AEC PCA SERIES Specification sheet

OPERATIONANDINSTALLATIONMANUAL
PCA SERIES 0.5 – 1.5 hp
AIR COOLED
PORTABLE WATER CHILLERS
IMPORTANT:PLEASEREADCAREFULLYBEFOREATTEMPTINGTOINSTALL OR OPERATE
EQUIPMENT
$3000

Page 2 PCA Series Chillers
AEC, Inc. is committed to a continuous program of product improvement.
Specifications are subject to change without notice.
©AEC, Inc. 2008
All Rights Reserved
Effective 4-29-2008 Part Number A0537986 Bulletin: AE2-615A.5

PCA Series Chillers Page 3
Safety Considerations
AEC, Inc. PCA 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.

Page 4 PCA Series Chillers
Table of Contents
1General 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
2Chiller Installation ..................................................13
2-1 Electrical Connections
2-2 Process Water Connections
2-3 PCA Condenser Air Supply
2-4 Water Reservoir
2-5 Overhead Process Considerations
3Sequence of Operation ..........................................17
3-1 Chilled Water Circuit
3-2 Refrigeration Circuit
3-3 High Pressure Cutout
3-4 Low Pressure Cutout
3-5 Remote Start/Stop Interlock

PCA Series Chillers Page 5
Table of Contents
4Startup Checklists..................................................23
4-1 Introduction
4-2 PCA Pre-Startup Checklist
4-3 PCA Startup Checklist
4-4 PCA Water Circuit Pressure Drop Table
5Microprocessor Control.........................................25
5-1 Introduction
5-2 Setting the Process Water Temperature
5-3 LED Indicators
5-4 Temperature Controller Keys
5-5 Auto-Tuning PCA Series Chillers
5-6 Optional Communications
6Optional Graphic Panel..........................................30
6-1 Indicator Lights
6-2 Switches
7Routine Maintenance .............................................32
7-1 Lubrication
7-2 Condenser Maintenance
8Troubleshooting Guide..........................................36

Page 6 PCA Series Chillers
Charts and Figures
Figure 1: PCA050 Process Pump Curves..................................................................................... 11
Figure 2: PCA100 Process Pump Curves..................................................................................... 11
Figure 3: PCA150 Process Pump Curves..................................................................................... 11
Figure 4: PCA Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW)......................................... 12
Figure 5: PCA Series Chiller Specifications................................................................................. 13
Figure 6: Ethylene Glycol Curve.................................................................................................. 16
Figure 7: Overhead Piping........................................................................................................... 17
Figure 8: PCA Component Identification..................................................................................... 20
Figure 9: Piping Schematic - 1 Pump with Reservoir................................................................... 21
Figure 10: Piping Schematic - 1 Pump Without Reservoir........................................................... 22
Figure 11: Piping Schematic - No Pump, No Reservoir............................................................... 23
Figure 12: Typical PCA Series E5CK Microprocessor Controller............................................... 27
Figure 13: Optional Graphic Panel............................................................................................... 32
Figure 14: Typical PCA Subpanel................................................................................................ 33
Figure 15: Typical PCA Wiring Schematic.................................................................................. 34
Figure 16: PCA Wiring Schematic for Chillers with No Pump or Reservoir............................... 35

PCA Series Chillers Page 7
1General Information
1-1 Introduction
AEC, Inc.'s PCA Series Water Chillers are reliable, accurate, and easy-to-use air cooled
chillers designed for use with water/glycol. Standard range of operation is 30°F (-1°C)
to 65°F (18°C) for applications using glycol and 45ºF (7ºC) to 65°F (18°C) for water-
only applications. A crankcase pressure regulating valve option is available for
processes requiring a leaving water temperature of up to 75°F (24°C). PCA models are
available in 1/2 hp (373 W), 1 hp (746 W), and 1-1/2 hp (1,118 W) models and have an
internal six gallon (23 liter) reservoir. All models are self contained, fully assembled,
and shipped ready to use.
A properly installed, operated, and maintained PCA 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
of AEC, Inc.'s PCA Series Chillers. Additional copies are available from AEC, Inc.
Familiarize the appropriate personnel with these documents:
;This manual.
;The electrical schematic and connection diagram mounted inside the control
enclosure. Typical schematics for general reference are provided in Figure 15 and
Figure 16 on pages 34 and 35.
;The operation and installation manuals for installed accessories and options.
;The Customer Parts List included in the information packet.
1-3 Models Covered
This manual provides operation, installation, and maintenance instructions for AEC,
Inc. PCA 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 AEC, Inc.
PCA Series Chiller models are designated by approximate compressor horsepower. A
PCA050 chiller has a 1/2 hp (373 W) compressor, a PCA100 chiller has a 1 hp (746
W) compressor, and a PCA150 chiller has a 1-1/2 hp (1,118 W) compressor.

