Installation, Operation, and Maintenance
Koolman Air-Cooled Chiller and Heat pump R410A
SAFETY WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment.
March 2014
PKGP-SVX03A-EN 500002250200
Warnings, Cautions and Notices Important tips: This manual belongs to the client and shall be used with the water chiller. After the completion, please put it back into the technical information kit.
WARNING: Before the installation or maintenance, the power supply and disconnecting switch of the water chiller shall be kept in de-energized status to avoid injury or death due to the electric shock or touch of a moving part. All installation procedures of the air conditioner must conform to the national, provincial and local regulations. Before the installation of the air conditioner, please carefully read this manual. Please install and maintain the water chiller according to this manual to ensure the air conditioner can operate properly and reliably. The installation of the air conditioner must be completed by the professional personnel appointed by Trane. This manual does not aim to summarize the differences of all the water chillers or any possible problem in the installation. If the buyer needs further information or has any special problem, please contact the local sales offices of Trane.
NOTICE: There may be warnings and cautions in this manual if applicable. In order to ensure personal safety and proper operation of the water chiller, please adhere to this manual carefully. The manufacturer will not be liable for the installation or maintenance performed by the unqualified personnel.
CAUTION: This machine works on R410 refrigerant. Charging of non-qualified refrigerant would damage the compressor & will be very DANGEROUS. So please charge machine with correct refrigerant. Or call customer care for help about purchasing the correct refrigerant.
2
PKGP-SVX03A-EN
Table of Contents Model Nomenclature ………………………………………………………………………………………5 Unit Outline and Dimension ………………………………………………………………………………7 A. Mini type: CGAK/R-0305R/0306R/0505R/0605R …………………………………………………7 B. Mini type: CGAK/R-0755R …………………………………………………………………………8 C. Standard type: ………………………………………………………………………………………9 D. Standard type: Unit Installation
……………………………………………………………………………………10
…………………………………………………………………………………………11
Handling ………………………………………………………………………………………………11 Please check the following items before installation ……………………………………………12 Arrival ………………………………………………………………………………………………12 Installation position ………………………………………………………………………………12 Water supply pipe
………………………………………………………………………………12
Pressure water tank system …………………………………………………………………………17 Electric water heater …………………………………………………………………………………18 Electric Specifications ……………………………………………………………………………………19 Electric wiring …………………………………………………………………………………………19 Power supply of the water chiller
…………………………………………………………………19
Electric Circuit Diagram …………………………………………………………………………………21 CGAR/K0305R*/0505R*/0605R* circuit diagram …………………………………………………21 CGAR/K0306* circuit diagram ………………………………………………………………………22 CGAR/K0606R* circuit diagram ……………………………………………………………………23 CGAR/K0755R* circuit diagram ……………………………………………………………………24 CGAR/K1005R*/1205R*/1505R*/2005R* circuit diagram ………………………………………25 Preparations before Starting ……………………………………………………………………………26 Voltage range …………………………………………………………………………………………26 Voltage unbalance ……………………………………………………………………………………26 Water flow ………………………………………………………………………………………………26 Water pressure drop …………………………………………………………………………………26 Items to be checked before starting ………………………………………………………………27 Jumper settings
……………………………………………………………………………………30
Dial switch settings
…………………………………………………………………………………30
System bit settings
………………………………………………………………………………… 31
Operation parameter settings ………………………………………………………………………31 Running Operation of the Water Chiller ………………………………………………………………32
PKGP-SVX03A-EN
3
Table of Contents Start procedures
……………………………………………………………………………………32
Long-term shutdown
………………………………………………………………………………32
Restart this system after Long-term shutdown
…………………………………………………33
System protection ……………………………………………………………………………………33 Low voltage protection (LP1, LP2)
…………………………………………………………33
High voltage protection (HP1, HP2)
…………………………………………………………33
Antifreezing function in winter …………………………………………………………………33 Antifreezing of plate type heat exchanger ……………………………………………………33 High voltage protection of plate type heat exchanger
……………………………………33
Overload protection of motor …………………………………………………………………33 Flow protection
…………………………………………………………………………………34
Running operation of the water chiller ……………………………………………………………34 Temperature probe (TH1) ………………………………………………………………………34 Controller
…………………………………………………………………………………………………35
Material object of wire controller
…………………………………………………………………35
Schematic diagram ……………………………………………………………………………………35 Instructions of control panel and display …………………………………………………………36 Control panel ………………………………………………………………………………………36 Display panel ………………………………………………………………………………………36 Operation instruction of the panels ……………………………………………………………36 Functional description…………………………………………………………………………………38 Temperature control in the refrigeration status
……………………………………………38
Single compressor control …………………………………………………………………38 Double compressor control
………………………………………………………………38
Temperature control in the heating status
…………………………………………………39
Single compressor control …………………………………………………………………39 Double compressor control
………………………………………………………………39
Compressor protection time-delay function …………………………………………………39 Electric heating control …………………………………………………………………………39 Failure analysis and handling method ……………………………………………………………40 Failure alarm table of controller …………………………………………………………………40 Failure analysis and handling method …………………………………………………………41
4
PKGP-SVX03A-EN
Model Nomenclatures C
G
A
R
0
5
0
5
R
B
N
A
R
R
N
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Digit 1,2,3
CGA = Air-Cooled Chiller and Heat Pump
Digit 4
Model K = Cooling Only R = Heat Pump
Digit 5,6,7
Digit 8
Model 030
100
050
120
060
150
075
200
Power Supply 5 = 380V/50Hz/3ph (For Model 030,050,060,07 5,100,120,150,200) 6 = 220V/50Hz/1ph (for 030 with single compressor and 060 with double compressors)
Digit 9
Manufacturing Code (defaulted by factory) R = R410A
Digit 10
Control B=Microprocessor- based adjustable water temperature controller
Digit 11
Water Side Electric Heater N=None
Digit 12
Service Sequence A=The first time
Digit 13
Water Pump for Unit R=With Pump inside (standard) N=Without Pump
Digit 14
Applicable Ambient Temperature R = Standard ambinent temperature/Blue-fin
Digit 15
Fitting Options N = None (Standard Unit)
Digit 16
Other option B = Export
PKGP-SVX03A-EN
5
Dimensions Mini casing
393
402
CGAK/R-0305R/0306R/0505R/0605R (Unit: mm)
Mini-Koolman
647
Ø1"Water outlet
740
1285
Ø1"Water inlet
90 186
670 950
393
402
CGAK/R-0705 R (Unit: mm)
1590
Mini-Koolman
1 1/4 Water inlet
90
1 1/4 Water outlet
732 824
186
670 950
6
PKGP-SVX03A-EN
Dimensions
Standard casing
500
CGAK/R-0606R/1005R (Unit: mm)
1290
900
580
155 120
50
99
1000
1900
TM
75 500
Power cable inletØ40 FPT 1 1/4"B Water inlet FPT 1 1/4"B Water outlet
Drain waterFPT 1/2" B
500
CGAR/K-1505R (Unit: mm)
580
TM
TM
1000
1900
900
1990
120
50
90
985
Ø40 Drain water 125
FPT 1/2" B FPT 1-1/4"B FPT 1-1/4"B
PKGP-SVX03A-EN
500
Water inlet Water outlet
7
Dimensions
500
CGAR/K-1505R (Unit: mm)
580
TM
TM
TM
TM
1000
1900
900
1990
120
50
90
985
Ø40 Drain water 125
FPT 1/2" B FPT 1-1/4"B FPT 1-1/4"B
500
Water inlet Water outlet
500
CGAR/K-2005R (Unit: mm)
490.0000
580
1990 1990
1900
900
90
985
1000
120
50
125
Ø40 Drain water
8
FPT 1/2" B FPT 1-1/2"B FPT 1-1/2"B
500.0000
Water inlet Water outlet
PKGP-SVX03A-EN
Unit Installation Handling Please use the forklift with proper capacity tonnage to transport and handle, for weight of each model please refer to reference table 1. Table 1. Model 0305R 0306R 0505R 0605R 0606R 0755R 1005R 1205R 1505R 2005R
The maximum net weight (kg)≈ 130 131 141 149 320 202 449 530 530 540
Please install the water chiller at a place with well drainage facilities to facilitate massive drainage during shutdown or repair. Please use the forklift with proper capacity tonnage to move this water chiller to its installation position. During lifting work, please use canvas sling, which shall be wrapped across the water chiller pedestal and tied tightly, as shown in Figure 1.
