Blue Star Chiller Air & Water Cooled Screw Chiller R22 DX Manual

Air Cooled and Water Cooled Screw Chillers High on reliability Low on operating costs

USER’S MANUAL

SCREW CHILLER (Air & Water Cooled)

Revised January 2008 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.

2

USER'S MANUAL

Contents Introduction ...................................................................................................................... 4 Features ........................................................................................................................... 5 Nomenclature.................................................................................................................... 8 Technical Specifications .................................................................................................... 9 Rigging and Installation .................................................................................................... 27 Carel Controller ............................................................................................................... 30 Screw Compressor ......................................................................................................... 47 Pre start up, Testing, Commissioning and Operation ....................................................... 54 Trouble Shooting ............................................................................................................. 84 Maintenance .................................................................................................................... 87 Spares Part List .............................................................................................................. 90 Field Feed Back Form ....................................................................................................114 Commissioning and Handing over report ........................................................................116 Water Quality .................................................................................................................117 Log Report .....................................................................................................................118 Warranty Claim Form .....................................................................................................119 Warranty ....................................................................................................................... 120 Blue Star Service Offices .............................................................................................. 121

3

SCREW CHILLER (Air & Water Cooled)

Introduction Blue Star, India’s preferred Air conditioning Company has been providing expert cooling solutions for over six decades. It is with this expertise Blue Star brings to you a wide range of Air and Water Cooled Screw Chillers, manufactured at its ISO 9001 factory with world class capabilities. These Chillers which operate on HCFC-22 refrigerant come in a quality range of eleven models varying from 75 TR – 366 TR in the air cooled version and 115 TR – 400 TR in the water cooled version. The condensers are designed for operation under a wide range of ambient conditions. Due to lesser moving parts, these chillers are reliable and rugged. Further, with its automatic step capacity control, it provides better efficiency under part loads making it ideal for varying load applications such as office spaces, hotels, hospitals, malls and multiplexes. In short, these chillers offer reliable, energy efficient performance year after year.

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USER'S MANUAL

Features Compressor The BSC Series semi hermetic screw compressors incorporated in the chillers follow state-of-the-art manufacturing processes which are ISO 9001 certified and use high precision machinery. The salient features of these compressors are:

•

Highly efficient with low noise levels

•

Tested in accordance with ARI Standards

•

Due to few moving parts such as Male and Female Screws and Slider valve, these compressors have minimal wear and tear

•

Each compressor has the latest 5 to 6 Patented Profile design, with separate Radial and Axial force Bearings, Built-in Oil Separator, PTC Motor winding protection, Discharge temperature protection with its controller, Oil level switch and Oil differential pressure switch. This guarantees reliability and long life of bearings under heavy working operating conditions.

•

Each Compressor has Step capacity control from 25% to 100%, making it suitable for part load applications and efficient under part load conditions. The capacity control also helps in limiting the starting current.

Liquid Injection The refrigerant suction gas cools the winding of the Semi hermetic Screw Compressor Motor. During part load operation where the suction gas circulation is less, as an abundant precaution, liquid refrigerant is injected to the suction side of the compressor to cool the motor winding. Liquid injection during this period keeps the motor winding temperature within limits. This is provided as a standard feature to enhance the life of the compressor.

Evaporator The shell and tube evaporator has inner grooved copper tubes for better heat transfer. The tubes are designed to optimize for refrigerant and water velocities.

5

SCREW CHILLER (Air & Water Cooled)

Control Centre The control centre is mounted in the framework of the chiller. It is provided with an advanced microprocessor control panel which has unique features and advantages.

•

The cooler outlet temperature can be controlled accurately within a close tolerance of + 0.5°F

•

In-built time delays for compressor single phase / phase reversal protection and anti freeze protection

•

Password protection at two levels.

Optional features in Control Centre

•

RS 485 port & TCP/ IP web gate for remote connectivity, fault indication and status facility

•

PC connectivity and remote monitoring without BMS through dedicated telephone line, Gateway and Modem.

•

BMS compatibility with JC N2, BACnet and Modbus protocol with Translator.

•

Windows based support system to provide complete status on all operations both locally and remotely. History, static and dynamic graphing to aid in commissioning, trouble shooting and evaluation. These features help in accurate operation and protection of the chiller.

Following additional features are available in Air Cooled version:

Economiser Refrigerant liquid to liquid plate type heat exchanger is provided for the economiser system. The liquid refrigerant is sub cooled to enhance the capacity thereby reducing power consumption (IKW/ TR) and enhancing the Coefficient of Performance (COP).

Oil Cooler Effective lubrication of bearing depends on the viscosity of lubricant, which in turn depends on the oil temperature. To ensure effective lubrication for longevity, oil cooler is provided as a standard option for Aircooled Application.

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USER'S MANUAL

Air cooled condenser The air cooled condenser coils uses copper tubes and aluminum fins. The inner grooved type copper tubes used in the condenser provide increased surface area for better heat transfer.

Fans The propeller type fan profiles are with 5 lobes, bird wing design which optimizes both the noise level and the power consumption against required air flow and static pressure.

Springs Specially designed springs are supplied along with the units to minimize the transmission of vibration.

Optional items available in air cooled version are:

• Hydrophobic coated aluminium fins • Coil protection guards

7

SCREW CHILLER (Air & Water Cooled)

Nomenclature Nomenclature - Air Cooled Chiller L

C

A

X

1 - 075

D i A

REVISION REFRIGERANT R22 DIRECT EXPANSION LIQUID

NOMINAL CAPACITY NO. OF COMPRESSORS

CHILLER

SCREW COMPRESSOR

AIR COOLED

Nomenclature - Water Cooled Chiller L

C

W

X

1 - 115 D i B

REVISION REFRIGERANT R22 DIRECT EXPANSION LIQUID

NOMINAL CAPACITY

CHILLER

WATER COOLED

8

NO. OF COMPRESSORS SCREW COMPRESSOR

USER'S MANUAL

Technical Specifications Technical Specification for Air Cooled Screw Chiller (Single Compressor) Description Nominal Cooling Capacity

Unit

LCAX1-075 D i A

LCAX1-102 D i A

LCAX 1-145 D i A

LCAX1-206 D i A

KW (TR)

263.7 (75)

359.3 (102)

509.82(145)

724.29 (206)

BSC-075A

BSC-105A

BSC-145A

BSC-210A

1

1

1

1

Compressor

Semihermetic Screw

Model Quantity

No.

Motor type Operating Speed

Semi-hermetic Refrigerant Cooled, 3Ph., 2 Pole Squirrel Cage, Induction Motor RPM

2950

Power Supply

2950

2950

2950

400 V(+/- 10%) , 3 Ph. , 50Hz

Ccompressor Rated Current.

Amp.

131.9

182.6

250.9

357

Compressor Locked Rotor Current

Amp.

730

735

1100

1760

Compressor Starting Current

Amp.

230

245

370

590

F

F

F

F

Class of Insulation Compressor Power Consumption

kW

81.1

112.3

154.7

219.8

Unit starting Current

Amps

235

252.5

380

605

Unit Maximum Full Load Current

Amp.

180

251

345

490

kW

85.9

119.5

164.3

234.2

Unit Power Consumption R-22 Refrigerant Charge Oil Charge (Blue Star ACS)

Kg

67

90

130

175

Litres/compr

16

16

23

28

Sq. Mt.(Sq Ft)

10.28 (110)

14.9 (160)

19.8 (213)

29.7(320)

No.

3

3

3

3

9.5 x 0.304

9.5 x 0.304

Condenser Total Face Area Rows Deep Tube Material (D) OD x Thickness

3/8" Inner grooved,.Copper mm x mm

9.5 x 0.304

9.5 x 0.304

Type of Aluminium Fins

Super Slit

Fins per Inch

14

14

14

14

915

915

915

915

Fan for Air Cooled Condenser Fan Dia

mm

Quantity

No.

4

6

8

12

Air Flow

CFM

48,000

72,000

96000

1,44,000

No.

4

6

8

12

Speed

RPM

700

700

700

700

Full Load Current

Amp.

2.6

2.6

2.6

2.6

KW

1.2

1.2

1.2

1.2

Condenser Fan Motor Type Quantity

Power Input

Totally enclosed, Pad Mounted

9

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Air Cooled Screw Chiller (Single Compressor) Description

Unit

LCAX1-075 D i A

LCAX1-102 D i A

LCAX 1-145 D i A

LCAX1-206 D i A

DX-Cooler Model

YCH-92A

YCH-103A

YCH-152A

YCH-222A

Shell ID

mm

311.2

371

419.1

488

Shell Thickness

mm

6

8

8

8

Tube Type and Material

Inner Grooved Tubes with External Plain

No. of Tubes Tube OD and Thickness Tube Length

Nos

196

252

310

508

IN

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

FT

7

7

8

8

Surface Area Inside

Sq. FT

347.39

446.64

627.93

1029

Surface Area Outside

Sq. FT.

224.37

290.09

407.75

668.00

Nos

1

1

1

1

No of Pass (water side) No of Pass (Refrigerant side)

Nos

4

4

4

4

No of Refrigerant Circuit

NOS

1

1

1

1

Water Connection Size In/Out

INCH

6" NB

6" NB

6" NB

8" NB

Min..

USGPM

150

204

290

412

Max..

USGPM

225

306

435

618

Water Flow Rate

Expansion Valve

Thermostatic

Economiser

Brazed Plate Heat Exchanger

Overall Dimension Length

mm

2700

3800

4820

7260

Wideth

mm

2040

2040

2040

2040

Height

mm

2486

2495

2495

2495

Net Weight (approx)

Kg.

2600

3300

4180

6050

Operating Weight (approx)

Kg.

2677

3382

4358

6250

Rating Conditions 1. Entering Air over Condenser Temperature: 95oF 2. Entering Cooler Water Temperature: 54oF, Leaving Cooler Water Temperature: 44oF 3. Cooler Fouling Factor : 0.0001 Hr. Sq.ft.Deg. F/BTU

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USER'S MANUAL

Technical Specification for Air Cooled Screw Chiller (Twin Compressors) Description Nominal Cooling Capacity

Units

LCAX2-150 D i A

LCAX2-177 D i A

LCAX2-204 D i A

LCAX 2-247 D i A

KW (TR)

527.4 (150)

622.3(177)

717.2 (204)

868.4(247)

Compressor

Semihermetic Screw

Model Quantity

No.

Motor type Operating Speed

BSC-075A

BSC-075A + BSC-105A

BSC-105A

BSC-105A + BSC-145A

2

2

2

2

Semi-hermetic Refrigerant Cooled, 3Ph., 2 Pole Squirrel Cage, Induction Motor RPM

2950

Power Supply

2950

2950

2950

400 V(+/- 10%) , 3 Ph., 50Hz

Ccompressor Rated Current.

Amp.

263.8 (131.9 X 2)

314.5 (131.9 + 182.6)

365.2 (182.6 X 2)

433.5 (182.6 + 250.9)

Compressor Locked Rotor Current

Amp.

685, 685

685, 735

735, 735

735, 1100

Compressor Starting Current

Amp.

230, 230

230, 245

245, 245

245, 370

F

F

F

F

Class of Insulation Compressor Power Consumption

kW

162.2

192.3

224.6

267.3

Unit starting Current

Amps

377

397

450

578

Unit Maximum Full Load Current

Amp.

360

430

502

596

Unit Power Consumption

kW

171.8

204.3

239

284.1

R-22 Refrigerant Charge

Kg

135

159

184

222

Litres/compr

16 + 16

16 + 16

16 + 16

18+23

Sq. Mt.(Sq Ft)

19.8 (213)

9.84 (106) + 19.8 (213)

29.7(320)

34.6(373)

No.

3

3/2

3

3

Oil Charge (Blue Star ACS)

Condenser Total Face Area Rows Deep Tube Material (D) OD x Thickness

3/8" Inner grooved,.Copper mm x mm

9.5 x 0.304

9.5 x 0.304

Type of Aluminium Fins

9.5 x 0.304

9.5 x 0.304

Super Slit

Fins per Inch

14

14

14

14

Fan for Air Cooled Condenser Fan Dia

mm

915

915

915

915

Quantity

No.

8

12

12

14

Air Flow

CFM

96,000

144,000

144,000

168,000

Condenser Fan Moror Type

Totally enclosed, Pad Mounted

Quantity

No.

8

12

12

14

Speed

RPM

700

700

700

700

Full Load Current

Amp.

2.6

2.6

2.6

2.6

KW

1.2

1.2

1.2

1.2

Power Input

11

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Air Cooled Screw Chiller (Twin Compressors) Description

Units

LCAX2-150 D i A

LCAX2-177 D i A

LCAX2-204 D i A

LCAX 2-247 D i A

YCH-177 A

YCH-202A

YCH-222 A

YCH103A+YCH-152A

DX-Cooler Model Shell ID

mm

419.1

445

488

371 + 419.1

Shell Thickness

mm

8

8

8

8

Tube Type and Material

Inner Grooved Tubes with External Plain

No. of Tubes

Nos

378

412

508

252+310

Tube OD and Thickness

IN

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

Tube Length

FT

8

8

8

7'+8'

Surface Area Inside

Sq. FT

765.67

834.54

1029

446+627

Surface Area Outside

Sq. FT.

497.19

541.91

668.00

290+407

No of Pass (water side)

Nos

1

1

1

1

No of Pass (Refrigerant side)

Nos

4

4

4

4

No of Refrigerant Circuit

NOS

2

2

2

2

Water Connection Size In/Out

INCH

8" NB

8" NB

8" NB

6'’NB+6'’NB

Min..

USGPM

300

354

408

494

Max..

USGPM

450

531

612

741

Water Flow Rate

Expansion Valve

Thermostatic

Economiser

Brazed Plate Heat Exchanger

Overall Dimension Length

mm

4820

7260

7260

8630

Wideth

mm

2040

2040

2040

2040

Height

mm

2495

2495

2495

2495

Net Weight (approx)

Kg.

4700

5300

6300

7350

Operating Weight (approx)

Kg.

4873

5485

6500

7618

Rating Conditions 1. Entering Air over Condenser Temperature: 95oF 2. Entering Cooler Water Temperature: 54oF, Leaving Cooler Water Temperature: 44oF 3. Cooler Fouling Factor : 0.0001 Hr. Sq.ft.Deg. F/BTU

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USER'S MANUAL

Technical Specification for Air Cooled Screw Chiller (Twin Compressors) Description Nominal Cooling Capacity

Units

LCAX2-290 D i A

LCAX2-320 D i A

LCAX2-366 D i A

KW (TR)

1019.6(290)

1125.1(320)

1286.8.1(366)

Compressor

Semihermetic Screw

Model Quantity

No.

Motor type Operating Speed

BSC-145A + BSC-145A

BSC-160A

BSC-160A +BSC-210A

2

2

2

Semi-hermetic Refrigerant Cooled, 3Ph., 2 Pole Squirrel Cage, Induction Motor RPM

Power Supply

2950

2950

2950

400V(+/- 10%), 3Ph., 50Hz

400V(+/- 10%), 3Ph., 50Hz

400V(+/- 10%), 3Ph., 50Hz

Ccompressor Rated Current.

Amp.

502 (250.9 + 250.9)

552 (276 X 2)

633 (276 + 357)

Compressor Locked Rotor Current

Amp.

1100, 1100

1480, 1480

1480, 1760

Compressor Starting Current

Amp.

370, 370

495, 495

495, 590

F

F

F

kW

309.4

336.6

389.4

Unit starting Current

Amps

651

808

903

Unit Maximum Full Load Current

Amp.

690

766

867

kW

328.6

360.6

415.8

Kg

265

288

329.4

Litres/compr

23+23

23+23

23+28

Sq. Mt.(Sq Ft)

39.6(426)

39.6(426)

49.53(533)

No.

3

4

3

mm x mm

9.5 x 0.304

Class of Insulation Compressor Power Consumption

Unit Power Consumption R-22 Refrigerant Charge Oil Charge (Blue Star ACS)

Condenser Total Face Area Rows Deep Tube Material (D) OD x Thickness

3/8" Inner grooved,.Copper

Type of Aluminium Fins

9.5 x 0.304

9.5 x 0.304

Super Slit

Fins per Inch

14

14

16

Fan for Air Cooled Condenser Fan Dia

mm

915

915

915

Quantity

No.

16

16

20

Air Flow

CFM

192,000

232,000

260,000

Condenser Fan Moror Type

Totally enclosed, Pad Mounted

Quantity

No.

16

16

20

Speed

RPM

700

860

700/860

Full Load Current

Amp.

2.6

3.5

3.5

KW

1.2

1.5

1.2/1.5

YCH-152A+YCH152A

YCH-177 A+ YCH177A

YCH-177A+YCH222A

419.1+419.1

419.1+419.1

419.1+488

Power Input

DX-Cooler Model Shell ID

mm

13

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Air Cooled Screw Chiller (Twin Compressors) Description

Units

LCAX2-290 D i A

LCAX2-320 D i A

LCAX2-366 D i A

mm

8

8

8

Nos

310+310

378 +378

378+508

Tube OD and Thickness

IN

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

Tube Length

FT

8+8

8+8

8 + 8

Shell Thickness Tube Type and Material

Inner Grooved Tubes with External Plain

No. of Tubes

Surface Area Inside

Sq. FT

627+627

765.67+765.67

765.67 + 1029

Surface Area Outside

Sq. FT.

407+407

497.19+497.19

497.2 + 668

No of Pass (water side)

Nos

1

1

1

No of Pass (Refrigerant side)

Nos

4

4

4

No of Refrigerant Circuit

NOS

2

2

2

Water Connection Size In/Out

INCH

6'’NB+6'’NB

8" NB+8'’NB

8" NB + 8'’NB

Min..

USGPM

580

640

732

Max..

USGPM

870

960

1098

Water Flow Rate

Expansion Valve

Thermostatic

Economiser

Brazed Plate Heat Exchanger

Overall Dimension Length

mm

9650

9650

12090

Width

mm

2040

2040

2040

Height

mm

2495

2495

2495

Net Weight (approx)

Kg.

8034

9135

9753

Operating Weight (approx)

Kg.

8390

9430

10126

Rating Conditions 1. Entering Air over Condenser Temperature: 95oF 2. Entering Cooler Water Temperature: 54oF, Leaving Cooler Water Temperature: 44oF 3. Cooler Fouling Factor : 0.0001 Hr. Sq.ft.Deg. F/BTU

14

USER'S MANUAL

Technical Specification for Water Cooled Screw Chiller (Single Compressor) Description Nominal Cooling capacity

Units

LCWX1-115 D i B

LCWX1-135 D i B

LCWX1-160 D i B

KW(TR)

404.5 (115)

474.8( 135)

562.7 (160)

COMPRESSOR :

Semi Hermetic Screw

Model Quantity

No.

Motor Type

BSC-105A

BSC-130W

BSC-145A

1

1

1

Refrigerant Cooled Semi-hermetic, 3Ph., 2 Pole, Squirrel Cage Induction Motor

Operating Speed

RPM

Power Supply

2950 400 V(+/- 10%), 3 PH., 50HZ

2950

2950

400 V(+/- 10%), 3 PH., 50HZ 400 V(+/- 10%), 3 PH., 50HZ

Compressor rated Current

Amp.

132.4

155

183.5

Max. Compressor Operating Current

Amp.

160

185

220

Compressor Locked Rotor Current

Amp.

735

965

1100

Compressor starting Current

Amp.

245

325

370

Unit Starting Current

Amp.

247

327

365

F

F

F

KW

82.4

96.2

110

Ltrs.

16

18

23

Kg

95

112

136

YCD-101A

YCD-131A

YCD-151A

Class of Motor Insulation Power Consumption Type of Oil

Blue Star ACS

Oil Charge Refrigerant R 22 Charge

CONDENSER : Model Shell ID

mm

330

390

390

Shell Thickness

mm

8

8

8

No. of Tubes

Nos

127

140

168

Tube OD and Thickness

Inch

3/4" OD x 0.028 Thk

3/4" OD x 0.028 Thk

3/4" OD x 0.028 Thk

Tube Length

Ft.

