PCA Series Air Cooled Portable Water Chiller Operation Manual Write Down Your Serial Numbers Here For Future Reference: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________
We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice.
Chapter 1: 1-1 Safety How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining your equipment. The purpose is to assist you in applying efficient, proven techniques that enhance equipment productivity. This manual covers only light corrective maintenance. No other maintenance should be undertaken without first contacting a service engineer. The Functional Description section outlines models covered, standard features, and optional features.
Table of Contents 1 General Information .................................................7 1-1 Introduction 1-2 Necessary Documents 1-3 Models Covered 1-4 Available Options 1-5 Uncrating Your New Chiller 1-6 In the Event of Shipping Damages 1-7 If the Shipment is Not Complete 1-8 If the Shipment is Incorrect 1-9 Returns 2 Chiller Installation ..................................................
4 Startup Checklists ..................................................23 4-1 Introduction 4-2 PCA Pre-Start-up Checklist 4-3 PCA Start-up Checklist 4-4 PCA Water Circuit Pressure Drop Table 5 Microprocessor Control.........................................25 5-1 Introduction 5-2 Setting the Process Water Temperature 5-3 LED Indicators 5-4 Temperature Controller Keys 5-5 Auto-Tuning PCA Series Chillers 5-6 Optional Communications 6 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).......................................
General Information 1-1 Introduction 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 -1°C to 18°C for applications using glycol and 7ºC to 18°C for water only applications. A crankcase pressure regulating valve option is available for processes requiring a leaving water temperature of up to 24°C. PCA models are available in 373 W (1/2 hp.), 746 W (1 hp.), and 1.1 kW (1-1/2 hp.
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. 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 2.07 Bar to 4.14 Bar are available. Reservoirs PCA Series Chillers are available without a reservoir for processes that use their own reservoir.
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 Fleming Dynamics 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 Fleming Dynamics.
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(¾” BSP) (¾” BSP) (¾” BSP) (inches BSP) (inches BSP) Page | 13
2 Chiller Installation 2-1 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.
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 Fleming Dynamics Pty Ltd. The 23 litre reservoir is not designed to withstand water pressure above 34 kPa. The fill opening and vent line must be vented to the atmosphere for proper operation. Figure 6: Ethylene Glycol Curve Ethylene Glycol Required For Evaporator Freeze Protection 30% Ethylene Glycol 20% Percent By Volume 10% 0% -3.8o 1.6o 7.
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 30 cm above the highest point in the system. In applications where the process or its piping is 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 -1°C to 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 -1°C and 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 Cuts out if condensing pressure exceeds: PCA050 PCA100 PCA150 1.897 Bar 1.897 Bar 2.759 Bar IMPORTANT! Call Fleming Dynamics to arrange a service technician to analyse the problem if high pressure recurs.
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4 Startup Checklist 4-1 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 Start-up 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.
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5 Microprocessor Control 5-1 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. PCA Control Operation Range Standard models -1ºC to 18ºC 5-2 Setting the Process Water Temperature To change the process water temperature set point: • Press the Up Arrow button to raise the set point.
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. Changing it is not recommended without consulting the Fleming Dynamics Service Department. MANU LED The orange MANU LED does not light because it is not used.
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 Fleming Dynamics Service Department. The Fleming Dynamics Pty Ltd 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 RS485 communications. The E5CK communications function allows you to read/write parameters, do operating instructions, and select the setting level.
6 Optional Graphic Panel 6-1 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 cut-out resets. The light then goes out and the chiller automatically restarts. Call a qualified refrigeration service technician for service.
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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.
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Contact Details Australia Wide Phone: Australia Wide Fax: New Zealand Phone: International Phone: International Fax: Email: 1300 730 736 1300 730 739 0800 442 569 +61 2 8976 9200 +61 2 8976 9299 sales@coolpakchillers.com.au Sales NSW, QLD and New Zealand: Sales VIC, ACT, WA, SA AND TAS: Customer Service: Service: Dispatch: Tim Fleming Stuart Mackenzie Anthea Harper George Polles Paul Norman tim@fleming.net.au stuart@fleming.net.au anthea@fleming.net.au george@fleming.net.au paul@fleming.net.
