$3000 OPERATIONANDINSTALLATIONMANUAL PCA SERIES 0.5 – 1.
AEC, Inc. is committed to a continuous program of product improvement. Specifications are subject to change without notice. Effective 4-29-2008 Page 2 © AEC, Inc. 2008 All Rights Reserved Part Number A0537986 Bulletin: AE2-615A.
Safety Considerations AEC, Inc. PCA Series Chillers are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating or maintaining this equipment, use good judgment and follow these safe practices: * * * * * * * * * * * Follow all SAFETY CODES. Wear SAFETY GLASSES and WORK GLOVES.
Table of Contents 1 General Information ................................................. 7 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 2 Chiller Installation .................................................. 13 2-1 2-2 2-3 2-4 2-5 3 Electrical Connections Process Water Connections PCA Condenser Air Supply Water Reservoir Overhead Process Considerations Sequence of Operation ..........................................
Table of Contents 4 Startup Checklists .................................................. 23 4-1 4-2 4-3 4-4 5 Microprocessor Control......................................... 25 5-1 5-2 5-3 5-4 5-5 5-6 6 Indicator Lights Switches Routine Maintenance ............................................. 32 7-1 7-2 8 Introduction Setting the Process Water Temperature LED Indicators Temperature Controller Keys Auto-Tuning PCA Series Chillers Optional Communications Optional Graphic Panel......................
Charts and Figures Figure 1: PCA050 Process Pump Curves ..................................................................................... 11 Figure 2: PCA100 Process Pump Curves ..................................................................................... 11 Figure 3: PCA150 Process Pump Curves ..................................................................................... 11 Figure 4: PCA Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW).........................................
1 1-1 General Information Introduction AEC, Inc.'s PCA Series Water Chillers are reliable, accurate, and easy-to-use air cooled chillers designed for use with water/glycol. Standard range of operation is 30°F (-1°C) to 65°F (18°C) for applications using glycol and 45ºF (7ºC) to 65°F (18°C) for wateronly applications. A crankcase pressure regulating valve option is available for processes requiring a leaving water temperature of up to 75°F (24°C).
1-4 Available Options PCA Series Chillers are available with options that tailor the unit to your requirements. Some are factory installed, some can be retrofitted in the field. Consult your local AEC, Inc. Sales Representative. Some of these options are: Special Pumps Special pump options are available for greater pressure and flow rates. Bronze and stainless steel wetted surface standard flow pumps ranging from 30 psi (207 kPa) to 60 psi (414 kPa) are available.
1-6 In the Event of Shipping Damages IMPORTANT! According to the contract terms and conditions of the Carrier, the responsibility of the shipper ends at the time and place of shipment. The Carrier then assumes full responsibility of the shipment. ; Notify the transportation company's local agent. ; Hold the damaged goods and packing material for the examining agent's inspection. Do not return any goods to AEC, Inc. before the transportation company inspection and authorization.
1-9 Returns IMPORTANT! Do not return any damaged or incorrect items until you receive shipping instructions from AEC, Inc.
Figure 1: PCA050 Process Pump Curves PCA 050 - PROCESS PUMPS SELECTIONS TOTAL HEAD MTRS PSI FEET 49 69 160 37 52 120 24 35 80 12 18 40 U. S. GALLONS PER MINUTE LITRES PER MINUTE 60 HERTZ PUMP CURVE BZ050A BZ050C BZ050B 0.4 0.8 1.2 1.6 2.0 2.4 2.8 3.2 3.6 4.0 4.4 4.8 1.5 3.0 4.5 6.1 7.6 9.1 10.6 12.1 13.6 15.1 16.7 18.
Figure 4: PCA Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW) PCA - PROCESS PUMP: CI CENTRIFUGAL TOTAL HEAD MTRS PSI FEET 15 22 50 14 19 45 60 HERTZ PUMP CURVE Cast Iron 18.3 43 13.5 U. S.
Figure 5: PCA Series Chiller Specifications Optional gauge package Optional gauge package Power cable entrance, either side Side cover handle Sight glass Drain plug (3/4" NPT) PUMP PRESSURE Mini Chiller PC Series Portable Chiller No Flow indicator (for pumpless units only) ON PUMP ON COMPRESSOR ON LOW REFRIGERANT PRESSURE To Process (3/4" NPT) HIGH REFRIGERANT PRESSURE POWER OFF A0537868 NO FLOW 34" Application Engineering 18 7/16" From Process 13 7/16" (3/4" NPT) Rear View Optional Caster
2 2-1 Chiller Installation Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms. See Figure 5 on page 13 for total running amps. Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the main power terminal in the chiller's electrical enclosure.
Process Water Bypass All PCA chillers have an internal bypass device (patent pending). If the process flow becomes blocked during chiller operation, this component allows water to flow through the chiller. This protects the chiller from freeze-up, excessive pressures, and pump damage, and allows other safety features to remain effective. 2-3 PCA Condenser Air Supply PCA chillers use the surrounding air to cool the condenser. ; Condenser air entering the PCA unit should be at least 65°F (18°C).
