Manual Chiller 10 14

$30.
00
Operation and Installation Manual
Glacier Series
Air- and Water-Cooled
Portable Chillers
Important! Read Carefully Before Attempting to Install or Operate Equipment
Part No. A0533711 Bulletin No. AE2-610B

Performance figures stated in this manual are based on a standard atmosphere of 59°F
(15°C) at 29.92” Hg (1,014 millibars) at sea level, using 60 hz power. Altitude is an
important consideration when specifying chillers. 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. 2006

All rights reserved. Effective 3/8/2006
Part No. A0533711 Bulletin No. AE2-610B.2
Page 2 Glacier Series Portable Chillers

Safety Considerations
Application Engineering Glacier Series portable 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.
; Disconnect and/or lock out power before servicing or maintaining the chiller.
; Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment.
; Operate this equipment within design specifications.
; OPEN, TAG, and LOCK ALL DISCONNECTS before working on equipment. You
should remove the fuses and carry them with you.
; Make sure the chiller and components are properly GROUNDED before you switch on
power.
; When welding or brazing in or around this equipment, make 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 (3,447.5 kPa/
34.47 bars). DO NOT CUT into the system until pressure has been relieved.
; 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.
Glacier Series Portable Chillers Page 3

Table of Contents
1 General Information ................................................. 7

1-0 Introduction
1-1 Necessary Documents
1-2 Models Covered
1-3 Available Options
2 Shipping Information.............................................. 11
2-1 Unpacking and Inspection
2-2 In the Event of Shipping Damages
2-3 If the Shipment is Not Complete
2-4 If the Shipment is Not Correct
2-5 Returns
3 Installation............................................................... 13
3-0 Electrical Connections
3-1 Process Water Connections
3-2 Water Connection Sizing
3-3 Bypass Valve
3-4 Galvanic Corrosion
3-5 Water Treatment
3-6 Water Cooled Chiller Water Connections
3-7 Air Cooled Chiller Air Supply
3-8 Condensing Air Temperature
3-9 Motor Direction Check
3-10 Water Reservoir
3-11 Automatic Reservoir Make Up Installation
4 Sequence of Operation .......................................... 23

4-0 Chilled Water Circuit
4-1 Refrigeration Circuit
4-2 Freezestat Control
4-3 Crankcase Heater
4-4 High Pressure Cut Out
4-5 Low Pressure Cut Out
4-6 Oil Pressure Safety Switch
4-7 Fan Cycling Switch
4-8 Float Switch
4-9 Remote Start/Stop Interlock

Table of Contents
5 Startup Checklist .................................................... 37

5-0 Introduction
5-1 Water-Cooled Pre-Startup Checklist
5-2 Water-Cooled Chiller Startup
5-3 Air-Cooled Pre-Startup Checklist
5-4 Air-Cooled Chiller Startup
6 Control Operation ................................................... 41

6-0 The NX Control
6-1 NX Display Interpretation
6-2 NX Control Buttons
6-3 NX Control Operation
6-4 Auto-Tune Procedure
7 Graphic Panel.......................................................... 45
7-0 Introduction
7-1 Low Water Level Light
7-2 High Refrigerant Pressure Light
7-3 Low Refrigerant Pressure Light
7-4 Freezestat Light
7-5 Low Oil Pressure Light
7-6 Power Light
7-7 Hot-Gas Bypass Light
7-8 Compressor Light
7-9 Pump Light
8 Routine Maintenance ............................................. 53

8-0 Lubrication
8-1 Filter Cleaning
8-2 Condenser Maintenance
8-3 Preventative Maintenance Service
9 Troubleshooting ..................................................... 59

Charts and Figures
1 Dimensions - NXGA 5 - 15 7
2 Dimensions - NXGA 20 - 25 8
3 Dimensions - NXGW 5 - 15 9
4 Dimensions - NXGW 20 - 30 10
5 Pump Curves - 60 Cycle 13
6 Pump Curves - 50 Cycle 14
7 Evaporator GPM/Pressure Drop Curves 15
8 Condenser GPM/Pressure Drop Curves 16
9 Typical Ductwork, NXA 5 - 15 20
10 Typical Ductwork NXA 20 - 25 21
11 Central and Gravity Return Piping 24
12 Automatic Reservoir Make Up Option 26
13 Piping Diagram - NXG 1-Pump 28
14 Piping Diagram - NXG 2-Pump 29
15 Piping Diagram - NXG 1-Pump w/o Tank 30
16 Piping Diagram - NXG 2-Pump w/o Tank 31
17 Piping Diagram - NXG w/o Pump, w/o Tank 32
18 Freezing Point Curve 34
19 The NX Control 39
20 Typical Graphic Panel 44
21 Typical NX Series Sub-Panel Layout 46
22 Typical Electrical Schematic - NXA 47
23 Typical Electrical Schematic - NXG 48

1 General Information
1-1 Introduction
AEC/Application Engineering Glacier Series portable water chillers are reliable, accurate, and
easy to use process cooling units. They are available in both air and water cooled designs in a
range of sizes from 5 to 30 tons. All are self contained, fully portable, and shipped ready to use.
A properly installed, operated, and maintained Glacier Series portable chiller provides 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 an
Application Engineering Glacier Series portable chiller. 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 Figures 21 through 23.
• 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 Application
Engineering Glacier Series Portable Chillers.
Model numbers can be found on the chiller serial tag. You should know the model number, serial
number, and operating voltage of your chiller if you need to contact AEC/Application
Engineering.
Glacier Series chiller models are designated by compressor horsepower (5, 7.5, 10, 15, 20, 25,
30, 35, and 40) and the cooling method used—air-cooled are NXGA, water-cooled are NXGW,
and remote air-cooled units are NXGR. All sizes are available with either cooling method with
the exception of the 35 hp and 40 hp systems, which are available in the water-cooled
configuration only.

