air cooled inverter chiller

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Air Cooled Inverter ChillerAir Cooled Inverter Chiller

Air Cooled Inverter Chiller

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Contents

Product rangeProduct range

ComponentsComponents

Schematic diagramSchematic diagram

Inverter technology Inverter technology

FeaturesFeatures

Chiller panel controllerChiller panel controller

Self diagnosis & TroubleshootingSelf diagnosis & Troubleshooting

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Product range

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Product range

• 5ACV100/135CR

• R410A refrigerant circuit

• Rated Cooling capacity 27.8kW (5ACV100CR), 38.5kW (5ACV135CR)

• Rated Heating capacity 29.3kW (5ACV100CR), 41.5kW (5ACV135CR)

• Power supply : 380-415V / 3 phase / 50Hz

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Product range

• Nominal Sound pressure level 63 dBA (5ACV100CR), 67 dBA (5ACV135CR)

• Nominal Sound pressure level 78 dBA (5ACV100CR), 81 dBA (5ACV135CR)

• Width 1500mm x Depth 960mm x Height 1260mm (5ACV100CR)

• Width 1800mm x Depth 1150mm x Height 1260mm (5ACV135CR)

Refrigerant circuit high port

Refrigerant circuit low port

For Power cables

Drain BSPT 1/2”

Water In BSPT 1 ¼”

Water Out BSPT 1 ¼”

Isolator switch

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Components

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Components

Variable speed fan motors (100%, 70% & 50%)

Heat exchangers with gold fin as standard

Water pump

True dual circuits BPHE (Brazed plate heat exchanger)

Expansion tank ( 8L)

Control box assembly

Coil guards

Fan guards

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Components

Variable drive system compartment

Fixed drive system compartment

High pressure switch(NC) 600 psi – open, 480psi – close.Low pressure switch(NC) 18 psi – open, 28 psi – close.

Pump OLP (overload protector)

Differential pressure switch

Over pressure relief valve

Anti freeze heater on BPHE

Compressor OLP (overload protector)

Chiller panel controller

Fixed speed scroll compressor (R410A)Variable speed scroll compressor (R410A)

EXV (Electronics expansion valve

4 Way valve

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Components

Control box assembly

Power board

IPM board(Intelligent power module)

Main boardMagneticcontactors

EMI filterCapacitor board

PFC capacitor(Power factor correction)

Uni-directional bridge diode

3 phase rectifier bridge diode

Fan capacitors

PTC starter(Positive temperature coefficient)

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Schematic diagram

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Condenser Coil 1

Acc

Acc

Liq Rvr

Liq Rvr

BPHE FS

Condenser Coil 2

DischTemp 2

(Disch Comp 2)

DischTemp 1

(Disch Comp 1)

InvComp

StdComp

SuctTemp

(Suction)

HP1

HP2

LP2

LP1

Cond InTemp 1

(Condenser)

Cond OutTemp 1

(Def Comp 1)

BPHE OutTemp

(BPHE Out)

BPHE InTemp

(BPHE In)

EWT (Water In)

LWT (Water Out)

Pump

Cond OutTemp 2

(Def Comp 2)

FilterDrier

Heating Cap Tube

Check valve

Cooling Cap Tube

Check valve

FilterDrier

EXV

O/A Temp(Outdoor Air)

Summary Pages-Screen 3

Display Menu-Defrost Sensor

Display Menu-Inverter Chiller

Display Menu-Discharge Sensor

5ACV100CR

4WV

4WV

Schematic diagram

Inverter chiller schematic diagram

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Inverter technology

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Inverter technology

• Less Start & Stop • Fast Cooling/ Heating

• Smart Loading/ Unloading

• Better Compressor Reliability

Conventional System

Inverter System

What Inverter can do for us ?

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Inverter technology

Brief Introduction on Inverter Technology

Inverter control technology convert AC supply to DC and convert it back to AC. The frequency & voltage of each phase can be controlled and applied on asynchronous motor for variable load control.

Inverter basic structure

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• To minimize emission effect (EMC) and raise immunity level (EMS), a LC filter is used.• PTC resistor acts to cushion start up current to capacitor.• Diode bridge inverts AC to DC.

