AIR-COOLED SCREW WATER CHILLER · 1) Air-cooled condenser with upside down M shape layout to improve space using ratio, heat exchange area of air-cooled condenser and to reduce unit

Top Holdings International Limited Shenzhen Topchiller Co.,Ltd

********************************************************************* Tel: 86-18620340004 Email:[email protected] www.topchiller.com

AIR-COOLED SCREW WATER CHILLER

Air-cooled water screw chiller

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Please read this manual carefully before installation and operation. Note: For your reference only, we reserves the rights to change the data without previous notice Please kindly contact us in time if you have special requirements. 1. SUMMARY

Air Cooled Screw Chillers are the products developed by Shenzhen Topchiller Co. Ltd. These series products adopt Bitzer brand semi-hermetic screw type compressor, famous refrigeration parts, and electrical control elements from world. These series chillers have features of impact design, reliable control system, economical and flexible installation. The computer control system increases precision and reliable. It may regulate energy multi-steps to make output cooling energy to best match practical running load. Therefore this chiller unit runs in best economical state. Pre-set operating mode and program realizes unit run in energy saving all the time. The computer may also connect network system to realize building management control automatically. Air-cooled integrity structure saves cooling tower and reduce constructing investment. It suitable for various hotels, shopping centers, and office buildings central air conditioning system and textile industrial, chemical industrial, metallurgy industrial, pharmacy and electrical power, etc.

2. WORKING PRINCIPLE AND TECHNICAL DATA IN COOLING SYSTEM

2.1 WORKING PRINCIPAL OF AIR-COOLED WATER CHILLER

Cooling circulating compressor absorbs low-pressure, over-heated refrigerant gasify from dry type evaporator and changes the refrigerant into high-temperature. High-pressure, over-heated refrigerant gasify, and radiates heat energy into ambient, then refrigerant is condensed into liquid status and pass by expansion valve. After throttling refrigerant drops pressure, then goes into dry type evaporator to absorb heat energy and is absorbed by compressor again to finish one circulation.

Cooling system working principle of series air-cooled screw water chiller shows as Appendix:

Air-cooled water chiller unit is integrity structure with modular structure design, condenser upside-down M layout. The compressor, dry type evaporator, receiver, cooling pipes and accessories arrange on steel foundation uniform.

Electrical control box is at one end of the unit, the flange connector for refrigerant inlet locates side of the machine. The shell of the unit is made by high strength pained steel plate with nice look and long service life. It is suitable for outdoor atrocious weather. The side of the unit has high/low pressure meters, semi-piston type compressor has oil-pressure gauge.

TECHNICAL,INSTALLATION,OPERATIONANDMAINTENANCEINSTRUCTIONS

COMPANYWITHQUALITYSYSTEM

CERTIFIEDBY ===ISO9001:2000======ISO14001:2004===


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2.2 THE FEATURES OF AIR-COOLED SCREW TYPE WATER CHILLER

2.2.1 Wide capacity range: 1) The various type unit with range of cooling capacities from 180KW – 1730KW;

2) Each one has cooling only and cooling (heating) type;

3) There are integrity and optional modular structure;

4) Each one has regular computer control type and luxury computer control type;

5) Provide optional components of auxiliary electrical heater, build-in water pump, and paddle flow switch etc.

according to customer requirements.

6) The unit may use no-standard refrigerant. It may be low water temperature type glycol for air-cooled water

chiller unit, or double refrigerants unit, air-cooled compress condensing unit, etc. Please contact us for detail.

2.2.2 The unit has high efficient, less energy consume, and low operating fee features. TopChiller imports brand high EER semi-hermetic crew type compressor ( Hanbell or Fusheng as standard), Bitzer

from Germany are also available.Condenser, and cooling accessories from world and adopt advance technology

in air conditioning and control. High quality process equipment and testing-center to ensure the units have energy

saving and reliable features

2.2.3 Unit protection components The chiller units have thermal protection switch, overload relay, high/low pressure switch, paddle flow switch and

delay-starting protection devices to ensure unit runs under safety, reliable working condition and unit is easy to

maintain and repairing

2.2.4 Optional Modular design Multi-modular units adopt module combined structure to increase unit’s flexibility in transportation, installation,

adjustment and maintain and reduce fee for transportation, installation and equipment maintain

2.2.5 Super low noise, operating quietly. And optional Low noise cabinet for compressor 1) Semi-hermetic screw compressor has operating steady, low noise, and less vibration features.

2) Brand condensing axial fan is used in the unit. The blades and exterior-rotor motor design integrally. The unit

structure is simply with good air dynamic features and to ensure fan works under low noise and high efficiency.

2.2.6 Advance control system, steady quality and reliable features. 1) Micro-computer control intelligently, English display, and friendly interface. Operating information is clear at a

glance.

2) High automatic management with completely features to realize unit start up and shut down, timing control,

water pump control, malfunction alarm and self-diagnosis features. It has optional RS485/RS232

communication port and convenience for centralize controlling and lone distance monitoring and long distance

control.

3) Micro-computer and electrical control elements are brand products and imported from world. The products has

good quality, and reliable features

4) Micro-computer controller defrosts intelligently with accuracy and efficiency. The controller also has

self-diagnosis, energy management; anti-freeze and operating mode automatically control abilities. The unit

has protections of high/low pressure, anti-freeze, oil temperature, overload, phase sequence, and water lacking

to ensure unit run safety.

2.2.7 Nice outline 1) Air-cooled condenser with upside down M shape layout to improve space using ratio, heat exchange area of

air-cooled condenser and to reduce unit overall size

2) The components and system pipes layout reasonable.

3) The shell of the unit pained with statically treatment. The color of shell may design by customer when order is

placed. The stainless steel plate is also available for shell.


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2.2.8 Save outdoor space. 1) The unit may install on roof of the building, ground or other location, where does not need equipment room. 2) The unit uses high efficient heat exchanger. It adopts outdoor structure design and system matching with small

volume, lightweight, and less area occupied. 2.2.9 Easy to maintenance 1) The installation of the unit is flexible. It can control at job site and long-distance 2) Open type structure is convenience for maintenance and reduces service space. 2.3 TECHNICAL DESCRIPTION 2.3.1 Refrigerant: R22/R134a/R407c 2.3.2 Nominal cooling working condition: 1) Condenser inlet temperature DB 35 , WD 24 . 2) Evaporator inlet temperature 12�, outlet temperature 7 � 2.3.3 Nominal heating working condition: 1) Condenser inlet temperature DB 7 , WD 6 . 2) Evaporator inlet temperature 40�, outlet temperature 45 � 2.3.4 Fin type air-cooled condenser 1) Fin type air-cooled condenser adopts imported high purely, seamless screw thread copper and special

aluminum fin after mechanical expanding joint closely. It ensures fin type condenser work in best efficiency. 2.3.5 Tube in tube type evaporator 1) It is tube in tube structure with new developed fire-proof and water-proof material as heat preservation. The

water-side working pressure may reach to 2.0 MPa. 2) There is PVC engineering plastic breakwater inside of evaporator with strong anti-corrosion ability. Chilling

water circuitous goes up and down to increase tumble effect, and heat exchange ability. 3) Adopt new technology DAC weave interior screw threat, high efficient heat exchange tube to ensure good

cooling characters. 2.3.6 Semi-hermetic screw compressor The unit uses imported semi-hermetic screw type compressor. Comparing piston and scroll type compressors, the semi-hermetic screw type compressor has following advantages: 1) Less accessories (Approximately 1/3 of piston compressor). The unit structure is simply and long service life). 2) The unit EER ≥3.1W/W; 3) Screw type compressor may adjust energy in range 25% - 100%. this is for energy saving consideration 2.3.7 Four-way valve TopChiller air-cooled water chiller adopts famous four-way valve like PE, so that solves reversing and system consume great problem exist in other same kind of products. 2.3.8 Condenser 1) Axial fan, protection grade reached IP55. long service ling and reliable. 2) External rotator and blades combined into integrity. Design compact, run in high speed and low noise. 2.3.9 Optional Heat recovery functions for free living hot water 1) Partial heat recovery for free hot water. 2) Total heat recovery with multi functions, and could be controlled.


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FOULING FACTOR CORRECTION COEFFICIENT

Evaporator Recovery condenser

Fouling factor [m2 ºC / W] F1 FP1 F2 FP2

0 clean heat exchanger 1 1 1 1

4,4 × 10-5 0,98 0,99 0,99 1,03

8.8 × 10-5 0,96 0,98 0,98 1,04

17.6 × 10-5 0,93 0,97 0,95 1,06

F1 – F2 = Energy correction coefficient

FP1 – FP2 = Compressor power input correction coefficient The performance data given refer to conditions with clean heat exchangers (fouling factor =1). For different fouling factors, , unit performances should be corrected with the correction factors shown above.

OPEARTING RANGE

-10

-5

0

5

10

15

20

25

30

-15 -10 -5 0 5 10 15 20 25 30 35 40 45 50

ETHYLENE GLYCOL SOLUTIONS The use of ethylene glycol mixtures is intended to prevent freezing in chiller heat exchangers. The use of low freezing point mixtures causes a modification in the main thermodynamic properties of the units. The major parameters affected by the use of glycol mixtures are the following:

u Cooling capacity

u Power input

u Mixture flow

u Pressure drop

In the table below is reported correction factors referred to the most common ethylene glycol mixtures.

