User Manual Screw Chiller Water Cooled

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Water Cooled Screw ChillerHigh on Features

Low on Operating Costs

First published March 2006

No part of this publication may be reproduced in anymanner whatsoever without permission in writing from theExecutive 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 consequenceof any action taken, on the basis of this publication.

Since ASHRAE standards use the FPS system, FPS nomenclatureis 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.

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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

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Blue Star has been a pioneer in developing and manufacturingChillers for various applications. A new generation of Water CooledScrew Chiller is being added to the present range of Reciprocatingand Scroll Chillers. The Chiller is energy-efficient and robust inconstruction. These chillers are developed with state of art technologywhich includes Hanbell screw compressor, high-efficiency cooler,water-cooled condenser, refrigerant liquid injection for motor coolingespecially during part load operation, electronic expansion valveand Micro Control Panel. The units have low input KW/TR and aretested 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 usesthe BSC Series compressors specially manufactured for Blue Starby Hanbell.

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CompressorThe Screw Compressor has advantages compared to othercompressors, due to its inherent design features. The Compressorhas only two moving parts, viz. Male & Female Screws and SlideValve. The wear and tear is thus minimum, the life of the Compressoris higher. Due to its inherent characteristics, a Screw Compressorhas the highest volumetric efficiency, and de-rating at highertemperature is negligible.

It has stepless capacity control, usually from 25% to 100%. Thisfeature makes it ideally suitable for varying load applications, andhas better efficiency under part load conditions (Condenser andEvaporator are designed for 100% capacity). This capacity control,also helps in limiting the starting current as the system can bestarted in unloaded condition (25%), and the loading is done stepless.

The Screw Compressor is Semi-Hermetic in construction, whichmakes it serviceable. Due to geometrically symmetrical moving parts,the Compressor has extremely low vibrations. The Compressor istested in accordance with ARI standards.

CoolerThe shell and tube evaporator has been built using inner groovedcopper tubes, and has been optimised for refrigerant and watervelocities. The shell is manufactured from high-grade steel. Theexpansion of the tube is done with controlled process.

Water Cooled condenserThe copper tubes used are inner grooved type, with higher heighttrapezoidal cross section, to increase the internal surface area ofheat transfer.

Refrigerant liquid injectionThe refrigerant suction gas cools the winding of the semi hermeticscrew compressor motor. As an abundant precaution, liquidrefrigerant will be injected to the suction side of the compressor tocool the motor winding. This is especially required during part loadoperation where the suction gas quantity reduces. Liquid injectionduring this period keeps the motor winding temperature within limits.This is provided as a standard feature.

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Electronic expansion valveThe Screw Chillier is fitted with an electronic expansion valve withits drivers, as an integral part of the Micro Control Panel. Thealgorithm is built to ensure most appropriate operation of theexpansion valve motor. This system adjusts the opening of thevalve with shorter response time, against varying load conditions,resulting into optimising of power. Coupled with the stepless capacitycontrol which is a feature of the Screw Compressor, the electronicexpansion valve will maximise power savings.

The electronic expansion valve operates on a principle of openingand closing of valve through a Stepper motor, which has 6386 stepsper revolution. The signal for the Stepper motor is received throughthe Micro Control Panel. Electronic expansion valves thus haveadvantage over normal Thermostatic expansion valves, which haveslower response for the changing conditions. The electronicexpansion valve adjusts itself based on suction superheat andmonitors the flow of refrigerant quickly and accurately, as comparedto thermostatic expansion valve. This inherent feature allows thesystem to operate in a very narrow band of superheat, resulting inpower saving.

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Control PanelThe Control panel has been designed with construction features, sothat it is mounted on the same structure. Electronic Micro ControlPanel, the Power section and the Termination sections are clearlyseparated for ease of installation and servicing.

Micro Control PanelMicro Control Panel has Digital Control and setting of Temperaturevalues, Temperature setting and control is in the range of ± 0.5°F.Micro Control Panel has step less capacity control from 25% to100%, Non-Volatile Memory backup for all set points, Automaticpower failure reset, Built-in time delays for compressors, Singlephase/phase reversal protection, Password protection at 4 levelsand in-built Anti-freeze and Flow switch safety.

Micro Control Panel is provided with RS-232 port for direct remotecomputer connectivity (up to 50 feet), Fault Indication and Statusfacility and RS-485 connection (up to 6000 ft). PC connectionProgram provides both local and remote communication to MicroControl Panel. The Micro Control Panel automatically performshistory logging and this program will graph the selected items.

Micro Control Panel has BMS Compatibility (J C N2, Bacnet andModbus protocol available). Translator is optional.

Micro Control Panel has Remote Monitoring and Access throughP.C. with Modem and dedicated telephone line without BMS as astandard feature through RS232 & RS485 (P.C., Modem, Gatewayfor units are Optional and not in the scope). Also remote monitoringcan be done with a web monitor connected to the panel and furtherto customer’s LAN.

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Two Levels of SafetyThe Chiller is protected with Primary and Secondary Safety Systems.This has been done to protect the Chiller, even in the case of failureof any of the protection devices. Care has been taken to ensurethat there are no nuisance alarms generated. The Protection deviceis as tabulated below:

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SR DESCRIPTION UNIT MODEL

No. LCWX2-208 LCWX2-250 LCWX2-290 LCWX2-320 LCWX2-370

1 Nominal Capacity kW (TR) 731.8 ( 208) 879 (250) 1019.64 (290) 1125.12 (320) 1300 (370)

2 Compressor Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw

Model BSC-105W, 2# BSC-105W + BSC-145W BSC-145W , 2# BSC-160W+BSC-160W BSC-160W+BSC-210W

3 Refrigerant R22 R22 R22 R22 R22

Power Supply V/PH/HZ 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.,

50HZ 50HZ 50HZ 50HZ 50HZ

4 Power Consumption KW 170.1 202.3 234.4 260 299

5 Refrigerant/Oil Charge Kg./Ltr 180/32 237/38 275/46 304/46 351/51

6 Cooler (DX -Shell & Tube Type) Model YCH-222A YCH-105A + YCH-152A + YCH-177A + YCH-177A +

YCH-152A YCH-152A YCH-177A YCH-222A

Water Flow Min USGPM 416 500 580 640 740

Max USGPM 624 750 870 960 1110

Connection Sizes INCHES 8 8 8 8 8

7 Condenser (Shell & Tube type) Model YCD-222A YCD-105A + YCD-151A + YCD-176A + YCD-176A +

YCD-151A YCD-151A YCD-176A YCD-222A


Max USGPM 832 1000 1160 1280 1480

Inlet & Outlet connection Slip on INCHES 6 (1each) 8 (1 each) 8 (1 each) 8 (1 each) 8 (1 each)

Length mm 3100 3400 3400 3400 3400

Width mm 1200 1800 1800 1800 2000

Height mm 2300 2300 2300 2450 3000

8 OPERATING WEIGHT/UNIT (APPROX) Kg 5000 5526 6526 6862 7541

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 Factorand 90 / 97.5 Deg. F Condenser Water with 0.001 Deg. F Sq. Ft HR /BTU. Fouling Factor

SR DESCRIPTION UNIT MODEL

No. LCWX1-104 LCWX-125 LCWX1-145 LCWX1-160 LCWX1-210

1 Nominal Capacity kW (TR) 365.6 (104) 439.5 (125) 509.8 (145) 562.5 (160) 738.5(210)

2 Compressor Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw

Model BSC-105W, 1# BSC-125W , 1# BSC-145W , 1# BSC-160W ,1# BSC-210W , 1#

3 Refrigerant R22 R22 R22 R22 R22

Power Supply V/PH/HZ 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.,

50HZ 50HZ 50HZ 50HZ 50HZ

4 Power Consumption KW 85.1 101.1 117.2 130 169.3

5 Refrigerant/Oil Charge Kg./Ltr 95/16 112/18 136/23 150/23 195/28

6 Cooler (DX -Shell & Tube Type) Model YCH-103A YCH-122A YCH-152A YCH-177A YCH-222A


Max USGPM 312 375 435 480 630

Connection Sizes INCHES 6 6 6 8 8

7 Condenser (Shell & Tube type) Model YCD-101A YCD-131A YCD-151A YCD-176A YCD-221A


Max USGPM 416 500 580 640 840

Inlet & Outlet connection Slip on INCHES 4 (1 each) 4 (1 each) 4 (1 each) 5 (1 each) 6 (1 each)

Length mm 2700 2953 2979 2987 3087

Width mm 800 900 900 900 900

Height mm 2000 2102 2102 2102 2269

8 OPERATING WEIGHT/UNIT (APPROX) Kg 2500 2700 3365 3650 4600

Technical Data for Water Cooled Screw Chiller DX R22

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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. Synchronisedsignals to the motor provide discrete angular movement, whichtranslates into precise linear positioning of the valve piston. Valvepistons and ports are uniquely characterised, providing improvedflow resolution and performance. The valves are easily interfacedwith microprocessor based controllers.

