TWCF###H (PCD) - IOM (Eng. Version) PDF

Water Cooled Centrifugal chiller H&E series
Installation, Operation and Maintenance Manual

TWCF ***H/E
Description
 The "Installation Part" in this manual is only available to professional installers.
 Before equipment installation, unpacking inspection shall be carried out, and a written acceptance
test record shall be completed.
 Before use, be sure to read the "User Part" first to avoid any damage to the unit or accidents
caused by your misoperation.
 Product implementation standard: GB/T18430.1.
 Before and after use, the pressure vessel unit shall be reported to, enrolled and registered at the
local relevant management institution.
 The contents of this manual are subject to change without any prior notice upon improvement of
individual or various models.
Safety Warning
The centrifugal chiller is relatively complicated. In the process of installation, operation,
maintenance or overhaul, personnel may have come into contact with certain parts or their
surroundings, such as a certain amount of pressurised refrigerant, oil, materials, moving parts,
high/low voltage etc. If used or handled improperly, each of the above items may cause serious
damage to equipment and property, and even personal injury or death. Operators have the
responsibility and obligation to be aware of these potential dangers, protect themselves and complete
the tasks safely and correctly.
This manual is intended to provide guidance to the installation, operation and maintenance
personnel authorized by the user. The above personnel should have received professional training and
be able to correctly and safely carry out the assigned tasks. It is very important that the
above-mentioned personnel carefully read the contents of this manual and related reference materials
before performing any operation on the unit. They shall also be familiar with and abide by the relevant
national and industry standards and regulations.
Before performing any operation or maintenance, please observe the following principles:
 Unless you are a qualified electrician, please do not work on high-voltage equipment!
 Do not close the valve of any safety device unless the unit is overhauled or pressure tested!
 Before operating electrical components, please make sure that all power supplies are turned
off and no residual voltage is released from capacitors or other solid-state components!
 If the unit leaks, please do not let your hands make directly contact with the leaking point.
Otherwise, it may cause severe frostbite!
 Before all refrigerants are removed from the unit, do not weld or cut any unit pipelines or
containers, or not allow any high-temperature heat source over 43℃ approach the unit!
 The pressure parameters mentioned in this manual are all gauge pressure unless otherwise
specified, and the pressures displayed by the unit control system are also all gauge pressure.
 The nameplate of the unit provides a lot of Information. Please read it carefully before using
the unit!
Warning
"Warning" sign indicates some factors that may lead to any danger in operation. Failure to follow
the instructions will result in serious damages to the unit or cause casualties!
Attention
The "Attention" sign is intended to point out some factors causing minor personal injury or
property loss, or to give specific prompts for some operations, which can be followed such that the
personnel achieve the purpose more safely and easily.
Contents
1 Introduction to the Unit and the System ······························ 1
1.1 Brief Introduction to the Refrigeration Principles ······················· 1
1.2 Appearance and Main Parts of the Unit ·························· 2
1.3 Lubricating System ·································· 3
1.4 Motor/Lubricating Oil Cooling System ·························· 5
1.5 Automatic Oil Return Device ······························ 7
2 Unit Control System (PCD Series) ································ 9
2.1 Unit Operation Control ································· 9
2.2 Introduction to the Touch Screen Interface ························ 12
2.3 Schematic Diagram and Wiring Diagram of the Control System ················ 30
3 Unit Use ········································· 45
3.1 Unit Installation in Place ······························· 45
3.2 Preparation before Unit Operation ··························· 64
3.3 Work Guidance during Unit Operation ·························· 72
3.4 Shutdown ····································· 73
3.5 Precautions for Long-term Shutdown ·························· 73
4. Unit Maintenance ····································· 74
4.1 Work Outline for Unit Maintenance ··························· 74
4.2 Maintenance Methods for Oil System ·························· 76
4.3 Maintenance Methods for the Cooling System ······················· 78
4.4 Maintenance Methods for the Automatic Oil Return System ················· 79
4.5 Maintenance Methods for the Refrigerant System ····················· 80
4.6 Inspection and Maintenance Methods for the Water System ················· 81
4.7 Maintenance Methods for the Electrical System ······················ 83
5 Analysis and Treatment of Common Exceptions in the Unit ····················· 85
Appendix I Temperature-Pressure Correspondence Table for R134a Saturation State ············ 88
Appendix II Unit Status Record Form (Template) ·························· 89
Appendix III Unit Parameter Setting Table····························· 91
Appendix IV Technical Requirements for High-voltage Starter Panel Matching with the Unit ········· 92
Appendix V Names and Contents of Hazardous Substances in Products (TWCF Centrifugal Chillers) ····· 94
Annex VI Guide on Insulation Resistance Test of the Starter Panel ··················· 96
1 Introduction to the Unit and the System
1.1 Brief Introduction to the Refrigeration Principles
The vapor compression refrigeration cycle comprises of four processes namely compression, condensing, throttling
and evaporating. The four processes of the refrigeration cycle are given as follows:
Compression process: After the refrigerant vapor in the evaporator is sucked into the centrifugal compressor, the
prime mover (usually a motor) applies energy to it through the compressor impeller to increase the pressure & temperature
of the refrigerant vapor and enters the condenser.
Condensing process: high temperature and high pressure refrigerant vapor from the compressor emits heat into the
cooling water in the tube in the condenser and condenses into liquid. At this point, the temperature of the cooling water
rises due to the heat taken from the refrigerant vapor. Condensing temperature (condensing pressure) is directly related to
the temperature of cooling water.
Throttling process: When flowing through the throttling orifice, the high-temperature and high-pressure refrigerant
liquid from the bottom of the condenser will expand under reduced pressure, decreasing in both pressure and temperature,
and become a low-temperature and low-pressure gas-liquid mixture to enter the evaporator.
Evaporating process: Low-temperature and low-pressure refrigerant absorbs heat from the coolant (such as cold water)
in the evaporator and evaporates into gas, and at the same time, the temperature of the coolant is reduced, thus realizing
artificial refrigeration. The refrigerant vapor in the evaporator is sucked into the compressor for compression, and the
above compression, condensing, throttling and evaporating processes are repeated. This goes round and round to achieve
continuous cooling.
The refrigerating capacity is proportional to the suction flow of the compressor. Therefore, an adjustable guide vane
adjusting mechanism is installed at the inlet of the centrifugal compressor to control the air flow direction and suction flow
into the compressor, thus realizing stepless adjustment of refrigeration capacity within a certain range.
The main structural components of the above refrigeration cycle includes the main motor, compressor, evaporator,
condenser and throttling device, which are also the main structural components of the Manufacture centrifugal chiller.
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Condenser
Cooling water outlet
Cooling water inlet
Throttle orifice
Impeller
Economizer Inlet guide vane
Throttle orifice
Compressor Main motor
Chilled water outlet
Chilled water inlet
Evaporator
Fig. 1.1 System Schematic Diagram of TWCF Centrifugal Chillers

1.2 Appearance and Main Parts of the Unit
Front view
1 2 3 4 5 1. Economizer
2. Vapor injection valve
3. Electric actuator
4. Compressor
5. Motor
6. Refrigerant charging valve
7. Oil level sight glass
8. Evaporator
9. Control panel
9 8 7 6
2
11 10
Rear view
10. Evaporator relief valve
11. Condenser relief valve
12. Refrigerant charging valve
13. Condenser
14. Refrigerant recovery valve
14 13 12
Fig. 1.2 Schematic Diagram of TWCF Centrifugal Chillers
1.3 Lubricating System
The lubricating system of TWCF series units consists of oil pump, oil filter, oil cooler, high-level oil tank and
intermediate pipeline. The lubricating oil in the oil tank of the compressor is pressurized by the oil pump which enters the
oil cooler through the oil filter. After being cooled to a certain temperature in the oil cooler, the lubricating oil enters the
high-level oil tank and is finally supplied to each bearing through the oil supply pipeline inside the compressor.
Oil pressure regulating valve
Oil filter
Oil pump
Oil cooler liquid outlet Oil cooler
Oil cooler liquid inlet
a)
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Oil pressure regulating valve
Oil filter
Oil pump
Oil cooler liquid outlet

Oil cooler
Oil cooler liquid inlet
b)
a)TWCF 500H-TWCF 1300H,TWCF 2300H-TWCF 3000H b)TWCF 1400H10-TWCF 3000H10
Fig. 1.3 Lubricating Oil System Components and Pipeline Connection Diagram
Cut-off valve
Positions of each
bearings in the unit
Cooler liquid outlet

High level oil tank
Oil cooler
Cooler liquid inlet
Main oil tank Oil pump Oil pump outlet valve Oil filter
Fig. 1.4 Flow Chart of Lubricating Oil System
The pressure & temperature of the oil system are crucial to the safe operation of the unit. After lubricating oil enters
the bearing under the action of pressure difference, an oil film is formed between the shaft and the bearing to support the
operation of the shaft and prevent direct friction between the shaft and the bearing. The viscosity of the oil is inversely
proportional to the oil temperature, so it is necessary to restrict the temperature of the lubricating oil to a suitable
temperature to ensure that it will not increase the friction force too much while providing sufficient supporting force.
Appropriate oil temperature can also prevent poor oil performance resulting from too much refrigerant dissolving into
lubricating oil.
The normal range of oil supply pressure difference is given as follows: 220 kPa to 300 kPa in the process of unit
startup. This pressure difference is intended to ensure that the shaft can form a stable oil film at low speed during unit
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startup. After the main motor is started, the oil supply pressure difference should be within 120 kPa to 220 kPa.
The oil supply pressure difference is adjusted through an oil pressure regulating valve. The steps are as follows:
1. Remove the valve cap of the regulating valve and slowly rotate the valve stem. Clockwise rotation increases the
pressure difference, anticlockwise rotation reduces the pressure difference. Rotate 1 turn at a time, then observe the change
in oil supply pressure difference, and make another adjustment once the oil pressure is stable.
2. After adjusting the oil supply pressure difference to the normal range (it is recommended to adjust it to 240 ~ 270
kPa in standby state), observe it for 15 seconds and re install the valve cap after confirming its stable value.
3. If the oil supply pressure difference has been adjusted to the recommended value in standby mode, the lubricating
oil will flow under the drive of the shaft after the unit is started, and the oil pressure will automatically drop to the normal
range in operation mode.
Warning
There are discharge pipes and motor terminals around the oil pressure regulating valve. Do not adjust
the oil pressure when the unit is running under non-emergency conditions. Otherwise, attention should be
paid to the high noise and temperature of the discharge pipes and the high voltage of the terminals, which
may cause injury to the body!
Attention
When rotating the oil pressure regulating valve to adjust the oil pressure during the operation of the
unit, adjust slowly while observing the change in oil pressure difference. Avoid large fluctuation of oil
pressure difference caused by adjustments made too fast.
In the running state, the oil supply temperature after it passes through the oil cooler is between 35℃ and 52℃.
When the unit is shut down, the temperature of the oil tank is automatically adjusted by the electric heater. When the
unit is running, the oil supply temperature is adjusted by adjusting the amount of cooling liquid in the oil cooler.
1.4 Motor/Lubricating Oil Cooling System
The motor and lubricating oil are cooled by refrigerant liquid coming from the bottom of the condenser. When the
unit is running, the pressure of the condenser is always higher than that of the motor cavity and the oil cooler. The
refrigerant flows under this pressure difference and reaches the cooled components through the cooling liquid pipeline.
Flow path 1: Refrigerant liquid is divided into two parts after it passes through the cut-off valve and filter. One part is
sent to the tail end of the motor to cool the rotor and stator of the motor. The other part is sent to the middle of the motor
casing to cool the motor stator.
Flow path 2: Refrigerant liquid passes through the cut-off valve and filter, then passes through the regulating valve
and then enters the oil cooler to cool the lubricating oil.
5
Fig. 1.5 Unit Cooling Pipeline (500~1300RT)
Fig. 1.6 Unit Cooling Pipeline (1400~3000RT)
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The amount of liquid supplied to the stator and rotor of the motor has been set by Manufacture before the unit leaves
the factory. Generally, it does not need to be adjusted by the user. However, if there is a warning of overheating of the
motor winding during the operation of the unit, the user may, in addition to timely feedback to the Manufacture after-sales
service department, appropriately turn up the regulating valves distributed on the casing tail end of the motor and observe
whether the unit alarm is released.
Warning
When operating the motor cooler spray regulating valve, necessary protective measures should be
taken to prevent the risk of an electric shock.
The cooling liquid volume of the oil cooler is automatically adjusted by the electronic liquid valve according to the
oil supply temperature. The oil cooler is a plate heat exchanger, into which the cooling liquid enters, evaporates and
absorbs the heat from the lubricating oil. If the oil supply temperature exceeds 52℃ during the operation of the unit, the
opening extent of the liquid regulating valve of the large oil cooler can be gradually turned up. After each adjustment,
observe the change in the oil supply temperature of the unit, and then decide whether or not to continue to turn up the
opening extent of the regulating valve according to this change.
Attention
Too large an opening extent of the regulating valve will make the refrigerant unable to evaporate in
the motor cavity, causing a poor cooling effect. Therefore, when the motor temperature is on the high side,
the adjustment of the liquid valve is not as large as possible. Find a suitable opening extent after
observation and adjustment.
1.5 Automatic Oil Return Device

When the unit is running, a small amount of lubricating oil will inevitably be mixed into the refrigerant. Since the
specific gravity of the lubricating oil is small and it will not evaporate, this part of the oil will eventually stay at the liquid
level of the evaporator. The refrigerant purification and automatic oil return device is intended to recover lubricating oil
mixed with refrigerant, and its flow chart is as follows:
7
Fig. 1.7 Schematic Diagram of the Pipeline Connection of the Automatic Oil Return Device
The automatic oil return device is powered by two Venturi nozzles. The front and rear of the Venturi nozzles are
respectively connected to the high-pressure gas and the oil tank at the bottom of the condenser or volute. The resulting
injection force sucks the lubricating oil accumulated in the evaporator back to the oil tank. The oil return effect can be
observed through the sight glass at the outlet of the Venturi nozzle (when the automatic oil return device works normally,
liquid refrigerant can be seen boiling and evaporating in the sight glass cavity).
Under the automatic oil return mode, adjust all valves according to Table 1.1, and the device can automatically suck
lubricating oil back to the oil tank.
Table 1.1 Operation Table of Refrigerant Purification and Automatic Oil Return Device
No. Valve k1 k2 k3 k4 k5
Process
1 Automatic mode △ 〇〇〇〇
Note: 〇: open △: slightly open (valve opens for 1-2 turns)
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2 Unit Control System (PCD Series)
2.1 Unit Operation Control
2.1.1 Control System Components
The Centrifugal Chillers use the control system of PCD series to monitor and control its own operation. The unit
control system of PCD series makes the refrigerating capacity of the unit match with the user's load, while providing
comprehensive unit safety protection.
The internal structure and components of the unit control system are described as follows:
Isolation Switching power Main control Electronic expansion valve
transformer supply panel drive plate
+V +V -V -V DC +V +V -V -V DC +V +V -V -V DC
OK OK OK
24V/1.7A 24V/1.7A 12V/5A
DC OK DC OK DC OK
+ + +
N L N L N L
4 5 6
1 23
电源
电源
7 8 9
101112
Miniature circuit AC contactor Thermal relay Current transducer Intermediate relay

breaker
Fig. 2.1 Schematic Diagram of Internal Layout of 500RT ~ 2200RT Centrifugal Chiller Control Panel
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RESET button for

malfunction reset
STOP button for

commissioning
Fig. 2.2 Oil Pump and Oil Heating Control Part
Table 2.1 Functions of Components of Control Panel

Parts Effect
Controlling the input/output instructions of the unit as required serves as the
Main control panel
core of unit operation and control
Isolation transformer Power interference isolation
Electronic expansion valve
Used to control/drive the oil-temperature electronic expansion valve
drive plate
Convert these secondary current of the starting panel into an analog quantity
Current transducer
which can be collected by the main control board
Provide stable and reliable power supply for the main control board, touch
Switching power supply
screen and sensor
Miniature circuit breaker Switching power supply for each loop in the panel
Intermediate relay Switching device between unit control signal and executive component
AC contactor A device used to turn on/off the working power of oil pump and oil heater
Thermal relay Implement thermal overload protection on the oil pump
The unit signals collected by the control system include: inlet and outlet water temperature of chilled and cooling
water, evaporating pressure, condensing pressure, oil tank temperature and oil supply temperature, oil tank pressure and oil
supply pressure, chilled water flow switch signal, main motor current ratio, oil pump and oil heater operation state, main
motor winding overheat switch signal and the like, and instructions are output to control the actions of the adjustable vane
actuators and safety devices through analysis of the collected data. The layout of sensors for the unit are as follows:
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Adjustable vane actuator
Oil tank pressure & Condensation Cooling water
temperature sensor pressure sensor temperature sensor
Microcomputer Evaporation Oil supply Oil supply Chilled water

control panel pressure sensor pressure sensor temperature sensor temperature sensor
(a)500RT-1300RT mid-range models (if there is any change in customized units, the real object should prevail)
Oil tank pressure & Condensation Cooling water

Adjustable vane actuator temperature sensor pressure sensor temperature sensor
Evaporation Control panel Oil tank pressure Oil tank temperature Chilled water
pressure sensor sensor sensor temperature sensor
(b) 1400RT-3000RT large-range models (if there is any change in customized units, the real objects should prevail)
Fig. 2.3 Layout of External Sensors for the Unit
11
2.1.2 Automatic Operation Control Principle for the Unit

