Haier CA0035EAND, Service Manual

Page 1: ...1 Service Manual AIR COOLED MODULAR CHILLER SYJS 05 2021 B Edition 2021 05 ...

Page 2: ...ring Diagram 35 9 Commissioning Operation and Maintenance 39 10 PCB Photo and Address Code Setting 43 11 Fault Code 44 12 Trouble Shooting 46 13 Unit Operating Range and Service Condition 48 14 Technical Parameters 49 15 Modular pressure drop water flow 51 16 Sensor Charistic 55 17 Central control connection 56 18 Appendixi table for manual updated information 63 ...

Page 3: ...er cooled 0 0 1 2 R132 C Earth source E 115 220V 50 60Hz 3 DC inverter R Z Earth source R134A D 220 220V 60Hz 4 Air cooled module chiller A R410A E 110V 50 60Hz 5 Light chiller Split packaged H Cooling only R22 M 220V 50 60Hz 6 Single packaged R R407C N 127V 60Hz 7 Water cooled cabinet chiller W R132 O 240V 50Hz 8 Hydronic system Cassatte B R134A P 110 220V 50 60Hz 9 Duct D R410A Q 330V 50Hz A Cab...

Page 4: ...ondensation temp Motor Low sound power level axial fan together with the high efficient motor making higher efficiency and lower sound power level EEV High efficient EEV thermostatic expansion valve to adjust the overheating degree of system to control refrigerant volume High efficient evaporator to make part load and full load COP the highest 3 2 1 2 4 3 1 4 Compact design reduce footprint New Y ...

Page 5: ...ic aluminum fin coil type structure increase the heat exchange efficiency 20 Operation Operation Operation Service Stop Stop Malfunction Three phase fan motor Three phase fan motor compared with one phase fan motor low starting current high speed and more stable Shell Tube heat exchanger The new modular chiller adopt Shell Tube heat exchanger avoid dirty plugging higher efficiency and reliability ...

Page 6: ...ures 2 2 1 The modular design capacity can be broadened The unit uses modular design module a plurality of modules are connected together the unit can be connected to 16 separate unit module can be done to expand the width capacity between 65kW 1040kW at the same time each individual module no distinction between them both it can be used as a host also be used as auxiliary use high design and inst...

Page 7: ...otection compressor discharge temperature protection anti overheating protection flow switches protection sensor fault protection 2 2 4 Environmental protection R410A refrigerant higher cooling heating efficiency Improve air conditioning performance do not damage the ozone layer 2 2 5 Ultra wide operating range 50 degrees in ultra high temperatures cooling but also can meet the ultra low temperatu...

Page 8: ...ter dirt coefficient m2 KW 0 018 0 018 Standard pressure Mpa 1 0 1 0 Water resistance kPa 40 45 Sound pressure level 1m away dB A 60 65 Sound power level 1m away dB A 76 83 External dimension Unit length mm 918 2060 Unit width mm 1038 780 Unit height mm 1810 2170 Package dimension Unit length mm 1075 2200 Unit width mm 940 830 Unit height mm 1950 2280 Weight Unit weight kg 270 630 Gross weight kg ...

Page 9: ...rnal screw thread Water dirt coefficient m2 KW 0 018 0 018 Standard pressure Mpa 1 0 1 0 Water resistance kPa 50 60 Sound pressure level 1m away dB A 67 68 Sound power level 1m away dB A 85 86 External dimension Unit length mm 2060 2060 Unit width mm 1603 1603 Unit height mm 2170 2170 Package dimension Unit length mm 2200 2200 Unit width mm 1650 1650 Unit height mm 2280 2280 Weight Unit weight kg ...

Page 10: ...8 4 Dimension CA0035EAND 6 Unit Base Diagram ...

Page 11: ...9 CA0070EAND Unit Base Diagram Water Outlet Water Inlet Draining Valve Electric control cabinet 0 0 0 1 5 2 7 1320 2170 ...

Page 12: ...10 CA0100EAND CA0130EAND 7 Unit Base Diagram 5 2 8 1 0 5 5 1 1320 0 7 1 2 ...

Page 13: ...11 5 Refrigerant system diagram HPs dry evaporator 4wv TXV Tewo Tewi heat exchanger Td Ps Ts Tdef1 Tdef2 ...

Page 14: ... T e A2 Tewo Tewi Drier heat exchanger T e A1 T e A2 Drier heat exchanger T e A1 T e A2 Drier WVA heat exchanger COMP A INV D E C S Segregator TXV Accumulator Td A T e A1 T e A2 Ts A LPs A HPs A Drier Accumulator Accumulator Segregator SYSTEM D SYSTEM B SYSTEM A SYSTEM C Segregator TXV TXV ...

