Home

Pinnacle Series Central Chilling Stations

Contents

1. CE ccc Device External to Enclosure Optional Components Customer Supplied Application Engineering MODEL 310 SERIES 200 FLOW SENSOR Pinnacle Series Central Chilling Stations TC 1 HOT WELL 2 COLD WELL GROUND RED N YELLOW COLD JUNCTION COMP 7 DO NOT REMOVE i RED YELLOW 24VDC 18 GA BLUE 18 GA BLUE E 31 10L o THERMAL OVERLOAD gt T OVERLOAD 191 37 53 ciBoveRLoAD 201 THERMAL OVERLOAD 1 30 1 4 34 35 2 FLOW SWITCH Z 30 36 2 FREEZESTAT TAS 2 37 2 Ba 5 HIGH PRES 1PS gt 30 59 2 LOW PRES PLC INPUTS 30 140 CPU 30L 7 C2A OVERLOAD THERMAL VERLOAD 30 1 m lt c2B ovERLoAD 401 THERMAL OVERLOAD 43 44 D 9 S FLOW SWITCH 2 2 5 2 FREEZESTAT NO 2 s 2 30 a LOW PRES 30 as OVERLOAD 59 THERMAL OVERLOAD 195 5 30 0 2 c3B OVERLOAD 601 THERMAL OVERLOAD 706 30 50 52 2 FLOW SWITCH E 30 53 2 31 17 FREEZESTAT TAS P PLC INPUTS 54 2 10211 co oF HIGH PRES 3PS LOW PRES 2 30 56 c2 RECIRC PUMP 1 OVERLOAD 79 2 57 2 31 c3 2 RECIRC PUMP 2 OVERLOAD BOL 2 Ti PROCE
2. Drawing 2 PLC INPUTS CPU 31 PLC INPUTS 1D211 ANALOG INPUTS 0041 24VDC 18 GAUGE BLUE TYPICAL 18 GA BLUE TYP ctAovertoan 10 THERMAL OVERLOAD 2 32 33 ciBovERLoAD 20 THERMAL OVERLOAD 8 E J 34 35 2 FLOW SWITCH 30 36 2 FREEZESTAT TAS 2 37 30 HIGH PRES m LOW PRES 30 0 2 2 OVERLOAD 301 THERMAL OVERLOAD ud caBovERLoAD 40L THERMAL OVERLOAD 2 44 9 FLOW SWITCH 30 45 DO FREEZESTAT 2 ae 10 HIGH PRES o 30 6 0 LOW PRES 30 48 c3a OVERLOAD 501 THERMAL OVERLOAD 30 49 50 c3B overLoap 601 THERMAL OVERLOAD 30 51 52 FLOW SWITCH 30 ams FREEZESTAT 54 HIGH PRES g 55 Q e 2 LOW PRES 30 56 2 c2 RECIRC PUMP 1 OVERLOAD 791 Z 57 2 RECIRC PUMP 2 OVERLOAD 591 5 ca 90 PROCESS PUMP 1 OVERLOAD c5 100L 00 PROCESS PUMP 2 OVERLOAD T 2 99 2 BROWN GREEN A Ba WHITE 61 BROWN WHITE 62 v D P99V 30 GND Bp 63 MODEL 310 zA X RED E lt YELLOW HOT WELL 2 COLD JUNCTION COMP Legend DONOTREMOVE Device External to Enclosure RED Optional Components SERIES 200 79 7 2 p QO
3. Return lt From Process d 1 Water makeup _ float valve y x Y Flow sensor 70 qe E optional 178 cm gs d lt X MEL IL S S 3 flange supply Process N ee N 30 76 recommended gt 39 60 152 cm clearance em recommended LED TEL ZH Front View Optional general fault alarm 422 LL AL E Color touch screen with elevated light stack Y strainer Electrical enclosure with ball valve Replaceable core N __ Single point filter dryer ptiona 7 electrical connection Y E sight glass 1712 clearance Condenser 4 N 44 5 cm f Optional water cooled only N N 2 disconnect N E Bt 3 flange supply _ Process P 71 180 68 pe approx 36 7 cm ce overall Optional compound pressure gauge N N Drain 1 1 2 lt 4 Y ae Evaporator P1 Optional P2 Optional recommended um m P2 pum clearance pump P1 pump pump pump Compressor CUE Appli i Page 10 SEC Endincering Pinnacle Series Central Chilling Stations Figure 2 Pinnacle Water Cooled Two Circuit Central Chilling Station Specifications American Standards Chilled Cond P2 P To proc water water Tank pump pump connection Model EER O Refrig flow Class 150 Tank gal std std Class 150
4. 65 8 1 Lubrication 8 2 Condenser Maintenance 8 3 Evaporator Maintenance 8 4 Pump Motor Seal 8 5 Makeup Valve 8 6 Recommended Pump Tank Spare Parts 8 7 Preventive Maintenance Service 9 Tro bleshootifig sue pene Drs Gaio 69 Page 4 SEC Endincoring Pinnacle Series Central Chilling Stations Charts and Figures 1 Typical Pinnacle Two Circuit Central Chilling Station Top View and Front View 11 2 Pinnacle Water Cooled Two Circuit Central Chilling Station Specifications 12 3 Pinnacle Remote Air Cooled Two Circuit Central Chilling Station Specifications 12 4 Typical Pinnacle Three Circuit Central Chilling Station Top View and Front View 13 5 Pinnacle Water Cooled Three Circuit Central Chilling Station Specifications 14 6 Pinnacle Remote Air Cooled Three Circuit Central Chilling Station Specifications 14 7 Pinnacle Remote Condenser Assembly Models 15 8 Pinnacle Remote Condenser Specifications and Configurations 15 9 Pinnacle 60 Hz 5 to 15 hp P1 Pump Curves 24 1 0 Pinnacle 60 Hz 20 to 40 hp P1 Pump Curves 25 1 1 P2 Recirculation Pump Curves 26 1 2 Evaporator Pressure Drops 27 1 3 Condenser Pressure Drops 28 14 Typical Remote Air Cooled Condenser Piping Installation 29 1 5 One Circuit Process Standby Two Pump Piping Schematic 30 1 6 Freezing Protection Curve 32 1 7 Pinnacle Graphic Panels 40 1 8 Typical Water Cooled Pinnacle Electrical Schematic Drawings 1 and 2 44 45
5. ing Stations Central Chilli les le Ser ion _ ing Pinnac Applicat Engineer com ccc Page 30 4 Sequence Of Operation 4 1 4 2 Note 4 3 Staging Compressors stage in sequence beginning with Circuit 1 Compressor 1A through Circuit 3 Compressor 3B If not all circuits are started the unit stages around the Off circuit The Throttling Range 4 That is 0 to 100 compressor operation occurs over this range TR is typically centered around process set point Compressor interstage time is thirty 30 seconds Compressor anti recycle time is three 3 minutes Alarms 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 If only one circuit trips an alarm the other circuit s will continue to operate If you attempt to start any compressor circuit without having a recirculation pump run the flow alarm activates Any pump alarm condition will turn off Pump Lead Lag mode if the unit is a four pump configuration 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 If the lead circuit was in an alarm condition compressors will momentarily shut down re sequence and start again beginning with circuit 1 compressor 1 upon correct
6. 908 80 241 920 6 2124 HCFC 22 750 2 838 11 19 O Capacities rated at 50 F 10 C leaving water temperature 2 4 per ton with 95 F 35 C ambient supply air Capacities are not adjusted for pump heat As published by compressor manufacturer Conditions may vary depending on operating temperature and ambient conditions 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 Model 1 w Dy Operating Shipping Amp draw values 460 360 em in in em Kg tbs Kg Kg FLAO RLArunning PINN3 75R 90 229 120 305 88 224 8 932 PINN3 90R 90 229 120 305 Weights do include pumps Amp draw values do not include P1 pump Appli i Page 14 SEC Endincering 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 p 50 125 00 50 00 20 25 875 dia 3850 intg holes 108 00 114 00 End Model B 30 ton models 45 50 Model B 30 ton remote condenser m 42 50 180 00 50 00 5 20 25 A0537153 e75dia 38 50 _ L 54 00 55 00 du 54 00 169 00 Figure 8 Pinnacle Remote Condenser Specifi
7. 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 Appli i Page 20 SEC Endincering 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 11 2 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 circ
