Draft Chiller Manualpackagingmachines.co.za/files/Videos & Manuals... · press COMP2), the...

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t’s freeze the industry- - 0 Content I Assembling requirements……………………….………………………………………..……………....1 II Preparations for starting the machine...………………...…………………….……………..……….1 III Operation sequences……...……….…………………...……………………….………………..………...2 IV Operation panel sketch map and operating instruction………..…………………..………..………...2 V Instructions for modifying the parameters……….……..……..…………….………………….……....3 VI Parameter setting form……………………………….…….……………………...……………….……….4 VII Instructions for fault code………………………………….…………………….………………...……..6 VIII Notes for operation…………………………………...………..………………………….……….……......7 IX Maintenance………………………………………….……………………………………….……..........8 X Solutions for faults…………………………………………………………….……………………..........9 XI Electric appliances connecting sketch map…………………………………………………….......11 XII Internal structure sketch map of the air cooled chiller…………………………………………..........12 XIII Internal structure sketch map of the water cooled chiller…………………..………………....………..13 XIV Installation sketch map of air cooled chiller…………………………………………………..…….........14 XV Installation sketch map of water cooled chiller………………………………………………..……....15

Transcript of Draft Chiller Manualpackagingmachines.co.za/files/Videos & Manuals... · press COMP2), the...

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Content

I Assembling requirements……………………….………………………………………..……………...….1

II Preparations for starting the machine…...………………...…………………….……………..……….…1

III Operation sequences……...……….…………………...……………………….………………..………...2

IV Operation panel sketch map and operating instruction………..………………….….………..………...2

V Instructions for modifying the parameters……….……..……..…………….………………….……..…..3

VI Parameter setting form……………………………….…….……………………...……………….……….4

VII Instructions for fault code………………………………….…………………….……………….…..……..6

VIII Notes for operation…………………………………...………..………………………….……….……......7

IX Maintenance………………………………………….……………………………………….……...….......8

X Solutions for faults…………………………………………………………….…………………….......…...9

XI Electric appliances connecting sketch map……………………………………………………..….…....11

XII Internal structure sketch map of the air cooled chiller…………………………………………...….......12

XIII Internal structure sketch map of the water cooled chiller…………………..………………....………..13

XIV Installation sketch map of air cooled chiller…………………………………………………..…….........14

XV Installation sketch map of water cooled chiller………………………………………………..…….…...15

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Thanks for choosing ANGES chillers. In order to use the chiller

correctly and efficiently, please read the following instructions in detail.

� Installation requirements: 1. Position the chiller unit to a steady and clean environment without corrosion and

pollution, sunshine and rain. 2. Choose the proper cooling tower to match the chiller unit. The pipe of the chiller should

be installed according to the dimension of the chiller’s jets. Do not thin the pipe, or it would cause high pressure overload, affecting the refrigeration and increasing the power consumption.

3. Air cooled chiller unit must be installed more than 1 meter far from the walls, avoiding badly cooling, high pressure overload, affecting refrigeration and increasing the power consumption. Remark: (1) Power load and the grounding parts should be installed in accordance with

the relevant construction regulations. (2) The refrigerating pipe of the new installed chiller should be wrapped with

warm layer.

� Preparations for starting the machine. For the first time operation, please confirm the below items

1. Check the nameplate to confirm the supply voltage and phase proper or not. (Note: while the power of the compressor is above 3HP, the power supply adopts three-phase five wire standard. Voltage: 380V~415V/50HZ; the phase wire of the power supply are R, S ,T, and the neutral wire is N and the earthed wire is E, which is a Dual-color line. The protector for the error phase or the missing phase is inside. For the first operation, if the light is not on or the light is red with the fault code and alarm, turn off the switch after exchanging and connecting the random two phases. While the power of the compressor is under 3HP, the chiller is adopted one-phase three wire standard. Voltage: 220~240V/50HZ; the power-supply phase wire is L, the neutral wire is N and the earthed wire is E.

