EP - Operating Manual

O P E R A T I N G M A N U A L
1 - 8 0 0 - 3 3 4 - C O O L ( 2 6 6 5 ) W W W . C H I L L E R M F G . C O M
S E R I A L #
M O D E L #
1-800-334-COOL (2665) Page 1 of 38 www.chillermfg.com
CONTENTS:

1. Warranty
2. Line Set Caution
3. Warning
4. Part Number Explanation
5. Warranty Checklist
6. Installation Procedures
7. Start Up Checklist
8. Line Set Installation
9. Electrical
10. Wiring Diagram
a) 208-240/1/60 EP2301
b) 208-240/1/60 EP2301C
c) 208-240/3/60 EP2303
d) 208-240/3/60 EP2303C
e) 460/3/60 EP4603
f) 460/3/60 EP4603C
11. Control Wire Connections Condensing Unit
12. Control Wire Connections Indoor
13. Control Wire Connections Air Handler
14. Chilled Water Piping
15. Controller Operation
a) Operation
b) Temperature Controls
c) Faults
d) Status
e) Air Handler Controls
16. Controller Screen Map
17. Converting 240 Volts to 208 Volts
18. Cold Weather Antifreeze Selection Guide
19. Maintenance
20. Troubleshooting
21. Dimensions

*
*
*
*if applicable

CHILLER MAUFACTURIG
WARRATY POLICY

Chiller Manufacturing Inc warrants all new equipment to be free from defects PARTS AD
CRAFTMASHIP for a period of one (1) year from the date of purchase. Labor charges are not included in
warranty and are the responsibility of the purchaser or end user(s).

This warranty extends to the original purchaser of Chiller Mfg. products and to those persons who under
applicable state law are entitled to rely hereon as third party beneficiaries, but in no event shall Chiller Mfg. be
held liable for property damage or damage to the chiller by such third party beneficiary if said applicable
state law contemplates such liability but permits its exclusion.

All new replacement parts for equipment manufactured by Chiller Mfg. for which the one (1) year warranty
period has expired or for all new repair or replacement parts for equipment, the warranty period is limited to ninety
(90) days from the date of sale. The warranty period on each new replacement part furnished by Chiller Mfg. in
fulfillment of the warranty on all new replacement parts shall be for the unexpired portion of the original warranty
period on the part replaced.

Chiller Mfg. liability does not include furnishing or paying for any labor such as that required to service,
remove, or install, to diagnose troubles, to adjust, remove, or replace defective equipment or part, nor does it include
any responsibility for transportation or insurance or other related expense which is involved therein.

Chiller Mfg. will apply a thirty five percent (35%) restocking fee for any equipment returned within sixty
(60) days. Equipment being returned must be in perfect condition, not installed, and Glycol must be present in
system with return. After sixty (60) days Chiller Mfg. will not accept any returns of Equipment because of purchaser
negligence to order correctly or purchaser negligence to acquire correct sizing data. Credit will only be issued when
Chiller Mfg. has determined that equipment or parts being returned has been used under normal operating
conditions. Credit will be issued sixty (60) to ninety (90) after equipment or part has been reviewed by Chiller Mfg.
The use of automotive antifreeze may VOID warranty.

The warranty of Chiller Mfg is conditioned upon installation and use of its equipment and parts under
normal operating conditions. The warranty is void on equipment and parts: that have been subjected to misuse,
accident or negligent damage, operated under loads, pressures, electrical connections, plumbing, or conditions other
than those specified by Chiller Mfg. Warranty is void if damaged by fire, flood, vandalism, or such other causes
beyond the control of Chiller Mfg, altered or repaired in any way that affects the reliability or detracts from its
performance, which have had the Serial Data Plate altered, effaced, or removed.

No defective equipment or part may be returned to Chiller Mfg. for repair or replacement without prior
written authorization from Chiller Mfg. Any charges for unauthorized repairs will not be accepted or paid for by
Chiller Mfg.

Chiller Mfg. is not responsible for any injury, property damage, or other consequential or incidental
damages arising directly or indirectly from the purchase or use of its products or from any defect in material
or workmanship.

Chiller Mfg. makes no other express or implied warranty, statutory or otherwise, concerning the
equipment, parts, or service, including, without limitation, a warranty of fitness for a particular purpose, a
warranty of merchantability, or any other implied warranties which may arise from course of dealing or
usage of trade. The warranties given here are expressly in lieu of all other warranties, express or implied.
Chiller Mfg. neither assumes, nor authorizes any person to assume for it, any other warranty or liability in
connection with the manufacture, use, or sale of its equipment or parts.

For warranty service, contact the Distributor from whom the Chiller Mfg. equipment or part was purchased.

