EN,OM,TurboChiller,2StageHtype,AC Smart Premium

EN,OM,TurboChiller,2StageHtype,AC Smart Premium
ENGLISH
INSTRUCTION MANUAL
Water-Cooled Turbo Chiller
Please read the safety precautions before use.
This content is to ensure the safety of users and to prevent property damages.
Keep the instruction manual in a place that is accessible to other users.
Only authorized people can use the product.
Model : RCWFH Series (200-3000RT)
(For AC Smart Premium Control System)
P/NO : MFL68929306 (Rev 0)
www.lge.com
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ENGLISH
For your records
Staple your receipt 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 :
3
It can be dangerous when moving, installing and placing the system for its high pressure, electric
devices and heavy weight especially when lifting the unit in a limited space(rooftop, lifted structure, etc.).
Please read carefully the warnings and cautions on this manual and the labels attached on the
unit, and follow the instructions.
Please follow the following instructions to prevent any injury or property damage
• It may result in an injury or damages when neglecting the instructions on in this manual.
The seriousness of the result can be classified as the following signs.
• Please note that any failure of system resulted by user’s careless maintenance, natural disaster
or the failure of the power cable shall not be warranted regardless of the warranty period.
• Please note that any part of this manual can be revised without notice for the product improvement.
! WARNING
It can result in serious injury or death when the directions are ignored.
! CAUTION
It can result in minor injury or product damage when the directions are ignored.
The meanings of the symbols used in this manual are as follows.
!
This is the symbol to call attention for the issues and operations that may cause danger.
To prevent the occurrence of the danger, read carefully and follow the instructions.
This is the symbol showing the how-to-use instruction in order to prevent danger.
Follow the direction.
1-1. WARNING
• Have all electric work done by a licensed electrician according to "Electric Facility Engineering Standard" and "Interior
Wire Regulations" and the instructions given in this manual and always use a special 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 of fire, electric shock, explosion, or injury.
• Make sure to equip the circuit breaker and fuse.
- Improper wiring or installation may cause fire or electric shock.
• Do not disassemble, repair or reconfigure the unit.
- LG Electronics is not responsible for the any damage or loss from the arbitrary disassembly, repair or reconfiguration of the unit.
• Make sure to ground the unit properly.
- There is risk of fire or electric shock.
• Do not store or use flammable gas or combustibles near the chiller unit
- There is risk of fire or failure of product.
• Do not reconstruct to change the settings of the protection devices.
- If the pressure switch, thermal switch, or other protection device is shorted and operated forcibly, or parts other
than those specified by LGE are used, fire or explosion may result.
• Install the unit on a foundation where the heavy weight can be supported.
- Insufficient strength of the foundation to support the chiller operation may cause the unit failure or injury.
ENGLISH
1. CAUTIONS FOR SAFETY _ WARNING/CAUTION
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• Installing the product in small space requires separate measures to keep the leakage of the refrigerant within the
safety limits in case of any leakage.
- Consult the authorized dealer for appropriate measures to prevent the refrigerant leakage from exceeding the
safety limits. The leakage of refrigerant exceeding the safety limit may result in dangerous situations due to the
lack of oxygen level in the room.
• Securely install the cover of control box and the panel.
- If the cover and panel are not installed securely, dust or water may enter the unit and fire or electric shock may result.
• Do not operate the unit arbitrarily.
- Incorrect operation of the unit may cause dangerous situations such as unit defects, leakage or electric shock. Always consult the authorized dealer.
• Do not use damaged circuit breaker or fuse works correctly all the time.
- It may cause fire, electric shock or injury.
• Keep the control panel from any water getting in.
- Do not wash the control panel with water. It can cause electric shock or defects.
• When the product is soaked (flooded or submerged), contact an Authorized Service Center.
- There is risk of fire or electric shock.
• Use a dedicated outlet for this unit.
- There is risk of fire or electric shock.
• Make sure to charge only the exclusive refrigerant R134a when installing or moving to other place.
- If a different refrigerant or air is mixed with the original refrigerant, the refrigerant cycle may malfunction and the
unit may be damaged.
• Do not touch the power switch with wet hands.
- There is risk of fire, electric shock, explosion, or injury.
• Ventilate before operating the chiller unit when gas leaked out.
- Do not use a phone or operate the power switch at this time. It may cause fire or explosion.
• Do not put any heavy object on the top of the unit or climb on the unit.
- It may cause defects or injury.
• Be careful with the rotating part.
- Do not put your fingers or a stick to the rotating part. It can cause injury.
• Use the fuse and circuit breaker with 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.
• Follow the permitted pressure level
- Follow the regulated pressure for cold water, cooling water, refrigerant etc.
• Do not change the set values.
- Do not change the set values of the controller and safety devices. Operating with inappropriate setting can cause
damages. When changing the setting values, please consult with the specialist.
• Be careful of fire, earthquake and lightening.
- In case of any natural disaster such as fire, earthquake or lightening, immediately stop operating the unit. If you
continue to operate the unit, it can cause a fire or electronic shock.
• Follow all safety code.
- When operate the chiller, follow the precautions on the manual, tag, sticker and label.
• Use of undesignated refrigerant and oil is prohibited.
- Do not use undesignated refrigerant, freezer oil and brine. It may cause serious effect to the compressor and
parts defect.
• During the installation and service, shut down the power supply.
- Electric shock can cause injury and death. Mark and check all switches so that the power is not recovered until
the work is completed.
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• Wear safety equipment
- Wear safety glasses and work gloves. Be careful when installing or operating the chiller and operating the electrical components.
• Always run fluid through heat exchangers when adding or removing refrigerant charge.
- Potential damage of the tube within the heat exchanger can be prevented. Use Appropriate brine solution in
cooler fluid loops to prevent the freezing of heat exchangers when equipment is exposed to temperature below
0°C.
• Do not vent refrigerant relief valves within a building.
- Outlet from relief valves must be vented outdoors in accordance with the latest edition of ANSI/ASHRAE(American National Standards Institute/American Society of Heating, Refrigeration and Air Conditioning Engineers) 15
(Safety Code for Mechanical Refrigeration). The accumulation of refrigerant in an enclosed space can displace
oxygen and cause asphyxiation. Provide adequate ventilation in enclosed or low overhead areas. Inhalation of high
concentrations of refrigerant gas is harmful and may cause heart irregularities, unconsciousness or death. Misuse
can be critical. Refrigerant gas is heavier than air and reduces the level of oxygen. It can cause irritation to eyes
and skin.
• Be careful of water leakage.
- In case of any water leakage in the pump or pipe, immediately stop operating the unit. It may cause electric
shock, electricity leakage or defects. Be careful of electric shock.
• Always ground the chiller during installation.
- It may cause electric shock.
• Do not leave refrigerant system open to air any longer than necessary.
- If the repair cannot be completed, seal the circuits to prevent any contamination or rust within the product, and
charge dry nitrogen.
• Do not reuse compressor oil.
- It can damage the product.
• During installation, make the specified grounding before supplying the power, and during the dismantling, remove
the grounding line at the end of the task.
• Use appropriate meters for measurement. Otherwise, it may cause injury or electric shock.
• Check all power connected to the control panel or starter panel to be shut off while applying the power.
- It may cause electric shock.
• Make sure to discharge the electric current before inspection or repair work.
- It may cause injury or electric shock.
• Do not open the 2nd phase side of the current transformer when power is on.
- High voltage could be discharged causing an electric shock.
• Remove foreign objects(working tools, wires, bolts, washers) after installation, inspection, and repair work.
- They may cause injury, fire, or damage.
• When using a condenser, make sure to verify the complete discharge before applying the power again. (Re-powering 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.
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1-2. CAUTION
Operation & Maintenance
• Always check for gas(refrigerant) leakage after installation or repair of product.
- Low refrigerant levels may cause failure of product.
• Do not install the unit where combustible gas may leak.
- There is risk of fire or failure of product
• Keep level even when installing the product.
- Unleveled refrigerant can cause problems to the product.
• Do not use the product for special usage or location such as preserving animal/plant, precision machine, artifact,
etc.
- It may cause property damage.
• Use exclusive wire for the product. Use power cables of sufficient current carring capacity and rating.
- It may cause fire and electric shock.
• When installing the unit in a hospital, communication station, or similar place, provide sufficient protection against
noise.
- The inverter equipment, private power generator, high-frequency medical equipment, or radio communication
equipment may cause the chiller to operate erroneously, or fail to operate. On the other hand, the chiller may affect such equipment by creating noise that disturbs medical treatment or image broadcasting.
• To protect the product from corrosion, do not install the product where it is exposed to sea wind(salt spray) directly.
If necessary, please install shield.
- It may cause product deformation and defects.
• Make the connections securely so that the outside force of the cable may not be applied to the terminals.
- Inadequate connection and fastening may generate heat and cause fire. If the power cable got damaged, do not
directly replace it, but call the service center for replacement first.
• Do not use the product in special environments.
- Oil, steam and sulfuric steam can deteriorate the product performance or cause damage to the parts.
• Be careful when transporting the product.
- When carrying the chiller, always consult with the specialized expert.
• When transporting the chiller, always follow the methods described in the manual.
- If not, it can cause overturn, fall etc.
• Do not touch any of the refrigerant piping during and after operation.
- Pipe during and after the operation can be hot or cold depending on the condition of the refrigerant flowing
through the refrigerant pipe, compressor and refrigerant cycle parts.
Touching the pipes at this time can cause burns or frostbites.
• Turn on the main power 12 hours before starting to operate the product.
- If you operate the product immediately after turning on the main power, it can severely damage the internal parts.
Keep the main power on while operating.
• Do not immediately turn off the main power after the product stops operating.
- Wait at least 5 minutes before turning off the main power. Failure to do so can cause water leak or other issues.
• Do not operate the product with the panel or safety devices removed.
- Rotating parts or high temperature/pressure parts can cause safety accidents.
• Be careful when disposing the product.
- When disposing the chiller, request to the specialized expert.
• Use a firm stool or ladder when cleaning or maintaining the chiller.
- It may cause an injury.
• Be careful of high temperature.
- Be careful not to make body contact to the parts of the chiller in high temperature.
It may cause a burn.
• 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 and fire.
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• Be careful of chiller installation.
- Keep enough clearance around the product for service and especially for air cooling type, install the 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 product.
- When a safety device is triggered, remove the cause and then restart the product. Repeating the operation arbitrarily can cause fire and defect.
• Use appropriate tools.
- Use tools appropriate for the repair work and calibrate the measuring devices accurately before using. Using inappropriate tools can cause an accident.
• Be careful of sound and odor.
- If you hear a weird sound or smell an odor, immediately stop operating the system and contact the service center.
It may cause fire, explosion or injury.
• Be careful of injury.
- Check the safety label of the safety device. Follow the above precautions and the contents in the label. It may
cause fire and injury. To prevent the formation of the condensed water, the pipe connected to the evaporator as
well as the evaporator itself should be well insulated.
• Check.
- Perform periodic checks. If any problem occurs, stop the operation and contact the service center. Insufficient
check may cause fire, explosion or error.
• Do not attempt to bypass or alter any of the factory wiring.
- Any compressor operation in the reverse direction will result in a compressor failure that will require compressor
replacement.
• Do not use jumpers or other tools to short out components, or bypass the parts differently from recommended procedures.
- Short-circuiting the control board ground line with other wires can damage the electric module or electric components.
• Water must be within design flow limits, and should be treated cleanly.
- This make it possible to ensure proper machine performance and reduce the potential of tubing damage due to
corrosion, scaling, erosion and algae. LG Electronics is not responsible for any damage caused by cooling water
not treated or improperly treated.
• Consult a water treatment specialist for proper treatment procedures.
- Hard scale may require chemical treatment for its prevention or remove.
• Do not overcharge refrigerant to the system.
- Refrigerant overcharging results in higher discharge pressure with higher cooling fluid consumption. Also it can
damage the compressor and increase the power consumption. Also it can damage the compressor and increase
the power consumption.
• Do not add different type of oil.
- It may cause abnormal operation of chiller.
• Turn controller power off before service work.
- It secures safety and prevents damage to the controller.
• Maintain the compressor oil pressure to normal level.
- Use proper safety precautions whem relieving pressure.
• Welding the evaporator head or nozzle part is not recommended.
- If the part requires welding, remove the chilled water flow switch and entering/leaving fluid thermistors before
welding.
- After the welding is completed, reinstall the flow switch and thermistors.
- Failure to remove these devices may cause component damage.
• Do not open the circuit breaker arbitrarily during the operation.
- It may cause damage or malfunction.
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• Do not operate with wet hand.
- It may cause electric shock.
• During maintenance work, check whether all of the power lines connected to the control panel or starter panel are
interrupted.
- It may cause electric shock.
• When power is on, do not open the door of control panel or starter panel, and protective 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 manual should operate the control panel or starter panel.
- Otherwise, it may cause injury, fire, malfunction, or damage.
• Do not perform welding work near cables connected to the main unit.
- Otherwise, it may cause fire or damage.
• Connect only the input/output signal cables specified in the drawing to the control panel or starter panel.
- Otherwise, it may cause malfunction or damage.
• Use the rated electrical cables.
- If not, it may cause fire or damage.
• Use specified parts for repair.
- If not, it may cause fire or damage.
• Install the machine, control panel, and starter panel at a place where there is no combustible material.
- Otherwise, it may cause fire.
• Do not exceed the voltage supply limit described in the relevant manual.
- Otherwise, it may cause damage or malfunction.
• Connect the signal cables connected to the control devices following the circuit diagram.
- It may cause damage or malfunction.
• Do not store the product in a place where is a flooding risk or a lot of moisture.
- Otherwise, it may cause damage or malfunction.
• Do not use the indoor control panel or starter panel outside of the building.
- Otherwise, it may cause damage or malfunction.
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CONTENTS
3
3
6
1. CAUTIONS FOR SAFETY
_ WARNING/CAUTION
1-1. WARNING
1-2. CAUTION
10 2. INTRODUCTION
10
10
11
11
12
2-1. General Information
2-2. System structure
2-3. Nomenclature
2-4. Name plate
2-5. Main unit conversions
14 3. STRUCTURE OF TWO
STAGE CENTRIFUGAL
CHILLER
14
15
3-1. Cycle of the chiller
3-2. Main components of the two stage
centrifugal chiller
21 4. CONTROL SYSTEM
21
26
27
27
28
28
29
29
30
33
36
37
38
4-1. Components and Major Parts of the
Control Panel
4-2. Components and Major Parts of the
Starter Panel
4-3. Control Parts Attached on the Product
4-4. Basic Control Algorithm
4-5. BMS Support Function
4-6. Remote Control Signal and Status Signal Connection
4-7. Power Panel and Interface Signal
4-8. Central Monitoring Panel and Interface
Signal
4-9. Start and Control Order
4-10. Product Protection Function
4-11. Checklists before inspection
4-12. Checklists after inspection
4-13. General Checklist
39 5. HMI
39
43
50
52
54
80
90
90
91
5-1. Start HMI
5-2. Home Screen Composition
5-3. Schedule
5-4. History
5-5. Device Setting
5-6. Environment Settings
5-8. Data Storage
5-7. Screen Saver
5-9. Web Function
93 6. START-UP
93
95
102
105
106
6-1. Delivery and Installation Check
6-2. Preparation for start-up
6-3. Start-up
6-4. Startup procedure after long-period of
stoppage
6-5. System Shutdown
107 7. MAINTENANCE
107
111
117
118
119
120
121
123
7-1. Maintenance criteria
7-2. Periodic maintenance
7-3. Maintenance during off-season
7-4. Annual maintenance(1/2)
7-4. Table for Annual maintenance(2/2)
7-4. Table for Annual maintenance
7-5. Oil maintenance
7-6. General Maintenance
126 8. TROUBLESHOOTING
126
8-1. Causes and actions for alarms
139 9. Operation inspection
record
139
9-1. Check list for operation record
ENGLISH
Thank you for using the Water-Cooled Turbo Chiller.
You may use the product more conveniently and safely by installing the product following the standard after reading
the instruction manual.
• Make sure to read the instruction manual to install the Turbo Chiller safely and correctly before use.
• Make sure to conduct a test run and an inspection following instructions after completing installation.
h The instruction manual consists of instructional information about the product, controls, test runs, maintenance
and problem-solving relating the Chiller.
10
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2. INTRODUCTION
2-1. General Information
This manual describes the installation of water cooled screw type two stage centrifugal chiller using R-134a refrigerant and X30 controller applied.
2-2. System structure
Fig. 1 shows the general structure and parts composition of two stage centrifugal chiller.
The location of control panel, the shape of waterbox, direction of inlet and outlet of the chilled water and cooling
water, and some of the pipes may vary by model or customer’s specifications. Thus, please refer to the approved
drawings for the details.
Front view
2
1
3
4
5
6
7
8
10
1. Terminal box for compressor motor
2. Actuator (Variable diffuser)
3. Actuator (Vane motor)
4. Oil separator
5. Relief valve for Evaporator
6. Relief valve for Condenser
7. Air Vent for Cooling water
8. Oil cooler
9. Drain for Chilled water
10. Drain for Cooling water
9
Rear view
12
11
13
18
15
19
14
16
17
Fig 1. Main components of two-stage centrifugal chiller
11. Control panel
12. Economizer sight glass
13. Hot gas bypass
14. Condenser level sensor
15. Economizer level sensor
16. Air Vent for Cooling water
17. Drain for cooling water
18. Air Vent for Chilled water
19. Drain for Chilled water
11
The nomenclature for the Fig. 2 centrifugal chiller is as follows.
R : R134a
W : Water-Cooled
Cooling Only
K : Water-Cooled
Heating Pump
Compressor Code
Condensor
Code
R C W F H D 3 E A D E
Code for Certification & Safety
H : STANDARD
A : ASME VIII
U : UL
C : CE(PED)
C : CHILLER
F : Centrifugal
Compressor
Evaporator
Code
Fig 2. Nomenclature
Combination Table
Capacity
Comp.
code
Evap.
code
Cond.
code
Power
ConMotor sumption
Shipping
weight
Operation
Weight
Refrigerant
weight
kW
kg
kg
kg
RT
kW
200 ~ 400
700 ~ 1406
A
AA~CC
AA~CC
4
~280
7,000 ~ 8,300
8,350 ~ 9,450
450 ~ 650
350 ~ 570
1230 ~ 2005
B
AA~CC
AA~CC
4
~350
7,900 ~ 9,500
8,85 ~ 11,100
550 ~ 750
480 ~ 785
1690 ~ 2760
C
BA~DC
BA~DC
5
~500
8,600 ~ 12,000
9,850 ~ 14,100
650 ~ 900
715 ~ 1114
2515 ~ 3920
D
CA~EC
CA~EC
5~6
~700
11,000 ~ 15,000 12,800 ~ 17,900 750 ~ 1050
940 ~ 1635
3300 ~ 5750
E
DA~GC
DA~GC
6~7
~1000
12,500 ~ 26,200 14,850 ~ 30,600 900 ~ 1650
1320 ~ 2200
4640 ~ 7740
F
DF~GG
DF~GG
7
~1350
19,000 ~ 33,000 22,450 ~ 38,900 1050 ~ 2000
2050 ~ 3000 7200 ~ 10548
G
GA~FC
GA~FC
7
~2100
30,000 ~ 38,500 35,000 ~ 45,000 2300 ~ 2500
2-4. Name plate
Name plate for the unit is attached on the right side of the control panel. General information of the product can be
achieved from the plate, and the information can be used for quicker service later.
