AUKS ACWCSC-960A5/MS Technical Manual

Flooded type water cooled screw chiller

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Flooded Type Water Cooled Screw Chiller Technical Manual
Flooded Type Water Cooled Screw Chiller
Technical Manual
Central Air Conditioniner

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Summary of Contents for AUKS ACWCSC-960A5/MS

  • Page 1 Flooded Type Water Cooled Screw Chiller Technical Manual Flooded Type Water Cooled Screw Chiller Technical Manual Central Air Conditioniner...
  • Page 2: Table Of Contents

    Flooded Type Water Cooled Screw Chiller Technical Manual Contents Chapter I Product Selection ........................1 1. General .............................. 1 1.1 Product Overview ......................... 1 1.2 Naming Rule ..........................3 1.3 Function ............................4 2. Unit Performance ..............................5 2.1 Performance Parameter Table ...................... 5 2.2 Performance Parameter Table on Variable Working Condition ...........
  • Page 3 Flooded Type Water Cooled Screw Chiller Technical Manual 4. Failure Detection of Electrical Parts..................... 66 5. Schematic Diagram of System and Electrical Schematic Diagram ............. 67 6. Exploded Chart and Bill of Material ..................... 69...
  • Page 4: Chapter I Product Selection

    Flooded Type Water Cooled Screw Chiller Technical Manual Chapter I Product Selection 1. General 1.1 Product Overview Flooded-type water-cooled screw chiller unit has characteristics such as high efficiency ratio, compact structure, beautiful shape, convenient operation and simple cooling system. The unit can be put into operation immediately after simple installation, water and electricity connection, with improved operating reliability, safety and economical efficiency of system.
  • Page 5 Flooded Type Water Cooled Screw Chiller Technical Manual It uses high-pressure injection oil return technology to ensure reliable oil-return in all working conditions. Accurate matching and higher energy efficiency: Compressor provides stepless energy adjustment, which can accurately match with actual working condition and save more energy;...
  • Page 6: Naming Rule

    Flooded Type Water Cooled Screw Chiller Technical Manual 1.2 Naming Rule Design Revision No.: A, B, C and others follow by analog Code of refrigerant type: code of R22 is omitted; code of R407C is “R”; code of R134a is “R3”; Serial number of energy efficiency: “G”...
  • Page 7: Function

    Flooded Type Water Cooled Screw Chiller Technical Manual 1.3 Function Item Fuction Name Description high pressure shutdown when high pressure exceeds set value protection low pressure protection shutdown when low pressure is lower than set value Compressor overload shutdown when operating current of compressor exceeds max protection operating current superheat protection of...
  • Page 8: Unit Performance

    Flooded Type Water Cooled Screw Chiller Technical Manual 2. Unit Performance 2.1 Performance Parameter Table Note of performance parameters: 1. Nominal cooling capacity of unit is tested under following working conditions: Chilled water Inlet temperature: 12 ℃ Outlet temperature: 7℃ Cooling water Inlet temperature of: 30℃...
  • Page 9 Flooded Type Water Cooled Screw Chiller Technical Manual dimen W (mm) 1150 1150 1150 1200 1200 1200 1300 1350 sion H (mm) 1500 1500 1500 1630 1670 1670 1700 1700 Opera ting dB(A) noise Unit 1700 1830 2000 2450 2550 2850 2900 3050...
  • Page 10 Flooded Type Water Cooled Screw Chiller Technical Manual Unit 3850 4300 4600 5250 6900 7500 8100 9000 weight 2.2.2 Performance Parameter Table of Unit with High Energy Efficiency ACWCS ACWCS ACWCS ACWCS ACWCS ACWCS ACWCS ACWCS Model C-960A5 C-1080A C-1180A C-1380A C-1570A C-1740A...
  • Page 11 Flooded Type Water Cooled Screw Chiller Technical Manual Continued ACWCS ACWCS ACWCS ACWCS ACWCS ACWCS ACWCS ACWCS Model C-2425A C-2730A C-3070A C-3480A C-4200A C-4845A C-5460A C-6140A 5/MSG 5/MSG 5/MSG 5/MDG 5/MDG 5/MDG 5/MDG 5/MDG 1020 1230 1420 1600 1800 Cooling kcal/h×1 capacity 1058...
  • Page 12: Performance Parameter Table On Variable Working Condition

