Acson international AMAC40C User manual

Technical Manual
AIR-COOLED
MINI CHILLER
AMAC 20-150 C/CR
A4AC 20-150 C
A4AC 60-150 CR
A5AC 20-55 CR

TABLE OF CONTENTS
1. NOMENCLATURE .................................................................................................. 1
- PRODUCT LINE UP
2. FEATURES............................................................................................................. 5
3. APPLICATION INFORMATION ............................................................................... 7
- REFRIGERANT CIRCUIT DIAGRAM
- CHILLER PANEL CONTROLLER
- PRECAUTIONS AND INSTALLATION
4. SOUND DATA ........................................................................................................ 57
5. SELECTION PROCESS ........................................................................................64
- WATER PRESSURE DROP VS FLOW RATE
- GLYCOL
6. ENGINEERING AND PHYSICAL DATA .................................................................67
- SPECIFICATIONS
7. PERFORMANCE DATA ....................................................................................... 114
8. OUTLINE AND DIMENSION ............................................................................... 126
9. ELECTRICAL DATA ............................................................................................. 130
10. WIRING DIAGRAMS ......................................................................................... 138
11. SERVICING AND MAINTENANCE .................................................................... 154
12. TROUBLESHOOTING ......................................................................................155
13. EXPLODED VIEW AND PART LIST .................................................................. 156

1
1. NOMENCLATURE
A 4 AC 20 C R
Brand
A :Acson
Refrigerant
“ “ : Omitted if R22
4 : R407C
5 : R410A
Model Name
AC : Air-Cooled Mini Chiller
Capacity Index
020 : 20,000 Btu/h
Chasis
C : C Series
Model Type
“ “ : Omitted if cooling only
R : Heat pump

2
PRODUCT LINE UP
AMAC-C/CR
Nomenclature
PCB-MC01 LCD Panel - Chiller Panel CE Mark Scroll Compressor Rotary Compressor CCH (Crank Case Heater) Terminal Block Magnetic Contactor Water Tank + Pump Without Tank / Pump Only Expansion tank Gold Fin Antifreeze & Auto pump on Phase Protector Three Phase Fan Motor Capillary Tube TXV
AXAC XXXXXXXXXX
AXAD XXXXXXXX XX X
AXAC XXXX XXXXXXX
AXAD XXXX XXXXX XX X
AXAC XXXX XXXXXXX
AXAD XXXX XXXXX XX X
FXAC XXXX XXXXXXX X
FXAD XXXX XXXXX XXX X
FXAC XXXX XXXXXXX X
FXAD XXXX XXXXX XXX X
FXAC XXXX XXXXXXX X
FXAD XXXX XXXXX XXX X
FXAE XXXX XXXX
XXXX X
FXAF XXXX XXXX
XXX X
FXAE XXXX XXXX
XXXX X
FXAF XXXX XXXX
XXX X
FXAC XXXX XXXX
XXXX X
FXAD XXXX XXXX
XXX X
FXAC XXXX XXXX
XXXX X
FXAD XXXX XXXX
XXX X
20CR AXAB X X XXXXX XXX X
25CR AXAB X X XX XXXX XXX X
30CR AXAB X X XX XXXX XXX X
FXAC X X XX XXXX XXXX X
FXAD X X XX XXXX XXXX X
50CR FXAC X X XX XXXX XXXX X
60CR FXAC X X XX XXXX XXXX X
FXAE X X XX XXXX XXXX X
FXAF X X XX XXXX XXXX X
FXAE X X XX XXXX XXXX X
FXAF X X XX XXXX XXXX X
120CR FXAC X X XX XXXX XXXX X
150CR FXAC X X XX XXXX XXXX X
HEATPUMP
60C
150C
80C
100C
120C
40CR
80CR
100CR
20C
25C
30C
40C
50C
AMAC
COOLING ONLY