Page 8 PCA Series Chillers
1-4 Available Options
PCA 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 AEC,
Inc. Sales Representative. Some of these options are:
Special Pumps
Special pump options are available for greater pressure and flow rates. Bronze and
stainless steel wetted surface standard flow pumps ranging from 30 psi (207 kPa) to 60
psi (414 kPa) are available.
Reservoirs
PCA Series Chillers are available without a reservoir for processes that use their own
reservoir.
Power Cord
A 10 foot (3 meter) power cord is available to speed PCA installation.
Casters
Four 2 inch (5 cm) swivel casters add mobility to the PCA unit.
CPR Valve
A crankcase pressure regulating (CPR) valve is available for leaving water
temperatures up to 75°F (24°C).
1-5 Uncrating Your New Chiller
PCA 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.

PCA Series Chillers Page 9
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.
The Carrier then assumes full responsibility of the 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 AEC, Inc. before the transportation company inspection
and authorization.
;File a claim against the transportation company. Substantiate the claim by referring
to the agent's report. A certified copy of our invoice is available upon request. The
original Bill of Lading is attached to our original invoice. If the shipment was
prepaid, write us for a receipted transportation bill.
;Advise AEC, Inc. regarding your wish for replacement.
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:
;PCA 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 AEC, Inc. immediately of the shortage.
1-8 If the Shipment is Incorrect
;If the shipment is not what you ordered, contact AEC, Inc. immediately. Include
the order number and item.
;Hold the items until shipping instructions are received.

Page 10 PCA Series Chillers
1-9 Returns
IMPORTANT!
Do not return any damaged or incorrect items until
you receive shipping instructions from AEC, Inc.

PCA Series Chillers Page 11
Figure 1: PCA050 Process Pump Curves
60 HERTZ PUMP CURVE
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
PCA 050 - PROCESS PUMPS SELECTIONS
PER MINUTE
LITRES
PER MINUTE
U. S. GALLONS
24
12 18 40
35 80
49
37 52 120
69 160
MTRS
TOTAL HEAD
PSI FEET
1.5
0.4
3.0
0.8
4.5
1.2
6.1
1.6
7.6
2.0
9.1
2.4
10.6
2.8 3.2
12.1
3.6
13.6 15.1
4.0 4.4
16.7
4.8
18.2
BZ050C
BZ050A BZ050B
Figure 2: PCA100 Process Pump Curves
60 HERTZ PUMP CURVE
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
PCA100- PROCESS PUMPS SELECTIONS
PER MINUTE
LITRES
PER MINUTE
U. S. GALLONS
24
12 18 40
35 80
49
37 52 120
69 160
MTRS
TOTAL HEAD
PSI FEET
6.1
1.6
7.6
2.0
9.1
2.4
10.6
2.8
BZ100A
3.2
12.1
3.6
13.6 15.1
4.0 4.4
16.7
4.8
18.2
BZ100B BZ100C
5.65.2 6.0 6.4
19.7 21.2 22.8 24.2
Figure 3: PCA150 Process Pump Curves
60 HERTZ PUMP CURVE
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
PCA150 - PROCESS PUMPS SELECTIONS
PER MINUTE
LITRES
PER MINUTE
U. S. GALLONS
24
12 18 40
35 80
49
37 52 120
69 160
MTRS
TOTAL HEAD
PSI FEET
10.6
2.8 3.2
12.1
3.6
13.6 15.1
4.0 4.4
16.7
4.8
18.2
5.2 5.6 6.0 6.4 6.8
19.7 21.2 22.7 24.3 25.8
2.42.0
9.17.6
BZ150A
BZ150C
BZ150B

