Sakura FVCA Series User manual

Air Cooled Mini Chiller
Installation, Operation and Maintenance Manual
Models: FVCA 40-200 B(R), 50-80 C(R)
Ref, S- 080 / 05 / 12
Sakura Air Conditioner
User-friendly, Earth-friendly

1
Air Cooled Mini Chiller
Installation, Operation and Maintenance Manual
Note：Please read this Manual carefully before install and operate the unit,
and keep it probably for reference in the future.
Air Cooled Mini Chiller

Mini Air Cooled Chiller
2
Contents:
1.Notes on Safety ------------------------------------------------------------3
2.Installation ------------------------------------------------------------------------ 4
3. lectric ------------------------------------------------------------------------ 6
4.Test Run -------------------------------------------------------------------------- 12
5.Control ------------------------------------------------------------------------- 14
6.Service and Maintenance ------------------------------------------------16

Mini Air Cooled Chiller
3
1. Notes on Safety
◆
◆◆
◆ Read the following points carefully before operation.
◆ Please strictly comply with below stated regulations.
1．
．．
．Signs
Warning：Must comply with the warning to avoid any injury to the body.
Electric Shock Protection：
：：
： This sign is for electrical installation and maintenance.
Must have electrical technicians to do the job.
Caution：
：：
：Must comply with the caution to avoid any damage to the unit.
．
．．
．Notes for Installation
Warning:
 Prepare the base before unit installation to ensure the stable operation.
 Use the appointed accessories and re uest the installation and service from the
manufacturers or dealers.
 Don’t install the unit by yourself, which may cause water leakage, electric shock or
fire.
Caution:
 Please install the electric cutoff.
 The main control must use same power supply with the unit. The wire of control
should be separate from the power supply wire. Must properly install the earth
wires avoid electric shock.
3．
．．
．Attention:
Warning:
 Don’t put your hand or other objects into the air outlet/inlet to avoid injury and unit
damage.
 Don’t damage the power supply wire. Using the power supply plugs to switch
on/off the unit is prohibited.
Cautions:
 Don’t directly wash the unit with water, otherwise it may cause electric shock or
other accidents.
 Keep good ventilation of the air outlet/inlet.
 Don’t fre uently switch on/off the unit.
 Please discharge the water from the unit during winter time not long-term stop. If

Mini Air Cooled Chiller
4
keeping water inside the unit, please keep the power on to protect the water from
freezing.
 Don’t try to fix the unit by yourself. Any improper operation may cause trouble or
burn the unit. Please contact your local office or dealer to fix the unit if it is
necessary.
Attention：
：：
：When the ambient temp. is lower than 16℃, the standard unit cannot
perform cooling. If the cooling is re uirement under this condition, please mention it when
you place the order.
. Installation
1. Transportation
Keep the unit well packed before lifting the unit.
Please pay attention to the following items:
 Carefully transport the unit and keep the unit
vertical。
 Avoid the unit been touched by other objects
while lifting. Standing under the unit or closely
to the unit is not allowed.
 To avoid scratching the surface of the unit, put
gasket between the rope and unit.
. Installation
The base of the unit can be made of concrete. The unit also can be set on the supporter,
which can be installed on the wall or pillar. An isolator pad should be used between the unit
and base.
Unit Installation
The unit can be placed on the balcony, ground or roof.
Please pay attention to the following points while installing the unit.
 Keep enough space and good ventilation. Min. maintenance space refers to the drawing
No.2.
 Make sure that the air discharge and noise won’t affect the neighbors and unit is not
installed facing strong wind.
 Put rubber or spring isolators and level the unit.
 Select the place where is easy for discharging water.
 Put the unit close to the power supply plug to avoid large voltage drop.
 Avoid keeping the outdoor unit exposed to sunshine or rain. If it necessary, use some
shelter if it will not affect the air discharge.
If use several units, keep at least 2M between each unit for keeping good heat exchange.
St r ong Ropes
Br acket s
（Must be st r ong
and no def or amt i on. ）
Prot ect i on Pad
（Must be st r ong
and no def or amt i on. ）