3
A4AC-C/CR
Nomenclature
PCB-MC01 LCD Panel - Chiller Panel CE Mark Scroll Compressor Rotary Compressor CCH (Crank Case Heater) Terminal Block Isolator Switch Magnetic Contactor Water Tank + Pump Pump Only Expansion tank Gold Fin Antifreeze & Auto pump on Phase Protector Three Phase Fan Motor Capillary Tube TXV
AXAC XXXXXXXXXX
AXAD XXXXXXXX XX X
AXAC XXXX XXXXXXX
AXAD XXXX XXXXX XX X
AXAC XXXX XXXXXXX
AXAD XXXX XXXXX XX X
FXAC XXXX XXXXXXX X
FXAD XXXX XXXXX XXX X
FXAC XXXX XXXXXXX X
FXAD XXXX XXXXX XXX X
FXAC XXXX XXXXXXX X
FXAD XXXX XXXXX XXX X
FXAI XXXXXXXX
XXXX X
FXAJ XXXXXXXX
XXX X
FXAI XXXXXXXX
XXXX X
FXAJ XXXXXXXX
XXX X
FXAG XXXXXXXX
XXXX X
FXAH XXXXXXXX
XXX X
FXAG XXXXXXXX
XXXX X
FXAH XXXXXXXX
XXX X
20CR
25CR
30CR
40CR
50CR
60CR FXAB X X XX XXXX XXXX X
FXAE X X XX XXXX XXXX X
FXAF X X XXXXXX XXXX X
FXAE X X XX XXXX XXXX X
FXAF X X XXXXXX XXXX X
120CR FXAD X X XXXXXX XXXX X
150CR FXAD X X XX XXX XXXX X
80C
100C
120C
150C
80CR
100CR
Classification
HEATPUMP
A4AC
COOLING ONLY
20C
25C
30C
40C
50C
60C

4
A5AC-CR
Nomenclature
PCB - TC01 PCB - TC1.1r4 LCD Panel - Chiller Panel CE Mark Scroll Compressor Rotary Compressor CCH (Crank Case Heater) Terminal Block Isolator Switch Magnetic Contactor Water Tank + Pump Pump Only Expansion tank Gold Fin Antifreeze & Auto pump on Phase Protector Single Phase Fan Motor Capillary Tube TXV
20CR AXAA X X XXXXX XXX X
25CR AXAA X X XXXXX XXX X
30CR EXAB X X XXXXXXX XX
40CR EXAC X X XXXXXXX XX
50CR EXAC X X XXXXXXX XX
55CR EXAC X X XXXXXXX XX
HEATPUMP
Classification
A5AC

5
2. FEATURES
REFRIGERANT CIRCUIT
Models AMAC/A4AC80~150C/CR has been designed with two separate refrigerant circuits, i.e. it has two
compressors. By doing so, the unit has part loading capabilities, i.e. 0-50-100% of rated capacity. This will
improve the reliability and energy efficiency of the unit, especially during low loading operations. Each circuit
is factory brazed and evacuated before accurately charged with refrigerant to ensure optimum performance.
Because each circuit is separated, there is no danger of cross-contamination should either one of the
compressor experiences a burnt-up. Each circuit is also equipped with a carefully sized thermostatic expansion
valve (for cooling only units) to give optimum performance characteristic. For the heatpump version, the
expansion process is done with capillary tubes.
SCROLL COMPRESSOR
Scroll Compressors are used (for model which is available) for the units (AMAC/A4AC20C/CR using rotary
compressor) to give quiet and reliable performance over a wide operating temperature range. However, in
order to protect the compressors from damage, a phase protector (for model which is available) is provided to
prevent the compressors from rotating in the wrong directions.
TANDEM COMPRESSOR
A5AC models are using R410A rotary compressors in tandem configuration. Tandem compressors are highly
efficient and cost saving. It reduces mechanical losses, minimize gas flow losses and turbulence. There are 3
steps capacity loading (0-40-60-100%) for A5AC40/50CR and 2 steps capacity loading (0-50-100%) for A5AC30/
55CR.
CONDENSER FAN MOTOR
Models AMAC/A4AC80~150C/CR is equipped with two high air flow propeller fan blades which are made of
metal. The fans are driven vertically by weather proof motors which are single phase type.
EVAPORATOR
The heat exchanger is made of stainless steel plates closely arranged and brazed together (BPHE) to ensure
high heat exchange efficiency. For models AMAC/A4AC80~150C/CR, the water flow through the BPHE in a
channel on its own, while because of the two compressors, the refrigerant flows through another two separate
channels. The refrigeran t will either be in a counter-flow or parallel-flow with respect to the water, depending
on the mode of operation (cooling or heating).
SAFETY PROCETECTION
The safety protections provided for the mini chiller are:
a) High and low pressure switches
b) Differential water flow switch
c) Compressor, water pump and fan motor overload protectors
d) Anti-freeze protection sensor
During abnormal condition, chiller panel controller will turn off the unit and then display the faults of operation.
WATER TANK AND PIPING CONNECTION
The models A4AC/AMAC80~150C/CR does not come with a water buffer tank. However, the unit does come
with an 8 liters expansion tank. Besides that, an optional 135L hydraulic tank is also available.
The external water piping connection can be made either from the left or right side of the unit. Connection is
done with Ø1-1/4 “ female thread couplings for both supply and return pipes.
Meanwhile, AMAC/A4AC20~60C/CR does come with a 22 L or 40 L (refer to specification) water buffer tank.

