SERVICE MANUAL Modular Chiller (R22 50HZ)
SCOPE This course is intended to support engineering staff that are installing, commissioning, servicing or maintaining AUX Modular chiller systems.
Issued by AUX Electric Appliance CO., LTD CODE: SYJS-SM-027 DATE: 2008-1-1
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Table of Contents 1. Overview···························································································································································· 5 1.1 Naming rule ············································································································································· 5 1.2 Technical data ·········································································································································· 6 1.3 System principle drawing ······················································································································· 7 1.3.1 Systematic schematic diagrams for smart series ············································································· 7 1.4 Outline Dimension ··································································································································· 9 1.5 Electric Philosophy Disgram ················································································································ 10 2. Design guide for Air-Cooling Cold (Hot) Water Module-Model Unit ························································· 13 2.1 Determination of design parameter ····································································································· 13 2.1.1 Outdoor design parameter············································································································· 13 2.1.2 Indoor Design Parameter ·············································································································· 13 2.2 Principle of Loading Calculation and Selection ·················································································· 15 2.2.1 Determine indoor air conditioner area ·························································································· 15 2.2.2 Determine cold load index for unit area ························································································ 15 2.2.3 Determination of cofficient of simultaneous use ··········································································· 15 2.2.4 Determination and air conditioner and main model selective ························································ 15 2.2.5 Selective ancillary electric heater·································································································· 16 2.3 Design principle of water system ·········································································································· 17 2.3.1 As balanceble as possible for hydraulic force ··············································································· 17 2.3.2 Avoid large flow rate but small difference in temperature ····························································· 17 2.3.3 Expansion supplement water and drainage and exhaust in water system ······································ 18 2.3.4 Water treatment and filtering in water system ··············································································· 18 2.4 Heat stability of water system ··············································································································· 19 2.4.1 Heat stability of water system ······································································································· 19 2.4.2 Calculation of system water capacity ···························································································· 19 2.4.3 Thermal stability requirement of system ······················································································· 20 2.4.4 Minimum capacity of requirement of system ················································································ 20 2.5 Installation manner of water system ···································································································· 20 2.5.1 Closed type cold and hot water system ························································································· 20 2.5.2 Cold and hot water system of open expansion watertank ······························································ 21 2.6 Water conduit design····························································································································· 21 2.6.1 Basic requirement of water conduit design ··················································································· 21 2.6.2 Design the circulation conduit system subject to building structure ·············································· 22 2.7 Design and select and configuration of the pipe, pipe material and pipe caliber ······························ 23 2.7.1 Pipe design ··································································································································· 23 2.7.2 Select and seal connection for pipe material ················································································· 23 2.7.3 Determination of caliber ··············································································································· 23 2.8 Design and installation of expansion water tank ················································································· 24 2.8.1 Type selective and design of expansion water tank ······································································· 24 2.8.2 Installation of expansion water tank ····························································································· 24 2.9 Design of condesating water discharge system ···················································································· 25 2.9.1 Condesating water discharge system····························································································· 25 2.9.2 Determination of pipe material and pipe caliber for condesating water ········································· 25 2
2.9.3 Arrangement of condesating water pipe ························································································ 25 2.9.4 Concentration drainage tubing and connection ············································································· 26 2.9.5 Bracket pitch of condesating water pipe ······················································································· 27 2.10 Constitution of construction program ································································································ 27 3. Installation Manual for Air-Cooled Cold (Hot) Water Unit of Mudular Type ··········································· 28 3.1 Installation of main unit························································································································ 28 3.1.1 Preparation before installation ······································································································ 28 3.1.2 Location selection requirement ····································································································· 29 3.1.3 Lifting and hailing of the unit ······································································································· 30 3.1.4 Requirements and points for attention while unit installation························································ 31 3.2 Installation of the circulation conduit ·································································································· 31 3.3 Electric standard requirement ············································································································· 33 3.3.1 Electric standard requirement: ······································································································ 33 3.3.2 Electric correlative standard requirement······················································································ 33 3.3.3 Standard requirement of switch electric appliance ········································································ 33 3.3.4 Standard requirement of line distribution ······················································································ 33 3.3.5 Standard requirement for wiring ··································································································· 34 3.3.6 Earthing requirement ···················································································································· 34 3.3.7 Control layout······························································································································· 35 3.3.8 Selection of the conduit ················································································································ 35 3.3.9 Conduit requirement ····················································································································· 35 3.3.10 Fixing spacing of conduit (see the table as followed)·································································· 35 3.3.11 Minimum spacing between electric line and other pipes (see the table as followed) ··················· 35 3.4 Hydraulic test and heat preservation of pipe ······················································································· 36 3.4.1 Hydraulic test ······························································································································· 36 3.4.2 Heat insulation of pipe ·················································································································· 36 3.5 Injection and commissioning of cold medium water ··········································································· 37 3.5.1 System cleanout and injection of cold medium water ··································································· 37 3.5.2 Inspection before commmissioning ······························································································ 37 3.5.3 Commissioning····························································································································· 38 3.5.4 Examination of protection and temperature control ······································································ 38 3.5.5 Unit operation condition ··············································································································· 39 3.5.6 Unit normal operation ··················································································································· 39 3.6 Project acceptance and maintenance ··································································································· 40 3.6.1 Project acceptance ························································································································ 40 3.6.2 Maintenance ································································································································· 40 4.Instruction of controller for module-type air cool cold (hot) water unit ······················································ 42 4.1 Instruction of bi-system controller for module-type unit ···································································· 42 4.1.1 System description ······················································································································· 42 4.1.2 Parameter set ································································································································ 44 4.1.3 Parameters for system operation temperature ··············································································· 45 4.1.4 Parameters of system operation time ···························································································· 45 4.1.5 Protection temperature parameters ································································································ 45 4.1.6 Time protection parameters ·········································································································· 46 4.1.7 Frost parameter ····························································································································· 46 4.1.8 Failure protection under cold generation work·············································································· 46 3
4.1.9 Failure protection under heat generation condition ······································································· 47 4.1.10 Unfreezing operation ·················································································································· 49 4.1.11 System failure protection and code ····························································································· 50 4.2 Instruction of quadri-system controller for module-type unit ···························································· 52 4.2.1 System description ······················································································································· 52 4.2.2 Parameter set ································································································································ 54 4.2.3 Failure protection under cold generation······················································································· 56 4.2.4 Failure protection under heat generation ······················································································· 57 4.2.5 Unfreezing operation ···················································································································· 57 4.2.6 System failure protection and code ······························································································· 59 4.3 Instruction of expansion module controller for electronic expansion valve ······································· 60 4.3.1 Interface description of electronic expansion controller ································································ 60 4.3.2 Parameter set ································································································································ 61 4.3.3 Frost unfreezing···························································································································· 62 4.3.4 Orientation ··································································································································· 63 4.3.5 Malfunction ·································································································································· 63
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1. Overview
1.1 Naming rule A C T MC – H 220 A 5 /A D R AI Hr Heating recovery: Hr Iverter or variable capacity: AI: Ac Inverter, DI: Dc Inverter, Va: Variable capacity Refrigerant TYPE： R22 omit；R407c:R、R410a:R1、R134a:R3 Compressor quantity： S: single D: double T: three F: four M: multiCode of design improvement： A、B、C etc. Code of power supply: 1—220V-1-50Hz; 2—208V-230V-1-60Hz; 3—115V-1-60Hz; 4—220V-240V-1-50Hz; 5—380V-415V-3-50Hz; 6—380V-3-60Hz; 7—208V-230V-1-50Hz;
8—440V-460V-3-60Hz
Cooling or heating rate under the same capacity Btu: cooling capacity, for example: 220000Btu is 220. H: means heat pump unit, Cooling-only unit omit. Unit structure code: WCSC：Water-Cooled Screw Chiller Type ACSC：Air-Cooled Screw Chiller Type WCF：Water-Cooled Floor Mounted Type MHC：Mono-Household Chiller Type SHC：Split Household Chiller Type MC：Module Chiller Type Code of working condition: T ：T3 working condition unit, T1 omits Class structure code： C：Central Air Conditioner Type Brand code：AUX.
Examples： ACMC-H220A5/D: Air-Cooling Cold (Hot) Water Module-Model Unit; compressor quantity:double; nominal refrigeration capacity: 220000BTU(namely 65kW),with three-phase 380V-415V, 50Hz power.
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1.2 Technical data Technical data for the modular chiller air conditioner Heat-pump
Product model
Cooling-onl y
ACMC-H190A5/F
ACMC-H220A5/D
ACMC-H340A5/F
ACMC-190A5/F
ACMC-220A5/D
ACMC-340A5/F
Rated cooling capacity
kW
55
65
115
Rated heating capacity
kW
60
71.5
126
Input cooling power
kW
19.2
20.5
38.3
Input cooling current
A
36.9
35.3
68.5
Input heating power
kW
20.1
21
39
Input heating current
A
38.8
36.0
70.2
Max. input current
A
42
44.5
84.0
Power source Model
Compressor
Totally enclosed vortex compressor
Quantity
Piece
2
Injection
kg
4×3.8(4×3.55)
2×9(2×7.5)
Heat exchanger model
2×15(2×13)
High efficiency fin heat exchanger
Fan model
Low noise axial-flow fan
Fan q’ty
Piece
Rate power
kW
2 2×0.75
2×0.75
2×1.5
High/low voltage protection, defect/counter phase protection, cut-off protection, water flow protection, antifreeze protection
Cold medium control manner
Capillary
Model water-side
4 R22
Safety protection device
Heat exchanger in
4
Refrigerant
air-side
exchanger in
Heat
380V-415V 3N～/50Hz
Patent throttle technique
external equalizer thermostaice expansion valve
High efficiency plate
double-pipe heat exchanger of high efficient copper rifled
heat exchanger
tube
Water resistance
kPa
52
53
54
Water flow rate
3
m /h
8.6
11.2
17.2
mm
DN50
DN50
DN65
Dimension of Pipe connection
Outline dimension (L×W×H)
mm
1921×1145×1288
1150×2200×1115
1600×2700×1515
Packaging dimension (L×W×H)
mm
2075×1250×1600
1245×2345×1310
1695×2845×1700
Unit weight
kg
420
600
1100
Unit operation weight
kg
500
720
1320
dB(A)
≤69
≤69
≤73
Unit noise
Note: The above-mentioned represents description of performance parameter of single module, which on demand could be assemblied into more models, even 8 modules as an ultimate way. Model ACMC-190A5/F has been canceled.
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Note: 1. Rated refrigeration work condition: inlet/outlet temperature of cool water 12℃/7℃, ambient temperature 35℃; 2. Rated heating work condition: Inlet/outlet temperature of hot water 40℃/45℃, ambient temperature 7℃, wet bulb temperature 6℃; 3. “Maximum operation current” work condition: Inlet temperature of cool water 12℃, outlet temperture 7℃, dry bulb temperature of outlet of air side 47℃, 90% of rated voltage; 4. the contents in parenthesis in the colume of injection quantity means injection quantity for single cooling unit; 5. No advance notice while the parameters above-mentioned varies resulting in enhancement performance.
1.3 System principle drawing 1.3.1 Systematic schematic diagrams for smart series
ACMC-(H)190A5/F Principle System Drawing 7
ACMC-(H)220A5/D
Principle System Drawing
1. Vortex compressor 2. Neddle valve 3A. Low Pressure Switch 3B. Low Pressure Switch 4. High Pressure switch 5. Suction trap 6. Process pipe 7A. One-way valve 7B. One-way valve 8. Accumulator tank 9. Drying filter 10A. Cooling thermostatic expansion valve 10B. Heating thermostatic expansion valve 11. Four-way valve ACMC-(H)340A5/F Principle System Drawing
Note: —→: Refrigerant direction while cooling; — →: Refrigerant direction while heating The cooling-ongly unit, no four-way valve, Suction trap, One-way valve, heating thermostatic expansion valve or heating capillary. 8
1.4 Outline Dimension
ACMC-(H)190A5/F Outline Dimension
Dimension
A
B
C
D
E
F
G
H
I
Inlet
Outlet
ACMC-(H)220A5/D
919
1100
1126
728
140
85
2200
1150
1115
DN50
DN50
ACMC-(H)340A5/F
990
1500
1576
890
193
116
2700
1600
1600
DN65
DN65
Model
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1.5 Electric Philosophy Disgram
ACMC-H190A5/F Electric Philosophy Disgram
ACMC-190A5/F Electric Philosophy Disgram
10
ACMC-H220A5/D Electric Philosophy Disgram
ACMC-220A5/D Electric Philosophy Disgram 11
ACMC-H340A5/F Electric Philosophy Disgram
ACMC-340A5/F Electric Philosophy Disgram
Note: single cooling unit has no four-way valve.
12
2. Design guide for Air-Cooling Cold (Hot) Water Module-Model Unit As a systematic project, centric condition must be designed after selected of unit based on the specific condition of building, which should be performed as following steps: Project design
Model selective of master and terminal
Design electric project in water system
Air Draft distribution
installation
lifting of of master and terminal
commissioning and acceptance
commissioning (including preparation)
tubing and condesatiing discharge of water system
performance test electric and system airproof
Drawing drafting
function protection test
fill-in of commissioning and acceptance report
thermal insulation
information handover
Maintenance description
2.1 Determination of design parameter 2.1.1 Outdoor design parameter Outdoor meteorological parameter selection is stipulated in nation standard “Design Specification of Heating Ventilation and Air Conditioning” GBJ19-87, and the meteorological parameter for various major cities could refer to the manual concerned. Outdoor design parameter mainly includes 7 models in the table followed: Outdoor Design Parameter 1. Outdoor calculation dry bulb
5. Outdoor calculation mean daily temperature of air
temperature of Air conditioner in summer
conditioner in summer
2. Outdoor calculation wet bulb temperature of Air conditioner in summer
6. Average outdoor wind velocity
3. Outdoor calculation temperature of Air conditioner in summer 4. Outdoor calculation relative humidity of air
7. Atmospheric pressure
conditioner in summer
2.1.2 Indoor Design Parameter Based on the stipulation in “Design Specification of Heating Ventilation and Air Conditioning”, indoor design parameter for confort air conditioner should be listed as followed: Indoor Design Parameter for Confort Air Conditioner Index
Summer
Winter
Temperature ℃
24～28
18～22
Relative humidity%
40～65
40～60
Wind velocity m/
≤0.3
≤0.2
The selection of indoor air parameter, generally, subject to the requirement of people’s confort under various conditions, as well as economical, energy-saving and etc. middle and small capacity air conditioner, mostly, 13
should be applied to commerce and industry location such as office building, hotel, factory, of which Indoor design parameter should refer to the following table: Recommandation Value of Indoor Design Parameter of Air Conditioner for Civil Building Summer Building Model (Room Name)
φ
t
v
φ
t
m/s
% 55 60 65 70
m/s
% 50 40 30 /
0.30
30
0.15
50
℃ 24 23 22 22 23 21 21 20 24 23 22 22 23 21 20 20 20 18 17 16 23
0.30
65
Beauty parlor, hairdressing room
0.15
60
Gymnasium
0.25
60
24
0.25
40
19
Bowling room
0.25
60
25
0.25
40
21
Indoor swimming pool
0.15
65
26
0.15
50
24
Billiard room
0.25
60
27
0.25
40
22
No dancing
0.15
60
26
0.15
40
23
Dancing
0.15
65
23
0.15
50
18
0.15
60
25
0.15
40
21
0.15
60
26
0.15
50
22
60
25
40
23
70
26
/
22
60
25
40
23
70
26
/
22
Level 1 Level 2 Level 3 Level 4 Level 1 Level 2 Level 3 Level 4 Level 1 Level 2 Level 3 Level 4 Level 1 Level 2 Level 3 Level 4 Level 1 Level 2 Level 3 Level 4
Refectory Banqueting hall Meeting room, office, reception room Store, service organization
Hall, aisle, atrium, Season hall
Tour hotel
v
℃ 24 25 25 26 24 25 25 26 25 26 27 27 24 25 26 27 25 26 27 27 26
Hotel room
Tour hotel
Winter
Ballroom, Bar
Refectory, banqueting hall (non dinner time)
Hotel toom (sleep at night)
Bedroom
Senior
0.25
0.25
65
0.25
55 60 65 70
0.25
65
0.25
Ordinary
Apartment
Sitting room
Senior
0.25
Ordinary
0.15
0.15
40
0.15
50 40 30 /
0.15
40
0.15
0.15
Senior ward, CTdiagnosis
0.25
60
25
0.15
40
23
Surgery
0.15
60
26
0.15
50
25
0.25
65
26
0.20
40
20
0.25
65
26
0.15
40
20
0.25
70
27
0.25
35
18
0.25
65
26
0.15
40
20
Hospital Hall, gym, exhibit hall Office building, bank Mall, department store, emporium Cinema, theatre, airport lounge
14
Outside air quantity
Noise level NC
m3/h 100 80 60 30
dB 30 35 35 50 35 40 40 50 30 35 40 40
40m3/h·人 25 m3/h·人 18 m3/h·人 50 m3/h·人 30 m3/h·人
18 m3/h·人
Aisle, mid-court, season hall: 18 m3/h·person Hall :0
30m3/h·person 80 m3/h·person 40 m3/h·person 30m3/h·person 30 m3/h·person 18 m3/h·person 40m3/h·person 18 m3/h·person Deduce respectively 20m3/h 30 m3/h·person 20m3/h·person 90 m3/h·person 70m3/h·person 20 m3/h·person 20 m3/h·person 10 m3/h·person 20 m3/h·person 10 m3/h·person 15 m3/h·person
50 40 45 45 50 35
Dust content in air mg/m3 0.15 0.30 0.30 0.30 0.30 0.30 0.15 0.30
0.30
0.30 0.15
40
0.15
40
0.30
40
0.15
40
0.15
40
0.30
40
0.30
30
0.30
30
0.30
35
0.30
35
0.30
40 35 35 50 40 55 40
2.2 Principle of Loading Calculation and Selection In design of central air conditioner project, the factors of calculating cold load including, apron structure, heat conduct, solar radiation, convection, lamp illumination, human budy emission, equipment emission and etc. air conditoner load covers two different implications: 1) Air conditioner load in each room: to determine the model of coil indoor fan (refer to relative product sample). 2) Actual air conditioner load for building: to determine the model and quantity for central air conditioner. Generally, concise calculation should be done based on the steps as followed: 2.2.1 Determine indoor air conditioner area Aie conditioner area means, the area required to be conditioned by air, determined by occupaying area in each room. 2.2.2 Determine cold load index for unit area The determination of cold load index is affected by various factors, and, the estimated index (cold load index should be adjusted based on different phase) for ordinary building models are listed and reader can select based on real conditon as a reasonable way. Estimated Index for Air Conditioner Load of Various Buildings No. 1
Building model & room name Tour hotel: guest room (standard storey)
Cold load index 2
（W/m ）
Bar, coffee house
100～180
3
Western cuisine room
160～200
Chinses cuisine room, banqueting hall
180～350
5
Store, canteen
100～160
6
Parlor, antiroom
90～120
7 8
Small meeting room (a little smoking) Large meeting room (no smoking)
120～180
10
Gymnasium, bowling room
100～200
11
Billiard room
90～120
12
Indoor swimming pool
200～350
13
Ball room (companionship)
200～250
14
Ball room (disco)
15 16
X-ray 、 CT 、 B supersonic diagnosis room
18
Business room of Mall, department store Theatre: auditorium
19
180～280
Hairdressing & beauty parlor
Pure surgery
17
200～300
9
Building model & room name Hospital: ordinary surgery
80～110
2
4
No.
