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4. CONTROL SYSTEM

ENGLISH

4-3. Basic control algorithm

Unique P(proportional), I(integral), and D(differential) algorithms are applied to chilled water temperature control.
Compared to the conventional method, it allows optimal control by minimizing time to approach the target value, re-
maining deviation, Under-Shoot and Over-Shoot during initial startup and automatic/manual conversion of operation.

Under-shoot

Over-shoot

LG’s New Control

Algorithm

General Control

Algorithm

Figure 19. Control algorithm

• Soft Loading

- Approach to the control target value with Soft startup

- Solved unnecessary stops caused by voltage change during startup

• Advanced Control

- Advanced high class control algorithm developed for high precision control compared to existing PID control

method.

- Prevention of temperature Cycling phenomenon caused by Overshoot/Undershoot during conversion from manual

mode to automatic mode.

- Reinforced safety control(Intensive Safety Control): By executing preventive control before chiller reaching abnor-

mal stop point, it minimizes unnecessary stops of the chiller.

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Summary of Contents for LCWW

Page 1: ... for safety before installing the product The purpose of this manual is to keep the user safe and to prevent any property damage After reading this installation manual please retain it for future reference thoroughly Installation work must be performed in accordance with this installation manual by authorized personnel only ENGLISH ...

Page 2: ...to this page in case you need it to prove the date of purchase or for warranty purposes Write the model number and the serial number here Model number Serial number You can find them on a label on the side of each unit Dealer s name Date of purchase ...

Page 3: ...ial circuit If the power source capacity is inadequate or electric work is performed improperly electric shock or fire may result Ask the dealer or an authorized technician to install the chiller unit Improper installation by the user may result in water leakage electric shock or fire For re installation of the installed product always contact a dealer or an Authorized Service Center There is risk...

Page 4: ...aker of rated capacity It may cause fire and defects Redesigning the control box is prohibited Lock the control box with possible locking device and if you need to open the control box inevitably turn off the main power first Do not touch the wiring or a parts inside the panel It may cause electric shock fire or defects PRECAUTIONS BEFORE INSTALLATION Follow the permitted pressure level Follow the...

Page 5: ...e When using a condenser make sure to verify the complete discharge before applying the power again Re power ing within 5 min is prohibited It may cause electric shock fire damage or malfunction Change the condenser in case that the expansion exceeds the recommended limit It may cause electric shock fire damage or malfunction 1 2 Caution Operation Maintenance Always check for gas refrigerant leaka...

Page 6: ...product at well ventilated location where there is no obstacle Harsh chemical household bleach or acid cleaner should not used to clean outdoor or indoor coils of any kind These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion at the fin tube interface where dissimilar materials are in contact Use environment friendly cleaner Be careful when restarting the produ...

Page 7: ...rotective cover It may cause electric shock Do not open the circuit breaker without permission while running It may cause damage or malfunction Tighten bolts and screws with the specified torque Otherwise it may cause fire damage or malfunction Do not change electric or control devices arbitrarily It may cause fire damage or malfunction Only the persons who have sufficiently studied the user s man...

Page 8: ...4 CONTROL SYSTEM 22 4 1 Components of control panel and main parts 29 4 2 Outside view of Startup panel Stan dard Type 30 4 3 Basic control algorithm 31 4 4 BMS support function 32 4 5 Control screen Product function 34 4 6 Screw Chiller Timing Sequence Run Stop 70 4 7 Product Protection Function 70 Check points before inspection 73 5 CHECK AND TROU BLESHOOTING 74 5 1 Check 74 Check points before ...

Page 9: ...he site 1 2 10 4 5 6 7 8 3 9 12 11 13 15 14 16 18 17 19 Part Name 1 Screw compressor 2 Relief valve for condenser 3 Relief valve for evaporator 4 Air vent for cooling water 5 Air vent for chilled water 6 Drain for cooling water 7 Drain for chilled water 8 Lifting hole 4 holes for condenser 9 Lifting hole 4 holes for evaporator 10 Sight glass for evaporator 11 Control panel 12 Starter panel 13 Flow...

Page 10: ...f chilled water and cooling water 2 3 Nomenclature The model naming for screw chiller is done as follows R C W W 030 A A 1 1 R R 134a Compressor quantity C Chiller Develop ment se quence order W Screw compressor A Flooded type B Direct expansion type C Falling film system M Ice Storage High Efficiency R Heat recovery N Nuclear PJT High Efficiency W W type condenser V V type Condenser S Special W W...

Page 11: ... 79 80 81 82 83 84 85 86 87 88 89 90 16 1 16 7 17 2 17 8 18 3 18 9 19 4 20 0 20 6 21 1 21 7 22 2 22 8 23 3 23 9 24 4 25 0 25 6 26 1 26 7 27 2 27 8 28 3 28 9 29 4 30 0 30 6 31 1 31 7 32 2 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 32 8 33 3 33 9 34 4 35 0 35 6 36 1 36 7 37 2 37 9 38 3 38 9 39 4 40 0 40 6 41 1 41 7 42 2 42 8 43 3 43...

Page 12: ...11 112 113 114 115 116 117 118 119 120 5 695 5 765 5 836 5 906 5 976 6 046 6 117 6 187 6 257 6 328 6 398 6 468 6 539 6 609 6 679 6 750 6 820 6 890 6 968 7 031 7 101 7 171 7 242 7 312 7 382 7 453 7 523 7 593 7 663 7 734 7 804 7 874 7 945 8 015 8 085 8 156 8 226 8 296 8 367 8 437 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 1...

