HMD4085 Ess Manual

ENERGY SAVING SYSTEM
INSTRUCTION MANUAL
Ver. 131001R0
PAGE 1 / 92
Contents
1. General Description
1.1 Introduction
1.2 Legend
2. Installation
2.1 Environmental Condition
2.2 ESS Panel General Specification
2.3 ESS Panel Appearance Description
2.4 ESS Panel Install
2.5 Ventilation & Maintenance Space
2.6 Power Cable Selection
2.7 ESS Power Cable Install
3. System
3.1 Type of ESS System
3.1.1 Inverter Mode
3.1.2 By-Pass Mode
3.2 ESS System Interface
3.2.1 Instrument Interface
3.2.2 Remote Control interface
3.2.3 Yard Equipment Interface
3.3 Other System Interface
3.3.1 Field Bus Communication
3.3.2 Hard Wire Interface
3.4 Inverter System Protection
3.4.1 Motor Protection
3.4.2 Inverter Protection
3.4.3 Cooling Seawater System Protection
3.4.4 Panel Electrical Protection
4. Operation
4.1 Operator Interface
4.2 Touch screen Operating
4.3 Preparation of ESS Operation
4.3.1 Mechanical Visual Check
4.3.2 Safety Inspection
4.3.3 Instrument Condition Check & Setting
PAGE 2 / 92
4.4 ESS System Start
4.4.1 By-Pass Mode Start
4.4.2 ESS Manual Control Mode Start
4.4.3 ESS Automatic Control Mode Start
4.4.4 Flushing Setting
4.4.5 Motor Space Heating
5. ESS System Management

5.1 Calculation of Energy Saving
5.2 Alarm
5.3 System Log Trend
5.4 Touch Screen Software Back-Up
5.5 Hardware Maintenance
6. Troubleshooting
6.1 Automation System Trouble
6.2 Starter Section Trouble
7. System Flow Chart
8. ESS Panel Component
PAGE 3 / 92
1. General Description
ESS (Energy Saving System) is computer system to optimize Central Cooling System of
ship.
It saves the Energy by reducing the Fuel Consumption of Ship’s Generator Engine.
In addition, it also reduces the Green House Gas Emission
1.1 Introduction
ESS monitors the temperature of sea water and low temperature fresh water, the position
of 3-way valve and then it controls the speed of main cooling sea water pump to optimize
the capacity of sea water pump, so that it can save the required power consumption for
operating main cooling sea water pump. As result, it reduces the running cost of ship.
For most ships, the aux. machine was designed with sea water temperature 32℃ but
the real sea water temperature is below design, so that thermal capacity of these aux.
machines is increased. It means that the cooling capacity increase in lower
temperature.
In case of central cooling system, the central f.w cooler (a kind of aux. machine) can
cooling down to setting value as 36℃. In other words, the central f.w cooler have more
margin and the 3-way valve open to the by-pass side.
Herewith, this central cooling system is inefficient because the main cooling sea water
pump is always operating 100% load regardless of real sea water temperature.
So, it is clearly necessary to launch the ESS and ESS can give an economy cut in your
vessel.
PAGE 4 / 92
1.2 Legend
ESS : Energy System

Inverter : Motor Speed Control Drive (=VFD)
M.C.S.W : Main Cooling Sea Water
L.T System : Low Temp System
F.W : Fresh Water
PLC : Programmable Logic Controller
HMI : Human Machine Interface (=Touch Screen)
CB : Circuit Breaker
MCCB : Molded Case Circuit Breaker
MC : Magnetic Contactor
OCR : Over Current Relay
AMS : Ship Alarm Monitoring System
ECR : Engine Control Room
SWBD : Switchboard
GSP : Group Starter Panel
T/B : Terminal Board
T/R : Transformer
THD : Total Harmonic Distortion
EMC : Electromagnetic Compatibility
DOL : Motor starting Method / Direct On Line
PAGE 5 / 92
2. Installation
2.1 Environmental Condition
ESS Control Panel is designed to meet the conditions of the ship effect.
However, It is necessary to pay attention to meet the environmental conditions for the
installation of Electric Panel as follows.
 Panel ingress protection Grade (IP) : Standard IP grade 44
Above IP grade 44 is Special Order
 Humidity : 90%
 Ambient temperature : Standard temperature 45℃
 Vibration : Frequency range : 3~25Hz
Amplitude : 1.6 (Peak value)
Frequency range : 25~100Hz
Acceleration amplitude : 0.7g (DNV class requirement)
It is needed to install according to the required condition of guideline for

classification society in addition to the project of ESS panel Environmental conditions.
2.2 ESS Panel General Specification
ESS Control Panel의 Mechanical General Specification

 Panel Type : Self standing type
 Structure :
- Under 100kW : Only front maintenance
- Over 100kW : Front & rear maintenance
 Case material : Mild steel
 Steel Thickness :
- External plate : 2.3t
- Frames : 3.2t X 40 X 40mm / 3.2t X 70 X 70mm
- Inside component arrange plate : 3.2t
- Base sheet & lifting angle : 9t X 100 X 100 mm / 75 X 75mm
 Cable Entry : Standard open coaming
 Color : Project specification
 Electrical character
- THD, EMC Level : Class requirement
- Main input power : Standard AC440V
- Control power : Standard AC220V, AC22V, DC24V
PAGE 6 / 92
2.3 ESS Panel Appearance Description
ESS Panel is divided into Power Section and Control Section as shown drawing.
↑ Control Section ↑ Power Section ↑ Power Section ↑ Power Section ↑
Automation Component such as PLC, Touch screen is installed on the Control Section for
the control of Pump for Energy Saving.
In order to maintain the independent control environment without being affected by the
Condition of Power Section, the supply of separate 220V Control Power is necessary.
At this case, for the stable and continuous system operation, the control power is
supplied with the AC220V UPS Power, DC24V Battery Power.
However, if the Control Section Power is failed, DC24V, AC110V, 220V, 230V Control
Power in general is supplied because of the each Power section System is able to
independently operate.
The same number of power section for motor is installed.
PAGE 7 / 92
Each power section will be supplied with the main 440V. and Control Power is made to
power itself used by internal Isolated T/R.
Even though control section or power section is fail, power section operation of stand-by
state is possible.
Isolation switch is installed on the each power section for the safety of operator, also the
door is opened only when the power is shut off.
Manual switch, indicating lamp and meter are installed on the each power section
because the pump can be operated independently in case of emergency.
- Control section
Component :
1. Touch screen
2. Control switch & indicating lamp
Control section 220V power check
Control section 24V power check
Pump inverter control mode condition

Indicating the status of controlling
the pump using inverters.
Inverter by-pass mode condition

In this case, the pump is forcibly
started by DOL power circuit instead
of the inverter.
Not possible ESS auto control

Indicating the status of disability the
ESS System using the inverters.
Mode select push of pump control

ESS : Inverter operating mode
PAGE 8 / 92
Mode select push of pump control
By-pass : Pump DOL. Start control
AUTO: Inverter is controlled by PLC

for the energy saving.
MANU : Inverter operator manual
Control
Auto control system fault reset

push button.
Button for recovery from ESS
system fault or alarm.
Indicating lamp simulation test

Push button
PAGE 9 / 92
- Power section
Component :
1. Digital power meter
Measuring : Indication each

power qualities which are
kW, kWh, Ampere, Voltage,
etc.,also kWh for check
Energy Saving rate
2. By-pass motor controller

Controller to start the
pump on by pass mode, 1
set for each pump.
3. Control switch & indicating lamp
AC440V main power check
Pump running condition
Starter common alarm lamp

By-pass mode : Overload alarm
Inverter mode : Inverter fail
ON/OFF switch to heat the motor on

stop state.
In order to use the space heater,
the position of switch should be ON.
In case of starting motor, the heater
will be off automatically, in case of
stop the motor, the heater will be off
automatically.
PAGE 10 / 92
The inverter which has had problem
shall maintain Fault condition. In
order to be re-operation, the inverter
reset switch should be used after
solving the problem for inverter.
Pump start button on By-pass

mode, ESS Manual mode
Pump stop button on By-pass

mode, ESS Manual mode
Simulation test button to check the

lamp condition of Power section
Operation to select the auto starting

more for pump on By-PASS-MODE
in case of ESS Fail. (the system will
be change to BY-PASS-MODE
automatically.)
ON : Auto change to By-pass mode
Pump auto start
OFF :Auto change to By-pass mode
Pump manual start.
PAGE 11 / 92
2.4 ESS Panel Install
The set needs based on No.2.l, 2.2 should be checked and then suitable place will be
selected for installation of Electric control panel.
- ESS Panel Lifting

75mm angle is on top side of ESS Panel, it has 4EA of 35Ø lifting hole for moving.
Fitting holes is at bottom side to fix ESS Panel after installation.
- Moving packaged ESS Panel.
- ESS Panel Lifting

4EA of 35Ø lifting hole shall be used for lifting as described as below photo, also
consideration lifting equipment for weight of the panel.
In case of lifting wire, the maximum angle has to be under 30° and some damage is
possible if the angle is over the maximum
PAGE 12 / 92
- ESS Panel Deck Install
100mm Angle for installation ESS panel.
Welding to fix the panel on deck after selection the installation place.
Various ways for installation is possible after technical discussion if requested.
PAGE 13 / 92
2.5 Ventilation & Maintenance Space
- Panel Ventilation
ESS panel controls pumps using inverters. Thus, there should be devices which supply
fresh air or circulate air to make cooling inverters because inverters are heated,
Spot cooling towards ventilation hole of panel is recommended.
In addition, installation of large heating equipments is prohibited in order to long-term use
of ESS panel.
As shown in the fig 2.5.1 below, ESS panel above capacity of 100kW or more is a
structure using of front and rear.
In this case, air Ventilation is needed on the panel's front and rear.
If it is difficult to install ventilation on the panel's front and rear, ventilation must be
installed on the panel's rear which is installed inverters.
Fig. 2.5.1
PAGE 14 / 92
Fig. 2.5.2
- Maintenance Space
For a convenient maintenance of ESS panel, minimal distance is required.

