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TICA PRO TWSF-FC Series User Manual

Flooded water-cooled screw chiller
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FLOODED WATER-COOLED
SCREW CHILLER (User Manual)
TWSF-FC Series

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Summary of Contents for TICA PRO TWSF-FC Series

  • Page 1 FLOODED WATER-COOLED SCREW CHILLER (User Manual) TWSF-FC Series...

  • Page 2: Table Of Contents

    Contents Safety Precautions..................1 Cooling System and Its Installation and Maintenance ......3 1.1 Overview ..................3 1.2 Nomenclature ................... 3 1.3 Unit Lifting Diagram and Maintenance Space ........3 1.4 Installation of the Unit ............... 5 1.5 Installation of Differential Pressure Switch ........11 1.6 Selection of Water System Components ........

  • Page 3: Safety Precautions

     Be sure to make a base before installing the unit to ensure stable operation of the unit.  Use the accessories specified by TICA and ask specialized institutions such as the manufacturer or authorized distributor to provide installation and technical services.
  • Page 4  Do not use water to flush the unit directly; otherwise electric shock or other accidents are easily caused.  Be sure that the quality of water entering into the heat exchanger has met the requirements.  Do not turn on/off the unit frequently; otherwise the unit may be damaged due to frequent startup.

  • Page 5: Cooling System And Its Installation And Maintenance

    Over 40 product models have been widely applied to various situations for comfortableness and arts and crafts. All of TICA units have applied eco-friendly refrigerants, such as R22 and R134a. The user-friendly display screen of the unit meets the environmental requirements in different countries and regions.
  • Page 6 1. This diagram is for illustration only. For specific dimensions, refer to the corresponding manual. 2. The units' dimensions may vary. This lifting method is applicable to all TICA flooded screw chillers (heat pumps). Figure 1 Single-compressor unit lifting diagram...

  • Page 7: Installation Of The Unit

    Before installation, check whether the local voltage and frequency of power supply are suitable for the unit; TICA shall not be liable for any damage caused after the unit is accepted. Page 5...
  • Page 8 When lifting, it has to tighten the lifting hole on the unit by sufficient Unit lifting load-bearing ropes or chains, and must follow the instructions listed on unit lifting diagram, so as to protect the control cabinet and other parts of the unit from damages. Also, please use spreader bar when lifting.
  • Page 9 Sulfate ion SO mg(SO < 200 Acid consumption mg(CaCO < 100 (pH=4.8) Full hardness mg(CaCO < 200 Iron Fe mg(Fe)/L < 1.0 Sulfion S mg(S Reference Detected Items Ammonium ion NH mg(NH < 1.0 Silica SiO mg(SiO < 50 Note: O indicates the relevant factors of corrosion or scaling tendency. If the water quality cannot meet the requirements in the above table, refer to GB50050-2007 Code for Design of Industrial Recirculating Cooling Water Treatment for treatment, or consult the local water treatment company for treatment according to the above water...
  • Page 10 Caution TICA shall not be responsible for any damage to the unit caused by the use of untreated or improperly treated water, seawater or saline water. Check valve must be installed at the water inlet and outlet for the Pipe installation convenience of regular maintenance of water system.
  • Page 11 pump inlet to prevent impurities from entering into the pump and heat exchanger; pipeline seal pre-inspection should be carried out before pipes heat preservation and before water entering the unit; vibration damping devices should be installed on the pipes that connect to the unit;...
  • Page 12 through direct sensing of cooling-side pressure as required. For example, the free-standing condensate pressure control valve added as shown in Figure 4, or the three-way bypass valve can be used to control the chilled water flow, so as to maintain a lowest possible and constant outlet pressure.

  • Page 13: Installation Of Differential Pressure Switch

    9. Pipes and connectors should be supported independently so as not to exert pressure on the unit. It is suggested to install elastic connectors to reduce shocks to the pipelines. 10. Foreign matters in the water system would result in the fouling of the heat exchanger. Therefore, the filter of at least 60-mesh should be installed in front of the pump.
  • Page 14 to Figure 5 If the chiller is installed outdoors, the differential pressure switch should be installed slightly above the water inlet of the heat exchanger for the heat exchanger (cooling-only unit), so that the water on the differential pressure switch side can be drained. Never try to open the copper shell of the differential pressure switch! 2 Nut Differential pressure flow switch...
  • Page 15 and screw the other end of the tube into the pressure measurement opening of the water outlet pipe in the same way; in order to keep pipelines look pleasant, the tube should be fixed as necessary to prevent it from being damaged. 5.