Valve operationThe valves modulate by theelectronically controlled rotation of astep motor. The step motor drives a geartrain and lead screw to position a piston.The piston is used to modulate flowthrough a port, as referred in the figure.

Red

Q3 Q4 Q7 Q8

Motor

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Ball BearingGear Cup

Strain Relief

42mm stepperMotor

Gear Shaft

Bronze Guide

Retaining Nut

O-Ring

Gear

Lead Screw

4-Pin Feed Through

Motor Housing

Q1 Q2 Q5 Q6Bipolar Drive Sequence

STEP Q1-04 Q2-Q3 Q5-Q8 Q6-Q7

1 ON OFF ON OFF

2 ON OFF OFF ON

3 OFF ON OFF ON

4 OFF ON ON OFF

1 ON OFF ON OFF

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The motor is a two-phase type driven in the bi-polar mode. Twodiscrete sets of motor stator windings are powered in sequence torotate the rotor 3.6 degrees per step. Polarity of the drive signalreverses for each step.

The sequencing is accomplished through the bi-polar drive circuitshown on page 10. The drive transistors, Q1 through Q8, areelectronically biased in pairs by the controller as shown in the table.

Large valves have an operating stroke of 0.5 inches and 6386 stepsof control; therefore each step translates into 0.000783 inches(0.02mm) of travel. When used with the Micro control panel, thevalves provide unsurpassed accuracy in resolution of flow andrepeatability of position.

External parts of the valve are brass and copper and meet or exceed2000 hours salt spray tests per ASTM B-117.

The motor housing is equipped with hermetic cable connection tothe motor and a 10 feet motor lead is supplied as standard length.

Total power consumption is 4 watts when operating a rate of 200steps per second with standard L/R type drive circuitry.

The valves have a safe working pressure of 420 psig. Operatingambient temperature range is –50 deg. F to 140 deg. F (-45 deg Cto 60 deg. C) but temperature of up to 250 deg. F (120 deg. C) maybe used for dehydration.

The electronic expansion valve controls the flow of refrigerantentering the direct expansion evaporator in response to signals sentby the controller. These signals are calculated by the controller fromthe sensor inputs. A set of sensors, either two temperature sensorsor a pressure transducer and a temperature sensor, are used tomeasure superheat. Typical control is based on superheat setpoint.

The ability of the EEV to control the amount of refrigerant in theevaporator to allow reaching discharge set point while preventingflood back makes the EEV the ideal expansion device for most airconditioning, Chiller, Environmental chamber and refrigerationapplications.

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SPECIFICATIONS

Motor type : 2 phase permanent magnet,2 coil bipolar

Supply Voltage : 12 VDC, -5% + 10%, measured at thevalve leads

Connections : 4 lead, 18 AWG, PVC insulationjacketed cable.

Phase Resistance : 75 ohms per winding ± 10%

Current Range : 0.131 to 0.215 amps/winding;0.262 to 0.439 amps with twowindings energised.

Maximum power : 4 watts

Inductance per winding : 62±20% mH

Required step rate : 200 steps per second

Number of steps : 6386

Resolution : 0.000783 inches/step (0.02mm/step)

Total stroke : 0.50 inches (12.7mm)

Maximum allowable : less than 200 cc/min at 100 psiinternal leakage estimated

Maximum allowable : less than 0.10 oz/year at 300 psigexternal leakage (0.20 gr/year at 20 bar)

Safe working pressure : 420 psig (29 bar)

Operating temperature : -50 Deg. F to 140 Deg.Frange (-45 Deg. C to 60 Deg. C)

Maximum dehydration : 250 Deg. F (120 Deg. C)temperature

Compatibility : All common CFC, HCFC and HFCrefrigerants except R-410A;all common mineral, Polyolesterand Alkylbenzene oils.

Materials of construction : Copper-fittings; brass-valve body,motor housing, and adaptors:synthetic materials-seating andseals.

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Micro Control PanelThe Micro Control Panel is a rugged microprocessor based controllerthat 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 bothlocally and remotely. The Micro Control Panel provides flexibilitywith set points and control options that can be selected prior tocommissioning a system or when the unit is live and functioning.Displays, alarms and other interfaces are accomplished in a clearand simple language that informs the user as to the status of thecontroller.

The Micro Control Panel is designed to safeguard the system thatis being controlled, eliminate the need for manual intervention andto provide a simple but meaningful man-machine-interface.

PC Support Software forMicro Control Panel

PC-Config: Program provides the configuration file: points list, setpoints, options, etc., for all versions of software. This program isuser friendly with English questions and drop down menus.

PC-Conn: Program provides both local and remote communicationsto the Micro Control Panel independent of the type of software.Through this program the status of the controller can be viewed andwith proper authorisation changes can be made to the system.Configuration files can be transmitted to or received from an MCS-8 unit. The MCS-8 automatically performs history logging; thisprogram will graph selected items.

Micro Control Panel Network

The Micro Control Panel Network can support up to 50 Micro ControlPanel and its associated I/O’s. Access to this network can be localor remote via a 14.4K Baud modem. There will be no degradationin the performance of the network. The PC connected to the networkmust be running Windows 3.1 or higher with PC-Connect providingthe actual interface program.

Each Micro Control Panel in the network must be assigned a uniqueaddress when the configuration file is build using the PC - Configprogram. This address will be the key in establishing communicationswith the appropriate Micro Control Panel system. This address canbe changed from the LCD / keypad of a unit.

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MICRO CONTROL PANEL NETWORKLOCAL PC SUPPORT ONLY

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RS485 RS485

RS485

Micro Control PanelRS 485 Gateway

Remote PC withWindows & PC-Connection

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MICRO CONTROL PANEL NETWORKREMOTE PC SUPPORT ONLY

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RS485 RS485

RS485

Micro Control PanelRS 485 Gateway

14.4k baudmodem

14.4k baudmodem

Remote PC withWindows & PC-Connection

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REQUIREMENTS FOR PC SOFTWARE

To install and run the program we suggest the following systemrequirements:

Front End System Requirements

� Windows 95

� Pentium 166 MHz

� 2 Gigabyte hard disk with at least 25 Megabytes free

� 3 ½ “ 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

� Windows 3.1

� 486 66 MHz

� 500 Megabyte Hard Drive

� 3½” Floppy Drive

� VGA Display

� 8 Megabytes RAM

� 14.4k baud modem

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Authorisation function

The authorisation code is a special four-character code that enablesaccess in to the Micro Control Panel System. The code must benumeric with values between 1 and 8 if it is to be entered from theKeypad/Display. If the system is being accessed via PC-Connectprogram, the code may consist of any valid alpha/numeric characters.Each system can have up to 15 different authorization codes. Thisprovides the capability of issuing different codes to different peopleif desired. There are four levels of authorization, which providedifferent capabilities with in the system. The authorization code andthe associated level cannot be displayed or viewed in an MicroControl Panel System. These are established when building theconfiguration file in the PC-Configuration program. The authorizationcodes must be protected and remain confidential, if they arecompromised unauthorized personnel can gain access to the system.

From the Keypad/Display the following changes can be made basedupon the authorization level:

Micro Control Panel

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• No authorization is required in theDISPLAY STATUS section for viewinginformation.

• Pressing a key selects the 1st two linesof data. Repressing the same key selectsthe next two lines, etc.

• The ALARM STATUS displays all alarmsand lockouts while LOCKOUT STATUSdisplays only active lockouts.

• The “+” and “-” keys may be used withalarm & lockout status to allow scrolling.

