Vdocuments - MX - Blue Star Chiller Air Water Cooled Screw Chiller r22 DX Manual PDF

Air Cooled and Water Cooled Screw Chillers
High on reliability
Low on operating costs
USER’S
MANUAL
SCREW CHILLER (Air & Water Cooled)
Revised January 2008
No part of this publication may be reproduced in any

manner whatsoever without permission in writing from the
Executive Vice President, Airconditioning Projects Division,
Blue Star Limited.
While due care has been taken to avoid errors or misinterpretation,

Blue Star Limited is neither liable nor responsible for consequence
of any action taken, on the basis of this publication.
Since ASHRAE standards use the FPS system, FPS nomenclature

is used in some places in this publication for convenient reference.
Published by Blue Star Limited, Airconditioning Projects Division.
For restricted circulation only. Not for sale.
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USER'S MANUAL
Contents
Introduction ...................................................................................................................... 4
Features ........................................................................................................................... 5
Nomenclature.................................................................................................................... 8
Technical Specifications .................................................................................................... 9
Rigging and Installation .................................................................................................... 27
Carel Controller ............................................................................................................... 30
Screw Compressor ......................................................................................................... 47
Pre start up, Testing, Commissioning and Operation ....................................................... 54
Trouble Shooting ............................................................................................................. 84
Maintenance .................................................................................................................... 87
Spares Part List .............................................................................................................. 90
Field Feed Back Form ....................................................................................................114
Commissioning and Handing over report ........................................................................116
Water Quality .................................................................................................................117
Log Report .....................................................................................................................118
Warranty Claim Form .....................................................................................................119
Warranty ....................................................................................................................... 120
Blue Star Service Offices .............................................................................................. 121
3
Introduction
Blue Star, India’s preferred Air conditioning Company has been providing expert cooling solutions for over six
decades. It is with this expertise Blue Star brings to you a wide range of Air and Water Cooled Screw Chillers,
manufactured at its ISO 9001 factory with world class capabilities.
These Chillers which operate on HCFC-22 refrigerant come in a quality range of eleven models varying from
75 TR – 366 TR in the air cooled version and 115 TR – 400 TR in the water cooled version. The condensers
are designed for operation under a wide range of ambient conditions.
Due to lesser moving parts, these chillers are reliable and rugged. Further, with its automatic step capacity
control, it provides better efficiency under part loads making it ideal for varying load applications such as
office spaces, hotels, hospitals, malls and multiplexes.
In short, these chillers offer reliable, energy efficient performance year after year.
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USER'S MANUAL
Features
Compressor
The BSC Series semi hermetic screw compressors incorporated in the chillers follow state-of-the-art
manufacturing processes which are ISO 9001 certified and use high precision machinery.
The salient features of these compressors are:
• Highly efficient with low noise levels
• Tested in accordance with ARI Standards
• Due to few moving parts such as Male and Female Screws and Slider valve, these compressors have
minimal wear and tear
• Each compressor has the latest 5 to 6 Patented Profile design, with separate Radial and Axial force
Bearings, Built-in Oil Separator, PTC Motor winding protection, Discharge temperature protection with
its controller, Oil level switch and Oil differential pressure switch. This guarantees reliability and long
life of bearings under heavy working operating conditions.
• Each Compressor has Step capacity control from 25% to 100%, making it suitable for part load
applications and efficient under part load conditions. The capacity control also helps in limiting the
starting current.
Liquid Injection
The refrigerant suction gas cools the winding of the Semi hermetic Screw Compressor Motor. During part
load operation where the suction gas circulation is less, as an abundant precaution, liquid refrigerant is injected
to the suction side of the compressor to cool the motor winding. Liquid injection during this period keeps the
motor winding temperature within limits. This is provided as a standard feature to enhance the life of the
compressor.
Evaporator
The shell and tube evaporator has inner grooved copper tubes for better heat transfer. The tubes are designed
to optimize for refrigerant and water velocities.
5
Control Centre
The control centre is mounted in the framework of the chiller. It is
provided with an advanced microprocessor control panel which has
unique features and advantages.
• The cooler outlet temperature can be controlled accurately

within a close tolerance of + 0.5°F
• In-built time delays for compressor single phase / phase

reversal protection and anti freeze protection
• Password protection at two levels.
Optional features in Control Centre
• RS 485 port & TCP/ IP web gate for remote connectivity,

fault indication and status facility
• PC connectivity and remote monitoring without BMS

through dedicated telephone line, Gateway and Modem.
• BMS compatibility with JC N2, BACnet and Modbus protocol with Translator.
• Windows based support system to provide complete status on all operations both locally and remotely.
History, static and dynamic graphing to aid in commissioning, trouble shooting and evaluation.
These features help in accurate operation and protection of the chiller.
Following additional features are available in Air Cooled version:
Economiser
Refrigerant liquid to liquid plate type heat exchanger is provided for the economiser system. The
liquid refrigerant is sub cooled to enhance the capacity thereby reducing power consumption (IKW/
TR) and enhancing the Coefficient of Performance (COP).
Oil Cooler
Effective lubrication of bearing depends on the viscosity of lubricant, which in turn depends on
the oil temperature. To ensure effective lubrication for longevity, oil cooler is provided as a standard
option for Aircooled Application.
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USER'S MANUAL
Air cooled condenser

The air cooled condenser coils uses copper tubes and aluminum fins. The inner grooved
type copper tubes used in the condenser provide increased surface area for better heat
transfer.
Fans
The propeller type fan profiles are with 5 lobes, bird wing design which optimizes both the
noise level and the power consumption against required air flow and static pressure.
Springs
Specially designed springs are supplied along with the units to minimize the transmission of vibration.
Optional items available in air cooled version are:

• Hydrophobic coated aluminium fins
• Coil protection guards
7
Nomenclature
Nomenclature - Air Cooled Chiller
L C A X 1 - 075 D i A
REVISION
REFRIGERANT R22
DIRECT EXPANSION
LIQUID NOMINAL CAPACITY
NO. OF COMPRESSORS
CHILLER
AIR COOLED SCREW COMPRESSOR
Nomenclature - Water Cooled Chiller
L C W X 1 - 115 D i B
REVISION
REFRIGERANT R22
DIRECT EXPANSION
LIQUID NOMINAL CAPACITY
CHILLER NO. OF COMPRESSORS
WATER COOLED SCREW COMPRESSOR
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USER'S MANUAL
Technical Specifications
Technical Specification for Air Cooled Screw Chiller (Single Compressor)
Description Unit LCAX1-075 D i A LCAX1-102 D i A LCAX 1-145 D i A LCAX1-206 D i A
Nominal Cooling Capacity KW (TR) 263.7 (75) 359.3 (102) 509.82(145) 724.29 (206)
Compressor Semihermetic Screw
Model BSC-075A BSC-105A BSC-145A BSC-210A
Quantity No. 1 1 1 1
Motor type Semi-hermetic Refrigerant Cooled, 3Ph., 2 Pole Squirrel Cage, Induction Motor
Operating Speed RPM 2950 2950 2950 2950
Power Supply 400 V(+/- 10%) , 3 Ph. , 50Hz
Ccompressor Rated Current. Amp. 131.9 182.6 250.9 357
Compressor Locked Rotor Current Amp. 730 735 1100 1760
Compressor Starting Current Amp. 230 245 370 590
Class of Insulation F F F F
Compressor Power Consumption kW 81.1 112.3 154.7 219.8
Unit starting Current Amps 235 252.5 380 605
Unit Maximum Full Load Current Amp. 180 251 345 490
Unit Power Consumption kW 85.9 119.5 164.3 234.2
R-22 Refrigerant Charge Kg 67 90 130 175
Oil Charge (Blue Star ACS) Litres/compr 16 16 23 28
Condenser
Total Face Area Sq. Mt.(Sq Ft) 10.28 (110) 14.9 (160) 19.8 (213) 29.7(320)
Rows Deep No. 3 3 3 3
Tube Material 3/8" Inner grooved,.Copper
(D) OD x Thickness mm x mm 9.5 x 0.304 9.5 x 0.304 9.5 x 0.304 9.5 x 0.304
Type of Aluminium Fins Super Slit
Fins per Inch 14 14 14 14
Fan for Air Cooled Condenser
Fan Dia mm 915 915 915 915
Air Flow CFM 48,000 72,000 96000 1,44,000
Condenser Fan Motor
Type Totally enclosed, Pad Mounted
Speed RPM 700 700 700 700
Full Load Current Amp. 2.6 2.6 2.6 2.6
Power Input KW 1.2 1.2 1.2 1.2
9
Technical Specification for Air Cooled Screw Chiller (Single Compressor)
Description Unit LCAX1-075 D i A LCAX1-102 D i A LCAX 1-145 D i A LCAX1-206 D i A
DX-Cooler
Model YCH-92A YCH-103A YCH-152A YCH-222A
Shell ID mm 311.2 371 419.1 488
Shell Thickness mm 6 8 8 8
Tube Type and Material Inner Grooved Tubes with External Plain
No. of Tubes Nos 196 252 310 508
Tube OD and Thickness IN 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031
Tube Length FT 7 7 8 8
Surface Area Inside Sq. FT 347.39 446.64 627.93 1029
Surface Area Outside Sq. FT. 224.37 290.09 407.75 668.00
No of Pass (water side) Nos 1 1 1 1
No of Pass (Refrigerant side) Nos 4 4 4 4
No of Refrigerant Circuit NOS 1 1 1 1
Water Connection Size In/Out INCH 6" NB 6" NB 6" NB 8" NB
Water Flow Rate
Min.. USGPM 150 204 290 412
Max.. USGPM 225 306 435 618
Expansion Valve Thermostatic
Economiser Brazed Plate Heat Exchanger
Overall Dimension
Length mm 2700 3800 4820 7260
Wideth mm 2040 2040 2040 2040
Height mm 2486 2495 2495 2495
Net Weight (approx) Kg. 2600 3300 4180 6050
Operating Weight (approx) Kg. 2677 3382 4358 6250
Rating Conditions
1. Entering Air over Condenser Temperature: 95oF

2. Entering Cooler Water Temperature: 54oF, Leaving Cooler Water Temperature: 44oF
3. Cooler Fouling Factor : 0.0001 Hr. Sq.ft.Deg. F/BTU
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USER'S MANUAL
Technical Specification for Air Cooled Screw Chiller (Twin Compressors)
Description Units LCAX2-150 D i A LCAX2-177 D i A LCAX2-204 D i A LCAX 2-247 D i A
Nominal Cooling Capacity KW (TR) 527.4 (150) 622.3(177) 717.2 (204) 868.4(247)
Model BSC-075A BSC-075A + BSC-105A BSC-105A BSC-105A + BSC-145A
Operating Speed RPM 2950 2950 2950 2950
Power Supply 400 V(+/- 10%) , 3 Ph., 50Hz
Ccompressor Rated Current. Amp. 263.8 (131.9 X 2) 314.5 (131.9 + 182.6) 365.2 (182.6 X 2) 433.5 (182.6 + 250.9)
Compressor Locked Rotor Current Amp. 685, 685 685, 735 735, 735 735, 1100
Compressor Starting Current Amp. 230, 230 230, 245 245, 245 245, 370
Class of Insulation F F F F
Compressor Power Consumption kW 162.2 192.3 224.6 267.3
Unit starting Current Amps 377 397 450 578
Unit Maximum Full Load Current Amp. 360 430 502 596
Unit Power Consumption kW 171.8 204.3 239 284.1
R-22 Refrigerant Charge Kg 135 159 184 222
Oil Charge (Blue Star ACS) Litres/compr 16 + 16 16 + 16 16 + 16 18+23
Condenser
Total Face Area Sq. Mt.(Sq Ft) 19.8 (213) 9.84 (106) + 19.8 (213) 29.7(320) 34.6(373)
Rows Deep No. 3 3/2 3 3
(D) OD x Thickness mm x mm 9.5 x 0.304 9.5 x 0.304 9.5 x 0.304 9.5 x 0.304
Fins per Inch 14 14 14 14
Fan Dia mm 915 915 915 915
Air Flow CFM 96,000 144,000 144,000 168,000
Condenser Fan Moror
Speed RPM 700 700 700 700
Full Load Current Amp. 2.6 2.6 2.6 2.6
Power Input KW 1.2 1.2 1.2 1.2
11
Description Units LCAX2-150 D i A LCAX2-177 D i A LCAX2-204 D i A LCAX 2-247 D i A
DX-Cooler
Model YCH-177 A YCH-202A YCH-222 A YCH103A+YCH-152A
Shell ID mm 419.1 445 488 371 + 419.1
Shell Thickness mm 8 8 8 8
No. of Tubes Nos 378 412 508 252+310
Tube OD and Thickness IN 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031
Tube Length FT 8 8 8 7'+8'
Surface Area Inside Sq. FT 765.67 834.54 1029 446+627
Surface Area Outside Sq. FT. 497.19 541.91 668.00 290+407
No of Pass (water side) Nos 1 1 1 1
No of Pass (Refrigerant side) Nos 4 4 4 4
No of Refrigerant Circuit NOS 2 2 2 2
Water Connection Size In/Out INCH 8" NB 8" NB 8" NB 6'’NB+6'’NB
Water Flow Rate
Min.. USGPM 300 354 408 494
Max.. USGPM 450 531 612 741
Overall Dimension
Length mm 4820 7260 7260 8630
Wideth mm 2040 2040 2040 2040
Height mm 2495 2495 2495 2495
Net Weight (approx) Kg. 4700 5300 6300 7350
Operating Weight (approx) Kg. 4873 5485 6500 7618
Rating Conditions

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USER'S MANUAL
Description Units LCAX2-290 D i A LCAX2-320 D i A LCAX2-366 D i A
Nominal Cooling Capacity KW (TR) 1019.6(290) 1125.1(320) 1286.8.1(366)
Model BSC-145A + BSC-145A BSC-160A BSC-160A +BSC-210A
Quantity No. 2 2 2
Operating Speed RPM 2950 2950 2950
Power Supply 400V(+/- 10%), 3Ph., 50Hz 400V(+/- 10%), 3Ph., 50Hz 400V(+/- 10%), 3Ph., 50Hz
Ccompressor Rated Current. Amp. 502 (250.9 + 250.9) 552 (276 X 2) 633 (276 + 357)
Compressor Locked Rotor Current Amp. 1100, 1100 1480, 1480 1480, 1760
Compressor Starting Current Amp. 370, 370 495, 495 495, 590
Class of Insulation F F F
Compressor Power Consumption kW 309.4 336.6 389.4
Unit starting Current Amps 651 808 903
Unit Maximum Full Load Current Amp. 690 766 867
Unit Power Consumption kW 328.6 360.6 415.8
R-22 Refrigerant Charge Kg 265 288 329.4
Oil Charge (Blue Star ACS) Litres/compr 23+23 23+23 23+28
Condenser
Total Face Area Sq. Mt.(Sq Ft) 39.6(426) 39.6(426) 49.53(533)
Rows Deep No. 3 4 3
(D) OD x Thickness mm x mm 9.5 x 0.304 9.5 x 0.304 9.5 x 0.304
Fins per Inch 14 14 16
Fan Dia mm 915 915 915
Quantity No. 16 16 20
Air Flow CFM 192,000 232,000 260,000
Condenser Fan Moror
Quantity No. 16 16 20
Speed RPM 700 860 700/860
Full Load Current Amp. 2.6 3.5 3.5
Power Input KW 1.2 1.5 1.2/1.5
DX-Cooler
Model YCH-152A+YCH152A YCH-177 A+ YCH177A YCH-177A+YCH222A
Shell ID mm 419.1+419.1 419.1+419.1 419.1+488
13
Description Units LCAX2-290 D i A LCAX2-320 D i A LCAX2-366 D i A
Shell Thickness mm 8 8 8
No. of Tubes Nos 310+310 378 +378 378+508
Tube OD and Thickness IN 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031
Tube Length FT 8+8 8+8 8 + 8
Surface Area Inside Sq. FT 627+627 765.67+765.67 765.67 + 1029
Surface Area Outside Sq. FT. 407+407 497.19+497.19 497.2 + 668
No of Pass (water side) Nos 1 1 1
No of Pass (Refrigerant side) Nos 4 4 4
No of Refrigerant Circuit NOS 2 2 2
Water Connection Size In/Out INCH 6'’NB+6'’NB 8" NB+8'’NB 8" NB + 8'’NB
Water Flow Rate
Min.. USGPM 580 640 732
Max.. USGPM 870 960 1098
Overall Dimension
Length mm 9650 9650 12090
Width mm 2040 2040 2040
Height mm 2495 2495 2495
Net Weight (approx) Kg. 8034 9135 9753
Operating Weight (approx) Kg. 8390 9430 10126
Rating Conditions

