HP PS-025 User's Manual
Contents
1. K The coolant flows to the process and returns to repeat the cycle M A chilled water bypass assembly between the supply and return lines guarantees a constant flow through the evaporator during intermittent low or no flow conditions 3 2 Refrigeration Circuit M Liquid refrigerant passes through the thermal expansion valve which allows the refrigerant to expand and cool the inside of the heat exchanger The refrigerant flows through the suction line to the compressor E The refrigerant gives up its heat as it re condenses to a liquid in the condenser and the cycle starts over again SEC PS QuarterHorse Series Chillers Page 15 Notes Page 16 dc O PS QuarterHorse Series Chillers aC PS 025 QuarterHorse Series 0 25 hp Portable Chiller Operation and Installation Manual Notes Page 18 dc O PS QuarterHorse Series Chillers Microprocessor Control 9 1 9 3 Introduction Standard PS Series chillers use a microprocessor based 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 Setting the Process Water Temperature e Press and hold the star key e While holding down the star key press the arrow up or arrow down key to raise or lower the process water temperature set point Power Switch POWER This switch energizes the control circuit it also turns off th2. SEC Service Department Call toll free 8am 5pm CST 800 233 4819 or call 847 273 7700 Emergencies after 5pm CST call 847 439 5655 AEC Application Engineering has a qualified service department ready to help Service contracts are available for most AEC Application Engineering products ac O Sales Department Call 847 273 7700 Monday Friday 8am 5pm CST AEC Application Engineering products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you ac Contract Department Call 847 273 7700 Monday Friday 8am 5pm CST Let AEC Application Engineering install your system The Contract Department offers any or all of these services project planning system packages including drawings equipment labor and construction materials and union or non union installations AEC Inc 1100 E Woodfield Road Suite 588 Schaumburg IL 60713 Page 26 AC O PS QuarterHorse Series Chillers AEC Inc warrants all equipment manufactured by it to be free from defects in workmanship and material when used under recommended conditions The Company s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which in the Company s opinion are defective Any replacement part assumes the unused portion of this warranty This parts wa
3. amps M Electrical connections must comply with all applicable electrical codes M The chiller must be grounded in accordance with NEC Article 250 M Voltage must be within 10 of the chiller s nameplate rating Process Water Connections M All external chilled water connections to the process must be of adequate size M See Figure 4 on Page 14 for sizing recommendations M The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment Important Keep any pressure drop in external process piping to an absolute minimum for optimum unit operation To Process Connect the TO PROCESS chilled water supply outlet to the process being cooled From Process Connect the FROM PROCESS chilled water return inlet to the return from the process back into the chiller for cooling and recirculation M This chiller model has a strainer on the FROM PROCESS return line SEC PS QuarterHorse Series Chillers Page 11 Process Water Bypass All PS chillers have an internal bypass device 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 PS Condenser Air Supply PS chillers use the surrounding air to cool the condenser M Condenser air entering th
4. 25 QuarterHorse 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 Application Engineering The PS QuarterHorse Series chiller model is designated by approximate compressor horsepower An PS025 chiller has a 1 4 hp 187 W compressor SEC PS QuarterHorse Series Chillers Page 7 1 4 Available Options PS 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 Application Engineering Sales Representative Some of these options are Power Cord A 6 foot 1 8 m power cord is available to speed PS installation Feet Four leveling feet are mounted to the base of the PS unit 1 5 Uncrating Your New Chiller PS Series chillers are shipped mounted on a skid enclosed in a plastic wrapper and open crated on all four sides and top M Pry the crating away from the skid and remove Use a pry bar to remove the blocks securing the unit to the skid M 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 M Lift slowly and only high enough to clear the skid Use a pry bar if necessary to remove the skid from the uni
5. S HANDLING REGLAIM EXTRUSION CONTRAGTING 801 AEC Drive e Wood Dale IL 60191 1198 USA 630 595 1060 e Fax 630 595 6641 http www aecinternet com
6. aC PS 025 QuarterHorse Series 0 25 hp Portable Chiller Operation and Installation Manual AEC Inc Application Engineering is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice O Copyright AEC Application Engineering and AEC Inc 2002 All rights reserved Effective 9 24 02 Page 2 ac O PS QuarterHorse Series Chillers Safety Considerations PS 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 ez M M M M K 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 i