By taking consideration of ESS panel door size, it must not interfere with the door opening
and closing, and the minimum space moving for engineers is required.
.
In Fig. 2.5.1 & Fig. 2.5.2, 700mm minimum amount of space is the minimum amount of
space for repairs of components inside ESS panel.
Thus, By taking consideration of project specification, class rule and ship space condition,
the maximum space is recommended.
PAGE 15 / 92
2.6 Power Cable Selection
ESS system uses invert to control pump’s rpm.

Inverter occurs to noise due to changing AC wave.
There are additional devices and filer to reduce noise generated from the inverter system
because noise can affect power system.
Attention to the selection and installation of ESS panel external field Cable is required as
well.
The field cable recommended by maker should be installed because THD and EMC which
is major factors of noise on inverters are directly related to field cables.
- SWITCHBOARD TO ESS POWER CABLE :

Yard can use the general power cable.
In order for the noise of inverter power system reliability, use the amore cable.
- ESS PANEL TO MOTOR POWER CABLE :

Symmetrical power cable equipped with concentric protection wire and intended for
the specific main voltage. (NKCABLES / MCMK or Similar recommended)
In case of cables between SWBD and ESS panel, the noise can be filtered out, but in
case of cables exposed to noise is between ESS and motor, higher attention is required.
ESS system uses invert to control pump’s rpm.

Inverter occurs to noise due to changing AC wave.
There are additional devices and filer to reduce noise generated from the inverter system
because noise can affect power system.
Attention to the selection and installation of ESS panel external field Cable is required as
well.
The field cable recommended by maker should be installed because THD and EMC which
is major factors of noise on inverters are directly related to field cables.
- SWITCHBOARD TO ESS POWER CABLE :

Yard can use the general power cable.
In order for the noise of inverter power system reliability, use the amore cable.

Symmetrical power cable equipped with concentric protection wire and intended for
the specific main voltage. (NKCABLES / MCMK or Similar recommended)
PAGE 16 / 92
In case of cables between SWBD and ESS panel, the noise can be filtered out, but in
case of cables exposed to noise is between ESS and motor, higher attention is required.
As mentioned item 2.6), installation of field cables of ESS panel requires much attention in
order to reduce noise on inverter system.
Although devices reducing noise are installed on the inverters,
The maximum separation is recommended because it can not be guaranteed in
prescribed noise level of peripheral equipments.
- SWITCHBOARD TO ESS PANEL CABLE :

- Cable length : The maximum length of ESS Panel Power Cable.
There is no restriction of the length of power cable to the ESS panel from yard
switchboard. There is no restriction of length of cable, drop doesn't affect 440V
power system.
- Cable separation : ESS Input power cable and other system signal cable
separation. There is no restriction the input power of ESS panel and cable
separation distance.

- Cable length : The maximum length of motor power cable.
Over motor capacity 2.1HP : 984ft (abt. 300m)
- Cable separation & Distance :
* Motor cable length 0~164ft (abt. 50m) : Maintained over 1ft (abt. 30cm)
* Motor cable length 164ft in excess, 0~656ft (abt. 200m) : 3.3ft (abt. 1m)
separation must be maintained.
- Signal cable, Communication cable, Analog cable must be separated.

Dry contact signal must be separated, because automation I/O of other system
can be affect.
- Power cable of other system motor parallel installation. :

Power factor small influence but low impact, so considering signal cable of other
system separation.
2-3) Other system cable and causing a cross-point maintain a 90° angle.
* Parallel running of cables not applicable.
PAGE 17 / 92
- MOTOR CABLE AND GROUNDING
The most basic guideline within installations is to optimise the physical separation
between interference sources and potentially sensitive equipment. In drive systems,
shielded cables are often the key to appropriate protection, as motor cables are the main
source of interference. Grounding also needs special attention.
The motor cable plays an important role in relation to the electromagnetic interference of
the drive system. With right cable selection interferences can be avoided. The type of the
cable is of particular importance for the radiated emission of the cable.
In the industrial environment a shielded cable is usually sufficient. In public environment,
a cable with a low impedance shield for high frequencies is needed.
We recommend that you use symmetrical three-phase cables with symmetrical phase
conductors, symmetrical PE conductors and symmetrical shield, whenever possible.
Single core cables are not recommended
Fig. 2.7.1
If the cable shield is made of iron, it offers protection from EMC disturbance, but cannot
be used as PE. An iron shield cable can only be connected at the inverter end, and it
must be isolated at the motor end. A separate PE conductor must be used. For EMC
purposes, both ends of the motor cable shield must be 360° grounded.
Grounding may not form a loop, but it must be in star configuration. If there is a potential
difference between the devices, it must be equalised by proper grounding.
Keep the motor cable as short as possible, both inside and outside the drive enclosure.
You can use the shield of the motor cable for grounding purposes when the cross section
of the shield is greater than 50% of one phase conductor. Otherwise, use a separate
ground conductor. If you install components between the motor and the drive, make sure
that the shield is continuous.
The standard EN/IEC 61800-5-1 defines the requirement of the PE conductor as follows:
Fig. 2.7.2
PAGE 18 / 92
3. System
It is a system that controls the Pump using the Inverter, for more stable System
management, ESS System is propose to various Starter Type.
Main Cooling sea water system has a 2set of the stand-by pump at all times, it can be
maintained in a normal state the system to activate the Stand-by pump when the problem
occurred.
ESS System also has a Stand-by Function, it can be stably maintained the system at all
times to activate the Stand-by pump when the problem occurred in the Pump running.
ESS System can be set a variety of Stand-by function by Option, ESS System makes it
possible to maintain the System more reliable.
Auto control of ESS system uses several sensors such as temp. sensors, pressure sensor.
However, in case that panel has some damage or unavoidable condition for saving energy,
the system can be operated by operator.
ESS System uses the Transmitter Sensor for Auto. Control.
However, the unavoidable environment or ignoring the Energy Saving function depending
on the setting of the Operator, By-pass control is possible to use the Pressure Switch
from Full Speed Running status of the Pump.
Also, when the inverter control is difficult by the determination of the Operator,
It is possible to forcibly operate the Pump using the DOL Power Circuit to bypass the
inverter Power line.
Therefore, it is supply with the 4 type of ESS System as below 3.1) using the variety of
Control Concept on the ESS Panel such as Pressure switch, Motor Starting method
change , and so on.
PAGE 19 / 92
3.1 Type of ESS System
Type.1 Type.1
In the most general ESS type,

It is possible to pump control of By-pass mode using the
DOL. Power Circuit and pump control(VFD) without using
the VFD.
The difference from the ESS Type2 is included all function

in order that the St’by start Pump Control is possible at the
By-pass mode.
Therefore, The user is possible to use ESS in case of

connect to the sensors and power supply.
The St’by start function in the By-pass mode is able to

more stable operate on the MCSW system without using
ESS mode.
Type.2 Type.2

the VFD.
It is possible to forcibly pump start using the By-pass mode

in case of not available Inverter system.
At this case, All function is possible to only manual running

by operator.
However, it is possible to Stand-by Control by the logic of

Ship Automation System using the Remote Start/Stop Circuit
of By-pass mode.
PAGE 20 / 92
Type.3 Type.3

the VFD.
It is possible to forcibly pump start using the By-pass mode

in case of not available Inverter system.
At this case, All function is possible to only manual running

by operator.
However, it is possible to Stand-by Control by the logic of

Ship Automation System using the Remote Start/Stop Circuit
of By-pass mode.
Type.4 Type.4
ESS Panel has the same composition with Type.2.
However, pump control can be operate at other system in

By-pass mode.
At this case, it is necessary to interface between ESS
System and Other system.
The general interface signal is Start, Stop, Fault signal

circuit and it can be additionally supply with the necessary
signal for the project.
PAGE 21 / 92
3.1.1 Inverter Mode
Select the “Inverter(ESS)” using the System push button and the operation of
inverter mode is possible when the ESS mode lamp turned light.
This mode is a motor starting method using the inverter for

controlling RPM of the main cooling sea water pump.
In the inverter mode, it is possible to control the pump about the

two type of operating mode.
The two type of Operating mode is as in the following.

- Auto mode (ESS mode)
- Manual mode
3.1.1.1 Inverter Auto mode (ESS Mode)
Inverter Auto mode(ESS Mode) can control the best of the pump rpm for the energy
saving to accept the each value of the sensors that installed on ESS System.
In order to operate ESS SYSTEM, the variety of sensor is used as below.
The three Temperature sensors

1) Seawater inlet temperature sensor (Central cooler inlet)
2) Seawater outlet temperature sensor (Central cooler outlet)
3) Fresh water (LT Water) temperature sensor (3Way valve outlet)
The one Pressure sensor

1) Seawater inlet pressure sensor (Central cooler inlet)
Differential pressure sensor

