Water Cooled Screw Chiller

Water Cooled Screw Chiller

  • Cooling capacity 40Ton to 680Ton
  • Temperature control 7℃ to 35℃
  • Shell and tube evaporator and condenser
  • Bizer or Hanbell semi-hermetic screw compressor
  • Optional refrigerant R134a,R407c and R410a
  • Safety protection devices of whole screw chiller
  • All models and cooling capacity available

Your Premier Water Cooled Screw Chiller Manufacturer

As a leading water-cooled screw chiller manufacturer with almost 20 years of experience since 2003, TopChiller provides a complete range of water-cooled screw chiller from TPWS-WSH series.

The cooling capacity of screw water chiller is from 30Ton to 480Ton/105KW to 1688KW and the chiller temperature control range from +30℃ to -30℃.

Besides the standard water-cooled screw chiller control temperature from 7℃ to 30℃, TopChiller also has a water-cooled glycol screw chiller control temperature below zero from 0℃ to -30℃ for some special industrial applications.

With 20 years experience in design and manufacturing water-cooled screw chiller from TopChiller has the following features:

Using famous brand Semi-hermetic Screw Compressor- Bitzer from Germany and Handbell from Taiwan.

Each screw compressor comes with 4 steps of energy control 0-25%-50%-75%-100% to make sure the whole screw chiller operates when stable with high refrigeration performance.

Each water-cooled screw chiller with high-efficiency shell and tube type heat exchanger and aluminum foil with a copper tube air cooled condenser.

Integrated PLC control system with human-computer interface and big LED touch screen panel for easy operation.

Other refrigeration parts are world famous refrigeration spare parts like Danfoss thermal expansion valve, Alco dryer filter, Schneider contactor, and overload relay will make sure the whole screw chiller works under normal condition.

Compared with air cooled screw chiller, water cooled screw chiller should run together with external cooling tower and water pump. This is the biggest difference between air cooled screw chiller and water cooled screw chiller.

As a professional water cooled screw chiller manufacturer, TopChiller has exported many water cooled screw chillers to the Philippines, Australia, New Zealand, Malaysia, Singapore, Indonesia, Chile, Mexico, Costa Rica, Brazil, Argentina, Colombia, South Africa, Nigeria, Saudi Arabia, Dubai, Spain, Italy, etc.

If you are searching for a water-cooled screw chiller supplier, you are coming to the right place. TopChiller is a high reputation brand in the refrigeration market.

If you have any water-cooled screw chiller inquiry, please contact our engineering for a solution and free quotation.

Water Cooled Screw Chiller Technical Specifications

Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller Water Cooled Screw Chiller

water cooled screw chiller

Chillers Related With Water Cooled Screw Chiller

  • Central Chiller
  • Water Cooled Screw Chiller
  • Air Cooled Screw Chiller
  • Water Cooled Screw Chiller
  • Water Cooled Screw Chiller

TopChiller: Your Best Water Cooled Screw Chiller Supplier

Full protection devices including compressor overheating protection, low-temperature protection, high/low pressure, anti-freezing, phase-missing, anti-phase with overload, water flow switch and startup latency.

A various refrigerant such as R134a, R407c, R410a, and R404a are all available depending on screw chiller working condition, application requirements and ambient temperature.

Compared with air cooled screw chiller, this water cooled screw chiller is more efficient in cooling performance which is a requirement in the condenser water pump and a cooling tower.

Besides the above features, TopChiller water-cooled screw chiller also has optional functions for special requirements including soft-starting, economizer for higher efficiency, complete stainless steel non-ferrous chilled water circuit for high water quality requirement, electronic expansion valve and remote control for monitoring the screw chiller working status.

water cooled screw chiller

water cooled screw chiller

Water cooled screw chillers are widely used for various industries applications such as HAVC, big building&hotel air conditioning, central chilled water supply, chemical processing, die casting,food&beverage processing, pet food, Pharmaceutical, plastic processing, automotive, energy&power project, packing, and printing.

TopChiller aims at providing water-cooled screw chiller with stable quality, operation efficiency, and energy savings. It is suitable for air conditioning applications, industry-type process cooling, and large-scale district heat source systems.

As a professional water-cooled screw chiller manufacturer, TopChiller provides all technical support to clients. Please contact TopChiller team to get the best water cooled screw chiller solution.

Water Cooled Screw Chiller: The Complete Buying Guide from TopChiller

What Is Water Cooled Screw Chiller?

Water cooled screw chillers are devices used to dissipate heat from a location where the heat is not unwanted. Cost and efficiency are two crucial factors when considering the production of products.

In order to have a clear idea of  water cooled screw chiller, please have a view of below video. It is a brief introduction of  water cooled screw chiller.

As water-cooled screw chillers are equipped with cooling towers, they are more efficient than air-cooled chillers and are commonly used to cool products and machinery in a wide range of industrial applications including injection molding, tool and die-cutting, beverage, lasers, machine tool, semiconductors and more.

Water-cooled screw chillers are also applied inside sophisticated diagnostic devices as they are efficient in preventing the temperatures of the machines from getting higher than expected.

water cooled screw chiller working diagram

How Does A Water Cooled Screw Chiller Work?

In the cooling process, it starts with a low-pressure liquid or gas mix entering the evaporator where the heat from the water changed to a low-pressure gas.

Then the gas went to the compressor to get compressed into a high-pressure gas, which then enters the condenser where ambient air or condenser water expels heat to transform it into a high-pressure liquid.

The heating and cooling of the refrigerant and its change from a gas to a liquid is so-called the water cooled screw chiller refrigeration cycle.

Water cooled screw chiller working principle

Water cooled screw chiller working principle

Now let’s take a deep look at the key components of a water-cooled screw chiller.

Key Components of a Water Cooled Screw Chiller

1. Cooling Tower

Generally, the cooling tower is installed on the roof and is where the unwanted heat ends up.

Cooling towers are used to cool condenser water with the help of evaporation.

water-cooling-tower

water-cooling-tower

After the water is pumped to the cooling tower, it will flow down to the basin of the cooling tower and heat is released through evaporation during this process.

Cooling-Tower-Working-Principle

After the heat is released from water, the water will return to the chiller barrel through piping and absorbs more heat, then the water will go back to the cooling tower to get the heat released and the cycle continues.

TopChiller can provide you a full set of water cooling systems including: water cooled screw chiller, water pumps and water cooling tower.

But how to install a cooling tower? Please watch below the video of water cooling tower installation guide.

 

2. Semi-hermetic Screw Compressor

A screw-driven compressor is primarily used to compress the refrigerant with two interlocking rotating helical rotors.

Hanbell Screw Compressor

Hanbell Screw Compressor

The screw compressor contains one or two screws which can compress the low-pressure refrigerant to a higher pressure refrigerant.

TopChiller water-cooled screw chillers are equipped with highly efficient, semi-hermetic compressor. This compressor enables 0%-100% step-less capacity control and achieves highest part-load efficiency, thus bringing about a huge saving on the electricity costs.

Hanbell semi-hermetic screw compressor is the regular compressor brand we are using for standard chiller models.

Hanebll screw compressor technical features:

Full product range- RC2 series compressor consists of 26 models with displacement ranging from 98/118 m3/hr up to 1539/1847 m3/hr (50/60Hz) compatible with different refrigerants and applications.

Multinational patents of high-efficiency screw rotors- The new 5:6 high-efficiency screw rotor profile is patented in Taiwan, UK, US, and China.

This new large-volume, high-efficiency rotor profile is designed especially for modern refrigerant characteristics. High-efficiency screw rotors are accomplished by using precision CNC machining centers, rotor milling machines, rotor grinding machines.

Strict ISO 9001 process controlling and the application of precise inspection equipment, such as ZEISS 3D coordinate measuring machines, ensure high-efficiency, high-quality, low noise and low-vibration HANBELL RC2 series screw compressors.

High-efficiency motor- Premium grade low-loss core steel with special motor cooling slot and refrigerant guide vane which pilot the cold suction refrigerant gas through the motor provides the highest operating efficiency possible no matter how strict operating conditions are.

Long life bearings and high reliability- The screw compressors utilize a combination of 10 axial and radial bearings and α axial balance piston to ensure longer bearing life and higher compressor reliability.

Double-walled rotor housing- Double casing structure with high strength inner ribs has been designed to minimize noise and ensure rigidity.

The rotor housing is made of high-strength gray cast iron FC25 that is extremely stable.

therefore no expansion will occur even at the high-pressure condition.

These casings are machined by computer-aided machining centers and inspected by precision measuring machines to enhance reliability.

Direct flange-on oil separator- A vessel made of ductile material FC 500 specially designed to withstand high pressure and provide the highest efficiency of oil separation.

Simple oil management, three-staged oil separator(models above RC2-1020), low-pressure-drop demister to ensure the minimum refrigerant dilution in the oil and maintain high oil viscosity.

Precise capacity control- The slide valve for capacity control is located in the compressor chamber. The slide valve is actuated by injection of pressurized oil into the cylinder from the oil sump as well as the bypass of oil through the solenoid valves in each oil lines with a pressure differential.

Perceptive protection modules- RC2 series screw compressors are equipped with PTC thermistors and motor protection module which could monitor discharge and motor coil temperatures as well as phase sequence and phase loss.

Accessories also include oil level switch to monitor the level of oil, pressure differential switch, and pressure relief valve for the optional application.

Adaptable with additional cooling- Liquid injection connection port located at the motor casing and in the compression chamber, oil cooler connection port, and a middle-pressure economizer connection port for customer’s desired application.

RC2 series compressors not only continue RC series compressors’ characteristics of high efficiency & reliability design mentioned above, but are also designed with the following newly added advantages to meet customers’ needs more adequately:
1. Design the fittest high-efficiency motor for respective refrigerant, operation condition and electrical power.
2. Dual capacity control of steps or continuous create more accurate and reliable mechanism (Option)
3. Part load effective economizer application.

Bitzer Screw Compressor

Bitzer Screw Compressor

3. Condenser

The condenser for a water-cooled screw chiller usually connects with the cooling tower for heat dissipation purpose.

The water cooled condensers work as the air-cooled condensers do, but they require two different steps to achieve the heat transfer.

First, the heat will be transferred from the refrigerant vapor into the condensing water by a water cooled shell and tube condenser.

Next, the temperature of the condenser water gets warm and will be pumped into the cooling tower where the unwanted heat is transferred to the ambient air.

TopChiller® condenser is featured by a shell and tube type heat exchanger that is easy for cleaning and its high quality helps the whole chiller work at an optimized efficiency level.

Structure-diagram-of-shell-and-tube-condenser

Structure-diagram-of-shell-and-tube-condenser

But there is another important issue, how to clean and maintain the water-cooled condenser?

The water cooled shell and tube type condenser is prone to scale formation after long-term use. If it is not disposed of in time, the scale will affect the heat transfer effect, resulting in an increase in the condensing temperature of the unit, which will result in a decrease in cooling capacity and an increase in unit power consumption.

Dirty shell and tube

Therefore, the condenser should be frequently cleaned of scale.

There are three main methods for preventing and removing scale:

A. Mechanical descaling method:

Mechanical descaling is a method of descaling a condenser of a steel cooling pipe with a soft shaft washer, and is particularly suitable for a vertical shell and tube condenser.

The methods of operation are as below:

1. The refrigerant in the condenser is withdrawn.

2. Turn off all valves connected to the condenser and the refrigeration system.

3. The cooling water of the condenser is normally supplied.

4. The umbrella-shaped gear scraper connected by the soft shaft washer is rotated and descaled from top to bottom in the riser of the condenser.

And the cooling heat generated by the friction between the scraper and the pipe wall is cooled by the circulating cooling water. Flushed dirt, rust and other dirt are washed into the pool.

clean shell and tube condenser

In the descaling process, according to the fouling thickness of the condenser and the degree of corrosion of the pipe wall and the length of the used pipe, the hob with the appropriate diameter is selected.but the diameter of the hob selected in the first pass descaling is smaller than that of the cooling pipe.

The inner diameter should be appropriately small to prevent damage to the pipe wall, and the second round of descaling should be carried out with a hob close to the inner diameter of the cooling pipe. The descaling can remove more than 95% of the scale and rust of the condenser.

The method of mechanical descaling is to use the bevel gear-shaped hob to rotate and vibrate the hob during the rotation of the cooling tube, and remove the scale and rust in the condenser cooling tube, after the descaling is completed.

The water in the condensate pool is completely removed, and the dirt, rust and other dirt removed from the bottom of the pool are cleaned and refilled.

B. Chemical pickling and descaling method:

The condenser is cleaned with the prepared weakly acidic descaling agent to make the scale fall off and improve the heat transfer efficiency of the condenser.

Chemical pickling and descaling clean

The method of operation is:
1. Prepare the descaling solution in the pickling tank, start the pickling pump, and let the descaling agent solution circulate in the condenser tube for 24 hours. Under normal circumstances, the scale is basically removed after 24 hours.

2. After stopping the pickling pump, use a round steel brush to brush back and forth in the pipe wall of the condenser pipe, and rinse the scale and rust with clean water.

3. Repeat the cleaning of the detergent solution remaining in the tube with clean water until it is completely clean. The chemical pickling and descaling method are suitable for vertical and horizontal shell and tube condensers.

