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Econo-Cool Chillers
User Manual
69 pgs549.97 Kb0

AEC Econo-Cool Chillers User Manual

$30.00
Operation and Installation Manual
Economical Series
Water Temperature
Control Units
Important! Read Carefully Before Attempting to Install or Operate Equipment
Write down your unit serial number(s) ________________ ________________ here for future reference ________________ ________________ ________________ ________________ ________________ ________________
AEC 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, Inc. 2006 All rights reserved. Effective 7/27/2006 Part No. 682.91343.00 Revision NEW Bulletin No. AE1-655
Page 2 AEC Water Temperature Control Units
Please note that our address and phone information has changed. Please reference this page for updated contact information.
These manuals are obsolete and are provided only for their technical information, data and capacities. Portions of these manuals detailing procedures or precautions in the operation, inspection, maintenance and repair of the products may be inadequate, inaccurate, and/or incomplete and shouldn’t be relied upon. Please contact the ACS Group for more current information about these manuals and their warnings and precautions.
Parts and Service Department
The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in expediting your phone or fax order, please have the model and serial number of your unit when you contact us. A customer replacement parts list is included in this manual for your convenience. ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service.
For immediate assistance, please contact:
• North, Central and South America, 8am – 5pm CST +1 (800) 483-3919 for drying, conveying, heating and cooling and automation. For size reduction: +1 (800) 229-2919. North America, emergencies after 5pm CST (847) 439-5855
North America email: acsuscanadacustserv@corpemail.com
• Mexico, Central & South America Email: acslatinamericacustserv@corpemail.com
• Europe, Middle East & Africa +48 22 390 9720
Email: acseuropecustserv@corpemail.com
• India +91 21 35329112
Email: acsindiacustserv@corpemail.com
• Asia/Australia +86 512 8717 1919
Email: acsasiacustserv@corpemail.com
Sales and Contracting Department
Our products are sold by a worldwide network of independent sales representatives. Contact our Sales Department for the name of the sales representative nearest you.
Let us install your system. The Contract Department offers any or all of these services: project planning; system packages including drawings; equipment, labor, and construction materials; and union or non-union installations.
For assistance with your sales or system contracting needs please Call:
North, Central and South America +1 (262) 641-8600 or +1 (847) 273-7700 Monday–Friday, 8am–5pm CST
Europe/Middle East/Africa +48 22 390 9720 India +91 21 35329112 Asia/Australia +86 512 8717 1919
Facilities:
ACS offers facilities around the world to service you no matter where you are located. For more information, please visit us at www.acscorporate.com
United States:
ACS Schaumburg – Corporate Offices
1100 E. Woodfield Road Suite 588 Schaumburg, IL 60173 Phone: + 1 847 273 7700 Fax: + 1 847 273 7804
ACS New Berlin – Manufacturing Facility
2900 S. 160th Street New Berlin, WI 53151 Phone : +1 262 641 8600 Fax: + 1 262 641 8653
Asia/Australia:
ACS Suzhou
109 Xingpu Road SIP Suzhou, China 215126 Phone: + 86 8717 1919 Fax: +86 512 8717 1916
Europe/Middle East/Africa:
ACS Warsaw
Ul. Działkowa 115 02-234 Warszawa Phone: + 48 22 390 9720 Fax: +48 22 390 9724
India
ACS India
Gat No. 191/1, Sandbhor Complex Mhalunge, Chakan, Tal Khed, Dist. Pune 410501, India Phone: +91 21 35329112 Fax: + 91 20 40147576
Safety Considerations
Economical Series temperature control units 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:
; Only PROPERLY TRAINED personnel familiar with the
information within this manual should work on this equipment.
; Follow all local SAFETY CODES. ; AEC Economical Series cabinets and piping are hot and are
a BURN HAZARD.
; Do not operate an AEC system without all outer panels
installed. Pressurized hot water leaks can cause serious injury.
; Wear SAFETY GLASSES and WORK GLOVES. ; Use care when LOADING, UNLOADING, RIGGING,
or MOVING this equipment.
