MODEL:SPAC-08N/10N

User’s
Manual
First published September 2006

Designed and manufacturing by Blue Star Limited.

No part of this publication may be reproduced in any

manner whatsoever without permission in writing from the
Head, OEM Business,
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.

Published by Blue Star Limited, OEM Business.

For restricted circulation only. Not for sale.

Process Chiller
(Model : SPAC-08N/10N)

Contents
Features ..................................................................................................................2~7

Nomenclature ..............................................................................................................8

Technical Specification ...............................................................................................9

Safety Consideration ......................................................................................................10

Installation Instructions ........................................................................................11~17

GA Drawing ..............................................................................................................18

Refrigeration & Hydronic circuit......................................................................................19

Exploded View..................................................................................................................20

Hydronic View...................................................................................................................21

Electrical Wiring Diagram & Legend ................................................................ 22~24

Pre Start Checkup ....................................................................................................25

Control ................................................................................................................ 26~28

Operating Instructions ...............................................................................................29~34

Trouble Shooting ................................................................................................ 35~36

Maintenance ....................................................................................................... 37~38

Maintenanace schedule ..................................................................................................39

Spare Parts List ..................................................................................................40-41

Warranty ....................................................................................................................42

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 Process Chiller
(Model SPAC-08N/10N)

Features
Structure
The base structure is of the pre – painted galvanized MS sheets
which is powder coated with Broken white color. The panel design
is such that to ease of removable for serviceability.

Compressor
The Chiller is equipped with the most energy efficient Scroll
compressors. Addition to the energy efficiency it has the following
features.

Advantages of scroll compressor

• Scroll design has superior liquid handling capability and
requires no tip seals that wear out.
• Scroll compressors achieve high efficiencies due to
100% volumetric efficiency during the compression
process.
• Its small footprint and vertical orientation reduces the
square footage you need. It is lightweight and stackable,
making it the ideal.
• Scroll compressors function with fewer moving parts,
and no discharge or intake valves. This enables the
Copeland Scroll compressor to operate more smoothly
and quietly, with less vibration.

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Process Chiller
(Model SPAC-08N/10N)

Evaporator
The evaporator used in this model is of brazed type plate heat
exchanger usually called as PHE. The brazed type PHE has the
following advantages over other type of heat exchangers.

• Compact
• Low Weight
• Less Space Required
• Highly reliable for Same Result
• No Gaskets
• No leaks
• High Heat Transmission Rate
• High Operation Temperatures and High Working
Pressure
• SUS316 (AISI 316) Stainless Steel for Effective
Corrosion Resistance
• Easy Installation and Replacement,
• Low Maintenance Requirements

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 Process Chiller
(Model SPAC-08N/10N)

PHE has the following construction.

A Plate Heat Exchanger, or PHE, is constructed of a series of
plates that have been either stamped or embossed with channels.
The channels are where the fluid flows as it passes through the
system.
The plates are stacked so they form a multi-layered alternating path
for each fluid to travel through. Each layer or circuit is linked to a
inlet and outlet via a manifold at either end. The design of a PHE
maximizes surface area to provide greater heat dissipation.
There are two independent circuits in a PHE. One is used for the
fluid to be cooled or heated, the other circuit for fluid source, providing
the chilling or heat dissipated from the fluid, then transferred through
plates of the exchanger body for pickup by the cooling or heating
fluid.
Brazed type PHE are constructed in such a manner that Plate and
Frame system are connected with exception that they do not contain
gaskets and are assembled with high temperature brazing rather
than frames.

Condenser Coil:
Condenser coil used in the system is of fin and tube type. The
condensers are properly designed for the ambient conditions through
design software’s. The fins in the condenser are of hydrophobic
coated (corrosive resistance) aluminum and the tubes are of copper.
The fins used in the condenser are of sinusoidal and slitted fins,
which increase the air side heat, transfer. The copper tubes are of
inner-grooved type, which increases the heat transfer in the
refrigerant side.

Condenser Fans:
The chiller is fitted with 4-blade fans made of aluminium.
All the fans are designed for excellence in the vibration and
noise levels for all flow rate and static pressures. The lightweight
fan enhances the motor performance like low input power, better
mechanical efficiencies.

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Process Chiller
(Model SPAC-08N/10N)

Controller
These chillers are provided with CAREL, Italy controllers. These
controllers are specifically developed for the chillers applications.
The controller has the following salient functions.

• Control of the water inlet and outlet temperature

• Complete alarm management
• Auto loading/ unloading of compressor
• Automatic starting of unit in case of Power failure
• Built-in time delays for Compressor and Evaporator
Pump
• Single phase/Phase reversal protection
• External alarm facility
• Password protection at various levels
• In-built antifreeze safety

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 Process Chiller
(Model SPAC-08N/10N)

Safety:
The chillers are provided with safety features for the normal
operations of the unit.
The following are protections provided.

S.No. Components Safeties

1 Compressor High-pressure switch

Low-pressure switch
Motor protection
Circuit breaker
Single phase/phase reversal
Anti freeze cut out and
LWT temp sensors
Time delay for compressor on/off
Crankcase heater

2 Pump Overload trip

Flow switch

3 Hydronic circuit
Suction Strainer
Flow switch

4 Electrical IP-54
Fuses for control and crankcase
heater

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Process Chiller
(Model SPAC-08N/10N)

Hydronic System

Pump:
These chillers are fitted with CH series of Grundfoss make pumps.
The CH pumps are non-self-priming, horizontal, centrifugal pumps
with mechanical shaft seal and extended pump/motor shaft. The
pumps have axial suction port and radial discharge port and are
mounted on a base plate. All movable parts in contact with the
pumped liquid are made of stainless steel. The pump is fitted with
a totally enclosed, fan-cooled, squirrel-cage Grundfoss motor.

Hydronic Piping:
The hydronic systems are piped with corrosion resistance Grade
SS 304 seamless pipes. Pipes are argon welded and pressure
tested for leaks.

Strainer:
The hydronic circuit is provided with Y type strainers The strainers
protect the pump impeller from dust particles and debris. Brass
material construction of the strainer prevents the strainer from rusting.