If the Distributor cannot be reached, Contact Chiller Mfg. at 1-800-334-2665

C A U T I O N
D O N O T L O O P L I N E S E T S V E R T I C A L L Y
I M P O R T A N T N O T I C E : L I N E S E T C O I L S H O U L D A L W A Y S B E I N A
H O R I Z O N T A L P O S I T I O N A N D N E V E R V E R T I C A L . L I N E S E T C A N C R E A T E A N
O I L T R A P I N A V E R T I C A L P O S I T I O N .
H O R I Z O N T A L
C O R R E C T
V E R T I C A L
N O T C O R R E C T
WARNING WARNING WARNING WARNING

CHILLER IS SET TO COOL TO A MINIMUM OF 50 DEGREES F. IF A
LOWER OUTPUT TEMPERATURE IS DESIRED, A GLYCOL MIXTURE
MUST BE USED. PROPYLENE GLYCOL ACTS, NOT ONLY AS A FREEZE
INHIBITOR, BUT ALSO AS A LUBRICANT FOR THE WATER PUMP
AND VALVES AND IS SUGGESTED FOR USE WITH ANY OF OUR
WATER CHILLER SYSTEMS.

DO NOT USE AUTOMOTIVE TYPE GLYCOL! DO NOT USE AUTOMOTIVE TYPE GLYCOL! DO NOT USE AUTOMOTIVE TYPE GLYCOL! DO NOT USE AUTOMOTIVE TYPE GLYCOL!

CAUTION CAUTION CAUTION CAUTION

THE INITIAL FILL OF WATER INTO THE CHILLER UNIT SHOULD BE
DONE THROUGH THE PLUMBED WATER INLET ASSEMBLY WITH THE
CHILLER POWER OFF THIS ALLOWS WATER TO FILL THE PUMP HEAD
BEFORE BEING ENERGIZED AND POSSIBLY DAMAGING THE WATER
PUMP. AFTER INITIAL FILL TIME WITH THE MIDGET TWIST BLACK
THERMOSTAT PLUG(S) DISCONNECTED, TURN ON UNIT POWER AND
TOGGLE SWITCHES TO FINISH CIRCULATING WATER THROUGH THE
SYSTEM. AFTER APPROXIMATELY 10 MINUTES, TURN OFF CHILLER
DISCONNECT AND PLUG IN THERMOSTAT PLUG(S). EXPOSE CHILLER
TO HEAT LOAD AND TURN ON CHILLER DISCONNECT.

DO NOT USE DE DO NOT USE DE DO NOT USE DE DO NOT USE DE- -- -IONIZED OR DISTILLED WATER IN IONIZED OR DISTILLED WATER IN IONIZED OR DISTILLED WATER IN IONIZED OR DISTILLED WATER IN
CHILLER SYSTEM. THIS WILL VOID WARRANTY. CHILLER SYSTEM. THIS WILL VOID WARRANTY. CHILLER SYSTEM. THIS WILL VOID WARRANTY. CHILLER SYSTEM. THIS WILL VOID WARRANTY.
Polar Series Part Numbers

E P - 4 -

VINTAGE
EXAMPLE (A..Z)

DESIGNATES ELECTRICAL VOLTAGE
2 22 2 = 230/1/60 (Use Control Panel EP2301)

DESIGNATES WATER PUMP HORSEPOWER
15 15 15 15 = 1.5 HP
20 20 20 20 = 2.0 HP
25 25 25 25 = 2.5 HP
30 30 30 30 = 3.0 HP

REFRIGERANT
4 44 4 = 410a

DESIGNATES ELECTRICAL DIAGRAM
S SS S = Standard (Use Control Panel EPXXXX)
C CC C = 6 Independent Dedicated Relays ( Use Control Panel EPXXXXC)

E EE E = Expandable
F FF F = Fixed

T TT T = Tank (120 Gallon)
S = S = S = S = Tank (90 Gallon)
W WW W = Without Tank

DESIGNATES TONNAGE
(# of Modules)
5 55 5 (1) 5 Ton Refrigeration Module
10 10 10 10 (2) 5 Ton Refrigeration Modules

P PP P = Polar Model Series

E EE E = ETL Approved
POLAR Series - Indoor Unit Standard Features
Touchscreen PLC
Controller
Programmed for
Energy Effciency
Brazed Plate Heat Exchanger
Best performance and energy effciency
Heat Exchanger available
24v Signal
Wire Plugs,
Pre-wired for
expansion
Adjustable Pressure
Bypass Valve
Stainless Steel
Water Pump
High Performance Noryl Impeller
with Energy Effcient TEFC* Motor
*Totally Enclosed Fan Cooled
Intake
Water
Strainer
with Mesh
Screen
Filter
Fluid Flow Switch
Safety Level Switch
Fully Tig Welded, Anodized
Aluminum Frame
Water Level
Sight Glass
Fully Insulated, accessible
120 Gallon Poly Tank
Typical Electric Panel
Non-Ferrous Plumbing
Tank Overfow
ETL / UL 1995 STD
WARRANTY CHECKLIST