2. The refrigerated water plumbing and the cooling water circulating plumbing are connected, and the valve should be kept open; (Please refer to the installation sketch map.)

3. Before starting the water pump, fulfill the refrigerating water tank with water or some other refrigerant (Note: Please choose the right refrigerant according to the requirements.)

4. Please pay attention to the moving direction of the water pump and confirm the tower fans not moving reversely.

� Operation sequences 1. Turn the Power Switch to “ON” 2. Start the switches of the cooling tower and the cooling water pump, and open the

inlet/outlet cooled water valve. 3. Turn on the switch of chiller. Meanwhile the water pump is running. Make sure the

inlet/outlet valves should be opened. The Condenser will be started automatically after the delaying switch delayed, check and adjust the temperature needed.

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� Face plate sketch map and operating instruction.

(1)Start the chiller unit:

� Turn on the air switch inside the electric tank of the chiller; � Put the “RUN” button to start the chiller, at the same time start the water pump. �Compressors can be started by pressing the buttons of COMP1 and COMP2

after compressor starting delay (If there is only one compressor, it is void to press COMP2), the compressor running indicator on the upper-left corner is green. At the same time, the cooling fan runs (The cooling tower and the cooling water pump of the water cooled chiller should be started first), and the chiller is working.

(2)Set the temperature regulation: the PV zone shows the actual temperature, while the SV zone shows the set temperature. If the set temperature of the SV Display needs to be adjusted, please operate according to the following steps:

� Press the “SET” button, while the number is twinkling on the SV display, it means the temperature can be set; � First adjust the temperature by buttoning “UP” and “DOWN”, then confirm the temperature by buttoning “SET”.

(3)Stop the machine: button “STOP” for stopping. If the chiller is not used for a long time, please shut down the power supply of the chiller and discharge the refrigerant of the water tank or of the shell-and-tube evaporator.

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Note: Energy regulation: A. Only one compressor: During the temperature rising process, the

compressor will automatically start while the displaying temperature is equal to or higher than the total of the set temperature and the temperature difference; during the temperature falling process, the compressor will automatically stop if the displayed temperature is lower than the total of the set temperature and the temperature difference.

B. Two compressors: During the temperature rising process, if the displayed temperature is higher than the set temperature, one compressor will start automatically, and if the displayed temperature is equal to or higher than total of the set temperature and the temperature difference, these two compressors will start automatically; During the temperature setting process, if the displayed temperature is lower than the set temperature, one compressor will stop automatically; if the displayed temperature is lower than the difference of the set temperature and the temperature difference, two compressors will stop automatically.

� Introductions for modifying parameters (there is no need to do this if

everything is normal)

1. After the main program starting, the PV zone displays the actual temperature, and the SV zone displays the set temperature. Then the current set temperature can be changed by buttoning “SET” firstly and then using the buttons of “UP” and “DOWN”. After changed the temperature, quit by

buttoning “SET”.(If built-in parameters, the temperature setting function of

“SET” is “LOC”, that means temperature setting parameter cannot be modified, and the “PV” shows “LOC”

2. Entering built-in parameter settings, press “SET” for 5 seconds, “PV” zone shows “LOC”, “SV” shows “0” and blinking; Press “UP” and enter into correct password “38”. Then check the current parameter by “UP” and “DOWN”. If modify the parameter, press “SET”, and then modify with “UP” and “DOWN”, after finished, press “SET” for 5 seconds or without do anything for 30 seconds, the modified parameter will be saved and auto quit.

3. If there is an error, the “PV” zone will display “ERR”, the “SV” zone displays the fault code. Press “RESET” for eliminating; after cleared the fault, press “RESET” again for running the chiller. (Note: if the fault of outlet water temperature too low is happened, after cleared the fault, the chiller must be restart by pressing “ON/OFF” for normally running.)

