TICA TCAV-BHE Installation & Operation Manual
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TICA TCAV-BHE Installation & Operation Manual

Modular air-cooled chiller (heat pump)
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NSTALLATION &
OPERATION MANUAL
MODULAR AIR-COOLED
CHILLER (HEAT PUMP)
TCAV-BHE
MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP)
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Summary of Contents for TICA TCAV-BHE

  • Page 1 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) NSTALLATION & OPERATION MANUAL MODULAR AIR-COOLED CHILLER (HEAT PUMP) TCAV-BHE Contents...

  • Page 2: Table Of Contents

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) I. Overview ........................3 II. Safety Precautions ...................... 5 III. Unit Description ......................7 1. Scope of Application, Purposes and Characteristics ..........7 2. Standard Compliance ....................9 IV. Specifications ......................10 1. Nomenclature ......................10 2.

  • Page 3: Overview

    Only the professional appointed by TICA can undertake the installation work of the air conditioning unit. The vendor shall not bear any responsibility if any unqualified operator installs or maintains the unit or the unit is not installed or operated according to requirements of this manual.
  • Page 4 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Danger Prior to installation or maintenance, lock the unit power supply and disconnecting switch in the power-off state, avoiding personal casualties caused by electric shock or contact with a moving part. All the installation procedures of the air conditioning unit must comply with the national, provincial, and local regulations.

  • Page 5: Safety Precautions

    Be sure to make a foundation platform before installing the unit to ensure stable operation of the unit.  Use only the accessories specified by TICA and ask the manufacturer or authorized distributor to provide installation and technical services. ...
  • Page 6 The circulating water pump of the water system must be interlocked with the main control board of the unit. Otherwise, commissioning and acceptance cannot be performed. TICA will not bear any responsibilities for the incurred damage of the water-side heat exchanger and other accidents.

  • Page 7: Unit Description

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) III. Unit Description 1. Scope of Application, Purposes and Characteristics The modular Inverter air-cooled chiller (heat pump) uses the innovative inverter technology and modular design. The entire unit is composed of one or more modules, each of which consists of one or two independent cooling systems.
  • Page 8 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Intelligent defrosting The unit automatically determines the optimal defrosting time based on the ambient temperature and actual operation parameters, to prevent frost residue or frequent defrosting. In addition, intelligent defrosting can prevent air conditioning effect from being affected by large water supply temperature fluctuation during unit defrosting.

  • Page 9: Standard Compliance

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) 2. Standard Compliance This unit complies with the national product standard. GB/T 18430.1 Water Chilling (Heat Pump) Packages Using the Vapor Compression Cycle — Part 1: Water Chilling (Heat Pump) Packages for Industrial & Commercial and Similar Application GB/T 18430.2 Water Chilling (Heat Pump) Packages Using the Vapor Compression Cycle —...

  • Page 10: Specifications

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) IV. Specifications 1. Nomenclature T CAV B HE Feature: cooling-only type-C; heat pump type-H; cooling and heating in all operating conditions all the year round-HA strong-heat high-efficiency-HE Design SN: A, B, C... Model: 035, 065, 130 Name code: modular Inverter air-cooled chiller (heat pump) 2.
  • Page 11 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) connection connection connection connection type Operating – Automatic operation controlled by microcomputers mode – Type Scroll type DC inverter EVI Compressor – Type DC low-noise axial flow fan Air flow 13000 26000 47000 – Refrigerant Type R410A...

  • Page 12: Structure Diagrams

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) 3. Structure Diagrams TCAV035BHE Water outlet DN40 external thread Electrical control cabinet Water inlet DN40 external thread Incoming signal cable Incoming power cable 1170 4- 13(Hole for installation) TCVA065BHE Electrical control cabinet Water outlet Water inlet DN65 flange DN65 flange...

