On the market climate control equipment Chillers are in particular demand. They are refrigeration devices whose main task is to maintain the microclimate. The equipment is vapor compression and is installed indoors for various purposes. During the operation of the devices, the air is cooled, filtered and heated.
Devices can be included in the basic package modern systems conditioning. Technologies make it possible to produce two types of chillers, in which the condenser is operated using water or air. These two methods are in quite wide demand. But air-cooled devices are the most popular, due to the lack of need for coolant. In order to install such a unit, it is necessary to familiarize yourself with the technology of the work.
Chiller installation is quite complex look works that require a special approach and high qualifications. From correct installation The efficiency of operation and the duration of its operation will depend. Considering the main stages, we can highlight the design of the system, determination of the installation location, and calculation of the load on the structure.
The next step is to prepare the support frame or base. The installation instructions for the MTA AS299 N chiller, like devices of any other brand, provide for rigging work and installation of the unit itself. The system is connected to the coolant, as well as the power supply network.
The final stage is then commissioning. During design, calculations of heat inputs and coolant flows are carried out. This data allows you to select a machine and its design. After approval of the type of chiller, you should decide on the installation location and prepare it correctly.
Main types design- unit indoor installation and monoblock devices for outdoor installation. Internal equipment may include a water-cooled or remote condenser. If you have to work with a monoblock chiller, then a support frame is made for it, which must have a certain height. It protects equipment from precipitation and evenly distributes the load on the structure. The support must be carried out in compliance with all the rules, because noise and abnormal vibrations may appear.
Installation of a chiller, which will be located from the inside, involves organizing a site. Refrigeration devices operate at significant levels sound pressure, therefore it is not worth placing them near office and residential premises. It is important to select and correctly install vibration supports that will reduce the level of vibration transmitted to building structures.
One of the most critical stages is connecting the equipment to the coolant and power supply. In order to ensure normal operation of the system, you should follow the installation recommendations and understand which components should be in the hydraulic circuit.
Installation of the chiller is accompanied by the use of certain elements. A bypass and a filter with a shut-off valve should be located along the flow of the coolant. This measure will prevent contamination of the heat exchanger when flushing the system, otherwise you may experience equipment failure.
You will also need a balancing valve, which will be located at the outlet of the evaporator. It is required to regulate water flow and bring values to normal. Shut-off valves will be located at the outlet and inlet of the chiller. If the system depressurizes, the coolant will have to be drained.
Care should be taken to ensure that they are installed at the highest points of the system. Installation of an absorption chiller is carried out in several stages. One of them is the installation of thermometers and pressure gauges before and after the equipment described. This will allow you to monitor the temperature and degree of contamination of the heat exchanger.
A filter is installed in front of the pump. It must face the direction of flow of the coolant. This will prevent mechanical damage in the area of the pump impeller. The emergency valve and damper expansion tank must be located in front of the pump. This will eliminate the increase and decrease in pressure at the pump inlet.
Installation instructions for the chiller are included with the equipment. After reading it, you can find out that the device can be placed at ground level or on the roof, but in these cases, you should ensure that there is space for ventilation. The unit must be located taking into account the requirements for vibration and noise.
The device should be protected from exposure to ultraviolet radiation by placing it away from chimneys. It should not be exposed to atmospheric air which could cause corrosion of the condenser coils and copper pipes. If access to the chiller is possible for unauthorized persons, then measures should be taken to limit it. For this purpose, protective devices are used.
The chiller is installed on a base whose height is 300 mm or more. It is important to ensure there are drainage channels that will remove water and deal with leaks. When the unit is located at ground level, the base must be mounted on a concrete foundation, which is laid below the soil freezing line. The base should not be in contact with the foundation of the building to eliminate vibrations and noise.
When installing the bases, it is necessary to ensure the presence of holes that will allow fastening to the foundation. When installed on the roof, the latter must support the weight of the chiller and operating personnel. The device can rest on a base or a steel frame.