Buffer Tank:
Stainless steel buffer tank is provided in the Hydronic circuit to take
up the load fluctuation on chiller. The tank is argon welded and
tested for leaks.

Float Valve:
Brass float valve is provided in the inlet makeup water for
automatically maintaining the water level in the buffer tank.

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 Process Chiller
(Model SPAC-08N/10N)

Nomenclature

S P A C - 10 N

New Series
Capacity
in TR
Special Chiller

Process
Process Air-cooled

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Process Chiller
(Model SPAC-08N/10N)

Technical Specifications of Air Cooled Packaged Process Chillers

Nominal Capacity ** TR / Kw 7.5 / 26.4 10 / 35

Model UNIT SPAC-08 SPAC-10
Size L mm 1410
Size W mm 755
Size H mm 1275
Net Weight Kg. 485 535
Operating weight Kg. 605 655

Electric power supply V/PH/Hz 400/3/50 400/3/50

Incoming Cable Size mm² AL/Cu 4/6 10 / 6

Compressor
Type Scroll
Make Copeland
Input Power (each) Watts 3885 5450
Qty Nos. 2

Evaporator Type Brazed Plate heat exchanger

Qty Nos. 1 (Dual)
Construction material Stainless steel

3/8” OD inner grooved tubes, 0.14mm thk hydrophobic coated slit

Condenser Type fins
Coil Face Area Sq. Ft. 24.4
Coil Fins per inch / Rows Nos. 14 / 1.5 14 / 2
Total Air Flow CFM 8200 8500
Fan Dia x Qty. Inch x Nos. 22” x 2
Fan Material Aluminium
Motor Make, Type & Speed RPM GE, Totally enclosed, 900
Motor Input Power (each) Watts 325
Qty Nos 2

Chilled Water Pump Type Centrifugal , monoblock

Make Grundfoss
Max Flow Rate LPM/USGPM 167/ 44 167/ 44
Maximum Pressure head meter 47 47
Pump Power Input Watts 1290 1290

Total (input) Load Electrical Watts 9710 1290

High pressure switch, Low pressure switch, Flow switch, Antifreeze protection,
Safety Devices Alarm with buzzer
Electrical Safety Crankcase heater, Overload for pump, Circuit breaker for compressor
(Single phase/Phase reverse protection only for scroll compressors)

Tank Capacity Lts. 120

Chilled water connection - Inlet NB. 1 ¼”

-Outlet NB. 1 ¼”

** Rating Conditions:
The ratings are based on 12.2 0C (54 0F) chilled water inlet and 6.7 0C (44 0F) chilled water outlet for Cooler with
0.00010F.ft2.hr/ Btu fouling factor and 35 0C (95 0F) ambient temperature.

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 Process Chiller
(Model : SPAC-08N/10N)

Safety Considerations.
Installing, starting up, and servicing air-conditioning equipment Can
be hazardous due to system pressures, electrical components, and
equipment location (roofs, elevated structures, Etc.).Only trained,
qualified installers and service mechanics should install, start up,
and service this equipment.
Untrained personnel can perform basic maintenance functions Such
as cleaning coils. Trained service personnel should perform all other
operations.
When working on the equipment, observe precautions in the literature
and on tags, stickers, and labels attached to the equipment.
• Follow all safety codes.
• Wear safety glasses and work gloves.
• Keep quenching cloth and fire extinguisher nearby when brazing.
• Use care in handling, rigging, and setting bulky equipment.

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Process Chiller
(Model SPAC-08N/10N)

Installation Instruction
Step 1- Rig and place the unit
Rigging
The rigging of the unit to be done with nylon ropes. Use hooks of
the ropes in the hooks provided in the Base. Rig at a single point
using four ropes. While rigging the units panels should be in position.
See technical specification for the holes for rigging, its dimensions
and lifting ring dimensions. See fig. For rigging.
If overhead lifting is not possible, place the chiller on a skid or pad
for rolling or dragging. While rolling use minimum of 3 rollers. When
dragging the unit should be dragged by applying force to the pad.
Applying force on the unit should not drag the unit. When in final
position raise the unit to lift from pad.
CAUTION: All panels should be in place while rigging.

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 Process Chiller
(Model SPAC-08N/15N)

Placement
The placement of the unit should be as specified in the drawing. The unit should be placed in
this position for good serviceability and air flow for the condenser.
Mounting Unit:
When the unit is in proper position, Use of mounting holes in the base is recommended for
securing the unit to the foundation or for mounting the unit in vibrating isolator. See fig for the
dimensions of the mounting holes.
Be sure that the level of the foundation on which the unit is placed is leveled properly to ensure
proper oil return of the compressor

Airflow 1000mm

1000mm 1000 mm

1000 mm

ROOF

2500 mm

GROUND

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 Process Chiller
(Model : SPAC-08N/10N)

Step 2. Hydronic Circuit

The chillers with factory-installed hydronic packages with
buffertank to supply the proper quantity of water to the
system. Makeup water with float valve and overflow
connections are provided to automatic makeup in the water
system in case of any water loss in the circuit.
Flow switch is provided for safety of the system in case of
non water availability in the circuit.
Suction strainer is provided in the system to avoid unwanted
particles and dusty particles in the system.It is recomended
to provide the strainer in the makeup water in case the
makeup water quality is not good.Factory-supplied hydronic
systems are available with pumps.

Installation of water systems should follow sound

engineering practice as well as applicable local and industry
standards. Improperly designed or installed systems may
cause unsatisfactory operationand/or system failure. Consult
a water treatment specialist orappropriate literature for
information regarding filtration, watertreatment, and control
devices. Figure shows a typical installationwith components
of the hydronic package of the unit

IMPORTANT NOTE:
Please ensure that Y strainer is installed before inlet water makeup in
the field.

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Process Chiller
(Model SPAC-08N/10N)

Water Connection
The water connection to the units Evaporator should be with
corrosion resistant material SS 304 seamless pipe.
The connection as follows
Water Connection IN / OUT of PHE Chiller: are
1-1/4” threaded (M) BSP connections.

