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Operation and Installation Manual
Pinnacle Series
Central Chilling Stations
Important! Read Carefully Before Attempting to Install or Operate Equipment
Part No. A0556333
Bulletin No. AE3-610
Performance figures stated in this manual are based on a standard atmosphere of 95°F
(35°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 hz power. Altitude is an
important consideration when specifying chillers with pump tanks. AEC/Application
Engineering can advise you on proper selection and sizing of systems for your
operating environment.
AEC/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.
© Copyright AEC/Application Engineering and AEC, Inc. 2002
All rights reserved.
Effective 10/3/02
Part No. A0556333
Bulletin No. AE3-610.1
Safety Considerations
AEC/Application Engineering Pinnacle Series central chillers with pump tanks 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.
; Disconnect and/or lock out power before servicing or maintaining the chiller.
; 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. You
should remove the fuses and carry them with you.
; Make sure the chiller and components are properly GROUNDED before you switch on
power.
; Do not jump or bypass any electrical safety control.
; Do not restore power until you remove all tools, test equipment, etc., and the chiller and
related equipment are fully reassembled.
; Only PROPERLY TRAINED personnel familiar with the information in this manual should
work on this equipment.
Page 2
Pinnacle Series Central Chilling Stations
Table of Contents
1
General Information ............................................................ 7
1-1
1-2
1-3
1-4
1-5
2
Shipping Information ........................................................ 17
2-1
2-2
2-3
2-4
2-5
2-6
3
Unpacking and Inspection
In the Event of Shipping Damages
If the Shipment is Not Complete
If the Shipment is Not Correct
Returns
Uncrating Your Chiller
Installation ......................................................................... 19
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
4
Introduction
Necessary Documents
Models Covered
Standard Features
Available Options
Installation Location Considerations
Electrical Connections
Piping Considerations
Process Water Connections
Tank Piping Connections
Water Connection Sizing
Galvanic Corrosion
Water Treatment
Water-Cooled Condenser Connections
Remote Air-Cooled Condenser Installation
Motor Direction Check
Sequence of Operation..................................................... 31
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
Chilled Water Circuit
Refrigeration Circuit
Freezestat Control
High Pressure Cutout
Low Pressure Cutout
Flow Switch
Control Nipple
Control Probe
Chilled Water Manifold
Condenser Water Manifold
Pinnacle Series Central Chilling Stations
Page 3
Table of Contents
5
Startup Checklists............................................................. 35
5-1
5-2
5-3
5-4
5-5
5-6
5-7
6
Graphic Panel .................................................................... 41
6-1
6-2
7
Page 4
Touchscreen Interface Introduction (MMI)
Using the Pinnacle Touchscreen Interface
Getting Started on the Pinnacle Touchscreen Interface
Operating Chiller Station Pumps
Viewing System Statuses and Handling Alarm Conditions
Operating Chiller Station Compressors
Viewing Current Pump Pressures
Setting and Viewing System Temperatures
Viewing Current System Capacities
Routine Maintenance ........................................................ 65
8-1
8-2
8-3
8-4
8-5
8-6
8-7
9
Indicator Lights
Switches
Using the Touch Screen Interface ................................... 49
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
8
Introduction
Water-Cooled Pinnacle Startup Checklist
Water-Cooled Pinnacle Startup
Remote Air-Cooled Pinnacle Startup Checklist
Remote Air-Cooled Pinnacle Startup
Determining Flow Rate
Shutdown
Lubrication
Condenser Maintenance
Evaporator Maintenance
Pump Motor Seal
Makeup Valve
Recommended Pump Tank Spare Parts
Preventive Maintenance Service
Troubleshooting................................................................ 69
Pinnacle Series Central Chilling Stations
Charts and Figures
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Typical Pinnacle Two-Circuit Central Chilling Station,
Top View and Front View
11
Pinnacle Water-Cooled Two-Circuit Central Chilling Station Specifications
Pinnacle Remote Air-Cooled Two-Circuit Central Chilling Station
Specifications
Typical Pinnacle Three-Circuit Central Chilling Station,
Top View and Front View
12
Pinnacle Water-Cooled Three-Circuit Central Chilling Station Specifications
Pinnacle Remote Air-Cooled Three-Circuit Central Chilling
Station Specifications
14
Pinnacle Remote Condenser Assembly Models
15
Pinnacle Remote Condenser Specifications and Configurations
15
Pinnacle 60 Hz 5 to 15 hp P1 Pump Curves
24
Pinnacle 60 Hz 20 to 40 hp P1 Pump Curves
25
P2 Recirculation Pump Curves
26
Evaporator Pressure Drops
27
Condenser Pressure Drops
28
Typical Remote-Air Cooled Condenser Piping Installation
29
One Circuit, Process/Standby Two Pump Piping Schematic
30
Freezing Protection Curve
32
Pinnacle Graphic Panels
40
12
13
14
Typical Water-Cooled Pinnacle Electrical Schematic, Drawings 1 and 2
44-45
Typical Remote Air-Cooled Pinnacle Electrical Schematic, Drawings 1 and 2
46-47
Typical Pinnacle Subpanel Layout
48
Pinnacle Control Panel
49
Pinnacle Touchscreen Flow Chart
50
Recommended Spare Parts List
70
Pinnacle Series Central Chilling Stations
Page 5
1
General Information
1-1
Introduction
AEC/Application Engineering Pinnacle Series central water chilling stations are available in
water-cooled and remote air-cooled designs. They differ only in the condensing media used.
Pinnacle units can be configured with two or three independent circuits using multiples of 15 ton
(45,360 Kcal/hr.) compressors for each circuit. This manual lists information for two-circuit and
three-circuit Pinnacle units.
Pinnacle chilling stations include stainless steel pump tanks for use as reservoirs for chilled water
processes. These dual-well models hold hot and cold water before and after it is pumped through
the chiller. Tanks have recirculation pump(s) to send return water to the chiller and process
pump(s) to pump cooled water directly to process. Standby pumps may be utilized to distribute
pump service or to allow uninterrupted chiller operation during pump maintenance.
Properly installed, operated, and maintained Pinnacle chilling stations 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
These documents are necessary for the operation, installation, and maintenance of
AEC/Application Engineering Pinnacle chilling stations. Additional copies are available from
AEC, Inc. Make sure that the appropriate personnel get familiar with these documents:
•
This manual.
•
The schematic and connection diagram in the control enclosure.
•
Operation and installation manuals for accessories and options selected by the customer.
•
The Customer Parts List included in the information packet.
1-3
Models Covered
Model numbers are listed on the serial tag of the chiller. A -Q following the model number
indicates a specially constructed unit; not all information in this manual may apply. Make sure
that you know the model number, serial number, and operating voltage of your chilling station if
you need to contact AEC, Inc.
Page 6
Pinnacle Series Central Chilling Stations
Pinnacle chiller models are designated by the number of refrigeration circuits, total compressor
horsepower of all circuits (30 through 90), and the cooling method used. Remote air-cooled
models are designated PINN2-xxR and water-cooled models are designated PINN2-xxW. For
example, a two-circuit remote air-cooled Pinnacle with two 15 hp scroll compressors is
designated as PINN2-30R.
1-4
Standard Features
Your Pinnacle central chilling station comes standard with the following features:
•
High-efficiency scroll compressors
•
Off-the-shelf PLC control with NEMA 4 color touch screen interface (MMI)
•
Integral SS 304L stainless steel reservoir
•
Stainless steel brazed plate evaporator
•
Process and recirculation pumps
•
NEMA 12 electrical enclosure
•
High and low refrigerant pressure safeties
•
Touch-safe branch circuit fusing
•
Pre-piped water circuit
•
Two-way water regulating valve (water-cooled models)
•
Cleanable shell and tube condenser(s) (water-cooled models)
•
Remote condenser(s) with variable speed lead fan and fan cycling (remote air-cooled
models)
•
Digital low temperature freezestat
•
Liquid line solenoid and shut-off valves
•
Chilled water flow switches
•
Insulated tank cover
•
Automatic water makeup valve
•
AEC Warm Gray and black paint
•
1 year warranty on parts and labor
•
3 year warranty on controller
•
Y-strainer on recirculating water system
Pinnacle Series Central Chilling Stations
Page 7
Standard Features on Remote Condensers
•
Direct-drive 3-phase fan motors are 1½ hp (1.12 kW) at 1,140 rpm with ball bearings and
internal overload protection; variable speed fan motor is 1 hp (0.75 kW), 1-phase
•
Electronic variable-speed control of lead fan and fan cycling for constant condenser head
pressure control
•
Fans are 30” (76 cm) in diameter and have PVC-coated steel fan guards; 1½ hp (1.12 kW)
variable-speed fans are 26” (66 cm) in diameter
•
Internal baffles between fan cells
•
UL listed in the United States and Canada
•
Patented floating tube coil to eliminate tube sheet leaks
•
Copper tube condenser coils have corrugated aluminum fins
•
Weather-proof control panel with factory-mounted door interrupt switch
•
High-efficiency condenser coil, designed for optimum performance
•
Aluminum housing provides corrosion protection for outdoor applications
1-5 Available Options
Pinnacle units are available with options to tailor the unit to your requirements. Some are factory
installed, some can be retro-fitted in the field. Contact your AEC sales representative for more
information.
Operating Voltages
Pinnacle chillers are available configured for the following operating voltages:
•
208 V to 230 V / 3 phase / 60 Hz
•
380 V / 3 phase / 50 Hz (derate capacity by multiplying by 0.83)
•
460 V / 3 phase / 60 Hz
•
575 V / 3 phase / 60 Hz
Advanced Control Package
The Advanced Control package includes a flow meter on process pumps with volumetric flow
rate displayed through touch screen control interface. The package also provides compressor
lead-lag, which lets you use the touch screen control interface to enter the rotation schedule you
want (from 100 hours to 500 hours) for the lead refrigeration circuit. Pumps include this same
feature when standbys are ordered. Pressure transducers provide a digital display of discharge
and recirculation pump manifold pressures.
Note: The temperature profile displays a graph of leaving water temperature (LWT) over time.
Page 8
Pinnacle Series Central Chilling Stations
Pressure Gauges
Liquid filled compound dual scale pressure gauges are available for all pumps.
Tank Sight Glass
The 30” (76 cm) tank sight glass includes isolation valves.
Non-Fused Disconnect
The non-fused disconnect provides convenient means for local power disconnection.
Special Voltages
Pinnacle units voltages include a re-rated 380/3/50.
General Fault Alarm with Elevated Light Stack
This general fault alarm offers an elevated light stack mounted on top of the NEMA 12
enclosure. It displays a red light for any system fault and green light for STATUS O. K. The
lights provide convenient system observation from a distance.
Push the Push to Silence button on the control panel to silence the alarm horn. The red lights on
the door and the light stack remain illuminated until the operator corrects the alarm condition.
Pinnacle Series Central Chilling Stations
Page 9
Figure 1
Typical Pinnacle Two-Circuit Central Chilling Station
Top View
3" flange to tower
(water-cooled only)
3" flange from tower
(water-cooled only)
Water regulating valve
(water-cooled only)
30" (76 cm)
recommended
clearance
3" NPT
overflow
Tank cover
Return
(From Process)
Water makeup
float valve
70"
178 cm
Flow sensor
(optional)
3" flange supply
(To Process)
30" (76 cm)
recommended
clearance
110"
279 cm
60" (152 cm)
recommended
clearance
Front View
Optional general fault alarm
with elevated light stack
Y-strainer
with ball valve
Replaceable core
filter/dryer
Condenser
(water-cooled only)
Optional
sight glass
Color touch screen
Electrical enclosure
Single point
electrical connection
17 1/2"
(44.5 cm)
30" (76 cm)
recommended
clearance
Optional
disconnect
3" flange supply,
To Process
71" (180 cm)
approx.
overall
Optional compound
pressure gauge
68"
36.7 cm
Drain: 1 1/2"
gate valve
30" (76 cm)
recommended
clearance
Page 10
Evaporator
Compressor
P1
pump
Optional
P1 pump
P2
pump
Optional
P2 pump
Pinnacle Series Central Chilling Stations
Figure 2
Pinnacle Water-Cooled Two-Circuit Central Chilling Station Specifications
American Standards
Chilled
water
Model
Capacity
EER d Refrigflow
no.
tons c Stages Btuh/w
erant
gpm
PINN2-30W
28
2
15.9 HCFC-22
67
PINN2-45W
42
3
15.9 HCFC-22 101
PINN2-60W
57
4
15.9 HCFC-22 137
Cond. Cond.
P2
P1
To proc.
water conn.
Tank pump pump connection
flow Class 150 Tank gal. std. std.
