Download Inverter Mini Chiller

TECHNICAL TRAINING
2007
Technical Training 2007
INVERTER MINI CHILLER
Technical Training 2007
Product Lineup & Features
5ACV100/135/210 CR
5ACV55/75 CR
5ACV30 CR
Technical Training 2007
Capacity
Model
Capacity (kW)
Cooling
Heating
5ACV030CR
7.94
9.66
5ACV055CR
14.65
16.12
5ACV075CR
20.52
21.99
5ACV100CR
27.80
29.30
5ACV135CR
38.54
41.47
5ACV210CR
58.62
61.55
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Features
New Technology BPHE- True Dual Circuits
Conventional Back to Back Circuits BPHE
Secondary Circuit
Primary Circuit 1
Primary Circuit 2
5ACV True Dual Circuits BPHE
Primary Circuit 1
Primary Circuit 2
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Features
Inverter Compressor
Conventional System
Inverter System
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Features
Elimination of Water Tank
Inverter system provide constant Water Temperature band, or
much lesser water temperature fluctuation. With this, water tank
of mini chiller system can be eliminated
Modular Installation
A network up to 50 chillers in a system is possible. Control on the
operation of chillers will be done through the microprocessor
controller. The external water piping connection can be made
either from the left or right side of the unit.
Safety Protection
• High & Low Pressure Switches
• Anti Freeze Protection Sensor
• Discharge Temperature Sensor
• Over Pressure Relief Valve
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• Water Pressure Differential Switch
• Anti Freeze Heater on BPHE
• Compressor, Water Pump
Overload Protector
Schematic diagram
Inverter chiller schematic diagram
Cond In
Temp 1
(Condenser)
5ACV100CR
Cond Out
Temp 1
(Def Comp 1)
Condenser Coil 1
HP1
Filter
Drier
4WV
Disch
Temp 1
(Disch Comp 1)
LP1
EXV
Suct
Temp
(Suction)
Inv
Comp
O/A Temp
(Outdoor Air)
BPHE In
Temp
(BPHE In)
BPHE Out
Temp
(BPHE Out)
Liq Rvr
Acc
Pump
BPHE
EWT (Water In)
FS
LWT (Water Out)
HP2
Cooling Cap Tube
4WV
Disch
Temp 2
(Disch Comp 2)
Check valve
LP2
Liq
Rvr
Std
Comp
Acc
Condenser Coil 2
Cond Out
Heating Cap Tube
Temp 2
(Def Comp 2)
Check valve
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Summary PagesScreen 3
Display MenuDefrost Sensor
Filter Display MenuDrier Inverter Chiller
Display MenuDischarge Sensor
Installation &
Commissioning
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Installation & Commissioning
• Unit Handling
• Unit Placement
• Maintenance Access
• Water Piping & Fitting
• Power Supply & Electrical Connection
• Preliminary Checking before Start-up
• General Control Flow Chart
Technical Training 2007
Unit Handling
5ACV 100/135/210 CR
Technical Training 2007
Unit Placement
• Air Cooled Chiller are cooled by air, space restriction will reduces the air
flow, decrease the cooling capacity, increase the power input and, in come
cases, prevent the unit from operating because of an excess of
condensation pressure.
• 5ACV equipped with propeller fan, which doesn’t need ductwork on fan
outlet.
• Direct effect of the wind on the discharge surface of the fan should be
avoided.
• Enough clearance around the unit for maintenance works.
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Unit Placement
Minimum clearances
5ACV30/55/75CR
5ACV100/135/210CR
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Unit Placement
Technical Training 2007
Maintenance Access
5ACV 30 / 55 / 75 CR
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Maintenance Access
5ACV 100 / 135 CR
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Maintenance Access
5ACV 210 CR
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Water Piping & Fitting
!
Install piping with minimum bends and changes in elevation to
minimize pressure drop. Consider the following;
• Vibration eliminators to reduce vibration and noise transmission to the
building.
• Shut off valves to isolate the unit from the piping system during unit
servicing.
• Manual or automatic air vent valves at the highest points of the chilled
water piping.
• A means of maintaining adequate system water pressure (expansion
tank or regulating valve)
• Temperature and pressure indicators located at the unit to air in unit
servicing.
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Water Piping & Fitting
!
Water connection could be damaged by an excessive stress
when screwing them. Use a second spanner to compensate
the stress of tightening.
• Safety differential pressure switch is used to ensure adequate water
flow to evaporator before starting up the unit.
• Balancing valve to regulate the amount of water flow rate through the
unit.
!
It is mandatory to install a strainer at the inlet of the unit.
