A-EON WJ-5000 Series User manual

WJ-5000/5200 SERIES WJ-5000/5200 SERIES
0201
WJ-5000/5200
series
INDUSTRIAL REFRIGERATION CHILLER
USER MANUALUSER MANUAL
<1>Cautions
<2>Parts introduction
<3>Installation
<4>Operation and
<5>Flow alarm and
<6>Specifications
<7>Simple troubleshooting
CONTENTS
parameters adjustment
output ports
03
04
05
06
10
11
13
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<1>Cautions
WJ-5000/5200 SERIES WJ-5000/5200 SERIES
0403
Thank you for purchasing Stepless Electrical Co., Ltd., Dongguan City,
the product, please read the installation instructions carefully before use and
safekeeping.
The installation instructions are not using quality assurance, to correct
typographical errors in the information the fallacy of errata, and improved
products, by the Electrical and Mechanical Services Ltd. of Dongguan City,
stepless explanation at any time, without prior notice, amendments will be
incorporated Republication using the installation instructions.
01
Please ensure that the power supply and electrical outlet are in good contactand the earth wire
must be firmly grounded!
Although the average operating current of the chiller is small, but theinstantaneous operating current could be up to 6~10amps
sometimes (Theinstantaneous operating current of models of AC110V power supply arepossible to be up to 10~15amps).
02
Please make sure there is stable and normal voltage for the working chiller!
As the refrigeration compressor is more sensitive to the power supply and voltage, so the operating voltage of our standard
product is of 200~250V (110V model is of 100~130V). If you do need a wider operating voltage range,customization is
available for us.
03
Unmatched power frequency can cause the chiller damage!
Please choose model of 50Hz or 60Hz according to actual circumstance.
04
To protect the pump, it’s strictly forbidden to run the chiller without water in the storage water tank!
The new machine is packed after draining whole water in the tank, so please make sure the tank has water inside before machine
starting, otherwise it’s easily to have the pump damaged. When the water level is below the green(NORMAL) range of the water level
gauge, the cooling capacity of our chiller will go down slightly. Hence please ensure the water level is within the green (NORMAL)
range. To drain through circulating pump is strictly prohibited!
05
Please be sure that the air inlet and air outlet are in good ventilation!
There must be at least 30cm from obstructions to the air outlet which is in the back of the cooler, and should leave at least 8cm
between obstructions and the side air inlet.
06
The filter screen must be regularly cleaned!
It’s essential to unpick and wash the dust gauze, or the serious blockage will cause breakdown to the chiller.
07
Please pay attention to the effect of the condensate water!
With greater ambient humidity, when the water temperature is lower than the ambient temperature, the condensate water will
generate on the surface of water circular pipes and the cooled components. If above circumstance appears, it is recommended to set
a higher water temperature or keep pipes and cooled parts warm.
Professional use only!
The appliance is not to be used by children or persons with reduced physical,sensory or mental capabilities, or lack
of experience and knowledge, unless they have been given supervision or instruction, children being supervised not
<2> Parts introduction
TEMPERATURE CONTROLLER
FLOW ALAMR (RED)
NORMAL FLOW (GREEN)
POWER SWITCH
AIR INLET
(FILTER GAUZE)
WATER INJECTION PORT
POWER SOCKET(WITH FUSE)
ALARM OUTPUT TERMINAL
COOLING WATER OUTLET
COOLING WATER INLET
AIR OUTLET
WATER LEVEL GAUGE
OUTFALL
AIR OUTLET
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WJ-5000/5200 SERIES WJ-5000/5200 SERIES
0601
<3> Installation
It is very simple to install this industrial cooling machine. The installation for the first time of the new
machine can be carried out by following steps:
05
6
Open the package to check if the machine is
intact and all the necessary accessories are
completed.
Open the injection port to feed cooling water.
(Do not let the water spill over!)
Observing the water level gauge and adding water slowly, be
careful not to have the water overflowed! For the cooling of
carbon steel equipment, the water should be added an
appropriate amount of cooling water additive(anti-corrosion
water aqua). Working in cold north area, it’s better to use
noncorrosive antifreeze fluid.