（W/m2） 100～150 300～500 120～150 150～250 180～350
Lobby (yes smoking)
300～400
Powder room
90～120
Gymnasium: play hall 20
Cold load index
120～250
Spectator (yes smoking)
300～400
Honoured guest’s room
100～120
Exhabit hall, showroom
130～200
Auditoria, reporting hall
150～200
22
Books reading room
75～100
250～350
23
Scienfic research and office room
90～140
Office
90～120
24
Apartment, dwelling house
80～90
Hospital: senior ward
80～110
25
Restaurant
21
200～250
2.2.3 Determination of cofficient of simultaneous use Little possibility exists in air-conditioning simultaneously in various rooms for different building; thus, the proper selection of application location could induce good economic benefit and expected result. Simultenous use cofficient should be acquired between 0.7～1.0. 2.2.4 Determination and air conditioner and main model selective Air conditioner load for each room should be calculated subject to the following formula: Air conditioner load area for each room（Q）＝area of air conditioner（S）×cold load for unit area（q） Air conditioner load for building should be calculated subject to the following formula: 15
Air conditioner load for building（Q total）＝sum of area of air conditioner（S total）×Simultenous use cofficient（k） Note: a. Simultenous use cofficient should be assigned a proper large value to ensure use requirement of consumer. b. In general, provided no particular requirement, no terminal device should be installed in kitchen and toilet, and thus cold load should not be involved. c. In southern region with temperature above -5℃ in winter, if the heat pump model module unit is selected, ancillary electric heater should be be attached to water system. d. In the northern region with temperature below -5℃ in winter, heat pump module unit can be selected and collocated with hot water furnace. 2.2.5 Selective ancillary electric heater （1）selective ancillary electric heater Select of ancillary electric heater. Firstly, determine heat load of dwelling house and heat generation quantity of air conditioner under the condition of design work condition in winter. Selection method is followed: 1) The heat generation quantity of heat pump unit, is measured under normal work condition (ambient outdoor temporature is 7℃), and will decrease 3% with every fall 1℃ of ambient outdoor temporature, accordingly, electric heater power could be estimated based on fall of ambient outdoor temporature. 2) While ambient outdoor temporature in winter is a bit low (0℃～-10℃), electric heater power could be selected according to 20～30％ of unit capacity. 3) Auxillary electric heater with lager capacity should be selected under condition of ambient temporature below -10℃. （2）Wiring Diagram of Auxillary Electric Heater
Wiring Diagram of Auxillary Electric Heater 16
（3）Installation Instruction of Auxillary Electric Heater
Installation Instruction of Auxillary Electric Heater During installation, electric heater should be installed in parallel in the conduit of outlet side. As shown in diagram 31, while cold generation in summer, open valve1 and close valve 2 and valve 3 in order that cold water will not go through electric heater; as heat generation in winter, open valve 2 and valve 3, and close valve 1 in order that hot water from unit go through electric heater that heats circulating water and then tansfer it to indoor trmination. Note: because installation and application for various heaters differs quite a few, relative technician should perform installation.
2.3 Design principle of water system 2.3.1 As balanceble as possible for hydraulic force The design of heat and cold supply should reach the requirement of hydraulic balance in various loops. The loop provided by much pressure difference shold set secondary circulation pump. Moreover, various loops should be provided by balance valve or diverting tee or etc. if adequent area of ppipe shaft, it should be as possible as we can to adopt pipe vertical homology program. 2.3.2 Avoid large flow rate but small difference in temperature 1) The cause of large flow rate but small difference in temperature (1) Design water rate, generally, is determined subject to maximum design cold load (or hot load), as well as 5℃（or10℃）temperature different of supply and requrn water. However, actually, the time period of maximum design cold load (or hot load), i.e. time period of full load operation, is very short, on the contrary, in most of time, operate under partial load. (2) Pump head, ordinarily is determined farest loop and maximum resistance which multiply certain safety cofficient, and then, based on design flow rate above to find pump nameplate accordant with it to determine pump model. Actual water flow rate should be more 20％～50％ than design flow rate. (3) In design of a little large water system, while design and calculation, it is not frequent to check hydraulic equilibrium for each loop, neither mostly equilibrium device such as balance valve, etc. is set for loops with wide gap of pressure difference, nor debugging is carried out after installation. Thermodynamic Maladjustment in work condition and hydrauolic work condition induced by resistance unbalance between loops has no choise but to be cloaked by large flow rate. 2) Method of avoid large flow rate but small difference in temperature (1) Considering that it is hard to hold the rigorous equilibrium among loops while design, as well as various indetermination factors existing in installation, equilibrium valve should be set in various loops to ensue to 17
achieve best hydraulic equilibrium among loops during actual operation. (2) If too much pressure difference existing between one or several certain sub-loops and other loops (resistance difference more than 10 Pa), secondary circulation pumps should be set on those certain loops. 2.3.3 Expansion supplement water and drainage and exhaust in water system 1) Expansion of water system Considering cold system of air conditioner is an enclosed system, solution of water expansion raised by water temperature changes should be done by way of setting expansion water tank in which is 1～2m above highest point of return pipe. Volume of water tank should be determined by capacity of water system, ordinarily normal water tank with the volume 0.2～4.0m3 could be used. And the volume of water tank may be augmented for water system with large capacity. Expansion water tank should be provided by expansion pipe, make-up pipe, overflow pipe, level control instrument and float ball valve. 2) Water make-up and drainage of watersystem (1) Make-up Water make-up and drainage should be via Expansion water tank, accordingly, expansion pipe should be connected separately with return manifold (or water trap) of unit so as to inject water via expansion water tank as for fresh injection water during system installation and commissioning, or make-up water routine operation. The injection water of whole water system should progress from return manifold (or water trap) in lower location as a low-to-high way so that air in conduit system should be exhausted via exhaust valve and expansion water tank as a down-to-up way. In many project installation, in order to save time and material, expansion pipe of expansion water tank was connected to the closer return manifold in a little high location so as to instable hydraulic pressure for a long time as a result of air in system hard to exhaust. (2) Drainage Drainage valve should be set at the lowest point of system (lowest point of system water conduit or water trap) so that water in pipe system should be drained entirely during overhauling. 3) Exhaust in water system Install the automatic exhaust valve in fan coil, fresh air unit and highest point of return pipe termination in each storet of building. If turns of pipe a bit many due to long loop, or some pipes are provided with up-and-down turns in order to leave room for fire extinguish pipe, fresh air pipe and section cable laid in ceiling, etc., the highest point of the turns should be procided with automatic exhaust valve. One of common faults in water system air water is entrained with air that is hard to be eliminated, of which reason is lack of automatic valve or inappropriate setting. 2.3.4 Water treatment and filtering in water system Air conditioner water quality in system in civil buildings has not been paid enough attention and popularization by design personnel. The chilled water that long-time circulating use inducing bicarbonate, bacteria, algae and other foreign matters will scale or corrode the exchange devices such as exchange shutter, vaporizer and condesator so as to augment heat resistance of the device and lower cold generation quantity and unit in-service life. 1) Water treatment The better effect methods involve pharmic water treatment and electronic water treatment. (1) Pharmic water treatment is applied for water quality treatment of cooling water system, involving common model, corrosion inhibition model and antiscalant model. (2) Electronic water treatment is applied for not only cooling water system, but also water quality treatment of chilled water (cold medium water). Electronic water handler with various standards should be installed in electronic water treatment conduit with pipe diameter DN12~DN300 and provided with distinct result, which has been applied widely for some projects at present. 2) Water filtration 18
It is quite an importance that set water filter in water system to remove the dust fiber, gravel and brick, vegetable debris and etc. general filteration device covers metal mesh, nylon mesh filter, Y-shape pipe filter and etc. filter should be cleaned periodically during operation of water system to guarantee water passway fluent and smooth.
2.4 Heat stability of water system 2.4.1 Heat stability of water system 1) Definition Heat stability of water system means temperature fluctuation ranges of water system self under the condition of thermal disturbance. Commonly, during unit time, temperature in watersystm fluctuation varies unconspicuous under the condition of thermal disturbance, which is deemed good thermal stability of water system; on the contrary, bad thermal stability of water system. 2) Influence of thermal stability on system effect Erengy of system is adjusted commonly by way of switch on and switch off the compressor that system is equipped with constant-speed compressor. Under the condition of partial load, system temperature will reach requirement value while compressor operates for a short time, and then compressor stops; if capacity of water system is small, system water temperature will deviate the temperature range specified, subsequently compressor must switch on, which will conduct compressor on and off too frequent so as to short in-service life of themaster. Moreover, decreasing over-amplitude of water temperature while antifrost in winter will affect heat supply result and conduce to cold blow air phenomenon. 3) Relationship between heat stability and water capacity More capacity of system holds better thermal stability, on the contrary, worse. Thus, while design watersystem, should collate and calculate water capacity of system whether satisfy the requirement of system thermal stability. 2.4.2 Calculation of system water capacity Water capacity of system should be the sum of pipe water capacity and equipment water capacity.
Pipe
water capacity should be calculated subject to the formula as followed: n
M = ∑ qiLi i =1
M——system water capacity（kg） qi——Water capacity （kg/m）of per meter for pipe with certain caliber see following table; Li——Length of pipe with certain caliber (m) Common pipe data Max. Flow Caliber (m)
velosty (m/s)
Friction resistance
Flow rate
(Pa/m)
(m³/h)
△t=load 4℃ (kW)
△t=load 5℃
Capacity
(kW)
(kg/m)
DN15
0.5
390
0.35
1.63
2.04
0.196
DN20
0.6
370
0.77
3.58
4.48
0.356
DN25
0.7
360
1.44
6.70
8.37
0.572
DN32
0.7
350
2.53
11.77
14.71
1.007
DN40
0.9
360
4.28
19.91
24.89
1.320
DN50
1.0
290
7.94
36.94
46.17
1.964
DN70
1.1
260
14.38
66.90
83.62
3.421
DN80
1.3
290
23.82
110.81
138.4
5.153
19
2.4.3 Thermal stability requirement of system Combining indoor ambient confort, master in-service life, system cost, possibility of system project execution and etc, the requirement ofthermal stability on central air conditioner system is as followed: 1. Operation in summer, master stops for 10 minutes, which requires raise range of water supply temperature less than 5℃. 2. Operation in winter, master antifrost for 10 minutes, which requires raise range of water supply temperature less than 45℃. 2.4.4 Minimum capacity of requirement of system According to thermal equilibrium agenda and termal stability requirement, calculate respectively the minimum requirement of air conditioner system in summer and winter on water capacity subject to the following formula: M=Qτ/(Cp△t) Q——cold or thermal supply of terminal equipment（kw）; τ——thermal stability duration: summer T=10×60s, winter T=3×60s; Cp——specific constant pressure and thermal capacity of water [kJ/ (kg·k)] △t——Value required of temperature fluctuation of water (summer △t=5℃, winter △t=3℃); Water capacity of syatem cannot satisfy requirement, enlarge system main pipe caliber or set one more water storage tank.
2.5 Installation manner of water system Closed type cold and hot water system subject to common type of water tank should be sorted into closed type and open type, which is showed as, followed: 2.5.1 Closed type cold and hot water system
AUX household heat pump (cold water) unit
Closed type circulation water system
Points of attention in intallation of cloaed circulation water tank: (1) Connect the outlet pipe of circulation water tank and pump inlet by U-shape pipe (in-situ fabrication). (2) Install horizontally automatic make-up water pump and appropriate safety valve on pump input pipe. (3) Must install automatic gas make-up valve on the highest point of water system. 20
(4) In order to avoid too high or small of pipe inner pressure, whien system pressure less than the set value of make-up water pressure, make-up water valve open automatically to supply water; on the contrary, safety valve open and drain the water. The set value of make-up water pressure could be adjusted subject to field condition. (5) Water storage tank could be installed in any location of pump suction side. 2.5.2 Cold and hot water system of open expansion watertank
1-anti-vibration throat 7-stop valve
2-discharge valve
8-check valve
3-water flow switch 4-barometer
9-open tank
10-float ball make-up valve
5-thermometer 6- Y-shape filter 11-automatic exhaust valve
Open expansion water tank system (1) In order to prevent pressure too large in pipe even pipe breakage as a result of temperature change and air hammer generation, connect the open expansion water tank to the location 1.5 meters above highest point of input pipe to ensure certain static pressure exists in master, which are integrated to make up of open type water tank system. (2) Expansion water tank must be put at the pump side and as close as possible to the pump so as to be in favor of air releasing to water tank. (3) The fittings of open type expansion must include make-up water pipe, overflow pipe, expansion pipe, signaling switch, blowdown pipe, etc., as well as air permeable pipe on tank lid. Moveover, in northern region with chilled climate, circulation pipe should be considered to install. (4) Tank must be taken measure to preserve heat, and if expansion water tank is applied for two work conditions involving heat supply and cold supply, pay special attention to the installation condition in case failure of tank structure resulting in water in tank frozen in winter.
2.6 Water conduit design 2.6.1 Basic requirement of water conduit design Water system commomly adopts bi-pipe and the building wit requirement of extraordinary confort may adopt quadri-pipe. In order to ensure each room with air conditioner to reach the desig nrequirement, it is suggested that water conduit adopt reverse-return system conduit so as to bebefit flow rate equilibrium.