Class 150
gpm
flange
matrl. oper. hp
hp
flange
84
3”
SS 304L 500
1½
5
3”
126
3”
SS 304L 500
2
7½
3”
171
3”
SS 304L 500
3
10
3”
Metric Standards
Chilled
water
Model
Capacity
EER d Refrigflow
no.
Kcal/hr c Stages Btuh/w erant
lpm
PINN2-30W 84,672
2
15.9 HCFC-22 253
PINN2-45W 127,008
3
15.9 HCFC-22 382
PINN2-60W 172,368
4
15.9 HCFC-22 518
Cond. Cond.
water
conn.
Tank
flow Class 150 Tank liters
lpm flange e matrl. oper.
317
3”
SS 304L 1,892
476
3”
SS 304L 1,892
647
3”
SS 304L 1,892
P2
pump
std.
kW
1.12
1.49
2.24
P1
To proc.
pump connection
std. Class 150
kW
flange e
3.73
3”
5.59
3”
7.46
3”
c Capacities rated at 50ºF (10ºC) leaving water temperature, 2.4 gpm per ton with 85ºF (29ºC) condenser supply
water. Capacities are not adjusted for pump heat.
d As published by compressor manufacturer. Conditions may vary, depending on operating temperature and
ambient conditions.
e Metric dimension is approx. 76 mm. Customer is responsible to convert to metric.
Water-Cooled Dimensions, Weights, Amp Draw Values
Dimensions
Weights c
Model
L
W
H
Dry
Operating
Shipping Amp draw values @ 460/3/60
no.
in. cm in. cm in. cm lbs.
Kg
lbs.
Kg
lbs.
Kg
FLA d
RLA running
PINN2-30W 70” 178 110” 280 71” 181 6,645 3,017 10,800 4,904 7,145 3,244
59
41
PINN2-45W 70” 178 110” 280 71” 181 7,410 3,365 11,565 5,251 7,910 3,592
87
60
PINN2-60W 70” 178 110” 280 71” 181 8,475 3,848 12,630 5,734 8,975 4,075
115
79
c Weights do not include pumps.
d Amp draw values do not include P1 pump.
Pinnacle Series Central Chilling Stations
Page 11
Figure 3
Pinnacle Remote Air-Cooled Two-Circuit Central Chilling Station Specifications
American Standards
Model
Capacity
no.
tons c
PINN2-30R
26
PINN2-45R
39
PINN2-60R
53
EER d RefrigStages Btuh/w
erant
2
12.4
HCFC-22
3
12.4
HCFC-22
4
12.4
HCFC-22
Cond.conn.
Tank P2 pump P1 pump To proc. conn.
Class 150
Tank
gal.
std.
std.
Class 150
flange
matrl. oper.
hp
hp
flange
3”
SS 304L 500
1½
5
3”
3”
SS 304L 500
2
7½
3”
3”
SS 304L 500
3
10
3”
Metric Standards
Model
no.
PINN2-30R
PINN2-45R
PINN2-60R
Capacity
EER d RefrigKcal/hr c Stages Btuh/w
erant
78,624
2
12.4
HCFC-22
117,936
3
12.4
HCFC-22
160,272
4
12.4
HCFC-22
Cond. conn.
Class 150
flange e
3”
3”
3”
Tank
matrl.
SS 304L
SS 304L
SS 304L
Tank P2 pump P1 pump To proc. conn.
liters
std.
std.
Class 150
oper.
kW
kW
flange e
1,892 1.12
3.73
3”
1,892 1.49
5.59
3”
1,892 2.24
7.46
3”
c Capacities rated at 50ºF (10ºC) leaving water temperature, 2.4 gpm per ton with 95ºF (35ºC) ambient supply air.
Capacities are not adjusted for pump heat.
d As published by compressor manufacturer. Conditions may vary, depending on operating temperature and
ambient conditions.
e Metric dimension is approx. 76 mm. Customer is responsible to convert to metric.
Remote Air-Cooled Dimensions, Weights, Amp Draw Values
Dimensions
Model
L
W
H
Dry
no.
in. cm in. cm in. cm lbs.
Kg
PINN2-30R 70” 178 110” 280 71” 181 6,037 2,741
PINN2-45R 70” 178 110” 280 71” 181 6,641 3,015
PINN2-60R 70” 178 110” 280 71” 181 7,545 3,426
c Weights do not include pumps.
d Amp draw values do not include P1 pump.
Page 12
Weights c
Operating
lbs.
Kg
10,192 4,627
10,796 4,902
11,700 5,312
Shipping Amp draw values @ 460/3/60
lbs. Kg
FLA d
RLA running
6,537 2,968
59
47
7,141 3,242
87
69
8,045 3,653
115
91
Pinnacle Series Central Chilling Stations
Figure 4
Typical Pinnacle Three-Circuit Central Chilling Station, Top View
Water regulating valve
(water-cooled units only)
30" (76 cm)
recommended
clearance
4" flange from tower
(water-cooled units only)
4" flange to tower
(water-cooled units only)
Tank cover
4" NPT
overflow
Return
(From Process)
Water makeup
float valve
90"
228 cm
Flow sensor
(optional)
To Process supply
flange (3" flange on
3-75 models, 4" flange
on 3-90 models)
30" (76 cm)
recommended
clearance
60" (152 cm)
recommended
clearance
120"
305 cm
Front View
30" (76 cm)
recommended
clearance
Replaceable core
filter/dryers
Condenser
(water-cooled
models only)
General fault alarm with
elevated light stack (optional)
Y-strainer
with ball valve
Sight
glass
(optional)
Color touch screen
Electrical enclosure
Single point
electrical connection
17 1/2"
(44.5 cm)
Disconnect
(optional)
4" NPT
overflow
To Process supply
flange (3" flange on
3-75 models, 4" flange
on 3-90 models)
88"
approx.
overall
Compound pressure
gauge (optional)
Drain: 1 1/2"
gate valve
Evaporator
Compressor
P1
pump
P2
P1
pump
pump
(optional)
P2
pump
(optional)
30" (76 cm)
recommended
clearance
Pinnacle Series Central Chilling Stations
Page 13
Figure 5
Pinnacle Water-Cooled Three-Circuit Central Chilling Station Specifications
Chilled
American standards
water
Model
Capacity
EER d Refrigflow
no.
tons c Stages Btuh/w
erant
gpm
PINN3-75W
72
5
15.9 HCFC-22 173
PINN3-90W
87
6
15.9 HCFC-22 209
Chilled
Metric standards
water
Model
Capacity
EER d Refrigflow
no.
Kcal/hr c Stages Btuh/w erant
lpm
PINN3-75W 217,728
5
15.9 HCFC-22 654
PINN3-90W 263,088
6
15.9 HCFC-22 791
Cond. Cond.
water conn.
flow Class 150 Tank
gpm
flange
matrl.
216
4”
SS 304L
261
4”
SS 304L
Cond. Cond.
water conn.
flow Class 150 Tank
lpm flange e matrl.
817
4”
SS 304L
988
4”
SS 304L
P2
P1
Tank pump pump
gal. std. std.
oper. hp
hp
750
3
15
750
5
15
P2
P1
Tank pump pump
gal. std. std.
oper. kW
kW
750 2.24 11.19
750 3.73 11.19
To proc.
connection
Class 150
flange
3”
4”
To proc.
connection
Class 150
flange e
3”
4”
c Capacities rated at 50ºF (10ºC) leaving water temperature, 2.4 gpm per ton with 85ºF (29ºC) condenser supply
water. Capacities are not adjusted for pump heat.
d As published by compressor manufacturer. Conditions may vary, depending on operating temperature and
ambient conditions.
e Approx. metric for 3” is 76 mm; 4” is 101 mm. Customer is responsible for conversion to metric.
Water-Cooled Dimensions, Weights, Amp Draw Values
Dimensions
Weights c
Model
L
W
H
Dry
Operating
Shipping
Amp draw values @ 460/3/60
no.
in. cm in. cm in. cm
lbs.
Kg
lbs.
Kg
lbs.
Kg
FLA d
RLA running
PINN3-75W 90” 229 120” 305 88” 224 10,105 4,588 16,338 7,418 10,605 4,815
142
97
PINN3-90W 90” 229 120” 305 88” 224 10,810 4,908 17,043 7,738 11,310 5,135
172
118
c Weights do not include pumps.
d Amp draw values do not include P1 pump.
Figure 6
Pinnacle Remote Air-Cooled Three-Circuit Central Chilling Station Specifications
Model
Capacity c
no.
tons Kcal/hr Stages
PINN3-75R 68 205,632
5
PINN3-90R 80 241,920
6
EER d
Btuh/w
12.4
12.4
Cond.
conn.
Tank
Refrig- Class 150 Tank gal./liters
erant
flange e matrl.
oper.
HCFC-22
4”
SS 304L 750/2,838
HCFC-22
4”
SS 304L 750/2,838
P2
P1
To proc.
pump
pump connection
std.
std.
Class 150
hp kW hp kW flange e
3 2.24 15 11.19
3”
5 3.73 15 11.19
4”
c Capacities rated at 50ºF (10ºC) leaving water temperature, 2.4 gpm per ton with 95ºF (35ºC) ambient supply air.
Capacities are not adjusted for pump heat.
d As published by compressor manufacturer. Conditions may vary, depending on operating temperature and
ambient conditions.
e Approx. metric for 3” is 76 mm; 4” is 101 mm. Customer is responsible for conversion to metric.
Remote Air-Cooled Dimensions, Weights, Amp Draw Values
Dimensions
Weights c
Model
L
W
H
Dry
Operating
Shipping
Amp draw values @ 460/3/60
no.
in. cm in.
cm in. cm lbs.
Kg
lbs.
Kg
lbs.
Kg
FLA d
RLA running
PINN3-75R 90” 229 120” 305 88” 224 8,932 4,056 15,165 6,885 9,432 4,283
142
112
PINN3-90R 90” 229 120” 305 88” 224 9,495 4,311 15,728 7,151 9,995 4,438
172
136
c Weights do not include pumps.
d Amp draw values do not include P1 pump.
Page 14
Pinnacle Series Central Chilling Stations
Figure 7
Pinnacle Remote Condenser Assembly Models
End view
Model A 15-ton model
45.50
Model A 15-ton remote condenser
42.50
125.00
50.00
20.25
38.50
.875 dia.
mtg. holes
108.00
114.00
End view
Model B 30-ton models
45.50
Model B 30-ton remote condenser
42.50
180.00
50.00
20.25
A0537153
38.50
.875 dia.
54.00
55.00
169.00
54.00
Figure 8
Pinnacle Remote Condenser Specifications and Configurations
Model
A
B
Size
in tons
15
30
Air
No.
flow
fans in cfm
2
23,200
3
32,900
Amps
FLA
460/3/60
7
101/2
Connections
Dimensions
in. dia. Cu
in inches
Weights in pounds
Inlet Outlet
L
W
H
Dry
Shipping Operating
15/8
15/8
125” 451/2” 50”
770
945
800
21/8
21/8
180” 451/2” 50” 1,210
1,465
1,270
Note: The following table lists the quantity and model (A or B from the above table) of remote
condensers supplied with Pinnacle remote air-cooled condenser models.
Quantity
Quantity
Quantity
Quantity
Quantity
supplied
supplied
supplied
supplied
supplied
Model
A
B
Model
A
B
Model
A
B
Model
A
B
Model
A
B
PINN2-30R 2
0 PINN2-45R 1
1 PINN2-60R 0
2 PINN3-75R 1
2 PINN3-90R 0
3
Pinnacle Series Central Chilling Stations
Page 15
2
2-1
Shipping Information
Unpacking and Inspection
You should inspect your central chilling station for possible shipping damage. If the container
and packing materials are in re-usable condition, save them for reshipment if necessary.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc. In case of
breakage, damage, shortage, or incorrect shipment, refer to the following sections.
2-2
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 if you discover damage.
; 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 and to obtain an RMA (return
material authorization) number.
2-3
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:
; AEC/Application Engineering Pinnacle Series central chilling station
; Bill of lading
; Packing list
; Operating and Installation packet
; Electrical schematic and panel layout drawings
Pinnacle Series Central Chilling Stations
Page 17
; Component instruction manuals
; Parts list
Re-inspect the container and packing material to see if you missed any smaller items during
unpacking. Determine that the item was not inadvertently taken from the area before you
checked in the shipment. Notify AEC, Inc. immediately of the shortage.
2-4
If the Shipment is Not Correct
If the shipment is not what you ordered, contact AEC, Inc. immediately. Include the order
number and item. Hold the items until you receive shipping instructions.
2-5
Returns
Important!
Do not return any damaged or incorrect items
until you receive shipping instructions from AEC, Inc.