Glycol percentage [%] 10 20 30 40 50

Freezing point [ºC] -3,20 -7,80 -14,10 -22,30 -33,80

Cooling capacity corr. factor 0,986 0,980 0,973 0,966 0,960

Power input corr. factor 1,000 0,995 0,990 0,985 0,975

Mixture flow corr. factor 1,023 1,054 1,092 1,140 1,200

Pressure drop corr. factor 1,061 1,114 1,190 1,244 1,310

Cooling

With ethylene glycol

Ambient temperature [°C]

Out

let u

ser

wat

er te

mpe

ratu

re [°

C]

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CALCULATION EXAMPLE

An example can help to use properly the coefficients reported in the table.

Suppose that a single water chiller presents the following performances at the nominal working conditions:

Cooling capacity: 184.9kW

Input power: 58.4kW

Water temp. in-out: 12/7 ºC

With a 30% glycol mixture these parameters will change to the following values, according to the correction factors:

Cooling capacity: 184.9×0,973 = 179.91 kW

Input power: 58.4×0,990 =57.82 kW

LOW TEMPERATURES CORRECTIONS FACTORS

Outlet water temperature 2 ºC 0 ºC -2 ºC -4 ºC -6 ºC

Cooling capacity 0,628 0,569 0,510 0,459 0,410

Compressor power input 0,868 0,830 0,802 0,774 0,745

Minimum glycol percentage 10% 20% 20% 30% 30%

CALCULATION EXAMPLE

Suppose that for a single unit performances should be required at the following conditions:

- Evap. in/out water temperature: 0/-4 °C

- Glycol: 30%

- Ambient temperature: 35 °C

For such a unit nominal performances (inlet/outlet water temp. 12/7 °C, ambient temperature 35 °C) are:

Cooling capacity: 184.9kW

Input power: 58.4 kW

Performances at the required conditions can be calculated as follows:

1st step:

Performances are calculated without taking in account the use of glycol mixtures.

Cooling capacity: 184.9x0.459 = 84.87kW

Input power: 58.4x0.774 = 45.2 Kw

2nd step:

The use of glycol mixtures is taken in account (please refer to glycol correction factor tables). In our case we have (30% glycol):

Cooling capacity: 84.87x 0.973 =82.58kW

Input power: 45.2x0.990 = 44.75 kW

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5. Unit Dimension and foundation size recommended

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6. ELECTRICAL CONTROL SYSTEM THEORY

Electrical control system controls cooling system by thermal sensor. Electrical protection devices and

alarm system act to monitor, protect, and alarm.

Electrical control system sees electrical drawing and <electrical manual for users>

System wiring refers wiring suggestion (Appendix 2) for detail.

7. INSTALLATION REQUIREMENT

In order to act safely and avoid malfunction occur, installation must be implemented by experienced

technician and carefully read the manual before installation.

7.1 CHECK AND ACCEPT

After arriving, the user should check the units as following documents

7.1.1 Random check if package has documents below. a. Certification. b. User manual. c. Warranty card. d. Package list

7.1.2 Check the model, specifications and accessories according to packing list.

7.1.3 Check if there is any damage or any missing accessories.

7.1.4 Check if refrigerant leaks. If there is any problem or question, please contact TopChiller or agent right now, therefore problem can be fixed as

soon as possible.

Note: Please don‘t open the package of the unit until installation avoiding the equipment damaged

7.2 TRANSPORTATION

Every unit passed strictly inspection and testing to ensure performance and quality. User has to pay

attention for handling the unit to avoid damage caused by installation and transportation.

The unit should be placed in the location where near the installing destination before unpackaged it.

Unit should be placed upward, then transit unpackaged accessories.

7.2.1 Lift hook

The unit has to be handled by professional company. The handling method recommend below: Use two slings on

the top of the machine to support the steel cable preventing panel damaged. The intensity of steel cable must be

3-times intensity more than the total weight of the unit. It doesn’t allow anyone stay under the unit during lift hook.

The weight of machine is on the nameplate. Please refer the figure below for handling method..


7.1.2 Installation

1) Location and foundation (Foundation drawing as above)

The unit is outdoor installation. It should be installed on level up roof, ground, or other available place. The

foundation supporting should be two parallel U-steel or I-steel and installed on flat base.

The foundation and installation refer below drawing:

200

200

100 1001010

C B10

100

1010

0

AD

reserve holeΦ100

2. Please leave the fixing holes for the base in the installation areaA,D is the size of lengh,B,C is the size of width

Note:1. Fixing hole's size of A,B,C,D please refer to each unit's outline size,

2) The space for maintenance and ventilation

The unit should have good ventilation. The minimum distance between objects should be equal or greater than 1.5

meters. Herringbone shed May be built up 2 meters high from the highest point of the unit if allows.

7.3 COOLING WATER SYSTEM (REFER APPENDIX III)

Each jointer of pipe has label. Please connect it according to label.

7.3.1 All pipes have to place jointer or flanges to the location where nearest the unit, so that

uninstall easily when necessary.


7.3.2 The connector of the cooling water inlet and outlet should use vibration absorbs connector to

avoid machine’s vibration and pipe system damaged.

7.3.3 Water pipe system should install paddle flow switch and interlock with compressor control to

ensure enough water flow.

7.3.4 Turn on cooling water inlet/outlet valve and check if there is any leakage in cooling system. In

addition, there should be a discharge water valve at water inlet, and a discharge air valve at

water outlet. The unit is running, the valve handler has to be taken away to ensure valve

doesn’t close by mistake. If discharge water valve is open while the unit is running, the accident

will occur by no water.

7.3.5 Cooling water pipes have to be heat-preservation to avoid condensing water generated

7.3.6 The unit operation has to follow manual specially in the area where temperature is below zero

in winter. 1) Air cooled screw chiller is cooling only in summer and shutdown in winter. After the unit shutdown, the water

inside of water pipe has to be discharged completely from pipe avoiding pipe freeze to broken

2) If Air cooled screw chiller is heat pump type unit. If it works in heating only during day time and water pump

should be kept running at nigh. It may work in heating mode at nigh according water temperature to prevent the

unit can not start up because over low water temperature. The anti-freeze precaution has to be taken in chilling

area.

3) In the area where ambient temperature is below - 5�, this air cooled screw chiller unit should install auxiliary water

heater to endure the unit running reliable.

4) In the area where ambient temperature is below -10�, It is not suitable to use heat pump type unit because low

heating efficiency of heat pump.

7.4 WATER QUALITY CONTROL

The industrial water as cooling water source has less furring. The well water or river water as cooling

water source has more furring and even deposit as sand, etc., these can cause water flow reducing

and freeze accident in evaporator, and so cooling water has to pass filter and soft by chemical

substance before go into cooling system. The PH value, conductivity, chlorine ion, and sulphur ion

have to meet TopChiller standard.

The water purity standard

PH 6.5-8.0

Conductivity ≤200uv/cm 25°

chlorine ion ≤50ppm

vitriol ion ≤50ppm

Total iron ≤0.3ppm

Alkali ion ≤50ppm

Total hardness ≤50ppm

sulphur ion None

Ammonia ion None

Sand ≤30ppm

Sodium ion None


NOTE: (1) Please not install the unit indoor. If have to install it indoor, the minimum distance from ceiling to the vent has to be

equal or greater than 1.5 meters, and enough airflow.

(2) The refrigerant is R22. It is no-flammable, no poison substance. Because special gravity of R22 is heavy than air, it

will spread and may cause people strangle if leakage occurs. So good ventilation has to implement if the unit is

indoor.

(3) If leakage occurs, stop the unit immediately, and contact repairing personnel. It forbids the any lighter in the site.

Because if R22 touches lighter, it will spread harmful gas.

(4) The unit has to be reliable grounded; the wiring has to be correct, tight.

8. TESTING-RUN AND ADJUSTMENT

8.1 INSPECTION BEFORE RUNNING

Before adjusting unit, TopChiller personnel have to regular check the unit and accessories to ensure

unit quality. The check items refer the sheet 1

8.1.1 Inspection Debugging personnel should check items according sheet 1, if there is any unqualified item, modify it before entering

adjusting program.

8.1.2 Water system operating After time after time cleaning water system and water quality meets the requirement, turn on two service valve that

connect to unit. Filling water one more time, discharge it, and then switch on water pump, confirm outlet pressure of

water flow.

8.1.3 The unit simulating operation In the condition of air breaker of compressor and condenser are off, refer electrical principle drawing and < Electrical

usage instruction > tests actions on electrical parts and control logic (Note: If phase sequence error, the unit can not

start up).

8.2 TESTING-RUN

Under item�1�normal condition, the test-run may take and method is as below.

8.2.1 Adjust cooling system flow valve carefully (or the unit inlet service valve), to make system water

flow be 90% water flow required by nameplate on the unit.

