Iom Kac Scroll

KIRLOSKAR CHILLERS PRIVATE LIMITED
A Kirloskar Group Company
Installation, Start-up, Operation &

Maintenance Manual
Scroll Liquid Chillers – KAC
DUAL COMPRESSOR KAC 11 ~ 22 with HFC410A

FOREWORD
At the outset, we thank you for purchasing chiller manufactured and supplied by
KIRLOSKAR CHILLERS PRIVATE LIMITED. We are sure that our chiller will help you in
satisfying your chilling requirement.
This manual will guide you about the installation, Operation and maintenance of the system.
Please read this manual carefully and keep it in proper place in order to refer the same
whenever required. To prolong the life of your chiller and reduce maintenance cost, follow
the instructions given in this manual.
All information in this manual is based on the latest product information

available at the time of publication. Due to improvements or other changes,
there may be discrepancies between information in this manual and your
chiller. KIRLOSKAR CHILLERS PRIVATE LIMITED reserves the right to
make changes at any time without notice.
Table of Contents
FOREWARD …………………………………………………………………………….. 1
Chiller Nomenclature …………………………………………………………………….. 1
Operating Limits …………………………………………………………………………. 1
Safety considerations …………………………………………………………………….. 2
Some safety tips ………………………………………………………………………... 2
General ……………………………………………………………………………….. 3
Pressure Test …………………………………………………………………………. 3
Refrigerant …………………………………………………………………………… 4
Electrical ……………………………………………………………………………... 4
Sharp edges …………………………………………………………………………... 4
Mechanical Strength ………………………………………………………………….. 4
Suitability for Application ……………………………………………………………. 4
1. Introduction …………………………………………………………………………… 5
1.1 General Description ………………………………………………………………... 5
1.2 Distinctive features ………………………………………………………………… 5
1.2.1. Scroll Compressor …………………………………………………………… 5
1.2.2. Reliability Factory …………………………………………………………… 5
1.3. Inspection …………………………………………………………………………... 6
1.4. Handling and Lifting ……………………………………………………………….. 6
1.5. Life Cycle Perspective and Disposal of Product …………………………………… 7
1.5.1. Instructions for Disposal after End of Life of Chiller …………………………. 8
2. Installation ……………………………………………………………………………... 9
2.1. Space Requirement for Servicing …………………………………………………. 9
2.2. Unit Location ……………………………………………………………………… 9
2.3. Evaporator Water / Brine (Liquid) Piping ………………………………………… 10
2.4. Foundation and Anti-Vibration Mounts …………………………………………… 11
2.4.1. Foundation …………………………………………………………………… 11
2.4.2. Anti-Vibration Mounts ……………………………………………………… 12
2.5. Water Treatment / Quality ………………………………………………………… 12
2.6. Installation of Flow Switch……………………………….……………………….. 14
2.7. Installation Check Report for KAC Chiller Units ………………………………… 14
3. Operation ………………………………………………………………………………. 16
3.1. Liquid Chilling Systems - Principle ………………………………………………. 16
3.2. Components and Their Functions …………………………………………………. 17
3.3. Equipment Description and Cycle Operation ……………………………………… 18
3.3.1. Hermetic Type Scroll Compressor …………………………………………….. 19
3.3.2. Air Cooled Condenser …………………………………………………………. 20
3.3.3. Electronic Expansion Valve …………………………………………………… 21
3.3.4. Dry-Expansion Type Evaporator ……………………………………………… 21
3.3.5. Control Center …………………………………………………………………. 21
3.3.6. System Accessories ……………………………………………………………. 22
3.4. Preparing the System for Start-Up ………………………………………………… 22
3.5. Startup and Operation ……………………………………………………………... 23
3.6. Stop or Weekend or Temporary Shutdown ………………………………………. 24
3.7. Extended Shutdown ………………………………………………………………. 24
3.8. Recommended Log Format for KAC Units ………………………………………. 25
3.9. Sequence of Operation for Packaged Chiller Units ……………………………….. 26
3.10. Standard Controls ………………………………………………………………… 28
3.10.1. High Pressure Control ………………………………………………………... 28
3.10.2. Low Pressure Control ………………………………………………………… 28
3.10.3. Voltage Protection Device …………………………………………………… 29
4. System Maintenance…………………………………………………………………… 30
4. Maintenance Instruction……………………………………………………………… 30
4.1. Tips for Preventive Maintenance…………………………………………………… 30
4.2. System Service……………………………………………………………………… 32
4.2.1. Condenser and Evaporator……………………………………………………… 32
4.2.1.1. Air-Cooled Condensers …………………………………………………….. 32
4.2.1.2. Evaporator ………………………………………………………………….. 33
4.2.1.3. Testing Of Condenser and Evaporator Tube Leaks………………………… 33
4.2.2. Liquid Refrigerant Drier Replacement ………………………………………… 34
4.2.3. Refrigerants …………………………………………………………………….. 34
4.2.4. Vacuum / Dehydration Procedure ……………………………………………… 34
4.2.5. Refrigerant Properties …………………………………………………………. 35
4.2.5.1. Charging the Refrigerant…………………………………………………… 35
4.2.5.2. Adjusting the Refrigerant Charge…………………………………………. 36
4.2.5.3. Pressure Testing After Service or Repair or Major Leak ………………….. 36
Chapter 5 Troubleshooting 38
6. Controls and settings …………………………………………………………………... 41

6.1. About the controller ………………………………………………………………... 41
6.2. PCOOEM+ Board Carel Controller ………………………………………………. 41
6.2.1. Features of K-smart Controller ………………………………………………… 42
6.2.2. Connector Details ……………………………………………………………… 44
6.3. K-Smart Inputs/Outputs ……………………………………………………………. 45
6.4. PCO OEM+ Technical specification ……………………………………………….. 47
6.5 pLDPRO Carel Keypad/Display …………………………………………………… 49
6.5.1. Keys and display functions …………………………………………………….. 51
6.6. Troubleshooting ……………………………………………………………………. 53
7. Technical Data ………………………………………………………………………… 56

7.1. Refrigerant Pressure – Temperature Chart ………………………………………… 56
7.2. Useful Conversion Factors …………………………………………………………. 57
8. Annexures ……………………………………………………………………………... 58
8.1. Start-Up and Check Form …………………………………………………………. 58
Chiller Nomenclature
KA C 011 . 2 0
0- R-410A
No. of Compressors
Nominal capacity, TR
Scroll compressor
KA – Kirloskar Air-cooled unit
Operating Limits
Description Unit R-410A
KAC
Min leaving evaporator water ºC 3 ºC
temperature (without glycol) (ºF) ( 37.4 ºF)
Min leaving evaporator water ºC -10 ºC

temperature (with glycol) (ºF) ( 14 ºF)
Min ambient temperature ºC 13 ºC

(ºF) ( 55.4 ºF)
Max ambient temperature for ºC 46 ºC

standard ambient units (ºF) ( 114.8 ºF)

A Kirloskar Group Company IOM-KAC-ENG - Page 1
Safety Considerations
Installation, starting up and servicing packaged liquid chillers can be hazardous due to system
pressures, electrical components and equipment location viz. roofs, elevated structures, etc.
Kirloskar Chillers make liquid chillers are designed for safe and reliable operation, when
operated within design limits. When operating this equipment, use good judgment and safety
precautions to avoid damage to equipment, property or injury to personnel. Be sure that you
understand and follow the procedure and safety precautions.
NOTE: ONLY TRAINED, QUALIFIED INSTALLERS AND SERVICE

MECHANICS SHOULD INSTALL, START AND SERVICE THIS
EQUIPMENT.
When working on the equipment, observe precautions in the literature, tags, stickers attached to
the equipment.
Some of the Safety Tips:

General
 DO NOT CLIMB over the chiller or DO NOT STEP on refrigerant lines. Broken lines
can bang and release high-pressure refrigerant, causing personal injury.
 USE platform, catwalk or staging. Follow safe practices when using ladders.
 NEVER SHORT CIRCUIT any safety controls in the system.
 Care in HANDLING & RIGGING; check weight before rigging any item. Always use
lifting hooks provided in the unit. Use suitable capacity crane to lift the unit
 DO NOT ATTEMPT TO REMOVE pipefitting, flanges, covers etc., while chiller is
under pressure OR chiller is running. Ensure the pressure is at 0 kg/cm2g (0 psig) before
opening any refrigerant line OR connection.
 WORK CAREFULLY, when working near OR in line with a compressed spring. Sudden
release of the spring can cause it and objects in its path to act as projectiles.
 PERIODICALLY INSPECT all valves, fittings and piping for corrosion, rust, leaks OR
damages.
 DRAIN WATER completely before loosening the bolts of water box / heat exchanger
dish ends.

Pressure Test
 USE ONLY DRY NITROGEN for pressure test. Use a regulating valve between the
Nitrogen cylinder and the system to regulate the pressure.
 DO NOT USE OXYGEN or ACETYLENE to pressurize the refrigeration system.
Oxygen may react with oil and form an explosive chemical compound. Acetylene is an
explosive gas.
 HANDLE THE CYLINDERS carefully. Do not drop the cylinder.
 NEVER EXCEED specified TEST PRESSURE; verify the allowable test pressure by
checking the equipment nameplate. Contact Kirloskar Chillers if in doubt for further
details.
Refrigerant
 Refrigerant R-134a, R-407C, R-410A is generally considered chemically non-toxic and

non-inflammable; however, any refrigerant vapor UNDER PRESSURE CAN BE
HAZARDOUS. AVOID SPILLING liquid refrigerant on skin or getting it into the eyes.
USE SAFETY GOGGLES. A sudden release of refrigerant liquid sprayed on the skin can
cause serious damage to skin tissues. Keep eyes and exposed skin areas away from any
potential refrigerant discharge. If such refrigerant burn occurs flush it immediately with
cold water, apply ice packs. If liquid refrigerant enters the eyes, IMMEDIATELY
FLUSH EYES with water. Consult a physician immediately.
 DO NOT VENT refrigerant directly within the plant room. Refrigerant must be vented to
outdoor. The accumulation of refrigerant in an enclosed space can displace Oxygen and
cause asphyxiation. Also, PROVIDE adequate VENTILATION for enclosed plant room.
 DO NOT WELD or FLAMECUT any refrigerant line or vessel until complete refrigerant
has been removed from chiller. Traces of vapor should be displaced with dry Nitrogen
and the work area should be well ventilated. Refrigerant in contact with an open flame
produces toxic gases.
 CHECK THE REFRIGERANT TYPE before adding refrigerant to the chiller package.
Usage of wrong refrigerant can cause damage to OR malfunction of chiller package.
Contact KCPL for further information for using other refrigerant in the chiller package.
 NEVER HEAT refrigerant cylinder WITH AN OPEN FLAME, to remove the refrigerant
vapor. When it is necessary to heat the refrigerant cylinder, use only warm water {43C
(109.4F) maximum}.