According to system conditions, please
connect the water inlet and outlet pipe well.
Plug in power, turn on the power switch. (Do
not start up without water in the water tank!)
(1)Power switch turned on, the circulation pump of the chiller starts working. The
first time of operating may cause more bubbles in the pipe leading to a flow
alarming occasionally, but running for a few minutes later, it will go back to
(2)After the first boot, you must immediately check whether the water pipe leaks.
(3)
fans and other components of the machine do not work. The temperature controller will
automatically control the working conditions of the compressor,magnetic valve, fans
and other parts based on the set controlling parameters.
Power switched on, if the water temperature is below the set value, it is normal that
(4)As it takes a longer time to start over the compressor and other components,
according to different conditions, the time is range from seconds to minutes, so do
not turn off the power and again on frequently.
Check the water level in the water tank.
The first startup of the new chiller empties the air in the water pipe, leading a
slight water level decline, but in order to keep the water level in the green area,
it’s allowed to add adequate water again. Please observe and record the current
water level, and inspect it again after the chiller running for a period of time, if
the water level drops obviously, please re-inspect the water pipeline leakage.
Adjust parameters of temperature controller.
WJ-5000/5200 series use an intelligent thermostat. Normally users do not need
to adjust it. If it is really necessary, please refer to page 09, “Operating status
and parameters adjustment.”
<4> Operation status and parameters adjustment
The new T500 intelligent temperature controller does not need to adjust the controlling parameters under normal circumstance. It will self-
adjust controlling parameters according to room temperature for meeting equipment cooling requirements.
The new T504 intelligent temperature controller is selected constant temperature control mode as factory setting with water temperature at
25℃.User can adjust it as needed.
T503 and T600 controllers are of same functions and structure except factory parameters setting.
D1
D2
1.Temperature controller panel description
ON: thermostat works in intelligent control mode;
OFF: thermostat works in temperature control mode;
FLASHES: thermostat works in parameters setting mode or
displaysvalue of room temperature;
ON: chiller works in refrigerating state;
OFF: chiller works in the insulation working state;
FLASHES: chiller works in the energy-saving state;
(2) Press▼ button will show the room temperature, 6 seconds later to display the restore defaults.
(Meanwhile, D1 is flashing, displaying room temperature.)
(3) ▲▼keys are for adjusting the display status of the controller, parameters selection and adjustment.
(4) RST key: enter key.
(5) SET key: function setting key.
2.Restore to factory settings
Before machine startup, please press and hold▲▼button until the controller displays rE, 6 seconds later after releasing the button, the
controller works in normal order. Then all parameters settings of the controller have been restored to factory settings.
Wat er le vel is to o hig h
Norma l wat er leve l
Wat er le vel is to o low
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WJ-5000/5200 SERIES WJ-5000/5200 SERIES
0807
E1 E2 E3 E4 E5
1
2
3
4
5
6
7
8
9
10
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
25
-2
0 8.
1
10
15
45
8
30
20
F9~F8
-15~+5
0.1~3.0
0~1
1~20
00~99
1~F0
25
-2
0 1.
0
10
15
45
8
30
20
1~20
40~50
F0~40
3.Alarm function
4.Thermostat parameters list
(1) Alarm Display:
Over high room
temperature
Over high water
temperature
Over low water
temperature
Room temperature
sensor failure
Water temperature
sensor failure
When alarm occurs, the error code and the temperature will be alternately displayed.
(2) To suspend the alarm:
In alarming state, the alarm sound could be suspended by pressing any button,but the alarm display remains until the alarm
condition is eliminated.
Temperature
Controller
Factory Setting
Order Code Item Range Note
Temperature
Controller
Factory Setting
T-503 T-504
Temperature setting
Temperature
Difference values
Cooling hysteresis
Way of control
Alarm for over high
water temperature
Alarm for over low
water temperature
Alarm for over high
room temperature
Password
The allowed highest
water temperature
The allowed lowest
water temperature
1: intelligent
0: constant temperature
Constant temperature
control effecting
Intelligent control
effecting
5.General settings adjustment
Press SET button（SET）to enter into the user-defined state. Meanwhile, D1 flashes to indicate that the controller
is in parameters setup status.