8.2.2 Switch on air breaker of compressor and condenser, modify setting-up value for temperature,

after press “ON/OFF” key (switch on/off key), the unit displays “On” state and then start the unit

up. If malfunction occurs, the unit will shutdown and display malfunction message.

8.2.3 Test and record items according to contents in sheet 3. If any abnormal occurs, press

emergency off key quickly to stop running (note: normal shutdown the unit does not allow to

press this button). After analysis the problem, do this procedure again.

8.2.4 After testing-run 15 minute, observe sigh glass and check if it is blue color, is any air bubble or

steam, it does, please add refrigerant R22.

8.2.5 After testing-run 30 minutes, the water temperature at outlet reaches to prescriptive value,

adjust water flow to nominal value, then set up outlet temper and dynamic different according to

user load, and system actual instance to ensure the unit operation normally. After the unit

stopping, wait for 10 minutes to restart. The unit can not start and stop frequently. Finally, check


controllers setting values of the unit to finish the testing and inspecting.

Warning!

1) When cleaning water system, the impurity water does not allow go into dry type evaporator. Please turn off the inlet valve of the unit, and turn on outlet valve when cleaning water system.

2) Before discharge water from water system, the unit forbids to start up. 3) Water pump and paddle flow switch have to be interlocked, otherwise user take full

responsibility for any problem occurs by lacking water. 4) During test-run, the interval of the unit has to be longer than 4 minutes.

9. Operating and maintenance

For ensuring the unit running in long period, the unit should be tested and adjusted by TopChiller

professional personnel or skills technician under TopChillert’s expertise supervising Daily operation and

maintenance has to be done by trained air conditioning technician,

The operator has to pay attention to following components.

TYPE AND FREQUENCY OF SCHEDULED MAINTENANCE All maintenance operations must be done by experienced personnel, qualified to work with conditioning and cooling systems. Always switch off the unit to cut off power supply before any maintenance work, even if only inspection is involved.

In order to guarantee regular, efficient unit operation, it is advisable to schedule an overall inspection at regular intervals, in order to prevent irregular functioning which could damage the machine’s main components

PERIODIC CHECKS LIST Item Every month Every 4 months

Check the refrigerant charge and humidity via the sight glass !

Ensure all electrical terminals are tightened securely inside the electrical panel and on the compressor terminal boards. !

Ensure that there are no refrigerant leaks from the cooling circuit !

Ensure that there are no leaks from the hydraulic circuit !

Ensure correct operation of the high and low pressure switches !

Ensure correct operation of the flow switch !

Clean the metal filters in the water pipes !

Check compressor crankcase heaters !

Check the noise level of the unit !

Check correct operation of all control equipments !

Check that air heat exchanger is clean !

9.1 MAIN ACCESSORIES

9.1.1 Compressor: Observe discharge pressure, absorb pressure, oil supply pressure, and oil level,

etc, If anything is abnormal, find out problem, fix it. The frequency of the unit start and stop should

be less than 6 times per hour, and each time the unit start and run should be 5 minutes and more.

9.1.2 Oil pressure difference control’s reliability ( for semi-hermetic piston type compressor)

9.1.3 Electrical equipment: should be attention to working voltage, current, and phase sequence. For


the contactors, check wire connectors, and see if there is any oxide or other reason to cause

problem.

9.1.4 Control and protecting equipment: Don’t adjust any setting value at job site.

9.1.5 Regular check electrical wiring, if find out any loose connector, tight it up right way.

9.1.6 Regular check electrical components, if find out any unreliable part, replace right way.

9.1.7 Pay attention to electrical control box at any time for heating, It should has good ventilation. If

wire becomes aging, change it in time.

9.2 LUBRICATION

The compressor has been filled lubrication before leaving factory.

9.2.1 The operator has to monitor the oil level from sight glass while the unit is running, Oil level has

to be above bottom of sight glass; after shut the unit down, the oil level should be above middle of

sight glass.

9.2.2 Every spring and fall is maintenance season. if find oil color become black, or copper pieces in

the oil, oxygenated impurity, the lubricating oil must be replaced with same model after clean the

oil filter, and bottom of oil tank. This job should be done under TopChiller’s expertise guide.

9.2.3 When cleaning oil filter, should also clean magnet which in under oil tray.

9.3 CLEANING DIRTY

After long period running, the inside of pipe in dry type evaporator is accumulated calcium oxide or

other mine substance. It conducts electrical consume increase, discharge air pressure rising, and

absorb pressure dropping.

9.4 SHUT THE UNIT DOWN IN WINTER

When shut the unit down in winter, the unit should be clean from inside or out side. Refrigerant

should be sucked into condenser and then close the inlet gas valve and outlet liquid valves, Covering

the unit up to prevent dust, and make sure tighten the pressure covers, valve’s nuts and screw off the

discharge water nuts. In ice-freezing area in winter, the water has to be completely discharged from

condenser to avoid freeze to split accidents.

9.5 START THE UNIT IN SPRING

After long period time the unit shutdown, the following preparation work have to be done first before

restart the unit.

6.5.1 Inspect and clean the unit completely,

6.5.2 Clean water pipeline,

6.5.3 Inspect pump, cooling tower, and adjustment valve,

6.5.4 Tighten all wiring connectors tightly.

Note� If the unit had been shutdown for a long time, it should pre-heat compressor oil 24 hours before the unit startup. Pre-heat time for lubrication of the compressor according to weather and ambient environment, but preheat time cannot to be less than 12 hours.

9.6 REPLACE PARTS

The replaced parts should be TopChiller’s parts; it does not allow to use other manufacture’s parts to

instead without TopChillert’s permission

9.7 COOLING SYSTEM


6.7.1 Filter net: Please check absorbing filter net and make sure it doesn’t block when turn on

cooling system.

6.7.2 Filling Refrigerant: When filling refrigerant, observe sucking and discharging pressure from

sight glass. If there is any leakage, or replace the parts, the air-seal testing is required.

Filling refrigerant should be treated in two ways. 1) Because leaking, there is no refrigerant left. Before filling refrigerant,

2) The cooling system has to be dry and vacuumed completely.

l Turn on all valves.

l Connect vacuum between low pressure and high pressure.

l Whole system is vacuumed by vacuum pump.

l The proper refrigerant amount and main technical data are shown on nameplate. Refrigerant filling uses

refrigerant filler.

l The refrigerant filled by weight may be affected by ambient temperature. In this case, turn off fluorin container

valve temperately temporarily, let cooling water circulating in evaporator and startup the unit, at same time,

short-circuit low pressure controller temporarily.

Note: After filling refrigerant, re-connect wires back to normal!

3) Filling refrigerant

The refrigerant filler is connected into low-pressure side filling connector, and connect pressure gauge at low

pressure and high pressure side.

l Make cooling water circulating, and startup the unit, short-circuit controller if necessary.

l Slowly fill refrigerant into system, monitor absorb, discharge pressure value. The open degree of filling fluor in

valve should be in pressure between 0.15-0.2Mpa, It doesn't allow to open completely.

Warning!

When inspecting leakage and airtight test, it forbids filling oxygen, ethane, etc., burnable or poisoned gas. This kind of gas may cause explosion or dangerous situation.

9.8 UNINSTALL COMPRESSOR

Please following below steps for uninstall.

6.8.1 Turn off the unit power supply switch;

6.8.2 Turn off service valves of the inlet and outlet of compressor.

6.8.3 Take off the connecting bolts of sucking, discharging flanges of the compressor

6.8.4 Take off the power supply cable connection.

6.8.5 Take off the fixing bolts of the compressor.

6.8.6 Remove away the compressor.

9.9 SYSTEM ANTI-FREEZE

If heat exchanger of evaporator or pipes freezes to broke, it will result serious leaking. This kind of

damage is not on guarantee. The user has to pay attention to three things.

6.9.1 The unit stops and backups in low ambient temperature.

6.9.2 If the temperature of outdoor unit is below 0�, the water in evaporator should be

discharged completely.

6.9.3 The unit is operating If the cooling water flow switch and low-pressure protection is unavailable, the water pipe may freeze. So


that cooling water flow switch and unit control system should be interlock.

6.9.4 Maintenance When the system pressure is under 0.4Mpa, the pipe freeze may occur, so the water in system should be

flow or discharge water completely.

Note:

1) Maintenance regularly The unit should be maintained regularly to ensure the unit operating in good state.

2) Fireproofing If there is a fire, the main switch should be off, use fire extinguisher.

3) Prevent flammable gas. The unit should be far away from gasoline, alcohol, oil made production, etc. flammable gas to avoid explosion.

4) Operation panel and electrical control box Operation panel is installed inside of electrical box. When operating, need to open control box cover first. Be

careful to avoid electrical shock.

5) Please don’t touch discharge pipe avoiding to be burned. The temperature may reach to 100� and

higher. (1) Don’t cool or heat the drink water and food.

(2) Malfunction

If there is any malfunction occurs, find out cause first, and then restart the unit. In addition, if the unit has

abnormal vibration and noise, please stop the unit right way, find out cause.

(3) Insurance

The fuse has to use in allow range, it forbids to use iron wire or copper wire to instead fuse.

(4) Protection equipments

Don’t short-circuit the protected equipment, otherwise, It will cause serious problem.

