User Manual Screw Chiller Water Cooled

Water Cooled Screw Chiller
High on Features Low on Operating Costs
USERS MANUAL
First published March 2006 No part of this publication may be reproduced in any manner whatsoever without permission in writing from the Executive Vice President, Airconditioning Projects Division, Blue Star Limited. While due care has been taken to avoid errors or misinterpretation, Blue Star Limited is neither liable nor responsible for consequence of any action taken, on the basis of this publication. Since ASHRAE standards use the FPS system, FPS nomenclature is used in some places in this publication for convenient reference. Published by Blue Star Limited, Airconditioning Projects Division. For restricted circulation only. Not for sale.
Contents
Introduction ................................................................................................................ 2 Features .................................................................................................................... 3 Nomenclature ............................................................................................................ 7 Technical Specification ............................................................................................. 8 Electronic Expansion Valve ...................................................................................10 MCS Panel ..............................................................................................................13 MCS Panel Troubleshooting ..................................................................................24 Rigging and Installation .........................................................................................29 Screw Compressor .................................................................................................32 Pre-Start Check up, Operation and Commissioning ..........................................40 Troubleshooting ......................................................................................................48 Maintenance ............................................................................................................51 Spare Parts Lists ....................................................................................................53 Field Feedback Card .............................................................................................65 Commissioning and Handing Over .......................................................................67 Water Quality ..........................................................................................................68 Log Report ..............................................................................................................69 Warranty Claim Form .............................................................................................70 Warranty ..................................................................................................................71 GA Drawing..........................................................provided on last inner wrapper Electrical Wiring Diagrams..................................provided on last inner wrapper
User's Manual
Introduction
Blue Star has been a pioneer in developing and manufacturing Chillers for various applications. A new generation of Water Cooled Screw Chiller is being added to the present range of Reciprocating and Scroll Chillers. The Chiller is energy-efficient and robust in construction. These chillers are developed with state of art technology which includes Hanbell screw compressor, high-efficiency cooler, water-cooled condenser, refrigerant liquid injection for motor cooling especially during part load operation, electronic expansion valve and Micro Control Panel. The units have low input KW/TR and are tested in Blue Star's Test Laboratory to validate performance. The capacities of the Chillers range from 104 TR to 370. TR with single and multi compressors in 10 models. Blue Star uses the BSC Series compressors specially manufactured for Blue Star by Hanbell.
Screw Chiller (Water Cooled)
Features
Compressor
The Screw Compressor has advantages compared to other compressors, due to its inherent design features. The Compressor has only two moving parts, viz. Male & Female Screws and Slide Valve. The wear and tear is thus minimum, the life of the Compressor is higher. Due to its inherent characteristics, a Screw Compressor has the highest volumetric efficiency, and de-rating at higher temperature is negligible. It has stepless capacity control, usually from 25% to 100%. This feature makes it ideally suitable for varying load applications, and has better efficiency under part load conditions (Condenser and Evaporator are designed for 100% capacity). This capacity control, also helps in limiting the starting current as the system can be started in unloaded condition (25%), and the loading is done stepless. The Screw Compressor is Semi-Hermetic in construction, which makes it serviceable. Due to geometrically symmetrical moving parts, the Compressor has extremely low vibrations. The Compressor is tested in accordance with ARI standards.
Cooler
The shell and tube evaporator has been built using inner grooved copper tubes, and has been optimised for refrigerant and water velocities. The shell is manufactured from high-grade steel. The expansion of the tube is done with controlled process.
Water Cooled condenser

The copper tubes used are inner grooved type, with higher height trapezoidal cross section, to increase the internal surface area of heat transfer.
Refrigerant liquid injection

The refrigerant suction gas cools the winding of the semi hermetic screw compressor motor. As an abundant precaution, liquid refrigerant will be injected to the suction side of the compressor to cool the motor winding. This is especially required during part load operation where the suction gas quantity reduces. Liquid injection during this period keeps the motor winding temperature within limits. This is provided as a standard feature.
User's Manual
Electronic expansion valve

The Screw Chillier is fitted with an electronic expansion valve with its drivers, as an integral part of the Micro Control Panel. The algorithm is built to ensure most appropriate operation of the expansion valve motor. This system adjusts the opening of the valve with shorter response time, against varying load conditions, resulting into optimising of power. Coupled with the stepless capacity control which is a feature of the Screw Compressor, the electronic expansion valve will maximise power savings. The electronic expansion valve operates on a principle of opening and closing of valve through a Stepper motor, which has 6386 steps per revolution. The signal for the Stepper motor is received through the Micro Control Panel. Electronic expansion valves thus have advantage over normal Thermostatic expansion valves, which have slower response for the changing conditions. The electronic expansion valve adjusts itself based on suction superheat and monitors the flow of refrigerant quickly and accurately, as compared to thermostatic expansion valve. This inherent feature allows the system to operate in a very narrow band of superheat, resulting in power saving.
Control Panel
The Control panel has been designed with construction features, so that it is mounted on the same structure. Electronic Micro Control Panel, the Power section and the Termination sections are clearly separated for ease of installation and servicing.
Micro Control Panel

Micro Control Panel has Digital Control and setting of Temperature values, Temperature setting and control is in the range of 0.5F. Micro Control Panel has step less capacity control from 25% to 100%, Non-Volatile Memory backup for all set points, Automatic power failure reset, Built-in time delays for compressors, Single phase/phase reversal protection, Password protection at 4 levels and in-built Anti-freeze and Flow switch safety. Micro Control Panel is provided with RS-232 port for direct remote computer connectivity (up to 50 feet), Fault Indication and Status facility and RS-485 connection (up to 6000 ft). PC connection Program provides both local and remote communication to Micro Control Panel. The Micro Control Panel automatically performs history logging and this program will graph the selected items. Micro Control Panel has BMS Compatibility (J C N2, Bacnet and Modbus protocol available). Translator is optional. Micro Control Panel has Remote Monitoring and Access through P.C. with Modem and dedicated telephone line without BMS as a standard feature through RS232 & RS485 (P.C., Modem, Gateway for units are Optional and not in the scope). Also remote monitoring can be done with a web monitor connected to the panel and further to customers LAN.
User's Manual
Two Levels of Safety

The Chiller is protected with Primary and Secondary Safety Systems. This has been done to protect the Chiller, even in the case of failure of any of the protection devices. Care has been taken to ensure that there are no nuisance alarms generated. The Protection device is as tabulated below:
Primary Single Phasing Reverse Phase Motor winding Temp Discharge Temp SPPR module SPPR module Motor Protector Compressor PTC sensor Current sensing Electronic Expansion Valve Star-Delta method Pressure sensors Pump-down Compressor Discharge Check valve Lubrication Oil Oil Level Switch
Secondary Current sensing Suction & Discharge pressures Current sensing Temperature sensor on Discharge Line (Micro Control Panel) Superheat measurement by Micro Control Panel Unloaded start by Micro Control Panel
Motor Overload Suction Superheat
Starting Current HP / LP Refrigerant Migration
Oil Pressure Difference Oil Pressure Cut-out (Micro Control Panel) Crankcase Heater Anti-freeze Water Flow Sudden Compressor On/Off LWT sensor Flow switch interlock Time delay AFT cut-out KP61 Anti-cycle cut-out (10 min.)
Nomenclature
Nomenclature:
X - 1 104
LIQUID CHILLER WATER COOLED
NOM. CAP. IN TR NO. OF COMPRESSORS SCREW COMPRESSOR
User's Manual
Technical Specification
Technical Data for Water Cooled Screw Chiller DX R22
SR DESCRIPTION No. 1 2 3 Nominal Capacity Compressor Model Refrigerant Power Supply 4 5 6 Power Consumption Refrigerant/Oil Charge Cooler (DX -Shell & Tube Type) Water Flow Connection Sizes 7 Condenser (Shell & Tube type) Water Flow Min Max Inlet & Outlet connection Slip on Length Width Height 8
OPERATING WEIGHT/UNIT (APPROX)
UNIT LCWX1-104 kW (TR) 365.6 (104) Semi-hermatic Screw BSC-105W, 1# R22 V/PH/HZ KW Kg./Ltr Model USGPM USGPM INCHES Model USGPM USGPM INCHES mm mm mm Kg 400 V(+/- 10), 3 PH., 50HZ 85.1 95/16 YCH-103A 208 312 6 YCD-101A 312 416 4 (1 each) 2700 800 2000 2500 LCWX-125 439.5 (125) Semi-hermatic Screw BSC-125W , 1# R22 50HZ 101.1 112/18 YCH-122A 250 375 6 YCD-131A 375 500 4 (1 each) 2953 900 2102 2700
MODEL LCWX1-145 509.8 (145) Semi-hermatic Screw BSC-145W , 1# R22 50HZ 117.2 136/23 YCH-152A 290 435 6 YCD-151A 435 580 4 (1 each) 2979 900 2102 3365 LCWX1-160 562.5 (160) Semi-hermatic Screw BSC-160W ,1# R22 50HZ 130 150/23 YCH-177A 320 480 8 YCD-176A 480 640 5 (1 each) 2987 900 2102 3650 LCWX1-210 738.5(210) Semi-hermatic Screw BSC-210W , 1# R22 50HZ 169.3 195/28 YCH-222A 420 630 8 YCD-221A 630 840 6 (1 each) 3087 900 2269 4600
400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH.,
Min Max
SR DESCRIPTION No. 1 2 3 Nominal Capacity Compressor Model Refrigerant Power Supply 4 5 6 Power Consumption Refrigerant/Oil Charge Cooler (DX -Shell & Tube Type) Water Flow Connection Sizes 7 Condenser (Shell & Tube type) Water Flow Min Max Inlet & Outlet connection Slip on Length Width Height 8
OPERATING WEIGHT/UNIT (APPROX)
UNIT LCWX2-208 kW (TR) 731.8 ( 208) Semi-hermatic Screw BSC-105W, 2# R22 V/PH/HZ KW Kg./Ltr Model USGPM USGPM INCHES Model USGPM USGPM INCHES mm mm mm Kg 50HZ 170.1 180/32 YCH-222A 416 624 8 YCD-222A 624 832 6 (1each) 3100 1200 2300 5000 LCWX2-250 879 (250) Semi-hermatic Screw BSC-105W + BSC-145W R22 50HZ 202.3 237/38 YCH-105A + YCH-152A Min Max 500 750 8 YCD-105A + YCD-151A 750 1000 8 (1 each) 3400 1800 2300 5526
MODEL LCWX2-290 1019.64 (290) Semi-hermatic Screw BSC-145W , 2# R22 50HZ 234.4 275/46 YCH-152A + YCH-152A 580 870 8 YCD-151A + YCD-151A 870 1160 8 (1 each) 3400 1800 2300 6526 LCWX2-320 1125.12 (320) Semi-hermatic Screw BSC-160W+BSC-160W R22 50HZ 260 304/46 YCH-177A + YCH-177A 640 960 8 YCD-176A + YCD-176A 960 1280 8 (1 each) 3400 1800 2450 6862 LCWX2-370 1300 (370) Semi-hermatic Screw BSC-160W+BSC-210W R22 50HZ 299 351/51 YCH-177A + YCH-222A 740 1110 8 YCD-176A + YCD-222A 1110 1480 8 (1 each) 3400 2000 3000 7541
400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH.,
NOTE:1) The Rating given are based on 54 / 44 Deg. F Chilled Water for Cooler with 0.0005 Deg. F Sq. Ft,Hr/BTU Fouling Factor and 90 / 97.5 Deg. F Condenser Water with 0.001 Deg. F Sq. Ft HR /BTU. Fouling Factor
PRESSURE DROP (FT.H20)
A A A
User's Manual
Electronic Expansion Valve

