Chiller Manual

ENERGY EFFICIENT WATER COOLED SCREW CHILLERS
INTRODUCTION
This manual is prepared to provide all the necessary information for

installation, operation and maintenance of Voltas make, factory assembled,
Water Cooled Packages with Screw Type Compressor and Flooded
Evaporator.
These chiller packages have been manufactured under strict quality checks.
This manual will provide the user guidance to ensure many years of
satisfactory service of chillers.
These chiller packages are equipped with sophisticated microprocessor /

PLC panels. It is therefore essential that only those personnel who are
qualified and experienced in air conditioning and refrigeration, must carry
out the installation, operation and maintenance.
1
SECTION 1
PHYSICAL DATA
2
Voltas Electro-mechanical & Refrigeration Business Group, an ISO 9001 company, a pioneer & leader in the field
of electromechnical & refrigeration introduces new series of Energy Efficient Green Chillers using environment
friendly refrigerant R-134a. As a result of commitment to provide customers the latest green technology and 'best
value for money', Voltas chillers have become an ideal choice for Green Building Projects and other air conditioning
applications. The chillers are available in wide range of capacities and each unit is tested in state-of-the art test
facility matching international standards prior to delivery, ensuring reliability and optimum performance.
1.1 MODEL NOMENCLATURE
EG W F X R 350 2 M Z F
Energy Efficient F - Special Model

Green Series Blank - STD Model
A - Air cooled Z/L Series-Semi

W - Water Cooled Hermatic Screw
Compressor
D - DX Chiller M - Microp. Std. Panel

F - Flooded Chiller A - Microp. Advanced
BMS
X - Screw Compressor No. of Compressors
R 134a Refrigerant Nominal Tons
3
FEATURES
Exceptional energy efficient by design
Today conservation & efficient use of energy resources have become vital for global sustainability. Ministry of
Power, Government of India has thus come up with Energy Conservation Building Code (ECBC) with stringent
efficiency norms for air conditioning equipments. Voltas new energy efficient green series chillers are at par with
ECBC equipment efficiency norms.
The achievements in performance of these chillers are due to improvement in basic design and precise control
system. The highlights are given below.
O Basic equipments are designed to operate compressor comparatively on better suction pressure and optimum
discharge pressure to maximize efficiency benefit.
O Compressor having step less capacity control mechanism operates in response to the chilled water outlet
temperature and precisely matches part load requirements without hunting.
O Electronic Expansion with controller & sensors respond fast to variable operating conditions & enhance
efficiency.
O Compressor staging has been programmed such as to save energy by running adequate numbers of
compressors at maximum efficiencies at different loads.
4
TABLE 1.1 PHYSICAL SPECIFICATIONS

CHILLER PKG. MODEL EGWFXR EGWFXR EGWFXR EGWFXR EGWFXR EGWFXR EGWFXR EGWFXR EGWFXR
100 1M 120 1M 150 1M 175 1M 210 1M 240 2M 270 2M 300 2M 350 2M
NOM CAPACITY -TR. 100 120 150 175 210 240 270 300 350
COMPRESSOR
COMPRESSOR TYPE SEMI HERMETIC SCREW ("Z" SERIES OR "L" SERIES)
QTY/UNIT 1 1 1 1 1 2 2 2 2
MIN % UNIT CAPACITY
REDUCTION 25% 25% 35% 30% 35% 12.50% 17.50% 17.50% 15%
OIL CHARGE, LITER
(Z/L SERIES) / COMP. 19/18 35/23 35/28 35/28 35/28 35/23 35/23 35/28 35/28
UNIT STARTING CURRENT 612 A ∆ 465 A Y / 465 A Y / 586 A Y / 805 A Y / 593 A Y / 723 A ∆ 593 A Y / 635 A Y /
AT 400V (Z SERIES) (OF PW) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF PW) (OF λ-∆) (OF λ-∆)
MAX. ALLOWABLE OPERATING
CURRENT - AMPS AT 400V 196 A 330 A 310 A 320 A 450 A 330 A 233 A 266 A 306 A
(Z SERIES) PER COMP.
UNIT STARTING CURRENT 282 A Y 305 A Y 467 A Y 498 A Y 693 A Y 434 A Y 578 A Y 632 A Y 681 A Y
AT 400V AMPS (L SERIES) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF λ-∆) (OF PW) (OF λ-∆) (OF λ-∆)
MAX. ALLOWABLE OPERATING
CURRENT - AMPS AT 400V 236 A 277 A 347 A 384 A 465 A 277 A 301 A 347 A 384 A
(L SERIES) PER COMP.
EVAPORATOR
EVAPORATOR TYPE FLOODED FLOODED FLOODED FLOODED FLOODED FLOODED FLOODED FLOODED FLOODED
EVAPORATOR MODEL J1R - 2P K1R-3P L1R-3P M1R-3P M2R-3P U1R-3P V2R-3P W1R-3P W2R-3P
QTY/UNIT 1 1 1 1 1 1 1 1 1
WATER FLOW RATE -GPM 240 288 360 420 504 576 648 720 840
WATER SIDE PR. DROP -PSI 3.6 10.99 11.11 11.02 11.15 10.02 9.96 10.11 11.41
NO. OF PASS 2 3 3 3 3 3 3 3 3
WATER CONNECTION SIZES
(NB, MM) 150 150 150 200 200 200 200 200 200
CONDENSER
CODENSER MODULE H2R H3R J2R K1R R2R T1R T2R T3R V1R
CONDENSER QTY/UNIT 1 1 1 1 1 1 1 1 1
WATER FLOW RATE -GPM 300 360 450 525 630 720 810 900 1050
WATER PR. DROP - PSI 9.92 11.28 9.61 8.53 7.77 7.41 8.58 9.60 6.22
NO. OF PASS 3 3 3 3 3 3 3 3 3
WATER CONNECTION SIZES
(NB, MM) 150 150 150 200 200 200 200 200 250
CHILLER DIMENSIONS & GENERAL
UNIT LENGTH (MM) 4350 4320 4375 4480 4410 4555 4535 4590 4590
UNIT WIDTH (MM) 1475 1530 1640 1750 1800 2300 2380 2420 2630
UNIT HEIGHT (MM) 1580 1730 1780 1880 1890 1890 1940 1990 2100
REFRIGERENT QTY. (KGS) 180 216 270 315 378 432 486 540 630
Notes :
*Capacity rated for evaporator leaving water temperature 6.70C, Condenser Water inlet temperature of 29.40C.
Evaporator water side fouling factor 0.000018 m2 degree C/watt.
Condenser water side fouling factor 0.000044 m2 degree C/watt.
Power supply voltage is 360-440 V.
Control supply voltage is 210-240 V.
Frequency 50 Hz
For higher ambient application please refer to EM&R BG Engineering
Lubrication oil codes are BSE 170 & SOLES 120 respectively for Z & L Series Compressors.
5
G. A. DRAWING 100 - 210 TR (SINGLE CIRCUIT)
6
G. A. DRAWING 240 - 350 TR (SINGLE CIRCUIT)
7
G. A. DRAWING 240 - 350 TR (DOUBLE CIRCUIT)
8
9
GENERAL SCHEME FOR LIFTING OF WATERCOOLED CHILLER PACKAGE
10
11
12
ELECTRICAL & MECHANICAL DATA FOR COMPRESSORS
13
INSTALLATION
1. GENERAL
The installer or operator shall read this manual carefully and become familiar with the information
contained therein.
2. INSPECTION ON ARRIVAL
It is recommended that the following inspection is completed in presence of the transporter's
representative, when the chiller package is received at site.
2.1 Check the number of crates/packages with packing list and ensure receipt of full consignment.
2.2 Check for damages, shortages or any other discrepancies and note them on the Delivery Challans.
2.3 In the event of any damage or shortage, a suitable claim shall be immediately filed with Insurance
company and/or transporter.
3. RIGGING AND MOVING

3.1 Ensure that chains, cables or other moving equipments are placed carefully, to avoid damage
to the unit/piping.
3.2 Do not use the refrigerant piping as ladder or lifting support.
3.3 Do not attach a chain hoist or hook to the piping or equipment.
3.4 The unit shall be moved in an upright position and gently on rollers and tracks.
3.5 When units are moved using forklift, care should be taken to ensure no damage to the base
frame of the unit by forks.
3.6 Spreader bars shall be used for lifting of unit. The unit shall be lifted using all rigging points provided.
3.7 Do not raise the unit more than 50 mm off the floor level.
4. SPACE REQUIREMENTS AND CLEARANCES

4.1 The dimensional data and clearances given in this manual shall be used to determine the overall
space requirements.
4.2 The units shall be installed in such a way that clearances indicated for service are available.
Failure to allow these clearances may cause serious trouble that can result in higher cost of
repair/maintenance/operation.
4.3 The units shall be installed considering the noise sensitivity of adjoining spaces buildings.
4.4 The units shall be adequately supported to avoid transmission of vibration as well as noise into
the buildings.
4.5 Where the units are to be installed at intermediate floor levels and/or for critical applications,
acoustic and structural specialists shall be consulted for detailing the necessary treatments in
order to achieve noise and vibration levels within acceptable limits.
14
5. FOUNDATION
5.1 The unit dimensions and point loads are shown. The support shall be suitable for these
loadings given.
5.2 All foundations must be levelled for proper operation and functioning of controls.
6. VIBRATION ISOLATION
6.1 We recommend provision of vibration isolators under the base of the units.
6.2 Rubber-in-shear or spring type vibration isolators are available and shall be selected based on
the loading and permissible deflection.
When spring type vibration isolators are used appropriate flexible connections must be installed
in the condenser and chiller water piping systems as well as for electrical services.
7. WATER PIPING CONNECTIONS

