Change for life

Modular Air-Cooled Screw

Chiller

Owner's Manual
Commercial Air Conditioners

Thank you for choosing Commercial Air Conditioners, please read this
owner’s manual carefully before operation and retain it for future reference.
 Contents
1 Summary ...................................................................................................... 1
2 Operation Instructions for the Display of the Controller.............................. 2
2.1 Brief Introduction to the Display........................................................................... 2
2.2 Operation Instructions to the Display.................................................................... 2
3 Electric Principles....................................................................................... 16
3.1 Connections for external control ........................................................................ 16
3.2 Wirings List......................................................................................................... 16
3.3 Connection of units and external connection wires.............................................. 16
3.4 Connection among Modules................................................................................ 17
3.5 Dial-up switch to main board ............................................................................ 17
4 Instruction to installation of unit................................................................. 17
4.1 Inspection ........................................................................................................... 17
4.2 Outline and dimension of the unit ...................................................................... 20
4.3 Installation and maintenance space..................................................................... 23
4.4 Connection of water- pipe system ...................................................................... 23
5 Maintenance ............................................................................................... 25
5.1 Daily startup or stop of the unit .......................................................................... 25
5.2 Maintenance of the main parts ........................................................................... 25
5.3 Requirements to water and contaminant release................................................. 25
5.4 Maintenance for lengthy shut down .................................................................. 25
5.5 Startup of the unit after lengthy shut down ....................................................... 26
5.6 Replacing components ....................................................................................... 26
5.7 Cooling system ................................................................................................... 26
5.8 Anti-freezing........................................................................................................ 26
5.9 Other notifications............................................................................................... 27
6 Trouble Shooting......................................................................................... 28
7 Attachments ................................................................................................ 31
 Modular Air-Cooled Screw Chiller

1 Summary
Modular Air-Cooled Screw Chiller (Modular Air-Cooled Screw Chiller is short) is a type of refrigerant
facility which supplies cooling water in summer as well as heating water in winter. It can be combined with
the terminal units with air processing such as air-cooled unitary standing units and combined type units to be
various types of large-scale and centralized air-conditioning system. This air-cooled design can avoid installing
cooling tower and cooling water pump for users, so the units are especially suitable for water deficient regions.
The units can be installed on the rooftop, ground outside and so on instead of being equipped with a special
machine house. It can widely applied in new–built or reconstructed industry and civil-building project, such as
hotels, apartments, restaurant, office building, shopping mall, theater, gymnasium, hospitals and so on, as well
as supplies required cooling (heating) water for factories in technical process of producing, so it’s especially
suitable for some special locations around where there are high-level requirements for noise and environments
and boiler and cooling tower are difficult to install.
a. Modularization: The patented design of that any unitary module can be as master module, makes
various emergencies easy. Each unitary module can be combined with another module with different capacity
so that different units with different cooling capacity are formed in a wider application range. Balanced
running of compressor extends the lifetime of unit. The compressor of each unitary module will be started one
after another to ensure less attack to power network. The design of combination of modular makes the unit
compact in size and configuration, convenient in delivery and installation.
b. High efficiency: The new generation of screw compresses with balanced load and high-efficiency
and helical twin screw with nearly 100,000-hour lifetime can efficiently avoid leakage and improve the
compressing efficiency. Combined with perfectly-matched refrigerant and reliable control technology, they
can also make the units efficiently run at full load as well as at partial load.
c. High reliability: As a specialized air-conditioning company, this company has been engaging in
technical improvement and innovation; it adopts perfect service parts, strict control on each manufacturing
procedure and strict test to each ongoing product in performance to ensure quality and performance, moreover,
reliable motor- cooling technology and oil return technology for refrigerant system ensure the compress
running in well conditions.
d. Energy saving: With perfect design, the energy levels of each unitary module can be adjusted by 0-25-
50-75-100%; in addition to it the combination of many unitary modules make the unloading capacity of unit
fold increased, which totally matches the practical load. Because units running at partial load most of time, the
energy consumption is much less than before.
e. Quiet running and long life: The double-shaft of the compressor is accurately located by axial direction
and radial of rolling bearing to ensure even stress, quick compressing procedure without decentration and
reciprocate, low pressure fluctuation, low vibration and reliable running of the compressor.
f. Long-distance monitoring: Adopting high-performance C Builder Software to program under Windows
system and graphic means, the computer can clearly display running curve of the units. International universal
485 industrial buses are used for communication with the distance as long as 800m, which can connect and
simultaneously monitor 255 units to form a monitoring network, furthermore, all the functions of manual
controller owned by the unit can be displayed in the computer so that there is no necessary to monitor or
control the units in computers’ house.
g. Environmental friendly refrigerant:The R134a,whose ODP(Ozone Depletion Potential) value is 0,is a
environmental friendly refrigerant.It does no harm to Ozone complately, and its usufruct is unlimited.
h. Running in atrocious weather:Adopting multifarious atrocious weather,the units can reliably running in
a large temperature scale,from 18 to 52 degrees centigrade.

