TRI-PLATE B INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS PART NO. 8801469 EFFECTIVE MARCH 1, 1983 REPRINT APRIL 16, 1999 THE MILK COOLING SYSTEMS SPECIALISTS TM
FRE-HEATER Part No. 8801469 Table of Contents TRI-PLATE B INSTALLATION, OPERATION, AND MAINTENANCE INSTRUCTIONS Section 1.0 - General Information Page 1.1 Description of the System..........................................................1 1.2 Capacity.......................................................................1 1.3 Fre-Heater Location...............................................................1 Figure 1 Suggested Water Piping Diagram.............................................2 Figure 2 Suggested Location and Plumbing Diagram......................................2 Section 2.0 - Installation Instructions 2.1 Leveling Units...................................................................3 2.2 Installing Fre-Heater with Mueller Installation Kits.........................................3 Figure 3 Temperature Booster Arrangement............................................3 2.3 Thermal Expansion Tank...........................................................4 2.4 Hot Water Bypass................................................................4 Figure 4 Hot Water Bypass Valve....................................................4 2.5 Pressure/Temperature Relief Valve....................................................4 2.6 Refrigeration Connections..........................................................4 2.7 Electrical Connections.............................................................5 Figure 5 Wiring Diagram for 2 and 3 HP Single Phase Fre-Heaters............................6 Figure 6 Wiring Diagram for 2 and 3 HP Three Phase Fre-Heaters............................7 Figure 7 Wiring Diagram for 4 and 5 HP Single Phase Fre-Heaters............................8 Figure 8 Wiring Diagram for 4 and 5 HP Three Phase Fre-Heaters............................9 Section 3.0 - Operation and Maintenance Instructions 3.1 Test Run......................................................................10 3.2 Heat Exchanger Component Description...............................................10 3.3 Refrigerant Charge...............................................................10 3.4 Descaling the Condenser..........................................................11 Figure 9 Acid Vessel to Heat Exchanger Inlet and Outlet Connections........................12 3.5 Instructions for Modifying Tri-Plate Wiring for Use with Old-Style HiPerForm Control Cabinets with Single Control Wire..........................................................12
SECTION 1.0 - GENERAL INFORMATION 1.1 Description of the System The Mueller Fre-Heater is designed to recover heat removed by refrigeration or air conditioning systems and to utilize that heat for heating water. The Tri-Plate B is a self-contained unit with 3, 4, or 5 hp compressor, controls, and rectangular cabinet, ready for installation. The Fre-Heater water circuit is designed for 150 psi working pressure and is furnished with a 150 psi 210 F pressure/temperature relief valve. 1.2 Capacity The amount of hot water that can be generated will vary, but as a rule of thumb, a Fre-Heater operating on 60 F supply water will produce approximately the volume of hot water shown below: Fre-Heater will produce Refrigeration load: approximately: 3 ton (36,000 Btu/hour) = 60 gallons 140 F water/hour 4 ton (48,000 Btu/hour) = 90 gallons 140 F water/hour 5 ton (60,000 Btu/hour) = 120 gallons 140 F water/hour 1.3 Fre-Heater Location 1.3.1 The Mueller Fre-Heater must be installed where the surrounding air temperature does not drop below freezing, and as near as practical to the cooler. See suggested water piping diagram (Figure 1). 1.3.2 Careful planning of Fre-Heater location and plumbing can reduce installation cost and save time during installation and future maintenance. The installation (Figure 2) is based on close-coupled 5 /8" O.D. soft copper between the Fre- Heater and water storage tank. Adequate space must be provided between walls, Fre- Heater(s), and storage tank(s) for convenient access to all components. 1.3.3 It is not necessary that the storage tank be next to the Fre-Heater. However, the piping between the Fre-Heater and the storage tank should not exceed 30 feet. Tri-Plate B Instructions 1 Effective March 1, 1983
Figure 1 - Suggested Water Piping Diagram Hot Water To Hot Water Supply Front View 67" 67" Mueller Fre-Heater Tri-Plate B Cold Water Thermal Expansion Tank Water Filter Diffuser Tube Figure 2 - Suggested Location and Plumbing Diagram Minimum 4" Mueller Fre-Heater Tri-Plate B Storage Tank Water Filter Minimum 6" Minimum 24" for Service/Maintenance Minimum 16" To Hot Water Supply Hot Water Pressure/Temperature Relief Valve 75" Mueller Fre-Heater Tri-Plate B Cold Water Cold Water Supply Tri-Plate B Instructions 2 Effective March 1, 1983