  • Page 13: Unit Installation

    If a unit is damaged, record it in the delivery note and notify the carrier and local TICA sales office of the damage in written form within three days. Check whether the power supply for the unit is consistent with the information specified in the nameplates of the unit compressor, fan motor, and 4-way valve, and other components, and check whether information on the unit nameplates is correct.

  • Page 14: Installation Diagrams

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Caution Acid, alkali, salt spray and other corrosive gases will damage the unit casing, pipeline or electrical components. The unit installation position must be far away from the site with corrosive gases. 2. Installation Diagrams (1) Installation Foundation Diagrams The unit can be directly placed on a base with drains reserved around.
  • Page 15 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) TCAV065/130BHE Installation Foundation Diagrams stand column Concrete of C20 or higher grade Drain Rubber pad I-steal 20a （L+m）*a-m I、I-steel foundation diagram Concrete of C20 or Rubber pad higher grade Concrete of C20 or ≥300 higher grade Drain...
  • Page 16 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (2) Installation Space Diagrams Installation Space Diagrams for Modular Combinations: Installation Spacing Model ≥ 500 TCAV035BHE ≥ 500 TCAV065BHE ≥ 500 TCAV130BHE 1150 Air outlet ≥500 ≥500 Air inlet Air inlet ≥ ≥ ≥...
  • Page 17 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) ≥ ≥ ≥ TCAV035BHE Installation Space Diagrams ≥1800 ≥1800 ≥500 ≥3000 Inlet/outlet pipe ≥500 ≥500 Unit height Inlet/outlet pipe Top view Front view TCAV065/130BHE Installation Space Diagrams Notes: The installation space of the unit must meet relevant dimension requirements for the ease of overhaul and maintenance.
  • Page 18 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) regions, the installation height of the unit needs to be increased according to the snow amount or the condensate freezing thickness. Snow Cover Installation Diagram Snow cover Monsoon Snow cover 1.5m 1.5m Installation diagram of accumulated snow-proof regions or cold regions which are prone to freeze: ≤100 Steel beam...
  • Page 19 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Caution Anti-freezing and ice-melting engineering installation for heating unit used in North: A: For the unit to be used for northern heating, foundation must be prepared and cannot be made into a platform. The bottom channel steel of the unit must be supported at a height at least 1 m.

  • Page 20: Unit Installation

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) 3. Unit Installation Caution After a unit is delivered from the factory to the installation site, keep the proper package before hoisting. Pay attention to the following points during hoisting: A: Handle the unit with care and keep the unit upright. B: Prevent sliding caused by collision with other objects.
  • Page 21 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Strong sling Support (strong without Protection pad deformation) (firm without deformation) Steel pipe for lifting TCAV035BHE Lifting Diagram...