Mini Air Cooled Chiller
5
Water Discharge
Valve
Electric Heater
Filter
Soft Connect Pipe
Flow Switch
Check Valve
Auto Water Supply
Valve
Auto Discharge
Valve
Thermometer
Pressure Gauge
Safety Valve
valve
Mini Chiller
Expansion Water
Tank
Code Description
This diagram is for close type water system.
One Way Different Way
Water System Installation
For pipe connection, please refer to diagram No. 3. Some of the accessories are provided by
TICA.
3. Important Points:
 The water flow switch must be installed on the horizontal straight pipes and keep the
distance of 5 times of pipe diameter from the elbow or valve etc. The flow switch must
be installed.
 The close type expansion tank is used to protect the water pipe from breaking caused over
high pressure.
 The auto water supply valve and water discharge valve. When water pressure drops, the
water supply valve will open automatically. When the water pressure is over 5bar, the
water discharge valve will open to discharge the water. The water supply pressure can
be determined by the actual situation at site.
 To avoid fre uent stop the unit, the water tank needs to be installed.
 Install an air discharge valve at the top of the whole water system and some higher
places.
 Well insulate the water pipes.
 Install the pressure gauge and thermometer at the water inlet/outlet.
Di st ance to
Wal l
＞500mm ＞800mm
Di st ance to
Wal l ＞500mm
＞1500mm
＞500mm
00mm
TVCA

Mini Air Cooled Chiller
6
Caution: If using the industrial detergent, please set a bypass to protect the evaporator.
Caution: Please connect the pipes correctly.
Warning：
：：
：Install the filter at the water inlet and clean it regularly. The max working
pressure should not higher than 0.5Mpa to avoid any damage.
Warning：
：：
：Before connecting the pipes, wash the outside pipes first.
4. Optional Parts Installation：
：：
：
Expansion Tank
The enclosed expansion tank can be used for the various water volume caused by
temperature change. It can protect the water pipe from over high pressure.
 Installing the expansion tank at the lower place of the water system is recommended.
 The tank needs to be insulated in the cold place to avoid freezing.
Safety Valve
The valve can be installed vertically or horizontally. The safety valve can be either vertical or
horizontal installing on the high pressure section (water outlet of water pump), but can not be upside
down. The drain pipe needs to be connected. Turning on the red knob can manually drain the water.
5br safety valve is recommended.
Auto Water Supply Valve
 Auto water supply valve can be either vertically or horizontally installed at the water
return circuit, but not upside down. The water supply volume should be adjusted
according to actual situation.
 Shut off the auto water supply valve and open the check valve for maintenance. Loosen
the screw. Take out the valve core to wash or replace it. Set the water supply pressure
after the maintenance.
Electric Heater
When the chiller is working during the wintertime, the heating capacity may be
affected with the drop the ambient temp. In that case electric heater is necessary.
The electric heater is e uipped with protection, which can cut off the power to avoid burning.
Open the water valve and start the water pump to discharge the air in the system first. After
the water system works stably, turn on the electric heater. If the electric heater will not be
used during wintertime, please discharge the water.
Install the electric heater at the water outlet through parallel connection. Refer to the
diagram of piping connection.
3. Electric Specifications
1. Power Supply
Over high/low voltage will damage the unit. The voltage fluctuation may cause electric
current overflow and the unit cannot be started.

Mini Air Cooled Chiller
7
The minimal voltage must be over 85% of the rated voltage. The voltage should be 10%
of the rated voltage for unit running. The voltage difference should
be within ±2% among different phases.
Check if the power supply complies with the re uirement. The phase protection is
provided. Check if the phase is correct before starting the unit. If the green light is on, it
indicates the power supply is connected correctly. If the yellow light is on, it indicates
missing phase. If red light is on, it means wrong phase.
. Unit Wiring
Must take the voltage drop and electric current into consideration while wiring.
Comply with electric regulations and decide the wiring and switch capacity to ensure the
normal operation.
Suggest to use the following chart to select the wires (RV or BVR):
The data in the following chart is the minimal re uirement:
Model Power Min. Wire
Current Mini Power Supply
FHCA40C(R) 220/50/1 25 6
FHCA40B(R) 380/50/3 12.5 2.5
FHCA50B(R) 380/50/3 13.5 4
FHCA60B(R) 380/50/3 14 4
FVCA50C(R) 220/50/1 25 6
FVCA60B(R) 380/50/3 14 4
FVCA60C(R) 220/50/1 38 10
FVCA80C(R) 220/50/1 45 15
FVCA80B(R) 380/50/3 23 6
FVCA100B(R) 380/50/3 24 6
FVCA120B(R) 380/50/3 31 10
FVCA150B(R) 380/50/3 35 10
FVCA200B(R) 380/50/3 42 16
Note:
1.Connect the power supply wire to main connector in the control box and the unit must
be grounding.
2.Connect the wire from the control panel to main control board.
3.The unit must be well earthen.
4.If the electric heater is e uipped, please connect its wire connection terminal to the
power supply.
5.If use FCU, please refer to the electric diagram and control manual
6.Connect the flow switch to the connector in the circuit board。
Warning
Don’t put power on before wires are well connected to avoid any accidents.
Use copper wires for wire terminal connection to avoid rust and over heating.

