MANUAL FOR AIR COOLED INDUSTRIAL CHILLERS MODEL: UCS-10A

MANUAL FOR AIR COOLED INDUSTRIAL CHILLERS MODEL: UCS-10A

Universal Chilling Systems, LLC. 2 Unit Manual Contents 1. Specification 2. Transportation 3. Unit Installation 4. Electrical Installation 5. Commissioning 6. Troubleshooting Operation Manual Contents 1. Appearance of DM500B 2. Face of pages 3. User's inquiry operation 4. User's set 5. Unit Operation 6. Trouble disposal 7. Settings 8. Diagram of electrical connection

Universal Chilling Systems, LLC. 3 1.1 Product Description The UCS series Products are chillers that can produce cooling medium of temperature around 7º C or - 5º C, and lower on requirement of our customers. The chillers are applicable to the industries of textile, chemicals, machinery, electronics, medicine and health, food etc. Main components World famous brand refrigeration parts are employed for all products; World leading brand compressors High efficient heat exchangers of shell & pipe or copper & fin type Digital control system Multi-Protection devices for over loading, high and low pressure, phase lacking and water lacking etc.

Universal Chilling Systems, LLC. 4 1.2 Specifications Cooling Condition MODEL Chilled Water Inlet Temp. Chilled Water Outlet Temp. Ambient Temp. UCS-10A 12º C 7º C 35º C Nominal Cooling Capacity Power Supply KW 30 x 10³kcal/Hr 25.8 3P-440V-60Hz Type/QTY Fully Closed Scroll/1 piece Compressor Cooling Input Power(KW) 10.40 Cooling Operation Current(A) 15.10 Evaporator Chilled Water Flow(m³/h) 5.16 Interface Size DN40 Quantity 2 Condenser Fan Power/KW 0.64 Operation Current(A) 0.99 Safety Protection Device High &low voltage protection, current overload protection, antifreezing protection, electronical delay protection Power (KW) 1.1 Water Pump Current (A) 2.42 Head(M) 30 Water Tank Material 304SS Volume(L) 140 Length (mm) 1810 Overall Size Width (mm) 975 Height (mm) 1730 Weight /KG 435 Overall Unit Power/KW 12.78 Current(A) 19.5 Refrigerant Type R407C Notice: 1) Normal conditions: Chilled water inlet temperature 12º C, outlet temperature 7ºC, ambient temperature 35ºC 2) Standard power supply: 3P-440V-60Hz, proposed three-phase four-system, allowing voltage fluctuation -25~10%, frequency fluctuation ± 2%. 3) Host for the actual lift is pump lift host internal head loss minus. (1mH20=9.8kPa)

Universal Chilling Systems, LLC. 5 2. Transportation Only the bottom support is allowed to support the unit, and fort vehicle or crane vehicle is required to move the unit. The unit must be kept vertical in the transportation; the chains cannot touch the side heat exchanger, top, and side plates. 3. Installation 3.1. Positioning The unit must be installed where the air flow is good, in door sheltered from raining. The space on the top must be larger than 2 meters, which is good enough to bring the hot air to environment. The space at the air inlet side of the unit must be larger than 1.5 meters that is necessary to normal operation of it. A strong, water level concrete base, with height over 20 cm is needed. The repair and maintenance space for man is to be left. The environment of the unit is -15~50 C, relative humidity 80%.

Universal Chilling Systems, LLC. 6 3.2 Air Duct An air duct is needed for the place where the air flow is not guaranteed. As shown below in the diagram. 3.3. Pipeline Installation The unit has been tested and inspected before delivery. What the users need to do is to just fix on its chosen position, connect to chilled water system, and power supply following the instructions. The water flow protection switch is necessary in the chilled water system to prevent accident of evaporator freezing broken in case there is no water or too less water in the pipe. It is recommended to fix the water flow switch outside the unit box. 4. Electrical Installation 4.1 The UCS Chillers have temperature controller and electrical control box in the unit, the work of electrical installation is only to connect the unit to power supply. 4.2 In case other control is needed, it must be done observing the local electrical standard and rules to guarantee the safety and stable operation. 4.3 Wire Selection It is recommended to select the wire thickness based on 1.25-1.3 multiple the total current of the chiller and other auxiliary facility as pumps etc. 4.4 Power Supply Requirement Voltage: Rated V -25~10%; Frequency: Rated Hz±2%; In case the Voltage is over the limit, it is not allowed to start the unit.