1-4 Standard Features
Mechanical
Compressors
Hermetic compressors are used on on 5 hp to 10 hp models, Semi-hermetic Discus compressors
are used on 15 to 40 hp models.
Evaporator
Cleanable shell and tube evaporators are used on Glacier chillers.
Condenser
Fin/tube condensers are used on NXGA air-cooled units with air filter(s), package unit only.
Cleanable shell and tube condensers are used on NXGW water-cooled units with cooling water
regulating valves for tower or city water.
Remote air-cooled copper tube/aluminum fin with low ambient control via pressure-actuated fan
staging and a variable-speed primary fan are used on NXGR remote air-cooled models.
Reservoir
40-gallon polyethylene tanks are used on 5 hp to 30 hp models.
60-gallon mild steel tanks are used on 35 and 40 hp models.
Pump
Non-overloading ODP motor, horizontally-mounted with seal flush line.
Other Mechanical Features

• NEMA-rated ODP fan/blower motor(s) (air-cooled units)
• Painted structural steel frame and panels with 4” swivel casters
• Mounting rails for NXGR models
• Pressure-actuated Process water bypass valve (single pump models only)
• Valved Process water connections
• External fill/drain sight glass
• To Process 2½” dual scale liquid-filled water pressure gauge
• Low Process water temperature freezestat
• Low oil pressure cut-outs on 15 to 40 hp models
• Low water flow switch
• Fully insulated refrigeration and process piping
Electrical Features
• Fully accessible NEMA 1-style electrical control enclosure
• Single-point connection
Refrigeration Features
• R-22 refrigerant
• Hot gas bypass capacity control
• Refrigerant suction accumulator
• High and low refrigerant pressure cut-outs
• High pressure relief valve
• Multiple refrigeration access ports
Control Features
• Off-the-shelf microprocessor-based PID auto-tuning control with To Process and Set Point
LED readout
• Graphic control panel with indicating and warning status lights
Other Features
• New AEC Warm Gray paint
• 1 year warranty on parts and labor
• 3 year warranty on controller parts
1-5 Available Options

Glacier Series portable chillers are available with options that tailor the unit to your
requirements. Some are factory installed and some can be retro-fitted in the field. Consult your
sales representative for more information.

Automatic Water Make Up
This option includes a pressure regulating valve, a float valve in the reservoir and the necessary
solenoid valve and pipe fittings to connect a Glacier Chiller to an automatic make up system.
AEC, Inc. offers the necessary components for automatic make-up and water treatment systems.
See Chapter 3 for more information.
Crankcase Pressure Regulating (CPR) Valve

A crankcase pressure regulating (CPR) valve is available for leaving water temperatures up to
75°F (24°C). This valve extends compressor life by limiting maximum allowable suction
pressure.
Operating Voltages
Glacier Series portable chillers are available configured for 208-230/3/60, 380-415/3/50,
460/3/60, 515/3/50, and 575/3/60 volts.
Note: Make sure that you de-rate system capacity by 17% when running your unit at 50 Hz.
Available Communications Options

External communications protocols for your Glacier Series chiller include single-port NX
protocol with RS-232C, RS-422, and RS-485; SPI protocol is also available.
Reservoirs
A 40-gallon polyethylene reservoir is standard, with mild steel and stainless steel as optional
tank materials. Glacier Series portable chillers are available without a reservoir for processes that
use their own reservoir.
Fan Cycling Pressure Switch

Applications with low ambient temperatures benefit from this option. A pressure switch cycles
the primary fan OFF and ON in low ambient temperatures to maintain efficient condensing
pressures. Fan cycling switches are standard on Glacier Series chillers; a second switch is
optional on two (2) fan/blower models.
UL Listed Electrical Subpanel

This option includes branch fusing, which offers multiple fuse protection on major components.
Branch Fusing
Branch fusing provides multiple fuse protection on major components.
NEMA 12 Electrical Enclosure

This option provides NEMA 12-level electrical enclosure protection. It includes an accessible
protective window kit over the graphic panel.

Door Interlock
The door interlock option is a solenoid installed on the door which automatically locks the
enclosure door when you apply power to your chiller.
Non-Fused Through-Door Disconnect

This option provides fast, safe power disconnection for your chiller. This large rotary switch is
located on the front door of the unit enclosure. The design also lets you place a padlock on the
switch for added safety. It is available in 208, 230, 460, and 575 voltages.
General Fault Indicator

This option transmits an alarm signal to alarm device(s) when any of the inherent safeties are
tripped.
Audible/Visual High-Temperature Alarms

These options provide a strobe and buzzer to alert the operator of temperatures above the alarm
set point. It also includes an audible alarm silence switch. A separate visual-only alarm option is
available without the buzzer.
High Pressure Fans

High pressure fans are available for installations where the exiting air is to be exhausted though
ductwork. These fans are available on 5 through 15 horsepower air-cooled Glacier chillers. They
may be retro-fitted without sheet metal modification.
Mounting Options
All standard air-cooled NXGA and water-cooled NXGW Glacier chillers come standard with 4”
swivel casters, which can be deleted at the time of order. Remote air-cooled NXGR Glacier
chillers come standard with mounting rails, which are available as an option to air- and water-
cooled Glacier models. Mounting rails add 5” to unit length.
Other mounting options include 5”-diameter swivel casters with brake and rubber mounting feet.
The larger casters add 1” to unit height.
Compressor Hour Meter

This option keeps track of the total time that the compressor runs when your Glacier chiller is
operating.
Special Pumps
Special pump options are available for greater pressure and flow rates. One and two pump
configurations with 1.5, 3, 5, 7.5, and 10 horsepower pumps are offered. A special high-pressure
10-hp pump is also available.

Figure 1
Glacier NXGA Air-Cooled Chiller Capacities and Specifications
Air
out
1"
Air in Air in
10-30 hp 5-30 hp
F
Controller with
graphic panel
System fill
2.5"-dia. To Process
pressure gauge
To Process
D
Sight glass
From Process
3/4" drain plug
Electrical
E
enclosure
B A Allow 6" to 8" for piping
Glacier Series NXGA Air-Cooled Model Capacities

