Open Type Compressor Troubleshooting Trainer Experiment Manual

2
ABOUT THE TRAINER

2.1. LIST OF ITEMS THAT COME WITH THE TRAINER

Open Type Compressor Troubleshooting Trainer has some main components as follows:
• Mobile bench.
• Refrigeration system.
• Instrument and control panel which is completed with ELCB, MCB, voltmeter, ammeter
indicator lamps and DOL starter.
• Fault simulators and test points board.
• Open type compressor and compressor motor part diagram.

Figure 2.1. Open Type Compressor Troubleshooting Trainer.

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Experiment Manual
This trainer is completed with experiment manual that provides information about the general
comprehension of the trainer. By guiding you to learn easily, the manual also consists of basic
theory, Pre-operation procedures, experiments and the other references as described in
appendix. The experiment manual will guide you to understand the operation of Open Type
Compressor Troubleshooting Trainer and also to explore compressor parts and their
characteristics including the system analysis of the electrical and mechanical system. The
troubleshooting and diagnosis technique also explained to familiarize the students with
common trouble that found in open type compressor motor.

2.2. SETTING-UP THE TRAINER

Please do the following procedure for setting up the trainer :
1. Unpack the trainer unit from its package.
2. Please do an inventory of all trainer parts according to the list in point 2.1 above.
3. Install the frame. Please do the following procedure to install the main frame of the trainer:
a) Learn Figure 2.2 carefully before installing the main frame.

Figure 2.2. Main Frame Installation; (1) Casters, (2) Frame Stand, (3) Frame Support, (4) Main Frame.

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b) Install the casters to main frame's stand. Make sure they are tightened properly.
c) Connect the frame's stand with frame support. Use M8 bolt to tighten the connection.
Make sure the bolts are tightened properly.
d) Place the stand of frame in a sufficient area and ventilation, then lock the casters.
e) Install the main frame onto the frame's stand. Tighten the installation by using M8
bolt. Make sure the bolts are tightened properly. For safety reason when you are doing
this procedure, we recommend to use a forklift truck to pull up the main frame.
f) Now, the main frame has been installed completely.
4. Check the trainer to ensure there is no damage during shipping.
5. Ensure all switches on the Instrument and Control Panel are OFF.
6. Connect the power plug to the suitable power supply.

2.3. PARTS IDENTIFICATION

Before operating the trainer make sure you understand the function of the components. This
sub-chapter will explain general information of the components as classified in sub-chapter
2.1 above.

2.3.1. Refrigeration System

Figure 2.3. Refrigeration System Components Arrangement.

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1. Open Type Compressor with Compressor Motor

Open Type Compressor is the heart of a vapor compression refrigeration system. Its
functions are to raise the pressure of the refrigerant and provide the primary force in
circulating the refrigerant. This open type compressor is driven by an electrical motor
which is powered by 380-415VAC, 50Hz.
2. Refrigerant Pressure Gauges.
There are two pressure gauges:
a) PG1: Suction Pressure
b) PG2: Discharge Pressure
3. Capillary tube
Capillary tube is refrigerant control system in which pressure difference is maintained
through the use of a thin capillary tube.
4. Solenoid valve
This solenoid valve is used to simulate low compression condition.
5. High Pressure Control
High Pressure Control is an electrical control switch, operated by the high side pressure
that will open the electrical circuit automatically if it reaches the cut-out setting.
Factory adjustment for High Pressure Control:
Cut-Out = 18.3 bar (270 psig) adjustable
Differential = 3 bar (43 psi) fixed

Figure 2.4. High Pressure Control Setting.

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2.3.2. Instrument and Control Panel

Figure 2.5. Instrument and Control Panel Component Arrangement.

Instrument and Control Panel is provided as electrical system control. There are several
components installed on this panel, which consist of :
1. Earth Leakage Circuit breaker (ELCB)
ELCB is used to protect the circuit from leakage current.
2. Miniature Circuit Breaker (MCB)
MCB is used to protect the circuit from over current and short-circuit.
3. Push Button consists of :
a) Start Button Switch
The start button switch is used as the main switch to start the compressor motor.
b) Stop Button Switch
The stop button switch is used as the main switch to stop the compressor motor.
4. Indicator Lamps
Indicator lamps are used to monitor the operation of the training unit. There are Run and
Trip indicator lamps that describe as follows :
a) Run indicator. It lights up when the compressor is working.
b) Trip indicator. It lights up when the safety device such as high pressure control (HPC)
and trip of compressor motor thermal overload reach their cut-out set points.

