AEC PCA SERIES Technisches Datenblatt
OPERATIONANDINSTALLATIONMANUAL
PCA SERIES 0.5 – 1.5 hp
AIR COOLED
PORTABLE WATER CHILLERS
IMPORTANT:PLEASEREADCAREFULLYBEFOREATTEMPTINGTOINSTALL OR OPERATE
EQUIPMENT
$3000
Page 2 PCA Series Chillers
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 Bulletin: AE2-615A.5
PCA Series Chillers Page 3
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.
*Use care when LOADING, UNLOADING, RIGGING, or MOVING this
equipment.
*Operate this equipment within design specifications.
*OPEN, TAG, and LOCK ALL DISCONNECTS before 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 equipment, be sure
VENTILATION is ADEQUATE. PROTECT adjacent materials from flame
or sparks by shielding with sheet metal. An approved FIRE
EXTINGUISHER should be close at hand and ready for use if needed.
*The refrigeration system can develop refrigerant pressures in excess of 500
PSI (3,450 kPa). DO NOT CUT into the system without first relieving
pressure.
*Do not jump or bypass any electrical safety control.
*Do not restore power until all tools, test equipment etc. have been removed
and the panels replaced.
*Only PROPERLY TRAINED personnel familiar with the information within
this manual should work on this equipment.
Page 4 PCA Series Chillers
Table of Contents
1General 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
2Chiller Installation ..................................................13
2-1 Electrical Connections
2-2 Process Water Connections
2-3 PCA Condenser Air Supply
2-4 Water Reservoir
2-5 Overhead Process Considerations
3Sequence of Operation ..........................................17
3-1 Chilled Water Circuit
3-2 Refrigeration Circuit
3-3 High Pressure Cutout
3-4 Low Pressure Cutout
3-5 Remote Start/Stop Interlock
PCA Series Chillers Page 5
Table of Contents
4Startup Checklists..................................................23
4-1 Introduction
4-2 PCA Pre-Startup Checklist
4-3 PCA Startup Checklist
4-4 PCA Water Circuit Pressure Drop Table
5Microprocessor 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
6Optional Graphic Panel..........................................30
6-1 Indicator Lights
6-2 Switches
7Routine Maintenance .............................................32
7-1 Lubrication
7-2 Condenser Maintenance
8Troubleshooting Guide..........................................36
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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)......................................... 12
Figure 5: PCA Series Chiller Specifications................................................................................. 13
Figure 6: Ethylene 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 11: Piping Schematic - No Pump, No Reservoir............................................................... 23
Figure 12: Typical PCA Series E5CK Microprocessor Controller............................................... 27
Figure 13: Optional Graphic Panel............................................................................................... 32
Figure 14: Typical PCA Subpanel................................................................................................ 33
Figure 15: Typical PCA Wiring Schematic.................................................................................. 34
Figure 16: PCA Wiring Schematic for Chillers with No Pump or Reservoir............................... 35
PCA Series Chillers Page 7
1General Information
1-1 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 water-
only applications. A crankcase pressure regulating valve option is available for
processes requiring a leaving water temperature of up to 75°F (24°C). PCA models are
available in 1/2 hp (373 W), 1 hp (746 W), and 1-1/2 hp (1,118 W) models and have an
internal six gallon (23 liter) reservoir. All models are self contained, fully assembled,
and shipped ready to use.
A properly installed, operated, and maintained PCA Series Chiller will provide many
years of reliable operation. To get the most satisfaction from your new chiller, read and
follow the instructions in this manual.
1-2 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 appropriate personnel with these documents:
;This manual.
;The electrical schematic and connection diagram mounted inside the control
enclosure. Typical schematics for general reference are provided in Figure 15 and
Figure 16 on pages 34 and 35.
;The operation and installation manuals for installed accessories and options.
;The Customer Parts List included in the information packet.
1-3 Models Covered
This manual provides operation, installation, and maintenance instructions for AEC,
Inc. PCA Series Chillers.
Model numbers are on the serial tag. Please know the model number, serial number and
operating voltage of your chiller if you need to contact AEC, Inc.
PCA Series Chiller models are designated by approximate compressor horsepower. A
PCA050 chiller has a 1/2 hp (373 W) compressor, a PCA100 chiller has a 1 hp (746
W) compressor, and a PCA150 chiller has a 1-1/2 hp (1,118 W) compressor.
Page 8 PCA Series Chillers
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.
Reservoirs
PCA Series Chillers are available without a reservoir for processes that use their own
reservoir.
Power Cord
A 10 foot (3 meter) power cord is available to speed PCA installation.
Casters
Four 2 inch (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 Series Chillers are shipped mounted on a skid, enclosed in a plastic wrapper, and
open crated on all four sides and top.
;Pry the crating away from the skid and remove. Use a pry bar to remove the blocks
securing the unit to the skid.
;Lift the unit off the skid with a fork truck. Insert forks between skid and chiller from
the side until they protrude beyond the opposite side of the unit. The forks must be
equidistant from the center line of the unit and the unit must be balanced on the
forks.
;Lift slowly and only high enough to clear the skid. Use a pry bar if necessary to
remove the skid from the unit.
;Lower slowly. The unit will land on its feet or casters and can be moved into
position.
PCA Series Chillers Page 9
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.
;File a claim against the transportation company. Substantiate the claim by referring
to the agent's report. A certified copy of our invoice is available upon request. 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 Shipment is Not Complete
Check the packing list. The apparent shortage may be intentional. Back-ordered items
are noted on the packing list. You should have:
;PCA Series Chiller
;Bill of Lading
;Packing List
;Operating and Installation Packet
Re-inspect the container and packing material to see if smaller items have been missed
during unpacking. Determine that the item was not taken from the area before the
shipment was checked in. Notify AEC, Inc. immediately of the shortage.
1-8 If the Shipment is Incorrect
;If the shipment is not what you ordered, contact AEC, Inc. immediately. Include
the order number and item.
;Hold the items until shipping instructions are received.
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.
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