Inverter technology

Rectification circuit

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• PTC capacitor acts to restraint PF losses caused

by fluctuation of DC voltage.

Inverter technology

DC stage

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• Inversion circuits consists of 6 IGBT. (Insulated Gate Bipolar Transistor)

• By controlling the linkages, different frequency and 3 phase AC voltage

can be generated.

• IPM (Intelligent Power Module) encased the inversion circuitry, error

detection & protection features.

Inverter technologyInversion circuit

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By computing the on-off frequency and timing of IGBT, a series of output voltage pulse widths can be integrated to form a sine wave for application on VVVF. (Variable Voltage Variable Frequency)

Inverter technology

SPWM ( Sine pulse width modulation )

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• Every inverter chiller has its typical characteristic and VVVF (variable

voltage variable frequency) curve.

• To control Asynchronous motor, it is desirable to maintain magnetic

flux for torque requirement.

• Excessive of magnetic flux will cause excitation and diminish the flux.

• To maintain optimum flux, the voltage varies with frequency.

Inverter technology

VVVF (Variable voltage variable frequency)

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Features

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Features

Variable Drive Compressor Control

Cooling mode

Start up condition :

• Pump runs normally for 2 minutes *

• 2°C T water return – T set 4°C

• No irreversible errors in variable drive and the systems• Satisfy a delay of 3 minutes before restart #

Note : If fixed drive system starts first, the variable drive system should trail after 30 sec.

* Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default 120s )# Depends on Parameter C5 (pump on--> compressor on delay. Min 0s, max 1990s, default 180s)

For example :Return water temp.= 14 to 16 °CSet temp = 12°C T = 2 to 4°C

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FeaturesCooling modeCooling mode selected water pump starts Outdoor fan starts variable drive compressor starts

Rated Freq.

55Hz

5Hz

t

3 min 5 sec 1 min

ONOFF

ONOFF

Variable drive comp

Outdoor fan

Outdoor fan will start 5 sec before compressor start

Inverter compressor will start from 5Hz to 55Hz and maintain this frequency for 1 min.

Increase to rated frequency with the rate of 1Hz/s5ACV100CR=75Hz

5ACV135CR=95Hz

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Features

Cooling mode

Shut down condition :

• Cooling mode terminates, OR

• T water return – T set -2°C

• Variable drive system error occurs, OR

For example :Return water temp.= 10°CSet temp = 12°C T = -2°C

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Features

Heating mode



• 2°C T set - T water return 4°C

• No irreversible errors in variable drive and the systems• Satisfy a delay of 3 minutes before restart #

* Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default 120s )# Depends on Parameter C5 (pump on --> compressor on delay. Min 0s, max 1990s, default 180s)

Note : If fixed drive system starts first, the variable drive system should trail after 30 sec.

For example :Set temp = 40°CReturn water temp.= 36 to 38 °C T = 2 to 4°C

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Heating mode selected water pump starts Variable drive 4WV engages Outdoor fan starts compressor starts

Features

Heating mode

Rated Freq.

45Hz

5Hz

t

3 min 10 sec 1 min

ONOFF

ONOFF

Variable drive comp

Outdoor fan

ONOFFVariable 4WV

5 sec Outdoor fan will start 5 sec before compressor start

Variable drive 4WV start 10 sec before compressor start

Inverter compressor will start from 5Hz to 45Hz and maintain this frequency for 1 min.

Increase to rated frequency with the rate of 1Hz/s

5ACV100CR=65Hz5ACV135CR=90Hz

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Heating mode


• Heating mode terminates, OR

• T set - T water return -2°C

• Variable drive system error occurs, OR

Features

For example :Set temp = 40°CWater return temp = 42°CT = -2°C

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Features

Fixed Drive Compressor Control

Cooling mode



• T water return – T set > 4°C

• No irreversible errors in fixed drive and the systems• Satisfy a delay of 3 minutes before restart #

Note : If variable drive system starts first, the fixed drive system will only start after the frequency of variable drive drops to 50Hz.


