ACS HE Series Operation And Instruction Manual Download

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HE Series Central Chillers

OPERATION AND INSTRUCTION MANUAL

MODELS COVERED:

HECR-20T, HECR-25T, HECR-30T, HECR-40T, HECR-50T,
HECR-60THEWC-20T, HECW-25T, HECW-30T, HECW-40T,
HECW-50T, HECW-60T

Part Number: 882.03862.00

Revision: 12/02/2021

Summary of Contents for HE Series

Page 1: ...tral Chillers OPERATION AND INSTRUCTION MANUAL MODELS COVERED HECR 20T HECR 25T HECR 30T HECR 40T HECR 50T HECR 60THEWC 20T HECW 25T HECW 30T HECW 40T HECW 50T HECW 60T Part Number 882 03862 00 Revisi...

Page 2: ...__________________ _________________________ _________________________ _________________________ _________________________ We are committed to a continuing program of product improvement Specification...

Page 3: ...and union or non union installations Disclaimer All rights reserved No part of the contents of this manual may be reproduced copied or transmitted in any form or by any means including graphic electro...

Page 4: ...turned Material Policy 13 Warranty Returns 13 2 2 Unit Storage 13 2 3 Unit Information 14 Chapter 3 Functional Description 16 3 1 Models Covered in This Manual 16 3 2 General Description 16 3 3 Standa...

Page 5: ...hip Loose Items 29 Chapter 5 Remote Air Cooled Condenser Installation 32 5 1 Location 32 5 2 Lifting Remote Condensers 34 5 3 Remote Air Cooled Chiller Condensers 35 5 4 Interconnecting Refrigerant Pi...

Page 6: ...y Step how to Instructions 59 Changing the Circuit Number on the C pCO PLC 59 Updating a C pCO s Program Using a USB Stick 60 Saving or Restoring Settings to a USB Stick 61 Updating an Exor HMI Progra...

Page 7: ...HE Series Central Chillers 882 03862 00 12 02 2021 vii 10 1 Piping Schematic for Water Cooled Chiller 74 10 2 Piping Schematic for Remote Cooled Chiller 75 10 3 Spare Parts List 77...

Page 8: ...ludes instructions checks and adjustments that should be followed before commencing with operation of the equipment These instructions are intended to supplement standard shop procedures performed at...

Page 9: ...se symbols to avoid possible injury or death DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING indicates a potentially hazardous si...

Page 10: ...igned to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage wh...

Page 11: ...Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this...

Page 12: ...e 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 u...

Page 13: ...e Warranty Returns Prior to the return of any material authorization must be given by the manufacturer A RMA number will be assigned for the equipment to be returned Reason for requesting the return m...

Page 14: ...3 1190 Remote Condenser MODEL THR BTUH Total CFM DIMENSIONS IN INCHES CM Shipping Wt Lbs Kg Height Width Depth 20T 315 423 19 800 50 127 45 5 116 127 323 650 295 25T 394 048 19 000 50 127 45 5 116 127...

Page 15: ...HE Series Central Chillers 882 03862 00 12 02 2021 15 50T 760 106 37 000 50 127 45 5 116 127 323 1350 612 60T 975 301 46 200 50 127 45 5 116 127 323 1700 771...

Page 16: ...ady to use Remote air cooled chillers require field installation by qualified technicians In the standard configuration the chiller basically consists of a compressor condenser evaporator metering dev...

Page 17: ...ls Welded structural steel frame powder coated with painted electrical enclosure Fully insulated refrigeration and process water piping 20 mesh strainer in the evaporator Electrical Features Fully acc...

Page 18: ...verified periodically See Figure 6 on page 18 for the correct mixture Crankcase Heater All of the chillers are equipped with a compressor crankcase heater It is wired through the control transformer...

Page 19: ...re The low discharge warning is set for 200 psig 1 379 kPa and the compressor will fault at 180 psig 1 241 kPa To prevent nuisance tripping there are delays built in to the program but while this alar...

