Catalogue

Company Introduction-----------------------------------------------------P2

Product Introduction-----------------------------------------------------P3-4

ChapterⅠ Installation--------------------------------------------------P5-17

1.1 Preparation before Installation

1.2 Swing and Placement

1.3 Pipe Connection

1.4 Refrigerant Charging

1.5 Electricity Connection

ChapterⅡ Operation--------------------------------------------------P18-35

2.1 Inspection Item before Operation

2.2 Unit Operation

2.3 Operation Control

2.4 Operation Guidance and Stop Notice

ChapterⅢ Maintenance and Fault Processing-----------------36-44

3.1 Summarize

3.2 Maintenance

3.3 Water Quality Management

3.4 Fault Processing

Operator should be completely familiar with the operation manual and other
necessary files before initial installation and debugging of the water cooled
screw-type chiller. Then read this manual to realize the relevant installation,
debugging, maintenance and requirement. Thereby to assure the installation is
correct and the unit is operated in the optimum condition.

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  Company Introduction:
Establish in 1992,HStars group is a foreign Investment company which has
been professionally manufacturing Central Air-conditioning Equipments,
Industrial Chillers, S&T heat exchangers, Air handling unit, Fan coil units and
whole refrigerating system solution.
The products are widely used in Hotel, Shopping mall, Electronic fields,
Pharmacy, Plastic Injections industry…
From the beginning, we have been focusing on the product’s quality to meet
customer’s requirements. Meanwhile, Stars has been creating the
value-added service. Our system aim at the energy saving, clean and green.
Today, Stars yearly turnover has achieved more than 15 million U.S dollars
and has been one of the biggest AC equipments suppliers in China;
furthermore, our marketing network has covered all Chinese territory.
Based on more than 10 years professional experiences, we get many awards,
such as ISO9001:2000, CE(PED) certificate. Moreover, we also got high
praise from our clients “most reliable manufacturer” many times
Stars will go on moving forwards based on continuous research&
developments to build “Comfortable Environment” for all the end-users. We
would like to join with your hand for our prosperous future.
More information about us, please visit our website: www.chillermaker.com &
www.hstars.net.
Water cooled screw-type low temperature chiller units with heat recovery is a
central air conditioning which take the water as the coolant medium, its
condenser and evaporator adopt the special high efficiency heat tube,
compared to the same cooling capacity air cooled chiller, its more compact,
efficient and small size. The noise is very low because the unit does not has
the condensate blower. The heat recover can reclaim the heat while the unit
operate, and used to get the hot water and heating.
We have developed technique, sophisticated technologies and advanced
testing equipment of manufacturing the water cooled screw-type low
temperature chiller units with heat recovery. Superadd the international
well-chosen components, so that to guarantee the unit operate steady and
high efficient.

2
  Product Introduction

1. Unit name plate---generally place on the left side of the control box

2. System Part

 Compressor
Equipped with semi-hermetic screw-type compressor with double screw,
differential-pressure feeding for lubrication system, and pump for lubricating oil
not needed. Piston valve applying for multi-stage capacity control, motor of two
poles three phases’ induction motor. Use refrigerant cooling, ensuring correct
driving direction of screw, equipped with protection for wrong phase.
Discharging gas temperature overload protection is set to prevent discharging
gas temperature too high.

 Condenser
It applies the tube condenser, the heat exchanger tube is the copper tube, the
end cap is demountable,avail to demount the end cap to clean the copper tube.
The fusible plug on the condenser is to gurantee the cooling system operate
safely.

 Evaporator
Dry type shell and tube evaporators and heat exchangers apply inner finned
copper tube, and are equipped with refrigerant distribution device so as to
distribute refrigerant homogeneously to heat exchanging tubes and improve
thermal efficiency. As to chillers with multi-compressors, each compressor has
its evaporator and condenser, and these three units comprise of separate
refrigerating system. As a result of its structure, normally water ways of two
evaporators are connected, but refrigerating circuits still work separately.
Evaporators are covered with heat preservation material to prevent loss of
cooling capacity.

 Thermal expansion valve

3
Use imported thermal expansion valve to ensure reliability of performance of
refrigeration system, accuracy and long service life of expansion valve.

 Heat recovers
Heat recover utilize the effect of refrigerant steam exchange the heat with the
water, transform the exhaust heat to available hot water. So that to achieve
energy-saving. This was called “desuperheater” or “wate heater” in America, is
a kind of commendatory energy-saving equipment, and more and more people
like it now.

 Components of system
Main components of refrigerating system and control system are adopt
imported elements, which is featured with high quality and performance, so as
to ensure accuracy and reliability of refrigerating system.

4
  Chapter One Installation

1．1 Preparation before installation

1.1.1. Special machinery room for the unit. Exhaust the heat from the
machinery room which was caused while operation, the air flow capacity is to
keep the temperature inside the room below 40 centigrade.
1.1.2. The unit should be installed on a ametabolic rigidity base or a flat
concrete foundation, which can endure the weight while unit operate.
1.1.3. Install gutter or something that can drain the water around the base of
the unit, with the purpose to drain the water from the system when stop
seasonally or maintenance.
1.1.4. Enough room should be prepared for installation and maintenance in the
machinery room; No pipeline or hose can be put above the compressor.
1.1.5. Suggest to remain space between the hose and unit when install the
vulcanite nozzle, so as to keep enough space for construction and
maintenance after the unit arrival.
1.1.6.The unit should keep far away from the high humidity, bad air pollution or
corruptive Aluminum/copper environment.
1.1.7. Stuff and tools to be prepared: flexible joint, antivibration cushion,
hoisting equipment, hoisting beam, sling chain, skid, roller, crowbar.

1.2 Swing and Placement

1.2.1 Swing
Suggest to transit by crane.
1.2.1.1. Before delivery, the chiller has been tested and packed, so as to make
sure the unit can be transferred to the destination at the right situation. The
mounter, bearer and the hoisting worker should avoid the angle valve, pipes
and some other place to collision, or improper operation to damage the unit,
otherwise the refrigerant will leak out.
1.2.1.2. Keep the chiller horizontal when transfer, crane with the lifting mark is
available, use the bottom holding hole. Strutting should be put to the place
where sling contact the unit, and ensure the sling can hold the weight of the
chiller. Otherwise it will make serious bodily injury or damage to the chiller. Do

5
not use the forklift to lift or move the unit.
1.2.1.3. If do not have the vertical lifting equipment, horizontal scroll method
can be used, use the jack to lift a certain high, put the roller under the skid
base, take down the skid after the unit was rolled to the position. The strength
can only be put on the frame or the skid by using this method.

Notice:Do NOT damage the chiller, remain the unit on the

skid when haulage or swing, remove the skid unless the unit is in

1.2.2 Placement
After the unit is in right position, remove the skid, adjust horizon by bubble cell,
fix the bottom of the chiller to the base by using anchor bolt. Suggest to put a
15~20 cm anti-vibration cushion between the bottom of the chiller and the
base.
The chiller shall be installed in basement, ground floor or special machinery
room. If install in the building is necessary, make sure the floor can endure the
running weight of the chiller, reinforce the floor board if needed. Meanwhile,
check the floor if it is horizontal. We suggest to set the spring snubber
according to the running weight.