Page 15: ...ve In heating refrigerant flow control φ6 4 4 way valve 4WV Changing over between cooling and heating AC220V electrified in heating powered off in cooling or defrosting Temp sensor Td Check the dis temp of compressor R100 6 5K 2 5 B0 100 4010 3 Ts Check the suction temp of compressor R25 5K 3 B0 100 3470 3 Ta Check ambient temp and control defrost condition Tdef1 Tdef2 Check frost condition of out...

Page 16: ...er from the water system via the drain valve to prevent the freezing crack of the heat exchanger the water pipe and other parts on water side Furthermore the water pump shall be power off to avoid starting up against frost without water To prevent the heat exchanger on water side from being frozen due to foreign matters entered a self contained water filter must be installed on the water return pi...

Page 17: ...tural beams of the building so as to avoid vibration transmitted live and work areas Ensure that the pipeline will not add additional pressure to the unit Be careful not to use metal tube shock absorbers because the frequency range of plant operation the damper is ineffective 4 Frost protection Note In the case of low ambient temperature in winter overnight shutdown period heat exchangers and wate...

Page 18: ...t during operation 2 The base may be of U steel designed by users as per overall dimensions of the unit or concrete structure and shall have flat surface 3 A 10 20 mm rubber shock pad shall be placed between the unit and the base 4 The unit and the base may be fastened with ø16 or ø18 anchor bolts Unit Base Diagram CA0035EAND Unit Base Diagram ...

Page 19: ...17 CA0070EAND Unit Base Diagram CA0100EAND CA0130EAND Unit Base Diagram Water Outlet Water Inlet Draining Valve Electric control cabinet 0 0 0 1 5 2 7 5 2 8 1 0 5 5 1 1320 1320 2170 0 7 1 2 ...

Page 20: ...g down due to earthquake or strong wind In order to withstand strong wind and earthquake the unit must be positioned properly and can not be installed at such a place exposed to strong wind Depending on installation conditions vibration may be transferred to fitted parts and base plates and walls may produce vibration and noise Therefore proper vibration protections e g setting shock pad dumper br...

Page 21: ... Diagram of installation space for single chiller unit Unit mm Installation Space 4 8 300 1000 Guiding device 2 Diagram of installation space for multiple chiller units Unit mm 450 450 450 450 450 1500 1500 ...

Page 22: ... it s a n d w a ll 4 5 0 S p a c e b e t w e e n u n i t s a n d w a l l 1 0 0 0 S p a c e b e t w e e n u n it s 4 5 0 S p a c e b e t w e e n u n it s 4 5 0 S p a c e b e t w e e n u n it s 4 5 0 S p a c e b e t w e e n u n i t s 9 0 0 S p a c e b e t w e e n u n i t s 9 0 0 S p a c e b e t w e e n u n i t s 9 0 0 Unit height ...

Page 23: ...ing and heating of water pipe shall be carried out prior to the connection between the pipe and the unit 6 The drain valve on the outlet pipe is self contained manual or automatic exhaust valve shall be set at the highest point of the water circulation system for the normal operation of the unit the valve handle must be removed so that the valve is not adjusted 7 Water quality control Industrial w...

Page 24: ... outlet pipe is very low the unit will automatically operate for a period to maintain the temperature of the water system and prevent the water pipe from being frozen so the unit must be energized in winter If the unit is not used in winter drain the water from the water system or fill such anti freezing mixture as ethylene glycol and glycerol into the water system The water filter must be install...

Page 25: ...cessary for panels are installed firmly and securely 5 Confirm no refrigerant is leaked 6 Confirm electrical and pipe connection is consistent with the scope shown on unit nameplate wiring diagrams and other relevant documents 7 Confirm insulations of all temperature sensors are not damaged Inspection before operation 1 Ensure power supply is consistent with what required on unit nameplate 2 Unit ...

Page 26: ...ed at the water inlet of the unit and insulated see the above diagram 7 The heat exchanger ports and the site pipelines shall be flexibly connected to reduce vibration transmitted to buildings 8 To facilitate troubleshooting a thermometer or pressure gauge shall be installed on the water inlet and outlet pipelines Pressure or temperature instrument are not provided with the unit and are at users o...

Page 27: ...nt alarm or shutdown Overall Nozzle Dimensions during Module Combination Maximum 16 modules combined Number of modules 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Manifold pipe dimensions mm 65 80 100 125 150 200 250 Calculations of Water System Inventory Model of unit Preset return water temperature C Minimum effective water capacity Vmin L CA0035EAND 12 155 CA0070EAND 12 310 CA0100EAND 12 465 CA0130EAN...