• Nominal operating parameters for Glacier Series NXGA air-cooled models are 50ºF
leaving water temperature at 2.4 gpm per ton with 95ºF ambient air.
Nominal cooling capacity c Water Com- Nom. Power in amps f, 460/3/60 g
Model tons flow pressor pump Discharge air e 1 pump 2 pumps
number no pump 1 pump 2 pump gpm d hp hp openings cfm rated running rated running
NXGA5 5.03 4.73 4.63 11.4 5 1.5 1 @ 27” 6,000 13.79 12.42 14.69 13.32
NXGA7.5 7.69 7.39 7.29 17.7 7.5 1.5 1 @ 27” 6,000 20.53 17.68 22.33 21.43
NXGA10 9.91 9.61 9.51 23.1 10 1.5 2 @ 27” 12,000 27.93 23.13 29.73 28.83
NXGA15 15.23 14.93 14.83 35.8 15 1.5 2 @ 27” 12,000 35.83 31.13 38.43 37.13
NXGA20 17.07 16.47 16.27 39.5 20 3.0 2, @17.5”x19” 18,000 51.54 44.09 52.99 45.54
NXGA25 21.52 20.92 20.72 50.2 25 3.0 2, @17.5”x19” 18,000 59.64 51.69 62.25 54.30
NXGA30 25.11 24.11 23.71 57.9 30 5.0 2, @17.5”x19” 18,000 67.24 60.84 69.85 63.45
c Based on 50ºF chilled water supply temperature and 95ºF ambient air. Optional additional process pump hp reduces
chiller capacity by 0.2 tons per hp.
d Based on 2.4 gpm per ton, nominal 1 pump. Optional additional process pump hp reduces chiller capacity by 0.2 tons
per hp.
e Customer use of ductwork requires optional high-pressure fan for 5 hp to 15 hp models.
f An optional oversized process pump adds to the total rated or running chiller amperage. To find the new total chiller
amperage, subtract the standard process pump amperage from the optional pump amperage (see bottom of Page 4),
and add it to the chiller rated or running amperage.
g Multiply 460/3/60 amperage by 2.0 for 208-230/3/60 amperages; multiply by 0.8 for 575/3/60 amperages.
Glacier Series NXGA Model Specifications

• NXGA portable chillers come standard with 4” swivel casters.
Com- Process connections, in. NPT Dimensions Shipping Operating
Model pressor 1 2 no pump, 1 pump, no in inches weight weight
number hp pump pumps no tank tank, to/from A B C D E F lbs. lbs.
NXGA5 5 1.5 2.0 1.5 1.5 / 2.0 65 34 77.5 31.75 9.5 17 1,309 1,502
NXGA7.5 7.5 1.5 2.0 1.5 1.5 / 2.0 65 34 77.5 31.75 9.5 17 1,377 1,570
NXGA10 10 1.5 2.0 1.5 1.5 / 2.0 65 34 77.5 31.75 9.5 17 1,530 1,723
NXGA15 15 2.0 2.5 2.0 2.0 / 3.0 65 34 77.5 32.88 9.5 17 2,108 2,205
NXGA20 20 2.0 2.5 2.0 2.0 / 3.0 78 34 87.5 32.88 9.5 17 2,477 2,671
NXGA25 25 2.0 2.5 2.0 2.0 / 3.0 78 34 87.5 32.88 9.5 17 2,493 2,687
NXGA30 30 2.5 3.0 2.5 2.5 / 3.0 78 34 87.5 34.50 9.5 17 2,782 3,022

Figure 2
Dimensions - Inches
20 to 25 Horsepower Air-Cooled Glacier Chiller A0533703

Figure 3
Dimensions - Inches
5 to 15 Horsepower Water-Cooled Glacier Chiller A0533700

Figure 4
Dimensions - Inches
20 to 30 Horsepower Water-Cooled Glacier Chiller A0533700

Figure 5
NXGW Series Water-Cooled Chiller Design Specifications
Condenser q
Model Cooling Chilled Standard Pipe Total City Tower Approximate Approx.
Number Capacity Water Pump Size Running Water Dimensions Shipping
Amps p LXWXH Weight
Tons n gpm o Hp Inches GPM GPM Inches (Lbs)
NXGW5 6 12 1½ 2 27 6 18 65 X 34 X 45 1,400
NXGW7.5 8 18 1½ 2 35 10 24 65 X 34 X 45 1,600
NXGW10 10 24 1½ 2 47 12 31 65 X 34 X 45 1,625
NXGW15 15 36 1½ 2 65 18 45 65 X 34 X 45 1,900
NXGW20 19 45 3 2 79 25 60 78 X 34 X 45 2,100
NXGW25 24 60 3 2 95 30 75 78 X 34 X 45 2,200
NXGW30 27 72 5 2 131 36 90 78 X 34 X 45 2,200
n Based on 50°F chilled water supply temperature. Consult factory for other requirements.
o Flow rate based on 2.4 gpm/ton. Alternate pump selections available.
p 208-230/3/60
q Requirement based on availability of 70°F city water or 85°F tower water at 25 psi minimum. Consult factory for other
conditions.
Table 2
NXGA Series Air-Cooled Chiller Design Specifications
Model Cooling Chilled Standard Pipe Size Total Condenser Approximate Approx.
Number Capacity Water Pump Running Air Flow Dimensions Shipping
Amps p LXWXH Weight
Tons n GPMo Hp Inches CFM Inches (Lbs)
NXGA5 5 12 1½ 2 30 6,000 65 X 34 X 77 1,300
NXGA7.5 7 18 1½ 2 39 6,000 65 X 34 X 77 2,100
NXGA10 8½ 24 1½ 2 54 12,000 65 X 34 X 77 2,300
NXGA15 13½ 36 1½ 2 72 12,000 65 X 34 X 77 2,400
NXGA20 17½ 45 3 2 105 18,000 78 X 34 X 87 2,450
NXGA25 23 60 3 2 121 18,000 78 X 34 X 87 2,600
n Based on 50°F chilled water supply temperature and 95°F ambient air temperature. Consult factory for other requirements.
o Flow rate based on 2.4 gpm/ton. Alternate pump sizes available.
p 208 - 230/3/60

- Notes -

2 Shipping Information
2-1 Unpacking and Inspection

You should inspect your AEC/Application Engineering Glacier Series portable chiller for
possible shipping damage. If the container and packing materials are in re-usable condition, save
them for reshipment if necessary.
Thoroughly check the equipment for any damage that might have occurred in transit, such as
broken or loose wiring and components, loose hardware and mounting screws, etc. In case of
breakage, damage, shortage, or incorrect shipment, refer to the following sections.
2-2 In the Event of Shipping Damages

Important!
According to the contract terms and conditions of the Carrier,
the responsibility of the Shipper ends at the time and place of shipment.
The Carrier then assumes full responsibility of the shipment.
; Notify the transportation company’s local agent if you discover damage.

