Operation & Maintenance Manual CHILLER AIR-COOLED SCREW Please read this manual carefully before operating your set and retain it for future reference. TYPE : Chiller Air-cooled Screw R134a MODELS : RCAW - COMPACT P/NO : MFL63291701 www.lg.
Air cooled Screw Operation & Maintenance Manual TABLE OF CONTENTS SAFETY CONSIDERATIONS Warning...................................................................................................................................3 Caution....................................................................................................................................7 GENERAL Manipulation of HMI Unit .......................................................................................................
Safety Considerations SAFETY CONSIDERATIONS Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roof, elevated structures, etc). Only trained, qualified installers and service technicians should install, start up, and service this equipment. When working on this equipment, observe precautions in the literature, and on tags, stickers, and labels attached to the equipment, and any other safety precautions that apply.
Safety Considerations Always ground the product. • There is risk of fire or electric shock. For re-installation of the installed product, always contact a dealer or an Authorized Service Center. • There is risk of fire, electric shock, explosion, or injury. Do not store or use flammable gas or combustibles near the chiller. • There is risk of fire or failure of product. Do not install the product on a defective installation stand. • It may cause injury, accident, or damage to the product.
Safety Considerations Do not damage or use an unspecified power cord. • There is risk of fire, electric shock, explosion, or injury. Be cautious that water could not enter the product. • There is risk of fire, electric shock, or product damage. When the product is soaked (flooded or submerged), contact an Authorized Service Center. • There is risk of fire or electric shock. Follow the permitted pressure level. • Follow the regulated pressure for cold water, cooling water, refrigerant etc.
Safety Considerations Changing the set value is prohibited. • Do not change the set value of the safety device. • If you operate the product with incorrectly set values, it can cause defect, fire or explosion. Electric shock prevention. • When installing the freezer, always ground the wire. • It can cause electric shock. • When you change the control setting value, please consult with the specialized expert. Follow all safety codes.
Safety Considerations Do not leave refrigerant system open to air any longer than necessary. • Seal circuits being serviced and charge with dry nitrogen to prevent oil contamination when timely repairs cannot be completed. Always check for gas (refrigerant) leakage after installation or repair of product. • Low refrigerant levels may cause failure of product. Keep level even when installing the product. • To avoid vibration or water leakage.
Safety Considerations Do not use the chiller in special environments. Make the connections securely so that the outside force of the cable may not be applied to the terminals. • Oil, steam, sulfuric smoke, etc. can significantly reduce the performance of the chiller or damage its parts. • Inadequate connection and fastening may generate heat and cause a fire. Be sure the installation area does not deteriorate with age. Be very careful about product transportation.
Safety Considerations Be careful of disposal. • When disposing the device, request to the specialized expert. Be careful of high voltage. • Install separate wiring for the power and always install and use dedicated power supply and circuit breaker. • It can cause electric shock or fire. Be careful of high temperature. Be careful of restarting. • Because the machine part can be hot, do not touch it with any part of your body.
Safety Considerations Consult a water treatment specialist for proper treatment procedures. Water must be within design flow limits, clean and treated. • Hard scale may require chemical treatment for its prevention or removal • This make it possible to ensure proper machine performance and reduce the potential of tubing damage due to corrosion, scaling, erosion, and algae. • LG assumes no responsibility for chiller or condenser damage resulting from untreated or improperly treated water.
General GENERAL This manual is composed of information on control, operation, start-up, service and troubleshooting of RCAW Air Cooled Chiller. ■ Manipulation of HMI(Human Machine Interface) Unit If it is strongly recommended that the user NOT change any programing without consulting LGE service personnel. Unit damage may occur from improper programming. LG Flooded Air-Cool Screw Chiller SYS 2.71 PG 14.01 System Setting Main Display Par.
General Main Menu CHW Out Temp Condensate Temp Main Menu System Setting User Setting Content +17.9 C +17.2 C Status Message Closed-down Hand/Auto Mode Control Mode Start Interval Modbus Auto Control Local Control Complete Use Date2009/03/03 CHW In Temp Ambient Temp Exhaust Temp 13:05:00 +17.9 C +16.9 C +17.3 C Comp Running Hrs Running Capacity 2Hr 0% Fig. 2 The main menu is composed of 4 screen cuts. Moving among them is accomplished by the manipulation of the arrow keys ▽△.
General User Setting User Setting I/O Display Main Menu Content Week Modify Week Setting Week OFF Mon 5 C ~12 C Temp Setting Target Temp Outage Temp Restart Temp SET 7.0 C 5.0 C 12.
General Compressor shutdown temperature means the temperature where the compressor must be shut downed by low temperature. Here, the default value is 5.0°C(41°F). Compressor restart temperature means the temperature where the compressor must restart after shutdown. Here the default value is 12°C(53.6°F). By difference between the shutdown temperature and the restart temperature, the compressor is protected from frequent starting.