Universal Chilling Systems, LLC. 7 5. Commissioning 5.1. Check before Start Operation A. Check the environment that everything is normal. B. Check the power supply connection and the power supply to be sure the phase voltage conforms to the requirement. C. Check the water valves on the chiller water pipelines to be sure it is opened. Check the pumps are normal after pressure test, dirt discharge, air discharge and trial operation. D. Check the water level in the water vessel, the connection of the water supplementary inlet to the vessel, overflowing outlet is connected to the sewer. 5.2. Operation of Chilled Water System A. The chilled water need to be processed, to keep the PH value between 7.0-8.5. The higher alkalinity may accelerate the corrosion of the copper pipes, decrease the use time of the heat exchangers. B. After the unit and auxiliary facility are fixed, the water lines need to be processed for pipe cleaning, pressure test, air discharge, trial running of chilled water system etc. The unit commissioning and trial running can be started after confirmation of all is normal. C. Operation of the unit a. Over 12 hours of power supply on to the unit is needed before the unit start. b. Start order for the air cooled unit: chilled water pumps unit; c. Stop order for the air cooled unit: unit chilled water pumps; D. After start, judge the operation status by observing the high and low pressure gauges. The normal range of the high pressure is 8-16kg/cm2, the low pressure range is 1.5-4kg/cm2 a. For the air cooled unit, observe the rotation direction of the fans, if it runs in wrong direction, change the power supply wire connection to correct it before start. b. The set value of all protection devices must not be changed, they have been set at correct value before delivery. c. In case the error alarm is on and the unit is stopped, first press the stop button, the alarm will go off, and then check the trouble reason. Do not start forcibly before the trouble is eliminated. d. Do not stop the unit by cut off the main power supply unless in emergency case. If the unit needs to be stop for long time in winter, stop the unit first, then cut off the main power supply, and drain the water in the system. e. To guarantee the normal and stable operation of the unit, keep clean, tidy, and air flow in the machine rooms; clean the condensers periodically. 5.3. Maintenance A. Keep the clean of the condensers, clean it periodically and good air flow condition. B. Clean the condensers after a period of operation, especially for the dirty environment and the H/L differential pressure acts and refrigeration capacity deceased.

Universal Chilling Systems, LLC. 8 6. Troubleshooting Troubles Causes Solutions Cannot start High pressure too high Low pressure too low Frosty of suction line and/or compressor 1. Power supply is not available or voltage too low 2. Wrong Temperature set, the contactor is always off 3. Over load protection not recovered after cut off 1. Clear the electrical trouble, and provide the power supply on requirement 2. Make correct temperature set 3. Press the recovery button 1. Too dirty of the condensers 1. Clean the condensers 2. Too much refrigerant filled 2. Discharge some refrigerant 3. The expansion valve opens too small 3. Adjust the opening of the valve 1. Too little of the refrigerant. 1. Leakage check, increase refrigerant and adjust the valve 2. Blockage of the filter. 2. Clean or change the filter 3. The expansion valve opens too small 3. Adjust the opening of the valve 1. The expansion valve opens too large 1. Adjust the opening of the valve 2. Too much refrigerant filled 2. Discharge some refrigerant 3. Load too small 3. Increase the load

Universal Chilling Systems, LLC. 9 Operation Manual of Electrical Control of UCS Series Industrial Chillers 1. Appearance of DM500B 2. Face of pages 3. User's inquiry operation 4. User's set 5. Unit Operation 6. Trouble disposal 7. Settings 8. Diagram of electrical connection Contents

Universal Chilling Systems, LLC. 10 1. Appearance of DM500B The panel as fig 3-1, with 12 keys, 6 of them is lighted; the panel dimension is 196mm x 115.5mm W 2. Face of Pages 2.1. Start Display WELCOME TO OUR CONTROLLER 9 Air-Water Cool 500ATYF02V1002 First page shows "welcome" count down is shown at the right bottom in reverse color. The second page, first line shows model and mode, second line shows version number of the program at the left, and count down is shown at the right bottom in reverse color. 2.2. Main Face After the count down if finished, the user's main face is shown as below: TIN: l0 C T.OUT 5 C SET: 5 C STOP Means turn up, means turn down.

Universal Chilling Systems, LLC. 11 If the sensor of T.out or T.in shows no temp, the show will be C, ERR shows ºC a. Welcome show WELCOME TO OUR CONTROLLER b. Model show (Water cooled chiller), mode (cool only, Heat pump, E heating), run mode (cool, heat, fan, water, defrost) and start type (manual, timing). Air Water. M. H.PUMP COOL c. Face show: show main temp (T.in, T.out), set temp and running status (run, time delay, stop). The reverse color shows the control temp for energy adjustment (T.in as control temp as fig below). T.IN means temperature of returning water or air; T.OUT means temperature of out water or air 3. User s Inquiry Operation Press ENQIRE, shows as below: TROUBLE LIST TROUBLE HIS. This system includes inquiring content as below: TROUBLE LIST TROUBLE HIS. RUN TIME CHECK CLOCK CHECK Select by or, enter each page by OK, by RETURN come back to main face.