Electrical
 DO NOT WORK ON HIGH-VOLTAGE equipment unless you are a qualified

electrician.
 DO NOT WORK ON electrical components, including controls panels, switches, starters
OR oil heater until you are sure ALL POWER IS OFF and NO RESIDUAL VOLTAGE
can leak from capacitors OR solid state components.
 LOCK OPEN & TAG electrical circuits during servicing. IF WORK IS INTERRUPTED,
confirm that all circuits are de-energized before resuming work.
Sharp Edges
The fins on the air-cooled condenser coils have sharp metal edges. Reasonable care should be
taken when working in contact with the coils to avoid the risk of minor abrasions and lacerations.
The use of gloves is recommended. Frame rails, brakes, and other components may also have
sharp edges. Reasonable care should be taken when working in contact with any components to
avoid risk of minor abrasions and lacerations.
Mechanical Strength
The unit is not designed to withstand loads or stresses from adjacent equipment, pipework or
structures. Additional components must not be mounted on the unit. Any such extraneous loads
may cause structural failure and may result in injury to the operator, or damage to the equipment.
Suitability for Application
The unit is intended for cooling water and is not suitable for purposes other than those specified
in these instructions. Any use of the equipment other than its intended use, or operation of the
equipment contrary to the relevant procedures may result in injury to the operator, or damage to
the equipment. The unit must not be operated outside the design parameters specified in this
manual.

Chapter 1 Introduction
1.1. General Description

Kirloskar Chillers hermetic scroll liquid chiller, type KAC (Air-cooled) comes complete, self-
contained automatic refrigerating units and ready for installation. These units include the latest in
engineered components arranged to provide a compact and efficient unit. Each unit is completely
factory assembled, factory wired, pressure tested before evacuation, refrigerant and lubricating
oil charged and factory run tested. Run test can be witnessed at an extra cost.
Each KAC unit consists of air-cooled condensers with integral sub-cooler sections, multiple
hermetic compressors, direct expansion (Dx) type shell-and-tube evaporator, complete
refrigerant piping and control panel.
Refrigerant piping components include compressor suction and discharge, main liquid line, main
liquid line filter driers, electronic expansion valves. The control panel includes all safety and
operating controls necessary for dependable automatic operation. Compressors are fused in all
three phases and started by respective three-pole contactors.
1.2. Distinctive Features

1.2.1. Scroll Compressor
A scroll compressor actually consists of two scrolls or spirals. One scroll is moving, whereas
the second one is fixed (attached to the compressor body). The first scroll orbits (rotates) in a
path defined by fixed scroll. The orbiting scroll is connected to the compressor's crankshaft. As a
result of the scroll's movement, gas pockets are formed between the two scrolls. At the outer part
of the scrolls, the pockets suck in gas and then move towards the center of the scroll, where the
compressed gas is discharged. As the gas moves into the continuously smaller internal pockets,
both its temperature and pressure are increased. Thus a desirable discharge pressure is achieved
by the motion of the compressor scrolls.
1.2.2. Reliability
Testing of all units ensures a trouble free start-up. Extensive tests make sure that all safety
controls are adjusted properly and operate correctly.

1.3. Inspection
Upon receipt of the units at site, ensure the complete shipment against delivery note OR bill of
lading / bill of entry invoice / packing list and also inspect the units for any transit damage. If any
transit damage is found, report the shipping damage to the transporter and file the insurance
claim.
NOTE: PHYSICAL DAMAGE TO UNIT AFTER ACCEPTANCE IS NOT THE

RESPONSIBILITY OF KIRLOSKAR CHILLERS PRIVATE LIMITED.
1.4. Handling and Lifting

Use spreader bars and suitable capacity crane & lifting cables. Refer Fig. 1.4a for details. Never
allow any part of the unit to fall during unloading or moving as this may result in serious
damage. Lifting rope hole on spreader bars shall be minimum 300mm more than the width of the
unit.
Refer lifting diagram instruction pasted on unit.
Fig 1.4a : Lifting diagram for scroll chiller
CAUTION: SHARP EDGES AND IMPROPER BALANCING DURING HANDLING

AND LIFTING ARE POSSIBLE INJURY HAZARDS.
NOTE: DO THE UNIT HANDLING ONLY WITH QUALIFIED PERSONNEL WHO

ARE FAMILIAR AND EXPERIENCED WITH THIS TYPE OF EQUIPMENT.

1.5. Life Cycle Perspective and Disposal of Product:
Sr. Raw Category KSC/ KAS KA KW KWE KWK KWI KCM KAC
no. Material KDC A S
1 Refrigeran Hazardo √ √ √ √ √ √ √ √ √
t (R134a, us
R407C
and
R410A)
2 Refrigeran Hazardo NA NA NA NA NA NA √ NA NA
t(R1234ze us
)
3 Lubricatin Hazardo √ √ √ √ √ √ √ NA √
g Oil us
4 Electronic Hazardo √ √ √ √ √ √ √ √ √
-Waste us
5 Brass Hazardo √ √ √ √ √ √ √ √ √
us
6 Copper Hazardo √ √ √ √ √ √ √ √ √
us
7 Plastic Hazardo √ √ √ √ √ √ √ √ √
us
8 Stainless Non √ √ √ √ √ √ √ √ √
steel Hazardo
us
9 Cast iron Non √ √ √ √ √ √ √ √ √
Hazardo
us
10 Carbon Non √ √ √ √ √ √ √ √ √
steel Hazardo
us
11 Nitrile Non √ √ √ √ √ √ √ √ √
foam for Hazardo
insulation us
12 All Non √ √ √ √ √ √ √ √ √
casting Hazardo
componen us
t

1.5.1. Instructions for Disposal after End of Life of Chiller
 Isolate chiller from location.

 Take out refrigerant and oil separately and store in different containers.
 Dismantle all components/sub-components of chiller.
 Segregate all metallic, non-metallic parts and plastic material.
 Collect hazardous material like E-waste, oil and refrigerant separately.
 Store all scrap material at proper place.
 Refrigerant can be disposed either by reuse as per the purity or handing over to specialized
disposal agencies.
 Oil can be disposed by authorized disposal agencies.
 Dispose the metal scrap to the authorized recycler.
 Handle all hazardous materials by using PPE (for any additional information regarding PPE,
please contact our service engineer) and follow all safety norms.
 Dispose it with Pollution control approved hazardous waste disposal agencies.
 Dispose all remaining non-hazardous waste like non-metallic parts, plastic as per Pollution
control board norms.
 Follow the legal norms for the waste disposal as per the local, state, national, international
applicable legislation.

Chapter 2 Installation
2.1. Space Requirement for Servicing

Each side of the unit must be accessible for periodic service work. Servicing needs to be done
on system components like compressor(s), shut off valves, filter drier(s) etc. Compressor(s),
compressor suction and discharge isolation valves are accessible from the side(s) of the unit.
Typical location of control panel for air-cooled chillers is shown in Fig. 2.2a. The panel has
power and control section. The power section includes the required switchgear components. The
control section includes the state of art dedicated Microprocessor ‘K-smart’ controller for the
efficient operation of the chiller. Other refrigerant controls and valves are main liquid line and
liquid injection line shut-off valves, liquid line and injection line filter driers, Electronic
expansion valve that are accessible from the back end of the unit OR from side(s) of the unit
(depending on the model).
2.2. Unit Location

1. Minimum side clearance between two KAC chillers shall be 2000 mm.
2. Minimum top clearance for KAC shall be 10000 mm.
3. Over and above this, the side clearance around the chiller shall be maintained as shown in the
Fig 2.2a
Fig. 2.2a : Typical fan arrangement and minimum clearances required

4. Failure to pay heed to recommended clearances may result in reduced system performance,
nuisance shutdown & / or servicing problems.
In all air-cooled units, condenser air inlet and condenser fan air discharge must be free from
obstruction. Unit installed less than the minimum recommended clearance to a wall OR top
clearance OR between units may experience a combination of coil starvation and warm air re-
circulation. Warm air re-circulation occurs when the discharge air from condenser fan is recycled
back to the condenser coil inlet. Coil starvation occurs when free airflow to the condenser is
restricted. Both warm air recirculation and coil starvation reduces the unit capacity and operating
efficiency because of the high head pressure. Hence, unit must be located at a place where it gets
free air supply.
2.3. Evaporator Water / Brine (Liquid) Piping

All Evaporator water nozzles come with standard grooved neck type nozzles for Flexible
couplings (Victaulic couplings). Victaulic coupling is in customers scope.
a) Isolation valves shall be provided at evaporator water / brine (liquid) inlet and outlet
connections. This helps in accomplishing the normal servicing without draining the liquid in total
system.
b) It is recommended to use flexible connections between the evaporator liquid nozzle
connection and the system OR process piping, suitable for the system liquid pressure to eliminate
vibration transformation either from system to unit OR vice versa.
c) Although evaporator has an air vent on shell side, it is recommended that the main chilled
liquid header shall have vent valve at the top most point in the header to facilitate purging on
evaporator liquid headers.
d) Entering evaporator liquid connection must always be to the nozzle near to the head cover
having refrigerant liquid in and vapor out connections. Refer Fig. 2.3a for details
Fig. 2.3a Typical Evaporator Water/ Brine (liquid) Piping

e) It is recommended that thermometers and pressure gauges be installed at the evaporator inlet
and outlet. This will aid to check the liquid temperature.
f) It is recommended that installation of a wire mesh strainer at the pump suction to protect the
pump and the exchanger from foreign matter; otherwise provide a strainer as shown in Fig. 2.3a.
This prevents damage to control valves and evaporator tubes.
g) All chilled liquid piping should be insulated to prevent condensation over the chilled liquid
pipelines. If insulation is not of the self-contained vapor barrier type, it should be covered with a
vapor seal. Vent and drain connections must extend beyond proposed insulation thickness for
accessibility.
NOTE: DO THE LEAK CHECK BEFORE INSULATING THE CHILLED LIQUID PIPE.
h) Flow control devices such as balancing valves shall be mounted in the chilled liquid piping to
have the controlled and constant liquid flow. Refer design data sheet for the evaporator liquid
flow rate data.
REMOVE THE TEMPERATURE SENSORS FROM THERMOWELLS TO

PREVENT DAMAGE TO THE SENSORS WHEN WELDING THE FLANGE
CONNECTIONS.
2.4. Foundation and Anti-Vibration Mounts
2.4.1. Foundation
Kirloskar Chillers make KAC units have very minimum vibrations and do not require any special
type of mounts. These units can be set directly on the floor with the mounting pads supplied
along with the unit. For further details refer Fig. 2.4.1a.
a) Unit must be mounted on flat and level foundation, floor capable of supporting the entire
operating weight of the equipment. Refer the enclosed unit general arrangement drawing OR
physical data sheet for operating weight.
b) When floors are weak or of inadequate strength, supplementary structural OR concrete
supports must be provided. Such kind of supplementary supports must be designed to distribute /
transfer the unit weight to the nearest stronger beams.