7

8

8

Surface Area (Inside)

Sq. Ft.

129.05

162.58

195.10

Surface Area (Outside)

Sq. Ft.

560.07

705.60

846.72

No. of Pass (Refrigerant side)

Nos

1

1

1

No. of Pass (Water side)

Nos

3

2

2

Water connection size

Inch

4"

4"

4"

No. of Refrigerant circuit

NOS

1

1

1

USGPM

312

375

435

USGPM

416

500

580

Tube type and Material

Water flow Rate

External Finned Copper Tubes

Min. Max

.

15

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Water Cooled Screw Chiller (Single Compressor) Description

Units

LCWX1-115 D i B

LCWX1-135 D i B

LCWX1-160 D i B

DX-COOLER Model

YCH-103A

YCH-122A

YCH-152A

Shell ID

mm

371

371

416

Shell Thickness

mm

8

8

8

Tube type and Material

Inner Groove Copper Tubes

No. of Tubes

Nos

252

252

310

Tube OD and Thickness

Inch

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

Tube Length

Ft.

7

8

8

Surface area (Inside)

Sq. Ft.

446.64

510.45

627.93

Surface Area (Outside)

Sq. Ft.

290.09

323.17

407.75

No. of Pass (Water side)

Nos

1

1

1

No. of Pass (Refrigerant side)

Nos

4

4

4

Water Connection Size

Inch

6" NB

6" NB

6" NB

No. of Refrogerant Circuits

Nos

1

1

1

Min.

USGPM

208

250

290

Max.

USGPM

312

375

435

Water Flow Rate

EXPANSION VALVE

Thermostatic

Make

Sporlan

Model

VVE-100

VVE-100

OVE-70-2#

OVERALL DIMENSIONS : Length

mm

2700

2953

2979

Width

mm

800

900

900

Height

mm

2000

2102

2102

Net Weight Approx

Kg.

2500

2700

3365

Operating Weight

Kg.

2725

3025

3750

Rating Conditions 1. Entering Cooler Water temp 54oF, Leaving Cooler Water temp. 44oF 2. Cooler Fouling Factor 0.0001 Hr.Ft2.F/Btu 3. Entering Condenser Water temperature 85oF, Leaving Coondenser Water temperature 95oF 4. Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu

16

USER'S MANUAL

Technical Specification for Water Cooled Screw Chiller (Single Compressor) Description Nominal Cooling capacity

Units

LCWX1-175 D i B

KW(TR)

615.5 (175)

LCWX1-225 D i B 791.3 (225)

COMPRESSOR :

Semi Hermetic Screw

Model Quantity

No.

Motor Type

BSC-160A

BSC-210A

1

1

Refrigerant Cooled Semi- hermetic, 3 Ph., 2 Pole, Squirrel Cage Induction Motor

Operating Speed

RPM

Power Supply

2950

2950

400 V(+/- 10%), 3PH., 50HZ

400 V(+/- 10%), 3PH., 50HZ

200.7

258.6

Compressor rated Current

Amp.

Max. Compressor Operating Current

Amp.

240

310

Compressor Locked Rotor Current

Amp.

1480

1760

Compressor starting Current

Amp.

495

590

Unit Starting Current

Amp.

489

580

F

F

KW

120.7

156.1

Ltrs.

23

28

Kg

150

195

YCD-176A

YCD-221A 457

Class of Motor Insulation Power Consumption Type of Oil

Blue Star ACS

Oil Charge Refrigerant R 22 Charge

CONDENSER : Model Shell ID

mm

390

Shell Thickness

mm

8

Tube type and Material

8 External Finned Copper Tubes

No. of Tubes

Nos

199

248

Tube OD and Thickness

Inch

3/4" OD x 0.028 Thk

3/4" OD x 0.028 Thk

Tube Length

Ft.

8

8

Surface Area (Inside)

Sq. Ft.

231.10

288.00

Surface Area (Outside)

Sq. Ft.

1002.96

1249.92

Nos

1

1

No. of Pass (Refrigerant side) No. of Pass (Water side)

Nos

2

2

Water connection size

Inch

5"

6"

No. of Refrigerant circuit Water flow Rate

NOS

1

1

Min.

USGPM

480

630

Max.

USGPM

640

840

17

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Water Cooled Screw Chiller (Single Compressor) Description

Units

LCWX1-175 D i B

LCWX1-225 D i B

YCH-177 A

YCH-222 A

DX-COOLER Model Shell ID

mm

416

416

Shell Thickness

mm

8

8

No. of Tubes

Nos

378

508

Tube OD and Thickness

Inch

5/8" OD * 0.031

5/8" OD * 0.031

Ft.

8

8

Surface area (Inside)

Sq. Ft.

765.67

1029

Surface Area (Outside)

Sq. Ft.

497.19

668.00

Nos

1

1

Tube type and Material

Inner Groove Copper Tubes

Tube Length

No. of Pass (Water side) No. of Pass (Refrigerant side)

Nos

4

4

Water Connection Size

Inch

8" NB

8" NB

No. of Refrogerant Circuits Water Flow Rate

Nos

1

1

Min.

USGPM

320

420

Max.

USGPM

480

630

EXPANSION VALVE

Thermostatic

Make

Sporlan

Model

OVE-70-2#

VVE-100-2#

2987

3087

OVERALL DIMENSIONS : Length

mm

Width

mm

900

900

Height

mm

2102

2269

Net Weight Approx

Kg.

3650

4600

Operating Weight

Kg.

4000

5040

Rating Conditions 1. Entering Cooler Water temp 54oF, Leaving Cooler Water temp. 44oF 2. Cooler Fouling Factor 0.0001 Hr.Ft2.F/Btu 3. Entering Condenser Water temperature 85oF, Leaving Coondenser Water temperature 95oF 4. Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu

18

USER'S MANUAL

Technical Specification for Water Cooled Screw Chiller (Twin Compressors) Description Nominal Cooling capacity

Units

LCWX2-225 D i B

LCWX2-270 D i B

LCWX2-315 D i B

KW(TR)

791.3 ( 225)

949.6 (270)

1107.9 (315)

BSC-150A

BSC-110A + BSC-145A

BSC-145A

2

2

2

COMPRESSOR :

Semi Hermetic Screw

Model Quantity

No.

Motor Type

Refrigerant Cooled Semi- hermetic, 3 Ph., 2 Pole, Squirrel Cage Induction Motor

Operating Speed

RPM

Power Supply

2950 400 V(+/- 10%), 3PH., 50HZ

2950

2950

400 V(+/- 10%), 3PH., 50HZ

400 V(+/- 10%), 3PH., 50HZ

Compressor rated Current

Amp.

264.8

315.9

367

Max. Compressor Operating Current

Amp.

320 (160 x 2)

380 (160+220)

440

Compressor Locked Rotor Current

Amp.

735, 735

735, 1100

1100, 1100

Compressor starting Current

Amp.

245, 245

245, 370

370, 370

Unit Starting Current

Amp.

385

481.5

550

F

F

F

KW

164.9

192.5

220

Ltrs.

16 + 16

16 + 23

23 + 23

Kg

180

231

275

YCD-222 A

YCD101A+YCD151A

YCD-151A+YCD151A

Class of Motor Insulation Power Consumption Type of Oil

Blue Star ACS

Oil Charge Refrigerant R 22 Charge

CONDENSER : Model Shell ID

mm

457

330+390

390+390

Shell Thickness

mm

8

8

8

No. of Tubes

Nos

248

127+168

168+168

Tube OD and Thickness

Inch

3/4" OD x 0.028 Thk

3/4" OD x 0.028 Thk

3/4" OD x 0.028 Thk

Ft.

8

8

8

Tube type and Material

Tube Length

External Finned Copper Tubes

Surface Area (Inside)

Sq. Ft.

288.00

324.15

390.19

Surface Area (Outside)

Sq. Ft.

1249.92

1406.79

1693.44

Nos

1

1

1

No. of Pass (Refrigerant side) No. of Pass (Water side)

Nos

2

2

2

Water connection size

Inch

6"

4"+4"

4"+4"

No. of Refrigerant circuit Water flow Rate

NOS

2

2

2

Min.

USGPM

624

750

870

Max.

USGPM

832

1000

1160

19

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Water Cooled Screw Chiller (Twin Compressors) Description

Units

LCWX2-225 D i B

LCWX2-270 D i B

LCWX2-315 D i B

DX-COOLER Model

YCH-222 A

YCH-103A+YCH152A

YCH-152A+YCH152A

Shell ID

mm

488

371+416

416+416

Shell Thickness

mm

8

8

8

Tube type and Material

Inner Groove Copper Tubes

No. of Tubes

Nos

508

252+310

310+310

Tube OD and Thickness

Inch

5/8" OD * 0.031

5/8" OD * 0.031

5/8" OD * 0.031

Ft.

8

8+8

8+8

Tube Length Surface area (Inside)

Sq. Ft.

1029

1074.57

627+627

Surface Area (Outside)

Sq. Ft.

651.46

697.84

407+407

No. of Pass (Water side)

Nos

1

1

1

No. of Pass (Refrigerant side)

Nos

4

4

4

Water Connection Size

Inch

8" NB

6"NB+6"NB

6'’NB+6'’NB

No. of Refrogerant Circuits

Nos

2

2

2

Min.

USGPM

416

500

580

Max..

USGPM

624

750

870

Water Flow Rate

EXPANSION VALVE

Thermostatic

Make

Sporlon

Model

VVE-100-2#

V V E-100-1# + OVE-70-2#

OVE-70-2# + OVE-70-2#

OVERALL DIMENSIONS : Length

mm

3100

3400

3400

Width

mm

1220

1800

1800

Height

mm

2300

2300

2300

Net Weight approx

Kg.

5000

5400

6526

Operating Weight

Kg.

5450

6050

7280

Rating Conditions 1. Entering Cooler Water temp 54oF, Leaving Cooler Water temp. 44oF 2. Cooler Fouling Factor 0.0001 Hr.Ft2.F/Btu 3. Entering Condenser Water temperature 85 oF, Leaving Coondenser Water temperature 95oF 4. Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu

20

USER'S MANUAL

Technical Specification for Water Cooled Screw Chiller (Twin Compressors) Description Nominal Cooling capacity

Units

LCWX2-345 D i B

KW(TR)

1213.4 (345)

LCWX2-400 D i B 1406.8 (400)

COMPRESSOR :

Semi Hermetic Screw

Model Quantity

No.

Motor Type

BSC-160A

BSC-160A+BSC-210A

2

2

Refrigerant Cooled Semi-hermetic, 3 Ph., 2 Pole, Squirrel Cage Induction Motor

Operating Speed

RPM

Power Supply

2950

2950

400 V(+/- 10%), 3PH., 50HZ

400 V(+/- 10%), 3PH., 50HZ

Compressor rated Current

Amp.

401.4

459.3

Max. Compressor Operating Current

Amp.

480 (240 x 2)

550 (240 + 310)

Compressor Locked Rotor Current

Amp.

1480, 1480

1480, 1760

Compressor starting Current

Amp.

495, 495

495, 590

Unit Starting Current

Amp.

692

769

F

F

Class of Motor Insulation Power Consumption

KW

241.4

Type of Oil

276.7 Blue Star ACS

Oil Charge Refrigerant R 22 Charge

Ltrs.

23 + 23

23 + 28

Kg

304

351

CONDENSER : Model

YCD-176A+YCD176 A

YCD176A+YCD222A

Shell ID

mm

390+390

390+457

Shell Thickness

mm

8

Tube type and Material

8 External Finned Copper Tubes

No. of Tubes

Nos

199+199

199+248

Tube OD and Thickness

Inch

3/4" OD x 0.028 Thk

3/4" OD x 0.028 Thk

Ft.

8

8

Tube Length Surface Area (Inside)

Sq. Ft.

462.19

519.10

Surface Area (Outside)

Sq. Ft.

2005.92

2252.88

No. of Pass (Refrigerant side)

Nos

1

1

No. of Pass (Water side)

Nos

2

2

Water connection size

Inch

5"+5"

5"+6"

No. of Refrigerant circuit

NOS

2

2

Water flow Rate

Min.

USGPM

960

1110

Max.

USGPM

1280

1480

21

SCREW CHILLER (Air & Water Cooled)

Technical Specification for Water Cooled Screw Chiller (Twin Compressors) Description

Units

LCWX2-345 D i B

LCWX2-400 D i B

DX-COOLER Model

YCH-177A+YCH177A

YCH-177A+YCH222A

Shell ID

mm

416+416

416+488

Shell Thickness

mm

8

Tube type and Material

8 Inner Groove Copper Tubes

No. of Tubes

Nos

378 +378

378+508

Tube OD and Thickness

Inch

5/8" OD * 0.031

5/8" OD * 0.031

Ft.

8+8

8 + 8

Surface area (Inside)

Sq. Ft.

765.67+765.67

765.67 + 1029

Surface Area (Outside)

Sq. Ft.

497.19+497.19

497.2 + 668

Tube Length

No. of Pass (Water side)

Nos

1

1

No. of Pass (Refrigerant side)

Nos

4

4

Water Connection Size

Inch

8" NB+8'’NB

8" NB + 8'’NB

No. of Refrogerant Circuits

Nos

2

2

Min.

USGPM

640

740

Max..

USGPM

960

1110

Water Flow Rate

EXPANSION VALVE

Thermostatic

Make

Sporlon

Model

OVE-70-2# + OVE-70-2#

OVE-70-2# + VVE-100-2#

OVERALL DIMENSIONS : Length

mm

3400

3400

Width

mm

1800

1800

Height

mm

2450

3000

Net Weight approx

Kg.

6862

7541

Operating Weight

Kg.

7500

8300

Rating Conditions 1. Entering Cooler Water temp 54oF, Leaving Cooler Water temp. 44oF 2. Cooler Fouling Factor 0.0001 Hr.Ft2.F/Btu 3. Entering Condenser Water temperature 85 oF, Leaving Coondenser Water temperature 95 oF 4. Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu

22

USER'S MANUAL

Pressure Drop YCH-52A

YCH-62A

YCH-77A

YCH-92A

20

1.5

40

2.5

1.4

60

3.5

2.5

1.75

80

5

4

3

100

7

6

4.5

120

10

8.3

6.5

140

13

11

9

5.5

160

16.5

14

11.5

6.5

180

21

17.5

14.5

8

200

26

21

18

10

220

25

21

12

240

29

24.5

14

260

28.3

16

280

32.5

18.5

300

21

320

24

340

26

360

28

380 400

YCH-103A YCH-122A

YCH-132A YCH-177A YCH-202A YCH-222A YCH-152A

100 150

6

200

10

7.5

5.5

4.5

2.8

0.5

250

15

10.3

8.3

6.5

4.6

2.5

300

21

14

11

8.5

6.5

4

350

27

19

14

12

9.2

5.8

400

25

18

15

12

7.5

450

36

22

19

15

9.3

500

26

23

19

11.5

550

32

28

24

14

600

40

33

28

17

32

20

650 700

3.5

2

24

23

SCREW CHILLER (Air & Water Cooled)

24

USER'S MANUAL

YCD-51A

YCD-61A

2

YCD-77A

YCD-91A

YCD-101 A

0.5

60

3.5

2.5

1.5

80

5.5

3.6

2.5

100

8

5.5

4

3

2

120

10.5

7.5

5.5

4

3

140

14

10.5

7.5

5

4

160

17.5

13

9.5

6.5

5.5

180

21.5

16

11.5

8

7

200

26.5

19

14

10

8.5

220

22.5

16.5

12

10

240

26

19

14

12

260

21.5

16

13.5

280

24.5

18.5

15.5

300

21

17

320

23.5

19

340

21

360

23

YCD-122

YCD-132

YCD-152 A

YCD-177 A YCD-202 A

YCD-222 A

100 150

2

200

4.6

3.6

2

250

7

5.5

3.5

2.8

300

10

7.5

6

4.7

350

13

9.2

8

6.5

5

3

400

16

12

10.2

8.2

6.1

4.5

450

20

15

12.5

10

8

6

500

24

18

15

12

10

8

550

30

23

19

15

12

10

600

35

27.5

22

18

14

12

35

25

21

16

13.5

25

18

15

650 700

3.5

2

25

SCREW CHILLER (Air & Water Cooled)

26

USER'S MANUAL

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 retained 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.

Installation (Aircooled) Proper care should be taken to make the foundation for the Chiller. Study the GA drawings of respective models and arrange for wider foundation as rquired to accommodate all the springs within the width of foundation since the springs centres ar enot in one straight line. In case the Chiller is located on the roof top, 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.

27

SCREW CHILLER (Air & Water Cooled)

Install the Chiller on the springs specifically designed and supplied along with the unit. The unit should not be located nearer to any heat source or any high tension line running above. (Especially near the Control Panel end) Adequate space around the Chiller as recommended in the GA 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. Alternately 2 nos. of National Couplings in series can be provided for the cooler connection. Use recommended size of power cable to be terminated to the Control Panel of the unit. Use 3½ 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. Two separate incomer cables are required for the chillers with twin compressors.

28

USER'S MANUAL

Installation (Watercooled) Proper care should be taken to make the foundation for the Chiller. In case the Chiller is located on the roof top, 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 GA 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. Alternately use 2nos. of national couplings in series. Use recommended size of power cable to be terminated to the Switch Fuse unit of the Panel of the unit. Use 3½ 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. Two separate incomer cables are required for the chillers with twin compressors.

29

SCREW CHILLER (Air & Water Cooled)

Carel Controller For Screw Chiller with Step Capacity Control

1.General Characteristics pCO1 Medium (18 Din modules)

•

12 optically-isolated digital inputs, 24Vac 50/60 Hz or 24Vdc;

•

Optically-isolated digital inputs, 24Vac/Vdc or 230Vac (50/60Hz);

•

Digital relay outputs (3 of which with changeover contact and 4 optional SSR);

•

4 analog inputs, configurable as NTC, 0/1V, 0/5V, 0/20mA, 4/20mA.

•

2 analog inputs, configurable as NTC and ON-OFF

•

2 NTC analogue inputs

•

2 x 0/10Vdc analogue outputs.

•

2 PWM outputs for phase-cutting speed controllers.

30

USER'S MANUAL

2. Hardware Structure The structure of the pCO1 features:

•

The pCO1 controller, fitted with a 16bit microprocessor for running the control program, and the set of terminals required for connection to the controlled devices (for example: valves, compressors, fans). The program and the parameters are saved permanently in the FLASH memory, preventing data loss in the event of power failure (without requiring a backup battery). The pCO1 also allows connection to a local pLAN network made up of a series of pCO1 boards and terminals. Each board can exchange information (any variable, digital or analogue, according to the application software) at high transmission speeds. Up to 32 units can be connected, sharing information in very short times. The connection to the supervisor/tele-maintenance serial line, based on the RS485 standard, is made using the optional serial cards (PCO1004850) and the Carel or Mod Bus communication protocol.

•

The terminal, also managed by microprocessor, fitted with display, keypad and LEDs to allow the programming of the control parameters (Set Point, differential band, alarm thresholds) and basic functions by the user (ON/OFF, display of the controlled values, optional printing).The terminal does not have to be connected to the pCO1 for normal operation, but can be used for the initial programming of the fundamental parameters.

•

The pCO1 has a variation of only on input and output configuration and available memory.

