LG RCAW090PBAA User Manual

Operation & Maintenance ManualLGMODELS: RCAW - Compact (50Hz)website http://www.lgservice.comIMPORTANT• Please read this Operation & Maintenan

Safety Considerations10 Chiller Air-cooled ScrewConsult a water treatment specialist for propertreatment procedures.• Hard scale may require chemical

GeneralOperation & Maintenance Manual 11GENERALThis manual is composed of information on control, operation, start-up, service and troubleshootin

General12 Chiller Air-cooled ScrewMain MenuThe main menu is composed of 4 screen cuts. Moving among them is accomplished by the manipulation of the ar

GeneralOperation & Maintenance Manual 13User Setting The user setting is composed of 8 screen cuts. Moving among them is accomplished by the mani

General14 Chiller Air-cooled ScrewCompressor shutdown temperature means the temperature where the compressor must be shut downed by low temper-ature.

GeneralOperation & Maintenance Manual 15The I/O display is composed of 9 screen cuts. Through the I/O Display, switch status of signal inputs to

General16 Chiller Air-cooled ScrewThe liquid flow switch detects chilled water flow, and the water flow must build during running the chiller. The ope

GeneralOperation & Maintenance Manual 17Alarm DisplayThrough the alarm display, recent 10 alarms are displayed with their invocation time. The al

General18 Chiller Air-cooled ScrewSystem SettingThe system setting is composed of 2 screen cuts. Through the system setting, the temperature readings

GeneralOperation & Maintenance Manual 19Parameter SettingFig. 7Par. SettingSystem SettingDelay SettingContentFan Start Temp3Fan Start Temp2Fan St

2 Chiller Air-cooled ScrewSAFETY CONSIDERATIONSWarning...

General20 Chiller Air-cooled ScrewDelay SettingFig. 8Delay SettingPar. SettingAlarm Display ContentTemp AlarmSystem OilWater FlowSystem PressureStart

ControlsOperation & Maintenance Manual 21 PLC and HMI UnitPLC and HMI UnitCONTROLSThe HMI (Human Machine Interface) side of the PLC (Programmabl

Controls22 Chiller Air-cooled ScrewAmong the menu items, some items are protected from access with authorization code system. The user setting is pro-

ControlsOperation & Maintenance Manual 23The back side of the PLC and HMI assembly is shown in the below picture. The PLC is composed of base boa

Controls24 Chiller Air-cooled ScrewOn the top side of the PLC, DIP switches and indicating LEDs are installed. Normally, the D2 LED has to blink with

ControlsOperation & Maintenance Manual 25Actual locations of the connectors are shown in the above pictures and detail descriptions of the connec

Controls26 Chiller Air-cooled ScrewConnector PinDescriptionWire No.CN1(POW)AC1AC2FGO012627717224VDC-PositiveCN2(DO-1)O02O03O04O05O06O07O08COM737475767

ControlsOperation & Maintenance Manual 27Connector PinDescriptionWire No.CN4(DI -1)I01 31Remote ControlI02 32 System Oil PressureI03 33I04 34I05

Controls28 Chiller Air-cooled ScrewConnector MODBUSPinDescriptionRX2/D2+TX2/D2-Wire No.MODBUS on RS-485: D+MODBUS on RS-485: D-CN6(RTDI)RTD1+RTD1-RTD1

ControlsOperation & Maintenance Manual 29The MODBUS address map of registers is shown in the below table.MODBUS Address Meaning Indicating UnitNO

Safety ConsiderationsOperation & Maintenance Manual 3Installing, starting up, and servicing this equipment can be hazardous due to system pressur

Controls30 Chiller Air-cooled Screw Machine On/off ControlThere are two modes to turn on/off the machine. One is the Hand Mode and the other is the A

Start-upOperation & Maintenance Manual 31 Pre Start-UpDo not attempt to start the chiller until the following checks have been completed.• Check

Start-up32 Chiller Air-cooled ScrewDo not manually operate contactors. Serious damage to the machine may result. The following procedureshould be foll

Start-upOperation & Maintenance Manual 33After the above procedure, allow unit to operate and confirm that everything is functional properly. Che

Start-up34 Chiller Air-cooled ScrewTemperatureVoltageTemperatureTemperature limits during the operation of the unit are as follows.Maximum ambient tem

