PS-025 QuarterHorse Series
0.25 hp Portable Chiller
Operation and Installation Manual
AEC, Inc./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 9/24/02
Page 2 PS QuarterHorse Series Chillers
Safety Considerations
PS Series Chillers are designed to provide safe and reliable operation when
installed and operated within design specifications, following national and local
safety codes.
To avoid possible personnel injury or equipment damage when installing,
operating or maintaining this equipment, use good judgment and follow these
safe practices:
; Follow all SAFETY CODES.
; Wear SAFETY GLASSES and WORK GLOVES.
; 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. It is a good idea to remove the fuses and carry them
with you.
; Make sure the chiller 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.
; The refrigeration system can develop refrigerant pressures in excess
of 500 psi (3,450 kPa). DO NOT CUT into the system without first
relieving pressure.
; 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.
; Only PROPERLY TRAINED personnel familiar with the
information within this manual should work on this equipment.
PS QuarterHorse Series Chillers Page 3
Table of Contents
1
2
3
General Information .................................................7
1-1 Introduction
1-2 Necessary Documents
1-3 Models Covered
1-4 Available Options
1-5 Uncrating Your New Chiller
1-6 In the Event of Shipping Damages
1-7 If the Shipment is Not Complete
1-8 If the Shipment is Incorrect
1-9 Returns
Chiller Installation...................................................11
2-1 Electrical Connections
2-2 Process Water Connections
2-3 PS Condenser Air Supply
2-4 Water Reservoir
2-5 Overhead Process Considerations
Sequence of Operation ..........................................15
3-1 Chilled Water Circuit
3-2 Refrigeration Circuit
Page 4 PS QuarterHorse Series Chillers
Table of Contents
4
5
6
7
Startup Checklists ..................................................17
4-1 Introduction
4-2 PS Pre-Startup Checklist
4-3 PS Startup Checklist
Microprocessor Control.........................................19
5-1 Introduction
5-2 Setting the Process Water Temperature
5-3 Power Switch
Routine Maintenance .............................................21
6-1 Lubrication
6-2 Condenser Maintenance
Troubleshooting Guide .......................................... 23
PS QuarterHorse Series Chillers Page 5
Charts and Figures
1
PS050A Process Pump Curves 10
2
PS Series Chiller Specifications 10
3
Ethylene Glycol Curve 13
4
Overhead Piping 14
Page 6 PS QuarterHorse Series Chillers
1 General Information
1-1 Introduction
PS Series Water Chillers are reliable, accurate, and easy-to-use air cooled chillers
designed for use with water/glycol. Standard range of operation is 50°F to 70°F (10°C
to 21°C). This PS chiller is a ¼ hp (187 W) model and has an internal one gallon (3.8
liter) reservoir. It is self contained, fully assembled, and shipped ready to use.
A properly installed, operated, and maintained PS Series Chiller will provide many
years of reliable operation. To get the most satisfaction from your new chiller, read and
follow the instructions in this manual.
1-2 Necessary Documents
The following documents are necessary for the operation, installation and maintenance
PS Series Chillers. Additional copies are available from Application Engineering.
Familiarize the appropriate personnel with these documents:
; This manual.
; The electrical schematic and connection diagram.
; The operation and installation manuals for installed accessories and options.
1-3 Models Covered
This manual provides operation, installation, and maintenance instructions for PS-025
QuarterHorse Series chillers. Model numbers are on the serial tag. Please know the
model number, serial number and operating voltage of your chiller if you need to
contact Application Engineering.
The PS QuarterHorse Series chiller model is designated by approximate compressor
horsepower. An PS025 chiller has a ¼ hp (187 W) compressor.
PS QuarterHorse Series Chillers Page 7
1-4 Available Options
PS Series chillers are available with options that tailor the unit to your requirements.
Some are factory installed, some can be retrofitted in the field. Consult your local
Application Engineering Sales Representative. Some of these options are:
Power Cord
A 6 foot (1.8 m) power cord is available to speed PS installation.
Feet
Four leveling feet are mounted to the base of the PS unit.
1-5 Uncrating Your New Chiller
PS Series chillers are shipped mounted on a skid, enclosed in a plastic wrapper, and
open crated on all four sides and top.
; Pry the crating away from the skid and remove. Use a pry bar to remove the
blocks securing the unit to the skid.
; Lift the unit off the skid with a fork truck. Insert forks between skid and chiller
from the side until they protrude beyond the opposite side of the unit. The forks
must be equidistant from the center line of the unit and the unit must be balanced
on the forks.
; Lift slowly and only high enough to clear the skid. Use a pry bar if necessary to
remove the skid from the unit.
; Lower slowly. The unit will land on its feet or casters and can be moved into
position.
Page 8 PS QuarterHorse Series Chillers
1-6 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.
