Pneumatech Refrigerated Water Chillers

PCA-200 – PCA-2000 Instruction Book 9829 2106 91 February 2014

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PCA Series Refrigerated Water Chillers PCA-200 to PCA-2000 Instruction Book Original Instructions Copyright Notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings. No. 9829 2106 91 February 2014 www.pneumatech.com

DATE OF PURCHASE MODEL SERIAL NO.

Record above information from nameplate. Retain this information for future reference.

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TABLE OF CONTENTS

General Information 3 Receiving 3 Safety Instructions 3

Installation & Operation 4

Installation Instructions 4 General 5 Start-Up and Operation 6 Operating Conditions 7 Electronic Temperature Controller 7

Maintenance 8

General 8

Troubleshooting 9

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GENERAL INFORMATION This Pneumatech Refrigerated System is designed to chill water. When properly installed, the unit requires little maintenance or adjustment.

WARNING

DO NOT install, operate, maintain, adjust or service this unit without thoroughly reading this manual.

This manual contains important safety information. Read THOROUGHLY and follow the Safety Instructions provided in this manual and posted on the unit. Keep this manual near the unit and in a safe place. Replace this manual if it becomes torn or dirty and cannot be properly used. Please read the Installation & Operation section of this manual before attempting to operate the unit. Please read the Maintenance and Troubleshooting sections of this manual before beginning any maintenance or service work on this unit. RECEIVING – INSPECTION Inspect equipment. Any concealed shipping damage must be reported to the carrier immediately. Damage claims should be filed by the consignee with the carrier. All the equipment shipped F.O.B. Houston, TX becomes the property of the purchaser. In all cases of damage, visible or suspected, contact your local distributor or Pneumatech before attempting to install equipment.

SERVICE INQUIRIES: Provide Model No., Serial No., Operating Pressure, Inlet Temperature, Nature of Problem. See Chiller Specification Tag located on the control panel.

SAFETY INSTRUCTIONS When using water chillers and associated accessories, basic safety rules and precautions must always be followed, including the following. 1. READ ALL INSTRUCTIONS FULLY.

2. WIRING & BREAKERS

Wiring, breakers and other electrical equipment must conform to local and national electrical codes. Do not operate this unit with damaged wiring or after the unit or air handling parts have been dropped or damaged in any manner. Notify authorized service facility for examination, repair or other adjustments.

WARNING

Comply with the National Electrical Code, Federal, State and Local Codes when installing or operating this unit.

3. USE SUITABLE PARTS & ACCESSORIES

Do not use pressurized accessories or parts in the system not suitable for the maximum pressure used. Be sure maximum pressure specified by the accessory manufacturer is well above the working pressure of your compressor

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INSTALLATION & OPERATION INSTALLATION INSTRUCTIONS

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GENERAL A. Install the water chiller in an area where the

ambient temperature will be above 55°F and below 100°F. Ambient temperatures below 55°F and above 100°F will cause erratic operation of the water chiller. CAUTION 1. Operation of the chiller with water temperature

below 40°F requires glycol to be added to the system to prevent system freeze-up. FAILURE TO COMPLY WILL VOID THE WARRANTY.

2. Operation of the chiller with ambient temperatures below 32°F requires glycol to be added to the system, or heat tracing of all water lines and chiller barrel to prevent freeze-up. FAILURE TO COMPLY WILL VOID THE WARRANTY.

B. Position the chiller to permit free circulation of cool air through the panel. Keep (2) feet minimum clearance space around the chiller, and also on the top for servicing. Do not install the chiller against the wall on the condenser air intake side. If the room doesn’t have proper ventilation, the chiller should be relocated or duct the outside air in to the condenser. Consult factory for the details. Lack of ventilation can build up the room temperature by recalculating the same air through the condenser over and over again for cooling. This will eventually shut down the refrigeration compressor on high head pressure and/or on internal overload.

C. Make sure when piping is in place that no undue stress is placed on chiller fittings. Union joints or flexible connections are recommended to relieve stress. Also properly support the pipes as needed with hangers or brackets.