Caution !
Any pipe connection to the chiller water package should be of
material, which can withstand the operating pressure of around 6
bars.

Water Quality
Since Brazed Heat Exchangers with stainless steel plates and copper
brazing are closed units and cannot be opened for mechanical
cleaning or inspection, it is suggested that precautions are taken so
that fouling/corrosion on the units does not occur.
In water systems, if the water is dirty and contains sediments, a
strainer of a mesh size of approximately 0.5-1.0 mm is to be installed
in the water circuit at the inlet to the heat exchanger.
Avoid using water containing a high percentage of dissolved solids.
This can form scales on the heat transfer surface and reduce the
thermal efficiency of the Heat Exchanger, which is then to be cleaned
in place by circulating a suitable CIP solution to dissolve the scales.
The water also should not contain chlorides, which can attack the
stainless steel plates and can cause pitting, crevice corrosion, which
will develop into pinholes on the plates. The permissible chloride
content is less than 50ppm at a Ph of 7.0 for the water. At lower Ph
values, the chloride limits are still lower.
Usually it is advisable to maintain a Ph 6.5 - 7.5, as a higher Ph will
increase the risk for scaling and a lower Ph will increase the risk of

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 Process Chiller
(Model SPAC-08N/10N)

corrosion attack by the chlorides.

For preventing scaling, it is necessary to keep the following as low
as possible.
Total Solids
Alkanity
Calcium Content
It is suggested a check made, about the scaling tendencies of the
water by analyzing the above factors and the Ph value of water.
There can be various combinations of the above values which give
an acceptable analysis at the operating temperature. One such
typical water analysis is given below.

pH Value-7
Alkalinity as CaCo3, ppm – 50
Calcium as CaCo3, ppm – 100
T.D.S. ppm – 500
** This water will have less scaling tendency up to an operating
temp of 60 deg.
Another set of values is as below:

pH Value-8
Alkalinity as CaCo3, ppm – 30
Calcium as CaCo3, ppm – 200
T.D.S. ppm – 500
** This water will have less scaling tendency up to an operating
temp of 50 deg.

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 Process Chiller
(Model SPAC-08N/10N)

Step 3: Electrical Wiring

WARNING

Check that the power supply is off when working on the unit electrical
system. The unit must be connected to the earth.

Caution !
It is the installer responsibility to check that the external wiring
complies with the local safety regulations.

Electrical Supplies
The Following connections are required:
For the unit 415 V /50 Hz Three phases: 3 phases + neutral
Supply and isolating Devices must be designed with fully independent
lines.

Electrical Connections
Supply lines shall consist of insulated copper connectors sized
for maximum current draw.
Terminal connection must be made according to the connection
diagram.

Caution !
Before connecting the main supply check that the main voltage
is within the range shown in the electrical data.

For the 3 phases supply also check that the phase unbalance does
not exceed 2 % .The check is performed by measuring the difference
between the voltages during operation .The maximum measured
difference must not exceed 2% of the average voltage. If the
unbalance is not correct the electricity supplier must be contacted
to be correct the difference.
.

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 Process Chiller
(Model SPAC-08N/10N)

Step 4. Refrigerant Circuit.

Leak Testing
Units are shipped with complete operating charge of refrigerant R22
and should be sufficient for leak testing. Leak test to be conducted
to ensure that there is no leak due to shipment. Dehydration is not
required unless entire system charge is lost. Repair any leak found
by good refrigeration practice.

Dehydration
Connect the vacuum pump on both suction and discharge side
(service valve provided) do the dehydration reaching a minimum
absolute pressure of 50 Pa. The vacuum has to hold for 30 minutes

Refrigerant Charging
Proper charging of Refrigerant is done by continously monitoring
the operating pressure of the refrigerant system. The refrigerant
should be as mentioned in the technical specification.

Caution
1. While charging, circulate water through the cooler to avoid
freezing.
2. Do not overcharge the system. Overcharging results in high
discharge pressures, consumption more cooling fluid, possible
compressor damage and high compressor power consumption.

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Process Chiller
(Model SPAC-08N/10N)

GA Drawing
Process Chiller
(Model SPAC-08N/10N)

Refrigeration & Hydronic Circuit-Packaged Process Chiller

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Process Chiller
(Model SPAC-08N/10N)

EXPLODED VIEW

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Process Chiller
(Model SPAC-08N/10N)

HYDRONIC VIEW

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 Process Chiller
(Model SPAC-08N/10N)

ELECTRICAL WIRING DIAGRAM

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Process Chiller
(Model SPAC-08N/10N)

LEGEND FOR ELECTRICAL CONTROL BOX

HERMETIC PACKAGED CHILLERS SPAC-08N / 10N

S. DESCRIPTION SPAC-08N SPAC-10N

NO. SPECIFICATIONS SPECIFICATIONS QTY LEGEND
CONTACTOR & SNUBBER 415 V,12 A SIEMENS 3TF31 1 415 V,16 A SIEMENS 3TF32 1
1 2 1M, 2M
FOR COMPRESSOR NC,2NO, 220V NC,2NO, 220V
CONTACTOR & SNUBBER FOR
2 415 V, 9A SIEMENS 3TF30 415 V, 9A SIEMENS 3TF30 1 3M
PUMP
3 OVERLOAD RELAY FOR PUMP 2.5-4 A, SIEMENS 3UA50 00-1E 1 O/L1
MINI CIRCUIT BREAKER FOR 16 A, 3 POLE,10kA SCHNEIDER 20 A, 3 POLE,10kA SCHNEIDER
4 2 CB1, CB2
COMPRESSOR C16 C20
5 MINI CIRCUIT BREAKER FAN 6 A 2 POLE, SCHNEIDER C6 6 A 2 POLE, SCHNEIDER C6 2 CB3,CB4

