Manual Screw Chiller Water Cooled PDF

Water Cooled Screw Chiller
High on Features
Low on Operating Costs
USERS
MANUAL
First published March 2006
No part of this publication may be reproduced in any

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

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

is used in some places in this publication for convenient reference.
Published by Blue Star Limited, Airconditioning Projects Division.
For restricted circulation only. Not for sale.

Contents
Introduction ................................................................................................................ 2
Features .................................................................................................................... 3
Nomenclature ............................................................................................................ 7
Technical Specification ............................................................................................. 8
Electronic Expansion Valve ...................................................................................10
MCS Panel ..............................................................................................................13
MCS Panel Troubleshooting ..................................................................................24
Rigging and Installation .........................................................................................29
Screw Compressor .................................................................................................32
Pre-Start Check up, Operation and Commissioning ..........................................40
Troubleshooting ......................................................................................................48
Maintenance ............................................................................................................51
Spare Parts Lists ....................................................................................................53
Field Feedback Card .............................................................................................65
Commissioning and Handing Over .......................................................................67
Water Quality ..........................................................................................................68
Log Report ..............................................................................................................69
Warranty Claim Form .............................................................................................70
Warranty ..................................................................................................................71
GA Drawing..........................................................provided on last inner wrapper
Electrical Wiring Diagrams..................................provided on last inner wrapper
User's Manual 1
Introduction
Blue Star has been a pioneer in developing and manufacturing
Chillers for various applications. A new generation of Water Cooled
Screw Chiller is being added to the present range of Reciprocating
and Scroll Chillers. The Chiller is energy-efficient and robust in
construction. These chillers are developed with state of art technology
which includes Hanbell screw compressor, high-efficiency cooler,
water-cooled condenser, refrigerant liquid injection for motor cooling
especially during part load operation, electronic expansion valve
and Micro Control Panel. The units have low input KW/TR and are
tested in Blue Star's Test Laboratory to validate performance.
The capacities of the Chillers range from 104 TR to 370.
TR with single and multi compressors in 10 models. Blue Star uses
the BSC Series compressors specially manufactured for Blue Star
by Hanbell.
2 Screw Chiller (Water Cooled)

Features
Compressor
The Screw Compressor has advantages compared to other
compressors, due to its inherent design features. The Compressor
has only two moving parts, viz. Male & Female Screws and Slide
Valve. The wear and tear is thus minimum, the life of the Compressor
is higher. Due to its inherent characteristics, a Screw Compressor
has the highest volumetric efficiency, and de-rating at higher
temperature is negligible.
It has stepless capacity control, usually from 25% to 100%. This
feature makes it ideally suitable for varying load applications, and
has better efficiency under part load conditions (Condenser and
Evaporator are designed for 100% capacity). This capacity control,
also helps in limiting the starting current as the system can be
started in unloaded condition (25%), and the loading is done stepless.
The Screw Compressor is Semi-Hermetic in construction, which
makes it serviceable. Due to geometrically symmetrical moving parts,
the Compressor has extremely low vibrations. The Compressor is
tested in accordance with ARI standards.
Cooler
The shell and tube evaporator has been built using inner grooved
copper tubes, and has been optimised for refrigerant and water
velocities. The shell is manufactured from high-grade steel. The
expansion of the tube is done with controlled process.
Water Cooled condenser

The copper tubes used are inner grooved type, with higher height
trapezoidal cross section, to increase the internal surface area of
heat transfer.
Refrigerant liquid injection

The refrigerant suction gas cools the winding of the semi hermetic
screw compressor motor. As an abundant precaution, liquid
refrigerant will be injected to the suction side of the compressor to
cool the motor winding. This is especially required during part load
operation where the suction gas quantity reduces. Liquid injection
during this period keeps the motor winding temperature within limits.
This is provided as a standard feature.
User's Manual 3
Electronic expansion valve
The Screw Chillier is fitted with an electronic expansion valve with
its drivers, as an integral part of the Micro Control Panel. The
algorithm is built to ensure most appropriate operation of the
expansion valve motor. This system adjusts the opening of the
valve with shorter response time, against varying load conditions,
resulting into optimising of power. Coupled with the stepless capacity
control which is a feature of the Screw Compressor, the electronic
expansion valve will maximise power savings.
The electronic expansion valve operates on a principle of opening
and closing of valve through a Stepper motor, which has 6386 steps
per revolution. The signal for the Stepper motor is received through
the Micro Control Panel. Electronic expansion valves thus have
advantage over normal Thermostatic expansion valves, which have
slower response for the changing conditions. The electronic
expansion valve adjusts itself based on suction superheat and
monitors the flow of refrigerant quickly and accurately, as compared
to thermostatic expansion valve. This inherent feature allows the
system to operate in a very narrow band of superheat, resulting in
power saving.