4. “COMP1” and “COMP2” are two buttons for starting the corresponding compressors, Compressor 1 and Compressor 2.After the chiller started by “ON/OFF”, then “COMP1” and “COMP2” are effective.

5. Indicators: POWER: power supply; RUN: the unit running state; COMP1: the running state of the compressor 1 COMP2: the running state of Compressor 2; ERROR: fault.

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� Parameter setting table Serial

no. Display Function Set area Factory

Default Instruction

1 LOC Entering built-in

parameter 0~255 0

Password“38” (correct:changeable

parameter, error: unchangeable parameter)

2 S E t Setting temperature key locked or not

ON……LOc ON ON=not locked,LOC=locked

3 SPH Locking the max temperature setting

SPL……100� 35 Lock the upper limit setting, permit the max setting, SPH

4 SPL Locking the min temperature setting

-30�……SPH 2 Lock the lower limit settings, permit the min setting, SPL

5 Adj Main control sensor temperature

differentia adjust

-10.0�……10.0� 0 “+” =decrease the temperature,“-”=increase the temperature.

6 S2 water temperature overlow protection

The second control head-30�……100�

1� water temperature overlow protection (When the

temperature is lower than the set temperature, it will alarm)

7 T2 Antifreezing Switch

Set y:yes / n:no y:yes

Choose“y”,S2,antifreezing probe and relative alarm are in effective; Choose “n”S2 and relative alarm is useless.

8 Hy1 Compressor 1 returning

temperature differentia

0.1�……50.0� 2� Compressor 1 returning temperature differentia

9 Hy2 Compressor 2 returning

temperature differentia

0.1�……50.0� 1� Compressor 2 returning temperature differentia

10 Co t Delay for against frequently starting the compressor.

Compressor delay 0~255 seconds

60 Delay for against frequently starting the compressor.

11 PUP Compressor quantities

1~2 2 Compressor quantities

12 AL Fault alarm Alarm means 0~1 0

Alarm output means choice (0:when there is a fault, it will alarm s;1:it will not alarm when

it is muted)

13 Pon Mode choice when electricity goes on.

Electricity mode0~2 2

Started function choice when electricity goes on.

(0=off,1=on,2=remain original memory.)

14 L t d Delay before the Delay after the 5 Delay before the refrigerating

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refrigerating water pump is closed.

refrigerating water pump is

started.0~255 Seconds

water pump is close.

15 F o t Delay before the cooling water pump or the cooling fan is

closed.

Delay of the cooling water pump or the cooling fan 0~255

Seconds

5 Delay before the cooling water pump or the cooling fan is

closed.

16 Fpt Delay before the cooling water pump or the cooling fans

start

Delay of the cooling water pump or the cooling fan 0~255

Seconds

5 Delay before the cooling water pump or the cooling fans start

17 Cp t Delay for the water-flow shortage of the cooling water pump 备 用

Delay when the cooling water pump

stops 0~255 seconds

5 Delay for the water-flow shortage of the cooling water pump 备 用

18 F n t Delay for the water-flow shortage of the cooling water pump and the cooling fan 备 用

It will stop0~255 seconds when the the cooling water

pump and the cooling fan

5 Delay for the water-flow shortage of the cooling water pump and the cooling fan 备 用

19 J o t Delay for the normal failure testing

Delay for the normal failure testing 0~255

seconds

5 Stop when the normal failure testing delays

20 E t Delay for the phase

failure testing Delay for the phase

failure testing 0~255 seconds

1 Delay for the phase failure testing

21

P L t Delay after the unit

starts.

