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Chiller Manual Installation, Operation & Maintenance

INTRODUCTION

 
Turbo Refrigerating is a supplier of fluid chillers, icemaking, and ice storage equipment. TURBO® does not engineer or design fluid chilling systems, ice systems, ice plants, or processing lines. TURBO can provide assistance in locating qualified companies familiar with the installation and operation of TURBO chillers. Contact the factory at the address or telephone numbers listed at the end of this section.
Information on safety, installation, operation, maintenance and trouble- shooting is contained in this manual. If you have questions concerning any of these phases, contact TURBO or one of its distributors to ensure that you fully understand the instructions and guidelines.
You must read all of the information carefully and make sure that all personnel involved in the installation have also read and understood the information and safety instructions. This

will help avoid injury to personnel and/or damage to the equipment. Both are valuable assets to your operation. Take the time to protect them.
Read the manual contents before you start your installation or operation. This will save time by ensuring that all necessary materials and tools are available when the equipment arrives.

History
TURBO has been producing a line of fluid chillers since 1984 equipment as well as icemakers and ice generators for the ice industry since 1960. The chillers described in this manual are part of a family of products designed specifically for the industrial market for a variety of cooling needs.
Fluid Heat Exchangers HTD and HF series heat exchangers are designed to instantaneously chill fluids

falling over vertical stainless steel plates in a thin falling film. Because of method of chilling the liquid heat exchangers are often referred to as falling film chillers.

HTD Series
HTD stands for High Temperature Difference. Fluids are chilled or heated over large temperature differences, ranging from 5°F to 60°F in a single pass using R-22, ammonia or glycol as the refrigerant inside the plate. Systems are available in direct expansion (DX), flooded and recirculated models.
Flow rates are available over a wide range but are typical considered relatively low. Higher flow rates can be obtained with HF chillers.
HF Chillers
HF stands for High Flow. Fluids are chilled over narrow temperature differences, ranging from 1°F to 2°F. The plate’s long narrow geometry enables high fluid flow over the
 
 
 
plate. Ammonia, R-22 and glycol are all available for use in direct expansion, flooded and recirculated systems.

Applications
HTD/HF chillers are suitable for a variety of applications including:
  • Food
  • Beverage
  • Chemical
  • Manufacturing
Models
A number of standard and special chiller plates are available in a variety of configurations to meet many applications. Standard plate sizes include:
  • 48” x 60”
  • 72’ x 60”
  • 96” x 60”
  • 144” x 24”
Refrigerants/Refrigerant Feed
Chillers are available in R- 22, ammonia, and glycol with direct expansion (DX), flooded, and recirculated refrigerant feed. Chillers can be furnished with their own high side and condensing unit or connected to existing refrigeration systems.
Associated Equipment

Icemakers/Ice Generators TURBO® C-Line Icemakers
Packaged ice applications require a dry sub-cooled ice

and uniform fragmented nuggets. TURBO has produced the C-line icemaker since 1964. This product line uses a water defrost to produce ice in capacities ranging from 1 ton per dry to 200 tons per day in CAR and CAR-LR (ammonia) and CF (R-22) models.

TURBO® TIG/TIGAR
Ice Generators
In industrial applications where ice is being used for processing or for top icing, TURBO produces a series of wet ice generators called the TIG (R-22) and TIGAR (NH3) series. These hot gas defrost icemakers are built with the same high quality standards and engineering as the TURBO® icemakers of the sixties. The only difference is that the icemaking process produces slightly wetter ices due to the hot gas defrost, and the standard system used to produce dry, uniform ice nuggets is eliminated. As a result, a random shaped piece of fragmented ice is produced at a lower cost per ton.
In applications where totally dry, uniform ice is not required; the TIG/TIGAR series offers a low cost alternative.