Page 20: ...nt to the PLC s configurable analog input instead of the setpoint entered via the display 3 5 Optional Features Options marked with indicate options that can be factory installed or retrofitted in the...

Page 21: ...Chiller Foundation Chiller should be installed on a concrete foundation non warping mounting pads or level floor suitable to support the full operating weight of the equipment When installed the equi...

Page 22: ...HE Series Central Chillers 882 03862 00 12 02 2021 22 Fork Lift...

Page 23: ...connections should be run full size to and from the plumbing system Flow and pressure information is available in the chart below Flow control valves are supplied and should be used to adjust flow an...

Page 24: ...erations The materials used in the water module piping of these chillers are non ferrous and react electro chemically with ferrous metallic materials Some water has dissolved minerals that greatly acc...

Page 25: ...ure The refrigerant then passes through the electronic modulating expansion valve which allows the refrigerant to expand boil off and cool remove the heat from the fluid inside of the evaporator From...

Page 26: ...tactors Three Phase Compressors Scroll compressors are directionally dependent and compress in one rotational direction Reversing rotation direction results in an elevated sound level and a substantia...

Page 27: ...per steel stainless steel and bronze in the system from corrosion If you intend to use straight water we strongly advise a minimum tank temperature of 50 F 10 C or contact the service department The f...

Page 28: ...lt with a voltage specific compressor and cannot be re wired for an alternate voltage Check the transformer primary voltage connections to be sure they are configured for the electrical power you are...

Page 29: ...protection could result in a damaged evaporator ACS Group does not warrant the freeze up of the evaporator under any circumstances The tower or city water condenser cooling in and out connections sho...

Page 30: ...HE Series Central Chillers 882 03862 00 12 02 2021 30...

Page 31: ...HE Series Central Chillers 882 03862 00 12 02 2021 31...

Page 32: ...when locating the condenser to allow adequate room for proper maintenance and servicing of the unit Avoid locating piping or conduit over the unit to ensure easy access with an overhead crane or lift...

Page 33: ...HE Series Central Chillers 882 03862 00 12 02 2021 33...

Page 34: ...ING INSTRUCTIONS 1 Spreader bar must be used for all rigging 2 Under no circumstance should coil connections coil headers return bends or electrical box be used in lifting or moving the condenser 3 Un...

Page 35: ...erant piping Read this entire section before installation Note Piping should be hard drawn type L or type K air conditioning refrigerant grade copper AC R tubing only Proper sizing and installation ha...

Page 36: ...ACS Group supplied 650 psi approved R 410a refrigerant relief valve in the discharge line at the condenser following all applicable codes page 38 of the Appendix Flow dry nitrogen through the system...

Page 37: ...HE Series Central Chillers 882 03862 00 12 02 2021 37 Remote Air Cooled Chiller Configurations A separate Double Riser is needed for every 25ft of up flow discharge piping...

Page 38: ...nected above the liquid refrigerant level and installed so that they are accessible for inspection and repair and so that they cannot be readily rendered inoperative Refer to Figure 1 Figure 1 Remote...

Page 39: ...ion is not required unless the line is installed in a high ambient area i e boiler room or on a roof Install a liquid line charging valve to facilitate refrigerant charging Discharge Line Sizing Disch...

Page 40: ...HERC 30T HERC 40T Total Equiv Length Ft Liquid Line Size OD Total Equiv Length Ft Liquid Line Size OD Horizontal or Down Flow Up flow 1 5 Ft Up flow 6 10 Ft Up flow 11 15 Ft Horizontal or Down Flow Up...

Page 41: ...5 8 1 5 8 1 5 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 HERC 50T 1 5 8 1 5 8 1 5 8 1 5 8 1 5 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 HERC 60T 1 5 8 1 5 8 1 5 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1 8 2 1...

Page 42: ...checking the liquid line sight glass 5 11 Refrigerant Charge Determination Chiller Model Condenser and Chiller Charge LBS of R 410a Minimum Design Ambient F 60 50 40 30 20 10 0 10 20 HERC 20T 25 25 25...

