FALLING FILM CHILLER

Installation Instructions

Part No. 9843514

Effective February 12, 2003

Revised June 6, 2017

REFRIGERATION PRODUCTS
 FALLING FILM CHILLER
Installation Instructions

TABLE OF CONTENTS
Section 1.0 – Introduction
1.1 Model 3 x 5 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Model 3 x 5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3 Model 4 x 8 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Model 4 x 8 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.5 Plate Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 1: Plate Design for Direct Expansion or Recirculated Refrigeration Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Figure 2: Plate Design for Flooded Refrigeration Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.6 Falling Film Chiller Refrigerant Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.7 Model Number Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Section 2.0 – Installation

2.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.2 Locating and Leveling the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.3 Obtaining Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.4 Locating Refrigeration Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.5 Connecting the Refrigerant Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.6 Liquid Line Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.7 Water Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.8 Make-Up Water Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.9 Connecting the Overflow Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2.10 Cooling Control Mueller Multi-Stage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Figure 3: Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.11 Setting Chiller Recirculation Flow and Water Make-Up Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.12 Distribution Pan Water Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.13 Recommended Chilled Water Line Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.14 Cleaning the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.15 Test Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.16 Chlorine Gas Rusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Section 3.0 – Condensing Unit Set-Up/Start-Up Procedures

3.1 Head Pressure Control Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2 Plate Superheat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.3 Hot Gas Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.4 Liquid Injection Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.5 Ambient Fan Cycling Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 4: Condensing Unit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Figure 5: Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
 SECTION 1.0 – INTRODUCTION

1.1 Model 3 x 5 Standard Features

A. Constructed of Type 304 or 316L stainless steel.

B. Designed for use with R-22, R-134A, R-404A, R-507, or R-717.

C. Required water flow rates:

1. Using high-flow distribution pan:

Minimum flow rate: 14.7 gpm per plate
Maximum flow rate: 29.0 gpm per plate

2. Using low-flow distribution pan:

Minimum flow rate: 9.1 gpm per plate
Maximum flow rate: 14.3 gpm per plate

3. Using extra-low-flow distribution pan:

Minimum flow rate: 5.8 gpm per plate
Maximum flow rate: 8.95 gpm per plate

D. Nominal operating capacity of insulated tank (tankless cabinets are also available):
• 2–8 plates: 173 U.S. gallons
• 2–8 plates, oversized reservoir: 365 U.S. gallons

E. Circulation water connection size:

• 2–8 plates: Inlet: Single, extra-low-flow pan, 2" MPT Outlet*: 4" MPT
Inlet: Single, low-flow pan, 2" MPT Outlet*: 4" MPT
Inlet: Single, high-flow pan, 3" MPT Outlet*: 4" MPT

*Optional 6", 8", and 10" RFSO pipe flanges are also available.

F. Electronic make-up water solenoid assembly is optional.

G. Hinged and gasketed top doors are available as an option.

H. Clamp-type ferrule and male pipe-thread adapter included for inlet.

I. Falling film chiller expansion valves for each refrigeration plate are available.

J. Refrigeration capacity and refrigerant type must be specified at time of ordering.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 1 Revised June 6, 2017
 1.2 Model 3 x 5 Dimensions

Length Width Height Height with Weight Weight with

3 x 5 Tankless (in) (in) (in) Top Door (in) (lb) Top Door (in)
2–8 plate cabinet 70 40.75 46.75 49.25 436 420
Refrigerant plate 64
Glycol plate 48
Pan 49
Length Width Height Height with Weight Weight with
3 x 5 Tankless (in) (in) (in) Top Door (in) (lb) Top Door (in)
2–4 plate cabinet 68 24.75 46.75 49.25 354 348
Refrigerant plate 64
Glycol plate 48
Pan 33
Length Width Height Height with Weight Weight with
3 x 5 with Tank (in) (in) (in) Top Door (in) (lb) Top Door (in)
2–8 plate cabinet 68.5 39.13 77.13 79.63 770 754
Refrigerant plate 64
Glycol plate 48
Pan 49
Length Width Height Height with Weight Weight with
3 x 5 Oversized (in) (in) (in) Top Door (in) (lb) Top Door (in)
2–8 plate cabinet 68.5 39.13 97.13 99.63 837 821
Refrigerant plate 64
Glycol plate 48
Pan 49

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 2 Revised June 6, 2017
 1.3 Model 4 x 8 Standard Features

