2021 BROAD Chiller Service Webinar Series 4#

Fault and Troubleshooting

BROAD U.S.A.
Bill Huang

Service manager
BROAD North America Office

17 years working experience for

BROAD Chiller startup and service
Control specialist Tel: 201-678-3010
Email: [email protected]
 Fault and Troubleshooting
Four different types of faults:

a. Fault stop

b. Fault Alarm

c. Abnormal
reminding

d. Abnormal record

The touch screen will display current fault types icon.

Fault stop

➢ Chiller will enter “dilution shut off” cycle immediately if “fault stop”
occurs during chiller operation.

➢ Faults can be reset through “fault reset” signal, except several faults
which should be manually reset on control components; otherwise it
will lead to chiller stoppage and cause safety accident.

➢ Chiller restart required.

Fault alarm

➢ The chiller will remain in operation and continuously alarming.

➢ Should be solved and reset within 24 hours, otherwise it will

cause “fault stop”.

➢ Some fault alarms (such as burner, chilled w. pump, cooling w.

pump and so on) will be reset automatically at intervals, or
turned to “fault stop” if the resetting failed.
Abnormal Reminder

➢ The chiller will be continuously running.

➢ Abnormal should be solved within 10 days, otherwise it will lead to

“fault stop”.

➢ Some control functions will be disenabled. If the automatic resetting

fails for several times, it will turn to “fault alarm”.
Abnormal record

➢ Not affect chiller operation

➢ Not show on the main monitor screen

➢ recorded for service engineer’s review and reference.

Any fault should be solved immediately

Any fault shall be solved in time even though some faults or abnormalities will not lead
to immediate chiller shut off. If not, chiller maybe stop soon.

Chiller running with any fault is prohibited, otherwise it will waste more energy, reduce
the life span of the unit, increase maintenance difficulties, or even cause greater loss.
Troubleshooting Flow Chart:
“Fault stop”, “Fault Check touchscreen “Fault stop” must be
alarm” or “Abnormal to display possible notified to the service
reminding” occur. cause and treatment. engineer immediately.

Reset. Chiller keeps Notify the service “Fault alarm”, “Abnormal

running. If reset can engineer and do reminding”, though not
not be done, notify troubleshooting upon affecting the operation
the service engineer. approval. shall be handled on time.

Re-check to make sure Keep troubleshooting

chiller is in normal record carefully and
operation and there are report to the service
no other faults or engineer.
abnormalities.
Check Current Fault

Caution icon and short

description will display on
main screen when occurred

Different type of caution icon

will display base on the fault
category.
Check fault detail and history

1. Enter fault record by pressing

the caution icon
2. Fault record will enable you to
see: Fault name, occurring time of
the fault, resetting time and
abnormal reminder
3. Press the fault and follow the
instructions
Broad chiller monitoring (Cloud base)

➢Fault and abnormalities notification will email or APPs on real time

➢Registered User and Local service engineers will receive the notification

Date server
Troubleshooting - HVAC Water system issue
Check and compare with chiller nameplate:

Chilled water inlet temperature , Chilled water DP pressure *

Cooling water inlet temperature , Cooling water DP pressure *
Gas pressure
Steam pressure
Hot water temperature
Troubleshooting - HVAC Water system issue

Chilled W. pressure
checking valve

Condenser W. pressure
checking valve

Open the Check valves one by one, note down the inlet
pressure and outlet pressure to calculate pressure drop,
compare it with rated data
Troubleshooting - HVAC water system issue

Practice (1) - Water flow issue

Chilled water flow switch fault
Two chilled water flow switches are closed before the chilled water pump
gets started. Chiller and system can not be started.

Chilled water off fault during operation

2 flow switches are both disconnected in operation, burner is off suddenly, R-pump,
cooling water pump are off at the same time. When the chilled water flow is regained,
the chiller enters into dilution off process automatically.

Cooling water off during operation alarm

Touch screen alarms “cooling water off” in operation. Alarm will switch to “fault stop” if it is
up for 5 minutes and the flow is still not regained.
Cooling water flow switch abnormal
No influence on chiller operation. Touch screen prompts “Please check and repair cooling water
flow switch”.
Troubleshooting - HVAC water system issue
Practice (1) - Water flow issue

Flow rate Open Flash Close

Chilled water flow switch <45% 45%~55% >55%

Condenser water flow switch <40% 45%~55% >50%

Troubleshooting - HVAC water system issue

Practice (2) - Water temperature

Chilled water outlet temperature lower than 39 ºF

Cooling water inlet temperature over upper limit 96 ºF, Heat source stop

Cooling water inlet temperature below the lower limit 71.4 ºF

Cooling water outlet temperature over high limit 115 ºF, cooling water pump stop

Steam Condensate outlet temperature over high limit 220 ºF, steam valve close

Gas pressure low alarm, burner can not start, burner fault
Troubleshooting – Power Failure

Sudden power failure

In chiller operation, if power failure duration is between 90 seconds and

30 minutes, the chiller can be restarted automatically when the power is
regained.