The following is a description of the pCO1 (Medium version) with reference to the basic layout:

Fig. 2.1.1

31

SCREW CHILLER (Air & Water Cooled)

1. Power supply connector [G (+), G0 (-)] 2. 250Vac, 2A fuse, slow-blow (T2 A) 3. Universal analogue inputs, NTC, 0/1V, 0/5 V, 0/20mA, 4/20mA 4. Passive analogue inputs, NTC and ON/OFF 5. Passive analogue inputs, NTC 6. Yellow power LED and 3 signal LEDs 7. 0/10V analogue outputs and PWM phase-cutting outputs 8. Digital inputs, 24Vac/Vdc 9. Digital inputs, 230Vac or 24Vac/Vdc 10. Connector with Vref for power to 5V ratiometric probes, and Vterm for power to ARIA terminal 11. Connector for all the standard pCO* series terminals and for downloading the application software 12. PLAN local network connector 13. Connector for the programming key 14. Digital relay outputs 15. Door for selecting the type of analogue inputs 16. Door for inserting the serial card: - RS485 for supervisor - RS232 for modem interface - Gateway (protocol converter) 17. Door for inserting the clock card

32

USER'S MANUAL

Installation Power supply The pCO1 can be powered at: 22/38Vdc and 24Vac ±15%, 50 z, with a maximum power input Pmax= 13W. For alternating current power supplies, during installation use a Class II safety transformer, rated to at least 40VA and with a 24Vac output. To supply more than one pCO1 controller with the same transformer, its rated power must be n x 40VA, where n is the number of controllers supplied by the transformer, independently of the version of the controller. The power supply to the pCO1 controller/controllers and the terminal/terminals must be separated from the power supply to the other electrical devices (power contactors and other electromechanical components), inside the electrical panel. If the transformer secondary is earthed, make sure that the ground wire is connected to terminal G0.When powering a series of pCO1 boards connected in a pLAN network, make sure that the G and G0 connections are correct (G0 must be same for all the boards). The table below summaries the possible status of the power LED.

LED Status Yellow On Off

Description Power Supply Present Power Supply absent Table 4.2.1

Fig. 4.2.1

33

SCREW CHILLER (Air & Water Cooled)

The following warnings must be respected for correct connection: •

Power supply different from that specified can seriously damage the system;

•

Use cable plugs suitable for the terminals being used. Loosen each screw and insert the cable plug, and then tighten the screws. At the end of the operation lightly tug the cables to check that they are tight;

•

Separate as much as possible the probe signal and digital input cables from the inductive load and power cables, to avoid possible electromagnetic disturbance. Never use the same channeling (including that used for the electrical cables) for the power cables and probe cables. Avoid the probe cables being installed in the immediate vicinity of power devices (contactors, circuit breakers or the like);

•

Reduce the length of the sensor cables where possible and avoid spiraling around power devices. The probe connection must be made using shielded cables (minimum cross section for each lead: 0.5 mm2);

•

Avoid touching or nearly-touching the electronic components on the boards, to avoid (extremely dangerous) electrostatic discharges from the user to the components;

•

If the power supply transformer secondary is earthed, check that the ground wire corresponds to the lead connected to terminal G0 in the controller;

•

Separate the power supply to the digital outputs from the power supply to the pCO1;

•

Do not fasten the cables to the terminals by pressing the screwdriver with excessive force, to avoid damaging the pCO1.

Connecting the analog inputs The analog inputs can be configured for the more common sensors on the market: NTC, 0/1V, 0/ 10V, 0/20mA, 4/20mA. The different types of sensors can be selected using the corresponding dipswitches, as in the following figure.

Fig. 4.4.1

34

USER'S MANUAL

Warning: for the power supply to the active probes, the 24Vdc available at the +VDC terminal can be used; the maximum current is 100mA, thermally protected against short-circuits.

Fig. 4.4.2

35

SCREW CHILLER (Air & Water Cooled)

Connecting universal NTC temperature probes : All the analogue inputs, from B1 to B8, are compatible with NTC 2-wire sensors, after having configured the program and the corresponding dipswitches on the board. The connection diagram Fuse and the correct position of the dipswitches on the board are shown below:

Fig.4.4.2.1

pCO3 terminal GND

NTC probe wire 1

B1, B2, B3, B4, B5, B6, B7, B8

2

Table 4.4.2.1

36

USER'S MANUAL

Fig. 4.4.4.1

pCO1 terminal +5V ref GND B1, B2, B3, B4

Probe wire colour black green White

description Power supply Power supply ground Signal

Table 4.4.4.1

Warning: the two wires of the NTC probes are equivalent, as they have no polarity therefore it is not necessary to respect any specific order when connecting to the terminal block.

37

SCREW CHILLER (Air & Water Cooled)

Connecting 0/5V ratio metric pressure probes : The pCO1 can be connected to all the Carel SPKT series active probes pressure or any other pressure sensor available on the market with a 0/5V ratio metric signal. The following inputs can accept these sensors: B1, B2, B3 and B4, after having configured the program and the corresponding dipswitches on the board. The connection diagram and the correct position of the dipswitches are shown below:

Fig. 4.4.5.1

Input type NTC 1 (Current) V (Voltage)

C.sect. (mm2) for lengths upto 50m 0.5 0.25 0.25 Table 4.4.6.2

38

C.sect. (mm2) for lengths until 100m 1.0 0.5 0.5

USER'S MANUAL

Connecting the digital inputs : The pCO1 features up to 14 digital inputs for connecting safety devices, alarms, device status, and remote switches. These inputs can work at 24Vac, 24Vdc and some at 230Vac.

WARNING: separate the probe signal and digital input cables as much as possible from the inductive load and power cables, to avoid possible electromagnetic disturbance 24Vac digital inputs : The following figure represents one of the more common connection diagrams for the 24Vac digital inputs.

Connecting the digital outputs : The pCO1 features up to 13 digital outputs with electromechanical relays. For ease of installation, the common terminals of some of the relays have been grouped together. If the diagram in Fig. 4.8.1.1 is used, the current at the common terminals must not exceed the rating (nominal current) of a single terminal. The relays are divided into groups, according to the degree of insulation. Inside each group, the relays have just single insulation and thus must have the same voltage (generally 24Vac or 110/230Vac). Between the groups there is double insulation and thus the groups can have different voltages.

Electromechanical relay outputs :

Fig. 4.8.1.1

Installing the user terminal : The connection between the user terminal and the pCO1 is made using a 6-way telephone cable supplied by Carel.To make the connection, simply insert the telephone connector in terminal J10 on the pCO1 and in terminal B on the user terminal. Insert the connector fully into in the terminal until it clicks into place. To remove the connector, simply press lightly on the plastic flap and remove the cable. The pCO1 can also work without the terminal; do not disconnect and then reconnect the terminal to the pCO1 without first having waited around 5 seconds (if the operation is performed with the unit on). For devices used in residential environments or similar, and thus subject to CEI EN 55014-1 -04/98, any standard terminals connected by J10 must use a shielded cable. The shield must be connected to the GND terminal of J11.

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SCREW CHILLER (Air & Water Cooled)

The electrical connections are the following. Connect the telephone cable (code S90CONN00* from the power board (code PCO1*) into the corresponding jack. For model PCOI00PGL0 only, connect the 24Vac (30VA) power supply to the screw terminal block. If the same transformer is used for the pCO1, G and G0 must be the same on the pCO1 and the terminal.

pAN network : As already mentioned, the pCO1 controllers can be connected to the pLAN local network, allowing the communication of data and information from one location (node) to another. Each pCO1 can be connected to a Carel supervisory network, using the optional PCO1004850 cards.

The pCO1 terminals can monitor the control variables (temperature, humidity, pressure, I/O, alarms) from one or more boards. If one or more terminals are disconnected or malfunctioning, the control program continues to function correctly on each pCO1 board. Generally, the application program can monitor the status of the network and intervene as a consequence to ensure the continuity of the control functions. Figure 5.1, shows the pLAN network connection diagram: a maximum of 32 units can be connected (including I/O interface cards and user interface cards).The 32nd unit can only be a terminal. All the versions of the pCO1 can be connected in a local pLAN network without requiring additional boards (Fig. 5.1). The programs for the different applications (e.g.: standard chiller, standard air-conditioner, compressor packs, ...) can not be automatically integrated into a local network: they must be modified to consider the network strategy and structure, and then be recompiled using the Easy Tools system. All the devices connected to the pLAN network are identified by their own individual address, from 1 to 32 for the terminals and from 1 to 31 for the I/O boards. As the terminals and the pCO1 I/O boards use the same type of address, terminals and pCO1 boards cannot have the same identifier. The addresses are set for the terminals using the dipswitches on the rear. The network can be made up of any type of terminal, LED, 4x20 LCD and graphic, as well as pCO and pCO1 controllers.

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USER'S MANUAL

Setting the pCO1 address : The pCO1 controller does not have dipswitches for setting the pLAN network address.The pLAN address is set using a standard 4x20 LCD terminal. Proceed as follows: •

Disconnect the pCO1 from the power supply;

•

Organise a standard Carel 4x20 LCD terminal with the address set to 0;

•

Connect the terminal to the pCO1;

•

Disconnect the pCO1 from any plan connections to other controllers (terminal J11);

•

Power the pCO1, pressing the UP and ALARM buttons at the same time;

•

After a few seconds the following screen will be displayed:

•

To modify the address simply use the UP and DOWN buttons, and then press ENTER to confirm.

Setting the terminal address : The address can be set in the range from 1/32 using the dipswitches 1/6 on the rear. The graphic terminal does not require the setting of the address, as this is determined by the program EPROM. Fig. 5.2.1 shows the rear view of the terminal board.

Fig. 5.2.1

Important Warning: if the application software does not envisage a pLAN local network, the dipswitches must be positioned to 0.

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SCREW CHILLER (Air & Water Cooled)

5.4 pLAN Electrical Connections Connection between boards in a pLAN network is carried out using an AWG20/22 shielded cable, twisted pair plus shield. The boards are connected in parallel, with terminal J11 as the reference. Pay ATTENTION to the network polarity: RX/TX+ on one board must be connected to RX/TX+ on the other boards; the same is true for RX/TX-. Fig. 5.4.1 shows a diagram of a number of boards connected in a pLAN network and powered by the same transformer, typical for a number of boards connected inside the same electrical panel. Remote installation of the terminal in a pLAN network when pCO1 boards are connected in a pLAN network, the terminal can be remotely-installed at a distance of up to 50metres, if using a telephone-type cable, while it can be located at a distance of up to 200metres if using an AWG shielded cable. The following figures show the connection diagrams for the various configurations. Remote installation of the terminal in a pLAN network using a telephone cable. This type of remote installation requires the insertion of two ferrites, code 0907858AXX, at the markings with the letter F in Fig. 5.5.1.1. Figs. 5.5.1.2a and 5.5.1.2b show respectively the ferrites to be installed the open and closed position. The ferrites are mounted on the telephone connection cable, one on the pCO1 side (see Fig.5.5.1.3) and the other on the terminal side (see Fig. 5.5.1.4). Note: The graphic terminal, unlike the other LCD models, requires a 24Vac power supply from the Plug-In terminals (terminals G and G0).This may be the same line that powers the pCO1 (in this case, make sure G and G0 correspond), or alternatively may be supplied by another transformer; in this case, do not earthy the secondary.

Warning: the telephone cable must exit the pCO1 perpendicularly. Reading the 3 LEDs on the pCO1 board The pCO1 board features 3 signal LEDs (red, yellow and green) that provide information on the operation of thepCO1 board and the status of the connection to WinLoad32.

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USER'S MANUAL

Key


LED off

 LED on

 LED flashing

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SCREW CHILLER (Air & Water Cooled)

*: Cases in which pCO1 reverts to Low Level status: - When starting the pCO1 detects that Win Load is connected. - When starting the pCO1 detects “Application corrupted…”. - During normal operation the pCO1 runs a JUMP atom without the correct reference or backwards. After 20 seconds of Low Level status without Win Load connected, the pCO1 is automatically reset. •

If the pCO1 is started with the key inserted and the key switch is set to Key (see Fig. 6.1.1), (SELECTION LED red ), without pressing the buttons on the local terminal, the program resident in the key is run, without modifying the program resident in the pCO1. In practice, the pCO1 controller can run an alterative program and/or setup to the resident version. This function is useful for testing upgrades to the BIOS and/or APPLICATION, without overwriting the software resident in the pCO1. It is also very useful for running special functions or parts of programs (e.g. final functional tests) using special parameter Configurations and/or programs (expressly developed for these functions), without modifying the program resident in the pCO1.Only the program and/or parameter configuration resident in the key are modified. Once this phase is complete, switch off the pCO1 controller, remove the key, and when starting the pCO1 the next time, the original program and setup are used.

•

If, on the other hand, the key switch is set to pCO1 (SELECTION LED green) and the buttons on the local terminal are not pressed, the key has no effect.

•

To display or modify the pLAN address, use the local terminal: switch off the pCO1, remove the terminal from the pLAN network, connect the user terminal with address set to 0, start the pCO1 and hold the ALARM and UP buttons until the screen is displayed showing the pLAN address, then follow the instructions on the screen.

•

The current version of program can be checked at any time (by CRC code expressed in hexadecimal), and whether the program on the key or the resident program is used. To check this, simply proceed as follows. Press the alarm and enter buttons together for 3 seconds, and the following screen will be displayed:

Confirming with enter displays a second table, as shown in the following example:

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USER'S MANUAL

1st row BOOT: version and date. The pCO1 is working with BOOT 2.05, 24/01/02 2nd row BIOS: version and date. The pCO1 is working with BIOS 2.40, 20/02/02 3rd row Flash ON BOARD and KEY, if present. The characters (>_ +15% Instant Running => +10% Frequency : +2 % 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

Set Point

Motor winding

Cut out 120 Deg. C

temperature protector

Cut in 75 Deg.

High discharge

Cut out 110 Deg. C

temperature protector

Cut in 60 Deg. C

Phase reversal protector

Phase reversal when power on

Hi – Low pressure protector

Highest pressure 25 Kg/Sq.cm g

Phase failure protector

Phase failure when compressor starting or running

Motor overload relay

Set by a related application value, any setting should be tripped in 15 sec.

Hi-Low Voltage protector

Rated Voltage + 15 %

Oil level switch

Oil level lower than the floating ball

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SCREW CHILLER (Air & Water Cooled)

Operation of Micro Controller The control circuit for the Chiller comprises of analog sensor inputs such as suction pressure(s), discharge pressure(s), entering and leaving water temperatures etc. and digital sensor inputs such as flow switch, oil level switch, SP/PR faults; etc. It consists of relay outputs that drive the compressor(s), condenser fans, economizer(s) etc. Before switching ON the Screw chillier, ensure that the flow switch is connected between points 7 & 8 (and 7A & 8A for twin cooler models) in the wiring diagram and there is sufficient water flow. The crankcase heater should be ON for a period of min. 8 hours. In the OFF state, the condition of the outputs is as follows (provided incoming power supply is ON): Relay output

Condition

Main 1, 2

OFF

Load/ Unload sol (SV1)1/2

OFF

Load/ Unload sol (SV2)1/2

OFF

Load/ Unload sol (SV3)1/2

OFF

Pilot Solenoid valve 1, 2

OFF

Liquid Injection 1, 2

OFF

Economiser *

OFF

Oil Cooler Fan *

OFF

Condenser Fan A,B,C etc. *

OFF

*Applicable only for Air Cooled Screw chillers (1) Switch on power supply through Rotary Switch (mounted in control section). The unit goes in power up mode. In this state, all relay outputs are turned OFF. Controller will initialise & monitor Power Supply stability for 90 seconds. Switch ON individual system toggle switches (mounted in control section) to enable demand for respective compressors. (2) After the power up delay, the system goes in ON state. Controller checks for any anti-cycle (fault) timers leftovers and then generates demand for the first compressor based on set point and actual chilled water temperature. (3) All three Solenoid Valve (SV1, SV2, and SV3) are kept de-energised after initial power up delay to ensure unloaded start of compressor.

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USER'S MANUAL

(4) Compressor starts with ‘Fast Unload’ logic. Condition of the relay outputs is as follows: Relay output

Condition

Main 1, 2

ON

Load/ Unload sol (SV1)1/2

OFF

Load/ Unload sol (SV2)1/2

OFF

Load/ Unload sol (SV3)1/2

OFF

Pilot Solenoid valve 1, 2

ON

Liquid Injection 1, 2

OFF

Economiser *

OFF

Oil Cooler Fan *

OFF

Condenser Fan A,B,C etc. *

OFF

*Applicable only for Air Cooled Screw chillers (5) One bank of condenser fans goes ON with corresponding compressor. (Applicable in case of Air Cooled Chillers) (6) Depending on difference between the leaving water temperature and set point, the system shall load or unload. The operation of the load or unload solenoid valves is as under for individual compressor

Sl. No.

Capacity Control System

SV1

SV2

SV3

1

100 % Of Full Load

On

On

On

2

75 % Of Full Load

On

Off

On

3

50 % Of Full Load

On

On

Off

4

25 % Of Full Load

Off

On

On

5

Shut Down and Initial Fast Unloading

Off

Off

Off

(7) When compressor-1 is at 100% load (or unable to load further due to safety hold), demand for the second system is generated to meet further load. (8) The 1st Compressor unloaded to minimum 50% slide position and 2nd compressor is started as per the sequence given in steps 4 to 6 (9) Thereafter both compressors are loaded / unloaded simultaneously .If load goes below 50 %, one compressor will switched off and other will utilizes the available full capacity. (Unless any of the compressors goes in safety hold).

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SCREW CHILLER (Air & Water Cooled)

Shut down sequence

•

To shut down complete chiller switch off rotary switch provided in panel. To switch OFF a particular compressor, respective toggle switch should be switched off.

•

During normal shut-down through controller, Compressor runs for preset time to enable unloading of slide to minimum position before switching OFF

•

Run Time Equalization

Controller has ‘minimum run time equalization’ logic option (set point 103 should be 0 and set point 104 should be 1). Compressor which runs for minimum time shall start first during next operation cycle.

Safety Parameters During normal running of compressor (s) following safety Parameters are monitored : Sr. No.

Set Point Description

Trip Delay (Seconds)

Default Setting

1

Hi amps

2

105 %

2

Low amps

5

15 %

3

Low suction

120

20 psig

4

Low gas / LSV FLT

10

15 psig

5

High discharge

2

250/375 psig

6

Low discharge

90

80 psig

7

Low oil differential

180

50 psig

8

Unsafe Oil

4

20 psig

9

Anti freeze *

5

39oF

* In case of Anti Freeze, all the Circuits of the entire Chiller are locked out.

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USER'S MANUAL

To avoid nuisance tripping during compressor start up, following initial by pass / time delay adjustment procedure is observed.

Set Point Description

Bypass

Time Delay Adjustment*

Hi amps

For first 3 seconds

—

Low amps

For first 3 seconds

—

Low suction

During pump down

Low gas / LSV FLT Low oil differential Oil Level Switch

—

2 Min for 30 PSI

First 5 seconds

25 psig for next 30 seconds.

First 1 Minute

—

Operating Specifications The following are the Operating Specifications and default set points: 1.

Leaving water temperature is set at 45ºF with a control of ±0.5ºF.

2.

Liquid injection system switches ON at Discharge Temperature of 165ºF and switches OFF at Discharge Temperature of 155ºF.

3.

The Economizer Solenoid Valve activates at 75% of Slide positions and turns off at 65% of slide position. (Applicable for air cooled chillers only)

4.

One bank (50% of the total No. of fans) of condenser fans switches ON at discharge pressure 200 psig and turns OFF at 140 psig. (Applicable for air cooled chillers only)

5.

The delay between the Star and Delta connection is preset at 3 seconds.

6.

Low-pressure setting is at 15 psig and High-pressure setting is at 250 /375 psig.

7.

Anti Freeze Thermostat setting is at 39ºF

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SCREW CHILLER (Air & Water Cooled)

1. Capacity Control Method The capacity control method is based upon to develop the control zone on both side of Water leaving temperature set point, and accordingly add or subtract the capacity control stages of chiller. To accomplish this system will constantly monitor the set point, trend of load and slide position in relationship to the control zone.

1.1 Common Definitions 1.1.1 Target The control target is “Water Leaving Set point”. This will be the base of developing the control zone.

1.1.2. Control Zone The control zone is developed by adding the set points for the control target and the dead band + to obtain the upper limit. The lower limit is obtained by subtracting the dead band - set point from the control target Once the control zone has been established, the system will attempt to keep the control sensor reading with in this range. The capacity control stage calculation is in hold if the chiller running in control zone.