For example :Water return temp = 16°CSet temp = 12°CT = 4°C

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FeaturesCooling modeCooling mode selected water pump starts Outdoor fan starts compressor starts


Fixed drive compressor starts

Fixed drive comp

Outdoor fan

1 min3 min 5 sec

ON

OFF

ON

OFF

Outdoor fan will stop after compressor has stopped for 1 min

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Features

Cooling mode


• Cooling mode terminates, OR

• T set - T water return > 2°C and variable frequency drops pass 20Hz

• Fixed drive system error occurs, OR

For example :Set temp = 12°CWater return temp = 10°CT = 2°C

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Features

Heating mode



• T set - T water return > 4°C

• No irreversible errors in fixed drive and the systems• Satisfy a delay of 3 minutes before restart #

Note : If variable drive system starts first, the fixed drive system will start after the variable drive frequency drops to 50Hz.


For example :Set temp = 40°CWater return temp = 36°CT = 4°C

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Heating mode selected water pump starts Fixed drive 4WV engages Outdoor fan starts compressor starts

Features

Heating mode


Fixed drive 4WV start 10 sec before compressor start

3 min 10 sec 1 min

ON

OFF

ON

OFF

Fixed drive comp

Outdoor fan

ON

OFFVariable 4WV 5 sec

Fixed drive compressor starts

Outdoor fan and 4WV will stop after compressor has stopped for 1 min

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Heating mode


• Heating mode terminates, OR

• T water return - T set > 2°C

• Fixed drive system error occurs, OR

Features

For example :Water return temp = 42°CSet temp = 40°CT = 2°C

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Features

Pump Control

Pump start up

When starting the system, pump will run for 2 minutes * before proceeding to next step.

* Depends on Parameter P2 (flow switch alarm delay at pump start. Min = 0s, Max = 199s, default = 120s)

Pump shut down

After both compressors shut down for 1 minute, pump shuts down.

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System error

When errors occur in the system and require system to shut down, the pump will shut down 1 minute after the system shuts down. If compressor is not running, the pump shuts down immediately.

Pump Control

Features

Note : When changing operating mode or when temperature reaches setting, pump continues to run.

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Start up conditions• System in heating mode AND• System no error alarm AND• After heating starts for 1 hour and T set – T water return > 5°C The second time start up is not time –dependent.

Auxiliary heater control (Info only)

Features

Heating No error

Running 1 hour T>5°C

For example:Set temp = 40°CWater return temp = 34°C T = 6°C

Switch off conditions

• System terminates heating mode OR• Wired handset withdraws auxiliary heating command, OR• System errors trigger alarm and require shut down, OR• When T set – T water return < 2°C

Heating Error

T< 2°CX

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• When system operates for the first time, EXV will operate to preset openings.

• After system operates for 10 minutes, the EXV will preset to superheat regulation for variable drive system.

EXV control (Electronic expansion valve)

Features

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• When selecting heating mode, 4 way valve will engage 5 seconds before heating start up. • When heating stops, 4 way valve will disengage 60 seconds after compressor stops.

4 way reversible valve control

Features

• Fixed drive compressor crankcase heater is driven by the fixed drive contactor (NC). • Variable drive compressor crankcase heater is driven by main board relay.• Crankcase heater will be ON whenever compressors are not in operation.

Compressor crankcase heater control

Heating starts4 WV engage 5 sec Select heating mode

compressor stops

4 WV disengage 60 sec Stop heating mode

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Outdoor fan control

Features

Control basic

• Fixed drive and variable drive outdoor fan are independently controlled.

• During start up, fan operates at fixed speed. During operation, fans operate at variable speed.

• There are 3 fan speeds in High, Medium and Low fan speed.

• The High fan speed is 680 RPM and 3800CFM for each fan motor.

• The ratio of fan speed is 100%, 70% and 50% respectively.

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Outdoor fan control

Features

Fan control for Cooling• Within 20 minutes of normal operation, when Te (Outdoor ambient temp.) 28°C, fan operates at highest speed.• Within 20 minutes of normal operation, when Te (Outdoor ambient temp.) <28°C, fan operates at medium fan.• After normal operation for 20 minutes, when 40°C < (Ta3, Tb2) < 48°C, the operates to variable speed (PI regulation). The lower the temperature the lower the speed.