; Hold the damaged goods and packing material for the examining agent’s inspection. Do not
return any goods to AEC, Inc. before the transportation company inspection and
authorization.
; File a claim against the transportation company. Substantiate the claim by referring to the
agent’s report. A certified copy of our invoice is available upon request. The original Bill of
Lading is attached to our original invoice. If the shipment was prepaid, write us for a
receipted transportation bill.
; Advise AEC, Inc. regarding your wish for replacement and to obtain an RMA (return
material authorization) number.
2-3 If the Shipment is Not Complete

Check the packing list. The apparent shortage may be intentional. Back-ordered items are noted
on the packing list. You should have:
; AEC/Application Engineering Glacier Series portable chiller

; 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, Inc. immediately of the shortage.
2-4 If the Shipment is Not Correct

If the shipment is not what you ordered, contact AEC, Inc. immediately. Include the order
number and item. Hold the items until you receive shipping instructions.
2-5 Returns
Important!
Do not return any damaged or incorrect items
until you receive shipping instructions from AEC, Inc.
2-6 Uncrating
Glacier Series portable chillers are shipped mounted on a skid, enclosed in a plastic wrapper, and
open-crated on all four sides and top.
1. Pry the crating away from the skid and remove.

2. Use a pry bar to remove the blocks securing the unit to the skid.
3. Lift the unit off the skid with a fork truck.
4. Insert forks between skid and portable 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.
5. Lift slowly and only high enough to clear the skid. Use a pry bar if necessary to remove
the skid from the unit.
6. Lower slowly. The unit will land on its casters and can be rolled into position.
Retain the crating for reshipping the chiller if you find hidden shipping damage.

3 Installation
3-1 Electrical Connections

Check serial tag voltage and amperage requirements and make sure your electrical service
conforms. Total running amps for Glacier Series Portable Chillers can also be found in the
specification tables in Figures 5 and 6.
Bring properly sized power leads and ground from a fused disconnect (installed by your
electrician) to the unit. Use fusetrons in the disconnect switch, sized according to National
Electrical Code recommendations.
! WARNING !
1. Make sure that electrical connections comply with all applicable
electrical codes.
2. Ground the chiller in accordance with NEC Article 250.
3. Operation voltage must be within plus or minus ten percent
(±10%) of the nameplate rating.
4. Phase imbalance must be below 10%.
3-2 Process Water Connections

All Models
All Glacier Series portable chillers have two chilled water connections:
• The chilled water supply, labeled TO PROCESS, is the outlet for the chilled water leading
to the process being cooled.
• The chilled water return, labeled FROM PROCESS, is the inlet leading from the process
back into the chiller to be cooled and recirculated.

3-3 Water Connection Sizing
All external chilled water connections should be run full size to the process (See Figures 5 and 6
on Page 11). 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!
Make sure you reduce any external pressure drop
to the unit as much as possible!
Figure 7
Pump Curves - 60 Cycle

Figure 8
Pump Curves - 50 Cycle

Figure 9
Evaporator GPM-Pressure Drop Curves
A0533716

Figure 10
Condenser GPM-Pressure Drop Curves
A0533717

3-4 Bypass Valve
Glacier Series portable chillers have a spring loaded by-pass valve used as a safety feature.
If the chilled water shut-off valves are inadvertently closed while the chiller is running, the
factory set bypass valve will open and allow a small amount of water to flow through the chiller.
This protects the chiller from freeze-up and allows the other safety features to remain effective.
The by-pass valve should not be adjusted or tampered with.
3-5 Galvanic Corrosion

The materials used in the construction of the water circuit piping of these chillers are partially
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.
PVC or ferrous piping is recommended to reduce galvanic action. If you must use copper piping,
use dielectric unions at the chiller.
3-6 Water Treatment

Water treatment is an integral part of any piping system. In some locations, raw water may be
used in the system without problem; in other locations, it results in large deposits of scale and
corrosion.
AEC, Inc. offers a complete line of water treatment equipment. Contact your AEC, Inc. Sales
Representative for water testing and treatment options.
3-7 Water-Cooled Chiller Condenser Water

Connections
NXW Series portable chillers can use either city or tower water as a cooling medium. All of the
external piping and connections supplying and discharging water to and from the condenser
should be full size.
Two connections are made to the water cooled condenser:
1. The condenser water supply, labeled CONDENSER WATER IN, is located at the rear of
the chiller, and is the inlet for city or tower water.
Water should be supplied at a maximum temperature of 85°F (29°C) and a minimum
pressure of 25 psi.

Caution!
The water regulating valve is set at the factory.
It should not be adjusted except by a qualified refrigeration technician!
Normal R-22 refrigerant condensing pressure with 85°F (27°C) water at 25 psi entering
condenser water pressure is 210 psi.
2. Condenser water return, labeled CONDENSER WATER OUT, is located at the rear of the
chiller, and is the outlet for water after it has passed through the condenser.
It is connected to the tower inlet or to a sewer or other approved discharge receiver. A
water regulating valve is a standard feature in the condenser water return line.
3-8 Air-Cooled Condenser Chiller Air Supply

Air cooled chillers use the surrounding air to cool the condenser.
Install the chiller in an area where there is free passage of air for condensing and provisions for
removal of heated air from the area.
Do not locate this chiller in locations where steam, hot air or fume exhausts will be drawn into
the chiller.
Caution!
Clean air-cooled condensers and filters frequently.
Failure to do so results in reduced capacity, increased
operating costs, and possible failure of the equipment.
See Section 8-1 on Page xx for cleaning instructions.
Normal maximum R-22 refrigerant condensing pressure with 95°F (35°C) air entering the
condenser is 260 psi.
3-9 Condensing Air Temperature

NXG Series portable chillers are designed to operate at a minimum condenser entering air
temperature of approximately 60°F (15.5°C).
Operation of the equipment at a lower condenser entering air temperature can cause the low
pressure cutout to shut down the unit due to the low refrigerant pressure.
It is recommended that the ambient temperature be maintained at 60°F (15.5°C) or above.

Figure 11
Typical Ductwork - Air Cooled Glacier Chiller - 5-15 Horsepower A0533713
Figure 12
Typical Ductwork - Air Cooled Glacier Chiller - 20-25 Horsepower A0533714
3-10 Motor Direction Check

Compressors
Compressors will run properly in either direction.
Water Pumps
Correct pump rotation is indicated by a positive pressure of 20 to 30 psi on the pump pressure
gauge. Pump rotation should be clockwise when viewed from the motor end. See the following
section.
On Glacier Series portable chillers with special order oversized pumps, check the appropriate
pump curve in Figures 7 and 8 on Page xx.
Condenser Fan
Air should be drawn through the condenser and discharged vertically from the chiller. See the
following section.
To change rotation direction:

• Disconnect and lock out power at the fused disconnect.
• Reverse any two motor leads at the power source.
• Do not switch leads at the motor or motor starters.
3-11 Water Reservoir