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Water Piping & Fitting
Recommended Piping Connection
Technical Training 2007
Power Supply & Electrical Connection
Recommended Fuses & Cable Size
Model
5ACV30CR
5ACV55CR
5ACV75CR
Voltage Range **
230 / 1 / 50
415 / 3 / 50
415 / 3 / 50
Recommended Fuse (A) *
36
25
10
Power Supply Cable Size (mm2) *
Number of Conductor
10
3
10
5
10
5
Interconnection Cable Size (mm2) *
1.5
1.5
1.5
5ACV100CR
5ACV135CR
5ACV210CR
Model
380 – 415 / 3 / 50
Voltage Range **
Recommended Fuse (A) *
40
60
100
Power Supply Cable Size (mm2) *
Number of Conductor
10
3
10
5
10
5
Interconnection Cable Size (mm2) *
1.5
1.5
1.5
IMPORTANT: * The figures shown in the table are for information purpose only. They should be
checked and selected to comply with local/national codes of regulation. This is also
subject to the type of installation and conduction used.
** The appropriate voltage range should be checked with label data on the unit.
Technical Training 2007
Power Supply & Electrical Connection
!
Before carrying out any operations on the electrical system, make
sure that the unit is de-energized.
!
It is important that the appliance is grounded.
!
Before connecting the power supply lines, check that the available
voltage value does not exceed the range specified in the electrical
data being provided in Installation Manual.
!
It’s recommended to check the correct sequence of the 3 supply
phases R-S-T before the unit start up.
Technical Training 2007
Preliminary Checking before Start-up
• Check the power supply and grounding cable.
• Check that any voltage and phase variation in the power supply does
not exceed the prefixed thresholds.
• Check that components of the external water circuit have been installed
properly, and according to the manufacturer’s instructions.
• Check that the filling of the hydraulic circuits, and make sure that the
fluid circulation is correct, without any trace of leaks and air bubbles.
• Check that the direction of rotation of the pumps is correct.
• Adjust the liquid distribution network in such a way that the flow rate is
within the specified range.
• Check that the water quality is up to the specification.
Technical Training 2007
General Control Flow Chart
General Control Flow Chart
Start
No
System On?
Yes
Clash between
current & selected
mode of operation?
Yes
No
Stop Inverter Comp
Cooling?
60s
No
Yes
Heating?
No
Yes
Stop pump
Cooling mode
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Heating mode
General Control Flow Chart
Cooling Mode Control Flow Chart
Start
DT = Actual Entering water temp Cooling water temp set point
Pump on
No
Pump on for
>3 min?
Yes
No
No
DT < -2°C
for > 180s?
Yes
No
Frequency &
EXV opening
adjustment
Yes
DT > -2°C ?
Inverter Comp
Off?
Yes
No
DT > 2°C ?
Yes
Stop Inverter
Comp
5s
30s
Return
Technical Training 2007
Shut Inverter
4WV & start
Inverter O/Fan
Start Inverter
Comp
General Control Flow Chart
Heating Mode Control Flow Chart
Start
DT = Heating water temp set point Actual Entering water temp
Pump on
No
Pump on for
>3 min?
Yes
No
No
DT < -2°C
for > 180s?
Yes
No
Frequency &
EXV opening
adjustment
Yes
DT > -2°C ?
Inverter Comp
Off?
Yes
No
DT > 2°C ?
Yes
Stop Inverter
Comp
Shut Inverter
4WV & start
5s Inverter O/Fan
30s
Return
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Start Inverter
Comp
Self Diagnosis &
Troubleshooting
Technical Training 2007
Components
Fan guards
Coil guards
Variable speed
fan motors
(100%, 70% &
50%)
Heat
exchangers with
gold fin as
standard
True dual circuits BPHE
(Brazed plate heat
exchanger)
Control box
assembly
Technical Training 2007
Expansion
tank ( 8L)
Water pump
Components
High pressure switch
(NC) 600 psi – open,
480psi – close.
Low pressure switch
(NC) 18 psi – open,
28 psi – close.
