Download Universal Chilling Systems, LLC.

MANUAL FOR
AIR COOLED
INDUSTRIAL CHILLERS
MODEL: UCS-20A
Universal Chilling Systems, LLC.
Unit Manual Contents
1. Specification
2. Transportation
3. Unit
Installation
4. Electrical
Installation
5. Commissioning
6. Troubleshooting
Operation Manual Contents
1. Appearance
2. Face
3. User's
of DM500B
of pages
inquiry operation
4. User's
5. Unit
set
Operation
6. Trouble
disposal
7. Settings
8. Diagram
of electrical connection
Manual Model 20 Air Cooled Chiller
2
Universal Chilling Systems, LLC.
3
1.1 Product Description
The UCS series Products are chillers that can produce cooling medium of temperature around 7º C or 5º C, and lower on requirement of our customers.
The chillers are applicable to the industries of textile, chemicals, machinery, electronics, medicine and
health, food etc.
Main components
© World famous brand refrigeration parts are employed for all products;
© World leading brand compressors
© High efficient heat exchangers of shell & pipe or copper & fin type
© Digital control system
© Multi-Protection devices for over loading, high and low pressure, phase lacking and water lacking
etc.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
4
1.2 Specifications
MODEL
Cooling Condition
Nominal Cooling Capacity
UCS-20A
Chilled Water Inlet Temp.
12º C
Chilled Water Outlet Temp.
7ºC
Ambient Temp.
35º C
Ton
17.06
x 10³kcal/Hr
37.4
Power Supply
Compressor
Evaporator
Condenser Fan
Safety Protection Device
Water Pump
Water Tank
Overall Size
Overall Unit
Refrigerant Type
3P-480V-60Hz
Type/QTY
Fully Closed Scroll/2 pieces
Cooling Input Power(HP)
27.88
Cooling Operation Current(A)
30.20
Chilled Water Flow(m³/h)
10.32
Interface Size
DN50
Quantity
6
Power/HP each
0.61
Operation Current(A) each
0.72
High &low voltage protection, current overload protection,
antifreezing protection, electronical delay protection
Power (HP)
4.02
Current (A)
6.60
Head(M)
19
Material
304SS
Volume(L)
325
Length (inches)
79.5
Width (inches)
57
Height (inches)
67
Weight/Lbs
1,875
Power/HP
35.56
Current(A)
41.12
R407C
Notice:
1) Normal conditions: Chilled water inlet temperature 12º C, outlet temperature 7ºC, ambient temperature
35ºC
2) Standard power supply: 3P-480V-60Hz, proposed three-phase four-system, allowing voltage fluctuation
-15~10%, frequency fluctuation ± 2%.
3) Host for the actual lift is pump lift host internal head loss minus. (1mH20=9.8kPa)
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
5
2. Transportation
Only the bottom support is allowed to support the unit, and fort vehicle or crane vehicle is required to move the
unit.
The unit must be kept vertical in the transportation; the chains cannot touch the side heat exchanger, top, and
side plates.
3. Installation
3.1. Positioning
The unit must be installed where the air flow is good, in door sheltered from raining.
The space on the top must be larger than 2 meters, which is good enough to bring the hot air to environment.
The space at the air inlet side of the unit must be larger than 1.5 meters that is necessary to normal operation of
it.
A strong, water level concrete base, with height over 20 cm is needed. The repair and maintenance space for
man is to be left. The environment of the unit is -15~50°C, relative humidity 80%.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
6
3.2 Air Duct
An air duct is needed for the place where the air flow is not guaranteed. As shown below in the diagram.
3.3. Pipeline Installation
The unit has been tested and inspected before delivery. What the users need to do is to just fix on its chosen
position, connect to chilled water system, and power supply following the instructions.
The water flow protection switch is necessary in the chilled water system to prevent accident of evaporator
freezing broken in case there is no water or too less water in the pipe. It is recommended to fix the water flow
switch outside the unit box.