1
Modular Air-Cooled Screw Chiller

2 Operation Instructions for the Display of the Controller

2.1 Brief Introduction to the Display
As for the networking control to 1~8 modules, only one display is equipped for displaying the control
menus, receiving and displaying all kinds of parameters from the main board controller, setting the adjustable
parameters, as well as sending the adjusted parameters back to the main board controller.
Control Panel of the Display:

① . “POWER” Indicating Lamp: the lamp shines when the display is energized.
② . “ERROR” Indicating Lamp: the lamp flickers in the event of a fault.
③ . “RUN” Indicating Lamp: the lamp shines when the display is turned on.
④ . “ON/OFF”: switchover between the ON/OFF statuses of the unit. Under the OFF state, press it for
5 seconds to go to the ON state, and it is also available to go to the OFF state in the same way under the ON
state. Besides, no continuous clicking is allowed.
⑤ . “MENU”: go to the Menu interface immediately by pressing this button at any condition.
⑥ . “▲”: Move the cursor upward or leftward by pressing this button for selecting an option. When
modify some data, the value of the data can be increased also by pressing it. Additionally, pressing this key for
much longer time can make the incremental change to the value of the data.
⑦ . “▼”: Move the cursor downward or rightward by pressing this key for selecting an option. When
modify some data, the value of the data can be decreased also by pressing it. Additionally, pressing this button
for much longer time can make the decremental change to the value of the data.
⑧ . “ENTER”: Confirm the option you want to select by pressing this key. Also, press this button to
make the final confirmation to some changed parameters and then move the cursor away.
⑨ . “EXIT”: quit from the current operation by pressing this button.
⑩ . “Status Column”: Where a brief indication is offered to tell the function of the current function key.

2.2 Operation Instructions to the Display

2.2.1 Homepage
When the controller is power-on, the microcomputer will take several seconds for the self-examination

2
 Modular Air-Cooled Screw Chiller

and the LCD display will be like as follows:

00:00 Sat. 2010-05-01

C/O SCREW UNIT

State：Cooling ON ON-OFF Mode：Manual

Module Qty： 01 pcs Error：No

Anti-freezing：Yes Modbus：Yes

Press <MENU> to open menu interface. Menu

The date and time is displayed on the upper left, and in the middle is the status of the unit. When an alarm
is raised for frequency protection or the unit is locked due to frequency protection, the display will back to the
homepage and show up the alarm text which then can be canceled by pressing the “EXIT” button.When there
is no any button operation on the wired controller in ten minutes, the display will automatically back to the
homepage.
Remarks:
About the State, apart from Cooling OFF, Cooling ON can also be displayed.
The ON-OFF mode can be either manual or timing. Regarding the error status, if there is no any error, it
will be black lettering in white; if there is, it will be shaded in black.

00:00 Sat. 2010-05-01

C/O SCREW UNIT

State：Cooling ON ON-OFF Mode：Manual

Module Qty： 01 pcs Error：No

Anti-freezing：Yes Modbus：Yes

Press <MENU> to open menu interface. Menu

Under any condition, Pressing ON/OFF button can jump to the homepage. If it is the operation for
startup, meanwhile a window will pop up to indicate “Please input password”. If it is the operation for OFF,
the unit will be turned off directly without the popup of such a hint window. (It is not applicable in the
condition of the remote shield).If the input passwords are correct, the unit will run normally, while if they are
incorrect, a window will pop up to indicate “Wrong Password”. In this case, press ENTER or EXIT and then
this window will disappear.

3
Modular Air-Cooled Screw Chiller

2.2.2 Menu Interface

Under any condition, pressing MENU can go to the Menu interface, through which you can select the
option you want to control or view, as shown below.

Remarks:
Select the option in the menu through “▲”and “▼”and then press ENTER for confirmation. When the
menu interface pops up, press MENU and EXIT to quit from this menu interface
2.2.3 User Setting
The interface of User Setting allows the user to set all kinds of parameters for the unit.
Select the option of User Setting in the Menu interface and then press ENTER to go to the User Setting
interface. Subsequently, a window indicating “Please input password” will pop up.
Remarks:
The password for the User Setting is the same with the one for the Startup; however, it can be changed
through the User Setting.
Once the correct password is verified by the system, the user can go to the setting interface. If the
password is input incorrectly, a suggestive window will pop up.
Through the setting interface, the following items can be adjusted: default parameter (Default Par.), inlet
water temperature for cooling (C Water-in T), hot return water temperature (Hot BW. T), Memory ON-OFF
state (Memo. ON-OFF), volume of clicking keys (Key Volume), LCD backlight (Backlight), ON-OFF Mode,
timer setting, clock setting, password revision(Pwd. Revision), and Modbus address setting (Modbus Add.).
Remarks:
Return Hot Water Temperature (Hot BW.T) is not applicable for the unit without the function of heat
recovery.
Select an option through the buttons of “▲” and “▼” and then press ENTER to go to the sub-window of

4
 Modular Air-Cooled Screw Chiller

it to set the desired value.

Clock Setting:

Timer Setting
Timer setting aims to set the ON-OFF time for the unit. Based on the actual need, the user can take one
week (Monday---Sunday) as a cycle to set the timer mode for each day. There are three available timer modes
provided for the user, each with four time phases.
a. Setting of the Time Phase under the Timer Mode
Go to the Timer Setting, and put the cursor on the place of Mode 1.

5
Modular Air-Cooled Screw Chiller

Press ENTER and then the cursor will move to the interface of Mode 1. After that, press “▲” and “▼”
to change the time, or select “√” or “--” ( “√” indicated it has been selected, while “--” means it has not). Then,
press ENTER to move the cursor away.

After finish the setting of Mode 1, press EXIT to quit from this mode to the main menu shown as below.

The setting of Mode 2 and Mode 3 can also be done in the same way as above.

6
 Modular Air-Cooled Screw Chiller

Press ENTER and then the cursor will move to the interface of Mode 2. After that, press “▲” and “▼”
to change the time, or select “√” or “--” ( “√” indicated it has been selected, while “--” means it has not). Then,
press ENTER to move the cursor away.

b. Move the cursor to Set week and press ENTER to select the timer mode for each day within one week.

Press “▲” and “▼” to change the Timer Mode, and press ENTER to change the date.