(5) The setting value has been setup before the unit delivery to users. The users don’t change it, otherwise, it will

cause serious problem. Don’t touch any electrical components except switch includes emergency switch.

(6) The unit should manage by skilled air condition operators. Record relative data and analysis it to judge the

operating situation.

10 Malfunction analysis and trouble-shooting

Main malfunction and trouble-shooting:

Malfunction Possible cause Trouble -shooting

Unit does not start.

No electrify Main switch doesn’t on Control circuit has no electrify The unit malfunction(alarm The temperature setting value is higher than evaporator inlet.

Phase sequence is wrong, phase sequence protector action.

Electrify Switch on the main switch Electrify control circuit Find out cause and fix it Check and modify setting value Change two of three phase

Compressor does not start up

Compressor has no electricity Thermal protection switch act or fuse broke Motor short-circuit Contactor coil burn Compressor motor doesn’t rotary Pressure controller to make system stop. Liquid valve work abnormal Water system malfunction, water flow switch break off.

Electrify compressor Find out cause and reset switch or replace fuse Check motor Replace contactor or coil Fix compressor Find out cause before reset pressure controller Repair or replace Ensure proper water flow

Compressor low cooling efficiency or no cooling

Compressor gas valve damaged

Replace compressor gas valve and valve plate Find out leak source fix it, then fill refrigerant


Refrigerant leaks Four-way valve leak or damaged (heat pump) Thermal expansion valve doesn’t adjust correctly.

Thermal expansion valve damaged Air and no-condensing gas in the system Condenser fin dirty or evaporator heat exchanger dirty

Replace four-way valve Adjust thermal expansion valve open degree. Replace thermal expansion valve Discharge air from condenser or receiver Clean condenser and heat exchanger

Compressor run continuously low efficiency or no heating ability (heat pump)

Refrigerant leak Compressor air valve damaged Four-way valve leak or coil burn

Find out leak source, fix it, then fill refrigerant Replace valve and valve plate Replace four-way valve or coil

Compressor stop because high-pressure protection act

Ambient environment too high, condensing air flow no enough Condensing fan motor malfunction High-pressure shutdown, the setting value is not correct Over fill fluidizers System has air or other no-condensing air Defrost (heat pump) time setting too long Four-way valve damaged The inlet temperature of evaporator is not correct

Repair condensing fan motor Repair or replace condensing fan motor Check high-pressure, pressure controller Check amount of fluidizers, then discharge portion fluidizers Discharge air from condenser or receiver Set up reasonable defrost time. Replace four-way valve Check water system

Compressor stop because motor overload

Volt is too high or low Discharge pressure is too high or low Water temperature is too high Overload element malfunction Ambient temperature is too high The motor or terminal short-circuit

Check volt, and ensure volt is in 10% range Check discharge pressure. Check back water temperature Check compressor full load current. Increase ventilating ability Check resistance of motor and terminal

Temperature protection switch inside compressor act to force compressor stop

Voltage is too high or low Discharge pressure is too high Jet type magnetic valve damaged (screw compressor) Condensing water inlet temperature is too high The protection switches is malfunction inside compressor.

Check voltage and make sure voltage is in required range

Check discharge pressure and find out cause Replace new one Check cooling water inlet and find out cause Stop running 10 minutes and check if any leak, repair and refill fluidizer

Unit suck pressure is too low in heating ( heat pump)

Heating expansion valve malfunction or dirty Pipe blocked Four-way valve leak Fan motor damaged Refrigerant is not enough Ambient temperature is too low

Repair or replace thermal expansion valve Clean bloke substance Replace four-way valve Check fan motor Fill refrigerant The unit should be stop when ambient temperature low than unit allowed temperature

Compressor stop because low-pressure protection

Dry filter blocked Expansion valve is malfunction Refrigerant is not enough

Replace filter Adjust or replace expansion valve Check if any leak, repair and refill.

Defrosting doesn’t stop(heat pump)

Refrigerant is not enough Defrost control adjustment is improper Defrost sensor damaged Reversing valve malfunction Compressor air valve damaged

Repair, fill refrigerant Re-adjust defrost time. Change defrost sensor Check and replace Replace air valve and valve plate

Refrigerant in liquid status goes into compressor when Heat pump running

Thermal expansion valve setting is improper Thermal expansion valve probe is in improper position Thermal expansion valve size is improper

Re-setup the thermal expansion valve Replace temperature probe Clean or replace thermal expansion valve

When double system running or multi-system running, one pressure drop suddenly and other system pressure increase

Dry type evaporator leak Take off two end cover, replace washer, and tight up screw.

Discharge pressure is too low

Liquid refrigerant goes into compressor from evaporator to generate bubble. Compressor discharge valve damaged

Check and adjust expansion valve Ensure expansion probe contact suck pipe closely and isolate heat from outside. Repair or replace discharge valve Refill it


Refrigerant is not enough

Suck pressure too high

Discharge pressure too high Refrigerant filled too much The liquid status refrigerant goes into compressor from evaporator. Cooling water inlet temperature is higher than allowed highest value

See” discharge pressure too high” Discharge partly refrigerant Check and adjust expansion valve Check water supply system

Compressor sound level too high

Oil level too low Suck, discharge valve damaged Thermal expansion valve open too wide, and liquid status refrigerant goes into compressor

Find out cause and replace same model oil Replace compressor suck, discharge valve Check thermal probe location or adjust

overheat ratio

Compressor off of oil

Lacking refrigerant Sucking pressure is too high Crankcase heat exchange damaged Oil filter blocked

Check leaking, and refill refrigerant Adjust expansion valve Check and replace Clean oil filter

Unload device doesn’t work

Thermal sensor or computer is malfunction Magnetic valve malfunction Unload device wear and tear mechanically

Check if computer has output or not when temperature vary Check if any coil broke in magnetic valve Check unload system parts of compressor

11. Warranty

12-month Warranty - This Product is warranted to be free from defects in material and workmanship. If defect appears within 12 months from the date of original installation, whether or not actual use begins on that date, then the product does meet this warranty. A new or remanufactured part, at the manufacturer’s sole option, to replace any defective part will be provided without charge for the part itself; PROVIDED the defective part is returned to the distributor through a qualified servicing dealer. THIS WARRANTY DOES NOT INCLUDE LABOR OR OTHER COSTS incurred for diagnosing, repairing, removing, installing, shipping, servicing or handling of either defective parts or replacement parts. Such costs may be covered by a separate warranty provided by the installer. THIS WARRANTY APPLIES ONLY TO PRODUCTS IN THEIR ORIGINAL INSTALLATION LOCATION AND BECOMES VOID UPON REINSTALLATION. LIMITATIONS OF WARRANTIES – ALL IMPLIED WARRANTIES (INCLUDING IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY) ARE HEREBY LIMITED IN DURATION TO THE PERIOD FOR WHICH THE LIMITED WARRANTY IS GIVEN. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE MAY NOT APPLY TO YOU. THE EXPRESSED WARRANTIES MADE IN THIS WARRANTY ARE EXCLUSIVE AND MANY NOT BE ALTERED, ENLARGED, OR CHANGED BY ANY DISTRIBUTOR, DEALER, OR OTHER PERSON WHATSOEVER. ALL WORK UNDER THE TERMS OF THIS WARRANTY SHALL BE PERFORMED DURING NORMAL WORKING HOURS. ALL REPLACEMENT PARTS, WHETHER NEW OR REMANUFACTURED, ASSUME AS THEIR WARRANTY PERIOD ONLY THE REMAINING TIME PERIOD OF THIS WARRANTY. THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR: 1. Normal maintenance as outlined in the installation and servicing instructions or owners manual including filter cleaning and/or replacement and lubrication. 2. Damage or repairs required as a consequence of faulty installation, misapplication, abuse, improper servicing, unauthorized alteration or improper operation. 3. Failure to start due to voltage conditions, blown fuses, open circuit breakers or other damages due to the inadequacy or interruption of electrical service. 4. Damage as a result of floods, winds, fires, lightning, accidents, corrosive environments or other conditions beyond the control of the Manufacturer. 5. Parts not supplied or designated by the Manufacturer, or damages resulting from their use. 6. Electricity or fuel costs or increases in electricity or fuel costs from any reason whatsoever including additional or unusual use of supplemental electric heat. 7. ANY SPECIAL INDIRECT OR CONSEQUENTIAL PROPERTY OR COMMERCIAL DAMAGE OF ANY NATURE WHATSOEVER. Some states do not allow the exclusion of incidental or


consequential damages, so the above may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which may vary form

area to area.

