R134a WC DX SCREW CHILLER USER MANUAL USER MANUAL 1 PDF

R134a Water-cooled DX
Screw Chillers
High on reliability
Low on operating costs
Environment Friendly Green Chillers
User’s Manual
100 to 190 Nominal Tons - R134a
(345 to 665 kw) 50Hz
SCREW CHILLER (Water-cooled)
Revised - December 2010
No part of this publication may be reproduced in any manner whatsoever without

permission in writing from the President, Electro Mechanical Projects, 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.
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USER'S MANUAL
Contents
Introduction ................................................................................................................... 4
Features ......................................................................................................................... 5
Nomenclature ................................................................................................................. 7
Technical Specifications ................................................................................................. 8
Rigging and Installation ................................................................................................ 14
Carel Controller ............................................................................................................ 17
Compressor .................................................................................................................. 36
Pre start up, Testing, Commissioning and Operation ................................................... 69
Troubleshooting of Controller ....................................................................................... 97
Troubleshooting ........................................................................................................... 98
Maintenance ............................................................................................................... 100
Spares Part List .......................................................................................................... 102
Field Feed Back Form ................................................................................................ 107
Commissioning and Handing over report ................................................................... 109
Water Quality ............................................................................................................. 110
Log Report ................................................................................................................. 111
Warranty Claim Form ................................................................................................. 112
Warranty ..................................................................................................................... 113
Blue Star Service Offices ........................................................................................... 114
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Introduction
Blue Star, India’s preferred airconditioning company, has been providing expert cooling solutions for over six decades.
It is with this expertise that Blue Star brings you a wide range of Water-cooled Screw Chillers, manufactured at its
ISO 9001 factory with world class capabilities.
These Chillers which operate on refrigerant R134a come in a quality range of five models varying from 100TR –
190TR.
Due to lesser moving parts, these chillers are reliable and rugged. Further, with its 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 RC2A 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 35% 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.
Water-cooled Condenser
The shell and tube Condenser has been built using imported highly efficient finned copper tubes of
19 mm dia, and has been optimised for refrigerant and water velocities. The shell is manufactured from high-grade steel.
The expansion of the tube is done with torque controlled process. The condenser is fitted with safety relief valve and purge
valve.
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.
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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.
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USER'S MANUAL
Nomenclature
L C W X 1 - 0345 D
DIRECT EXPANSION
LIQUID NOMINAL CAPACITY

CHILLER NO. OF COMPRESSORS
WATER COOLED SCREW COMPRESSOR
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Technical Specifications
Technical Specifications for Water-cooled Screw Chiller DX R134a
(Single Compressor)
Sr. No. Description Units LCWX1-0345D LCWX1-0525D

(A) Nominal Cooling Capacity kW 345 525
(B) Compressor
1 Quantity No. 1 1
2 Type Semi Hermetic Screw Semi Hermetic Screw
3 Model RC2-510A RC2-830A
4 Motor Type :
Refrigerant Gas Cooled 3Phase, -2pole, Squirrel Cage Induction Motor
5 Rated current Amp. 109 170
6 Max. Operating Current Amp. 258 401
7 Locked Rotor Current Amp. 845 1610
8 Starting Current Amp. 282 537
9 Class of Motor Insulation F F
10 Operating Speed RPM 2950 2950
11 Oil Charge Ltrs. 20 28
12 Type of Oil CPI120 POE OIL CPI120 POE OIL
13 R-134a Refrigerant Charge Kg 76 124
14 Oil Separation System Inbuilt In the Compressor Inbuilt In the Compressor
(C) Electrical Power Supply

1 Power Supply 400 V(+/- 10%) , 3 PH. , 50HZ
2 Power Consumption kW 68 106.2
3 Power Consumption Per unit TR kW/TR 0.20 0.20
(D) Condenser
1 Model YCD-105A YCD-151A
2 Shell OD mm 404 410
3 Shell Thickness mm 8 8
4 Tube type and Material External Finned Inner Plain External Finned Inner Plain
5 Tube OD and Thickness mm 19.05 OD x 0.71 Thk 19.05 OD x 0.71 Thk
6 Tube Length mm 2438 2438
7 No. of Tubes Nos. 112 168
8 No. of Pass (Water side) Nos 2 2
9 Water Connection Size In/Out mm 100 100
10 No. of Refrigerant Circuit Nos 1 1
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USER'S MANUAL
Technical Specifications for Water-cooled Screw Chiller DX R134a

(Single Compressor)
Sr. No. Description Units LCWX1-0345D LCWX1-0525D

(E) DX Cooler
1 Model BCH-152 A YCH-222 A
2 Shell OD mm 443 462
3 Shell Thickness mm 8 8
4 Tube type and Material mm Inner Groove Tubes with External Plain
5 Tube OD and Thickness mm 15.875 OD x 0.5 Thk 15.875 OD x 0.5 Thk
6 Tube Length mm 2438 2438
7 No. of Tubes Nos. 310 508
8 No. of Pass (Water side) Nos. 4 4
9 Water Connection Size In/Out mm 150 200
10 No. of Refrigerant Circuit Nos. 1 1
(F) Expansion Valve Thermostatic Thermostatic
(G) Overall Dimensions (approx.)

1 Length mm 2900 2958
2 Width mm 950 1364
3 Height mm 2125 2224
Net Weight
(H) Operating Weight (approx.) Kg. 2725 3300
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 temp 85oF, at the Flow rate of 3 USGPM/TR
4) Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu
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Technical Specifications for Water-cooled Screw Chiller R134a DX (Twin Compressors)

Sr. No. Description Units LCWX2-0385D LCWX2-0525D LCWX2-0665D
(A) Nominal Cooling Capacity kW 385 525 665
(B) Compressor
1 Quantity No. 2 2 2
2 Type Semi Hermetic Screw Semi Hermetic Screw Semi Hermetic Screw
3 Model RC2-310A + RC2-310A RC2-410A + RC2-410A RC2-510A+RC2-510A
4 Motor Type:
Refrigerant Gas Cooled 3Phase, -2pole, Squirrel Cage Induction Motor
5 Rated current Amp. 63, 63 87.8, 87.8 110, 110
6 Max. Operating Current Amp. 95, 95 205, 205 258, 258
7 Locked Rotor Current Amp. 625 + 625 730 + 730 845 + 845
8 Starting Current Amp. 208 + 208 233 + 233 282 + 282
9 Class of Motor Insulation F F F
10 Operating Speed RPM 2950 2950 2950
11 Oil Charge Ltrs. 15 + 15 15 + 15 20 + 20
12 Type of Oil CPI120 POE OIL CPI120 POE OIL CPI120 POE OIL
13 R-134a Refrigerant Charge Kg 94 120 152
14 Oil Separation System Inbuilt In the Compressor
(C) Electrical Power Supply

1 Power Supply 400V (+/- 10%), 3 PH., 50HZ
2 Power Consumption kW 76 110 136.4
3 Power Consumption Per unit TR kW/TR 0.20 0.21 0.21
(D) Condenser
1 Model BCD-152A BCD-152A YCD-202A
2 Shell OD mm 410 410 457
3 Shell Thickness mm 8 8 8
4 Tube type and Material External Finned Inner Plain
5 Tube OD and Thickness mm 19.05 OD x 0.71 Thk 19.05 OD x 0.71 Thk 19.05 OD x 0.71 Thk
6 Tube Length mm 2438 2438 2438
7 No. of Tubes Nos. 168 168 216
8 No. of Pass (Water side) Nos 2 2 2
9 Water Connection Size In/Out mm 100 100 150
10 No. of Refrigerant Circuit Nos 2 2 2
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USER'S MANUAL
Technical Specifications for Water-cooled Screw Chiller R134a DX (Twin Compressors)

Sr. No. Description Units LCWX2-0385D LCWX2-0525D LCWX2-0665D
(E) DX Cooler
1 Model BCH-152 A BCH-222 A BCH-222 A
2 Shell OD mm 443 462 462
3 Shell Thickness mm 8 8 8
4 Tube type and Material mm Inner Groove Tubes with External Plain
5 Tube OD and Thickness mm 15.875 OD x 0.5 Thk 15.875 OD x 0.5 Thk 15.875 OD x 0.5 Thk
6 Tube Length mm 2438 2438 2438
7 No. of Tubes Nos. 310 508 508
8 No. of Pass (Water side) Nos. 4 4 4
9 Water Connection Size In/Out mm 150 200 200
10 No. of Refrigerant Circuit Nos. 2 2 2
(F) Expansion Valve Thermostatic Thermostatic Thermostatic
(G) Overall Dimensions (approx.)

1 Length mm 3231 3231 3525
2 Width mm 1324 1350 1350
3 Height mm 2075 2110 2350
Net Weight
(H) Operating Weight (approx.) Kg. 3050 3750 4950
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 temp 85oF, at the Flow rate of 3 USGPM/TR
4) Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu
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Cooler - Pressure Drop
USGPM PRESSURE DROP IN FT OF WATER COLUMN

BCH-152 YCH-222A, BCH-222A BCH-300
165 2.1
200 4.5
250 6.6 2.5
300 9.3 4 4.2
350 12.5 5.8 7.0
400 16 7.5 8.9
450 20 9.3 11.2
500 11.5 13.6
550 14 15.5
600 17 18.2
650 21.1
700 24.3
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USER'S MANUAL
Condenser - Pressure Drop
USGPM PRESSURE DROP IN FT OF WATER COLUMN

YCD-105A YCD-151A, BCD-152A YCD-202A YCD-222 A
300 16.5 6
350 21.6 8
400 27.5 10.2 8 4.5
450 31.5 12.5 10 6
500 15 12.3 8
550 19 15 10
600 22 19 12
650 22 13.5
700 15.4
750 18
800 20.5
850 23.2
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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 (Water-cooled)
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.
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USER'S MANUAL
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.
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National Couplings
Parts Identification
1. Grooved water in/out connection on cooler

2. Grooved pipe for field connection
3. Gasket for connections
4. Upper & Lower split of coupling
5. Botls & Nuts
Connection Procedure
Step 1: Loose the bolts and nuts from the couplings.