Centrifugal chillers use adjustable guide vanes arranged at the impeller inlet for energy regulation. The adjustable
guide vanes are driven by actuators. The unit control system implements stepless energy regulation of the whole machine
by controlling the actions of actuators.
When the unit is in automatically operated the energy regulation loading/unloading should be determined by the
following principles:
Current Priority Control: To prevent the main motor from running over current, the main motor current priority
control is adopted in this control system. If the main motor current reaches the rated current during the operation of the
unit, the unit will not carry out energy regulation loading. If the current of the main motor reaches 105% of the rated
current, energy regulation will be automatically unloaded to reduce the current of the main motor to the rated current. If
the current reaches 110% of the rated current, the unit will automatically shut down.
Attention
To prevent the main motor from long-term overload operation, the "Current Priority Control"
function is valid in any energy regulating mode! Therefore, even in the "Manual" control mode, when the
main motor current is fully loaded, the opening extent of inlet guide vane still cannot be turned up.
Surge limit control: To prevent the unit from surging due to too small of an opening extent of the guide vane, the unit
is provided with a surge limit for the opening extent of the guide vane (the default opening extent is 10%), and when the
opening extent of the guide vane reaches this value, it cannot be turned down again (the energy regulation fails to
implement loading).
Unit fault control: When some unit malfunctions, the limit of energy regulation control will be triggered, at which
time the energy regulation of the unit will act according to the system treatment measures for the malfunction.
Load (chilled water temperature) control: Under the above conditions, if the chilled water outlet temperature is less
than the target value, automatic unloading is implemented; otherwise, automatic loading is implemented until the water
temperature meets the target demand.
2.2 Introduction to the Touch Screen Interface

PCB series control system implements interaction with user through a touch screen, which is installed in the middle
of the body panel of the control panel.
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Touch screen
Emergency stop button

Panel door lock
Note: The control panel cannot be used after the emergency stop button is pressed, and it can be reset by turning
the button clockwise.
Fig. 2.4 Unit Control Panel
After the touch screen is powered on, the user can access the system after inputting the user password (58806 or
40828) on the touch screen. The user can read the unit operation data collected by sensors on the screen to evaluate the
state of the unit, or set the parameters of the controller to implement the required functions.
Overview of Touch Screen Operations:
13
2.2.1 Welcome Interface
After the control system is powered on and initialized, access the welcome interface first.
Note: The actual operation interfaces of different series of products may be slightly different, but the operation
methods are basically the same. Other series of models may refer to the operation. The pictures used are only used as
14
operation introduction and do not represent the physical properties.
System clock
Program version
number
Fig. 2.5 Homepage
On the [Homepage] click to enter [Password input interface]. To cancel the password, enter [Homepage] to
return to [Homepage].
Software version: software version number of current system
System time: displayed in the upper left corner
Select Language (different units may vary): select the required language.
Figure 2.3 Password Input Interface
After entering the right password, you will enter the homepage. Otherwise, an "incorrect password" prompt will appear on
screen.
15
Switch to
other pages
Back to Home
Switch to
other pages
Figure 2.4 Homepage (different units may vary)
Figure 2.5 [Homepage]-[Evaporator] Status viewing interface (different units may vary)
On the [Homepage] tap on a part (different units may vary) to view its
details. You can also view details of other parts. Return to the Homepage.
On the [Homepage] click and the interface shown in Figure 2.7 appears. Click analog quantity or digital
quantity to enter the parameter interface. Input status: "ON" indicates that the input point is connected, and "OFF"
16
indicates that the input point is disconnected. Output status: "ON" indicates that the output point is connected, and "OFF"
indicates that the output point is disconnected. Click to return to Homepage.
Figure 2.6 Status Information Interface
Return to
Homepage
Switch to other
pages
Figure 2.7 State information-analog/digital parameters interface (different units may vary)
17
Figure 2.8 Parameter Setting Interface (different units may vary)
Figure 2.9 Alarm record interface (different units may vary)
On the [Homepage] click and the interface shown in Figure 2.10 appears. Click Alarm Record or
Total Alarm Information. Click to return to Homepage.
18
Figure 2.10 Alarm Information Interface
Figure 2.11 Total AlarmInformation Interface (different units may vary)
2.2.2 Description of Public Area

Public area displays the current operating status and operating mode. You can switch to various parameter settings, alarm
information and status information without having to return to the homepage.
(1) Description of Unit Status
Unit statuses include standby, starting up, normal running, halt, stop, and error.
Standby: The unit enters the standby state in normal cases after it is powered on.
Starting up: The unit is being started up.
Normal running: The unit has been started up and is running.
Halt: The unit enters halt status if the water temperature is lower than the limit during initial startup or if it is lower than
the unit halt temperature.
Compressor running: The unit enters running status if the water temperature is higher than the compressor startup
temperature, causing the compressor to start up.
Stop: The unit enters standby status after it awakens from the manual stop state. If a fault occurs, the unit displays "faults"
after it stops.
Fault: The unit status is "faulty" when a fault alarm occurs. Users can query information about the alarm.
19
(2) Description of Unit Model
Set parameters in [Parameter setting]-[Mode setting].
The unit can be controlled locally (touchscreen), remotely (hardware), set to turn on/off with a timer, or BMS (group
control and upper computer). The unit will power on/off based on the current mode. For example: When the unit is in the
timer mode, powering on/off the unit via touch screen is disabled. The unit will be powered on/off according to the set
time.
Note: Only one of the control modes is valid. If "Local" is selected, the "REMOTE", "TIMED" and "BMS" control modes
will not generate a power-on/off signal to trigger power-on/off. The unit can be switched between control modes in any
status. For power-on/off operation, see section 2.2.3 Description of power-on/off operation in various modes.
(3) Parameter Description
Target temperature: user sets the target temperature in [Parameter setting]-[User parameter].
Current temperature: actual evaporator LWT.
(4) System Time
System time: time reference for faults in real time, historical faults and timed on/off functions. Adjust the current time in
[Parameter setting]-[Time setting].
2.2.3 Description of Power-on/off Operation in Various Modes

(1) Power on/off via touch screen
Choose [Parameter settings]-[Mode setting]-"Local" and click the button in the upper right corner. A startup
confirmation interface will appear. Then confirm the startup procedure.
1) If the unit is not set to "Local", an "invalid startup" prompt will appear. 2) You cannot click Start button in case of faults.
Click anywhere during running, and a shutdown confirmation interface will appear. Click it to confirm shutdown
and the unit will stop.
(2) Remote Switch
Choose [Parameter settings]-[Mode setting]-"Remote" and the unit will turn on/off by dry contact. Choose [Parameter
settings]-[Function selection]-"Remote Pulse Mode", represented by the icon . The "Remote on" is
immediately disabled and the unit starts. The "Remote off" is immediately disabled and the unit stops. Choose [Parameter
settings]-[Function selection]-"Remote Hold Mode", represented by the icon . The "Remote on point" is
kept closed and the unit starts. The "Remote on point" is disconnected and the unit stops.
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Notes: If the unit is on or switched to Remote mode, the "Remote on point" is closed. You need to disconnect and then
close the "Remote on point" to turn the unit on. If the unit encounters a fault and stops working, you need to disconnect
and then close the "Remote on point" to turn on the unit.
(3) Powering-on/off in Timer Mode
Choose [Parameter settings]-[Mode settings]-"Timed" and select the timed period and whether to enable the function in
[Parameter settings]-[Timer settings]. You can set eight timed periods, each of which has start/stop time. The timed periods
can be any day(s) from Monday to Sunday. Actions will be executed according to the publicly-displayed time. Adjust the
current time in [Parameter settings]-[Time settings]. For details, see Section 2.4 Timer settings.
The unit turns on/off according to the set time. During the same timed period, timed off takes precedence over timed on. If
the unit is powered on later than the start time of the timed period, the timed on command will be ignored. If the unit fails,
powers off or just stops, timed on will be ignored. The unit will be timed on until the next timed period begins.
(4) Power-on/off in the BMS mode
Choose [Parameter settings]-[Mode settings]-"BMS" and the unit will turn on/off through a communication operation. Set
the communication address in [Parameter settings]-[Serial port settings]. The communication parameter is 9600 8 N 1. If
you need the table of communication parameters, or want to change communication parameters, contact the after-sales
personnel. For details, see the description of serial port settings.
2.2.4 Start/stop Logic

(1) Unit startup:
The unit cannot be started if there is an unresolved fault. After receiving the startup instruction, the unit shows "starting
up". Tap on , and on [Homepage]-[Start status] you can view the startup process. The red indicator shows that
the conditions are not met or that instruction has not been executed, while the green indicator shows that the conditions are
met or that instruction has been executed, as shown below. After the startup procedure, the page contents are voided.
After the unit starts up, the use-side water pump will start. After startup conditions are met, the heat source-side water
pump will start. Then check the guide vane position and oil pressure difference, among other parameters, based on the
actual model. After all the conditions are met, the switch on signal is sent to the compressor before the starter begins
running. Upon receipt of an On signal from the starter, the startup process is completed.
21
Figure 2.12 On/Off Status Interface (different units may vary)
(2) Power Off:
Click the Stop button, and the unit will display "stopping". Start the unloading logic, switch off, resetting control
components, and water shutdown system to complete the shutdown logic. After the shutdown process is completed, the
unit will display "standby", or "fault" if any faults have occurred.
2.2.5 Fault Query and Resetting

If the unit reports an alarm while running, rectify the faults. After rectifying the faults, enter [Homepage]-[Alarm
information]-[Real-time alarm] and then the fault query page to check the real-time faults. Alarm time means the time
when a fault occurred, and reset time means the time a fault was eliminated. After all the faults have been eliminated, click
and the unit will show "standby".
Note that the Oil pump overload and Starter panel fault must be manually rectified in order to clear alarms.
Oil pump overload:
If the running current of the oil pump exceeds the permissible range, the unit will stop and give prompt message on the
touch screen. Find out and rectify the fault and touch Reset to reset the thermal relay of the oil pump; otherwise, the oil
pump will not be started up. Start up the oil pump in standby mode, check oil system parameters, and check whether the
oil pump runs normally. After the confirmation, restart the unit.
Starter panel fault:
It may indicate the VFD fault for an inverter unit. To reset the unit, first clear the VFD fault.
22
For a non-inverter unit, check the thermal relay and general power protector. The thermal relay is used to protect the
startup panel in the event of overload. This thermal relay functions as the thermal relay inside the control panel. When an
overload occurs, manually reset the thermal relay.
The general power protector is used to monitor the power supply of the unit and implements protection in case of
overvoltage, undervoltage, phase lack, inverse phase, or inter-phase imbalance. If the power supply does not meet
requirements for unit running, the protector will act and the LED indicator on the protector will be on. The protector boasts
automatically reset function. After the protector acts, the unit can be restarted only after the LED indicator on the protector
indicates that the fault has been rectified.
On [Homepage]-[Alarm]-[Total Alarm Information], check the [Total Alarm Information] when a fault occurs. The faults
are recorded only after the compressor is switched on. There are 10 fault entries in total, the last entry being the latest.
Switch between the

previous or next
fault
Turn to the next page to

view the details of one
fault.
Figure 2.13 Total Alarm Information
2.2.6 Indicators
indicates that the unit runs properly; indicates that the unit has faults. The unit can only
be started after the faults have been cleared;
indicates an alarm but the unit can still keep running.
If [Homepage] prompts "starter power not ready" or "starter ready" disconnected at the input point, it indicates that the
starter panel is not powered on or the "starter ready" signal is abnormal.
If [Homepage] prompts "Emergency Stop Button Action", it indicates that the urgency switch has been pressed.
If [Homepage] prompts "Maintenance Reminder. Please Contact After Sales Engineers", so the unit operation can proceed.
23
It is recommended that the unit be maintained to ensure reliable operations in the future.
If [Homepage] prompts "Restart Delaying, s left", it indicates that the unit fails to meet the interval restrictions.
2.2.7 Function Settings

(1) User Parameter Setting
Target water outlet temp. for cooling: target temperature of chilled water outlet
(2) Difference temp./pause: When the current temperature <= the target temperature - difference temp./pause, the unit
stops.
(3) Difference temp./quit pause: When the current temperature >= the target temperature + the difference temp./quit pause,
the unit meets the required water temperature and starts again.
(4) Temp. difference to maintain capacity regulation: not regulate temperature within the range of target temperature ±
temp. difference to maintain capacity regulation.
(5) Temp./cooling tower fan unit 1 on, temp. difference for cooling tower fan regulation
When the cooling water temperature is higher than this set temperature, the cooling tower fan 1 will be enabled.
When the cooling water temperature is lower than this set temperature minus the temp. difference for cooling tower fan
regulation, the cooling tower fan 1 will be enabled.
When the cooling water temperature is higher than this set temperature for 2℃, cooling tower fan 2 will be enabled.
When the cooling water temperature is lower than this set temperature minus 2℃ and then minus the temp. difference for
cooling tower fan regulation, cooling tower fan 2 will be enabled.

2.2.8 Settings
Adjust the current time in [Parameter settings]-[Time settings].
Click to access
the time setting
interface
24
Figure 2.15 Time setting interface
Click to enter editing mode, as shown in Figure 2.15.
Click to enter time
Figure 2.16 Time Input Interface
2.2.9 Timer Setting
Timer setting: set the timer to on/off while in timer mode. Such timer setting is only valid when the control mode of the
unit is set to "Timer". See Figure 2.17 for the timer setting interface.
Enable Click to set

buttons effective date
Segment
number
Click to enter the

power-on/off time
25
Figure 2.17 Timer on/off Setting Interface
You can set eight timed periods, each of which is to be enabled with the "enable" buttons. indicates that timing
is disabled, while indicates that it is enabled. indicates the timing is applicable to Monday (in
blue), rather than Tuesday (in black).
Notes: ① If the unit is in standby mode and the "Start Time" and "Stop Time" settings in this segment are the same, when
the set start/stop time arrives, the shutdown priority rule will prevent the unit from starting up.
② If the unit is in operating mode and the "Stop Time" of the current segment is the same as the "Start Time" of the other
segments of the current day, when the set start/stop time comes, the unit will be stopped normally and will not be started
again during this period of time.
③ It is advised to set a difference of over 15 minutes between the "Start Time" of other segments of the current day and
the "Stop Time" in this segment of the current day; otherwise, if the unit is in operating mode, the stopping of the unit will
be triggered when the "Stop Time" of this segment arrives. Because it takes a certain period of time to complete a stop, if
the "Start Time" of other segments comes during stopping of the unit, the startup signal will be ineffective, and the unit
will not be started again in this period of time after being stopped.
2.2.10 Description of Serial Port Settings
Communication settings: set controller (PCB or PLC) communication interface (serial port) parameters in BMS
mode, as shown in Figure 2.18.
26
Set value
Current
value
Click to save
settings
Figure 2.18 Serial Port Setting Interface
You can only set the station number (address) from 1-15. The default parameters are 9600 8 N 1. To change the parameters,
contact after sales personnel.

2.2.11 Description of Touch Screen Settings
Figure 2.19 Touch Screen Settings Interface
You can set touch screen brightness, buzzer and calibrate touch screen.
Click the "screen calibration" button to enter the calibration page. Click until the calibration process is completed.
Then click anywhere to exit.
27
2.2.12 Quick Start
This function needs to be customized. On [Homepage]-[Parameter settings]-[User function], click Quick Start and then set
the time. If the power-off time is less than the set time, perform Quick Start; otherwise, do not perform Quick Start. If
Quick Start is enabled, the homepage displays "Quick Start Enabled".
Enable Start-up after Restoration of Power and set time. If the power-off time is less than the set time, perform Start-up
after Restoration of Power; otherwise, do not perform it. If time is set to 0, the unit may be started at any time. If Start-up
after Restoration of Power is enabled, the homepage displays "Start-up after Restoration of Power Enabled".
If the power-off time is less than the set time, perform Quick Enable/disable Quick Start
Start; otherwise, do not perform Quick Start.
If the power-off time is less than the set time, perform Enable/disable Start-up after
Start-up after Restoration of Power; otherwise, do not Restoration of Power
perform it.
Notes: If time is set to 0, the unit may be started at any time.
2.2.13 Manual Operation
(1) Oil Pump Control
Enter [Homepage]-[Oil system]- . Oil pump manual control interface appears.
Figure 2.20 Oil Pump Control Interface
During unit startup, running, or stopping, the oil pump is running, so never touch the manual control buttons.
When the unit is in standby mode, touch the manual control buttons to start or stop the oil pump. After the oil pump starts,
check the oil pressure difference. If the oil pressure difference is abnormal, stop the oil pump immediately. Otherwise, the
oil pump will stop automatically after 90s.
When an oil pump stop signal is generated, the main unit current is larger than or equal to 10% of the rated current, or the
starter is closed. At this time, the oil pump will continue running and cannot be stopped manually. Check the unit.
28
2.2.14 User Restrictions
The current values shall be set for the fixed frequency unit and power values for the inverter unit. To set the proper current
and power percentage, first enable this feature by setting it to ON.
The unit load cannot exceed the set value.
Note: For details about the starter panel, refer to the starter panel use instructions.
29
Fig. 2.3.1 Schematic Diagram of Control System for 500RT~ 2200RT Centrifugal Chiller 1
2.3 Schematic Diagram and Wiring Diagram of the Control System
～
～～
30
M
M
3～
Oil Control Isolation Cooling Switching power supply Switching power supply
Oil pump power transformer
fan Upper computer communication / Switching power supply
touch screen
heater switch cloud platform module
Winding overheating
Module
Reserved
Reserved
Remote ON
Remote OFF
Alarm
fault
31
Fig. 2.3.3 Schematic Diagram of Microcomputer Control System for 500RT~ 2200RT Centrifugal Chiller 3
/1.E6
/1.E6
801 802 PE
COM DI22 DI23 DI24 DI25 DI26 DI27 DI28 DC12V GND GND B A A B A A
CN1 CN8 CN13 CN14
A1
32
CN15 CN25 CN26 CAN2 CAN1 COM1 COM2
COM2 DO23 DO24 DO25 DO26 DO27 DO28 DO29 DO30 L H COM L H COM COM B A COM B A
102 126 127
X2:16 X2:18
X2:17 X2:19
PCD(SJM)-DKD
θ
（Suitable for heat pump models ）
～
33
Green
Red
M
White
Black
34
Electronic
expansion valve
opening input
Compressor Public
Alarm Fault
ON port
Open Close Public Power
valve valve port supply
Guide vane electric actuator
Active contacts need to be bridged
Fig. 2.3.6 Wiring Diagram of Control System for 500RT~ 2200RT Centrifugal Chiller 6
green red white black
Control panel Oil Oil Starter
panel
Starter
panel
Starter
panel
Compressor Compressor Compressor OFF Oil temperature
power supply current ON (Pulse signal) electronic
pump heater fualt operation ready
expansion valve
Alarm Fault Running User Heat source Cooling Cooling Heat Refrigerant Remote Remote
Upper computer
indicator side side water tower fan tower fan recovery pump ON OFF
communication interface
water pump group 1 group pump
pump
Remarks
35
Actuator Guide Guide Guide vane
Evaporator Condenser Winding Guide Guide Guide vane Oil return Secondary Secondary vane vane Level
Actuator power supply opening feedback
flow switch flow switch overheating vane vane opening feedback solenoid valve air valve air valve open close
power supply feedback
open close open close
Electric actuators - passive contact control (two-wire
Electric Actuator - Active Contact Control system)
Green red White
Liquid
Evaporator Evaporator Condenser Condenser Discharge Evaporation Condensing Oil Oil tank level
Oil tank Oil supply
water outlet water inlet outlet water inlet water temperature temperature temperature pressure pressure supply
pressure
pressure feedback
Power
supply Input Output
temperature temperature temperature temperature (for heat pump (three-wire
Liquid level control electric valve
models) system)
Suitable for liquid level control models