Cliver
Protection Protection Tape
Protection Protection
Tape
sling sling Base
Figure 1. Hoisting diagram
PKGP-SVX03A-EN
9
Unit Installation
Check the following items before installation As received If the content of the machine's name plate is the same as that of the order. • If there is any damage or material shortage during transportation of the unit; if yes, please notify the deliverer timely.
Installation position • If there is adequate ventilation available at the installation position. • If drainage facilities are installed for handling the seeper at the pedestal. • Unpack the water chill er and dispose the packing materials (such as paperboard, prospective film and etc.). • If there are enough repair passages available. • Fit springs or rubber shockproof gaskets. • Fix the unit in its installation position. • Adjust the levelness of the water chiller. Adoption of the following water chiller fixing methods can minimize the noise of the water chiller: • Install the unit on an independent concrete foundation. • Fit spring or rubber shockproof gasket at each fixing foot. For overall dimension of the water chiller and the dimension of the foundation, please refer to Figure 2. For recommended minimum maintenance space, please refer to Figure 3.
CGAR(K)0606R/1005R
CGAR(K)1205R/1505R/2005R 150
1630
640
450
640
30
30
40
40
850
2330
1630
CGAR(K)0305R/0306R/0505R/0605R/0755R 640
402
393
950
10
Figure 2. Installation dimensions
PKGP-SVX03A-EN
740
740
640
496
730
496
450
640
Unit Installation Unit: mm
1500
500
Air Direction
Mini-Koolman
300
500
300
Figure 3. Service and Maintenance Space Requirement
Water supply pipe Evaporator piping: • Clean out all cold water piping. • Connect the evaporator piping. • Exhaust the air in the cold water system at the highest point of this system piping. • Install pressure meters, temperature meters and valves at the inlet piping and outlet piping. • Install strainer at the inlet piping of evaporator, mesh number of the strainer screen shall be equal to or more than 40 meshes. • Install balance valve and flow switch at the outlet.
NOTICE: If commercial acidic cleaning agent is used, a temporary bypass tube shall be set at the side of the water chiller for prevention of damage to evaporator. Please do not use untreated or improperly treated system water supply to avoid damage to machine. For installation positions of each typical accessory on water supply piping of the water chiller, please refer to Figure 4. Piping assembly may be changed depending on positions of joint and water supply. For installation diagram of typical system piping, please refer to Figure 5.
CAUTION: • To avoid damaging the water chiller, the piping for system water shall not be fitted reversely. The water inlet tube must be connected to the inlet connector indicated by "water inlet". The water outlet tube must be connected to the outlet connector indicated by "water outlet". • Exhaust valve shall be set at the highest point of the piping, in order to exhaust the air in the cold water system.
CAUTION: • Water the pressure of the evaporator shall not be more than 0.5MPa (i.e. maximum operation pressure) to avoid damage of the parts at the cold water side of the water chiller. • The return water temperature of heating shall not be set more than 40℃; otherwise, the compressor will not be exchanged as per the Three Guarantees. • Before the final piping connection of the water chiller, all external water supply piping systems shall be washed thoroughly. Any impurity mixed in the piping system is strictly forbidden; otherwise, we will assume no liability for any consequence so incurred.
PKGP-SVX03A-EN
11
Unit Installation
Make-up water
Expansion tank
Water intake Oil-return inlet Manual gate valve Automatic air vent
Manual gate valve
Balancing valve ball valve
Thermometer
Filter
Flow switch Shockproof hose
Manometer
Shockproof gasket
Water intake Water outlet
Figure 4. Installation diagram for typical piping accessories (the model of this diagram is CGAR100)
12
PKGP-SVX03A-EN
Unit Installation
Make-up water FCU=3
Tee valve
FCU=2
FCU= 1
FCU=6
Water drainage FCU=5
Direct return FCU=4
Manual gate valve Reversed return
Thermometer Flow switch Shockproof hose Manometer
Figure 5. Installation diagram for typical system piping (the model of this diagram is CGAR100)
Pressure water tank system This system is used for adjustment of water pressure and amount in the water loop. Please install one manual shut-off valve at each side of the system during installation to facilitate future maintenance. Please refer to Figure 6 for the detailed installation mode. F
A
H
D
G
E
C
B
water intake (Ø12.7mm)
Dimension Model
PKGP-SVX03A-EN
A
inlet/outlet (Ø12.7mm)
water drainage (Ø12.7mm)
B
C
D
E
F
G
H
wtank-5
470
263
230
132
254
435
415
455
wtank-12
620
400
324
162
356
569
440
475
13
Unit Installation
Electric water heater Fan coil X4
Primary Unit
pressurised water tank
Makeup water valve Tap water
water strainer
Automatic air vent Drain Valve Water drainage
P
Direct return
Reversed return
P
Shockpro of hose
flow switch Thermometer
Electric heater
Shut-off
Note: the automatic exhaust valve shall be set at the highest point of the piping
Figure 6. detailed installation mode.
Principle description 1. A pressure water tank shall be added in the piping system to avoid pipe rupture resulting from overpressure of piping due to ambient temperature fluctuation and to prevent air hammer generated in the pipe. 2. To avoid overpressure or underpressure in the pipe, a makeup water valve and a drainage valve shall be added; when the pressure is lower than 0.6bar, the makeup water valve will open to make up water automatically; and the drainage valve will open to drain water automatically while the pressure is more than 5bar.
14
PKGP-SVX03A-EN
Electrical Electrical wiring • Connect the power wiring to the terminal block (TB) of the water chiller distribution cabinet. • Connect the control panel (installed indoor) and the master control board of the primary water chiller with connecting line of control panel. • If the model is the one without water pump, please connect the power wiring of the cold water pump to the corresponding terminal of the pump. • Earth the water chiller, cold water pump's motor (the model without water pump) and all devices needing to be grounded. • If the electric heater is equipped, connect the power wiring and the control wiring on Terminal TB2 of the electric heater. • If the fan coil two-way valve will be used for interlocking, jumper JP6 on the control panel shall be disconnected on site, and connect the interlocking point (dry contact) to the point between the control terminals 12 and U. • Connect the flow switch to the point between connecting terminals U (or L) and 15 of the water chiller control box.
WARNING: Before completion of electric wiring, please do not supply power to avoid possible injury or death.
CAUTION: • Only copper conductor can be used for connection to the terminals, to avoid corrosion or overheat. For minimum current, fuse specification and electrical specifications of motor, please refer to Table 2.
Power supply of the water chiller Please refer to the wiring diagram on the cover plate of the water chiller control box; the installation unit shall supply power with proper voltage and provide a suitable breaker to the water chiller. For typical installation wiring diagram of the water chiller, please refer to Page 20~24. For the actual wiring diagram, please refer to the diagram on the cover plate of the control box.
NOTICE: • The voltage of the power supply shall change within ±10% of the standard value.
PKGP-SVX03A-EN
15
Electrical
Electrical specifications -50Hz Full load current of water pump FLA(A)
Full load current of chiller unit FLA(A)
Rated current of the fan RLA(A)
Minimum Recommended Maximum current of the fuse specification water unit specification of the fuse circuitMCA(A) REC(A) FMS(A)
Minimum specification of the power supply copper core wire diameter (mm2)
MODEL
Power supply (V/Hz/Ph)
0305R
380-415/50/3
1.1
8.6
1
12.85
15
21.45
4
0306R
220/50/1
2.4
25.6
1
35.4
41.8
61
10
0505R
380-415/50/3
1.1
9.6
1
14.1
16.5
23.7
4
0605R
380-415/50/3
1.1
13
1
18.35
21.6
31.85
6
0755R
380-415/50/3
1.4
14
1.5
20.4
23.9
34.4
6
0606R
220/50/1
2.4
51.2
4.8
63.5
71.2
85.6
16
1005R
380-415/50/3
1.4
16.4
1.6
23.5
27.6
39.9
6
1205R
380-415/50/3
3.26
22.4
3.2
34.46
40.06
58.5
10
1505R
380-415/50/3
2.6
24.6
8.4
41.75
47.9
61.15
10
2005R
380-415/50/3
3.2
26.6
8.4
44.85
51.5
68.7
16
• The difference between the power voltage and the standard voltage shall not exceed 10 percent of the standard value. • Rated current(RLA)=the current of the machine under the ARI or UL standard conditions • Minimum circuit current(MCA)=maximum loadx1.25+sum of the extra load (to decide the diameter of the wire) • Recommended fuse specification(REC)=maximum loadx1.5+sum of the extra load (to select the fuse closest in specification) • Maximum fuse specification(MFS)=maximum loadx2.25+sum of the extra load (to select the fuse same or smaller in specification)
NOTICE: Scroll compressor is adopted in 380V water chiller and power reverse-phase & open phase protection controllers are installed in the water chiller, so the water chiller shall be energized for inspection before starting. If the green light of the phase sequence control in the electric control box brightens, the phase sequence is correct. If the red light brightens, it means reverse phase, and any two phases of the power line shall be exchanged with each other. If the yellow light brightens, it means open phase and it is necessary to cut off the electricity for inspection. If the reverse phase or open phase appears, the water chiller will automatically stop running or starting.
