Survey
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project
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 Technical Training 2007 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 Technical Training 2007 Features Inverter Compressor Conventional System Inverter System Technical Training 2007 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 Technical Training 2007 • 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 Technical Training 2007 Summary PagesScreen 3 Display MenuDefrost Sensor Filter Display MenuDrier Inverter Chiller Display MenuDischarge Sensor Installation & Commissioning Technical Training 2007 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. Technical Training 2007 Unit Placement Minimum clearances 5ACV30/55/75CR 5ACV100/135/210CR Technical Training 2007 Unit Placement Technical Training 2007 Maintenance Access 5ACV 30 / 55 / 75 CR Technical Training 2007 Maintenance Access 5ACV 100 / 135 CR Technical Training 2007 Maintenance Access 5ACV 210 CR Technical Training 2007 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. Technical Training 2007 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. Technical Training 2007 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 Technical Training 2007 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 Technical Training 2007 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) Technical Training 2007 Main board Magnetic contactors Components Main Board For Model 55, 75, 100 & 135 Technical Training 2007 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 Technical Training 2007 Components Capacitor Board Technical Training 2007 Components IPM 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 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