1) Install each one for each pump
For more information on the use and detailed setting of the each sensors see “Chapter
4.5.3 Instrument Condition Check & Setting”, “Chapter 3.2.1 Instrument interface”
3.1.1.2 ESS Mode Pump Stand-by Control
PAGE 22 / 92
In order to meet to the needs of a classification societyand and stable operation of MCSW
System in Inverter Auto mode (ESS Mode), under the following conditions, Stand-by
control works automatically.
1) Pump starter section main power fail.
2) Pump motor overload
3) Pump inverter fail (Refer to inverter error code)
4) Pump differential pressure low
1 Pump Running / 1 Pump Stand-by operation is general rule in the Pump System.
It is automatically change to the Stand-by Pump when the problem occurred on the
Control circuit or the Pump in running.
2 Pump Running / 1 Pump Stand-by operation is general rule in the 3 Pump system.
It is automatically change to the Stand-by Pump when the problem occurred on the
Control circuit or the Pump in running.
when the more than two pumps occurred fail, it is automatically change to the By-pass
mode.
In order to maximize the Energy Saving, it is possible to maintain the one Pump Running
state rather than two Pump.
3.1.1.3 Inverter Manual mode
Manual mode can control the Pump rpm by the operator regardless of the value of the
sensor or PLC Control logic on ESS System.
However, the operation is impossible below the Low Limit Frequency on the inverter
setting.
In the manual mode, the Pump control is possible that using the Remote Start / stop
button.
Although panel is not installed near to the Pump, Start / stop Operation is possible for the
maintenance or test.
With the utilization of Remote Start / Stop Circuit in using the Manual Mode, Remote Start
/ Stop is possible in the other system. Therefore, the variety of the Pump operation can be
possible in accordance with separately ready to the Control circuit in other system.
However, Frequency control on the inverter is possible in the only ESS System.
Therefore, for the Inverter Frequency Setting, it is can be used only Touch screen of ESS
Panel or ESS Remote Touch screen(*Option).
PAGE 23 / 92
3.1.2 By-pass Mode
Selection “BY-P” by system push button and then “BY-PASS” lamp is on,
By-pass mode is available.
Also, in the ESS System fail, it is automatically change to the By-pass mode.
If ESS system is not able to keep its operation, for example,

inverter is not operated or PLC fail, the emergency back up
function maintain Cooling sea water system
When the By-pass mode is running, the inverter power that offered
to pump is blocked.
And it is forcibly operate a pump using the DOL. Power circuit.
3.1.2.1 By-pass Mode Auto Change & Auto Start
In the inverter mode, it is possible to Auto change to the By-pass mode for the stable
operation of MCSW System.
It is automatically change to the By-pass mode in ESS System Fail Condition.
1) PLC Fail
2) Control section power fail
3) 3 Pump system – 2 Inverter fail / 2 Pump system – 2 Inverter fail
4) 3 Pump system – 2 Pump starter fail / 2 Pump system – 2 Pump starter fail
The pump that is set time count after By-pass auto change is automatically start.
It is automatically start in order of the No.1 Pump -> No.2 Pump -> No.3 Pump.
If the By-pass is controlled in the other system such as type2 and type4, the
automatically start function is not exist.
Configuration of control logic at other system to control “By-pass mode” and then the
signal of start command should be transduction to By-pass Start circuit of ESS panel.
3.1.2.2 By-pass Mode Pump Stand-by Control
PAGE 24 / 92
In the By-pass Mode, Stand-by control is automatically operated in the as follows
conditions in order to stable running of MCSW System.
1) Pump starter section main power fail.

2) Pump motor overload
3) Pump discharge pressure low (*Option)
The selector switch of “SMC

505” controller that installed
the panel is always pointed to
the “Auto change” in order to
use the Stand by control in
By-pass mode.
“SMC 505 Controller”
3.1.3 Black-out Recovery (Sequential Start)
- Inverter mode Black-out recovery
ESS System is able to Black-out recovery depending on the design condition of ship.
When the power has been restored after the Black-out condition of ship, ESS Panel is
running the pump to keep final state.
 Ship power black out

 ESS system off
 Ship power recovery
 ESS system on
 ESS system time count (PLC Program time setting : Ship design spec.)
 Pump start / maintain the same state previous Black out
- By-pass mode black-out recovery
PAGE 25 / 92
It is running to the same sequence about the inverter.
It is necessary to the “SMC505” controller setting for black-out recovery function setting
in By-pass mode.
There is a dial that can be set several functions the

back of the “SMC505” controller. (Fig.3.1.3.1)
Black-out recovery delay Time Setting is possible

By adjusting the dial of Fig. 3.1.3.2,
It is possible to time setting from 3sec to 99sec.
Fig. 3.1.3.1
Fig. 3.1.3.2
PAGE 26 / 92
3.2 ESS System Interface
Several interfaces which are instrument interface, other system interface are requested to
operate ESS, also device instrument interfaces to protect equipment as Fig. 3.2.1.
No.1 block on Fig 3.2.1 is communication with Ship automation system, No2. Block is for
hardwire interface with ship automation system, No.3 block is field equipment interface.
Configurations, roles of each interface are described in this chapter.
PAGE 27 / 92
3.2.1 Instrument interface
Field instrument interface is configured for operation ESS as Fig. 3.2.1.
Fig. 3.2.1
Instruments to input into ESS Control panel are as below.
1) Seawater inlet temperature sensor (Central cooler inlet) / ESTT1

2) Seawater outlet temperature sensor (Central cooler outlet) / ESTT2
3) Fresh water (LT Water) temperature sensor (3Way valve outlet) / ESTT3
4) Seawater inlet pressure sensor (Central cooler inlet) / ESPT1
5) No.1 L.T Cooler Seawater outlet pressure sensor (Central cooler inlet) / ESPT2
6) No.2 L.T Cooler Seawater outlet pressure sensor (Central cooler inlet) / ESPT3
7) Differential pressure sensor for each pump / ESDP1, 2, 3
6) 3 Way valve position / ESVV1
7) Pressure switch / ESPS1, 2, 3
PAGE 28 / 92
- Signal function
1) Seawater inlet temperature sensor (Central cooler inlet) / ESTT1

Signal type : 4~20mA
Temperature range : 0~100℃
Default setting value : 32℃
To check sea water temperature and it has an influence on value for control pump RPM.
It shall be affected decreasing the RPM of pump in case of sea water temperature is
under setting value. In case that sea water temperature is above set value, it is affected
increasing the RPM of pump.
2) Seawater outlet temperature sensor (Central cooler outlet) / ESTT2

To check sea water temperature passed central cooler, it affect value for control pump
RPM. It shall be affected decreasing the RPM of pump in case of sea water temperature is
3) Fresh water (LT Water) temperature sensor (3Way valve outlet) / ESTT3
To check fresh water temperature mixed at 3-way valve, it affect value for control pump
RPM. It shall be affected decreasing the RPM of pump in case of sea water temperature is
* ESTT1, ESTT2, ESTT3, 3 of sensor value are calculated synthetically at PLC in order to
be optimization for energy saving.
PAGE 29 / 92
4) Seawater inlet pressure sensor / ESPT1
Pressure range : 0~6bar
Default setting value : 0.6bar
The setting value for pressure is minimum pressure within the limits of the possible to
pass central cooler. The pressure is above setting point during operation ESS, it’s not
affected to inverter, but it counts 10 sec in case that it’s under setting point.
If the pressure is under setting point after10 sec, ESS controller rises output power
frequency. Pressure is higher 0.1bar higher than setting point, the inverter control by
pressure is stop.
4) No.1 & No.2 L.T Cooler Seawater outlet pressure sensor / ESPT2&3
It is monitoring the L.T Cooler Sea water outlet pressure to check the cooler scale with
sea water inlet pressure. It can check the cooler during the flushing. S/E decides the
setting value during sea-trial. If process value is over the setting value during flushing,
ESS occur the alarm for Cooler maintenance. This is optional alarm. Normal is monitoring
the pressure.
5) Differential pressure sensor

It checks the condition of pump. ESS system is operated with low pressure and to check
differential pressure in order to reduce effect of the pressure change according to ship
draft.
If the pressure is risen up, the status shall be alarm under condition closed filter in case of
filter line which has differential pressure sensor. Pump shall recognize high differential
pressure as right condition. If the pressure us under the setting point, pump shall
recognize as degradation of pump discharging with alarm.
ESS panel change over to Stand-by pump in case of Differential pressure low alarm
6) 3-way valve position

Range : 0~100%
PAGE 30 / 92
Signal for check 3-way valve position at ESS panel, not affect to the function of ESS
system, only for monitoring. If system cooling is declined, cause can be found.
7) Pressure switch
Sensor for Pump stand-by control at By-pass mode.
Please refer to the Chapter 3.1.2.2.
This is option based on yard spec, yard supply scope.
3.2.1.1 Type of Sensor
Refer to “Chapter 8.3 Instrument”for detailed specification of sensors.
1) Temperature transmitter sensor
Element tube type의 transmitter is applied with

ESS system as Fig.3.2.1.1
Boss is applied with seawater pipe to fit the

sensor. Basic spec of install thread type is PT1/2”
Also, various type of thread type is supplied
according to yard specification.
Pocket Length is for check the temperature of

seawater inside of Pipe. Sensor pocket length is
200mm. it’s based on pocket length data( 2/3 of
diameter) from yard as Fig. 3.2.1.1.1
Cable Gland is “JIS15” type for installation cable.

Shield type cable is recommended with Out-
diameter 9~11mm
Temperature sensor specification

- PT100 element type
- Cable gland type : JIS15
- Pocket length : Order spec. (Standard : 200mm)
- Install thread type : Order spec. (Standard : PT1/2)
PAGE 31 / 92
- Protection type : Explosion proof type (ExdIICT6)
- Temperature range : 0~100℃
- Output signal type : 4~20mA analog signal
2) Pressure transmitter sensor
Trafag 8202 type of Pressure sensor is applied.

Thin film on steel type of sensor is applied.
8Ø Pipe connection is applied for sensor, but 10Ø Pipe is

available with special order.
Pipe Connection type is PF3/8”, PT1/2” is supplied as Standard.
Other size is available with special order.
Fig. 3.2.1.1.2
Installation of sensor is Wall mount type as Fig 3.2.1.1.4 of bracket.
Fig. 3.2.1.1.3 Fig. 3.2.1.1.4
Out-diameter of cable for installation on sensor Out-diameter is 9~11mm and

recommend Shield type cable.
Pressure sensor specification

- Thin film on steel type
- Cable gland type : M20
- Pipe connection type : Order spec. (Standard : PF3/8, PT1/2)
- Protection type : IP65
PAGE 32 / 92
- Pressure range : 0~6bar
- Output signal type : 4~20mA analog signal
3) Differential pressure transmitter sensor
Same specification of sensor with Pressure transmitter is

applied
Trafag 8024 type of Differential pressure sensor is applied.
8Ø Pipe connection is applied for sensor, but 10Ø Pipe is

available with special order.
Pipe Connection type is PF3/8”, PT1/2” is supplied as
Standard. Other size is available with special order.
Fig. 3.2.1.1.5
Installation of sensor is Wall mount type as Fig 3.2.1.1.7 of bracket.
Fig. 3.2.1.1.6 Fig. 3.2.1.1.7
2 line of seawater should be input into sensor in order to check differential pressure.
Sensor has P1, P2, 2 sets of port, P1 is for pump suction line, P2 is for pump discharge
line. For the rest, the specification is same as the pressure sensor.
3.2.2 Remote Control interface
2 of option items for Remote control are available.
PAGE 33 / 92
1) Remote touch screen
2) Remote start / stop push button box (RPB)
3.2.2.1 Remote Touch Screen
Same touch screen from attached screen on panel is applied. All system is operated on
Remote touch screen. (Refer to “Chapter 8.2 Automation Component” for Device of
detailed Specification.)
Touch screen type is Schneider HMIGTO5310을 사용한다.