A. Constructed of Type 304 or 316L stainless steel.

B. Designed for use with R-22, R-134A, R-404A, R-507, or R-717.

C. Required water flow rates:

1. Using high-flow distribution pan:

Minimum flow rate: 31.0 gpm per plate
Maximum flow rate: 50.2 gpm per plate

2. Using low-flow distribution pan:

Minimum flow rate: 17.9 gpm per plate
Maximum flow rate: 28.7 gpm per plate

3. Using extra-low-flow distribution pan:

Minimum flow rate: 8.3 gpm per plate
Maximum flow rate: 15.5 gpm per plate

D. Nominal operating capacity of insulated tank:

• 2–8 plates: 293 U.S. gallons • 17–24 plates: 750 U.S. gallons
• 9–16 plates: 525 U.S. gallons • 25–32 plates: 1,113 U.S. gallons

NOTE: 2–8, 9–16, and 17–24 plate tankless cabinets are also available.

E. Circulation water connection size:

• 2–8 plates: Inlet: Single, extra-low-flow pan, 2" MPT Outlet*: 4" MPT
• 2–8 plates: Inlet: Single, extra-low-flow pan, 4" MPT Outlet*: 4" MPT
Inlet: Single, low-flow pan, 4" MPT Outlet*: 4" MPT
Inlet: Single, high-flow pan, 6" MPT Outlet*: 4" MPT
• 9–16 plates: Inlet: Dual, extra-low-flow pan, 4" MPT Outlet*: 6" RFSO pipe flange
Inlet: Dual, low-flow pan, 4" MPT Outlet*: 6" RFSO pipe flange
Inlet: Dual, high-flow pan, 6" MPT Outlet*: 6" RFSO pipe flange
• 17–24 plates: Inlet: Triple, extra-low-flow pan, 4" MPT Outlet*: 8" RFSO pipe flange
Inlet: Triple, low-flow pan, 4" MPT Outlet*: 8" RFSO pipe flange
Inlet: Triple, high-flow pan, 6" MPT Outlet*: 8" RFSO pipe flange
• 25–32 plates: Inlet: Quad, extra-low-flow pan, 4" MPT Outlet*: 10" RFSO pipe flange
Inlet: Quad, low-flow pan, 4" MPT Outlet*: 10" RFSO pipe flange
Inlet: Quad, high-flow pan, 6" MPT Outlet*: 10" RFSO pipe flange

*Optional 6" , 8", and 10" RFSO pipe flanges are also available.

F. Electronic make-up water solenoid assembly is optional.

G. Hinged and gasketed top doors are available as an option.

H. Clamp-type ferrule and male pipe-thread adapter included for inlet.

I. Falling film chiller expansion valves for each refrigeration plate are available.

J. Refrigeration capacity and refrigerant type must be specified at time of ordering.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 3 Revised June 6, 2017
 1.4 Model 4 x 8 Dimensions

Length Width Height Height with Weight Weight with

4 x 8 with Tank (in) (in) (in) Top Door (in) (lb) Top Door (in)
2–8 plate cabinet 104.38 39.13 90.63 92.88 1,169 1,164
9–16 plate cabinet 104.38 72.38 90.63 92.88 1,621 1,604
17–24 plate cabinet 104.38 105.63 90.63 92.88 2,060 2,035
25–32 plate cabinet 104.38 138.88 90.63 92.88 3,700 3,642
Refrigerant plate 130
Glycol plate 100
Pan 100
Length Width Height Height with Weight Weight with
4 x 8 Tankless (in) (in) (in) Top Door (in) (lb) Top Door (in)
2–8 plate cabinet 108.75 41.75 61.44 63.59 787 782
9–16 plate cabinet 108.75 75.88 61.44 63.59 1,041 1,024
17–24 plate cabinet 108.75 109.13 61.44 63.59 1,444 1,419
Refrigerant plate 130
Glycol plate 100
Pan 100

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 4 Revised June 6, 2017
 1.5 Plate Design

Paul Mueller Company manufactures plates for the falling film chiller in two basic styles. Figure 1 shows the plate
used for direct expansion or recirculated refrigeration systems. Figure 2 shows the plate used for flooded
refrigeration systems.