(1)Under intelligent mode, the control panel displays the temperature difference value between water and air
(2)Under constant temperature mode, the control panel displays the set temperature value (F0).
At this moment, press▲ ▼ key to change settings. After modifying the value, press the ENTER button (RST) to save
and exit, then new parameters take effect, or press SET key (SET) to exit without saving parameters. If there is no
more action within 20 seconds, it will automatically exit modifying status without saving parameters.
6.Advanced settings adjustment
(1)
select the password have been set, and then click the SET button (SET) again, if the password is correct, F0 would be
shown,entering the set status, D1 flashing to indicate that the controller is under parameters setup status. What if the
Press and hold the▲ key while press SET button (SET) for 5 seconds until 0 displayed. Then press▲ button to
(2)
circulation. Select an item, click SET button (SET) to proceed next parameters modifying, original settings being
displayed, then press▲▼key to modify parameter values, and press SET button (SET)to return to the previous setup
menu. Press ENTER button (RST) at any time to exit parameters setup with saving modified parameters and return to
temperature display, then the chiller runs under the new parameters. If no button is pressed within 20 seconds, the
controller will automatically exit parameters setup without saving the modified parameters.
Enter setup state, press▲key to enter and select set items circularly, or press▼to go in contrary direction
1. During parameters setting condition, system still runs under original parameters.
2. Under temperature control mode, the water temperature is controlled by (F0) parameters;
3. Under Intelligent control mode, the water temperature will be automatically adjusted according to temperature
changes.The temperature difference is commanded by (F1) parameter.
Note:
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WJ-5000/5200 SERIES WJ-5000/5200 SERIES
1009
5.Advanced parameters adjustment case:
0.5
1
2
3
4
5
6
7
8
9
10
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
25
-2-2
0.1
0
10
15
45
8
30
20
-3
1
10
10
45
8
31
25
28
2.0
0
5
10
45
8
30
5
25
1.0
0
4
14
45
8
30
5
25
0.8
1
10
15
45
8
30
20
Temperature setting
Temperature
Difference values
Cooling hysteresis
Alarm for over high
water temperature
Alarm for over low
water temperature
Alarm for over high
room temperature
The allowed highest
water temperature
The allowed lowest
water temperature
Way of control
Password
Order Code Item Value in
case 1
Value in
case 2
Value in
case 3
Temperature
Controller
Factory Setting
Temperature
Controller
Factory Setting
T504T503
(1)Case 1: cooling water temperature is controlled by intelligent mode. Requiring water temperature to be between 25℃to
31℃. Ambient temperature keeping constant, when the set water temperature is 3℃lower than the ambient, the
fluctuation will not exceed ±0.5℃.There will be an alert when water temperature is 10℃ lower or higher than target.
(e.g.when ambient temperature is 30.0℃, cooling water temperature is between 27.5℃to 26.5℃,if ambient temperature is
up to 30.5℃, water temperature will be between 28.0℃ to 27.0℃.)
(2)Case 2: cooling water temperature is controlled by constant mode. Requiring water temperature is constant in 28℃,
and the fluctuate does not exceed ±2℃.The alarm of over high water temperature will be on when water temperature is
5℃ higher than normal, and the alarm of over low water temperature will be on when water temperature is 10℃ lower
than normal.
(2)Case 3: cooling water temperature is controlled by constant mode. Requiring water temperature is constant in 25℃,
and the fluctuate does not exceed±1℃.The over high water temperature will be on then water temperature is higher
than 30℃, and the alarm of over low water temperature will be on when water temperature is lower than 10℃. (No
matter what is the ambient temperature,the cooling water temperature is constant in 24.0℃ to 26.0℃)
<5> Flow alarm and output ports
In order to guarantee the equipment will not be damaged while cooling water circulation is out of
control, WJ-5000/5200series chillers possesses an unique low flow alarm protection.