Main specification.
- 65536 colors
- 10.4 inch
- 640 x 480 pixels
- Back lifespan : 50000 hour
- Power consumption : DC24V, 17W
- Ambient operating temperature : 55℃
- IP degree of protection : Front surface / 65, Rear / 20
Installation space for Remote touch screen can be ECR consol, Panel of control room and
Consol. it should be installed vertically, also available until 30°. If it’s more 30° ventilation
has to be installed inside of panel. For example, in case of installation as Fig. 3.2.2.1.1 or
the temperature inside of panel is under 30℃,
ventilation is not requested.
Fig. 3.2.2.1.1
PAGE 34 / 92
Fig. 3.2.2.1.2
Wiring of Remote touch screen is as Fig. 3.2.2.1.2.
Cable from ESS Panel terminal block to yard panel is recommended to apply shield cable,
it is supplied by Yard. Cable from panel terminal block to touch screen is supplied by
maker, Cat.5e class of UTP LAN cable is applied and supplied by 5m.
3 UTP cables are used for RS485 communication.
(Blue : + , Blue/White : -, Brown : E)
DC24V should be supplied with Remote touch screen, DC power cable need to be Twist
for reducing noise. DC Power cable size is between 0.75mm~2.5mm.
Connector for supplying power with touch screen is as Fig. 3.2.2.1.3.
+ : 24V / - : 0V / FG : Grounded terminal connected to the panel chassis

Fig. 3.2.2.1.3
The terminal lug of cable is pin type,
Fig. 3.2.2.1.4 Cable connection by pressing the operating button is

available in Fig. 3.2.2.1.4.
Fig. 3.2.2.1.4
PAGE 35 / 92
3.2.2.2 Remote Start / Stop Push Button Box (RPB)
RPB is installed for controlling manual start / stop of pump,

RPB can be installed in the adjacent to pump.
There are not constraints on installation location of RPB. Hence, RPB can be installed for
operator’s convenience of any place.
If start / stop signal is matched, all switch type can be installed.

Start : Normal open contac / close contac -> Motor start
Stop : Normal open contac / close contac -> Motor stop
Fig. 3.2.2.2.2 Switch box and the circuit

is configured to connect to the ESS is
available
Switch box which is configured to circuit
of Fig. 3.2.2.2.2 can be used on
connecting on ESS
Fig. 3.2.2.2.2
Maker can supply RPB as option.
RPB supplied by maker is as Fig. 3.2.2.2.3.
Material : steel
IP degree of protection : 44
Green start button / Red stop button / Green run lamp
Yard Cable out-diameter : 10 ~ 15mm
RPB 1set per unit is supplied with a Pump 1set
Fig. 3.2.2.2.3
The controlling on pump using RPB can be start / stop on Inverter manual
mode and By-pass mode. In inverter auto mode, operators are not
possible to control pump because the controlling on pump is automatically
controlled by ESS PLC.
PAGE 36 / 92
3.2.3 Yard Equipment interface
ESS panel consists of yard’s equipment controlling circuit needed in cooling seawater
system.
Yard equipment interface circuit is installed in starter section(inverter section) on ESS
panel.
The main interface of Cooling pump system is as follows:
- Pump motor power supply

- Pump motor heating power supply
- Pump air ejector or priming unit power supply
- Pump motor PTC Temperature sensor signal input
Heating power supply :

Maker standard is supplied to the heating element type.
In case of winding heating, it should be mentioned and reflected in the contract stage.
Winding heating effect can be reflected at the time that the contract should be mentioned
in step.
PTC sensor :
PTC sensor is installed for overheating protection.
Please refer to chapter 3.4.1 for more details.
PAGE 37 / 92
3.3 Other system Interface
ESS panel provides interface for remote control or monitoring in other system.
2 kinds of interface type is provided as maker standard.
1) Field bus communication (RS485 Modbus communication)
2) Hard wire interface (on / off contactor signal)
3.3.1 Field Bus Communication
ESS panel uses Field bus communication of RS485.

In case of needed in communication of other type, it should be indicated in Project order
spec.
For stable operating of ESS system, communication data is provided with only monitoring
value. Kinds of data are as table 3.3.1.
(*Please refer to the separate project alarm list in case of non-standard interface signal.)
N Typ Norm From/ ICMS Chan Rem
Description Text
o. e al To nel ID ark
No.1 PUMP BYPASS/INVERTER STAT INVERTER/BY BYPA

1 Bool To
US PASS SS

2 Bool To
US PASS SS

3 Bool To
US PASS SS
No.1 INVERTER AUTO/Manual STAT AUTO/MANU MAN

4 Bool To
US AL UAL

5 Bool To
US AL UAL

6 Bool To
US AL UAL
7 No.1 PUMP RUN/STOP STATUS Bool RUN/STOP STOP To
FLUSHING/OF
10 No.1 INVERTER FLUSHING STATUS Bool OFF To
F
FLUSHING/OF
F
FLUSHING/OF
F
LOCAL/REMO LOCA
13 LOCAL/REMOTE STATUS Bool To
TE L
PAGE 38 / 92
FAULT/NORM NORM
14 No.1 INVERTER FAULT STATUS Bool To
AL AL
FAULT/NORM NORM
AL AL
FAULT/NORM NORM
AL AL
HIGH/NORMA NORM
17 FW WATER HIGH TEMP ALARM Bool To
L AL
HIGH/NORMA NORM
18 SW INLET HIGH TEMP ALARM Bool To
L AL
HIGH/NORMA NORM
19 SW OUTLET HIGH TEMP ALARM Bool To
L AL
HIGH/NORMA NORM
20 NO.1 PUMP HIGH TEMP ALARM Bool To
L AL
HIGH/NORMA NORM
L AL
HIGH/NORMA NORM
L AL
LOW/NORMA NORM
23 NO.1 DP LOW ALARM Bool To
L AL
LOW/NORMA NORM
L AL
LOW/NORMA NORM
L AL
LOW/NORMA NORM
26 SW INLET PRESS LOW ALARM Bool To
L AL
STARTED/OF
27 NO.1 INVERTER STANDBY STARTED Bool OFF To
F
STARTED/OF
F
STARTED/OF
F
HIGH/NORMA NORM
30 NO.1 INVERTER HIGH TEMP ALARM Bool To
L AL
HIGH/NORMA NORM
L AL
HIGH/NORMA NORM
L AL
NO.1 L.T COOLER OUTLET PRESSURE LOW/NORMA NORM

33 Bool To
LOW L AL
PAGE 39 / 92
NO.2 L.T COOLER OUTLET PRESSURE LOW/NORMA NORM
34 Bool To
LOW L AL
WO
35 SW INLET TEMP. 0 ~ 100℃ To
RD
WO
36 SW OUTLET TEMP. 0 ~ 100℃ To
RD
WO
37 FW OUTLET TEMP. 0 ~ 100℃ To
RD
WO
38 FW INLET TEMP. 0 ~ 100℃ To
RD
WO
39 BY-PASS V/V OPEN POSITION 0 ~ 100℃ To
RD
WO
40 NO.1 PUMP DP 0 ~ 6 bar To
RD
WO
RD
WO
RD
WO
43 SW INLET PRESSURE 0 ~ 6 bar To
RD
NO.1 L.T COOLER OUTLET PRESSUR WO

44 0 ~ 6 bar To
E RD
NO.2 L.T COOLER OUTLET PRESSUR WO

45 0 ~ 6 bar To
E RD
NO.1 INVERTER MANUAL MODE REF WO

46 0 ~ 60Hz To
ERENCE HZ RD

47 0 ~ 60Hz To
ERENCE HZ RD

48 0 ~ 60Hz To
ERENCE HZ RD
INVERTER ESS MODE REFERENCE H WO

49 0 ~ 60Hz To
Z RD
WO
50 NO.1 INVERTER ACTUAL HZ 0 ~ 60Hz To
RD
WO
RD
WO
RD
WO
53 NO.1 INVERTER SAVING RATE 0 ~ 100% To
RD
PAGE 40 / 92
WO
RD
WO
RD
WO
56 TOTAL SAVING RATE 0 ~ 100% To
RD
WO
57 NO.1 PUMP USING KW 0 ~ 200KW To
RD
WO
RD
WO
RD
Table 3.3.1
3.3.2 Hardwire Interface
Hardwire interface is provided to check remote control and status of ESS panel.
Basically, kinds of signal provided are as table 3.3.2.
(*Please refer to the separate project alarm list in case of non-standard interface signal.)
No.1 pump run Contac close : run
No.1 pump common alarm Contac open : alarm
No.1 pump by-pass mode stand-by start Contac close : stand-by started
ESS system common alarm Contac open : alarm
Inverter mode selected Contac close : selected
By-pass mode selected Contac close : selected
No.1 pump start command input Contac close : start
No.1 pump stop command input Contac close : start
No.2 pump start command input Contac close : start
No.2 pump stop command input Contac close : stop
No.3 pump start command input Contac close : stop
No.3 pump stop command input Contac close : stop
PAGE 41 / 92
3.4 Inverter System Protection
There are protecting functions for stable operating of ESS system in ESS panel.
In ESS system, there are 4 kinds of protection.
1) Motor Protection
2) Inverter Protection
3) Cooling Seawater System Protection
4) Panel Electrical Protection
3.4.1 Motor protection
There are 2 type of motor’s protecting function following operating mode in ESS system.
1) Inverter mode protection :
There are various motor’s protecting functions in inverters.
- Over current protection
- Over/Under voltage protection
- Line fault protection
- Earth fault protection
In inverter mode, inverters protect motors through inverter’s functions.
2) By-pass mode :
Thermal type over current relay (OCR) is installed in ESS panel.
Trip point of OCR sets motor’s rating current.
Trip signal is output from OCR in case that 1.1~1.2 times more of current are flowing
caused by overload pump.
Trip time of OCR depends on the characteristic’s curve of each product.
Hence, OCR installed in ESS panel is used

OCR used in ESS Panel is used for the Marine class type’s products to ensure the
reliability of performance.
3.4.2 Inverter Protection
There are various protecting functions in inverters.

devicess that satisfying the Protection function requested by he IEC and other Marin class
are used. It is possible to check alarm code on inverter keypad in case of protection alarm.
Please refer to inverter manual for details.
PAGE 42 / 92
3.4.3 Cooling Seawater System Protection
ESS panel is for saving energy. Hence, cooling seawater system always keeps the
minimum cooling condition.
But, a case of keeping normal status of cooling system occurs according to ship’s
condition, cooler’s condition and 3-Way valve’s condition.
Hence, the status of seawater and LT fresh water should be checked.
1) Seawater outlet temperature protection (Cooler outlet temperature)

Normally, ESS system supplies coolers the minimum flow rate.
In case seawater outlet temperature is higher than setting value, pumps are operated with
full load till seawater outlet temperature is lower than setting value.
2) LT Fresh water temperature protection (3-Way valve outlet)
If fresh water temperature needed in LT system is not maintained and getting up, pump’s
rpm should be raised until the temperature is down.
3) Seawater inlet pressure protection (Cooler inlet)
if the minimum seawater’s pressure is not maintained to pass coolers, pump’s rpm should
be raised and do not control energy saving.
3.4.4 Panel Electrical Protection
Various devices are installed for protecting electric on ESS panel.