Figure 1: Plate Design for Direct Expansion or Recirculated Refrigeration Systems

DX or Recirculated

Figure 2: Plate Design for Flooded Refrigeration Systems

Flooded

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 5 Revised June 6, 2017
 1.6 Falling Film Chiller Refrigerant Volumes

MODEL 3 X 5
No. of Plates 1 2 3 4 5 6 7 8 9 10 11 12
Lbs. of R-22 @ 25°F 12 24 36 48 60 72 84 96 108 120 132 144
Lbs. of R-717 @ 25°F 6 12 18 24 30 36 42 48 54 60 66 72
Lbs. of R-507 @ 25°F 11 22 33 44 55 66 77 88 99 110 121 132

MODEL 4 X 8
No. of Plates 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Lbs. of R-22 @ 25°F 34 68 102 136 170 204 238 272 306 340 374 408 442 476 510 544
Lbs. of R-717 @ 25°F 17 34 51 68 85 102 119 136 153 170 187 204 221 238 255 272
Lbs. of R-507 @ 25°F 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450 480

MODEL 4 X 8
No. of Plates 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Lbs. of R-22 @ 25°F 578 612 646 680 714 748 782 816 850 884 918 952 986 1,020 1,054 1,088
Lbs. of R-717 @ 25°F 289 306 323 340 357 374 391 408 425 442 459 476 493 510 527 544
Lbs. of R-507 @ 25°F 510 540 570 600 630 660 690 720 750 780 810 840 870 900 930 960

The capacities listed above are for the plates ONLY. They do not include any manifolds or piping.

1.7 Model Number Breakdown

Plate Size ASME Manifolds

N = 3x5 A = ASME 1 = Yes
No. of Plates
L=4x8 N = Non-ASME 2 = No
3 x 5 (2–12)
4 x 8 (2–36)
Sanitary / Pan Type
Non-Sanitary 1 = High Flow
Cabinet Model Cabinet /
1 = Sealed Edge 2 = Low Flow
(If overflow is located Plate Material
under front door) 2 = Non-Sealed Edge Refrigerant / Control Type 3 = Extra Low
1 = 304 / 304
Flow
A = Tankless A = R-22 / DX 2 = 304 / 316L
J = 293 (2–8 4 x 8) B = R-404A, R-507A / DX 3 = 316L / 316L
K = 525 (9–16 4 x 8) C = R-134A / DX 4 = 304 / 304 EP
L = 750 (17–24 4 x 8) D = R-717 / DX 5 = 304 / 316L EP
M = 1,113 (25–32 4 x 8) E = R-22 / Flooded 6 = 316L / 316L EP
N = 173 (2–8 3 x 5) F = R-404A, R-507 / Flooded 7 = Other
O = 365 (2–8 3 x 5) G = R-134A / Flooded
H = R-717 / Flooded
I = R-22 / Recirculated
Cabinet Model J = R-404A, R-507 / Recirculated
(If overflow is located K = R-134A / Recirculated
on the side of chiller) L = R-717 / Recirculated
I = Tankless M = Glycol
J = 361 (2–8 4 x 8) N = Other
K = 706 (9–16 4 x 8)
L = 1,084 (17–24 4 x 8)
M = 1430 (25–32 4 x 8)
N = 150 (2–8 3 x 5)
O = 345 (2–8 3 x 5)

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 6 Revised June 6, 2017
 SECTION 2.0 – INSTALLATION

2.1 Inspection

It is important to inspect the chiller and parts for any damage when it is received. Note the damage on the bill of
lading and file a claim immediately if needed. It is very difficult to obtain claims if the damage is not noted on the
bill of lading with the driver’s signature.

Open all packages and check against the bill of lading for shortages of parts. This allows you to order them
immediately, before actual installation time.

2.2 Location and Leveling the Chiller

A. Location

The chiller should be located in a position as close as practical to the process and to the refrigeration units. A
drain should be close by for draining the chiller.

When selecting a location for the Mueller falling film chiller, disassembly for cleaning and the possible future
addition of more vertical evaporator plates should be considered. To take full advantage of the chiller’s “easy-
clean” feature, a 3' clearance should be left on each side of the chiller and a clearance equal to the length of the
evaporator plate should be left at the end (opposite refrigeration connections).

B. Leveling

The falling film chiller is equipped with adjustable legs for leveling. The chiller must be level for proper operation
of the distribution pan and to maintain an even film flow over the vertical evaporator plates. Leveling also
provides for complete drainage of the holding tank.

A carpenter’s level placed on the top edge of the distribution pan in both directions or on the top edge of the
water storage tank will place the chiller at the proper pitch.