Step 2: Put the gasket over the grooved pipe.
Step 3: Mate the grooves face of pipe with the grooved face of in/out connection on cooler
and adjust the gasket so that it rests between the grooves on the connections.
Step 4: Fit the upper and lower split of the couplings over the gasket and ensure the projections
of the couplings are properly fixed in the grooves.
Step 5: Put the bolts in the couplings and tighten the nuts properly
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USER'S MANUAL
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.
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2. Description of the Products

2.1 pCO3 Controller
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3. Description of the Products

3.1 General installation instructions
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4. Configuration of the Plan Network

4.1 Introduction
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4.2 Setting the pLAN address on the pCO1, pCOxs, pCOc and pCO3
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I/O Expansion Board Led Indication
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Compressor
The HANBELL RC2 series semi-hermetic screw compressor is developed especially for applications in air-conditioning and
refrigeration. With a built-in high operating load design, each compressor has high efficiency and reliability in all working
conditions. Each compressor has the latest and advanced 5 to 6 Patented Screw Rotor Profile. Each unit is carefully
manufactured and inspected by high precision THREAD SCREW ROTOR GRINDING MACHINE, CNC MACHINING
CENTER, and 3-D COORDINATE MEASURING MACHINE. Each compressor at HANBELL follows the ISO 9001 certification
quality system.
The new developing RC2 series compressors combined an á Balance Piston with separated radial and axial force bearings,
oil cooler connector, liquid injection & economizer connector, PTC motor coil protection and discharge temperature protection
and its controller, oil level switch and oil pressure differential switch and other accessories.
RC2 Series Compressor Construction:

RC2-410, RC2-510, RC2-580 Construction
No. Name No. Name No. Name

1 Compressor casing 11 Piston spring 21 Male rotor
2 Motor casing 12 Piston rod 22 Suction bearings
3 Oil separator 13 Bearing seat’s cover plate 23 Suction bearings inner/outer spacer ring
4 Motor rotor assembly 14 Modulation solenoid valve 24 Oil guiding ring
5 Motor stator assembly 15 Modulation slide valve 25 Suction filter
6 Motor rotor washer 16 Slide valve key 26 Oil heater
7 Motor rotor spacer ring 17 Discharge bearings 27 Refrigeration Lubricant
8 Oil separator baffle 18 Discharge fixed ring
9 Oil separator cartridge 19 Disc spring
10 Piston 20 Bearing lock nut
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USER'S MANUAL
RC2-830 Construction
No. Name No. Name No. Name

1 Compressor casing 14 Modulation solenoid valve 27 Oil filler cartridge
2 Motor casing 15 Modulation slide valve 28 Suction filter
3 Oil separator 16 Slide valve key 29 Oil heater
4 Motor rotor assembly 17 Discharge bearings 30 Refrigeration Lubricant
5 Motor stator assembly 18 Discharge fixed ring 31 Suction flange
6 Motor rotor washer 19 Disc spring 32 Discharge flange
7 Motor rotor spacer ring 20 á-Balance piston 33 Cable box
8 Oil separator baffle 21 Bearing lock nut 34 Power bolt
9 Oil separator cartridge 22 Male rotor 35 Thermostat terminals
10 Piston 23 Suction bearings 36 Motor cable cover plate
11 Piston spring 24 Suction bearings inner/ outer spacer ring 37 Discharge check valve
12 Piston rod 25 Oil guiding ring
13 Bearing seat’s cover plate 26 Oil level sight glass
Design Features:
HANBELL screw compressor features simple and robust construction, by elimination of some components such as pistons,
piston rings, valve plates, oil pump, and mechanical linkages…, which are found in reciprocating compressors. With the
elimination of such components, such features of the screw compressor have resulted in low noise, minimized vibration,
high reliability and durability. HANBELL screw compressors are of two-shaft rotary displacement design with the latest and
advanced screw rotors with 5:6 patented profile designs. The screw rotors are precisely situated at both the suction and
discharge ends in rolling contact bearings, i.e. axial and radial bearings. A three-phase, two-pole squirrel cage induction
motor drives the compressor. The motor rotor is located on the shaft of the male screw rotor. Cooling of the motor is achieved
by suction refrigerant vapor.
Compressor Technical Features:

Multi-nation patents of high efficiency screw rotor- The new 5:6 ratio high efficiency screw rotor profile is patented in
Taiwan, UK, US, Japan, and China. This new high volume, high efficiency rotor profile was designed specifically for
modern refrigerant characteristics. The new higher efficient screw rotor is accomplished by using high precision
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CNC machining center, rotor milling machines, rotor grinding machines. Strict ISO 9001 process control and the use
of precise inspection equipment, such as ZEISS 3D coordinate measuring machine, ensures high efficiency, high
quality, low noise, low vibration HANBELL RC series screw compressors for worldwide distribution.
High efficiency motor- Premium grade low-loss core steel with the special RC motor cooling slot design plus the inner
and outer refrigerant guide design pilots the cold suction refrigerant gas through the motor, providing the highest operating
efficiency possible no matter how heavy the operating conditions.
Long life bearings and high reliability- The screw compressors utilize the combination of 11 axial and radial bearings
and á axial balance piston design for excellent bearing life and superior compressor reliability.
Double-walled rotor housing- Double casing structure with high strength inner ribs has been designed to minimize
noise and ensure rigidity. The rotor housing is made of high strength gray cast iron FC25 that is extremely stable, therefore no
expansion even at high-pressure level. These casings are machined by a computer aided machining center and used the
high precise measuring machine to enhance reliability and productivity.
Directly flange on oil separator- A vessel made of ductile material FC 500 specially design to withstand high pressure
and perform highest efficiency. Simple oil management, three stage oil separator, low pressure drop demister to ensure very
minimal refrigerant dilution in the oil and maintain high oil viscosity.
Precise capacity control- The capacity control slide valve is located in the compressor cylinder. The valve is actuated
by oil pressure from the oil sump, and its function is to admit or relieve oil to or from the solenoid valves, depending on pressure
differential.
Perceptive electronics- RC2 series screw compressors are equipped with PTC temperature protection module for
monitoring discharge and motor coil temperature as well as phase sequence and phase loss. It is also equipped with oil level
switch to monitor the level of oil, pressure differential switch, and pressure relief valve for optional application.
Compression process:
As shown in figure 6 below, during rotation of the rotors the meshing shifts from the suction side to the discharge side. The
meshing rotors enclose a working space, which is continuously reduced as it moves in the axial direction. This causes a V-
shaped lobe space between each of the male and female lobes. This lobe space increases to a maximum size (suction and
sealing process). As the rotors rotate further, the new meshing on the suction side closes the V-shaped lobe space. The lobe
space is then constantly reduced by continuing intermeshing of the lobes (compression process).
The reduction in lobe space takes place on the suction side of the rotors towards the discharge side. The volume is steadily
reduced and it is thereby compressed in the sealed condition. As soon as the peaks of the rotor teeth are free to the outlet port,
the vapor is discharge to the high-pressure side and flows to the oil separator where the high-pressure gas will be separated
from the lubrication oil. The size and geometry of the discharge port determine the so called “internal volume ratio (Vi)” of the
compressor. This ratio must have a defined relationship to operating pressure ratio to avoid losses in efficiency due to under
or over compression.
(C) Discharge (B) Compression (A) Suction and Sealing
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USER'S MANUAL
Capacity Control System

The RC2 series screw compressors are equipped with 3-step/4-step capacity control system. The capacity control systems
consist of a modulation slide valve, piston rod, cylinder, piston and piston rings. The slide valve and the piston are connected
by a piston rod. The principle of operation is using the oil pressure to drive the piston in the cylinder. See Fig below, the
lubrication oil flows from the oil sump through the oil filter cartridge and capillary then fills into the cylinder due to the positive
oil pressure bigger than the right side of spring force plus the high pressure gas. The positive pressure differential causes the
piston to move toward the right side in the cylinder. When the slide valve moves toward the right side, the effective compression
volume in the compression chamber increases. This means the displacement of refrigerant gas also increases, as a result
the refrigeration capacity also increases. However, when any of the step solenoid valve (for 3-step/4-step capacity control
system) is opened, the high pressure oil in the cylinder bypasses to the suction port, which causes the piston and the slide
valve to move toward the left side, and then some of the refrigerant gas bypasses from the compression chamber back to the
suction end. As a result, the refrigeration capacity decreases because of the reduction of displacement of refrigerant gas
flowing in the system.
The piston spring is used to push the piston back to its original position, i.e. minimum load position in order to reduce the
starting current for the next starting-up. If the compressor started at full load capacity it may result in over current start. The
capillary is used to maintain and restrain a suitable amount of oil flow into the cylinder.
If the oil filter cartridge, capillary, or modulation solenoid valves are not working well in the capacity control system, this may
result in the abnormality and ineffectiveness of the capacity control system. Before stopping the compressor, HANBELL
strongly recommends that the unloading solenoid valve of step-less control system or minimum load solenoid valve
of steps control system should be kept opened for 30~60 seconds so that oil pressure in the cylinder is then released.
When starting the compressor again, it is in unloading position for light duty start.
4-Steps Capacity Control
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3 or 4 Steps Capacity Control System:

There are two / three normally closed (NC) solenoid valves that are used to control the various required capacity. For the
compressor with 3 steps / 4 steps capacity control system, it is usual to use the sequence of min.%-66%-100% / min.%-
50%-75%-100% to load the capacity of compressor and to use the sequence of 100%-66%-min.%/100%-75%-50%-min%
to unload the capacity. If min% capacity is essential to be kept running for a long time, the problem of oil return, motor cooling,
high discharge temperature should be considered seriously to control by adding the accessories such as oil level switch for
monitoring the oil level, liquid injection devices for cooling motor coil and reducing discharge temperature.(Fig 8)
Note: For 3 or 4 steps capacity control system, Hanbell equipped with Normal Close (NC) type solenoid valve as standard
accessory.
No. Component No. Component

1 Suction filter 10 Lubricant
2 Gas in (low pressure) 11 Oil separator demister
3 Motor 12 Gas out (high pressure without oil)
4 Oil filter cartridge 13 Capillary
5 Suction bearings 14 Solenoid valve (min. %), SV1
6 Male rotor 15 Solenoid valve (50% of full load), SV3
7 Discharge bearings 16 Solenoid valve (75% 66% of full load), SV2
8 Oil separator baffle 17 Slide valve
9 Gas out (high pressure with oil) 18. For RC2-100, 140 & 180 the SV3 omitted
RC2-410~830
capacity control system SV1(NC) SV2(NC) SV3(NC)
100% full load Not energize Not energize Not energize
75% of full load Not energize energize Not energize
50% of full load Not energize Not energize energize
35% (for start) energize Not energize Not energize
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USER'S MANUAL
a. min% capacity
When starting the compressor SV1 solenoid valve is energized and the piston is in
min% capacity position, so even the oil coming from the oil sump is continuouslly
injecting into the cylinder thru the capillary, the high pressure oil in the cylinder
bypasses directly into the suction port, so the piston is held to its initial position. Be
sure to take 30 seconds at least after every starting of the compressor at this low
capacity stage. After that, the compressor could be loaded gradually.
It is strongly recommended to energize SV1 solenoid valve for 1~3 minutes, before
starting the compressor to ensure the slide valve is in min% position.
b. 50% capacity
When solenoid valve of SV3 is energized by the temperature controller, the high-
pressure oil in the oil sump flows into the cylinder due to the closing of min% valve
that pushes the piston moving toward the position where a hole at exactly 50% position
drains the oil back to the suction port then the piston is held on that position.
c. 75% / 66% capacity

When solenoid valve of SV2 is energized, the 50% (SV3) solenoid valve will de-
energized simultaneously, the high pressure oil will push the piston towards the
position where a hole at exactly 75%/66% position drains the oil back to the suction
port and the piston will be held on that position.
d. 100% full load

When all the two/three modulation solenoid valves are de-energized, the high-
pressure oil flows into the cylinder continuously to push the piston toward the suction
side gradually until the slide valve touches the end side of the compression chamber
and the piston also reaches its dead end entirely where no bypass of compression
gas occurred. So full load is achieved.
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X It is strongly recommend to start /stop compressors as per above illustration
Note:
1. Above T temp. and T’ temp. should be determined by experience of system design and really end user application
2. Above t1 time & t2 time should be longer than 60sec as recommended.
3. The capacity control must be remained at min% loading after start or before stop, and it should be withstanding for
30~60sec.
Volume Ratio (Vi)

The Volume ratio (Vi) of the compressor can be defined as the ratio of suction volume of gas divided by discharge volume of
gas of the compressor. The volume ratio directly affects the internal compression ratio or Pi of the compressor. A low Vi
compressor corresponds to a low compression ratio compressor and high Vi compressors are used on higher compression
ratio systems. In the equation below, in order to avoid over or under compression, the system compression ratio (CR) should
be equal to the compressor internal compression ratio (Pi). Refer also to the P-V (pressure – volume) diagram below to
show the relation.
CR = Pd/Ps
Pi = Vi k
Vi = Vs/Vd
Where: CR : system compression ratio Pi : internal compression ratio

