AUKS ACWCSC-1180A5/MS, ACWCSC-1570A5/MS, ACWCSC-1380A5/MS, ACWCSC-1080A5/MS, ACWCSC-1880A5/MS Technical Manual

Flooded Type Water Cooled Screw Chiller Technical Manual

Flooded Type Water Cooled Screw Chiller

Technical Manual

Central Air Conditioniner

Flooded Type Water Cooled Screw Chiller Technical Manual

Contents

Chapter I Product Selection .................................................................................................................... 1

1． General .............................................................................................................................................. 1

1.1 Product Overview ......................................................................................................................... 1

1.2 Naming Rule ................................................................................................................................ 3

1.3 Function ....................................................................................................................................... 4

2. Unit Performance ................................................................................................................................................. 5

2.1 Performance Parameter Table ...................................................................................................... 5

2.2 Performance Parameter Table on Variable Working Condition ................................................... 9

3. Unit Outline Dimension ........................................................................................................................ 17

Chapter II Installation and Commissioning .............................................................................................. 19

1 Preparation and Tools before Installation ..................................................................................... 19

1.1 Preparation before Installation .................................................................................................... 19

1.2 Tools to be Prepared .................................................................................................................. 20

2 Installation of Unit .......................................................................................................................... 20

3 Connection of Water Pipeline ........................................................................................................ 22

3.1 Basic Requirements of Pipeline Connection ............................................................................. 22

3.2 Pipeline Connection of Condenser ............................................................................................ 23

3.3 Pipeline Connection of Evaporator ............................................................................................ 24

4 Electrical Wiring............................................................................................................................. 26

4.1 Requirements for Power Supply ................................................................................................. 26

4.2 Wiring Requirements .................................................................................................................. 27

5 Commissioning of Unit .................................................................................................................. 28

5.1 Preparation before Commissioning ........................................................................................... 28

5.2 Operation of Unit ........................................................................................................................ 30

Chapter III Operation and Maintenance .................................................................................................. 32

1. Operation Instruction ........................................................................................................................... 32

1.1 Button Instruction of Wired Controller ........................................................................................ 32

1.2 Operation Instruction of Wired Controller .................................................................................. 33

1.2.1 Setting of Parameter ............................................................................................................... 33

1.2.2 Instruction of Main Screen ....................................................................................................... 33

2. Maintenance ........................................................................................................................................ 42

2.1 Daily Maintenance ...................................................................................................................... 42

2.2 Regular Maintenance ................................................................................................................. 43

Chapter IV After-sales Service ................................................................................................................ 46

1. Main Parts of Unit ................................................................................................................................ 46

1.1 Main Pats of Cooling System ..................................................................................................... 46

1.2 Main Parts of Electrical System .................................................................................................. 49

2. Function and Control of Unit ................................................................................................................ 50

2.1 Function and Control of Unit ....................................................................................................... 50

2.2 Loading/Unloading Process Control of Unit ............................................................................... 51

2.3 Protection Function .................................................................................................................... 51

3. Failure Analysis and Solution .............................................................................................................. 55

3.1 Analysis and Solution of Failure with Failure Code ................................................................... 55

3.2 Analysis and Solution of Failure without Failure Code .............................................................. 63

Flooded Type Water Cooled Screw Chiller Technical Manual

4. Failure Detection of Electrical Parts..................................................................................................... 66

5. Schematic Diagram of System and Electrical Schematic Diagram ..................................................... 67

6. Exploded Chart and Bill of Material ..................................................................................................... 69

Flooded Type Water Cooled Screw Chiller Technical Manual

1

Chapter I Product Selection

1． General

1.1 Product Overview

Flooded-type water-cooled screw chiller unit has characteristics such as high efficiency ratio, compact

structure, beautiful shape, convenient operation and simple cooling system. The unit can be put into

operation immediately after simple installation, water and electricity connection, with improved

operating reliability, safety and economical efficiency of system.

Applicable places:

It is applicable to shopping mall, hospital, hotel, factory, office building, etc.

Product Characteristics:

Flooded-type dedicated compressor:

 Adopted semi-hermetic twin-screw compressor and 5:6 unsymmetrical serrated structure which

realize high compression efficiency, 10% energy saving and stable operation;

 Since oil level switch is above oil level, it is easy to maintain and repair;
 Air suction filter has characteristics of high precision (25μm), large area and less pressure drop,

ensuring best filtering effect;

 Oil filter has characteristics of high precision (10μm), large area and less pressure drop, which can

be used and set with maintenance and replacement;

 Dual-layer casting wall structure effectively reduces operation noise;
 Depressurized bearing housing design reduces content of refrigerant in lubricating oil entering into

bearing and can greatly prolong service life of bearing;

 Screw of compressor has compact structure and low length/diameter ratio, which is hard to deform

and more efficient;

Flooded-type shell and tube heat exchanger:

 Tailor-made refrigerant distributor makes temperature field of heat exchanger distribute more

evenly. Its total heat transfer coefficient is more than three times of traditional dry evaporator, so it

can transfer heat at low temperature difference, effectively improve cooling capacity and

energy/efficiency ratio of unit and save operating cost;

 Chilled water flows in pipe at turbulent flow and is difficult to scale. Removable end plate is easy to

clean and service;

Wide range of cooling capacity:

 Wide range of cooling capacity, which can meet different places’ requirement.

 Two types: common energy efficiency and high energy efficiency can meet different demands of

users.

More reliable oil-return system:

 It uses high-efficiency technology for separating oil two times to minimize oil displacement of

compressor.

Flooded Type Water Cooled Screw Chiller Technical Manual

2

 It uses high-pressure injection oil return technology to ensure reliable oil-return in all working

conditions.

Accurate matching and higher energy efficiency:

 Compressor provides stepless energy adjustment, which can accurately match with actual working

condition and save more energy;

 Twin-compressor has parallel connection design and high seasonal energy efficiency;

Intelligent control system:

 Visual Operation Control. The set information such as operating status, setting parameter and

failure alarm can reflect to controller and make easier operation and more comprehensible;

 Balance control function. Unit automatically adjusts operation time of each system according to

operation status of compressor, which ensures roughly the same operation time of each system,

achieves balanced operation among multiple systems and ensures overall operation stability of
unit.

 Unit can select manually or automatically ON/OFF at specified time which bring great convenience

to users. Unit can completely record the last twenty alarm records and occurrence time, providing
detailed information for after-sales maintenance;

 It has complete protection function including over high pressure protection, less low pressure

protection, overload protection of compressor, superheat protection of coil, phase lost and reversal

protection, high/low voltage protection, oil level protection, high discharge temperature protection

of compressor, oil pressure difference protection of compressor, chilled water and cooling water

flow protection, overload protection of cooling tower fan and protection function for external linkage.

Multiple protection functions ensure reliable protection of unit at the first time in case of
abnormality and ensure safety of unit;

 Optional remote network control function. It can be connected with communication interface of

computer or modulator through RS-485 protocol and easily connected to BAS of standard
industrial bus and public telecom switch network to monitor remote communication;

Flooded Type Water Cooled Screw Chiller Technical Manual

3

1.2 Naming Rule

Example:

ACWCSC-1180A5/MS indicates flooded-type water-cooled screw chiller unit with common energy efficiency,

one twin-screw compressor and nominal cooling capacity approximate to 345kW.

Design Revision No.: A, B, C and others follow by analog

Code of refrigerant type: code of R22 is omitted;

code of R407C is “R”;

code of R134a is “R3”;

Serial number of energy efficiency: “G” refers to unit model of high
energy efficiency and serial number of common energy efficiency is
omitted

Quantity of compressor: S stands for single compressor; D stands for
dual-compressor;

Type of evaporator: “M” refers to flooded type;

Nominal cooling capacity: figure×103 W

Cooling type of condenser: “S” refers to water-cooled type;

Code of mode: no indication for single cooling;

Type of compressor: SLG-twin-screw type

Code of cooling water unit: LS

Flooded Type Water Cooled Screw Chiller Technical Manual

4

1.3 Function

Item Fuction Name Description

Protection
function

high pressure
protection

shutdown when high pressure exceeds set value

low pressure protection shutdown when low pressure is lower than set value

Compressor overload
protection

shutdown when operating current of compressor exceeds max
operating current

superheat protection of
compressor winding

shutdown when winding of compressor motor exceeds a certain
temperature

high discharge
temperature protection

Shutdown when discharge temperature exceeds setting value

phase sequence
protection (phase lost
and reversal)

shutdown in case of phase lost or reversal

Excessive voltage and
less voltage protection

shutdown when input voltage is morer or les than set high voltage and
low voltage value

high and low voltage
difference protection

shutdown when the difference between high voltage and low voltage is
lower than setting value

Oil pressure difference
protection

shutdown when front and rear pressure difference of oil filter of
compressor exceed set value

oil level protection of
compressor

shutdown under when oil level of compressor is too low

anti-freezing protection shutdown when temperature is too low

failure protection of
temperature sensor

shutdown in case of temperature sensor failure

failure protection of
pressure sensor

shutdown in case of pressure sensor failure

temperature difference
protection when back
water flow

shutdown when temperature difference of cooling water exceeds set
value

temperature difference
protection when
excessive water flow

shutdown when temperature difference of cooling water is lower than
setting value

flow protection of chilled
water pump

protect in case of chilled water flow lacking

flow protection of
cooling water pump

protect in case of I cooling water flow lacking

Operation
function

clock display display year, month, day and time

timing ON/OFF function Set timing ON/OFF function

operating parameter
display

display inlet & outlet temperature and high & low pressure of chilled
water and cooling water

protection information
inquiry

display and inquire protection information

automatic load and
unload

automatically load and unload according to actual requirement

water temperature set Set water temperature within a certain range (10℃～15℃)

Flooded Type Water Cooled Screw Chiller Technical Manual

5

2. Unit Performance

2.1 Performance Parameter Table

Note of performance parameters:

1. Nominal cooling capacity of unit is tested under following working conditions:

Chilled water Inlet temperature: 12 ℃ Outlet temperature: 7℃

Cooling water Inlet temperature of: 30℃ Outlet temperature: 35℃

Fouling coefficient of evaporator: 0.0176m2. /W ℃

Fouling coefficient of condenser: 0.043m2. /W℃

2. Noise is tested at a distance 1m front and 1.5m high of the unit. Ambient noise is lower than

30dB(A);