C. Electromagnetic water descaling method:

The working principle of the electronic magnetic water device is to dissolve calcium, magnesium and other salts in the cooling water flowing through the condenser in water in a positive and negative ion state at normal temperature.

When the cooling water flows through the transverse magnetic field of the magnetic water at a certain speed, the dissolved calcium and magnesium ions receive the induced electric energy, the charge state changes.

And the electrostatic attraction between the ions is disturbed and destroyed, thus changing its The crystallization condition makes the structure of the crystal lose.

The tensile and compressive resistance is reduced, and the hard scale with strong adhesion cannot be formed, and the loose sludge is discharged with the flow of the cooling water.

Electromagnetic water descaling

This descaling method can effectively prevent the generation of a new scale, and can also remove the original scale, because the ion loses the scaleability after using the electronic water magnetizer, which loses the protective effect on the original scale.

In addition, the magnetized cooling water has a certain amount of inductive electric energy.

At the same time, due to the different expansion coefficients of the steel pipe and the scale in the condenser, the original scale gradually cracks, and the magnetized water invades the crack without interruption.

This will also destroy the adhesion of the original scale makes it gradually loose and falls off on its own and is continuously taken away by the circulating cooling water.

Electromagnetic water descaling

 

The descaling method of the electronic magnetic water device is simple and easy to operate, has low labor intensity, and performs descaling and prevention of scaling without affecting the normal operation of the refrigeration system.

The significance of descaling and energy saving:
Once the condenser is scaled, the thermal resistance increases, so the thermal resistance increases, and the heat transfer coefficient value decreases.

Because the condensation temperature is inversely proportional to the heat transfer coefficient, the condenser temperature rises and the condensing pressure increases accordingly.

The more serious the fouling of the condenser, the more significantly the condensing pressure is increased, so that the power consumption of the refrigerator is increased, and the power consumption of each operating device of the refrigeration system is correspondingly increased, resulting in a waste of electric energy.

clean shell and tube condenser

4. Oil Separator

Some oil in the chiller will come out when the refrigerant is compressed by the compressor.

If the oil is not removed in time, it will flow through cooling components after leaving the condenser, which will hinder heat transfer and even reduce the capacity of the evaporator and condenser.

The oil separator is to make the oil detached from the refrigerant and minimize the amount of oil flowing in the water-cooled screw chiller.

As a result, it is particularly crucial to prevent oil from gathering in the unit.

water-cooled-screw-chiller-Oil-Recovery-System-Oil-Separator

Water cooled screw chillers manufactured by TopChiller® contain oil separators that are smaller in size and fewer moving parts, which make them more effective in the removal of oils in the refrigerant and also lower in terms of failure rates.

A double screw compressor integrated with an oil separator maximizes the efficiency of the water cooled screw chiller.

5. Evaporator

The evaporator of water cooled screw chiller is where the chilled water is formed.

shell-and-tube-evaporator-for-water-cooled-screw-chiller

In a shell-and-tube evaporator, the liquid refrigerant at low pressure enters the shell and flows through the tubes, absorbing heat from higher-temperature water that flows through the tubes.

When the water has reached a particular temperature, it will send the heat back to the refrigerant in the evaporator and get evaporated.

In the meantime, the water temperature cools down when the heat is extracted by the refrigerant.

Generally, the evaporator is installed between the compressor and the expansion valve.

Water cooled screw chillers manufactured by TopChiller® are featured by shell and tube heat exchanger, and also provides options for plate heat exchangers.

All are suitable for R22, R407c, R134a, R404A and many other refrigerants.

Here we must pay more attention to one important point. As all know, for regular water cooled screw chiller, we are using tap water or well water as the cooling water source, also the inlet and outlet chilled water also tap water or freshwater.

But sometimes there are lots of end-users using seawater, marine water as the water cooling sources, to cool down marine water, brine water, sulfuric acid or other chemical liquid.

In this case, the regular shell and tube heat exchanger can’t be used due to all these coolant and liquid are with strongly corrosive.

So we must go for a titanium material shell and tube heat exchanger as an ideal solution for a chemical factory, seawater cooling, marine or brine chiller and shrimp or seafood hatchery.

Please check below titanium material shell and tube heat exchanger

Titanium Shell and Tube Heat Exchangers, Including Multiple Shells

Titanium material shell and tube heat exchanger can cool the corrosive liquids include hydrochloric acid, sulfuric acid, nitric acid, chromic acid, acetic acid and hydrofluoric acid, seawater, marine or brine water directly.

Please check below titanium material shell and tube heat exchanger:

titanium material shell and tube heat exchanger

Please contact TopChiller refrigeration expert to customize your screw chiller.

6. Expansion Valve

The expansion valve connects the evaporator and condenser to keep the pressure difference between the two sides, and controls the fluid flow of the refrigerant into the evaporator and eventually into the compressor as well.

thermal expansion valve

The pressure has to be reduced if we need to reduce the temperature and as thus, some kind of restriction is required for this to take place.

Expansion valves enable users to regulate the capacity load based on the requirements of the production process.

TopChiller® designed thermostatic expansion valves for water cooled screw chillers to ensure the unit is operating at the optimized level.

The thermostatic expansion valve is a restriction device which can adjust the refrigerant pressure and maintain superheat at the outlet of the evaporator.

What’s more, it can achieve stable evaporator temperature as well as maintain the pressure according to the required saturation temperature by simply employing an evaporator pressure regulating valve to the chiller.

Both air-cooled chiller and water cooled chiller consist of compressor, evaporator, condenser, oil separator and expansion value. What are the advantages of water-cooled screw chillers compared to air cooled screw chillers?

The Advantages of Water Cooled Screw Chiller Compared to Air Cooled Screw Chiller

Both kinds of chillers operate based on similar principles to complete the heat transfer but they use different components to cool the condensers.

Water cooled chillers use water consumption while air cooled chillers need air.

The major difference is that water cooled screw chiller requires a cooling tower and the water cooled screw chiller is worth considering as it has the following advantages compared to air cooled screw chiller.

1. Quiet Operation

Water cooled screw chillers are more silent than air cooled screw chillers when they are in operation.

Noise in some workplaces can be annoying, especially in hospitals or other business offices. Air cooled screw chillers generally create more noise because of their fans.

Air Cooled Screw Chiller

2. Environment Adaptability

As water cooled screw chillers do not need ambient air while they are operating, there are no strict requirements for the ventilation conditions around the unit.

If the ventilation is minimal around an air cooled screw chiller, the operating performance will be badly affected because they rely on the ambient air for cooling.

Therefore, water cooled screw chillers are the better choice in places where the air recirculation is restricted.

For the air cooled screw chillers, they require open areas such as roof, parking lot, or ground level area to utilize the air for cooling.

3. Energy Efficiency

Although air cooled screw chiller may cost less than water cooled screw chiller in terms of the purchase price as water cooled screw chillers require cooling towers and water pumps, etc.

Air Cooled Chiller Performance VS Water Cooled Chiller Performance

However, the compressor costs and the energy consumption costs for air cooled screw chillers are generally higher due to their basic operating design.

However, water cooled screw chillers are more energy efficient as water cooled screw chillers are equipped with cooling towers that allow the cooling system to operate at low consumption costs.

water cooled screw chiller and cooling tower

Water-cooled screw chiller VS air-cooled screw chiller:

The air-cooled screw chiller unit is suitable for medium and small systems with tight water sources in the region due to the longer the annual operating hours, the more advantageous the air-cooled refrigeration unit is.

Also the annual comprehensive cost of the air-cooled chiller unit is lower than that of the water-cooled chiller system.

But water-cooled chiller If the system is managed and the water supply is controlled below 3%, the initial investment of the air-cooled refrigeration unit compared with the water-cooled refrigeration unit is difficult to recover.

This article is a comprehensive analysis and comparison of air-cooled/water-cooled chiller units, and I hope to be useful to everyone.

Air Cooled Screw Chiller VS Water Cooled Screw Chiller

First, the comparison of two chiller units

1. The water-cooled chiller must be equipped with a cooling tower. For the open cooling circulating water system, since the cooling water absorbs heat, it is in contact with the air, and CO2 escapes into the air.

The dissolved oxygen and turbidity in the water increase, resulting in a cooling circulating water system. Big problems: corrosion, scaling, bacterial growth, sludge.

If the water quality is not treated, the refrigeration equipment will be seriously damaged, and the heat exchange efficiency will be greatly reduced, resulting in a waste of energy.

Therefore, it is very important to carry out corrosion inhibition, scale inhibition, sterilization and algae treatment on the water system.

The water-cooled chiller cooling system must be equipped with an electronic water treatment device or a strong magnetic water treatment device.

Otherwise, the heat dissipation efficiency is too large. The longer the use time, the worse the system effect. The annual water treatment cost is high, and the effect cannot reach 100. % descaling.

The quality of cooling circulating the water is the key. The processing of cooling circulating the water is divided into physical and chemical methods.

Air Cooled Screw Chiller VS Water Cooled Screw Chiller

Air Cooled Screw Chiller VS Water Cooled Screw Chiller

2. Water-cooled/air-cooled chillers can be used on small systems. Most of the large screw chiller units are water-cooled.

The initial investment in water cooling is less than that of air cooling. But with the cooling tower and the machine room\electronic water treatment instrument, etc., there is no place to go!

Besides, in terms of long-term operation, the cooling efficiency of water-cooled chiller units will decrease relatively, and the air cooling will drop. Very small.

3. The air-cooled screw chiller adopts air cooling mode, which eliminates the cooling tower, cooling water pump and piping system that is essential for the cooling water system, avoids condensation of the condenser, blockage of water pipes, and saves water resources in areas with poor water quality.

water cooled screw chiller with cooling tower

It is the most economical and simple machine for maintenance and repair of the air-cooled screw chiller.

The air-cooled chiller has a slightly higher one-time investment than the water-cooled chiller, but the annual operating cost is lower than that of the water-cooled chiller.

The construction cost of the equipment room is the least in various air-conditioning cold and heat source systems, and the maintenance cost is about half of the cost of water-cooled screw chiller.

The air-cooled chillers are louder of in noise level than water-cooled chillers and can only be installed outdoors. Most of the water-cooled chiller units are installed at the basement.

4. The service life of water-cooled screw chiller is 15-20 years; the service life of air-cooled screw chiller is around 6-11 years.

The COP value represents the energy efficiency ratio of the air-cooled chiller. The water cooled screw chiller refrigeration efficiency is higher than the air cooled screw chiller.

The higher the cop value, the higher the air cooling efficiency and the better energy saving. (COP = air cooling nominal cooling capacity / compression input power).

Air cooled screw chiller’s  COP value is 3.44; while water-cooled screw chiller COP value is 5.2. This is a big difference in the cost of cooling performance.

2.  The technical and economic comparison of the air cooled screw chiller and water cooled screw chiller units

Considering that the number of air-cooled condensers of large refrigeration units is too large, it is usually difficult to arrange.

On the other hand, too small water-cooled screw chiller units are also unfavorable for use, so for medium-sized air-cooled screw chiller units and the same amount of cooling. Water-cooled chiller units are compared.

Now compare a model of water-cooled screw chiller unit with the same air-cooled screw chiller unit with main unit and evaporator:

The annual operating time of the screw compressor is 1000 hours to 3000 hours, and the annual running time of the cooling tower and the pump is 1400 hours to 4200 hours.

For a summary, The initial investment of air-cooled screw chiller units is relatively high, and the power consumption per unit of refrigeration capacity is also slightly higher than that of water-cooled screw chiller units.

water cooled screw chiller

However, the annual comprehensive cost of air-cooled chiller units is basically the same as that of water-cooled units.

The longer the annual running time of the screw chiller, the more favorable it is to the air-cooled chiller unit.

The initial investment recovery period of the air-cooled screw chiller unit compared with the water-cooled screw chiller unit is shorter.

The amount of water replenishment of the water cooling unit is an important factor affecting its cost.

Strengthening maintenance management and reducing water consumption are important aspects of reducing the cost of water-cooled chiller units.

Industrial Applications of Water Cooled Screw Chiller

Different types of screw chillers are used in various industries. However, let’s talk about the most common applications of water cooled screw chillers.

1. HVAC

Heating, Ventilation and Air Conditioning (HVAC) systems are used to dehumidify the air and to cool the temperature to create a comfortable interior environment despite the different external conditions.

water cooled screw chiller for air conditioning

Water cooled screw chillers have become an essential part in HVAC systems and are being used in various facilities, including restaurants, hospital, hotels, office buildings, supermarkets, etc.

TopChiller® water-cooled screw chillers are suitable for being a key component for HVAC systems.

As a long-time chiller supplier for many medical facilities, TopChiller® water-cooled screw chillers can provide an exact cooling effect as required.

Whether you are in need of a water-cooled screw chiller for an HVAC system, your facility will be comfortable and the occupants can find the peace of mind even in the hottest time of the day.

2. Milk Cooling

Keeping milk at a cool temperature during processing is very important. The milk could go bad easily in a short period of time if it’s not stored in a certain environment.

Therefore, chillers are very popular for milk cooling as they can extend the storage life before the milk is transported to the market for sales.

The milking machines will automatically pump the milk into a storage tank for pasteurization which will generate heat during the process.

