment meets
product or property damage. applicable installation
Safety Definitions codes for your area as well
Note as state and federal
Statements or labels in this Gives helpful information. requirements.
manual or on the product • Have sufficient safety
preceded by the following Machinery Is Dangerous warnings on all equipment.
words are of special • Make sure all safety
significance: Machinery can hurt you if you devices and guards are in
are not careful. Use caution place.
Warning during assembly and operation
Indicates severe personal of equipment. Note:
injury or death will result if Warning labels attached to the
instructions are not followed. ALWAYS: chiller, equipment installed
• Read the entire manual with the chiller, and on access
Caution first. panels should be followed.
Indicates a strong possibility of • Use common sense and be They are shown in Figures 2-1,
severe personal injury or death careful. and 2-2.
if instructions are not followed. • Have enough manpower.
• Have the proper tools.

Safety 2/04 Turbo Refrigerating, LLC 2-1

 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

Figure 2-1 Warning Labels on Control Panels

Figure 2-2 Warning Label on Access Panels

If all labels are not attached Turbo Refrigerating Phone:940-387-4301

and visible or labels start to Service Department Fax: 940-382-0364
become illegible, contact: P.O. Box 396
Denton, Texas 76202-0396

2-2 Turbo Refrigerating, LLC 2/04 Safety

 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.
Involve Your People area and notify qualified through the relief system.
personnel. Consideration should be given
Before operating equipment, to prevailing winds to ensure
have the people involved in the Use only recommended ice that refrigerant releases are not
operating or maintenance of machine cleaners suitable for carried to or trapped in
the equipment meet to discuss stainless steel. Follow occupied areas. The contractor
the dangers and safety aspects instructions and warnings should verify that the method
of the chiller. supplied by the manufacturer used meets local, state, and
of the cleaning agents. federal codes.
• Warn them of the danger of
miscommunication. Never open the control panel Note:
• Turn electricity off and (by others unless otherwise Field piping is required by
lock it out when working specified) without others from all safety relief
on the chiller. disconnecting and locking out devices supplied with the
• Have a person trained and electrical service. All electrical various components.
qualified in the operation work should be performed by a
of the equipment on duty to qualified electrician. A written evacuation plan
ensure that the electricity should be available to all
stays locked out to protect When servicing the chiller employees and the local fire
personnel working on the TURBO recommends that at department should be provided
equipment. least two (2) people be present with a copy. The written plan
at all times. should be developed jointly
Pull disconnect and lock out all between the fire department
electrical service before If an outside contractor is and operators or other
removing any guards, access required to install or service designated personnel familiar
panels, and/or covers. your chiller, require him to with the refrigeration system.
furnish you with a certificate Fire department personnel
Never operate the unit without of insurance before performing should be familiarized with the
all guards, access panels, and any work on your equipment. refrigeration system, including
covers in place and securely TURBO recommends that the the location of isolation valves
fastened. person hiring a contractor to and controls for terminating
perform work be satisfied with operation of the system and/or
If leaks in the refrigerant their experience and isolating leaks. Emergency
piping require welding, be sure competence. phone numbers should be
refrigerant is bled off and the posted in a visible manner near
system is open before All refrigerant field piping all areas in which the
attempting to repair. Protect should be done in compliance equipment is located.
eyes with the proper eye with section 5 of Standard
protection. ANSI/IIAR 74-2-1984 (or the IMPORTANT
latest edition, if available). A copy of the evacuation
Always wear proper eye Field piping is not supplied by plan should be available in
protection when cleaning the TURBO. each area in which
system. equipment is located. The
All refrigerant relief valve location should be clearly
Do not expose insulation vent lines must be routed to a marked, easily accessible,
(polyurethane) to open flame. safe discharge location having and away from piping or
If ignited, it will give off adequate ventilation to components from which
highly toxic fumes. Leave the dissipate refrigerant discharged
Safety 2/04 Turbo Refrigerating, LLC 2-3
 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