Page 13: ...enser The condensed refrigerant is gathered in the bottom of the condenser and goes through the dryer filter orifice or expansion valve by differential pressure and into the evaporator The chilled water is finally obtained in the chiller s evaporator Dur ing the gasification stage the refrigerant in liquid state absorbs a large amount of heat from the cooling water and is converted into gas state ...

Page 14: ...ler cartridge 9 Oil separator cartridge 28 Suction filter 10 Piston 29 Oil heater 11 Piston spring 30 Refrigeration lubricant 12 Piston rod 31 Suction flange 13 Bearing seat s cover plate 32 Discharge flange 14 Solenoid valve 33 Cable box 15 Slide valve 34 Power connection bolt 16 Slide valve key 35 Thermostat terminals 17 Discharge bearings 36 Motor cable cover plate 18 Discharge fixed ring 37 Di...

Page 15: ... oil filter and capillary then is charged into the cylinder due to the positive oil pressure which is bigger than the opposite side of spring force plus the high pressure of the gas This pressure difference causes the piston to move toward the right side in the cylinder and the slide valve to move toward the right side increasing the amount of compressor outlet thereby increasing the refrigeration...

Page 16: ...eding oil into the compression chamber is to increase the efficiency and to form oil sealing layer in order to absorb a part of the compression heat In order to separate the oil from the refrigerant in which oil is mixed to gether the oil separator is designed to allow the oil flow into the system to the minimum The oil temperature which is a very important factor to the life of the compressor bea...

Page 17: ...et Body Refrigerant distributor Refrigerant inlet tube Refrigerant inlet Collision prevention plate Refrigerant inlet tube Safety valve Inlet Body Inlet Figure 8 Evaporator Figure 9 Condenser Figure 10 Butterfly valve Figure 11 Orifice Expansion unit consists of butterfly valve and orifice At 100 load situation the pressure loss at the orifice is smaller than the refrigerant pressure loss in the c...

Page 18: ... switch installed in the normal method Oil flow switch Figure 12 Flow switch 18 3 STRUCTURE OF SCREW CHILLER ENGLISH Num ber Description Quantity 1 Cover 1 2 Insulation board 1 3 Micro switch 1 4 Adjustment screw 1 5 Metal plate installation for flow control switch 1 6 Flow control screw 1 7 Operation plate 1 8 Adjustment spring 1 ...

Page 19: ...et side The oil level of the compressor should be kept at a proper level during the compressor operation and if the oil amount is not enough the oil should be added to the oil tank If oil amount is insufficient abrasion occurs at bearings and rotor which is the cause of the compressor damage Oil filter which is to filter the foreign material in oil is easily disassembled for cleaning Oil is filled...

Page 20: ...r motor and the temperature drops to 1 5 C or below the chiller will stop 1 5 Compressor discharge high temperature Compressor outlet Compressor dis charge temp If compressor discharge gas temperature be comes 100 C or higher the chiller will stop 1 6 Refrigerant high low pres sure difference low Evaporator shell Con denser shell Pressure difference between Evapora tor Condenser If the pressure di...

Page 21: ...m the chiller will stop 1 13 Motor power problem Control panel Motor power When there is a problem in the motor power sup ply the chiller will stop 1 14 External problem Control panel External fault signal If a buyer makes a fault signal from the buyer s system the chiller will stop 1 15 Chilled water Cooling water pump interlock Control panel Chilled water Cooling water pump interlock When chille...

Page 22: ... valve 2 and Compressor 2 compressor lead lag lamp and chilled water coolant flow lamp keys There are function keys at the bottom of the screen that change according to the current screen to be able to ac cess lower categories Controller Function key Function key Function key Figure 14 Controller Front view of controller Back view of controller Internal diagram of controller ...

Page 23: ...3 ENGLISH Schematic diagram of the main board main control unit PCB Figure 15 Internal diagram of Master Slave boards Power supply unit POWER SUPPLY PART POWER FILTER Power input COMMUN ICATION Communication Power filter ...

Page 24: ...ed control function to protect the chiller 8 Self diagnosis function for easy checking of abnormal situation 9 Help function describing actions to take when problem occurs 10 Operation data and operaton status error and control action saving function 11 Automatic sensor setting function to set the sensors automatically set by software 12 Automatic repeat key function for setting values easily 13 M...

Page 25: ...ve MICOM PT100 INPUT 4 20mA INPUT 4 20mA OUTPUT DIGITAL INPUT DIGITAL OUTPUT UART BMS UART Slave UART DISPLAY MICOM DC 0 5V INPUT DIGITAL OUTPUT MICOM UART Master PT100 INPUT 4 20mA INPUT 4 20mA OUTPUT DIGITAL INPUT DIGITAL OUTPUT MICOM ARM RS485 RS485 RS485 DC 0 5V INPUT DIGITAL OUTPUT UART Master LCD DISPLAY 7inch KEY PAD MICOM ARM UART MAIN DATA DOWN UART DISPLAY UART BMS UART Slave MICOM PT100...

Page 26: ...26 4 CONTROL SYSTEM ENGLISH Control panel Standard type The above configuration may change according to design enhancement type or user convenience so please refer to the approved drawing for details ...

Page 27: ...pe or user convenience so please refer to the approved drawing for details Control panel component layout Standard type TAG NAME USE CB Main power for wiring circuit breaker NF Micom power protection Noise Filter SMPS Control power supply Transformer Fuse Control power protection fuse Realy Auxiliary relay for start TB Terminal blocks for control signal and main power source MICOM Control device u...

