02 - Inverter Mini Chiller System and Control

TECHNICAL TRAINING
2008
Technical Training 2008
Inverter Mini Chiller

System and Control
Content
1. Introduction
2. Basic Inverter Technology
3. Components
4. Control Algorithm
5. Protection
Introduction
Introduction
5ACV100/135/210 CR
5ACV55/75 CR
5ACV30 CR
Introduction
Capacity (kW)
Model
Cooling
Heating
5ACV030CR
7.94
9.66
5ACV055CR
14.65
16.12
5ACV075CR
20.52
21.99
5ACV100CR
27.80
29.30
5ACV135CR
38.54
41.47
5ACV210CR
58.62
61.55
Introduction
New Technology BPHE- True Dual Circuits
Conventional Back to Back Circuits BPHE
Secondary Circuit
Primary Circuit 1
Primary Circuit 2
5ACV True Dual Circuits BPHE
Primary Circuit 1
Primary Circuit 2
Introduction
Inverter Compressor
Conventional System
Inverter System
Introduction
Elimination of Water Tank
Inverter system provide constant Water Temperature band, or
much lesser water temperature fluctuation. With this, water
tank of mini chiller system can be eliminated
Modular Installation
A network up to 50 chillers in a system is possible. Control on
the operation of chillers will be done through the
microprocessor controller. The external water piping connection
can be made either from the left or right side of the unit.
High & Low
Safety
Protection
Pressure
Switches
Anti Freeze Protection
Sensor
Discharge Temperature
Sensor
Over Pressure Relief Valve
Water Pressure Differential

Switch
Anti Freeze Heater on BPHE
Compressor, Water Pump
Overload Protector
Basic Inverter
Technology
Basic Inverter Technology

The system:-
Power supply
Input frequency
50Hz
Inverter
t1
AC/DC
Rectifier
DC/AC
Inverter
50 Hz
100 Hz
15 Hz
(compressor motor input)

PWM
AC
DC
Power
supply unit
Temperature
detection signal
Operating
frequency signal
AC
Three-phase
inverter
PWM control
(Waveform formation)
AC Inverter Unit
Compressor
Three-phase
induction motor

Inverter Basic Structure
DC Link
Converter
AC
Rectification
AC
Inversion
SMPS
PLC Control
PWM Signal

Rectification Circuit
Rectifier Bridge
Relay
EMI
Filter
PTC Starter
EMI filter to minimize emission effect (EMC) and raise immunity

level (EMS)
PTC to cushion start-up current to capacitor
Diode bridge inverts AC to DC

DC Stage
PFC Capacitor
Reactor
Diode
Stabilizing
Capacitor
PFC capacitor acts to curb PF losses caused by DC voltage

fluctuation in order to drive the asynchronous motor

Inversion Circuit
Consists of 6 IGBT (Insulated Gate Bipolar Transistor)

Controlling the ON/OF linkages, different frequency and voltage of 3phase AC can be generated
IPM (Intelligent power module) encased the inversion circuitry together
with error detection and protection features

Advantages of Inverter Air Conditioners
Item
Fixed Speed AC
Inverter AC
No
Yes, by 30% - 40%
2C
0.5C
No
Yes
Current surge of 711x
Soft-start. No
current surge
No
Yes, operates at
high freq.
Slow
Fast
Less efficient
Accurate and fast
Protection Features
Basic
Complete
Auto-Mode Features
Basic
Complete
Energy Saving
Temp. Fluctuation
Adjust to Load
Start-up
Full Load Op.
Speed of Cool/Heat
Defrosting
Components
Components
Fan guards
Coil guards
fan motors
Heat
exchangers with
gold fin as
standard
True dual circuits BPHE
(Brazed plate heat
exchanger)
Control box
assembly
Expansion
tank ( 8L)
Water pump
Components
High pressure switch
(NC) 600 psi open,
480psi close.
Low pressure switch
(NC) 18 psi open,
28 psi close.
Chiller panel
controller
Differential pressure
switch
Over pressure relief
valve
Fixed speed
scroll
compressor
(R410A)
Anti freeze heater on