Notice:This chiller is not suitable for open field that without

any protective measures

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1.3 Pipes connection
Do the construction of the water pipes after the chiller has been installed, or
connect the arranged water pipes to the evaporator and condenser.

1.3.1 General requirement

1.3.1.1. Water pipe line installation and insulation work shall be designed and
directed by professional under the relevant rules of HVAC Installation criterion.
1.3.1.2. Connect the inlet/outlet water pipe line as the requirement on the unit.
General requirement is: the lower line of the condenser is inlet while the upper
line is outlet; but for evaporator, face the electrical cabinet, the right side is the
chilled water outlet while the left side is inlet.
1.3.1.3. In order to ensure the normal water supply, select the proper flow and
delivery lift water pump. Besides the anti-vibration flexible joint among the
water pump, the chiller and the water pipe line, there should be set bracket to
avoid taking strength. The weld also should be avoided damaging the unit.
1.3.1.4. Install the flow switch on the evaporator and condenser’s outlet pipe
line. Interlock the flow switch and the connection point in the cabinet. The
install requirement as below:

* Flow switch should be vertically installed on the outlet line.

* There should be five times diameter straight length than the pipe line on
both sides of the flow switch; do not install the flow switch near the syphon,
pore plate and valve.
* The direction of arrow should accord with the water flow direction.
* Exhaust the air in the water system to avoid the shake of the flow switch.
* Adjust the flow switch, make it in discrete state if its flow rate below the
lowest flow, (the lowest flow is 40% of designed flow). And make it in close
state if the flow satisfy the request
1.3.1.5, Above 16 mesh water filter should be installed ahead of inlet line
1.3.1.6. Rinse to the pipe lines and heat preservation should done before
connected to the chiller, avoid spoiling the chiller.
1.3.1.7. The designed hydraulic pressure burden of evaporator water side is
1.0Mpa. While for condenser the hydraulic pressure burden is 1.0Mpa. Do not
over-pressure use in order to protect the evaporator and condenser. If have
7
any special request for the water side, please contact us.

Warning: Strictly do not connected to the chiller before the

pipe lines has been rinsed

1.3.2 Connection of the condenser pipe

1.3.2.1. Chilled water pipe system should be installed anti-vibration flexible
joint, thermometer, pressure gauge, drain valve, stop valve, water filter and
target meter controller first, then connect to the inlet & outlet of the cooling
tower. Please see the connection diagram Ⅱ as below:

Ⅱ Chilled water connection diagram

COOLING TOWER

FLOW SWITCH MANOMETER

TEMPERATER

GATE VALVE DAMPING JOINT

COOLING WATERR OUTLET

FILTER CLAPPER VALVE COOLING WATERR INTLET

COOLING WATER PUMP

BACKER COOLING WATER PUMP

1.3.2.2. The water supply line should be short as soon as possible, the
specification of the pipe should be decided by the water pump’s effective head,
lines flow and rate, but not by the specification of the joint.
1.3.2.3. Drain and exhaust joint should be installed on the condenser pipes.
1.3.2.4. The direction of the condenser water pipe can be changed according

8
to user’s request, please notice the below items:
* Affirm the right clapboard position, using new grommet.
* The temperature of the chilled water, flow measuring equipment need to
be redispose.
* When dismounting the end cap of the water chamber, binding the bolt
need to follow the order: lightly bind the first bolt, then bind the second bolt on
the opposite of the first one, then follow this way bind the third one, then bind
the fourth one which is on the opposite of third one. After binding the first lap
bolts, follow this way bind all the bolts until they accord with the corresponding
torque of tableⅠ(Notice: Do not bind the bolt to its ultimate torque when the
first lap binding. That will make the surface of the flange tilting and water leak.
Use the torque spanner, adjust the torque to one-third of the ultimate torque
when binding the first lap)
TableⅠ Recommend ultimate torque of binding bolt
Seal with rubber flat gasket
Bolt spec.
Min. torque Max. torque
M10 16 24
M12 45 68
M16 95 122
M20 142 210

Notice: One drain pipe should be installed to the chilled

water outlet pipes, the bypass pipe for rinse and maintenance

1.3.3 Connection of the evaporator pipes

1.3.3.1. Chilled water pipes should be installed anti-vibration flexible joint,
water filter, thermometer, electronic scale-borer, target meter controller,
exhaust valve, drain valve, stop valve and expansion tank. Please see diagram
Ⅲ。

9
 Ⅲ Chilled water pipe diagram

CHILLED WATER INLET CHILLED WATER OUTLET EXPANSION

TANK
AIR CONDITIONING
END EQUIPMENT

GATE VALVE

FLOW SWITCH
CLAPPER VALVE

DAMPING JOINT MANOMETER

CHILLED WATER PUMP TEMPERATER

BACKER CHILLED WATER PUMP

FILTER

CUT-OFF VALVE BY-PASS VALVE

1.3.3.2. Expansion tank should be installed at 1-1.5 meters over the top of the
chiller, the volume of the tank is approximately one tenth of the whole system’s
water capacity.
1.3.3.3. There are drain connection on the evaporator, 3/4 inch brass ball valve
has been installed to the outlet.
1.3.3.4. Avoid any vertical movement of the water pipes, set a manual or
automatic exhaust valve between the high place of the pipe and expansion
tank.
1.3.3.5. Set a thermometer and pressure gauge on the straight length of inlet
and outlet pipes, instead of installed near the syphon. To drain the relict water,
each low place should set a discharge joint. Between the inlet and outlet of the
evaporator, there should be a by-pass line, convenient to rinse, maintenance
and adjust flow.
The flexible joint can reduce the transfer of the vibration.
1.3.3.6. Heat preservation treatment is necessary to the chilled water pipes
and expansion tank, the valve joints should remain some place for
maintenance.
1.3.3.7. Enwind the insulating course after airtightness test, to avoid heat
transfer and sweating, the insulating course should has dampproof
confinement.

10
1.3.4 Connection of the heat reclaimer pipe (Only for the chiller with the
heat recover)
S C H E M A T IC D IA G R A M O F D O M E S T IC W A T E R M O U N T IN G

H E A T R E C O V E R Y

W A TE R
S U P P LY

W A TE R TA N K

LE G E N D S

P U M P TE M P E R A TE R

D A M P IN G J O IN T P R E S S U R E C O N TR O LLE R

G A TE V A LV E S TO P C O C K
FLO A T V A LV E
C LA P P E R V A LV E

1.3.4.1. Insulation cabinet and circulating water pump need to be installed due
to water inertance, storage volume and usage amount. Keep the storage water
remain the request temperature(50°C-60°C)
1.3.4.2. Insulating course should added to the tank, so as to reduce thermal
热 水 系 统 安 装 说 明
losses. The volume should be designed by the constructional force by the field,
power of the
1.由unit,
于 考 usage
虑 水 amount
惯 性 , 刹and
间 使user’s
用 量 request.
及 储 存 量
,系 统 必 须 配 置 保 温 箱 及
循 环 水 泵 ,让 储 存 热 水 经 常 保 持 在 要 求 温 度 (50 C-60 C)。
1.3.4.3. In order to keep the hot water’s temperature, circulating water pump
need to be long term loading and equipped pump.
1.3.4.4. Two or more pressure water pump need to be installed to the hot
water system, its flow and head are designed to requirement, and controlled by
the pressure controller within 24hours
1.3.4.5. This system supply user ultra-low-cost hot water, but the hot water
flow is determined by the usage of the chiller and season. User should retrofit
another hot water assistant system when use this system, parallel-use.