Chiller panel
controller
Differential pressure
switch
Over pressure relief
valve
Fixed speed
scroll
compressor
(R410A)
Anti freeze heater on
BPHE
Pump OLP (overload
protector)
Compressor OLP
(overload protector)
Variable speed
scroll
compressor
(R410A)
Variable drive system
compartment
Technical Training 2007
Fixed drive system
compartment
Components
Control box assembly
Unidirectional
bridge diode
IPM board
(Intelligent power module)
3 phase
rectifier
bridge diode
Fan
capacitors
Power board
EMI filter
PFC capacitor
Capacitor
board
(Power factor correction)
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Main board
Magnetic
contactors
Components
Main Board
For Model 55, 75, 100 & 135
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For Model 30
Components
Power Board
- To convert rectified DC current
+500VDC to respective desired
voltages
- 12VDC relay
- MCU +5VDC
- IPM +15VDC
- Ensure stability of above voltages
within power supply voltage fluctuation
range (304-480 VAC)
- Over voltage feedback
- Output short circuit protection
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Components
Capacitor Board
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Components
IPM
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Self Diagnosis & Troubleshooting
Error Code
Error Display
Error Description
Reset
(default)
Control Measure
Pump
System 1
(Variable Drive)
System 2
(Fixed Drive)
Comp
Fan
Comp
Fan
Phase Missing
Phase Missing
Manual
OFF
OFF
OFF
OFF
OFF
Phase Seq Error
Wrong phase
Sequencing
Manual
OFF
OFF
OFF
OFF
OFF
Memory Error
EEPROM read/write
error
Auto
OFF
OFF
OFF
OFF
OFF
IPM Error
IPM over-current or over
heat
Auto
OFF
OFF
OFF
OFF
OFF
Continue….
Technical Training 2007
Self Diagnosis & Troubleshooting
Error Code
Error Display
Error Description
Reset
(default)
Control Measure
Pump
System 1
(Variable Drive)
System 2
(Fixed Drive)
Comp
Fan
Comp
Fan
Entering Water Sensor
Open/Short
BPHE water in
sensor error
Auto
OFF
OFF
OFF
OFF
OFF
Leaving Water Sensor
Open/Short
BPHE water out
sensor error
Auto
OFF
OFF
OFF
OFF
OFF
V-Hx inlet Temp sensor
Open/Short
BPHE refrigerant
in sensor error
Auto
-
OFF
OFF
-
-
V-Hx outlet Temp sensor
Open/Short
BPHE refrigerant
out sensor error
Auto
-
OFF
OFF
-
-
Coil 1 inlet Temp
Open/Short
Coil in system 1
sensor error
Auto
-
OFF
OFF
-
-
Outdoor Air Sensor
Open/Short
Ambient Temp
sensor error
Auto
OFF
OFF
OFF
OFF
OFF
Continue….
Technical Training 2007
Self Diagnosis & Troubleshooting
Error Code
Error Display
Error Description
Water Flow Error
Cv Contact
opened
Cool Mode Antifreeze
Reset
(default)
Control Measure
Pump
System 1
(Variable Drive)
System 2
(Fixed Drive)
Comp
Fan
Comp
Fan
Manual
OFF
OFF
OFF
OFF
OFF
Leaving water
temp too low
Auto
OFF
OFF
OFF
OFF
OFF
Pump overload
Pump OLP
opened
Auto
OFF
OFF
OFF
OFF
OFF
Comp 1 Overload
Comp 1 Overload
Auto
-
OFF
OFF
-
-
Comp 2 Overload
Comp 1 Overload
Auto
-
-
-
OFF
OFF
Continue….
Technical Training 2007
Self Diagnosis & Troubleshooting
Error Code
Error Display
Error Description
Reset
(default)
Control Measure
Pump
System 1
(Variable Drive)
System 2
(Fixed Drive)
Comp
Fan
Comp
Fan
Comp 1 Discharge
Overheat
Comp 1 discharge
Overheat
Auto
-
OFF
OFF
-
-
Comp 1 Defrost
Sensor Open/Short
Coil Out system 1
sensor error
Auto
-
OFF
OFF
-
-
Comp 1 Suct Sensor
Open/Short
Suction comp system
1 sensor error
Auto
-
OFF
OFF
-
-
Comp 1 Discharge
Sensor Open/Short
Discharge Comp
system 1 sensor error
Auto
-
OFF
OFF
-
-
Comp 2 Defrost
sensor Open/Short
Coil out system 2
sensor error
Auto
-
-
-
OFF
OFF
Comp 2 Discharge
Sensor
Open/Short/Overheat
Discharge comp
system 2 sensor
error
Auto
-
-
-
OFF
OFF
Continue….
Technical Training 2007
Self Diagnosis & Troubleshooting
Error Code
Error Display
Error Description
Reset
(default)
Control Measure
Pump
System 1
(Variable Drive)
System 2
(Fixed Drive)
Comp
Fan
Comp
Fan
OV/UN Voltage
Comp. High Voltage
(>490V)
<460V,
Auto
OFF
OFF
OFF
OFF
OFF
OV/UN Voltage
Comp. Low Voltage
(<310V)
>340V,
Auto
OFF
OFF
OFF
OFF
OFF
High Pressure 1
System 1 high
pressure
Auto
-
OFF
OFF
-
-
Low Pressure 1
System 1 low
pressure
Auto
-
OFF
OFF
-
-
High Pressure 2
System 2 high
pressure
Auto
-
-
-
OFF
OFF
Low Pressure 2
System 2 low
pressure
Auto
-
-
-
OFF
OFF
Technical Training 2007
Self Diagnosis & Troubleshooting
1. No response after power-on
No response
Yes
Is main board
LED light?
