AEC PCA SERIES, Operation And Installation Manual

Page 1: ...OPERATIONANDINSTALLATIONMANUAL PCASERIES0 5 1 5hp AIRCOOLED PORTABLEWATERCHILLERS IMPORTANT PLEASEREADCAREFULLYBEFOREATTEMPTINGTOINSTALL OR OPERATE EQUIPMENT 3000...

Page 2: ...illers AEC Inc is committed to a continuous program of product improvement Specifications are subject to change without notice AEC Inc 2008 All Rights Reserved Effective 4 29 2008 Part Number A0537986...

Page 3: ...working on equipment It is a good idea to remove the fuses and carry them with you Make sure the chiller is properly GROUNDED before switching power on When welding or brazing in or around this equipm...

Page 4: ...ages 1 7 If the Shipment is Not Complete 1 8 If the Shipment is Incorrect 1 9 Returns 2 Chiller Installation 13 2 1 Electrical Connections 2 2 Process Water Connections 2 3 PCA Condenser Air Supply 2...

Page 5: ...e 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...

Page 6: ...Glycol Curve 16 Figure 7 Overhead Piping 17 Figure 8 PCA Component Identification 20 Figure 9 Piping Schematic 1 Pump with Reservoir 21 Figure 10 Piping Schematic 1 Pump Without Reservoir 22 Figure 1...

Page 7: ...2 Necessary Documents The following documents are necessary for the operation installation and maintenance of AEC Inc s PCA Series Chillers Additional copies are available from AEC Inc Familiarize the...

Page 8: ...nch 5 cm swivel casters add mobility to the PCA unit CPR Valve A crankcase pressure regulating CPR valve is available for leaving water temperatures up to 75 F 24 C 1 5 Uncrating Your New Chiller PCA...

Page 9: ...The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill Advise AEC Inc regarding your wish for replacement 1 7 If the...

Page 10: ...Page 10 PCA Series Chillers 1 9 Returns IMPORTANT Do not return any damaged or incorrect items until you receive shipping instructions from AEC Inc...

Page 11: ...E ADJUSTED FOR INTERNAL BY PASS PCA100 PROCESS PUMPS SELECTIONS PER MINUTE LITRES PER MINUTE U S GALLONS 24 12 18 40 35 80 49 37 52 120 69 160 MTRS TOTAL HEAD PSI FEET 6 1 1 6 7 6 2 0 9 1 2 4 10 6 2 8...

Page 12: ...0 249 kW 60 HERTZ PUMP CURVE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS PCA PROCESS PUMP CI CENTRIFUGAL PER MINUTE LITRES PER MINUTE U S GALLONS MTRS TOTAL HEAD PSI FEET 8 2 3 11 4...

Page 13: ...onnection Amp Draw 230 1 60 Dimensions inches Operating Weight Shipping Weight Number Btuh Btuh gpm hp inches NPT Running L W H lbs lbs PCA 050 8 100 4 800 1 2 1 2 1 3 hp 1 2 gpm 24 psig 3 4 8A 20 26...

Page 14: ...he chiller s nameplate rating 2 2 Process Water Connections All external chilled water connections to the process must be of adequate size See Figure 7 on page See 17 for sizing recommendations The la...

Page 15: ...m the chiller Do not put the PCA unit where steam hot air or fume exhausts will be drawn into the condenser Air cooled condensers must be cleaned frequently Neglect reduces capacity increases operatin...

Page 16: ...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 Figure 6 Ethylene Glyc...

Page 17: ...tem drains into the reservoir To prevent this install a check valve in the unit TO PROCESS line and a vacuum breaker at the high point of the return FROM PROCESS line See Figure 7 below for more infor...

Page 18: ...ocess and enters the reservoir tank The process water is pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle A chilled water bypass assemb...

Page 19: ...electro mechanical safety feature that prevents compressor suction pressure from dropping below a preset point It is factory set to open the control circuit when pressure drops below a safe level The...

Page 20: ...Page 20 PCA Series Chillers Figure 8 PCA Component Identification...

Page 21: ...End of unit piping Liquid line Suction Line Tank Vent Fill glass Sight Process From To P Evaporator Pump Power element Equalizing line Discharge line Bypass Refrigeration access valve Relief valve Ai...