The steel channel should be aligned with the shock absorber mounting holes. The channel must have a width that is sufficient for mounting the shock absorber. When installing a chiller, it is important to avoid obstacles to connecting water pipes and wires. The water inlet must be free of heat sources, steam, harmful gases and noise. The equipment coming from the equipment is hot and cold air should not affect the environment.
At installation work should be considered technological features and requirements. For example, the volume for installation should not be limited by the dimensions of the machine, it should include additional parameters, including space:
As for the first recommendation, it is true for chillers that require air intake and exhaust for operation. There are also safety regulations, they dictate the rules in which space for maintenance and access must be taken into account.
No matter how high-quality the equipment is, one should take into account the likelihood that the device may fail. Therefore, space should be left for replacement of parts and repairs, which may be required for compressors and shell-and-tube heat exchangers.
Installation of chillers and fan coil units allows for smooth operation of the system. The work involves the use of thermally insulated pipelines. If there is no insulation, the efficiency of the system will drop significantly. Fan coil units have individual piping units, with which you can adjust the performance in terms of heat and cold production.
The refrigerant flow is regulated by special fittings. If it is necessary to separate the coolant and cold agent, the water should be heated in a separate heat exchanger. The scheme is supplemented circulation pump. To smoothly regulate the fluid flow when installing the piping circuit, you should use a three-way valve.
If the building has a two-pipe system, then heating and cooling will occur due to the chiller. In order to make heating more efficient, fan coil units are connected during the cold period and supplemented with boilers. If we compare two-pipe system with a four-pipe heat exchanger, then the latter contains the two mentioned units. At the same time, the fan coil operates for heating and cooling, using in the first case the liquid that circulates in the heat exchanger system.
If you decide to install a chiller and fan coil in the building, installation of a cooling system in Moscow can be carried out. The cost of carrying out such work will be mentioned below. Speaking of the above, it can be noted that during installation one of the heat exchangers is connected to a pipeline with refrigerant, while the second is connected to a pipe with coolant. The heat exchanger must have an individual valve that is controlled by a remote control. If a similar scheme is used, the refrigerant does not move with the coolant.
Installation of chillers in Kaliningrad can be carried out with the help of specialists. Prices in Russia are approximately the same everywhere. The final cost will depend on the power of the equipment. If it does not exceed 100 kW, then you will have to pay 16,000 rubles. With an increase in the mentioned parameter to 250 kW, the price increases by 50 rubles. for every kilowatt. When purchasing a fan coil unit whose power does not exceed 6 kW, you will pay 2,900 rubles for its installation.
What's happened ? A chiller is a refrigeration unit used for cooling and heating liquid coolants in central systems conditioning systems, which can be air supply units or fan coils. Basically, a chiller is used to cool water in production - it cools various equipment. By the water better characteristics compared to a glycol mixture, so running on water is more efficient.
Wide range power makes it possible to use the chiller for cooling indoors various sizes: from apartments and private houses to offices and hypermarkets. In addition, it is used in Food Industry for drinks, in the sports and health sector - for cooling skating rinks and ice rinks, in pharmaceuticals - for cooling medicines.
The following main types of chillers exist:
An industrial chiller consists of three main elements: a compressor, a condenser and an evaporator. The main task of the evaporator is to remove heat from the object being cooled. For this purpose, water and refrigerant are passed through it. As the refrigerant boils, it takes energy away from the liquid. As a result, water or any other coolant is cooled, and the refrigerant is heated and goes into a gaseous state. After this, the gaseous refrigerant enters the compressor, where it acts on the compressor motor windings, helping to cool them. There, the hot steam is compressed, again heating up to a temperature of 80-90 ºС. Here it is mixed with oil from the compressor.
In the heated state, freon enters the condenser, where the heated refrigerant is cooled by a flow of cold air. Then the final cycle of work begins: the refrigerant from the heat exchanger enters the subcooler, where its temperature decreases, as a result of which the freon turns into a liquid state and is supplied to the filter drier. There it gets rid of moisture. The next point on the path of refrigerant movement is the thermal expansion valve, in which the freon pressure decreases. After leaving the thermal expander, the refrigerant is steam low pressure in combination with liquid. This mixture is fed to the evaporator, where the refrigerant boils again, turning into steam and superheating. The superheated steam leaves the evaporator, which is the beginning of a new cycle.