…
Fig. 2.3.7 Schematic Diagram of Control System for 2300RT ~ 3000RT Centrifugal Chiller 1
～
～～
36
M
M
3～
Oil Control Isolation Cooling Switching power supply Switching power supply
Oil pump power transformer
fan Upper computer communication / Switching power supply Touch screen
heater switch cloud platform module
Winding overheating
Reserved
Reserved
Remote ON
Remote OFF
Alarm
Fault
37
/1.E6
801 802 /1.E6 PE

CN1 CN8 CN13 CN14
A1
38
102 126 127 722 723 724
X2:16 X2:18
X2:17 X2:19
/2.E8
/6.D4
/8.E1
/2.E8 /8.E1
PCD(SJL)-DKD
θ
（Suitable for heat pump models ）
～
39
COM DI1 DI2 DI3 DI4 DI5 DI6 DI7 COM DI8 DI9 DI10 DI11 DI12 DI13 DI14 COM DI15 DI16 DI17 DI18 DI19 DI20 DI21
CN4 CN3 CN2
A2
40
CN7 CN11 CN16
COM DO1 DO2 DO3 DO4 DO5 DO6 DO7 D08 DO9 DO10 DO11 DO12 DO13 DO14 DO15 DO16 DO17 DO18 DO19 DO20 DO21 DO22
PCD(SJL)-DKD
/1.E6
/1.E6
801 802 PE
CN1 CN8 CN13 CN14
A2
41
722 723 724
/3.D4
PCD(SJL)-DKD
Fig. 2.3.13 Schematic Diagram of Microcomputer Control System for 2300RT ~ 3000RT Centrifugal Chiller 7
Configured Bypass Valve
Two-way Val. Opening

Opening
- -
X4:43 X4:55
X4:42 X4:54
806 525 + 526 +
AIT1 AIT2 AIT3 AIT4 AIT5 AIT6 AIT7 AIT8 D3V3 AO-10V-A AO-10V-B GND AI-10V-1 AI-10V-2 AO-20mA-A AO-20mA-B
CN10 CN5
A2
42
COM3 COM4 COM5 COM6 CN12
COM B A COM B A B A COM B A COM AII8 AII7 AII6 AII5 AII4 AII3 AII2 AII1
519 518 516
X4:57
X4:45
X4:56
X4:44
5
4
I I
6 3
A5 D D
7
2
1
YM6 YM4
520
521
X4:29 X4:30
806 805
/1.D8
/1.D8
PCD(SJL)-DKD
/3.E2
/3.E2
X4:52
X4:53
X4:40
X4:41
X4:34
X4:35 201 211 601 602
803
24V GND
/1.E7
X3:19 KA5
valve valve port
Open Close Public
804
/1.E7
X3:21 136 KA6
KM1
PE
X3:20 137
603
X3:9
604
supply
Power
X3:10
(Active contacts need to be bridged )
expansion valve
opening input
Electronic
512
605
+
Guide vane electric actuator
/4.C8
-
606
/4.B8
X3:11 140
X1:27
X1:26
X1:25
X1:24
X3:12 141 KA3
ENTER
X3:13 142 KA4

White
Green
Red
Black
806
CANCLE
M
UP
DOWN
X1:20 143 SB
Compressor
144
ON
X1:21 145 KA1

X1:22 146 SB
KA2
X1:23 148
Public
port
X2:4 149
X2:5 150
Alarm Fault
1KA
X2:6 151 2KA
PCD(SJL)-DKD
X2:7 152 3KA
43
Fig. 2.3.15 Wiring Diagram of Control System of 2300RT ~ 3000RT Centrifugal Chiller 1
green red white black
Control panel Starter Starter Starter Compressor Compressor Compressor
Oil Oil panel panel panel ON OFF
Oil temperature
power supply current electronic
pump heater
fault operation ready
(Pulse signal) expansion valve
Alarm Fault Running User Heat source Cooling Cooling Heat Refrigerant Remote Remote
Upper computer
indicator side side water tower fan tower fan recovery pump ON OFF
communication interface
pump pump group 1 group pump
Remarks
44
Guide Guide Guide vane
Condenser Guide Guide Actuator
Evaporator Winding Actuator Guide vane Oil return The 2nd The 2nd vane vane opening feedback Liquid
Flow switch vane vane stage vapor power supply
Flow switch overheating power supply opening feedback solenoid valve stage vapor open close level
open close injection injection feedback
valve valve Electric actuators - passive contact control
Electric Actuator - Active Contact Control (two-wire
open close
system)
Green red White
Liquid
Evaporator Evaporator Condenser Condenser Oil tank Oil supply
Discharge Evaporation Condensing Oil Oil tank Motor Winding level
water outlet water inlet outlet water inlet water temperature temperature temperature pressure pressure supply
pressure
pressure
Temp. feedback
power
supply Input Output
temperature temperature temperature temperature (for heat pump models) (three-wire
Liquid level control electric valve
system) Suitable for liquid level control models
…
Power Input Output Power Input Output
Hot Gas Bypass Valve
3 Unit Use
3 Unit Use
3.1 Unit Installation in Place
Warning
Centrifugal Chillers are relatively complicated, and should be installed by professionals!
The following table describes the steps for the installation and positioning of the unit. The right side of the table
shows the tools or components required to be provided by the user on site. Any omission of work or components in the
installation process may cause some damage to the unit. Please check carefully before installation.
Work steps Detailed Provided by To be provided on site
description Manufacture
Confirming the 3.1.1
machine room
conditions
Site 3.1.2
confirming
Machine room 3.1.3
foundation
construction
Moving the unit 3.1.4 1. Crane
into the machine
room 2. Lifting beam
3. Wirerope
4.U-shaped lifting lug

Unit 3.1.5 1. Shock absorbing pad 1.Base steel plate Note 1
installation for the unit
2. Nut M30 (8 pcs. )
3. Washer 30 (8 pcs. )
4. Anchor bolts M30×400(8 pcs. )
5. Necessary building concrete

Water piping 3.1.6 1. Pipe connecting flange 1. Flow controller Note 2
construction and bolt
2. Pressure gauge
3. Flexible damping joint
45
3 Unit Use
4. Pipeline support
5. Other components on the pipeline (water

valve, filter and the like)
Relief valve 3.1.7 1. Refrigerant discharge pipe
discharge pipe
Electrical wiring 3.1.8/3.1.9 1. Starting panel 1. Control line (refer to Table 3.3)
Note 3
(optional)
2. Power cable (refer to 3.1.8)
2.3M insulation kit Note 4
3. Contactor and wiring of chilled water
pump
4. Contactor and wiring of cooling water

pump
5. Grounding wire
Cold insulation 3.1.10 1. Thermal insulation
construction cotton (optional)
Note 1: Refer to the general drawing of refrigeration unit for the specifications and quantity of base steel plates.
Note 2: The flow controller should be strictly model-selected as described in 3.1.6 of this manual.
Note 3: The electrical wiring shall be provided by the user. Please strictly follow the configuration described in 3.1.8
of this manual.
Note 4: 3M insulation kit is only configured when the main motor is at high-voltage (above 6000V).
Warning
The field tools or components provided by the user should be configured according to the
requirements of this manual, and the loss caused by the user’s using of inappropriate tools or wrong
components shall be borne by the user.
3.1.1 Conditions on the Installation Site

1. Refrigerator shall not be located near a fire and inflammables. When it is collocated with heating elements such as
boilers, full attention should be paid to the influence of thermal radiation.
2. Select a well-ventilated place with room temperature below 43℃ and relative humidity below 90%; Installation
and storage outside or in the open air are not allowed.
3. Places with less dust are favorable.
4. The site should be well-lighted to facilitate maintenance and inspection.
46
3 Unit Use
5. To meet the needs of maintenance, overhaul and cleaning of evaporator-condenser heat exchange tubes, sufficient
maintenance space should be left around the unit (see the following figure for specific dimensions).
Fig. 3.1 Diagram of Unit Maintenance Space
Table 3.1 Dimension of Maintenance Space for TWCF Series Centrifugal Chillers
Cooling capacity range of Maintenance space size (mm)
the unit M T Y S Z
500-1300RT 1500 4500 1300 1300 1000
1400-2200RT 1600 5000 1300 1800 1000
2300RT-3000RT 2000 5000 1300 2000 1000
6. To facilitate the lifting and maintenance of the machine, do install a bridge crane or derrick car, and make sure the
room has enough height.
7. The area around the unit and the whole machine room should be able to achieve complete drainage.
3.1.2 Site Confirming
To make necessary preparations in advance and make the installation correct, quick and work safe, the following
conditions should be confirmed in advance with relevant constructors:
1. Installation site: Confirm whether it meets the requirements of 3.1.1.
2. Move-in hole: Confirm its size, height and lifting allowance, and remove the move-in obstacles.
3. Move-in sequence: Confirm the move-in method and move-in sequence are according to the installation site
conditions and equipment to be installed.
4. Move-in path: Remove the obstacles hindering handling from the move-in path.
3.1.3 Foundation Construction
Make sure the rotor of Manufacture Centrifugal Chillers refrigeration compressor undergoes strict static balance and
dynamic balance, and its residual centroid skewing is below 0.001mm; Therefore, its dynamic load on the foundation is
47
3 Unit Use
very small, and static load (please refer to Appendix 1 to this manual for the static load amount of the unit) can only be
considered for the unit foundation.
To prevent the corrosion of the unit footing, it is required that the area around the unit shall allow good drainage, and
the foundation plane corresponding to the machine-base steel plate shall be smooth and flat. The specific requirements are:
1. The maximum height difference (levelness) between each foundation surface should be less than 3mm.
2. To facilitate the refrigerator maintenance/inspection, the foundation height should be greater than 100mm.
3. Drainage ditches should be set up around the refrigeration unit.
3.1.4 Move-in Construction
1. Inspection of machines reaching the site: When unpacking, check the appearance of machines reaching the site and
the accessories for damages, and the delivered quantities should be checked according to the "Packing List" to see if there
are any missing pieces.
2. Lifting: To lift up the unit, the wirerope should be hung in the lifting holes in tube plate of the machine, and the
load should be evenly distributed; Take care not to damage the accessories (see Fig. 3.2).
(1) Lift up the unit horizontally as far as possible.
(2) Inclined lifting/handling is an important cause for damages to the unit. When the unit has to be tilted and lifted,
the maximum allowable inclination angle of the unit is 20° and should be carefully taken care of.
(3) In case the machine is impacted, the bearings may be damaged and the shaft may be bent, thus shortening the
service life of the machine. Therefore, great care should be taken to prevent the machine from being impacted during
handling.
(4) When the unit is transported by rollers, the unit should be prevented from turnover.
3. Unit disassembly and hoisting construction: In order not to damage the sealing performance of the unit, it is better
for the unit to reach the site as a whole. If disassembly is required before it reaches the site due to the limitation of site
location, the following points should be noted:
(1) Remove the compressor and the motor as a whole from the evaporator-condenser, and hoist them according to the
main points given in the lifting diagram of the compressor unit shown in Fig. 3.3.
(2) The evaporator-condenser hoisting should be carried out according to the overall hoisting essentials shown in Fig.
3.2.
(3) The shorter the exposure time during hoisting and after disassembly, the better, as the residual refrigerant in the
unit will cause corrosion inside the unit after the exposure to air.
Fig. 3.2 Schematic Diagram of Unit Lifting
48
3 Unit Use
Within 60
Fig. 3.3 Schematic Diagram of Centrifugal Compressor Hoisting
Attention
After the unit is disassembled, it should be installed in place on time. Before the installation conditions
have not fully met the requirements, the unit should not be disassembled hurriedly, so as not to cause
internal corrosion of the unit, which may affect the safe operation of the unit.
3.1.5 Installation Construction

1. First of all, confirm whether the foundation meets the requirements of foundation size on the general drawing. The
footing and foundation plane of the machine should be smooth and level.
2. Prepare all parts according to Fig. 3.4.
3. Place the refrigerator on the base steel plate.
4. Use a bubble level meter to check the horizontal inclination of the unit in the lengthwise and widthwise directions.
5. Lift up the refrigeration unit, place the damping rubber pad on the base steel plate, and then place the refrigeration
unit on the damping rubber pad.
6. Fasten the anchor bolts, confirm again that the inclination of the unit meets the requirements, and then fix the area
around the base steel plate and the adjusting pad by secondary grouting.
49
3 Unit Use
Nut M30
Washer M30
Unit-body bottom plate
Rubber pad
Base plate
Anchor bolt M30×400
Fig. 3.4 Installation Diagram of the Unit Foundation
50
3 Unit Use
3.1.6 Water Piping Construction
Warning
Before the construction of the water piping, the user should first complete the cleaning of and pressure
test on the water system, and it can only be connected to the unit after being confirmed as qualified.
Otherwise, impurities in the system could enter into the unit and block or damage the heat exchange tubes!
The construction of water piping shall be carried out according to the general drawing of Centrifugal Chillers.
Connect the water system pipeline to the unit through flange according to the pipe size indicated in the general drawing.
Please refer to the following for the installation of some necessary parts on the water pipeline.
Attention
To carry out the construction of water piping, supports should be erected along the pipeline to prevent
the unit from bearing the weight of this section.
Pressure gauge installation:
The pressure gauge should be installed on the straight pipe section of the pipeline near the water chamber, and its
installation point should be at least one pipe diameter away from the upstream and downstream components (such as
elbows, water valves and the like) that may generate turbulence.
Pressure gauges shall be installed on the water inlet and outlet pipelines of the evaporator and condenser of the unit.
The pressure gauges should be connected to the pipelines through buffer bends, which is helpful to judge the state of the
waterway system.
Filter installation:
A filter is installed on the inlet pipeline of each water chamber to prevent sundries from entering the water chamber
and block the pipeline or cause damage to the water chamber.
Warning
A filter should be installed on the water inlet pipe of the unit!
Installation of water valve:
It is recommended to install shut-off valves before and after parts (e. g. filters, water pumps and the like) that may
need to be replaced on the water pipelines, so as to save time and amount of work for their replacement.
Installation of flexible damping joint:
A flexible joint is installed on the pipeline to prevent the vibration of the unit from being transmitted to the pipe
network, and also to prevent the vibration of the water pump and the unit from overlapping each other and affect the
service life of the pipeline.
Attention
Secondary motor should not be used for the water pump on the pipeline to avoid resonance with the
unit.
Installation of cooling tower bypass circuit:
When the external temperature is relatively low and the unit needs to be used, to ensure the normal operation of the
cooling system of the unit with sufficient pressure difference between the condenser and the evaporator, it is recommended
that the user install a bypass circuit on the water inlet pipe of the cooling tower of the unit. The schematic diagram is as
follows:
51
3 Unit Use
Three-way temperature-controlled valve Cooling tower
From the condenser
To the condenser
Fig. 3.5 Installation Diagram of Bypass Circuit for the Cooling Tower
Where, the three-way valve with temperature control should be able to implement the following functions:
(1) When the temperature of unit cooling water is low, the three-way valve shall be able to control the opening
extent so that the cooling water inlet temperature is greater than 15℃.
(2) On the premise that the conditions mentioned above are satisfied, the three-way valve shall be able to control the
opening extent so that the inlet temperature of cooling water is as small as possible to save energy.
3.1.7 Relief Valve Discharge Pipe
The relief valve is a component used to protect the unit. When the pressure in the evaporator or condenser of the unit
exceeds the rated discharge pressure, the relief valve will open. With the loss of refrigerant, the pressure in the unit will
drop. To install a discharge pipe for the relief valve, the following matters should be noted:
1. The connection of pipelines should comply with local laws and regulations.
2. The relief valve discharge pipe should be made of materials compatible with R134a refrigerant. The diameter of the
pipe should be selected according to the size of the relief valve. When the unit uses parallel relief valves, the diameter
should be selected according to the size of the two relief valves.
Table 3.2 Dimensions of Relief Valve Discharge Pipe
Parallel
Installation of relief valve Single
connection
Diameter of discharge pipe mm 25 35
3. Remove the protective cover from the relief valve and connect the discharge port of the relief valve to the outside
as shown in Fig. 3.6. A certain volume should be reserved at the bottom of the pipe for collecting the liquid. The relief
valve and the discharge pipe are connected by threads, and the joint is provided by the user. The thread specification is
G1-1/4.
4. The outdoor outlet of the discharge pipe should be kept far away from the fresh air inlet of the building.
52
3 Unit Use
It can also be discharged from the roof
Roof
Exterior wall
Bent down to prevent rainwater and

sundries from entering the pipe
Flexible connection to
prevent vibration transfer
Discharge valve
Fig. 3.6 Schematic Diagram of Relief-Valve Discharge Pipe