Water Cooled Screw Chiller For Milk Cooling

Water cooled screw chillers manufactured by TopChiller® are able to remove heat from pasteurization and reduce the temperature of the milk to an appropriate point. Maintaining milk at a low temperature prevents the milk from deteriorating.

3. Die Casting

Die casting is a process in which the molten metal is pushed into a steel mold under high pressure into mold cavities.

In the metal casting process, there are basically five steps involved: clamping, injection, cooling, ejection, and trimming.

The cooling is required when the molten metal is injected into the mold and the metal will be in final shape after it is solidified and cooled down.

Die Casting cooling diagram

TopChiller® water cooled screw chillers are efficient in cooling die casting machines and can provide premium reliability and achieve high efficiency at all operating conditions.

Excellent design and high value make water cooled screw chillers supplied by TopChiller® are being used by many industrial companies from different countries all over the world.

Trouble Shooting of Water Cooled Screw Chiller

It is really annoying if your water cooled screw chiller always alarm or error happens. Let’s study some common alarm and error we always meet:

1.Low exhaust temperature, oil level protection

Phenomenon:After the power is turned on for about 1~2 minutes or 2~3 minutes, the oil level protection occurs, the unit alarms and stops; when the oil level is protected, the oil does not see the oil in the compressor oil sight glass; the exhaust temperature of the unit is always up, only 40 Around °C

screw chiller Low exhaust temperature oil level protection

Analysis: Before the start-up, the oil heater is not heated to more than 8H, so that all the oil in the compressor accumulates in the evaporator, resulting in poor heat exchange effect of the evaporator, easy to bring liquid with suction, so the exhaust temperature is low every time.

The low gas temperature affects the separation effect of the oil separator, which ultimately causes the compressor to be oil-deficient. Also need to check for oil leaks.

Disposal: Recycle or release all the refrigerant and oil in the system, then refill the refrigerant according to the factory procedures, add lubricating oil; the unit runs normally.

The main reasons for the protection of the oil level of the water-cooled screw chiller unit are:

A. Oil leakage.

Phenomenon: Turn on the machine and do not see the oil level when stopping.

B. The oil level switch is damaged.

Phenomenon: start-up, the oil level is full when stopping, oil level protection occurs;

C. There is too much refrigerant in the oil.

Phenomenon: The oil level is full when starting, and the oil level is not seen after starting. After a long-term shutdown or a long-term power failure, the electric heating time is not enough.

2. The safety valve is opened

Phenomenon: The water-cooled screw chiller unit safety valve is opened.

Analysis: There are multiple water flow switch protections on the touch screen.

The initial judgment is that the cooling water pump suddenly stops, the high pressure rises, and the opening pressure of the safety valve is exceeded.

Disposal: Replace the safety valve and refill the refrigerant.

After starting the machine, the parameters are basically normal, but the high pressure is high and the cooling water flow is small. It is also the reason for the safety valve to open.

There are two cases in which the water-cooled screw chiller unit safety valve is opened:

1. The evaporator safety valve is opened.

Generally occurs when the unit is in shutdown:
During the transportation of the screw chiller unit, it is exposed to the sun; The screw chiller unit was installed on the roof without any shading measures.

The safety valve is not tested or updated for a long time.

Cause: In this case, the refrigerant pressure exceeds the opening pressure of the evaporator safety valve. The safety valve is open.

2. The water cooled condenser safety valve is opened:
Occurs when the unit is turned on: the high voltage rises rapidly due to sudden causes.
A. The cooling water pump is powered off;
B. A cooling tower fan is powered off;
C. The cooling water system is dirty.

water chiller cooling tower

Reason: In this case, the refrigerant pressure will suddenly rise, the high-pressure protection will not be able to move, or the action will be high. The high pressure has exceeded the opening pressure of the safety valve.

Special Note: After the unit safety valve is opened, the copper tube of the evaporator may be cracked due to a large amount of leakage of the refrigerant. A water ingress accident occurred. The safety valve is a safety device and the safety valve must be tested every year as required.

3. Water cooled screw chiller unit cannot be loaded

Phenomenon: The water cooled screw chiller unit cannot be loaded during operation, and it is always maintained at 50% operation, and the chilled water temperature cannot be reduced.

Analysis: The high pressure of the screw chiller unit was found to be above 17kG. According to the control of the unit, at this time, in order to prevent the high pressure from continuing to rise.

The screw chiller unit is actively unloaded, and it is normal from the signal of the solenoid valve. The temperature difference between the cooling water reaches 10 ° C or more. The cooling water pump has a small flow rate.

Handling: Replace the water pump. The screw chiller unit is operating normally.

screw compressor cannot be loaded

There are many reasons why the screw compressor is not loaded, and the organic group actively unloads, which has the reason for the compressor itself.

High-pressure unloading problems are more common, mainly due to high condensing pressure of the unit. Also need to pay attention to the compressor oil circuit blockage.

4. Water cooled screw chiller unit cannot be loaded

Phenomenon: There are two main situations
The screw chiller unit has high pressure protection within 3 minutes of starting;
The unit has high pressure protection during operation;

Reason: There are many reasons, and it is necessary to check them one by one, but the most common cause is the problem of the water system:

  • The cooling tower is dirty and the heat exchanger copper tube is fouled.
  • The cooling tower has a small capacity.
  • Small water flow;
  • The screw chiller unit is at the highest point on the roof and the water pipes cannot be drained.
  • The screw chiller unit electronic expansion valve is stuck;
  • The maintenance unit has a short vacuum time when flushing the refrigerant.

shell and tube with dust

Note: After scaling, the performance of the heat exchanger is very large.                                                  It is difficult to clean the dirt by the method of passing bubbles. It is necessary to use the syrup.

5. Water cooled screw chiller low-pressure error/alarming

Phenomenon: There are two main situations:
The screw chiller unit has low voltage protection within 3 minutes of starting;
The screw chiller unit has low voltage protection during operation;

Reason: There are many reasons, and it is necessary to check them one by one, but the most common cause is the problem of the water system:

  • The heat exchanger copper tube is fouled.
  • The unit is at the highest point on the roof and the water pipes cannot be drained.
  • Small water flow;
  • The unit electronic expansion valve is stuck;
  • Refrigerant leaks.

The method of starting the refrigerant and adding the refrigerant is very wrong. When flushing the refrigerant, it is often added first. After adding it, add the refrigerant by means of booting.

When discharging refrigerant and adding tank refrigerant, the chilled water pump must be turned on, otherwise, the shell and tube may be frozen.

Water-cooled screw chiller debugging process and troubleshooting

The water-cooled screw chiller is mainly composed of a semi-hermetic screw compressor, a shell and tube condenser, a dry filter, a thermal expansion valve, a shell and tube evaporator, and an electric control part.

water cooled screw chiller drawing

water cooled screw chiller drawing

Please note!

When the operating temperature of the water cooled screw chiller unit is low in winter (below 0 degrees), it is recommended to increase the anti-freezing measures to protect the operation of the unit.

The screw chiller unit must drain the water in the heat exchanger and the outdoor water pipe during the winter period, otherwise it is easy to freeze. The screw chiller unit is damaged.

Because the screw water chiller unit is not operating in the winter, it is recommended to drain the water in the water line, or add enough ethylene glycol solution to the line as a precautionary measure to refill the water when the next operating season arrives.

water cooled screw chiller working diagram

water cooled screw chiller working diagram

First, the water cooled screw chiller normal operating status

The height of the refrigerant liquid level: R134a water-cooled screw unit evaporator liquid level: Under the condition of stable working conditions and water flow, the height of the liquid surface is just the best.

Exhaust gas temperature: Under nominal conditions, the exhaust gas temperature should be in the range of 45 °C-65 °C (R134a) and 50 °C-75 °C (R22) (exhaust temperature and evaporator and condenser outlet temperature) related).

screw compressor oil circuit

screw compressor oil circuit

Compressor oil sight glass: The high oil sight glass is full, and the oil level of the low oil sight glass is not lower than 1/2 of the oil sight glass.

High and low pressure values: high pressure value is not higher than 1.14MPa (R134a) and 1.8MPa (R22), low pressure value is not higher than 0.18Mpa (R134a) and 0.3MPa (R22), oil pressure difference is 250kPa, suction and exhaust pressure difference It is 0.4 MPa.

Saturation pressure: At any time, the corresponding saturation pressure at the inlet temperature of the evaporator and condenser should not exceed the design pressure of the container.

Otherwise, the safety valve will start to jump and the refrigerant will leak out (the water temperature should not exceed 45 °C).

Exhaust superheat: Refrigeration exhaust superheat is between 10 °C and 20 °C, and the suction superheat is 0.5 °C – 3 °C. Adjusting the suction superheat depends on the exhaust superheat and the evaporator level.

Outlet water temperature: The evaporator outlet water temperature should be controlled within the range of 3-20 °C; the condenser outlet water temperature should be controlled within the range of 21 °C-45 °C.

Voltage and current: The maximum allowable phase voltage imbalance is 2% and the phase current imbalance is 10%. The phase voltage imbalance is greater than 2% and must not be turned on.

Second, debugging common troubleshooting problems

Suction superheat adjustment: Suction superheats = suction temperature – evaporator saturation temperature on the outlet side of the evaporator. Adjusting the suction superheat depends on the exhaust superheat and the evaporator level.

Suction superheat mainly determines whether the expansion valve selection is appropriate.
The purpose of adjusting the suction superheat is to prevent liquid shock; to fully exert the performance of the evaporator.

Inhalation superheat target value: 0.5 ~ 3 °C.
The suction superheat is lower than the target value, indicating that the expansion valve opening is large, which easily leads to liquid hammer.

If the suction superheat is higher than the target value, the expansion valve opening is too small, which will result in low evaporator utilization and impact on capacity.

If the suction superheat is too high, the expansion valve opening may be too small, which may cause low pressure to be too low.

The low-voltage fault of the unit: R134a low-pressure alarm value is 0.18Mpa. R22 Low-pressure alarm value is 0.3Mpa Unit low-pressure alarm Possible causes:

Less refrigerant.
The electronic (thermal) expansion valve is faulty or has a small opening.
The compressor suction shut-off valve or the liquid line valve is closed (on alarm).
The sensor is damaged or the collected data does not match the actual value.

Differential pressure alarm: In order to avoid the shortage of oil supply to the compressor, sufficient pressure difference must be ensured during the operation of the unit to ensure the normal return of the compressor.

The oil level is too low: during the operation of the unit, attention should be paid to the state of the oil mirror of the press, the state of the return line and the liquid level of the evaporator, and the liquid level of the evaporator and the superheat of the exhaust.

Pay attention to the following points when the oil level of the press oil sight glass drops:
Observe the high and low pressure side view liquid mirror of the return line, whether the high pressure side oil mirror has oil flowing quickly, and whether the low pressure side glass returns oil.

If it is found that the oil flow is not smooth, it is necessary to check whether the return line of the return line is not open or the opening is too small;

Observe whether the liquid level of the evaporator is suitable.

It is usually better to use the liquid level to flow over the first row of heat exchange tubes. If the low pressure cannot return the oil because the liquid level is too low, the evaporator can be opened and the evaporator level can be increased by adjusting the superheat degree. rise.

If the oil or exhaust temperature is too low due to the liquid suction caused by the liquid level being too high, the opposite adjustment is made.

Observing the system pressure difference, the pressure difference is too small can also lead to insufficient oil return. The pressure difference can be established as soon as possible by adjusting the water temperature.

Undercooling: Undercooling = liquid saturation temperature – condenser outlet refrigerant temperature

The degree of undercooling mainly determines whether the refrigerant filling amount is appropriate.

The purpose of adjusting the degree of subcooling is to ensure that the refrigerant entering the expansion valve is a liquid and prevent the liquid from flashing before the expansion valve.
Undercooling target value: 4 ~ 6 ° C

If the degree of subcooling is lower than the target value, the refrigerant may be less filled or the number of supercooled tubes may be less.

The refrigerant may be added or the supercooled pipe may be added.

If the degree of subcooling is higher than the target value, the refrigerant may be excessively filled and the refrigerant may be properly discharged.

Common error and alarm analysis of water cooled screw chillers

1. High-pressure fault:

The screw compressor discharge pressure is too high, causing the high-voltage protection relay to operate. The compressor discharge pressure reflects the condensing pressure.

The normal value should be 1.40~1.60MPa, and the protection value should be set to 2.00MPa.

If the long-term pressure is too high, it will lead to an excessive operating current of the compressor, easy to burn the motor, and easily cause damage to the valve port of the compressor exhaust port.

What should be done is to control the discharge pressure of the compressor in a safe range.

The reasons for the high pressure fault are as follows:

  • The cooling water temperature is high and the condensation effect is poor;
  • The cooling water flow is insufficient to reach the rated water flow rate;
  • Condenser fouling or blockage;
  • Excessive refrigerant charge;
  • A non-condensable gas such as air or nitrogen is mixed in the refrigerant;
  • False positives caused by electrical faults.

2. Low-pressure fault:

The suction pressure of the compressor is too low, resulting in the action of the low-voltage protection relay.

The venting pressure of the compressor is the evaporation pressure, the normal value should be 0.40~0. 60MPa, and the protection value is set to 0. 20MPa.