Mini Air Cooled Chiller
8
63 4
Yellow FM
CM PUMP
Red
Outer Coil 2
Sensor
Outer Coil 1 Sensor
Water Leaving
Temp Sensor
50 Ambient Temp
Sensor
Return Water Temp Sensor
2
12
MMP
2
13 8
P
9
SR T
50
White White
Low Pressure Switch
Power Supply Protection
KM1-2
FR1-2
FL
MMP
LP
RVR
Flow Switch
Wire control
AC Contactor
Relay
FVCA6
0BR

Mini Air Cooled Chiller
9
CM2CM1 PUMP
UMBER
BLACK
BLUE
P
θ
P
θ
P P
FAN
2
3
5
Ret ur n Wat er
Temp Sensor
Wat er Leavi ng
Temp Sensor
Out er Coi l 2
Sensor
Out er Coi l 1
Sensor MMP
Ambi ent Temp
Sensor
Pl ease i nst al l t he f l ow swi t ch,
ot her wi se t he syst em wi l l al ar m!
Wi r e cont r ol
Fl ow Swi t ch
Power Suppl y Pr ot ect i on
RVR
AC Cont act or
Rel ay
FR1- 2
KM1- 2
FL
MMP
LP
Wi r e cont r ol Low Pressur e Swi t ch
HP Hi gh Pressur e Swi t ch
FVCA80BR

Mini Air Cooled Chiller
10
Out er Coi l 2
Sensor
YELLOW YELLOW
Wat er Leavi ng
Temp Sensor
Out er Coi l 1
Sensor
Ambi ent Temp
Sensor
Ret ur n Wat er
Temp Sensor
P P
Low Pr essur e Swi t ch
Power Suppl y Pr ot ect i on
KM1- 2
FR1- 2
FL
MMP
LP
RVR
Fl ow Swi t ch
Wi r e cont r ol
AC Cont act or
Rel ay
FVCA100BR

Mini Air Cooled Chiller
11
θ
P
Outer Coi l 2 Sensor
yellow
Wat er Leavi ng
Temp Sensor
Outer Coi l 1 Sensor
Ambi ent Temp
Sensor Ret urn Wat er
Temp Sensor
P
θ
P P
Low Pr essur e Swi t ch
Power Suppl y Pr ot ect i on
KM1- 2
FR1- 2
FL
MMP
LP
RVR
Fl ow Swi t ch
Wi r e cont r ol
AC Cont act or
Rel ay
yellow
FVCA120BR

Mini Air Cooled Chiller
12
YELLOW
GREEN
RED
P P P P
Outer Coi l 2
Sensor
Outer Coi l 1
Sensor
Ret urn Wat er
Temp Sensor
Wat er Leavi ng
Temp Sensor
Ambi ent Temp
Sensor
LP Low Pr essur e Swi t ch
Wi r e cont r ol
MMP
AC Cont act or
Fl ow Swi t ch
Hi gh Pr essur e Swi t ch
KM1-
FL HP
FR1- 3 Rel ay
FVCA200BR

Mini Air Cooled Chiller
13
4. Test Run and Operation
1. Voltage Range
The power supply must comply with requirements. The fluctuation of voltage must be
kept in the stated range.
The voltage among each phase must be within ±10% of the stated voltage. Improper
voltage may cause control problem and shorten the electric components and compressor’s
life span.
If the voltage between three phase are not well balanced, it will cause motor overheat.
The max voltage difference is 2% among each phase.
Voltage imbalance%=100*|Va-Vd|/Va
Average Voltage：Va=（V1+V2+V3）/3 Voltage of Each Wire：V1，V2，V3
Max Va Voltage among wires：Vd
. Water Flow Rate
Low flow rate will result in abnormal unit pressure and unit stoppage. It will also
produce low water leaving temp, which may freeze the heat exchanger. The high pressure
caused by large water flow rate will damage the water pump and the whole water system.
Recommended Water Flow Rate：（m3/h）
Unit Pipe Size
Min
Flow Rate
Standard
Flow Rate
Max
Flow Rate
FHCA40 1" 1.056 1.6 2.4
FHCA50 1" 1.188 1.8 2.7
FHCA60 1" 1.452 2.2 3.3
FVCA50 1 1/4" 1.155 1.75 2.625
FVCA60 1 1/4" 1.551 2.35 3.525
FVCA80 1 1/4" 2.178 3.3 4.95
FVCA100 1 1/4" 3.036 4.6 6.9
FVCA120 1 1/4" 3.564 5.4 8.1
FVCA150 1 1/4" 4.62 7 10.5
FVCA200 1 1/2" 5.76 8.7 13.05
Check following items before starting the unit
※ Check all the wire connections and make sure all the wires are properly connected.
※ Check if the phases are correct and if the voltage is in the normal range.
※ Fill in the water and open the air discharge valve to make sure the system is filled
with water.
※ Put power on and check if the flow switch is closed. Start the water pump and make
the water circulate to check if there is a leakage and if the water flow rate is in the
normal range.
※ Water flow switch：Operate the water pump and adjust the water flow rate to the half
of the max flow rate and put the water flow switch off.