3.1.8 Electrical Wiring Construction
Warning:
Electric connection must conform to the local and national standards.
Use of unqualified personnel or failure to comply with the relevant provisions specified in the Warning may result in
serious personal injury or substantial property damage. Only professionals qualified in the training relating to equipment
installation, commissioning and operation are permitted to operate this equipment.
The power supply of the unit shall be provided with a dedicated disconnector to allow isolation from other electrical
equipment.
During electric connection, remember to disconnect the unit from the power supply, lock the circuit breaker and place
the warning. Note that metal filings generated during electric connection cannot enter the starter panel.
Permanently fasten the power cord. The unit must be grounded reliably. Grounding must be performed on site
according to the local grounding regulations.
Do not maintain the unit while energized. The VFD starter panel must be checked or repaired 15 minutes after power
is cut off.
Do not attempt to repair the line by yourself to avoid damage or injury. Improper repairs may result in damage to the
unit, injuries or property damage. For any repairs, contact Manufacture after-sales personnel.
Only use electrical components from brands and models approved by Manufacture. Users can apply for installation
services or technical support from the manufacturer or authorized distributor.
Carefully read the instruction labels attached to the electric control box.
Warning
Electric Safety Requirements
(1) Reliable grounding: The unit must be grounded. Before installation, check whether the user's power supply is
equipped with a grounding cable. If not, and no effective rectifications are made on site, do not install the unit;
(2) Current leakage detection: use a leakage current detection device to conduct the test. If it is found that the
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grounding cable of the user is energized, stop installation before any rectifications are made;
(3) Leakage protection: This unit may generate DC power in the protective conductor. When using a residual
current device (RCD) to provide additional protection, we recommend using Class B (delayed-type) RCD for the
power supply.
(4) Cable diameter check: If the cable diameter is too small, it may result in overheating and even fire. If the cable
diameter is less than what is actually required, or fails to meet electricity load requirements, do not install the
unit. See Table 3.6 for cable diameter selection.
(5) Rat-proofing design: Upon completion of wiring, seal the inlet holes to prevent rats from entering the electric
control panel.
Warning
All electrical wiring should adopt copper cables!
Please confirm the insulation resistance value of the following electrical circuit when it is powered on for the first
time or after long-term shutdown.
1. The insulation resistance of the control loop to the ground should not be less than 1MΩ (Use a 500 V megger
to measure insulation resistance).
2. The interphase insulation and ground insulation of the main circuit of the low-voltage starter panel should not
be less than 5MΩ (Use a 500 V megger to measure insulation resistance).
3. The interphase insulation and ground insulation of the main circuit of the high-voltage starter panel should not
be less than 10MΩ (Use a 10000 V megger to measure insulation resistance).
The installation of equipment, electrical devices and instruments is the same as that of electrical devices and
instruments for general industrial equipment, and the installation should comply with the national installation procedures.
The installation of electric control and instruments of the unit should be carried out according to the wiring diagram
of the automatic control system of the centrifugal chiller. The power line from the user's power distribution panel to the
starter panel and the control panel, the cable from the starter panel to the compressor motor, and the control line between
the starter panel and the control panel shall be provided by the user.
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User side control User side power

panel (pump, fans distribution panel
and remote on/off,
etc.)
User side
User side control cable Unit side
Cable inlet of starter panel
Unit
control
panel Starter
panel
Power cable of unit

control panel Compressor
Unit control panel-starter panel Cable outlet of starter panel

control cable
Note:
1. When the unit is equipped with a low-voltage closed wye-delta starter panel, the unit control panel can use power from the
starter panel or from the user side power distribution panel.
2. The wiring diagram in this drawing is only a schematic diagram. The actual electrical wiring diagram shall prevail.
Fig. 3.7 Wiring diagram of centrifugal chiller
Warning
The signal cable and the power cable should be vertically crossed or divided into slots. Failure to pay attention to
this warning will lead to electromagnetic interference in the control cable.
1 Control panel and starter panel wiring

When the unit uses a unit-mounted (VFD) starter panel, the wiring between the starter panel and the control panel has been
connected before leaving the factory, and the user does not need to change it. For units using a low-voltage closed
wye-delta starter panel, it is suggested that the unit control panel take electricity directly from the terminal of the
low-voltage closed wye-delta starter panel or from the user side distribution panel. For units that use other free-standing
starter panels, the unit control panel shall take electricity from the user side distribution panel. The power requirements are
shown in Table 3.3.
Table 3.3 Power requirements for unit control panel
Power system TN system
Input voltage 3 AC 380V±10%
Input frequency 50Hz±2%
Imbalance of the voltage The three-phase imbalance of the unit voltage should not
exceed 2%
Power supply capacity of unit
6.5KVA
control panel
The wiring between the unit control panel and the starter panel shall be made according to the "Schematic Diagram
and Wiring Diagram of the Control System" of the unit. The cable type and diameter requirements are shown in Table 3.4.
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When the actual distance of the site is far, the line diameter can be appropriately increased.
Fig. 3.4 Unit control panel and starter panel wiring
Terminal of unit Function Recommended Min.
control panel cable type cross-section
area
X1:1，X1:2， Unit control panel BVR 2.5 mm2
X:3,X:4(PE) power supply
X1:20，X1:21 Compressor ON KVVP 1.5 mm2
X1:15，X1:16 Compressor current KVVP2 2.5 mm2
X1:10，X1:11 Starter panel fault KVVP 1.5 mm2
X1:10，X1;12 Starter panel running KVVP 1.5 mm2
X1:22，X1;23 Compressor OFF KVVP 1.5 mm2
X1:13，X1:14 Starter panel ready KVVP 1.5 mm2
X1:17，X1;18， VFD communication KVVP2 1.5 mm2
X1:19Note 1 wire
Note 1: only VFD starter panel has communication wire.
2 Starter panel wiring
The power cables from the user side distribution panel to the unit's starter panel are configured according to the
following description. Please install and run the cables according to the attached Schematic Diagram and Wiring Diagram
of the Control System. The incoming and outgoing terminals of the starter panel are of bus structure, and the wiring shall
be:
(1) Galvanized bolts of grade 8.8 should be used. When connecting, the contact surface should be kept clean and
coated with electrical joint compound;
(2) There shall be plain washers between the bolt and the busbar fastening surface, and spring washers or locking nuts
shall be installed on the nut side, and the bolt length shall be exposed to nut 2 ~3 circle.
(3) The connection lug/bus shall be closely connected with the bus contact surface of the control panel. The
connection bolt shall be tightened with torque wrench. The tightening torque value shall conform to the provisions in Table
3.5.
(4) When installing the power cable, sufficient electrical clearance and creepage distance between the adjacent
conductors (power cable, bolts, nuts, gaskets, etc.) and between the conductor and the chassis should be ensured, as shown
in Table 3.6.
Table 3.5 Steel bolt tightening torque value
Steel bolt tightening torque value Steel bolt tightening torque value
(mm) (Nꞏm)
M8 8.8～10.8
M10 17.7～22.6
M12 31.4～39.2
M14 51.0～60.8
M16 78.5～98.1
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M18 98.0～127.4
M20 156.9～196.2
M24 274.6～343.2
Table3.6 Electrical clearance and creepage distance requirements

Voltage Electrical clearance Creepage distance
300<V≤500 10.0mm 12.0mm
10kV 125mm 200mm
According to the different models of units, the main motor of the centrifugal chiller adopts a 10kV high voltage motor
or a 380 V low voltage motor. With different voltage levels of the motor, the requirements for power cables are also
different. Power cable recommendations are shown in Table 3.7.
Table 3.7 Wiring reference for TWCF series centrifugal chiller

Voltage 380V 10kV
High voltage
Closed wye-delta starter panel/solid (direct/series
VFD starter panel
Capacity soft start starter panel reactance/autotransforme
r/VFD) starter panel
Cable inlet Cable outlet Cable inlet Cable outlet Cable inlet/outlet
500RT 3*(2*BVR150) 6*(1*BVR18 3*(2*BVR185 3*(2*BVR185
+BVR150 5)+BVR150 )+BVR185 )+BVR185
550RT 3*(2*BVR150) 6*(1*BVR18 3*(2*BVR185 3*(2*BVR185
+BVR150 5)+BVR150 )+BVR185 )+BVR185
600RT 3*(2*BVR1 6*(1*BVR18 3*(2*BVR185 3*(2*BVR185
50)+BVR150 5)+BVR150 )+BVR185 )+BVR185
650RT 3*(2*BVR1 6*(1*BVR18 3*(2*BVR185 3*(2*BVR185
50)+BVR150 5)+BVR150 )+BVR185 )+BVR185
700RT 3*(2*BVR1 6*(1*BVR24 3*(2*BVR240 3*(2*BVR240
85)+BVR185 0)+BVR185 )+BVR240 )+BVR240
YJV22-3*25
750RT 3*(2*BVR2 6*(1*BVR24 3*(2*BVR240 3*(2*BVR240
40)+BVR240 0)+BVR240 )+BVR240 )+BVR240
800RT 3*(2*BVR2 6*(2*BVR12 3*(4*BVR120 3*(4*BVR120
40)+BVR240 0)+BVR240 )+BVR240 )+BVR240
850RT 3*(2*BVR2 6*(2*BVR12 3*(4*BVR120 3*(4*BVR120
40)+BVR240 0)+BVR240 )+BVR240 )+BVR240
900RT 3*(4*BVR1 6*(2*BVR12 3*(4*BVR120 3*(4*BVR120
20)+BVR240 0)+BVR240 )+BVR240 )+BVR240
950RT 3*(4*BVR1 6*(2*BVR12 3*(4*BVR150 3*(4*BVR150
20)+BVR240 0)+BVR240 )+BVR240 )+BVR240
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1000RT 3*(4*BVR1 6*(2*BVR15 3*(4*BVR150 3*(4*BVR150
20)+BVR240 0)+BVR240 )+BVR240 )+BVR240
1100RT 3*(4*BVR1 6*(2*BVR15 3*(4*BVR150 3*(4*BVR150
50)+BVR240 0)+BVR240 )+BVR240 )+BVR240
1200RT 3*(4*BVR1 6*(2*BVR18 3*(4*BVR185 3*(4*BVR185
50)+BVR240 5)+BVR240 )+BVR240 )+BVR240
1300RT 3*(4*BVR1 6*(2*BVR18 3*(4*BVR240 3*(4*BVR240
85)+BVR240 5)+BVR240 )+BVR240 )+BVR240
1400RT
1500RT
1600RT -- -- -- -- YJV22-3*35
1700RT
1800RT
1900RT
2000RT -- -- -- -- YJV22-3*50
2100RT
2200RT
-- -- -- -- YJV22-3*70
2300RT
2400RT
2500RT
2600RT
2700RT -- -- -- -- YJV22-3*95
2800RT
2900RT
3000RT
1. Referring to GB50217 Cable Design Specification for Power Engineering, 10KV wiring shall be laid under the
conditions of bridge laying, ambient temperature of 45℃, wire body temperature of 65℃, cable type YJV22, copper core
cable.
2. For low-voltage wiring, refer to GB/T 16895.6 Low-voltage Electrical Installations Part 5-52: Selection and installation
of electrical equipment-wiring system. The conditions for laying are bridge laying (flat laying, horizontal laying with
spacing), ambient temperature of 40℃, wire body temperature 70℃, cable type PVC insulation, copper core cable.
3. If the cable material, the laying method is not consistent with the recommendation (such as multi-layer bridge, pipe
threading, high temperature), or the cable line pressure loss >2% caused by distance, please select the cable according to
the maximum operating current of the unit. When using other types of cables, please pay attention to the size of the lug to
ensure that the electrical clearance conforms to the standard.
4. Taking 3*(2*BVR150)+BVR150 as an example, the meaning of the expression means that two BVR150 cables are used
for each phase of 3, and 1 BVR150 cable is used for grounding.
5. The above recommended cable is the min. allowable cable diameter of the unit. The cable shall be prepared by the user.
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6. Cables of the same specification (same length, same cross-sectional area, same manufacturer) shall be used in parallel.
7. The fixed-frequency compressor has 6 terminal posts. Taking 6*(2*BVR120)+BVR240 as an example, 6 sets of phase
cables and 1 ground cable are required to lead into the terminal box of the compressor.
8. The terminal column of the inverter compressor has been shorted. The customer only needs to lead 3 sets of phase
cables and 1 ground cable to the terminal box of the compressor.
9. Rated voltage of cable for 10kV starter panel: YJV22-8.7/15kV. Cables shall be sheathed steel tape armored cables. For
example, the incoming/outgoing cable of the high voltage starter panel of TWCF 600 is YJV22-3*25, which means 1
3-core cable, each core cable section is 25mm2.
10. The recommended distribution cable for 10kV starter panel is based on the current carrying capacity. In practical
engineering, the final selection of cable should be determined according to the calculation of short-circuit thermal stability
conditions.
3 Starter panel and main motor Wiring
The terminals of the main motor are marked with letters (U1, U2; V1, V2; W1, W2). For 380V low-voltage, when using
closed Wye-Delta (QSF series) starter panel, please follow the wiring label of the motor terminal during installation. 6
phase cables and 1 ground cable are drawn from the starter panel to the motor terminal, as shown in Figure 3.7 below.
When a free-standing VFD starter panel is adopted, U1 and W2, V1 and U2, W1 and V2 are shorted when the unit leaves
the factory. The user only needs to lead out 3 phase cables and 1 ground cable from the VFD starter panel to connect to the
motor terminal, as shown in Figure 3.8.
Wye-delta starter panel
M
3～

Fig. 3.8 Wiring schematic diagram of closed wye-delta starter panel and the motor
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VFD starter
panel
M
3～

Fig.3.8 Wiring schematic diagram of free-standing VFD starter panel
The high-voltage 10kV motor has only three terminals. When high-voltage direct start, high-voltage series reactance
start, high-voltage autotransformer start or high-voltage VFD start is adopted, the wiring shall be conducted directly in
accordance with the Figure 3.9.
High voltage starter panel
M
3～

Fig. 3.9 Wiring schematic diagram of high voltage starter panel and the motor
As the terminal post is easy to be stressed during the cable installation and connection, which will affect the
compressor seal, please note the following points for the connection of the main motor terminal:
(1) All motor terminal connections must be on-site connected by authorized service personnel.
(2) During connection, do not exert too much force, and the cable should be properly fixed.
(3) When connecting, fix the nut below with a wrench. Just fix the nut without allowing it to rotate. Do not let the
terminal post bear too much force in its radial direction. Force on the upper nut as much as possible in the tangent
direction.
4 Control Panel and User-side Control Wiring
See Figure 3.7 for terminals reserved at electric control panel of the centrifugal chiller. Please note that:
(1) Signal outputs for chilled water pump (user side) start/stop, cooling water pump (heat source side) start/stop, and
cooling tower fan start/stop are 220 V (active output), and only drive intermediate relay or low-power indicators. If a water
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pump or cooling tower fan is connected, use an intermediate relay for isolation. Never directly drive the contactor coil.
(2) If the linkage control is not enabled for the water pump and cooling tower fan, make sure the water pump has
been enabled before startup.
(3) The water pump/cooling tower fan must be separately powered, and the power supply cannot be led out from the
power cable of the unit.
(4) Input signal from the user (start/stop remotely) must be passive dry contact.
Input signal
Remote on X2:20
(pulse)
X2:21
Notes:
Remote off X2:21 1 Optional signal is provided for users.
(pulse) 2 Custom-made signal is only available after the
X2:22 feature is customized.
3 Signal outputs for chilled water pump start/stop,
Public port X2:4 cooling water pump start/stop, cooling tower group
Alarm output signal X2:5 start/stop are 220 V AC signals, and only drive
intermediate relay or low-power indicators. The alarm
Fault output signal X2:6 output signal, the fault output signal, and the
Operation output X2:7 operation output signal are passive dry contact
signals.
User output signal
signal
4 The pump feedback and water flow switch signals
Chilled water pump X2:8
must be connected to the unit; otherwise, the unit
start/stop X2:9 cannot be turned on.
5 The diagrams are only used for illustrative purpose
Cooling water X2:10
only. The materials involved need to be provided by
pump start/stop X2:11 the customer.
6 1.5mm2 ≤ Control cable and communication cable
Cooling tower fan X2:12 diameter ≤ 2.5mm2.
group 1 start/stop X2:13 7 Use a shielded twisted pair as a communication
X2:14 cable and ground the shield layer.
Cooling tower fan
group 2 start/stop X2:15
User communication
RS485+ X2:1
RS485-
interface
X2:2
GND X2:3
Figure 3.10 Terminals Reserved for Users at the Control Panel

