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CONTENTS
1. SAFETY PRECAUTION
2. HANDLING, LOCATION AND FOUNDATION
2.1 Handing
2.2 Location
2.3 Foundation
2.4 The Precautions of Unit Installation With Diagram
2.5 Maintenance Space
3. APPLICATION LIMITED
3.1 Chiller water flow rate
3.2 Chiller water temperature
3.3 Hydraulic pressure of chiller water
3.4 Power source
3.5 Ambient condition
3.6 Re-start frequency
4. NOTICE FOR CHILLER OPERATION
4.1 General
4.2 Notice items for running beginning
4.3 Notice items for everyday running
5. INSPECTION AND NOTICE BEFORE DAILY RUNNING
5.1 Inspection before running
6. OPERATION SEQUENCE
6.1 Sequence of start
6.2 Sequence of stop
7. UNIT MAINTENANCE
7.1 Caution
7.2 Description
7.3 Preventive Maintenance Schedule
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1. Safety Precautions
Before using your equipment, read this to understand its correct using method.
In this instruction manual, the marks of WARNING and CAUTION emphasize dangerous
and important information.
1. WARNING: wrong operation can cause a death or a serious injury on persons.
2. CAUTION: wrong operation can cause an injury on persons or a damage on only materials. 3. Please follow the
instructions exactly to avoid causing the above-mentioned harm.
4. We request you to establish safety measures for safe operation and maintenance of your equipment and facilities
according to various standards.
5. We are not liable at all for an accident caused by your neglecting these safety precautions.
Important Safety Notices: (Please observe following important safety notices)
Deformation of marks:
Strictly prohibited
Follow instructions
Circuit engineering
is required
Keep this manual in a place where you can read it at any time.
A. INSTALLATION PRECAUTIONS
WARNING
(1) Be sure the installation is performed by qualified persons. Improper installation may result
in water leakage, electric shock or fire due to improper work.
(2) Installation movement must be performed by qualified and licensed persons to avoid tumbling or falling of the units.
(3) Be sure to install it in a place where it will not be exposed to water and wind. Water and
wind could cause electric leakage and electric shock.
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(4) Electric work must be conducted according to local Electrical wiring regulations. Use of
(5) If any replacement for the parts during installation, be sure to performed by qualified and
licensed persons following manufacturers instructions.
CAUTION
(6) Proper grounding engineering work is necessary.
Do not connect the ground wire to gas pipes, water pipes, lightning rod, or telephone lines.
Improper groundng could cause damage of equipment or electric shock.
(7) Do not install the equipment near heat sources or the place where flammable substances
nearby which may cause fire.
(8) Do not install the equipment in an environment like hot spring, coast area and oily places
etc. These could cause corrosion, electric shock or fire.
(9) Standard unit (case material is SECC, condenser material is copper tube-aluminum fins)
strictly forbid install near acid, alkali environment and hot spring.
B. OPERATION PRECAUTIONS
WARNING
(10) Do not put fingers or a rod in rotating parts (like fans and pumps etc.) which might cause
injury.
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(11) If the smell of burning arises, stop operation immediately. Asking for professional consulting to fix the problem. It could cause breakdown of the unit if keep operating.
(12) Do not turn the switches (ON & OFF) very frequently in a short period. It may result in
damage of the equipment.
(13) Do not change second refrigerant type (city water) and concentration. If change second
refrigerant type and concentration make chiller exchanger (evaporator) frozen, damaged or
chiller unit breakdown and damaged.
CAUTION
(14) Do not touch switches on the panel or operate with wet hands. Doing so may cause
electric shock/
(15) Check the installation area from time to time after the units starting running. Insufficient
reinforcement or poor balance would cause water leakage, noise or tumbling of the equipment.
(16) The cleaning of air cooling condenser must be performed by professional personnel.
Improper handling or any negligence for the cleaning may cause human injury (electric shock
CHAPTER
1
etc.)
1.1 TECHNICAL DATA OF MACHINE
(17) Be sure to turn off the equipment when cleaning or inspecting the cooling tower fan, etc.