8. service to find repair Refrigerant charge is low 9 the leak Add refrigerant Check for partially closed Pump pressure is too high Restricted water flow valves etc Be sure all lines are properly sized Refrigerant is too low Appli Page 74 Pinnacle Series Central Chilling Stations Problem _____ PossibleCause 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 Process water pressure low coolant solution Coolant pressure at pump high solution should good at least 10 F 6 C below leaving water temperature Restricted condenser air flow Clean air nlrers clean condenser check water flow Refrigerant not feeding Check superheat n expansion valve Make sure that coolant improper Waleniglyeo mixture protection is right for solution Unit runs contin ly but ne process Poor heat transfer in Backflush and clean not enough cooling t t SG evaporator evaporator P Unit low on refrigerant Call service Increase flow to design flow Low waer flow through evaporator of 2 4 gpm ton See Figure 12 on Page Inefficient compressor Call service Unit under sized for application Pump
9. 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 Paro Partdescripiion Quantity 0550190 1 0102396 Float valve 1 approx 25 mm per tank 1 A0069538 Plastic ball float 6 approx 152 mm 1 per tank A0102394 Float rod 10 25 cm 1 per tank Call AEC Parts Pump seal and casing gasket 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 Appli i Page 70 SEC Endincering 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 pu
10. e 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 Appli i Page 22 SEC Endincering 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 29 C outdoor air temperature Install the remote air cooled condenser where there is e Greater than or equal to 20 F 29 C air temperature e Free passage of air for condensing Adequate structural support e Protection from strong winds and drifting snow Provisions for removal of heated air from the area e steam hot air or fume exhausts drawn into the condenser coils e Service accessibility Pinnacle condensing pressure with 95 F 35 C 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 e Never switch contacto
11. screen button next tothe Start Auto screen prompt The Automatic Lead Lag mode is activated or To deactivate the Automatic Lead Lag mode Press the screen button next tothe Stop Auto screen prompt The Automatic Lead Lag mode is deactivated To return to the Main Menu screen B Press The Menu screen displays CUE Appli i Page 62 SEC Endincering Pinnacle Series Central Chilling Stations Viewing Compressor Run Times To navigate to the Compressor Run Times display screen from the Compressors On Off screen Run Times B Press at the bottom center of the screen The Compressor Run Times screen displays Compressor Run Times Circurt 1 430 Hours Circuit 1 Hours Circuit 2 Hours Hours Db 397 Hours Gircuit 3 Gircult 3 Hours 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 B Press The Main Menu screen displays 7 7 Viewing Current Pump Pressures To view current pump pressures start at the Main Menu screen then B Press CUE Appli i Engineering Pinnacle Series Central Chilling Stations Page 63 The Pump Pressures display screen displays Pu
12. screen button turns green all pumps are available for activating or deactivating the Pump Lead Lag mode Ifthe 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 screen button next tothe Start Pumps screen prompt The pumps start or To stop pumps Press the screen button next tothe 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 The Menu screen displays Viewing Pump Run Times To navigate to the Pump Run Times display screen start at the Pumps On Off screen then R Ti B Press at the bottom of the screen i i SEC Endincoring Pinnacle Series Central Chilling Stations Page 55 The Pump Run Times screen displays Pump Run Times Recirculation P2 8 50 Recirculation P2 8 102 PA 54 Hours D fors Menu 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
13. 10 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 12 below the operating temperature you want Figure 16 below shows the proper mixtures needed to provide protection to 20 F 12 C below the operating temperature you want You can then reset the freezestat cutout temperature to a temperature 10 F 6 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 Ethylene glycol required for evaporator freeze protection 60 SSE EEE 50 Ethylene glycol percent by volume 20 10 HHM ee qr SEE nu ES NS 50 F 40 F 30 F 20 F 10 F O F 10 F 20 F 30 F 40 F 50 F 60 F 46 C 40 C 34 C 29 C 23 C 18 C 12 C 7 C 1 C 4 C 10 C 16 Chilled water operating temperature F C Appli 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 psi bars Pinnacle water cooled chilling stations 290 psi 2 000 k
14. 4 M m COMPRESSOR 1B EARTH GROUND SUBPANEL Boek TR GROUND PUE 1 213 gt FU oL 2 P no am COMPRESSOR 2 _ 12 y am FLA is xs s FUSE SIZE 4FU 4n E COMPRESSOR2B HP 12 2 FLA MAIN POWER MUST BE NUES EAS 1 PHASED AS SHOWN ALL A SFU un ae sni MOTORS WILL RUN BACKWARDS 9 X COMPRESSOR3A ____ IF MAIN POWER 15 NOT CORRECT i L2 5L2 572 NEVER CORRECT DOWNSTREAM OF DB m ae FUSE SIZE SFU 1 COMPRESSOR ___HP 12 sL2 6 2 ELT 11FU gt fix s ara FUSE SIZE NEVER JUMPER Fu M AS 1 m LOW PRESSURE SWITCH La PUMP RECIRCULATION 1 __ A 12 n2 7 2 COMPRESSOR DAMAGE WILL RESULT PERAK gt FLA FUSE SIZE IF OPERATED IN A VACUUM Y 115VAC BFU PUMP RECIRCULATION 2 ____ 12 8L2 A 2 Optional Low Voltage o S Monit fus ional Low Voltage Sequence Monitor pi gelo Seq ais FUSE SIZE 13u 2 ana Li ry 12 J PUMP PROCESS 1 _ TD 22206 12 9L2 2 La Monitor FLA 2 m FUSE SIZE 30M Contact Location for Optional Low i Voltage a Sequence Monitor y PUMP PROCESS 2 ____ 12 1002 A 1072 10MTR FLA 5 FUSE SIZE GROUND 1 18 GAUGE RED TYPICAL 1 _ 18 GAUGE WHIT
15. Capacities Process Flow Rate Chiller Percent Output 9 Compressor System Capacities Display Screen The System Capacities screen lets you e View the current process flow rate in gpm Ipm e View current chiller output in percent at maximum capacity e View current compressor status Notes Not all models have all compressors e Ifyou have 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 CUE Appli Pire iens el Pinnacle Series Central Chilling Stations Page 67 return to the Menu screen Press The Menu screen displays cw H i Page 68 SEC Endincoring Pinnacle Series Central Chilling Stations 8 Routine Maintenance 8 1 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 Dirt
16. std std Class 150 no tons O Btuh w erant flange matrl hp hp flange HCFC 22 HCFC 22 SS 304L HCFC 22 SS 304L Metric Standards Cond conn Tank P2 1 pump To proc conn Model Capacity Refrig Class 150 Tank liters std std Class 150 no Kcal hr Btuh w erant flange matri kW kW flange Capacities rated at 50 F 10 C leaving water temperature 2 4 per ton with 95 F 35 C ambient supply air Capacities are not adjusted for pump heat As published by compressor manufacturer Conditions may vary depending on operating temperature and ambient conditions Metric dimension is approx 76 mm Customer is responsible to convert to metric Remote Air Cooled Dimensions Weights Amp Draw Values Dimensions Weights tL Dry Operating Shipping Amp draw values 460 3 60 Lin cm cm in cm Ibs Kg lbs Kg Ibs Kg RLA running PINN2 45R 70 178 110 280 71 181 6 6413 015 10 7964 902 7 141 3 242 87 469 Weights do not include pumps Amp draw values do not include P1 pump Appli i Page 12 SEC Endincering Pinnacle Series Central Chilling Stations Figure 4 Typical Pinnacle Three Circuit Central Chilling Station Top View Water regulating valve 4 flange from water cooled units only 4 flange to tower water cooled units only tower water cooled