2.1.1 Performance Parameter Table of Unit with Common Energy Efficiency

Model

ACWCS

C-960A5

/MS

ACWCS

C-1080A

5/MS

ACWCS

C-1180A

5/MS

ACWCS

C-1380A

5/MS

ACWCS

C-1570A

5/MS

ACWCS

C-1740A

5/MS

ACWCS

C-1880A

5/MS

ACWCS

C-2120A

5/MS

Cooling

capacity

kW 280 315 340 405 460 510 550 620

kcal/h×10

3

241 271 297 348 396 439 473 533

Cooling

power

kW 57.5 64.8 70.5 82.7 92.0 101.8 108.6 122.2

Max.

running

current

A 171 193 220 241 310 336 355 377

Power supply 380V3N～/50Hz

Compr

essor

Model semi-hermetic screw-type

Quantity (pcs) 1

Startup mode Y－△, shunt winding

Power of oil

heater (W)

300

Adjustment of

cooling

capacity

stepless adjustment

Evapo

rator

Type flooded-type evaporator

Quantity 1

Pipe diameter DN100 DN100 DN125 DN125 DN125 DN125 DN150 DN150

Cooling water

flow (m3/h)

48.2 54.2 59.3 69.6 79.1 87.7 94.6 106.6

Hydraulic

resistance

(Kpa)

44 52 55 56 57 59 59 60

Conde

nser

Type shell and tube condenser

Quantity 1

Pipe diameter DN100 DN100 DN125 DN125 DN125 DN125 DN150 DN150

Cooling water

flow (m3/h)

58.0 65.3 71.5 83.9 94.9 105.2 113.3 127.6

Hydraulic

resistance

(Kpa)

50 54 57 58 59 61 61 62

Refrig

erant

Type R22

Control mode electronic expansion valve

Unit L(mm) 3200 3200 3250 3250 3250 3500 3500 3550

Flooded Type Water Cooled Screw Chiller Technical Manual

6

dimen

sion

W (mm) 1150 1150 1150 1200 1200 1200 1300 1350

H (mm) 1500 1500 1500 1630 1670 1670 1700 1700

Opera

ting

noise

dB(A) 74 74 75 76 78 78 79 79

Unit

weight

kg 1700 1830 2000 2450 2550 2850 2900 3050

Continued

Model

ACWCS

C-2425A

5/MS

ACWCS

C-2730A

5/MS

ACWCS

C-3070A

5/MS

ACWCS

C-3480A

5/MD

ACWCS

C-4200A

5/MD

ACWCS

C-4845A

5/MD

ACWCS

C-5460A

5/MD

ACWCS

C-6140A

5/MD

Cooling

capacity

kW 710 800 900 1020 1230 1420 1600 1800

kcal/h×1

03

610 688 774 877 1058 1221 1376 1548

Cooling

power

kW 140.0 157.1 181.7 200.0 240.3 283.5 312.6 351.1

Max.

running

current

A 453 498 534 672 786 906 996 1068

Power supply 380V3N～/50Hz

Compr

essor

Model semi-hermetic screw-type

Quantity (pcs) 1 2

Startup mode Y－△, shunt winding

Power of oil

heater (W)

300

Adjustment of

cooling

capacity

stepless adjustment

Evapo

rator

Type flooded-type evaporator

Quantity 1

Pipe diameter DN150 DN150 DN150 DN200 DN200 DN250 DN250 DN250

Cooling water

flow (m3/h)

122.1 137.6 154.8 175.4 211.5 244.2 275.2 309.5

Hydraulic

resistance

(Kpa)

64 66 68 70 73 75 76 78

Conde

nser

Type shell and tube condenser

Quantity 1

Pipe diameter DN150 DN150 DN200 DN200 DN200 DN250 DN250 DN250

Cooling water

flow (m3/h)

146.2 164.6 186.0 209.8 252.8 292.9 328.9 369.9

Hydraulic

resistance

(Kpa)

66 68 70 72 75 77 78 80

Refrig

erant

Type R22

Control mode electronic expansion valve

Unit

dimen

sion

L(mm) 3550 3550 3550 4120 4180 4680 4680 4680

W (mm) 1350 1400 1400 1400 1400 1550 1550 1700

H (mm) 1850 1850 1960 2050 2050 2100 2100 2100

Opera

ting

noise

dB(A) 81 82 82 82 82 83 83 83

Flooded Type Water Cooled Screw Chiller Technical Manual

7

Unit

weight

kg 3850 4300 4600 5250 6900 7500 8100 9000

2.2.2 Performance Parameter Table of Unit with High Energy Efficiency

Model

ACWCS

C-960A5

/MSG

ACWCS

C-1080A

5/MSG

ACWCS

C-1180A

5/MSG

ACWCS

C-1380A

5/MSG

ACWCS

C-1570A

5/MSG

ACWCS

C-1740A

5/MSG

ACWCS
C-1880A

5/MSG

ACWCS

C-2120A

5/MSG

Cooling

capacity

kW 280 315 340 405 460 510 550 620

kcal/h×1

03

241 271 297 348 396 439 473 533

Cooling

power

kW 52.2 58.9 64.1 75.1 83.6 92.6 98.7 111.1

Max.

running

current

A 171 193 203 241 268 310 336 355

Power supply 380V3N~/50Hz

Comp
ressor

Model semi-hermetic screw-type

Quantity

(pcs)

1

Startup mode Y－△

Power of oil

heater (W)

300

Adjustment of

cooling

capacity

stepless adjustment

Evapo

rator

Type flooded-type evaporator

Quantity 1

Pipe diameter DN100 DN100 DN125 DN125 DN125 DN125 DN150 DN150

Cooling water

flow (m3/h)

48.2 54.2 59.3 69.6 79.1 87.7 94.6 106.6

Hydraulic

resistance

(Kpa)

44 52 55 56 57 59 59 60

Conde

nser

Type shell and tube condenser

Quantity 1

Pipe diameter DN100 DN100 DN125 DN125 DN125 DN125 DN150 DN150

Cooling water

flow (m3/h)

57.1 64.3 70.4 82.6 93.5 103.6 111.6 125.7

Hydraulic

resistance

(Kpa)

50 54 57 58 59 61 61 62

Refrig

erant

Type R22

Control mode electronic expansion valve

Unit

dimen

sion

L(mm) 3200 3200 3250 3250 3250 3250 3500 3550

W (mm) 1150 1150 1150 1200 1200 1200 1300 1350

H (mm) 1500 1500 1500 1630 1670 1670 1700 1700

Opera

ting

noise

dB(A) 74 74 75 76 78 78 79 79

Unit

weight

kg 1750 1900 2100 2550 2700 2850 3000 3200

Flooded Type Water Cooled Screw Chiller Technical Manual

8

Continued

Model

ACWCS
C-2425A

5/MSG

ACWCS

C-2730A

5/MSG

ACWCS

C-3070A

5/MSG

ACWCS

C-3480A

5/MDG

ACWCS

C-4200A

5/MDG

ACWCS

C-4845A

5/MDG

ACWCS
C-5460A

5/MDG

ACWCS

C-6140A

5/MDG

Cooling

capacity

kW 710 800 900 1020 1230 1420 1600 1800

kcal/h×1

03

610 688 774 877 1058 1221 1376 1548

Cooling

power

kW 127.2 142.9 165.1 181.8 218.5 257.7 284.2 319.1

Max.

operating

current

A 393 453 498 620 672 786 906 996

Power supply 380V3N～/50Hz

Comp
ressor

Model semi-hermetic screw-type

Quantity

(pcs)

1 2

Startup mode Y－△

Power of oil

heater (W)

300

Adjustment of

cooling

capacity

stepless adjustment

Evap

orator

Type flooded-type evaporator

Quantity 1

Pipe

diameter

DN150 DN150 DN150 DN200 DN200 DN250 DN250 DN250

Cooling water

flow (m3/h)

122.1 137.6 154.8 175.4 211.5 244.2 275.2 309.5

Hydraulic

resistance

(Kpa)

64 66 68 70 73 75 76 78

Cond

enser

Type shell and tube condenser

Quantity 1

Pipe

diameter

DN150 DN150 DN200 DN200 DN200 DN250 DN250 DN250

Cooling water

flow (m3/h)

144.0 162.1 183.2 206.7 249.1 288.5 324.0 364.4

Hydraulic

resistance

(Kpa)

66 68 70 72 75 77 78 80

Refrig

erant

Type R22

Control mode electronic expansion valve

Unit

dimen

sion

L(mm) 3550 3550 3550 4120 4180 4180 4680 4680

W (mm) 1350 1400 1400 1400 1400 1550 1550 1700

H (mm) 1850 1850 1960 2050 2050 2100 2100 2100

Opera

ting

noise

dB(A) 81 82 82 82 82 83 83 83

Unit

weigh

t

kg 4000 4500 4800 5400 7100 7800 8400 9300

Flooded Type Water Cooled Screw Chiller Technical M

anual

9

2.2 Performance Parameter Table on Variable Working Condition

2.2.1 Operating Range

2.2.2 Variable Working Condition Table of Unit with Common Energy Efficiency

LSSLGS280MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

363
357
351
345
339
333
327
321
315
309
303
297
291
285
279
273
267
261
255
249
243
237
231
225

67
65
63
61
59
57
55
53
51
49
47

43

45

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS315MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

47

49

51

53

55

57

59

61

63

65

67

69

71

73

75

77

249

255

261

267

273

279

285

291

297

303

309

315

321

327

333

339

345

351

357

363

369

375

381

387

393

399

405

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Specification of Cooling Capacity All Specifications

Power supply 380V3N~/50Hz

Voltage range 342~418V

Cooling

Inlet temperature range

of cooling water

19~38℃

Outlet temperature

range of chilled water

5~15℃

Chart of Variable Working Condition o

f

ACWCSC-960A5/MS

Chart of Variable Working Condition

of ACWCSC-1080A5/MS

Cooling Capacity (Kw)

Power (Kw)

Inlet temperature ofcooling water (

℃

)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Inlet temperature ofcooling water (

℃

)

Powe

r

(Kw)

Cooling
Capacity
(Kw)

Flooded Type Water Cooled Screw Chiller Technical M

anual

10

LSSLGS345MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

441
435
429
423
417
411
405
399
393
387
381
375
369
363
357
351
345
339
333
327
321
315
309
303
297
291
285
279
273

83
81
79
77
75
73
71
69
67
65
63
61
59
57
55
53

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS405MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