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USER'S MANUAL
Technical Specification for Water Cooled Screw Chiller (Single Compressor)
Description Units LCWX1-115 D i B LCWX1-135 D i B LCWX1-160 D i B
Nominal Cooling capacity KW(TR) 404.5 (115) 474.8( 135) 562.7 (160)
COMPRESSOR : Semi Hermetic Screw
Model BSC-105A BSC-130W BSC-145A
Quantity No. 1 1 1
Motor Type Refrigerant Cooled Semi-hermetic, 3Ph., 2 Pole, Squirrel Cage Induction Motor
Power Supply 400 V(+/- 10%), 3 PH., 50HZ 400 V(+/- 10%), 3 PH., 50HZ 400 V(+/- 10%), 3 PH., 50HZ
Compressor rated Current Amp. 132.4 155 183.5
Max. Compressor Operating Current Amp. 160 185 220
Compressor Locked Rotor Current Amp. 735 965 1100
Compressor starting Current Amp. 245 325 370
Unit Starting Current Amp. 247 327 365
Class of Motor Insulation F F F
Power Consumption KW 82.4 96.2 110
Type of Oil Blue Star ACS
Oil Charge Ltrs. 16 18 23
Refrigerant R 22 Charge Kg 95 112 136
CONDENSER :
Model YCD-101A YCD-131A YCD-151A
Shell ID mm 330 390 390
Tube type and Material External Finned Copper Tubes
No. of Tubes Nos 127 140 168
Tube OD and Thickness Inch 3/4" OD x 0.028 Thk 3/4" OD x 0.028 Thk 3/4" OD x 0.028 Thk
Tube Length Ft. 7 8 8
Surface Area (Inside) Sq. Ft. 129.05 162.58 195.10
Surface Area (Outside) Sq. Ft. 560.07 705.60 846.72
No. of Pass (Refrigerant side) Nos 1 1 1
No. of Pass (Water side) Nos 3 2 2
Water connection size Inch 4" 4" 4"
No. of Refrigerant circuit NOS 1 1 1
Water flow Rate Min. USGPM 312 375 435
Max . USGPM 416 500 580
15
DX-COOLER
Model YCH-103A YCH-122A YCH-152A
Shell ID mm 371 371 416
Tube type and Material Inner Groove Copper Tubes
No. of Tubes Nos 252 252 310
Tube OD and Thickness Inch 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031
Surface area (Inside) Sq. Ft. 446.64 510.45 627.93
Water Connection Size Inch 6" NB 6" NB 6" NB
No. of Refrogerant Circuits Nos 1 1 1
Water Flow Rate Min. USGPM 208 250 290
Max. USGPM 312 375 435
EXPANSION VALVE Thermostatic
Make Sporlan
Model VVE-100 VVE-100 OVE-70-2#
OVERALL DIMENSIONS :
Length mm 2700 2953 2979
Width mm 800 900 900
Height mm 2000 2102 2102
Net Weight Approx Kg. 2500 2700 3365
Operating Weight Kg. 2725 3025 3750
Rating Conditions
1. Entering Cooler Water temp 54oF, Leaving Cooler Water temp. 44oF
2. Cooler Fouling Factor 0.0001 Hr.Ft2.F/Btu
3. Entering Condenser Water temperature 85oF, Leaving Coondenser Water temperature 95oF
4. Condenser Fouling Factor 0.00025 Hr.Ft2.F/Btu
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USER'S MANUAL
Description Units LCWX1-175 D i B LCWX1-225 D i B
Nominal Cooling capacity KW(TR) 615.5 (175) 791.3 (225)
Model BSC-160A BSC-210A
Quantity No. 1 1
Motor Type Refrigerant Cooled Semi- hermetic, 3 Ph., 2 Pole, Squirrel Cage Induction Motor
Operating Speed RPM 2950 2950
Power Supply 400 V(+/- 10%), 3PH., 50HZ 400 V(+/- 10%), 3PH., 50HZ
Compressor rated Current Amp. 200.7 258.6
Max. Compressor Operating Current Amp. 240 310
Compressor Locked Rotor Current Amp. 1480 1760
Compressor starting Current Amp. 495 590
Unit Starting Current Amp. 489 580
Class of Motor Insulation F F
Power Consumption KW 120.7 156.1
Oil Charge Ltrs. 23 28
Refrigerant R 22 Charge Kg 150 195
CONDENSER :
Model YCD-176A YCD-221A
Shell ID mm 390 457
Shell Thickness mm 8 8
No. of Tubes Nos 199 248
Tube OD and Thickness Inch 3/4" OD x 0.028 Thk 3/4" OD x 0.028 Thk
Tube Length Ft. 8 8
Surface Area (Inside) Sq. Ft. 231.10 288.00
Surface Area (Outside) Sq. Ft. 1002.96 1249.92
No. of Pass (Refrigerant side) Nos 1 1
No. of Pass (Water side) Nos 2 2
Water connection size Inch 5" 6"
No. of Refrigerant circuit NOS 1 1
Water flow Rate Min. USGPM 480 630
Max. USGPM 640 840
17

DX-COOLER
Model YCH-177 A YCH-222 A
Shell ID mm 416 416
No. of Tubes Nos 378 508
Tube OD and Thickness Inch 5/8" OD * 0.031 5/8" OD * 0.031
Tube Length Ft. 8 8
Surface area (Inside) Sq. Ft. 765.67 1029
Water Connection Size Inch 8" NB 8" NB
No. of Refrogerant Circuits Nos 1 1
Water Flow Rate Min. USGPM 320 420
Max. USGPM 480 630
Make Sporlan
Model OVE-70-2# VVE-100-2#
Length mm 2987 3087
Width mm 900 900
Height mm 2102 2269
Net Weight Approx Kg. 3650 4600
Operating Weight Kg. 4000 5040
Rating Conditions
3. Entering Condenser Water temperature 85oF, Leaving Coondenser Water temperature 95oF
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USER'S MANUAL
Technical Specification for Water Cooled Screw Chiller (Twin Compressors)
Nominal Cooling capacity KW(TR) 791.3 ( 225) 949.6 (270) 1107.9 (315)
Model BSC-150A BSC-110A + BSC-145A BSC-145A
Quantity No. 2 2 2
Motor Type Refrigerant Cooled Semi- hermetic, 3 Ph., 2 Pole, Squirrel Cage Induction Motor
Power Supply 400 V(+/- 10%), 3PH., 50HZ 400 V(+/- 10%), 3PH., 50HZ 400 V(+/- 10%), 3PH., 50HZ
Compressor rated Current Amp. 264.8 315.9 367
Max. Compressor Operating Current Amp. 320 (160 x 2) 380 (160+220) 440
Compressor Locked Rotor Current Amp. 735, 735 735, 1100 1100, 1100
Compressor starting Current Amp. 245, 245 245, 370 370, 370
Unit Starting Current Amp. 385 481.5 550
Class of Motor Insulation F F F
Power Consumption KW 164.9 192.5 220
Oil Charge Ltrs. 16 + 16 16 + 23 23 + 23
Refrigerant R 22 Charge Kg 180 231 275
CONDENSER :
Model YCD-222 A YCD101A+YCD151A YCD-151A+YCD151A
Shell ID mm 457 330+390 390+390
No. of Tubes Nos 248 127+168 168+168
Tube OD and Thickness Inch 3/4" OD x 0.028 Thk 3/4" OD x 0.028 Thk 3/4" OD x 0.028 Thk
Surface Area (Inside) Sq. Ft. 288.00 324.15 390.19
Water connection size Inch 6" 4"+4" 4"+4"
No. of Refrigerant circuit NOS 2 2 2
Water flow Rate Min. USGPM 624 750 870
Max. USGPM 832 1000 1160
19

DX-COOLER
Model YCH-222 A YCH-103A+YCH152A YCH-152A+YCH152A
Shell ID mm 488 371+416 416+416
No. of Tubes Nos 508 252+310 310+310
Tube OD and Thickness Inch 5/8" OD * 0.031 5/8" OD * 0.031 5/8" OD * 0.031
Tube Length Ft. 8 8+8 8+8
Surface area (Inside) Sq. Ft. 1029 1074.57 627+627
Surface Area (Outside) Sq. Ft. 651.46 697.84 407+407
Water Connection Size Inch 8" NB 6"NB+6"NB 6'’NB+6'’NB
No. of Refrogerant Circuits Nos 2 2 2
Water Flow Rate Min. USGPM 416 500 580
Max.. USGPM 624 750 870
Make Sporlon
Model VVE-100-2# V V E-100-1# + OVE-70-2# OVE-70-2# + OVE-70-2#
Length mm 3100 3400 3400
Width mm 1220 1800 1800
Height mm 2300 2300 2300
Net Weight approx Kg. 5000 5400 6526
Operating Weight Kg. 5450 6050 7280
Rating Conditions
3. Entering Condenser Water temperature 85 oF, Leaving Coondenser Water temperature 95oF
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USER'S MANUAL
Nominal Cooling capacity KW(TR) 1213.4 (345) 1406.8 (400)
Model BSC-160A BSC-160A+BSC-210A
Quantity No. 2 2
Motor Type Refrigerant Cooled Semi-hermetic, 3 Ph., 2 Pole, Squirrel Cage Induction Motor
Operating Speed RPM 2950 2950
Power Supply 400 V(+/- 10%), 3PH., 50HZ 400 V(+/- 10%), 3PH., 50HZ
Compressor rated Current Amp. 401.4 459.3
Max. Compressor Operating Current Amp. 480 (240 x 2) 550 (240 + 310)
Compressor Locked Rotor Current Amp. 1480, 1480 1480, 1760
Compressor starting Current Amp. 495, 495 495, 590
Unit Starting Current Amp. 692 769
Class of Motor Insulation F F
Power Consumption KW 241.4 276.7
Oil Charge Ltrs. 23 + 23 23 + 28
Refrigerant R 22 Charge Kg 304 351
CONDENSER :
Model YCD-176A+YCD176 A YCD176A+YCD222A
Shell ID mm 390+390 390+457
No. of Tubes Nos 199+199 199+248
Tube OD and Thickness Inch 3/4" OD x 0.028 Thk 3/4" OD x 0.028 Thk
Tube Length Ft. 8 8
Surface Area (Inside) Sq. Ft. 462.19 519.10
Water connection size Inch 5"+5" 5"+6"
No. of Refrigerant circuit NOS 2 2
Water flow Rate Min. USGPM 960 1110
Max. USGPM 1280 1480
21

DX-COOLER
Model YCH-177A+YCH177A YCH-177A+YCH222A
Shell ID mm 416+416 416+488
No. of Tubes Nos 378 +378 378+508
Tube OD and Thickness Inch 5/8" OD * 0.031 5/8" OD * 0.031
Tube Length Ft. 8+8 8 + 8
Surface area (Inside) Sq. Ft. 765.67+765.67 765.67 + 1029
Surface Area (Outside) Sq. Ft. 497.19+497.19 497.2 + 668
Water Connection Size Inch 8" NB+8'’NB 8" NB + 8'’NB
No. of Refrogerant Circuits Nos 2 2
Water Flow Rate Min. USGPM 640 740
Max.. USGPM 960 1110
Make Sporlon
Model OVE-70-2# + OVE-70-2# OVE-70-2# + VVE-100-2#
Length mm 3400 3400
Width mm 1800 1800
Height mm 2450 3000
Net Weight approx Kg. 6862 7541
Operating Weight Kg. 7500 8300
Rating Conditions
3. Entering Condenser Water temperature 85 oF, Leaving Coondenser Water temperature 95 oF
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USER'S MANUAL
Pressure Drop
YCH-52A YCH-62A YCH-77A YCH-92A

20 1.5
40 2.5 1.4
60 3.5 2.5 1.75
80 5 4 3
100 7 6 4.5
120 10 8.3 6.5
140 13 11 9 5.5
160 16.5 14 11.5 6.5
180 21 17.5 14.5 8
200 26 21 18 10
220 25 21 12
240 29 24.5 14
260 28.3 16
280 32.5 18.5
300 21
320 24
340 26
360 28
380
400
YCH-103A YCH-122A YCH-132A YCH-177A YCH-202A YCH-222A

YCH-152A
100
150 6 3.5 2
200 10 7.5 5.5 4.5 2.8 0.5
250 15 10.3 8.3 6.5 4.6 2.5
300 21 14 11 8.5 6.5 4
350 27 19 14 12 9.2 5.8
400 25 18 15 12 7.5
450 36 22 19 15 9.3
500 26 23 19 11.5
550 32 28 24 14
600 40 33 28 17
650 32 20
700 24
23
24
USER'S MANUAL
YCD-51A YCD-61A YCD-77A YCD-91A YCD-101 A
2 0.5
60 3.5 2.5 1.5
80 5.5 3.6 2.5
100 8 5.5 4 3 2
120 10.5 7.5 5.5 4 3
140 14 10.5 7.5 5 4
160 17.5 13 9.5 6.5 5.5
180 21.5 16 11.5 8 7
200 26.5 19 14 10 8.5
220 22.5 16.5 12 10
240 26 19 14 12
260 21.5 16 13.5
280 24.5 18.5 15.5
300 21 17
320 23.5 19
340 21
360 23
YCD-122 YCD-132 YCD-152 A YCD-177 A YCD-202 A YCD-222 A
100
150 2
200 4.6 3.6 2
250 7 5.5 3.5 2.8
300 10 7.5 6 4.7 3.5 2
350 13 9.2 8 6.5 5 3
400 16 12 10.2 8.2 6.1 4.5
450 20 15 12.5 10 8 6
500 24 18 15 12 10 8
550 30 23 19 15 12 10
600 35 27.5 22 18 14 12
650 35 25 21 16 13.5
700 25 18 15
25
26
USER'S MANUAL
Rigging and Installation

Rigging
When the chiller arrives at Warehouse/Site, proper rigging and handling is mandatory during unloading and
leading the unit into position.
Care must be taken to keep the unit upright during rigging. Avoid unnecessary jerking or rough handling.
Proper hoisting straps should be used when rigging (nylon flat rope). It is also mandatory that an experienced
and reliable rigger be selected to handling unloading and final placement of the equipment. The rigger must
be advised that the unit contains internal components that require to be kept in an upright position. Care
must be exercised to avoid twisting of the equipment.
Storage
Check for transportation damages if any and take up with factory for any damages.
In case the site is not ready to install the chiller, proper care should be taken to store the chiller in a covered
space. Check up the pressure of the unit when received. If the pressure is not retained in the system, the
system should be pressure tested immediately, repair the leakages if any and charge the system with
Nitrogen. Never keep the system without pressure.
Installation (Aircooled)
Proper care should be taken to make the foundation for the Chiller. Study the GA drawings of respective
models and arrange for wider foundation as rquired to accommodate all the springs within the width of
foundation since the springs centres ar enot in one straight line. In case the Chiller is located on the roof
top, ensure that the same is located in such a way that the load of the same is transferred to the columns
and not to the slab directly. The foundation should be properly levelled.
27
Install the Chiller on the springs specifically designed and supplied along with the unit.
The unit should not be located nearer to any heat source or any high tension line running above. (Especially
near the Control Panel end)
Adequate space around the Chiller as recommended in the GA Drawing should be made available for
maintenance purpose.
The chilled water and condenser water piping connections to the cooler and condenser should be terminated
preferably with flexible connections to avoid transmission of vibration if any. The piping shall be supported
external to the unit as per the recommended practice. Alternately 2 nos. of National Couplings in series can
be provided for the cooler connection.
Use recommended size of power cable to be terminated to the Control Panel of the unit. Use 3½ core
Aluminium cable along with double earthing and terminate through proper lugs. Avoid any sharp bend for the
cable at the termination point. The cable shall be adequately supported. Two separate incomer cables are
required for the chillers with twin compressors.
28
USER'S MANUAL
Installation (Watercooled)
Proper care should be taken to make the foundation for the Chiller. In case the Chiller is located on the roof
top, ensure that the same is located in such a way that the load of the same is transferred to the columns
and not to the slab directly. The foundation should be properly levelled.
Install the Chiller on the Foundation/Pedestal and grout by using foundation bolts. The Chiller should be levelled
on the foundation. The unit should not be located nearer to any heat source or any high tension line running
above.
Adequate space around the Chiller as recommended in the GA Drawing should be made available for
maintenance purpose.
The chilled water and condenser water piping connections to the cooler and condenser should be terminated
preferably with flexible connections to avoid transmission of vibration if any. The piping shall be supported
external to the unit as per the recommended practice. Alternately use 2nos. of national couplings in series.
Use recommended size of power cable to be terminated to the Switch Fuse unit of the Panel of the unit.
Use 3½ core Aluminium cable along with double earthing and terminate through proper lugs. Avoid any sharp
bend for the cable at the termination point. The cable shall be adequately supported. Two separate incomer
cables are required for the chillers with twin compressors.
29
Carel Controller
For Screw Chiller with Step Capacity Control
1.General Characteristics
pCO1 Medium (18 Din modules)
• 12 optically-isolated digital inputs, 24Vac 50/60 Hz or 24Vdc;
• Optically-isolated digital inputs, 24Vac/Vdc or 230Vac (50/60Hz);
• Digital relay outputs (3 of which with changeover contact and 4 optional SSR);
• 4 analog inputs, configurable as NTC, 0/1V, 0/5V, 0/20mA, 4/20mA.
• 2 analog inputs, configurable as NTC and ON-OFF
• 2 NTC analogue inputs
• 2 x 0/10Vdc analogue outputs.
• 2 PWM outputs for phase-cutting speed controllers.
30
USER'S MANUAL
2. Hardware Structure
The structure of the pCO1 features:
• The pCO1 controller, fitted with a 16bit microprocessor for running the control program, and the set
of terminals required for connection to the controlled devices (for example: valves, compressors, fans).
The program and the parameters are saved permanently in the FLASH memory, preventing data loss
in the event of power failure (without requiring a backup battery).
The pCO1 also allows connection to a local pLAN network made up of a series of pCO1 boards and
terminals. Each board can exchange information (any variable, digital or analogue, according to the
application software) at high transmission speeds. Up to 32 units can be connected, sharing information
in very short times. The connection to the supervisor/tele-maintenance serial line, based on the RS485
standard, is made using the optional serial cards (PCO1004850) and the Carel or Mod Bus
communication protocol.
• The terminal, also managed by microprocessor, fitted with display, keypad and LEDs to allow the
programming of the control parameters (Set Point, differential band, alarm thresholds) and basic
functions by the user (ON/OFF, display of the controlled values, optional printing).The terminal does
not have to be connected to the pCO1 for normal operation, but can be used for the initial programming
of the fundamental parameters.
• The pCO1 has a variation of only on input and output configuration and available memory.
The following is a description of the pCO1 (Medium version) with reference to the basic layout:
Fig. 2.1.1
31
1. Power supply connector [G (+), G0 (-)]

2. 250Vac, 2A fuse, slow-blow (T2 A)
3. Universal analogue inputs, NTC, 0/1V, 0/5 V, 0/20mA, 4/20mA
4. Passive analogue inputs, NTC and ON/OFF
5. Passive analogue inputs, NTC
6. Yellow power LED and 3 signal LEDs
7. 0/10V analogue outputs and PWM phase-cutting outputs
8. Digital inputs, 24Vac/Vdc
9. Digital inputs, 230Vac or 24Vac/Vdc
10. Connector with Vref for power to 5V ratiometric probes, and Vterm for power to ARIA
terminal
11. Connector for all the standard pCO* series terminals and for downloading the application
software
12. PLAN local network connector
13. Connector for the programming key
14. Digital relay outputs
15. Door for selecting the type of analogue inputs
16. Door for inserting the serial card:
- RS485 for supervisor
- RS232 for modem interface
- Gateway (protocol converter)
17. Door for inserting the clock card
32
USER'S MANUAL
Installation
Power supply
The pCO1 can be powered at: 22/38Vdc and 24Vac ±15%, 50 z, with a maximum power input Pmax= 13W.
For alternating current power supplies, during installation use a Class II safety transformer, rated to at least
40VA and with a 24Vac output. To supply more than one pCO1 controller with the same transformer, its rated
power must be n x 40VA, where n is the number of controllers supplied by the transformer, independently of
the version of the controller. The power supply to the pCO1 controller/controllers and the terminal/terminals
must be separated from the power supply to the other electrical devices (power contactors and other
electromechanical components), inside the electrical panel. If the transformer secondary is earthed, make
sure that the ground wire is connected to terminal G0.When powering a series of pCO1 boards connected
in a pLAN network, make sure that the G and G0 connections are correct (G0 must be same for all the
boards). The table below summaries the possible status of the power LED.
LED Status Description

Yellow On Power Supply Present
Off Power Supply absent
Table 4.2.1
Fig. 4.2.1
33
The following warnings must be respected for correct connection:

• Power supply different from that specified can seriously damage the system;
• Use cable plugs suitable for the terminals being used. Loosen each screw and insert the cable plug,
and then tighten the screws. At the end of the operation lightly tug the cables to check that they are
tight;
• Separate as much as possible the probe signal and digital input cables from the inductive load and
power cables, to avoid possible electromagnetic disturbance. Never use the same channeling
(including that used for the electrical cables) for the power cables and probe cables. Avoid the probe
cables being installed in the immediate vicinity of power devices (contactors, circuit breakers or the
like);
• Reduce the length of the sensor cables where possible and avoid spiraling around power devices.
The probe connection must be made using shielded cables (minimum cross section for each lead:
0.5 mm2);
• Avoid touching or nearly-touching the electronic components on the boards, to avoid (extremely
dangerous) electrostatic discharges from the user to the components;
• If the power supply transformer secondary is earthed, check that the ground wire corresponds to the
lead connected to terminal G0 in the controller;
• Separate the power supply to the digital outputs from the power supply to the pCO1;
• Do not fasten the cables to the terminals by pressing the screwdriver with excessive force, to avoid
damaging the pCO1.
Connecting the analog inputs

The analog inputs can be configured for the more common sensors on the market: NTC, 0/1V, 0/
10V, 0/20mA, 4/20mA. The different types of sensors can be selected using the corresponding
dipswitches, as in the following figure.
Fig. 4.4.1
34
USER'S MANUAL
Warning: for the power supply to the active probes, the 24Vdc available at the +VDC terminal can be used;
the maximum current is 100mA, thermally protected against short-circuits.
Fig. 4.4.2
35
Connecting universal NTC temperature probes : All the analogue inputs, from B1 to B8, are compatible
with NTC 2-wire sensors, after having configured the program and the corresponding dipswitches on the
board. The connection diagram Fuse and the correct position of the dipswitches on the board are shown
below:
Fig.4.4.2.1
pCO3 terminal NTC probe wire

GND 1
B1, B2, B3, B4, B5, B6, B7, B8 2
Table 4.4.2.1
36
USER'S MANUAL
Fig. 4.4.4.1
pCO1 terminal Probe wire colour description

+5V ref black Power supply
GND green Power supply ground
B1, B2, B3, B4 White Signal
Table 4.4.4.1
Warning: the two wires of the NTC probes are equivalent, as they have no polarity therefore it is not necessary
to respect any specific order when connecting to the terminal block.
37
Connecting 0/5V ratio metric pressure probes : The pCO1 can be connected to all the Carel SPKT
series active probes pressure or any other pressure sensor available on the market with a 0/5V ratio metric
signal. The following inputs can accept these sensors: B1, B2, B3 and B4, after having configured the program
and the corresponding dipswitches on the board. The connection diagram and the correct position of the
dipswitches are shown below:
Fig. 4.4.5.1
Input type C.sect. (mm2) for C.sect. (mm2) for

lengths upto 50m lengths until 100m
NTC 0.5 1.0
1 (Current) 0.25 0.5
V (Voltage) 0.25 0.5
Table 4.4.6.2
38
USER'S MANUAL
Connecting the digital inputs :

The pCO1 features up to 14 digital inputs for connecting safety devices, alarms, device status, and remote
switches. These inputs can work at 24Vac, 24Vdc and some at 230Vac.
WARNING: separate the probe signal and digital input cables as much as possible from the inductive load
and power cables, to avoid possible electromagnetic disturbance
24Vac digital inputs :

The following figure represents one of the more common connection diagrams for the 24Vac digital inputs.
Connecting the digital outputs :

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

The connection between the user terminal and the pCO1 is made using a 6-way telephone cable supplied
by Carel.To make the connection, simply insert the telephone connector in terminal J10 on the pCO1 and in
terminal B on the user terminal. Insert the connector fully into in the terminal until it clicks into place. To remove
the connector, simply press lightly on the plastic flap and remove the cable.
The pCO1 can also work without the terminal; do not disconnect and then reconnect the terminal to the pCO1
without first having waited around 5 seconds (if the operation is performed with the unit on).
For devices used in residential environments or similar, and thus subject to CEI EN 55014-1 -04/98, any
standard terminals connected by J10 must use a shielded cable. The shield must be connected to the GND
terminal of J11.
39
The electrical connections are the following. Connect the telephone cable (code S90CONN00* from the power
board (code PCO1*) into the corresponding jack. For model PCOI00PGL0 only, connect the 24Vac (30VA)
power supply to the screw terminal block. If the same transformer is used for the pCO1, G and G0 must be
the same on the pCO1 and the terminal.
pAN network :
As already mentioned, the pCO1 controllers can be connected to the pLAN local network, allowing the
communication of data and information from one location (node) to another. Each pCO1 can be connected
to a Carel supervisory network, using the optional PCO1004850 cards.
The pCO1 terminals can monitor the control variables (temperature, humidity, pressure, I/O, alarms) from
one or more boards. If one or more terminals are disconnected or malfunctioning, the control program
continues to function correctly on each pCO1 board. Generally, the application program can monitor the status
of the network and intervene as a consequence to ensure the continuity of the control functions.
Figure 5.1, shows the pLAN network connection diagram: a maximum of 32 units can be connected (including
I/O interface cards and user interface cards).The 32nd unit can only be a terminal. All the versions of the
pCO1 can be connected in a local pLAN network without requiring additional boards (Fig. 5.1).
The programs for the different applications (e.g.: standard chiller, standard air-conditioner, compressor packs,
...) can not be automatically integrated into a local network: they must be modified to consider the network
strategy and structure, and then be recompiled using the Easy Tools system.
All the devices connected to the pLAN network are identified by their own individual address, from 1 to 32 for
the terminals and from 1 to 31 for the I/O boards. As the terminals and the pCO1 I/O boards use the same
type of address, terminals and pCO1 boards cannot have the same identifier.
The addresses are set for the terminals using the dipswitches on the rear. The network can be made up of
any type of terminal, LED, 4x20 LCD and graphic, as well as pCO and pCO1 controllers.
40
USER'S MANUAL
Setting the pCO1 address :

The pCO1 controller does not have dipswitches for setting the pLAN network address.The pLAN address is
set using a standard 4x20 LCD terminal. Proceed as follows:
• Disconnect the pCO1 from the power supply;
• Organise a standard Carel 4x20 LCD terminal with the address set to 0;
• Connect the terminal to the pCO1;
• Disconnect the pCO1 from any plan connections to other controllers (terminal J11);
• Power the pCO1, pressing the UP and ALARM buttons at the same time;
• After a few seconds the following screen will be displayed:
• To modify the address simply use the UP and DOWN buttons, and then press ENTER to confirm.
Setting the terminal address :

The address can be set in the range from 1/32 using the dipswitches 1/6 on the rear.
The graphic terminal does not require the setting of the address, as this is determined by the program EPROM.
Fig. 5.2.1 shows the rear view of the terminal board.
Fig. 5.2.1
Important Warning: if the application software does not envisage a pLAN local network, the dipswitches
must be positioned to 0.
41
5.4 pLAN Electrical Connections

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

Reading the 3 LEDs on the pCO1 board
The pCO1 board features 3 signal LEDs (red, yellow and green) that provide information on the operation of
thepCO1 board and the status of the connection to WinLoad32.
42
USER'S MANUAL
Key
LED off LED on LED flashing
43
*: Cases in which pCO1 reverts to Low Level status:

- When starting the pCO1 detects that Win Load is connected.
- When starting the pCO1 detects “Application corrupted…”.
- During normal operation the pCO1 runs a JUMP atom without the correct reference or backwards.
After 20 seconds of Low Level status without Win Load connected, the pCO1 is automatically reset.
• If the pCO1 is started with the key inserted and the key switch is set to Key (see Fig. 6.1.1), (SELECTION
LED red ), without pressing the buttons on the local terminal, the program resident in the key is run,
without modifying the program resident in the pCO1.
In practice, the pCO1 controller can run an alterative program and/or setup to the resident version. This
function is useful for testing upgrades to the BIOS and/or APPLICATION, without overwriting the software
resident in the pCO1. It is also very useful for running special functions or parts of programs (e.g. final
functional tests) using special parameter
Configurations and/or programs (expressly developed for these functions), without modifying the program
resident in the pCO1.Only the program and/or parameter configuration resident in the key are modified.
Once this phase is complete, switch off the pCO1 controller, remove the key, and when starting the pCO1
the next time, the original program and setup are used.
• If, on the other hand, the key switch is set to pCO1 (SELECTION LED green) and the buttons on the
local terminal are not pressed, the key has no effect.
• To display or modify the pLAN address, use the local terminal: switch off the pCO1, remove the terminal
from the pLAN network, connect the user terminal with address set to 0, start the pCO1 and hold the
ALARM and UP buttons until the screen is displayed showing the pLAN address, then follow the
instructions on the screen.
• The current version of program can be checked at any time (by CRC code expressed in hexadecimal),
and whether the program on the key or the resident program is used. To check this, simply proceed as
follows.
Press the alarm and enter buttons together for 3 seconds, and the following screen will be displayed:
Confirming with enter displays a second table, as shown in the following example:
44
USER'S MANUAL
1st row BOOT: version and date. The pCO1 is working with BOOT 2.05, 24/01/02
2nd row BIOS: version and date. The pCO1 is working with BIOS 2.40, 20/02/02
3rd row Flash ON BOARD and KEY, if present. The characters (>_<) indicate the pCO flash: to the left if
the pCO1 is booted
From the flash ON BOARD (switch on )and SELECTION LED red green ), or to the right if the
pCO1 is booted from the key (key switch on Key and SELECTION LED red ). In the example, the
pCO1 is running the BOOT, BIOS and application present ON BOARD, and has a 2MB key inserted.
4th row APPLICATION: CRC and flash occupied. the application CRC Is FA90 and requires a memory of
1MB to be run. If this row shows the indication 2MB, a pCO1 with 2MB is required.
Exit these two screens by pressing the menu button on the local terminal, or automatically by timeout after
around 40 seconds.
General diagram of the electrical connections :

Below are two examples (Figs.8.1 and 8.2) of the electrical connections of the pCO1 to the various devices.
Fig. 8.1
45
pCO1
pCO1 Medium (18 Din modules)
Fig. 12.12
I/O Expansion Board Led Indication
46
USER'S MANUAL
Screw Compressor
Construction
HANBELL semi-hermetic twin-screw compressors are constructed with the following three major
components; the compressor compartment, the hermetic motor compartment and the oil separator
compartment.
The compressor compartment includes twin-screw helical rotors, bearings and components for capacity
control system.
The hermetic motor compartment includes the motor stator, motor rotor, six terminal plugs for electric power
connections, an internal thermostat inserted into the stator coil to protect the motor from burning out, two
terminal plugs for the thermostat, and a suction gas strainer.
The oil separator compartment consists of demister and chambers to serve as an oil separator and an oil
reservoir. The rotor of the hermetic motor is connected directly at the suction end of the male rotor shaft and
drives the rotor shaft at rated speed of 2,950 rpm at 50 Hz and 3,550 rpm at 60 Hz respectively.
47
Fig. 1 Construction of Screw Compressor
1. Compressor casing 19. Disc spring
2. Motor casing 20. α Balance piston

3. Oil separator 21. Bearing slot nut
4. Motor rotor assembly 22. Male rotor
5. Motor stator assembly 23. Suction bearings
6. Motor rotor washer 24. Suction bearings inner/outer
spacer ring
7. Motor rotor spacer ring
25. Oil guiding ring
8. Oil Separator Baffle
26. Oil level sight glass
9. Oil separator cartridge
27. Oil filler cartridge
10. Piston
28. Suction filter
11. Piston spring
29. Oil heater
12. Piston rod
30. Refrigeration Lubricant
13. Bearing set’s cover plate
31. Suction flange
14. Modulation solenoid valve
32. Discharge flange
15. Modulation slide valve
33. Cable box
16. Slide valve key
34. Power bolt
17. Discharge bearings
35. Thermostat terminals
18. Discharge fixed ring
36. Motor cable cover plate
48
USER'S MANUAL
Capacity Control System

The BSC (RC) series screw compressors are equipped with 4-step capacity control system. The capacity
control systems consist of a slide valve, piston rod, cylinder, piston and its rings. The slide valve and the
piston are connected by the piston rod. The principle of operation is using the oil pressure to drive the piston
in the cylinder. See Fig 2.2 , The lubrication oil flows from the oil tank through the oil filter cartridge and capillary
and then fills into the piston cylinder due to the positive oil pressure higher than the right side of spring force
plus the high pressure gas. The positive pressure differential causes the piston to move towards the right
side within the cylinder. When the slide valve moves towards the right side, the effective compression volume
in the compression chamber increases. This means the displacement of refrigerant gas also increases as
a result to achieve higher refrigeration capacity. However, when any of the step solenoid valves is energized,
the high pressure oil from the piston cylinder bypasses to the suction port to cause the piston with piston
rod link for the slide valve moving towards the left slide, then some of refrigerant gas by passes from the
compression chamber back to the suction end. as a result, the refrigeration capacity decreases owing to
the reduction in displacement of refrigerant gas flow in the system.
The piston spring is used to force the piston back to its original position, i.e. 25% position in order to reduce
the starting current while the next startup. If the compressor starts at full load, will result in larger starting
current which could damage the compressor motor. The capillary is used to maintain and restrain a stable
amount of oil flow to the cylinder.
If there is any oil filter cartridge, capillary, or modulation solenoid valve malfunction in the capacity control
system, will result in the abnormal operation of the capacity control system.
4-step capacity control system (See FIG 2.2)
There are three solenoid valves equipped on compressor that control the compressor capacity from dead
stop (25%) to full load (100%). They are 25% capacity, 50% capacity, 75% capacity and 100% capacity. There
are three normally closed solenoid valves that are used to control the various required in the capacity. For
the compressor if selected for 4-step capacity control system, it is usual to be used with the sequence of
25%-50%-75%-100% to load the capacity of compressor and to be used in sequence of 100%-75%-50%
to unload the capacity. If 25% capacity is essential to be kept running for a long time, the problem of oil return
and motor cooling and high discharge temperature etc should be considered by adding the accessories such
as liquid injection devices.
a. 25% capacity
When solenoid valve of SV1 is activated, the high pressure oil in the cylinder bypasses directly to the
suction port, so the piston be held at its initial position. Be sure to take 30 seconds at least after every
starting the compressor at this low capacity stage. After that, the compressor could be loaded gradually.
b. 50% capacity
When solenoid valve of SV3 is energized by the temperature controller and also de-energized of 25%
(SV1) solenoid value simultaneously, the high-pressure oil in the oil tank flows into cylinder due to the
closure of 25% valve that pushes the piston towards the position where a hole is provided which also
drains the oil back to the suction port at exactly 50% position in case the piston holding there..
49
c. 75% capacity
When solenoid valve of SV2 is energized, the 75% capacity solenoid valve will perform the same way as
the above b. 50% capacity illustrated.
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 right side gradually until the slide valve touches the
end side in the compressing chamber and the piston also reaches its dead end entirely where no bypass
of compression gas occurs. Hence full load is achieved.
Step Capacity Control System
No. Component No. Component
1 Suction fiilter 10 Lubricant
2 Gas in low pressure 11 Oil separator cartridge
3 Motor 12 Gas out (high pressure without oil)
4 Oil filter cartridge 13 Capillry
5 Suction bearings 14 Solenoid valve (25% of full load),SV1
6 Male rotor 15 Solenoid valve (50% of full load),SV3
7 Discharge bearings 16 Solenoid valve (75% of full load),SV2
8 Discharge silencer 17 Slide valve
9 Gas out high pressure with oil
50
USER'S MANUAL
Lubricant
The main functions of the lubrication oil in screw compressor are lubrication, internal sealing, cooling and
capacity control. The positive oil pressure in the cylinder pushes the piston and the slide valve, which is
connected by a piston rod to move forward and backwardin the compression chamber. The design with
positive pressure differential lubrication system in the BSC series is available to eleminate an extra oil pump
in the compressor.
The bearings used in BSC compressor require a small but steady quantity of oil for lubrication; the oil injection
into the compression chamber creates an oil sealing film in the compression housing for increasing the
efficiency and absorbing a portion of heat of compression.
In order to separate the oil from the mixed refrigerant gas, an oil separator is required to ensure the least
amount of oil carried into the system. Pay more attention to the oil temperature, which is a very significant
factor for the compressor bearings’ life. High oil temperature will reduce the oil viscosity and cause poor
lubrication and heat absorption in the compressor as well. It is recommended to keep the oil viscosity above
15mm2/s at any temperature. If the compressor is operated under the critical conditions, (high discharge
pressure) then extra oil cooler is required. Some high viscosity oil is recommended for applications with high
working condition. It happens often that the return oil from the evaporator is insufficient due to the high viscosity
of oil, which is difficult to be carried back, that causes the loss of oil in compressor. If the system encounters
the oil return problem then it is recommended to install extra 2nd oil separator between the compressor
discharge connection and condenser.
Each of BSC series of compressors are equipped with two oil sight glasses as a standard; one is the oil
high level sight glass and the other is the oil low level sight glass. The normal oil level in the compressor oil
tank should be maintained above the top of the low oil sight glass and in the middle level of high oil sight
glass when compressor is running. It is recommended strongly to install the optional accessory of oil level
switch to prevent from low oil level in compressor.
Warnings:
a. Use specified oil and do not mix with different brands of oil. Different kinds of refrigerant should
match with different kinds of oil. Note that some synthetic oils are incompatible with mineral oil.
Prior to fillery oil in the compressor, the system should be totally cleaned up during the initial startup
and ensure that it is clean completely.
b. For the chiller system using synthetic oil, avoid the exposure of oil to the atmosphere too long, it
is also necessary to vacuum the system completely when installing the compressor.
c. The table below shows the oil replacement standard. Each compressor at HANBELL charges
standard quantity of oil.
d. In order to take out the moisture from the system, it is suggested to clean the system by hot air or
Nitrogen, thereafter vacuum the system as long as possible. It is essential to change new oil into
the system especially after the motor burn out, the acidic debris will still remain inside the system,
hence follow the above mentioned procedures to overhaul the system. Check the oil acidity after
72 hours operating and then change it again and again if the limit is still over the oil acidity standard
until been qualified.
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Oil Replacement Standards