Typical Applications
  • Produce (broccoli, carrots, etc.) – top icing in

the field (trailer mounted units) or in the processing area
  • Concrete icing
  • Ingredient icing (bakeries)
  • Fish icing
  • Poultry icing
  • Chemical and dye processes
  • Emergency cooling loads
  • Ice slurries
  • Catering trucks
  • Salad bars or display ice
  • Food processing

Ice Storage Systems TURBO® rakes and storage bins were introduced in 1967. There are three basic sizes in the hydraulic version as well as two larger versions known as automatic ice rakes (described in this manual). The smaller hydraulic models range in capacity from 20 to 87 tons while the larger automatic ice rakes range from 100 to 300 tons of ice storage.
TURBO rakes have been used in USDA inspected installations.
USDA Design
All TURBO® ice storage systems are designed to meet USDA guidelines and meet rugged industrial standards which make them the most reliable in the industry. Each system is designed to make the loading and unloading of the ice storage system as
 
 
 
safe and simple as possible. Regardless of size, all of the ice storage systems operate in basically the same simple yet reliable manner.

The entire load and unload sequence is automatic and does not require the operator to be in contact with the ice or any moving parts in the ice storage system.
The continuous presence of an operator is not required although it is recommended. At the end of the day, the bin is empty (on a design day). The bin refills overnight and is full when personnel return to work.

NOTE: All controls are adjustable to allow the load or unload rate to match the customer’s production and/or delivery requirements.
Rake Variations
CB and Automatic rakes are available in a number of standard sizes to accommodate bulk storage capacities ranging from 20 tons to 400 tons. Models are available in standard 10’, 12’-6”, 15’ and 20’ widths;
20’ to 55’ length; heights
from 9’ to 25’ making it possible to produce a variety of standard capacities.

Optional Rake Features
Although TURBO designs and builds the ice storage system to be as flexible as possible, the standard system may not meet a particular application.
TURBO can design a storage system to meet almost any need.

TURBO® Block Press TURBO offers another feature to make optimum profits from your ice production. Instead of throwing away the snow produced by the breaker bar, ice sizer, screw conveyors, or other handling devices, install a TURBO® block press. This block press converts the snow into ten or fifty-five pound blocks of ice.
Introduced in 1977, the block press is a completely automatic, hydraulic powered unit capable of producing from 120 to an excess of 400 ten pound blocks per hour.
The block press is available with a block bagger attachment, which means:
  • Eliminates handling until the block is in the bag
  • A better product
  • Higher profits
Rugged industrial construction and stainless steel or UHMW in all areas of ice contact make the

TURBO® block press the most reliable on the market.

Special Applications
TURBO is in the business of supplying equipment to meet the needs of the customer. If you have an application or a need that is not discussed here, contact:

Turbo Refrigerating, LLC Sales Department
P.O. Box 396
Denton, Texas 76202-0396
Phone: 940-387-4301
Fax:    940-382-0364
Web Site:
WWW.vogtice.com

Customer Service
The TURBO service department provides assistance for all customer needs. TURBO conducts training schools at the factory and at various locations throughout the world.

NOTE: The model and serial number of your TURBO equipment is located on the data nameplate attached to the electrical control panel.
Please refer to the model and serial number when making inquiries about the equipment. This will enable our personnel to handle your questions quickly and accurately.
 



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.
 
 
 



Turbo Refrigerating, LLC (the “Company”) agrees to sell the Equipment described herein upon the following terms and conditions of sale which, accordingly, supersede any of Buyer’s additional or inconsistent terms and conditions of purchase.
 
  1. Terms and Prices
    1. All orders are to be accompanied by a twenty percent (20%) down payment or an acceptable irrevocable letter of credit confirmed on a U.S. Bank acceptable to Turbo. No orders are to be entered without payment or L/C in hand.
    2. All orders are subject to the approval of the Company’s home office. Unless otherwise stated, standard terms of payment are thirty (30) days net from the earlier of date of shipment or readiness of the Equipment for shipment. If partial shipments are made, payment shall become due and payable to the partial shipment.
    3. In addition to the purchase price, Buyer shall pay any excise, sales, privilege, use or any other taxes, Local, State or Federal, which the
 

TERMS & CONDITIONS

Company may be required to pay arising from the sale or delivery of the Equipment or the use thereof. Prepaid freight, if applicable, will be added to the purchase price and invoiced separately. Where price includes transportation or other shipping charges, any increases in transportation rates or other shipping charges from date of quotation or purchase order shall be for the account of and paid by Buyer.
    1. Contract prices are subject to adjustment to the Company’s prices in effect at time of shipment unless otherwise specified in a separate Price Adjustment Policy attached to the proposal or other contract document of the Company.
    2. If Buyer requests changes in the Equipment or delays progress of the manufacture or shipment of the Equipment, the contract price shall be adjusted to reflect increases in selling price caused thereby.
 