    Cooling Outlet temperature 5~15℃ range of chilled water 2.2.2 Variable Working Condition Table of Unit with Common Energy Efficiency Chart of Variable Working Condition of Chart of Variable Working Condition ACWCSC-960A5/MS of ACWCSC-1080A5/MS LSSLGS280MS变工况图表 LSSLGS315MS变工况图表 20℃ 20℃ Cooling Capacity 25℃...
  • Page 13 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition LSSLGS345MS变工况图表 LSSLGS405MS变工况图表 of ACWCSC-1180A5/MS of ACWCSC-1380A5/MS 20℃ 20℃ 25℃ 25℃ 30℃ 30℃ 35℃ 35℃ ℃ ℃ 35℃ 35℃ 30℃ 30℃ 25℃ 25℃...
  • Page 14 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition LSSLGS550MS变工况图表 LSSLGS620MS变工况图表 of ACWCSC-1880A5/MS of ACWCSC-2120A5/MS 20℃ 20℃ 25℃ 25℃ 30℃ 30℃ 35℃ 35℃ 35℃ 35℃ ℃ ℃ 30℃ 30℃ 25℃ 25℃...
  • Page 15 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition of LSSLGS900MS变工况图表 LSSLGS1020MD变工况图表 of ACWCSC-3070A5/MS ACWCSC-3480A5/MD 1146 1293 20℃ 20℃ 1131 1275 1116 1257 1101 1239 1086 1221 1071 1203 1056 25℃...
  • Page 16 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition LSSLGS1600MD变工况图表 LSSLGS1800MD变工况图表 of ACWCSC-5460A5/MD of ACWCSC-6140A5/MD 2031 2301 20℃ 20℃ 2001 2265 1971 2229 1941 2193 1911 2157 1881 2121 25℃ 1851 25℃...
  • Page 17 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition LSSLGS405MSG变工况图表 LSSLGS345MSG变工况图表 of ACWCSC-1180A5/MSG of ACWCSC-1380A5/MSG 20℃ 20℃ 25℃ 25℃ 30℃ 30℃ 35℃ 35℃ 35℃ 35℃ ℃ ℃ 30℃ 30℃ 25℃ 25℃...
  • Page 18 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition LSSLGS620MSG变工况图表 LSSLGS550MSG变工况图表 of ACWCSC-1880A5/MSG of ACWCSC-2120A5/MSG 20℃ 20℃ 25℃ 25℃ 30℃ 30℃ 35℃ 35℃ 35℃ 35℃ ℃ ℃ 30℃ 30℃ 25℃ 25℃...
  • Page 19 Flooded Type Water Cooled Screw Chiller Technical M anual Chart of Variable Working Condition Chart of Variable Working Condition LSSLGS1020MDG变工况图表 LSSLGS900MSG变工况图表 of ACWCSC-3070A5/MSG ofACWCSC-3480A5/MDG 1311 1152 1296 1138 20℃ 20℃ 1281 1124 1266 1110 1251 1096 1236 1082 1221 1068 1206 1054 25℃...
  • Page 20: Unit Outline Dimension

    ℃ ℃ 30℃ 30℃ 25℃ 25℃ 20℃ 20℃ 冷冻水出水温度(℃) 冷冻水出水温度(℃) Outlet temperature of chilled water (℃) Outlet temperature of chilled water (℃) 3. Outline Dimension of Unit Outline and connection dimension diagram of unit – single compressor (ACWCSC-960A5/MS~ ACWCSC-3070A5/MS )
  • Page 21 Outlet of cooling water ③ ⑧ oil separator inlet of cooling water ④ ⑨ Control cabinet ⑤ Dimension of twin-screw water-cooled chiller unit: Unit: mm Model ACWCSC-960A5/MS(G) 3200 1150 1500 2600 DN100 DN100 ACWCSC-1080A5/MS(G) 3200 1150 1500 2600 DN100...
  • Page 22: Chapter Ii Installation And Commissioning