  • Page 22: Installation Of The Water System

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Support Protection pad (strong without (firm without deformation) deformation) Strong steel rope TCAV065/130BHE Lifting Diagram 4. Installation of the Water System Refer to the following specifications for the diameters of the main water inlet and outlet pipes of the unit: Cooling capacity 20 - 40 50 - 60...
  • Page 23 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (1) Unit Pipe Schematic Diagram Components of the water system Replenish Flexible water Gate Globe 3-way Water pump Y type filter Full connector Expansion valve valve solenoid valve water tank Drain Pressure Thermometer Check Solenoid valve Float valve Automatic...
  • Page 24 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (2) Precautions for Construction of the Water System Complete piping for the water system as per the method described in this manual, and correctly carry out the construction according to the water heating pipe construction standard.
  • Page 25 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Water supply valves and check valves must be installed indoor, lest water supply pipes and valves will crack due to water freezing in winter. The indoor unit and pipeline system should be designed and installed by professionals based on the actual pipeline direction of buildings in accordance with relevant technical specifications.
  • Page 26 For the water treatment, see the Code for Design of Industrial Recirculating Cooling Water Treatment or other relevant standards. TICA will not bear any liabilities for the unit damage caused by water quality problems or improper processing of water quality.
  • Page 27 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (4) Pressure Testing and Flushing The strength test pressure of the whole metal pipe network water system should be 1.5 times the design work pressure, but should not be smaller than 0.6 MPa. After the pressure is maintained for 10 minutes, the pressure drop is not greater than 0.02 MPa and no leakage, deformation, and other abnormal phenomenon occur.
  • Page 28 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) In order to meet the water volume requirements above, one energy storage tank needs to be added for general sites, and baffle plates need to be installed in the water tank, to prevent short water flow. The figure below shows the general installation of baffle plates. Recommended Poor Poor...
  • Page 29 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) The figure below shows the installation method of the water flow switch and flow direction plates. Bolt 3-way Flow guiding rod Horizontal Gasket pipeline Flow direction A≥5D A≥5D The value of A must be counted from 1"...
  • Page 30 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) The dotted-line frame indicates customer selected functions. See the following table for the BOM details of a unit. Name Remarks Size Chloroprene DN65 δ ≥ Flange rubber TCAV065/130 gasket 5 mm GB/T 14647 GB/T Bolt M16*70 5781...
  • Page 31 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) areas, resulting in poor air discharge and affecting circulating operation of the water system. d. Maintain the slope of 0.5% to 1% in the arrangement of condensate drain pipes. Do not elevate the condensate drain pipes regardless of the hoisting elevation of air-side devices and whether pipelines are wound around the beam.
  • Page 32 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Water flow and resistance loss per unit length Pipe diameter 0.12 - 0.22 - 0.46 - 0.7 - 1.4 - Flow L/s 2.2 - 6 4 - 11 8 - 22 15 - 18 0.14 0.32 0.60...

  • Page 33: Electrical Installation

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) C. Check valve: A check valve is used to prevent water backflow from damaging water pumps. The valve caliber is the same as the diameter of the inlet and outlet of water pumps. D. Bypass valve for air-side devices: A bypass valve for air-side devices is used to interlock with indoor FCU 2-way valves.
  • Page 34 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Minimum Maximum Circuit cross-sectional area Communication operating breaker Copper bar size of power wire (mm connecting wire Model current capacity (A x B) (RVVP) Phase Neutral line line TCAV035 30.5 cross-sectional The standard TCAV065 wire for area of the copper connecting the...
  • Page 35 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Notes: The standard unit power is 380 V 3N~ 50 Hz. Q0 and Q1/Q2/Q3 are air switches and type D air switches are recommended. Q0 and (Q1/Q2/Q3) must be selected together. Consider water pumps and other loads during installation, and select air switches, power wires, and copper bars based on actual situation.
  • Page 36 The selected phase sequence protector must be able to reset automatically. Recommended model: DPB52CM44; brand: CARLO GAVAZZI (which can be procured from TICA) For a set of parallel master/slave units, it is sufficient to add a phase sequence protector. The phase sequence protector is installed in the distribution cabinet of the main power input.
  • Page 37 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (5) Unit Interconnection Schematic Diagram Caution The following circuit diagrams are applicable to standard units. The circuit diagram in the manual may differ from the actual circuit diagram pasted to the unit due to product innovation and improvement. The circuit diagram pasted to the unit shall prevail.
  • Page 38 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) TCAV035BHE X30A X31A X32A X34A X33A X35A X38A X39A X36A X37A 38 0 V 3 N ～ 5 0H z...
  • Page 39 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) TCAV065BHE...
  • Page 40 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) TCAV130BHE...

  • Page 41: Unit Commissioning And Operation Description

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) VI. Unit Commissioning and Operation Description Caution Be sure to check the entire air conditioning unit system before powering on for trial operation. Pay attention to the following aspects: 1. Checking the air-side devices of the air conditioner ...
  • Page 42 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP)  Check whether all the power supply lines and control lines are connected in place, whether the wires are connected correctly in accordance with the wiring diagram, whether the grounding is reliable, and whether all the wiring terminals are fastened. ...
  • Page 43 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Clean the water filter after trial operation, and fasten all the electrical wiring terminals again. Then, the unit can be put into normal use. Do not frequently start or stop the unit to prolong the service life of the unit. When the unit is faulty, find out the cause of the fault as per the fault causes displayed on the controller, and rectify the fault.

