Control Algorithm Variable Drive Compressor Control Cooling mode Start up condition : • Pump runs normally for 2 minutes * For example : Return water temp.= 14 to 16 °C • 2°C ≤ ≤ 4°C Set temp = 12°C T water return – T set Δ T = 2 to 4°C • No irreversible errors in variable drive and the systems Technical Training Technical Training Technical Training • Satisfy a delay of 3 minutes before restart # Note : If fixed drive system starts first, the variable drive system should trail after 30 sec. * Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default 120s ) # Depends on Parameter C2 (compressor min stop time. Min 0s, max 1990s, default 180s) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Cooling mode Cooling mode selected � water pump starts � Outdoor fan starts � variable drive compressor starts Increase to rated Rated Freq. frequency with the 5ACV100CR=75Hz rate of 1Hz/s 5ACV135CR=95Hz 55Hz Inverter compressor will 5Hz start from 5Hz to 55Hz and maintain this t Technical Training Technical Training Technical Training frequency for 1 min. 3 min 5 sec 1 min Variable drive comp ON OFF ON OFF Outdoor fan Outdoor fan will start 5 sec before compressor start Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Cooling mode Shut down condition : • Cooling mode terminates, OR • Variable drive system error occurs, OR Technical Training Technical Training Technical Training ≤ -2°C • T water return – T set For example : Return water temp.= 10°C Set temp = 12°C Δ T = -2°C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Heating mode Start up condition : • Pump runs normally for 2 minutes * For example : Set temp = 40°C • 2°C ≤ T set - T water return ≤ 4°C Return water temp.= 36 to 38 °C Δ T = 2 to 4°C • No irreversible errors in variable drive and the systems Technical Training Technical Training Technical Training • Satisfy a delay of 3 minutes before restart # Note : If fixed drive system starts first, the variable drive system should trail after 30 sec. * Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default 120s ) # Depends on Parameter C2 (compressor min stop time. Min 0s, max 1990s, default 180s) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Heating mode Heating mode selected � water pump starts � Variable drive 4WV engages � Outdoor fan starts � compressor starts Increase to rated frequency with the rate of 1Hz/s Rated Freq. 5ACV100CR=65Hz 5ACV135CR=90Hz Inverter compressor will 45Hz start from 5Hz to 45Hz and maintain this 5Hz frequency for 1 min. Technical Training Technical Training t Technical Training 3 min 10 sec 1 min Variable drive comp ON OFF ON OFF Variable 4WV ON OFF Outdoor fan 5 sec Variable drive 4WV start 10 Outdoor fan will start 5 sec sec before compressor start before compressor start Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Heating mode Shut down condition : • Heating mode terminates, OR • Variable drive system error occurs, OR Technical Training Technical Training Technical Training ≤ -2°C For example : • T set - T water return Set temp = 40°C Water return temp = 42°C Δ T = -2°C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Fixed Drive Compressor Control Cooling mode Start up condition : • Pump runs normally for 2 minutes * For example : Water return temp = 16°C • T water return – T set > 4°C Set temp = 12°C Δ T = 4°C Fixed drive starts first followed by variable drive • No irreversible errors in fixed drive and the systems Technical Training Technical Training Technical Training • Satisfy a delay of 3 minutes before restart # Note : I f variable drive system starts first, the fixed drive system will only start after the frequency of variable drive drops to 50Hz. * Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default 120s ) # Depends on Parameter C2 (compressor min stop time. Min 0s, max 1990s, default 180s) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Cooling mode Cooling mode selected � water pump starts � Outdoor fan starts � compressor starts Fixed drive compressor starts ON Fixed drive comp OFF 3 min 5 sec 1 min ON Technical Training Technical Training Technical Training Outdoor fan OFF Outdoor fan will start 5 sec Outdoor fan will stop after before compressor start compressor has stopped for 1 min Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Cooling mode Shut down condition : • Cooling mode terminates, OR • Fixed drive system error occurs, OR Technical Training Technical Training Technical Training • T set - T water return > 2°C and variable frequency drops pass 20Hz For example : Set temp = 12°C Water return temp = 10°C Δ T = 2°C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Heating mode Start up condition : • Pump runs normally for 2 minutes * For example : Set temp = 40°C • T set - T water return > 4°C Water return temp = 36°C Δ T = 4°C • No irreversible errors in fixed drive and the systems • Satisfy a delay of 3 minutes before restart # Technical Training Technical Training Technical Training Note : I f variable drive system starts first, the fixed drive system will start after the variable drive frequency drops to 50Hz. * Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default 120s ) # Depends on Parameter C2 (compressor min stop time. Min 0s, max 1990s, default 180s) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Heating mode Heating mode selected � water pump starts � Fixed drive 4WV engages � Outdoor fan starts � compressor starts Fixed drive compressor starts ON Fixed drive comp OFF 1 min 10 sec 3 min ON Technical Training Technical Training Technical Training 5 sec Variable 4WV OFF ON Outdoor fan OFF Outdoor fan and 4WV will Fixed drive 4WV start 10 sec Outdoor fan will start 5 sec stop after compressor has before compressor start before compressor start stopped for 1 min Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Heating mode Shut down condition : • Heating mode terminates, OR • Fixed drive system error occurs, OR • T water return - T set > 2°C Technical Training Technical Training Technical Training For example : Water return temp = 42°C Set temp = 40°C Δ T = 2°C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Pump Control Pump start up When starting the system, pump will run for 2 minutes * before proceeding to next step. * Depends on Parameter P2 (flow switch alarm delay at pump start. Min = 0s, Max = 199s, default = 120s) Pump shut down Technical Training Technical Training Technical Training After both compressors shut down for 1 minute, pump shuts down. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Pump Control System error When errors occur in the system and require system to shut down, the pump will shut down 1 minute after the system shuts down. If compressor is not running, the pump shuts down immediately. Technical Training Technical Training Note : When changing operating mode or when temperature reaches Technical Training setting, pump continues to run. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Auxiliary heater control (I nfo only) Start up conditions • System in heating mode AND Heating No error • System no error alarm AND Running 1 hour Δ T > 5°C • After heating starts for 1 hour and T set – T water return > 5°C For example: Set temp = 40°C The second time start up is not time –dependent. Water return temp = 34°C Δ T = 6°C Technical Training Technical Training Switch off conditions Technical Training • System terminates heating mode OR • Wired handset withdraws auxiliary heating command, OR • System errors trigger alarm and require shut down, OR • When T set – T water return < 2°C Heating X Error Δ T < 2°C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm EXV control (Electronic expansion valve) • When system operates for the first time, EXV will operate to preset openings. • After system operates for 10 minutes, the EXV will preset to superheat regulation for variable drive system. Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm 4 way reversible valve control Select heating mode 4 WV engage 5 sec Heating starts Stop heating mode compressor stops 4 WV disengage 60 sec • When selecting heating mode, 4 way valve will engage 5 seconds before heating start up. • When heating stops, 4 way valve will disengage 60 seconds after compressor stops. Compressor crankcase heater control Technical Training Technical Training Technical Training • Fixed drive compressor crankcase heater is driven by the fixed drive contactor (NC). • Variable drive compressor crankcase heater is driven by main board relay. • Crankcase heater will be ON whenever compressors are not in operation. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Outdoor fan control Control basic • Fixed drive and variable drive outdoor fan are independently controlled. • During start up, fan operates at fixed speed. During operation, fans operate at variable speed. Technical Training Technical Training Technical Training • There are 3 fan speeds in High, Medium and Low fan speed. • The High fan speed is 680 RPM and 3800CFM for each fan motor. • The ratio of fan speed is 100%, 70% and 50% respectively. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Outdoor fan control Fan control for Cooling • Within 20 minutes of normal operation, when Te (Outdoor ambient temp.) ≥ 28°C, fan operates at highest speed. • Within 20 minutes of normal operation, when Te (Outdoor ambient temp.) < 28°C, fan operates at medium fan. • After normal operation for 20 minutes, when 40°C < (T a3 , T b2 ) < 48°C, the fan operates to variable speed (PI regulation). The lower the temperature the lower the speed. T a3 , T b2 T a3 = condenser outlet temp. High fan zone Technical Training Technical Training Technical Training (Variable drive system) 48°C Constant fan speed PI control zone T b2 = condenser outlet temp. control zone (Fixed drive system) 40°C PI = program intelligent Te ≥ 28°C (High fan) Te < 28°C (Med fan) Low fan zone 20 min Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Outdoor fan control Fan control for Heating • When Te (Outdoor ambient temp.) < 10°C, fan operates at highest speed. • When 10°C ≤ Te (Outdoor ambient temp.) ≤ 12°C, fan operates at medium fan. • When Te (Outdoor ambient temp.) > 12°C, fan operates at variable speed to PI regulation. The higher the temperature the lower the speed. Te Low fan Technical Training Technical Training Technical Training PI control PI= program intelligent 12°C Constant fan speed control zone (medium fan) 10°C Constant fan speed control zone (high fan) High fan High fan t Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Outdoor fan control Fan operation during defrosting Defrost start Defrost end 70 Hz Variable drive comp 30 Hz 30 Hz Resume heating mode Variable 4WV Technical Training Technical Training Technical Training Outdoor fan Fan stops 1 minute after the compressor stops. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Anti freeze heater control Anti freeze on/off control during system standby • Runs when system in standby mode • If Te (outdoor ambient temperature) ≤ 5°C and T water return ≤ 5°C, water pump runs 5 minutes every hour and antifreeze heater will run on and off together with the water pump. • If T water return > 6°C water pump and antifreeze heater will stop. • If Te ≤ 2°C and T water return ≤ 2°C, system enters heating mode and returns to standby when T water return > 30°C Technical Training Technical Training Technical Training Run 5 min/hr ON Water pump Antifreeze heater ON °C System enters 2 5 6 30 heating mode Water return temperature/Outdoor ambient temperature Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Anti freeze heater control Anti freeze during cooling • When T water leaving ≤ 5°C, antifreeze heater will operate until T water leaving > 7°C. • When T water leaving ≤ 3°C, alarm will set off until T water leaving > 5°C. Technical Training Technical Training Technical Training Factory setting for antifreeze heater = 5°C Antifreeze heater alarm set point = 3°C ON °C 3 5 7 Water leaving temperature Alarm on Alarm off Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Defrosting control Automatic defrosting Shall satisfying the below automatic defrosting condition for 3 minutes : • Compressor operates continuously for at least the duration of the defrosting interval. T a3 = condenser outlet temp. • When T a3 or T b2 ≤ 0°C * OR (Variable drive system) T b2 = condenser outlet temp. (Fixed • When T water return > 18°C drive system) * Depends on Parameter D1 (Start defrost temperature. Min -20°C, max 14°C, default 0°C ) Note : Factory defrost interval depends on Parameter D4 (Defrost interval time). Technical Training Technical Training Technical Training Intelligent defrost interval varies. Under Parameter defrost mode, Intelligent defrost is set as default under DISABLE mode. Factory standard defrost will be activated when the parameter is set to ENABLE. Manual defrosting Manual defrosting can be carried out when T a3 or T b2 < 7°C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Defrosting control Defrosting process Variable drive defrosting process • When defrosting conditions are met for variable drive, variable drive compressor stops � outdoor fan stops � 4WV disengages � variable drive starts defrost at 90Hz. • When variable drive defrosting terminates, variable drive compressor stops � 4WV engages � outdoor fan starts � variable drive compressor starts � Resume heating operation. Defrost start Defrost end 90 Hz Variable drive comp Technical Training Technical Training Technical Training Resume heating 30 Hz 30 Hz mode Variable 4WV ON OFF Outdoor fan ON OFF Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Defrosting control Defrosting process Fixed drive defrosting process • When defrosting conditions are met for fixed drive, fixed drive compressor stops (15 sec) � outdoor fan stops (2 sec) � 4WV disengages (10 sec) � fixed drive compressor starts defrost • When fixed drive defrosting terminates, fixed drive compressor stops � outdoor fan starts at high speed for 30 sec � 4 WV engages � Fixed drive compressor starts � Resume heating operation. Defrost start Defrost end Resume heating mode Technical Training Technical Training Technical Training Fixed drive comp ON OFF 15 sec 10 sec 10 sec Outdoor fan ON OFF 2 sec 4WV ON OFF 2 sec 2 sec Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Defrosting control Defrosting process • As the outdoor fan ducts are independent, defrosting is independent, system restricts defrosting of fixed drive and variable drive at the same time. • When either variable or fixed drive high pressure protection is triggered, compressor will stop. Technical Training Technical Training Technical Training • During defrosting, low pressure operation will not trigger protection. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Defrosting control Defrosting termination conditions When either of the below condition is met, defrosting terminates : • T a3 or T b2 > 14°C * , OR T a3 = condenser outlet temp. (Variable drive system) • Defrosting time exceed 10 minutes # , OR T b2 = condenser outlet temp. (Fixed • T water return < 10°C drive system) Technical Training Technical Training Technical Training * Depends on Parameter D2 (End defrost temperature. Min= 0°C, max= 40°C, default = 14°C) # Depends on Parameter D3 (Maximum duration of defrost cycle. Min= 1min, max= 40min, default= 10min) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Defrosting control Defrosting cycle self-adaptive adjustment The next defrosting cycle depends on that of the previous. 1. Defrosting time < 2 minutes, next cycle 120 minutes 2. Defrosting time 2 to 4 minutes, next cycle 80 minutes 3. Defrosting time 4 to 6 minutes, next cycle 60 minutes 4. Defrosting time 6 to 8 minutes, next cycle 40 minutes 5. Defrosting time > 8 minutes, next cycle 30 minutes < 2 min 120 min Technical Training Technical Training Technical Training 2 – 4 min 80 min 4 – 6 min 60 min 6 – 8 min 40 min > 8 min 30 min Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection Compressor over-current protection Variable drive compressor • When variable drive compressor current reaches the maximum limit, over-current protection triggers and the compressor frequency will reduce. • When the compressor current drops below the limit, frequency variation resumes. • When compressor current increase rapidly and reaches the maximum limit, the system will be determined as compressor overload and stop the compressor. Comp amp Variable compressor stops (A) Technical Training Technical Training Technical Training 20.5 Frequency step down 18 Maintain frequency 17 Normal Operation Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection High discharge temperature protection Variable drive system • When variable drive discharge temperature reaches 110°C, system stops. • When variable drive discharge temp. between 100°C and 110°C, frequency drops. • When variable drive discharge temperature is less than 97°C and more than 100°C, frequency increased restricted. • When discharge temperature falls below 94°C, normal operation resumes. Compressor discharge System shuts down temperature 110°C Technical Training Technical Training Technical Training Frequency step down 100°C Maintain frequency 97°C 94°C Normal operation Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection High discharge temperature protection Fixed drive system • When fixed drive discharge temperature reaches 110°C, system stops. • When discharge temperature falls below 94°C for 3 minutes, system resumes. Td = Compressor discharge temperature Td Comp Cut 110°C Technical Training Technical Training Technical Training Comp start 94°C 3 min Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection Outdoor coil high temperature protection Variable drive system • During cooling, when T coil1 > 60 °C, frequency drops. • During cooling, when T coil1 < 55 °C, system resumes. Fixed drive system • During cooling, when T coil2 > 64°C, compressor stops. Technical Training Technical Training Technical Training • During cooling, when T coil2 < 51°C, system resumes. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection Low pressure switch protection • Alarm delayed at compressor startup : 30 sec depends on Parameter P3* . • No protection during defrosting. • If variable drive or fixed drive low pressure switch is activated for 5 seconds, alarm will be triggered. * Parameter P3 (Low pressure alarm delay at compressor start up. Min=0s, max=199s, default=30s) Technical Training Technical Training Technical Training Note : If low pressure alarm occur more than 3 times within 30 minutes, system shuts down to irreversible error. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection High pressure switch protection • If fixed drive high pressure switch is activated for 30 sec, alarm will be triggered. • If variable drive high pressure switch is activated, frequency of variable drive compressor will decrease at 1Hz/s. If it is re-activated for 30 sec, alarm will be triggered. Technical Training Technical Training Technical Training Note : If high pressure alarm occur more than 3 times within 30 minutes, system shuts down to irreversible error. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Control Algorithm Control system protection 3 phase AC phase sequence protection If 3 phase AC phase sequence is incorrectly connected, system will not start and controller will indicate error. System will resume after rectification. 3 phase AC phase missing protection Technical Training Technical Training Technical Training If phase missing happens, system will not operate. Controller will indicate error. System will resume after rectification. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Short cut key Navigation key LCD Display Switching On/Off Cool Mode Indicator Switching Heat Navigation Mode Key (Up & On/Off Shortcut Down) Key Execute Technical Training Technical Training Technical Training Instruction Key Show Alarm Key Cancel Instruction Key Short cut key can only be used in the summary page! Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller CMOS Reset Jumper (JH2) Backup Reset some of the Battery settings to the DEFAULT value Technical Training Technical Training Technical Training Chiller Terminal Memorize of Date, Unit Connection Time & Timer Schedule (CN8) +12Vdc, GND; A, B Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Menu structure Status Mode Cool Set Operation Menu General Heat Set Regulator Manual Defrost Compressor Set Parameter [#] Defrost Change Password Antifreeze [#] Main Menu Settings Menu Inverter Panel Option Alarm and Contact Set Panel ID Summary Pages Clock Setting Unit Selection Menu Date Setting Technical Training Technical Training Timer Menu Technical Training Time Schedule Timer Show Alarms Alarm Menu Erase All Alarms Defrost Sensor Discharge Sensor Display Menu Comp Run Time [#] Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Setting menu Setting parameter for I nverter I nverter parameter setting page on the chiller panel controller SETTINGS MENU Set Parameter Change Password Panel Option Set Panel ID Technical Training Technical Training Technical Training 1. General V1 Cp Freq : 0Hz 2. Regulator V2 EXV : 0 3. Compressor V3 Cp Manual : Disable 4. Condenser Defrost V4 EXV Manual : Disable 5. Cool Mode Antifreeze V5 Def Mode : Disable 6. Inverter 7. Alarm & Contact Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller There are 5 setting parameters for I nverter ( V1 to V5 ) INVERTER Unit Default Min Max Resolution V1 Compressor frequency Hz Auto 0 120 1 V2 EXV Opening Flag Auto 0 480 1 Compressor manual setting Flag 0 (disable) 0 1 1 V3 0 = disable 1 = enable EXV Manual setting Flag 0 (disable) 0 1 1 V4 0 = disable 1 = enable Defrost Mode Flag 0 (disable) 0 1 1 V5 0 = disable 1 = enable V1 : Compressor frequency It allows to set the inverter compressor frequency (max frequency varies according Technical Training Technical Training Technical Training to models) V2 : EXV (Electronic expansion valve) It allows to set the EXV opening (0-480 pulsation) V3 : Cp Manual This parameter enable automatic or manual setting for the compressor frequency. ( Enable : manual setting is possible, Disable : frequency auto-run ) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller INVERTER Unit Default Min Max Resolution V1 Compressor frequency Hz Auto 0 120 1 V2 EXV Opening Flag Auto 0 480 1 Compressor manual setting Flag 0 (disable) 0 1 1 V3 0 = disable 1 = enable EXV Manual setting Flag 0 (disable) 0 1 1 V4 0 = disable 1 = enable Defrost Mode Flag 0 (disable) 0 1 1 V5 0 = disable 1 = enable V4 : EXV Manual This parameter enable automatic or manual setting for the EXV opening. ( Enable : manual setting is possible, Disable : EXV opening auto-run ) Technical Training Technical Training Technical Training V5 : Def Mode This parameter enable automatic intelligent or standard defrosting. ( Enable : manual setting is possible in Parameter D1-D6, Disable : Intelligent defrosting [auto-run] ) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Display menu Display menu for I nverter I nverter display menu page on the chiller panel controller Screen 1 Inverter Chiller DISPLAY MENU Defrost Sensor Comp Freq : 75Hz Discharge Sensor EXV : 320 Comp. Run Time Comp Amp : 9.7A Inverter Chiller DC Bus : 555V Technical Training Technical Training Technical Training Screen 2 Inverter Chiller : 15.5 ° C Suction : 45.9 ° C BPHE In : 18.3 ° C BPHE Out Condenser : 28.4 ° C Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Display menu Inverter Chiller Comp Freq : 75Hz Display menu for I nverter EXV : 320 Comp Amp : 9.7A DC Bus : 555V Compressor Frequency It shows the operating inverter compressor frequency. (Hz) EXV It shows