48°C

40°C

Constant fan speed control zone

Te 28°C (High fan)Te < 28°C (Med fan)

20 min

High fan zone

PI control zone

Low fan zone

Ta3, Tb2

Ta3 = condenser outlet temp. (Variable drive system)

Tb2 = condenser outlet temp. (Fixed drive system)

PI = program intelligent

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Outdoor fan control

Fan control for Heating• When Te (Outdoor ambient temp.) < 10°C, fan operates at highest speed.

• When 10°C Te (Outdoor ambient temp.) 12°C, fan operates at medium fan.• When Te (Outdoor ambient temp.) > 12°C, fan operates at variable speed to PI regulation. The higher the temperature the lower the speed.

Features

12°C

10°C

Low fan

PI control

Constant fan speed control zone (medium fan)

Constant fan speed control zone (high fan)High fan High fan

t

Te

PI=program intelligent

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Outdoor fan control

Fan operation during defrosting

Features

Defrost start Defrost end

Variable drive comp

Variable 4WV

Outdoor fan

30 Hz 30 Hz

70 Hz

Resume heating mode

Fan stops 1 minute after the compressor stops.

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Anti freeze heater control

Anti freeze on/off control during system standby

Features

• Runs when system in standby mode• If Te 5°C and T water return 5°C, water pump runs 5 minutes every hour and antifreeze heater will run on and off together with the water pump.• If T water return > 6°C water pump and antifreeze heater stops.• If Te 2°C and T water return 2°C, system enters heating mode and returns to standby when T water return > 30°C

Water return temperature/Outdoor ambient temperature

°C52 6 30

Water pump

Antifreeze heater

ON

ON

System enters heating mode

Run 5 min/hr

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Anti freeze heater control

Anti freeze during cooling

Features

• When T water leaving 5°C, antifreeze heater will operate until T water leaving > 7°C.

• When T water leaving 3°C, alarm will set off until T water leaving > 5°C.

Water leaving temperature

°C53 7

Antifreeze heater

ON

Alarm on Alarm off

Factory setting for antifreeze heater = 5°C alarm set point = 3°C

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Defrosting control

Automatic defrosting

Features

Shall satisfying the below automatic defrosting condition for 3 minutes :• Compressor operates continuously for at least the duration of the defrosting interval. • When Ta3 or Tb2 0°C * OR• When T water return > 18°C

* Depends on Parameter D1 (Start defrost temperature. Min -20°C, max 14°C, default 0°C )Note : Factory defrost interval depends on Parameter D4 (Defrost interval time). Intelligent defrost interval varies. Under Parameter defrost mode, Intelligent defrost is set as default under DISABLE mode. Factory standard defrost will be activated when the parameter is set to ENABLE.

Ta3 = condenser outlet temp. (Variable drive system) Tb2 = condenser outlet temp. (Fixed drive system)

Manual defrosting

Manual defrosting can be carried out when Ta3 or Tb2 < 7°C

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Defrosting controlDefrosting process

Features

Variable drive defrosting process• When defrosting conditions are met for variable drive, variable drive compressor stops outdoor fan stops 4WV disengages variable drive starts defrost at 70Hz.• When variable drive defrosting terminates, variable drive compressor stops 4WV engages outdoor fan starts variable drive compressor starts Resume heating operation.


Variable drive comp

Variable 4WV

Outdoor fan

30 Hz 30 Hz

70 Hz

Resume heating mode

ONOFF

ONOFF

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Defrosting controlDefrosting process

Features

Fixed drive defrosting process• When defrosting conditions are met for fixed drive, fixed drive compressor stops (15 sec) outdoor fan stops (2 sec) 4WV disengages (10 sec) fixed drive compressor starts defrost• When fixed drive defrosting terminates, fixed drive compressor stops outdoor fan starts at high speed for 30 sec 4 WV engages Fixed drive compressor starts Resume heating operation.