; Operate this equipment within design specifications. ; OPEN, TAG, and LOCK ALL DISCONNECTS before
working on equipment. We recommend following OSHA Lock-Out/Tag-Out Standard 29 CFR 1910.147.
; Make sure the unit is properly GROUNDED before
switching power on.
; When welding or brazing in or around this equipment, be
sure VENTILATION is ADEQUATE. PROTECT adjacent materials from flame or sparks by shielding with sheet metal. An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed.
; Do not jump or bypass any electrical safety control. ; Do not restore power until all tools, test equipment, etc.
have been removed and the panels replaced.
AEC Water Temperature Control Units Page 3
Table of Contents
1-1 Introduction.....................................................................................7
1-2 Necessary Documents....................................................................8
1-3 Models Covered.............................................................................. 8
1-4 Standard Features .......................................................................... 8
1-5 Available Options............................................................................ 9
2-1 Unpacking and Inspection............................................................. 13
2-2 In the Event of Shipping Damages................................................13
2-3 If the Shipment is Not Complete....................................................14
2-4 If the Shipment is Not Correct....................................................... 14
2-5 Returns ......................................................................................... 14
2-6 Uncrating Your New Economical Series System........................... 15
3-1 Installation Location Considerations.............................................. 17
3-2 Process Approach Temperature Considerations........................... 17
3-3 External Piping Sizing Considerations .......................................... 17
3-4 Piping Considerations for Permanent Installations........................ 18
3-5 Piping Considerations for High Mobility Installations.....................19
3-6 Process Water Considerations......................................................19
3-7 Making Process Water Connections............................................. 20
3-8 Making Cooling Water Connections.............................................. 21
3-9 Making System Purge Connections.............................................. 22
3-10 Making Electrical Connections...................................................... 25
4-1 Identifying Mechanical Controls and Features .............................. 27
4-2 The Microprocessor Controller...................................................... 31
4-3 Controller Display..........................................................................31
4-4 Using Controller Keys ................................................................... 32
4-5 Using Graphic Panel Buttons........................................................ 33
4-6 Alarms........................................................................................... 34
4-7 Controller Factory Setup............................................................... 34
4-8 Controller Internal Switches.......................................................... 35
4-9 Controller Factory Setup............................................................... 35
4-10 Auto-Tuning the Controller............................................................ 35
4-11 Changing from Fahrenheit to Celsius............................................36
4-12 Operating the Unit with the Controller........................................... 36
Page 4 AEC Water Temperature Control Units
5-1 Introduction...................................................................................38
5-2 Startup Checklist........................................................................... 38
5-3 Starting the Temperature Control Unit .......................................... 39
5-4 Operating the Unit with the Controller........................................... 40
5-5 Sequence of Operation................................................................. 41
5-6 Checking Motor Rotation Direction................................................ 42
5-7 Shutting Down the Temperature Control Unit ...............................42
6-1 Preventive Maintenance................................................................ 43
6-2 Corrective Maintenance................................................................ 44
6-3 Restoring the Controller to Factory Setup.....................................46
6-4 Electrical Connections................................................................... 54
6-5 Safety Devices.............................................................................. 55
6-6 Cleaning and Storage ................................................................... 57
AEC Water Temperature Control Units Page 5
Charts and Figures
Typical Economical Series Water Temperature Control Unit
1 2 3 4 5 6 7 8
and Specifications 11
Economical Series Unit Full-Load Amps 11
Typical Piping Schematic 23
Pump Curves; 60 Hz and 50 Hz 24
Pressure Drops 24
Typical E5CK Microprocessor Controller 31
Display Readout for Mode Settings 50
Setting List for Process Temperature Controller 53
9
Pressure Switch; Side View and Top View 58
Page 6 AEC Water Temperature Control Units
1 General Information
1-1 Introduction
AEC water temperature control units are reliable, accurate, and easy-to-use process temperature control units. They are self-contained, portable, and shipped ready to use.
