LG Centrifugal Chiller Manual

The LG Centrifugal Chiller is a high-efficiency cooling system designed for commercial and industrial applications, featuring advanced centrifugal compression technology, variable speed drive, integrated control system, multiple safety protections, energy optimization modes, remote monitoring capabilities, and environmentally friendly refrigerants. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Settings 6. Connecting Systems 7. Operating Procedures 8. Safety Features 10. Maintenance & Service 11. Regulatory Information 12. Troubleshooting

Features at a Glance

Key components: Centrifugal compressor, Variable Speed Drive (VSD), Control panel, Heat exchanger, Water pumps, Safety valves, Pressure sensors.

Feature	Description
Centrifugal Compressor	High-efficiency oil-free magnetic bearing technology
Variable Speed Drive	Optimizes energy consumption based on cooling demand
Control Panel	Touchscreen interface with real-time monitoring
Heat Exchanger	Enhanced tube design for maximum heat transfer
Water Pumps	Integrated pump system for chilled water circulation
Safety Valves	Pressure relief and emergency shutdown systems
Pressure Sensors	Continuous monitoring of system pressures
Remote Monitoring	Network connectivity for remote operation
Energy Optimization	Automatic load balancing and efficiency modes
Environmental Compliance	Uses low-GWP refrigerants

Installation

Unpack and inspect all components. Ensure proper foundation and clearance.

Foundation Preparation: Level concrete pad with proper load capacity.
Water Connections: Connect chilled water supply and return lines.
Electrical Connections: Connect main power supply and control wiring.
Piping Installation: Install water treatment system and isolation valves.
Final Checks: Verify all connections and clearances before startup.

WARNING! Chiller is extremely heavy; use proper lifting equipment. Ensure all electrical connections are made by qualified personnel.

First-Time Setup

Power on chiller; follow startup sequence on control panel.

System Initialization: Press POWER to begin startup sequence.
Parameter Configuration: Set operating parameters via control panel.
Water Flow Verification: Confirm proper water flow through system.
Leak Testing: Check all connections for leaks.
Test Run: Perform initial test run and monitor system performance.

CAUTION! Only trained technicians should perform initial setup. Follow all safety procedures.

Specifications

Cooling Capacity: 200-2000 tons (depending on model)
Compressor Type: Oil-free magnetic bearing centrifugal
Refrigerant: R-1234ze or R-134a
Power Supply: 380-480V, 3-phase, 50/60Hz
Control System: Microprocessor-based with touchscreen
Efficiency: COP up to 6.8, IPLV up to 12.0
Sound Level: 75-85 dBA at 1 meter
Operating Range: Chilled water 40-55°F, condenser water 65-95°F
Dimensions: Varies by model (consult specific model data)
Weight: 3,000-15,000 lbs (depending on model)

Controls and Settings

Access control system via touchscreen panel. Main controls: POWER, START/STOP, MODE SELECT, ALARM RESET.

Control Panel: Display screen, Navigation buttons, Function keys, Emergency stop.

Operating Modes: COOLING, STANDBY, SERVICE. Settings: Temperature setpoint, Flow rates, Pressure limits, Schedule programming, Alarm settings, Maintenance reminders. Safety: High/low pressure cutouts, Motor protection, Flow switches, Temperature sensors.

Connecting Systems

Water Connections: Chilled water supply/return, Condenser water supply/return. Electrical: Main power, Control wiring, Network connections.

Turn off all power before making connections.
Connect water piping with proper isolation valves.
Connect electrical wiring according to wiring diagram.
Connect network cables for remote monitoring if required.
Verify all connections are secure and properly labeled.

Tip: Use torque wrenches for all pipe connections to ensure proper sealing.

Operating Procedures

Supports automatic operation with manual override capability.

Startup: Press POWER, then START to begin cooling cycle.
Monitoring: Watch display for system parameters and alarms.
Adjustment: Modify setpoints via control panel as needed.
Shutdown: Press STOP, then allow system to complete shutdown sequence.
Emergency Stop: Use red emergency stop button for immediate shutdown.
Mode Selection: Choose between automatic and manual operation.
Data Logging: Access historical data through control panel.
Remote Operation: Control via network connection if configured.

WARNING! Do not attempt to override safety controls. Follow proper shutdown procedures.

Safety Features

Multiple safety systems: High pressure cutout, Low pressure cutout, Motor overload, Flow switches, Temperature sensors, Emergency stop, Leak detection, Vibration monitoring.

Maintenance & Service

Regular maintenance required for optimal performance. Unlock control panel before servicing.

Daily: Visual inspection, Check for leaks, Monitor performance

Monthly: Clean strainers, Check water treatment, Verify control operation

Annually: Complete system inspection, Refrigerant analysis, Motor bearing inspection, Control calibration

CAUTION! Only qualified technicians should perform maintenance. Follow lockout/tagout procedures.

Regulatory Information

UL/CSA certified; complies with ASHRAE standards and local building codes. EPA refrigerant handling certification required for service. Copyright © 2024 LG Electronics; all rights reserved. For technical support, visit www.LGcommercialhvac.com or contact 1-800-243-0000.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Unit will not start	Power supply/Safety lockout	Check main power; reset safety controls; verify flow switches.
High pressure alarm	Condenser issues	Clean condenser tubes; check water flow; verify fan operation.
Low pressure alarm	Refrigerant/Evaporator	Check refrigerant charge; inspect evaporator; verify expansion valve.
Vibration/noise	Motor/Compressor	Check motor bearings; inspect compressor alignment; verify mounting.
Reduced capacity	Fouling/Controls	Clean heat exchangers; check control settings; verify water treatment.

Reset: Control panel > System > Reset after addressing fault condition.

Service: 1-800-243-0000; www.LGcommercialhvac.com