1.1.3. Controlling Sensor This is the sensor that has been specified as leaving temperature.

1.1.4. Trend of Load The Trend of Load is how fast the control value is changing over a period of time. If the control value is increasing the rate will be positive, if decreasing the rate will be a negative value. How fast the input is changing, its direction and where the current input reading is in relationship to the control zone will determine what action the system will take.

1.1.5. Slide Valve Countdown The system will not attempt to take action until the Slide Valve Count down reaches zero. The speed that it is decrement by is based upon the Trend of Load of control input value and the slide Response that has been specified.

1.1.6. Slide Response The purpose of the Slide Response value is to limit or dampen how fast the slide reacts to changes indicated by the control sensor. The lower the number, the faster the system will react to changes of the control sensor. The Control Status portion of the Status screen is shown below. Chiller information:

62

•

Capacity Control State - State of chiller

•

TIME - time in that state, if the state is UNIT IN POWER UP time will decrement to zero

•

Steps wanted / Steps Actual On - Number of steps wanted on verses the actual steps turned on verses the total steps on the chiller.

USER'S MANUAL

•

Slide Valve Countdown - value that is counted down. The Slide Response and where the control temperature is in relationship to the control zone will determine the speed of the count down. When the value decrements to zero, the system will determine if a change in the systems capacity is required.

•

Wanted Slide % - Wanted slide percentage

•

Trend Of Load – Trend Of Load of control sensor, the speed at which the control sensor is changing. Circuit information (all active circuits will be displayed):

•

Circuit Number and State - Circuit number and state.

•

TIME - time in that state, if the state is CMP ANTICYCLE time will decrement to zero.

•

Oil Diff - Oil differential pressure. Oil differential pressure is calculated as follows: Semi hermetic screws; Oil psi – Suction psi or Discharge psi – Suction psi.

•

Lead - indicates the lead compressor.

•

FLA %: Full Load Amps based on the set point.

2. Capacity Control State Capacity Control States are active for all five releases of software.

UNIT IN POWER UP This state is entered when the Controller is powered up or the system has been reset. The system will remain in this state for the time specified in set point POWER UPDELAY, set point 23, or if not active for 60 seconds. In this state all points (RO’s) are turned off. This is a time delay to insure the controller has stable power before starting the algorithm.

UNIT IN LOCKOUT This state is entered whenever a critical situation is encountered that could cause harm to the chiller package. Items such as freeze protect and emergency stop will force the system into this state. Lockouts can be reset with user level authorization from the keypad; however if the lockout condition has not been corrected, the system will again be forced into the LOCKOUT state. NOTE: If the Lockout reset is pressed more than 10 times in a day the unit cannot be reset till Factory authorization.

EXPANSION BOARD OFFLINE This state will be entered whenever the controller loses communications with any of the I/O boards that are connected via the network. When this state is entered the system will generate an off line alarm, which locks out the unit. The lockout-reset key must be depressed to reset the system, after the lost I/O has been corrected.

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SCREW CHILLER (Air & Water Cooled)

SWITCHED OFF This state is entered when the run stop switch is off, in the stop position. When the chiller is in this state, the individual circuit states if active are moved to the CMP IS OFF state through the normal states.

SCHEDULED OFF This state is entered when the schedule is calling for the package to be off. When the chiller is in this state, the individual circuit states if active are moved to the CMP IS OFF state through the normal states.

OFF- NO EVAP FLOW This state is entered when the evaporator flow switch is off. When the chiller is in this state, the individual circuit states if active are moved to the CMP IS OFF state through the normal states. The controller will generate the alarm in this condition and not required to be reset if alarm is clear.

UNIT IS HOLDING This state is entered when one of three conditions exists: 1. The control sensor reading is being maintained with in the control zone. 2. Control sensor reading is above the control zone but the Trend Of Load is less than the value in the set point. This indicates that the temperature is decreasing toward the target at an acceptable speed. Therefore, no additional cooling is needed at this time. 3. The temperature is below the control zone but the Trend of Load is greater than the set point. This indicates that the temperature is increasing toward the target.Therefore, no reduction in cooling is needed at this time. This state indicates that there is no need to adjust the cooling capacity of the chiller package. This state will be exited when more or less capacity is required.

3. Circuit Control States The action of the circuit control states actually result in more, less or no change in the amount of cooling capacity. The CAPACITY CONTROL STATES dictate how the individual circuits move within their states.

CMP LOCKED OUT This state is entered when the Capacity Control State is LOCK OUT or a safety set point for this circuit has indicated that a critical situation has been encountered. Set points such as LOW SUCTION, HI DISCHARGE PRESSURE etc. are examples of safety set points. Lockouts can be reset with USER level authorization from the keypad; however if the lockout condition has not been corrected, the circuit will again be forced into the LOCKOUT State.

SAFETY TRIPPED This state is entered when a safety trips but a lockout is not to be generated. An alarm is generated but the system will restart after the delay specified in the corresponding set point. If a second trip occurs within the time specified in the set point, the circuit will be placed in the CMP LOCK EDOUT State.

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USER'S MANUAL

CMP OFF / READY This state is entered when no cooling capacity is required from this circuit or the prior state was CMP ANTICYCE, LOST IO LOCKED or SWITCHED OFF. In this state the circuit is ready to provide cooling capacity if needed. The circuit will remain in this state for a minimum of 60 seconds.

CMP PMP DOWN This state is entered whenever the pump down switch has been turned on or if this circuit is no longer wanted on. The compressor is on and the liquid line solenoid is closed. This state is active until the suction pressure reaches the value in the set point PMP DWN DELAY. The circuit will then move to the ANTICYC State.

CMP ANTICYCLE This state is entered when the PMP DWN State has been completed. The circuit will stay in this state with all circuit points off for the period of time contained in either set point “ANTYRECYCLE TIME “. The circuit will then move to the OFF State.

FAST UNLOADING For screw compressors, this state is entered when the compressor is turned on. The system will remain in this state for 60 seconds while the “fast unloader” and unload points are on. This is to ensure that the screw is unloaded.

CMP IS HOLDING This state only exists for infinite step compressors (Three solenoid valve SV1,SV2 & SV3 ). In this state, the required refrigeration capacity of system is being meant; no movement of the slide valve is required.

CMP IS AT 25% This state is when the compressor is providing 25% of its capacity. In this state, the relay output to activate the 25% valve is turned on.

CMP IS AT 50% This state is when the compressor is providing 50% of its capacity. In this state, the relay output to activate the 50% valve is turned on.

CMP IS AT 75% This state is when the compressor is providing 75% of its capacity. In this state, the relay output to activate the 75% valve is turned on.

CMP IS AT 100% This state is when the compressor is fully loaded. In this state, the circuit is providing the maximum amount of cooling capacity.

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SCREW CHILLER (Air & Water Cooled)

HI DISC UNLOAD Refer to set points HI DISCH PSI, HI DISC UNLD, HI DISC RELD7 and HI DISCH TMP, HI DISCH UNLD and HI DISCH RELD. This state is entered when a fully loaded circuit, that has more than one step, has encountered either a dangerously high discharge pressure or discharge temperature. One step of cooling capacity will be turned off. The circuit will remain in this state for a minimum of five minutes before returning to the LOADED state if the dangerous condition has been corrected. When capacity is being held due to a high discharge condition, once the discharge goes to normal operating condition the circuit will return to its appropriate state.

LO SUCT UNLOAD Refer to set points, LOW SUCTION, LO SUCT UNLD and

LO SUCT RELD.

This state is entered when a fully loaded circuit, that has more than one step, has encountered a dangerously low suction pressure. One step of cooling capacity will be turned off. The circuit will remain in this state for a minimum of five minutes before returning to the LOADED State if the dangerous condition has been corrected. When capacity is being held due to a low suction pressure condition, once the suction pressure returns to a normal operating condition the circuit will return to its appropriate state. This should be same for “LOW GAS “

LO TMP UNLOAD The circuits leaving liquid temperature have caused the system to unload. When the leaving liquid temperature gets to within 1.5 degrees F of the Freeze set point, the unload will occur before we hit the freeze protect safety.

HI AMP HOLD This state is entered when a fully loaded circuit, that has more than one step, has encountered a dangerously high AMP draw. Refer to set points for FLA per circuit and HI AMPS %. In this state, one step of cooling capacity will be turned off. The circuit will remain in this state for a minimum of five minutes before returning to the LOADED State if the dangerous condition has been corrected.

4. Condenser Control Logic 4.1 Condenser Fan Cycling Logic The air condenser set points are as follows: Set point CND STG1 ON - Condenser stage 1 cut in (ON). Set point CND STG1 OFF - Condenser stage 1 cut out (OFF). Set point CND DIFF ON - Differential between condenser stages for cut in (ON). Set point CND DIFF OFF - Differential between condenser stages for cut out (OFF). Set point CND MIN RUN - Minimum run time for a condenser stage when the discharge pressure reaches this value the first condenser point is turned on. If additional condenser points exist, they will be turned on when the pressure exceeds the previous cut in value plus the value contained in (COND DIFF IN) set point.

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USER'S MANUAL

As the discharge pressure is reduced, the condenser points will be turned off based upon the set point (COND ST1 OFF) value plus the condenser step times the value contained in (COND DIFF OUT) set point. The first step will be turned off based upon the valve in the set point (COND ST1 OFF). Example Set point 45 CND STG1 ON = 200.0P Set point 46 CND STG1 OFF = 170.0P Set point 47 CND DIFF IN = 20.0P Set point 48 CND DIFF OFF = 5.0P COND FAN1 ON @ 200.0P DISCHARGE COND FAN 1 OFF @ 170.0 P COND FAN2 ON @ 220.0p (200.0 + 20.0) COND FAN2 OFF @ 175.0p (175.0 + 5.0) COND FAN3 ON @ 240.0p (220.0 + 20.0) COND FAN3 OFF @ 180.0p (170.0 + 10.0), etc.

5. Set Point Definitions 5.1 SET POINT TYPES: There are three different types of set points. The type determines the action that the system will take.

5.1.1. SET POINT This type of set point’s value contains a target or provides information for some type of action. The time element in this type is not used

5.1.2. LOCKOUT This type of set point’s value contains a safety level and the time that the safety must be violated before the safety will trip. Once a safety has tripped the system will take the appropriate action, shutting down the entire package or an individual circuit (compressor) depending on the purpose of the safety. The system will then wait the safety down time contained in that set point before trying to return the system to normal. If successful, the system will continue to operate. If a second trip occurs on the same set point with in the lock out delay time that is contained in that set point the system will move to a LOCKOUT state. IF THE LOCKOUT DELAY TIME IS SET TO ZERO THE LOCKOUT WILL OCCUR ON THE FIRST TRIP. This will require manual intervention to reset the system. With each safety trip, the system will generate an alarm; refer to Alarms and Safeties section of this manual.

5.1.3. ALARM This type is similar to the LOCKOUT set point except it will never cause a lock out. The system will continue to try to return to normal operation after waiting the safety down time. An ALARM set point type will never require manual intervention to reset the system.

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SCREW CHILLER (Air & Water Cooled)

6. Set Points for Chiller Controller Algorithm 6.1 Control set points 1.

CTL TARGET Controlling target is used with the ctl zone & slope and is leaving liquid

2.

CTL ZONE + Added to the CTL TARGET to create the top of the control zone.

3.

CTL ZONE - Subtracted from the CTL TARGET to create the bottom of the control zone.

4.

L.INJECT.ON Liquid injections is turned on when the discharge temperature is equal to or greater than this set point and turned off when the discharge temperature is less than this set point minus 5.

5.

POWERUP DELAY This is the time that the system will remain in the START UP state before moving to the next state.

6.2 Capacity Control Logic 1

SLIDE RESPONCE This value is used to adjust the speed of responding to changes in the control algorithm. 1= faster response HIGHER number’s = slower response.

2

SLIDE VALVE COUNTDOWN This is the time delay before increasing or decreasing the number of refrigeration steps.

3

MAX TREND OF LOAD - Maximum negative Trend of Load allowed before stopping the unit from loading. If the actual ROC is less than this value the capacity control state is placed in the HOLDING state.

4

MAX TREND OF LOAD + Maximum positive Trend of Load allowed before stopping the unit from unloading. If the actual ROC is greater than this value the capacity control state is placed in the HOLDING state.

5

TREND OF LOAD INTERVAL Number of second between the samples used for calculating the actual Trend of Load

6.3 Set Points for Compressor Control 1

ANTYCYCLE This is the anti cycle time delay (in seconds) based on when the compressor was turned off. It will vary from compressor to compressor.

2

PMP Down Delay Maximum time delay (in seconds) that a compressor can remain in the PUMP DOWN state.

3

Comp Min Run this is the minimum run time (in minutes) for a compressor once it is turned on. This minimum run time is bypass only for the safeties.

4

FLA Comp#1 Full Load Amps for the compressor on circuit 1. This value is used to calculate the high and the low ampere safeties limits.

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USER'S MANUAL

6.4 Set Points for Compressor Safeties 1.

HI AMPS : This set point is a percentage of the FLA; it is used to create the high amp draw limit. This value is tested in the high amp safety, if the amps exceed this value for the time specified in this set point the safety is tripped.

2.

LOW AMPS : This set point is a percentage of the FLA; it is used to create the low amp draw limit. This value is tested in the low amp draw safety, if the amps exceed this value for the time specified in this set point the safety is tripped.

3.

LOW SUCTION : If active, the system checks for low suction pressure for each running compressor. The system will compare the suction pressure sensor reading to this value. It must be less than the value for the period of time specified in the set point before this set point will trip.

4.

LOW SUCT UNLOAD: The purpose of this set point is to take corrective action before a low suction pressure safety occurs. If a circuit has more than one step and it is fully loaded and if the suction pressure is less than the value of the safety set point (LOW SUCTION) plus the value of this set point, the system will turn off one step of capacity.. The circuit state will be changed to LO SUCT HOLD. The circuit will remain in this state for a minimum of 5 minutes. At that time, if the suction pressure has increased to a level greater then the value of set point LOW SUCTION plus the value of set point LOW SUCT RELD the compressor will return to normal control.

5.

LOW SUCT RELD: The system will force to load if requirement ,if this setpoint is satisfied

6.

UNSAFE SUCT : If active, the system checks for low suction pressure that is in an unsafe condition for each running compressor. The system will compare the suction pressure sensor reading to this value. It must be less than the value for the period of time specified in the set point before this set point will trip. Note the time period specified should be very short, 2-5 seconds. This safety set point trips the circuit to the LOCKOUT state immediately, no retry.

7.

HI DISC PSI : If active, the system checks for high discharge pressure condition for each running compressor. The system will compare the discharge pressure sensor reading to this value. It must be greater for the period of time specified in the set point before this safety will trip.

8.

HI DISC UNLOAD : The purpose of this set point is to take corrective action before a high discharge pressure safety occurs. If a circuit has more than one step and it is fully loaded and its discharge pressure exceeds the value of the safety set point HI DISCH PSI minus this set point, the system will turn off one step of capacity. A screw compressor will be forced to unload until the discharge pressure falls below the calculated value. The circuit state will be changed to HI DISC HLD. The circuit will remain in this state for a minimum of 5 minutes. At that time if the discharge pressure has dropped below the value of the HI DISCH PSI minus the HI DISC RELD the compressor will return to normal control.

9.

HI DISC RELD : This set point works same as Low Suct Reld

10. LOW DISC PSI : If active, the system checks for low discharge pressure. The system will compare the sensor reading to this value. It must be less than the value for the period of time specified in the set point before a safety trip occurs. 11. HI DISC TMP : If active, the system checks for high discharge temperature condition for each circuit that has at least one step on. The system will compare the discharge temperature sensor reading to this value. It must be greater for the period of time specified in the set point before this safety will trip.

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SCREW CHILLER (Air & Water Cooled)

12. HI DISC UNLOAD : The purpose of this set point is to take corrective action before a high discharge temperature safety occurs. If a circuit has more than one step and it is fully loaded and its discharge temperature exceeds the value of the safety set point HI DISCH TMP minus this set point, the system will turn off one step of capacity. A screw compressor will be force to unload until the discharge temperature falls below the calculated value. The circuit state will be changed to HI DISC HLD. The circuit will remain in this state for a minimum of 5 minutes. At that time if the discharge temperature has dropped below the value of the HI DISCH TMP minus the HI DISC RELD the compressor will return to normal control. 13. HI DISC T RELD : This set point works same as LOW SUCT RELD 14. LOW OIL DIF : If active, the system checks for low differential oil pressure. The system will compare the calculated differential oil pressure to this value. It must be less than the value for the period of time specified in the set point before the safety will trip. 15. UNSAFE OIL : If active, the system checks for low differential oil pressure. The system will compare the calculated differential oil pressure to this value. It must be less than the value for the period of time specified in the set point before the safety will trip. The time delay for this set point should be very short 2-5 seconds. These safeties trips to a lockout no retry are attempted. Manual intervention is required. 16. HII OIL TEMP : If active, the system checks for high oil temperature. The system will compare the oil temperature sensor reading to this value. It must be ON or greater for the period of time specified in the set point before this set point will trip. The sensor can be either an analog or digital input. 17. SAFETY HOLD DELAY : Time in seconds to hold before trying to reload when the capacity has been decreased to avoid a safety, (Examples: high disc psi, high disc temp, low suct psi, etc,) 18. LEAD COMP. Enables the user to specify the lead compressor. 19. COMP. ROTATION Specifies the number of days between rotation

6.5 Set points for Unit Safeties 111 FREEZE If active, the system checks for freeze protection. The system will compare the chilled water out temperature to this value. It must be less than the value for the period of time specified in the set point before this safety will trip.

6.6 Economizer Set Points Economizer On % the set point at which Economizer will get ON Economizer Off % the set point at which Economizer will get OFF

6.7 Oil Differential Calculation The calculation is DISCHARGE PRESSURE minus SUCTION PRESSURE.

7. Authorization Function The authorization code is a special four-character code that enables access in to the system. The code must be numeric with values between 0 and 9if it is to be entered from the Keypad/Display. 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

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USER'S MANUAL

associated level cannot be displayed in system. The authorization codes must be protected and remain confidential, if they are compromised unauthorized personnel can gain access to the system. The two level of safety has been provided 1. User level - Authorized to Change Water leaving set point within the Min & Max value, lockout reset and control zone 2. Factory Level - Authorized for rest of all the things

7.1 RESTORE FACTORY SETTING AND DATA LOGGING 7.1 .1 If some modification has been made in the program SETPOINT, the factory setting can be restored through the set point “Restore Factory Setting” at any movement. 7.1.2. Maximum 100 alarms can be stored with SP, DP and Current reading during trip. The last 20 Dynamic reading with the interval of 1 second will also get stored which will updated with the mention time interval.

8. On/Off Switches The following digital input switches can be associated with the system, their action will affect the chiller package or an individual circuit, and then action will only affect that circuit:

•

Flow switch, if off the system has lost flow. The system wills either lock out, if NO FLOW set point is active, or shut down, if NO FLOW set point is inactive.

•

Pump down switch, if on and the compressor is off, will not start the compressor. If the compressor is on, the system moves to the pump down state to begin the process of turning off the compressor(s) in normal steps.

•

Run/Stop, if off the system will not run. This is usually wired to a RUN/STOP switch that is manually positioned. If the system is running, the system moves all circuits (compressor) to off in normal steps. (If a RUN/STOP and a Network RUN/STOP are both available they operate in series.)

•

Emergency Stop switch, if on, the system will be shut down immediately and will remain disabled until the switch is off.

9. Operating Schedules Two operating schedules per each day of the week and 8 holidays are supported. Each schedule contains a start and end time, if the time and day of the system is with in these limits the schedule is true and the system will be allowed to run. If not, the system will be off due to schedule.

10. Compressor The compressor with the least number of TOTAL RUN HOURS will become the lead. Refer to Set points #103 & #104.

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SCREW CHILLER (Air & Water Cooled)

11. Alarms and Safeties 11.1 Introduction There are three types of alarms that are generated by the Carel control logic:

•

Information only alarms,

•

Controller system alarms and

•

Chiller set point safety alarms.