2-6
Uncrating Your Chiller
! WARNING !
DUE TO THE SIZE AND WEIGHT OF PINNACLE SERIES CHILLERS,
AEC, INC. RECOMMENDS USING BONDED PROFESSIONAL
MILLWRIGHTS TO UNLOAD AND MOVE PINNACLE CHILLERS.
Rig the chiller from the frame only, using spreader bars to prevent load transfer to any chiller
components. Rig the frame from at least four points and balance the load before lifting to clear
the skid. Use a forklift of adequate size when lifting the chiller by the fork pockets.
Insert the forks all the way into the pockets and be sure to balance the load before lifting the
chiller to clear the skid. Lift only as high as necessary. Use a pry bar to free the skid if necessary.
Lower slowly. Retain the crating in case reshipment is necessary due to hidden shipping damage.
Caution!
Due to the weight of these units, use extreme caution
when moving and placing Pinnacle Series chillers.
Page 18
Pinnacle Series Central Chilling Stations
3
Installation
3-1
Installation Location Considerations
The following points should be considered when selecting a location for an Pinnacle unit:
•
Locate close to the process to reduce piping expense.
•
Locate adjacent to drain and city water sources.
•
Consult a structural engineer to assure that the floor, mounting pad or structural steel
support is of adequate strength.
•
Allow for required service clearances necessary for condenser maintenance and easy access
to all components.
3-2
Making Electrical Connections
Check the serial tag voltage and amperage requirements and make sure your electrical service
conforms.
Bring properly sized power leads and ground from a fused disconnect (installed by your
electrician) to the unit. Use fuses in the disconnect switch, sized according to the National
Electrical Code recommendations listed on the electrical schematic in the control enclosure.
Caution!
•
Electrical connections must comply with all applicable electrical codes.
•
The chiller must be grounded in accordance with NEC Article 250.
•
Voltage must be within plus or minus ten percent (±10%) of the nameplate
rating.
•
Phase imbalance must be less than two percent (<2%) in accordance with
NEMA MG1-14.32.
•
Air-cooled remote condensers must have properly sized disconnects
conforming with all local codes.
Pinnacle Series Central Chilling Stations
Page 19
Note: The scroll compressors were phased with the pumps at the factory.
•
Never switch contactor leads or motor leads for reversing rotation.
•
Do not use contactor or motor leads for phase matching.
•
Compressor noise from reverse rotation is noticeable. Do not run in this mode for
more than ten (10) seconds. The compressor shuts off if run longer in this mode.
•
Reverse rotation can cause suction and discharge pressures to be approximately
equal; amp draws will be lower than normal.
•
If you discover that compressor rotation is reversed, correct it by switching any two
main power leads into the disconnect switch or distribution block on the unit.
Check your work and proceed to the following Piping Considerations section.
3-3
Piping Considerations
Piping systems vary with process application and pump tank configuration. Typical system
configuration drawings are provided in this manual; the details may or may not apply to your
application. Piping systems must be designed by a person knowledgeable in piping system
design and configuration. AEC’s Contracting Department can design and install a piping system
tailored to your process.
•
All piping returning to the pump tank must be equipped with an inverted trap with a
vacuum breaker at the high point of the system to prevent mains from siphoning into the
pump tank.
•
Run mains full size in order to reduce pressure drop in the system and provide maximum
pressures at the ends of the mains.
3-4
Making Process Water Connections
All Models
All Pinnacle chilling stations have two chilled water connections per unit, and on water-cooled
models, one more set of water connections for condenser water:
To Process
The chilled water supply outlet leading to the process being controlled.
From Process
The chilled water return for water returning back to the chiller from the process to be cooled and
recirculated.
Page 20
Pinnacle Series Central Chilling Stations
3-5
Making Tank Piping Connections
Return
Bring the chilled water returning from the process to the pump tank warm From Process side.
This line is sized according to the flow rate from the process to the pump tank. See Section 3-3
on Page 20 for more information on piping considerations.
Important!
Do not use the Pinnacle unit to support piping.
Makeup
Connect a city water source to maintain water level in the pump tank.
Overflow
Connect the OVERFLOW outlet to an approved, trapped drain to permit excess water in the
pump tank to overflow to the drain. The overflow line is sized according to the size of the pump
tank.
To Drain
Connect to a 1½” line (approx. 63 mm) leading to an approved, trapped drain. You can drain the
pump tank if necessary.
3-6
Water Connection Sizing Considerations
Important!
•
Run all external chilled water connections with adequate size to the process.
•
Provide the largest possible openings and passages for the flow of chilled
water through platens, dies, molds, or other pieces of equipment.
•
Minimum external pressure drop is critical for proper operation.
3-7
Galvanic Corrosion Considerations
Water circuit piping components are primarily ferrous (iron) and react electro-chemically with
non-ferrous metallic materials such as copper. Some water has dissolved minerals that will
greatly accelerate the reaction between dissimilar metals.
Use PVC or ferrous piping to minimize galvanic action. If piping must be copper, use dielectric
unions at the chiller.
Pinnacle Series Central Chilling Stations
Page 21
3-8
Water Treatment Considerations
Water treatment is important in any piping system. In some locations, raw water may be used in
the system without problem; in other locations, it will result in large deposits of scale and
corrosion.
AEC, Inc. offers a complete line of water treatment equipment. Contact your AEC, Inc. sales
representative for water testing and treatment options.
3-9
Making Water-Cooled Condenser Connections
Pinnacle water-cooled chilling stations use city or tower water as a cooling medium. All external
condenser supply and discharge piping and connections should be of adequate size.
Two connections are made to each Pinnacle unit:
Condenser Water In
The city or tower water supply inlet is located at the side or rear of the chiller.
•
Water pressure ≥25 psi (≥172.4 kPa/≥1.72 bars)
•
Water temperature ≤85°F (≤29ºC)
Condenser Water Out
The return outlet, located at the chiller side or rear is connected to a cooling tower inlet, a sewer
or other approved discharge receiver.
•
A water regulating valve is a standard feature in the condenser water out line.
Caution!
The water regulating valve is set at the factory.
It must not be adjusted except by a qualified refrigeration technician.
Page 22
Pinnacle Series Central Chilling Stations
3-10 Installing the Remote Air-Cooled Condenser
Pinnacle models use the surrounding air to cool the remote condenser. All models have variable
speed fans and low ambient controls to allow proper operation down to -20°F (-29ºC) outdoor air
temperature.
Install the remote air cooled condenser where there is:
•
Greater than or equal to -20°F (-29ºC) air temperature.
•
Free passage of air for condensing.
•
Adequate structural support.
•
Protection from strong winds and drifting snow.
•
Provisions for removal of heated air from the area.
•
No steam, hot air or fume exhausts drawn into the condenser coils.
•
Service accessibility.
Pinnacle condensing pressure
with 95ºF (35ºC) condenser air
R-22 = 260 psi (1,793 kPa/17.93 bars)
Note: Due to the variables involved in remote air-cooled condenser installations, no set or
standard piping procedure exists. Each installation must be designed and installed by
qualified persons. Follow the instructions supplied with the condenser.
3-11 Checking Motor Direction
Compressor
Note: The scroll compressor was phased with the pump and fan motor at the factory.
•
Never switch contactor leads or motor leads for reversing rotation.
•
Do not use contactor or motor leads for phase matching.
•
Compressor noise from reverse rotation is noticeable. Do not run in this mode for
more than ten (10) seconds. The compressor shuts off if run longer in this mode.
•
Reverse rotation can cause suction and discharge pressures to be approximately
equal; amp draws will be lower than normal.
•
If you discover that compressor rotation is reversed, correct it by switching any two
main power leads into the disconnect switch or distribution block on the unit.
Pinnacle Series Central Chilling Stations
Page 23
Water Pump
A positive pressure of 20 to 30 psi (137.9 to 206.8 kPa/1.38 to 2.07 bars) on the TO PROCESS
line indicates correct pump rotation.
Condenser Fan
On Pinnacle remote air-cooled units, air should draw through the condenser and discharge up
from the condenser.
Changing fan rotation direction
•
Disconnect and lock out power at the fused disconnect.
•
If all fans are going backwards, reverse any two main power leads.
•
If only some of the fans are going backwards, switch any two of their respective motor
leads.
Figure 9
Pinnacle 60 Hz 5 to 15 hp P1 Pump Curves
Total Head
Meters PSI
Feet
61
87
200
55
78
180
49
69
160
43
61
140
37
52
120
30
43
3,500 rpm 1.0 S. G.
60 Hertz
70ºF
15 hp
10 hp
7.5 hp
5 hp
100
US gallons
0
per minute
Cubic meters 0
per hour
Page 24
Pinnacle Central Chilling Stations
Process (P1) Pump Selections
50
100
150
200
250
300
11
22
34
45
56
68
Pinnacle Series Central Chilling Stations
Figure 10
Pinnacle 60 Hz 20 to 40 hp P1 Pump Curves
Total Head
Meters PSI
Feet
61
87 200
58
82 190
55
78 180
52
74 170
49
69 160
46
65 150
43
61 140
40
56 130
37
52 120
US gallons
0
per minute
Cubic meters 0
per hour
3,500 rpm 1.0 S. G.
70ºF
60 Hertz
Pinnacle Central Chilling Stations
Process (P1) Pump Selections
40 hp
30 hp
20 hp
75
150
225
300
375
450
17
34
52
68
86
102
Pinnacle Series Central Chilling Stations
Page 25
Figure 11
P2 60 Hz Recirculation Pump Curves
Total Head
Meters PSI
Feet
30
43 100
27
39
90
24
35
80
21
30
70
18
26
60
15
22
50
12
17
40
9
13
30
6
9
20
3
4
10
US gallons
0
per minute
Cubic meters 0
per hour
Page 26
Pinnacle Central Chilling Stations
Recirculation (P2) Pump Selections
1.5 hp
3,500 rpm 1.0 S. G.
60 Hertz
70ºF
2 hp
5 hp
3 hp
50
100
150
200
250
300
11
22
34
45
56
68
Pinnacle Series Central Chilling Stations
Figure 12
Evaporator Pressure Drops
15 Ton Circuit
12
psid
10
8
6
4
2
0
10
20
30
40
50
60
flow (gpm)
30 Ton Circuit
10
psid
8
6
4
2
0
0
20
40
60
80
100
flow (gpm)
Pinnacle Series Central Chilling Stations
Page 27
Figure 13
Condenser Pressure Drops
Pinnacle 15 hp condenser
Design gpm
45
6.4
Design ∆ P
Pressure
gpm
drop
8
50.9
Pinnacle 30 hp condenser
Design gpm
90
1.6
Design ∆ P
Pressure
gpm
drop
8
N/A
7
47.4
7
N/A
6
43.7
6
184.8
5
39.9
5
166.9
4
35.3
4
149.0
3
30.5
3
128.0
2
24.2
2
104.0
1
16.6
1
A0537137
72.0
Notes:
1. Design gpm and ∆ P are based on 3 gpm per
nominal compressor horsepower.
2. Actual gpm is calculated by determining
chilled water capacity ton = ∆ T x gpm
x3
24
(formula for water systems, no additives).
3. ∆P readings are taken directly across the condenser.
Page 28
Pinnacle Series Central Chilling Stations
Figure 14
Typical Remote-Air Cooled Condenser Piping Installation
Compressor Trap
(required on all compressors)
Condenser Over Trap
(required only if condenser is
located above compressor)
6" (15 cm) min.
18" (46 cm) min.
Long-radius 90º bend (typical)
Long-radius 90º bend (typical)
Relief
valve
Air-cooled condenser
Angle
valve
Relief
valve
Air-cooled condenser
Angle
valve
Legend
End of AEC piping
Pinnacle Central
Chilling Station,
PINN2-60R shown
Note: Consult a qualified refrigeration technician to design a proper remote condenser piping
system tailored to your installation.
Pinnacle Series Central Chilling Stations
Page 29
Page 30
Ball
valve
Legend
Refrigeration lines
Condenser manifold piping
Chilled water piping
Condenser water piping
Optional *
End of AEC piping
BF Check
valve valve
Equalizing line
To
Process
Low
pressure
control
1/4 FPT
access
P1 *
P1
Sight
glass
Butterfly
valve
Flow
switch
*
1/4 FPT
access
T Freezestat
Process
pump
Brazed
plate
evaporator
Power element
Suction line
Liquid line
Expansion
valve
Relief Angle
valve valve
Water-cooled
condenser
A
Gate
valve
Cold
BF
valve
B
Tower or city
water return
Check BF
valve valve
From
Process
Recirculation
pump
* P2
P2
Overflow
Water
makeup
Tower or city
water supply
Replaceable
core filter
dryer
Drain
Hot
Gate
valve
Solenoid
valve
Tank
Shutoff
valve
Sight
glass
BF
valve
BF
valve
Water
regulating valve
Y-strainer
Scroll
compressor
Oil
Highpressure P
control
Shutoff
valve
Equalizing line
Power element
Liquid
line
B
(to filter dryer)
Shutoff
valve
Relief
valve
Shutoff
valve
Relief
valve
BF
valve
Discharge
line
A
(from compressor)
Liquid
line
B
(to filter dryer)
Shutoff
valve
Sight
glass
BF
valve
BF
valve
D
Replaceable
core filter
dryer
Air-cooled condenser
Air-cooled condenser
Lead fan is pressureactuated variable speed.