Page 28: ...d controller Figure 18 Converter Table 3 Converter lamp names LED name Status Description TX485 RX485 Flashing Normal data communication with micom Off Error check communication line TX232 RX232 Flashing Normal data communication with BACnet Off Error check communication line RUN Flashing every second Board has finished Power on test and is normally operating Keeping On Off state Error press reset...

Page 29: ... the starter panel has various layouts based on starter method option etc please refer to the drawing provided together with the product h The above configuration may change according to design enhancement type or user convenience so please refer to the approved drawing for details ...

Page 30: ...l Algorithm General Control Algorithm Figure 19 Control algorithm Soft Loading Approach to the control target value with Soft startup Solved unnecessary stops caused by voltage change during startup Advanced Control Advanced high class control algorithm developed for high precision control compared to existing PID control method Prevention of temperature Cycling phenomenon caused by Overshoot Unde...

Page 31: ...asic communication protocol is Modbus protocol and it is compatible with the higher level communi cation methods Communication protocol support Communication method Basic RS 485 Ethernet Optional Protocol Basic MODBUS Option BACnet TCP IP Figure 18 Detailed diagram of BMS ...

Page 32: ...status 2 Input status check Motor status 2 Output status check Power status 2 System information timer Timer check Compressor startup operation check 2 Operation information saving cycle Communication address Machine No Communication speed Language selection Temperature unit selection Pressure unit selection Flow rate unit selection Screen brightness adjusting Chilled water pump operation Abnormal...

Page 33: ...ooling water outlet temperature Evaporator pressure Condenser pressure Current limit Remote control temperature setting Compressor discharge temperature Compressor suction temperature Current Compressor suction temperature 2 Compressor discharge temperature 2 Evaporator pressure 2 Condenser pressure 2 Current 2 Compressordischargetemperature hightemperatureprevention Evaporatorrefrigerantlowtemper...

Page 34: ... QWV TIUX PQTTML _I MZ X UX PQTTML _I MZ X UX QV MZTWKS PQTTML _I MZ NTW_ _Q KP WWTQVO _I MZ X UX PQTTML _I MZ X UX QV MZTWKS PQTTML _I MZ NTI_ _Q KP MTIa QUMZ 5IQV UW WZ WX IZ X KWUXTM M QOVIT 5 WV ZWT IZ X KWUXTM M QOVIT QVX KPMKS 5 IZ X KWUXTM M KPMKS MK VVQVO IT M WXMVQVO TW_MZ TQUQ I MZ KWWTQVO aXM IXWZI WZ WVLMV MZ LQNNMZMV QIT XZM ZM KPMKS QZ KWWTQVO aXM PQTTML _I MZ NTW_ ZI M KPMKS IZVQVO ...

Page 35: ...k and system menu which is for sensor setting and system pertain item setting Menu operation method and operation panel nomenclature Run Stop key Status indicator lamp LCD screen Menu operation key Alarm lamp Flow control valve manual operation key Interlock operation manual operation key Compressor 2 run stop key Figure 19 Controller front view CAUTION Do not operate controller with a sharp part ...

Page 36: ... possible and it starts to operate when it is pressed down for about 1 5 seconds or longer Alarm lamp When a problem or caution warning occurs the alarm lamp is turned on When the alarm lamp is on the message on about the alarm is displayed on the message display line in the LCD screen At this time the release key shows up and buzzer will sounds If you press the release key at this time the buzzer...

Page 37: ... Out of 2 machine types of R134a and R134_D one can be selected When selected the main board is automati cally reset and changed to the selected model _D indicates the model which uses two compressors Operation mode selection display There is only the cooling operation in the ventilation chiller so only the cooling mode is displayed and for low tem perature use air conditioning and ice making mode...

Page 38: ...w chiller It shows up as the initial screen when the micom s power is turned on 1 Main Movement path 2 Evaporator Movement path 38 4 CONTROL SYSTEM ENGLISH Figure 21 Main screen It shows the animation screen of the whole chiller and its relevant data Figure 22 Evaporator screen It shows the evaporator animation screen and its relevant data ...

Page 39: ... Condenser Movement path 4 Compressor Movement path Figure 23 Condenser screen It shows the condenser animation screen and its relevant data Figure 24 Compressor screen It shows the compressor animation screen and its relevant data ...

Page 40: ...TROL SYSTEM ENGLISH 5 History Movement path 6 Menu Movement path Figure 25 Operation history screen It shows operation data operation history and problem history data Figure 26 Menu screen It shows Menu screen ...

Page 41: ...ter outlet temperature 40 0 140 0 C Compressor suction temperature 40 0 140 0 C Compressor discharge temperature 40 0 140 0 C Compressor 2 inlet temperature 40 0 140 0 C Compressor 2 outlet temperature 40 0 140 0 C Evaporator pressure 0 00 30 00kg cm2 Condenser pressure 0 00 30 00kg cm2 Current 0 1999A Current 2 0 1999A Chilled water outlet setting 3 30 0 C Evaporator refrigerant temperature 26 1 ...

Page 42: ...ation control information setting abnormal condition setting safety control set ting timer setting VGD VFD setting and sensor setting can be done by the system manager only through pass word input Menu screen Movement path Figure 27 Input status check screen 1 2 Use buttons to move and when you select a menu it will move to the sub menu If you press SELECT key the screen will be con verted to the ...