5 HI PR. SWITCH 400 PSIG CUT-OFF 400 PSIG CUT-OFF 2 PS2, PS4

340 PSIG CUT-ON 340 PSIG CUT-ON

SAGINOMIYA ACB-DB138 SAGINOMIYA ACB-DB138

6 LO PR. SWITCH 35 PSIG CUT-OFF 35 PSIG CUT-OFF 2 PS1, PS3

50 PSIG CUT-ON 50 PSIG CUT-ON

SAGINOMIYA LCB-DA80 SAGINOMIYA LCB-DA80

7 FLOW SWITCH 1" NPT,10 BAR PR., 250 V SAGINOMIYA FQS U30G 1 FS

8 FUSE (CONTROL CKT) 2A CARTRIDGE TYPE ELCOM MAKE 1 F1

9 FUSE (CRANK CASE) 3A CARTRIDGE TYPE ELCOM MAKE 2 F2, F3

11 TERMINAL 60 A PROGRESS TRM60 10 R,Y,B,N

CR1,CY1,CB1

CR2,CY2,CB2

20 A PROGRESS TRM20 21 F1,F2,N

CCH1,CCH

CCH2,B1,B2,B3,ID2

ID3,ID4,ID5,ID8,ID9

ATH,GND,N05,N

12 COMPRESSOR COPELAND ZR 57 KC TFD COPELAND ZR 81 KC TFD 522 2

400 V, 3PH,7.8 A 400 V, 3PH,10.1 A COMP1, COMP2

EVAP TEMP : 1.2 °C EVAP TEMP : 1.2 °C

COND TEMP: 52 °C COND TEMP: 52 °C

SUB COOLING : 5°C SUB COOLING : 5°C

SUPERHEAT : 10°C SUPERHEAT : 10°C

13 CRANKCASE HEATER 230 V,70 W COPELAND 018-0053-00 2 CCH1, CCH2

14 PUMP CH8-50 Flow: 8 m3/h, 31.8 m head, 415 V AC/ 50 Hz, 3 A 1 PUMP

15 COND. FAN MOTOR 1/3HP, 1 PH ,230 V, 50 Hz, 2.4 A, 900 RPM 2 FAN 1,2

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 Process Chiller
(Model SPAC-08N/10N)

16 TRANSFORMER 230V/ 24VAC 13VA, Kavita 1 TR

17 ISOLATOR SWITCH TRIPLE POLE 50A VCF-1 SCHNEIDER 1 SW1

18 CONTROLLER CAREL MICROCHILLER-2, 24 VAC, 4 ANALOG INPUTS, 1 CNTR

5 DIGITAL INPUTS, 5 RELAYS,MCH2000001

19 CONNECTOR KIT CAREL MCH2CON001 1

20 TEMP. SENSOR CAREL NTCO30HP00, 3.0 m,-50 - 105 °C,10 k Ω at 25°C 2 PB1,PB2

21 CONTROLLER EXP. BOARD CAREL MCH2000021, 24 VAC,3 ANALOG INPUTS, 1 EXP. BOARD

5 DIGITAL INPUTS,5 RELAYS

22 EXP. BOARD CONNECTOR KIT 1

CAREL MCH2CON021

23 SINGLE PHASING / 1 SP/PR

240 V AC, MINILEC MAKE, VSP D1
PHASE REVERSE PREVENTOR

24 TOWER LIGHT JAI BALAJI JBTL99, 230 V AC, WITH BUZZER 1 AL

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Process Chiller
(Model SPAC-08N/10N)

Pre-Start Check-up
1. Proper sizing of mains incoming cable
2. Unit is properly earthed.

3. Water inlet and outlet isolating valves are open.

4. Temperature sensors are properly placed in their respective

positions.

5. De-mineralized water priming of evaporator pump and storage

tank.

6. Proper sizing of inlet/outlet water pipe connections.

7. Positioning of Chiller in order to prevent air movement on the

condenser and fan.

8. Unit is fully charged with refrigerant

9. Main Isolator switch must be on at least 8 hours before starting

the chiller (Ensure Crank case heater for compressor is ON).

10. Setting of overload relay for Pump

11. Check for proper rotation of the condenser fans before starting
of the compressor and pumps.

12. Check for the oil level in the compressor sight glass. Normally
the oil should be from ¼ to ¾ of the sight glass. Charge the oil
if required as mentioned in service condition.

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 Process Chiller
(Model SPAC-08N/10N)

Control
Main Functions:
Control of the water inlet and outlet temperature;
Complete alarm management
Auto loading/ unloading of compressor
Automatic starting of unit in case of Power failure
Built-in time delays for Compressor and Evaporator Pump
Single phase/Phase reversal protection
External alarm facility
Password protection at various levels
In-built antifreeze safety

Controlled devices
Compressor;
Water pump for evaporator;
External alarm signal device.

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Process Chiller
(Model SPAC-08N/10N)

User Interface

Display
The display features 3 digits, with the display of the decimal point
between -99.9 and 99.9.
Outside of this range of measurement, the value is automatically
displayed without the decimal (even if internally the unit still operates
considering the decimal part).
In normal operation, the value displayed corresponds to the
evaporator water outlet temperature. Fig. 1 shows the symbols
present on the display and on the keypad and their meanings.

Compressors
Number Programming
Cooling

Up
Heating
N.A.

Alarm

Down

Antifreeze
Selecting

Defrosting Fan
N.A. N.A. Compressor
Pump

NA.: Not Applicable

Symbols on the Display:

Display with 3 green digits (plus sign and decimal point), amber
symbols and red alarm symbols.
Symbol Color Meaning
When LED is on When LED is flashing
1 Amber Compressor 1 ON Start up request
Amber At least one compressor ON
Amber Pump ON
Red Alarm active
Amber Chiller mode

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 Process Chiller
(Model SPAC-08N/10N)

Functions associated with the buttons

Button Unit status Button press

mode
Go up a sub-group inside the programming area,
until exiting (saving changes to E2PROM) Press once
In the event of alarms mute the buzzer(if present)
and deactivate the alarm relay Press once
Access the direct parameters Press for 5s
Select item inside the programming area and
display value of direct parameters/confirm
changes to the parameters Press once
Program parameters after entering the password Press and hold
together for 5s

Select top item inside the programming area Press once or

press and hold
Increase value Press once or
press and hold
Switch from standby to Chiller mode and
vice-versa Press for 5s
Select bottom item inside the programming area Press once or
press and hold
Decrease value Press once or
press and hold
Manual alarm reset Press and hold
for 5s
Immediately reset the hour counter
(inside the programming area) Press for 5s

