Table of Contents
Troubleshooting
Related Manuals for ACS HE Series
Summary of Contents for ACS HE Series
- Page 1 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...
- Page 2 We are committed to a continuing program of product improvement. Specifications, appearance, and dimensions described in this manual are subject to change without notice. ECN No. ____________ © Copyright 2023 All rights reserved. HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 3: Technical Assistance
ACS Group. Manufacturer reserves the right to change specifications, design without notification or obligation. ACS Group does not assume any responsibility for any errors that may appear in this manual. In no event will ACS Group be liable for technical or editorial omissions made herein, nor for direct, indirect, special, incidental, or consequential damages resulting from the use or defect of this manual. -
Page 4: Table Of Contents
Remote Start/Stop Interlock ..............20 Remote Setpoint ..................20 Optional Features ...................20 General Fault Indicator Audible/Visual Alarm* ........20 Fluid differential pressure switch* ............20 Evaporator flow meter* ................20 UL/cUL Labeled Electrical Subpanel ............20 HE Series Central Chillers • 882.03862.00 • 12/02/2021... - Page 5 Refrigerant Charge Determination ............42 5-12 Oil Charge Determination ...............43 Chapter 6: General Operation Overview ................44 HMI Buttons, Indicator Lights, and Switches ...........44 Finishing Setup: Password Protection ............44 Initial Start-Up /Setting Tank Temperature Setpoint ........46 HE Series Central Chillers • 882.03862.00 • 12/02/2021...
- Page 6 Water-Cooled Chillers ................66 Maintaining the Evaporator ..............66 Evaporator Process Strainer ..............67 Preventative Maintenance Service ............68 Chapter 9: Troubleshooting Alarms ..................69 Troubleshooting Warnings and Faults from the PLC ......70 Chapter 10: Appendix ......................74 HE Series Central Chillers • 882.03862.00 • 12/02/2021...
- Page 7 10-1 Piping Schematic for Water Cooled Chiller ..........74 10-2 Piping Schematic for Remote Cooled Chiller ..........75 10-3 Spare Parts List ..................77 HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 8: Chapter 1: Safety
Refer to this section for a listing of spare parts for purchase. Have your serial number and model number ready when ordering. HE Series Central Chillers • 882.03862.00... -
Page 9: Safety Symbols Used In This Manual
CAUTION indicates a potentially hazardous situation or practice which, if not avoided, may result in minor or moderate injury or in property damage. HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 10: Warnings And Precautions
To avoid possible personal injury or equipment damage when installing, operating, or maintaining this equipment, use good judgment and follow these safe practices: HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 11: Responsibility
Each individual must take responsibility for observing the prescribed safety rules as outlined. All warning and danger signs must be observed and obeyed. All actual or potential danger areas must be reported to your immediate supervisor. HE Series Central Chillers • 882.03862.00... -
Page 12: Chapter 2: Pre Installation
If the shipment is not what you ordered, contact the parts and service department immediately at . Have the order number and item number available. [800] 423-3183 Hold the items until you receive shipping instructions. HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 13: Returned Material Policy
Close all refrigerant valves, water valves and cover the units to prevent dirt build up. Units that are charged with refrigerant should be stored in areas cooler than 145⁰F. HE Series Central Chillers • 882.03862.00... -
Page 14: Unit Information
THR BTUH Total CFM Lbs (Kg) Height Width Depth 315,423 19,800 50(127) 45.5(116) 127(323) 650(295) 394,048 19,000 50(127) 45.5(116) 127(323) 700(317) 583,597 28,500 50(127) 45.5(116) 127(323) 1030(467) 597,893 38,600 50(127) 45.5(116) 127(323) 1250(567) HE Series Central Chillers • 882.03862.00 • 12/02/2021... - Page 15 760,106 37,000 50(127) 45.5(116) 127(323) 1350(612) 975,301 46,200 50(127) 45.5(116) 127(323) 1700(771) HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 16: Chapter 3: Functional Description
Thermal spray After-coolers (air compressors, dryers, etc.) Laser Printing (offset, gravure, digital) System Limitations System should be sized so that at a minimum a Master and a Drone module exist. HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 17: Standard Features
High refrigerant pressure cutout switch (manual reset) Suction and discharge pressure transducers. High refrigerant pressure spring actuated relief valve Multiple refrigeration access ports Liquid line shut-off ball valves Filter-dryer with replaceable cores Sight glass Modulating electronic expansion valve HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 18: Controls Features