16
PKGP-SVX03A-EN
MP MC MF CCH COMP Cfr HEAT A-HT PUMP FUN AL-OUT/IN N-COM
Name
30
MC
BK
RD
RD
C B A
BL
BL
Description
BK
＃ M ２ 1～ FAN
3
Factory wiring
On-site wiring
Outer Cool/Heat Pump Setting
Reversing Valve
Terminal Blocks
Low pressure switch
High pressure switch
Compressor Overload
Pump Overload
Energy Saving/2-Way Valve Interlock Flow Switch
Common Neutral Line
EN-SAVE FLOW OV-PUMP OV-COMP HP LP TB 4WV C/H
Name
RFS
RD
RD
C0MP
PUMP
Alarm Output/Input
Fan Motor
Water Pump
Water Circuit Based Electrical Heating Control Plate Heat Exchanger Heater
Fan start capacitance
Compressor
Crankcase Heater
Fan Motor Contactor
Compressor's Start Contactor
Chiller's Water Pump Contactor
M 3～
M 3～
option
＃ M 1 1～ FAN
R
RD (L1)
WH(L2)
T S
RD
WH
YL
YL (L3)
OVP
TO CONTROL WIRING
U
CCH
Description
N
N
V
MF
MC
MP
(11)
RFS
(14)
L
Transformer
N
RD
R
CN2
CN6
3
4MV
8
N
AL
TH4 CN4
N
OVP
LP1
22
FLOW
C/H
EG-SAVE
3
CN1 B AGND+12V
main controller (option)
Communication with other units
21
20
U
16
15
U
25
12
power supply of the main controller
ABG
LP1
ACD_OD_CO2 TH3
OV-FAN HP1
TH2
OV-PUMP
FLOW
OV-COMP
(one compressor)
TH1
SW2
N-COM EN-SAVE OV-HEAT
Alarm indicator
11
3
MF
SW1
7
MP
6
4
6
Microprocessor control board
Control panel (Indoor installation)
WH
CN1
N
L
1
MC
3
CGAR/K0605R* CGAR/K0505R* CGAR/K0305R*
For all fault inputs.the unit is normal when power on and gives an alarm when power off. The flow switch in the on-site installation is connected to between terminal U and terminal 15. Single unit the pump is optional,if customer provide pump,each unit can use digital output 7 to control it , while remove the wire jumer between terminal U and 22,connection to the pump protection signal. 4. If use 2-valve inerlock,please dial SW2-7 to "ON". TRANE P/N 500003080100 Control panel and main controller are optional. 5. 1. 2. 3.
Description
Neutral wire
AC 220V～
U
water inlet sensor
Live wire
HP1
Auxiliary plate heat electrical exchange heater electrical heater
4WV A-HT
water outlet sensor suction sensor
U V W
COMP HEAT
cooling only not have
PUMP
Defrost sensor
TB1
N
FAN cooling only not have defrost sensor
Wiring Diagram
AL_IN
PKGP-SVX03A-EN AL_OUT
380V～/50Hz/3Ø～N
Wiring Diagram The following circuit diagrams are only for reference, and the supplied circuit diagram shall prevail.
CGAR/K0305R*/0505R*/0605R*
17
L
L
N
MP MC MF CCH COMP Cfr HEAT A-HT PUMP FUN AL-OUT/IN N-COM
Water Pump
Plate Heat Exchanger Heater
Water Circuit Based Electrical Heating Control
Fan start capacitance
Compressor
Crankcase Heater
Fan Motor Contactor
Compressor's Start Contactor
Description
Chiller's Water Pump Contactor
Name
Common Neutral Line
Alarm Output/Input
Fan Motor
BK
CCH
MF
MC OL
YL
YL
MC
Cfr1
RD
RD
WH
Cr1
RD
YL
RD
BL
BL
M 1～
M 1～
M 1～
EN-SAVE FLOW OV-PUMP OV-COMP HP LP TB 4WV C/H
Name
BL
BL
BK
M 1～
On-site wiring
Factory wiring
Outer Cool/Heat Pump Setting
Reversing Valve
Terminal Blocks
Low pressure switch
High pressure switch
Compressor Overload
Pump Overload
Flow Switch
Description
Cfr2
＃
Energy Saving/2-Way Valve Interlock
FAN
1
COMP
PUMP
option
＃
4. 5.
1. 2. 3.
RD
L
Transformer
N
R
CN2
CN1
CN6
3
3
4MV
6
4
6
7
MP
8
11
3
MF
SW1
N
AL
Alarm indicator
TH1
TH2
TH3
TH4
N-COM
N
22
21
20 LP1
FLOW
L
15 16
C/H OL
18
EG-SAVE
25
12
3
CN1 B AGND+12V
main controller (option)
Communication with other units
LP1
OV-FAN HP1
OV-PUMP
FLOW
OV-COMP
EN-SAVE OV-HEAT
CGAR/K0306R*
power supply of the main controller
ABG
CN4
Microprocessor control board (one compressor) ACD_OD_CO2 SW2
1
MC
Control panel (Indoor installation)
WH
N
L
HP1
For all fault inputs.the unit is normal when power on and gives an alarm when power off. The flow switch in the on-site installation is connected to between terminal U and terminal 15. Single unit the pump is optional,if customer provide pump,each unit can use digital output 7 to control it , while remove the wire jumer between terminal U and 22,connection to the pump protection signal. If use 2-valve inerlock,please dial SW2-7 to "ON". Control panel and main controller are optional. TRANE P/N 500003080200
Description
FAN
２
AC 220V～ L
water inlet sensor water outlet sensor suction sensor
Live wire Neutral wire
Auxiliary plate heat electrical exchange heater electrical heater
COMP HEAT
cooling only not have
4WV A-HT
Wiring Diagram
PUMP
Defrost sensor
MP
TO CONTROL WIRING
N
L
FAN cooling only not have defrost sensor
TB1
N
AL_IN
18 AL_OUT
220V～/50Hz/
Wiring Diagram
CGAR/K0306*
PKGP-SVX03A-EN
RD
BK
RD
BK
OL2
Description
Common Neutral Line
N-COM EN-SAVE RUN-OUT/IN C/H
Outer Cool/Heat Pump Setting
Run Output/Input
Energy Saving/2-Way Valve Interlock
Alarm Output/Input
Fan Motor
Water Pump
Plate Heat Exchanger Heater
Water Circuit Based Electrical Heating Control
Compressor
Crankcase Heater
Fan Motor Contactor
Compressor's Start Contactor
Chiller's Water Pump Contactor
RD
BK
WH
YK
BL
YK
BL
C S R
C S R
M 1~
OVF HP LP TB 4WV OL
OV-COMP FS OVP
Name
BK
Cfr
RD
Cr2
RD
Cr1
YK
YK
OL1
CCH1
MC1
MF
MC2
RD
BK
MC1
YK
TO CONTROL WIRING
L N
L N
AL-OUT/IN
MP MC MF CCH COMP HT/EV1 A-HAT PUMP H/FAN
Name
MP
BK
RD
option
3
FAN MOTOR
COMP2
COMP1
On-site wiring
Factory wiring
OVerload
Reversing Valve
Terminal Blocks
Low pressure switch
High pressure switch
Fan Overload
Pump Overload
Flow Switch
Compressor Overload
