ecoenergy

Original Instructions

A Series Inverter Modular Air-cooled Chiller (Heat Pump)


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 A Series Inverter Modular Air-cooled Chiller (Heat Pump)

CAUTION
(1)Installation should be done in accordance with this manual. Please read it manually
prior to startup or troubleshooting.
(2)Installation should be done by qualified servicemen, as incorrect installation would
lead to water leakage, electrocution or fire hazards etc.
(3)Before installation, check for all power supplies with the nameplate and check for its
safety.
(4)The unit should be grounded and there should be specialized grounding line for the
power socket to avoid of electrocution. Do not connect the groundling line to the gas
tank, water line, lightning rod, or telephone line.
(5)Only specialized accessories and parts are allowed for installation, otherwise it
would lead to water leakage, electrocution or fire hazards etc.
(6)Size of the power lines should be large enough. Only specialized power lines are
allowed for replacing the damaged ones.
(7)When power lines have been connected, install the electric box as well to avoid of
any safety problems.
(8)After all installation has been finished, take an overall check to the unit before
powering it on.

ႷSafety Precautions for Usage and Maintenance

WARNING
(1)When there is something unusual (like burnt smell), cut off the power supply at once
and contact the sales agent. The ongoing unusual condition would lead to
malfunctions, electrocution or fire hazards.
(2)When refrigerant leaks, take corrective measures to prevent oxygen depletion by
increasing refrigerant concentration.
(3)Do not use or place inflammable or explosive substances near the unit.
(4)Do not do troubleshooting personally, as incorrect troubleshooting would lead to
electrocution or fire hazards. Instead, please contact CARDIFF after-sales service
center.
(5)When the unit is charged with refrigerant, do not solder or cut any pipeline, fined
heat exchanger, shell-and-tube heat exchanger or other containers.

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 A Series Inverter Modular Air-cooled Chiller (Heat Pump)

 General Introduction
See the nameplate for the main technical data.
The all-inverter modular air-cooled chillers are capable of performing cooling all year around
with high energy efficient. It requires no cooling towers and is quite applicable to water-
deficient areas, and can be widely used at newly built or retrofitted industrial and civil buildings
in various sizes, such as, hotels, apartments, restaurants, office buildings, shopping malls,
theaters, gyms, workshops, hospitals, places where there is requirement on cooling under
ultra-low temperature, like cold storages, places where require cooling for dairy products,
foods and industrial products, and especially places where there are high requirements on
noise level and surrounding environment and boils and cooling towers are not allowed or hard
to be installed.
 Product Features
The all-inverter modular air-cooled chillers work outstandingly by virtue of their major
features stated below..
Ŷ Excellent compatibility᧶
The all-inverter modular air-cooled chillers can be constructed of multiple single units with
the same or different structure or capability (35kW, 60kW, 65kW and 70kW). For the 35kW
unit, it has only one cooling system; for the 60kW, 65kW and 70kW units, they are of two
independent systems. Up to 16 single units can be modularized, with cooling capacity ranging
from 35kW to 1104kW.
Ŷ Comfort and energy saving᧶
The variable-frequency technology can quickly respond to load change and lead to
decreased water temperature fluctuation and better comfort.
Ŷ Ultra-quiet᧶
The high-efficiency and low-noise fan blades and motor as well as the optimized air passage
can greatly lower operation noise of the unit. Besides, the quite mode can provide the user a
ultra-quite environment.
Ŷ Powerful self-protection᧶
It is equipped with the top-end microcomputer control system which is capable of providing
well-rounded protection and self-diagnosis.
Ŷ High reliability᧶
It is constructed of well-designed refrigeration parts and well-designed system, structure
and electric control, adequately guaranteeing reliable operation
Ŷ Remote ON/OFF᧶
The unit can be started or stopped by the ON/OFF key operation.
Ŷ Equilibrium running᧶
It indicates each compressor will run alternately so as to extend their service life.
Ŷ Shiftwork of water pumps᧶

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 A Series Inverter Modular Air-cooled Chiller (Heat Pump)

 Outline Dimensions
(1) CWCH4IN-35KT(unit:mm)

9
A Series Inverter Modular Air-cooled Chiller (Heat Pump)

(2) CWCH4IN-60KT, CWCH4IN-65KT, CWCH4IN-70KT (unit:mm)