Item Value Item Value
Color, ASTM Above 6.0 Total acid number Above 0.5
mg KOH/g
Particle Matters mg/100ml Above 5.0 Copper Strip 100oC/3hrs Above 2.0
Viscosity 40oC Variation ±10% of Moisture ppm Above 100
2
15mm / Sec or more
Changing oil
Lubrication oil is the most important factor to maintain the operating, lubricating, cooling, sealing and driving
the capacity piston of the compressor. Following are the probable problems existing in the system that should
be faced:
1. Contamination of oil by debris causes clogging in the oil filter.
2. Acidified system due to the moisture causes corrosion in the motor.
3. Spoiled oil due to the compressor running at long duration of high discharge temperature reduces life
of bearing.
Refer to the following oil change intervals to ensure normal running of the compressor.
1. Change the oil periodically: Check the oil for after every 10,000 hours of running periodically for the
first operation cleaning of filter and oil change is recommends after 20,000 hours of operation hours is
recommended. Due to the piping debris could be accumulated inside the system after operation, check
the oil after 2,500 hours or after one year of running. Check the system whether clean or not and then
change the oil after every 20,000 hours or after 4 years running while the system is operated under
good condition.
2. Prevent debrics from getting clogged in the oil filter. Clogging can cause fearing failure. Installing an
optional oil pressure differential switch is recommended an optional oil pressure differential switch is
recommended to be installed. The switch will trip when the oil pressure differential reaches the set
point between the primary and secondary sides and the compressor, will shut down to prevent the
bearings damage to bearingsdue to lack oil.
3. If the compressor discharge temperature often keeps high approaching to the set point, then the oil
will be spoiled gradually in short time, hence check the oil characterestic every 2 months if possible.
It is necessary to change the oil if the character of the oil is out of the standard. In case oil characterestic
could not be checked periodically, then change the oil after 4 years’ of installation or after 20,000 hours’
of running which reaches first.
4. Acidity in lubrication oil shortens life of bearing and motor. Check the oil acidity periodically and change
the oil if the oil acidity value measured is lower than PH 6. Change the deteriorated drier periodically if
possible to keep the system dry. Check the acidity of oil after 72 hours of initial of operation.
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USER'S MANUAL
5. Refer to the oil changing procedures especially after the system overhaul owing to the motor burn out.
Check the oil monthly or periodically and change the oil if it is if bad quality, it is necessary to take care
of the oil quality and system cleanness and dryness in the system periodically.
The Compressors are charged with Blue Star ACS oil for the Air Cooled and Water Cooled Application
and for R22
Liquid injection
The liquid injection to the suction side of the compressor, is carried out by providing a separate thermostatic
expansion valve in the system. (Low-temp type expansion valve) The flow of liquid refrigerant is controlled
through the expansion valve by the suction superheat directly.
Application of liquid injection :

The compressor motor temperature and its compression chamber temperature will be very high almost
approaching the setting of motor thermister and discharge temperature thermister, which often result in the
trip of the sensors under the above working conditions causing the chillers to shut down.
The purpose of installing a liquid injection system is to prevent the compressor motor from overheating, an
expansion valve is installed in the system with tube piped between the liquid line and compressor for cooling
down the compression chamber and motor to ensure that the compressor can be run continuously and safely.
The suction superheat should be controlled between 5 to 10 deg.C for the application of water cooled screw
chillers by means of the expansion valve devices. During the initial start up, the loading of the chillers will be
heavy due to the higher temperature of return chilled water, hence the liquid injection devices of adequate
capacity should be selected to reduce the overheat of the compressor.
When the compressor is operated for low temperature system (E.T=< -10 deg. C), the compression ratio
will be high at this condition and also the discharge temperature. Hence the use of liquid injection system is
essential.
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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 50
Deg.C before starting the compressor. Keep the oil heater energised after the compressor is shutdown
for preparation of next start-up, to keep the oil temperature over the minimum required value, which is
essential especially under low ambient condition.
3. Recheck the settings on each controls
4. Establish the chilled water flow through the cooler. Adjust the water flow rate to the designed rated flow.
Connect the Chilled water flow switch with Micro Control Panel.
5. 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.
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2) Maximum Discharge Pressure: 18 kg/cm2 g

3) Minimum Suction Pressure: 6~8 kg/cm2 g
4) Maximum designed discharge pressure: 28 kg/cm2 g
5) Maximum designed discharge temperature: 110 Deg. C
Starting 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
BSC-075A 685 230

BSC-105A/ BSC-110W 735 245
BSC-130W 965 325
BSC-145A/ BSC-155W 1100 370
BSC-160A/ BSC-170W 1480 495
BSC-210A/ BSC-220W 1760 590
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 25% capacity.
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USER'S MANUAL
The running restraint of compressor

1. Compressor restart frequency
The restart counts for the models BSC - 077W, BSC - 105W, BSC - 145W, BSC - 160W and BSC
- 210W 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 25% capacity.
3. Supply power
Long term running => +15%
Instant Running => +10%
Frequency : +2 %
Phase current unbalance: The difference in phase current between the biggest phase current differential
and smallest phase current differential is required to be less than 3 %
4. Phase voltage unbalance: +2.25 %
5. Range of ambient temperature: -10 Deg. C to 55 Deg. C
6. The control voltage is normally 220 V
7. Protection switch
The table below shows the list of protection switches, which are essential to protect the compressor and
operate safely
Protection Switch Set Point
Motor winding Cut out 120 Deg. C

temperature protector Cut in 75 Deg.
High discharge Cut out 110 Deg. C

temperature protector Cut in 60 Deg. C
Phase reversal protector Phase reversal when power on
Hi – Low pressure protector Highest pressure 25 Kg/Sq.cm g

Phase failure protector Phase failure when compressor
starting or running
Motor overload relay Set by a related application
value, any setting should be
tripped in 15 sec.
Hi-Low Voltage protector Rated Voltage + 15 %
Oil level switch Oil level lower than the

floating ball
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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
Liquid Injection 1, 2 OFF
Economiser * OFF
Oil Cooler Fan * OFF
Condenser Fan A,B,C etc. * OFF
*Applicable only for Air Cooled Screw chillers
(1) Switch on power supply through Rotary Switch (mounted in control section). The unit goes in power up
mode. In this state, all relay outputs are turned OFF. Controller will initialise & monitor Power Supply
stability for 90 seconds.
Switch ON individual system toggle switches (mounted in control section) to enable demand for
respective compressors.
(2) After the power up delay, the system goes in ON state. Controller checks for any anti-cycle (fault) timers
leftovers and then generates demand for the first compressor based on set point and actual chilled water
temperature.
(3) All three Solenoid Valve (SV1, SV2, and SV3) are kept de-energised after initial power up delay to ensure
unloaded start of compressor.
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USER'S MANUAL
(4) Compressor starts with ‘Fast Unload’ logic. Condition of the relay outputs is as follows:
Relay output Condition

Main 1, 2 ON
Pilot Solenoid valve 1, 2 ON
Liquid Injection 1, 2 OFF
Economiser * OFF
Oil Cooler Fan * OFF
Condenser Fan A,B,C etc. * OFF
*Applicable only for Air Cooled Screw chillers

(5) One bank of condenser fans goes ON with corresponding compressor. (Applicable in case of Air Cooled
Chillers)
(6) Depending on difference between the leaving water temperature and set point, the system shall load or
unload. The operation of the load or unload solenoid valves is as under for individual compressor
Sl. No. Capacity Control System SV1 SV2 SV3

1 100 % Of Full Load On On On
2 75 % Of Full Load On Off On
3 50 % Of Full Load On On Off
4 25 % Of Full Load Off On On
5 Shut Down and Initial Fast Unloading Off Off Off
(7) When compressor-1 is at 100% load (or unable to load further due to safety hold), demand for the second
system is generated to meet further load.
(8) The 1st Compressor unloaded to minimum 50% slide position and 2nd compressor is started as per the
sequence given in steps 4 to 6
(9) Thereafter both compressors are loaded / unloaded simultaneously .If load goes below 50 %, one
compressor will switched off and other will utilizes the available full capacity. (Unless any of the
compressors goes in safety hold).
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Shut down sequence
• To shut down complete chiller switch off rotary switch provided in panel. To switch OFF a particular
compressor, respective toggle switch should be switched off.
• During normal shut-down through controller, Compressor runs for preset time to enable unloading
of slide to minimum position before switching OFF
• Run Time Equalization
Controller has ‘minimum run time equalization’ logic option (set point 103 should be 0 and set point 104 should
be 1). Compressor which runs for minimum time shall start first during next operation cycle.
Safety Parameters
During normal running of compressor (s) following safety Parameters are monitored :
Sr. No. Set Point Description Trip Delay (Seconds) Default Setting
1 Hi amps 2 105 %
2 Low amps 5 15 %
3 Low suction 120 20 psig
4 Low gas / LSV FLT 10 15 psig
5 High discharge 2 250/375 psig
6 Low discharge 90 80 psig
7 Low oil differential 180 50 psig
8 Unsafe Oil 4 20 psig
9 Anti freeze * 5 39oF
* In case of Anti Freeze, all the Circuits of the entire Chiller are locked out.
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USER'S MANUAL
To avoid nuisance tripping during compressor start up, following initial by pass / time delay adjustment
procedure is observed.
Set Point Description Bypass Time Delay Adjustment*

Hi amps For first 3 seconds —
Low amps For first 3 seconds —
Low suction During pump down
Low gas / LSV FLT — 2 Min for 30 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. Liquid injection system switches ON at Discharge Temperature of 165ºF and switches OFF at
Discharge Temperature of 155ºF.
3. The Economizer Solenoid Valve activates at 75% of Slide positions and turns off at 65% of slide
position. (Applicable for air cooled chillers only)
4. One bank (50% of the total No. of fans) of condenser fans switches ON at discharge pressure 200
psig and turns OFF at 140 psig. (Applicable for air cooled chillers only)
5. The delay between the Star and Delta connection is preset at 3 seconds.
6. Low-pressure setting is at 15 psig and High-pressure setting is at 250 /375 psig.
7. Anti Freeze Thermostat setting is at 39ºF
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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.
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USER'S MANUAL
• Slide Valve Countdown - value that is counted down. The Slide Response and where the control
temperature is in relationship to the control zone will determine the speed of the count down.
When the value decrements to zero, the system will determine if a change in the systems
capacity is required.
• Wanted Slide % - Wanted slide percentage
• Trend Of Load – Trend Of Load of control sensor, the speed at which the control sensor is
changing.
Circuit information (all active circuits will be displayed):
• Circuit Number and State - Circuit number and state.
• TIME - time in that state, if the state is CMP ANTICYCLE time will decrement to zero.
• Oil Diff - Oil differential pressure. Oil differential pressure is calculated as follows:
Semi hermetic screws; Oil psi – Suction psi or Discharge psi – Suction psi.
• Lead - indicates the lead compressor.
• FLA %: Full Load Amps based on the set point.
2. Capacity Control State

Capacity Control States are active for all five releases of software.
UNIT IN POWER UP
This state is entered when the Controller is powered up or the system has been reset. The system will
remain in this state for the time specified in set point POWER UPDELAY, set point 23, or if not active for
60 seconds. In this state all points (RO’s) are turned off. This is a time delay to insure the controller has
stable power before starting the algorithm.
UNIT IN LOCKOUT
This state is entered whenever a critical situation is encountered that could cause harm to the chiller
package. Items such as freeze protect and emergency stop will force the system into this state.
Lockouts can be reset with user level authorization from the keypad; however if the lockout condition has
not been corrected, the system will again be forced into the LOCKOUT state.
NOTE: If the Lockout reset is pressed more than 10 times in a day the unit cannot be reset till Factory
authorization.
EXPANSION BOARD OFFLINE

This state will be entered whenever the controller loses communications with any of the I/O boards that are
connected via the network. When this state is entered the system will generate an off line alarm, which
locks out the unit. The lockout-reset key must be depressed to reset the system, after the lost I/O has been
corrected.
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SWITCHED OFF
This state is entered when the run stop switch is off, in the stop position. When the chiller is in this state,
the individual circuit states if active are moved to the CMP IS OFF state through the normal states.
SCHEDULED OFF
This state is entered when the schedule is calling for the package to be off. When the chiller is in this state,
the individual circuit states if active are moved to the CMP IS OFF state through the normal states.
OFF- NO EVAP FLOW

This state is entered when the evaporator flow switch is off. When the chiller is in this state, the individual
circuit states if active are moved to the CMP IS OFF state through the normal states. The controller will
generate the alarm in this condition and not required to be reset if alarm is clear.
UNIT IS HOLDING
This state is entered when one of three conditions exists:
1. The control sensor reading is being maintained with in the control zone.
2. Control sensor reading is above the control zone but the Trend Of Load is less than the value in
the set point. This indicates that the temperature is decreasing toward the target at an acceptable
speed. Therefore, no additional cooling is needed at this time.
3. The temperature is below the control zone but the Trend of Load is greater than the set point. This
indicates that the temperature is increasing toward the target.Therefore, no reduction in cooling is
needed at this time.
This state indicates that there is no need to adjust the cooling capacity of the chiller package. This
state will be exited when more or less capacity is required.
3. Circuit Control States

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

This state is entered when the Capacity Control State is LOCK OUT or a safety set point for this circuit
has indicated that a critical situation has been encountered. Set points such as LOW SUCTION, HI
DISCHARGE PRESSURE etc. are examples of safety set points. Lockouts can be reset with USER level
authorization from the keypad; however if the lockout condition has not been corrected, the circuit will again
be forced into the LOCKOUT State.
SAFETY TRIPPED
This state is entered when a safety trips but a lockout is not to be generated. An alarm is generated but
the system will restart after the delay specified in the corresponding set point. If a second trip occurs within
the time specified in the set point, the circuit will be placed in the CMP LOCK EDOUT State.
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USER'S MANUAL
CMP OFF / READY

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

This state is entered whenever the pump down switch has been turned on or if this circuit is no longer
wanted on. The compressor is on and the liquid line solenoid is closed. This state is active until the suction
pressure reaches the value in the set point PMP DWN DELAY. The circuit will then move to the ANTICYC
State.
CMP ANTICYCLE
This state is entered when the PMP DWN State has been completed. The circuit will stay in this state with
all circuit points off for the period of time contained in either set point “ANTYRECYCLE TIME “. The circuit
will then move to the OFF State.
FAST UNLOADING
For screw compressors, this state is entered when the compressor is turned on. The system will remain
in this state for 60 seconds while the “fast unloader” and unload points are on. This is to ensure that the
screw is unloaded.
CMP IS HOLDING
This state only exists for infinite step compressors (Three solenoid valve SV1,SV2 & SV3 ). In this state,
the required refrigeration capacity of system is being meant; no movement of the slide valve is required.
CMP IS AT 25%
This state is when the compressor is providing 25% of its capacity. In this state, the relay output to activate
the 25% valve is turned on.
CMP IS AT 50%
CMP IS AT 75%
CMP IS AT 100%
This state is when the compressor is fully loaded. In this state, the circuit is providing the maximum amount
of cooling capacity.
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HI DISC UNLOAD
Refer to set points HI DISCH PSI, HI DISC UNLD, HI DISC RELD7 and HI DISCH TMP, HI DISCH UNLD
and HI DISCH RELD.
This state is entered when a fully loaded circuit, that has more than one step, has encountered either a
dangerously high discharge pressure or discharge temperature. One step of cooling capacity will be turned
off. The circuit will remain in this state for a minimum of five minutes before returning to the LOADED state
if the dangerous condition has been corrected.
When capacity is being held due to a high discharge condition, once the discharge goes to normal operating
condition the circuit will return to its appropriate state.
LO SUCT UNLOAD
Refer to set points, LOW SUCTION, LO SUCT UNLD and LO SUCT RELD.
This state is entered when a fully loaded circuit, that has more than one step, has encountered a dangerously
low suction pressure. One step of cooling capacity will be turned off. The circuit will remain in this state
for a minimum of five minutes before returning to the LOADED State if the dangerous condition has been
corrected. When capacity is being held due to a low suction pressure condition, once the suction pressure
returns to a normal operating condition the circuit will return to its appropriate state. This should be same
for “LOW GAS “
LO TMP UNLOAD
The circuits leaving liquid temperature have caused the system to unload. When the leaving liquid temperature
gets to within 1.5 degrees F of the Freeze set point, the unload will occur before we hit the freeze protect
safety.
HI AMP HOLD
This state is entered when a fully loaded circuit, that has more than one step, has encountered a dangerously
high AMP draw. Refer to set points for FLA per circuit and HI AMPS %. In this state, one step of cooling
capacity will be turned off. The circuit will remain in this state for a minimum of five minutes before returning
to the LOADED State if the dangerous condition has been corrected.
4. Condenser Control Logic

4.1 Condenser Fan Cycling Logic
The air condenser set points are as follows:
Set point CND STG1 ON - Condenser stage 1 cut in (ON).
Set point CND STG1 OFF - Condenser stage 1 cut out (OFF).
Set point CND DIFF ON - Differential between condenser stages for cut in (ON).
Set point CND DIFF OFF - Differential between condenser stages for cut out (OFF).
Set point CND MIN RUN - Minimum run time for a condenser stage when the discharge pressure reaches
this value the first condenser point is turned on. If additional condenser points exist, they will be turned on
when the pressure exceeds the previous cut in value plus the value contained in (COND DIFF IN) set point.
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USER'S MANUAL
As the discharge pressure is reduced, the condenser points will be turned off based upon the set point
(COND ST1 OFF) value plus the condenser step times the value contained in (COND DIFF OUT) set point.
The first step will be turned off based upon the valve in the set point (COND ST1 OFF).
Example Set point 45 CND STG1 ON = 200.0P
Set point 46 CND STG1 OFF = 170.0P
Set point 47 CND DIFF IN = 20.0P
Set point 48 CND DIFF OFF = 5.0P
COND FAN1 ON @ 200.0P DISCHARGE
COND FAN 1 OFF @ 170.0 P
COND FAN2 ON @ 220.0p (200.0 + 20.0)
COND FAN2 OFF @ 175.0p (175.0 + 5.0)
COND FAN3 ON @ 240.0p (220.0 + 20.0)
COND FAN3 OFF @ 180.0p (170.0 + 10.0), etc.
5. Set Point Definitions

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

This type of set point’s value contains a target or provides information for some type of action. The time
element in this type is not used
5.1.2. LOCKOUT
This type of set point’s value contains a safety level and the time that the safety must be violated before
the safety will trip. Once a safety has tripped the system will take the appropriate action, shutting down the
entire package or an individual circuit (compressor) depending on the purpose of the safety. The system
will then wait the safety down time contained in that set point before trying to return the system to normal.
If successful, the system will continue to operate. If a second trip occurs on the same set point with in the
lock out delay time that is contained in that set point the system will move to a LOCKOUT state. IF THE
LOCKOUT DELAY TIME IS SET TO ZERO THE LOCKOUT WILL OCCUR ON THE FIRST TRIP. This
will require manual intervention to reset the system. With each safety trip, the system will generate an
alarm; refer to Alarms and Safeties section of this manual.
5.1.3. ALARM
This type is similar to the LOCKOUT set point except it will never cause a lock out. The system will continue
to try to return to normal operation after waiting the safety down time. An ALARM set point type will never
require manual intervention to reset the system.
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6. Set Points for Chiller Controller Algorithm

6.1 Control set points
1. CTL TARGET Controlling target is used with the ctl zone & slope and is leaving liquid
2. CTL ZONE + Added to the CTL TARGET to create the top of the control zone.
3. CTL ZONE - Subtracted from the CTL TARGET to create the bottom of the control zone.
4. L.INJECT.ON Liquid injections is turned on when the discharge temperature is equal to or greater
than this set point and turned off when the discharge temperature is less than this set point
minus 5.
5. POWERUP DELAY
This is the time that the system will remain in the START UP state before moving to the next state.
6.2 Capacity Control Logic