  • Page 16: Selection Of Water System Components

    no shut-off devices such as a valve between the pressure measurement opening of the differential pressure switch and the water inlet and outlet of the heat exchanger. Selection of Water System Components 1. Check valve: selected based on the pipe diameter; usually the selected valve diameter should be consistent with the unit connecting pipe.

  • Page 17: Unit Startup And Operation

    The volume V (m ) of storage tank is (Q/27.9n) - VS Q - Cooling capacity (kW) n - Number of compressors VS - water capacity (m ) in the internal pipeline and heat exchanger of the chilled system Caution Pipeline test pressure should be greater than 1.25 times the working pressure, but it should be not less than 0.6 Mpa.
  • Page 18 the water capacity is correct, ensure that the connection of temperature sensor is correct. Disconnect the main isolator switch, check all the starting circuit and Electric circuit control circuit of the control cabinet, and confirm that all switches are disconnected. Check the power supply of the unit of which the voltage fluctuation range should not exceed ±...
  • Page 19 Frequency Item Check Method Control Standard (R134a) Check high pressure 1. Exhaust pressure display value (air 0.6~1.2 MPa discharge) Check high pressure 2. Suction pressure 0.1~0.3 MPa display value (air suction) 3. Air discharge Check air discharge 12~20° C superheat degree overheated display value Voltage should not exceed 4.
  • Page 20 2. Adjustment to expansion valve is incorrect 3. Chilled water flow is insufficient 4. Evaporator scaling Phase inverter protector Power wiring is wrong Overcurrent relay (compressor motor) Same with high pressure protection The pressure of working medium system is Safety valve exceeded Unit recommended operating range: Schematic diagram of...

  • Page 21: System Maintenance

    If the unit stops due to failures, the operator should promptly deal with them. For failures that cannot be resolved, please immediately contact TICA service personnel, and do not force a continuous boot in case of failures, or it may damage the unit.
  • Page 22 refrigerant capacity to ensure that the superheat degree of R22 unit air charge is between 18° C to 28° C under the rated working condition, and the R134a unit is between 12° C and 20° C. 1.8.4 Water system In some areas, due to hard water will make the condenser scaling, result in condensate pressure too high or the heat transfer effect of the evaporator poor, and lead to shutdown due to failures or the unit operates uneconomically, water quality inspection has to be carried out before the air conditioner goes into the vessel.
  • Page 23 6. After cleaning, reinstall the water system. 1.8.4.2 Cleaning of condenser and flow unit Check and clean the condensation tube after the first quarter of unit operation. The water loop system of the condenser is usually an open system (open to the air at the cooling tower) so that the condensation tubes are more susceptible to scaling.
  • Page 24 1.8.5 Recommended maintenance cycle for unit First Later Maintenance Maintenance Type Maintenance Content (3,000 (5,000 hours/two hours/two years) years) Check whether the phase sequence protector of chiller ★ ★ is normal, or any shortage of phases or not Check whether the touch panel displays and operates ★...

  • Page 25: Common Troubleshooting

    The operation current of the overload protection relay. Operate the compressor overloaded compressor is too high with the checking current. Do not exceed 1.25 RL. Please contact TICA services. a) Motor coil failure a) Check the insulation resistance 5. High oil temperature 6.
  • Page 26 c) Check the evaporating temperature of the evaporator at full load or near full load. If the c) Severe scaling on the water temperature difference of evaporating temperature side of the evaporator and outlet water temperature is greater than 3° C, it may be caused by scaling.

  • Page 27: Electromechanical Installation And Control System Maintenance

    2 Electromechanical Installation and Control System Maintenance Control System Features and characteristics of controller The advanced single-chip microcomputer implements automatic monitoring for the unit's entire operating process, such as on/off, operating status monitoring, and failure monitoring and processing. When the controller is faulty, an alarm will be sent and the unit will automatically stop for not being damaged.