Yes
Check
setting &
operating
condition
No
Is connection
IPM and Main
Board OK?
Yes
Main Board or IPM
Board Faulty
No
No
Is R,S,T Input
voltage
normal?
Check Input
power supply
vac
Connection Wire or
Connector Faulty
Rectifier
Yes
Is Power
Board
OK?
No
Change Power
Board
Power
Board
Main Board
Technical Training 2007
IPM
Self Diagnosis & Troubleshooting
2. LED on main board normal, but no output.
LED lighted, No output
Is Setting
Parameter ok?
No
Change the Setting
Parameter
No
Check Operating
condition
Yes
Is Operating
Condition OK?
Yes
Is main board’s
fuse ok?
Yes
Replace main board
Technical Training 2007
No
Change Fuse
Self Diagnosis & Troubleshooting
3. Other functions normal but compressor not functioning
Others OK, Comp
not functioning
Is fuse in DC
loop ok?
Yes
Check operating conditions
No
Yes
Is IPM OK?
Check IPM
No
Is compressor
ok?
Yes
Change Fuse
Technical Training 2007
No
Replace
Compressor
Self Diagnosis & Troubleshooting
4. Flow switch protection -E01
Water flow error
Short JK4
JK4 on main board
Is water
flow error
persists?
Yes
Main board faulty ,
replace main board
Technical Training 2007
No
Flow switch
faulty or pump
stopped.
Self Diagnosis & Troubleshooting
5. Over voltage protection -E02
OV/UN Voltage
Is Power
supply >
490VAC?
Yes
No
Is Power
supply <
460VAC?
Yes
Power board error,
rectify.
Technical Training 2007
No
Check the
Electrical supply
Self Diagnosis & Troubleshooting
6. Under voltage protection -E03
OV/UN Voltage
Is Power
supply <
310VAC?
Yes
No
Is Power
supply >
340VAC?
Yes
Power board error,
rectify.
Technical Training 2007
No
Check the Power
supply
Self Diagnosis & Troubleshooting
7. Pump overload protection- E05
Pump overload
JK8 on main board
Is voltage of 97,
98 on heat relay
VDC = 0 V
No
Yes
Remove JK8, 97 &
98, check
connectivity
Yes
Pump overload
Technical Training 2007
No
Main board faulty
Self Diagnosis & Troubleshooting
8. Phase missing – E06
Phase missing
Is Voltage between
R,S,T 415VAC
±20%?
No
Check incoming supply
Yes
Is J-RST on main
board 415VAC
±20%?
3 Phase supply
Yes
No
Disconnect power,
remove J-RST, is
voltage of socket
415VAC ±20%?
No
To Check/replace EMI filter
Technical Training 2007
Yes
Main board faulty
Self Diagnosis & Troubleshooting
Phase seq error – E07
- Interchange any 2 phase of R, S, T.
Memory Error – E08
- Replace chip 24C02
Sensor Error – E09, E12, E14, E20, E21, E22, E23, E24, E25, E30,
E31, E33, E34
- Check against the resistance cable.
Technical Training 2007
Self Diagnosis & Troubleshooting
9. IPM protection –E15
IPM Error
Yes
Is IPM ok?
Replace
Display Menu for Inverter
No
Inverter Chiller
Is current at
rated frequency
ok?
No
Check
compressor
Yes
Is IPM Error
persists?
No
Technical Training 2007
Normal
Comp Freq
: 75Hz
EXV
: 320
Comp Amp
: 9.7A
DC Bus
: 555V
Self Diagnosis & Troubleshooting
9. IPM protection –E15
Yes
Is heat sink
temperature
>100°C?
No
Is IPM
temperature
>100°C?
• Use thermocouple.
Yes
Rectify
Heat Sink
• Use thermocouple.
No
Main board faulty
or wrong signal
Yes
Is heat
compound dried
out?
No
Change IPM
Yes
Reapply heat
compound
Technical Training 2007
IPM
Heat Compound
Self Diagnosis & Troubleshooting
10. Variable compressor over-current protection –E16
Comp 1
overload
Restart. Check
compressor current on
the handset.
< 18 A?
