Sinclair SCV-100EA, Service Manual

Page 1: ...SCV xxEA SERVICE MANUAL AIR COOLED MINI CHILLER UNIT AIR CONDITIONING...

Page 2: ...y Tables 18 10 Operation Limits 24 11 Water Pressure Drop 26 12 Sound Level 29 Exploded View 89 13 Installation 30 14 Checking and Starting Up the Unit 43 15 Running and Maintenance 45 16 Controller 4...

Page 3: ...t pump Built in R410A Power Supply V Ph Hz Capacity Compressor type Heat exchanger A C mode Hydraulic module Refrigerant er Plate type Heat pump Built in R410A rter Plate type Heat pump Built in R410A...

Page 4: ...re power and enhance heat exchange performance Hydrophilic film fins and inner threaded copper pipes optimize heat exchange efficiency 2 3 Low operating sound design Optimally design fan shape and new...

Page 5: ...3 30 COP 2 5 Wide operation temperature range Stable and safe running at wide ambient temperature range cooling performance from 5 C to 46 C heating from 15 C to 27 C COOLING MODE HEATING MODE Outdoor...

Page 6: ...and friendly user interface The chiller can be controlled by wired controller KJR 120F also which is optional chosen Note When connecting wired controller outdoor unit control panel is mainly used fo...

Page 7: ...ty 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 2 11 Water pump starts stops compulsory function Press Check button for 3 seconds to start the water pump operating when the unit is standb...

Page 8: ...eel to ensure high heat exchange efficiency complete with electric heater and differential pressure switch The complete heat exchanger is insulated with thermal insulation closed cell rubber foam to g...

Page 9: ...valve 4 Axial flow fan 5 Differential pressure switch 6 Condenser 7 Accumulater 8 Security discharge 9 Electric expansive valve 10 Plate heat exchanger 11 Electrical panel 12 High pressure switch 13 4...

Page 10: ...copper tube Inner grooved copper tube Coil length height mm 885 880 885 880 Number of circuits 6 6 Water pump Type RS15 6 3 WILO RS15 6 3 WILO Input H M L W 93 67 46 93 67 46 Pumping head m 5 5 5 5 Ou...

Page 11: ...Motor DC Motor Brand Panasonic Panasonic Input W 100 100 Speed r min 800 800 Outdoor coil Number of rows 2 2 Tube pitch a row pitch b mm 22 19 05 22 19 05 Fin spacing mm 1 6 1 6 Fin type Hydrophilic...

Page 12: ...protector Inner Inner Refrigerant oil ml VG74 1400 VG74 1400 Outdoor fan motor Model WZDK100 38G WZDK100 38G Type DC Motor DC Motor Brand Panasonic Panasonic Input W 100 100 Speed r min 800 800 Outdo...

Page 13: ...tdoor ambient temperature 35 C DB 2 Heating 3 warm water inlet outlet temperature 40 45 C outdoor ambient temperature 7 C DB 6 C WB 4 warm water inlet outlet temperature 30 35 C outdoor ambient temper...

Page 14: ...5 Dimensions SCV 50EA SCV 70EA Unit mm 966 366 354 990 624 SCV 100EA SCV 120EA SCV 140EA SCV 160EA Unit mm 1327 900 970 600 348 320 400 360 12...

Page 15: ...Way Valve 3 Accumulatior 4 Air Side Heat Exchanger 5 Electronic Expansion Valve 6 Storage Tank 7 Strainer 8 Water Side Heat Exchanger Plate Heat Exchange 9 Differential Pressure Switch 10 High Pressu...

Page 16: ...7 Wiring Diagram SCV 50EA SCV 70EA 14...

Page 17: ...SCV 100EA 15...

Page 18: ...SCV 120EA SCV 140EA SCV 160EA 16...

Page 19: ...SCV 100EA 50Hz 220 240V 1Ph 198V 264V 15 1 25 0 30 52 12 1 0 20 1 8 SCV 120EA 50Hz 380 415V 3Ph 342V 456V 8 6 8 9 15 44 6 9 0 20 1 8 SCV 140EA 50Hz 380 415V 3Ph 342V 456V 8 6 9 6 15 44 6 9 0 20 1 8 S...

Page 20: ...3 6 60 1 68 3 92 6 17 1 74 3 55 5 85 1 82 3 21 5 45 1 91 2 85 Note The inlet outlet water temperature difference is 5 C Heating Note The inlet outlet water temperature difference is 5 C Hot water outl...