- Isolation switch handle :
In case of Voltage On, doors can not be opened by operators.
If doors should be opened for maintenance, it is only possible under power off.
- MCCB (Molded case circuit breaker) :
MCCB is installed to not effect ship power system when short circuit is occurred on the
ESS system main power line.
MCCB should be installed to cut main power of each starter, and can be cut main
power in status of switch off due to connection with isolation switch.
- Fuse
HRC cartridge type fuses are used in ESS panel with excellent compatibility, and easy to
change. Fuses are separately installed per electrical circuit.
For example, main power is not going to shut off due to lamp’s errors.
PAGE 43 / 92
4. Operation
ESS panel can be operated through auto control setting and manual operation to save
energy by operator.
Panel is divided with control section and power section(inverter section).
Various setting and mode can be choosing to save energy on control section.
Power section is operated by controlling starter panel which is included in starter circuit.
And the status of starter panel and the quality of power can be checked. Thus,
independent operating can be operated through by-pass on the ESS control section fail
condition, and can be operated with minimum seawater system.
There are various interface devices of easy control for operator in Fig 4.1.
↑ Control section ↑ Power section ↑ Power section ↑ Power section ↑

Fig. 4.1
PAGE 44 / 92
4.1 Operator Interface
- Mechanical operating switch & lamp :Refer to Chapter 2.3 “ESS Panel
Appearance description”
* Indicating lamp
- To easily check the status of ESS panel by operator.
- It is possible to check the status of ESS panel through lamp’s
color and lighting.
Lamp’s color applied for ESS panel is determined based on

project specification, and Standard color is determined based are as follows:
1) Power on : white (Lamp on = Power on / Lamp off = Power fail)

2) Running : Green (Lamp on = Motor running / Lamp off = Motor stop)
3) Heating : Blue (Lamp on = Heating power on / Lamp off = Heater power off)
4) Mode : White (Lamp on = Mode selected / Lamp off = Mode not selected)
5) Alarm : Red (Lamp on = Alarm condition / Lamp off = Normal condition)
Operating voltage of lamp is AC220V and LED type is used due to life time and good
visibility. It can be easily replaced when lamp occur defects.
Refer to the Chapter "5.6 Hardware Maintenance" for how to maintain.
* Push button
Push button of full guide type to prevent malfunction due to
interference is used.
Push button of Push / Release type is used.

Push button’s Color is determined according to purpose of use.
1) Start : Green
2) Stop, Reset : Red
3) Mode select, Lamp Test : Black
* Selector switch with lamp

It is used for space heater control.
Select the position of selector switch turning left/right, and
lamp of handle turn during actual operation.
The lamp used selector switch with lamp can be used for other
lamp on the panel
The color of handle is determined based on project
specification. Blue is standard color of ESS Panel.
PAGE 45 / 92
- Running hour counter
This device is to count running time of pump

5 digit type of counter is used and counted to 99999 hours.
Rotary indicator is installed to check the status of counter operating.

Rotary indicator slowly rotates when power goes to counter, and the status of counter
operating can be checked.
- Power meter
Power meter is installed to check power quality including

ampere meter.
The function of watt hour meter is included in power meter
so that operator can easily check the saved amount of
power as applied for ESS.
The important data of power meter can be checked on the
touch screen by communicating with ESS PLC.
Refer to PM1000 User manual of Chapter “9.2 Automation
Component” on how to use and the detailed of power meter.
- Touch screen : Chapter 4.2 “Touch screen operating”
ESS system uses automatic control using PLC.

Touch screen is used to check the status of ESS system and to
input setting value.
Installation of Remote Touch screen is available in order to
make easy to operate ESS
Refer to the Chapter “3.2.2.1 Remote touch screen”, “4.2 Touch screen operating”, “9.2
Automation Component” on the manual.
PAGE 46 / 92
4.2 Touch screen Operating
Touch screen to control the ESS System consists of a total of seven pages(Monitoring
page, Setting page…)
1) MONITORING page : this page is to control ESS System and to check the status of
sensor and data.
MONITORING page consists of 3 parts.

- Title section
– System monitoring section
- Control section
The control mode and circuit condition confirmation of ESS panel can Title section.
ESS system is controlled by touch screen in panel.
ESS system is controlled by touch screen in remote.
ESS system is controlled by Auto mode
PAGE 47 / 92
ESS system is controlled by Manual mode
ESS system is controlled by by-pass mode.
ESS system is controlled by inverter mode.
ESS system is controlled by GSP button.
Any mode is not selected. Operator can use it for maintenance.
ESS system is impossible to control as fail condition.
- System Monitoring section
ESS System operation condition and each sensor value and pump operating condition can
be confirmed by System monitoring section.
The status of pump is displayed.

Green color turns on when motor is running.
Running : Green
Stop : Gray
Stand-By : Yellow
Fault : Red
Yellow box : The value of differential pressure sensor installed in

pump is displayed.
PAGE 48 / 92
Each sensor value is displayed on Monitoring page.
1) Seawater inlet temp : The value of temperature sensor installed in seawater inlet
pipe (Central cooler inlet) is displayed.
2) Seawater outlet temp : The value of temperature sensor installed in seawater
outlet pipe (Central cooler inlet) is displayed.
3) Seawater inlet pressure : The value of pressure sensor installed in seawater inlet
pipe (Central cooler inlet) is displayed.
4) No.1 cooler seawater outlet pressure : The value of pressure sensor installed in
seawater outlet pipe(No.1 central cooler outlet) is displayed.
5) No.2 cooler seawater outlet pressure : The value of pressure sensor installed in
seawater outlet pipe(No.2 central cooler outlet) is displayed.
6) Freshwater outlet temp : The value of temperature sensor installed in fresh water
outlet pipe (3-Way valve outlet) is displayed.
7) Freshwater inlet temp : The value of temperature sensor installed in fresh water
inlet pipe (central cooler inlet) is displayed.
8) By-pass valve position : The position of 3-way valve is displayed.
- Control section
Pump can be controlled by control section.

Normal color is gray. The color of clicked most buttons are changed to Green color
except stop & system reset button. The color of clicked their buttons are changed to Red
color.
This button can be clicked for controlling in Local panel.

This button can be clicked for controlling in ECR.
This button can be clicked for inverter mode.

This button can be clicked for by-pass mode.
This button can be clicked for auto mode in inverter mode.

This button can be clicked for manual mode in inverter mode.
PAGE 49 / 92
This button can be clicked for auto start.
This button can be clicked for auto stop.
This button can be clicked for resetting the inverter fault.
Pump is known condition by setting and lamp for auto

control of ESS system.
This meter is operated according to the

inverter output frequency.
Frequency, Ampere, kilowatt value,

Energy saving rate -> meter display
Motor starter section power on of ESS panel

Red color condition -> White color display.
Inverter trouble ->red color / Pump panel is displayed Alarm.
Motor high temp. is occurred ->red color / Pump panel is
displayed Alarm.
Operating Flushing mode of ESS system-> White color
Pump state -> Running : Green, Stop : Gray, Stand-By : Yellow,
Fault : Red
Operating Air ejector-> Green color
This is a push button with lamp to select leading pump and following. The
operating time can be controlled by using an appointed pump. The
st
selected pump as “LEAD” will be main pump, the selected pump as “1
nd
st-by” will have function of Following. The selected pump as “2 st-by”
will have function of stand-by.
this is possible to use Inverter manual mode

the operated behavior of pump control can
control to start/stop as push button and frequency input.
This menu bar is for change to next page. Push button with lamp.
When push this button, moving to next page and turns on green lamp.
PAGE 50 / 92
2) ALM SET (Alarm setting) : This page is to set alarm point of sensor, measuring value of
ESS system.
Title of measuring value of a party is displayed, in-put “SV” and set.

SV : Alarm point setting value in-putted by operator.
PV : The measuring value of sensor in-putted to ESS controller.
When the sensor measuring value in-putted in ESS system is

normal, green color turns on, and red color turns on when the
sensor measuring value is out of alarm point.
*Pressure and differential alarm occurs when low pressure is maintained for 1 minute after
running pump.
PAGE 51 / 92
3) ALM HISTORY (Alarm history) : Function to check the history of alarm for ESS System
Alarm history page consists of List table to indicate what kind of alarm and button for
control alarm.
Alarm list table indicate occurrence time of alarm, kind of alarm, recovery time of alarm
and alarm check time.
Button to control alarm consists with as below.
Check all alarm contents / check content of the selected alarm 1 unit
Move one step up and down of decided alarm cursor
Alarm history page UP / DOWN move button
Check alarm deletion / all alarm deletion
Storage SD memory card for check the computer to alarm history

contents
PAGE 52 / 92
4) LOG TREND : Saved main operation date value can be checked on the log trend. LOG
TREND consists of 5 pages with ESS system sensor value and other page to check, save
motor data (kW, Frequency, Save rate). The operation status can be checked in change
operation condition.
No.1 Log trend page : No.1 Sensor log trend.