The benefits of using electronic expansion valves are: Step motor operated for precise control High resolution drive assembly 0.000783 inches (0.02mm) per step Tight seating Corrosion resistant materials used throughout Field proven reliability Low power consumption 4 watts Compatibility tested with most CFC, HCFC, and HFC refrigerants and oils Self lubricating materials used for longer life High linear force output
These are electronically operated step motor flow control valves, intended for the precise control of liquid refrigerant flow. Synchronised signals to the motor provide discrete angular movement, which translates into precise linear positioning of the valve piston. Valve pistons and ports are uniquely characterised, providing improved flow resolution and performance. The valves are easily interfaced Strain Relief with microprocessor based controllers.
Valve operation
The valves modulate by the electronically controlled rotation of a step motor. The step motor drives a gear train and lead screw to position a piston. The piston is used to modulate flow through a port, as referred in the figure.
Motor
Retaining Nut
4-Pin Feed Through

O-Ring Motor Housing
42mm stepper Motor Gear Ball Bearing Gear Cup Gear Shaft
Bronze Guide Lead Screw
Red + < Green
Q1
Q2
Q5
White + < Black
Q6
Bipolar Drive Sequence
Close
STEP 1 2 3 4 1
Q1-04 Q2-Q3 ON ON OFF OFF ON OFF OFF ON ON OFF
Q5-Q8 Q6-Q7 ON OFF OFF ON ON OFF ON OFF OFF
Q3
Q4
Q7
Q8
10
Open
ON
The motor is a two-phase type driven in the bi-polar mode. Two discrete sets of motor stator windings are powered in sequence to rotate the rotor 3.6 degrees per step. Polarity of the drive signal reverses for each step. The sequencing is accomplished through the bi-polar drive circuit shown on page 10. The drive transistors, Q1 through Q8, are electronically biased in pairs by the controller as shown in the table. Large valves have an operating stroke of 0.5 inches and 6386 steps of control; therefore each step translates into 0.000783 inches (0.02mm) of travel. When used with the Micro control panel, the valves provide unsurpassed accuracy in resolution of flow and repeatability of position. External parts of the valve are brass and copper and meet or exceed 2000 hours salt spray tests per ASTM B-117. The motor housing is equipped with hermetic cable connection to the motor and a 10 feet motor lead is supplied as standard length. Total power consumption is 4 watts when operating a rate of 200 steps per second with standard L/R type drive circuitry. The valves have a safe working pressure of 420 psig. Operating ambient temperature range is 50 deg. F to 140 deg. F (-45 deg C to 60 deg. C) but temperature of up to 250 deg. F (120 deg. C) may be used for dehydration. The electronic expansion valve controls the flow of refrigerant entering the direct expansion evaporator in response to signals sent by the controller. These signals are calculated by the controller from the sensor inputs. A set of sensors, either two temperature sensors or a pressure transducer and a temperature sensor, are used to measure superheat. Typical control is based on superheat set point. The ability of the EEV to control the amount of refrigerant in the evaporator to allow reaching discharge set point while preventing flood back makes the EEV the ideal expansion device for most air conditioning, Chiller, Environmental chamber and refrigeration applications.
User's Manual
11
SPECIFICATIONS Motor type Supply Voltage Connections Phase Resistance Current Range : : : : : 2 phase permanent 2 coil bipolar magnet,
12 VDC, -5% + 10%, measured at the valve leads 4 lead, 18 AWG, PVC insulation jacketed cable. 75 ohms per winding 10% 0.131 to 0.215 amps/winding; 0.262 to 0.439 amps with two windings energised. 4 watts 6220% mH 200 steps per second 6386 0.000783 inches/step (0.02mm/step) 0.50 inches (12.7mm) less than 200 cc/min at 100 psi estimated less than 0.10 oz/year at 300 psig (0.20 gr/year at 20 bar) 420 psig (29 bar) -50 Deg. F to 140 Deg.F (-45 Deg. C to 60 Deg. C) 250 Deg. F (120 Deg. C) All common CFC, HCFC and HFC refrigerants except R-410A; all common mineral, Polyolester and Alkylbenzene oils. Copper-fittings; brass-valve body, motor housing, and adaptors: synthetic materials-seating and seals.
Maximum power Inductance per winding Required step rate Number of steps Resolution Total stroke Maximum allowable internal leakage Maximum allowable external leakage Safe working pressure Operating temperature range Maximum dehydration temperature Compatibility
: : : : : : : : : : : :
Materials of construction :
12
MCS Panel
Micro Control Panel
The Micro Control Panel is a rugged microprocessor based controller that is designed for the hostile environment of the HVAC/R industry. It is designed to provide primary control, no mechanical controls; interface with building management systems; communicate both locally and remotely. The Micro Control Panel provides flexibility with set points and control options that can be selected prior to commissioning a system or when the unit is live and functioning. Displays, alarms and other interfaces are accomplished in a clear and simple language that informs the user as to the status of the controller. The Micro Control Panel is designed to safeguard the system that is being controlled, eliminate the need for manual intervention and to provide a simple but meaningful man-machine-interface.
PC Support Software for Micro Control Panel

PC-Config: Program provides the configuration file: points list, set points, options, etc., for all versions of software. This program is user friendly with English questions and drop down menus. PC-Conn: Program provides both local and remote communications to the Micro Control Panel independent of the type of software. Through this program the status of the controller can be viewed and with proper authorisation changes can be made to the system. Configuration files can be transmitted to or received from an MCS8 unit. The MCS-8 automatically performs history logging; this program will graph selected items.
Micro Control Panel Network

The Micro Control Panel Network can support up to 50 Micro Control Panel and its associated I/Os. Access to this network can be local or remote via a 14.4K Baud modem. There will be no degradation in the performance of the network. The PC connected to the network must be running Windows 3.1 or higher with PC-Connect providing the actual interface program. Each Micro Control Panel in the network must be assigned a unique address when the configuration file is build using the PC - Config program. This address will be the key in establishing communications with the appropriate Micro Control Panel system. This address can be changed from the LCD / keypad of a unit.
User's Manual
13
MICRO CONTROL PANEL NETWORK LOCAL PC SUPPORT ONLY
Micro Control Panel-I/Os
RS485
RS485
RS485
Micro Control Panel RS 485 Gateway
Remote PC with Windows & PC-Connection
14
MICRO CONTROL PANEL NETWORK REMOTE PC SUPPORT ONLY
RS485
RS485
RS485
Micro Control Panel RS 485 Gateway
14.4k baud modem Remote PC with Windows & PC-Connection 14.4k baud modem
User's Manual
15
REQUIREMENTS FOR PC SOFTWARE
To install and run the program we suggest the following system requirements: Front End System Requirements
n n n n n n n
Windows 95 Pentium 166 MHz 2 Gigabyte hard disk with at least 25 Megabytes free 3 Floppy Disk Drive Super VGA display capable of displaying 256 colors 16 Megabytes of RAM or more is recommended 33.6k baud modem
Minimum System Required to Run Program

n n n n n n n
Windows 3.1 486 66 MHz 500 Megabyte Hard Drive 3 Floppy Drive VGA Display 8 Megabytes RAM 14.4k baud modem
16
Micro Control Panel

Authorisation function The authorisation code is a special four-character code that enables access in to the Micro Control Panel System. The code must be numeric with values between 1 and 8 if it is to be entered from the Keypad/Display. If the system is being accessed via PC-Connect program, the code may consist of any valid alpha/numeric characters. Each system can have up to 15 different authorization codes. This provides the capability of issuing different codes to different people if desired. There are four levels of authorization, which provide different capabilities with in the system. The authorization code and the associated level cannot be displayed or viewed in an Micro Control Panel System. These are established when building the configuration file in the PC-Configuration program. The authorization codes must be protected and remain confidential, if they are compromised unauthorized personnel can gain access to the system. From the Keypad/Display the following changes can be made based upon the authorization level:
Function Sensor offsets Sensor diagostics Clear alarm history Clear point information Date & time set Day of week set Change no flow lockout or shut down Change rotate yes or no Change manual/auto settings Change setpoint values* Change operating schedules Change holiday dates Lock out reset
View No No No No Yes Yes No No No No no no Yes
Service Yes Yes No No Yes Yes No No No Yes Yes Yes Yes
Supervisory Yes Yes No No Yes Yes No No Yes Yes Yes Yes Yes
Factory Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
*Note - Before a set point can be changed the set point must be able to be viewed.
User's Manual
17
The Micro Control Panel Keypad Display Quick Reference - STATUS KEYS
No authorization is required in the DISPLAY STATUS section for viewing information. Pressing a key selects the 1st two lines of data. Repressing the same key selects the next two lines, etc. The ALARM STATUS displays all alarms and lockouts while LOCKOUT STATUS displays only active lockouts. The + and - keys may be used with alarm & lockout status to allow scrolling. If one or more Micro Control Expansion units are connected to a Micro Control Center the data will be presented in a continuous sequence. ADDITIONAL STATUS information shows names, total, run hours and starts for all ROs. SYSTEM PRESSURE displays information by circuit, SP suction pressure, DP discharge pressure, OPD oil pump differential, AMP or motor fault. LOCKOUT STATUS for lockouts caused by either suction, discharge, oil or amps, the actual value at the time of the lockout of the associated sensor is displayed.
COMP MAIN/DELTA ON LOAD SOLENOID ON/OFF UNLOAD SOLENOID ON/OFF LIQ. LINE SOLENOID ON/OFF
1 SP DP OPD AMP 65 260 195 44
DISPLAY STATUS
COMPRESSOR STATUS
1 2 3 4
SYSTEM PRESSURE
5 6 7 8
SUCT TMP + 55.6F DISC TMP + 180.5F LIQ. OUT + 47.3F FLOW ON UNIT CTL ON END/SELECT NEXT
FANS 1LOT ON/OFF FANS 2LOT ON/OFF
CONDENSOR STATUS
SYSTEM SENSORS
LIQ.OUT TEMPERATURE
EVAPORATOR STATUS
ADDITIONAL STATUS INFO
Chiller Configuration Example

One screw compressor One each load/unload solenoid per compressor One liquid line solenoid per compressor Suction & discharge pressure per compressor Oil pressure per compressor Leaving liquid temperature sensor Return liquid temperature sensor
18
1 JAN 30 09:13:00 REASON FOR ALARM 2 JAN 30 09:12:51 LOCKOUT RESET 3 JAN 30 09:12:19 POWER RETURNED 4 JAN 30 09:12:13 POWER FAILED 5 JAN 30 09:11:45 ALARM LIQ.OUT 6 JAN 30 09:11:44 LOCKOUT RESET
7 JAN 30 09:11:33 COMPUTER RESET 8 JAN 30 09:11:12 FREEZE 9 JAN 30 09:11:01 LOCKOUT RESET 10 JAN 30 09:10:56 ALARM LIQ.OUT 11 JAN 30 09:07:30 LOCKOUT RESET 12 JAN 30 09:07:18
ALARM STATUS
LOCKOUT STATUS
1 SUCT SAT S HEAT +55 +37 +18.1 1 DISC SAT S HEAT +180 +120 +60.4
COMP 1 = STARTS = STARTS = LOAD = STARTS = UNLOAD = STARTS =
000016h 000000040 000000029 000002h 000007996 000001h 00000863
LIQ.LINE STARTS STARTS STARTS ALARM STARTS
= = = = = =
000016h 000000028 000000035 000000034 000000h 000000015
5 JAN 30 09:11:45 ALARM LIQ OUT 5 SP DP OPD AMP 8 JAN 30 09:11:02 FREEZE 10 JAN 30 09:10:56 ALARM LIQ.OUT
The Micro Control Center Keypad Display Quick Reference - ENTRY KEYS
The ENTRY keys (SERVICE, SETPOINT, MANUAL and PROGRAM) provide menu items, some of which when selected will present sub menus. When making value changes the INCREASE (+) & DECREASE (-) keys may be held for continuous updating. Enter authorization code at the authorization function within the SERVICE DIAGNOSTIC key menu. Different items will appear depending on the package configuration and options selected. Units may be English or Metric. The clock is factory set at EST or EDST based on time of year.
CONTROL STATUS ENTR CHG OPTION AUTHORIZATION ENTER CHG OPTION SENSOR OFFSETS ENTR CHG OPTION CLEAR ALRM HSTRY ENTR CHG OPTION CLEAR PT INFO ENTR CHG OPTION UNIT INFORMATION ENTR CHG OPTION
ENTRY
SERVICE DIAGNOSTIC PROGRAM OPTIONS
DATE DISPLAY ENTR CHG OPTION TIME DISPLAY ENTR CHG OPTION DATE & TIME SET ENTR CHG OPTION DAY OF WEEK SET ENTR CHG OPTION OPERATING SCHEDS ENTR CHG OPTION HOLIDAY DATES ENTR CHG OPTION
#1 LVG LIQ OUT TARGET TEMP #2 CTRL ZONE ENTR CHG TEMP #5 CNTRL ZONE ENTR CHG TEMP #7 POWER UP DELAY ENTR CHG TIME IN SEC
#8 STEP SENSITIVITY ENT CHG #9 STEP DELAY TIME IN SECONDS #10 MAXIMUM ROC #11 ENT CHG TEMPERATURE
SETPOINTS (SAFETIES)
INCREASE (+)
LOCKOUT RESET
ENTER
NO ACTIVE LOCKETS SEL NEXT OPTION ECT
RELAY OUTS MANUAL ENTR CHG OPTION ANALG OUTS MANUAL ENTR CHG OPTION SENSOR INS MANUAL ENTR CHG OPTION
MANUAL OVERRIDES
DECREASE (-) ENTER KEY Selects options or enters changes after adjustments have been made
INCREASE KEY(+) & DECREASE KEY(-) Used To adjust values or change options selected. (SERVICE, SETPOINTS, PROGRAM keys)
User's Manual
19
Wiring Guide Notes Relay Outputs (RO) 230 VAC 10 amps. SI 1-4 factory set for 4 wire differential inputs. (0 to 100 milli volts dc) SI 5-8 factory set for MCS-T100 temperature inputs. (0 to 5 volts dc) All analog inputs must have shield tied to GND. Mircro Control Panel-I/O factory set address to Mircro Control Panel I/O Items refer page 21.
High Voltage Wireway Relay Ouptus & 220 VAC 50/60 hertz Input Preferred direction of wire
220 VAC
Low Voltage Wireway Sensor Input, Analog Output & Communications Terminals Shielded cable only, preferred direction of wire
20
Detail of Micro Control Panel and I/O Key Items