  • Page 28: Electrical Control And Operation Instructions

    core component of the control device. Except for the logic control function, it also supports computing, data transmission and processing. In this control device, the entire control program of the unit is running in the single-chip microcomputer. It constantly processes the collected data such as temperature, pressure, current, and voltage and outputs commands, implementing such operations as alarming, power-off, power-on, and stop.
  • Page 29 Initial Interface This manual takes the single compressor as an example to explain the operation methods on the human-machine interface of TWSF series of flooded water screw chillers. The interfaces and operation methods of a dual-compressor and tri-compressor are basically the same with that of a single compressor.
  • Page 30 This interface displays the main option menu of the user interface. You can choose from the following options: Basic Operation: mainly used by the operator to switch on and off the unit, set basic parameters, and query basic data. Running Parameter: used by the operation engineer. The password for advanced operations is required.
  • Page 31 Compressor Interface In the control bar at the upper right of the unit, there are several buttons to control the power-on/off of the unit, as below: ON: After sliding the ON button, a window as below pops up, which requires power-on confirmation (press the ON button after 3 seconds) to prevent misoperation by users.
  • Page 32 The evaporator interface displays the water inlet/outlet temperature, water temperature change rate, and water flow status of the evaporator. Condenser Interface The condenser interface displays the water inlet/outlet temperature and water flow status of the condenser. Expansion Valve Interface Page 30...
  • Page 33 The expansion valve interface displays the opening of the electronic expansion valve, as well as the liquid level and discharge superheat parameters of the condenser. It is a parameter setting interface provided for the operator to set the control temperature of the unit operation.
  • Page 34 when the water temperature is lower than the set temperature, the unit will unload. The allowable water temperature setting range for outlet water is 4~20° C, and the factory default setting is 7° C; the allowable water temperature setting range for return water is 9~25°...
  • Page 35 This interface displays the timed power-on/off function available to the unit. Four groups of timed power-on/off can be set. In this interface, you can enable or disable the automatic efficiency gain function. If the automatic efficiency gain function is enabled, the set value of the unit's outlet water temperature can be adjusted automatically as the ambient temperature changes.
  • Page 36 temperature set value and its adjustment range as the ambient temperature changes. At the bottom of the interface, you can see the current ambient temperature and the actual water temperature set value. For example, for perennial cooling unit, click the three-way valve control button to enter the three-way valve setting interface: Compressor on/off control: After the unit receives the command to start up, if the chilled outlet water temperature...

  • Page 37: Wire Specifications

    Notes:  The preceding specifications are recommended configurations for standard units. For non-standard units, contact TICA.  The recommended specification of the power wire is the copper core cable used by the 70° C multi-core PVC insulated cable passing through sleeves and laid through the insulating wall at the ambient temperature of 30°...

  • Page 38: Electric Installation And Maintenance

    the layout conditions by referring to the conducting wire specifications provided by the wire manufacturer.  The selection of power wires is closely related to the local climate, soil characteristics, cable length, and layout mode. Such unit engineering projects are often designed by design institutes according to the maximum operating current or maximum input power of the unit, and the selection of power wires is subject to the design of the design institutes.

  • Page 39: Common Electric Control Faults And Troubleshooting

    external forces during installation and use. It should be installed in a relatively protected position to avoid hoists or moving parts from contacting the sensor. Regularly tighten terminals to reduce measurement errors. Avoid corrosive substances contacting the sensor. To reduce interference, connect the sensor with shielded cables. Control the sensor to operate under the normal range.
  • Page 40 symptom: Troubleshooting: A. Check whether the program version is correct. B. Check whether the wiring of the transmitter is correct. C. If the wiring is correct, but the collected voltage data is wrong, change the transmitter. 4. Fault The screen displays "CPU no response". symptom: Troubleshooting: A.
  • Page 41 section). C. Check whether the alarm settings are correct. 9. Fault "Cooling water/Chilled water flow stopped" is displayed. phenomenon: Troubleshooting: A. Check whether the water switch is cut off. B. If the water switch is started, check whether the set value is correct.

  • Page 42: Appendix Maintenance (Repair) Record Table

    Appendix Maintenance (Repair) Record Table Troubleshooting Description Result Recorder Date Measures Page 40...
  • Page 43 Appendix Maintenance (Repair) Record Table Troubleshooting Description Result Recorder Date Measures Page 41...
  • Page 44 TIСA PRO LLC 141014, Russia, Moscow oblast, Mytishchi, Very Voloshinoy Ulitsa, office 705 and 805 Tel.: +7(495)822-29-00 E-mail: info@tica.ru www.tica.ru...

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