ATFM-60Z-C
Tube in
Filler
is applicable
theby
filling
Failure to doAutomatic
so may result
electric
shock or for
injury
the and
fan. sealing of metal tube.
Main technical data is marked on the specification Machine Plate of the machine.
Nameplate is on the back and lower part of the electric cabinet.
The nameplate size is 80 mm 130 mm.
(18) Use only fuses of the specified capacity. Using materials out of the specifications may
result in damage to the equipment or cause fire etc.
1.2 CONTENT ON THE NAMEPLATE. (Main technical data)
Production (30-60 Tubes/min.)
(19) Do not place heavy things on the equipment, starting panel. Injury might happened if the
Matching
Motor (1.1 Kw)
things fall..
External Dimension 1250 x 750 x 1750 mm
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(20) Please follow this manual about the quality to supply good cooling or chilled water.
Bad water quality will bring leaking.
(21) Please add chiller or free water from piping during stop unit for a long time or not run in
winter. It will bring leaking when water filled piping all the time.
(23) Do not change settings of safety devices and protective devices. Operation under improper settings may result in damage to the equipment. (If setting value is different between
this manual and protective devices label, please comply with devices label.)
(24) Do not touch the high temperature side of the compressor & refrigerant tabulation with
bare hand. It may cause ambustion to touch the high temperature surface.
(26) Do not reassemble unit. Reassemble unit will catch electric shock or fire.
(27) Order a qualified person or consulting a licensed pro to transport or move the equipment.
Improper work may result in water leak, electric shock or fire.
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CAUTION
(28) Do not use wrong refrigerant or refrigeration oil. Use wrong refrigerant or refrigeration oil
will catch blast.
(31) Once the safety device or protective device trips, remove the cause before restarting the
equipment. Restarting without removing the cause may result in damage to the equipment or
fire.
(32) Do not locked fusible plug of refrigerant. Abnormal fusible plug will catch blast.
(33) Do not touch the air side heat exchanger. Prohibition touch to the heat exchange may
cause injury.
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Remarks: Must place the support frame above the chiler, must pay attention to the personal security and prevent
chillers appearance from being damaged while freighting.
3) It is must to conform the local safety requirement for transport the chiller unit. When handing the unit, ought to
consign someone for command and offer the warning device to keep the safety of human and mechanism.
4) Take sufficient care for transport unit and avert excessive swing and shock to prevent damaging the unit and
injuring human or building.
5) In the first, please carry out the transport plan of unit that the content ought to include moving date, outline dimensions, unit weight, preparatory opening and transport/hang tool. Like as next table.
Table 2-1 Inspect Items for Handling.
Items
Trasnport
Modify Path
Inspect Items
Path
Unloading
Moving
1. If possible, the large chiller ought to disassemble for delivery and reassemble in the location.
2. If the chiller cant be disassembling, it is necessary to retaining preparatory opening on the wall or floor for transportation or hang.
If necessary, please modify the wall or floor for transportation expendiently.
2.2 Location
1) Chiller units can be mounted on a roof or ground level. Set chiller units on a solid and level foundation. For roof
mounted applications, install the unit on a steel channel or I beam frame to support the unit above the roof. For
ground level applications, install the unit on a substantial base that will not settle.
2) Be sure the foundation is level (within 12 mm over its length and width). On ground level applications protect the
unit against vandalism by using the optional lower wire mesh guards or by erecting a screen fence. The fence must
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allow free flow of air to the condenser coil for proper unit.
3) The flow of air to and from the condenser coils must not be limited. Restricting air flow or allowing air recirculation
will result in a decrease in unit performance and efficiency. There must be no obstruction above the unit that would
deflect discharge air downward where it could be recirculated back to the inlet of the condenser coil.
4) The condenser fans are propeller type and will not operate with ductwork on the fan outlet. Install the unit with
enough side clearance for air entrance to the coil and for servicing. Provide service access to the evaporator, compressors, electrical control panel and piping components.