Glacier Series Portable Chillers are shipped with an antifreeze solution to protect against freeze-
up damage in transit. The reservoir has a solution of 70% water and 30% ethylene glycol during
the summer months and 50% water and 50% ethylene glycol during the winter months.
During startup and when additional solution is required, refer to the ethylene glycol curve in
Figure 20 on Page xx. Add a pre-mixed solution of industrial quality (not automotive) ethylene
glycol (AEC Part No. A0538024) and water to provide freeze protection to a temperature 20°F
below normal chiller operating temperature.
For corrosion protection, an inhibitor suitable for the protection of the materials in the system
should be added. If straight water use is desired, contact the AEC, Inc. Engineering Department.
Caution!
Do not connect makeup water directly to the chilled water reservoir
unless you have an approved automatic water makeup system installed.
See Section 3-12 on Page xx for more information.
The reservoir is not designed to withstand water pressure in excess of 5 psi. The fill opening and
vent line must be vented to the atmosphere for proper operation. The optional automatic make up
system is described in Section 3-12 on Page xx.
If your application has chilled water or process piping above the reservoir fill and vent level,
install a standpipe to a point 1'0" (30 cm) above the highest point in the system.

Installation Note: In applications where the process or process piping is 15 feet (3 m) or more
above the reservoir, 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 13 on the following page for more information.
Figure 13
Central and Gravity Return Piping with Standpipe A0533715
3-12 Automatic Water Makeup Option

The Glacier Series Chiller may be connected to an automatic make up system if the optional
package (float switch, pressure regulating, pipe fittings, solenoid valve and ½" NPT City Water
Make Up connection) is factory installed.
Refer to Figure 12 for the additional components necessary for this installation. Your piping
must provide backflow protection and prevent over-pressurization of the reservoir.
Caution!
• Prevent reservoir over-pressurization by setting the required pressure
regulating valve to limit make up water pressure to less than 5 psi. The
reservoir must remain vented to the atmosphere.
• If the automatic make up system is connected to a city water system, make
provisions to prevent backflow contamination. Install an approved backflow
preventer in accordance with local codes. See Figure 12 (Page 26) for a
suggested piping arrangement.
• Adding straight city water into a glycol/water mixture dilutes the solution
and eventually leads to system freeze-up. Damage from freeze-up is not
covered by the AEC, Inc. warranty!

To prevent system freeze-up in automatic makeup applications, use a system to replenish the
glycol. AEC suggests the following methods:
Chemical Feeder
Use a chemical feeder to meter glycol into the makeup water and to maintain the water/glycol
mixture you want. Contact the Application Engineering Sales Department for more information
on this equipment.
Make Up Reservoir
You may mix a glycol/water solution in a tank and use it as a source of makeup fluid. Consult
the Application Engineering Sales Department for more information on this piping
configuration.
Figure 14
Automatic Makeup Option A0533876

- Notes -

4 Sequence Of Operation
4-1 Chilled Water Circuit

Figures 15 to 19
Process cooling water supply and return connections are made at the gate valves provided
outside the unit. Warm coolant (water and ethylene glycol mixture) returns from the process and
goes into the reservoir tank. The coolant is then pumped through the evaporator where it is
cooled.
The coolant flows to the process and returns to repeat the cycle.
A chilled water bypass valve between the supply line and reservoir tank guarantees a constant
flow in the unit during intermittent fluctuating flow conditions.
4-2 Refrigeration Circuit

Glacier Series portable chillers are available with either air or water cooled refrigerant
condensing. The refrigeration cycles differ only in the way the compressed gas is condensed to a
liquid.
Liquid refrigerant from the condenser passes through a shutoff valve into a filter/dryer that
removes moisture and other contaminants. A refrigerant sight glass is provided. 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 accumulator into the
compressor.
The refrigerant gives up its heat as it re-condenses to a liquid in the condenser. A hot gas bypass
valve is used to control cooling capacity during intermittent or partial load conditions. This
feature contributes substantially to chiller longevity by eliminating excessive cycling of the
compressor and providing close temperature control.

Figure 15
Piping Schematic, One Pump Chiller A0533704

Figure 16
Piping Schematic, Two Pump Chiller A0533705

Figure 17
Piping Schematic, One Pump - No Tank A0533718

Figure 18
Piping Schematic, Two Pump - No Tank A0533719

Figure 19
Piping Schematic, No Pump - No Tank A0530720

4-3 Freezestat Control
The freezestat is a safety feature that shuts down the compressor if the chilled water temperature
approaches the freezing point. The chilled water pump continues to run.
The freezestat cutout temperature is factory-set at 40°F (4°C). This is correct for a supply water
temperature of 50°F (10°C) - the rated capacity operating temperature. If you want lower chilled
water temperatures, mix process water with antifreeze to provide protection down to 20°F (11°C)
below the operating temperature you want. See Figure 21 on Page xx for more information. You
can then reset the freezestat cut out temperature to a temperature 10°F (6°C) below the operating
temperature you want.
Caution!
Allow only a qualified refrigeration service technician to adjust the freezestat.
Your AEC, Inc. product warranty does not cover system freeze-ups!
4-4 Crankcase Heater

Glacier Series portable chillers have a crankcase heater wired through the control transformer
that operates continuously whenever you apply power to the chiller.
Caution!
Energize the crankcase heater for at least 24 hours before initial startup
to drive dissolved refrigerant from compressor oil.
Failure to do so damages the compressor!
4-5 High Pressure Cutout

This electro-mechanical safety feature opens the control circuit if the system condensing
pressure exceeds 350 psi.
Important!
The high pressure cutout is a manual reset control.
Call a refrigeration service technician to
analyze the problem and to reset the control.

Figure 20
Freezing Point Curve

4-6 Low Pressure Cutout
This electro-mechanical safety feature prevents the evaporator temperature from dropping below
a pre-set point.
It is factory set to open the control circuit at 32 psi for R-22. This permits 20°F (-7°C) operation
with a 70% water, 30% ethylene glycol coolant mixture. This control automatically resets when
the refrigerant pressure reaches 50 psi.
4-7 Oil Pressure Safety Switch

This safety feature is a differential pressure switch that monitors crankcase oil pressure.
If the pressure should drop to an unsafe level for more than two minutes, the switch will open the
control circuit.
Important!
The oil pressure safety switch is a manual reset control.
Call a refrigeration service technician to
analyze the problem and to reset the control.
4-8 Fan Cycling Switch

Air-Cooled Models Only
NXGA-5 and NXGA-7.5 Models
These models have one fan. The fan cycling switch turns on the fan when the condenser pressure
reaches 275 psi and turns it off when the pressure drops below 200 psi.
NXGA-10 through NXGA-25 Models

These models have two fans (NXGA-10 & NXGA-15) or two blowers (NXGA-20 & NXGA-
25). One turns on every time the compressor operates.
The fan cycling switch turns on the second fan when the condenser pressure reaches 275 psi and
turns it off when the pressure drops below 200 psi.
NXGA-10 Through NXGA-25 Models with the Optional Fan Cycling Switch
Glacier Series portable chillers may be supplied with an optional fan cycling switch for
applications with low ambient air temperatures. This switch cycles the second fan or blower ON
and OFF to maintain efficient condensing pressures.