1 SLIDE RESPONCE This value is used to adjust the speed of responding to changes in the control
algorithm. 1= faster response HIGHER number’s = slower response.
2 SLIDE VALVE COUNTDOWN This is the time delay before increasing or decreasing the number
of refrigeration steps.
3 MAX TREND OF LOAD - Maximum negative Trend of Load allowed before stopping the unit from
loading. If the actual ROC is less than this value the capacity control state is placed in the
HOLDING state.
4 MAX TREND OF LOAD + Maximum positive Trend of Load allowed before stopping the unit from
unloading. If the actual ROC is greater than this value the capacity control state is placed in the
HOLDING state.
5 TREND OF LOAD INTERVAL Number of second between the samples used for calculating the
actual Trend of Load
6.3 Set Points for Compressor Control

1 ANTYCYCLE This is the anti cycle time delay (in seconds) based on when the compressor was
turned off. It will vary from compressor to compressor.
2 PMP Down Delay Maximum time delay (in seconds) that a compressor can remain in the PUMP
DOWN state.
3 Comp Min Run this is the minimum run time (in minutes) for a compressor once it is turned on.
This minimum run time is bypass only for the safeties.
4 FLA Comp#1 Full Load Amps for the compressor on circuit 1.
This value is used to calculate the high and the low ampere safeties limits.
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USER'S MANUAL
6.4 Set Points for Compressor Safeties

1. HI AMPS : This set point is a percentage of the FLA; it is used to create the high amp draw limit.
This value is tested in the high amp safety, if the amps exceed this value for the time specified
in this set point the safety is tripped.
2. LOW AMPS : This set point is a percentage of the FLA; it is used to create the low amp draw
limit. This value is tested in the low amp draw safety, if the amps exceed this value for the time
specified in this set point the safety is tripped.
3. LOW SUCTION : If active, the system checks for low suction pressure for each running compressor.
The system will compare the suction pressure sensor reading to this value. It must be less than
the value for the period of time specified in the set point before this set point will trip.
4. LOW SUCT UNLOAD: The purpose of this set point is to take corrective action before a low
suction pressure safety occurs. If a circuit has more than one step and it is fully loaded and if the
suction pressure is less than the value of the safety set point (LOW SUCTION) plus the value of
this set point, the system will turn off one step of capacity.. The circuit state will be changed to
LO SUCT HOLD. The circuit will remain in this state for a minimum of 5 minutes. At that time, if
the suction pressure has increased to a level greater then the value of set point LOW SUCTION
plus the value of set point LOW SUCT RELD the compressor will return to normal control.
5. LOW SUCT RELD: The system will force to load if requirement ,if this setpoint is satisfied
6. UNSAFE SUCT : If active, the system checks for low suction pressure that is in an unsafe
condition for each running compressor. The system will compare the suction pressure sensor
reading to this value. It must be less than the value for the period of time specified in the set point
before this set point will trip. Note the time period specified should be very short, 2-5 seconds. This
safety set point trips the circuit to the LOCKOUT state immediately, no retry.
7. HI DISC PSI : If active, the system checks for high discharge pressure condition for each running
compressor. The system will compare the discharge pressure sensor reading to this value. It must
be greater for the period of time specified in the set point before this safety will trip.
8. HI DISC UNLOAD : The purpose of this set point is to take corrective action before a high
discharge pressure safety occurs. If a circuit has more than one step and it is fully loaded and its
discharge pressure exceeds the value of the safety set point HI DISCH PSI minus this set point,
the system will turn off one step of capacity. A screw compressor will be forced to unload until the
discharge pressure falls below the calculated value. The circuit state will be changed to HI DISC
HLD. The circuit will remain in this state for a minimum of 5 minutes. At that time if the discharge
pressure has dropped below the value of the HI DISCH PSI minus the HI DISC RELD the compressor
will return to normal control.
9. HI DISC RELD : This set point works same as Low Suct Reld
10. LOW DISC PSI : If active, the system checks for low discharge pressure. The system will
compare the sensor reading to this value. It must be less than the value for the period of time
specified in the set point before a safety trip occurs.
11. HI DISC TMP : If active, the system checks for high discharge temperature condition for each
circuit that has at least one step on. The system will compare the discharge temperature sensor
reading to this value. It must be greater for the period of time specified in the set point before this
safety will trip.
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12. HI DISC UNLOAD : The purpose of this set point is to take corrective action before a high
discharge temperature safety occurs. If a circuit has more than one step and it is fully loaded and
its discharge temperature exceeds the value of the safety set point HI DISCH TMP minus this set
point, the system will turn off one step of capacity. A screw compressor will be force to unload until
the discharge temperature falls below the calculated value. The circuit state will be changed to HI
DISC HLD. The circuit will remain in this state for a minimum of 5 minutes. At that time if the
discharge temperature has dropped below the value of the HI DISCH TMP minus the HI DISC
RELD the compressor will return to normal control.
13. HI DISC T RELD : This set point works same as LOW SUCT RELD
14. LOW OIL DIF : If active, the system checks for low differential oil pressure. The system will
compare the calculated differential oil pressure to this value. It must be less than the value for the
period of time specified in the set point before the safety will trip.
15. UNSAFE OIL : If active, the system checks for low differential oil pressure. The system will
compare the calculated differential oil pressure to this value. It must be less than the value for the
period of time specified in the set point before the safety will trip. The time delay for this set point
should be very short 2-5 seconds. These safeties trips to a lockout no retry are attempted. Manual
intervention is required.
16. HII OIL TEMP : If active, the system checks for high oil temperature. The system will compare
the oil temperature sensor reading to this value. It must be ON or greater for the period of time
specified in the set point before this set point will trip. The sensor can be either an analog or digital
input.
17. SAFETY HOLD DELAY : Time in seconds to hold before trying to reload when the capacity has
been decreased to avoid a safety, (Examples: high disc psi, high disc temp, low suct psi, etc,)
18. LEAD COMP. Enables the user to specify the lead compressor.
19. COMP. ROTATION Specifies the number of days between rotation
6.5 Set points for Unit Safeties

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

Economizer On % the set point at which Economizer will get ON
Economizer Off % the set point at which Economizer will get OFF
6.7 Oil Differential Calculation

The calculation is DISCHARGE PRESSURE minus SUCTION PRESSURE.
7. Authorization Function
The authorization code is a special four-character code that enables access in to the system. The code
must be numeric with values between 0 and 9if it is to be entered from the Keypad/Display.
This provides the capability of issuing different codes to different people if desired. There are four levels
of authorization, which provide different capabilities with in the system. The authorization code and the
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USER'S MANUAL
associated level cannot be displayed in system. The authorization codes must be protected and remain
confidential, if they are compromised unauthorized personnel can gain access to the system. The two level
of safety has been provided
1. User level - Authorized to Change Water leaving set point within the Min & Max value, lockout reset
and control zone
2. Factory Level - Authorized for rest of all the things
7.1 RESTORE FACTORY SETTING AND DATA LOGGING

7.1 .1 If some modification has been made in the program SETPOINT, the factory setting can be
restored through the set point “Restore Factory Setting” at any movement.
7.1.2. Maximum 100 alarms can be stored with SP, DP and Current reading during trip. The last 20
Dynamic reading with the interval of 1 second will also get stored which will updated with the
mention time interval.
8. On/Off Switches
The following digital input switches can be associated with the system, their action will affect the chiller
package or an individual circuit, and then action will only affect that circuit:
• Flow switch, if off the system has lost flow. The system wills either lock out, if NO FLOW set point
is active, or shut down, if NO FLOW set point is inactive.
• Pump down switch, if on and the compressor is off, will not start the compressor. If the compressor
is on, the system moves to the pump down state to begin the process of turning off the
compressor(s) in normal steps.
• Run/Stop, if off the system will not run. This is usually wired to a RUN/STOP switch that is
manually positioned. If the system is running, the system moves all circuits (compressor) to off
in normal steps. (If a RUN/STOP and a Network RUN/STOP are both available they operate in
series.)
• Emergency Stop switch, if on, the system will be shut down immediately and will remain disabled
until the switch is off.
9. Operating Schedules
Two operating schedules per each day of the week and 8 holidays are supported. Each schedule contains
a start and end time, if the time and day of the system is with in these limits the schedule is true and the
system will be allowed to run. If not, the system will be off due to schedule.
10. Compressor
The compressor with the least number of TOTAL RUN HOURS will become the lead. Refer to Set points
#103 & #104.
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11. Alarms and Safeties

11.1 Introduction
There are three types of alarms that are generated by the Carel control logic:
• Information only alarms,
• Controller system alarms and
• Chiller set point safety alarms.

All of the alarms have the same format. The alarm is identified and it is date time stamped. Alarms can be
viewed from Carel controller by pressing the ALARM STATUS (4) key or from the PC-Connect Program.
Sensor inputs used in conjunction with Controller set point safeties:
11.1.1 Suction Pressure - Pressure transducer to read the suction pressure.
11.1.2 Discharge Pressure - Pressure transducer to read the discharge pressure.
11.1.3 Oil Differential Pressure - Calculated value of the oil pressure as follows:
Screws without oil pump, discharge psi minus suction psi
11.1.4 Oil Temperature - Either a temperature sensor or a digital input that indicates when a high
temperature condition exists.
11.1.5 Discharge Temperature - Either a temperature sensor or a digital input that indicates when a high
temperature condition exists.
11.1.6 Motor Amps - Sensor input that measures AMP draw of the compressor. (Optional digital input)
11.1.7 Liquid Temperature - Temperature sensor that can be used to detect a freeze condition
11.1.8 Flow Switch - A digital input that indicates that flow through the chiller barrel exists. There can be
one switch per chiller or one for each circuit.
11.1.9 Set point safeties - For a safety to be interrogated, both the associated sensor input and the
lockout set point must be active. If a safety trips, the alarm name will consist of the set point name
plus additional identification such as point number or circuit number if applicable.
The system exercises “smart” safety testing in the following manner:
If a safety applies to a circuit and it is an active lockout type of a set point, the first time this safety trips
an alarm will be generated and the circuit will be shut down and placed in a safety state. The system will
attempt to reactivate this circuit after waiting the length of time specified in this set point, safety down time.
If successful the system will continue to run. If the same safety trips the time specified in the lockout delay
time, the circuit will be locked off and a manual intervention is required. If the lockout delay time is set to
zero, the system will generate a lockout condition the first time that the safety occurs.
The time in the safety state and the time between safeties are specified in the individual set points.
This enables the times to be unique for each lock out set point.
Most safeties are checked only if the Compressor is running, if he safety is always checked
it will be so noted.
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USER'S MANUAL
The following are a list of safeties that are incorporated in the standard chiller algorithm control. These
safeties are checked every second. Note, for a multiple circuit system, each circuit is tested individually.
If a safety condition exists, action will be taken with that circuit only, other circuits will continue to function.
11.1.10 Freeze Protection (Safety is always checked)

If the leaving liquid temperature drops below the set point value the system, and all circuits, will enter a
lockout state and a freeze notification alarm will be generated. You have the option of one freeze protect
for the package or individual freeze protections by circuit..
11.1.11 No Flow Protection

If the flow switch is for the chiller system, then the entire system will be shut down and automatically
restarted when the flow switch is on, indicating that there is flow.
11.1.12 Phase Loss Protection

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

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

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

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

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

If the discharge pressure drops below the value of the set point and it remains there for the time specified
in the safety time of that set point, the compressor will be locked out and a low discharge alarm generated.
11.1.18 High Discharge Pressure (Safety is always checked)

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

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

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

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

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

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

Control States tell the user the system’s status; this information is critical. From the Carel keypad / display,
press the menu key and select STATUS> The control status is the second line. Carel Control States Quick
Reference.
Control States tell the user the system’s status; this information is critical!
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USER'S MANUAL
Capacity Control States Description
UNIT IN POWER System Reset or PowerReturned

(delay of 60 seconds or set point value)
CMP OFF/READY Circuit ready but not required or has not
been in this state for 60 seconds
UNIT IS OFF System ready to run but no cooling
capacity required
RUN/STOP SW OFF Disabled: run/stop switch is off.
FAST UNLOADING Fast unload screw compressor at start up.
SCHEDULED OFF Disabled: operating schedule is false.
OFF NO EVAP FLOW Disabled: no evaporator flow.
CMP IS HOLDING Control temperature with in target
control band,
UNIT IN LOCKOUT Chiller locked out, all pointsexcept
alarm point are OFF
HI DISC UNLOAD Pulse screw unload solenoid because
discharge temp or pressure is too high
NO RUN- IO LOST Lost communication Chiller locked out
HI DISC HOLD Holding until discharge temp or
pressurereturns to normal
UNIT IS HOLDING No change in capacity
LO SUCT UNLOAD Pulse screw unload solenoid or unload 1step,
suction temp or pressure is too low
LO TEMP UNLOAD Comp unloading, temperature less than
1.5 F above freeze point.
LO TEMP HOLD Hold until temperature is 3.0 F
above freezing point.
CMP PUMP DOWN Pumping down
CMP ANTICYCLE Delay after turning off circuit
SWITCHED OFF Pump down switch on or system state is
SAFETY TRIPPED Safety tripped not LOCKOUT
EXPANSION BOARD OFFLINE Lost communication
HI AMP HOLD Circuit is in hold due to hi amps.
Can only be unloaded.
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13. User Interface

User interface connected to the controller will show the current value of parameters (e.g. Temperature),
current status of equipments (fans, compressors) and current setting of set points. Changing of set point
is password protected to avoid unauthorized intervention.
Whenever the curser is at left extreme of first line Keys are used to scroll though the screens
of same level.
Left extreme of first line
When the curser is at any input variable same keys are used to increment or decrement the value of
parameter.
Leaving Water temp.
Control Set Point
Set Temp. 00.0°C Parameter
Differential 00.0°C
While key is used to enter the displayed parameter in CPU memory & the curser moves to next
parameter.
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USER'S MANUAL
Depending upon level of access all screens can be divided into 3 categories:
1. Status level:
Information on these screens can be viewed only & not allowed to be modified. No password is required
for accessing these screens.
2. User level:
This is password-protected level & contains process related set points, which an operator may need to
change.
3. Factory Level
This is again password-protected level, which has parameters, related at manufacturing level. These
parameters are not needed to be changed frequently.
a) Default
LWT 70.0°F This is a default screen i.e. if Esc (Esc) key is

Comp1 OFF 0% pressed from any screen an operator will
finally return on this screen. This displays Leaving
Comp2 OFF 0%
water Temperature and status of compressors
Status of compressor is displayed as explained
after this table with present loading of compressor
and countdown timers(for antirecycle ,Ready and
safety unload).
By using arrow keys, different screens
of this level can be accessed
SP 000.0PSI Comp 1 These two consecutive screens show different

DP 000.0 PSI analog readings values related to Compressor1.
DT 000.0°F SP – Suction pressure
CU 000.0Amp DP – Discharge pressure
DT – Similar screens for Compressor
CU – Current
Comp 1
Sucion Saturation
Temperature 000.0°F
Diff Pres 000.0PSI
77
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
Diff Pres 000.0PSI
Next screen shows Entering water temperature and

Entering water
individual cooler leaving temperature (only in case of
twine 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 this screen is shown
alarm history
Alarm history screen shows resent alarm with

01 01/12/55 10:30
corresponding date, time and suction pressure
Unsafe Oil comp 1
discharge pressure and current of related
SP 70 DP 80 CU 90 compressor at the time of alarm. With
keys past 100 alarms can be viewed. Upper
left corner always shows the index of Esc
present alarm. By pressing key one can go
back to previous screen
This screen present login status and also provides

02/12/07 01:43:52 facility to logout. In login status it will show “User” or
Current Login “Factory” if respective password is entered earlier.
None In case of logout it will show “None”. Pressing Enter
Press Enter to Logout while this screen is displayed enables logout.
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USER'S MANUAL
Meaning of status display of compressor –

1. Comp1 OFF :- Compressor is selected to be off by the toggle switch
2. Comp1 Ready: - Compressor is selected to be ON by selector switch, all safety delays are over (if
compressor was tripped earlier), lockout is reset and the compressor ready to get ON. This state is hold for
1 minute and then compressor is turned ON depending upon the demand.
a. Comp1 Low Demand: - Compressor is healthy but OFF because of low demand.
b. Comp1 ON:- Compressor is ON with required loading. This is accompanied with the loading
percentage (25%, 50%, 75% or 100%)
c. Comp1 Loading:- Compressor is loading.
d. Comp1FastUnl:- This state comes at every start of compressor for initial 30 seconds during which
compressor first to 25% if not during last shutoff.
e. Comp1 Unloading:- Compressor is Unloading due to decreasing demand or proactive unloading.
f. Comp1 Safty Hold:- In the course of proactive unloading when compressor comes out of unloading
condition and gets ready to load again this state is held for 3 min for confirmation. During this stage
loading of compressor as per demand is prohibited.
g. Comp1 Trip: - Compressor is tripped on some safety interlock and the fault condition still persists.
h. Comp1AntiRe:- Compressor has tripped due to some fault or low demand and waiting for anti recycle
time. During this state countdown in seconds is also displayed on the display. Compressor is
prohibited from starting until countdown timer reaches zero.
i. Comp1 Lockout:- Compressor had one of the serious fault occurred twice in the interval of one hour
due to which compressor is locked out. In this situation compressor will not start even if fault condition
is cleared and anti recycle is over. An operator has to reset the lockout with keypad at User level.
After resetting compressor goes in Ready state.
j. Comp1DayLockout:- Compressor had 10 lockouts in the interval of one day (starting from 00:00 at
midnight till next mid night). In this situation compressor is prohibited from starting for that day. Number
of lockouts of each day is reset at mid night. After that an operator can start the compressor.
b) User Level
For going to this level from any screen operator needs to press Prg (Prg) key once & he will reach the
navigation screen
This screen shows 3 options out of which middle

Status Level one is bold and big. On pressing Enter key on this
screen Operator will be taken to that level which
User appears at middle(only after entering
Factory Level respective password). With keys
different options can be called.
79
This is the password entry screen. Operator can

get to the value of password with keys
User Password while pressing key will enter the
0000 password. If 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
Setpoint 045.0°F values can be changed with keys

Con Zone (-) 01.0°F
° while pressing key will enter the set
point.
Con Zone (+) 02.0°F
This screen allows facility to reset the lockout.

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

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

Analog Inputs Comp 1 inputs, Digital outputs and the important parameters
WaterOut T 000.0°F related to the compressor. It doesn’t requires any
password as the screens are only for
viewing and modification is not possible
Dig Inputs Comp 1 at this level. Using keys one can go
Flow Switch Close through all of these screens
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
81

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

T.O.L. Parameters:-
the control algorithm getting executed according to
T.O.L. 00.0 the trend of load
SP Countdown 000
Demand 000
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USER'S MANUAL
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

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

but it is blank or shows connected properly. for proper insertion of telephone
“NO LINK” connector.
• Address setting of PGD or
3. After making PGD controller is not proper. Check for address of PGD
address 0 and (UP+DOWN+ENTER keys for 5
controller power OFF/ • Telephone cable between sec) it should be 32.
ON cycle “self test” PGD and controller is faulty
screen of controller If PGD address is 32 and still it
doesn’t appear. • Address setting of PGD or is blank then check for controller
controller is not proper. address. It should be 1
4. On default screen
LWT is seen in smaller • Probe is disconnected Check for proper connection of
font. (-999.9) or shorted(999.9) telephone cable and it’s
connector.
5. Temperature reading • Wrong probes are
shows -999.9 or 999.9 connected Check for lead wise continuity
value between two ends of cable.
• Dip switch setting is not
6. Temperature or done properly Make controller address 1 and
pressure reading PGD address as 32.
shows erratic or • Wiring for digital input is
negative reading. open at terminal block or at Check for proper connection of
field probe
7. Digital input giving
nuisance alarm • IDC for digital input is not Check for proper probes and
connected to G0 of connection.
8. Output is not getting controller
ON Check +Vdc connection for
• Common for that output pressure probe
block is not given proper
power Check for continuity between
GND on electrical terminal and
on pCO1 terminal
Check for correct dip switch

setting.
While making analog input

connections isolation from mains
supply is must
84
USER'S MANUAL
Troubleshooting
Shut Down of Compressor
1) Shut down the Chiller by switching off the required switch provided in the Panel.
2) Stop the chilled water supply to the Cooler.