21
Installation schematic drawing of reverse-return system (1) Water flow velocity in air conditioner pipe is correlative with cost and noise, and it is suggested that velocity should be subject to data of common pipe. (2) The resistance of water conduit should be calculated to check the head of pump of master whether satisfy the requirement. (3) If the build-out expansion high tank is adopted, the make-up water should be regulated by floating ball valve in expansion water tank; if the build-inexpansion high tank is adopted, intall an automatic make-up water valve on input pipe of unit. Once water pressure in unit input water pipe less than design pressure, make-up valve will open automatically to feed water. (4) To avoid air retention in the pipe, install automatic discharge valve in the highest location of the water pipe. (5) The joint between the unit and water pipe should be provided with hose to reduce the influence resulting in vibration of unit proper to indoor pipe. (6) In order to facilitate maintenance of the unit, the joint between input and output pipes and outer pipe of air conditioner should be provided with thermometer and barometer so as to be easy to examine while routine operation. (7) Set Y-shape filter in the unit inlet to avoid bocking the unit heat exchanger. (8) In order to be easy to regulate the flow rate, it is a proper way to select stop valve or ball valve with certain regulating function as for branch cut valve of unit and fan coil. 2.6.2 Design the circulation conduit system subject to building structure Basic steps are followed: (1) Make the conduit drawing of water circulation system subject to room structure (2) Determine flow rate for various loops subject to total normal fow rate for various units. (3) Design the flow velocity of various loops. (4) Calculate the caliber of the water pipe and standardize its value. (5) Calculate the maximum friction resistance subject to the most disadvantageous loop. (6) Compare the maximum friction resistance and pump head to check whether it reaches the requirement or not. If not reach the requirement, reset flow velosity and recalculate it. (7) Calculate the capacity of expansion water tank. (8) Select the appurtenance. 22
2.7 Design and select and configuration of the pipe, pipe material and pipe caliber 2.7.1 Pipe design (1) Pipe design includes design for water pipe system and air pipe system. (2) Water pipe system commonly adopts reverse-return system. (3) If the direct return system is adopted, various branches should be set flow rate equilibrium valve to balance the water quantity. (4) In order to reduce the systematic resistence of water circulation system; minimize the usage amount of pipe connection parts while design. (5) Avoid use straight pipe between the supply air outlet and return air outlet. It is a proper way to affix sound absorbing material on the inner surface of metal air duct or set acoustic absorber. 2.7.2 Select and seal connection for pipe material (1) In recent years, new type material PP-R pipe has been applied widely, which is provided with performance of long-term heat resistance and anticorrosion, as well as certain performance thermal preservation. (2) The traditional pipe material for water system include galvanized pipe and seamless steel pipe (adopt seamless steel pipe if caliber more than DN50), it is suggested that user to select new type plastic material such as PP-R etc as a priority option in order to ensure to prolong the in-service life of the unit. (3) The connection of PP-R pipe, different from galvanized pipe adopting screw connection, adopts thermal splicing, which is characterized with tight and safe and avoid leaking but tending to distort that should be paid special attention while fixing by bracket. (4)Connection parts including elbow, tee, union etc. and the threaded joint should be bound with twine or crude strap and coated by white lead oil to avoid leakage. 2.7.3 Determination of caliber (1) Caliber should not be too small in case that affect normal celosity and flow rate of circulation resulting in increasing of system resistance; but caliber too large will conduct installation cost and expanditure. In general, the tubing caliber outside of unit should not be less than the junction caliber of input and output pipe of the unit (calculation subject to total flow rate as for multi-unit parallel connection), moreover, minimize the resistance raised by elbow. (2) Selection of caliber of main water supply and return pipe should be determined subject to flow rate in pipe and selected flow velocity, commonly velosity≦1.3m/s. (3) Flow rate should generally be rated at rating flow rate of the unit. (4) flow velocity of main manifold should be selected subject to GBJ13-86 “design specification for outdoor water supply” (comparison table of pipe caliber and flow rate) (5) The caliber of various branch pipe connecting with fan coil should noe be less than mating pipe of coil, also determined subject to flow rate and selected velocity. Velocity in pipe should generally be between 0.6-1.0m/s. most of fan coils in project adopt DN20 pipe material. Comparison table of water pipe caliber and flow rate Pipe diameter（mm²） Pump suction pipe velosity (m/s) Pump output pipe velocity (m/s)
25
25-160
>160
1.0-1.2
1.2-1.6
1.5-2.0
1.5-2.0
2.0-2.5
2.0-3.0
Calculation formula of inner pipe diameter:
D = 35.69 L / v 23
L-water volume flow rate（L/s），v-water velosity（m/s） Select proper type of pipe subject to inner pipe diameter. Example 3: Please work out the pipe caliber needed by paralleled 3 units of ACMC-H220A5/D module units
D = 35.69 (11200 × 3 / 3600) /1.3 = 35.69 × 2.679 ≈ 95.6 According to result of calculation, select the pipe with metric didameter DN100.
2.8 Design and installation of expansion water tank 2.8.1 Type selective and design of expansion water tank While air conditioner water system adopts closed type system, generally connect the expansion water tank on conduit system in order to realize: (1 Aotumatic make-up water and exhaust air in water feed system (2) To leave room for heat expansion and cold shrinkage of system water to ensure the system to hold invariable pressure. (3) To avoid dust, foreign matters and mass air into system to reduce bacteria propagation and scaled. In water system project of large-scale and middle-scale air conditioner, open –type water expansion tank is adopted and the capacity is determined subject to the following formula: V=a ×∆T×Vs Note:
3
V-effective capacity of expansion water tank [m ]
a-water volume expanion coafficient, commonly 0.0006[L/℃] ∆T- max. Water remperature variable [℃] 3 Vs- vilume in system [m ] Nite: if the open type expansion water tank and correlative floating ball make-up valve are arranged in system, automatic make-up valve and safety valve will not be used any longer. The selective should be subject to the field condition. example: ∆T=60℃，Vs=1000L, please work out the volume of the expansion water tank selected. V=0.0006×60×1000 ≈ 36L We can work out based on the above formula, effectivevolume of water tank 36 L, and we should select the water tank with the capacity doubling effective volume, i.e. expansion water tank with volume 72 L. 2.8.2 Installation of expansion water tank (1) In circulation system, expansion water tank should be installed in the suction side of the pump, and its inner level should be high 1.5 meters than the highest point of the system, and the water volume should account for about 10% of the volume in whole system. (2) Expansion water tank should be provided with expansion pipe, signaling switch, make-up pipe (manual and automatic). Overflow pipe should not set valve and the caliber of overflow pipe should be more than expansion pipe. (3) Tank proper should be preserved with heat and be provided with cover plate on which connecting an air permeable pipe that is made of steel pipe with the metric caliber 100mm. (4) While expansion water tank is applied to two work conditions involving heat supply and cold supply, generally, a circulation pipe without valve should be protruded from expansion water tank in order to avoid tank structure breakage resulting in water icing in the tank even inducing accident while heating in winter. Expansion water tank and circulation pipe should be arranged on same conduit with certain distance that is generally is 1.5～3.0m between the joints soas to water in tank to keep flowing slowly under the condtion of pressure difference. (5) It is strictly inhibited that install valve on expansion pipe, overflow pipe and circulation pipe, but install valve on blowdown pipe and signaling switch. (6) The expansion pipe, circulation pipe and signaling pipe arranged in non-heating supply room should be 24
taken measures of heat preservation. (7) Wate temnperature in open type expansion tank should generally not more than 60℃. (8) Limited by installation condition, the closed type circulation is applied to small-scale unit (such as household unit) at present (details refer to closed type circulation system above-mentioned), which solve the difficuty on installation height of expansion water tank.
2.9 Design of condesating water discharge system 2.9.1 Condesating water discharge system Temperature in the surface of coil is generally lower than air dew temperature while cold generation in summer and exchanger surface will frost, which requires that the receiving tray under fan coil is connected with sewage pipe or cloaca by water pipe so as to drain the condesating water of the receiving tray in time. The drainage pipes of condesating water raised by dewing on surface of fan coil evaporator make up of condesating water drainage system. 2.9.2 Determination of pipe material and pipe caliber for condesating water (1 It is suggested that condesating water pipe adopt PVC or galvanized steel pipe. (2) Caliber of branch pipe of condensating water connecting directly with fan coil should conformable to cabliber of pipe for receiving tray. (3) If condesating main water pipe required to be set, caliber of main pipe should be determined subject to the gradient of total cold load Q (kW) of fan coil unit connecting with main pipe, i.e. subject to main cold load, condesating water flow rate, gradient of condensating pipe. (4) Flow rate of condesating water may be calculated subject to 0.4-0.8kg/h condesating water engendered by 1 KW cold load. Usually, select the caliber of condesating water pipe subject to the recommended calue listed as following based on cold load of the unit. (5) If the gradient of condensating water pipe is difficult to reach requirement, may set additionally lifting pump of condesating water in room. (6) According to the project experience, common branch adopts DN25 and main (manifold) pipe adopts DN25, DN32. Selection of caliber of condesating water main pipe Min. pipe gradient
Cold load (kW)
0.008
〈7
7～18
18～100
100～170
170～600
Metric dia. DN (mm)
20
25
32
40
50
2.9.3 Arrangement of condesating water pipe (1) Drainage pipe is inclined down at the rate of over 1/100 (see the diagram below).
Arrangement of condesating water pipe (2) The arrangement of drainage pipe should be as short as possible. (3) Traverse arrangement pipe should be short as possible. As for the long pipe arrangement, set separation diatance between bracket and hang up by lifting bolt. (4) Indoor unit which negative pressure exists in joint location of drainage tubing should set U-shape elbow (or call “trap”). Every indoor unit should set drainage U-shape elbow and at the bottom of the elbow should set seal plug (open/close) so as to be easy to clean. (5) Points for attention for drainage tubing: 25
1) The size of the drainage tubing should be more or conformable to the size of junction of drainage pipe foe indoor unit. 2) Coat the coherent agent while connection 3) The heat preservation of drainage tubing should be done by serious manner. Dewing will be raised without heat preservation. The heat preservation location should be up to the connection location of indoor unit. 4) It is suggested that condesating water pipe adopt fire retardant type transpired rubber plastic material. 2.9.4 Concentration drainage tubing and connection 1) Selection of diameter for concentration drainage tubing The number of indoor unit connecting with concentration tubing→calculation of drainage amount→selection of tubing diameter. (1) Calculation of folw rate of allowable flow rate allowable flow rate=cold generation amount of all indoor units connecting with concentration drainage pipe (unit: HP)×2L/h note: As for drainage amount from indoor unit, 1HP is equivalent to 2（L/h）. (2) Select the caliber subject to the allowable flow rate table from calculation:
Comparison table of flow rate and pipe caliber of concentrate drainage pipe Concentrate drainage pipe
Allow flow rate (L/h) (gradient 1/100)
Inner dia. (mm)
Wall thickness (mm)
Hard PVC
∽≤14
φ25
3.0
Hard PVC
14〈∽≤88
φ30
3.5
Hard PVC
88〈∽≤175
φ40
4.0
Hard PVC
175〈∽≤334
φ50
4.5
Hard PVC
334〈∽
φ80
6.0
Note: the table above is only applied to traversed protruded tubing. 2) Connection of concentration drainage pipe
Schematic drawing of concentration drainage tubing (1) Connect the traverse main tubing from the end and the metric diameter of concentration drainage tubing (manifold) is more than φ30mm. (2) In order to shorten the length of the traverse main tubing; minimize the indoor units while design. (3) The indoor unit with drainage pump and indoor tubing of natural drainage should be concentrated to the respective traverse protrude pipe. (4) It is necessary to arrange addtinally “extended ventilation pipe” in the drainage project. (5) If necessary, install a trap in the drainage output pipe so that the pressure in the unit while operation will be less than the ambent atmospheric pressure. If the trap is not installed, spattering and smelling occur. 26
2.9.5 Bracket pitch of condesating water pipe Bracket pitch of condesating water pipe Pipe dia (mm)
φ15
φ20
φ25
φ32
φ40
φ50
Pitch (m)
1.5
2.0
2.5
3.0
3.5
4.0
2.10 Constitution of construction program After type selection of main unit and termination and pipe desing, make the main unit foudation drawing, systematic pipe arrangement drawing, elelctric qiring drawing, plan drawing, lifting drawing, etc., and prepara the construction program subject to room air flow arrangement, actual condition in field and national specification. Firstly, referring to the design program and construction drawing, define the contents such as installation procedure and direction location for unit and components of water circulation system in field, connection method of control system and installation and orientation of the control switch. The construction program of central air conditioner not only ensures air conditioner operates in normal way, but also considers the decration beautification for users.
27
3. Installation Manual for Air-Cooled Cold (Hot) Water Unit of Mudular Type 3.1 Installation of main unit 3.1.1 Preparation before installation (1) As civil work going, carrying out the installation foundation of main unit, execute the pipe reservation, embedding for installation bracket, hanger, cable and various protection casing. (2) Open package inspection must be done for each unit, before construction conform the reliability of unit and appurtenance. (3) Preparation of termination device and material: verify air conditioner unit, termination device and installation spares and material. Collate and select the components as followed: (a) Termination device 1) Generally adopt fan coil. Consider the decration style of the house while select fan coil. Commonly the horizontal fan coil characterized with good invisibility, smaller noise should be applied widely. 2) While verify the fan coil, except inspect the appearance and size whether conformable to the desing matching requirement, moreover, verify the left pattern or right pattern direction of the installation location for input and output conduit in the design drawing so that ensure the convience and exactitude for installation. (b) Circulation pump 1) While multi-level pump in actual operation, the gate valve or butterfly valve should be installed on the input water pipe, and check valve should be installed on the output pipe. 2) During calculation of the pump head, should consider various friction resistance of the pipe, valve, instrument and junction parts, therefore the flow rate andhead of the pump should hold certain margin. 3) Backup pump should be reserved during design of water system for middle-size unit such as module unit. (c) Expansion water tank Module unit mostly adopts open type water tank because located in open position (such as roof or reserved location). Desing of water system for household-unit may adopt closed mechanical circulation system. In order to fit installation of apartment house, the low flush expansion water tank. (d) Water collector and water diverter Water collector and diverter, actually is a pipe with large caliber, can be installed on the water supply or return main line of the water system. Chilled water generated from cold-water unit firstly flow into diverter, and then via pipe to various air conditioner regions; return water from various air conditioner regions feed to water collector and return to unit finally. The advantage of such arrangement is, good to resistance equilibrium of the water pipe system, flexible and convient in water quantity distribution and regulation, avoidable frequent start of the compressor while small load. (e) Flow switch To avoid damaging the cut-off protection device being set resulting in water shortage of system, usually adopt target flow switch. (f) Thermometer and barometer In order to facilitate the monitor and maintenance on operation of unit, thermometer and barometer should be installed on the water supply and return conduit. Generally select subject to the design standard, and suggestion is as followed except otherwise specified: Thermometer: 0～50 glass thermometer Hydraulic pressure meter: 0～1.0Mpa Note: observe the water pressure difference of the input and output ends, and get the head outside of unit under the water quantity. (g) Water pipe and valve 28
1) Water pipe: in order ensure the clean and bearable pressure (1.0～1.2MPa), temperature (-20-80℃), select the heat meltable PPR material. Copper plastic pipe and aluminum plastic pipe also are applied widely due to convenient connection. The material of throughway pipe, reducer pipe and elbow, etc. should be straight and clean, and inside of pipe should be smooth and unobstructed. 2) Valve: it is suggested that select copper core valve so as to ensure system clean and reliability. Valves in common use including: gate valve, stop valve, throttle valve, ball valve, automatic exhaust valve, check valve, solenoid valve, etc. (h) Heat preservation material: common glass wool, soft polyesters ammonia foam plastic and rubber plastic pipe. (i) Fixing frame: angular steel (or channel steel) support, hanger, tray (j) Control switch and auxillary components: Power source breaker, remote controller, trisspeed switch, automatic temperature switchm cable wire, supply and return outlet and condensating water pipe.
(4) Preparation work for the equipments of lifting, cutting, welding, punching, impulsing and cold medium perfusion, etc. 3.1.2 Location selection requirement (1) He unit can installed on balcony, roof, special platform or any other location where is easy to install and bearable to the unit weight while operation. (2) Location is provided with good ventilation condition and exhausting fluently. Side plate of the main unit should keep space of over 1000mm, at least 2500mm between top exhausting cover and the top barrier, more than 1500mm on the unit maintenance face, and the cold and hot exhaust and as well as noise should not affect the neighbourhood. (3) Avoid install the unit at the ventilation shaft, yard or other place where is limited in case the echo raised by wall enlarge unit noise or backflow exhausted from unit affect unit performance. (4) While unit is placed on roof, notice the perennial wind direction and outlet should avoid face directly to the perennial wind direction; if installed on the ground, avoid as possible as we can to keep away from the strong wind gap. (5) Unit should be installed on the location where far from heat source or exhaust vent of combustible gas and corrosive gas. (6) If open installation of unit, install the sunshading board to avoid sun direct exposure, deluge of the rain, accumulation of snow. (7) Protection defence round the unit should be provided in case touch and impact by kids. (8) Location where free from bough, fall leaves, insect and etc in case block the condesator and damage fan vane. (9) Location where convenient to arrange input pipe and output pipe, water tank, valves and distribution. (10) Proper space around the unit should be provided so as to install, maintain and operate normally, and it is suggested that installation space and foundation should be subject to the drawing as followed:
29
Schematic drawing of unit installation space
ACMC-H190A5/F schematic drawing drawing for foundation
Type Dimension
ACMC-H220A5/D
ACMC-H340A5/F
A 1490 1926 B 2200 2330 (11) Drainage sewage should be reserved under the unit ground. 3.1.3 Lifting and hailing of the unit (1) The unit is transported from warehouse to site. The unit should keep good perpendicularity condition and pay attention to avoid collide or damage. (2) While lifting, it is proper to adopt fork –lift truck, oil hydraulic trailer or crane with carefulness. (3) Gredient should be less than 30° while unit haulage. (4) While lifting, the length of strut should avoid impacting unit. (5) People should not stand under the unit or close-by location while lifting to ensure safety. 30
(6) Strut should be provided with sufficient strength. Sling should adopt wide-flat strap with enough strength or flexible steel cable.
lifting cable
lifting cable
3.1.4 Requirements and points for attention while unit installation (1) Fix the unit on the separated prefabricated pedestal by expansion bolt and ant-vibration rubber washer, and reserve the drainage gully. (2) Steel bracket made of angular steel or channel steel, as well as antivibration rubber washer should be installed on concrete foundation ground, balcony, roof or outdoor gallery, etc., and ensure the unit in horizontal level. (3) In order to aoid unit vibration and noise into the room, the thickness of the washer should be 30～50mm. (4) obliquity of the unit should not more than 5°. (5) Fix the unit joint and revolve the connection joint by pipe forceps while pipe conncetion, it is strictly prohibited that execute the rotating torsion force on the reserved joint directly. (6) All the power cable and signaling line should be arranged in standard and professionally to ensure absolute safety on electric connection. (7) Condensator of the unit must be put on the place with good ventilation, and there is at least 1-meter distance between the outer side of the coil fin and wall. (8) Necessary room should be reserved on the unit operation maintenance face(≧１.５m). (9) After installation and debugging, wipe the outer shell of units indoor & outdoor by clean cloth in case affect aspect beautification and bad impression to users.