If the optional fan cycling switches are installed, the primary fan or blower turns on at 250 psi,
and off at 200 psi. The second fan or blower cycles on at 275 psi and off at 225 psi.
4-9 Float Switch

This safety feature shuts down the system if the water in the reservoir falls below a safe level.
Pump cavitation and freeze- up would otherwise occur.
4-10 Remote Start/Stop Interlock

An additional contact is provided to allow the remote starting or stopping of the Glacier Chiller
from a remote location. To use this feature, remove the jumper between terminals X1 and 1 on
TB2. Supply a switch or dry contact interlock connected in series between these two terminals.
Refer to the schematic glued inside the control enclosure door or the typical schematics in
Figures 22 and 23.

5 Startup Checklists
5-1 Introduction
Follow the check lists below for the start-up of your new chiller. These lists assume the
installation information elsewhere in this manual has been read and followed. New chillers
should be started up and checked by a qualified refrigeration service technician.
5-2 Water-Cooled Glacier Chiller Startup Checklist

; Check the shipping papers against the serial tag to be sure chiller size, type and voltage is
correct for the process that will be controlled.
; Check the transformer primary voltage connections to be sure they are configured for the
electrical power used. The voltage at the main power connection must be within +/-10% of
the voltage on the serial tag. Electrical connections must conform to all applicable codes.
; The chilled water To-Process and From-Process connections should be completed.
; The chilled water supply valve on the chiller must be open.
; Be sure the reservoir tank and chilled water circuit piping are filled to the full mark with a
water/glycol mixture. The water/glycol mixture should provide for freeze protection to at
least 20°F below the desired leaving water temperature.
; The tower or city condenser-cooling WATER IN and WATER OUT connections should be
completed and an adequate supply of condenser water must be available.
; Connect the main power to the unit and bump-start it to check for proper rotation direction.
See Section 3-10. The crankcase heater should be ON for at least 24 hours before start
up to force dissolved refrigerant gas from the compressor oil.
; Check your work and proceed to Start-Up, Section 5-2.
5-3 Starting Up Water-Cooled Glacier Chillers

1. Turn ON the chiller and put it under a process load.
2. Set the NX control to the process temperature you want by pressing the Up or Down
arrow buttons behind the access door on the NX control.
3. Adjust the freezestat cutout dial, located in the electrical enclosure, to 10°F below the
process temperature you want.
4. Check the pump amp draw and pump pressure. The amp draw reading must be within the
running load and service factor amps.

5. Operate the chiller, looking for leaks and listening for unusual noises or vibrations that
could indicate improper operation.
5-4 Air-Cooled Glacier Series Startup Checklist

; Check the shipping papers against the serial tag to be sure chiller size, type and voltage is
correct for the process that will be controlled.
; 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. Electrical
connections must conform to all applicable codes.
; Complete chilled water TO PROCESS and FROM PROCESS connections.
; The chilled water supply valve on the chiller must be open.
; Be sure the reservoir tank and chilled water circuit piping are filled to the full mark with a
water/glycol mixture. The water/glycol mixture should provide for freeze protection to at
least 20°F below the leaving water temperature you want.
; The air cooled condenser should have an adequate supply of air for proper operation.
; Connect the main power to the unit and bump-start it to check for proper rotation direction of
fans and pump. See Section 3-10. The crankcase heater should be ON for at least 24
hours before start-up to force dissolved refrigerant gas from the compressor oil.
; Check your work and proceed to Section 5-5 below.
5-5 Starting Up Air-Cooled Glacier Series Chillers

1. Turn ON the chiller and put it under a process load.
2. Set the NX control to the desired process temperature, using the up or down arrow
buttons behind the door on the NX control.
3. Adjust the Freezestat Cut-Out dial, located in the electrical enclosure, to 10°F below the
desired process temperature.
4. Check the pump amp draw and pump pressure. The amp draw reading must be within the
running load and service factor amps.
5. Operate the chiller, looking for any leaks and listening for unusual noises or vibrations
that could indicate improper operation.

Figure 21
The NX Control A0533724

- Notes -

6 Operation
6-1 Introduction
Standard Glacier chillers use a microprocessor based PID 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.
NXGA & NXGW Control Operation Range

Standard Models 20°F to 65°F
Low Temp Models 0°F to 30°F
6-2 LED Indicators

PV or Process Value Numeric LED
During normal operation, this large red LED on the control displays the actual process
temperature at the To Process thermocouple. It also lists parameters during setup and error
messages if an error occurs.
SV or Set Value Numeric LED

During normal operation, this green LED on the control displays the process set point you want
the chiller to maintain. It also displays parameter and pre-set function values during setup.
Figure 22
Microprocessor Control

OUT or Output LED
This orange LED lights when the control output energizes the hot gas bypass valve.
RMT or Remote LED

This lights when remote operation occurs on chillers equipped with optional communications.
SHIFT LED
This orange LED is not used.
AT or Auto-Tune LED
This orange LED flashes during the Auto-Tune sequence.
ALM1 or Alarm 1 LED

This red LED lights when the process temperature is two degrees [2°F] or more above the
setpoint. The compressor will turn on and run until the temperature at the To-Process
thermocouple is two degrees below the setpoint. This +2°F control point is factory set for proper
compressor operation. Changing the control point is not recommended without consulting the
AEC/Application Engineering.
ALM2 or Alarm 2 LED

The ALM 2 red LED lights whenever the temperature at the To Process thermocouple drops 2°F
below the process set point.
This red LED lights when the process temperature is two degrees (2°F) or more below the set
point. The compressor is shut down until the process temperature at the To Process
thermocouple is 2°F above the set point. This control point is factory-set for proper compressor
operation. Changing the control point is not recommended without consulting AEC/Application
Engineering.
6-3 Temperature Controller Keys

Level Key
This key is not used during normal operation. It is used during control programming only.
RMT or Remote Key

This key is on controls with optional communications. For information on RS-232C, RS-422, or
RS-485 communications, refer to the Communications Manual (AEC Part No. A0535959). For
RS-232C units with the SPI CPC protocol converter, see the specific O&I Manual (AEC Part
No. A0536527).