In case of long term shutdown required because of the retrofit of the system or overhauling
of the compressor follow the above instructions after reinstallation of the system before
starting up again to ensure the safety and good running condition of the compressor
Troubleshooting
Sr. 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.
85
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 25 %

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.
86
USER'S MANUAL
Maintenance
Maintenance Schedule
Maintain the Chiller periodically in accordance with the schedules shown in the tables that follow:
Air Cooled Screw Chiller Maintenance Schedule

Check Points Daily Weekly Monthly Quarterly Annually
General
Log parameters X
Check Water Level in expansion tank X
Check up Oil Level X
Check for any refrigerant leaks through X
flare joints, valve glands etc
Check and clean refrigerant strainer X
Check condition of refrigerant drier X
Clean Air cooled condenser coils X
Chemical Cleaning of Condenser Coils X
Clean water line strainers X
Check quality of water X
Check healthy operation of safety devices X
Check tightness of all electrical terminations X
Top up grease for all motors X
Apply thermal paste on the temperature sensors X
Check for any abnormal noise and vibration X
Check liquid line sight glass/moisture indicator X
Check water pressure drop in cooler X
Analyse Oil sample 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 fan control function X
Check Clock X
87
Maintenance
Maintenance Schedule
Maintain the Chiller periodically in accordance with the schedules shown in the tables that follow:
Water Cooled Screw Chiller Maintenance Schedule
Check Points Daily Weekly Monthly Quarterly Annually
General
Log parameters X
Check Water Level in expansion tank X
Check Water Level in Cooling Tower X
Check for any refrigerant leaks through 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
88
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
89
Spare Parts List

Spares for LCAX1-075 D i A / LCAX2-150 D i A
Item Baan Description LCAX1-075 DiA LCAX2-150DiA Specification
Code Qty Nos. Qty Nos.
Compressor Spares
CDSAI0075 BSC-075A (RC15) Screw Compressor 1 2 VI- 3.0
3101-1143A Oil Filter 1 2 Φ40*200
3101-1146A Inner Gasket of Oil Filter Flange 1 2 Teflon 1.5t
3101-1147A-3 Outer Gasket of Oil Filter Flange 1 2 REINZ-AFM 34, 1.5t
3101-1051B Oil Heater (220V) 1 2 220V, 150W
EASCZ0010 Solenoid Coil for RC comprs. 3 6 220V, SANLAN SMG 1
4401-30 Solenoid Valve (Step Control) 3 6 2743K0R30-4344 SDH12223DS
3101-1003A Solenoid Valve Gasket 3 6 NOK,1515SPS
3103-2104B Oil sight glass (O’ ring included) 1 2 Aluminium
3131-1004A-3 3" Gasket 1 2 REINZ-AFM 34, 1.5t
3103-1024C Suction Filter 1 2 Φ110*103L, 60 Mesh
4405-56 Oil Level Switch 1 2 RFS-8-2, 1200mm
CDSPI0710 Blue Star ACS Oil 16 Litres 32 Litres
Controls & Accessories Spares

RDEAI0060 Sporlan Expansion Valve OVE-70 1 2
EASBI0140 Sporlan SV B10 S2 Solenoid Valve for Liq.Inj. 1 2 15/208 -230/50
EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil 1 2 MKC - 2
EASBI0170 Sporlan SV B14 S2 Solenoid Valve 1 2
for Economiser
EASBI0175 Sporlan SV B14 S2 Solenoid Vavle Coil 1 2
FEDBI0140 CTG Dehydrator (core) 2 4
RDEAI0120 Sporlan Expansion Valve TDEX-11 1 2
for Economiser
VAAAZ2010 Valve Angle 1/4 “ 8 12
VAAAZ2106 Sporlan Expansion Valve BBIVE-4 for Liq. Inj. 1 2
EASBZ0040 Pilot Sol. Valve (230V) 1 2 SANLAN 1/4" SAE Flare, /
15/240/50 MKC-2 Coil
FAPAZ7020 Bird Wing Fan 4 8 36" Dia. 5 blades
Electrical Spares
FAPAZ7018 Motor for Condenser 4 8 1.2 kW, 2.6 A, 700 RPM, 400 V/
3 Ph/ 50 Hz
MBSAZ1900 Oil Cooler Fan Motor Assessmbly 1 - 230 V, 1 Ph, 70 W, 1250 RPM,
350 mm Dia. FA/23/3514/K3/F
MBSAZ1800 Oil Cooler Fan Motor Assembly - 1 1 phase, 230 V, 90 W, 1350
RPM, 450 mm dia., VBM,
FA 23/4514/K5/F
90
USER'S MANUAL
Item Baan Description LCAX1-075 DiA LCAX2-150DiA Specification

EAMAZ0440 Siemens Contactor, 3TF30 10-0A-M0 415 V 2 4 415 V,9 A, 220 VAC Coil, 1 NO
for Condenser fan
EAMAZ0450 Coil for Siemens Contactor, 3TF30,9A, 220 VAC 2 4 AC 50 Hz
EAMAZ0607 SFU Switch 250 Amp. 3 pole, 80KA, DIN Fuse 1 2 Siemens 3KL8321-3UJ00
EAMAZ0608 Fuse link for 250 Amp. SFU 1 2
EATCZ0010 Star Delta Timer Siemens 3RP15 76-1NP30 1 2 24 VAC, 3-60 Seconds, 1 No.
Inst. & 1 No. Delayed
EAMAZ0599 Siemens Contactor, 3TF51 02-0A-M0, 415 VAC 2 4 415 V,140 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0600 Coil for Siemens Contactor, 3TF51 02-0A-M0, 2 4 AC 50 Hz
220 V AC
EAMAZ0500 Siemens Contactor, 3TF47 72-0A-M0, 220V Coil 1 2 415 V, 70A, 220 VAC Coil, 2
NO, 2NC
220 VAC
EAMAZ0525 SP/PR Minilec Make, VSP D1 1 2 230 V
EASHZ0060 4 Position Selector Switch - Salzer 61198 ON/OFF 1 1 5 A, Rocker Type, SPST
EAMAZ0205 MCB - 4A, 2 Pole, 415V, 10KA, for Controller 1 1 Schneider C60H2P4AC
EAMAZ0316 MCB - 16A, 3 Pole, 415V, 1 0KA, for Fan 2 4 Schneider C60H3P16AC
EAMAZ0530 MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan 1 1 Schneider C60H1P2AC
EATDZ0020 Control Transformer, Kavita Make 1 1 0-230V primary 24V secondary,
40VA
Micro Control Panel Spares

EATFZ0050 Current Sensor (Samcon) 0 to 300 amps. 1 2 Samcon CT-300
EAMAZ0550 INT 69 module 1 2
EBMCI0002 PCO1000CM0 pCO1 - Medium version, 1 1 24 V AC, I/P, R/O
1 MB Flash memory
EBMCI0009 Input expansion board, Carel PCOE00TLN0 - 1
EBMCI0004 PCO1CON0M0 Removable connector kit for pCO1 1 1
- Screw version for pCO1 Medium
1 MB Flash memory
- PCO100CLK0 pCOC options - Clock card 1 1
EBMCI0003 PGD0000F01 PGD0 terminal for built-in assembly 1 1 LCD, 120x32 pixels, without
external frame
- PGD000FR11 PGD0 terminal for built-in assembly 1 1
- Dark grey frame and silver
glass for PGD0, neutral
- S90CONN000 Telephone-type connection cable,
1.5 m long, with telephone connectors 1 1
EBMCI0100 NTC015WP00 WP type NTC probes 4 6 IP68, 1.5m cable, -50T105°C
EBMCI0080 SPKT00B1C0 Pr Transducer 2 4 0-44.8bar
EBMCI0090 SPKC002300 Cable 2m for pr sensor 2 4
91
Spares for LCWX1-115 D i B / LCWX2-225 D i B

Item Baan Description LCWX1-115DiB LCWX2-225DiB Specification
Compressor Spares
CDSAI0080 BSC-105A (RC16) Screw Compressor 1 2 VI 3.0
for R 22
3105-1143A Oil Filter 1 2 Φ56*200
3101-1051B Oil Heater (220V) 1 2 220V, 150W
4401-30 Solenoid Valve 3 6 2743K0R30-4344 SDH12223DS
4804-01 Oil Sight Glass (O-Ring Included) 1 2 ALCO
3105-1024C Suction Filter 1 2 Φ110*103L
3105-1004A-3 Gasket for 4" Flange 1 2 REINZ-AFM 34, 1.5t
CDSPI0710 Blue Star ACS Oil 18 Liters 36 Liters
Controls & Accessories spares

RDEAI0070 Sporlan Expansion Valve VVE-100 1 2
EASBI0170 Sporlan SV B14 S2 Solenoid Valve - -
for Economiser
for Economiser Coil
EASBI0140 Sporlan SV B10 S2 Solenoid Valve for Liq. Inj. 1 2
EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil 1 2
for Liquid injection
RDEAI0120 Danfoss Expansion Valve TDEX-11 - -
for Economiser
FEDBI0140 CTG Dehydrator (Core) (L Type Strainer) 3 6
SAMAI0010 Indicator Moisture 1 2 1-5/8"
EASBZ0040 Pilot Sol. Valve (230V) 1 2 SANLAN 1/4" SAE Flare,
15/240/50 MKC-2 Coil
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 1 2
for Liquid Injection
Electrical spares
EATCZ0010 Star Delta Timer Siemens 3RP15 76-1NP30 1 2 24 VAC, 3-60 Seconds,
1 NO Inst. & 1 NO Delayed
EAMAZ0594 SFU switch 200 Amp, 3 pole, 80KA 1 2 Siemens 3KL8311-3UJ00
EAMAZ0596 Fuse Link for 200 Amp SFU 1 2
2 NO, 2NC
EAMAZ0598 Coil for Contactor, 3TF50, 110A ,220 V 2 4 AC 50 Hz
92
USER'S MANUAL

EAMAZ0500 Siemens Contactor, 3TF47 72-0A-M0, 1 2 415 V,70 A, 220 VAC Coil,
220 VAC Coil 2 NO, 2NC
220 VAC
EASHZ0060 4 Positionn Selector Switch-Salzer 61198 ON/OFF 1 1 5 A, Rocker Type, SPST
EATDZ0020 Control Transformer, Kavita Make 1 1 0-230V primary
24V secondary, 40VA
Micro Control Panel spares
1 MB Flash memory
external frame
- Dark grey frame and silver glass
for PGD0, neutral
- S90CONN000 Telephone-type connection cable, 1 1
1.5 m long, with telephone connectors
EBMCI0100 NTC015WP00 WP type NTC probes 3 4 IP68, 1.5 m cable, -50T105 °C
93
Spares for LCAX1-102 D i A / LCAX2-204 D i A

Item Baan Description LCAX1-102DiA LCAX2-204DiA Specification
Compressor Spares
CDSAI0080 BSC-105A (RC16) Screw Compressor 1 2 VI 3.0
for R 22
3105-1143A Oil Filter 1 2 Φ56*200
3101-1051B Oil Heater (220V) 1 2 220V, 150W
3105-1024C Suction Filter 1 2 Φ110*103L

for Economiser
for Economiser Coil
for Liquid injection
RDEAI0120 Danfoss Expansion Valve TDEX-11 1 2
for Economiser
15/240/50 MKC-2 Coil
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 1 2
Electrical spares
FAPAZ7018 Motor for condenser 6 12 1.2 KW, 2.6 A, 700 RPM,
400V/ 3Ph/ 50 Hz
MBSAZ1800 Oil Cooler Fan Motor Assembly 1 2 1 Ph, 230 V, 90 W, 1350 RPM,
450 mm dia., VBM,
FA 23/4514/K5/F
EAMAZ0440 Siemens Contactor, 3TF31 10-0A-M0 415VAC 2 4 415 V,12 A, 220 VAC Coil,
1 NO
94
USER'S MANUAL

EAMAZ0450 Coil for Siemens Contactor, 3TF31,12A, 220 VAC 2 4 AC 50 Hz
EAMAZ0599 Siemens Contactor, 3TF51 02-0A-M0 415 VAC 2 4 415 V,140 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0600 Coil for Contactor, 3TF51,140A 2 4 AC 50 Hz
2 NO, 2NC
EASHZ0060 4 Position Selector Switch-Salzer 61198 ON/OFF 1 1 5 A, Rocker Type, SPST
EAMAZ0316 MCB - 16A, 3 Pole, 415V, 10KA, for Fan 2 4 Schneider C60H3P16AC
EAMAZ0316 MCB - 2A, 1 Pole, 415V, 10KA, 1 2 Schneider C60H1P2A
for Oil Cooler Fan
EATDZ0020 Control Transformer, Kavita Make 1 1 0-230V primary
24V secondary, 40VA
1 MB Flash memory
external frame
for PGD0, neutral
95
Spares for LCWX1-135 D i B

Item BaaN Description LCWX1-135DiB Specification
Code QTY, Nos.
Compressor Spares
CDSAI0080 BSC-130W (RC17) Screw 1 VI 3.0
Compressor for R 22
3105-1143A Oil Filter 1 Φ 56*200
3105-1146A Inner Gasket of Oil Filter Flange 1 Teflon 1.5t

3101-1148A-3 Outer Gasket of Oil Filter Flange 1 REINZ-AFM 34, 1.5t
3101-1051B Oil Heater (220V) 1 220V, 150W
EASCZ0010 Solenoid Coil for RC comprs. 3 220V, SANLAN SMG 1
4401-30 Solenoid Valve 3 2743K0R30-4344 SDH12223DS
3101-1003A Solenoid Valve Gasket 3 NOK,1515SPS
4804-01 Oil Sight Glass (O-Ring Included) 1 ALCO
3105-1024C Suction Filter 1 Φ 110*103L
3105-1004A-3 Gasket for 4" Flange 1 REINZ-AFM 34, 1.5t

4405-56 Oil Level Switch 1 RFS-8-2, 1200mm
CDSPI0710 Blue Star ACS Oil 18 Liters

RDEAI0070 Sporlan Expansion Valve VVE-100 1
EASBI0140 Sporlan SV B10 S2 Solenoid Valve 1
Coil for Liquid Injection
FEDBI0140 CTG Dehydrator (Core) (L Type Strainer) 3
SAMAI0010 Indicator Moisture 1 1-5/8"
EASBZ0040 Pilot Sol. Valve (230V) 1 SANLAN 1/4" SAE Flare, 15/240/50
MKC-2 Coil
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 1
VAAAZ2010 Valve Angle 1/4 “ 8
Electrical spares
EATCZ0010 Star Delta Timer Siemens 1 24 VAC, 3-60 Seconds,
3RP15 76-1NP30 1 NO. Inst. & 1 NO Delayed
- SFU switch 200 Amp, 3 pole, 80KA 1 Siemens 3KL8311-3UJ00
- Fuse Link for 200 Amp SFU 1
EAMAZ0591 Siemens Contactor, 3TF50 02-0A-M0, 2 415 V,110 A, 220 VAC Coil,
415 VAC 2 NO, 2NC
96
USER'S MANUAL
Item BaaN Description LCWX1-135DiB Specification

Code QTY, Nos.
EAMAZ0598 Coil for Contactor, 3TF50, 110A ,220 V 2 AC 50 Hz
EAMAZ0500 Siemens Contactor, 3TF47 72-0A-M0, 1 415 V,70A, 220 VAC Coil,
220 VAC Coil 2 NO, 2NC
EAMAZ0510 Coil for Siemens Contactor, 3TF47 1 AC 50 Hz
72-0A-M0, 220 VAC
EAMAZ0525 SP/PR Minilec Make, VSP D1 1 230 V
EASHZ0060 4 Positionn Selector Switch 1 5 A, Rocker Type, SPST
- Salzer 61198 ON/OFF
EAMAZ0205 MCB - 4A, 2 Pole, 415V, 10KA, for Controller 1 Schneider C60H2P4AC
EATDZ0020 Control Transformer, Kavita Make 1 0-230V primary 24V secondary,
40VA

EATFZ0050 Current Sensor (Samcon) 0 to 300 amps. 1 Samcon CT-300
EAMAZ0550 INT 69 module 1
EBMCI0002 PCO1000CM0 pCO1 - Medium version, 1 24 VAC, I/P, R/O
1 MB Flash memory
EBMCI0004 PCO1CON0M0 Removable connector kit 1
for pCO1 - Screw version for pCO1 Medium
- PCO100CLK0 pCOC options - Clock card 1
EBMCI0003 PGD0000F01 PGD0 terminal for built-in 1 LCD, 120x32 pixels, without
assembly external frame
- PGD000FR11 PGD0 terminal for built-in 1
assembly - Dark grey frame and silver
glass for PGD0, neutral
- S90CONN000 Telephone-type connection 1
cable, 1.5 m long, with
telephone connectors
EBMCI0100 NTC015WP00 WP type NTC probes 3 IP68, 1.5 m cable, -50T105 °C
EBMCI0080 SPKT00B1C0 Pr Transducer 2 0-44.8bar
EBMCI0090 SPKC002300 Cable 2m for pr sensor 2
97
Spares for LCWX1-160 D i B / LCWX2-315 D i B

Compressor spares
CDSAI0090 BSC-145A (RC18) Screw Compressor 1 2 Vi - 3.0
3105-1143A Oil Filter 1 2
3101-1051B Oil Heater (220V) 1 2 220V,150W
3101-1006A-3 Gasket (For Motor Cable Cover Plate) 1 2 REINZ-AFM 34, 1.5t
4804-01 Oil Sight Glass (O-Ring included) 1 2 ALCO
CDSPI0710 Blue Star ACS Oil 18 liters 36 liters
Controls and Accessories Spares