7.1 The locations of inlet and outlet connections for condenser and chiller is indicated in the General
Arrangement Drawing.
7.2 The piping near condenser and chiller shall be provided with easily removable sections of pipe
(with flanged joints or unions) to facilitate cleaning and/or replacement of tubes at some future
date and removal of heads/end shields.
7.3 The piping shall be supported properly, to avoid stresses on condenser/chiller.
7.4 The piping shall be complete with suitable provision of venting and draining of water, measurement
of temperature and pressure at the inlet and outlet of condenser as well as chiller.
7.5 The outlet piping for condenser and chiller shall have suitable provision to control water flow &
isolate the unit for maintenance/servicing.
8. ELECTRICAL WIRING
8.1 All field wiring shall be in accordance with the State and Local Statutory regulations and codes.
8.2 Check the unit wiring for possible damage and all terminal connections for tightness.
8.3 Check voltage value and variations and ensure that variation is not beyond + 10%. The voltage
imbalance between phases must not exceed 2% at any time during the operation of the unit.
8.4 Check phase sequence to connectors for correctness.
9. CONTROLS AND INTERLOCK

9.1 Connect a set of normally open auxiliary contacts from chilled water pump into the unit controls
as shown in unit wiring drawing.
9.2 Connect a set of normally open auxiliary contacts from condenser water pump into the unit
control as shown in unit wiring diagram.
9.3 The safety controls are preset at factory while the operating controls are field adjustable and
need to be set based on actual operating requirements.
15
OPERATION
SYSTEM EVACUATION
The system should be vacuumised from both the low and high pressure sides. Use a two stage rotary vacuum
pump and an electronic vacuum gauge to achieve not less than 500 microns vacuum level. Use of a triple evacuation
method (doing the evacuation in three stages with breaking of vacuum upto 2 Psig using the system refrigerant)
gives very good result in keeping the moisture and non-condensable gases away from the system.
The compressor must never be started under vacuum pressure, as serious damage will be done to the
motor winding and terminals, in case of semi-hermatic compressor.
The presence of air and moisture in a system can lead to failure of the compressor through corrosion, slugging,
copper plating, oil break-down, carbon formation, valve chocking etc. The liquid line driers used in
the system can take care of residual moisture only and one should not depend on the driers to take care of
the system moisture or to provide back-up for an ineffective evacuation process. It is the system manufacturers'
responsibility to ensure that air and moisture are kept out of the system and no chemical reaction takes place
inside.
1. OPERATING INSTRUCTIONS FOR CHILLER PACKAGE

1.1 Before starting the plant make sure that there is sufficient water in the cooling tower.
1.2 Switch on the main switch in the Maintenance Room and check the voltage and ensure that the
same is within the permissible limits.
1.3 Observe the sequence of Microprocessor operation (programmable parameters & keyboard
operation).
2. GENERAL
2.1 The condenser and chiller are suitable for operation with soft and uncontaminated water. If the
water used is corrosive, high in mineral content or entrained solids, it can cause derated
performance and can even lead to failure of condenser and chiller. Therefore, it may be necessary
to check the quality of water available and provide suitable water treatment plant in consultation
with specialist.
2.2 The chiller packages are dispatched from factory with a nominal charge of refrigerant and
oil. The user shall check the system pressure and ensure that there is no damage to the unit in
transit/installation, resulting in gas leakage.
If the refrigerant gas has leaked out due to transit/installation damage, then the complete system
will have to be pressure tested, vacuumised and charged with refrigerant & oil at site.
2.3 The crankcase heater shall be energized in order that the sump temperature is maintained at
about 100 Deg F before commissioning. This will ensure that the oil is warm enough to vaporise
any dissolved refrigerant while keeping the oil within a normal operating parameters and temperature
range.
2.4 The unit shall be commissioned and operated only by a competent refrigerant technician who is
familiar with accepted operation practices for refrigeration systems.
16
3. INITIAL STARTUP
The units are ready for start up when the following checks are complete.
3.1 Water piping connections to and from condenser and chiller are installed flushed and tested.
3.2 Electrical connections are made and tested
Electrical Service
The chiller packages are shipped from the factory completely prewired. When fan motors are supplied
loose, the fan motor leads need to be connected at site. Power supply required is balanced
3 phase, 4 wire, 50 cycles. AC supply voltage must be 400 + 10%. All control wiring is suitable for
230 V, single-phase 50 cycle AC.
1. Electrical Test :
Any test that have to be conducted to check electrical performance of the unit or its
components must be done by authorised maintenance personnel only. Improper test
procedures may lead to damage of the unit and fatal accidents. Disconnect main supply
before attempting to touch any electrical component. Following test/procedures are required
to be carried out on the unit.
a) Continuity Tests
i) Use a multimeter for checking continuity of the electric circuit. When checking a
motor, disconnect power leads to the motor and see resistance of each pair of
compressor terminals.
ii) A healthy winding will indicate 0.5 to 2.0 megaohms resistance.
iii) An open winding will indicate infinite resistance.
(Caution : even a burnt or internally short winding will show continuity).
iv) It is essential to carry out megger test to check the insulation resistance of any
motor.
v) Check the motors for earthed winding by checking each motor terminals
with the body of compressor.
b) Megger Test
i) Use a 500 V hand cranking DC megger. Higher voltage might damage insulation
of the winding.
ii) Do not carry out megger test on a compressor, which is under vacuum.
iii) The resistance of a healthy winding is normally more than 1 megaohms when
windings are cool.
iv) If the resistance is between 0.5 megaohms to 1 megaohms the winding should
be baked once again to 120 deg. C for 3-4 hours and resistance should be
rechecked after the windings are cooled.
v) If resistance does not improve with rebaking, the motor must be rewound.
17
vi) If resistance of motors can be improved on field by either running motor from the
unit and heating the motor body with the help of 2 or 3 100 W bulbs placed
around the motor.
c) Measurement of Motor Current and its Adjustments
i) Measurement of current is done by using a Tong tester or clip-on ammeter.

To measure current of any motor, set the ammeter range to the maximum first
and measure line current at the starter outlet feeders.
ii) In case of a Star Delta Starter, line current is obtained by measuring phase
current at outgoing of main contactor and multiplying the current so obtained by
1.732 (i.e. square root of 3). The line current of any motor should never exceed
rated full load current on the Motor Name Plate for a long time.
iii) A fan or a pump motor is designed to give a design flow rate at an estimated
head (the resistance offered by the system). An over estimation of head results
in excess flow (through fan or pump) which is generated to create additional
head. This results in increase of BHP observed and therefore overloading of
motor. Adjust flow by regulating globe valve (on the outlet of condenser) in case
of pumps and by reducing fan RPM or by regulating volume control dampers in
case of fans.
iv) For compressor motor check system for overcharge, mechanical fault or
non-condensable in system.
3.3 Unit has been checked for initial refrigerant and oil charge from factory to be intact and full
charging done at site.
3.4 Crank case heater energised to keep sump warm.
3.5 Pressure gauges have been connected to suction and discharge side of compressor.
3.6 Start the condenser water recirculation pump; check the direction of rotation for correctness.
3.7 Start the cooling tower fan (in case of induced/forced draft cooling tower.)
3.8 Start the chilled water recirculation pump; check the direction of rotation for correctness.
Flushing of condenser/chiller pipe work after 3 to 8 hours depending system size.
3.9 Chiller and condenser water flow rates
a. Charts for condenser and chiller water flow rates and pressure drops are available in this
manual. The quantity of water flowing through the chiller and condenser shall be computed
by plotting the measured pressure drop figures on these graphs. Design values shall be
achieved by necessary adjustments by regulating valves.
b. The pressure gauges shall be accurate and pressures shall be measured at inlet and outlet
of chiller and condenser.
c. As a cross reference, these water flow rates for condenser and chiller shall be compared
from the respective circulation pump characteristics curves from pump manufacturer.
d. Stabilize the condenser and chiller water circulation by purging trapped air.
18
3.10 Check all refrigerant valves to ensure that they are in OPEN position.
3.11 Start the unit through MCP.
4. AFTER STARTING THE PLANT