    Flooded Type Water Cooled Screw Chiller Technical M anual Chapter II Installation and Commissioning 1 Preparation and Tools before Installation 1.1 Preparation before Installation 1.Dedicated machine room should be available for unit. Measures should be taken to exhaust heat generated by unit during operation and ventilation volume should be able to keep maintain room temperature no more than 40 .
  • Page 23: Tools To Be Prepared

    Flooded Type Water Cooled Screw Chiller Technical M anual 5.When installing water pipe, it’s recommended to reserve space between water pipe and connecting pipe to install damping rubber connecting pipe, and to provide suitable construction and adjustment space after unit arrives at site. 6.To ensure normal working of electrical elements, don’t put unit at places with dust, filth and much corrosive fume that must be corrected if any.
  • Page 24 If it’s required to install at high floor, it’s necessary to consider if basic structure of floor has sufficient strength to stand weight of chiller unit during operation. Unit should be installed as follows: Installation Diagram of Unit – Single Compressor (ACWCSC-960A5/MS~ ACWCSC-3070A5/MS ) Installation Diagram of Unit – Twin-Compressor (ACWCSC-3480A5/MD~ ACWCSC-6140A5/MD)
  • Page 25: Connection Of Water Pipeline

    (Add requirements for flange connection) 4.Install flow switch (to be supplied by AUKS, excluding joint) on outlet water pipe of evaporator and condenser. Interlock input contact in flow switch and control cabinet. The installation...
  • Page 26: Pipeline Connection Of Condenser

    Flooded Type Water Cooled Screw Chiller Technical M anual Flow switch must be installed on a section of straight pipeline and there should be at least straight line travel five times of pipe diameter at both sides. (see the diagram below) Water flow swtich Three-way joint or...
  • Page 27: Pipeline Connection Of Evaporator

    Flooded Type Water Cooled Screw Chiller Technical M anual valve. Target-type flow controller Automatic makeup valve Overflow pipe Circulating water pump with Stop valve Stop valve Anti-vibration flexible joint Inlet pipe of cooling water Water filter Blow-down valve Bypass stop valve Flow switch Blow-down valve Outlet pipe of cooling water...
  • Page 28 Flooded Type Water Cooled Screw Chiller Technical M anual system. 3.Discharge valve is installed on cylinder of evaporator. 4.Vertical change should be prevented for water pipe where possible. Manual or automatic discharge valve should be installed between high part of pipeline and expansion water tank. 5.Thermometer and pressure gauge should be installed at straight pipe section of inlet and outlet water pipeline, which shouldn’t be installed at the location near elbow pipe where possible.
  • Page 29: Electrical Wiring

    Flooded Type Water Cooled Screw Chiller Technical M anual 4 Electrical Wiring Electrical wiring must comply with low-voltage distribution device and circuit design specification. Low-voltage circuit breaker for short circuit protection should be installed for power supply circuit. Rated current of circuit breaker should be at least one class higher than max operating current of unit.Setting current of transient overcurrent release shouldn’t be more than 1/1.3 of short circuit current if unit.
  • Page 30: Wiring Requirements

    Flooded Type Water Cooled Screw Chiller Technical M anual 3.Permissible tolerance of source voltage is ±10% and unbalance of phase voltage is less than 2.25%. Max.voltag average voltage × voltage unbalance ratio average voltage 4.2 Wiring Requirements Carrying capacity of supply power cord should be higher than max operating current of unit and takes impact of working environment into account.
  • Page 31: Commissioning Of Unit

    Flooded Type Water Cooled Screw Chiller Technical M anual Sectional area of Earth Line Sectional area of phase wire for device “S”(mm2) Earth line (mm2) S≤16 16<S≤35 35<S≤400 400<S≤800 S>800 5 Commissioning of Unit 5.1 Preparation before Commissioning Step 1: Check wiring of power supply and electrical system Before initial startup, check if distribution capacity complies with power of the unit and if diameter of power cable can stand max working current of main unit.
  • Page 32 Flooded Type Water Cooled Screw Chiller Technical M anual Normal startup sequence of star-delta: switch on power supply; press startup key of unit; three minutes later, main and star A/C contactor attract; after 2-5s, star A/C contactor disconnects; angle A/C contactor attracts; unit begins to start at startup load and load gradually.
  • Page 33: Operation Of Unit