11
 1.3.5 Connection of the water source heat
The cool and heat switching is the water line switching, the connection is as
below:
EXPANSION
TANK

AIR CONDITIONING
END EQUIPMENT

TEMPERATER FLOWSWITCH
P

MANOMETER
BY-PASS VALVE

GATE VALVE

GROUNDWATER
PIPING

FILTER PUMP DAMPINGJOINT SWITCHING BOX FOR HOT AND COLD WATER PIPELINE

1.4 Charging of the refrigerant

About how to charge the refrigerant due to the installation or maintenance is as
below:
1.4.1 Extract the vacuum till under 1bar by using the vacuum pump.(refer to
the chiller pressure gauge) , it prove that vacuum test is qualified if no
changes occurred to the pressure gauge after 12 hours.
1.4.2 Make sure the chilled water pump is load after the vacuum test is
qualified, when the chilled water is in flowage in the evaporator, inject
prescribed volume refrigerant through the angle valve at the bottom of
the condenser.

1.5 Electric connection

To avoid the terminal joint corrosive or overheat when connected the pipes, all
the electrical wire are required to be copper conductor. The cable and power
line should be installed separately and retrofit protective pipes. This will
prevent the power line disturb the cable. The cover of the chiller should
be earthed. Meanwhile do not put the low-pressure control line(24V) into

12
the same line tube with those conducting wire that larger than 24V.

Caution: In order to avoid loss of life. Cut off the electricity supply

before all the pipe liens are connected to the chiller.

1.5.1 Electricity power
1.5.1.1. Connect the power line to the control cabinet after the chiller is
delivered to the field.The Inlet of the control cabinet is on the top of it. The
inlet lines should be one meter higher than the chiller, and no pressure is
allowed to give to upper cabinet. Connect the power line to joint R,S,T,N,
rebinding the joint after operate for 24 hours(the shortest time permitted)
Notice: A separate power supply box is supposed to use for water
pump and cooling tower fan.
1.5.1.2. The power part in electric control cabinet contains: main power copper
bar connection, Y-Δ compressor start electric installation.
1.5.1.3. The power supply for the chiller is: 3N~ ， AC440V ， 60Hz. External
power need to coincide with the chiller’s electric character. The main power is
connected through eye needle orifice at the upper place in the back, and
connected with power copper bar connection or terminal.
1.5.1.4. All power supply installation should meet the Chinese Eclectic
Criterion.
1.5.1.5. All power lines connected to the control cabinet should refer to the
RLA current on the nameplate. Main power furnish should has some allowance,
suggest value is over 1.25~1.3 times than the unit parameter. The carrying
capacity should a bit large than the largest current of the chiller, and consider
the affection of the environment. User’s self-contained power supply should be
earthed and automatic cut-out device the same as in the control cabinet. The
super-current chiller should apply to double circuit power supply, but both of
the power line should be the same brand and equivalent.

1.5.2 Control
The core control part of central air conditioner of the water cooled screw-type
chiller with heat recovery applies the micro-computer control touch screen
system, the control interface has Chinese and English language, is very

13
convenient to control,
The whole control system is highly automatic with stable performance.

1.5.2.1, Relay is installed in electric cabinet, power line fault indicating lamp,
connection terminal, and programmable controller. The control box type is
depended on different compressor and customer's request.。
1.5.2.2．The front part of electric cabinet is stop switch of control cabinet.
1.5.2.3 ． The electric connection must accord with Chinese Standard
Specification, all control circuit is 220 voltages, the connection way refers to
the virable drawing inside.
1.5.2.4, If the chiller is composed by mainframe unit and subsidiary unit, the
communication line between them should apply shrouding wire with protecting
sleeve pipe, and separately laid.
1.5.2.5, All the control output cable in the field should be AC250V-1mm2
（24V）.。
1.5.2.6, Notice: Read the electrical connection drawing carefully and connect
all the lines strictly under the connection terminal drawing; The connection line
for the temperature sensor should be three-core shielded
cable(RVVP3×0.5mm2); The connection line for flow switch should be twin
core cable(RVV2×0.5mm2), the point connected to is the point when no water
obtained. The interlocking of cooling tower fan, chilled water pump and cooling
water pump is the parasitic contactor inside the control cabinet. The remote
start and stop can connect two point starting button.
1.5.3 Control accessories interlock
1.5.3.1, The line between the control cabinet and main motor, electrical power
element and pressure temperature and some other transducer components
has been connected. It is very simple for the line connection after the chiller
reached the field. The chiller without cooling tower only have to connect the
chilled, cooling water switch, chilled and cooling water pump gang control lines;
The chiller without cooling tower should connect to cooling water temperature
sensor, chilled and cooling water flow switch, and the gang control line for
chilled and cooling water pumps.
1.5.3.2, No target meter controller was installed to the chilled and cooling

14
water pipes, please install to the outlet of the chilled and cooling water, the
connection for normally open contactor of chilled and cooling water system's
target meter controller should connected to control circuit.
Note: The cabinet may stop the chiller within continuous 10 seconds after it
receive the stop comint, for the tohubohu of the water flow may mistake the
flow switch.
1.5.3.3, Lubricating oil or other grease which will not concrete when it lower
than the outlet temperature of the chilled water should be injected into the
sensing probe installation tube, enabling the heat transfer, the sensor should
insulating and hermetic.

15
 1.6. Screw-type water chiller debugging process

1. 6. 1. Preparation before debugging：

Confirm refrigerant Pressure gauge not point

to zero graduation，
volume

Main circuit in cabinet and

Be sure compressor angle control circuit line not
valve& liquid solenoid valve confirmation of angle valve and flexible, insulating
opend connection resistance is normally or not

Confirmation of main power Normal voltage, correct

sequence

All valves Confirmation of water system

Chilled &cooling water
opened, pipes installation, accord with installation
injected into pipes,
cleaned requirement
exhaust air

Chilled & cooling water Screw unit powe on 12 hours before test running
switch installation and
connection correct

Operation controller, inlet

Inspect the main unit with power
Confirm oil heater work well &outlet temp. shows normally

abnormal labnorma

Check the heater and connection check if there are conducting oil
in temperature detector tube of
the inlet &outlet temperature
transducer
Preparation is ready, electrify to preheat

16
 1.6.2. Debugging：

Start the unit 12 hours after preheat

Whether running direction is right Debug water pump Run smoothly,Not too much noise

Water switch runs correct

Confirm inlet &outlet water pressure, take record

Open auto-exhaust valve, exhaust the air in the system, water pump
operate over 15 mins, let the water system operate smoothly