Note:
Solenoid
valve
Water regulating
valve
Discharge
line
A
(from compressor)
Butterfly
valve
Flow
switch
1/4 FPT
access
T Freezestat
Brazed
plate
Expansion
evaporator
valve
1/4 FPT
access
Liquid line
Relief Angle
valve valve
Water-cooled
condenser
C
Suction line
Lowpressure
control
Discharge line
P
* Typical for all four [4] pumps
Ball Pressure
valve gauge
Scroll
compressor
Oil
Highpressure P
control
Shutoff
valve
Discharge line
Figure 15
Two-Circuit Process/Standby Four-Pump Piping Schematic
Pinnacle 2-60 W/R shown
A0556929
P
Pinnacle Series Central Chilling Stations
4
Sequence Of Operation
4-1
Staging
1. Compressors stage, in sequence, beginning with Circuit 1, Compressor 1A, through
Circuit 3, Compressor 3B.
2. If not all circuits are started, the unit stages around the Off circuit.
3. The Throttling Range (TR) = 4ºF. That is, 0% to 100% compressor operation occurs
over this range. TR is typically centered around process set point.
4. Compressor interstage time is thirty (30) seconds.
5. Compressor anti-recycle time is three (3) minutes.
4-2
Alarms
1. Any circuit 1, 2, or 3 Alarm condition will shut down the corresponding circuit. Manually
restart from the Compressors operation screen after correcting the alarm condition.
2. If only one circuit trips an alarm, the other circuit(s) will continue to operate.
3. If you attempt to start any compressor circuit without having a recirculation pump run,
the flow alarm activates.
4. Any pump alarm condition will turn off Pump Lead Lag mode if the unit is a four pump
configuration.
5. Any alarm condition on chiller circuits will turn off the Compressor Lead Lag mode if
the chiller is configured with the Advanced Control Package. Restart Lead Lag mode.
6. If the lead circuit was in an alarm condition, compressors will momentarily shut down,
re-sequence, and start again beginning with circuit 1, compressor 1a upon correction and
circuit re-start.
Note: Thirty (30) -second interstage and three (3) -minute anti-recycle timers still govern the
unit at this point.
4-3
Lead-Lag Compressors
1. You, the user, must be responsible to start Lead Lag mode. The Lead Lag mode does not
work if all compressor circuits are not started. Furthermore, the All CKTS Available
option would not respond. The control button is green if all circuits are on.
Pinnacle Series Central Chilling Stations
Page 31
2. Start Lead Lag by pushing the Start Auto button.
The button color changes to green.
3. Set the lead-lag set point (the auto-switchover point) between 100 and 400 hours. The
Comp. Lead Lag screen displays elapsed time and the counter resets to zero at the
switchover point.
4. At set point, compressors resequence using the following sequence:
Model
PINN2-30
PINN2-45
PINN2-60
PINN3-75
PINN3-90
Staging: Lead
1a – 2a
1a – 2a – 2b
1a – 1b – 2a – 2b
1a – 2a – 2b – 3a – 3b
1a – 1b – 2a – 2b – 3a – 3b
Staging: Lag
2a – 1a
2b – 2a – 1a
2a – 2b – 1a – 1b
3a – 3b - 2b – 1a – 2a
3a – 3b– 2a – 2b – 1a – 1b
5. Compressors revert back at the next cycle.
6. Any alarm or circuit power down turns off Lead Lag Auto mode. The CNT time,
however, is not lost. Upon restarting the Lead Lag mode, CNT picks up where it left off.
4-4
•
Lead-Lag Pumps
Functions similar to Compressor Lead Lag operation.
4-5
Chilled Water Circuit
Make the process cooling water supply connection at the P1 manifold at the right side of the
chiller at the exposed flanged connection. Bring the process cooling water return connection to
the Hot well of the tank on the right side at the flanged connection.
Warm coolant (water and ethylene glycol mixture) returns from the process to the tank, then gets
pumped through the evaporator where it is cooled. The coolant flows to the process and returns
to repeat the cycle.
4-6
Refrigeration Circuit
•
Pinnacle chilling station air- and water-cooled unit refrigeration cycles differ only in the
way the compressed gas is condensed to a liquid.
•
Liquid refrigerant from the condenser passes through a shut-off valve into a filter/dryer.
•
The refrigerant then passes through the sight glass and solenoid valves into the thermal
expansion valve which regulates flow; the valve lowers pressure and boiling point. Heat
from the fluid causes the refrigerant to boil off into a vapor.
•
The refrigerant vapor flows through the suction line back into the compressor.
•
The refrigerant gives up heat as it re-condenses to a liquid in the condenser.
Page 32
Pinnacle Series Central Chilling Stations
4-7
Freezestat Control
The freezestat shuts down the compressor if the chilled water temperature approaches the
freezing point. The chilled water pump on the system will continue to run. It is factory-set at
40°F (4ºC) or 10°F (6ºC) below the rated capacity operating temperature of 50°F (10ºC).
If you want lower chilled water temperatures, you’ll need to mix process water with industrial(not automotive) grade ethylene or propylene glycol with rust inhibitor to provide protection
down to 20°F (12ºC) below the operating temperature you want. Figure 16 below shows the
proper mixtures needed to provide protection to 20°F (12ºC) below the operating temperature
you want. You can then reset the freezestat cutout temperature to a temperature 10°F (6ºC)
below the operating temperature you selected.
Caution!
Make sure all freezestat adjustments are performed
by a qualified refrigeration service technician.
The AEC, Inc. product warranty does not cover system freeze-up!
Figure 16
Freezing Protection Curve
60
Ethylene glycol required for evaporator freeze protection
50
Ethylene
glycol
percent by
volume
40
30
20
10
0
-50ºF -40ºF -30ºF -20ºF -10ºF 0ºF 10ºF 20ºF 30ºF 40ºF 50ºF 60ºF
-46ºC -40ºC -34ºC -29ºC -23ºC -18ºC -12ºC -7ºC -1ºC 4ºC 10ºC 16ºC
Chilled water operating temperature ºF / ºC
Pinnacle Series Central Chilling Stations
Page 33
4-8
High Pressure Cutout
This electro-mechanical safety feature opens the control circuit if the system condensing pressure
exceeds a safe level.
High pressure cutout setting
Model
psi
Pinnacle water-cooled chilling stations
290 psi
Pinnacle remote air-cooled chilling stations
375 psi
kPa
2,000 kPa
2,586 kPa
bars
20 bars
26 bars
Important!
The high pressure cutout is a manual reset control,
so you should reset it once.
If the problem persists, call a refrigeration service technician
to analyze the problem and to reset the control.
4-9
Low Pressure Cutout
This encapsulated switch safety feature prevents the compressor suction pressure from dropping
below a pre-set point. It is factory set to open the control circuit when pressure drops below a
safe level. The chiller will need to be restarted when the suction pressure reached above 65 psi
(448.2 kPa/4.5 bars).
Model
Pinnacle water-cooled chilling stations
Pinnacle remote air-cooled chilling stations
Opens control circuit @
Resets control circuit @
psi
kPa
bars
psi
kPa
bars
15 psi 103.4 kPa 1.0 bars 30 psi 206.9 kPa 2.1 bars
15 psi 103.4 kPa 1.0 bars 30 psi 206.9 kPa 2.1 bars
4-10 Flow Switch
The flow switch shuts down the chiller if the evaporator water flow falls below a safe operating
gallons-per-minute (liters-per-minute) flow rate.
4-11 Control Nipple
All Pinnacle chilling station evaporators have two control nipples. The flow switch, freezestat,
and flush port are located in the control nipple. Optional pressure gages can be mounted in the
control nipples to aid in achieving proper flow through the evaporator and balancing flows.
Page 34
Pinnacle Series Central Chilling Stations
Coupling mounts for customer-installed pressure gauges are included on both control nipples.
Pressure drop between evaporator entering water pressure and evaporator leaving water pressure
can be converted to gallons per minute using the pressure drop charts provided.
4-12 Control Probe
Two control probes sense temperatures. One probe measures the temperature of the hot well and
the other does the same for the cold well of the reservoir. These temperatures are used by the
PLC controller to sequence the compressors, based on load.
4-13 Chilled Water Manifold
The chilled water manifold allows one-point connections of TO PROCESS piping. The Sch. 40
steel piping includes butterfly valves at each evaporator for flow balancing and circuit isolation;
optional pressure gauges can be installed.
4-14 Condenser Water Manifold
The condenser water manifold allows one-point connection of TO TOWER (drain) and FROM
TOWER (city water) piping. Sch. 40 steel include butterfly valves for each condenser. Drain
points are at the bottom of the header.
Pinnacle Series Central Chilling Stations
Page 35
- Notes -
Page 36
Pinnacle Series Central Chilling Stations
5
5-1
Startup Checklists
Introduction
Important!
These lists assume the installation information
in this manual has been read and followed.
Have new chillers started up and checked
by a qualified refrigeration service technician.
AEC Inc. offers factory startup for Pinnacle Series chilling stations.
Call the AEC/Application Engineering Service Department
at 1 (800) 233-4819 for more details.
5-2
Water-Cooled Pinnacle Startup Checklist
; Check the shipping papers against the serial tag to be sure chiller size, type and voltage is
correct for the process.
; Check the transformer primary voltage connections to be sure they are configured for the
electrical power you are using.
; The voltage at the main power connection must be within plus or minus ten percent (±10%)
of the voltage listed on the serial tag.
; Phase imbalance must be less than two percent (<2%).
; Electrical connections must conform to all applicable codes.
; Complete the chilled water TO and FROM PROCESS connections.
; The optional or field installed chilled water supply and return valves on the chiller must be
open.
; Be sure the pump tank and chilled water circuit are filled with a water/glycol mixture that
provides freeze protection to 20°F (12ºC) below the leaving water temperature you want.
; Complete the tower or city condenser WATER IN and WATER OUT connections. Provide an
adequate condenser water supply; 2 gpm per ton for city water or 3 gpm per ton for tower
water operation.
; Remove all tools, foreign matter and debris from the pump tank reservoir and piping.
; Complete all piping leading to and from the pump tank. Observe all applicable codes.
; Complete all electrical wiring. Observe all applicable codes.
; Prepare all related equipment in the system for operation.
Note: The scroll compressors were phased with the pump(s) at the factory.
Pinnacle Series Central Chilling Stations
Page 37
•
Never switch contactor leads or motor leads for reversing rotation.
•
Do not use contactor or motor leads for phase matching.
•
Compressor noise from reverse rotation is noticeable. Do not run in this mode for
more than ten (10) seconds. The compressor shuts off if run longer in this mode.
•
Reverse rotation can cause suction and discharge pressures to be approximately
equal; amp draws are lower than normal.
•
If you discover that compressor rotation is reversed, correct it by switching any two
main power leads into the disconnect switch or distribution block on the unit.
; Open the 1” (approx. 25 mm) makeup water valve and allow the tank to fill until the
automatic float valve shuts off. The float level should be adjusted so the standing water level
is 8” (20 cm) from the top of the tank.
; Check for proper pump rotation direction. To confirm proper rotation:
1. Observe a pump pressure gauge connected to the suction and discharge sides of the pump
casing through two ¼” (approx. 6.4 mm) gauge cocks.
2. Close the gauge cock leading to the pump suction and open the gauge cock leading to the
pump discharge.
3. Close the discharge butterfly valve, crack it open, then start the pump and observe the
gauge.
•
If the gauge indicates within 15 psi (103.4 kPa/1.03 bars) below the pump curve,
pump rotation is correct. Pump rotation is clockwise opposite the shaft end.
•
If the gauge indicates 20 psi (137.9 kPa/1.38 bars) or more below the pump curve,
the pump is running backwards. Reverse rotation by interchanging any two power
mains to the pump motor or starter.
•
Recheck the pressure to be sure it increased.
; Check the water level in the pump tank to be sure the pump does not run dry while the
system piping is being filled.
; Check your work and proceed to the Startup procedure.