General I/O Display DISCRETE INPUTS1 I/O Display User Setting Alarm Display Content DISCRETE INPUTS5 Fan4A5A Fan2B3B Fan4B5B Emergency Stop DISCRETE INPUTS2 Remote Control System Oil Main Contactor Contactor OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF DISCRETE OUTPUT1 25% Magnet Valve 50% Magnet Valve 75% Magnet Valve Pump OFF OFF OFF OFF OFF OFF OFF OFF DISCRETE OUTPUT2 DISCRETE INPUTS4 Dif-pressure Comp Overload Fan 1A1B Fan 2A3A OFF OFF DISCRETE INPUTS6 Alarm Outpu
General The liquid flow switch detects chilled water flow, and the water flow must build during running the chiller. The openness of the switch during starting up or running compressor is considered to be water flow alarm by the PLC. The DP switch means differential pressure switch input to the PLC. Normally, the switch must be closed when the compressor runs. The switch opens when the differential pressure between condenser and evaporator is lower than the setting value even with running compressor.
General Alarm Display Alarm Display Delay Setting User Setting Content Alarm History 1/10 5E Alarm 2009/03/03 Date 12:53:50Time Clear ---- Alarm History 2/10 5E Alarm 2009/03/03 Date 12:53:50Time Clear Alarm History 10/10 5E Alarm 2009/03/03 Date 12:53:50Time Clear Fig. 5 Through the alarm display, recent 10 alarms are displayed with their invocation time. The alarm also can be cleared in this screen cut.
General System Setting System Setting Main Display Par. Setting Content Temp and Hours Correction Chilled In +0.0 °C Chilled Out +0.0 °C Condensate Temp +0.0 °C Ambient Temp Exhaust Temp Limit Comp Hrs Clear Comp Hrs +0.0 °C +0.0 °C 100000 ---- Fig. 6 The system setting is composed of 2 screen cuts. Through the system setting, the temperature readings can be adjusted when there are some problems with the sensor themselves. Additionally running hours can be cleared in this screen.
General Parameter Setting SET H Exhaust Temp Par. Setting System Setting Delay Setting Content 90.0 C 80.0~150.0 SET Fan Start Temp3 Fan Start Temp2 Fan Start Temp1 Load Interval 35.0 C 30.0 C 26.0 C 60S Limit Temp Low Temp Outage DT Restart DT 15.0 C 2.0 C 2.0 C 2.0 C 34.0~37.9 29.0~33.9 25.0~28.9 29.0~200.0 SET 10.0~20.0 1.0~5.0 1.0~3.0 1.0~3.0 Fig. 7 The system setting is composed of 3 screen cuts.
General Delay Setting SET Delay Setting Par. Setting Alarm Display Content Fan Feedback Contactor-feed DP Delay Comp Protect 2.0S 3.0S 300.0S 1.0S 0.3~1.5 0.3~5.0 90.0~350.0 0.5~1.5 Fan Stop Delay 30S 15.0~60.0 SET Temp Alarm System Oil Water Flow System Pressure 3.0S 30.0S 9.0S 3.0S Start Interval Comp Start Delay Comp Stop Delay 10Min 30S 60S 1.0~30.0 10.0~900.0 1.0~20.0 0.0~900.0 SET 8~15 20~200 60~200 Fig. 8 The delay setting is composed of 3 screen cuts.
Controls CONTROLS ■ PLC and HMI Unit PLC and HMI Unit The HMI (Human Machine Interface) side of the PLC (Programmable Logic Controller) and HMI assembly is shown on the door side as shown in the below picture. The HMI is composed of wide full dot LCD with 4 line display and back light, 9 functional keys, and 15 indicating LEDs for rich user interface. ESC SET START Full dot LCD :4 line text display with backlight ENTER STOP Arrow keys Indicating LED Fig.
Controls Protected with User Code Main Menu User Setting I/O Display Alarm Display Protected with System Code Protected with System Code Protected with System Code Delay Setting System Setting Para.
Controls LED Indication OUTPUT1 Auto/Manual Control OUTPUT2 Local/Remote Control OUTPUT3 Remote Start Input OUTPUT4 Start Interval Lapse OUTPUT5 Compressor Recycle OUTPUT6 Condenser Coil Contamination OUTPUT7 MODBUS Application OUTPUT8 Preheating Application OUTPUT9 Preheating Performing Indicating Status Automatic Control: ON Manual Control: OFF Remote Control: ON Local Control: OFF Run: ON Stop: OFF Delaying: ON Complete: OFF Recycle Stop: ON Running: OFF Warning: ON Normal: OFF Applyi
Controls On the top side of the PLC, DIP switches and indicating LEDs are installed. Normally, the D2 LED has to blink with 4 Hz frequency, and D3~D6 has to be off. The other LEDs blink according to communication status of the PLC. All switches of the 4-position DIP switch have to be positioned at off, and switches of the 8-position DIP switch have to indicate MODBUS slave device address. The 8-position DIP switch represents 8 bit hexa number with two digits in inverted value.
Controls CN5 CN3 CN1 CN2 CN4 Fig. 13 MODBUS CN6 Fig. 14 Actual locations of the connectors are shown in the above pictures and detail descriptions of the connectors are shown in the below table. The power of discrete outputs is 220VAC and the power of the discrete inputs is 24VDC.
