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TECHNICAL TRAINING 2007

TECHNICAL TRAINING 2007. INVERTER MINI CHILLER. Product Lineup & Features. 5ACV100/135/210 CR. 5ACV55/75 CR. 5ACV30 CR. Capacity. Features. New Technology BPHE- True Dual Circuits. Conventional Back to Back Circuits BPHE. Secondary Circuit. Primary Circuit 1. Primary Circuit 2.

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TECHNICAL TRAINING 2007

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  1. TECHNICAL TRAINING 2007

  2. INVERTER MINI CHILLER

  3. Product Lineup & Features 5ACV100/135/210 CR 5ACV55/75 CR 5ACV30 CR

  4. Capacity

  5. 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

  6. Features Inverter Compressor Conventional System Inverter System

  7. 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 • Water Pressure Differential Switch • Anti Freeze Heater on BPHE • Compressor, Water Pump Overload Protector

  8. Schematic diagram Inverter chiller schematic diagram

  9. Installation & Commissioning

  10. Installation & Commissioning • Unit Handling • Unit Placement • Maintenance Access • Water Piping & Fitting • Power Supply & Electrical Connection • Preliminary Checking before Start-up • General Control Flow Chart

  11. Unit Handling 5ACV 100/135/210 CR

  12. 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.

  13. Unit Placement Minimum clearances 5ACV100/135/210CR 5ACV30/55/75CR

  14. Unit Placement

  15. Maintenance Access 5ACV 30 / 55 / 75 CR

  16. Maintenance Access 5ACV 100 / 135 CR

  17. Maintenance Access 5ACV 210 CR

  18. 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.

  19. 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.

  20. Water Piping & Fitting Recommended Piping Connection

  21. Power Supply & Electrical Connection Recommended Fuses & Cable Size 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.

  22. 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.

  23. 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.

  24. 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? Heating? No No 60s Yes Yes Stop pump Cooling mode Heating mode

  25. 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 DT > -2°C ? DT < -2°C for > 180s? Yes No No Inverter Comp Off? Frequency & EXV opening adjustment Yes Yes No DT > 2°C ? Yes Stop Inverter Comp Shut Inverter 4WV & start Inverter O/Fan 5s Start Inverter Comp 30s Return

  26. 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 DT > -2°C ? DT < -2°C for > 180s? Yes No No Inverter Comp Off? Frequency & EXV opening adjustment Yes Yes No DT > 2°C ? Yes Stop Inverter Comp Shut Inverter 4WV & start Inverter O/Fan 5s Start Inverter Comp 30s Return

  27. Self Diagnosis & Troubleshooting

  28. 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) Water pump Expansion tank ( 8L) Control box assembly Components

  29. High pressure switch (NC) 600 psi – open, 480psi – close. Low pressure switch (NC) 18 psi – open, 28 psi – close. Differential pressure switch Over pressure relief valve Anti freeze heater on BPHE Pump OLP (overload protector) Compressor OLP (overload protector) Variable drive system compartment Fixed drive system compartment Components Chiller panel controller Fixed speed scroll compressor (R410A) Variable speed scroll compressor (R410A)

  30. 3 phase rectifier bridge diode IPM board (Intelligent power module) Fan capacitors Uni-directional bridge diode Power board EMI filter Magnetic contactors Main board Capacitor board PFC capacitor (Power factor correction) Components Control box assembly

  31. Components Main Board For Model 30 For Model 55, 75, 100 & 135

  32. 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

  33. Components Capacitor Board

  34. Components IPM

  35. Self Diagnosis & Troubleshooting Error Code Continue….

  36. Self Diagnosis & Troubleshooting Error Code Continue….

  37. Self Diagnosis & Troubleshooting Error Code Continue….

  38. Self Diagnosis & Troubleshooting Error Code Continue….

  39. Self Diagnosis & Troubleshooting Error Code

  40. Self Diagnosis & Troubleshooting No response Connection Wire or Connector Faulty 1. No response after power-on Yes Check setting & operating condition Is connection IPM and Main Board OK? Yes Main Board or IPM Board Faulty Yes Is main board LED light? No No No Is R,S,T Input voltage normal? Check Input power supply vac Rectifier Yes Power Board No Is Power Board OK? Change Power Board Main Board IPM

  41. 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 Yes No Is Operating Condition OK? Check Operating condition Yes No Is main board’s fuse ok? Change Fuse Yes Replace main board

  42. Self Diagnosis & Troubleshooting Check operating conditions 3. Other functions normal but compressor not functioning Yes Is fuse in DC loop ok? Others OK, Comp not functioning No Yes Is IPM OK? Check IPM No No Is compressor ok? Replace Compressor Yes Change Fuse

  43. Self Diagnosis & Troubleshooting 4. Flow switch protection -E01 Water flow error Short JK4 Is water flow error persists? Flow switch faulty or pump stopped. No JK4 on main board Yes Main board faulty , replace main board

  44. Self Diagnosis & Troubleshooting 5. Over voltage protection -E02 OV/UN Voltage Is Power supply > 490VAC? Yes Check the Electrical supply No Is Power supply < 460VAC? No Yes Power board error, rectify.

  45. Self Diagnosis & Troubleshooting 6. Under voltage protection -E03 OV/UN Voltage Is Power supply < 310VAC? Yes Check the Power supply No Is Power supply > 340VAC? No Yes Power board error, rectify.

  46. Self Diagnosis & Troubleshooting 7. Pump overload protection- E05 Pump overload JK8 on main board No Is voltage of 97, 98 on heat relay VDC = 0 V Yes No Remove JK8, 97 & 98, check connectivity Main board faulty Yes Pump overload

  47. Self Diagnosis & Troubleshooting 8. Phase missing – E06 Phase missing No Is Voltage between R,S,T 415VAC ±20%? Check incoming supply Yes Yes Is J-RST on main board 415VAC ±20%? Main board faulty 3 Phase supply No Disconnect power, remove J-RST, is voltage of socket 415VAC ±20%? Yes No To Check/replace EMI filter

  48. 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.

  49. Self Diagnosis & Troubleshooting 9. IPM protection –E15 IPM Error Yes Is IPM ok? Replace Display Menu for Inverter No Inverter Chiller Comp Freq : 75Hz EXV : 320 Comp Amp : 9.7A DC Bus : 555V No Is current at rated frequency ok? Check compressor Yes No Is IPM Error persists? Normal

  50. Self Diagnosis & Troubleshooting 9. IPM protection –E15 Yes • Use thermocouple. Yes Is heat sink temperature >100°C? Heat Compound Rectify Heat Sink No • Use thermocouple. No Is IPM temperature >100°C? Main board faulty or wrong signal Yes No Is heat compound dried out? Change IPM IPM Yes Reapply heat compound

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