AEC GPWC70 User manual

OPERATING INSTRUCTIONS
FOR
WATER CHILLER
(Water-cooled, Microprocessor Controlled)
CE
Conformity

OPERATING INSTRUCTIONS
INSTALLATION
Install this water cooled chiller on a solid foundation. The installation location should be convenient for
operation and proper distance from the cooling tower. If the cooling tower is installed outdoors, make sure it is
in an environment with good air convection, free of pollution and gas. If the cooling tower is installed at a
factory, use an exhaust fan to keep good air convection. Because the exhausted air will contain considerable
moisture, mounting the exhaust fan too close to the machine will affect the switches and the controllers.
INSTALLATION NOTICES
1. Make sure the power source voltage and Hz comply with those indicated on the instruction plate attached to
the machine.
2. Connecting power wire and grounding should conform to local regulations.
3. Use only separate power wires and power switch. The power wire diameter should not be smaller then
those applied in the electrical control box.
4. The power wire connection points should be tightened securely.
5. Make piping work according to the installation layout drawing. Protect the ice water pipes with
thermal-keeping piping.
6. The pipe diameter for the cooling tower and circulation pump should not be smaller than the condensing
pipes. (Inlet and outlet piping are installed according to installation layout drawing.)
7. Open the ice water inlet and outlet valves, but close the water exhaust valve.
8. Connect the power wires of the cooling tower fan motor and circulation pump to the electrical control box
of water chiller.
9. Properly set the current valve on overload relay of the cooling tower.
NOTICES FOR OPERATION
1. Turn on the main power source switch. When the control panel power is turned on, it has a safety guard
when power is shut off.
Note: When the control box cover must be opened for inspection of the control system, turn the main power
source switch counter-clockwise. Pull out the control panel, and press the safety pin located at the side
of the main power switch. Turn on the switch for inspection.
2. When start the machine, if error code indication displays 01 (reverse phase running), then the chilling pump
is running in reverse. If this occurs, turn the power off, and change any two of the power wires.
3. Check to see if the fan motor of the cooling tower and circulation pump run to the directions as arrowhead
instruction. Do not allow them to run in the opposite direction.
4. The Chilling pump must not run if there is no water in the water tank. Start the cooling tower running for
about 15 minutes. When the water tank is fully filled with water, start the chilling pump and the
compressor.
5. Once the chilling pump is started, check to see if the water pressure gauge indicates over 1 kg.
6. Start the compressor running. When the water temperature reaches the set temperature, the running
indication lamp will extinguish. This is the normal condition.
7. Do not set the temperature switch lower than 5℃(except for special models)
8. When the compressor is running, the ideal conditions are when the high/low pressure gauge is in the blue
range. (High pressure range 180-250 PSI, low pressure range 45-75 PSI)
9. If and abnormal motion occurs, first stop the alarm, then make the correction. After the trouble is corrected,
press the reset key the restart the machine.
10.If your machine has no water tank provided, then it is equipped with a filter screen and flow control switch.
Make sure the water circulates in the pipe before starting the compressor. After a long period of operation,
if the water flow is too little (or the error code indication lamp displays ‘11’), the clean the Y shape filter
located in front of the pump at the water suction port.
11.To ensure high efficiency operation and to extend the service life of the machine, it is important to perform
monthly cleaning for the cooling tower, water suction filter screen, and make sure the heat dissipation pipes
flow and rotate smoothly.
12.If any emergency condition occurs, press the red emergency stop switch immediately. Troubleshooting
should be done only by qualified personnel.

HOW TO OPERATE THE MACHINE
A. OPERATING SEQUENCE
1. Push on the Main Isolator to “1” (ON) position.
2. Push on the switch of cooling tower and indicator lamp lighting.
3. Push on the chilled water pump switch and indicator lamp lighting.
Notice: The outlet ball valve of condensing water must be opened.
4. At last, to push the switch of compressor and indicator lamp lighting, and check the temperature
controller.
5. When stop machine, the operating procedures is accorded as the above mentioned but reversely.
B. AUTO/MANUAL OPERATION MODE
1. If the control panel is something trouble, you can change the machine to the MANUAL mode, and
continue using the machine.
2. The position of AUTO/MANUAL mode is located at the AMS bar of PC2 control board of electrical
door, then push AMS bar to left or right direction. (Refer to the figure introduction)

3
EMBRANE TOUCH PANEL：

TB2
PC1
TMP.SW.
PB
Q1
K1 K2 K3 K4
G
PC2
CN23 CN22
YUTING-2-B
CN24
AMS

REFRIGERANTAND WATER SYSTEM DIAGRAM
No.
Description
No.
Description
1.
Temperature Sensor
12.
High Pressure Switch
2.
Water Tank
13.
Water Condenser
3.
Automatic Water Supply
14.
Pressure Release Valve
4.
Pump Motor
15.
High Pressure Gauge
5.
Water Pressure Gauge
16.
Dry Strainer
6.
Bypass Valve
17.
Expansion Valve
7.
Evaporator
18.
Mesh Filter
8.
Anti-Frozen Switch
19.
Mold
9.
Low Pressure Gauge
20.
Cooling Tower
10.
Low Pressure Switch
21.
Cooling Tower Pump
11.
Compressor