2.3 Obtaining Parts

Before going to the installation site, it will save time if you make a list of parts you need that are not furnished
with the chiller. The following is a list you may wish to use as a guide. The quantity, size, and type will vary with
each installation.

A. Refrigeration

• Liquid line tubing.

• Suction line tubing.
• Reducers.
• Elbows (if elbows are used, we recommend the long, radius type).
• Refrigerant (R-22, R-404A, R-507, etc.).
• Hangers and brackets to support refrigerant lines or water lines.
• Support stands (if compressors are to be stacked or wall-mounted).
• Insulation: Due to evaporator temperatures, the lines will sweat excessively. It will be necessary to cover
refrigerant lines.
• Liquid line solenoid valve (if necessary).

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 7 Revised June 6, 2017
 2.3 Obtaining Parts (Continued)

B. Water Lines

• Chilled water line (see Table 2.13 for recommended chilled water line size).
• Adapter, tri-clamp to pipe thread. The 2" is Mueller Part No. 9840758; the 3" is Mueller Part No. 9840759;
the 4" Mueller Part No. is 9819684; and the 6" Mueller Part No. is 9841439.
• Fittings: Elbows, tees, unions, valves, adapters, etc.
• Circulating pump.
• Flow switch. Please call for sizing.
• Overflow line, 3⁄4" PVC.
• Propylene glycol will be required if the cooling water is to be operated below 34°F.

2.4 Locating Refrigeration Units

Air flow (for air-cooled condensing units only): There are several factors to consider when locating the
refrigeration units; the most important is air flow. Whether located inside or outside, it is absolutely necessary
that the condenser have a supply of unrestricted fresh air. When units are located inside, it is very important that
the louvers be at least the same dimension as the condensing unit face.

• An exhaust fan or opening large enough to prevent any increase in static pressure must be provided.

• The units must be located so that routine maintenance can be accomplished (cleaning the condensers,
replacing the compressors, etc.).

• Avoid areas with machines that would create dust or oil.

2.5 Connecting the Refrigerant Lines

• Do not use tubular fittings that are smaller in diameter than the connections on the condensing unit or a
flow restriction will result. Use practical refrigeration practices for refrigerant line sizes.

• Use long radius fittings and do not bend tubing in a manner that will cause it to flatten.

• Always clean and debur all fitting and tubing ends before soldering and purge with nitrogen.

• After soldering is complete, pressurize the tubing and leak test before evacuating and insulating the lines.

SAFETY/ALERT: EPA Statement on hydrochlorofluorocarbon (HCFC): A substance that is released

into the environment, HCFC contributes to a serious public health and environmental problem by
depleting the ozone layer. Ozone layer depletion increases the risk of skin cancer and other diseases
in humans and is harmful to plant and animal life. This equipment shall be serviced and disposed of
only in accordance with EPA Section 608 Regulations and the Ozone Depleting Substances
Regulation (Clean Environment Act.) N.B.

2.6 Liquid Line Solenoid Valve

The Mueller condensing unit is designed to start and stop based on water temperature. It is not designed as a
pump-down system. In some cases it may be necessary to install a liquid line solenoid valve to prevent
refrigerant migration during down time. The solenoid should be wired to close upon compressor shut down and
open when the compressor restarts. Contact points are provided on the Mueller condensing unit to connect a
customer-supplied solenoid valve.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 8 Revised June 6, 2017
 2.7 Water Line Connections

• The water connections on the falling-film chiller will be male pipe thread or tri-clamp fittings with an adapter
to male pipe thread.

• A short length of flexible hose must be used between the pump and chiller outlet to prevent damage to the
outlet due to vibration.

• We recommend you mount the pump reasonably close to the chiller with a gate-type valve on both the
inlet and outlet of the pump so it can be isolated for servicing.

• A flow switch can be installed in the pump discharge line. It should be wired to shut the refrigeration units
off and activate an alarm if the cooling solution flow should stop for some reason.

• If the chilled water is to be routed to more than one piece of equipment, a balancing valve must be used to
regulate the flow of water to each piece of equipment. It may be more effective to use a second pump for
the additional equipment.

• It is recommended to insulate the chilled water lines or they will drip condensate at lower operating
temperatures.