7
Modular Air-Cooled Screw Chiller

c. Move the cursor to Save and press ENTER to save the changed value of the Timer Setting. (Only with
this operation, all changes to the Timer Setting can be saved)

When the user is intended to set some parameter under the remote control shielding mode, a prompt
dialogue box will pop up, as shown below, indicating “Remote shield! No setting!”

8
 Modular Air-Cooled Screw Chiller

2.2.4 Module View

Select the Module View on the Menu interface and press ENTER to go to the module view interface.

Remarks:
The existent module will be indicated by “Yes”, while the inexistent will be indicated by “No”. Besides,
the module marked by “!’ means it is in error or has the automatic anti-freeze function or defrosting function.
The inexistent module hasn’t any submenu.
Press EXIT to quit this interface and back to the previous menu. Or press “▲” and “▼” to select the
expected module. After that, press ENTER for confirmation.
For the existent module, the user can view the submenus of Sampling Information, State View, Current
Error, and Error Record. Press the “▲” and “▼” to switch over four three submenus and then press Enter
for more details.
a. Sampling Information
It is used to view the temperature and pressure of each temperature spot of this module, and it can be
refreshed in real time.

Remarks:
When the function of heat recovery of the unit is deactivated, there is no Hot BackWater Temperature
(Hot Backwater T).
The displayed pressure is relative pressure, equal to the absolute pressure minus 1.01bar.
b. State View
It aims to view the load status of each module and it can be refreshed in real time.

9
Modular Air-Cooled Screw Chiller

Remarks:
Items which are started will show ON, or show OFF. For the compressor, there are several statuses: OFF,
25%, 50%, 75%, and 100%.
c. Current Error
It aims to view the error status of the current module and it can be refreshed in real time.

When one page is not enough for listing all errors, more pages are needed. Move the cursor to Current
Error and then press ENTER, the cursor will go to the place of Next Page. At this time, in the top middle of
the page shows Page 1 and the whole page is about the contents of page 1.

Then press ENTER, and the cursor will be at the place of Last page. At this time, in the top middle of the
page will show Page 2 of the Current error and the whole page is about the contents of page 2.

10
 Modular Air-Cooled Screw Chiller

Switch page one to page two by pressing ENTER and press “ ▲” or “ ▼” to switch submenus.
Frequent Protection Alarm
① . Frequent protection times are accumulated by the single unit, of which the timing and counting are
done individually.
② . W hen “LP protection of comp.,Comp.Phase fault Pro.,Overload pro.of comp. ,Comp.built-in
pro.”occur to the running compressor, its protection times will be accumulated.
③ . Protection times will not be accumulated when the unit is in downtime.
④ . During the specified period, if both the above conditions happen once, one more frequent protection
time will be accumulated.
When it is detected that the accumulated protection times for the compressor are up to 4 in 12 hours, the
frequent protection alarm will work.
The following is the interface of the frequent protection alarm.

Remarks:
When an alarm is raise for frequency protection, the page will go to the homepage and also show a hint
textbox, saying “Moduls 1 is frequently protected, Please handle it as soon as possible! Or the unit will be
locked”. At this time, press ENTER, then all alarm information and lock information will be listed on by one
(During this time,all buttons expect ON/OFF and ENTER are deactivated). After that, this textbox will fade
away.
Frequent Protection Lock
If it is detected that the accumulated protection time for the running compressor is up to 6 in 12 hours,
then the unit will be locked.

11
Modular Air-Cooled Screw Chiller

Remarks:
When the unit is locked due to frequency protection, this page will back to the homepage and a textbox
will pop up, saying “Module 1 is locked for frequent protections. Startup is forbidden”. At this time, all
operations are the same as those of the frequent protection alarm.
Recovery of the Frequent Protection Lock
Once the frequent protection is locked, it can be only recovered by inputting the correct unlocking
password. Refer to the factory parameter settings for more details.
d. Error Record
It is used for viewing the error status of the current module. This page contains 16 latest error records,
including error type and occur time. The smaller the serial number of the error, the later it occurs. This error
record can still be kept even in the event of power-off and can be refreshed in real time.
Move the cursor to Error Record and press ENTER and then the cursor will go to the place of Next page.
At this time, in the top middle of the page shows the Page 1 of the Error Record and all contents are about
page 1.

After that, press ENTER and then the cursor will go to the place of Last Page. At this time, in the top
middle of the page shows Page 2 of the Error Record and all contents are about page 2.

12
 Modular Air-Cooled Screw Chiller

2.2.5 Factory Parameter

Select Factory Parameter on the Menu interface. After inputting the correct password, you can go to this
interface, which offers all adjustable parameters of the unit. However, this interface is only available to the
factory staffs who know the correct password. Additionally, all contents of this page can be kept even in the
event of power-off.

Press “▲” and “▼" to adjust the value of figures and press ENTER to switch to other option . The access
to this page is only allowed by inputting the correct password, or it will tell the input password is incorrect.

Press “▲” and “▼" to move the cursor to the place of System password revision and then press ENTER
to access to a textbox of system password revision, shown as the below figure.

13
Modular Air-Cooled Screw Chiller

Press “▲” and “▼" to move the cursor to the expected option and then press ENTER to go to the
submenu of it to adjust the value of some items.
2.2.6 Reset
Go to the menu interface by pressing MENU at any condition and then press “▲” and “▼" to select Reset
error.

Press ENTER and then a text window will pop up. In this case, select Yes and press ENTER, reset of the
unit starts.