All of the alarms have the same format. The alarm is identified and it is date time stamped. Alarms can be viewed from Carel controller by pressing the ALARM STATUS (4) key or from the PC-Connect Program.

Sensor inputs used in conjunction with Controller set point safeties: 11.1.1 Suction Pressure - Pressure transducer to read the suction pressure. 11.1.2 Discharge Pressure - Pressure transducer to read the discharge pressure. 11.1.3 Oil Differential Pressure - Calculated value of the oil pressure as follows: Screws without oil pump, discharge psi minus suction psi 11.1.4 Oil Temperature - Either a temperature sensor or a digital input that indicates when a high temperature condition exists. 11.1.5 Discharge Temperature - Either a temperature sensor or a digital input that indicates when a high temperature condition exists. 11.1.6 Motor Amps - Sensor input that measures AMP draw of the compressor. (Optional digital input) 11.1.7 Liquid Temperature - Temperature sensor that can be used to detect a freeze condition 11.1.8 Flow Switch - A digital input that indicates that flow through the chiller barrel exists. There can be one switch per chiller or one for each circuit. 11.1.9 Set point safeties - For a safety to be interrogated, both the associated sensor input and the lockout set point must be active. If a safety trips, the alarm name will consist of the set point name plus additional identification such as point number or circuit number if applicable. The system exercises “smart” safety testing in the following manner: If a safety applies to a circuit and it is an active lockout type of a set point, the first time this safety trips an alarm will be generated and the circuit will be shut down and placed in a safety state. The system will attempt to reactivate this circuit after waiting the length of time specified in this set point, safety down time. If successful the system will continue to run. If the same safety trips the time specified in the lockout delay time, the circuit will be locked off and a manual intervention is required. If the lockout delay time is set to zero, the system will generate a lockout condition the first time that the safety occurs. The time in the safety state and the time between safeties are specified in the individual set points. This enables the times to be unique for each lock out set point.

Most safeties are checked only if the Compressor is running, if he safety is always checked it will be so noted.

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USER'S MANUAL

The following are a list of safeties that are incorporated in the standard chiller algorithm control. These safeties are checked every second. Note, for a multiple circuit system, each circuit is tested individually. If a safety condition exists, action will be taken with that circuit only, other circuits will continue to function.

11.1.10 Freeze Protection (Safety is always checked) If the leaving liquid temperature drops below the set point value the system, and all circuits, will enter a lockout state and a freeze notification alarm will be generated. You have the option of one freeze protect for the package or individual freeze protections by circuit..

11.1.11 No Flow Protection If the flow switch is for the chiller system, then the entire system will be shut down and automatically restarted when the flow switch is on, indicating that there is flow.

11.1.12 Phase Loss Protection Phase loss, as indicated by the phase loss monitor, will result in the system and all circuits being locked off and a phase loss notification alarm will be generated. No set point is required.

11.1.13 Emergency Stop Emergency stop, as indicated by the emergency stop switch, will result in the system and all circuits being locked off and an emergency stop notification alarm will be generated. No set point is required.

11.1.14 Low Differential Oil Pressure This safety is designed to meet the compressor manufacturer requirements on oil pressure. For the first 5 (60 seconds if setup as Hitachi screw compressors) seconds following a compressor start this safety is NOT checked. For the next 30 seconds, if the oil differential pressure drops below ½ of the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time of that set point, the compressor will be locked out and a low oil alarm generated. After this time period, if the oil differential pressure drops below the value of the set point

11.1.15 Low Suction Pressure If the suction pressure drops below the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time, the compressor will be locked out and a low suction alarm generated. For the first 5 minutes after the compressor has started the set point will be ½ , this enables the set point safety time to be set much tighter for normal operation. This safety is bypassed when the compressor is in the “CMP PUMP DOWN” state. This safety can also be used as a freeze protection based upon the suction PSI.

11.1.16 Unsafe Suction Pressure This safety is similar to the low suction pressure safety except this set point can be set up with a lower value and a very short safety time. If the suction pressure drops below the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time of that set point, the compressor will be locked out and a low suction alarm generated. This safety will always cause a lock out on the first trip requiring a manual reset to restart the compressor. For the first 5 minutes after the compressor has started the safety time is extend by twice the normal time delay, this enables the set point safety time to be set much tighter for normal operation. . This safety is bypassed when the compressor is in the “CMP PUMP DOWN” state.

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SCREW CHILLER (Air & Water Cooled)

11.1.17 Low Discharge Pressure If the discharge pressure drops below the value of the set point and it remains there for the time specified in the safety time of that set point, the compressor will be locked out and a low discharge alarm generated.

11.1.18 High Discharge Pressure (Safety is always checked) If the discharge pressure rose above the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time of that set point, the compressor will be locked out and a high discharge alarm generated.

11.1.19 High Discharge Temperature (Safety is always checked) If the discharge temperature analog input rises above the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time, the compressor will be locked out and a high temperature alarm generated.

11.1.20 HI Motor Temperature or Motor Fault (Safety is always checked) If the high motor temperature input rises above the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time, the compressor will be locked out and a high motor temperature or motor fault alarm generated.

11.1.21 Hi Oil Temperature If the oil temperature rises above the value of the set point or the digital input turns ON and it remains there for the time specified in the safety time of that set point, the compressor will be locked out and a high oil temperature alarm generated.

11.1.22 Low Motor Ampere If the ampere analog input drop below the value of the set point and it remains there for the time specified in the safety time of that set point, the compressor will be locked out and a low motor amp alarm generated. This alarm can be used to indicate low refrigerant. This safety is bypassed for the first 3 seconds after a compressor has started.

11.1.23 Oil Level Low If oil level drop below the required minimum level, the controller will display the alarm as ‘Low Oil Level”. The safety will bypass for 60 minutes during running and 60 second during the start up of compressor.

12. Control States Quick Reference Control States tell the user the system’s status; this information is critical. From the Carel keypad / display, press the menu key and select STATUS> The control status is the second line. Carel Control States Quick Reference. Control States tell the user the system’s status; this information is critical!

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USER'S MANUAL

Capacity Control States Description UNIT IN POWER

System Reset or PowerReturned (delay of 60 seconds or set point value)

CMP OFF/READY

Circuit ready but not required or has not been in this state for 60 seconds

UNIT IS OFF

System ready to run but no cooling capacity required

RUN/STOP SW OFF

Disabled: run/stop switch is off.

FAST UNLOADING

Fast unload screw compressor at start up.

SCHEDULED OFF

Disabled: operating schedule is false.

OFF NO EVAP FLOW

Disabled: no evaporator flow.

CMP IS HOLDING

Control temperature with in target control band,

UNIT IN LOCKOUT

Chiller locked out, all pointsexcept alarm point are OFF

HI DISC UNLOAD

Pulse screw unload solenoid because discharge temp or pressure is too high

NO RUN- IO LOST

Lost communication Chiller locked out

HI DISC HOLD

Holding until discharge temp or pressurereturns to normal

UNIT IS HOLDING

No change in capacity

LO SUCT UNLOAD

Pulse screw unload solenoid or unload 1step, suction temp or pressure is too low

LO TEMP UNLOAD

Comp unloading, temperature less than 1.5 F above freeze point.

LO TEMP HOLD

Hold until temperature is 3.0 F above freezing point.

CMP PUMP DOWN

Pumping down

CMP ANTICYCLE

Delay after turning off circuit

SWITCHED OFF

Pump down switch on or system state is

SAFETY TRIPPED

Safety tripped not LOCKOUT

EXPANSION BOARD OFFLINE

Lost communication

HI AMP HOLD

Circuit is in hold due to hi amps. Can only be unloaded.

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SCREW CHILLER (Air & Water Cooled)

13. User Interface User interface connected to the controller will show the current value of parameters (e.g. Temperature), current status of equipments (fans, compressors) and current setting of set points. Changing of set point is password protected to avoid unauthorized intervention.

Whenever the curser is at left extreme of first line Keys
 are used to scroll though the screens of same level.

Left extreme of first line

When the curser is at any input variable same keys are used to increment or decrement the value of parameter. Leaving Water temp. Control Set Point Set Temp.

00.0°C

Parameter




Differential 00.0°C

While key is used to enter the displayed parameter in CPU memory & the curser moves to next parameter.

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USER'S MANUAL

Depending upon level of access all screens can be divided into 3 categories: 1. Status level: Information on these screens can be viewed only & not allowed to be modified. No password is required for accessing these screens. 2. User level: This is password-protected level & contains process related set points, which an operator may need to change. 3. Factory Level This is again password-protected level, which has parameters, related at manufacturing level. These parameters are not needed to be changed frequently. a) Default

LWT 70.0°F Comp1 OFF Comp2 OFF

0% 0%

This is a default screen i.e. if Esc (Esc) key is pressed from any screen an operator will finally return on this screen. This displays Leaving water Temperature and status of compressors Status of compressor is displayed as explained after this table with present loading of compressor and countdown timers(for antirecycle ,Ready and safety unload). By using arrow
 keys, different screens of this level can be accessed

SP DP DT CU

000.0PSI Comp 1 000.0 PSI 000.0°F 000.0Amp

These two consecutive screens show different analog readings values related to Compressor1. SP – Suction pressure DP – Discharge pressure DT – Similar screens for Compressor CU – Current

Comp 1 Sucion Saturation Temperature 000.0°F Diff Pres 000.0PSI

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SCREW CHILLER (Air & Water Cooled)

SP DP DT CU

000.0PSI Comp 2 000.0 PSI 000.0°F 000.0Amp Similar Screens for Compressor 2

Comp 2 Sucion Saturation Temperature 000.0°F Diff Pres 000.0PSI

Press enter to view alarm history

 01 01/12/55 10:30 Unsafe Oil comp 1 SP 70 DP 80 CU 90

02/12/07 01:43:52 Current Login None Press Enter to Logout

78

Next screen shows Entering water temperature and individual cooler leaving temperature (only in case of twine cooler)

Alarm history can be accessed by pressing key while this screen is shown

°

Entering water Temperature 000.0°F WaterOut 1 T 000.0°F WaterOut 2 T 000.0°F

Alarm history screen shows resent alarm with corresponding date, time and suction pressure discharge pressure and current of related compressor at the time of alarm. With
 keys past 100 alarms can be viewed. Upper left corner always shows the index of Esc present alarm. By pressing key one can go back to previous screen This screen present login status and also provides facility to logout. In login status it will show “User” or “Factory” if respective password is entered earlier. In case of logout it will show “None”. Pressing Enter while this screen is displayed enables logout.

USER'S MANUAL

Meaning of status display of compressor – 1. Comp1 OFF :- Compressor is selected to be off by the toggle switch 2. Comp1 Ready: - Compressor is selected to be ON by selector switch, all safety delays are over (if compressor was tripped earlier), lockout is reset and the compressor ready to get ON. This state is hold for 1 minute and then compressor is turned ON depending upon the demand. a.

Comp1 Low Demand: - Compressor is healthy but OFF because of low demand.

b.

Comp1 ON:- Compressor is ON with required loading. This is accompanied with the loading percentage (25%, 50%, 75% or 100%)

c.

Comp1 Loading:- Compressor is loading.

d.

Comp1FastUnl:- This state comes at every start of compressor for initial 30 seconds during which compressor first to 25% if not during last shutoff.

e.

Comp1 Unloading:- Compressor is Unloading due to decreasing demand or proactive unloading.

f.

Comp1 Safty Hold:- In the course of proactive unloading when compressor comes out of unloading condition and gets ready to load again this state is held for 3 min for confirmation. During this stage loading of compressor as per demand is prohibited.

g.

Comp1 Trip: - Compressor is tripped on some safety interlock and the fault condition still persists.

h.

Comp1AntiRe:- Compressor has tripped due to some fault or low demand and waiting for anti recycle time. During this state countdown in seconds is also displayed on the display. Compressor is prohibited from starting until countdown timer reaches zero.

i.

Comp1 Lockout:- Compressor had one of the serious fault occurred twice in the interval of one hour due to which compressor is locked out. In this situation compressor will not start even if fault condition is cleared and anti recycle is over. An operator has to reset the lockout with keypad at User level. After resetting compressor goes in Ready state.

j.

Comp1DayLockout:- Compressor had 10 lockouts in the interval of one day (starting from 00:00 at midnight till next mid night). In this situation compressor is prohibited from starting for that day. Number of lockouts of each day is reset at mid night. After that an operator can start the compressor.

b) User Level For going to this level from any screen operator needs to press navigation screen

User Factory Level

(Prg) key once & he will reach the

This screen shows 3 options out of which middle one is bold and big. On pressing Enter key on this screen Operator will be taken to that level which appears at middle(only after entering respective password). With keys different options can be called.




Status Level

Prg

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SCREW CHILLER (Air & Water Cooled)

User Password 0000

This is the password entry screen. Operator can get to the value of password with keys while pressing key will enter the 
password. If password is wrong message will be shown otherwise operator will directly go to the next screen of user level.

°

80

°

New User Password 0000

This screen allows facility to reset the lockout. Operator need to bring the curser an “N” by pressing. Then with keys it has to be made “Y” and then key 
should be pressed to reset the lockout.

°

Reset Lockout for Comp 1 N Comp 2 N

From this screen operator can enter the set point & differential for each Unit. Again the
values can be changed with keys  while pressing key will enter the set point.

°

Leaving Water Temp Setpoint 045.0°F Con Zone (-) 01.0°F Con Zone (+) 02.0°F

This screen is meant for the operator to change the password for USER LEVEL.

USER'S MANUAL

c) Status Level For going to this level from any screen operator needs to press (Prg) navigation screen

Status User Level

key once & he will reach the

This screen shows 3 options out of which middle one is bold and big. On pressing Enter key on this screen Operator will be taken to that level which appears at middle(only after entering respective password). With keys different options can be called.




Factory Level

Prg

Analog Inputs Comp 1 Suction P 000.0PSI Discharge P 000.0PSI Discharge T 000.0°F

Analog Inputs Comp 1 Suct Sat T 000.0°F Current 000.0Amp Diff Pres 000.0PSI

Dig Inputs Comp 1 Flow Switch Close SPPR Close Oil Float sw Close

Status screens show status of analog inputs, Digital inputs, Digital outputs and the important parameters related to the compressor. It doesn’t requires any password as the screens are only for viewing and modification is not possible at this level. Using keys one can go through all of these screens




Analog Inputs Comp 1 WaterOut T 000.0°F

Dig Outputs Comp 1 Comp main OFF USV1|USV2|USV3|LQINV OFF |OFF |OFF |OFF

Comp 1 Lockouts Today 00 Runhours 00000Hrs

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SCREW CHILLER (Air & Water Cooled)

Analog Inputs Comp 2 Suction P 000.0 PSI Discharge P 000.0PSI Discharge T 000.0°F

Analog Inputs Comp 2 Suct Sat T 000.0°F Current 000.0Amp Diff Pres 000.0 PSI Similar screens fir compressor 2 if present Analog Inputs Comp 2 WaterOut T 000.0°F Dig Inputs Comp 2 Flow Switch Close SPPR Close Oil Float sw Close

Dig Outputs Comp 2 Comp main OFF USV1|USV2|USV3|LQINV OFF |OFF |OFF |OFF

Comp 2 Lockouts Today 00 Runhours 00000Hrs

T.O.L. Parameters:T.O.L. 00.0 SP Countdown 000 Demand 000

82

This screen shows important parameters related to the control algorithm getting executed according to the trend of load

USER'S MANUAL

Press enter to view Current log for Compressor 1

Press enter to view Current log for Compressor 2

 01 Comp 1 Data Log 01/11/07 10:32:44 Current 096.0Amp SP 056.0 DP 120.0

Last 20 readings of present compressors during running can be accessed from these screens. Pressing key on particular screen will show readings of respective compressor

This is an example of data log screen which shows last reading of current suction discharge pressure along with date and time stamp. Similar screen can also show data of compressor 2. With 
keys past 20 logs can be viewed. Upper left corner always shows the index of Esc present log. By pressing key one can go back to previous screen.

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SCREW CHILLER (Air & Water Cooled)

Troubleshooting of Controller Description

Possible causes

Remedies

1. PDG terminal is blank (no backlit )

•

Controller is not powered ON.


Check controller power status from yellow power LED.

2. Backlit of PGD is ON but it is blank or shows “NO LINK”

•

Display cable is not connected properly.


If controller is powered ON check for proper insertion of telephone connector.

•

Address setting of PGD or controller is not proper.

•

Telephone cable between PGD and controller is faulty

•

Address setting of PGD or controller is not proper.

•

Probe is disconnected (-999.9) or shorted(999.9)

•

Wrong probes are connected

3. After making PGD address 0 and controller power OFF/ ON cycle “self test” screen of controller doesn’t appear. 4. On default screen LWT is seen in smaller font. 5. Temperature reading shows -999.9 or 999.9 value

•

6. Temperature or pressure reading shows erratic or negative reading.

•

7. Digital input giving nuisance alarm

•

8. Output is not getting ON

•

Dip switch setting is not done properly Wiring for digital input is open at terminal block or at field IDC for digital input is not connected to G0 of controller Common for that output block is not given proper power


Check for address of PGD (UP+DOWN+ENTER keys for 5 sec) it should be 32.
If PGD address is 32 and still it is blank then check for controller address. It should be 1
Check for proper connection of telephone cable and it’s connector.
Check for lead wise continuity between two ends of cable.
Make controller address 1 and PGD address as 32.
Check for proper connection of probe
Check for proper probes and connection.
Check +Vdc connection for pressure probe
Check for continuity between GND on electrical terminal and on pCO1 terminal
Check for correct dip switch setting.
While making analog input connections isolation from mains supply is must

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USER'S MANUAL

Troubleshooting 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 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 worn out or broken, or Cylinder damaged resulting in 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.

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SCREW CHILLER (Air & Water Cooled)

Sr. No. 4

Problems

Problem Cause

Poor insulation value

1) Bad compressor motor coil

of motor

2) Motor power terminal or bolt wet or 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

5

Compressor starting failure or star-delta starter shifting failure

1) Slide valve piston unable to move back to its 25 % original position. 2) Voltage incorrect 3) Voltage drop too high when starting the compressor or magnetic contactor failure. 4) Motor breakdown 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.

6

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.

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USER'S MANUAL

Maintenance Maintenance Schedule Maintain the Chiller periodically in accordance with the schedules shown in the tables that follow:

Air Cooled Screw Chiller Maintenance Schedule Check Points

Daily

Weekly

Monthly

Quarterly

Annually

General Log parameters

X

Check Water Level in expansion tank

X

Check up Oil Level

X

Check for any refrigerant leaks through flare joints, valve glands etc

X

Check and clean refrigerant strainer

X

Check condition of refrigerant drier

X

Clean Air cooled condenser coils

X

Chemical Cleaning of Condenser Coils

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

Analyse Oil sample Check suction superheat Check crank case heater

X X X

Carel Controller Check program settings

X

Check fault history

X

Check load/unload furnction

X

Check pump down function

X

Check fan control function

X

Check Clock

X

87

SCREW CHILLER (Air & Water Cooled)

Maintenance Maintenance Schedule Maintain the Chiller periodically in accordance with the schedules shown in the tables that follow:

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 Cooling Tower

X

Check for any refrigerant leaks through flare joints, valve glands etc

X

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 Check suction superheat Check crank case heater

X X X

Carel Controller

88

Check program settings

X

Check fault history

X

Check load/unload furnction

X

Check pump down function

X

Check Clock

X

USER'S MANUAL

Maintenance schedule : Compressor Check Points Compressor

Time period 1000 hrs

2500 hrs

5000 hrs

10000 hrs

15000 hrs

20000 hrs

25000 hrs

30000 hrs

Electrical Insulation

X

X

X

Oil filter cartridge

X

X

X

Suction filter

X

Capacity control piston rings

R

Oil level

X

Oil Motor thermal protector Bearings

X

X

X

X

X

X

X

X

X

Check or Clean

R

Replacement

X

X

X

X

R X

X

X

X

X X

R

Note: If acidity of oil measured is lower than PH 6, replace the oil

89

SCREW CHILLER (Air & Water Cooled)

Spare Parts List Spares for LCAX1-075 D i A / LCAX2-150 D i A Item Baan Code

Description

LCAX1-075 DiA Qty Nos.