 Installation Instructions
 Pre-check
Installation should be performed by the skilled technician to guarantee the normal operation
and prevent malfunctions and please read this manual carefully prior to installation.
The chiller is manufactured, inspected and tested strictly in accordance with the quality
control program and it will work properly within the expected service life as long as its
installation, operation and service.
 Acceptance Check
The user is responsible for organizing personnel to perform the acceptance check at the
regulated plate of delivery. Checks listed below should be taken as a minimum.
(1)If all required documents and accessories are provided as per the packing list.
(2)Check the equipment model.
(3)If the equipment is damaged and all parts are provided.
(4)If refrigerant leaks.
(5)Do not remove the protective cover on the flagon of the shell-and-tube heat exchanger
before connecting the water tube and check if the water pipe is clean.
(6)Check if the installation and operation are within the allowable conditions.

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A Series Inverter Modular Air-cooled Chiller (Heat Pump)

(1)Be sure the planeness of the concrete foundation is within ±3mm and the foundation
shall be covered by a rubber pad.
(2)Lift the unit until to the height where it is available to install the spring shock absorber.
(3)Remove screws fixing the spring shock absorber.
(4)Place the unit on the spring shock absorber and align the bolt holes of the spring shock
absorber with the mounting holes on the base of the unit.
(5)Tighten screws removed in step 2.
(6)Adjust the height of the spring shock absorber and make sure the deflection is equal all
round the spring shock absorber.
(7)Tighten the locking screws.
 Installation of the Water System
Ŷ Considerations stated below shall be taken carfelly for the water system.
(1)Each water inlet and outlet should be labeled properly to avoid misconnection.
(2)A flexible connector should be used at the chilled water outlet to reduce vibration
transmission.
(3)A manometer, a thermometer and a gate valve shall be installed at the chilled water
inlet /outlet. Moreover, a drain valve shall be installed at the outlet and an air release
valve shall be installed at the inlet. At the highest point of the water system, another
release valve shall be installed, while at the lowest point of the water system, another
drain valve shall be installed to facilitate drainage.
(4)The water inlet/outlet pipe should be tightly insulated to reduce heat loss and dewing.
When pipes are exposed under 0ഒ, a electric heater shall be installed.
(5)There surely be some foreign matters in the water system which would generate scale
on the surface of the heat exchanger, so a filter shall be installed upstream of the
water pump.
(6)The unit shall be bypassed during flushing to prevent drain out from entering the
system.
(7)Under ultra-low temperature in winter, showdown at night will cause the evaporator
and pipeline frozen up, so it is highly recommended to add alcohol and propanol
mixture in chilled water. Do not cut off the power supply when the unit is turned off,
otherwise the freeze protection does not work. Alternatively, cut off the power supply
and drain the water system thoroughly.
(8)When the unit runs under the low load requirement, in order to avoid low load
protection which would affect the service life of the unit, make sure the water capacity
is more than 1/6 of total rated flow rate per hour of each module (for instance, for
some project with four modularized CWCH4IN-60KT units, if the rated water
flow of each unit is 10.3m3/h, then the required capacity of the whole project should be
larger than 10.3*4*1/6=6.87m3/h). When the water course is quite short, a water tank
is required; otherwise the service life of the unit would be affected.

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A Series Inverter Modular Air-cooled Chiller (Heat Pump)

(2)Remove anticlockwise the blind plug located at the bottom of the heat exchanger to let
the chilled water flow out, after that, tighten the blind plug and reinstall the panel. (-
Note: place the drainage equipment beneath the drain pipe to prevent pollution
caused by the drain water.

NOTE
Keep the purge valve of the water system open in order to drain the evaporator and
condenser completely.

 Introduction to the Display Panel

See the Operation Instructions for the Display Panel of the inverter modular type chillers for
more details.
 Electric Wiring
 External Wiring of the Electric Control Cabinet
Ŷ CWCH4IN-35KT, CWCH4IN-60KT, CWCH4IN-65KT, CWCH4IN-70KT

Note: the output control lines of the AC contactors for the running indicator, water pump 1,
water pump 2, auxiliary electric heater 1, auxiliary electric heater 2 can be wired to the
16
 A Series Inverter Modular Air-cooled Chiller (Heat Pump)

corresponding wiring board of any one unit, while those for the error indicator and extemal
passive contact switch should be wired to the corresponding wiring board of all units as shown
in the figure below.