4. Electrical Installation
4.1 The UCS Chillers have temperature controller and electrical control box in the unit, the work of electrical
installation is only to connect the unit to power supply.
4.2 In case other control is needed, it must be done observing the local electrical standard and rules to
guarantee the safety and stable operation.
4.3 Wire Selection
It is recommended to select the wire thickness based on 1.25-1.3 multiple the total current of the chiller and
other auxiliary facility as pumps etc.
4.4 Power Supply Requirement
Voltage: Rated V -25~10%; Frequency: Rated Hz±2%; In case the Voltage is over the limit, it is not allowed to
start the unit.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
7
5. Commissioning
5.1. Check before Start Operation
A. Check the environment that everything is normal.
B. Check the power supply connection and the power supply to be sure the phase voltage conforms to the
requirement.
C. Check the water valves on the chiller water pipelines to be sure it is opened. Check the pumps are
normal after pressure test, dirt discharge, air discharge and trial operation.
D. Check the water level in the water vessel, the connection of the water supplementary inlet to the vessel,
overflowing outlet is connected to the sewer.
5.2. Operation of Chilled Water System
A. The chilled water need to be processed, to keep the PH value between 7.0-8.5. The higher alkalinity may
accelerate the corrosion of the copper pipes, decrease the use time of the heat exchangers.
B. After the unit and auxiliary facility are fixed, the water lines need to be processed for pipe cleaning,
pressure test, air discharge, trial running of chilled water system etc. The unit commissioning and trial running
can be started after confirmation of all is normal.
C. Operation of the unit
a. Over 12 hours of power supply on to the unit is needed before the unit start.
b. Start order for the air cooled unit: chilled water pumps  unit;
c. Stop order for the air cooled unit: unit  chilled water pumps;
D. After start, judge the operation status by observing the high and low pressure gauges. The normal range
of the high pressure is 8-16kg/cm2, the low pressure range is 1.5-4kg/cm2
a. For the air cooled unit, observe the rotation direction of the fans, if it runs in wrong direction,
change the power supply wire connection to correct it before start.
b. The set value of all protection devices must not be changed, they have been set at correct value
before delivery.
c. In case the error alarm is on and the unit is stopped, first press the stop button, the alarm will go
off, and then check the trouble reason. Do not start forcibly before the trouble is eliminated.
d. Do not stop the unit by cut off the main power supply unless in emergency case. If the unit
needs to be stop for long time in winter, stop the unit first, then cut off the main power supply, and
drain the water in the system.
e. To guarantee the normal and stable operation of the unit, keep clean, tidy, and air flow in the
machine rooms; clean the condensers periodically.
5.3. Maintenance
A.
Keep the clean of the condensers, clean it periodically and good air flow condition.
B.
Clean the condensers after a period of operation, especially for the dirty environment and the H/L
differential pressure acts and refrigeration capacity deceased.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
8
6. Troubleshooting
Troubles
Cannot start
High pressure too
high
Low pressure too
low
Frosty of suction
line and/or
compressor
Causes
Solutions
1. Power supply is not available or
voltage too low
1. Clear the electrical trouble, and provide the
power supply on requirement
2. Wrong Temperature set, the contactor
is always off
2. Make correct temperature set
3. Over load protection not recovered
after cut off
3. Press the recovery button
1. Too dirty of the condensers
2. Too much refrigerant filled
3. The expansion valve opens too small
1. Clean the condensers
2. Discharge some refrigerant
3. Adjust the opening of the valve
1. Too little of the refrigerant.
1. Leakage check, increase refrigerant and
adjust the valve
2. Blockage of the filter.
3. The expansion valve opens too small
1. The expansion valve opens too large
2. Too much refrigerant filled
3. Load too small
2. Clean or change the filter
3. Adjust the opening of the valve
1. Adjust the opening of the valve
2. Discharge some refrigerant
3. Increase the load
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
Operation Manual of Electrical Control of
UCS Series Industrial Chillers
Contents
1.