220
220 VAC
User's Manual
21
IB Series interface boards (IB 6)

These interface boards are used to accept 0 to 10 V DC analog input signals and are designed to allow externally supplied control signals to control one or two Sporlon step motor valves including electronic expansion valves. IB 6 boards are used on valves with 6386 steps.
CN4 CN2
+4-20 -4-20 Black White Green Red IN GND 24V-1 24V-2
Configure the Board
CN3
When used with a 0-10 volt input signal, a jumper should be placed on the pins labelled CN3 as shown in the above Figure 1. This is the default jumper position. The impedence for this input is 40 k ohms. Choose Open on Rise or Close on Rise operation using the middle two pins on jumper CN2. The jumper is stored on one pin only and will cause the valve to open as input signal rises, i.e. valve is closed at 0 volts or 4 milliamps and fully open at 10 volts or 20 milliamp input. By placing the jumper on both pins, the operation is reversed so that the valve will be fully open at 0 volts or 4 milliamps. Other pins on CN2 have been clipped at the factory and are not used for operation of the valve. Wiring Instructions and Cautions Use the chart given next page No.24 as a guide for wire connections. Certain precautions must be taken in wiring and operation of the IB Series. 1. The 24 volts must be supplied by a transformer not used for any other purpose. In addition, the secondary winding of the transformer must not be connected to chassis ground. 2. The primary input of the transformer should be protected by Metal Oxide Varister (MOV) surge suppressors, supplied with the IB. For protection from electrical transients, connect one MOV between one leg of the input voltage of the 24 VAC transformer and earth ground. Connect a second MOV between the other leg of the input voltage of the 24 VAV transformer and earth ground. 3. The pumpdown terminals must be supplied with a dry contact from a switch or relay. No external
power should be applied to these terminals. OPERATION and TROUBLESHOOTING When properly configured and installed the IB Series requires no maintenance. They incorporate a number of operational features to assure trouble free service. On power-up the board will initialize by giving the valve a large number of steps to assure that the valve is fully shut. The routine will require approximately 8 seconds for the IB1, 16 seconds for the IB3 and 32 seconds for the IB6. The valve will not respond to input signals during this time. If the valve is required to shut during operation, the pumpdown terminals should be used. When given a pumpdown signal, the board will shut the valve immediately and overdrive by 250 steps to reset valve position. On removal of the pumpdown signal the valve will resume position as dictated by the external control signal. If power is lost to the IB or wire to the valve severed, the valve will remain in its last position. Solenoid valves may be desired before the step motor valve on critical applications. To force the valve shut during operation for test purpose, simply remove the jumper from CN4 or CN3, depending on configuration. To resume normal operation, replace the jumper. To allow for component tolerances, the IB will shut the valve when the input signal reaches 4.25 milliamps or .015 volts depending on the configuration. The IB can power one or two valves. The valves will operate simultaneously and will open and close by the same number of steps. Valve wires must be connected exactly the same for both valves.
22
Wiring Connections
From left to right when the board is oriented with the terminal strip across the bottom. +4-20 -4-20 B W G R IN GND 24V-1 24V-2 connection for the positive leg of a 4-20 milliamp or 0-10 volt signal connection for negative leg of a 4-20 milliamp or 0-10 volt signal black wire from valve, or both valves when two valves are used white wire from valve, or both valves when two valves are used green wire from valve, or both valves when two valves are used red wire from valve, or both valves when two valves are used from external pumpdown switch or relay. See wiring instructions. to external pumpdown switch or relay. See wiring instructions. from 24 volt, 15 VA transformer. See wiring instructions. from 24 volt, 15 VA transformer. See wiring instructions.
3.0 inches Dia. 0.125 typical & places
Jumper for close on input rise
4-20 mA. 1000 ohms .0 inches 4-20 mA. 600 ohms 4-20 mA. 300 ohms 0-10 VDC 4-20 mA or valve B-in VDC b wg r input digital 24 vac input input
025 typical 4 places
0.25 typical 4 places
+ Lead
Ground Lead
Pump down 24 VAC Power Signal In
User's Manual
23
MCS Panel Troubleshooting

TROUBLE SHOOTING FOR SPORLAN IB6 INTERFACE CARD
TEST THE VALVE:
The resistance of the motor winding may be tested without operating the system as follows: 1) Check voltage (24V) at IB or Transformer 2) Remove power from the external controller and /or IB 3) Remove the valve leads from IB 4) Measure the resistance between the black and white leads of the valve. The resistance should be 75 Ohms with the valve at room temperature or approximately 65 Ohms if the valve is at -40 deg F. 5) Measure the resistance between green and red leads this value should be between +/-5 %of the resistance between black and white leads 6) Measure the resistance from any lead to valve body. Resistance should be infinite, that is to say, open
24
TEST THE IB:

SR. NO. 1 2 PARAMETER Is there 24VAC at terminal? Is the valve connected to terminal (B,W,G,R)with wire colors correct ? Connect voltmeter on AC scale to the black and white terminal. Interrupt and restore power to IB. Does the meter read 12 VAC1? Repeat test using red and green terminal. Does the meter read 12VAC +/-1? Are wires for external signal connected to terminal +4-20 and -4-20 Is external signal present? Signal should be 0-10VDC? Is polarity of signal correct? Terminal (+) to terminal +4-20 and (-) to terminal -4-20 Pin jumper in not required on CN2 & CN4; but required in CN3 IF NO Repair or replace power supply or supply wiring Shut off power to IB and correct wiring Check the step motor. If operational replace the IB IF YES Go for 2 Go for 3
Go for 4
Same as in 4
Go for 5
Shut off power to IB and external controller and correct input signal observing polarity Shut off power Test or correct wiring Shut off power. If not correct wiring Shut off power. And correct jumper position
Go for 6
Go for 7
Go for 8
Go for 9
IB IS FUNCTIONAL,TEST EXTERNAL CONTROLLER
User's Manual
25
The Micro Control Panel Troubleshooting

Quick Reference Sheet
PROBLEM No Sensor + 5 V D C POTENTIAL SOLUTION Indicates a possible shorted input sensor Remove all sensor + 5 V DC wires. Wait about 30 to 60 seconds. If + 5 V DC returns, replace one sensor wire at a time until the + 5 V DC is lost again. This will be the shorted sensor. This indicates an open sensor input signal or 5 VDC problem. Check sensor wiring for missing wire or poor connection. Check sensor for bad sensor Check + 5 V DC on sensor input to ground. If less than 5 VDC is on the sensor 5 VDC terminal block, the problem is with probably a shorted sensor. (A poly fuse protects the board) Remove all sensor input terminals. Wait about 1 min. or until 5 VDC restored at sensor input. Connect terminals 1 at time until short reappears & fix bad sensor. This indicates a shorted sensor input signal. Check sensor wiring for +5VDC shorted to signal etc. Check sensor for bad sensor. This indicates the transducer sensor input needs to be calibrated via the offset capability in the software. (Transducers by design need to be calibrated based on construction and altitude.) You need to have a valid Auth code to change sensor offsets You must use the Windows based software package P Conn See P Conn Interactive section for instructions. (Change SI Status, Manual Value and / or offset.) This indicates an input problem with 1 sensor. Verify jumper settings correct for that SI. Indicates Micro in constant reset. Check incoming power > 220 VAC Indicates software chip problem possible. Possible U11 software version incorrect or chip bad. Possible U13 GAL chip incorrect or chip bad. Possible bad connection or cable between LCD and Micro Control Panel
A sensor input reads -99.9
A sensor input reads +999.9
A pressure sensor is reading more than 1 psi off (The temperature & humidity sensors do not require calibration.)
Invalid reading on one sensor input. MCS CONTROLLER INITIALIZATION on LCD display. Top row of LCD display all bars & 2nd row blank.
26
PROBLEM LCD blank.
POTENTIAL SOLUTION Indicates bad connection. Connector J2 on Micro Control Panel not on or offset on connector. Resistor adjustment VR1 out of adjustment. Indicates communications problem. Verify RS485 LED blinking. Verify termination jumper J6 only on at Micro Control Panel & last I/O. Verify Micro Control Panel & I/O addresss set correctly. Verify wiring from Micro Control Panel to each I/O correct. Check fuses/220 VAC on I/O units This indicates inability to write to chip U10. Verify EEP WRITE ENABLE jumper W6 is on. Not authorized This indicates you are not at a proper authorization level. Follow steps below for proper authorization. From either the SYSTEM INFO or STATUS screen, under P Conn, click on the AUTH button on the lower right of your LCD display. Follow prompts and enter a valid 4-digit authorization number. The authorization level is displayed at the top of the display and is reflected via the colour of the AUTH button. RED = view only YELLOW = service level BLUE = Supervisor level Green = Factory level This indicates an invalid auth number. Follow steps below for proper authorization Press SERVICE DIAGNOSTICS key until the authorization option appears Press the ENTER key From the Display Status press keys corresponding to your authorization number. Press ENTER This indicates a problem with this SI only. Jumper setting on this SI in wrong position. Incorrect sensor type used. Indicates layout of CFG wrong. CFG layout for different version than software chip U11.
User's Manual
Lost I/O
Changes to MCS not being made from the units keypad. P Conn cannot make changes
Invalid authorization
SI from AMPS board 10 A low.
INVALID CONFIG VER
27
Problem
INVALID CONFIG TYPE
Potential Solution
Indicates U10 CFG incompatible with U11 software. Example U10 CFG for home while U11 for chiller. Indicates Checksum invalid Reload CFG Verify Berg jumpers using Quick Reference Sheets Check board version number Check wiring of sensor
INVALID CONFIG Sensor input believed invalid (Under Sensor Diagnostic Sub Menu) Communications to Micro Control Panel 485-GATEWAY from PCConnect not working.
The Verify red LED (located just to the left of the RS-485 connector) on the gate way blinking indicates that the PC-Connect program is talking to the gateway. Verify that the two wire shielded cable is properly wired from the RS-485 connector to the gateway. If both of LEDs are blinking, check the address of the Micro Control Panel and any other Micro Control Panels that are on the network. Each must have a unique address. This address can be changed from the Micro Control Panel Proper authorization is required. Enter the UNIT INFORMATION screen by depressing the SERVICE DIAGNOSTIC key and scrolling to this item. Depress the ENTER key and scroll to the NETWORK ADDRESS screen. Change address if needed. Verify +12 V DC to Micro Control Panel RS485. GATEWAY INVALID CONFIG indicates Checksum invalid. Either set to factory defaults or reset settings.
NOTE : All sensosr inputs should be shielded cable with shield tied to ground on Micro Control Panel Sensor Input Groung Terminal.
28
Rigging and Installation

