TECHNICAL TRAINING 2007 Technical Training 2007 INVERTER MINI

TECHNICAL TRAINING 2007 Technical Training 2007

INVERTER MINI CHILLER Technical Training 2007

Product Lineup & Features 5 ACV 100/135/210 CR 5 ACV 55/75 CR 5 ACV 30 CR Technical Training 2007

Capacity Model Capacity (k. W) Cooling Heating 5 ACV 030 CR 7. 94 9. 66 5 ACV 055 CR 14. 65 16. 12 5 ACV 075 CR 20. 52 21. 99 5 ACV 100 CR 27. 80 29. 30 5 ACV 135 CR 38. 54 41. 47 5 ACV 210 CR 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 5 ACV 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 Technical Training 2007

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 5 ACV 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. • 5 ACV 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 5 ACV 30/55/75 CR 5 ACV 100/135/210 CR Technical Training 2007

Unit Placement Technical Training 2007

Maintenance Access 5 ACV 30 / 55 / 75 CR Technical Training 2007

Maintenance Access 5 ACV 100 / 135 CR Technical Training 2007

Maintenance Access 5 ACV 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 5 ACV 30 CR 5 ACV 55 CR 5 ACV 75 CR Voltage Range ** 230 / 1 / 50 415 / 3 / 50 Recommended Fuse (A) * 36 25 10 Power Supply Cable Size (mm 2) * Number of Conductor 10 3 10 5 Interconnection Cable Size (mm 2) * 1. 5 5 ACV 100 CR 5 ACV 135 CR 5 ACV 210 CR Model Voltage Range ** 380 – 415 / 3 / 50 Recommended Fuse (A) * 40 60 100 Power Supply Cable Size (mm 2) * Number of Conductor 10 3 10 5 Interconnection Cable Size (mm 2) * 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 Start No System On? Yes Clash between current & selected mode of operation? Yes No Stop Inverter Comp Cooling? 60 s Stop pump No Yes Cooling mode Technical Training 2007 Heating? 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 > 180 s? Yes No Frequency & EXV opening adjustment Yes DT > -2°C ? Inverter Comp Off? Yes No DT > 2°C ? Yes Stop Inverter Comp 5 s 30 s Return Technical Training 2007 Shut Inverter 4 WV & 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 > 180 s? Yes No Frequency & EXV opening adjustment Yes DT > -2°C ? Inverter Comp Off? Yes No DT > 2°C ? Yes Stop Inverter Comp Shut Inverter 4 WV & start 5 s Inverter O/Fan 30 s 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 ( 8 L) Water pump

Components High pressure switch (NC) 600 psi – open, 480 psi – 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 (R 410 A) Anti freeze heater on BPHE Pump OLP (overload protector) Compressor OLP (overload protector) Variable drive system compartment Technical Training 2007 Fixed drive system compartment Variable speed scroll compressor (R 410 A)