Description
CCH2
MC2
M 1~
M 1~
M 1~
PUMP
Cpr
Transformer
R
RD
2
CN6
CON2
CON1
(Indoor installation)
6
7
MP
8
MF
3
N 10
N 11
RUN
AL
TH2 TH3
TH5
TH4
ACD_OD_CO1
TH6
(Two compressors)
Microprocessor control board
SW1
5
TH1
SW2
4
4WV2
4WV1
3
Control panel
WH
N
L
1
MC2
MC1
6
AL_OUT
LP1
HP1
OV-COMP2
OV-FAN OV-COMP1
OV-PUMP
FLOW
HP2 LP2
C／H
N
21
20
CN1 B AGND+12V
3
Communication with other units
YL
YL
maincontroller(option)
LP1
OL2
OVF1
19
22
LP2 FS
OL1
YL
YL
C/H
EG-SAVE
18
17
16
15
14
13
25
12
power supply of the main controller
ABG
CN4
N-COM EN-SAVE
CGAR/K0606R*
Description 1.For all fault inputs.the unit is normal when power on and gives an alarm when power off. 2.The flow switch in the on-site installation is connected to between terminal U and terminal 15. 3. Single unit the pump is optional,if customer provide pump,each unit can use digital output 7 to control it, while remove the wire jumer between terminal U and 22,connection to the pump protection signal. 4.If use 2-valve inerlock,please dial SW2-7 to "ON". 5. Control panel and main controller are optional. 500003100100
N
HP1
RD
HP2
COMP1
L
COMP2
Live wire Neutral wire
HE/EV1
TB1
3
water outlet sensor
220Vac
PUMP
Ccooling only not have
4WV2
plate heat exchange electrical heater
A-HAT
suction sensor 1
Auxiliary electrical heater
H/FAN1
Defrost sensor 1
Wiring Diagram
M/FAN2
Defrost sensor 2
220V～/50Hz
AL_IN
Live wire L
RUN_IN cooling only not have defrost sensor
4WV1
water inlet sensor
RUN_OUT
PKGP-SVX03A-EN suction sensor 2
Neutral wire N
Wiring Diagram
CGAR/K0606R*
19
N-COM OV-COMP OV-HEAT
EN-SAVE AL-OUT/IN
HEAT A-HT PUMP FUN
CCH COMP
MF
MP MC
N
V
Water Pump
Plate Heat Exchanger Heater
Auxiliary electrical heater
Compressor
Crankcase Heater
Fan Motor Contactor
Compressor's Start Contactor
Chiller's Water Pump Contactor
TB RFS 4WV C/H
HP LP
MOTOR
FAN
Factory wiring
On-site wiring
Commpressor overload
Outer Cool/Heat Pump Setting
Reversing Valve
Phase Sequence Controller
Terminal Blocks
Low pressure switch
High pressure switch
RD
L
(11)
RFS
(14)
R
Transformer
N
U
BK CN6
N
L
TH1
3
TH2
TH3
SW2
CON-S
CON-P
1
MC
3
6
7
MP
SW1
8
N
3
MF
11
AL Alarm indicator
TH4
ABG
CN4
N-COM
LP1
HP1
OV-FAN
OV-PUMP
FLOW
OV-COMP
OV-HEAT
EN-SAVE
21
20
16 U
15
U
25
12
N
YL
OVP
LP1
22
YL
FLOW
C/H
EG-SAVE
3
CGAR/K0755R*
CN1 B AGND+12V
controller(option)
Communication with other units
Microprocessor control board (One compressor) ADC_OD_C02
6
4WV
4
cooling only not have
power supply of the main controller 1. For all fault inputs.the unit is normal when power on and gives an alarm when power off. 2. The flow switch in the on-site installation is connected to between terminal U and terminal 15. 3. Single unit the pump is optional,if customer provide pump,each unit can use digital output7 control it, while remove the wire jumer between terminal U and 22,connection to the pump protection signal. 4. If use 2-valve inerlock,please dial SW2-7 to "ON". 500003090100 5. Control panel and main controller are optional.
Description
Control panel
BK
M 1~
(Indoor installation)
3# RD
Fan Overload
MOTOR
FAN
2#
3
Flow Switch Pump Overload
BK
M RD 1~
RD
COMP
PUMP
option
RFS
Heater overload
Alarm Output/Input Common Neutral Line
C B A
BK
MOTOR
FAN
M 3~
M 3~
Name Description
FS OVP OVF
Energy Saving/2-Way Valve Interlock
Fan Motor
BL
1~
RD M BL
1#
(L3) R
F1 RD
YL
RD (L1) T WH (L2) S
CCH
MC
MF
MC
YL
WH
MP OVP RD
TO CONTROL WIRING
Name Description
TB1
Live wire Neutral wire
Auxiliary electrical heater
HP1
220V~
plate heat exchange electrical heater
FAN
380V~/50Hz/3Ø-N
4WV
Defrost sensor
COMP
water outlet sensor
PUMP
Wiring Diagram
water inlet sensor
A-HEAT cooling only not have defrost sensor
HEATER
suction sensor
AL-IN
20 AL-OUT
N U V W
Wiring Diagram
CGAR/K0755R*
PKGP-SVX03A-EN
HTR
HS1 HS2
HC
TB2 3 N
Name Description Chiller's Water Pump Contactor MP Compressor's Start Contactor MC Fan Motor Contactor MF Crankcase Heater CCH COMP Compressor Water Circuit Based Electrical HT/EV1 Heating Control A-HAT Plate Heat Exchanger Heater PUMP Water Pump H/FAN Fan Motor AL-OUT/IN Alarm Output/Input N-COM Common Neutral Line Run Output/Input RUN-OUT/IN Saving/2-Way Valve EN-SAVE Energy Interlock Outer Cool/Heat Pump Setting C/H
water circuit electrical heater option
electrical heater side
HC
TB2
Name OV-COMP FS OVP OVF HP LP TB RFS 4WV HC HS HTR
3 N
TB1
main manchine side
30 CCH1 31 MC2
MC1
On-site wiring
Factory wiring
Water Circuit Heater
Heater Protector
Heater Contactor
Reversing Valve
Phase Sequence Controller
Terminal Blocks
Low pressure switch
High pressure switch
Fan Overload
Pump Overload
Flow Switch
Compressor Overload
Description
CCH2 TO CONTROL WIRING
N
V
RD
WH
BK
M 3～
M 3～
(L3) T (L2) S M 3～ (L1) R
FAN MOTOR 2
FAN MOTOR 1
COMP2
COMP1
3.
C B A
(Indoor installation)
WH
N
L
HP1 CN6
1
CON2
CON1
2
3
SW2
MC2
MC1
4
4WV1
6
7
8
MF
3
N 10
N 11
RUN AL
TH5
TH4
TH3
TH2
TH1
TH6
ABG
CN4
Microprocessor control board (Two compressors) ACD_OD_CO1
SW1
5
4WV2
MP
HP1 LP1
0V-C0MP2
0V-C0MP1
0V-PUMP 0V-FAN
FL0W
FREZ/LP2
VHT/HP2
C/H
EN-SAVE
N-COM
Run indicator Alarm indicator
21
20
U
U
17
16
15
14
13
25
12
N
22
LP1
OVF2
FS
LP2
YL
YL
3
4
CN1 B AGND+12V
maincontroller(option)
Communication with other units
YL
OVF1
OVP
YL
C/H
EG-SAVE
CGAR/K1005R* CGAR/K1505R* CGAR/K2005R*
3.