Controls Connector CN1 (POW) CN2 (DO-1) Pin Wire No. Description AC1 26 24VDC-Positive AC2 27 24VDC-Ground FG - Frame Ground O01 71 System Alarm O02 72 M1 Contactor (Main Contactor) O03 73 M2 Contactor ( O04 74 M3 Contactor (Wye Contactor) O05 75 25% Magnet Comp Loading Valve O06 76 50% Magnet Comp Loading Valve O07 77 75% Magnet Comp Loading Valve O08 78 Water Pump COM 7 Contactor) Common: 220VAC Live Table 3 Connector CN3 (DO-2) Pin Description Wire No.
Controls Connector CN4 (DI -1) Pin Wire No.
Controls Connector Pin Description Wire No. RTD1+ 11 RTD1- 10 RTD1- - RTD2+ 13 RTD2- 12 RTD2- - RTD3+ 15 RTD3- 14 RTD3- - RTD4+ 17 RTD4- 16 RTD4- - RTD5+ 19 RTD5- 18 RTD5- - Chilled Water In Temperature Chilled Water Out Temperature Compressor Exhaust Temperature CN6 (RTDI) MODBUS RX2/D2+ TX2/D2 - Ambient Temperature Refrigerant Cond Out Temperature MODBUS on RS-485: D+ MODBUS on RS- 485: D Table 7 The MODBUS communication capability is provided by standard.
Controls The MODBUS address map of registers is shown in the below table.
Controls ■ Machine On/off Control There are two modes to turn on/off the machine. One is the Hand Mode and the other is the Auto Mode. HAND MODE – Hand Mode is the default set mode from the factory, and the user can turn on/off the power of the product by pressing the Start/Stop button on the control box for 3 seconds. You can set up this mode by selecting [User Setting] and selecting the [Hand Control] from [Hand/Auto Mode].
Start-up START-UP ■ Pre Start-Up Do not attempt to start the chiller until the following checks have been completed. • Check auxiliary facilities, such as the chilled water circulating pump, air-handling equipment, or other equipments to which the chiller supplies liquid are operational. Consult manufacturerʼs instructions. If the unit has field-installed accessories, be sure all are properly installed and wired correctly. Refer to unit wiring diagrams.
Start-up ■ Start-Up Procedure Do not manually operate contactors. Serious damage to the machine may result. The following procedure should be followed. • Be sure that water side load such as air-handling equipment, or other equipment to which the chiller supplies liquid are working. Starting of the water side load equipments can be delayed if the chilled water temperature is too high. • Be sure that water circulating pump is operating if not on automatic control from the chiller.
Start-up RTD Temperature Vs Resistance Table Temperature (F) Resistance() Temperature(F) Resistance() Temperature(F) Resistance() -328 18.49 50 103.90 428 183.17 -310 22.80 68 107.79 446 186.32 -292 27.08 86 111.67 464 190.45 -274 31.32 104 115.54 482 194.07 -256 35.53 122 119.40 500 197.69 -238 39.71 140 123.24 518 201.29 -220 43.87 158 127.07 536 204.88 -202 48.00 176 130.89 554 208.45 -184 52.11 194 134.70 572 212.02 -166 56.19 212 138.
Start-up ■ Operation Limits Temperature Temperature Temperature limits during the operation of the unit are as follows. Maximum ambient temperature: 129.2°F(54°C) Minimum ambient temperature: 64.4°F(18°C) Maximum outlet water temperature: 59°F(15°C) Minimum outlet water temperature: 41°F(5°C) * Temperature of inlet water must not exceed 68°F(20°C) during continuous operation. Voltage Permitted maximum voltage and minimum voltage are displayed on PDB.
Start-up Flow Rate The basic flow rate of the chiller must follow the values of the table showing the maximum, minimum and designed flow rate. Higher or lower flow rates are permitted to make the lower or higher temperature rise. In order to assure appropriate heat exchange and turbulent flow inside the evaporator, the flow rate must exceed the Minimum flow rate. 50Hz Model RCAW060*BAA Minimum Nominal Maximum gpm l/s gpm l/s gpm l/s 75 4.7 149 9.4 298 18.8 RCAW070*BAA 82 5.2 164 10.
Start-up ■ Pressure Drop 50Hz Chilled water pressure drop (SI Unit) Chilled water pressure drop (English Unit) Note: For flow out of this range, consult LG.
Start-up Chilled water pressure drop (SI Unit) Chilled water pressure drop (English Unit) Note: For flow out of this range, consult LG.
Start-up 60Hz Chilled water pressure drop (SI Unit) Chilled water pressure drop (English Unit) Note: For flow out of this range, consult LG.
Start-up Chilled water pressure drop (SI Unit) Chilled water pressure drop (English Unit) Note: For flow out of this range, consult LG.
Operation OPERATION ■ Sequence of Operation The sequence of the operation is depicted by the flow chart in the below. When the start is in effect, the condenser fan and water pump run concurrently. Additionally, for the minimum load position of the compressor, the MV1 is turned on. After condenser fan feedback delay, the feedback inputs from the contactors are checked. The PLC shutdown the chiller if there is problem with the contactor feedback.