• If PVC plastic pipe is used with solutions containing propylene glycol, the manufacturers’ of PVC or CPVC
pipe recommend that Schedule-80 purple primer and Schedule-80 gray adhesive be used. The following
procedure should be used to assemble PVC or CPVC:

a. Scour primer into the surface with a hard bristle brush. It should be alternately applied to the surface of
the pipe once and to the fitting socket twice.

b Solvent cement should be applied with a hard bristle brush while the primer is wet. It should be
alternately applied to the surface of the pipe twice and to the fitting socket once.

IMPORTANT: Galvanized pipe should not be used for applications with propylene glycol, as propylene
! glycol can strip the zinc coating from galvanized pipe.

2.8 Make-Up Water Valve

An optional water make-up valve is available (see separate instructions).

There may be an increase in volume due to condensation if the unit is operated without the splash covers in
place or if the unit is operated with chilled water at very low temperatures.

2.9 Connecting the Overflow Line

This line should be installed with PVC pipe and must have a continuous pitch to the drain, as any trapping may
prevent drainage of this line.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 9 Revised June 6, 2017
 2.10 Mueller Multi-Stage Cooling Control

If you purchased the Mueller multi-stage cooling and pump control, please reference the multi-stage manual for
install and setup procedures.

A crucial step in the installation of the multi-stage is the location of the temperature sensors. A rise in water
temperature inside the chiller’s distribution pan is going to turn on Stage 1 and the condensing unit. The most
efficient way to accomplish this is sense the temperature entering the pan. Sensor A should be installed in the 1⁄2"
FPT port between the water make-up valve and the chiller distribution pan connection. See Figure 3,
“Temperature Sensors.” Sensor B should be located in the 1⁄2" FPT port on the process pump connection under
the chiller door. Sensor B is use for only referencing the temperature inside the chiller reservoir.

Figure 3: Temperature Sensors

OVERFLOW

2.11 Setting Chiller Recirculation Flow and Water Make-Up Flow

After your temperature and pump controls are installed it is time to set the water flows. The flows are important
for several reasons. When the two flows meet in the chiller’s distribution pan they create the blended
temperature that was used to size the chiller. If the blend temperature is not correct, the chiller will not operate
properly. The two flows account for a depth of water inside the chiller’s distribution pan that directly affects the
speed at which the water will flow down the evaporator plates. The idea behind the falling film chiller is that
when the chiller calls for make-up water, the sensor sees the rise in temperature as the water enters the pan.
Immediately the refrigeration unit turns on, cooling the water down to the designed temperature in one pass
across the evaporator plates. These flows can be regulated by flow control setters or a manual valve that can be
set and maintain the set position. For inches of water in the distribution pan versus flows, please see Section 2.10
or call Paul Mueller Company Refrigeration Products Service Department at 1-800-683-5537.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 10 Revised June 6, 2017
 2.12 Distribution Pan Water Flow Rates

Water Flow Rate (GPM) Per Plate vs. Height of Water in Pan
Distribution Pan Plate
Description Size 1" 1.25" 1.5" 1.75" 2" 2.25" 2.5" 2.75" 3" 3.25" 3.5" 3.75" 4" 4.25" 4.5" 4.75"
High Flow 3' x 5' 14.7 17.8 19.8 21.1 22.3 23.5 24.6 25.5 26.3 27.4 28.2 29
Low Flow 3' x 5' 9.1 9.9 10.7 11.3 11.9 12.5 12.9 13.5 13.9 14.3
Extra Low Flow 3' x 5' 5.8 6.4 6.75 7.2 7.45 7.8 8.15 8.4 8.65 8.95
High Flow 4' x 8' 31 33.3 35.8 37.6 39.3 40.5 42.4 43.5 44.8 46.5 47.8 48.8 50.2
Low Flow 4' x 8' 17.9 19.3 20.5 21.8 22.6 23.6 24.5 25.3 26.3 27.2 27.8 28.7
Extra Low Flow 4' x 8' 8.3 9.2 10 10.6 11.3 11.9 12.5 13 13.4 13.9 14.3 14.6 15.2 15.5

2.13 Recommended Chilled Water Line Size

Recommended Suction Line Size Recommended Discharge Line Size

Maximum Velocity Maximum Velocity
Line Size Flow (gpm) (ft/sec) Line Size Flow (gpm) (ft/sec)
3" 70 3.04 11⁄2" 60 10.5
4" 120 3.02 2" 100 10.1
6" 260 2.89 3" 220 10.1
8" 450 2.89 4" 400 10.5
10" 700 2.85 6" 850 10

TECHNICAL NOTES:
1. Maximum velocity recommended on the suction line to the circulator pump is 2–3 FPS.
2. Maximum velocity recommended on the discharge line and through the plate heat exchanger is 7–10 FPS.