2.2.7 Helping
This interface introduces four kinds of information: “Operation Instruction”, “Units Introduction”, “Other
Instruction”, and “Version Introduction”, shown as follows:

14
 Modular Air-Cooled Screw Chiller

15
Modular Air-Cooled Screw Chiller

3 Electric Principles
3.1 Connections for external control
Connections for external control

Neutral line for outgoing control

Chiller water pump contactor for outgoing control (220V front line)
Water pump associate

3.2 Wirings List

Specification for power cord and breaker is recommended as follow:

Model LSBLGF230MT3/Nb-M LSBLGF 350MT3/Nb-M LSBLGF 430MT3/Nb-M

Size of the Power Cable (mm2) 150 185 300
2
Size of the Ground Wire(mm ) 70 95 150

Capability of the Air Switch(A) 250 320 400

Note:
① . The specifications of the breaker and power cable listed in the table above are determined based on
the maximum power (maximum amps) of the unit.
② . The specifications of the power cable listed in the table above are applied to the conduit-guarded
multi-wire copper cable (like, YJV XLPE insulated power cable) used at 50℃ environment temperature and
capable of enduring 90 ℃ cable temperature (see GB/T 16895.15). If the working condition changes, they
should be modified according to the related national standard.
③ . The specifications of the breaker listed in the table above are applied to the breaker used at 40 ℃
environment temperature. If the working condition changes, they should be modified according to the related
national standard.
A piece of square sheet metal removable is equipped where the inlet wire comes in. During installation,
remove the metal sheet firstly, which shoud be drilled a hole accoding to dimesion of the cable joint, and then
keep the cable through the hole and fix the cable.
Hole Cable Square sheet metal

Square sheet metal Local cable joint Local cable joint Cable sleeve

3.3 Connection of units and external connection wires

3.3.1 General rules
 All leads, facilities and connection wires supplied at field must be in accordance with all applicable
laws and project standard.
 All the connections of wirings at field must be performed by electrician with certification.
 Connections must be performed after cutting off all power supply.

16
 Modular Air-Cooled Screw Chiller

 The persons who perform the installation must be responsible for any damage resulting from
incorrect connection of exterior lines.
 Warning- Copper leads must be adopted.
3.3.2 Connect the power cord into electric cabinet of the unit
 Keep the power cord through slot, wire duct or cable trench.
 The power cord connected into electric cabinet of the unit must be protected with rubber or plastic
to prevent the edge of the sheet metal from scratching it.
 The part of power cord near the electric cabinet of the unit must be reliably fixed to prevent external
force affecting the power terminal board of electric cabinet of the unit.
 The power cords must be reliably ground.
3.3.3 Control wires
2
 The minimum length of the control lead at filed is 1mm
 The wires connected with water flow switch is with DC light current signal, so never side by side
line it and the lead with 50V or more voltage; provided that is actually unavoidable, keep the light
current signal above 150mm from the heavy current signal.
 The signals for chilled water pump and auxiliary electric heater in electric cabinet of the unit (220V
AC; Capacity: 5A), can drive the AC contactors to chilled water pump and auxiliary electric heater,
but do not directly drive the chilled water pump and auxiliary electric heater.
 The power cord inserted into the unit can not be too long .Never bind the rest of the power cord in
the electric cabinet.

3.4 Connection among Modules

Module1 2 ModuleN

Communication Line

3.5 Dial-up switch to main board

Four-bit dial-up switch indicates the address of each module (0-7), and the display panel displays in turn
“Module 1, Module 2…….Module 8”. .1234 in the dial-up are binary codes, in which 1 is the least significant
bit, and 4 is the most significant bit.

17
Modular Air-Cooled Screw Chiller

4 Instruction to installation of unit

4.1 Inspection
In order to ensure normal running of the unit and avoid malfunction, the installation should be operated by
the professionals with air-conditioning knowledge and working experience, please read this manual carefully
before installation.
The units were manufactured under strict quality control system of the company, and have passed through
the strict inspection. Please install, operate and maintain the units according to the manual to keep the unit
normally run and extend the unit lifespan. If neglect some special factors in installation, some danger such as
installation, startup and maintenance of the unit will occur.
4.1.1 Receiving and checking
When units are delivered to the appointed place by contract, the user should organize personnel to check
and accept.
a. In terms of the attached documents check equipment model and specification.
b. Check whether the unit is damaged and spare parts are all completed.
c. Check whether the refrigerant charge is leaked.
Having passed through the above checking, if the damage and problems exist, please inform the local
office of our company to solve them.
Note：After the equipment checking is completed, safeguard is necessary to be adopted. Do not open the
packing too early to avoid damage to the facility.
4.1.2 Delivery and hoisting
Each unit has passed through strict inspection and test, to ensure the unit performance and quality, it
should be very careful to install and carry to avoid damage to control system and parts of pipeline.
Before opening the packing, carry the unit closely to the final installation place, and keep the units
upward. When carry the unit, of which the packing has been opened, the process should accord with follows:
a. Move the unit with rolling lever: Put three pieces of rolling lever under the unit, make sure the length
of lever is 1/5 longer than the unit width, and keep the unit balanced.
b. Hoisting（Please refer to attached Fig.1）
Stay bar

Rigging hole
Fig.1 Sketch for hoisting of the unit
① . Pease use the stay bar not less than 2300mm for rigging.

18
 Modular Air-Cooled Screw Chiller

② . Apply the hole marked with the rigging symbol for figging.
③ . When rigging,ensure the angle between the bottom of the unit and the horizontal plane is not large
than 15°.
④ . The fan quantity is allowed to be different with that showed in the schematic diagram,and they share
the same rigging means.
4.1.3 Base of Unit installation
a. The base of unit installation must be conducted and designed by the professionals according to field
conditions.
b. The base of installation must be made of concrete or steel frame, which can bear the running weight of
unit and whose surface must be level.
c. Please refer to the base of unit installation sketch (Fig. 2). Exactly put a steel plate and shockproof
rubber joint on the base, and then install the unit with the ground bolts which should be installed 60mm higher
than the installation level, at last, perform the second grouting.
d. Keep required space for installation, operation and maintenance of the unit.
e. Keep the installation place from fire, tinderbox, and corrosive gas or exhaust gas; spacer for ventilation
should be reserved; take applicable measures as much as possible to decrease noise and vibration.