1. For
power supply of the main controller all fault inputs.the unit is normal when power on and gives an alarm when power off. 2. The flow switch in the on-site installation is connected to between terminal U and terminal 15. Single unit the pump is optional,if customer provide pump,each unit can use digital output 7 to control it , while remove the wire jumer between terminal U and 22,connection to the pump protection signal. 4 CGAR/K1505/2005 have the fan2 overload protect switch. 5. If use 2-valve inerlock,please dial SW2-7 to "ON". 6. Control panel and main controller are optional. 500002290100
Description
R
RD
L
(11)
RFS
Transformer
Neutral wire N
(14)
AC 220V～ Live wire U
Control panel
RFS
FOR CGAR/K 1505 2005 ONLY
RD
RD
BK WH
MF
RD
WH
MC2BK
WH
BK
WH RD
BK
RD
WH
MC1BK (L3) T M WH (L2) S 3～ RD (L1) R
RD
BK
RD
PUMP
option
HP2
COMP1
M 3～
HT/EV1
WH
COMP2
BK
water inlet sensor
MP OL
4WV1
cooling only not have
4WV2
water outlet sensor
BK
A-HAT
suction sensor 1
WH
PUMP
Defrost sensor 1
TB1
M/FAN2
Defrost sensor 2
U V W
cooling only not have defrost sensor
380V～/50Hz/3Ø
H/FAN1
Auxiliary electrical heater 3
RUN-IN
plate heat exchange electrical heater 6
AL-IN
Wiring Diagram
RUN-OUT
380V～/50Hz/3Ø
AL-OUT
PKGP-SVX03A-EN suction sensor 2
N UV W
Wiring Diagram
CGAR/K1005R* 1205R/1505R*/2005R*
21
Preparations before starting Voltage range Power supply of the water chiller must conform to the operation power supply marked on the name plate, and the power voltage & unbalances between each phase must be within the following scope. Gauge the voltages between each phase, readings of which must be within the acceptable voltage tolerance (±10%) marked on the name plate. If any voltage between two phases is not within the tolerance, electricity company shall be notified to correct such condition before the water chiller running. Improper voltage will result in abnormal control function, and shorten the life of various electrical parts & compressor motor.
Voltage unbalance If there is significant voltage unbalance between each phase of the three-phase electricity system, it will result in motor overheat and then induce motor failure. The maximum allowable voltage unbalance is 2%, voltage unbalance is defined as follows: 100x|Va-Vd| voltage unbalance %= % Va Wherein: Va=(V1+V2+V3)/3 (average voltage) V1,V2,V3=voltage between phases Vd=voltage between phases with maximum difference to Va
Water flow The flow rate of the cold water passing through the water chiller must be between the upper limit and the lower limit listed in table 4. If the flow rate of the cold water coming into the evaporator is below the lower limit, it will result in discontinuous water flow and reduce the heat transfer effect, and then lead to out-of-control expansion valve or abnormal underpressure jump. Conversely, if the flow rate is above the upper limit, parts inside of the evaporator will be corroded.
Water pressure drop Gauge the water pressure difference between the inlet and outlet of the water chiller (with water pump), then the head outside the water chiller at this water amount can be acquired, which shall be basically shown as the "head outside the water chiller " curve. When the standard model with water pump is used, for the design of piping system please refer to the "head outside the water chiller" curve. If the model without water pump is used (water pump is installed outside of the water chiller), internal water pressure drop of the water chiller shall be basically shown as the "water pressure drop of the water chiller " curve. When the model without water pump is used, for the design of piping system please refer to the "water pressure drop of the water chiller" curve.
22
PKGP-SVX03A-EN
Preparations before starting
• Check connection of all wiring, and all electric connection points shall be kept clean and locked tightly. • Check if the power voltage of the water chiller is normal. • Fully fill the cold water loop with water, and the exhaust valve of the system shall be kept open during filling, which shall be closed after the loop being filled fully. • Make short circuit connection on flow switch to test the water system. • Power on the main power and press the ON/OFF button on the control panel to start the water chiller, then the water pump shall start up and the water flows circularly in the cold water system, please check if there is any leakage at all piping connection points. • Adjust the water flow in the cold water loop, to inspect the external water pressure of the water chiller (for the standard model) or pressure drop of the evaporator (for the model without water pump). • Stop operation of the water pump. Shut off all power supply. • Connect the flow switch to the connection point on the terminal block in the control box.
CAUTION: When the water pump is running, the water flow shall be adjusted to 50%of the maximum flow rate, and the connection point of the flow switch shall be adjusted as open circuit. Please use ohmmeter to verify if the connection point of the switch is open or close.
WARNING: When the ambient temperature is below 16℃ in winter, please do not cut off the power, and preheat the water chiller 24 hours before starting it, or else the compressor will be damaged.
m3/h
Table 3. Water flow of the primary water chiller
Type
Lower limit of flow
Rated flow
Upper limit of flow
Connection Dimension
CGAR0305 CGAR0306 CGAR0505 CGAR0605 CGAR0755 CGAR0606 CGAR1005 CGAR1205 CGAR1505 CGAR2005
19.4 20.7 24.2 30.4 41.7 41.4 49.4 72.1 86.1 98.7
29.8 31.8 37.3 46.7 64.2 63.6 76.0 110.3 132.4 151.9
38.8 41.4 48.4 60.7 83.5 82.7 98.8 143.4 172.1 197.5
1" 1" 1" 1" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/2"
NOTICE: If the actual water flow rate is less than70%*rated flow, the return water temperature of refrigeration is required being set ≥10℃; or else it is necessary to add antifreezer into the water system (volume concentration of glycol in the water system has to be ≥15%);
PKGP-SVX03A-EN
23
Preparations before starting Figure 7. Unit Hydraulic curve diagram CGAR0305
CGAR0306
35
Water Pressure Drop ( mH2O)
Water Pressure Drop ( mH2O)
35 30
25
20
15
10
5
0 1.07
30 25 20 15 10 5 0 1.146 1.337 1.528 1.719
1.25
1.43
1.61
1.79
1.97
2.15
2.33
Water Flow：m3/h
CGAR0605 30
25
Water Pressure Drop ( mH2O)
Water Pressure Drop ( mH2O)
30
20
15
10
5
1.568
1.792
2.016
2.24
2.464
2.688
2.912
25
20
15
10
5
3.136
0 1.68
Water Flow：m3/h
30
25
25
20
15
10
5
2.674
3.056
3.438
3.82
4.202
4.584
4.966
3.08
3.36
3.64
10
5
0 2.31
5.348
2.70
3.08
3.47
3.85
4.24
4.62
5.01
5.39
Water Flow：m3/h
CGAR1205
CGAR1005 30
35
30
25
Water Pressure Drop ( mH2O)
Water Pressure Drop ( mH2O)
2.8
15
Water Flow：m /h
20
15
10
5
3.19
3.65
4.10
4.56
Water Flow：m3/h
24
2.52
20
3
0 2.74
2.24
CGAR0755
30
Water Pressure Drop ( mH2O)
Water Pressure Drop ( mH2O)
1.96
Water Flow：m3/h
CGAR0606
0 2.292
2.101 2.292 2.483 2.674
Water Flow：m3/h
CGAR0505
0 1.344
1.91
2.51
5.02
5.47
5.93
25
20
15
10
5
0 4.03
4.70
5.37
6.04
6.71
7.38
8.05
Water Flow：m3/h
PKGP-SVX03A-EN
Preparations before starting
CGAR1505
CGAR2005 55
35
50
Water Pressure Drop ( mH2O)
Water Pressure Drop ( mH2O)
30
25
20
15
10
5
45 40 35 30 25 20 15 10
0 4.76
5.56
6.35
7.15
7.94
8.73
9.53
5 5.47
6.38
7.29
Water Flow：m3/h
Pump Head
8.20
9.11
10.02
10.93
11.84
Water Flow：m3/h
Internal Pressure Drop
Allowable External Pressure Drop
Unit Settings Before starting or debugging of the water chiller, please configure the functional parameters and operation parameters of the water chiller as per the following methods firstly. Function setting of the water chiller is mainly conducted through jumper, dial switch and system bit. Incorrect settings will result in misoperation of water chiller and even not running.
Jumper settings Jumper JP1 is used for control in software version, and software download can be conducted with the JP1 removed; if short circuit is made to JP1, the system will operate normally.