TRANE condensing units carry one year parts warranty and a five year pro-rated
compressor warranty.
Chiller Factory Warranty Policy is one year parts, from date of invoice.
Warranty parts are replaced on an exchange basis. If the customer has an open
account with the factory, parts may be placed on account with credit issued upon
the return of the warranty part. If the customer does not have an open account with
the factory, parts will be shipped C.O.D. with full refund issued upon receipt of
warranty part. All warranty parts are tested before credit or refund is issued.
Factory will not be responsible for any charges from any other company without
prior authorization accompanied by a factory purchase order.
There is to be no variation of this policy without prior written authorization from
factory.
Minimum pipe size of 1 1/4 for header system must be used.
A bypass valve or pressure release valve is installed between the water outlet and
the tank. A BALL VALVE MUST BE OPEN ENOUGH TO SUPPORT THE
CHILLERS MINIMUM FLOW RATE IN THE EVENT THAT THE SUPPLY
THROUGH THE CUSTOMERS PROCESS IS INTERUPTED. UNDER O
CIRCUMSTANCES SHOULD THIS BYPASS VALVE BE CLOSED!
Refrigerant connections must be leak tested with provided bubble leak testing
solution. Provided oil shall be used when these connections are made. A BACK
UP WRECH MUST BE USED!
If the chiller is to cool 50 degrees F or lower, a mixture of propylene glycol must
be used.
Chiller is to be installed on a separate disconnect than the condenser unit (s).

INSTALLATION PROCEDURES

1. Uncrate and check packing slip.

2. Check all items for damage and possible freight claims. Freight claims are the
responsibility of the purchaser.

3. Place Polar unit at desired indoor location. Condensing unit(s) should be placed
outdoors within 25 feet of Polar unit. Additional tubing may be added to
enclosed line set if necessary.

4. Locate condensing unit(s) outdoors with a minimum clearance of 24 from
other equipment, walls, shrubbery, etc

5. When mounting and locating all equipment, conform to all local and state
codes.

LINE-SET INSTALLATION INSTRUCTIONS

1. Apply refrigerant oil to the entire surface of diaphragm, o-ring, and threaded area of
male coupling assembly. The amount of lubricant must be applied liberally to cover
all designated surfaces sufficiently.

2. Ensure that the coupling halves are held in proper alignment with each other prior to
starting the threads of the female coupling nut onto the male half. The coupling end
faces should be parallel with each other and visually in line with each other, this
allows the female coupling nut to be easily threaded on by hand for the initial 2-3
rotations of the union nut. These initial rotations bring the diaphragm in contact and a
sharp increase in torque will be felt when they come into contact.

IF THE UT WILL OT START BY HAD, - ADJUST THE POSITIO OF THE LIE SET
TO ESURE PROPER COUPLIG ALIGMET AD ELIMIATE/MIIMIZE
ALL SIDE-LOAD FORCE O THE COUPLIG DURIG ASSEMBLY.

3. Using appropriate size wrenches, reference table below, for the female coupling body
and female union nut, tighten the female union nut while preventing rotation of the
female body with respect to the female half. The nut should be tightened until a
definite increase in resistance, metal to metal contact occurs, is felt (at this point, the
nut will have covered most of the threads on the male body). It is important to ensure
the male and female coupling bodies DO NOT ROTATE during any portion of the
wrench installation.

4. Using a permanent marker or scribe, mark a line lengthwise from the female coupling
union nut to either the bulkhead or female coupling body. Then tighten an additional
turn/rotation (90degrees); refer to the marking on the union nut to confirm the
turn/rotation has occurred. This final turn/rotation is necessary to ensure the
formation of the leak-proof seal, between the male and female couplings.

5. After line sets are tightened, use a couple drops of bubble leak to test your fittings
both the Chiller and the condensing unit. If bubbles are not prevalent continue. If
bubbles are produced tighten fittings, with a back up wrench, in small increments
until the bubbles cease. If tightening of fitting is no longer an option consult the
factory.

6. Repeat steps 1 thru 5 for all connections.

Coupling Size Torque Values
-Copper-06 10-12 Ft/Lbs
ELECTRICAL

WARIG: WHE ISTALLIG OR SERVICIG THIS EQUIPMET.
ALWAYS EXERCISE BASIC SAFETY PRECAUTIOS TO AVOID THE
POSSIBILITY OF ELECTRIC SHOCK.

ALL COECTIOS TO THIS CHILLER UIT SHALL BE COMPLIET
WITH EC CODE. Connections shall be made from a fused disconnect or equivalent.
Main power wire installation hole NOT provided. Drill hole where necessary. IT IS
ISTALLERS RESPOSIBILITY TO REMOVE ALL METAL
CHIPS/SHAVIGS AD PROTECT COMPOETS FROM SUCH. DAMAGE
OR ELECTRICAL HAZARD COULD OCCUR IF CHIPS/SHAVIGS FALL
ITO COMPOETS. Fuses shall be provided in the field and rated at 125% of the
full load amperes as marked on the ID LABEL of the chiller unit. Field wiring to the
chiller control box shall be #12 AWG or larger. (FOLLOW NEC CODE)

1. Polar unit is to be mounted inside, electric brought to the system switch box
located on the control end of the Polar unit.

2. Condensing unit is to be located outdoors with the proper service connected.
Consult the condensing unit information plate for proper voltage and amperage.