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Process Chiller
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Operating Instruction
Activity Procedure

1. Switching ON the Chiller 1. The controller is in standby mode and the Leaving
Water temperature is displayed.
2. Press “ ” key on the keypad and hold it pressed
for 5 seconds to start the unit.
3. The “ ” symbol is displayed indicating that the
Pump is ON.
4. After a factory preset delay, if the system is healthy,
the compressor and condenser fans will start
depending on the Leaving Water temperature and
Cooling Set Point.
5. The symbols “1” and “ ” are displayed,indicating
that the Compressor is ON.
2 Viewing Entering Water 1. Press “ ” key and hold it pressed for 5 seconds.
Temperature 2. Use “ “ and “ “ to select the parameter menu
(S-P) and then press “ ”
3. Use “ “ and “ “ to select the Probe reading
parameter group (b) and then press “ ”.
4. Use “ “ and “ “ to select the Probe reading
parameter ‘b01’ which gives the Entering Water
Temperature.
5. Press “ “ repeatedly until reaching the main
menu.
3. Switching OFF the Chiller 1. Press “ ” key on the keypad and hold it
pressed for 5 seconds to stop the unit and
bring it to standby mode.
2. The Compressor and Condenser fans get switched
off immediately and the Crankcase Heater is
switched ON automatically.
3. The Pump is turned OFF after a preset delay.

4. Setting the cooling set 1. Press “ “ and “ ” together for 5 seconds;

point and cooling differential
2. The heating and cooling symbol and the figure
“00” are displayed;
3. Use “ “ and “ “ to set the user level password
22 and confirm by pressing “ ”;

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 Process Chiller
(Model SPAC-08N/10N)

Activity Procedure

4. Select the parameter menu (S-P) by pressing “ ”

5. Use “ “ and “ “ to select the Control setting
parameter group “ – r – “ and then press “ ”
6. Use “ “ and “ “ to select the cooling set point
parameter “– r01–”and then press “ ”.
7. Use “ “ and “ “ to make changes to the cooling
set point.
8. After making the changes to the parameter, press
“ ” to confirm.
9. In order to set the cooling differential select
parameter “– r02–”in step 6 and repeat steps 7
and 8.
10. Press “ “ repeatedly until reaching the main
menu.

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Process Chiller
(Model SPAC-08N/10N)

Table of Alarms:
Alarm Alarm type Resetting Compr. Pump Alarm Warning Supervis Var.Type
display & Superv.Variab.
Cond.
Fans description
HP1 High pressure Manual OFF - ON - Circuit alarm Digital
LP1 Low pressure Manual OFF - ON - Circuit alarm Digital
tP Single Phasing / Manual OFF OFF ON - Circuit alarm Digital
Phase Reversal
FL Flow controller Manual OFF OFF ON - Circuit alarm Digital
alarm
E1 Probe B1 alarm Automatic OFF OFF ON - Probe alarm Digital
E2 Probe B2 alarm Automatic OFF OFF ON - Probe alarm Digital
Hc1-4 Hour warning Automatic - - - ON Compressor Digital
C1-4 advice
EPr EEPROM error Automatic - - - ON General advice Digital
during operation
EPb EEPROM error Automatic OFF OFF OFF OFF General warning Digital
at thestart-up
A1 Antifreeze alarm Automatic OFF OFF ON - Circuit Alarm Digital
Ht High temperature Automatic - - ON - Temperature Digital
Temperature advice
warning
AHt High temperature Automatic OFF - - ON General advice Digital
at start-up
Alt Low temperature Automatic OFF - - ON General Advice Digital
at start-up
ELS Low supply Automatic - - - ON General advice Digital
voltage
EHS High supply Automatic OFF OFF - ON General advice Digital
voltage
Note: The warning relay differs from the alarm relay as it is only activated for warnings, that is, signals only, which have
no direct effect on the operation of the unit, and the display does not show the alarm symbol (bell).

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 Process Chiller
(Model SPAC-08N/10N)

Resetting of Alarms:
As shown in the table above alarms such as HP1, LP1, FL and tP
are to be reset manually by the user, once the respective fault has
been cleared. In order to reset these alarms, press and hold the
& keys together for 5 seconds.

Description of Alarms:

HP1: High pressure

The alarm is detected irrespective of the status of the pump and
the compressors. The compressor and the condenser fans
corresponding to circuit are immediately stopped (ignoring the set
protection times), the buzzer and alarm relay are activated, and the
display starts flashing. It is reset manually by the user once the
fault has been cleared.

LP1: Low pressure

The alarm is detected if the compressor in the circuit is ON, and
after the time P03 from when the compressor started, otherwise it
is immediate. The compressor and condenser fans corresponding
to circuit are immediately stopped (ignoring the set protection times),
the buzzer and alarm relay are activated, and the display starts
flashing. It is reset manually by the user once the fault has been
cleared.

FL: Flow alarm

This alarm is detected only if the pump is ON (excluding the delays
when starting P01 and in steady operation P02), irrespective of the
status of the compressor. All of the outputs are disabled: pump,
compressor and condenser fans (without observing the OFF times)
and the buzzer sounds, the alarm relay is activated and the display
flashes. It is reset manually by the user once the fault has been
cleared.

32
Process Chiller
(Model SPAC-08N/10N)

tP: Single Phasing/Phase reversal

The alarm is detected in case of Phase reversal or failure of any

one phase. The alarm is triggered irrespective of the status of the
pump and the compressors. The compressors, the pumps and fans
stop (without observing the protection times) or are inhibited from
starting, the alarm relay is activated, the display flashes the
corresponding message, and the LED flashes. It is reset manually
by the user once the fault has been cleared.

E1, E2: probe error detected even when the unit is in

Standby
The presence of a probe alarm causes the deactivation of the
compressor, the condenser fans, the pump; the buzzer and alarm
relay are activated, and the display starts flashing.