3.2 Installation of the circulation conduit (1) Based on the cold generation quantity and tubing size stipulated in the instruction, select the relative pipe with the caliber not less than caliber of outlet and inlet pipe, and construct in right way subject to the heat and ventilation standard and minimize the resistance loss of water system. (2) Hose antivibration coupling should be installed at the joint of the inlet &outlet pipe of the main unit in case unit vibration and noise into the room. (4) Water conduit safety valve and automatic make-up valve must be installed if adopt closed type water system, which should be installed on the input pipe of the pump. Automatic exhaust vavle (installation vertically) is at the location 0.5-1.0m above the highest system point. (5) Automatic exhaust vavle should be installed at highest system point for the open type water tank, and floating ball valve regulates the system volume. No necessary to installed water conduit safety valve and automatic make-up valve. But if adopt the two types of water tanks, automatic exhaust vavle under which install a gate valve should be should be installed at the location 0.5-1.0m above the highest system point and avoid at the pump outlet. (6) Whether in prectise or in theory, all the top of the ballonets that possibly accumulate air in water system should set automatic exhaust valve, moreover, enlarge the diameter of partial pipe while install automatic exhaust valve. 31
(7) Must install Y-shape filter (40 mesh/inch²) on the unit input pipe in order to avoid filth in water system obstruct heat exchanger of waterside to conduce unit damage. Pay attention the flow direction while installtion and install stop valve additionally at both sides of the filter so as to disassembly and clean filter. Suggestion: users had better install the electronic scale remover with relative standard to ensure unit in good operation condition for a long time. (8) Thermometer and barometer should be installed at the straight pipe (cannot install at the elbow) of unit input & output so as to inspect unit operation status. The sensor of the thermometer must be insert into the flowable water in pipe to guarantee the accuracy of temperature measurement. Install hand exhaust valve at the junction between barometer and pipe in order to exhaust at any moment and keep system balance. (9) Offlet valve (clean the valve) should be installed at the lowest location of unit input & output pipe. Offlet should be connected to the ultimate system to discharge the clod medium water of the unit from two outlets while nonuse in winter in case coild medium water in winter is frozen in converter and pump and damage the unit. (10) In northern, automatic make-up valve and stop valve of expansion water tank in water system should be installed in the room in case the make-up pipe and valve are frozen to fissure whild use in winter. (11) Separate bracket in water system conduit should be set, and the applied force should not be imposed on the main unit. Commonly the space of the bracket should be subject to the material performance and caliber dimension. PP-R pipe with length 0.8～1M should be fixed by support. (12) Design and installation for indoor unit and pipe system, in principle, should be carried out by professional personnel subject to relative technical specification. The pipe direction should be designed subject to actual house type. Refer to drawing as followed, adopt conduit A direction not conduit B and aviud “U” shape curve (see the drawing as followed) in case conduce flow disfluency, anlaragement water resistance and form air plug.
Schematic design drawing of pipe direction (14) Flat and straight pipe should hold certain gradient so as to exhaust the gas. (15) After installation, according to installation specification of heat and ventilation, carry out hydraulic pressure leakage test and execute the cleanout, blowdown and washing to ensure clean and no rust residue and debris in system pipe in case obstruct the conduit and heat exchanger of waterside and pump even unit damage. (17) “U”-sahpe bypass unit must be used while clean the indoor pipe. It is qualified that no leakage under 1.0Mpa hydraulic pressure. Moreover, after clean the indoor pipe, connect the main unit (avoid blockage of heat exchanger of waterside). After operation of pump for 30 minutres, cleanthe filter. (18) Valve switch must be flexible and untact while installation of water conduit, and the valve handle should avoid bend. (19) Valve handle should be installation on horizontal pipe in vertical upward or oblique up ward way so as to open. It is prohibited that valve handle in installed downward. Under the vertical pipe, valve handle should be installed perpendicular to the wall. 32
3.3 Electric standard requirement Electric installation must conform to the regulation of electric equipment and distribution. The breaker of power source should be installed and ensured good grounding performance based on maximun work current applied by electric equipment. 3.3.1 Electric standard requirement: (1) Unit power source should be connected with special line provided with reserved special power source that should avoid employing same power supply system with other power source. (2) The indoor fan coil and outer unit should be provided by same power source respectively. (3) power source voltage class of outdoor unit: three-wire～220V, five-wire～380V. power source voltage class of indoor unit: three-wire～220V. power source voltage class of heat assistance: three-wire～220V, five-wire～380V. (4) Permitted passiveness of power source voltage: ±10%. Phase-to-phase potential difference for three-phase power source: ±2%. (5) Power source class matched air conditioner should conform to unit requirement. 3.3.2 Electric correlative standard requirement (1) Special power source must use appropriate breaker and prohibit using gate switch and socketing. Based on project experience, the capacity for cpmmon breaker could be selected subject to the principle of more than maximum unit work current. (2) Power supply of indoor coil connecting with same outdoor unit is shared with breaker (i.e.power supply for the indoor coil in same system is shared with outdoor unit). (3) Each module unit should set special breaker respectively. 3.3.3 Standard requirement of switch electric appliance (1) Special power source must use automatic air switch or leakage breaker that can protect main unit, and prohibit strictly using gate switch and socket. Based on the project experience, common breaker should be selected subject to doubling the work current. (2) Accordig to regulation: minimum line current=maximum load×1.25+total of additional load (to determine line diameter). Therefore, the work current of breaker for household central air conditioner must be 1.25 times (total current less than 50A) or 1.1～1.2 times (total current more than 50A)of the rated current , which could satisfy the overload requirement for indoor temperature raise and compressor pressure increase. (3) Power supply of indoor coil connecting with same outdoor unit is shared with leakage switch and air switch (i.e.power supply for the indoor coil in same system is shared with outdoor unit). 3.3.4 Standard requirement of line distribution (1) Diameters of power incoming line for various standards unit must reach the data requirement in the following table:
33
Schematic drawing of parallel connection of multiple module units Power supply line standard of each single module unit No.
Type
1
ACMC-H190A5/F
2
ACMC-H220A5/D
3
ACMC-H340A5/F
Standard of power line
Remark
16mm2×3+10mm2×2 25mm2×3+16mm2×2
(2) Length means generally the cable length between the main unit and special power source. As for commercial-purpose central air conditioner, must consider length of line distributions while select distribution line in order to ensure the potential descend in the range of 2% of the rated voltage as motor starts. (3) Cable, component and material procured must conform to national standard and only allow to use copper conductor. (4) Cable must be temperature resistance copper core conductor wit the performance of not less than 75℃. (5) Power cable should be chloroprene-armored line, i.e. type YZ、YZW in table 18 of GB5013.2 3.3.5 Standard requirement for wiring (1) Phase line, zero sequence line and grounding line of single-phase power source should be connected with red, bule and yellow/green conductor. Yellow, green, red light blue, yellow/green of the three-phase powersource are relative to L1, L2, L3, zero and ground line. (2) Communication line and power supply line should not be close or laid in parallel. (3) If the three-phase pump motor or fan motor reverse rotation, alternate any relative two power supply lines of three-phase pump motor or fan motor. (4) Connect the power supply line to the connection pole and press the conduct by connector and then fix it by screw. Distinguish the color and diameter of the power supply line while installation. (5) Conductor should be connected firmly; otherwise failure or disastrous consequence for unit such as fire etc. will occur resulting in too hot. (6) Connect the main control panel of outdoor unit and control board in indoor control box. (7) After finish installation of cable, inspect carefully referring to the electric wiring diagram so as to ensure right connection and then energize to operate. Prohibit operate at a venture in case unit fails. 3.3.6 Earthing requirement Electric project must be provided with earthing system and the selection of layout commonly should be done subject to the regulation as followed: (1) Commonly select copper core conductor. (2) Section area≥1.5mm2, generally use one-third of section area for relative phase line 34
(3)1/2 of section area of phase line ≤section area of the earthing conductor≤20 mm2。 (4) Commonly select subject to the following table: Section area of the earthing conductor Section area of phase line for device (mm2)
Earthing line (mm2)
S≤2.5
S
2.5＜S≤30
S/3
30＜S
S/2
3.3.7 Control layout (1) Control conductor is weak loop and neither contact directly to the power AC220V、AC380Vsupply layout nor put in one conduit pipe. (2) Prohabit use control conductor as the ring distribution line. (3) To prevent noise interruption, the transmission line special for control is recommended that use four-core shield cable and the section had better in more than 0.25 m2 of the copper core. (4) The maximum length of communication cable should not excess 1000m. (5) All the signaling control cable should be with steel conduit. 3.3.8 Selection of the conduit Conductor conduits commonly include the following types subject to lay surrounding: (1) Metal pipe: Commonly applied to the location with strong electromagnetic interference indoor and outdoor. The lay of metal conduit laid open in damp location or undergound lay should adopt water gas steel pipe. The lay of metal conduit laid open in dry location should adopt electric line pipe. (2) Hard plastic pipe (PVC pipe) Commonly applied to the location with acid or alkali or salt corrosion or indoor location, but except where exists machanic damage or strong electromagnetic interference, moreover, the pipe material must be provided with fire retardant. 3.3.9 Conduit requirement (1) The withstand voltage level for the conductor laid by conduit should not be less than 500V. (2) Easy of conduit and heat radiation; total area of conduit conductor≤40％ of effective area in pipe. (3) Metric diameter of conduit≥15mm. (4) Wall thickness of hard plastic pipe≥3mm. 3.3.10 Fixing spacing of conduit (see the table as followed) Fixing spacing of conduit Metric diameter of conduit (mm)
Fixing max. Spacing of conduit (m) Metal pipe
Hard plastic
15-20
1.5
1.0
25-32
2.0
1.5
40-50
2.5
2.0
3.3.11 Minimum spacing between electric line and other pipes (see the table as followed) Minimum spacing between electric line and other pipes Laying mode Parallel
Conduit name
Conduit
Cable
Insulalaing conductor
Stream pipe
1.0/0.5
1.0/0.5
1.0/0.5
Hot water pipe
0.3/0.2
0.5
0.3/0.2 35
Cross
Ventilation pipe
/
0.5
0.1
Water pipe
0.1
0.5
0.1
Stream pipe
0.3
0.3
0.3
Hot water pipe
0.1
0.1
0.1
Ventilation pipe
/
0.1
0.1
Water pipe
/
0.1
0.1
3.4 Hydraulic test and heat preservation of pipe 3.4.1 Hydraulic test (1) After installation of pipe system, main unit, termination, accessory parts, electrics etc., hydraulic test should be done to inspect the seal performance of the water system. (2) General test pressure should be 1.2 times of the operation pressure and the minimum pressure should noe be less than 1.0Mpa. (3) While hydraulic test, connect the manual test pressure pump and fill water to exhaust the air, and then close the input and output valve of main unit, and switch off the power supply and automatic exhaust valve, and finally carry out the pressure-holding test of water system. (4) Fill water into the pipe, and pressurize the pipe by manual test pump, and observe whether the pipe leak or not in one hour. After confirmation of no leakage, pressurize the system up to indicating 1.0～1.2Mpa in braometer, and record pressure valve. Keep the pressure more than 6 hours. (5) Ensure finally no leakage for pipe and each joint. Handle leakage in time and carry out hydrauic test again if leakage occurs. 3.4.2 Heat insulation of pipe After confirmation of non-leakage of pipe system, must paint the antirust painting for the welding spots for pipe system, valve pats and joints on the pipe, and then carry out heat preservation in case cold or hot loss and generate condesating water resulting in dew on surface. Heat. There are many kinds of heat preservation material, but the material of commonly used invilve rubber-plastic insulating wool, glass wool, rock wool, soft polyesters ammonia foam plastics etc. (1) Economic cold-hold thickness for cold water pipe of air conditioner Economic cold-hold thickness for cold water pipe of air conditioner should follow national standard the regulation of GB50189-93, and should not be less than date in following table: Economic cold-hold thickness for cold water pipe of air conditioner Cold-hold
Cold supply duration
material
one year /h
Rock wool pipe shell Glasss wool pipe shell
2880 3600 4320
Thichness of Metric diameter /mm
economic cold-hold /mm
15-150
30
200-350
40
15-150
30
65-350
40
15-80
40
100-350
50
(2) Economic heat-hold thickness for cold water pipe of air conditioner According to stipulation in GB50189-93, should not be less than date in following table: Economic heat-hold thickness for cold water pipe of air conditioner Heat preservation material 36
Metric diameter /mm
Thichness of economic cold-hold /mm
Rock wool pipe shell Glasss wool pipe shell
15-25
20
32-150
30
200-195
40
(3) Thichness of economic cold-and-heat-hold water supply pipe /mm Water supply pipe of cold and hot water should generally be selected subject to the economic heat insulation thickness in table “Economic cold-hold thickness for cold water pipe of air conditioner� (4) While pipe binding, not too loose or tight in case affect the heat preservation of the material. (5) The connection accessory parts should be insulated and bind the naked metal parts in case dew generation. (6) Surface of heat preservation layer should be characterized with flat, no fracture and no disjoint, no dew generation and leakage even more. After fixing of heat preservation of water pipe, carry out the hydraulic test for water system to ensure no seepage in system.
3.5 Injection and commissioning of cold medium water 3.5.1 System cleanout and injection of cold medium water (1) After installation of air-cooled type cold (hot) water unit, clean whole the water system. Firstly, open blowdown valve and dismantle the water filter, and clean it by fresh water and install and fill water. After that, switch on pump and whole water system circulates. 10 minutes later, switch off punp and open blowdown valve and dismantle water filter. The circulation above should repeat many times till the limpidity of input and output water tends to uniform and no debris in the water filter than is dismantled. (2) The clean soft tap water after disposed should be treated as cold carrier agent, i.e. cold medium water (PH valve between 6.8-8) for circulation system and injected system from return pipe of the unit. After the system full, exhaust the air in water system. And confirmation of air exhaust in water system, energize the unit for preheating for 8 hours. Note: manual exhaust valve in system must keep open while injection, and then close after water full. 3.5.2 Inspection before commmissioning (1) check distribution system 1) Check the conformance between power supply voltage and supply voltage required in this technical manual and unit nameplate 2) Check all the supply line and control line whether are connected or not, whether right wiring, whether the earthing is correct or not, whether all the connection terminals are cleaned and fastened.
3) Check air switch, breaker and leakage protector of the unit whether the switch range are enough or not, whether movement of the open or close is maneuverable or not, whether is safe and reliable or not.