Fig. 2 Sketch for base of units installation

A（mm) B(mm)

LSBLGF230MT3/Nb-M 2350 2000

LSBLGF350MT3/Nb-M 3430 2000

LSBLGF430MT3/Nb-M 4350 2000

19
 maintenance
space
LSBLGF230MT3/Nb-M
Modular Air-Cooled Screw Chiller

abov m
e 100 00m
0mm e 18
abov
ide
4.2 Outline and dimension of the unit

ts
fron

mm
e 1800
abov

20
nameplate electric cabinet

2300
water in
water out

430
2000
380 2020
hoisting location hoisting location 1522 880
200 2350 2000 water-in/out pipe location
ground bolt location ground bolt location
3150
2100
front side
 maintenance
space
LSBLGF350MT3/Nb-M

abov
e 100
0mm
mm
e 1800
t side abov
fron
m
800m
abo ve 1

21
electric cabinet
nameplate

water in
water out

hoisting location
water-in/out pipe location
hoisting location
ground bolt location
ground bolt location
front side
Modular Air-Cooled Screw Chiller
 maintenance
space
LSBLGF430MT3/Nb-M
Modular Air-Cooled Screw Chiller

abov
e 100
0mm
m
00m
e e 18
t sid abov
fron
m
800m
ve 1

22
abo

electric
nameplate cabinet

2300
water in
water out

365 2000
1070 3000 hoisting location 2745 1120
hoisting location 2000 water-in/out pipe location
200 4350 ground bolt location
2100
ground bolt location
front side
5250
 Modular Air-Cooled Screw Chiller

4.3 Installation and maintenance space

a. The unit should be levelly installed without obstacles, keep each unit above 1m from another unit
lengthways, and above 2 m or much more than 2m breadth wise. If there are obstacles on either side of the
units, keep it above 1.8 m from the units. If barrier is on the top of the units, keep it above 2.5m from the units.

m
n1
t ha
re se
mo thwi
a d
m its bre
an 1 e un
t h h
more than 2m re ut t
more than 1. mo p
put the units 8m
lengthways

b. If obstacles are around the units, keep the unit above 1m from another unit. Keep the unit above 1.8 m
from the obstacles on either side of the units; moreover, the obstacles can not be higher than 2.1m. If barrier is
on the top of the units, keep it above 3m from the units.
more than 3m

more than 1m more than 1.8m

more than 1.8m
less than 2.1m

4.4 Connection of water- pipe system

During connection, pay more attention to following points:
a. Notice marks of water-in(out) pipe for shell and tube evaporator to prevent incorrect connection of
pipes.
b. Flexible joints should be used for the chilled water-in (out) pipe joints of the units to decrease
vibration.
c. Thermometer, manometer and sluice valve should be installed at the chilled water inlet (outlet).
d. To ensure normal running of the units water flow switch must be installed, which is suggested to
associate with the controller of the units.
e. The drain valve should be installed on water-out pipe and manual or auto air release valve should be
installed on the peak or raised location in the water-pipe system. When the units are normally running, it is
better to take away the valve handle to ensure that the valve cannot be opened, if not, the water-break accident
should happen.
f. Chilled water pipe should be covered with heat insulator to avoid loss of heat as well as condensation.

23
Modular Air-Cooled Screw Chiller

g. Impurities in the water-pipe system is unavoidable and will deposit on the shell and tube evaporator, so
filter should be installed in front of the water pump.
h. Make sure pass by the units before cleaning the waterway system to avoid sewage flowing into the
units.
i. When the ambient temperature is very low in winter, if the units is stopped at night, water in the shell
and tube evaporator and the pipes may be frozen to damage the facilities and pipes. In order to avoid freezing,
the water pump should be always kept running when the units is stopped. The safe ways are to drain out the
water of the pipes or add mixture of ethanol and propanol in water-pipe system to prevent freezing.
Note: Never adopt salt mixtures to prevent it from corroding and damaging the units.

Temp. Gage
flexible
joints

Gage
Water switch
Temp. Gage
Pres. Gage
flexible
joints

By-Pass Valve
Spare Pump Check Valve

Auxiliary Electric Heater

Power Cabinet
Connect to the

Power Cabinet
Connect to the
Water Pump
C N

ANB C

C N
AB

AB
Temp. Limit
Check Valve Filter

Drainage Pipe
Discharge Valve
Water Tank

Auto Aire

Fan-Coil Unit

Fig. 5-3 Installation sketch for the units and water-pipe system.

24
 Modular Air-Cooled Screw Chiller

5 Maintenance
In order to make the unit reliably run for a long time, the unit debugging should be operated by
professionals or personnel with air-conditioning knowledge by the guide, the daily operation and maintenance
should be operated by the personnel with specialized training.

5.1 Daily startup or stop of the unit

The daily startup or stop of the unit should be operated by the manual controller. The knob switch on the
electric cabinet gate is used to turn on /off the unit during maintenance or in emergencies. The sequence of
starting the unit is: turning on the water pump first, then the main unit. The sequence of stopping the unit is:
turning off the main unit, then water pump. The power supply must have been supplied for 8 hours before
turning off the unit (do not start the water pump), so that heat tape of the compressor can operate, liquid
refrigerant kept in the compressor can volatilize to avoid damage to compressor by direct startup of the unit.