Dial switch settings Dial switch SW1 is used for encoding the centralized control address bit, and it is used for setting the address of each water chiller in networking control. Dial switch SW2 is used for definition of the water chiller's main functions, each bit definition of which is in the following table, wherein, Bit3 and Bit4 are only valid for the water chiller with double compressors. Bit1
Bit2 Mode
Bit3 C/H
Bit4 Fan
Bit5
Bit6 type
Bit7 EnSave
Bit8 Control
Mode: 00 Normal operation mode
01 Computer supervision mode
10 System self-checking and configuration mode
11 On-site commissioning mode
C/H: 0 "external refrigeration/heating switch" invalid
1 "external refrigeration/heating switch" valid
Fan: 0 single fan
1 double fans
Type: 00 heat pump + electric heating
01 single refrigeration method + electric heating
10 single refrigeration method + electric heating
11 single refrigeration method
EnSave: 0 routine
1 two-way valve interlock
Control: 0 single machine control PKGP-SVX03A-EN
1 module control 25
Preparations before starting
System position setup System bit is a byte of memory. It can be set through a wire controller (to input "as password). Each bit is defined as below: Bit8 Temp
Bit7 Flow
Bit6 void
Bit5 Ambient
Bit4 Mode
Bit3 Defrost
Bit2 Pulse
Bit1 Auto
Auto: (50) 0 Power-on manual start (default) 1 Power-on auto start (in the event of power failure) Defrost: (51) 0 "Manual defrost" in vain (default) 1 "Manual defrost" in force Flow: (52) 0 "Water switch mode" in vain (default) 1 "Water switch mode" in force (to give an alarm in 30S upon stop of water pump if switch is in closure) Ambient: (53) 0 Ambient thermo probe in vain (default) 1 Ambient thermo probe in force Temp: (54) 0 "Suction temperature" in force (default, new Koolman) 1 "Suction temperature" in vain (old Koolman)
Operating parameter setting The protection and operation parameters of the water chiller can be set through the controller in a shutdown state. Default parameters are set as below: Parameter setup Refrigerating return water temperature Heating return water temperature Winter antifreezing temperature Defrost interval Minimum running time of defrost Password input range
Maximum value Minimum value 25℃ 50℃ 5℃ 90min 8min 75
5℃ 25℃ 1℃ 30min 1min 50
Regulation precision
Factory setting
1℃ 1℃ 1℃ 1min 1min -
12℃ 40℃ 3℃ 45min 3min 50
NOTICE: a. It is recommended that refrigerating return water temperature be kept as factory setting; otherwise low temperature setting may lead to low outlet water temperature and cause an antifreezing alarm. b. In case actual water flow is less than 70% of rated flow, refrigerating return water temperature setting shall be at least , otherwise the addition of antifreezing agent into water system is necessary (volume concentration of ethylene glycol in the water system is not lower than 15%). c. To prevent antifreezing alarm at low refrigerating return water temperature setting, please increase the addition of antifreezing agent or use a large flow water pump in the water system. Please consult Trane after-sales service personnel to modify the antifreezing setting.
26
PKGP-SVX03A-EN
Running Operation of the Water Chiller Starting procedures • Switch the water chiller power on, press MODE button on the control panel to choose refrigerating or heating, and then press ON/OFF button to start the water chiller operation. • Keep the water chiller operating for more than 30MIN, and when system operation is stable, check the following items to ensure the normal operation of the water chiller: 1.Check whether the water flow and pressure of the water chiller are stable in a normal range. 2.Test high and low pressure of the water chiller. During normal operation, low pressure shall be 85-145psig (0.586-1.0MPa), while high pressure shall be 2.290-500psig (2.0-3.45MPa). 3.Check current of compressor. 4.Check power supply. 5.Check whether there is water in the sight glass of liquid line. 6.Test system superheat degree. Under ARI circumstances (inlet water temperature at , outlet water temperature at and ambient temperature at ), normal system superheat degree of each circuit is 5. In case superheat degree of any circuit measured is beyond this range, superheat setting of expansion valve shall be appropriately regulated. In such case, the new setting shall be stabilized in 15-30min. 7.Under ARI circumstances, the normal system supercooling degree of each circuit is 5. In case supercooling degree of any circuit measured is beyond this range, necessary regulation shall be carried out following the check of supercooling. In the case of normal superheat but abnormal supercooling, please contact professional maintenance personnel. 8.In the case of inadequate cooling agent exhibited through running pressure, sight glass, superheat degree and supercooling degree, leak points shall be identified, and gaseous cooling agent shall be charged to the circuit. During the water chiller operation, cooling agent is filled from low pressure line till normal working pressure becomes available. Low running pressure gives an indication of low supercooling degree, meaning inadequate cooling agent. 9.In case working pressure reveals excessive cooling agent, cooling agent shall be reclaimed from liquid line little by little (so as to reduce loss of refrigerant oil as far as possible). • Ensure that all temperature sensors are correctly located with their capillary tubes firmly fixed so as to prevent vibration and abrasion. • Check the water chiller, and clear away wastes, tools and parts. Secure all sheet metal parts of the housing, including control panel and compressor access panel, and restore all screws. Cautions:
CAUTION: • In winter, close water supply valve of all evaporators, open drain valve and the vent valve in the pipeline of the water chiller so as to discharge water from the evaporator, and mount a drain plug. Regarding to ultra-thin top cooling fans, completely release water in the pipeline by a drain valve, and then open the bottom drain valve to remove all residual water in the evaporator. In case water in the cold water pipe cannot be completely discharged, proper antifreezing solution can be injected so as to prevent freezing of residual water that may lead to damage of the water chiller.
PKGP-SVX03A-EN
27
Running Operation of the Water Chiller
Long-term shutdown • For long-term shutdown, the following procedures shall be carried out before system halt: 1. Check whether cooling agent piping leaks, and if so, be sure to have it repaired. 2.Maintain water pump and air conditioning plant as proposed by manufacturer. 3.Discharge all circulating water from the system, unscrew dewatering outlet in the water supply and return circuit, dismantle side panel of the water chiller, and unscrew the dewatering outlet in the bottom of water pump and plate type heat exchanger so as to ensure complete discharge of circulating water. 4.Turn off power switch of the water chiller and water pump.
CAUTION: • In winter, close water supply valve of all evaporators, open drain valve and the vent valve in the pipeline of the water chiller so as to discharge water from the evaporator, and mount a drain plug. Regarding to ultra-thin top cooling fans, completely release water in the pipeline by a drain valve, and then open the bottom drain valve to remove all residual water in the evaporator. In case water in the cold water pipe cannot be completely discharged, proper antifreezing solution can be injected so as to prevent freezing of residual water that may lead to damage of the water chiller.
Restarting the system after long-term shutdown 1.Open the valve of the water return and supply pipeline, and charge clean water into the cold water pipeline. Be sure to exhaust at the time of water charge, and close the vent valve when the system is full of water. 2.Bring connection of flow switch into short circuit so as to measure the water system. 3.Switch on power switch of the water chiller. 4.Press ON/OFF button on the control panel to start the water chiller. When cold water is circulated in the water system, check whether there is any piping joint leaking. 5.Regulate flow of the cold water pipeline by a balance valve, and check the water pressure of the water chiller. 6.Regulate the flow switch (arranged in the water discharge pipe of the water chiller), so as to ensure normal running. 7.Press ON/OFF button on the control panel to stop the water chiller. 8.Restore connection of the flow switch. In this way, the water chiller can run normally at once.
CAUTION: • During water pump operation, regulate water flow to half of maximum flow, and disconnect the contact of the flow switch. Please use ohmmeter to verify if the connection point of the switch is open or close.
System protection Low voltage protection (LP1, LP2) A low voltage switch is provided to protect the water chiller. When the operation voltage is below 21±7psig(1.145±0.048MPa), compressor operation is stopped, and when it reaches 36±7psig(0.248±0.048MPa), compressor operation is automatically restored. Two-minute short circuit is necessary for starting up, in case of unnecessary trip.
28
PKGP-SVX03A-EN
Running Operation of the Water Chiller
High voltage protection (HP1, HP2) A high voltage switch gear is provided to protect the water chiller. When high voltage exceeds 602±22psig(4.15±0.15MPa), compressor operation is stopped, and when the pressure is dropped to 479±22psig(3.303±0.152MPa), compressor operation is automatically restored.
Antifreezing function in winter In winter, when the water chiller is in a standby state, if water temperature is below the winter antifreezing temperature setting, the water chiller automatically will enter antifreezing operation, displaying "AP". Therefore, the water chiller power supply in winter shall be switched on even if the water chiller is in a standby state.
Antifreezing of plate type heat exchanger In a refrigeration state, in case outlet water temperature is below , compressor shall be closed, and water pump shall continue to run, displaying "E3".
High voltage protection of plate type heat exchanger In the case of heating by a single compressor system, when cooling agent pressure at plate side is over a certain value, the fan or both the fan and compressor shall be closed, displaying "E.
Overload protection of motor • Compressor motor overload and superheat protection • Water pump motor overload protection • Fan motor superheat protection • Thermo probe protection In case the thermo probe fails, an alarm will be sent and the system will be halted. * As all alarm protection is subject to manual reset, before the system is restored by pressing the RESET key or being restarted, the failure needs to be eliminated firstly.