4.1 Observe suction and discharge pressure for 30 minutes.
4.2 The normal discharge pressure will be between 118 psig to 150 psig for refrigerant R134a for watercooled.
IMPORTANT
1. "Under no circumstances the compressor should be run on vacuum".
2. For the initial Start Up of the plant we recommend the following procedures :
a. Establish the full circulation of chilled water through all the AHUs, FCUs or other process
load by purging the air in the circulation with the blower/fan in "OFF" position.
b. Similarly the condenser water circulation shall be established.
c. The blower/fans shall be started one by one once the chilled water temperature is brought
down to about 8-100 C.
5. COMMISSIONING
5.1 Pre-commissioning Checks
After completing the installation, before starting the compressor, check the following points :
1. Check all electrical connections for looseness and whether they are as per the electrical
wiring diagram.
2. Check the wiring connections of the sentronic, motor protection module and the capacity
control module.
3. Check the phase sequence of supply wires at the compressor terminals 1, 2, 3 and 7, 8, 9.
They should be the same.
4. Observe compressor oil level before starting. It should be at or above the centre level of the
sight glass.
5. Check the setting of thermostat, low and high pressure cutouts, overload relays etc. and
adjust them to the required range and differential setting values.
6. To verify if the electrical panel is wired correctly, it will be a good practice to disconnect the
compressor supply cables right in the panel and start the unit. The pressure cutouts and/
or control may have to be bypassed for few seconds to see if the compressor contactors
hold correctly-particularly in a part-winding start circuit.
7. If the contactors hold correctly, connect all the cables and wires as per initial wiring and get
ready to start the compressor. Verify and keep the service valves of compressor fully open.
8. Check the direction of rotation of cooling tower fan, condenser water pump, air cooled
condenser fan, chilled water pump, evaporator fan etc. and rectify if required.
19
5.2 Commissioning Procedure
1. After evacuation, charge approximately 70% of system charge in the liquid line; note down
the initial system pressures. Switch on the unit and let the compressor start.
2. With the compressor running, monitor suction, discharge, current, oil level etc. if the charge
is found to be less, add refrigerant vapour, monitoring the pressure and current. Keep a
record of the weight of refrigerant charge put in the system.
Do not charge trying to remove bubbles in the liquid sight glass. It may end up in
overcharging the unit.
3. Observe system pressure during charging and initial operation. Do not add oil when the
system is short of refrigerant, unless oil level is dangerously low.
4. Do not leave the system unattended until the system has reached normal operating
conditions and the oil charge has been properly adjusted to maintain the oil level at the
centre of the sight glass.
5.3 Operational Checks
After the system is fully charged and has run for approximately two hours without any indication of
malfunction, a thorough recheck of the entire system operation should be made as described below :
1. Check operating suction and discharge pressures. If not within system design limits, determine
the cause and take corrective actions.
2. Observe oil level in the compressor and add oil if required to bring it to the centre of sight glass.
Procedure to add oil to compressor is given in this manual.
3. Check the proper functioning of EXV by measuring the superheat.
4. Check the line voltage and current of compressor. It should be within the design limits permitted.
If the current drawn is more than 120% of the specified value, determine the cause and immediately
take corrective actions.
5. Check proper function of all safety controls - like LP cutout, HP cutout, single phase preventor,
water flow switch, anti-freeze thermostat etc.
6. Check the operational of compressor motor protection module, by removing the sensor wires.
The LED will turn red immediately and trip the compressor in two minutes. On connecting sensor
wires & manually pressing the reset button on the module, the control circuit is reset and after the
on-delay timing is completed (either through the motor protection module or additional on-delay
timer), the compressor should re-start.
7. Record all the system operating parameters and the range and differential setting of all operating
and safety controls for future reference.
8. Monitor the system operation on operating thermostat for few on-off cycles and ensure that
everything is normal, before leaving the site.
9. After running the unit for 48 hours, check the oil colour and any dirt or contamination. If the oil is
contaminated, replace the oil.
20
6. FIELD SERVICE OPERATION
6.1 Pressure Testing

Pressure Testing (followed by vacuum test) a refrigerant circuit is essential, before refrigerant is
charged in the system either initially for topping up gas after a suspected leak. It is advisable
to locate the leak, rectify and then charge gas after pressure testing (before pressure testing the
remaining FREON gas should be removed into empty cylinder). In case of a semi-hermatic
compressor winding burnout, the system should be thoroughly flushed with R11 to drive out
contaminants generated in the system, before the compressor is replaced. It is imperative that
the new catchall drier is fitted in circuit.
a. Charge dry nitrogen in the system by connecting cylinder at the compressor service valve
and check pressure in the system. Charge nitrogen up to a pressure of 3 to 4 kg/cm.
b. Check all joints with soap solution. Locate all leaks.
c. If no leaks are found increase pressure up to 10.5 kg/cm 2 adding more nitrogen.
Check for leaks.
d. After all leaks are located, remove nitrogen completely by opening the charging line.
Repair leak and retest. Do not start repair work unless entire nitrogen is removed from the
system.
Caution : Never use oxygen gas for pressure testing as fatal explosions may occur. Avoid use
of CO2 for pressure test as CO2 gas may contain excessive moisture, which might remain in
system. Do not use compressor to build pressure for leak tests as overheating might damage
the compressor.
Note : Minor leak suspected during operation can be located by using Halide leak detector or
electronic leak detector.
6.2 Vacuumising and Charging of Refrigerant

Evacuating the system by pulling deep vacuum enables dehydrating the system and removing
of air (non-condensable). In the event of a compressor burnout, it helps remove carbon deposits
and smoke that is generated. A good 2 stage vacuum pump should be employed to get vacuum
down to 5 microns (1 microns = 0.001 mm) of Hg absolute. A vacuum gauge for reading vacuum
should be used.
a. Put a jumper line (1/4 OD) to equalise high and low side on the compressor.
Connect vacuum pump and vacuum gauge to the system. Open compressor service valves
and start the pump.
b. Run pump till vacuum reaches to boiling point of moisture (water) will be about 0 deg. C.
Hence, for normal ambient temperature (10 deg. C and above pulling a deeper vacuum is
neither recommended nor necessary).
c. If vacuum is stabilized, close charging valve and stop the pump.
d. Allow vacuum in the system for an hour also. Recheck vacuum, break vacuum by charging
21
refrigerant vapor from the 1/4" FPT service port at compressor suction shut-off valve.
Revacuumise and check. Charge gas.
For charging, back seat the suction and discharge shut off valve, install a pressure gauge
in the discharge valve port and connect 1.4 inch OD charging line to the cylinder. Take care
that only vapor refrigerant is charged to the system as liquid entering compressor is likely
to damage compressor parts.
e. Open the cylinder valve a little and purge air in the charging line by cracking the flare nut at
compressor valve port and allowing some refrigerant to drive out air. Tighten the flare nut.
Open compressor service valve partially by turning stem clockwise and start compressor.
Follow start-up procedure.
6.3 Purging Non-condensable Gases

Non-condensable gases are like to be accumulated at the higher portions of the systems.
This causes reduction in cooling capacity and waste or power resulting from higher condensing
temperature.
a. Close liquid line shut off valve and connects gauges on suction and discharge service
valves.
b. Start the compressor. Suction pressure will drop as the liquid valve is closed. Stop the
compressor after suction pressure drops down to zero psig. The suction pressure will start
rising. When it becomes steady start compressor again. When suction pressure again
drops to zero, stop the compressor. Repeat this procedure till suction pressure stays more
or less close to zero after stopping compressor.
c. Run the condenser water pump for about half an hour and read the condensers shell
pressure compare this with saturation pressure of the refrigerant gas at cooling tower water
temperature. If the shell pressure is more than 2 to 5 psi than the saturation pressure crank
open the purge valve on the condenser. Repeat the process till the shell pressure comes
down to the saturation pressure of the refrigerant at water temperature.
d. Close fully the purge valve and restart the unit. Compare operating pressure. If the pressure
are not within limits follow steps (a) and (b) once again. Investigate unit performance if
results are not satisfactory.
22
PLC CONTROLLER OPERATION
&
BMS INTERFACE SPECIFICATION
AND IO MAPPING
23
CONTROLLER & DISPLAY
PHYSICAL CHARACTERISTICS
Controller Specifications
Dimensions ...................... 12.0" w, 8.0" h, 2.0"d
Mounting Holes ................ Mounts on a backplane
using eight #6 sheet metal
screws
Operating Temperature .... (-) 400F to +1580F (-400C
to 700C)
Storage Temperature ........ (-) 400F to +1580F (-400C
to 700C)
Microprocessor ................ Zilog e280 Acclaiml @
50mhz
Keypad / LCD Specification
Sensor Inputs .................. 12 inputs 0-5vdc
(10-bit A/D) Display ............................ 128 x 64 dot pixel STN
monochrome graphics
Digital Inputs .................... 4 inputs 0 or 5vdc only
LCD with 2.8" diagonal
Relay Outputs (RO) ......... 10 outputs 6.3 amps @ viewing area
230vac
Colour .............................. White characters on a
Analog Outputs (AO) ....... 4 outputs 0-10 vdc blue background
Printed Circuit Board ....... Six layer with separate (Reversible)
power and ground planes Keypad Size .................... 5.25" w x 6.50" h
Input Power (Standard) .... 115 or 230 vac +10% 50/ (6 mounting holes)
60Hz@ 77 0 F (25 0 C) Keypad Layout ................ 9 keys (3 function keys)
ambient, 20VA max
Connection ...................... 6 conductor shielded
(Voltage is field
cable (max length of cable
selectable)
is 50 feet)
MCS-I/O Comm Port ....... 1@38,400 baud
Operating Temperature .... -40F to +1580F (-200C to
RS-485 Comm Port ......... 1@ 19,200 baud, select +700C)
from MCS Protocol,
Storage Temperature ........ -220F to + 1850F (-300C to
BACnet MTSP, Modbus
+850C)
RTU or Johnson N2
RS-232 Comm Port ......... 1 @ 19,200 baud Product Description
Ethernet ........................... 10/100 Mbps Ethermet
The Controller is a rugged microprocessor based
supporting MCS IP,
controller designed for the hostile environment of the
BACnet IP and Modbus IP
HVAC/R industry. It is designed to be the primary
at the same time
manager of the package it is controlling. This controller
Real Time Clock .............. Battery backup provides flexibility with setpoints and control options
Power Detection .............. Automatic power fail reset that can be selected prior to commissioning a system
24
or when the unit is live and functioning. Display, alarms other manufacturers systems. Additionally, a built-in
and other interfaces are accomplished in a clear and RS-485 to RS-232 converter allows communication over
simple language that informs the user as to the status the RS-485 port via the RS-232 port. Other features
of the controller. include the intergration of BACnet, Modbus and
Johnson N2 into the Magnum. LONTALk allows
The controller consists of a master micro controller interfacing with Building Management Systems (BMS)
along with a keypad and display. Complementing the communicating via LonWorks and MCS's open protocol
controller micro controller are I/O, RO8 and SI16 provides the user with direct communication.
expansion boards. This allows for system expansion
to a maximum of 48 inputs and 48 outputs. A complete software support package is available for
Communication to these units occur at 38,400 baud your PC allowing for system configuration, dynamic
over the I/O port which is dedicated for this purpose. on-line display screens, remote communication,
graphing and more.
A-RS-485 port is also provided for communication with
USER LEVEL PASSWORD - 1234