Rigging
When the chiller arrives at Warehouse/Site, proper rigging and handling is mandatory during unloading and leading the unit into position. Care must be taken to keep the unit upright during rigging. Avoid unnecessary jerking or rough handling. Proper hoisting straps should be used when rigging (nylon flat rope). It is also mandatory that an experienced and reliable rigger be selected to handling unloading and final placement of the equipment. The rigger must be advised that the unit contains internal components that require to be kept in an upright position. Care must be exercised to avoid twisting of the equipment.
Storage
Check for transportation damages if any and take up with factory for any damages. In case the site is not ready to install the chiller, proper care should be taken to store the chiller in a covered space. Check up the pressure of the unit when received. If the pressure is not holding in the system, the system should be pressure tested immediately, repair the leakages if any and charge the system with Nitrogen. Never keep the system without pressure.
User's Manual
29
Installation
Proper care should be taken to make the foundation for the Chiller. In case the Chiller is located on rooftop, ensure that the same is located in such a way that the load of the same is transferred to the columns and not to the slab directly. The foundation should be properly levelled. Install the Chiller on the Foundation/Pedestal and grout by using foundation bolts. The Chiller should be levelled on the foundation. The unit should not be located nearer to any heat source or any high tension line running above. Adequate space around the Chiller as recommended in the G A Drawing should be made available for maintenance purpose. The chilled water and condenser water piping connections to the cooler and condenser should be terminated preferably with flexible connections to avoid transmission of vibration if any. The piping shall be supported external to the unit as per the recommended practice. Use recommended size of power cable to be terminated to the MCCB of the Panel of the unit. Use 3 core Aluminium cable along with double earthing and terminate through proper lugs. Avoid any sharp bend for the cable at the termination point. The cable shall be adequately supported.
30
Legend for Control & Power Wiring Diagram for Water Cooled Screw Chiller
Sr. no
1 2 3 4 5 6 7 8 9 CB EMG INT-69 OCTH 1M, 2M, 3M, 4M, 5M G S1 C NO
Acronym
Description
Circuit breaker Emergency Off Mushroom Type Motor protector module Oil cooler thermostat Contactors Ground terminal Sensor input terminal Common connection for relay output Normally open connection for relay output
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
NC L N TB SP/PR OL MCCB CT RLY SI8 MCS LCD OCF MP HTR SV TR EEV Card EEV
Normally closed connection for relay output Phase Line Neutral Terminal Block Single phasing preventer / Phase reversal protector Overload relay Molded Case Circuit Breaker Current transformer Relay output Sensor Input card Micro Control Main Board Touch key pad for MCS Oil Cooler Fan Compressor Motor Protector Oil Heater Solenoid Valve Transformer Interface Board for EEV Electronic Expansion Valve
User's Manual
31
Screw Compressor
32
Construction of Compressor
Fig. 1
1. 2. 3. 4. 5. 6. 7. 8. 9.
Compressor casing Motor casing Oil separator Motor rotor assembly Motor stator assembly Motor rotor washer Motor rotor spacer ring Oil Separator Baffle Oil separator cartridge
19. Disc spring 20.
-Balance piston
21. Bearing slot nut 22. Male rotor 23. Suction bearings 24. Suction bearings inner/outer spacer ring 25. Oil guiding ring 26. Oil level sight glass 27. Oil filler cartridge 28. Suction filter 29. Oil heater 30. Refrigeration Lubricant 31. Suction flange 32. Discharge flange 33. Cable box 34. Power bolt 35. Thermostat terminals 36. Motor cable cover plate
10. Piston 11. Piston spring 12. Piston rod 13. Bearing sets cover plate 14. Modulation solenoid valve 15. Modulation slide valve 16. Slide valve key 17. Discharge bearings 18. Discharge fixed ring
User's Manual
33
Capacity control system

The BSC series screw compressors are equipped with continuous (step less) capacity control system, which consist of a slide valve, piston rod, cylinder, piston and its rings. The slide valve and the piston are connected by the piston rod. The principle of operation is by using the oil pressure to drive the piston in the cylinder. See figure on next page. The lubrication oil flows from the oil tank through the oil filter cartridge and capillary then fills into the piston cylinder due to the positive oil pressure higher than the right side of spring force plus the high pressure gas. The positive pressure differential causes the piston to move towards the right side in the cylinder. When the slide valve moves towards the right side; the effective compression volume in the compression chamber is increasing thereby increasing the displacement of refrigerant gas and hence increase in the refrigeration capacity. The piston spring is to force the piston back to its original position, i.e. 25% position to reduce the starting current during the next startup. The compressor started at full load, will result in a larger starting current that could damage the compressor motor seriously. The capillary is provided to maintain and restrain a stable amount of oil flow to cylinder. The modulation (step less) solenoid valves (SV1 & SV2) that are controlled by micro controller with the temperature sensor to modulate the piston position smoothly with stable output of capacity. If the oil filter cartridge, capillary, or modulation solenoid valves are not working very well in the capacity control system; will result in the abnormality and ineffectiveness of the capacity control system. In continuous (step less) capacity control system, a normally open solenoid valve (SV2) and a normally close solenoid valve (SV1) are equipped to the inlet and outlet of piston cylinder respectively. These two solenoid valves are controlled by the Chiller temperature controller or micro controller, refrigeration capacity control and hence can be modulated at anywhere within 25% - 100%. Therefore, it is available to control the capacity output stably by modulating the inlet of SV2 and outlet of SV1 alternatively.
34
The continuous (step less) capacity control system needs to be associated by a micro controller such as the Micro Control Panel as well as PLC with LCD displayer etc. It is very important for any controller to control the load and unload stably. For a smooth modulation, it is suggested to install an additional orifice valve in the oil line while a fast speed of loading and unloading is happening.
Continuous capacity control system

No. Component 1 2 3 4 5 6 7 8 9 Suction filter Gas in (low pressure) Motor Oil filter cartridge Suction bearings Male rotor Discharge bearings Discharge silencer Gas out (high pressure with oil) SV1 (Unload) Start Loading Unloading Stable On Off On Off SV2 (Load) On/Off Off On On No. Component 10 11 12 13 14 15 16 17 Slide valve Lubricant Oil separator cartridge Gas out(high pressure without oil) Capillary Solenoid valve (normally open), SV2 (Loading) Solenoid valve (normally closed), SV1 (Un Loading)
User's Manual
35
Lubricant
The main functions of the lubrication oil in screw compressor are lubrication, internal sealing, cooling and capacity control. The positive oil pressure in the cylinder pushes the piston and the slide valve, which is connected by a piston rod to move forward and backward in the compression chamber. The design with positive pressure differential lubrication system in the BSC series is available to eleminate an extra oil pump in the compressor. The bearings used in BSC compressor require a small but steady quantity of oil for lubrication; the oil injection into the compression chamber creates an oil sealing film in the compression housing for increasing the efficiency and absorbing a portion of heat of compression. In order to separate the oil from the mixed refrigerant gas, an oil separator is required to ensure the least amount of oil carried into the system. Pay more attention to the oil temperature, which is a very significant factor for the compressor bearings life. High oil temperature will reduce the oil viscosity and cause poor lubrication and heat absorption in the compressor as well. It is recommended to keep the oil viscosity above 15mm2/s at any temperature. If the compressor is operated under the critical conditions, (high discharge pressure) then extra oil cooler is required. Some high viscosity oil is recommended for applications with high working condition. It happens often that the return oil from the evaporator is insufficient due to the high viscosity of oil, which is difficult to be carried back, that causes the loss of oil in compressor. If the system encounters the oil return problem then it is recommended to install extra 2nd oil separator between the compressor discharge connection and condenser. Each of BSC series of compressors are equipped with two oil sight glasses as a standard; one is the oil high level sight glass and the other is the oil low level sight glass. The normal oil level in the compressor oil tank should be maintained above the top of the low oil sight glass and in the middle level of high oil sight glass when compressor is running. It is recommended strongly to install the optional accessory of oil level switch to prevent from low oil level in compressor.
Warnings:
a. Use the qualified oil and do not mix with different brand of oil. Different kinds of refrigerant should match with different kinds of oil. Note that some synthetic oil is incompatible with mineral oil. Prior to the oil is filled into the compressor, the system should be totally cleaned up during the initial startup and ensure that it is clean completely.
36
b. For the chiller system using synthetic oil, avoid the exposure of oil to the atmosphere too long, it is also necessary to vacuum the system completely when installing the compressor. c. The table below shows the oil replacement standard. Each compressor at HANBELL charges standard quantity of oil. d. In order to take out the moisture from the system, it is suggested to clean the system by hot air or Nitrogen, thereafter vacuum the system as long as possible. It is essential to change new oil into the system especially after the motor burn out, the acidity debris will still remain inside the system, hence follow the above mentioned procedures to overhaul the system. Check the oil acidity after 72 hours operating and then change it again and again if the limit is still over the oil acidity standard until been qualified. Oil Replacement Standards Item Color, ASTM Value Above 6.0 Item Total acid number mg KOH/g Value Above0.5
Particle Matters mg/100ml Viscosity 40 Deg. C
Above 5.0 Variation 10% of 15mm2 / Sec or more
Copper Strip Above 2.0 100 Deg C /3hrs Moisture ppm Above 100
Changing oil
Lubrication oil is the most important factor to maintain the operating, lubricating, cooling, sealing and driving the capacity piston of the compressor. Following is the probable problems existing in the system that should be faced: 1. Contamination of oil by debris causes the oil filter clogged. 2. Acidified system due to the moisture causes the motor corroded. 3. Spoiled oil due to the compressor running at long duration of high discharge temperature causes the bearings life shortened. Refer to the following oil change timing to ensure the compressor runs normally: 1. Change the oil periodically: Check the oil for every 10,000 hours of running periodically for the first operation, to change oil and clean oil filter after running 20,000 hours is recommended. Due to the piping debris could be accumulated inside the system after operation, check the oil after 2,500 hours or after one year of running. Check the system whether clean or not and then change the oil after every 20,000 hours or after 4 years running while the system is operated under good condition.
User's Manual
37
2. Avoid the debris clogged in the oil filter causing the bearings failure, an optional oil pressure differential switch is recommended to be installed. The switch will trip when the oil pressure differential reaches the set point between the primary and secondary sides and the compressor, will shut down to prevent the bearings damage due to lack of oil. 3. If the compressor discharge temperature often keeps high approaching to the set point, then the oil will be spoiled gradually in short time, hence check the oil characterestic every 2 months if possible. It is necessary to change the oil if the character of the oil is out of the standard. In case oil characterestic could not be checked periodically, then change the oil after 4 years of installation or after 20,000 hours of running which reaches first. 4. Acidity in lubrication oil causes the reduction of bearings life and motors life. Check the oil acidity periodically and change the oil if the oil acidity value measured is lower than PH 6. Change the deteriorated drier periodically if possible to keep the system dry. Check the acidity of oil after 72 hours of initial of operation. 5. Refer to the oil changing procedures especially after the system overhaul owing to the motor burn out. Check the oil quality monthly or periodically and change the oil if the oil is not qualified, it is necessary to take care of the oil quality and system cleanness and dryness in the system periodically.
The Compressors are charged with Blue Star ACS oil for the Water Cooled application and for R22.
38
Liquid injection
The liquid injection to the suction side of the compressor, is carried out by providing a separate thermostatic expansion valve in the system. (Low-temp type expansion valve) The flow of liquid refrigerant is controlled through the expansion valve by the suction superheat directly. Application of liquid injection The compressor motor temperature and its compression chamber temperature will be very high almost approaching the setting of motor thermister and discharge temperature thermister, which often result in the trip of the sensors under the above working conditions causing the chillers to shut down. The purpose of installing a liquid injection system is to prevent the compressor motor from overheat, an expansion valve is installed in the system with tube piped between the liquid line and compressor for cooling down the compression chamber and motor to ensure that the compressor can be run continuously and safely. The suction superheat should be controlled between 5 to 10 deg. C for the application of water cooled screw chillers by means of the expansion valve devices. During the initial start up, the loading of the chillers will be heavy due to the higher temperature of return chilled water, hence the liquid injection devices of adequate capacity should be selected to reduce the overheat of the compressor. When the compressor is operated for low temperature system (E.T =< -10 deg. C), the compression ratio will be high at this condition and also the discharge temperature. Hence the use of liquid injection system is essential.
User's Manual
39
Pre-Start up, Testing, Commissioning & Operation