escaping refrigerant would Refrigerating, and Air- 2. The safety lockout

prevent access. Conditioning Engineers, Inc. procedure is on pages 2-9
(ASHRAE) bulletin through 2-11.
All leaks should be reported ANSI/ASHRAE 15-1994 –
and repaired immediately. “Safety code for Mechanical Checklist for Lock Out Of
Refrigeration”. Controls-By others unless
Each pressure vessel (if otherwise specified
supplied) is equipped with a To request information contact
safety relief valve to prevent RETA at: To lock out the chiller
operation over design limits. Refrigerating Engineers and controls:
Smaller models use a single Technicians Association
relief valve. Larger models use 4700 West Lake Avenue 1. Pull disconnects and lock
dual safety relief type valves Glenview, Ill.60025-1485 out all electrical service –
with a three-way manifold. If a Phone: 847-375-4738 single-phase and three-
safety relief valve discharges, Fax: 847-375-6338 phase power. Refer to the
the three-way valve position E-mail: info@reta.com “Safety Lockout
should be changed to the Procedure” on page 2-9.
“good" relief valve and the Contact IIAR at:
“discharged” relief valve International Institute of 2. Turn the master control
immediately replaced. Ammonia Refrigeration selector switch (provided)
1100 North Glebe Road to the “off” position.
WARNING Arlington, VA 22201
Never install a second relief Phone: 703-312-4200 Emergency Stop Button-By
valve in the outlet of the Fax: 703-312-0065 others unless otherwise
original valve. All relief E-mail: http://www.iiar.org specified
valves used in this system are
atmospheric relief devices. Contact ASHRAE at: A red push/pull mushroom
Installation of any restriction American Society of head emergency switch is on
in the valve outlet, including Heating, Refrigerating, and the control panel door for
a second relief valve, will Air-Conditioning Engineers, emergency cut-off of the
prevent proper operation of Inc. control circuit power. This
the safety relief valve. 1791 Tullie Circle, N.E. button is not to be used for
Failure to carefully follow Atlanta, GA 30329 service or lock out. This is an
these instructions could Phone: 404-636-8400 emergency button only.
result in permanent injury or Web: http://www.ashrae.org
loss of life. If you have any questions, call
Notes: Turbo Refrigerating Service
Additional information on Department at:
refrigeration system safety 1. Per the OSHA Hazard
may be obtained through Communication Standard, Telephone: 940-387-4301
International Institute of material safety data sheets Fax: 940-382-0364
Ammonia Refrigeration (IIAR) for refrigerants and
for ammonia systems, refrigerant oils are on
Refrigerating Engineers and pages 2-9 through 2-16.
Technicians Association
(RETA) for Freon systems, or
American Society of Heating,

2-4 Turbo Refrigerating, LLC 2/04 Safety

 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

SAFETY LOCKOUT PROCEDURE

Effective November 1, 1989

I. Purpose III. Supervisory It is the responsibility of the

Responsibility Safety Coordinator to inspect
The purpose of this procedure the plant on a periodic basis to
is to prevent injury and/or It is the responsibility of all ensure compliance with this
death to personnel by requiring supervisors having contact procedure. If it is determined
that certain precautions be with such operations to: that this procedure is not being
taken before servicing or complied with, immediate
repairing equipment. It has A. Instruct all affected corrective action will be
been developed and employees as to the content of initiated. Wherever possible,
implemented so as to comply this program. such action will be taken in
with 29 CFR 1910.147, of the B. Ensure compliance with conjunction with the first-line
Occupational Safety and this procedure. supervisor; however, higher
Health Act, as amended. level management personnel
IV. Safety Locks will be involved if the
These precautions include: violation is of a serious or
Safety locks and keys will be repetitive nature.
1. Shutting off and locking issued to designated
out electrical power. employees. Locks and keys VI. Rules and Regulations
2. Releasing pressure in must be returned to the plant
pneumatic and hydraulic manager when an employee The following rules and
systems. transfers to another assignment regulations have been
3. Effectively isolating those or terminates his employment. established and are mandated:
portions of equipment and Safety and supervisory
machinery that are energy personnel shall have access to A. Any electrician or
intensive and are being master keys for protective maintenance person whose
serviced or maintained. locks, and under certain duties require that he or
controlled conditions, be others be exposed to the
II. Scope available to assist in the hazards of electrical shock
removal of safety locks. or moving equipment must
This procedure includes those perform those duties in a
employees whose duties Safety locks are painted yellow safe and uncompromising
require them to do for electricians and red for manner. The following
maintenance work on power- maintenance personnel. These steps outline such
driven equipment. It covers the locks are to be used only for precautions:
servicing or maintenance of locking out machinery, tooling,
machines or equipment in and equipment described in 1. The employee must
which the unexpected this procedure. understand the equipment
energization, start-up or with which he is working
release of stored energy could V. Safety Department and its hazards.
cause injury. Responsibility

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 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