  1. Shipment
Shipment is F.O.B. Company’s plant or place of manufacture, unless otherwise specified. Risk of loss shall pass to Buyer




upon delivery to transporting carrier.

 
  1. Delivery
    1. The Company will endeavor to make shipment of orders as scheduled. However, all shipment dates are approximate only, and the Company reserves the right to readjust shipment schedules.
    2. Under no circumstances will the Company be responsible or incur any liability for costs or damages of any nature (whether general, consequential, as a penalty or liquidated damages or otherwise) arising out of or owing to (i) any delays in delivery or (ii) failure to make delivery at agreed or specified times due to circumstances beyond its reasonable control.
    3. If shipment is delayed or suspended by Buyer, Buyer shall pay (i) Company’s invoice for the Equipment as per payment terms, (ii) Company’s handling and storage charges then in effect, and (iii) demurrage charges if loaded on rail cars.
 
  1. Limited Warranty: Warranty Adjustment:
 
 
 
Exclusions: Limitation of Liability
  1. LIMITED WARRANTY

The Company warrants that at the time of shipment the Equipment manufactured by it shall be merchantable, free from defects in material and workmanship and shall possess the characteristics represented in writing by the Company. The Company’s warranty is conditioned upon the Equipment being properly installed and maintained and operated within the Equipment’s capacity under normal load conditions with competent supervised operators and, if the Equipment uses water, with proper water conditioning. Equipment, accessories and other parts and components not manufactured by the Company are warranted only to the extent of and by the original manufacturer’s warranty to the Company, in no event shall such other manufacturer’s warranty create any more extensive warranty obligations of the Company to the Buyer than the Company’s warranty covering Equipment manufactured by the Company.
  1. EXCLUSIONS FROM WARRANTY
 
    1. THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, ORAL OR EXPRESS OR IMPLIED, INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION OF THE EQUIPMENT. THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE CONTAINED IN THIS PARAGRAPH 4 AND TO THE EXTENT PERMITTED BY LAW THERE ARE NO IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE. THE PROVISIONS OF THIS PARAGRAPH 4 AS TO DURATION, WARRANTY ADJUSTMENT AND LIMITATION OF LIABILITY SHALL BE THE SAME FOR BOTH IMPLIED WARRANTIES (IF ANY) AND EXPRESS WARRANTIES.
    2. The Company’s warranty is solely as stated in (a) above and does not apply or extend, for example, to expendable items, ordinary wear and tear, altered units; units repaired by persons not expressly approved by the Company, materials not of the Company’s manufacture, or damage caused by accident, the elements, abuse, misuse, temporary heat, over-

loading, or by erosive or corrosive substances or by the alien presence of oil, grease, scale, deposits or other contaminants in the Equipment.
  1. WARRANTY ADJUSTMENT
Buyer must make claim of any breach of any warranty by written notice to the Company’s home office within thirty (30) days of the discovery of any defect. The Company agrees at its option to repair or replace, BUT NOT INSTALL,
F.O.B. Company’s plant, any part or parts of the Equipment which within twelve (12) months from the date of initial operation but no more than eighteen
(18) months from date of shipment shall prove to the Company’s satisfaction (including return to the Company’s plant, transportation prepaid, for inspection, if required by the Company) to be defective within the above Warranty. Any warranty adjustments made by the Company shall not extend the initial warranty period set forth above. The warranty period for replacements made by the Company shall terminate upon the termination of the initial warranty period set forth above. Expenses incurred by Buyer in replacing or repairing or
 