SERVICE LEVEL PASSWORD - 1547
25
1. Display
1.1 Status Display - Chiller (Default at Power Up)
The CURRENT STATE OF THE PACKAGE.
The display shows the current capacity of the package and how long we have been at this level. By
pressing the PG↑ OR PG↓ you will get additional information on each circuit.
1.2 Status Display - Circuit (x)
THE CURRNET STATE OF A CIRCUIT.
The display shows the current capacity of circuit (x) and how long we have at this level. By pressing
the PG↑ you will go back to the Chiller state display OR PG↓ you will get additional information on
this circuit.
By pressing the PG↑ you will go back to the previous display OR PG↓ you will get information on
the next circuit. After all circuit information is displayed pressing the PG↓ will return the user to the
chiller display.
26
1.3. Menu Key
Pressing the ` Menu' Key provides the following: The display shows options available.
1.4. Status
Selecting the `Status' option provides the following:
Selecting the Page Down option provides the following:
27
1.5. Outputs
Selecting the Òutputs' opdtion provides the following:
28
1.6. Inputs
Selecting the Ìnputs' opdtion provides the following:
29
1.7. Alarms
Selecting the Àlarms' option provides the following:
1.8. Graphics
Selecting the Àlarms' option provides the following:
1.9. Setpoints
Selecting the `Setpoints' option provides the following:
30
1.10. Service Tools
Selecting the `Service Tools' option provides the following:
Pressing the down arrow provides the following:
1.11. Lockout Reset
Selecting the `Lockout Reset' option provides the following:
1.12. Lockout Alarms
Selecting the `Lockout Alarm' option provides the following:
31
1.13. Passwords
Selecting the `Passwords' option provides the following:
INPUT / OUTPUT LIST FOR SINGLE COMPRESSOR UNIT
Digital Output Digital Input

1. CMP Main 1. MPD VPD
2. CMP Delta 2. CHW FLOW
3. Load Solenoid Valve 3. CND FLOW
4. Unload Solenoid Valve 4. EXT INT
5. Economizer Solenoid Valve 5. OIL LVL
6. Chilled Water Pump Command 6. WPS ( Winding Protection S/W)
7. RUN Status 7. Hi REF LVL
8. TRIP Status 8. LOCAL S/W
9. SPARE 9. REMOT S/W
10. SPARE 10. SPARE
Analog Output Analog Input

1. EXV 1. SUC PR
2. SPARE 2. DISCH PR
3. SPARE 3. COMP AMP
4. SPARE 4. CHW OUT TEMP
5. SUC TEMP
6. DISC TEMP
7. CHW IN TEMP
32
INPUT / OUTPUT LIST FOR TWIN COMPRESSOR UNIT
Digital Output:
Analog Input:
1. CMP1 Main
1. CHW OUT TEMP
2. CMP1 Delta
2. CHW IN TEMP
3. Load Solenoid Valve 1
3. SUC TMP1
4. Unload Solenoid Valve 1
4. SUC TMP2
5. Economizer Solenoid Valve 1
5. SUC PR
6. CMP2 Main
6. DISC PR
7. CMP2 Delta
7. CMP1 AMP
8. Load Solenoid Valve 2
8. CMP2 AMP
9. Unload Solenoid Valve 2
9. WDG TMP1
10. Economizer Solenoid Valve 2
10. WDG TMP2
11. SPARE
Analog Output:
12. SPARE
1. EXV
13. SPARE
2. ALARM (used as RO by using external relay)
14. SPARE
3. Oil Recovery 1 (used as RO by using external
15. SPARE
relay)
4. Oil Recovery 2 (used as RO by using external 16. SPARE
relay) 17. SPARE
18. SPARE
Digital Input: 19. SPARE
1. CHW FLOW
2. CND FLOW
3. Unit RUN/STOP (Local / Remote)
4. Pump Dwn1
5. Pump Dwn2
6. MPD VPD 1
7. MPD VPD 2
8. OIL LVL1
9. OIL LVL 2
10. WPS 1 (Winding Protection S/W)
11. WPS 2 (Winding Protection S/W)
12. Hi REF LVL
13. External INT
33
SET POINT
Set Point Value Min Max Author Description

1 CHW TARGT 7 5 15 View This value will be used to develope the Control
Zone, refer to set points #2 & #3.
The control target is used with the control

zone & rate of change of the controlling
sensor to determine required action.
2 CTL ZONE + 0.3 0.3 2 View Added to the CTL TARGET to create the top
of the control zone. This value will be used
to develop the Control Zone, refer to set
points # 2 & #3. The control target
3 CTL ZONE - 0.3 0.3 2 View Subtracted from the CTL TARGET to create
the bottom of the control zone.
4 SUPERHT TRGT 1.7 1 12 Service This is the target for SUPERHEAT that the
system will maintain.
5 EXV MIN% 20 10 50 Service This is the minimum valve position allowed

when modulating the expansion valve. The
calculated position is not allowed to be less
then this set point.This value should be set
so when hot gas is applied the valve opening
isadequate
6 EXV MAX% 100 40 100 Service This is the maximum position allowed when
modulating the expansion valve to maintain
the SUPERHEAT target. This value should
be the valve% opening at 100% capacity +
10 to 15 %.
7 LOAD PULSE 6 1 15 Service Length of time to turn on the slide valve load
solenoid. Time is expressed in 1/10 of a
second. (This value should be between
1 & 9.)
8 UNLOAD PULSE 8 1 15 Service Lengths of time to turn on the slide valve

unload solenoid. Time is expressed in 1/10
of a second. . (This value should be between
1 & 9.)
9 PULSE DELAY 3 3 5 Service Used with infinite capacity screws.

The number of seconds between load or
unload pulses. (Should be between 3 & 5.
Allows load change to be checked before
next pulse. Eliminates oil foaming when
unloading too fast.)
34

10 ANTcycFrmOFF 180 180 600 Service This is the anti cycle time delay (in seconds)
based on when the compressor was turned
off. This value is used in a calculation to
determine how long a compressor should be
in the anti-cycle state. Refer to the Standard
Control Options section, Compressor Anti-
Cycle Logic. (OFF to ON)
11 PMP DWN OFF 48 30 60 Service This is the suction pressure value for turning
off the compressor when in the PUMP DOWN
state.
12 PMP DWN DELY 60 0 60 Service Maximum time delay (in seconds) that a
compressor can remain in the PUMP DOWN
state.
13 ANTcycFrmON 600 240 900 Service This is the anti cycle time delay (in seconds)
based on when the compressor was turned
on. This value is used in a calculation to
determine how long a compressor should be
in the anti-cycle state. Refer to the Standard
Control Options section, Compressor Anti-
Cycle Logic. (ON to ON)
14 FLA COMP#1 110 80 160 Service For screw compressors, the ampere when
the compressor is fully loaded. This value is
used to calculate the compressor current
FLA %, which is used to control the loading
and unloading of the slide valve. This value
is used to calculate the high and the low
ampere safeties limits. Refer to set points
75 and 76.
15 HI AMPS 115 95 125 Service This set point is a percentage of the FLA;
it is used to create the high amp draw limit.
Depending on the circuit that is being tested:
the value of this set point is multiplied by
value in set point 65 to obtain the circuit’s
high limit. This value is tested in the high
amp safety, if the amps exceed this value
for 2 Sec then the safety is tripped.
16 LOW SUCTION 20 20 40 Service The system checks for low suction pressure
for running compressor. The system will
compare the suction pressure sensor reading
to this value. It must be less than the value
for the period 180sec before this will trip.
35

17 UNSAFE SUCT 14 10 30 Service The system checks for low suction pressure
that is in an unsafe condition for running
compressor. The system will compare the
suction pressure sensor reading to this value.
It must be less than the value for the 2 Sec
before this set point will trip.
18 HI DISCH PSI 185 150 210 Service The system checks for high discharge
pressure condition for running compressor.
The system will compare the discharge
pressure sensor reading to this value. It must
be greater for the period of 2 Sec before this
safety will trip.
19 LO DISC PSI 75 70 120 Service The system will compare the sensor reading
to this value. It must be less than the value
for the period 90 Sec before a safety trip
occurs.
20 LOW OIL DIF 25 20 50 Service The system checks for low differential oil
pressure. The system will compare the
differential between oil pressure minus Suc
Pressure to this value. It must be less than
the value for the period of 60 Sec before the
safety will trip.
21 UNSAFE OIL 15 10 30 Service The system checks for low differential oil
pressure. The system will compare the
differential between oil pressure minus Suc
Pressure to this value. It must be less than
the value for the period 5 Sec before the
safety will trip.
22 Hi WIND TEMP 55 40 120 Service If active, the system checks for high motor
temperature the system will compare the
sensor reading to this value. It must be
greater for the 2 Sec before this set point
will trip.
23 ECON ON% 70 50 80 Service When the chiller capacity wanted is greater

then this value the ECON solenoid will open.
When the circuit capacity is below 20 than
the value then it will be turned off.
24 FREEZE 4 4 10 Service The system will compare the chilled water

out temperature to this value. It must be less
than the value for the period of 5 Sec before
this safety will trip.
36
FAULT DISPLAY
Sr No Fault Display Fault display description