Operation STOP No Alarm Alarm Start Yes Condenser Fan=ON 3 Sec Water Pump = ON MV1= ON : M4 : 25% 9 Sec No No Flow Check Contactor Check : Flow S/W Yes Yes : 30 - 60 sec Water Temp. Check No : Temp Leaving > Setpoint ? Yes Y Start : M1=ON & M3=ON : Oil Heater=OFF : Oil Solenoid Valve(SV1)=ON 0.5 Sec Comp.
Operation Stop logic Stop? Yes MV2=OFF & MV3=OFF MV1=ON, SV2=OFF 60 Sec M2 =OFF & M1=OFF SV1=OFF 4-10Min Water Pump =OFF Fan = OFF MV1=OFF stop Fig.
Operation Delay control for the chiller is summarized in the below picture. There are two essential delays, stop to start delay and oil pre-heating delay in the picture. The stop to start delay is the duration between the stoppage of the compressor and the restart of the compressor. The factory setting value of the delay is 10 minutes and configurable through delay setting of the HMI unit. The delay is designed to protect the compressor from frequent starting.
Operation Fig.
Operation ■ Sensors RTD (Resistance Temperature Detect) To monitor the inlet water temperature, outlet water temperature, discharge temperature of the compressor, ambient temperature and discharge temperature of the condenser of the cooler during chiller operation, RTD (Resistance Temperature Detect) is used.
Service SERVICE ■ Cycle Components The structure of the air-cooled cooling cycle is shown in the below. Fig. 20 No. (1) (2) (3) (4) (5) (6) PART Compressor Condenser Reciever Oil Filter Oil Seperator / Economizer Flow Control Device No. (7) (8) (9) (10) (11) (12) PART Flow Control Device Flow Control Device Dryer Evapolator Oil Heater Oil Level Sight Glass No. (13) (14) (15) (16) (17) (18) PART Oil Level Switch Oil Solenoid Valve Oil Flow Switch Discharge Temp.
Service Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Compressor casing Motor casing Oil separator Motor rotor assembly Motor stator assembly Motor rotor washer Motor rotor spacer ring Oil separator baffle Oil separator cartridge Piston Piston spring Piston rod Bearing seatÅfs cover plate Modulation solenoid valve Modulation slide valve Slide valve key Discharge bearings Number 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Description Discharge fixed ring Disc spring Bearing lock nut
Service This means the displacement of refrigerant gas also increases, as a result the refrigeration capacity also increases. However, when any of the step solenoid valve is energized, the high pressure oil in the piston cylinder bypasses to the suction port causing the piston and the slide valve to moved toward the left side, then some of the refrigerant gas by pass from the compression chamber back to the suction end.
Service The bearings used in the compressor required a small but steady quantity of oil for lubrication; the oil injection into the compression chamber creates an oil sealing film in the compression housing for increasing the efficiency and absorbing a part of heat of compression. In order to separate the oil from the mixed refrigerant gas, an oil separator is required to ensure the least amount of oil carried into the system.
Service SYMPTOMS COMPRESSOR DOES NOT RUN CAUSE REMEDY Power line open Control fuse open High-Pressure Switch (HPS) tripped Loose terminal connection Improperly wired controls Low line voltage Compressor motor defective Seized compressor Pre-lubrication not successful Loss of charge COMPRESSOR CYCLES Bad transducer OFF Low refrigerant charge ON LOW SATURATED Failed expansion device SUCTION TEMPERATURE Partially plugged or plugged strainer High-pressure switch erratic in action COMPRESSOR Compressor disc
Service Condenser ■ Maintenance and cleaning of condenser coil Periodically cleaning the surface of the coil is essential in maintaining the normal operation of the unit. By removing any contaminant or hazardous substance on the coil, you can extend the life of the coil and the unit. The following maintenance and cleaning method is recommended as part of the periodical maintenance activity to extend the life of the coil.
Service ■ Condenser fan The fan motor and the fan must be fixated firmly on the top plate of the condenser with the metallic bracket. Shroud protects the parts from the fan rotating in high speed. Assembly of the condenser fan is as shown in the picture. as follows. Apply the grease on the exposed part of the motor to protect it from the rain. You have to apply the grease again on the fan axis and then reinstall the Shroud.
Service Cooler ■ Flow Switch Flow Switch is installed on the water outlet nozzle for all units as factory setting. The following pictures shows the Flow Switch in generally installed method. parts name cover insulation plate microswitch adjusting screw metal fitting for flow adjusting screw flow adjusting screw actuating plate adjusting spring Qty 1 1 1 1 1 1 1 1 Table 17 Fig.
Service ■ Dual Pressure Switch Dual pressure switch has low pressure cutout switch and high pressure cutout switch inside. The cutoff points can be adjustable. The factory setting values are shown in the below. Low Pressure Cutout 3.2kgf/cm2 High Pressure Cutout 22kgf/cm2 Table 18 The low pressure switch and the high pressure switch are normally closed and tripped to opening when the detected pressure exceeds the setting value.