Vi : internal volume ratio Pd : system pressure (absolute pressure)
Pd’ : discharge pressure (absolute pressure) Ps : suction pressure (absolute pressure)
Vs : suction volume Vd : discharge volume K: refrigerant specific heat ratio
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USER'S MANUAL
Application Limit
Compressor Operating Limits vary significantly with the type of refrigerant used. The operating limits shown below
are based on saturated suction and discharge operating conditions, for continuous operation over extended periods
of time. It is important to operate within these limits to maintain proper compressor life. Operating at extra low
saturated suction temperature, may cause oil management and motor cooling problems, and operating at extra
high saturated condensing temperature will shorten the compressor life due to insufficient motor and compressor
chamber cooling.
“Operating Limits” are described on the respective refrigerant charts.
R134a Application Limits
Hanbell recommends monitoring oil pressure differential and keep it 4 kg/cm2G over the suction pressure for adequate
seal, lubrication and capacity control by pressure differential switch passively or by additional oil pump actively. Especially
under operation conditions with low condensing temperature and high evaporating temperature like application in flooder
water-cooled chillers, high-low pressure differential tends to be less than 4kg/cm2G, installation of oil pump is recommended
to ensure regular oil pressure.
The minimum discharge superheat is recommended to be kept 10°k higher than the condensing temperature ( normally
discharge superheat is around 20°K for R134a ) to avoid liquid filling back to compressor and lubrication failure.
Lubricants
The main functions of the lubrication oil in the screw compressor are lubrication, internal sealing, cooling and capacity control.
The positive oil pressure in the cylinder pushes the piston and the slide valve that is connected by a piston rod to move
forward and backward in the compression chamber. The design with positive pressure differential lubrication system in the
RC2 series is available to omit an extra oil pump in the compressor like reciprocating compressor. However, in some special
applications, it is still necessary to install an extra oil pump to the compressor for safety.
The bearings used in RC2 compressor require a small but steady quantity of oil for lubrication; the oil injection into the
compression chamber creates an oil sealing film in the compression housing for increasing the efficiency and absorbing a
part of heat of compression. In order to separate the oil from the mixed refrigerant gas, an oil separator is required to ensure
the least amount of oil carried into the system. Pay more attention to the oil temperature, which has a very significant factor
to the compressor bearings’ life. High oil temperature will reduce the oil viscosity and cause the poor lubrication and heat
absorption in the Compressor as well. The oil viscosity is recommended to keep over 10 mm 2 / s at any temperature. The
43
oil temperature just kept above system condensing temperature to avoid the refrigerant migration into system in the summer.
There is high oil viscosity in the low ambient temperature circumstance, it could cause compressor in heavy duty to be started
up resulting less oil pressure in oil line to load the compressor. The better solution is to have higher condensing temperature
in a short time by warming up the oil. If the compressor is operated under the critical condition, then extra oil cooler is required
– please refer to Hanbell selection software for the required capacity and oil flow of extra oil cooler. Some high viscosity oil
is recommended to apply to the high working condition due to the high discharge temperature that will cause low viscosity
of oil. It happens more often that the return oil from evaporator is insufficient such as refrigeration system ´0Ì$%.—
flooded chiller…etc. which is difficult to be carried back, that causes the loss of oil in the compressor. If the system
encounters the oil return problem then an extra 2nd oil separator is recommended to be installed between the compressor
discharge tube and condenser.
Each of HANBELL RC2-410 ~ RC2-830 compressors is equipped with two oil sight glasses as a standard other is the oil low-
level sight glass (RC2-510 and RC2-580) (550 & 610~ 930). The functions of internal oil line sight glass are to monitor lubricant
flow to capacity control system and bearings. While reverse running, it is unable to see the oil flow via sight glass. The normal
oil level in the compressor oil tank should be maintained above the top of the low oil sight glass and in the middle level of high
oil sight glass when compressor is running. It is recommended strongly to install the optional accessory of oil level switch to
prevent compressor’s failure from getting low oil level in the compressor.
SPECIFICATION UNITS CPISOLEST

120
Specific Gravity 0.94
2
Viscosity 40! mm /s (cSt) 131
100! 14.53
Flash Point ! 254
Pour Point ! -36.5
Pre-cautions in changing of oil:
1. Use only qualified oil and do not mix different brand of oil together. Different kinds of refrigerant should match
different kinds of oil, note that some synthetic oil are incompatible with mineral oil. The oil filled into the
compressor should be totally cleaned up in the system, fill the compressor with oil during the initial startup then
re-fill the oil again to ensure that it is completely clean.
2. When using the synthetic oil for the chiller system, be sure not to expose the oil to atmosphere for a long
time, it is also necessary to vacuum the system completely when installing the compressor.
3. In order to ensure no moisture inside the system, it is suggested to clean the system by charging it with dry
Nitrogen and then vacuum the system repeatedly as long as possible.
4. It is essential to change for new oil especially after the motor burns out; the acidity debris still remain inside the
system so follow the procedures mentioned in changing of oil to overhaul the system. Check the oil acidity after
72 hours of operation and then change it again until the oil acidity is in the standard value.
5. Contact local distributor/agent for concerning unqualified oil to be used.
Oil Change
1. Change oil periodically: Check the lubrication oil for every 10,000 hours of continuous running. For the first
operation of the compressor, it is recommended to change oil and clean oil filter after running at 2,000 hours.
Check the system whether clean or not and then change the oil every 20,000 hours or after 3 years of
continuous running while the system is operated under good condition.
2. Avoid the debris or swarf clogging oil filter, this may caused bearings failure. An optional oil pressure differential
switch is recommended to be installed. The switch will trip when the oil pressure differential reaches the critical
point between the primary and secondary sides. The compressor will automatically shut down to prevent the
bearings from getting damaged due to the lack of lubricating oil.
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USER'S MANUAL
Compressor handling and installation

Compressor handling
After the compressor arrives at the warehouse, check the crate if it is kept in good condition and check all the compressor
accessories and the shipping documents to see if there is any discrepancy.
Each HANBELL screw compressor is carefully tested at the factory where every precaution and care is taken to make sure
that the compressor will reach the customer in perfect condition. When lifting the compressor, it is recommended to use a
steel chain or steel cable as shown in the figure below, and also a safety rope can also be used provided it has loading
capacity of 2000kgf.
Make sure that the chains, cables, ropes or other lifting equipment are properly positioned so as to avoid damage to compressor
or its accessories. Keep the compressor in horizontal position when lifting, and avoid the compressor to crash or fall on the
ground, hit the wall or any other event that may damage it or its accessories.
Mounting the compressor

The installation of the compressor in the refrigeration system should be made accessible and make sure that the chiller
base or site are far enough from the heat source to prevent heat radiation. The compressor should also be installed as close
as possible to the electrical power supply for easier connection and must keep good ventilation and low humidity condition
in the site. Make sure that the frame or supporter is strong enough to prevent excessive vibration and noise while the
compressor is running and must reserve enough space for compressors’ future overhauling work.
Installation of anti-vibration pad

The compressor must be installed horizontally and in order to prevent excessive vibration transferred by the structure and
piping of the chiller while in operation, the cushion or anti-vibration pad should be installed. The installation of the anti-vibration
pad is shown in the figure below. The screws should only be tightened until slight deformation of the rubber pad is visible.It
is strongly recommended position compressor higher than evaporator
Attention on the compressor piping works

The unsuitable piping works done to the compressor could cause abnormal vibration and noise that might damage the
compressor. Take notice of the following pointers to prevent this situation from happening:
Fig. Lifting the compressor with steel chain or steel cable Fig. Lifting the compressor with safety ropes
45
1. Cleanliness of the system should be kept after welding the piping to avoid any
swarf or debris contained inside the system as it may cause serious damage to
the compressor during operation.
2. In order to reduce the vibration on the piping tubes, it is recommended to use
copper tube to be the suction and discharge piping tubes. Copper tubes are better
to minimize the vibration in the piping while the compressor is in operation. In
case steel tubes are to be used in piping system, then the suitable welding works
are very important to avoid any stress in the piping. This inner stress can cause
harmonic vibration and noise that can reduce the life of the compressor. If a large-
caliber copper tube is not easily accessible and a steel tube is used instead in suction port, Hanbell also recommends
the use of a copper tube in discharge port to best minimize abnormal vibration and noise.
3. Remove the oxidized impurities, swarf or debris caused by welding in the piping tubes, if these fall into the compressor
the oil filter might be clogged resulting in the malfunctioning of lubrication system, bearings and capacity control system.
4. The material of suction and discharge flanges is forged steel and it can be welded directly with piping connectors. After
welding the flanges and pipes, it must be cooled down by ambient air. Do not use water to cool it down because water
quenching is prohibited.
Limitation of oblique angle for compressor installation

Figure shows the limitation of oblique angle for compressor installation. In case the oblique angle is higher than the limit, it
is very easy for the compressor to shut down because of low oil level. For special application like installation in the ships,
fishing boat, etc…, where the oblique angle might exceed the limit, an external oil separator and related accessories are
recommended to be installed. Please contact HANBELL or local distributor for further layout recommendation.
Limitation of oblique angle for compressor installtion
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USER'S MANUAL
RC2 Compressor outline drawings RC2-410A
No. Name Note No. Name Note

1. Angle Valve 1/4" Flare 17. Refrigerant Service Valve 1/4" Flare
2. Discharge flange 2 1/2" 18. Connector 1/4" Flare
3. Solenoid Valve 50% (NC) 19. Liquid injection 5/8" Flare, option
4. Solenoid Valve 75% (NC) 20. Suction flange 4"
5. Solenoid Valve 35% (NC) 21. Cable bod Standard
6. Liquid (Oil or refrigerant) 3/8" Flare, Option 22. Service flange
injection connector
7. Capillary 23. Oil drain valve option
8. Check valve 2 1/2" 24. Oil level switch option
9. Oil sight glass Low side 25. Discharge temp. 110cC
10. Oil heater150W/300W 26. Safety Valve option
11. Oil filter cartridge 27. Economizer port 7/8", Solder
12. Oil pressure differential switch Connector, option 28. Oil Sight glass High side
13. Oil Cooler 5/8" Flare, Option 29. Oil temp. sensor option
14. Stop pin Option 30. Over flow port option
15. Oil cooler 5/8" Flare, Option 31. Solenoid valve Stepless(No), option
16. Angle valve 1/4" Flare
47

1 Angle valve 1/4”Flare 17 Refrigerant service valve 1/4”Flare
2 Discharge flange 3” 18 Connector 1/4”Flare
3 Solenoid valve 50%(NC) 19 Liquid injection connector 5/8”Flare option
4 Solenoid valve 75%(NC) 20 Suction flange 4”
5 Solenoid valve 35%(NC) 21 Cable box Standard
6 Liquid (oil or refrigerant) 3/8” Flare, option 22 Service flange
injection connector
7 Capillary 23 Oil drain valve option
8 Check valve 3” 24 Oil level switch option
9 Oil sight glass Low side 25 Discharge temp. sensor 110
10 Oil heater150W/300W 26 Safety valve option
11 Oil filter cartridge 27 Economizer port 7/8”, solder
12 Oil pressure differential switch Connector, option 28 Oil sight glass High side
13 Oil cooler connector(out) 5/8”Flare, option 29 Oil temp. sensor option
14 Stop pinoption 30 Over flow port option
15 Oil cooler connector(in) 5/8”Flare, option 31 Solenoid valve Stepless(NO), option
16 Angle valve 1/4”Flare
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USER'S MANUAL