Fig. 2.4.1a Typical Unit Mounting Arrangement
NOTES:
a) Standard Neoprene Rubber Pads are supplied along with the chiller.
b) For KAC chillers, Anchoring / Foundation bolts are not required.
2.4.2. Anti-Vibration Mounts

If minimum vibration is an important consideration, it is recommended that vibration isolators of
a suitable type be installed under the base. The isolators must be designed for the operating
weight of the unit and can be supplied by Kirloskar Chillers as an OPTIONAL ACCESSORY at
an extra cost. To further reduce the transmission of vibrations it is recommended to use flexible
connections, suitable for the system water pressure, be installed on the water connections, refer
water piping, section 2.3 for further details.
Sr.no. Type of Installation Recommended type of Isolator

1 Floor mounting Rubber-in-shear isolators
2 Supplementary support mounting Spring isolators
2.5. Water Treatment / Quality
If the unit is operating with a cooling tower (KAC units), clean and flush the cooling tower.
Make sure that the tower “blow-down” or “bleed-off” is operating. Atmospheric air contains
many contaminants, which increases the need for water treatment. This is also applicable for
liquid chiller / evaporator side.
The use of untreated water in cooling towers, closed water systems etc. frequently results in one
or more of the following:
a) Scale formation
b) Corrosion or erosion
c) Slime and Algae formation and the growth of the bacterium Legionella pneumophila
(Legionnaires Disease).
NOTE: Kirloskar Chillers is not responsible for damage or under performance or

faulty operation from untreated or improperly treated water
It is therefore to the benefit of the end user to provide for proper water treatment to provide for
longer and more economical life of the equipment. The following recommendation is to
understand the condition of the water.
Recommended water quality standard for KAC liquid chillers
Tendency if the conditions are

Chilled water line
Test Item not met
Circulation Make up Corrosion Scale
pH (@ 25C) - 6.8 ~ 8.0 6.8 ~ 8.0 √ √
Chloride Ion Ppm below 50 below 50 √
Sulphuric
Ppm below 50 below 50 √
Acid Ion
Total
Hardness
Calcium
Hardness
Silica Ion Ppm below 30 below 30 √
Iron Ppm below 1.0 below 0.3 √ √
Copper Ppm below 1.0 below 0.3 √
Should not be
Sulphide Ion Ppm √
detected
Ammonium
Ppm below 1.0 below 0.1 √
Ion
Residual
Chlorine
Free Carbon-
dioxide
Ryzner
Stability RSI --- --- √ √
Index
2.6. Installation of Flow Switch
For the safety of the unit, install flow-sensing instrument (shall be supplied at extra cost) in each
evaporator water / brine line. It may be a flow switch.
 Flow switch installation: Mount individual flow switch in the leaving water line of the
evaporator and condenser. Refer Fig. 2.3a for flow switch installation.
2.7. Installation Check Report for KAC Chiller Units

Customer : ________________________________________________________
End User Consultant : __________________________________________________________
Unit model : ________________________________________________________
Unit serial # : _________________________________________________________
SR PARTICULARS
No
1 UNIT:
1. In case of transit damage, has it been attended completely?
2. Is there any damage during installation?
3. If any damage as per #2, has it been attended?
4. Whether unit is mounted as per recommendations?
5. Is there free space available to attend compressor(s)?
3 AIR-COOLED CONDENSERS:
1. Sufficient space allowed for cleaning and replacing tubes.
2. Air vent and Water drain valves are provided.
3. Flow switch is mounted in the leaving water line
4. Service valves are provided for de-scaling / servicing
4 EVAPORATOR / CHILLER:
1. Sufficient space allowed for air entry & service facilities?
2. Coil guard provided
5 POWER AND CONTROL PANEL:
Sufficient space allowed for accessing and servicing the panel.
6 MISCELLANEOUS:
Sufficient space allowed to access and attend refrigerant liquid line valves,
Electronic expansion valves and moisture & liquid flow indicator.

Use following Alpha Numeric symbols to answer above questions:
: for YES, : for NO / NIL, NA: for NOT APPLICABLE

Chapter 3 Operation
3.1. Liquid Chilling Systems - Principle

Kirloskar Chillers make KAC liquid chilling package system shall be utilized for chilling water
OR brine (for details please contact Kirloskar Chillers). These units work on vapor compression
principle. The basic components of a vapor-compression liquid chilling system are as follows:
 Compressor
 Condenser,
 Liquid refrigerant expansion or flow control device
 Evaporator
 Refrigerant and
 Power and Control Panel.
The basic vapor compression refrigeration cycle is explained in Fig. 3.1a.
Fig. 3.1a Vapor Compression system
In cooler / evaporator, entering hot liquid (usually water) is cooled by the evaporating refrigerant
which is at a lower pressure and lower temperature. The evaporated refrigerant is drawn by the
compressor, which increases the temperature and pressure of the gas above ambient temperature
in case of air-cooled and above entering water in case of water cooled, so that it may be
condensed at the higher temperature in the condenser.
The cooling medium is circulated through the condenser to condense the high pressure & high
temperature refrigerant vapors. The condensed liquid refrigerant then flows back to the
evaporator through an expansion device. A fraction of the liquid refrigerant flashes to vapor as
the pressure drops between the condenser pressure and the evaporator pressure at the expansion
valve. In evaporator the low pressure and low temperature liquid refrigerant evaporates and the
process continues.
3.2. Components and Their Functions

a) COMPRESSORS are used in vapor compression cycle. It is the most important component in
the vapor compression cycle, usually called the HEART of the system. For the vapor leaving the
evaporator the compressor serves as the reclaiming agent. The vapors are sucked from
evaporator at lower pressure, compressed to a pressure corresponding to the saturation
temperature that will be higher than the coolant available to condense it. The other function of
the compressor in the refrigeration cycle is to continuously circulate the refrigerant through the
system. Principally the compressors can be classified into:
 Positive displacement type (Examples: Screw type , Scroll and Reciprocating)
 Dynamic type (Example: Centrifugal type)
b) CONDENSER in the vapor compression cycle is a heat exchanger, which rejects heat from
the refrigerant to the condensing medium. The function of condenser in a refrigeration system is
to de-superheat, condense and sub cool the discharged refrigerant vapor from compressor.
Condensers may be water-cooled type OR aircooled type OR evaporative type. Condenser in
water-cooled versions may be tube-in-tube, shell-and-coil, shell-and-tube or plate type heat
exchangers. Between air-cooled and evaporative type, air-cooled condensers are more common.
Less maintenance is required for air-cooled heat exchangers than the evaporative type.
c) EXPANSION DEVICE is also a very important component of the vapor compression

refrigeration system. The function of the expansion / throttling device is to expand the liquid
refrigerant from condensing pressure to the evaporator pressure. Also, the expansion device
throttles the required refrigerant flow into the evaporator depending on the load conditions.
Commonly used expansion devices in refrigeration industry are:
 Capillary tubes
 Thermostatic expansion valves / Electronic expansion valves

 Low and high pressure side float valves
 Constant pressure expansion valves etc.
d) EVAPORATOR in the vapor compression cycle is a heat exchanger in which the heat is
rejected by the fluid to be cooled to the refrigerant. Principally the evaporators can be classified
as dry type and flooded type. As the name implies, flooded evaporators have submerged liquid
refrigerant coverage over the heat transfer surface. Dx type of evaporator are used in KAC
chillers. Evaporator in liquid-chilling versions may be either tube-in-tube, shell and-coil, shell-
and-tube or plate type heat exchangers.
e) REFRIGERANT is the working fluid, which absorbs heat from the fluid to be cooled and
rejects heat to the atmosphere, through evaporation and condensation. The refrigerant does not
undergo any chemical change as far as there is no contamination of moisture or air. It alternately
vaporizes from the liquid state to absorb heat in evaporator and by rejecting heat in condenser
where it condenses into a liquid for reuse in evaporator. The refrigerant should possess certain
chemical, physical and thermodynamic properties to make it safe and economical for use in the
refrigeration system.
f) CONTROL PANEL is the control center, which contains all the necessary switchgear
components and control section for safe operation of the refrigeration plant.
3.3. Equipment Description and Cycle Operation

Basic components used in Kirloskar Chillers make KAC (air cooled) units are:
 Hermetic scroll compressor
 Air-cooled condenser in KAC units
 Electronic expansion valve
 Shell-and-tube direct expansion type liquid chiller / evaporator
 Control panel
 System Accessories and
 Refrigerant, piping and Miscellaneous

3.3.1. Hermetic Type Scroll Compressor
In a Performer scroll compressor, the compression is performed by two scroll elements located in
the upper part of the compressor.
Suction gas enters the compressor at the suction connection. As all of the gas flows around and
through the electrical motor, thus ensuring complete motor cooling in all applications, oil
droplets separate and fall into the oil sump. After exiting the electrical motor, the gas enters the
scroll elements where compression takes place. Ultimately, the discharge gas leaves the
compressor at the discharge connection.
The figure below illustrates the entire compression process. The center of the orbiting scroll (in
grey) traces a circular path around the center of the fixed scroll (in black). This movement
creates symmetrical compression pockets between the two scroll elements. Low-pressure suction
gas is trapped within each crescent-shaped pocket as it gets formed; continuous motion of the
orbiting scroll serves to seal the pocket, which decreases in volume as the pocket moves towards
the center of the scroll set increasing the gas pressure. Maximum compression is achieved once a
pocket reaches the center where the discharge port is located; this stage occurs after three
complete orbits. Compression is a continuous process: the scroll movement is suction,
compression and discharge all at the same time.

Compressor Oil
Oil levels in the oil equalizing line sight glass should be between the bottom and the middle of
the sight glass with the system OFF. High oil levels may cause excessive oil carryover in the
system. High oil concentration in the system may cause nuisance trips resulting from incorrect
readings on the level sensor and temperature sensors. Temperature sensor errors may result in
poor liquid control and resultant liquid overfeed and subsequent damage to the compressor.
While running, a visible sign of oil splashing in the sight glass is normal.
Oil sight glass
Higher capacity scroll compressors come equipped with a sight glass which may be used to
determine the amount and condition of the oil contained within the sump.
Compressor Heaters
If power is OFF more than two hours, the crankcase heaters must be energized for 18 – 24 hours
prior to restarting a compressor. This will assure that liquid slugging and oil dilution does not
damage the compressors on start
3.3.2. Air Cooled Condenser
All KAC units are equipped with compactly packed air-cooled condensers. These air-cooled
condensers are manufactured with the latest technology 9.53mm (3/8”) O.D internally enhanced
seamless copper tubes and super-slit aluminum fins. The copper tubes are precisely expanded
and brazed to the corresponding headers. These condensers are provided with the separate sub-
cooler circuit to get positive liquid subcooling of condensed high pressure liquid refrigerant.