Appearance of DM500B
2.
Face of pages
3.
User's inquiry operation
4.
User's set
5.
Unit Operation
6.
Trouble disposal
7.
Settings
8.
Diagram of electrical connection
Manual Model 20 Air Cooled Chiller
9
Universal Chilling Systems, LLC.
10
1. Appearance of DM500B
The panel as fig 3-1, with 12 keys, 6 of them is lighted; the panel dimension is 196mm x 115.5mm W
2. Face of Pages
2.1. Start Display
WELCOME TO OUR
CONTROLLER
9
Air-Water Cool
500ATYF02V1002
First page shows "welcome" count down is shown at the right bottom in reverse color.
The second page, first line shows model and mode, second line shows version number of the program at
the left, and count down is shown at the right bottom in reverse color.
2.2. Main Face
After the count down if finished, the user's main face is shown as below:
TIN: l0 °C T.OUT 5°C
SET: 5 °C STOP
Means turn up,
means turn down.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
11
If the sensor of T.out or T.in shows no temp, the show will be °C , ERR shows…ºC
a. Welcome show
WELCOME TO OUR
CONTROLLER
b.
Model show (Water cooled chiller), mode (cool only, Heat pump, E heating), run mode
(cool, heat, fan, water, defrost) and start type (manual, timing).
Air Water. M.
H.PUMP COOL
c. Face show: show main temp (T.in, T.out), set temp and running status (run, time delay,
stop).
The reverse color shows the control temp for energy adjustment (T.in as control temp as fig below).
T.IN means temperature of returning water or air; T.OUT means temperature of out water or air
3. User’s Inquiry Operation
Press ENQIRE, shows as below:
TROUBLE LIST
TROUBLE HIS.
This system includes inquiring content as below:
TROUBLE LIST
TROUBLE HIS.
RUN TIME CHECK
CLOCK CHECK
Select by
or
, enter each page by OK, by RETURN come back to main face.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
1) TROUBLE LIST
In inquire page, select TROUBLE LIST by
show.
and
12
, press OK to enter TROUBLE LIST
INQUIRE
COMMU.ERR
The second line shows trouble. Press RETURN to up level menu.
2) TROUBLE HIS.
In inquire page, select TROUBLE HIST. by
HIST show.
and
, press OK to enter TROUBLE
1: INVERSE PHASE
2: CM1 ERR
The max number of historical trouble is 8, with the present trouble placed in front lines.
Press RESET for 3 S to remove the historical trouble.
3) RUN TIME CHECK
In inquire page, select RUN TIME CHECK by
and
, press OK to enter RUN TIME
CHECK show.
COM1:
COM2:
0
0
H
H
0 H
0 H
The accumulated run time will be showed according to the compressor number.
4) CLOCK CHECK
In inquire page, select CLOCK CHECK by
show.
2009/01/04
13:14:40
and
, press OK to enter CLOCK CHECK
WED.
The time show here is the real time, the start and stop time will act according to this time.
Press SET to enter time set state for hour, minute setting.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
13
4. User’s Set
In user’s main face, press SET entering user’s set face, the show as below:
SET T.OUT: 5º C
SET Mode: COOLING
The set face includes:
Set T. OUT: 5 °C (shows T. OUT set when the T. OUT is to be controlled.)
Set mode: cool
On/Off: M. (M/week timing/timing once)
TIMING SET
Use set
Only 2 will be shown, other contents can be inquired by
and
. Select one of the 4 items,
change it by <+> , <->, the change will go into effect immediately. The change will be kept after power
off. It will return to main face in this face more than 30 S without touch. After the change, press
RETURN to come back to main face.