#1 Compressor
The compressor has two functions in refrigeration cycle. It compresses and moves refrigerant vapor in the chiller. When vapor is compressed, pressure and temperature increase. Next, the compressed gas enters where it cools and turns into a liquid, then the liquid enters the evaporator (at the same time its pressure and temperature decrease), where it boils, turns into a gas, thereby taking heat from the water or liquid that passes through the evaporator chiller. After this, the refrigerant vapor enters the compressor again to repeat the cycle.
#2 Air-Cooled Condenser
An air-cooled condenser is a heat exchanger where the heat absorbed by the refrigerant is released into the surrounding space. The condenser usually receives compressed gas - freon, which is cooled and, condensing, passes into the liquid phase. A centrifugal or axial fan forces air flow through the condenser.
#3 Relay high pressure(High Pressure Limit)
Protects the system from overpressure in the refrigerant circuit.
#4 High Pressure Pressure Gauge
Provides a visual indication of refrigerant condensation pressure.
#5 Liquid Receiver
Used to store freon in the system.
#6 Filter Drier
The filter removes moisture, dirt, and other foreign materials from the refrigerant that would damage refrigeration system and reduce efficiency.
#7 Liquid Line Solenoid
Solenoid valve is simply an electrically controlled shut-off valve. It controls the flow of refrigerant, which is closed when the compressor stops. This prevents liquid refrigerant from entering the evaporator, which could cause water hammer. Water hammer can cause serious damage to the compressor. The valve opens when the compressor is turned on.
#8 Refrigerant Sight Glass
The sight glass helps to observe the flow of liquid refrigerant. Bubbles in the fluid flow indicate a lack of refrigerant. The moisture indicator provides a warning if moisture enters the system, indicating that maintenance is required. The green indicator does not indicate any moisture content. And yellow indicator signals indicate that the system is contaminated with moisture and requires maintenance.
#9 Expansion Valve
A thermostatic expansion valve or expansion valve is a regulator whose position of the regulating body (needle) is determined by the temperature in the evaporator and whose task is to regulate the amount of refrigerant supplied to the evaporator, depending on the superheat of the refrigerant vapor at the outlet of the evaporator. Therefore, at any given time, it must supply only such an amount of refrigerant to the evaporator that, taking into account the current operating conditions, can completely evaporate.
#10 Hot Gas Bypass Valve
Hot Gas Bypass Valve (capacity regulators) are used to match the compressor capacity to the actual evaporator load (installed in the bypass line between the low and high pressure sides of the refrigeration system). The hot gas bypass valve (not included as standard on chillers) prevents compressor short cycling by modulating compressor output. When activated, the valve opens and diverts hot refrigerant gas from the discharge into the liquid refrigerant stream entering the evaporator. This reduces the effective throughput systems.
#11 Evaporator
An evaporator is a device in which a liquid refrigerant boils, absorbing heat as it evaporates, from the coolant passing through it.
#12 Low Pressure Refrigerant Gauge
Provides a visual indication of refrigerant evaporation pressure.
#13 Low Refrigerant Pressure Limit
Protects the system from low pressure in the refrigerant circuit to prevent water from freezing in the evaporator.
#14 Coolant Pump
Pump for circulating water through a refrigerated circuit
#15 Freezestat Limit
Prevents liquid freezing in the evaporator
#16 Temperature sensor
Sensor that shows the water temperature in the cooling circuit
#17 Coolant Pressure Gauge
Provides a visual indication of the coolant pressure supplied to the equipment.
#18 Automatic topping up (Water Make-Up Solenoid)
It turns on when the water in the tank drops below the permissible limit. The solenoid valve opens and the tank is filled from the water supply to the desired level. The valve then closes.
#19 Reservoir Level Float Switch
Float switch. Opens when the water level in the tank decreases.
#20 Temperature Sensor 2 (From Process Sensor Probe)
A temperature sensor that shows the temperature of the heated water that returns from the equipment.