5.2 Maintenance of the main parts

a. During running of the unit, pay more attention to the pressure of air out / in, if any abnormity exists,
please check and debug.
b. Control and protect the equipment, do not adjust any set points on the spot.
c. Periodically check tightness of the electric connection wires to timely fasten the loose one.
d. Periodically check the reliability of electrical components to timely replace the ineffective and unsafe
parts.

5.3 Requirements to water and contaminant release

When the industrial water is used as the refrigerant liquid, there will be little scale incrustation produced,
but if use the water from well or river, that would be a lot of scale incrustation and sand produced, this
is because when the sand and clay is in the evaporator, that will reduce the water flow volume and cause
the freezing accident. Therefore, before flowing into the refrigerant liquid system, the water should be
filtrated, and demineralized the water by demineralizing plant. Before it is using, the PH value, conductivity,
consistence of chlorion, consistence of sulphion etc. should be analyzed. The following is the required water
quality standard for the unit:
PH value: 6.5~8.0
Conductivity: <200uV/cm(25℃ )
Chlorion：<50ppm
Sulphuricacid hydronium：<50ppm
Content of iron：<0.3ppm
Alkali hydronium：<50ppm
Total hardness：<50ppm
Sulphion：None
Ammonia hydronium：None
Silicon：<30ppm
Natrium hydronium：Has no requirement
In spite of qualified water and after lengthy running of the unit, burnt lime and other mineral substances
may still deposit on the surface of shell and tube exchanger, which will affect the performance of heat transfer
and can be cleared by organic acid like citric acid and acetic acid.

25
Modular Air-Cooled Screw Chiller

5.4 Maintenance for lengthy shut down

If the unit is need to be lengthily shut, inside and outside of the units should be clean and dry. Cover the
units to prevent dust and turn on the water drain valve to drain the water stored in the evaporator.

5.5 Startup of the unit after lengthy shut down

Following work should be prepared if stat the unit after lengthy shut down
Completely check and clean the units:
a. Clean the water-pipe system.
b. Check the water pump.
c. Fasten all the joints to lines.

5.6 Replacing components

When replacing the components, should only adopt the components, which are supplied by GREE, the
similar components of other company could not be used.

5.7 Cooling system

Check the refrigerant charging by checking the air in pressure and air out pressure, if there is leakage or
replacing the components of cooling system, that will need to examine the air tightness, when charging the
refrigerant, should accord to the following:
5.7.1 The refrigerant leaks completely
If this kind of situation happened, high-pressure nitrogen (15~20 kilogram pressure) or refrigerant
should be adopted for system leak hunting, if need to fill the welding, after the air of system inside drained
out, it could be weld. Before charging refrigerant, the whole cooling system should be dry and vacuumized
completely.
a. Connect the vacuum pipe at the low-pressure side and high-pressure side of fluorine charging mouth.
b. To vacuumize the system pipelines by vacuum pump.
c. When it had reached the requirement of vacuity (absolute pressure below 100Pa), to charge the cooling
system by refrigerant bottle, the appropriate charging volume has been marked on the nameplate and the
technical parameter list. The refrigerant should be charged from the side of low-pressure pipe.
d. The ambient temperature would affect the refrigerant charge volume, if they haven’t meet the required
charge volume, can make the refrigerant liquid circulated, and start up the unit for charging, could short circuit
the low-pressure control switch. (Note: After charging, the wiring should be resumed )
5.7.2 Recharge the refrigerant
To connect the refrigerant charging bottle at the low-pressure side of the fluorine charging mouth, and
connect the pressure gauge at the low-pressure side and high-pressure side.
a. Make the refrigerant liquid circulated, start up the unit, to short circuit the low-pressure control switch
when it is necessary.
b. To charge the refrigerant to the system slowly, and check the air in pressure and air out pressure.
Warning ！！
When it is in the leak hunting test and air tightness test, could not charge the oxygen, acetylene etc. such
these kind of inflammable and poisonous gas to the system, the high-pressure nitrogen and refrigerant only
could be used.

5.8 Anti-freezing
If the freezing of tubular heat exchanger flow vent happed, that will cause the serious damage, that is

26
 Modular Air-Cooled Screw Chiller

the tubular heat exchanger damaged and leaked, but the damage due to the freezing is not belong to the
maintenance range, so should pay more attention to the anti-freezing of following:
a. The units are stopping and stand-by under the lower ambient temperature: If the units are placed out of
the room with the outdoor temp. is lower than 0℃ , water in the evaporator should be drained out.
b. When running: If the chilled water flow switch and anti-freezing temp. sensor are ineffective, they may
cause water pipes freeze, so water flow switch must be kept the interlocking with the units.
c. When maintaining: When charging the refrigerant or discharge the refrigerant while maintaining, the
evaporator may be frozen. Whenever the pressure of the refrigerant in the container is lower than 0.4Mpa,
the pipes should be possibly freezing. So, water in the evaporator should be kept flowing or drained out
completely.

5.9 Other notifications

a. Regular maintenance: Regularly maintain the units according to the requirement of the specification
to ensure the units operate excellently.
b. Refrigerant leakage: If there is any leakage of the refrigerant, stop the unit at once and communicate
with the maintenance worker. Do avoid any fire nearby, as the fire can break down the leaking gas into
poisonous gas.
c. Fireproofing: If it happens, turn off the switch of the main power source immediately, and then
extinguish the fire by the fire extinguisher.
d. Prevent flammable gas: The units should be kept from the combustibles things such as gasoline,
alcohol, etc. to prevent explosion.
e. Error: If the units are stopping due to the malfunction, the reason should be found out and the error
should be solved, and then restart the units. It is forbidden to start the units while the error isn’t eliminated. If
the refrigerant or the chilled water is leak, turn off all the switches. At this time, if the units cannot be closed
through the controller, turn off the switch of the main power source.
f. Please don’t make the circuit that needs the protectors into short connection, or it can cause the error.
In order to prolong service life and enhance efficiency and saves energy, it is necessary to conduct check,
maintenance, and repair regularly. User should keep down the check, repair and maintenance circumstance
in every month, every season and every year. What is more important is to keep down damage and repair
circumstance of unit in detail, it is convenient for technician to deal with error.
Maintenance record of the unit