2. When working with completed his own task, when it has actually been
electrical equipment and remove his own lock. turned back on.
where the accidental
starting of such C. If the equipment controls F. If a machine is locked out
equipment or release of are so located that only one and it is necessary to leave
stored energy would lock can be the area, recheck the lock
create a hazard, the accommodated, a special upon returning to make
employee must turn off attachment that sure that the machine is
all power to the unit or accommodates several still locked out. While
use energy isolating locks must be used. This supervision will make
devices and apply his attachment will be issued every attempt to avoid the
personal lock, and have to all designated removal of locks, there
the supervisor of that employees. may be situations when it
area apply his personal must be done. This recheck
lock. At all times when D. Should an employee be is for your protection.
maintenance is being required to work on
performed on our another piece of equipment G. It is sometimes necessary
equipment, that and need to leave his lock to operate equipment for
equipment will have 2 on the present equipment, purposes of testing or
locks on it, one by the another lock must be making adjustments prior
person performing the obtained from the plant to the actual completion of
maintenance plus the manager. the work. It is recognized
one of the supervisor. that electricians must work
E. Should it be necessary to on live circuits from time
3. In instances where operate a piece of to time, particularly when
multiple circuits are in equipment which is locked trouble-shooting, but
a circuit breaker box, out, every effort should be extreme caution must be
an attaching made by supervision to used under these
mechanism will be locate the employee whose circumstances. Never work
placed on the outside of lock is on the equipment. If alone when changing live
the box to allow that that employee cannot be wiring.
box to be locked out located, the supervisor may
and prevent the door obtain a master key for the VII. Outside Contractors
from being opened. lock. The supervisor must
personally assure himself Whenever outside servicing
B. Each employee who that it is safe to remove the personnel are to be engaged in
performs the duties lock. The lock should than activities covered by the scope
prescribed above will be be returned to the proper and application of this lockout
provided with an individual employee. and tag procedure, such
safety lock and one key. If personnel are to be informed of
more that one employee is This procedure must be used this procedure by the person
assigned to a task, each with extreme caution and good responsible for their work
employee is required to judgement. There is danger activity and are to direct them
place his own lock and tag that the employee involved to follow its requirements.
so the controls cannot be will return thinking that the Failure to do so shall require
operated, even though machine is still locked out, that they do not be permitted to
another person may have continue working in the plant.

2-6 Turbo Refrigerating, LLC 2/04 Safety

 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

VIII. Failure to Follow

Procedures

These procedures have been

developed to protect
employees from serious injury.
It is necessary that all
employees follow them. Those
employees not complying with
the provisions in this
procedure will be subject to
disciplinary action, up to and
including discharge.

Safety 2/04 Turbo Refrigerating, LLC 2-7

 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

Material Safety Data Sheets (MSDS)

Material Safety Data Sheets (MSDS) are provided for all refrigerants (ammonia, Freon, glycol, refrigerant
oils) typically used in chiller applications.

See MSDS sheets attached for details.

2-8 Turbo Refrigerating, LLC 2/04 Safety

 WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

Safety 2/04 Turbo Refrigerating, LLC 2-9

WARNING! Read this section first. Failure to carefully follow these instructions could result in
permanent injury or loss of life.

2-10 Turbo Refrigerating, LLC 2/04 Safety

WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.

Chiller Operation & Maintenance Manual

Section 5: TROUBLE-SHOOTING
This section lists common problems and suggests solutions with various chillers and chiller systems. Some of the problems and solutions
apply to optional equipment o r equipment supplied by others and may vary. Many problems are easy to solve if you know what caused
them. If your problem is not covered in this section, contact Turbo Refrigerating at: 1-940-387-4301 Ask for the Service Department.
The following pages describe problems you might encounter and provide diagnostic instructions and solutions.

PROBLEMS AND SOLUTIONS

Problem Causes Solutions
Compressor will not start. No three phase or control circuit Check fuses and disconnect. Reset tripped circuit breakers.
Note: For optional power, tripped circuit breaker.
compressor supplied
by others or Blown fuse. Reset or replace manual reset.
separately, consult
supplier’s data for Refrigerant recirculation unit or Determine cause of low recirculator before restarting.
additional pump(s) “off” or “tripped”.
information.
Improper signal at the programmable The run and power lights must be on for unit to operate. Check
controller. for loose connection and control circuit power to controller.

Chiller MCS turned off. Turn switch to “ON” position. For dedicated system the
icemaker should be on before the compressor starts.

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WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.

Problem Causes Solutions

Emergency stop button depressed. Determine reason emergency stop button was used and correct
before resetting.

Overload relay on magnetic starter Determine cause of motor overload. Depress manual reset
tripped. button.

Unit drawing high amps Loose terminal connections. Tighten connections (qualified electrician).
(compressor or water pump
motors).
Defective motor bearings or motor. Replace. Check compressor/motor alignment and mounting
bolts before restarting.