#21 Evaporator Flow Switch
Protects the evaporator from freezing of water in it (when the water flow is too low). Protects the pump from dry running. Indicates that there is no water flow in the chiller.
#22 Capacity (Reservoir)
To avoid frequent starts of compressors, use a container of increased volume.
A chiller with a water-cooled condenser differs from an air-cooled one in the type of heat exchanger (instead of a tube-fin heat exchanger with a fan, a shell-and-tube or plate heat exchanger is used, which is cooled by water). Water cooling of the condenser is carried out with recycled water from a dry cooler (drycooler) or cooling tower. In order to save water, the preferred option is to install a dry cooling tower with a closed water circuit. The main advantages of a chiller with a water condenser: compactness; Possibility of indoor placement in a small room.
Is it possible to use a chiller to cool liquid per flow by more than 5 degrees?
The chiller can be used in a closed system and maintain a set water temperature, for example, 10 degrees, even if the return temperature is 40 degrees.
There are chillers that cool water through flow. It is mainly used for cooling and carbonating drinks, lemonades.
What is better: chiller or dry cooler?
The temperature when using a dry cooler depends on the temperature environment. If, for example, it is +30 outside, then the coolant will be at a temperature of +35...+40C. Drycoolers are used mainly in the cold season to save energy. The chiller can achieve the desired temperature at any time of the year. It is possible to manufacture low-temperature chillers to obtain liquid temperatures with negative temperature to minus 70 C (the coolant at this temperature is mainly alcohol).
Which chiller is better - with a water or air condenser?
The water-cooled chiller is compact in size, so it can be placed indoors and does not generate heat. But cold water is required to cool the condenser.
A chiller with a water condenser has a lower cost, but may additionally require a dry cooling tower if there is no water source - a water supply or a well.
What is the difference between chillers with and without a heat pump?
A chiller with a heat pump can operate for heating, that is, not only cool the coolant, but also heat it. It must be taken into account that as the temperature decreases, heating worsens. Heating is most effective when the temperature drops at least minus 5.
How far can an air condenser be moved?
Typically the capacitor can be carried up to a distance of 15 meters. When installing an oil separation system, the height of the condenser is possible up to 50 meters, provided correct selection diameter of copper lines between the chiller and the remote condenser.
Until what time minimum temperature is the chiller working?
When installing a winter start-up system, the chiller can operate up to an ambient temperature of minus 30...-40. And when installing arctic fans - up to minus 55.
It is used if the temperature difference ∆T l = (T L - T Kl) ≤ 7ºС (cooling of technical and mineral water)
It is used if the temperature difference ∆T l = (T L - T Kl) > 7ºС or for cooling food products, i.e. cooling in a secondary gasket heat exchanger.
For this scheme, it is necessary to correctly determine the flow rate of the intermediate coolant:
G x = G x n
G x – mass flow rate of intermediate coolant kg/h
Gf – mass flow rate of cooled liquid kg/h
n – circulation rate of the intermediate coolant
n =
where: C Рж – heat capacity of the cooled liquid, kJ/(kg´ K)
C Рх – heat capacity of the intermediate coolant, kJ/(kg´ K)
∆T x = (T Nx – T Kx)– temperature difference of the intermediate coolant in the evaporator
Before you start operating the equipment, carefully read the chiller operating manual, which contains very important information about the placement, installation of the chiller, the conditions for using chillers and the care of the water-cooling unit.
Since the chiller operating manual is a source of information about the conscious and safe operation water cooling unit, it must be preserved.
The manufacturer is not responsible if users of the installation do not comply with the information provided below:
The operating instructions have been prepared in accordance with Directive 98/37/EC of the European Union and standard EN 60204-1, 1997 for the purpose of using installations made according to the latest technologies, with maximum safety and maximum performance.
This instruction manual has been prepared to ensure safe and effective use device manufactured using new technologies in accordance with the standards established in Turkey.
The service life of the device is set by the Ministry of Industry at 10 years.