Mode Key
This button toggles the green LED display between the set point, the upper alarm (AL1), and the
lower alarm (AL2). When the control is powered up, the green LED displays the set point
Press this button once and the red LED displays AL 1 and the green LED displays the upper
alarm setting. Press again and the red LED displays AL 2 and the green LED displays the lower
alarm setting. Press a third time and the control display returns to Normal mode, displaying the
process set point and process temperature.
Caution!
Use this button to display alarm settings only.
Do not change alarm limits without
consulting AEC/Application Engineering!
Down Key
The key with the arrows pointing down lowers the process water set point temperature.
Up Key
The key with the arrows pointing up raises the process water set point temperature.
AT Key
This key initiates the auto-tune function. See Section 7-5 on Page XX for more information.
6-4 Setting Process Water Temperature

To change the process water temperature set point:
• Press the Up button to raise the set point.
• Press the Down Button to lower the set point.

6-5 Auto-Tuning Glacier Chillers
Auto-tune fine tunes the control's PID to process requirements. Auto-tune whenever the process
under control changes. Don't be alarmed by the control's response. It may take the process
temperature above and below the set points as many as three times. It will then level off and
control to the process set point. Auto-tuning can take up to 30 minutes, and is best done before
any product is being run.
To auto-tune the controller:
• Press and hold down the AT key for several seconds until the AT indicator flashes.
The AT LED flashes to indicate that the control is tuning itself.
When the AT LED light stops flashing, the controller is tuned and ready for operation.
6-6 Optional Communications

Standard Protocol
For RS-232C, RS-422, and RS-485 communications, a connection port on the cabinet permits
hookup to the host. The connection port is a direct pin-to-pin extension from the plug on the
back of the temperature controller. For pin outs, consult the control module communication
manual (AEC Part No. A0535959).
SPI Protocol
A connection port on the electrical cabinet permits easy hookup to an SPI network. For complete
information, refer to the AEC, Inc. Communication Protocol Converter manual (AEC Part No.
A05365273).

7 Graphic Panel
7-1 Low Water Level Light

This indicator lights and the chiller shuts down when the float switch in the reservoir senses that
the water/glycol level has dropped below an acceptable level.
Add enough water/glycol mixture to fill the tank to the operating level, or check the operation of
the automatic water makeup if one is installed. Use a mix that provides freeze protection to at
least 20°F below the process temperature.
7-2 High Refrigerant Pressure Light

This indicator lights if the condensing pressure exceeds 350 psi. The compressor stops and the
pump continues to run until you manually reset the high pressure cut out. Call a qualified
refrigeration service technician or contact the Application Engineering Service Department for
service.
7-3 Low Refrigerant Pressure Light

This indicator lights if the refrigerant pressure drops below a safe level. The compressor stops
and the pump continues to run. The indicator turns off and compressor restarts automatically
when the refrigerant pressure reaches 50 psi.

Figure 23
Typical Graphic Panel A0533723

7-4 Freezestat Light
This indicator lights if the chilled water temperature drops below the Freezestat setting. This
prevents possible system freeze-up. The compressor will shut off and the chilled water pump will
continue to operate.
Caution!
Your AEC, Inc. warranty does not cover damage from system freeze-up.
Make sure the freezestat is set properly to prevent freeze-up!
7-5 Low Oil Pressure Light

This indicator light, installed on chillers with 15 horsepower compressors and larger, lights if
compressor oil pressure drops to a dangerous level. After two minutes of low oil pressure, the
compressor will shut down.
This is a manual reset control. Call a qualified refrigeration service technician or the Application
Engineering Service Department for repairs.
7-6 Power Light

This indicator lights whenever the power switch is in the ON position and the control circuit is
energized.
Note: The crankcase heater is energized whenever main power is applied to the chiller. The
position of the power switch does not affect the operation of the crankcase heater.
7-7 Hot-Gas Bypass Light

This indicator lights when the hot-gas bypass valve is in operation. The "OUT" LED on the NX
Controller will also light when the hot-gas bypass valve is in operation.
7-8 Compressor Light

This indicator lights whenever the compressor is operating.

7-9 Pump Light
This indicator, installed on chillers with pumps, lights whenever the pump(s) operate.
Figure 24
Typical Subpanel Layout

Figure 25
Typical Air Cooled Glacier Chiller
Electrical Schematic A0534353

Figure 26
Typical Water Cooled Glacier Chiller
Electrical Schematic
A0534368

8 Routine Maintenance
8-1 Lubrication
Quarterly
Grease all fan bearings, 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 which will eventually cause bearing failure.
Compressors are hermetically sealed and no oiling is required.
8-2 Filter Cleaning

Air Cooled Models
Filter cleaning is important to keep your Glacier Series Air Cooled Portable Chiller operating at
peak capacity. Clean them whenever they are dirty.
To clean, slide the filter from its mount and hose down with clean water. If the dirt is heavy, use
a mild detergent and rinse well. Allow the filter to dry completely before replacing it on the
chiller.
Note: AEC recommends keeping a spare filter on hand. Install and use it when cleaning the
other filter.
Caution!
Do not use compressed air to blow off a dirty filter.
You won’t clean it very well, and you could damage it, too!
NEVER RUN THE CHILLER WITHOUT PROPERLY-INSTALLED FILTERS!