The condenser consists of fan. They are designed for maximum efficiency and are statically and
dynamically balanced for vibration free operation. They are directly driven by independent
motors, and positioned for vertical air discharge. The fan guards are constructed of heavy gauge,
rust resistant, coated steel. All blades are statically and dynamically balanced for vibration free
operation.
3.3.3. Electronic Expansion Valve
The KAC systems are equipped with Electronic expansion valve (EXV). Every EXV will:
 Expand the high pressure, high temperature liquid refrigerant to low pressure, low temperature
refrigerant and
 Precisely feed the required quantity of expanded low pressure, low temperature liquid
refrigerant into the evaporator to maintain the constant super-heat at the evaporator outlet.
The “K-smart’ Controller will calculate the suction refrigerant vapor super-heat at the outlet of
the evaporator by sensing saturated evaporator temperature and suction line temperature through
temperature sensors. The controller will manage the opening of the electronic expansion valve
based on preset suction superheat value. The unit comes with factory-preset super-heat and
normally does not require any field adjustment.
3.3.4. Dry-Expansion Type Evaporator
The KAC units are equipped with compact shell-and-tube type dry expansion evaporators (U-
bundle design). These evaporators are manufactured with the latest technology 9.53 mm (3/8”)
O.D integrally grooved copper tubes having high heat transfer properties. These tubes are
precisely expanded into the tube-sheet to form leak tight joints. For high-performance and
minimum pressure drop values, all evaporators are provided with special pass partition assembly
on refrigerant side and special baffle assembly on liquid side.
3.3.5. Control Center
KAC chillers consist of microprocessor based control section and power section.
a) Power section includes all necessary switchgear components for hermetic type compressor
motor.
b) Control section includes all necessary safety and operating controls necessary for dependable
automatic unit operations.
The control section will automatically control the unit based on the load requirement of the
secondary system, the leaving chilled liquid temperature. Refer the controller operation manual
for details.

3.3.6. System Accessories
a) Compressor Isolation & Liquid Line Valves: Every hermetic type scroll compressor is
provided with ball valves in the liquid line. For easy service access in refrigerant side; service
valves are mounted at each suction, discharge and liquid lines. The Electronic expansion valve is
mounted on liquid line after the filter drier.
b) Liquid Line Filter Drier: The Filter drier assembly is provided on liquid line. This Filter drier
removes moisture as well as foreign particles.
3.4. Preparing the System for Start-Up
NOTE: DO NOT ATTEMPT TO START THE CHILLER UNTIL THE

FOLLOWING CHECKS HAVE BEEN COMPLETED.
a) Crankcase heaters should be operated at least 24 hours prior to startup.

b) With mains disconnect open, check all electrical connections in control panel and starter
to be sure they are tight and they provide good electrical contact. Although all the
connections are tightened at the factory, they might have loosened enough during
shipment, which may cause system malfunction.
c) Check the actual line voltage to the unit to make sure it is the same as specified in the
compressor nameplate and TDS also phase voltage unbalance does not exceed 2%.
Verify that adequate power supply and capacity is available to meet the required load.
Following is example to calculate phase unbalance tolerance.
% Voltage Imbalance = 100 X max. voltage deviation from average voltage

Average voltage
The maximum voltage deviation is the largest difference between a voltage measurement
across two legs and the average across all three legs. Example:
a) Supply Voltage is 415 V, 3 Ph, 50 Hz Voltage across RY = 410V Voltage across YB =
419V Voltage across BR = 405V Average = 411.33V
b) Maximum deviation from average voltage: RY = 1.33V; YB = 7.67V; BR = 6.33V
Hence, maximum deviation is 7.67V
% Voltage Imbalance = 100 X 7.67 = 1.86 %

411.33

c) Make sure all interlock wiring is completed as per Kirloskar Chillers wiring diagram.
d) Check compressor lubricating oil level. ‘Prior to startup, the oil level should cover at
least half level of the oil sight glass.
e) Turn the main power switch ON; this will energize the crankcase heaters of the
compressor. Make sure the Emergency stop push button is in "OFF" position.
IMPORTANT: CRANKCASE HEATERS SHOULD BE OPERATED AT

LEAST 24 HOURS PRIOR TO START- UP. CRANKCASE SHOULD BE
WARM.
g) The unit might have been shipped from factory with the liquid line valves closed.
Open the refrigerant line valve.
NOTE: ALWAYS REPLACE VALVE SEAL CAPS.
h) Check and inspect all evaporator liquid piping. Make sure that the flow direction is
correct and piping is made to correct water nozzle connections on the respective heat
exchangers and open the isolation valves of secondary side.
i) Start manually evaporator liquid pumps. Check all piping for leaks. Vent the air from
the evaporator liquid header / from the entire secondary system.
j) The secondary circuit in the evaporator side should contain clean, non-corrosive
liquid.
k) Set the required liquid flow with the help of balancing valve(s) or any other flow
measuring device, the flow rate data is given in the unit design and physical data sheet.
l) Ensure that adequate load is available for initial start-up.
3.5. Startup and Operation

a) Make sure that all refrigerant line valves are open and always replace the valve caps.
b) Check supply voltage in all three phases. Verify crankcase heaters have operated for at
least 24 hours prior to startup. During unit off cycle, crankcase heaters are energized.
c) Turn the RUN / STOP selector switch of compressor(s) to RUN position.
d) Turn the SYSTEM RUN / STOP to RUN position.
e) Once the liquid flow in evaporator are established, the controller samples the chilled
liquid temperature and compares it against the set point. Based on the load the controller
gives signal for further action.

f) If unit is with more than one compressor, the lead / lag compressor is selected by the
controller will be decided and started by the controller as explained in the controller
operation manual.
g) The controller continuously monitors the condensing pressure, suction super heat and
discharge super heat and will adjust the opening of electronic expansion valve
accordingly.
h) The unit will stage-up automatically to meet system demand based on the set points
stored in controller.
i) After reaching steady operation and the leaving chilled liquid temperature has been
pulled down to the required temperature and suction super-heat. Compressor suction
super-heat should be approx. 5C ~ 10C (41F ~ 50F) . 7 C is designed superheat. The
suction superheat below 5C is not recommended due to the risk of liquid flow back.
j) Optimum operating characteristics are viewable on the controller display.
NOTE: INITIAL START-UP IS TO BE PERFORMED ONLY BY KIRLOSKAR

CHILLERS AUTHORIZED SERVICE TECHNICIAN. THIS IS A MUST TO
OBTAIN THE COMPLETE WARRANTY BENEFITS.
3.6. Stop or Weekend or Temporary Shutdown
a) Turn the RUN/STOP circuit switches to STOP position. Each circuit will pump-down
and the respective compressor to STOP position.
b) After the circuits have been pumped down stop the evaporator / chiller liquid pump(s).
NOTE: FOR TEMPORARY SHUTDOWNS, KEEP THE UNIT’S
POWER SUPPLY ON.
3.7. Extended Shutdown

a) Isolate the compressor with the help of isolation valves.
b) After the circuits have been pumped down, stop the evaporator / chiller liquid pump(s).
c) Drain all water from the evaporator system piping.
d) To start the unit again, follow the steps from unit Start-up.
e) Use isolation valve and Completely closed EEV to change filter.

NOTE: CRANKCASE HEATERS SHOULD BE OPERATED AT
LEAST 24 HOURS PRIOR TO START- UP. CRANKCASE SHOULD
BE WARM. OPEN ALL THE CLOSED VALVES BEFORE
STARTING.
3.8. Recommended Log Format for KAC Units

Sr no. Description Unit ↓ 1 2 3 4
Date of Log :
1 Compressor run hours Hrs
2 No. of Compressors ON
3 Leaving evaporator liquid C
temperature
4 Evaporator water flow LPM
5 Saturated suction pressure kg/cm2g
6 Saturated suction C
temperature
7 Suction line temperature C
8 Suction Superheat, C
(difference of Sr. 10 & 11)
9 Number of fans ON at the #
time of log (air-cooled units)
10 Saturated discharge pressure kg/cm2g
11 Saturated discharge C
temperature
12 Discharge line temperature C
13 Current Amp
14 Supply voltage V
15 Expansion valve opening %
NOTE:
a) This is a sample recommended log sheet format given only for guidance. Customer shall have
a detailed log than the sample shown here.
b) Operational data of the unit shall be recorded for minimum interval of two hours of operation.

c) If unit is having more than one refrigeration circuit, it is mandatory to log the suction and
discharge pressure and temperature readings for all the circuits separately.
d) It is customer’s responsibility to send the log readings once in fortnight to Kirloskar Chillers
Pvt. Ltd., Service department at Head Office. This may help KCPL to keep continuous
monitoring of unit for its trouble free operation
3.9. Sequence of Operation for Packaged Chiller Units

ITEMS ACTIONS REMARKS
a. Check all the electrical b. Shall be within ±5%
connections are tight d. Check crank case is warm /
b. Check the supply voltage Crank case heaters have been
with-in permissible limit kept ON for at least 24 hours.
c. Check all the refrigerant
line and water circuit valves
are open.
Step-I Initial checks d. Check the oil level in the
compressor oil sight-glass
e. Check that secondary
system of evaporator (water /
brine) is filled.
f. Verify the oil heater has
operated for minimum period
of 24 hours.
a. Check all the safety inter- b. Check pressure at pump
locks. suction and discharge
b. Start the evaporator chilled c. Check pressure at pump
liquid pump(s) suction and discharge
c. Check and adjust the
evaporator liquid flow as per
Step-II Sequence of starting requirement & purge the air.
a. There is no abnormal noise

and vibration b. Check temperature of
b. No switch gear components switch gear components with
are running hot temperature gun
Step-III Observation a. After steady operation at

design condition, see that the
refrigerant pressures are
stabilized.
b. Take all the readings of b. Operating pressure of
evaporator liquid temperatures compressor should be normal.
& flow, compressor suction, Log readings should be
discharge pressure, supply entered.
voltage, Amps. etc., and log it.
c. Periodically check oil level c. Verify this conscientiously
in oil level sight-glass Oil level in the compressor
should be half the level of
sight glass.
d. Check for spurting of oil in
sight glass.
Important: After starting the
unit always do check:
e. There is no abnormal noise
and vibration
f. No switch gear components
are running hot
a. Turn the circuit switch to a. It is not advisable to switch
STOP position. off the entire unit from main
supply in one go. In such case
switch gear is likely to get
damaged.
b. Stop the evaporator liquid
Step-IV Stopping
pump(s)
c. Check that oil return to
crank case is in order and the
heater comes on.
d. If required, close the
compressor isolation valve

3.10. Standard Controls
3.10.1. High Pressure Control:
This is a manual reset type pressure controlled electromechanical device used as safety cutout
against high discharge pressure. When the discharge pressure OR saturated condensing pressure
increases beyond the high-pressure set point, this control opens the compressor motor power
circuit, causing the compressor to stop. Press manual reset button for resetting the controller.
Refer controls, setting and functions section for set point details.
NOTE: ‘DO NOT RESET’ THE CONTROL UNLESS THE CAUSE

FOR TRIPPING DUE TO HIGH PRESSURE IS ASCERTAINED.
Checking Control Operation - (This test has to be performed only in presence of Kirloskar
Chillers authorized service personal)
a) Observe the discharge pressure on the panel.
b) When the discharge pressure rises above the control cut-out set point, the control should stop
the compressor.
3.10.2. Low Pressure Control
This is an auto reset type pressure controlled electromechanical device used as safety cutout
against low discharge pressure.
When the suction pressure OR saturated evaporation pressure decreases below the low pressure
set point, this control opens the compressor motor power circuit, causing the compressor to stop.
Refer controls, setting and functions section for set point details.
Checking Control Operation - (This test has to be performed only in presence of Kirloskar
Chillers authorized service personal)
a) To check the control, either close the liquid line shut off valve or switch off the pilot solenoid
valve, which in-turn close the electronic expansion valve.
b) Observe the suction pressure on the panel.
c) When the suction pressure drops lower than the control set point, the control should stop the
compressor.