The high-pressure cutout is a manual reset device typically mounted on the compressor discharge line behind the electrical enclosure. Call a refrigeration service technician to analyze the problem and reset the control. HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 19: Pressure Transducers
75°F or higher. Note: Call a refrigeration service technician to analyze the problem to prevent recurring low pressure faults. Discharge Pressure Transducer Suction Pressure Transducer HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 20: Flow Switch
UL/cUL Labeled Electrical Subpanel This option provides for the subpanel to be listed with Underwriters Laboratory, with UL-related benefits and features. Sub-panels marked by the UL/cUL sticker are accepted within Canada. Optional Operating Voltages 208-230/3/60, 460/3/60, and 575/3/60 volt available HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 21: Chapter 4: Chiller - Installation
The indoor modules have been designed to be moved with a forklift. Use caution when moving the modules to ensure proper weight distribution. Caution! Use care when LOADING, UNLOADING, RIGGING, or MOVING this equipment. HE Series Central Chillers • 882.03862.00 • 12/02/2021... - Page 22 Fork Lift HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 23: Process Water Connections
A thermal dispersion flow switch on the evaporator inlet is used to ensure flow through the evaporator. If the flow switch is not made the controller shuts down the compressor to prevent freezing inside the evaporator WARNING! - ACS Group does not warrant the freeze up of the evaporator under any circumstances. Note: Be sure to reduce external pressure drop as much as possible by generously sizing piping. -
Page 24: Flow And Pressure Considerations
The use of poor quality water may result in inefficient operation, heat exchanger damage, and pump seal damage. Consult a qualified water treatment specialist to determine what type of treatment is needed. HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 25: Refrigeration Circuit And Water Condenser Piping
Each water cooled condenser is equipped with a two way electronic water regulating valve to control the amount of water allowed to pass through the condenser in order to maintain proper refrigeration pressures in the circuit. HE Series Central Chillers • 882.03862.00... -
Page 26: 4-10 Checking Motor Direction
Warning! Operating the tank temperature setpoint below 50°F (10°C) without the proper amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances. HE Series Central Chillers •... - Page 27 20.0 30.0 40.0 50.0 60.0 % Gl ycol by Vol um e Example: 45°F set point minus 20°F = 25°F. From Figure 28, 25°F equates to 10% by volume of glycol required. HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 28: 4-12 Electrical Connections
C phase. Check for proper rotation direction of fan(s) and pump(s). The best route for the main power wiring is from the floor up to the right side of the enclosure on the top. Check that all wire connections are secure and correct. HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 29: 4-14 Ship Loose Items
Warning! Operating the chiller tank temperature setpoint below 50°F (10°C) without the proper amount of glycol for freeze 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 should be completed and an adequate supply of 85ºF (30ºC) tower or 70ºF (21ºC) city water, at 25 psi (1.7 bar/0.17 MPa) - Page 30 HE Series Central Chillers • 882.03862.00 • 12/02/2021...
- Page 31 HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 32: Chapter 5: Remote Air Cooled Condenser - Installation
It is also good practice to consider locating the condenser where the fan noise and vibration transmissions don’t affect work areas. Avoiding locations near exhaust fans, plumbing vents, flues, or chimneys is also recommended. HE Series Central Chillers • 882.03862.00... - Page 33 HE Series Central Chillers • 882.03862.00 • 12/02/2021...
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Page 34: Lifting Remote Condensers
Lifting brackets or holes are located at the corners for the use of lifting slings. Use spreader bars when lifting to apply the lifting force vertically. Under no circumstances use the coil headers or return bends in the lifting or moving of the condensers. HE Series Central Chillers • 882.03862.00... -
Page 35: Remote Air-Cooled Chiller Condensers
1,950 psi. Warning! CHILLERS AND REMOTE CONDENSERS ARE PRESSURIZED WITH NITROGEN FOR SHIPPING. PRESSURE MUST BE RELIEVED PRIOR TO CUTTING OR BRAZING COPPER TUBING. INJURY WILL RESULT IF PRESSURE IS NOT RELIEVED HE Series Central Chillers • 882.03862.00 • 12/02/2021... -
Page 36: Interconnecting Refrigerant Piping
(type “L” or type “K” air conditioning & refrigerant grade tubing) for oil return, with high temperature brazes joints using a minimum of 15% silver solder. Install an 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). -
Page 37: Remote Air-Cooled Chiller Configurations
Remote Air-Cooled Chiller Configurations A separate Double Riser is needed for every 25ft of up flow discharge piping. HE Series Central Chillers • 882.03862.00 • 12/02/2021... - Page 38 (Refer to Figure 1) ACS Group has supplied with this chiller one (1) refrigerant relief valve and one (1) 3/8 x 3/8 FPT forged bronze fitting.