Page 43: ...hecking present time operation data saving cycle communication address communication speed language selection model selection etc Sensor calibration Menu to change password or management number Control information setting Menu to calibrate the displayed value of each sensor Safety control setting Menu to set the most basic items for the chiller operation Abnormal condition setting Menu to set cate...

Page 44: ...on setting menu where user set the chiller Run Stop time and temperature Refer to Scheduled operation setting 2 Control mode selection This menu can be used for the chiller which is manufactured for the ice storage system purpose where ice making is possible In the system function setting the menu shows up when ice making mode is used When ice making mode is not used the menu does not show up Air ...

Page 45: ...Not used Always 0 0 C 10 0 C 3 0 C 0 1 Always 1 100 100 1 Always 10 0 50 0 C 32 0 C 0 1 Always 1 0 C 10 0 C 4 0 C 0 1 Always 0 3 600 seconds 0sec 1 Always 0 sec 360sec 0sec 1 Always 4 Setting display screen Operation mode setting Control mode setting Chilled water outlet temperature Ice maker outlet temperature Chilled water temperature P Chilled water temperature I Chilled water temperature D Aut...

Page 46: ...nditioning operation I value in the integral control zone is set which is used for PID control of the chilled water 4 Chilled water temperature D value Differential In air conditioning operation D value in the differential control zone is set which is used for PID control of the chilled water 5 Chilled water outlet temperature ice making Menu to set the chilled water outlet control temperature in ...

Page 47: ...r temperature I value When using inverter to control the cooling water inlet temperature the integral zone I of PID control should be set Cooling water temperature D value When using inverter to control the cooling water inlet temperature the differential zone D of PID control should be set Cooling water inlet temperature Cooling water inlet temperature is set which will be the standard to control...

Page 48: ...ossi ble time Selecting interlock conversion method Automatic manual Automatic Now in stop Selecting interlock conversion time 0 1 000 300 Time Always LAG compressor startup load current 30 100 80 Always LAG compressor startup delay time 60 1 800 300 Sec Always LAG compressor stop load current 30 100 80 Always LAG compressor stop delay time 60 1 800 300 Sec Always Selecting compressor 1 control Ma...

Page 49: ...t in LAG compressor run delay At this time the operation key lamp for the LAG compressor should be kept turned on When the stop key is pushed the stop key lamp is turned on and the LAG compressor is not operated LAG compressor startup delay time This screen is to set the time to delay the startup of the subordinate compressor when Current control proximity value reaches the run condition The subor...

Page 50: ...calendar Description of an example for Scheduled application Aug 1 2009 Run at 06 00 Stop at 09 00 Run at 09 00 Stop at 12 00 Aug 9 2009 Run at 06 00 Stop at 09 00 Run at 09 00 Stop at 12 00 Run at 12 00 Stop at 15 00 Run at 15 00 Stop at 18 00 In each step it is possible to set Operate time Stop time applicable weekdays and control temperature In User setting make sure whether the present date an...

Page 51: ...ation data saving cycle when operation the chiller However the problem data is saved in MICOM s memory regardless of the saving cycle 3 Screen brightness adjustment This menu is for adjusting the brightness of LCD Pressing Increase key makes the figure increase making the LCD brighter while pressing Decrease key makes the figure decrease making the LCD darker Pressing End key terminates adjustment...

Page 52: ...ck Selecting ice making mode Condenser high pressure 2 Oil status 2 Motor status 2 Power supply status 2 Compressor startup check 2 When in the ice making mode Circuit closed When run signal input is made Circuit closed When remote operation is made Circuit closed When there is an external problem Circuit closed When pressure is normal Circuit closed When flow rate is normal Circuit closed When co...

Page 53: ...n compressor is running Circuit closed ON OFF When compressor is running Circuit closed ON OFF When valve is operated Circuit closed Optional ON OFF When valve is operated Circuit closed Optional ON OFF When a problem occurs Circuit closed 0 100 Optional 0 100 When flow rate is controlled Circuit closed 0 60Hz When flow rate is controlled Circuit closed ON OFF When flow rate is controlled Circuit ...

Page 54: ...ircuit closed ON OFF When flow rate is controlled Circuit closed ON OFF When flow rate is controlled Circuit closed ON OFF When valve is operated Circuit closed Optional ON Relay Close OFF Relay Open 7 Timer status check This menu displays status of various timers under arithmetic calculation in micom The menu is constructed for easier checking of the operation status Settings cannot be done in th...

Page 55: ...water pump startup delay timer Cooling water pump stop delay timer Chilled water flow check timer Valve open limit timer 1 Valve open limit timer 2 Valve open limit timer 3 Valve open limit timer 4 50 operation delay timer 75 operation delay timer Oil problem check timer Valve closing timer before startup Valve closing timer when stopping Valve closing timer after startup Compressor startup check ...

Page 56: ...bration The value of each sensor can be calibrated The calibration ranges are 5 C 5 C for temperature 2kg cm2 2kg cm2 for pressure 50m3 h 50m3 h for flow rate 200 200A V KW for current voltage and power Movement path Figure 37 Sensor screen ...

Page 57: ...00 380V 5 R134A R22 R134A_D R22_D R134A 6 1 600 5 sec Optional 7 0 60 10 Optional 8 0 30 1 9 4 step stepless 4 step 10 Modbus X21 Modbus 11 0 3 000 180 0A 12 30 99 0 65 C Optional 13 30 99 0 90 0 C Optional 14 30 99 0 80 0 C Optional 15 0 5 50 0 2 0sec 16 Y D External Y D Optional Control calculation cycle Control temperature non sensing zone Motor rated current Motor rated voltage Model selection...