  • Page 44: Operation Description Of The Unit Controller

    ● Only accessories provided or specified by TICA can be used. Using any unauthorized accessories may result in a failure of the controller or an electric shock. ●...

  • Page 45: Application Scope

    Universal products are delivered if no requirement is specified. 2. Application Scope Air-cooled chiller (heat pump) series are modular combined air-conditioning products of TICA. Their control system consists of the chiller control chip (input/output), sub-board control chip, and centralized operation control panel.

  • Page 46: Unit Operation Description

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (5)Password protection permissions are used for parameter setting. All parameters that need to be set have appropriate default values, which are used at the first startup or when default values need to be restored. 4.
  • Page 47 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Main interface Jan. 1, 2019, 12:00:00 The display screen displays current time information in the first Unit status: Cooling line, the current water inlet and outlet temperatures and set Air conditioner water outlet: values of the unit in the second and third lines respectively, and 30.5°...
  • Page 48 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) 1) Temperature sensor values, including ambient temperature, discharge temperature, suction temperature, coil temperature and water inlet/outlet temperature Unit Port Status 2) Pressure sensor value 3) Operating current of unit 4) EXV steps 1) Operating mode settings, including mode, temperature and humidity 2) Configuration parameter settings, including centralized control Modify User...
  • Page 49 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Interface Function Description Page Note 1. Homepage is the initial page after the touch screen is powered on and reset. 2. Water temperature set values and actual values are displayed. Homepage 3. Temperatures can be set. 4.
  • Page 50 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) (3) Description of the DIP Switch on the Main Board a. Functions of the S1 DIP Switches DIP Switches of TCAV035BHE Functions: Master unit: quantity of slave units; slave unit: address of slave unit S1-1: ON –...
  • Page 51 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) The addresses of slave units are 1-15. b. Functions of the S2 DIP Switches S2 (Functional DIP Switch) S2-1 S2-2 S2-3 S2-4 S2-5 S2-6 S2-7 S2-8 Cooling Remote OFF OFF OFF V series OFF OFF Shared air R410A only...
  • Page 52 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) DIP Switches of TCAV130BHE Functions: Functions of the S1 DIP Switches S1-1 S1-2 S1-3 S1-4 Configuration 1: Master common type Slave unit S1(5678) (Master unit: number of slave units; slave unit: address of slave unit ) S1-5 S1-6 S1-7...
  • Page 53 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) in parallel connection Single compressor TCAV130 (4) Unit Configuration Model Refrigerant Expansion Valve Type Air System Water System TCAV035BHE R410A Independent air Shared water TCAV065BHE R410A Shared air Shared water TCAV130BHE R410A Shared air Shared water (5) Failure Code List Failure Code List...
  • Page 54 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Failure 68 Fan 2 drive communication fault Failure 76 1# compressor zero speed protection Failure 69 Vapor injection 1# temperature fault Failure 77 1# compressor phase loss Failure 70 Vapor injection 1# saturation temperature fault Failure 78 1# compressor overcurrent Failure 71...

  • Page 55: Unit Maintenance

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) VIII. Unit Maintenance TICA air-cooled chillers (heat pumps) are highly automated devices. Therefore, check the operation status periodically. Long-term and effective maintenance can greatly enhance the operation reliability of the unit and prolong the unit's service life.
  • Page 56 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) pipeline against damage caused by freezing of water in the pipeline of the air conditioning water system. (9) If the ambient temperature is higher than 5° C, especially in summer, do not drain water to prevent air flowing into the pipeline and causing internal rust and corrosion and ensure normal water pressure of the system.