5) Each end of the unit must be accessible after installation for periodic service. The condenser fan and motors can
be removed from the top of the unit.
6)
A. Unit must not be installed in a pit or enclosure that is deeper or taller than the height of the unit unless extra
clearance is provided per not 4.
B. Minimum clearance on each side is 2.5m when installed in a pit no deeper than the unit height.
C. Minimum side clearance to a side wall or building taller than the unit height is 2.5m provided no solid wall above
2m is closer than 4m to the opposite side of the unit.
D. The evaporator can be removed from the side of the unit.
E. Do not mount electrical conduits, etc, above the side rail on either side if the unit. f. There must be no obstruction
of the fan discharge.
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2.3 Foundation
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Width (mm)
Height (mm)
A+500
B+400
180
2) The foundation must be made of concrete or steel frame that sufficiently bears the operation weight.
3) When the foundation will locate on the concrete floor or roof, please make the projection and recess on the
surface in contact with the foundation; next clean the surface and advisable perfusion before construct.
4) Produce the concrete by mixing cement, sand and gravel on scale1:2:4 and embed the anchor bolts according
to the dimension of chiller unit. The foundation ought to finish and level.
5) Install the chiller unit after the concrete of foundation is rigidified.
6) The surrounding of foundation ought to keep smooth drain and dont exist sump to worsen the ambient
environment.
7) Each end of the unit must be accessible after installation for periodic service.
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2) Air-cooled chillers (condensing unit) shall arrange with more than 1 meter between the rows.
(2-side air suction, up-blast and raked-blast type)
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3) When there are barriers around the air-cooled unit, the barrier cant be higher than dispelling condenser coil
4) Side-blast type, because the dispelling heating coil is U type, while connecting in parallel, the distance shall be
half of the height of dispelling condenser coil.
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5) Side-blast and raked-blast type shall not connect in column parallel layout,
it is apt to cause short cycle with hot wind.
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3. Application Limited
3.1 Chiller Water Flow-rate
Maximum
-15%
+15%
85~115%
Items
Chiller water outlet temperature
Chiller water inlet/outlet temperature difference
Minimum
Normal
Maximum
5C
7C
15C
3C
5C
7C
The hydraulic pressure of chilled water ought to operating under 6.5kg/cm2 (general hydraulic pressure).
Rating value 10% (the voltage drop between wiring shall not exceed 3% rating value).
Low Temp.
Normal
High Temp.
-20~43C
(High pressure control)
20~43C
(35C)
21~50C
(Large condenser)
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Pressure switch
One year
The chiller unit must be located on the open circumstance where if refrigerant leaking will not cause worker
hard breathing or asphyxiation during maintenance.
4. Ground wiring is necessary for chiller unit.
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5. Chiller unit ought to interlock control with chilled water pump. When the water pump running, then circulating
water will actuate the flow switch to start chiller unit.
Ambient temperature
20~45C
{R-22}15.5~21.5
{R-134a}9~16
{R-22}3.4~5.5
{R-134a}1.5~2.7
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2. Electric items
A) Check the rating voltage is 10% or not
3.Items for chiller
A) Check the chiller water flow rate is normal or not. (15%)
B) Check the temperature of chiller water is too low or not. (>normal value -4C)
C) Check the outlet temperature of chiller water is steady or not.
D) Check expansion valve is working normally and the suction line of compressor is frosted or not. Wet compression is always not allowed under any conditions.
E) Keep super-heating degree within 8~12C.
4. Items of condenser
A) Check the condenser temperature is too high or not. The value of high pressure must less than 22kg/cm2 G [R22], 15kg/cm2 G [R-134a] under 35C ambient temperature.
B) Check refrigerant leaking or not. The high/low pressure and amphere (full load) will reduce if refrigerant leaking.
C) Keep sub-colled degree within 3~8C.
5. Others
A) Check the regular solenoid valve is working normally or not.
B) Check protective device is working normally or not.
C) Record running condition.