3. The Polar unit has a 24 volt AC control circuit transformer. This is wired via din
rail to the small receptacle on the front panel of the Polar unit.

4. Locate disconnects wherever needed. Conform to all local and state codes.

5. If multiple outdoor units are being installed, run separate electrical services to
each condenser. NOTE: Always check condensing unit nameplate for electrical
ratings.

6. Wire Polar unit per wiring diagram displayed in control box.

7. When connecting thermostat wires to Polar unit, always connect the stages as
labeled on front of chiller. Stage A to condenser A, Stage B to condenser B etc

8. When connecting Air Handlers to Chiller Control Cabinet, use the wiring chart
located in the control box.

Emergency Stop stops
Chiller Operation Only!
EMERGENCY STOP
DOES NOT BREAK HIGH
VOLTAGE
L1 L2 L3
T1 T2 T3
PUMP
OVLOAD
AUX
NO
NO
13
33
14
34
T1 T2 T3 A2
L1 L2 L3 A1
PUMP
CONTACTOR
LC1D18BD
PUMP
DISCONNECT
SWITCH
FSLPS25
L1
DIST
FSPD
B2A
208-240/1/60
Incoming Line
Voltage
L2
DIST
FSPD
B2A
DC
POWER
SUPPLY
ABL8RPS2
4030
G LV C HV
+ + - -
24VAC
TRANS-
FORMER
ZET-460
207 240 C
24V 24V
BREAKER
NB1-D2
BREAKER
(PWRSUP)
NB1-D2
BREAKER
NB1-D2
BREAKER
(XFORM)
NB1-D3
+

2
4

V
D
C

D
I
S
T
(
1
3
-
1
4
)
-
2
4

V
D
C

D
I
S
T
(
1
5
)
I1
I2
I3
I4
I5
I6
I7
I8
H1
0V
A1
A2
A3
A4
0V
C6
R6
C5
R5
C4
R4
C3
R3
C2
R2
C1
R1
H4
H3
H2
- +
POWER NWORK
V- cL SH cH V+
Horner xLT
PLC Controller
HE-XT-102-14
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
STAGE
A
PLUG
STAGE
B
PLUG
STAGE
C
PLUG
STAGE
D
PLUG
1
6
1
7
PANEL
DOOR
E-STOP
S
T
A
G
E

A

T
E
M
P

P
R
O
B
E
S
T
A
G
E

B

T
E
M
P

P
R
O
B
E
S
T
A
G
E

C

T
E
M
P

P
R
O
B
E
S
T
A
G
E

D

T
E
M
P

P
R
O
B
E
J.C. COLLINS
NASHVILLE,TN
WIRE DIAGRAM & CONNECTIONS
CONTROL VOLTAGE
Chiller Polar Model
208-240/1/60 ETL
SIZE FSCM NO DWG NO REV
N/A ETLPOLAR EP2301 5
SCA
LE
N/A 11-1-10
SHE
ET
1 OF 1
L
E
V
E
L

S
W
I
T
C
H
F
L
O
W

S
W
I
T
C
H
CAUTION
USE COPPER CONDUCTORS ONLY! UNIT
TERMINALS ARE NOT DESIGNED TO ACCEPT
OTHER TYPES OF CONDUCTORS. FAILURE TO
DO SO MAY CAUSE DAMAGE TO THE
EQUIPMENT
WARNING
HAZARDOUS VOLTAGE !
DISCONNECT ALL ELECTRIC
POWER INCLUDING REMOTE
DISCONNECTS BEFORE
SERVICING.
FAILURE TO DISCONNECT
POWER BEFORE SERVICING CAN
CAUSE SEVERE PERSONAL
INJURY OR DEATH.
L1 L2 L3
T1 T2 T3
3
A

F
U
S
E
24 VAC DIST
(18-19)
Wiring Diagram 1 208-240/1/60 (EP2301)
Example: EP- * * * S * - * 2 *
- See Polar Series Part Number for assistance in identifying the correct wiring diagram for your specific Chiller
EMERGENCY STOP DOES
NOT BREAK HIGH
VOLTAGE
L1 L2 L3
T1 T2 T3
PUMP
OVLOAD
AUX
NO
NO
13
33
14
34
T1 T2 T3 A2
L1 L2 L3 A1
PUMP
CONTACTOR
LC1D18BD
PUMP
DISCONNECT
SWITCH
FSLPS25
L1
DIST
FSPD
B
208-240/1/60
Incoming Line
Voltage
L2
DIST
FSPD
B
DC
POWER
SUPPLY
ABL8RPS2
4030
G LV C HV
+ + - -
24VAC
TRANS-
FORMER
ZET-240
208 240 C
24V 24V
BREAKER
NB1-D2
BREAKER
(PWRSUP)
NB1-D2
BREAKER
NB1-D2
BREAKER
(XFORM)
NB1-D3
+