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5. Ammeter
Ammeter is an instrument for measuring current consumption of compressor motor.
It displays current consumption for each phase (L1, L2 and L3).
6. Voltmeter
Voltmeter is an instrument for monitoring AC voltage of training unit power source.
It displays voltage of L1 to N, L2 to N, L3 to N.

2.3.3. Electrical Component and Circuit Board

Figure 2.6. Electrical Component and Printing Circuit Board (PCB) layout.

There are many electrical components that are installed in open type compressor
troubleshooting trainer, such as magnetic contactor, thermal overload, relay, Printed Circuit
Board (PCB) and other components that have been laid out at the back of the trainer. Each
component has special function and make integrated system to build a good system
performance. The functions of the components are as follows:
1. Disconnect Relay Board
Disconnect relay board is used to connect and disconnect the components. It is also
possible to do resistance or continuity measurement of electrical components on fault
simulator and test point board without taking measurements on real components. The
circuit board will be active to disconnect each component when component measurement
button is pressed in the continuity/resistance condition.
2. Power Supply Board
Power supply board is used to convert AC Voltage (220VAC) into DC voltage (12VDC)
to be used to disconnect relay board and fault relay board.
3. Fault Relay Board
Fault relay board is used to make fault simulation in the system. This circuit will be active
when the fault switch simulator switch is pressed.

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4. Magnetic Contactors (MC)

Magnetic contactor is an electromagnetic switch that is used for connecting and
disconnecting the electrical current. It has a similar function to a relay except that the
magnetic contactor has a higher current rating. In addition to that, a magnetic contactor
can be controlled remotely. They are used for safety when full voltage starting or stopping
torques may be applied to the driven machinery and for protecting the circuit from inrush
current resulting from the starting line.
5. Programmable Timer
Programmable Timer 4 Input 4 Output Circuit Board is used as time delay adjustment. It is
installed on the control wiring to delay the system to turn OFF when fault switch number
1, 2, 3, 4, 5, 6, 7 and 11 are pressed.
6. Thermal Overload (OL)
The function of overload relay is to protect the motor from overload. When a motor is
mechanically overloaded, it will draw more current than its rated value. The factory
setting for thermal overload is 1.8A
7. Step Down Transformer
Step down transformer is used to simulate the low voltage supply to the compressor motor.
8. Terminal Block is used to determine neutral and ground cable terminal connection.
9. Exhaust fan is used to cool the electrical components.

2.3.4. Fault Simulators and Test Points

How to Use Fault Simulators
Trainer features its unique interactive electronic troubleshooting fault insertion system on
many of its Air Conditioning trainers. This system was developed for the real hands in which
the area of troubleshooting electrical circuits and systems for Air Conditioning and
Refrigeration is difficult to be taught. It will strengthen the understanding of logical trouble
shooting procedures, enable you to observe and test the system under a variety of faults. The
faults are easily activated and the system can instantly be reset back to normal operating
conditions. In addition, the faults can be hidden for testing purposes. The system is fun to use
as you will enjoy seeing what happens to the system when the various combinations of faults
are introduced.

System Description
The system consists of control panel onto which a schematic of electrical circuit is silk-
screened. Test points are provided at strategic locations in their appropriate places on the
circuit diagram. The fault system is located next to the circuit diagram and each fault has
LED indicator (to show when the fault is being activated). Beside of the LED there are faults
activation button provided which control the faults. The faults are electronically activated by
Push Button Switches. When any fault is activated the LED light will automatically turn on.
Any number of faults can be activated at the same time. After the faults are activated, you can
then use the test points which is located on the circuit diagram with appropriate
electrical/electronic test instruments to diagnose the problem.
The system can be set back to normal operation easily and quickly by using the Reset switch.

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The LED display can also be switched off even though the faults are still active. In this mode
the system can be used for blind testing in order to assess the troubleshooting skills. Major
Features of the Interactive Troubleshooting System are as follows:

Figure 2.7. Electrical Circuit Diagram Complete with Test Points.

a) Electrical Circuit Block Diagram Display

The Electrical Circuit Block Diagram is silk screened onto a display panel which is
centrally located on the front of the trainer. The highly visible electrical circuit diagram
strengthens your understanding about the systems circuitry and is essential to develop
the troubleshooting skills.
b) Integrated Test Points
Test points are integrated into the circuit block diagram at strategic locations and
include all important measurement points that are required by the exercises. You will
be able to carry out testing of the circuit in an easy manner and in a way that
reinforces his understanding of the circuit’s operational characteristics. This feature
also has added the benefit of protecting the trainer from possible damage which would
otherwise result from yourself when you have to open up various components to take
measurements. See Figure 2.8.
c) LED Fault Display
Each fault has an LED display light to show when the fault is activated. This helps you
to visualize the relationships between the faults and their corresponding symptoms.

