210 Technical Specification

7/28/2019 210 Technical Specification

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AIR-COOLED CHILLERINVERTER CONTROLLER

(3 compressors)


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TABLE OF CONTENTS

1. PRODUCT DESCRIPTION

1.1. General Description

1.2. Chiller System Sampling and Control Points Layout

1.3. Inverter System Control Block Diagram

2. DEFINITION

3. STANDARDS COMPLIANCE & KEY PERFORMANCE INDICATORS

3.1. Standards Compliance

3.2. Key Performance Indicators

4. CONTROL FLOW CHARTS

4.1. Mode Selection Control Flow Chart

4.2. Cooling Mode Control Flow Chart

4.3. Heating Mode Control Flow Chart

5. CONTROLLER INPUTS & OUTPUTS

5.1. Controller Inputs

5.2. Controller Outputs

6. DIP SWITCH SETTINGS

7. CONTROL SYSTEM OPERATION

7.1. General Guidelines

7.2. System Operation Options

7.3. Combination of Compressor Operation

8 COMPRESSOR START UP


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15. OUTDOOR FAN CONTROL

15.1. Outdoor Fan Dip Switch Settings

15.2. Pressure Regulation Mode Fan Control

15.3. Main Board Triad Control Mode Fan Control

15.4. Fan Control During Defrosting

16. ANTI-FREEZING CONTROL

16.1. Antifreeze Control During System Standby

16.2. Antifreeze During Cooling

17. DEFROSTING CONTROL

17.1. Defrosting Conditions and Methods

17.2. Defrosting Process

17.3. Defrosting Termination Conditions

17.4. Intelligent Defrosting Cycle Self-Adaptive Adjustment

18. OIL BALANCING

19. SYSTEM PROTECTIONS

19.1. Compressors Overload Protection

19.2. Pump Overload Protection

19.3. Inverter System High Discharge Temperature Protection

19.4. Fixed System High Discharge Temperature Protection

19.5. Outdoor Coils High Temperature Protection

19.6. Low Pressure (Low Refrigerant) Protection

19 7 High Pressure (Overloading) Protection


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1.2. Chiller System Sampling and Control Points Layout

HP1

HP2

LP1

LP2

SuctionTemp (T16

)

DischargeTemp (T

17)

D

i

s

c

h

a

r

g

eTemp (T

21)

Condin Temp (T

12)

Cond outTemp (T

13)

Cond inTemp (T

22)

BPHE ref in 1Temp (T

14)

BPHE ref out

1 Temp (T15)

EWT

(Tr)

LWT

(To)

EV1

4WV1 4WV2

InvComp Fixed

Comp 2

dps(C

v)

AmbientTemp (T

e)

Filterdrier

Filterdrier

Accumulator

Accumulator

LR LR

EV2

Cond outTemp (T

23)

BPHE ref out

2 Temp (T25)

BPHE ref in 2Temp (T

24)

FixedComp 1

Oilseparator

SuctionTemp (T

26)

DischargeTemp (T

11)

BPHE


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1.3. Inverter System Control Block Diagram