D. Connect cooling water lines to the water-cooled

chillers from the city water supply or the cooling

tower as specified on the chiller specifications. Chillers are specifically piped for each application. Field conversions are possible from one to the other. Do no connect city water to a condenser which is piped for tower water or vice versa. Strainers are recommended at the water inlet to the condenser. Proper chemical treatment is recommended for cooling tower water to avoid scaling and sludge inside the condenser.

E. To fill the chiller system with water or glycol, open

all the coin vents to purge the air. Once all the air is purged, close the coin vents and check the water pump instructions for proper pump priming.

F. Connect power lines as per the nameplate power

supply requirements to the electrical terminals. The refrigeration chiller is designed to run continuously; therefore, it must be wired separately from the heat source to prevent cycling. All units are pre-wired internally. Follow the recommendation on the electrical drawing for the fuse size and the incoming power details. Connect the power to the chiller only through proper fused disconnect switches. Wiring to the chiller should meet the national and local code requirements. Check the voltage specified on the nameplate to the electrical power connected to the dryer.

CAUTION

Do not reduce pipe sizes connected to air, water and/or drain lines. They should be the same or larger than sizes supplied on the chiller.

G. Turn the on/off switch momentarily and check the water pump rotation. Check the water pump rotation per the rotation arrow on the pump housing, or check the water pump instructions. If the pump rotation is not correct, reverse two primary leads.

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START-UP & OPERATION The non-cycling design of the refrigerant chiller assures proper temperature control at all load conditions. The refrigerant compressor and condenser fan run continuously when the chiller is “on”. Chillers with multiple fans are installed with fan cycling switches. These fans will cycle with respect to the load changes, ambient temperature fluctuations, and the cleanliness of the condenser. Units are designed to operate under the following conditions:

Maximum entering water temperature: 85°F Maximum entering water pressure: 75 PSIG Ambient air temperature: 55°F to 100°F

Water chillers with (3) phase power supply are equipped with a compressor crankcase heater. This heater must be energized by closing the disconnect switch a minimum of (6) to (10) hours before start-up. Power can be left on to energize the crankcase heater for off-cycle, during weekend or evening shut-downs.

CAUTION Starting the chiller without energizing the crankcase heater will cause premature failures on the refrigeration compressor. Failure to comply with this procedure of energizing crankcase heater before start-up may void warranty.

Check the temperature on the crankcase of the compressor to make sure the crankcase heater is working before starting the chiller. Check the individual data sheet and the wiring diagram to identify the chillers with crankcase heaters. Generally single phase chillers units do not have crankcase heaters installed. REFRIGERANT SUCTION AND DISCHARGE PRESSURE RANGES SUCTION PRESSURE

Refrigerant-134a 28 to 47 PSIG Refrigerant-22 53 to 84 PSIG Refrigerant-404a 70 to 105 PSIG

DISCHARGE PRESSURE

Refrigerant-134a 70 to 150 PSIG Air-cooled models without fan cycling Refrigerant-134a 75 to 170 PSIG Air-cooled models with fan cycling Refrigerant-134a 90 to 120 PSIG Water-cooled models Refrigerant-22 155 to 260 PSIG Air-cooled models without fan cycling Refrigerant-22 135 to 275 PSIG Air-cooled models with fan cycling Refrigerant-22 190 to 220 PSIG Water-cooled models Refrigerant-404a 185 to 315 PSIG Air-cooled models with fan cycling Refrigerant-404a 235 to 250 PSIG Water-cooled models

Start the chiller by turning the on/off switch to the “on” position. The amber light will be “on” and the chiller is running. The suction pressure will come down to the proper range with respect to the type of refrigerant used in the water chiller. For initial start-up, it may take several minutes before the suction and discharge pressures reach the proper operating ranges. If the suction pressure gauge is reading zero, it means loss of refrigerant charge. Call the factory for service.

The red high temperature light will come “on” when the refrigeration compressor is not running. The reasons can be low suction pressure, high discharge pressure, electrical problems, loss of refrigerant, dirty condenser, leaking chiller, etc. Troubleshoot the chiller as per the chart. If that is not solving the problem, call the factory.