2 Discharge flange 3” 18 Connector 1/4”Flare
3 Solenoid valve 50%(NC) 19 Liquid injection connector 5/8”Flare option
5 Solenoid valve 35%(NC) 21 Cable box Standard
6 Liquid (oil or refrigerant) 3/8” Flare, option 22 Service flange
injection connector 23 Oil drain valve option
7 Capillary 24 Oil level switch option
8 Check valve 3” 25 Discharge temp. sensor 110
9 Oil sight glass Low side 26 Safety valve option
10 Oil heater 150W/300W 27 Economizer port 7/8”, solder
11 Oil filter cartridge 28 Oil sight glass High side
12 Oil pressure differential switch Connector, option 29 Oil temp. sensor option
13 Oil cooler connector(out) 5/8”Flare, option 30 Over flow port option
14 Stop pin option 31 Solenoid valve Stepless(NO), option
15 Oil cooler connector(in) 5/8”Flare, option
49

2 Discharge flange 4” 18 Connector1/4”Flare
3 Solenoid valve 50%(NC) 19 Liquid injection connector 5/8”Flare
5 Solenoid valve 30%(NC) 21 Cable boxStandard
6 Liquid (oil or refrigerant) 3/8” Flare 22 Service flange
injection connector
7 Capillary 23 Oil drain valve
8 Check valve 4” 24 Oil level switch
9 Oil flow sight glass 25 Discharge temp. sensor 110
10 Oil heater 150W/300W 26 Safety valve option
11 Oil filter cartridge 27 Economizer port 1 1/8”, solder
12 Oil pressure differential switch Connector, option 28 Oil level sight glass High side
13 Oil cooler connector(out) 3/4”Flare, option 29 Oil temp. sensor option
14 Stop pin option 30 Over flow port option
15 Oil cooler connector(in) 3/4”Flare, option 31 Solenoid valve Stepless(NO), option
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USER'S MANUAL
Description of accessories
a. Steps or step-less capacity control system
b. Compatible steps and step-less capacity control system
For customers’ ease of stock control, possible modification of capacity-control logic in the future, or other special
requirements of capacity control, Hanbell deliberately designs devices for stepless/step dual capacity control as
nonstandard optional accessory for customers’ choices. Logic of stepless/step dual capacity control is basically identical
to that of stepless or step capacity control respectively.
c. Discharge check valve

Hanbell standard check valve is gravity-driven with characteristics of large flow volume and low pressure differential.
After shut-down of compressor, Teflon taper guider inside can simultaneously seal up the precisely machined base of
check valve by gravity force to effectively prevent return of high-pressured gas to compressor. The gravity-driven check
valve is equipped vertically. Due to limitation of space or piping requirements, alternative horizontal check valve is
accessible.
Discharge Check Valve outline drawing
d. Suction and discharge connection bushings
51
e. Suction and discharge stop valves

For maintenance and service of compressor, it is recommended to install the suction and discharge stop valves.
Dimension of Stop Valve Suction Stop Valve
• Specification of Stop Valve
Maximum Working Pressure Hydrostatic Pressure Test Refrigerant Temperature Range

28 kg / cm2 G 42kg/cm2 G HFC, HCFC -40oC~150oC
f. INT69 control module and PTC temperature sensor

In order to protect compressor, each RC2 series compressor has been installed three PTC temperature sensors
inside motor coil and another one at the discharge side of compressor. These sensors are connected to an INT69
control module to monitor the motor coil temperature and discharge temperature as well. If the temperature in one
of the positions monitored exceeds the nominal response temperature of the respective PTC thermistor, the
sensor resistance increases and the INT69 control module output relay trips. The module resets when the
temperature drops below the response temperature by approx. 5K. The output replay provides a potential-free
change-over contact and is energized as long as the nominal response temperature is not exceeded.
Technical data of INT69

• Supply voltage
220V ~ 240V ±10%, 3VA , 40 ~60 Hz
115V -15% ~ +10%, 3VA , 50/60 Hz
• Ambient temperature
-30 ~ +70!
• Relay output
Switch voltage AC 250V
Continuous current max. 6A
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USER'S MANUAL
INT69 & PTC temperature sensors connection diagram ( Fig.)
g. INT69Y motor protector

In addition to the temperature monitoring function of INT69, Hanbell also supplies INT69Y motor protector with the
monitoring functions of phase loss, phase sequence, motor temperature, discharge temperature as an optional accessory.
INT69Y & PTC temperature sensors connection diagram (Fig. 30)
Note: Electric plate with PT100Ù/PT1000Ùconnection (B) shown in above diagram is optional accessory. Only when
customer chooses PT100Ù/PT1000Ù function, Hanbell will supply this type of electric plate.
INT69Y connection diagram PT100Ù/PT1000Ùconnection diagram
Phase loss, Phase sequence:

Phase sequence and phase loss monitoring functions are active during a 5s window 1s after compressor start ( power on
L1-L2-L3) If one of these parameter is incorrect, the relay locks out ( contacts M1-M2 are open). The lockout can be cancelled
by mains reset of approx. 5s (disconnect L-N)
Note: To make sure phase loss and phase sequence protection function well, please connect L1, L2 and L3 to motor side .
Motor temperature:
Motor temperature is constantly measured by a thermistor (PTC) loop connected on S1-S2.
If any thermistor exceeds its response temperature, its resistance increases above trip level and the output relay trips (contacts
M1-M2 are open ). After cooling down below the response temperature , a 5min time delay is activated. After the delay has
elapsed, the relay pulls in again (contacts M1-M2 are closed ).
The time delay can be cancelled by mains reset of approx. 5s (disconnect L-N )
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Note: When choosing aforementioned INT69 or INT69Y motor protection, Hanbell strongly recommends adding “Shutdown
Lock-out” function and restarting by manual reset after abnormal trip and troubleshooting to prevent too frequent cycle of
“abnormal trip!auto reset!restart.”
Technical data of INT69Y
• Supply voltage
115V ~ 240V -15% ~ +10% 3VA , 50/60 Hz
• Relay output
Switch voltage AC 240V, max. 2.5A, C300
• Ambient Temperature
-30 ~ +60 !
• Phase sensor
3 AC, 50/60Hz, 200 ~ 575 V ± 10%
h. INT69HBY motor protector

Hanbell develops an optional accessory, INT69HBY motor protector, of which major functions are the same with those
of INT69Y: monitoring of phase loss, phase sequence, motor temperature, discharge temperature but with manually
reset function.
INT69HBY & PTC temperature sensors connection diagram:
Other major functional descriptions are as follow:

1. When supply voltage is applied, the output relay pulls in after an initialization period of approx. 3 seconds,
provided all thermistors lie below their rated response temperature.
2. 1 to 9 PTC thermistors with varied rated response temperatures can be connected in series to the input
terminals.
3. If any thermistor resistance increases above trip level the relay drops out. This failure results in a lockout.
(5 minutes delay for 1st PTC failure, 60 minutes delay for 2nd failure, lockout for 3rd failure.)
4. If a rapid temperature increase is detected (locked rotor condition), the output relay drops out. This failure
results in a lockout.
5. The phase monitoring function is active 1 second after motor start during a 10 second window. Incorrect phase
sequence results in lockout trip. Phase loss results in lockout trip.
6. Lockout and time delay can be cancelled by mains reset of approx. 5 seconds.
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USER'S MANUAL
7. To avoid nuisance tripping due to reverse running after shutdown (pressure equalization), the phase monitoring
function is only re-enabled approx. 20 seconds after motor stop.
8. A twin LED (red / green) provides operational information.
9. The relay is fed out as a N/O dry contact, which is closed under good conditions.
10. Sensor and supply circuits are galvanic isolated.
11. The motor protector is not suitable for use with frequency converters.
Technical data of INT69HBY

• Supply voltage • Relay output
AC 50/60 Hz 115/120V-15 …+10% 3VA max. AC 240V, max. 2.5A, C300
AC 50/60 Hz 230/240V-15…+10% 3VA min. 24V AC/DC, >20 mA
• Ambient temperature • Phase monitor
-30 … +70 ! 3 AC, 50/60Hz, 200 ~ 575 V ± 10%
Blink code INT69 HBY Phase monitoring / General
PTC Phase monitoring / General
i. 150W oil heater

A UL approved 150W oil heater has been installed in every compressor as a standard accessory.
Before restart of compressor after shutdown for a long time, please turn on oil heater at least 8 hours to make the
temperature inside compressor higher than system temperature and ambient temperature and then it can prevent
condensation of refrigerant inside oil sump of compressor which may result in liquid compression in next start and poor
lubrication due to too low viscosity of lubricant oil. In addition, Hanbell also offers 300W oil heater to keep adequate
lubricant oil temperature for large external oil separator and applications in areas with low ambient temperature.
Specification 150W, 300W; 110V or 220V; IP 54; UL approval
Note: If compressor is installed in low ambient temperature, it is recommended to insulate oil separator against cold ambience.
55
j. Oil Level Switch (fig. )

There are 3 wires in oil level switch, 2 wires for the interlock to main control circuit or any micro controller’s independent
circuit, and one wire with green color for grounding. To prevent from oil level switch trip caused by oil foaming or surging
in the sump, a time delay around 60 ~ 90 seconds is recommended before shut down the compressor.
Max. contact capacity = 50VA DC/AC
Initial contact resistance = 150mÙ (Max.)
Switching voltage = 600V DC
Max. voltage = 300V DC/AC
Max. current = 0.5A DC/AC
Oil Level Switch Oil Drain Valve
k. Oil drain valve

Oil drain valve is installed in compressor to drain out oil for maintenance.
i. IP54 cable box

Hanbell designs and makes the cable box which meets IP54 specification.
o. Horizontal check valve

Horizontal check valve is standard accessory of RC2- F Series compressor. Considering limitation of clearance for
installation, horizontal check valve would be alternative to aforementioned vertical check valve for RC2 Series compressor.
Its dimension and installation drawing are as follow:
Dimension: Installation:
Dimensions and installation of horizontal check valve
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USER'S MANUAL
r. Oil flow switch

Oil flow switch operates with external oil separator to prevent oil deficient compressor. Specification and
installation of oil flow switch are shown as below:
Specification : Pt100 sensor

• Recommended max. meas. Current for heat coefficient <0.1K - DC 1 ~ 3 mA
• Heating coefficient - 10mÙ/K
• Sensor resistance at 0 - 100Ù±0.12Ù
• Change of resistance 0 ~ 100- 0.385Ù/K
• Insulation test voltage U is – AC 1.5kV
Specification : Pt1000 sensor
• Recommended max. meas. Current for heat coefficient
< 0.1K – DC0.2 ~ 2mA
• Sensor resistance at 0 - 1000Ù±1.20Ù
• Change of resistance 0 ~ 100- 3.85Ù/K
• Insulation test voltage U is – AC 1.5kV
Please specify PT100 or PT1000 sensor when placing orders to Hanbell. In addition, except RC2-1090, 1280 & 1520
compressors, other models can also be equipped with PT100 or PT1000 sensor to adjust liquid injection to precisely control
motor coil while running. Their connection refer to the diagram.
57
Installation and connection of compressor:

RC2-410, RC2-510, RC2-580
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USER'S MANUAL
Motor design
HANBELL RC2 series screw compressors are fitted with Y- motor as standard.
Y- Starting
Y- motor connects motor coil by Y connection during starting therefore reducing voltage on coils to 1/ 3 of input voltage and
reconnects motor coil by connection after starting. By doing so, we can decrease starting current thorough voltage drop,
i.e., so-called voltage-drop starting.
Y- motor connection method is shown in the following motor wiring diagram:
In Y connection, MCM&MCS are inductive while motor leads Z,X,Y are tied together as a neutral connecting as Y fashion. A
few seconds later ( 3 ~ 5 sec is recommended), MCM, MCS become deductive. Around 0.25 sec later, MCM,MCD are inductive,
it turns out % run connection.
After Y start, MCM & MCS are deductive for 0.25msec and then MCM & MCD are inductive for run. Within as transient as
0.25msec, pseudo short circuit might occur due to inappropriate action of contactors, causing trip of compressors. When it
Fig. Y - ∆ Motor diagram

occurs, we recommend usage of adjustable Y- dedicated Timer or slightly lengthen span of time for MCM, MCS deduction
- MCM,MCD re-induction from 0.25 msec to 0.5 msec max directly in micro controller or PLC program. Please refer to Y-
shift time diagram for details. Because motor is not powered during Y- shift, shorter Y- shift span is suggested to prevent
second start due to decreased rotation speed. However, if Y-shift span is too short, aforementioned pseudo short circuit
might occur.
Characteristics of Y-∆ Starting