INVERTERAIR-CO

NCONTR

O

Fan21

, Fan22

CP1

CP2

CCH2

Fan11, Fan12

4WV1

VVVF

JDC

CCH11

, CCH12

IAC11

IAC12

To ,

Tr

Te

T11, T12, T13, T14, T15, T16, T17

T21,

T22,

T23,

T24,

T25,

T26

HP1, LP1

VDC

IAC2

HP2, LP2 4WV2


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2. DEFINITION

2.1. To - Leaving-water temperature

2.2. Tr - Entering-water temperature

2.3. Ts Set water temperature

2.4. Te - Outdoor ambient temperature

2.5. T11 System 1 inverter compressor discharge temperature

2.6. T12 System 1 outdoor Coil inlet temperature

2.7. T13 - System 1 outdoor Coil outlet temperature

2.8. T14 System 1 BPHE inlet temperature2.9. T15 - System 1 BPHE outlet temperature

2.10. T16 - System 1 suction temperature

2.11. T17 - System 1 fixed compressor discharge temperature

2.12. T21 - System 2 fixed compressor discharge temperature

2.13. T22 - System 2 outdoor Coil inlet temperature

2.14. T23 - System 2 outdoor Coil outlet temperature

2.15. T24 - System 2 BPHE refrigerant inlet temperature

2.16. T25 - System 2 BPHE refrigerant outlet temperature

2.17. T26 - System 2 fixed compressor suction temperature

2.18. HP1 - System 1 high pressure switch

2.19. LP1 - System 1 low pressure switch

2.20. HP2 - System 2 high pressure switch

2.21. LP2 - System 2 low pressure switch

2.22. IAC11 System 1 inverter compressor input current (any phase)

2.23. IAC12 - System 1 fixed compressor input current (any phase)


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3. STANDARDS COMPLIANCE & KEY PERFORMANCE INDICATORS

3.1. Standards Compliance

GB4706.1 1998: General Safety Requirement (Part I) of Home Appliances and Similar Electrical

Appliances (equivalent: IEC 335 1: 1991)

GB4706.32 1996: Specific Safety Requirement of Heat Pumps, Air-Cons and Dehumidifiers in Home

Appliances and Similar Electrical Appliances (equivalent: IEC 60335 2 4C: 1995)

GB/T18430.2 2001: Steam Compressed Chiller (Heat Pump) assembly and similar chiller (Heat

Pump) assembly

GB3797 1987: Electrical Products (Part II) with Electronic Devices

GB4343.1 2003: Electromagnetic Compatibility for Home Appliances and Similar Products, Emission

Standard (equivalent: CISPR 14 1: 2000 + A1)

3.2. Key Performance Indicators

3.2.1. Power Supply: 3-phase/415V/50Hz, Permitted range 340V to 470V

3.2.2. Indoor Temperature Precision: 0.5C (when adopt individual wired handset to control)

3.2.3. Inverter Outputs:

Voltage : 70V to 390V

Power : 10 kW

Start up frequency : 5Hz

Rate of frequency change : 1Hz/s

Operating frequency : 20Hz to 120Hz


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4. CONTROL FLOW CHARTS

4.1. Mode Selection Control Flow Chart

System

On?

Start

Clash between currentand selected mode of

operation?

Stop Inverter Comp

YES

NO

NO

YES

Cooling?NO NO

Heating?


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4.2. Cooling Mode Control Flow Chart

T = Actual Entering Water Temp Cooling Water Temp Set point

Pump on >3 min?

T >-2C ?

start

T > 2C ?

Only onecomprun ?

T < 2C

Pump on

Y

N

Y

N

Y

N

Y

N

Y

N

T > -5C?

T < -2C

for>30s?

T > 4C?

Y

Y

N

N

N


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4.3. Heating Mode Control Flow Chart

T = Heating Water Temp Set point -Actual Entering Water Temp

Pump on >3 min?

T >-2C ?

start

T > 2C ?

Only onecomprun ?

T < 2C

Pump on

Y

N

Y

N

Y

N

Y

N

Y

N

T > -5C?

T < -2C

for>30s?

T > 4C?

Y

Y

N

N

N


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5. CONTROLLER INPUTS & OUTPUTS

5.1. Controller Inputs

5.1.1. System 1 Outdoor Condenser Coil Inlet Temperature Input ( 0.5C)

5.1.2. System 1 Outdoor Condenser outlet Temperature Input ( 0.5C)

5.1.3. System 1 Inverter Compressor Discharge Temperature Input ( 1C)

5.1.4. System 1 Fixed compressor Discharge Temperature Input ( 1C)

5.1.5. System 1 Inverter Compressor Suction Temperature Input ( 0.5C)

5.1.6. System 1 BPHE Inlet Refrigerant Temperature Input ( 0.5C)

5.1.7. System 1 BPHE Outlet Refrigerant Refrigerant Temperature Input ( 0.5C)

5.1.8. System 2 Outdoor Condenser Coil Inlet Temperature Input ( 0.5C)

5.1.9. System 2 Outdoor Condenser outlet Temperature Input ( 0.5C)

5.1.10. System 2 Fixed compressor Discharge Temperature Input ( 1C)

5.1.11. System 2 Fixed compressor Suction Temperature Input ( 0.5C)

5.1.12. System 2 BPHE Inlet Refrigerant Temperature Input ( 0.5C)

5.1.13. System 2 BPHE Exchanger Outlet Refrigerant Temperature Input ( 0.5C)

5.1.14. Outdoor Ambient Temperature Input ( 0.5C)

5.1.15. System 1 Inverter AC Current Input (any one phase)

5.1.16. System 1 Inverter Compressor DC Voltage Input

5.1.17. System 1 High Pressure Protection Input (OFF: 3.0 MPa, ON: 1.72 MPa)

5.1.18. System 1 Low Pressure Protection Input (OFF: 0.055 MPa, ON: 0.172 MPa)

5.1.19. System 1 Fixed compressor AC Current Input (any one phase)

5 1 20 S t 2 Fi d AC C t I t ( h )