This page, record to All sensors value per 10 seconds.
Storage input value of all sensor installed

Can decide to sensor type as Graph line color.
Push “View log table” button-> Pop up window and can see any
sensor value as each line color
PAGE 53 / 92
Log count window -> once a log record for one second and once a log SD
card record for one hour. From 0 to 4320 count.
After record SD memory card, from 0 to 4320 count again
Push this button -> Change the display between No.1 sensor and
No.2 sensor.
Push this button -> Save to file directly and reset the Log count window as
“0”.
Push “ Set date & time” button -> Pop up window as below.
Operator can set the current date & time.
PAGE 54 / 92
No.2 Log trend page : No.2 Sensor log trend.
PAGE 55 / 92
No.3 Log trend page : No.1 Pump data log trend.
This page, record to power of Pump motor, Inverter output frequency, total energy saving
rate per 10 seconds.
Push this button -> Change the display from No.1 pump
to No.3 pump.
PAGE 56 / 92
PAGE 57 / 92
PAGE 58 / 92
5) ENERGY MONITOR page : This is to set for auto controlling of ESS system.
This page can set and monitor the pump energy saving calculation.
PAGE 59 / 92
Need to set value input for calculation.
Set value of saving rate calculation -> KW consumed By-pass
mode.Before Inverter in ESS system control, operated By-pass
mode -> input each pump kW value.
Displayed consuming kW
kW value-> displayed power meter install Starter section.
Displayed total consuming KW since the delivery.
Displayed the running hour for by-pass mode operation.
Displayed the running hour for inverter mode operation.
Displayed the saving rate based on the C.S.W pump kw SV.
6) ENGINEER SETTING page : This page can set the all parameter for ESS control.
Therefore, there is a password input display to block the easy access.
Operator should input the password and click

the OK button to move the ENGINEER SETTING
page.
PAGE 60 / 92
-ENGINEER SETTING section
Operator can input the setting value for each temperature. Another values can not be
changed.
-INVERTER LIMIT Hz SETTING section
This value set the minimum frequency. Inverter cannot operate below this value.
- Auto Flushing setting section
PAGE 61 / 92
FLUSHING :This page is for setting flushing function of ESS System
Flushing function -> Can Activation or not by operator decision
Push Button-> changed “Green” color
* Periodic Mins : the cycle of flushing running can be set
* Pump run time : Time to operate flushing is counted.
After setting periodic hours, select Auto mode and then time is counted, flushing is
starting.
- Two inverter on/off setting section
This section setting -> ESS controls the pump running according to sensor temperature.
On Hz SV : When running Hz is over this setting, Two pump will be operated.
Off Hz SV : When running Hz is below this setting, Only one pump will be operated.
- D.P low auto change setting section
This section setting->DPT(Different pressure transmitter) sensor value installed each

pump
DPT installed Each pump use to pump change over. If pressure is lowered below setting
value, after setting time, change over stand-by pump.
Can Input change over value for DPT sensor setting Stand-by pump
SV : DPT Setting value for Stand-by pump change over
- Inverter sequential start time setting section
Operator can set the sequential time.

If operator want to change all SV to factory setting, please click the button.
PAGE 62 / 92
4.3 Preparation of ESS Operation
Several important matters have to be checked before operating ESS.

ESS can be operated in correct connection for electric wire and panel status
4.3.1 Mechanical Visual Check
Automation components which are PLC touch screen, inverter are installed at ESS panel.
So, visual inspection is requested before system start because damage can be occurred
during move, installation
Panel Outside : Crack, damage of steel case shall be checked, also each component
installed on panel door.
Panel Inside : Installation of status for each component shall be checked, also
unseated as all most component is kind of DIN rail type.
Also, status of bolt shall be checked by torque wrench in case of heavy such
as inverter. In case of power cable, it can be checked by paint marking.
PAGE 63 / 92
4.3.2 Safety Inspection
Safety inspection should be checked before power on ESS.

Insulation condition of electric panel can be checked by mega ohm tester.
Test Line check the power line. Several matters need to be checked before insulation test.
→ Main circuit breaker off
→ Control fuss off
→ Earth cable connection condition
→ Test according to Fig. 4.5.2.1 Check point
→ Earth to switchboard power cable check
PHASE to PHASE BEFORE ( MΩ )

R Phase to Earth MΩ DC500V
S Phase to Earth MΩ DC500V
T Phase to Earth MΩ DC500V
→ Earth to motor power cable check
PHASE to PHASE BEFORE ( MΩ )

R Phase to Earth MΩ DC500V
S Phase to Earth MΩ DC500V
T Phase to Earth MΩ DC500V
→ Fuse shall be back to original status after

checking correct insulation level.
Fig. 4.5.2.1
PAGE 64 / 92
4.3.3 Instrument Condition Check & Setting
Sensor of connection to whole system shall be checked before supplying power with
panel. Please refer to the terminal diagram on panel drawing.
* Terminal number can be different according to project.
Fig. Terminal drawing
Fig. Panel의 Terminal block
Check method is as below.

Panel of terminal block 401, 402 should be connected with ESTT2 Sensor cable
→ To check TAG for ESTT2 of yard cable

→ Yard cable core number 1 is 401terminal connection, core number 2 should be to
No.402
→ To check ESTT Sensor terminal
→ “+” terminal에는 Yard cable core number 1 connection
→ “-“ terminal에는 Yard cable core number 2 connection
PAGE 65 / 92
4.4 ESS System Start
Initial start of ESS System is possible after check Chapter 4.3
1) ESS control section system start
→ ESS/BY-P. mode push button

→ ESS Control section main power circuit breaker on
→ PLC power condition check (PLC lamp on check)
→ Fuse condition check
→ Power on lamp check
→ Touch screen power on
→ Sensor and each input value check on touch screen
2) ESS Power (Inverter section) power on
→ Motor space heater switch off

→ Door close
→ Isolation switch (Main power circuit breaker) on
→ Power on lamp check
→ Voltage check (ex. AC440V) on power meter
3) ESS System Check
→ ESS control section “Reset“ button push

→ ESS system normal condition check
→ ESS control section alarm lamp off check
Until here, ready for starting ESS is finish.
PAGE 66 / 92
4.4.1 By-Pass Mode Start
Condition for motor power cable, pump condition shall be check by By-pass running.
→ ESS Control section의 By-pass mode push button :

By-pass position
→ Motor controller installed on door of power section (SMC505) LED
lamp on.
→ Select Motor controller (SMC505)의 mode selector switch to Manual.
Fig. 4.4.1.1 Motor controller mode selector switch
→ Space heater selector switch “ON” position

→ Space heater selector switch lamp on check
→ “Pump start” push button push
→ “Pump run” green lamp on
→ Space heater selector switch with lamp off
→ Check condition of pump by noise, vibration

→ Same method shall be applied with No.2, No.3 Starter panel as By-pass starting
→ After By-pass mode, Motor controller (SMC505)의 mode selector
Switch shall be Auto change
PAGE 67 / 92
4.4.2 ESS Manual Control Mode Start
PLC, Touch screen, Inverter and condition, communication of automation component

shall be check through manual operation status before auto control.
ESS Automatic control is available under condition of no problem at manual mode.
→ ESS Control section ESS mode selector switch :

ESS position
→ ESS Control section Inverter MANU / AUTO selector switch :

Manu position
Push ”Hz”->input Inverter output frequency

Push Start / Stop button-> Pump control
Accordingly frequency set is entered by operator, can control pump rotating speed.
* Operator can start/stop the pump by pushing start/stop on HMI or in panel or at R.P.B in
Manual mode.
4.4.3 ESS Automatic Control Mode Start
Control mode for electric power saving of cooling seawater pump system.
ESS automatic control is available after manual mode operation.
For Automatic mode control, several set should be done by touch screen.
Select Alarm setting page.
PAGE 68 / 92
Input alarm point setting for each sensor
1) Freshwater inlet temperature high alarm :
2) Freshwater outlet temperature high alarm
3) Seawater inlet temperature high alarm :
4) Seawater outlet temperature high alarm :
5) Seawater inlet pressure low alarm :
6) No.1 Seawater outlet pressure low alarm :
7) No.2 Seawater outlet pressure low alarm :
8) No.1, No.2 & No.3 pump differential pressure alarm :
9) No.1, No.2 & No.3 inverter temperature high alarm :
PAGE 69 / 92
Select monitoring page.
st nd
Button to select lead pump or 1 st-by pump or 2 st-by by push button.
Lead selected pump is always to operate until pump occur the fault or
another pump is selected as “Lead”.
st
1 st-by selected pump is to operate while running Hz is over On Hz SV
or Lead selected pump occur the fault.
nd st
2 st-by selected pump is to operate while 1 st-by selected pump
occur the fault.
→ ESS Control section Inverter MANU / AUTO selector switch :

ESS position
→ Push Auto start button -> start Automatic control of ESS system
PAGE 70 / 92
4.4.4 Flushing Setting
Cooling system is operated with minimum pressure after application ESS, so seawater is
passed central cooler very slow and low pressure. It can be cause of creation scale and
blockage of waterline, so ESS system has flushing function.
Flushing cycle shall be set in order to use flushing function and then it will be started
according to setting value, time.
Inverter operation under flushing is as below.
Control for energy saving is blocked after flushing mode, operation pump will be with full
speed, it make get scale out.
Select Flushing setting. Please refer to the “4.2.6) ENGINEER SETTING”
Input time at orange color of “Periodic time” and “Pump run”. Setting time.
For example, Period 1440, time is 60, it will be operated as 60sec/24hour.
Push the select button after enter the time for flushing.
Push “Flushing Activate” button -> changed “Auto control” and

started flushing auto control
PAGE 71 / 92
4.4.5 Motor space heating
The motor is heated in state of the stop in order to prevent frostiness.

The two type of the heating circuit is supplied in accordance with the moter option.
The motor space heating method is as below.