6
ANTIFREEZE PROTECTION
The chiller unit has several anti-freeze protection features:
1. Brazed plate heat exchanger anti-freeze
The BPHE has a strip heater around it to prevent water freezing inside
2. Auto mode
The chiller controller will force on the unit to the heat mode if the outdoor ambient air temperature
becomes too cold.
MAINTENANCE
In order to facilitate of the controller, a rocker switch is provided to power-off the supply to the PCB. However,
switching off the switch will not disconnect the main incoming power supply to the chiller unit.

7
3. APPLICATION INFORMATION
P
P
FIL TER
DRIER CAP TUBE
BPHE
COMPRESSOR
WATER PUMP
AUT O PRESS RELIEF V ALV E
WATER
OUT
WATER
IN
EXP ANSION
TANK
WATER ST ORAGE
T ANK
FIL TER
DRIER CAP TUBE
BPHE
COMPRESSOR
WATER PUMP
AUT O PRESS RELIEF V ALV E
WATER
OUT
WATER
IN
EXP ANSION
TANK
WATER ST ORAGE
T ANK
PART NO : 70-03-4-067460
PART NO : 70-03-4-087461
A4AC / AMAC 20C / 25C / 30C
Water / Refrigerant Circuit Diagram
A4AC / AMAC 40C / 50C / 60C
Water / Refrigerant Circuit Diagram
REFRIGERANT CIRCUIT DIAGRAM

8
P
P
CHECK
VALVE
BPHE
COMPRESSOR
CHARGE
COMPENSATOR
AUTO PRESS RELIEF VALVE
WATER
OUT
WATER
IN
EXPANSION
TANK
WATER STORAGE
TANK
PART NO : 70-03-4-067458
BPHE
COMPRESSOR
WATER PUMP
AUTO PRESS RELIEF VALVE
WATER
OUT
WATER
IN
EXPANSION
TANK
WATER STORAGE
TANK
PART NO : 70-03-4-067459
CHECK
VALVE
FILTER
DRIER
HEATING
CAP
TUBE
COOLING
CAP
TUBE
SUCTION
ACCUMULATOR
CHECK
VALV E
LIQUID
RECEIVER
CHECK
VALV E
FILTER
DRIER
HEATING
CAP
TUBE
COOLING
CAP
TUBE
SUCTION
ACCUMULATOR
AMAC 40CR / 50CR, A4AC/ AMAC 60CR
Water / Refrigerant Circuit Diagram
A4AC / AMAC 20CR / 25CR / 30CR
Water / Refrigerant Circuit Diagram

9
FIN TUBE
HEA T EXCHANGER
(SYSTEM 1)
FIN TUBE
HEA T EXCHANGER
(SYSTEM 2)
4-W AY V A LV E
COMPRESSOR COMPRESSOR
SUCTION
ACCUMULA TO R
SUCTION
ACCUMULA TOR
WATER
OUT
WATER
IN
LIQUID
RECEIVER
LIQUID
RECEIVER
CHECK
VA L V E
CHECK
VA L V E
CHECK
VA L V E
CHECK
VA L V E
HEA TING
CAP
TUBE
HEA TING
CAP
TUBE
FIL TER
DRIER
FIL TER
DRIER
COOLING
CAP
TUBE
COOLING
CAP
TUBE
PAR T NO : 70-03-4-056764
FIN TUBE
HEA T EXCHANGER
(SYSTEM 1)
FIN TUBE
HEA T EXCHANGER
(SYSTEM 1)
COMPRESSOR COMPRESSOR
FIL TER DRIER FIL TER DRIER
WATER
OUTLET
WATER
INLET
4-W AY V A LV E
THERMOST ATIC
EXP ANSION
VA L V E
THERMOST AT IC
EXP ANSION
VA L V E
BRAZED PLA TE
HEA T EXCHANGER
A4AC / AMAC 80CR / 100CR / 120CR / 150CR
Water / Refrigerant Circuit Diagram
A4AC / AMAC 80C / 100C / 120C / 150C
Water / Refrigerant Circuit Diagram