Page 58: ...rtup output time This menu is used when control valve selection is set on Stepless Smooth startup output cycle refers to the interval of the valve movements and the smooth startup output time is set to the maximum time of ON Close output of the valve within the smooth startup output cycle 8 Control valve selection This menu is used for selecting the output method of the capacity control valve of t...

Page 59: ...on 2 Compressor discharge temperature high This is the menu to set the compressor discharge temperature upper limit 3 Refrigerant temperature low This is the menu to set the evaporator temperature lower limit If the evaporator temperature is lower than the set ting value during the chiller operation the chiller will stop in abnormal condition 4 Evaporator pressure low This is the menu to set the e...

Page 60: ...o implement the control to prevent the chiller from abnormal stop Although the setting value can be changed based on the operation condition of the in stallation site of the chiller consult an expert for correct setting since incorrect setting can affect the temperature control of the chiller 2 To prevent evaporator refrigerant temperature low If the evaporator refrigerant temperature is lower tha...

Page 61: ...Movement path The method of use is the same as in 2 User setting Setting item Setting range Default value Unit Chilled water pump stop delay timer 1 1 800 300 Cooling water pump operation timer 1 60 2 Cooling water pump stop timer 1 180 60 Flow rate vibration ignore timer 1 60 2 Pressure control timer 1 1 600 30 Pressure control timer 2 1 600 60 Pressure control timer 3 1 600 60 Pressure control t...

Page 62: ...ure control inside the controller Prohibit the setting 6 50 75 100 valve open control timer This is the menu to set the open delay time by each step when operating the screw compressor This is used for selecting the control valve of control information setting in step 7 Oil check timer It delays the operation of oil status switch If the time set to open the oil switch during the operation elapses ...

Page 63: ...the selected sensors only You can complete the setting by manually changing the AD values of capacity control valve and diffuser valve to Mini mum Maximum and then changing Reserved to ON and finally selecting the applicable settings Minimum setting Maximum setting Movement path The method of use is the same as in 2 User setting Figure 42 Sensor setting screen ...

Page 64: ...er and major peripheral devices and the total cumulative operation hours Movement path It shows the history data 1 Operation data Movement path Comp in 6 2C Comp out 60 3C Amps 121 4A Eva Press 2 51 kg cm2 Cond Press 8 11 kg cm2 Chilled water inlet 14 9C Chilled water outlet 9 3C Cooling water inlet 29 3C Cooling water oultet 34 1 It shows the Operation history data 1 300 pieces of data can be che...

Page 65: ... Operation history data 3 Problem history Movement path It shows the problem history data 1 300 pieces of data can be checked using buttons Required problem history data can be checked using buttons Figure 45 Operation history data screen Figure 46 Problem history data screen ...

Page 66: ...lp key in the Problem Caution display Help screen will show up and show the pertinent message Pressing Previous key will retrieve tips in the previous message number and pressing Next key tips in the next mes sage number Movement path It shows the tips for the selected problem history data Figure 47 Help screen ...

Page 67: ... as of now Operation information print 1 300 pieces of Operation information can be printed Automatic print It will print the Operation information continuously in a fixed time interval Print mode 1 Displays all data 2 Displays only the values and units for commissioing operator s use Operation history print 1 300 pieces of operation history data can be printed Problem history print 1 300 pieces o...

Page 68: ...uto Manual shifting key or Open Close keys for control valves shown in the front side of the display When stopped the valves cannot be opened manually because they are closed by force through the circuit This menu is for selecting Acti vate Deactivate the graph expres sion for the required data which has been selected by moving but tons Activated data will be shaded in the rectangle Figure 49 Data...

Page 69: ...l signal two wire type Chiller control panel Operation signals Status of chiller ON OFF Operatio Stop 101 Operation DIC1 User control panel h Minimum Run Stop pulse maintaining time Minimum 2 seconds Figure 51 Remote control signal detailed diagram Connecting the remote control signals and status signals ...

Page 70: ...top Problem Cooling water flow low rate abnormal Flow rate interlock abnormal during Operation detected Chiller stop Problem Temperature Pressure Condenser high pressure abnormal Condenser pressure high detected Chiller stop Problem Evaporator low pressure ab normal Evaporator pressure low detected Chiller stop Problem Evaporator refrigerant tem perature low abnormal Evaporator refrigerant tem per...

Page 71: ... set value 100 set value 2 삭제 Display caution message for Condenser high pressure preventive control Caution Prevent Evaporator low pressure Close guide vane when Evaporator pressure is below Low pressure prevention set value 100 set value 2 삭제 Display caution message for Evaporator low pressure preventive control Caution Prevent Evaporator refrigerant low tem perature Close guide vane when Evapor...

Page 72: ...Stop Output non voltage con tact Signals to start stop the fan or pump Access this only when you try to interlock it into the start stop sig nals from the chiller Use this only with a resistance load of AC250V 0 1A or below Signals of access to the central monitoring panel Signal name Signal type Meaning Cautions Check motor start Contact point for signal Output Zero voltage contacts ON when there...

Page 73: ...ischarging the previous remaining electric currents Do not reconnect within 5 min It can cause electric shock fire damage or malfunction If a condenser is used change it with a new one if the swelling goes beyond the standard It can cause electric shock fire damage or malfunction CAUTION Do not try to operate the control or operation panel if you are not acquainted with the details of User s Man u...