17. Chilling Station Specifications American standards 5 Tank connection tons Btuh w erant matrl oper hp hp flange HCFC 22 750 5 i 2 1 Kd r Tank gal std std Class 150 Kcal hr Btuh w erant flange matri kW kW flange 750 2 24 PINN3 90W 263 088 6 15 9 22 791 988 4 55304 750 3 73 Capacities rated at 50 F 10 C leaving water temperature 2 4 per ton with 85 F 29 C condenser supply water Capacities are not adjusted for pump heat As published by compressor manufacturer Conditions may vary depending on operating temperature and ambient conditions 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 Model L w H Dry __ Operating Shipping no _ in cm in cm in Ibs Kg lbs Kg Ibs Kg RLA running PINN3 75W 90 229 120 305 88 224 PINN3 90W 90 229 120 305 88 224 Weights do not include pumps Amp draw values do not include P1 pump Figure 6 Pinnacle Remote Air Cooled Three Circuit Central Chilling Station Specifications P2 P pump pump connection Model Capacity EER Refrig std std tons erant PINN3 75R 68 205 632 HCFC 22 750 2 838 11 19
18. 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 e Pinnacle chilling station air and water cooled unit refrigeration cycles differ only in the way the compressed gas is condensed to a liquid e Liquid refrigerant from the condenser passes through a shut off valve into a filter dryer e 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 e The refrigerant vapor flows through the suction line back into the compressor The refrigerant gives up heat as it re condenses to liquid in the condenser Appli i Page 32 SEC Endincering 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 409 4 or 10 F 6 C below the rated capacity operating temperature of 50 F
19. anjen N ey X ieg JOUIE4 S A Jesuepuoo pjoo y dnayew sies lt 439M einsseid Ieg peeds ejqeueA pejenjoe ainssaid si peo Apong Perd Apang e Josseduioo em eunssoid Josso1duio2 1096 M01 lois yams 1 N Mold ved i es 14 jejsozoo14 1 3235929914 T ij Burzyenb3 a uoo buizijenb 3 1 d 9 ainssaud 19d 7 juawaja sejem __ fiddns 22 Se ce domus fie do ssej6 domus 3 5581 aed anea fis uojsuedxg HAS ejsuedy3 i AR 1 lt 3 ae 1 plouajog sahap a 210 9109 Sso22e sjqeeoedoy 1 aiqeeoe doy ldd uonans 81 25 pinbr E pinbrg M goius Er P L ANE e b aT 2 S x DOTT RE ELE T RASA T amer a i anak PATA Jefe ebieuosiq Bune nBa1 321194 UE
20. is running in reverse Pump pressure is too low Check for foreign matter Call sales representative Figure 23 Recommended Spare Parts List A0006023 Sight glass 175 7 0006027 Filter dry core RC 4864 A0006099 Valve angle Henry 7761 A0015430 Valve gate BR 1 0015434 Valve gate BR 11 2 COE Applicati DEC Engineering Pinnacle Series Central Chilling Stations Page 75 Figure 23 Recommended Spare Parts List Cont A0015555 Gasket Clarbestos 2 5 A0015556 Gasket Clarbestos 3 A0015658 Valve butterfly 21 2 A0069538 Ball plastic float 6 PF 6 A0102394 Rod float 20 x 10 Valve relief 350 3 4 MPT x 3 8 flare A0104093 Valve relief 400 3 MPT x 3 8 flare Fuse 600 V CL DETD 40 amp 0537164 Transformer 500 VA 208 230 460 120 A0534843 _ Fuse 600 V CL DETD 12 amp A0536825 0544074 Light 22 mm lens optic red A0546248 Relay deck adder AB 195 FA04 A0546280 Power supply 24 VDC 0 6 15 W S82KO CO Applicati Page 76 SEC Engineering Pinnacle Series Central Chilling Stations Figure 23 Recommended Spare Parts List Cont A0550077 Controller pressure TI 20PS008MAOS30E015D A0550145 Clamp hose T bolt 2 500 2 6875 A0556037 PLC Omron ANLPWR 1 1 501 A0556038 0556039 0556041 A0556483 Transducer pressure 0 100
21. no Btuh w erant matri hp hp flange HCFC 22 HCFC 22 HCFC 22 Metric Standards Chilled Cond P2 P1 To proc water water connection Model Capacity 2 Refrig flow Class 150 Tank liters std std Class 150 no Kcal hr Btuh w erant flange matri kW kW flange Capacities rated at 50 F 10 C leaving water temperature 2 4 per ton with 85 F 29 C condenser supply water Capacities are not adjusted for pump heat As published by compressor manufacturer Conditions may vary depending on operating temperature and ambient conditions Metric dimension is approx 76 mm Customer is responsible to convert to metric Water Cooled Dimensions Weights Amp Draw Values Dimensions Weights Model L w H Dry Operating Shipping Amp draw values 460 3 60 no in cm in Ibs Kg lbs Kg Ibs Kg FLAO 2 45 70 178 110 280 71 181 7 410 3 365 11 565 5 251 7 910 3 592 87 60 Weights do include pumps Amp draw values do not include P1 pump Appli i GEC Engineering Pinnacle Series Central Chilling Stations Page 11 Figure 3 Pinnacle Remote Air Cooled Two Circuit Central Chilling Station Specifications American Standards Cond conn Tank P2 pump P1 pump To proc conn Model Capacity EER Refrig Class 150 Tank gal
22. shelf PLC control with NEMA 4 color touch screen interface MMI Integral SS 304L stainless steel reservoir e Stainless steel brazed plate evaporator Process and recirculation pumps NEMA 12 electrical enclosure e High and low refrigerant pressure safeties Touch safe branch circuit fusing e Pre piped water circuit e 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 e Digital low temperature freezestat e Liquid line solenoid and shut off valves e Chilled water flow switches e Insulated tank cover e Automatic water makeup valve e AEC Warm Gray and black paint e year warranty on parts and labor e 3 year warranty on controller e Y strainer on recirculating water system Appli i Engineering Pinnacle Series Central Chilling Stations Page 7 Standard Features on Remote 5 Direct drive 3 phase fan motors are 11 2 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 e Fans 30 76 cm in diameter and have PVC coated steel fan guards 11 2 hp 1 12 kW variable speed fans are 26 66 cm in diameter e Internal baffles between
23. the pump and make note of the discharge pressure in psi kPa bars Check the pump curves on Pages 24 and 25 for the appropriate horsepower kW pump at the discharge pressure in psi kPa bars Project this point down to find the flow in gpm lpm 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 Shutdown Ready process and related equipment for shut down Shut down the individual chiller circuits Shut down all pumps li Pinnacle Series Central Chilling Stations Page 41 4 Turn off main power 5 Close the water make up valve 6 Ifthe system is to be drained open the 11 2 approx 38 mm drain valve Figure 17 Pinnacle Control Panel Application Engineering System Main Menu Compressors pom Series Appli i Page 42 SEC Engineering Pinnacle Series Central Chilling Stations 6 Graphic Panel Devices 6 1 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 t