1 “ALARM SUC PR “ Suction Pressure analog sensor is not connected or Out of range.
2 “ALARM DISC PR “ Discharge Pressure analog sensor is not connected or Out of range
3 “ALARM OIL PR “ Oil Pressure analog sensor is not connected or Out of range
4 “ALARM CH OUT “ Chiller Out temperature analog sensor is not connected or Out of
range
5 “ALARM CH IN “ Chiller IN temperature analog sensor is not connected or Out of range
6 “ALARM SUC TMP “ Suction temperature analog sensor is not connected or Out of range
7 “ALARM DISC TMP “ Discharge temperature analog sensor is not connected or Out of
range
8 “Trip MPD/VPD “ The system will check the MPD/VPD digital input. It must be TRIP for
the period of 4 Sec before trip
9 “ WIND SW TRIP “ The system will check the INT 69 digital input. It must be TRIP for the
period of 2 Sec before trip
10 “ LO OIL Level “ The system will check the OIL LVL digital input. It must be TRIP for
the period of 60 Sec before this trip
11 “ HI AMPS % “ The system will check the compressor Amp % if it is more then set HI
AMP %. System will trip on this fault
12 “ LoAmpNoStart “ The system will check amp feed back after staring the compressor if
it is low than set Value. The System will trip on this fault
13 “ LOW SUCTION “ The system will compare the suction pressure sensor reading to set
value. If it is less than the set value for the period 60sec then the
system will trip on this fault.
14 “UNSAFE SUCT “ The system will compare the suction pressure sensor reading to set
value. If it is less than the value for 2 Sec then the system will trip on
this fault.
15 “ HI DISCH PSI “ The system will compare the discharge pressure sensor reading to
set value. If it is greater for the period of 5 Sec the system will trip on
this fault
16 “LO DISC PSI “ The system will compare the sensor reading to set value. If it is less
than the value for the period 90 Sec then the system trip on this fault.
37
Sr No Fault Display Fault display description
17 “ LOW OIL DIF “ The system will compare the differential between oil pressure minus
Suc Pressure to set value. If it is less than the value for the period of
120 Sec the system will trip on this fault
18 “UNSAFE OIL” The system will compare the differential between oil pressure minus
Suc Pressure to set value. If it is less than the value for the period of
4 Sec the system will trip on this fault
19 “Hi WIND TEMP” The system will compare the Winding PT1000 temperature to set value.
If it is high than the value for the period of 2 Sec the system will trip on
this fault.
20 “No CH/CD FLW “ The system will check the chiller flow switch digital input. If it is OFF
The system will trip on this Fault
21 “ FREEZE “ The system will compare the chilled water out temperature to set
value. If it is less than the value for the period of 5 Sec the system will
trip on this fault.
22 “EXT DEV TRIP” The system will check the Ext Device digital input. It must be TRIP for
the period of 4 Sec before trip
23 “HIGH LQD LVL” The system will check the Liquid Level digital input. It must be TRIP
for the period of 30 Sec before trip
SYSTEM GENERATED ALARMS

The following alarms are generated to provide information; they will not cause a change in the control algorithm
such as a lock out condition or a relay output being forced off.
POWER FAILED
POWER RETURNED
COMPUTER RESET
LCD FAILURE
WATCHDOG RESET
LOST A/D CONVTR
LOST DISPLAY
38
CONTROL ZONE CONTROL METHOD OPTIONS

This control strategy is based upon developing a control zone and then to step the compressor(s) through thier
stages to maintain the control sensor reading within this zone. To accomplish this the system will constantly
monitor the control value, its rate of change and position in relationship to the control zone.
The actual strategy of a fixed step system, reciprocating compressor, and a variable (slide) step system, screw
compressor or a reciprocating compressor with an inverter. is slightly different. The variable step system allows for
infinite variations of capacity while the fixed step system does not.
1.1 Common Definition

1.1.1 Target
The control target is specified in set point 1. 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 (set point) and the dead band
+(set point) to obtain the upper limit. The lower limit is obtained by substracting the dead band -
(set point 3) set point from the control target (set point 1).
Temperature Control Zone+

Target Control Zone
Temp 450 Control Zone-
Once the control zone has been established, the system will attempt to keep the control sensor reading
with in this range.
1.1.3. Controlling Sensor

This is the sensor that has been specified in the Config program as providing the
control value reading. It will normally be either the entering, leaving temperature or the suction
pressure. The set points must be adjusted to agree with the controlling value.
1.1.4. The Rate of Change of The Control Input

The rate of change 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. Step Delay

The system will not attempt to take action until the Step Delay reaches zero. Set point 26
contains the initial value. The speed that it is decrement by is based upon the rate of change of
control input value and the sensitivity that has been specified.
1.1.6. Sensitivity
The sensitivity value is contained in set point 25. The purpose of the sensitivity value is to limit
or dampen how fast the system reacts to changes indicated by the control sensor. The lower the
number, the faster the system will react to changes of the control sensor.
39
SOFTWARE FEATURE :
1 Option of Schedule / Auto / Manual Mode / Remote :

SCHEDULE MODE : One year programming for starting & stopping of chiller.
AUTO : Every day starting & stopping of chiller as per customer's requirement by Run / Stop Key.
MANUAL : Only for service personal. It can be accessed by service level password. (All safties get by-pass)
2 Sequential start :
Starting of condenser water pumps/fans, chilled water pump and compressor with time delay of 15 seconds.
3 Auto start on power restoration :

Automatic switching "ON" of chiller on power restoration. (Only if chiller is kept in auto mode).
4 CHW & CW water pump starting interlock :

The chiller is allowed to start only if pumps are started. (Only if interlocks are connected).
5 Auto stop :
Compressor stops when chilled water outlet temperature is less than Set temperature minus Auto stop
temperature.
6 Auto restart of chiller :

If chiller stops on low chilled water outlet temp. The chiller shall restart on chilled water outlet temperature
raising 5 deg. C above set point. (Set temperature + auto start temperature).
7 Anti recycle timer :

The timer shall allow compressor to start after 7 minutes whenever it stops/trips, which shall avoid compressor
ON / OFF cycling.
8 Current limiting : (Adaptive control)

In case the current drawn by compressor is more than rated FLA, the compressor shall unload, so as to keep
chiller operating till corrective action is taken. If current still continues to exceed rated FLA, the compressor
shall trip on overcurrent problem, through PLC.
9 Discharge pressure limiting : (Adaptive control)

If the discharge pressure reaches below discharge pressure trip limit the compressor shall be unloaded, so
as to keep chiller operating till corrective action is taken. If discharge pressure still continues to exceed cut
out setting, the compressor shall trip on high discharge pressure, through analog input.
40
10 Suction pressure limiting : (Adaptive control)

If the suction pressure reaches above trip limit, the compressor shall unload, so as to keep the chiller
operating till corrective action is taken. If suction pressure still continues to drop further, the compressor shall
trip on low suction pressure, through analog input.
11 Maintenance trip :
Upon completion of 8000 running hours, the chiller shall be locked OFF for maintenance. A warning message
for requirement of maintenance shall get displayed 50 hours before completion of 8000 hours. The maintenance
trip hours to be reset by resetting maintenance operating hours to 0000, using third level password.
12 Crank case heater :

Crank case heater shall switch ON immediately after switching OFF compressor. It shall switch OFF once
compressor is switched ON.
13 Analog input error :

Sensor error shall display in case temperature sensor pressure transducers are not connected properly or
sensor is faulty.
14 Economiser operation :
Economiser solenoid valve will be ON if chiller has sufficient load even after economiser set delay time is
over.
15 One year programming :

Controller has build in real time clock (RTC), based on weekly start-stop schedule & yearly holiday schedule,
unit shall run in automatic mode for one year.
16 Scheduling
Entering the correct schedule is very important for proper working of the Chiller package. The Chiller package
works in accordance with the scheduled programme, time and date.
The following example table shows the necessary data that the user should enter for proper operation of
chiller package.
41
EXAMPLE : WEEKLY SCHEDULE

DAY OF THE WEEK START TIME-1 STOP TIME-2
hh:mm hh:mm
Day 1 - Monday 09 : 00 18 : 00
Day 2 - Tuesday 09 : 00 18 : 00
Day 3 - Wednesday 09 : 00 18 : 00
Day 4 - Thursday 09 : 00 18 : 00
Day 5 - Friday 09 : 00 18 : 00
Day 6 - Saturday 09 : 00 13 : 00
Day 7 - Sunday 00 : 00 00 : 00
Entries for weekly off i.e. Sunday or any other day of the week can be made by entering "0 0" for start & stop
time. Please note that the start time should be less than stop time.
HOLIDAY SCHEDULE
HOLIDAY NO. DATE NO. DATE (dd:mm)
HOLI 1 DATE 1 26:01
HOLI 2 DATE 2 01:05
HOLI 3 DATE 3 15:08
HOLI 15 DATE 5 25:12
The holiday schedule takes precedence over the weekly schedule. At the start of each day the holiday table
is scanned for a date match. If any of the 15 holiday dated match the current date. The weekly schedule will
be ignored and unit will not be started.
The holiday schedule is useful for entering special schedules like public holidays for festivals, elections,
compensatory holidays. Upto 15 holidays and their corresponding dates can be programmed.
17 Under/over current and voltage trip

With the provision of microprocessor based motor protection device & voltage protection device the compressor
motor is protected.
18 Delay between star to delta changeover
Pause time between start to delta transition is provided for smooth changeover, in case of star delta starter.
19 Easy diagnosis
With the help of diagnosis key and alarm history, it is easy to diagnosis the problems.
20 Continuous display of all relevant parameters
With pre-determine scroll time, all parameters (Analog Inputs) can be viewed.
21 Validation
Entering erroneous values of parameter while programming may lead to chiller operation at default values,
which shall be safe for operation of Chiller.
22 Alarm history
Previous five faults with date & time are stored in a memory and same can be used for troubleshooting.
42
BMS COMMUNICATION PROTOCOLS