LCAX2-150DiA Qty Nos.

Specification

Compressor Spares CDSAI0075

BSC-075A (RC15) Screw Compressor

1

2

VI- 3.0

3101-1143A

Oil Filter

1

2

Φ40*200

3101-1146A

Inner Gasket of Oil Filter Flange

1

2

Teflon 1.5t

3101-1147A-3

Outer Gasket of Oil Filter Flange

1

2

REINZ-AFM 34, 1.5t

3101-1051B

Oil Heater (220V)

1

2

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve (Step Control)

3

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

6

NOK,1515SPS

3103-2104B

Oil sight glass (O’ ring included)

1

2

Aluminium

3131-1004A-3

3" Gasket

1

2

REINZ-AFM 34, 1.5t

3103-1024C

Suction Filter

1

2

Φ110*103L, 60 Mesh

4405-56

Oil Level Switch

1

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

16 Litres

32 Litres

RDEAI0060

Sporlan Expansion Valve OVE-70

1

2

EASBI0140

Sporlan SV B10 S2

Solenoid Valve for Liq.Inj.

1

2

15/208 -230/50

EASBI0145

Sporlan SV B10 S2

Solenoid Valve Coil

1

2

MKC - 2

EASBI0170

Sporlan SV B14 S2 for Economiser

Solenoid Valve

1

2

EASBI0175

Sporlan SV B14 S2

Solenoid Vavle Coil

1

2

FEDBI0140

CTG Dehydrator (core)

2

4

RDEAI0120

Sporlan Expansion Valve TDEX-11 for Economiser

1

2

VAAAZ2010

Valve Angle 1/4 “

8

12

VAAAZ2106

Sporlan Expansion Valve BBIVE-4 for Liq. Inj.

1

2

EASBZ0040

Pilot Sol. Valve (230V)

1

2

SANLAN 1/4" SAE Flare, / 15/240/50 MKC-2 Coil

FAPAZ7020

Bird Wing Fan

4

8

36" Dia. 5 blades

Controls & Accessories Spares

Electrical Spares FAPAZ7018

Motor for Condenser

4

8

1.2 kW, 2.6 A, 700 RPM, 400 V/ 3 Ph/ 50 Hz

MBSAZ1900

Oil Cooler Fan Motor Assessmbly

1

-

230 V, 1 Ph, 70 W, 1250 RPM, 350 mm Dia. FA/23/3514/K3/F

MBSAZ1800

Oil Cooler Fan Motor Assembly

-

1

1 phase, 230 V, 90 W, 1350 RPM, 450 mm dia., VBM, FA 23/4514/K5/F

90

USER'S MANUAL

Item Baan Code

Description

LCAX1-075 DiA Qty Nos.

EAMAZ0440

Siemens Contactor, 3TF30 10-0A-M0 415 V for Condenser fan

2

4

415 V,9 A, 220 VAC Coil, 1 NO

EAMAZ0450

Coil for Siemens Contactor, 3TF30,9A, 220 VAC

2

4

AC 50 Hz

EAMAZ0607

SFU Switch 250 Amp. 3 pole, 80KA, DIN Fuse

1

2

Siemens 3KL8321-3UJ00

EAMAZ0608

Fuse link for 250 Amp. SFU

1

2

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

1

2

24 VAC, 3-60 Seconds, 1 No. Inst. & 1 No. Delayed

EAMAZ0599

Siemens Contactor, 3TF51 02-0A-M0, 415 VAC

2

4

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0600

Coil for Siemens Contactor, 3TF51 02-0A-M0, 220 V AC

2

4

AC 50 Hz

EAMAZ0500

Siemens Contactor, 3TF47 72-0A-M0, 220V Coil

1

2

415 V, 70A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0510

Coil for Siemens Contactor, 3TF47 72-0A-M0, 220 VAC

1

2

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

2

230 V

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole,

1

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 1 0KA, for Fan

2

4

Schneider C60H3P16AC

EAMAZ0530

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

1

1

Schneider C60H1P2AC

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

Samcon CT-300

415V, 10KA, for Controller

LCAX2-150DiA Qty Nos.

Specification

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 amps.

1

2

EAMAZ0550

INT 69 module

1

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

-

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium 1 MB Flash memory

1

1

PCO100CLK0 pCOC options - Clock card

1

1

PGD0000F01

1

1

1

1

EBMCI0003

PGD0 terminal for built-in assembly

24 V AC, I/P, R/O

LCD, 120x32 pixels, without external frame

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

EBMCI0100

NTC015WP00 WP type NTC probes

4

6

IP68, 1.5m cable, -50T105°C

EBMCI0080

SPKT00B1C0 Pr Transducer

2

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

4

91

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX1-115 D i B / LCWX2-225 D i B Item Baan Code

Description

LCWX1-115DiB Qty Nos.

LCWX2-225DiB Qty Nos.

Specification

Compressor Spares CDSAI0080

BSC-105A (RC16) Screw Compressor for R 22

1

2

VI 3.0

3105-1143A

Oil Filter

1

2

Φ56*200

3105-1146A

Inner Gasket of Oil Filter Flange

1

2

Teflon 1.5t

3101-1148A-3

Outer Gasket of Oil Filter Flange

1

2

REINZ-AFM 34, 1.5t

3101-1051B

Oil Heater (220V)

1

2

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

6

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

1

2

ALCO

3105-1024C

Suction Filter

1

2

Φ110*103L

3105-1004A-3

Gasket for 4" Flange

1

2

REINZ-AFM 34, 1.5t

4405-56

Oil Level Switch

1

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 Liters

36 Liters

Controls & Accessories spares RDEAI0070

Sporlan Expansion Valve VVE-100

1

2

EASBI0170

Sporlan SV B14 S2 for Economiser

Solenoid Valve

-

-

EASBI0175

Sporlan SV B14 S2 for Economiser Coil

Solenoid Valve

-

-

EASBI0140

Sporlan SV B10 S2 Solenoid Valve for Liq. Inj.

1

2

EASBI0145

Sporlan SV B10 S2 Solenoid Valve Coil for Liquid injection

1

2

RDEAI0120

Danfoss Expansion Valve TDEX-11 for Economiser

-

-

FEDBI0140

CTG Dehydrator (Core) (L Type Strainer)

3

6

SAMAI0010

Indicator Moisture

1

2

1-5/8"

EASBZ0040

Pilot Sol. Valve (230V)

1

2

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liquid Injection

1

2

VAAAZ2010

Valve Angle 1/4 “

8

12

Electrical spares EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

1

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0594

SFU switch 200 Amp, 3 pole, 80KA

1

2

Siemens 3KL8311-3UJ00

EAMAZ0596

Fuse Link for 200 Amp SFU

1

2

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

2

4

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

2

4

AC 50 Hz

92

USER'S MANUAL

Item Baan Code

Description

LCWX1-115DiB Qty Nos.

EAMAZ0500

Siemens Contactor, 3TF47 72-0A-M0, 220 VAC Coil

1

2

415 V,70 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0510

Coil for Siemens Contactor, 3TF47 72-0A-M0, 220 VAC

1

2

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

2

230 V

EASHZ0060

4 Positionn Selector Switch-Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA,

1

1

Schneider C60H2P4AC

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

Samcon CT-300

for Controller

LCWX2-225DiB Qty Nos.

Specification

Micro Control Panel spares EATFZ0050

Current Sensor (Samcon) 0 to 300 amps.

1

2

EAMAZ0550

INT 69 module

1

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

-

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0 pCOC options - Clock card

1

1

EBMCI0003

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

NTC015WP00 WP type NTC probes

3

4

IP68, 1.5 m cable, -50T105 °C 0-44.8bar

-

EBMCI0100 EBMCI0080

SPKT00B1C0 Pr Transducer

2

4

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

4

24 V AC, I/P, R/O

LCD, 120x32 pixels, without external frame

93

SCREW CHILLER (Air & Water Cooled)

Spares for LCAX1-102 D i A / LCAX2-204 D i A Item Baan Code

Description

LCAX1-102DiA Qty Nos.

LCAX2-204DiA Qty Nos.

Specification

Compressor Spares CDSAI0080

BSC-105A (RC16) Screw Compressor for R 22

1

2

VI 3.0

3105-1143A

Oil Filter

1

2

Φ56*200

3105-1146A

Inner Gasket of Oil Filter Flange

1

2

Teflon 1.5t

3101-1148A-3

Outer Gasket of Oil Filter Flange

1

2

REINZ-AFM 34, 1.5t

3101-1051B

Oil Heater (220V)

1

2

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

6

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

1

2

ALCO

3105-1024C

Suction Filter

1

2

Φ110*103L

3105-1004A-3

Gasket for 4" Flange

1

2

REINZ-AFM 34, 1.5t

4405-56

Oil Level Switch

1

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 Liters

36 Liters

Controls & Accessories spares RDEAI0070

Sporlan Expansion Valve VVE-100

1

2

EASBI0170

Sporlan SV B14 S2 for Economiser

Solenoid Valve

1

2

EASBI0175

Sporlan SV B14 S2 for Economiser Coil

Solenoid Valve

1

2

EASBI0140

Sporlan SV B10 S2 Solenoid Valve for Liq. Inj.

1

2

EASBI0145

Sporlan SV B10 S2 Solenoid Valve Coil for Liquid injection

1

2

RDEAI0120

Danfoss Expansion Valve TDEX-11 for Economiser

1

2

FEDBI0140

CTG Dehydrator (Core) (L Type Strainer)

3

6

SAMAI0010

Indicator Moisture

1

2

1-5/8"

EASBZ0040

Pilot Sol. Valve (230V)

1

2

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liquid Injection

1

2

VAAAZ2010

Valve Angle 1/4 “

8

12

FAPAZ7020

Bird Wing Fan

6

12

36" Dia. 5 blades

Electrical spares FAPAZ7018

Motor for condenser

6

12

1.2 KW, 2.6 A, 700 RPM, 400V/ 3Ph/ 50 Hz

MBSAZ1800

Oil Cooler Fan Motor Assembly

1

2

1 Ph, 230 V, 90 W, 1350 RPM, 450 mm dia., VBM, FA 23/4514/K5/F

EAMAZ0440

Siemens Contactor, 3TF31 10-0A-M0 415VAC

2

4

415 V,12 A, 220 VAC Coil, 1 NO

94

USER'S MANUAL

Item Baan Code

Description

LCAX1-102DiA Qty Nos.

EAMAZ0450

Coil for Siemens Contactor, 3TF31,12A, 220 VAC

2

4

AC 50 Hz

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

1

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0594

SFU switch 315 Amp, 3 pole, 80KA

1

2

Siemens 3KL8331-3UJ00

EAMAZ0596

Fuse Link for 315 Amp SFU

1

2

EAMAZ0599

Siemens Contactor, 3TF51 02-0A-M0

2

4

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0600

Coil for Contactor, 3TF51,140A

2

4

AC 50 Hz

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

1

2

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

1

2

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

2

230 V

EASHZ0060

4 Position Selector Switch-Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA,

1

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

2

4

Schneider C60H3P16AC

EAMAZ0316

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

1

2

Schneider C60H1P2A

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

Samcon CT-300

415 VAC

for Controller

LCAX2-204DiA Specification Qty Nos.

Micro Control Panel spares EATFZ0050

Current Sensor (Samcon) 0 to 300 amps.

1

2

EAMAZ0550

INT 69 module

1

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

-

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0 pCOC options - Clock card

1

1

EBMCI0003

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

EBMCI0100

NTC015WP00 WP type NTC probes

4

6

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

2

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

4

-

24 V AC, I/P, R/O

LCD, 120x32 pixels, without external frame

95

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX1-135 D i B Item BaaN Code

Description

LCWX1-135DiB QTY, Nos.

Specification

Compressor Spares CDSAI0080

BSC-130W (RC17) Screw Compressor for R 22

1

VI 3.0

3105-1143A

Oil Filter

1

Φ 56*200

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

3101-1051B

Oil Heater (220V)

1

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

1

ALCO

3105-1024C

Suction Filter

1

Φ 110*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

18 Liters

Controls & Accessories spares RDEAI0070

Sporlan Expansion Valve VVE-100

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) (L Type Strainer)

3

SAMAI0010

Indicator Moisture

1

1-5/8"

EASBZ0040

Pilot Sol. Valve (230V)

1

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liquid Injection

1

VAAAZ2010

Valve Angle 1/4 “

8

Electrical spares EATCZ0010 Star Delta Timer Siemens 3RP15 76-1NP30

24 VAC, 3-60 Seconds, 1 NO. Inst. & 1 NO Delayed Siemens 3KL8311-3UJ00

-

SFU switch 200 Amp, 3 pole, 80KA

1

-

Fuse Link for 200 Amp SFU

1

Siemens Contactor, 3TF50 02-0A-M0,

2

EAMAZ0591 415 VAC

96

1

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

USER'S MANUAL

Item BaaN Code

Description

LCWX1-135DiB QTY, Nos.

Specification

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

2

AC 50 Hz

EAMAZ0500 220 VAC Coil

Siemens Contactor, 3TF47 72-0A-M0,

1

415 V,70A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0510

Coil for Siemens Contactor, 3TF47 72-0A-M0, 220 VAC

1

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

230 V

EASHZ0060

4 Positionn Selector Switch - Salzer 61198 ON/OFF

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

Schneider C60H2P4AC

EATDZ0020

Control Transformer, Kavita Make

1

0-230V primary 24V secondary, 40VA

Samcon CT-300

Micro Control Panel spares EATFZ0050

Current Sensor (Samcon) 0 to 300 amps.

1

EAMAZ0550

INT 69 module

1

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

-

PCO100CLK0

1

EBMCI0003

PGD0000F01 assembly

pCOC options - Clock card PGD0 terminal for built-in

1

24 VAC, I/P, R/O

LCD, 120x32 pixels, without external frame

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

EBMCI0100

NTC015WP00

3

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

2

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

WP type NTC probes

97

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX1-160 D i B / LCWX2-315 D i B Item Baan Code

Description Compressor

LCWX1-160DiB Qty Nos.

LCWX2-315DiB Qty Nos.

Specification

spares

CDSAI0090

BSC-145A (RC18) Screw Compressor

1

2

Vi - 3.0

3105-1143A

Oil Filter

1

2

3105-1146A

Inner Gasket of Oil Filter Flange

1

2

Teflon 1.5t

3101-1051B

Oil Heater (220V)

1

2

220V,150W

3101-1006A-3

Gasket (For Motor Cable Cover Plate)

1

2

REINZ-AFM 34, 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

6

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring included)

1

2

ALCO

3105-1004A-3

Gasket for 4" Flange

1

2

REINZ-AFM 34, 1.5t

4405-56

Oil Level Switch

1

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

36 liters

Controls and Accessories Spares RDEAI0060

Sporlan Expansion Valve OVE-70

2

4

EASBI0140

Sporlan SV B10 S2

Solenoid Valve for Liq. Inj.

1

2

EASBI0145

Sporlan SV B10 S2

Solenoid Valve Coil

1

2

FEDBI0140

CTG Dehydrator (Core)

3

6

EASBZ0040

Pilot Sol. Valve (230V)

1

2

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liq. Inj.

1

2

VAAAZ2010

Valve Angle 1/4 “

8

16

1

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed Siemens 3KL8321-3UJ00

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

Electrical Spares EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

EAMAZ0607

SFU Switch 250 Amp. 3 pole, 80KA

1

2

EAMAZ0608

Fuse link for 250 Amp. SFU

1

2

EAMAZ0603

Siemens Contactor 3TF53 02-0A-M0, 415 VAC

-

-

415 V,205 A, 220 VAC Coil, 2NO, 2 NC

EAMAZ0599

Siemens Contactor, 3TF51 02-0A-M0, 415 VAC

2

4

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0600

Coil for Siemens Contactor, 3TF51 02-0A-M0, 220 VAC

2

4

AC 50 Hz

EAMAZ0599

Siemens Contactor, 3TF49 22-0A-P0, 415 VAC

1

2

415 V,85 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0600

Coil for Siemens Contactor, 3TF49 22-0A-P0, 220 VAC

1

2

AC 50 Hz

98

USER'S MANUAL

Item Baan Code

Description

LCWX1-160DiB Qty Nos.

LCWX2-315DiB Qty Nos.

EAMAZ0525

Specification

SP/PR Minilec Make, VSP D1

1

2

230 V

EASHZ0060

4 Position Selector Switch-Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

1

Schneider C60H2P4AC

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

Samcon CT-300

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

1

2

EAMAZ0550

INT 69 module

1

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

-

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0 pCOC options - Clock card

1

1

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

EBMCI0100

NTC015WP00 WP type NTC probes

3

6

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

2

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

4

EBMCI0003

24 V AC, I/P, R/O

LCD, 120x32 pixels, without external frame

99

SCREW CHILLER (Air & Water Cooled)

Spares for LCAX1-145 D i A/ LCAX2-290 D i A Item Baan Code

Description Compressor

LCAX1-145DiA Qty Nos.

LCAX2-290DiA Qty Nos.

Specification

spares

CDSAI0090

BSC-145A (RC18) Screw Compressor

1

2

Vi - 3.0

3105-1143A

Oil Filter

1

2

3105-1146A

Inner Gasket of Oil Filter Flange

1

2

Teflon 1.5t

3101-1051B

Oil Heater (220V)

1

2

220V,150W

3101-1006A-3

Gasket (For Motor Cable Cover Plate)

1

2

REINZ-AFM 34, 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

6

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring included)

1

2

ALCO

3105-1004A-3

Gasket for 4" Flange

1

2

REINZ-AFM 34, 1.5t

4405-56

Oil Level Switch

1

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

36 liters

Controls and Accessories Spares RDEAI0060

Sporlan Expansion Valve OVE-70

2

4

EASBI0140

Sporlan SV B10 S2

Solenoid Valve for Liq. Inj.

1

2

EASBI0145

Sporlan SV B10 S2

Solenoid Valve Coil

1

2

EASBI0190

Sporlan SV B19 S2 for Economiser

Solenoid Valve

1

2

EASBI0195

Sporlan SV B19 S2

Solenoid Valve Coil

1

2

FEDBI0140

CTG Dehydrator (Core)

4

8

RDEAI0125

Sporlan Expansion Valve TDEX-19

1

2

EASBZ0040

Pilot Sol. Valve (230V)

1

2

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liq. Inj.

1

2

VAAAZ2010

Valve Angle 1/4 “

8

16

FAPAZ7020

Bird Wing Fan

8

16

SATAZ0140

Anti freeze thermostat Sub-Zero 7510

-

2

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

36" Dia. 5 blades

Electrical Spares FAPAZ7018

Motor for Condenser

8

16

1.2 KW, 2.6 A, 700 RPM, 400V/ 3 Ph/ 50 Hz

MBSAZ1800

Oil Cooler Fan Motor Assembly

1

2

1 Ph, 230 V, 90 W, 1350 RPM VBM, FA 23/4514/K5/F

EAMAZ0605

Siemens Contactor, 3TF32 00-0A-M0 415 VAC

2

4

415 V,16 A, 220 VAC Coil

EAMAZ0606

Coil for Contactor 3TF32/ 16 A, 220 VAC

2

4

AC 50 Hz

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

1

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0595

SFU switch 400 Amp.3 pole, 80KA

1

2

Siemens 3KL8341-3UJ00

EAMAZ0597

Fuse link for 400 Amp. SFU

1

2

100

USER'S MANUAL

Item Baan Code

Description

LCAX1-145DiA Qty Nos.

LCAX2-290DiA Qty Nos.