CAUTION

Contact the factory before authorizing any refrigeration servicemen to perform any work on the water chiller. Identify the water chiller with model and serial number.

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OPERATING CONDITIONS Units are designed for a maximum entering water temperature of 85°F. If the temperature of entering water is to be greater than 85°F, the factory should be consulted to determine the water chiller performance.

CAUTION

The increased heat content of higher temperature water requires the chiller to be oversized to prevent overloading of the refrigerant compressor.

The allowable ambient temperature range is 55°F to 100°F. At temperatures below 55°F frost or icing may develop and at temperatures above 100°F refrigeration capacity will decrease. ELECTRONIC TEMPERATURE CONTROLLER (PETC) The Electronic Temperature Controller (PETC) maintains precise water temperature. Set Point Instructions 1. Press the SET key to get into the program mode. 2. Select “F” or “C” for the Fahrenheit or Celsius scale by pressing the arrow key. 3. Press the SET key again to set the compressor unloader, (SP1), temperature set point by pressing

the arrow keys. The factory set point is 60°F. 4. Press the SET key again to set the differential to 2 by pressing the arrow keys. 5. Press the SET key again to set the mode to C1 by pressing the arrow keys. 6. Press the SET key again to set the water outlet set point, (SP2), temperature set point by pressing

the arrow keys. The set point is 36°F. 7. Press the SET key again to set the differential to 5 by pressing the arrow keys. 8. Press the SET key again to set the mode to C1 by pressing the arrow keys. 9. Press the SET key again to read the actual chilled water temperature.

Note: The SP1 and SP2 set points are adjustable. Consult factory before adjusting. Operation The Electronic Temperature Controller senses the chilled water temperature in the tank. Once the water temperature reaches one degree below the set point, PETC activates the refrigeration control valve to maintain the set point temperature. In the process of controlling, actual water temperature may fluctuate 1 or 2 degrees +/- to the set point.

CAUTION

Do not set water temperatures below 45 degrees. Freezstat should be set 36 or above to avoid system freeze-up.

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MAINTENANCE GENERAL The chiller is factory tested before shipping. All the safety controls are calibrated for automatic operation. If the chiller is installed in a clean surrounding, with the temperature limits of the specified ambient, the chiller will run trouble-free for a very long time. Routine maintenance procedures recommended are the following:

1. Check the fan motors for proper operation to

maintain the cooling air to be drawn through the condenser and blow it over the refrigeration compressor. If the chiller is equipped with condenser ambient filters, check and replace as needed to maintain the proper airflow through the condenser. Plugged up ambient filters will reduce the airflow through the condenser, and thus tripping the compressor “off” on overload.

2. Clean the condenser periodically to maintain the proper heat transfer on the condenser coil. Dirty condenser will raise the head pressure of the refrigeration system and eventually shut off the compressor. Running the compressor on high head pressures may cause premature failures. Check the ambient temperature limits to be maintained at the installation.

3. Check and clean water-cooled condensers for

dirt, scale and sludge build-up every year or as needed. Cooling tower water condensers may need cleaning more often if the water is not properly treated with chemicals.

4. Check the suction pressure gauge to be within

the specified range after a few minutes after start-up. Suction pressure below the range will cause freeze-up inside the water system.

5. Check the pressure drop across the water chiller

at full flow capacity. If it is higher than specified valve (normally 5 PSI), back-flush the chiller with any MILD DETERGENT. To back-flush, plug the drain line and ill the water system with the detergent. Hold it for 4-6 hours. Circulate the detergent from water outlet to water inlet with a pump. Flush the system with warm water. If pressure drop still exists, contact factory.