516
507
498
489
480
471
462
453
444
435
426
417
408
399
390
127
124
121
118
115
112
109
106

97
94
91
88
85
82
79
76
73
70
67
64
61

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS460MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

591
582
573
564
555
546
537
528
519
510
501
492
483
474
465
456
447
438
429
420
411
402
393
384
375

106
103
100

97
94
91
88
85
82
79
76
73
70
67

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS510MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

76

79

82

85

88

91

94

97

100

103

106

109

112

115

118

411

420

429

438

447

456

465

474

483

492

501

510

519

528

537

546

555

564

573

582

591

600

609

618

627

636

645

654

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-1180A5/MS

Chart of Variable Working Condition

of ACWCSC-1380A5/MS

Cooling Capacity (Kw)

Power (Kw)

Power (Kw)

Cooling Capacity (Kw)

Inlet temperature ofcoolin

g

water

(℃)

Inlet temperature ofcooling water (

℃

)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Power (Kw)

Power (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-1570A5/MS

Chart of Variable Working Condition

of ACWCSC-1740A5/M

Flooded Type Water Cooled Screw Chiller Technical M

anual

11

LSSLGS550MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

82

85

88

91

94

97

100

103

106

109

112

115

118

121

124

127

447

456

465

474

483

492

501

510

519

528

537

546

555

564

573

582

591

600

609

618

627

636

645

654

663

672

681

690

699

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS620MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

89

93

97

101

105

109

113

117

121

125

129

133

137

141

145

501

513

525

537

549

561

573

585

597

609

621

633

645

657

669

681

693

705

717

729

741

753

765

777

789

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS710MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

105

109

113

117

121

125

129

133

137

141

145

149

153

157

161

165

573

585

597

609

621

633

645

657

669

681

693

705

717

729

741

753

765

777

789

801

813

825

837

849

861

873

885

897

909

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS800MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1017
1005

993
981
969
957
945

117

121

125

129

133

137

141

145

149

153

157

161

165

169

173

177

181

185

189

645

657

669

681

693

705

717

729

741

753

765

777

789

801

813

825

837

849

861

873

885

897

909

921

933

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-1880A5/MS

Chart of Variable Working Condition

of ACWCSC-2120A5/MS

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Power (Kw)

Power (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Inlet temperature ofcoolin

g

water

(℃)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-2425A5/MS

Chart of Variable Working Condition

of ACWCSC-2730A5/MS

Inlet temperature o

f

cooling water (

℃

)

Inlet temperature o

f

cooling water (

℃

)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Power (Kw)

Power (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Flooded Type Water Cooled Screw Chiller Technical M

anual

12

LSSLGS900MS变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1146

137

142

147

152

157

162

167

172

177

182

187

192

197

202

207

212

726

741

756

771

786

801

816

831

846

861

876

891

906

921

936

951

966

981

996

1011

1026

1041

1056

1071

1086

1101

1116

1131

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1020MD变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1293
1275
1257
1239
1221
1203
1185
1167
1149
1131
1113
1095
1077
1059
1041
1023
1005

987
969
951
933
915
897
879
861
843
825
807

235
229
223
217
211
205
199
193
187
181
175
169
163
157
151

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1230MD变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1581
1557
1533
1509
1485
1461
1437
1413
1389
1365
1341
1317
1293
1269
1245
1221
1197
1173
1149
1125
1101
1077
1053
1029
1005

981

285
277
269
261
253
245
237
229
221
213
205
197
189
181
173

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1420MD变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1725
1701
1677
1653
1629
1605
1581
1557
1533
1509
1485
1461
1437
1413
1389
1365
1341
1317
1293
1269
1245
1221
1197
1173
1149
1125

333
325
317
309
301
293
285
277
269
261
253
245
237
229
221
213

1749

1773

1797

1821

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-3070A5/MS

Chart of Variable Working Condition of

ACWCSC-3480A5/MD

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Power (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Power (Kw)

Cooling Capacity (Kw)

Cooling
Capacity
(Kw)

Powe

r

(Kw)

Power (Kw)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-4200A5/MD

Chart of Variable Working Condition

of ACWCSC-4845A5/MD

Flooded Type Water Cooled Screw Chiller Technical M

anual

13

LSSLGS1600MD变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

2031
2001
1971
1941
1911
1881
1851
1821
1791
1761
1731
1701
1671
1641
1611
1581
1551
1521
1491
1461
1431
1401
1371
1341
1311
1281

377
367
357
347
337
327
317
307
297
287
277
267
257
247
237
227

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1800MD变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

2301
2265
2229
2193
2157
2121
2085
2049
2013
1977
1941
1905
1869
1833
1797
1761
1725
1689
1653
1617
1581
1545
1509
1473
1437

421
409
397
385
373
361
349
337
325
313
301
289
277
265

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

2.2.3 Variable Working Condition Table of Unit with High Energy Efficiency

LSSLGS280MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

354
354
347
340
333
326
319
312
305
298
291
284
277
270
263
256
249
242
235
228

61
59
57
55
53
51
49
47

43
41
39

45

37

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS315MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

403
396
389
382
375
368
361
354
347
340
333
326
319
312
305
298
291
284
277
270
263
256

69
67
65
63
61
59
57
55
53
51
49
47

43

45

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-5460A5/MD

Chart of Variable Working Condition

of ACWCSC-6140A5/MD

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Power (Kw)

Power (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-960A5/MSG

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-1080A5/MSG

Cooling Capacity (Kw)

Power (Kw)

Powe

r

(Kw)

Cooling
Capacity
(Kw)

Flooded Type Water Cooled Screw Chiller Technical M

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14

LSSLGS345MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

445
438
431
424
417
410
403
396
389
382
375
368
361
354
347
340
333
326
319
312
305
298
291
284
277

75
73
71
69
67
65
63
61
59
57
55
53
51
49
47

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS405MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

522
515
508
501
494
487
480
473
466
459
452
445
438
431
424
417
410
403
396
389
382
375
368
361
354
347
340
333
326

87
85
83
81
79
77
75
73
71
69
67
65
63
61
59
57
55

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS460MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

592
585
578
571
564
557
550
543
536
529
522
515
508
501
494
487
480
473
466
459
452
445
438
431
424
417
410
403
396
389
382
375
368

97
95
93
91
89
87
85
83
81
79
77
75
73
71
69
67
65
63
61

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS510MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

70

73

76

79

82

85

88

91

94

97

100

103

106

411

420

429

438

447

456

465

474

483

492

501

510

519

528

537

546

555

564

573

582

591

600

609

618

627

636

645

654

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-1180A5/MSG

Cooling Capacity (Kw)

Power (Kw)

Outlet temperature of chilled water (℃)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-1380A5/MSG

Cooling Capacity (Kw)

Power (Kw)

Inlet temperature ofcooling water (

℃

)

Outlet temperature of chilled water (℃)

Chart of Variable Working Condition

of ACWCSC-1570A5/MSG

Cooling Capacity (Kw)

Power (Kw)

Inlet temperature ofcooling water (

℃

)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Cooling Capacity (Kw)

Power (Kw)

Inlet temperature ofcooling water (

℃

)

Chart of Variable Working Condition

of ACWCSC-1740A5/MSG

Flooded Type Water Cooled Screw Chiller Technical M

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15

LSSLGS550MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

73

76

79

82

85

88

91

94

97

100

103

106

109

112

115

447

456

465

474

483

492

501

510

519

528

537

546

555

564

573

582

591

600

609

618

627

636

645

654

663

672

681

690

699

708

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS620MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

82

85

88

91

94

97

100

103

106

109

112

115

118

121

124

127

130

498

507

516

525

534

543

552

561

570

579

588

597

606

615

624

633

642

651

660

669

678

687

696

705

714

723

732

741

750

759

768

777

786

795

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS710MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

93

97

101

105

109

113

117

121

125

129

133

137

141

145

149

573

585

597

609

621

633

645

657

669

681

693

705

717

729

741

753

765

777

789

801

813

825

837

849

861

873

885

897

909

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS800MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1020

105

109

113

117

121

125

129

133

137

141

145

149

153

157

161

165

169

648

660

672

684

696

708

720

732

744

756

768

780

792

804

816

828

840

852

864

876

888

900

912

924

936

948

960

972

984

996

1008

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-1880A5/MSG

Chart of Variable Working Condition

of ACWCSC-2425A5/MSG

Chart of Variable Working Condition

of ACWCSC-2730A5/MSG

Chart of Variable Working Condition

of ACWCSC-2120A5/MSG

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Power (Kw)

Power (Kw)

Power (Kw)

Power (Kw)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Flooded Type Water Cooled Screw Chiller Technical M

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16

LSSLGS900MSG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1152
1138
1124
1110
1096
1082
1068

121

125

129

133

137

141

145

149

153

157

161

165

169

173

177

181

185

189

193

718

732

746

760

774

788

802

816

830

844

858

872

886

900

914

928

942

956

970

984

998

1012

1026

1040

1054

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1020MDG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1311
1296
1281
1266
1251

137

142

147

152

157

162

167

172

177

182

187

192

197

202

207

212

816

831

846

861

876

891

906

921

936

951

966

981

996

1011

1026

1041

1056

1071

1086

1101

1116

1131

1146

1161

1176

1191

1206

1221

1236

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1230MDG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1579
1558
1537

163

169

175

181

187

193

199

205

211

217

223

229

235

241

247

253

259

970

991

1012

1033

1054

1075

1096

1117

1138

1159

1180

1201

1222

1243

1264

1285

1306

1327

1348

1369

1390

1411

1432

1453

1474

1495

1516

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1420MDG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

1810
1789
1768
1747
1726
1705
1684
1663
1642
1621
1600
1579
1558
1537

193

199

205

211

217

223

229

235

241

247

253

259

265

271

277

283

289

295

301

1138

1159

1180

1201

1222

1243

1264

1285

1306

1327

1348

1369

1390

1411

1432

1453

1474

1495

1516

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

Chart of Variable Working Condition

of ACWCSC-3070A5/MSG

Inlet temperature ofcooling water (

℃

)

Power (Kw)

Cooling Capacity (Kw)

Outlet temperature of chilled water (℃)

Chart of Variable Working Condition

ofACWCSC-3480A5/MDG

Chart of Variable Working Condition

of ACWCSC-4200A5/MDG

Chart of Variable Working Condition

of ACWCSC-4845A5/MDG

Power (Kw)

Power (Kw)