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Page 39: Sizing Refrigerant Lines
Pressure drop Equivalent Pipe Length (Feet) Line 90⁰ Angle 90⁰ 90⁰ 45⁰ 45⁰ Size Long Radius Valve Standard Street Standard Street (inches) 1 1/8 1 3/8 1 5/8 2 1/8 2 5/8 HE Series Central Chillers Chapter 5: 39 of 83... -
Page 40: Liquid Line Sizing
1 3/8 1 3/8 Proper line sizing is the responsibility of the installation contractor! Applications Department recommendations are listed in the manual furnished. Refer to the line sizing charts in these instructions. HE Series Central Chillers Chapter 5: 40 of 83... -
Page 41: Discharge Line Sizing
B-1-5/8 B-1-5/8 B-1-5/8 Proper line sizing is the responsibility of the installation contractor! Applications Department recommendations are listed in the manual furnished. Refer to the line sizing charts in these instructions. HE Series Central Chillers Chapter 5: 41 of 83... -
Page 42: 5-10 Refrigerant Charge Determination
142.1 2 5/8 21.4 219.5 Note: The amounts listed above are based on 100 feet of pipe. Actual amounts will be in direct proportion to the actual length of the piping. HE Series Central Chillers Chapter 5: 42 of 83... -
Page 43: 5-12 Oil Charge Determination
Calculate the amount of additional oil required by using the following formula: Pints of oil (Copeland Ultra 22cc) = lbs. of R-410a added for field installed piping / 100. HE Series Central Chillers Chapter 5: 43 of 83... -
Page 44: Chapter 6: General Operation Overview
The service password allows access to everything the supervisor password allows access to as well as all the service settings. These passwords are 4 digits long. HE Series Central Chillers Chapter 6: 44 of 83... - Page 45 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 without requiring a password. HE Series Central Chillers Chapter 6: 45 of 83...
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Page 46: Initial Start-Up /Setting Tank Temperature Setpoint
3. Set the Tank temperature by following these steps. First make sure the proper password has been entered, and then Start by touching menu button to launch the main menu. HE Series Central Chillers Chapter 6: 46 of 83... - Page 47 Warning! Operating the chiller setpoint below 50°F (10°C) without the proper amount of glycol for freeze protection could result in a damaged evaporator. ACS Group does not warrant the freeze up of the evaporator under any circumstances. HE Series Central Chillers...
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Page 48: Chiller Operation
If the noted temperature is above the chiller’s setpoint, the chiller’s setpoint is used as the circuit’s setpoint. Otherwise the noted temperature is used as the circuit’s setpoint Local Staging HE Series Central Chillers Chapter 6: 48 of 83... -
Page 49: Compressor Anticycle
Three sets of parameters/defaults for the PID loop are present. The ambient / condenser in temperature determines which set is used. Staging On HE Series Central Chillers Chapter 6: 49 of 83... -
Page 50: Hot Gas
When more than one loop is configured to control the hot gas analog output, the loop with the highest output percent is used. The hot gas control variable can be set to the following: HE Series Central Chillers Chapter 6: 50 of 83... -
Page 51: Discharge Pressure Control
SP. The minimum and maximum for the output are set by the discharge pressure minimum and discharge pressure maximum setpoints. HE Series Central Chillers Chapter 6: 51 of 83... -
Page 52: Electronic Expansion Valve
0. Pump down remains active until either the suction pressure is less than or equal to the pump down SP or the pump down override delay expires. HE Series Central Chillers Chapter 6: 52 of 83... -
Page 53: Chiller Control Sensor
• Suction Pressure (Carel ratio metric) • Tank Temperature (Modbus IP) * Optional Analog Out (0-10 VDC) • Condenser Fan / Water Regulating Valve • Retransmission of the Chiller In Temperature HE Series Central Chillers Chapter 6: 53 of 83... -
Page 54: Pump Enable
When this option is installed and enabled (remote SP mode variable set to remote), the chiller will be controlled to the setpoint sent to the PLC’s configurable analog input instead of the setpoint entered via the display. Remote Start HE Series Central Chillers Chapter 6: 54 of 83... -
Page 55: Runtime Meters
Each alarm that occurs will be logged on the Alarm History screen. In addition to the alarm name, data logged at the time the alarm is be displayed. HE Series Central Chillers Chapter 6: 55 of 83... - Page 56 X times in Y seconds at which point it must be reset by a user. Optionally, two variables can be sampled at the time of the alarm. The samples are stored in the alarm history. HE Series Central Chillers Chapter 6: 56 of 83...