Page 28: ...the unit Q2 Q Q1 The capacity of auxiliary electric heater generally selected W W a Q2 a Q Q1 In which a refers to margin coefficient taking between 1 0 and 1 5 and it is larger in northern area e g taking 1 5 in Hubei province and its northern area CAUTION CAUTION In heating mode the unit capacity may drop with the decreasing ambient temperature thus users shall add the auxiliary electric heater ...

Page 29: ...system after the unit is started all water pumps except for standby pumps are started and the number of running water pumps is independent of the number of running units Selection of water pumps shall be in accordance with requirements of units the water flow and the nominal water flow on the nameplate shall not exceed 30 End linkage control The passive normally open contact open if the end contro...

Page 30: ...r UL2791 wire standards 3 The length of control wire shall not exceed 1000 m 4 The control wire routing must be more than 200 mm away from the heavy current installations 4 Requirements for Communication Wires 6 Address Code Setting The former four digits of the eight digit code switch are for module address setting and the latter four for unit mode and capacity setting The unit mode and capacity ...

Page 31: ...ke sure none of the particles and impurities pipeline before connecting with the unit 8 And the unit is connected to the inlet and outlet pipe joints should be soft joints vibration generated when the work so that the unit is not transmitted to the line 9 In order to ensure the normal operation of the water system the expansion tank should be installed To ensure that the first open and then open t...

Page 32: ...s 5 Set key press this key to enter the parameter setting interface after logging into the parameter setting interface general items set time timing mode set timing and special items can be set 6 Select key this key is used to select setting items press or on the Select key to select items and the selected character object is displayed on a black background 7 Ok key this key is used to confirm the...

Page 33: ...r on the Modify key to set the temperature within 10 C 25 C Timing icon is displayed only the timing is valid on the same day Current fault is displayed in the fourth line The current fault codes and the address of fault unit are displayed If a module has several faults the fault with a small code is reported in a priority manner if several modules are fault the fault with a small module address i...

Page 34: ...fy key again to set the time Upon the completion of setting press the Exit key to return to the previous interface the setting and adjustment of Cycle Timing mode is finished Upon the setting completion the system unit will start up or shut down at scheduled times set in the Cycle Timing mode on daily basis c If the Day Timing mode is selected the following interface will be displayed When you pre...

Page 35: ...ay and then press Modify or to set between 10 20 O C 2 Press SELECT or to enter the second system parameter setting interface A Press SELECT or to select the call restart function when the call restart function bar is displayed in black press Modify or to set allow or cancel In the allow state the unit in the run time if the sudden power off the unit can automatically operate according to the orig...

Page 36: ... select it for manual defrost and press Modify or to make cancel or allow setting this function is in heating or heating Water mode on the module machine for manual defrost function A press query key enter the query interface press Modify or for module selection B Press SELECT or to select manual defrost press Modify or to set the Allow setting enter manual defrost function 6 Press SELECT or to se...

Page 37: ...35 8 Wiring Diagram ...

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Page 41: ...ed 9 2 Operating instructions Users at every turn strictly follow the steps specified in the instructions sequentially operations to ensure human machine safety The first start operation should be conducted under the guidance of the company commissioning engineers 1 In accordance with the requirements connect all of cable wire internal inspection cabinet and compressor terminal is solid if loose r...

Page 42: ...corrosion or scale re adsorption after cleaning In the case of cleaning agents according to the deposition of dirt adjust the concentration of the cleaning agent the cleaning time and temperature at the same time after the completion of the associated need for passivation After the completion of acid washed clean the need for ongoing and waste treatment waste reprocessing must contact the waste di...

Page 43: ... unit if necessary pressure switch shorted Slow charging refrigerant into the system and check the suction and discharge pressure Warning When performing leak detection and tightness test do not filling oxygen acetylene or other flammable or toxic gases into the cooling system use only high pressure nitrogen or refrigerant 9 Disassemble compressor Such as the compressor needs to be removed follow ...

Page 44: ...unit on the outdoor temperature is below 0 environment shutdown should spare the water side heat exchanger in the water drained 5 The runtime will likely result in runtime if the chilled water flow switch and antifreeze temperature sensor failure pipes freeze and therefore the flow switch must be wired according to the wiring diagram 6 When the maintenance unit to the refrigerant charge or for mai...

