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Originally Posted by
IndustrialTech
Anyone know what the trigger board output voltage should be so I can test and make sure there not stuck on? Or sequence of operation for the trigger board?
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0.5 to 6volts
There is not better place for the working men than the union! 100% UA the only HVAC union!
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Used a diode checker the other 2 checks out the same one in the middle had continuity on both sides
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Originally Posted by
IndustrialTech
Used a diode checker the other 2 checks out the same one in the middle had continuity on both sides
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Thats they way to do it, you can also trigger the gate with a battery
There is not better place for the working men than the union! 100% UA the only HVAC union!
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Just want to clarify this since it blew the fuses with the switch in the off position. I can unplug the SCR's from the trigger board and throw the power back too it without anything crazy happening. I'm getting ready to drop in 3 new SCR's and 3 new fuses.
I want to test the trigger board before I allow full voltage onto the DC buss???
Thanks everyone for all your input it has helped me tremendously. I'm very grateful for everyone's assistance.
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Originally Posted by
IndustrialTech
I can unplug the SCR's from the trigger board and throw the power back too it without anything crazy happening. I'm getting ready to drop in 3 new SCR's and 3 new fuses.
I want to test the trigger board before I allow full voltage onto the DC buss???
That should work without issue!
There is not better place for the working men than the union! 100% UA the only HVAC union!
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If the diode check works out on the remaining diodes, and is everything ok on the DC Buss, caps ok, OUTPUT IGBT's ok ? Then I would be tempted to put small fuses on the input, maybe 100amp, turn circuit breaker setting to minimum if it has settings, disconnect the motor output leads at the the copper bars where motor and VSD meet. Power up, log the DC Buss Voltage on trend along with three phase input , start the chiller, it will trip after a few seconds on 'Low Motor Current' because although the DC Buss is energised and the IGBT's switch on, the motor won't run if you have dis-connected 3 phase to it, so the Optiview is expecting to see current once it has given the RUN command and DC Buss is charged. This will give you a pretty good idea if everything else is ok. I use a volt scope on the OUT poles to check for momentary voltage output, but you could also put a DMM with peak volt capture on one phase, any, your choice. If all is ok, check trend for correct DC Buss volts re-connect motor leads, in the correct phase of course, then go for a start. Hope it all works. Generally if I have Output IGBT failures then I replace all 3 poles as the remaining 2 phases get stressed electrically. I would be tempted to change the trigger board too for a known good one.
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Just started system back up. So far so good. Thanks again to everyone for all of your help. I greatly appreciate each and every one of you.
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Nice thanks for the update. Any reason why the speed is still high or did it drop after a bit?
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That was during the pull down demand. I'll upload the same pictures in the morning after it runs over night.
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Pull down is set for 5 minutes at 100% , which takes pull down out of the picture. Hopefully someone has not set speed at fixed.
Older software may run speed at 60 Hz and then let it slow down , will need to check that in an old book.
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It has only been running 4 minutes so it’s likely that the water temperature hasn’t stabilized yet so the bad won’t slow down and open the vanes until it is inside the stability envelope
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Update on same unit. Just up sized the cooler for the vsd to a 1 million btu exchanger because you couldn't close the enclosure even with everything thing clean. It's tempt in.
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The tube and shell ones are cleanable. Use clean chilled water with a control valve and now no cleaning needed.
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Hi guys, I have to congratulate all of you for the support given to Industrialtech throughout this repair. Congratulations!!
Industrialtech, this is for you, I noticed something on pg2-4th photo. That is that the surge margin adjust parameter is set to 0.0 hz. Meaning if the chiller does surge, it has not been given a direction of change. So it will remain at the surge point, I suggest setting it at 1.0 or 0.5 hz, so it has command to either increase or decrease by the above setting.
Good work and good luck in all you do.
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Thanks for the input and this thread has become a work of art. I'm trying to keep everything in one location to help others later down the road. We have crossed many bridges on this thread related to a single chiller style. I need to fill out the app for Pro I've just been to busy.
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Just a couple of other points, I noticed on the Evaporator Screen you have the 50% setting for the vanes, this is normally set to 100% , the 50% setting slows down the response of the vanes by half. You may want to put that back up to default setting. Also, do you know from the compressor screen what the Surge Shutdown Count is and the time period, I find that the current default setting of 15 surges in 3 minutes to trigger Surge Shutdown is too much , a typical surge lasts around 10-15 secs, 4 surges a minute so over a 3 minute period means you will get 12 surges and the chiller won't shut-down on surge, surge can cause stress to the DC capacitor bank , SCR's and IGBT's . I typically set the Surge Shut-down count to 5 surges 5 minutes so you only need 1 surge per minute and after 5 minutes you will shut-down. And I agree with Bklyntek regarding the surge margin adjust. Good luck.
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That sounds like it may have been the primary reason the IGBT exploded. I'll make the corrections and I greatly appreciate all the advice.
Originally Posted by
raptyr
Just a couple of other points, I noticed on the Evaporator Screen you have the 50% setting for the vanes, this is normally set to 100% , the 50% setting slows down the response of the vanes by half. You may want to put that back up to default setting. Also, do you know from the compressor screen what the Surge Shutdown Count is and the time period, I find that the current default setting of 15 surges in 3 minutes to trigger Surge Shutdown is too much , a typical surge lasts around 10-15 secs, 4 surges a minute so over a 3 minute period means you will get 12 surges and the chiller won't shut-down on surge, surge can cause stress to the DC capacitor bank , SCR's and IGBT's . I typically set the Surge Shut-down count to 5 surges 5 minutes so you only need 1 surge per minute and after 5 minutes you will shut-down. And I agree with Bklyntek regarding the surge margin adjust. Good luck.
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the prv control arm may have rusted in the cover and locked up. you can remove the cover and polish it the put the cover back on and see if it moves
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Anyone have the 160.55-M1 manual? the books referencing out for the tear down and troubleshooting guide for the purge unit on this machine. The motor failed on the purge unit.
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