‫ڸ‬
‫ڹ‬
‫ں‬
‫ڻ‬
‫ڼ‬
‫ڽ‬
‫ھ‬
‫ڿ‬
‫ۀ‬
‫ہ‬
‫ۂ‬
‫ۃ‬
‫ۄ‬
‫ۅ‬
① Model name
② Refrigerant
③ Cooling capacity
④ Power and current required for motor
⑤ Manufacture's serial number
⑥ Internal pressure test pressure
⑦ Maximum working pressure (Design pressure)
⑧ Volume of Evaporator
⑨ Volume of Condenser
⑩ Power electricity
⑪ Control electricity
⑫ Temperatures of Chilled water inlet/outlet
⑬ Temperatures of Cooling water inlet/outlet
⑭ Maximum pressure of chilled water and cooling water
Fig. 3. Name plate
ENGLISH
2-3. Nomenclature
12
ENGLISH
2-5. Main unit conversions
Temperature conversion table (°F ↔ °C)
• °F = (9/5 x °C) + 32
• °C = 5/9 x (°F - 32)
°F
°C
°F
°C
°F
°C
°F
°C
°F
°C
1
-17.2
31
-0.6
61
16.1
91
32.8
121
49.4
2
-16.7
32
0
62
16.7
92
33.3
122
50.0
3
-16.1
33
0.6
63
17.2
93
33.9
123
50.6
4
-15.6
34
1.1
64
17.8
94
34.4
124
51.1
5
-15.0
35
1.7
65
18.3
95
35.0
125
51.7
6
-14.4
36
2.2
66
18.9
96
35.6
126
52.2
7
-13.9
37
2.8
67
19.4
97
36.1
127
52.8
8
-13.3
38
3.3
68
20.0
98
36.7
128
53.3
9
-12.8
39
3.9
69
20.6
99
37.2
129
53.9
10
-12.2
40
4.4
70
21.1
100
37.9
130
54.4
11
-11.7
41
5.0
71
21.7
101
38.3
131
55.0
12
-11.1
42
5.6
72
22.2
102
38.9
132
55.6
13
-10.6
43
6.1
73
22.8
103
39.4
133
56.1
14
-10.0
44
6.7
74
23.3
104
40.0
134
56.7
15
-9.4
45
7.2
75
23.9
105
40.6
135
57.2
16
-8.9
46
7.8
76
24.4
106
41.1
136
57.8
17
-8.3
47
8.3
77
25.0
107
41.7
137
58.3
18
-7.8
48
8.9
78
25.6
108
42.2
138
58.9
19
-7.2
49
9.4
79
26.1
109
42.8
139
59.4
20
-6.7
50
10.0
80
26.7
110
43.3
140
60.0
21
-6.1
51
10.6
81
27.2
111
43.9
141
60.6
22
-5.6
52
11.1
82
27.8
112
44.4
142
61.1
23
-5.0
53
11.7
83
28.3
113
45.0
143
61.7
24
-4.4
54
12.2
84
28.9
114
45.6
144
62.2
25
-3.9
55
12.8
85
29.4
115
46.1
145
62.8
26
-3.3
56
13.3
86
30.0
116
46.7
146
63.3
27
-2.8
57
13.9
87
30.6
117
47.2
147
63.9
28
-2.2
58
14.4
88
31.1
118
47.8
148
64.4
29
-1.7
59
15.0
89
31.7
119
48.3
149
65.0
30
-1.1
60
15.6
90
32.2
120
48.9
150
65.6
Table 1. Temperature conversion table
13
ENGLISH
Pressure conversion table (lb/in2 ↔ kg/cm2)
• lb/in2 = psi
ex) 1 lb/in2 = 0.07030696 kg/cm2
lb/in2
kg/cm2
lb/in2
kg/cm2
lb/in2
kg/cm2
lb/in2
kg/cm2
lb/in2
kg/cm2
1
0.070
41
2.883
81
5.695
121
8.507
161
11.32
2
0.141
42
2.953
82
5.765
122
8.577
162
11.39
83
5.836
123
8.648
163
11.46
3
0.211
43
3.023
4
0.281
44
3.094
84
5.906
124
8.718
164
11.53
5
0.352
45
3.164
85
5.976
125
8.788
165
11.60
6
0.422
46
3.234
86
6.046
126
8.859
166
11.67
7
0.492
47
3.304
87
6.117
127
8.929
167
11.74
8
0.563
48
3.375
88
6.187
128
8.999
168
11.81
89
6.257
129
9.070
169
11.88
9
0.633
49
3.445
10
0.703
50
3.515
90
6.328
130
9.140
170
11.95
11
0.773
51
3.586
91
6.398
131
9.210
171
12.02
12
0.844
52
3.646
92
6.468
132
9.281
172
12.09
13
0.914
53
3.726
93
6.539
133
9.351
173
12.16
14
0.984
54
3.797
94
6.609
134
9.421
174
12.23
95
6.679
135
9.491
175
12.30
15
1.055
55
3.867
16
1.125
56
3.987
96
6.750
136
9.562
176
12.37
17
1.195
57
4.008
97
6.820
137
9.632
177
12.44
18
1.266
58
4.078
98
6.890
138
9.702
178
12.51
19
1.336
59
4.148
99
6.968
139
9.773
179
12.58
20
1.406
60
4.218
100
7.031
140
9.843
180
12.66
101
7.101
141
9.913
181
12.73
21
1.477
61
4.289
22
1.547
62
4.359
102
7.171
142
9.984
182
12.80
23
1.617
63
4.429
103
7.242
143
10.05
183
12.87
24
1.687
64
4.500
104
7.312
144
10.12
184
12.94
25
1.758
65
4.570
105
7.382
145
10.19
185
13.01
26
1.828
66
4.640
106
7.453
146
10.26
186
13.08
107
7.523
147
10.34
187
13.15
27
1.898
67
4.711
28
1.969
68
4.781
108
7.593
148
10.41
188
13.22
29
2.039
69
4.851
109
7.663
149
10.48
189
13.29
30
2.109
70
4.921
110
7.734
150
10.55
190
13.36
31
2.180
71
4.992
111
7.804
151
10.62
191
13.43
32
2.250
72
5.062
112
7.874
152
10.69
192
13.50
113
7.945
153
10.76
193
13.57
33
2.320
73
5.132
34
2.390
74
5.203
114
8.015
154
10.83
194
13.64
35
2.461
75
5.273
115
8.085
155
10.90
195
13.71
36
2.531
76
5.343
116
8.156
156
10.97
196
13.78
37
2.601
77
5.414
117
8.226
157
11.04
197
13.85
38
2.672
78
5.484
118
8.296
158
11.11
198
13.92
119
8.367
159
11.18
199
13.99
120
8.437
160
11.25
200
14.06
39
40
2.742
2.812
79
80
5.554
5.625
Table 2. Pressure conversion table
14
ENGLISH
3. STRUCTURE OF TWO STAGE CENTRIFUGAL
CHILLER
3-1. Cycle of the chiller
The two Stage Centrifugal chiller uses environment friendly high pressure refrigerant R-134a.
- In this cycle, as shown in the following figure, the vaporized low temperature and low pressure refrigerant gas
passes the Inlet Guide Vane, and enters the 1st impeller of the compressor.
Since the inlet gas amount is dependent on the guide vane’s opening, the chiller capacity can be controlled.
- Refrigerant gas that entered the 1st impeller is compressed to a mid-temperature and mid pressure, passes
through the return channel, cooled by low temperature gas from the economizer, and then enters the 2nd impeller.
- The refrigerant gas entered the 2nd impeller is compressed as high-temperature and high-pressured refrigerant
gas, and discharged to the condenser. The gas loses its heat via cooling water in the heat transfer tubes and eventually condensed to liquid.
- The condensed refrigerant liquid passed the 1st orifice, becomes mixed state and enters the lower part of the
economizer which divides into gas and liquid of refrigerant. The gas part is mixed with the mid temperature and
mid pressured gas which was compressed in the 1st impeller, and then enters the 2nd impeller. The liquid part of
the refrigerant enters the lower part of evaporator via 2nd orifice.
- The liquid refrigerant entered into the evaporator, is then spread into wider surface of evaporator by distributor. Finally the distributed refrigerant evaporates by taking the heat from the chilled water inside the evaporator tubes
and repeats the cycle.
- Some part of the over-cooled refrigerant liquid in the condenser, flows through the valve, filter, moisture indicator,
and enters into the motor and oil cooling system individually.
- The refrigerant liquid flew into the motor is being sprayed so that it can cool the motor's coil and is returned to the
evaporator.
- The refrigerant flew into the oil cooling system, flows through the disc-shaped oil cooler. Refrigerant that left the
oil cooler is then returned to evaporator.
2nd Compressor
2nd Impeller
1st Impeller
I.G.V
Condenser
Cooling water outlet
Chilled water inlet
Chilled water outlet
Cooling water inlet
Evaporator
1st orifice
2nd orifice
Refrigerant liquid
Refrigerant gas
Fig 4. Two stage centrifugal chiller
15
Compressor
1) Hermetic Motor with Refrigerant Cooling Method
2) Open type Impeller
3) Diffuser
4) High speed gear device (Helical gear type)
5) Thrust Bearing
Fig 5. Hermetic two-stage high-speed compressor
*Two-stage centrifugal chiller compressor is composed of impeller, bearing, diffuser, capacity control device and
high-speed gear. The low temperature and low pressured gas taken from the evaporator, goes through impeller, diffuser and finally discharged to condenser as high temperature high pressure gas.
The characteristics of the compressor main components are as follows.
1. Impeller
• The vane of impeller designed aerodynamically based on the 3D fluid analysis, guarantees the reliability in any operational condition.
• To minimize vibration, the impeller took dynamic balancing work. It also guarantees the overall reliability of the
impellers by taking the strength test, hardness test, non-destructive test, etc. for every impellers produced.
2. Bearing
1) Compressor type : A0 ~ E3
1.1) Ball bearing is composed of isolated bearing on motor axis and angular contact bearings on the impeller
axis.
1.2) Ball bearing structure is subjected to a radial and axial load at the same time.
1.3) Because oil supply flow in ball bearing structure is small, the rotation system is more compact design.
2) Compressor type : F1 ~ G3
2.1) Bearing is composed of bearing in motor axis, radial bearings and thrust bearings on the impeller axis.
2.2) Bearing are made out of white metal to achieve persistence and corrosion resistance. By designing to lubricate to radial bearing and thrust bearing it can avoid the metal to metal contact during the operation.
2.3) To increase the reliability of the journal bearings, Offset type and 3-Lobe type bearings are applied.
3. Capacity control device
• It adjusts the refrigerant amount taken through the compressor inlet to adjust the capacity of the chiller, and it adjusts the opening of the vanes using the external actuator. The amount of refrigerant taken in is adjusted according to the set of chilled water outlet temperature.
ENGLISH
3-2. Main components of the two stage centrifugal chiller
16
ENGLISH
Heat exchanger
Heat exchanger of two-stage centrifugal chiller is composed of two shell type for easy separation into evaporator and
condenser. The tubes are arranged so as to maximize the heat exchanging ability. It is also designed so that the refrigerant can be spread evenly on all tubes for the sake of surge prevention and the COP decrease in part load operation. Efficiency increasing purpose sub cooler is adopted for the subcool of the condensed refrigerant.
A relief valve for an abnormal situation is at the upper part of the heat exchanger.
Body
Body
Refrigerant outlet
Refrigerant inlet
Relief valve
Relief valve
Waterbox
Waterbox
Refrigerant
distributor
Baffle
Accumulator
Refrigerant outlet
Tubes
Figure 6. Evaporator
Tubes
Figure 7. Condenser
Expansion device and economizer
Expansion device is composed of butterfly valve and fixed orifice. At 100% load, the pressure loss of orifice is lower
than the level of refrigerant in condenser. Thus the subcooled refrigerant passes through the orifice while the maximum refrigerant flows through the evaporator. If the load decreases gradually, the circulation of the refrigerant also
decreases resulting in decreasing of refrigerant level in the condenser. If the refrigerant liquid level decreases, more
gas generated in the orifice and the resistance increased, which becomes to control the flow rate.
The condensed refrigerant liquid passed the 1st orifice
enters the economizer which divides into refrigerant gas
and liquid. The refrigerant gas is mixed with mid-temperature, mid-pressure gas compressed in the 1st impeller.
The refrigerant liquid goes through 2nd orifice to be
taken into evaporator. The mid-temperature and midpressured gas between the 1st and the 2nd impeller become cool by mixing with the cool refrigerant gas
supplied from economizer before sucked in to the 2nd
impeller.
Figure 8. Economizer
As such, when the 2nd impeller discharge gas temperature is decreased by decreasing 1st impeller discharge
gas, the power required by the compressor is decreased
-increasing the cycle efficiency. The efficiency increase
much higher than by the 1 Stage compressing method.
17
ENGLISH
Lubrication system
Bearing
Oil inlet
Oil tank
Oil outlet
Oil outlet
Oil cooler
sight glass
Oil filter
Oil inlet
Figure 9. Lubrication cycle
Introduction
The discharged lubricating oil by the oil pump enters the oil filter to get rid of any unnecessary foreign substance.
This oil becomes cooled to the temperature appropriate for operation condition after through the oil cooler, part of it
directly enters gear and high speed side bearings, and the remainder directly enters motor shaft bearings. After the
process, it will be drained into the oil tank. The above figure shows the lubrication system of two-stage compression
type.
Lubrication cycle
Lubricating oil is forwarded through the manual oil charge valve to the Lubrication System.
Oil level can be detected through a sight glass on the oil tank. During the operation, the level should be able to be detected at least from one of them.
The temperature of the oil tank is indicated on the control panel and its temperature range is 30~65 °C while operating. What the oil pump does is to transfer the oil from the oil tank to the system and the adequate pressure different
would be above 1.0 kg/cm2 that is maintained by the oil pressure controller. The differential pressure can be seen on
the control panel pressure gauge display by the differential pressure between oil tank and oil pump.
The oil pump also helps to send the oil to the oil filter. A valve is installed at the oil filter so that no need to drain the
whole oil when replacing the filter only.
After the oil is sent to the oil cooler it is cooled by the refrigerant flowing from the condenser. The refrigerant cools
the oil at the temperature between 40~60 °C.
A part of the oil flows through the thrust bearing and gear spray, whereas the rest lubricates the motor shaft bearings
and the radial bearings. The oil temperature in the oil tank is measured by temperature sensor and displayed.
The timer automatically activates the oil pump for 120~180 seconds to maintain a constant pressure first before
starting compressor. After the system has been shut down, 300~600 seconds lubricating is taken place after the
compressor is stopped.
18
ENGLISH
Oil reclaim system
Oil reclaim system provides the system to reclaim the oil from the heat exchanger and let it come back to the oil
tank. Normally, it is reclaimed at the evaporator, and the vane housing. Refrigerant which came back into the oil tank
will then be evaporated to the gas and flow through the Oil Seperator line which is located at the upper part of the
casing, and then it will be sent to the inlet of the compressor. Oil that is contained in the refrigerant is separated by
the demister filter.
MAINTENANCE
Most of the lubrication related deficiencies in rotating parts of the chiller are because of the oil itself. If adequate viscosity, pressure and flow are not obtained, lubricating performance will decrease. Impure substances that are present in the oil also are a cause for the deficiencies.
Freon type refrigerant have chemical attraction with the oil. The viscosity changes according to the temperature and
pressure of oil. We have designed the chiller with these problems into consideration.
An oil pump run by hermetic electro motor and a heater controlled by the controlling device are installed in the oil
tank to prevent the trouble caused by the refrigerant inflow into the oil, decrease of the viscosity, damage of the
pump caused by the cavitation (vaporizing of water and formation of bubbles as becoming partially low pressurized
when water or flow at high speed) and the oil inflow into the refrigerant by forming. For these reasons the oil tank is
maintained at a high temperature.
The reason to start the oil pump for certain while before the startup of the chiller, is to prevent the compressor's initial unsteady operation because the left over oil in bearings or in the oil line may contain significant amount of refrigerant flow in during the stoppage.
After the chiller has been shut down, oil pump will be operated until the compressor is totally stopped since the compressor rotates due to the internal force.
The only action that can be taken to prevent lubrication inferiority caused by blazing of the oil is replacing the oil itself.
Thus when it is time for cooling operation, make sure that you do the oil replacing adequately.
19
For the sake of safe operation and the protection of the chiller, safety devices are ready as the next table.
No. Safety Devices
1
Chilled Water
Temperature
Low
2
Evaporator
Pressure Low
(Temperature
Low)
3
Condenser
Pressure High
(Temperature
High)
Installation
Location
Measurement Item
Description
Quantity
Chilled water
inlet nozzle
Chilled water inlet
temperature
Chiller stops operation if the chilled water outlet
temperature below 3°C to prevent freezing of the
chilled water. Do not change this set value.
1
Evaporator
shell
Vaporizing pressure
(temp.)
If the pressure inside of evaporator reaches
below of the following table, then the chiller
stops operation. (Based on the design temperature 43 ? )
Standard setting value
Condenser
shell
Condensing pressure
(temperature)
1.95kg/cm2
If the pressure inside of condenser reaches above
of the following table, then the chiller stops operation.(Based on the design temperature 43 ? )
Standard setting value
1
1
10.00kg/cm2
Motor coil
Motor coil temperature
To prevent the motor of the compressor, temperature sensors were installed on each phase of
coil and when the temperature exceeds 90°C,
the chiller stops operation.
3
Compressor
outlet
Compressor discharge temperature
If the discharging gas temperature of the compressor exceeds over 70°C, the chiller stops operation.
1
4
Motor Temperature High
5
Compressor
Temperature
High
6
Temperature sensor is installed on the thrust
Bearing Tembearing that holds the impeller's thrust. Chiller
Thrust bearing Bearing temperature
perature High
will stop operation if the temperature exceeds
85°C.
7
Oil Differential
Pressure Low
8
Oil Temperature High
Oil tank
Oil temperature inside of oil tank
The chiller will stop if the oil temperature in the
oil tank is above 74°C.
1
9
Oil Temperature Low
Oil tank
Oil temperature inside of oil tank
The temperature should be over 30°C as an initial
operating condition to enable the chiller to operate.
1
10
Chilled Water
Pump Abnormal
Chilled water
header
Chilled water head
loss
The chiller will stop if the head loss of the chilled
water flow passing through the evaporator tubes
decreases so much that the loss head becomes
lower than the standard.
1
11
Cooling Water
Cooling water
Pump Abnorheader
mal
Cooling water head
loss
The chiller will stop if the head loss of the cooling
water flow passing through the condenser tubes
decreases so much that the loss head becomes
lower than the standard.
1
12
Current Limiting Function
It is a controlling function of Motor Amps that can
be set freely in the range of 40 ~ 100% to adjust
the current load to the motor of compressor.
1
13
Moisture Indicator
If the differential pressure between the oil presDifferential pressure
sure supplied to the bearing and the oil pressure
Oil tank, oil
of supplied and intake
in the oil tank is below 0.8kg/cm2 , the chiller will
pump outlet
oil pressure
stop the operation.
Control panel
Refrigerant
supply pipe
Current
The moisture indicator changes the color depending
on the amount of moisture in the refrigerant. When
Moisture in the refrigthere is no moisture it will be green, but if not it will
erant
be yellow. It is the time to change into a new filter
if you can see the yellow color.
1
1
1
ENGLISH
Safety devices
20
ENGLISH
No.
14
Item
Relief Valve
Vane Full Close
15
Interlock
Installation
Location
Evaporator &
condenser
shell
Vane motor
Measurement Item
Description
Quantity
Relief valves
To prevent the accident by unexpected fire, and
so on which can cause pressure increase in the
chiller, the relief valve will be operated and exhaust the refrigerant into the air if the pressure
exceeds more than the standard.
If the chiller is used in a closed environment,
please install a pipe that starts from the relief
valve to the outer air.
1
To minimize the starting current, it is a function
Operability of temper- to enable the compressor to operate only after
full close of the guide vane installed at the inlet
ature sensors
of the impeller.
1
16
Temperature 6 locations inSensor Abnor- cluding chilled
mal
water nozzle
17
4 locations inIt alarms when pressure sensor is not connected
Pressure Sencluding Evapo- Each pressure sensor
or due to the sensor’s own flaw.
sor Abnormal
rator shell
18
Overload relay Control panel
19
Hot Gas Bypass Valve
Evaporator
shell, Condenser shell
Each temperature
sensor
Current
It alarms when temperature sensor is not connected or due to the sensor’s own flaw.
If overload is imposed on compressor motor or
oil pump motor, it stops the motor.
It prevents frequent start ups at low load, and
hot gas bypass valve opens proportionally when
vane becomes 30% or lower.
Guide vane / hot gas
At this time, hot refrigerant gas of condenser
valve opening
goes to evaporator and makes certain chiller load
to prevent surge and to prevent frequent startup
stop of the chiller.
Table 3. Safety devices
1
1
1
1
21
4-1. Components and Major Parts of the Control Panel
HMI
FRONT
BACK
BOTTOM
Figure 10. HMI Components
No.
Item
①
Touch screen
②
Description
• 10.2 inch LCD control panel
• AC Smart Premium control and display various information
SD memory slot (for services) SD card memory slot for S/W upgrades
③
DO port
2CH DO port
④
DI port
2CH DI port
⑤
485 port
⑥
DC 12V input port
⑦
LAN port
⑧
AC 24V input port
⑨
Micro USB port
⑩
Mini USB port (for services)
⑪
Power ON/OFF
2CH 485 port
DC 12V power input port
LAN Cable connection port for Ethernet connection
(Support 100Mbps/10Mbps)
AC 24V power input port
Support port USB 2.0 for USB memory Stick connection
PC connection power for S/W upgrades
• Control AC Smart Premium LCD backlight for pressing less than 10 seconds
• Reset AC Smart Premium system for pressing more than 10 seconds
• LCD for not using AC Smart Premium for a long period
• It is recommended to turn off when AC Smart Premium is not used for a
long time so that the lifespan of LCD backlight could be extended.
Table 4. HMI Component Names and Functions
ENGLISH
4. CONTROL SYSTEM
22
ENGLISH
MASTER/SLAVE
The Master board and Slave board has the same hardware. They are used as Master or Slave by DIP switch settings.
(SW4 OFF : Master, ON : Slave)
Analog input/output and digital input/output consist of RS232 and RS485 communication connectors for the user’s
convenience.
Figure 11. Master/Slave Board Internal Diagram
23
The Master, Slave, HMI and Relay boards communicate in the RS485 communication method, and one Master/Slave
board consists of the analog input (12 channels for temperature, 10 channels for current), analog output (4 channels
for current), digital input (20 channels) and digital output (16 channels).
The Relay board is responsible for controlling the guide vane and diffuser vain.
PT100
INPUT
UART
(DISPLAY)
RS485
MICOM
UART
(BMS)
UART
(Slave)
4-20mA
INPUT
4-20mA
OUTPUT
DIGITAL
INPUT
DIGITAL
OUTPUT
MASTER: TEMPERATURE, PRESSURE
DIGITAL INPUT/OUTPUT CONTROL
HMI: SCREEN DISPLAY AND
COMMUNICATION
RS485
5
48
RS
PT100
INPUT
UART
(DISPLAY)
DC 0~5V
INPUT
DIGITAL
OUTPUT
MICOM
UART
(Master)
RELAY: GUIDE/DIFFUSER VANE CONTROL
MICOM
4-20mA
INPUT
UART
(BMS)
4-20mA
OUTPUT
UART
(Slave)
DIGITAL
INPUT
DIGITAL
OUTPUT
SLAVE: TEMPERATURE, PRESSURE
DIGITAL INPUT/OUTPUT CONTROL
Figure 12. Controller Block Diagram
ENGLISH
Control System Block Diagram
24
ENGLISH
Other control parts
TRANSFORMER
NOIS
FILTER
FUSE
MASTER /
SLAVE BOARD
Fan
BREAKER
RELAY BOARD
RELAY
MAGNETIC
CONTACTOR
SUMMER
RELAY
BUZZER
TERMINAL
BLOCK
Fig 13 Control system.
Figure 13. Control System
h Please refer to the approved diagram for details as the arrangement shown above may vary by model and change
for design improvements and the user’s convenience.
25
BACnet Converter
Our controller basically supports Modbus communication protocol.
If the higher communication protocol is BACnet, the protocol should be converted by applying a separate BACnet.
A communication converter can only be attached inside the control board.
Refer to the table shown below for meanings and explanations for each lamp.
Figure 14. Converter
LED name
State
TX485
RX485
Flicker
TX232
RX232
Flicker
Explanation
Communication with the MYCOM works normally
Off
Error, check communication lines
Communication with BACnet works normally
Off
Error, check communication lines
Flicker every second
Board works normally after completing a Power-On test
Maintain On/Off status
Error. Press reset button, or cut and resupply the power
RUN
ETX
ERX
ELK
Ethernet Line status LED
ELK is always on when LAN cables are connected, ERX is on when
receiving data and ETX flickers when transmitting data
Table 5. LED Status Display
ENGLISH
Option Parts Related to Control
26
ENGLISH
4-2. Components and Major Parts of the Starter Panel
Starter
Starter is an electric panel to protect and to start the motor of the Turbo Chiller compressor and has protection function from the short-circuit current and overcurrent.
This has the effect of reducing electric capacity of services by lowering the starting current when operating the
motor.
Refer to the drawing supplied with the product for an arrangement of the starter, as the starter is arranged in various
ways based on starting methods, high/low pressure power, options, etc.