Hc1: compressor operating hour limit exceeded

warning
When the number of operating hours for the compressor exceeds
the maintenance threshold (as default equal to zero, and
consequently the function is disabled), the maintenance request
signal is activated. The buzzer and the alarm relay are not activated,
however the warning relay is activated.

Epr, EPb: EEPROM error

A problem has occurred when saving the parameters to the unit’s
non-volatile memory (EEPROM); in the event of an Epr error, the
µC2 continues to perform the control functions with the data present
in the volatile memory (RAM), where there is a physical copy of all
of the data. After the first power failure the configuration will be
lost. The buzzer and the alarm relay are not activated. If the fault
occurs when starting the unit, “EPb”, the controller will not operate.

A1: antifreeze alarm

The alarm is detected by the evaporator water outlet probe (B2).
The compressor and the condenser fans in the circuit are
immediately stopped, the buzzer and alarm relay are activated,
and the display starts flashing. If the µC2 is in Standby, the alarm
condition is not detected. The unit restarts automatically if the
temperature is above the value A01 + A02.

33
 Process Chiller
(Model SPAC-08N/10N)

Ht: high temperature warning

This alarm is activated when the threshold is exceeded (read by
B1), set for the parameter P16. It is delayed at power ON by the
parameter P17 and causes the activation of the alarm relay and
the buzzer, without deactivating the outputs. It is reset automatically
when conditions that caused the alarm are no longer present.

AHt: high temperature warning when starting the

system.
The advice does not activate the relay, and displays the message
“AHt”.

ALt: low temperature warning when starting the

system
The advice does not activate the relay, and displays the message
“ALt”.

ELS/EHS: warning, low/high power supply alarm

If the power supply voltage is too low or too high, the corresponding
message is displayed. In these cases, the correct operation of the
µC2 is no longer guaranteed. In the low voltage conditions only the
requests to deactivate the loads are effected. Any start-up requests
remain pending. The high voltage condition involves the deactivation
of all the energized relays.

34
Process Chiller
(Model SPAC-08N/10N)
Trouble Shooting
S.NO. FAULT
1 Low suction pressure
2 High discharge pressure
3 Compressor cycling for
long time
4 Compressor loses oil
5 Hot liquid line
6 Frosted liquid line
7 Frosted suction line
8 High superheat
9 Leaving water
temperature is high
10 Less superheat
11 Less water flow
12 Pump runs but gives no
water
13 Pump runs at reduced
capacity
PROBABLE CAUSE
Filter /drier blocked
Expansion valve blocked
Loss of refrigerant
Condenser coil blocked
Air in the refrigerant system
Check for the blockage
in the filter/drier
Leakage in the system
and loss of refrigerant
Air in the system
Partially plugged filter/drier
Compressor failure
Leak in the system
Oil trapped in line
Loss or shortage of refrigerant
Restricted flow in filter/drier
Expansion valve giving more
refrigerant
Expansion valve malfunctioning
Loss of refrigerant
Compressor not running
Expansion valve malfunction
Blocked suction filter
Malfunctioning of check valve
Pump running in opposite direction
Pump is not filled with liquid
Suction or discharge pipe is
blocked by impurities
Suction lift is too great
Leakage in Suction pipe
Foot or Non-return valve is Blocked
Wrong direction of rotation (3 ph)
Suction lift is too great
Suction or discharge pipe is blocked
Pump is blocked by impurities
Foot or non – Return valve is
partly blocked
REMEDY
Change the filter/drier
Change the Expansion valve
Arrest the leak and
Charge the system
Clean the condenser coil out of
debris and dust
Purge the system
Change the filter/drier
Arrest the leak and
charge the system
Purge the system
Change the filter/drier
Check for the compressors
operation
Check for the leak
Check for the oil traps
Charge the system
Change the filter drier
Check the superheat and adjust
the expansion valve
Check for the expansion valve
operation and change the
superheat
Charge the system
Check the compressor
Check for operation and setting
of superheat or change the
expansion valve
Clean and replace
Check of its operation or replace
Change two of the line supplies
Priming to be done
Clean and replace Pump is
blocked by impurities
Clean and replace
Arrest the leak and run
Clean and replace
Check the connection
Clean the impurities
35
 Process Chiller
(Model SPAC-08N/10N)

S.NO. FAULT PROBABLE CAUSE REMEDY

15 Pump stops during Thermal overload switch in motor or Check for overload on pump
operation external motor protection cuts out and rectify
Control circuit has cut out
16 Unit does not start Isolator switch damaged Replace the isolator switch.
Control fuse blown Replace the fuse.
Transformer failure Replace the transformer.
System under fault Check the fault displayed
on the controller and clear it.
Controller connectors not Make sure the connectors are
inserted properly. inserted and secured into their
respective slots.
17 Cooler pump not Pump has tripped on Check overload relay
working overload. setting and reset.
Poor wiring Check for loose
connections or poor
crimping of lugs at the
terminals.
18 Compressor not Circuit breaker tripped. Reset the breaker and check
working the current drawn by the
compressor.
Winding failure or Locked Replace the compressor.
rotor
Poor wiring Check for loose
connections or poor
crimping of lugs at the
terminals.
19 Condenser fan not Auxiliary contact failure Replace the contact.
working Poor wiring Check for loose
connections or poor
crimping of lugs at the
terminals.
Motor winding failure or Replace the motor.
locked rotor.
20 Crankcase heater not Crankcase heater fuse Replace the fuse
functioning. blown
Auxiliary contact failure. Replace the contact
Poor wiring Check for loose
connections or poor
crimping of lugs at the
terminals.

36
Process Chiller
(Model SPAC-08N/10N)

Maintenance
WARNING !
Never release refrigerant to the atmosphere when emptying the
refrigerant circuit. Suitable equipment must be used. Refrigerant
cannot be re-used, it must be return to the refrigerant manufacturer.

WARNING !
The safety section of this manual must read carefully before any
maintenance operation on the unit.

General Requirement
The chillers have been designed to work continuously and must be
regularly serviced and operated in the limits given by this manual.
It is the responsibility of the owner to provide the regular maintenance
and this can enter into a maintenance contract
If damage or a failure occurs due to an incorrect maintenance
during the warranty time, the warranty will not be applied.