5-3
Water-Cooled Pinnacle Startup
1. Start the chiller by pushing the Start button on the control panel of the unit.
Both panel lights flash about four (4) times; this is a light bulb test.
2. Touch the screen anywhere to display the Main Menu screen.
3. Turn on the pumps by selecting Pumps on the Main Menu screen; select the pumps
you want to turn on at the Pumps screen.
4. Adjust the Freezestat cut-out, located in the main electrical enclosure, to 10°F (6ºC)
below the process temperature set point you want.
Note: Make sure that a recirculation pump is running before you start any compressor circuit.
Page 38
Pinnacle Series Central Chilling Stations
5. To turn the compressor circuit(s) ON, return to the Main Menu screen, then select
Compressors; select the compressors you want to turn on at the Compressors screen.
6. Put the chiller under a process load.
7. To set process temperature, return to the Main Menu screen, then select
Temperature; select the process temperature you want by pressing V or W.
8. Check the pump(s) amp draws and pressures. The amp draws must be within the pump(s)
running load and service factor amps.
9. Operate the chiller, looking for leaks and listening for unusual noises or vibrations that
could indicate improper operation.
5-4
Remote Air-Cooled Pinnacle Startup Checklist
; Check the shipping papers against the serial tag to be sure chiller size, type and voltage is
correct for the process.
; Check the transformer primary voltage connections to be sure they are configured for the
electrical power you are using.
; The voltage at the main power connection must read within plus or minus ten percent (±10%)
of the voltage listed on the serial tag.
; Phase imbalance must be less than two percent (<2%).
; Electrical connections must conform to all applicable codes.
; Complete the chilled water TO and FROM PROCESS connections.
; The optional or field installed chilled water supply and return valves must be open.
; Be sure the tank and chilled water circuit piping are filled with a water/glycol mixture. The
water/glycol mix should provide freeze protection to 20°F below the leaving water
temperature you’ve selected.
; The air cooled condenser should have an adequate supply of air for proper operation.
; Connect the main power to the unit and bump-start it to check for proper rotation direction. If
the fans are operating backwards, reverse any two main power leads at the incoming terminal
block.
; Remove all tools, foreign matter and debris from the pump tank reservoir and piping.
; Complete all piping leading to and from the pump tank. Observe all applicable codes.
; Complete all electrical wiring. Observe all applicable codes.
; Prepare all related equipment in the system for operation.
Note: The scroll compressors were phased with the pump(s) at the factory.
•
Never switch contactor leads or motor leads for reversing rotation.
Pinnacle Series Central Chilling Stations
Page 39
•
Do not use contactor or motor leads for phase matching.
•
Compressor noise from reverse rotation is noticeable. Do not run in this mode for
more than ten (10) seconds. The compressor shuts off if run longer in this mode.
•
Reverse rotation can cause suction and discharge pressures to be approximately
equal; amp draws are lower than normal.
•
If you discover that compressor rotation is reversed, correct it by switching any two
main power leads into the disconnect switch or distribution block on the unit.
; Open the 1” (approx. 25 mm) makeup water valve and allow the tank to fill until the
automatic float valve shuts off. The float level should be adjusted so the standing water level
is 8” (20 cm) from the top of the tank.
; Check for proper pump rotation direction. To confirm proper rotation:
1. Observe a pump pressure gauge connected to the suction and discharge sides of the pump
casing through two ¼” (approx. 6.4 mm) gauge cocks.
2. Close the gauge cock leading to the pump suction and open the gauge cock leading to the
pump discharge.
3. Close the discharge butterfly valve, crack it open, then start the pump and observe the
gauge.
•
If the gauge indicates within 15 psi (103.4 kPa/1.03 bars) below the pump curve,
pump rotation is correct. Pump rotation is clockwise opposite the shaft end.
•
If the gauge indicates 20 psi (137.9 kPa/1.38 bars) or more below the pump curve,
the pump is running backwards. Reverse rotation by interchanging any two power
mains to the pump motor or starter.
•
Recheck the pressure to be sure it increased.
; Check the water level in the pump tank to be sure the pump does not run dry while the
system piping is being filled.
; Check your work and proceed to the Startup procedure in the following section.
5-5
Remote Air-Cooled Pinnacle Startup
1. Start the chiller by pushing the Start button on the control panel of the unit.
Both panel lights flash about four (4) times; this is a light bulb test.
2. Touch the screen anywhere to display the Main Menu screen.
3. Turn on the pumps by selecting Pumps on the Main Menu screen; select the pumps
you want to turn on at the Pumps screen.
4. Adjust the Freezestat cut-out, located in the main electrical enclosure, to 10°F (6ºC)
below the process temperature set point you want.
Note: Make sure that a recirculation pump is running before you start any compressor circuit.
Page 40
Pinnacle Series Central Chilling Stations
5. To turn the compressor circuit(s) ON, return to the Main Menu screen, then select
Compressors; select the compressors you want to turn on at the Compressors screen.
6. Put the chiller under a process load.
7. To set process temperature, return to the Main Menu screen, then select
Temperature; select the process temperature you want by pressing V or W.
8. Check the pump(s) amp draws and pressures. The amp draws must be within the pump(s)
running load and service factor amps.
9. Operate the chiller, looking for leaks and listening for unusual noises or vibrations that
could indicate improper operation.
10. Check condenser fans for pressure switch settings as shown in the table below:
Fan
number
1
2
3
4
5
5-6
psi
240
265
285
305
Set on
Set off
kPa
bars
psi
kPa
bars
not applicable; Fan 1 is a variable-speed fan
1,654.8
16.5
190
1,310.1
13.1
1,827.2
18.3
215
1,482.4
14.8
1,965.1
19.7
235
1,620.3
16.2
2,102.9
21.1
255
1,758.2
17.6
Determining Flow Rate
Note: If your chilling station is equipped with the Advanced Control package, see Section 7-9
on Page 67 for more information on flow rates.
To determine flow:
1. Close the gauge cock leading to the pump suction side and open the gauge cock leading
to the pump discharge.
2. Start the pump and make note of the discharge pressure in psi (kPa/bars).
3. Check the pump curves on Pages 24 and 25 for the appropriate horsepower (kW) pump at
the discharge pressure in psi (kPa/bars).
4. Project this point down to find the flow in gpm (lpm).
5. Flow-through evaporator(s) set at factory; recheck based on curves in Figure 12 on Page
27. Process pumps can be left wide open if running amps are below full load amps.
5-7
Shutdown
1. Ready process and related equipment for shut down.
2. Shut down the individual chiller circuits.
3. Shut down all pumps.
Pinnacle Series Central Chilling Stations
Page 41
4. Turn off main power.
5. Close the water make up valve.
6. If the system is to be drained, open the 1½” (approx. 38 mm) drain valve.
Figure 17
Pinnacle Control Panel
Page 42
Pinnacle Series Central Chilling Stations
6
6-1
Graphic Panel Devices
Indicator Lights and Control Switches (MMI)
System On
The green System On indicator lights when the main power switch is on and the control circuit
is energized.
Alarm
The red Alarm indicator lights when any alarm condition exists. If so equipped, the optional
alarm light stack activates during a general fault alarm as well.
Start
The Start push-button lets you energize the unit.
Stop
The Stop push-button lets you de-energize the unit.
Touchscreen Interface
The color touchscreen interface gives you control over the chilling station. It has an easy-to-use
control menu that lets you quickly change or adjust chiller settings and also gives you all the
operation information you need to control the unit effectively.
See Chapter 7 on Page 49 for more information on touchscreen interface operation.
Note: During startup, the System On and Alarm indicators flash about four (4) times; this is a
light bulb test and is a normal routine of the startup cycle.
Pinnacle Series Central Chilling Stations
Page 43
Figure 18
Typical Water-Cooled Pinnacle Electrical Schematic, Drawing 1
NF DISC
DISTRIBUTION
BLOCK
L1 - PHASE A
L1
L1
L2 - PHASE B
L2
L2
L3 - PHASE C
L3
L3
1FU
1M
1L1
1OL
1T1
COMPRESSOR 1A _____ HP
1L2
1L3
2FU
L1
EARTH
GROUND
1MTR
FLA
FUSE SIZE
1T3
2M
2L1
2OL
2T1
COMPRESSOR 1B _____ HP
DISTRIBUTION
BLOCK
SUBPANEL
GROUND
1T2
L2
L1
2L2
L3
L2
2T2
2L3
3FU
L1
2MTR
FLA
FUSE SIZE
2T3
3M
3L1
3OL
3T1
COMPRESSOR 2A _____ HP
L3
L2
3L2
L3
CAUTION
3T2
3L3
4FU
L1
3MTR
FLA
FUSE SIZE
3T3
4M
4L1
4OL
4T1
COMPRESSOR 2B _____ HP
L2
MAIN POWER MUST BE
4L2
L3
PHASED AS SHOWN. ALL
MOTORS WILL RUN BACKWARDS
L1
IF MAIN POWER IS NOT CORRECT.
L2
NEVER CORRECT DOWNSTREAM OF DB
L3
4T2
4L3
5FU
4MTR
FLA
FUSE SIZE
4T3
5M
5L1
5OL
5T1
COMPRESSOR 3A _____ HP
5L2
5L3
6FU
L1
WARNING
5T2
5MTR
FLA
FUSE SIZE
5T3
6M
6L1
6OL
6T1
COMPRESSOR 3B _____ HP
11FU
L2
11FU
6L2
L3
NEVER JUMPER
11L3
LOW PRESSURE SWITCH.