12. Appendix

Air-cooled water chiller system drawing (Appendix 1)

Electric control board

Water Outlet

2

cooling

Water Inlet

11 9

10

867

5

15

1

1918 17

13

16

12

14

4 4

3

1. screw compressor 2.dry type evaporator 3. fin heat exchanger 4. condenser fan 5. liquid container 6. safety valve 7. shut off valve 8. dry filter 9. sight glass 10. solenoid valve 11. cooling expansion valve 12.spray solenoid valve 13. spray expansion valve 14. condenser pressure controller 15. high pressure controller 16. high pressure fluorine gauge 17. low-pressure controller 18. low pressure fluorine gauge 19. small shut-off valve 20.pin valve

Air-cooled water chiller system drawing (Appendix II)

heating sensor

21

19

2223

20

7

6

1718

9

10

11

12

14

3

13 8

cooling

Water Inlet

heating

15 16

25

Controller Box

Water Outlet

24

1. screw compressor 2. 4-way valve 3. dry type evaporator 4. fin heat exchanger 5. condenser fan 6. storage container 7. safety valve 8. shut-off valve 9. dry filter 10. sight glass 11. solenoid valve 12. cooling expansion valve 13. 0ne-way valve 14. gas-liquid separator 15. heating expansion valve 16.gas-liquid mixing 17.heating by-pass valve 18.small shut-off valve


19. jet solenoid valve 20. jet flowing control gauge 21. condenser pressure controller 22. high pressure controller 23. high-fluorine-pressure gauge 24. low pressure controller 25. low-fluorine pressure gauge WATER CIRCUIT CONNECTIONS (Appendix III Sample only)

Code Description Code Description

Metal mesh filter Pressure gauge

Manual shut-off valves

Thermometer

Ball valve Flexible coupling joint

Non-return valve F

Water flow switch

Automatic air vent valve

Water pump

Drainage valve

Expansion tank *

ST

Inertial storage tank Additional electric heater

F

B

C

A

AEH

D

E

F

G

CHILLER

FROM THE SYSTEM

TO THE SYSTEM

PLUMBING LINES

RETURNING WATER

LEAVING WATER ST

The technical data in this document are not binding. TopChiller reserves all the right to make whatever modifications if necessary to improve the product at any time without previous notice.

Shenzhen TopChiller Co.,Ltd Tel.: +8618620340004 E-mail: [email protected] www.topchiller.com


DM23C temperature controller for air cooled screw chiller unit

Temperature controller instruction manual


Description of Keypad of Controller 1. Layout of the controller

2. Description of LEDs

Power supply LED Ø When the unit is powered on, the LED will illuminate in RED color indicating the unit is connected to the power

mains. Ø When the display enters into screen saver status, the LED will flash in RED color.

Running LED Ø When the unit is switched on, the LED will illuminate in GREEN color indicating the unit is in On status..

Error alarming LED Ø When the unit is working, if any alarm appears, the LED will begin to flash in YELLOW color.

User Operation and setting

1. Power supply to the unit The units leave the factory completely cabled and ready for connection to the power supply and for the external interlocks to be connected to the terminals provided inside the electrical box. It’s necessary to install a main switch near the unit in order to connect or disconnect the unit from power mains. Electrical connections must be carried out by qualified personnel in respect of current legislation. For all electrical work refer to the electrical wiring diagrams in this manual. You are also recommended to check that the characteristics of the power mains are adequate for the absorptions of the units, also bearing in mind the possible of other equipments being used at the same time. For the functional connection of the unit, bring the power supply cable to the electrical box and connect it to the terminals, when the unit is powered on, the controller will be switched on.

2. Operation main interface

First display is the count down interface as below:

ERR

RUN

PWR

PWRRUNERRDM23C

6

EN


After over the countdown within 10 seconds, then will enter into the start up interface as below:

Display the environment temperature in start up interface as above

No display the environment temperature in start up interface as above

NOTE: About the environment temperature display can be setup based on that needed or not. Detail explain how to setup, please refer to the page 17 [ tem 2 : Sensor setup ]

display above interface if happen alarm

10/19/2007 Friday 16:25:03

WorkMode: Cool R/S Mode : Manu WeekTime: Inef Crel In :12°C Anti-HT :4°C

User set

C.In°C E.In°C 18 12

STOP RUN

History Guide Query Sta

Unit Sta ; Machine is idle.

10/19/2007 Friday 16:25:03


User set

C.In°C E.In°C 18 12

STOP RUN


Unit Sta ; Machine is alarm….

Querry Err

10/19/2007 Friday 16:25:03


User set

C.In°C E.In°C Envi°C 18 12 35

STOP


Unit Sta ; Machine is idle.

RUN


Description of every button in the start up interface as below:

l WorkMode : working mode s Heat: heating mode s Cool: Cooling mode

l R/S Mode : control mode s Manu : manual control s Time : Timing control

l Weektime : week timing s Inef : be of no effect s Effi : in effect

l Crel In : control water in temperature s This temperature is the setup temperature

l Anti-HT : anti-heat protection will be displayed when heating mode Anti-ice : anti-freeze protection will be displayed when cooling mode

l C.In°C : water out temperature on user side l E.In°C : water in temperature on user side l Run : press this button to start up the unit l Stop : press this button to turn off the unit l Query Err : press this button to check the current alarms list l User set : press this button to enter in user setting parameter menu. (need password) l Query Sta : press this button to check the parts state list l History : history error record l Unit Sta : unit state

s Machine is idle : unit is stand by s Machine is alarm : unit is in alarm

l Guide : user guide

1) Start up the unit In the main operation interface, press RUN button to start up the unit,

l The following window will come up on the display,

l Press ENTER to confirm to start up the unit l The RUN LED will illumate in green color. l Components parts start up the sequence step by step as below :

� the first runiing part is the air conditioning water pump � the second running part is the well water pump after several seconds � the third running part is the compressor after 3 minutes and the energy the compressor will run base on the energy load from 0-25%-50%-100% step by step

l After above,The unit will be completely started up

2) Shut down the unit In the main operation interface, press STOP button to turn off the unit

l The following window will come up on the display:

l Press Enter to confirm the operation, l Components parts start up the sequence step by step as below :

� the first stop part is the compressor , the RUN LED will turn off at the same time � the second stop part is the well water pump after 3 minutes � the third stop part is air conditioning water pump after several minutes

l After above,The unit will be completely shouted down

Suretorununit?

ConfirmBox

ENTER CANCEL

Suretostopunit?

ConfirmBox

ENTER CANCEL


3) Change the operating mode Please refer to page 10 >>> Item 1:Set user parameters

4) View the main components status On the main operation interface, press Query sta button to view state of the component parts interface as below: Description of every button in the start up interface as below: l CM State % : compressor state

s Stop : in stopping s Running : in running s 0 (25/50/100) : energy load from 0/25%/50%/100%

l A /C Pump : air conditioning water pump state

s Stop : in stopping s Running : in running

l Well Pump : well water pump state s Stop : in stopping s Running : in running

l Exit : Press this button to go level up and return to the main operation interface l Unit : Press this button can enter into the Unit Status Query interface l Hcurve : Hour curve (display the water out and water in temperature curve within one hour) l Dcurve : Day curve (display the water out and water in temperature curve within one day)

s Note : the Hcurve button and the Dcurve button is the same button Hour curve interface Day curve interface

l Input : Press this button can inquiry and display 24 routes switch input’s name and states in every back board. Please see below interface :

Unit Status Query

#1 CM State % : Stop A /C Pump : Stop Well Pump : Stop

Exit Unit Hcurve Input Output Guide


s Press Up/Down button to select the page number s Press Subb(-)/Add(+) is no use s Press exit to go level up s Please see below table for detail opposite item s running LED

If the LED illuminate in highlight indicating the component is running If the highlight is off indicating the component is in stand by status.

Display on the interface

Setup item Water source

heat pump Explain

- pump overload × ON stand for cut normal, closed when happen fault - user side pump overload × OFF stand for close normal, cut when happen fault JP2- 2 A/C PumpDL air conditioning pump overload OFF Same as above - water flow lack × Same as above - load water flow lack × Same as above JP2- 3 A/C Wa.ins air conditioning pump lack OFF Same as above - cooling water pump overload × Same as above JP2- 4 WellPumpDL well water pump overload OFF Same as above - cooling water flow lack × Same as above JP2- 4 Well Wa.ins well water flow lack OFF Same as above - middle pressure switch × Same as above See NOTE 1 - outside circle pump overload ON Same as above See NOTE 2 - condenser fan superheat × Same as above - cooling tower fan overload × Same as above JP3- 4 CM LP compressor low pressure OFF Same as above JP3- 5 CM HP compressor high pressure OFF Same as above JP3- 6 CM OLoad compressor overload OFF Same as above JP3- 7 CM OHeat compressor superheat ON Same as above JP4- 2 CM OP compressor oil pressure switch OFF Same as above JP4- 3 Oil level compressor oil level switch OFF Same as above JP4- 4 CM IN Port compressor inside protection OFF Same as above JP4- 5 Rmote SW line control switch ON Same as above JP4- 6 Phase Prct fault and lack phase protection ON Same as above JP4- 7 C-Switch outside catenation switch ON Same as above

- compressor low protection when heating × Same as above

- compressor gas pressure switch × Same as above

SW Input Query

PCB- 1 JP2- 2 A/C PumpDL JP2- 3 A/C Wa.ins JP2- 4 WellPumpDL JP2- 4 Well Wa.ins JP2- 6 standby JP2- 7 standby JP3- 2 standby JP3- 3 standby

Exit Prev Next Subb Add

SW Input Query

PCB- 1 JP3- 4 CM LP JP3- 5 CM HP JP3- 6 CM OLoad JP3- 7 CM OHeat JP3- 8 standby JP4- 2 CM OP JP4- 3 Oil level JP4- 4 CM IN Port


SW Input Query

PCB- 1 JP4- 5 Rmote SW JP4- 6 Phase Prct JP4- 7 C-Switch JP4- 8 standby JP4- 9 standby JP4-10 standby JP4-11 standby JP4-12 standby



NOTE

1 control condenser fan when setup “discharge temperature”, that can not see; when setup “middle pressure switch”, that can see.