Control Panel
The Control panel has been designed with construction features, so
that it is mounted on the same structure. Electronic Micro Control
Panel, the Power section and the Termination sections are clearly
separated for ease of installation and servicing.
Micro Control Panel

Micro Control Panel has Digital Control and setting of Temperature
values, Temperature setting and control is in the range of ± 0.5°F.
Micro Control Panel has step less capacity control from 25% to
100%, Non-Volatile Memory backup for all set points, Automatic
power failure reset, Built-in time delays for compressors, Single
phase/phase reversal protection, Password protection at 4 levels
and in-built Anti-freeze and Flow switch safety.
Micro Control Panel is provided with RS-232 port for direct remote
computer connectivity (up to 50 feet), Fault Indication and Status
facility and RS-485 connection (up to 6000 ft). PC connection
Program provides both local and remote communication to Micro
Control Panel. The Micro Control Panel automatically performs
history logging and this program will graph the selected items.
Micro Control Panel has BMS Compatibility (J C N2, Bacnet and
Modbus protocol available). Translator is optional.
Micro Control Panel has Remote Monitoring and Access through
P.C. with Modem and dedicated telephone line without BMS as a
standard feature through RS232 & RS485 (P.C., Modem, Gateway
for units are Optional and not in the scope). Also remote monitoring
can be done with a web monitor connected to the panel and further
to customer’s LAN.
User's Manual 5
Two Levels of Safety
The Chiller is protected with Primary and Secondary Safety Systems.
This has been done to protect the Chiller, even in the case of failure
of any of the protection devices. Care has been taken to ensure
that there are no nuisance alarms generated. The Protection device
is as tabulated below:
Primary Secondary
Single Phasing SPPR module Current sensing

Reverse Phase SPPR module Suction & Discharge
pressures
Motor winding Temp Motor Protector Current sensing
Discharge Temp Compressor PTC Temperature sensor
sensor on Discharge Line
(Micro Control Panel)
Motor Overload Current sensing
Suction Superheat Electronic Expansion Superheat
Valve measurement by
Micro Control Panel
Starting Current Star-Delta method Unloaded start by
Micro Control Panel
HP / LP Pressure sensors
Refrigerant Migration Pump-down
Compressor
Discharge
Check valve
Lubrication Oil Oil Level Switch
Oil Pressure Difference Oil Pressure Cut-out
(Micro Control Panel)
Crankcase Heater
Anti-freeze LWT sensor AFT cut-out KP61
Water Flow Flow switch interlock
Sudden Compressor On/Off Time delay Anti-cycle cut-out
(10 min.)

Nomenclature
Nomenclature:
L C W X - 1 104
LIQUID NOM. CAP. IN TR
CHILLER NO. OF COMPRESSORS
SCREW COMPRESSOR
WATER COOLED
User's Manual 7
Technical Specification
Technical Data for Water Cooled Screw Chiller DX R22
SR DESCRIPTION UNIT MODEL

No. LCWX1-104 LCWX-125 LCWX1-145 LCWX1-160 LCWX1-210
1 Nominal Capacity kW (TR) 365.6 (104) 439.5 (125) 509.8 (145) 562.5 (160) 738.5(210)
2 Compressor Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw
Model BSC-105W, 1# BSC-125W , 1# BSC-145W , 1# BSC-160W ,1# BSC-210W , 1#
3 Refrigerant R22 R22 R22 R22 R22
Power Supply V/PH/HZ 400 V(+/- 10), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH.,
50HZ 50HZ 50HZ 50HZ 50HZ
4 Power Consumption KW 85.1 101.1 117.2 130 169.3
5 Refrigerant/Oil Charge Kg./Ltr 95/16 112/18 136/23 150/23 195/28
6 Cooler (DX -Shell & Tube Type) Model YCH-103A YCH-122A YCH-152A YCH-177A YCH-222A
Water Flow Min USGPM 208 250 290 320 420
Max USGPM 312 375 435 480 630
Connection Sizes INCHES 6 6 6 8 8
7 Condenser (Shell & Tube type) Model YCD-101A YCD-131A YCD-151A YCD-176A YCD-221A
Max USGPM 416 500 580 640 840
Inlet & Outlet connection Slip on INCHES 4 (1 each) 4 (1 each) 4 (1 each) 5 (1 each) 6 (1 each)
Length mm 2700 2953 2979 2987 3087
Width mm 800 900 900 900 900
Height mm 2000 2102 2102 2102 2269
8 OPERATING WEIGHT/UNIT (APPROX) Kg 2500 2700 3365 3650 4600
SR DESCRIPTION UNIT MODEL