SECTION 2.0 - INSTALLATION INSTRUCTIONS 2.1 Leveling Units Leveling legs are provided with Tri-Plate B Fre-Heaters and Mueller glass-lined water storage tanks. Adjust legs on Fre-Heater(s) and storage tank(s) so that each unit is level. 2.2 Installing Fre-Heater with Mueller Installation Kits 2.2.1 Tri-Plate B Fre-Heaters are shipped with the fittings and accessories (except for the 5 /8" soft copper) necessary to install piping between the Fre-Heater and the storage tank, for one Fre- Heater and one storage tank installation. Installations with Fre-Heater and two storage tanks will require additional fittings available in the kit, Part No. 8801443 (one Fre-Heater and two storage tanks.) 2.2.2 Use silicone sealant provided with the Fre-Heater as a joint compound on all connections when installing PVC and CPVC fittings, piping and water filter. Be sure to locate water filter for easy access in changing filter cartridge. Do not over tighten joints. Screw joints together with one hand, then use both hands to tighten for additional 1 /4 to 1 /2 turn. Allow one hour for silicone sealant to cure before turning on water. Note: The red dot on the diffuser tube fitting must face up to assure proper diffuser hole alignment inside the storage tank. Improper alignment will result in poor stratification of hot and cold water levels in the storage tank. 2.2.3 Connect temperature control valve to hot water discharge connection with arrow position upwards. 2.2.4 Run 5 /8" O.D. soft copper tubing from temperature control valve and Fre-Heater to the water storage tank. Slide flare nuts (provided) onto ends of copper tubing and flare ends. Connect as shown in Figures 1 and 2. 2.2.5 When boosting water temperature above that provided by the Fre-Heater, install a check valve as shown in Figure 3 to prevent backflow of high temperature water from the conventional water heater. Figure 3 - Temperature Booster Arrangement Approximately 140 F Water Out Approximately 140 F Water In from Fre-Heater Storage Tank Check Valve Pressure/Temperature Relief Valve Hot Water Out Above 140 F Conventional Water Heater Tri-Plate B Instructions 3 Effective March 1, 1983
2.3 Thermal Expansion Tank 2.3.1 A thermal expansion tank must be installed on Tri-Plate B Fre-Heaters. The pressures that can be generated by the expansion of water when it is heated could cause damage to the storage tank and heat exchanger. 2.3.2 The thermal expansion tank should be installed in the cold water line supplying the storage tank and after the check valve as shown in Figure 1. 2.4 Hot Water Bypass 2.4.1 The hot water bypass valve supplied with Tri-Plate B is designed to automatically drain hot water from the water storage tank to prevent the tank from becoming completely full of hot water. This ensures a continuous supply of cold water to the Fre-Heater for maximum cooling efficiency. Figure 4 - Hot Water Bypass Valve To Contactor Terminals T1 and T2 24V Solenoid Valve 240V Primary Wires (See Diagram) Butt Connectors Thermostat (See Figure 1) A. Install hot water bypass solenoid valve in top fitting of water storage tank using the 3 /4" tee and adapters provided as shown in Figures 1 and 2. Attach drain hose to bypass valve with clamp provided and route hose to a holding tank or the nearest drain. B. Attach thermostat to the outside of the hot water storage tank using the stainless steel wire and spring provided with the valve kit as shown in Figure 1. Position thermostat 13" above the water inlet on the side of the tank. Mounted Inside Control Box on Tri-Plate B Fre-Heater 24V Secondary Wires C. Using S-O cord provided, connect 24-volt wiring from solenoid valve at top of storage tank thermostat to the storage tank thermostat and transformer located in the compressor-contactor box. See Figures 4, 5, 6, 7, and 8. 2.5 Pressure/Temperature Relief Valve 2.5.1 A 150 psi, 210 F pressure/temperature relief valve is provided and should be installed in the 3 /4" tee in the top of the water storage tank as shown in Figures 1 and 2. 2.5.2 The discharge from the pressure/temperature relief valve must be piped off the top of stoarge tank to within 6 inches of floor or as required by local codes. Note: If a storage tank other than a Mueller glass-lined storage tank is used, check specifications of storage tank to ensure that it is designed for 150 psi working pressure. 2.6 Refrigeration Connections 2.6.1 Tri-Plate B HiPerForm Fre-Heaters are equipped with refrigerant stubs for fast, trouble-free hook-up. 2.6.2 Pre-Insulated Tubing: All Mueller Tri-Plate B Fre-Heaters are supplied with a nitrogen charge which must be relieved before piping is connected. Insulated refrigerant tubing is also available at an extra cost for faster, easier installation. Tri-Plate B Instructions 4 Effective March 1, 1983