10
WATER / REFRIGERANT
4WV
EXPANSION TANK
FILTER
DRIER
OIL
RETURN
TUBE
COMPRESSOR 1
CHECK
VA LV E
OIL
RETURN
TUBE
TWIN TUBE
JOINT
COMPRESSOR 2
BPHE
WATER OUT
WATER IN
PUMP
CHARGE
COMPENSATOR
TXV
P
CHECK
VALVE
BPHE
COMPRESSOR
CHARGE
COMPENSATOR
AUTO AIR VENT
WATER
OUT
WATER
IN
EXPANSION
TANK
WATER STORAGE
TANK
CHECK
VALVE
FILTER
DRIER
HEATING
CAP
TUBE
COOLING
CAP
TUBE
SUCTION
ACCUMULATOR
PART NO : 70-03-4-080547
WATER PUMP
A5AC 20CR / 25CR
Water / Refrigerant Circuit Diagram
A5AC 30CR
Water / Refrigerant Circuit Diagram

11
4WV
FILTER
DRIER
OIL
RETURN
TUBE
COMPRESSOR 1
CHECK
VA LV E
OIL
RETURN
TUBE
TWIN TUBE
JOINT
LIQUID RECEIVER
COMPRESSOR 2
BPHE
WATER
OUT
WATER
IN
EXPANSION
TTANK
PUMP
W
TXV
SUB -
ACCUMU-
LATOR
4WV
FIL TER
DRIER
OIL
RETURN
TUBE
COMPRESSOR 1
CHECK
VA LV E
OIL
RETURN
TUBE
TWIN TUBE
JOINT
LIQUID RECEIVER
COMPRESSOR 2
BPHE
WATER
OUT
WATER
IN
EXP ANSION
TANK
PUMP
WATER / REFRI
TXV
SUB -
ACCUMU-
LA TO R
A5AC 40 / 50CR
Water / Refrigerant Circuit Diagram
A5AC 55CR
Water / Refrigerant Circuit Diagram

12
1. SAFETY CONSIDERATION
Only specially trained and technicians and installers are authorized to install and service this
equipment..
1.1 General Installation Recommendations
•Only supply DC voltage (9-17V, typically 12V, maximum current 200mA) as a power source
to the device.
•Input contact voltage supply should limit to 12VDC or 24VAC.
•Isolated all the low voltage wiring (communication bus, etc) from high voltage power supply
wiring.
2. GENERAL DESCRIPTION
2.1 General
The chiller panel controller is designed to control the chiller operation. This device allows the
user to have customized control for each connected unit.
2.2 Features
The requirements of user friendly and easy to use have been taken into account in designing
this chiller panel controller. It can do the task as follow:
•Whole system configuration
•Unique parameter settings
•Operation status display
•Tracing fault record (easy in hardware troubleshooting)
The display is shown in an 8-lines graphical LCD display. There are 8 dedicated keys available
in the panel,
•Menu selection
•Navigation on the screen
•Modification of the selected value
During first start-up, the panel will have a default configuration (timer schedule, set point,
miscellaneous settings, etc) User can do the changes on that particular configuration later.
2.3 Panel Position
The chiller panel controller can be installed anywhere, as long as it is easy to accessed by
authorized personnel.
The requirements of installation are:
•Avoid exposure to shocks
•Avoid any source of electromagnetic pollution
•Avoid installation on uneven vertical surface
2.4 Operation Environmental Condition
•Temperature:
-10°C to 65°C operating temperature
-20°C to 85°C storage temperature
•Relative Humidity:
0 to 95% non-condensing
CHILLER PANEL CONTROLLER

13
3. HARDWARE DESCRIPTION
1 & 2 Navigation key
3 Execute instruction key
4 Cancel instruction key
5 Switching to heat mode shortcut key
6 Switching to cool mode shortcut key
7 Toggle ON/OFF shortcut key
8 Show alarm key
9 Graphical LCD display
10 ON/OFF indicator
Legend
1 & 2 Chiller terminal unit connection
3Not availab le
4 CMOS rset jumper (JH2)
5 Chiller bus resist or configuration (JH3)
6Not availab le
7Not availab le
8Not availab le
9Not availab le
10 Backup battery
Legend
3.1 Key Explanation
The 2 navigation keys permit item selection and modifying the selected value.
ENTER key is used to execute the navigation instruction
ESC key is used to cancel the navigation instruction
Shortcut key to switch the operation mode in the summary pages
Shortcut key to trigger ON/OFF in the summary pages
Shortcut key to show fault / alarm in the summary pages