3.10.3. Voltage Protection Device
The KAC liquid chilling package unit comes along with voltage protection device, having
manual reset. The VPD is incorporated in the unit to safe-guard the hermetic compressor motor
failure from:
 Single phasing, phase reversing & Voltage imbalance
 Under & over voltage on any of the above fault condition, the VPD will trip the compressor
with the indication in the panel.

Chapter 4- System Maintenance
4. Maintenance Instructions
A conscientiously administered inspection and maintenance program will enhance the value of
the package chiller by:
 Increased life of the unit
 Assuring the proper operation without costly shutdown at critical times
 Minimizing repair costs
 Assure operation of the package at maximum efficiency.
Under normal conditions, the packaged chiller will require nothing more than periodic thorough
visual inspections to assure operation at maximum performance. Maintenance and inspections
shall be handled by qualified service person. If the operator of the package unit has limited
refrigeration and electrical maintenance knowledge, he should confine his maintenance of the
equipment to periodic inspection, filter service and cleaning of condenser coils (in air-cooled
units) only.
4.1. Tips for Preventive Maintenance

The following points are listed as a GUIDELINE for periodic inspection. To ensure proper unit
operation and to avoid damage to package components, follow periodic inspections set up.
Perform the following with the qualified personnel who are familiar and experienced with this
type of equipment to assure trouble-free performance.
a) Record readings as detailed earlier and maintain the ‘LOG-BOOK’ in plant room.
b) Maintain history of parts used with date and reason for replacement.
d) Keep all the valve stems clean and oiled.
e) Keep the condenser coil surface clean. If required, perform the cleaning operation.
f) Safety guards must be in place after any service and before operation.
g) PLEASE BE AWARE THAT ALL REFRIGERANT PIPING MATERIAL IS COPPER.
h) Use correct chiller parts as per our recommendation. Always mention correct part number /
description, refer spare part manual for details.

WARNING: USE GENUINE SPARE PARTS. USAGE OF WRONG PARTS MAY
DAMAGE THE UNIT.
i) Maintain correct water quality.
j) Check the oil level. Oil level should cover one half of the oil sight glass.
k) Never close valves on pressure, never close liquid lines during normal operation, and never
close valves before safety devices.
l) Tighten the cables and electrical connections every month. Study the wiring diagram before
attending any service on control panel.
m) Keep all equipment and machine room clean and ventilated.
n) If liquid flood back occurs in compressor, do not run the compressor. Investigate and rectify
the defects.
CAUTION: IT IS NECESSARY TO DE-ENERGIZE THE COMPLETE

PANEL, BEFORE DOING ANY SERVICING INSIDE.
Sr. TYPE OF OPERATION PERIODICITY

Daily Monthly Quarterly Yearly
1 Read and observe the outlet evaporator √
liquid temperature.
2 Read and observe the suction pressure √
& corresponding temperature.
3 Read and observe the discharge √
pressure & corresponding temperature.
4 Reading and recording of supply √
voltage.
6 Reading and recording of current in 3 √
Phases.
7 √
8 Check the refrigerant suction √
superheat temperature.
9 Check setting and operation of safety √
devices.
10 Check lubricating oil quality and level. √
11 Check setting and proper operation of √
control devices.
12 Inspect the contacts of the motor √
starters and controls.
WARNING:
 The warranty becomes void if the wiring is not in accordance with Kirloskar Chillers
specifications.
 The warranty is void if the settings on any of the protection devices are altered.
 A blown fuse or tripped protector indicates a short ground or overload. Before replacing the
fuse or restarting the compressor, the cause must be found and corrected. Unqualified tampering
with the controls can cause serious damage to equipment and void the warranty.
 Maintain history of service and any type of work done, including refrigerant charging, filter
drier changing, strainer cleanup / changing, compressor overhaul, electrical component failure
replacement etc.
 Maintain log of the unit.
 Maintain the history unit wise, in every unit item wise.
 In case of any failure, these details will enable us to approach the problem in correct path.
NOTE: THE FREQUENCY OF INSPECTIONS MAY VARY WITH

TYPE OF APPLICATION OF THE PACKAGE.
4.2. System Service

4.2.1. Condenser and Evaporator
4.2.1.1. Air-Cooled Condensers
The KAC units are mounted with air-cooled condensers. Generally, no maintenance is required
except the occasional removal of dirt and debris from the outside surface of the fins. We
recommend the use of foaming coil cleaners available at air conditioning supply outlets. Care
should be taken not to damage the fins during cleaning.

4.2.1.2. Evaporator
The evaporator is of the direct expansion shell-and-tube type U bundle design, the tubes are
precisely expanded into the tube-sheets to form leak tight joints. In dry expansion type
evaporators, refrigerant flows through the tubes and water flowing through the shell over the
tubes. Normally no service work is required on this type of evaporator.
4.2.1.3. Testing Of Evaporator Tube Leaks
There may be instances where a tube leak in evaporator may result in refrigerant leak into the
waterside of the system or vice versa depending on the pressure levels. The tube leak may be due
to any of these reasons:
i) Improper tube expansion
ii) Freeze failure / impingement of foreign solid particles
Once the tube leak is established in evaporator, the old tube shall be plugged. Follow the steps
involved in plugging a failed tube:
i) Stop the unit.
ii) Drain water completely.
iii) Isolate the evaporator from the system.
iv) Open the refrigerant head covers and close the water nozzle with dummy flanges.
v) Gradually increase the pressure level with the help of dry nitrogen on the shell side and check
for the probable leak at the tube joints.
vi) The tubes are mechanically expanded to the tube sheets at the ends. Identify the leaking tubes
and gradually reduce the pressure on shell side.
vii) In cases where only one or two tubes leak, the problem can be solved by plugging the tube at
both ends. If no of failed tubes are more then, it is recommended to replace complete evaporator.
viii) Reassemble the evaporator, perform the leak test with dry Nitrogen gas and once the
exchanger passes pressure test, vacuum the evaporator, break vacuum with refrigerant and hook
up the evaporator with system.
CAUTION: THE BOND PRODUCED BY EXPANSION MUST BE
REFRIGERANT TIGHT. THIS BOND SHALL BE PRODUCED BY
APPLYING LOCKTITE (GRADE 638) OVER THE OUTER SURFACE OF
THE TUBE AND ROLLING IT INTO THE TUBE SHEET.

4.2.2. Liquid Refrigerant Filter Drier Replacement
KAC units are equipped with high capacity replaceable filter drier in liquid line. The purpose of
the filter drier is to keep the refrigeration circuit clean of solid contaminants, water and acid.
Contamination can cause corrosion and ice building as well as malfunction of the unit. The filter
drier cartridge is specially made out of Molecular sieves and Activated alumina. To change the
filter drier follow the procedure given below:
i) Isolate the filter drier by closing ball valve and 100% closing EEV
ii) Drain out the liquid refrigerant available in the filter drier area.
iii) Gradually reduce the pressure to 0.0 kg /cm2(g).
iv) Open solder joint and braze new filter drier.
v) For injection line, replace the existing drier with the new drier. Use wet clothe on both side to
avoid heat dissipation.
vi) Vacuum the isolated line. Break the vacuum with refrigerant and connect the filter drier
assembly to the system.
4.2.3. Refrigerants
Kirloskar Chillers make KAC units are designed to work with refrigerant R-410A. All units shall
be shipped factory charged. For details of approximate refrigerant charge, refer the design data
sheet. In case, if moisture is noticed in the system, remove the refrigerant from the system,
evacuate the system and charge the refrigerant through the high capacity filter drier cores to
eliminate cause of trouble. Contact Kirloskar Chillers for further details.
4.2.4. Vacuum/ Dehydration Procedure
After performing leak test, the chiller OR part OR equipment shall be subjected to vacuum and
dehydration
1. Triple vacuum method is recommended.
2. Use vacuum pump of capacity approximately 0.5 cu.ft/min  2 cu.ft/min.
A suitable calibrated vacuum micron gauge OR a mercury manometer shall be connected to the
system. For vacuuming, follow the steps given hereunder:
1. Evacuate the system to a pressure of 500 μm Hg( 0.5 mm of Hg) /(0.67 mbar) absolute.

2. The required moisture level in the circuit after vacuum dehydration must be <100ppm for
systems
4.2.5. Refrigerant Properties
R-410A is highly efficient nearly azeotropic mixture (gases evaporate at nearly the same
temperatures) of two gasses ideally suited for replacing R-22 in scroll compressor packages. R-
410A will not damage the ozone and has a significantly higher vapor pressure than R-22.These
refrigerants are practically odorless. Refrigerants are non-combustible at atmospheric pressure.
Read the ‘Material Safety Data Sheet (MSDS) and the latest ASHRAE Safety Guide for
Mechanical Refrigeration’ to know more about safe handling of these refrigerants.
Refrigerant R410A
Compressor type 11 TR 22 TR
Working pressure range high side [bar(g)] 15.8 – 44.5 13.5 – 44.7
Working pressure range low side [bar(g)] 1.9 – 10.8 1.7 – 11.6
Maximum high pressure safety switch setting [bar(g)] 45 46.1
Minimum low pressure safety switch setting [bar(g)] 0.5 1.5
Minimum low pressure pump-down switch [bar(g)] 2.3 1.7

setting
4.2.5.1. Charging the Refrigerant
If it becomes necessary to charge the refrigerant at site, follow the procedure given below:
a) Connect the refrigerant cylinder with a connecting pipe to the charging valve provided in the
liquid line.
NOTE: RELEASE THE AIR AVAILABLE INSIDE THE TUBE

BEFORE MAKING THE FIRM CONNECTION TO THE
CHARGING VALVE.
b) Open the valves and allow the refrigerant to flow into the refrigeration system. Refrigerant
will get charged till the pressures are equalized.

c) Then start the compressor and complete the refrigerant charge.
d) Check the moisture and liquid indicator, it should show the bubble free liquid refrigerant flow,
also check the refrigerant vapor suction super-heat and liquid refrigerant sub-cool temperature
details for concluding the correct charge of refrigerant.
IMPORTANT: WHILE CHARGING R410A IN THE CHILLER

ALWAYS CHARGE IN LIQUID FORM IN LIQUID LINE BY
INVERTING THE CYLINDER. CHARING IN VAPOUR FORM WILL
NOT GIVE THE DESIRED PERFORMANCE.
NOTE: DO NOT DISCHARGE THE REFRIGERANT INTO THE ATMOSPHERE.
To recover it, use empty, clean and dry cylinders OR refrigerant storage vessel. The liquid
refrigerant recovery can be performed with the help of the valve provided on the liquid line. To
facilitate the recovery of refrigerant, place the receiver / cylinder inside a container full of ice.
Weigh the bottle frequently to avoid excessive filling of the containers (70 ~ 80% max by
volume can be stored in the containers). If it is necessary to top-up the refrigerant follow the
same procedure. Before toping-up the refrigerant, find out and attend the cause of refrigerant
loss.
BEFORE MAKING ANY NECESSARY REPAIRS TO A

LEAK, TRANSFER ALL REFRIGERANT FROM THE
LEAKING VESSEL.
4.2.5.2. Adjusting the Refrigerant Charge
If it becomes necessary to adjust the refrigerant charge to obtain optimum chiller performance,
operate the chiller at design load and then add or remove refrigerant slowly until the refrigeration
parameters reaches design conditions. DO NOT OVERCHARGE. Refrigerant may be added
either through the storage vessel OR directly into the chiller.
4.2.5.3. Pressure Testing After Service or Repair or Major Leak
After attending the repair, the chiller OR equipment OR part of the equipment must be
pressurized and leak tested. Pressurize the system with dry nitrogen and use a soap solution to
determine if leaks are present. The leak test has to be performed only after evacuating the
complete refrigerant from the part OR equipment OR chiller.

a) Connect a copper tube from the pressure regulator on the dry nitrogen gas cylinder to the
refrigerant charging valve OR any other access valve available in the part OR equipment. Never
apply full cylinder pressure to the pressurizing line.
b) Open the charging valve fully.
c) Gradually increase the pressure by slowly opening the cylinder-regulating valve.
d) Observe the pressure gauge on the chiller OR part OR the equipment and close the regulating
valve when the pressure reaches test level. Refer recommended leak pressure test values
mentioned in technical specification of chillers or concern Kirloskar Chillers Pvt. Ltd.
e) Close the charging valve on the chiller OR part OR the equipment. Remove the copper tube if
no longer required.
f) After pressurizing, test for leaks with soap bubble solution.
g) Bring the chiller back to atmospheric pressure, repair any leaks found, and retest.
h) After retesting and finding no leak, vacuum and dehydrate the chiller OR part OR equipment.