; Hold the damaged goods and packing material for the examining agent’s
inspection. Do not return any goods to Application Engineering before the
transportation company's 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.
1-7 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:
; PS Series Chiller
; Bill of Lading
; Packing list
; Operating and Installation packet
Re-inspect the container and packing material to see if smaller items have been missed
during unpacking. Determine that the item was not taken from the area before the
shipment was checked in. Notify Application Engineering immediately of the shortage.
1-8 If the Shipment is Incorrect
; If the shipment is not what you ordered, contact Application Engineering
immediately. Include the order number and item.
; Hold the items until shipping instructions are received.
PS QuarterHorse Series Chillers Page 9
1-9 Returns
Do not return any damaged or incorrect items until
you receive shipping instructions from Application Engineering.
Important!
Figure 1
PS025 Process Pump Curve
TOTAL HEA D
MTRS
PSI FEE T
49
69 160
37 52 120
24
35 80
12 18 40
U. S. GALLONS
PER MINUTE
LITRE S
PER MINUTE
0.4
1.5
0.8
3.0
1.2
4.5
CURVES R EPRESEN T PUMP DISC HARGE ADJUSTED FOR IN TERNAL BY-PASS
PS025 - PROCESS PUMPS SELECTION
1.6
6.1
60 HERTZ PUMP CURVE
2.0
7.6
2.4
9.1
2.8
10. 6
3.2
12. 1
3.6
13. 6
4.0
15. 1
4.4
16. 7
4.8
18. 2
Do not extrapolate pump curves.
Figure 2
PS Series Chiller Specifications
PS
Quarter-
Horse
Series
PS-025 BTUH gpm hp Pump inches NPT running L W H lbs. lbs.
American
standards
Cap. @
65°F lwt,
90°F
ambient
Nominal
chilled
water Compressor
2,213 2 ¼
1
/3 hp,
2 gpm @
50 psig
Amp
Process
connection
draw
230/1/60
Dimensions
inches
Oper.
weight
½ 6.7 A 20 26 34 100 100
weight
Ship.
PS
Quarter-
Horse
Series
Cap. @
18°C lwt,
24°C
ambient
Nominal
chilled
water Compressor
Process
connection
Amp
draw
230/1/60
DimensionscmOper.
weight
Ship.
weight
PS-025 watts lpm watts Pump inches NPT running L W H kg kg
Metric
standards
64.8 7.6 187
224 watts,
7.6 lpm @
345 kPa
½ 6.7 A 483266 46 46
Page 10 PS QuarterHorse Series Chillers
2 Chiller Installation
2-1 Electrical Connections
Check serial tag voltage and amperage requirements and make sure your electrical
service conforms. See Figure 2 on Page 10 for total running amps.
; Electrical connections must comply with all applicable electrical codes.
; The chiller must be grounded in accordance with NEC Article 250.
; Voltage must be within 10% of the chiller’s nameplate rating.
2-2 Process Water Connections
; All external chilled water connections to the process must be of adequate
size.
; See Figure 4 on Page 14 for sizing recommendations.
; The largest possible openings and passages should be provided for the flow
of chilled water through platens, dies, molds or other pieces of equipment.
Important!
Keep any pressure drop in external process piping
to an absolute minimum for optimum unit operation.
To Process
Connect the
From Process
Connect the
back into the chiller for cooling and recirculation.
TO PROCESS
FROM PROCESS
; This chiller model has a strainer on the
chilled water supply outlet to the process being cooled.
chilled water return inlet to the return from the process
FROM PROCESS
return line.
PS QuarterHorse Series Chillers Page 11
Process Water Bypass
All PS chillers have an internal bypass device. If the process flow becomes blocked
during chiller operation, this component allows water to flow through the chiller. This
protects the chiller from freeze-up, excessive pressures, and pump damage, and allows
other safety features to remain effective.
2-3 PS Condenser Air Supply
PS chillers use the surrounding air to cool the condenser.
; Condenser air entering the PS unit should be at least 65°F (18°C). Operation
with air below 65°F (18°C) can cause the chiller to have low refrigerant
pressure.
; Install the chiller in an area where there is free passage of air for
condensing.
; Provide 18” (46 cm) or more clearance for the chiller’s air intake.
; Make provisions to exhaust the heated air discharged from the chiller.
; Do not put the PS unit where steam, hot air or fume exhausts will be drawn
into the condenser.
; Air-cooled condensers must be cleaned frequently. Neglect reduces
capacity, increases operating costs, and leads to possible chiller failure. See
Chapter 6 on Page 21 for cleaning instructions.
; Normal condensing pressure with 95°F (35°C) air is approximately 180 psi
(1,241 kPa).