Service ■ Anti-freezing Switch The anti-freezing switch is used to detect too low water temperature. The switch is normally closed and tripped when the chilled water leaving temperature is under 35.6°F(2°C). The switch returns to the normal status when the temperature increases over 41°F(5°C). The Anti-freezing switch is installed on the evaporator. Fig.
Service Refrigerant Cycle ■ Leakage test As described in the installation manual, the unit is sufficiently charged with R134a refrigerant as factory setting. If the refrigerant pressure is lower than the factory setting, you must check for leakage. If the pressure inside the unit has dropped, use the Nitrogen to do a leakage test. When repairing the leaking part, you must use good refrigeration practice. After the leakage is repaired, any water inside the chiller must be removed and vacuumed.
Service Refrigerant Cycle ■ Oil Filter The oil filter is installed on the oil separator in oil return line to the compressor. Differential pressure between the inlet and outlet of the oil filter must be checked periodically. On the oil separator, the core valves for connection of the inlet/outlet with pressure gauge are installed. If the differential pressure is over 5kg/cm2 it is recommended to disassemble the oil filter and wash the oil filter mesh.
Service ■ Oil Heater The oil heater prevents poor lubrication due to too low viscosity. The oil heater is also installed on the oil separator. The 150W oil heater has 220VAC power input. Fig. 32 ■ Solenoid Valve One of the Solenoid Valve is installed between the Flash Gas Tank where the oil separator is installed and the other is installed between the oil filter and Flash Gas Tank. Valve on the compressor side is turned on during Full Load operation, and off during other operations.
Service ■ Control System The structures of the power panel and control panel are shown in the below. The power panel in the left is composed of the electrical components related to main power, and the control in the right is composed of low-voltage components such as the PLC and the HMI unit. Both panels are designed to be water proof by dual door system. The panels comply with IP55. Control Panel Power Panel Fig.
Service Power Panel On the left side of the power panel, terminal blocks for main power connection are prepared. The field supplied main power lines and neutral line for control power are connected to these terminal blocks. There are three magnetic contactors for the wye-delta starting of the compressor and OCR (Over Current Relay) for the compressor. For wye-delta starting, there are three magnetic contactors installed inside of the power panel.
Service Wye Starting Delta Running 1M 1 L1 L1 4 2M VP= S S 1M L3 L2 3 S VL 3 1M 2M 6 S VP=VL S 1M 2 1 2M 5 6 1M L3 I L= I P L2 3 S 4 1M 2M 5 2 I L= 3x I P 2M Fig. 36 There is one magnetic contactor for each condenser fan. On the right bottom side of the power panel, voltage monitoring relay is installed to monitor proper power input. There are three fuses installed for the power input to the voltage monitoring relay.
Service ■ Compressor OCR (Over Current Relay) The compressor OCR is thermal type and used to protect the compressor from overload condition. The OCR contact used for the control system is normally closed and the OCR contact switch is to be opened if it detects excessive current. The OCR needs manual reset by switch on the OCR to be recovered to normal after tripping.
Service ■ Voltage Monitoring Relay (5E) The voltage monitoring relay is used for the verification of proper power supply. The voltage monitoring relay is shown in the below. Existing 3-phase voltage will be shown ordinally every 3 seconds as shown in the below. R S T V S R S T V S R S T V S Fig. 38 The voltage monitoring relay monitors 5 abnormal conditions of the power supply. The abnormal conditions include over voltage, under voltage, phase reverse, phase loss, and voltage unbalance.
Service UNBAL. REV. AUTO 5S 1S OFF REV. UNBAL. AUTO 5S/1S ON OFF ON OFF ON OFF ON OFF Reverse phase protected Reverse phase unprotected Unbalance protected Unbalance unprotected Auto reset Manual reset Auto reset delay 5 sec Auto reset delay 1 sec Table 22 The voltage unbalance tripping is activated when the unbalance exceeds +5% more than 3 seconds. Similarly, phase loss tripping has 2 second delay and phase reverse tripping has 0.5 second delay.
Service ■ Assist Relay Assist Relay is the relay to check power supply of 220V to the controller. Assist Relay is as follows. Fig. 40 ■ Compressor Contactor Compressor Contactor controls the start, stop and static range of the compressor motor when the product is operating. Fig.
Service ■ Fan Contactor Fan Contactor controls the start, stop and static range of the fan motor when the product is operating. Fig.
Service Control Panel On the external door of the control panel there is emergency switch for the instant cutting out of control outputs from the PLC. By pushing the emergency switch, the 220VAC power supplied to the PLC relay outputs are cut out instantly. By turning the switch in clock-wise direction, the power to the output is recovered. On the internal door of the control panel, operator can access the HMI unit.
Service In the control panel, the PLC is installed as a central control station. The PLC is assembled with the HMI unit in a black case. The PLC is supplied 24VDC power from the SMPS (Switched Mode Power Supply) on the right side. Switched Mode Power Supply Control fuse Control Relay Fig. 44 The relay is to confirm proper 220VAC power supply and start/stop switch which is installed on the door is positioned at start. The ventilation fan of the control panel runs permanently after power on.