24. units only Tank cover optional DE L 30 76 cm recommended clearance 4 NPT overflow Return From Process Water makeup float valve 90 228 cm Flow sensor To Process supply flange 3 flange 3 75 models 4 fl nge on 3 90 models 60 152 cm recommended clearance 30 76 cm recommended 129 clearance Sos em N Front View WA 4 Y strainer Replaceable core with ball valve filter dryers 30 76 cm Condenser Sight recommended water cooled glass clearance models only optional A l N a r 2 X gt 88 f k of x d E Evaporator P1 Compressor pump LN 30 76 cm recommended clearance CE Eec Application Engineering Pinnacle Series Central Chilling Stations General fault alarm with elevated light stack optional Color touch screen 17 44 12 5 cm P1 P2 pump pump optional Electrical enclosure Single point electrical connection Disconnect optional 4 NPT overflow iY Process supply flange 3 flange on 3 75 models 4 flange on 3 90 models Compound pressure gauge optional Drain 1 1 2 gate valve P2 pump optional Page 13 Figure 5 Pinnacle Water Cooled Three Circuit Central
25. 03 bars below the pump curve pump rotation is correct Pump rotation is clockwise opposite the shaft end e Ifthe 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 l Note Water Cooled Pinnacle Startup 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 Touch the screen anywhere to display the Main Menu screen Turn on the pumps by selecting Fumps the Main Menu screen select the pumps you want to turn on at the Pumps screen Adjust the Freezestat cut out located in the main electrical enclosure to 10 F 6 below the process temperature set point you want Make sure that a recirculation pump is running before you start any compressor circuit COE Application Page 38 cXCEngineering Pinnacle Series Central Chilling Stations 5 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 pr
26. 1 9 Typical Remote Air Cooled Pinnacle Electrical Schematic Drawings 1 and 2 46 47 2 0 Typical Pinnacle Subpanel Layout 48 2 1 Pinnacle Control Panel 49 2 2 Pinnacle Touchscreen Flow Chart 50 2 3 Recommended Spare Parts List 70 CUNE Appli i GEC Engineering 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 Documen
27. 20 7 5 5 30 434 100 US gallons 4 50 100 150 200 250 300 per minute Cubic meters 11 22 34 45 56 68 per hour CUE Appli i Page 24 SEC Endincering Pinnacle Series Central Chilling Stations Figure 10 Pinnacle 60 Hz 20 to 40 hp P1 Pump Curves Total Head Pinnacle Central Chilling Stations 3 500 rpm 1 0 S Meters PSI Feet Process P1 Pump Selections 60 Hertz 70 F 61 871 200 554 781 180 52 741 170 495 69 30 465 651 150 43 611 140 20 hp 405 564 130 374 521 120 USgallons 0 75 150 225 300 375 450 per minute Cubic meters 0 17 34 52 68 86 102 per hour Eec Pinnacle Series Central Chilling Stations Page 25 Figure 11 P2 60 Hz Recirculation Pump Curves Total Head Pinnacle Central Chilling Stations 3 500 rpm 1 0 S G Meters PSI Feet Recirculation P2 Pump Selections 60 Hertz 70 F 30 431 100 27 391 90 24 35 80 21 30 70 18 26 60 15 22 50 12 174 40 2 hp 9 13 30 n 5 hp 6 91 20 h 3 4 10 Sp US gallons 50 100 150 200 250 300 per minute T T T T T T T T T Cubic meters 14 22 34 45 56 68 per hour Page 26 SEC Endincoring Pinnacle Series Central Chilling Stations
28. 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 minus ten percent 10 of the voltage listed on the serial tag Phase imbalance must be less than two percent lt 2 Electrical connections must conform to all applicable codes Complete the chilled water TO and FROM PROCESS connections K N F FH 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 water glycol mixture that provides freeze protection to 20 F 12 C 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 M 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 i
29. COM Application ET Engineering Operation and Installation Manual Pinnacle Series Central Chilling Stations Important Read Carefully Before Attempting to Install or Operate Equipment 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 K Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or m
30. E TYPICAL i 1PB 2 MASTER CONTROL RELAY SYSTEM START SYSTEM STOP v 1 D 6 G 4 SYSTEM ON 1MCR 1 cs 2 1 gt 2 1 R ALARM 2 T 2 8 1M COMPRESSOR 1A T e 9 2M COMPRESSOR 1B D COMPRESSOR 2 5 n 4M COMPRESSOR 28 6 PLC PWR SUPPLY gt 206 7 2 12 5M COMPRESSOR 3A 2 13 om COMPRESSOR 3B 8 5 2 RECIRCULATION PUMP 1 2 RECIRCULATION PUMP 2 Bo 10 PROCESS PUMP 1 18 GAUGE BLUE TYPICAL PLC OUTPUTS h t 95222 PROCESS PUMP 2 12 2 D 4 13 2 4 JUMPER 14 D 2 17 16 PLC 5 Gal Dy 5 E M FREEZESTAT 1 2 7 2 FREEZESTAT 1 POWER L N 5 FREEZESTAT2 gt 2 TE 2 FREEZESTAT 2 POWER L 5 FREEZESTAT 3 2 2 WAS FREEZESTAT 3 POWER 2 2 SYSTEM OK ALARM PLC INTERFACE NTO EXTENDED LIGHT STACK N v T 115VAC 18 GAUGE BLUE pz VDG lt 22 D 24 SILENCE BUTTON GND HOLDING RELAY A0556308 1PWR GROUND S82K05024 5 I cA Page 44 SEC Endincering Pinnacle Series Central Chilling Stations Figure 18 Typical Water Cooled Pinnacle Electrical Schematic Drawing 2
31. Figure 12 Evaporator Pressure Drops 15 Ton Circuit psid flow apm 30 Ton Circuit psid flow apm COE Applicati Pinnacle Series Central Chilling Stations Page 27 Figure 13 Condenser Pressure Drops Pinnacle 15 hp condenser Pinnacle 30 hp condenser Design gpm 45 Design gpm 90 Design AP 6 4 Design AP 1 6 Pressure Pressure drop gpm drop gpm 8 50 9 8 N A 7 747 4 7 N A 6 43 7 6 184 8 39 9 5 7 166 9 4 35 3 4 149 0 3 30 5 3 128 0 2 24 2 2 104 0 1 16 6 72 0 A0537137 Notes 1 Design gpm and A P are based on 3 gpm per nominal compressor horsepower 2 Actual gpm is calculated by determining chilled water capacity ton A T x gpm Mo formula for water systems no additives 3 AP readings are taken directly across the condenser Appli i Page 28 SEC Endincering Pinnacle Series Central Chilling Stations Figure 14 Typical Remote Air Cooled Condenser Piping Installation Compressor Trap Condenser Over Trap required on all compressors required only if condenser is i located above compressor 6 15 cm min 18 46 cm min i dius 90 bend typical Long radius 90 bend typical W Relief L aye gee e Air
32. LD WELL YELLOW Customer Supplied Q FLOW SENSOR 5 A0556340 vy COE Application OECEngineering Pinnacle Series Central Chilling Stations THERMOCOUPLE INPUTS 1 47 Figure 20 Typical Pinnacle Subpanel Layout 39 00 Master control relay PLC P Wer SPRAY Primary transformer fuse block Lae gt gt 2 8 2 an N 88 a 3 e gi 55 28 38 52 g 3 d s z a 9 e Terminal a blocks j N P 1TAS 2TAS E E Sls E 1PWR 1MCR RAE Fuses h IN Freezestats Contactors COMP 1A COMP IB COMP 2A 2 BER E P1 A P2 B 2999 95019 SIS TES suse 399 Overloads 09 S s 5 adas aden A 8 her eee 5 eere re CABOL C2A0L C2B0L jin PA P2 B 1 10L 20L COE Application i Distribution blocks 33 00 48 cXCEngineering Pinnacle Series Central Chilling Stations 7 Using Touchscreen Interface 7 1 Touchscreen Interface Introduction MMI The touchscreen interface lets you control your Pinnacle central chilling station You can do such things as e Control pumps and compressors e View current statuses of operation such as pressures temperatures and capacities e Handle alarm conditions T