• If one or more Micro Control Expansion

units are connected to a Micro ControlCenter the data will be presented in acontinuous sequence. ADDITIONALSTATUS information shows names, total,run hours and starts for all RO’s.

• SYSTEM PRESSURE displaysinformation by circuit, SP suctionpressure, DP discharge pressure, OPDoil pump differential, AMP or motor fault.

LOCKOUT STATUS for lockouts causedby either suction, discharge, oil or amps,the actual value at the time of the lockoutof the associated sensor is displayed.

The Micro Control Panel Keypad DisplayQuick Reference - STATUS KEYS

COMP MAIN/DELTA ONLOAD SOLENOID ON/OFFUNLOAD SOLENOID ON/OFFLIQ. LINE SOLENOID ON/OFF

FANS 1LOT ON/OFFFANS 2LOT ON/OFF

COMPRESSORSTATUS

CONDENSORSTATUS

EVAPORATORSTATUS

ALARMSTATUS

SYSTEMPRESSURE

SYSTEMSENSORS

ADDITIONALSTATUSINFO

LOCKOUTSTATUS

LIQ.OUTTEMPERATURE

1 JAN 30 09:13:00REASON FOR ALARM2 JAN 30 09:12:51LOCKOUT RESET3 JAN 30 09:12:19POWER RETURNED4 JAN 30 09:12:13POWER FAILED5 JAN 30 09:11:45ALARM LIQ.OUT6 JAN 30 09:11:44LOCKOUT RESET

7 JAN 30 09:11:33COMPUTER RESET8 JAN 30 09:11:12FREEZE9 JAN 30 09:11:01LOCKOUT RESET10 JAN 30 09:10:56ALARM LIQ.OUT11 JAN 30 09:07:30LOCKOUT RESET12 JAN 30 09:07:18

DISPLAY STATUS

1 SP DP OPD AMP 65 260 195 44

1 SUCT SAT S HEAT +55 +37 +18.1

1 DISC SAT S HEAT +180 +120 +60.4

SUCT TMP + 55.6FDISC TMP + 180.5FLIQ. OUT + 47.3FFLOW ONUNIT CTL ONEND/SELECT NEXT

COMP 1 = 000016hSTARTS = 000000040STARTS = 000000029LOAD = 000002hSTARTS = 000007996UNLOAD = 000001hSTARTS = 00000863

LIQ.LINE = 000016hSTARTS = 000000028STARTS = 000000035STARTS = 000000034ALARM = 000000hSTARTS = 000000015

5 JAN 30 09:11:45ALARM LIQ OUT5 SP DP OPD AMP8 JAN 30 09:11:02FREEZE10 JAN 30 09:10:56ALARM LIQ.OUT

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

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• The ENTRY keys (SERVICE, SETPOINT,MANUAL and PROGRAM) provide menuitems, some of which when selected willpresent sub menus.

• When making value changes theINCREASE (+) & DECREASE (-) keysmay be held for continuous updating.

• Enter authorization code at the

authorization function within the SERVICEDIAGNOSTIC key menu.

• Different items will appear depending onthe package configuration and optionsselected.

• Units may be English or Metric.

• The clock is factory set at EST or EDSTbased on time of year.

The Micro Control Center Keypad DisplayQuick Reference - ENTRY KEYS

#1 LVG LIQ OUT TARGETTEMP

#2 CTRL ZONEENTR CHG TEMP

#5 CNTRL ZONEENTR CHG TEMP

#7 POWER UP DELAYENTR CHG TIME IN SEC

SERVICEDIAGNOSTIC

SETPOINTS(SAFETIES)

MANUALOVERRIDES

LOCKOUTRESET

PROGRAMOPTIONS

INCREASE(+)

DECREASE(-)

ENTER

RELAY OUTS MANUALENTR CHG OPTIONANALG OUTS MANUALENTR CHG OPTIONSENSOR INS MANUALENTR CHG OPTION

NO ACTIVE LOCKETSSEL NEXT OPTIONECT

ENTRY

INCREASE KEY(+)& DECREASE KEY(-)Used To adjust values or changeoptions selected. (SERVICE,SETPOINTS, PROGRAM keys)

ENTER KEYSelects options or enterschanges after adjust-mentshave been made

#8 STEP SENSITIVITYENT CHG

#9 STEP DELAYTIME IN SECONDS

#10 MAXIMUM ROC

#11 ENT CHGTEMPERATURE

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CONTROL STATUSENTR CHG OPTIONAUTHORIZATIONENTER CHG OPTIONSENSOR OFFSETSENTR CHG OPTIONCLEAR ALRM HSTRYENTR CHG OPTIONCLEAR PT INFOENTR CHG OPTIONUNIT INFORMATIONENTR CHG OPTION

DATE DISPLAYENTR CHG OPTIONTIME DISPLAYENTR CHG OPTIONDATE & TIME SETENTR CHG OPTIONDAY OF WEEK SETENTR CHG OPTIONOPERATING SCHEDSENTR CHG OPTIONHOLIDAY DATESENTR CHG OPTION

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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 toMircro Control Panel I/O Items refer page 21.

High Voltage Wireway Relay Ouptus & 220 VAC 50/60 hertz InputPreferred direction of wire

Low Voltage Wireway Sensor Input, Analog Output & CommunicationsTerminals Shielded cable only, preferred direction of wire

220 VAC

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Detail of Micro Control Panel and I/O Key Items

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220 VAC

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Configure the BoardWhen used with a 0-10 volt input signal, a jumpershould be placed on the pins labelled CN3 as shownin the above Figure 1. This is the default jumperposition. The impedence for this input is 40 k ohms.Choose “Open on Rise” or “Close on Rise” operationusing the middle two pins on jumper CN2. The jumperis stored on one pin only and will cause the valve toopen as input signal rises, i.e. valve is closed at 0volts or 4 milliamps and fully open at 10 volts or 20milliamp input. By placing the jumper on both pins, theoperation is reversed so that the valve will be fullyopen at 0 volts or 4 milliamps. Other pins on CN2have been clipped at the factory and are not used foroperation of the valve.Wiring Instructions and CautionsUse the chart given next page No.24 as a guide forwire connections. Certain precautions must be takenin 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, thesecondary winding of the transformer must not beconnected to chassis ground.

2. The primary input of the transformer should beprotected by Metal Oxide Varister (MOV) surgesuppressors, supplied with the IB. For protectionfrom electrical transients, connect one MOVbetween one leg of the input voltage of the 24VAC transformer and earth ground. Connect asecond MOV between the other leg of the inputvoltage of the 24 VAV transformer and earthground.

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 TROUBLESHOOTINGWhen properly configured and installed the IB Seriesrequires no maintenance. They incorporate a numberof operational features to assure trouble free service.On power-up the board will initialize by giving the valvea large number of steps to assure that the valve isfully shut. The routine will require approximately 8seconds for the IB1, 16 seconds for the IB3 and 32seconds for the IB6. The valve will not respond toinput signals during this time.If the valve is required to shut during operation, thepumpdown terminals should be used. When given apumpdown signal, the board will shut the valveimmediately and overdrive by 250 steps to reset valveposition. On removal of the pumpdown signal the valvewill resume position as dictated by the external controlsignal.If power is lost to the IB or wire to the valve severed,the valve will remain in its last position. Solenoid valvesmay be desired before the step motor valve on criticalapplications.To force the valve shut during operation for testpurpose, simply remove the jumper from CN4 or CN3,depending on configuration. To resume normaloperation, replace the jumper.To allow for component tolerances, the IB will shut thevalve 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 willoperate simultaneously and will open and close by thesame number of steps. Valve wires must be connectedexactly the same for both valves.

�#� �� $�� %�� &�#� '(These interface boards are used to accept 0 to 10 V DC analog input signals and are designed to allowexternally supplied control signals to control one or two Sporlon step motor valves including electronic expansionvalves. IB 6 boards are used on valves with 6386 steps.

CN4 CN2

+4-20-4-20BlackWhiteGreenRedIN

GND24V-124V-2

CN3

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Wiring ConnectionsFrom left to right when the board is oriented with the terminal strip acrossthe bottom.