EAMAZ0603

Specification

Siemens Contactor 3TF53 02-0A-M0, 415 VAC

2

4

415 V,205 A, 220 VAC Coil, 2 NO, 2 NC

EAMAZ0604

Coil for Contactor, 3TF53/205A, 220 V

2

4

AC 50 Hz

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

1

2

415 V, 110 A, 220 VAC Coil, 2 NO, 2 NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

1

2

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

2

230 V

EASHZ0060

4 Position Selector Switch-Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

2

4

Schneider C60H3P16AC

EAMAZ0316

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

1

2

Schneider C60H1P2AC

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

Samcon CT-300

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

1

2

EAMAZ0550

INT 69 module

1

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

-

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0 pCOC options - Clock card

1

1

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

NTC015WP00 WP type NTC probes

4

6

IP68, 1.5 m cable, -50T105 °C 0-44.8bar

EBMCI0003

EBMCI0100 EBMCI0080

SPKT00B1C0 Pr Transducer

2

4

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

4

24 V AC, I/P, R/O

LCD, 120x32 pixels, without external frame

101

SCREW CHILLER (Air & Water Cooled)

Spares for LCAX2-177 D i A Item BaaN Code

Description

LCAX2-177 D i A QTY, Nos.

Specification

Compressor Spares CDSAI0080

BSC-105A (RC16) Screw Compressor for R 22

1

VI- 3.0

3105-1143A

Oil Filter

1

Φ56*200

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

3101-1051B

Oil Heater (220V)

1

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

1

ALCO

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

18 Liters

CDSAI0075

BSC-075A (RC15) Screw Compressor

1

3101-1143A

Oil Filter

1

Φ40*200

3101-1146A

Inner Gasket of Oil Filter Flange

1

Teflon 1.5t

3101-1147A-3

Outer Gasket of Oil Filter Flange

1

REINZ-AFM 34, 1.5t

3101-1051B

Oil Heater (220V)

1

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve (Step Control)

3

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

NOK,1515SPS

VI- 3.0

3103-2104B

Oil sight glass (O’ ring included)

1

Aluminium

3131-1004A-3

3" Gasket

1

REINZ-AFM 34, 1.5t

3103-1024C

Suction Filter

1

Φ110*103L, 60 Mesh

4405-56

Oil Level Switch

1

RFS-8-2, 1200mm

Blue Star ACS Oil

16 Litres

CDSPI0710

Controls and Accessories Spares RDEAI0060

Sporlan Expansion Valve OVE-70

1

RDEAI0070

Sporlan Expansion Valve VVE-100

1

EASBI0140

Sporlan SV B10 S2 for Liquid Injection

Solenoid Valve 2

EASBI0145

Sporlan SV B10 S2

Solenoid Valve Coil

EASBI0170

Sporlan SV B14 S2 for Economiser

Solenoid Valve

EASBI0175

Sporlan SV B14 S2

Solenoid Vavle Coil

FEDBI0140

CTG Dehydrator (core)

5

RDEAI0120

Danfoss Expansion Valve TDEX-11 for Economiser

2

VAAAZ2010

Valve Angle 1/4“

16

VAAAZ2106

Sporlan Expansion Valve BBIVE-4 for Liquid Injection

1

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liquid Injection

1

EASBZ0040

Pilot Sol. Valve (230V)

2

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

Bird Wing Fan

12

36" Dia. 5 blades

12

1.2 KW, 2.6 A, 700 RPM, 400 V/ 3 Ph/ 50 Hz

FAPAZ7020

2 2 2

Electrical Spares FAPAZ7018

102

Motor for Condenser

USER'S MANUAL

Item BaaN Code

Description

LCAX2-177 D i A QTY, Nos.

Specification

MBSAZ1800

Oil Cooler Fan Motor Assembly

2

1 Ph. 230 V, 90 W, 1350 RPM, 450mm dia., VBM, FA 23/4514/K5/F

EAMAZ0605

Siemens Contactor, 3TF32 00-0A-M0 415 VAC for condenser fan

2

415 V,16 A, 220 VAC Coil

EAMAZ0606

Coil for Contactor 3TF32,16A, 220 VAC

2

AC 50 Hz

EAMAZ0440

Siemens Contactor, 3TF30 10-0A-M0 415 VAC for Condenser fan

2

415 V,9 A, 220 VAC Coil, 1 NO

EAMAZ0450

Coil for Siemens Contactor, 3TF30,9A, 220 V

2

AC 50 Hz

EAMAZ0607

SFU Switch 250 Amp. 3 pole, 80KA

1

Siemens 3KL8321-3UJ00

EAMAZ0608

Fuse link for 250 Amp. SFU

1

EAMAZ0594

SFU switch 315 Amp, 3 pole, 80KA

1

EAMAZ0596

Fuse Link for 315 Amp SFU

1

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0599

Siemens Contactor, 3TF51 02-0A-M0, 415 V

4

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0600

Coil for Siemens Contactor, 3TF51 02-0A-M0, 220 V

4

AC 50 Hz

EAMAZ0500

Siemens Contactor, 3TF47 72-0A-M0, 415 VAC

1

415 V,70 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0510

Coil for Siemens Contactor, 3TF47 72-0A-M0, 220 VAC

1

AC 50 Hz

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

1

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

1

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

2

230 V

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

4

Schneider C60H3P16AC

EAMAZ0530

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

2

Schneider C60H1P2AC

EATDZ0020

Control Transformer, Kavita Make

1

0-230V primary 24V secondary, 40VA Samcon CT-300

Siemens 3KL8331-3UJ00

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

2

EAMAZ0550

INT 69 module

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

EBMCI0003

PCO100CLK0 PGD0000F01 assembly

pCOC options - Clock card PGD0 terminal for built-in

24V AC, I/P, R/O

1 1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

-

S90CONN000 Telephone-type connection cable, 1.5m long, with telephone connectors

1

LCD, 120x32 pixels, without external frame

EBMCI0100

NTC015WP00 WP type NTC probes

6

IP68, 1.5m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

4

103

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX2-270 D i B, LCAX2-247 D i A Item Baan Code

Description

LCWX2-270DiB Qty Nos.

LCAX2-247DiA Qty Nos.

Specification

Compressor Spares CDSAI0080

BSC-105A (RC16) Screw Compressor for R 22

1

1

Vi - 3.0

3105-1143A

Oil Filter

1

1

Φ 56*200

3105-1146A

Inner Gasket of Oil Filter Flange

1

1

Teflon 1.5t

3101-1148A-3

Outer Gasket of Oil Filter Flange

1

1

REINZ-AFM 34, 1.5t

3101-1051B

Oil Heater (220V)

1

1

220V, 150W

EASCZ0010

Solenoid Coil for RC comprs.

3

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

3

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

3

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

1

1

ALCO

3105-1024C

Suction Filter

1

1

Φ 110*103L

3105-1004A-3

Gasket for 4" Flange

1

1

REINZ-AFM 34, 1.5t

4405-56

Oil Level Switch

1

1

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 Liters

18 Liters

CDSAI0090

BSC-145A (RC18) Screw Compressor for R 22

1

1

3105-1143A

Oil Filter

1

1

3105-1146A

Inner Gasket of Oil Filter Flange

1

1

Teflon 1.5t

3101-1051B

Oil Heater (220V)

1

1

220V,150W

3101-1006A-3

Gasket (For Motor Cable Cover Plate)

1

1

REINZ-AFM 34, 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

3

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

3

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring included)

1

1

ALCO

3105-1004A-3

Gasket for 4" Flange

1

1

REINZ-AFM 34, 1.5t

4405-56

Oil Level Switch

1

1

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

18 liters

Vi - 3.0

Controls & Accessories spares RDEAI0070

Sporlan Expansion Valve VVE-100

1

1

RDEAI0060

Sporlan Expansion Valve OVE-70

2

2

EASBI0170

Sporlan SV B14 Solenoid Valve for Economiser

-

1

EASBI0175

Sporlan SV B14 Solenoid Valve for Economiser Coil

-

1

EASBI0140

Sporlan SV B10 S2

EASBI0145

Sporlan SV B10 S2 Solenoid Valve Coil for Liquid Injection

RDEAI0120

Sporlan Expansion Valve TDEX-11 for Economiser

-

1

FEDBI0140

CTG Dehydrator (Core) (L Type Strainer)

7

7

Solenoid Valve

2

2

2

2

SAMAI0010

Indicator Moisture

2

2

1-5/8"

EASBZ0040

Pilot Sol. Valve (230V)

2

2

SANLAN 1/4" SAE Flare, 15/ 240/50 MKC-2 Coil

VAAAZ7090

Danfoss Expansion Valve TDEX-7.5 for Liq.Inj.

2

2

VAAAZ2010

Valve Angle 1/4 “

12

12

FAPAZ7020

Bird Wing Fan

-

14

EASBI0190

Sporlan SV B19S2 Solenoid Valve for Economiser

-

1

EASBI0195

Sporlan SV B19S2 Solenoid Valve Coil

-

1

RDEAI0125

Sporlan Expansion Valve TDEX-19 for economiser

-

1

SATAZ0140

Anti freeze thermostat Sub-Zero 7510

-

2

36" Dia. 5 blades

Electrical spares FAPAZ7018

Motor for Condenser

-

14

1.2 KW, 2.6 A, 700 RPM, 400V/ 3 Ph/ 50 Hz

MBSAZ1800

Oil Cooler Fan Motor Assembly

-

2

1 Ph., 230 V, 90 W, 1350 RPM, 450 mm dia., VBM, FA 23/4514/K5/F

104

USER'S MANUAL

Item Baan Code

Description

LCWX2-270DiB Qty Nos.

LCAX2-247DiA Qty Nos.

-

2

EAMAZ0605

Siemens Contactor, 3TF32 00-0A-M0 415V for condenser fan

EAMAZ0606

Coil for Contactor 3TF32,16A, 220 VAC

-

2

AC 50 Hz

EAMAZ0440

Siemens Contactor, 3TF31 10-0A-M0 415VAC for condenser fan

-

2

415 V,12 A, 220 VAC Coil, 1NO

EAMAZ0450

Coil for Siemens Contactor,3TF31,12A, 220 V

-

2

AC 50 Hz

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

2

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0594

SFU switch 315 Amp, 3 pole, 80KA

-

1

Siemens 3KL8331-3UJ00

EAMAZ0596

Fuse Link for 315 Amp SFU

-

1

EAMAZ0595

SFU switch 400 Amp.3 pole, 80KA

-

1

EAMAZ0597

Fuse link for 400 Amp. SFU

-

1

-

SFU switch 200 Amp, 3 pole, 80KA

1

-

-

Fuse Link for 200 Amp SFU

1

-

Specification 415 V,16 A, 220 VAC Coil

Siemens 3KL8341-3UJ00 Siemens 3KL8311-3UJ00

EAMAZ0607

SFU Switch 250 Amp. 3 pole, 80KA

1

-

EAMAZ0608

Fuse link for 250 Amp. SFU

1

-

Siemens 3KL8321-3UJ00

EAMAZ0603

Siemens Contactor 3TF53 02-0A-M0, 415 VAC

-

2

415 V,205 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0604

Coil for Contactor, 3TF53/205A, 220 V

-

2

AC 50 Hz

EAMAZ0599

Siemens Contactor, 3TF51 02-0A-M0 415 VAC

2

2

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0600

Coil for Contactor, 3TF51,140A

2

2

AC 50 Hz

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

2

2

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

2

2

AC 50 Hz

EAMAZ0500

Siemens Contactor, 3TF47 72-0A-M0, 220V Coil

1

-

415 V,70 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0510

Coil for Siemens Contactor, 3TF47 72-0A-M0, 220V

1

-

AC 50 Hz

EAMAZ0599

Siemens Contactor, 3TF49 22-0A-P0, 415 VAC

1

-

415 V,85 A, 220 VAC Coil, 2NO, 2NC

EAMAZ0600

Coil for Siemens Contactor, 3TF49 22-0A-P0, 220V

1

-

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

2

2

230 V

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

-

4

Schneider C60H3P16AC

EAMAZ0316

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

-

2

Schneider C60H1P2AC

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

EATFZ0050

Current Sensor (Samcon) 0 to 300 amps.

2

2

Samcon CT-300

EAMAZ0550

INT 69 module

2

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

Micro Control Panel spares

EBMCI0009

Input expansion board, Carel PCOE00TLN0

1

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

-

1

1

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly -Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

EBMCI0100

NTC015WP00

6

6

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

4

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

4

4

EBMCI0003

PCO100CLK0

pCOC options - Clock card

24C AC, I/P, R/O

WP type NTC probes

LCD, 120x32 pixels, without external frame

105

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX1-175 D i B & LCWX2-345 D i B Item Baan Code

Description

LCWX1-175DiB Qty Nos.

LCWX2-345DiB Qty Nos.

CDSAI0092

Specification

BSC-160A (RC-19) Compressor

1

2

Vi - 3.0

3107-1005A-3

3'’ Gasket for Discharge Flange

1

2

REINZ-AFM 34, 1.5t

3107-1143A

Oil Filter

1

2

3107-1146A

Inner Gasket of Oil Filter Flange

1

2

Teflon 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve (Step Control)

3

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

6

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

2

4

ALCO

3107-1024C

Suction Filter

1

2

60mesh

3107-1004A-3

Gasket for Suction Filter Flange

1

2

REINZ-AFM 34, 1.5t

3101-1052C

Oil Heater

1

2

Φ12.7,220V*300 W

4405-56

Oil Level Switch

1

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

36 liters

Controls & Accessories Spares RDEAI0060

Sporlan Expansion Valve OVE-70

2

4

EASBI0140

Sporlan SV B10 S2

Solenoid Valve for Liq. Inj.

1

2

EASBI0145

Sporlan SV B10 S2

Solenoid Valve Coil

1

2

EASBI0190

Sporlan SV B19 S2 for Economiser

Solenoid Valve

-

-

FEDBI0140

CTG Dehydrator (Core)

3

6

VAAAZ2010

Valve Angle 1/4

8

12

RDEAI0120

Danfoss Expansion Valve TDEX-11 for liq. Inj.

1

2

EASBZ0040

Pilot Sol. Valve (230V)

1

2

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

Electrical Spares EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

1

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0594

SFU switch 315 Amp, 3 pole, 80KA

1

2

Siemens 3KL8331-3UJ00

EAMAZ0596

Fuse Link for 315 Amp SFU

1

2

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

1

2

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A, 220 V

1

2

AC 50 Hz

EAMAZ0601

Siemens Contactor, 3TF52-02-0A-M0 415 V

2

4

415 V,170 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0602

Coil for Contactor, 3TF52 170A 220 VAC

2

4

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

2

230 V

106

USER'S MANUAL

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA,

1

1

Schneider C60H2P4AC

Samcon CT-300

for Controller

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

1

2

EAMAZ0550

INT 69 module

1

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

-

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0 pCOC options - Clock card

1

1

EBMCI0003

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

NTC015WP00 WP type NTC probes

3

6

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

2

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

4

-

EBMCI0100

24 V AC, I/P, R/O

LCD, 120x32 pixels, without external frame

107

SCREW CHILLER (Air & Water Cooled)

Spares for LCAX2-320 D i A Item BaaN Code

Description

LCAX2-320DiA QTY, Nos.

Specification

CDSAI0092

BSC-160A (RC-19) Compressor

2

Vi - 3.0

3107-1005A-3

3'’ Gasket for Discharge Flange

2

REINZ-AFM 34, 1.5t

3107-1143A

Oil Filter

2

3107-1146A

Inner Gasket of Oil Filter Flange

2

Teflon 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

6

220V, SANLAN SMG 1

4401-30

Solenoid Valve (Step Control)

6

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

6

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

4

ALCO

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

4405-56

Oil Level Switch

2

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

36 liters

Controls & Accessories Spares RDEAI0060

Sporlan Expansion Valve OVE-70

4

EASBI0140

Sporlan SV B10 S2 Solenoid Valve for Liq. Inj.

2

EASBI0145

Sporlan SV B10 S2 Solenoid Valve Coil

2

EASBI0190

Sporlan SV B19 S2 Solenoid Valve for Economiser

2

EASBI0195

Sporlan SV B19 S2 Solenoid Valve Coil

2

FEDBI0140

CTG Dehydrator (Core)

8

RDEAI0125

Sporlan Expansion Valve MVE-21 for economiser

2

VAAAZ2010

Valve Angle 1/4

12

RDEAI0120

Danfoss Expansion Valve TDEX-11 for liq. Inj.

2

EASBZ0040

Pilot Sol. Valve (230V)

2

FAPAZ7020

Bird Wing Fan

16

SATAZ0140

Anti freeze thermostat Sub-Zero 7510

2

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

Electrical Spares MBSAZ2080

Motor for Condenser

16

1.5 kW, 3.5 A, 860 RPM, 400V/ 3 Ph/ 50 Hz

MBSAZ1800

Oil Cooler Fan Motor Assembly

2

1 ph, 230 V, 90 W, 1350 RPM, 450 mm dia., VBM, FA 23/514/K5/F

EAMAZ0605

Siemens Contactor, 3TF32 00-0A-M0 415V for condenser fan

4

415 V,16 A, 220 VAC Coil

EAMAZ0606

Coil for Contactor 3TF32,16A, 220 VAC

4

AC 50 Hz

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0610

SFU switch 630 Amp, 3 pole, 80KA

-

Siemens 3KL8421-3UJ00

Fuse Link for 500 Amp SFU

2

-

108

USER'S MANUAL

Item Baan Code

Description

LCWX2-345DiB Qty Nos.

Specification

-

Siemens Contactor 3TF54 02-0A-M0, 415 V

4

415 V,250 A, 220 VAC Coil, 2NO, 2NC

-

Siemens Coil for Contactor 3TF54, 220 VAC

4

AC 50 Hz

-

Siemens Contactor, 3TF51 02-0A-M0 415 VAC

2

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

-

Coil for Contactor, 3TF51,140A 220 VAC

2

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

2

230 V

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

5 A, Rocker Type, SPST

EATDZ0020

Control Transformer, Kavita Make

1

0-230V primary 24V secondary, 40VA

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

4

Schneider C60H3P16AC

EAMAZ0316

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

2

Schneider C60H1P2AC

Samcon CT-300

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

2

EAMAZ0550

INT 69 module

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

-

24 V AC, I/P, R/O

PCO100CLK0 pCOC options - Clock card

1

EBMCI0003

PGD0000F01 PGD0 terminal for built-in assembly

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

EBMCI0100

NTC015WP00 WP type NTC probes

6

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

4

LCD, 120x32 pixels, without external frame

109

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX1-225 D i B & LCAX1-206 D i A Item Baan Code

Description

LCWX1-225DiB Qty Nos.

LCAX1-206DiA Qty Nos.

CDSAI0091

Specification

BSC-210A (RC-20) Compressor

1

1

Vi - 3.0

3105-1004a-3

4"Gasket for Discharge Flange

1

1

Reinz-Afm 34, 1.5t

3107-1143a

Oil Filter

1

1

3107-1146a

Inner Gasket of Oil Filter Flange

1

1

Teflon 1.5t

3101-1051B

Oil Heater (220V)

1

1

220V,150W

4804-01

Oil Sight Glass (O-Ring included)

1

1

ALCO

3101-1006a-3

Gasket (For Motor Cable Cover Plate)

1

1

Reinz-Afm 34, 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

3

2743K0R30-4344 SDH12223DS

3101-1003a

Solenoid Valve Gasket

3

3

Nok,1515sps

3107-1054a

Gasket For Suction Filter

1

1

Φ161.5*1.5t

3107-1024c

Suction Filter

1

1

Φ159*210l

4405-56

Oil Level Switch

1

1

Rfs-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

18 liters

RDEAI0070

Sporlan Expansion Valve - VVE-100

2

2

EASBI0140

Sporlan SV B10 S2

Solenoid Valve for Liq. Inj.

1

1

EASBI0145

Sporlan SV B10 S2

Solenoid Valve Coil

1

1

EASBI0190

Sporlan SV B19 S2 for Economiser

Solenoid Valve

-

1

EASBI0195

Sporlan SV B19 S2

Solenoid Valve Coil

-

1

FEDBI0140

CTG Dehydrator (Core)

4

6

RDEAI0125

Sporlan Expansion Valve MVE-21 for economiser

1

1

VAAAZ2010

Valve Angle 1/4

6

6

RDEAI0120

Danfoss Expansion Valve TDEX-11 for liq. Inj.