Power (Kw)

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Outlet temperature of chilled water (℃)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Flooded Type Water Cooled Screw Chiller Technical M

anual

17

LSSLGS1600MDG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

2034
2006

213

221

229

237

245

253

261

269

277

285

293

301

309

317

325

333

1278

1306

1334

1362

1390

1418

1446

1474

1502

1530

1558

1586

1614

1642

1670

1698

1726

1754

1782

1810

1838

1866

1894

1922

1950

1978

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

LSSLGS1800MDG变工况图表

20℃

25℃

25℃

30℃

30℃

35℃

35℃

2286
2258
2230
2202
2174
2146
2118
2090
2062
2034
2006

237

245

253

261

269

277

285

293

301

309

317

325

333

341

349

357

365

373

1418

1446

1474

1502

1530

1558

1586

1614

1642

1670

1698

1726

1754

1782

1810

1838

1866

1894

1922

1950

1978

20℃

4 5 6 7 8 9 10

冷冻水出水温度(℃)

3. Outline Dimension of Unit

Outline and connection dimension diagram of unit – single compressor (ACWCSC-960A5/MS~ ACWCSC-3070A5/MS )

Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃)

Chart of Variable Working Condition

o

f

ACWCSC-5460A5/MDG

Chart of Variable Working Condition

of ACWCSC-6140A5/MDG

Inlet temperature ofcooling water (

℃

)

Inlet temperature ofcooling water (

℃

)

Power (Kw)

Power (Kw)

Cooling Capacity (Kw)

Cooling Capacity (Kw)

Flooded Type Water Cooled Screw Chiller Technical M

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18

Outline and connection dimension diagram of unit – twin-compressor (ACWCSC-3480A5/MD~ ACWCSC-6140A5/MD)

Sign Name Sign Name

① screw compressor ⑥ Inlet of chilled water

② evaporator ⑦ outlet of chilled water
③ condenser ⑧ Outlet of cooling water
④ oil separator ⑨ inlet of cooling water
⑤ Control cabinet

Dimension of twin-screw water-cooled chiller unit: Unit: mm

Model A B C D E DNX DNY

ACWCSC-960A5/MS(G) 3200 1150 1500 2600 900 DN100 DN100

ACWCSC-1080A5/MS(G) 3200 1150 1500 2600 900 DN100 DN100

ACWCSC-1180A5/MS(G) 3250 1150 1500 2730 960 DN125 DN125

ACWCSC-1380A5/MS(G) 3250 1200 1630 2730 1000 DN125 DN125

ACWCSC-1570A5/MS (G) 3250 1200 1670 2730 1000 DN125 DN125

ACWCSC-1740A5/MG 3250 1200 1670 2730 1000 DN125 DN125

ACWCSC-1740A5/M

ACWCSC-1880A5/MS(G)

3500 1300 1700 2800 1100 DN150 DN150

ACWCSC-2120A5/MS(G) 3550 1350 1700 2800 1100 DN150 DN150

ACWCSC-2425A5/MS(G) 3550 1350 1850 2800 1100 DN150 DN150

ACWCSC-2730A5/MS(G) 3550 1400 1850 2800 1200 DN150 DN150

ACWCSC-3070A5/MS (G) 3550 1400 1960 2800 1200 DN150 DN200

ACWCSC-3480A5/MD(G) 4120 1400 2050 3300 1200 DN200 DN200
ACWCSC-4200A5/MD(G) 4180 1400 2050 3300 1200 DN200 DN200

ACWCSC-4845A5/MDG 4180 1550 2100 3300 1250 DN250 DN250

ACWCSC-4845A5/MD

ACWCSC-5460A5/MD(G)

4680 1550 2100 3800 1300 DN250 DN250

ACWCSC-6140A5/MD(G) 4680 1700 2100 3800 1500 DN250 DN250

Flooded Type Water Cooled Screw Chiller Technical M

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Chapter II Installation and Commissioning

1 Preparation and Tools before Installation

1.1 Preparation before Installation

1．Dedicated machine room should be available for unit. Measures should be taken to exhaust

heat generated by unit during operation and ventilation volume should be able to keep

maintain room temperature no more than 40 . ℃

2． Unit should be installed on non-deformable rigid pedestal or concrete foundation that should

be flat and stand weight of unit during operation.

3． Sufficient drainage measures such as draining channel should be available for around the

foundation of unit to discharge water from system in case of seasonal shutdown or

maintenance.

4．Machine room should be spacious enough to install and maintain unit, and pull pipe;

meanwhile, pipeline and line pipe shouldn’t be laid above compressor; the distance from the

highest point of unit to the top of machine room shouldn’t be less than 500mm. See the

following diagram for space requirement.

A

= length of uni

t

Maintenance space

Front of unit

Flooded Type Water Cooled Screw Chiller Technical M

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20

5．When installing water pipe, it’s recommended to reserve space between water pipe and

connecting pipe to install damping rubber connecting pipe, and to provide suitable

construction and adjustment space after unit arrives at site.

6．To ensure normal working of electrical elements, don’t put unit at places with dust, filth and

much corrosive fume that must be corrected if any.

1.2 Tools to be Prepared

Flexible joint, anti-vibration bolster, lifting equipment, lifting beam, lifting chain, lifting jack, skid,

underlay roll and crow bar

2 Installation of Unit

1. Before leaving factory, unit has been subjected to strict inspection and package to ensure

unit arrives at destination under normal conditions. Installers, handlers and lifting worker

should protect unit, prevent damaging unit due to rough operation and especially pay

attention to preventing refrigerant leaking due to impact on angle valve and pipeline.

2. Unit should be moved horizontally with gradient no more than 30°. It’s allowed to use crane.

When using crane, it’s required to use bottom lug hole. Contact part between sling and unit

should be separated with support. It’s necessary to ensure sling can stand weight of the

whole unit, otherwise, unit will be damaged or serious physical injury will be caused. Don’t lift

or move unit with forklift.

3. If vertical lifting conditions are or available, horizontal rolling method can be used. In other

words, prop up both ends with lifting jack to a certain height, put underlay roll under skid

support of unit, and remove skid after rolling unit into proper position. When moving unit with

horizontal rolling method, it’s only allowed to apply force on unit frame or skid.

4. After unit is put into proper position, remove skid, adjust levelness with spirit level and fix

footing of unit on foundation with anchor bolt. It’s recommended to put anti-vibration flexible

pad with thickness of 15~20mm between footing of unit and foundation.

5. When unit is put into proper position, put anti-vibration flexible pad under unit, and adjust

levelness of unit within a range of 2mm per meter. Unit should be leveled with gasket of

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standard length. Unit must be put inside machine room and non-deformable rigid pedestal

or concrete foundation should be provided. It’s recommended to install unit at basement or

ground floor. If it’s required to install at high floor, it’s necessary to consider if basic

structure of floor has sufficient strength to stand weight of chiller unit during operation. Unit

should be installed as follows:

Installation Diagram of Unit – Single Compressor (ACWCSC-960A5/MS~ ACWCSC-3070A5/MS )

Installation Diagram of Unit – Twin-Compressor (ACWCSC-3480A5/MD~ ACWCSC-6140A5/MD)

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3 Connection of Water Pipeline

After installing unit into proper position, conduct installation of water system pipeline or connect the

arranged water system pipeline with water pipe of evaporator and condenser.

3.1 Basic Requirements of Pipeline Connection

1．Installation and insulation of water pipeline of A/C system should be designed and instructed

by professional designers, and should follow relevant requirements of heating A/C system

installation specification.

2．Inlet & outlet water pipeline should be connected according to requirements indicated on unit.

3．Water system must be equipped with water pump of suitable flow and lift to ensure unit can

set water supply. Water pump should be connected to unit and water system pipeline with anti-

vibration flexible joint, and should also be self-supported to prevent applying force on unit. During

installation, welding should prevent damaging unit. (Add requirements for flange connection)

4．Install flow switch (to be supplied by AUKS, excluding joint) on outlet water pipe of evaporator

and condenser. Interlock input contact in flow switch and control cabinet. The installation

requirements are as follows:

 Flow switch is single-pole double-throw (SPDT) flow switch used to induct flow change

of liquid such as water, glycol or other non-hazardous fluids flowing across pipeline. It is

typically used at places requiring linkage function or “discontinuous flow” protection.

 When installing flow switch, its wiring terminal should be installed at the position that is

easy for wiring.

 Tightly screw slow switch to keep liquid flow at a correct angle, arrow on enclosure must

be in the same direction as that of liquid flow.

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 Flow switch must be installed on a section of straight pipeline and there should be at

least straight line travel five times of pipe diameter at both sides. (see the diagram

below)

5． Water filter of 16~40 meshes must be installed in front of inlet pipeline of unit.

6．Water pipeline of system should be flushed before connecting unit to prevent filth damaging unit.

7．Water chamber is designed to stand water pressure of 1.0Mpa. Don’t use it under excessive

pressure to prevent damaging evaporator and condenser.

3.2 Pipeline Connection of Condenser

1．Pipeline system of cooling water must be connected with outlet water pipeline of cooling tower

after it is connected with anti-vibration flexible joint, thermometer, pressure gauge, drain

valve, stop valve, water filter, check valve and target-type flow controller.

2．Water supply pipeline should be as short as possible. Specification of pipeline should be

determined by effective lift of water pump, flow and flow rate of pipeline, rather than

specification of joint.

3．Drainage and discharge joints are installed at sealing end of condenser and sealed with screw

plug. Screw plug should be replaced with (1/4NPT discharge and 1/2NPT drainage) ball

Note: It’s strictly prohibited to connect pipeline with unit before thoroughly
flushing the pipeline.

Three-way joint or

welded two-way joint

Water flow swtich

Stop valve

Flow direction

Size “A” must be at least five times of pipe diameter from the nearest

elbow, valve or other pipe res

trictor

s

Flow direction

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valve.

3.3 Pipeline Connection of Evaporator

1．Pipeline system of refrigeration water must be installed with anti-vibration joint, thermometer,

pressure gauge, water filter, electronic scale-borer, check valve, target-type flow controller,

discharge valve, drainage valve, stop valve and expansion water tank, etc.

2．Expansion water tank should be installed at the location 1~1.5m away from the highest point

of system. Capacity of water tank should be approximately 1/10 of water volume of the whole

Target-type flow controller

A

utomatic makeup valve

Stop valve

Overflow pipe

Stop valve

Water filter

Circulating water
pump with

A

nti-vibration

flexible joint

Inlet pipe of cooling water

Blow-down valve

Bypass stop valve

Flow switch

Blow-down valve

Outlet pipe of cooling water

Stop valve

Pressur

e gauge

Thermomet

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system.