2.14 Cleaning the System

It is very important that the system be cleaned before the reservoir is filled. This will retard the growth of algae
which could result in fouling of the distribution pan.

Before filling the reservoir with water, you should follow the cleaning procedures as follows:

1. Remove all dirt, paper, and any other debris that accumulated during shipment and installation.

2. Fill the reservoir with 30-50 gallons of water and operate the circulating pump with the refrigeration
compressor turned off. Check all liquid solution piping and components for leaks.

3. After confirming that the system has no leaks, drain the reservoir and proceed with the outlined cleaning
procedure.

4. Fill the reservoir with approximately 50 gallons of 160°F water and 8 pounds of high-quality trisodium
phosphate. (Mix trisodium phosphate with water before pouring into reservoir.)

5. Operate the circulating pump for 30 minutes with the refrigeration unit(s) off. During this time, brush the
inside of the reservoir to clean the areas that are not submerged.

6. Drain the wash solution and fill with 30–50 gallons of lukewarm rinse water.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 11 Revised June 6, 2017
 2.14 Cleaning the System (Continued)

7. Operate the circulating pump for 10 minutes while manually rinsing the reservoir walls that are not
submerged.

8. Drain the rinse water and fill the reservoir to within 8" of the top with deionized or distilled water. Do not use
softened water from a standard water softener as there is an increased possibility of chloride corrosion to
the stainless steel evaporator or remote, secondary plate heat exchanger.

2.15 Test Running

After the refrigeration and water piping has been completed, the flows are set, all the electrical connections have
been made, both water temperature sensors are installed, and the system has been cleaned, it is time to test run
the system.

Start the circulating pump. When it is determined that the chilled-water system is operating properly, start the
refrigeration system(s) and check the set points of the refrigeration units as described in Section 3.

2.16 Chlorine Gas Rusting

IMPORTANT: In rare cases it is possible for chlorine gas to escape from the water as it passes over the
! falling film chiller. When this occurs you will see red rust begin to form inside the chiller on the areas
that are not constantly wet.

The use and regular maintenance of a charcoal filter on the incoming city water will remove most of the chlorine
from the water before it enters the chiller and help to prevent this from occurring.

If filtering the water is not possible, venting the cabinet will also eliminate the chlorine gas. Venting can be
accomplished by installing a fan in the top of the chiller and an air intake in the lowest point possible at the other
end. This cross flow of air will remove the gas from the interior of the chiller.

If it is necessary to clean the chiller due to rusting, a #2 metal conditioner is recommended.

Contact Paul Mueller Company at 1-800-683-5537 for further technical assistance and recommendations.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 12 Revised June 6, 2017
 SECTION 3.0 – CONDENSING UNIT SET-UP/START-UP PROCEDURES

3.1 Head Pressure Control Valve Adjustment

The head pressure control valve is required to maintain stable head pressure when the outdoor ambient
temperature falls. This condensing unit has an adjustable control, which is factory set at 120 psig. The setting is
increased by turning the adjusting stem clockwise, and decreased by turning it counterclockwise. Approximately
15–20 psi change in head pressure results from one complete turn of the adjusting stem. This adjustment should
be made during low-ambient conditions. Refer to the table below for condensing temperatures vs. pressure.

Head Pressure (psig)

Condensing
Temperature R-134A R-22 R-404A R-507
70 71 121 149 154
80 87 144 176 180
90 104 168 210 204
100 124 196 244 237
110 146 226 281 272
120 171 260 322 312

3.2 Plate Superheat Adjustment

De-energize the hot gas solenoid valve and the liquid injection solenoid valve so they do not interfere with the
plate superheat adjustment.

The evaporator plate superheat should be adjusted with a product temperature higher than what the final
design product temperature requires. With a 34°F final product temperature, the superheat should initially be
adjusted with a product temperature of 50°F. The superheat should be adjusted at the expansion valves located
on the liquid line of the evaporator plate. Take a pressure measurement at the suction Schrader valve located on
the suction header. Measure the temperature at the expansion valve suction bulb location. Set the superheat at
12°F to 13°F, which is a little high because of the 50°F product temperature. As the product temperature pulls
down, the superheat should drop down to around 8°F to 10°F. If not, make final adjustments as the product
temperature continues to drop.