PS Ambient Temperature Ranges
Ambient temperature range Minimum temperature Maximum temperature
Operation 65°F (18°C) 100°F (38°C)
Storage 40°F (4°C) 120°F (49°C)
2-4 Water Reservoir
During startup and when additional solution is required, see Figure 3 on Page 14 for the
recommended ethylene glycol/water solution. This chart shows the proportions needed
to provide freeze protection to 20°F/11°C below the desired process set point.
; Add a pre-mixed solution to provide freeze protection to a temperature 20°
F/11°C below the normal operating temperature of the chiller.
; Use industrial quality (not automotive) ethylene glycol.
; A corrosion inhibitor suitable for the materials in the system should be
added to the glycol/water solution.
Page 12 PS QuarterHorse Series Chillers
; If you want to use straight water, contact Application Engineering’s,
Engineering Department.
; The 1 gallon (3.8 liter) reservoir is not designed to withstand water pressure
above 5 psi (34 kPa).
; The fill opening and vent line must be vented to the atmosphere for proper
operation.
Properly Venting and Filling the Reservoir Tank
To properly vent and fill the tank:
• Remove the side panel, then remove the bushing installed on the top of the
tank.
• Install a pipe nipple and tee to the ¾” coupling on top of the tank.
• Use one side of the tee for the vent line and the other side for the fill line.
• Fill the tank.
• Remove the fittings and re-install the bushing
• Extend the vent line from the tank to a proper drain.
Ethylene
glycol
percent
by
volume
• Re-install the side panel.
Figure 3
Ethylene Glycol Curve
Ethylene glycol required
30%
20%
10%
0%
0º 30º 40º 50º 60º 70º
Normal operating range is between 30°F and 70°F
for evaporator freeze protection
Chilled water
operating temperature °F
(set point)
PS QuarterHorse Series Chillers Page 13
2-5 Overhead Process Considerations
If your application has chilled water or process piping above the reservoir fill and vent
level, install a standpipe to a point 1’ (30 cm) above the highest point in the system.
In applications where the process or its piping is 15 feet (4.6 m) or more above the
reservoir, you must take steps to prevent over-pressurization of the reservoir. This
condition can occur on system shutdown when the water in the system drains into the
reservoir.
To prevent this, install a check valve in the unit
breaker at the high point of the return
FROM PROCESS
TO PROCESS
line. See Figure 4 below for
line and a vacuum
more information.
Note: The reserve capacity of the reservoir can hold a volume equal to 20 feet (6.1 m) of 1-inch
(2.5 cm) pipe.
Figure 4
Overhead Piping
The reservoir vent & fill line
to be piped 12" above the highest
point of the system. The vent line
must remain open to the atmosphere.
Vent
12"
1/4"
Vacuum Breaker
Assembly
Check
Valve
Process Return
Cap
1/8"
Hole
6" Min.
Strainer
Add check valve
if system piping
extends 15 feet
above reservoir.
Indicates end of Application Engineering piping
Process Supply
Page 14 PS QuarterHorse Series Chillers
3 Sequence of Operation
Important!
The PS unit has a leaving water temperature range of 50°F to 70°F (10°C to 18°C).
Do not attempt to run the PS unit outside this temperature range
or damage to the unit may occur
3-1 Chilled Water Circuit
; Process cooling water supply and return connections are made at the pipe
stubs at the rear of the chiller.
; Warm water returns from the process, passes through the strainer, and enters
the reservoir tank.
; The process water is pumped through the evaporator where it is cooled.
; The coolant flows to the process and returns to repeat the cycle.
.
; A chilled water bypass assembly between the supply and return lines
guarantees a constant flow through the evaporator during intermittent low or
no-flow conditions.
3-2 Refrigeration Circuit
Liquid refrigerant passes through the thermal expansion valve which allows
the refrigerant to expand and cool the inside of the heat exchanger. The
refrigerant flows through the suction line to the compressor.
The refrigerant gives up its heat as it re-condenses to a liquid in the
condenser and the cycle starts over again.
PS QuarterHorse Series Chillers Page 15
- Notes -
Page 16 PS QuarterHorse Series Chillers
PS-025 QuarterHorse Series
0.25 hp Portable Chiller
Operation and Installation Manual
- Notes -
Page 18 PS QuarterHorse Series Chillers
5 Microprocessor Control
5-1 Introduction
Standard PS Series chillers use a microprocessor based controller. The controller is a
modular, self-contained unit that can slide from its mounting housing. It is factory set
and adjusted; no field adjustment to the internal controls is necessary.
5-2 Setting the Process Water Temperature
• Press and hold the star key.
• While holding down the star key, press the arrow up or arrow down key to
raise or lower the process water temperature set point.
5-3 Power Switch
POWER
This switch energizes the control circuit; it also turns off the chiller.