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5.2.7. System 2 Fixed compressor Crankcase Heater Output (normally closed)CC-H2

5.2.8. System 1 Fan Motor Relay Output (Load current 8A, connected to pressure sensor & inverter speed)

FAN11

5.2.9. System 2 Fan Motor Relay Output (Load current 8A, connected to pressure sensor & inverter speed)FAN12

5.2.10. System 1 Fan Motor Triad Control Output (Max Power 1KW)FAN21

5.2.11. System 2 Fan Motor Triad Control Output (Max Power 1KW)FAN22

5.2.12. System 1 4-way Valve Relay Output (Load current 8A)4WV1

5.2.13. System 2 4-way Valve Relay Output (Load current 8A)4WV2

5.2.14. System 1 EXV 4-phase/8-pace Pulse Output (Load power 6W)

EV1

5.2.15. System 2 EXV 4-phase/8-pace Pulse Output (Load power 6W)EV2

5.2.16. Control Main Board LED Alarm Output

5.2.17. Pump Relay Output (driven through contactor, 3 phase, max 12KW)

5.2.18. Auxiliary Heater Relay Output (max 5A)

5.2.19. Wired Handset RS485 Communication Signal Output

5.2.20. BPHE Heater Output (max 5A)

5.2.21. Boiler Relay Output (max 5A)

6. DIP SWITCH SETTINGS

6.1. Main Board 5 Digit DIP Switch Settings

6.1.1. Positions 1: System 1 Inverter Compressor Manual Setting

a. When C1 setting is OFF, compressor operation enable.


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6.2. Main Board 3 Digit DIP Switch Settings

6.2.1. Position 7: Fan Speed Adjustment Mode

(For installation & commissioning testing)

a. When C7 setting is OFF, fan speed through main board triad control.

b. When C7 setting is ON, fan speed through fan speed controller (pressure type).

6.2.2. Position 6 & 8: Not in use.

Sys 1 Invdisabled

Sys 1 Inv operatesnormally

System operatesmanually

ON

OFF ON

1 2 3 4 5 System cant

operate manually

Manually Heating mode

Manually Cooling mode

Sys 2 Fix drivedisabled

Sys 2 Fix drive

operates normally

Sys 1 fixdisabled

Sys 1 fix operatesnormally

ON

OFF ON6 7 8 F d

Not in use


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Temperature should decrease when cooling and increase when heating. VT sampling at 30 secondsinterval. If VT value is large, it means that the load is small and second compressor operation is notrequired.

Note: For super low temperature cooling water requirement, a separate control algorithm is required foron-site setting.

7.2. System Operation Options:

7.2.1. Operate using wired handsets (Refer to OYL wired handset operating manual)

7.2.2. Start pump

7.2.3. Check status of Cv after 3 minutes (duration adjustable). If Cv is OFF, outdoor unit stops and flow switch error alarm triggers.

If Cv is ON, T and VT determine compressors operations.

7.3. Combination of Compressor Operation

There are 7 different compressor combinations, A to G. Selection of combination depends on thetemperature differential, T and temperature differential variation in 3 min, VT.

VT T >4C A B D D

4C > T >2C C C D D

2?> T >-2C D D D D

-2C > T >-5C D F F E

T 5C G G G G


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b. Combination E and F will only be chosen if -5C< T 3mins)

c. Minimum gap between start ups for one compressor [C3]

d. Minimum gap between different compressors start up [C4] (recommended > 3mins)

8. INVERTER COMPRESSOR CONTROL

8.1. System 1 Inverter Compressor Start Up

8.1.1. Cooling mode selected, water pump starts.

8.1.2. Inverter System Cooling Mode Conditions Precedence:

i. Cv is still ON after running pump for 180 seconds (default setting, [C5]).

ii. Tr Ts > 2C. (default setting, [1/2*R2])

iii. No irreversible errors exist in inverter drive and the systems.

iv. Satisfy a delay of 180 seconds before restart. (default setting, [C2])

8.1.3. Inverter System Cooling Process:

Unit ON Unit OFF OD fan starts Inv comp starts frequency increases from5Hz to 55Hz frequency increases toxHz

180s 5s

60s


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b. Cv indicates OFF OR Inverter system error occurs.

c. When Tr Ts < -2C, compressor will switch off after a delay. Time delay before depends on the

temperature differential. Maximum delay is 180s.