1) Element type heating (maker standard type) :
This method is applied to a motor that uses an additional heater device installed on it
for heating in the stop state.
Turn “ON” the Selector switch installed in the Inverter section, it will work
automatically.
Shut off the power supply to the heater when the motor is running. Wait until
the motor stops, and then supply AC220V to heat the motor. In case of the
motor running state, the power supply of the heater is blocked.
2) Winding heating type :

It is a method for the motor heating without the install of the heating device at the motor.
The low voltage is supplied to the winding of the motor in order to heat to use self
heating.
The time delay is required for ON / OFF operation Because the low voltage that supplied
to motor winding is a risk of generating a Short circuit and low voltage Main AC440V
voltage .
In the case of motor stop state, the winding heating power is supplied after 20~30
second.
You need to have some delay time for the motor to prevent the short circuit that may be
caused by the voltage and heating power generated by the motor in the stop state but
idling with inertial force.
In case of the Winding Heating type, you will also need to have a short delay time for
the motor when starting it.
Such delay time is required to prevent the AC440V main power short circuit that may be
caused by the back electromotive force generated at the point of the heating power
cut-off.
Therefore, it works after 1~2 second delay time when it comes to Motor start.
The Winding Heating type requires the supply of high current/low voltage, and this will
demand you to have a bigger panel for the motor than you applies the Element Heating
type for it.
PAGE 72 / 92
5. ESS System Management
In this Chapter, you will be explained about the management of various data that you will
need for the operation of the ESS system as well as the maintenance of the system for
the stable operation of it as long as possible.
5.1 Calculation of Energy Saving
You can check how much you have saved energy during the entire period of the ESS
System operation.
Running time X By-pass power consumption =①

Running time X ESS power consumption = ②
①-② = Saving power
Can see Energy Monitor page.
PAGE 73 / 92
5.2 Alarm
All the ESS System alarms are saved in the Alarm History page on the Touch screen.
This will be a help for you to check the Alarm History on a regular basis and use the ESS
Panel as long as possible no matter if you have trouble with the ESS Panel or not.
The ESS System Alarms are widely categorized into 2 types.

One is the Alarm that displays the Warning status only, not causing any trouble with the
continuous operation of the ESS system. The other is the Alarm that stops all the
functions of the system along with the ringing of the Alarm.
1) Warning alarm
The main target of this alarm is the temperature sensor installed on the cooling system.
In case of the freshwater, seawater inlet/outlet temperature high alarm, the system
operation is continued with the supply of more sea water by increasing the inverter output
frequency to decrease the temperature of the High alarm section.
The seawater inlet pressure low alarm indicates the low pressure state of the inlet line.
Therefore, the system shutdown may cause a more dangerous consequence.
PAGE 74 / 92
To cope with this situation, you need to continue the operation of the system if it is still
running and increase the inverter output frequency to get higher pressure.
In case of the Warning alarm, you need to check the Alarm History on a regular basis that
you might not otherwise know about it.
False alarms may ring due to unstable surrounding environments or equipment reactions.
However, you need to note that normal alarms ringing due to the system instability or
failure may cause serious trouble with the stable operation of the system as well as the
lifespan of equipments.
For example, If you have the seawater outlet temp high alarm, you can check the alarm-
ringing time and diagnose the problem by checking the temperature of various sensors
and the inverter output frequency recorded in the log trend for the corresponding time
zone.
If the seawater inlet temperature is high or the fresh water outlet temperature is very high
at the point when the corresponding alarm rang, you may conclude that this is not a
serious alarm that rings in the ordinary course of ESS control.
However, if the log trend data indicates that there has been no or insignificant change of
Inverter output frequency, you need to check the state of the control logic, the inverter or
the pump. Therefore, you need to establish an alarm check and maintenance plan and
execute the plan on a regular basis.
2) Trip Alarm
If you keep the corresponding function working in spite of the Alarm ringing, you may
have the trip alarm that causes serious trouble to the system.
The trip alarm generates the common alarm or individual alarm signal from the
corresponding pump and transmit this signal to the external systems such as the ship
automation system.
If you have the trip alarm, you need to check the state of the ESS panel as quick as
possible and take a corrective action according to the trouble shooting manual.
PAGE 75 / 92
5.3 System Log Trend
The log trend records the sensor and inverter operation data generated in the course of
the ESS System operation.
The data temporarily saved on the touch screen is then transferred into the USB Flash
memory card mounted on the touch screen.
You can check the data saved in this USB Flash memory card anytime through the Office
program(Excel program) installed in your PC.
The PC-based log trend check method is as follows.
1) Remove the SD memory card installed on the back of the touch screen.
2) Install the USB memory at the PC.
3) Check the file that saved USB memory stick in the PC.
4) Entry into the “Logging folder”.
PAGE 76 / 92
5) Select the “CSV” file that is saved in “Logging” folder.
6) Check the data that is recorded in the “CSV”.
PAGE 77 / 92
5.4 PLC Software Back-Up
1) Control section Power off
2) Remove the SD memory card installed on the PLC.
3) Installed on the PLC to new SD memory card stored Back-up software.
4) Control section power on -> installed new program in PLC automatically, started
System
PAGE 78 / 92
5.4 Touch Screen Software Back-Up
The software back up is possible in a simply way when the software of touch screen is
damaged.
The way is as below.
1) Control section power off
2) Check the USB flash memory stick that is installed on the back of the touch screen.
3) Control section power on
4) The touch screen that removed software marked as below.

Click the “YES” button.
PAGE 79 / 92
5) ) That indicates a normal install condition when the program copy window appears as
below.
6) Remove the USB memory stick.
7) Click the “Restart” button
8) The ESS system page appears as below when the touch screen program install is finish.
That means program back up is done.
PAGE 80 / 92
5.5 Hardware Maintenance
The ESS System panel is an automation power system panel, and it is very important to
check it on a regular basis.
Especially, the inverter that directly controls the pump motor generates a lot of heat and is
sensitive to high temperature. Therefore, you need to check the ventilation system on a
regular basis for the maintenance of it.
1) Panel ventilation maintenance
The ESS Panel is sensitive to high temperature. Therefore, you need to check if the
ventilation system including the ventilation fan, filter and inverter cooling fan installed on
the panel works normally on a regular basis at least once a month.
You can check the ventilation system by visual inspection and functional inspection.
Open the panel door, and you will find the ventilation fan on the upper part and the filter
on the lower part of the panel.
External air is supplied to the inside of the panel through the filter on the lower part of the
panel, while the internal air is exhausted to the outside through the ventilation fan.
Therefore, you need to note that if the filter is clogged or the ventilation fan malfunctions,
the inverter cooling fan in the panel does not work, and this causes serious damage to the
system.
You can check the panel fan by visual inspection and functional inspection.
Before the functional inspection, open the panel door with the panel power turned off and
check if there is damage or crack of the fan wing.
If there is too much dust on the fan, you must wipe off the dust because it may be a
direct cause of fan damage.
PAGE 81 / 92
You need to remove the dust in the panel on a regular basis at least once every 3 months.
You can do the functional inspection on the ventilation fan by turning on the panel power
and using the ventilation hole on the surface of the door.
You can check if the ventilation fan works
normally by check the exhaustion of air through
ventilation hole.
The air filter that installed on the ventilation of the panel is necessary to periodic check
and change.
The filter that set up for ESS panel is the air filter
that made polyester fiber.
In case of the filter, we recommend that the

inspect is needed at least once a months.
Also, we recommend that you should change the
filter at least once six months.
Check the Inverter cooling fan
The cooling fan is installed on the top of the

inverter.
If the inverter fan stops, the inverter fail alarm
rings, and another inverter is on stand-by and
starts.
The inside temperature of the inverter is
abnormally increase in the event that the
inverter cooling fan performance is degraded.
Therefore, we recommend that you check the
inverter temperature of the touch screen.
PAGE 82 / 92
You can check the current
internal temperature of the
inverter through the inverter
temperature PV value on the
Alarm Setting page.
In general, the internal
temperature of the inverter for
the normal operating status is
≤60℃. Since this is the mean
temperature of the heat-
generating point of the inverter,
you may have the trip alarm at
90℃.
Therefore, you can check and record the Inverter Operating Temp under the normal
condition and use it as reference data.
2) Check the Bolt, Component tightness state
The panel that installed on the ship is always affected by the vibration.
Therefore, we recommend that you check the bolt tightness more than once a six months.
For the safety in checking the bolting condition in the panel, you must turn off the power
for the corresponding section.
The check list is the Power cable terminal lug, Inverter fitting bolt.
Also, you should periodic check on the tightness state of the component fitting bolt.
The major point has been marked in paint marking as below.

Therefore, you can judge by the visual inspection about the loose bolt.
PAGE 83 / 92
It is possible for the visual inspection to consider
of the spring washer tension that installed on the
bolt.
However, the accurate check is impossible by the

visual inspection of the bolt in the period of use.
Therefore, we recommend that you should periodically check the connection state of the
more than M6 size bolt to use the tool.
The component connection check is possible by the simple visual inspection.

The general electric component is installed on a 35mm din rail channel.
Therefore, the component connection check is possible to inspect that the stopper, clip
set up for the component as below.
3) Cleaning
We recommend that the panel cleaning is necessary at least once a year.