2 outside circle pump function when setup NO, that can not see. Or can see in above interface 3 For Digital variables input, If there is no Digital variables input in the unit, that can setup “NO” and not connect with

electrical line; if setup “OFF”, need short circle when connect with electrical line

l output : Press the Output button and enter into the relay output interface display and inquiry the name and state of 20 routes input in every board. Please see below interface :

s Press Up/Down button to select the page number s Press Subb(-)/Add(+) is no use s Press exit to go level up s Please see below table for detail opposite item s running LED

If the LED illuminate in highlight indicating the component is running If the highlight is off indicating the component is in stand by status.

l Theory : Press this button can see the interface.

5) Alarm report and compressor work time On the main operation interface, press History button to check the alarm report and the compressor work time as below interface:

s Press Up/Down button to select the Item s Press enter button is confirm and enter into s Press exit to go level up

SW Output Query

JP6- PCB- 1 2 Standby 3 CM Wind 1 4 CM Wind 2 5 Standby 6 25% valve 7 50% valve 8 75% valve 9 H spray V.


SW Output Query

JP8- PCB- 1 2 L spray V. 3 Standby 4 Standby 5 Standby 6 Well pump 7 Alarm lamp 8 Run Lamp 9 A/C Pump


SW Output Query

JP7- PCB- 1 2 Standby 3 Standby 4 BackOil V. 5 Liquid V.


History

Exit Up Down Enter

Item 1: Query errors Item 2: Query compressor work time


a) Item 1 : Query errors

Press the Up(Down) button and enter button, then can enter into the query error interface as below:

l Press Up/Down button to select the Item s By number: to check the alarm by the number if the alarm happened s By times: to check the alarms history by how many times this code has happened s By time: to check the alarms history by when it happened, the new alarm is on the top of the list

l Press enter button is confirm and enter into l Press exit to go level up

b) Item 2 : Query compressor work time

Press the Up(Down) button to choose the Item 2 and press the enter button, then can enter into the query error interface as below:

This interface display the compressor run add-up time. l Press exit to go level up

6) Guide Item On the main operation interface, press Guide button to see the controller explain and version as below interface:

This interface display will support the controller summary and version for reference . l Press Up/Down button to select the Item l Press enter button is confirm and enter into l Press exit to go level up

Query Record

Exit Up Down Enter

Item 1: Query errors based on NO. Item 2: Query errors based on times Item 3: Query errors based on time

Item 2:Query compressor work time

Exit

#1MC add-up time : 15Hour19Minu

Help

Exit Up Down Enter

1 . Controller summary 2 . About version


3. User operation interface Press the user set button on the main interface, then will display the interface as below:

On this interface, need input the password (12345678) and then can enter into next interface: If the password is not right, then will come up the below interface:

Please press the enter button to go lever up the main interface and try it again: If the password is right, then will come up the below interface:

l Press Up/Down button to select item l Press enter button and enter into the item which be choosed l Press Exit button to go level up

1) Item 1:Set user parameters

Choose the Item 1 and press the enter button, then can enter into the below interface:

Please Enter Password

1 2 3

4 5 6

7 8 9

0

Incorrect password input?

ConfirmBox

ENTER

User Setup

Item 1:Set user parameters Item 2:Set week timing Item 3:Use or nor Item 4:Set user time Item 5:Set contrast Item 6:Set display mode Item 7:Select language Item 8:Adjust screen Item 9:Modify user password

Exit Up Down Enter

Item 1 : Set user parameters

Work mode: Cool Control temperature : 12°C Week timing : inef Once timing : 00:00



In this item you can modify work mode, Control temperature, Week timing and once timing � Press Up/Down button to select the item, � Then press the Subb(-)/Add(+) button to modify the content and parameter � After one item is modified press the Up/Down button to select another item

l Work mode : unit working mode (NOTE: This item will be not changed when the unit is running.) s Cool : setting the unit in cooling mode s Heat : setting the unit in heating mode

l Control temperature : unit water in temperature setting l Week timing : work time setting for every work

s inef : be of no effect s effi : be effect

l Once timing : If the unit is running ,this setting time will be the shut down time If the unit is stopping state, this setting time will be the start up time

s Unset : no setting the once timing s 00:00 : use the week timing setting as this setting timing

NOTE: When choose this Item and setting, Subb(-)/Add(+) button is choose the Unset or timing (00:00) When choosed the timing (00:00), Up/Down button is choose the hour(front 00) and the

minute/second(back 00) Then press the Subb(-)/Add(+) button to setting the timing

� When the operation is finished press Exit button to go level up

2) Item 2:Set week timing On the user setup interface, choose the Item 2 by the Up/Down button and press the enter button to enter into the below interface: This operation can set up the start and stop timing for the unit as every week. This setting function is the unit will start and stop as the setting time for automatic within every week. This can set up 7 days in one week and 3 times for starting and stopping time in one day.

The detail operation as below : � Press the Up/Down button to choose the idiographic setting Item hour(00) and minute/second(back 00) � Press the Subb(-)/Add(+) button to modify the time number � Press the Clear button to cancel all of the time number if the setting are wrong. � When the operation is finished press Exit button to go level up

NOTE: The MAX. display number time in the pane is 23:59. 00:00 is be of no effect setting time. It need set up in effect for Week timing in the [Item 1] interface, then your setting can use.

3) Item 3:Use or not On the user setup interface, choose the Item 3 by Up/Down button and press the enter button to enter into the below interface:

Item 2 : Set week timing

Start Stop Start Stop Start Stop 1 00:00 00:00 00:00 00:00 00:00 00:00 2 00:00 00:00 00:00 00:00 00:00 00:00 3 00:00 00:00 00:00 00:00 00:00 00:00 4 00:00 00:00 00:00 00:00 00:00 00:00 5 00:00 00:00 00:00 00:00 00:00 00:00 6 00:00 00:00 00:00 00:00 00:00 00:00 7 00:00 00:00 00:00 00:00 00:00 00:00

Exit Up Down Subb Add Clear


This interface function is choose and control the compressor to run or not. The detail operation as below: � Press the Up/Down button to choose the every compressor � Press the Subb(-)/Add(+) button to modify

l Use : The compressor is running l Unuse : The compressor is not running

� When the operation is finished press Exit button to go level up

4) Item 4:Set user time On the user setup interface, choose the Item 4 by Up/Down button and press the enter button to enter into the below interface:

This interface function is setting the current time and will display in the main interface. This setting will not effect SYSTEM TIME. Same as a bell . The detail operation as below: � In this item you can set the clock according to the local time � Press the number button to input

� Press button to confirm the input and choose next Item � When the operation is finished, then press Exit button to go level up

5) Item 5:Set contrast On the user setup interface, choose the Item 5 by Up/Down button and press the enter button to enter into the below interface:

Item 3 : Use or not

#1Comp Use #2Comp Use

Exit Up Down Subb Add

Item 3: Set User Time

Current Date: 10/29/2007

Current Time: 14:16:08

Monday

1 2 3

4 5 6

7 8 9

Exit 0

Item 6: Set display mode

Return Subb Add


You can adjust the contrast at any time according to the requirement through this operation. The detail operation as below : � Press Add(+)/Subb(-) button to adjust. � Press Return button to confirm and go level up.

6) Item 6:Set display mode On the user setup interface, choose the Item 6 by Up/Down button and press the enter button. Press Enter button can change the screen color from BLUE to WHITE and vice versa.

7) Item 7:Select language

On the user setup interface, choose the Item 7 by Up/Down button and press the enter button to enter into the below interface:

Choose the English or button, then press the Exit button to confirm and go lever up. 8) Item 8:Adjust the screen

On the user setup interface, choose the Item 8 by Up/Down button and press the enter button to enter into the below interface:

Please operate as the clue on display in the interface.

9) Item 9:Modify user password On the user setup interface, choose the Item 9 by Up/Down button and press the enter button to enter into the below interface:

The detail operation as below :

� Input the right password and press button to confirm

Item 7: Select language ¢ English

¢

Exit

«Toucher standard operation«

1.OK ! 2nd operation. â 2.OK ! 3nd operation. â

3.OK ! 4nd operation. â

4.OK ! Touch center to return.

Please input Password

1 2 3

4 5 6

7 8 9

0


� If the password is right, it will request you to input the new password

� Press button to confirm the input and it will request to repeat the 2nd time new password input

� If the 2nd time new password input is different from the first one. It will display as blow

� Press Enter to repeat the above steps and to set up the new password. � Press Enter button to confirm and go level up.