- Page 57 HE Series Central Chillers Chapter 6: 57 of 83...
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Page 58: Optional Communications
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 the controller. HE Series Central Chillers Chapter 6: 58 of 83... -
Page 59: Chapter 7: Step By Step How To Instructions
Chapter 7: Step By Step how to Instructions Changing the Circuit Number on the C.pCO PLC HE Series Central Chillers Chapter 7: 59 of 83... -
Page 60: Updating A C.pco's Program Using A Usb Stick
Updating a C.pCO’s Program Using a USB Stick HE Series Central Chillers Chapter 7: 60 of 83... -
Page 61: Saving Or Restoring Settings To A Usb Stick
Saving or Restoring Settings to a USB Stick HE Series Central Chillers Chapter 7: 61 of 83... -
Page 62: Updating An Exor Hmi Program Using A Usb Stick
Updating an Exor HMI Program using a USB Stick HE Series Central Chillers Chapter 7: 62 of 83... -
Page 63: Downloading Alarm History To A Usb Stick
Downloading Alarm History to a USB Stick HE Series Central Chillers Chapter 7: 63 of 83... -
Page 64: Downloading Chiller Logs To A Usb Stick
Downloading Chiller Logs to a USB Stick HE Series Central Chillers Chapter 7: 64 of 83... -
Page 65: Changing The Exor Ip Address
Changing the Exor IP Address HE Series Central Chillers Chapter 7: 65 of 83... -
Page 66: Chapter 8: Maintenance
2. Open the upper and lower evaporator ball valves to drain the process fluid from the evaporator. 3. Connect an isolated pumping system (similar to ACS Part number 602.83607.00) to the upper and lower evaporator ball valves with the inlet to the lower valve and the outlet to the upper valve 4. -
Page 67: Evaporator Process Strainer
3. Remove the clip that holds the top sensor cap to the evaporator. 4. Remove the sensor cap off the evaporator. 5. Remove the strainer out of the evaporator. HE Series Central Chillers Chapter 8: 67 of 83... -
Page 68: Preventative Maintenance Service
The warranty does not cover chiller failures from a dirty evaporator. Should the screen be damaged contact ACS Customer Service Group and purchase the screen associated with the size of chiller. -
Page 69: Chapter 9: Troubleshooting Alarms
Unit runs continuously, but Unit low on refrigerant. glass on liquid line upstream of the expansion not enough cooling power. valve. Compressor not operating efficiently. Call service. Unit under-sized for application. Call sales rep HE Series Central Chillers Chapter 9: 69 of 83... -
Page 70: Troubleshooting Warnings And Faults From The Plc
Failure Faulty sensor cable Replace cable Faulty sensor Replace sensor Condenser inlet temperature too high Contact ACS Group Aftermarket Service for water or remote cooled units assistance High Discharge Pressure Contact refrigeration technician about removing Refrigerant overcharge Fault (Discharge pressure... - Page 71 High Fluid Temp Fault Load may be too high for chiller Contact your sales representative for assistance. (Leaving fluid temperature has exceeded fault Clean evaporator inlet strainer Evaporator dirty setpoint) Back flush evaporator HE Series Central Chillers Chapter 9: 71 of 83...