M/week timing/time once: M means the automatic on and off is stopped; week time means to start
or stop on set time on the set week day. Time once means to start or stop on set time each day in the
set period. If the clock is set as 0, it means no timing in the period. If the timing once is selected, when
the set date is expired, press SET, the present date will set automatically. When select the week
timing and timing once at the same time, the priority will be to the timing once.
i) The TIMING SET
In the user's page, select TIMING SET by
and
, press OK to enter TIMING SET.
a) If the ON/OFF is set to M, the TIMING SET will not be available.
b) If the ON/OFF is set to WEEK TIMING, it shows below:
WEEK TIMING SET
DATE TIMING SET
c) If the Timing is set to timing once, it shows below:
DATE TIMING SET
CLOCK TIMING SET
In the B face, select WEEK TIMING by
show will below:
and
, to set WEEK TIMING, press OK, then
SUN.
> MON.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
14
Select weekday by
and
, press OK to change the state. If there is > before the
weekday, it means on the weekday the automatic ON/OFF will act, if no >, the ON/OFF will not be
acted automatically.
In C face, select DATE TIMING by
and
, press OK to enter DATE TIMING, the show is
below:
DATE:
Select the item to be changed by
In b or c face, select SET CLOCK by
2005 / 01 / 01
2005 / 01 / 01
and
and
, press <+> , <-> to change the item.
, press OK to enter time set page as below:
ON: 07h 59 m
OFF: 22h 30 m
Select the item to be changed by
and
, press <+>,<-> to change the item.
The data will be kept in memory after the power is off. After the change, press RETURN to come
back to menu of up level.
ii) USE SET
In user's page, select USE SET by
and
, it will show as below:
COMP.1: NONE
COMP.2: USE
The show depends on the number of compressor and heater in RUN SETTINGS  SYS. SETTINGS and
mode of OUTPUMP. The energy adjustment and trouble check will not be available in case the
compressor or heater is set at NONE.
Select the item to be changed by
and
, press <+>,<-> to change the item. The data will be
kept in memory after the power is off. After the change, press RETURN to come back to menu of up
level.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
15
5. Settings
Default password of repairman's: 1 2 3, that is the key: START, INQUIRE, SET.
When system is in STOP page in the user's main face, press
and <+> at the same time, it will
enter SYS. SETTINGS page as below.
INPUT PASSWORD
****
Then input the password, press OK. If is the wrong password, the show will be below:
ERROR! TRY AGAIN
Press RETURN to come back to main face.
The password is two levels, after password of manufacturer’s or repairman’s is put in, it will enter RUN
SETTINGS menu as below:
1: RUN SETTINGS
2: MODIFY PWD
When enter by the repairman's password, there will be 2 items in front of the menu.
1: RUN SETIINGS
2: MODIFY PWD.
I. RUN SETTINGS
In RUN SETTINGS, select RUN SETTINGS by
below:
and
, press OK to enter RUN SETTINGS show
1: SYS. SETTINGS
2: SETTINGS 1
There are 10 items for RUN SETIINGS, and there are sub-items under each item. The 10 items are
below:
1. SYS. SETTINGS (Manufacturer's password can set all; repairman's password can change only
the items of POINT and SWITCH)
2. TIME SETTINGS 1
3. TIME SETTINGS 2
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
16
4. TEMP. SETTINGS 1
5. TEMP. SETTINGS 2
6. TEMP. SETTINGS 3
7. TEMP REVISE
8. INPUT SET 1
9. INPUT SET 2
10. SENSOR SET
II. MODIFY PWD
Select MODIFY PWD by
and
, press OK to enter MODIFY PWD as below:
All keys on the panel can be taken for password except OK and RETURN.
A. When enter by the manufacturer's password , only the manufacturer 's password can be
modified, show is below. First new password show:
INPUT5-6BIT PWD
******
The manufacturer's password must be 5-6 Bit; after the new password is in, the show is below:
PASSWORD CHECK !
******
If the password is the same for both times, the show is below:
PASSWORD ACCEPT
PRESS ANY KEY !
If the check password is not the same as the new password, return to new password
(manufacturer's page).
B. When enter by the repairman's password, only the repairman's password can be modified ,
show is below:
First new password show:
INPUT1-4BIT PWD
****
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
17
The repairman’s password must be 1-4 Bit; after the new password is in, the show is below:
PASSWORD CHECK !