Page 74: ...ound the wires 6 Prevention of mal operation Interrupt the power supply and attach caution sign 7 Preparation of protective insulation devices Wear safety gear suitable for the rated voltage including insulation gloves safety hat insulation boots safety suit etc 8 Measures for intrusion of rats or insects Establish appropriate measures to prevent rats insects and snakes intruding the panels Check ...

Page 75: ...s There should be no problem Terminal bars Is there any parts damaged There should be no problem Relays Contactors Is there any vibration during operation Is there any damage in contactor There should be no problem Space heater Is there any discoloration in heater element starter panel There should be no problem Sensors Switches Is there any disconnected or short circuit wires Is there any damage ...

Page 76: ...up Startup and after startup inspection Stop Operation under load and operation adjustment Chilled water pump operation cooling water pump operation Draw up operation data Chilled water and cooling water quality analysis Operation guidance Finishing Unsatisfactory Add pressure with nitrogen gas If you have about one month or more until Operation start Wiring construction between Starter panel and ...

Page 77: ...g maintenance and tubes maintenance Foundation Build the foundation to withstand the concentrated load of the chiller The foundation level should be higher than the surface level of the water and install the drain plumbing around Install the drain plumbing in the sewer Delivery installation Deliver the Chiller horizontally as far as possible The installation order Place isolation pad on the base b...

Page 78: ...n after bringing in and installing the chiller or re operation after stopping the operation for a long time more than a month as Get Ready for Commissioning Commissioning preparation work is the most fundamental and a very important task conducting the maintenance or repair work at least once a year after delivery and installation of the Chiller Checking the leakage area in the machine It is recom...

Page 79: ...est sequentially until the cabin pressure reaches 2 kg cm2 5 kg cm2 or 9 9 5 kg cm2 2 Conduct soapy water checks to all connection areas 3 When the test pressure is kept for 30 minutes get ready to check small leak areas 4 Mark the leak areas 5 Discharge the pressure from the machine 6 Repair all leak areas 7 Conduct the leak test again to check the repaired areas 8 Please increase the cabin press...

Page 80: ... 28 6 3819 64 17 784 7 1 2713 29 6 6001 65 18 223 6 1 361 30 6 8231 66 18 67 5 1 4535 31 7 051 67 19 124 4 1 5486 32 7 2838 68 19 587 3 1 6466 33 7 5216 69 20 057 2 1 7474 34 7 7644 70 20 536 1 1 8512 35 8 0124 71 21 023 0 1 9579 36 8 2657 72 21 518 1 2 0675 37 8 5242 73 22 023 2 2 1803 38 8 788 74 22 535 3 2 2962 39 9 0578 75 23 057 4 2 4153 40 9 3318 76 23 587 5 2 5376 41 9 6128 77 24 127 6 2 66...

Page 81: ...o the ambient air 4 When the vacuum pump is running in the ambient temperature of 15 6 C or above outside the machine and the pressure indicates 756mmHg operate the vacuum pump for about 2 hours further If the cabin pressure is kept lower than 756 mmHg the moisture concentrated in the machine will freeze to ice and this ice will evaporate slower thus the vacuum drying work will be delayed In such ...

Page 82: ...e oil pressure and temperature stay within the limit values the oil foaming phenomenon is not a problem 4 Be careful that the air should not be induced when oil is filled Insulation resistance test 1 Megger test is to obtain the insulation resistance by measuring the leakage current which is flowing through the insulation material by directly applying a voltage to the insulation material For 380 a...

Page 83: ...ke following actions based on the insulation condition Condition Indicated value after 1 minute Action 2 MΩ or less Repair or replace Less than 50 MΩ Troubleshooting 50 100 MΩ Troubleshooting 100 500 MΩ 500 1000 MΩ 1000 MΩ or bigger Condition Insulation absorption rate Dangerous 1 or lower In poor state Lower than1 5 Uncertain 1 5 or higher lower than 2 Fair 2 or higher lower than 3 Good 3 or high...

Page 84: ... done Especially make sure the power line wiring is correctly done 2 After supplying power check the status displayed on the panel For the initial five seconds after supplying the power pay a special attention for any indication of short circuit In case the following symptoms occur interrupt the power supply immediately and conduct a check to find out any problem 3 Checking displayed values Check ...

Page 85: ...ing If water flows out continuously after air is expelled out of the air outlet close the air valve 4 Start a cooling water pump Care is needed as in 3 above 5 Check whether the display window in the control panel is working Check whether the current status of the chiller is dis played as operational in the display window 6 Check the rotating direction of the compressor motor If the rotating direc...

Page 86: ...ing again 1 Troubleshoot the unsafe or problem areas for the proper operation of the machine 2 Make the following inspections mandatory in order to avoid refrigerant loss due to leakage during the stop period 1 Lubrication system Loosening and cracking of oil pipes Oil change Cleaning or change of Oil filter 2 Chilling system Refrigerant contamination checking Tube cleaning Cleaning or change of f...

Page 87: ...Stop button in the control panel is pressed the slide valve will be closed automatically 2 Items to check after stopping Stop the cooling water pump Close slowly the pump outlet valve before stopping the pump Stop the chilled water pump Close slowly the pump outlet valve before stopping the pump Record the levels of the refrigerant and oil after stop ping Figure 55 Stopping Procedure ...