The complete water cooling unit is used for machines for the production and forming of plastic, soles, metal products, for extruders, in the textile and chemical industries, dairies, any industrial and production complexes where cold water is required, as well as in air conditioning systems.
The devices are manufactured in different capacities - 18 different types, with a capacity starting from 3,000 kcal/h. up to 320,000 kcal/h.
All system units are installed on a durable and corrosion-resistant frame in compliance with the necessary safety measures. After installation, all pressure-bearing parts are tested for leaks.
During the manufacture of the equipment, necessary precautions have been taken to protect the equipment from external influences(corrosion, impacts, pressure).
Due to the fact that the equipment has a large mass, it must be lifted and moved using a winch or hoist. There are no special notes regarding transporting equipment using a lift, just make sure that the equipment is well balanced on the lift pins.
When transporting equipment using a winch, you should tie a belt of appropriate strength around the bottom beam of the equipment, and then hook it to the center of gravity.
If the water cooler will be inoperative for a long time, some operations should be carried out before doing so.
The incoming electricity must be turned off and the power cable must be disconnected. The water in the cooling system must be drained through the valve.
To protect the equipment from dust and dirt, it should be covered.
Do not place any weight on the unit.
The equipment should not be stored tilted.
The main consideration for the equipment is the location in which it will be placed. The place in which the equipment will be placed must be cool, well ventilated, away from heat sources, and not exposed to direct sunlight.
If the equipment is located in a hot, poorly ventilated place, then the excess hot air coming from the equipment must be disposed of using a special air duct. Otherwise, the equipment, as a result of greater load, will consume excess electricity. Therefore, carrying out this procedure will be useful for you.
If you are faced with the need to construct an air channel, it is recommended to place the equipment in a place closest to external environment, in order to minimize the distance for the release of hot air.
It is advisable to use a separate room for installing chillers. Select a site for installing the chiller, taking into account its dimensions and weight. It is not allowed to install the chiller in unheated premises and rooms where the temperature can drop below + 5°C.
- The room should be easily accessible and well lit.
- To be able to maintain and repair it is necessary to provide minimum distance between equipment 1.5 meters and at least 1 meter to protruding parts of the walls.
1. According to the operating temperature of the chiller, select a room in which the temperature will be maintained from + 5°C to +30°C. It is necessary to ensure the necessary ventilation of the room. Room temperatures below +5°C are unacceptable for operation and storage of the chiller.
2. In case of insufficient ventilation, it is necessary to install a casing to remove hot air outside. Do not allow cooling air to recirculate. To do this, it is preferable to do the air intake and outlet according to to different parties premises
3. When making a casing that removes hot air, please note that its cross-section must be no less than the outlet cross-sectional area on the chiller. The length of such a casing should not exceed 4 meters and have no more than one turn. Great length and large quantity turning the casing creates great resistance to air flow and will lead to insufficient cooling.
4. If it is impossible to manufacture casings, you should install exhaust fan the same capacity as the chiller condenser fan in close proximity to the hot air outlet from the chiller.
5. Passage section clean air should be 1.5 -2 times larger than the inlet cross-section on the chiller.
6. Protect the premises from explosive and corrosive gases.
The equipment operates on AC electric current, whose voltage is 400 V and whose frequency is 50 Hz.
The input terminals located on the control panel must be connected to the type of electrical cable indicated on the label located on the inside panel, the connection must be made in accordance with EN 60204-1. Before supplying power to the installation, it is necessary to protect the power line with a fuse with the capacity indicated on the panel plate.
Connection electric cable and fuses should only be carried out by responsible personnel.
The installation must be provided with a grounding line and connected to the specified terminals.
Depending on the type of equipment, water pipes of different diameters inside the equipment should be extended with pipes of the same diameters outside the equipment and connected to your system.
In order to ensure water supply to the equipment, a pipe of diameter should be brought to the place marked “power” on the back of the installation and equipped with a valve.
a) Water pump switch.
Used to turn the water pump on and off. To operate the cooling system, the water pump must be running and circulate water through the system.
b) Compressor switch.
Used to activate and disable cooling system functions.
c) Thermostat switch.