Mini Air Cooled Chiller
14
3. Unit Operation
1.Start up
※ Start the unit and select the running mode.
※ After the unit runs for 30 minutes, check the following items.
1. Check if Water flow rate and water pressure are in the normal range.
2. Measure the high/low pressure. The low pressure should be
between0.3~0.6Mpa and high pressure should be between 1.35~2.1Mpa.
3. Check the compressor electric current.
4. Make sure all the temp. sensors are properly set and the capillary should be
fastened to avoid any damage.
2.Long-term Unit Stoppage
Pay attention to the following items for long time stoppage：
1. Check if any leakage and make sure the unit is filled with refrigerant.
2. Discharge the water from system to avoid freezing during wintertime.
3. Turn off the power of the unit and water pump.
3.Startup after long time stoppage
1. Fill in the water again and open the air discharge valve at the same time. After the
water is filled, close the valve.
2. Put the power on and check water flow rate and if any leakage.
3. Put the power on for 24 hours to warm up the compressor before starting the unit.
4. System Protection
※ Anti-freezing during Winter
For heat pump unit which is in the status of power save during winter time, when the water
temp is lower than the set anti-freezing temp, the unit will automatically start the anti-freezing
function. Thus please put the power on during the winter time when the unit is used.
※ Anti-freezing of plate heat exchanger
While cooling and the water leaving temp is lower than 3℃，the compressor will be stopped
to protect the heat exchange. The water pump will keep running.
※Motor Overload Protection
Compressor over high temp or overload protection.
Water pump motor protection
Fan motor protection.
※ Temp Sensor Protection
The system will alarm if anything wrong with the temp sensor.
※ Compressor startup protection
The compressor has 2 minutes delay for starting. If the compressor is stopped while
operation has the delay of 3 minutes.
※ Flow rate protection
Install the flow switch to protect system from over low water flow rate and stop the unit while

Mini Air Cooled Chiller
15
the flow rate is lower than 50% of the rated flow rate.
※ Pressure Protection
When the pressure is lower than 0.05Mpa or higher than 2.8Mpa, the protection will work
and stop the compressor. The above-mentioned pressure is only suitable for normal
operation.
The condition of starting the unit and defrosting is not for the case.
Warning：If the ambient temp is less than 16℃, the unit cannot cooling. Please
specify if it is re uired while placing the order.
5. Control
Functions:
 Mode——Cooling，Heating
 Separate cooling and heating mode
 Water entering/leaving temp display
 Time Display
 Timer Set
 Manual Defrost
 Key Lock
 Memory——keep the same set information after the electricity is cut off.
 Colorful LCD Display
 Trouble Codes Display
 Time clock still works if no electricity.
1、 Mode
Switching the mode by pressing the mode key.
2、 Temperature set under cooling mode
Under the cooling mode, adjust the temp by pressing “up”&”down” key. The temp
range is 3℃ -25℃。
3、 Temperature set under heating mode:
The temperature range is from 25℃ to 50℃。
4、 Temp Display
Under normal operation, the chilled water temp will be displayed. The temp range is
from -40℃ to 87℃。 Press the “up” or “down” key for 5 seconds, the enter and leaving
water temp will be displayed. Any water temp sensor has problem, the system will
display the temperature obtained by other working sensors. If the water leaving temp
sensor doesn’t work, the system will display the outdoor temp.
5、 Time clock
Setting the time through the set key and +/- key.