33. N um E COMPRESSOR2B_ HP 12 412 N 4T2 MAIN POWER MUST BE EE 196 AMTR FLA ___ 2 PHASED AS SHOWN ALL MOTORS WILL RUN BACKWARDS BUS a 1 1 s xh 7 5MTR NEVER CORRECT DOWNSTREAM OF DB 7 FUSE SIZE 13 513 513 2 T n sU P NE wo gt COMPRESSOR3B sL2 2 Cle NEVER JUMPER is La ON FUSE SIZE _ LOW PRESSURE SWITCH TU PU mo COMPRESSOR DAMAGE WILL RESULT _ PUMP RECIRCULATION 1 ___ HP 12 7L2 712 IF OPERATED IN VACUUM ind eU X FOR ___ L3 7L3 773 113 X OPTIONAL LOW VOLTAGE o SEQ MONITOR PUMP RECIRCULATION 1 HP 2 AAAKA FLA u mone r P E pi ui FUSE SIZE 12 1112 LOW VT UN 9M soL MONITOR n DE 3n T d v7 PUMP PROCESS 1 12 912 ___ Ls CONTACT LOCATION FOR OPTIONAL LOW 12 0 t A VOLTAGE o SEQUENCE MONITOR gt 10FU gt 10M 2 ren x PUMP PROCESS 2 1434 L2 10L2 1072 X 10MTR FLA 1 13 10L3 1073 1 18 GAUGE RED TYPICAL _ 1 18 GAUGE WHITE TYPICAL z 2 GND 1PB 2PB o o 3 4 MCR 4 MASTER CONTROL SYSTEM STARE SYSTEM a RELAY 1 6 G SYSTEM ON 1MCR 12 Z 1 2 7 R ALARM 16 2 e a aw C
34. OMPRESSOR 1A GND 3 P 22 9 2M COMPRESSOR 1B 4 o COMPRESSOR 2A Z o 11 AM COMPRESSOR 28 ae D PLC PWR SUPPLY EA COMPRESSOR E COMPRESSOR 3B 5 4 RECIRCULATION PUMP 1 9 15 RECIRCULATION PUMP 2 Bo pi 10 16 4 PROCESS PUMP 1 18 GAUGE BLUE TYPICAL PLC OUTPUTS 14 0c222 e H PROCESS PUMP 2 12 T 8 REMOTE COND cIRCUIT 2801 13 gt 4 REMOTE COND CIRCUIT 2 JUMPER 20 2 PLC i REMOTE COND CIRCUIT 3 5 FREEZESTAT 1 2 2 FREEZESTAT 1 POWER N rreezestat 2 2 E 2 FREEZESTAT 2 POWER E N FREEZESTAT 3 2 5 FREEZESTAT 3 POWER 2 2 PLC INTERFACE PEL system ox NT30 i 18 GA BLUE VDC NDE 2 E 2 115VAC 5 2 18 GA BLUE 22 VDC T kg HORN EXTENDED LIGHT STACK GENERAL FAULT ALARM 1PWR GND 2 moin cR SILENCE BUTTON A0556340 HOLDING RELAY cA Page 46 SEC Endincering Pinnacle Series Central Chilling Stations Figure 19 Typical Remote Air Cooled Pinnacle Electrical Schematic 30 31
35. Pa Pinnacle remote air cooled chilling stations 375 psi 2 586 kPa 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 Opens control circuit Resets control circuit Pinnacle water cooled chilling stations 103 4 kPa 06 9 kPa Pinnacle remote air cooled chilling stations 15 psi 103 4 kPa 30 psi 206 9 kPa 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 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 Appli i Page 34 SEC Endincering Pinnacle Series Central Chilling Stations Coupling mounts for customer installed pressure gauges included on both control nipp
36. SS PUMP 1 OVERLOAD ss z cs 100 PROCESS PUMP 2 OVERLOAD 4 ce BROWN GREEN Ba lt WHITE 61 2 Qy a BROWN WHITE 62 Ges Qv 1 7 ANALOG INPUTS AD041 30 es S THERMOCOUPLE INPUTS 1 0556308 45 Figure 19 Typical Remote Air Cooled Pinnacle Electrical Schematic Drawing 1 NF DISCONNECT DISTRIBUTION BLOCK L1 PHASEA gu BUS qi 29 m 2 _ COMPRESSOR 1A ____ L2 PHASE a 12 a2 m 2 FLA L3 PHASEC e z L3 13 ry 113 FUSESME 2FU 2 201 2 2 1 DISTRIBUTION compressor 18 BLOCK L2 212 272 GROUND Q 24 FUSE SIZE o 4 TR ABES y 02 2 COMPRESSOR2A___HP 2 12 312 y 3T2 T 2 FLA La FUSE SIZE _ C CAUTIO
37. ain Menu screen displays CON Applicati Engineering 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 Lead L B Press at the bottom of the screen The Pump Lead Lag screen displays Pump Lead Lag Stop Pumps Pumps s CNT DOD nes 000 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 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 set or adjust the pump lead lag rotation schedule at any time To decrease the pump lead lag rotation schedule interval Press V decrease The pump lead lag interval decreases by 25 hour increments Appli 54 SEC Engineering Pinnacle Series Central Chilling Stations increase the pump lead lag rotation schedule interval by 25 hour increments Press A increase The pump lead lag value increases by 25 hour increments To activate or deactivate the Pump Lead Lag mode Press the screen button next tothe All Pumps Available screen prompt Ifthe
38. aintaining 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 COE Application Page 2 cXCEngineering Pinnacle Series Central Chilling Stations Table of Contents 1 General Information eee 7 Introduction Necessary Documents Models Covered Standard Features Available Options 2 Shipping Information esee enne nnne 17 2 1 Unpacking and Inspection 2 2 Inthe Event of Shipping Damages 2 3 If the Shipment is Not Complete 2 4 Ifthe Shipment is Not Correct 2 5 Returns 2 6 Uncrating Your Chiller O Installation nan 19 3 1 Installation Location Considerations 3 2 Electrical Connections 3 3 Piping Considerations 3 4 Process Water Connections 3 5 Tank Piping Connections 3 6 Water Connection Sizing 3 7 Galvanic Corrosion 3 8 Water Treatment 3 9 Water Cooled Conden
39. atus Alarm operation screen Compressors e the screen button containing the Compressors On Off operation screen the Compressor Run Times display screen and the Lead Lag display screen e the screen button containing the Pump Pressures display screen Temperatures e the screen button containing the Temperatures operation screen and the Temperature Profile display screen Capacities the 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 Appli i Page 52 SEC Endincering Pinnacle Series Central Chilling Stations 7 4 Operating Chiller Station Pumps To operate chiller station pumps start at the Main Menu screen then Pumps Qn OT Proc 1 On 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 Uf f is red and the opposite selection is black To return to the Main Menu screen B Press The M
40. cations and Configurations Air Dimensions flow in inches Weights in pounds in cfm 460 3 60 Inlet Outlet L W H Dry Shipping Operating 23 200 800 30 3 32900 1 210 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 PINN2 30R 2 0 PINN2 45R 1 1 PINN2 60R 0 2 PINN3 75R 1 2 9 o 3 Appli SEC Endlncoring Pinnacle Series Central Chilling Stations Page 15 2 Shipping Information 2 1 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 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 M Notify
41. cooled condenser i Angle gt Relief d Sgi valve Air cooled condenser Angle valve L TSG GPT MGL G GS J G 7777 gt pv y EN Pinnacle Central Legend Reth 9 Chilling Station End of AEC piping PINN2 60R shown Note Consult a qualified refrigeration technician to design a proper remote condenser piping system tailored to your installation CUE Appli i GEC Engineering Pinnacle Series Central Chilling Stations Page 29 Figure 15 t Process Standby Four Pump P IC Schemat iping IrcUI Two C 8 vin uea S Homus 03 dwnd dwnd gt T 6893044 934 pinbr 2 F PK d Buidid Jasuapuog PHOS anen mE did pany J M x 38 49849 zd di xo9u9 48 P o o y o e e bd 03 p 11 404 y g lt sse901d VON ION A pinbri 8 g 1 d sse oL DAVID X ised ud o P m s