2
4

V
D
C

D
I
S
T
(
1
3
-
1
4
)
-
2
4

V
D
C

D
I
S
T
(
1
5
)
C1
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
C2
Q9
Q10
Q11
Q12
Q13
Q14
Q15
Q16
Horner
DQM602
Relay
SmartStick
HEX ID:
4B
HI:4
Low:B
NETWORK
V- cL SH cH V+
I1
I2
I3
I4
I5
I6
I7
I8
H1
0V
A1
A2
A3
A4
0V
C6
R6
C5
R5
C4
R4
C3
R3
C2
R2
C1
R1
H4
H3
H2
- +
POWER NWORK
V- cL SH cH V+
Horner xLT
PLC Controller
HE-XT-102-14
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
Connection for Air Handlers
STAGE
A
PLUG
STAGE
B
PLUG
STAGE
C
PLUG
STAGE
D
PLUG
1
6
1
7
PANEL
DOOR
E-STOP
S
T
A
G
E

A

T
E
M
P

P
R
O
B
E
S
T
A
G
E

B

T
E
M
P

P
R
O
B
E
S
T
A
G
E

C

T
E
M
P

P
R
O
B
E
S
T
A
G
E

D

T
E
M
P

P
R
O
B
E
J.C. COLLINS
NASHVILLE,TN
CONTROL VOLTAGE
Chiller Polar Model
208-230/1/60 ETL
N/A ETLPOLAR EP2301C 6
SCA
LE
N/A 11-1-10
SHE
ET
1 OF 1
L
E
V
E
L

S
W
I
T
C
H
F
L
O
W

S
W
I
T
C
H
CAUTION
EQUIPMENT
WARNING
HAZARDOUS VOLTAGE !
DISCONNECTS BEFORE
SERVICING.
INJURY OR DEATH.
L1 L2 L3
T1 T2 T3
3
A

F
U
S
E
24 VAC DIST
(18-19)
Wiring Diagram 2 208-240/1/60 (EP2301C)
Example: EP- * * * C * - * 2 *
EMERGENCY STOP DOES
NOT BREAK HIGH
VOLTAGE
L1 L2 L3
T1 T2 T3
PUMP
OVLOAD
AUX
NO
NO
13
33
14
34
T1 T2 T3 A2
L1 L2 L3 A1
PUMP
CONTACTOR
LC1D18BD
PUMP
DISCONNECT
SWITCH
FSLPS25
L1
DIST
FSPD
B2A
208-240/3/60
Incoming Line
Voltage
L2
DIST
FSPD
B2A
L3
DIST
FSPD
B2A
DC
POWER
SUPPLY
ABL8RPS2
4030
G LV C HV
+ + - -
24VAC
TRANS-
FORMER
ZET-460
207 240 C
24V 24V
BREAKER
NB1-D2
BREAKER
(PWRSUP)
NB1-D2
BREAKER
NB1-D2
BREAKER
(XFORM)
NB1-D3
+

2
4

V
D
C

D
I
S
T
(
1
3
-
1
4
)
-
2
4

V
D
C

D
I
S
T
(
1
5
)
I1
I2
I3
I4
I5
I6
I7
I8
H1
0V
A1
A2
A3
A4
0V
C6
R6
C5
R5
C4
R4
C3
R3
C2
R2
C1
R1
H4
H3
H2
- +
POWER NWORK
V- cL SH cH V+
Horner xLT
PLC Controller
HE-XT-102-14
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
STAGE
A
PLUG
STAGE
B
PLUG
STAGE
C
PLUG
STAGE
D
PLUG
1
6
1
7
PANEL
DOOR
E-STOP
S
T
A
G
E

A

T
E
M
P

P
R
O
B
E
S
T
A
G
E

B

T
E
M
P

P
R
O
B
E
S
T
A
G
E

C

T
E
M
P

P
R
O
B
E
S
T
A
G
E

D

T
E
M
P

P
R
O
B
E
J.C. COLLINS
NASHVILLE,TN
CONTROL VOLTAGE
Chiller Polar Model
208-240/3/60 ETL
SCA
LE
N/A 11-1-10
SHE
ET
1 OF 1
L
E
V
E
L

S
W
I
T
C
H
F
L
O
W

S
W
I
T
C
H
CAUTION
EQUIPMENT
WHEN INSTALLING 3 PHASE
POWER
CHECK PUMP FOR PROPER
ROTATION
WARNING
HAZARDOUS VOLTAGE !
DISCONNECTS BEFORE
SERVICING.
INJURY OR DEATH.
L1 L2 L3
T1 T2 T3
3
A

F
U
S
E
24 VAC DIST
(18-19)
Wiring Diagram 3 208-240/3/60 (EP2303)
Example: EP- * * * S * - * 3 *
EMERGENCY STOP DOES
NOT BREAK HIGH
VOLTAGE
L1 L2 L3
T1 T2 T3
PUMP
OVLOAD
AUX
NO
NO
13
33
14
34
T1 T2 T3 A2
L1 L2 L3 A1
PUMP
CONTACTOR
LC1D18BD
PUMP
DISCONNECT
SWITCH
FSLPS25
L1
DIST
FSPD
B2A
208-240/3/60
Incoming Line
Voltage
L2
DIST
FSPD
B2A
L3
DIST
FSPD
B2A
DC
POWER
SUPPLY
ABL8RPS2
4030
G LV C HV
+ + - -
24VAC
TRANS-
FORMER
ZET-240
208 240 C
24V 24V
BREAKER
NB1-D2
BREAKER
(PWRSUP)
NB1-D2
BREAKER
NB1-D2
BREAKER
(XFORM)
NB1-D3
+