If the suction pressure is low, the amount of return air is small, the cooling capacity is insufficient, and the electric energy is wasted.

The heat of the compressor motor for return air cooling is poor, and the motor is easily damaged! The solution is the same as the high pressure fault, try to keep the compressor within the normal pressure range.

The reasons for the low pressure fault are as follows:

  • Insufficient refrigerant or leakage;
  • Insufficient flow of refrigerant water, less heat absorbed;
  • Electrical faults cause false positives;
  • The outside temperature is low.

3, low valve temperature failure:

Thermal expansion valve outlet temperature reflects the evaporation temperature, is a factor affecting heat transfer, generally it is different from the refrigerant water effluent temperature difference of 5.0 ~ 6.0 ° C.

When a low valve temperature fault occurs, the compressor will stop. When the valve temperature rises, it will automatically resume operation with a protection value of -2.0 °C.

The reasons for the low valve temperature fault are as follows:

  • A small amount of refrigerant leaks, generally manifested as a low valve temperature fault rather than a low pressure fault;
  • The expansion valve is blocked or opened too small, and the system is not clean;
  • Insufficient flow of refrigerant water or blockage of the evaporator;
  • False alarms caused by electrical faults, such as poor valve temperature contact

4. Compressor overheating fault:

The thermistor is embedded in the winding of the compressor motor, and the resistance is generally 1kΩ.

When the winding is overheated, the resistance value will increase rapidly.

When the winding exceeds 141kΩ, the thermal protection module SSM will act to cut off the unit operation and display the overheat fault and the fault indicator light.

The reasons for the compressor overheating fault are as follows:

  • The compressor load is too large and the overcurrent is running;
  • Compressor overcurrent operation caused by electrical failure;
  • The overheat protection module M is wet or damaged, the intermediate relay is damaged, and the contacts are defective.

5. Communication failure:

The control of each module by the computer controller is realized through the communication line and the total interface board.

The main cause of communication failure is poor contact or open circuit of the communication line, especially the interface is affected by moisture oxidation, and the unit is bad.

If the electronic board or the total interface board is faulty, the address dial switch is improperly selected, and the power failure can cause a communication failure.

The above five kinds of fault phenomena are the most common, and understanding these fault phenomena and judgment ability and solution has an irreplaceable effect on extending the service life of the screw chiller.

Why TopChiller® Can Be a Reliable Supplier for Water Cooled Screw Chillers?

1. Optimum Performance of  Water Cooled Screw Chiller

TopChiller® water cooled screw chillers are helpful to improve energy efficiency, and by using a semi-hermetic dual screw compressor, these chillers are able to realize step-less capacity control.

Working at high noise levels will affect the health of the workers and it’s also important that companies should focus on noise reduction, especially in workplaces sensitive to sounds.

Running noise created by TopChiller® water cooled screw chillers is also very low as there is little friction in the compressor.

The compressor can serve for a long time thanks to the high-quality oil separator inside.

The safety protection devices are also the main reason that TopChiller® chillers have a longer lifespan than other brands of chillers.

Their features include but are not limited to the following functions: overheat protection, overcurrent protection, over-pressure protection, over-temperature protection, flow rate protection, anti-freezing protection, low-level coolant protection.

These protection methods prevent the chillers from being damaged by overload situations and the chillers can maintain smooth operation and long service life.

Water Cooled Screw Chiller

2. Decades of Professional Experience in Screw Chillers

TopChiller® was founded in 2003 and has been specialized in the research and sales of industrial cooling equipment and replacement parts since then.

Decades of expertise has helped TopChiller® earn clients from over 58 countries and regions. All water-cooled screw chillers manufactured by TopChiller® are CE marked and comply with standards products sold in Europe countries.

TopChiller® also earned a series of awards conferred by the government in China for energy saving and technology innovation.

Water Cooled Screw Chiller

3. Worry-Free After-Sales Service

As the chillers are used for the production every day, it’s very crucial to make sure they are operating smoothly without malfunction issues.

If by any chance the unit goes out of order, quick technical assistance must be available on hand to solve the problem. At TopChiller®, we have a professional team in charge of quality inspection before the shipment and maintenance support.

For every chiller purchased from TopChiller®, its quality must be carefully checked before shipment to ensure the client will receive a satisfying chiller.

In the meantime, TopChiller® also provides a comprehensive range of services for pre-sales questions and after-sales issues, covering everything from product inquiries to maintenance support.

All clients can still expect professional and personal care and reliable services from our support team at any time.

All of our water cooled screw chillers come with an 18-month warranty and we are always ready to offer lifetime technical support to our valued clients.

Water Cooled Screw Chiller

4. Customizable Water Cooled Screw Chillers

There are many factors involved when selecting the right chiller for industrial production. Different chillers in different sizes have cooling capacities.

It’s very important to assess if a chiller can just fit your specific requirements and help bring maximum profitability for the production process.

TopChiller® has developed a wide range of water cooled screw chillers that also come with various specifications for the customers to choose.

In the meantime, we also accept customization requests to help your business reduce operating costs and create more profits.

Water Cooled Screw Chiller

DM23C temperature controller for water cooled screw chiller operation manual

Description of Keypad of Controller
1.The layout of the controller

temperature controller of screw chiller

temperature controller of screw chiller

2.Description of LEDs
Power supply LED

When the unit is powered on, the LED will illuminate in RED color indicating the unit is connected to the power mains.
When the display enters into screen saver status, the LED will flash in RED color.
Running LED
When the screw chiller unit is switched on, the LED will illuminate in GREEN color indicating the unit is in On status.
Error alarming LED
When the screw chiller unit is working, if any alarm appears, the LED will begin to flash in YELLOW color.

User Operation and setting

1.Power supply to the screw chiller unit
All screw chiller units leave the factory completely cabled and ready for connection to the power supply and for the external interlocks to be connected to the terminals provided inside the electrical box.
It’s necessary to install a main switch near the unit in order to connect or disconnect the unit from power mains.
Electrical connections must be carried out by qualified personnel in respect of current legislation.

For all electrical work refer to the electrical wiring diagrams in this manual.
You are also recommended to check that the characteristics of the power mains are adequate for the absorptions of the units, also bearing in mind the possibility of other equipment being used at the same time.
For the functional connection of the unit, bring the power supply cable to the electrical box and connect it to the terminals, when the unit is powered on, the controller will be switched on.

2.Operation main interface
First display is the count down interface as below:

temperature controller of screw chiller

temperature controller of screw chiller

After over the countdown within 10 seconds, then will enter into the start up the interface as below:

 

temperature controller for screw chiller

temperature controller for screw chiller

Display the environment temperature in start up interface as above

temperature controller for screw chiller

temperature controller for screw chiller

No display the environment temperature in start up the interface as above

NOTE: About the environment temperature display can be setup based on that needed or not.
Detail explains how to setup, please refer to page 17 [ tem 2: Sensor setup ]

display above interface if happen alarm

display above interface if happen the alarm

Description of every button in the start up interface as below:
WorkMode: working mode
Heat: heating mode
Cool: Cooling mode
R/S Mode: control mode
Manu: manual control
Time: Timing control
Weektime: week timing
Inef: be of no effect
Effi : in effect
Crel In : control water in temperature
This temperature is the setup temperature
Anti-HT : anti-heat protection will be displayed when heating mode
Anti-ice : anti-freeze protection will be displayed when cooling mode
C.In°C : water out temperature on user side
E.In°C : water in temperature on user side
Run : press this button to start up the unit
Stop : press this button to turn off the unit
Query Err : press this button to check the current alarms list
User set : press this button to enter in user setting parameter menu. (need password)
Query Sta : press this button to check the parts state list
History : history error record
Unit Sta : unit state
Machine is idle : unit is stand by
Machine is alarm : unit is in alarm
Guide : user guide

1)Start up the unit
In the main operation interface, press RUN button to start up the unit,
The following window will come up on the display,

temperature controller

temperature controller

Press ENTER to confirm to start up the unit
The RUN LED will illuminate in green color.
Components parts start up the sequence step by step as below :
the first running part is the air conditioning water pump
the second running part is the well water pump after several seconds
the third running part is the compressor after 3 minutes and the energy
the compressor will run base on the energy load from 0-25%-50%-100% step by step
After above, The unit will be completely started up

2)Shut down the unit
In the main operation interface, press the STOP button to turn off the unit
The following window will come up on the display:

Press Enter to confirm the operation,
Components parts start up the sequence step by step as below :
the first stop part is the compressor , the RUN LED will turn off at the same time
the second stop part is the well water pump after 3 minutes
the third stop part is air conditioning water pump after several minutes
After above,The unit will be completely shouted down

3)Change the operating mode
Please refer to page 10 >>> Item 1:Set user parameters

4)View the status of the main components
On the main operation interface, press the Query sta button to view the state of the component parts interface as below:

temperature controller for screw chiller

temperature controller for screw chiller

Description of every button in the start up interface as below:
CM State % : compressor state
Stop : in stopping
Running : in running
0 (25/50/100) : energy load from 0/25%/50%/100%

A /C Pump : air conditioning water pump state
Stop : in stopping
Running : in running
Well Pump : well water pump state
Stop : in stopping
Running : in running
Exit : Press this button to go level up and return to the main operation interface
Unit : Press this button can enter into the Unit Status Query interface
Hcurve : Hour curve (display the water out and water in temperature curve within one hour)
Dcurve : Day curve (display the water out and water in temperature curve within one day)
Note : the Hcurve button and the Dcurve button is the same button

Hour curve interface

Hour curve interface

Day curve interface

Day curve interface

Input: Press this button can inquiry and display 24 routes switch input’s name and state in every backboard. Please see the below interface :

Press Up/Down button to select the page number
Press Subb(-)/Add(+) is no use
Press exit to go level up
Please see below table for detail opposite item
 running LED
If the LED illuminate in highlight indicating the component is running
If the highlight is off indicating the component is in stand by status.

NOTE:
1、【control condenser fan】 when setup “discharge temperature”, that can not see; when setup “middle pressure switch”, that can see.
2、【outside circle pump function】 when setup NO, that can not see. Or can see in above interface
3、For Digital variables input, If there is no Digital variables input in the unit, that can set up “NO” and not connect with an electrical line; if setup “OFF”, need short circle when connecting with the electrical line.

output: Press the Output button and enter into the relay output interface display and inquiry the name and state of 20 routes input in every board. Please see the below interface :

Press Up/Down button to select the page number
Press Subb(-)/Add(+) is no use
Press exit to go level up
Please see below table for detail opposite item
 running LED
If the LED illuminate in highlight indicating the component is running
If the highlight is off indicating the component is in stand by status.
Theory: Press this button can see the interface.

5)Alarm report and compressor work time
On the main operation interface, press the History button to check the alarm report and the compressor work time as below interface:

Press Up/Down button to select the Item
Press enter button is confirmed and enter into
Press exit to go level up

a)Item 1: Query errors
Press the Up(Down) button and enter button, then can enter into the query error interface as below:

Press Up/Down button to select the Item
By number: to check the alarm by the number if the alarm happened
By times: to check the alarms history by how many times this code has happened
By time: to check the alarms history by when it happened, the new alarm is on the top of the list
Press enter button is confirm and enter into
Press exit to go level up

b)Item 2: Query compressor work time
Press the Up(Down) button to choose the Item 2 and press the enter button, then can enter into the query error interface as below:

This interface displays the compressor run add-up time.
Press exit to go level up

6)Guide Item
On the main operation interface, press the Guide button to see the controller explain and version as below interface:

This interface display will support the controller summary and version for reference.
Press Up/Down button to select the Item
Press enter button is confirmed and enter into
Press exit to go level up
3.User operation interface
Press the user set button on the main interface, then will display the interface as below:

On this interface, need input the password (12345678) and then can enter into the next interface:
If the password is not right, then will come up the below interface:

Please press the enter button to go lever up the main interface and try it again:
If the password is right, then will come up the below interface:

Press Up/Down button to select item
Press enter button and enter into the item which be choosed
Press Exit button to go level up

1)Item 1:Set user parameters
Choose Item 1 and press the enter button, then can enter into the below interface:

In this item you can modify work mode, Control temperature, Week timing and once timing
Press Up/Down button to select the item,
Then press the Subb(-)/Add(+) button to modify the content and parameter
After one item is modified press the Up/Down button to select another item
Work mode : unit working mode (NOTE: This item will be not changed when the unit is running.)
Cool : setting the unit in cooling mode
Heat : setting the unit in heating mode
Control temperature : unit water in temperature setting
Week timing : work time setting for every work
inef : be of no effect
effi : be effect
Once timing : If the unit is running ,this setting time will be the shut down time
If the unit is stopping state, this setting time will be the start up time
Unset : no setting the once timing
00:00 : use the week timing setting as this setting timing
NOTE: When choose this Item and setting, Subb(-)/Add(+) button is choose the Unset or timing (00:00)
When choosed the timing (00:00), Up/Down button is choose the hour(front 00) and the minute/second(back 00)
Then press the Subb(-)/Add(+) button to setting the timing
When the operation is finished press Exit button to go level up

2)Item 2:Set week timing
On the user setup interface, choose the Item 2 by the Up/Down button and press the enter button to enter into the below interface:
This operation can set up the start and stop timing for the unit as every week.
This setting function is the unit will start and stop as the setting time for automatic within every week.
This can set up 7 days in one week and 3 times for starting and stopping time in one day.

