S&A CW-5200 Series - User Manual

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Summary

Chiller Alarm (red light flash)-With Water Circulation

Testing Flow Switch and Relay

Steps to test flow switch and relay issues for chiller alarms.

Flow Switch Wiring Test

Testing baffle and Hall flow switches by manipulating wires for alarm diagnosis.

Chiller Alarm (red light flash)-Without Water Circulation

Reasons and Testing Method

Lists reasons and outlines testing for alarms without water circulation.

Power Supply and Pump Diagnosis

Diagnosing power supply or pump failure based on voltage checks.

DC Pump Rotor Check

Checking the DC pump rotor for choking or wear as a potential solution.

CW-5000 Series Temperature Controller T-503 alarm

Alarm Code E1: Ultrahigh Room Temperature

Addresses E1 alarm for ultrahigh room temperature and its causes/solutions.

Alarm Code E2: Ultrahigh Water Temperature

Details E2 alarm for ultrahigh water temperature, reasons, and troubleshooting methods.

E2 Testing: Fan and Thermostat

Testing fan input voltage and thermostat output for E2 alarm.

E2 Testing: Compressor and Capacitor

Testing compressor voltage, capacitor, and overload protector for E2 alarm.

E2 Troubleshooting: Refrigerant and Solenoid Valve

Checking refrigerant leakage and solenoid valve issues for E2 alarm.

Compressor Rotor Not Working

Diagnoses compressor rotor malfunction based on vibration and heating.

Alarm Code E3: Ultralow Room Temperature

Explains E3 alarm for ultralow room temperature and its resolution.

Alarm Code E4: Room Temperature Sensor Failure

Addresses E4 alarm for room temp sensor failure and its causes/testing.

Alarm Code E5: Water Temperature Sensor Failure

Covers E5 alarm for water temp sensor failure and its causes/testing.

The machine does not work when power is on

Fuse and Power Supply Testing

Testing fuse and switching mode power supplies for machine failure.

This document outlines the malfunction testing and repair procedures for the S&A CW-5000/5200 Series Industrial Chiller. This chiller is designed to provide cooling for industrial applications, ensuring stable operation of connected equipment by maintaining a consistent water temperature.

Function Description

The S&A CW-5000/5200 Series Industrial Chiller serves as a crucial component in various industrial setups, primarily to dissipate heat generated by machinery. Its core function is to circulate cooled water through a system, absorbing heat from the application and then releasing that heat into the ambient environment. This process is managed by a temperature controller, specifically the T-503 model for the CW-5000 series, which monitors and regulates the water temperature to prevent overheating of the connected equipment. The chiller is equipped with a refrigeration system, including a compressor, condenser, and evaporator, to achieve the necessary cooling. A pump circulates the water, and a flow switch ensures that water is indeed moving through the system, triggering an alarm if circulation is interrupted.

Usage Features

The chiller is designed for straightforward operation and includes several features to ensure reliable performance and user awareness. When the chiller is powered on, it initiates water circulation. The temperature controller displays the current water temperature and allows for setting the desired temperature. In normal operation, a green light indicates proper functioning.

A key usage feature is its alarm system, which provides immediate feedback on potential issues. Alarms are indicated by a red light flash and, in the case of the T-503 controller, an audible buzzer accompanied by a specific error code display. These codes, such as E1 for ultrahigh room temperature, E2 for ultrahigh water temperature, E3 for ultralow room temperature, E4 for room temperature sensor failure, and E5 for water temperature sensor failure, guide the user in diagnosing problems. The alarm sound can be temporarily suspended by pressing any button on the controller, but the visual display of the alarm condition persists until the underlying issue is resolved.

For optimal performance, the chiller requires a ventilated location, with specific clearances for air inlet (at least 30cm from obstructions) and air outlet (at least 50cm). Regular cleaning of the dust gauze is also essential to maintain efficient heat exchange and prevent the accumulation of dust on the condenser. The chiller operates with purified water, and users are advised to ensure the water level in the tank is above the pump inlet.

Maintenance Features

The manual provides comprehensive guidance for troubleshooting and repairing common malfunctions, emphasizing a systematic approach to maintenance.

Alarm with Water Circulation (Red Light Flash): If the chiller alarms with a red light flash while water is circulating, the first step is to perform a short-circuit test by connecting the chiller's outlet and inlet with a 1-meter water pipe.