3．Discharge valve is installed on cylinder of evaporator.

4．Vertical change should be prevented for water pipe where possible. Manual or automatic

discharge valve should be installed between high part of pipeline and expansion water tank.

5．Thermometer and pressure gauge should be installed at straight pipe section of inlet and

outlet water pipeline, which shouldn’t be installed at the location near elbow pipe where

possible. Bypass pipeline should be installed between inlet and outlet water pipes of

evaporator to facilitate cleaning and overhauling pipeline.

6．Drain valve (wash-out valve) should be installed at the lowest part of inlet and outlet water

pipeline of unit. Drainage pipe should be connected to the lowest side of system to discharge

refrigeration water of unit from two outlets, prevent refrigeration water freezing in heat

exchanger and water pump in winter, and prevent damaging unit when it is not used in winter.

7．Separate support should be installed for pipeline of water system and external force

shouldn’t be applied on main unit. Usually, spacing of support is determined by material

performance and pipe diameter.

8．Pipeline of refrigeration water and expansion water tank should be insulated. Maintenance

space should be reserved at joint of valves.

9．Pipeline should be wrapped with insulation layer after airtight test to prevent heat transfer

and sweating. Insulation layer should be covered with damp-proof sealing device.

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4 Electrical Wiring

Electrical wiring must comply with low-voltage distribution device and circuit design specification.

Low-voltage circuit breaker for short circuit protection should be installed for power supply circuit.

Rated current of circuit breaker should be at least one class higher than max operating current of

unit.Setting current of transient overcurrent release shouldn’t be more than 1/1.3 of short circuit

current if unit.

4.1 Requirements for Power Supply

1．Power supply of unit should use dedicated power supply system. Total power supply capacity

must be more than the power corresponding to max operating current of unit.

2． Power supply system of unit: three-phase five-wire system: 380V 3N~/50Hz.

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3．Permissible tolerance of source voltage is ±10% and unbalance of phase voltage is less than

2.25%.

%100

voltageaverage

voltageaverage-eMax.voltag

ratiounbalancevoltage ×=

4.2 Wiring Requirements

Carrying capacity of supply power cord should be higher than max operating current of unit and

takes impact of working environment into account. As for unit using duplex power supply, diameter

of two power cords should be the same.

Wiring for user is as follows:

1．Three-phase power supply respectively uses yellow, green, red, light blue and yellow/green

wire corresponding to L1, L2, L3, N and PE.

2．Communication line shouldn’t tightly rely on power cord or be laid parallel with power cord.

3．Confirm phase sequence of power cord when installing power cord. Firmly press connection

terminal, then connect it to power supply terminal of unit. It is must be tightened, otherwise,

disastrous results such as unit failure or even fire hazard will be caused by superheat.

4．After installing power cord, it is a must to carefully check according to wiring diagram and

supply power after ensuring correct wiring.

5． Grounding requirements

Unit must be reliably grounded and wire of earth line is usually selected according to the

following requirements:

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Sectional area of Earth Line

Sectional area of phase wire for device “S”(mm2) Earth line (mm2)

S≤16 S

16＜S≤35 16

35＜S≤400 S/2

400＜S≤800 200

S＞800 S/4

5 Commissioning of Unit

5.1 Preparation before Commissioning
Step 1: Check wiring of power supply and electrical system

 Before initial startup, check if distribution capacity complies with power of the unit and if

diameter of power cable can stand max working current of main unit.

 Check is power system complies with the unit; power system of the unit: three-phase five-line

system (L1, L2, L3, N, PE, 380V 3N~/50Hz), check if phase sequence is correct.

 Check power supply line of compressor and retighten if it is loose. Otherwise, A/C contactor or

even the compressor will be damaged.

 Measure with megohmmeter the insulation resistance of earth line at phase line end of power

supply, and measure the insulation resistance of earth line for motor winding; resistance

shouldn’t be less than 10MΩ; if the insulation resistance of earth line at compressor winding

end is more than 2MΩ, check if earth line is correctly and reliably installed;

 Check if power cord meets capacity requirement.

 Check if circuit breaker is installed on power cord of supply unit.

 Check external wiring (wiring of target flow switch, interlocking control of water pump)

according to wiring diagram and check if inside and outside, especially each wiring joint, of

electrical cabinet are clean without sundries.

Before starting, check if external system of unit meets condition of startup. As for water pump

controlled externally, it’s necessary to firstly open water pump before starting main unit.

 Conduct trial operation when main loop disconnects and check if electrical components act

normally.

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Normal startup sequence of star-delta: switch on power supply; press startup key of unit;

three minutes later, main and star A/C contactor attract; after 2-5s, star A/C contactor

disconnects; angle A/C contactor attracts; unit begins to start at startup load and load

gradually.

Normal startup sequence of shunt winding: switch on power supply; press startup key of unit;

three minutes later, main contactor attract; after main contactor attracts for 0.5s, unit begins to

start at startup load and load gradually.

 Before starting, check if external system of unit meets condition of startup (if refrigeration water

pump and cooling water pump of system are in mode of external control or main linkage; as

for external control, it’s necessary to firstly open water pump before starting main unit)

(enclosed with checklist)

Step 2: Check compressor and refrigeration pipeline

All refrigerant valves (angle valve at outlet of condenser, intake and discharge cut-off valve of

compressor, cut-off valve at connection of high & low pressure switch of compressor) in refrigeration

system should be opened to make refrigeration system smooth;

 Check if oil level in compressor is normal; normal oil level of compressor is usually in the

middle of sight glass;

 Check if protection setting value (shown below) of high and low pressure is normal;

Item Setting value

Protection value of high pressure 1.8MPa

Protection value of low pressure 0.35MPa

Protection value of difference between high and low pressure 0.4 MPa

 Check if pipeline system of unit is damaged during transportation and handling;

 Check if there is pressure in refrigerating system and if there is leaking point of refrigerant;

Step 3: Check Water System

  Check if pipeline of cooling and refrigeration water is cleanly flushed and if there are sundries

at the connection part of cooling and water pool with outside, ensure there are no sundries

and foreign matters in pipe.

 Check if pressure gauge and thermometer at water side are correctly connected. Pressure

gauge should be installed vertically to the water pipe. Thermometer should be installed in

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such as a way to ensure its sensing probe directly inserts into water pipeline.

 Check if flow switch at outlet side of refrigeration and cooing water is correctly installed, and

confirm flow switch and control cabinet are correctly wired.

 Inch refrigeration and cooing water pump and check rotation direction of water pump. Correct

rotation direction of water pump should be clockwise, otherwise retest wiring of water pump.

 Start refrigeration and cooing water pump and enable water flow to circulate. Check if there is

leakage of water pipeline, such as obvious water leakage and dripping.

  Conduct trial operation on cooling and refrigeration water pump. Observe if water pressure is

stable. Observe pressure gauge at inlet and outlet of water pump, there is slight change on

reading of pressure gauge and difference between inlet and outlet pressure when water pressure

is stable. Observe if operating current of water pump is within the range of rated operating current.

If there is great discrepancy compared with rated operating current, check if the resistance of

system is too high, and eliminate system failure until actual operating current meets requirement.

  Check if makeup device of cooling tower and expansion water tank is smooth and if automatic

discharge valve in water system can automatically discharge. As for manual discharge valve,

open discharge valve of refrigeration water pipeline and cooling water pipeline, and evacuate

air from pipe.

  Adjust water flow and check if water pressure drop of evaporator and condenser meets

operation requirement set by unit. In other words, inlet & outlet pressure of refrigeration water

and cooling water of unit should be at least above 0.2MPa.

Step 4: Check A/C end (coil pipe of fan)

 Check if all power supplies of indoor fan coil pipe and control wirings are correct, if fan rotation

is set flexibly.

  Check if all stop valves and flow adjusting valves at inlet and outlet of fan coil pipe are open.

  Check if air in coil pipe of fan is evacuated completely. If there is air in coil pipe, abnormal

noise can be heard. In this case, it’s necessary to rotate manual discharge valve to exhaust

air ad tightly close discharge valve until there is steady water flow

 Check if there are sundries deposited in stagnant water pan of fan coil pipe.

5.2 Operation of Unit

Step 1: Before starting unit, it’s required to preheat crankcase of compressor at eight hours;

Step 2: Properly open coil pipe of indoor fan;

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Step 3: Firstly start refrigeration water pump, then start cooling water pump, listen if there is

abnormal sound from water pump and observe if water pressure is within setting range (pressure

difference of inlet and outlet water is no less than 50KPa). Flow switch protection indicates ultralow

flow of water pump, which requires finding out cause and solving the problem;

Step 4: After starting (add compressor and observe change of high & low pressure), compressor

operates from 25% energy to 50% energy; then compressor performs upload control according to

temperature; when temperature is lower than setting value, compressor offloads. During this

process, it’s necessary to measure if operating current of compressor is within designated range of

nameplate, observe if there is abnormal sound, record parameters such as high & low pressure,

inlet & outlet water temperature, operating current.

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Chapter III Operation and Maintenance

1. Operation Instruction

1.1Button Instruction of Wired Controller

Button

Function

1. start

button

1. Stop

button

Button

Function

1. Switch

picture

upwards.

2. Switch

numerical

value.

1. Switch

picture

downwards.

2. Switch

numerical

value.

1. Switch

picture

leftwards.

2. Return

to

navigation

menu.

3. Move

cursor of

numerical

value

field.

1. Switch

picture

rightwards.

2. Move

cursor of

numerical

value field.

Exit

numerical

value

setting or

function

selection

state.

Enter into

numerical

value

setting or

function

selection

state.

After

modifying

numerical

value,

press this

key to

confirm

input.

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1.2 Operation Instruction of Wired Controller

1.2.1 Setting of Parameter

 First enter into picture whose parameters need to be adjusted.

 Then press . Usually, parameter consists of several digits. It’s allowed to select any

parameter to modify.

 Press and to select digit of numerical value.

 Press and to respectively increase and decrease numerical value within

0~9.

 Press to confirm modifying numerical value of this field and automatically switch to

next field of parameter. If it’s unnecessary to modify numerical value of this field, directly

press to switch to next field.