Page 88: ...ufac turing should be prevented by checking in the factory before shipping out After a certain amount of time is passed during the Stable period it enters into the Breakdown period by wearout following the change of machine use pattern In this stage the failure rate increases drastically there fore conducting the overhaul inspection repairs just before this stage will prevent accidents and allow t...

Page 89: ... the machine will be always identified through the regular maintenance and therefore accurate advice can be provided for a breakdown even via telephone Even during the busy season for service work a prompt action can be provided preferentially for the maintenance contract service Contents of Maintenance Contract standard Machine for air conditioning only 1 Inspection before air conditioning 1 Tigh...

Page 90: ...action 7 Tightness test 8 Electricity related insulation test 9 Operation test between starter panel control panel 10 Chiller operation adjustment 3 Water quality analysis Analysis frequency standard 1 Air conditioning only equipment at the start of air conditioning x 1 during air conditioning x 1 at the completion of air conditioning x1 2 Machine operating throughout the year during operation x 5...

Page 91: ...ure Check whether the color of the moisture indicator in the refrigerant supply line is green If green changes to yellow it shows that the moisture amount in the machine is above the permitted limit so re place the filter drier Figure 57 Compressor daily inspection standard ENGLISH Condenser daily inspection standard If cooling water outlet temperature becomes lower than 21 C the condensing pressu...

Page 92: ...9 Evaporator daily inspection standard Classification Inspection items Inspection method Standard Evaporator Chilled water Inlet Check in the panel 5 15 C or lower Outlet Check in the panel 3 C or higher Evaporation pressure temper ature Check in the panel 2 5 kg cm R134a 4 8 kg cm R22 Heat exchanging status Difference between evaporation temperature and chilled water outlet temperature 0 5 3 C Am...

Page 93: ...evel reaches to the designated position immediately interrupt the oil valve After the pressure went up open the suction valve and discharge valve and start the chiller Oil change In normal situation it is not needed to change oil frequently When the chiller s run time reaches 2 000 hours change oil after the sampling test to judge whether the oil change is needed Since oil adding or oil change is ...

Page 94: ... etc deteriorate the water quality even more Corrosion on the copper pipe or scale attachment caused by the contamination of the cooling water makes holes in the tube or blocks copper tube or makes heat exchange capacity drop This causes the tube to be changed power cost to increase or chiller to be broken down Therefore it is necessary to maintain the cooling water quality adequately Carry out pe...

Page 95: ...the machine store the machine with about 5kg of refrigerant inside and 0 5kg of ni trogen charged with pressure 3 If the temperature of the place where the machine is installed goes below 0 C frequently to prevent freezing drain the chilled water cooling water and condensed water and the water box room should be left open 4 Leave the oil filled in the machine and in order to maintain the minimum o...

Page 96: ... Timer High pressure Low pressure condolpa reactor Actual measurement Start up time T 5 25 sec t sec sec C A Touch the surface of the motor with hand Measured at 1000V Check current value After chiller is stopped check from half load side of the motor when the meter axes stopped time Measure the surface of the bolts with thermometer Touch with hand or check with ears Motor insulation Start up char...

Page 97: ...outlet temp and vaporizing temp Check with manometer thermometer Check with thermometer Check with thermometer Difference between condensing temp and coolant outlet temp Check with manometer thermometer Check with thermometer Check with thermometer 34 C or less standard condition 24 C or more standard condition 6 10 kg cm2 26 42 C 2 5 kg cm2 0 21 C kg cm2 C kg cm2 C C C C C 1 3 C 1 3 C 6 15 C 4 C ...

Page 98: ...put KW Rated current A Inspection date Year Month Day Note 1 The manufacturer is not responsible for problems caused by water quality defect wrong repair and maintenance by the customer or natural disaster 2 Disassembly and assembly for repair inspection of the compressor should be done after 5 years or after 10 000 hours of operation whichever is earlier 3 There may be changes for product enhance...

Page 99: ...lowly against the chiller pressure 4 After closing the service valves of the compressor use the upper side valve to gradually reduce the pressure within the oil filter and then change the oil filter 5 Refill oil into the machine using pump To fill the oil to the level of middle or higher of the sight glass about 50 60ℓ of oil is needed Oil level should be possible to be observed through the sight ...

Page 100: ...on Using an appropriate device measure the insulation value between a winding and another winding in the compressor and the winding and ground contact area Before supplying power to the compressor this test should be conducted The insulation resistance value test should follow the following steps Interrupt the auxiliary power switch Open the compressor wiring box Disengage compressor power supply ...

Page 101: ...rigerant is used in a high pressure it is easier to have leakage than to have air inside When cleaning the tube use a specially designed brush not to scratch the tube wall Never use wire brush Refrigerant charging amount adjustment To enhance the performance of the machine in case it is required to adjust the refrigerant charging amount run the machine at the designed load and slowly add or remove...

Page 102: ... pipe cleaning vaporizer condenser Heat exchanger tube inspection Evaporator When the first operation season is over clean the vaporizer tubes These tubes have foreign objects inside so to completely clean the tubes it requires a special caution The tube condition at this time will become the data to de cide how often tube needs to be cleaned and whether water handling in the chilled water brine s...

Page 103: ...d Especially power lines need to be inspected in detail 2 After applying the power check the display status of the panel Be especially careful to see whether there is any sign of short circuit for about 5 seconds after applying the power If any of the following symptoms occurs immediately interrupt the power and check for the problem 3 Check values displayed on the panel Check whether each sensor ...