+4-20 - connection for the positive leg of a 4-20 milliamp or 0-10 volt signal

-4-20 - connection for negative leg of a 4-20 milliamp or 0-10 volt signal

B - black wire from valve, or both valves when two valves are used

W - white wire from valve, or both valves when two valves are used

G - green wire from valve, or both valves when two valves are used

R - red wire from valve, or both valves when two valves are used

IN - from external pumpdown switch or relay. See wiring instructions.

GND - to external pumpdown switch or relay. See wiring instructions.

24V-1 - from 24 volt, 15 VA transformer. See wiring instructions.

24V-2 - from 24 volt, 15 VA transformer. See wiring instructions.

3.0 inches

Dia. 0.125 typical & places Jumper for close oninput rise

4-20 mA. 300 ohms

4-20 mA. 1000 ohms

4-20 mA. 600 ohms

0-10 VDC

24 VAC PowerIn

Pump downSignal

Ground Lead+ Lead

0.25 typical4 places

025 typical4 places

.0 inches

4-20 mA orB-in VDCinput

digitalinput

24 vacinput

valve

b w g r

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TROUBLE SHOOTING FOR SPORLAN IB6INTERFACE CARD

TEST THE VALVE:

The resistance of the motor winding may be tested without operatingthe 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 ofthe valve. The resistance should be 75 Ohms with the valve atroom temperature or approximately 65 Ohms if the valve is at-40 deg F.

5) Measure the resistance between green and red leads this valueshould be between +/-5 %of the resistance between black andwhite leads

6) Measure the resistance from any lead to valve body. Resistanceshould be infinite, that is to say, open

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TEST THE IB:

SR. PARAMETER IF NO IF YESNO.1 Is there 24VAC at terminal? Repair or replace power Go for 2

supply or supply wiring

2 Is the valve connected to Shut off power to IB and Go for 3terminal (B,W,G,R)with correct wiringwire colors correct ?

3 Connect voltmeter on Check the step motor. Go for 4AC scale to the black If operational replace the IBand white terminal.Interrupt and restore powerto IB. Does the meter read12 VAC±1?

4 Repeat test using red and Same as in 4 Go for 5green terminal.Does the meter read12VAC +/-1?

5 Are wires for external Shut off power to IB and Go for 6signal connected to external controller and correctterminal +4-20 and -4-20 input signal observing polarity

6 Is external signal present? Shut off power Go for 7Signal should be Test or correct wiring0-10VDC?

7 Is polarity of signal correct? Shut off power. Go for 8Terminal (+) to terminal +4-20 If not correct wiringand (-) to terminal -4-20

8 Pin jumper in not required Shut off power. And correct Go for 9on CN2 & CN4; jumper positionbut required in CN3

9 IB IS FUNCTIONAL,TEST EXTERNAL CONTROLLER

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The Micro Control Panel Troubleshooting� )��*� +�$�� ,��

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� � � � � � � �Problem Potential Solution

INVALID CONFIG TYPE Indicates U10 CFG incompatible with U11 software.Example U10 CFG for home while U11 for chiller.

INVALID CONFIG Indicates Checksum invalid Reload CFG

Sensor input believed invalid Verify Berg jumpers using Quick Reference Sheets(Under Sensor Diagnostic Check board version number Check wiring of sensorSub Menu)

Communications to Micro The Verify red LED (located just to theControl Panel left of the RS-485 connector) on the gate way485-GATEWAY from PC- blinking indicates that the PC-Connect program isConnect not working. talking to the gateway. Verify that the two wire

shielded cable is properly wired from the RS-485connector to the gateway.

If both of LEDs are blinking, check the address ofthe Micro Control Panel and any otherMicro Control Panels that are on the network.Each must have a unique address.This address can be changed from the Micro ControlPanel Proper authorization is required. Enter theUNIT INFORMATION screen by depressing theSERVICE DIAGNOSTIC key and scrolling to this item.Depress the ENTER key and scroll to the NETWORKADDRESS screen. Change address if needed.Verify +12 V DC to Micro Control Panel RS485.

GATEWAY INVALID CONFIG indicates Checksuminvalid. Either set to factory defaults or resetsettings.

NOTE : All sensosr inputs should be shielded cable with shield tied to ground on MicroControl Panel Sensor Input Groung Terminal.

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RiggingWhen the chiller arrives at Warehouse/Site, proper rigging andhandling is mandatory during unloading and leading the unit intoposition.

Care must be taken to keep the unit upright during rigging. Avoidunnecessary 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 beselected to handling unloading and final placement of the equipment.The rigger must be advised that the unit contains internal componentsthat require to be kept in an upright position. Care must be exercisedto avoid twisting of the equipment.

StorageCheck for transportation damages if any and take up with factoryfor any damages.

In case the site is not ready to install the chiller, proper care shouldbe taken to store the chiller in a covered space. Check up thepressure of the unit when received. If the pressure is not holding inthe 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.

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InstallationProper care should be taken to make the foundation for the Chiller.In case the Chiller is located on rooftop, ensure that the same islocated in such a way that the load of the same is transferred tothe columns and not to the slab directly. The foundation should beproperly levelled.

Install the Chiller on the Foundation/Pedestal and grout by usingfoundation bolts. The Chiller should be levelled on the foundation.The unit should not be located nearer to any heat source or anyhigh tension line running above.

Adequate space around the Chiller as recommended in the G ADrawing should be made available for maintenance purpose.

The chilled water and condenser water piping connections to thecooler and condenser should be terminated preferably with flexibleconnections to avoid transmission of vibration if any. The pipingshall be supported external to the unit as per the recommendedpractice.

Use recommended size of power cable to be terminated to theMCCB of the Panel of the unit. Use 3 ½ core Aluminium cablealong with double earthing and terminate through proper lugs. Avoidany sharp bend for the cable at the termination point. The cableshall be adequately supported.

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Sr. no Acronym Description

1 CB Circuit breaker

2 EMG Emergency Off Mushroom Type

3 INT-69 Motor protector module

4 OCTH Oil cooler thermostat

5 1M, 2M, 3M, 4M, 5M Contactors

6 G Ground terminal

7 S1 Sensor input terminal

8 C Common connection for relay output

9 NO Normally open connection for

relay output

10 NC Normally closed connection for relayoutput

11 L Phase Line

12 N Neutral

13 TB Terminal Block

14 SP/PR Single phasing preventer / Phase reversalprotector

15 OL Overload relay

16 MCCB Molded Case Circuit Breaker

17 CT Current transformer

18 RLY Relay output

19 SI8 Sensor Input card

20 MCS Micro Control Main Board

21 LCD Touch key pad for MCS

22 OCF Oil Cooler Fan

23 MP Compressor Motor Protector

24 HTR Oil Heater

25 SV Solenoid Valve

26 TR Transformer

27 EEV Card Interface Board for EEV

28 EEV Electronic Expansion Valve

Legend for Control & Power Wiring Diagram forWater Cooled Screw Chiller

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Capacity control systemThe 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 thepiston are connected by the piston rod. The principle of operationis by using the oil pressure to drive the piston in the cylinder. Seefigure on next page. The lubrication oil flows from the oil tankthrough the oil filter cartridge and capillary then fills into the pistoncylinder due to the positive oil pressure higher than the right sideof spring force plus the high pressure gas. The positive pressuredifferential causes the piston to move towards the right side in thecylinder. When the slide valve moves towards the right side; theeffective compression volume in the compression chamber isincreasing thereby increasing the displacement of refrigerant gasand 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 nextstartup. The compressor started at full load, will result in a largerstarting current that could damage the compressor motor seriously.The capillary is provided to maintain and restrain a stable amountof oil flow to cylinder. The modulation (step less) solenoid valves(SV1 & SV2) that are controlled by micro controller with thetemperature sensor to modulate the piston position smoothly withstable output of capacity.

If the oil filter cartridge, capillary, or modulation solenoid valves arenot working very well in the capacity control system; will result inthe abnormality and ineffectiveness of the capacity control system.

In continuous (step less) capacity control system, a normally opensolenoid 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 temperaturecontroller or micro controller, refrigeration capacity control and hencecan be modulated at anywhere within 25% - 100%. Therefore, it isavailable to control the capacity output stably by modulating theinlet of SV2 and outlet of SV1 alternatively.