Page 21: ...4 3 78 8 63 2 52 3 43 8 19 2 65 3 10 7 64 2 78 2 75 Note The inlet outlet water temperature difference is 5 C Heating Note The inlet outlet water temperature difference is 5 C Hot water outlet temp Am...

Page 22: ...5 13 20 3 20 4 12 12 33 3 30 3 73 11 71 3 47 3 37 10 91 3 64 3 00 Note The inlet outlet water temperature difference is 5 C Heating Note The inlet outlet water temperature difference is 5 C Hot water...

Page 23: ...5 14 78 3 67 4 03 13 81 3 78 3 65 13 11 3 97 3 30 12 22 4 17 2 93 Note The inlet outlet water temperature difference is 5 C Heating Note The inlet outlet water temperature difference is 5 C Hot water...

Page 24: ...16 50 4 24 3 89 15 42 4 37 3 53 14 63 4 59 3 19 13 64 4 81 2 83 Note The inlet outlet water temperature difference is 5 C Heating Note The inlet outlet water temperature difference is 5 C Hot water o...

Page 25: ...14 4 92 3 89 17 88 5 07 3 53 16 97 5 33 3 19 15 82 5 59 2 83 Note The inlet outlet water temperature difference is 5 C Heating Note The inlet outlet water temperature difference is 5 C Hot water outle...

Page 26: ...col solutions used as a thermal vector in the place of water reduce the performance of the unit Multiply the performance figures by the values given in the following table Freezing point C 0 5 10 15 2...

Page 27: ...rs to upper parameters for the charged volume b Fouling Factors The performance data given refer to conditions with clean evaporator plates fouling factor 1 For different fouling factors multiply the...

Page 28: ...11 Water Pressure Drop SCV 50EA SCV 70EA SCV 100EA Heat exchanger pressure drop water side 26...

Page 29: ...SCV 120EA SCV 140EA 27...

Page 30: ...SCV 160EA 28...

Page 31: ...0EA 58 SCV 70EA 58 SCV 100EA 59 SCV 120EA 59 SCV 140EA 60 SCV 160EA 60 Note 1 High low air flow of outdoor fan motor 2 It is tested 1 meter away from the machine in a semi anechoic room sound pressure...

Page 32: ...reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for...

Page 33: ...ht distribution of the unit To lift the unit insert tubes long enough to allow positioning of the lifting slings and safety pins in the feet on the unit To avoid the slings damaging the unit place pro...

Page 34: ...ations of the outdoor units Fasten the feet of this unit with bolts firmly to prevent it from collapsing in case of earthquake or strong wind 6 0 c m Fix with bolt Single unit installation 300 600 300...

Page 35: ...ine system For SCV 50EA SCV 70EA 9 2 4 1 14 15 11 14 7 16 2 3 10 5 6 T 6 T F 1 1 13 13 8 14 Installer connections WATER OUTLET WATER INLET Factory connections 1 Pressure gauge 2 Vibration damper joint...

Page 36: ...able for obstruction breakage or noise resulting from the failure to install filters or vibration dampers Particular types of water used for filling or topping up must be treated with appropriate trea...

Page 37: ...the closed tank is too large when the water temperature drops the system pressure may decrease to a level below the minimum allowable value and cause trouble in the air vent Therefore accurate sizing...

Page 38: ...ed such as PH value conductivity concentration of chloride ion concentration of sulfide ion and so on PH 6 8 Total hardness less than 50 ppm Electrical conductivity less than 200 mV cm 25 C Sulfide io...

Page 39: ...installation must be filled to a pressure of between 1 and 2 bars b It is recommended that this operation be repeated after the unit has been operating for a number of hours The pressure of the instal...

Page 40: ...pstream with a suitable device to protect against short circuits and leakage to earth isolating the installation from other equipment Voltage must be within a tolerance of 10 of the rated power supply...

Page 41: ...connect it to terminals L N and respecting the L phase N neutral and earth in the case of single phase units 220 240V 50Hz 2 SCV 100EA N L 3 1 2 6 4 5 7 8 GND PUMP2 Remote alarm Remote shutdownRemote...

Page 42: ...n 1 SCV 50EA SCV 70EA AC CANTACTOR L N 220 240 V 220 240 V L N Addtitiona l pump Reserved 1 2 1 2 L 1 PUMP 2 BOI L ON OFF Switch 1 PUMP2 wiring terminal supplies ON OFF signals only Standby water pump...

Page 43: ...te alarm 3 4 Main control board Remote alarm terminal only provides passive switching signal Current passing through the terminal interface should less than 1 5A otherwise please use AC contactor to c...