No. LCWX2-208 LCWX2-250 LCWX2-290 LCWX2-320 LCWX2-370
1 Nominal Capacity kW (TR) 731.8 ( 208) 879 (250) 1019.64 (290) 1125.12 (320) 1300 (370)
2 Compressor Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw Semi-hermatic Screw
Model BSC-105W, 2# BSC-105W + BSC-145W BSC-145W , 2# BSC-160W+BSC-160W BSC-160W+BSC-210W
3 Refrigerant R22 R22 R22 R22 R22
Power Supply V/PH/HZ 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH., 400 V(+/- 10%), 3 PH.,
50HZ 50HZ 50HZ 50HZ 50HZ
4 Power Consumption KW 170.1 202.3 234.4 260 299
5 Refrigerant/Oil Charge Kg./Ltr 180/32 237/38 275/46 304/46 351/51
6 Cooler (DX -Shell & Tube Type) Model YCH-222A YCH-105A + YCH-152A + YCH-177A + YCH-177A +
YCH-152A YCH-152A YCH-177A YCH-222A
Max USGPM 624 750 870 960 1110
Connection Sizes INCHES 8 8 8 8 8
7 Condenser (Shell & Tube type) Model YCD-222A YCD-105A + YCD-151A + YCD-176A + YCD-176A +
YCD-151A YCD-151A YCD-176A YCD-222A
Max USGPM 832 1000 1160 1280 1480
Inlet & Outlet connection Slip on INCHES 6 (1each) 8 (1 each) 8 (1 each) 8 (1 each) 8 (1 each)
Length mm 3100 3400 3400 3400 3400
Width mm 1200 1800 1800 1800 2000
Height mm 2300 2300 2300 2450 3000
8 OPERATING WEIGHT/UNIT (APPROX) Kg 5000 5526 6526 6862 7541
NOTE:-
1) The Rating given are based on 54 / 44 Deg. F Chilled Water for Cooler with 0.0005 Deg. F Sq. Ft,Hr/BTU Fouling Factor
and 90 / 97.5 Deg. F Condenser Water with 0.001 Deg. F Sq. Ft HR /BTU. Fouling Factor

PRESSURE DROP
(FT.H20)
A
A
A
User's Manual
9
Electronic Expansion Valve
The benefits of using electronic expansion valves are:
• Step motor operated for precise control
• High resolution drive assembly – 0.000783 inches (0.02mm)
per step
• Tight seating
• Corrosion resistant materials used throughout
• Field proven reliability
• Low power consumption – 4 watts
• Compatibility tested with most CFC, HCFC, and HFC
refrigerants and oils
• Self lubricating materials used for longer life
• High linear force output
These are electronically operated step motor flow control valves,
intended for the precise control of liquid refrigerant flow. Synchronised
signals to the motor provide discrete angular movement, which
translates into precise linear positioning of the valve piston. Valve
pistons and ports are uniquely characterised, providing improved
flow resolution and performance. The valves are easily interfaced
with microprocessor based controllers. Strain Relief
Valve operation Retaining Nut
4-Pin Feed Through

The valves modulate by the O-Ring
Motor Housing
electronically controlled rotation of a
step motor. The step motor drives a gear
train and lead screw to position a piston. 42mm stepper
Motor
The piston is used to modulate flow Gear
Ball Bearing Gear Shaft
through a port, as referred in the figure.
Gear Cup
Motor
Bronze Guide
Lead Screw
Green
White
Black
Red
+
<
+
<
Q1 Q2 Q5 Q6
Bipolar Drive Sequence
STEP Q1-04 Q2-Q3 Q5-Q8 Q6-Q7
Close
1 ON OFF ON OFF
2 ON OFF OFF ON
Open
Q3 Q4 Q7 Q8 3 OFF ON OFF ON
4 OFF ON ON OFF
1 ON OFF ON OFF