Check the lubricant level Every day

Check the water-flow volume Every day
Power Volt and power Every day
Check the refrigerant amount Every day
Check the wiring and electric parts insulation condition Every season
Check and setup the temp. info Every season
Check the dry filter Every season
Change compressor oil filter Every 3000 Hours
Change the compressor axletree Every 40000 Hours

27
Modular Air-Cooled Screw Chiller

6 Trouble Shooting
Malfunction Possible cause Solution

A. Cooling
① . Atmosphere or other non-condensing gas
in the system;
② . Condenser fins are dirty or blocked;
③ . The condense air volume is not sufficient
or the condensing fan is malfunction;
④ . Air suction pressure is too high;
⑤ . The refrigerant is too much;
⑥ . The ambient temperature is too high.
⑦ . Inner system is dirty and blocked (e.g. one- it.
Discharge way valve, dry filter)
pressure is too ⑧ . S et value for high pressure stop is
high incorrect.
B. Heating
① . There is air or other non-condensing gas in
the system
② . Shell and tube heat exchanger scaling or
waterway system filter blocked.
③ . Water flow volume is small.
④ . Suction pressure is too high
⑤ . Heating is started when terminal load is too
small.
⑥ . S et value for high pressure stop is
incorrect.
Exhaust the air from the freon intake. If
needed, the unit is vacuumized again;
Cleaning the condenser fins;
To overhaul the condensing fan and get
back the operation;
Please see “Air suction pressure is too
high”;
Discharge the part refrigerant.
Check if installation environment for
unit contains well ventilation, and improve
Change the dirty components.
Check high pressure switch.
Exhaust the air from the freon intake. If
needed, the unit is vacuumized again;
Clean the shell and tube heat exchanger
and waterway system.
Adjust water flow volume.
Refer to “Suction pressure too high”.

Check high-pressure switch

① . Air suction pressure is too low Please see “Air suction pressure is too
Exhaust
low”
pressure is too
② . T he refrigerant is leak or charge is not Check the leakage and charge the freon
low
enough
① . Air exhaust pressure is too high Please see “Air exhaust pressure is too
high”
② . The refrigerant charge is too much Discharge the part refrigerant
Suction
③ . T he liquid refrigerant flows into the Check and adjust the expansion valve
pressure is too
compressor from the evaporator. to ensure the expansion valve sensor is
high
④ . The chilled water-in temp. is higher than closely touching air suction pipe and
the max. accepted value. completely insulated from the outside.

28
 Modular Air-Cooled Screw Chiller

A. Cooling
① . The ambient temp. is too low Check leakage and charge Freon.
② . Chilled water in temp is obviously lower Check installation circumstance.
than stipulated value.
③ . F low volume of chilled water is not
Check if water intake and outlet pipe
enough.
pressure at evaporator is too low, adjust
greater chilled water flow volume in
④ . System dirty and blocked (e.g. one-way proper.
valve, dry filter) Change blocked components.
Suction
⑤ . Set value for low-pressure stop is incorrect.
pressure is too
B. Heating
Check low-pressure switch.
low
① . Environmental temperature is too low.
② . System dirty and blocked (e.g. one-way
Change blocked components.
valve, dry filter).
Adjust to proper overheat temperature,
③ . E xpand valve is not adjusted or error
and check if there is leakage at expand
occurred.
valve sensor.
④ . Refrigerant is charged too less.
Adjust defrost set parameter.
⑤ . If defrost is normal.
⑥ . Set value for low-pressure stop is incorrect.

Check low-pressure switch.

① . The voltage is too high or low The voltage cannot exceed ±10% of the
rated voltage.
② . Air exhaust pressure is too high or low
Check air exhaust pressure and find out
the reason
Check water return temp. and find out
③ . Water return temp. is too high the reason
Compressor
Check the compressor current and
stops due to
compare it to the full load current
motor overload
④ . T he overload components have the stipulated on the specification
malfunction Check is installation space of unit
⑤ . The ambient temp. is too high contains well ventilation and improve it.

Check the corresponding resistors of the

⑥ . The motor or the terminal has short circuit.
motor and terminal.

① . The voltage is too high or low Check the voltage and it cannot exceed
the above prescribed limit.
Compressor ② . Air exhaust temperature is too high Check air exhaust temperature and find
stops due to out the reason
the action of ③ . The chilled water-in temp. is too high
Check the chilled water-in temp. and
the inner temp. find out the reason
controller ④ . T h e i n n e r t e m p . c o n t r o l l e r o f t h e
compressor has the malfunction
Check the freon leakage
⑤ . The refrigerant of the system is not enough

29
Modular Air-Cooled Screw Chiller

Noise of ① . T he liquid refrigerant can flow into the Adjust the charging refrigerant and
compressor is compressor from the evaporator. It can arise “liquid check if the expansion valve and the
large impact” degree of air suction superheat is normal
Recharge compressor oil.
② . Compressor lacks oil.