Daily maintenance
The maintenance checks should be carried out in accordance with
the maintenance schedule detailed below by a skilled staff. Any
faults or problem found during the checks must be corrected.

Refrigerant charge
The refrigerant must be charged when the refrigerant is the liquid
phase to ensure that a correct refrigerant charge. A valve is provided
for charging the refrigerant at low pressure.
An insufficient charge will lead to low performances and maybe to
low-pressure alarm, which locks the unit.
Excessive charge will raise the condensing pressure increasing the
electrical consumption and maybe can lead to the high-pressure
alarm, which locks the unit.

Caution !
Before charging the circuit must be clean and dry and vacuum
reaching a minimum absolute pressure of 50 pa.

37
 Process Chiller
(Model SPAC-08N/10N)

Compressor
The compressor is supplied with the correct quantity of oil required
for operation. Under normal condition of operating the oil life
expectancy is the same as the unit life expectancy. As long as no
repair operations have been done it is not necessary to add oil. The
compressor replacement must be carried out by Blue star service or
an authorized service center.

Filter drier
The chillers are provided with filter drier. The filter drier dirty can be
detected either by bubbles on the sight glass or a temperature
difference between the inlet and the outlet of the filter.

Thermostatic expansion valve

The chillers are provided with a thermostatic expansion valve with
an external equalizer.
For checking the temperature rise:
Read the evaporating temperature (Tsa) using gauge connected on
the suction side.
Read the suction effective suction temperature (Tse) using a contact
thermometer on the evaporator outlet fitting.
Temperature rise S is given by: S = Tse-Tsa
The temperature rise can be connected using the adjuster screw on
the thermostatic expansion valve. Turn the adjuster screw through
a single revolution and operate the unit for five minutes. Then check
the temperature rise again and correct it if necessary.
If the thermostatic valve does not react to temperature rise calibration,
it is probably malfunctioning and must be replaced. The valve
replacement must be performed by an Authorized BLUE STAR
service center.

Heat exchanger
Check regularly the temperature difference across the heat exchanger
and compare them to the evaporating temperature. For an efficient
exchange the difference between leaving water temperature and
evaporating temperature should not exceed 5 to 7°C. A larger
difference indicates that the heat exchanger is dirty and it must be
chemically cleaned by an authorized BLUE STAR service center.

38
Process Chiller
(Model SPAC-08N/10N)

Maintenance Schedule

Sno Check points Daily Weekly Monthly Quaterly Annually

1 Log Parameters X
2 Check for any refrigerant leaks
through flare joints valve
glands etc., X
4 Check and clean refrigerant
strainer X
5 Check condition of refrigerant
drier X
6 Clean Air cooled condenser
coils X
7 Chemical Cleaning of condenser
coils X
Clean water line strainers X
8 Check quality of water X
9 Check healthy operation of
safety devices X
10 Check tightness of all electrical
terminations X
Top up grease for all motors
11 Apply thermal paste on the
temperature sensers X
12 Check for abnormal noise
and vibration X
13 Check liquid line sight glass /
moiture indicator X
14 Check water pressure drop
in cooler X
16 Analyse oil sample X
17 Check suction superheat X
18 Check crank case heater X