3.1.9 Insulation Treatment of Motor Terminal
Attention
1. Insulation treatment of connecting terminals can only be carried out after the motor connection
is confirmed by professionals and the motor rotating direction is confirmed to be correct after
mechanical operation. The mechanical operation is described in 3.2.5 of this manual.
2. For insulation treatment of connecting terminals, the motor junction box shall be installed first,
and the panel of the junction box should be removed.
Compressor motor terminals, wire ends and wires should be insulated to prevent condensing and arcing. For
low-voltage units, the installation contractor should conduct insulation treatment according to local electrical
specifications.
The high-voltage unit has materials specially used for insulation in its packing box. Please ask the constructors to
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follow the following regulations:
1. Materials for the treatment

No. Material Effect
1 3M CC-2 cleaning kit Remove oil and scale
3M SCOTCHFIL putty-like electrical Filling irregular parts to make them smooth
2
insulating-material putty tape to aid insulation
3M Scotch 130C Linerless high-voltage self-adhesive
3 Main insulation
insulation tape
Ultraviolet resistance, abrasion resistance,
4 3M Scotch Super 33+ PVC insulation tape corrosion resistance and mechanical
protection
2. Treatment Steps
(1) Use 3M CC-2 cleaning kit to remove oil stains and scale from high-voltage motor terminals and cable joints, and
keep them dry and clean.
(2) Use 3M SCOTCHFIL Putty-like electrical insulating-material putty adhesive tape to fill the irregular parts at the
connecting terminals and cable joints of the high-voltage motor. After filling, the whole parts should be smooth and neat to
facilitate the wrapping operation of other adhesive tapes.
(3) Perform semi-overlapping wrapping using 3M Scotch 130C unlined high-voltage self-adhesive insulation tape,
and properly extend and wrap the entire part to be insulated and its two ends to achieve complete covering. During
wrapping, stretching and uniformity are required, the stretching rate is about 100%, and the wrapping thickness needs to
reach 9mm, that is, the outer diameter needs to be increased by 18mm, so as to achieve the effect of main insulation.
(4) Perform semi-overlapping wrapping with five layers of 3M Scotch Super33+PVC insulating tape at the part
wrapped with 3M Scotch 130C unlined high-voltage self-adhesive insulating tape, and properly extend and wrap at both
ends to cover the whole part, thus achieve good mechanical and surface protection.
3. Maintenance treatment: To remove the cables due to the maintenance of the unit, the maintainers can directly cut
open the entire insulation layer at the junction of the terminal using a knife and peel it off. This insulation layer is
disposable. After the cable is installed, the insulation treatment shall be carried out according to the above method again.
3.1.10 Cold Insulation Construction
There are two conditions for the cold insulation construction of water chilling units:
1. The cold insulation construction of the unit has been completed in the manufacturing plant.
2. Due to other reasons, the cold insulation construction of the unit should be carried out on the installation site. In
this case, the unit should be subject to leakage inspection, mechanical operation and test runs before construction with
reference to the cold insulation construction drawing. The following points should be noticed during cold insulation
construction:
(1) After cold insulation construction, the movement of movable parts (such as inlet guide vane adjusting device,
valve handle and the like) should not be hindered, nor should some valves needing adjustment be embedded into the cold
insulation layer.
(2) Open the water chamber cover when cleaning the evaporator pipe, and use a detachable cold insulation layer at the
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connecting bolt part when cold insulation construction is performed (please also note the parts where the flange part of the
water pipe needs to be disassembled frequently).
(3) To facilitate maintenance, do not bury the connecting bolts between the compressor and the suction pipe into the
cold insulation layer.
(4) Do not bury the temperature sensing part of the temperature sensor on the cold water outlet pipe into the cold
insulation layer.
(5) To find leakage during the airtight test, do not bury the joint of the auxiliary pipe and the instrument pressure
guiding pipe into the cold insulation layer, or use a detachable cold insulation layer there.
(6) Do not bury the nameplate in the cold insulation layer.
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3.2 Preparation before Unit Operation
After the installation of the unit is completed, the following steps should be followed before the unit is put into
operation:
Unit installation complete
Air tightness test

(Refer to 3.2.1)
Find the leaks Vacuum test

(Refer to 3.2.2)
Release the internal pressure

of the machine, and repair the
leaks.
Lubricating oil filling Vacuum drying
(Refer to 3.2.3)
Component confirmation
(Refer to 3.2.4)
Mechanical operation
(Refer to 3.2.5)
Make corresponding Refrigerant filling

adjustment as per the (Refer to 3.2.6)
phenomena
Check all parameters of the unit

(Refer to 3.2.7)
Simulation test run

(Refer to 3.2.8)
Loaded startup
(Refer to 3.2.9)
Put into use
Fig. 3.12 Flow Chart of Preparation Work
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3.2.1 Air Tightness Test
Air tightness test should be conducted after the unit is installed or assembled, and the test pressure is 1.15Mpa
(allowable deviation is ±0.05MPa). The test gas should be dry, clean air, nitrogen or other inert gasses. The gas
temperature during the test should not be lower than 5℃.
Warning
Do not use flammable gas or oxygen for air tightness tests! During the test, the unit is in a high
pressure state, and the cut-off valve before the relief valve should be completely closed!
Attention
During the air tightness test, the inside-unit pressure is measured by an external pressure gauge. It is
recommended not to use the pressure sensor on the unit.
The test process goes as follows: Connect the test pressure gauge (double pressure gauge with accuracy of 1.6 grade)
with the unit (connected to the cut-off valve above the condenser), connect the high-pressure gas interface to the
refrigerant charging valve, gradually turn on the gas valve to charge the test gas into the unit after confirmation, so that the
pressure slowly rises, maintain the pressure for 24 hours after the test pressure is reached, and spray foaming agent or soap
water on all connection parts and valves during the pressure maintaining process for checks.
Conforming criteria: After pressure dwelling, the eyeballed pressure gauge reading should not drop, and all
connecting parts shall not leak.
If a pressure drop is found, the leaking part should be identified and marked, and the refrigerant filling valve shall be
opened to remove the pressure in the machine and then the leaking point shall be treated. After the treatment, repeat the
above steps until it is qualified.
Warning
Treatment of leakage points should be carried out after the high-pressure gas inside the unit is
completely released; otherwise, serious personal injury may result!
During the pressure maintaining process, if the atmospheric temperature changes, the measured pressure should be
corrected as follows:
273  t '
P'  P
273  t
Where, the inside-unit pressure before pressure dwelling P
P ' -Inside-unit pressure after pressure dwelling

t -Inside-unit temperature (℃) before pressure dwelling
t ' -Inside-unit temperature (℃) after pressure dwelling
Vacuum test can only be carried out after air tightness test is rated as qualified.
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3.2.2 Vacuum Test
Warning
When the inside of the unit is in a vacuum state, it is strictly prohibited to start the main motor and oil
pump motor, conduct insulation test, or withstand voltage test; otherwise, serious safety accidents may be
caused!
First, turn on the refrigerant charging valve to relieve the positive pressure out of the machine. After reaching
atmospheric pressure, turn off the refrigerant charging valve and connect the vacuum pump to the unit. If the vacuum
pump does not have pressure display function, two vacuum pressure gauges with accuracy level 1.6 shall also be
connected to the unit for measuring the internal pressure. Turn on the vacuum pump after it is confirmed to be correct.
Warning
It is forbidden to use pressure the sensor to measure the pressure when the inside of the unit is in
vacuum state (the cut-off valve connected to the sensor is in full closed state); otherwise, the sensor will be
damaged!
Conforming criteria: The absolute pressure in the unit is below 0.3kPa, and the pressure will not rise more than
0.15kPa after pressure dwelling lasts for at least 30min.
Note: If there are significant changes in atmospheric pressure and air temperature at the beginning and end of the
inspection, the measured value of pressure rise should be corrected according to the following calculation method:
273 273
H （P2  H 2） （P1  H 1）
273  t 2 273  t1
Where, - atmospheric pressure at the end of placement P2
H 2 -Vacuum degree at the end of placement

t 2 -Room temperature at the end of placement
P1 -Atmospheric pressure at the start of placement
H 1 -Vacuum at the start of placement
t1 -Room temperature at the start of placement.
If the vacuum pump is unable to pump the internal pressure to the target pressure the entire time, then there is leakage
in the unit. The vacuum test should be stopped and the air tightness test shall be conducted again.
If the inside-unit pressure is pumped to the target pressure, and the pressure rises beyond the standard after pressure
dwelling lasts for 30min, then there is moisture or wet vapor in the unit, and the unit should be dried according to the
following steps:
1. Connect a vacuum pump (vacuum gauge with wet bulb temperature indication ceremony) to the refrigerant
charging valve, and then start the vacuum pump. If conditions permit, hot water not exceeding 40℃ can be supplied to the
water side of the evaporator and the condenser (vapor cannot be used), so as to shorten the drying time and achieve better
results.
2. As the inside-unit pressure decreases, the temperature and pressure in the wet bulb temperature indicator or vacuum
gauge will also decrease until the saturated temperature and pressure of water are reached. At this moment, the water in the
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unit begins to vaporize. As long as the vaporization process is not finished, the temperature and pressure will remain
constant. Once the vaporization process is over, both pressure and temperature will drop continuously, and finally drop to
an absolute pressure of 0.3kPa; then turn off the vacuum pump.
3. When the above state point is reached, normally, the wet air in the system is thoroughly pumped out. If there is still
some moisture left, vacuum pumping can be carried out once again: Dry nitrogen is filled into the machine to make the
pressure in the machine close to atmospheric pressure. Start the vacuum pump again to vacuumize, so that the temperature
and pressure indicated by the vacuum gauge drop at the same time to the absolute pressure is 0.3kPa.
4. The drying time duration of the unit is related to the following factors: unit size and volume, pumping rate and
efficiency of vacuum pump, ambient temperature and moisture content in the unit. When using the vacuum gauge, it
should be noted that the pressure in the measuring tube of the vacuum gauge should be pumped to the same pressure as
that of the unit.
5. Conduct vacuum test again after the unit is dried. If it is still unqualified, the system has leakage. Vacuum drying
and a vacuum test should be carried out after the leakage is eliminated until it is qualified.
3.2.3 Filling the Lubricating Oil
Centrifugal Chillers use high-grade special ester refrigerator oil synthesized with POE oil base, which can dissolve
R134a. This type of refrigerating machine oil has very strong water absorption. When transporting, storing and using this
type of lubricating oil, it should be sealed to prevent water in the air from entering the oil, which will deteriorate the
lubricating oil, reduce the insulation performance of the oil and increase the corrosiveness inside the unit.
Warning
The exposure time of lubricating oil in the air shall not exceed 15 minutes!
Lubricating oil is charged from the oil charging/discharging valve, and the oil level should be within the range of high
and low sight glass during the operation of the refrigerator.
The filling of lubricating oil should be carried out after the unit passes the vacuum test, and the steps are given as
follows:
1. Keep the inside-machine absolute pressure below 0.3kPa during the vacuum test.
2. Connect one end of the oil filling pipe to the oil filling valve/drain valve (the oil filling valve is located at the
bottom of the oil tank and is a right angle cut-off valve), and insert the other end into the oil container (the oil filling pipe
should be as short as possible).
3. Insert the oil filling pipe into the container first, then turn on the oil filling valve. Lubricating oil is sucked into the
unit under the action of pressure difference.
4. Oil filling quantity: Refer to nameplate of the compressor.
5. After the oil filling amount reaches the specified value (the oil level is at the top of the uppermost sight glass at this
time), turn off the oil filling valve. Too much or too little oil is not conducive to the normal operation of the machine.
6. Mark the current oil level after filling.
3.2.4 Electric Connection Check
Warning
Do not check the power supply without proper devices or precautions. Otherwise, it will result in serious
injury. Please comply with the provisions of the electricity company.
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Warning
Wiring must be conducted by personnel authorized by the company. Otherwise, it will result in damages.
Caution
When the unit is powered on for the first time, Manufacture technicians must be on site. Otherwise,
electrical shock may occur, resulting in serious personal injuries or death.
1. Before checking the wiring, disconnect the power supply from user's power distribution panel, lock the circuit
breaker and place the warning. Make sure that there is no voltage at the operation side (you have to wait 15 minutes in case
of a VFD starter panel) and no residual current at the electrical parts before any operations proceed.
2. Check whether there are scraps (such as metal filings) inside the unit. If yes, remove them and check whether there
is short circuit between phases or between the phase line and grounding cable.
3. Check whether there is dust or corrosive gas around the unit and whether the ambient temperature meets the
requirements.
4. Check whether the internal and external cable connections of the control panel, starter panel, and various electric
devices are correct, all sensors are correctly installed, and connectors are properly connected. Meters and controllers must
be checked and rectified. Damaged parts must be repaired or replaced.
5. Make sure that the factory settings for operation and safety control measures (such as the circuit breaker) are not
altered.
6. Check the starter panel incoming cables and control panel incoming cables L1, L2 and L3. Connect the wires
according to the phase sequence of the power supply. If wires are connected in reverse, correct the direction immediately.
Check the wires between the starter panel and the motor. Make sure the wires are connected according to wiring diagram
and in the right phase sequence.
7. Make sure that there is sufficient creepage distance and electrical clearance between the starter panel cables
(including power cables, bolts, nuts, and washers) and between the cables and case. Make sure the cables are intact.
8. The grounding must be reliable and in accordance with local and national standards.
9. Check whether the user's power distribution panel is equipped with circuit breakers and whether the setting
parameters are correct.
3.2.5 Confirmation before Mechanical Operation
After the filling of lubricating oil is completed, the following inspections and confirmations should be carried out:
1. Install a pressure gauge (capable of detecting vacuum) at the installation position of the oil supply pressure sensor
of the high-level oil tank. Turn on the refrigerant charging valve of the unit to allow the inside-unit pressure to gradually
rise to gauge pressure -0.027MPaꞏG～-0.04 MPaꞏG, and maintain the pressure for mechanical operation.
2. Heat the lubricating oil in the oil tank to above the specified too-low set value of the oil tank temperature.
3. Select "Energy Regulation" on the main interface of the touch screen as manual, conduct loading first till until the
energy regulation state is displayed as " Manual Stop", then conduct unloading till “Manual Stop", repeat the steps for 3-5
times, observe the external structural action of the energy regulation mechanism, and it shall be consistent with the
program action and free from jamming.
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3.2.6 Mechanical Operation
The mechanical operation should be carried out in the following order:
1. Disconnect the molded case circuit breaker on the starter panel and turn on the air switch in the starter panel.
According to the wiring diagram, connect the switch-on signal input terminal of the starter panel to the outside of the
starter panel with a wire connected in series with an air switch (the following switch-on and switch-off actions for the
starter panel refer to the air switch).
2. Turn on the air switch, check whether the components of the starter panel are operating normally, and disconnect
the air switch after confirming that they are normal.
3. Short circuit the closing signal input terminal of the oil-pump control panel against the wiring diagram. Turn on the
air switch of the oil-pump control panel to start the oil pump. Observe whether the oil supply pressure is stable through the
pressure gauge on the high-level oil tank and its value is between 0.18 MPaꞏG and 0.27 MPaꞏG.
4. Confirm that the oil level of the unit (between the high and low sight glass ) and the oil temperature of the oil tank
are normal (≥ the specified set value of too low oil tank temperature).
5. After confirmation, turn on the molded case breaker on the starter panel, close the starter panel door, turn on the air
switch, and the main motor starts. Turn off the air switch after the main motor rotates for about 1 second. During the idle
rotation of the main motor, check the rotating direction of the main motor from the sight glass at the tail end of the motor.
If it is found that the rotating direction of the main motor is reversed, the main motor should be inched again
according to the above operation steps after the phase sequence of the main motor power supply is changed, so as to
confirm that the steering is correct.
6. After confirming that there are no exceptions, turn on the control panel air switch again to put the unit into
mechanical operation.
The mechanical operation shall not exceed 5 minutes. During this period, make sure that the gyrator has no rubbing
sound, the vibration of each section is less than 0.03mm, and check whether the oil supply pressure can be adjusted to the
specified pressure. After confirmation, disconnect the air switch and the unit stops running. At the same time, check
whether the idle time of the unit is normal.
Warning
Mechanical operation time shall be restricted to below 5 minutes; otherwise, insulation damage may
be caused by excessive motor heating or bearing damage may be caused by too high lubricating oil
temperature!
7. After the mechanical operation is completed, remove the wires and air switches used for short circuiting the closing
signal terminals in the starter panel and the oil-pump control panel.
3.2.7 Charging the Refrigerant
Warning
To fill the refrigerant, the water pump should be turned on to allow water supply to the evaporator
and condenser; otherwise, the heat exchange tubes will be frost-damaged!
The refrigerant charging steps are given as follows:
1. Keep the internal pressure below 0.3kPa (the higher the vacuum degree, the better).
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3 Unit Use
2. Connect one end of the conduit to the refrigerant charging valve of the evaporator and the other end to the drain
valve of the refrigerant container. The conduit should be as short as possible to reduce the amount of air sucked in and the
loss of refrigerant.
3. Start the water pump to supply water to the evaporator and the condenser, so as to prevent the charged refrigerant
from rapidly evaporating and frost-cracking the heat transfer tubes.
4. Turn on the drain valve of the refrigerant container, unscrew the collar nut on the refrigerant charging valve at the
other end to blow thoroughly the air from the conduit (white refrigerant gas will come out at the collar nut), screw down
the collar nut and then turn on the refrigerant charging valve, and the refrigerant is automatically sucked into the
evaporator.
5. The nameplate of the unit should be consulted for charging refrigerant. When the weight of the refrigerant charged
is 80% of the nameplate value or the refrigerant cannot be charged (whichever comes first), turn off the unit refrigerant
charging valve. Record the charging amount.
Attention
Do not directly charge to the rated value for the first charge, and make up for the missing part when
the unit runs for the first time.
3.2.8 Pre-start Inspection