8.2. Heating

8.2.1. Heating mode selected, water pump starts.

8.2.2. Inverter System Heating Conditions Precedence:

i. Cv still ON after running pump for 180 seconds (default setting, [C5]).

ii. Ts Tr > 2C. (default setting, [1/2*R4])

iii. No irreversible errors exist in inverter drive and the system.

iv. Satisfy a delay of 180 seconds before restart. (default setting, [C2])

v. Note: 15 seconds start delay between inverter and fixed compressors.

8.2.3. Inverter System Heating Process:

Unit ON Unit OFF 4WV engages OD fan starts Inv comp starts

frequency increases from 5Hz to 55Hz frequency increases toxHz

xHz

5HzT

55Hz

180s 1s

60s

4s


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8.3. Inverter Maximum Frequency under Different Conditions

Cooling

Max freq Ambient temp (Te)

85 Te > 41C

80 28C Te 38C

70 Te < 25C

Heating

Max freq Ambient temp (Te)

60 Te > 21C

6513C

Te

18C70 -4C Te 10C

80 Te < -7C

9. FIXED DRIVE COMPRESSOR CONTROL

9.1. Cooling

9.1.1. Cooling mode selected, water pump starts.

9.1.2. Fixed Drive Cooling Start-up Process:Unit ON Unit OFF OD fan starts fixed comp starts complete fixed systemcooling cycle

If inverter compressor is already in operation, reduce the frequency to 30Hz before the System 1 fixedcompressor starts.

ON

OFFFix sys fan

ON

Fi

180s 4s


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9.2.3. Fixed Drive Compressor Shut-Down during Heating

When either of the below conditions is met, the compressor shuts down:

a. Heating terminates.

b. Cv is OFF OR fixed drive system error.

c. Ts Tr < -2C, compressor will switch off after a delay. Time delay depends on the temperaturedifferential. Maximum delay is 20s.

10. PUMP CONTROL

10.1. Pump Start-up

10.1.1. System is ON.

10.1.2. System is in antifreeze mode.

10.1.3. Manually operated by DIP switch.

10.2. Pump Shut-down

10.2.1. When error occurs in the system. (Refer to error code table)

10.2.2. When system OFF, pump stops 60 seconds after compressor shut down. (default setting, [C6])

Inv comp

Pump

ON

ON

OFF

OFF60

Fix comp ON

OFF


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System 1 consists of inverter and fixed compressors. Control of EXV1 depends on the operation of bothcompressors. See table below for System 1 EXV.

EXV 1 OpeningMin 45/max 480

Inverter Compressor

A B C D

FixedCompressor

A 350 350 X Y

B 350 350 350 350

C X 350 X X

D Y 350 X Y

Definition of A-D:

A: Compressor not in operation

B: 3 minutes before compressor operation

C: 3rd to 10th minutes after compressor operation

D: 10 minutes after compressor operation

X is opening data of testing. After compressor starts, operate to the operating data during 3 rd to 10thminute. EXV1 opening during X:

Cooling:

Fixed Comp Inverter Comp EXV1

ON ON 330

ON OFF 230

OFF ON 430

Heating:

Fixed Comp Inverter Comp EXV1 Outdoor Ambient Temp (Te)

ON ON 450 T 21C


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Definition of A-D is similar to 12.2.

X is opening data of testing. After compressor starts, operate to the operating data during 3 rd to 10th

minute. EXV2 opening during X:During cooling, opening is set at 230.