Confirm the cooling tower runs normally

Confirm the feed flow

Whether pressure change is Start the chiller after confirm parameters
solenoid valve behind the
right when start compressor
condenser has electrified

Press the Stop button and fine the reason Whether the unit is load 25% 50%
if high pressure turns low while low 75%, the relevant solenoid valve is
pressore turns high electrify untill 100%，then disconnect
5

ii Recording temperature of inlet

Recording the suction and exhaust
Recording operation parameters & outlet cooling and chilled
pressure, the voltage and current
water pressure

Load-off by 75% 50% 25% Load-off if the temperature achieve The unit can load by 25% 50%
when the temperature is attain anticipant, then load to run 75% when temperatur rise

Cooling water is in given range,finish debug

17
  Chapter two Chiller Operation

Preparation of tools：
 Refrigeration tools
 Numeric VOM
 Clip-on ammeter
 Absolute gauge or wet bulb universal indicator
 500V high megohmmeter（earthometer）

2.1 Checking items before run the chiller

2.1.1 Power and electrical instrumentation system checking
2.1.1.1 Check if the distribution capacity is accord with the chiller's voltage
before run the chiller, and the selected wire can bearing the
highest operation current. 。
2.1.1.2 Whether the electric system accord with this chiller: three phase
fivewire system(three live wires, one zero line and one ground wire,
440V±10%）
2.1.1.3 Check the compressor power supply wire connect closed or not,
tighten it if any flexible happened. The screw may flexible after long
delivery and lifting. Otherwise it may cause damage to the electric
component in the control cabinet(e.g. air switch, AC
conductor) or compressor.
2.1.1.4 Check all electrical wire carefully by multimeter. See if connection
have been correctly installed to the right position; make sure there is
no short-circuit to the outer shell by using megameter. Check if the
earth wire has been connected right position, insulation against
ground large than 2MΩ; check if the power wire meet the capacity
request.
2.1.1.5 Check if there is cut-out switch installed to the chilled power supply
wire.
2.1.1.6 Electrify after complete inspection all main circuit connections and

18
 outer connections refer to connection drawing(for instance: cycle
water temperature sensor, switch connection, water pump joint
control); check if the terminal screw tighten. Check if every electrical
control device, instrument are correctly installed, inspect if the
electric cabinet is clean.
2.1.1.7 Inspect if outer system of the chiller accord with start condition(eg.
Cooling and chilled water pump is external control or main-interlock,
external control should start the water pump before run the main
unit)
2.1.2 Inspection of the compressor and pipe system
Check if oil at normal level in compressor, the right level is in middle of sight
galss.
2.1.2.1 Check if the compressor solenoid widing tighten and capillarity
damaged.
2.1.2.2 Turn on all refrigerant valves (angle valve around condenser outlet,
compressor suction and exhaust valve).
2.1.2.3 Check if compressor lubricant warm-up over 8 hours, In order to
prevent chilled oil bubbling, electrify the oil heater to warm-up 8 hours
before test run Oil heat time should be longer if the environment
temperature low. It will be difficult to run and bad load, unload when run the
chiller in low temperature, this because the large viscidity of lubricant,
normally the unit will start only when the lowest temperature of the
lubricant reach 23℃.
2.1.2.4 Confirm the compressor connection to be right. shut down the unit
when compressor is turn on, examine instantaneous system pressure
change, make sure exhaust pressure is rising, and return pressure drop.
Contrariwise the compressor is backrun, should adjust compressor
connection order again.
2.1.2.5 Testing run the chiller when main circuit is disconnected, check it load
in right order. While the right order is: put through the power, star AC
conductor pickup 3 minutes after press the Start button, then the Star AC
conductor break short time later, delta conductor pickup, the chiller will run
with the starting value, progressive loading.

19
2.1.3 Inspection of water system
2.1.3.1 Confirm the chilled & cooling water pipe has been rinsed, there is no
sundries in cooling tower, water basin.
2.1.3.2 Confirm the connection of water side pressure gauge and
thermometer, the pressure gauge perpendicularly installed to water pipes.
Installation of thermometer should ensure the thermoelectric probe insert
to the water pipe.
2.1.3.3 Confirm the cooling illed water side switch correctly installed, and the
flow switch is correctly connected to the control cabinet.
2.1.3.4 Start the cooling illed water pump, check the direction of the rotation.
The right rotation direction of water pump is clockwise, otherwise please
recheck connection.
2.1.3.5 Testing run the cooling illed water pump. Check if the hydraulic
steady. And check water pump inlet/outlet pressure gauge, the manometer
reading and difference of inlet/outlet pressure are exiguity. Examine if the
water pump current in rated current, please check whether resistance is
too large if it is too much different from the rated current, please eliminate
system failure until running current satisfy the requirement.
2.1.3.6 Make sure the cooling towre/expasion water tank is clear, the
auto-exhaust valve can automatic exhaust. If it is a manual exhaust valve,
exhaustion all gas in the pipe by turn on the exhaust valve on
chilled/cooling water pipes.
2.1.3.7 Adjust the water flow and make sure the water pressure drop through
the evaporator and condenser can meet the requirement of normally run.
Which means the differential pressure of chilled/cooling water inlet and
outlet should less than 1Mpa.
2.1.3.8 Note: For the low temperature chiller, examine the concentration of
secondary refrigerant, the secondary refrigerant freezing point should
below user’s demand temperature, avoid any damage to the water pipe
system.
2.1.4 Examine and confirm the fan of cooling tower and other equipment
operate regularly without any noise

Notice: Reverse phase of cooling tower fan will cause failure

20
2.1.5 Examine each terminal equipment run regularly, confirm every
water valve and wind valve have been opened
Terminal equipment can run without failure and abnormal noise, blow area and
wind speed accord with the design requirement.
2.1.6 Adjust the chilled water temperature (the chilled water temperature
will design to practical situation for that special request chiller)
After set the return water temperature according to operation instruction, the
unit can automatic operate refer to settled temperature. Once the chilled return
water temperature reached settled temperature, the compressor will auto
control cooling capacity, reduce the cooling capacity till the unit stop. Note: Do
not adjust the chilled water temperature too low, because it will reduce
the cooling efficiency, increase the cooling loss on the chilled water pipe,
even freeze on the cover of evaporator copper pipe. Adjust the chilled
water temperature as high as possible on the premise of satisfy the using
requirement.
Recommended chilled water temperature range:
Permitted lowest temperature of chilled water out from evaporator is 5℃,
Permitted highest temperature of chilled water return to evaporator is 20℃,
commendatory chilled water outlet temperature is 7∽12℃, temperature rise
5℃.
Chilled water temperature range:
Cooling water into condenser should lower than 35℃, and out from the
condenser should low than 40℃, commendatory temperature rise is 5℃。
Protection device: this series chiller has many protection devices.
High-low tension relay, it can connect or cut off compressor power by pressure
in the system, pressure switch’s operant pressure number has been settled ex
factory, we suggest the user don’t adjust facilely.
Pressure switch’s operant number:
High pressure cut off number is 18kg/cm２
Low pressure cut off number is 2kg/cm２
Low temperature cut off protection: the compressor supply power will be

21
cut off when outlet temperature of chilled water lower than 4℃ in order to
prevent chilled water in evaporator freezing, and the yellow light will turn on to
alarm; the low temperature will cut off the connection once the outlet chilled
water temperature is higher than 6℃. This device has been set up, user
shouldn’t change it facilely.