 When the whole parameter is modified, press

to exit setting state.

1.2.2 Description of Operating Picture
Classification of man-machine picture: It can be divided into three classes by class authority

permission that is managed by third-class password.

¾ Class-1 picture: user picture, which can be accessed without password;

¾ Class-2 picture: picture of Preferences, which can be accessed by using class-2 or class-3

password and maintenance parameter can be modified;

¾ Class-3 picture: picture of Unit setting, which can be accessed by class-3 or super

password and system parameter can be modified;

Design of man-machine picture:

Control program of this version is single/dual unit cooling program, which can only display

corresponding picture according to operating mode of unit.

For example: if single control mode is selected, control parameter and display picture of dual unit

will be concealed.

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Note: The following pictures are subject to modification without notice. Actual pictures shall
apply.

1.2.2.1 Description of Main Operating Picture

After starting, controller displays welcome picture as follows firstly.

When welcome picture is displayed, by pressing will enter into picture of main menu

respectively.

1． Main Display Picture

Left half part of main menu picture

prompts main contents under this menu;

right half part displays main menus for

upward, downward, leftward and

rightward switching.

Fig. 1

By pressing or key, it will enter into another six main menu pictures:

2． I/O State Display Picture

Display current state of input/output contact of

system.

Fig. 2

3．Alarm Picture

Display alarm information for

abnormality of unit operation.

Fig. 3

Flooded Chiller

WELCOME

AUKS Central Air Conditioning

System VX.XX ProgramVX.XX

Home page

Main screen I/O status

User Setting

Detail

I/O status Alarm

Main screen

Detail

Alarm display Unit setting

I/O status

Detail

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4．Factory Setting Picture

This page can be switched to picture of next level

by using third-class password and then operating

parameters of unit can be set.

Change is only allowable for professional

maintenance personnel!

Fig. 4

5. Maintenance Setting Picture

This page can be switched to picture of next level

by using second-class password. Then system

parameters including selection of single & dual unit

system, temperature adjustment, adjustment of

operating hours and parameter backup can be set.

Change is only allowable for professional

maintenance personnel!

Fig. 5

6．User Setting Picture

It can directly enter into picture of next level to set

service parameters, adjust system time and set

automatic ON/OFF function.

Fig. 6

1.2.2.2 Description on Parameter and State Inquiry Pictures

1． Main screen (when it displays main display picture, pressing will respectively enter

into the following pictures and pressing on each picture will switch back to main

picture):

Unit setting Preferences

Alarm

Detail

Preferences User Setting

Unit setting

Detail

User Setting Main screen

Preferences

Detail

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Date xxxx/xx/xx Time xx:xx:xx

CHW in XX.X℃

CTW in XX.X℃

Operation Prompt Operation Prompt

1. Display system time.

2. Current page displays real-time outlet water temperature

a

inlet water temperature.

3. Prompt real-time information of system operation.

Fig. 1

Display relevant operating parameters of unit 1.

Fig. 2

Display relevant operating parameters of unit 2.

Fig. 3

Display pressure value of unit 1.

Fig. 4

Display pressure value of unit 2.

Fig. 5

CHW out XX.X℃

CTW out XX.X℃

1# exhaust XX.X℃

1# suction XX.X℃

2# exhaust XX.X℃

2# suction XX.X℃

1# pressure Inquiry

High pressure X.XXMPa

Low Pressure X.XXMPa

1# oil pressure X.XXMPa

2# pressure Inquiry

2# oil pressure X.XXMPa

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Display operating hours and startup times of unit 1.

Fig. 6

Display operating hours and startup times of unit 2.

(dual-unit system only)

Fig. 7

1. Display current control mode of unit.

2. Display operating hours of water pump.

3. Display current opening of expansion valve.

Fig. 8

3. Alarm Display Picture:

When alarm picture appears, pressing

will enter into the following pictures:

When system sends alarm, this picture will pop up

automatically, display alarm content and record time.

Fig. 3

Display historical record of alarm and record

alarm content, date and time of occurrence (there

are twenty alarm records totally which are twenty

latest records).

Note: 1/20 refers to the first record out of twenty

records.

1# running XXXXXXX Hours

1# start-up XXXXXXX Times

2# running XXXXXXX Hours
2# start-up XXXXXXX Times

Control mode Site control /Remote Control

CTW pump running XXXXXXX Hours

CHW pump running XXXXXXX Hours

Current position XXX %

Instant alarm display picture

Alarm information

DateXXXX/XX/XX TimeXXXX/XX/XX

Alarm Record 1/20

Alarm information

DateXXXX/XX/XX TimeXXXX/XX/XX

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Fig. 4

The second record out of twenty historical alarm

records.

(The same below, omitted)

Fig. 5

1.2.2.3 Preferences of Unit

When this menu appeatrs, pressing will enter password prompt picture and inputting correct

password will enter into the following pictures:

Service setting of unit 1 and unit 2: it is used to

select the start of unit 1 or unit 2. If nonuse is set,

the unit won’t start even startup conditions of this

unit are meet.

Fig. 1

1. Temp drop rate: it is used to set velocity and

temperature drop and judge loading and

unloading of unit;

2. Temp gather: it is used to set temperature

sampling cycle;

3. Temp range: it is used to set temperature of

water return; temperature of water return

plus control temperature of water return is

the reset temperature of unit;

4. Alarm recording: if the same serious failure

occurs three times within 24 hours, unit will

be locked; this item is used to unlock serious

failure;

Fig. 2

1. Setting of Alarm Time Delay

2. when cooling water temperature diff. is

lower than set value, system will send

alarm;

Fig. 3

1# Compressor Use/Nonuse
2# Compressor Use/Nonuse

Temp drop rate X.X ℃

Temp gather XXX Sec.

Temp range X.X ℃
Alarm recording Clear/Cancel

Temp diff max XX.X ℃

Temp diff min X.X ℃

Low pressure X.XX Mpa
High pressure X.XX Mpa

Alarm Record 2/20

Alarm information

DateXXXX/XX/XX TimeXXXX/XX/XX

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1． If high/low pressure difference is lower than set

value, system will send alarm and shut down.

2． If other actual values are higher than set value,

system will send alarm and shut down.

Fig. 4

1．If actual value of cooling water is higher than set

value, system will send alarm and shut down.

Fig. 5

Fill in positive or negative offset according to actual

measurement.

Fig. 6

Fig. 7

Exhaust overheat XXX.X ℃

Oil diff fault X.XX Mpa
Press diff fault X.XX Mpa

Oil diff delay XXX Sec.

Press diff delay XXX Sec.

CTW overheat XX.X ℃

CHW pump running XXX Min.

Unit temp correction

CHW in XX.X ℃
CTW in XX.X ℃

CHW out XX.X ℃

CTW out XX.X ℃

1# exhaust XX.X ℃
1# suction XX.X ℃

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Fig. 8

Fig. 9

Fig. 10

1. Load parameters: load default parameter from system

program into picture;

2. Password change of maintenance personnel;

1.2.2.4 Description on the Following User Setting Pictures:

When this menu appears, pressing will enter into the following pictures:

Setting picture of water return temperature of unit

cooling.

Fig. 1

Cooling control setting

Water in temp XX.X ℃

Load parameters Load/Cancel

Password modify ****

Password again ****

Password modify successful

/Password modify failure

2# oil pressure X.XX MPa

Unit pressure correction

High pressure X.XX MPa

Low pressure X.XX MPa
1# oil pressure X.XX MPa

2# exhaust XX.X ℃

2# suction XX.X ℃

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1. Selection of control mode: when control mode is

set as remote control, it’s possible to conduct

ON/OFF operation with external input point; in

this case, manual ON/OFF function is still

available;

2. Power failure protection function selection of

unit.

3. Status memory function is available during certain

setting time.

Fig. 2

It is used to adjust system clock. It’s possible to

change system time when system time appears under

setting mode and after entering into editing mode.

Fig. 3

After automatic ON/OFF function is enabled, unit will

automatically start and shut down according to set

time.

Note: setting of automatic ON/OFF time doesn’t judge

second (“0” second shall prevail); if both hour and

minute of ON/OFF time are set as 0000, it indicates

this function isn’t enabled.

Fig. 4

When automatic ON/OFF function is selected, priority of each setting is as follows:

Single timer > Holiday timer > Week timer. At this time, manual ON/OFF key is still effective.

It can set start time including year,

month, day, hour and minute of

holiday shutdown and shutdown time

including year, month, day, hour and

minute (it can set consecutive

holidays).

Fig. 5

Holiday timer
Start XXXX/XX/XX XX:XX:XX
Stop XXXX/XX/XX XX:XX:XX

Auto setting Enable/Cancel

Single timer Date XXXX/XX/XX
Start XX:XX:XX Stop XX:XX:XX

System time setting

Date XXXX/XX/XX

Week X

Time XX:XX:XX

Control mode Site control /Remote Control

Status memory Enable/Disable
Holding time XXXXX Hours

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Control system can set and change

timetable of Sunday and Monday ~

Saturday. After the setting is enabled,

unit will operate according to this

timetable every week.

Fig. 6

Timing clear: clear all the setting timer

Fig. 7

2. Maintenance

2.1 Daily Maintenance

 Implement startup and shutdown sequence according to required procedure every day;

 Record operating parameters of unit according to certain timer interval;

 Clean filter of refrigeration water and cooling water one time after unit operates for 24

hours.

 Check pressure of evaporator and condenser of unit according to indication on pressure

gauge on control cabinet. Check difference between evaporation temperature and outlet

temperature of refrigeration water, difference between condensation temperature and

outlet temperature of cooling water, according to comparison table of pressure and

temperature. Pay attention to trend of change. Usually, reading of evaporation should be

0.4~0.6MPa and condensation pressure should be 1.0~1.8MPa.

 Check filter dryer of refrigerant. Frosting at outlet of filter dryer indicates blockage, which is

usually followed with ultralow evaporation pressure and increased difference between

evaporation temperature and outlet temperature of refrigeration water. It’s necessary to

pay attention to timely replace filter dryer of refrigerant;

 Check oil level in oil tank. Oil level is usually set at middle position of sight glass. It’s

Saturday timer
Start XX:XX:XX Stop XX:XX:XX
Timing clear Clear/Cancel

Sunday timer
Start XX:XX:XX Stop XX:XX:XX
Monday timer
Start XX:XX:XX Stop XX:XX:XX

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necessary to timely fill refrigeration oil if oil level drops greatly;

 Any shutdown failure should arouse attention and cause should be analyzed. Before

notifying AUKS customer service department, analysis based on failure help of this

manual may be conducive to the solution of problem.