Used to regulate tank temperature cold water. Multifunctional sensor, shows the current temperature if no button is pressed and no alarm is given. In order to set the desired temperature, read the information about using the thermostat, which is given in the application.
1) Condenser fan in action.
Indicates that the fan motors are powered.
2) The thermal fuse of the condenser fan has blown.
This signal is used in cooling groups with high capacity. If the fans used in the cooling group operate at a voltage of 400 V, then they are protected from sudden voltage drops and loss of one of the phases by a thermal relay located on electrical panel. If this signal lights up, press the reset button for the fan thermal relay located on the electrical panel.
3) Crankcase heater in action.
When the compressor crankcase heats up, this signal comes on. This time is the compressor stop period.
4) Frost thermostat warning light.
Reduced water temperature is a period of interruption of work. If the water temperature drops below the adjusted one, this entails stopping the entire cooling system. Once the water temperature reaches the required level, the cooling system will come into operation automatically.
5) Water flow signal.
If there is no water flow in the heat exchanger or the flow has decreased, the cooling system turns off automatically. This means the system is clogged or the water pump is leaking air.
6) Thermal fault of the water pump.
Designed to prevent damage to the electric motor of the water pump, which can be caused by sudden voltage changes and the absence of one of the phases. If this signal comes on, press the water pump thermal relay reset button.
7) Water pump in action.
Once the water pump fuse is turned on, the water pump starts working. This signal means it is working.
8) The thermostat is set to automatic mode.
The cooling system turns off automatically after its temperature reaches the one that was set on the thermostat. Until the system comes into operation again, this signal remains on, which means that the system has reached the desired temperature.
9) Phase loss signal.
This equipment operates on electricity, voltage 380 V and frequency 50 Hz, in the event of sudden voltage changes (over 10%) or in the absence of one of the phases, the cooling system turns off automatically using a phase loss relay located on the electrical panel. After the cause of the work stoppage is eliminated, the system starts working automatically.
10) High low pressure signal.
Indicates that the gas pipes or condensers are clogged, there is a refrigerant leak, the temperature working environment system has risen higher permissible level and the system automatically turned off.
11) Thermistor signal.
This signal lights up if the thermal thermistor in the engine compartment of the compressor has interrupted the operation of the motor. The thermal thermistor is designed to protect the motor winding from overheating in the event of prolonged operation of the motor. In this case, you should wait until the engine cools down.
12) Oil pressure switch signal.
This signal is used in cooling groups of type GRS 1505 and higher. If the compressor is not lubricated or the oil level drops below the permissible level, the system stops automatically. In this case, you should contact the manufacturer.
13) Compressor thermal fault.
In order to protect the compressor electric motor from voltage surges and phase loss, the electrical panel is used as additional protection This thermal relay is installed. In the cases described above, this relay interrupts electrical circuit. In order for the system to work, you must press the reset button located on the thermal relay.
14) Compressor in action.
Some time after the compressor fuse is turned on, the cooling system is activated and this signal means that the cooling system is working.
Check that the water container is filled to the correct level.
- Check the grounding of the equipment.
- Make sure that the fuse placed before installation on the power cable and the fuses on the electrical panel are turned on.
- Make sure that all three phases are connected to the terminals located on the electrical panel. Do not forget that when connecting electricity to the cooling group for the first time, or after the equipment has been idle for a long time, you must wait at least 8 hours.
- Check the thermostat settings.
Turn on the circulation pump several times in short intervals. Make sure the motor rotates in the specified direction. Otherwise, swap the two power wires connected to the terminals on the electrical panel.
After the water pump begins to rotate in the required direction, it pumps water to the cooled body, which will result in a decrease in the water level in the tank. If the water level drops below half, turn off the motor and do not turn it on until the water is replenished. This procedure can be repeated 1-2 times.
If the pump does not pump water into the system, open the air bleed valve located on top of the pump and bleed air from the system.
Once you are sure that water is circulating normally in the system, turn the compressor switch to on. The equipment will begin cooling.