Page 45: ...efault to ON ON ON and ON Dip1 Dip2 Dip3 Dip4 Dip5 Dip6 Dip7 Dip8 Description ON ON ON ON Module address 0 ON ON ON OFF Module address 1 ON ON OFF ON Module address 2 ON ON OFF OFF Module address 3 ON OFF ON ON Module address 4 ON OFF ON OFF Module address 5 ON OFF OFF ON Module address 6 ON OFF OFF OFF Module address 7 OFF ON ON ON Module address 8 OFF ON ON OFF Module address 9 OFF ON OFF ON Mod...

Page 46: ...et temperature sensor 2 of System B 21 E38 Refrigerant lack protection of System C 22 E39 Refrigerant lack protection of System D 23 E40 Overtemperature of suction temperature sensor of System C compressor 24 E41 Overtemperature of suction temperature sensor of System D compressor 25 E43 Open circuit or short circuit in coil outlet temperature sensor 2 of System C 26 E44 Open circuit or short circ...

Page 47: ...tem D 57 E89 Over current protection of System D compressor 58 E90 Open circuit or short circuit in exhaust temperature sensor of System D compressor 59 E91 Open circuit or short circuit in coil outlet temperature sensor 1 of System D 60 E92 Open circuit in low pressure sensor of System D 61 E93 Low pressure protection of System D 62 E94 Open circuit or short circuit in suction temperature sensor ...

Page 48: ...rge of refrigerant Cooling heating 2 Undesirable low pressure switch Replace the low pressure switch Cooling heating 3 Insufficient water flow Check the water flow Cooling 4 Low water inlet temperature at water side Check the water temperature Cooling 5 Water side heat exchanger scaling or with foreign matters inside Clean up the incrustation scale Cooling 6 Insufficient air capacity Check the fan...

Page 49: ...ing 2 Water side heat exchanger scaling or with foreign matters inside Clean up the incrustation scale 3 Poor switch Replace the target flow switch 4 Unevenly distributed flow in water pipelines Adjust the flow in water pipelines via the shut off valve 5 Out of service water pump Machine installation must be ganged 6 Insufficient types of water pumps Check it and try to fix it 9 Fault in communica...

Page 50: ...fference between two phases of the power supply is less than 2 of the rated voltage Chilled water flow Within 30 of the rated water flow Chilled water pressure Below 0 7MPa Chilled water quality Free from corrosive copper iron dissolved matters of welding materials Installation site Provided with snow protection and ventilation Ambient temperature Refer to the above diagram operating range Relativ...

Page 51: ...nt temperature C 15 10 7 5 Cooling capacity KW Power input KW Cooling capacity KW Power input KW Cooling capacity KW Power input KW Cooling capacity KW Power input KW 30 1 23 0 84 1 15 0 82 1 11 0 82 1 06 0 81 35 1 13 0 91 1 10 0 89 1 08 0 89 0 83 0 88 40 1 13 0 95 1 09 0 94 1 05 0 93 0 83 0 92 45 1 13 1 01 1 09 0 99 1 00 1 00 0 83 0 98 50 1 13 1 11 1 07 1 09 0 92 1 09 0 81 1 08 55 1 12 1 16 1 06 ...

Page 52: ...ture C 15 10 7 5 Cooling capacity KW Power input KW Cooling capacity KW Power input KW Cooling capacity KW Power input KW Cooling capacity KW Power input KW 30 1 26 0 85 1 16 0 83 1 12 0 83 1 07 0 82 35 1 24 0 92 1 15 0 90 1 11 0 90 1 06 0 89 40 1 22 0 96 1 14 0 95 1 10 0 94 1 05 0 93 45 1 19 1 02 1 12 1 00 1 00 1 00 0 98 0 99 50 1 19 1 12 1 11 1 10 0 98 1 10 0 97 1 09 55 1 14 1 17 1 07 1 16 0 97 ...

Page 53: ...ow CA0035EAND water flow pressure drop m3 h Kpa 5 32 6 5 60 40 0 6 45 3 7 59 8 8 76 0 9 94 0 10 113 6 11 134 8 12 157 7 13 182 0 0 20 0 40 0 60 0 80 0 100 0 120 0 140 0 160 0 180 0 200 0 7 8 9 10 11 12 13 14 resistance Kpa water flow m3 h ...

Page 54: ...70EAND water flow pressure drop m3 h Kpa 8 21 7 9 26 8 10 32 4 11 38 5 12 45 0 13 52 0 14 59 4 15 67 2 16 75 5 17 84 2 18 93 4 0 10 20 30 40 50 60 70 80 90 100 7 9 11 13 15 17 19 resistance Kpa water flow m3 h ...