8-3 Condenser Maintenance
Dirty condenser heat exchange surfaces reduce system capacity.
Air-Cooled Chillers
Brush or vacuum light dirt accumulations. Avoid bending or damaging the fins. Heavy soil
accumulations on the coil require professional steam cleaning, so attempting to wash the
condenser from the outside will only make matters worse.
Water-Cooled
Remove dirt in the condenser tubes with a nylon tube brush. Remove mineral deposits by
circulating AEC Liquid De-Scaling Solution (AEC Part No. A0502600) through the water side
of the condenser. Follow the directions on the container.
The refrigerant side is sealed and requires no routine maintenance.
8-4 Preventive Maintenance Service

A systematic preventive maintenance program helps avoid costly down time. Call the AEC/
Application Engineering Service Department to arrange a schedule of inspections. This service,
described in Bulletin No. 10-106.3, can be tailored to fit your maintenance requirements. These
inspections include:
; Checking refrigerant suction and discharge pressures

; Checking safety and operating conditions
; Checking voltage and amperage of all motors
; Checking all electrical connections
; Checking quantity of refrigerant
; Checking compressor oil level
; Checking lubrication of motor and pump bearings.
; Checking circulating pump operation
; Checking flow through heat exchangers
; Checking compressor efficiency
; Checking noise levels
; Checking cleanliness of equipment area

9 Troubleshooting
Problem Possible cause Solution

Unit does not run. No power. Check main disconnect,
fuses, wiring, and power lead
to unit.
Wrong voltage supplied to Voltage must be within plus
unit. or minus 10% of nameplate
rating.
Defective on/off switch. Replace.
Control circuit fuse blown. Replace control circuit fuse.
Check transformer.
Check crankcase heater.
Defective control transformer. Replace.
Reservoir float switch circuit Add anti-freeze solution as
open. required to bring liquid level
up to normal.
Pump motor off on overload. Reset and test.
Pump runs; compressor does Freeze control set higher Lower freeze control set to
not. than temperature of liquid in 10°F (12°C) below desired
system. leaving temperature.
Defective freezestat. Replace.
Low refrigerant. Check refrigerant charge.
Refrigerant low pressure Sight glass should be clear
switch contacts open. while compressor runs. Call
for service if bubbling or
foaming occurs.
Refrigerant high pressure Clean the air filters.
cutout switch contacts open. Check condenser fans for
proper rotation.
Check for dirty condenser.
Check for condenser air
obstruction.
Fan motor out on overload. Reset and test.
Defective fan cycling control. Replace.
Defective fan motor. Repair or replace.
Compressor internal overload Allow time to cool and reset,
open. then check for high/low
voltage. It must be within
plus or minus 10% of the
nameplate rating.
Check for poor compressor
electrical connections.

Problem Possible cause Solution
Pump runs; compressor does Compressor contactor Repair or replace.
not (cont’d.) holding coil open.
Defective pump motor to Repair or replace.
compressor interlock control
circuit.
Broken wire in the Locate and repair.
compressor control circuit.
Pump runs, compressor Freeze control setting too Lower set point to 10°F
cycles at short intervals. high. below desired leaving water
temperature.
Water temperature is too Antifreeze mixture Make sure that the antifreeze
high. inadequate for process. mixture protection is right for
the process.
Defective or improperly-set Adjust or replace.
freezestat.
Refrigerant low pressure Call service to adjust
switch is set too high. pressure control.
Refrigerant charge is low. Call service to find and repair
the leak, then have
refrigerant added.
Pump pressure low (refer to Pump running in reverse. Verify rotation; if running in
curves for normal pressure reverse rotation, reverse any
for various pumps). two main power leads. Re-
verify for correct pump
rotation.
Check for foreign matter. Clean the system.
Pump pressure is too high. Restricted water flow. Check for partially closed
valves etc. Make sure that all
lines are properly sized.
Unit runs continuously, but Restricted condenser air. Clean filters.
not enough cooling power. Clean condenser.
Unit low on refrigerant. Check the refrigerant charge.
Compressor not operating Call service.
efficiently.
Unit under-sized for Call sales rep.
application.

Service Notes

Technical Assistance
Parts Department
Call toll-free 7am–5pm CST [800] 423-3183 or call [847] 273-7700, Fax [847] 273-7812
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.
Service Department
Call toll-free 8am–5pm CST [800] 233-4819 or call [847] 273-7700
Emergencies after 5pm CST, call [847] 439-5655
We have a qualified service department ready to help. Service contracts are available for most
products.
Sales Department
Call [847] 273-7700 Monday–Friday, 8am–5pm CST
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales
Department for the name of the sales representative nearest you.
Contract Department
Call [847] 273-7700 Monday–Friday, 8am–5pm CST
Let 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.

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Operation and Installation Manual

Part No. A0533711 Bulletin No. AE2-610B

AEC/Application Engineering is committed

© Copyright AEC/Application Engineering and AEC, Inc. 2006

Page 2 Glacier Series Portable Chillers

To avoid possible personnel injury or equipment damage when installing, operating, or

; Follow all SAFETY CODES.

Glacier Series Portable Chillers Page 3

1 General Information ................................................. 7

4 Sequence of Operation .......................................... 23

Page 4 Glacier Series Portable Chillers

5 Startup Checklist .................................................... 37

6 Control Operation ................................................... 41

8 Routine Maintenance ............................................. 53

Glacier Series Portable Chillers Page 5

Page 6 Glacier Series Portable Chillers

1-2 Necessary Documents

1-3 Models Covered

Glacier Series Portable Chillers Page 7

60-gallon mild steel tanks are used on 35 and 40 hp models.

Other Mechanical Features

1-5 Available Options

Glacier Series Portable Chillers Page 9

Crankcase Pressure Regulating (CPR) Valve

Available Communications Options

Fan Cycling Pressure Switch

UL Listed Electrical Subpanel

NEMA 12 Electrical Enclosure

Page 10 Glacier Series Portable Chillers

Non-Fused Through-Door Disconnect

General Fault Indicator

Audible/Visual High-Temperature Alarms

High Pressure Fans

Compressor Hour Meter

Glacier Series Portable Chillers Page 11

Glacier Series NXGA Air-Cooled Model Capacities

Glacier Series NXGA Model Specifications

Page 12 Glacier Series Portable Chillers

Glacier Series Portable Chillers Page 13

Page 14 Glacier Series Portable Chillers

Glacier Series Portable Chillers Page 15

Page 16 Glacier Series Portable Chillers

Glacier Series Portable Chillers Page 17

2-1 Unpacking and Inspection

2-2 In the Event of Shipping Damages

; Notify the transportation company’s local agent if you discover damage.

2-3 If the Shipment is Not Complete

; AEC/Application Engineering Glacier Series portable chiller

Page 18 Glacier Series Portable Chillers

2-4 If the Shipment is Not Correct

1. Pry the crating away from the skid and remove.

Glacier Series Portable Chillers Page 19

3-1 Electrical Connections

3-2 Process Water Connections

Page 20 Glacier Series Portable Chillers

Glacier Series Portable Chillers Page 21

Page 22 Glacier Series Portable Chillers

Glacier Series Portable Chillers Page 23

Page 24 Glacier Series Portable Chillers

3-5 Galvanic Corrosion

3-6 Water Treatment

3-7 Water-Cooled Chiller Condenser Water