FDS POWER FUSE BREAKER
PT
(TRANSFORMER FOR GAUGES)
SERIES REACTOR (OPTION)
PHASE ADVANCE CAPACITOR
(OPTION)
VACUUM CONTACTOR
REACTOR (STARTER)
MOMENTARY POWER FAILURE
COMPENSATION DEVICE (OPTION)
MOTOR PROTECTION RELAY
Figure 15. 6600V Reactor Starter Method
h Please refer to the approved diagram for details as the arrangement shown above may vary by model and change
for design improvements and the user’s convenience.
27
ENGLISH
4-3. Control Parts Attached on the Product
Slave board
Transformer
Fuse
Relay
board
Magnetic contactor
& Thermal relay
Breaker
Display board
Terminal block
Master board
Figure 16. Control Board
4-4. Basic Control Algorithm
The algorithm managed to implement the best control by minimizing Under-shoot and Over-shoot when automatically/manually converting time to approach a goal, steady status error, initial operation and vane adjustment compared to the previous method by applying unique P (proportion), I (integration) and D (differentiation) algorithms to the
cold water temperature control.
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cŽ”’Œ
aŒ‡’‰”ˆ
g…Ž…’Œ
cŽ”’Œ
aŒ‡’‰”ˆ
o–…’M“ˆ”
uŽ„…’M“ˆ”
Figure 17. P.I.D Operating Control
• Soft loading
- Approach a control goal by soft operation
- Resolved unnecessary emergency stop due to rapid guide vane opening which occur in operating
• Advanced control
- High precision control is realized by applying the far advance algorithm compared with existing PID control methods.
- Prevent temperature Cycling phenomenon due to Over-shoot/Under-shoot when converting from manual to automatic mode.
- Intensive Safety Control
Minimized unnecessary stops for abnormality of the Chiller by implementing preventive control before the Chiller
starts to stop for abnormality
28
ENGLISH
4-5. BMS Support Function
The basic communication of the Turbo Chiller is Modbus protocol, and it is compatible with higher communication
methods.
Communication Protocol Support
• Communication method
- Standard: RS-485, Ethernet (option)
• Protocol
- Standard: MODBUS
- Option: BACnet, TCP/IP
rsMTXU
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tcpOip
s…’‰Œ@”@lan
cŽ–…’”…’
rsMRSRƒ@”@rsMTXU
cŽ–…’”…’
Protocol
p’”ƒŒ@cŽ–…’”…’
1 SET OF THE CONVERTER CAN BE
cŽ–…’”…’@Q“…”‫@م‬XʅŮ‫ِ@ݖ‬ă@Ãɣ
CONNECTED UP TO 8 UNITS
Figure 18. BMS Detail Drawing
4-6. Remote Control Signal and Status Signal Connection
How to connect remote start/stop signals
Two wire consecutive signals for a point of contact of zero voltage
CHILLER
CONTROL BOARD
CUSTOMER
CONTROL BOARD
101
OPERATION
DIC1
ON
OPERATION SIGNAL
CHILLER STATUS
OFF
START
/STOP
Figure 19. Control Signal
h Minimum time to maintain start/stop pulse: maintain for at least 2 seconds.
29
Signal name
Cold water pump interlock
Coolant pump interlock
Cold water pump start/stop
Coolant pump start/stop
Cooling tower fan start/stop
Signal type
Signal meaning
Notes
Input
(contact of zero voltage)
The interlock checks the operation of the electric contactor for pump operation.
If there is no signal when
operating, the Chiller does
not start.
No input even when operating may cause abnormalities.
Detect status of a contact
by outputting DC24V.
Make sure to avoid resistance of contact above
100Ω.
(Conduit process should not
be carried out with other
power lines.)
Output
(contact of zero voltage)
This is the start/stop signal
of the pump or fan.
Access when operating by
linking with start/stop signals from the Chiller.
Use it at AC250V 0.1A (resistance load)
4-8. Central Monitoring Panel and Interface Signal
Signal name
Signal type
Signal meaning
Check motor operation
Contact for signal
Output
(contact of zero voltage)
ON when inputting operational signal
OFF when inputting stop
signal
Contact for
start/stop display
Output
(contact of zero voltage)
ON when operating the
Chiller
OFF when stop operating
the Chiller
Contact for
abnormality display
Output
(contact of zero voltage)
ON when the Chiller has a
defect
For remote
operation display
Output
(contact of zero voltage)
ON when remote operation
mode is selected
Contact for
warning display
Output
(contact of zero voltage)
ON when alarm is activated
Notes
Use it at AC250V 0.1A (resistance load)
ENGLISH
4-7. Power Panel and Interface Signal
30
ENGLISH
4-9. Start and Control Order
Turbo Chiller Signal Flow Graph
Figure 20. Turbo Chiller Signal Flow Graph
31
ENGLISH
Turbo Timing Sequence - Run
Start button
Start lamp
Check cold water pump interlock alarm
Cold water pump
start/stop
Check cold water pump interlock abnormality
Check cold water flow alarm
Check cold water flow abnormality
Cold water pump
interlock
Cold water differential
pressure switch
Check coolant pump interlock alarm
Coolant pump start/stop
Check coolant flow alarm
Check coolant pump interlock abnormality
Check coolant flow abnormality
Coolant pump interlock
Coolant differential
pressure switch
Check oil differential pressure abnormality
Check vane closed switch alarm
Check operation - oil temperature low alarm
Oil pump start/stop
Display soft operation and
safety control message
convert
Compressor start/stop
Check operation complete signal (2M) abnormality
Operation complete
signal (2M)
Stop
Stop
Message
1.5 sec
coolant
pump
operation
timer
oil
pressure
check
timer
operation
5 sec
10 sec
oil pump
circulation
timer
Compressor
Start
Check
timer
180 sec
20 sec
Vane
Reoperaopening tion block
delay timer
timer
60 sec
Operation
1800 sec
Signal ON/OFF
time
32
ENGLISH
Turbo Timing Sequence - Stop
Stop button
Stop lamp
Cold water pump
start/stop
Cold water pump
interlock
Cold water differential
pressure switch
Coolant pump start/stop
Coolant pump interlock
Coolant differential
pressure switch
Oil pump start/stop
Based on the one that operates first among vane closed switches,
soft stop settings or vane closed timer
Compressor start/stop
Operation complete
signal (2M)
RUN
RUN
Message
Vane closed Coolant pump
timer when
stop timer
stopping
1.5 sec 120 sec
30 sec
Cold water
stop and stop
oil circulation
timer
STOP
300 sec
Signal ON/OFF
time
Figure 21. Timing Sequence
33
Category
Sensor
Description
Sensor abnormality such as temDetected temperature, pressure
perature, pressure and current, etc. and current sensor abnormality
Temperature
&
Pressure
Voltage
Status
Abnormal
Detected pump interlock abnormal- The Chiller
ity when operating
stops
Abnormal
Coolant pump interlock abnormality Detected pump interlock abnormal- The Chiller
ity when operating
stops
Abnormal
Low cold water flow abnormality
Detected flow interlock abnormality The Chiller
when operating
stops
Abnormal
Low cold coolant flow abnormality
Detected flow interlock abnormality The Chiller
when operating
stops
Abnormal
High oil temperature abnormality
control
Detected high oil temperature
The Chiller
stops
Abnormal
High condenser pressure abnormal- Detected high condenser pressure The Chiller
ity
stops
Abnormal
Low evaporator pressure abnormal- Detected low evaporator pressure
ity
The Chiller
stops
Abnormal
Evaporator refrigerant block abnormality
Detected low evaporator refrigerant The Chiller
temperature
stops
Abnormal
high Compressor outlet temperature abnormality
Detected high condenser outlet
temperature
The Chiller
stops
Abnormal
high Motor winding temperature
abnormality
Detected high motor winding temperature
The Chiller
stops
Abnormal
high Bearing temperature abnormality
Detected high bearing temperature The Chiller
stops
Abnormal
low Cold water temperature abnor- Detected low cold water outlet
mality
temperature
Surging
Action
The Chiller
stops
Cold water pump interlock abnormality
Interlock
Cause
The Chiller
stops
Abnormal
Compressor surge current abnormality
Detected compressor surge current The Chiller
stops
Abnormal
Low voltage abnormality
Detected low compressor motor
voltage
Abnormal
The Chiller
stops
ENGLISH
4-10. Product Protection Function
34
ENGLISH
Category
Description
Action
Status
Display low oil temperature
block control caution message
Caution
The guide closes the vane when a comDisplay low voltage block conBlock low voltage pressor motor voltage goes below low
trol caution message
voltage block setting -(100-setting)/2.
Caution
Block low oil run
Cause
Oil temperature ≤ operation oil
Low temperature setting value
The guide vane closes when a conDisplay high condenser presdenser pressure goes above high pres- sure block control caution
sure block setting + (100- setting)/2.
message
Caution
The guide vane closes when an evapo- Display low condenser presBlock low evaporator pressure goes below low pressure sure block control caution
rator pressure
block setting -(100-setting)/2.
message
Caution
Block low evapo- The guide vane closes when an evapo- Display low evaporator refrigrator refrigerant
rator temperature goes below low tem- erant temperature block contemperature
perature block setting -(100-setting)/2. trol caution message
Caution
Block high condenser
The guide vane closes when a comDisplay high compressor outlet
pressor outlet temperature goes above
temperature block control cauhigh temperature block setting - (100tion message
setting)/2.
Caution
The guide vane closes when a bearing Display high bearing temperaBlock high bearing
temperature goes above high tempera- ture block control caution mestemperature
ture block setting + (100-setting)/2.
sage
Caution
The guide vane closes when a cold
Low cold water
water temperature goes below low
temperature block
temperature block setting - (100-setcontrol
ting)/2.
Display low cold water outlet
temperature block caution
message
Caution
Display compressor surge current block control caution message
Caution
The guide vane closes when a comMotor overcurrent pressor motor current reaches setblock control
ting*105% to make the current go
below the setting.
Display compressor motor
overcurrent block control caution message
Caution
The guide vane closes when a motor
High motor windwinding temperature goes above high
ing temperature
temperature block setting + (100-setblock
ting)/2.
Display high motor winding
temperature block control caution message
Caution
Block high compressor outlet
temperature
Block
control
Compressor
surge current
block
The guide vane closes when current
goes above a setting value for more
than the setting (setting number/3)
within setting time.
Caution
Condensing block 1. The refrigerant gets condensed in oil
Display condense block control (Operation
control
2. Viscosity of oil is low
unavailable)
35
Description
High motor winding temperature contact opens
Cause
Coil temperature input contact opens
Action
Status
The Chiller stops
Abnormal
Low evaporator refrigerant
Low evaporator refrigerant temperature
temperature contact
The Chiller stops
contact closes
closes
Abnormal
Thermal type overcurrent relay contact
Oil pump overcurrent conattached on the oil pump power line
tact closes
closes
The Chiller stops
Abnormal
High bearing temperature High bearing temperature contact
contact closes
closes
The Chiller stops
Abnormal
High condenser pressure
contact closes
High condenser pressure contact closes The Chiller stops
Abnormal
Failure to operate
No input signal for compressor operation complete
The Chiller stops
Abnormal
Delta contactor opens
when operating
Starter contactor opens when operating The Chiller stops
Abnormal
Starter abnormality contact closes
Starter abnormality input contact closes The Chiller stops
Abnormal
Switch
contact
Compressor motor power Compressor power contact opens
contact opens
when operating
The Chiller stops
Abnormal
Low oil pump pressure
The Chiller stops
Abnormal
Low oil pump pressure contact closes
Table 6. Protection Logic
ENGLISH
Category
36
ENGLISH
4-11. Checklists before inspection
1) Thorough preparation
Check emergency treatment method, cleanness of surroundings, and safety of facilities and machines.
2) Review based on the circuit diagram
When the power system is supplied through other systems, check various power sources, if the 1st breaker is
supplying the power or not and installation status of the ground wire.
3) Contact
Check if you can closely and clearly communicate with relevant organizations.
4) Check zero voltage status and safety measures
Review lists shown below for safety when reviewing the main circuit.
a) Make the main circuit zero voltage by opening related breaker and disconnecting switch.
b) Check zero voltage stage with an electroscope and ground at needed spots.
c) Take out circuit breakers to make short a circuit and attach display “inspecting.”
d) Adjust disconnecting switches after cutting the power.
e) Especially when the power is supplied with incoming/distributing panel from a consumer, automatic control, or
MCC board, take measures in (c) and (d) above for those switches.
5) Warnings about current and voltage
Implement grounding after discharging the remaining current when inspecting parts of the condenser and cable.
6) Prevention of malfunction
Attach power cut and caution marks.
7) Prepare for protective tools for insulation
Wear protective tools for safety that match the rated voltage such as insulated gloves, safety helmets, insulated
tall boots, safety apparel, etc.
8) Measures for invasion of mice and insects
Prepare measures to prevent mice, insects, snakes, etc. from entering the site.
37
1) Final check list
- Check if a worker is inside the site.
- Check if demolishment of temporary buildings constructed for inspection is not delayed.
- Check that bolts are tightened properly.
- Check if tools, etc. are left.
- Check if mice and insects, etc. did not invade.
2) Inspection history
Make sure to record main points of inspection and repair, failure status and dates when inspecting to utilize histories as reference for next inspection.
! CAUTION
Set the routine inspection to check loading, operating hours, and operating environment, etc. of the operating
machine.
As the inspection period suggested in this manual is routine inspection, establish inspection plans depending on
the load of the machine and frequency of use.
Do not conduct insulation resistance tests on second transformers for the controller or control power.
Do not conduct insulation resistance tests on parts (sensors, switches, etc.) connected to the controller, etc.
ENGLISH
4-12. Checklists after inspection
38
ENGLISH
4-13. General Checklist
Inspec- Inspection
tion categories
All
Ambient
environment
Daily
Is there any dust?
Is the ambient temperature and humidity adequate?
Is there any abnormal vibration?
1 year 2 years
Criteria
Refer to Chapter 1. Environmental conditions
Equipment
Is there any vibration or noise?
Input voltage
Is the main circuit voltage normal?
Is the main circuit voltage normal?
Refer to Chapter 1. Environment
Insulation
resistance
test
Disconnect all power before testing insulation
resistance.
Insulation between the transformer 1st side and
grounding bus-bar.
When measuring the resistance, disassemble all
grounding wires connected to grounding bus–
bar.
*Low voltage (600Vac or
less) DC 500V class mega,
it shall be 5MΩ or more.
*High voltage (exceeding
600Vac, 7000Vac)
DC 1000V class mega, it
shall be 30MΩ or more.
Overheating
Is there any trace of overheating in each component?
No abnormality
Fixed parts
Is there any missing fixed parts?
No abnormality
Is there any contamination of conductor?
Is there any damage in the wires?
No abnormality
Is there any damaged part?
No abnormality
Is there any oscillation during operation?
Is there any damage on the connector?
No abnormality
Is there any color change of the heater component in starter panel?
No abnormality
Sensor &
switch
Is there any disconnection or short circuit?
Is there any damage in the contact part?
No abnormality
Grounding
Is there any rust on the connection part?
Is there any damage in the grounding conductor?
Is there any noise in the grounding system?
Note: Grounding resistance shall meet the requirements of the related codes and standards.
No abnormality
Conductor/wire
Main
circuit Terminal
/ ConRelay
trol
/contactor
circuit
Space
heater
No abnormality
Phase advance
Is the expansion under the limit?
capacitor
No abnormality
Cooling fan Is there any abnormal noise? (Control Panel)
No abnormality
Control Safety function
function
Display
Inspection items
Analog
value
Indication
Lamp
Is the safety function in normal operation?
Is the start-up sequence normally carried out?
Is the stop sequence normally carried out?
Is the temp. regulation within the specification?
Normal control
Is the displayed value correct?
No abnormality
Is the indication lamp displayed with the normal
brightness?
No abnormality
Table 7. General Checklists
39
ENGLISH
5. HMI
5-1. Start HMI
1.1 Menu Structure
START
HOME
SCHEDULE
HISTORY
VIEW ALL
VIEW
SCHEDULE
VIEW
HISTORY
ADD/EDIT
SCHEDULE
VIEW DETAILS
EVAPORATOR
CONDENSER
COMPRESSOR
MANUAL CONTROL
DEVICE
SETTING
ENVIRONMENT
SETTING
USER
GENERAL SETTING
SYSTEM
SCREEN SETTING
REGISTER
A DEVICE
CUSTOMER SETTING
LOG IN
NETWORK SETTING
ADVANCED SETTING
CHANNEL SETTING
Figure 22. Menu Structure
1.2. How to Input Information
A touch keyboard appears at the bottom of the screen by touching the information input column.
Enter information using the touch keyboard.
Figure 23. Login Screen
40
ENGLISH
1.3. How to LOGIN
It is divided into LOGOUT/LOGIN (ADMINISTRATOR/INSTALLER).
General users other than the administrator and installer cannot access major setup items by categorizing accessible
areas for each authority.
All setup items except operation stop can be accessed after login including operation start.
Function
LOG OUT
LOG IN
(administration
authority)
LOG IN
(installer
authority)
Top menu (stop operating)
○
○
○
Top menu (start operating)
X
○
○
Top menu (operation mode)
X
○
○
Schedule (add/edit/delete)
X
○
○
History (delete items)
X
X
○
Device setting (user)
X
○
○
Device setting (user → initialization of operating hours)
X
X
○
Device setting (system)
X
X
○
Device setting (device registration)
X
X
○
Environment setting (general setting)
X
○
○
Environment setting (screen setting)
X
○
○
Environment setting (customer setting)
X
○
○
Environment setting (network setting)
X
○
○
Environment setting (advance setting)
X
X
○
Environment setting (channel setting)
X
X
○
Table 8. LOGIN Policy
41
The top menu consists of date/time information, product information, control mode, temperature settings, operation
status, warning message, operation mode and the operation control button.
When messages for abnormality appear, the disable warning button feature is additionally provided on the right side
of operation status and warning message area.
1.Product information
2.Control
mode
3. Setting temperature
1.Date/time information
4. Operation status &
warning message
6. Operation
control button
5. Operation mode
Figure 24. Top Menu
1. Date/hour/product information
- Display the connected product information (brand + product type + model no.).
- Display current date and time information in the order of date, day and time.
2. Control mode
- There are three control modes. Local Operation directly operates on site. Schedule Operation automatically operates the product according to a scheduled time. Remote Operation operates the product remotely. The control
mode currently set is displayed on the screen.
3. Setting temperature
- Display the temperature setting of the evaporator outlet.
4. Operation status & warning message/Disable warning button
- Display the system operation status information and warning message.
- Display the warning message and Disable Warning button message by expanding to the control mode/temperature setting/operation mode area in case of abnormality.
- When a message appears, yellow represents warning and red represents abnormality.
5. Operation mode
- Display the currently set operation mode.
6. Operation control setting
- The Chiller starts operating when the start button is pressed, and the Chillers stops operating when the stop button is pressed.
ENGLISH
1.4. Top Menu
42
ENGLISH
1.5. Bottom Menu
The bottom menu consists of the main menu and the login button at the bottom of the screen.
1.Home
2. Schedule
3. History
4.Device setting
5. Environment
setting
Figure 25. Bottom Menu
1. Home
Go to Home screen.
2. Schedule
Go to schedule screen.
3. History
Go to history screen.
4. Device setting
Go to user menu of device setting screen.
5. Environment setting
Go to language setting menu of the environment setting screen.
6. LOGIN/LOGOUT toggle button
Display LOGIN button when logged out.
Display LOGOUT button when logged in.
* Automatically log out when there is no control for 30 minutes after logging in.
6.LOGIN
43
ENGLISH
5-2. Home Screen Composition
2.1. View All
This consists of the main menu and LOGIN buttons at the bottom of the screen.
1
12
6
2
3
4
5
8
9
7
10
11
Figure 26. View All
No.
Component
Description
1
Device name
Provides device names.
2
View all tab
This tab provides overall information about the Chiller, and it is the default
when accessing the home screen for the first time.
3
Evaporator tab
Provides evaporator information screen when selected.
4
Compressor tab
Provides compressor information screen when selected.
5
Condenser tab
Provides condenser information screen when selected.
6
Manual control button
Provides manual control list.
7
Animation
Provides a current animation of the Chiller (R134a, 2Stage, R123).
8
Major information of the device
Provides evaporator leaving water temperature and motor current.
Provides the same information when moving to other information tabs.
9
Evaporator
Provides evaporator entering water temperature/leaving water temperature/ refrigerant temperature/ pressure information.
10
Compressor
Provides compressor oil differential pressure/oil temperature/bearing temperature/motor winding information.
11
Condenser
Provides condenser entering water temperature/leaving water temperature/ refrigerant temperature/pressure information.
12
Operation mode
Provides different colors depending on an operation mode.
Blue: cooling, orange: heating, ice manufacturing: blue-black, stop: gray.
Table 9. View All Items
44
ENGLISH
2.2 Evaporator
Displays DATA related to the animation screen of the evaporator.
2
3
1
4
Figure 27. Evaporator
No.
Component
Description
1
Animation
Provides the evaporator animation.
2
Major information of the device
Displays evaporator leaving water temperature and motor current. Provides
same information when moving to other information tabs.
3
Main information
Provides evaporator pump interlock/flow contact/outlet water setting temperature information.
4
Additional information
Displays evaporator entering water temperature/leaving water temperature/pressure/refrigerant temperature/LTD/ flow/ECO level/ECO calculation/ECO valve information.
Table 10. Evaporator Items
45
ENGLISH
2.3. Compressor
Display data related to the compressor animation display.
2
3
1
4
Figure 28. Compressor
No.
Component
Description
1
Animation
Provides the compressor animation.
2
Major information of the device
Displays evaporator leaving water temperature, inverter pressure and flow.
Provides the same information when moving to other information tabs.
3
Main information
Provides inverter frequency/one stage variable diffuser/two stage variable
diffuser/hot gas valve information.
Additional information
Provides compressor inverter outlet current/inverter outlet frequency/ inverter DC LINK voltage/inverter temperature/PID calculation/ motor winding
R temperature/motor winding S temperature/motor winding T temperature/outlet temperature/bearing temperature/vibration information.
4
Table 11. Compressor Items
46
ENGLISH
2.4. Condenser
Display DATA related to the condenser animation.
2
3
1
4
Figure 29. Condenser
No.
Component
Description
1
Animation
Provides the condenser animation.
2
Major information of the device
Displays evaporator leaving water temperature and motor current. Provides
the same information when moving to other information tabs.