14
4. INSTALLATION
4.1 Chiller Bus
Chiller Network
Chiller panel needs to be energized with +12Vdc. The 5 way wires that provided is once on the easiest
solution to establish a communication between the panel and chiller main board (CN8-CN8). If the 5-way
wires socket has been occupied in main board, just using 2 insulation wired are needed to establish a
communication between panel and chiller main board.
Chiller panel can support maximum up to 50 units of chiller. In the chiller network, duplication of main board
unit address is not allowed. Each chiller main board should have their unique unit address (0-50).
For first time running, user need to assign a unique unit address to each main board in the chiller network.
User should follow the procedure below:
•Only power ON one main board at once time. Make sure not others main boards are energize.
•By using the panel connected to the main board.
<ENTER> <ENTER>
Summary Pages Main Menu Setting Menu
<ENTER>
G7 Unit No 1. General Set Paraameter
<ENTER> <ENTER>
key in "0001" as passw ord
• Key in unique unit address and press ENTER to execute.
• De-energized the main board and repeat the procedures again all the main boards have been
assigned a unique unit address.
IMPORTANT : Do not assign a same unit address to more than one chiller main board.
RECOMMENDATION : Please select a coherant model (G1 Model) to all the chiller main boards in
the same network.
Supported up to 50 units of Chiller
Chiller 0 Chiller 1 Chiller 2
Chiller Panel 0 Chiller Panel 1
(Master) (Slave)
5 way wire (CM8)
Chiller
Communication bus

15
4.2 Others Configuration
•JH2 in chiller panel should let it open (put the jumper header on one pin only) all the time
unless user need to do CMOS reset to that particular panel.
•JH3 should let it open (put the jumper header on one pin only) all the time as well.
•Remember to put in the coin cell battery on the panel. Without the backup battery, the panel will
always reset the time to 12:00am, 1st Jan 2000.
4.3 Installation of the Chiller Panel Controller
•Disconnect the unit and ensure no others unit energy source that supplies the panel.
•Open the rear panel of the Chiller Panel (insert a ‘flat-head’ screwdriver in the top joint of main
casing with rear panel to open the real panel).
•Pass the necessary wires of the panel across the large opening in the rear panel. Place the rear
panel flat support against the wall and make marks on the wall through the four installation holes
(inner and outer).
•Drill four appropriate holes in the marked places.
•Attach the rear panel to the wall and put on the screws on it. Ensure that all cables are passed
through the hole of the rear panel.
•Connect the wires to the corresponding terminal according to the wiring bus network. The
power supply and communication wires must be correctly connected to ensure that the
panel works.
•Close the chiller panel (ensure the bottom joint is aligned for the casing, then complete others joint
part. Ensure that the contacts at the back of the panel are aligned with each others).
Bus Wiring Diagram

16
5. SOFTWARE DESCRIPTION
5.1 Introduction
The Chiller Panel Controller can be used to control / display the status of Chiller.
Status viewing:
• ON/OFF status
• Mode (Cooling / Heating/ Boiling)
• Mode set temperature
• Compressor status (ON/OFF/ DEFROST)
• Water in, Water Out, Outdoor air and Panel temperature
• Chiller model (Chiller, Heat Pump, Chiller/ Boiler, Chiller+Boiler, Heat Pump/Boiler, Heat Pump+
Boiler
• Advance parameter settings
• Defrost sensor temperatures
• Compressor discharge sensor temperatures
• Compressor run times
• Incoming alarm/ fault/ error
Status settings:
• ON/OFF switching
• Mode setting (Cooling / Heating/ Boiling)
• Mode set temperature
• Manual entering defrost
• Advance parameter settings
• Password changing
• Panel option setting (Backlight, Alarm Buzzer, Screen saver, Contrast, Brightness, temperature
unit)
• Time and date settings
• Clearing compressor run time

17
5.2 Menu Structures
Menu Structure Diagram for Chiller

18
5.3 Chiller Menu Structure
5.31 Summary Pages
There are 4 pages in [Summary Pages]. Press UP or DOWN for page scrolling. Press ENTER to go to
[Main Menu]. Time and date are shown on top of each page. Beside that, the bottom of each page shows
current control unit of the Chiller.
For example: [00] - Chiller Panel controls Chiller ID 0 currently
[03] - Chiller Panel controls Chiller ID 3 currently
[All] - Chiller Panel controls all Chiller currently
1st page: Display ON/OFF status, Mode settings and Temperature settings.
2nd page: Display Compressor status.
3rd page: Display Water In, Water Out, Outdoor air and Panel temperature
4th page: DisplayChiller model, Compressor No. and Chiller ID.
01/01/2000 12:00am
Status : ON
Mode : Cooling
Cool Temp : 12.0°C
[00]
01/01/2000 12:00am
Compressor : ON
[00]
01/01/2000 12:00am
Water In :19.8°C
Water Out : 25.6°C
Outdoor Air : 32.2°C
Panel : 20.5°C
[00]
01/01/2000 12:00am
Model : Chiller
No. Comp : 1 Comp
Unit No : 0