    Flooded Type Water Cooled Screw Chiller Technical M anual such as a way to ensure its sensing probe directly inserts into water pipeline.  Check if flow switch at outlet side of refrigeration and cooing water is correctly installed, and confirm flow switch and control cabinet are correctly wired.
  • Page 34 Flooded Type Water Cooled Screw Chiller Technical M anual Step 3: Firstly start refrigeration water pump, then start cooling water pump, listen if there is abnormal sound from water pump and observe if water pressure is within setting range (pressure difference of inlet and outlet water is no less than 50KPa).
  • Page 35: Chapter Iii Operation And Maintenance

    Flooded Type Water Cooled Screw Chiller Technical M anual Chapter III Operation and Maintenance 1. Operation Instruction 1.1Button Instruction of Wired Controller Button 1. start 1. Stop Function button button Button 1. Switch picture leftwards. After 1. Switch Exit Enter into 1.
  • Page 36: Operation Instruction Of Wired Controller

    Flooded Type Water Cooled Screw Chiller Technical M anual 1.2 Operation Instruction of Wired Controller 1.2.1 Setting of Parameter First enter into picture whose parameters need to be adjusted. Then press . Usually, parameter consists of several digits. It’s allowed to select any parameter to modify.
  • Page 37 1.2.2.1 Description of Main Operating Picture After starting, controller displays welcome picture as follows firstly. Flooded Chiller WELCOME AUKS Central Air Conditioning System VX.XX ProgramVX.XX When welcome picture is displayed, by pressing will enter into picture of main menu respectively.
  • Page 38 Flooded Type Water Cooled Screw Chiller Technical M anual 4.Factory Setting Picture This page can be switched to picture of next level by using third-class password and then operating Unit setting Preferences parameters of unit can be set. Alarm Detail Change is only allowable for professional maintenance personnel! Fig.
  • Page 39 Flooded Type Water Cooled Screw Chiller Technical M anual Date xxxx/xx/xx Time xx:xx:xx 1. Display system time. CHW in XX.X℃ 2. Current page displays real-time outlet water temperature a CTW in XX.X℃ inlet water temperature. Operation Prompt Operation Prompt 3. Prompt real-time information of system operation. Fig.
  • Page 40 Flooded Type Water Cooled Screw Chiller Technical M anual 1# running XXXXXXX Hours Display operating hours and startup times of unit 1. 1# start-up XXXXXXX Times Fig. 6 2# running XXXXXXX Hours Display operating hours and startup times of unit 2. 2# start-up XXXXXXX Times (dual-unit system only)
  • Page 41 Flooded Type Water Cooled Screw Chiller Technical M anual Fig. 4 Alarm Record 2/20 Alarm information The second record out of twenty historical alarm records. DateXXXX/XX/XX TimeXXXX/XX/XX (The same below, omitted) Fig. 5 1.2.2.3 Preferences of Unit When this menu appeatrs, pressing will enter password prompt picture and inputting correct password will enter into the following pictures: 1# Compressor...
  • Page 42 Flooded Type Water Cooled Screw Chiller Technical M anual Exhaust overheat XXX.X ℃ Oil diff fault X.XX Mpa 1. If high/low pressure difference is lower than set value, system will send alarm and shut down. Press diff fault X.XX Mpa 2....
  • Page 43 Flooded Type Water Cooled Screw Chiller Technical M anual 2# exhaust XX.X ℃ 2# suction XX.X ℃ Fig. 8 Unit pressure correction High pressure X.XX MPa Low pressure X.XX MPa 1# oil pressure X.XX MPa Fig. 9 2# oil pressure X.XX MPa Fig.
  • Page 44 Flooded Type Water Cooled Screw Chiller Technical M anual 1. Selection of control mode: when control mode is set as remote control, it’s possible to conduct Control mode Site control /Remote Control ON/OFF operation with external input point; in Status memory Enable/Disable Holding time XXXXX Hours...
  • Page 45: Maintenance