Heating:

EXV2Opening

Outdoor Ambient Temp (Te)

350 Te > 21C

220 13C Te 18C

200 2C Te 10C

150 Te < -1C

Y indicates automatic control. After compressor operates for 10 min, EXV2 operates to below algorithm:

a. EXV opens at 10 parts per 75 seconds

b. when T21 96C, the opening increases. The higher the temperature, the greater the increase. When itis 96C, 100C and 106C, opening increases by 2, 10 and 20 respectively.

c. EXV closes at 5 parts per 75 seconds when ALL below conditions are met:

i. T21 60C

ii. During heating, suction temperature (T26) is not higher than condenser out temperature (T23) by 3C. T26< T23 - 3C

iii. During cooling, suction temperature (T26) is lower than BPHE ref in temperature (T24). T26 < T24

12.4. EXV Reset after compressors stop

When all the compressors in the respective system have stopped operation, respective EXV openingsets at 350. After 30 minutes, it resets and sets to 350 to remove errors.


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Each system has independent fan control. System 1 fan will operate when either of its compressorsoperates and stop only after both compressors stopped. System 2 operates a separate fan when itscompressor starts.

15.1. Outdoor Fan Pressure Regulator Mode

Fan relay 1 is connected with pressure regulator. Fan relay 2 is connected with fan.

15.1.1. Cooling Mode

Fan relay 1 & 2 start at the same time. Fan relay 2 de-energized after 30 seconds. Then fan relay 1controls fan speed through pressure regulator.

15.1.2. Heating Mode

Fan relay 1 & 2 start. Fan is driven by fan relay 2 and operates at high speed.

15.2. Outdoor Fan Main Board Triac Control Mode

Fan relay 2 is connected with fan. Fan relay 1 is not connected. If fan relay 1 is connected with fan, fanspeed regulation is disabled.

15.2.1. Cooling Mode

Fan relay 1 & 2 start at the same time. 10 minutes before system 1 compressor starts, system 1 fanspeed is controlled according to the outdoor ambient temperature (Te).

Fan Speed Ambient Temp (Te)

High Te > 30C

CompressorOFF

Outdoor fan OFF

ON

ON

60s5s


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16.1.2. If Te 5C and Tr 5C, water pump runs 5 minutes every hour and BPHE Heater will turn on and offtogether with the water pump.

16.1.3. If Tr> 6C, water pump and antifreeze stops.16.1.4. If Te 2C and Tr 2C, system enters heating mode and returns to standby when T r> 30C

16.1.5. Only one compressor is involved in the heating operation. In order of preference: System 1 fixed comp,System 1 inverter comp ,System 2 fixed comp

16.2. Anti-freeze during cooling

16.2.1. When To < A1, BPHE Heater will operate until To > A1 + A2

(default: A1=5C, A2=2C). Sampling point: To (default, [A3]).

16.2.2. When To < A4, alarm will set off until To > A4 + A5. (default: A4=3C, A5=2C)

17. DEFROSTING CONTROL

17.1. Defrosting Conditions and Methods

To prevent outdoor coil frost up during heating which will result in a drop in heating efficiency.

Defrosting for system 1 and system 2 depend on T 13 and T23 respectively. The defrosting process foreach system is independent and only one system can undergo defrosting process at any one time.

17.1.1. OYL or Intelligent (default, [V5]) Defrosting Conditions Precedence

Upon meeting ALL of the following conditions for 3 minutes, auto-defrosting is triggered.

a. Continuous compressor operation for at least the defrosting interval duration

b. T13 < 0C or T23 < 0C (default, [D1])

c. Tr > 18C

O f f ( f )


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17.2.2. System 2 Defrosting Process

a. When defrosting conditions are met for system 2,

Fixed comp stops OD fan stops 4WV disengages Start fixed comp todefrost

b. When system 2 defrosting terminates,

Fixed comp stops 4WV engages OD fan ON resume heating cycleNote:

a. As the fan ducts are separate, defrosting is independent. System restrictsdefrosting of system 1 and 2 at the same time to avoid water temperature becoming too low resulting inincomplete defrosting.

b. During defrosting, HP1 & HP2 might trigger protection whereas LP1 & LP2 will not trigger protection.

ON

ON

OD fan(sys 1)

4-way valve(sys 1)

EndStart Defrosting

ON

Resumeheating modeInv frequency 90Hz

30Hz 30Hz

Fixed comp(sys 1)

Start End Resume

15 s 2 s 10 s

60 s 2 s60 s


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18. OIL BALANCING

When frequency of System 1 inverter compressor < 45Hz, oil balance control time Tx > 60 min.