Delay 0~255 seconds after the

unit starts. 5

Time delay setting for the water level switch testing after the unit

started. (Anyhow the water level switch can be tested after the unit is running for about the

set delaying time.) 22 FAn ON:water cooled,OFF:

air cooled Cooling pump

ON~OFF OFF Model choice (ON:water

cooled,OFF:air cooled)

23 Abc Power supply fault Phase error

NO~NC NO Set of machine location NC and

NO (NC:normal close, NO:normal open)

24 CPH1 Compressor 1 high pressure

Compressor 1 high pressure NO~NC

NO Compressor high pressure (NC:normal close, NO:normal

open) 25 CPL1 Compressor 1 low

pressure Compressor 1 low pressure NO~NC

NO Compressor low pressure (NC:normal close, NO:normal open)

26 CO1 Compressor 1 fault overload

Compressor 1 fault overload NO~NC

NO Compressor fault overload (NC:normal close, NO:normal

open) 27 CPH2 Compressor 2 high

pressure Compressor 1 high pressure NO~NC

NO Compressor high pressure (NC:normal close, NO:normal

open)

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28 CPL2 Compressor 2 low pressure

Compressor 2 low pressure NO~NC

NO Compressor 2 low pressure (NC:normal close, NO:normal

open) 29 CO2 Compressor 2 fault

overload Compressor 2 fault overload NO~NC

NO Compressor 2 fault overload (NC:normal close, NO:normal

open) 30 POL The cooling water

pump pressure overlow

The cooling water pump pressure overlow NO~NC

NO The cooling water pump pressure overlow (NC:normal

close, NO:normal open) 31 PO Refrigerating water

pump overload Refrigerating water

pump overload NO~NC

NO Refrigerating water pump overload (NC:normal close,

NO:normal open) 32 FL Cooling water

pressure overlow Cooling water

pressure overlow NO~NC

NO Cooling water pressure overlow/cooling fan overheat

/line switch (NC : normal

close, NO:normal open) 33 FO Cooling pump

overload Cooling pump

overload NO~NC NO Cooling pump overload /cooling

fan overload (NC:normal close, NO:normal

open) 34 L t antifreezing Antifreezing

NO~NC NO Antifreezing switch (NC:normal

close, NO:normal open) 35 」O Line switch Line switch OFF:

NO NC OFF NC=striking,NO=pulse,

OFF=close

� Introductions for fault code Serial no. PV SV Fault Remark

1 Err 01 Wrong phase protection 3phase power supply error(error phase/

phasing missing/ reversed phase)

2 Err 02 COMP1 High pressure Stop COMP1

3 Err 03 COMP1 Low pressure Stop COMP1

4 Err 04 COMP1 overloading Stop COMP1

5 Err 05 COMP2 High pressure Stop COMP2

6 Err 06 COMP2 Low pressure Stop COMP2

7 Err 07 COMP2 overloading Stop COMP2

8 Err 08 Chilled water flow/level Chilled pump water shortage (STOP

THE CHILLER UNIT)

9 Err 09 Chilled pump overload STOP THE CHILLER UNIT

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10 Err 10 Cooling water pressure too low(cooling fan overheating)

Cooling pump water shortage (Stop all the compressors and cooling

pump,keep chilled pump running)

11 Err 11 Cooling pump overload(cooling

fan overload) Stop all the compressors and cooling

pump,keep chilled pump running

12 Err 12 Chilled water temperature lower

than SV setting temperature STOP THE CHILLER UNIT

13 Er1 LLL Outlet temperature sensor open STOP THE CHILLER UNIT

14 Er1 HHH Outlet temperature sensor short STOP THE CHILLER UNIT

15 Err 15 Anti-freezing STOP THE CHILLER UNIT

16 Er2 LLL Anti-freezing sensor open STOP THE CHILLER UNIT

17 Er2 HHH Anti-freezing sensor short STOP THE CHILLER UNIT

� Notes for Handling introduction 1. The refrigerating water pump should not work if there is no water in the water tank;

(For chiller with compressors, which power is above 7.5 HP, there is a built-in water level protector in the water tank. While the water level is too low or the tank is empty, the water pump will be stopped automatically, and it displays the water-level fault code and alarm.)