Motor defective. Replace or rewind.

Debris or restriction preventing Clear obstruction and restart.

normal operation.

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WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.

Problem Causes Solutions

Chiller evaporator temperature too High discharge pressure: Check pressure sensing connection to regulator. Replace if
high; leaving water temperature too - Defective water regulating valve necessary.
high (water cooled).

- Fouling at condenser (water cooled). Clean condenser by brushing and/or acid treatment. Consult
. manufacturer for water treatment recommendations.

- Faulty water pump (water or Replace pump. Check pump suction and discharge for
evaporative cooled). obstructions.

- Fouling at condenser (air cooled). Clean with air, water hose, or brushing. Remove debris from
condenser inlet.

- Flood back valves out of adjustment Adjust to maintain 180 PSIG.

(air or evaporative cooled).

- Belt worn or loose causing belts to Adjust, replace belts.

slip (air or evaporative cooled).

- Fan turning too slow (air cooled). Change sheave to increase speed up to FLA of motor. Consult
factory before restarting. Check for restrictions.

Ammonia Recirculated Models:

NH3 pump off or flow restricted Check pump overload. Check pump suction and discharge for
(recirculated system). obstructions. Check bypass pressure regulator. Rebuild pump.

Low on NH3. Search for leak and repair. Add refrigerant to maintain proper
. level in recirculator or surge drum (flooded) and high pressure
receiver

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WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.

Problem Causes Solutions

Hand expansion valve improperly Balance all hand expansion valves to maintain adequate
adjusted. refrigerant to all sections. Open the valve(s) if necessary until
proper evaporator temperature is obtained. Note: It may be
necessary to close the hand TXV to other sections/chillers to
increase flow to chiller that is not operating properly. Adjust
hand expansion valve to maintain 40-45 PSIG in each chiller.
Reference chiller specifications for evaporator temperature.

Plugged or restricted strainer on Clean strainer. Restrictions can be observed by temperature

liquid or recirculation unit (by others). drop across the strainer resulting in lower temperature at outlet.
If temperature can not be measured isolate the strainer and
remove it for visual inspection.

Plugged or restricted liquid line Clean strainer. Restrictions can be observed by temperature
strainer. drop across the strainer resulting in lower temperature at outlet.
If temperature can not be measured isolate the strainer and
remove it for visual inspection.

Air or other non-condensable in Bleed air from condenser. Replace refrigerant charge if
refrigerant system. contamination can not be removed.

Restriction in piping. Check all isolation valves for proper position – open or closed.
Except for the hand expansion valves all other valves should be
fully open or closed and should not be used for throttling or
flow control.

Power off to condensing unit. Check power, circuit breaker, and disconnects to all motors,
starters, and control switches.

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WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.
Problem Causes Solutions
Insufficient water flow to condenser Clean or replace.
(water cooled): Check adjustment. Replace if required.

- Strainer plugged. Check water pump impeller for wear – replace impeller or
-Float valve defective (make-up water pump if necessary.
line to cooling tower).
-Pump impeller worn

Condenser pump prime lost – low Add water to cooling tower. Determine cause of water loss.
water level in sump. - leak in sump or piping
. - water line broken
- isolation valve in water line closed

Condenser water make-up valve closed Clean, repair, open, or replace valve.
or restricted.

Recirculating water pump off: Check pump for restrictions. Reset starter overload relay.
-Motor overloads tripped. Locate water feed restriction. Add water to tank.
-Water recirculating pump prime lost. Remove and clean.
Low water level in reservoir. Remove and clean.
-Strainer plugged. Clean, repair, or replace valve. This check is installed and
-Check valve stuck closed. normally located outside the unit at the liquid line connection to
-water connection broken or water the ice generator
supply lost
-water level sensor switch defective Verify connection to the water solenoid valve and check the
upstream water piping and valves outside unit.

Verify the solenoid opening in response to the water level

sensor switch signal. Verify the water level assembly is
properly positioned – make sure assembly in firmly in place and
has not slipped down in the mounting bracket.

Note: Some older models were not equipped with a make-up

water header. Consult the factory for additional information.

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WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.

Problem Causes Solutions

-water solenoid coil failed Verify the coil energizes when the output for the water solenoid
is on. It can also be tested by applying power from the control
circuit L1 to the water solenoid coil using a jumper to
temporarily pulse the coil

Evaporator plates oil logged. Drain oil from NH3 recirculation unit oil reservoir. Raise
evaporator plate temperature by placing manual defrost switch
(MDS) in manual position or by spraying plates with warm
water (not to exceed 90°F).