Service ETC ■ Temp. Sensor in Control Box This is used to detecting the temperature within the Control Box when operating the product. The shapes and characteristics are as follows. Fig. 45 ■ Ventilation Fan Ventilation Fan is attached on both sides of the Power Box and the Control Box. This fan responds to the temperature increase within both boxes while the product is operating and sends the air outside to prevent any issues from temperature increase within each box. Fig.
Service ■ Maintenance Maintenance Schedule Daily Monthly 10h 500h Every Every Every 2 months 3 months 6 months Every 1 year Every 2 years Every 3 years Every 6 years 5000h 10000h 15000h 30000h Check Point 1000h 1500h 2500h 1. Cycle Status Check 2. Electric part - Check Monthly check 3. Safety switches - Check Monthly check 4. Water Loop System - Check 5. Condenser cleanness - Clean - - Check 6. Cooling tower cleanness - - Check 7.
Trouble Shooting TROUBLE SHOOTING If a stoppage occurs more than once as a result of any of the safety devices, determine and correct the cause before attempting another restart. General Malfunction Before specific alarm trouble shooting, general troubles and their possible remedies are introduced. When the unit does not run at all, you have to check power supply to the chiller, refrigerant, configuration, and alarm invocation.
Trouble Shooting Symptom Unit does not run Compressor operates too long continuously Circuit does not run Possible Remedy Possible Cause Check for power to unit Check over current protection device Check no-fused disconnect (if equipped) Restore power to unit Low refrigerant charge Check for leak and add refrigerant Wrong or incorrect unit configuration Check unit configuration Active alarm Check Alarm status.
Trouble Shooting Alarm Specific alarms, their recognition method, and their possible causes are listed here. To clear alarm and recover from the alarm, clear the alarm history after correction of the cause of the alarm. The emergency trouble means that the emergency switch installed on the right side of the control panel is pushed by operator. This switch input is normally closed and the trouble means the switch input is opened.
Trouble Shooting Displayed Alarm Message Recognition Possible Cause Emergency Stop • Emergency switch input(switch off) Dp Alarm • Trip of differential pressure switch (switch off) • Too high chilled CHW temperature after the compressor run (default: DP < • Too low ambient temperature 4kgf/cm2) • Trip of emergency Possible Remedy • Turn the emergency switch clockwise to return • Review chilled CHW temperature, ambient temperature or applicable sensor • Over voltage 5E Alarm • Under voltage • Tri
Trouble Shooting Displayed Alarm Message Pressure Alarm Recognition • Trip of low pressure switch Possible Remedy Possible Cause • Insufficient refrigerant • Refrigerant leakage • Low pressure switch setting too high • Low pressure switch error • Controller DI point error • Charge additional refrigerant • Test/Repair as necessary and charge additional refrigerant • Adjust low pressure switch setting • Repair or replace Low pressure switch • Repair or replace controller • Oil dryer clogged • Oil flow
Trouble Shooting Displayed Alarm Message Recognition • Trip of compressor internal protector (switch off) by high compressor winding temperature Possible Cause • Voltage error • Controller DI or DO point error • Comp error • Internal protective switch error • Condenser fan motor error • Contamination of condenser fin.