1. Starting current in Y connection is 1/3 of lock rotor ampere.
2. Starting torque in Y connection is 1/3 of lock rotor torque.
3. Acceleration of motor rotor becomes smaller at full-load starting, therefore compressors require starting at partial
load.
Compressor protection devices

The table below shows the list of protection devices which are essential to protect the compressor and operate safely. Follow
the protection devices listed in the below table to ensure the compressor running under normal condition.
59
Protection device Set point Remark
Motor wiring temperature protector Cutout 110, Cut in 100oc X Standard

(PTC sensor)
Discharge temperature protector (PTC sensor ) Cutout 110, Cut in 100oc X Standard
Phase reversal protector (INT69Y) Optional
Phase failure protector (INT69Y) Optional
Oil level switch Optional
X Manual Reset Suggested

The motor thermistor and discharge thermistor are the temperature sensors with quick response while the temperature
approach to their set point; the thermistors must be connected in series to a controller (INT69 or INT69Y) in terminal box as
a guardian to protect the compressor. Alarm lamp for this protector is required to be embedded on the control panel as indicator.
Any intention to short the controller for startup the compressor is prohibited especially in Hanbell. It is beyond Hanbell’s
responsibility to keep the warrantee of compressor if there is any above action found.
Note: when any protection device trips, please do troubleshooting and reset manually. Do not let compressor automatically
reset after abnormal trip!
The supply power

1. Limitation of supply power:
a. Voltage Limitation b. Frequency :
Long term running : rated voltage ±5% Rated frequency ±2%
Instant running : rated voltage ±10%
Note that in the region where the electricity power is unstable, install an additional Hi-Low voltage protector with ± 5%
under and over tolerance outside the normal voltage to ensure the safe running of the compressor.
2. Unbalanced Voltages :
Unbalanced voltages usually occur because of variations in the load. When the load on one or more of the phases is different
than the other(s), unbalanced voltages will appear. This can be due to different impedances, or type and value of loading on
each phase.Unbalanced voltages can cause serious problems, particularly to motor.
NEMA defines voltage unbalance as follows :
Percent voltage unbalance = 100 x (maximum voltage deviation from average voltage)
(average voltage)
NEMA states that polyphase motors shall operate successfully under running conditions at rated load when voltage unbalance
at the motor terminals does not exceed 1%. Further, operation of a motor with above a 5% unbalance condition is not
recommended, and will probably result in damage to the motor.
Unbalanced voltages at motor terminals cause phase current unbalance ranging from 6 to 10 times the percent voltage
unbalance for a fully loaded motor. This causes motor over current resulting in excessive heat that shortens motor life, and
hence, eventual motor burnout. If the voltage unbalance is great enough, the reduced torque capability might not be adequate
for the application and the motor will not attain rated speed.
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USER'S MANUAL
Some of the more common causes of unbalance voltages are :
• Unbalanced incoming utility supply

• Faults or grounds in the power transformer
• Large single phase distribution transformer on the system
• Open phase on the primary of a 3 phase transformer on the distribution system
• A blow fuse on 3 phase bank of power factor improvement capacitors
• Unequal impedance in conductors of power supply wiring
• Unbalanced distribution of single phase loads such as lighting
• Unequal transformer tap settings
• Open delta connected transformer banks
• Heavy reactive single phase loads such as welders
Grounding:
There’s a grounding terminal inside cable box. Please accurately connect it to grounding of control panel for the system.
Suggestion:
a. The regular setting of electric leak protection should be greater than
50mA; for a humid location, 25mA is better.
b. Grounding voltage of casing should be no greater than 50V; for a humid
location, the limit is 25V.
c. Grounding resistance should be no greater than 500 Ohm.
d. Air cut board (ACB) is regularly equipped with electric leak protection.
Please refer to related settings for its normal action.
e. If electric leak protection is active, please check if insulation of
equipments is normal and if its wiring and setting are correct. Please
make sure nothing is wrong before turning on the power. If there are
any questions, please contact the supplier of equipments.
Grounding Terminal
61
Operation and Maintenance

Compressor start-up
PRE-START CHECKING- Table below shows the required procedures and checkpoints before starting-up the compressor
during commissioning or initial operation of the unit.
Items Things to be checked States or Standard values
1. Accessories 1. Oil level 1. Higher than the middle line of oil level sight glass
2. Oil heater 2. Should be kept energizing after compressor shut
down.
3. System valves status 3. Opened
4. Solenoid valves 4. Fixed
5. Capillary 5. No serious distortion or damaged
2. Electrical system 1. Voltage of main power 1. Electricity voltage should be kept within 5% to the
rated voltage, instant maximum voltage drop while
starting should be less than 10% to the rated
voltage.
2. Voltage of control circuit 2. Standard voltage is 220V. Maximum voltage is 230V.
If there is other demand, contact HANBELL.
3. Insulation resistance value of 3. Insulation resistance value should be above 5MW.
the motor between phase to
phase and phase to ground.
4. Power terminals and wire 4. Power terminals are firmly fixed on terminal block
and
cables terminal connection. well insulated. Keep wire
cables away from heat source and sharpened
metal. Power terminals are fixed firmly and well
insulated. Terminal screw and block are both
required.
5. Grounded 5. (Ruled by the local Electricity Regulations)
6. Capacity of electrical 6. Properly selected (or inquired by the system
designer) accessories
7. Settings of switches, 7. Properly set (or inquired by the system designer)
sensors and controllers.
3. Piping system 1. Outer piping system 1. Fixed firmly
2. Leakage test 2. No leakage
3. Bolts to fix the compressor. 3. Fix the compressor tightly.
4. Safety devices 1. Motor coil sensor (thermistor) 1. Connected in series with discharge sensor to
controller.
2. Discharge sensor (thermistor) 2. Connected in series with motor sensor to controller.
3. Controller 3. Closed circuit with N.C. & N.O.
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USER'S MANUAL
In addition to the pre-start checking given in the above table, also consider the following:
a. It is necessary to pay more attention to the auxiliary facilities while the chiller is commissioning at the job-site and the
periodic maintenance after the initial start-up.
b. In order to keep the capacity control smoothly under the low ambient temperature with the normal viscosity of oil, oil
heater should be kept energizing after compressor has been shut down for preparation for the next start-up.
c. Check that all the settings on each pressure switch are correct.
d. Check if all the stop valves in the system are already open.
e. Check the rotating direction of the compressor by starting the compressor for a split second (approx. 0.5…1 sec.) and
check the suction and discharge pressure gauges. The correct rotating direction is: suction pressure drops immediately
and the discharge pressure will going up.
f. The compressor lubrication oil should be check immediately after starting. Oil level should be within sight glass range or
higher than the middle line of oil level sight glass.
g. Oil foaming can be generated during starting phase, but it should reduce when the compressor is under stable operating
conditions. Otherwise this can indicate excessive liquid in the suction gas.
h. The running condition of compressor after commissioning at the job-site should be adjusted as; the discharge temperature
will be at least 20K above the saturated condensing temperature and the suction vapor superheat should be within 10K
to the saturated evaporating temperature.
i. The whole plant, especially the pipelines and capillary tubes must be checked for abnormal vibrations. Contact HANBELL
or local distributor if any abnormal vibrations or noise found while the compressor is running.
j. Regularly check-up the plant according to national regulations and the following items should also be checked:
• Operating data of the machine

• Check the lubrication/level of oil
• All compressor monitoring parts
• Check electrical cable connections and tightness
63
Troubleshooting
The table below shows some problem that might encounter in the jobsite during commissioning or upon operation of
compressor. This table will only serve as a guide for the Engineer to understand the situation once the problem occurred in
the site.
PROBLEMS PROBABILITY CAUSES REMEDY / CORRECTIVE ACTION
Sudden trip of Low suction pressure cause low refrigerant flow rate Check compressor working unloaded
motor thermister/ for a long period
sensor Refrigerant shortage Charge refrigerant
Suction filter clogged Clean filter
High suction temperature Check refrigerant liquid level
High suction superheat Adjust the superheat less than 10 K
Unstable electricity system or failure Check electricity power supply
Motor overload Check and rectify
Bad motor coil causing temperature rising rapidly Check and rectify
Turn on the oil heater before

Low ambient temperature or high oil viscosity.
compressor start.
Capillary clogged. Clean or replace capillary
Modulation solenoid valve clogged or solenoid valve Clean / purge solenoid valve core or
Compressor coil burnt. replace the solenoid valve coil
unable to load
Internal built-in oil line clogged. Check and clean the compressor oil
circuit
Piston stuck-up. Change piston or piston ring
Oil filter cartridge clogged. Clean oil filter (replace if needed)
Too small the high-low pressure differential. Minimum pressure differential is 4 bar.
Consider to install an oil pump.
Modulation solenoid valve clogged or burnt. Clean or replace the solenoid valve
Compressor Piston rings worn off or broken, or cylinder damaged Change piston (if cylinder damaged
unable to unload resulting leakage. severely, change the cylinder)
Lubrication oil insufficient. Check the oil level of the compressor

if enough, add some oil if necessary
Leakages at internal discharge cover plate end side. Check or replace the gasket and
tighten the bolts.
Solenoid valve voltage misused. Check the control voltage
Piston stuck-up. Change the piston set, and check the

cylinder and slide valve.
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USER'S MANUAL
Poor insulation Capacity control logic unsuitable. Check

of motor
1. Bad compressor motor coil.
2. Motor power terminal or bolt wet or frosty. Check the coil or change the motor
stator
3. Motor power terminal or bolt bad or dusty.
4. Bad insulation of magnetic contactors.
5. Acidified internal refrigeration system.
6. Motor coil running long time continuously under
high temperature.
7. Compressor restart counts too many times.
Slide valve piston unable to go back to its lowest % Check if the unloading SV is
original position. energised once the compressor shut
down.Unload the compressor before
shot down.
Voltage incorrect. Check the power supply
Compressor Voltage drop too big when starting the compressor or Check the power supply and the
starting failure or magnetic contactor failure or phase failure. contactor.
Y-∆ starter
Motor broken down Change the motor
shifting failure
Motor thermister sensor trip. See “sudden trip of motor sensor”
above
Incorrect supply power connection. Check and re-connect
Y-∆ timer failure. Check or replace.