The Economical Series water temperature control unit is designed to circulate water through your process and to precisely, automatically, and reliably maintain it at a specified temperature. Standard unit operating range is from 0ºF (-17ºC) to 250°F (121°C), or up to 300°F (149°C) as an option. The unit is suited for use with city water, water from portable or central chillers or towers, or well water.
These units are designed for rapid recirculation of a relatively small amount of water to provide close and uniform temperature relation between To Process and From Process lines. This performance, of course, depends on the configuration of your process and any restrictions within the mold. The recirculation, combined with the large immersion heater and cooling capability, gives fast and accurate response to bring the water up to temperature or to changes in the settings when needed.
The ECU Series water temperature control unit is a self-contained system consisting of a centrifugal pump, electric immersion heater, cool/vent solenoid valve, and electrical control, including a PID microprocessor controller and thermocouple. It is designed for use in process temperature control applications using water or a water/glycol mix. Any other use or fluid is prohibited.
Some standard safety devices include a mechanical overtemperature safety thermostat, a pressure relief valve, motor overload protection, a low pressure cutout switch, branch fusing, and non-fused lockable rotary disconnect.
A properly installed, operated, and maintained AEC system provides years of reliable operation. Please read and follow the instructions in this manual to get the most satisfaction from your AEC system.
AEC Water Temperature Control Units Page 7
1-2 Necessary Documents
The following documents are necessary for the operation, installation, and maintenance of AEC water temperature control units. Additional copies are available from AEC.
Familiarize the appropriate personnel with these documents:
; This manual. ; The controller operation manual. ; The electrical schematic and connection diagram placed inside
the control enclosure.
; The 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
This manual provides operation, installation, and maintenance instructions for AEC water temperature control unit.
Make sure that you know the model number, serial number, and operating voltage of your temperature control unit if you contact AEC.
1-4 Standard Features
• Compact, rugged cabinet with easy-access side panels
• Cast-and-flange design to reduce connection points
• Incoloy™ immersion heater with IEC contactors
• NEMA 1 electrical enclosure
• Off-the-shelf microprocessor controller; display includes
diagnostics features with indicator and warning status lights; CE and CUL
Page 8 AEC Water Temperature Control Units
• Independent high temperature safety thermostat
• Branch fusing
• ¼” cooling solenoid valve on all sizes
• EPDM/NI-Resist pump seal
• Adjustable low supply water pressure switch; factory-set at
16 psig (110 kPa/1.1 bars)
• 150 psig (1,034 kPa/10.3 bars) pressure relief valve
• ¾” water supply and drain connections; 1½” process
connections
• Automatic vent sequence
• 2” (76 mm) casters
• Operating range of 0ºF to 250ºF (-17ºC to 121ºC)
• One (1) -year parts and labor warranty at the factory; three
(3) -year controller warranty, and limited lifetime warranty on wetted pump components.
1-5 Available Options
Economical Series systems are available with options to tailor the unit to your requirements. Some are factory installed; some can be retro-fitted in the field. Consult your sales representative for more information. Available Economical Series options include:
• RS-232 or RS-485 communications
• Heater upgrade available to 12 kW
• Quick Cool function
• Manual bypass
• Auto system water purge (mold purge)
• Y-strainer
• Hammer arrestor (water hammer shock stop)
• Remote start/stop control
• Rubber feet; available in lieu of casters
• ½” slow-close cooling solenoid valves available on all sizes
• Two-zone stack rack with casters, common wiring and piping
available
AEC Water Temperature Control Units Page 9
• 300ºF (149ºC) operation; includes graphite-impregnated
silicon carbide seal
• Audible and visual general fault alarm
• Electrical operation available in 208, 230, 460, and 575 volts,
60 Hz; 200, 380, and 415 volts, 50 Hz
• 10 foot power cord; no plug, shipped loose
• UL/CUL-listed electrical subpanel
Page 10 AEC Water Temperature Control Units
Figure 1
Typical Economical Series Water Temperature Control Unit and Specifications
Direct Injection
Model Dimensions Shipping
number Pump H W D weight
460 / 230 hp
ECU,
9 kW heater
1 2 3 5 7½
¾
kW
0.56
0.75
1.50
2.24
3.73
5.60
gpm
30 35 50 60 75 90
lpm
113.6
132.5
189.3
227.1
283.9
454.2
psig
25 30 30 35 54 63
kPa
172.4
206.9
206.9
241.3
372.3
434.4
in.