4) Use megger to check the insulation. (2) check air conditioner end (fan coil) 1) Check all the power supply and wiring of the indoor fan coil whether it is correct or not, whether the fan movement is normal or not. 2) Check the check valve at outlet of fan coil and flow control valve whether all open or not. 3) Check air in fan coil whether exhaust or not, and abnormal noise will occur of air exists in coil, at that time, turn the manual exhaust valve to exhaust the air and close mannualexhaust valve till stable water flow occurs. 4) Check trap of fan coil whether accumulative debris exists or not. (3) unit inspection 1) Check conduit in unit whether damage or not during transportation and haulage. 2) Check fan vane whether friction exists between the fan fixing board and fan guard screen or not. 3) Check refrigeration system whether pressure exists or not, whether leakage point of coolant exists. 4) Check compressor whether is preheated for more than 8 hours (especially commissioning in winter) (4) inspect the conduit system 1) Check valve should-be open in system whether all open and in normal condition or not, and check valve 37
should-be closed in system whether all closed. 2) Check conduit system whether electric leakage occurs or not. 3) Check all the tubing joint whether cold medium water leaks or not. 4) Check condesating water pipe whether prvided with certain gradient or not, drainage fluent or not (by water-drop test). 5) According to indication of barometer, check and adjust hydrostatic system pressure whether up to design index (commonly above 50Kpa required) or not, automatic make-up valve work under m\normal condition or not. 6) Check heat preservation of system conduit intact or not. 7) Check system conduit clean or not, if necessary clean repeatedly. 8) Check cold medium in conduit whether full or not, air exhausted or not, and automatic exhaust valve whether operates under normal condition. 3.5.3 Commissioning (1) After an all-round inspect for all system and confirmation of reaching requirement, select cool or hot module subject to remperature and press the relative functional key in line controller panel to prepare commissioning. (2) Install high/low pressure barometer in refrigeration system; clamp amperemeter in power supply main loop so as to inpect the pressure and current while system operates. (3) Adjust pressure of the make-up valve: while adjust make-up valve, in order to avoid pressure too high resulting in expansion, distirsion even fracture of circulation water tank, adjust pressure of make-up valve up to minimized location (turn counterclockwise), open stop valve in front of make-up valve, and then adjust gradually to specified valve referring to pressure status of make-up valve (around 0.1MPa). (4) operation 1)Switch on and open properly the indoor fan coil. 2)Pump starts as first step and check abnormal noise occurs or not, and observe the water pressure whether included in normal range or not (pressure difference of input and output water not less than 50KPa). 3)Occurance of flow switch protection indicates punp flow is too small, which requires research reason and solve. 4) Check rotation direction of the fan and punp for three-phase power supply right or not, if not, turn off power supply immediately and adjust phase sequence. Measure the work current of compressor whether normal or not, abnormal sound or not. 5) After time extended, compressor starting and unit under normal work condition, at that time, check unit whether abnormal vibration and abnormalnoise or not, and observe temperature varying for suction and exhaust of compressor. Check unit current whether in normal and make relative record. 6) While unit in normal work, reference valve of suction and exhaust pressure of compressor as followed: cool generation:suction pressure: 0.30～0.5Mpa (depend on water temperature) exhaust pressure: 1.30～2.2Mpa (depend on ambient temperature) hot generation:suction pressure: 0.18～0.42Mpa (depend on ambient temperature) exhaust pressure: 1.30～2.10Mpa (depend on water temperature) 3.5.4 Examination of protection and temperature control (1) Protection test of flow switch: under unit normal work condition, close gradually return valve, at that time the water supply falls gradually and pressure falls, and observe flow switch whether switch off and stop unit and indicate failure of insufficient flow. Warning: prohibited strictly turn down the flow control switch, or short-cut connection of line of the flow switch (2) Low temperature protection test: if flow insufficient and set valve of temperature too low, low temperature protection will actuate. So, decreasing flow rate or lower the set valve of controller will conduce unit stop. 38
(3) Test for temperature control system: under cool generation work condition, close the entire fan coil. While temperature of return water highten (lower) set valve (commonly 12℃ for cool generation, 40℃ for heat generation), compressor stops, and then open fan coil ti raise (decrease) temperature of return water, which results in compressor normal start and work. (4) Units operate continuously over 4 hours and observe variance of output temperature and temperature difference and record the debugging data. If the data is not fallen in to the normal scope, execute relative inspection again (in normal condition, temperature difference of input and output water≧4℃) up to normal measurement result acquired. (5) Based on room’s cool (heat) generation result, adjust relative flow adjust valve of fan coil of air conditioner in various rooms so that the water supply in each room could reach required flow. (6) Subject to demands from users, set tri-speed (temperature control) switch and observe work status whether satisfy the requirement or not. (7) Operate normaly for a common duration (commonly 3 days) and observe temperature variance in room whether satisfy requirements concerned. (8) After conformation of non-fault, clean the water filter again and fasten all the electric wiring terminals again. (9) As for the system with electromotive two-way valve or three-way valve, should observe electromotive valve whether has adjusted water quantity normally during working. If bad control, adjust in time. (10) During unit commissioning, after finish examination for all basic functions, close main unit and dismantle examinatin apparatus, and fasten electric wiring terminal again in case wiring terminal loose resulting in machinery failure, and finally install the cover plate. (11) In order to ensure cleanliness of water system, it is necessary to clean water filter at unit inlet finally. Only after conformation of trouble-free for system and unit, hand unit over to users for normal operation. (12) While handover to users, debugging staff should guide user to use air conditioner following operation regulation in product instruction, if necessary, demonstrate operation till users can use it correctly. 3.5.5 Unit operation condition (1) Suction and exhaust pressure of compressor while cool generation operation normally: suction pressure: 0.30～0.50Mpa (depend on water temperature) exhaust pressure: 1.3～2.2Mpa (depend on ambient temperature) (2) Pump flow quantity should not be less than unit flow rate under nominal work condition while unit operates normally, if flow rate decreasing, temperature diference of input and output water increasing (common temperature difference of input and output water while operation normally), and protective shutdown for flow rate protector or water temperature protector occurs, should find reason why flow rate deduce. After eliminate the failure, start the unit to operate. 3.5.6 Unit normal operation After commissioning and confirmation of system normal operation, install cover plate of overhaul hole and then unit enter notmal operation condition. A few pints should be attrened by users while unit operation, which are followed: (1) Beore use, check the outdoor unit condesator to ensure no foreign matter such as fallen leaves, winceyette, insect, debris and hull etc.; contamination will not only increase power consumption but also result in high-voltage shutdown. Dust collector may be used to clean outside while contamination removing and not damage aluminum radiator. (2) Room temperature should be proper aoid too high and too low, and ensure satisfy demand. It is suggested that 23～28℃ for cool generation and 18～23℃ for heat generation. (3) Use control switch and execute on process while switch on or off unit. It is absolutely prohibited that use the power switch as the switch of unit, which will induce system damage. (4) Other electric appliance (such as TV, radio, acoustics, etc.) should keep over 1 meter diatance from indoor unit 39
and controller, otherwise air conditioner unit will interfere image and sound or raise noise. (5) Window receiving sunshine should hang curtain and shutter to wnsure the heat preservation effect while air conditioner operation. (6) It is not proper way that keeps window or door open for a long time while air conditioner operation; otherwise the condesating water will occur at supply air outlet. (7) If perculiar smell occura (such as burn smell) while air conditioiner operation, should switch off and search for reason. (8) It is prohibited strictly of live unit cleaning and washing air conditioner by water. (9) User can use remote controller to switch on/off and diverse cold/hot generation. (10) On snow days, open unit should be shielded by tarpaulin, and if snow accumulative on the unit, switch on after clean the snow. (11) points for attention while unit shutdown: 1) While unit opeates normally, if shut down due to personnel factor and start again, compressor should start 3 minutes later, and prohibit forcing start compressor by other means. 2) If shut down for a short time under cold operation in summer, commonly press “on/off” button on remote controller, and it is no need to cut off power, which is benefit to heat the lubrication by heater. 3) If shut down for a short time under hot operation in winter, must press “on/off” button on remote controller. 4) Shutdown for a long time in usage season or non-usage season, drain the cold medium in unit through unit outlet (drain valve while open the control penel) and cut off all power supply. While use again, inject water into the system subject to relative instruction. 5) Inspect the input and output temperature, fan, pump of the unit as a routine way while unit operates. 6) Regularly check power supply and electric parts of the unit whether are normal or not, and inspect the cleanliness of heat exchanger and clean it subject to actual condition. 7) Prohibit close at random input and output water valve of indoor fan coil while unit operates in case affect unit operation and heat exchanger frozen.
3.6 Project acceptance and maintenance 3.6.1 Project acceptance Central air conditioner commonly should be accepted into two stages during installation and commissioning: (1) After installation of system conduit, before indoor decoration, carry out the preliminary acceptance for hidden items involving indoor fan coil, water system conduit, condesating conduit (direction, seal performance of stable location, heat preservation), line conduit, etc. in order that user can confirm installation quality of hidden project whether reach the installation requirement and design standard to avoid regard mistakenly the damage resulting in indeliberately destroy in decoration as the problem of installation quality. (2) After entire project finish and operate normally by debugging, carry out the acceptance aiming at air conditioner system conduit, rationality, cool (hot) generation performance of installation of valve parts and etc, if qualified, fill jointly the debugging report of centralair conditioner and assist user to fill maintenance guarantee card, meanwhile, guide user to use and maintain subject to instruction and demonstrate if necessary. 3.6.2 Maintenance Module air-cooled clod (hot) water unit is a kind of high automatization equipment, and inspect the unit operation condition regularly during operation. If maintain the unit is maintained as a long-term and effective way, the operation reliability and in-service life of the unit will achieve unexpected enhancement. (1) Circulation should use tap soft water being handled instead of underground water, hard water and other sewage. Ensure water quality clean and pressure in normal condition in water system. 40
(2) Points for attrention during use and maintnenance of this unit: all safety devices in unit are set before ex-factory, and prohibit self-regulation by user. Damage of unit due to self-regulation by user should not fall into the scope of our responsibility. (3) Water filter outside of unit should be cleaned regularly to ensure water quality clean in system in case damage resulting in unit filter blockage or contamination. (4) Check make-up and exhaust devices in water system whether in normal or not in case circulation water quantity deduction or water circulation difficuty, even resulting in cold/hot generation effection and operation reliability of the unit as a result of air into the system. (5) Regularly check the wiring of power supply and electric system whether normal or not, whether motion of electric components normal or not. Once abnormity occurs, repair and replace in time. (6) Regularly check operation conditions of various components of unit and check the work pressure of the cold generation system whether normal or not, and check conduit joint and air pneumatic valve whether oil filth or not so as to ensure no leakage in the unit cold generation system. (7) Avoid pile junks around the unit in case block inlet and outlet, and clear the filter mesh at air return vent of indoor terminal device. Keep clean, dry and good ventilation around the unit in order to keep good heat exchanger effect and save electric power. (8) If keep the unit not use for a long time, drain the water in unit pipe; as for the unit with additional electric heat device, drain the water in the electric heater and vut off power supply. Before use next time, inject water into the system and exhaust as well as inspect the system completely, and then clean it by water. Switch on the unit before confirmation of all status in normal. (9) Water system should be cleaned by chemical water every at least four years, additionally, purge the fin-type copper pipe heat exchanger every 2-3 monthes in order to hold good radiation result and save energy. (10) To avoid frozen hazard in winter, brew glycol solotion or propylene glycol solution subject to the proportion as followed table: Modified coafficient using glycol Percentage of glycol and
Freezing
Modification of
Modification of
Modification of
water %
point ℃
cold generation
water flow
pressure fall
10
-3.6
0.990
1.015
1.06
20
-7.6
0.980
1.040
1.12
30
-14
0.970
1.080
1.18
40
-22.3
0.965
1.135
1.24
(11) Under the condition of lower ambient temperature in winter, the unit must be preheated by way of switching on the power supply ahead of 8 hours while first start. (12) the impurity in filter of return water end of pump must be cleared after commissioning 24 hours. (13) The unit should avoid disconnectin of power supply in winter in case frost fissure occurs for heater exchanger waterside in unit and pipe (product is provided with function of anti-freeze as energized). (14) Avoid frequent operation of the switch in orderto prolong in-service life of unit.
41
4.Instruction of controller for module-type air cool cold (hot) water unit 4.1 Instruction of bi-system controller for module-type unit the controller is applied to LSQWRF65MZ/D、LSQWRF100MQ/F unit, and electronic expansion valve module refer to the instruction of “electronic expansion valve extension module” 4.1.1 System description 4.1.1.1 structural composition of controller system The controller system of central air conditioner for commerce-purpose should be consisting of some controllers and one or multiple line controllers, and the various parts are connected by RS485 communication interface. System composition structure frame diagram is as followed. HAC-F2S-M controller（1#）
HAC-F2S-M controller（2#）
HAC-F2S-M controller（3#）
RS485
HAC-F2S-M controller（4#）
HAC-F2S-M controller（16#）
Line controller
Frame diagram of control structure Controller system consists of controllers with 1-15 controller and oneor multiple line controllers. The multiple line controller are applied should be used in parallel. In this system, there is at least one master controller addressed 0, and sub-controller can be connected at most 15 with the address from 1 to 15. Each controller must be set a different and unrepeatable address. Each module sub-cntroller could control 2 compressors and a circulation pump to inspect the output temperature of that module, indoor coil temperature and exhaust temperature of compressor. 4.1.1.2 controller (1) structural composition of controller Structural composition of controller can refer to “structure fram diagram of controller” The module master controller control two compressors that share a four-way diverting valve outlet and fan 42
outlet. Each compressor should correspond to a crankcase electric heater. The objects of inspection temperature by module mater controller panel including total return water temperature of circulation water and outdoor ambient total temperature. Each mode is used to inspect the output temperature, coil temperature of each outdoor coil and exhaust temperatuen for each compressor. Power supply transformor used by outdoor controller is provided with two stages, one is treated as work voltage of controller component after rectification and wave filtration, and the other is treated as work voltage of protective switch directly. Protective shielding switch is used to shield the input signal of each protection inlet. While the shielding switch is turned to “ON” location for certain protective inlet, which means that will shield the protective signal. This function can be performed if certain protective inlet not use or non-shutdown overhauling. Protective switch signals for controller include flow switch of circulation, overload protection switch of outdoor fan, phase sequence and phase-absence switch, ice-point protection switch of circulation, high/low voltage protection switch for each compressor and etc. (2) address set of controller Address set switch is a four-position dial code switch that could set 15 status, and the set information refers to “information table of address set” Cranecase 2
Cranecase 1
Circulation Water punp
Outer fan
Four-way valve
Electric heater
Compressor 1
Compressor 1
220V 50Hz
Total return water temperature
Transformer
Output temperature
Fuse Outdoor ambient temperature
Air-cooled cold/hot water module controller
1#outer pipe temperature
Address select switch
2#outer pipe temperature
Protection shielding switch
1#exhaust temperature 2# exhaust temperature
Outer fan overload
Flow switch
Phase Phase sequence/phase sequence/phase absence absence
Icing switch
High voltage protection1
Low voltage protection 1
High voltage protection 2
Low voltage protection 2
Line controller
Structural frame diagram for actuator Information table of address set Switch 1
Switch 2
Switch 3
Switch 4
Address code
Controller code
OFF
OFF
OFF
OFF
0000(0)
1#module 43
OFF
OFF
OFF
ON
0001(1)
2# module
OFF
OFF
ON
OFF
0010(2)
3# module
OFF
OFF
ON
ON
0011(3)
4# module
OFF
ON
OFF
OFF
0100(4)
5# module
OFF
ON
OFF
ON
0101(5)
6# module
OFF
ON
ON
OFF
0110(6)
7# module
OFF
ON
ON
ON
0111(7)
8# module
ON
OFF
OFF
OFF
1000(8)
9# module
ON
OFF
OFF
ON
1001(9)
10# module
ON
OFF
ON
OFF
1010(10)
11# module
ON
OFF
ON
ON
1011(11)
12# module
ON
ON
OFF
OFF
1100(12)
13# module
ON
ON
OFF
ON
1101(13)
14# module
ON
ON
ON
OFF
1110(14)
15# module
4.1.2 Parameter set 4.1.2.1 parameter set mothod Controller is provided with many parameter set and may inquire and regulate content via line controller. Operation of entering parameter set is: under off condition, press 【inquire】for 5 seconds and loose when hear “tick” of the line controller and then enter parameter set operation. 4.1.2.2 select parameter of system function There are two select parameters of system function including “ON” and “OFF”m, and change the parameter status by way of press 【time▲】and【time▼】. Table of select parameter of system function Ex-factory
ON
OFF
ON
Unit 1permit
Unit 1 prohibit
SA02
ON
Unit 2permit
Unit 2 prohibit
Type
SA03
ON
Hot pump type
Single cold type
Frost form
SA04
OFF
Compressor operation
Frost of unfreeze and melt of compressor
unfreeze frost
interstice
SA05
ON
Electric heater operation
Electric heater no operation while
while unfreeze frost
unfreeze frost
SA06
OFF
Exist together after all the
After satisfy condition and shutdown and
units satisfy exit condition
wait for end of other unit
SA07
OFF
Parameter name
Unit No.
Compressor
SA01
conbination
set
Operation
Operation status of frost lelctric heater Coordinating device Exit form Mode conversion Selection
Converse operation mode operation condition
Cut-off holding under work
SA08
OFF
44
under operation condition
for controller while power
Off status for controller while power on
on
Selection of timing/circulation
Can’t Converse operation mode both
Keep on/off former status
condition combination
both under standby and
SA09
ON
Circulation timing (every 24
Combination timing (effective in 24
hours circulation operation)
hours)
4.1.2.3 conpensate parameter of temperature sensor conpensate parameter of temperature sensor is adjusted by way of key 【temperature▲】and key 【temperature▼】.while parameter is up to maximum or minimum value, if continue to regulate, 【- -】occurs indicating cancel status. Under this condition, this temperature sensor may not be installed and relative the operation function and protection function will be cancelled. Table of conpensate parameter of temperature sensor Parameter name
Unit No.
Ex-factory
Min.
Max.
set
value
Value
Potential
Cancel
difference
①
Total return water temperature
PC01
0℃
-9℃
9℃
1℃
Output temperature
PC02
0℃
-9℃
9℃
Total outside temperature
PC04
0℃
-9℃
9℃
--
1℃
1#outer pipe temperature
PC05
0℃
-9℃
9℃
--
1℃
2# outer pipe temperature
PC06
0℃
-9℃
9℃
--
1℃
1#exhaust temperature
PC07
0℃
-9℃
9℃
--
1℃
2# exhaust temperature
PC08
0℃
-9℃
9℃
--
1℃
1℃
Note①: some parameter should not set “cancel” and 【- -】status will not occur in parameter adjustment. 4.1.3 Parameters for system operation temperature Parameters for system operation temperature are some temperature set parameters correlative to operation of central air conditioner and regulated by way of key 【temperature▲】and key【temperature▼】. Parameters for system operation temperature Ex-factory
Min.
Max.
set
value
Value
SP01
4℃
5℃
1℃
SP02
35℃
99℃
0℃
Parameter name
Unit No.