GPWC70

27

FAULT FINDING HINTS
CONDITION
STATUS
TROUBLE SHOOTING
Power is normal, no error
code is displayed, but
machine does not run.
1.Fuse burnt out.
2.Microprocessor board
faulty.
1.Replace the fuse.
2.Replace PC board or set AMS switch
Error code displays ‘00’,
but compressor does not
run.
1.PC1 board on control
Panel faulty.
2.Protection switch faulty.
1.Replace PC1 board or set AMS switch
to manual position.
2.Make correction according to
Appendix 5.
Power fuse burnt out
1.Power cable grounded or
Short circuit.
2.Compressor, pump or heat
dissipation motor damaged.
1.Replace.
2.Repair or replace.
Phase Reversed of power
cable
(Error code display ‘01’)
Reverse running of circulation
pump.
Inverse any of two live wires.
Anti-freezing
(Error code display ‘02’)
1.Chiller frozen.
2.Anti-freeze switch tripped.
3.Anti-freeze switch faulty.
4.Water tank is out of water.
5.Pump damaged or reverse
running.
1.Open by-pass valve.
2.Raise high temperature. On control
switch or low anti-freeze temperature.
Anti-freeze temperature should not
be lower than 3℃(except for special
models)
3.Replace.
4.Check water condition in water tank.
5.Make sure pump is normal.
Insufficient refrigerant
(Error code display ‘03’
or ‘04’)
1.Insufficient refrigerant, low-
pressure switch tripped.
2.Chiller frozen, or pump
damaged.
3.Water by-pass not open,
circulating water too little.
4.Y strainer jammed (On
models without water tank)
1.Add refrigerant. (See Appendix 2)
2.Check if expansion tank holds water.
Make sure the circulation pump is
running.
3.Open water by-pass valve.
4.Clean Y strainer.
Insufficient Radiation
(Error code display ‘05’
or ‘06’)
1.High temperature switch
tripped.
2.filter screen jammed
1.See Appendix 1
2.Clean filter.
Chilled water pump over-
loaded
(Error code display ‘07’)
Cooling fan motor over-
loaded
(Error code display ‘08’)
1.Abnormal voltage. Lack of
phase running.
2.Coil burnt out or bearing
damaged on the motor or
pump.
3.Poor terminal connection or
loose power wires/relays.
4.Relay overload (current is
Set too high)
1.Three phase power source dropped
unstable voltage or lack of phase.
2.Replace bearing or motor.
3.Tighten or replace.
4.Properly adjust overload current.

Compressor overload
(Error code display ‘09’
or ‘10’)
1.Abnormal voltage, or lack
of phase running.
2.Compressor damage.
3.Overload, or water
temperature too high.
4.Overload current on relay
set too high.
1.Three phase power source voltage
dropped, unstable voltage or lack of phase.
2.Replace.
3.Reduce load.
4.Properly adjust overload current.
Insufficient flow of
chilled water
(Error code display ‘11’)
1.Filter screen jammed.
2.Chiller frozen, insufficient
flow through bypass valve.
3.Pump reverse running or
damaged.
4.Flow control switch
damaged.
1.Clean Y shaped filter screen at
water suction port.
2.Raise temperature. Open water
bypass valve.
3.Change any two load wires or
replace pump.
4.Replace.
Water is not cooled in
chilled water tank.
1.Poor heat dissipation.
2.Insufficient refrigerant.
3.Overload.
4.Temperature switch set too
high or damaged.
5.Compressor vane broken.
6.Refrigerant jammed.
1.Poor cooling efficiency. (See
Appendix 1 for correction)
2.Add refrigerant. (See Appendix 2
for correction)
3.Increase capacity of chiller.
4.Reduce temperature or replace
switch.
5.Replace compressor. (Check
according to Appendix 3)
6.Replace the jammed parts, dry filter
or expansion valve. Vacuum treat
then add refrigerant.
Insufficient refrigerant
cause by high pressure
valve release
1. High pressure switch damaged.
When refrigerant pres
sure
exceeds 23kg/cm2, the high
pressure valve releases for
safety.
2. High pressure valve damaged.
1. Repair high/low pressure switch, then
fill with refrigerant.
2. Replace high pressure valve.
Temperature controller
faulty.
1.Trouble ‘E1’displayed or
Unstable temperature.
2.Controller damaged.
3.LED damaged.
1.Replace temperature-sensor wire.
2.Set parameter according to
instructions for temperature
controller.
3.Replace temperature control switch.
After the above troubles have been corrected, the machine can be reset automatically for trouble displays 01,02
and 11. Press the reset key on the control panel for trouble displays 03, 04, 05 and 06. Press the reset key on
the relay for trouble displays 07, 08, 09 and 10.

