This document is a manual for Universal Chilling Systems' Air Cooled Industrial Chillers, specifically model UCS-10A. It covers specifications, installation, operation, troubleshooting, and maintenance.
Function Description:
The UCS series chillers are designed to produce a cooling medium with temperatures around 7°C or -5°C, with lower temperatures available upon customer request. These chillers are suitable for various industrial applications, including textile, chemicals, machinery, electronics, medicine and health, and food industries. The system incorporates world-famous brand refrigeration parts, leading brand compressors, high-efficiency heat exchangers (shell & pipe or copper & fin type), and a digital control system. It also features multi-protection devices to safeguard against overloading, high and low pressure, phase lacking, and water lacking.
Important Technical Specifications (Model UCS-10A):
- Cooling Condition:
- Chilled Water Inlet Temperature: 12°C
- Chilled Water Outlet Temperature: 7°C
- Ambient Temperature: 35°C
- Nominal Cooling Capacity:
- KW: 30
- x 10³kcal/Hr: 25.8
- Power Supply: 3P-440V-60Hz
- Compressor:
- Type/QTY: Fully Closed Scroll/1 piece
- Cooling Input Power (KW): 10.40
- Cooling Operation Current (A): 15.10
- Evaporator:
- Chilled Water Flow (m³/h): 5.16
- Interface Size: DN40
- Condenser Fan:
- Quantity: 2
- Power (KW): 0.64
- Operation Current (A): 0.99
- Safety Protection Device: Includes high & low voltage protection, current overload protection, antifreezing protection, and electrical delay protection.
- Water Pump:
- Power (KW): 1.1
- Current (A): 2.42
- Head (M): 30
- Water Tank:
- Material: 304SS
- Volume (L): 140
- Overall Size:
- Length (mm): 1810
- Width (mm): 975
- Height (mm): 1730
- Weight /KG: 435
- Overall Unit:
- Power (KW): 12.78
- Current (A): 19.5
- Refrigerant Type: R407C
Notes on Specifications:
- Normal conditions for these specifications are: Chilled water inlet temperature 12°C, outlet temperature 7°C, ambient temperature 35°C.
- Standard power supply is 3P-440V-60Hz, a proposed three-phase four-system, allowing voltage fluctuation of -25% to +10% and frequency fluctuation of ±2%.
- The actual pump lift for the host is the pump lift minus the host's internal head loss (1mH2O = 9.8kPa).
Usage Features:
- Transportation: The unit must be kept vertical during transportation. Only the bottom support should be used for lifting with a forklift or crane. Chains should not touch the side heat exchanger, top, or side plates.
- Installation (Positioning):
- Install in a well-ventilated indoor area, sheltered from rain.
- Maintain a minimum of 2 meters of clear space above the unit for hot air dissipation.
- Ensure at least 1.5 meters of clear space at the air inlet side for normal operation.
- Requires a strong, level concrete base, at least 20 cm high.
- Adequate space for repair and maintenance must be provided.
- Operating environment temperature range: -15°C to 50°C, relative humidity 80%.
- Air Duct: An air duct is required if the installation location does not guarantee sufficient airflow.
- Pipeline Installation: The unit is pre-tested and inspected. Users only need to fix it in position, connect it to the chilled water system, and power supply. A water flow protection switch is essential in the chilled water system to prevent evaporator freezing due to insufficient water flow. It is recommended to install this switch outside the unit box.
- Electrical Installation: The chiller includes a temperature controller and electrical control box. Electrical installation primarily involves connecting the unit to the power supply. Any additional control wiring must comply with local electrical standards for safety and stable operation.
- Wire Selection: Recommended wire thickness should be 1.25-1.3 times the total current of the chiller and auxiliary facilities (e.g., pumps).
- Power Supply Requirement: Voltage must be within -25% to +10% of the rated voltage, and frequency within ±2% of the rated Hz. The unit must not be started if the voltage is outside these limits.
- Commissioning (Before Start Operation):
- Verify the environment is normal.
- Check power supply connections and ensure phase voltage meets requirements.
- Confirm all water valves on the chiller pipelines are open.
- Ensure pumps are normal after pressure test, dirt discharge, air discharge, and trial operation.
- Check water level in the water vessel, connection of the water supplementary inlet, and overflow outlet to the sewer.
- Operation of Chilled Water System:
- Chilled water needs to be processed to maintain a pH value between 7.0-8.5 to prevent corrosion of copper pipes and extend heat exchanger life.
- After installation, water lines require pipe cleaning, pressure testing, air discharge, and trial running.
- Start Order: Power supply on for over 12 hours → chilled water pumps → unit.
- Stop Order: Unit → chilled water pumps.
- Monitoring: After starting, observe high and low pressure gauges. Normal high pressure: 8-16kg/cm², normal low pressure: 1.5-4kg/cm².
- For air-cooled units, verify fan rotation direction. Correct wiring if incorrect.
- Protection device set values should not be altered from factory settings.
- If an error alarm sounds and the unit stops, press the stop button to clear the alarm, then troubleshoot. Do not force a restart until the issue is resolved.
- Avoid stopping the unit by cutting off the main power supply unless in an emergency. For long winter shutdowns, stop the unit, then cut power and drain the system.
- Maintain a clean, tidy machine room with good airflow; clean condensers periodically.
- Control Panel (DM500B): Features 12 keys, 6 of which are lighted. Dimensions: 196mm x 115.5mm.
- Start Display: Shows "WELCOME TO OUR CONTROLLER" and version information.
- Main Face: Displays inlet temperature (T.IN), outlet temperature (T.OUT), set temperature, and running status (run, time delay, stop). T.IN refers to returning water/air temperature; T.OUT refers to outgoing water/air temperature.
- User's Inquiry Operation: Allows checking "TROUBLE LIST," "TROUBLE HIS." (historical troubles), "RUN TIME CHECK" (accumulated run time per compressor), and "CLOCK CHECK" (real time).
- User's Set: Allows setting T.OUT, mode (cooling), On/Off status (manual, week timing, timing once), and TIMING SET.
- Settings: Accessible from the STOP page by pressing
< and <+> simultaneously. Requires a password (default repairman's password: 123). Allows access to "RUN SETTINGS" (SYS. SETTINGS, TIME SETTINGS 1/2, TEMP SETTINGS 1/2/3, TEMP REVISE, INPUT SET 1/2, SENSOR SET) and "MODIFY PWD."
- Unit Operation:
- Start Sequence: START button → pump start → time delay → cooling fan start → time delay → compressor start. All delay times are adjustable.
- Stop Sequence: STOP button → running compressor stop → time delay → cooling fan stop → time delay → pump stop. Delay times are adjustable.
- Run Indication: Indicator closes when all systems are running, opens when equipment stops.
- Alarm: Activates when a system is out of order, deactivates when all troubles are resolved.
Maintenance Features:
- Condenser Cleaning: Keep condensers clean and ensure good airflow. Clean periodically, especially in dirty environments, to prevent H/L differential pressure issues and decreased refrigeration capacity.
- Trouble Disposal: When an alarm occurs, the alarm sound will stop by pressing the sound erasing key, but the reset indicator will continue to flicker. After the trouble is resolved, press RESET to clear the trouble record and turn off the reset indicator. If a new trouble occurs, the system will automatically enter error inquiry mode.
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