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$30.00 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