The detail operation as below :
Press the Up/Down button to choose the idiographic setting Item hour(00) and minute/second(back 00)
Press the Subb(-)/Add(+) button to modify the time number
Press the Clear button to cancel all of the time number if the setting are wrong.
When the operation is finished press Exit button to go level up
NOTE: The MAX. display number time in the pane is 23:59.
00:00 is be of no effect setting time.
It need set up in effect for Week timing in the [Item 1] interface, then your setting can use.

3)Item 3:Use or not
On the user setup interface, choose the Item 3 by Up/Down button and press the enter button to enter into the below interface:

This interface function is choose and control the compressor to run or not.
The detail operation as below:
Press the Up/Down button to choose the every compressor
Press the Subb(-)/Add(+) button to modify
Use : The compressor is running
Unuse : The compressor is not running
When the operation is finished press Exit button to go level up

4)Item 4: Set user time
On the user setup interface, choose the Item 4 by Up/Down button and press the enter button to enter into the below interface:

This interface function is setting the current time and will display in the main interface.
This setting will not effect SYSTEM TIME. Same as a bell .
The detail operation as below:
In this item you can set the clock according to the local time
Press the number button to input
Press button to confirm the input and choose next Item
When the operation is finished, then press Exit button to go level up

5)Item 5:Set contrast
On the user setup interface, choose the Item 5 by Up/Down button and press the enter button to enter into the below interface:

You can adjust the contrast at any time according to the requirement through this operation.
The detail operation as below :
Press Add(+)/Subb(-) button to adjust.
Press Return button to confirm and go level up.

6)Item 6:Set display mode
On the user setup interface, choose the Item 6 by Up/Down button and press the enter button.
Press Enter button can change the screen color from BLUE to WHITE and vice versa.

7)Item 7:Select language
On the user setup interface, choose the Item 7 by Up/Down button and press the enter button to enter into the below interface:

Choose the English or中文 button, then press the Exit button to confirm and go lever up.
8)Item 8: Adjust the screen
On the user setup interface, choose the Item 8 by Up/Down button and press the enter button to enter into the below interface:

Please operate as the clue on display in the interface.

9)Item 9: Modify user password

On the user setup interface, choose the Item 9 by Up/Down button and press the enter button to enter into the below interface:

The detail operation as below :
Input the right password and press button to confirm
If the password is right, it will request you to input the new password.

Press button to confirm the input and it will request to repeat the 2nd time new password input.

If the 2nd time new password input is different from the first one. It will display as below:

Press Enter to repeat the above steps and to set up the new password.
Press Enter button to confirm and go level up.

Machine setting
Press and hold the top left corner on the main interface for 3 seconds, then input the right password and enter into “unit setup”, only manufactory and debugging people have the right to operate. Please see the below interface:

Input the right password (12345678)
If input the password id wrong , press button the to cancel
Press the button to confirm and enter into the machine setting interface as below

On above interface, the operation as below :
Press Up/Down button to select item
Press enter button and enter into the item which be choosed
Press Exit button to go level up

1.Item 1 : Machine type setup
Below is the Machine type setup interface:

On above interface, the operation as below:
Press Up/Down button to select item
Press Subb(Add) button to modify
Press Exit button to go level up
Temperature CTRL. Object: Temperature Control Mode
in : control water in temperature
out : control water out temperature
Remote switch type: Line(Remote) control type
Dial: Dial or Manual
Pulse: Pulse
Screen protection time:
10Min: the time for Screen protection

Below table is the description for the setting item:

Setup ItemWater source heat pumpExplain
Temperature Control ModeWater in temperatureSetting “water in temperature” or “water out temperature” as the energy adjustment.  See energy adjustment
Line controller typeManualOr “pulse”, Used to the remote control, See NOTE 1
Screen protection time10 minute(0~20)See NOTE 2
outside pump control modeManualOr “automatism”,

See NOTE 3 and outside circle pump

NOTE:
1、Used to remote control unit. If setup “Manual”, base on the [ Line control switch ] and setup “ON”, if the switch is on and the unit will be start up; if the switch is off and unit will be shut down. If the switch “OFF”,the setup and result is reverse to above. If setup “pulse”, press the line control switch, base on the unit state and decide whether start up or shut down, the “start” and “Stop” key on the touch is available.
2、The screen protection function, if not touch the screen within 10 minutes, system will into the screen protection state, touch the screen lightly and can be back.
3、If set up the [outside pump function] is NO, that will not see, Or will see.

1.Item 2 : Sensor setup
Below is the Sensor setup interface:

On above interface, the operation as below :
Press Up/Down button to select item
Press Subb(Add) button to modify
Use: set up to use this sensor
Unuse: set up to nonuse this sensor
Press Exit button to go level up

Below table is the description for the setting item:

Setup ItemWater source heat pumpExplain
system water out temperature sensorUseCan not setup, only have on the first board
system water in temperature sensorUseCan not setup, only have on the first board
discharge temperature sensorUseCan setup, have on the every board
environment temperature sensorUseCan setup, only have on the first board
Evaporator water outUseCan setup, or have on the every board
Condenser water outUseCan setup, or have on every board
outside circle pump temperature sensorUseCan not setup, Please see NOTE 2.

NOTE:
1、[ outside circle pump temperature sensor ] it will be saw when using it and under the automatic mode.
2、Above said the sensor can not setting which stand for the unit must use this sensor., here display just for reference. When the sensor will setting “Un-use” , the alarm will be of no effect, when unit is running, it will not administer the action or not display the temperature number.

2.Item 3 : Time parameter setup
Below is the Time parameter setup interface:

On above interface, the operation as below :

Œ Press Up/Down button to select item

 Press Subb(Add) button to modify

Ž Press Exit button to go level up

 

Below table is the description and setting range for the setting item

Setup ItemWater source heat pumpExplain
Shut oil EM valve time /

Back oil electromagnetism valve shut time

0 Second

(0~255)

Bizter compressor’s will not be saw,

Please see NOTE 3

Run oil EM valve time /

Back oil electromagnetism valve run time

0 Second

(0~255)

Bizter compressor’s will not be saw,

Please see NOTE 3

CM restart delay /

protection compressor high frequency start delay

5 minutes

(0~60)

The interval time of one compressor start up two timing is 4 minutes
C/H valve run/stop delay /

Cooling and heating valve run/stop delay

5 Second

(0~255)

Delay of cooling and heating then start pump,

use to switch the water road

C/H valve run/stop delay /

Cooling and heating valve run/stop delay

5 Second

(0~255)

Delay of cooling and heating then start pump,

use to switch the water road

A/C pump run delay /

delay after air conditioning pump start

15 Second (0~255)Start well pump after air conditioning pump start for delay 15 second
Well pump run delay /

delay after well pump start

120 Second (0~600)Start compressor after well pump start for 120 second
25% EM valve delay /

delay after 25% electromagnetism valve start

10 Second

(0~60)

Start electromagnetism valve of heating after 25% valve start for 15 second
Wind grounp 1 run delay /

delay after contactor start(part wiring NO.1)

500 millisecond (300~800)part wiring NO.2 will turn on after part wiring NO.1 turn on for 500 millisecond
Wind group 2 run delay /

delay after contactor start(part wiring NO.2)

10 Second

(0~60)

50% electromagnetism valve will be open after part wiring NO.2 turn on for 10 second
 

delay after contactor start(STAR)

7 Second

(0~10)

Corner contactor start after star contactor turn on for 4 second
delay after contactor start(Corner)15 Second

(0~255)

50% electromagnetism valve will be open after Corner contactor start for 30 second
50% EM valve run delay /

delay after 50% electromagnetism valve start

60 Second

(0~180)

Interval delay from 50% electromagnetism valve to 75% % electromagnetism valve open
75% EM valve run delay /

delay after 75% electromagnetism valve start

60 Second (0~240)Interval delay from 75% electromagnetism valve to 100% electromagnetism valve open
CM unload delay /

delay of compressor uninstall

0 Second

(0~240)

The least time for 25% electromagnetism valve operate when compressor stop
CM unload interval delay /

delay of compressor uninstall interval

15 Second

(0~240)

The least interval time for two compressors stop
Well pump delay stop /

delay of well pump stopping

120 Second (0~600)Well pump will delay for 10 seconds after all compressor stop
A/C pump delay stop /

delay after air conditioning pump stopping

15 Second

(0~180)

Air conditioning pump will stop for delay 60 seconds after well pump stop
Common error check dly /

delay for common fault testing

3 Second

(0~20)

Delay 2 seconds after tested the normal fault
Water flow error delay /

delay of water flow fault

15 Second

(0~255)

It will alarm for delay 10 seconds after Water flow lack
Oil level error delay /

delay of oil level testing

30 Second

(0~255)

It will alarm for delay 30 seconds when tested the oil level fault
delay of oil pressure difference protection120 Second (0~255)It will alarm for delay 120 seconds when tested the oil pressure fault
protection time of compressor of shut down30 minute

(0~255)

See anti-freezing logic
Under loaded CM runtime /

compressor operation time of un-full load

0 minute  0~255)See NOTE 2
Force CM full load time /

compressor operation time of forcing full load

0 minute  (0~255)Avoid compressor operation in un-full load lead to lack oil

NOTE: 1 [delay after contactor start(part wiring NO.1) ]and [delay after contactor start(part wiring NO.2] will be displayed only when setup part wiring start- up; [delay after contactor start(STAR)] and [delay after contactor start(Corner) ]will be displayed only when setup staring start-up;

       2 [compressor operation time of un-full load][compressor operation time of forcing full load] use to solve  the problem of compressor return oil. Because worry to lead to the lubricate system bad and happen the lack oil and harm the compressor’s life if compressor will be operated under un-full load for long time. It is forbidden to uninstall when the compressor will reach the time [compressor operation time of un-full load] but not, and will be forced to enter the full operation but not. Except happen stop or compressor fault or communication fault that compressor opposite back board etc.

3 When the two parameters will be set up with “0”, that stand for nonuse the return oil valve. Usually the compressor do not use the return oil, then use the two parameter, use to solve the problem of the compressor return oil. When the compressor is running, the return oil valve will start to act, then open the return oil valve (Run oil EM valve time), then close the return oil valve (Shut oil EM valve time), then open the return oil valve (Run oil EM valve time) again, then go on.

  1. Item 4 : Input setup

Below is the Input setup interface:

On above interface, the operation as below :

Œ Press Up/Down button to select item

 Press Subb(Add) button to modify

Ž Press Exit button to go level up

Below table is the description and setting for the setting item

Display on the interfaceSetup itemWater source heat pumpExplain
A/C PumpDLair conditioning pump overloadNC
A/C Wa.insair conditioning pump lackNC
WellPumpDLwell water pump overloadNC
Well Wa.inswell water flow lackNC
outside circle pump overloadNOSee NOTE 2
CM LPcompressor low pressureNC
CM HPcompressor high pressureNC
CM OLoadcompressor overloadNC
CM OHeatcompressor superheatNO
CM OPcompressor oil pressure switchNC
Oil levelcompressor oil level switchNC
CM IN Portcompressor inside protectionNC
Rmote SWline control switchNO
Phase Prctfault and lack phase protectionNO
C-Switchoutside catenation switchNO

NOTE:

1、[control condenser fan] when setup “discharge temperature”, that can not see; when setup “middle pressure switch”, that can see.