Back difference temperature Output water temperature condition while electric heater open
Cancel
Potential difference
X①
1℃ 1℃
4.1.4 Parameters of system operation time parameters of system operation time are some time set parameters correlative to operation of central air conditioner and regulated by way of key 【time▲】and key【time e▼】. Parameters of system operation time Parameter name
Unit No.
Duration of sample temperature inspection
SC01
Interval time of various units starts
Ex-factory
Max. Value
10 seconds
60 seconds
5 seconds
1second
SC02
30 seconds
120 seconds
5 seconds
1second
Interval time of various units shutdown
SC03
30 seconds
120 seconds
5 seconds
1second
Extended time of compressor starts
SC04
5 seconds
60 seconds
1 seconds
1second
Extended close time of outer fan
SC05
5 seconds
60 seconds
1 seconds
1second
Lighten time of back light source
SC06
5 seconds
60 seconds
3 seconds
Glitter time of parameter inquiry LCD
SC07
10 seconds
30 seconds
3 seconds
Interval time of automatic mode judge
SC08
2 hours
24hours
0 hours
set
Cancel
Potential
Min. value
①- -
difference
1second 1second
--
1 hour
Note①:after lighten time of back light source set cancel status【- -】, back light source is constant light on; If dark scree required, press reset/dark screen. 4.1.5 Protection temperature parameters protection temperature parameters are some temperature set parameters correlative to failure check and judge of operation of central air conditioner and regulated by way of key 【time▲】and key【time▼】. Table of protection temperature parameters 45
Min.
Max.
value
Value
3℃
7℃
-5℃
--
1℃
EP02
70℃
80℃
50℃
--
1℃
Coolant insufficient protection of cold generation
EP03
--
40℃
10℃
--
1℃
Over temperature protection of heat generation
EP04
60℃
80℃
55℃
--
1℃
Coolant insufficient protection of heat generation
EP05
--
45℃
15℃
--
1℃
Temperature difference protection of insufficient flow
EP06
10℃
20℃
2℃
1℃
Anti-freeze protection in winter
EP07
3℃
8℃
-2℃
1℃
50℃
-19℃
Parameter name
Unit No.
Ex-factory set
Anti-freeze protection of cold generation
EP01
Anti-overload of cold generation
Exhaust temperature protection
EP08
20℃
①
Cancel
Potential difference
--
1℃
Note: ①【EP08】because of display of line controller, protection parameter of compressor exhaust temperature only displays single-digital and decade-digital and not hundred-digital. While set temperature is 10℃, actual protection set parameter temperature is 110℃; if set temperature is -19℃, actual protection set parameter temperature is 81℃. 4.1.6 Time protection parameters time protection parameters are some time set parameters correlative to failure check and judge of operation of central air conditioner and regulated by way of key 【time▲】and key【time▼】. Time protection parameters Ex-factory
Min.
Max.
set
value
Value
EC01
3 minute
10 minute
1 minute
1 minute
Required time of compressor operation
EC02
3 minute
10 minute
1 minute
1 minute
Pressure check time of shielding low pressure
EC05
3 minute
10 minute
0 minute
1 minute
Duration of protection condition
EC06
3 second
10 second
1 second
1second
Continous check time of flow switch
EC07
10 second
60 second
1 second
1second
Parameter name
Unit No.
Compressor start protection
Potential
Cancel
difference
4.1.7 Frost parameter Frost parameter includes temperature and time parameters of entering frost, and temperature and time parameters of exit frost. Temperature parameter is regulated by way of key 【 Temperature▲ 】 and key 【Temperature▼】, and time parameter is regulated by way of 【Time▲】and key 【Time▼】 Table of frost parameter Parameter name
Unit No.
Ex-factory set
Min.
Max.
value
Value
Cancel
--
①
Potential difference
Outdoor ambient temperature entering frost
HF01
8℃
20℃
0℃
Outdoor ambient temperature-outer pipe temperature
HF02
8℃
20℃
1℃
--
1℃
Outdoor coil temperature entering frost
HF03
-10℃
0℃
-19℃
--
1℃
Outdoor coil temperature while exist frost
HF04
10℃
20℃
0℃
--
1℃
Accumalative time of compressor entering frost
HF05
45 minute
120 minute
30 minute
1 minute
Longest frost time
HF06
8 minute
15 minute
2 minute
1 minute
Time constion of multiple units entering unfreeze
HF07
25 minute
50 minute
5 minute
--
1℃
1 minute
Note①: while outdoor temperature <【HF01】, accumulate the compressor operation time. If cancel set of 【HF01】, accumulate compressor operation time and not judge outdoor ambient temperature. 4.1.8 Failure protection under cold generation work Under the condition of cold generation work, at the same time of operation, controller should check failure possible occurs and execute relevant treatment. 4.1.8.1 anti-freeze protection under cold generation work (failure code 【Pr05】) 46
The prerequisite of entering anti-freeze protection under cold generation work: ①compressor in operation; ②output temperature T output <【EP01】 and last 1 minute. After entering anti-freeze protection under cold generation work, display failure code 【Pr05】, the code of relative module glittering fast, and compressor shutdown protection, electric heater starts. Condition of exit of anti-freeze protection under cold generation work: ①output temperature T output≥【EP01】+3℃, electric heater close and the relative failure code disappears. ②After reach the requiremnt of shutdown protection, compressor return to cold generation work. 4.1.8.2 anti-overload protection under cold generation (failure code 【Pr04】 or 【Pr05】) Insufficient cool of indoor fan will result in overload protection under cold generation. Prerequisite of entering anti-overload protection under cold generation; ①compressor in opearion status ②outdoor coil temperature T outer pipe ≥【EP02】 。 Entering anti-overload under cold generation, displaying failure code 【Pr04】 or 【Pr14】, relevant module number glittering fast, the relevant compressor shutdown, room 4-1-8-2 continuous cooling till satisfy exit protection requirement. ①outdoor coil temperature T outer pipe ≤50℃, relevant failure code disappears. ②Reaching requirement of shutdown protection, compressor returns cood generation work. 4.1.8.3 failure protection for temperature sensor ①While temperature sensor for total return water damage, failure code 【Eo01】 displays and system shut dwon for protection. ②While temperature sensor for main module output temperature damage, failure code 【Eo03】 displays and system shuts dwon for protection. ③While temperature sensor for output temperature of sub-module damage, failure code 【Eo08】 displays and relevant module number glliters and sub-module shuts dwon for protection. ④While outdoor total temperature sensor damage, failure code 【Eo01】 displays and unit number glitters. ⑤While temperature sensor of 1# outdoor coil damage, failure code 【Pr01】displays . Retive module number glitters and cancels anti-overload protection under cold generation. ⑥While temperature sensor of 2# outdoor coil damage, failure code【Pr11】displays . Retive module number glitters and cancels anti-overload protection under cold generation. ⑦While temperature sensor of 1# compressor damage, failure code 【Pr03】displays. Retive module number glitters and cancels compressor over-temperature protection under cold generation. ⑧While temperature sensor of 2# compressor damage, failure code 【Pr13】displays. Retive module number glitters and cancels compressor over-temperature protection under cold generation. 4.1.8.4 temperature difference protection of insufficient flow (failure code 【Pr06】) During operation, in order to provent insufficient flow, failure code 【Pr06】displays, relative module glittering fast and compressor outer fan shutdown if temperature difference between total return water and output water ＞【EP06】set value and lasts more than 5 minutes. The condition satisfying exist: ①temperature difference between toatal return water and output water＜【EP06】set value and relative failure code disappears. ②Reaching requirement of shutdown protection, compressor returns cood generation work. 4.1.9 Failure protection under heat generation condition Under heat generation condition, at the same time of operation, controller will inspect the failure possible occurs and executes relevant treatment. 4.1.9.1 anti over temperature protection under heat generation condition (failure code 【Er17】) 47
Entering process of anti over temperature protection under heat generation condition ①after compressor or electric heater operate and generate heat, if output water temperature ≥【SP02】+2, switch off electric heater. ②If output water temperature raises continuously and T output water ≥【EP04】, switch outer fan off. ③after that, if output water temperature falls and T output water <【EP04】-4℃, outer fan recovers to normal; If reaching the conditon of starting electric heater, start electric heater. ④If output water not falls, while reaching the condition of T output water ≥【EP04】 and lasts 5 minutes, enter anti-over temperature protection under heat generation work. ⑤If outer water temperature raises and satisfies the condition of T output water ≥【EP04】+5℃, enter anti-over temperature protection under heat generation work. After unit entering enter anti-over temperature protection under heat generation work, failure code 【Er17】 displays, relative module number glittering fast, compressor, electricheater and outer fan shutdown, circulation pump operation continuously and shutdown till output water temperature satisfying the reqirement of T output water <【EP04】-4℃. After press reset key and resets, the relevant failure code disappears. 4.1.9.2 failure protection of temperature sensor ①While temperature sensor for total return water damage, failure code 【Eo01】 displays and system shut dwon for protection. ②While temperature sensor for main module output temperature damage, failure code 【Eo03】 displays and system shuts dwon for protection. ③While temperature sensor for output temperature of sub-module damage, failure code 【Eo08】 displays and relevant module number glliters and sub-module shuts dwon for protection. ④While sensor of outdoor total ambient temperature damage, failure code 【Eo01】 displays and unit number glitters. Cancel the function of accumulating compressor operation time of subject to outdoor ambient temperature for frost unfreezing, and also cancel judge function of outdoor temperature for anti-frozen protection. ⑤While temperature sensor of outdoor coil of 1 # unit damage, displays failure code 【Pr01】, and relevant module number glittering. Cancel outdoor coil temperature condition during frost unfreezing judge fot 1#unit, and treat subject to periodical frost unfreezing. ⑥While temperature sensor of outdoor coil of 2 # unit damage, displays failure code 【Pr11】, and relevant module number glittering. Cancel outdoor coil temperature condition during frost unfreezing judge fot 2# unit, and treat subject to periodical frost unfreezing. ⑦While exhaust temperature sensor of 1# compressor, displays failure code 【Pr03】, and relevant module number glittering. Cancel over temperature protection of compressor of 1# unit. ⑧While exhaust temperature sensor of 2# compressor, displays failure code 【Pr13】, and relevant module number glittering. Cancel over temperature protection of compressor of 2# unit. 4.1.9.3 anti-freezing protection in winter (failure code 【Pr07】) In order to prevent circulation freezing of air condition while non-work in winter, it is necessary to take steps of anti-freezing protection. The prerequisite of anti-freezing protection in winter is: ①air conditioner in off condition; ②while T total return water≤【EP07】+3℃, Entering anti-freezing protection in winter. Starting circulation pump, and auxiliary electric heater operates in manner of operation for 5 minutes and then stop 30 minutes as an alternate way. ③if outdoor ambient temperature T outdoor ambient ≤5℃ and T total return water≤【EP07】, compressor and auxiliary heater should operate. After entering anti-freezing protection in winter, exit only satisfying the following conditions: ①air conditioner switch-on; 48
②while T total return water ≥【EP07】+6℃, exit from anti-freezing protection in winter. 4.1.9.4 temperature difference protection of insufficient flow (failure code【Pr06】) During operation, in order to provent insufficient flow, failure code 【Pr06】displays, relative module glittering fast and compressor outer fan shutdown if temperature difference between total return water and output water ＞【EP06】set value and lasts more than 5 minutes. The condition satisfying exist: ①temperature difference between toatal return water and output water＜【EP06】set value and relative failure code disappears. ②Reaching requirement of shutdown protection, compressor returns cood generation work. 4.1.10 Unfreezing operation During heat generation, outdoor unit will frosts due to too low temperature, which will affect heat generation work. HAC-F2S-M controller designs many parameters for unfreezing and can satisfy unfreezing work process under different conditions. Detailed introduction about unfreezing mode for HAC-F2S-M controller as followed: 4.1.10.1 entering condition of single unit unfreezing Based on the set of unfreezing parameter, combine several entering unfreezing modes. After satisfying a few prerequisites entering unfreezing, unit can enter unfreezing. (1) accumulative operation duration of compressor Subject to parameter PC04】and【HF01】, select whether consider the influence of outdoor ambient temperature or not while accumulation of compressor operation. If there is only one set mode 【- -】for 【PC04】or【HF01】, outdoor outdoor ambient temperature should not be involved in accumulation of compressor operation, otherwise subject to set parameter of 【HF01】, only accumulate compressor operation time satisfying the condition of T outdoor temperature≤【HF01】. Accumulation operation time of compressor is beyond set value of 【HF05】, which is one of time parameter of satisfying unfreezing. (2) compressor operation continuance time Start duration of compressor is beyond the set value of the parameter【EC02】for compressor operation protection time, unit can enter unfreezing if unit satisfying all other unfreezing condition. (3) temperature difference condition between outdoor coil and outdoor ambient temperature Compressor heat generation operation will result in outdoor coil temperature lower than ambient temperature. if set parameter 【HF02】, before enter unfreezing, must satisfy the condition T outdoor ambient-T outer pipe≥ 【HF02】. If set mode of 【HF02】is cancel and sensor of outdoor temperature land the sensor of outdoor coil temperature damage, shoul cancel the judge condition. (4) Outdoor coil temperature condition Outdoor coil temperature is determined by parameter 【HF03】. Entering unfreezing is permitted right after satisfy the condition of T outer pipe≤【HF03】. If set mode of 【HF03】 is cancel, cancel the judge condition. 4.1.10.2 entering condition of cooperation unfreezing for multiple units If one unit in system datisfying the entering conditon of single unit unfreezing, other units could judge whether cooperation unfreezing or not subject to compressor operation time set by parameter【HF07】. If parameter 【HF07】set mode is cancel, accordingly, cancel the function of cooperation unfreezing for multiple units, and various units execute unfreezing work by themselves respectively. 4.1.10.3 conditon of exit unfreezing for single unit After unit entering unfreezing and 3 minutes later, judge whether exit unfreezing or not according to coil temperature variance and unfreezing operation duration. Exit unfreezing only satisfying one of the conditions of exit unfreezing. (1) exit unfreezing due to high pressure of compressor 49