PS QuarterHorse Series Chillers Page 19
- Notes -
Page 20 PS QuarterHorse Series Chillers
6 Routine Maintenance
6-1 Lubrication
Every three months, grease all fan motors and pump motors that do not have
permanently sealed bearings. Remove grease relief plug (motors only) before adding
grease. Failure to do so may result in dislodging the bearing grease retainer, eventually
causing bearing failure.
Compressors are hermetically sealed; no oiling is required.
6-2 Condenser Maintenance
Dirty condenser heat exchange surfaces reduce system capacity.
Brush or vacuum light dirt accumulations. Avoid bending or damaging the fins. Heavy
soil accumulations on the coil require professional steam cleaning; washing from the
outside only makes matters worse.
PS QuarterHorse Series Chillers Page 21
- Notes -
Page 22 PS QuarterHorse Series Chillers
7 Troubleshooting Guide
Problem Possible cause Solution
Check main disconnect
No power.
Wrong voltage supplied to
Chiller will not run.
The leaving water
temperature is too high.
Pump pressure is low
(see pump curve).
Pump pressure is too high. Restricted water flow.
Pump runs, compressor will
not.
Unit runs continuously, but
not enough cooling power.
the chiller.
Defective on/off switch. Replace.
Control circuit fuse blown.
Defective control transformer. Replace.
Refrigerant is low. Check the refrigerant charge.
Improper water/glycol
solution.
Check for foreign matter. Clean the system.
Refrigerant is low. Check the refrigerant charge.
Defective fan motor. Repair or replace.
Compressor internal overload
is open. Allow time to cool
and reset.
Broken wire in the
compressor control circuit.
Restricted condenser airflow. Clean the condenser.
Unit low on refrigerant. Call Service.
Inefficient compressor. Call Service.
Unit undersized for
application.
fuses, wiring, and power lead
to the unit.
Voltage must be within plus
or minus 10% of the
nameplate rating.
Replace, check the
transformer.
Make sure that the coolant
solution is right for the
process — must be 75%
water and 25% glycol.
See Figure 3 on Page 13 for
more information.
Check for partially closed
valves, etc. Be sure all lines
are properly sized.
Check for high/low voltage.
Must be within plus or minus
10% of the nameplate rating.
Check for poor compressor
electrical connections.
Locate and repair.
Call Sales Representative.
PS QuarterHorse Series Chillers Page 23
Service Notes
Page 24 PS QuarterHorse Series Chillers
Service Notes
PS QuarterHorse Series Chillers Page 25
Parts Department
Call toll-free 7am–6pm CST [800] 423-3183 or call
The AEC/Application Engineering Parts Department at AEC, Inc. is ready to provide the parts to keep your systems
up and running. AEC/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.
[847]
273-7700
Service Department
Call toll-free 8am–5pm CST [800] 233-4819 or call
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.
[847] 273
-7700
Sales Department
[847]
Call
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.
273-7700 Monday –Friday, 8am-5pm CST
Contract Department
[847]
Call
Let AEC/Application Engineering 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.
AEC, Inc.
1100 E. Woodfield Road, Suite 588
Schaumburg, IL 60713
Page 26 PS QuarterHorse Series Chillers
273-7700 Monday–Friday, 8am–5pm CST
Warranty
AEC, Inc. warrants all equipment manufactured by it to be free from defects in workmanship and
material when used under recommended conditions. The Company’s obligation is limited to repair
or replace FOB the factory any parts that are returned prepaid within one year of equipment
shipment to the original purchaser, and which, in the Company’s opinion, are defective. Any
replacement part assumes the unused portion of this warranty.
This parts warranty does not cover any labor charges for replacement of parts, adjustment repairs,
or any other work. This warranty does not apply to any equipment which, in the Company’s opinion,
has been subjected to misuse, negligence, or operation in excess of recommended limits, including
freezing or which has been repaired or altered without the Company’s express authorization. If the
serial number has been defaced or removed from the component, the warranty on that component
is void. Defective parts become the property of the warrantor and are to be returned.
The Company is not liable for any incidental, consequential, or special damages or expenses. The
Company’s obligation for parts not furnished as components of its manufactured equipment is
limited to the warranty of the manufacturers of said parts.
Any sales, use, excise, or other tax incident to the replacement of parts under this warranty is the
responsibility of the purchaser.
The company neither assumes nor authorizes any other persons to assume for it any liability in
connection with the sale of its equipment not expressed in this warranty.
Many types of AEC, Inc. equipment carry an additional one-year service policy. Consult your AEC
sales representative for specific details.
801 AEC Drive • Wood Dale, Illinois 60191-1198 USA
Phone (630) 595-1060 • Fax (630) 595-6641
http://www.aecinternet.com
801 AEC Drive • Wood Dale, IL 60191-1198 USA
(630) 595-1060 • Fax (630) 595-6641
http://www.aecinternet.com
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