42. e 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 im Whitlock HydReclaim 24 F d Nelmor 801 AEC Drive Wood Dale IL 60191 1198 USA 630 595 1060 Fax 630 595 6641 http www aecinternet com
43. ect 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 1 necessary due to hidden shipping damage Caution Due to the weight of these units use extreme caution when moving and placing Pinnacle Series chillers Appli i Page 18 SEC Endincering 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 proces
44. elow the process temperature set point you want Make sure that a recirculation pump is running before you start any compressor circuit COE Application Page 40 cXCEngineering Pinnacle Series Central Chilling Stations turn the compressor circuit s return to the 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 Note To set process temperature return to the Main Menu screen then select Temperature select the process temperature you want by pressing or V Check the pump s amp draws and pressures The amp draws must be within the pump s running load and service factor amps Operate the chiller looking for leaks and listening for unusual noises or vibrations that could indicate improper operation Check condenser fans for pressure switch settings as shown in the table below Fan Set on Set off e speed fan O 1 27 1 654 8 1 310 1 3 265 18272 1 482 4 1 620 3 16 2 2 102 9 21 1 255 1 758 2 17 6 AJo N e co o eov N e Determining Flow Rate 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 l C ecc Eg Close the gauge cock leading to the pump suction side and open the gauge cock leading to the pump discharge Start
45. er rotation l Observe a pump pressure gauge connected to the suction and discharge sides of the pump casing through two 1 4 approx 6 4 mm gauge cocks Close the gauge cock leading to the pump suction and open the gauge cock leading to the pump discharge Close the discharge butterfly valve crack it open then start the pump and observe the gauge e Ifthe 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 e Ifthe 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 l Note Remote Air Cooled Pinnacle Startup 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 Touch the screen anywhere to display the Main Menu screen Turn on the pumps by selecting the Main Menu screen select the pumps you want to turn on at the Pumps screen Adjust the Freezestat cut out located in the main electrical enclosure to 10 F 6 b
46. fan cells e UL listed in the United States and Canada e Patented floating tube coil to eliminate tube sheet leaks e 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 e 208 V to 230 V 3 phase 60 Hz e 380 V 3 phase 50 Hz derate capacity by multiplying by 0 83 e 460V 3 phase 60 Hz e 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 gra
47. 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 e Reverse rotation can cause suction and discharge pressures to be approximately equal amp draws will be lower than normal Ifyou 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 e 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 Models 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
48. he System Status Refrigeration Circuit screens displays oystem Status Fefrigeration Circuit 1 Comp 14 Overload Comp 1B Overload Gircuit Gircuit Circult Circuit back more 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 n this example Circuit 1 Flow indicates an alarm condition To navigate to other System Status alarm display screens Press to go forward to the next screen or Press to display the previous screen To return to the Main Menu screen The Main Menu screen displays Appli i Page 58 SEC Engineering Pinnacle Series Central Chilling Stations Checking the CPU Battery To navigate to the System Status CPU screen Press The System Status CPU screen displays System Status CPU Low CPU Battery 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 B Press The Main Menu screen displays 7 6 Operating Chiller Station Compressor
49. he process temperature set point Press and hold A The temperature set point increments upward by single degrees F CUE Appli Pinnacle Series Central Chilling Stations Page 65 return to the Main Menu screen Press The Menu screen displays Viewing Temperature Trends To navigate to the Temperature Trend Graph display screen from the Temperatures screen GRPH B Press at the bottom left of the screen The Temperature Trend Graph screen displays Trend Graph LWI F Ju leg 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 30 F and 90 F 1 C and 32 C This function is available only with the optional Advanced Control Package Appli 66 Pinnacle Series Central Chilling Stations return to the Main Menu screen Press The Menu screen displays 7 9 Viewing Current System Capacities To view current system capacities start at the Main Menu screen then B Press The System Capacities screen displays
50. he 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 COE Application Engineering System Main Menu Compressors Pressures Temperatures Capacities innacle Series Appli i Engineering 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 screen button of the Main Menu screen The first System Status screen then displays 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 System Main Menu Startup Boot screen screen Pumps Alarms Compressors Pressures Temperatures Capaci
51. he 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 CON Applicati Engineering Pinnacle Series Central Chilling Stations Page 43 Figure 18 Typical Water Cooled Pinnacle Electrical Schematic Drawing 1 NF DISC DISTRIBUTION BLOCK E ___1 EE FU m 19 amt 4 _ COMPRESSOR 1A L2 PHASE gt 12 12 112 y 172 s G lt AMTR FLA t L3 PHASE 1 der 2FU 2 20L 2 211
52. ion and circuit re start Thirty 30 second interstage and three 3 minute anti recycle timers still govern the unit at this point Lead Lag Compressors 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 CKTS Available option would not respond The control button is green if all circuits are on CUE Appli i GEC Engineering Pinnacle Series Central Chilling Stations Page 31 2 Start Lead Lag by pushing the Start Auto button The button color changes to green 3 Setthe 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 Atset point compressors resequence using the following sequence Model Staging Lead PINN2 30 PINN2 45 1a 2a 2b 2b 2a 1a 1a 1b 2a 2b PINN3 75 1a 2a 2b 3b 2b 1 2 PINN3 90 1 16 2 26 3b 36 2a 2b 1a 1b Compressors revert back at 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 e Functions similar to Compressor Lead Lag operation 4 5 Chilled Water Circuit Make the process cooling water supply connection at the
53. les 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 COE Appli i Engineering Pinnacle Series Central Chilling Stations Page 35 Notes Appli i Page 36 SEC Endincering Pinnacle Series Central Chilling Stations 5 Startup Checklists 5 1 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