Fixed drive comp

Outdoor fan

4WV

Resume heating mode

ONOFF

ONOFF

15 sec 10 sec

2 sec

10 sec

2 sec 2 sec

ONOFF

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Defrosting control

Defrosting process

Features

• As the outdoor fan ducts are independent, defrosting is independent, system restricts defrosting of fixed drive and variable drive at the same time.

• When either variable or fixed drive high pressure protection is triggered, compressor will stop.

• During defrosting, low pressure operation will not trigger protection.

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Defrosting control

Features

Defrosting termination conditions

When either of the below condition is met, defrosting terminates :

• Ta3 or Tb2 > 14°C *, OR• Defrosting time exceed 10 minutes #, OR• T water return < 12°C

* Depends on Parameter D2 (End defrost temperature. Min=0°C, max=40°C, default =14°C)# Depends on Parameter D3 (Maximum duration of defrost cycle. Min=1min, max=40min, default=10min)

Ta3 = condenser outlet temp. (Variable drive system) Tb2 = condenser outlet temp. (Fixed drive system)

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Defrosting control

Features

Defrosting cycle self-adaptive adjustmentThe next defrosting cycle depends on that of the previous.

1. Defrosting time < 2 minutes, next cycle 120 minutes2. Defrosting time 2 to 4 minutes, next cycle 80 minutes3. Defrosting time 4 to 6 minutes, next cycle 60 minutes4. Defrosting time 6 to 8 minutes, next cycle 40 minutes5. Defrosting time > 8 minutes, next cycle 30 minutes

120 min< 2 min

80 min2 – 4 min

60 min4 – 6 min

40 min6 – 8 min

30 min> 8 min

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Control system protection

Features

Compressor over-current protectionVariable drive compressor • When variable drive compressor current reaches the maximum limit, over-current protection triggers and the compressor frequency will reduce.• When the compressor current drops below the limit, frequency variation resumes.• When compressor current increase rapidly and reaches the maximum limit, the system will be determined as compressor overload and stop the compressor. 20.5

17

Variable compressor stops

Maintain frequency

Normal Operation

Comp amp (A)

18Frequency step down

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Features

High discharge temperature protectionVariable drive system• When variable drive discharge temperature reaches 110°C, system shuts down.• When variable drive discharge temp. between 100°C and 110°C, frequency drops.• When variable drive discharge temperature is less than 97°C and more than 100°C, frequency increased restricted.• When discharge temperature falls below 94°C, normal operation resumes.

System shuts down

Frequency step down

Maintain frequency

Normal operation

Compressor dischargetemperature

110°C

100°C

97°C94°C

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Features

High discharge temperature protection

Fixed drive system• When fixed drive discharge temperature reaches 110°C, system shuts down.• When discharge temperature falls below 94°C for 3 minutes, system resumes.

Td = Compressor discharge temperature

Td = 110°C

Td <94°CComp start

Comp Cut3 min

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Features

Outdoor coil high temperature protection

Variable drive system• During cooling, when Tcoil1 > 60 °C, frequency drops.• During cooling, when Tcoil1 < 55 °C, system resumes.

Fixed drive system• During cooling, when Tcoil2 > 64°C, frequency drops.• During cooling, when Tcoil2 < 51°C, system resumes.

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Features

Low pressure switch protection

• Alarm delayed at compressor start up : 30 sec depends on Parameter 3*.• No protection during defrosting.• If variable drive or fixed drive low pressure switch is activated for 5 seconds, alarm will be triggered.* Depends on Parameter P3 (Low pressure alarm delay at compressor start up. Min=0s, max=199s, default=30s)

Note : If low pressure alarm occur more than 3 times within 30 minutes, system shuts down to irreversible error.

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Features

High pressure switch protection

• If fixed drive high pressure switch is activated for 30 sec, alarm will be triggered.• If variable drive high pressure switch is activated, frequency of variable drive compressor will decrease at 1Hz/s. If it is de-activated for 30 sec, alarm will be triggered.

Note : If high pressure alarm occur more than 3 times within 30 minutes, system shuts down to irreversible error.

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Features

3 phase AC phase sequence protection

If 3 phase AC phase sequence is incorrectly connected, system will not start and controller will indicate error. System will resume after rectification.