    Flooded Type Water Cooled Screw Chiller Technical M anual Sunday timer Control system can set and change Start XX:XX:XX Stop XX:XX:XX timetable of Sunday and Monday ~ Monday timer Start XX:XX:XX Stop XX:XX:XX Saturday. After the setting is enabled, unit will operate according to this timetable every week.
  • Page 46: Regular Maintenance

    Any shutdown failure should arouse attention and cause should be analyzed. Before notifying AUKS customer service department, analysis based on failure help of this manual may be conducive to the solution of problem.
  • Page 47 No wire brush is allowed to use. Maintenance personnel should detect insulation resistance among motor winding and grounding resistance of winding. 2.2.5 Maintenance Every Three Years Items of the above-mentioned annual maintenance and check. Contact qualified maintenance organization such as AUKS local customer...
  • Page 48 Flooded Type Water Cooled Screw Chiller Technical M anual department to conduct overall check for unit. Especially check vibration status of compressor and ensure parts in compressor are in good conditions; conduct airtight test on unit and check if copper pipe for heat transfer leaks; conduct non-destructive test on main weld seams (longitudinal seam and circumferential seam of evaporator and condenser cylinder) of pressure vessels when necessary to ensure operation safety;...
  • Page 49: Chapter Iv After-Sales Service

    Flooded Type Water Cooled Screw Chiller Technical M anual Chapter IV After-sales Service 1. Main Parts of Unit 1.1 Main Pats of Cooling System Name of Outline drawing and internal structural Description Parts drawing Compressor is used to compress low-temperature low-pressure refrigerant evaporated...
  • Page 50 Flooded Type Water Cooled Screw Chiller Technical M anual Evaporator is used to evaporate low pressure Shell and liquid refrigerant from tube throttling parts after the evaporator refrigerant exchanges heat with refrigeration water in evaporator. Orifice plate is used to Orifice generate pressure...
  • Page 51 Flooded Type Water Cooled Screw Chiller Technical M anual Dry filter cartridge is used to filter and dry refrigerant Dry filter by installing filter element cartridge usually on liquid pipe and filter element removed. Stop valve is used to cut off or dredge refrigerant, which is only applicable to Stop valve...
  • Page 52: Main Parts Of Electrical System

    Flooded Type Water Cooled Screw Chiller Technical M anual 1.2 Main Parts of Electrical System Name Outline drawing and internal structural Description drawing parts Controller is used to control movement of relay through program, switch on and off each part of Contr unit according to external oller...
  • Page 53: Function And Control Of Unit

    Flooded Type Water Cooled Screw Chiller Technical M anual It is a kind of electrical element used detect temperature and pressure, whose physical Senso characteristics vary with change (e.g. resistance of NTC varies with change of temperature) of temperature and pressure. 2.
  • Page 54: Loading/Unloading Process Control Of Unit

    Flooded Type Water Cooled Screw Chiller Technical M anual 2.2 Loading/Unloading Process Control of Unit Emergency Unloading Area Stability Area Stability Area loading Area Speedup Loading Shutdown Area Area When shutdown time of compressor exceeds set time of 300S and return temperature of cold water exceeds set value plus 1℃, compressor starts.
  • Page 55 Flooded Type Water Cooled Screw Chiller Technical M anual Abnormal tie delay of water flow reaches 5S; ③ Conditions for exiting flow protection of refrigeration water pump: Manually reset and set flow feedback of refrigeration water pump. Flow Protection of Cooling Water Pump Prerequisites for flow protection of cooling water pump: After cooling water pump operates for 30S in case of set operation or power-on initial startup;...
  • Page 56 Flooded Type Water Cooled Screw Chiller Technical M anual ① After compressor operates for 10min; Inlet and outlet water temperature difference of condenser is no more than 2℃ and ② abnormal time delay reaches 1min. Conditions for exiting temperature difference protection under too large water flow: Manually reset and lock (password is controlled by maintenance personnel) it after three times of accumulated protection within 48 hours.
  • Page 57 Flooded Type Water Cooled Screw Chiller Technical M anual Press “unloading & shutdown” flow to enter into standby state after entering into ultralow outlet water temperature protection. Conditions for exiting ultralow outlet water temperature protection: Water return temperature is no less than [set water return temperature of refrigeration water] plus 2; manually reset.
  • Page 58: Failure Analysis And Solution