54. mp Pressures Process Pump PL 105 Recirculation Pump P2 68 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 B Press 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 Appli i Page 64 SEC Engineering Pinnacle Series Central Chilling Stations The System Temperatures operation screen displays Temperatures Process Supply Actual Proc Rn ss Decrease Increase System Temperatures Operation Screen The System Temperatures operation screen lets you e View process supply actual temperature in F e View process return actual temperature in F 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 The temperature set point increments downward by single degrees F or To increase t
55. mp operation Check flow through heat exchangers Check compressor efficiency Check noise levels Check cleanliness of equipment area COE Application Engineering Pinnacle Series Central Chilling Stations Page 71 Notes Appli i Page 72 SEC Endincering Pinnacle Series Central Chilling Stations 9 Troubleshooting Possible Cause Solution Check main disconnect fuses wiring and power lead to unit Voltage must be within plus Vrong vollage Supplied te or minus ten percent 10 unit of nameplate rating Replace fuse check transformer check wiring for loose wires check for shorted coils on contactors and Unit does not run solenoids check crankcase heater Defective control transformer Flow switch circuit is open pump for proper rotation Pump motor off on overload Reset and test motor Check that the chiller pump is running open switch or pressure switch Lower freeze control setting to 10 F 69 below the leaving temperature you want Air cooled units Check and clean air filters Check condenser fans for proper rotation Check for dirty Pump runs condenser Check for No power Control circuit fuse blown Unit is off on flow switch or pressure switch Freeze control set higher than temperature of liquid in system compressor does not condenser air obstruction High pressure refrigerant Check for tripped motor cu
56. n the system for operation Note The scroll compressors were phased with the pump s at the factory CUE Appli i Engineering 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 e 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 f 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 l Observe a pump pressure gauge connected to the suction and discharge sides of the pump casing through two 1 4 approx 6 4 mm gauge cocks Close the gauge cock leading to the pump suction and open the gauge cock leading to the pump discharge Close the discharge butterfly valve crack it open then start the pump and observe the gauge e Ifthe gauge indicates within 15 psi 103 4 kPa 1
57. ocess temperature return to the Main Menu screen then select Temperature select the process temperature you want by pressing or V 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 lt 2 M 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 M 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 fo
58. on 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 Appli i Page 78 SEC Endincering Pinnacle Series Central Chilling Stations AEC Inc warrants 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 liabl
59. optional Advanced Control Package To return to the Main Menu screen B Press 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 CUE Appli i Page 56 SEC Engineering Pinnacle Series Central Chilling Stations The System Status Process P1 amp Recirculation P2 Pumps screen displays System Status 5 Pi Pumps ok Alarm Pump Overload Pump P1 B Overload Pump P amp Overload Pump P B Overload more 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 n 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 Appli Pire iens Pinnacle Series Central Chilling Stations Page 57 The first of t
60. ph of leaving water temperature LWT over time Appli i Page 8 SEC Endincering 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 Appli i Engineering Pinnacle Series Central Chilling Stations Page 9 Figure 1 Typical Pinnacle Two Circuit Central Chilling Station Top View L WU 3 flange to tower 3 flange from tower water cooled only water cooled only 30 76 cm Water regulating valve recommended water cooled onl clearance y Tank cover S overflow
61. psig P99V1C A0556485 Transmitter flow sensor Data Ind 220B A0556486 Transmitter flow Data Ind Model 310 Service Notes Applicati Engineering Pinnacle Series Central Chilling Stations Page 77 COME Application Engineering 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 COM Application Engineering 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 COM Application OCC Engineering 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 COM Application Engineering Contract Department Call 847 273 7700 Monday Friday 8am 5pm CST Let AEC Applicati
62. r leads or motor leads for reversing rotation Do not use contactor or motor leads for phase matching e 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 Ifyou 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 Appli i GEC Engineering 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 e Disconnect and lock out power at the fused disconnect e 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 Pinnacle Central Chilling Stations 3 500 rpm 1 0 S G Meters PSI Feet Process P1 Pump Selections 60 Hertz 70 F 61 871 200 55 784 180 15 49 694 160 434 614 140 10 hp 37 524 1
63. r 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 M M M Complete all electrical wiring Observe all applicable codes M Prepare all related equipment in the system for operation Note The scroll compressors were phased with the at the factory e Never switch contactor leads or motor leads for reversing rotation Appli i Engineering Pinnacle Series Central Chilling Stations Page 39 not use contactor or motor leads for phase matching e 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 e Reverse rotation can cause suction and discharge pressures to be approximately equal amp draws are lower than normal e Ifyou 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 prop
64. s To operate chiller station compressors start at the Main Menu screen then B Press Appli i Engineering Pinnacle Series Central Chilling Stations Page 59 The Compressors On Off operation screen displays Compressors Orn OEE Circuit i Off Circuit 2 Off 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 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 is green is red and the opposite selection is black To return to the Main Menu screen The Main Menu screen displays Appli i Page 60 SEC Engineering Pinnacle Series Central Chilling Stations Viewing and Setting Compressor Circuit Times To navigate to the Compressor Lead Lag display screen Lead L B Press at the bottom of the screen The Compressor Lead Lag screen displays Comp Lead Lag All GETS Start Auto CHT SP 000 Compressor Lead Lag Operation Screen The Compressor Lead Lag operation screen lets you activate and deactivate the Compressor Lead Lag mode as