Discharge or suction stop valve closed. Open the stop valve
Improper connection between node terminals of Y-∆ wiring. Check and re-connect the wiring
Rotor locked Check and repair
Earth fault Check and repair
Protection device trip Check
Damaged bearings. Change bearing.
Phenomenon of liquid compression. Adjust proper suction superheat
Friction between rotors or between rotor and compression Change screw rotors or/and
chamber. compression chamber.
Check the oil level of the compressor
Abnormal vibration Insufficient lubrication oil.
if enough, add some oil if necessary.
and noise of
compressor Dismantle the compressor and change
Loosen internal parts. the damaged parts.
Electromagnetic sound of the solenoid valve. Check and repair / replace
System harmonic vibration caused by improper piping Check the system piping and if
system. possible improve it using copper pipe.
65
External debris fallen into the compressor. Dismantle the compressor and check
the extent of the damage.
Friction between slide valve and rotors. Dismantle the compressor and change
the damaged parts.
Motor rotor rotates imbalance. Check and repair.
Motor line open Check
Compressor does Tripped overload Check the electrical connection
not run
Screw rotors seized Replace screw rotors, bearings etc.
Motor broken Change motor.
Insufficient refrigerant. Check for leaks. Charge additional

refrigerant and adjust suction superheat
less than 10 K
Condenser problem of bad heat exchange. Check and clean condenser
Refrigerant overcharge. Reduce the refrigerant charge
Air / moisture in the refrigerant system Recover and purify refrigerant and
vacuum system
High discharge Improper expansion valve. Check and adjust proper suction super
temperature heat
Insufficient lubrication oil. Check the oil level and add oil.
Damaged bearings. Stop the compressor and change the
bearings and other damaged parts.
Improper Vi value. Change the slide valve.
No system additional cooling Install additional system cooling (liquid

(Liquid injection or oil cooler) injection or oil cooling or both base on
working condition limitation)
Lack of refrigerant Check for leaks. Charge additional

Compressor refrigerant.
loses oil
Improper system piping Check and correct the piping or install
an external oil separator
Refrigerant fills back Maintain suitable suction superheat at

compressor
Lack of refrigerant Check for leaks. Charge additional

refrigerant.
Low suction
pressure Evaporator dirty or iced Defrost or clean coil
Clogged liquid line filter drier Replace the cartridge
Clogged suction line or compressor suction strainer Clean or change suction strainer
Expansion valve malfunctioning Check and reset for proper superheat
Condensing temperature too low Check means for regulating condensing

temperature
Note: The replacement of compressor internal parts should be performed only by a qualified / certified service technician
with full knowledge of HANBELL screw compressor or it should be a Service Engineer from Blue Star.
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USER'S MANUAL
Important note of applications of compressor

1. Pump down
Do not pump down the compressor on the chiller as a routine operation except only for temporary maintenance or a long
term shut down. Because pump down will cause extremely high temperature in the compression chamber and overheat
of the motor as well due to less amount of refrigerant in the suction side. When doing the pump down, be sure to take
notice of the items listed below :
a. Hanbell recommends that whenever doing the pumping down of the compressor, the compressor is also recommended
to run at 100% capacity.
b. Pump down should be done once each time, as it may be dangerous to the compressor, compression chamber for
pumping down repeatedly.
c. The minimum suction pressure when doing the pump down should be over 0.5kg/cm2G
d. The allowable length of time for pumping down a compressor should not be over 15 seconds.
e. When doing the pump down of compressor, must take notice of the high discharge temperature should not exceed
110.
f. Take notice of high/low pressure by reading the oil level of the compressor and the noise of running as well. If there
is any abnormal value or situation, then emergently stop the pump down.
2. Long term partial load operation

If compressors have to run at partial load below 50% continuously, though maybe within operation limits under such
operation condition and with temperature of motor below trip setting for overheating, insufficient dissipation of heat in
motor will occur due to lower flow rate of suction gas at partial load. If compressors operate under high temperature for
a long time, insulation of motor will deteriorate gradually at risk of serious motor damage finally. In such severe operation
conditions, Hanbell strongly recommends installation of liquid injection system to cool motor coil and use of Pt100Ù or
Pt1000Ùsensor as described in chapter 4.4-s, to effectively control temperature of motor while running. It is suggested
to switch on liquid injection when temperature of motor coil is higher than 60 and turn off liquid injection when it’s lower
than 50.
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Pre-Startup, Testing,
Commissioning & Operation
Prior to starting of the unit, check up the procedure detailed herein
S.No. Items Things to be checked Standard Values
1. Accessories 1. Oil level 1. Higher than the middle

line of oil level sight
glass.
2. Time for heating the oil 2. Turn on the oil heater at
least 8 hrs. before starting.
3. System valve status. 3. Opened

4. Capillary 4. No distortion or damage
2. Electrical 1. Voltage of the main power. 1. Electricity voltage should be

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

1) Lowest Starting Voltage: The power voltage cannot be lower than 10% of rated voltage during start-up period of compressor.
2) Maximum Discharge Pressure: 18 kg/cm2 g
3) Minimum Suction Pressure: 6~8 kg/cm2 g
4) Maximum designed discharge pressure: 28 kg/cm2 g
5) Maximum designed discharge temperature: 110oC
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Starting Current of the compressor

The starting current of different model compressor is as given below (LRA). This will be approximately 3.0
to 3.5 times the rated current.
Compressor Model Locked Rotor Starting

Current (LRA), A Current A
RC2 410A 730 233

RC2 510A 845 282
RC2 580A 910 303
RC2 830A 1610 537
A. The starting for the Y start is usually set at 4 ± 1 second, and the maximum allowable shift time from
Y to ∆ is 40 milliseconds. It is advisable to change the Y starting time prior to different working condition
in the job site in accordance with the current variation of Y starting. It is recommended that the duration
of Y starting is not over 15 seconds at the step of 35% capacity.
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USER'S MANUAL
The running restraint of compressor

1. Compressor restart frequency
The restart counts for all the models are recommended below 6 times in one hour
2. The starting for the Y start is usually set at 4 + seconds and the maximum allowable shift time from
Star to Delta is 40 Sec. However it is recommended that the duration of the Y starting is not over 15
seconds at the step of 35% capacity.
3. Supply power
Long term running = > + 5%
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 : -10oC to 55oC
6. The control voltage is normally : 220V
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 120oC
temperature protector Cut in 75o
High discharge Cut out 110oC
temperature protector Cut in 60oC
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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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
Pilot Solenoid valve 1, 2 OFF
(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.
(4) Compressor starts with ‘Fast Unload’ logic. Condition of the relay outputs is as follows:
(5) 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
Relay output Condition

Main 1, 2 ON
Pilot Solenoid valve 1, 2 ON
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USER'S MANUAL
Sl. No. Capacity Control System SV1 SV2 SV3

1 100% of Full Load Off Off Off
2 75% of Full Load Off On Off
3 50% of Full Load Off Off On
4 35% of Full Load On Off Off
5 Shut Down and Initial Fast Unloading On On On
(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).
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. 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 2 110 %
2 Low amps 5 15 %
3 Low suction 120 20 psig
4 Low gas / LSV FLT 10 15 psig
5 High discharge 2 180 psig
6 Low discharge 90 55 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.
73
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 — 2 Min. for 22 PSI
Low oil differential First 5 seconds 25 psig for next 30 seconds.
Oil Level Switch 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. The delay between the Star and Delta connection is preset at 3 seconds.
3. Low-pressure setting is at 15 psig and High-pressure setting is at 180 psig.
4. Anti Freeze Thermostat setting is at 39ºF
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USER'S MANUAL
Oil Management in Screw Compressors:

Oil flow is critical in screw compressors for lubrication as well as slide loading and unloading mechanism.
Screw Compressors do not have pump for oil circulation unlike Reciprocating Compressors. Oil circualtion in a Screw
Compressor is managed by Pressure Differential between suction and discharge. Oil is on discharge side; hence at the
same pressure as discharge. Minimum Oil Pressure Differential (OPD) is essentail for safe operation of a screw compressor.
Operation of a screw compressor with lower Oil Pressure Differential may result in failure of Bearing/s or may affect capacity
modulation system of a compressor.
As per recommendation from screw compressor manufacturers, the minimum OPD of 40 PSI need to be ensured by
controller safety mechanism. Chiller will trip on “Low Oil Differential’” when OPD falls below 40 psig continuously for 180
seconds. This condition may arise during low ambient winter operation. The safety becomes very critical when chilled
water temp is also higher e.g. initial pull down.
Application Limits for maintaining safe OPD:

In order to maintain the OPD for safe operation of screw compressors, relation between Minimum Condenser Entering
Water Temperature (CEWT) with respect to Evaporator Leaving Water Temperature (CLWT) is shown in the graph below.
Different Methods:
Oil Pressre Differential can be maintained using the following methods:
1. Cycling of Cooling Tower Fan: Cooling tower fan is cycled using a temperature controller sensing Condenser
Entering Water Temperature.This can be effective for moderate ambient conditions. Switching OFF the cooling tower
fan can be ineffective in severe winter conditions as water gets cooled when sprinkled within the cooling tower.
Frequent cycling of the motor may adversely affect the motor life.
2. Variable Frequency Driver for Cooling Tower Fan: This method is better than Fay cycling. Fluctuations in
condenser water temp are avoided with gradual control of air flow. This method also is effective for moderate ambient
and may not be effective in severe winter conditions. A separate temp controller with analogue output capability will
be required.
75
3. Variable Frequency Drive for Condenser Water Pump: Flow of condenser water pump is varied based on
discharge pressure of the compressor. chiller controller gives analogue input to pump VFD to increase or decrease
condenser water flow so that necessary discharge pressure is maintained. This method can be used for applications
where dedicated pump serves as chiller. Stand-by pump, in case provided, also needs to have VFD provision.
4. 3-Way Modulating Valve in Condenser Piping: To ensure trouble free operation of water cooled screw chillers
during low condenser water conditions, a 3-way modulating valve is installed at condenser water piping. The chiller
controller has logic to modulate this valve to maintain desired OPD. 3-way valve starts diverting cold water from
condenser inlet to outlet; bypassing condenser as shown in schematic diagram. This is the most convenient method
as multiple chillers connected to common cooling tower-pump combination can be handled individually. More details
are given in the following annexure.
Annexure:
1. Annexure I : Installation Guidelines for 3-way Modulating Valve
2. Annexure-II : Wiring Modifications
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USER'S MANUAL
Annexure I
Installation Guidelines for 3-Way Modulating Valve
The valve is installed in the condenser outlet piping and will bypass cooling water flow going to the condenser. The valve
will modulate based on analogue signal from the chiller controller. This arrangement will prevent the Discharge Pressure
from dropping down to unsafe limits due to lesser water through the condenser.
Typical mounting guideline for the valve installation:
For selection of the 3 way Modulating Valve refer the catalogue and selection guideline of the valve manufactures. As a
general guideline, sizing of 3-way Modulating Valve is selected one size lower than the Condenser line diameter.
77
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:
• 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.
• 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.
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USER'S MANUAL
• 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.
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.
79
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.
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 35%
This state is when the compressor is providing 35% of its capacity. In this state, the relay output to activate the 35% valve is
turned on.
CMP IS AT 50%
turned on.
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USER'S MANUAL
CMP IS AT 75%
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.
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. Set Point Definitions

4.1 SET POINT TYPES:
There are three different types of set points. The type determines the action that the system will take.
4.1.1. 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
4.1.2. 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
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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.
4.1.3. 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.
5. Set Points for Chiller Controller Algorithm

5.1 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. POWERUP DELAY
This is the time that the system will remain in the START UP state before moving to the next state.
5.2 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
5.3 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
5.4 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.
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
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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
5.5 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.
5.6 Oil Differential Calculation

The calculation is DISCHARGE PRESSURE minus SUCTION PRESSURE.
6. 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 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
6.1 RESTORE FACTORY SETTING AND DATA LOGGING

6.1.1 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.
6.1.2. 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.
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USER'S MANUAL
7. 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.
8. 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.
9. Compressor
The compressor with the least number of TOTAL RUN HOURS will become the lead. Refer to Set points #103 & #104.
10. Alarms and Safeties