BPHE
Pump OLP (overload
protector)
Compressor OLP
(overload protector)
Variable drive system

compartment
Fixed drive system

compartment
Variable speed
scroll
compressor
(R410A)
Components
Control box assembly
IPM board
Unidirectional
bridge
diode
(Intelligent power module)
3 phase
rectifier
bridge
diode
Fan
capacitors
Power board
EMI filter
Capacitor
board
PFC capacitor Main board
(Power factor correction)
Magnetic
contactors
Components
EMI Filter
Function
EMI Filter is a device placed between the power source and
control device circuit.
Prevents external electromagnetic interference from getting
into the controller.
Prevents internal electromagnetic emission from polluting
the supply grid.
Components
Main Board
For Model 55, 75, 100 & 135
For Model 30
Components
Power Board
- To convert rectified DC current
+590VDC to respective desired voltages
- 12VDC relay
- MCU +5VDC
- IPM +15VDC
- Ensure stability of above voltages
within power supply voltage fluctuation
range (304-480 VAC)
- Over voltage feedback
- Output short circuit protection
Components
Capacitor Board
Components
IPM
Function
Invert DC to AC current
Drive variable compressor
In-Built Protection
Low voltage lock-out
Over-heating, over-current and short-circuit protection.
Components
Schematic Diagram
Cond In
Temp 1
(Condenser)
5ACV100CR
Cond Out
Temp 1
(Def Comp 1)
Condenser Coil 1
HP1
Disch
Temp 1
(Disch Comp 1)
Filter
Drier
4WV
LP1
EXV
Suct
Temp
(Suction)
Inv
Comp
BPHE In
Temp
(BPHE In)
BPHE Out
Temp
(BPHE Out)
Acc
O/A Temp
(Outdoor Air)
Liq Rvr
Pump
BPHE
HP2
EWT (Water In)

LWT (Water Out)
Cooling Cap Tube
4WV
Disch
Temp 2
(Disch Comp 2)
FS
Check valve
LP2
Liq
Rvr
Std
Comp
Acc
Condenser Coil 2
Cond Out
Heating Cap Tube
Temp 2
(Def Comp 2)
Check valve
Summary PagesScreen 3
Display MenuDefrost Sensor
Filter Display MenuDrier Inverter Chiller
Display MenuDischarge Sensor
Control Algorithm
Control Algorithm
General Control Flow Chart
Start
No
System On?
Yes
Clash between
current & selected
mode of operation?
Yes
No
Stop Inverter Comp
Cooling?
10s
No
Heating?
No
Stop Fixed Comp

Yes
60s
Yes
Stop pump
Cooling mode
Heating mode
Control Algorithm
Variable Drive Compressor Control
Cooling mode
Start up condition :
Pump runs normally for 3 minutes * For example :
2C T
water return
set
4C
Return water temp.= 14 to 16 C

Set temp
= 12C
T
= 2 to 4C
No irreversible errors in variable drive and the

systems
Satisfy a delay of 3 minutes before restart #
Note : If fixed drive system starts first, the variable drive system
should trail after 30 sec.
* Depends on Parameter P2 (flow switch alarm delay at pump start. Min 0s, max 199s, default
180s )
#
Depends on Parameter C2 (compressor min stop time. Min 0s, max 1990s, default 180s)
Control Algorithm
Cooling mode
Cooling mode selected water pump starts
Outdoor fan starts variable drive compressor
starts
Increase to rated
frequency with the
rate of 1Hz/s
Rated Freq.
5ACV100CR=75Hz
5ACV135CR=95Hz
55Hz
5Hz
t
3 min 5 sec
1 min
Variable drive comp
ON
OFF
ON
OFF
Outdoor fan
Outdoor fan will start 5 sec

before compressor start
Inverter compressor
will start from 5Hz to
55Hz and maintain
this frequency for 1
min.
Control Algorithm
Cooling mode
Shut down condition :
Cooling mode terminates, OR
Variable drive system error occurs, OR
T
water return
set
-2C
For example :
Return water temp.=
10C
Set temp
=
12C
T
=
-2C
Control Algorithm
Fixed Drive Compressor Control
Cooling mode
Pump runs normally for 3 minutes * For example :
Water return temp =
16C
T water return T set > 4C
=
Fixed drive starts first followed by variable driveSet temp
12C
T the
=
No irreversible errors in fixed drive and
4C
systems
Satisfy a delay of 3 minutes before restart
Note : If variable drive system starts first, the fixed drive

system will only start after the frequency of variable drive
drops to 50Hz.
180s )
#
Control Algorithm
Cooling mode
Cooling mode selected water pump starts
Outdoor fan starts compressor starts
Fixed drive
compressor starts
ON
Fixed drive comp
OFF
3 min
5 sec
1 min
ON
Outdoor fan
Outdoor fan will start 5

sec before compressor
start
OFF
Outdoor fan will stop

after compressor has
stopped for 1 min
Control Algorithm
Cooling mode
Cooling mode terminates, OR
Fixed drive system error occurs, OR
T set - T
20Hz
water return
> 2C and variable frequency drops pass