Flow protection In order to prevent too low water flow that may lead to freezing of the evaporator, a flow switch (or any other flow sensing device) shall be arranged in the water pipe of the evaporator. Its setting shall meet the requirement that when water flow is below 70% of total design flow of the system, compressor shall be stopped immediately.
Running operation of the water chiller Thermo probe (TH1) Thermo probe (TH1) senses inlet water temperature of the system as a basis of starting or stopping the compressor under cold and hot states.
PKGP-SVX03A-EN
29
Running Operation of the Water Chiller
Cooling mode: Dual system When the system is started, the water pump shall run at once. After a period of 2MIN, the water pump continues to run. When return water temperature reaches or more, No.1 compressor will be started. In one minute, No. 2 compressor will be started provided return water temperature is more than . On condition that the cooling requirement is met, and return water temperature is lowered to , No. 1 compressor will be stopped. In case return water temperature continues to lower to , No. 2 compressor will also be stopped. Later on, as load is increased and return water temperature is raised to , No. 1 compressor will be started again. In case return water temperature continues to increase to , No. 2 compressor will also be started. The water pump will not stop unless the water chiller is shut down.
Single system When the system is started, the water pump shall run at once. The water pump continues to run after 2MIN; and in case return water temperature is over , the compressor will be started. On condition that the cooling requirement is met, and return water temperature is lowered to , the compressor will be stopped. Later on, as load is increased and return water temperature is raised to , No. 1 compressor will be started again. The water pump will not stop unless the water chiller is shut down.
Heating mode: Dual system When the system is started, the water pump shall run at once. 2min later, the water pump remains in operation; if return water temperature is below , No. 1 compressor will be started. 1MIN later, if return water temperature is below, No. 2 compressor will be started. If the heating requirement is met and return water temperature is increased to , No. 1 compressor will be stopped; and if return water temperature continues to rise to, No. 2 compressor will also be stopped. Later on, load is changed; if return water temperature is lowered to , No. 2 compressor will be started; and return water temperature continues to drop to , No. 1 compressor will also be started. The water pump will not stop unless the water chiller is shut down.
Single system Operation of water pump, fan and compressor of single system is the same as that of dual system. The only difference is that when return water temperature of single system is below , the compressor will be started, and when return water temperature of single system is over , the compressor will be stopped.
Ambient temperature operation limit Outdoor ambient temperature Cooling mode
Heating mode
mini
21℃
-7℃
max
43℃
21℃
Leaving water temperature Cooling mode
30
Heating mode
mini
5℃
40℃
max
15℃
50℃
PKGP-SVX03A-EN
Controller Wired controller
PKGP-SVX03A-EN
31
Controller
Operation and display panel Control panel 1. On/Off button 2. Mode button, controlling refrigeration and heating. Mode setting must be carried out in a shutdown state. 3. Fault resetting button, pressed for manual resetting when a failure alarm is given. 4. Parameter setting button, pressed to perform parameter setting (password is necessary). 5. Time browse/setting/timing setting button, specifying timed on/off time as 00:00-23:59. 6. Timing function option button 7. Setting button, the two buttons are pressed to examine or modify parameter setting.
Display panel 8. Defrost display 9. Water pump start display 10. Antifreezing function start display 11. Second compressor start display 12. Electric heater start display 13. Water chiller heating display 14. First compressor start display 15. Water chiller refrigeration display 16. Temperature or parameter display window
Operation instructions of the panels 1. On/off operation Firstly choose the wanted mode, then press the key to run this mode, and again press the key to close the system. Frequent on/off operation is strictly prohibited. 2. Mode selection The modes of refrigeration and heating must be set in a shutdown state. 3. Parameter browse Parameters to be browsed cover refrigerating return water temperature, heating return water temperature, winter antifreezing temperature, defrost interval and running time of defrost. By double control of the key, the five parameters can be browsed. 4. Outlet water temperature display When the system is on, upon pressure of the mode key, the LCD displays outlet water temperature for 6 seconds by flashing. 5. Fault resetting operation When the system is out of order, an alarm sounds for 2 seconds with backlight flashing. Press the key to remove the failure and stop alarming. If the failure cannot be removed, the alarm continues to sound for 2S with backlight flashing. 6. Parameter setup Parameter setting refers to separate setting of the above five parameters according to user requirements. "、" key is involved. It functions as increase and decease. 7. Normal state display In a power-on state, current return water temperature, as well as working conditions of compressor, heater and water pump, is displayed. In a timed state, ON lights for timed start, and OFF lights for timed shutdown. The five parameters can be set in a shutdown state. If no key is in service, normal state display will be restored in 10S, with backlight stopped in 15S. Backlight flashes upon failed communication. 32
PKGP-SVX03A-EN
Functional description Refrigeration state temperature control Single compressor control Control action
Low water temperature Change of return water temperature High water temperature
compressor start compressor stop
Temperature descriptions
Set value
Noting: Control action is performed when temperature reaches the arrow.
Double compressor control Control action
Low water temperature Change of return water temperature High water temperature
compressor start compressor start compressor stop compressor start
Temperature descriptions Set value Noting: Control action is performed when temperature reaches the arrow.
PKGP-SVX03A-EN
33
Functional description
Temperature control in the heating status Single compressor control Control action
Low water temperature Change of return water temperature High water temperature
compressor start compressor stop
Temperature descriptions
Set value
Noting: Control action is performed when temperature reaches the arrow.
Double compressor control Control action
Low water temperature Change of return water temperature High water temperature
compressor start compressor start compressor stop compressor start
Temperature descriptions Set value Noting: Control action is performed when temperature reaches the arrow.
Compressor protection time-delay function When the water chiller is powered on, the compressor needs to be delayed for at least 2MIN. Then when the water chiller is automatically started and stopped, the compressor needs to be delayed for at least 3min.
Electric heating control When the return water temperature is lower than the set value of (single compressor unit) or when return water temperature is not greater than the set value of (double compressor unit), start the electric heater. When return water temperature is not lower than (set value), stop the electric heater.
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PKGP-SVX03A-EN
Failure analysis and handling method Failure alarming table "EE" code is displayed as controller and control panel communication fails. A total of 13 fault input alarm switches, as well as 1 failure output alarm switch, are provided for single compressor system S/N
Input port Fault Description
Type
Code
Troubleshooting
A
SE
All peripherals are to be closed.
1
TH1
Return water temperature sensing line in short/open circuit
2
TH2
Outlet water temperature sensing line in short/open circuit
A
SL
All peripherals are to be closed.
3
TH3
Suction temperature 1 in short/open circuit
A
Sd
All peripherals are to be closed.
4
TH4
Defrost temperature sensing line 1 in short/open circuit
A
S1
All peripherals are to be closed.
B
H2
The electric heater is to be closed.
D
FL
All peripherals are to be closed.
B
OP
All peripherals are to be closed.
B
OF
All peripherals are to be closed.
C
C1
Only compressor 1 is to be shut down.
5 6 7 8 9
OVHT/HP2 Electric heating overload FLOW
Inadequate water flow
OV-PUMP Water pump overloaded OV-FAN
Fan overloaded
OV-COMP1 Compressor 1 overloaded
10
HP1
Compressor 1 high voltage alarming
C
H1
Only compressor 1 is to be shut down.
11
LP1
Compressor 1 low voltage alarming
C
L1
Only compressor 1 is to be shut down.
12
///
Refrigerating outlet water temperature is too low.
D
E3
The compressor is to be shut down, while the auxiliary heater of water pump is to work.
13
///
Suction temperature is too low.
D
E4
The compressor is to be shut down, while the auxiliary heater of water pump is to work.
A total of 17 failure input alarm switches, as well as 1 fault output alarm switch, are provided for dual compressor system S/N
Type
Code
Troubleshooting
A
SE
All peripherals are to be closed.
1
TH1
Return water temperature sensing line in short/open circuit
2
TH2
Outlet water temperature sensing line in short/open circuit
A
SL
All peripherals are to be closed.
3
TH3
Suction temperature 1 in short/open circuit
A
Sd
All peripherals are to be closed.
4
TH4
Defrost temperature sensing line 1 in short/open circuit
A
S1
All peripherals are to be closed.
5
TH5
Defrost temperature sensing line 2 in short/open circuit
A
S2
All peripherals are to be closed.
6
TH6
Suction temperature short/open circuit
A
S3
All peripherals are to be closed.