Start-upOperation & Maintenance Manual 35Flow RateThe basic flow rate of the chiller must follow the values of the table showing the maximum, min

Start-up36 Chiller Air-cooled Screwn Compact Fig. 15Note: For flow out of this range, consult LG.* : P – 380V, Q - 400V, R - 415V02040608010012014016

OPERATION Sequence of OperationThe sequence of the operation is depicted by the flow chart in the below. When the start is in effect, the condenser f

Operation38 Chiller Air-cooled ScrewCondenserFan=ONWater Pump= ONAlarmY Start: M4 : M1=ON & M3=ON: Oil Heater=OFF: Oil Solenoid Valve(SV1)=ON: Tem

OperationOperation & Maintenance Manual 39Fig. 17MV2=OFF & MV3=OFFMV1=ON, SV2=OFFM2 =OFF & M1=OFFSV1=OFFWater Pump=OFFFan = OFF4-10MinYe

Safety Considerations4 Chiller Air-cooled ScrewFor re-installation of the installed product,always contact a dealer or an AuthorizedService Center.• T

Operation40 Chiller Air-cooled ScrewDelay control for the chiller is summarized in the below picture. There are two essential delays, stop to startdel

OperationOperation & Maintenance Manual 41Fig. 19Table 11CONTROL POINT DEFAULT RANGET1 34 30 ~ 34T2 39 35 ~ 39 T3 44 40 ~ 45T4 - -T5 - -100RT

Operation42 Chiller Air-cooled ScrewTo monitor the inlet water temperature, outlet water temperature, discharge temperature of the compressor,ambient

ServiceOperation & Maintenance Manual 43 Cycle ComponentsThe structure of the air-cooled cooling cycle is shown in the below. The unit is equipp

Service44 Chiller Air-cooled ScrewAs shown in the below, during rotation of the rotors the meshing shifts from the suction side to the dischargeside.

ServiceOperation & Maintenance Manual 45This means the displacement of refrigerant gas also increases, as a result the refrigeration capacity als

Service46 Chiller Air-cooled ScrewThe bearings used in the compressor required a small but steady quantity of oil for lubrication; the oil injectionin

ServiceOperation & Maintenance Manual 47In order to protect the compressor, the compressor has been installed three PTC temperature sensors insid

Service48 Chiller Air-cooled Screw Maintenance and cleaning of condenser coilPeriodically cleaning the surface of the coil is essential in maintainin

ServiceOperation & Maintenance Manual 49 Condenser fanThe fan motor and the fan must be fixated firmly on the top plate of the condenser with th

Safety ConsiderationsOperation & Maintenance Manual 5Do not damage or use an unspecified powercord.• There is risk of fire, electric shock, explo

Service50 Chiller Air-cooled ScrewCooler Flow SwitchFlow Switch is installed on the water outlet nozzle for all units as factory setting. The followi

ServiceOperation & Maintenance Manual 51 Dual Pressure Switch Differential Pressure SwitchDifferential pressure switch is also used for checkin

Service52 Chiller Air-cooled Screw Anti-freezing SwitchThe anti-freezing switch is used to detect too low water temperature. The switch is normally c

ServiceOperation & Maintenance Manual 53Refrigerant Cycle Leakage testAs described in the installation manual, the unit is sufficiently charged

Service54 Chiller Air-cooled Screw Oil FilterThe oil filter is installed on the oil separator in oil return line to the compressor. Differential pres

ServiceOperation & Maintenance Manual 55 Oil Heater Solenoid ValveOne of the Solenoid Valve is installed between the Flash Gas Tank where the o

Service56 Chiller Air-cooled Screw Control SystemThe structures of the power panel and control panel are shown in the below. The power panel in the l

ServiceOperation & Maintenance Manual 57Power PanelOn the left side of the power panel, terminal blocks for main power connection are prepared. T

Service58 Chiller Air-cooled ScrewL1L3L21M2M1452361M1M2MSSS3LPVV=PLII=Wye Starting Delta RunningL1L3L21M2M1M1M2M2MSSS145263LPVV=PLIIx=3Fan contactor &

ServiceOperation & Maintenance Manual 59n Compressor OCR (Over Current Relay)The compressor OCR is thermal type and used to protect the compresso

Safety Considerations6 Chiller Air-cooled ScrewChanging the set value is prohibited.• Do not change the set value of the safety device.• If you opera

Service60 Chiller Air-cooled Screwn Voltage Monitoring Relay (5E) The voltage monitoring relay is used for the verification of proper power supply of

ServiceOperation & Maintenance Manual 61The voltage unbalance tripping is activated when the unbalance exceeds +5% more than 3 seconds. Similarly

Service62 Chiller Air-cooled Screw Assist RelayAssist Relay is the relay to check power supply of 220V to the controller. Assist Relay is as follows.