The motor is a two-phase type driven in the bi-polar mode. Two
discrete sets of motor stator windings are powered in sequence to
rotate the rotor 3.6 degrees per step. Polarity of the drive signal
reverses for each step.
The sequencing is accomplished through the bi-polar drive circuit
shown on page 10. The drive transistors, Q1 through Q8, are
electronically biased in pairs by the controller as shown in the table.
Large valves have an operating stroke of 0.5 inches and 6386 steps
of control; therefore each step translates into 0.000783 inches
(0.02mm) of travel. When used with the Micro control panel, the
valves provide unsurpassed accuracy in resolution of flow and
repeatability of position.
External parts of the valve are brass and copper and meet or exceed
2000 hours salt spray tests per ASTM B-117.
The motor housing is equipped with hermetic cable connection to
the motor and a 10 feet motor lead is supplied as standard length.
Total power consumption is 4 watts when operating a rate of 200
steps per second with standard L/R type drive circuitry.
The valves have a safe working pressure of 420 psig. Operating
ambient temperature range is –50 deg. F to 140 deg. F (-45 deg C
to 60 deg. C) but temperature of up to 250 deg. F (120 deg. C) may
be used for dehydration.
The electronic expansion valve controls the flow of refrigerant
entering the direct expansion evaporator in response to signals sent
by the controller. These signals are calculated by the controller from
the sensor inputs. A set of sensors, either two temperature sensors
or a pressure transducer and a temperature sensor, are used to
measure superheat. Typical control is based on superheat set
point.
The ability of the EEV to control the amount of refrigerant in the
evaporator to allow reaching discharge set point while preventing
flood back makes the EEV the ideal expansion device for most air
conditioning, Chiller, Environmental chamber and refrigeration
applications.
User's Manual 11
SPECIFICATIONS
Motor type : 2 phase permanent magnet,

2 coil bipolar
Supply Voltage : 12 VDC, -5% + 10%, measured at the
valve leads
Connections : 4 lead, 18 AWG, PVC insulation
jacketed cable.
Phase Resistance : 75 ohms per winding ± 10%
Current Range : 0.131 to 0.215 amps/winding;
0.262 to 0.439 amps with two
windings energised.
Maximum power : 4 watts
Inductance per winding : 62±20% mH
Required step rate : 200 steps per second
Number of steps : 6386
Resolution : 0.000783 inches/step (0.02mm/step)
Total stroke : 0.50 inches (12.7mm)
Maximum allowable : less than 200 cc/min at 100 psi
internal leakage estimated
Maximum allowable : less than 0.10 oz/year at 300 psig
external leakage (0.20 gr/year at 20 bar)
Safe working pressure : 420 psig (29 bar)
Operating temperature : -50 Deg. F to 140 Deg.F
range (-45 Deg. C to 60 Deg. C)
Maximum dehydration : 250 Deg. F (120 Deg. C)
temperature
Compatibility : All common CFC, HCFC and HFC
refrigerants except R-410A;
all common mineral, Polyolester
and Alkylbenzene oils.
Materials of construction : Copper-fittings; brass-valve body,
motor housing, and adaptors:
synthetic materials-seating and
seals.

MCS Panel
Micro Control Panel
The Micro Control Panel is a rugged microprocessor based controller
that is designed for the hostile environment of the HVAC/R industry.
It is designed to provide primary control, no mechanical controls;
interface with building management systems; communicate both
locally and remotely. The Micro Control Panel provides flexibility
with set points and control options that can be selected prior to
commissioning a system or when the unit is live and functioning.
Displays, alarms and other interfaces are accomplished in a clear
and simple language that informs the user as to the status of the
controller.
The Micro Control Panel is designed to safeguard the system that
is being controlled, eliminate the need for manual intervention and
to provide a simple but meaningful man-machine-interface.
PC Support Software for

Micro Control Panel
PC-Config: Program provides the configuration file: points list, set
points, options, etc., for all versions of software. This program is
user friendly with English questions and drop down menus.
PC-Conn: Program provides both local and remote communications
to the Micro Control Panel independent of the type of software.
Through this program the status of the controller can be viewed and
with proper authorisation changes can be made to the system.
Configuration files can be transmitted to or received from an MCS-
8 unit. The MCS-8 automatically performs history logging; this
program will graph selected items.
Micro Control Panel Network