2.2 Regular Maintenance

Regular maintenance includes weekly, monthly, quarterly, biannual and annual maintenance.

Customer should establish scientific and regular maintenance plan according to the following content,

and implement carefully, which will play very important role for preventing problems.

2.2.1 Weekly Maintenance

Check and analyze record table of operating parameters.

2.2.2 Monthly Maintenance

 Check and analyze record table of operating parameters;

 Check if set bolt of power supply wiring is loose;

 Check if there is noise in each moving part of unit and if operation is set;

 Check if high pressure and low pressure of cooling system is set;

 Check operating current of motor and insulating resistance of unit are set;

 Check if dry filter and sight glass are set; frosting at outlet of filter indicates filth blockage

in filter, which requires cleaning filter net; if there is humidity indication (red color)on

sight glass, it’s required to replace filter element;

 Check if lubricating oil of compressor is set; if oil level is lower than 1/2 of sight glass, it’s

necessary to add lubricating oil; if there is filth or oil is deteriorated, it’s necessary to

replace lubricating oil, clean or replace oil filter ad replace element of dry filter;

2.2.3 Quarterly Maintenance

 Check and analyze record table of operating parameters;

 Check oil level of compressor;

 Clean filter of evaporator and condenser water system pipeline;

 When unit operates under full capacity, check temperature drop of refrigerant generated

when it passes filter dryer.

2.2.4 Biannual Maintenance

 Check and analyze record table of operating parameters;

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 Conduct physical and chemical analysis on refrigeration oil to judge water content and

acidity of refrigerant in unit;

 Check tightness of all electrical joints that may be loose in control cabinet, startup

cabinet and motor.

2.2.5 Annual Maintenance

 Check and analyze record table of operating parameters;

 Check oil level and conduct physical and chemical analysis on refrigeration oil; Replace

refrigeration oil of the same grade if oil is emulsified.

 Replace filter of refrigeration oil when necessary. Maintenance personnel should check

this item.

 Dismantle connecting pipe at outlet of safety valve at last once a year and check valve

body carefully to see if there is corrosion, rust, scale and leakage inside. Replace safety

valve in case of corrosion or leakage. Maintenance personnel should check this item.

 Verify set value of high pressure switch of condenser and ensure high pressure switch

acts at 1.8MPa.

 Check scale formation degree of pipe pass of condenser. Evaporator that connects open-

type system should also be checked. According to result of checking, it can be determined

that if cleaning cycle and treatment of water in water loop are suitable; if serious scale

formation is found, clean pipe pass. Clean heat transfer pipe at least once a year with

rotary cleaning equipment. If water is polluted, it’s necessary to clean more frequently.

Ultrahigh condensing pressure and insufficient cooling capacity of unit are usually

caused by scale in pipe or air in unit. Compare outlet temperature of cooling water with

refrigerant temperature of condenser. If the difference between them is more than 6℃,

scale may have formed in condensation pipe.

Note: during cleaning heat transfer pipe, it’s necessary to use dedicated brush to prevent

scratching and scraping pipe wall. No wire brush is allowed to use.

 Maintenance personnel should detect insulation resistance among motor winding and

grounding resistance of winding.

2.2.5 Maintenance Every Three Years

 Items of the above-mentioned annual maintenance and check.

 Contact qualified maintenance organization such as AUKS local customer

service

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department to conduct overall check for unit. Especially check vibration status of

compressor and ensure parts in compressor are in good conditions; conduct airtight test

on unit and check if copper pipe for heat transfer leaks; conduct non-destructive test on

main weld seams (longitudinal seam and circumferential seam of evaporator and

condenser cylinder) of pressure vessels when necessary to ensure operation safety;

check electrical operation and safety control to ensure electrical parts are in good

conditions.

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Chapter IV After-sales Service

1. Main Parts of Unit

1.1 Main Pats of Cooling System

No.

Name of

Parts

Outline drawing and internal structural

drawing

Description

1

Screw

compressor

Compressor is used to

compress

low-temperature

low-pressure refrigerant

gas evaporated by

evaporator, make it into

high-temperature

high-pressure refrigerant

gas, then send it to

condenser and make

refrigerant to cycle.

This series product uses

semi-closed screw

compressor integrating

motor and compressor.

2

Shell and

tube

condenser

Water-cooled condenser

is used to cool

high-temperature

high-pressure refrigerant

gas discharged by

compressor and

exchange heat with

condensed (liquefied)

heat exchanger and

cooling water.

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3

Shell and

tube

evaporator

Evaporator is used to

evaporate low pressure

liquid refrigerant from

throttling parts after the

refrigerant exchanges

heat with refrigeration

water in evaporator.

4

Orifice

plate

(throttling

part)

Orifice plate is used to

generate pressure

difference by utilizing

change of orifice diameter

and control flow &

pressure refrigerant.

5

Electronic

expansion

valve

(throttle

part)

Electronic expansion

valve is used to change

throttle flow and control

refrigerant flow and

pressure by controlling

step motor.

6 Injector

Injector is used to inject

oil and refrigerant in

evaporator to return air

pipe by using

high-temperature

high-pressure gas and

liquid as injection source.

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6

Dry filter

cartridge

Dry filter cartridge is used

to filter and dry refrigerant

by installing filter element

usually on liquid pipe and

filter element can be

removed.

7 Stop valve

Stop valve is used to cut

off or dredge refrigerant,

which is only applicable to

full opening and full

closing and can’t be used

to adjust and throttle.

8 Globe valve

Globe valve is used to cut

off or dredge refrigerant,

which has throttling

function partially.

10

Angle-type

cutoff valve

Angle-type cutoff valve is

used to cut off or dredge

refrigerant, which is only

applicable to full opening

and full closing, and is not

allowed to adjust and

throttle.

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1.2 Main Parts of Electrical System

No.

Name

of

parts

Outline drawing and internal structural

drawing

Description

1

Contr

oller

Controller is used to
control movement of relay
through program, switch
on and off each part of
unit according to external
conditions such as
temperature and
pressure, and realize
automatic control of unit.

3

A/C

contac

tor

When electromagnetic coil of

contactor isn’t powered on,

reacting force of spring and

deadweight of armature core

keep main contact at

disconnected position. When

electromagnetic coil is

powered on, electromagnetic

force attracts armature

towards static iron core by

overcoming reacting force of

spring, which drives main

contact to close, switches on

circuit. AUKSiliary junction

acts accordingly.

4

Therm

al

relay

Thermal relay is usually

composed by overcurrent

element of bimetal. When

current is too high, bimetal

will generate heat that makes

it deform, offset and pry up

protective contact. Control

loop of contactor disconnects

and power of main circuit

fails. Then,

temperature drops, bimetal

cools, circuit is switched on

again. However,

self-insurance control loop of

main circuit has disconnected

and it’s necessary to press

“Start” button again to start it.

Normal open main contact

Normal closed AUKSiliary contac

t

Normal open AUKSiliary contact

Armature

Sucking coil

Iron core

Arcing chamber

Reset rod

Setting knob of current

Thermal element

Contact

Driving push rod

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5

Senso

r

It is a kind of electrical

element used to detect

temperature and pressure,

whose physical

characteristics vary with

change (e.g. resistance of

NTC varies with change of

temperature) of temperature

and pressure.

2. Function and Control of Unit

2.1 Function and Control of Unit

Manually ON/OFF

By pressing “start” button on controller, unit starts after 5s; when it’s necessary to stop operation, by

pressing “stop” button, unit shuts down.

Timely ON/OFF

Users can set ON/OFF time in for of year, month and day, or set ON/OFF time for a week or set

ON/OFF time for every day. If user sets ON/OFF time, unit automatically starts and shuts down at the

set time.

ON/OFF Control Process of Unit

 Electrify control cabinet and preheat oil heater of compressor. unit can be started after oil

heater is preheated at least eight hours;

During startup process, firstly start refrigeration/cooling water pump; after time is delayed for 60S,

unit begins to start. If water temperature exceeds set value plus 2℃, compressor starts; Compressor

operates at 25% at first and switches to operate at 50% 30S later, then loads according to

temperature.

 In case of shutdown, unit unloads to 25% and shuts down after operating for 30 seconds. Stop

cooling and refrigeration water pump after time is delayed for 180S.

 If cooling water pump isn’t interlocked with refrigeration water pump, it’s required to stop cooling and

refrigeration water pump after compressor stops and time is delayed for 180S in case of shutdown.

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2.2 Loading/Unloading Process Control of Unit

 When shutdown time of compressor exceeds set time of 300S and return temperature of

cold water exceeds set value plus 1℃, compressor starts. When starting, it automatically

selects and makes head with the shortest time start firstly.

 Unit operates by loading when return temperature of cold water is in loading area and

speedup loading area.

 Unit unloads when return temperature of cold water is in unloading area. All compressors

stop operation if return temperature of cold water reaches emergency shutdown area.

 Time interval of previous ON/OFF and next ON/OFF of each heads is at least five

minutes.

2.3 Protection Function

Flow Protection of Chilled Water Pump
Prerequisites for flow protection of refrigeration water pump:

① After refrigeration water pump operates for 30S in case of set operation or power-on initial

startup;

② ON/OFF state reflected by flow of refrigeration water pump is OFF state;

Emergency

Shutdown Area

Unloading Area Stability Area Stability Area loading Area Speedup Loading

Area

T

set

=12

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③ Abnormal tie delay of water flow reaches 5S;

Conditions for exiting flow protection of refrigeration water pump:

Manually reset and set flow feedback of refrigeration water pump.

Flow Protection of Cooling Water Pump
Prerequisites for flow protection of cooling water pump:

① After cooling water pump operates for 30S in case of set operation or power-on initial startup;

② ON/OFF state reflected by flow of refrigeration water pump is OFF state;
③ Abnormal tie delay of water flow reaches 5S;

Conditions for exiting flow protection of cooling water pump:

Manually reset and set flow feedback of cooling water pump.

High Pressure Protection

Prerequisites for high pressure protection:

① Unit is under operation or standby state;

② Pressure of high pressure sensor is higher than [set value of overhigh protection for high

pressure] maintenance (second-class);

③ Abnormal time delay reaches 3s;

Conditions for exiting high pressure protection:

Manually reset and lock it after three times of accumulated protection within 48 hours.