Prior to starting of the unit, check up the procedure detailed herein
Items 1. Accessories Things To be checked 1. Oil level 2. Time for heating the oil Standard Values 1. Higher than the middle line of oil level sight glass. 2. Turn on the oil heater at least 8 hrs. before starting. 3. Opened 4. No distortion or damage
3. System valve status. 4. Capillary 2. Electrical System
1. Voltage of the main power. 1. Electricity voltage should be kept within +_15% to the rated voltage. Instant maximum voltage drop while starting should be less than 10% to the rated voltage. 2. Standard voltage is 220 V. 2. Voltage of the control Maximum voltage is 230 V. circuit. 3. Insulation resistance value 3. Insulation Resistance value should be above 5 M ohms of the motor between 4. Power terminals are firmly phase to phase and phase fixed on terminal block and to ground. well insulated. Keep wire 4. Power terminals and wire cables away from heat cables terminal source and sharpened connections. metal. Terminal screw and block, both are required. 5. Earthling 5. As per local Electricity 6. Settings of switches, regulations. sensors and controllers. 6. Properly set. 1. External piping 2. Leakage test 3. Compressor fixed tightly Leakage test 1. Motor winding sensor Discharge temp. sensor 1. Fixed properly 2. No leakage 3. Check up the tightness
3. Piping system
4. Safety devices
1. Connected properly 2. Connected properly
40
Operation
1) In addition to above pre start-up check up, it is also necessary to pay attention to the auxiliary facilities while the chiller is commissioned at the job site and the periodic maintenance after the initial start up. 2) In order to keep the capacity control smoothly under the low ambient temperature with the normal viscosity of oil, it is required to heat the oil by heater at least 8 hours before next starting. The lower the ambient temperature is, the longer the time of heating of oil should be. The oil temperature should be over 50 Deg. C before starting the compressor. Keep the oil heater energised after the compressor is shutdown for preparation of next start-up, to keep the oil temperature over the minimum required value, which is essential especially under low ambient condition. 3) Recheck the settings on each controls 4) Establish the chilled water flow through the cooler. Adjust the water flow rate to the designed rated flow. Connect the Chilled water flow switch with Micro Control Panel. 5) Check if all the stop valves in the system are already opened 6) Check if the setting on each timer relay is correct. 7) Check up the idle pressure of the system 8) Recheck the wiring to the compressor motor is as per the wiring diagram with Star Delta connection given below.
MCS
MCD User's Manual
41
Following are the start up limitations

1) 2) 3) 4) 5) Lowest Starting Voltage: The power voltage cannot be lower than 10% of rated voltage during start-up period of compressor. Maximum Discharge Pressure: 18 kg/cm2 g Minimum Suction Pressure: 6~8 kg/cm2 g Maximum designed discharge pressure: 28 kg/cm2 g Maximum designed discharge temperature: 110 Deg. C
Starting Procedure: Operation of Micro-Controller for Single / Twin System

The MCS control circuit for Blue Star Water Cooled (DX) Screw Chiller comprises of analog sensor inputs such as System Pressures, System Temperatures, Chilled Water Temperatures etc. and digital sensor inputs such as flow switch, External Anti-freeze interlock, Single Phase/ Phase Reversal fault, etc.. It consists of various relay outputs that drive the compressor, liquid line solenoid valve, liquid injection control etc. Analog outputs (0-10V DC) are used to drive the Electronic Expansion Valves. Before switching ON the chiller, ensure that the flow switch is connected between points 7 and 8 in the wiring diagram and there is sufficient water flow. The crankcase heater should be ON for a period of 8 hours before starting the compressor. In the OFF state, the condition of the outputs is as follows:
System 1 Relay output

Main1 Delta1 Loadsol1 Unloadsol1 LLS1 LIQinjct 1
Condition
OFF OFF OFF ON OFF OFF
System 2 Relay output

Main2 Delta 2 Loadsol2 Unloadsol2 LLS2 LIQinjct 2
Condition
OFF OFF OFF ON OFF
OFF
42
Starting Specifications:
(1) Switch on power supply. The unit goes in power up mode. System stays in this mode for a time period as specified in MCS set point 23(factory set=90s). In this state, all relay outputs are turned OFF. After the power up delay, the system-1 goes in ON state. Controller will initialise & monitor Power Supply stability for 90 seconds. When this happens, the condition of the relay outputs is as follows: Condition ON OFF,ON after time corresponding to set point factory set=3s OFF ON OFF OFF Controller will check for any anti-cycle (fault) timers leftovers During start-up, the MCS Controller will monitor cooling demand as per Leaving water temperature (set point 1), condition of Flow Switch, Anti Freeze and other Compressor Safeties and start compressor of the first system with fast unloading control logic for initial 30 seconds. Compressor will pump down till the suction pressure reaches 60 psig. During pump down the liquid line solenoid is kept de-energized (closed). Once suction pressure drops to 60 psig Liquid Line Solenoid (LLS) valve is opened. Even though the suction pressure does not reach the set value, the LLS will be opened after 5 seconds. Depending on set point and actual leaving water temperature, the system shall load or unload. The operation of the load or unload solenoid valves is as under:
(2)
Relay output Main1 Delta1
Loadsol1 Unloadsol1 LLS1 LIQinjct 1 (3)
(4)
(5)
(6)
User's Manual
43
SV1 (Unload)
Start Loading Unloading Stable ON OFF ON OFF
SV2 (Load)
ON/OFF OFF ON ON
(7)
When compressor-1 is at 100 % load, then demand for the second system will be activated based on load requirement. Compressor-2 shall be ON when compressor-1 is at 100% load or even if compressor1 is unable to load further due to any of the safeties. Compressor-2 is started as per the sequence given in steps 4 to 7. Compressor-1 will get unloaded and then both the compressors will load/ unload simultaneously approximately at the same percentage (unless any of the compressors goes in safety hold). To shut down chiller switch off rotary switch provided in panel. Initially system-2 & then system 1 will go into shutdown mode. MCS has minimum run time equalization logic option (set point 103 should be 0 and set point 104 should be 1). The compressor, which runs for minimum time, will be stat first during next operation.
(8)
(9)
(10)
(11)
During normal running of compressors, following safety parameters are monitored:
Sr. No.
1 2 3 4 5 6 7 8 9
Set Point Description

Hi amps Low amps Low suction Low gas / LSV FLT High discharge Low discharge Low oil differential Unsafe Oil Anti freeze *
Trip Delay (Seconds)

2 5 90 10 1 40 180 4 5
Default Setting
110 % 15 % 48 psig 20 psig 275 psig 100 psig 50 psig 25 psig 39oF
44
* In case of Anti Freeze, both Circuits of the Chiller will be locked out. To avoid nuisance tripping during compressor start up, following Initial Bypass/ Time Delay adjustment procedure is observed:
Set Point Description

Hi amps Low amps Low suction
Bypass
For first 3 seconds For first 3 seconds During pump down
Time Delay Adjustment *

-
Low gas / LSV FLT Low oil differential
2 minutes 45 seconds for first 5 minutes of Compressor running. 4 seconds, for first 5 inutes of compressor. First 5 seconds 25 psig for next 30 seconds.
All the above parameters for time delay adjustment are as per default set points. Operating Specifications:
The following are the Operating Specifications and default set points: NOTE: Lock out delay: If any critical fault reoccurs within 2 hours of running, the controller will trip the unit and would go in lock out, after which manual intervention is required to diagnose and rectify the fault. Leaving water temperature is set at 45F with a control of 0.5 F. Liquid injection system switches on at Discharge Temperature of 165 F The delay between the Star and Delta connection is set at 3 seconds. Low-pressure setting is at 48 psig and High-pressure setting is at 275 psig. Anti Freeze Thermostat setting is at 39 F.
User's Manual
45
FAST UNLOADING For screw compressors, this state is entered when the compressor is turned on. The system will remain in this state for 45 seconds while the fast unloader and unload points are on. This is to ensure that the screw is unloaded. COMPRESSOR IS LOADING For screw compressors, this state is when the load solenoid is being pulsed to increase the cooling capacity of the circuit. COMPRESSOR IS UNLOADING For screw compressors, this state is when the unload solenoid is being pulsed to reduce the cooling capacity of the circuit by moving the slide valve.
Starting Current of the compressor

The starting current of different model compressor is as given below (LRA). This will be approximately 3.0 to 3.5 times the rated current.
Compressor model BSC-075A BSC-105A/ BSC-105W BSC-125W BSC-145A/ BSC-145W BSC-160A/ BSC-160W BSC-210A/ BSC-210W Locked Rotor Current (LRA), A 685 735 965 1100 1480 1760 Starting current, A 230 245 325 370 495 590
A. The starting for the Y start is usually set at 4 1 second, and
46
the maximum allowable shift time from Y to D is 40 milliseconds. It is advisable to change the Y starting time prior to different working condition in the job site in accordance with the current variation of Y starting. It is recommended that the duration of Y starting is not over 15 seconds at the step of 25% capacity.
The running restraint of compressor