2．2 Unit operation

2．2．1 Start of the unit
2．2．1．1 Daily start
2.2.1.1.1 The unit cabinet control chilled/cooling water pump and cooling
tower by on-off. If many unit parallel connection, please adjust to confirm the
water flow pass each unit meet using requirement.
2.2.1.1.2 Check or reset each setting in cabinet accord with using
requirement (normally no need to change, it has been set to optimality)
2.2.1.1.3 Execute the following logic control after chilled/cooling water pump
and cooling tower’s relay joint connected to the interlock in cabinet: start the
chilled water pump before start the unit. Two minutes later start the cooling
water pump, one minute later start the unit. Control the cooling tower’s
start-stop accord to settled cooling water temperature.
2.2.1.1.4 Make sure there is no abnormal vibration or noise to the
compressor after the unit started, otherwise stop it and examine or contact the
after service.
2.2.1.1.5 When the unit is operated, check every operate current by
clip-style ammeter to see if it satisfy design requirement.
2．2．1．2 Unit seasonal desterilization
2.2.1.2.1 Maintenance inspection according to water pump and cooling
tower and other assistant equipment manufacturer’s operating procedure
2.2.1.2.2 Shut off water system discharge valve (or spin the plug screw),
open main water circuit stop valve and exhaust valve, charge required water
for the water system, then close the exhaust valve after air exhausted
2.2.1.2.3 Check if any components on the electric circuit flexible, if
conductor works well and insulated wrap damage, sweep the dust.
2.2.1.2.4 Close the main power switch to transmit electricity to start cabinet,

22
confirm the compressor’s lubricant oil has been warm-up over eight hours
2.2.1.2.5 Start and run the unit under the daily procedure.

2．2．2 Units stop

2．2．2．1 Units daily stop
Press the normal stop button on the touch screen, the compressor will stop
after the unit unload, then electrify the oil heater. When stop, 25% energy of
compressor will run for 30 seconds before it stop, one minute later stop the
cooling water pump, two minutes later stop the chilled water pump. If rotate the
key on cabinet to emergency stop, the unit will stop the compressor
immediately in spite of load condition. Do not use it random.
If the chilled/cooling water pump didn’t interlock with the control cabinet,
manually close the chilled/cooling water pump a while after the compressor
stopped
2．2．2．2 Unit seasonal stop
Close the water system stop valve which close to unit after the water pump
stopped.
Shut off compressor suction & exhaust stop valve.
Turn on the exhaust & discharge valve on the water system, discharge all
water in the system. To prevent the water pipe corrosion, inject tallish atmos
nitrogen into possible section to lustrate the air, and then tighten both valves to
avoid rust.
Maintain the unit and system

2．3 Control of the unit

Control system contains the start part and control part.
Compressor adopt star delta start when standard collocation, this start way
can effectively avoid current transfer peak when start.
2．3．1 Unit start process control
Step One: Electrify the control cabinet warm-up the compressor oil heater, the
unit can be started only when warm-up over eight hours(no need to electrify
the control circuit under this situation)
Step Two: start the circulating water pump (cold water pump) then the cooling

23
water pump.
Step Three: For the single compressor unit, press the start button directly after
cold water pump and cooling water pump system circulate.
Step Four: ： Start the chilled water pump first, 2 minutes later start cooling
water pump, 1 minute later start the unit. the compressor will start with star
delta(Y-△), transition time is 5 seconds. 25% energy of compressor will
transform to 50% operation after 30 seconds when start, then control upload
by the temperature.
Step Five: Whether the inlet & outlet temperature of cold water system is
correct (inlet temperature is higher than outlet). Inspect if the operate
current within the standard range.
Step Six: Stop the unit by press stop button, 25% energy of the compressor
will run for 30 seconds before compressor stop; Stop the cooling water pump 1
minute later, and stop the chilled water pump 2 minutes later.
Step Seven: If cooling water pump didn’t interlock with the chilled water pump,
manually stop the cooling water pump after the compressor stopped, and stop
the chilled water pump 2 more minutes.

2．3．2 Unit load/unload process control

2．3．2．1 Load process
a. The unit will start-up when connection time of the control device over
designed 【 compressor shortest stop time 】 , and outlet temperature higher
than(setting value+ temperature difference value)【normally setting value is 7℃,
temperature difference value can set among 1.0℃～5.0℃】, automatic choose
the shortest time operate compressor to start-up.
b. Interval between each compressor start and stop is at least 5 minutes.
2．3．2．2 Unload process
a. The unit will unload when cold water outlet temperature is lower than【setting
value 】 , unload the longest time operated compressor; After satisfy unload
interval, cold water outlet temperature still lower than【setting value 】 , then
continue unload.
b ． When suddenly stop by failure or the unit stop, the unit will fast unload

24
operate, 25% energy of each compressor operate for 30 seconds before stop.
c． The compressor will stop if failure happened to it, remove the failure, and
press the reset button to automatic operate again.

2．3．3 Illumination for computer operational control

Safety

Important Message

Attention: Please read carefully this manual before carry out the works of installation,
operation and service. Special message list below and appears in unit for
warning of potential danger and risk.

When this icon and “Danger” or “Warning” for safety

appear, it indicates electrical risk. Unproper operation
without following to the manual guidance, personal injury
will result if
This is a Safety warning icon, potential risk of personal
injury. Please follow the instruction written to avoid injury
or death.

DANGER indicates danger is to be occurred, no action to prevent such situation,

death will happen and serious damage to the equipment unit..

WARNING indicates potential risk of danger, no action to prevent such situation,

death will happen and serious damage to the equipment unit..

CAUTION indicates potential risk of danger, no action to prevent such situation, it

will cause serious damage to the equipment unit..

Attention: Only qualified enduser personnel is allowed to operate this equipment. Violation
against the manual instruction, Stars, the manufacturer is not liable to any
responsibility.

25
 After press of “Start”button, wait, there is a time lack before unit is started.
Press of “Stop”button, the unitis not stopped instantly. The unit will stop as per the program
sequence, to avoid impact of power supply interruption. When unit is not completed with the
start sequence, no effect to unit even the stop button is pressed.

User entering password is 12345678. It is recommended not to change the factory

pre-set data. In case there is a need, contact the manufacturer.

For emergency stop, turning off the key will disconnect the power supply to the

unit.Attention: donot operate in this way unless in case of emergency. Frequent emergency stop
will cause damage to compressor.
In order to re-start the unit whenever there are fault of : chilled water flow fault, Chilled
water pump overloaded, the unit should be reset. For fault of individual compressor circuit such
as Low-pressure cut off, high pressurecut-off, compressor overload, Phase reverse, only
respective compressor will be stopped. It will not affect the other compressor circuit. After the
fault is rectified, unit capacity control will monior the chilled water temperature to load and
unload as per the control logic.