Machine setting Press and hold the top left corner on the main interface for 3 seconds, then input the right password and enter into “unit setup”, only manufactory and debugging people have the right to operate. Please see below interface:

� Input the right password (12345678)

Please input new password

1 2 3

4 5 6

7 8 9

0

Please input new password again

1 2 3

4 5 6

7 8 9

0

Twiceinputsdon’tagree

ConfirmBox

ENTER

Modifypasswordsuccessfully

ConfirmBox

ENTER


1 2 34 5 67 8 9

0


� If input the password id wrong , press button the to cancel � Press the button to confirm and enter into the machine setting interface as below

On above interface, the operation as below :

� Press Up/Down button to select item � Press enter button and enter into the item which be choosed � Press Exit button to go level up

1. Item 1 : Machine type setup

Below is the Machine type setup interface:

On above interface, the operation as below: � Press Up/Down button to select item � Press Subb(Add) button to modify � Press Exit button to go level up

l Temperature CTRL. Object: Temperature Control Mode s in : control water in temperature s out : control water out temperature

l Remote switch type: Line(Remote) control type s Dial: Dial or Manual s Pulse: Pulse

l Screen protection time: s 10Min: the time for Screen protection

Below table is the description for the setting item:

Setup Item Water source heat pump Explain

Temperature Control Mode Water in temperature Setting “water in temperature” or “water out temperature” as the energy adjustment. See energy adjustment

Line controller type Manual Or “pulse”, Used to the remote control, See NOTE 1 Screen protection time 10 minute(0 20) See NOTE 2

outside pump control mode Manual Or “automatism”, See NOTE 3 and outside circle pump

Machine Setup

Item 1:Machine type setup Item 2:Sensor setup Item 3:Time para . setup Item 4:Input setup Item 5:Temperature para . setup Item 6:Temp . control para. setup Item 7:Initialize parameters Item 8:Modify machine password

Exit Up Down Enter

Item 1 : Machine type setup 1/3

Temperature CTRL. Object in Remote switch type Dial Screen protection time 10Mn



NOTE

1 Used to remote control unit. If setup “Manual”, base on the [ Line control switch ] and setup “ON”, if the switch is on and the unit will be start up; if the switch is off and unit will be shut down. If the switch “OFF” the setup and result is reverse to above. If setup “pulse”, press the line control switch, base on the unit state and decide whether start up or shut down, the “start” and “Stop” key on the touch is available. 2 The screen protection function, if not touch the screen within 10 minutes, system will into the screen protection state, touch the screen lightly and can be back. 3 If set up the [outside pump function] is NO, that will not see, Or will see.

1. Item 2 : Sensor setup Below is the Sensor setup interface:

On above interface, the operation as below : � Press Up/Down button to select item � Press Subb(Add) button to modify

s Use: set up to use this sensor s Unuse: set up to nonuse this sensor

� Press Exit button to go level up

Below table is the description for the setting item:


system water out temperature sensor Use Can not setup, only have on the first board system water in temperature sensor Use Can not setup, only have on the first board discharge temperature sensor Use Can setup, have on the every board environment temperature sensor Use Can setup, only have on the first board Evaporator water out Use Can setup, or have on the every board Condenser water out Use Can setup, or have on the every board outside circle pump temperature sensor Use Can not setup, Please see NOTE 2.

NOTE

1 [ outside circle pump temperature sensor ] it will be saw when using it and under the automatic mode. 2 Above said the sensor can not setting which stand for the unit must use this sensor., here display just for reference. When the sensor will setting “Un-use” , the alarm will be of no effect, when unit is running, it will not administer the action or not display the temperature number.

2. Item 3 : Time parameter setup Below is the Time parameter setup interface:

Page 1 Page 2

Item 2 : Sensor setup 1/6

Sys.Cond In TEMP.sensor Use Sys.Evap In TEMP.sensor Use Exhaust TEMP.sensor Unuse Enviroment TEMP.sensor Unuse Evap out water TEMP.sensor Unuse Cond out water TEMP.sensor Unuse


Item 3 : Time para. setup 1/22

Shut oil EM valve time 255Se Run oil EM valve time 0Se CM restart delay 5Mn C/H valve run/stop delay 5Se A/C pump run delay 15Se Well pump run delay 10Se 25% EM valve delay 10Se Wind grounp 1 run delay 500ms



Wind group 2 run delay 10Se 50% EM valve run delay 60Se 75% EM valve run delay 60Se CM unload delay 0Se CM unload interval delay 15Se Well pump delay stop 120Se A/C pump delay stop 15Se Common error check dly 3Se



Page 3

On above interface, the operation as below : � Press Up/Down button to select item � Press Subb(Add) button to modify � Press Exit button to go level up

Below table is the description and setting range for the setting item


Shut oil EM valve time / Back oil electromagnetism valve shut time

0 Second (0 255)

Bizter compressor’s will not be saw, Please see NOTE 3

Run oil EM valve time / Back oil electromagnetism valve run time

0 Second (0 255)

Bizter compressor’s will not be saw, Please see NOTE 3

CM restart delay / protection compressor high frequency start delay

5 minutes (0 60)

The interval time of one compressor start up two timing is 4 minutes

C/H valve run/stop delay / Cooling and heating valve run/stop delay

5 Second (0 255)

Delay of cooling and heating then start pump, use to switch the water road

A/C pump run delay / delay after air conditioning pump start

15 Second (0~255)

Start well pump after air conditioning pump start for delay 15 second

Well pump run delay / delay after well pump start

120 Second (0 600)

Start compressor after well pump start for 120 second

25% EM valve delay / delay after 25% electromagnetism valve start

10 Second (0 60)

Start electromagnetism valve of heating after 25% valve start for 15 second

Wind grounp 1 run delay / delay after contactor start(part wiring NO.1)

500 millisecond (300 800)

part wiring NO.2 will turn on after part wiring NO.1 turn on for 500 millisecond

Wind group 2 run delay / delay after contactor start(part wiring NO.2)

10 Second (0 60)

50% electromagnetism valve will be open after part wiring NO.2 turn on for 10 second

delay after contactor start(STAR)

7 Second (0 10)

Corner contactor start after star contactor turn on for 4 second

delay after contactor start(Corner) 15 Second (0 255)

50% electromagnetism valve will be open after Corner contactor start for 30 second

50% EM valve run delay / delay after 50% electromagnetism valve start

60 Second (0 180)

Interval delay from 50% electromagnetism valve to 75% % electromagnetism valve open

75% EM valve run delay / delay after 75% electromagnetism valve start

60 Second (0 240)

Interval delay from 75% electromagnetism valve to 100% electromagnetism valve open

CM unload delay / delay of compressor uninstall

0 Second (0 240)

The least time for 25% electromagnetism valve operate when compressor stop

CM unload interval delay / delay of compressor uninstall interval

15 Second (0 240) The least interval time for two compressors stop

Well pump delay stop / delay of well pump stopping

120 Second (0 600)

Well pump will delay for 10 seconds after all compressor stop

A/C pump delay stop / delay after air conditioning pump stopping

15 Second (0 180)

Air conditioning pump will stop for delay 60 seconds after well pump stop

Common error check dly / delay for common fault testing

3 Second (0 20) Delay 2 seconds after tested the normal fault

Water flow error delay / delay of water flow fault

15 Second (0 255)

It will alarm for delay 10 seconds after Water flow lack

Oil level error delay / delay of oil level testing

30 Second (0 255)

It will alarm for delay 30 seconds when tested the oil level fault


Water flow error delay 15Se Oil level error delay 15Se Anti-freeze shut time 30Mn Under loaded CM runtime 0Mn Force CM full load time 0Mn



delay of oil pressure difference protection 120 Second (0 255)

It will alarm for delay 120 seconds when tested the oil pressure fault

protection time of compressor of shut down 30 minute (0 255) See anti-freezing logic

Under loaded CM runtime / compressor operation time of un-full load

0 minute 0 255) See NOTE 2

Force CM full load time / compressor operation time of forcing full load

0 minute (0 255)

Avoid compressor operation in un-full load lead to lack oil

NOTE: 1 [delay after contactor start(part wiring NO.1) ]and [delay after contactor start(part wiring NO.2] will be displayed only when setup part wiring startup; [delay after contactor start(STAR)] and [delay after contactor start(Corner) ]will be displayed only when setup staring start-up;

2 [compressor operation time of un-full load] [compressor operation time of forcing full load] use to solve the problem of compressor return oil. Because worry to lead to the lubricate system bad and happen the lack oil and harm the compressor’s life if compressor will be operated under un-full load for long time. It is forbidden to uninstall when the compressor will reach the time [compressor operation time of un-full load] but not, and will be forced to enter the full operation but not. Except happen stop or compressor fault or communication fault that compressor opposite back board etc. 3 When the two parameters will be set up with “0”, that stand for nonuse the return oil valve. Usually the

compressor do not use the return oil, then use the two parameter, use to solve the problem of the compressor return oil. When the compressor is running, the return oil valve will start to act, then open the return oil valve (Run oil EM valve time), then close the return oil valve (Shut oil EM valve time), then open the return oil valve (Run oil EM valve time) again, then go on.