11L1
6T2
6L3
7FU
L1
6MTR
FLA
FUSE SIZE
6T3
7M
7L1
7OL
7T1
PUMP RECIRCULATION 1 _____ HP
L2
COMPRESSOR DAMAGE WILL RESULT
1T
IF OPERATED IN A VACUUM
7L2
L3
7T2
7L3
115VAC
8FU
L1
7MTR
FLA
FUSE SIZE
7T3
8M
8L1
8OL
8T1
PUMP RECIRCULATION 2 _____ HP
L2
Optional Low Voltage/ø Sequence Monitor
L1
13FU
L3
12FU
11L1
L2
11L2
L3
11L3
8T2
8L3
9FU
L1
Low
Voltage
Monitor
8MTR
FLA
FUSE SIZE
8T3
9M
9L1
9OL
9T1
PUMP PROCESS 1 _____ HP
L2
1
2
9L2
L3
9T2
9L3
10FU
L1
Contact Location for Optional Low
Voltage/ø Sequence Monitor
5
8L2
9MTR
FLA
FUSE SIZE
9T3
10M
10L1
10OL
10T1
PUMP PROCESS 2 _____ HP
5A
1
18 GAUGE RED (TYPICAL)
1
L2
10L2
10T2
L3
10L3
10T3
18 GAUGE WHITE (TYPICAL)
3
SYSTEM START
SYSTEM STOP
L1
1
1MCR
2
2
2PB
1PB
10MTR
MCR
6
G
7
R
8
1M
COMPRESSOR 1A
9
2M
COMPRESSOR 1B
10
3M
COMPRESSOR 2A
11
4M
COMPRESSOR 2B
12
5M
COMPRESSOR 3A
13
6M
COMPRESSOR 3B
14
7M
RECIRCULATION PUMP 1
15
8M
RECIRCULATION PUMP 2
16
9M
PROCESS PUMP 1
17
10M
PROCESS PUMP 2
1
1
LG
GROUND
MASTER CONTROL
RELAY
4
0
L2
FLA
FUSE SIZE
1LT
SYSTEM ON
2LT
ALARM
2
1MCR
G ND
3
+VDC
4
-VDC
5
6
PLC PWR SUPPLY
PA206
7
8
5
9
30
31
10
18 GAUGE BLUE (TYPICAL)
PLC OUTPUTS
OC222
11
1SOL
12
2
18
2SOL
13
2
19
JUMPER
3SOL
14
2
20
17
PLC COM
5
16
5A
L
5
N
1TAS
FREEZESTAT 2
5
L
2TAS
FREEZESTAT 1
2
N
2
L
5
N
3TAS
FREEZESTAT 3
2
PLC INTERFACE
NT30
N
+V
18 GAUGE BLUE
115VAC
24VDC
L
18 GAUGE BLUE
Page 44
21
22
G
G
7
R
3LT
FREEZESTAT 3 POWER
SYSTEM OK
4LT
ALARM
2
2CR
23
ALARM HORN
EXTENDED LIGHT STACK
GENERAL FAULT ALARM
1AH
-VDC
GROUND
6
+VDC
+VDC
-VDC
3PB
G ND
2CR
24
-V
1PWR
S82K05024
FREEZESTAT 2 POWER
2
2
5
FREEZESTAT 1 POWER
G
2 CR
SILENCE BUTTON
HOLDING RELAY
A0556308
GROUND
Pinnacle Series Central Chilling Stations
Figure 18
Typical Water-Cooled Pinnacle Electrical Schematic, Drawing 2
+24VDC
0VDC
18 GA BLUE (TYP)
18 GA BLUE (TYP)
30
30
30
C1A OVERLOAD
C1B OVERLOAD
31
1OL
32
2OL
34
FLOW SWITCH
30
FREEZESTAT
0
TO1
THERMAL OVERLOAD
33
1
TO2
THERMAL OVERLOAD
35
2
1FLS
36
3
1TAS N O
37
4
38
HIGH PRES
30
LOW PRES
30
30
30
C2A OVERLOAD
C2B OVERLOAD
5
1PS
39
6
2PS
40
3OL
41
4OL
43
FLOW SWITCH
30
FREEZESTAT
HIGH PRES
30
LOW PRES
30
30
30
C3A OVERLOAD
C3B OVERLOAD
7
TO3
THERMAL OVERLOAD
PLC INPUTS
CPU
42
8
TO4
THERMAL OVERLOAD
44
9
2FLS
45
10
2TAS N O
46
11
3PS
47
12
4PS
48
5OL
49
6OL
50
FLOW SWITCH
30
13
TO5
THERMAL OVERLOAD
50
14
TO6
THERMAL OVERLOAD
52
15
3FLS
53
31
16
17
FREEZESTAT
0
2TAS N O
54
C0
HIGH PRES
30
PLC INPUTS
ID211
1
3PS
55
C1
LOW PRES
30
2
4PS
56
C2
RECIRC PUMP 1 OVERLOAD
3
7OL
57
31
C3
RECIRC PUMP 2 OVERLOAD
4
8OL
58
C4
9OL
5
PROCESS PUMP 1 OVERLOAD
59
C5
10OL
6
PROCESS PUMP 2 OVERLOAD
60
C6
P99V
BROWN
1XDCR
GREEN
31
WHITE
61
V+
WHITE
62
COM
V+
VI+
BROWN
2XDCR
VI+
COM
V+
ANALOG INPUTS
AD041
P99V
VI+
COM
V+
V-
30
GROUND
I+
COM
63
RED
BLACK
SHIELD
MODEL 310
- RED
TC 1
HOT WELL
+ YELLOW
COLD JUNCTION COMP
DO NOT REMOVE
Legend
Device External to Enclosure
Optional Components
- RED
SERIES 200
TC 2
COLD WELL
THERMOCOUPLE INPUTS
TC001
+ YELLOW
Customer Supplied
FLOW SENSOR
Pinnacle Series Central Chilling Stations
A0556308
Page 45
Figure 19
Typical Remote Air-Cooled Pinnacle Electrical Schematic, Drawing 1
NF DISCONNECT
DISTRIBUTION
BLOCK
1FU
1M
1L1
1OL
L1 - PHASE A
L1
L1
L2 - PHASE B
L2
L2
1L2
1T1
1T2
L3 - PHASE C
L3
L3
1L3
1T3
COMPRESSOR 1A _____ HP
2FU
L1
EARTH
GROUND
DISTRIBUTION
BLOCK
SUBPANEL
GROUND
2M
2L1
2OL
1MTR
2T1
COMPRESSOR 1B _____ HP
L2
2L2
2T2
2MTR
L1
L3
2L3
L2
3FU
L1
2T3
3M
3L1
3OL
COMPRESSOR 2A _____ HP
L2
3L2
3T2
CAUTION
L3
3L3
3T3
MAIN POWER MUST BE
L2
4L2
4T2
PHASED AS SHOWN. ALL
L3
4L3
4T3
MOTORS WILL RUN BACKWARDS
L1
5M
5L1
5OL
4MTR
FLA _____
FUSE SIZE _____
5T1
5L2
5T2
L3
5L3
5T3
6FU
6M
6L1
6OL
5MTR
FLA _____
FUSE SIZE _____
6T1
COMPRESSOR 3B _____ HP
6L2
L3
6T2
6L3
7FU
L1
COMPRESSOR DAMAGE WILL RESULT
6MTR
6T3
7M
7L1
7OL
FLA _____
FUSE SIZE _____
7T1
PUMP RECIRCULATION 1 _____ HP
IF OPERATED IN A VACUUM
11FU
L2
7L2
7T2
L3
7L3
7T3
7MTR
11FU
11L3
8M
8L1
8OL
FLA _____
FUSE SIZE _____
8T1
PUMP RECIRCULATION 2 _____ HP
11L1
1T
LOW
VOLTAGE
MO NI TOR
8FU
L1
11L1
OPTIONAL LOW VOLTAGE/ø SEQ MONITOR
115VAC
L2
8L2
8T2
L3
8L3
8T3
9FU
L1
9M
9L1
9OL
8MTR
FLA _____
FUSE SIZE _____
9T1
PUMP PROCESS 1 _____ HP
L2
9L2
L3
12FU
CONTACT LOCATION FOR OPTIONAL LOW
VOLTAGE/ø SEQUENCE MONITOR
5
FLA _____
FUSE SIZE _____
4T1
L2
L2
LOW PRESSURE SWITCH.
11L3
5FU
L1
NEVER JUMPER
L3
4L1
4OL
COMPRESSOR 3A _____ HP
WARNING
11L2
4M
3MTR
COMPRESSOR 2B _____ HP
IF MAIN POWER IS NOT CORRECT.
L2
4FU
L1
NEVER CORRECT DOWNSTREAM OF DB
13FU
FLA _____
FUSE SIZE _____
3T1
L3
L1
FLA _____
FUSE SIZE _____
9T2
9L3
10FU
L1
9MTR
9T3
10L1
10M
10OL
FLA _____
FUSE SIZE _____
10T1
PUMP PROCESS 2 _____ HP
5A
1
1
18 GAUGE RED (TYPICAL)
1PB
2
1
L2
10L2
10T2
L3
10L3
10T3
18 GAUGE WHITE (TYPICAL)
SYSTEM START
SYSTEM STOP
L1
1
1MCR
2
2
2PB
3
10MTR
M CR
6
G
7
R
8
1M
COMPRESSOR 1A
9
2M
COMPRESSOR 1B
10
3M
COMPRESSOR 2A
11
4M
COMPRESSOR 2B
12
5M
COMPRESSOR 3A
13
6M
COMPRESSOR 3B
14
7M
RECIRCULATION PUMP 1
15
8M
RECIRCULATION PUMP 2
16
9M
PROCESS PUMP 1
17
10M
1
1
LG
G ND
4
0
L2
FLA _____
FUSE SIZE _____
MASTER CONTROL
RELAY
1LT
SYSTEM ON
2LT
ALARM
2
1MCR
G ND
3
+VDC
4
-VDC
5
6
PLC PWR SUPPLY
PA206
7
8
5
9
30
31
10
18 GAUGE BLUE (TYPICAL)
PLC OUTPUTS
OC222
11
PROCESS PUMP 2
1SOL
12
2
18
REMOTE COND
CIRCUIT#1
2SOL
13
2
19
REMOTE COND
CIRCUIT#2
JUMPER
3SOL
14
2
20
17
PLC COM
5
5A
L
5
FREEZESTAT 2
5
16
L
2TAS
1TAS
REMOTE COND
CIRCUIT#3
N
FREEZESTAT 1
2
N
2
L
5
3TAS
N
FREEZESTAT 3
2
N
Page 46
+V
18 GA BLUE
115VAC
1PWR
S82K05024
FREEZESTAT 2 POWER
FREEZESTAT 3 POWER
2
2
5
FREEZESTAT 1 POWER
24VDC
L
18 GA BLUE
21
22
+VDC
PLC INTERFACE
NT30
6
G
+VDC
7
R
-VDC
-VDC
G ND
G ND
G ND
SYSTEM OK
4LT
ALARM
2
2CR
23
-V
G
3LT
G
24
2CR
ALARM HORN
1AH
3PB
2CR
SILENCE BUTTON
HOLDING RELAY
EXTENDED LIGHT STACK
GENERAL FAULT ALARM
A0556340
Pinnacle Series Central Chilling Stations
Figure 19
Typical Remote Air-Cooled Pinnacle Electrical Schematic, Drawing 2
30
30
30
31
+24VDC
0V DC
18 GAUGE BLUE (TYPICAL)
18 GA BLUE (TYP)
C1A OVERLOAD
C1B OVERLOAD
1OL
32
2OL
34
FLOW SWITCH
30
FREEZESTAT
1TAS
0
TO1
THERMAL OVERLOAD
33
1
TO2
THERMAL OVERLOAD
35
2
1FLS
36
3
NO
37
4
38
HIGH PRES
30
LOW PRES
30
C2A OVERLOAD
30
C2B OVERLOAD
30
5
1PS
39
6
2PS
40
3OL
41
4OL
42
FLOW SWITCH
30
FREEZESTAT
HIGH PRES
30
LOW PRES
30
C3A OVERLOAD
30
C3B OVERLOAD
30
2TAS
7
TO3
THERMAL OVERLOAD
PLC INPUTS
CPU
42
8
TO4
THERMAL OVERLOAD
44
9
2FLS
45
10
NO
46
11
3PS
47
12
4PS
48
5OL
49
6OL
51
FLOW SWITCH
30
13
TO5
THERMAL OVERLOAD
50
14
TO6
THERMAL OVERLOAD
52
15
3FLS
53
31
16
17
FREEZESTAT
3TAS
0
NO
54
C0
HIGH PRES
30
PLC INPUTS
ID211
1
5PS
55
C1
LOW PRES
30
2
6PS
56
C2
RECIRC PUMP 1 OVERLOAD
3
7OL
57
31
C3
RECIRC PUMP 2 OVERLOAD
4
8OL
58
C4
9OL
5
PROCESS PUMP 1 OVERLOAD
59
C5
10OL
6
PROCESS PUMP 2 OVERLOAD
60
C6
INSTALLED OUTDOORS
NO
7
SP=40°F
99
C7
P 99V
BR OWN
1XDC R
G R EEN
31
W HITE
61
V+
W HITE
62
COM
V+
VI+
BR OWN
2XDC R
VI+
COM
V+
P 99V
ANALOG INPUTS
AD041
VI+
COM
V+
VI+
COM
30
GND
63
R ED
BLACK
MODEL 310
SHIELD
4TAS
+ YELLOW
COLD JUNCTION COMP
DO NOT REMOVE
Legend
Device External to Enclosure
Optional Components
- RED
TC 1
HOT WELL
- RED
SERIES 200
TC 2
COLD WELL
THERMOCOUPLE INPUTS
TC001
+ YELLOW
Customer Supplied
FLOW SENSOR
A0556340
Pinnacle Series Central Chilling Stations
Page 47
Figure 20
Typical Pinnacle Subpanel Layout
39.00"
Master control relay
PLC
Power supply
Primary transformer fuse block
Terminal
blocks
Distribution
blocks
1 TAS
2 TAS
1 PWR 1 MCR
Fuses
33.00"
Freezestats
Contactors
COMP-1A
COMP-1B
COMP-2A
COMP-2B
C1A0L
C1B0L
C2A0L
C2B0L
P2-A
P2-B
P2-A
1 0L
P2-B
2 0L
P1-A
P2-B
P1-A
1 0L
P2-B
2 0L
Overloads
Page 48
Pinnacle Series Central Chilling Stations
7
7-1
Using the Touchscreen Interface
Touchscreen Interface Introduction (MMI)
The touchscreen interface lets you control your Pinnacle central chilling station. You can do such
things as:
•
Control pumps and compressors
•
View current statuses of operation, such as pressures, temperatures, and capacities
•
Handle alarm conditions
The sections in this chapter list special instructions for operating your Pinnacle touchscreen
interface.
Note: The screens shown in this chapter are sample screens. Actual screen representations may
be slightly different in appearance, but are no different in operation.
Figure 21
Pinnacle Control Panel
Pinnacle Series Central Chilling Stations
Page 49
7-2
Using the Pinnacle Touchscreen Interface
The Pinnacle touchscreen interface is the “manager” of your Pinnacle central chilling station.
The screen contains screen buttons you can press to control system operation.
For example, if you need to resolve an alarm condition, press the
the Main Menu screen. The first System Status screen then displays.
Alarms
screen button of
Menu
To return to the Main Menu screen at this point, press the
screen button of the screen,
usually located in the lower right corner. The Main Menu screen then displays.
Some screens let you directly control the operation of the chilling station, while others are for
information purposes and are “display-only” screens. This chapter distinguishes between
operation and display screens.