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Figure 2.8. LED fault indicator will glow when fault is activated.

d) Easy Fault Activation

A push button switch is used to activate each fault. Faults may be introduced one a
time or in groups of various combinations. There is no limit to the number of faults
that can be activated at any one time; you can even activate them all as desired.

Figure 2.9. Activate the Fault Simulation.

e) Interactive Fault Learning

You will receive immediate feedback upon activation of the fault. The corresponding
symptoms are readily apparent. This is able to observe and learn the corresponding
symptoms to each type of fault. This greatly speeds up the process of gaining valuable
troubleshooting experience in seeing systems fail due to a wide range of problems.

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f) Troubleshooting Instruction
Many trainers include troubleshooting diagrams as part of the courseware. These
diagrams will help you on how to approach fault diagnosis in a logical, quick and
efficient manner. You will also gain experience with troubleshooting ladder logic and
how to logically approach a problem from a systematic and symptomatic point of
view. So, it helps you to develop professional troubleshooting skills quickly.

Figure 2.10. Fault tracing.

It is not a problem if you want to check the electrical by using Voltage, Continuity or
Resistance. Just turn the Component Measurement mode to “Voltage” or
“Continuity/Resistance”.

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Figure 2.11. Voltage, Continuity/Resistance Measurement Mode.

g) Testing Mode
The LED fault indicator display can be deactivated, so that faults can be active but the
display is switched off. In this mode, you (as instructor) can introduce a series of faults
and someone else will not know which faults was used. You will then be able to ask
him/her to use the test points to identify where the faults are.

Figure 2.12. Hiding Active Fault to Test the Student Capability.

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h) Fault Reminder
It is helpful for the instructor in case he/she forgot which one fault was activated. Just
press the LED Control Button while system is under hidden fault, it shows the last
fault activated. When the button releases, the fault mode will be back to the hidden.

Figure 2.13. Fault Reminder.

i) Return back to normal mode

By pressing the Reset Button, the system will be automatically back to normal.

Figure 2.14. Returning the System to Normal Mode.

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2.4. SAFETY CARE AND MAINTENANCE

For the safety during operation of the Open Type Compressor Troubleshooting Training Unit,
follow advice below:
For safety reason:
1. Keep clean and dry around electrical wiring, instrument and control panel to avoid short-
circuit.
2. Ensure the earthing wire is properly connected to the unit. This wire is used as protection
against electric shock.
3. Make sure there are no leaks in the refrigeration system before operating the system.
Check the pressure gauges to make sure that refrigerant is entering the system.
4. Make sure that the trainer is powered by 380-415VAC before switching ON the system.
5. Do not put your hands on moving parts such as motor.
6. Do not touch hot surfaces such as compressor and refrigerant discharge line.
7. Never connect any test points without experiment guidance to avoid trainer from short
circuit and fatal damage.
8. Follow the procedures that explained in operation procedures and experiments guidance
when operating the system and experimental activity.
9. Never remove test points cover to avoid you from electric shock.
10. Wear goggles and gloves when you attach or remove the gauges to transfer refrigerant or
to check the pressure.
11. Do not change the factory setting of all printed circuit board, if the user revises the setting,
it will affect the system performance.
12. Observe all electrical safety precautions. Be careful at all times and common sense.

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For long life and better trainer performance:

1. Always pay attention to working voltage, amperage and phase imbalance. Check for faulty
contacts caused by loosened terminal connections, oxidized contact, foreign material or
other factors.
2. Always check the refrigerant pressure according to technical specification of the trainer.
The system must be running with sufficient refrigerant.
Note: Running the Compressor without refrigerant charge may reduce the life of the
Compressor and/or damage the Compressor.
3. Immediately repair if the refrigeration system leaks.
Note : do not charge Oxygen, Acetylene or other flammable and toxic gasses into the
refrigeration system when performing the leakage test or an airtight test. Those types of
gas are extremely dangerous because the explosion can occur. It is recommended that
compressed air, nitrogen or refrigerant to be charged for this test.
4. If the unit needs to be recharged, ensure the refrigerant is R-134a.
5. Test all safety components periodically such as protection pressostat.

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