If any of the fuses shuts down the system, investigate the cause and only then operate the system. Under no circumstances continue to operate by pressing the reset button.
If the machine does not turn off for any reason, it can continue to work.
A digital thermometer-thermostat will automate the operation of your equipment.
If, after putting the equipment into operation, none of the alarms come on, and the equipment itself is operating smoothly, this means that all requirements have been met correctly.
Possible emergency situations and measures to eliminate them are given below.
1. Error: THE SYSTEM IS NOT WORKING.
Cause: The fuse is not turned on.
Remedy: Turn on the fuse.
Cause: The equipment is not receiving power.
Remedy: Check the ends of the power cable.
2. Error: COMPRESSOR DOES NOT WORK.
Cause: The motor contactor is not receiving power.
Remedy: Check the fuse.
Cause: The fuses are tripping.
Remedy: Possible jamming of the compressor due to internal damage. Contact the company service for control.
Cause: The low-high pressure pressure switch has opened a circuit.
Remedy: The system is clogged or there is a lack of gas. In this case, the condenser should be cleaned. One of the fans is not working.
Cause: The oil pressure switch has opened a circuit.
Remedy: Check the oil level in the compressor. If the level is sufficient, restart the compressor.
Cause: The thermostat has opened circuit.
Remedy: Check water temperature and thermostat settings.
Cause: The freeze thermostat has opened circuit.
Remedy: Check the heat exchanger for freezing. If there is no freezing, wait until the water warms up.
Cause: The compressor motor thermistor has opened circuit.
Remedy: Find and remove the cause of the motor overheating. Wait 5-6 hours until the engine cools down.
3. Error: COMPRESSOR OPERATES INTERMITTENTLY.
Cause: The low pressure setting is adjusted to high level.
Remedy: Adjust the low pressure setting to normal level.
Cause: The solenoid valve on the fluid connection is leaking and there is frost around the valve.
Remedy: Call service to replace the solenoid valve.
Cause: The liquid pipe is too cool.
Remedy: The drying filter is clogged. Call service to replace the drying filter or solenoid valve bobbin.
Cause: The water in the heat exchanger is frozen.
Remedy: Wait for the ice to melt and investigate the cause of the freezing.
4. Error: COMPRESSOR RUNS CONSTANTLY.
Remedy: Set the thermostat to +10, 11°C.
Cause: Lack of gas in the system.
Remedy: Find out the reasons and call service to replenish the gas.
Cause: The contacts in the motor are stuck.
Remedy: Replace contacts.
5. Error: LACK OF OIL IN COMPRESSOR.
Cause: Oil level has dropped.
Remedy: Find out the cause. Call service to replenish the oil.
Cause: The system is operating at low pressure.
Remedy: There is a gas leak in the system. Locate the leak and call service to replenish the gas.
Cause: The crankcase plug is leaking oil.
Remedy: If the crankcase plug is loose, tighten it. If the leak does not stop, call service.
Cause: The expansion valve is loose.
Remedy: Attach with a metal strip.
6. Error: COMPRESSOR IS NOISY
Cause: Oil level has dropped.
Remedy: Find out the cause. Call service to replenish the oil.
Cause: Oil level too high.
Remedy: Check the oil level. If the level is too high, call service.
Cause: The internal parts of the compressor are damaged.
Remedy: Call service to remove and further repair the compressor.
Cause: The expansion valve remained in open position.
Remedy: Call service to replace the valve.
Reasons: Weakened mounting bolts compressor.
Remedy: Tighten the bolts.
7. Error: SUCTION PRESSURE TOO HIGH.
Causes: The liquid level in the heat exchanger is too high, the expansion valve does not control the liquid level.
Remedy: Call service to replace or adjust the expansion valve.
Cause: Suction valve is broken.
Remedy: Call service to replace or repair the valve.
8. Error: SUCTION PRESSURE TOO LOW.
Cause: The gas level has dropped and bubbles are visible in the sight glass.
Remedy: Call service to determine if there is a gas leak and top it up if necessary.
Cause: The expansion valve remained in the closed position.
Remedy: Call service to replace the expansion valve.