Page 44: ...wire to connect the wired controller and the shielding layer must be grounded When connecting wired controller outdoor unit control panel is mainly used for display which can check parameters and inq...

Page 45: ...cated in the manual The water circuit is filled and vented When draining after heat pump operation take care as the water may be hot The water circuit valves are open Electrical connections have been...

Page 46: ...t e s 1 2 3 3 To access the control panel open the door remove the screw 1 and screw 2 lift the door 3 44...

Page 47: ...g from the pressure probe thus enabling heat exchange to be increased and or decreased maintaining the condensing or evaporation temperature practically constant The fan functions independently of the...

Page 48: ...eration Refrigerant gas content The chillers are filled with R410a refrigerant gas and tested in the factory In normal conditions there should be no need for the Technical Assistance Service to interv...

Page 49: ...damage to the compressor d Shutting down for long periods If it is previewed not to use the machine for long periods After deactivating the chiller Make sure the model is in the power off model or al...

Page 50: ...er temperature When checking will display the result of checking When water heating is broken down or in protection display the error code and protection code Clock icon It will display when finish se...

Page 51: ...ndby status press to enter mode choice function Press circularly to choose one kind of power on mode the mode icon will flicker at the moment Press to confirm the power on mode The unit will run as th...

Page 52: ...and press to enter timing off setting At this moment the last 2 digits of the nixie tube display 01 which means the first group setting begins Press to the next step By this time the first 2 digits o...

Page 53: ...simultaneously for 3s to unlock 16 1 4 Factory Reset In main interface long press for 3s the unit will close and recovers to factory default mode Display panel will display OFF 51...

Page 54: ...ess for 3sec to cancel timer Press for 3sec to unlock MODE FUNCTIONS Operation icon Code area Setting temperature Timing On Off Function Icon Unit number Water Level Indication reserved Clock Water te...

Page 55: ...g displays the setting timing details refer to page 15 of the manual 9 Water temperature Under normal status display water temperature Under water temperature setting status displays the setting value...

Page 56: ...on the LCD will disappear Press one time RUN WATER TEM P TIMER ONLINE QUANTIT Y Press for 3sec to cancel timer Press for 3sec to unlock MODE FUNCTIONS b Setting operating mode and function parameters...

Page 57: ...erature setting check To check the water temperature setting value press the or key under the main page the page displayed after the controller is powered on c Setting function parameters Press FUNCTI...

Page 58: ...ich means the current setting is the hour of Timer 1 Off press the or to adjust press key when finished and then the minute of the clock will flash which means the current setting is the minute of Tim...

Page 59: ...he On time of Timer 1 to be 07 10 and O ff time of Timer 1 Off to be 12 30 then back to the main page Finish setting the On time of Timer 1 to be 07 10 and O ff time to be 12 30 then enter the setting...

Page 60: ...or to adjust press OK key when finished or wait for 7 seconds to confirm During the setting process pressing the CANCEL key to exit without saving NOTE To get the correct timing On and timing Off time...

Page 61: ...wired controller keeps synchronizing with the unit If forcing water pump function is still on going the controller keeping showing its status d The outdoor unit does not response after activating the...

Page 62: ...etting 6 T3 temperature value 7 T4 temperature value 8 Tp temperature Value 9 Tin temp Value Inlet water temperature 10 Tout temp Value Outlet water temperature 11 Tb1 temp Value Temperature 1 of heat...

Page 63: ...2 11 6 4 3 5 12 10 8 1 Input rectifier bridge port 1 2 Input rectifier bridge port 2 3 PFC inductance port 1 4 P OUT 5 PFC inductance por 2 6 N OUT 7 PFC control port 8 18V port 9 IPDU communication...

Page 64: ...of compressor 11 Pump 12 Electric heater of water flow switch 13 4 way valve 14 Additional pump Boil Reserve 15 Transformer input 16 Electronic expansion valve 17 Remote control 18 DC fan power suppl...

Page 65: ...DC filter panel 1 2 3 4 5 1 IPM Power supply N 2 IPM Power supply P 3 PFC output power P 4 PFC output power N 5 DC 380V DC fan power supply port 63...

Page 66: ...r Tb2 Temperature 2 of plate heat exchanger 3 Radiator temperature sensor port Reserved T6 4 Discharge temperature sensor port 5 1 Outlet of outdoor heat exchanger temperature sensor port T3 5 2 Ambie...

Page 67: ...er 22 Differential pressure valve electric heater port 23 Built in water pump port 24 Compressor electric heater 25 4 way valve port 26 External pump Remote alarm port 27 Transformer input port 38 P N...