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Continuous capacity control system

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The continuous (step less) capacity control system needs to beassociated by a micro controller such as the Micro Control Panel aswell as PLC with LCD displayer etc.

It is very important for any controller to control the load and unloadstably. For a smooth modulation, it is suggested to install anadditional orifice valve in the oil line while a fast speed of loadingand unloading is happening.

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LubricantThe main functions of the lubrication oil in screw compressor arelubrication, internal sealing, cooling and capacity control. The positiveoil pressure in the cylinder pushes the piston and the slide valve,which is connected by a piston rod to move forward and backwardin the compression chamber. The design with positive pressuredifferential lubrication system in the BSC series is available toeleminate an extra oil pump in the compressor.

The bearings used in BSC compressor require a small but steadyquantity of oil for lubrication; the oil injection into the compressionchamber creates an oil sealing film in the compression housing forincreasing the efficiency and absorbing a portion of heat ofcompression.

In order to separate the oil from the mixed refrigerant gas, an oilseparator is required to ensure the least amount of oil carried intothe system. Pay more attention to the oil temperature, which is avery significant factor for the compressor bearings’ life. High oiltemperature will reduce the oil viscosity and cause poor lubricationand heat absorption in the compressor as well. It is recommendedto keep the oil viscosity above 15mm2/s at any temperature. If thecompressor is operated under the critical conditions, (high dischargepressure) then extra oil cooler is required. Some high viscosity oilis recommended for applications with high working condition. Ithappens often that the return oil from the evaporator is insufficientdue to the high viscosity of oil, which is difficult to be carried back,that causes the loss of oil in compressor. If the system encountersthe oil return problem then it is recommended to install extra 2nd oilseparator between the compressor discharge connection andcondenser.

Each of BSC series of compressors are equipped with two oil sightglasses as a standard; one is the oil high level sight glass and theother is the oil low level sight glass. The normal oil level in thecompressor oil tank should be maintained above the top of the lowoil sight glass and in the middle level of high oil sight glass whencompressor is running. It is recommended strongly to install theoptional accessory of oil level switch to prevent from low oil levelin 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 ofoil. Note that some synthetic oil is incompatible with mineral oil.Prior to the oil is filled into the compressor, the system should betotally cleaned up during the initial startup and ensure that it isclean completely.

��

b. For the chiller system using synthetic oil, avoid the exposure ofoil to the atmosphere too long, it is also necessary to vacuum thesystem completely when installing the compressor.

c. The table below shows the oil replacement standard. Eachcompressor at HANBELL charges standard quantity of oil.

d. In order to take out the moisture from the system, it is suggestedto clean the system by hot air or Nitrogen, thereafter vacuum thesystem as long as possible. It is essential to change new oil intothe system especially after the motor burn out, the acidity debriswill still remain inside the system, hence follow the abovementioned procedures to overhaul the system. Check the oilacidity after 72 hours operating and then change it again andagain if the limit is still over the oil acidity standard until beenqualified.

Oil Replacement Standards

Item Value Item Value

Color, ASTM Above 6.0 Total acid Above0.5number

mg KOH/g

Particle Matters Above 5.0 Copper Strip Above 2.0mg/100ml 100 Deg C /3hrs

Viscosity Variation ±10% of Moisture Above 10040 Deg. C 15mm2 / Sec or more ppm

Changing oilLubrication oil is the most important factor to maintain the operating,lubricating, cooling, sealing and driving the capacity piston of thecompressor. Following is the probable problems existing in thesystem 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 highdischarge temperature causes the bearings’ life shortened.

Refer to the following oil change timing to ensure the compressorruns normally:

1. Change the oil periodically: Check the oil for every 10,000 hoursof running periodically for the first operation, to change oil andclean oil filter after running 20,000 hours is recommended. Dueto the piping debris could be accumulated inside the system afteroperation, check the oil after 2,500 hours or after one year ofrunning. Check the system whether clean or not and then changethe oil after every 20,000 hours or after 4 years running while thesystem is operated under good condition.

��

2. Avoid the debris clogged in the oil filter causing the bearingsfailure, an optional oil pressure differential switch is recommendedto be installed. The switch will trip when the oil pressure differentialreaches the set point between the primary and secondary sidesand the compressor, will shut down to prevent the bearingsdamage due to lack of oil.

3. If the compressor discharge temperature often keeps highapproaching to the set point, then the oil will be spoiled graduallyin short time, hence check the oil characterestic every 2 monthsif possible. It is necessary to change the oil if the character of theoil is out of the standard. In case oil characterestic could notbe checked periodically, then change the oil after 4 years’ ofinstallation or after 20,000 hours’ of running which reaches first.

4. Acidity in lubrication oil causes the reduction of bearing’s life andmotor’s life. Check the oil acidity periodically and change the oilif the oil acidity value measured is lower than PH 6. Change thedeteriorated 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 systemoverhaul owing to the motor burn out. Check the oil quality monthlyor periodically and change the oil if the oil is not qualified, it isnecessary to take care of the oil quality and system cleannessand dryness in the system periodically.

The Compressors are charged with Blue Star ACS oil for the Water Cooled applicationand for R22.

� ��

Liquid injectionThe liquid injection to the suction side of the compressor, is carriedout by providing a separate thermostatic expansion valve in thesystem. (Low-temp type expansion valve)

The flow of liquid refrigerant is controlled through the expansionvalve by the suction superheat directly.

Application of liquid injection

The compressor motor temperature and its compression chambertemperature will be very high almost approaching the setting ofmotor thermister and discharge temperature thermister, which oftenresult in the trip of the sensors under the above working conditionscausing the chillers to shut down.

The purpose of installing a liquid injection system is to prevent thecompressor motor from overheat, an expansion valve is installed inthe system with tube piped between the liquid line and compressorfor cooling down the compression chamber and motor to ensurethat 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 theexpansion valve devices. During the initial start up, the loading ofthe chillers will be heavy due to the higher temperature of returnchilled water, hence the liquid injection devices of adequate capacityshould 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 conditionand also the discharge temperature. Hence the use of liquid injectionsystem is essential.

�! � ��

Prior to starting of the unit, check up the procedure detailed herein

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Operation1) In addition to above pre start-up check up, it is also necessary

to pay attention to the auxiliary facilities while the chiller iscommissioned at the job site and the periodic maintenanceafter the initial start up.

2) In order to keep the capacity control smoothly under the lowambient temperature with the normal viscosity of oil, it is requiredto heat the oil by heater at least 8 hours before next starting.The lower the ambient temperature is, the longer the time ofheating of oil should be. The oil temperature should be over 50Deg. C before starting the compressor. Keep the oil heaterenergised after the compressor is shutdown for preparation ofnext start-up, to keep the oil temperature over the minimumrequired value, which is essential especially under low ambientcondition.

3) Recheck the settings on each controls

4) Establish the chilled water flow through the cooler. Adjust thewater flow rate to the designed rated flow. Connect the Chilledwater 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 thewiring diagram with Star – Delta connection given below.

MCD

MCS

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Following are the start up limitations

1) Lowest Starting Voltage: The power voltage cannot be lowerthan 10% of rated voltage during start-up period of compressor.

2) Maximum Discharge Pressure: 18 kg/cm2 g

3) Minimum Suction Pressure: 6~8 kg/cm2 g

4) Maximum designed discharge pressure: 28 kg/cm2 g

5) 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) ScrewChiller comprises of analog sensor inputs such as System Pressures,System Temperatures, Chilled Water Temperatures etc. and digitalsensor inputs such as flow switch, External Anti-freeze interlock,Single Phase/ Phase Reversal fault, etc.. It consists of various relayoutputs that drive the compressor, liquid line solenoid valve, liquidinjection control etc. Analog outputs (0-10V DC) are used to drivethe Electronic Expansion Valves.

Before switching ON the chiller, ensure that the flow switch isconnected between points 7 and 8 in the wiring diagram and thereis sufficient water flow. The crankcase heater should be ON for aperiod of 8 hours before starting the compressor.