- Page 72 18 in (46 cm) above the pump warning setpoint sensor is enabled in suction centerline while the pump is operating Supervisor Menu) Contact ACS Group Aftermarket Service for Condenser inlet temperature too low Compressor Differential assistance Pressure Fault...
- Page 73 Input to PLC is missing Verify wiring at PLC Tank Level Sensor Failure Faulty sensor cable Replace cable Faulty sensor Replace sensor Low Suction Pressure at Contact ACS Group Aftermarket Service for Startup assistance HE Series Central Chillers Chapter 9: 73 of 83...
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Page 74: Chapter 10: Appendix
Chapter 10: Appendix 10-1 Piping Schematic for Water Cooled Chiller HE Series Central Chillers Chapter 10: 74 of 83... - Page 75 10-2 Piping Schematic for Remote Cooled Chiller HE Series Central Chillers Chapter 10: 75 of 83...
- Page 76 HE Series Central Chillers Chapter 10: 76 of 83...
- Page 77 460V ZPT472KCE-TED 722.92126.00 746.00871.00 575V ZPT472KCE-TED 722.92126.00 746.00872.00 208-230V ZPT592KCE-TED 722.92126.00 746.00844.00 460V ZPT592KCE-TED 722.92126.00 746.00873.00 575V ZPT592KCE-TED 722.92126.00 746.00875.00 208-230V ZPT770KCE-TED 722.92102.00 746.00806.00 460V ZPT770KCE-TED 722.92102.00 746.00838.00 575V ZPT770KCE-TED 722.92102.00 HE Series Central Chillers Chapter 10: 77 of 83...
- Page 78 ACS P/N HEWC-20T 229.00052.01 LVC20(2013) 044.01016.00 HEWC-25T 229.00053.01 LVC25 (2013) 044.01016.00 HEWC-30T 229.00054.01 LVC30 (2013) 044.01017.00 HEWC-40T 229.00057.01 LVC40 (2013) 044.01018.00 HEWC-50T 229.00058.01 LVC50 (2013) 044.01018.00 HEWC-60T 229.00059.01 LVC60 (2013) 044.01019.00 HE Series Central Chillers Chapter 10: 78 of 83...
- Page 79 AEC P/N HERC-20T 229.00090.00 LNKS02A015-10 575V 229.00108.00 HERC-25T 229.00091.00 LNKS02A017-10 575V 229.00109.00 HERC-30T 229.00092.00 LNKS03A026-10 575V 229.00110.00 HERC-40T 229.00093.00 LNKS04A029-10 575V 229.00111.00 HERC-50T 229.00094.00 LNKS04A034-10 575V 229.00112.00 HERC-60T 229.00095.00 LNKS05A044-10 575V 229.00113.00 HE Series Central Chillers Chapter 10: 79 of 83...
- Page 80 HERC-30T 229.00092.01 LNKS03A026-10 575V 229.00110.01 HERC-40T 229.00093.01 LNKS04A029-10 575V 229.00111.01 HERC-50T 229.00094.01 LNKS04A034-10 575V 229.00112.01 HERC-60T 229.00095.01 LNKS05A044-10 575V 229.00113.01 E.C. FAN MOTOR ACS # 460/3/60 & 575/3/60 162.00099.14 230/3/60 162.00099.15 HE Series Central Chillers Chapter 10: 80 of 83...
- Page 81 044.01102.00 SERI-JS 1-1/8 X 1-3/8, 10FT CABLE HE-50T 044.01102.00 SERI-JS 1-1/8 X 1-3/8, 10FT CABLE HE-60T 044.01109.00 SERI-KS 1-1/8 X 1-5/8, 10FT CABLE HOT GAS BYPASS ACS # ALL SIZES 044.01396.00 HE Series Central Chillers Chapter 10: 81 of 83...
- Page 82 Filter HE-20T A0556048 A0006027 C-487-G, 7/8 HE-25T 161.01710.00 A0006027 C-489-G, 1-1/8 HE-30T A0551984 A0006027 C-969-G, 1-1/8 HE-40T A0551984 A0006027 C-969-G, 1-1/8 HE-50T A0500547 A0006027 C-14411-G, 1-3/8 HE-60T A0500547 A0006027 C-14411-G, 1-3/8 HE Series Central Chillers Chapter 10: 82 of 83...
- Page 83 PARTS SUPPORT ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service. 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.
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