Figure 22
Pinnacle Touchscreen Flow Chart, Typical 3-Circuit Unit
Pinnacle
Main Menu
screen
System
Startup/Boot
screen
Pumps
selection
Alarms
selection
Compressors
selection
Pressures
selection
Temperatures
selection
Capacities
selection
Pumps
On/Off
screen
System Status
P1/P2 Pumps
screen
Compressors
On/Off
screen
Pump
Pressures
screen
Temperatures
Operation
screen
System
Capacities
screen
Pumps
Lead/Lag
screen
System Status
Ref. Circ. #1
screen
Compressors
Lead/Lag
screen
Pump Run
Times
screen
System Status
Ref. Circ. #2
screen
Compressor
Run Times
screen
Temperature
Trend Graph
screen
System Status
Ref. Circ. #3
screen
PLC BATT
(battery)
Page 50
Pinnacle Series Central Chilling Stations
7-3
Getting Started on the Pinnacle Touchscreen
Interface
To start the Pinnacle touchscreen interface:
„ Push the ON/OFF button on the cabinet.
The Pinnacle control panel energizes and the System On and Alarm indicators flash five
times.
The screen displays the initial System Startup/Boot screen:
System Startup/Boot Screen
„ Press anywhere on the System Startup/Boot screen to continue.
Pinnacle Series Central Chilling Stations
Page 51
The Main Menu screen displays:
Main Menu Screen
The Main Menu screen lets you gain access to:
Pumps
•
screen button, containing the Pump On/Off operation screen, the Pump
the
Run Times display screen, and the Lead/Lag display screen
•
the
screen button, containing System Status operation and display screens and
PLC Status Alarm operation screen
•
the
screen button, containing the Compressors On/Off operation screen, the
Compressor Run Times display screen, and the Lead/Lag display screen
•
the
•
screen button, containing the Temperatures operation screen and the
the
Temperature Profile display screen
•
the
Alarms
Compressors
Pressures
screen button, containing the Pump Pressures display screen
Temperatures
Capacities
screen button, containing the System Capacities display screen
The following sections in this chapter list the information you need to navigate through these
screens for operating and monitoring your Pinnacle central chilling station.
Page 52
Pinnacle Series Central Chilling Stations
7-4
Operating Chiller Station Pumps
To operate chiller station pumps, start at the Main Menu screen, then:
„ Press
Pumps
.
The Pumps On/Off operation screen displays:
Pumps On/Off Operation Screen
The Pumps On/Off operation screen lets you turn on and off process and recirculation pumps. It
also lets you navigate to the Pump Run Times display screen and the Lead/Lag display screen.
To control pumps:
„ Select the pump(s) you want to turn on or off, then press the screen button at the pump you
want to control.
The pump you selected responds by turning on or off, as indicated by the colored portion
you selected on the screen. On is green, Off is red, and the opposite selection is black.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Pinnacle Series Central Chilling Stations
Page 53
Setting Pump Lead/Lag Times and Activating Pump Lead/Lag
Operation
To navigate to the Pump Lead Lag screen, start at the Pumps On/Off screen, then:
„ Press
Lead/Lag
at the bottom of the screen.
The Pump Lead/Lag screen displays:
Pump Lead/Lag Operation Screen
The Pump Lead/Lag operation screen lets you activate and deactivate the Pump Lead/Lag mode,
as well as set the rotation schedule interval you want. This function is available only with the
optional Advanced Control Package, and only if your unit has four (4) pumps. CNT is the
elapsed count on the lead pump motor. SP is the of the lead/lag rotation schedule set point you
can set.
Note: You can set or adjust the pump lead/lag rotation schedule at any time.
To decrease the pump lead/lag rotation schedule interval:
„ Press W (decrease).
The pump lead/lag interval decreases by 25-hour increments.
- or -
Page 54
Pinnacle Series Central Chilling Stations
To increase the pump lead/lag rotation schedule interval (by 25-hour increments):
„ Press V (increase).
The pump lead/lag value increases by 25-hour increments.
To activate or deactivate the Pump Lead/Lag mode:
„ Press the Y/N screen button next to the All Pumps Available? screen prompt.
If the Y/N screen button turns green, all pumps are available for activating or
deactivating the Pump Lead/Lag mode.
- or If the Y/N screen button stays red, an alarm condition exists that prohibits you from
activating or deactivating the Pump Lead/Lag mode.
Make sure you correct any alarm condition before continuing.
To start pumps, first check pump status as listed in the previous procedure, then:
„ Press the Y/N screen button next to the Start Pumps? screen prompt.
The pumps start.
- or To stop pumps:
„ Press the Y/N screen button next to the Stop Pumps? screen prompt.
The Pumps On/Off screen displays. Select the pumps you want to stop from this screen.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Viewing Pump Run Times
To navigate to the Pump Run Times display screen, start at the Pumps On/Off screen, then:
„ Press
Run Times
at the bottom of the screen.
Pinnacle Series Central Chilling Stations
Page 55
The Pump Run Times screen displays:
Pump Run Times Display Screen
The Pump Run Times display screen lets you view the number of hours that each listed pump
has run. This information is useful for determining regular maintenance events. This screen also
lets you navigate to the Lead/Lag screen. This function is available only with the optional
Advanced Control Package.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
7-5
Viewing System Statuses and Handling Alarm
Conditions
This series of screens let you view system statuses and any alarm conditions for process and
recirculation pumps and refrigeration circuits.
To begin, start at the Main Menu screen, then:
„ Press
Page 56
Alarms
.
Pinnacle Series Central Chilling Stations
The System Status Process (P1) & Recirculation (P2) Pumps screen displays:
System Status Process (P1) and Recirculation (P2) Pumps Alarm Display Screen
The System Status Process (P1) and Recirculation (P2) Pumps alarm display screen lets you
view any pump overload alarm condition so you can make corrections and reset the alarm. In this
example, the P2 A pump is in an overload alarm condition. Make sure you correct any alarm
condition before continuing.
This screen also lets you navigate to other System Status screens.
Checking System Refrigeration Circuit Status
The next three screens contain alarm information on refrigeration circuits 1, 2, and, if applicable,
3. To navigate to the screen(s):
„ Press more .
Pinnacle Series Central Chilling Stations
Page 57
The first of the System Status Refrigeration Circuit screens displays:
System Status Refrigeration: Circuit #1 Alarm Display Screen
The System Status Refrigeration: Circuit #1 alarm screen is the first of two (or three, if your
Pinnacle chiller station is so equipped) screens that lets you view refrigeration circuit
information and any alarm condition. As on the previous screen, check and correct any alarm
condition before continuing. In this example, Circuit 1 Flow indicates an alarm
condition.
To navigate to other System Status alarm display screens:
„ Press more to go forward to the next screen.
- or „ Press back to display the previous screen.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Page 58
Pinnacle Series Central Chilling Stations
Checking the CPU Battery
To navigate to the System Status CPU screen:
„ Press more .
The System Status CPU screen displays:
System Status CPU Screen
The screen indicator glows green to indicate a good battery. If the indicator glows red, replace
the CPU battery as soon as possible. Typical CPU battery life is approximately five (5) years.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
7-6
Operating Chiller Station Compressors
To operate chiller station compressors, start at the Main Menu screen, then:
„ Press
Compressors
.
Pinnacle Series Central Chilling Stations
Page 59
The Compressors On/Off operation screen displays:
Compressors On/Off Operation Screen
The Compressors On/Off operation screen lets you turn on and off circuit compressors. It also
lets you navigate to the Compressor Run Times display screen and the Lead/Lag display screen.
To control compressors:
„ Select the circuit(s) you want to turn on or off, then press the screen button at the circuit
you want to control.
The circuit you selected responds by turning the appropriate compressor(s) on or off, as
indicated by the colored portion you selected on the screen. On is green, Off is red,
and the opposite selection is black.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Page 60
Pinnacle Series Central Chilling Stations
Viewing and Setting Compressor Circuit Lead/Lag Times
To navigate to the Compressor Lead/Lag display screen:
„ Press
Lead/Lag
at the bottom of the screen.
The Compressor Lead/Lag screen displays:
Compressor Lead/Lag Operation Screen
The Compressor Lead Lag operation screen lets you activate and deactivate the Compressor
Lead/Lag mode, as well as set the rotation schedule interval you want. This function is available
only with the optional Advanced Control Package. CNT is the elapsed count on the lead pump
motor. SP is the of the lead/lag rotation schedule set point you can set.
Note: You can set or adjust the compressor lead/lag rotation schedule at any time.
To decrease the compressor lead/lag rotation schedule interval:
„ Press W (decrease).
The compressor lead/lag interval decreases by 25-hour increments.
- or To increase the compressor lead/lag rotation schedule interval (by 25-hour increments):
„ Press V (increase).
The compressor lead/lag value increases by 25-hour increments.
Pinnacle Series Central Chilling Stations
Page 61
To activate or deactivate the Compressor Lead/Lag mode:
„ Make sure that you have energized all compressor circuits before continuing this
procedure.
„ Press the Y/N screen button next to the All CKTS Available? screen prompt.
If the Y/N screen button turns green, all compressor circuits are available for activating
or deactivating the Compressor Lead/Lag mode.
- or If the Y/N screen button stays red:
•
An alarm condition exists that prohibits you from activating or deactivating the Compressor
Lead/Lag mode. Make sure you correct any alarm condition before continuing.
- or -
•
You may not have energized all compressor cirucits.
To activate the Automatic Lead/Lag mode:
„ Press the Y/N screen button next to the Start Auto? screen prompt.
The Automatic Lead/Lag mode is activated.
- or To deactivate the Automatic Lead/Lag mode:
„ Press the Y/N screen button next to the Stop Auto? screen prompt.
The Automatic Lead/Lag mode is deactivated.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Page 62
Pinnacle Series Central Chilling Stations
Viewing Compressor Run Times
To navigate to the Compressor Run Times display screen from the Compressors On/Off screen:
„ Press
Run Times
at the bottom center of the screen.
The Compressor Run Times screen displays:
Compressor Run Times Display Screen
The Compressor Run Times display screen lets you view the number of hours that each listed
circuit compressor has run. This information is useful for determining regular maintenance
events. This function is available only with the optional Advanced Control Package.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
7-7
Viewing Current Pump Pressures
To view current pump pressures, start at the Main Menu screen, then:
„ Press
Pressures
.
Pinnacle Series Central Chilling Stations
Page 63
The Pump Pressures display screen displays:
Pump Pressures Display Screen
The Pump Pressures screen lets you view current pressures in psig for the process (P1) and
recirculation (P2) pumps that are currently operating. This function is available only with the
optional Advanced Control Package.
Note: If you have a metric version of the Pinnacle controller, the screens display in converted
metric values.
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
7-8
Setting and Viewing System Temperatures
To set and view system temperatures, start at the Main Menu screen, then:
„ Press
Page 64
Temperatures
.
Pinnacle Series Central Chilling Stations
The System Temperatures operation screen displays:
System Temperatures Operation Screen
The System Temperatures operation screen lets you:
•
View process supply actual temperature in ºF
•
View process return actual temperature in ºF
•
Change the process set point temperature
•
Navigate to the Temperature Trend Graph display screen
Note: If you have a metric version of the Pinnacle controller, the screens display in converted
metric values.
To decrease the process temperature set point:
„ Press and hold
Decrease
.
The temperature set point increments downward by single degrees F.
- or To increase the process temperature set point:
„ Press and hold
Increase
.
The temperature set point increments upward by single degrees F.
Pinnacle Series Central Chilling Stations
Page 65
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Viewing Temperature Trends
To navigate to the Temperature Trend Graph display screen from the Temperatures screen:
„ Press
GRPH
at the bottom left of the screen.
The Temperature Trend Graph screen displays:
Temperature Trend Graph Display Screen
Notes: • The Temperature Trend Graph display screen shown is only a representation. The
actual screen on your Pinnacle unit will graph the trending more evenly.
• If you have a metric version of the Pinnacle controller, the screens display in
converted metric values.
The Temperature Trend Graph display screen lets you view the real time temperature track in
increments of ten (10) seconds, represented by the graph line modulating between 30ºF and 90ºF
(-1ºC and 32ºC). This function is available only with the optional Advanced Control Package.
Page 66
Pinnacle Series Central Chilling Stations
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
7-9
Viewing Current System Capacities
To view current system capacities, start at the Main Menu screen, then:
„ Press
Capacities
.
The System Capacities screen displays:
System Capacities Display Screen
The System Capacities screen lets you:
•
View the current process flow rate in gpm (lpm)
•
View current chiller output in percent at maximum capacity
•
View current compressor status
Notes: • Not all models have all compressors.
• If you have a metric version of the Pinnacle controller, the screens display in
converted metric values.