Page 104: ...ooling water outlet tem perature sensor Chilled water outlet temper ature sensor problem Sensor disconnected short circuit Main board malfunction Check part condition or wiring Replace part or re wire Compressor discharge tem perature sensor Compressor discharge tem perature sensor problem Sensor disconnected short circuit Main board malfunction Check part condition or wiring Replace part or re wi...

Page 105: ...ature displayed on the micom screen Check the set value and correct if it is wrong Compressor discharge tem perature 2 Compressor dis charge temperature 2 Compressor discharge tem perature high Check compressor discharge tem perature displayed in the micom screen Check the set value and correct if it is wrong Compressor 1 current Compressor 1 current abnormal Compressor current is de tected to be ...

Page 106: ...ace the part or re wire Evaporator pres sure Evaporator pressure low Evaporator pressure is de tected to be lower than set value Check the evaporator pressure shown in micom Check the set value and correct if it is wrong Evaporator 2 pres sure Evaporator 2 pressure low Starter panel problem con tact is activated Check the evaporator pressure shown in micom Check the set value and correct if it is ...

Page 107: ...oblem is detected by the motor power supply detec tion device Check part status or wiring Replace part or re wire Cooling water flow interlock Chilled water flow rate low abnormal Flow rate signal is disconnected during normal r operation Pump stopped Flow differential pressure switch setting problem Wrong wiring IO board malfunction Correct set value and check Check part status or wiring Replace ...

Page 108: ...n the resistances between a b c and main body are measured it should not form an angled line If the valve sensor is normal re connect the sensor completely close the valve and check whether the valve value is 0 and after completely opened 100 If the value was changed and the valve opening is wrong the sensor needs to be set again If there is no change in the value check whether 100 is set in senso...

Page 109: ... is changed check the main power of the main board again If the power is normal and there is no sensor input value Master or Slave board needs to be replaced Temp C Rt Ω Temp C Rt Ω Temp C Rt Ω Temp C Rt Ω 200 18 52 20 107 79 240 90 47 450 264 18 190 22 83 30 111 67 250 194 1 460 267 56 180 27 1 40 115 54 260 197 71 470 270 93 170 31 34 50 119 4 270 201 31 480 274 29 160 35 54 60 123 24 280 204 9 ...

Page 110: ...e current of the circuit Refer to Figure 1 Is the current value proportional to the measurement value Measure the current of the sensor Refer to Figure 2 Is the current of the sensor normal Check whether the wiring between sensor and controller is correctly connected Sensor problem Check the auxiliary power If the auxiliary power is normal replace the sensor Master board slave board display board ...

Page 111: ...ould be within DC 22V 5 DC24V Even if the inspection was carried out as above the cause was not still found connect current generator to the input connector DC 24V and of the controller and check whether the indicated value changes according to the change of the current In this case if the controller indicator value does not change according to the change of the current it should be judged as cont...

Page 112: ...roller digital inputs which are not activated to COM connectors 23 24 of controller I O board to check whether the LED LAMPs corresponding to the I O board input connector are lighted Select Menu Key System Information I O input of the controller display and short circuit open problem con nectors with COM connector to see whether input status changes to ON OFF Measure DC voltage between COM connec...

Page 113: ...the connector properly connected Is I O board voltage normal Check the condition of communi cation cable connection between master board and slave board Is the main power of controller normal Replace main board Measure the voltage of the controller Refer to Figure 2 Are they normally connected Re connect the cable ﬁrmly Replace I O board Check whether the pertain wires and input sensor are operati...

Page 114: ...suring circuit Figure 71 Master or slave board current measuring circuit Communication error It is the error caused by no communication corresponding to the displayed messages between each board First check the communication line connection status between each board At this time 2 RDX and RDX lines of master board should be connected to the same polarity of RDX and RDX of slave board and as well a...

Page 115: ...xcessively low 5 Charge sufficient amount of refrigerant Suction pressure is excessively high 1 Discharge pressure is excessively high 2 Refrigerant is overcharged 3 Liquid refrigerant flowing from evaporator to compressor 4 Defective insulation in chilled water pipe 1 Refer to Discharge pressure is excessively low 2 Discharge excessive amount of refrigerant 3 Check and adjust expansion valve chec...

Page 116: ...d over 10 minutes 5 Check the cause of refrigerant leakage Compressor low pressure switch ac tivated 1 Refrigerant liquid pipe filter clogged 2 Expansion unit defect 3 Insufficient refrigerant charge 4 Liquid outlet valve is not fully opened 1 Check or repair strainer or filter 2 Check expansion unit 3 Replenish refrigerant 4 Open valve Noise generated from compressor Liquid refrigerant is flowing...

Page 117: ...ervice load exceeding the designed ca pacity Inefficient compressor Add refrigerant Replace control unit Clean or replace Replace or repair Examine load condition Check loader solenoid valve If needed replace Abnormal noise Pipe vibration If needed install supportive piping Expansion valve noise Add refrigeran Check clogged piping strainer Compressor noise Replace compressor worn out bearing Check...

Page 118: ...t temperature C Cooling water Inlet pressure kg cm2 Outlet pressure kg cm2 Inlet temperature C Outlet temperature C Cooling water flow rate m3 h Con denser Pressure kg cm2 Refrigerant temperature C Oil Pressure difference kg cm2 Compres sor Current limit value Operating current A Discharge gas temperature C Others 1 Chiller operation time 2 Chiller stop time 3 Maintenance items 4 Run hours 5 Numbe...

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