In the OFF state, the condition of the outputs is as follows:

System 1

Relay output ConditionMain1 OFF

Delta1 OFF

Loadsol1 OFF

Unloadsol1 ON

LLS1 OFF

LIQinjct 1 OFF

System 2

Relay output ConditionMain2 OFF

Delta 2 OFF

Loadsol2 OFF

Unloadsol2 ON

LLS2 OFF

LIQinjct 2 OFF

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� Starting Specifications:

(1) Switch on power supply. The unit goes in power upmode. System stays in this mode for a time period asspecified in MCS set point 23(factory set=90s). Inthis state, all relay outputs are turned OFF.

(2) After the power up delay, the system-1 goes in ONstate. Controller will initialise & monitor Power Supplystability for 90 seconds. When this happens, thecondition of the relay outputs is as follows:

Relay output Condition

Main1 ON

Delta1 OFF,ON after timecorresponding to setpoint factory set=3s

Loadsol1 OFF

Unloadsol1 ON

LLS1 OFF

LIQinjct 1 OFF

(3) Controller will check for any anti-cycle (fault) timersleftovers

(4) During start-up, the MCS Controller will monitorcooling demand as per Leaving water temperature(set point 1), condition of Flow Switch, Anti Freezeand other Compressor Safeties and start compressorof the first system with fast unloading control logicfor initial 30 seconds.

(5) Compressor will pump down till the suction pressurereaches 60 psig. During pump down the liquid linesolenoid is kept de-energized (closed). Once suctionpressure drops to 60 psig Liquid Line Solenoid (LLS)valve is opened. Even though the suction pressuredoes not reach the set value, the LLS will be openedafter 5 seconds.

(6) Depending on set point and actual leaving watertemperature, the system shall load or unload. Theoperation of the load or unload solenoid valves is asunder:

��

SV1 (Unload) SV2 (Load)Start ON ON/OFF

Loading OFF OFF

Unloading ON ON

Stable OFF ON

(7) When compressor-1 is at 100 % load, then demandfor the second system will be activated based onload requirement. Compressor-2 shall be ON whencompressor-1 is at 100% load or even if compressor-1 is unable to load further due to any of the safeties.

(8) Compressor-2 is started as per the sequence givenin steps 4 to 7.

(9) Compressor-1 will get unloaded and then both thecompressors will load/ unload simultaneouslyapproximately at the same percentage (unless anyof the compressors goes in safety hold).

(10) To shut down chiller switch off rotary switch providedin panel. Initially system-2 & then system –1 will gointo shutdown mode.

(11) MCS has ‘minimum run time equalization’ logic option(set point 103 should be 0 and set point 104 shouldbe 1). The compressor, which runs for minimum time,will be stat first during next operation.

During normal running of compressors, followingsafety parameters are monitored:

Sr. Set Point Trip Delay Default SettingNo. Description (Seconds)1 Hi amps 2 110 %

2 Low amps 5 15 %

3 Low suction 90 48 psig

4 Low gas / LSV FLT 10 20 psig

5 High discharge 1 275 psig

6 Low discharge 40 100 psig

7 Low oil differential 180 50 psig

8 Unsafe Oil 4 25 psig

9 Anti freeze * 5 39oF

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* In case of Anti Freeze, both Circuits of the Chillerwill be locked out.

To avoid nuisance tripping during compressor startup, following Initial Bypass/ Time Delay adjustmentprocedure is observed:

Set Point Bypass Time DelayDescription Adjustment *Hi amps For first

3 seconds —-

Low amps For first3 seconds —-

Low suction During pump 2 minutes 45 secondsdown for first 5 minutes of

Compressor running.

Low gas / LSV FLT —- 4 seconds, for first 5inutes of compressor.

Low oil differential First 5 seconds 25 psig for next30 seconds.

• All the above parameters for time delay adjustmentare as per default set points.

�� Operating Specifications:

The following are the Operating Specifications and default set points:

- Leaving water temperature is set at 45°F with a controlof ±0.5 °F.

- Liquid injection system switches on at DischargeTemperature of 165 °F

- The delay between the Star and Delta connection isset at 3 seconds.

- Low-pressure setting is at 48 psig and High-pressuresetting is at 275 psig.

- Anti Freeze Thermostat setting is at 39 °F.

NOTE:

Lock out delay: If any critical fault reoccurs within 2 hours ofrunning, the controller will trip the unit and would go in lock out,after which manual intervention is required to diagnose and rectifythe fault.

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FAST UNLOADING

For screw compressors, this state is entered when the compressoris turned on. The system will remain in this state for 45 secondswhile the “fast unloader” and unload points are on. This is to ensurethat the screw is unloaded.

COMPRESSOR IS LOADING

For screw compressors, this state is when the load solenoid isbeing pulsed to increase the cooling capacity of the circuit.

COMPRESSOR IS UNLOADING

For screw compressors, this state is when the unload solenoid isbeing pulsed to reduce the cooling capacity of the circuit by movingthe 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 Locked Rotor StartingCurrent (LRA), A current, A

BSC-075A 685 230

BSC-105A/ BSC-105W 735 245

BSC-125W 965 325

BSC-145A/ BSC-145W 1100 370

BSC-160A/ BSC-160W 1480 495

BSC-210A/ BSC-210W 1760 590

A. The starting for the Y start is usually set at 4 ± 1 second, and

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the maximum allowable shift time from Y to D is 40 milliseconds.It is advisable to change the Y starting time prior to different workingcondition in the job site in accordance with the current variation ofY starting. It is recommended that the duration of Y starting is notover 15 seconds at the step of 25% capacity.

The running restraint of compressor1) Compressor restart frequency

The restart counts for the models BSC - 125W, BSC - 105W,BSC - 145W, BSC - 160W and BSC - 210W are recommendedbelow 2 times in one hour

2) The starting for the Y start is usually set at 3 seconds and themaximum allowable shift time from Star to Delta is 40 Sec.However it is recommended that the duration of the Y startingis not over 15 seconds at the step of 25% capacity.

3) Supply power

Long term running => +5%

Instant Running => +10%

Frequency: +2 %

Phase current unbalance: The difference in phase current betweenthe biggest phase current differential and smallest phase currentdifferential 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 switchThe table below shows the list of protection switches, which areessential to protect the compressor and operate safely

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Shut Down of Compressor

1) Shut down the Chiller by switching off the required switch provided in the Panel.

2) Stop the chilled water supply to the Cooler.

In case of long term shutdown required because of the retrofit of the system or overhaulingof the compressor follow the above instructions after reinstallation of the system beforestarting up again to ensure the safety and good running condition of the compressor

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Maintain the Chiller periodically in accordance with the schedule shown in table below

Water Cooled Screw Chiller Maintenance Schedule

Check Points Daily Weekly Monthly Quarterly Annually

General

Log parameters X

Check Water Level in expansion tank X

Check Water Level in the Cooling Tower Sump X

Check for any refrigerant leaks through X

flare joints, valve glands etc

Check and clean refrigerant strainer X

Check condition of refrigerant drier X

Clean Cooling tower sump X

Clean water line strainers X

Check quality of water X

Check healthy operation of safety devices X

Check tightness of all electrical terminations X

Top up grease for all motors X

Apply thermal paste on the temperature sensors X

Check for any abnormal noise and vibration X

Check liquid line sight glass/moisture indicator X

Check water pressure drop in Cooler X

Check water pressure drop in Condenser X

Analyse Oil sample X

Check suction superheat X

Check crank case heater X

MCS Panel

Check program settings X

Check fault history X

Check load/unload furnction X

Check pump down function X

Check Clock X

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SPARES FOR LCWX1-104

Item BAAN Description QTY. Specification CODE Nos.