65. s to reduce piping expense e Locate adjacent to drain and city water sources e 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 lt 2 in accordance with NEMA MG1 14 32 Air cooled remote condensers must have properly sized disconnects conforming with all local codes Appli i Engineering Pinnacle Series Central Chilling Stations Page 19 Note The scroll compressors were phased with the pumps at the factory e Never switch contactor leads or motor leads for reversing rotation Do not use contactor or motor leads for phase matching e Compressor noise
66. ser Connections 3 10 Remote Air Cooled Condenser Installation 3 11 Motor Direction Check 4 Sequence of Operation eceauoccceeaauascccnnnu 31 4 1 Chilled Water Circuit 4 2 Refrigeration Circuit 4 3 Freezestat Control 4 4 High Pressure Cutout 4 5 Low Pressure Cutout 4 6 Flow Switch 4 7 Control Nipple 4 8 Control Probe 4 9 Chilled Water Manifold 4 10 Condenser Water Manifold COE Application Engineering Pinnacle Series Central Chilling Stations Page 3 Table of Contents 5 Startup Checklists eecccccccocococaue 35 5 1 Introduction 5 2 Water Cooled Pinnacle Startup Checklist 5 3 Water Cooled Pinnacle Startup 5 4 Remote Air Cooled Pinnacle Startup Checklist 5 5 Remote Air Cooled Pinnacle Startup 5 6 Determining Flow Rate 5 7 Shutdown 6 Graphic 41 6 1 Indicator Lights 6 2 Switches 7 Using the Touch Screen Interface 49 7 1 Touchscreen Interface Introduction MMI 7 2 Using the Pinnacle Touchscreen Interface 7 3 Getting Started on the Pinnacle Touchscreen Interface 7 4 Operating Chiller Station Pumps 7 5 Viewing System Statuses and Handling Alarm Conditions 7 6 Operating Chiller Station Compressors 7 7 Viewing Current Pump Pressures 7 8 Setting and Viewing System Temperatures 7 9 Viewing Current System Capacities 8 Routine
67. 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 M Advise AEC Inc regarding your wish for replacement and to obtain an 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 M Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Appli i Engineering Pinnacle Series Central Chilling Stations Page 17 M Component instruction manuals M 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 Inc immediately of the shortage 2 4 If the Shipment is Not Corr
68. ties selection selection selection selection selection selection Pumps System Status Compressors Pump Temperatures System On Off P1 P2 Pumps On Off Pressures Operation Capacities Screen Screen screen Screen Screen Screen Pumps System Status Compressors Temperature Lead Lag Ref Circ 1 Lead Lag Trend Graph Screen Screen Screen Screen Pump Run System Status Compressor Times Ref Circ 42 Run Times Screen Screen screen System Status Ref Circ 3 screen PLC BATT battery CUE Appli i Page 50 SEC Endincering Pinnacle Series Central Chilling Stations 7 3 Getting Started on the Pinnacle Touchscreen Interface To start the Pinnacle touchscreen interface B 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 Pinnacle System Startup Boot Screen Press anywhere on the System Startup Boot screen to continue CUE Appli Pinnacle Series Central Chilling Stations Page 51 The Menu screen displays Main Menu Bam Conpressors Pressures Main Menu Screen The Main Menu screen lets you gain access to e the screen button containing the Pump On Off operation screen the Pump Run Times display screen and the Lead Lag display screen e the screen button containing System Status operation and display screens and PLC St
69. tout switch contacts open 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 Appli i GEC Engineering Pinnacle Series Central Chilling Stations Page 73 Possible Cause Solution Allow time to cool and reset Check for high low voltage Voltage must be within plus or minus ten percent 10 Compressor internal overload of nameplate rating electrical connections on scroll compressors Repair or replace holding coil open Pump runs compressor does not cont d Sight glass should be clear Low refrigerant pressure while comperssor runs Call switch contact open for service if bubbling or foaming Defective pump motor interlock to compressor Repair or replace control circuit Broken wire in the Locate and repair compressor control circuit Lower set point to 10 F 690 Pump runs compressor Freezestat control setting is below the leaving water cycles at short intervals too high 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 5 mixture Leaving water temperature is the process not at set point Defective freezestat control Replace Refrigerant charge is low
70. ts 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 e 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 Appli i Page 6 SEC Endincering 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
71. uit 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 Applicati Engineering 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 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 e Water pressure 225 psi 2172 4 kPa gt 1 72 bars e Water temperature lt 85 lt 299 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
72. well as set the rotation schedule interval you want This function is available only with the optional Advanced Control Package C T 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 V 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 A increase The compressor lead lag value increases by 25 hour increments CON Applicati Engineering Pinnacle Series Central Chilling Stations Page 61 activate or deactivate the Compressor Lead Lag mode Make sure that you have energized all compressor circuits before continuing this procedure Press the screen button next tothe All CKTS Available screen prompt If the screen button turns green all compressor circuits are available for activating or deactivating the Compressor Lead Lag mode 0r Ifthe screen button stays red e alarm condition exists that prohibits you from activating or deactivating the Compressor Lead Lag mode Make sure you correct any alarm condition before continuing 0r You may not have energized all compressor cirucits To activate the Automatic Lead Lag mode Press the
73. y 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 Appli i Engineering 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

Download Pdf Manuals

Related Search

Related Contents

Delta 3564-SSMPU-DST Installation Guide  HSM Classic 225.2  Fiche produit  IDE/SATA HDD Enclosure - CNET Content Solutions  Guía del usuario de HP CD  Manual de Patrocinio y Esponsorización  Plasma/Serum HIV RT-PCR Detection Kit  2 Cliccate su [OK].  TARGET2 user Manual v1.3 changes  Samsung EV-1 Benutzerhandbuch  

Copyright © All rights reserved. Failed to retrieve file