3. Item 4 : Input setup

Below is the Input setup interface:

On above interface, the operation as below : � Press Up/Down button to select item � Press Subb(Add) button to modify � Press Exit button to go level up

Below table is the description and setting for the setting item

Display on the interface

Setup item Water source

heat pump Explain

A/C PumpDL air conditioning pump overload NC - A/C Wa.ins air conditioning pump lack NC - WellPumpDL well water pump overload NC - Well Wa.ins well water flow lack NC - outside circle pump overload NO See NOTE 2 CM LP compressor low pressure NC - CM HP compressor high pressure NC - CM OLoad compressor overload NC - CM OHeat compressor superheat NO - CM OP compressor oil pressure switch NC - Oil level compressor oil level switch NC - CM IN Port compressor inside protection NC - Rmote SW line control switch NO - Phase Prct fault and lack phase protection NO - C-Switch outside catenation switch NO -

Item 4 : Input setup 1/14

A/C Pumpol NO A/C Wa.ins NO WellPumpOL NO WellWa.ins NO CM LP NO CM HP NO CM OLoad NO CM OHead NO


Item 4 : Input setup 9/14

CM OP NO Oil Level NO CM IN Port NO Remote SW NO Phase Prct NO C-switch NO



NOTE

1 [control condenser fan] when setup “discharge temperature”, that can not see; when setup “middle pressure switch”, that can see.

2 [outside circle pump function] when setup NC, that can not see. Or can see in above interface 3 For Digital variables input, If there is no Digital variables input in the unit, that can setup “NC” and not connect with

electrical line; if setup “NO”, need short circle when connect with electrical line 4 NO stand for “normal open”, NC stand for the “normal close”

4. Item 5 : Temperature parameter setup Below is the Temperature parameter setup interface:

Page 1 Page 2

Page 3On above interface, the operation as below: � Press Up/Down button to select item � Press Subb(Add) button to modify � Press Exit button to go level up



SYS.C.in TEMP. compensation / Condenser water in TEMP compensation

0°C (-10~10)

Use to compensation system water out temperature

SYS.E.in TEMP. compensation / Evaporator water in TEMP compensation

0°C (-10 10)

Use to compensation system water in temperature

Exhaust TEMP. too high / Exhaust TEMP too high

100°C (0 120) Use to the Exhaust TEMP too high alarm

Cool TEMP.lower limit / TEMP. lower limit when cooling

7°C (-30 60)

Use to limit the control temperature range that user can set up

Heat TEMP. upper limit / TEMP. upper limit when heating

50°C (0 80)

Use to limit the control temperature range that user can set up

Enter CL Evap.out TEMP. low / Evaporator water out TEMP too low protection when cooling

4°C (-30 60)

When the water temperature ≤4°C, the compressor will stop

Exit CL Evap. out TEMP. low Evaporator water out TEMP normal return when cooling

4°C (-30 60)

When the water temperature ≥10°C, the compressor can run

Item 5 : Temperature para setup 1/21

SYS.C.in TEMP. compensation 5°C SYS.E.in TEMP. compensation 5°C Exhaust TEMP. too high 100°C Cool TEMP.lower limit 7°C Heat TEMP.upper limit 50°C Enter CL Evap.out TEMP.low 6°C Exit CL Evap.out TEMP.low 10°C Enter HT Evap.out TEMP.low 6°C


Item 5 : Temperature para setup 921 Exit HT Evap.out TEMP.low 10°C

Exit HT Evap.out TEMP.high 60°C Exit CL CondOut TEMP.high 55°C Enter HT CondOut TEMP.low 60°C Exit HT CondOut TEMP.low 55°C Anti-freeze run pump TEMP 6°C Anti-freeze run heater TEMP 4°C Anti-freeze run CM TEMP 2°C


Item 5 : Temperature para setup 17/21

Anti-freeze stop TEMP 15°C EM spray run exhaust TEMP 85°C EM spray stop exhaust TEMP 79°C Midspray run exhaust TEMP 95°C Midspray stop exhaust TEMP 89°C



Enter HT Evap. out TEMP. low Evaporator water out TEMP too low protection when heating

2°C (-20 20)

When the temperature water out ≤2°C, The compressor stop and display alarm

Exit HT Evap. out TEMP. low Evaporator water out TEMP normal return when heating

8°C (-20 25)

When the temperature water out ≥8°C, The compressor get right

Exit HT Evap.out TEMP. high / Evaporator water out TEMP too high return when heating

50°C (0 80)

When heating, the temperature water out ≤50°C, the compressor can run

Exit CL Cond. Out TEMP. high / Condenser water out TEMP too high return when cooling

Enter HT CondOut TEMP.low / Condenser water out TEMP too high protection when heating

Exit HT CondOut TEMP.low / Condenser water out TEMP too high return when heating

Anti-freeze run pump TEMP / Anti-freeze run pump water out TEMP

6°C (0 30) See the anti-freeze logic

Anti-freeze run heater TEMP / Anti-freeze run heater water out TEMP


Anti-freeze run CM TEMP / Anti-freeze run compressor water out TEMP


Anti-freeze stop TEMP / Anti-freeze stop compressor water out TEMP


EM spray run exhaust TEMP / exhaust TEMP of motor electromagnetism run

85°C (0 120)

When the exhaust temperature ≥80°C, Then open the motor electromagnetism

EM spray stop exhaust TEMP / exhaust TEMP of motor electromagnetism stop

79°C (0 120)

When the exhaust temperature ≤70°C, Then close the motor electromagnetism

Midspray run exhaust TEMP / exhaust TEMP of middle electromagnetism run

95°C (0 120)

When the exhaust temperature ≥90°C, Then open the middle electromagnetism

Midspray stop exhaust TEMP / exhaust TEMP of middle electromagnetism stop

89°C (0 120)

When the exhaust temperature ≤80°C, Then close the middle electromagnetism

5. Item 6 : Temperature control parameter setup

Below is the Temperature control parameter setup interface:

On above interface, the operation as below: � Press Up/Down button to select item � Press Subb(Add) button to modify � Press Exit button to go level up



TEMP. control period / TEMP control period

60 seconds (0 240) Use to the cooling and heating control

Sudden stop control period / Suddenly stop control period

0 seconds (0 180) Use to the suddenly stop area

C/H load TEMP.diff setup / Cooling/heating to load TEMP different setup 2°C(0 10) Use to the cooling and heating control

C/H unload TEMP.diff setup Cooling/heating uninstall TEMP different setup 3°C(0 10) Use to the cooling and heating control

Item 6 : Temperature control para setup7/21

TEMP. control period 60Se Sudden stop control period 0Se C/H load TEMP.diff setup 2°C C/H unload TEMP.diff setup 3°C



6. Item 7 : Initialize parameters Below is the Initialize parameter operation interface:

On above interface, the operation as below: � Press Up/Down button to select item � Press enter button to confirm and enter into � Press Exit button to go level up

l Initialize machine para: Initialize all of the machine setup parameter to set up the windows default l Initialize error record: Initialize and eliminate all of the history error record l Initialize comp work time: Initialize comressor runnig add-up the time and reset to 0 l Initialize user parameter: Initialize all of the user setup parameter to set up the windows default

1) Item 1: Initialize machine para Use the Up/Down button to choose this Item and press the enter button to enter into the interface as below:

Then press the enter button to confirm and go level up. NOTE: The operation of the Item 2 / Item 3 / Item 4 are all same as the Item 1.

1. Item 8: Modify machine password The operation of this Item is same as the MODITY USER PASSWORD. Please refer to the page 15 [tem 9:Modify user password]

Manufacturer setup Press the top corner on the main start interface, then will display the interface as below:

Input the right password and press button to confirm, then will enter into the manufacturer setup interface:

Reset Data

Item 1: Initialize machine para. Item 2: Initialize error record. Item 3: Initialize comp work time Item 4: Initialize user parameter

Exit Up Down Enter

Overwritecurrentdata?

PromptBox

ENTER Cancel


1 2 3

4 5 6

7 8 9

0

Manufacturer Setup

Item1:Set manufacturer para. Item2:Set usage term Item3:Select language Item4:Reset system data Item5:Modify manufacturer passwd

Exit Up Down

Enter


On above interface, the operation as below: � Press Up/Down button to select item � Press enter button to confirm and enter into � Press Exit button to go level up

1. Item1:Set manufacturer para

Use the Up(Down) button and press the enter button, then enter into the below interface:

Page 1 page 2 On above interface, the operation as below: � Press Up/Down button to select item � Press Subb/Add button to modify � Press Exit button to go level up

Note: Only the professional technical engineer is allowed to change the machine parameters! Please turn to TopChiller sales or engineering to work out the problem if there is any error alarm.

Item 1: Set manufacturer para. 1/12

Machine type Water HP Startup mode D wind Outer-Cyc pump function None AUX.heater quantity 0 Compressor quantity 1 Controller quantity 1 Controller No. 1 C/H LP switch type self


Item 1: Set manufacturer para. 9/12

Water HP switch object water If use PC control? Unuse Self-start when power on Inef Manufacturer choice


The technical data in this document are not binding. TopChiller reserves all the right to make whatever modifications if necessary to improve the product at any time without previous notice.

Shenzhen TopChiller Co.,Ltd Tel.: +8618620340004 E-mail: [email protected] www.topchiller.com

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