2
4

V
D
C

D
I
S
T
(
1
3
-
1
4
)
-
2
4

V
D
C

D
I
S
T
(
1
5
)
C1
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
C2
Q9
Q10
Q11
Q12
Q13
Q14
Q15
Q16
Horner
DQM602
Relay
SmartStick
HEX ID:
4B
HI:4
Low:B
NETWORK
V- cL SH cH V+
I1
I2
I3
I4
I5
I6
I7
I8
H1
0V
A1
A2
A3
A4
0V
C6
R6
C5
R5
C4
R4
C3
R3
C2
R2
C1
R1
H4
H3
H2
- +
POWER NWORK
V- cL SH cH V+
Horner xLT
PLC Controller
HE-XT-102-14
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
Connection for Air
Handlers
STAGE
A
PLUG
STAGE
B
PLUG
STAGE
C
PLUG
STAGE
D
PLUG
1
6
1
7
PANEL
DOOR
E-STOP
S
T
A
G
E

A

T
E
M
P

P
R
O
B
E
S
T
A
G
E

B

T
E
M
P

P
R
O
B
E
S
T
A
G
E

C

T
E
M
P

P
R
O
B
E
S
T
A
G
E

D

T
E
M
P

P
R
O
B
E
J.C. COLLINS
NASHVILLE,TN
CONTROL VOLTAGE
Chiller Polar Model
208-230/3/60 ETL
SCA
LE
N/A 11-1-10
SHE
ET
1 OF 1
L
E
V
E
L

S
W
I
T
C
H
F
L
O
W

S
W
I
T
C
H
CAUTION
EQUIPMENT
POWER
ROTATION
WARNING
HAZARDOUS VOLTAGE !
DISCONNECTS BEFORE
SERVICING.
INJURY OR DEATH.
L1 L2 L3
T1 T2 T3
3
A

F
U
S
E
24 VAC DIST
(18-19)
Wiring Diagram 4 208-240/3/60 (EP2303C)
Example: EP- * * * C * - * 3 *
EMERGENCY STOP
DOES NOT BREAK HIGH
VOLTAGE
L1 L2 L3
T1 T2 T3
PUMP
OVLOAD
AUX
NO
NO
13
33
14
34
T1 T2 T3 A2
L1 L2 L3 A1
PUMP
CONTACTOR
LC1D18BD
PUMP
DISCONNECT
SWITCH
FSLPS25
L1
DIST
FSPD
B2A
460/3/60
Incoming Line
Voltage
L2
DIST
FSPD
B2A
L3
DIST
FSPD
B2A
DC
POWER
SUPPLY
ABL8RPS2
4030
G LV C HV
+ + - -
24VAC
TRANS-
FORMER
ZET-460
460 C
24V 24V
BREAKER
NB1-D2
BREAKER
(PWRSUP)
NB1-D2
BREAKER
NB1-D2
BREAKER
(XFORM)
NB1-D3
+

2
4

V
D
C

D
I
S
T
(
1
3
-
1
4
)
-
2
4

V
D
C

D
I
S
T
(
1
5
)
I1
I2
I3
I4
I5
I6
I7
I8
H1
0V
A1
A2
A3
A4
0V
C6
R6
C5
R5
C4
R4
C3
R3
C2
R2
C1
R1
H4
H3
H2
- +
POWER NWORK
V- cL SH cH V+
Horner xLT
PLC Controller
HE-XT-102-14
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
STAGE
A
PLUG
STAGE
B
PLUG
STAGE
C
PLUG
STAGE
D
PLUG
1
6
1
7
PANEL
DOOR
E-STOP
S
T
A
G
E

A

T
E
M
P

P
R
O
B
E
S
T
A
G
E

B

T
E
M
P

P
R
O
B
E
S
T
A
G
E

C

T
E
M
P

P
R
O
B
E
S
T
A
G
E

D

T
E
M
P

P
R
O
B
E
J.C. COLLINS
NASHVILLE,TN
CONTROL VOLTAGE
Chiller Polar Model
460/3/60 ETL
SCA
LE
N/A 11-1-10
SHE
ET
1 OF 1
L
E
V
E
L

S
W
I
T
C
H
F
L
O
W

S
W
I
T
C
H
CAUTION
EQUIPMENT
POWER
ROTATION
WARNING
HAZARDOUS VOLTAGE !
DISCONNECTS BEFORE
SERVICING.
INJURY OR DEATH.
L1 L2 L3
T1 T2 T3
3
A