The Micro Control Panel Network can support up to 50 Micro Control
Panel and its associated I/O’s. Access to this network can be local
or remote via a 14.4K Baud modem. There will be no degradation
in the performance of the network. The PC connected to the network
must be running Windows 3.1 or higher with PC-Connect providing
the actual interface program.
Each Micro Control Panel in the network must be assigned a unique
address when the configuration file is build using the PC - Config
program. This address will be the key in establishing communications
with the appropriate Micro Control Panel system. This address can
be changed from the LCD / keypad of a unit.
User's Manual 13
MICRO CONTROL PANEL NETWORK
LOCAL PC SUPPORT ONLY
Micro Control Micro Control Micro Control

Panel-I/Os Panel-I/Os Panel-I/Os
RS485 RS485
RS485
Micro Control Panel

RS 485 Gateway
Remote PC with
Windows & PC-Connection

MICRO CONTROL PANEL NETWORK
REMOTE PC SUPPORT ONLY
Micro Control Micro Control Micro Control

Panel-I/Os Panel-I/Os Panel-I/Os
RS485 RS485
RS485
Micro Control Panel

RS 485 Gateway
14.4k baud
modem
Remote PC with
Windows & PC-Connection
14.4k baud
modem
User's Manual 15
REQUIREMENTS FOR PC SOFTWARE
To install and run the program we suggest the following system

requirements:
Front End System Requirements

n Windows 95
n Pentium 166 MHz
n 2 Gigabyte hard disk with at least 25 Megabytes free
n 3 ½ “ Floppy Disk Drive
n Super VGA display capable of displaying 256 colors
n 16 Megabytes of RAM or more is recommended
n 33.6k baud modem
Minimum System Required to Run Program

n Windows 3.1
n 486 66 MHz
n 500 Megabyte Hard Drive
n 3½” Floppy Drive
n VGA Display
n 8 Megabytes RAM
n 14.4k baud modem

Micro Control Panel
Authorisation function
The authorisation code is a special four-character code that enables
access in to the Micro Control Panel System. The code must be
numeric with values between 1 and 8 if it is to be entered from the
Keypad/Display. If the system is being accessed via PC-Connect
program, the code may consist of any valid alpha/numeric characters.
Each system can have up to 15 different authorization codes. This
provides the capability of issuing different codes to different people
if desired. There are four levels of authorization, which provide
different capabilities with in the system. The authorization code and
the associated level cannot be displayed or viewed in an Micro
Control Panel System. These are established when building the
configuration file in the PC-Configuration program. The authorization
codes must be protected and remain confidential, if they are
compromised unauthorized personnel can gain access to the system.
From the Keypad/Display the following changes can be made based
upon the authorization level:
Function View Service Supervisory Factory
Sensor offsets No Yes Yes Yes
Sensor diagostics No Yes Yes Yes
Clear alarm history No No No Yes
Clear point information No No No Yes
Date & time set Yes Yes Yes Yes
Day of week set Yes Yes Yes Yes
Change no flow lockout or shut down No No No Yes
Change rotate yes or no No No No Yes
Change manual/auto settings No No Yes Yes
Change setpoint values* No Yes Yes Yes
Change operating schedules no Yes Yes Yes
Change holiday dates no Yes Yes Yes
Lock out reset Yes Yes Yes Yes
*Note - Before a set point can be changed the set point must be able to be viewed.
User's Manual 17
The Micro Control Panel Keypad Display
Quick Reference - STATUS KEYS
• No authorization is required in the units are connected to a Micro Control
DISPLAY STATUS section for viewing Center the data will be presented in a
information. continuous sequence. ADDITIONAL
STATUS information shows names, total,
• Pressing a key selects the 1st two lines
run hours and starts for all RO’s.
of data. Repressing the same key selects
the next two lines, etc. • SYSTEM PRESSURE displays
information by circuit, SP suction
• The ALARM STATUS displays all alarms
pressure, DP discharge pressure, OPD
and lockouts while LOCKOUT STATUS
oil pump differential, AMP or motor fault.
displays only active lockouts.
LOCKOUT STATUS for lockouts caused
• The “+” and “-” keys may be used with
by either suction, discharge, oil or amps,
alarm & lockout status to allow scrolling.
the actual value at the time of the lockout
• If one or more Micro Control Expansion of the associated sensor is displayed.
COMP MAIN/DELTA ON
LOAD SOLENOID ON/OFF
UNLOAD SOLENOID ON/OFF 1 SP DP OPD AMP
LIQ. LINE SOLENOID ON/OFF 65 260 195 44
ï
ï
1 SUCT SAT S HEAT