2. The operating switches should be avoided frequently switching over. 3. While the refrigerated-water temperature reaches the set temperature,the

compressor will stop. 4. In order to prevent the evaporator freezing, do not set temperature below

5�;( except the low temperature chillers) 5. To make sure the best refrigerating effect and best state, please clean the

condenser, evaporator and the water filter regularly. Note: Please turn off chiller as long as if it is alarming. And start chiller after the failures are removed according to the way stated as item 7 and item 10. Or you can contact with our after-sale service staff shortly.

Footnote (1):

Bad cooling and the solution While the condenser cooling bad, the compressor will be inefficient, the operating

current creased; While high pressure of the air cooled chiller reaches 24kg/cm2, and high pressure of the water cooled chiller is up to 20 kg/cm2, the compressor can be trip-out under the protection of the high pressure switch, it will stop running because of bad cooling, high pressure overload, and it will display fault code or fault indication, then please check that the circulating water in the cooling tower is running well, the temperature of cooling water is not overhigh, the fan of the cooling tower and the water pump are running, and the cooling water valve is fully open (If it is an air cooled chiller, please confirm that the radiator is not dirty or choked.). All the stated come back to normal, the chiller can be running well

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after restartingr by pressing “REST”. If the high pressure overload state is a frequent problem, please clean the condenser as soon as possible.

Footnote (2) Solution to low pressure for the shortage of refrigerant : 1. While water temperature is over 5� and the pressure displays by the low pressure

gauge is below 2 kg/cm2, indicates shortage of refrigerant,firstly the leak should be

filled, the dryer filter should be changed, and it should be drawing vacuum again, and incharge refrigerant with proper volume.

2. While leaking part in water, please stop the chiller immediately, and discharge water of the water tank quickly. In order to avoid that the chiller is damaged badly for the compressor suck water, please notify the after-sale service for dealing with the problem.

Footnote (3) Check the low and high pressure:

If the compressor of the water cooled chiller is running well, it is the best state while it displays high pressure within the scope of 12.5 kg/cm2 to 15 kg/cm2 (while for the air

cooled chiller, it is best within the scope of 14~17 kg/cm2 ), but it should not be above 19.5

kg/cm2. If the pressure of the water cooled chiller is above 19.5 kg/cm2, or the pressure of the air cooled chiller is above 24 kg/cm2, the high pressure switch will turn off by itself, then please deal with it according to Footnote(1). It is the best state when the low pressure is within the scope of 3.1 kg/cm2 to 4.5 kg/cm2, but it could not be lower than 2 kg/cm2. If the low pressure is below 2 kg/cm2, the switch of the low pressure will turn off by itself, please deal with it according to Footnote (2).

If the difference between high pressure and low pressure is little or they are equal, while the compressor is running, that means the valve of the compressor damaged or broken up, then the machine should be stopped immediately and notify the company to deal with the problem. Please be aware that the stated conditions would happen when the compressor is running. If the compressor is not operating, it is normal while the high pressure and the low pressure come into equilibrium.

Footnote(4)

If the fault indicator and the protecting switch are both normal,But the compressor can not start, please check the following:

1. The set temperature is too high or the temperature switch is damaged; 2. The switch is damaged; 3. The antifreezing switch is damaged; 4. The pressure switch is shut off by itself or damaged; 5. The overload protector of the compressor is damaged or turn off by itself; 6. The electromagnetic relay is damaged or the overload protector is damaged; 7. The level of the water tank is too low; 8. The refrigerating water protecting switch is damaged;

Note: The compressor can not be operated if the stated controlling switch or the circuit is faulty;

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� Maintenance

Please clean the condenser and the evaporator regularly for keeping the unit running well; 1. Keep the cooling tower neat and clean, and clean it regularly, and confirm there are

no adulterant and other obstruction; 2. Please clean the surface of the cooler of the air refrigerating chiller regularly and

keep the functional performance of the machine well.