******
If the password is the same for both times, the show is below:
PASSWORD ACCEPT
PRESS ANY KEY !
If the check password is not the same as the new password, return to new password (repairman’s
page).
6. Unit Operation
6.1. Start
Press the START to start the unit: start the pump time delay start the cooling fan time delay
start the compressor. All the delay time can be changed.
6.2. Stop
Press the STOP to stop the unit. Stop the running compressor time delay stop the cooling fan
time delay stop the pump. The delayed time can be changed. In the delaying period, the user's page
show: time delay, after the delay, the show is stop.
6.3. Trouble and Cause
i)
ii)
Compressor breakdown: the cause may be compressor overload, overheat, too high or low
pressure.
Unit breakdown: Pump overload, water lack, error of sensors of in and out water, error of
power etc.
6.4. Run Indication
The run indicator will close after all system is running; it will open after all equipment stop.
6.5. Alarm
The alarm will be on if some system is out of order; if all trouble is disposed, the alarm will be off.
Manual Model 20 Air Cooled Chiller
Universal Chilling Systems, LLC.
18
7. Trouble Disposal
When trouble occurs, the alarm will work and the reset indicator flickers. Press the sound erasing key,
the alarm sound will stop; the reset indicator flickers continue. After the trouble is disposed, press
RESET and the trouble record is erased. When all trouble is reset, the reset indicator will go off. RESET
is available in all pages of user's face. When the system occurs trouble from the no trouble state, it will
enter error inquire automatically. After it enters the AUTOMATI C INQUIRE, it will not return even if no
key is pressed
8. Settings
Settings may vary with different types of unit.
Main menu
Sub menu
Content
1: SYS. SETTINGS
SYS.
AIR-WATER ,W-W SYS.WATER-AIR, AIR-AIR
MODE
COOL, HEATER, H.PUMP
OUTPUMP
NONE, CIRCLE, RECYCLE
COMP.NUM
Max 4 - Min 1
ELEC.H.NUM
Max 3 - Min 1
POINT
T.IN, T.OUT
SWITCH
SW.1, SW.2
Co.
None
2:TIME SETTINGS 1
PROTECT
Max 255S; Min OS ;
CYCLE
Max 255S; Min OS;
COOLER_D
Max 255S; Min OS ;
CHILLER_D
Max 255S; Min OS;
ERR.DELAY
Max 99S; Min OS;
SCR .SAVER
Max 255M; Min OM;
4:TEMP SETTINGS 1 ADD DIF
Max 25º C | Min 1º C
SUB DIF
Max 25º C | Min 1º C
LOWER_L
Max 35º C | Min -20º C
LOW T
Max 20º C | Min -20º C
LOWT.RE
Max 25º C | Min -20º C
7: TEMP REVISE
IN
Max 9º C | Min -9º C
OUT
Max 9º C | Min -9º C
8: INPUT SET 1
CM HP
Normally closed, Normally open
CM LP
Normally closed, Normally open
CM ERR
Normally closed, Normally open
PW ERR
Normally closed, Normally open
Manual Model 20 Air Cooled Chiller
AIR-WATER
AIR-WATER
COOL
NONE
2
0
T.OUT
SW.1
None
180S
120S
15S
30S
2S
30M
2
2
-10
-7
-5
0
0
Normally closed
Normally closed
Normally open
Normally open
Universal Chilling Systems, LLC.
9: INPUT SET 2
10: SENSOR SET
PUMP LACK
FAN OVERL.
FAN OVERH.
P_SWITCH
IN
OUT
Normally closed, Normally open
Normally closed, Normally open
Normally closed, Normally open
Normally closed, Normally open
Use, No Use
Use, No Use
Manual Model 20 Air Cooled Chiller
19
Normally closed
Normally open
Normally open
Normally closed
Use
Use
Universal Chilling Systems, LLC.
Manual Model 20 Air Cooled Chiller
20