Compressor Spares

CDHAI0140 BSC-105W (RC16) Screw Compressor for R 22 1

3105-1143A Oil Filter 1 φ56*200L

3101-1051B Oil Heater (220V) 1 220V, 150W

3105-1146A Inner Gasket of Oil Filter Flange 1 TEFLON 1.5t

3101-1148A-3 Outer Gasket of Oil Filter Flange 1 REINZ-AFM 34, 1.5t

4401-30 Solenoid Coil 2 220V

4401-30 Solenoid Valve (Stepless Control) 2 2743K0R30-4344SDH12223DS

3101-1003A Solenoid Valve Gasket 2 NOK,1515SPS

4804-01 Oil Sight Glass (O-Ring Included) 1 ALCO

3105-1004A-3 4" Gasket 1 REINZ-AFM 34, 1.5t

3105-1024C Suction Filter 1 φ110*103L

3105-1004A-3 Gasket for 4" Flange 1 REINZ-AFM 34, 1.5t

4405-56 Oil Level Switch 1 RFS-8-2, 1200mm

CDSPI0710 Blue Star ACS Oil 15 Litres

Controls & Accessories spares

EAECI0010 Sporlan SEH-100 Electronic Expansion Valve 1

EAGAI0040 Sporlan Interface Board IB6 1

EASBI0140 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection 1

EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil for Liquid Injection 1

FEDBI0140 CTG Dehydrator (Core) 3

SAMAI0010 Indicator Moisture 1

VAAAZ2106 Sporlan Expansion Valve BBIVE-4 for Liquid Injection 1

Electrical spares

EAMAZ0470 MCCB Siemens - 3VL3720, 200A 1

EAMAZ0480 Siemens Contactor, 3TF50,110A, 220 VAC 2

EAMAZ0490 Coil for Contactor, 3TF50,110A 2


EAMAZ0510 Coil for Siemens Contactor, 3TF47, 70A ,220 V 1

EAMAZ0520 SPPR, GIC SM-101 1

EASHZ0060 4 Positionn Selector Switch - Salzer 61198 ON/OFF 1

EAMAZ0205 MCB - 4A, 2 Pole, 415V, 3KA, for controller 1

Micro Control Panel spares

EATFZ0010 Constant Voltage Transformer, 150 VA 1

EBMBI0040 MCS Board Panel Mount Type- MCS 8 (230v.) 1

EBMBI0140 SI-16 Extension Board, 230V. 1

SATAI0075 Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 1


SATAI0080 Temp. Sensor with 20' Cable -MCS- T100-20 4

EATDI0060 Current Sensor (CT) 0 to 250 amps. - CT-250 1

EAMAZ0550 INT 69 module 1

EAMAZ0560 E PROM chip 1

EAGAI0050 Control Panel Fuse 1

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Item BAAN Description Qty. Specification

CODE Nos.

Compressor Spares

CDSAI0145 BSC-125W (RC17) Screw Compressor for R 22 1

3105-1143A Oil Filter 1 φ56*200L

3101-1051B Oil Heater (220V) 1 220V, 150W


















SAMAI0010 Indicator Moisture 1


Electrical spares




















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Item BAAN Description Qty. Specification CODE Nos.

Compressor spares

CDSAI0150 BSC-145W (RC18) Screw Compressor for R22 1

3105-1143A Oil Filter 1

3101-1051B Oil Heater (220V) 1 220V,150W


3101-1006A-3 Gasket (For Motor Cable Cover Plate) 1 REINZ-AFM 34, 1.5t




4804-01 Oil Sight Glass (O-Ring included) 1 ALCO



4404-056 Oil Level switch 1 RFS-8-2, 1200 mm


Controls & Accessories Spares




EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil 1



Electrical Spares

EAMAZ0470 MCCB 3VL3725, 250A 1

EAMAZ0480 Siemens Contactor 3TF49 / 85A ., 220 VAC 1

EAMAZ0490 Coil for Contactor,3TF49/85A ,220 V 1

EAMAZ0500 Siemens Contactor,3TF51,140A , 220 VAC 2

EAMAZ0510 Coil for Contactor, 3TF51, 140A ,220 V 2




Micro Control Panel Spares


EBMBI0040 MCS Board Panel Mount Type- MCS 8 (230V.) 1

EBMBI0140 SI-16Extension Board, 230V. 1


SATAI0070 Pressure Sensor with 20' Cable (0-500psig)- TI 500-20 2

SATAI0080 Temperature Sensor with 20' Cable -MCS- T100-20 4





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Item BAAN Description Qty.Nos. Specification CODE

Compressor spares



3101-1051B Oil Heater (220V) 1 220V,150W


















Electrical Spares




















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Item BAAN Description Qty. SPECIFICATION CODE Nos.

Compressor spares

CDSAI0180 BSC-210W (RC-20) Screw Compressor for R22 1

3105-1004a-3 4"Gasket For Discharge Flange 1 Reinz-Afm 34, 1.5t

3107-1143a Oil Filter 1

3101-1051B Oil Heater (220V) 1 220V,150W

3107-1146a Inner Gasket Of Oil Filter Flange 1 Teflon 1.5t

3101-1006a-3 Gasket (For Motor Cable Cover Plate) 1 Reinz-Afm 34, 1.5t

4401-30 Solenoid Coil 2 220v

4401-30 Solenoid Valve (Stepless Control) 2 2743k0r30-4344Sdh12223ds

3101-1003a Solenoid Valve Gasket 2 Nok,1515sps


3107-1054a Gasket For Suction Filter 1 φ161.5*1.5t

3107-1024c Suction Filter 1 φ159*210l









Electrical Spares

MCCB 3VL 4731, 315 A 1


EASHZ0060 4 Position Selector Switch - Salzer 61198 ON/OFF 1


EAMAZ0480 Siemens Contactor 3TF53, 205A ., 220 VAC 2


EAMAZ0500 Siemens Contactor,3TF52, 170 A , 220 VAC 1

EAMAZ0510 Coil for Siemens Contactor, 3TF52,170A, 220 V 1












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Compressor Spares

CDSAI0140 BSC-105W (RC16) Screw Compressor for R 22 2

3105-1143A Oil Filter 2 φ56*200L

3101-1051B Oil Heater (220V) 2 220V, 150W
















EASBI0145 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Coil 2

FEDBI0140 CTG Dehydrator (Core) ( L Type Strainer) 6


Electrical spares











EBMBI0040 MCS Board Panel Mount Type- MCS 8 (230V) 1


SATAI0075 Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 2




EAGAI0040 Interface board IB6Q Sporlan 2




EBMBI0050 MCS I/O Expansion Board (230 V) 1

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Compressor Spares

CDHAI0140 BSC-105W (RC16) Screw Compressor for R 22 1

3105-1143A Oil Filter 1 φ56*200L

3101-1051B Oil Heater (220V) 1 220V, 150W















3101-1051B Oil Heater (220V) 1 220V,150W

















Electrical spares







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Compressor Spares

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Compressor spares



3101-1051B Oil Heater (220V) 2 220V,150W











Control & Accessories Spares







Electrical Spares




















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Item Baan Description Qty. Specification CODE Nos.



3101-1051B Oil Heater (220V) 2 220V,150W

3107-1005A-3 3'’ Gasket For Discharge Flange 2 REINZ-AFM 34, 1.5t





3107-1024C Suction Filter 2 60mesh

3107-1004A-3 Gasket for Suction Filter Flange 2 REINZ-AFM 34, 1.5t

3101-1052C Oil Heater 2 φ12.7,220V*300w










Electrical Spares




















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Item Baan Description Qty. Specification CODE Nos.



3101-1051B Oil Heater (220V) 1 220V,150W




4401-30 Solenoid Valve (Stepless Control) 2 2 7 4 3 K 0 R 3 0 - 4 3 4 4SDH12223DS








3105-1004a-3 4"Gasket For Discharge Flange 1 Reinz-Afm 34, 1.5t

3107-1143a Oil Filter 1

3107-1146a Inner Gasket Of Oil Filter Flange 1 Teflon 1.5t

3101-1006a-3 Gasket (For Motor Cable Cover Plate) 1 Reinz-Afm 34, 1.5t

4401-30 Solenoid Coil 2 220v

4401-30 Solenoid Valve (Stepless Control) 2 2743k0r30-4344Sdh12223ds

3101-1003a Solenoid Valve Gasket 2 Nok,1515sps


3107-1054a Gasket For Suction Filter 1 φ161.5*1.5t

3107-1024c Suction Filter 1 φ159*210l









Electrical Spares





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MCCB 3VL 4731, 315 A 1

EAMAZ0480 Siemens Contactor 3TF53, 205A ., 220 VAC 2


EAMAZ0500 Siemens Contactor,3TF52, 170 A , 220 VAC 1

EAMAZ0510 Coil for Siemens Contactor, 3TF52,170A, 220 V 1















Item Baan Description Qty. Specification CODE

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The field feed back card as per the format below shall be send to factoryon receipt of the Chiller

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Field Feed Back Card - Commissioning of Chiller at Site