 
 
returning the Equipment or any part or parts will not be reimbursed by the Company.
  1. SPARE AND REPLACEMENT PARTS WARRANTY ADJUSTMENT
The Company sells spare and replacement parts. This subparagraph (d) is the Warranty Adjustment for such parts. Buyer must make claim of any breach of any spare or replacement parts warranty by written notice to the Company’s home office within thirty
(30) days of the discovery of any alleged defect for all such parts manufactured by the Company. The Company agrees at its option to repair or replace, BUT NOT INSTALL,
F.O.B. Company’s plant, any part or parts of material it manufactures which, within one (1) year from the date of shipment shall prove to the Company’s satisfactory (including return to the Company’s plant, transportation prepaid, for inspection, if required by the Company) to be defective within this Parts Warranty. The Warranty and warranty period for spare and replacement parts not manufactured by the Company (purchased by the Company, from third party suppliers) shall be limited to

the Warranty and Warranty Adjustment extended to the Company by the original manufacturer of such parts, in no event shall such other manufacturer’s warranty create any more extensive warranty obligation of the Company to the Buyer for such parts than the Company’s Warranty Adjustment covering parts manufactured by the Company as set forth in this subparagraph (d). Expenses incurred by the Buyer in replacing, repairing, or returning the spare or replacements parts will not be reimbursed by the Company.
  1. LIMITATION OF LIABILITY
The above Warranty Adjustment sets forth Buyer’s exclusive remedy and the extent of the Company’s liability for breach of implied (if any) and express warranties, representations, instructions or defects from any cause in connection with the sale or use of the Equipment. THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES OR FOR LOSS, DAMAGE OR EXPENSE, DIRECTLY OR INDIRECTLY ARISING FROM THE USE OF THE EQUIPMENT OR FROM

ANY OTHER CAUSE WHETHER BASED ON WARRANTY (EXPRESS OR IMPLIED) OR TORT OR CONTRACT, and
regardless of any advices or recommendations that may have been rendered concerning the purchase, installation or use of the Equipment.

 
  1. Patents
    1. PATENT INDEMNITY AND CONDITIONS

The Company agrees at its own expense to defend and hold Buyer harmless in the event of any suits instituted against Buyer for an alleged infringement of any claim of any United States Patent covering solely to the structure of the Equipment as originally manufactured by the Company per the Company’s specifications, and without modification by the Buyer, provided buyer shall (i) have given the Company immediate notice in writing of any such claim or institution or threat of such suit, and (ii) have permitted the Company to defend or settle the same, and have given all needed information assistance and authority to enable the Company to do so. Buyer shall defend and indemnify the Company against all expenses, costs and loss by reason of any real or alleged infringement by the
 
 
 
Company’s incorporating a design or modification requested by Buyer.
    1. LIMITATION OF LIABILITY

The Company’s total liability hereunder is expressly limited to an amount no greater than the sales price of the Equipment and may be satisfied by the Company’s refunding to Buyer, at the Company’s option, the sales price of the Equipment in the event the Company elects to defend any such suit and the structure of the said Equipment is held to infringe any such United States Patent and if the Buyer’s use thereof is enjoined, the Company shall, at its expense and at its option (i) obtain for the Buyer the right to continue using the Equipment, or (ii) supply non-infringing Equipment for installation by Buyer, or (iii) modify the Equipment so that it becomes non-infringing, or
(iv) refund the then market value of the Equipment.
  1. Prior Use
If damage to the Equipment or other property or injury to persons is caused by use or operation of the Equipment prior to being placed in initial operation (“Start up”) by the Company where start up is

included in the purchase price, then Buyer shall indemnify and hold the Company harmless from all liability, costs and expenses for all such damage or injury.

 
  1. Equipment Changes
The Company may, but shall not be obligated to, incorporate in the Equipment any changes in specifications, design, material, construction, arrangement, or components.
 