After the above operations are completed, confirm the pre-start confirmation of the refrigerator according to the
following items:
1. Oil level in the oil tank is correct (the highest oil level is near the middle of the sight glass).
2. Connect each pressure sensor on the unit to the unit, and the pressure inside the unit is normal (refer to Annex 2,
find the saturated pressure of refrigerant at the current water temperature, and after subtracting atmospheric pressure, it
should be consistent with the value displayed by the sensor. Each pressure of the unit should be approximately the same).
3. Start the oil pump for 2-3 minutes, and then check whether the oil supply pressure difference is stable and between
220kPa and 300kPa. And whether the oil supply temperature is consistent with the oil tank temperature and the
temperature is above the specified too-low set value of the oil tank temperature.
4. Unload the compressor manually to the "Manual Stop" state.
5. Check the microcomputer control panel and starter panel, check the unit for alarms that are not cleared, and check
whether the switch input signals are consistent with the actual ones.
6. Check the starter panel incoming cables and control panel incoming cables L1, L2 and L3. Connect the wires
according to the phase sequence of the power supply. If wires are connected in reverse, correct the direction immediately.
7. The evaporator and the condenser have been connected to water, and the air in the water chamber and the water
pipe is thoroughly drained through the discharge valve.
8. Confirm that the chilled water pump, cooling water pump and cooling tower are operating normally, and the water
quantity conforms to the rated value (the pressure difference between the inlet and outlet is not much different from the
standard pressure difference indicated in Appendix 1). Notice that the cooling water inlet temperature should fall within
20℃ ~ 34℃.
9. Confirm that the spherical cut-off valve under the relief valve is turned on.
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3 Unit Use
10. According to the nameplate to confirm the evaporator water flow, and confirm whether the cut-off protection is
correctly wired.
3.2.9 Simulation Test Run
The purpose of a simulation test run is to verify the control program and starter panel of the unit. Before the unit is
used for the first time, a simulation test run should be carried out (take closed star-delta starter panel as an example, other
startup methods can be referred to and shall be operated by the Company's after-sales professional engineers).
Warning
During the simulation test run, the main air switch or circuit breaker of the main-motor starter panel
should be kept in their OFF positions!
Turn off the main air switch of the main-motor starter panel, turn on the air switch of the control section, turn on the
power supply of the control panel, start the oil pump to adjust the oil supply pressure difference, start the unit through the
touch screen, check the working conditions of the chilling pump, cooling pump, cooling tower and main-motor starter
panel, and check them against the unit starting process described in Fig. 2.23 of this manual. The following tests should be
conducted after the main motor has been simulation-started, and about 15 seconds after the energy regulation plus action is
started:
Low oil supply pressure difference: Manually adjust the opening extent of the oil pressure regulating valve, it will
gradually increase so that the oil supply pressure difference is less than 220kPa 15 seconds after the oil pump is started, or
the oil supply pressure difference is less than 100kPa after the main motor is simulated to start, and the corresponding
warning dialog box will pop up on the operation screen.
The oil supply pressure difference is too low: by manually adjusting the opening extent of the oil pressure regulating
valve, gradually turn it up again, so that the oil supply pressure difference lasts less than 200kPa for 120 seconds after the
oil pump is started for 15 seconds or less than 80kPa after the main motor is simulation-started, and the tripping relay is
actuated.
Chilled water outage: Implemented by gradually reducing the chilled water quantity until the flow controller activates
the tripping relay.
Emergency stop: Press the emergency stop button on the control panel panel to actuate the tripping relay of the starter
panel.
3.2.10 Initial Loaded Start
Turn on the air switch of the main-motor starter panel, set the energy regulation control mode key to its automatic
position, and start the unit.
During the startup of the unit, check whether the startup process of the unit is normal and whether there is abnormal
rubbing of the gyrator during the startup.
After starting, the refrigerant can be filled to the same value as the nameplate according to the steps described in
3.2.6.
Observe the operation of the unit after the refrigerant is filled to the nameplate value, check the operation of the oil
system, cooling system and refrigerant purification device of the unit, and observe whether there are exceptions like
vibrations and noises in the unit.
Set the energy regulation mode to manual, load the load gradually on the premise that the running current of the main
motor does not exceed its rated current. Gradually apply the load. After the chilled water temperature gradually drops to
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3 Unit Use
normal value, load the load to 100%, and check the refrigerating capacity of the refrigerator.
Setting of P parameters: set P and I parameters to the maximum and D parameters to the minimum. After the
chilled-water outlet temperature is stable, gradually reduce the P parameter, and appropriately increase the P parameter
when the temperature oscillation changes.
Setting of I parameter: Gradually reduce the I parameter, and appropriately increase I parameter after temperature
oscillation changes.
Setting of D parameter: Gradually increase the D parameter, and appropriately reduce the D parameter after a
short-period temperature oscillation changes.
3.3 Work Guidance during Unit Operation
After the unit is started, the unit will enter a stable operation state as the output cooling capacity of the unit matches
the actual load of the user. Under normal circumstances, the unit in stable operation is safe and reliable, but the record of
operation status and the inspection of parts are still essential.
3.3.1 Unit Operation Status Record
The unit operation status record table provides continuous operation data records of the unit, which is helpful for
preparing daily maintenance plans, judging and eliminating unit faults, and is a guarantee for long-term stable operation of
the unit. A qualified equipment user should form the habit of keeping status records on time.
Appendix 2 to this instruction manual is the template for the unit status record forms; data should be read from the
touch screen and recorded in order. It is recommended to make records once every 4 hours while the unit is running. The
completed record forms should be sorted out and filed in sequence.
3.3.2 Inspection during Unit Operation
For a unit operating stably, the operation parameters read from the touch screen should fall within a certain range, and
all components of the unit shall operate normally.
1. The evaporating pressure and chilled water temperature of unit vary with the operating conditions of the unit.
Generally speaking, the saturation temperature detected at evaporating pressure is 0.5 ~ 1.5℃, lower than the outlet water
temperature.
2. Condensing pressure and cooling water temperature of the unit vary with the operating conditions of the unit.
Generally speaking, the saturation temperature detected by condensing pressure is 1 ~ 3℃ higher than the cooling water
outlet temperature. To make the unit operate at a higher efficiency, the inlet temperature of cooling water shall be reduced
as much as possible (but the inlet temperature shall not be lower than 15℃).
3. The pressure value of the oil tank shall be slightly higher than or equal to the evaporating pressure.
4. Oil pressure difference shall fall within 120 ~ 220kPa. The oil supply pressure can be adjusted through the oil
pressure regulating valve, such the pressure difference meet the requirements.
5. Oil supply temperature shall fall within 35 ~ 52℃, free of any obvious fluctuations.
6. During the automatic operation of the unit, the energy regulation loading/unloading operations meet the principles
stated in section 2.1.2 of this manual. During the loading/unloading process of the unit, the action of the electric actuator
shall be free of exceptions.
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3.4 Shutdown
1. If a timed shutdown is set, the unit will automatically shut down according to the set time.
2. During the operation of the unit, if the chilled water temperature reaches the set "Suspension Temperature", the unit
will enter into its suspension state.
Warning
The unit is still in the automatic operation state in the suspension state. Do not touch any electrical
components or carry out any overhaul operation in this state; otherwise, serious personal injury may
occur!
3. Press the main screen and select "Confirm" in the pop-up dialog box when the unit is started/running/suspended.
The unit will access the automatic shutdown program until it is completely shut down. The complete shutdown of the unit
shall be subject to the stop of the oil pump.
Warning
Do not try to pull off the isolating switch during the operation of the unit so as to cut off the power of
the unit, which will lead to high-intensity electric arc! It is strictly prohibited to restart the unit before the
fault is completely eliminated.
Attention
Unless the unit is overhauled or the refrigerant in the unit is removed, the unit control panel and the
oil-pump control panel should be in an energized state even if the unit is shut down.
3.5 Precautions for Long-term Shutdown

1. Keep the room well-ventilated, and protect the unit from direct sunlight. If the machine room is dusty, the unit shall
be covered with plastic film.
2. Drain all water from the water pipe and the water chamber of the refrigerator, and keep the drain valve of the water
chamber open during shutdown.
3. Keep the unit control panel in an energized state and maintain the temperature of the oil tank of the unit.
4. To restart the unit after a long-term shutdown, you need to first turn off the drain valve and clean the water system
pipeline. Check the evaporating pressure and condensing pressure of the unit, the two values shall be similar, and the
saturation temperature inquired through the pressure value shall be similar to the water temperature. Before starting the
machine, conduct over again the control program simulation start, and the unit shall not be officially started until it is rated
as qualified. Ensure the electric heater is in working condition.
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4. Unit Maintenance
4. Unit Maintenance
4.1 Work Outline for Unit Maintenance
Maintenance and inspection of the refrigeration unit have great influence on its service life. For a unit newly put into
use, the inspection and maintenance of some parts shall be conducted more frequently. After the unit has been in operation
for one year, generally speaking, the running-in between various parts has been completed. Here, the maintenance can be
carried out according to the standard frequency. It shall be noted that the unit shall also be maintained according to the new
unit standard after disassembling the unit or replacing key components.
Table 4.1 Standard Schedule of Maintenance and Inspection Items for the Refrigeration Unit
Time Record/inspect/maintain items Detailed Executor Remarks
frequency description
Unit operation record 3.4.1 ○ Once every four hours
Daily Observe the startup and 2.3.1 ○ At each startup/shutdown
shutdown of the unit
Oil level confirmation 4.4.1 ○
Appearance inspection of 4.2.1 ○
lubricating oil
Weekly Water flow confirmation 4.6.2 ○
Operational record analysis ○ Refer to the detailed
maintenance of each part for
specific methods
Operation analysis of 4.4.1 ○
automatic oil return system
Water quality analysis 4.6.1 △
Monthly Inspection and dust removal of 4.7.1 ○
starter panel and control panel
Refrigerant level check of 4.5.1 ○
evaporator
Fouling analysis of heat 4.6.3/4.6.4 ○
exchange tubes
Relief valve inspection 4.5.4 ○
State analysis of cooling 4.3 ○
pipeline filter
Quarterly
Electric control simulation 3.2.8 ○
Confirmation of energy 4.7.2 ○
regulation system
Replace the drying agent of 4.7.1 ○
starter panel and control panel
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4. Unit Maintenance
Heat exchanger cleaning 4.6.3/4.6.4 ☆/○
Lubricating oil quality 4.2.2 △
analysis
Oil filter replacement 4.2.4 ☆
Yearly Insulation confirmation of 4.7.2 ☆
main motor
Refrigerant analysis 4.5.3 △
Leakage check 4.5.2 ○
Replace refrigerant filter 4.3 ☆
Replace the automatic oil 4.4.2 ☆
return filter.
Every 3
Leakage check of heat 4.5.2 ○
years
exchange tubes
Change the lubricating oil 4.2.3 ☆
Compressor disassembly ☆ Contact Manufacture's
Every 5 inspection after-sales service department
years Main motor disassembly and 4.7.3 ☆ Contact Manufacture's
inspection after-sales service department
Note: 1. “○” means “executed by the user”; “△” means “executed by a third party organization”; “☆” means
“executed by service personnel authorized by Manufacture Company”.
2. The frequency listed in this table is the standard frequency for normal operation. If the inspected components or
items are found to have a tendency to deteriorate performance or affect the normal operation of the unit during
maintenance, the corresponding inspection and maintenance frequency shall be increased.
The items listed in the following table shall increase the frequency of inspection for units newly put into use:
Table 4.2 Items of New Unit Requiring to Increase Maintenance Frequency

Time Detailed Executor Remarks
frequency Record/inspect/maintain items description
Oil level confirmation 4.4.1 ○
Daily Appearance inspection of 4.2.1 ○
lubricating oil
Operation analysis of 4.4.1 ○
automatic oil return system
Weekly
Refrigerant level check of 4.5.1 ○
evaporator
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4. Unit Maintenance
Confirmation of energy 4.7.2 ○
regulation system
Monthly
State analysis of cooling 4.3 ○
pipeline filter
Lubricating oil quality 4.2.2 △
Quarterly analysis
Relief valve inspection 4.5.4 ○
Replace the automatic oil 4.4.2 ☆
Yearly return filter.
Change the lubricating oil 4.2.3 ☆
4.2 Maintenance Methods for Oil System

Please read the introduction given in 1.3 of this manual carefully before maintaining the oil system.
Warning
Incorrect maintenance of oil system, including wrong brand of oil, too much oil, unqualified quality of
lubricating oil, incorrect operation of oil pipeline and the like, will affect the normal use of the unit. Only
the service personnel approved by Manufacture can conduct the maintenance!
4.2.1 Appearance Inspection of Lubricating Oil

During the operation cycle of the unit, the appearance of oil shall be confirmed weekly.
Observe through the sight glass on the compressor casing of the unit (use flashlight if there is insufficient light or
color light interference). Normal lubricating oil should be light yellow transparent clear liquid, and its color will get dark
slightly as the operation hours of the unit increases. Bubbles in lubricating oil during unit operation belong to normal
phenomenon, but there shall be no solid particles or other impurities.
If the color of lubricating oil obviously darkens, thickens, blackens or contains more impurities, contact the after-sales
service department of the Company for replacement.
4.2.2 Lubricating Oil Quality Analysis
The quality inspection of lubricating oil should be conducted once a year, and a small amount of lubricating oil shall
be discharged from the oil drain port on the compressor casing as a sample according to the steps described in 4.2.3. It is
recommended that the user send the sample to a professional testing company for analysis. The quality of normal
lubricating oil should meet the following table:
Table 4.3 Inspection Quality Indexes for Lubricating Oil
No. Test item Unit Standard value
1 Color ≤L1.0
2 Density g/cm3 0.965～0.975
At 40℃ mm2/s 64.6～71.4
3 Viscosity
At 100℃ mm2/s 8.0～9.4
4 Acid value mgKOH/g ≤0.1
5 Moisture ppm ≤50
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4. Unit Maintenance
4.2.3 Changing the Lubricating Oil
Before replacing lubricating oil, please confirm the lubricating oil with after-sales service department of the Company.
Incorrect use of lubricating oil will result in abnormal operation of the unit.
We suggest that the lubricating oil shall be changed once in the first year when the unit is put into use, and then at
least once every 3 years. In addition, whether to replace the lubricating oil in advance shall be determined according to the
inspection results of the lubricating oil. See the following table for fault inspection indexes for lubricating oil:
Table 4.4 Malfunction Inspection Indicators for Lubricating Oil
No. Test item Unit Fault index
Transparency decreases and the color
1 Color
changes to orange or reddish brown.
There are metal debris, insoluble
2 Impurity
pollutants and the like
3 Smell Strong smell
At 40℃ mm2/s ≤54.9
4 Viscosity
At 100℃ mm2/s ≤6.8
5 Acid value mgKOH/g 0.3～0.45
6 Moisture ppm ＞100

The process for changing lubricating oil is given as follows:
1. Disconnect all power supplies to the unit (before disconnecting the power supplies, ensure that the temperature of
the oil tank of the unit is higher than the too-low set value of the specified oil-tank temperature).
2. Use a DN8 copper pipe with a wall thickness of 1.5mm and not shorter than 4 meters. Connect one end of the
copper pipe to the oil drain valve on the box of the unit through a bell mouth, and extend the other end into the container
collecting waste oil.
3. Slowly rotate the valve stem of the drain valve clockwise for 3 turns, and the lubricating oil is discharged from the
box of the unit under the action of pressure difference.
4. When there is gas in the oil ejected from the oil drain pipe, turn off the oil drain valve, and connect the oil filling
device to the copper pipe. Users can use a manual or an electric oil pump. When electric oil pump is selected, it is required
to notice that the pump lift is not less than 800kPa.
5. Before formal oil filling, loosen the bell mouth connecting the copper pipe to the box, use the oil filling device to
blow the gas from the pipe, tighten the connection, turn on the filling valve to start oil filling, and turn off the filling valve
when the oil level rises to the top of the uppermost sight glass . Lubricating oil changing is complete.
When the changing is completed, mark the oil level again.
Attention
The changed waste lubricating oil cannot be drained at will, and local regulations shall be followed.
4.2.4 Replacing the Oil Filter