ServiceOperation & Maintenance Manual 63 Fan ContactorFan Contactor controls the start, stop and static range of the fan motor when the product

Service64 Chiller Air-cooled ScrewControl PanelOn the external door of the control panel there is emergency switch for the instant cutting out of cont

ServiceOperation & Maintenance Manual 65In the control panel, the PLC is installed as a central control station. The PLC is assembled with the HM

Service66 Chiller Air-cooled ScrewETC Temp. Sensor in Control BoxThis is used to detecting the temperature within the Control Box when operating the

ServiceOperation & Maintenance Manual 67 MaintenanceMaintenance ScheduleCheck Point Daily Monthly Every2 monthsEvery3 monthsEvery6 monthsEvery1

Trouble Shooting 68 Chiller Air-cooled ScrewIf a stoppage occurs more than once as a result of any of the safety devices, determine andcorrect the cau

Trouble Shooting Operation & Maintenance Manual 69SymptomUnit does not runCompressor operates toolong continuouslyPossible CausePossible RemedyCh

Safety ConsiderationsOperation & Maintenance Manual 7Do not leave refrigerant system open to air any longer than necessary. • Seal circuits being

Trouble Shooting 70 Chiller Air-cooled ScrewAlarmSpecific alarms, their recognition method, and their possible causes are listed here. To clear alarm

Trouble Shooting Operation & Maintenance Manual 71Displayed AlarmMessageRecognitionPossible CausePossible Remedy• Turn the emergency switchclockw

Displayed AlarmMessageRecognitionPossible CausePossible RemedyTrouble Shooting 72 Chiller Air-cooled Screw• Charge additional refrigerant• Test/Repair

Displayed AlarmMessageRecognitionPossible CausePossible RemedyTrouble Shooting Operation & Maintenance Manual 73• Review voltage • Repair or repl

Displayed AlarmMessageRecognitionPossible CausePossible RemedyTrouble Shooting 74 Chiller Air-cooled Screw• Charge additional refrigerant orreview val

Displayed AlarmMessageRecognitionPossible CausePossible RemedyTrouble Shooting Operation & Maintenance Manual 75FAN2B3B AlarmFAN4B5B AlarmExhaust

Appendix76 Chiller Air-cooled ScrewAppendix Wiring DiagramFig. 47SYMBOLFusesP/Box Heat dissipation fan LEGENDDESCRIPTIONAssist relayC/Box Heat dissip

AppendixOperation & Maintenance Manual 77Fig. 48SYMBOLFusesP/Box Heat dissipation fan LEGENDDESCRIPTIONAssist relayC/Box Heat dissipation fanOil

Appendix78 Chiller Air-cooled Screwn Cycle DiagramFig. 49DESCRIPTIONNoCompressor1Condensing coil2Receiver3Oil Filter4Oil separater 5Ejector for Oil Re

AppendixOperation & Maintenance Manual 79n Check List1. Project information2. Model informationChecklist for installation, and operationContents

Safety Considerations8 Chiller Air-cooled ScrewDo not use the chiller in special environments.• Oil, steam, sulfuric smoke, etc. can significantlyredu

Appendix80 Chiller Air-cooled Screw3. PRELIMINARY EQUIPMENT CHECK 4. Chilled Water System CheckCheckContentsNoYesDrain pipe is not clogged.NoYesInlet

AppendixOperation & Maintenance Manual 815. START-UP & OPERATIONAmbient air temperature%CCCCompressor capacitypsigCooler pressure droppsigRef

P/No.: MFL63291701Printed in KoreaAfter reading this manual, keep it in a place easily accessible to the user for future reference.

Safety ConsiderationsOperation & Maintenance Manual 9Be careful of disposal.• When disposing the device, request to the spe-cialized expert. Be