For example :
Set temp
=
12C
Water return temp =
10C
T
=
2C
Control Algorithm
Heating mode
Pump runs normally for 3 minutes *
2C T
set
- T
water return
4C
For example :
Set temp
= 40C
Return water temp.= 36 to 38 C
T
= 2 to 4C
No irreversible errors in variable drive and the

systems
Satisfy a delay of 3 minutes before restart #
Note : If fixed drive system starts first, the variable drive system
should trail after 30 sec.
180s )
#
Control Algorithm
Heating mode
Heating mode selected water pump starts Variable

drive 4WV engages Outdoor fan starts compressor
Increase to rated
frequency with the
starts
rate of 1Hz/s
Rated Freq.
5ACV100CR=65Hz
5ACV135CR=90Hz
Inverter compressor
will start from 5Hz to
45Hz and maintain
this frequency for 1
min.
45Hz
5Hz
3 min 10 sec
Variable drive comp
ON
OFF
ON
OFF
ON
OFF
Variable 4WV
Outdoor fan
Variable drive 4WV start 10

Technical
Training 2008
start
1 min
5 sec

Control Algorithm
Heating mode
Heating mode terminates, OR

Variable drive system error occurs, OR
T
set
- T
water return
-2C
For example :
Set temp
= 40C
Water return temp = 42C
T
= -2C
Control Algorithm
Heating mode
Pump runs normally for 3 minutes *
T
set
- T
water return
> 4C
For example :
Set temp
=
40C
Water return temp =
36C
and the
T
=
4C
No irreversible errors in fixed drive

systems
Satisfy a delay of 3 minutes before restart
Note : If variable drive system starts first, the fixed drive

system will start after the variable drive frequency drops to
50Hz.
180s )
#
Control Algorithm
Heating mode
Heating mode selected water pump starts Fixed drive
4WV engages Outdoor fan starts compressor starts
Fixed drive
compressor starts
ON
Fixed drive comp
OFF
3 min
10 sec
1 min
5 sec
Variable 4WV
ON
OFF
ON
Outdoor fan
Fixed drive 4WV start 10

start
OFF

Outdoor fan and 4WV

will stop after
compressor has stopped
for 1 min
Control Algorithm
Heating mode
Heating mode terminates, OR
Fixed drive system error occurs, OR
T
water return
-T
set
> 2C
For example :
Water return temp = 42C
Set temp
= 40C
T
= 2C
Control Algorithm
Pump Control
Pump start up
When starting the system, pump will run for 3 minutes *
before proceeding to next step.
* Depends on Parameter P2 (flow switch alarm delay at pump start. Min = 0s, Max = 199s,
default = 120s)
Pump shut down

After both compressors shut down for 1 minute, pump shuts
down.
Protection
Protection
Compressor Over-Current Protection
Variable drive compressor
When variable drive compressor current reaches the Ib, over-current

protection triggers and the compressor frequency will reduce.
When the compressor current drops into Ic to Ib, frequency will not
increase.
When the compressor current drops below the Id, frequency variation
resumes.
When compressor current increase rapidly and reaches the Ia, the
Comp amp
system will be determined
as compressor overload and stop the
Variable compressor stops
(A)
compressor.
Ia
Ib
Frequency step down