Oil filter should be replaced every year or when the unit is opened for maintenance. The oil circuit system is provided
with a cut-off valve specially used for replacing parts. The replacement of the oil filter can be carried out without
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4. Unit Maintenance
withdrawing refrigerant. The specific operations are given as follows
1. Turn off all power supplies to the unit.
2. Turn off the cut-off valves at both ends of the filter clockwise.
3. Unscrew the nut at one end of the filter and collect the out flowing oil in the container.
4. After the oil is drained, remove the nuts from both ends of the filter and remove the oil filter.
Attention
A small amount of oil will remain in the filter. Take it horizontally at removal, and pour the oil into the oil
container.
5. Install the new filter, tighten the nuts at both ends, and thoroughly blow the air in the pipe.
6. When oil flows out from the needle valve, turn off the oil pump, install the needle valve cap quickly, turn on the K1
valve, and check for leakage.
4.2.5 Other Parts of Oil Circuit
Generally speaking, the operation of the oil pump and oil cooler is safe and reliable. Users can choose to disassemble
and inspect these two components during the disassembly and maintenance of the unit. If replacement is really needed,
please contact the after-sales service department of Manufacture to solve the problem.
4.3 Maintenance Methods for the Cooling System
Please refer to section 1.5 of this manual for an introduction to the cooling system of the unit.
The flow power for cooling refrigerant comes from the pressure difference between the condenser and the motor
cavity/oil cooler. A filter is arranged at the front end of the pipeline of the cooling system. Too many impurities in the filter
may result in too high refrigerant flow loss, and the cooling effect may be affected. Therefore, the filter for coolant line
shall be replaced at least once a year. Users shall also pay close attention to the working state of the filter during the
operation of the unit. At the start of the new unit operation, the temperature difference can be felt by touching the copper
tubes before and after the filter (if conditions permit, it can be confirmed by using a temperature meter), and then it can be
confirmed quarterly. If the temperature difference becomes significantly bigger, the filter has too many impurities and can
be replaced. The procedure for replacing the cooling system filter is given as follows:
1. Power off the main motor.
2. Turn off the cut-off valve and ball valve according to Fig. 1.7 of this manual (refer to Fig. 1.8 for non-high-pressure
units).
3. Unscrew slightly the nuts at both ends of the filter to drain the refrigerant out of the pipeline.
Attention
Never fail to wear gloves when you unscrew the filter nut, so as to keep the body parts (especially
hands) as far away from the nut as possible; otherwise, the sprayed liquid refrigerant may contact the skin
and cause frostbite!
4. Remove the filter, install the new filter, and tighten the nuts at both ends.
5. Unscrew the nut of the cut-off valve slightly, turn on the ball valve, and blow the air out of the pipe using
refrigerant.
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4. Unit Maintenance
Attention
After disassembling and inspecting a certain pipeline of the unit or replacing pipeline components,
after reinstalling the pipeline, the air in the pipeline shall be blowed thoroughly using refrigerant to
prevent air from entering into the system. After installation, use soapy water or a foaming agent to check
the unscrewed connections to ensure that they are free of leakage.
6. When white mist refrigerant is sprayed out of the nut of cut-off valve, lock up the nut quickly. Turn on the cut-off
valve and check the connections for leakage.
In addition, the user can evaluate the working conditions of the cooling system by comparing the operating conditions
of the units. Under the condition that the opening extent of the regulating valve is the same, check the operation records
consistent with the current operation conditions of the unit (especially the evaporating pressure and condensing pressure
parameters), and compare the cooling temperature difference of oil (the difference between the oil tank temperature and
the oil supply temperature). If the temperature difference is significantly reduced compared with the initial operation
period of the unit, the pipeline of the cooling system needs to be maintained.
4.4 Maintenance Methods for the Automatic Oil Return System
Refer to Section 1.5 of this manual for an introduction to the automatic oil return system of the unit.
4.4.1 Operation, Maintenance, and Disassembly and Inspection of the Automatic Oil Return System
Before the unit is initially put into use, mark the oil level. Then during the unit operation, observe the change in the
oil level through the sight glass on the box once a week and record it in the Unit Status Record Form. If the oil level
changes significantly (more than half of the sight glass), the automatic oil return system of the unit shall be checked.
Observe the sight glass on the oil return pipe. When the automatic oil return system is in normal operation, a small
amount of liquid can be observed through the sight glass to evaporate in the cavity of the sight glass. In addition, the
temperature of this section of copper pipe is relatively low; otherwise, the automatic oil return device fails to work
normally.
If the automatic oil return device fails to work normally, it can be debugged according to the following steps:
1. According to Fig. 1.7 of this manual, turn up the K1 valve counterclockwise for 1 ~ 2 turns, and observe whether
there is any liquid evaporating in the oil return sight glass.
2. If the working condition of the oil return device is still not improved through adjustment, the oil return pipe shall
be disassembled and inspected.
The disassembly and inspection steps for the automatic oil return pipeline are as follows:
3. According to Fig. 1.7, rotate the valve rods K1, K2, K3, K4 and K5 clockwise until they are completely closed.
4. Unscrew the connection between K1 valve and pipeline slightly to drain the refrigerant out of the pipeline. When
there is no refrigerant gushing out of the joint, remove the joint between the pipeline and the above-mentioned valves, and
remove the pipeline from the unit.
5. At this time, the filters and pipes on the pipeline can be checked.
4.4.2 Replacing the Automatic Oil Return Filter
As shown in Fig. 1.7, according to the disassembly and inspection steps for the automatic oil return pipe, turn off the
valve to completely turn off the pipe where the filter is located, and remove the pipeline. After replacing the filter, reinstall
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4. Unit Maintenance
the pipeline. Slightly unscrew the collar nut between K5 valve and the pipe section, turn on the other valves, blow air out
of the pipe, lock up the nut, adjust the opening extent of each valve as indicated in Table 1.1, confirm there are no leakages,
and the replacement is over.
4.5 Maintenance Methods for the Refrigerant System
4.5.1 Daily Maintenance
After charging refrigerant for the first time, the liquid level of the refrigerant shall be recorded through the
evaporator’s sight glass before the unit operates, and shall be recorded again when the unit operates stably after starting up.
These two liquid levels will be used as the basis for later evaluation of the unit operation. After the unit is in operation, the
refrigerant level shall be recorded and checked once a month.
If the refrigerant of the unit leaks, the operating parameters under the same operating conditions will change to a
certain extent: The liquid level of evaporator drops; the evaporating pressure decreases at the same chilled water outlet
temperature; The capacity of the unit drops at the same freezing water temperature and cooling water temperature. When
the liquid level drops, the user can judge whether refrigerant leakage occurs by observing these parameters.
4.5.2 Leakage Inspection
For the unit, a minor leakage will not bring significant changes in the operating condition of the unit; therefore, the
unit shall be checked for leakage once a year. Since there is refrigerant inside the unit and the pressure is higher than that
of the outside, foaming agent or soapy water can be directly applied to all connections of the unit to inspect leakage.
Leakage inspection of heat exchange tubes is relatively complicated and can be done once every 3 years. If the water
quality of the system is poor, the leakage inspection frequency shall be increased. Because it is hard to access the inside of
heat exchange tubes, it is recommended that the user uses professional electronic leakage detectors or notifies Manufacture
Company's after-sales service personnel to solve the problem.
4.5.3 Refrigerant Analysis
The purity of the refrigerant has a great influence on the operation efficiency of the unit, so the refrigerant analysis
shall be conducted once a year, and it is recommended to conduct the analysis before using it before the arrival of the
season each year. A small amount of refrigerant sample is discharged from the refrigerant charging valve into a closed
container for testing, and judge whether purification of refrigerant is required according to the testing result. The judging
criteria are as follows:
Table 4.5 Criteria for Determining whether to Purify Refrigerant
Refrigerant purifying Content of entrained oil (%) Acid (ppm) Free moisture
Yes. Over 5% Over 5ppm Can be perceived
Purification would be
3~5% 3~5ppm 3~5ppm
best
Not Below 3% Below 3ppm Cannot be perceived
Purification of refrigerants requires more professional tools. It is recommended that the user hires a professional
company or contact the Manufacture's after-sales service department.
4.5.4 Relief Valve Inspection
Relief valves installed on evaporator and condenser can protect the unit from danger when internal pressure is too
high, so these components shall be checked at least once every six months. The inspection contents include:
80
4. Unit Maintenance
1. Open the drain pipe connected to the valve and carefully check the valve body for rust or corrosion, dust
accumulation, scaling, leakage and the like
2. If there is rust, corrosion or accumulation of impurities, the relief valve shall be replaced and cannot be repaired or
reused.
3. The steps for replacing the relief valve are as follows: Turn off the ball valve below the relief valve (the ball valve
can only be turned off when people replaces the relief valve or overhauls the unit), replace the original relief valve on the
unit with a qualified relief valve after confirmation, turn on the ball valve again after completion, and confirm that there is
no leakage at the connection between the relief valve and the valve seat (if any, tighten the relief valve after turning off the
ball valve, then check the leakage again until there is no leakages), and finally reconnect the drain pipe.
4. Check whether the air around the unit is corrosive. If yes, increase inspection frequency for the relief valve.
4.6 Inspection and Maintenance Methods for the Water System
Regular inspection and maintenance of the water system is very important to improve the operation efficiency and
ensure the safe operation of the unit. The user needs to check the water quality once a month, confirm the water flow once
a week, and clean the evaporator and condenser once a year.
4.6.1 Water Quality Inspection
The water quality shall meet the cooling water quality requirements given in Appendix D to GB/T 18430.1-2007
Vapor Compression Cycle Water Cooling (Heat Pump) Unit - Part I: Water Cooling (Heat Pump) Units for Industrial or
Commercial Use and Similar Uses. If the water quality fails to meet the requirements, the operation efficiency of the unit
will be reduced and even the pipelines will be damaged.
Water quality inspection shall be conducted once a month and shall meet the requirements of the following table:
Table 4.6 Water Quality Requirements
Tendency
Item Reference value
Corrosion Scaling
PH (at 25℃) 6.5～8 √ √
Conductivity (at 25℃) μS/cm ＜800 √ √
Chloridion Cl- mg(Cl-)/L ＜200 √
Reference
Sulfate ion SO2- mg(SO2-)/L ＜200 √
item
Acid consumption
mg(CaCO3)/L ＜100 √
(pH=4.8)
Full hardness mg(CaCO3)/L ＜200 √
Ferrum Fe mg(Fe)/L ＜1.0 √ √
Sulfur ion S2- mg(S2-)/L ND √
Reference
NH+
items mg(NH+)/L ＜1.0 √
Ammonium ion NH+
Silica SiO2 mg(SiO2)/L ＜50 √
Note: “√” means the relevant factors of corrosion or scaling tendency.
If the testing value fails to meet the requirements of the above table, you can consult the local water treatment
company for treatment.
81
4. Unit Maintenance
4.6.2 Confirming the Water Flow
The flow rate of water in the heat exchange tube is closely related to tube corrosion, and shall not exceed the rated
water flow in operation. Once the flow rate of water in the pipe reaches 3.5 ~ 4m/s, the pipe may be eroded. During the use
of the unit, check the water flow once a week. For standard units, it can be roughly determined that the difference between
the operating water quantity and the rated water quantity is not too big by detecting the water pressure drop at the
inlet/outlet of evaporator and condenser and comparing it with the rated water pressure drop of the unit. For non-standard
units, the standard water pressure drop should be subject to the parameters provided when the units are ordered.
4.6.3 Cleaning the Evaporator
Inspect and clean the evaporator once a year. By checking the scaling condition of evaporating pipes, the working
condition of water treatment equipment in the pipe network can be evaluated, and whether to clean the pipes in advance
can be determined. The scaling of the tubes can also be judged by the operating parameters of the unit. At the same chilled
water outlet temperature, if the evaporating pressure drops more than 15kPa compared with the initial operation, the
evaporating tubes may need to be cleaned, and scaling inspection needs to be carried out on the evaporating tubes. The
inspection and cleaning steps for the evaporator are as follows:
1. Disconnect all power supplies to the unit.
2. Close the valves of the chilled water pump and evaporator inlet/outlet pipes, and turn on the drain valve of the
unit’s water chamber to drain the residual water out of the unit.
3. Disconnect the unit from the water system, remove the water-chamber bolts from both ends of the evaporator of the
unit, and hoist away the water chambers separately.
Attention
To disassemble and hoist the water chambers, never fail to protect the thermal insulation layer of the
water chamber. The water chambers can only be hoisted with lifting lugs!
4. At this point, components (flow meter, temperature sensor and the like) on evaporating pipe and water system can
be checked.
5. Clean the evaporating pipe. If the flow meter, temperature sensor and other components have corrosion or scaling,
they need to be replaced or descaled.
Attention
Evaporating tube and condensing tube are high-efficiency fin heat exchange tubes, which can only be
cleaned with professional tools. It is recommended that the user hires a professional cleaning company or
contacts the after-sales department of the Company.
6. After cleaning, re-install the water system.
4.6.4 Cleaning the Condenser
The water loop system of the condenser is usually an open system (open to the atmosphere at the cooling tower), so
the pipes are more prone to fouling. Cleaning should be carried out at least once a year. If the water quality inspection
reveals that the water system is polluted, the cleaning shall be done more frequently.
Similarly, the scaling of condenser tubes can also be judged by the operating parameters of the unit: Under the same
cooling water outlet temperature, if the condensing pressure of the unit rises more than 20kPa compared with the initial
operation, the scaling of condenser tubes needs to be checked and cleaned if necessary.
82
4. Unit Maintenance
Cleaning of the condenser is consistent with that of the evaporator. Attention should also be paid to protect the
condenser tube during cleaning, and check and handle the components on the pipe network while cleaning.
4.7 Maintenance Methods for the Electrical System
Warning
Before maintaining the electrical system of the unit, all power supplies of the unit should be
disconnected!
4.7.1 Maintenance of Starter panel and Control Panel

1. During use, the starter panel and control panel of the unit shall be dedusted once a month. At the same time, the
connecting terminals of the main circuits shall be tightened, and the cables, wires and connections of the main circuits and
control circuits shall be checked for any exceptions.
2. If the use of equipment is to be suspended for a long time, the starter panel and control panel shall be dedusted.
Fasten the connecting terminals, and do well the dust and moisture prevention.
3. Appropriate temperature and humidity are conducive to the safe operation of electrical components. Too high or too
low temperature and humidity will affect their safe operation and reduce their service life. Therefore, it is necessary to pay
attention to the changes in temperature and humidity in the use environment. It is recommended to replace the desiccant in
the panel quarterly. If the on-site temperature and humidity are high, the replacement time shall be shortened.
4. If rust is found on the wiring terminals, they should be replaced in time to avoid bad contact which will have a
great impact on the normal operation of the equipment.
4.7.2 Confirming Energy Regulation System and Simulating Electronic Control
The normal operation of the energy regulation system is of vital importance to the unit. The new unit shall be
confirmed once a month, and confirmed once quarterly after the unit is run in. There are two ways to confirm the energy
regulation system: In the standby state of the unit, set the energy regulation mode to manual through the touch screen, load
the energy regulation mode to manual stop, unload it to manual stop, repeat the steps several times, and observe whether
the guide vane of the unit fails. Under the unit operation state, observe whether the opening/closing (i. e. energy regulation
loading/unloading) actions of the guide vanes of the unit meet the principle stated in 2.1.2 and there is no exceptions in the
loading/unloading process.
Electric control simulation should be carried out according to 3.2.8 once quarterly. Through electronic control
simulation, it is possible to test whether the key protection measures for the unit can operate normally.
4.7.3 Maintenance and Inspection of the Main Motor
The maintenance and inspection cycle of the main motor shall be determined according to the operating conditions
and environmental conditions, and cannot be generalized. Usually, disassembly inspection is carried out every 5 years. The
disassembly inspection of the motor shall be conducted under the guidance of the Company's service personnel. However,
the measurement of insulation resistance shall be carried out every year.
According to the supply voltage for the main motor, select a megohmmeter as indicated in the table below:
Table 4.7 Insulation Resistance Test Voltage of the Main Motor
Rated voltage of the motor U 36V＜U≤500V 500V＜U≤3300V U＞3300V
Megohmmeter test voltage 500V 1000V 2500V
Use the selected megohmmeter to measure the insulation resistance between the phases of the motor stator winding
83
4. Unit Maintenance
(For Y-connection motor, it is necessary to check the insulation between the winding of each phase) and between each
winding and the ground. The insulation resistance shall not be lower than the value calculated as per the following
formula:
RMC≥U(75-t)/5000
Where, RMC - Insulation resistance assessment value, in megohm (mΩ);
U - Rated voltage of main motor, in volts (V);
t — Winding temperature of main motor during the test (generally room temperature), in ℃.
If the measured insulation resistance is lower than the calculated value, the following method shall be used to dry the
main motor, and the insulation should be re-tested after treatment.
1. Vacuum drying method
Pump the internal pressure of the machine to a vacuum with an absolute pressure of at least 1kPa(-700mmHg), and
keep it dry for 2 days and nights (the specific time varies with the ambient temperature).
2. Electric drying method (only for low voltage motor)
If the insulation resistance cannot rise by the 1st method, electric drying can be adopted, that is to say, AC voltage of
5% of rated voltage is applied to the stator coil for electric drying. However, since this motor is of sealed type of which the
coil temperature cannot be directly measured, the thermal resistors of the coils should be installed to protect the coil from
overheating.
84
5 Analysis and Treatment of Common Exceptions in the Unit
If a running state different from normal state is found during running of the chiller, check against Table 5.1 to find out
the cause and rectify the faults so that the equipment resumes normal running as soon as possible.
If fault symptoms other than those specified in the table are found, contact Manufacture after-sales service to
determine the cause.
Table 5.1 Common faults and troubleshooting
Symptom Likely causes Troubleshooting