3
Main information
Provides condenser pump interlock/flow contact/pressure information.
4
Additional information
Provides condenser entering water temperature/leaving water temperature/pressure/refrigerant temperature/LTD/ CON level/CON
calculation/CON valve information.
Table 12. Condenser items
47
ENGLISH
2.5. Manual control
Display DATA related to the condenser animation screen.
1
2
3
4
5
6
Figure 30. Manual Control
No.
Component
Description
1
Vane opening
Displays a vane opening value and provides 0~100% control function when
selecting manual/automatic setting and automatic by pressing the setting
button.
Manual opening does not work when the product doesn’t operate since
closing is enforced by circuit.
2
Diffuser opening
Displays a diffuser opening value and provides manual/automatic setting
function and 0~100% control function when manual is selected by pressing the setting button.
3
Hot gas valve
Displays a hot valve value and provides manual/automatic setting function
and 0~100% control function when manual is selected by pressing the setting button.
4
Eco valve
Displays a ECO valve value and provides manual/automatic setting function
and 0~100% control function when manual is selected by pressing the setting button.
5
CON valve
Displays CON valve value and provides manual/automatic setting function
and 0~100% control function when manual is selected by pressing the setting button.
6
Oil pump
Displays oil pump status and provides manual/automatic setting and
ON/OFF control function by selecting the setting button.
Manual stop does not work while operating to protect the Chiller.
Table 13. Manual Control Items
48
ENGLISH
2.6. Home Screen Display Information
No.
Display menu
Display item
Display range
Display unit
1
Displays evaporator leaving water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
2
Displays motor current
4 digit and 1 decimal places (XXXX.X)
A
3
Displays evaporator flow contact
3 digit and 1 decimal places (XXX.X)
°C(°F)
4
Displays evaporator entering water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
5
Displays evaporator leaving water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
6
Displays evaporator refrigerant temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
7
Displays evaporator pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 (kPa, psi, mmHg)
8
Notes
Note 2.
2
Displays compressor oil differential pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm (kPa, psi)
9
Displays compressor oil temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
10
Displays compressor bearing temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
11
Displays compressor motor winding temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
12
Displays condenser flow contact
ON / OFF
13
Displays condenser entering water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
14
Displays condenser leaving water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
15
Displays condenser refrigerant temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
16
Displays condenser pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 ( kPa, psi)
17
Displays evaporator pump interlock
ON / OFF
18
Displays evaporator flow contact
ON / OFF
19
Displays evaporator outlet water setting temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
20
Displays remote temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
21
Displays evaporator entering water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
22
Displays evaporator leaving water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
Displays evaporator pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 ( kPa, psi)
24
Displays evaporator refrigerant temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
25
Displays LTD
3 digit and 1 decimal places (XXX.X)
View All
23
Evaporator
Note 1.
°C(°F)
3
26
Displays evaporator flow
4 digit places (XXXX)
m /h (gal/min)
Note 1.
27
Displays ECO level
0.0% ~ 100.0% (XXX.X)
%
Note 1.
28
Displays ECO calculation
0.0% ~ 100.0% (XXX.X)
%
Note 1.
29
Displays ECO valve
0.0% ~ 100.0% (XXX.X)
%
Note 1.
30
Displays vane opening
0% ~ 100% (XXX)
%
31
Displays diffuser opening
0% ~ 100% (XXX)
%
32
Displays hot gas valve
0% ~ 100% (XXX)
%
33
Displays inverter
3 digit and 1 decimal places (XXX.X)
Hz
34
Displays oil differential pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 ( kPa, psi)
Displays oil pump pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 ( kPa, psi)
36
Displays oil tank pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 ( kPa, psi)
37
Displays P.I.D calculation
0 ~ 100 (XXX)
38
Displays overheat
3 digit and 1 decimal places (XXX.X)
°C(°F)
39
Displays compressor oil temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
40
Displays compressor outlet temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
35
Compressor
Note 1.
49
Display menu
Display item
Display range
Display unit
41
Compressor
Displays bearing temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
42
Displays vibration
3 digit and 1 decimal places (XXX.X)
mm/s
Note 1
43
Displays power
4 digit places (XXXX)
KW
Note 1.
44
Displays motor winding R temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
Note 1
45
Displays motor winding S temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
Note 1.
46
Displays motor winding T temperature시
3 digit and 1 decimal places (XXX.X)
°C(°F)
Note 1.
47
Displays motor bearing temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
Note 1.
Displays condenser pump interlock
ON / OFF
49
Displays condenser flow contact
ON / OFF
50
Displays condenser inlet water setting temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
51
Displays condenser entering water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
52
Displays condenser leaving water temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
53
Displays condenser pressure
4 digit and 2 decimal places (XXXX.XX)
kgf/cm2 ( kPa, psi)
54
Displays condenser refrigerant temperature
3 digit and 1 decimal places (XXX.X)
°C(°F)
55
Displays LTD
3 digit and 1 decimal places (XXX.X)
°C(°F)
56
Displays condenser flow
4 digit places (XXXX)
m3/h (gal/min)
Note 1.
57
Displays CON level
0.0% ~ 100.0% (XXX.X)
%
Note 1.
58
Displays CON calculation
0.0% ~ 100.0% (XXX.X)
%
Note 1.
59
Displays CON Valve
0.0% ~ 100.0% (XXX.X)
%
Note 1.
Vane opening
Automatic/manual, 3 digit places (XXX)
%
61
Diffuser opening
Automatic/manual, 3 digit places (XXX)
%
Note 1.
62
Hot gas valve
Automatic/manual, 3 digit places (XXX)
%
Note 1.
63
ECO valve
Automatic/manual, 3 digit places (XXX)
%
Note 1.
64
CON valve
Automatic/manual, 3 digit places (XXX)
%
Note 1.
65
Oil pump
Automatic/manual, ON/OFF
-
48
60
Condenser
Manual control
Note 1. Displayed on the screen depending on whether the sensor is used or not.
Note 2. Displayed in mmHg unit for R123 model.
Table 14. Home Screen Display and Setting Items
Notes
ENGLISH
No.
50
ENGLISH
5-3. Schedule
The schedule is function for the device to implement desired actions at a specific time by appointing actions in advance.
The device can operate automatically only with the set schedules if the device is controlled at a fixed schedule. However, the schedule control for starting the operation can be implemented only when the device is standby to implement scheduled actions.
3.1 View Schedule
1
2
3
4
5
6
7
9
8
10
2
Figure 31. Schedule
No.
Component
Description
1
Today button
Goes to current year/month of the calendar and display screen for today’s
date when selecting the button.
2
Weekly/monthly display button
Provides weekly/monthly screen when selecting the button.
3
All schedule button
Displays all schedule information lists that are currently stored on the device on the right side of schedule.
4
Monthly navigation button
Navigation to move to the last/next month.
The left button and right button provide functions to go to the last month
and next month respectively.
5
Calendar year/month
Displays year/month that the calendar is displaying
6
Add schedule
You may add new schedules and go to add schedule screen when selecting the button.
7
Delete schedule
You may delete registered schedules. The button is enabled only when the
checkbox is checked.
8
Display schedule
Displays whether there is a schedule or not by icons.
Icon and number is displayed if there is any schedule.
9
Schedule
Provide schedule lists for selected date.
10
Checkbox
“Delete schedule” button is enabled when checkbox is selected.
11
Edit schedule
Provides schedule edit function when selecting the button.
Table 15. Schedule Items
51
ENGLISH
3.2 Add/Edit Schedule
1
2
3
4
5
6
7
8
9
13
10
11
12
Figure 32. Add/Edit Schedule
No.
Component
Description
1
Enter schedule name
2
Enter setting time
Enters time to implement corresponding actions.
3
Set setting period
Sets valid period for corresponding schedules.
*Default when adding schedules: today’s date .
4
Repeating pattern setting combo box
Set repeating pattern for schedules.
Available to select once/everyday/selected day setting .
5
Day setting button
Available to set when repeating pattern is day selection.
Enters schedule name after selecting
Repeat schedule on selected day for setting period.
6
Operation status button
Setting button that defines the operation status
when implementing schedules.
7
Operation mode
Setting button that defines operation mode when implementing schedules.
Cooling operation in case of air conditioning chillers.
Cooling and ice manufacturing operation in case of ice thermal chiller.
Cooling and heating operation in case heat pump chiller is set.
8
Motor current block
Setting button that defines motor current block when implementing schedules.
Available to adjust in the range of 50-100% by pressing up/down button.
9
Cooling setting temperature
Setting button that defines cooling setting
temperature when implementing schedules.
Available to adjust in the range of 3-50 °C by pressing the up/down button.
Heating setting temperature
(heat pump chiller)
10
Ice manufacturing setting temperature (ice storage chiller)
Setting button that defines heating/ice manufacturing
setting temperature when implementing schedules.
Available to adjust in the range of 10-90 °C / -20 ~ 30 °C
by pressing the up/down button.
11
Cancel
Returns to the previous screen after cancelling all input until now
12
Confirm
Confirms, stores and applies all input until now
Return to the previous screen when completed
13
Animation
Provides animation of the current chiller
*Provides corresponding image depending on the model no.
(2stage/R134a/R123)
Table 16. Add/Edit Schedule Items
52
ENGLISH
5-4. History
This function displays the history related to operation and errors of the Chiller.
4.1. View History (operation/ Error)
1
2
3
4
5
6
7
Figure 33. History
No.
Component
Description
1
All category tab
Provides all information whether it is an operation or error
when selecting the all category tab.
2
Operation category tab
Provides list information corresponding to operation data
when selecting the operation button.
3
Error category tab
Provides list information corresponding to error data
when selecting the error button.
4
Report delete button
Function to delete operation/error data report.
Delete function is enabled when each operation/error data
checkbox is selected.
5
Operation/error history data
Provides operation/error occurrence date/occurrence time/ device
name/code/detailed information.
6
Checkbox
Button available to select for each operation/error data.
7
View details button
Provides details for each list.
Provides detailed information pop-up of a selected list when selected.
Table 17. History Items
53
ENGLISH
4.2 View details
1
2
3
Figure 34. View Details
No.
Component
Description
1
Error code
Displays error code
2
Detailed information
Displays error message information.
3
Help
Provides cause of error and help inspection and corrective actions.
Table 18. View Details Items
54
ENGLISH
5-5. Device Setting
5.1 User
5.1.1 Basic Setting
This menu for users to set values needed for operation of the Chiller.
Figure 35. Basic Setting
1) Select Control Mode
- Local: This is to start/stop the Chiller by using the start/stop key on the control board of the controller at the site
of installation.
- Remote: This is to start/stop the Chiller by using remote start/stop (zero voltage contact signal: switch, relay contact signal) from a remote area (office on site or automatic control board).
- Schedule: This is to start/stop the Chiller automatically according to scheduled programs by setting time and temperature in the controller to start/stop the Chiller.
2) Select Operation Mode
- Standard Chiller: Provides cooling setting.
- Ice Thermal Chiller: Provides cooling/ice manufacturing setting.
- Heat pump Chiller: Provides cooling/heating setting.
55
The optimized control is implemented by minimizing Under-Shoot and Over-Shoot when automatically/manually
changing time to approach a goal, steady status error, initial operation and vane operation compared to the previous method by applying unique P (proportion), I (integration) and D (differentiation) algorithms to cold water temperature control.
Control Quantity
Control Quantity
Target
Target
Figure 36. Previous Control Method
Approaching the target with flexibility
Figure 37. LG Control Method
(1) Evaporator exit water temperature
This is menu to set to the P.I.D. control temperature of the cold water outlet when cooling
This is setting temperature is a goal in P.I.D control calculation.
(2) Evaporator Temperature P
Set P value of proportional control sections used for P.I.D control of cold water temperature when cooling.
(3) Leaving Water Temperature of condenser/ice manufacturing
This menu sets control temperature of exit in ice manufacturing mode.
4) Fan inverter control of the cooling tower
This is a control method to supply stable coolant inlet temperature, and this is applied when an inverter is used in a
fan motor control of the cooling tower.
Inverter should be selected for main menu/system menu/safety control setting/cooling tower control of the control
device.
- Operation is available only when an inverter is attached on the user MCC(Motor Control Center) panel.
This is an option, and this can be applied after a consultation with LG.
- Control output of the cooling tower fan is available to have one of 4~20mA, 0~5Vdc or 0~10Vdc signals from the
controller.
(1) Condenser temperature P
Set P, proportional section, of the P.I.D control when using an inverter to control coolant inlet control.
(2) Condenser entering water temperature
Set coolant inlet temperature that is the standard for the inverter control of the cooling tower.
ENGLISH
3) P.I.D Temperature Control
56
ENGLISH
5) Motor Current Block
This is to set motor and current control actions to protect the motor from overload.
The current block action is implemented as shown below, and temperature control is not implemented when current block action is under operation.
However, it is implemented in accordance with the P.I.D calculation value when P.I.D calculation value is smaller
than the vane opening value while current control action is under operation.
- Current Block Action
For example, if the current block is set to 80% and rated current is 518A, at point (1) when the current is 80% of
the rated current as shown in the figure below, vane opening stops, and when the current reaches point (2) that
is 105% of the current block setting, the vane is closed until current goes down to point (1).
When the current is lower than the point (1), a normal temperature control starts again.
518
Rated current
A
80% (518×0.8 A Ƒ 414)
Current block setting
100%
105%
Vane closed
Current control action
Vane open
‫ڸ‬
‫ڹ‬
(414A) (414×1.05 A Ƒ 435 A)
Figure 38. Motor Current Block
57
7) Hot Gas (Vane %)
This is an item to set when applying a hot gas bypass valve.
Action to open a hot gas bypass valve is implemented when opening reaches the setting when closing the vane
after reading feedback signals for controlling the opening of the guide vane.
If this value is set to 30%, the hot gas bypass vale opens from the point when opening of the main guide vane
reaches 30%, and when opening of the guide vane becomes 0%, the hot gas bypass valve opens to 100% (hot
gas maximum setting).
8) Hot Gas Maximum
This is an item to set when applying the hot gas bypass valve.
This item is to set the maximum value of opening of the hot gas bypass valve and blocks the valve from opening
larger than the setting.
If this value is set to 50%, the hot gas bypass valve does not open larger than that value.
9) Hot Gas Minimum
This is an item to set when applying the hot gas bypass valve.
The item is to set the minimum value of opening of the hot gas bypass valve and blocks the valve from closing
smaller than the setting.
If this value is set to 5%, the hot gas bypass valve does not close smaller than that value.
Main Guide Vane Opening Rate (%)
30%
Hot gas valve action point
Hot gas valve opening rate(%)
Control signal
Stops opening
starts opening
10%
5%
Control signal
Figure 39. Hot Gas Valve Action
ENGLISH
6) Guide Vane Maximum
This function is to protect the motor from overload or to block a load of the Chiller artificially.
This blocks the guide vane from opening bigger than the setting.
58
ENGLISH
Item name
Control mode
Setting Setting
Availability
UI
●
Select
a list
Unit
Minimum
Value
-
-
Maximum Adjustment
value
Unit
-
-
Notes
Local/Schedule/Remote
Control Mode : Cool
→ Cool
Operation mode
●
Select
a list
-
-
-
-
Control Mode : Cold
→ Cool/Cold
Control Mode : Heat
→ Cool/Heat
Evaporator leaving
water temperature
Condenser leaving
water temperature
●
●
Select a
number
Select a
number
°C
3
50
0.1
10
90
0.1
Operation Mode : Heat
-20
30
-5
Operation Mode : Cold
°C
Automatic operation
(+)
●
Select a
number
°C
0
10
0.1
Automatic temperature (-)
●
Select a
number
°C
0
10
0.1
Hot gas (vane %)
●
Select a
number
%
0
100
1
Hot gas maximum
●
Select a
number
%
1
100
1
Hot gas minimum
●
Select a
number
%
0
100
1
Guide vane Maximum
●
Select a
number
°C
1
100
1
Condenser entering
water temperature
●
Select a
number
°C
10
50
0.1
Motor current block
●
Select a
number
%
50
100
1
Evaporator temperature P
●
Select a
number
°C
1
10
0.1
Condenser temperature P
●
Select a
number
°C
1
10
0.1
Table 19. Basic Setting Items
59
ENGLISH
5.1.2 System Check
Figure 40. System Check
Item name
Setting availability
Setting UI
Unit
Minimum
value
Maximum
value
Adjustment
Unit
Notes
Master
-
-
V
-
-
-
Monitoring
(SW version)
Slave
-
-
V
-
-
-
Monitoring
(SW version)
Master
-
-
°C
-
-
-
Monitoring
(PCB temperature)
Slave
-
-
°C
-
-
-
Monitoring
(PCB temperature)
Table 20. System Check Items
60
ENGLISH
5.1.3 Check Input status
Display ON (Closed circuit)/OFF (open circuit) of the digital input port.
This menu is to check input signal ground stages connected to the control board of the Chiller.
When inspecting the digital input, make sure to check the control circuit drawing so that other signals are not
input to the input terminal of the controller.
Mixed connection with other signal lines may damage the controller board.
5.1.3.1 Master
Figure 41. Input Status Check Master
Item Name
Setting
availability
Contact Action Status
Notes
Normal Condenser flow contact
-
When flow is normal: closed circuit
ON/OFF
Evaporator pump interlock
-
When pump operates: closed circuit
ON/OFF
Condenser pump interlock
-
When pump operates: closed circuit
ON/OFF
Key Lock
-
-
ON/OFF
Purge
-
-
ON/OFF
Table 21. Input status Check Master Items
61
ENGLISH
5.1.3.2 Slave
Figure 42. Input Status Check Slave
Item Name
Setting
availability
Contact Action Status
Notes
High bearing temperature contact
-
When temperature is high: closed circuit
ON/OFF
High motor winding temperature contact
-
When temperature is high: closed circuit
ON/OFF
Oil pump overload contact
-
When there is overload: closed circuit
ON/OFF
Closed vane contact
-
When vane closes: closed circuit
ON/OFF
Normal compressor motor power
-
When power is supplied: closed circuit
ON/OFF
Compressor operation check
-
When compressor operate: closed circuit
ON/OFF
Abnormal starter
-
When there is abnormality: closed circuit
ON/OFF
Table 22. Input status Check Slave Items
62
ENGLISH
5.1.4 Check Output Status
Display the status of ON (Closed circuit)/OFF (open circuit) of the digital output port and analog output.
This menu is to display the output status by internal calculation in the controller, and is structured in the way
that output results by controller calculations can be found.
Status and wirings of the controller I/O board should be inspected when the actual output status and menu differ.
5.1.4.1 Master
Figure 43. Output Status Check Master
Item Name
Setting
availability
Contact Action Status
Notes
Control mode display
-
When it is on ice manufacturing mode: closed circuit
ON/OFF
Remote selection display
-
When selecting remote operation: closed circuit
ON/OFF
Evaporator water pump operation
-
When pump operates: closed circuit
ON/OFF
Condenser water pump operation
-
When pump operates: closed circuit
ON/OFF
Hot gas valve
-
-
ON/OFF
VFD
-
-
ON/OFF
Cooling tower fan 1 operation
-
When pump operates: closed circuit
ON/OFF
Cooling tower fan 2 operation
-
When pump operates: closed circuit
ON/OFF
Cooling tower fan 3 operation
-
When pump operates: closed circuit
ON/OFF
Cooling tower fan 4 operation
-
When pump operates: closed circuit
ON/OFF
Table 23. Output Status Check Master Items
63
ENGLISH
5.1.4.2 Slave
Figure 44. Output Status Check Slave
Item Name
Setting
availability
Contact Action Status
Notes
Oil heater run
-
When heater operates: Closed circuit
ON/OFF
Oil pump run
-
When pump operates: Closed circuit
ON/OFF
Buzzer
-
When there is abnormality: Closed circuit
ON/OFF
Run status display
-
When operating: Closed circuit
ON/OFF
Compressor abnormal stop
-
When warning alarms: Closed circuit
ON/OFF
Abnormality status display
-
When there is abnormality: Closed circuit
ON/OFF
Compressor run status
-
When compressor operates Closed circuit
ON/OFF
Compressor motor run
-
When motor operates: Closed circuit
ON/OFF
Vane opening
-
-
%
Diffuser opening
-
-
%
Table 24. Output Status Check Slave Items
64
ENGLISH
5.1.5 Check Operation Hours
Figure 45. Check Operation Hours
Item name
Setting availability
Setting UI
Unit
Minimum
value
Maximum
value
Adjustment
Unit
Notes
Number of Chiller
operation
●
-
Rounds
-
-
-
-
Hours of Chiller
operation
●
-
Hours
-
-
-
-
Number of compressor operation
●
-
Rounds
-
-
-
-
Hours of compressor operation
●
-
Hours
-
-
-
-
Table 25. Operation Hours Check Items
No.
Component
Description
1
Initialization button
When logged in with the installer account, chiller operation
hours/numbers are initialized to 0 by pressing the button
2
Initialization button
When logged in with the installer account, compressor operation
hours/numbers are initialized to 0 by pressing the button
Table 26. Operation Hours Check Initialization
65
ENGLISH
5.2 System
5.2.1 Control Information
This is menu for the user to set values needed to operate the Chiller.
Figure 46. Control Information
Item name
Setting availability
Setting
UI
Unit
Minimum
value
Maximum Adjustment
value
Unit
Automatic restart
●
Select
a list
-
-
-
-
Motor Amps
●
Select a
number
A
0
3000
0.1
Refrigerant level
use setting
●
Select
a list
-
-
-
-
Use/not use
Control mode
●
Select
a list
-
-
-
-
Unused/Cold/Heat
Model selection
●
Select
a list
-
-
-
-
2stage/R134a/R123
Time block
●
Select
a list
-
-
-
-
Use/not use
Table 27. Control Information Items
Notes
Stop/Restart
66
ENGLISH
5.2.2 Abnormality Condition
This is menu to set values related to the abnormality of the Chiller.
Figure 47. Abnormality Condition
1) Oil differential pressure Maximum
This is to set the minimum oil differential pressure.
The chiller stops due to abnormality if an oil differential pressure is below the setting when operating.
2) Low evaporator pressure
This is to set the minimum evaporator pressure.
The chiller stops due to abnormality if an evaporator pressure is lower than the setting when operating.
3) High condenser pressure
This is to set condenser pressure maximum.
The Chiller stops due to abnormality if a condenser pressure is lower than the setting when operating.