Chapter 5 Troubleshooting
POSSIBLE CORRECTIVE
PROBLEM POSSIBLE CAUSES
STEPS
Main switch open. Close switch.
Check electrical circuits and motor

winding for shorts Investigate for
Fuse blown. Circuit breakers
possible over-loading. Replace fuse
open.
or reset breakers after fault is
corrected.
Overloads are auto reset. Check

Thermal overloads tripped. unit closely when unit comes back
on line.
Defective contactor or coil. Repair or replace
A.
Determine type and cause of
COMPRESSOR WILL
System shut down on safety. shutdown and correct it before
NOT START
restart.
Wait until unit calls for cooling /

No Load.
load.
Liquid line expansion valve has

Repair or replace motor.
not operated.
Check all wire junctions. Tighten

Loose wiring.
terminal screws.

Check and rewire.
Erratic wire connections.
Check supply voltage
B.
COMPRESSOR WILL
NOT RUN BUT Faulty starters. Replace.
NOISY
Worn Compressor. Replace.
Check oil heater.

Low oil level.
D. Top-up oil.
LOSS OF OIL
Suction superheat too low. Increase superheat setting.
Non-condensable in system Purge the non-condensable.
System over-charged with

E. Remove excess.
refrigerant.
HIGH DISCHARGE
PRESSURE
Liquid ball valve partially
Open valve.
closed.
Insufficient refrigerant in Check for leaks. Repair and add

system. charge.
F.
LOW DISCHARGE
See corrective steps for low suction
PRESSURE Low suction pressure.
pressure.
Reduce load or add additional

Excessive load.
equipment
G. Check remote bulb / check

HIGH SUCTION Expansion valve overfeeding. superheat setting. Regulate
PRESSURE superheat.
High return water temperature. Reduce load or add additional

equipment.
Check for leakage, arrest it

Lack of refrigerant
properly and top-up the gas.
Evaporator fouled / dirty. Clean chemically.
Clogged liquid line filter drier. Replace.
H.
Expansion valve not opening /
LOW SUCTION Check wiring connections of EXV.
malfunctioning.
PRESSURE
Condensing temperature too Check cooling water flow and

low. entering water temperature.
Insufficient water flow. Adjust water flow.

Chapter 6 Controls and settings
6.1. About the controller

The Kirloskar “PRODIGYTM SERIES” Scroll Chillers have a state of the art control system ‘K
– Smart’ which consists of main controller, the temperature and pressure transducers, expansion
boards, and a backlit LCD display. The K-Smart controller is a rugged microprocessor based
controller. It is designed to provide primary control, monitor the chiller, protect the chiller in
case of any unhealthy condition, interface with building management systems and communicate
both locally and remotely. The K-Smart controller provides flexibility with set points and control
options that can be selected prior to commissioning the chiller or when the unit is live and
functioning. Displays, alarms and other interfaces are accomplished in a clear and simple
graphics / language that inform the user as to the status of the unit. The K-Smart controller is
designed to safeguard the chiller, eliminate the need for manual intervention and to provide a
simple but meaningful man-machine-interface. The K-Smart controller provides the information
that would generally be available via gauges, temperature measuring devices, an amp probe, etc.
In addition to it, it also controls and gives commands to the various unit mounted devices such
as, solenoid valves, etc. to achieve optimum operation of the chiller. The controller also displays
information on alarms, lockouts and various control states.
6.2. PCOOEM+ Board Carel Controller

The pCOOEM+ (medium) is a microprocessor-based, programmable electronic controller that is
fully compatible (hardware and software) with the pCO Sistema family of devices, which
includes programmable controllers, user terminals, gateways, communication devices and remote
management devices. These devices represent a powerful control system that can be easily
interfaced with most Building Management Systems (BMS) available on the market. The
controller is fitted with a 32-bit microprocessor and has up to 4 Mbytes of memory to ensure
high performance in terms of speed and memory space for running the control program. The
program and parameters are saved permanently in a non-volatile memory (fl ash memory),
preventing data loss in case of power failures (without requiring a backup battery);

6.2.1. Features of K-smart Controller:
A) K-smart controller with
1) CPU, 32 bit, 100MHz.
2) Program Memory 9MB (2MB BIOS + 7MB application program), 4MB logs
3) Data memory (RAM) 4 MB, 32bit
4) Parameter memory 32 KB
5) Working cycle duration approx. 200 ms
B) Data Available on Display:
1) Suction Pressure
2) Discharge Pressure
3) Chilled Water Inlet Temp
4) Chilled Water Outlet Temp
5) Liquid Line Refrigerant Temp
6) Suction Line Ref. Temp.
7) Sat. Suction Temp.
8) Suction Super Heat

9) Sat. Discharge Temp.
10) Discharge line Ref. temp.
11) Discharge Super Heat
12) Date & Time
13) Comp On / Off
14) Water flow ON/OFF indication (Evaporator)
15) Motor winding temperature – Healthy or Un-healthy
16) Voltage Protection Device – Healthy or Un-healthy
17) EXV opening %
C) Safeties: Following safeties are directly sensed by the controller & acted upon
1) High Pressure, Low pressure
2) Low Evaporator Pressure
3) Antifreeze Trip
4) No Flow (Evaporator Flow)
5) High suction temperature
D) Other safeties which are sensed by other devices, but action is taken by the controller
1) Over Voltage /Under Voltage/Single phasing/Reverse phasing/Voltage unbalance.
2) Low Chilled Water Flow
E) Other Features:
1) Battery backup for memory and clock to take care of power failures
2) Automatic startup on resumption of power after power failure.
3) Compressor lead-lag and sequencing facility for multi compressor units

Now it will follow schedule of each weekdays but on specified holidays it will follow schedule
mentioned for holiday).
4) Alarm History :- Logging of last 99 alarms with 4 Variables (critical parameters) which
can be viewed with display
5) RTC based Anti-recycle time (Start to Start / Stop to Start).
6) Starting / Stopping on Chilled Water Outlet is automatic.
7) PC-Connectivity is possible (separate software/hardware to be procured for this).
8) Important variables list incorporated for getting connected to BMS system
6.2.2. Connector Details:
1. Power supply connector [G (+), G0 (-)];
2. Yellow power LED and 3 status LEDs
3. Additional power supply for the terminal and 0 to 5 V ratio metric probes;
4. Universal analogue inputs: NTC, 0 to 1 V, 0 to 5 V ratio metric, 0 to 10 V, 0 to 20 mA, 4 to 20

mA;
5. Passive analogue inputs: NTC, PT1000, ON/OFF;
6. 0 to 10 V analogue outputs;
7. 24 VAC/VDC digital inputs;
8. 230 VAC or 24 VAC / VDC digital inputs;
9. Connector for the display panel (external panel with direct signals);
10. Connector for all standard PCO series terminals and for downloading the application
program;
11. Relay digital outputs;
12. Connector for connection to the I/O expansion board;
13. PLAN network connector;
14. Cover for inserting the supervisor (Modbus) card option

15. Cover for inserting the field card option
6.3. K-Smart Inputs/Outputs

Connector Signal Description
J1-1 G Supply voltage A(*)
J1-2 G0 Supply voltage A(*)
J2-1 U1 Universal input/output 1
J2-4 GND Common for universal inputs/outputs 1, 2, 3
J3-3 +Vdc Power to active probes 4, 5
J3-4 +5VR Power to 0 to 5 V ratiometric probes 4, 5
J3-5 GND Common for universal inputs/outputs4, 5
J4-3 +Vdc Power to active probes 6, 7
J4-4 +5VR Power to 0 to 5 V ratiometric probes 6, 7
J4-5 GND Common for universal inputs/outputs 6, 7
J5-4 +Vdc Power to active probes 8, 9, 10
J5-5 +5VR Power to 0 to 5 V ratiometric probes 8, 9, 10
J5-6 GND Common for universal inputs/outputs 8, 9, 10
J6-1 GND Common for analogue outputs or PWM Y1, Y2, Y3
J6-2 Y1 Analogue output 1, at 0 to 10V or PWM (several types)
J7-1 DI1 Voltage free contact - digital input 1
J7-5 GND Common for voltage free contact - digital inputs 1, 2, 3, 4
J8 - Connector for unipolar valve 2

J9-1 Vout Power to additional terminal
J9-2 Tx/Rx - Tx-/Rx- RS485 Fieldbus 1 port
J9-3 Tx/Rx + Tx+/Rx+ RS485 Fieldbus 1 port
J9-4 GND GND for RS485 Fieldbus 1 port and additional terminal
J10 - PLD terminal connector
J11-1 Tx/Rx - Tx-/Rx- RS485 BMS 2 port
J11-2 Tx/Rx + Tx+/Rx+ RS485 BMS 2 port
J11-3 GND GND for RS485 BMS 2 port
J12 - Connector for unipolar valve 1
J13 - Connector for BMS 1 option serial card
J14-1 Tx-/Rx- Tx-/Rx- RS485 pLAN port
J14-2 Tx-/Rx- Tx+/Rx+ RS485 pLAN port
J14-3 GND GND for RS485 pLAN port
J15 - pLAN telephone cable connector
J16-1 NO1 Relay 1, normally open contact
J16-2 NC1 Relay 1, normally close contact
J16-3 C1 Relay 1, common
J17-1 Out2 Relay 2 (or SSR), powered-on digital output, Out 2
J17-2 C2 Common for Out2, Out3, Out4, Out5
J18-1 Out3 Relay 3 (or SSR), powered-on digital output, Out 3
J19-1 Out4 Relay 3, powered-on digital output, Out 4
J20-1 Out5 Relay 4, powered-on digital output, Out 5
Common for input power supply for "powered-on digital outputs"
J21-1 C2
Out2, Out3, Out4, Out5
Power supply input for "powered-on digital outputs" Out2, Out3,
J21-2 V-IN
Out4, Out5
J25-1 * DI7H Digital input 7, at voltage B(**)
J25-2 * DI7 Digital input 7, at voltage A(*)
J25-3 * DI7C Common for digital inputs 7, 8