F
U
S
E
24 VAC DIST
(18-19)
Wiring Diagram 5 460/3/60 (EP4603)
Example: EP- * * * S * - * 4 *
EMERGENCY STOP DOES
NOT BREAK HIGH
VOLTAGE
L1 L2 L3
T1 T2 T3
PUMP
OVLOAD
AUX
NO
NO
13
33
14
34
T1 T2 T3 A2
L1 L2 L3 A1
PUMP
CONTACTOR
LC1D18BD
PUMP
DISCONNECT
SWITCH
FSLPS25
L1
DIST
FSPD
B2A
460/3/60
Incoming Line
Voltage
L2
DIST
FSPD
B2A
L3
DIST
FSPD
B2A
DC
POWER
SUPPLY
ABL8RPS2
4030
G LV C HV
+ + - -
24VAC
TRANS-
FORMER
ZET-460
460 C
24V 24V
BREAKER
NB1-D2
BREAKER
(PWRSUP)
NB1-D2
BREAKER
NB1-D2
BREAKER
(XFORM)
NB1-D3
+

2
4

V
D
C

D
I
S
T
(
1
3
-
1
4
)
-
2
4

V
D
C

D
I
S
T
(
1
5
)
C1
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
C2
Q9
Q10
Q1
Q12
Q13
Q14
Q15
Q16
Horner
DQM602
Relay
SmartStick
HEX ID:
4B
HI:4
Low:B
NETWORK
V- cL SH cH V+
I1
I2
I3
I4
I5
I6
I7
I8
H1
0V
A1
A2
A3
A4
0V
C6
R6
C5
R5
C4
R4
C3
R3
C2
R2
C1
R1
H4
H3
H2
- +
POWER NWORK
V- cL SH cH V+
Horner xLT
PLC Controller
HE-XT-102-14
1 2 3 4 5 6 7 8 9
1
0
1
1
1
2
Connection for Air Handlers
STAGE
A
PLUG
STAGE
B
PLUG
STAGE
C
PLUG
STAGE
D
PLUG
1
6
1
7
PANEL
DOOR
E-STOP
S
T
A
G
E

A

T
E
M
P

P
R
O
B
E
S
T
A
G
E

B

T
E
M
P

P
R
O
B
E
S
T
A
G
E

C

T
E
M
P

P
R
O
B
E
S
T
A
G
E

D

T
E
M
P

P
R
O
B
E
J.C. COLLINS
NASHVILLE,TN
CONTROL VOLTAGE
Chiller Polar Model
460/3/60 ETL
SCA
LE
N/A 11-1-10
SHE
ET
1 OF 1
L
E
V
E
L

S
W
I
T
C
H
F
L
O
W

S
W
I
T
C
H
CAUTION
EQUIPMENT
POWER
ROTATION
WARNING
HAZARDOUS VOLTAGE !
DISCONNECTS BEFORE
SERVICING.
INJURY OR DEATH.
L1 L2 L3
T1 T2 T3
24 VAC DIST
(18-19)
3
A

F
U
S
E
Wiring Diagram 6 460/3/60 (EP4603C)
Example: EP- * * * C * - * 4 *
EMERGENCY STOP
DOES NOT BREAK HIGH
VOLTAGE
CONTROL WIRE CONNECTION(S) -
CONDENSING UNIT

ENSURE STAGE LETTER IS CONNECTED WITH MATCHING PLUG (A,B,C,D)

1. Locate 24 volt wires on the condensing unit.
a. Twist together red wire and blue wire.
b. Twist together black wire and yellow wire.

2. Use a crimp cap to make sure that you will have a good connection.

3. Crimp wires together, inspect to make sure that wires are securely
crimped together.

4. Repeat steps 1 thru 3 for each condensing unit.
CONTROL WIRE CONNECTION(S) - INDOOR

ENSURE STAGE LETTER IS CONNECTED WITH MATCHING PLUG (A,B,C,D)

1. Locate female midget plug receptacle on the side of Chiller electrical box.

2. Lift dust cap off of female midget plug.

3. Push male midget plug into female receptacle.

4. Twist bottom of male plug to lock into place. Repeat steps 1 through 4 for each
condensing unit.

CONTROL WIRE CONNECTION(S)
AIR HANDLER

(if applicable)
CONTROLLER OPERATION

Operation:

Temperature Settings:

Faults:

EMERGENCY STOP DOES
NOT BREAK HIGH
VOLTAGE
Status:

Air Handler Controls:

(if applicable)
alternative screen:
CONTROLLER SCREEN MAP

COLD WEATHER ANTIFREEZE SELECTION GUIDE

When the chiller unit sits idle overnight during cold weather, water in the heat exchanger
can freeze. To avoid freezing, a proper solution of inhibited glycol antifreeze must be
added. The following chart illustrates the number of gallons of antifreeze needed to
protect against freeze up at various temperatures.

FREEZE TEMPERATURE F % PROPYLENE GLYCOL BY VOLUME
26 10
19 20
8 30
-7 40
-28 50
-60 60
<-60 70

Propylene Glycol does not have silicates that are harmful to pump seals and gaskets at chiller
water operating temperatures compared to automotive type antifreeze. The rust inhibitors are
also specially formulated to work in cold, cooling temperatures rather than hot engine
environments.