Universal Chilling Systems, LLC. 12 1) TROUBLE LIST In inquire page, select TROUBLE LIST by and, press OK to enter TROUBLE LIST show. INQUIRE COMMU.ERR The second line shows trouble. Press RETURN to up level menu. 2) TROUBLE HIS. In inquire page, select TROUBLE HIST. by and, press OK to enter TROUBLE HIST show. 1: INVERSE PHASE 2: CM1 ERR The max number of historical trouble is 8, with the present trouble placed in front lines. Press RESET for 3 S to remove the historical trouble. 3) RUN TIME CHECK In inquire page, select RUN TIME CHECK by and, press OK to enter RUN TIME CHECK show. COM1: 0 H 0 H COM2: 0 H 0 H The accumulated run time will be showed according to the compressor number. 4) CLOCK CHECK In inquire page, select CLOCK CHECK by and, press OK to enter CLOCK CHECK show. 2009/01/04 13:14:40 WED. The time show here is the real time, the start and stop time will act according to this time. Press SET to enter time set state for hour, minute setting.

Universal Chilling Systems, LLC. 13 4. User s Set In user s main face, press SET entering user s set face, the show as below: SET T.OUT: SET Mode: 5º C COOLING The set face includes: Set T. OUT: 5 C (shows T. OUT set when the T. OUT is to be controlled.) Set mode: cool On/Off: M. (M/week timing/timing once) TIMING SET Use set Only 2 will be shown, other contents can be inquired by and. Select one of the 4 items, change it by <+>, <->, the change will go into effect immediately. The change will be kept after power off. It will return to main face in this face more than 30 S without touch. After the change, press RETURN to come back to main face. M/week timing/time once: M means the automatic on and off is stopped; week time means to start or stop on set time on the set week day. Time once means to start or stop on set time each day in the set period. If the clock is set as 0, it means no timing in the period. If the timing once is selected, when the set date is expired, press SET, the present date will set automatically. When select the week timing and timing once at the same time, the priority will be to the timing once. i) The TIMING SET In the user's page, select TIMING SET by and, press OK to enter TIMING SET. a) If the ON/OFF is set to M, the TIMING SET will not be available. b) If the ON/OFF is set to WEEK TIMING, it shows below: WEEK TIMING SET DATE TIMING SET c) If the Timing is set to timing once, it shows below: DATE TIMING SET CLOCK TIMING SET In the B face, select WEEK TIMING by and, to set WEEK TIMING, press OK, then show will below: SUN. > MON.

Universal Chilling Systems, LLC. 14 Select weekday by and, press OK to change the state. If there is > before the weekday, it means on the weekday the automatic ON/OFF will act, if no >, the ON/OFF will not be acted automatically. In C face, select DATE TIMING by and, press OK to enter DATE TIMING, the show is below: DATE: 2005 / 01 / 01 2005 / 01 / 01 Select the item to be changed by and, press <+>, <-> to change the item. In b or c face, select SET CLOCK by and, press OK to enter time set page as below: ON: OFF: 07h 59 m 22h 30 m Select the item to be changed by and, press <+>,<-> to change the item. The data will be kept in memory after the power is off. After the change, press RETURN to come back to menu of up level. ii) USE SET In user's page, select USE SET by and, it will show as below: COMP.1: NONE COMP.2: USE The show depends on the number of compressor and heater in RUN SETTINGS SYS. SETTINGS and mode of OUTPUMP. The energy adjustment and trouble check will not be available in case the compressor or heater is set at NONE. Select the item to be changed by and, press <+>,<-> to change the item. The data will be kept in memory after the power is off. After the change, press RETURN to come back to menu of up level.

Universal Chilling Systems, LLC. 15 5. Settings Default password of repairman's: 1 2 3, that is the key: START, INQUIRE, SET. When system is in STOP page in the user's main face, press and <+> at the same time, it will enter SYS. SETTINGS page as below. INPUT PASSWORD **** Then input the password, press OK. If is the wrong password, the show will be below: ERROR! TRY AGAIN Press RETURN to come back to main face. The password is two levels, after password of manufacturer s or repairman s is put in, it will enter RUN SETTINGS menu as below: 1: RUN SETTINGS 2: MODIFY PWD When enter by the repairman's password, there will be 2 items in front of the menu. 1: RUN SETIINGS 2: MODIFY PWD. I. RUN SETTINGS In RUN SETTINGS, select RUN SETTINGS by and, press OK to enter RUN SETTINGS show below: 1: SYS. SETTINGS 2: SETTINGS 1 There are 10 items for RUN SETIINGS, and there are sub-items under each item. The 10 items are below: 1. SYS. SETTINGS (Manufacturer's password can set all; repairman's password can change only the items of POINT and SWITCH) 2. TIME SETTINGS 1 3. TIME SETTINGS 2