J25-5 * DI8H Digital input 8, at voltage B(**)
J26-1 * Y4 Analogue output 4, at 0 to 10V
J26-2 * Y5 Analogue output 5, at 0 to 10V
J26-3 * U11 Universal input/output 11
Common for universal inputs/outputs 11, 12 and analogue outputs
J26-4 * GND
Y4, Y5
J26-5 * U12 Universal input/output 12
J26-6 * GND Common for universal inputs/outputs 11, 12
J26-9 * DI9C Common for digital inputs 9, 10
J27-1 * NO9 Relay 9, normally open contact
J27-2 * C9 Relay 9, common
J27-3 * NC9 Relay 9, normally close contact
J27-5 * C10 Relay 10, common
J27-6 * NC10 Relay 10, normally close contact
J28-1 * C11 Relays 11, 12, 13, common
J28-5 * C11 Relays 11, 12, 13, common
J29-1 * Tx/Rx - Tx-/Rx- RS485 Fieldbus 2 port
J29-2 * Tx/Rx + Tx+/Rx+ RS485 Fieldbus 2 port
J29-3 * GND GND RS485 Fieldbus 2 port
- 7 segment display for pLAN address
Button for setting pLAN address, secondary display, indicator
-
LEDs
(*): voltage A: 24 Vac o 28...36 Vdc;

(**): voltage B: 230 Vac - 50/60 Hz.
6.4. PCO OEM+ Technical specification:

Analog input:
Analogue conversion: 10-bit A/D converter embedded in CPU
Maximum number 10 Nos
Type: •NTC probes (-50T90°C; R/T 10 kΩ•}1% at
25°C)
NTC input precision •+0.3% fs
Digital input:
Maximum number 10 Nos
Power supply to the input 24 Vac or 24 Vdc
Analog output:
Type PWM (2kHz or 100Hz or syncronized with
mains supply Mode 1 and Mode 2) on Y1...Y3
0 to 10 V optically-isolated on Y4 to Y5
Number of analoge output 5 nos.
Power supply 24 Vac (+10/-15%) or 28 to 36 Vdc on VG(+),
VG0(-)
Presicion 3% full scale
Maximum load 1 kΩ (10 mA)
Digital output:
Type Relay. Min. contact current: 50 mA
No of digital output 13 nos.
Mechanical:
Dimension 111 x 27,5 x 78,5 mm
Material Technopolymer
Flame retardancy V2 (standard UL94) and 850 °C (standard IEC
60695)
Colour White RAL 9016
Electrical Specification:
Power supply 24 Vac (+10/-15%), 50/60 Hz , 28 to 36 Vdc
(-20/+10%)
Maximum current with terminal connected
Terminal block With plug-in male/female connectors
Cable cross-section min 0.5 mm2 - max 2.5 mm2 ; To use in 70°C
environment, use 105°C approved cable.
CPU 32 bit, 100 MHz
Program memory (FLASH MEMORY) 9MB (2MB BIOS + 7MB application
program), 4MB logs
Data memory (RAM)
T memory, buffer (EEPROM) 13 kB
P memory, parameters (EEPROM) 32 kB (not visible from pLAN)
Working cycle duration 0.2 s (typical)
Clock with battery Supplied, accuracy 100 ppm
Other features:
Operating conditions -40T70 °C, 90% RH non-condensing
Storage conditions -40T70 °C, 90% RH non-condensing
Index of protection IP20 (front panel only)
Type of disconnection or micro switching Microswitching
Ageing characteristics (operating hours) 80.000
No. of automatic operating cycles 100.000 (EN 60730-1); 30.000 (UL 60730-1)
6.5 pLDPRO Carel Keypad/Display

With the keypad/display the user can monitor the chiller’s operating conditions, system alarms,
operating schedules and has the ability to utilize diagnostic tools. With the proper authorization
level the user has the ability to clear system alarms, system lockouts, change setpoints, and
operating schedules. It allows complete management of graphics by the display of icons (defined
at application software development level), and the management of international fonts, in two
sizes: 6x8 and 12x16 pixels, and acoustic signal through piezoelectric buzzer as well.The
application software resides on the PCO board, and therefore the terminal does not require any
additional software for operation.
Technical specifications:
Display:
Type: FSTN graphic
Backlighting: white LED
Graphic resolution: 132x64 pixels
Text mode: 8 rows x 22 columns (font sizes 6x8pixels) 4
rows x 11 columns (font size 12x16 pixels) or
mixed modes
Character height: 2 mm (font sizes 6x8pixels)
4 mm (font size 12x16 pixels)
Size of active area: 36.94*15.98mm
Size of display area: 38.9*19.4mm
Power supply:
Voltage: pLAN Port: power supply from pCO through
telephone cable(18…30Vdc Class II only);
Maximum power input: 0.5 W
Maximum distances:
Maximum pLAN length: 500 m with AWG22 twisted pair cable
pCO terminal distance: 50m with telephone cable 500m with AWG22
twisted pair cable and TCONN6J000 Note: to

reach the max. length,use a bus layout, with
branches not exceeding 5m
Materials:
Transparent front panel: transparent polycarbonate
Charcoal grey container back piece polycarbonate +ABS
Film Keypad: polycarbonate film
Self-extinguishing classification: V0 for back piece
V2 for transparent front panel
HB for fi lm keypad and remaining parts
Others:
Index of protection: IP65
Operating conditions: -20T60 °C, 90% r.H. non-condensing
Storage conditions: -20T70 °C, 90% r.H. non-condensing
Software class and structure: A
PTI of insulating materials: 175
Environmental pollution: 2
These terminals have been designed for panel installation; the drilling template measures
71x29mm.
For installation, proceed as follows:
a) Connect the telephone cable; Insert the terminal, with the front frame removed, into the
opening, and fasten the device to the panel using the flush-head screws, supplied in the
packaging, as shown in Fig. Finally, fit the click-on frame.
b) Electrical connection - Connect the telephone cable (code S90CONN00*) from the PCO
board to the connector provided (RJ12) on the rear of the terminal.
c) Configuring the address - The address of the terminal can be configured only after having
connected the power supply, using the RJ12 telephone jack (the factory default value is 32).
To access configuration mode, press the buttons together and hold them for at least
5seconds; the screen shown in Fig below will displayed.

with the cursor flashing in the top left corner: To change the address of the terminal (display
address setting), press the button once: the cursor will move to the address field (nn). Use the
buttons to select the desired value, and confirm by pressing again. If the value
selected is not the same as the one saved previously, the screen shown in Fig. below
will be displayed, and the new value will be saved to the permanent memory. Protocol (not
pLAN) and the field “I/O Board address:xx” will not be displayed, as it has no meaning.
d) Fault signals: - If the terminal detects the off-line status of the pCO board it is associated with,
the display shows the message: I/O Board xx fault. On the other hand, if the terminal receives no
signal from the network, the display shows the following message: NO LINK.
6.5.1. Keys and display functions:
Actual display Descriptions for the display

This is the main screen displayed on
display when we power on the machine.
This is main menu from where you need to

navigate.

This screen displays the actual evaporator
outlet.
This screen displays the on/ off condition

of the compressor. It displays the high side
and low side pressure along with suction
and discharge temperature.
For acknowledge & reset this alarm

key want to press twice.
Only after entering the proper password

the controller will allow the parameters
which are in user level. For enter the
password we can use keys.

This screen shows the percentage of
expansion valve open. And it also
indicates the amount of superheat in
Kelvin.
This screen is displayed when we press

key & there is no any active alarm in
the system.
After entering the Supervisory password we can able to access user level parameters also. Only
after entering the supervisor level password we can change the tripping parameters of the
pressures, tripping parameters of the temperatures, all alarm delays, anti-recycle timers etc. The
authorization code is a special four-character code that enables access in to the CAREL
controller system. The code must be numeric with values between 1 and 9 if it is to be entered
from the Keypad/Display. Each system can have three different authorization levels & for each
level there are different passwords. This provides the capability of issuing different codes to
different people if desired. The authorization code cannot display. The authorization codes must
be protected and remain confidential, if they are compromised unauthorized personnel can gain
access to the system.
6.6. Troubleshooting:
Problem Check points
1. The mains power supply;
2. 24 Vac/Vdc is available downstream of the power
The unit does not start (power
transformer;
LED off)
3. The 24 Vac/Vdc power connecter is plugged in correctly;

1. Correct software in the flash
2. The PLAN address on the PCO and the terminal
(compliant with the requirements of the application used);
On power-up various problems
3. The built-in display, is featured, is working correctly; the
occur on the LCD (strange
problem lies in the connection between the PCO and the
characters, blank display).
PGD (display) terminal: make sure that the cable is plugged
in correctly.
1. The correct power supply to the PCO;

2. The correct power supply to the probes: if the voltage
(+Vdc>20V) is near zero, disconnect the probe and measure
the power supplied by the PCO. If this is still near zero, turn
the controller off and wait a few minutes. If the problem
persists, contact KCPL service; otherwise the connection
that was removed was short-circuiting the power supply.
3. The separation of the power supply to the digital inputs
from the power supply to the PCO. A 24 Vac/24 Vac
Incorrect reading of the input
transformer with a proper rating can be used.
signals
4. The probe wires are connected according to the wiring
diagram
5. There is not a high thermal resistance between the sensor
and any probe socket that may be used. If necessary, place
conductive paste or oil in the socket to ensure correct
transfer of the temperature;
6. If there is a probe error or a conversion error on the PCO,
the checks to be made depend on the type of probe.
1. The analogue inputs used for the probes are not connected
Pressure probes: if errors occur in as per wiring diagram (in the application program);
the reading of these probes 2. The probe capillary is not blocked.
1. The analogue inputs used for the probes are not connected
Temperature probes: if errors
as per wiring diagram (in the application program);
occur in the reading of these
2. The probe capillary is not blocked.
probes
The voltage between the common terminal “IDC1” and the

Doubtful alarm signal from terminal of the digital input indicating the alarm “IDn”, in
digital input the following conditions:
1. If there is voltage (24 Vdc, depending on the power

supply used for the digital inputs) the contact of the alarm
device connected is closed;
2. If the voltage is less than 10 Vac or 10 Vdc (see above)
the contact is open;
1. The serial board code PCOE00TLNO is connected

correctly
2. The identification number of the expansion board has
The serial connection to the local been set correctly (for details contact KCPL service)
expansion board does not work 3. The serial cables are connected correctly according to the
wiring diagram shown in the documents corresponding to
the TLAN network;
1. The terminal has not been disconnected and then

reconnected to the PCO without waiting 5 seconds. In this
case, turn the PCO off and on again with the terminal
The user terminal is blocked (it
connected
does not respond to the buttons)
2. The software on the PCO has been corrupt. (contact to
KCPL service)