Page 68: ...pply port W of the compressor 6 PFC output N 7 PFC output P 8 PFC inductance port L_1 9 PFC inductance port L_2 10 PFC input N 11 IPM input N 12 Communication port to main control board SCV 120EA SCV...

Page 69: ...switch 10 Differential pressure valve port 11 Factory debugging port 12 Wired controller port 13 AC Current transformer 14 Remote on off and remote cooling heating port 15 Electronic expansion valve p...

Page 70: ...output port 2 communication port to main control board 3 IPM input port N 4 Compressor connection port W 5 Compressor connection port V 6 Compressor connection port U 7 IPM input P 8 Power supply por...

Page 71: ...port N 5 Ground wire 6 Loaded power supply port for main control board 7 Power supply port for main control board 8 Power output port L1 after filtering 9 Power output port L2 after filtering 10 Powe...

Page 72: ...ter pump 2 cooling 3 heating 4 force cooling 3 Operating fan speed level 0 Power off 1 7 4 The total required capacity before revised Actual value Force cooling displays 5 5 Capacity requirements afte...

Page 73: ...oling displays 5 6 Temperature set Actual setting temperature under cooling or heating mode 7 T3 Actual value Outlet temperature of outdoor heat exchanger 8 T4 Actual value Outdoor ambient temperature...

Page 74: ...P1 High pressure protection The same as 10 16kW P2 Low pressure protection P3 Current protection of the compressor P4 Discharged temperature protection P5 T3 high temperature protection of outdoor con...

Page 75: ...erature 2 of plate heat exchangers for 10 16kW PL Reserved for 10 16kW P1 High pressure protection The same as 5 7kW P2 Low pressure protection P3 Current protection of the compressor P4 Discharged te...

Page 76: ...ED displays E9 EEPROM malfunction Check whether EEPROM is installed properly Yes NO Installed properly again Replace main PCB LED displays H0 Communication malfunction between main chip and IPDU Wheth...

Page 77: ...tion Sensor temperature 2 of plate heat exchangers for 10 16kW T3 outlet temperature of outdoor heat exchanger T4 outdoor ambient temperature E5 malfunction Voltage protection malfunction LED displays...

Page 78: ...rom 277V to 354V in waiting state YES Check whether the power and voltage of the DC fan motor is normal or not and whether the voltage between white and black terminal of DC motor is from 15V in waiti...

Page 79: ...whether the cooling system is normal or not Replace main PCB NO Check whether pressure of the system is too high YES Stop the system NO Whether side air duct of outdoor unit meets the standard NO Rec...

Page 80: ...bient temperature is too low YES Stop the unit NO Whether refrigerant system leaks YES Leakage detecting add nitrogen or refrigerant into the system si si will sound evidently if leaks heavily Use soa...

Page 81: ...high YES Stop the unit NO NO Check whether the outdoor unit ventilates well YES Make the outdoor unit ventilates well NO Whether the heat exchanger needs cleaning or not YES Clean heat exchanger NO If...

Page 82: ...her the discharged temperature of the compressor is higher than 115 C NO Check whether the compressor discharged temperature sensor connects with PCB correctly according to the wiring diagram YES Chec...

Page 83: ...r than 62 degrees NO Check whether the resistance of condenser temperature sensor is correct YES Replace the outdoor main PCB NO Replace the temperature sensor YES Whether outdoor temperature is too h...

Page 84: ...tifier If wire body terminal is connected firmly NO Connect wire correctly YES Check if wiring connection between DC filter and IPM module is fasten or not YES Check whether wiring connection of the c...

Page 85: ...two outdoor units blows each other NO Check whether the fan motor is damaged YES Replace outdoor fan motor NO Replace the outdoor main PCB LED displays CH CL CP PH Protection when temperature differen...

Page 86: ...e and plate heat exchanger temperature is less than 5 the unit enter heating mode in force Compressor works too This is normal LED displays Pb Anti freeze protection The actual measured temperature of...

Page 87: ...onnected to water pump NO YES To configure external water pump Whether water system is stuck Repair the leaks and add the water again YES Wash or replace the stuck components and pipeline YES Whether...

Page 88: ...18 Optional Accessories No Name Specification Remark 1 Wired controller KJR 120F Customized 86...

Page 89: ...Appendix Accessories Item Name of accessory Qty Shape 1 Installation and operation manual 1 2 Rubber sealed ring 2 3 Outlet connection pipe 1 4 Straight screwdriver 1 87...