26
 Introduction to Operation

(1)、Start display

Diagram 1
Note: Click button“Chinese”，panel display language in Chinese.
Click button“English”，panel display language in English.
Click button “Enter”，it will go to touch screen control panel.

（2)Main Menu
This is the main menu page, from here, it can go to other menu for
operation, history of fault, user parameter setting;

27
 Diagram 2

(3)、Start and Stop

On the main menu, click to “Operating picture”will open the display as shown in diagram
3. From this display , it shows the compressor status, chilled water in/out temperature, more is
shown as in diagram 3.
Under this menu, click “Start”or“Stop”can start and stop the unit. When there is a fault, the
“Fault query”soft button will flash, click to“Fault" query”，to investigate the fault.
After the fault is rectified, check unit condition is comply with standard (such as power
voltage, control circuit votage). Then click screen button “Start” to start chilled water pump.

28
 Diagram 3
1）State query
From menu with “ Operating picture ” , click “ State of the query “ button, to read system
temperature and operation status data as shown in diagram 4.

Diagram 4
2）Fault query
From menu with “Operating picture”, click“Fault query “ button to read present fault as shownin
diagram 5.

Diagram 5
After the fault is rectified, click“Failure reset” to reset unit. Press “History fault”button to read

29
fault history.

(4)、User Setting Menu

Click “User Setting”with input password 12345678 to enter this menu as shown in diagram
7. After password input, click “ enter ” . To input password again, or input incorrect password,
click “BSP” to input password again. Click “ESC” to leave this User Setting menu.
Note: entering at this menu, it is recommended NOT to change already set parameter.
Setting. parameter is shown as in diagram 8.

Diagram 7
1） User preferences setting.
Under this menu, the temperature can be set for loading and unloading temperature
difference, and water pump control mode of manual or auto

30
 Diagram 8
Click“Down” to enter time setting menu.
2）Run Time Query Menu
For user convenience, this unit provides time schedule setting. User can set week or day
operating time schedule. When time schedule is set, unit will operate as the set time set for Start
and Stop daily as shown in diagram 9 and 10. Under the menu shown in diagram 8, user can click
“Down” to enter time setting. Select time schedule use or unuse. For example, set Monday use, it
displays Monday schedule will auto run to star and stop the unit as the time set.i If Saturday unuse
is set, the unit will not auto start and stop on Saturday, but the unit can start and stop manually.
Under diagram 10 menu, user can set Start timing (Timing boot) and Stop timing (Timing
shutdown) for 3 schedules. Click the first 3 buttons to select timing use or unused. The rear
buttons input the Start timing (Timing boot) and Stop timing (Timing shutdown). Once timing
schedule is set, unit will start and stop as user set.

Diagram 9

31
 Diagram 10

(5)、Control Logic

1. Unit start sequence.

After press the control panel “Start”button, unit chilled water pump will start first. Then it
analysis the water temperature, say water temperature fulfils start condition, the condenser fans
will be delayed, compressor start will be delayed. The controller will calculate the system
compressors running hours to start a shorter run time compressor to start.
2. Unit stop sequence:
When the unit has not complete the start sequence, press “Stop” button will notfunction to
ensure longer compressor life. When “Stop” button is pressed, control system will unload
compressor to 25%, after certain time delay, the compressor is stopped. Further time delay, the
condenser fans wil stop. Then after further timing delay, the chilled water pump and external
pump will stop. And stop sequence is completed.
3 Capacity Control
The control system is based on analog mode control. The temperature control zone is divided
into loading zone, unchanged zone, unloading zone, emergency stop zone. The controller
regards the temperature control cycle as unit interval timing to justify the temperature zone
status. Controller refers to the unit working zone status to determine capacity loading or
unloading. Control system will select the shorter run time compressor to run first, and unload
the longer run time compressor to even the compressor running hours.
Examples:
Temperature Control 12℃
Temperature control cycle (interval) 60 sec
Emergency stop cycle 60 sec
Loading temperature difference 1℃

32
 Unloading temperature difference 1℃
（1）Control Logic is as follow：
Set T as Temperature control cycle (interval), and t as Emergency stop cycle
T Actual temp≥13℃ （Loading zone） Increase 1 capacity load unit
2 T 12℃≤Actual temp≤13℃ (unchange zone） Unchange
3 T 12℃≤Actual temp≤13℃ (maintain zone） Unchange
4 T 11℃≤Actual temp≤12℃ (unload zone) Unload 1 capacity load unit
5 T 12℃≤Actual temp≤13℃ (unchange zone） Unchange
6 T 12℃≤Actual temp≤13℃ (unchange zone） Unchange
7 T Actual temp >13℃ （Loading zone） Increase 1 capacity load unit
8 T 12℃≤Actual temp≤13℃ (unchange zone） Unchange
9 T 12℃≤Actual temp≤13℃ (unchange zone） Unchange
10T 11℃≤Actual temp≤12℃ (unload zone) Unload 1 capacity load unit
11T 11℃≤Actual temp≤12℃ (unload zone) Unload 1 capacity load unit
11T+t Actual temp≤11℃ （Emergency） Unload 1 compressor
11T+2t Actual temp≤11℃ （Emergency） Unload 1 compressor
11T+3t Actual temp≤11℃ （Emergency） Unload 1 compressor
11T+3t+T 11℃≤Actual temp≤12℃ (unload zone) Unload 1 capacity load unit
11T+3t+2T 11℃≤Actual temp≤12℃ (unload zone) Unload 1 capacity load unit
11T+3t+3T 12℃≤Actual temp≤13℃ (unchange zone） Unchange

（2）Control curve as follow

33
2．4 Operation Management and Notice for Stop
2.4.1 Screw-type chiller operation management and notice for stop
2.4.1.1 Start/stop of the unit should strictly according to each step of manufacturer’s
operation instructions.
2.4.1.2 Make record for parameters timely and correctly while the unit is running.
2.4.1.3 Notify maintenance man to inspect the unit prompt if alarm stop occur, contact
the manufacturer if fault can not be removed.
2.4.1.4 Strictly prohibit jump out the water switch when running the unit, avoid to freeze
off the water pipes.
2.4.1.5 Special person should take in charge of the machine room, prevent those people
without fixed duties enter the room and handle the unit.
2.4.1.6 The machine room should equiped safe guarding and maintenance device, for
instance pressure gauge, thermometer and so on. And put these tools in fixed place.
2.4.2 Screw-type chiller Stop Notice:
2.4.2.1 Cut off the main power switch after the unit stop.
2.4.2.2 Discharge all chilled/cooling water in system when the unit long shutdown, tube
ends should tighten.
2.4.2.3 Maintain the unit while long shutdown.
2.4.2.4 To avoid dust, cover all the unit while stop.
2.4.2.5 Keep those people without fixed duties away from the unit while stop.