If it is over 30 minutes, manual restart is necessary.

Momentary power failure

Power failure duration is less than 90 seconds.

Restart automatically when power is regained,

Troubleshooting – Chiller electric components

Electrical Components
❑ Fuses
❑ Transformers
❑ Contactors
❑ Level Sensors
❑ Temperature Module/ sensors
❑ Wiring terminal
❑ Internet monitoring
❑ VFD voltage and amperage check
❑ VFD settings
Troubleshooting – Chiller electric components

Level Sensor Flow switch Pressure switch

Temperature Sensor

Program Logic
controller(PLC)
Inverter for pump
Touchscreen

Steam/Hot water Valve Canned Pump

Troubleshooting - Chiller electric components

Practice (3)

Chilled w. outlet, HTG temperature sensor fault

Dilution off automatically and touch screen displays “999.9”.

Temperature detecting module fault

Dilution off automatically.

S-pump VFD fault *

Dilution off automatically and burner stops immediately followed by S-
pump and R-pump off. Inverter displays fault code.

No solution level in HTG (Cooling )

HTG solution level is still in zone A after S-pump runs for 5 minutes at maximum
frequency. Dilution off automatically
Troubleshooting - Chiller electric components

Practice (3)

Chilled/heating/ hot w. outlet, and cooling w. Inlet, temperature sensor fault

touch screen displays “999.9”.

HTG solution level control fault

The chiller keeps running, adjusting S-pump frequency according to HTG temperature.
Switch to normal solution level control automatically after the fault is reset.
Burner, steam, hot water valve fault
If reset successfully will start as normal, otherwise the alarm will switch to “fault stop”.
Refrigerant pump inverter fault *
Stop the R-pump. The chiller continues the cooling operation and the touch screen alarms.
Fault code is displayed on the R-pump inverter.

Absorption pump and vent pump fault

If reset successfully will start as normal, otherwise the alarm will switch to “fault stop”.
 Solution pump and Refrigerant pump Fault
Pump motor can not run, chiller goes to dilution off and pump inverter displays
fault code. Chilled code on VFD manual.

Causes Keys
1. Inverter damaged. 1. Repair or replace inverter.

2. Communication failure occurs between PLC 2. Check the communication port, network
and inverter. gateway and communication circuit.

3. Too great fluctuation of power voltage and 3. Ask power supply company to guarantee the stable
frequency. supply of voltage and frequency.﹡
4. Open/short circuit or loose connection with 4. Inverter control circuit troubleshooting.
control circuits, or water in wire box.
5. PLC output module fault. 5. Replace output module

6. S-pump damaged. 6. Check and replace the S-pump.

7. Strong interference source exists 7. Check and get rid.

 Over-pressure/over-temperature fault
Pressure control actuates and burner off, valve close. after pressure control is reset. The
chiller resumes operation, and 5 times over-pressure will switch to “fault alarm”.

Causes Keys
1. Poor vacuum condition 1. Vacuum check and verification
2. Cooling water flow rate is too low or 2. Increase cooling water flowrate or
temperature is too high reduce cooling water temperature

3. Steam angle valve opening is too small 3. Check the steam angle valve﹡
4. Scaling with cooling water copper tubes. 4. De-scale.
5. Too small LTG solution circulation 5. Readjust the solution circulation
6. Pressure control setting value is too low (3psi) 6. Reset
7. Pressure control damaged 7. Replace
8. low or no flow in heating mode 8. check the heating water loop
 Refrigerant over flow *
Burner switches to low fire, and will turn off when the refrigerant is still overflowing at low
fire operation for a while.

Causes Keys

1. Poor vacuum condition 1. Refer to poor vacuum eliminating method

2. Refrigerant water polluted 2. Refer to refrigerant polluted eliminating method

3. Cooling water low flow with high temperature 3. Increase cooling water flow or improve cooling
tower performance
4. Comprehensive solution concentration low 4. Increase solution concentration properly

5. Heating capacity input too high 5. Decrease heat input

6. Scaling in absorber copper tubes 6. Remove scale in absorber copper tubes

7. Refrigerant water bypass valve damaged. 7. Check refrigerant water bypass valve

8. low or no flow in heating mode 8. check the heating water loop

Troubleshooting How to bypass refrigerant water manually.

1. Press “Setting” on the left primary menu;

2. Press “Other choice” on the bottom secondary
menu;
3. Press “Bypass” to regenerate the refrigerant water,
do it 2~3 times, wait refrigerant water level drop to
B or A zone.
Troubleshooting

Crystallization Phenomenon

HTHE crystallization:
a. HTG over-temperature. Auto de-crystallization process is started.
b. Chilled water temperature increases rapidly. Touch screen prompts “De-
c. S-pump frequency is low. crystallization in process”.
d. Solution off from sight glass.
e. HTG pressure decreases. Cooling water pump and cooling tower
f. Auto de-crystallization process is started. fan are off.