25¾”
cm
65.4
in.
12 “
cm
30.5
in.
23”
cm
58.4
lbs.
210
240
Kg
96
109
Figure 2
Economical Series Unit Full-Load Amps
Model Full-load amps at 460 volts
hp kW 9 kW heater 12 kW heater
0.75 hp
1.00 hp
2.00 hp
3.00 hp
5.00 hp
7.50 hp
0.56 kW
0.75 kW
1.50 kW
2.24 kW
3.73 kW
5.60 kW
12.7 amps 16.5 amps
13.1 amps 16.9 amps
14.7 amps 18.5 amps
16.1 amps 19.9 amps
18.9 amps 22.7 amps
22.3 amps 26.1 amps
AEC Water Temperature Control Units Page 11
-Notes-
Page 12 AEC Water Temperature Control Units
2 Shipping Information
2-1 Unpacking and Inspection
You should inspect your Economical Series temperature control unit 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.
; 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 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, contact AEC at (847) 273-7700 for a receipted transportation bill.
; Advise AEC regarding your request for assistance and to
obtain an RGA (return goods authorization) number.
AEC Water Temperature Control Units Page 13
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 Economical Series water temperature control unit ; Bill of lading ; Packing list ; Operating and Installation packet ; Electrical schematic and panel layout drawings ; Component instruction manuals
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 immediately of the shortage.
2-4 If the Shipment is Not Correct
If the shipment is not what you ordered, contact AEC immediately. Include the order number and item. Hold the items until you receive shipping instructions.
2-5 Returns
Do not return any damaged or incorrect items
until you receive shipping instructions from AEC.
Important!
Page 14 AEC Water Temperature Control Units
2-6 Uncrating Your New Economical Series System
; AEC Economical Series water temperature control units are
shipped in a cardboard box surrounded by individual foam pieces.
; Carefully open the top of the box and remove the front and
back pieces of foam.
Caution!
Be careful when cutting straps.
Straps may spring back and cause injury!
; From the top, slip two lifting straps between the bottom piece
of foam and temperature control unit. Spread the straps from the center line so it is balanced.
; Loop the straps over a fork truck fork. Lift slowly and only
high enough to clear the box..
; Carefully slide the box from beneath the unit and lower the
unit. Lower slowly. The unit should land on its casters and can be rolled into position.
; Retain the crating in case reshipment is necessary due to
hidden shipping damage.
AEC Water Temperature Control Units Page 15
- Notes -
Page 16 AEC Water Temperature Control Units
3 Installation
3-1 Installation Location Considerations
Economical Series systems are portable and can be installed almost anywhere. As with all equipment installations, follow all applicable codes and regulations.
; The recommended ambient temperature range for Economical
Series installations is from +14ºF (-10ºC) to a maximum operating ambient temperature of 131°F (55ºC). Recommended
ambient storage temperature range is from -13ºF to 149ºF (­25ºC to 65ºC). If storing the unit below freezing temperatures, make sure the unit has an antifreeze mixture circulated inside.
; Provide a minimum of twelve inches (12” or about 30 cm)
clearance on all sides of the cabinet to allow circulation of cooling air.
; Locate the unit as close to the process as is practical.
3-2 Process Approach Temperature Considerations
If the differential (U) between COOLING WATER IN and TO PROCESS temperatures is less than 10°F (7ºC), consult our Sales Department for advice on how to control low
approach applications.
3-3 External Piping Sizing Considerations
; All external hose and piping should be adequately sized to
assure minimum external pressure drop.
; Low external piping pressure drop is needed for best operation.
AEC Water Temperature Control Units Page 17
Note: Use a backup wrench to support Economical Series system piping when making process piping connections.