1) Compressor restart frequency The restart counts for the models BSC - 125W, BSC - 105W, BSC - 145W, BSC - 160W and BSC - 210W are recommended below 2 times in one hour The starting for the Y start is usually set at 3 seconds and the maximum allowable shift time from Star to Delta is 40 Sec. However it is recommended that the duration of the Y starting is not over 15 seconds at the step of 25% capacity. Supply power Long term running => +5% Instant Running => +10% Frequency: +2 %
2)
3)
Phase current unbalance: The difference in phase current between the biggest phase current differential and smallest phase current differential is required to be less than 3 % 4) Phase voltage unbalance: +2.25 % 5) Range of ambient temperature: -10 Deg. C to 55 Deg. C 6) The control voltage is normally 220 V 7) Protection switch The table below shows the list of protection switches, which are essential to protect the compressor and operate safely
Protection Switch Motor winding temperature protector High discharge temperature protector Phase reversal protector Hi Low pressure protector Phase failure protector Motor overload relay Hi-Low Voltage protector Oil level switch Oil pressure differential switch Set Point Cut out 120 Deg. C Cut in 75 Deg. Cut out 110 Deg. C Cut in 60 Deg. C Phase reversal when power on Highest pressure 25 Kg/Sq.cmg Phase failure when compressor starting or running Set by a related application value, any setting should be tripped in 15 sec. Rated Voltage + 15 % Oil level lower than the floating ball Cut out 2.5 Kg/Sq.cmg
User's Manual
47
Troubleshooting
Shut Down of Compressor
1) 2) Shut down the Chiller by switching off the required switch provided in the Panel. Stop the chilled water supply to the Cooler.
In case of long term shutdown required because of the retrofit of the system or overhauling of the compressor follow the above instructions after reinstallation of the system before starting up again to ensure the safety and good running condition of the compressor
Troubleshooting
SR. NO. 1 PROBLEMS Sudden trip of motor thermister / Sensor PROBLEM CAUSE 1) Low suction pressure or high suction temperature (lack of refrigerant or clogged suction filter) or high suction superheat. 2) Motor overload. Liquid injection system failure. 3) Motor winding thermister failure. 4) Unstable electrical system or failure. 5) Bad motor coil winding causing the motor temperature to rise rapidly. 2 Compressor unable to load 1) Low ambient temperature or High oil viscosity. 2) Capillary clogged 3) Modulation solenoid valve clogged or burnt. 4) Internal built in oil lines clogged.- Clean the oil line. 5) Oil filter cartridge clogged. - Clean Oil filter cartridge. 6) Piston stuck up 3 Compressor unable to unload 1) Modulation solenoid valve clogged or burnt.repair Solenoid valve. 2) Piston rings worm off or broken, or Cylinder damaged resulting leakage. 3) Insufficient lubricant. Add Lubricant 4) Leakage at discharge cover plate end side. 5) Solenoid valve voltage incorrect. 6) Capacity control logic unsuitable piston stuck-up.
48
SR. NO 4
PROBLEMS Poor insulation value of motor
PROBLEM CAUSE 1) Bad compressor motor coil 2) Motor power terminal or bolt wet of frosty 3) Motor power terminal or bolt bad or dusty 4) Bad insulation of magnetic contactors 5) Acidified internal refrigeration system 6) Motor coil running for a long time continuously under High Temperature 7) Compressor restart counts too many times
Compressor starting failure or star-delta starter shifting failure
1) Slide valve piston unable to back to its 25 % original position. 2) Voltage incorrect 3) Voltage drop too high when starting the compressor or Magnetic contactor failure. 4) Motor broken down 5) Phase failure or phase reversal. 6) Motor thermistor sensor trip. 7) Incorrect power supply connection. 8) Star delta starter timer failure. 9) Discharge stop valve closed. 10) Improper connection between the terminal of star delta wiring. 11) In anti recycling period.
High Suction Pressure
1) Cooler water flow rate is higher than the rated flow rate - Maintain the rated flow rate. 2) Cooler water inlet temperature is higher than rated - Supply the rated temperature cooling water at cooler inlet. 3) System is overcharged - Remove the excess refrigerant.
User's Manual
49
SR. NO. 7
PROBLEMS High discharge temperture
PROBLEM CAUSE 1) Condenser problem.- Check cooling water temperature or Condenser Tubes clogged. 2) Refrigerant overcharged - Remove excess refrigerant. 3) Air in refrigeration syste - Air should be vented during start-up and periodically. 4) Insufficient lubrication oil.-Add the lubrication Oil. 5) Damaged bearing, mutual friction of rotors. 6) High compression ratio. 7) Improper expansion valve. 8) Improper Vi value. No system extra cooling devices. (Liquid Injection or oil cooler)
Low suction pressure
1) Cooler water flow rate is lower than the rated flow 2) Cooler water inlet temperature is lower than the rated temperature. 3) System is undercharged. Charge the refrigerant
High suction temperature
1) High suction Pressure.- Refer Sr. No.-6
10
Abnormal vibration 1) Damaged bearings and noise of compressor 2) Phenomenon of liquid compression 3) Friction between rotors or between rotor and compression chamber 4) Insufficient lubrication oil 5) Loosen internal parts 6) Electromagnetic sound of the solenoid valve 7) External debris fallen into the compressor.
50
Maintenance
Maintain the Chiller periodically in accordance with the schedule shown in table below Water Cooled Screw Chiller Maintenance Schedule
Check Points General Log parameters Check Water Level in expansion tank Check Water Level in the Cooling Tower Sump Check for any refrigerant leaks through flare joints, valve glands etc Check and clean refrigerant strainer Check condition of refrigerant drier Clean Cooling tower sump Clean water line strainers Check quality of water Check healthy operation of safety devices Check tightness of all electrical terminations Top up grease for all motors Apply thermal paste on the temperature sensors Check for any abnormal noise and vibration Check liquid line sight glass/moisture indicator Check water pressure drop in Cooler Check water pressure drop in Condenser Analyse Oil sample Check suction superheat Check crank case heater MCS Panel Check program settings Check fault history Check load/unload furnction Check pump down function Check Clock X X X X X X X X X X X X X X X X X X X X X X X X X Daily Weekly Monthly Quarterly Annually
User's Manual
51
Maintenance schedule : Compressor

Check Points Compressor Electrical insulation Oil filter cartridge Suction filter Capacity control piston rings Oil level Oil Motor thermal protector Bearings X X X X X X X X X X X X X R X X X X R X 1000 hrs 2500 hrs 5000 hrs Time period 10000 hrs X X 15000 hrs 20000 hrs X X 25000 hrs 30000 hrs X X X R X
X R
Check or Clean Replacement
Note : If acidity of oil measured is lower than PH 6, replace the oil
52
Spare Parts Lists

SPARES FOR LCWX1-104
Item BAAN CODE Compressor Spares CDHAI0140 3105-1143A 3101-1051B 3105-1146A 3101-1148A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1004A-3 3105-1024C 3105-1004A-3 4405-56 CDSPI0710 EAECI0010 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 SAMAI0010 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0010 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAMAZ0560 EAGAI0050 BSC-105W (RC16) Screw Compressor for R 22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Outer Gasket of Oil Filter Flange Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring Included) 4" Gasket Suction Filter Gasket for 4" Flange Oil Level Switch Blue Star ACS Oil Controls & Accessories spares Sporlan SEH-100 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil for Liquid Injection CTG Dehydrator (Core) Indicator Moisture Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical spares MCCB Siemens - 3VL3720, 200A Siemens Contactor, 3TF50,110A, Coil for Contactor, 3TF50,110A Siemens Contactor, 3TF47,70A, 220 VAC Coil for Siemens Contactor, 3TF47, 70A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel spares Constant Voltage Transformer, 150 VA MCS Board Panel Mount Type- MCS 8 (230v.) SI-16 Extension Board, 230V. Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module E PROM chip Control Panel Fuse 1 1 1 1 2 4 1 1 1 1 ON/OFF 220 VAC 1 2 2 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 15 Litres 56*200L 220V, 150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO REINZ-AFM 34, 1.5t 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200mm Description QTY. Nos. Specification
User's Manual
53

Item BAAN CODE Compressor Spares CDSAI0145 3105-1143A 3101-1051B 3105-1146A 3101-1148A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1004A-3 3105-1024C 3105-1004A-3 4405-56 CDSPI0710 EAECI0010 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 SAMAI0010 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0010 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAMAZ0560 EAGAI0050 BSC-125W (RC17) Screw Compressor for R 22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Outer Gasket of Oil Filter Flange Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring Included) 4" Gasket Suction Filter Gasket for 4" Flange Oil Level Switch Blue Star ACS Oil Controls & Accessories spares Sporlan SEH-100 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil for Liquid Injection CTG Dehydrator (Core) Indicator Moisture Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical spares MCCB Siemens - 3VL3720, 200A Siemens Contactor, 3TF50,110A, Coil for Contactor, 3TF50,110A Siemens Contactor, 3TF47,70A, 220 VAC Coil for Siemens Contactor, 3TF47, 70A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel spares Constant Voltage Transformer, 150 VA MCS Board Panel Mount Type- MCS 8 (230v.) SI-16 Extension Board, 230V. Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module E PROM chip Control Panel Fuse 1 1 1 1 2 4 1 1 1 1 ON/OFF 220 VAC 1 2 2 1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 18 Litres 56*200L 220V, 150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO REINZ-AFM 34, 1.5t 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200mm Description Qty. Nos. Specification
54

Item BAAN CODE Compressor spares CDSAI0150 3105-1143A 3101-1051B 3105-1146A 3101-1006A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1024C 3105-1004A-3 4404-056 CDSPI0710 EAECI0010 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0010 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAMAZ0560 EAGAI0050 BSC-145W (RC18) Screw Compressor for R22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Suction Filter Gasket for 4" Flange Oil Level switch Blue Star ACS Oil Controls & Accessories Spares Sporlan SEH-100 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical Spares MCCB 3VL3725, 250A Siemens Contactor 3TF49 / 85A ., 220 VAC Coil for Contactor,3TF49/85A ,220 V Siemens Contactor,3TF51,140A , 220 VAC Coil for Contactor, 3TF51, 140A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel Spares Constant Voltage Transformer, 150 VA MCS Board Panel Mount Type- MCS 8 (230V.) SI-16Extension Board, 230V. Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Sensor with 20' Cable (0-500psig)- TI 500-20 Temperature Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module E PROM chip Control Panel Fuse 1 1 1 1 2 4 1 1 1 1 ON/OFF 1 1 1 2 2 1 1 1 1 1 1 1 3 1 1 1 1 1 1 2 2 2 1 1 1 1 23 Litres 220V,150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200 mm Description Qty. Nos. Specification
User's Manual
55

Item BAAN CODE CDSAI0170 3105-1143A 3101-1051B 3105-1146A 3101-1006A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1024C 3105-1004A-3 4404-056 CDSPI0710 EAECI0030 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0010 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAMAZ0560 EAGAI0050 Description Compressor spares BSC-160W (RC19) Screw Compressor for R22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Suction Filter Gasket for 4" Flange Oil Level switch Blue Star ACS Oil Controls & Accessories Spares Sporlan SEH-175 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical Spares MCCB 3VL3725, 250A Siemens Contactor 3TF52 / 170A ., 220 VAC Coil for Contactor,3TF52/170A ,220 V Siemens Contactor,3TF50,110A , 220 VAC Coil for Contactor, 3TF50, 110A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel Spares Constant Voltage Transformer, 150 VA MCS Board Panel Mount Type- MCS 8 (230V.) SI-16Extension Board, 230V. Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Sensor with 20' Cable (0-500psig)- TI 500-20 Temperature Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module E PROM chip Control Panel Fuse 1 1 1 1 2 4 1 1 1 1 ON/OFF 1 2 2 1 1 1 1 1 1 1 1 1 6 1 1 1 1 1 1 2 2 2 1 1 1 1 23 Litres 220V,150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200 mm Qty.Nos. Specification
56

Item BAAN CODE Compressor spares CDSAI0180 3105-1004a-3 3107-1143a 3101-1051B 3107-1146a 3101-1006a-3 4401-30 4401-30 3101-1003a 4804-01 3107-1054a 3107-1024c CDSPI0710 EAECI0030 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 BSC-210W (RC-20) Screw Compressor for R22 4"Gasket For Discharge Flange Oil Filter Oil Heater (220V) Inner Gasket Of Oil Filter Flange Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Gasket For Suction Filter Suction Filter Blue Star ACS Oil Controls & Accessories Spares Sporlan SEH-175 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical Spares MCCB 3VL 4731, 315 A EAMAZ0520 EASHZ0060 EAMAZ0205 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EATFZ0010 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAMAZ0560 EAGAI00500 SPPR, GIC SM-101 4 Position Selector Switch - Salzer 61198 ON/OFF MCB - 4A, 2 Pole, 415V, 3KA, for controller Siemens Contactor 3TF53, 205A ., 220 VAC Coil for Siemens Contactor, 3TF53, 205A ,220 V Siemens Contactor,3TF52, 170 A , 220 VAC Coil for Siemens Contactor, 3TF52,170A, 220 V Micro Control Panel Spares Constant Voltage Transformer, 150 VA MCS Board Panel Mount Type- MCS 8 (230V.) SI-16Extension Board, 230V. Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Sensor with 20' Cable (0-500psig)- TI 500-20 Temperature Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module E PROM chip Control Panel Fuse 1 1 1 1 2 4 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 6 1 1 1 1 1 1 1 2 2 2 1 1 1 28 Litres 220V,150W Teflon 1.5t Reinz-Afm 34, 1.5t 220v 2743k0r30-4344 Sdh12223ds Nok,1515sps ALCO 161.5*1.5t 159*210l Reinz-Afm 34, 1.5t Description Qty. Nos. SPECIFICATION
User's Manual
57