Trouble Shooting Displayed Alarm Message Exhaust Temp Alarm Recognition Possible Remedy Possible Cause • Compressor discharge • Refrigerant flow rate insufficient temperature is over ≤194°F(90°C) after the • Comp error • Too high ambient temperature compressor run • Charge additional refrigerant or review valve condition • Repair comp • Check ambient temperature Contact fault alarm • Communication failure • Communication failure between the PLC and the HMI unit • Check connection between PLC and H
Trouble Shooting Displayed Alarm Message Recognition Possible Cause Possible Remedy FAN2B3B Alarm • FAN2B3B magnetic contactor contact input or overload relay contact input (switch off) after the compressor run • Malfunction of FAN2B3B • Condenser FAN2B3B overload • Replace FAN2B3B motor, check magnetic contactor or relay • Check FAN2B3B lock FAN4B5B Alarm • FAN4B5B magnetic contactor contact input or overload relay contact input (switch off) after the compressor run • Malfunction of FAN4B5B • Con
FAN 1B 4T2 6T3 3L2 5L3 FAN 2A FAN 2B 2T1 4T2 6T3 1L1 3L2 5L3 OLF1B FN1B OLF1A 2T1 4T2 6T3 FAN 3A OLF3A T3 L3 FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF3B FN3B 4 2 47 40 +V -V 4 2 W 2 4 EMRG EMRG N L 7 2 4 INTERNAL PROTECTOR (INT69) 4 12 11 U V Y COMP Z X 2T1 4T2 6T3 HMI UNIT 27 SMPS 26 T2 2T1 4T2 6T3 L2 L1 TO MAIN CONTROL UNIT OLF2A 2T1 4T2 6T3 7 27 +24V -24V 2 71 COM O01 26 2 1 OLC1 M1 M1 THC START/STOP SWITCH 4 4 3 3 F1 1 R 22
FAN 2B 2T1 4T2 6T3 OLF1B FN1B FAN 2A 1L1 3L2 5L3 OLF1A 2T1 4T2 6T3 FAN 3A FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF2A 2T1 4T2 6T3 FAN 4A 1L1 3L2 5L3 OLF3B FAN 4B 2T1 4T2 6T3 FN3B OLF4A OLF4B FN4B L3 4 2 47 40 +V -V 4 2 W 2 4 EMRG EMRG N L 7 2 4 INTERNAL PROTECTOR (INT69) 4 12 11 Z Y COMP X U V 2T1 4T2 6T3 HMI UNIT 27 SMPS 26 T3 2T1 4T2 6T3 T2 M3 L2 L1 TO MAIN CONTROL UNIT OLF3A 2T1 4T2 6T3 7 27 +24V - 24V 2 71 COM O01 26 2 1 OLC1
4T2 6T3 2T1 FAN 2B 2T1 4T2 6T3 1L1 3L2 5L3 OLF1B FN1B FAN 7A FAN 8A FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF7A T3 OLF3B FN3B 2T1 1L1 FAN 6B 4T2 6T3 3L2 5L3 T2 4 2 12 11 U V W 1 FAN 7B 2T1 4T2 6T3 2T1 OLF7B FAN 8B 2T1 4T2 6T3 1L1 3L2 5L3 OLC2 M4 FN7B INTERNAL 2 PROTECTOR (INT69) Y COMP Z X 2T1 4T2 6T3 OLF8B FN8B FAN 1A 4T2 6T3 FAN 2A 2T1 4T2 6T3 OLF1A FN1A OLF2A FN2A 28 FAN 3A +V -V L3 L2 L1 HMI UNIT 29 4 2 4 EMRG EMRG N L 7 2 4 7 29
4T2 6T3 FAN 2B 2T1 4T2 6T3 1L1 3L2 5L3 OLF1B 7A (4~10) FN1B FAN 7A 2T1 4T2 6T3 OLF6A 7A (4~10) FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 FAN 8A 2T1 4T2 6T3 OLF2B 7A (4~10) FN2B OLF7A 7A (4~10) 1L1 3L2 5L3 7A (4~10) OLF3B FAN 4B 2T1 4T2 6T3 FN3B OLF9A 7A (4~10) OLF4B 7A (4~10) FN4B 11 U V 2T1 1L1 FAN 6B 4T2 6T3 3L2 5L3 4 2 12 FAN 7B 2T1 4T2 6T3 2 1 1L1 3L2 5L3 FAN 8B 7A (4~10) FAN 9B 2T1 4T2 6T3 FN8B OLF9B 7A (4~10) FN9B FAN 2A 2T1 4T2 6T3 OLF1A 7A (4~10) FN1A 1L1 3L2
FAN 1B 4T2 6T3 3L2 5L3 FAN 2B 2T1 4T2 6T3 OLF1B FN1B FAN 2A 1L1 3L2 5L3 OLF1A 2T1 4T2 6T3 FAN 3A OLF3A FAN 3B 2T1 4T2 6T3 OLF2B FN2B 1L1 3L2 5L3 OLF3B FN3B 4 2 47 40 +V -V 4 2 W 2 4 EMRG EMRG N L 7 2 4 INTERNAL PROTECTOR (INT69) 4 12 11 U V Y COMP Z X 2T1 4T2 6T3 HMI UNIT 27 SMPS 26 T3 L3 2T1 4T2 6T3 T2 M3 L2 L1 TO MAIN CONTROL UNIT OLF2A 2T1 4T2 6T3 7 27 +24V -24V 2 71 COM O01 26 2 1 OLC1 M1 220VAC THC START/STOP SWITCH L 8 N 9 220