1.Flow alarm output ports and the wiring diagram
2.Flow alarm causes of circulating cooling water and working state
Flow-sw
BZ
Red light Green light
Alarm outpout ports
Output poorts diagram
OFF
ON
OFF
OFF
OFF
ON
ON
ON
Breakover
Disconnection
Disconnection
Disconnection
Disconnection
Breakover
Disconnection
Breakover
Breakover
Breakover
Output ports
H1 H2
Output ports
H1 H3
Buzzer
Flow
indicator
alarm
Normal
indicator
flow
DISPLAY
CONDITION
Note: The flow alarm is connected to the normally open relay and normally closed relay contacts, requiring
operating current less than 5A, working voltage less than 300V.
Circulating pump works properly
Blocked cooling water
circulation loop
Alarm of water shortage
Faulted circulating pump
Power interruption
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WJ-5000/5200 SERIES WJ-5000/5200 SERIES
1211
<6> Specifications
1.WJ-5000 Series compressional type chiller
*
WJ-5000AG WJ-5000BG WJ-5000DG WJ-5000AH WJ-5000BH WJ-5000DH WJ-5000AI WJ-5000BI WJ-5000DI
AC 1P 220V AC 1P 110VAC 1P 220VAC 1P 220VAC 1P 110VAC 1P 220VAC 1P 220VAC 1P 110VAC 1P 220V
50Hz 60Hz 60Hz 60Hz60Hz50Hz 50Hz 60Hz 60Hz
1.4~2.1A 1.4~2.1A 1.4~2.1A 1.4~2.1A 1.4~2.1A 1.4~2.1A 3.5~5.6A3.5~5.6A3.5~5.6A
0.295KW 0.38KW 0.305KW 0.295KW 0.38KW 0.3055KW 0.295KW 0.38KW 0.305KW
0.40HP 0.52HP 0.41HP 0.40HP 0.52HP 0.41HP 0.40HP 0.52HP 0.41HP
2361Btu/h 2999Btu/h 2866Btu/h 2361Btu/h 2999Btu/h 2866Btu/h 2361Btu/h 2999Btu/h 2866Btu/h
0.692KW 0.879KW 0.84KW 0.692KW 0.879KW 0.84KW 0.692KW 0.879KW 0.84KW
595Kcal/h 756Kcal/h 595Kcal/h 756Kcal/h 595Kcal/h 756Kcal/h722Kcal/h 722Kcal/h 722Kcal/h
R-134a
300g 320g 280g 300g 320g 280g 300g 320g 280g
±0.3℃
0.03KW 0.05KW 0.1KW
580X290X470mm(LX W X H)
700X430X580mm (LXWXH)
6L
25M10M 12M
13L/min10L/min 16L/min
24Kgs
27Kgs
Model
Voltage
Frequency
Current
Compressor
power
Refrigeration
capacity
Refrigerant
Refrigerant
charge
Precision
Reducer
Protection
Pump power
Tank
capacity
Inlet and
outlet
Max.lift
Max.flow
N.W
G.W
Dimension
Package
dimension
Capillary
Overcurrent protection for compressor, flow alarm, over temperature alarm
External Ø10mm brass connector Ø10mm speedy connector
With heating and higher temperature precision functions are optional.
2.WJ-5200 Series compressional type chiller
*With heating and higher temperature precision functions are optional.
Model
Voltage
Frequency
Current
Compressor
power
Refrigeration
capacity
Refrigerant
Refrigerant
charge
Precision
Reducer
Protection
Pump power
Tank
capacity
Inlet and
outlet
Max.lift
Max.flow
N.W
G.W
Dimension
Package
dimension
AC 1P 220V AC 1P 110V AC 1P 220VAC 1P 220VAC 1P 110VAC 1P 220VAC 1P 220VAC 1P 110VAC 1P 220V
50Hz 60Hz 60Hz 60Hz60Hz
50/60Hz 50Hz 60Hz 60Hz
2.4~3.1A 2.6~3.3A 4.5~6.5A
0.52KW 0.5KW 0.68KW 0.49/0 57KW.