10.1 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:
10.1.1 Suction Pressure - Pressure transducer to read the suction pressure.
10.1.2 Discharge Pressure - Pressure transducer to read the discharge pressure.
10.1.3 Oil Differential Pressure - Calculated value of the oil pressure as follows:
Screws without oil pump, discharge psi minus suction psi
10.1.4 Oil Temperature - Either a temperature sensor or a digital input that indicates when a high temperature
condition exists.
10.1.5 Discharge Temperature - Either a temperature sensor or a digital input that indicates when a high temperature
condition exists.
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10.1.6 Motor Amps - Sensor input that measures AMP draw of the compressor. (Optional digital input)
10.1.7 Liquid Temperature - Temperature sensor that can be used to detect a freeze condition
10.1.8 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.
10.1.9 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.
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.
10.1.10 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.
10.1.11 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.
10.1.12 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.
10.1.13 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.
10.1.14 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
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USER'S MANUAL
10.1.15 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.
10.1.16 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.
10.1.17 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.
10.1.18 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.
10.1.19 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.
10.1.20 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.
10.1.21 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.
10.1.22 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.
10.1.23 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.
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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 COND. EVAP FLOW Disabled: no condenser 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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USER'S MANUAL
11. 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!
12. 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
Parameter
Set Temp. 00.0°C
Differential 00.0°C
While key is used to enter the displayed parameter in CPU memory & the curser moves to next parameter.
89
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 This is a default screen i.e. if (Esc) key Esc is pressed from
any screen an operator will finally return on this
Comp1 OFF 0% screen. This displays Leaving water Temperature and
Comp2 OFF 0% 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
These two consecutive screens show different analog

SP 000.0PSI Comp 1 readings values related to Compressor1.
DP 000.0 PSI SP – Suction pressure
DT 000.0°F DP – Discharge pressure
CU 000.0Amp DT – Similar screens for Compressor
CU – Current
Comp 1
Sucion Saturation
Temperature 000.0°F
Diff Pres 000.0PSI
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USER'S MANUAL
SP 000.0PSI Comp 2
DP 000.0 PSI
DT 000.0°F
CU 000.0Amp
Similar Screens for Compressor 2
Comp 2
Sucion Saturation
Temperature 000.0°F
Diff Pres 000.0PSI
Next screen shows Entering water temperature and

Entering water individual cooler leaving temperature (only in case of twine
Temperature 000.0°F cooler)
WaterOut 1 T 000.0°F
WaterOut 2 T 000.0°F

Press enter to view Alarm history can be accessed by pressing key while
alarm history this screen is shown
Alarm history screen shows resent alarm with corresponding

01 01/12/55 10:30 date, time and suction pressure discharge pressure and
Unsafe Oil comp 1 current of related compressor at the time of alarm. With keys
SP 70 DP 80 CU 90 past 100 alarms can be viewed. Upper left corner always
shows the index of present alarm. By Esc
pressing key one can go back to previous
screen
02/12/07 01:43:52 This screen present login status and also provides facility to
Current Login logout. In login status it will show “User” or “Factory” if
None respective password is entered earlier. In case of logout it
Press Enter to Logout will show “None”. Pressing Enter while this screen is
displayed enables logout.
91
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 (35%,
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 35% 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 (Prg) key once Prg & he will reach the navigation screen
This screen shows 3 options out of which middle one is bold

Status Level and big. On pressing Enter key on this screen Operator will
be taken to that level which appears at middle(only after
User entering respective password). With keys

different options can be called.
Factory Level
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USER'S MANUAL
This is the password entry screen. Operator can

get to the value of password with keys while

pressing key will enter the password. If
User Password
0000
password is wrong message will be shown otherwise
operator will directly go to the next screen of user
level.

From this screen operator can enter the set point &
Leaving Water Temp differential for each Unit. Again the values can be
changed with keys while pressing key will
Setpoint 045.0°F
enter the set point.
Con Zone (-) 01.0°F
Con Zone (+) 02.0°F
This screen allows facility to reset the lockout. Operator

Reset Lockout for need to bring the curser an “N” by pressing. Then
with keys it has to be made “Y” and then
Comp 1 N
key should be pressed to reset the
Comp 2 N lockout.
New User Password This screen is meant for the operator to change the
password for USER LEVEL.
0000
93
c) Status Level
For going to this level from any screen operator needs to press (Prg) key once Prg & he will reach the navigation screen
This screen shows 3 options out of which middle one is bold

Factory Level and big. On pressing Enter key on this screen Operator will
be taken to that level which appears at middle(only after
Status entering respective password). With keys
different options can be called.
User Level
Analog Inputs Comp 1

Suction P 000.0PSI
Discharge P 000.0PSI
Discharge T 000.0°F

Suct Sat T 000.0°F
Current 000.0Amp
Diff Pres 000.0PSI
Status screens show status of analog inputs, Digital inputs,

Analog Inputs Comp 1 Digital outputs and the important parameters related to the
WaterOut T 000.0°F 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
Dig Inputs Comp 1 go through all of these screens
Flow Switch Close
SPPR Close
Oil Float sw Close
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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USER'S MANUAL

Suction P 000.0 PSI
Discharge P 000.0PSI
Discharge T 000.0°F

Suct Sat T 000.0°F
Current 000.0Amp
Diff Pres 000.0 PSI
Similar screens fir compressor 2 if present

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
This screen shows important parameters related to the

T.O.L. Parameters:-
control algorithm getting executed according to the trend of
T.O.L. 00.0 load
SP Countdown 000
Demand 000
95
Press enter to view

Current log for
Compressor 1 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
Press enter to view
Current log for
Compressor 2
This is an example of data log screen which shows last

01 Comp 1 Data Log reading of current suction discharge pressure along with
date and time stamp. Similar screen can also show data of
01/11/07 10:32:44
compressor 2. With keys past 20 logs can be
Current 096.0Amp viewed. Upper left corner always shows the index
SP 056.0 DP 120.0 of present log. By pressing key one can go
Esc
back to previous screen.
96
USER'S MANUAL
Troubleshooting of Controller
Description Possible causes Remedies
1. PDG terminal is blank. • Controller is not powered ON. Check controller power status from
(no backlight) yellow power LED.
• Display cable is not connected If controller is powered ON check for

properly. proper insertion of telephone
connector.
2. Backlit of PGD is ON but it is • Address setting of PGD or Check for address of PGD
blank or shows “NO LINK” controller is not proper. (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.
3. After making PGD address • Telephone cable between PGD Check for proper connection of
0 and controller power and controller is faulty. telephone cable and its connector.
OFF/ON cycle "self test"
screen of controller doesn't Check for lead-wise continuity between
appear. two ends of cable.
4. On default screen LWT is • Address setting of PGD or Make controller address 1 and PGD
seen in smaller font. controller is not proper. address as 32.
5. Temperature reading shows • Probe is disconnected Check for proper connection of probe.
-999.9 or 999.9 (-999.9) or shorted (999.9).
6. Temperature or Pressure • Wrong probes are connected. Check for proper probes and connection.
reading shows erratic or
negative reading. • Dip switch setting is not Check + VDC connection for pressure
done properly. probe.
Check for continuity between GND on

electrical terminal and on pCO1 terminal.
Check for correct dip switch setting.
While making analogue input connections

isolation from mains supply is must.
7. Digital input giving nuisance • Wiring for digital input is open Check for continuity of completed wiring
alarm. at terminal block or at field. wiring of digital input.
• IDC for digital input is not Check for IDC of respective digital input
connected to G0 of controller. block to be connected to G0.
Correct working should be confirmed with

status on PGD.
8. Output is not getting ON. • Common for that output block Check for all common to be shorted with
is not given proper power 230V AC.
97
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. Problems Problem Cause

No.
1 Sudden trip of motor 1) Low suction pressure or high suction temperature
thermister / Sensor (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 1) Low ambient temperature or High oil viscosity.
to load
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 1) Modulation solenoid valve clogged or burnt.-

to unload 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.
98
USER'S MANUAL
Sr. Problems Problem Cause

No.
4 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 1) Slide valve piston unable to move back to its 35 %

failure or star-delta original position.
starter shifting failure
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.
99
Maintenance
Maintenance Schedule
Maintain the Chiller periodically in accordance with the schedules shown in the tables that follow:
Water Cooled Screw

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 X
flare joints, valve glands etc
Check and clean refrigerant strainer X
Check condition of refrigerant drier X
Clean Cooling tower sump X
Clean water line strainers X
Check quality of water X
Check healthy operation of safety devices X
Check tightness of all electrical terminations X
Top up grease for all motors X
Apply thermal paste on the temperature sensors X
Check for any abnormal noise and vibration X
Check liquid line sight glass/moisture indicator X
Check water pressure drop in cooler X
Check water pressure drop in Condenser X
Analyse Oil sample X
Check suction superheat X
Check crank case heater X
Carel Controller
Check program settings X
Check fault history X
Check load/unload furnction X
Check pump down function X
Check Clock X
100
USER'S MANUAL
Maintenance schedule : Compressor
Check Points Time period
Compressor 1000 2500 5000 10000 15000 20000 25000 30000

hrs hrs hrs hrs hrs hrs hrs hrs
Electrical Insulation X X X
Oil filter cartridge X X X
Suction filter X
Capacity control R
piston rings
Oil level X X X X X X X X
Oil X X X R
Motor thermal X X X X X X
protector
Bearings X X R
X Check or Clean
R Replacement
Note:
If acidity of oil measured is lower than PH 6, replace the oil
101
Spare Parts List

Spares for LCWX1 - 0345D
SAP CODE Description Net Quantity Nos.
Compressor spares
CMSWG132L3202 COMP-SCREW-RC2-510A-VI 2.6 1
CHOL-001-00 OIL-SPARE CPI 120 WC FLOODED 20 Liters
RCSC-0000001-00 SOLENOID COIL-FOR RC COMPR. 3
3101-1051B OIL HEATER (300W) 1
4401-30 SOLENOID VALVE 3
3101-1003A SOLENOID VALVE GASKET 3
4404-056 OIL LEVEL SWITCH 1
Ref. Controls & Accessories Spares

RCTXV-TRAE45M-00 EXP VALVE-TRAE45M R134A EMERSON MAKE 2
RCSL-06001-00 SOLENOID VALVE-PILOT 230V 1
RCPR-00001-00 PRE CONTROL-VALVE RELIEF 022-01887-000 1
VAAN-12T001-00 VALVE ANGLE TYPE 1-5/8 IN 1
RCSG-013-00 SIGHT GLASS-SADDLE -2 1/8 IN-HFC-DANFOSS 1
RCFS-0342001-00 FILTER SHELL-DEHYDRATOR 1 5/8 IN 1
RCCO-00HF001-00 FILTER DRIER CORE (48-DM) 3
FBAN-GT004-00 GP-VALVE ANGLE 1/4 IN X 1/4 IN 3
Electrical & Micro Control Panel Spares

CBCL-RT050-00 CONT PANEL CAREL LCWX1-100DEF 1
ECCO-CA007-00 CAREL- PCO3 SET-SCROLL-4/SCRW-1 1
SPPC-T012-00 SPKT00B1C0 PR TRANSD 0-44.8BAR 2
ECCO-OT005-00 SPKC002300 CABLE 2M FOR PR SEN 2
STTD-T004-00 CAREL SENSOR-1.5MTS-NTC015WP00 1
ELCT-000001-00 TRANSFORMER MCS-CT250- AMPS 1
102
USER'S MANUAL
Spares for LCWX2 - 0385D

SAP CODE Description Net Quantity Nos.
Compressor spares
CMSCG800K3200 COMP-SCREW -RC2-310A-VI 2.6 2
3101-1051B OIL HEATER (300W) 2

RCTXV-THR 68M-00 EXP VALVE-THR 68M R134A EMERSON MAKE 2
RCFS-0235001-00 FILTER SHELL-DEHYDRATOR 1-3/8 IN 2

CBCL-RT184-00 CTRL PNL CAREL LCWX2-110DEF W HARNESS 1
103
SPARES FOR LCWX1 - 0525D

SAP CODE DESCRIPTION NET QUANTITY
NOS.
Compressor spares
3101-1051B OIL HEATER (300W) 1