Cause: Thermostat is set low.
Remedy: Set the thermostat to +10, 11°C.
Cause: There is a large amount of oil in the system, the expansion valve needle is frozen.
Remedy: Call service to drain the oil and replace the drying filter.
9. Error: DISCHARGE PRESSURE TOO HIGH.
Cause: The condenser fan motor is faulty.
Elimination: Investigate the causes and call service for elimination.
Causes: The condenser fan rotates in the wrong direction.
Remedy: Valid only for 3-phase fans. Swap the two input pins.
Cause: There is too much gas in the system.
Remedy: Call the service for monitoring.
Cause: There is foreign gas in the system.
Remedy: Call service for gas release and control.
Cause: The capacitors are clogged.
Remedy: Clean the capacitors compressed air.
10. Error: DISCHARGE PRESSURE TOO LOW.
Cause: A large amount of cold air enters the condenser (winter conditions).
Remedy: If the system has two fans, winter conditions one of them must be switched off using a fuse.
Cause: The start relief or power control systems remain permanently switched on.
Remedy: Call service to determine the cause.
Cause: Gas leak.
Remedy: Call service to identify and repair the gas leak and test for leakage.
Before carrying out maintenance work, the main fuse installed on your side must be turned off. The person authorized to carry out the repair must lock the electrical panel and remove the key for storage.
The most vulnerable point in refrigeration equipment is the compressor. Largest quantity breakdowns in refrigeration compressors occur for the following reasons: 1 - refrigerant entering the compressor in liquefied form, 2 - insufficient lubrication of the compressor with oil. Compressor wear and tear as a result of prolonged operation under normal conditions is practically impossible. Prevention of breakdowns is only possible if correct use equipment and its regular inspection.
1. Once a week.
Check the oil level. If the level is below the average mark on the glass eye, and during operation of the equipment, when checking every half hour, the level continues to rise and fall, call the service to top up the oil level. If the oil color is too dark and close to black, you should call a service to change the oil. It is recommended to use the same type of oil as before the change.
- The cracks in the condenser should be blown out with compressed air.
- If abnormal signs of operation (noise, vibration, icing, increase or decrease in operating pressure, heating) of the equipment appear, you should immediately contact service center.
In addition, the system discharge pressure should be constantly monitored. If this pressure is too high, then there is a possibility of non-liquefiable gases appearing in the system.
The refrigerant amount should be checked regularly through the sight glass. If there are a large number of bubbles in the gas, the gas should be topped up. The lack of gas can be judged by insufficient cooling, as well as excessive heating of the compressor.
2. Once a month.
It is recommended to repeat all operations performed every week.
- All engines should be inspected and oil added if necessary.
- Check the strength of the motor mounts.
- If the system uses belts, their tension should be checked regularly. If the belt, when pressing on it with a finger, deviates by 20-25 mm, then the tension can be considered normal.
3. Once a year
The water cooling machine must repeat all weekly and monthly procedures technical inspection.
- Inspect the contacts on the electrical panel and check the functions. To control the operation of thermal relays, test them by lowering the settings below the established ones.
- Check the main fuse contacts.
- Clean the filters of the water supply system.
- Replace the drying filter in the cooling system by calling a service team.
- If there is an air channel, inspect it (dents, damage, sagging, etc.).
IMPORTANT NOTE:
Interventions in freon systems should only be carried out by experienced personnel from your company.
If the ambient temperature in which the chiller operates is below 0 o C, there is a possibility of freezing of the water in the cooler. If the chiller will not be used for a long time, antifreeze should be added to the water or the water should be drained.
The determination of the repair technique, as well as the parts to be repaired or replaced, is entirely carried out by our company.
Damage caused by shipping, handling and installation after the product has been shipped by our company is not covered by the warranty.
Damage caused by use of the equipment that is not in accordance with the above recommendations for use is not covered by the warranty.
The warranty period begins from the day the goods are shipped.
If the use of the equipment is consistent with the above-described recommendations for use, and repair procedures were carried out only by professional personnel of our company, the warranty period for servicing the equipment is 1 year.