3 phase AC phase missing protection

If phase missing happens, system will not operate. Controller will indicate error. System will resume after rectification.

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LCD Display

On/Off Indicator

Navigation Key (Up &

Down)

Cancel Instruction Key

Execute Instruction Key

Switching Heat Mode

Switching Cool Mode

Show Alarm Key

On/Off Shortcut Key

Short cut key can only be used in the summary page!

Short cut key Navigation key

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Backup Battery

CMOS Reset Jumper (JH2)

Chiller Terminal Unit Connection

(CN8)

+12Vdc, GND; A, B

Reset some of the settings to the

DEFAULT value

Memorize of Date, Time & Timer

Schedule

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Chiller panel controllerMenu structure

Summary Pages

Main Menu

Unit Selection Menu

Operation Menu

Settings Menu

Timer Menu

Alarm Menu

Display Menu

Status

Mode

Cool Set

Heat Set

Manual Defrost

Set Parameter [#]

Change Password [#]

Panel Option

Set Panel ID

Clock Setting

Date Setting

Time Schedule

Timer

Show Alarms

Erase All Alarms

Defrost Sensor

Discharge Sensor

Comp Run Time [#]

Inverter Chiller

General

Regulator

Compressor

Defrost

Antifreeze

Inverter

Alarm and Contact

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Chiller panel controllerSetting menu

Setting parameter for Inverter

Inverter parameter setting page on the chiller panel controller

SETTINGS MENU

Set Parameter

Change Password

Panel Option

Set Panel ID

1. General

2. Regulator

3. Compressor

4. Condenser Defrost

5. Cool Mode Antifreeze

6. Inverter

7. Alarm & Contact

V1 Cp Freq : 0Hz

V2 EXV : 0

V3 Cp Manual : Disable

V4 EXV Manual : Disable

V5 Def Mode : Disable

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V1 : Compressor frequency It allows to set the inverter compressor frequency (max frequency varies according to models)V2 : EXV (Electronic expansion valve) It allows to set the EXV opening (0-480 pulsation)

INVERTER Unit Default Min Max ResolutionV1 Compressor frequency Hz Auto 0 120 1V2 EXV Opening Flag Auto 0 480 1

Compressor manual setting Flag 0 (disable) 0 1 10 = disable 1 = enableEXV Manual setting Flag 0 (disable) 0 1 10 = disable 1 = enableDefrost Mode Flag 0 (disable) 0 1 10 = disable 1 = enable

V3

V4

V5

There are 5 setting parameters for Inverter ( V1 to V5 )

V3 : Cp Manual This parameter enable automatic or manual setting for the compressor frequency. ( Enable : manual setting is possible, Disable : frequency auto-run )

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INVERTER Unit Default Min Max ResolutionV1 Compressor frequency Hz Auto 0 120 1V2 EXV Opening Flag Auto 0 480 1

Compressor manual setting Flag 0 (disable) 0 1 10 = disable 1 = enableEXV Manual setting Flag 0 (disable) 0 1 10 = disable 1 = enableDefrost Mode Flag 0 (disable) 0 1 10 = disable 1 = enable

V3

V4

V5

V5 : Def Mode This parameter enable automatic intelligent or standard defrosting. ( Enable : manual setting is possible in Parameter D1-D6, Disable : Intelligent defrosting [auto-run] )

V4 : EXV Manual This parameter enable automatic or manual setting for the EXV opening. ( Enable : manual setting is possible, Disable : EXV opening auto-run )

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Chiller panel controllerDisplay menu

Display menu for Inverter

Inverter display menu page on the chiller panel controller

DISPLAY MENU

Defrost Sensor

Discharge Sensor

Comp. Run Time

Inverter Chiller

Inverter Chiller

Comp Freq : 75Hz

EXV : 320

Comp Amp : 9.7A

DC Bus : 555V

Inverter Chiller

Suction : 15.5 °C

BPHE In : 45.9 °C

BPHE Out : 18.3 °C

Condenser : 28.4 °C

Screen 1

Screen 2

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Compressor FrequencyIt shows the operating inverter compressor frequency. (Hz)

EXVIt shows the operating EXV opening (pulse).