7 8 9 10
OVHT/HP2 Compressor 2 high voltage alarming FLOW
Inadequate water flow
OV-PUMP Water pump overloaded OV-FAN
Fan overloaded
E
H2
Only compressor 2 is to be shut down.
D
FL
All peripherals are to be closed.
B
OP
All peripherals are to be closed.
B
OF
All peripherals are to be closed.
11
OV-COMP1 Compressor 1 overloaded
C
C1
Only compressor 1 is to be shut down.
12
OV-COMP2 Compressor 2 overloaded
E
C2
Only compressor 2 is to be shut down.
13
HP1
Compressor 1 high voltage alarming
C
H1
Only compressor 1 is to be shut down.
14
LP1
Compressor 1 low voltage alarming
C
L1
Only compressor 1 is to be shut down.
FREZ/LP2 Compressor 2 low voltage alarming
E
L2
Only compressor 2 is to be shut down.
15
PKGP-SVX03A-EN
Input port Fault Description
16
///
Refrigerating outlet water temperature is too low.
D
E3
The compressor is to be shut down, while the auxiliary heater of water pump is to work.
17
///
Suction temperature is too low.
D
E4
The compressor is to be shut down, while the auxiliary heater of water pump is to work.
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Failure analysis and handling method A. Compressor cannot be started, but remains silent. "EE" code is displayed as controller and control panel communication fails. A total of 13 fault input alarm switches, as well as 1 failure output alarm switch, are provided for single compressor system Possible cause
Solution
The power is not connected.
Check the following items: a. Main power switch is off. b. Fuse blows.
No refrigerating instruction is available.
Check the following items: a. Main power switch is off. b. Fuse blows. Check the following items: a. Thermo probe is damaged. b. Control wiring is disconnected or improper. c. Control power fuse blows.
Microcomputer outputs no compressor control signals.
Check the following items: a. High voltage switch trips as a result of excessive high- voltage. b. High voltage switch fails. c. Low voltage switch trips as a result of insufficient coolant. d. Flow switch or antifreezing switch trips as water valve is not switched on. e. Internal protection contact of fan trips. f. Microcomputer controller goes wrong.
Electromagnetic switch of compressor fails in exciting.
Check the following items: a. Poor function of compressor contact b. Poor wiring c. Open circuit of low voltage switch
Internal protection contact of compressor trips.
Check the following items: a. Check compressor current. b. Await restoration of internal contact (for about 10-20MIN).
B. Compressor cannot be started, but makes a sound. Possible cause
Solution
Too low compressor voltage
Check the following items: a. Some fuses blow. b. Too low power voltage c. Electromagnetic contactor of compressor goes wrong. d. Loose wiring
Compressor failure
Check the following items: a. Motor winding is in open circuit. b. Phase current is excessive.
Starting voltage is inadequate (single phase type).
Check the following items: a. Poor starting of capacitor b. Poor starting of relay
C. Compressor 2 cannot be started.
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Possible cause
Solution
No refrigeration or heating signal is available.
Check the following items: a. Temperature switch is damaged. b. Control wiring is disconnected or improper.
Microcomputer outputs no compressor control signals.
Please refer to the third item in Section A.
Electromagnetic switch of compressor fails in exciting.
Please refer to the fourth item in Section A.
PKGP-SVX03A-EN
Failure analysis and handling method D. Too short running period of compressor Possible cause
Solution
Control circuit is intermittently connected.
Check the following items: a. Poor contact of contactor d. Loose wiring connection
E. Compressor runs without stop Possible cause
Solution
Power of the water chiller is not enough to bear a load Check causes that lead to excessive load. (unloading water temperature cannot be provided). Poor thermo probe or control line
Change the thermo probe. Change or repair the control line.
Electromagnetic contactor of compressor goes wrong.
Repair or change the electromagnetic contactor.
Valve block of compressor leaks (low discharge pressure Change the compressor or high suction pressure) Insufficient coolant (low capacity, too high superheat degree, too low superheating degree, and low low- Identify leak points of coolant, repair, and fill with coolant. pressure pressure)
F. Motor winding of compressor is in open circuit. Possible cause
Solution
Too high evaporator load (high return water temperature)
Check the following items: a. Excessive water flow b. Tool high return water temperature
Inadequate motor cooling (too high superheat degree)
Check the following items: a. Improper setting of expansion valve b. Failure of expansion valve c. Blocked liquid line
Improper compressor voltage
Check the following items: a. Too low or unbalanced power voltage b. Loose power wiring c. Poor electromagnetic contactor of compressor
Internal parts of compressor are damaged.
Change the compressor
G. Too high noise of compressor Possible cause
Solution
Internal parts of compressor are damaged or broken Change the compressor (compressor sounds like striking). Liquid backflow (low pressure pipe is abnormally cold and Check and regulate superheat degree presents low superheat degree) Liquid coolant is available in the compressor when the compressor is started (compressor housing is abnormally Check whether the coolant is excessive. cold).
PKGP-SVX03A-EN
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Failure analysis and handling method H. Inadequate air cooling capacity Possible cause
Solution
I n s u ff i c i e n t c o o l a n t ( l ow s u p e r h e a t d e g r e e a n d Supply coolant. supercooling degree) Blocked dry filter (temperature from coolant pipe to dryer Change the dry filter room is changed) Improper regulation of expansion valve
Regulate the expansion valve again.
Blocked expansion valve (too high superheat degree and Repair or change the expansion valve. too high water temperature) Too low water flow of evaporator
Check the filter screen and regulate water flow.
Non-condensed gas in the system
Vacuumize the system and re-fill it with the coolant.
Leak of compressor valve and high suction pressure (high Change the compressor high-pressure pressure, and low low-pressure pressure)
I. Too low suction pressure Possible cause
Solution
Insufficient charge of coolant (high superheat degree and Identify the leak point, repair it, and recharge the coolant. low supercooling degree) Too low setting of temperature switch (too low lowRegulate the temperature switch again. pressure pressure and too low outlet water temperature) Too low cold water flow
Check whether the filter screen is blocked and whether the balance valve is correctly set.
Blocked dry filter
Check whether the dry filter is frosted, and if necessary, change it.
Blocked expansion valve (high superheat degree)
Clean or change the expansion valve.
J. Too high suction pressure Possible cause
Solution
Too high cooling load (high supply water temperature)
Please refer to Section E.
Excessive liquid feed of expansion valve (too low Regulate superheat setting and check whether the thermo probe superheat degree, leading to overflowing of liquid onto the is mounted in the gas line. compressor) Rupture of air suction valve (high noise of compressor)
Change the compressor
K. Too low discharge pressure Possible cause
Solution
Inadequate coolant (high superheat degree, low Identify the leak point, repair it, and recharge the coolant. supercooling degree and air bubbles in the sight glass)
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Rupture or leak of vent valve of compressor
Change the compressor
Poor low voltage switch
Change the poor control element.
Ensure minimum operating environmental temperature.
Exercise proper discharge pressure control or provide an ambient temperature locking switch
PKGP-SVX03A-EN
Failure analysis and handling method L. Too high discharge pressure Possible cause
Solution
Insufficient of excessive cooling air, flow choking
Clean the coiler and check whether fan and motor are normal.
Air or non-condensed gas present in the system Vacuumize the system and re-fill it with coolant. (abnormally hot condenser) Excessive coolant (high supercooling degree, low Reclaim redundant coolant. superheat degree, and high suction pressure) Too high system load
Lower the load.
Poor pressure control over condensation fan or fan (a Repair or change the switch. certain fan fails, and too high pressure of condenser)
M. The water chiller cannot function in heating (CGAR). Possible cause
Solution
Wrong or poor control line
Check the control line.
Four-way valve failure
Change the four-way valve.
N. Excessively low pressure—heating condition Possible cause
Solution
Insufficient coolant
Replenish coolant.
Too low or too cold of air entering the coiler
Clean the coiler and check whether fan and motor are normal.
The water chiller is operated at a temperature below Provide an environmental temperature disconnecting switch. minimum operating environmental temperature. Expansion valve failure
Change the expansion valve.
K. Too low discharge pressure
PKGP-SVX03A-EN
Possible cause
Solution
Too high cooling load (high supply water temperature)
Check whether the filter screen is blocked and whether the balance valve is correctly set.
Too low water flow
Check whether the filter screen is blocked and whether the balance valve is correctly set.
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© 2014 Trane All rights reserved PKGP-SVX03A-EN
March 2014