The controller supports BACnet IP, Modbus RTU, Modbus TCP/IP. Supported baud rates for Modbus RTU are
4800bps, 9600bps, 19200bps, 38400bps, and 57600bps.
*- Indicates value multiplied by 10 to include one decimal place. (ie. BMS value of 500 indicates actual value 50.0)
43
ANALOG OUTPUT
Sr. No. MAGNUM MODBUS Register BACnet Name BACnet ID
1 EXV1 *30201 EXV1 *AO:1
STATE
1 Chiller Unit State 30306 Chiller State MV:0
2 Comp State 30307 Circuit # 1State MV:1
CAPACITY CONTROL STATE CHART

The values exposed in the capacity state relate to the description in this table.
State Number Description

0 UNIT IN POWER UP
1 RUN NOTALLOWED
2 NO RUN-I/O LOST
3 INIT IN LOCKOUT
4 UNIT IS OFF
5 UNIT IS HOLDING
6 UNIT UNLOADING
7 UNIT IS LOADING
8 NO RUN - SAFETY
9 RUN/STOP SW OFF
10 SCHEDULED OFF
11 OFF-NO EVAP FLOW
12 OFF-NO COND FLOW
13 AMBIENT OFF
14 PROCESS HEAT OFF
15 UNIT IS UNLOADED
16 UNIT IS LOADED
17 OFF TMP-ICE MADE
18 ECONOMIZER ONLY
19 SWITCHING MODES
20 UNIT SMOKE UNLDG
21 UNIT OFF UNLDING
22 UNIT DMD UNLDING
23 UNIT HEAT UNLDNG
44
CAPACITY CONTROL STATE CHART

The values exposed in the capacity state relate to the description in this table.
State Number Description

0 LOST IO LOCKED
1 CMP LOCKED OUT
2 SWITCHED OFF
3 CMPPUMPDOWN
4 CMPANTICYCLE
5 CMP OFF/READY
6 OIL PMP LUBING
7 CMP IS RUNNING
8 CMP UNLOADED
9 UNLD1HGBP OFF
10 PART LOADED
11 CMP IS HOLDING
12 CMP IS LOADING
13 CMP IS UNLDING
14 CMP IS AT 100%
15 FAST UNLOADING
16 LO SUCT UNLOAD
17 LO SUCT HOLD
18 HI DISC UNLOAD
19 HI DISK HOLD
20 LO TEMP UNLOAD
21 LO TEMP UNLOAD
22 LO TEMP HOLD
23 HI AMP HOLD
24 HI DIS TMP HLD
25 CMP IS AT 40%
26 CMP IS AT 70%
27 HI WATER HOLD
28 EXTRA 70% STEP
29 OFF-LO OIL TMP
30 HIAMP UNLDING
31 DEFPREPMPOUT
32 DEFROSTING
33 DEF PUMP DOWN
34 HI TEMP UNLOAD
35 HI TEMP HOLD
45
MODBIS RTU
The Modbus RTU address can be verified and changed (with the proper authorization code) from the keypad/LCD
of a live unit.
To get authorized on magnum do the following :
O Press 'Menu'.
O Using ↑, ↓, →, or ← position cursor to 'Passwords'.
O Press ↵ key.
O Enter 4 digit password & press.
O Press 'Menu' to make next selection.
The Following steps will display the Modbus RTU Network address, and the Baud Rate:
(To change the address and the Baud Rate you must be authorised).
O Press the MENU key and then Using ↑, ↓, →, or ← position cursor to Serv Tools then press the ENTER
key.
O Select RS485 Network then press Enter.
O Select Protocol then press Enter. Change the protocol to Modbus.
O Select address then press Enter. Change the address then press Enter.
O Select Baud then press Enter. Set the baud rate then press Enter.
O Connect the communication wires to the TX RS485 three-position terminal located above the Ethernet
connector.
MODBUS TCP/IP
This protocol is always active.
Make sure the MCS-Magnum network setting are set correctly.
The following steps will display the Ethernet Network settings:

(To change the setting you first must be authorized).
To get authorised on controller do the following :

O Press 'Menu'.
O Press ↵ key.
If you are going to manually assign the IP Address, Subnet Mask, and Default Gateway.
O Press the MENU key and then using ↑, ↓, →, or ← position cursor to Serv Tools then press the ENTER
key.
46
O Select Ethemet Network then press Enter.

O Set "DHCP Enabled" to No.
O Set the "IP Address".
O Set the "Subnet Mask."
O Set "Default Gateway".
If you are going to let your network assign the IP Address, Subnet Mask, and Default Gateway.
key.
O Set "DHCP Enabled" to YES; Connect the MCS-Magnum to the network and cycle power to the board.
BACNET OVER IP :
The BACNET DEVICE ID is a five-digit number. T he first three digits are based on our Bacnet vendor ID that is 181,
and the last two are set by the Bacnet/MSTP address.
181 XX
↓ ↓
Bacnet Vendor ID Bacnet MS/TP Address
The Bacnet address can be verified and changed (with the proper authorization code) from the keypad/LCD of a live
unit
To get authorized on controller do the following :
O Press 'Menu'.
O Press ↵ key.
The Following steps will display the Modbus RTU Network address, and the Baud Rate:
(To change the address and the Baud Rate you must be authorised).
key.
O Select RS485 Network then press Enter.
O Select Protocol then press Enter. Change the protocol to BACnet MSTP.
O Select address then press Enter. Change the address so it matches the last two digits of the device ID
then press Enter.
O Select Protocol ID then press Enter.
47
The Following steps will display the Ethemet Network setting :
(To change the setting you first must be authorized).
If you are going to manually assign the IP Address, Subnet Mask, and Default Gateway.
O Press the MENU key and then using ↑, ↓, →, or ← position cursor to Serv Tools then press the ENTER
key.
O Set "DHCP Enabled" to No.
O Set the "IP Address".
O Set the "Subnet Mask."
O Set "Default Gateway".
If you are going to let your network assign the IP Address, Subnet Mask, and Default Gateway.
key.
O Set "DHCP Enabled" to YES; Connect the MCS-Magnum to the network and cycle power to the board.
MCS 485 Communications

MCS 485 Network with Local RS232 Communications
48
CONTROLLER STATUS QUICK REFERENCE

Control states tell the user the system's status; this information is critical. From the keyboard / display, press the
menu key and select STATUS > The control Status is the second line. Controller States Quick Reference - CHL R
& 18.00 Software. Control States tell the used the system's status; this information is critical.
CAPACITY CONTROL STATES CIRCUIT CONTROL STATES
STATE DESCRIPTION STATE DESCRIPTION

UNIT IN POWER System Reset or Power CMP OFF / READY Circuit ready but not required
Returned (delay of 60 seconds or has not been in this state for
or set point value) 60 seconds.
OIL PMP LUBING Screw wanted ON, waiting for
UNIT IS OFF System ready to run but no good oil pressure and temp
cooling capacity required. and slide fully unloaded.
RUN / STOP SW OFF Disabled : run/stop switch is FAST UNLOADING Fast unload screw compressor
off. at start up.
SCHEDULED OFF Disabled : operationg schedule CMP IS LOADING Pulsing screw load solenoid.
is false. CMP IS HOLDING Control temperature with in
target control band.
OFF NO EVAP FLOW Disabled : either high or low
ambient temperature CMP IS UNLOADING Pulsing screw unload solenoid.
AMBIENT OFF Disabled : either high or low HI DISC UNLOAD Pulse screw unload solenoid
ambient temperature. because discharge temp or
pressure is too high.
UNIT IN LOCKOUT Chiller locked out, all points
HI DISC HOLD Holding untill discharge temp
except alarm point are OFF
or pressure returns to normal.
NO RUN-IO LOST Lost communication Chiller LO SUCT UNLOAD Pulse screw unload solenoid
locked out or unload 1 step, suction temp
or pressure is too low.
UNIT IS HOLDING No change in capacity
LO SUCT HOLD Holding screw slide or 1
UNIT UNLOADING Reduce capacity unloader off until suction temp
or pressure returns to normal.
UNIT LOADING Increase capacity
LO TEMP UNLOAD Comp unloading, temperature
UNIT IS UNLOADED Unit is unloaded, No cooling less than 1.5 F above freeze point.
capacity is being provided.
LO TEMP HOLD Hold untill temperature is 3.0 F
UNIT IS LOADED Unit is loade, maximum cooling above freezing point.
capacity is being provided CMP UNLOADED Comp ON, all unloaders OFF.
CMP IS AT 100% Circuit is fully loaded, all
unloaders are OFF.
CMPPUMPDOWN Pumping Down.
CMPANTICYCLE Delay after turning off circuit.
SWITCHED OFF Pump down switch on or
system state is DISABLE.
SAFETY TRIPPED Safety tripped not LOCKOUT
CMP LOCKED OUT Safety tripped twice with in half
hour, circuit locked off.
LOST IO LOCKED Lost communication.
HI AMP HOLD Circuit is in hold due to hi amps.
Can only be unloaded
49
50
SENSOR QUICK REFERENCE SHEET
51
ELECTRICAL WIRING DIAGRAM
FOR
SINGLE COMPRESSOR UNIT
52
53
54
55
56
57
58
59
60
61
ELECTRICAL WIRING DIAGRAM
FOR
TWIN COMPRESSOR UNIT
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
MAINTENANCE
1. CONDENSER COOLING WATER MANAGEMENT