① . The overflow relay is tripping and the fuse Change the damaged components.
is burned.
② . The control circuit isn’t connected.
Check the control system wiring
③ . No current
Check the power supply
④ . High pressure protection or low pressure
Please see the above items, regarding
protection
the malfunction of air suction/exhaust
pressure.
⑤ . The winding of contactor is burned.
Change the damaged components.
⑥ . The phase sequence of the power source is
Compressor Connect the wires again, can adjust two
connected wrong
cannot start up wires among them
⑦ . Water system has the malfunction and
Check water system
water flow switch is broken
⑧ . The manual controller sends out alarm
Check the alarm type and adopt the
corresponding measures
⑨ . The on/off time of the manual controller is
Check the timer and set it again
set wrong
⑩ . T he temp. checked by the temp. sensor
exceeds the preset value.

① . No water in the system; Add water to the system;

② . Water switch error or not being correctly Change the water switch or reinstall it
installed; according to corresponding standard.
③ . Water pump error; Use spare water pump;
Water switch
④ . N ot complete vacuum of the water
protection Completely drain out things in the water
system;
system;
⑤ . Water volume is not enough and is lower
than the limit of the switch. Increase the water volume according to
the designation and inspection table.

30
 Modular Air-Cooled Screw Chiller

7 Attachments
Attached Table 1 : Inspection records before debugging
Min. dimension between the unit and the Recommended
Location
ambient barriers value ＞ 2m

Foundation (Cement/ steel structure) Dashpot

Installation
Guard mode (“ ∧ ”-type
The top point of air cylinder; The bottom Recommended
(Herringbone)/” ∨ ”-type
point of sunshade value ＞ 2m
(Herringbone reverse)
The state
Water flow (Water
The state of cut-off The state of drain valve (On/ of water The state of evacuation valve (On/
pump)
valve (On/Off) Off) filter (On/ Off)
（T/h）
Off)
Intake Outlet
The chilled
water pipe
system The value of hydraulic The value of Water flow Each cut-
pressure meter thermometer switch is Heat preservat off valve in Washing times of
Water quality
working condition the water the pipeline
Intake Outlet Intake Outlet normal or not pipes

Airtight space and heat

Smooth of air Exhaust The matching between the
Connected to fan coil insulation for user’s
Load supply outlet enough cooling capacity and the units
air conditioner
The voltage of power
Voltage Accepted
supply Accepted value: 360~400V %
fluctuation value: ＜ 3%
Power source （V）
(check it at Phase-to-phase insulation resistance Insulation resistance between three-phase and earth
the end of the Min. accepted
service cable.) Rab Rbc Rac Min. accepted value Rag Rbg Rcg
value

1 1

Insulation Phase-to-phase insulation resistance Insulation resistance between three-phase and earth
of the units Min. accepted
R12 R23 R13 Min. accepted value R1g R2g R3g
Routine (Check it in value
Inspection front of the
1 1
on user’s main breaker.)
supporting Phase-to-phase insulation resistance Insulation resistance between three-phase and earth
facilities Insulation of
Min. accepted
the compressor R12 R23 R13 Min. accepted value R1g R2g R3g
value
(Check it from
the terminal.) 1 1

Make-up
To vacuumize Max. accepted Maintenance time ＞
soldering of the 0.0080MPa
The cooling （MPa） value (min) 30min
pipeline
system
Balance pressure of system Balance pressure of Ambient temp.
I （MPa） system II（MPa） （℃）
Stopping
Three-phase supply Water-out temp.
Low pressure controller High pressure controller time of the
monitor （℃）
evacuation
Setting value
Moment Setting value Moment Setting
(Mpa) CO/ Setting value Amplitude Setting value
Check and (Mpa) (Mpa) (Mpa) value
HP
confirm the
preset value 0.15/0.05 0.05 2.60 0.2 380~400V 5S
of control &
protection Oil pressure difference
parts controller
Setting value Moment
(Mpa) (Mpa)

0.35 0.05

31
Modular Air-Cooled Screw Chiller

Attached Table 2: Inspection records on trial run and debug

Water temp.
Flow direction Full exhaust（Y/N）
Regular （℃）
checking Water Flow volume
before system （T/h） Water Intake Full load（Y/N）
operation pressure
90% Flow (Pa) Ambient temp.
Outlet
volume （℃）
Test the units
Pickup current （A） Startup state (Normal/Abnormal)
at starting state
High
Low pressure Error record Water-in
pressure Freezing temp.
Test the units
（℃）
after starting System Ⅰ Water-out
for 10min.
System Ⅱ Air-in temp.（℃）
Trial run
Test the units High
Low pressure Error record Water-in
after starting pressure Freezing temp.
for 30min. （℃）
(The water System Ⅰ Water-out
flow volume
should return
to the required System Ⅱ Air-in temp.（℃）
value.)

System
condition in
the running

Error handling
Flow control Finally, adjust water flow volume according to the Nominal
Water-out temp.
of the chilled water-in temp. and the load of user’s air conditioner. value
（℃）
water （T/h） 12/7℃
System Ⅰ --Water-out Water-out temp
Stop time The 2 nd stop
temp. at the stopping state at the restarting
（S） time（min）
（℃） state（℃）
Unloading
condition Stop time
System Ⅱ --Water-out
for the
temp. at the stopping state Runtime（min） 5S
evacuation
（℃）
Test （S）

System Ⅰ --Water-out Water-out temp

Stop time The 2nd stop
Adjustment temp. at the stopping state （S）
at the restarting
time（min）
records of （℃） state （℃）
water-out
temp. control Stop time
System Ⅱ --Water-out
on the spot for the
temp. at the stopping state Runtime（min） 5S
evacuation
（℃）
（S）
General
Emergency Special
Delivery train for the Notes
stop maintenance
operator

Summary

32
GREE ELECTRIC APPLIANCES, INC. OF ZHUHAI

Add: West Jinji Rd, Qianshan, Zhuhai, Guangdong, China, 519070

Tel: (+86-756) 8522218 Fax: (+86-756) 8669426
E-mail: gree@gree.com.cn www.gree.com