After compressor unfreezing resulting in pressure rising and high-pressure switch off, unit will exit unfreezing work. (2) Outdoor coil temperature condition Outdoor coil temperature will rise while compressor executes unfreezing work. Unit exits infreezing work when the conditon of T outer pipe ≥【HF04】is satisfied. (3) time condition of exit unfreezing 【HF06】 set the maximum operation time of unit unfreezing. If unfreezing beyond the【HF06】set time, ignoring whether outdoor coil satisfying the set condition of 【HF04】, exit unfreezing work. 4.1.10.4 exit condition of cooperation unfreezing for multiple units 【SA06】 selects the exit manner of cooperation unfreezing for multiple unit. While 【SA06】ON, exit unfreezing all together after all units those are executing unfreezing satisfy the exit condition; while 【SA06】OFF, unit satisfying exit conditon should shut down and wait other units not finish unfreezing; After all units exit unfreezing, start heat generation work again. 4.1.10.5 unfreezing process Parameter 【SA04】 set two types unfreezing function modules. While 【SA04】ON, compressor should not shut down and divert directly for unfreezing; while【SA04】 OFF, after compressor shutdown and four-way valve divert, switch on and execute unfreezing work. (1) process of non-shutdown unfreezing Set mode ON, after satisfying entering unfreezing condition, compressor should not shut down and four-way diverting valve switch-off divert, and then compressor in cold generation condition. 5 seconds later, outdoor fan switch off. Low-pressure switch should not be inspected during unfreezing. After satisfying the condition of exit unfreezing, four-way diverting valve diverts and outdoor fan switches on, and then compressor in heat generation condition. (2) process of shutdown for unfreezing set【SA04】OFF, after entering unfreezing condition, compressor should shut down and fan off 5 seconds, and another 5 seconds later, four-way valve switch-off divert and 30 seconds later compressor start again to execute unfreezing. Low-pressure switch should not be inspected during unfreezing. After satisfying the condition of exit unfreezing, compressor switches off. 30 seconds later four-way diverting valve switch in and divert, and then outdoor fan operates. If the compressor operation temperature condition is satisfied, compressor starts to preheat 5 seconds later. 4.1.11 System failure protection and code Controller will verdict various failure in system during operation automatically and perform relative protection according to failure type. Failure protection should be classified into four types subject to failure reason and treatment method: unit recoverable protection, system recoverable protection, unit serious failure protection and system serious failure protection. 4.1.11.1 unit recoverability protection Once the recoverable protection occurs in unit, relative protection measurement should be taken. After recovery, unit will recover to normal work again. Once the recoverable protection occurs in system, failure code will displayed with glittering on line controller. Failure code of unit recoverability protection
50
Failure reason
Failure code
Enter condition
Protection measurement
Touter pipe①sensor damage
Pr：01
Sensor short or cut
Texhause①sensor damage
Pr：03
Sensor short or cut
1# anti-overload protection under cold generation
Pr：04
Touter pipe①＞【EP02】
1#compressor shutdown, after satisfying exit condition, recover to operate
Touter pipe①≤50℃
Anti-frozen protection under cold generation
Pr：05
Toutput water≤【EP01】
Switch compressor off switch on electric heater
Toutput water≥【EP01】+3℃
Temperature different of insufficient flow
Pr：06
Ttotal return water-Toutput water≥or Toutput water-Ttotal return water≥ 【EP06】
Switch compressor off
Anti-frozen protection in winter
Pr：07
Ttotal return water≤【EP07】+3℃
Touter pipe②sensor damage
Pr：11
Sensor short or cut
Texhaust②sensor damage
Pr：13
Sensor short or cut
2#nti-overload protection under cold generation
Pr：14
Touter pipe②＞【EP02】
Cencel function Cencel function
Recovery condition
relative
protection
relative
protection
and
Switch circulationpump and electric heater Cencel relative protection function Cencel relative protection function 2#compressor shutdown, after satisfying exit condition, recover to operate
Repair or replace Repair or replace
Ttotal return water-Toutput water<or Toutput water-Ttotal return water<【EP06】 Ttotal return water≥【EP07】+6℃ Repair or replace Repair or replace Touter pipe②≤50℃
4.1.11.2 system recoverability protection While recoverability of air condition system occurs, the whole system should adopt relative protection measurement. After the failure is eliminated and recovered to normal, system recovers to operation normally Failure code of system recoverability protection Failure reason Touter pipe①sensor damage
Failure code
Po：01
Enter condition
Protection measurement
Recovery condition
Sensor short or cut
Cancel relavant function of outdoor ambient temperature
Repair or replace
4.1.11.3 serious protection for unit After serious failure protection occirs in unit, failure code will display inline controller. Switch off relative unit and other units operate continuously. After Unit failure shutd own, cannot operate with failure, except manual set failure reset status. Code table of serious protection for unit Failure reason
Failure code
Entering condition
Protection steps
Recovery condition
1#compressor pressure over high
Er：02
high pressure pressure switch continuous off【EC06】second
1#compressor shutdown
After high pressure switch in notmal, reset by pressing reset key
1#compressor pressure over low
Er：03
Low pressure pressure switch continuous off【EC06】second
1# compressor shutdown
After low pressure switch in notmal, reset by pressing reset key
1#exhaust temperature over high
Er：04
Texhaust①＞【EP08】
1# compressor shutdown
Reset by pressing reset key
Flow switch off
Er：05
Flow switch continuous off【EC07】 second
Module off alarm
Reset by pressing reset key
Outdoor fan overload
Er：06
Protection switch of outer fan off
Module off alarm
After protection switch in normal Reset by pressing reset key
Phase sequence, phase absence
Er：07
Module off alarm
After protection switch in normal Reset by pressing reset key
Output water temperature sensor damage
Er：08
Sensor short or cut
Module off alarm
After repair and replace sensor Reset by pressing reset key
2#compressor pressure over high
Er：12
high pressure pressure switch continuous off【EC06】second
2# compressor shutdown
After high pressure switch in notmal, reset by pressing reset key
2#compressor pressure over low
Er：13
Low pressure pressure switch continuous off【EC06】second
2# compressor shutdown
After low pressure switch in notmal, reset by pressing reset key
2# exhaust temperature over high
Er：14
Texhaust②＞【EP08】
2# compressor shutdown
After temperature in normal Reset by pressing reset key
Icing point switch protection
Er：15
Icing point protection off
Module off alarm
After protection switch in normal Reset by pressing reset key
Check board switch of sequence, phase absence off
Phase
51
Cold medium insufficient protection
Er：16
Toutput water≥【EP03】或 Toutput water≤【EP05】
Module off alarm
After inject cold medium Reset by pressing reset key
Over temperature protection under heat generation
Er：17
Toutput water≥【EP04】
Module off alarm
After output in normal Reset by pressing reset key
4.1.11.4 serious failure protection in system Once serious failure protection in system occurs, all units should shut down and wait for examination. Failure reason
Failure code
Entering condition
Protection steps
Recovery condition
Communication failure
Eo：00
Abnormal communication
Line controller alarm
Communication circuit normal
Eo：01
Sensor short or cut
System shutdown
Eo：03
Sensor short or cut
System shutdown
Flow switch of mainmodule off
Eo：05
flow switch of main flow switch off continuously 【EC07】second
System shutdown
Reset by pressing reset key
Serious failure occurs semulteneously in two units
Eo：08
Serious failure protection occurs semulteneously in two units
System shutdown
Reset by pressing reset key
Sensor of total return water temperature damage Sensor of main module output temperature damage
Reset by pressing reset key Reset by pressing reset key
4.2 Instruction of quadri-system controller for module-type unit This controller is applied to ACMC-H190A5/F module unit. 4.2.1 System description 4.2.1.1 structure composition of controller system Controller system consists in some controllers and one or multiple line controllers, and various sections are connected via RS485 communication interface. Structure composition frame diagram of controller system is followed: Module controller
Module controller
Module controller
（1#）
（2#）
（3#）
RS485
Line controller
Module controller
Module controller
（4#）
（16#）
Frame diagram of composition structure Controller system consists in 1-15 controllers and one or multiple line controllers, and the line controllers should be used in parallel while use multiple line controller. In this system at least exists a module controller with address 0000 and number 1#. Sub-module controller can be connected at most 14 with the address from 0001 to 1110 and number from 2# to 15#. Must set different address for each controller and avoid repeatness. 4.2.1.2 module controller (1) composition of module controller Module controller controls four compressor units and four-way diverting valve of each compressor and electric heater of each module, and each module uses a cooling air fan. Main module controller also controls system water pump operation. Object of temperature inspected by module controller includes output temperature of this module and coil temperature of each condesator coil. Main module controller also inispect total return water temperature, total output temperature and outdoor ambient temperature. Objects of control should be selected into output temperature or return water temperature. 52
Protection switches of module controller involve flow switch of this module, high/low pressure protection switch of each compressor, anti-frozen switch of evaporator and overload protection of outer fan. In addition, the constant-open contact of phase sequence check panel controls the power supply of module controller. If flow switch main module abnormal, whole system should shut down for protection. While unit model ON, controller works in single cold status; while unit model OFF, it is hot pump model. The selective sewitch of this unit model is only effective for main module. See table below: Switch 1
Switch 2
Function name
Descriptin
ON
ON
Single cold
Only cold generation model
OFF
OFF
Hot pump
Compressor cold/heat generation with accessory electric heater
Composition schematic drawing of module controller as followed: Circulation pump
Outer fan
Four-way valve 4
Four-way valve 3
Four-way valve 2
Four-way valve 1
Compressor 4
Compressor3
Compressor 2
Compressor 1
Electric heater
220V 50Hz
Total return water temperature Fuse
Total output water temperature Output water temperature
Transformer
Air-cooling cold/hot water module controller
Outdoor ambient temperature Address switch
Unit model switch
1#outer pipe temperature
Line controller
2# outer pipe temperature Protection shield switch
3# outer pipe temperature 4# outer pipe temperature
Water flow switch
Outer fan protection
Phase sequence protection
Anti-frost switch
High-pressure switch 1
Low-pressure switch 1
High-pressure switch 2
Low-pressure switch 2
High-pressure switch 3
Low-pressure switch 3
High-pressure switch 4
Low-pressure switcg 4
Linkage switch
Structure frame drawing of controller (2) structure frame drawing of controller Address set is four-digital dial code that can be set into 15 statuses as followed table: Information table of address set switch Switch 1 OFF OFF OFF OFF OFF
Switch 2 OFF OFF OFF OFF ON
Switch 3 OFF OFF ON ON OFF
Switch 4 OFF ON OFF ON OFF
Address code 0000(0) 0001(1) 0010(2) 0011(3) 0100(4)
Controller No. 1#module 2# module 3# module 4# module 5# module
OFF
ON
OFF
ON
0101(5)
6# module
OFF
ON
ON
OFF
0110(6)
7# module 53
OFF
ON
ON
ON
0111(7)
8# module
ON
OFF
OFF
OFF
1000(8)
9# module
ON
OFF
OFF
ON
1001(9)
10# module
ON
OFF
ON
OFF
1010(10)
11# module
ON
OFF
ON
ON
1011(11)
12# module
ON
ON
OFF
OFF
1100(12)
13# module
ON
ON
OFF
ON
1101(13)
14# module
ON
ON
ON
OFF
1110(14)
15# module
(3) controller wiring Controller wiring drawing refers to attached drawing “composition structure frame drawing” 4.2.2 Parameter set 4.2.2.1 parameter set way Controller is provided with many parameters to set and inquire and regulate parameter set by way of line controller. Operation of entering parameter set as followed: undershutdown condition, pressing key【inquire】for 5 seconds, once “tick” occurs in line controller and loosing, and then enter parameter set operation. 4.2.2.2 function selection parameter in system Function selection parameter in system is only provoded with two opinions “ON”and”OFF”. Vary parater status by way of pressing 【time▲】and【time▼】. Table of function selection parameter in system Parameter name
Unit No.
Ex-factory set
ON
Temperature control select
SA03
OFF
Control total output water temperature
Control total return water temperature
Unfreezing process
SA04
OFF
Compressor work for unfreezing
Compressor gap unfreezing
Mode conversion select
SA07
OFF
Converse operation mode under standby and operation status
Not conversion of mode under operation condition
Deenergization hold under operation
SA08
ON
After energization, control hold previous on/off status
After energization, controller in off condition
Combination timing/circulation timing select
SA09
ON
Circulation timing (every 24 hours circulation operation)
Combination timing (once effective in 24 hours)
Linkage switch select
SA10
OFF
Permit linkage at end
Prohibit linkage at end
OFF
4.2.2.3 compensation parameter of temperature sensor compensation parameter of temperature sensor is regulated by way of 【temperature▲】and【temperature▼】. If continue to regulate after reach maximum or minimum value, 【- -】occurs indicating cancel status. Under concel status, this temperature sensor may not be installed, and relative operation and protection function should be cancelled. Note: this parameter can be modified only under the condition of controller set value 1#. Table of compensation parameter of temperature sensor Parameter name Total return temperature sensor Total output temperature sensor① Output temperature sensor Outdoor ambient temperature sensor 54
Unit No.
Ex-factory set
Min. value
Max. Value
Cancel
Potential difference
PC01
0℃
-9℃
9℃
①
1℃
PC02
0℃
-9℃
9℃
1℃
PC03
0℃
-9℃
9℃
1℃
PC04
0℃
-9℃
9℃
--
1℃
1#outer ippe temperature sensor 2# outer ippe temperature sensor 3# outer ippe temperature sensor 4# outer ippe temperature sensor
PC05
0℃
-9℃
9℃
--
1℃
PC06
0℃
-9℃
9℃
--
1℃
PC07
0℃
-9℃
9℃
--
1℃
PC08
0℃
-9℃
9℃
--
1℃
①Some parameter cannot be set into cancel, so 【- -】may not occur in parameter regulation. 4.2.2.4 Temperature parameter of system operation Temperature parameters of system operation are temperature set parameters relative to central air conditioner unit operation and regulated by way of 【temperature▲】and【temperature▼】. Table of temperature parameter of system operation Parameter name Load return difference temperature Unload return difference temperature Output temperature of electric heater start
Unit No.
Ex-factory set
Min. value
Max. Value
Cancel
Potential difference
SP01
2℃
5℃
1℃
X①
1℃
SP02
2℃
5℃
1℃
X①
1℃
SP03
50℃
70℃
20℃
X①
1℃
4.2.2.5 time parameter of system operation Time parameters of system operation are time set parameters relative to central air conditioner unit operation and regulated by way of 【time▲】and【time▼】. Table of time parameter of system operation Cancel
Potential difference
Parameter name
Unit No.
Ex-factory set
Min. value
Max. Value
Temperature judge interval time
SC01
10sec
120sec
1sec
1sec
Various units start interval time
SC02
30sec
120sec
5sec
1sec
Various units shutdown interval time
SC03
30sec
120sec
5sec
1sec
Outer fan in-advanced start time
SC04
10sec
60sec
1sec
1sec
Outer fan delay off time
SC05
5sec
60sec
1sec
1sec
Back light source ignition time
SC06
10sec
60sec
3sec
LCD glittering time of parameter inquiry
SC07
10sec
30sec
3sec
--
1sec 1sec
4.2.2.6 temperature protection parameter temperature protection parameter temperature set parameters relative to central air conditioner failure inspection judge and regulated by way of 【temperature▲】and【temperature▼】. Table of temperature protection parameter Parameter name
Unit No.
Ex-factory set
Min. value
Max. Value
Cancel
Potential difference
Anti-frost protection under cold generation
EP01
3℃
7℃
-5℃
--
1℃
Anti-load protection under cold generation
EP02
70℃
80℃
50℃
--
1℃
EP04
60℃
80℃
55℃
--
1℃
EP07
3℃
8℃
-2℃
Anti-over temperature protection under heat generation Anti-frost protection in winter
1℃
4.2.2.7 time protection parameter time protection parameter are time set parameters relative to central air conditioner unit operation failure inspection judge and regulated by way of 【time▲】and【time▼】. Table of time protection parameter Parameter name
Unit No.