! CAUTION
All external valves, fittings, and hoses must be rated at a minimum of
150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC).
The exception is when the temperature control unit
is optionally rated for 300ºF (149ºC) operation;
external valves fittings and hoses must then be rated at a minimum of
150 psig and 300ºF (1,034.25 kPa/10.34 bars and 121ºC).
3-4 Piping Considerations for Permanent
Installations
We recommend an optional (or customer-installed) strainer on the COOLING WATER
IN
inlet.
The unit must have at least 16 psig (110.32 kPa/1.1 bars) water supply pressure to prevent pump cavitation that can be caused by the water “flashing” to steam. To avoid damage to the pump or other components, make sure that maximum supply pressure does not exceed 75 psig (517.1 kPa/5.17 bars).
Keep restrictions to a minimum by using proper inlet pipe sizing. If the water supply piping is larger than ¾”, reduce the size at the unit. The table below contains the pipe sizes that are used in the unit.
Pipe sizes for ¾ hp to 7.5 hp (0.56 kW to 5.59 kW) units
Location Size in inches NPT
To Process 1½” From Process 1½” Cooling Water In ¾” Cooling Water Out
Common black pipe is recommended for permanent installations. Economical Series water circuit piping is primarily ferrous (iron) and reacts electro-chemically with non­ferrous metallic materials such as copper. Some water contains dissolved minerals that greatly accelerate the reaction between dissimilar metals. Ferrous piping is recommended to minimize galvanic action. If piping must be copper, use dielectric unions at the unit.
- depends on solenoid used -
Page 18 AEC Water Temperature Control Units
3-5 Piping Considerations for High Mobility
Installations
Mobile Economical Series systems must use high quality hose rated for at least 150 psig and 250°F (1,034.25 kPa/10.34 bars and 121ºC). Special 300°F (149ºC) high temperature Economical Series systems must use hosing rated at 150 psig and 300°F
(1,034.25 kPa/10.34 bars and 149ºC) or greater.
Quick disconnects may be used for mobility, although they cause a drop in pressure. If used, they must be sized carefully to minimize pressure drop. Don’t use quick disconnects with check valves unless absolutely necessary.
! CAUTION
Non-relieving quick connect fittings or check valves on the water supply
must have a pressure relief piped to the drain.
Failure to do so could result in a dangerous over-pressure condition!
3-6 Process Water Considerations
Raw Water
Water treatment is vital in any piping system. In some cases, raw water may be used in the system without problems; in other cases, it can result in large deposits of scale and corrosion.
We offer a complete line of water treatment equipment. Contact your sales representative for water testing and treatment options.
Distilled Water
Non-ferrous (brass, copper, or high-temperature plastic) piping is recommended for distilled water processes.
AEC Water Temperature Control Units Page 19
Deionized Water
Stainless steel (316 SS minimum) or PVC plastic components must be used with deionized water. We recommends stainless steel because of the temperature constraints with plastic.
3-7 Making Process Water Connections
Direct Injection
On the back of each unit, the connections are labeled appropriately. For Direct Injection units connect the TO PROCESS hookup to the entrance of the process and the the exit of the process. Connect the
IN
to your plant water supply. Connect the COOLING WATER OUT line to an open drain, or to the return line of your central water system.
Make sure you carefully select the connecting lines and connectors between the temperature control unit and the process to suit the needs and requirements of your application.
If your unit has a maximum operating temperature of 250ºF (121ºC), the connecting lines and connectors should have a service rating of at least 250ºF (121ºC) and 150 psig (1,034.25 kPa/10.34 bars). If it has a maximum temperature of 300ºF (149ºC), the lines and connectors should have a service rating of at least 300ºF (149ºC) and 150 psig (1,034.25 kPa/10.34 bars).
TO PROCESS — 1½” NPT
FROM PROCESS hookup to
COOLING WATER
This is the outlet for the tempered water leading to the process being controlled.
FROM PROCESS — 1½” NPT
Water from the process re-enters Economical Series system to be tempered and re­circulated back into the process.
Page 20 AEC Water Temperature Control Units
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