1

1

EASBZ0040

Pilot Sol. Valve (230V)

-

1

FAPAZ7020

Bird Wing Fan

-

12

Controls & Accessories Spares

SANLAN 1/4" SAE Flare, 15/240/50 MKC-2 Coil

Electrical Spares FAPAZ7018

Motor for Condenser

-

12

1.2 kW, 2.6 A, 700 RPM, 400V/ 3 Ph./ 50 Hz

MBSAZ1800

Oil Cooler Fan Motor Assembly

-

2

1 phase, 230 V, 90 W, 1350 RPM, 450 mm dia., VBM, FA 23/4514/K5/F

EAMAZ0605

Siemens Contactor, 3TF32 00-0A-M0 415 VAC for condenser fan

-

3

415 V,16 A, 220 VAC Coil

EAMAZ0606

Coil for Contactor 3TF32, 16A, 220 VAC

-

3

AC 50 Hz

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

1

1

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0610

SFU switch 630 Amp, 3 pole, 80KA

-

1

Siemens 3KL8421-3UJ00

110

USER'S MANUAL

Item Baan Code

Description

LCWX1-225DiB Qty Nos.

LCAX1-206DiA Qty Nos.

EAMAZ0620

Specification

Fuse Link for 630 Amp SFU

-

1

EAMAZ0595

SFU switch 400 Amp.3 pole, 80KA

1

-

EAMAZ0597

Fuse link for 400 Amp. SFU

1

-

EAMAZ0603

Siemens Contactor 3TF53 02-0A-M0, 415 VAC

2

-

415 V,205 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0604

Coil for Contactor, 3TF53/205A, 220 V

2

-

AC 50 Hz

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

1

-

415 V,110 A, 220 VAC Coil, 2NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A, 220 V

1

-

AC 50 Hz

EAMAZ0603

Siemens Contactor 3TF55 02 0A-M0 415 V

-

2

415 V,300 A, 220 VAC Coil, 2NO, 2NC

EAMAZ0604

Coil for Contactor, 3TF55, 300A 220 VAC

-

2

AC 50 Hz

EAMAZ0601

Siemens Contactor, 3TF52-02-0A-M0 415 V

-

1

415 V,170 A, 220 VAC Coil, 2NO, 2NC

EAMAZ0602

Coil for Contactor, 3TF52 170A 220 VAC

-

1

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

1

1

230 V

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for Controller

1

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

-

3

Schneider C60H3P16AC

EAMAZ0316

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

-

1

Schneider C60H1P2AC

Siemens 3KL8341-3UJ00

Micro Control Panel Spares EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

1

-

Samcon CT-300

EATFZ0060

Current Sensor (Samcon) 0 to 500 Amps.

-

1

Samcon CT-500

EAMAZ0550

INT 69 module

1

1

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0 pCOC options - Clock card

1

1

EBMCI0003

PGD0000F01 PGD0 terminal for built-in assembly

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly - Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

EBMCI0100

NTC015WP00 WP type NTC probes

3

4

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

2

2

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

2

2

-

LCD, 120x32 pixels, without external frame

111

SCREW CHILLER (Air & Water Cooled)

Spares for LCWX2-400 DiB, LCAX2-366 D i A Item Baan Code

Description

LCWX2-400 DiB Qty Nos.

LCAX2-366DiA Qty Nos.

CDSAI0092 3107-1005A-3

Specification

BSC-160A (RC-19) Compressor

1

1

Vi - 3.0

3'’ Gasket for Discharge Flange

1

1

REINZ-AFM 34, 1.5t

3107-1143A

Oil Filter

1

1

3107-1146A

Inner Gasket of Oil Filter Flange

1

1

Teflon 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve (Step Control)

3

3

2743K0R30-4344 SDH12223DS

3101-1003A

Solenoid Valve Gasket

3

3

NOK,1515SPS

4804-01

Oil Sight Glass (O-Ring Included)

2

2

ALCO

3107-1024C

Suction Filter

1

1

60mesh

3107-1004A-3

Gasket for Suction Filter Flange

1

1

REINZ-AFM 34, 1.5t

3101-1052C

Oil Heater

1

1

Φ 12.7,220V*300W

4405-56

Oil Level Switch

1

1

RFS-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

18 liters

CDSAI0091

BSC-210A (RC-20) Compressor

1

1

Vi - 3.0

3105-1004a-3

4"Gasket for Discharge Flange

1

1

Reinz-Afm 34, 1.5t

3107-1143a

Oil Filter

1

1

3107-1146a

Inner Gasket of Oil Filter Flange

1

1

Teflon 1.5t

3101-1051B

Oil Heater (220V)

1

1

220V,150W

4804-01

Oil Sight Glass (O-Ring included)

1

1

ALCO

3101-1006a-3

Gasket (For Motor Cable Cover Plate)

1

1

Reinz-Afm 34, 1.5t

EASCZ0010

Solenoid Coil for RC comprs.

3

3

220V, SANLAN SMG 1

4401-30

Solenoid Valve

3

3

2743K0R30-4344 SDH12223DS

3101-1003a

Solenoid Valve Gasket

3

3

Nok,1515sps

3107-1054a

Gasket For Suction Filter

1

1

Φ 161.5*1.5t

3107-1024c

Suction Filter

1

1

Φ 159*210l

4405-56

Oil Level Switch

1

1

Rfs-8-2, 1200mm

CDSPI0710

Blue Star ACS Oil

18 liters

18 liters

RDEAI0060

Sporlan Expansion Valve OVE-70

2

2

RDEAI0070

Sporlan Expansion Valve - VVE-100

2

2

EASBI0140

Sporlan SV B10 S2 Solenoid Valve for Liquid Injection

2

2

EASBI0145

Sporlan SV B10 S2 Solenoid Valve Coil

2

2

EASBI0190

Sporlan SV B19 S2 Solenoid Valve for Economiser

-

2

EASBI0195

Sporlan SV B19 S2 Solenoid Valve Coil

-

2

EDBI0140

CTG Dehydrator (Core)

8

10

RDEAI0125

Sporlan Expansion Valve MVE-21 for economiser

-

2

VAAAZ2010

Valve Angle 1/4

8

12

RDEAI0120

Danfoss Expansion Valve TDEX-11 for liq. Inj.

2

2

EASBZ0040

Pilot Sol. Valve (230V) 50 MKC-2 Coil

2

2

FAPAZ7020

Bird Wing Fan

-

20

SATAZ0140

Anti freeze thermostat Sub-Zero 7510

-

2

Controls & Accessories Spares

SANLAN 1/4" SAE Flare, 15/240/

Electrical Spares MBSAZ2080

Motor for Condenser

-

8

1.5 kW, 3.5 A, 860rpm, 400V/ 3 Ph/ 50 Hz

FAPAZ7018`

Motor for Condenser

-

12

1.2 kW, 2.6 A, 700 RPM, 400 V/ 3 Ph/ 50 Hz

MBSAZ1800

Oil Cooler Fan Motor Assembly

-

3

1 phase, 230 V, 90 W, 1350 RPM, 450 mm dia., VBM, FA 23/ 4514/K5/F

112

USER'S MANUAL

Item Baan Code

Description

EAMAZ0605

Siemens Contactor, 3TF32 00-0A-M0 415 V for condenser fan

EAMAZ0606

Coil for Contactor 3TF32,16A, 220 VAC

-

5

AC 50 Hz

EATCZ0010

Star Delta Timer Siemens 3RP15 76-1NP30

2

2

24 VAC, 3-60 Seconds, 1 NO Inst. & 1 NO Delayed

EAMAZ0610

SFU switch 630 Amp, 3 pole, 80KA

-

2

Siemens 3KL8421-3UJ00

Fuse Link for 500 Amp SFU

-

1

-

LCWX2-400 DiB Qty Nos.

LCAX2-366DiA Qty Nos.

-

5

Specification 415 V,16 A, 220 VAC Coil

EAMAZ0620

Fuse Link for 630 Amp SFU

-

1

EAMAZ0595

SFU switch 400 Amp.3 pole, 80KA

1

-

EAMAZ0597

Fuse link for 400 Amp. SFU

1

-

EAMAZ0594

SFU switch 315 Amp, 3 pole, 80KA

1

-

EAMAZ0596

Fuse Link for 315 Amp SFU

1

-

-

Siemens Contactor 3TF54 02-0A-M0, 415 V

-

2

-

Siemens Coil for Contactor 3TF54, 220 VAC

-

2

AC 50 Hz

-

Siemens Contactor, 3TF51 02-0A-M0 415 VAC

-

1

415 V,140 A, 220 VAC Coil, 2 NO, 2NC

-

Siemens 3KL8341-3UJ00 Siemens 3KL8331-3UJ00 415 V,250 A, 220 VAC Coil, 2 NO, 2NC

Coil for Contactor, 3TF51,140A 220 VAC

-

1

AC 50 Hz

EAMAZ0603

Siemens Contactor 3TF55 02 0A-M0 415 V

-

2

415 V,300 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0604

Coil for Contactor, 3TF55, 300A 220 VAC

-

2

AC 50 Hz

EAMAZ0601

Siemens Contactor, 3TF52-02-0A-M0 415 V

2

1

415 V,170 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0602

Coil for Contactor, 3TF52 170A 220 VAC

2

1

AC 50 Hz

EAMAZ0591

Siemens Contactor, 3TF50 02-0A-M0, 415 VAC

2

-

415 V,110 A, 220 VAC Coil, 2 NO, 2NC

EAMAZ0598

Coil for Contactor, 3TF50, 110A ,220 V

2

-

AC 50 Hz

EAMAZ0603

Siemens Contactor 3TF53 02-0A-M0, 415 VAC

2

-

415 V,205 A, 220 VAC Coil, 2NO, 2NC

EAMAZ0604

Coil for Contactor, 3TF53/205A ,220 V

2

-

AC 50 Hz

EAMAZ0525

SP/PR Minilec Make, VSP D1

2

2

230 V

EASHZ0060

4 Position Selector Switch - Salzer 61198 ON/OFF

1

1

5 A, Rocker Type, SPST

EATDZ0020

Control Transformer, Kavita Make

1

1

0-230V primary 24V secondary, 40VA

EAMAZ0205

MCB - 4A, 2 Pole, 415V, 10KA, for controller

1

1

Schneider C60H2P4AC

EAMAZ0316

MCB - 16A, 3 Pole, 415V, 10KA, for Fan

-

5

Schneider C60H3P16AC

EAMAZ0316

MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan

-

2

Schneider C60H1P2AC

EATFZ0050

Current Sensor (Samcon) 0 to 300 Amps.

2

1

Samcon CT-300

EATFZ0060

Current Sensor (Samcon) 0 to 500 Amps.

-

1

Samcon CT-500

EAMAZ0550

INT 69 module

2

2

EBMCI0002

PCO1000CM0 pCO1 - Medium version, 1 MB Flash memory

1

1

EBMCI0009

Input expansion board, Carel PCOE00TLN0

1

1

EBMCI0004

PCO1CON0M0 Removable connector kit for pCO1 - Screw version for pCO1 Medium

1

1

PCO100CLK0

Micro Control Panel Spares

-

1

1

PGD0000F01 PGD0 terminal for built-in assembly external frame

1

1

-

PGD000FR11 PGD0 terminal for built-in assembly Dark grey frame and silver glass for PGD0, neutral

1

1

-

S90CONN000 Telephone-type connection cable, 1.5 m long, with telephone connectors

1

1

EBMCI0100

NTC015WP00 WP type NTC probes

6

6

IP68, 1.5 m cable, -50T105 °C

EBMCI0080

SPKT00B1C0 Pr Transducer

4

4

0-44.8bar

EBMCI0090

SPKC002300 Cable 2m for pr sensor

4

4

EBMCI0003

pCOC options - Clock card

24 CAC, I/P, R/O

LCD, 120x32 pixels, without

113

SCREW CHILLER (Air & Water Cooled)

Field Feed Back Form The field feed back card as per the format below shall be send to factory on receipt of the Chiller Field Feed Back Card on Receipt of Chiller at Site Return To : Manufacturing Unit - Thane PRODUCT

:

CHILLER MODEL

:

SR. NO.

:

CUSTOMER NAME

:

DATE

: Observation

Quality of Packing

LOCATION :

Comments

Details Of Defects

Ok / Damaged

Receipt of Documents - Packing List

Yes / No

- Test Report

Yes / No

- Truck No. Condition of Parts : - Frame Work

Ok /

- Condenser coils

Ok /

- Fan Mountings

Ok /

- Springs

Ok /

- Compressor

Ok /

- Condenser

Ok /

- Cooler

Ok /

- Electrical Panel

Ok /

- Oil Cooler

Ok /

- Economiser

Ok /

- Refrigerant Piping

Ok /

- Idle Pressure

Ok /

REMARKS :

Checked By For Factory Use :

114

-

Date of Receipt :

-

Comments :

- Action By :

USER'S MANUAL

The field feedback card as per the format below shall be sent to factory after Commisioning of the Chiller

Field Feedback Card - Commissioning of Chiller at Site Product :

Air Cooled / Water Cooled Screw Chiller

Chiller Model : Sr. No. : Customer Name :

Location :

Engineer’s Name : Observation

Comments

Remarks

Installation/Precommissioning Checks : - Unit Installed and levelled - 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 - Insulation Resistance of Cables checked - 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

Ok /

Ok / Ok / Ok / Ok / Ok / Ok / Ok / Ok Ok Ok Ok Ok Ok Ok Ok

/ / / / / / / /

Starting 400V + 10% Running 400V + 10% Long term running 400V ± 5%

- Commissioning By Remarks :

Note : Warranty will be valid only after receipt of this card at the factory For Factory Use : - Date Of Receipt : - Action By : - Comments :

115

SCREW CHILLER (Air & Water Cooled)

Commissioning and Handing Over Hand over the Chiller to the Customer as per the format below and establish Warranty COMMISSIONING & HANDING OVER REPORT Our Ref:

BLUE STAR LIMITED

Date:

Cust. Ref. PURCHASE ORDER

Date: Date:

Equipment :

Blue Star make Air / Water Cooled Screw Chiller

Model: Sl.Nos. Customer Name & Address

Equipment location : Call made by

COMMISSIONING

Service rendered Supplied,Installed,Tested and Commissioned Blue Star make Air Cooled Screw Chillers / 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 :

Attended by:

Blue Star Ltd.

Signature:

For office use:

The above equpiment has been installed and commissioned to our satisfaction. Other comments (if any).

Date : 5091-10C

116

Customer’s Stamp & Signature

Registered Office : Kasthuri Buildings, Jamshedji Tata Road, Mumbai 400 020

USER'S MANUAL

Water Quality Recommended Water Quality Standards Test items

Chilled Water Quality 7.2 - 8.5

Cooling Tower Water Quality 7.2 - 8.5

Makeup Water Quality 6.0 - 8.0

Max. 80

Less than 200

Max. 50

(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

pH Total hardness (CaCo3) ppm Total Alkalinity

117

SCREW CHILLER (Air & Water Cooled)

Log Report Customer's Name Date: Time

S.No

Description

Units

Voltage R-Y

Volts

Voltage Y-B

Volts

Voltage R-B

Volts

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.

0

8

Cooler Leaving Water temp.

0

9

Cooler Pressure drop

PSIG

10

Cooler water Flow rate

US GPM

Condenser Entering water temp.

0

12

Condenser Leaving water temp.

0

13

Condenser Pressure drop

PSIG

14

Condenser water Flow rate

US GPM

15

Refri. System temp. - Suction

0

16

Refri. System temp.-Discharge.

0

Refri. System temp. - Liquid

0

1

2

11

17

118

F F

F F

F F F

10.00

12.00

14.00

16.00

18.00

USER'S MANUAL

Warranty Claim Form For Blue Star Air / Water Cooled Screw Chillers A copy of this form is to be filled in case of the Chiller failure, by BSL Engineer) Location (City) ……......…………….

Date ………...…….

Chiller Model No:

Chiller Serial No.

Date of despatch

Date of commissioning

Warranty commencing date

Warranty expiry date

Application in which equipment is used Customer’s Name and Address

Dealer’s Name and Address

Noise at Starting

 

Noise while running



Starting Problem

Compressor :





Voltage



No No No

Vibration

Yes

 

Electrical problem

Yes



High Noise

Any mounting bolts loose :

Yes

 

Yes



No

 

Yes

No YesNo

Insulation resistance (Megger test)…………….....…….. Ohms

Any vibration in piping



Yes



No

Less cooling in cooler



Yes



No

Checked Water flow rate



Yes



No

Checked Compressor working in full Load



Yes



No

Operating pressure checked



Yes



No

Shortage of refrigerant



Yes



No

Signature & Seal of Customer Date …………….

Signature & Seal of BSL Engineer Date ……………………. (For Factory use only)

Claim settled



Credit advice No. …....................................……

Reasons for rejection

Claim rejected



……………………....................................................................................

Settlement authorised by : ……......………………..

Date …………………………….

119

SCREW CHILLER (Air & Water Cooled)

Warranty Blue Star Screw Chillers carry a warranty for a period of 12 months from the date 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.

2.

The warranty is valid only if:

2.1. Installation and commissioning is taken care of by BSL/their authorised persons. 2.2. The equipment is operated as per the Company’s 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.

5.

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

6.

Any repair/ replacement shall not extend the overall warranty period as specified above.

7.

The cost of transportation of material and of persons beyond Municipal jurisdiction shall be borne by the customer.

8.

This warranty may be read in conjunction with any other warranty on the Screw Chiller is supplied as part of a Project.

120

the installation as a whole, if

USER'S MANUAL

Service Centres EAST

SOUTH

WEST

BHUBANESHWAR 3A, Satya Nagar, 2nd Floor, Bhubaneswar 751 007. Tel: (0674) 2508270 / 2508303

BANGALORE Ozone Manay Technology Park Sy. No. 56/18 & 55/9 Hongasandra Village Begur Hobli, Garvebhavipalya Bangalore – 560 068 Phone : 41854000

BHOPAL “Star Arcade”, 2nd Floor Plot No.165A & 166, Zone-I Maharana Pratap Nagar Bhopal 462 011. Tel: (0755) 2553378 / 4273378 / 79

CHENNAI 104, ‘Garuda Building’, Cathedral Road, Chennai 600 086. Tel: (044) 42444200 28116707- 8

GOA 1st Floor, Flat No.1 Buddhaseth Apartments, Tonca, Caranzalem, Goa 403 002. Tel: (0832) 2461671 / 2462087

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

NORTH CHANDIGARH SCO 1, Madhya Marg, Sector 26 Chandigarh 160 019. Tel: (0172) 2790482 / 5024000 JAIPUR A-19, Main Sahakar Path, Near Sahakar Bhawan, Jaipur - 302 001. Tel: (0141) 2744033 LUCKNOW B-140, Nirala Nagar Lucknow 226 020. Tel: (0522) 2786172 / 2787274 NEW DELHI E-44/12 Okhla Ind. Area Phase II, Ohkla New Delhi 110 020. Tel: (011) 41494200 / 000

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) 44004000 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

MUMBAI Blue Star House 9A, Ghatkopar Link Road Saki Naka, Mumbai 400 072. Tel: (022) 66684200 / 66684000 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 411 001. Tel: (020) 26167230 / 26163031 / 26162307 VADODARA Ramakrishna Chambers 7th Floor, Productivity Road Alkapuri, Vadodara 390 005. Tel: (0265) 2338561 / 2332021 / 2332022

121

SCREW CHILLER (Air & Water Cooled)

For any assistance, CALL: Blue Star Service: Ph: ............................................................ Cell: ..........................................................

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

Blue Star Regional Manager: Ph: ............................................................ Fax: ..........................................................

Blue Star’s/Dealer’s engineer to fill above details before handing over this Manual to customer.

122

USER'S MANUAL

BREATHE

EASY

123