2T1 FAN 2B 2T1 4T2 6T3 OLF1B FN1B FAN 2A 1L1 3L2 5L3 OLF1A 2T1 4T2 6T3 FAN 3A FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF2A 2T1 4T2 6T3 FAN 4A 1L1 3L2 5L3 OLF3B FAN 4B 2T1 4T2 6T3 FN3B OLF4A OLF4B FN4B T3 4 2 47 40 +V -V 4 2 W 2 4 EMRG EMRG N L 7 2 4 INTERNAL PROTECTOR (INT69) 4 12 11 U V Y COMP Z X 2T1 4T2 6T3 M2 HMI UNIT 27 SMPS 26 T2 2T1 4T2 6T3 L3 M3 L2 L1 TO MAIN CONTROL UNIT OLF3A 2T1 4T2 6T3 7 27 +24V - 24V 2 71 COM O01 26 2 1
5L3 FAN 1B 4T2 6T3 3L2 FAN 2B 2T1 4T2 6T3 OLF1B FN1B FAN 2A 1L1 3L2 5L3 OLF1A 2T1 4T2 6T3 FAN 3A FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF2A 2T1 4T2 6T3 FAN 4A OLF3B FAN 4B 2T1 4T2 6T3 FN3B 1L1 3L2 5L3 OLF3A 2T1 4T2 6T3 FAN 5A OLF5A FAN 5B 2T1 4T2 6T3 OLF4B FN4B 1L1 3L2 5L3 OLF5B FN5B 26 T3 L3 +V -V 4 2 W 4 2 4 4 EMRG EMRG 7 N2 L INTERNAL PROTECTOR (INT69) 12 11 U V Y COMP Z X 2T1 4T2 6T3 M2 HMI UNIT 27 SMPS 4 2 47 40 2T1 4T2 6T3 T2 M3
4T2 6T3 2T1 FAN 8A OLF8A 2T1 FAN 3B 2T1 4T2 6T3 OLF3B FN3B 11 U V 2T1 1L1 FAN 6B 4T2 6T3 3L2 5L3 4 2 12 W 1 FAN 7B 2T1 4T2 6T3 2T1 FAN 8B 2T1 4T2 6T3 1L1 3L2 5L3 OLF7B FN7B INTERNAL 2 PROTECTOR (INT69) 1L1 3L2 5L3 OLF6B FN6B 4 2 55 Y COMP Z OLC2 202 107A (100~135) 48 T3 X 2T1 4T2 6T3 T2 48 2T1 4T2 6T3 L3 M6 L2 L1 TO MAIN CONTROL UNIT 1L1 3L2 5L3 OLF2B FN2B OLF7A 2T1 4T2 6T3 OLF8B FN8B FAN 1A 4T2 6T3 OLF1A FAN 2A 2T1 4T2 6T3 OLF2A 28 HMI UNIT 29
4T2 6T3 2T1 FAN 7A FAN 8A FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF7A 2T1 4T2 6T3 OLF3B FAN 4B 2T1 4T2 6T3 FN3B OLF9A T3 OLF4B FN4B 2T1 1L1 FAN 6B 4T2 6T3 3L2 5L3 T2 4 2 12 11 U V W FAN 7B 2T1 4T2 6T3 2 1 2T1 OLF7B FAN 8B 2T1 4T2 6T3 1L1 3L2 5L3 OLC2 FN7B INTERNAL PROTECTOR (INT69) Y COMP Z X 2T1 4T2 6T3 1L1 3L2 5L3 OLF6B FN6B 4 2 55 48 2T1 4T2 6T3 L3 M6 L2 L1 TO MAIN CONTROL UNIT FAN 9A 1L1 3L2 5L3 OLF8A 2T1 4T2 6T3 OLF8B FAN 9B 2T1 4T2 6T3
4T2 6T3 2T1 FAN 7A FAN 2B 2T1 4T2 6T3 1L1 3L2 5L3 OLF1B FN1B OLF6A 2T1 4T2 6T3 FAN 8A FAN 3B 2T1 4T2 6T3 1L1 3L2 5L3 OLF2B FN2B OLF7A 2T1 4T2 6T3 FAN 9A OLF3B FAN 4B 2T1 4T2 6T3 FN3B 1L1 3L2 5L3 OLF8A 2T1 4T2 6T3 FAN 10A OLF10A T3 FAN 5B 2T1 4T2 6T3 1L1 3L2 5L3 OLF4B FN4B OLF5B FN5B 2T1 1L1 FAN 6B 4T2 6T3 3L2 5L3 T2 4 2 12 11 U V W 1 FAN 7B 2T1 4T2 6T3 2T1 1L1 OLF7B FAN 8B 2T1 4T2 6T3 1L1 3L2 5L3 OLC2 M4 FN7B INTERNAL 2 PROTECTOR (INT69) Y COMP Z X
TS 3 OFS OS OLS HPS 5 TS 4 OH 1 Circuit 11 1 S 6 1. RCAW200*BAA, RCAW240*BAA, RCAW260*BAA, RCAW280*BAA, RCAW320*BAA: 2 circuit configuration NOTE 2 Flash gas from Economizer 7 9 10 LPS AFS 8 TS TS WFS DESCRIPTION Ejector for Oil Return 6 Economizer (Flash gas tank) Temperature sensor S OS Anti-freezing switch Refrigerant pipe Oil Pipe Line Service valve Check valve Refrigerant sol. valve Oil sol.
Appendix ■ Check List Checklist for installation, and operation 1. Project information Contents Description PJT name Address Installing contractor Sales office Start-up performer 2.
Appendix 3. PRELIMINARY EQUIPMENT CHECK Contents Check Is there any physical damage? Yes No Will this prevent start-up. Yes No All screws and bolts are tight. Yes No Power supply agrees with the unit nameplate. Yes No Electrical power wiring is installed properly. Yes No Unit is properly grounded. Yes No Electrical circuit protection has been sized and installed properly. Yes No All terminals are tight. Yes No All plug assemblies are tight.
Appendix 5. START-UP & OPERATION Contents Check All refrigerant line service valves are open. (discharge, suction, economizer, oil line part…) Yes No There is leakage of refrigerant. (Comp, Condenser, Economizer, Cooler…) Yes No Voltage at terminal block is within 10% Yes No Voltage imbalance is within 2% Yes No There is no abnormal noise or vibration Yes No Alarm is not generated, and the unit operates normally.