Item Name
Setting
availability
Setting
UI
Unit
Minimum
Value
Maximum
Value
Adjustment
Unit
Minimum Oil differential pressure
●
Select
a number
kgf/cm2
0
3
0.01
Maximum
vibration
●
Select
a number
mm/s
0
100
0.1
Condense block
time
●
Select
a number
hr
0
48
1
Low evaporator
pressure
●
Select
a number
kgf/cm2
0
13
0.01
High condenser
pressure
●
Select
a number
kgf/cm2
0
35
0.01
Table 28. Abnormality Condition Items
Notes
67
ENGLISH
5.2.3 Safety Control
This is to set values related to the safety control of the Chiller.
Figure 48. Safety Control
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Maximum
value
Adjustment
Unit
Notes
Automatic Control
Setting Value
●
Select
a list
-
-
-
-
Use/Not use
Surge High
Pressure
●
Select
a number
kgf/cm2
0
18
0.01
Surge Low
Pressure
●
Select
a number
kgf/cm2
0
18
0.01
Surge High
Temperature
●
Select
a number
°C
0
12
0.01
Surge Low
Temperature
●
Select
a number
°C
0
12
0.01
Soft Loading
Period
●
Select
a number
Seconds
1
60
1
Soft loading
Output
●
Select
a number
seconds
0.5
60
1
Table 29. Safety Control Items
68
ENGLISH
5.2.4 Timer
This is to set values related the timer needed for operation of the Chiller.
Figure 49. Timer
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Maximum
value
Adjustment
Unit
Evaporator Water
Pump Stop
●
Select
a number
Seconds
1
1800
1
Condenser Water
Pump Stop
●
Select
a number
Seconds
1
1800
1
Ignore Flow
●
Select
a number
Seconds
1
60
1
Oil Circulation
●
Select
a number
Seconds
30
600
1
Check Compressor
Run
●
Select
a number
Seconds
5
60
1
Block Restart
●
Select
a number
Seconds
5
3600
1
Table 30. Timer Items
Notes
69
5.2.5.1 Master
Figure 50. Sensor Setting Master
Item name
Setting
availability
Setting UI
Unit
Minimum
value
Remote Temperature
Setting
●
Select
a number
°C
0
10
0.1
Amps Sensor
●
Select
a number
A
0
3000
0.1
Table 31. Sensor Setting Master Items
Maximum Adjustment
value
Unit
Notes
ENGLISH
5.2.5 Sensor Setting
In the master tab, the current sensor and signal can be set. Make sure to set accurately, and it is only valid
when the sensor is being used.
In the guide vane/diffuser vane/ECO valve/CON valve tab, manually change AD values of the guide vane/diffuser vane/ ECO valve/ CON valve to minimum/maximum, change the sensor setting mode to ON and then select corresponding setting (minimum setting, maximum setting) to end the setting.
70
ENGLISH
5.2.5.2 Guide Vane
Figure 51. Sensor Setting Guide Vane
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Sensor setting mode
●
Select
a list
-
-
-
-
ON/OFF
Manual/Automatic
setting
●
Button
%
0
100
1
Manual/automatic
-
(Available when the sensor setting mode is ON)
Available to press the
minimum button
Minimum Guide Vane
●
Button
-
0
Maximum Adjustment
value
Unit
1023
Notes
Maximum Guide Vane
●
button
-
0
1023
-
(Available when the sensor setting mode is ON)
Available to press the
maximum button
Guide Vane AD
-
-
-
0
1023
-
Monitoring
Table 32. Sensor Setting Guide Vane Items
71
ENGLISH
5.2.5.3 Diffuser Vane
Figure 52. Sensor Setting Diffuser Vane
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Sensor setting mode
●
Select
a list
-
-
-
-
ON/OFF
Manual/Automatic
setting
●
Button
%
0
100
1
Manual/automatic
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
minimum button
Diffuser Vane
Minimum
●
Button
-
0
Maximum Adjustment
value
Unit
1023
Notes
Diffuser Vane
Maximum
●
button
-
0
1023
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
maximum button
Diffuser Vane AD value
-
-
-
0
1023
-
Monitoring
Table 33. Sensor Setting Diffuser Vane Items
72
ENGLISH
5.2.5.4 ECO Valve
Figure 53. Sensor Setting ECO Valve
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Sensor Setting Mode
●
Select
a list
-
-
-
-
ON/OFF
Manual/Automatic
Setting
●
Button
%
0
100
1
Manual/Automatic
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
minimum button
ECO Valve Minimum
●
Button
-
0
Maximum Adjustment
value
Unit
1023
Notes
ECO Valve Maximum
●
button
-
0
1023
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
maximum button
ECO Valve AD value
-
-
-
0
1023
-
Monitoring
Table 34. Sensor Setting ECO Valve Items
73
ENGLISH
5.2.5.5 CON Valve
Figure 54. Sensor Setting CON valve
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Sensor Setting Mode
●
Select
a list
-
-
-
-
ON/OFF
Manual/Automatic
setting
●
Button
%
0
100
1
Manual/automatic
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
minimum button
CON Valve Minimum
●
Button
-
0
Maximum Adjustment
value
Unit
1023
Notes
CON Valve Maximum
●
button
-
0
1023
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
maximum button
CON Valve AD value
-
-
-
0
1023
-
Monitoring
Table 35. Sensor Setting CON Valve Item List
74
ENGLISH
5.2.6 Sensor Offset
This is menu available for offset of each sensor value.
Figure 55. Sensor Offset
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Sensor Setting Mode
●
Select
a list
-
-
-
-
ON/OFF
Manual/Automatic
Setting
●
Button
%
0
100
1
Manual/Automatic
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
minimum button
ECO Valve Minimum
●
Button
-
0
Maximum Adjustment
value
Unit
1023
Notes
ECO Valve Maximum
●
button
-
0
1023
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
maximum button
ECO Valve AD value
-
-
-
0
1023
-
Monitoring
Table 36. Sensor Offset Item List
75
ENGLISH
5.2.7 Refrigerant Level
5.2.7.1 ECO Refrigerant Level
Figure 56. Refrigerant Level, ECO Refrigerant Level
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Sensor Setting Mode
●
Select
a list
-
-
-
-
ON/OFF
Manual/Automatic
setting
●
Button
%
0
100
1
Manual/automatic
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
minimum button
CON Valve Minimum
●
Button
-
0
Maximum Adjustment
value
Unit
1023
Notes
CON Valve Maximum
●
button
-
0
1023
-
(Available to use when
the sensor setting mode
is ON)
Available to press the
maximum button
CON Valve AD value
-
-
-
0
1023
-
Monitoring
Table 37. Refrigerant Level, ECO Refrigerant Level Item List
76
ENGLISH
5.2.7.2 CON Refrigerant Level
Figure 57. Refrigerant Level , CON Refrigerant Level
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
CON Refrigerant Level Setting
●
Select
a number
%
0
100
0.1
CON Refrigerant Valve Default
●
Select
a number
%
0
100
0.1
CON Refrigerant Level P
●
Select
a number
%
0
100
0.1
CON Refrigerant Level I
●
Select
a number
seconds
0
3600
1
CON Refrigerant Dead Zone
●
Select
a number
%
0
100
0.1
Maximum Adjustment
value
Unit
Table 38. Refrigerant Level, CON Refrigerant Level Items
Notes
77
ENGLISH
5.2.8 Option Setting
This is the menu to set to use/not use of the sensor.
5.2.8.1 Master
Figure 58. Option Setting Master
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Maximum Adjustment
value
Unit
Remote Setting Temperature
●
Select
a list
-
-
-
-
Use/not use
Hot Gas Valve
●
Select
a list
-
-
-
-
Use/not use
Evaporator Water Flow
●
Select
a list
-
-
-
-
Use/not use
Condenser Water Flow
●
Select
a list
-
-
-
-
Use/not use
Table 39. Option Setting Master Items
Notes
78
ENGLISH
5.2.8.2 Slave
Figure 59. Option Setting Slave
Item name
Setting
availability
Setting
UI
Unit
Minimum
value
Motor Winding R temperature
●
Select
a list
-
-
-
-
Use/not use
Motor Winding S temperature
●
Select
a list
-
-
-
-
Use/not use
Motor Winding T temperature
●
Select
a list
-
-
-
-
Use/not use
Oil Tank Pressure
●
Select
a list
-
-
-
-
Use/not use
Power
●
Select
a list
-
-
-
-
Use/not use
Vibration
●
Select
a list
-
-
-
-
Use/not use
Table 40. Option Setting Slave Item List
Maximum Adjustment
value
Unit
Notes
79
ENGLISH
5.2.8.3 Relay
Figure 60. Option Setting Relay
Item name
Setting
availability
Setting UI
Unit
Minimum
value
Maximum
value
Adjustment
Unit
Notes
Diffuser Vane
Sensor
●
Select a list
-
-
-
-
Use/not use
ECO Valve
●
Select a list
-
-
-
-
Use/not use
CON Valve
●
Select a list
-
-
-
-
Use/not use
Table 41. Option Setting Relay Item List
80
ENGLISH
5-6. Environment Settings
This consists of the general settings, screen settings, customer settings, network settings, advance settings and
channel settings. This is menu to set the HMI system.
6.1 General Setting
1
2
3
4
5
Figure 61. General Setting
No.
Component
Description
1
Language
Provides the evaporator animation.Provides lists of languages for setting
(Korean/ English/Chinese).
2
Time Setting
Displays the time of the HMI system. Provides a setting list pop-up when
selected.
3
Date Setting
Displays the date of the HMI system. Provides a time setting pop-up when
selected.
4
Holiday Setting
Sets holidays that schedules do not work.
5
Version Information
Displays a version of the information of the HMI
Table 42. General Setting Items
81
Korean/English/Chinese settings are available.
1. Log in and press General Settings - Language.
Figure 62. Language Selection List
2. Language change is completed by pressing “Apply” after selecting the desired language.
Figure 63. Language Setting → Korean
ENGLISH
6.1.1 Language Setting
82
ENGLISH
Figure 64. Language Setting → English
Figure 65. Language Setting → Chinese
83
ENGLISH
6.2 Screen Settings
1
2
3
4
Figure 66. Screen Settings
No.
Component
Description
1
Screen Saver
Sets use/not use for the screen saver.
Sets a waiting time with a list menu among 10, 20, 30, 40, 50 and 60 minutes.
2
Speaker Setting
Sets use/not use for the speaker.
3
Backlight
Power Setting
Sets use/not use for the backlight.
Sets a waiting time with a list menu among 10, 20, 30, 40, 50 and 60 minutes.
4
Screen Calibration
Screen calibration menu for accuracy of screen touch.
Table 43. Screen Setting Items
84
ENGLISH
6.3 Customer Settings
1
2
Figure 67. Customer Settings
No.
Component
Description
1
General Settings
Menu to change the password for currently logged in account and to add an administrator account.
2
User Management
Menu to delete or edit (change password) other administrator accounts.
Table 44. Customer Settings Item List
85
1. Log in with the installer account.
2. Select Environment Settings - Customer Settings – Add User.
Figure 68. Add User
3. Enter ID/Password/Password Confirm in the “Add User” pop-up and press “Confirm” button.
Figure 69. Add User Pop-Up
ENGLISH
6.3.1 Administrator Account
86
ENGLISH
4. An “Administrator Account” with ID entered in the pop-up is created when pressing “Confirm” button.
Figure 70. Administrator Account Creation
5. Log out and log in as the “Administrator account”
Figure 71. Log In
87
ENGLISH
6.4 Network Settings
Figure 72. Network Settings
No.
Component
Description
1
IP Address Settings
Set an IP address setting method
2
IP Information
Enter IP address/subnet mask/gateway
3
DNS Server
Enter Main DNS Sub DNS
Table 45. Network Setting Item List
88
ENGLISH
6.5. Advance Settings
1
2
3
Figure 73. Advance Settings
No.
Component
Description
1
Set interlocking
Displays units applied to the HMI system. Provides an unit setting list pop-up when selected.
Temperature Units: °C, °F
Pressure Units: kgf/cm2, kPa, psi
Flow Units: m3/h, gal/min
2
Update S/W
Provides a function to upgrade the system to a new S/W when selected.
(Only when SD CARD with a new S/W is inserted.)
3
DB management
Provides a function to manage DB that is used in the HMI system.
Table 46. Advance Settings Item List
89
ENGLISH
6.6. Channel Settings
1
Figure 74. Channel Settings
No.
1
Component
Channel Settings
Description
Provides a function to set a communication speed of CH1/CH2.
Communication speed: MODBUS_9600/ MODBUS_19200
Table 47. Channel Settings Item
90
ENGLISH
5-7. Screen Saver
Figure 75. Screen Saver
No.
1
Component
Screen Saver
Description
Displays the device name/operation state/operation mode/vane opening/evaporator
leaving temperature/motor current/condenser leaving temperature information.
Table 48. Screen Save Item
5-8. Data Storage
Component
Data Storage
Description
Generate important data in every 5 seconds.
Compressed to Year_Month-Day.tar.gz(ex. 2013_01_01.tar.gz) form in a SD card.
Table 49. Data Storage Item
91
This function monitors and controls the current status of the Chiller by remotely accessing it on the Web.
1. Connect LAN to HMI LAN port.
2. Select Environment Settings – Network Settings – IP Address Settings.
Figure 76. Network Settings
3. Press “Apply” button after selecting “Get the IP address using DHCP” in the “IP Address Setting Pop-up.”
Figure 77. IP Address Settings
ENGLISH
5-9. Web Function
92
ENGLISH
4. When the pop-up disappears, enter the IP address of the IP information in the Internet address bar in the form at
http://IPaddress.
Figure 78. IP address of IP Information
Figure 79. Enter IP address in the Internet Address Bar
5. HMI screen is displayed on the Web.
Figure 80. Web Access Screen
93
ENGLISH
6. START-UP
6-1. Delivery and Installation Check
From Receipt, Installation to Startup
Installation of Foundation
(foundation panel)
Receipt and Installation
Air tightness test
Wiring construction
between starter panel
and control panel.
(The order can be changed.)
Dissatisfaction
Vacuuming test
Charging
Nitrogen gas
If a month or more
left until operation,
Oil charging
Charge Refrigerant
Insulation resistance test
Lubrication system
operation adjustment
Function test for
starter and
controller panel
Function test
for safety devices
Check before start-up
Check before
and after start-up
Run chilled water pump
/Run cooling water pump
94
ENGLISH
Stop
Load operation
and operation setting
Record run data
Water quality analysis for
cooling and chilled water
Operation guide
Finishing
Figure 81. From receipt to Startup
Selecting a location
• If the chiller has to be installed near heat generating devices, keep distances more than 5 meters from boilers and
hot-air blowers, and more than 2 meters from other heat generating devices.
• Choose a well-ventilated place and avoid place with high temperature.
• Choose a place with less humid.
• Provide ample space for service (for control and maintenance of pipes and tubes)
Foundation
• Build the foundation to withstand the concentrated heavy weight of the chiller.
• The foundation should be higher than the surface of the water, and install the drainage around.
• Be sure to install the drain pipe to the drainage hole.
Receipt and Installation
• The chiller should be installed evenly leveled to the ground.
• Install the chiller on a foundation with flat support surfaces, level within ±1mm with the manufacturer-supplied isolation pad assemblies under the unit.
• Make sure the foundation surface is flat and leveled within ±1mm using a level, and if not, readjust it
within: ±1mm, using spacers.
95
ENGLISH
6-2. Preparation for start-up
Preparation for start-up
• It is called start-up run that the first run after receipt and installation or the run after long-term stoppage (over 1
month) before the regular operation of the chiller.
• Preparation for start-up is the maintenance and repairing work at least once a year after installation\, which is a very
basic and important task.
Air tightness test
Vacuuming test
Oil charge
Refrigerant charge
Insulation resistance test
Lubrication system
operation adjustment
Function test of
starter and
controller panel
Check safety devices
Figure 82. Preparation procedure for start-up
Checking the leak parts
It is recommended to perform leakage test following the steps in Fig 58.
Refer to the temperature and pressure values of the refrigerant in Table 18.
96
ENGLISH
Leakage Inspection
• The condition that requires the leak test
- After the chiller is disassembled and repaired,
- If the nitrogen's pressure charged in factory was lower during the transportation before the initial start-up:
• Weak Points for leak:
- Parts where the gasket is used
- Nut tighten part, bolt and nut
- Copper tube connecting part
- Sight-glass welded part
- Compressor motor terminal
Inspection method
1) Charge the nitrogen in order until the internal pressure of the machine reaches 2 kg/cm2, 5 kg/cm2, 9~9.5 kg/cm2.
2) Perform the soapy water test on every connecting part.
3) If the inspected pressure lasts for more than 30 min., prepare to do the soapy water test for smaller parts.
4) Mark the leaking point.
5) Eject the inner pressure of the machine.
6) Fix all the leaking points.
7) Do leak test again on the repaired points
8) After performing the large leaking test, increase the inner pressure up to the value of 9~9.5 kg/cm2.
9) Do the small leak test and fix them all.
10) After the leak test Is finished, exhaust the nitrogen gas very carefully.
* Please close the valve of evaporator, as when you increase the pressure inside of the chiller, the relief valve on the
evaporator may get open.
Note: Open the relief valve on the condenser by1.05 Mpa (10.71 kg/cm2).
The relief valve on the evaporator open at 0.99 Mpa (10.1 kg/cm2)
97
Temperature °C
Pressure 1kg/cm2
Temperature °C
Pressure 1kg/cm2
0
15
3.9517
51
12.740
-20
0.3255
16
4.1136
52
13.087
-19
0.3850
17
4.2793
53
13.400
-18
0.4465
18
4.4491
54
13.800
-17
0.5101
19
4.6230
55
14.167
-16
0.5758
20
4.6230
56
14.540
-15
0.6437
21
4.9932
57
14.921
-14
0.7138
22
5.1697
58
15.308
-13
0.7862
23
5.3605
59
15.703
-12
0.8610
24
5.5558
60
16.104
-11
0.9381
25
5.7555
61
16.513
-10
1.0176
26
5.9597
62
16.929
-9
1.0996
27
6.1685
63
17.353
-8
1.1841
28
6.3819
64
17.784
-7
1.2713
29
6.6001
65
18.223
-6
1.3610
30
6.8231
66
18.670
-5
1.4535
31
7.0510
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
2.6632
42
9.8988
78
24.676
7
2.7922
43
10.190
79
25.234
8
2.9246
44
10.488
80
25.802
9
3.0604
45
10.791
81
26.379
10
3.1998
46
11.101
82
26.966
11
3.3428
47
11.416
83
27.563
12
3.4894
48
11.738
84
28.171
13
3.6397
49
12.066
85
28.788
14
3.7938
50
12.400
86
29.417
-26.18
Table 50. HFC-134a Temperature / Pressure
ENGLISH
Pressure 1kg/cm2
Temperature °C
98
ENGLISH
Vacuum Dry & Vacuum Test
• The vacuum dry work has to be taken to eliminate the humidity when the machine is exposed to the atmospheric
air for a long time or it is indicated that the moisture got into the machine or complete pressure loss of refrigerant
happened due to refrigerant leak.
! WARNING
Do not operated the compressor motor or the oil pump motor, and do not take any insulation resistance test
when performing the vacuum dry work.
Even instant rotation for rotation check-up can damage the electrical insulation and cause huge damage.
• Generally the vacuum dry work is performed at a room temperature. The higher the room temperature is, the faster
the vacuum dry performance will be done. Stronger vacuum quality is required to evaporate the moist in the environment of lower room temperature. The vacuum dry working procedure is as follows.
1) Connect the high capacity vacuum pump (Approximately above 120 LPM) to the refrigerant charge valve.
The length of the pipe from the pump to the machine should be as short as possible and the diameter of the pipe
as big as possible for minimum gas flow resistance.
2) To measure the vacuum, if the pressure gauge is installed or pressure value from MICOM is available, the pressure gauge may be used.
3) When vacuuming work, open all the valves except the valves connected to external.
4) Allow approximately 2 hours of additional vacuum pump operation, if the surrounding temperature of the machine is above 15.6 °C, and while the vacuum pump is operated if the manometer is indicating 756mmHg.
If the internal pressure of the chiller is kept below 756 mmHg, the accumulated moist in the machine would be
frozen and then this ice is evaporated more slowly than in normal condition, which leads to a delay of the vacuum dry work. If there is hot water at this situation, let the evaporator and the condenser be flowed by the hot
water and then operate the vacuum pump.
5) Fasten the vacuum pump valve and stop the pump, and then record the vacuum gauge value.
When reading the degree of the vacuum while the surrounding temperature varies, it has to be compensated by
converting the temperature change into pressure using below equation.
△P + (760 + H)x
t2
273+ t2
-
t1
273+ t1
mmHg
H: Internal pressure before the inspection (mmHg)
t1: Surrounding temp. before the inspection (°C)
t2: Surrounding temp. after the inspection (°C)
Table 51. HFC-134a Temperature / Pressure
6) The vacuum dry work is terminated if there is no change in the vacuum gauge value after waiting for 4 hours.
The machine is well air-tight if the leak rate is below 0.1 mmHg/h(=0.1 Torr/h). If the vacuum gauge value rose
up, repeat step 4) and 5).
7) If the value still changes after several time of vacuum dry work, set the inner machine pressure above
9~9.5kg/cm2.G and perform the leak inspection. After fixing the part where it is leaking, redo the vacuum dry
work.
99
1) Generally the chiller is charged with the oil in the compressor when shipping from the manufacturer, but if not, follow the steps as described below.
2) Charge the oil through the charging valve located at the bottom of the oil tank. At this time, make the inner part of
the machine vacuum using a vacuum pump. (If the refrigerant charging is proceeded, the charged refrigerant will
evaporate and eventually the pressure will rise. Thus, do the oil charging first.) If the inner machine pressure is
high, use the pump from the tank for the charging. In this case, the Discharging pressure of the pump shall be
more than 14 kg/cm2.G when the suction pressure is 0kg/cm2.G. The oil charging or removal, however, must be
done at the condition that the chiller is totally stopped.
3) The oil level must be charged more than 2/3 of the sight glass. Also if only the oil pressure and the temperature
are within the designated range, oil foaming may be happening.
4) Be cautious not to let any air enter into during oil charging.
Refrigerant charge
! CAUTION
When the refrigerant charging or discharging is performed on a machine that uses springs for isolation at the bottom,
fix the springs not to move up and down. The spring moving may stress the connected pipe line.
1) The chiller is charged with nitrogen gas when leaving from the factory. Remove the nitrogen gas at the job-site before doing the refrigerant charging.