; A corrosion inhibitor suitable for the materials in the system should be added to the glycol/water solution. ; If straight water use is desired, contact the AEC, Inc. Engineering Department. ; The six gallon (23 liter) reservoir is not designed to withstand water pressure above 5 psi (34 kPa). ; The fill opening and vent line must be vented to the atmosphere for proper operation.
2-5 Overhead Process Considerations If your application has chilled water or process piping above the reservoir fill and vent level, install a standpipe to a point 1’ (30 cm) above the highest point in the system. In applications where the process or its piping is 15 feet (4.6 m) or more above the reservoir, you must take steps to prevent over-pressurization of the reservoir. This condition can occur on system shutdown when the water in the system drains into the reservoir.
3 Sequence of Operation IMPORTANT! • The PCA unit has a leaving water temperature range of 30°F (-1°C) to 65°F (18°C). Do not attempt to run the PCA unit outside this temperature range or damage to the unit may occur. • When operating the PCA unit between 30°F (-1°C) and 40°F (5°C), you must use a solution of 75% water and 25% industrial-grade ethylene glycol with a suitable corrosion inhibitor to protect the PCA unit from freeze-up. See Figure 6 on page 16 for more information.
3-3 High Pressure Cutout The high pressure cutout is an electro-mechanical safety feature that opens the control circuit if the system condensing pressure exceeds a safe level. The chiller will automatically restart when the pressure drops back to an acceptable level. Model PCA050 PCA100 PCA150 Cuts out if condensing pressure exceeds: 275 psi (1,897 kPa) 275 psi (1,897 kPa) 400 psi (2,759 kPa) IMPORTANT! Call a refrigeration service technician to analyze the problem if high pressure recurs.
Figure 8: PCA Component Identification Page 20 PCA Series Chillers
Figure 9: Piping Schematic - 1 Pump with Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Suction Line Expansion valve Evaporator Filter Drier Sight glass Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Equalizing line Power element Refrigeration access valve Temperature probe TC High pressure control S Optional pressure gauge P To Process Low pressure control By
Figure 10: Piping Schematic - 1 Pump Without Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Suction line Expansion valve Evaporator Equalizing line Sight glass Filter drier Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Power element Refrigeration access valve Temperature probe High pressure control TC Compressor Refrigeration access valve, compressor-mounted Pu
Figure 11: Piping Schematic - No Pump, No Reservoir Air-cooled condenser Discharge line Liquid line Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter Suction line Expansion valve Evaporator Sight glass Filter drier Legend Refrigeration lines Chilled water piping Condenser water piping End of unit piping Equalizing line Power element Refrigeration access valve Optional pressure gauge Temperature Probe High pressure control TC P S Low pressure control To Process B
4 4-1 Startup Checklists Introduction Follow the check lists below for the startup of your new chiller. These lists assume the installation information elsewhere in this manual has been read and followed. New chillers should be started up and checked by a qualified refrigeration service technician. 4-2 PCA Pre-Startup Checklist 1. Check the shipping papers against the serial tag to be sure chiller size, type and voltage is correct for the process that will be controlled. 2.
4-4 PCA Water Circuit Pressure Drop Table Model PCA050 PCA100 PCA150 Gallons per minute 2.0 2.4 3.6 4.8 2.0 2.4 3.6 4.8 2.0 2.4 3.6 4.8 PCA Series Chillers Liters per minute 7.5 9.0 13.6 18.1 7.5 9.0 13.6 18.1 7.5 9.0 13.6 18.1 ΔP (psig) 2.5 4.0 7.5 12.5 2.5 2.5 3.0 5.0 2.5 2.5 3.0 3.5 ΔP (kPa) 17.3 27.6 51.8 86.2 17.3 17.3 20.7 34.5 17.3 17.3 20.7 24.
5 5-1 Microprocessor Control Introduction Standard PCA Series chillers use a microprocessor-based PID controller. The controller is a modular, self-contained unit that can slide from its mounting housing. It is factory set and adjusted; no field adjustment to the internal controls is necessary.
Figure 12: Typical PCA Series E5CK Microprocessor Controller PV OUT1 SV OUT2 MANU STOP RMT AT SUB1 AT OMRON E5CK OUT2 LED The orange OUT2 energizes whenever the process temperature is two degrees (2°F/ºC) or more above the To Process set point. The compressor then comes on and runs until the temperature at the To Process thermocouple is two degrees (2°F/ºC) below the set point. This +2°F/ºC control set point is factory-set for proper compressor operation.
RMT LED The orange RMT LED is lit during remote operation. AT LED The orange AT LED flashes during auto-tuning. SUB1 LED The orange SUB1 LED energizes whenever the process temperature is two degrees (2°F/ºC) or more below the To Process set point. The compressor then shuts down by means of a latching circuit, and does not run again until the temperature at the To Process thermocouple is two degrees (2°F/ºC) above the set point. This +2°F/ºC control set point is factory-set for proper compressor operation.