Water-cooled condenser should have a soft, uncontaminated filtered water supply. Hard water
(a hardness over 60 ppm of CaCO3) circulated in the water circuit results in rapid scale formation inside
the tube surface. This results in reduction of heat transfer from condensing refrigerant to condenser
water, thereby resulting into reduction of system cooling capacity, increased discharge pressure,
clogging of tube and nozzles and eventual break down of AC system. Atmospheric oxygen,
carbon dioxide, sulphur dioxide absorbed from air in cooling tower and dissolved in water causes
corrosion.
As the condenser water is recycled the concentration of corrosive minerals increases. If repeated
operational problems are attributed to condenser water, then it is advisable, in critical cases, that
chemical analysis be asked for rather than frequent descaling operations which eventually shorten the
condenser life. Soft make-up water at rate of 1.5% to 2% of flow rate is recommended to be provided at
the cooling tower.
2. DESCALING OF CONDENSER
Carry out condenser descaling work when unit is not in operation. Rig up the descaling tank, pump and
connecting pipe work. Following precautions should be taken :
a. Do not run fan while descaling is being done. Fumes/gases liberated during descaling will cause
discomfort to the occupants and might.
b. Cause harm to instrument/apparatus kept in airconditioned space.
c. Descaling chemical should be circulated from bottom port of condenser water connections and
outlet pipe must be vented.
Add water to the tank and start descaling pump. Check that there is no leak in the connections.
Add descaling chemical slowly to the tank, do not exceed pH of 4. Maintain pH valve by checking
at regular intervals and adding chemical slowly. It should take about 2-3 hours. Use descaling
chemical approved by VOLTAS.
After descaling is over, flush the system with water till pH valve comes up to a little more that 7.
Inspect the condenser tubes by opening end covers. Use a nylon brush for brushing tubes if
necessary.
3. FAULTS AND REMEDIES

In case of any abnormal conditions, care should be taken to prevent any accident and / or damage to
the equipments.
The frequency of occurrence of the faults can be reduced but it cannot be avoided completely.
Hence the control system is provided in such a way that for the important faults before the compressor
is TRIPPED, to avoid damage or accident, the ALARM is provided to caution the plant attendant to take
corrective steps.
79
The following part of the chapter would deal with possible faults, their causes and remedies.
CAUSES REMEDIES
CONDENSER WATER FLOW LOW

Less water in cooling tower Make up for water sump probably losses cooling
water pump would get air lock
Suction strainer of cooling Water pump chocked Clean the strainer
Isolation valves in branch lines (from header) Open inlet/outlet valves to establish the proper flow
Partially Closed
Cooling Tower Water Pump Tripped/developed a Restart after checking the reason for tripping
fault
Spray nozzles choked Clean the nozzles and adjust the orientation
Choking of heat exchanger tubes due to scaling Thoroughly clean the tubes using nylon wire brush
CHILLER WATER TEMPERATURE LOW
Very less load Check the capacity control system.
Very less flow of chiller water Check the chiller flow
(Probably comp. may trip)
CHILLED WATER FLOW LOW
Choking of water pump Clean the strainer suction strainer
Pump inlet/outlet valves Chiller inlet/outlet Check these valves and ensure that except the valve
valves are not full OPEN in brine return line (to tank) all the valves are full
OPEN
NRV at pump outlet is closed (pump outlet OPEN the NRV and stuck closed repair or
Pressure will be equal to Shut off head) replace it.
Coupling between motor and pump broken Find out the reason for failure of coupling such as
jamming of pump, etc and replace the coupling after
attending to the fault
Damage to Impeller or Shearing of shaft Replace the damaged components
(very rare fault)
DISCHARGE PRESSURE HIGH
Less cooling water flow through condenser Refer Earlier
High cooling water inlet temperature Check performance of cooling tower
Fouling of condenser tubes Clean the tubes mechanically and if and if required,
chemically
80
CAUSES REMEDIES
Suction pressure high Refer earlier

Presence of non-condensable Gases in the Purge the non-condensable gases
refrigerant
Water side gasket damaged Gases in the Open the end covers and replace the gasket
refrigerant
SUCTION PRESSURE LOW
Loss of refrigerant from the system Top up the refrigerant
Expansion valve choked, dirt or moisture in the Replace the drier core due to and clean the strainer
system provided at the inlet of expansion valve
Low water temperature or Low water flow Check the setting of Antifreeze temperature and flow
Suction strainer choked Clean the strainer
Pressure gauge/Transmitter faulty Change the instrument or calibrate
Accumulation of excess oil in chiller Drain excess oil and check whether refrigerant in
the system is sufficient
OIL TEMPERATURE HIGH
High Oil temperature Probably comp. may trip Refer earlier
On that safety
Low oil flow due to choking Replace the filter paper of paper filter
High suction superheat or suction temperature Refer earlier
Low cooling water to oil cooler (if applicable) Check the cooling water
Excess fouling on oil cooler tubes (if applicable) Clean the oil cooler tubes
OIL LEVEL LOW
Loss of oil from system due to leakage Identify the leak and arrest. Recharge the required
quantity of oil
Oil accumulation in the chiller Lack of refrigerant in the system
High suction superheat or suction temperature Refer earlier
Low cooling water to oil cooler (if applicable) Check the cooling water
Excess fouling on oil cooler tubes (if applicable) Clean the oil cooler tubes
81
TROUBLESHOOTING FOR CONTROL PANEL
NO. PROBLEM POTENTIAL SOLUTION
1. A sensor input reads - 99.9 This indicated an open sensor input signal or 5 VDC problem
O Check sensor wiring for missing wire or poor connection
O Check sensor for bad sensor.
If less that 5 VDC is on the sensor 5 VDC terminal block, the
problem is with probably a shoted sensor. (A poly fuse protects
the board.
O Remove all sensor input terminals.
O Wait about 1 min. or until 5 VDC restored at sensor input.
O Connect terminals 1 at time untill short reappears.
2. A sensor input reads +999.9 This indicates a shorted sensor input signal.
O Check sensor wiring for +5VDC shorted to signal etc.
O Check sensor for bad sensor.
3. A sensor is reading less then This indicated the sensor needs to be calibrated. (You need to
or greater then 3% off have a valid Auth code to change sensor offsets)
O Press Service Diagnostics, press until LCD display a sensor
offset option.
O Press enter, 1st SI# & offset appears (i.e. Suct 1 = 0.0)
O Scroll using "increase (+) / decrease (-)" keys to find sensor to
be calibrated.
O Press enter, use "increase (+) / derease (-)" keys to change
the calibration value. When value is correct, press enter.
4. 'Controller Initialization' on Indicated Micro in constant reset.

LCD display O Check incoming power > 105 VAC or 22 VAC
5. Top row of LCD display Indicates software chip problem possible.

all bars & 2nd row blank O Possible U11 software version incorrect or chip bad.
O Possible U13 GAL chip incorrect or chip bad.
O Possible bad connection or cable between LCD and MCS8.
6. LCD blank Indicates bad connection

O Connector J2 on controller not on or offset on connector.
O Resistor adjustment VR1 out of adjustment.
7. Lost I/O Indicates communications problem.

O Verify RS485 LED blinking.
O Verify termination jumper J6 only on at MCS-8 & last I/O.
82
NO. PROBLEM POTENTIAL SOLUTION
O Verify MCS-8 & I/O address's set correctly.

O Verify winning from MCS - 8 to each I/O correct.
O Check fuses / 120 VAC on I/O units.
8. Invalid reading on one This indicates an input problem with 1 sensor.

sensor input O Verify jumper setting correct for that SI.
9. Changes to MCS not being This indicates inability to write to chip U10
made. O Verify 'EEP WRITE ENABLE' jumper W6 is on.
O Not authorized.
10. Invalid authorization This indicates an invalid auth #.

Follow steps below for proper authorization
O Press SERVICE DIAGNOSTICS until the auth. option appears
O Press the ENTER key.
O From the "Display Status" press keys corresponding to your
authorization #.
O Press ENTER
11. SI from AMPS board 10 A low. This indicates a problem with this SI only.
O Jumper setting on this SI in wrong position.
O Incorrect sensor type used.
12. Invalid Config Ver Indicates layout of CFG wrong.

O CFG layout with check sums are stored in flash
O Verify CFG and reload.
13. Invalid Config Type Indicates CFG type is incompatible with Software selected software.
14. Invalid Config Indicates Check sum invalid

15. Sensor input believed invalid O Verify Berg jumpers using Quick Reference Sheets
(Under Sensor Diagnostic O Check board version number
Sub Menu) O Check wiring of sensor.
83
NO. PROBLEM REASON REMEDY
16. Voltage Problem 1) Over Voltage 1) Check parameters on VPD display for
2) Under Voltage correct values.
3) Unbalance 2) Check VPD ferrule No 1 & 9 for continuity
4) Phase Reversal close.
5) Single Phasing
17. Current Problem 1) Over Current 1) Check parameters on MPD display for
2) Under Current correct Values.
3) Unbalance 2) Check MPD ferrule No. for continuity
4) Phase Reversal close.
5) Single Phasing 3) View DI using DI status on display
DI shall be high.
18. Chilled Water 1) Water flow is low 1) Check design CHW press drop across
Flow Low 2) Switch faulty chiller inlet & outlet.
2) Replace faulty switch.
3) Check control panel terminals for
continuity close.
19. CW Flow Low 1) Condenser Pump OFF 1) Switch ON Condenser water pump.
2) N. O. contact faulty 2) Check 230 AC voltage.
20. High winding 1) Module faulty 1) Check high winding module, if provided.
Temperature
21. Sensor Error 1) Sensor faulty 1) Check sensor, the resistance should be
(Temp Sensor) 2) Shield not properly 6 k ohms to 20 k ohms based on
earthed temperature.
2) Ensure shield is properly earthed at one
end only (Inside Panel).
3) Check electrically wiring is correct.
4) Check motor connector pins looseness
or improper fixing.
22. Sensor Error 1) Sensor faulty 1) Check sensor and whether it is