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 +500 VDC to respective desired voltages - 12 VDC relay - MCU +5 VDC - IPM +15 VDC - 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 Phase Missing Manual OFF OFF OFF Phase Seq Error Wrong phase Sequencing Manual OFF OFF OFF Memory Error EEPROM read/write error Auto OFF OFF OFF IPM Error IPM over-current or over heat Auto 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 Entering Water Sensor Open/Short BPHE water in sensor error Auto OFF OFF OFF Leaving Water Sensor Open/Short BPHE water out sensor error Auto OFF OFF OFF V-Hx inlet Temp sensor Open/Short BPHE refrigerant in sensor error Auto - OFF - - V-Hx outlet Temp sensor Open/Short BPHE refrigerant out sensor error Auto - OFF - - Coil 1 inlet Temp Open/Short Coil in system 1 sensor error Auto - OFF - - Outdoor Air Sensor Open/Short Ambient Temp sensor error Auto 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 Manual OFF OFF OFF Leaving water temp too low Auto OFF OFF OFF Pump overload Pump OLP opened Auto OFF OFF OFF Comp 1 Overload Auto - OFF - - Comp 2 Overload Comp 1 Overload Auto - - - 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 1 Discharge Overheat Comp 1 discharge Overheat Auto - OFF - - Comp 1 Defrost Sensor Open/Short Coil Out system 1 sensor error Auto - OFF - - Comp 1 Suct Sensor Open/Short Suction comp system 1 sensor error Auto - OFF - - Comp 1 Discharge Sensor Open/Short Discharge Comp system 1 sensor error Auto - OFF - - Comp 2 Defrost sensor Open/Short Coil out system 2 sensor error Auto - - - OFF Comp 2 Discharge Sensor Open/Short/Overheat Discharge comp system 2 sensor error Auto - - - 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 OV/UN Voltage Comp. High Voltage (>490 V) <460 V, Auto OFF OFF OFF OV/UN Voltage Comp. Low Voltage (<310 V) >340 V, Auto OFF OFF OFF High Pressure 1 System 1 high pressure Auto - OFF - - Low Pressure 1 System 1 low pressure Auto - OFF - - High Pressure 2 System 2 high pressure Auto - - - OFF Low Pressure 2 System 2 low pressure Auto - - - 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 R, S, T Input voltage normal? Is connection IPM and Main Board OK? Yes Main Board or IPM Board Faulty No No Check Input power supply vac Connection Wire or Connector Faulty Rectifier Yes Is Power Board OK? No Change 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 -E 01 Water flow error Short JK 4 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 -E 02 OV/UN Voltage Is Power supply > 490 VAC? Yes No Is Power supply < 460 VAC? Yes Power board error, rectify. Technical Training 2007 No Check the Electrical supply

Self Diagnosis & Troubleshooting 6. Under voltage protection -E 03 OV/UN Voltage Is Power supply < 310 VAC? Yes No Is Power supply > 340 VAC? Yes Power board error, rectify. Technical Training 2007 No Check the Power supply

Self Diagnosis & Troubleshooting 7. Pump overload protection- E 05 Pump overload JK 8 on main board Is voltage of 97, 98 on heat relay VDC = 0 V No Yes Remove JK 8, 97 & 98, check connectivity Yes Pump overload Technical Training 2007 No Main board faulty

Self Diagnosis & Troubleshooting 8. Phase missing – E 06 Phase missing Is Voltage between R, S, T 415 VAC ± 20%? No Check incoming supply Yes Is J-RST on main board 415 VAC ± 20%? 3 Phase supply Yes No Disconnect power, remove J-RST, is voltage of socket 415 VAC ± 20%? No To Check/replace EMI filter Technical Training 2007 Yes Main board faulty

Self Diagnosis & Troubleshooting Phase seq error – E 07 - Interchange any 2 phase of R, S, T. Memory Error – E 08 - Replace chip 24 C 02 Sensor Error – E 09, E 12, E 14, E 20, E 21, E 22, E 23, E 24, E 25, E 30, E 31, E 33, E 34 - Check against the resistance cable. Technical Training 2007

Self Diagnosis & Troubleshooting 9. IPM protection –E 15 IPM Error Yes Is IPM ok? Replace Display Menu for Inverter No Is current at rated frequency ok? Inverter Chiller No Check compressor Yes Is IPM Error persists? No Technical Training 2007 Normal Comp Freq : 75 Hz EXV : 320 Comp Amp : 9. 7 A DC Bus : 555 V

Self Diagnosis & Troubleshooting 9. IPM protection –E 15 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 –E 16 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 5 ACV 30 CR, Overload protection triggers when compressor current > 27 A Technical Training 2007

Self Diagnosis & Troubleshooting 11. Variable drive high pressure protection –E 17 & E 27 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 –E 18 & E 28 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 No Compressor stops 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 • Check continuity. Check on Compressor insulation, is it ok? Is supply voltage ok? No Yes Technical Training 2007 Yes 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 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 (+590 VDC) No Replace power Board JP-Power (+12 Vdc & 7 Vdc) Technical Training 2007 DC-Out (+15 Vdc)

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 590 Vdc 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 415 VAC 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) -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) -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