Item BAAN CODE Compressor Spares CDSAI0140 3105-1143A 3101-1051B 3105-1146A 3101-1148A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1004A-3 3105-1024C 3105-1004A-3 4405-56 CDSPI0710 EAECI0010 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0020 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAGAI0040 EAMAZ0550 EAMAZ0560 EAGAI0050 EBMBI0050 BSC-105W (RC16) Screw Compressor for R 22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Outer Gasket of Oil Filter Flange Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring Included) 4" Gasket Suction Filter Gasket for 4" Flange Oil Level Switch Blue Star ACS Oil Controls & Accessories Spares Sporlan SEH-100 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Coil CTG Dehydrator (Core) ( L Type Strainer) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical spares MCCB Siemens - 3VL3720, 200A Siemens Contactor, 3TF50,110A, Coil for Contactor, 3TF50,110A Siemens Contactor, 3TF47,70A, 220 VAC Coil for Siemens Contactor, 3TF47, 70A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel spares Constant Voltage Transformer, 500 VA MCS Board Panel Mount Type- MCS 8 (230V) SI-16 Extension Board, 230V. Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 Pr. Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 Interface board IB6Q Sporlan INT 69 module E PROM chip Control Panel Fuse MCS I/O Expansion Board (230 V) 1 1 1 2 4 6 2 2 2 1 1 1 ON/OFF 220 VAC 2 4 4 2 2 2 1 1 2 2 2 2 6 2 2 2 2 2 2 4 4 4 2 2 2 2 2 30 Litres 56*200L 220V, 150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO REINZ-AFM 34, 1.5t 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200mm Description Qty. Nos. Specification
58

Item BAAN CODE Compressor Spares CDHAI0140 3105-1143A 3101-1051B 3105-1146A 3101-1148A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1004A-3 3105-1024C 3105-1004A-3 4405-56 CDSPI0710 CDSAI0150 3105-1143A 3105-1146A 3101-1051B 3101-1006A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1024C 3105-1004A-3 4404-056 CDSPI0710 EAECI0010 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 BSC-105W (RC16) Screw Compressor for R 22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Outer Gasket of Oil Filter Flange Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring Included) 4" Gasket Suction Filter Gasket for 4" Flange Oil Level Switch Blue Star ACS Oil BSC-145W (RC18) Screw Compressor for R22 Oil Filter Inner Gasket of Oil Filter Flange Oil Heater (220V) Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Suction Filter Gasket for 4" Flange Oil Level switch Blue Star ACS Oil Controls & Accessories spares Sporlan SEH-100 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil for Liquid Injection CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical spares MCCB Siemens - 3VL3720, 200A Siemens Contactor, 3TF50,110A, Coil for Contactor, 3TF50,110A Siemens Contactor, 3TF47,70A, 220 VAC Coil for Siemens Contactor, 3TF47, 70A ,220 V SPPR, GIC SM-101 220 VAC 1 2 2 1 1 2 2 2 2 2 6 2 1 1 1 1 1 2 2 2 1 1 1 1 1 15 Litres 1 1 1 1 1 2 2 2 1 1 1 1 23 Litres TEFLON 1.5t 220V,150W REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200 mm 56*200L 220V, 150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO REINZ-AFM 34, 1.5t 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200mm Description Qty. Nos. Specification
User's Manual
59
Item BAAN CODE Compressor Spares EASHZ0060 EAMAZ0205 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EATFZ0020 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAGAI0050 EBMBI0050
Description
Qty. Nos. ON/OFF 1 1 1 1 1 2 2 1 1 1 2 4 6 2 2 1 1
Specification
4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller MCCB 3VL3725, 250A Siemens Contactor 3TF49 / 85A ., 220 VAC Coil for Contactor,3TF49/85A ,220 V Siemens Contactor,3TF51,140A , 220 VAC Coil for Contactor, 3TF51, 140A ,220 V Micro Control Panel spares Constant Voltage Transformer, 500 VA
MCS Board Panel Mount Type- MCS 8 (230v.) SI-16 Extension Board, 230V. Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module Control Panel Fuse MCS I/O Expansion Board (230 V)
60

Item BAAN CODE Compressor spares CDSAI0150 3105-1143A 3101-1051B 3105-1146A 3101-1006A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1024C 3105-1004A-3 4405-56 CDSPI0710 EAECI0010 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0020 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAGAI0050 EBMBI0050 BSC-145W (RC18) Screw Compressor for R22 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Suction Filter Gasket for 4" Flange Oil Level Switch Blue Star ACS Oil Control & Accessories Spares Sporlan SEH-100 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical Spares MCCB 3VL3725, 250A Siemens Contactor 3TF49 / 85A ., 220 VAC Coil for Contactor,3TF49/85A ,220 V Siemens Contactor,3TF51,140A , 220 VAC Coil for Contactor, 3TF51, 140A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel Spares Constant Voltage Transformer, 500 VA MCS Board Panel Mount Type- MCS 8 (230v.) SI-16 Extension Board, 230V. Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module Control Panel Fuse MCS I/O Expansion Board (230 V) 1 1 1 2 4 6 2 2 1 1 ON/OFF 2 2 2 4 4 2 1 1 2 2 2 2 6 2 2 2 2 2 2 4 4 4 2 2 2 2 46 Litres 220V,150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200mm Description Qty. Nos. Specification
User's Manual
61

Item Baan CODE CDSAI0170 3107-1143A 3101-1051B 3107-1005A-3 4401-30 4401-30 SDH12223DS 3101-1003A 4804-01 3107-1024C 3107-1004A-3 3101-1052C 4405-56 CDSPI0710 EAECI0030 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0020 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAGAI0050 EBMBI0050 Oil Filter Oil Heater (220V) 3' Gasket For Discharge Flange Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring Included) Suction Filter Gasket for Suction Filter Flange Oil Heater Oil Level Switch Blue Star ACS Oil Controls & Accessories Spares Sporlan SEH-175 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical Spares MCCB 3VL3725, 250A Siemens Contactor 3TF52 / 170A ., 220 VAC Coil for Contactor,3TF52/170A ,220 V Siemens Contactor,3TF50,110A , 220 VAC Coil for Contactor, 3TF50, 110A ,220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel Spares Constant Voltage Transformer, 500 VA MCS Board Panel Mount Type- MCS 8 (230v.) SI-16 Extension Board, 230V. Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module Control Panel Fuse MCS I/O Expansion Board (230 V) 1 1 1 2 4 6 2 2 1 1 ON/OFF 2 4 4 2 2 2 1 1 2 2 2 2 12 2 Description BSC-160W (RC-19) Screw Compressor for R22 Qty. Nos. 2 2 2 2 4 4 4 4 2 2 2 2 46 Litres 220V,150W REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 NOK,1515SPS ALCO 60mesh REINZ-AFM 34, 1.5t 12.7,220V*300w RFS-8-2, 1200mm Specification
62

Item Baan CODE CDSAI0170 3105-1143A 3101-1051B 3105-1146A 3101-1006A-3 4401-30 4401-30 3101-1003A 4804-01 3105-1024C 3105-1004A-3 4404-056 CDSPI0710 CDSAI0180 3105-1004a-3 3107-1143a 3107-1146a 3101-1006a-3 4401-30 4401-30 3101-1003a 4804-01 3107-1054a 3107-1024c CDSPI0710 EAECI0030 EAGAI0040 EASBI0140 EASBI0145 FEDBI0140 VAAAZ2106 EAMAZ0470 EAMAZ0480 EAMAZ0490 EAMAZ0500 Oil Filter Oil Heater (220V) Inner Gasket of Oil Filter Flange Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Suction Filter Gasket for 4" Flange Oil Level switch Blue Star ACS Oil BSC-210W (RC-20) Screw Compressor for R22 4"Gasket For Discharge Flange Oil Filter Inner Gasket Of Oil Filter Flange Gasket (For Motor Cable Cover Plate) Solenoid Coil Solenoid Valve (Stepless Control) Solenoid Valve Gasket Oil Sight Glass (O-Ring included) Gasket For Suction Filter Suction Filter Blue Star ACS Oil Controls & Accessories Spares Sporlan SEH-175 Electronic Expansion Valve Sporlan Interface Board IB6 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Sporlan SV B10 S2 Solenoid Valve Coil CTG Dehydrator (Core) Sporlan Expansion Valve BBIVE-4 for Liquid Injection Electrical Spares MCCB 3VL3725, 250A Siemens Contactor 3TF52 / 170A ., 220 VAC Coil for Contactor,3TF52/170A ,220 V Siemens Contactor,3TF50,110A , 220 VAC 1 2 2 1 2 2 2 2 12 2 Description BSC-160W (RC19) Screw Compressor for R22 Qty. Nos. 1 1 1 1 1 2 2 2 1 1 1 1 23 Litres 1 1 1 1 1 2 2 2 1 1 1 28 Litres Teflon 1.5t Reinz-Afm 34, 1.5t 220v 2743k0r30-4344 Sdh12223ds Nok,1515sps ALCO 161.5*1.5t 159*210l Reinz-Afm 34, 1.5t 220V,150W TEFLON 1.5t REINZ-AFM 34, 1.5t 220V 2743K0R30-4344 SDH12223DS NOK,1515SPS ALCO 110*103L REINZ-AFM 34, 1.5t RFS-8-2, 1200 mm Specification
User's Manual
63
Item Baan CODE EAMAZ0510 EAMAZ0480 EAMAZ0490 EAMAZ0500 EAMAZ0510 EAMAZ0520 EASHZ0060 EAMAZ0205 EATFZ0020 EBMBI0040 EBMBI0140 SATAI0075 SATAI0070 SATAI0080 EATDI0060 EAMAZ0550 EAGAI0050 EBMBI0050
Description Coil for Contactor, 3TF50, 110A ,220 V MCCB 3VL 4731, 315 A Siemens Contactor 3TF53, 205A ., 220 VAC Coil for Siemens Contactor, 3TF53, 205A ,220 V Siemens Contactor,3TF52, 170 A , 220 VAC Coil for Siemens Contactor, 3TF52,170A, 220 V SPPR, GIC SM-101 4 Positionn Selector Switch - Salzer 61198 MCB - 4A, 2 Pole, 415V, 3KA, for controller Micro Control Panel Spares Constant Voltage Transformer, 500 VA MCS Board Panel Mount Type- MCS 8 (230v.) SI-16 Extension Board, 230V. Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 Pressure Transducer with 20' Cable (0-500psig)- TI 500-20 Temp. Sensor with 20' Cable -MCS- T100-20 Current Sensor (CT) 0 to 250 amps. - CT-250 INT 69 module Control Panel Fuse MCS I/O Expansion Board (230 V) ON/OFF
Qty. 1 1 2 2 1 1 2 1 1 1 1 1 2 4 6 2 2 1 1
Specification
64
The field feed back card as per the format below shall be send to factory on receipt of the Chiller
Field Feed Back Card - Receipt of Chiller at Site Return To : Manufacturing Unit - Thane Water cooled Screw Chiller
Product : Chiller Model : Sr. No. :
Customer Name : Date : Observation Quality Of Packing Receipt of Documents - Packing List - Test Report - Truck No. Condition Of Parts : - Frame Work - Compressor - Condenser - Cooler - Electrical Panel - Refrigerant Piping - Controls - Idle Pressure Remarks : Ok / Ok / Ok / Ok / Ok / Ok / Ok / Ok / Yes / No Yes / No Comments OK / Damaged
Location : Details Of Defects
Checked By For Factory Use : - Date Of Receipt : - Comments : - Action By :
User's Manual
65
The field feed back card as per the format below shall be send to factory after Commisioning of the Chiller
Field Feed Back Card - Commissioning of Chiller at Site