Page 22: ...Refrigeration Compressor Pump Optional CPR valve evacuation valve Refrigeration Low control pressure access valve Refrigeration control pressure High Discharge line Equalizing line Power element Evap...

Page 23: ...igeration control pressure High Discharge line Refrigeration evacuation valve Equalizing line Power element Evaporator Suction line TC Probe S Bypass Process Air cooled condenser Liquid line Filter ga...

Page 24: ...led water TO PROCESS and FROM PROCESS connections should be completed 4 Be sure the reservoir tank and chilled water circuit piping are filled with water 5 The air cooled condenser should have an adeq...

Page 25: ...lons per minute Liters per minute P psig P kPa PCA050 2 0 7 5 2 5 17 3 2 4 9 0 4 0 27 6 3 6 13 6 7 5 51 8 4 8 18 1 12 5 86 2 PCA100 2 0 7 5 2 5 17 3 2 4 9 0 2 5 17 3 3 6 13 6 3 0 20 7 4 8 18 1 5 0 34...

Page 26: ...the Up Arrow button to raise the set point Press the Down Arrow button to lower the set point 5 3 LED Indicators PV or Process Value Numeric LED During normal operation the large red PV LED on the co...

Page 27: ...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 C below the set point This 2 F C control set point is factory set...

Page 28: ...F C above the set point This 2 F C control set point is factory set for proper compressor operation Changing it is not recommended without consulting the AEC Service Department 5 4 Temperature Contro...

Page 29: ...e control PID to process requirements Activate the Auto Tune function whenever the process under control changes Don t be alarmed by control response It may take the process temperature above and belo...

Page 30: ...d 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 commun...

Page 31: ...refrigeration service technician for service LOW REFRIGERANT PRESSURE red This indicator lights if the refrigerant pressure drops below a safe level The compressor will stop and remain off until the p...

Page 32: ...Page 32 PCA Series Chillers Figure 13 Optional Graphic Panel OFF ON PRESSURE LOW REFRIGERANT POWER ON PUMP COMPRESSOR ON Portable Chiller REFRIGERANT PRESSURE HIGH A0537868 PC Series ON AL O RO E5CS...

Page 33: ...using 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 accum...

Page 34: ...er On ON OFF 1L1 1L2 1L1 1L2 1L1 1L2 2 Control power 1PS 2PS 1 1 1CNTL RED YEL Type K Thermocouple Subpanel ground 1C 1T1 1T2 1MTR Pump 2C 2T1 2T2 Compressor 230V 115V Jumper 1 6 1 2 1 7 1 3 1 8 1 4 1...

Page 35: ...tor G 1S 1LT G Power On ON OFF 1L1 1L2 1L1 1L2 2 Control power 1PS 1PS 2PS 1 1CNTL RED YEL Type K thermocouple Subpanel ground 1C 1T1 1T2 1MTR Compressor 230V 115V Jumper 6 2 7 3 8 4 9 5 10 ground Ear...

Page 36: ...Page 36 PCA Series Chillers Notes...

Page 37: ...s compressor cycles at short intervals No process load on the chiller Increase the process load Refrigerant is low Check the refrigerant charge The leaving water temperature is too high Refrigerant is...

Page 38: ...nser air obstruction Defective fan motor Repair or replace Compressor internal overload is open Allow time to cool and reset Check for high low voltage Must be within plus or minus 10 of the nameplate...

Page 39: ...ermocouple 8 A0539409 150 VA Transformer A0103778 Rubber Feet A0537900 Tank Sight Glass Assembly A0537908 Handles A0537915 PCA050 100 Low Refrigerant Pressure Switch A0543063 PCA150 Low Refrigerant Pr...

Page 40: ...Page 40 PCA Series Chillers Notes...

Page 41: ...PCA Series Chillers Page 41 Notes...

Page 42: ...Page 42 PCA Series Chillers Notes...

Page 43: ...439 5655 AEC has a qualified service department ready to help Service contracts are available for most AEC products www acscustomerservice com Sales Department Call 847 273 7700 Monday Friday 8am 5pm...