LTHE crystallization: The chiller resumes to normal operation

a. Chilled water temperature increases abnormally.
after de-crystallization is completed. If
b. Auto de-crystallization tube temp. increases
abnormally. this process repeats 10 times in 24 hours
c. Auto de-crystallization process is started. it will switch to “Fault Alarm”.
Troubleshooting

Crystallization Causes Keys

1. Cooling water that is too 1. Check cooling water

cold or that fluctuates in temperature setting value; keep it
temperature too rapidly normal or add inverter to control it

2. Poor vacuum 2. Refer to “poor vacuum”

3. Excessive combustion 3. Readjust burner and reduce

combustion
4.Improper circulation 4.Readjust circulation amount
adjustment
5.Excessive corrosion inhibitors 5.Add corrosion inhibitors strictly
according to the standard
6. Power failure and chiller 7. Restart chiller ASAP after power
room temperature low back
 Refrigerant freezing
Actuate auto de-freezing process. Touch screen prompts “Ice melting in
process”. Stop cooling water pump .The chiller resumes to normal operation
after de-freezing. If this process repeats 10 times in 24 hours it will switch to “Fault
Alarm”.
Causes Keys

1. Low cooling water 1. Increase cooling water

temperature and Low cooling temperature and select energy-
load saving operation mode
2. Chilled water flowrate too 2. Check the chilled water
low system and increase chilled
water flow
3. Chilled water outlet target 3. Increase chilled water outlet
temperature setting too low target temperature
Cooling capacity lower than the rated
Chilled water outlet/inlet temperature both increase and temperature difference decreases;
Cooling water outlet/inlet temperature difference decreases.
Cause 7.Refrigerant water gets polluted

1.Poor vacuum 8.Refrigerant water spray or Refrigerant pump

filter clogged
2.Insufficient cooling water flow 9.Refrigerant inverter goes out of control

3.Cooling water inlet temperature high (above the 10.Fouling in copper tubes (condenser water
rated) tubes, Chilled/heating Water tubes)
4.HTG fire off temperature setting value is too low 11.Burner output low or gas pressure low

5.Chilled water flow or temperature measurement 12.Soot in combustion chamber and fire tubes
is inaccurate
6.Chiller heating/cooling switch angle valve are 13.Hot/heating water is overloaded
not fully opened
Troubleshooting - Vacuum

Signs of poor vacuum

❑ Chilled Water Temperature can not meet Setpoint

❑ Over Pressure or Over Temperature Alarm

❑ Refrigerant Water Over Flow Alarm

❑ Crystallization

Vacuum is the life of the chiller !

Troubleshooting - Vacuum

1. Chiller’s cooling capacity reduced.

• Non-condensable gases (air)

restrains solution generation in
generators
• Reduces the absorbing ability of
vapor in the absorber
• It will cause an increase in pressure
of the evaporator
• affect the evaporation and
absorption of the refrigerant water.
Troubleshooting - Vacuum

2. Chiller will be damaged due to air leakage in

the chiller.

• Cause corrosion- create rust

• Rust can clog the filters and spray nozzles
• Rust will pollute the LiBr solution,
• causing change in the composition
of the LiBr,
• increasing the corrosion inside the
chiller.
• Damages such as copper tube and steel
plate puncture will occur in a short time
Troubleshooting - Vacuum

Vacuum pump ultimate vacuum check

• vacuum meter pressure <= 0.009
inHg (0.23torr)
• Cannot be use if above 0.06inHg (1.5
torr)

Oil Sight Glass

• Level - 1/2 to 2/3
• Oil change every 40 hours, or oil
condition

Gas Ballast Valve

• Clockwise fully close (Bubble test
position)
• Anti clockwise 2-3 turns (Regular
purge position)
Troubleshooting - Vacuum

Cork must
remove before
hose connect
Troubleshooting - Vacuum

Poor vacuum

a. Sealing element aging

b. External vacuum valve is not closed tightly

c. Leakage is caused during transportation or new leakage occurred in operation

d. Leakage welding seam caused by serious inside or outside corrosion

e. Function loss of auto purge and air vent device

f. The chiller keeps running at high HTG temperature generating non-condensable gas

Overhaul maintenance
 Q&A
BROAD U.S.A Inc - New Jersey BROAD U.S.A. Inc - California
401 Hackensack Ave, Suite 503 100 Citrus St, Suite 250
Hackensack, NJ 07601 West Covina, CA 91791
Tel: (201) 678-3010 Tel: 626-967-8651
Fax: (201) 678-3011 Fax: 626-967-8654

[email protected]
[email protected]