34
  Chapter Ⅲ: Maintenance and Fault Processing

3.1 Summarization
This chapter introduces the prevention and fault maintenance . maintain the units right
and duly is good to ensure this units run in the best condition and high efficiency, and
can extend using time of the units.
Customers must have professional maintainer to maintain the units before and after fault
emerging according to this chapter of this instruction book. After the warranty term ,the
customer can sign a maintenance agreement with local customer service section of our
company in order to get right and timely maintenance.

Caution ： For the maintenance resulted from customer's fault we will

charge additionally.
It is essential to record running parameters of the units rightly in a proper time distance
everyday, for example, one hour. Real record of running parameters can be used to
forecast future run and fault.

For example ,analyse one-month record of running parameters,it may be found that the
gap between condensation temperature and that of cooling water at outlet is growing, is
suggests that cooling water may be dirty or has larger rigidity, so the inside wall of
heat-exchanging tubes is scaling.At this time ,it is need to intenerate cooling water or
clean tubes.

Caution ： It is very useful to keep and save the record of running

parameters in gear.

3.2 Maintenance
3.2.1 Daily maintenance
* Make the units start and stop according to the rule of the instruction everyday.
* Record running parameters of the units rightly in a proper time distance everyday.
* 24 hours after run, clean filters for both chilled water and cooling water.
* Check pressures inside the evaporator and condenser. Check the gap between the
35
evaporation temperature and temperature of chilled water at outlet, and that between
condensation temperature and that of cooling water at outlet .Pay attention to their
change trend.Generally, proper evaporation pressure should be in the range of 380 ～
500KPa,and condensation pressure should be in the range of 380 ～
500KPa.Temperature gap should be in the range of 1～3℃

Notice: evaporation pressure and condensation pressure will vary with

temperature of chilled water and cooling water at outlet

* Check dryer-filter of refrigerant .If there is frost at the outlet ,jam may be inside
which often emerges along with too low evaporation pressure and increase of difference
between condensation temperature and that of cooling water at outlet. Filtering core
should be replaced in time.
* Check the deepness of oil in the tank, normal condition should be that up level of
oil in the half of the watch mirror. If the deepness decrease large, the oil should be
increased.
* Any fault resulted in stop of the units should be stressed and analysed. It may help
to solve
* The problem that analyse the condition according to this instruction book before our
customer service personnel arriving.

3.2.2 Termly maintenance

Caution: Turn off main power swich before check and hang a sign which show "No
turning off power swich "near the power swich should be done which is in order to
avoid casualty.

Termly maintenance can be implemented weekly, monthly, quarterly and yearly. It is

helpful to make the units run well that establish a scientific "Termly maintenance plan
"refer to following content
3.2.2.1 Weekly maintenance
* Check and analyse record of running parameters
3.2.2.2 Monthly maintenance
* Check and analyse record of running parameters
* Check fastening bolt of the power connection
36
 * Make sure all components have no noise and run well
* Make sure the high and low pressures of the refrigerating system are normal
* Make sure current and insulation resistance are normal
* Make sure dry-filter and viewing mirror are normal ,if outlet of the dry-filter is
frosting ,the inside of filter must be jammed and dirty. At this time, filter gauze should be
cleaned ,and if humidity indication is found in the viewing mirror(indicator paper shows
red) ,filter element should be replaced .
* Make sure compressor's lube is enough, if lack ,don't replace or add at will.
Please contact our after-service section in time

Caution: Must ensure the specification of the lube is right before replacement or
addition. Otherwise the units might be mangled.

3.2.2.3 Quarterly maintenance

* Check and analyse record of running parameters
* Check deepness of the oil in the compressor
* Clean line strainers of evaporator and condenser
* Make sure refrigerant's temperature drop in dry-filter when the units operate at
full load
3.2.2.4 Half-yearly maintenance
* Check and analyse record of running parameters
* Do physical and chemical analyse to cold oil in order to estimate moisture
content and acidity.
* Make sure control cabinet,start-up cabinet and all electric connections are
fastened
3.2.2.5 Yearly maintenance
* Check and analyse record of running parameters
* Check deepness of the oil in the compressor and do physical and chemical
analyse to cold oil. If oil has been emulsified, replace same kind oil
* Replace filter of cold oil when needed, and this should be done by professional
maintainer.
Take apart connection tube of safety valve, check the valve clearly to make sure there
are no corruption, rust, scale deposition and leakage. If corrupt or leak, replace safety
valve.This should be done by professional maintainer.
* Check the scale deposition extent in the heat exchange tubes. (Evaporator
should be checked along with that,if it is connected with open system ).Cleaning period
37
and if the process of water in the ring-way is right can be ensured according to above
checking result. If scaling is serious, clean inside of tubes. Clean inside of heat exchange
tubes with revolving cleaning device at least one time annually. If water is polluted, clean
should be done more frequently. Condensing pressure is over high ,refrigerating
capacity is not enough both result from scaling deposition inside heat exchange tubes or
there is air inside the units. If temperature gap between cooling water at outlet and
refrigerant in condenser is larger than 6℃,it is may be scaling inside condensation tubes.
When clean tubes ,special brush should be used to avoid scratch .Line brush is not
recommended .
* Check the insulation resistance of winding of compressor motor and that of
winding to ground. This should be done by professional maintainer.

3.2.2.6 maintenance every three year

* Above yearly maintenance's operation
* Have qualified local customer service section of our company implement a fully
maintenance, especially vibration of compressor to ensure all components of
compressor are in order; Check seal of the units and make sure there is no leak in
tubes .Do non-destructive detection for main welding lines (longitudinal weld and ring
weld of evaporator and condenser) when needed, to make sure safety; Check electric
operation and safety control .Make sure they right to make all electric parts run well.

Caution: Three yearly maintenance can be shortened when needed according to

using scene, especially in scene where stop may result in serious problem,for
example ,air conditioning for process flow.

3．3 water quality management

Bad chilled and cooling water quality will not only scaling in heat transfer pipe, but also
affect the heat exchange efficiency, reduce the chiller’s performance, and will bring
corrosion to the heat transfer pipe cause major failure. The customer should do the water
conditioning apply to GB50050-1995《Code for design of industrial recirculating cooling
water treatment》. Use the softening water when closed system. Sampling analysis the
cooling water periodic during the chiller run, the water quality should coincide with table
3-3 requirement. Do water conditioning if it unable to.