2.63 Connecting Pre-Insulated Tubing: 2.6.3.1 Place entire coil of 3 /4" or 7 /8" suction line tubing beside the Fre-Heater and carefully straighten tubing and feed toward evaporator. Repeat above steps using 3 /8" liquid line tubing. Note: Do not remove protector caps until tubing is ready to be connected. 2.6.3.2 Carefully bend tubing around corners, being sure to keep each radius more than 6" in the 3 /4" line and 7 /8" line, and 3" in the 3 /8" line. Severe bends may crimp tubing and restrict refrigerant flow. 2.6.3.3 Bring tubing to refrigerant connection on evaporator. Remove protector caps. 2.6.3.4 Remove copper oxide and contaminates from tubing ends and refrigerant stubs with emery cloth. 2.6.3.5 Solder connection with 12 to 15% silver solder. Clean soldered area with emery cloth and slide insulation over solder joint. 2.6.3.6 Bring tubing to stubs on Fre-Heater and cut excess tubing off for a neat installation. Clean and solder connection the same as the evaporator end of tubing. 2.6.3.7 Repeat entire procedure for remaining refrigerant line. 2.6.3.8 Connect 1 /4" copper tubing to temperature control valve and to tee provided on high side at inlet to dryer. 2.6.3.9 Connect a nitrogen drum with a regulator set at 100 psig to service port and pressurize the system with all service valves open. Test all refrigerant joints for leaks and repair if required. Disconnect nitrogen drum and allow nitrogen charge to escape. 2.6.3.10 When nitrogen has stopped flowing, connect a suitable vacuum pump to the system and evacuate to 500 microns. 2.6.3.11 When evacuation is complete charge system with the refrigerant amount as shown in Section 3.3. 2.7 Electrical Connections Select a circuit breaker or fused disconnect switch and service wires of sufficient size to carry the Fre- Heater load in compliance with applicable codes. For wiring diagrams of specific Tri-Plate B Fre- Heaters, see Figures 5, 6, 7, and 8. Tri-Plate B Instructions 5 Effective March 1, 1983
Figure 5 - Wiring Diagram for 2 and 3 HP Single-Phase Fre-Heaters (HiPerForm and Conventional) Part No. 8801303 Tri-Plate B Instructions 6 Effective March 1, 1983
Figure 6 - Wiring Diagram for 2 and 3 HP Three-Phase Fre-Heaters (HiPerForm and Conventional) Part No.8801352 Tri-Plate B Instructions 7 Effective March 1, 1983
Figure 7 - Wiring Diagram for 4 and 5 HP Single-Phase Fre-Heaters (HiPerForm and Conventional) Part No.8801089 Tri-Plate B Instructions 8 Effective March 1, 1983
Figure 8- Wiring Diagram for 4 and 5 HP Three-Phase Fre-Heaters (HiPerForm and Conventional) Part No.8801290 Tri-Plate B Instructions 9 Effective March 1, 1983
SECTION 3.0 - OPERATION AND MAINTENANCE INSTRUCTIONS 3.1 Test Run 3.1.1 Turn on water supply and allow storage tank(s) and Fre-Heater to fill with water. 3.1.2 Before starting the unit, unscrew the water pump bearing cap two turns and purge until a trickle of water is present. Retighten bearing cap. 3.1.3 Move water circulating pump switch to Manual position to start the pump. (See Figure 9 for location of switch.) Loosen the flare nut on the 5 /8" copper line at the top of the storage tank to purge air from the water line. After air is purged, tighten flare nut and return water circulating pump-switch to Automatic position to stop the pump. 3.1.4 Place electrical disconnect switches in the On position, and set temperature control so that unit will run. 3.1.5 Set the temperature control low enough for the Fre-Heater to run continuously for 20 to 30 minutes. 3.1.6 Once the system is stabilized, adjust the water regulating valve to obtain a high side pressure of 260 psig. Turning clockwise will increase the pressure. This should be equal to approximately 140 F/60 C water temperature. 3.2 Heat Exchanger Component Description 3.2.1 The circulating pump is a low volume pump that is wired to run anytime the compressor contactor is energized. 3.2.2 The high side pressure actuated solenoid valve is energized through a pressure switch on the high side of the refrigeration system. The solenoid valve will open if the high side pressure reaches 350 psig and will close at 300 psig. This is a safety device and if repeated water discharge occurs, it is an indication that a problem exists, such as: faulty pump, water temperature regulating valve set too high, faulty storage tank hot water bypass kit, condenser is fouled with mineral scale, etc. 3.2.3 The water temperature regulating valve is an adjustable valve that restricts the water flow to maintain the high side pressure that is selected through adjustment of the valve. There is always some flow through the valve; consequently, the unit should be run for 10 to 15 minutes before attempting to adjust the output water temperature. 