Page 12 PCA Series Chillers
Figure 4: PCA Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW)
60 HERTZ PUMP CURVE
CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY-PASS
PCA - PROCESS PUMP: CI CENTRIFUGAL
PER MINUTE
LITRES
PER MINUTE
U. S. GALLONS
MTRS
TOTAL HEAD
PSI FEET
8
23
11
4
15
14
13.5 43
19 45
19
56
23
7
26
8910
30 34 38
10
4
15 22 50
18.3
Cast Iron

PCA Series Chillers Page 13
Figure 5: PCA Series Chiller Specifications
POWER
A0537868
OFF
ON REFRIGERANT
Mini Chiller
PUMP
ON COMPRESSOR ON
PortableChiller
HIGH
PRESSURE
REFRIGERANT
LOW
PRESSURE
PC Series
Application
Engineering
PUMP
PRESSURE
O
ptional gauge package
Side cover
handle Sight glass
To Process
(3/4" NPT)
From Process
(3/4" NPT)
(3/4" NPT)
Drain plug
Power cable entrance,
either side
Optional Casters
20" 26"
34"
Front View Right Side View
Rear View
13 7/16"
18 7/16"
units only)
No Flow indicator
(for pumpless NO FLOW
Optional gauge package
Model
Capacity
@ 65°F
LWT 75°F
Ambient
Capacity
@ 50°F
LWT 90°F
Ambient
Nominal
Chilled
Water Compressor Pump
Process
Connection
Amp
Draw
230/1/60
Dimensions
(inches)
Operating
Weight
Shipping
Weight
Number (Btuh) (Btuh) (gpm) (hp) (inches NPT) Running L W H (lbs) (lbs)
PCA-050 8,100 4,800 1.2
1/2
1/3hp,
1.2 gpm
@ 24 psig
3/4
8A 20 26 34 265 265
PCA-100 14,000 9,550 2.4
1
1/3hp,
2.4 gpm
@ 34 psig
3/4
10A 20 26 34 325 325
PCA-150 25,400 16,000 3.6
1-1/2
1/3hp,
3.6 gpm
@ 24 psig
3/4
12A 20 26 34 345 345
Model
Capacity
@ 18°C
LWT, 24°C
Ambient
Capacity
@ 10°C
LWT, 32°C
Ambient
Nominal
Chilled
Water Compressor Pump
Process
Connection
Amp
Draw
230/1/60
Dimensions
(cm)
Operating
Weight
Shipping
Weight
Number (watts) (watts) (lpm) (watts) (inches NPT) Running L W H (kg) (kg)
PCA-050 2,374 1,407 4.5 373 224 watts,
4.5 lpm
@207
kPa
3/4
8A 51 66 86 120 120
PCA-100 4,103 2,800 9.0 746
224 watts,
9.0 lpm
@234
kPa
3/4
10A 51 66 86 147 147
PCA-150 7,444 4,690 13.6 1,118
224 watts,
13.6 lpm
@207
kPa
3/4
12A 51 66 86 156 156

Page 14 PCA 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 5 on page 13 for total running amps.
Bring properly sized power leads and ground from a fused disconnect (installed by your
electrician) to the main power terminal in the chiller's electrical enclosure.
;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 7 on page See 17 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 TO PROCESS chilled water supply outlet to the process being cooled.
From Process
Connect the FROM PROCESS chilled water return inlet to the return from the process
back into the chiller for cooling and recirculation.
;AEC, Inc. recommends a strainer on the FROM PROCESS return line.