Mini Air Cooled Chiller
16
6、 Timer
Press“set”key three times to set the time of starting and shutting down the unit. Setting
the time through pressing +/- key。 If the time is never been set before, it will display
0:00. If no operation after 15 seconds, the screen will go back to normal display.
7、 Manual Defrosting
Pressing “set” and “cancel” key for 5 seconds to enter the mode of defrosting. The
function only can works under heating mode.
8、 Key Lock
To avoid improper operation, the key can be locked by pressing “set” and “temp lower”
keys for 5 seconds. Unlock the key through the same way. When the function keys are
locked, only the on/off keys can be used
9、 Memory
The system can keep some important data, such as the set temp, password etc.
10、 Trouble Codes
Code Item Condition
2 Low Temp Compressor Stop, Water Pump still works.
3 High Temp Compressor Stop, Water Pump still works.
4 Temp Sensor Problem If the defrosting mode is 1 ，the mode will be
automatically transferred to 2.
5 Return Water Temp
Sensor Problem Unit is stopped.
6 Leaving Water Temp
Sensor Problem Unit is stopped.
7 Interlock Problem Unit is stopped.
8 Flow Switch is cut off Unit is stopped.
9 Fin NO. 1 Temp is too
high. System 1 will stop(cooling mode)
11 Fin 1 Temp Sensor
Problem System 1 will stop(heating mode)
13 1# Fan Overload System 1 will stop.
15 1#Compressor
Overload System 1 will stop.
15 1#Compressor Low
Pressure System 1 will stop.
16 1#Compressor High
Pressure System 1 will stop.
17 Fin No.2 temp over
high System 2 will stop. (While cooling)

Mini Air Cooled Chiller
17
19 Fin 1 Temp Sensor
Problem System 2 will stop.
21 2# Fan Overload System 2 will stop.
22 2# Compressor
Overload System 2 will stop.
23 2# Compressor Low
Pressure System 2 will stop.
24 2# Compressor High
Pressure System 2 will stop.
Note：
1、For those problems that can be solved automatically, the unit will back to normal
operation after 5 minutes.
2、For those problems cannot be solved automatically, use the reset key on the control to
clear the code.
3、Press the “set”and“temp+” at the same time for 5 seconds to reset.
11、 Temp In uiry
Press “temp+”and “mode”key for 5 seconds to enter the mode of temp in uiry.
Submenu Description Remark
C1 Coil Temp Display Use“set”key to select the corresponding
system coil temp.
C2 Water Leaving Temp
C3 Outdoor Temp
12、 Pre-heating on compressor oil
If to pre-heat the compressor oil, the screen will display “oil”.
13、 LCD colorful display
The colure of background light changes for different operation mode. Red indicates
trouble. When the problem is resolved, it color will back to normal. The background
light will be turned off in thirty seconds after.
14、 Battery
If the unit is out of electricity，the battery will continue let the unit clock work.
6. Service and Maintenance
Please pay attention to the following items：
1、Wash the water filter regularly. Make sure the water inside the system is clean to
avoid any damage caused by filter blockage.
2、All the safety devices are set before ex-factory. Please don’t change any set by

Mini Air Cooled Chiller
18
yourself.
3、Cleaning the coil every one-two months is helpful to keep good unit performance and
save energy.
4、Check the water supply and air discharge device regularly to avoid the air entering the
system.
5、Check the electrical wires and power supply wires and the electrical components
regularly. If anything abnormal, fix it or replace it timely. The unit should be
grounding.
6、Check the unit operation status and working pressure regularly. Check if the pipe
connections and refrigerant charge valve to make sure the cooling system has no
leakage.
7、Please don’t put foreign objects around the air outlet. Keep it clean and good
ventilation.
8、Discharge the water from the system, cut off the power and put the cover (the cover is
not provided with the unit.) on the unit for a long-term stoppage. Before starting the
unit next time, fill in the water and check the unit again. Warming up the unit for 6
hours and make sure the unit is in good condition, then start the unit.
Note:
 Separate power supply should be prepared for the unit. The voltage fluctuation
range should be within ±
±±
±10%. Use the auto air switch. Its electric current is
1.5 times of the running current. The phase protection should be equipped.
The knife switch is not allowed.
 Warming up the unit for 1 hours for each time startup after a long-term stoppage.
If the cooling only unit is not used during winter time, be sure to discharge the
water from the system to avoid being frozen. If the heat pump unit is not used
during winter time, keep the power on to avoid being frozen.
 Please don’t start the unit frequently and try not to start the unit over four times
within one hour. The control box should be protected from moisture.
 Directly washing the unit by water is prohibited. It may cause electric shock or
other accident.