2) Operate the chilled and cooling water pump to prevent freezing when performing the refrigerant charging.
3) It is the most preferable to adjust the refrigerant charge amount when the Chiller is operated under the design
load. Adjust the amount of refrigerant by the difference between chilled water outlet temperature and evaporation
temperature and through the sight glass.
Insulation resistance test
1) Mega test is to apply the direct voltage to the insulation material to obtain insulation resistance by measuring the
leaking current through the material.
Insulation resistance =
Leak Current
Applied Voltage
For 3000 and 6000V class: use mega for 1000V.
For 380 and 440V class: use mega for 500V.
2) Keep away any unnecessary personnel during the test for it is using high voltage.
3) Cut all the exterior power that is supplied to the chiller before performing the test. The 3-phase motor that is for
above 500hp, can cause danger due to the electric charge when the inspection was performed. Thus, completely
discharge it after the inspection and then handle the ground terminal.
5) Do not perform the high voltage mega test in vacuum condition.
6) Electrical insulation resistance drops in accordance with the temperature increases, and is sensitive to the temperature change which means that it varies. The changed temperature can be written in temperature coefficient and
the temperature coefficient and applied equation is as follows.
Insulation Resistance in
inspecting (°C)
0
5
10
15.6
20
25
30
35
Temperature coefficient
0.4
0.5
0.63
0.81
1.00
1.25
1.58
2.00
Insulation Resistance in
inspecting (°C)
40
45
50
55
60
65
70
75
Table 52. Temperature coefficient under insulation temperature
Temperature coefficient
2.50
3.15
3.98
5.00
6.30
7.90
10.00
12.60
ENGLISH
Oil charge
100
ENGLISH
7) Other factors that influence the insulation resistance
<Pollution of the outer surface of the insulation body> If absorptive and deliquescent materials like acid, chloride
and etc are adhered on the surface of the insulation body, they influence the insulation resistance. Remove the foreign substances before the inspection. <Condensing Point> If the insulation body temperature is below the surrounding temperature's dew point, moisture condensation can be preset on the insulation body surface (especially
at the crack and the groove) and influence the insulation resistance. The inspection should be taken into action
when the insulation body temperature is above the surrounding temperature's dew point. Record the dry bulb and
the wet bulb temperature surrounding air. <Absolute Humidity> Even through the insulation body temperature is
above the dew point, the atmospheric vapor influences insulation resistance. Avoid conduction test at the place
where the absolute humidity is high present.
8) Apply an electric current for a minute to the spot to be measured up insulation resistance. Read and record the
value. Apply the inspection standard when the insulation body temperature is 20 °C. (When measured at a different temperature, use the temperature coefficient and convert the value indicated after a minute.)
9) Taking measures according to insulated condition.
Temp. of insulation body at inspection (°C)
Value indicated after a minute
Action
Danger
Bad
Re-inspection
Good
Better
Excellent
Below 2 MΩ
Below 50 MΩ
50~ 100 MΩ
100~500 MΩ
500~1000 MΩ
Above 1000 MΩ
Repair or Exchange
Troubleshooting
Troubleshooting
h Motor that is within the range of "Bad" and "Re-Inspection" at the mega insulation test, must take the POLARIZATION INDEX test.
Table 53. Insulation condition
10) Polarization Index Test
Record the indicated value appeared when performing the mega test after a minute and the one after 10 minutes.
Insulation Inhaling rate =
indicated value after 10 minutes
indicated value after 1 minute
Condition
Insulation Absorption Rate
Danger
Bad
Re-Inspection
Good
Better
Excellent
Below 1
Below 1,5
1.5~2
2~3
3~4
Above 4
If the motor's insulation absorption rate is within the range of "Danger", must be returned or replaced.
If the motor's insulation absorption rate is above the range of "Bad", must be checked additionally after 4 hours of
careful operation.
Table 54. Insulation absorption rate status
11) The following should be recorded when performing the mega test
- Type and voltage of the mega tester
- Connection part of the mega tester
- Surrounding temperature and humidity of the test taking place and the tank's internal pressure in case of hermetic type
- Stoppage period before the inspection
101
• Test before the Start-up
1. Control Panel and Electric lines
Cut the power and check the controlling parts and switches for any foreign substances. Also check for normal
operation and terminal connection conditions by handling the switches.
2. Voltage
Check if the voltage indicated at the voltage meter of the starter panel is identical to the rated voltage on the
chiller name plate.
3. Chilled and cooling water circulation system
Check if the chilled and cooling water operation is depicted properly on the display by activating individual pump.
• Control Device Operation Test
1. Check the wiring condition
Check whether the wiring of power, sensor, etc. are properly connected.
Special checking should be taken to power line.
2. Check the display condition after control power in
Be more cautious if there is any symptom of getting short for 5 seconds after the power is in.
If problem occurs, immediately cut the power and check for abnormality.
3. Check values displayed on the panel
Check if the display indicating sensor values are normal.
If the sensor indicates abnormal or error message is displayed, check the connection of the sensors.
4. No power operation
While the power of the main motor is cut, operate and check whether the operation is normal up to the Starter
panel operation signal. If a message displayed for abnormality, check the part.
• Check of Safety Device
Flow operation test for chilled water and cooling water
- Close the valves located at the pipe of the chilled and cooling water, and check whether the differential pressure
switches for flowing are working properly or not.
ENGLISH
Function test for starter and controller panel
102
ENGLISH
6-3. Start-up
• After the preparation is done for start-up, proceed as follows.
Preparation
for start-up
Power On
1) Input power to the control panel and the starter panel,
and check the status.
2) Input power to the oil heater 1~2 hours prior to the
main operation and make sure that the temperature of
the oil inside the tank is 30~65°C.
3) After checking the vane opening as 0%, set the
vane's operation to "Auto". The vane is to maintain 0%
on any condition of "Auto", "Open", "Stop", "Closed"
when the chiller stops.
Check oil temp.
in the oil tank
Check the vane
Oil pump operation
4) Set the oil pump condition of the control panel to
"Auto".
5) Activate the chilled water pump. When operating,
close the outlet valve, open the air ventilation valve
and then open the outlet valve to a small carefully to
avoid water hammering so that necessary amount of
flow passes through. If water keeps coming out after
the air discharged through the air outlet, close the air
valve.
6) Activate the cooling water pump. Caution required just
as step 5).
7) Check the control panel display if it is working properly. Check if the display is showing local operation
mode and chiller's possible operation condition.
Auxiliary
Operation
Control Panel
Display Check-up
Figure 83. Start-up procedure
103
Press the Operation
Button
Oil Pump Run
Start the compressor
motor
Start-up
competed
Operating
Figure 84. Start-up procedure (2)
1) Checking the oil pressure
When the operation button on the control panel is
pressed, oil pump will be activated that leads to an increase in the oil pressure and if the differential pressure between supplying oil to the bearing and the
inner tank oil lasts for 120~180 sec. above 1.0 kg/cm2,
the compressor motor will be operated.
2) Direction of the compressor motor's rotation.
3) Starting characteristic
At this time, 2 items check-up is needed simultaneously. Make sure 2 people are working together.
- Direction of the motor's rotation
Record the rotating direction at the counter load part
of the motor. If the direction is opposite, stop the
chiller and change the two among three phases.
- Starting Characteristic
Check the starting current, acceleration completion
time as on the "Check List".
4) Check the Operating Current
5) Motor Cooling Status
- Operating Current
After the start-up is done, the vane will be opened
gradually and the current increases simultaneously.
Operation current should not exceed the rated current.
If exceeds, set it referring to the “capacity control
module.”
- Motor Cooling Status
Periodic physical check-up of the motor surface temperature is required while operation.
- Checking the oil tank and the bearing temperature
Check if the oil tank and the bearing temperature is
preserved at 40~65°C. If not refer to "Trouble Shooting" and "Check List".
6) Checking all sorts of pressure status
7) Checking the operating sound and vibration
8) Chilled-water inlet and outlet temperature
9) Cooling-water inlet and outlet temperature
ENGLISH
• If the chiller is working under Local Operation Mode, follow the steps as follows. If strange situation is detected,
shut down the chiller immediately and follow the "troubleshooting" procedure. For more detailed information, refer
to the "Check list".
104
ENGLISH
• Load Operation and the Operational Setup
After the Start and the Stoppage operation, perform the Load Operation as follows.
In any cases, let do not exceed the electromotor rated current.
As mentioned already at the "Product Protection Function", it would not be able to be overloaded due to
the set of the motor current limiting function, but please double check.
Set the temperature control function according to the load.
Set the user's setting function as mentioned already in the "Product Protection Function".
When performing automatic operation
Set the vane operation mode to auto
1) In case of load increasing
To preserve the chilled water outlet temperature, the guide vane is opened up to the electromotor rated current.
2) When the load is parallel with present performance of the chiller
The guide vane is stopped at a certain degree of opening.
3) In case of load decreasing
- In opposition to 1), to preserve the chilled water temperature the guide vane is close.
- When the load is continuously decreased, the chilled water outlet temperature will be decreased and the chiller
will be stopped by the function of "Chiller operation/stoppage". If the chilled water outlet temperature increases to
the level of setup temperature, it will be operated automatically.
- The oil pump will perform additional operation even after the chiller's shut down.
The purpose of this action is to preserve the oil pressure (for inertia operation of about 1 min. after the chiller shut
down) and to protect the electromotor from frequent start and stoppage.
105
When letting the chiller to be still for a long period of stoppage, the refrigerant must be transferred to a separate refrigerant pot to prevent machine pressure decrease and leak.
Charge approximately 5kg of refrigerant into the machine to prevent air-entrance.
If the installed area of the chiller is frequently a place of below zero, drain the chilled water, cooling water and the
condensing water to prevent freezing. Also waterbox drain must be opened.
Leave the oil in the machine and supply heater power to maintain minimum oil tank temperature.
Before operating the centrifugal chiller after long-period of stoppage (longer than 1 month) or instant stoppage (less
than a month), follow the next steps.
1. The machine should be checked for unstable part or for abnormality for smooth operation.
2. To prevent refrigerant loss due to leak during the stoppage, following steps must be taken.
1) Compressor (simple inspection over the rotating part)
* Simply check from the appearance of the impeller, bearing and rotating part.
◇ Combination status of the impeller and the shaft
◇ Assemble condition of the Gear
◇ Foreign substance in the gear box
◇ End play of the impeller shaft
◇ Assemble condition of the guide vane
◇ Check the vane and the drive shaft
◇ Check the gap between the impeller and the cover with a thickness gauge
2) Lubrication system
◇ Loosen and crack of the oil pipe
◇ Replacing or clearing the oil filter
◇ Cleaning the oil tank
◇ Replacing the oil
3) Refrigeration System
◇ Check the refrigerant pollution possibility
◇ Clean the ejector
◇ Clean the tube
◇ Water quality analysis
◇ Exchange or clean filter related parts
4) Condenser, Evaporator Preservation (Corrosion countermeasures while stoppage)
During a long term period stoppage, follow the next steps for the corrosion countermeasures due to condenser
and evaporator tube corrosion.
- Each tube should be brushed and the scales must be removed completely. Fill it in with clean water. Finally
preserve it with rustic proof material in it.
- In principle preserve the chiller without water after complete drain.
- Execute all regular maintenance check-up and the inspection for the operation system with care. Controlling
test should be taken before the main operation.
If the compressor oil indicates an abnormal high-level display, there are possibilities that the oil absorbed the
refrigerant.
3. Start the machine in accordance with “Start-up” after checking the 1~2 items.
ENGLISH
6-4. Startup procedure after long-period of stoppage
106
ENGLISH
6-5. System Shutdown
• When stopping the product, perform it in the following order.
Press
the Stop button
1) The vane is automatically closed when the stop button
on the control panel is pressed.
2) Check the compressor motor stoppage time
- Measure the delay time to the compressor's mechanical stop after the chiller's shutdown; the delay
time due to motor's inertia moment.
Compressor stop
3) Check the oil pump remaining operation
- Check if the oil pump is operating till a resolved time
after the chiller's shut down.
4) Checklist after stoppage
- Stop the cooling water pump.
In this case, close the outlet valve of the pump gradually and then stop the cooling water pump.
Oil pump stop
- Stop the chilled water pump.
Close the outlet valve of the pump gradually and
then stop the chilled water pump.
- Record the oil and the refrigerant level after stop.
Stopping
completed
Figure 85. Stopping Procedure
107
ENGLISH
7. MAINTENANCE
7-1. Maintenance criteria
Maintenance and overhaul inspection (repairs)
• Usage Deterioration of Machine
Although there may not be any malfunction or structural deformation of the machine, it generally can be worn or
aged after a long time usage. Though a centrifugal chiller which has been operated for a long time is operating, the
motor can be declined and abrasion of the rotating section due to the secondary creation caused by oil burning, carbonization and etc. In many cases, such symptoms can normally be detected externally by the vibration and abnormal sounds that are present. In these cases, it is very important to take preventive action prior to the occurrence of
accident and maintain a proper working condition for the sake of the machine's longer life.
Failure rate
• Examination and thorough overhaul (Repair)
The trouble ratio of a machine is normally distributed as the following Fig.
Period for Overhaul(repair)
Initial trouble
Stable
Trouble by
Abrasion
Hour
Figure 86. Machine failure rate
<Period of Initial Failure> occurs at the beginning stage of the machine’s operation due to the manufacturing matter
from the factory itself.
Then it enters the <Period of Stabilization> that is followed by the <Period of Abrasion> after a certain period of time.
If it enters to the <Period of Abrasion> region, possibility of the machine's failure is going to rise up. Thus, it is very
essential to take thorough overhaul (repairing) action will prevent accidents and allow an optimum maintenance.
We recommend on the basis of a long term experience and statistical data that you take the thorough overhaul (repairing) action at the following period.
1) Chiller for commercial cooling : Every 5 years
2) If is an industrial process machine that is working throughout the whole year and requires a high reliance: Annually
• Criteria for Overhaul
Accidents may take place if there are irresistible abrasion and deformation that leap over the assigned limit of the machine’s individual parts.
For instance, if the bearing wears out, the destroyed oil film will cause the metallic contact to happen, which will lead
to a high possibility of the bearing burning out.
The impeller itself might be able to have a contact with other parts and be destroyed. If the central distance of the velocity increasing gear leaps over a certain number, teeth of gear could also be destroyed.
Thus LG Electronics sets up (1) Utilization Limit (2) Exchanging Standards and based on these criteria, "Thorough
Overhaul Procedure" was made to maintain the chiller under proper operating condition till next overhaul period, and
according to this standard, composing parts can be inspected and replaced.
108
ENGLISH
• Merits of the Maintenance Contract System
(1) Economic Efficiency
- Deterioration of machine can be minimized by a regular maintenance action.
- As machine life id prolonged, the possibility of huge accident is reduced, which can save maintenance cost.
- As the contact is performed based on yearly predetermined cost, the effective management over the budget
of the maintenance cost can be possible.
In order to prevent an unexpected cost caused by a sudden breakdown a counseling service with the customer
is provided in advance.
- Opportunity loss of customer's production process resulted from the unexpected stop of machine can be eliminated.
(2) Safeness
- Through checking a lot of safety devices, safe use of the machine without trouble can be possible.
- As a regular inspection is applied before trouble, breakdown is prevented beforehand.
- In case of maintenance contract, as training is provided, operator's management skill over the machine is developed.
(3) Quickness
- As machine status can be always checked through a regular inspection, precise instruction can be given to
even a trouble notice by phone call.
- Maintenance Contract machines will get the premium service as the first creditor even during the rush season
when there are plenty of service loads.
Maintenance Contract Work Details (Standard)
1. Inspection before the start cooling
(1) Air-tightness Test
(2) Refrigerant charging
(3) Electricity related insulation test
(4) Safety device setting
(5) Function test between Starter panel ~ Control
panel
(6) Vacuuming
(7) Chiller operation setup
2. Maintenance during the cooling period (1 time)
(1) Electricity related insulation test
(2) Checking the operation Setup
(3) Chiller operation setup
3. After finishing cooling season
(1) Refrigerant full extraction
(2) Nitrogen gas charging & sealing
(3) Filter checking(Replacing)
(4) Cleaning oil tank
(5) Checking the operation record
(6) Checking sensors (Replacing)
(7) Picking Oil
4. Water quality analysis (1 time)
(8) Air tightness test
(9) Electricity-relate insulation test
(10) Function test between Starter panel ~ Control
panel
(11) Checking the oil pump
(12) Chiller operation setup
109
ENGLISH
• Chiller for Annual Operation
1. Check-up during the Operation period (5 time)
(1) Electricity related insulation test
(2) Inspection the operation record
(3) Chiller operation setup
2. Overall Maintenance (once)
(1) Refrigerant full extraction
(2) Nitrogen gas charging & sealing
(3) Filter inspection (Replacing)
(4) Cleaning oil tank
(5) Checking the operation record
(6) Checking sensors (Replacing)
(7) Oil extraction
(8) Air tightness test
(9) Electricity-relate insulation test
(10) Function test between Starter panel ~ Control
panel
(11) Checking the oil pump
(12) Chiller operation setup
3. Water quality analysis
• Standard Maintenance Frequency
(1) Chiller for Cooling only; Cooling Start x 1, During operation x 1, Cooling Completion x 1
(2) Chiller for Annual Operation : During Operation x 5, Overall Maintenance x 1
• Excluded Items
(1) Cleaning the Heat Exchanger
(2) Overhaul(repair)
(3) Items that are not listed in the contract
Overhaul(repair)
• Compressor
1. Compressor Overhaul(repair)
(1) Preparation
(2) Disassemble Compressor
(3) Check capacity controlling device
(4) Inspection over the Compressor parts and cleaning
(5) High-speed gear inspection
(6) Inspecting Impeller shaft
(7) Assemble Compressor
(8) Check Flow rate
(9) Putting parts
(10) Cleaning
2. Auxiliary Work
(1) Air-tightness Test
(2) Vacuum drying
(3) Nitrogen gas charging & sealing
(4) Full extraction of Refrigerant
(5) Refrigerant charging
(6) Extraction of the Oil
(7) Cleaning the Oil tank
(8) Inspect the Filter types
(9) Electricity-relate insulation test
(10) Checking the Oil pump
(11) Inspect and control over the safety device
(12) Starter panel ~ Control panel operating test
(13) Chiller operation setup
(14) Check over the operation record
110
ENGLISH
• Motor
1. Motor overhaul (repair)
(1) Check Stator coil and rotor
(2) Check the Parts
(3) Measure Shaft Vibration, Concentricity degree
(4) Air gap, End Play measurement
(5) Gear disassemble and assemble
(6) Electricity wiring disassemble and assemble
(7) Insulation Resistance Measurement
(8) Winding Resistance measurement
2. Auxiliary works
(1) Refrigerant , Oil pipe Disassemble and Assemble
• Standard Contract Disassemble Inspection(Repairing) Parts
1. Compressor
(1) Bearing
(2) Shaft labyrinth
(3) Impeller shim (1st level, 2nd level)
(4) O-ring, Gasket
(5) Oil filter
2. Motor
(1) Bearing
(2) Rear cover
(3) O-ring, Gasket
(4) Filter Drier, Moisture Indicator
• Excluded Work from standard
1. Starter panel Disassemble Inspection(repairing)
2. Replacing Motor Coil
3. Cleaning the Heat exchanger
• The Others
1. Compressor
(1) Impeller
(2) Diffuser
(3) Impeller cover
(4) Impeller shaft
(5) Return channel 1, 2, 3
2. Motor
(6) Gear
(7) Plate type Heat exchanger
(8) Capacity adjustment device
(9) Lock nut, bolt
111
ENGLISH
7-2. Periodic maintenance
Daily inspection
Checks the evaporator and condenser pressure, oil tank pressure, differential oil pressure and discharge oil pressure
of the chiller. Compare the values with the ones of the general chillers maintenance table.
- Compressor and motor daily inspection standard
Classification
Compressor,
Motor
Inspection items
Inspection method
Criteria
Motor Cooling Condition
Check the refrigerant flow via. Mois- Able to see the refrigerture Indicator
ant flow
Able to see the refrigerant flow
Measure the temperature of the
outer surface of the motor using a
surface thermometer
Able to see the refrigerant flow
Motor Drain Temp.
Measure the draining pipe's outer
surface with the thermometer
Able to see the refrigerant flow
Motor Drain Oil Flow
Measure using Differential Pressure
Able to see the refrigerant flow
Compressor discharge gas temp.
Check temp. at the control panel
Able to see the refrigerant flow
Vibration/noise
Check with the hand and Ear
Measure using the vibration measuring instrument if necessary
Noise: Below 85dB
When there's no abnormal vibration
below x,y,z: 25μm
* The motor adopts liquid refrigerant cooling system. It supplies the liquid refrigerant by the differential pressure between the condensing and evaporation pressure.
* Check and make sure that the refrigerant liquid supplying line's moisture indicator is showing green.
If the green color is altered to yellow, it means that the moisture quantity has exceeded more than the standard
quantity in the machine. Thus, replace the filter dryer.
Figure 87. Compressor and motor daily inspection standard
112
ENGLISH
- Daily inspection of Condensers
Classification
Inspection items
Inspection method
Criteria
Inlet
Check at the Panel
Below 34 °C
Outlet
Check at the Panel
21°C or more
Condensing pressure state
Check at the Panel
5~10 kg/cm2
Heat exchanging state
Temperature difference between Temperature difference between
condensing temp. and cooling
condensing temp. and cooling
water outlet temp.
water outlet temp.
Cooling water
Condenser
* If the outlet temperature of the cooling water is below 21°C, condensing pressure would be decreased, which will
lead to a lack of differential pressure at the motor cooling and the oil cooler and finally become the situation of insufficient of cooling water.
The main cause of worsening the heat exchange can be seen for the scale attached inside cooling pipe and insufficient cooling water amount.
Figure 88. Condenser daily inspection standard
- Evaporator daily inspection standards
Classification
Inspection items
Inspection method
Criteria
Inlet
Check at the Panel
Below 5~15°C
Outlet
Check at the Panel
Above 3°C
Above 3°C
Check at the Panel
5~10 kg/cm2
Heat exchanger condition
Temperature Difference between
the evaporation temp. and the
0.5~3°C
chilled water outlet temp.
Refrigerant charging amount
Check through the sight glass
Refrigerant condition
Check through the sight glass
Chilled water
Evaporator
When evaporation pressure is decreased, the evaporator tube freezes and eventually damaged, or compressor surge
would also be possible. Causes of the decreased evaporating pressure would be insufficient refrigerant quantity, low
temperature water and abnormal heat exchanging efficiency. Like the condenser tubes, if foreign substances are in
or the scales adhered, corrosion may occur which will lead to a in efficient heat exchanging. This happens to decrease the refrigeration ability or may be the cause for surge.