Universal Chilling Systems, LLC. 16 4. TEMP. SETTINGS 1 5. TEMP. SETTINGS 2 6. TEMP. SETTINGS 3 7. TEMP REVISE 8. INPUT SET 1 9. INPUT SET 2 10. SENSOR SET II. MODIFY PWD Select MODIFY PWD by and, press OK to enter MODIFY PWD as below: All keys on the panel can be taken for password except OK and RETURN. A. When enter by the manufacturer's password, only the manufacturer 's password can be modified, show is below. First new password show: INPUT5-6BIT PWD ****** The manufacturer's password must be 5-6 Bit; after the new password is in, the show is below: PASSWORD CHECK! ****** If the password is the same for both times, the show is below: PASSWORD ACCEPT PRESS ANY KEY! If the check password is not the same as the new password, return to new password (manufacturer's page). B. When enter by the repairman's password, only the repairman's password can be modified, show is below: First new password show: INPUT1-4BIT PWD ****

Universal Chilling Systems, LLC. 17 The repairman s password must be 1-4 Bit; after the new password is in, the show is below: PASSWORD CHECK! ****** If the password is the same for both times, the show is below: PASSWORD ACCEPT PRESS ANY KEY! If the check password is not the same as the new password, return to new password (repairman s page). 6. Unit Operation 6.1. Start Press the START to start the unit: start the pump time delay start the cooling fan time delay start the compressor. All the delay time can be changed. 6.2. Stop Press the STOP to stop the unit. Stop the running compressor time delay stop the cooling fan time delay stop the pump. The delayed time can be changed. In the delaying period, the user's page show: time delay, after the delay, the show is stop. 6.3. Trouble and Cause i) Compressor breakdown: the cause may be compressor overload, overheat, too high or low ii) pressure. Unit breakdown: Pump overload, water lack, error of sensors of in and out water, error of power etc. 6.4. Run Indication The run indicator will close after all system is running; it will open after all equipment stop. 6.5. Alarm The alarm will be on if some system is out of order; if all trouble is disposed, the alarm will be off.

Universal Chilling Systems, LLC. 18 7. Trouble Disposal When trouble occurs, the alarm will work and the reset indicator flickers. Press the sound erasing key, the alarm sound will stop; the reset indicator flickers continue. After the trouble is disposed, press RESET and the trouble record is erased. When all trouble is reset, the reset indicator will go off. RESET is available in all pages of user's face. When the system occurs trouble from the no trouble state, it will enter error inquire automatically. After it enters the AUTOMATI C INQUIRE, it will not return even if no key is pressed 8. Settings Settings may vary with different types of unit. Main menu Sub menu Content AIR-WATER 1: SYS. SETTINGS SYS. AIR-WATER,W-W SYS.WATER-AIR, AIR-AIR AIR-WATER MODE COOL, HEATER, H.PUMP COOL OUTPUMP NONE, CIRCLE, RECYCLE NONE COMP.NUM Max 4 - Min 1 2 ELEC.H.NUM Max 3 - Min 1 0 POINT T.IN, T.OUT T.OUT SWITCH SW.1, SW.2 SW.1 Co. None None 2:TIME SETTINGS 1 PROTECT Max 255S; Min OS ; 180S CYCLE Max 255S; Min OS; 120S COOLER_D Max 255S; Min OS ; 15S CHILLER_D Max 255S; Min OS; 30S ERR.DELAY Max 99S; Min OS; 2S SCR.SAVER Max 255M; Min OM; 30M 4:TEMP SETTINGS 1 ADD DIF Max 25º C Min 1º C 2 SUB DIF Max 25º C Min 1º C 2 LOWER_L Max 35º C Min -20º C -10 LOW T Max 20º C Min -20º C -7 LOWT.RE Max 25º C Min -20º C -5 7: TEMP REVISE IN Max 9º C Min -9º C 0 OUT Max 9º C Min -9º C 0 8: INPUT SET 1 CM HP Normally closed, Normally open Normally closed CM LP Normally closed, Normally open Normally closed CM ERR Normally closed, Normally open Normally open PW ERR Normally closed, Normally open Normally open

Universal Chilling Systems, LLC. 19 9: INPUT SET 2 PUMP LACK Normally closed, Normally open Normally closed FAN OVERL. Normally closed, Normally open Normally open FAN OVERH. Normally closed, Normally open Normally open P_SWITCH Normally closed, Normally open Normally closed 10: SENSOR SET IN Use, No Use Use OUT Use, No Use Use

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