Yes
Check Compressor
winding resistance
No
Main board or
compressor faulty
Replace
* For 5ACV30CR, Overload protection triggers when compressor current > 27 A
Technical Training 2007
Self Diagnosis & Troubleshooting
11. Variable drive high pressure protection –E17 & E27
High
Pressure 1
• Remove hp pin from main board.
• Remove OF.
Is high pressure
switch ok?
Yes
Check AC system
for overload
Rectify
Technical Training 2007
No
Replace
Self Diagnosis & Troubleshooting
12. Variable drive low pressure protection –E18 & E28
Low
Pressure 1
Is low pressure
switch ok?
Yes
Check AC system
for low pressure
Rectify
Technical Training 2007
No
Replace
Self Diagnosis & Troubleshooting
13. Variable compressor high discharge temperature protection
Comp 1
Discharge
Overheat
> 110 °C ?
Temp sensor ok?
(<100°C?)
Check AC system
Rectify
Technical Training 2007
Yes
Compressor
stops
No
Replace
Self Diagnosis & Troubleshooting
14. Fixed compressor over-current protection
• Check VAC
Comp 2 Overload
• Check continuity.
Check on
compressor
winding
resistance, is
it to spec ?
Yes
No
Rectify
No
Rectify
Yes
• Check continuity.
Check on
Compressor
insulation, is it
ok?
Is supply
voltage ok?
No
Yes
Technical Training 2007
Check current
reading on handset
against actual
reading, is it very
big different?
Rectify
Yes
Current sensing circuit
error. Replace main
board
No
Normal
Self Diagnosis & Troubleshooting
Power Board Checking
Power Board
Power Board Checking
Is Power board
DC-IN voltage
normal?
No
Check bridge diode
Yes
Main Board or
IPM Board
Faulty
Yes
Is JP-power/DCOUT output
normal?
DC-IN (+590VDC)
No
Replace power
Board
JP-Power
(+12Vdc & 7Vdc)
Technical Training 2007
DC-Out
(+15Vdc)
Self Diagnosis & Troubleshooting
IPM Board Checking
P
N
Use multi-meter to check the Vdc between
the P and N. The voltage should be around
590Vdc
Technical Training 2007
Self Diagnosis & Troubleshooting
Power Supply Checking
• Use the multi-meter to check the power supply to controller.
• Refer to any of the 2 phase of supply (R&S, S&T or R&T).
• The supply should be 415VAC
Technical Training 2007
Self Diagnosis & Troubleshooting
Fuse Checking
Use multi-meter to check the continuity of the fuse. Fuse with
sound ‘BEEP’ is ok
Technical Training 2007
Self Diagnosis & Troubleshooting
Fuse Checking
Use multi-meter to check the continuity of the fuse. Fuse with sound
‘BEEP’ is ok
Technical Training 2007
Self Diagnosis & Troubleshooting
Compressor Checking
Check Compressor
Check on
compressor winding
resistance, is it ok?
No
Change
Compressor
Yes
Check on
Compressor
insulation, is it
ok?
No
Change
Compressor
Yes
Is
compressor
short body?
No
Compressor OK
Technical Training 2007
Yes
Change
Compressor
Self Diagnosis & Troubleshooting
Bridge Diode Checking
+
~
Use multi-meter to check the continuity of
the bridge diode.
~
-
Technical Training 2007
Resistance Table
Low Temperature Sensor (Coil sensor and room/ambient sensor)
Temperature
(°C)
Resistance
(k Ω)
Temperature
(°C)
Resistance
(k Ω)
-6
18.73
18
6.59
-4
17.06
20
6.08
-2
15.56
22
5.62
0
14.21
24
5.20
2
12.99
26
4.81
4
11.88
28
4.46
6
10.89
30
4.13
8
9.99
32
3.84
10
9.17
34
3.56
12
8.43
36
3.31
14
7.76
38
3.08
16
7.15
40
2.87
When Temp = 25°C, Resistance = 5 kΩ
Technical Training 2007
Resistance Table
High Temperature Sensor (Discharge sensor)
Temperature
(°C)
Resistance
(k Ω)
Temperature
(°C)
Resistance
(k Ω)
-6
457.41
18
137.52
-4
410.63
20
125.40
-2
369.25
22
114.46
0
332.55
24
104.59
2
299.94
26
95.67
4
279.90
28
87.60
6
245.00
30
80.30
8
221.86
32
73.67
10
201.16
34
67.66
12
182.60
36
62.21
14
165.95
38
57.24
16
150.98
40
52.73
When Temp = 100°C, Resistance = 6.5 kΩ
Technical Training 2007
Thank You
Technical Training 2007