Page 43: ...tory charged with the amount of oil required without field installed piping Additional oil required is dependent on the amount of additional refrigerant added Calculate the amount of additional oil re...

Page 44: ...Service The operator password will allow the user to start and stop the system change the chiller s setpoint and change the language displayed on the touchscreen The supervisor password allows access...

Page 45: ...ers Chapter 6 45 of 83 Note When the operator or supervisor password is set to 0000 the password is disabled When a password is disabled the functions and settings protected by it are adjustable witho...

Page 46: ...3 Section 2 1 2 With the main supply power switch in the ON position the screen will display the version of the software for a period of 5 seconds and then display the main status screen 3 Set the Tan...

Page 47: ...formation on the controller passwords the password screen will appear Touch the Chiller setpoint button and enter desired tank temperature Warning Operating the chiller setpoint below 50 F 10 C withou...

Page 48: ...te reverse rotation after several minutes of operation the compressor internal protector trips Communication Loss Control When a drone circuit loses communication with the master circuit it will conti...

Page 49: ...s done and a reminder will display every five minutes The module enable disable will determine if that module will be allowed to start in the sequence If any module is in an alarm condition that modul...

Page 50: ...e timer completes timing another stage is allowed to de activate if required Lead Lag When compressor lead lag is off compressor A will stage on before compressor B unless it is not ready to run when...

Page 51: ...Compressor activates The PID loop controls the discharge analog output When the discharge pressure hold time is greater than 0 the discharge analog output is set to the discharge pressure start percen...

Page 52: ...o the EEV start percent and the EEV hold timer starts When the timer expires the EEV PID loop is enabled and it then controls the EEV analog output If the EEV hold time is 0 the EEV PID loop controls...

Page 53: ...any of the following messages COMP ANTICYCLE DISCH PRES PROT ACTIVE FREEZE PROT ACTIVE OPN CND REG VLV OPN EXP VALVE PUMP DOWN ACTIVE STAGE OFF DELAY STAGE ON DELAY Hour Meters Total run time hour met...

Page 54: ...Fan Active Cooling Active The output activates when one or more compressors are active Pump Tank Enable The output activates when the system is online System Online The output activates when the syste...

Page 55: ...ork Addressing The circuit number is set using the small display and recessed button at the bottom of the PLC The program will set the network IP address based on the circuit number Circuit 1 Master 1...

Page 56: ...taken offline the circuit is disabled or the alarm has been reset Each alarm is in one of three reset categories Auto reset The alarms in this category are automatically reset when the alarm condition...

Page 57: ...HE Series Central Chillers Chapter 6 57 of 83...

Page 58: ...ral Chillers Chapter 6 58 of 83 6 7 Optional Communications The communications function allows you to monitor and set the parameters by a program prepared and running on a host computer connected to t...

Page 59: ...HE Series Central Chillers Chapter 7 59 of 83 Chapter 7 Step By Step how to Instructions Changing the Circuit Number on the C pCO PLC...

Page 60: ...HE Series Central Chillers Chapter 7 60 of 83 Updating a C pCO s Program Using a USB Stick...

Page 61: ...HE Series Central Chillers Chapter 7 61 of 83 Saving or Restoring Settings to a USB Stick...

Page 62: ...HE Series Central Chillers Chapter 7 62 of 83 Updating an Exor HMI Program using a USB Stick...

Page 63: ...HE Series Central Chillers Chapter 7 63 of 83 Downloading Alarm History to a USB Stick...

Page 64: ...HE Series Central Chillers Chapter 7 64 of 83 Downloading Chiller Logs to a USB Stick...

Page 65: ...HE Series Central Chillers Chapter 7 65 of 83 Changing the Exor IP Address...

Page 66: ...sealed and requires no routine maintenance Caution Do not use steam or water over 140 F 60 C to clean a condenser unless you are monitoring the refrigeration module for excessive pressure with gauges...