7. e PS unit should be at least 65 F 18 C Operation with air below 65 F 18 C can cause the chiller to have low refrigerant pressure Install the chiller in an area where there is free passage of air for condensing Provide 18 46 cm or more clearance for the chiller s air intake Make provisions to exhaust the heated air discharged from the chiller Do not put the PS unit where steam hot air or fume exhausts will be drawn into the condenser N NAN A Air cooled condensers must be cleaned frequently Neglect reduces capacity increases operating costs and leads to possible chiller failure See Chapter 6 on Page 21 for cleaning instructions M Normal condensing pressure with 95 F 35 C air is approximately 180 psi 1 241 kPa PS Ambient Temperature Ranges Ambient temperature range Minimum temperature Maximum temperature 65 F 18 C 100 F 38 C 40 F 4 C 120 F 49 C 2 4 Water Reservoir During startup and when additional solution is required see Figure 3 on Page 14 for the recommended ethylene glycol water solution This chart shows the proportions needed to provide freeze protection to 20 F 11 C below the desired process set point M Add a pre mixed solution to provide freeze protection to a temperature 20 F 11 C below the normal operating temperature of the chiller M Use industrial quality not automotive ethylene glycol M A corrosion inhibitor suitable for the materials in the system shou
8. e chiller SEC PS QuarterHorse Series Chillers Page 19 Notes Page 20 AC PS QuarterHorse Series Chillers 6 Routine Maintenance 6 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 6 2 Condenser Maintenance Dirty condenser heat exchange surfaces reduce system capacity Brush or vacuum light dirt accumulations Avoid bending or damaging the fins Heavy soil accumulations on the coil require professional steam cleaning washing from the outside only makes matters worse SEC PS QuarterHorse Series Chillers Page 21 Notes Page 22 dc O PS QuarterHorse Series Chillers 7 Troubleshooting Guide Problem Possible cause Check main disconnect No power fuses wiring and power lead to the unit Voltage must be within plus Wrong voltage supplied to or minus 10 of the Chiller will not run the chiller nameplate rating Defective on off switch Control circuit fuse blown Replace check the transformer Defective control transformer Refrigerant is low Check the refrigerant charge Make sure that the coolant solution is right for the The leaving water Improper water glycol process must be 75 temp
9. erature is too high solution water and 25 glycol See Figure 3 on Page 13 for more information see pump curve Check for partially closed Pump pressure is too high Restricted water flow valves etc Be sure all lines are properly sized Check for high low voltage Compressor internal overload Must be within plus or minus is open Allow time to cool 10 of the nameplate rating and reset Check for poor compressor electrical connections Broken wire in the tdi Locate and repair compressor control circuit Restricted condenser airflow Clean the condenser r Unit low on refrigerant Call Service Unit runs continuously but Call Service not enough cooling power p Unit undersized tor Call Sales Representative application Pump runs compressor will not SEC PS QuarterHorse Series Chillers Page 23 Service Notes Page 24 dc PS QuarterHorse Series Chillers Service Notes SEC PS QuarterHorse Series Chillers Page 25 ce Parts Department Call toll free 7am 6pm CST 800 423 3183 or call 847 273 7700 The AEC Application Engineering Parts Department at AEC Inc is ready to provide the parts to keep your systems up and running AEC Application Engineering replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers
10. f 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 SEC PS QuarterHorse Series Chillers Page 3 Table of Contents 1 General Information 1 s c1ccsccscesssssesseceecseseeceecees 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 Ifthe Shipment is Not Complete 1 8 Ifthe Shipment is Incorrect 1 9 Returns 2 Chiller Installation 11 2 1 Electrical Connections 2 2 Process Water Connections 2 3 PS Condenser Air Supply 2 4 Water Reservoir 2 5 Overhead Process Considerations 3 Sequence of Operation 15 3 1 Chilled Water Circuit 3 2 Refrigeration Circuit Page 4 ac O PS QuarterHorse Series Chillers Table of Contents Startup Checklist 4 1 Introduction 4 2 PS Pre Startup Checklist 4 3 PS Startup Checklist Microprocessor Control 5 1 Introduction 5 2 Setting the Process Water Temperature 5 3 Power Switch Routine Mainte
11. ld be added to the glycol water solution Page 12 SEC PS QuarterHorse Series Chillers M If you want to use straight water contact Application Engineering s Engineering Department M The 1 gallon 3 8 liter reservoir is not designed to withstand water pressure above 5 psi 34 kPa M The fill opening and vent line must be vented to the atmosphere for proper operation Properly Venting and Filling the Reservoir Tank To properly vent and fill the tank e Remove the side panel then remove the bushing installed on the top of the tank e Install a pipe nipple and tee to the coupling on top of the tank e Use one side of the tee for the vent line and the other side for the fill line e Fill the tank e Remove the fittings and re install the bushing e Extend the vent line from the tank to a proper drain e Re install the side panel Figure 3 Ethylene Glycol Curve Ethylene glycol required for evaporator freeze protection 30 0 Ethylene ane glycol percent 10 0 Chilled water operating temperature F set point Normal operating range is between 30 F and 70 F SEC PS QuarterHorse Series Chillers Page 13 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 m