RCFS-0454001-00 FILTER SHELL-SHELLR134A(4CORE) 1

CBCL-WE011-00 CONT PANEL CAREL LCWX1-150DEF 1
104
USER'S MANUAL

NOS.
Compressor spares
3101-1051B OIL HEATER (300W) 2

RCFS-0235001-00 FILTER SHELL-DEHYDRATOR 1-3/8 IN 2

CBCL-RT051-00 CONT PANEL CAREL LCWX2-150DEF 1
105

NOS.
Compressor spares
3101-1051B OIL HEATER (300W) 2

RCTXV-TRAE45M-00 EXP VALVE-TRAE45M R134A EMERSON MAKE 4
RCFS-0342001-00 FILTER SHELL-DEHYDRATOR 1 5/8 IN 2

CBCL-RT183-00 CONTROL PANEL WITH HARNESS LCWX2-190DEF 1
106
USER'S MANUAL
Field Feed Back Form

The field feedback card as per the format below shall be send to factory on receipt of the Chiller
Field Feed Back Form on Receipt of Chiller at Site

Return To : Manufacturing Unit - Thane
PRODUCT :
CHILLER MODEL :
SR. NO. :
CUSTOMER NAME : LOCATION :
DATE :
Observation Comments Details of defects
Quality of Packing Ok / Damaged
Receipt of Documents
- Packing List Yes / No
- Test Report Yes / No
- Truck No.
Condition of Parts :
- Compressor Ok /
- Condenser Ok /
- Cooler Ok /
- Electrical Panel Ok /
- Refrigerant Piping Ok /
- Idle Pressure Ok /
REMARKS :
Checked By
For Factory Use :
- Date of Receipt: - Action By :

- Comments :
107
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 Ok /
- Condenser water connection terminated
properly with isolation required
- Chilled water connection terminated
properly with isolation required Ok /
- Electrical connection with Earthing
terminated properly Ok /
- Condenser water and Chilled water system
properly flushed Ok /
- Water Quality checked Ok /
- Insulation Resistance of Cables checked Ok /
- Condenser water and Chilled water Pump
commissioned Ok /
Water flow adjusted to the design flow by
checking pressure drop Ok /
Water flow switches connected with
electrical panel Ok /
Check up Voltage Ok / Starting 400V + 10% Running 400V + 10%
Commissoned the Chiller Ok / Long term running 400V ± 5%
Noise Level Ok /
Vibration Ok /
Check Current Ok /
Testing done at site Ok /
Performance data as per format Ok /
- Commissioning Date
- Commissioning By
Remarks :
Note : Warranty will be valid only after receipt of this card at the factory
For Factory Use :
- Date Of Receipt : - Action By :

- Comments :
108
USER'S MANUAL
Com missioning and

Handing Over
Hand over the Chiller to the Customer as per the format below and establish Warranty
COMMISSIONING & HANDING OVER REPORT
Our Ref: Date:
BLUE STAR LIMITED Cust. Ref.
PURCHASE ORDER Date:
Date:
Equipment : Blue Star make 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 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 : Customer’s Stamp & Signature

5091-10C Registered Office : Kasthuri Buildings, Jamshedji Tata Road, Mumbai 400 020
109
Water Quality
Recommended Water Quality Standards
Test items Chilled Cooling Tower Makeup

Water Quality Water Quality Water Quality
pH 7.2 - 8.5 7.2 - 8.5 6.0 - 8.0
Total hardness
(CaCo3) ppm Max. 80 Less than 200 Max. 50
Total Alkalinity
(CaCo3) ppm Less than 100 Less than 100 Less than 80
Chloride Ion (ppm) Less than 50 Less than 200 Less than 50
Total Ion (Fe) ppm Less than 0.3 Less than 1.0 Less than 0.3
Silica (Sio2) ppm Less than 30 Less than 50 Less than 30
Ammonium Ion ppm Less than 0.2 Less than 1.0 Less than 0.2
110
USER'S MANUAL
LOG REPORT
After commissioning of the chiller at site; Maintain Log Report as per the format
Customer’s Name
Date:
Time
S.No Description Units 10.00 12.00 14.00 16.00 18.00
1 Voltage R-Y V
Voltage Y-B V
Voltage R-B V
2 Current - R A
Current - Y A
Current - B A
3 Supply Frequency Hz
4 Suction Pressure comp. PSIG
5 Discharge pressure comp. PSIG
6 Compressor current. A
0
7 Cooler Entering Water temp. F
0
8 Cooler Leaving Water temp. F
9 Cooler Pressure drop PSIG
10 Cooler water Flow rate USGPM
0
11 Condenser Entering water temp. F
0
12 Condenser Leaving water temp. F
13 Condenser Pressure drop PSIG
14 Condenser Water flow rate USGPM
0
15 Refri. System temp. - Discharge F
0
16 Refri. System temp. - Liquid F
0
17 Super heat (suction) F
0
18 Discharge superheat F
111
Warranty Claim Form

For Blue Star Water-cooled Screw Chillers
A copy of this form is to be filled in case of the Chiller failure, by BSL Engineer)
Location (City) ……......……………. 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
Starting Problem Yes No

Noise at Starting Yes No
Noise while running Yes No
Compressor : High Noise Vibration

Any mounting bolts loose : Yes No
Electrical problem Yes No

Voltage Yes No
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 Signature & Seal of BSL Engineer

Date ……………. Date …………………….
(For Factory use only)

Claim settled Credit advice No. …....................................…… Claim rejected
Reasons for rejection ……………………....................................................................................
Settlement authorised by : ……......……………….. Date …………………………….
112
USER'S MANUAL
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 installation as a whole, if the screw chiller is
supplied as part of a project.
113
24x7 Customer Care

Phone : 1800 209 1177
SMS : “Service” to 57007
Email : customerservice@bluestarindia.com
EAST SOUTH WEST

BHUBANESHWAR BANGALORE AHMEDABAD
3A, Satya Nagar, Ozone Manay Technology Park 2nd Floor, Shivalik - II,
2nd Floor, Sy. No. 56/18 & 55/9 Near Shivranjani Cross Roads,
Bhubaneshwar 751 007. Hongasandra Village 132 Feet Ring Road, Satellite,
Tel: (0674) 2572403 / 2573670 Begur Hobli, Ahmedabad 380 015.
Garvebhavipalya Tel: (079) 40224000
GUWAHATI Bangalore 560 068. BHOPAL
13, K C Patowari Road, Tel: 41854000
Ulubari, Guwahati - 781 007. “Star Arcade”, 2nd Floor
Tel: (0361) 2468496 CHENNAI Plot No.165A & 166, Zone-I
Maharana Pratap Nagar
104, ‘Garuda Building’,
KOLKATA Bhopal 462 011.
Cathedral Road, Tel: (0755) 2553378 / 4273378 / 79
7, Hare Street Chennai 600 086.
Kolkata 700 001. Tel: (044) 28124000 / 42444200 GOA
Tel: (033) 22134200 / 22106609 1st Floor, Buddhaseth Apartments,
KOCHI Tonca, Caranzalem, Goa 403 002.
NORTH 2nd Floor, Millennium Plaza, Tel: (0832) 2461671 / 2462087
MKK Nair Road,
CHANDIGARH Alinchuvadu Junction, MUMBAI
Adarsh Mall, 4th Floor, Kochi – 682 024. Blue Star House
Plot No 50, Tel: (0484) 4499000 / 4499043 9A, Ghatkopar Link Road
Industrial & Business Park, Saki Naka, Mumbai 400 072.
Phase - II, Chandigarh 160 002. SECUNDERABAD Tel: (022) 66684200 / 66684000
Tel: (0172) 2790482 / 5024000 207, Sikh Road, NAGPUR
Bantia Estate,
JAIPUR 219, Bajaj Nagar, 1st Floor,
Secunderabad 500 003.
South Ambazari Road,
A-19, Main Sahakar Path, Tel: (040) 44004000
Nagpur 440 010.
Near Sahakar Bhawan, Tel: (0712) 6624000 / 2249000
Jaipur - 302 001. TRIVANDRUM
Tel: (0141) 2744033 / 35 T.C. IX/1490 PUNE
‘Chandrika’, 201/A, Nityanand Complex
LUCKNOW Sasthamangalam 1st Floor, 247/A,
177/4, Faizabad Road Trivandrum 695 010. Bund Garden Road
Lucknow 226 007. (U.P.) Tel: (0471) 2720025 / 2720065 Pune 411 011.
Tel: (0522) 4034000 Tel: (020) 41044000 / 26169332
VISAKHAPATNAM
NEW DELHI VADODARA
D. No. 49-24-65/1,
E-44/12, Okhla Ind. Area Near Sankarmattam Road, Ramakrishna Chambers
Phase II, Okhla Madhura Nagar, 7th Floor, Productivity Road
New Delhi 110 020. Visakhapatnam 530 016. Alkapuri, Vadodara 390 005.
Tel: (011) 41494200 / 41494000 Tel: (0891) 2748405 / 2748433 Tel: (0265) 2332021 / 22 /
2330334 / 6614000
114
USER'S MANUAL
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.
115
116

R134a WC DX SCREW CHILLER USER MANUAL USER MANUAL 1 PDF

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R134a Water-cooled DX

Environment Friendly Green Chillers

Revised - December 2010

No part of this publication may be reproduced in any manner whatsoever without

While due care has been taken to avoid errors or misinterpretation,

Since ASHRAE standards use the FPS system, FPS nomenclature

Published by Blue Star Limited, Airconditioning Projects Division.

For restricted circulation only. Not for sale.

Technical Specifications ................................................................................................. 8

Rigging and Installation ................................................................................................ 14

Carel Controller ............................................................................................................ 17

Pre start up, Testing, Commissioning and Operation ................................................... 69

Troubleshooting of Controller ....................................................................................... 97

Maintenance ............................................................................................................... 100

Spares Part List .......................................................................................................... 102

Field Feed Back Form ................................................................................................ 107

Commissioning and Handing over report ................................................................... 109

Water Quality ............................................................................................................. 110

Log Report ................................................................................................................. 111

Warranty Claim Form ................................................................................................. 112

Warranty ..................................................................................................................... 113

Blue Star Service Offices ........................................................................................... 114

• Highly efficient with low noise levels

• Tested in accordance with ARI Standards

• The cooler outlet temperature can be controlled accurately within

• In-built time delays for compressor single phase / phase reversal

• Password protection at two levels.

Optional features in Control Centre

• PC connectivity and remote monitoring without BMS through

• BMS compatibility with JC N2, BACnet and Modbus protocol with

• Windows based support system to provide complete status on all

LIQUID NOMINAL CAPACITY

WATER COOLED SCREW COMPRESSOR

Sr. No. Description Units LCWX1-0345D LCWX1-0525D

(C) Electrical Power Supply

Technical Specifications for Water-cooled Screw Chiller DX R134a

Sr. No. Description Units LCWX1-0345D LCWX1-0525D

(F) Expansion Valve Thermostatic Thermostatic

(G) Overall Dimensions (approx.)

Technical Specifications for Water-cooled Screw Chiller R134a DX (Twin Compressors)

(C) Electrical Power Supply

Technical Specifications for Water-cooled Screw Chiller R134a DX (Twin Compressors)

(F) Expansion Valve Thermostatic Thermostatic Thermostatic

(G) Overall Dimensions (approx.)

Cooler - Pressure Drop

USGPM PRESSURE DROP IN FT OF WATER COLUMN

Condenser - Pressure Drop

USGPM PRESSURE DROP IN FT OF WATER COLUMN

Rigging and Installation

1. Grooved water in/out connection on cooler

Step 1: Loose the bolts and nuts from the couplings.

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

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

• 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.

2. Description of the Products

3. Description of the Products

4. Configuration of the Plan Network

I/O Expansion Board Led Indication