Page 67: ...or strainer requires periodic cleaning of its screen to insure the proper flow through the evaporator To clean the strainer screen 1 Close the evaporator inlet and outlet butterfly valves on the back...

Page 68: ...38 in long HE 40T 161 01790 00 20 mesh filter screen 10 5 in long HE 50T 161 01791 00 20 mesh filter screen 14 0 in long HE 60T 161 01789 00 20 mesh filter screen 16 75 in long Preventative Maintenan...

Page 69: ...ive compressor auxiliary contact Repair or replace Broken wire in the compressor control circuit Locate and repair Pump runs compressor s cycle s at short intervals Plugged evaporator strainer Clean H...

Page 70: ...alog output from PLC Verify wiring at analog output per print High Discharge Pressure Switch Discharge pressure has exceeded switch 575 psig setting Input to PLC is missing Hit Manual Reset Button on...

Page 71: ...separated from sensor Reconnect wire connector to sensor Input to PLC is missing Verify wiring at PLC Faulty sensor cable Replace cable Faulty sensor Replace sensor Leaving Water Temp Sensor Failure I...

Page 72: ...perating Compressor Differential Pressure Fault Condenser inlet temperature too low Contact ACS Group Aftermarket Service for assistance Condenser water regulating valve open Verify analog output on P...

Page 73: ...ss valve malfunction Verify wiring HGBP Pump Flow Sensor Failure Input to PLC is missing Verify wiring on PLC M12 connector on cable separated from sensor Reconnect M12 connector to top of sensor Faul...

Page 74: ...HE Series Central Chillers Chapter 10 74 of 83 Chapter 10 Appendix 10 1 Piping Schematic for Water Cooled Chiller...

Page 75: ...HE Series Central Chillers Chapter 10 75 of 83 10 2 Piping Schematic for Remote Cooled Chiller...

Page 76: ...HE Series Central Chillers Chapter 10 76 of 83...

Page 77: ...08KCE TED 746 00856 00 722 92094 00 30T 208 230V ZPT364KCE TED 746 00855 00 722 92094 00 460V ZPT364KCE TED 746 00852 00 722 92094 00 575V ZPT364KCE TED 746 00869 00 722 92094 00 40T 208 230V ZPT472KC...

Page 78: ...T 230 00114 00 161 01775 00 20 mesh filter screen 9 38 in long HE 30T 230 00125 00 161 01775 00 20 mesh filter screen 9 38 in long HE 40T 230 00107 00 161 01790 00 20 mesh filter screen 10 5 in long H...

Page 79: ...denser with E Coat AEC P N HERC 20T 229 00078 00 LNKS02A015 10 460V 229 00102 00 HERC 25T 229 00079 00 LNKS02A017 10 460V 229 00103 00 HERC 30T 229 00080 00 LNKS03A026 10 460V 229 00104 00 HERC 40T 22...

Page 80: ...20T 229 00078 01 LNKS02A015 10 460V 229 00102 01 HERC 25T 229 00079 01 LNKS02A017 10 460V 229 00103 01 HERC 30T 229 00080 01 LNKS03A026 10 460V 229 00104 01 HERC 40T 229 00081 01 LNKS04A029 10 460V 2...

Page 81: ...0 01 PLC C PCO CAREL MEDIUM W BUILT 744 00479 00 RELAY SPST 120VAC COIL 714 01253 00 RELAY SPST 24VDC COIL 714 01243 00 FUSE BLOCK TB 1 4X1 1 4 250V 719 00198 00 END PLATE TB FUSE BLOCK 719 00199 00 F...

Page 82: ...Cores ACS Number of Cores per Filter Description HE 20T A0556048 A0006027 1 C 487 G 7 8 HE 25T 161 01710 00 A0006027 1 C 489 G 1 1 8 HE 30T A0551984 A0006027 2 C 969 G 1 1 8 HE 40T A0551984 A0006027 2...

Page 83: ...e the model and serial number of your unit ready when you contact us TECHNICAL ASSISTANCE If you require any technical assistance we have a qualified service department ready to help We also offer ser...

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