2、[outside circle pump function] when setup NC, that can not see. Or can see in above interface

3、For Digital variables input, If there is no Digital variables input in the unit, that can setup “NC” and not connect with electrical line; if setup “NO”, need short circle when connect with electrical line

4NO stand for “normal open”, NC stand for the “normal close”

  1. Item 5 : Temperature parameter setup

Below is the Temperature parameter setup interface:

On above interface, the operation as below:

Œ Press Up/Down button to select item

 Press Subb(Add) button to modify

Ž Press Exit button to go level up

 

 

 

 

 

Below table is the description and setting range for the setting item

Setup ItemWater source heat pumpExplain
SYS.C.in TEMP. compensation /

Condenser water in TEMP compensation

0°C

(-10~10)

Use to compensation system water out temperature
SYS.E.in TEMP. compensation /

Evaporator water in TEMP compensation

0°C

(-10~10)

Use to compensation system water in temperature
Exhaust TEMP. too high /

Exhaust TEMP too high

100°C

(0~120)

Use to the Exhaust TEMP too high alarm
Cool TEMP.lower limit /

TEMP. lower limit when cooling

7°C

(-30~60)

Use to limit the control temperature range that user can set up
Heat TEMP. upper limit /

TEMP. upper limit when heating

50°C

(0~80)

Use to limit the control temperature range that user can set up
Enter CL Evap.out TEMP. low /

Evaporator water out TEMP too low protection when cooling

4°C

(-30~60)

When the water temperature ≤4°C,

the compressor will stop

Exit CL Evap. out TEMP. low

Evaporator water out TEMP normal return when cooling

4°C

(-30~60)

When the water temperature ≥10°C,

the compressor can run

Enter HT Evap. out TEMP. low

Evaporator water out TEMP too low protection when heating

2°C

(-20~20)

When the temperature water out ≤2°C,

The compressor stop and display alarm

Exit HT Evap. out TEMP. low

Evaporator water out TEMP normal return when heating

8°C

(-20~25)

When the temperature water out ≥8°C,

The compressor get right

Exit HT Evap.out TEMP. high /

Evaporator water out TEMP too high return when heating

50°C

(0~80)

When heating, the temperature water out ≤50°C, the compressor can run
Exit CL Cond. Out TEMP. high /

Condenser water out TEMP too high return when cooling

Enter HT CondOut TEMP.low /

Condenser water out TEMP too high protection when heating

Exit HT CondOut TEMP.low /

Condenser water out TEMP too high return when heating

Anti-freeze run pump TEMP /

Anti-freeze run pump water out TEMP

6°C

(0~30)

See the anti-freeze logic
Anti-freeze run heater TEMP /

Anti-freeze run heater water out TEMP

4°C

(0~30)

See the anti-freeze logic
Anti-freeze run CM TEMP /

Anti-freeze run compressor water out TEMP

2°C

(0~30)

See the anti-freeze logic
Anti-freeze stop TEMP /

Anti-freeze stop compressor water out TEMP

15°C

(0~30)

See the anti-freeze logic
EM spray run exhaust TEMP /

exhaust TEMP of motor electromagnetism run

85°C

(0~120)

When the exhaust temperature ≥80°C,

Then open the motor electromagnetism

EM spray stop exhaust TEMP /

exhaust TEMP of motor electromagnetism stop

79°C

(0~120)

When the exhaust temperature ≤70°C,

Then close the motor electromagnetism

Midspray run  exhaust TEMP /

exhaust TEMP of middle electromagnetism run

95°C

(0~120)

When the exhaust temperature ≥90°C,

Then open the middle electromagnetism

Midspray stop exhaust TEMP /

exhaust TEMP of middle electromagnetism stop

89°C

(0~120)

When the exhaust temperature ≤80°C,

Then close the middle electromagnetism

 

  1. Item 6 : Temperature control parameter setup

Below is the Temperature control parameter setup interface:

On above interface, the operation as below:

Œ Press Up/Down button to select item

 Press Subb(Add) button to modify

Ž Press Exit button to go level up

Below table is the description and setting range for the setting item

Setup ItemWater source heat pumpExplain
TEMP. control period /

TEMP control period

60 seconds

(0~240)

Use to the cooling and heating control
Sudden stop control period /

Suddenly stop control period

0 seconds

(0~180)

Use to the suddenly stop area
C/H load TEMP.diff setup /

Cooling/heating to load TEMP different setup

2°C(0~10)Use to the cooling and heating control
C/H unload TEMP.diff setup

Cooling/heating uninstall TEMP different setup

3°C(0~10)Use to the cooling and heating control

 

  1. Item 7 : Initialize parameters

Below is the Initialize parameter operation interface:

On above interface, the operation as below:
Press Up/Down button to select item
Press enter button to confirm and enter into
Press Exit button to go level up
Initialize machine para: Initialize all of the machine setup parameters to set up the windows default
Initialize error record: Initialize and eliminate all of the history error records
Initialize comp work time: Initialize compressor running add-up the time and reset to 0
Initialize user parameter: Initialize all of the user setup parameters to set up the windows default
1)Item 1: Initialize machine para
Use the Up/Down button to choose this Item and press the enter button to enter into the interface as below:

Then press the enter button to confirm and go level up.
NOTE: The operation of the Item 2 / Item 3 / Item 4 are all same as the Item 1.

1.Item 8: Modify machine password
The operation of this Item is same as the MODITY USER PASSWORD.
Please refer to the page 15 [tem 9:Modify user password]

Manufacturer setup
Press the top corner on the main start interface, then will display the interface as below:

Input the right password and press button to confirm, then will enter into the manufacturer setup interface:

On the above interface, the operation as below:
Press Up/Down button to select item
Press enter button to confirm and enter into
Press Exit button to go level up

1.Item1: Set manufacturer para
Use the Up(Down) button and press the enter button, then enter into the below interface:

On above interface, the operation as below:
Press Up/Down button to select item
Press Subb/Add button to modify
Press Exit button to go level up

Water Cooled Screw Water Chiller Installation guide

Note: For your reference only, TopChiller reserves the rights to change the data without previous notice;Please kindly contact We in time if you have special requirements.

Water cooled screw chiller has been designed to be utilized in commercial and industrial air conditioning. Units are suitable for indoor installation.

The products are used in hotels, supermarkets, office buildings, exhibition halls, airports and gym central air conditioning system, they are also fit for the requirements of precision air conditioning system of electric, pharmaceutics, biology, spinning, mechanism etc.

Where noise is a concern, water cooled water chillers provide the ideal solution for sound sensitive environments. The compact design makes installation more flexible.

Water cooled water chillers are designed with high-efficiency scroll or semi-hermetic screw compressors, shell and tube heat exchangers and various safety devices. The units are incorporated with a microprocessor control system allowing to monitor and manage all the functions and to communicate with an external management system.

The units are completely assembled in the factory, supplied with full refrigerant charge and control types of equipment, to reduce installation time and costs. The installation normally requires just hydraulic and electrical connections.

The R22&R407C range consists of 34 models, and the capacity is from 180 to 4120 KW. The unit is able to supply chilled water with the temperature 5-15 ℃

The R134a range consists of 29 models, and the capacity is from 130 to 2500 KW. The unit is able to supply chilled water with the temperature 5-15 ℃

The features of Water cooled screw water chiller system

1.Featured famous brand accessories, efficient, energy saving and durable unit

①Famous brand compressor, thermostatic expansion valve, heat exchanger tube, computer-control, ensure the unit efficiency, energy saving, durable
②Insulation materials used a flame retardant, to avoid fire accidents caused by human factors and ensure safe operation of the unit.

2.The complete control unit, multiple security measures to ensure the safe operation of the unit
①Control function
Startup and Shutdown Control
selection of remote or short-range control
unit’s program setting
Return water temperature control settings
Automatic control of energy regulation
High temperature low temperature alarm limits
Anti-freeze protection settings
Compressor start and stop program management
Compressor manually management
Time management unit
Water pump management
Programmable temperature management
Fully functional operating parameter display
Fault alarm and diagnostic functions
②Unit with security features
Compressor phase sequence protection
Compressor overload, overheat protection
System with high and low pressure protection device
System is equipped with the necessary safety valve, release valve, drain valve
Electrical components with electric shock protection
Frost protection
With water cut-off protection system

3. Highly intelligent unit control system with centralized monitoring and remote control interface

①Use of foreign brands unit microcomputer control, intelligent control unit, English display, friendly interface
②High degree of automation, functional and program management to achieve unit commitment, timing control, pump management, full-function fault alarm and fault self-diagnosis function. RS485/RS232communication interface with the same time, user-focused monitoring and implementation unit remote monitoring.
③With three levels of password protection to prevent the program and setting parameters are free to be changed.
④When the unit fails, automatically and immediately stop running, the alarm output signal and show the cause malfunction and fault in the place, in order to facilitate the timely troubleshooting and maintenance unit.
⑤Compressor and pump interlock control; for synchronized actions and compressor valve

4.Multi-loop cooling system designed to improve unit reliability and anti-jamming capability
The family unit such as the use of two sets or two or more compressor units, according to each compressor for a refrigeration circuit design. Mutual backup between each compressor to improve the reliability of the unit and anti-jamming capability.

5.Relying on the performance of advanced test equipment to ensure the unit stable, safe and reliable
TopChiller company has advanced “laboratory of water-cooled chillers, ” each air conditioners are operating
strictly in the factory test, to ensure the safety unit in poor condition and reliable operation, the factory’s products are qualified.

6. TOPCHILLER water-cooled screw chiller structural features:
Match the famous brand and efficient compressor Host well-known brands of semi-closed with screw compressors, semi-hermetic screw compressor compared with piston compressors has the following advantages:
①Fewer parts (about piston compressor’s 1 / 3), simple structure, less wearing parts, high reliability, long life.
②Compressor suction and discharge uniformly continuous, low exhaust temperature, vibration, on the wet compression is not sensitive ,strong resistance to fluid strike
③Unit EER ≥4.4W/W,Unit EER of large units of up to4.8W / W
④In the energy adjustment, the screw compressor advantages, the implementation of 25 – 100% non-class energy regulation

Matching high-performance dry-type evaporator with tube heat exchange tube evaporator
①Using the most advanced and efficient DAE  evaporation heat transfer pipes, the inner surface of the long thin spiral ribs and spiral processes, the heat transfer coefficient and heat capacity greatly increased.
②Optimization of the internal structure of the evaporator design, configuration, with efficient  liquid receiver, solve the system refrigerant distribution uniformity issues.
③Improved refrigerant water baffle seal structure to solve the problem of baffle leaks, greatly enhancing the efficiency of the evaporator heat exchanger to ensure units achieve higher levels of performance.
④Unique technical of heat exchanger  cooling process’s design, a reasonable match for the system to ensure the cooling process and the water side of the balance between cooling capacity, give full play to high-performance heat exchanger; also match a reasonable system, and the unit more energy efficient.
⑤In the dry type evaporator frost protection switch is also installed, release valve, to ensure the safety and clean of dry type evaporator, and ease of maintenance.

Matching high-performance shell and tube water cooled condenser with tube heat exchange.
①Using the most advanced and efficient DAE condensing heat transfer pipe, the outer surface of the long thin spiral ribs and spiral processes, the heat transfer coefficient and heat capacity greatly improved
②Internal structure of the optimal design, which greatly improved the condenser corrosion, anti-fouling ability, give full play to the condenser heat transfer, thus ensuring the unit to achieve a higher level of performance.
③Shell and tube condenser is also installed with the safety valve, release valve, to ensure the safety of shell and tube condenser, ease of maintenance and cleaning.

Anti-vibration unit designed to ensure unit low noise, low vibration
①Set the spring under compressor unit or rubber shock absorbers, damping efficiency more than 85% efficiency, that vibration transmission rate is less than 0.15, reducing unit vibration and system vibration, thereby reducing unit noise
Unit system, all the pipes are anti-vibration plastic pipe clamp, to avoid generating units and system vibration and noise

Matching famous brand refrigeration system accessories.
①Units refrigeration systems all use famous brand manufacturer’s products, such as removable drier-filter, external balanced thermostatic expansion valve for liquid solenoid valves, sight glass, high and low pressure control, air-exhaust temperature controller etc, to ensure that units have a high level of performance
②Unit by 100% inspection of all materials before passing into the factory to ensure that the refrigeration system of high reliability.

Matching advanced, highly reliable intelligent control systems and control technology
①Control system except with stand-alone automated configuration and function, also have shown multi-unit operation, according to the return water temperature automatically determine air-conditioning system is part of the unit operation or all of the unit operation
②With RS485/RS232 communication interface, easy to achieve the monitoring and remote monitoring by users.
③Control multiple units with the balance of the compressor to run functions to ensure efficient operation of unit.

Method of unit’s energy adjustment
Unit according to the temperature of returned chilled water to logical calculation and control unit and start running down. Each unit uses no stage energy regulation, energy efficient unit operation to achieve
Unit structure is reasonable, installation, convenient for maintenance and management

①unit with a unique stackable structure and form of box-type frame structure, compact and strong, has good mechanical strength, small footprint. The appearance of high-strength unit Powder coating, corrosion rust, beautiful appearance.
②Modular design, product adaptability, parts interchangeability, and flexible for a variety of models can be combined, in the most efficient way to provide users with the most attentive service.
③Unit layout is reasonable, according to human engineering, installation and maintenance space optimization settings to facilitate routine cleaning, maintenance and repair.
④Machine in the form of units, low pressure parts wrapped the insulation layer, the system has sufficient fluoride fuel, arrived at the scene and just to connect water way pipe. You can open the unit when power ready
⑤The computer will automatically start the pump motor, compressor, and refrigeration units, delay, interlock, protection and temperature regulation, and coordination of automatic control. Since then, the unit under the control of the computer running by setting the temperature and the evaporator inlet temperature according to changes in energy regulation automatically
⑥Unit installation flexibility, both on-site control can also be a remote control, easy for inspection and maintenance.

OPTIONAL FOR USER
Electronic expansion valve
Desuperheater as optional.
Electronic controller with BMS system.
Low noise compressor cabinet or outside full cover
Channel Steel base

Working Principle

The compressor absorbs low-pressure, overheat cooling medium steam from dry type evaporator, and pass through compressor to be compressed to became high-temperature, high-pressure, gaseous cooling medium, then go into condenser from discharge pipes to translate heat energy to cooling water and generate hot water for heating.

High-temperature and high-pressure gaseous cooling medium is condensed normal temperature liquid state medium by circulating water, and then dry filter dries water and clean impurity of liquid state medium.

After go through magnetic valve, expansion valve, and throttle, the pressure of cooling medium becomes low-pressure from high-pressure when entering evaporator.

In evaporator, middle, low temperature cooling medium absorbs heat energy from circulating water to evaporating continuously and becomes low-temperature, low-pressure overheat gaseous cooling medium when it arrives outlet of evaporator and finishes one circulation to achieve the purpose of heating/cooling.

water cooled screw chiller working principle

water cooled screw chiller working principle

OPERATING RANGE

OPERATING RANGE

Fouling factors correction

Fouling factors correction

Screw chiller unit performances listed in the tables are given for the condition of clean exchangers (fouling factor = 1). For different fouling factor values, unit performances should be corrected with the correction factors shown above.