  1. Security Interest Insurance
    1. To secure payment of the purchase price, Buyer agrees that the Company shall retain a security interest in the Equipment until Buyer shall have paid in cash the full purchase price when due, interest at the highest lawful contract rate until so paid and the costs of collection, including reasonable attorney’s fees. The Equipment shall at times be considered and remain personal property and Buyer shall perform all acts necessary to assure and perfect retention of the Company’s security interest against the rights or interests of third persons. In the event Buyer defaults in payment of any part of the purchase price when due, or

fails to comply with any and all provisions of this contract, the Company shall have the remedies available under the Uniform Commercial Code.
    1. So long as the purchase price is unpaid, Buyer at its cost shall obtain insurance against loss or damage from all external causes, naming the Company as an insured, in an amount and form sufficient to protect the Company’s interest in the Equipment.
  1. Cancellation
Buyer cannot cancel orders placed with the Company, except with the Company’s express written consent and upon terms and payment to the Company indemnifying the Company against loss, including but not limited to expenses incurred and commitments made by the Company.
 
  1. Loss, Damage or Delay
The Company shall not be liable for loss, damage or delay resulting from causes beyond its reasonable control or caused by strikes or labor difficulties, lockouts, acts or omissions of any governmental authority or the Buyer, insurrection or riot, war, fires, floods, Acts of God, breakdown of essential machinery, accidents,
 
 
 
priorities or embargoes, car and material shortages, delays in transportation or inability to obtain labor, materials or parts from usual sources. In the event of any delay from such sources, performance will be postponed by such length of time as may be reasonably necessary to compensate for the delay. In the event performance by the Company of this agreement cannot be accomplished by the Company due to any action of governmental agencies, or any laws, rules or regulations of the United States Government, the Company (at its option) may cancel this agreement without liability. In no event shall the Company be liable for any loss or damage of any kind, including consequential or special damages of any nature.
  1. Work By Others: Accessory and Safety Devices
The Company, being only a supplier of the Equipment, shall have no responsibility for labor or work of any nature relating to the installation or operation or use of the Equipment, all of which shall be performed by Buyer or others. It is the responsibility of Buyer to furnish such accessory and safety devices as may be

desired by it and/or required by law or OSHA standards respecting Buyer’s use of the Equipment. Buyer shall be responsible for ascertaining that the Equipment is installed and operated in accordance with all code requirements and other applicable laws, rules, regulations and ordinances.

 
  1. Complete Agreement
THE COMPLETE AGREEMENT BETWEEN THE COMPANY AND BUYER IS CONTAINED HEREIN AND NO ADDITIONAL OR DIFFERENT TERM OR CONDITION STATED BY BUYER SHALL BE BINDING UNLESS AGREED TO BY THE COMPANY IN WRITING.
No course of prior dealings and no usage of the trade shall be relevant to supplement or explain any terms used in this Agreement. This Agreement may be modified only by a writing signed by both the Company and Buyer and shall be governed by the Uniform Commercial Code as enacted the State of Texas. The failure of the Company to insist upon strict performance of any of the terms and conditions stated herein shall not be considered a continuing waiver of any such term or

condition or any of the Company’s rights.
 



Chiller Generator Operation & Maintenance Manual

Section 2: SAFETY

 
Here are some safety points to keep in mind when creating an efficient yet safe working environment.

Safety Definitions
Statements or labels in this manual or on the product preceded by the following words are of special significance:

Warning
Indicates severe personal injury or death will result if instructions are not followed.

Caution
Indicates a strong possibility of severe personal injury or death if instructions are not followed.

Important
Indicates hazards or unsafe practices which could cause minor personal injury or product or property damage.

Note
Gives helpful information.

Machinery Is Dangerous
Machinery can hurt you if you are not careful. Use caution during assembly and operation of equipment.

ALWAYS:
  • Read the entire manual first.
  • Use common sense and be careful.
  • Have enough manpower.
  • Have the proper tools.
 
  • Follow directions and illustrations.
  • Check to see that all equipment meets applicable installation codes for your area as well as state and federal requirements.
  • Have sufficient safety warnings on all equipment.
  • Make sure all safety devices and guards are in place.
Note:
Warning labels attached to the chiller, equipment installed with the chiller, and on access panels should be followed.
They are shown in Figures 2-1, and 2-2.
 




 
Figure 2-1 Warning Labels on Control Panels







Figure 2-2 Warning Label on Access Panels

 

If all labels are not attached and visible or labels start to become illegible, contact:

Turbo Refrigerating Service Department
P.O. Box 396
Denton, Texas 76202-0396

Phone:940-387-4301 Fax:  940-382-0364