Figure 89. Evaporator daily inspection standard
113
Classification
Oil
Inspection items
Inspection method
Criteria
Oil amount
Visual inspection
At least one of two sight
glasses should have oil level appearance.
Temp.
Check at the Panel
30~60°C
Differential Pressure
Check at the Panel
Above 1.3 kg/cm2
Oil Pressure Vibration
Check at the Panel
No Vibration
Leakage
Visual inspection of the oil system
There shall be no leak
Oil pump Noise
Check by ear
No abnormality
Oil pump remaining flow operation
Stop the chiller and check with
watch
300 sec.
Figure 90. Compressor and motor machine failure ratio
<Lubrication cycle>
The oil is taken through the manual valve into the tank. The level of the oil can be detected by the one sight glasses
on the oil tank. When the compressor is stopped oil should be able to be found through the sight glass.
The temperature of the oil tank is displayed on the panel and while operation, the temperature would be 30~65 °C.
The oil pump transfers the oil from the tank and the pressure at that time would be above 0.8kg/cm2.
The oil pump is sending the oil to the oil filter, where a valve is installed so that there is no need to drain the whole
system when replacing the filter.
Afterwards the oil is sent to the oil cooler and then cooled by the refrigerant from the condenser.
The refrigerant cools off the oil as low as 30~60°C.
Oil that left the cooler passes through the oil pressure transducer and then to the refrigerant expanding valve’s temperature sensor box, flows to the bearings and gears for lubrication.
The oil temperature is measured at the high-speed thrust bearing and the oil is drained to the oil tank that is located
at the lower part of the compressor.
The control device operates the oil to the oil pump prior to the main operation for 120~180 seconds at a constant
pressure. At stoppage when the main operation has stopped, it performs a 300 seconds of after lubrication.
Soft start-up opens guide vane slowly during the start-up to prevent foaming of the oil.
If the guide vane opens too quickly, it will let the refrigerant in the oil to be boiled because of the intake pressure's
rapid decrease, which will eventually cause foaming. This foaming will lead to dropping the pressure in oil pump, and
the low pressure of oil lead finally bad lubrication.
ENGLISH
- Daily inspection standard of Compressor and motor. Generally, the failure ratio of a machine is distributed as the
shape drawn in the following Fig.
114
ENGLISH
Monthly inspection
- Compressor and motor monthly inspection standard
Classification
Inspection category
Motor insulation
Criteria
Measure at 1000V mega
Above 100 MΩ
Visual inspection of the opening
status
In Vane Full Close, 0%
Check indication in Vane Full Open, 100%
Check the status of opening indication
Soft movement of Indication Value
Protector insulation
500V mega
(Protector ~ Main Coil, Protector
~ ground) Measuring
Above 3 MΩ
Characteristics of
start-up
Mark ● for the corresponding
start-up method
1. Direct standing start-up
2. Y-Δ start-up
3. Kondorfer start-up
4. Reactor start-up
* In case of chilled water outlet
temp _°C
Vane operation
Compressor
and Motor
Inspection method
Time of start-up current flow t:
5~25 sec.
Start-up current: A
Timer set value (sec.)
Figure 91. Compressor and motor monthly inspection standard
• Generally the starting current of the motor is about 600% that of the rated current in direct input. And in case of yΔ , it is 200%, for kondorfer 250%, and for Reactor 400%.
• Measuring frequency and record should be at least once a month for daily/monthly inspections. This data can be
the clue of solution if problems are occurred to the motor.
- Lubrication system monthly inspection standard
Classification
Inspection items
Inspection method
Criteria
Oil charging amount
Check through the sight glass
Refer to the standard charging
amount
Oil pump motor insulation
Check through the sight glass
3MΩ
Oil
Figure 92. Lubrication system monthly inspection standard
115
- Yearly inspection
Classification
Inspection items
Motor
Motor Terminal fasten bolt
Check the slackness
Chemical analysis
Water quality analysis
Tubes condition
Check it at the operation record or
No pollution
by opening the waterbox.
Chemical analysis
Water quality analysis
Tubes condition
Check it at the operation record or
No pollution
by opening the waterbox.
Oil cooler cleaning
Clean by refrigerant
No corrosion or pollution should be present
Ejector cleaning
Disassemble cleaning
No abnormality
Filter cleaning
Filter exchanging, Cleaning the
housing
No abnormality
Oil tank cleaning
Disassemble cleaning
No pollution
Condenser
Evaporator
Oil and lubricant
Oil Replacing
Inspection method
Criteria
Check the loose
Loose terminal finishing state
Water quality standard
Water quality standard
2000 hours or 1 year
Figure 93. Yearly inspection standard
<Water quality analysis>
The cooling water at the open circulation type cooling tower uses the evaporation latent heat to lower down the
water temperature and also recycles it.
At this time the water evaporates and the chloride ions in the water and the acid ions will increase. This will lead to
enrichment situation and eventually deteriorate the water quality.
Also, in the cooling tower, water and air are always in contact with each other and the contaminating material(automobile exhaust gas, sulfurous acid gas, dust, gas of chemical plants such as ammonia or petroleum gas, etc.) deteriorates the water quality even more.
These pollutant causes can corrode the pipe, scales adhered causes the tubes to have holes and lockouts which are
leading to a decreasing effect of heat exchanger.
Therefore, it may end to replacing the tubes, increased power cost, or the chiller failure.
Thus, cooling water quality must be maintained at a certain level.
Water quality analysis should be taken place periodically and if the results are out of the standards boundary(Table
23.), it must be replaced. At the beginning of the season and at the initial starting of the machine, water quality analysis is inevitable.
To prevent the cooling water enrichment, certain amount of cooling water should be drained during the circulation
and then supplying fresh cooling water. Another way of water quality analysis would be using chemical handling.
<Tubes State>
If water corroded dirt is adhered or foreign substances are mixed in the tubes, resistance is increased which makes it
hard for the chiller to have a good efficiency. It also makes it easy to cause surge.
If sandy like solid materials are mixed in the cooling water, erosion or corrosion may occur at the entrance of the
tubes, therefore when cleaning the tubes make sure that you check the inner surface of it.
Install a filter at the inlet of the cooling water pipe. Generally, a cooling tower is used for the cooling water system,
but when using the subterranean water or the riparian water it is possible for the scales to be adhered easily due to
low quality of water compared to the chilled water.
ENGLISH
Yearly inspection
116
ENGLISH
Cooling water system
Chilled water system
Once
Circulation type
through type
Item
Reference item
Standard item
Circulating Supplied
water
water
Once
through
water
Circulating Supplied
water
water
(Below 20°C)
Trend
Corrosion
Scaling
pH(25°C)
6.5~8.2
6.0~8.0
6.8~8.0
6.8~8.0
6.8~8.0
ㅇ
ㅇ
Electric conductivity
(Ma/m)(25°C) (㎲/cm) (25°C)
below 30
below 300
below 50
below 40
below 400
below 50
below 40
below 400
below 50
below 30
below 300
below 50
ㅇ
ㅇ
Chloride ion (mgCl ̄/L)
below 80
below 800
below 200
Sulfuric ion (mgSO4  ̄/L)
below 200
below 50
below 50
below 50
below 50
ㅇ
Acid consumption (pH4.8)
(mgCaCO3/L)
below 100
below 50
below 50
below 50
below 50
ㅇ
Total hardness (mgCaCO3/L)
below 200
below 70
below 70
below 70
below 70
ㅇ
Calcium hardness (mgCaCO3/L)
below 150
below 50
below 50
below 50
below 50
ㅇ
Ion silica (mgSiO2/L)
below 50
below 30
below 30
below 30
below 30
ㅇ
Iron (mgFe/L)
below 1.0
below 0.3
below 1.0
below 1.0
below 0.3
ㅇ
Copper (mgCu/L)
below 0.3
below 0.1
below 1.0
below 1.0
below 0.1
ㅇ
Sulfide ion (mgSO2 ̄/L)
Not
detected
Not
detected
Not
detected
Not
detected
Not
detected
ㅇ
Ammonium ion (mgNH4+/L)
below 1.0
below 0.1
below 1.0
below 1.0
below 0.1
ㅇ
Residual chlorine (mgCl/L)
below 0.3
below 0.3
below 0.3
below 0.3
below 0.3
ㅇ
Free carbon dioxide (mgCO2/L)
below 4.0
below 4.0
below 4.0
below 4.0
below 4.0
ㅇ
Stability index
5.0~7.0
ㅡ
ㅡ
ㅡ
ㅡ
ㅇ
2
ㅇ
ㅇ
ㅇ
Note)
(1) Name and unit of the items are based on KS MD100.
(2) O sign within the table refers to the factor related to the corrosion or scaling trend.
(3) Unit and value within the parenthesis show data based on the previous unit, for reference.
(4) If the temperature is high (40°C or above), generally the corrosion rate becomes high especially for steel that directly contacts water without any protective coating. It is recommended to have an effective plan for the water
such as adding anti-corrosive additive or air removal process, etc.
Table 55. Water quality management standard for chilled water/cooling water
# The charging amount of oil & refrigerant
Two Stage Centrifugal chiller
Frame
1
2
3
4
5
6
7
Cooling capacity
[RT]
Oil amount
[liter]
Refrigerant amount
[kg]
200
40
450
250 ~ 300
40
500
400 ~ 500
40
650
550 ~ 600
50
650
700
50
750
800
60
900
900 ~ 1000
60
1050
1100
60
1250
1300 ~ 1500
60
1650
1600
120
1800
1800 ~ 2000
120
2200
2150 ~ 3000
120
2500
Table 56. The charging amount of oil and refrigerant of the two stage centrifugal chiller
117
(1) If the operation needs to be stopped, to reduce the machine pressure and leak possibility, move the refrigerant to
a separate refrigerant container.
(2) To prevent intake of air into the machine, store the machine with about 5kg refrigerant charged or to apply 0.5kg
nitrogen.
(3) If the place where the machine is installed goes below 0°C frequently, to prevent the freezing, drain the cooling
water, chilled water and condensed water. Also open the waterbox drain.
(4) Leave the oil charged in the machine, and to maintain the minimum oil tank temperature, supply power to the oil
heater.
ENGLISH
7-3. Maintenance during off-season
118
Inspection items
Compressor
Motor cooling
status
Motor
insulation
Inspection method
Criteria
Check refrigerant flow status
from moisture indicator
Check flow status
Touch the surface of the motor
with hand
10~30 °C
Measured at 1000V
100MΩ or more
Start-up
characteristics
(mark O in the
corresponding
start-up
method)
Actual
measurement
Decision
MΩ
Start-up time
T=5~25 sec.
t=
sec.
Start-up current: A
A=
A
Timer set value (sec.)
Timer
Kondorfer, reactor
In case of chilled water
outlet temp. ( ) °C
Vane
operation
Vane opening
Actual
Kondorfer reactor measurement
Low pressure High pressure
ENGLISH
7-4. Annual maintenance(1/2)
Check timer set value with independent timer
operation test after disconnecting high voltage.
Check opening 0~100%
Check 0, 100%
Check opening status
Shall operate smoothly
Check opening ratio
In normal operation
Operation current Check current value
Less than 105% of the rated
A
Motor
stopped time
After chiller is stopped, check from 10~60 sec.
half-load side of the motor when
the meter axes stopped time
sec.
Discharge
gas temp.
Measure the surface of the bolts
with thermometer
About 30~90°C
°C
Vibration noise
Touch with hand or check
with ears
When there is no
problem
T1:
start-up
timer
T2:
subsi
-diary
timer
119
Inspection items
Inspection method
Criteria
Inlet
Check with thermometer
34°C or less
(standard condition)
°C
Outlet
Check with thermometer
24°C or more
(standard condition)
°C
Cooling water
Condenser
Condensing
pressure (temp.)
Check with manometer
(thermometer)
6~10 kg/cm
(26~42 °C)
Heat exchanging status
Difference between condensing
temp. and cooling water outlet temp.
1~3 °C
Inlet
Check with thermometer
6~15 °C
Outlet
Check with thermometer
Chilled water
Actual
measurement
2
kg/cm2 (°C)
°C
4°C or more
Evaporator
Lubrication system
Safety Device
Evaporating pressure
(temp.)
Check with manometer
(thermometer)
2~5 kg/cm2
(0~21 °C)
Heat exchanging status
Difference between chilled water
outlet temp. and evaporating temp.
1~3 °C
Refrigerant charging
amount
Check through sight glass
Boiling status
Visual inspection
Refrigerant
contamination
Check through sight glass
Whether contaminating
material, moisture,
oil is included
Oil amount
Visual inspection
Check with sight glass
on the gear box during
operation
Oil charging amount
Accumulated charging amount after
charging new refrigerant
Oil tank temp.
Check with thermometer
30~65 °C
°C
Temp. of Bearing
Check with thermometer
50~85 °C
°C
Oil differential
pressure
Check with manometer
Oil pressure vibration
Vibration of the pressure value
Oil leakage
Oil system visual inspection
Oil pump noise
Check with ears
Oil pump remaining
operation
Measure with watch
300 sec.
Vane operation
Manual opening of vane
• Stop at rated current
• Closed at 105%
Chilled water differential
pressure switch
Decrease chilled water amount to
check the operation
kg/cm2 (°C)
°C
Refer to 10.5 standard
charging amount
Refer to 10.5 standard
charging amount
Month
Day
Oil supply pressure –
Oil tank pressure
(above 1.3 kg/cm2)
Cooling water differential Decrease cooling water amount to
pressure switch
check the operation
Table 57. Table for Annual maintenance
min.
Decision
(OX)
ENGLISH
7-4. Table for Annual maintenance(2/2)
120
ENGLISH
7-4. Table for Annual maintenance
Operation Inspection Table (A)
Inspection date:
Address
Year
Month
Day
(Tel)
Company
(Staff in charge)
Serial No.
Model
Serial No.
Rated voltage(V):
Main motor
Max. output(KW):
Rated current(A):
Changes
Replaced parts
Conclusion
Person in charge of service:
Note:
1. The manufacturer is not responsible for the problems happened due to the reasons as follows; poor water quality,
customer's poor maintenance and natural disaster.
2. Overhaul for the compressor should be done in 5 years or in 10000 hours, whichever comes first.
3. Beware that some items can be changed without prior notice for the product improvement.
Table 58. Operation Inspection table
121
Compressor oil replacement
- Checking the Lubrication System
Record the level of the oil on the oil tank sight glass in operation, and check the level when the chiller is stopped. If the
level has dropped below the lower part sight glass, it is necessary to check whether the oil recovery system is working
properly. If oil is needed, add it through the oil charging valve. To charge the oil opposite from the refrigerant pressure, a
pump is needed. The charging quantity of the oil should be referred to LG Electronics and the specification of the additional oil should match with that of LG Electronic’s chiller oil. Added oil shall be recorded for its amount and date.
- Oil specification
Use oil recommended by LG.
Category
Unit
Characteristic value
Meaning
Density
kg/m3
960
Check for the specified product and for any foreign substance mixed
Color
°C °C
L0.5
Check initially specified product
Ignition point
mm3/s
250
Fire and explosion risk, preservation stability
Flowing point
mgKOH/g
- 40
Stability during the initial start-up, preservation stability
Kinematic viscosity @ 40 °C
67.3
Lubrication, friction loss, sealing effect, cooling capability
@ 100 °C
8.29
Viscosity index
90
Relationship to the viscosity change due to temp. change
Total acid value
0.01
Measure oxidation of the oil itself compared to the initial total
acid value
Corrosion of
the copper plate
1
Anti-corrosion ability of the oil
(100 °C, 3h)
Table 59. Oil specification
<Available oils>
- Oil from LG
- Japan sun oil : Icecold SW68
- Castrol : Castrol Icematic SW68
• Oil replacement
We recommend you to replace the oil on the first year of the chiller's operation and every 3-year period depending
on the oil analysis.
1) Mark the current oil level.
2) Open the control circuit breaker and oil heater circuit breaker.
3) Gradually open the oil charging valve to drain the oil. Opposite from the chiller pressure, open the valve very
slowly.
4) After locking the valves at both ends of the oil filter, use the valve to gradually reduce the pressure within the oil
filter, and change the oil filter.
5) Charge oil to the machine using a pump.
To be charged till the level of middle or higher at the sight glass, approximately 50~60ℓ of oil is needed. Heat
until the oil temperature reaches 40°C by turning on the oil heater. For the sake of controlling test, operate the oil
pump manually for 2 minutes. The level of the oil should be indicating at the sight glass.
ENGLISH
7-5. Oil maintenance
122
ENGLISH
Oil Filter Change
- Oil Filter Change
Replace the oil filter annually or in the time of overhaul.
Oil filter can be replaced in a condition that the refrigerant is in the chiller.
1) Check if the compressor is in the stop state and also if the compressor circuit breaker is opened.
2) Shut down the oil pump power.
3) Close the oil filter separator valves.
4) When opening the oil filter housing, do it slowly.
! CAUTION
Decrease the pressure of the oil filter housing very slowly because it is in a high temperature state.
5) Make vacuum in the filter housing after the filter exchange or assembling. After the vacuum has been done, open
the separation valve and if there is insufficient amount of oil, add oil through the charging valve.
123
Non-periodical maintenance
• Maintenance of the compressor bearing and the gear
The core of maintaining bearing and the gear can be said adequate lubrication. Preserve the recommended oil
amount, temperature and pressure by using the right level of oil. Do a thorough maintenance check-up on the lubrication system periodically. To inspect the bearing, the compressor must be completely disassembled.
To take out the bearing and to inspect it, a high technology specialist is needed. Excessive abrasion can occasionally be detected by excessive vibration or by the bearing's temperature.
• Refrigerant leak inspection
HFC-134a has higher pressure than air in room temperature, so it requires the refrigerant leak test utilizing electronic detector, halogen leak detector or soapy water.
If the refrigerant leak is overall the entire chiller with large volume, immediately stop using the system and fix it
first. If the refrigerant was lost or the machine has been opened during the service period, the chiller itself or related tank must be taken leak test by adding pressure.
Refer to 5-5-2 for leak inspection.
Charging refrigerant and leakage test
- Refrigerant characteristics
Usage refrigerant is HFC-134a.
HFC-134a evaporates at -26°C in normal air pressure, so it shall be stored in a pressured container or storage tank.
Refrigerant has almost no smell when it is mixed with air, and it is non-combustible in air pressure.
! CAUTION
The refrigerant HFC-134a dissolves oil and some non-metallic material, dries skin, and makes oxygen deficiency resulting in suffocation at high concentration. Thus be very careful not to inhale or touch by hand or eye contact when you handle the refrigerant.
<Characteristics Table>
Molecule formula
CH2F-CF3
Molecule amount
102.031
Boiling point (air pressure)
°C
- 26
Freezing point
°C
- 101
Critical temp.
°C
101
Critical pressure
kg/cm2.A
41.5
Density of saturated fluid (25°C)
kg/m3
1206
Specific volume of saturated vapor (25°C)
m3/kg
0.031
Specific heat ratio, vapor (25 °C, air pressure)
Evaporative latent heat (25°C)
1.1186
kcal/kg
Table 60. The property of HFC-134a
42.54
ENGLISH
7-6. General Maintenance
124
ENGLISH
- The adjustment of refrigerant charging amount
If it is necessary to control the refrigerant charging amount for a better performance of the machine itself, operate
the machine in a design load and add or remove the refrigerant until it satisfies the difference temperature of the
chilled water outlet and the evaporator refrigerant.
Do not over charge. Refrigerant can be charged through the storage tank or directly charged into the chiller.
- Refrigerant leak inspection
HFC-134a has higher pressure than air in room temperature, so it requires the refrigerant leak test utilizing electronic detector, halogen leak detector or soapy water. Check for a good room ventilation and check whether the
leaked refrigerant is concentrated in one place of the room to prevent a wrong measurement result.
Before performing any repair for leak, move all refrigerant from the leaked container.
- Refrigerant leakage
If there is large refrigerant leak, chiller performance degraded or operation impossible, it is recommended to stop
the chiller and repair first.
- Refrigerant filter
Refrigerant filter /drier in the refrigerant cooling pipes of the motor needs to be replaced once a year. It may require
more frequent replacement according to the status of the filter. To find the existence of moisture in the refrigerant,
sight glass is installed next to the filter. If moisture through the sight glass is detected, perform a thorough leak inspection to find the source of the water.
Cleaning Heat exchanger tubes (Evaporator/Condenser)
Inspect Heat exchanger tubes
- Evaporator
When the first operation season is over, clean the evaporator tubes.
These tubes have foreign substances inside. Thus to clean the tubes thoroughly, a special caution should be exercised. The tubes condition, at this time, will become the data to determine how often tubes needs to be cleaned
and whether the water treatment in the chilled water(brine) system is appropriate. Check for any corrosion or scale
in the chilled water inlet/outlet temperature sensor. For corrosion, replace the sensor, and for scale, remove the
scale.
- Condenser
Cooling water circuit is generally an open type system, so it is easy to have the tubes contaminated and scale to be
adhered. Therefore, the tubes in condenser need to be cleaned at least once a year. If the water quality is contaminated, clean more frequently. Check the corrosion or scale in the cooling water inlet/outlet temperature sensor. For
corrosion, replace the sensor, and For scale, remove the scale.
The reason that it is higher than the normal condenser pressure and not reaching previous chilling load is generally
because tubes are contaminated or there is an air in the machine.
If the temperature difference between cooling water outlet and condenser refrigerant is great, the condenser tubes
may be contaminated or water flow is not good.
HFC-134a is a high pressure refrigerant, so it is easier to have refrigerant leak than air enters inside.
During the cleaning of the tube, use a specially designed brush to prevent scratch on the tubes wall.
Never use wire brush.
! CAUTION
For the prevention of severe scales and the removal of the scales, treat with chemical. For a proper treatment, consult with
water treatment specialist.
125
- Check list before start-up
1. Control Panel and Electric lines
Shut down the breaker, check for any foreign substance in the control parts, switches, etc.. Controls the
switches to check whether it operates in normal and connection status for each connector are OK.
2. Voltage
Read the voltage meter on the starter panel and check if it matches with the usage voltage on the name plate of
the chiller.
3. Chilled and cooling water circulation system
Operate cooling water and chilled water pumps to check if their operation status are properly displayed on the
panel.