Page 90: ...0 42304 5 46 5725 35 6 40021 75 1 38703 115 0 41164 4 44 36 6 13059 76 1 34105 116 0 4006 3 41 5878 37 5 87359 77 1 29078 117 0 38991 2 39 8239 38 5 62961 78 1 25423 118 0 37956 1 37 1988 39 5 39689 7...

Page 91: ...Exploded view of unit SCV 50EA 22 7 22 6 22 5 22 4 22 2 22 1 22 3 89...

Page 92: ...106 1 16 Pump 202400600862 1 17 Hydraulic meter 201800100005 1 18 Display box ass y 203390490014 1 19 Water in pipe ass y 201690490418 1 19 1 Exhaust valve 201601601296 1 19 2 Electrical heater of dif...

Page 93: ...tion board 201290490144 1 36 DC motor 202400300063 1 37 Pipe temp sensor ass y 202301300808 1 38 Pipe Temp sensor ass y 202301300437 1 39 Discharge Temp sensor ass y 202301300130 1 40 Room Temp sensor...

Page 94: ...Exploded view of unit SCV 70EA 22 7 22 6 22 5 22 4 22 2 22 1 22 3 92...

Page 95: ...06 1 16 Pump 202400600862 1 17 Hydraulic meter 201800100005 1 18 Display box ass y 203390490014 1 19 Water in pipe ass y 201690490418 1 19 1 Exhaust valve 201601601296 1 19 2 Electrical heater of diff...

Page 96: ...tion board 201290490144 1 36 DC motor 202400300063 1 37 Pipe temp sensor ass y 202301300808 1 38 Discharge Temp sensor ass y 202301300130 1 39 Pipe Temp sensor ass y 202301300437 1 40 Room Temp sensor...

Page 97: ...Exploded view of unit SCV 100EA 25 1 25 2 25 3 25 6 25 7 25 4 25 5 25 9 25 8 95...

Page 98: ...Electrical heater of plate heat exchanger 202403101778 1 17 2 Plate heat exchanger 201700101124 1 18 Rubber gasket 202700601369 1 19 Coaming II 201290490135 1 20 Connection pipe ass y of differential...

Page 99: ...on Part Code Note Qty Price Code 37 Axial fan 201100300524 2 38 Front panel 201295190281 1 39 Outlet grille 201195190168 2 40 Handle 201195190001 1 MODEL SCV 100EA The data are subject to change witho...

Page 100: ...Exploded view of unit SCV 120EA 25 1 25 2 25 3 25 4 25 5 25 6 25 7 25 9 25 8 25 10 25 11 98...

Page 101: ...Plate heat exchanger 201700101123 1 17 2 Electrical heater of plate heat exchanger 202403101778 1 18 Rubber gasket 202700601369 1 19 Coaming II 201290490135 1 20 Connection pipe ass y of differential...

Page 102: ...601330001 1 34 Left supporting board rear 201295190084 1 35 Motor bracket ass y 201295190080 1 36 DC Motor 202400300216 2 37 Axial fan 201100300524 2 38 Front panel 201295190281 1 39 Outlet grille 201...

Page 103: ...Exploded view of unit SCV 140EA 25 1 25 2 25 3 25 4 25 5 25 6 25 7 25 9 25 8 25 10 25 11 101...

Page 104: ...Electrical heater of plate heat exchanger 202403101778 1 17 2 Plate heat exchanger 201700101122 1 18 Rubber gasket 202700601369 1 19 Coaming II 201290490135 1 20 Connection pipe ass y of differential...

Page 105: ...601330001 1 34 Left supporting board rear 201295190084 1 35 Motor bracket ass y 201295190080 1 36 DC Motor 202400300216 2 37 Axial fan 201100300524 2 38 Front panel 201295190281 1 39 Outlet grille 201...

Page 106: ...Exploded view of unit SCV 160EA 25 1 25 2 25 3 25 4 25 5 25 6 25 7 25 9 25 8 25 10 25 11 104...

Page 107: ...Electrical heater of plate heat exchanger 202403101778 1 17 2 Plate heat exchanger 201700101121 1 18 Rubber gasket 202700601369 1 19 Coaming II 201290490135 1 20 Connection pipe ass y of differential...

Page 108: ...601330001 1 34 Left supporting board rear 201295190084 1 35 Motor bracket ass y 201295190080 1 36 DC Motor 202400300216 2 37 Axial fan 201100300524 2 38 Front panel 201295190281 1 39 Outlet grille 201...

Page 109: ...unit is containing fluorinated gases included in the Kyoto protocol The maintenance and the liquidation must be carried out by qualified personnel Type of refrigerant R410A The composition of the cool...