(Pressure Sensor) 2) 24 VDC supply faulty connected to particular terminal (as per
3) Wrong polarity electrical drawing)
4) 24 Volt. Power 2) Check 24 VDC supply card and its fuse.
transformer faulty 3) Check polarity, check current 4 to 20 mA.
84
4) Check 24 volt power supply transformer

for 24 volt output.
5) Check electrically wiring is correct.
6) Check motor connector pins looseness
or improper fixing.
23. Low Oil Pressure 1) Pressure low 1) Check oil pressure. It should be above
2) Parameter setting high parameter setting.
3) Sensor faulty 2) Check sensor, it should be between 4 to
20 mA. Check polarity. It should be as
per sensor drawing.
24. Low Suction 1) Suction pressure low 1) Check suction pressure. It should be
Pressure 2) Parameter setting high above parameter setting.
3) Sensor faulty 2) Check sensor feedback. It should be
between 4 to 20 mA. Check polarity.
It should be as per sensor drawing.
25. High Discharge 1) Discharge Pressure high 1) Check discharge pressure. It should be
Pressure 2) Parameter setting high lower than parameter setting.
3) Sensor faulty 2) Check sensor feedback. It should be
between 4 to 30 mA.
3) Check polarity. It should be as per sensor
drawing.
26. Current Reading 1) C. T. (Current 1) Check C. T. for saturation. If it is

Faulty on PLC Transformer) faulty saturated, replace CT.
(Running display) 2) Current Transmitter 2) Check current Transmitter polarity
faulty as per electrical drawing, if required
3) Current Transmitter inter-change wires.
output polarity wrong
27. Condenser fan 1) Air-cooled condenser 1) Check parameter setting. Parameter

second stage not pressure PARA setting setting plus 40 PSI, shall switch ON 2nd
getting ON high fan stage.
2) Check fan motor & its contactor for
proper wiring.
28. Tripping on Low 1) Parameter setting for low 1) Check parameter setting. It should be
Refrigerant refrigerant temperature as per design requirement.
Temperature is high 2) Check sensor calibration.
2) CHW sensor faulty
85
29. VPD displays - 1) Glass fuse card 1) Check glass fuse card three fuse for
SPP (Single faulty R, Y, B.
Phasing) 2) Voltage drawn is 2) Check voltage parameter for correct
higher than setting setting.
30. Loading & 1) DO card faulty 1) Check DO card output & Diagnosis
Unloading faulty 2) Solenoid coil burnt display for DO high & low.
3) Wrong wiring 2) Check solenoid valve connections and
coil.
31. Pressure sensor 1) Sensor for Oil 1) Check for proper location of pressure
reading is wrong Suction & Discharge sensor.
pressure 2) Check pressure transducers for output
interchanged 4 to 20 mA.
2) Pressure sensor 3) Check 24 volt DC card for correct
faulty voltage output.
32. M/C does not stop 1) In PARAMETER Auto 1) Check Auto stop setting. "Set Point"
on Auto stop stop setting wrong minus "Auto Stop" temperature shall
temperature 2) Sensor faulty stop compressor on Auto stop.
3) Wrong display of 2) Check CHW sensor output resistance
temperature It should be between 6 k ohms to 20
k ohms based on temperature.
3) Check calibration of CHW temperature
sensor.
Note : 1) While checking next DI, ensure previous DI is/are close/short linked.
2) While checking the continuity of any external device for e. g. VPD, MPD, HP/LP switch etc. be sure
that contacts are potential free. (i. e. Remove wire 1 & 9 in case of VPD). Otherwise check voltages
with respect to neutral or ground.
86
COMMITMENT TO SERVICE
SERVICE AFTER WARRANTY
Voltas offers a range of Maintenance Service Contracts at reasonable prices, to its customers :
1. Comprehensive annual maintenance service scheme
a) Under this scheme all the spares & consumables required for repairs, overhauling the AC Plant are
included.
2. Annual Maintenance Service Scheme
Under this scheme repairs and overhauling is covered.
The following items of works are not covered under this scheme
a) The consumables like refrigerant, oil.
b) Transportation of equipment for repairs and octroi payment.
c) Replacement of defective equipment by new equipment.
ADVANTAGES OF ENTERING INTO AN MS CONTRACT WITH VOLTAS
Voltas technicians and authorised representatives are :
O Extensively trained in troubleshooting of airconditioning & refrigeration equipment & systems.
O Aware of the standards, tests & procedurs for upkeep of the unit, thus saving downtime of equipment.
O Responsive to your customised service needs beyond the above mentioned services.
O Possesing adequate knowledge to assists you in refurbishment of existing unit/system for providing totally
fresh solution for your new equipment.
O Voltas carries an inventory of genuine spares for various models.
O It works out economical in the long run.
YOU ARE ENTITLED TO GOOD SERVICE...

SO HOW DO YOU REACH VOLTAS FOR SERVICE ?
1. If your system is under warranty or Maintenance Service Contract :
Please contact the nearest Voltas service centre (See telephone nos. on next page). While lodging a complaint,
please inform the following :
O Whether the system is under warranty, and if so the date of Installation, the unit model number and the
unit serial number and G. O. No.
O Whether the system is under a Maintenance Service Contract, and if so, G. O. No.
O The nature of complaint.
2. If the system is out of warranty but NOT covered under any Maintenance Service Contract :
Please contact the nearest Voltas Service Centre, lodge your complaint, and ask for service on a chargeable
basis. Voltas will undertake to repair on a chargeable basis, but you will be required to sign a work-order
form.
3. If the warranty is getting over, and you wish to sign a Maintenance Service contract OR If the current
Maintenance Service Contract is expiring and you wish to renew the same :
Normally Voltas executives will get in touch with you, with the Maintenance Service Contract proposal.
For further assistance, you are requested to contact the Voltas Service Centre before the expiry of warranty
current Maintenance Service Contract.
87
CONTENT
DESCRIPTION PAGE NO.
1. Introduction .............................................................................................. 1
2. Model Nomenclature ................................................................................ 3
3. Physical Specification .............................................................................. 5
4. G. A. Drawing ........................................................................................... 6
5. Poing Load Diagram ................................................................................. 9
6. Installation ................................................................................................ 14
7. Operation ................................................................................................. 16
8. PLC Controller Operation & BMS Interface Specification and IO Mapping 23-51
9. Electrical Wiring Diagran for Single Compressor Unit .............................. 52-78
10. Maintenance ............................................................................................ 79
11. Troubleshooting ........................................................................................ 82

Installation, Operation & Maintenance Manual
Energy Efficient Water Cooled Screw Chillers

Chiller Manual

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chiller Manual

Uploaded by

Copyright:

Available Formats

ENERGY EFFICIENT WATER COOLED SCREW CHILLERS

This manual is prepared to provide all the necessary information for

These chiller packages are equipped with sophisticated microprocessor /

1.1 MODEL NOMENCLATURE

Energy Efficient F - Special Model

A - Air cooled Z/L Series-Semi

D - DX Chiller M - Microp. Std. Panel

X - Screw Compressor No. of Compressors

R 134a Refrigerant Nominal Tons

TABLE 1.1 PHYSICAL SPECIFICATIONS

G. A. DRAWING 100 - 210 TR (SINGLE CIRCUIT)

G. A. DRAWING 240 - 350 TR (DOUBLE CIRCUIT)

ELECTRICAL & MECHANICAL DATA FOR COMPRESSORS

3. RIGGING AND MOVING

4. SPACE REQUIREMENTS AND CLEARANCES

7. WATER PIPING CONNECTIONS

9. CONTROLS AND INTERLOCK

1. OPERATING INSTRUCTIONS FOR CHILLER PACKAGE

ii) A healthy winding will indicate 0.5 to 2.0 megaohms resistance.

iii) An open winding will indicate infinite resistance.

(Caution : even a burnt or internally short winding will show continuity).

c) Measurement of Motor Current and its Adjustments

i) Measurement of current is done by using a Tong tester or clip-on ammeter.

3.4 Crank case heater energised to keep sump warm.

3.9 Chiller and condenser water flow rates

3.11 Start the unit through MCP.

4. AFTER STARTING THE PLANT

5.2 Commissioning Procedure

5.3 Operational Checks

6. FIELD SERVICE OPERATION

6.1 Pressure Testing

b. Check all joints with soap solution. Locate all leaks.

6.2 Vacuumising and Charging of Refrigerant

c. If vacuum is stabilized, close charging valve and stop the pump.

6.3 Purging Non-condensable Gases

PLC CONTROLLER OPERATION

BMS INTERFACE SPECIFICATION

CONTROLLER & DISPLAY

USER LEVEL PASSWORD - 1234

1.1 Status Display - Chiller (Default at Power Up)

The CURRENT STATE OF THE PACKAGE.

1.2 Status Display - Circuit (x)

THE CURRNET STATE OF A CIRCUIT.

1.3. Menu Key

Selecting the `Status' option provides the following:

Selecting the Page Down option provides the following:

Selecting the Page Down option provides the following:

Selecting the Page Down option provides the following:

Selecting the `Outputs' opdtion provides the following:

Selecting the Page Down option provides the following:

Selecting the Page Down option provides the following:

Selecting the `Inputs' opdtion provides the following:

Selecting the Page Down option provides the following:

Selecting the Page Down option provides the following:

Selecting the Page Down option provides the following:

Selecting the Page Down option provides the following:

Selecting the `Alarms' option provides the following:

Selecting the `Alarms' option provides the following:

Selecting the `Setpoints' option provides the following:

1.10. Service Tools

Selecting the `Service Tools' option provides the following:

Pressing the down arrow provides the following:

1.11. Lockout Reset

Selecting the `Lockout Reset' option provides the following:

1 EXV1 30201 EXV1 AO:1