This information is useful for determining how well the chilling station is running. This function
is available only with the optional Advanced Control Package.
Pinnacle Series Central Chilling Stations
Page 67
To return to the Main Menu screen:
„ Press
Menu
.
The Main Menu screen displays.
Page 68
Pinnacle Series Central Chilling Stations
8
8-1
Routine Maintenance
Lubrication
Grease all fan bearings, fan motors, and pump motors that do not have permanently sealed
bearings. Remove the grease relief plug (motors only) before adding grease. Failure to do so
may dislodge the bearing grease retainer which will eventually cause bearing failure.
Lubricate components regularly, based only on the component manufacturer’s specifications for
frequency and lubricant.
Compressors require a special scroll oil (Suniso 3GSA or equivalent); failure to use this oil
when lubricating will void the warranty.
8-2
Condenser Maintenance
Dirty condenser heat exchange surfaces reduce system capacity. Inspect and clean as needed.
Remote Air-Cooled
Brush or vacuum light dirt accumulations. Avoid bending or damaging the fins. Heavy soil
accumulations on the coil require professional steam cleaning by a qualified refrigeration service
technician. Washing from the outside will only make matters worse.
Water-Cooled
Proper water treatment will greatly reduce cleaning intervals.
Remove dirt in the condenser tubes with a nylon tube brush. Mineral deposits can be removed by
circulating AEC Liquid De-Scaling Solution (AEC Model Number A0502600) through the water
side of the condenser. Follow the directions on the container.
The refrigerant side is sealed and requires no routine maintenance.
8-3
Evaporator Maintenance
The evaporator(s) may be accessed for back-flushing by removal of the 2” plug (approx. 51 mm)
in the return control nipple and the flow switch in the supply control nipple. If the suggested
piping recommendations have been followed, one circuit of a multiple circuit chiller may be
back-flushed without shutting down the entire system. Check Y-strainer for any clogging.
Pinnacle Series Central Chilling Stations
Page 69
8-4
Pump Motor Seal
Pump seals require water for lubrication, so the pump(s) must never be run dry. Always fill the
tank before attempting to operate the pump(s). Seal failures usually follow a period of dry
operation of the pump.
8-5
Makeup Valve
Periodically inspect the water makeup valve assembly for proper operation. If the valve no
longer shuts off completely or reliably, replace it. The plastic ball float should be buoyant for
proper operation.
8-6
Recommended Pump Tank Spare Parts
Part no.
A0550190
A0102396
A0069538
A0102394
- Call AEC Parts -
Part description
Pressure gauge
Float valve, 1” (approx. 25 mm)
Plastic ball float, 6” (approx. 152 mm)
Float rod, 10” (25 cm)
Pump seal and casing gasket
Quantity
1 per pump
1 per tank
1 per tank
1 per tank
1 per pump
Check your Customer Information Packet for a complete list of spare parts and part numbers for
your Pinnacle chilling station.
8-7
Preventive Maintenance Service
A systematic preventive maintenance program helps avoid costly down time. Call the AEC/
Application Engineering Service Department at AEC, Inc. to arrange a schedule of inspections.
This service, described in AEC, Inc. Bulletin No. 10-106.3, is tailored to fit your maintenance
requirements.
Page 70
Pinnacle Series Central Chilling Stations
Inspections include:
; Check refrigerant suction and discharge pressures.
; Check safety and operating controls.
; Check voltage and amperage of all motors.
; Check all electrical connections.
; Check quantity of refrigerant.
; Check compressor oil level.
; Check lubrication of motor and pump bearings.
; Check circulating pump operation.
; Check flow through heat exchangers.
; Check compressor efficiency.
; Check noise levels.
; Check cleanliness of equipment area.
Pinnacle Series Central Chilling Stations
Page 71
- Notes -
Page 72
Pinnacle Series Central Chilling Stations
9
Troubleshooting
Problem
Possible Cause
No power.
Wrong voltage supplied to
unit.
Defective On/Off switch.
Control circuit fuse blown.
Unit does not run.
Defective control transformer.
Flow switch circuit is open.
Pump motor off on overload.
Unit is off on flow switch or
pressure switch.
Freeze control set higher than
temperature of liquid in
system.
Pump runs,
compressor does not.
High pressure refrigerant
cutout switch contacts open.
Pinnacle Series Central Chilling Stations
Solution
Check main disconnect,
fuses, wiring, and power lead
to unit.
Voltage must be within plus
or minus ten percent (±10%)
of nameplate rating.
Replace switch.
Replace fuse, check
transformer, check wiring for
loose wires, check for shorted
coils on contactors and
solenoids, check crankcase
heater.
Replace.
Check pump for proper
rotation.
Reset and test motor.
Check that the chiller pump is
running.
Check that all valves are
open.
Check for defective flow
switch or pressure switch.
Lower freeze control setting
to 10°F (6ºC) below the
leaving temperature you
want.
Air cooled units: Check and
clean air filters. Check
condenser fans for proper
rotation. Check for dirty
condenser. Check for
condenser air obstruction.
Check for tripped motor
overload, blown fuses, or bad
condenser fan motor.
Water cooled units: Check for
water valves turned on.
Check for dirty condenser.
Check water flow through
condenser.
Page 73
Problem
Possible Cause
Compressor internal overload
open.
Pump runs,
compressor does not
(cont’d).
Compressor contactor
holding coil open.
Defective fan motor.
Fan motor out on overload.
Defective freezestat.
Refrigerant low.
Defective fan cycling control.
Low refrigerant pressure
switch contact open.
Defective pump motor
interlock to compressor
control circuit.
Broken wire in the
compressor control circuit.
Pump runs, compressor
cycles at short intervals.
Freezestat control setting is
too high.
Refrigerant is too low.
Leaving water temperature is
not at set point.
Improper water/glycol
mixture.
Defective freezestat control.
Refrigerant charge is low.
Pump pressure is too high.
Page 74
Restricted water flow.
Solution
Allow time to cool and reset.
Check for high/low voltage.
Voltage must be within plus
or minus ten percent (±10%)
of nameplate rating.
Check for poor compressor
electrical connections.
Check compressor rotation
on scroll compressors.
Repair or replace.
Repair or replace.
Reset and test.
Replace.
Check the refrigerant charge.
Replace.
Sight glass should be clear
while comperssor runs. Call
for service if bubbling or
foaming.
Repair or replace.
Locate and repair.
Lower set point to 10°F (6ºC)
below the leaving water
temperature you want with at
least 15 degrees differential.
Check refrigeration charge;
check refrigerant sight glass
for bubbles or a level in the
glass.
Be sure the antifreeze
mixture protection is right for
the process.
Replace.
Call service to find and repair
the leak. Add refrigerant.
Check for partially closed
valves etc. Be sure all lines
are properly sized.
Pinnacle Series Central Chilling Stations
Problem
Possible Cause
Pump is running in reverse.
Pump pressure is too low.
Check for foreign matter.
Process water pressure low,
pressure at pump high.
Evaporator frozen.
Restricted condenser air flow.
Refrigerant not feeding.
Improper water/glycol
solution.
Unit runs continuously, but
not enough cooling
power.
Poor heat transfer in
evaporator.
Unit low on refrigerant.
Low waer flow through
evaporator.
Inefficient compressor.
Unit under-sized for
application.
Solution
Verify proper rotation; if
incorrect, see Changing
Rotation Direction on Page
20 for more information.
Clean the system. You may
also have to pull the pump
and inspect the impeller.
Check for foam in the water
circuit; add anti-foam if
needed.
Isolate evaporator, thaw out,
check for leaks. Check
coolant solution. Coolant
solution should be good for at
least 10ºF (6ºC) below
leaving water temperature.
Clean air filters, clean
condenser, check water flow.
Check superheat on
expansion valve.
Make sure that coolant
mixture protection is right for
the process.
Backflush and clean
evaporator.
Call service.
Increase flow to design flow
of 2.4 gpm/ton. See Figure 12
on Page
Call service.
Call sales representative.
Figure 23
Recommended Spare Parts List
Part number
A0006023
A0006027
A0006099
A0015430
A0015434
Description
Sight glass, SA-17S, 7/8”
Filter, dry, core, RC-4864
Valve, angle, Henry, #7761-B
Valve, gate, BR, 1”
Valve, gate, BR, 11/2”
Pinnacle Series Central Chilling Stations
Page 75
Figure 23
Recommended Spare Parts List Cont’d.
Part number
A0015555
A0015556
A0015557
A0015652
A0015657
A0015658
A0066090
A0069538
A0102394
A0102396
A0102485
A0103830
A0500222
A0556048
A0556468
A0530723
A0530725
A0533819
A0500548
A0501642
A0104093
A0530372
A0534258
A0550162
A0550163
A0534843
A0536825
A0537164
A0537197
A0544058
A0544063
A0544068
A0544069
A0544073
A0544074
A0544076
A0544077
A0546247
A0546248
A0546280
Page 76
Description
Gasket, Clarbestos, 2.5”
Gasket, Clarbestos, 3”
Gasket, Clarbestos, 4”
Valve, check, 3”, Val-Mati7c, #1403
Valve, butterfly, 2”
Valve, butterfly, 21/2”
Switch, flow, MM #FS4-3
Ball, plastic, float, 6”, PF-6
Rod, float, 1/4”–20 x 10”
Valve, float, 1”, R-400
Valve, WR, Penn #V46AT-2, 2.50”, 2W
Valve, ball, BR, 3/4”
Filter, dry, MTG, bracket, A-685
Filter, dry, C-487-G, 7/8”
Strainer, Y, CI, 3.00”, FPT, 20M
Control, AB #100-A09ND3
Control, AB #100-A30ND3
Valve, refrigeration, ball, 7/8”
Valve, RFG, solenoid, 7/8”, E25S2
Valve, RFG, relief, 350#, 3/8” MPT x 3/8” flare
Valve, RFG, relief, 400#, 3/8” MPT x 3/8” flare
Thermocouple, K, UNG, 4” P, 304SS, 15’ L
Fuse holder, 600 V, CL #CC, 2P, 30 amp
Fuse holder, 600 V, CL #J, 1P, 30 amp, DIN
Fuse holder, 600 V, CL #J, 1P, 60 amp, DIN
Fuse, 600 V, CL #J, DETD, 12 amp
Fuse, 600 V, CL #J, DETD, 40 amp
Transformer, 500 VA, 208/230/460-120
Cond., water, STD-REF, HSE-30
Switch, PB, 22 mm, flush head, black
Switch, PB, 22 mm, mush head, red
Switch, 22 mm, contact, INO
Switch, 22 mm, contact, INC
Light, 22 mm, lens, optic, green
Light, 22 mm, lens, optic, red
Light, 22 mm, unit, 120 V, LED, green
Light, 22 mm, unit, 120 V, LED, red
Relay, Type-F, AB #700-F400A1
Relay, deck, adder, AB #195-FA04
Power supply, 24 VDC, 0.6 amp, 15 W, S82KO
Pinnacle Series Central Chilling Stations
Figure 23
Recommended Spare Parts List Cont’d.
Part number
A0550077
A0550078
A0550080
A0556046
A0550140
A0550145
A0556019
A0556037
A0556038
A0556039
A0556041
A0556483
A0556485
A0556486
Description
Controller, pressure, TI #20PS008MA030E015D
Controller, pressure, TI #20PS008MA060G035D
Controller, pressure, TI #29PSL012-162
Controller, temperature, RANCO #111000-000, DIG
Clamp, hose, T-bolt, 2.8750” – 3.1250”
Clamp, hose, T-bolt, 2.500” – 2.6875”
Furnace Overload1 460V CSHA150
PLC, Omron, ANLPWR, CQM1-IPS01
PLC, Omron, 4PTAI, CQM1-AD041
PLC, Omron, 8DI-24DC, CQM1-ID211
Display, Omron, NT30C-ST141B-E
Transducer, pressure, 0-100 psig, P99V1C
Transmitter, flow, sensor, Data Ind, 220B
Transmitter, flow, Data Ind Model 310
Service Notes
Pinnacle Series Central Chilling Stations
Page 77
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. 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.
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.
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.
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 as-built drawings; equipment, labor, and construction materials; union or
non-union installations; and field supervision.
AEC, Inc.
1100 E. Woodfield Road, Suite 588
Schaumburg, IL 60713
www.aecinternet.com
Page 78
Pinnacle Series Central Chilling Stations
Warranty
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 warranty 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 • Wood Dale, Illinois 60191-1198 USA
Phone (630) 595-1060 • Fax (630) 595-6641
http://www.aecinternet.com
801 AEC Drive • Wood Dale, IL 60191-1198 USA
(630) 595-1060 • Fax (630) 595-6641
http://www.aecinternet.com