Maintain frequency
Ic
Id
Normal Operation
Protection
Variable drive compressor
Inv
M5ACV M5ACV M5ACV M5ACV M5ACV M5ACV
Comp
030
055
075
100
135
210
Current
Ia
29
20.5
20.5
20.5
20.5
20.5
Ib
27
18
18
18
18
18
Ic
25
17
17
17
17
17
Id
25
16
16
16
16
16
Protection
Fix drive compressor
When fixed compressor current > Ie. The compressor will stops and
resumes after 3 minutes
Note: When either drive overload protection occurs more than 3 times
within 30 minutes, system triggers irreversible error protection.
Comp amp
(A)
Ie
Fixed compressor stops
Protection
High Discharge Temperature Protection
When variable drive discharge temperature reaches 110C, system

stops.
When variable drive discharge temp. between 100C and 110C,
frequency drops.
When variable drive discharge temperature is less than 97C and more
than 100C,
frequency increased restricted.
When discharge temperature falls below 94C, normal operation
Compressor
resumes.
discharge
temperature
System shuts down
110C
Frequency step down
100C
Maintain frequency
97C
94C
Normal operation
Protection
High Discharge Temperature Protection
Fixed drive system
When fixed drive discharge temperature reaches 110C, system stops.

When discharge temperature falls below 94C for 3 minutes, system resumes.
Td = Compressor discharge temperature
Td
Comp Cut
110C
94C
Comp start
3 min
Protection
Outdoor Coil High Temperature Protection
During cooling, when Tcoil1 > 60 C, frequency drops.
During cooling, when Tcoil1 < 55 C, system resumes.
Fixed drive system
During cooling, when Tcoil2 > 64C, compressor stops.
During cooling, when Tcoil2 < 51C, system resumes.
Protection
Low Pressure Switch Protection
Alarm delayed at compressor startup : 30 sec depends on

Parameter P3*.
No protection during defrosting.
If variable drive or fixed drive low pressure switch is activated
for 5 seconds, alarm will be triggered.
* Parameter P3 (Low pressure alarm delay at compressor start up. Min=0s, max=199s, default=30s)
Note : If low pressure alarm occur more than 3 times within

30 minutes, system shuts down to irreversible error.
Protection
High Pressure Switch Protection
If fixed drive high pressure switch is activated for 30 sec,

alarm will be triggered.
If variable drive high pressure switch is activated,
frequency of variable drive compressor will decrease at
1Hz/s. If it is re-activated for 30 sec, alarm will be triggered.
Note : If high pressure alarm occur more than 3 times within

30 minutes, system shuts down to irreversible error.
Protection
3 Phase AC Phase Sequence Protection
If 3 phase AC phase sequence is incorrectly
connected, system will not start and controller will
indicate error. System will resume after
rectification. (except M5ACV030CR)
3 Phase AC Phase Missing Protection
If phase missing happens, system will not operate.
Controller will indicate error. System will resume
after rectification.
Thank You

02 - Inverter Mini Chiller System and Control

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02 - Inverter Mini Chiller System and Control

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TECHNICAL TRAINING

Technical Training 2008

Inverter Mini Chiller

Technical Training 2008

Technical Training 2008

Technical Training 2008

Technical Training 2008

Technical Training 2008

Conventional Back to Back Circuits BPHE

5ACV True Dual Circuits BPHE

Technical Training 2008

Technical Training 2008

Technical Training 2008

Water Pressure Differential

Technical Training 2008

Basic Inverter Technology

(compressor motor input)

Technical Training 2008

Basic Inverter Technology

Technical Training 2008

Basic Inverter Technology

Technical Training 2008

Basic Inverter Technology

EMI filter to minimize emission effect (EMC) and raise immunity

Technical Training 2008

Basic Inverter Technology

PFC capacitor acts to curb PF losses caused by DC voltage

Technical Training 2008

Basic Inverter Technology

Consists of 6 IGBT (Insulated Gate Bipolar Transistor)

Technical Training 2008

Basic Inverter Technology

Yes, by 30% - 40%

Current surge of 711x

Accurate and fast

Technical Training 2008

Technical Training 2008

Technical Training 2008

Anti freeze heater on

Variable drive system

Technical Training 2008

Fixed drive system

(Intelligent power module)

PFC capacitor Main board

(Power factor correction)

Technical Training 2008

For Model 55, 75, 100 & 135

Technical Training 2008

Technical Training 2008

Technical Training 2008

EWT (Water In)

Cooling Cap Tube

Technical Training 2008

Technical Training 2008

Stop Fixed Comp

Technical Training 2008

Return water temp.= 14 to 16 C

No irreversible errors in variable drive and the

Technical Training 2008

Variable drive comp

Outdoor fan will start 5 sec

Technical Training 2008

Technical Training 2008