FEDBI0140 CTG Dehydrator (Core) 3 6
15/240/50 MKC-2 Coil
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 for Liq. Inj. 1 2
Electrical Spares
EAMAZ0607 SFU Switch 250 Amp. 3 pole, 80KA 1 2 Siemens 3KL8321-3UJ00
EAMAZ0603 Siemens Contactor 3TF53 02-0A-M0, 415 VAC - - 415 V,205 A, 220 VAC Coil,
2NO, 2 NC
2 NO, 2NC
220 VAC
EAMAZ0599 Siemens Contactor, 3TF49 22-0A-P0, 415 VAC 1 2 415 V,85 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0600 Coil for Siemens Contactor, 3TF49 22-0A-P0, 1 2 AC 50 Hz
220 VAC
98
USER'S MANUAL

EATDZ0020 Control Transformer, Kavita Make 1 1 0-230V primary 24V
secondary, 40VA

EATFZ0050 Current Sensor (Samcon) 0 to 300 Amps. 1 2 Samcon CT-300
1 MB Flash memory
external frame
for PGD0, neutral
99
Spares for LCAX1-145 D i A/ LCAX2-290 D i A

Compressor spares
3101-1051B Oil Heater (220V) 1 2 220V,150W

for Economiser
RDEAI0125 Sporlan Expansion Valve TDEX-19 1 2
15/240/50 MKC-2 Coil
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 for Liq. Inj. 1 2
SATAZ0140 Anti freeze thermostat Sub-Zero 7510 - 2
Electrical Spares
FAPAZ7018 Motor for Condenser 8 16 1.2 KW, 2.6 A, 700 RPM, 400V/
3 Ph/ 50 Hz
MBSAZ1800 Oil Cooler Fan Motor Assembly 1 2 1 Ph, 230 V, 90 W, 1350 RPM
VBM, FA 23/4514/K5/F
EAMAZ0605 Siemens Contactor, 3TF32 00-0A-M0 415 VAC 2 4 415 V,16 A, 220 VAC Coil
EAMAZ0606 Coil for Contactor 3TF32/ 16 A, 220 VAC 2 4 AC 50 Hz
EAMAZ0595 SFU switch 400 Amp.3 pole, 80KA 1 2 Siemens 3KL8341-3UJ00
100
USER'S MANUAL

EAMAZ0603 Siemens Contactor 3TF53 02-0A-M0, 415 VAC 2 4 415 V,205 A, 220 VAC Coil,
2 NO, 2 NC
EAMAZ0604 Coil for Contactor, 3TF53/205A, 220 V 2 4 AC 50 Hz
EAMAZ0591 Siemens Contactor, 3TF50 02-0A-M0, 415 VAC 1 2 415 V, 110 A, 220 VAC Coil,
2 NO, 2 NC
EAMAZ0316 MCB - 16A, 3 Pole, 415V, 10KA, for Fan 2 4 Schneider C60H3P16AC
EAMAZ0316 MCB - 2A, 1 Pole, 415V, 10KA, 1 2 Schneider C60H1P2AC
for Oil Cooler Fan
secondary, 40VA

1 MB Flash memory
external frame
for PGD0, neutral
101
Spares for LCAX2-177 D i A

Item BaaN Description LCAX2-177 D i A Specification
Code QTY, Nos.
Compressor Spares
CDSAI0080 BSC-105A (RC16) Screw Compressor 1 VI- 3.0
for R 22
3105-1143A Oil Filter 1 Φ56*200
3101-1051B Oil Heater (220V) 1 220V, 150W
4401-30 Solenoid Valve 3 2743K0R30-4344 SDH12223DS
3105-1024C Suction Filter 1 Φ110*103L
3105-1004A-3 Gasket for 4" Flange 1 REINZ-AFM 34, 1.5t
CDSPI0710 Blue Star ACS Oil 18 Liters
CDSAI0075 BSC-075A (RC15) Screw Compressor 1 VI- 3.0
3101-1143A Oil Filter 1 Φ40*200
3101-1051B Oil Heater (220V) 1 220V, 150W
4401-30 Solenoid Valve (Step Control) 3 2743K0R30-4344 SDH12223DS
3103-2104B Oil sight glass (O’ ring included) 1 Aluminium
3131-1004A-3 3" Gasket 1 REINZ-AFM 34, 1.5t
3103-1024C Suction Filter 1 Φ110*103L, 60 Mesh
CDSPI0710 Blue Star ACS Oil 16 Litres
RDEAI0060 Sporlan Expansion Valve OVE-70 1
RDEAI0070 Sporlan Expansion Valve VVE-100 1
EASBI0140 Sporlan SV B10 S2 Solenoid Valve
for Liquid Injection 2
EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil 2
for Economiser 2
EASBI0175 Sporlan SV B14 S2 Solenoid Vavle Coil 2
FEDBI0140 CTG Dehydrator (core) 5
RDEAI0120 Danfoss Expansion Valve TDEX-11 2
for Economiser
VAAAZ2010 Valve Angle 1/4“ 16
VAAAZ2106 Sporlan Expansion Valve BBIVE-4 1
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 1
EASBZ0040 Pilot Sol. Valve (230V) 2 SANLAN 1/4" SAE Flare, 15/240/50
MKC-2 Coil
FAPAZ7020 Bird Wing Fan 12 36" Dia. 5 blades
Electrical Spares
FAPAZ7018 Motor for Condenser 12 1.2 KW, 2.6 A, 700 RPM, 400 V/
3 Ph/ 50 Hz
102
USER'S MANUAL
Item BaaN Description LCAX2-177 D i A Specification

Code QTY, Nos.
MBSAZ1800 Oil Cooler Fan Motor Assembly 2 1 Ph. 230 V, 90 W, 1350 RPM,
450mm dia., VBM, FA 23/4514/K5/F
EAMAZ0605 Siemens Contactor, 3TF32 00-0A-M0 2 415 V,16 A, 220 VAC Coil
415 VAC for condenser fan
EAMAZ0606 Coil for Contactor 3TF32,16A, 220 VAC 2 AC 50 Hz
EAMAZ0440 Siemens Contactor, 3TF30 10-0A-M0 2 415 V,9 A, 220 VAC Coil, 1 NO
415 VAC for Condenser fan
EAMAZ0450 Coil for Siemens Contactor, 3TF30,9A, 220 V 2 AC 50 Hz
EAMAZ0607 SFU Switch 250 Amp. 3 pole, 80KA 1 Siemens 3KL8321-3UJ00

EAMAZ0608 Fuse link for 250 Amp. SFU 1
EAMAZ0594 SFU switch 315 Amp, 3 pole, 80KA 1 Siemens 3KL8331-3UJ00
EAMAZ0596 Fuse Link for 315 Amp SFU 1
EATCZ0010 Star Delta Timer Siemens 3RP15 2 24 VAC, 3-60 Seconds,
76-1NP30 1 NO Inst. & 1 NO Delayed
EAMAZ0599 Siemens Contactor, 3TF51 02-0A-M0, 415 V 4 415 V,140 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0600 Coil for Siemens Contactor, 3TF51 4 AC 50 Hz
02-0A-M0, 220 V
EAMAZ0500 Siemens Contactor, 3TF47 72-0A-M0, 415 VAC 1 415 V,70 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0510 Coil for Siemens Contactor, 3TF47 72-0A-M0, 1 AC 50 Hz
220 VAC
EAMAZ0591 Siemens Contactor, 3TF50 02-0A-M0, 415 VAC 1 415 V,110 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0598 Coil for Contactor, 3TF50, 110A ,220 V 1 AC 50 Hz
EASHZ0060 4 Position Selector Switch - Salzer 61198 1 5 A, Rocker Type, SPST
ON/OFF
EAMAZ0316 MCB - 16A, 3 Pole, 415V, 10KA, for Fan 4 Schneider C60H3P16AC
EAMAZ0530 MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan 2 Schneider C60H1P2AC
40VA
EATFZ0050 Current Sensor (Samcon) 0 to 300 Amps. 2 Samcon CT-300
EBMCI0002 PCO1000CM0 pCO1 - Medium version, 1
1 MB Flash memory
EBMCI0009 Input expansion board, Carel PCOE00TLN0 1 24V AC, I/P, R/O
EBMCI0004 PCO1CON0M0 Removable connector kit for 1
pCO1 - Screw version for pCO1 Medium
EBMCI0003 PGD0000F01 PGD0 terminal for built-in 1 LCD, 120x32 pixels, without
assembly external frame
- PGD000FR11 PGD0 terminal for built-in 1
assembly - Dark grey frame and
silver glass for PGD0, neutral
- S90CONN000 Telephone-type connection 1
cable, 1.5m long, with telephone connectors
EBMCI0100 NTC015WP00 WP type NTC probes 6 IP68, 1.5m cable, -50T105 °C
103
Spares for LCWX2-270 D i B, LCAX2-247 D i A

Item Baan Description LCWX2-270DiB LCAX2-247DiA Specification
Compressor Spares
for R 22
3105-1143A Oil Filter 1 1 Φ 56*200
3101-1051B Oil Heater (220V) 1 1 220V, 150W
3105-1024C Suction Filter 1 1 Φ 110*103L

for R 22
3101-1051B Oil Heater (220V) 1 1 220V,150W
EASBI0170 Sporlan SV B14 Solenoid Valve for Economiser - 1
EASBI0175 Sporlan SV B14 Solenoid Valve - 1
for Economiser Coil
RDEAI0120 Sporlan Expansion Valve TDEX-11 for Economiser - 1
EASBZ0040 Pilot Sol. Valve (230V) 2 2 SANLAN 1/4" SAE Flare, 15/
240/50 MKC-2 Coil
VAAAZ7090 Danfoss Expansion Valve TDEX-7.5 for Liq.Inj. 2 2
FAPAZ7020 Bird Wing Fan - 14 36" Dia. 5 blades
EASBI0190 Sporlan SV B19S2 Solenoid Valve for Economiser - 1
EASBI0195 Sporlan SV B19S2 Solenoid Valve Coil - 1
RDEAI0125 Sporlan Expansion Valve TDEX-19 for economiser - 1
Electrical spares
FAPAZ7018 Motor for Condenser - 14 1.2 KW, 2.6 A, 700 RPM, 400V/
3 Ph/ 50 Hz
MBSAZ1800 Oil Cooler Fan Motor Assembly - 2 1 Ph., 230 V, 90 W, 1350
RPM, 450 mm dia., VBM, FA
23/4514/K5/F
104
USER'S MANUAL

EAMAZ0605 Siemens Contactor, 3TF32 00-0A-M0 415V - 2 415 V,16 A, 220 VAC Coil
for condenser fan
EAMAZ0606 Coil for Contactor 3TF32,16A, 220 VAC - 2 AC 50 Hz
EAMAZ0440 Siemens Contactor, 3TF31 10-0A-M0 415VAC - 2 415 V,12 A, 220 VAC Coil,
for condenser fan 1NO
EAMAZ0450 Coil for Siemens Contactor,3TF31,12A, 220 V - 2 AC 50 Hz
EATCZ0010 Star Delta Timer Siemens 3RP15 76-1NP30 2 2 24 VAC, 3-60 Seconds, 1 NO
Inst. & 1 NO Delayed
EAMAZ0594 SFU switch 315 Amp, 3 pole, 80KA - 1 Siemens 3KL8331-3UJ00
EAMAZ0596 Fuse Link for 315 Amp SFU - 1
EAMAZ0595 SFU switch 400 Amp.3 pole, 80KA - 1 Siemens 3KL8341-3UJ00
EAMAZ0597 Fuse link for 400 Amp. SFU - 1
- SFU switch 200 Amp, 3 pole, 80KA 1 - Siemens 3KL8311-3UJ00
- Fuse Link for 200 Amp SFU 1 -
EAMAZ0607 SFU Switch 250 Amp. 3 pole, 80KA 1 - Siemens 3KL8321-3UJ00
EAMAZ0608 Fuse link for 250 Amp. SFU 1 -
EAMAZ0603 Siemens Contactor 3TF53 02-0A-M0, 415 VAC - 2 415 V,205 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0604 Coil for Contactor, 3TF53/205A, 220 V - 2 AC 50 Hz
EAMAZ0599 Siemens Contactor, 3TF51 02-0A-M0 415 VAC 2 2 415 V,140 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0600 Coil for Contactor, 3TF51,140A 2 2 AC 50 Hz
2 NO, 2NC
EAMAZ0500 Siemens Contactor, 3TF47 72-0A-M0, 220V Coil 1 - 415 V,70 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0510 Coil for Siemens Contactor, 3TF47 72-0A-M0, 220V 1 - AC 50 Hz
EAMAZ0599 Siemens Contactor, 3TF49 22-0A-P0, 415 VAC 1 - 415 V,85 A, 220 VAC Coil,
2NO, 2NC
EAMAZ0600 Coil for Siemens Contactor, 3TF49 22-0A-P0, 220V 1 - AC 50 Hz
EAMAZ0316 MCB - 16A, 3 Pole, 415V, 10KA, for Fan - 4 Schneider C60H3P16AC
EAMAZ0316 MCB - 2A, 1 Pole, 415V, 10KA, - 2 Schneider C60H1P2AC
for Oil Cooler Fan
40VA
EBMCI0002 PCO1000CM0 pCO1 - Medium version, 1 1
1 MB Flash memory
EBMCI0009 Input expansion board, Carel PCOE00TLN0 1 1 24C AC, I/P, R/O
external frame
-Dark grey frame and silver glass for PGD0, neutral
105
Spares for LCWX1-175 D i B & LCWX2-345 D i B

CDSAI0092 BSC-160A (RC-19) Compressor 1 2 Vi - 3.0
3107-1005A-3 3'’ Gasket for Discharge Flange 1 2 REINZ-AFM 34, 1.5t
3107-1024C Suction Filter 1 2 60mesh
3107-1004A-3 Gasket for Suction Filter Flange 1 2 REINZ-AFM 34, 1.5t
3101-1052C Oil Heater 1 2 Φ12.7,220V*300 W

for Economiser
VAAAZ2010 Valve Angle 1/4 8 12
RDEAI0120 Danfoss Expansion Valve TDEX-11 for liq. Inj. 1 2
15/240/50 MKC-2 Coil
Electrical Spares
2 NO, 2NC
EAMAZ0598 Coil for Contactor, 3TF50, 110A, 220 V 1 2 AC 50 Hz
EAMAZ0601 Siemens Contactor, 3TF52-02-0A-M0 415 V 2 4 415 V,170 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0602 Coil for Contactor, 3TF52 170A 220 VAC 2 4 AC 50 Hz
106
USER'S MANUAL
EASHZ0060 4 Position Selector Switch 1 1 5 A, Rocker Type, SPST

40VA

1 MB Flash memory
EBMCI0009 Input expansion board, Carel PCOE00TLN0 - 1 24 V AC, I/P, R/O
external frame
for PGD0, neutral
107
Spares for LCAX2-320 D i A

Item BaaN Description LCAX2-320DiA Specification
Code QTY, Nos.
CDSAI0092 BSC-160A (RC-19) Compressor 2 Vi - 3.0
3107-1005A-3 3'’ Gasket for Discharge Flange 2 REINZ-AFM 34, 1.5t
3107-1143A Oil Filter 2
4401-30 Solenoid Valve (Step Control) 6 2743K0R30-4344 SDH12223DS
3107-1024C Suction Filter 2 60mesh
3107-1004A-3 Gasket for Suction Filter Flange 2 REINZ-AFM 34, 1.5t
3101-1052C Oil Heater 2 Φ12.7,220V*300W
CDSPI0710 Blue Star ACS Oil 36 liters

RDEAI0060 Sporlan Expansion Valve OVE-70 4
EASBI0140 Sporlan SV B10 S2 Solenoid Valve for Liq. Inj. 2
for Economiser
FEDBI0140 CTG Dehydrator (Core) 8
RDEAI0125 Sporlan Expansion Valve MVE-21 for economiser 2
VAAAZ2010 Valve Angle 1/4 12
RDEAI0120 Danfoss Expansion Valve TDEX-11 for liq. Inj. 2
EASBZ0040 Pilot Sol. Valve (230V) 2 SANLAN 1/4" SAE Flare,
15/240/50 MKC-2 Coil
FAPAZ7020 Bird Wing Fan 16
SATAZ0140 Anti freeze thermostat Sub-Zero 7510 2
Electrical Spares
MBSAZ2080 Motor for Condenser 16 1.5 kW, 3.5 A, 860 RPM, 400V/
3 Ph/ 50 Hz
MBSAZ1800 Oil Cooler Fan Motor Assembly 2 1 ph, 230 V, 90 W, 1350 RPM,
450 mm dia., VBM, FA 23/514/K5/F
EAMAZ0605 Siemens Contactor, 3TF32 00-0A-M0 415V 4 415 V,16 A, 220 VAC Coil
for condenser fan
EAMAZ0606 Coil for Contactor 3TF32,16A, 220 VAC 4 AC 50 Hz
EATCZ0010 Star Delta Timer Siemens 3RP15 76-1NP30 2 24 VAC, 3-60 Seconds, 1 NO
EAMAZ0610 SFU switch 630 Amp, 3 pole, 80KA - Siemens 3KL8421-3UJ00
- Fuse Link for 500 Amp SFU 2
108
USER'S MANUAL
Item Baan Description LCWX2-345DiB Specification

Code Qty Nos.
- Siemens Contactor 3TF54 02-0A-M0, 415 V 4 415 V,250 A, 220 VAC Coil,
2NO, 2NC
- Siemens Coil for Contactor 3TF54, 220 VAC 4 AC 50 Hz
- Siemens Contactor, 3TF51 02-0A-M0 415 VAC 2 415 V,140 A, 220 VAC Coil,
2 NO, 2NC
- Coil for Contactor, 3TF51,140A 220 VAC 2 AC 50 Hz
EASHZ0060 4 Position Selector Switch 1 5 A, Rocker Type, SPST
40VA
EAMAZ0316 MCB - 16A, 3 Pole, 415V, 10KA, for Fan 4 Schneider C60H3P16AC
EAMAZ0316 MCB - 2A, 1 Pole, 415V, 10KA, 2 Schneider C60H1P2AC
for Oil Cooler Fan

EATFZ0050 Current Sensor (Samcon) 0 to 300 Amps. 2 Samcon CT-300
EBMCI0002 PCO1000CM0 pCO1 - Medium version, 1
1 MB Flash memory
EBMCI0009 Input expansion board, Carel PCOE00TLN0 1 24 V AC, I/P, R/O
EBMCI0004 PCO1CON0M0 Removable connector kit for pCO1 1
EBMCI0003 PGD0000F01 PGD0 terminal for built-in assembly 1 LCD, 120x32 pixels, without
external frame
- PGD000FR11 PGD0 terminal for built-in assembly 1
for PGD0, neutral
- S90CONN000 Telephone-type connection cable, 1
EBMCI0100 NTC015WP00 WP type NTC probes 6 IP68, 1.5 m cable, -50T105 °C
109
Spares for LCWX1-225 D i B & LCAX1-206 D i A