Orifice in liquid header to evaporator Consult factory.

plate plugged.

High suction pressure. Water temperature too high. Water temperature above 60°F (based on incoming city water).

Improperly adjusted hand expansion Check expansion valve adjustment (close to reduce refrigerant
valve (overfeeding refrigerant). flow). Set to maintain 15 PSIG in all sections.

High discharge pressure. Refrigerant system overcharged. Verify actual charge. Reduce charge as required.
Note: Optional condensing unit
supplied by others or Dirty condenser. Clean.
separately, consult supplier’s
data for additional information. Non-condensable in refrigerant. Air in system. Remove by purging.
Readjust to correct setting.

Head pressure controls improperly set. Normally 190–220 PSIG for water cooled; 170–190 PSIG for
evaporative cooled; 210–250 PSIG for air cooled.

Discharge line check valve inoperative Check and replace if required.

or partially open.
Trouble-Shooting 03/04 Turbo Refrigerating, LLC 5-6
WARNING! Read Safety Section before this section. Failure to carefully follow these instructions could result in permanent injury
or loss of life.
Problem Causes Solutions
Check position of all isolation valves Open all valves fully open or to correct position. Make sure all
and pressure controls. pressure controls are properly adjusted and in automatic
position.

Low oil pressure. Oil reservoir full indicating need for Drain oil reservoir and add new oil to compressor.
Note: Optional condensing unit maintenance.
supplied by others or
separately, consult supplier’s Plugged or stopped up oil strainer. Clean. Purge line.
data for additional information.
Low oil level in crankcase. Consult supplier’s data.

Defective compressor oil pump. Check rotation and wear. Replace as required.

Oil leak Check all areas around system for signs of oil leakage. Repair
leak and recharge system with oil.
Excessive vibration of motor Misalignment. Realign to within specifications.
and compressor.
Note: Optional condensing unit Loose motor/compressor hold down Tighten. Check alignment.
supplied by others or bolts.
separately, consult supplier’s
data for additional information. Flooding of compressor. Adjust high pressure liquid line hand expansion valve setting.
Check refrigerant level controls on NH3 recirculation unit to
Excessive motor temperature. Defective or worn bearing. ensure high refrigerant level switch is operative.
Note: Optional condensing unit
supplied by others or Structural support under unit Remove coupling and check bearing.
separately, consult supplier’s insufficient.
data for additional information. Reinforce structural support. Shim as required. Consult factory
for guidelines.

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 WARNING! Read the Safety Section before this section. Failure to carefully follow these instructions
could result in permanent injury or loss of life.

Chiller Operation & Maintenance Manual

Section 6: MAINTENANCE
To help you get the best Weekly Inspections (Includes • General neat
performance from your Chiller accessory equipment used housekeeping
system, follow the maintenance with the Chiller System)
instructions listed below. If you Clean the chiller weekly:
have questions concerning the Check the oil level in the • Clean the water
maintenance or upkeep of your compressor. distribution pan and
equipment, contact: header. The
Check for signs of oil leakage. distribution header
Turbo Refrigerating can be easily
Service Department Check the refrigerant liquid disassembled to
P.O. Box 396 level in the receiver (if remove debris inside
Denton, Texas 76202 applicable) or during pump- the header or clear
Phone: 940-387-4301 down to ensure that the level is plugged holes.
Fax: 940-382-0364 proper and has not changed • If necessary remove
the water distribution
Daily Inspections Check the receiver. Inspect header from the water
valve packings and relief valve distribution pan and
Inspect the chiller daily to for indications of refrigerant wipe out all loose
determine that the unit is loss. debris in the pans.
operating properly. Observe t he Unplug holes in the
fluid flow over the plates to Check for 20-30% refrigerant pans as required to
ensure the water distribution level in the receiver (or the ensure complete flow
system is free of debris. Check supplier’s recommendation) over the entire plate.
as required. while operating. • Check for indications
of discoloration on
When starting, observe that the Check unit at least once a week. the frame, water,
discharge and suction pressures A visual inspection includes and pans, panels, and
are correct on the gauges and is not limited to: headers. If necessary
are stable to ensure the proper • Leaks use citric acid to
refrigerant feed to the chiller. • Vibration of piping clean the areas using
on other components a non-abrasive
• Capillary tubes cleaning pad. Follow
rubbing the cleaning with a
• Unusual noises fresh water rinse.
• Tight bolts, nuts,
screws
Maintenance 03/04 Turbo Refrigerating, LLC 6-1