COMPRESSOR Refrigeration compressors normally do not need any maintenance. The compressor will unload or adjust for different load conditions with the refrigeration controls. Any time the power is coming to the compressor, and the suction pressure is higher than the specified readings, the compressor is either not pumping or failed electrically, or tripped “off” on the overload protection. If the compressor is not resetting within a few minutes, it needs servicing. Use a qualified refrigeration mechanic for servicing the expansion valve. EXPANSION VALVE All water chillers come equipped with an automatic expansion valve. These valves are factory adjusted for the proper cooling. The valve adjusting stem is secured to hold the calibration with a locknut in the factory. Larger units are equipped with a thermostatic expansion valve, factory set to maintain a super heat of 8° F to 10° F . These valves do not need any periodic adjustment in normal operation. Generally, super heat adjustments are needed only at the time of valve replacement. For any servicing on the expansion valves, use a qualified refrigeration mechanic. HOT GAS BYPASS VALVE All water chiller come equipped with modulating hot gas bypass valves. This valve maintains the refrigerant suction pressure in varying load conditions. The chiller can be running from ‘no’ load to ‘full’ load conditions without freeze-up. The operation of this valve is automatic. If the valve needs adjustment, turn the adjusting stem clockwise to raise the suction pressure, and counterclockwise to lower the suction pressure. When the adjustment is done, turn one quarter of a turn at a time, and wait 3 to 5 minutes between adjustments. Once the adjustment is complete, secure the adjusting stem with a locknut. Check the suction pressure gauge with a calibrated manifold gauge at the time of hot gas bypass adjustment. Careful adjustment of this valve is absolutely necessary for the normal operation of the water chiller. HOT GAS BYPASS SOLENOID VALVE Solenoid type hot gas Bypass Valves are used for precise outlet water temperature control within +/- 1°F. This valve will energize when the chilled water outlet temperature is reached. The valve will de-energize when the differential is reached. The Freeze-up/Chilled water outlet set point #1 controls this temperature.

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TROUBLESHOOTING THE FOLLOWING CONDITIONS CAN CAUSE ABNORMAL OPERATION OR MALFUNCTION OF THE WATER CHILLER

High inlet temperatures Low inlet pressures High cooling water inlet temperature Contaminated cooling water Untreated cooling water Condenser water pressure below 35 PSIG Dirty condenser High ambient temperature Low ambient temperatures Water flow over rated GPM Undersized fuses Refrigerant over charge Refrigerant under charge Leaky chiller barrel Electrical power supply more than

+/- 10% of the rated voltage

If any of these symptoms are noticed, troubleshoot the water chiller as per the following chart.

TROUBLE SHOOTING GUIDE

SYMPTOMS CAUSE REMEDY A. Unit does not run. 1. Motor line open. 1. Close disconnect switch, to start.

2. Fuse blown. 2. Replace fuse.

3. Tripped overload. 3. Turn switch off, wait 15 minutes, check for overload condition.

4. Safety controls open. 4. Repair or replace. Check freeze-up thermostat

5. Frozen (locked) compressor. 6. Repair or replace. 6. Wiring improper or loose. 7. Check wiring against diagram.

B. Unit short cycles. 1. Motor compressor overload cutting out.

1. Check for high head pressure, clogged condenser, high ambient, or air overload. Check high pressure cutout, repair or replace.

2. Shortage of refrigerant. 2. Repair leak and recharge. 3. Suction pressure low. 3. Check hot gas bypass adjust,

repair or replace. 4. Sticking expansion valve. 4. Repair or replace.

C. Compressor will not start - hums.

1. Improperly wired. 1. Check wiring against diagram. 2. Low line voltage. 2. Check voltage - correct. 3. Starting capacitor defective. 3. Replace. 4. Relay or contactor not closing. 4. Check for reason - repair or replace 5. Start winding open. 5. Check leads, of leads OK replace

motor 6. Single phasing. 6. Check fuses.

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TROUBLESHOOTING GUIDE

SYMPTOMS CAUSE REMEDY D. Compressor starts and runs - short cycles on overload.

1. Low voltage, or phase unbalance. 1. Check voltage to be within ± 10% of voltage listed on nameplate.

2. Additional current going through overload.

2. Check wiring diagram, check for added electrical devices connected through protector.

3. Overload protectors defective. 3. Check current, replace. 4. Run capacitor weak. 4. Check capacitance, replace. (Single Phase units) 5. High discharge pressure. 5. Refer to G 1-8. 6. Short in winding. 6. Check resistance, replace

compressor. 7. Current relay sticking. 7. Check floor level, tap & release. E. Relay burned out. 1. Low or high line voltage. 1. Check voltage to be within ± 10%

of voltage listed on nameplate. 2. Incorrect running capacitor. 2. Replace with proper capacitance. (Single Phase units) 3. Short cycling. 3. Refer to B and C. 4. Wrong relay. 4. Replace with proper relay. 5. Incorrect mounting. 5. Mount in correct, rigid position. F. Capacitors burn out. 1. Improper capacitor. 1. Replace with proper capacitor.