39
 Process Chiller
(Model SPAC-08N/10N)

SPARE PARTS LIST-SPAC-08N

SI.NO. COMPONENT BAAN CODE UNIT QTY. SOURCE

1 FAB.PANEL SET SPAC-08N/10N FC0000141 SET 1 SAMARTH

2 BRAZED PLATE HEAT EXCHANGER K105*20*20 HBPAI0097 NOS 1 SWEP

3 COMPR.ZR57-KC-TFD CDSBI0025 NOS 2 COPELAND

4 CRANKCASE HEATER HCSAI0035 NOS 2 COPELAND

5 COND-COIL-SET CCQAZ0380 NOS 2 PRIJAY

6 MOTOR HIN 1/3HP,1 PHASE MBSAB0440 NOS 2 GE

7 22" FAN GUARD(FLAT) GDRAZ7177 NOS 2 JEEKAY

8 AL.FAN 4 BLADE 22"DIA FBAAZ1047 NOS 2 GIRNAR

9 VALVE SERVICE BRASS 1/4" VAAAZ2080 NOS 4 AUTOCOM

10 NUT BRASS FLARE 1/2" HANBZ2050 NOS 4 AUTOCOM

11 FILTER DRIER EK 084/DML084 FEDBI0010 NOS 2 EMERSON

12 EXPN VALVE BBIVE-4 CP-100 SPOR VAAAZ2106 NOS 2 SPORLAN

13 INDICATOR MOISTURE 1/2" SAMAI0100 NOS 2 DANFOSS

14 FLOW SWITCH FQS 1" SAFAI0020 NOS 1 SAGINOMIYA

15 CONTR PNL SPAC-08N EBHAZ4130 NOS 1 SAMCON

16 LO PR SWITCH(SAGINO.)LCB_DA80 SAPAI0180 NOS 2 SAGINOMIYA

17 HI PR SWITCH(SAGINO.)ACB_DB138 SAPAI0190 NOS 2 SAGINOMIYA

18 GRUNDFOS INLINE PUMP CH8-50 PCIAZ0011 NOS 1 MULTITECH

19 SS PIPING SET SPAC-08/10N PBEAZ7097 NOS 1 AS CONTROLS

20 REDUCER CU 3/4 OD-5/8IDZR-81 FERAZ5055 NOS 2

21 CAREL CONTROLLER MICROCHILLER-2 EBMBZ 0035 NOS 1 CAREL

22 SENSORS 3.0 M LG NTC030HP00 EBMCI0008 NOS 2 CAREL

23 CONNECTOR KIT MCH2C0N001 SATAI0280 NOS 1 CAREL

24 MICROCHILLER-2 EXPANSION BOARD MCH2000021 EBMBZ0037 NOS 1 CAREL

25 CONNECTOR KIT FOR EXP. BOARD MCH2CON021 SATAI0290 NOS 1 CAREL

26 BUFFER TANK MOUNTING PADS AHI070000 NOS 2 ----

27 TOWER LIGHT, JBTL-99,230V,WITH 3 MTS WIRE LENGTH. EABZZ0010 NOS 1 JAIBALAJI

28 HANDLE FAHAZ0015 STD. 4 SIDDHARTHA

29 ANGLE BRACKET FOR LIFTING FX0005350 NOS 4 ----

30 EYE BOLT M10 HBHGZ0020 STD. 4 ----

31 FLOAT VALVE 1" VAFA00001 NOS 1 ----

32 CRATE PACKING PAFAZ0720 NOS 1 ----

33 HOTGAS BYPASS EASBI0220 NOS 1 DANFOSS

40
Process Chiller
(Model SPAC-08N/10N)

SPARES PARTS LIST-SPAC-10N

SI.NO. COMPONENT BAAN CODE UNIT QTY. SOURCE

1 FAB.PANEL SET SPAC-08N/10N FC0000141 SET 1 SAMARTH

2 BRAZED PLATE HEAT EXCHANGER B25H*26*26 HBPAI 0070 NOS 1 SWEP

3 COMPR.ZR81-KC-TFD-522 CDSBI0010 NOS 2 COPELAND

4 CRANKCASE HEATER HCSAI0035 NOS 2 COPELAND

5 COND-COIL-SET CCQAZ0375 NOS 2 PRIJAY

6 MOTOR HIN 1/3HP,1 PHASE MBSAB0440 NOS 2 GE

7 22" FAN GUARD(FLAT) GDRAZ7177 NOS 2 JEEKAY

8 AL.FAN 4 BLADE 22"DIA FBAAZ1047 NOS 2 GIRNAR

9 VALVE SERVICE BRASS 1/4" VAAAZ2080 NOS 4 AUTOCOM

10 NUT BRASS FLARE 1/2" HANBZ2050 NOS 4 AUTOCOM

11 FILTER DRIER EK 084/DML084 FEDBI0010 NOS 2 EMERSON

12 EXPN VALVE BBIVE-4 CP-100 SPOR VAAAZ2106 NOS 2 SPORLAN

13 INDICATOR MOISTURE 1/2" SAMAI0100 NOS 2 DANFOSS

14 FLOW SWITCH FQS 1" SAFAI0020 NOS 1 SAGINOMIYA

15 CONTR PNL SPAC-10N EBHAZ4140 NOS 1 SAMCON

16 LO PR SWITCH(SAGINO.)LCB_DA80 SAPAI0180 NOS 2 SAGINOMIYA

17 HI PR SWITCH(SAGINO.)ACB_DB138 SAPAI0190 NOS 2 SAGINOMIYA

18 GRUNDFOS INLINE PUMP CH8-50 PCIAZ0011 NOS 1 MULTITECH

19 SS PIPING SET SPAC-08/10N PBEAZ7097 NOS 1 AS CONTROLS

20 REDUCER CU 3/4 OD-5/8IDZR-81 FERAZ5055 NOS 2

21 CAREL CONTROLLER MICROCHILLER-2 EBMBZ 0035 NOS 1 CAREL

22 SENSORS 3.0 M LG NTC030HP00 EBMCI0008 NOS 2 CAREL

23 CONNECTOR KIT MCH2C0N001 SATAI0280 NOS 1 CAREL

24 MICROCHILLER2 EXPANSION BOARD MCH2000021 EBMBZ0037 NOS 1 CAREL

25 CONNECTOR KIT EXP MICROCHILLER2 MCH2CON021 SATAI0290 NOS 1 CAREL

26 BUFFER TANK MOUNTING PADS AHI070000 NOS 2 SIDDHARTHA

27 TOWER LIGHT, JBTL-99,230V,WITH 3 MTS WIRE LENGTH. EABZZ0010 NOS 1 JAIBALAJI

28 HANDLE FAHAZ0015 STD. 4 SIDDHARTHA

29 ANGLE BRACKET FOR LIFTING FX0005350 NOS 4 ----

30 EYE BOLT M10 HBHGZ0020 STD. 4 ----

31 FLOAT VALVE 1" VAFA00001 NOS 1

32 CRATE PACKING PAFAZ0720 NOS 1

33 HOTGAS BYPASS VALVE EASBI0220 NOS 1 DANFOSS

41
Process Chiller
(Model SPAC-08N/10N)

Warranty
Blue Star Process Chillers carry a warranty for a period of 12 months
from the data of commissioning or 15 months from the date of
delivery, whichever is earlier, unless stated otherwise in the contract
of sales.

Terms of Warranty
Blue Star extends a comprehensive warranty on its systems, which
entitles the customer to the following
1. Repair/reconditioning, by BSL 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 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.

42
SPAC Chiller services will be rendered by Blue Star.

In case of a breakdown of the chiller customers can contact our customer

coordination officers (CCO) at the service call desks situated in eighteen of our
offices across the country.

The customer will receive a call ticket number from the CCO’s for every
breakdown call. This number will help the customer to refer to a particular
breakdown and it will help us to have a track on the repair work.

LOCATION STD CCOs' Nos. Tel.No., Board

Western Region
Mumbai 022 66684200 66684000
Baroda 0265 6614200 6614000
Pune 020 9822978045 26167230
Bhopal 0755 4273379 4273378
Nagpur 0712 2243700 2249000
Goa 0832 2462200 2462789
Eastern Region
Kolkata 033 22134200 22134000
Guwahati 0361 2340620
Bhubhaneshwar 0674 2510190 2508270
Northern Region
Delhi 011 41494200 41494000
Chandigarh 0172 9815164291 5024000
Jaipur 0141 5124898 5124897
Lucknow 0522 2787274 4034000
Southern Region
Chennai 044 9842978800 42444000
Bangalore 080 9845946446 41854000
Cochin 0484 9846052557 2357933
Secunderabad 040 9989690000 44004000
Vishakapatnam 0891 2748405 2748405
 * 4 - ) 6 0 -   - ) 5 ;

OEM BUSINESS
No: 9, Bazullah road, T. Nagar, Chennai 600 017
Tel: (044) 2815 8855