  • Page 57: Common Fault Analysis Of The Unit And Handling Methods

    The unit may get faulty to different degrees during use. The table below provides some common faults and their handling methods. If the unit gets faulty, the user needs to contact an authorized distributor or branch company of TICA and cannot try to repair it independently. Symptom...
  • Page 58 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Symptom Possible Cause Solution ☆ Check whether the water pump ☆ The chilled water flow is too small The intake duct motor matches the unit ☆ The water line is blocked or air is of compressor is ☆...
  • Page 59 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Caution The following circumstances are normal phenomena: When the temperature reaches the set value during unit operation, the unit stops running automatically. After the temperature rises, the unit re-starts automatically according to the preset operating mode. When the outdoor temperature is low and the humidity is relatively large, the outdoor heat exchanger may frost during operation of the unit.

  • Page 60: After-Sales Service

    Caution Improper maintenance or repair may cause water leakage, electric shocks or fire. If the unit must be moved or reinstalled, ask authorized dealers or TICA service personnel for help.  Warranty Warranty details are subject to the order contract.

  • Page 61: Other Information

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) XI. Other Information A separate "control accessory box" contains a remote controller, a remote controller communication cable, temperature sensor blind pipe, main water temperature sensor, and other components. Trial operation can be carried out only after correct installation on site. 1.
  • Page 62 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) M4×25 screws 5. Install the wired controller body back to the backplane (in the opposite direction of removing). Note: User needs to purchase a 86mm×86mm exposed junction box for installation. Installation of 7" touch screen: When the remote controller is installed inside the control cabinet in the equipment room, install the remote controller as follows: Step 1:...

  • Page 63: Auxiliary Electric Heater

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) 2. Auxiliary Electric Heater (1) Characteristics The operation of the auxiliary heater is controlled intelligently. When the ambient temperature is low, the microcomputer automatically starts the auxiliary heating program to compensate for the heating lack caused by heat attenuation due to low ambient temperature.
  • Page 64 (for details, see the wiring diagram of the unit). Note: TICA does not provide auxiliary electric heaters for standard units. Please specify the auxiliary electric heater in the order if required. The startup electric control cabinets for auxiliary electric heaters need to be provided by customers.

  • Page 65: Interlock Controller

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Caution Open water valves of the unit during commissioning. Open the circulating water pump to discharge air out of the system. Then, electrify the unit for commissioning so as not to burn electric components. If the electric heater is not used, drain water out of the electric heater cartridge to prevent cartridge freezing or rust.

  • Page 66: Installation Description Of The Main Water Outlet Temperature Sensing Probe

    MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP) Caution Interlock controllers are not equipped for standard models at delivery. The wired control switch is short-connected to the common line. If an interlock controller needs to be connected, remove the short connection wire and connect wires as per the circuit diagram above.

  • Page 67: Description Of The Connection Between The Temperature Sensing Probe/Water Pump And The Chiller

    The service life is specified by TICA. The environmental protection service life is not equivalent to the service life of safe use.
  • Page 68 MODULAR INVERTER AIR-COOLED CHILLER (HEAT PUMP)  Names and content of hazardous substances in products Hazardous substance Hexavalent Polybrominated Polybrominated Part name Plumbum Mercury Cadmium chromium Biphenyls Diphenyl (Pb) (Hg) (Cd) (Cr(VI)) (PBB) Ethers (PBDE) Compressor and ○ ○ ○ ○...
  • Page 69 The actual configuration of sold products should prevail. Warning The copyright of this manual belongs to Nanjing TICA Climate Solutions. Anyone without consent or authorization shall not copy, reproduce or extract this manual without permission. TICA reserves the right to sue.
  • Page 70 +7 915 650 85 85, +7 969 190 85 85 E-mail: info@tica.pro www.tica.pro Note: Due to constant improvement and innovation of TICA's products, the product models, specifications and parameters contained in this document are subject to change without prior notice.

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