Chapter 7 Technical data
7.1.R410A Refrigerant Pressure – Temperature Chart

Temp Pressure Pressure Density Density Enthalpy Enthalpy Entropy Entropy
[˚F] Liquid Vapor Liquid Vapor Liquid Vapor Liquid Vapor
[psia] [psia] [lb/ftˆ3] [lb/ftˆ3] [Btu/lb] [Btu/lb] [Btu/R- [Btu/R-
lb] lb]
-40 25.6 25.5 82.02 0.4384 0.000 112.5 0.00000 0.2682
-35 28.9 28.9 81.45 0.4929 1.648 113.1 0.00389 0.2664
-30 32.6 32.6 80.88 0.5526 3.303 113.7 0.00774 0.2647
-25 36.7 36.6 80.30 0.6179 4.967 114.3 0.01157 0.2631
-20 41.1 41.0 79.71 0.6892 6.640 114.8 0.01537 0.2615
-15 46.0 45.8 79.12 0.7669 8.321 115.4 0.01915 0.2599
-10 51.2 51.1 78.51 0.8514 10.01 115.9 0.02290 0.2584
-5 56.9 56.8 77.91 0.9431 11.71 116.4 0.02663 0.2570
0 63.1 63.0 77.29 1.043 13.42 116.9 0.03035 0.2555
5 69.8 69.7 76.66 1.151 15.15 117.4 0.03404 0.2541
10 77.1 76.9 76.03 1.267 16.88 117.9 0.03771 0.2528
15 84.9 84.6 75.38 1.394 18.63 118.3 0.04137 0.2514
20 93.2 93.0 74.73 1.530 20.39 118.8 0.04502 0.2501
25 102.2 101.9 74.06 1.677 22.16 119.2 0.04865 0.2488
30 111.9 111.5 73.38 1.836 23.95 119.6 0.05227 0.2476
35 122.2 121.8 72.69 2.007 25.75 119.9 0.05588 0.2463
40 133.2 132.8 71.99 2.192 27.58 120.3 0.05949 0.2451
45 144.9 144.5 71.27 2.391 29.41 120.6 0.06309 0.2438
50 157.4 156.9 70.53 2.606 31.27 120.9 0.06668 0.2426
55 170.7 170.2 69.78 2.838 33.14 121.2 0.07028 0.2413
60 184.8 184.3 69.01 3.088 35.04 121.4 0.07387 0.2401
65 199.8 199.2 68.22 3.357 36.96 121.6 0.07747 0.2388
70 215.7 215.1 67.41 3.648 38.90 121.8 0.08107 0.2376
75 232.5 231.8 66.58 3.963 40.87 121.9 0.08469 0.2363
80 250.3 249.6 65.71 4.304 42.87 122.0 0.08832 0.2350
85 269.1 268.3 64.82 4.674 44.90 122.0 0.09196 0.2336
90 289.0 288.2 63.90 5.075 46.96 122.0 0.09562 0.2322
95 310.0 309.1 62.95 5.513 49.06 122.0 0.09932 0.2308
100 332.0 331.1 61.95 5.990 51.21 121.8 0.1030 0.2293
105 355.3 354.3 60.90 6.513 53.39 121.6 0.1068 0.2277

110 379.8 378.8 59.81 7.089 55.63 121.4 0.1106 0.2261
115 405.6 404.5 58.65 7.725 57.93 121.0 0.1145 0.2243
120 432.7 431.6 57.42 8.434 60.30 120.5 0.1185 0.2224
125 461.2 460.1 56.11 9.230 62.76 119.9 0.1225 0.2203
130 491.2 490.1 54.68 10.13 65.31 119.2 0.1267 0.2180
135 522.7 521.6 53.12 11.17 67.99 118.2 0.1310 0.2155
140 555.9 554.8 51.38 12.40 70.84 117.0 0.1356 0.2125
7.2. Useful Conversion Factors

Multiply By To Get Multiply By To Get
Mm 0.0393 In m3 /s 2119.5 cfm
M 3.2807 Ft m3 35.315 cu.ft
Kg 2.2046 Lb m3 /h 16.667 LPM
kcal/h 3.968 BTU/hr m3 /h 4.403 GPM
Watt 3.412 BTU/hr m3 /s 15873 GPM
kcal/h 0.00033 Ref. Ton L/s 15.87 GPM
kW 0.284 Ref. Ton kg/cm2 14.223 psi
m/s 3.2807 Fps kPa 0.145 psi
m/s 196.8 Fpm kW 1.359 HP metric
m3 /h 0.5886 Cfm kW 1.341 HP UK
C = {(5/9) x (F-32)} F = {((9/5) x C) + 32}, 1 bar = 105 Pascal = 105 N/mm2 = 14.504 psi 1
psi = 0.68948 x 105 N/m2 = 68.948 mbar = 2.0360” Hg = 51.7149 torr (mmHg)

Chapter 8 Annexures
8.1. Start-Up and Check Form
INSTALLATION: UNIT DATA

UNIT MODEL:
ADDRESS: UNIT SERIAL #:
START UP DATE:
1 Is Unit Damaged? (If yes specify)

2 R/Y Y/B R/B Hz
Unit voltage supply
V V V 50
3 Unit control voltage supply V
4 Are capacitors installed on the unit elec. Supply?
YES/NO
5 Capacitor value, in kVA
6 Are capacitor correctly installed? (If no please YES/NO
specify)
DESIGN ACTUAL
CONDITION CONDITION
7 Entering Evaporator Water temperature C (F)
8 Leaving Evaporator Water temperature C (F)
9 Evaporator water pressure drop kg /cm2
(psi)
10 Evaporator water flow Lpm
(USgpm)
11 Air temperature C (F)
12 Total air flow m3 /s
(CFM)
13 Do the water flow switches operate YES/NO
properly?
14 Do the condenser fans rotate in proper YES/NO
direction?
15 Is there a remote unit control? YES/NO REFRIGERANT TYPE R-410A
16 Are all electrical connections tightness YES/NO
checked?

17 Does oil pressure switch operate YES/NO
correctly?
18 Are thermal overload settings and YES/NO
manual resets checked?
19 Are motor temperature relay resets YES/NO
checked?
20 Has compressor on off sequence been YES/NO
checked?
21 Are time delay relay settings checked? YES/NO
22 Have compressor crankcase heaters YES/NO How long?
been energized prior to start-up?
Comp 1 Comp 2 Comp 3 Comp 4

23 Oil level (one column for one
compressor) 1) Prior to startup
2)Then compressor in operation
24 Compressor Model
25 Compressor Serial number
26 Discharge kg/cm2 g
Pressure (psig)
27 Suction Pressure kg/cm2 g
(psig)
28 Discharge line C (F)
refrigerant
temperature
29 Saturated C (F)
condensing
temperature
30 Suction line C (F)
refrigerant
temperature
31 Saturated Suction C (F)
temperature
32 Suction superheat C (F)
33 Compressor amps A
34 Air-cooled A
condenser fan
motors amps

35 Compressor run Hrs
hours, after start
up completion
36 Number of #
compressor stops
START-UP BY CUSTOMER’S SIGNATURE
REMARKS (if any)
After start-up :
 Keep one copy inside the control panel door.
 Send one copy to ‘Kirloskar Chillers Head Office’ within one week from the date of
commissioning; otherwise warranty claim may not be applicable.
Contact Details
For more information please contact:
Head Office:
A Kirloskar Group Company
8st Floor, Cello Platina, Fergusson College Road Shivajinagar,
Pune - 411005
- Phone: +91–20–66859800 
- Fax: +91–20–66859802
- Email: pune@kcpl.net.in


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KIRLOSKAR CHILLERS PRIVATE LIMITED

A Kirloskar Group Company

Installation, Start-up, Operation &

Scroll Liquid Chillers – KAC

DUAL COMPRESSOR KAC 11 ~ 22 with HFC410A

All information in this manual is based on the latest product information

6. Controls and settings …………………………………………………………………... 41

7. Technical Data ………………………………………………………………………… 56

KA – Kirloskar Air-cooled unit

Min leaving evaporator water ºC -10 ºC

Min ambient temperature ºC 13 ºC

Max ambient temperature for ºC 46 ºC

KIRLOSKAR CHILLERS PRIVATE LIMITED

NOTE: ONLY TRAINED, QUALIFIED INSTALLERS AND SERVICE

Some of the Safety Tips:

KIRLOSKAR CHILLERS PRIVATE LIMITED

 Refrigerant R-134a, R-407C, R-410A is generally considered chemically non-toxic and

KIRLOSKAR CHILLERS PRIVATE LIMITED

 DO NOT WORK ON HIGH-VOLTAGE equipment unless you are a qualified

Suitability for Application

KIRLOSKAR CHILLERS PRIVATE LIMITED

1.1. General Description

1.2. Distinctive Features

KIRLOSKAR CHILLERS PRIVATE LIMITED

NOTE: PHYSICAL DAMAGE TO UNIT AFTER ACCEPTANCE IS NOT THE

1.4. Handling and Lifting

Refer lifting diagram instruction pasted on unit.

Fig 1.4a : Lifting diagram for scroll chiller

CAUTION: SHARP EDGES AND IMPROPER BALANCING DURING HANDLING

NOTE: DO THE UNIT HANDLING ONLY WITH QUALIFIED PERSONNEL WHO

KIRLOSKAR CHILLERS PRIVATE LIMITED

KIRLOSKAR CHILLERS PRIVATE LIMITED

 Isolate chiller from location.

KIRLOSKAR CHILLERS PRIVATE LIMITED

2.1. Space Requirement for Servicing

2.2. Unit Location

Fig. 2.2a : Typical fan arrangement and minimum clearances required

KIRLOSKAR CHILLERS PRIVATE LIMITED

2.3. Evaporator Water / Brine (Liquid) Piping

Fig. 2.3a Typical Evaporator Water/ Brine (liquid) Piping

KIRLOSKAR CHILLERS PRIVATE LIMITED

REMOVE THE TEMPERATURE SENSORS FROM THERMOWELLS TO

2.4. Foundation and Anti-Vibration Mounts

KIRLOSKAR CHILLERS PRIVATE LIMITED

2.4.2. Anti-Vibration Mounts

Sr.no. Type of Installation Recommended type of Isolator

2.5. Water Treatment / Quality

NOTE: Kirloskar Chillers is not responsible for damage or under performance or

Recommended water quality standard for KAC liquid chillers

Tendency if the conditions are

2.7. Installation Check Report for KAC Chiller Units

End User Consultant : __________________________________________________________

Unit model : ________________________________________________________

Unit serial # : _________________________________________________________

KIRLOSKAR CHILLERS PRIVATE LIMITED

: for YES, : for NO / NIL, NA: for NOT APPLICABLE

KIRLOSKAR CHILLERS PRIVATE LIMITED

3.1. Liquid Chilling Systems - Principle

 Liquid refrigerant expansion or flow control device

 Power and Control Panel.

The basic vapor compression refrigeration cycle is explained in Fig. 3.1a.

Fig. 3.1a Vapor Compression system

3.2. Components and Their Functions

 Positive displacement type (Examples: Screw type , Scroll and Reciprocating)