3.3 Refrigerant Charge (R-22) 3 HP 10 Pounds 4 HP 12 Pounds 5 HP 14 Pounds For refrigerant charging methods of HiPerForm Tri-Plate B Fre-Heaters, consult the Maintenance Instructions for Model OH Mueller Milk Coolers.! CAUTION: Do not attempt to pump the entire refrigerant charge into the high side of a Tri- Plate B Fre-Heater refrigeration system. The condenser/heat exchanger will not hold the entire refrigerant charge and damage to the system could result. If necessary to remove charge, refer to weigh-out/weigh-in method in Model OH Maintenance Instructions. Tri-Plate B Instructions 10 Effective March 1, 1983
3.4 Descaling the Condenser Any water-cooled condenser is subject to fouling from mineral scale build-up. Therefore, the Fre- Heater heat exchanger should be inspected periodically and descaled as necessary. The mineral content or hardness of the water used will determine how often descaling will be necessary. In installations with known water hardness problems, frequent Fre-Heater inspection and descaling will help maintain optimum system performance. Note: The Fre-Heater should be inspected and descaled if necessary whenever water temperature drops and the Fre-Heater begins dumping water more frequently than normal, or if cooling time is extended beyond the normal time period. 3.4.1 Scale will first begin collecting at the hot water outlet of the Fre-Heater, so remove the water temperature regulating valve and inspect it and the connecting water line for scale build-up. If it is badly scaled, proceed with descaling as follows: 3.4.1.1 Obtain approximately two gallons of 35% phosphoric acid solution. Most pipeline acid cleaners are 35% phosphoric acid. Note: Do not use nitric, muriatic, or hydrochloric acid, or products containing these acids for descaling. These acids can adversely affect the corrosion resistance of the heat exchanger.! CAUTION: Wear protective clothing and have ample water available under pressure in case of accident. 3.4.1.2 Obtain an acid vessel and hoses for use in descaling that are not affected by phosphoric acid. The volume of the vessel should be five gallons or more. During the descaling procedure, care should be taken not to completely fill the acid vessel. Approximately four gallons of acid solution is required to maintain circulation. Descaling is best accomplished with a 140 F acid solution. 3.4.1.3 Disconnect 5 /8" copper tubing from temperature regulating valve and water inlet to heat exchanger. Remove the temperature control valve from heat exchanger. Connect hoses from acid vessel to heat exchanger inlet and outlet using 5 /8" copper tubing as shown in Figure 9. 3.4.1.4 Fill the acid vessel with one gallon of acid and two gallons of warm water (this will yield a 12% phosphoric acid solution). 3.4.1.5 Place the water circulating pump switch in the manual position and circulate the 12% solution for 30 minutes and observe the flow. If it is flowing freely add the second gallon of acid. Allow this to circulate for an additional 30 minutes and if it is still flowing freely, warm solution to 130 F and circulate until the flow is at least two gallons per minute. Note: It is recommended to start with a weak concentration of acid, such as 12%. If 35% is used in initial cleaning, large debris may be dislodged and clog heat exchanger water ports. 3.4.1.7 Reconnect 5 /8" copper tubing to the flare connection on the temperature control valve and water inlet. Place pump switch in the auto position and return system to operation. Tri-Plate B Instructions 11 Effective March 1, 1983
Figure 9 - Acid Vessel to Heat Exchanger Inlet and Outlet Connections Air Vent Acid Vessel Acid In Acid Out Manual Pump Switch 3.5 Instructions for Modifying Tri-Plate Wiring for Use with Old-Style HiPerForm Control Cabinets with Single Control Wire 3.5.1 Cut the butt connector off of the loose blue wire on No. 1 on terminal block and use the blue wire as a jumper between No. 1 and No. 2 on terminal block. 3.5.2 Move loose blue wire with butt connector from No. 2 to No. 3 on terminal block. 3.5.3 Remove and discard black wire from No. 3 on terminal block to L1 on contactor. 3.5.4 Control wire from the HiPerForm cabinet will connect to the loose blue wire with butt connector No. 3 on terminal block. Tri-Plate B Instructions 12 Effective March 1, 1983