7. Unit Maintenance
7.1 Caution
1) Service on this chiller unit is to be performed by qualified refrigeration personnel familiar with chiller unit operation, maintenance, correct servicing procedures, and the safety hazards inherent in this work. Causes for repeated
tripping of equipment protection controls must be investigated and corrected.
2) Disconnect all power before doing any service and maintenance.
3) Anyone servicing this equipment shall comply with the requirements set forth by the local ordinances in regards
to refrigerant reclamation and venting.
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7.2 Description
1) On initial start-up and periodically during operation, it will be necessary to perform certain routine service checks.
Among these are checking the liquid line sight-glasses, taking condensing and suction pressure readings. A recommended maintenance schedule is located at the end of this section.
2) It is suggested that the maintenance log be completed on a weekly basis. The log will serve as a useful tool for
a service technician in the event service is required.
3) No routine lubrication is required chiller units. The fan motor bearings are permanently lubricated and no further
lubrication is required. Excessive fan motor bearing noise is an indication of a potential bearing failure.
4) Electrical terminals should be checked semi-annually for tightness.
5) The condensers are air-cooled and no maintenance is ordinarily required except the routine removal of dirt and
debris from the outside surface of the fins.
Weekly
Monthly (1)
Annual (2)
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Operation
Weekly
Monthly (1)
Annual (2)
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[R-134a]18kg/cm2 G
Check process
1) Disconnect secondary side wiring of electromagnetic switch of fan motor. It is necessary to connect the
hose of high-pressure gauge to liquid line in the high-pressure side if unit no high- pressure gauge.
2) Turn on the main power and control unit.
3) Power on chilled water pump.
4) Push button or switch to [ON] and then chiller unit running.
5) High pressure uprising, and then record the value of high pressure when the high-pressure switch
tripped. Push the button [OFF] to stop unit if the high-pressure switch not trip when high pressure is come
to 0.7kg/cm2 G [R-22], 18kg/cm2 G [R-134a].
6) Recover the water quantity of condenser to the normal value, and then push the reset switch when running after 5 minutes. The abnormal indicator of high pressure will go out.
7) Turn off the power of chiller unit.
8) Push the button [OFF] to stop after inspection.
9) Power off the chiller water pump.
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[R-134a] 1kg/cm2 G
Check process
1) Turn on the main power and control circuit.
2) Power on chiller water pump.
3) Push button or switch to [ON] and then chiller unit running.
4) Close the liquid angle valve of condenser slowly, and then record the value of low pressure when the
low-pressure switch tripped. Please keep the low pressure over 0.5kg/cm2 to avoid non-condensable gas
inrush to refrigerant system.
5) Full open liquid angle valve and low pressure uprising then push the reset switch. The abnormal indicator of low pressure will go out.
6) Push the button [OFF] to stop after inspection.
7) Turn off the power of chiller.
8) Power off cooling and chilled water pump.
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Possible Causes
Compressor
will not run
1. No power supply.
2. Fuse blown. Circuit breakers open.
3. over-replay of compressor tripped
4. Defective contactor or coil.
5. System shutdown by safety devices
6. Liquid line solenoid will not open
7. Motor electrical trouble
8. Loose wiring for control circuit
Compressor
noisy or
vibrating
High
Discharge
Pressure
Low
Discharge
Pressure
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High Suction
Pressure
Low Suction
Pressure
1. Lack of refrigerant
2. Clogged liquid line filter drier
3. Expansion valve malfunctioning
4. Condensing temperature to low
5. Compressor will not unload
6. Insufficient water flow
7. Air in the chiller pipe or chiller
Compressor
will not
stage up
1. Replace
2. Replace
3. Reset thermostat setting for application
Compressor
Staging
Intervals to
short
Compressor
Oil Level
Too high or
Too low
Compressor
loses oil
1. Lack of refrigerant
2. Excessive compression ring blow-by
3. Suction superheat too high
4. Crankcase heater burnout
Motor
Overload
Relays or
Circuit
Breakers
Open
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Compressor
Thermal
Protection
Switch Open
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30
Layout 1
31
Layout 2