3105-1004a-3 4"Gasket for Discharge Flange 1 1 Reinz-Afm 34, 1.5t
3107-1143a Oil Filter 1 1
3107-1146a Inner Gasket of Oil Filter Flange 1 1 Teflon 1.5t
3101-1051B Oil Heater (220V) 1 1 220V,150W
3101-1006a-3 Gasket (For Motor Cable Cover Plate) 1 1 Reinz-Afm 34, 1.5t
3101-1003a Solenoid Valve Gasket 3 3 Nok,1515sps
3107-1054a Gasket For Suction Filter 1 1 Φ161.5*1.5t
3107-1024c Suction Filter 1 1 Φ159*210l
4405-56 Oil Level Switch 1 1 Rfs-8-2, 1200mm

RDEAI0070 Sporlan Expansion Valve - VVE-100 2 2
EASBI0190 Sporlan SV B19 S2 Solenoid Valve - 1
for Economiser
EASBI0195 Sporlan SV B19 S2 Solenoid Valve Coil - 1
RDEAI0125 Sporlan Expansion Valve MVE-21 for economiser 1 1
EASBZ0040 Pilot Sol. Valve (230V) - 1 SANLAN 1/4" SAE Flare,
15/240/50 MKC-2 Coil
FAPAZ7020 Bird Wing Fan - 12
Electrical Spares
FAPAZ7018 Motor for Condenser - 12 1.2 kW, 2.6 A, 700 RPM,
400V/ 3 Ph./ 50 Hz
RPM, 450 mm dia.,
VBM, FA 23/4514/K5/F
EAMAZ0605 Siemens Contactor, 3TF32 00-0A-M0 415 VAC - 3 415 V,16 A, 220 VAC Coil
for condenser fan
EAMAZ0606 Coil for Contactor 3TF32, 16A, 220 VAC - 3 AC 50 Hz
110
USER'S MANUAL

EAMAZ0595 SFU switch 400 Amp.3 pole, 80KA 1 - Siemens 3KL8341-3UJ00
EAMAZ0603 Siemens Contactor 3TF53 02-0A-M0, 415 VAC 2 - 415 V,205 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0604 Coil for Contactor, 3TF53/205A, 220 V 2 - AC 50 Hz
EAMAZ0591 Siemens Contactor, 3TF50 02-0A-M0, 415 VAC 1 - 415 V,110 A, 220 VAC Coil,
2NO, 2NC
EAMAZ0598 Coil for Contactor, 3TF50, 110A, 220 V 1 - AC 50 Hz
EAMAZ0603 Siemens Contactor 3TF55 02 0A-M0 415 V - 2 415 V,300 A, 220 VAC Coil,
2NO, 2NC
EAMAZ0604 Coil for Contactor, 3TF55, 300A 220 VAC - 2 AC 50 Hz
EAMAZ0601 Siemens Contactor, 3TF52-02-0A-M0 415 V - 1 415 V,170 A, 220 VAC Coil,
2NO, 2NC
EAMAZ0602 Coil for Contactor, 3TF52 170A 220 VAC - 1 AC 50 Hz
EASHZ0060 4 Position Selector Switch - Salzer 61198 1 1 5 A, Rocker Type, SPST
ON/OFF
secondary, 40VA
EAMAZ0316 MCB - 2A, 1 Pole, 415V, 10KA, - 1 Schneider C60H1P2AC
for Oil Cooler Fan

EATFZ0050 Current Sensor (Samcon) 0 to 300 Amps. 1 - Samcon CT-300
EATFZ0060 Current Sensor (Samcon) 0 to 500 Amps. - 1 Samcon CT-500
1 MB Flash memory
EBMCI0004 PCO1CON0M0 Removable connector kit for 1 1
external frame
for PGD0, neutral
111
Spares for LCWX2-400 DiB, LCAX2-366 D i A

Item Baan Description LCWX2-400 DiB LCAX2-366DiA Specification
3107-1005A-3 3'’ Gasket for Discharge Flange 1 1 REINZ-AFM 34, 1.5t
3107-1024C Suction Filter 1 1 60mesh
3107-1004A-3 Gasket for Suction Filter Flange 1 1 REINZ-AFM 34, 1.5t
3101-1052C Oil Heater 1 1 Φ 12.7,220V*300W

3105-1004a-3 4"Gasket for Discharge Flange 1 1 Reinz-Afm 34, 1.5t
3107-1143a Oil Filter 1 1
3107-1146a Inner Gasket of Oil Filter Flange 1 1 Teflon 1.5t
3101-1051B Oil Heater (220V) 1 1 220V,150W
3101-1006a-3 Gasket (For Motor Cable Cover Plate) 1 1 Reinz-Afm 34, 1.5t
3101-1003a Solenoid Valve Gasket 3 3 Nok,1515sps
3107-1054a Gasket For Suction Filter 1 1 Φ 161.5*1.5t
3107-1024c Suction Filter 1 1 Φ 159*210l
4405-56 Oil Level Switch 1 1 Rfs-8-2, 1200mm

RDEAI0070 Sporlan Expansion Valve - VVE-100 2 2
for Liquid Injection 2 2
EASBI0190 Sporlan SV B19 S2 Solenoid Valve for Economiser - 2
EASBI0195 Sporlan SV B19 S2 Solenoid Valve Coil - 2
EDBI0140 CTG Dehydrator (Core) 8 10
RDEAI0125 Sporlan Expansion Valve MVE-21 for economiser - 2
EASBZ0040 Pilot Sol. Valve (230V) 2 2 SANLAN 1/4" SAE Flare, 15/240/
50 MKC-2 Coil
FAPAZ7020 Bird Wing Fan - 20
Electrical Spares
MBSAZ2080 Motor for Condenser - 8 1.5 kW, 3.5 A, 860rpm, 400V/
3 Ph/ 50 Hz
FAPAZ7018` Motor for Condenser - 12 1.2 kW, 2.6 A, 700 RPM, 400 V/ 3
Ph/ 50 Hz
RPM, 450 mm dia., VBM, FA 23/
4514/K5/F
112
USER'S MANUAL
Item Baan Description LCWX2-400 DiB LCAX2-366DiA Specification

EAMAZ0605 Siemens Contactor, 3TF32 00-0A-M0 415 V - 5 415 V,16 A, 220 VAC Coil
for condenser fan
EAMAZ0606 Coil for Contactor 3TF32,16A, 220 VAC - 5 AC 50 Hz
- Fuse Link for 500 Amp SFU - 1
EAMAZ0595 SFU switch 400 Amp.3 pole, 80KA 1 - Siemens 3KL8341-3UJ00
EAMAZ0594 SFU switch 315 Amp, 3 pole, 80KA 1 - Siemens 3KL8331-3UJ00
EAMAZ0596 Fuse Link for 315 Amp SFU 1 - -
- Siemens Contactor 3TF54 02-0A-M0, 415 V - 2 415 V,250 A, 220 VAC Coil,
2 NO, 2NC
- Siemens Coil for Contactor 3TF54, 220 VAC - 2 AC 50 Hz
- Siemens Contactor, 3TF51 02-0A-M0 415 VAC - 1 415 V,140 A, 220 VAC Coil,
2 NO, 2NC
- Coil for Contactor, 3TF51,140A 220 VAC - 1 AC 50 Hz
EAMAZ0603 Siemens Contactor 3TF55 02 0A-M0 415 V - 2 415 V,300 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0604 Coil for Contactor, 3TF55, 300A 220 VAC - 2 AC 50 Hz
EAMAZ0601 Siemens Contactor, 3TF52-02-0A-M0 415 V 2 1 415 V,170 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0602 Coil for Contactor, 3TF52 170A 220 VAC 2 1 AC 50 Hz
EAMAZ0591 Siemens Contactor, 3TF50 02-0A-M0, 415 VAC 2 - 415 V,110 A, 220 VAC Coil,
2 NO, 2NC
EAMAZ0598 Coil for Contactor, 3TF50, 110A ,220 V 2 - AC 50 Hz
EAMAZ0603 Siemens Contactor 3TF53 02-0A-M0, 415 VAC 2 - 415 V,205 A, 220 VAC Coil,
2NO, 2NC
EAMAZ0604 Coil for Contactor, 3TF53/205A ,220 V 2 - AC 50 Hz
40VA
EAMAZ0205 MCB - 4A, 2 Pole, 415V, 10KA, for controller 1 1 Schneider C60H2P4AC
EAMAZ0316 MCB - 2A, 1 Pole, 415V, 10KA, for Oil Cooler Fan - 2 Schneider C60H1P2AC

EATFZ0060 Current Sensor (Samcon) 0 to 500 Amps. - 1 Samcon CT-500
1 MB Flash memory
EBMCI0009 Input expansion board, Carel PCOE00TLN0 1 1 24 CAC, I/P, R/O
EBMCI0004 PCO1CON0M0 Removable connector kit for 1 1
external frame
- PGD000FR11 PGD0 terminal for built-in assembly - 1 1
Dark grey frame and silver glass for PGD0, neutral
113
Field Feed Back Form

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

Return To : Manufacturing Unit - Thane
PRODUCT :
CHILLER MODEL :
SR. NO. :
CUSTOMER NAME : 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 :
- Frame Work Ok /
- Condenser coils Ok /
- Fan Mountings Ok /
- Springs Ok /
- Compressor Ok /
- Condenser Ok /
- Cooler Ok /
- Electrical Panel Ok /
- Oil Cooler Ok /
- Economiser Ok /
- Refrigerant Piping Ok /
- Idle Pressure Ok /
REMARKS :
Checked By
For Factory Use :
- Date of Receipt : - Action By :

- Comments :
114
USER'S MANUAL
The field feedback card as per the format below shall be sent to factory
after Commisioning of the Chiller
Field Feedback Card - Commissioning of Chiller at Site

Product : Air Cooled / Water Cooled Screw Chiller
Chiller Model :
Sr. No. :
Customer Name : Location :
Engineer’s Name :
Observation Comments Remarks
Installation/Precommissioning Checks :
- Unit Installed and levelled 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 :
115
Commissioning and
Handing Over
Hand over the Chiller to the Customer as per the format below and establish Warranty
COMMISSIONING & HANDING OVER REPORT
Our Ref: Date:
BLUE STAR LIMITED Cust. Ref.
PURCHASE ORDER Date:
Date:
Equipment : Blue Star make Air / Water Cooled Screw Chiller
Model:
Sl.Nos.
Customer Name & Address
Equipment location :
Call made by
COMMISSIONING
Service rendered
Supplied,Installed,Tested and Commissioned Blue Star make Air Cooled Screw Chillers / Water Cooled
Screw Chillers and they are put into regular operation. The Model No. & Serial Nos. of the units are given
below :
CHILLER MODEL :
SERIAL NO. OF MACHINE NO.1 :
SERIAL NO. OF MACHINE NO.2 :
The chillers are handed over to the customer for the beneficial use.
Equipment warranty expires on : Attended by: Blue Star Ltd. Signature:
For office use: The above equpiment has been installed and
commissioned to our satisfaction.
Other comments (if any).
Date : Customer’s Stamp & Signature

5091-10C Registered Office : Kasthuri Buildings, Jamshedji Tata Road, Mumbai 400 020
116
USER'S MANUAL
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
117
Log Report
Customer's Name
Date:
Time
S.No Description Units 10.00 12.00 14.00 16.00 18.00
1 Voltage R-Y Volts
Voltage Y-B Volts
Voltage R-B Volts
2 Current - R Amps.
Current - Y Amps.
Current - B Amps.
3 Supply Frequency Hz
4 Suction Pressure comp. PSIG
5 Discharge Pressure comp. PSIG
6 Compressor Current. Amps.
0
7 Cooler Entering Water temp. F
0
8 Cooler Leaving Water temp. F
9 Cooler Pressure drop PSIG
10 Cooler water Flow rate US GPM
0
11 Condenser Entering water temp. F
0
12 Condenser Leaving water temp. F
13 Condenser Pressure drop PSIG
14 Condenser water Flow rate US GPM
0
15 Refri. System temp. - Suction F
0
16 Refri. System temp.-Discharge. F
0
17 Refri. System temp. - Liquid F
118
USER'S MANUAL
Warranty Claim Form

For Blue Star Air / Water Cooled Screw Chillers
A copy of this form is to be filled in case of the Chiller failure, by BSL Engineer)
Location (City) ……......……………. Date ………...…….
Chiller Model No: Chiller Serial No.
Date of despatch Date of commissioning
Warranty commencing date Warranty expiry date
Application in which equipment is used
Customer’s Name and Address Dealer’s Name and Address
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 YesNo
Insulation resistance (Megger test)…………….....…….. Ohms
Any vibration in piping Yes No
Less cooling in cooler Yes No
Checked Water flow rate Yes No
Checked Compressor working in full Load Yes No
Operating pressure checked Yes No
Shortage of refrigerant Yes No
Signature & Seal of Customer 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 …………………………….
119
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.
120
USER'S MANUAL
Service Centres
EAST SOUTH WEST

BHUBANESHWAR BANGALORE BHOPAL
3A, Satya Nagar, Ozone Manay Technology Park “Star Arcade”, 2nd Floor
2nd Floor, Sy. No. 56/18 & 55/9 Plot No.165A & 166, Zone-I
Bhubaneswar 751 007. Hongasandra Village Maharana Pratap Nagar
Tel: (0674) 2508270 / 2508303 Begur Hobli, Garvebhavipalya Bhopal 462 011.
Bangalore – 560 068 Tel: (0755) 2553378 /
GUWAHATI
New Star Freeze Building Phone : 41854000 4273378 / 79
2nd Floor,
Opp. Kunjalata Bibah Bhawan, CHENNAI GOA
G. S. Road, 104, ‘Garuda Building’, 1st Floor, Flat No.1
Guwahati 781 005. Cathedral Road, Buddhaseth Apartments, Tonca,
Tel: (0361) 2340619 / 2340620 Chennai 600 086. Caranzalem, Goa 403 002.
Tel: (044) 42444200 Tel: (0832) 2461671 / 2462087
KOLKATA 28116707- 8
7, Hare Street MUMBAI
Kolkata 700 001. KOCHI Blue Star House
Tel: (033) 22134200 / 39/5766, Tharakandam Estate 9A, Ghatkopar Link Road
22106609 Kurisipally Road Saki Naka, Mumbai 400 072.
Kochi 682 015. Tel: (022) 66684200 / 66684000
NORTH Tel: (0484) 2356139 /
NAGPUR
2357933 / 2357934
CHANDIGARH 219, Bajaj Nagar, 1st Floor,
SCO 1, Madhya Marg, Sector 26 South Ambazari Road,
Chandigarh 160 019. SECUNDERABAD Nagpur 440 010.
Tel: (0172) 2790482 / 5024000 207, Sikh Road Tel: (0712) 2229244 / 2249000
Bantia Estates
JAIPUR Secunderabad 500 003.
A-19, Main Sahakar Path, PUNE
Tel: (040) 44004000
Near Sahakar Bhawan, 201/A, Nityanand Complex
Jaipur - 302 001. TRIVANDRUM 1st Floor, 247/A
Tel: (0141) 2744033 T.C. IX/1490 Bund Garden Road
‘Chandrika’, Sasthamangalam Pune 411 001.
LUCKNOW Trivandrum 695 010. Tel: (020) 26167230
B-140, Nirala Nagar Tel: (0471) 2720025 / 2720065 / 26163031 / 26162307
Lucknow 226 020.
Tel: (0522) 2786172 / 2787274 VISAKHAPATNAM VADODARA
47-12-6/7 Ramakrishna Chambers
NEW DELHI 2nd Floor 7th Floor, Productivity Road
E-44/12 Okhla Ind. Area Amaravathi Complex Alkapuri, Vadodara 390 005.
Phase II, Ohkla Dwarakanagar
New Delhi 110 020. Tel: (0265) 2338561 /
Visakhapatnam 530 016. 2332021 / 2332022
Tel: (011) 41494200 / 000
Tel: (0891) 2748405 / 2748433
121
For any
assistance,
CALL:
Blue Star Service:
Ph: ............................................................
Cell: ..........................................................
Blue Star Dealer:
Ph: ............................................................
Cell: ..........................................................
Blue Star Regional Manager:
Ph: ............................................................
Fax: ..........................................................
Blue Star’s/Dealer’s engineer to fill

above details before handing over
this Manual to customer.
122
USER'S MANUAL
BREATHE EASY
123

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Vdocuments - MX - Blue Star Chiller Air Water Cooled Screw Chiller r22 DX Manual PDF

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Available Formats

Air Cooled and Water Cooled Screw Chillers

Revised January 2008

No part of this publication may be reproduced in any

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 .................................................................................................... 9

Rigging and Installation .................................................................................................... 27

Carel Controller ............................................................................................................... 30

Screw Compressor ......................................................................................................... 47

Pre start up, Testing, Commissioning and Operation ....................................................... 54

Trouble Shooting ............................................................................................................. 84

Spares Part List .............................................................................................................. 90

Field Feed Back Form ....................................................................................................114

Commissioning and Handing over report ........................................................................116

Water Quality .................................................................................................................117

Log Report .....................................................................................................................118

Warranty Claim Form .....................................................................................................119

Warranty ....................................................................................................................... 120

Blue Star Service Offices .............................................................................................. 121

• Highly efficient with low noise levels

• Tested in accordance with ARI Standards

• The cooler outlet temperature can be controlled accurately

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

• Password protection at two levels.

Optional features in Control Centre

• RS 485 port & TCP/ IP web gate for remote connectivity,

• PC connectivity and remote monitoring without BMS

Following additional features are available in Air Cooled version:

Air cooled condenser

Optional items available in air cooled version are:

Nomenclature - Air Cooled Chiller

AIR COOLED SCREW COMPRESSOR

Nomenclature - Water Cooled Chiller

WATER COOLED SCREW COMPRESSOR

Description Unit LCAX1-075 D i A LCAX1-102 D i A LCAX 1-145 D i A LCAX1-206 D i A

Compressor Semihermetic Screw

Model BSC-075A BSC-105A BSC-145A BSC-210A

Operating Speed RPM 2950 2950 2950 2950

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

Ccompressor Rated Current. Amp. 131.9 182.6 250.9 357

Compressor Locked Rotor Current Amp. 730 735 1100 1760

Compressor Starting Current Amp. 230 245 370 590

Compressor Power Consumption kW 81.1 112.3 154.7 219.8

Unit starting Current Amps 235 252.5 380 605

Unit Power Consumption kW 85.9 119.5 164.3 234.2

R-22 Refrigerant Charge Kg 67 90 130 175

Oil Charge (Blue Star ACS) Litres/compr 16 16 23 28

Rows Deep No. 3 3 3 3

Tube Material 3/8" Inner grooved,.Copper

Type of Aluminium Fins Super Slit

Fins per Inch 14 14 14 14

Fan for Air Cooled Condenser

Fan Dia mm 915 915 915 915

Air Flow CFM 48,000 72,000 96000 1,44,000

Condenser Fan Motor

Type Totally enclosed, Pad Mounted

Speed RPM 700 700 700 700

Full Load Current Amp. 2.6 2.6 2.6 2.6

Power Input KW 1.2 1.2 1.2 1.2

Technical Specification for Air Cooled Screw Chiller (Single Compressor)

Description Unit LCAX1-075 D i A LCAX1-102 D i A LCAX 1-145 D i A LCAX1-206 D i A