1. The oil filter is blocked. 1. Replace the oil filter element.
Pre-start Oil Differ. 2. The opening of oil pressure control valve 2. Adjust the oil pressure control valve to
Press. Fault /Low Oil is too wide. raise the oil pressure to the rated value.
3. The output oil amount from oil pump is 3. Check the oil level at first, and then stop
Press. Differ. too low. and dismantle the unit to check the oil
4. The bearing is worn. pump as necessary.
5. Oil supply pressure sensor fails. 4. Stop and dismantle the unit to replace the
6. Too much refrigerant is mixed in the oil bearing.
due to the reduced oil pressure as 5. Recalibrate the pressure sensor and replace
refrigerant flushes occur in oil at start-up. the sensor as necessary.
6. Maintain power to the oil heater after
stopping the chiller to prevent compressor
damage (check whether the oil heater is
well connected and whether the
rectification value for temperature control
of the oil heater is correct).
1. The oil heating time is not enough. 1. Maintain power to the oil heater after
Low Oil Tank Temp. 2. No power supply to the oil heater. stopping the chiller to prevent compressor
damage.
2. Check and fix the power supply.
1. The oil supply or oil tank temperature 1. Check and replace the temperature sensor.
High Oil Cooling sensor fails. 2. Check the oil cooler and the piping.
Temp. Differ. Prot. 2. There is leakage in the oil cooler or 3. Refer to the “Oil Supply Temp. Prot.”
piping.
3. The oil supply temperature is too high.
1. The cooling capacity of the oil cooler is 1. Adjust the refrigerant supply amount to the
Oil Supply Temp. Prot. insufficient. oil temperature control valve.
2. Supply of refrigerant for the oil cooler is 2. Clean or replace the refrigerant filter
insufficient due to blocked refrigerant element as necessary.
filter element. 3. Check and replace the bearing.
3. The bearing is worn.
1. The current setting value of thermal 1. Check and adjust the current setting value
Oil Pump Overload relay protection is incorrect. of thermal relay to the rated value.
2. Oil pump has mechanical problems. 2. Check the oil pump.
3. The oil pump motor phase loss. 3. Check and correct the oil pump power
wiring.
1. The chilled water amount is insufficient. 1. Check the chilled water pump and chilled
Evaporator Water flow 2. The flow switch fails. water circuit and increase the water flow to
Prot. the normal value.
2. Check and replace the flow switch.
1. The cooling water amount is insufficient. 1. Check the cooling water pump and cooling
Condenser Water flow 2. The flow switch fails. water circuit and increase the water flow to
Prot. the normal value.
2. Check and replace the flow switch.
85
1. The throttling devices are blocked or fail. 1. Check and repair the throttling devices.
Evaporator Antifreeze 2. The temperature setpoint is too low. 2. Check and improve the temperature
Prot. 3. There is much loss of refrigerant in the setpoint.
system. 3. Inspect the piping and repair as necessary.
1. The cable is loose. 1. Check and tighten the cable.
Comp. Low Current 2. The current transducer setting parameters 2. Check the related parameters.
incorrect.
1. Phase voltage of the power supply is 1. Take measures to balance phase voltage of
Comp. Over Current imbalanced. the power supply.
2. The power line voltage drop is large. 2. Take measures to reduce the power line
3. The gas sucked by the compressor voltage drop.
contains liquid. 3. Discharge certain refrigerant from the
4. The cooling water temperature is high or evaporator.
cooling water amount is insufficient. 4. Check the cooling water system.
5. The chilled water temperature is high 5. Properly reduce the heat load.
due to large heat load.
1. No power supply. 1. Fix Power supply.
Long Time Start Prot. 2. The running feedback cable is loose. 2. Check and fix the wiring.
3. Starter problem. 3. Refer to the “starter Fault”.
1. The stop valves in the motor cooling 1. Open the stop valves.
Main Motor Winding tubing assembly are closed.
Overheat
1. The fault signal cable is connected 1. Check and correct the wiring.
Starter Fault incorrectly. 2. Contact the production factory.
2. Starter fault
1. The chilled water amount is insufficient.
Low Evaporation 1. Check the chilled water circuit and bring
2. The cooling load is low.
the chilled water amount to the rated value.
Press. 3. The heat transfer performance of
evaporator deteriorates due to the 2. Check the rectification temperature of the
pollution by scale deposits. automatic start/stop device.
4. The refrigerant amount is insufficient.
3. Clean the evaporator tubes.
4. Charge refrigerant to the required amount.

1. The cooling water amount is insufficient.
High Condensing 2. The capacity of the cooling tower is not 1. Check the cooling water circuit and increase
Press. enough. the flow rate to the rated value.
3. Incondensable gas exists in the system.
4. The heat transfer performance of 2. Check the cooling tower.
condenser deteriorates due to the
pollution by scale deposits.
3. Exhaust gas above the condenser.
4. Clean the condenser pipes.

1. The IGV could not move due to 1. Check and fix the IGV mechanical moving
IGV Fault mechanical problems. parts.
1. The condensing pressure is too high. 1. See "High Condensing Press.".
Surge Prot. 2. The evaporation pressure is too low. 2. See "Low Evaporation Press.".
3. See the above.
3. Both the preceding cases occur.
1. The IGV open degree feedback cable is 1. Check and fix the wiring.
IGV Open Degree loose. 2. Repair or replace the IGV actuator module
Transducer Fault 2. IGV actuator module is defective. as necessary.
86
1. The current signal is lost. 1. Check and fix the current signal feedback
Main Motor Current 2. The current transducer is defective. cable.
Transducer Fault 2. Check the current transducer.
1. The temperature sensor cable is loose. 1. Fix the wiring terminations.
** Temp. Sensor Fault 2. The temperature sensor is defective. 2. Check and replace the temperature sensor.
1. The pressure sensor cable is loose. 1. Fix the wiring terminations.
**Press. Transducer 2. The pressure sensor is defective. 2. Check and replace the pressure sensor.
Fault
1. The IGV faults. 1. Refer to the “IGV Fault”
High Second 2. The compressor motor spin direction is 2. Check and correct the compressor motor
Discharge Superheat wrong. wiring.
1. The Comm. Cable is loose. 1. Check and correct the wiring.
Liquid Level 2. The liquid level sensor is defective. 2. Check and replace the liquid level sensor.
Transducer Fault
1. The water flow rate of the heat-recovery 1. Increase the flow rate of the heat-recovery
Heat Recovery Water condenser is too low. condenser.
Flow Prot. 2. The heat-recovery water pump fault. 2. Check the heat-recovery water pump.
1. APF Comm. Cable is loose.
APF Fault 2. APF Enable. Cable is loose. 1&2. Check and fix the wiring.
3. AFP panel fault.
3. Contact the production factory.
Note: Common faults of the motor and main causes are as follows:
(1) Motor vibration: The rotor and stator of the motor do not align or the air gap is uneven. The motor installation is
incorrect, the main shaft is deformed, the bearing is worn, the stator inter-turn is short connected, the squirrel-cage bars of
the rotor rupture, or the motor is jointly vibrated under mechanical vibration of the compressor.
(2) Startup fault: The power cable is incorrectly connected, the line or startup device is faulty, the working voltage or
power frequency is incompliant, the load torque is too high, or the squirrel-cage bars rupture.
(3) Motor overheat: Supply of cooling medium for the motor is insufficient or is cut off, the terminal voltage of the
motor is deviated from the rated value, the winding insulation is damaged, and the unit is seriously overloaded. However,
overheat winding of the motor does not necessarily mean motor overload.
87
Appendix I Temperature-Pressure Correspondence Table for R134a Saturation State
Appendix I Temperature-Pressure Correspondence Table for R134a Saturation
State
Temperature-Pressure Correspondence Table for R134a Saturated State
℃ KPa ℃ KPa ℃ KPa ℃ KPa
-15 164 7 375 29 748 51 1351
-14 171 8 388 30 770 52 1385
-13 178 9 401 31 793 53 1420
-12 185 10 415 32 815 54 1455
-11 193 11 429 33 839 55 1492
-10 201 12 443 34 863 56 1528
-9 209 13 458 35 887 57 1566
-8 217 14 473 36 912 58 1604
-7 225 15 488 37 937 59 1642
-6 234 16 504 38 963 60 1682
-5 243 17 521 39 990 61 1722
-4 253 18 537 40 1017 62 1763
-3 262 19 554 41 1044 63 1804
-2 272 20 572 42 1072 64 1847
-1 282 21 590 43 1101 65 1890
0 293 22 608 44 1130 66 1934
1 304 23 627 45 1160 67 1978
2 315 24 646 46 1190 68 2024
3 326 25 665 47 1221 69 2070
4 338 26 685 48 1253 70 2117
5 350 27 706 49 1285 71 2165
6 362 28 727 50 1318 72 2213

Note: The pressure values listed in this table are all absolute pressure values, and the gauge pressure value (displayed by
the touch screen of the unit) is the difference between the absolute pressure value and the local atmospheric pressure.
88
Appendix II Unit Status Record Form (Template)
Date Time Parameter Remarks
Oil supply Cooling Cooling Chilled
Oil supply Oil tank Tank Oil supply Condensing Mainframe Evaporating Chilled
pressure water water water
pressure pressure temperature temperature pressure load pressure water inlet
difference inlet outlet outlet



Oil supply Oil tank Tank Condensing Mainframe Evaporating Chilled
pressure Oil supply water water water
pressure pressure temperature pressure load pressure water inlet
difference temperature inlet outlet outlet



Oil supply Oil tank Tank Oil supply Condensing Mainframe Chilled
pressure water water water Evaporating
pressure pressure temperature temperature pressure load water inlet
difference inlet outlet outlet pressure



89

Oil supply Oil tank Tank Condensing Mainframe Evaporating Chilled
pressure Oil supply water water water
pressure pressure temperature pressure load pressure water inlet
difference temperature inlet outlet outlet
Note: Fill in the remarks column as follows

1. When recording the operation parameters for the first time after startup, indicate the startup time in the remarks column, and record whether there are
any exceptions (malfunction alarm, abnormal noise, abnormal vibration and the like) during startup.
2. Record the oil level and evaporator refrigerant level once a week and write them in the remarks column in the format of upper-1/2 (indicating that the
liquid level is located at 1/2 of the upper sight glass, and so on).
3. After shutdown, record whether there are any exceptions during shutdown in the remarks column intended for the last parameter record.
90
Appendix III Unit Parameter Setting Table
Appendix III Unit Parameter Setting Table
Item Set value for standard unit Set value for non-standard
unit
Temperature when exiting from
15
suspension state
Temperature when entering into
5
suspension state
Mainframe full current/rated current Vary with the models
Target water outlet temperature 7
Evaporating pressure is low 1 226
Condensing pressure is high 1 944
Antifreeze protection of chilled water 3
High pressure ratio 2.85
Critical water temperature 15
Critical opening extent 15%
Note: This page is set to correspond to the contents given in 2.2.4 and 2.2.5 of this manual。For a standard unit, the column
of "Set value for non-standard unit" on the right is blank, and the parameter setting of the unit is implemented according to
"Set value for standard unit". For a non-standard unit, the setting values of each parameter may be different. The different
setting values will be indicated in the "Set value for non-standard unit". Please refer to them during implementation.
91
Appendix IV Technical Requirements for High-voltage Starter Panel Matching with the Unit
Appendix IV Technical Requirements for High-voltage Starter Panel Matching
with the Unit
The high-voltage 6kV and 10kV starter panels (hereinafter referred to as starter panels) for centrifugal refrigeration
motors are intended to work together with the microcomputer control system (hereinafter referred to as control panels) for
centrifugal refrigeration machines manufactured by the Company. The following technical requirements are specially set
forth:
(1) The starter panel has no start and stop buttons; however, the rest is the same as that for conventional starter panel.
(2) The action sequence of the closing and tripping passive contact (load capacity AC220V, 3A) provided by the
control panel for starting and stopping the motor is hown in the figure below.
Close
Closing
contact
Open
Close
Tripping
contact
Open
Give start signal Give stop signal
Fig. 4.1 Timing sequence of starter panel closing and tripping signal (gived by control panel)
Note：“Closing contact”is compressor ON/OFF on the schematic diagram；

“Tripping contact”is compressor OFF (pulse signal)
The starter panel provides two passive contact signals for the control panel to check the working status of the starter
panel.
(1) Fault signals: Normally, the contact is open, and in case of fault, the contact is closed.
(2) Operating signal: The contact is closed when the motor rotates and opened when the motor stops.
The current transformer of the starter panel provides a current signal for the control panel to monitor the motor
current, and its range is AC0-5A. The starter panel should have overcurrent, overload, short circuit and undervoltage
protection, and shall have an energy storage device to ensure that the primary circuit can trip in case the starting control
electricity is disconnected. The definition of the connecting terminals from the starter panel to the control panel is shown
in the figure below.
92
Appendix IV Technical Requirements for High-voltage Starter Panel Matching with the Unit
C o m p re sso r
T rip p in g O F F (p u lse
sig n a l)
C o m p re sso r
C lo sin g
ON
C u rre n t C o m p re sso r
tra n sfo rm e r c u rre n t
S ta rte r p a n e l S ta rte r p an e l re a d y
re a d y
F a u lt C o m p re sso r fa u lt
R u n n in g C o m p re sso r ru n n in g
P u b lic p o rt
S ta rte r p a n el T e rm in a ls C o n tro l p an e l
o f u n it
Fig. 4.2 Starter panel and unit control panel wiring
93
Appendix V Names and Contents of Hazardous Substances in Products (TWCF Centrifugal Chillers)
Appendix V Names and Contents of Hazardous Substances in Products (TWCF
Centrifugal Chillers)
Names and contents of hazardous substances in products (TWCF and LC Centrifugal Chillers)
Hazardous substance
Hexavalent Polybrominated
Part name Plumbum Mercury Cadmium Polybrominated
chromium diphenyl ether
(Pb) (Hg) (Cd) biphenyl (PBB)
(Cr(VI)) (PBDE)
Compressor and
× 〇〇〇〇〇
accessories
Oil pump × 〇〇〇〇〇
Actuator × × × × × ×
Heat exchanger 〇〇〇〇〇〇
Pipe fittings and
× 〇 × × 〇〇
valve body
Refrigerant 〇〇〇〇〇〇
Starter panel
× × × × × ×
(optional)
Electric
〇〇〇〇〇〇
panel/box
Electrical
components and × × × × × ×
power cords
Fasteners like
× 〇〇〇〇〇
screws and gaskets
Other rubber
× × × × × ×
and plastic parts
Insulation cotton
and sound insulation 〇〇〇〇〇〇
cotton
Glue, adhesive tape × × × × × ×
and other auxiliary
materials
Other metals 〇〇〇〇〇〇
Printed matter × × × × × ×
94
Appendix V Names and Contents of Hazardous Substances in Products (TWCF Centrifugal Chillers)
This form is prepared according to SJ/T 11364.
〇: Indicating that the content of the hazardous substance in all homogeneous materials of the component is below the
limit specified in GB/T 26572.
×: Indicating that the content of the hazardous substance in at least one homogeneous material of the
component exceeds the limit requirement specified in GB/T 26572.However, it is extremely difficult to make the
parts and components for the product completely free of the above hazardous substances under the existing technical
conditions, and the design will be gradually improved along with the technological progress.
95
Annex VI Guide on Insulation Resistance Test of the Starter Panel
Annex VI Guide on Insulation Resistance Test of the Starter Panel
Caution
The insulation resistance test of the starter panel shall be performed by experienced professionals who have
been authorized by Manufacture. Otherwise, the starter panel may be damaged.
Caution
Before testing, disconnect the incoming and outgoing power cables of the starter panel to remove
connections between the starter panel and electric control panel. Otherwise, the high voltage generated by the
tested unit may damage the starter panel and electric control panel.
The insulation resistance test of the starter panel should be performed as follows:
a. Disconnect the incoming and outgoing power cables of starter panel;
b. Disconnect the wires between the starter panel and electric control panel;
c. Short circuit the three-phase input terminals and output terminals of the main circuit, to act as test end A;
d. Use the ground terminals of the starter panel as test end B;
e. Touch the test end A and B with the megger based on the rated input voltage of the starter panel; use a 500 V
megger to test the 380 Vac starter panel (insulation resistance not less than 5 MΩ); use a 10000 V megger to test the 10 kV
starter panel (insulation resistance not less than 10 MΩ).
96
Nanjing TICA Climate Solutions Co.,Ltd.
ADD：NO.6 HENGYE ROAD,NANJING,CHINA，210046

TEL： 86-25-85326977
Service call：4008-601-601
Website：Http://global.ticachina.com/en/
Email: global@ticachina.com

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TWCF###H (PCD) - IOM (Eng. Version) PDF

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Water Cooled Centrifugal chiller H&E series

Installation, Operation and Maintenance Manual

 The "Installation Part" in this manual is only available to professional installers.

 Product implementation standard: GB/T18430.1.

Cooling water outlet

Cooling water inlet

Economizer Inlet guide vane

Compressor Main motor

Chilled water outlet

Chilled water inlet

Fig. 1.1 System Schematic Diagram of TWCF Centrifugal Chillers

2. Vapor injection valve

6. Refrigerant charging valve

7. Oil level sight glass

11. Condenser relief valve

12. Refrigerant charging valve

14. Refrigerant recovery valve

Oil pressure regulating valve

Oil cooler liquid outlet Oil cooler

Oil cooler liquid inlet

Oil pressure regulating valve

Oil cooler liquid outlet

Cooler liquid outlet

Cooler liquid inlet

Fig. 1.4 Flow Chart of Lubricating Oil System

Fig. 1.5 Unit Cooling Pipeline (500~1300RT)

Fig. 1.6 Unit Cooling Pipeline (1400~3000RT)

1.5 Automatic Oil Return Device

Miniature circuit AC contactor Thermal relay Current transducer Intermediate relay

RESET button for

STOP button for

Fig. 2.2 Oil Pump and Oil Heating Control Part

Table 2.1 Functions of Components of Control Panel

Microcomputer Evaporation Oil supply Oil supply Chilled water

Oil tank pressure & Condensation Cooling water

2.1.2 Automatic Operation Control Principle for the Unit

2.2 Introduction to the Touch Screen Interface

Emergency stop button

Fig. 2.4 Unit Control Panel

2.2.1 Welcome Interface

Fig. 2.5 Homepage

Software version: software version number of current system

System time: displayed in the upper left corner

Figure 2.3 Password Input Interface

Figure 2.4 Homepage (different units may vary)

indicates that the output point is disconnected. Click to return to Homepage.

Figure 2.6 Status Information Interface

Figure 2.8 Parameter Setting Interface (different units may vary)

Figure 2.9 Alarm record interface (different units may vary)

Total Alarm Information. Click to return to Homepage.

Figure 2.11 Total AlarmInformation Interface (different units may vary)

2.2.2 Description of Public Area

information and status information without having to return to the homepage.

(1) Description of Unit Status

Starting up: The unit is being started up.

Normal running: The unit has been started up and is running.

the unit halt temperature.

temperature, causing the compressor to start up.

(2) Description of Unit Model

Set parameters in [Parameter setting]-[Mode setting].

(3) Parameter Description

Current temperature: actual evaporator LWT.