Product : Chiller Model : Sr. No. : Customer Name : Engineers Name : Observation Installation/Precommissioning Checks : - Unit Installed and levelled - Installation - Condenser water connection terminated properly with isolation required - Chilled water connection terminated properly with isolation required - Electrical connection with Earthing terminated properly - Condenser water and Chilled water system properly flushed - Water Quality checked - Meggering of Cabling done - Condenser water and Chilled water Pump commissioned Water flow adjusted to the design flow by checking pressure drop Water flow switches connected with electrical panel Check up Voltage Commissoned the Chiller Noise Level Vibration Check Current Testing done at site Performance data as per format - Commissioning Date - Commissioning By Remarks : Ok / Ok / Ok / Comments Remarks Water cooled Screw Chiller
Location :
Ok / Ok / Ok / Ok / Ok / Ok / Ok / Ok Ok Ok Ok Ok Ok Ok Ok / / / / / / / /
Starting 400 10% Running 400 10% Long term running 400 5%
Note : Warranty will be valid only after receipt of this card at the factory For Factory Use : - Date Of Receipt : - Action By : - Comments :
66
Hand over the Chiller to the Customer as per the format and establish Warranty COMMISSIONING & HANDING OVER REPORT
Our Ref: Date: Date: Date: Equipment : Blue Star make Cooled Screw Chillers
BLUE STAR LIMITED
Cust. Ref. PURCHASE ORDER
Model: Sl.No.
Customer Name & Address
Programme Departure Arrival Work started Work completed Departure
Place
Date
Time
Equipment location : Call made by Nature of service COMMISSIONING
Arrival
Received by:
Date
Materials used
Time
Qty.
Service rendered Supplied,Installed,Tested and commissioned Blue Star make Water Cooled Screw Chillers and they are put into regular operation. The Model No. & Serial Nos. of the units are given below : CHILLER MODEL : SERIAL NO. OF MACHINE NO.1 SERIAL NO. OF MACHINE NO.2 : :
The chillers are handed over to the customer for the beneficial use.
Equipment warranty expires on : For office use: Attended by: Blue Star Ltd. Signature:
The above equpiment has been installed & commissioned to our satisfaction. Other comments (if any).
o To bill
5091-10C
o Not to bill
Date : Customers Stamp & Signature Registered Office : Kasthuri Buildings, Jamshedji Tata Road, Mumbai 400 020
User's Manual
67
Recommended water quality standards:

Test items Chilled water quality pH Total hardness (CACO3) ppm Total Alkalinity (CACO3) ppm Chloride Ion (ppm) Total Ion (Fe) ppm Silica (SiO2) ppm Ammonium Ion ppm Less than 100 Less than 50 Less than 0.3 Less than 30 Less than 0.2 Less than 100 Less than 200 Less than 1.0 Less than 50 Less than 1.0 Less than 80 Less than 50 Less than 0.3 Less than 30 Less than 0.2 Max. 80 Less than 200 Max. 50 7.2 - 8.5 Cooling Tower water quality 7.2 - 8.5 Make up water quality 6.0 - 8.0
68
Log report
Customer's Name Date: Time
S.No
1
Description
Voltage R-Y Voltage Y-B Voltage R-B
Units
Volts Volts Volts Amps. Amps. Amps. Hz PSIG PSIG Amps.
0 0
10.00
12.00
14.00
16.00
18.00
Current - R Current - Y Current - B
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Supply Frequency Suction Pressure comp. Discharge Pressure comp. Compressor Current. Cooler Entering Water temp. Cooler Leaving Water temp. Cooler Pressure drop Cooler water Flow rate Condenser Entering water temp. Condenser Leaving water temp. Condenser Pressure drop Condenser water Flow rate Refri. System temp. - Suction Refri. System temp.-Discharge. Refri. System temp. - Liquid
F F
PSIG US GPM
0 0
F F
PSIG US GPM
0 0 0
F F F
User's Manual
69
WARRANTY CLAIM FORM

For Blue Star Water Cooled Screw Chillers
A copy of this form is to be filled in case of the Chiller failure, by BSL Engineer) Location(City) ....... Chiller Serial No. Date of commissioning Warranty expiry date Date ....
Chiller Model No: Date of despatch Warranty commencing date Application in which equipment is used Customers Name and Address
Dealers Name and Address
Starting Problem Noise at Starting Noise while running Compressor: o High Noise
o o
Yes Yes
o o o o o o
No No
o Yes o Vibration o Vibration o Yes o Yes o
No Condenser/Oil cooler Shaft bend No
Unbalanced
o High Noise Fan: Any mounting bolts loose:

Electrical problem
Voltage Yes No Insulation resistance (Megger test)....... Ohms Motor
o o
No
Jammed Bearing noise
o o o o o o o o o o o
Burnt out No No No No No No No No No No
Any leakage in the condenser coil Any vibration in piping Less cooling in cooler Checked Water flow rate Checked Compressor working in full Load High Ambient Temperature Operating pressure checked Shortage of refrigerant Air cooled condenser coils clogged All the fans working
o o o o o o o o o o
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Signature & Seal of Customer Date . Claim settled
Signature & Seal of BSL Engineer Date . (For factory use only) Claim rejected
Credit advice No. ...........................
Reasons for rejection .................................................................................... Settlement authorised by: .. Date .
70
Warranty
Blue Star Screw Chillers carry a warranty for a period of 12 months from the data of commissioning or 15 months from the date of delivery, whichever is earlier, unless stated otherwise in the contract of sales.
Terms of Warranty
Blue Star extends a comprehensive warranty on its systems, which entitles the customer to the following 1. Repair / reconditioning, by BSL / BSL Dealer, through whom the machine has been purchased, of any part of the equipment found defective within 12 months from the date of commissioning or 15 months from the date of despatch whichever is earlier. The warranty is valid only if:
2.
2.1. Installation and commissioning is taken care of by BSL/their authorised persons. 2.2. The equipment is operated as per the Companys operating instructions. 3. The above said warranty does not cover the following:
3.1 Any leakage of Refrigerant due to improper operations 4. This warranty is not valid if any repair and/or modifications are carried out by the customer himself or his representative without written concurrence from Blue Star Limited. The warranty extended herein is in lieu of all implied conditions/ warranties under the law and is confined to the repairs or replacements of defective parts and does not cover any consequential or resulting liability damage or loss arising from such defect. Furthermore, the warranty in no case, shall extend to the payment or any monetary consideration whatever of the replacement or return of the Screw Chiller as a whole Any repair/ replacement shall not extend the overall warranty period as specified above. The cost of transportation of material and of persons beyond Municipal jurisdiction shall be borne by the customer. This warranty may be read in conjunction with any other warranty on the installation as a whole, if the Screw Chiller is supplied as part of a Project.
5.
6. 7. 8.
User's Manual
71
For any assistance, CALL:

Blue Star Service:
Ph: ............................................................ Cell: ..........................................................
Blue Star Dealer:

Ph: ............................................................ Cell: ..........................................................
Blue Star Regional Manager:

Ph: ............................................................ Fax: ..........................................................
Blue Stars/Dealers engineer to fill above details before handing over this Manual to customer.
72
Service Centres
EAST
BHUBANESHWAR 3A, Satya Nagar, 2nd Floor, Bhubaneswar - 751 007. Tel: (0674) 2508270 / 2508239 GUWAHATI New Star Freeze Building 2nd Floor, Opp. Kunjalata Bibah Bhawan, G. S. Road, Guwahati - 781 005. Tel: (0361) 2340619 / 2340620 KOLKATA 7, Hare Street Kolkata 700 001. Tel: (033) 22134200 / 22106609
SOUTH
BANGALORE Salarpuria Centre II No. 13, Ward No. 67 Koramangala Industrial Layout Koramangala Bangalore 560 095. Tel: (080) 51854200 / 51854000 CHENNAI 104, Garuda Building, Cathedral Road, Chennai 600 086. Tel: (044) 52444200 28116707- 8 KOCHI 39/5766, Tharakandam Estate Kurisipally Road Kochi 682 015. Tel: (0484) 2356139 / 2357933 / 2357934 SECUNDERABAD 207, Sikh Road Bantia Estates Secunderabad 500 003. Tel: (040) 27847553 / 27842057-58 / 27815469 TRIVANDRUM T.C. IX/1490 Chandrika, Sasthamangalam Trivandrum - 695 010. Tel: (0471) 2720025 / 2720065 VISAKHAPATNAM 47-12-6/7 2nd Floor Amaravathi Complex Dwarakanagar Visakhapatnam 530 016. Tel: (0891) 2748405 / 2748433
WEST
BHOPAL Star Arcade, 2nd Floor Plot No.165A & 166, Zone-I Maharana Pratap Nagar Bhopal - 462 011. Tel: (0755) 2553378 / 5273378 / 79 GOA 1st Floor, Flat No.1 Vaibhav Apartment Vidya Nagar Colony Miramar, Panjim, Goa 403 001. Tel: (0832) 2461671 / 2462087 MUMBAI Blue Star House 9A, Ghatkopar Link Road Saki Naka, Mumbai 400 072. Tel: (022) 56684200 / 56684000 NAGPUR 219, Bajaj Nagar, 1st Floor, South Ambazari Road, Nagpur 440 010. Tel: (0712) 2229244 / 2249000 PUNE 201/A, Nityanand Complex 1st Floor, 247/A Bund Garden Road Pune 411 011. Tel: (020) 26113031 / 26127230 / 26122307 VADODARA Ramakrishna Chambers 7th Floor, Productivity Road Alkapuri, Vadodara 390 005. Tel: (0265) 2338561 / 2332021 / 2332022
NORTH
CHANDIGARH SCO 1, Madhya Marg, Sector 26 Chandigarh 160 019. Tel: (0172) 2790482 / 5004000 JAIPUR 33, Kiran Path Suraj Nagar West, Civil Lines Jaipur 302 006. Tel: (0141) 5179359 / 2225326 LUCKNOW B-140, Nirala Nagar Lucknow 226 007. Tel: (0522) 2787274 / 2786172s NEW DELHI E-44/12 Okhla Ind. Area Phase II, Ohkla New Delhi - 110 020. Tel: (011) 41494200 / 000
* 4 - ) 6 0 - - ) 5 ;
User's Manual
73
* 4 - ) 6 0 - - ) 5 ;

User Manual Screw Chiller Water Cooled

Transféré par

Informations du document

Description originale:

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

User Manual Screw Chiller Water Cooled

Transféré par

Droits d'auteur :

Formats disponibles

Water Cooled Screw Chiller

High on Features Low on Operating Costs

Screw Chiller (Water Cooled)

Water Cooled condenser

Refrigerant liquid injection

Electronic expansion valve

Screw Chiller (Water Cooled)

Micro Control Panel

Two Levels of Safety

Motor Overload Suction Superheat

Starting Current HP / LP Refrigerant Migration

Screw Chiller (Water Cooled)

LIQUID CHILLER WATER COOLED

NOM. CAP. IN TR NO. OF COMPRESSORS SCREW COMPRESSOR

Screw Chiller (Water Cooled)

PRESSURE DROP (FT.H20)

Electronic Expansion Valve

4-Pin Feed Through

Bronze Guide Lead Screw

Red + < Green

White + < Black

Bipolar Drive Sequence

Q1-04 Q2-Q3 ON ON OFF OFF ON OFF OFF ON ON OFF

Q5-Q8 Q6-Q7 ON OFF OFF ON ON OFF ON OFF OFF

Screw Chiller (Water Cooled)

Screw Chiller (Water Cooled)

PC Support Software for Micro Control Panel

Micro Control Panel Network

MICRO CONTROL PANEL NETWORK LOCAL PC SUPPORT ONLY

Micro Control Panel-I/Os

Micro Control Panel-I/Os

Micro Control Panel-I/Os

Micro Control Panel RS 485 Gateway

Remote PC with Windows & PC-Connection

Screw Chiller (Water Cooled)

MICRO CONTROL PANEL NETWORK REMOTE PC SUPPORT ONLY

Micro Control Panel-I/Os

Micro Control Panel-I/Os

Micro Control Panel-I/Os

Micro Control Panel RS 485 Gateway

REQUIREMENTS FOR PC SOFTWARE

Minimum System Required to Run Program

Screw Chiller (Water Cooled)

Micro Control Panel

View No No No No Yes Yes No No No No no no Yes

Service Yes Yes No No Yes Yes No No No Yes Yes Yes Yes

1 SP DP OPD AMP 65 260 195 44

FANS 1LOT ON/OFF FANS 2LOT ON/OFF

ADDITIONAL STATUS INFO

Chiller Configuration Example

Screw Chiller (Water Cooled)

COMP 1 = STARTS = STARTS = LOAD = STARTS = UNLOAD = STARTS =

000016h 000000040 000000029 000002h 000007996 000001h 00000863

LIQ.LINE STARTS STARTS STARTS ALARM STARTS

000016h 000000028 000000035 000000034 000000h 000000015

NO ACTIVE LOCKETS SEL NEXT OPTION ECT

Screw Chiller (Water Cooled)

Detail of Micro Control Panel and I/O Key Items

IB Series interface boards (IB 6)

+4-20 -4-20 Black White Green Red IN GND 24V-1 24V-2

Configure the Board

Screw Chiller (Water Cooled)

Jumper for close on input rise