Propylene Glycol also provides freeze protection in the event a compressor contactor welds
shut. Bad contact points, stuck coil, or lightning will permit the condenser to run and
continually drive down the water temperature.

There are high costs associated with using the wrong type of glycol for freeze protection.
Corrosion damage, system downtime, occupant discomfort, high repair costs, frequent fluid
replacement and shortened system life are all potential consequences. Propylene Glycol
should be replaced every time the system is drained and cleaned.

WARIG: THE USE OF AUTOMOTIVE TYPE ATIFREEZE WILL
VOID WARRATY. AUTOMOTIVE ATIFREEZE CA FOUL AD
CLOG THIS CHILLER SYSTEM.
MAINTENANCE

1. Clean air cooled outdoor condenser(s) 2-times/year or sooner if needed.

2. Blow off pump motor air intake openings with compressed air yearly.

3. Monthly inspection:

a. Refrigerant site glass-should be clear at full load conditions.

b. Check compressor(s) amperage.

c. Check condenser(s) for any blockage.

d. Check/Clean pump strainers.

e. Check pump seal for leakage.

TROUBLESHOOTING

WARIG: WHE SERVICIG THIS EQUIPMET. ALWAYS EXERCISE
BASIC SAFETY PRECAUTIOS TO AVOID THE POSSIBILITY OF
ELECTRIC SHOCK.

1. Indoor pump will not run.
a. Check voltage connection to switch box located on indoor unit. Voltage
should be as per nameplate.
b. Check that switch is in the on position.
c. Check voltage at pump connection. Voltage should be as per nameplate.
d. Feel pump motor, if motor is hot to the touch. Pump is off on internal
overload. Allow pump to cool then restart. Check the amperage
immediately.
e. Check pump for blockage in impeller.
2. Indoor pump will start but shuts down after a few minutes.
a. Check for sufficient water in reservoir.
b. Check for proper voltage to pump.
c. Check wire connections at pump.
d. Check intake of pump for obstruction in impeller.
3. Indoor pump will run, but no water is circulating.
a. Check for sufficient water in reservoir.
b. Check that all valves in chiller header loops are open.
c. Check that all air is bled from any piping that is located above indoor
cabinet on non-tank madels.
4. Indoor pump unit will run but digital controller is not on.
a. Check voltage feed to controller. See wiring diagram on controller or
panel diagram.
b. Check fuses.
5. Indoor unit operates properly but outdoor condensing unit(s) will not run.
a. Check that unit is wired correctly.
b. Check main line voltage to unit. Voltage should be as per nameplate.
c. Check that temperature controller on indoor unit is set below temperature
of circulating water.
d. Check low voltage signal at the outdoor condensing unit. Control voltage
should be 24vac across the two control wires coming from the indoor unit
to the outdoor unit(s).
e. By breaking and making the 24vac control circuit, you should be able to
hear the compressor relay open and close. A snap will be heard at the
condensing unit when the compressor relay closes. Unit(s) should start.
f. On chiller with two or more outdoor units(s), the temperature control is
staged. There is a 5F differential between each stage.
g. Check refrigerant PSI. Ensure condenser is not off due to internal PSI
switch.
6. Outdoor compressor relay is closed but unit will not run.
a. Check main line voltage.
b. Check voltage at compressor connections.
c. Check compressor body. If you cannot hold your hand on the compressor
body because of heat, internal overloads may have tripped open. You must
allow compressor time to cool down and reset.
d. Perform a circuit test through compressor to verify if windings are open.
7. Outdoor compressor has tripped on internal overloads.
a. Allow time to reset.
b. Check all wire connections
c. Check compressor amperage draw.
d. Check voltage to compressor while unit is running.
e. Check that condenser fan is coming on.
f. Check that condenser is clean and not blocked.
g. Check that hot discharge air from another source is not being drawn into
condenser intake.
h. Check that unit is properly sized.
8. Outdoor main line voltage is correct to unit, 24vac control voltage is correct to unit,
compressor relay will not close.
a. Check that all wire connections are made.
b. Check that all refrigerant line connections are tightened properly. See
installation manual under Refrigeration Line Set.
c. Check that refrigeration service valves located on condensing unit are
open. See instructions with outdoor unit.
d. Check for any crimps in refrigeration line set.
e. Check refrigerant charge. Low-pressure control will open at 8psi and close
at 30 psi of suction pressure.
9. Pump is running but controller goes blank.
a. Check voltage to controller.
b. Check fuses.

1
0
/
1
0
N
E

1
0
/
1
0
N
E

Chiller South
568 Brick Church Park Dr.
Nashville, TN 37207
T 615.262.0307
F 615.262.0308
Chiller North
133 Harrison Ave
Jeffersonville, IN 47130
T 812.288.8413
F 812.285.5508
1.800.334.COOL (2665)
Thank you
for choosing Chiller Mfg.

EP - Operating Manual

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1-800-334-COOL (2665) Page 36 of 38 www.chillermfg.com

1-800-334-COOL (2665) Page 37 of 38 www.chillermfg.com

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