(Single Phase units) 2. High line voltage. 2. Lower voltage to not more than

10% above rating. G. Head pressure too high 1. Refrigerant overcharge. 1. Purge or vacuum and recharge.

2. Incondensable in system. 2. Check for reason, repair.

3. Dirty condenser. 3. Blow clean with compressed air.

4. Location too hot. 4. Cool ambient, relocate unit, add ventilation.

5. Defective fan pressure switch. 5. Repair or replace.

6. Defective fan motor. 6. Replace.

7. Fan operating in wrong direction. 7. Switch two wires at disconnect.

8. Defective water regulating valve. 8. Adjust, repair or replace. H. Head pressure too low 1. Refrigerant shortage. 1. Repair leak and recharge.

2. Compressor suction or discharge valves inefficient. 2. Repair or replace.

3. Defective fan pressure switch. 3. Repair or replace.

4. Defective water regulating valve. 4. Adjust, repair or replace. J. Noisy unit. 1. Mounting loose. 1. Tighten mounting, etc.

2. Bent fan blade. 2. Straighten or replace blade.

3. Fan motor bearing worn. 3. Replace.

4. Refrigerant flooding back. 4. Check expansion valve, adjust, repair or replace. Check crankcase heater.

5. Compressor oil charge low. 5. Check oil level.

K. Frosted liquid line. 1. High side service valve partially closed or restricted.

1. Open valve or remove restriction.

2. Restricted filter / dryer. 2. Replace. L. Frosted suction line. 1. Expansion valve and/or hot gas

bypass out of adjustment. 1. Adjust the hot gas bypass valve to bring the suction pressure into the proper range.

M. Top condenser coils cool when unit in operation

1. Refrigerant shortage. 1. Repair leak and recharge. 2. Compressor inefficient. 2. Repair or replace.

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TROUBLESHOOTING GUIDE SYMPTOMS CAUSE REMEDY N. Unit runs but water temperature is high.

1. Refrigerant leak. 1. Locate with leak detector. Repair or replace defective part.

2. Evaporator controls set too high. 2. Refer to L - above. 3. Filter / dryer clogged. 3. Replace. 4. Refrigerant shortage. 4. Repair leak and recharge.

5. Dirty condenser. 5. Clean condenser. NOTE: Outlet air temperature gauge may read higher than actual temperatures at low air flow conditions.

6. Incondensable in system. 6. Check reason, repair, vacuum, and recharge.

7. Compressor inefficient. 7. Repair or replace. 8. Evaporator control(s) stuck. 8. Repair as required, adjust.

9. Defective insulation. 9. Repair. 10. Water temperatures high 10. Reduce load. 11. Unit too small. 11. Add unit or replace. 12. High ambient. 12. Reduce or change location. P. Unit runs but low water pressure 1. System pressure low. 1. Increase pressure. 2. Check water pump operation 2.See water pump manual Q. Unit runs, but water flow erratic or zero.

1. Freeze-up. 1. Check suction temperature at evaporator outlet or turn off unit and allow it to thaw to determine if this is problem. Adjust controls at no-load if freezing is occurring.

2. Chiller barrel or water piping clogged.

2. Check and clean entire water system

3. Restriction in piping upstream from unit.

3. Correct as required.

R. Chiller barrel freeze-up. 1. Hot gas bypass valve out of adjustment

1. Adjust suction pressure. Adjust hot gas bypass valve.

S. Condenser fan blows outward. 1. Improper wiring at disconnect (3 phase only). 1. Reverse two wires.

www.pneumatech.com 1800 Overview Drive Rock Hill, SC 29730 Toll free 800.336.2285 Nearest Distributor: 800.336.2285 Email: info.website@pneumatech.com