ETHYLENE GLYCOL SOLUTIONS

The use of ethylene glycol solutions allows units to operate at lower leaving water temperatures and prevent freezing in chiller heat exchangers.

The use of low freezing point solutions causes a change in the main thermodynamic properties and performance of the units.

The major parameters affected by the use of glycol solutions are the following:

– Cooling capacity

– Power input

– Flow rate

– Pressure drop

The table below lists correction factors referred to the most common ethylene glycol m solutions.

ETHYLENE GLYCOL SOLUTIONS

ETHYLENE GLYCOL SOLUTIONS

LOW TEMPERATURES CORRECTIONS FACTORS

LOW TEMPERATURES CORRECTIONS FACTORS

Water cooled screw chiller cooling  principle

When screw chiller unit runs in cooling mode, well water as a carrier carries out heat from industrial appliactions.

Cooling medium absorbs heat from evaporator and cools water into 7 ℃, then cooling water is sent to room, cooling medium goes through compressor and becomes high-temperature, high-pressure overheat steam, goes into condenser and pull out heat by well water

cooling condition

cooling condition

Curve 1: cooling outlet temp. 7℃
Curve 2: cooling outlet temp. 10℃

Recommended foundation for installation-Standard

Recommended foundation for installation-Standard

APPLICATIONS OF USE

APPLICATIONS OF USE

APPLICATIONS OF USE

APPLICATIONS OF USE

APPLICATIONS OF USE

APPLICATIONS OF USE

IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES

This screw chiller unit is a relatively complicated apparatus.

During installation, operation, maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, oils, materials under pressure, rotating components and both high and low voltage.

Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and responsibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves and proceed safely in completing their tasks.

Failure to comply with any of these requirements could result in serious damage to the equipment and the property in which it is situated, as well as severe personal injury or death to themselves and people at the site.

This document is intended for use by owner-authorized operating/service personnel.

It is expected that this individual possesses independent training that will enable them to perform their assigned tasks properly and safely.

It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced materials.

This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.

SAFETY SYMBOLS

SAFETY SYMBOLS

1. Screw chiller installation space requirements:
A. For easy operating and maintenance, the space among the equipment should be 1.5-2.0 meter. And also we should reserve enough space for both the heat exchanger sides to draw out the heat exchanger, for the other 2 sides at least the serviceman can pass through.

B. When the equipment operating, the temperature of the compressor discharge pipe, and the shell of the condenser will be higher than the ambient temperature, so the room temperature will be increasing, then not good for the workers inside. In order to avoid the high temperature inside, the ventilator should be installed in the room, to make sure that the room temperature is lower than 35℃.

C. The room should be insulated to avoid the noise outside.

2. Equipment lifting and carrying
After the equipment is transported to the place where it will be installed, during lifting, we need to be very careful and avoid the damage of the equipment. Especially the compressor, control system and the pipes can not be damaged. Where the lifting rope touches the equipment, the block pads should be placed.

For the very heavy equipment, there should be support rods between the ropes above the equipment to reduce the pressure to the ropes.

When carrying, it is better to use the crane or forklift. During the lifting, the ropes should be tightened with the equipment, and make the equipment balance and no incline.

And the ropes can not be touched with the heat exchanger and the panel and the top directly.

See below:

During the lifting, the ropes strength should be triple more than the equipment weight, and make sure that no one is under the equipment. Please refer to the weight from the nameplate on equipment.

3. Foundation
Usually, there is no need to build the special anti vibration foundation, because the equipment working balance, slight vibration.

For easy operation and drainage, the foundation can be 20~30cm above the ground, the surface should be level.

4. Equipment installation
Every equipment has been tested carefully before leaving our factory, in order to make sure of the quality and performance, please be careful during carrying and installation, no any damage to the compressor, control system and pipes.

A.Before unpacking the equipment, move it to the closest place where installed, and make it upwards.

B.After the equipment is placed on the foundation, we must do the level correction, not more 0.02% required.

C.The size of chilled water and freezing water pipe connected with the equipment should be as per the regulations and not too small. And flow switch should be fitted on the pipe, and should be interlock with the compressor.

D.In order to observe the working conditions and changes of the equipment and whole system, the thermometers and pressure gauges should be fitted on the inlet and outlet of the chilled water and freezing water pipe.

E.The power supply should be sufficient and not over ±10%. Equipment should be earthing very well.

5. The connection of the water system.

A.The chilled water and freezing water pipe should be insulated to avoid the loss of the heat or cool and the condensate.

B.In order to ensure the water quality, the strainer and water soften device should be installed on the water inlet pipe; otherwise the user should take the responsibility.

C.The pipe size should be as per the regulations and our design.

D.The Pressurization Unit (Expansion vessel) should be installed on the water system, which should be located on the top of the system. And the auto discharge valve, water pump and flow switch should be installed as well.

E.The auto discharge valve should be located on the top of the system. After the water system connected, and leak test and pressure test both are OK, then open this valve and release the air in the system, after that close it. If the water inside is not good quality or the pipe is not clean, please clean the strainer 30days after working.

F.When initial operating of the system, shut off the inlet/outlet valve firstly, open the bypass valve, then open the outlet valve and shut off the bypass valve after the water pump is working for a while.

G.Multi equipments installed in parallel, the water segregator(Manifold), water collector and the water balance valve should be installed.

H.The drain valve should be installed on the lowest place of the system.

The water quality standard

The water quality standard

The water quality standard

7. Power cable connecting
A. Please refer to the wiring diagram to use the right size cable.

B. The equipment earth wire should be earthed properly. And it can not be connected with the gas pipe, water pipe, telephone line to avoid the electric shock.

C. Make sure the right phase sequence.

External wiring, unless specified as an optional connection in the manufacturer’s product line, is NOT to be connected inside the micro panel cabinet.

Devices such as relays, switches, transducers and controls may NOT be installed inside the micro panel. NO external wiring is allowed to be run through the micro panel.

All wiring must be in accordance with TOPCHILLER’s published specification and must be performed ONLY by qualified TOPCHILLER personnel.

TOPCHILLER will not be responsible for damages/problems resulting from improper connections to the controls or application of improper control signals.

Failure to follow this will void the manufacturer’s warranty and cause serious damage to property or injury to persons.

START-UP procedure

1. Pre-starting check
OIL HEATERS

If the oil heater is de-energized during a shutdown period, it must be energized for 12 hours prior to starting the compressor, or remove all oil and recharge compressor with new oil.

Remains energized as long as the fused disconnect switch to the starter.

The oil heater is thermostatically controlled and remains energized as long as the fused disconnect switch to the starter.

CHECKING THE OIL LEVEL IN THE OIL RESERVOIR

Proper operating oil level -the middle of the upper sight glass.
If the oil is excessively high after start-up, the excess oil may be drained from the oil filter drain valve while the compressor is running.
If the oil level is low, the oil should be added to the compressor.

Comply with Local regulations when removing or disposing of Refrigeration System oil!

2. Pre-Starting
Prior to starting the water chiller, pls observe the Control panel. Make sure the system ready to start.
To pre-start the water chiller, pls use the following procedure:

A. The oil heater must be energized for 12 hours prior to starting the water chiller .

The water chiller will not start if the oil is less than 40℃. If not possible, the compressor oil should be drained and new oil must be charged into the oil sump.

B. All Control setpoints should be programmed before the water chiller is started.

Prior to the start, the clock must be programmed for the proper day and time. Any set points which are desired to be changed may be programmed.

C. Check and make sure that the earth wire is connected properly and avoid the electric shock, and the electric leakage protector is recommended to use.

D. Check the insulation between the compressor motor, the phase balance, the phase sequence. Check the control box and other power facilities to comply with the nameplate requirements.

Check the protection device and the thermostat setting etc, make sure that the action is proper and the earthing is well.

E. Check and make sure that the compressor discharge valve is open, otherwise the compressor may be damaged by the extremely high pressure.

F. Check the chilled water and the freezing water system are connected properly, and make sure that the medium quality is suitable for the equipment.

Make sure that the air handling unit, expansion vessel, water strainer etc. will work properly. And all the necessary valves in the pipe system should be open.

G. After starting the circulation pumps, make sure the water flow rate and the water pressure gauge and the thermometer. And before the start, please make sure the below:

3. Start-Up

A. If the water pump is manually operated, pls start the pump firstly.

The Control will not allow the water chiller to start unless the liquid flow rate is established through the water chiller.

(A field supplied water flow switch is required.) If the liquid pump is wired to the Control, the pump will automatically start, therefore, this step is not necessary.

B. After checking the above datas and make sure that it is right, then start the water chiller, pls press the RUN button on the interface of the control panel. This button will automatically start the water chiller.

When the water chiller is working, if any alarm appears, the LED will begin to flash in YELLOW color.

C. Check Oil Pressure display. After the compressor started, LP gauge value should be 0.2~0.5MPa, if lower, please check the dry filter, may be an indication of a dirty filter, which should be replaced when pressure loss is 30% or more of the original pressure;

When a new system is firstly operated under normal full load conditions, the oil pressure should be recorded as a reference point with which to compare subsequent readings.

Also please check the expansion valve is open or close. If the pressure is still lower than 0.2Mpa, then please recharge the refrigerant.

The actual bearing oil pressure will vary with compressor suction and discharge pressures.

MAINTENANCE

1.CHECKING SYSTEM FOR LEAKS
A. LEAK TESTING DURING OPERATION
The refrigerant side of the system is carefully pressure tested and evacuated at the factory.

After the system is in operation under load, the high-pressure components should be carefully leak tested with a leak detector to be sure all joints are tight.

If a leak exists frequent purging will be required or refrigerant will be lost. If any leaks are indicated, they must be repaired immediately.

However, if it is necessary to repair a welded joint, the refrigerant charge must be removed.

B. VACUUM TESTING
With the refrigerant charge removed and all known leaks repaired, and then the system needs to be vacuumed and the Vacuum test should be conducted as follows:

Step1. Connect a high capacity Vacuum pump, with indicator, to the system charging valve and start the pump

Step2. Open wide all system valves, including the clean and gauge valves. Be sure all valves to the atmosphere are closed.

Step3. Operate the Vacuum pump until -0.096Mpa

Step4. Hold the Vacuum obtained in Step 3 in the system for 8 hours; the slightest rise in pressure indicates a leak or the presence of moisture, or both. If, after 8 hours, the pressure continued, the system may be considered tight.

Be sure the Vacuum indicator is valved off while holding the system Vacuum and be sure to open the valve between the Vacuum indicator and the system when checking the Vacuum after the 12 hour period.

Step5. If the Vacuum does not hold for 12 hours within the limits specified in Step 4 above, the leak must be found and repaired.

2. REFRIGERANT CHARGING
After Vacuum test is finished, the system should be charged with a small amount of refrigerant mixed with dry nitrogen so that a halide torch or electronic leak detector can be used to detect any leaks too small to be found by the soap test.

Do not use excessive amounts of refrigerant; use only enough for proper leak detection.

The refrigerant charge is specified for each water chiller model (See nameplate). Charge the correct amount of refrigerant and record the level in the evaporator sight glass.

The refrigerant charge should always be checked and trimmed when the system is shut down.

The refrigerant charge level must be checked after the pressure and temperature have equalized between the condenser and evaporator.

This would be expected to be 4 hours or more after the compressor and water pumps are stopped. The level should be at the center of the sight glass.

The refrigerant level should be observed and the level recorded after initial charging.

PREVENTIVE MAINTENANCE

It is the responsibility of the owner to provide the necessary daily, monthly and yearly maintenance requirements of the system.

IMPORTANT:

If a water chiller failure occurs due to improper maintenance during the warranty period;

TOPCHILLER will not be liable for costs incurred to return the system to satisfactory operation.

In any operating system, it is most important to provide planned maintenance and inspection of its functioning parts to keep it operating at its peak efficiency.

Therefore, the following maintenance should be performed when prescribed.

1. COMPRESSOR CHECK

Oil Filter
The oil filter is used to ensure proper lubrication quality for the compressor.

These filters should be inspected for excessive debris, and if found containing excessive debris, report this to the local Service office for evaluation.

The oil filter should be replaced when the operating oil pressure is bigger than 0.18Mpa from the oil pressure measured.

COMPRESSOR MOTOR
A. Check motor mounting screws frequently to ensure tightness.

B. Motor windings annually to be checked for deterioration of windings.

COMPRESSOR OIL
Oil has been charged before leaving the factory.
A. Check the reliability of oil pressure differential control.

B. Check the discharge/Suction, oil level.

C. During the operation, the oil level must be observed, and the oil level should be bottom of the oil glass. When shutdown, the oil level should be half of the oil glass.

D. Every Spring and Fall season is the preventive maintenance time.

If you find that the oil color is black or there is cupper particle or oxygenation impurity, the oil should be changed with the same type oil, and also clean the dry filter.

This work should be carried on the serviceman skilled.

Note: When recharging the gas and the oil, they should be dried and filtrated firstly to avoid the water and the impurity inside.