Ex-factory set
Min. value
Max. Value
Cancel
Potential
55
difference
Compressor start protection time
EC01
3min
10min
1min
1min
Compressor operation satisfaction time
EC02
3min
10min
1min
1min
Low pressure shielding inspection time
EC05
30sec
120sec
0sec
1min
Hold condition duration
EC06
3sec
10sec
1sec
1sec
Flow switch contant inspection time
EC07
10sec
60sec
1sec
1sec
4.2.2.8 unfreezing parameter Unfreezing parameter involves temperature and time parameters after entering and exit unfreezing condition. Temperature parameter is regulated by way of 【temperature▲】and【temperature▼】and time parameter is regulated by way of 【time▲】and【time▼】. Table of unfreezing parameter Unit No. HF01
Ex-facto ry set 8℃
HF02
Outer pipe temperature conditon of entering unfreezing
20℃
Max. Value 0℃
8℃
20℃
1℃
1℃
HF03
-8℃
0℃
-19℃
1℃
Outer pipe temperature conditon of exit unfreezing
HF04
10℃
20℃
0℃
1℃
Accumulation time conditon of entering unfreezing
HF05
45min
90min
30min
1min
Time conditon of exit unfreezing
HF06
8min
15min
2min
1min
Parameter name Outdoor ambient temperature conditon of entering unfreezing Outdoor ambient-pipe temperature conditon of entering unfreezing
Min. value
Cancel
Potential difference
1℃
4.2.3 Failure protection under cold generation Under cold generation, at the same time of operation, controller may check the failure possible raised and execute relevant treatment. 4.2.3.1 anti-frost protection under cold generation (failure code 【Pr07】) Prerequisite for entering anti-frost protection under cold generation: ①compressor in operation; ②output water temperatureT output <【EP01】and last 1 minute. After entering anti-frost protection under cold generation, line controller displays failure code and all compressors in module shut sown for protection. Exit condition of anti-frost protection under cold generation: ①output water temperature T output water ≥【EP01】+3℃. Failure code disappears; ②After satisfying shutdown protection, compressor recovers clod generation work. 4.2.3.2 anti-overload protection under cold generation (failure code 【Pr11】or【Pr14】) Insufficient cooling of outdoor fan will result in anti-frost protection under cold generation. The prerequisite of entering anti-frost protection under cold generation: ①compressor in operation; ②outdoor coil temperature T outer pipe ≥【EP02】. After entering anti-frost protection under cold generation, the relative compressor shutdown and outdoor fan keeps operation to continue cooling till satisfy the condition of exit protection. ①outdoor coil temperature T outer pipe <【EP02】-10℃. Failure code disappears; ②After satisfying shutdown protection, compressor recovers clod generation work. 4.2.3.3 failure protection of temperature sensor ①While total return water temperature sensor of main module failure, failure code 【Eo01】displays and system shuts down for protection. ②While total output water temperature sensor of main module failure, failure code 【Eo02】displays and system shuts down for protection. 56
③While module output water temperature sensor failure, failure code 【Eo08】displays and system shuts down for protection. ④While outdoor ambient temperature sensor failure, failure code 【Eo01】displays. ⑤While condensator coil temperature sensor failure, failure code 【Pr11】or【Pr14】displays, and cancel anti-overload protection under cold generation for relative unit. 4.2.4 Failure protection under heat generation Under heat generation, at the same time of operation, controller may check the failure possible rose and execute relevant treatment. 4.2.4.1 anti-over temperature protection under heat generation (failure code 【Pr08】) Process of entering anti-over temperature protection under heat generation ①if ouput water raises continuously and T output ≥【SP03】, deenergize and heat; After that if water temperature falls, electric heater recovers to normal operation; ②if ouput water raises continuously and T output ≥≥【EP04】, enter anti-over temperature protection under heat generation ③Unit entering anti-over temperature protection under heat generation, compressor and outer fan shuts down, and circulation operates continuously till output temperature satisfying the condition of Toutput < 【EP04】-10℃. 4.2.4.2 anti-frost protection in winter (failure code 【Po06】) In orderto prevent circulation water freezing while non-work in winter, iti s required to execute anti-frost protection. The prerequisite of entering anti-frost protection is: ①air conditioner in shutdown condition; ②while Ttotal output (return) temperature≤ 【EP07】+3℃时, entering anti-frost protection in winter. Circulation water pump starts and operates in alternative manner of operation 5 minutes and stop 30 minutes. While Ttotal output (return) temperature≤【EP07】, compressor executes heat generation and auxiliary electric heater operates; After entering anti-frost protection in winter, satisfy the following conditions and esit: ①air conditioner switches on; ②Ttotal output (return) temperature≥【EP07】+6℃, exit anti-frost protection in winter. 4.2.4.3 failure protection of temperature sensor ①While total return water temperature sensor for main module failure, failure code 【Eo01】displays and system shuts down for protection. ②While total return water temperature sensor for main module failure, failure code 【Eo02】displays and sub-module shuts down for protection. ③While module output water temperature sensor failure, failure code 【Er08】displays and sub-module shuts down for protection. ④While outdoor ambient temperature sensor failure, failure code 【Po01】displays. ⑤While condensator coil temperature sensor failure, failure code 【Po01】or 【Pr04】displays. 4.2.5 Unfreezing operation 4.2.5.1 entering condition of unfreezing operation (1) compressor accumulation operation time Aaccording to parameter 【PC04】and【HF01】, select whether consider affect of outdoor ambient temperature while compressor accumulation operation time or not. If 【PC04】set is 【- -】, outdoor ambient temperature should not be involved in compressor accumulation operation time, otherwise accumulates only compressor operation time satisfying the conditon of Toutdoor ambient ≤【HF01】according to set value of parameter 【HF01】. 57
If compressor accumulation operation time beyond set value of 【HF01】, satisfy one of time parameters entering unfreezing. (2) temperature difference between outdoor coil and outdoor ambient temperature Compressor operation under heat generation will conduce temperature of outdoor coil lower than outdoor ambient temperature. If the parameter of 【HF02】is set, must satisfy the condition of Toutdoor ambient-Touter pipe≥【HF02】and then enter unfreezing. If the sensor of outdoor ambient temperature or outdoor coil tmperature damage, cancel this judge condition. (3) outdoor coil temperature condition Ooutdoor coil temperature is determined by parameter 【HF03】. Before enter unfreezing must satisfy Touter pipe≤【HF03】. If sensor of outdoor emperature damage, cancel this judge condition. 4.2.5.2 multiple units coorperation unfreezing After one of unit in module satisfies entering condition of single unit above, the other units ignore pipe temperature condition and enter unfreezing together. 4.2.5.3 exit unfreezing conditon After unit entering unfreezing, according to compressor pressure variance condition, coil temperatuee variance and unfreezing work time, judge whether exits unfreezing. Exit unfreezing after satisfy only one of exit condition. (1) exit unfreezing due to compressor high pressure After compressor unfreezing results in pressure raising and high-pressure switch disconnection, the unit will exit unfreezing work. (2) outdoor coil temperature condition While compressor executes unfreezing work, outdoor coil temperature raises. After satisfying the condition of Touter pipe≥【HF04】, the unit exits unfreezing work. (3) time condition of exit unfreezing work 【HF06】 sets the maximum operation time of unit unfreezing. If unfreezing time beyond the time set by 【HF06】, ignore the fact that outdoor coil satisfy set condition of 【HF04】and exit unfreezing. 4.2.5.4 exit condition of cooperation unfreezing for multiple units After one unit satisfying the condition of exit unfreezing, if other units are still executing unfreezing, shut down and wait till all units exit unfreezing and perform heat generation again. 4.2.5.5 unfreezing process Parameter【SA04】set two types of process function modules for unfreezing. While 【SA04】set is ON, compressor should not shut down and divert for unfreezing directly; while parameter【SA04】is OFF, compressor shuts down and wait for divert of four-way diverting valve and then switches on for unfreezing. (1) non-shutdown unfreezing process 【After parameter 【SA04】set ON and satisfying entering condition of unfreezing, compressor should not shut down and four-way diverting valve deenergize and divert, and then compressor converses into cold generation mode, at same time, outdoor fan switches off. During unfreezing, low pressure switch should not be inspected. After satisfying exit condition of unfreezing, four-way valve engerizes and diverts, and compressor converses into heat generation mode, meanwhile, outdoor fan switches on. (2) shutdown unfreezing process After parameter 【SA04】 set OFF and satisfying entering condition of unfreezing, compressor shuts down, and 5 seconds later outdoor fan switches off, another 5 seconds later, four-way valve deenergizes and diverts, and 30 seconds again conpressor restarts for unfreezing. During unfreezing, low pressure switch should not be inspected. After satisfying exit condition of unfreezing, compressor shuts down and outdoor fan operates. After 58
satisfying temperature condition of compressor operation, 5 seconds later compressor starts for heat generation. 4.2.6 System failure protection and code Controller judges various failures during system operation automatically and executes protection treatment subject to failure type. Subject to failure reason and treatment method, failure protection should be classified 5 types that are followed: unit recoverability protection, system recoverability protection, unit serious failure protection and system serious failure protection. 4.2.6.1 unit recoverability protection While unit recoverability protection occurs, unit should take measurement concerned. After recovery, unit will recovers normal operation again. After unit recoverability protection occurs, failure code glitters in line controller. Table of failure code of unit recoverability protection Failure reason
Failure code
Entering condition
Recovery condition
Touter pipe①sensor damage
Pr：01
Sensor short or cut
Repair or replace
Touter pipe②sensor damage
Pr：02
Sensor short or cut
Repair or replace
Touter pipe③sensor damage
Pr：03
Sensor short or cut
Repair or replace
Touter pipe④sensor damage
Pr：04
Sensor short or cut
Repair or replace
Anti-frost protection under cold generation
Pr：07
Toutput water≤【EP01】
Toutput water≥【EP01】+3℃
Over temperatyre protection under heat generation
Pr：08
Toutput water≥【EP04】
Toutput water<【EP04】-10℃
1#unit anti-overload under cold generation 2# unit anti-overload under cold generation 3# unit anti-overload under cold generation 4# unit anti-overload under cold generation
Pr：11 Pr：12 Pr：13 Pr：14
Touter pipe①＞【EP02】 Touter pipe②＞【EP02】 Touter pipe③＞【EP02】 Touter pipe④＞【EP02】
Touter pipe①≤50℃ Touter pipe②≤50℃ Touter pipe③≤50℃ Touter pipe④≤50℃
4.2.6.2 system recoverability protection While recoverability protection occurs of air conditioner, whole system should adopt relative protection measurement. After failure being protected recovery, system will recover normal operation. Table of failure code of system recoverability protection Failure reason
Failure code
Entering condition
Outer ambient temperature sensor damage
Po：01
Sensor short or cut
Recovery condition Repair or replace
Anti-frost protection in winter
Po：06
Treturn water≤【EP07】+3℃
Treturn water≥【EP07】+6℃
4.2.6.3 unit serious failure protection After serious failure in unit occurs, failure code displays in line controller, and relative unit shuts down and other units operate continuously. Unit cannot recover operation after failure shutdown, except hand operates to reset the failure condition. Table of failure code of unit serious failure protection Failure reason
Failure code
Entering condition
Recovery condition
1#compressor pressure over high
Er：01
1#high pressure switch off【EC06】
Press reset key after switch normal
2# compressor pressure over high
Er：02
2# high pressure switch off【EC06】
Press reset key after switch normal
3# compressor pressure over high
Er：03
3# high pressure switch off【EC06】
Press reset key after switch normal
4# compressor pressure over high
Er：04
4# high pressure switch off【EC06】
Press reset key after switch normal
Icing point protection
Er：06
Icing point protection switch off
Press reset key after switch normal
Sub-module flow failure
Er：07
Flow switch off
Press reset key after switch normal
Output water temperature sensor of module damage
Er：08
Sensor short or cut
Repair or replace
1# compressor pressure over low
Er：11
1# low pressure switch off【EC05】
Press reset key after switch normal
2# compressor pressure over low
Er：12
2# low pressure switch off【EC05】
Press reset key after switch normal
3# compressor pressure over low
Er：13
3# low pressure switch off【EC05】
Press reset key after switch normal
4# compressor pressure over low
Er：14
4# low pressure switch off【EC05】
Press reset key after switch normal
59
Outer fan overload
Er：17
Sub-module phase sequence protection
Er：18
Outer fan protection switchi off
Press reset key after switch normal
【EC05】
Press reset key after switch normal
Phase sequence switch off
4.2.6.3 system serious failure protection After serious failure in system occurs, all units shut dwon and wait for inspection. Talbe of failure code of system serious failure protection Failure reason
Failure code
Entering condition
Recovery condition
Communication failure
Eo：00
Communication abnormal
Communication circuit normal
Total return water temperature sensor damage
Eo：01
Sensor short or cut
Repair or replace
Total output water temperature sensor damage
Eo：02
Sensor short or cut
Repair or replace
Main module phase sequence switch off
Eo：03
Main module flow switch off
Reset by pressing key reset
Main module flow switch off
Eo：04
Main module flow switch off
Reset by pressing key reset
4.3 Instruction of expansion module controller for electronic expansion valve 4.3.1 Interface description of electronic expansion controller ⑴ ⑵ as followed: ⑶ Physical photo of electronic expansion controller
⑷
⑸
⑹
⑺ ⑼
⑽ ⑻
⑾
⑿
⒀
⒁
⒂
⒃
⒄
⒅
Schematic srawing of interface description of electronic expansion controller ⑴1# electronic expansion interface ⑵2# electronic expansion interface ⑶ the relative controller address corresponding to control address switch of electronic expansion controller. Address corresponding table Switch 1
Switch 2
Switch 3
Switch 4
Address code
Corresponding controller code
OFF
OFF
OFF
OFF
0000(0)
1#module
OFF
OFF
OFF
ON
0001(1)
2# module
OFF
OFF
ON
OFF
0010(2)
3# module
OFF
OFF
ON
ON
0011(3)
4# module
OFF
ON
OFF
OFF
0100(4)
5# module
OFF
ON
OFF
ON
0101(5)
6# module
OFF
ON
ON
OFF
0110(6)
7# module
OFF
ON
ON
ON
0111(7)
8# module
ON
OFF
OFF
OFF
1000(8)
9# module
ON
OFF
OFF
ON
1001(9)
10# module
ON
OFF
ON
OFF
1010(10)
11# module
60
ON
OFF
ON
ON
1011(11)
12# module
ON
ON
OFF
OFF
1100(12)
13# module
ON
ON
OFF
ON
1101(13)
14# module
ON
ON
ON
OFF
1110(14)
15# module
If the corresponding controller is not module type, the address set should be 0000. ⑷manual increase-by-degree key Under manual mode, enery press this key, amplitude of electronic expansion valve increases one step.
⑸manual decrease-by-degree key Under manual mode, enery press this key, amplitude of electronic expansion valve decreases one step.
⑹220V/AC zero line interface ⑺220V/AC phase line interface ⑻power source transformer interface ⑼digital tube display Display electronic expansion amplitude, temperature and failure code. Each of amplitude of electronic expansion valve and three temperatures display in turn. And sequence as followed: amplitude→Axx (evaportaor inlet temperature under cold generation) →Bxx (evaportaor inlet temperature under hot generation) →Cxx (rerturn air pipe temperature) → amplitude ⑽switchover switch While switch turn to left, contents of display and control object of gradient-increase/decrease are in the scope of 1#electronic expansion valve; on the contrary, turn switch to right contents of display and control object of gradient-increase/decrease are in the scope of 2#electronic expansion valve. ⑾1# evaporator inlet temperature sensor under cold generation Is Intalled on cold-generation inlet pipe of 1# evaporator, which is abbreviated as Tcold-generation ①. ⑿1# hot-generation evaporator inlet temperature snesor Is Intalled on hot-generation inlet pipe of 1# evaporator, which is abbreviated as Thot-generation ① ⒀1#air return pipe temperature snesor Is Intalled on air return pipe of 1# evaporator, which is abbreviated as Tair return-generation ① ⒁2# evaporator inlet temperature sensor under cold generation Is Intalled on cold-generation inlet pipe of 2# evaporator, which is abbreviated as Tcold-generation ② ⒂2# hot-generation evaporator inlet temperature snesor Is Intalled on hot-generation inlet pipe of 2# evaporator, which is abbreviated as Thot-generation ② ⒃2#air return pipe temperature snesor Is Intalled on air return pipe of 2# evaporator, which is abbreviated as Tair return-generation ② ⒄RS485 communication interface ⒅test jumper switch Test jumper switch is used to enter self-inspection mode. 4.3.2 Parameter set 4.3.2.1 parameter set method Controller is provided with many parameter sets, and inquires and regulates parameter contents by way of line controller. Parameter set is only executed under hand mode. After communication interface of HAC-DPF-2 electronic expansion valve controller connects with line controller and enter hand mode, pressing key【inquire】for 5 seconds, and “tick” occurring from line controller and loosing, and then enters parameter set operation. 4.3.2.2 system function select parameter System function select parameter is provided with only two opinions: “ON” and ”OFF”. Change parameter status by way of pressing key【time▲】and【time▼】 Table of system function select parameter 61
Parameter name
Unit No.
Default
Standby
SA01
OFF
ON
OFF
4.3.2.3 compensation parameter of temperature sensor compensation parameter of temperature sensor is regulated by way of 【time▲】and【time▼】. while parameter up to maximum or minimum value, continues regulation, 【- -】occurs indicating cancel status. Under that status, temperature sensor cannot be installed, and relative operation function and protection function will be cancelled. Talble of compensation parameter of temperature sensor Cancel
Potential difference
Parameter name
Unit No.
Default
Min. value
Max. value
1#evaporator inlet temperature sensor under cold generation
PC01
0℃
-9℃
9℃
1℃
1#evaporator inlet temperature sensor under hot generation
PC02
0℃
-9℃
9℃
1℃
1# temperature sensor of air return pipe
PC03
0℃
-9℃
9℃
1℃
1#evaporator outlet temperature sensor under cold generation
PC04
0℃
-9℃
9℃
1℃
2#1#evaporator outlet temperature sensor under cold generation
PC05
0℃
-9℃
9℃
--
1℃
2# temperature sensor of air return pipe
PC06
0℃
-9℃
9℃
--
1℃
4.3.2.4 compensation parameter of temperature sensor Operation tenperature parameter of electronic expansion valve is the parameter relative to the temperature control of electronic expansion valve and regulated by way of 【temperature▲】and【temperature▼】. Table of compensation parameter of temperature sensor Potential
Parameter name
Unit No.
Default
Min. value
Max. value
Electronic expansion valve primary amplitude under cold generation
SP01
34
50
0
1
Electronic expansion valve primary amplitude under hot generation
SP02
26
50
0
1
Increase amplitude temperaturediference under cold generation
SP03
3℃
10℃
-10℃
1℃
Decrease amplitude temperaturediference under cold generation
SP04
5℃
10℃
-10℃
1℃
Increase amplitude temperaturediference under hot generation
SP05
3℃
10℃
-10℃
1℃
Decrease amplitude temperaturediference under hot generation
SP06
5℃
10℃
-10℃
1℃
Cancel
difference
4.3.2.5 electronic expansion valve operation time and amplitude parameter Electronic expansion valve operation time and amplitude parameter are the parameters relative to time set and amplitude range set, and regulated by way of 【time▲】and【time▼】. Table of electronic expansion valve operation time and amplitude parameter Cancel
Potential difference
Parameter name
Unit No.
Default
Min. value
Max. value
Amplitude regulation cycle
SC01
60sec
120sec
1sec
1sec
Fine regulation amplitude under cold generation
SC02
10p
50p
5p
1p
Coarse regulation amplitude under cold generation
SC03
25p
50p
5p
1p
Fine regulation amplitude under hot generation
SC04
10p
50p
5p
1p
Coarse regulation amplitude under hot generation
SC05
25p
50p
5p
1p
Back light ource ignite time
SC06
10sec
60sec
3sec
Parameter inquery LCD glittering time
SC07
10sec
30sec
1sec
Orientaion time interval
SC08
1hour
24hour
1hour
--
1sec 1sec
--
1sec
4.3.3 Frost unfreezing After relative unit of electronic expansion valve entering frost unfreezing, the amplitude of electronic expansion valve should be maximum 500P, and constant-maximum amplitude【SC01】time, amplitude regulation is 340 steps and regulates amplitude following cold-generation temperature automatically. After unfreezing finish, recovers to 260P amplitude and regulates amplitude following hot-generation temperature automatically. During frost freezing, display glitters and displays 【FRO】. 62
4.3.4 Orientation In order to provent amplitude error as a result of out of synchronizing of step-by-step motor, every 【SC08】 time later, orientates the electronic expansion valve again. Orientation process is increasing 500P amplitude to accretion direction to ensure electronic expansion valve to turn to maximum position from any position, and lasts 10 seconds, finally returns to 250P amplitude. During orientation freezing, display glitters and displays【REN】. 4.3.5 Malfunction Failure codes are listed as followed: Table of failure code Failure code Er0
Failure reason Communication failure
Er1
SensorTcold generation①damage
Er2 Er3
SensorThot generation①damage SensorTair return①damage
Er4
SensorTcold generation②damage
Er5 Er6
SensorThot generation②damage SensorTair return②damage
Treatment method Operation subject original amplitude. Operation of cold generation or dehumidification subject to original amplitude Operation of hot generation subject original amplitude. Operation subject original amplitude. Operation of cold generation or dehumidification subject to original amplitude Operation of hot generation subject original amplitude. Operation subject original amplitude.
63