APPENDIX 1: TREATMENT FOR POOR HEAT DISSIPATION
Poor heat dissipation on the condenser will result in low efficiency, current consumption increase and a poor
cooling effect. When pressure reaches 285 PSI, the high-pressure protection switch for the compressor will trip.
The compressor stops, and error code indication 05 or 06 will display, indication poor heat dissipation. If this
occurs, check according to the following steps:
1. Ensure that there is enough cooling water.
2. Make sure the pump and heat dissipation motors run clockwise.
3. Check if water suction filter and water suction pipes are jammed.
4. Make sure the nozzle and water tube run clockwise at 30℃
If all the above conditions are normal, the poor heat dissipation may be caused by too dust deposited in the
condenser. Clean the condenser as per the below instructions:
A. CLEAN WITH DETERGENT
First remove the dust deposited at the bottom of cooling tower, then clean the filter screen and the jammed parts
in the water pipe. When the water level reaches 1” above the water suction filter screen, add detergent at a
1:10 ratio into the cooling tower. Use the pump to circulate the detergent. Start the compressor running
every half an hour. When the compressor is running, and the high pressure lowers to 200 PSI, then the
condenser is well cleaned. Add a large amount of water into the cooling tower to neutralize the detergent.
Replacing with clean water three times will yield normal running conditions.
NOTE: Cleaning period should be no more than three hours.
B. CLEAN WITH COPPER BRUSH
Open the condenser cover, and use a copper brush to clean the deposited dust. Be careful not to damaged the
copper tubing when cleaning. After cleaning, close the condenser cover and reset the high pressure switch
before starting the machine.
APPENDIX 2: TREATMENT FOR INSUFFICIENT REFRIGERANT
1. While the chiller is running, if the low pressure gauge display is lower than 30 PSI, then there is insufficient
refrigerant. When this occurs, repair the locked parts, dry the filter and vacuum treat, then fill with the
proper amount of refrigerant.
2. If leaking parts are immersed in water, immediately stop the machine running and remove the water from the
water tank. Contact the machine manufacturer or your local distributor for maintenance. Continued
operation under this condition may cause serious damage.
3. Applicable refrigerant is R407C.
APPENDIX 3: NORMALVALUE FOR HIGH/LOW PRESSURE
When the compressor is running, the best condition for the high-pressure display is 180-230 PSI. However, the
pressure should not be higher than 285 PSI. If the high pressure exceeds 325 PSI then the high-pressure switch
will trip. When this occurs, make correction according to Appendix 1. The best condition for the low-pressure
display is 45-65 PSI. The low pressure should not be less than 30 PSI. When the low-pressure switch is
tripped, make correction according to Appendix 1. When the compressor is running, if there is little or not
difference between the high and low pressure then the valve in the compressor is damaged. When this occurs,
stop the machine running immediately and contact the distributor for maintenance. If the compressor does not
run, the high and low pressure should be at 130 PSI under normal temperature. A balance between the high and
low pressure is normal.
APPENDIX 4: TEMPORARY TREATMENT WHEN MACHINE SHUTS DOWN
When the compressor is damaged, but continuous operation is required, continuous running of the pump may
cause the temperature to rise rapidly. If the water temperature exceeds 50℃, water leakage will occur due to
damaged seals in the water pipe and pump. To prevent such problems, release a small amount of water through
the water outlet port, and automatically supply water to the tank to slow the rising of water temperature. Repair
the machine as soon as possible.

APPENDIX 5: PROTECTION SWITCH FAULTY
When the error code indication displays ’00’, but the compressor does not run, check the following items:
1. Check PC1 on the microcomputer control panel for damaged.
2. Check the relay coil on the compressor for damage or poor contact, and check the overload protector for
damage.
3. Make sure that the temperature controller is not set too high and is not damaged.
4. Check the anti-freeze switch for damaged.
5. Check the high/low pressure switch for damage.
6. If the machine has no water tank, check the flow control switch for damage.
The above control switches and circuits are connected in series, any damaged part may cause a stop of
compressor.
APPENDIX 6: PC BOARD DAMAGED
When the PC board for the microcomputer is damaged, turn the AMS switch on the PC2 to the manual control
position. This will enable the chiller to run not under the control of the microcomputer, without running
indication and without error code display. The temperature control and protection switch will work normally.
Under these circumstances, the machine can be operated temporarily.
OPERATING SAFETY PRECAUTION
1. Do not run the machine unattended.
2. Do not move guards while COOLING CHILLER is under power.
3. Do not allow distractions to interfere with COOLING CHILLER operations. Do not operate it while talking.
4. Beware of obstructions that prevent completely tightening the screws. Ensure that screw is tight.
5. To be sure that the power has been turned off when the COOLING CHILLER is not used for sometime.
6. To be sure that protective guards are in place of machine.
7. To know the function of each controller.
8. To know how to hold components properly when lifting.
PERSONAL PROTECTIVE EQUIPMENT
1. To take with the helmet protection when operating.
2. To take with the safety shoes when operating.
HOW TO MAINTAIN THE MACHINE
1. If the refrigerant is less, we can fill the type R407C refrigerant.
2. If the cooling water of tank is less, we can fill the water.
HOW TO DO THE INDUSTRIALWASTE
1. The machine is failure and useless, the cooling medium R407C must be treated inadvance or callfor
special waste company.
2. The other industrial waste must be followed national or local area rule to treat.