    Flooded Type Water Cooled Screw Chiller Technical M anual Manually reset and lock (password is controlled by maintenance personnel) it for three times; oil pressure difference switch is under ON state. High/Low Pressure Difference Protection (high pressure – low pressure) Prerequisites for high/low pressure difference protection: ①...
  • Page 59 Flooded Type Water Cooled Screw Chiller Technical M anual High Pressure Protection →...
  • Page 60 Flooded Type Water Cooled Screw Chiller Technical M anual Low Pressure Protection →...
  • Page 61 Flooded Type Water Cooled Screw Chiller Technical M anual Discharge Temperature Protection...
  • Page 62 Flooded Type Water Cooled Screw Chiller Technical M anual Failure of Temperature Sensor...
  • Page 63 Flooded Type Water Cooled Screw Chiller Technical M anual Overload Protection of Compressor...
  • Page 64 Flooded Type Water Cooled Screw Chiller Technical M anual Protection of Water Flow Switch...
  • Page 65 Flooded Type Water Cooled Screw Chiller Technical M anual Protection of High/Low Pressure Difference...
  • Page 66: Analysis And Solution Of Failure Without Failure Code

    Flooded Type Water Cooled Screw Chiller Technical M anual 3.2 Analysis and Solution of Failure without Failure Code No Display on Controller Namely that controller doesn’t display anything.
  • Page 67 Flooded Type Water Cooled Screw Chiller Technical M anual Water Temperature can’t reach Set Point Water temperature can’t reach set point despite of longtime startup.
  • Page 68 Flooded Type Water Cooled Screw Chiller Technical M anual No Startup of Compressor After Starting Compressor doesn’t start after pressing start key and normal time delay.
  • Page 69 Flooded Type Water Cooled Screw Chiller Technical M anual 4. Failure Detection of Electrical Parts Name of Detection Methods Parts 1. After detecting with OHM range of multimeter, there is correct resistance value (three-phase resistance value of compressor should be Compressor approximately the same) among windings.
  • Page 70 Flooded Type Water Cooled Screw Chiller Technical Manual 5. Schematic Diagram of System and Electrical Schematic Diagram Schematic Diagram of Screw Unit System with Flooded-type Independent System:...
  • Page 71 Flooded Type Water Cooled Screw Chiller Technical Manual Schematic Diagram of Flooded-type Double-head Screw Unit System: Cooling cycle: compressor sucks low-temperature low-pressure refrigerant from evaporator into compressor and discharges them into oil/gas separator after compressing them into high-temperature high-pressure gas; in oil separator, oil carried by high-pressure gas is filtered, remained in oil separator and then it returns to compressor through oil return pipeline;...
  • Page 72 Flooded Type Water Cooled Screw Chiller Technical M anual 6. Exploded Chart and Bill of Material Exploded Chart of Screw Unit with Flooded-type Independent System: Material code Part Name-Chinese Part Name-English Quantity Remark Compressor 压缩机 Capillary pipe 毛细管 Injection pump of oil 回油引射泵...
  • Page 73 Flooded Type Water Cooled Screw Chiller Technical M anual Material code Part Name-Chinese Part Name-English Quantity Remark Shell and tube condenser 壳管式冷凝器 Shell and tube 壳管式蒸发器 evaporator Body of electronic 电子膨胀阀阀体 expansion valve Coil of electronic 电子膨胀阀线圈 expansion valves Injection pump of oil 回油引射泵...
  • Page 74 •Consultation Service – AUKS headquarters and all distribution centers have established service hotline to accept consultation from users. • Training and Technical Support –users are welcomed to contact AUKS for any problem related to technology of A/C system. AUKS will provide training and technical support on operation and management of A/C system for users free of charge.
  • Page 75 Flooded Type Water Cooled Screw Chiller Technical M anual _______________________________________________________________________ ADD: NO. 1166 North MingGuang Road (AUKS Technology park), JiangShan Town, Zhejiang, P.R.China TEL:86-574-88220539 FAX:86-574-88220597 CODE:315191 URL:http://www.cnAUKS.com VERSION: Flooded Type Water Cooled Screw Chiller-2010-01...

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