Page 55: ...0EAND water flow pressure drop m3 h Kpa 8 12 0 9 14 8 10 17 9 11 21 2 12 24 8 13 28 7 14 32 8 15 37 1 16 41 7 17 7 50 18 51 5 0 0 10 0 20 0 30 0 40 0 50 0 60 0 7 9 11 13 15 17 19 resistance Kpa water flow m3 h ...

Page 56: ...D water flow pressure drop m3 h Kpa 12 17 3 13 20 0 14 22 8 15 25 8 16 29 0 17 32 4 18 35 9 19 39 6 20 43 4 21 47 4 22 51 5 23 55 8 24 60 2 25 64 8 0 10 20 30 40 50 60 70 10 15 20 25 resistance Kpa water flow m3 h ...

Page 57: ... 6 5K 3 B0 100 4010K 3 30 130 R25 5K 3 B25 50 3470K 3 30 105 CA0070EAND R100 6 5K 3 B0 100 4010K 3 30 130 R25 5K 3 B25 50 3470K 3 30 105 CA00100EAND R100 6 5K 3 B0 100 4010K 3 30 130 R25 5K 3 B25 50 3470K 3 30 105 CA00130EAND R100 6 5K 3 B0 100 4010K 3 30 130 R25 5K 3 B25 50 3470K 3 30 105 ...

Page 58: ...ral control connection 1 Chiller system Wiring and Address Setting 4 Chiller system Wiring and Address Setting 17 1 Modular Chiller wiring SW401 5 8 CA0035EAND 0100 CA0070EAND 0000 CA0100EAND 0010 CA0130EAND 0110 ...

Page 59: ...connect to Modbus system Transmission mode Baud rate 9600bps Start bit 1 bit Data bits 8 bits Odd even check Even Stop bit 1 bit Modbus RTU 17 2 Communication protocol The max cable length for bus A1 B1 and A2 B2 is 1000m ...

Page 60: ... off 1 on Startup Shutdown 0 shutdown 1 startup Mode 0 cooling mode 2 heating mode Model 0x27 CA0130EAND System Address Function Code Data The low byte CRC check The High byte CRC check 1 byte 1 byte N bytes 1 byte 1 byte System Address Gatway Address Range 1 32 Function Code Read or write function Data Communication data CRC check Each frame data error checking Communication Address is used to de...

Page 61: ...Compressor current 01025 Fan current Fan current 01026 Suction pressure Ps Suction pressure Ps 01027 Saturation temperature of suction pressure Saturation temperature of suction pressure 01028 PMV open angle PMV open angle 01029 Condenser outlet temperture 2 Tc 2 Condenser outlet temperture 2 Tc A2 01041 System B Discharge Temperature Td B 01042 Condenser outlet temperture Tc B1 01043 Suction temp...

Page 62: ...f auxiliary electric heater 01111 01112 01113 01114 01201 Output signal Pump Output signal Pump 01202 Compressor Compressor A 01203 Compressor B 01204 4 way valve 4 way valve A 01205 4 way valve B 01206 High speed of fan High speed of fan A 01207 High speed of fan B 01208 Auxiliary electric heater Auxiliary electric heater 01209 01210 01211 01212 01213 01214 01215 01216 01301 Chiller control Chill...

Page 63: ...e Ts B Suction temperture Ts B 4 01044 Compressor current Compressor current 4 01045 Fan current Fan current 4 01046 Suction pressure Ps Suction pressure Ps 4 01047 Saturation temperature of suction pressure Saturation temperature of suction pressure 4 01048 PMV open angle PMV open angle 4 01049 Condenser outlet temperture 2 Tc B2 Condenser outlet temperture 2 Tc B2 4 01061 System C Discharge Temp...

Page 64: ...113 High pressure signal of system D 2 01114 Overload signal of Fan D 2 01201 Output signal Pump Output signal Pump 1 01202 Compressor A Compressor A 1 01203 Compressor B Compressor B 1 01204 4 way valve A 4 way valve A 1 01205 4 way valve B 4 way valve B 1 01206 High speed of fan A High speed of fan A 1 01207 High speed of fan B High speed of fan B 1 01208 Auxiliary electric heater Auxiliary elec...

Page 65: ...on No Version Updated information 1 SYJS 07 2020 B Updated the 17 3 Comuunication address add CA0100EAND and CA0130EAND models 2 SYJS 08 2020 B Updated the datas of 14 Technical parameters 3 SYJS 05 2021 B Add air volume data to the specification table ...

Page 66: ...64 Haier Commercial Air Condition Web Http www haier com Haier reserves the right to make change without any notice ...