Temperature Difference Protection of Insufficient Water Flow

Prerequisites for temperature difference protection of insufficient water flow:

① Unit is under operation state;

② Inlet and outlet water temperature difference of condenser is no less than 8℃ and abnormal

time delay reaches 1min.

Press “shutdown due to serious failure” to enter into standby state after entering into

temperature difference protection of insufficient water flow.

Conditions for exiting temperature difference protection of insufficient water flow:

Manually reset and lock (password is controlled by maintenance personnel) it after three

times of accumulated protection within 48 hours.

Temperature Difference Protection under Too Large Water Flow

Prerequisites for temperature difference protection under too large water flow:

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① After compressor operates for 10min;

② Inlet and outlet water temperature difference of condenser is no more than 2℃ and

abnormal time delay reaches 1min.

Conditions for exiting temperature difference protection under too large water flow:

Manually reset and lock (password is controlled by maintenance personnel) it after three times of

accumulated protection within 48 hours.

Low Pressure Protection

Prerequisites for low pressure protection:

① Unit is under operation or standby state;

② Pressure of air suction pressure sensor is lower than [0.39MPa] set value of ultralow protection

for low pressure] maintenance (second-class), and abnormal time delay reaches 10S;

Conditions for exiting low pressure protection:

Manually reset; pressure of air suction pressure sensor is higher than ultralow protection of low

pressure plus 0.15;

Overload Protection of Compressor

Prerequisites for overload protection:

① Unit is under operation or standby state;
② Overload switch is under On state and protection time delay reaches 3s;

Conditions for exiting overload switch protection:

Manually reset; overload switch is restored to OFF state.

Anti-freezing Switch Protection
Prerequisites for anti-freezing switch protection:

① Unit is under operation or standby state;

② Magnetic anti-freezing switch (4℃) disconnects.

Conditions for exiting anti-freezing switch protection:

Manually reset;

Ultralow Outlet Water Temperature Protection (no alarm information)

Prerequisites for ultralow outlet water temperature protection:

○1 Unit is under operation or standby state;

○2 Outlet water temperature is no more than 5℃.

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Press “unloading & shutdown” flow to enter into standby state after entering into ultralow outlet

water temperature protection.

Conditions for exiting ultralow outlet water temperature protection:

Water return temperature is no less than [set water return temperature of refrigeration water] plus 2;

manually reset.

Ultrahigh Discharge Temperature Protection

Prerequisites for ultrahigh discharge temperature protection:

① Compressor works;

② Discharge temperature T

discharge

is higher than [ultrahigh discharge temperature]

(second-class password).

Conditions for exiting ultrahigh discharge temperature protection:

Lock it after manually reset three times and accumulated protection three times within 48 hours

(discharge temperature “T

discharge

“ is no more than [ultrahigh discharge temperature] minus

25℃ );
Temperature Sensor Failure Protection
Prerequisites for temperature sensor failure protection:

① Sensor is under open circuit or short circuit;

Conditions for exiting sensor failure protection:

Manually reset; setting of corresponding temperature sensor is restored;

Pressure Sensor Failure Protection

Prerequisites for failure protection of pressure sensor:

① Pressure sensor is under open circuit or short circuit and time is delayed for 3s;

Conditions for exiting high pressure sensor:

Manually reset and failure is eliminated.

Oil Pressure Difference Protection (high pressure – oil pressure)

Prerequisites for oil pressure difference protection:

① Compressor works (shield in case of shutdown);
② Oil pressure difference is higher than [0.2mpa], and time delay protection [time delay of oil

pressure difference protection] reaches 40S;

Conditions for exiting oil pressure difference protection:

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Manually reset and lock (password is controlled by maintenance personnel) it for three times; oil

pressure difference switch is under ON state.

High/Low Pressure Difference Protection (high pressure – low pressure)

Prerequisites for high/low pressure difference protection:

① Compressor works (shield when it is started less than 2min or in case of shutdown);
② High/low pressure difference is less than [0.4mpa], time delay protection [time delay of

high/low pressure difference protection] reaches 40S;

Conditions for exiting high/low pressure difference protection:

Manually reset; switch of high/low pressure difference is under ON state.

Oil Level Protection of Compressor

Prerequisites for oil level protection:

① Compressor works (shield in case of shutdown);
② Switch of oil level protection disconnects and time delay protection reaches 30S;

Conditions for exiting oil level protection:

Lock (password is controlled by maintenance personnel) it one time and oil level switch is under

ON state.

Ultrahigh Temperature Protection of Cooling Water

Prerequisites for ultrahigh temperature protection of cooling water:

Outlet temperature of cooling water is no less than 40℃ [ultrahigh temperature of cooling

water];

Conditions for exiting temperature protection of cooling water:

① Outlet temperature of cooling water is no more than 40℃ [ultrahigh temperature of

cooling water] minus 7℃ (automatic reset) ;

② Protectively lock it three times (password is controlled by maintenance personnel).

3. Failure Analysis and Solution

3.1 Analysis and Solution of Failure with Failure Code

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High Pressure Protection

NO

→

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

YES

YES

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Low Pressure Protection

→

YES

YES

YES

YES

NO

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

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Discharge Temperature Protection

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

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Failure of Temperature Sensor

NO

YES

YES

YES

NO

NO

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Overload Protection of Compressor

NO

NO

NO

YES

YES

YES

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Protection of Water Flow Switch
S

YES

YES

YES

YES YES

NO

NO

NO

NO

NO

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Protection of High/Low Pressure Difference

NO

NO

NO

NO

YES YES

YES

YES

YES

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3.2 Analysis and Solution of Failure without Failure Code

No Display on Controller

Namely that controller doesn’t display anything.

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

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Water Temperature can’t reach Set Point

Water temperature can’t reach set point despite of longtime startup.

YES

YES

YES

YES

NO

NO

NO

NO

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No Startup of Compressor After Starting

Compressor doesn’t start after pressing start key and normal time delay.

YES

YES

YES

YES

NO

NO

NO

NO

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4. Failure Detection of Electrical Parts

No.

Name of

Parts

Detection Methods

1 Compressor

1. After detecting with OHM range of multimeter, there is correct resistance

value (three-phase resistance value of compressor should be

approximately the same) among windings. Winding resistance to shell

resistance should be infinite.

2 Contactor

1、 Movable contact should act flexibly without blocking after contactor is

manually pressed.

2、 Contact of contactor shouldn’t be burnt out.

3、 Coil should have resistance value below K-class, but shouldn’t be “0”

or infinite.

3 Sensor

1. Measure resistance value with multimeter and find out temperature by

referring to resistance table. The temperature should be the same as

the temperature at location of sensor.

2. Resistance value shouldn’t be “0” or infinite.

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5. Schematic Diagram of System and Electrical Schematic Diagram

Schematic Diagram of Screw Unit System with Flooded-type Independent System:

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Schematic Diagram of Flooded-type Double-head Screw Unit System:

Cooling cycle: compressor sucks low-temperature low-pressure refrigerant from evaporator into

compressor and discharges them into oil/gas separator after compressing them into

high-temperature high-pressure gas; in oil separator, oil carried by high-pressure gas is

filtered, remained in oil separator and then it returns to compressor through oil return pipeline;

the filtered high-pressure gas comes into condenser; in condenser, high-temperature

high-pressure refrigerant gas exchanges heat with cooling water in pipeline, condenses into

high-temperature high-pressure refrigerant liquid after transferring heat to cooling water, and

comes into evaporator after being throttled, cooled and depressurized by orifice plate or

electronic expansion valve; gas-liquid two-phase refrigerant coming into evaporator totally

evaporates in evaporator to cool down refrigeration water; vapor from evaporator is sucked

and compressed by compressor again. It cycles continuously in this way. Cooled refrigeration

water is sent by pipeline to end equipment, creating comfortable living and working

environment.

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6. Exploded Chart and Bill of Material

Exploded Chart of Screw Unit with Flooded-type Independent System:

N0. Material code Part Name-Chinese Part Name-English Quantity Remark

1

压缩机

Compressor 1

2

毛细管

Capillary pipe 1

3

回油引射泵

Injection pump of oil

return

1

4

电控箱组件

Component of electric

control cabinet

1

5

油分离器(卧式)

Oil separators

(horizontal-type)

1

6

壳管式蒸发器

Shell and tube

evaporator

1

7

壳管式冷凝器

Shell and tube

condenser

1

8

干燥过滤筒

Dry filter cartridge 1

9

角阀

Angle valve 1

10

球阀

Two way ball valve 1

Exploded Chart of Flooded-type Parallel Screw Unit:

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N0. Material code Part Name-Chinese Part Name-English Quantity Remark

1

壳管式冷凝器

Shell and tube condenser 1

2

壳管式蒸发器

Shell and tube

evaporator

1

3

电子膨胀阀阀体

Body of electronic

expansion valve

6

4

电子膨胀阀线圈

Coil of electronic

expansion valves

6

5

回油引射泵

Injection pump of oil

return

2

6

电控箱组件

Electric control 1

7

油分离器(卧式)

Oil separators

(horizontal-type)

1

8

压缩机

Compressor 2

9

干燥过滤筒

Dry filter cartridge 1

10

节流电子膨胀阀 ETS

Electronic expansion

valves ETS

1

11

角阀

Angle valve 2

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•Consultation Service – AUKS headquarters and all distribution centers

have established service hotline to accept consultation from users.

• Training and Technical Support –users are welcomed to contact AUKS for any

problem related to technology of A/C system. AUKS will provide
training and technical support on operation and management
of A/C system for users free of charge.

•After-sales Service System – If A/C system breaks down, users can dial service

hotline of headquarters or number of local authorized
maintenance station. Maintenance personnel will quickly go
to the spot and deal with the problem within 24 hours after
receiving service requirement.

•Return visit and Follow-up Service – AUKS provides effective return visit and follow-up
services for the sold products and customer service status.

• Content published in this material may subject to change due to product update without notice.

• This material has proofread many times to ensure accuracy. However, it is used for reference only.

Everything should subject to physical object, nameplate of product and instruction manual.

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_______________________________________________________________________

ADD：NO. 1166 North MingGuang Road (AUKS Technology park), JiangShan
Town, Zhejiang, P.R.China
TEL:[phone]
FAX:[phone]
CODE：315191
URL：http://www.cnAUKS.com
VERSION: Flooded Type Water Cooled Screw Chiller-2010-01