� Solutions for faults:: State Reason Solution

Power supply is normal, but the unit can not be operated

�The fuse has blown; �Reversed relay is faulty

�Change the spare fuse; �Change the reversed relay

Switch of the power supply is trip-out

�The loading circuit of the power supply is grounded or short circuit; �The compressor, the pump or the motor is faulty or grounded;

�Change for a new one; �If there is a fault after checked, the switch should be changed or repaired;

Reversed phase �The pump, the compressor or the fan is running reversed �Missing phase

�Exchange any two phases of the power supply; �Test the three-phase source with a multimeter for checking that the power supply is in good condition;

Bad cooling and the fault indicator is on;

�Switch of the high pressure is shut off by itself; �Switch of the high pressure is damaged;

�Please deal with the problem according to the Footnote (1), clean the condenser and keep the temperature below 40 �; �Change for a new pressure switch

Shortage of refrigerant

�The low-pressure switch is shut off by itself for the refrigerant is not enough; �The evaporator is freezed; �The temperature controller does not allow, or the transducer is out of work;

�Deal with the problem according to Footnote(2); �Check whether the expansion water tank is lacking water and the circulating pump is running or not; While everything is going well, the chiller should be stopped and restarted or reset the low-pressure switch by buttoning "RESET"; �If the evaporator is freezed, please input warm water for melting the ice after drew off the iced water; �Change for a new one or repair it; Note: It is not allowed to use hard thing to hitting the ice, because that will break down the copper tube and damage the compressor;

Overload and the fault indicator is lightening

�The voltage is abnormal; �The bearing of compressor, the motor, or the pump is damaged; �Bad cooling; �The overload relay is too small

�The voltage of the three-phase source is decreasing or the voltage is not stable. Please adjust the voltage and check the reason of the missing phase; �Change for a new bearing, or change for

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or its regulating value is too low; �The joint of the circuit is not good or flexible;

a new one; �Deal with the problem according to Footnote(1); �Change for a big overload relay, or adjust the normal value higher; �Interlocked

The fault indicator is not on,but the compressor is not running.

The protection device is shut off by itself.

Please deal with the problem according to Footnote(4)

Water in the water tank is not cool, or the low pressure switch is shut off by itself.

�The capacity is not enough; �The refrigerant is not enough; �The water tank is choked by the refrigerating medium; �The valve is broken; �The temperature is set too high; �The temperature switch does not work; �Bad cooling; �The sensor does not work;

�Expanding the capacity of the major machine; �Deal with the problem according to the Footnote(3); �Change the choked part, and fill refrigerating medium after dealt with the problem with drying agent or expansion valve in the state of vacuum; �Change the compressor, confirm it according to Footnote(3) �Adjust the temperature lower; �Change for a new switch; �If the efficiency is low, it can be dealt according to Footnote(1); �Change for a new sensor;

Lacking water and the water flow is not enough

�Water is not enough in the water tank; �little water flow;

�Add water into the water tank; �Check that whether each valve is fully open;

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� Electric appliances connecting sketch map.

� Internal structure sketch map of the air cooled chiller

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X� Internal structure sketch map of the water cooled chiller

1.Compressor 7.Capillary(Expansion valve)

2.High pressure gauge 8.Evaporator

3.High pressure protector 9.Water pump

4.Condenser 10.Low pressure gauge

5.Cooling fan 11.Low pressure protector

6.Dryer Filter 12.13.Water valve

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�� Installation sketch map of Air cooled chiller

1.Compressor 8.Refrigerating water pump

2.High pressuregauge 9.Low pressure gauge

3.High pressure protector 10.Low pressure protector

4.Condenser 11.Cooling water pump

5.Drying filter 12.Cooling tower

6.Capillary(Expansion valve) 13、14、15、16.Water switch

7.Evaporator

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X� Installation sketch map of Water cooled chiller

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