Comp AmpIt shows the operating inverter compressor running current. (A)

DC BusIt shows the operating DC voltage in the inverter system. (V)

Inverter Chiller

Comp Freq : 75Hz

EXV : 320

Comp Amp : 9.7A

DC Bus : 555V

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SuctionIt shows the inverter compressor suction temperature. (°C)

BPHE InIt shows the refrigerant inlet temperature at the BPHE during cooling mode. During heating mode, the value represents the refrigerant outlet temperature at the BPHE. (°C)BPHE OutIt shows the refrigerant outlet temperature at the BPHE during cooling mode. During heating mode, the value represents the refrigerant inlet temperature at the BPHE. (°C)

CondenserIt shows the inverter condenser coil inlet temperature. (°C)

Inverter Chiller

Suction : 15.5 °C

BPHE In : 45.9 °C

BPHE Out : 18.3 °C

Condenser : 28.4 °C

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Self diagnosis & Troubleshooting

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Comp Fan Comp Fan Phase Missing Phase missing Manual OFF OFF OFF OFF OFFPhase Seq Error Wrong phase sequencing Manual OFF OFF OFF OFF OFFMemory Error EEPROM read/write error Auto OFF OFF OFF OFF OFFEntering Water Sensor Open/Short BPHE water in sensor error Auto OFF OFF OFF OFF OFFLeaving Water Sensor Open/Short BPHE water out sensor error Auto OFF OFF OFF OFF OFFOutdoor Air sensor Open/Short Ambient temp sensor error Auto OFF OFF OFF OFF OFFWater Flow Error Cv contact opened Manual OFF OFF OFF OFF OFFCool Mode Antifreeze Leaving water temp. too low Auto OFF OFF OFF OFF OFFOV/UN Voltage Comp. High Voltage (>490V) <460V, Auto OFF OFF OFF OFF OFFOV/UN Voltage Comp. Low Voltage (<310V) >340V, Auto OFF OFF OFF OFF OFFPump Overload Pump OLP opened Auto OFF OFF OFF OFF OFFIPM Error IPM over-current or overheat Auto - OFF OFF - -Comp 1 Overload Comp 1 overload Auto - OFF OFF - -Comp 1 Discharge Overheat Comp 1 discharge Overheat Auto - OFF OFF - -High pressure 1 System 1 high pressure Auto - OFF OFF - -Low pressure 1 System 1 low pressure Auto - OFF OFF - -Comp 1 Defrost sensor Open/Short Coil out system 1 sensor error Auto - OFF OFF - -Comp 1 Suct sensor Open/Short Suction comp system 1 sensor error Auto - OFF OFF - -Comp 1 Discharge sensor Open/Short Discharge comp system 1 sensor error Auto - OFF OFF - -Coil 1 Inlet Temp Open/Short Coil in system 1 sensor error Auto - OFF OFF - -V-Hx Inlet Temp sensor Open/Short BPHE refrigerant in sensor error Auto - OFF OFF - -V-Hx Outlet Temp sensor Open/Short BPHE refrigerant out sensor error Auto - OFF OFF - -Comp 2 Overload Comp 2 overload Auto - - - OFF OFFHigh pressure 2 System 2 high pressure Auto - - - OFF OFFLow pressure 2 System 2 low pressure Auto - - - OFF OFFComp 2 Defrost sensor Open/Short Coil out system 2 sensor error Auto - - - OFF OFFComp 2 Discharge sensor Open/Short/Overheat

Discharge comp system 2 sensor error Auto - - - OFF OFF

Error descriptionError displayPump

Control measureSystem 1

(Variable Drive)System 2

(Fixed drive)Reset

(default)

Self diagnosis & Troubleshooting

Error Code

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Self diagnosis & Troubleshooting1. No response after power-on

No response

Check Input conditions

Check Input power supply

Check DC rectifier circuit

Is Power board DC-IN voltage normal?

Is LED main board lit?

Is R,S,T Input voltage normal?