Important! Do not change any of the control settings without consulting the AEC Service Department. The AEC, Inc. warranty does not cover chiller failures from tampering with controller settings! Down Key Each press of the Down Arrow key decrements or reduces the values or settings on the SV display. Up Key Each press of the Up Arrow key increments or advances the values or settings on the SV display.
5-6 Optional Communications Standard Omron Protocol The communications function allows you to monitor and set E5CK parameters by a program prepared and running on a host computer connected to the E5CK controller. When using the communications function, you must add on the unit for RS-232C or RS-485 communications. The E5CK communications function allows you to read/write parameters, do operating instructions, and select the setting level.
6 6-1 Optional Graphic Panel Indicator Lights PUMP ON (green) This indicator lights when the pump is running. COMPRESSOR ON (green) This indicator lights when the compressor is operating. HIGH REFRIGERANT PRESSURE (red) This indicator lights if the condensing pressure exceeds a safe level. The chiller goes to Idle mode until the high refrigerant pressure cutout resets. The light then goes out and the chiller automatically restarts. Call a qualified refrigeration service technician for service.
Figure 13: Optional Graphic Panel PC Series ON Portable Chiller ON PUMP ON AL O RO E5CS COMPRESSOR ON LOW REFRIGERANT PRESSURE HIGH REFRIGERANT PRESSURE POWER OFF A0537868 Page 32 PCA Series Chillers
7 Routine Maintenance 7-1 Lubrication Every three months, grease all fan motors and pump motors that do not have permanently sealed bearings. Remove grease relief plug (motors only) before adding grease. Failure to do so may result in dislodging the bearing grease retainer, eventually causing bearing failure. Compressors are hermetically sealed; no oiling is required. 7-2 Condenser Maintenance Dirty condenser heat exchange surfaces reduce system capacity. Brush or vacuum light dirt accumulations.
Figure 15: Typical PCA Wiring Schematic 1C 1L1 1T1 1L2 1MTR Pump 2MTR Compressor 3MTR Fan 1T2 2C 1L1 2T1 1L2 2T2 3T1 Earth ground 3T2 Remote interlock by others 1L2 1L1 230V Control power ON/OFF 1S-1LT 1T Jumper 1 1FU X1 1 115V 2 G 3 1 1S-1LT G R 4 1 1PS "Hi Refrig Pres" 3LT R G 5 1 2PS G 1 7 1 8 1 9 1 2 1 3 1 "Pump On" 61 Condensing unit contactor 2C 5LT "Compressor On" 1 10 Jumper 1CNTL 2LT 4LT G 6 1 "Power On" Pump starter 1C "Low Refrig Pres" Su
Figure 16: PCA Wiring Schematic for Chillers with No Pump or Reservoir 1C 1L1 1L2 1L2 1MTR Compressor 2MTR Fan 1T2 1L1 2T1 Remote interlock by others Earth ground 1T1 2T2 230V Control power ON/OFF 1T Jumper 1S-1LT 1 1S 1FU 2 2 115V X1 G 31 "Low Refrig Pres" 3LT R "No Flow" R 4 1FLS 2LT 5 5 1PS 1S-1LT Subpanel ground "Power On" "High Refrig Pres" 4LT R 6 2PS 7 Condensing unit contactor 1C G 5LT "Compressor On" 2 Legend 6 7 8 9 10 Jumper 1 (+) YEL 2 3 Custo
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8 Troubleshooting Guide Problem Chiller will not run. Cause No power. Wrong voltage supplied to the chiller. Defective on/off switch. Control circuit fuse blown. Pump runs, compressor cycles at short intervals. Defective control transformer. No process load on the chiller. Refrigerant is low. The leaving water temperature is too high. Refrigerant is low. Improper water/glycol solution. Pump pressure is low (see pump curves). Pump pressure is too high.
Problem Pump runs, compressor will not. Cause Refrigerant is low. Pressure switch contacts are open. Refrigerant high pressure cutout switch contacts are open. Defective fan motor. Compressor internal overload is open. Allow time to cool and reset. Unit runs continuously, but not enough cooling power. Page 38 Broken wire in the compressor control circuit. Restricted condenser airflow. Unit low on refrigerant. Inefficient compressor. Unit undersized for application.
PCA Unit Parts List Part Number A0537868 A0537899 A0534584 A0534586 A0500857 A0534269 A0537955 A0533873 A0539409 A0103778 A0537900 A0537908 A0537915 A0543063 A0537916 A0537917 A0501642 A0104093 A0537974 Part Description PCA Graphic BZ Pressure Gauge Red Neon Graphic Light * Green Neon Graphic Light * 2” Swivel Casters 1/16 DIN Digital Temperature Controller Process Water Flow Switch Thermocouple, 8’ 150 VA Transformer Rubber Feet Tank Sight Glass Assembly Handles PCA050-100 Low Refrigerant Pressure Switch
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Technical Assistance Parts Department Call toll-free 7am - 5pm CST [800] 423-3183 Or call [847] 273-7700, Fax [847] 273-7812 The Parts Department at AEC, Inc. is ready to provide the parts to keep your systems up and running. AEC replacement parts ensure operation at design specifications. Please have the model and serial number of your equipment when you call.