- Control device operation test
1. Check the connection condition
Check if the power, sensor, etc. are properly connected.
Special checking should be taken to power line.
2. After power on, check the display status of the panel.
Pay special attention if there is any sign of short circuit for about 5 sec. after power on.
If any of the following symptoms occur, immediately disconnect power and check for problem.
3. Check values displayed on the panel
Check whether each sensor value displayed on the panel is correct.
If any error message is displayed or sensor value is not normal, check sensor connection status.
4. No power operation
Run while the main motor power is off, and check for normal operation to the operation signal of starter panel.
If any error message appears, check the corresponding part.
- Check safety devices
Flow operation test for chilled water and cooling water
Close the valves installed on the cooling water and chilled water pipes to check whether the flow checking switch is
working correctly.
ENGLISH
Check items before operation after long term stop
126
ENGLISH
8. TROUBLESHOOTING
8-1. Causes and actions for alarms
Actions for problems
• How to react to the problem display from controller
• Please take actions according to the following instructions
Check the displayed contents and refer to the help message. Select help menu corresponding to the problem
message and check the contents of the problem and how to react. Remove the cause of the problem according
to the parts or drawing of the circuit related to the problem or manual. If the contents for the problem is no in the
manual or drawing, consult our experts. Check the temperature control status, pressure status, etc.
Troubleshooting (1/3)
Abnormal category
Displayed contents
Chilled Water Inlet
temperature Sensor
Chilled Water Inlet temperature Sensor Error
Cause
Sensor disconnected/short-circuit
Chilled water outlet Chilled water outlet temSensor disconnected/short-circuit
temperature sensor
perature sensor Error
Cooling water inlet Chilled water outlet temSensor disconnected/short-circuit
temperature Sensor
perature sensor Error
Cooling water outlet Chilled water outlet temSensor disconnected/short-circuit
temperature Sensor
perature sensor Error
Compressor discharge Compressor discharge
Sensor disconnected/short-circuit
temperature sensor temperature sensor error
Bearing temperature Bearing temperature senSensor disconnected/short-circuit
sensor
sor problem
Motor winding R phase Motor winding R phase
Sensor disconnected/short-circuit
temperature sensor temperature sensor error
Motor winding S phase Motor winding S phase
sensor
sensor error
Sensor disconnected/short-circuit
Motor winding T phase Motor winding T phase
sensor
sensor error
Sensor disconnected/short-circuit
Evaporator pressure Evaporator pressure senSensor disconnected/short-circuit
sensor
sor error
Condenser pressure Condenser pressure senSensor disconnected/short-circuit
sensor
sor error
Oil tank pressure tem- Oil tank pressure temperSensor disconnected/short-circuit
perature sensor
ature sensor error
Oil pump pressure Oil pump pressure sensor
Sensor disconnected/short-circuit
sensor
error
Current transducer
Current sensor error
Sensor disconnected/short-circuit
Voltage transducer
Voltage sensor error
Sensor disconnected/short-circuit
Action
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
Main board malfunction
Check parts status or wiring
Replace parts or re-wire`
127
Abnormal category Displayed contents
Cause
Sensor disconnected / short
Power transducer Power sensor error
circuit
Compressor dis- Compressor discharge temCompressor discharge temperature perature is detected to be
charge temperature
over set value
high
Action
Main board malfunction
Check parts status or wiring
Replace parts or re-wire
Check compressor discharge temperature displayed on the controller screen.
Check the set value and correct if it is wrong.
Oil tank temperature
Oil tank temperature high
Oil tank temperature is detected to be over set value
Check oil tank temperature displayed on the
controller screen.
Check the set value and correct if it is wrong.
Bearing temperature
Bearing temperature high
Bearing temperature is detected to be over set value
Check bearing temperature displayed on the
controller screen.
Check the set value and correct if it is wrong.
Motor winding
R(S,T) phase temperature
Motor winding
R(S,T) phase temperature high
Check motor coil R(S,T) phase temperature disMotor winding R(S,T) phase
temperature is detected to be played on the controller screen.
over set value.
Check the set value and correct if it is wrong.
Condenser
pressure
Condenser
pressure high
Condenser pressure is detected to be over set value
Motor Winding high Motor Winding high Motor winding high temp.
contact is active
temp. contact
temp. active
Check condenser pressure displayed on the
controller screen.
Check the set value and correct if it is wrong
Check motor winding temp.
Check winding high temp. contact status and
wiring status
Chilled water outlet temp. is
Check chilled water outlet temp. or temp. on
Chilled water outlet Chilled water temp detected to be below set value. the thermometer.
temp
low Error
There is no or small cooling
Check the set value and correct if it is wrong
load
Evaporator
pressure
Evaporator pressure Evaporator pressure is detected to be below set value.
low
Check evaporator pressure displayed on the
controller screen.
Check the set value and correct if it is wrong
Oil differential
pressure
Oil differential
pressure low
Oil differential pressure is detected to be below set value.
Check oil differential pressure displayed on the
controller screen.
Check the set value and correct if it is wrong
Main power
voltage
Main power
voltage problem
Main power voltage is detected to be below set value.
Check the voltage of main power and the voltage set value.
Check the status of the related parts and wiring
Replace parts or repair
Starter panel
abnormal
Start-up failed
Starter panel abnor- Starter panel abnormal, contact is active
mal
Start-up failed
During the start-up 2M magnet switch is not working
Pump interlock signal is disconnected during normal opChilled water pump Chilled water pump eration. Pump stopped
Interlock
Interlock Error
Wrong wiring
IO board malfunction
Pump interlock signal is disconnected during normal opCooling water pump Cooling water pump eration. Pump stopped.
Interlock
Interlock Error
Wrong wiring
IO board malfunction
Check the contact status of the starter panel
and remove the cause of the contact.
Check related parts status or wiring
Replace parts of malfunction or re-wire
Check 2M magnet operating status.
Check the status of the parts or wiring
Replace parts or re-wire
Check parts status or wiring
Replace parts or re-wire
Check parts status or wiring
Replace parts or re-wire
ENGLISH
Troubleshooting (2/3)
128
ENGLISH
Troubleshooting (3/3)
Abnormal category Displayed contents
Vane closed switch Vane is not closed
Condenser high
pressure
Condenser high
pressure contact
active
Cause
Action
Start Vane Close
Switch is open
Check vane closed switch operation status and
wiring.
Adjust position of vane closed switch or re-wire
Condenser pressure is higher
than the pressure switch set
status
Check condenser pressure.
Check condenser high pressure contact status
or wiring
Replace parts or re-wire
Evaporator Refriger- Evaporator refrigerant temp.
Evaporator refrigerant Low Temp Con- is lower than the switch set
ant low temp.
status
tact Activate
Check surge current change amount
Reset the surge protection area
Surge occurred
Surge occurred
Oil pump
Oil pump overload
contact active
Check oil pump overload setting status and
Oil pump current is more than wiring
overload set current
Replace parts or re-wire
Chilled water flow
low abnormal
Flow signal is disconnected
during normal operation.
Pump stopped
Flow (differential pressure)
switch setting problem.
Wrong wiring.
IO board malfunction
Chilled water flow
interlock
Surge occurred
Check evaporator refrigerant temp.
Check evaporator refrigerant low temp. contact
status or wiring
Replace parts or re-wire
Pump interlock signal is disconnected during normal opCooling water flow Cooling water flow eration.
Pump stopped
interlock
low abnormal
Wrong wiring.
IO board malfunction
Correct set value and check
Check parts status or wiring.
Replace parts or re-wire
Check parts status or wiring.
Replace parts or re-wire
Delta contactor
Start-up competed
Delta contactor signal is disopen during operaconnected during operation
signal (2M)
tion
Check parts status or wiring.
Replace parts or re-wire
Evaporator refriger- Evaporator refrigerant temp.
Evaporator refrigerant temp. low temp. is detected to be lower than
ant temp.
set value
problem
Check evaporator refrigerant temp. displayed on
the controller screen.
Check the set value and correct if it is wrong.
Communication
MAIN <-> I/O com- Communication error bemunication error tween boards
Set value is damSensor correction aged. Sensor needs Sensor is not corrected
to be set
Main board
Main board reset
Display device
Display board reset
Check parts status or wiring.
Replace parts or re-wire
Calibration using precision resistance device
Check voltage applied to the controller and
Main board is reset during op- wiring.
eration
Remove cause of noise.
Display board is reset during
operation
Table 61. Troubleshooting
Check voltage applied to the controller
Remove cause of noise.
Check wiring
129
ENGLISH
Remedy for abnormal status
Vane sensor error
Figure 94. Vane sensor
Vane sensor
Release vane sensor connection from the relay board. After converting the tester to the resistance measurement
mode, measure resistance between a and b, and there shall be a certain resistance. And after converting the vane to
manual operation, when the vane is moved, there shall be vane sensor movement and change in resistance value.
Even if the vane sensor is moving but there is no change of resistance value, wiring is wrong or vane sensor is damaged. While vane is completely closed, and opened completely, if the resistance between a and b increases uniformly and resistance between b and c of the vane sensor decreases uniformly, vane sensor is OK. Also measure
resistance between a, b, c, and main body, and it shall not be angle line.
If the vane sensor is normal, re-connect the sensor, completely close the vane, and check if vane value is 0% and
100% after completely opening. If the value changes and vane opening % is wrong, sensor needs to be set again.
If there is no change of value, check if 100% is set in ‘sensor setting-guide vane setting” category, and check if A/D
value sensor value changes when vane moves. If sensor value changes, set vane again.
If sensor value does not change, convert tester to DC voltage 30V measuring position, and when voltage is measured
with + at the point where vane sensor “a” is connected and – at the point where vane sensor c is connected, DC 5V
must be measured.
If the voltage is not correct, check relay board main input power.
If relay main power is normal, vane sensor is normal, and sensor value does not change, then replace relay board.
130
ENGLISH
Temp. sensor(PT-100) problem
A
B
b
Figure 95. Temp. sensor
Release the temperature sensor connection from the controller and after converting the tester to resistance measurement mode, and when resistance between A and B, b is measured, the resistance shall be between 84.27Ω(40°C) and 153.58Ω(140°C). (If you check from PT-100 temperature table, you can find the value corresponding to the
actual temperature) If the resistance value is outside the measurement boundary, connection is wrong or sensor is
damaged. Connect resistance generator(Decade resistance box) to the controller and as changing to 0°C at 100.00Ω,
10°C at 103.90Ω, and 28°C at 110.9Ω, check if the temperature displayed on the controller changes according to the
change of the resistance. If normal value is not displayed on the screen, check if the sensor is set correctly.
If the sensor value does not change when the resistance value is changed, check the main power of the main board
again, and if 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
490
277.64
-150
39.72
70
127.08
290
208.48
500
280.98
-140
43.88
80
130.9
300
212.05
510
284.3
-130
48
90
134.71
310
215.61
520
287.62
-120
52.11
100
138.51
320
219.15
530
290.92
-110
56.19
110
142.29
330
222.68
540
294.21
-100
60.26
120
146.07
340
226.21
550
297.49
-90
64.3
130
149.83
350
229.72
560
300.75
-80
68.33
140
153.58
360
233.21
570
304.01
-70
72.33
150
157.33
370
236.7
580
307.25
-60
76.33
160
161.05
380
240.18
590
310.49
-50
80.31
170
164.77
390
243.64
600
313.71
-40
84.27
180
168.48
400
247.09
610
316.92
-30
88.22
190
172.17
410
250.53
620
320.12
-20
92.16
200
175.86
420
253.96
630
323.3
-10
96.09
210
179.53
430
257.38
640
326.48
0
100
220
183.19
440
260.78
650
329.64
10
103.9
230
186.84
Table 62. PT-100 Temp. Table
131
ENGLISH
4mA~20mA, 2-line type sensor, controller power used.
Check if the wiring between sensor and controller is properly connected.
4~20mA current input sensor problem
occurred (pressure sensor)
Check if the setting value is properly set in
sensor setting menu for 20mA.
N
Is it properly set?
Set the setting
value again.
Measure current of the circuit.
(Refer to Figure 99.)
N
Is the wiring properly
connected?
Wiring defect
Y
Y
Is there current proportional to the
measurement value?
Master board / slave board
/display board error
N
Measure the current of the sensor
(Refer to Figure 100.)
N
Is the current of the
sensor normal?
Sensor Error
- Check subsidiary power
- If subsidiary power is normal,
replace the sensor
Y
Check if the wiring between sensor
and controller is properly connected.
Figure 96. Pressure sensor
132
ENGLISH
Pressure sensor
(+)
(-)
(+)
DC24V
(-)
(+)
Controller board
Figure 97. Current loop measurement circuit
- Place at DC 30V
- The measurement shall
be within DC 22V±5%
(+)
DC24V
(-)
(+)
Controller board
Figure 98. Controller voltage measurement circuit
Even if the inspection was carried out as above, if the cause couldn’t be found, connect current generator to the
input connector(DC24V and (+)) of the controller and check if the indicator value changes according to the change of
the current.
In such case, if the controller indicator value does not change according to the change of the current, it shall be decided as controller defect.
133
ENGLISH
Current sensor
(-)
(+)
- Place at DC30mA
- Measurement shall
be between
4~20mA
(-)
(-)
- Place at DC30mA
- Measurement shall
be between
4~20mA
(+)
(-)
(+)
(-)
(+)
(+)
Controller board
Figure 99. Pressure sensor
Current sensor
Figure 100. Current sensor measurement circuit
Digital input signal is not checked by the controller.
If the no voltage contact signal is properly input to the digital input of the controller but controller finds it as abnormal
or if there is no change of all digital input signals, it is because of the defective connection of I/O board power connector or no communication between I/O board and main board.
Check communication line connection status between I/O board and main board, and it there is no problem, short-circuit the connector of the wiring among the controller digital inputs that does not work to COM connector (23, 24) of
controller I/O board to check whether LED LAMP corresponding to the I/O board input connector is lighted.
Select “menu key” – “system information” – “I/O input” of the controller display, short-circuit/open abnormal connectors and COM connector to see if input status changes to “ON”/”OFF”.
When DC voltage between COM connector of the controller digital input and the wire released digital input, check if
18V is measured.
If there is no problem, connect them again and check operation.
If the corresponding board main power and communication is normal and I/O input still does not work the board
needs to be replaced.
Check by referring to the below flow chart and tester connection diagram.
134
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Digital input problem
Connect tester to the digital input channel with
problem as in Figure 102,
and see if the input is normal.
N
Is input normal?
Check normal operation of related wires
and input sensor.
Y
Check controller power
connector connection status.
N
Is connector
connection normal?
Connect the
cable firmly
again.
Y
N
Is it properly connected?
Replace I/O board.
Y
Measure voltage of the controller.
(refer to Figure 103.)
N
Y
Is the main power of
controller normal?
Is I/O board voltage
normal?
N
Y
Check communication connection
status between master board and
slave board.
Replace main board.
Figure 101. Digital input problem
135
ENGLISH
D/I input
(-)
Com connector(23/24)
- Place at DC30V
- If D/I input is open, measured
voltage is within 18V±5%.
- If D/I input is closed, measured
(+)
voltage becomes 0V.
Corresponding input connector
Master or slave board
Figure 102. The current measurement circuit for master or slave board
- Place at DC30V
- Measured voltage shall be within
18V±5%.
Com connector(23/24)
Corresponding input connector
Master or slave board
Figure 103. The current measurement circuit for master or slave board
Communication error
It is the error caused by no communication corresponding to the displayed message is made between each board.
First, check communication line connection status between each board. At this time, 2 RDX+ and RDX- lines of master board shall be connected to the same polarity of RDX+ and RDX- of slave board and relay board, and 2 RDX+ and
RDX- of master board shall be connected to the same polarity. If it is not properly connected to the corresponding
communication connector, communication cannot be made, so it must be connected to the designated connector.
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Abnormal rise of condensing pressure (cause of surge)
Status
Decision
criteria
Cause
1. Air is mixed into machine
Temperature dif2. Tube contaminated
ference between
cooling water
Above 3°C 3. Insufficient cooling water amount
outlet and con4. Air taken in from cooling water pump
densing is large.
intake
Condensing
pressure is high
9.5 kg/cm
or more
2
1. High Temp. Cooling water ▷ Lower the
performance of cooling tower
2. Chilled water high temp.
3. Cooling water bypass in waterbox
4. Tubes contaminated
Chilled water
temperature is
normal. However
1. Cooling water amount decreased
the temperature Check
difference bechiller data 2. Air taken in from cooling water pump
tween the inlet
sheet
intake
and outlet of
cooling water is
large.
Remedy
1. Clean tube
2. Check cooling water system and increase to specified amount
3. Enhance pump intake
1. Check cooling tower performance
2. Lower chilled water temp.
3. Replace gasket in waterbox
4. Clean tube
1. Check the cooling water system and
increase to specified amount
2. Enhance pump intake
Table 63. Master or Slave board current measurement circuit
Abnormal drop of evaporator pressure (cause of surge)
Status
Decision
criteria
Cause
Remedy
Evaporating
pressure is low
and chilled water inlet/outlet temperature difference is small
1. Butterfly valve adjustment defect
2. Insufficient chilled water amount
3. Tube contaminated
4. Insufficient refrigerant amount
1. Butterfly valve opening adjustment
2. Check chilled water system (flow)
3. Clean tube
4. Recharge refrigerant
Difference between evaporating temperature Above 3°C
and chilled water
outlet temperature is increased
1. Insufficient charging of refrigerant
2. Contamination of refrigerant
3. Decreased chilled water amount
4. Air mixed in chilled water
5. Chilled water bypass in waterbox
6. Tube contaminated
1. Add refrigerant
2. Clean refrigerant
3. Check chilled water system and increase to specified amount
4. Enhance chilled water pump intake
5. Replace gasket in waterbox
6. Clean tube
Table 64. Cause and Action for drop of evaporating pressure
137
Status
Oil pressure is
low
Oil temp. is high
in oil tank
Rapid change of
oil pressure
Oil tank temp. is
low
Oil in oil tank increased when it
is stopped
Decision
criteria
(Oil discharge
pressure –
oil tank
pressure)
< 1.3
kg/cm2
Cause
1. Oil filter clogged
2. Insufficient oil
3. Pressure transducer defect
4. Oil pump defect
Remedy
1. Oil filter cleaning or replacement
2. Recharge oil
3. Change transducer
4. Check if oil supply valves are closed
5. Check if oil temp. is low
74°C or
more during operation
1. Oil is not sufficiently supplied to bearing
2. Oil heater setting value defect
3. Refrigerant is not sufficiently supplied
to oil cooler
4. Excessive oil amount
5. Bearing abrasion
1. Adjust oil pressure, and check oil filter,
oil system.
2. Adjust set value
3. Check condensed refrigerant amount
and filter drier.
4. Remove oil to make it adequate
amount
5. Need disassembly and repair
-
1. Oil manometer defect
2. Oil pump cavitation
3. Insufficient oil
1. Change manometer
2. Apply power to oil heater
3. Recharge oil
Below
30°C
1. Oil heater fuse disconnected
2. Oil heater disconnected
3. Black out for long time, power unit
stopped
1. Replace fuse
2. Replace oil heater
3. Wait until oil tank temperature meets
the specified temperature. And if it
does not rise, contact LG service personnel.
1. Oil temperature is too low and oil is
dissolved by solvent.
1. Check whether oil heater is disconnected.
2. Make sure the oil heater is on when
the chiller unit shut down for longterm.
-
Table 65. Cause and action for problem in lubrication system
ENGLISH
Problem in lubrication system
138
ENGLISH
Others
Status
Compressor discharge temp. is
low
Decision
criteria
Cause
Remedy
-
1. Intake of fluid refrigerant
1. Extract adequate amount
of refrigerant
Motor overload
-
1. Chilled water inlet temp. is high
2. Intake of liquid refrigerant
3. Intake of oil
4. Condenser high pressure
5. Gauge defect
1. Adjust chilled water temp. set value
2. Extract refrigerant
3. Regenerate refrigerant
4. Refer to 6-2-1
5. Change gauge
Abnormal vibration, current vibration
-
1. Oil pressure is higher than specification 1. Adjust to specified pressure
2. A lot of fluid refrigerant intake
2. Extract refrigerant
3. Bearing gap is big
3. Disassembly and inspection
Abnormal sound
in compressor
main body
-
1. Contact of the rotating part
2. Bearing abrasion, damage
1. Need to disassemble and repair
2. Need to disassemble and repair
Abnormal sound
-
1. Noise transferred from cooling water
and chilled water pipe
2. Guide vane assembly defect
3. Isolation device defect
1. Apply flexible join and spring isolator in
the pipes
2. Reassemble or replacement
3. Replace isolator device
Moisture indicator turns yellow
during operation
-
1. Moisture is 30ppm or more
2. Moisture indicator defect
1. Drain moisture in the machine
2. Replace moisture indicator
-
1. Condensing pressure is high
2. Evaporating pressure is low
3. Gauge defect
1. Refer to 6-2-1
2. Refer to 6-2-2
3. Replace gauge
1. Shaft stop bolt is not tightened
1. Tighten stop bolt clockwise and check
leakage
Insufficient chilling capability
leak in shaft part
capacity adjust- ment device
Table 66. Cause and countermeasure for chiller problems
139
ENGLISH
9. OPERATION INSPECTION RECORD
9-1. Check list for operation record
Operation record table
MODEL :
Manufacture NO. :
R-134a (1-level/2-level), R-123
Measurement Category
Chilled
water
Cooling
water
Outlet pressure
kg/cm2
Inlet temp.
°C
Outlet temp.
°C
Pressure
Refrigerant temp.
Oil
Others
4
5
6
7
8
:
:
:
:
:
:
:
:
°C
Outlet pressure
kg/cm2
Inlet temp.
°C
Outlet temp.
°C
m3/h
kg/cm2
°C
TANK pressure
kg/cm2
PUMP pressure
kg/cm2
Differential pressure
kg/cm2
Temp.
°C
Current limit value
%
Operating current
A
Winding temp.
CompresTemp. of Bearing
sor
Discharge gas temp.
3
kg/cm2
kg/cm2
Refrigerant temp.
2
m3/h
Inlet pressure
Pressure
1
2
kg/cm
Cooling W. Flow
Condenser
Hour:Min.
Inlet pressure
Chilled water flow
Evaporator
Unit
°C
°C
°C
Vane opening
%
Diffuser opening
%
1. Chiller start time
2. Chiller stop time
3. Maintenance issues
Table 67. Operation record table
4. Operation time
5. Number of start-ups
6. Moisture indicator color
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