2. PRESSURE TESTING
The water chiller should be pressure tested annually. Any leaks found must be repaired immediately.

If frequent purging has occurred, the water chiller must be pressure tested as soon as possible to prevent air and moisture from entering the water chiller.

Air and moisture are the worst enemies of the DX system and experience have shown that water chiller s which are maintained tight are systems that will provide trouble-free efficient operation.

3. EVAPORATOR AND CONDENSER
The major portion of maintenance on the condenser and evaporator will deal with the maintaining of the waterside of the condenser and evaporator in a clean condition.

The use of untreated water in cooling towers, closed water systems, etc. frequently results in one or more of the following:
A. Scale Formation
B. Corrosion or Rusting
C. Slime and Algae Formation

It is therefore to the benefit of the user to provide for proper water treatment to provide for a longer and more economical life of the equipment.

The following recommendation should be followed in determining the condition of the waterside of the condenser and evaporator tubes.
A. The condenser tubes should be cleaned annually or earlier if conditions warrant.
B. The evaporator tubes under normal circumstances will not require cleaning. If however the temperature difference between the refrigerant and the chilled water increases slowly over the operating season, it is an indication that the evaporator tubes may be fouling or that there may be a water by-pass in the water box requiring gasket replacement.

4. CLEAN THE WATER CHILLER SYSTEM

After long working, there will be some deposited calcium oxide or other minerals on the surface of the pipe in the evaporator, and if the thickness is increasing, then it will cause the higher power consumption and higher discharge air pressure and lower suction pressure.

5. ELECTRICAL CONTROLS CHECK

A. Electrical devices——We need to pay more attention to the working voltage, current and phase sequence of the water chiller, and check the contractors and make sure that well connected, and there is no oxygenation, rust or external impurity etc on the touch pint.

All electrical controls should be inspected for obvious malfunctions.
It is important that the factory settings of controls (operation and safety) not be changed. If the settings are changed with our approval the warranty will be affected.

B. Periodic check the loose of the electrical wire (The working vibration may cause the loose), if so, then please tighten it.
C. Periodic check the reliability of the electric device, you need to replace the failure or unreliable one.
D. We must often pay attention to the temperature conditions in the electric box, make sure good ventilation. We need to replace the aging wire because of the heating.

6. Shutdown in winter

When shutdown in winter needed, we need to make the refrigerant into the condenser and close the valves. Purging the surface and dry it with compressed air.

To avoid dust, the water chiller needs to be covered. Open the drain valve, and all the water inside needs to be drained completely when winter to avoid the pipe frozen and broken.

If the water chiller has been shut off for a long time in winter, the water in the system must be drained completely to avoid the pipe frozen and broken when the water temperature is lower than 0 ℃.
7. Startup next year

After a long time shut down, and then startup, the following procedures need to be done:
Check the and clean up the water chiller
Clean the water pipes system
Check the water pump and regulation valves.
Tighten all the wire connectors.

When the main switch is OFF position for a long time, then the main switch should be switched on 24 hours before the start-up to preheat the compressor oil.

According to the different seasons and ambient temperature, at least 12 hours are required.

And the source side water temperature range is 10~35℃, so the temperature of the underground water should be not lower than 10℃.

8. Safety operation notices:

If the compressor discharge valve is not opened wide enough, don’t startup.
After the compressor started, please don’t push the Emergency switch unless abnormal occurs.
When you weld the refrigerant systems, you must release the system pressure firstly to avoid the harmful light-gas caused by the refrigerant and the light fire reacted, even the explosion occurs.
When you start up the system, please start the water pumps firstly, after that you can start the compressor.

When you shut off the system, please shut off the compressor firstly, and keep the user side freezing water pump working till the water temperature in the evaporator is higher than 20℃, after that, you can shut off the water pump.
Please often check and collate the flow switch and the low temperature protection probe to avoid frozen broken while both are a failure at the same time.
While you open the electrical box door, avoid the electric shock.

The fuse can not be replaced by the copper wire or iron wire. Otherwise, the water chiller may be damaged.

Please don’t touch the discharge airline to avoid the scald.
Don’t change the setting value of the protection devices by yourself.
If you heard the abnormal noise from somewhere, please shutdown immediately. Then start up only if all the malfunctions are solved.

9. Usage notices:

If you set the water temperature lower than 0℃, antifreeze needs to be added in the freezing water.
Periodic purging the water system.
When the ambient temperature is abominable and lower than 0℃ in winter, we need to pay more attention to the frozen. And antifreeze or other methods need to be considered.

10. Malfunction analysis and solutions:

The water chiller should be managed by a professional or rich experienced person, and operate and maintain the water chiller properly and normally according to this manual.

Otherwise, the malfunction because of the improper use is not our responsibility and maintenance scope, and the repair costs need to be charged by the buyer.

Malfunction analysis and solutions

MalfunctionAnalysis Check and solutions
High Discharge air pressureThere is air or other foul gas in the system.Get rid of them from the condenser
The water temperature into the condenser is too high or water flow is insufficient.Adjust the valves on the pipe

Check the strainer no the pipe

 

There is much impurity deposited on the inner side of the condenser pipe clustersClean the condenser pipe clusters
Water pump malfunctionCheck the water pump
Refrigerant over charged and full liquid in the condenser shell.Release some refrigerant
The condenser refrigerant inlet valve is not opened widely.Open it widely
Low Discharge air pressureThe water temperature into the condenser is too low or water flow rate is too big.Adjust the water flow rate, and check the water pipe valve

Check the source side water flow rate

Liquid refrigerant flows into the compressor from evaporator, then make the compressor oil produce the foamCheck and adjust he expansion valve to make sure the expansion valve probe touched with the suction pipe but isolated from the ambient conditions.

The water temperature of inlet chilled water is lower than the set point.

Condenser refrigerant inlet valve is leakage.Check the HP/LP balance time after compressor shut off

Check the working current

If necessary, adjust or replace the valve

The refrigerant is insufficientCharge it
High suction air pressureRefrigerant over chargedRelease some refrigerant
Liquid refrigerant flows into the compressor from evaporatorCheck and adjust he expansion valve to make sure the expansion valve probe touched with the suction pipe but isolated from the ambient conditions.

The inlet water temperature of is higher than the highest set point.

Condenser refrigerant inlet valve is leakage.Check the valve
The inlet/outlet of the refrigerant pipe is not well insulated.Check the pipe heat insulation
Low suction air pressureThe condenser refrigerant inlet valve is not opened widely.Open it widely
Evaporator refrigerant inlet pipe or the compressor suction is not good smooth.Check the filters of liquid and gas, if blocked, please clean it at once.
Insufficient flow in the expansion valve or malfunctionAdjust it to the suitable over-heat temperature

Check the expansion valve probe.

No sufficient refrigerant in the systemCheck the leak
Over charged compressor oilCheck the oil level
The temperature of the inlet freezing water is much lower than the setting valve.Check the water pipe installation
Freezing water flow is insufficientCheck the pressure of the evaporator inlet/outlet pipe.
Discharge air pressure is too lowAdjust the chilled water throttle valve
Compressor shutdown because of the HPChilled water flow is insufficientAdjust the chilled water throttle valve
Condenser blocked, inlet throttle valve shut offCheck the condenser pipe cluster and the chilled water throttle valve
Compressor shutdown because of the motor overloadVoltage is too low or too high, or it is not balance between the 3 phases.Check the voltage and make sure that it is within ±10 % of the rated voltage, and the phase difference should be not over 3%.
Discharge air pressure is too low or too highCheck it and find out the reason, then solve it.
Overload device malfunctionCheck the compressor current and compare it with the FLA in the manual
Short circuit of the motor or terminalsCheck the resistance of the motor and terminals.
Compressor inside thermal control action, then compressor shutdown.The voltage is too low or too highCheck the voltage and make sure that it is within ±10 % of the rated voltage
Discharge air pressure is too highCheck it and find out the reason, then solve it.
Freezing water temperature is too high.Check the temperature and find out the reason, then solve it.
Compressor inside thermal control malfunctionAfter compressor shutdown 10 minutes, check the compressor temperature control touch point
Insufficient refrigerant in the systemCheck the leakage
Condenser inlet refrigerant valve shut offOpen the valve
Low pressure protection, then compressor shutdownRefrigerant filter blockedCheck, repair or replace it
Expansion valve malfunctionAdjust or replace the valve
Refrigerant insufficientRe-charge it
Refrigerant valve is not opened widelyOpen it widely
Big compressor noiseLiquid refrigerant flow into the compressor and cause the liquid strikeAdjust the refrigerant volume till the liquid refrigerant in the compressor is removed. Check the expansion valve and the over-heat temperature
Compressor malfunction(With obvious noise)Open the cylinder and check the valve blade
Compressor does not start upOver load relay(Circuit breaker) switch off and fuse brokenControl Circuit is set as manual and re start the compressor after repair
Control circuit disconnectedCheck the control system
No currentCheck the power supply
Suction pressure is too low and can not open the pressure switchCheck that the low suction pressure caused by the less refrigerant in the system
Contactor winding is brokenReplace it
Power supply phase failureRe-connect and change the connection
The malfunction relay failure in the water systemAdd the freezing water flow rate
Oil temperature too highMotor winding resistance brokenCheck the resistance and the insulation
Suction valve blade brokenReplace it
Piston brokenReplace it
Oil pressure is lowOil filter is blockedClean the oil filter
There is liquid in the oilHeat the oil to a certain temperature then start it

11.Warranty
24-month Warranty – This Product is warranted to be free from defects in material and workmanship.

If the defect appears within 24 months from the date of original installation, whether or not actual use begins on that date, then the product does meet this warranty.

A new or remanufactured part, at the manufacturer’s sole option, to replace any defective part will be provided without charge for the part itself;

PROVIDED the defective part is returned to the distributor through a qualified servicing dealer.

THIS WARRANTY DOES NOT INCLUDE LABOR OR OTHER COSTS incurred for diagnosing, repairing, removing, installing, shipping, servicing or handling of either defective parts or replacement parts. Such costs may be covered by a separate warranty provided by the installer.
THIS WARRANTY APPLIES ONLY TO PRODUCTS IN THEIR ORIGINAL INSTALLATION LOCATION AND BECOMES VOID UPON REINSTALLATION.
LIMITATIONS OF WARRANTIES – ALL IMPLIED WARRANTIES (INCLUDING IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY) ARE HEREBY LIMITED IN DURATION TO THE PERIOD FOR WHICH THE LIMITED WARRANTY IS GIVEN. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE MAY NOT APPLY TO YOU. THE EXPRESSED WARRANTIES MADE IN THIS WARRANTY ARE EXCLUSIVE AND MANY NOT BE ALTERED,
ENLARGED, OR CHANGED BY ANY DISTRIBUTOR, DEALER, OR OTHER PERSON
WHATSOEVER.

ALL WORK UNDER THE TERMS OF THIS WARRANTY SHALL BE PERFORMED DURING NORMAL WORKING HOURS. ALL REPLACEMENT PARTS, WHETHER NEW OR REMANUFACTURED, ASSUME AS THEIR WARRANTY PERIOD ONLY THE REMAINING TIME PERIOD OF THIS WARRANTY.

THE MANUFACTURER WILL NOT BE RESPONSIBLE FOR:
1. Normal maintenance as outlined in the installation and servicing instructions or owners manual including filter cleaning and/or replacement and lubrication.

2. Damage or repairs required as a consequence of faulty installation, misapplication, abuse, improper servicing, unauthorized alteration or improper operation.

3. Failure to start due to voltage conditions, blown fuses, open circuit breakers or other damages due to the inadequacy or interruption of electrical service.

4. Damage as a result of floods, winds, fires, lightning, accidents, corrosive environments or other conditions beyond the control of the Manufacturer.

5. Parts not supplied or designated by the Manufacturer, or damages resulting from their use.

6. Electricity or fuel costs or increases in electricity or fuel costs from any reason whatsoever including additional or unusual use of supplemental electric heat.

7. ANY SPECIAL INDIRECT OR CONSEQUENTIAL PROPERTY OR COMMERCIAL
DAMAGE OF ANY NATURE WHATSOEVER. Some states do not allow the exclusion of incidental or consequential damages, so the above may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which may vary forms area to area.

Conclusion

To select the right screw chiller, you have to make sure that you find a reputed manufacturer of water cooled screw chiller like TopChiller®.

Before ordering the right chiller, you need to calculate the amount of water which is required to be chilled, then decide on the requirement.

In this way, you can find the right chiller and as a result, your production will achieve efficiency to the maximum level.

TopChiller® is committed to sustainable development and the concept has been integrated into our corporate culture.

The water cooled screw chillers supplied by TopChiller® are energy efficient and suitable for MRI, CT, milk cooling, die casting, and many other industrial applications.

The cooling capacity of our premium water cooled screw chillers ranges from 40 Ton to 680 Ton and their operating sound levels are very low in all conditions.

TopChiller® water cooled screw chillers are widely used by all kinds of industrial companies all over the world. If you are not sure which chiller you should choose for your system, our chiller experts are always here to help.

 

Please contact us right away by sending an inquiry to check what your system requires. Choosing between water-cooled and air-cooled screw chillers is not an easy decision.

However, with decades of expertise, we will help you find which one is the best option for your company.

TopChiller having enough confidence that you will find using our water cooled screw chillers will help a lot with production efficiency and cost reduction.

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