12. nance 6 1 Lubrication 6 2 Condenser Maintenance Troubleshooting Guide SEC PS QuarterHorse Series Chillers Page 5 Charts and Figures 2 PS Series Chiller Specifications 10 3 Ethylene Glycol Curve 13 4 Overhead Piping 14 Page 6 SEC PS QuarterHorse Series Chillers 1 General Information 1 1 Introduction PS Series Water Chillers are reliable accurate and easy to use air cooled chillers designed for use with water glycol Standard range of operation is 50 F to 70 F 10 C to 21 C This PS chiller is a hp 187 W model and has an internal one gallon 3 8 liter reservoir It is self contained fully assembled and shipped ready to use A properly installed operated and maintained PS 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 PS Series Chillers Additional copies are available from Application Engineering Familiarize the appropriate personnel with these documents M This manual M The electrical schematic and connection diagram M The operation and installation manuals for installed accessories and options 1 3 Models Covered This manual provides operation installation and maintenance instructions for PS 0
13. ore 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 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 4 below for more information Note The reserve capacity of the reservoir can hold a volume equal to 20 feet 6 1 m of 1 inch 2 5 cm pipe Figure 4 Overhead Piping The reservoir vent amp fill line Vent Vacuum Breaker to be piped 12 above the highest Assembly point of the system The vent line Cap must remain open to the atmosphere Process Return Strainer Process Supply Add check valve if system piping extends 15 feet above reservoir Indicates end of Application Engineering piping Page 14 SEC O PS QuarterHorse Series Chillers 3 Sequence of Operation Important The PS unit has a leaving water temperature range of 50 F to 70 F 10 C to 18 C Do not attempt to run the PS unit outside this temperature range or damage to the unit may occur 3 1 Chilled Water Circuit M Process cooling water supply and return connections are made at the pipe stubs at the rear of the chiller M Warm water returns from the process passes through the strainer and enters the reservoir tank M The process water is pumped through the evaporator where it is cooled
14. rranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the Company s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the Company s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The Company is not liable for any incidental consequential or special damages or expenses The Company s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts under this warranty is the responsibility of the purchaser The company neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of AEC Inc equipment carry an additional one year service policy Consult your AEC sales representative for specific details 801 AEC Drive e Wood Dale Illinois 60191 1198 USA Phone 630 595 1060 e Fax 630 595 6641 http www aecinternet com EC S Y 3 MATERIAL HEAT amp GOOL BLEND amp GRANULATE al AUTOMATE SYSTEM
15. t M Lower slowly The unit will land on its feet or casters and can be moved into position Page 8 SEC PS QuarterHorse Series Chillers 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 M Notify the transportation company s local agent M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Application Engineering before the transportation company s inspection and authorization M 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 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 M PS Series Chiller M Bill of Lading M Packing list M 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 Application Engineering immediately of the shortage 1 8 Ifthe Shipment is Incorrect M If
16. the shipment is not what you ordered contact Application Engineering immediately Include the order number and item M Hold the items until shipping instructions are received SEC PS QuarterHorse Series Chillers Page 9 1 9 Returns Important Do not return any damaged or incorrect items until ou receive shipping instructions from Application Engineering Figure 1 PS025 Process Pump Curve PS025 PROCESS PUMPS SELECTION A OTALHEAD 60 HERTZ PUMP CURVE 49 69 be 374 52 SE 244 35 4 80 124 184 40 LITRES PER MINUTE CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS Do not extrapolate pump curves Figure 2 PS Series Chiller Specifications PS Cap Quarter 65 F Iwt Nominal Horse 90 F chilled Process draw Dimensions Oper Ship Series ambient water Compressor connection 230 1 60 are ie EA PS 025 BTUH gpm inches NPT running L hp American 1 3 hp standards 2213 2 Ya 2 gpm 6 7A 20 26 34 50 psig Cap Quarter 18 C Iwt Nominal Amp 24 C chilled Process draw cris Oper Ship ER ES a connection 230 1 60 n a EE inches NPT running L Metric watts standards 7 6 Ipm 6 7 A 48 32 345 kPa Page 10 ac O PS QuarterHorse Series Chillers Chiller Installation 2 1 Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms See Figure 2 on Page 10 for total running
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