Product : Water cooled Screw Chiller

Chiller Model :

Sr. No. :

Customer Name : Location :

Engineer’s Name :

Observation Comments Remarks

Installation/Precommissioning Checks :

- Unit Installed and levelled Ok /

- Installation Ok /

- Condenser water connection terminated Ok /properly with isolation required

- Chilled water connection terminatedproperly with isolation required Ok /

- Electrical connection with Earthingterminated properly Ok /

- Condenser water and Chilled water systemproperly flushed Ok /

- Water Quality checked Ok /

- Meggering of Cabling done Ok /

- Condenser water and Chilled water Pumpcommissioned Ok /

Water flow adjusted to the design flow bychecking pressure drop Ok /

Water flow switches connected withelectrical panel Ok /

Check up Voltage Ok / Starting 400 ± 10% Running 400 ± 10%

Commissoned the Chiller Ok / Long term running 400 ± 5%

Noise Level Ok /

Vibration Ok /

Check Current Ok /

Testing done at site Ok /

Performance data as per format Ok /

- Commissioning Date

- Commissioning By

Remarks :

Note : Warranty will be valid only after receipt of this card at the factoryFor Factory Use :

- Date Of Receipt : - Action By :

- Comments :

The field feed back card as per the format below shall be send to factoryafter Commisioning of the Chiller

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� To bill � Not to bill Date : Customer’s Stamp & Signature5091-10C Registered Office : Kasthuri Buildings, Jamshedji Tata Road, Mumbai 400 020

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Recommended water quality standards: Test items Chilled water Cooling Tower Make up

quality water quality water quality

pH 7.2 - 8.5 7.2 - 8.5 6.0 - 8.0

Total hardness

(CACO3) ppm Max. 80 Less than 200 Max. 50

Total Alkalinity

(CACO3) ppm Less than 100 Less than 100 Less than 80

Chloride Ion (ppm) Less than 50 Less than 200 Less than 50

Total Ion (Fe) ppm Less than 0.3 Less than 1.0 Less than 0.3

Silica (SiO2) ppm Less than 30 Less than 50 Less than 30

Ammonium Ion ppm

Less than 0.2 Less than 1.0 Less than 0.2

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Log report

Customer's Name

Date:

Time

S.No Description Units 10.00 12.00 14.00 16.00 18.00

1 Voltage R-Y Volts

Voltage Y-B Volts

Voltage R-B Volts

2 Current - R Amps.

Current - Y Amps.

Current - B Amps.

3 Supply Frequency Hz

4 Suction Pressure comp. PSIG

5 Discharge Pressure comp. PSIG

6 Compressor Current. Amps.

7 Cooler Entering Water temp. 0F

8 Cooler Leaving Water temp. 0F

9 Cooler Pressure drop PSIG

10 Cooler water Flow rate US GPM

11 Condenser Entering water temp. 0F

12 Condenser Leaving water temp. 0F

13 Condenser Pressure drop PSIG

14 Condenser water Flow rate US GPM

15 Refri. System temp. - Suction 0F

16 Refri. System temp.-Discharge. 0F

17 Refri. System temp. - Liquid 0F

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For Blue Star Water Cooled Screw Chillers,� ��%� �*� �� *�� $�� *�� *� �� *��>� $%� :�� !��

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Electrical problem � Yes � No

Voltage � � YesNoInsulation resistance (Megger test)…………….....…….. Ohms

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WarrantyBlue Star Screw Chillers carry a warranty for a period of 12 monthsfrom the data of commissioning or 15 months from the date ofdelivery, whichever is earlier, unless stated otherwise in the contractof sales.

Terms of WarrantyBlue Star extends a comprehensive warranty on its systems, whichentitles the customer to the following

1. Repair / reconditioning, by BSL / BSL Dealer, through whomthe machine has been purchased, of any part of the equipmentfound defective within 12 months from the date of commissioningor 15 months from the date of despatch whichever is earlier.

2. The warranty is valid only if:

2.1. Installation and commissioning is taken care of by BSL/theirauthorised persons.

2.2. The equipment is operated as per the Company’s operatinginstructions.

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 arecarried out by the customer himself or his representative withoutwritten concurrence from Blue Star Limited.

5. The warranty extended herein is in lieu of all implied conditions/warranties under the law and is confined to the repairs orreplacements of defective parts and does not cover anyconsequential or resulting liability damage or loss arising fromsuch defect. Furthermore, the warranty in no case, shall extendto the payment or any monetary consideration whatever of thereplacement or return of the Screw Chiller as a whole

6. Any repair/ replacement shall not extend the overall warrantyperiod as specified above.

7. The cost of transportation of material and of persons beyondMunicipal jurisdiction shall be borne by the customer.

8. This warranty may be read in conjunction with any other warrantyon the installation as a whole, if the Screw Chiller is suppliedas part of a Project.

��

For anyassistance,

CALL:

Blue Star Service:

Ph: ............................................................

Cell: ..........................................................

Blue Star Dealer:

Ph: ............................................................

Cell: ..........................................................

Blue Star Regional Manager:

Ph: ............................................................

Fax: ..........................................................

Blue Star’s/Dealer’s engineer to fillabove details before handing over

this Manual to customer.

��

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EAST

BHUBANESHWAR3A, Satya Nagar,2nd Floor,Bhubaneswar - 751 007.Tel: (0674) 2508270 / 2508239

GUWAHATINew Star Freeze Building2nd Floor,Opp. Kunjalata Bibah Bhawan,G. S. Road,Guwahati - 781 005.Tel: (0361) 2340619 / 2340620

KOLKATA7, Hare StreetKolkata 700 001.Tel: (033) 22134200 / 22106609

NORTH

CHANDIGARHSCO 1, Madhya Marg, Sector 26Chandigarh 160 019.Tel: (0172) 2790482 / 5004000

JAIPUR33, Kiran PathSuraj Nagar West, Civil LinesJaipur 302 006.Tel: (0141) 5179359 / 2225326

LUCKNOWB-140, Nirala NagarLucknow 226 007.Tel: (0522) 2787274 / 2786172s

NEW DELHIE-44/12 Okhla Ind. AreaPhase II, OhklaNew Delhi - 110 020.Tel: (011) 41494200 / 000

Service Centres

SOUTH

BANGALORESalarpuria Centre IINo. 13, Ward No. 67Koramangala Industrial LayoutKoramangalaBangalore 560 095.Tel: (080) 51854200 / 51854000

CHENNAI104, ‘Garuda Building’,Cathedral Road,Chennai 600 086.Tel: (044) 52444200 28116707- 8

KOCHI39/5766, Tharakandam EstateKurisipally RoadKochi 682 015.Tel: (0484) 2356139 /2357933 / 2357934

SECUNDERABAD207, Sikh RoadBantia EstatesSecunderabad 500 003.Tel: (040) 27847553 /27842057-58 / 27815469

TRIVANDRUMT.C. IX/1490‘Chandrika’, SasthamangalamTrivandrum - 695 010.Tel: (0471) 2720025 / 2720065

VISAKHAPATNAM47-12-6/72nd FloorAmaravathi ComplexDwarakanagarVisakhapatnam 530 016.Tel: (0891) 2748405 / 2748433

WEST

BHOPAL“Star Arcade”, 2nd FloorPlot No.165A & 166, Zone-IMaharana Pratap NagarBhopal - 462 011.Tel: (0755) 2553378 /5273378 / 79

GOA1st Floor, Flat No.1Vaibhav ApartmentVidya Nagar ColonyMiramar, Panjim, Goa 403 001.Tel: (0832) 2461671 / 2462087

MUMBAIBlue Star House9A, Ghatkopar Link RoadSaki Naka, Mumbai 400 072.Tel: (022) 56684200 / 56684000

NAGPUR219, Bajaj Nagar, 1st Floor,South Ambazari Road,Nagpur 440 010.Tel: (0712) 2229244 / 2249000

PUNE201/A, Nityanand Complex1st Floor, 247/ABund Garden RoadPune 411 011.Tel: (020) 26113031 /26127230 / 26122307

VADODARARamakrishna Chambers7th Floor, Productivity RoadAlkapuri, Vadodara 390 005.Tel: (0265) 2338561 /2332021 / 2332022

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User Manual Screw Chiller Water Cooled