Many materials in the panel inside are vulnerable to dust, humidity because the electric
component is installed.
In many case, the fine dust is flowing into panel inside in spite of the IP44 structure.
We recommend that the periodic clean is necessary because the automation component
is install on the ESS panel.
The hole is installed

on the electronic
equipment such as
PLC, Touch screen
for the ventilation.
When the fine dust

flows in the hall for a long time, the exothermic of electronic equipment and internal heat
is generated. That is the cause of the machine’s life shortening. We recommend that you
have to clean the electronic equipment to use the moistless air more than once a year.
PAGE 84 / 92
We recommend that the periodic check is necessary for you to long period usage of ESS
system. Please refer to the table below.
ESS Maintenance table
Check by - check the Ventilation fan working.

one month - check the door filter pollution.
- check the Inverter temperature.
Check by - check the Inverter. (refer to Inverter manual)

three month - check the Touch screen working.
(Check the touch sensitivity and data change value)
Check by - check the By-pass working.

six month - Bolt tightness
- check the Component fastened condition.
- check the Panel exterior.
- change the Door air filter.
Check by the year - Panel dust cleaning

- ESS Inverter manual mode working test
PAGE 85 / 92
Inverter Maintenance table
Inspection Service Proactive Maintenance

intervals Schedule
Environmental, cabling and Service is always performed in commissioning phase of product and continues according to
connections service schedule. Environmenral conditions will be documented in commissioing. E.g. heat,
dust, moisture, vibration etc.
Conditions of installation 1 year 1 year Check that installation and environmental conditions are
environment within Vacon specifivation. E.g. heat, dust, moisture, vibration
etc. Corrective actions based on findings.
Cleaning 1 year 1 year Product will be cleaned with an antistatic vacuum cleaner if
necessary.
Cleanliness of cooling 1 year 1 year The cleanliness of the cooling tunnel will be checked /
tunnel evaluated. Cleaning if necessary.
Air filters 3 months 3monthes The inspection and replacement intervals of filters depend on
in the environment. Replace at least once a year.
demandin
g
environme
nt
Sealings 1 year Based on Check cabinet and drive sealings. Check cable bushing
inspection visually. Corrective actions based in findings.
Visual inspection of 1 year 1 year Visual inspection for possible damage etc,e.g.vibration.
cablings Actions based on inspection.
Tightness of connections 1 year 1 year Cable and wire connection to be checked and tighten.
Drive Service is performed based on service schedule. The actions and recommendations will be
documented.
Main DC cooling fans 1 year 5 years Replace parts according to service scheule or based on
Main AC cooling fans and maintenance report recommendation.
fan capacitors internal
cooling fans for electronics.
DC-link capacitors 8 years in The expected life time of the capacitor is determined based on
demandin liad and the temperature of the environment. Replace parts
g according to service schedule.
environme
nt or
normal
load
Product upgrades 1 year 1 year Manufacturer offers product upgrades.
Printed circuit boards 1 year 12 years The printed circuit boards to be checked for contamination and
PAGE 86 / 92
in typical possible corrosion. In case of contamination or corrosion
environme printed circuit boards to be changed.
nt
Recommended reforming 1 year 1 year Reforming must be done once a year for products and spare
interval for electrolyic DC- part capacitors in storage. Please consuit manufacturer.
link capacitors (spare parts
and products in storage).
Cabinet Service is performed based on service schedule. The actions and recommendations will be
documented.
Auxiliary devices 1 year According Replace parts according to service schedule or based on
(contactors, switches, to maintenance report recommendation.
relays, push buttons, manufactu
indicators, heater, cooler rer
etc.) informatio
n.
Liquidcooling system Service is performed based on service schedule. The actions and recommendations will be
documented.
Coolant inhibitor 1 year 2 year Add inhibitor according to instructions.
Coolant 2 year 6 years Check and change coolant according to service schedule.
Coolant pipes, connections, 1 year Based on Check for signs of leakage, de-airing, operation of valves and
Vacon HX, pump, valves, inspection flow. Check pressure and temperature of the system. Compare
actuator, heat exchanger, to previous measurements.
expansion tank
Documentation of actions In case Vacon authorized service is carring proactive maintenance all actions and
recommendations are documented and document is givien to customer.
Saving of system and System and application software will be documented and current parameter settings saved.
applications software
Analysis of inspection A maintenance report, including recommendations for future repair / maintenance actions,
reports will be created.
PAGE 87 / 92
6. Troubleshooting
6.1 Automation System Trouble
Repair or Replacement
Yard supply power on
Circuit breaker on
Action
Program back up
more than half

Valve to close
Replacement
Replacement
Replacement
Replacement
Replacement
Replacement
Repair
Repair
Repair
ESS Automation system
Trouble shooting
14 3-Way valve condition check

13 Bulb or LED condition check
12 Communication cable check
16 Central cooler temp high

Trouble cause
9 Door limit switch defect
11 PLC card error lamp on

2 Main circuit breaker off
If the Overboard V/V is

1 Yard supply power off
7 Switch contac defect
10 Cooling fan coil fault
17 higher than sea level

3 Power supply fault
5 PLC card defect

6 Cable unfasten
15 Sensor fail
8 Relay fault
4 Fuse fault
No.
18
19
20
No. Trouble
1 Control section power off ∨ ∨ ∨ ∨
2 PLC Power off ∨ ∨ ∨ ∨ ∨ ∨ ∨
3 PLC Error ∨ ∨
4 Touch screen power off ∨ ∨ ∨ ∨ ∨
5 Touch screen error ∨ ∨
6 Not possible mode selection (INV. / By-pass) ∨ ∨ ∨
7 Cooling fan stop ∨ ∨ ∨ ∨
8 Inverter communication fault ∨ ∨ ∨ ∨
9 Not possible mode selection (Local/Remote) ∨ ∨ ∨ ∨
10 No indicating starter condition (Touch screen) ∨ ∨ ∨ ∨
11 Sensor fail ∨ ∨ ∨ ∨ ∨
12 Output signal fail ∨ ∨ ∨
13 Indicating lamp fail ∨ ∨ ∨ ∨
14 Not possible reset ∨ ∨ ∨ ∨ ∨
15 Freshwater temp high (ESS Control normal) ∨ ∨ ∨ ∨ ∨
16 Seawater inlet temp high ∨ ∨ ∨ ∨ ∨
17 Seawater outlet temp high ∨ ∨ ∨ ∨ ∨ ∨
18 Seawater inlet pressure low ∨ ∨ ∨ ∨ ∨
PAGE 88 / 92
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
No.
Lamp fault
Inverter alarm
Main power fail
Cooling fan stop

Control power fail
Inverter key pad fail
Motor space heater fail

Trouble
Inverter communication fail

Trouble Shooting
6.2 Starter section Trouble
ESS Starter Section
Running hour counter not run

SMC505 Motor controller alarm
Power meter fail or malfunction
Not possible by-pass auto start
Inverter normal / Inverter not start

SMC505 controller is run / pump not run
Not possible stand-by start (By-pass mode)
SMC505 Motor controller fail (By-pass mode)
No. Trouble cause Action
1 Ship power off Ship power on
2 Main MCCB off Main MCCB on
● ●
3 Fuse fault Replacement
●
4 Control transformer fault Replacement
● ● ●
● ● ● ●
5 Cable connection fail Repair
● ● ●
● ● ●
● ● ●
●
●
●
●
● ● ●
● ● ●
●
6 Pressure switch low alarm Pump check
7 Motor over load alarm pump & motor check
●
● ●
● ●
8 SMC505 communication fail Repair
9 SMC505 Auto/Manu switch "Auto" position select
● ● 10 SMC 505 controller fail Replacement
●
●
11 Air ejector timer fail Replacement

12 Air ejector timer check Time set : 5 ~ 30sec.
13 Magnetic contactor coil fault Replacement
PAGE 89 / 92
14 By-pass mode sel. S/W "By-pass" position select
● ● ● ● ●
15 By-pass autostart sel. S/W "ON" position select

16 Auto start Time relay time setting Time set : 5 ~ 30sec.
17 Control relay fault Replacement
●
●
● ● ● ● ● ● ● ●
18 Door open Door close

19 Door limit switch fail Repair or Replacement
20 Cooling fan coil fault Replacement
● ● ●
21 Ship power low voltage Ship power check

●
22 Alarm code check Refer to inverter alarm code

●
23 Inverter key pad fail Replacement

● ●
● ● ● ●
24 PLC Card fail Replacement

● ●
25 Inverter communication card fail Repair or Replacement

● ●
26 Inverter card disconnection Card connector check

27 Alarm holding condition Reset
● ●
28 Bulb or Led broken Replacement

●
29 Switch contac broken Replacement

30 Contactor aux. contac fault Replacement
● ●
31 Running hour counter fault Replacement

●
6.3 SMC505 Motor Controller Trouble
PAGE 90 / 92
7. System Flow Chart
PAGE 91 / 92
8. ESS Panel Component
PAGE 92 / 92

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ENERGY SAVING SYSTEM

5. ESS System Management

7. System Flow Chart

8. ESS Panel Component

ESS : Energy System

2.1 Environmental Condition

It is needed to install according to the required condition of guideline for

2.2 ESS Panel General Specification

ESS Control Panel의 Mechanical General Specification

↑ Control Section ↑ Power Section ↑ Power Section ↑ Power Section ↑

Control section 220V power check

Control section 24V power check

Pump inverter control mode condition

Inverter by-pass mode condition

Not possible ESS auto control

Mode select push of pump control

AUTO: Inverter is controlled by PLC

Auto control system fault reset

Indicating lamp simulation test

1. Digital power meter

Measuring : Indication each

2. By-pass motor controller

3. Control switch & indicating lamp

AC440V main power check

Pump running condition

Starter common alarm lamp

ON/OFF switch to heat the motor on

Pump start button on By-pass

Pump stop button on By-pass

Simulation test button to check the

Operation to select the auto starting

- ESS Panel Lifting

- Moving packaged ESS Panel.

- ESS Panel Lifting

100mm Angle for installation ESS panel.

Various ways for installation is possible after technical discussion if requested.

For a convenient maintenance of ESS panel, minimal distance is required.

ESS system uses invert to control pump’s rpm.

- SWITCHBOARD TO ESS POWER CABLE :

- ESS PANEL TO MOTOR POWER CABLE :

2.7 ESS Power Cable Install

ESS system uses invert to control pump’s rpm.

- SWITCHBOARD TO ESS POWER CABLE :

- ESS PANEL TO MOTOR POWER CABLE :

2.8 ESS Power Cable Install

- SWITCHBOARD TO ESS PANEL CABLE :

- ESS PANEL TO MOTOR POWER CABLE :

- Signal cable, Communication cable, Analog cable must be separated.

- Power cable of other system motor parallel installation. :

In the most general ESS type,

The difference from the ESS Type2 is included all function

Therefore, The user is possible to use ESS in case of

The St’by start function in the By-pass mode is able to

It is possible to pump control of By-pass mode using the

It is possible to forcibly pump start using the By-pass mode

At this case, All function is possible to only manual running

However, it is possible to Stand-by Control by the logic of

It is possible to pump control of By-pass mode using the

It is possible to forcibly pump start using the By-pass mode

At this case, All function is possible to only manual running

However, it is possible to Stand-by Control by the logic of

ESS Panel has the same composition with Type.2.