Yes

No

Yes

No

No

Is connection between main board and IPM normal?

Main board faulty, To replace.

Main board or IPM short circuit, To replace.

Is JP-power/DC-OUT output normal?

Yes

No

Replace power board components

No

Yes

Yes

JP-power (+12VDC &

+5VDC)

DC-OUT (+15VDC)

Power board

DC-IN (+590VDC)

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Self diagnosis & Troubleshooting2. LED on main board normal, but no output.

LED lit, No output

Is output condition ok?

No

Is load ok?

Is main board’s fuse ok?

Replace main board

Rectify

Rectify

Rectify

No

No

Yes

Yes

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Self diagnosis & Troubleshooting3. Other functions normal but compressor not functioning

Others OK, Comp not functioning

Is fuse in DC loop ok?

Yes

Is IPM ok?

Is compressor ok?

Change fuse

Check operating conditions

Replace

Replace

No

No

Yes

No

Yes

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Self diagnosis & Troubleshooting4. Flow switch protection

Water flow error

Short JK4

Is water flow error persists?

Main board faulty , replace main board

Flow switch faulty or pump stopped.

No

Yes

JK4 on main board

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Self diagnosis & Troubleshooting5. Over voltage protection

OV/UN Voltage

Is Power supply < 460VAC?

Power board error, rectify.

RectifyYesIs Power

supply > 490VAC?

No

No

Yes

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Self diagnosis & Troubleshooting6. Under voltage protection

OV/UN Voltage

Is Power supply > 340VAC?

Power board error, rectify.

RectifyYesIs Power

supply < 310VAC?

No

No

Yes

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Self diagnosis & Troubleshooting7. Pump overload protection

Pump overload

Remove JK8, 97 & 98, is it still conducting?

Pump overload

Main board faulty

NoIs voltage of 97, 98 on heat relay VDC = 0 V

Yes

No

Yes

JK8 on main board

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Self diagnosis & Troubleshooting8. Phase missing

Phase missing

Is Voltage between R,S,T

415VAC ±20%?

No

Is J-RST on main board 415VAC ±20%?

Disconnect power, remove J-RST, is voltage of socket 415VAC ±20%?

To Check/replace EMI filter

Check incoming supply

Main board faulty

Yes

No

No

Yes

Yes

3 Phase supply

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Self diagnosis & Troubleshooting9. IPM protection

Yes

IPM Error

Is IPM temperature >100°C?

Replace

Check compressor

Normal

Rectify

Main board faulty or wrong signal

Is heat sink temperature >100°C?

Is IPM Error persists?

Is IPM ok?

Is current at rated frequency ok?

Yes

No

No

Reapply heat compound

No

Yes

No

No

Yes

No

Is heat compound dried out?

Change IPM

Yes

Yes

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Self diagnosis & Troubleshooting10. Variable compressor over-current protection

Comp 1 overload

Main board or compressor faulty

Replace

Comp and current checked, circuit ok.

YesRestart. Set freq. with handset. Check current, is it ok?

No

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Self diagnosis & Troubleshooting11. Variable drive high pressure protection

High Pressure 1

Check AC system for overload

Rectify

Replace

NoIs high pressure switch ok?

Yes

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Self diagnosis & Troubleshooting12. Variable drive low pressure protection

Low Pressure 1

Check AC system for low pressure

Rectify

Replace

NoIs low pressure switch ok?

Yes

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Self diagnosis & Troubleshooting13. Variable compressor high discharge temperature protection

Comp 1 Discharge Overheat

Temp sensor ok? (<100°C?)

Rectify

Compressor stops

Yes> 110 °C ?

No

Check AC system

Replace

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Self diagnosis & Troubleshooting14. Fixed compressor over-current protection

Comp 2 Overload

Check on compressor winding resistance, is it to spec ?

No

Check on Compressor insulation, is it ok?

Check current reading on handset against actual reading, is it very big different?

Current sensing circuit error. Replace main board

Rectify

Rectify

NormalNo

Yes

No

Is supply voltage ok? Rectify

No

Yes

Yes

Yes

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Thank You

air cooled inverter chiller

Documents