When frequency rises to 80Hz, oil balance control time Tx is 3 min.

When frequency > 60Hz, Tx will decrease to 3 min. Then Tx reset.

19. CONTROL SYSTEM PROTECTION

19.1. Compressors Overload Protection

19.1.1. Inverter compressor overload protection When IAC11 > 18A, overload protection triggers, compressor reduces frequency, and so long as 16A 115C, T21> 115C, system shuts down.

When T17 < 99C, T21> 99C for 30 seconds, system resumes.

19.5. Outdoor Coil High Temperature Protection

19.5.1. Inverter system

When cooling: T13 > 60C, frequency drops.

When cooling: T13 < 56C, resumes normal.

T17

,T21

115C

99C

Systemstops

30s

Normal operationresumes

T

d

r

o

p


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20. ERROR CODE

No offlashes

Display Error Condition Reset Control Measure

Pump System 1 System 2

Inv Comp Fan Comp Fan

E01 Water Flow error Opened manual OFF OFF OFF OFF OFF OFF

E02 OV/UN voltage Over voltage VAC > 490V VAC340V, autoreset

OFF OFF OFF OFF OFF OFF

E04 External Alarm Opened Auto OFF OFF OFF OFF OFF OFF

E05 Pump overload Opened Auto OFF OFF OFF OFF OFF OFF

E06 Phase missing Auto OFF OFF OFF OFF OFF OFF

E07 Phase seq error Manual OFF OFF OFF OFF OFF OFF

E08 Memory error EEPORM read/write error Manual OFF OFF OFF OFF OFF OFF

E09 Entering water sensoropen/short

BPHE water in sensor Auto OFF OFF OFF OFF OFF OFF

E12 Leaving water sensor

open/short

BPHE water out sensor Auto OFF OFF OFF OFF OFF OFF

E14 Outdoor air sensor open/short Ambient temp sensor Auto OFF OFF OFF OFF OFF OFF

E15 IPM error IPM over-current/overheated Error signal toIPM

Auto - OFF - OFF - -

E16 Comp 1 overload Inverter comp overload Auto - OFF - - - -

E17 High pressure 1 System 1 high pressure Opened Auto - OFF OFF OFF - -

E18 Low pressure 1 System 1 low pressure Opened Auto - OFF OFF OFF - -

E19 Comp 1 discharge overheat Inv comp dischargeoverheat

Ta1>115C Auto - OFF OFF OFF - -

E20 Comp 1 defrost sensoropen/short

Sys 1 condenser out sensor Auto - OFF OFF OFF - -

E21 BPHE 1 inlet temp sensoropen/short

Sys 1 BPHE ref in sensor Auto - OFF OFF OFF - -

E22 BPHE 1 outlet temp sensoropen/short

Sys 1 BHPE ref out sensor Auto - OFF OFF OFF - -

E23 Comp1 suct temp sensoropen/short

Sys 1 suction temp sensor Auto - OFF OFF OFF - -

E24 Comp1 discharge sensoropen/short

Inv comp discharge sensor Auto - OFF OFF OFF - -

27


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E25 Coil 1 inlet temp sensoropen/short

System 1 condenser insensor

Auto - OFF OFF OFF - -

E27 High pressure 2 System 2 high pressure Opened Auto - - - - OFF OFF

E28 Low pressure 2 System 2 low pressure Opened Auto - - - - OFF OFF

E29 Comp 2 overload Sys 1 fixed comp overload > 16A Auto - - - - OFF OFF

E31 Comp 2 discharge overheat Sys 1 fixed comp discharge

sensor

>115C Auto - - - - OFF OFF

E32 Comp 3 overload Sys 2 fixed comp overload > 35A Auto - - - - OFF OFF

E33 Comp 3 defrost sensoropen/short

Sys 2 condenser out sensor Auto - - - - OFF OFF

E34 Comp 3 discharge overheat Sys 2 fixed comp dischargesensor

>115C Auto - - - - OFF OFF

E35 Sys 2 4WV reverse error manual - - - - - -

E36 Sys 1 inv comp error Auto - - - - - -

E37 Sys 1 fixed comp error Auto - - - - - -

E38 Sys 2 fixed comp error Auto - - - - - -

210 Technical Specification

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