3.3 Hot Gas Adjustment

Energize the hot gas solenoid valve keeping the liquid injection solenoid valve de-energized. As the product
temperature approaches 36°F, measure the suction pressure at the compressor. When the suction pressure
reaches approximately 48 psig, adjust the hot gas valve to raise the suction pressure back up to about 51 psig.
(This corresponds to a 27°F evaporator temperature for R-22. Refer to temperature-pressure charts for other
refrigerants.)

IMPORTANT: As you make the hot gas adjustments, observe on the compressor superheat. The
! superheat of the compressor will increase while you are hot-gassing since there is not any liquid
injection at this time. The compressor could over heat. (Do not allow the compressor’s superheat to
get above 40°F. You can also monitor the compressor discharge temperature, not allowing it to
exceed 200°F.) The compressor superheat adjustment will be discussed in step 3.4.

3.4 Liquid Injection Adjustment

Energize the liquid injection solenoid valve. Check the superheat at the suction line at the compressor. Open or
close the liquid injection expansion valve to adjust the superheat at the compressor to 20°F to 25°F. This should
result in a compressor discharge temperature below 200°F.

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 13 Revised June 6, 2017
 3.5 Ambient Fan Cycling Control Adjustment

With all fans running, the condensing temperature will range from 15 to 20 degrees above the outdoor ambient
temperature. If the resulting head pressure is too low for proper system operation, it can be raised by cycling
fans off and on in response to changes in the outdoor ambient temperature. Fan cycling thermostats should be
adjusted according to the number of condenser fans as follows:

Ambient Fan Control Setting (°F)

No. of Minimum
Condenser Fans Fan No. 1 1 Fan No. 2 or 42 Fan No. 3 Outdoor Ambient
701 N/A N/A N/A 75
2 or 42 N/A 75 N/A 62
3 N/A 67 75 52

1Fan No. 1 is closest to the header end.

2Four fan units are duplex design and fans are cycled in pairs.

Figure 4: Condensing Unit Schematic

IMPORTANT: The condensing unit schematics are for operational reference only. Please contact Paul
! Mueller Company’s Refrigeration Products division for unit specific schematics.

CONDENSER
SUB COOLER
SECONDARY LOOP
THROUGH THE
HEAD PRESSURE CONDENSER
HOT GAS REGULATING VALVE
COMPRESSOR
SOLENOID
VALVE
CR0059
RECEIVER
INLET/OUTLET
SHUT-OFF
VALVES

HEAD PRESSURE
DISCHARGE BYPASS REGULATING VALVE
VALVE

HOT GAS RECEIVER

VALVE
SUCTION
FILTER

MOISTURE/LIQUID
LIQUID LINE
ACCUMULATOR INDICATOR
FILTER DRIER
HEAT EXCHANGER SIGHT GLASS

TO EVAPORATOR

LIQUID
LIQUID INJECTION
INJECTION SOLENOID
VALVE VALVE

FROM EVAPORATOR

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 14 Revised June 6, 2017
 Figure 5: Wiring Schematic

LEGEND
C1 Compressor Contactor
C1–1 Auxiliary Contact on C1
CCH1 Crankcase Heater
F1 Condenser Fan Motor Fuse
F4 Control Circuit Fuse (Primary)
FCT Fan Cycling Thermostat
HGPS Hot Gas Pressure Switch
HGS Hot Gas Solenoid
HP High Pressure Contacts (Dual Pressure Control)
LIS Liquid Injection Solenoid
M1–M2 Condenser Fan Motors
MDS1 Main Disconnect Switch
OPSS Oil Pressure Safety Switch
PD Pump Down Contact (Dual Pressure Control)
PDS Pump Down Switch
PS Pressure Switch
R1 Control Relay
TF1 Control Transformer
Identifies Terminal Blocks
Factory Wired
Field Wired

Mueller Falling Film Chiller Installation Instructions Effective February 12, 2003
Part No. 9843514 15 Revised June 6, 2017
1600 West Phelps Street • Springfield, Missouri 65802, U.S.A.
Phone: 417-575-9000 • 800-MUELLER • Fax: 800-436-2466
www.paulmueller.com • Email: [email protected]
©2003–2017 Paul Mueller Company 9843514