0.71HP 0.68HP 0.93HP
5084Btu/h 4982Btu/h 5186Btu/h
1.49KW 1.46KW 1.52KW
1281Kcal/h 1256Kcal/h 1307Kcal/h
360g 380g 350g 360g 380g 350g 380g
±0.3℃
0.03KW 0.05KW 0.1KW
6L
25M10M 12M
13L/min10L/min 16L/min
26Kgs
29Kgs
WJ-5200AG WJ-5200BG WJ-5200DG WJ-5200TG WJ-5000AH WJ-5000DH WJ-5000AI WJ-5000BI WJ-5000DI
260g
360/380g 350g
R22/R-134a/R410a
WJ-5000BH
AC 1P 220V
50Hz
2.4~3.3A 2.4~3.1A 2.6~3.3A 4.5~6.5A 2.4~3.1A 2.6~3.3A 4.5~6.5A
0.52KW 0.5KW 0.68KW 0.52KW 0.5KW 0.68KW
0.66/0 77HP.
0.71HP 0.68HP 0.93HP 0.71HP 0.68HP 0.93HP
1281Kcal/h 1256Kcal/h 1307Kcal/h 1281Kcal/h 1256Kcal/h 1307Kcal/h
1.49KW 1.46KW 1.52KW 1.49KW 1.46KW 1.52KW
5084Btu/h 4982Btu/h 5186Btu/h 5084Btu/h 4982Btu/h 5186Btu/h
4825/5797Btu/h
1.41 1.70/KW
1219/1465 calK /h
Capillary
Overcurrent protection for compressor, flow alarm, over temperature alarm
External Ø10mm brass connector Ø10mm speedy connector
580X290X470mm(LX W X H)
700X430X580mm (LXWXH)
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WJ-5000/5200 SERIES WJ-5000/5200 SERIES
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<7> Simple troubleshooting
FAILURE FAILURE CAUSE APPROACH
Check and ensure the power interface and the
power plug is plugged in place and in good contact.
Power cord is not plugged in place
Fuse burnt-out
Pull out the fuse box from the power supply
interface of the chiller, check the fuse, replace with
spare fuse if necessary and check whether the
power supply voltage is stable; Check and ensure
the power interface and the power plug is plugged in
Check the water level gauge display, add water
until the level shown in the green area; And check
whether water circulation pipe leaks.
Check water circulation pipe
Flow Alarm (panel red light is
on)use a water pipe directly
connect to the water outlet and
inlet but still without water flowing
Machine turned on but
unelectrified
Ultra-high
temperature alarm
Alarm for ultra-high room temperature
Serious problem of condensate water
Water drains slowly from outfall
during water changing
Switch the power frequently
Blocked dust gauze, bad thermolysis
Poor ventilation for air outlet and inlet
Voltage is extremely low or astable
Improper parameter settings on thermostat
Excessive heat load
The working ambient temperature is too
high for the chiller
Water temperature is much lower than
ambient temperature, with high humidity
Injection port is not open Open the injection port
Increase water temperature or to preserve heat
for pipeline
To improve the ventilation to guarantee that the
machine is running under 40℃.
Reduce the heat load or use other model with
larger cooling capacity
To ensure there is sufficient time for refrigeration
(more than 5 minuets)
To reset controlling parameters
or restore factory settings
To improve the power supply
circuit or use a voltage regulator
To ensure a smooth ventilation for air outlet and inlet
To ensure a smooth ventilation for air outlet and inlet
Water level in the storage
water tank is too low
Water circulation pipes are blocked
or apipe bending deformation.
<4> Packing list
1.1 unit of industrial chiller.
2.1 copy of user manual.
3.1 pc of power cord.
4.1 pc of alarm signal output plug.
5.1 pc of spare fuse.
(held in the spare fuseholder of power socket.)
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