PCA Series Chillers Page 15
Process Water Bypass
All PCA chillers have an internal bypass device (patent pending). 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 PCA Condenser Air Supply
PCA chillers use the surrounding air to cool the condenser.
;Condenser air entering the PCA unit should be at least 65°F (18°C). Operation with
air below 65°F (18°C) can cause the low pressure cutout to shut down the chiller
due to the 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 PCA 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 7 on
Page 29 for cleaning instructions.
;Normal condensing pressure with 95°F (35°C) air is approximately 180 psi (1,241
kPa) for the PCA050 and PCA100; 275 psi (1,897 kPa) for the PCA150.
PCA 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 6 on page 16 for the
recommended ethylene glycol/water solution. This chart shows the proportions needed
to provide freeze protection to 20°F/°C below the desired process setpoint.
;Add a pre-mixed solution to provide freeze protection to a temperature 20°F/°C
below the normal operating temperature of the chiller.
;Use industrial quality (not automotive) ethylene glycol.

Page 16 PCA Series Chillers
;A corrosion inhibitor suitable for the materials in the system should be added to the
glycol/water solution.
;If straight water use is desired, contact the AEC, Inc. Engineering Department.
;The six gallon (23 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.
Figure 6: Ethylene Glycol Curve
E
t
h
y
l
ene
Gl
yco
l
R
equ
i
re
d
Normal Operating Range between 30°F - 70°F
for Evaporator Freeze Protection
Chilled Water
Operating Temperature °F
(Set Point)
10%
20%
30%
35°
25° 45° 55°
0% 65°
Ethylene
Percent
Glycol
by
Volume

PCA Series Chillers Page 17
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 TO PROCESS line and a vacuum
breaker at the high point of the return FROM PROCESS line. See Figure 7 below for
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 7: Overhead Piping
Vent
6" Min.
Process Return
Process Supply
1/8"
Hole
Vacuum Breaker
Assembly
Cap
Check
Valve
1/4"
12"
Add check valve
if system piping
extends 15 feet
above reservoir.
Strainer
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.
Indicates end of AEC piping

Page 18 PCA Series Chillers
3 Sequence of Operation
IMPORTANT!
•The PCA unit has a leaving water temperature range of 30°F (-1°C) to 65°F
(18°C). Do not attempt to run the PCA unit outside this temperature range or
damage to the unit may occur.
•When operating the PCA unit between 30°F (-1°C) and 40°F (5°C), you must
use a solution of 75% water and 25% industrial-grade ethylene glycol with a
suitable corrosion inhibitor to protect the PCA unit from freeze-up. See
Figure 6 on page 16 for more information.
Such damage is not covered by the AEC, Inc. warranty.
3-1 Chilled Water Circuit
Figure 9, Figure 10, and Figure 11
;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 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 (patent pending) between the supply and return
lines guarantees a constant flow through the evaporator during intermittent low or
no-flow conditions.
;A flow switch in units without pumps will prevent the compressor from running
without adequate flow through the evaporator
3-2 Refrigeration Circuit
;Liquid refrigerant from the condenser passes through a filter/dryer which removes
moisture and other contaminants.
;The refrigerant then 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.

PCA Series Chillers Page 19
3-3 High Pressure Cutout
The high pressure cutout is an electro-mechanical safety feature that opens the control
circuit if the system condensing pressure exceeds a safe level. The chiller will
automatically restart when the pressure drops back to an acceptable level.
Model Cuts out if condensing pressure exceeds:
PCA050 275 psi (1,897 kPa)
PCA100 275 psi (1,897 kPa)
PCA150 400 psi (2,759 kPa)
IMPORTANT!
Call a refrigeration service technician to analyze
the problem if high pressure recurs.
3-4 Low Pressure Cutout
The low pressure cutout is an electro-mechanical safety feature that prevents
compressor suction pressure from dropping below a preset point.
It is factory set to open the control circuit when pressure drops below a safe level. The
chiller will automatically restart when the suction pressure reaches an acceptable level.
Model Cuts out if suction pressure falls below:
PCA050 15 psi (103 kPa)
PCA100 15 psi (103 kPa)
PCA150 35 psi (241 kPa)
3-5 Remote Start/Stop Interlock
A contact is provided to allow interlocking of the PCA Series Chiller with process
controls. To use this feature, remove the jumper between Terminals X1 and 1 on
Terminal Block 1. Supply a switch or dry contact interlock connected in series between
these two terminals. See Figure 15 and Figure 16 on pages 34 and 35 for more
information.

Page 20 PCA Series Chillers
Figure 8: PCA Component Identification