Normal Water Circle, Alarm Stops (Green Light Flash): This indicates a blockage or bending in the pipes connecting the chiller to the application machine, or within the application machine itself. The solution involves cleaning or replacing the affected pipes.
Normal Water Circle, Alarm Continues (Red Light Flash): This points to issues with the flow switch or relay.
- Flow Switch Testing: The manual details how to locate the baffle flow switch or Hall flow switch and test it by cutting and connecting specific wires. If the alarm stops after bypassing the switch, the flow switch is deemed faulty and requires replacement.
- Relay Testing: If bypassing the flow switch doesn't resolve the alarm, the input voltage of the relay coil should be tested. Non-standard voltage suggests broken or loose wires connecting the flow switch to the relay, which need to be checked and repaired.

Water Current On and Off, Alarm Continues (Red Light Flash): This scenario suggests issues with pipe choking, switching mode power supplies, or the DC pump.

Pipe Inspection: Users are instructed to open the sheet metal and visually inspect the internal pipes for blockages or damage.
Switching Mode Power Supplies (SMPS) Testing: The output voltage of the SMPS should be checked. If it's below DC18V (for CW-5000 series, standard is DC24V), it indicates a failure of the SMPS or the pump due to low voltage. The SMPS should be replaced first, followed by pump testing if the issue persists. If the SMPS output is DC24V, the pump is likely at fault.
DC Pump Inspection: The DC pump's shell should be removed to check for choking or wear in the rotor. If the alarm continues after these checks, the DC pump needs replacement.

Alarm Without Water Circulation (Red Light Flash): This type of alarm often indicates a low water level, an issue with the switching mode power supplies, or a DC pump failure.

Water Level Check: The first step is to ensure the water level in the tank is not lower than the pump inlet. Purified water should be added if necessary.
SMPS and DC Pump Testing: The testing methods for the SMPS and DC pump are similar to those described for the "water current on and off" scenario, focusing on voltage output and physical inspection of the pump rotor.

Temperature Controller T-503 Alarms (with Code Display): The manual provides specific troubleshooting for each error code:

E1 (Ultrahigh Room Temperature): Reasons include ambient temperature above 40°C, poor ventilation, dirty dust gauze, or heavy dust accumulation on the condenser. Solutions involve relocating the chiller for better ventilation, cleaning the dust gauze, and clearing dust from the condenser.
E2 (Ultrahigh Water Temperature): This can be caused by external factors (high ambient temperature, poor ventilation, dirty dust gauze, condenser dust, chiller overload, low working voltage), or internal component failures (fan, temperature controller, compressor capacitor, compressor protector, refrigerant leakage, refrigerant solenoid valve, compressor).
- Testing Methods for E2: Involve checking fan input voltage, thermostat output voltage to the compressor and solenoid valve, compressor boost capacitor capacity, compressor input voltage, and compressor overload protector output voltage. Refrigeration piping is inspected for oil tracking or frosting, which indicates refrigerant leakage. If the compressor works but refrigeration capacity is low, the compressor boost capacitor might be faulty.
E3 (Ultralow Room Temperature): This is often normal in cold seasons during initial use. Adding warm water to the system can restore the temperature to the working range.
E4 (Room Temperature Sensor Failure) and E5 (Water Temperature Sensor Failure): These alarms suggest loose connections or sensor failure.
- Testing Method: Involves swapping the terminals of the room and water temperature sensors on the controller. If the alarm stops, it indicates a poor terminal contact. If the alarm shifts (e.g., E4 becomes E5), it points to the specific sensor failure. If both E4 and E5 display simultaneously, replacing both sensors and the temperature controller is recommended.

Machine Does Not Work When Power Is On:

Fuse Fusing: Users are instructed to check the fuse tube. If fused, it should be replaced with a standby insurance tube.
Switching Mode Power Supplies Failure: The AC220V voltage of the two wire groups on the SMPS should be checked. If only one group has AC220V, the SMPS is likely faulty and needs replacement.

Overall, the manual emphasizes a step-by-step diagnostic process, often involving visual inspection, voltage checks with testing tools, and component replacement as necessary. This structured approach allows users or technicians to effectively identify and resolve issues, ensuring the longevity and optimal performance of the S&A CW-5000/5200 Series Industrial Chiller.