38
 Chilled & propensity
Charging
Item Unit cooling Corros Scali
water
water ion ng
PH（25℃） 6.5-8.0 6.5-8.0 0 0
Basic
conductivity（25℃） S/cm <200 <800 0 0
Item
Chloride ion Cl- mg Cl-/L <50 <200 0
Sulfate ion SO-2 mg SO-2/L <50 <200 0
Acerbity consumption（PH4.8） mgCaCO3/L <50 <100 0
Tsuen hardness mgCaCO3/L <50 <200 0
Iron（Fe） mg Fe/L 〈0.3 <1.0 0 0
Refer
Sulfide（S2-） mgS2-/L Unable Unable 0
ence
ammonium fixation（NH4+） mgNH4+/L 〈0.2 <1.0 0
ITEM
silicon dioxide（SiO2） mgSiO2/L <30 <50 0
Table 3-3 water quality

Note: we will not responsible for any corrosion, scouring or bad

performance due to untreated water or mistreated

3．4 Treatment to the fault

Fault Description Solution
1 ． High Cooling water flow Check if water system’s pipes clog, if water
pressure alarm underfed pump reversal(clockwise direction when
look down is the right direction)
Water side scaling If condenser inlet &outlet temp. lower than 3 ℃
when full-load, it means copper water side too
dirty, and affect heat exchange,need to wash
Cooling tower dirty, jam Check cooling tower return filter,radiator and
filling

39
 Water replenisher didn’t Check it, outlet direction should slant towards
work one direction
Cooling tower fan failure Check the fan
2．Low pressure Evaporator under feeding Increase feeding (contact manufacturer)
alarm Chilled water flow Check vessel’s pressure drop, water pump
shortage and filter
Lack of refrigerant Leak hunting, find the reason
Chilled water side scaling Check chilled water quality
Excessive oil in system Release proper chilled oil(contact the
manufacturer
3 ． Chiller Lack of electricity No power supply pressure or fuse for main
cannot start-up circuit breakup
Power pressure abnormal Check three phase power accord with this
chiller’s standard
Wrong setting Check set point, run mode
4．High exhaust Expansion valve narrow Extend expansion valve
temperature opened
Less refrigerant in system Inject more refrigerant
Under feeding Check if filter works well, magnetic valve
opened
Condenser cleanout condenser
5 ． Exhaust dirty(oversized feeding)
temp. too low Expansion valve opened Turn down properly
too large
Excessive refrigerant in Release proper refrigerant
system cause bad
evaporate
Bad evaporate Check chilled water flow, if water pump be
evacuated or air exist in system
6 ． Low temp. Protection trip due to If the control temperature setting too low
alarm chilled water outlet
temperature too low

40
 Chilled water flow Check difference in temp between chilled
problem outlet and inlet(standard is 3-5 degree) see if
flow is normal so does water pump
If filter jammed and water Rinse filter, charge enough chilled water
7．Compressor charging system work
overcurrent Check if power voltage Extend wire rod, decrease the pressure drop
alarm accord with the chiller
request
Check if any failure to the Repair winding, rinse lubricate system,
compressor decrease friction energy loss(contact the
manufacturer)
Check chiller’s working Check the chilled & cooling water flow
8．Compressor condition high & low
oil level alarm pressure is in range
The unit leaking Chase leaks, dispose it and charge chilled
oil(contact with manufacturer)
Over feeding flow Adjust feed flow, ensure the suction
superheat temp. and oil return clear
Bad evaporate 1.insufficient anti-freeze fluid concentration
9. compressor 2.chilled water system failure
frosting and run
Chilled water system Air in the water system, exhaust air. irrational
pressure too
failure water pump head
low alarm

Stars chiller screen operation interface:

The three display lights on the top left corner of the screen are: power light(red), run
light(green), failure light(yellow)
Power light and run light on when regular working, failure light uninterrupted blink when
failure happens, the screen will also show the failure, press the failure query can find
what the failure is.

Display fault and solution：

fault Solution Note

41
1．No display 1）check the electrify to transformer output
AC9.8V
2）check the socket connector
3）check the connection
4）check if any adust smell or trail
5）check if water can go in
6）check if connection flexible
2．Touch screen response 1）confirm press strength and position
only after press 2）come into menu adjust touch screen
several times
3．Display shows dim 1）check the electrify to transformer output
AC9.8V
2）come into adjust reduced property
4．Stop without reason 1 ） confirm voltage is fluctuate within
reasonable range
2）check if button damage or distortion
5 ． Compressor cannot 1）if the unit pause when temp. is reached
load or uninstall 2）confirm adopt the outlet water or back
water control point
3）confirm the time delay
4）confirm temp. probe without fault and
temperature shows normal
6．Communication fault 1 ） check touch screen and backboard
power supply, and power light is on
2 ） check whether backboard skipped
stitches
3）check touch screen parameter setting
4）check the communication lines
5）check if backboard fuse blow-out
7 ． Many faults shows at 1）bad contact
the same time, but can 2）confirm connection right

42
 run after reset 3 ） confirm connection lines and
heavy-current are separated
4 ） Let connection line away from the
heavy-current wire,as far as it can
5）adopt connection line with the shield
6）output adopt filter and contactless coil
has pressure sensivity resistanor.
8．Input fault alarm 1 ） if chiller’s switch status the same
setting as computer
2）check input point relevant indicator light
is on or off
3）reset fault
9．No output 1）if unit is started
2）if any output showed by screen
3 ） if output relay goes through(use
multimeter)
4）if backboard fuse is blow-out
5）check common output voltage
10．Screen dazedly 1）if any damage
2）re-electrify
3）initialize parameter

43
AttachmentⅠ Plastic insulated wire safe current carrying capacity(Ampere)

Steel tube wire Plastic tube wire Sheath wire

Open wire Three or four Flexible wire
Two wire Three wire Four wire Two wire Three wire Four wire Twin core
Section core

（ squar
millimeter） cop alumi cop alum cop alum cop alum cop alum cop alum cop alum cop alumi cop alumi Single Doubl
per num per inum per inum per inum per inum per inum per inum per num per num core e core

0.5 7 8 7
0.75 13 10.5
0.8 11 9 14 11
1.0 17 12 11 10 10 10 9 13 9.6 17 13
1.5 21 16 17 13 15 11 14 10 14 11 13 10 11 9 17 13 10 8 21 17
2.0 19 13 25 18
2.5 28 22 23 17 21 16 19 13 21 16 18 14 17 12 23 17 17 14 29 21
4 37 28 30 23 27 21 24 19 27 21 24 19 22 17 30 23 23 19
6 48 37 41 30 36 28 32 24 36 27 31 23 28 22 37 29 28 22
10 65 51 56 42 49 38 43 33 49 36 42 33 38 29 57 44 45 35
16 91 69 71 55 64 49 56 43 62 48 56 42 49 38
25 120 91 93 70 82 61 74 57 82 63 74 56 65 50
35 147 113 115 87 100 78 91 70 104 78 91 69 81 61
50 187 143 143 108 127 96 113 87 130 99 114 88 102 78
70 230 178 177 135 159 124 143 110 160 126 145 113 128 100
95 282 216 216 165 195 148 173 132 199 151 178 137 160 121
44
120 324 246 250 190 224 168 198 148 233 173 207 155 185 138
150 371 281 285 216 259 194 229 173 263 198 237 179 216 160
185 423 328 328 296 294 220 259 198 307 229 268 203 242 183
240
300
40
500

45
Attachment Ⅱ Stars chiller operation data form

Model: Serial No:

Chilled water Cooling water

1# compressor 2# compressor
system system
Exhau
Oil st Oil
loa loa
lev temp. lev Exhaust
d cur d
Time el Low Cur el High Low temp.
ren High pressure Inlet Inlet outlet
pressure ren pressure pressure outlet℃
t kgf/cm2 ℃ ℃ ℃
kgf/cm2 tA kgf/cm2 kgf/cm2
A
℃
% %
% %
℃

46