the operating EXV opening (pulse). Technical Training Technical Training Technical Training Comp Amp It shows the operating inverter compressor running current. (A) DC Bus It shows the operating DC voltage in the inverter system. (V) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Chiller Panel Controller Display menu Inverter Chiller : 15.5 ° C Suction Display menu for I nverter : 45.9 ° C BPHE In : 18.3 ° C BPHE Out Condenser : 28.4 ° C Suction It shows the inverter compressor suction temperature. (°C) BPHE In It shows the refrigerant inlet temperature at the BPHE during cooling mode. During heating mode, the value represents the refrigerant outlet temperature at the BPHE. (°C) Technical Training Technical Training Technical Training BPHE Out It shows the refrigerant outlet temperature at the BPHE during cooling mode. During heating mode, the value represents the refrigerant inlet temperature at the BPHE. (°C) Condenser It shows the inverter condenser coil inlet temperature. (°C) Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting Error Code Control measure Reset System 1 System 2 Error display Error description (default) Pump (Variable Drive) (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 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 Outdoor Air sensor Open/Short Ambient temp sensor error Auto OFF OFF OFF OFF OFF Water Flow Error Cv contact opened Manual OFF OFF OFF OFF OFF Cool Mode Antifreeze Leaving water temp. too low Auto OFF OFF OFF OFF OFF 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 Pump Overload Pump OLP opened Auto OFF OFF OFF OFF OFF IPM Error IPM over-current or overheat Auto - OFF OFF - - Comp 1 Overload Comp 1 overload Auto - OFF OFF - - Comp 1 Discharge Overheat Comp 1 discharge Overheat Auto - OFF OFF - - Technical Training Technical Training Technical Training High pressure 1 System 1 high pressure Auto - OFF OFF - - Low pressure 1 System 1 low pressure 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 - - Coil 1 Inlet Temp Open/Short Coil in system 1 sensor error Auto - 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 - - Comp 2 Overload Comp 2 overload Auto - - - OFF OFF High pressure 2 System 2 high pressure Auto - - - OFF OFF Low pressure 2 System 2 low pressure Auto - - - OFF OFF Comp 2 Defrost sensor Open/Short Coil out system 2 sensor error Auto - - - OFF OFF Comp 2 Discharge sensor Discharge comp system 2 sensor error Auto - - - OFF OFF Open/Short/Overheat Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 1. No response after power-on Yes No response Yes I s JP-power/ DC- Main board faulty, OUT output To replace. normal? Check Yes I s LED main I nput board lit? conditions No No I s connection Yes Main board or between main I PM short circuit, board and I PM To replace. I s R,S,T No normal? Check I nput I nput voltage Technical Training Technical Training Technical Training power supply DC-IN (+ 590VDC) normal? No Yes Replace power I s Power board components No board DC-I N Check DC voltage rectifier circuit normal? JP-power DC-OUT (+ 12VDC & (+ 15VDC) + 5VDC) Power board Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 2. LED on main board normal, but no output. LED lit, No output No I s output Rectify condition ok? Yes No I s load Rectify ok? Technical Training Technical Training Technical Training Yes I s main No board’s fuse Rectify ok? Replace main board Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 3. Other functions normal but compressor not functioning Others OK, Comp not functioning Yes I s fuse in DC Check operating conditions loop ok? No No I s I PM ok? Replace Technical Training Technical Training Technical Training Yes No I s compressor Replace ok? Yes Change fuse Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 4. Flow switch protection Water flow error Short JK4 JK4 on main board I s water Flow switch No flow error faulty or pump persists? stopped. Technical Training Technical Training Technical Training Yes Main board faulty , replace main board Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 5. Over voltage protection OV/ UN Voltage I s Power Yes supply > Rectify 490VAC? No I s Power No Technical Training Technical Training Technical Training supply < 460VAC? Yes Power board error, rectify. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 6. Under voltage protection OV/ UN Voltage I s Power Yes supply < Rectify 310VAC? No I s Power No Technical Training Technical Training Technical Training supply > 340VAC? Yes Power board error, rectify. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 7. Pump overload protection Pump overload JK8 on main board I s voltage No of 97, 98 on heat relay VDC = 0 V Yes Remove JK8, No Technical Training 97 & 98, is it Technical Training Technical Training Main board faulty still conducting? Yes Pump overload Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 8. Phase missing Phase missing I s Voltage No between R,S,T Check incoming supply 415VAC ± 20% ? Yes I s J-RST on main Yes board 415VAC Main board faulty 3 Phase supply ± 20% ? Technical Training Technical Training Technical Training No Disconnect power, Yes remove J-RST, is voltage of socket 415VAC ± 20% ? No To Check/ replace EMI filter Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 9. I PM protection Yes I PM Error I s heat sink Yes temperature Rectify > 100°C? Yes No I s I PM ok? Replace No I s I PM Main board faulty temperature No or wrong signal > 100°C? No I s current at Check Yes rated frequency Technical Training Technical Training Technical Training compressor ok? No I s heat Change I PM compound dried Yes out? No I s I PM Error Yes Normal persists? Reapply heat compound Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 10. Variable compressor over-current protection Comp 1 overload Yes Restart. Set freq. Comp and current with handset. checked, circuit ok. Check current, is it ok? No Main board or Technical Training Technical Training Technical Training compressor faulty Replace Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 11. Variable drive high pressure protection High Pressure 1 No I s high pressure Replace switch ok? Yes Technical Training Technical Training Technical Training Check AC system for overload Rectify Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 12. Variable drive low pressure protection Low Pressure 1 No I s low pressure Replace switch ok? Yes Technical Training Technical Training Technical Training Check AC system for low pressure Rectify Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 13. Variable compressor high discharge temperature protection Comp 1 Discharge Overheat Yes Compressor > 110 °C ? stops No Temp sensor ok? Replace Technical Training (< 100°C?) Technical Training Technical Training Check AC system Rectify Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Self Diagnosis & Troubleshooting 14. Fixed compressor over-current protection Comp 2 Overload No I s supply Rectify voltage ok? Check on compressor No winding Rectify resistance, is Yes it to spec ? Check current No reading on handset Technical Training Technical Training Technical Training Normal against actual Yes reading, is it very big different? Check on No Compressor Rectify insulation, is Yes it ok? Current sensing circuit error. Replace main Yes board Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Installation Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Installation • Unit Handling • Unit Placement • Maintenance Access • Water Connection • Power Supply & Electrical Connection Technical Training Technical Training Technical Training • Piping Cleaning • Preliminary Checking before Start-up Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Unit Handling Technical Training Technical Training Technical Training 5ACV 100/135/210 CR Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
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 Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Minimum clearances 5ACV100/135CR 5ACV30/55/75CR Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Maintenance Access 5ACV30/ 55/ 75CR Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Maintenance Access 5ACV100/ 135/ 210 CR Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
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 Technical Training Technical Training water piping. Technical Training • 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. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Water Piping & Fitting…cont. 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. Technical Training Technical Training Technical Training It is mandatory to install a strainer at the inlet of the unit. ! Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Water Piping & Fitting…cont. Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Power Supply & Electrical Connection Electrical Data Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Power Supply & Electrical Connection…Cont. Recommended Fuses & Cable Size Technical Training Technical Training Technical Training Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
Power Supply & Electrical Connection…Cont. 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. Technical Training Technical Training Technical Training It’s recommended to check the correct sequence of the 3 supply ! phases R-S-T before the unit start up. Air Cooled Inverter Chiller Air Cooled Inverter Chiller Air Cooled Inverter Chiller
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