 Specification of Power Cord and Air Switch

See the table below for selectin of the power lines and the air switches.
Min. sectional area of the
Capability of the
power cable᧤mm2᧥
Model Power Supply Air Switch Live
Live Neutral Earth (A)
Line Line Line
380Vᨺ415VAC 3Ph
CWCH4IN-35KT 6 6 6 32
50Hz
380Vᨺ415VAC 3Ph
CWCH4IN-60KT 16 16 16 63
50Hz

17
A Series Inverter Modular Air-cooled Chiller (Heat Pump)

380Vᨺ415VAC 3Ph
CWCH4IN-65KT 16 16 16 63
50Hz
380Vᨺ415VAC 3Ph
CWCH4IN-70KT 16 16 16 63
50Hz

Notes:
(1)The specifications of the breaker and power cable listed in the table above are
determined based on the maximum power (maximum amps) of the unit.
(2)The specifications of the power cable listed in the table above are applied to the
conduit-guarded multi-wire copper cable (like, JYV copper cable, consisting of PV
insulated wires and a PVC cable jacket) used at 45ഒ and resistible to 90ഒ(GB/T
16895.15-2002). If the working condition changes, they should be modified according
to the related national standard.
(3)The specifications of the breaker listed in the table above are applied to the breaker
with the working temperature at 40ഒ. If the working condition changes, they should
be modified according to the related national standard.
 Wiring of the Electric Control Cabinet
Ŷ CWCH4IN-35KT, CWCH4IN-60KT, CWCH4IN-65KT, CWCH4IN-70KT

 Filed Wiring

Ŷ Safety Codes
(1)All wiring shall comply with applicable codes and engineering requirements.
(2)All field wiring shall be performed by the qualified electrician.
(3)Never perform wiring before the power supply is cut off.

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 A Series Inverter Modular Air-cooled Chiller (Heat Pump)

(2)The CN4 of the display panel should be connected to the unused CN47 at the main
board of the unit though the four-core grounded communication with the shielding
layer. Pay attention that the grounding wire of the communication line is close to the
main board and should be connected to it.
(3)The power lines should be connected to L1, L2, L3, and N at XT1 through a piece of
four-core rubber sleeve cable as shown in the figure above.
(4)There are two solutions for remote monitoring.
1) Install the remote monitoring software at the PC.
2) Based on CARDIFF provided Modbus protocol, the user can do second
development to this protocol.
Note: those enclosed by the dotted lines indicate the remote monitoring equipment.
When the quantity of the display panel exceeds 30 or length of the communication line
exceeds 800m, extra photoelectric relay is required. The photoelectric relays,
communication lines (class 5 twist pairs), converters are optional. PC should be
prepared by the user themselves.
(5) “35” indicates the unit CWCH4IN-35KT. Each unit is taken as a module.
“60” indicates the unit CWCH4IN-60KT. Each unit is taken as a module.
“65” indicates the unit CWCH4IN-65KT. Each unit is taken as a module.
“70” indicates the unit CWCH4IN-70KT. Each unit is taken as a module.
 Setup of Toggle Switches on the Motherboard
Five-bit toggle switches are used for indicating hardware address (1~16) of modules, with
module No. displayed in turn on the panel as Module 1, Module 2, ……, Module 16. Toggle
switches 1,2,3,4 and 5 are binary codes, with 1 for the lowest bit and 5 for the highest bit.
Comparison drawings are as follows (Caution: only in the condition of power supply shutoff
can toggle switches be set):

21
A Series Inverter Modular Air-cooled Chiller (Heat Pump)

Note: the black block represents where the projecting lever of the toggle switch is.
 Jumpers
When it is required to replace the main board, be sure the main board can match with the
applicable jumpers.
Table 7.7.1 Jumpers List
Matched
Model Code Jumper No
Compressor
QXAS-
CWCH4IN-35KT 4202021905
H80zN345H
QXAS-
CWCH4IN-60KT 4202021907
H80zN345H
QXAS-
CWCH4IN-65KT 4202021906
H80zN345H
QXAS-
CWCH4IN-70KT 4202021908
H80zN345H

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