+55 +37 +18.1
DISPLAY STATUS 1 DISC SAT S HEAT
+180 +120 +60.4
COMPRESSOR SYSTEM
STATUS 1 PRESSURE 5
ï
SUCT TMP + 55.6F
DISC TMP + 180.5F
FANS 1LOT ON/OFF
ï CONDENSOR SYSTEM LIQ. OUT + 47.3F
FANS 2LOT ON/OFF STATUS 2 SENSORS 6 FLOW ON

UNIT CTL ON
END/SELECT NEXT
LIQ.OUT
ï EVAPORATOR
ADDITIONAL ï COMP 1 = 000016h LIQ.LINE = 000016h
TEMPERATURE STATUS 3 STATUS

INFO
7 STARTS =
STARTS =
000000040
000000029
STARTS
STARTS
=
=
000000028
000000035
LOAD = 000002h STARTS = 000000034
STARTS = 000007996 ALARM = 000000h
ALARM LOCKOUT UNLOAD = 000001h STARTS = 000000015
4 8
ï
STATUS STATUS STARTS = 00000863
1 JAN 30 09:13:00 7 JAN 30 09:11:33
REASON FOR ALARM COMPUTER RESET
ï
2 JAN 30 09:12:51 8 JAN 30 09:11:12

LOCKOUT RESET FREEZE 5 JAN 30 09:11:45
3 JAN 30 09:12:19 9 JAN 30 09:11:01 ALARM LIQ OUT
POWER RETURNED LOCKOUT RESET Chiller Configuration Example 5 SP DP OPD AMP
4 JAN 30 09:12:13 10 JAN 30 09:10:56 • One screw compressor 8 JAN 30 09:11:02
POWER FAILED ALARM LIQ.OUT FREEZE
5 JAN 30 09:11:45
• One each load/unload solenoid per compressor
11 JAN 30 09:07:30
• One liquid line solenoid per compressor 10 JAN 30 09:10:56
ALARM LIQ.OUT LOCKOUT RESET ALARM LIQ.OUT
6 JAN 30 09:11:44 12 JAN 30 09:07:18 • Suction & discharge pressure per compressor
LOCKOUT RESET • Oil pressure per compressor
• Leaving liquid temperature sensor
• Return liquid temperature sensor

The Micro Control Center Keypad Display
Quick Reference - ENTRY KEYS
• The ENTRY keys (SERVICE, SETPOINT, authorization function within the SERVICE
MANUAL and PROGRAM) provide menu DIAGNOSTIC key menu.
items, some of which when selected will
present sub menus. • Different items will appear depending on
the package configuration and options
• When making value changes the selected.
INCREASE (+) & DECREASE (-) keys
may be held for continuous updating. • Units may be English or Metric.
• Enter authorization code at the • The clock is factory set at EST or EDST
based on time of year.
CONTROL STATUS
ENTR CHG OPTION
DATE DISPLAY
AUTHORIZATION
ENTR CHG OPTION
ENTER CHG OPTION
TIME DISPLAY
SENSOR OFFSETS
ENTR CHG OPTION
ENTR CHG OPTION
DATE & TIME SET
CLEAR ALRM HSTRY
ENTR CHG OPTION
ENTR CHG OPTION
DAY OF WEEK SET
CLEAR PT INFO
ENTR CHG OPTION
ENTR CHG OPTION
OPERATING SCHEDS
UNIT INFORMATION
ENTR CHG OPTION
ENTR CHG OPTION
HOLIDAY DATES
ï ENTR CHG OPTION
ENTRY
ï
#1 LVG LIQ OUT TARGET

TEMP #8 STEP SENSITIVITY
ENT CHG SERVICE PROGRAM
#2 CTRL ZONE DIAGNOSTIC OPTIONS
ENTR CHG TEMP #9 STEP DELAY
TIME IN SECONDS
ï
#5 CNTRL ZONE
ENTR CHG TEMP #10 MAXIMUM ROC ï SETPOINTS INCREASE INCREASE KEY(+)
#7 POWER UP DELAY #11 ENT CHG (SAFETIES) (+) & DECREASE KEY(-)
ENTR CHG TIME IN SEC TEMPERATURE
ï
Used To adjust values or change
options selected. (SERVICE,
SETPOINTS, PROGRAM keys)
RELAY OUTS MANUAL
ENTR CHG OPTION
ï MANUAL DECREASE
ANALG OUTS MANUAL OVERRIDES (-)
ï
ENTR CHG OPTION
SENSOR INS MANUAL ENTER KEY
ENTR CHG OPTION LOCKOUT Selects options or enters
RESET ENTER changes after adjust-
ï ments
have been made
NO ACTIVE LOCKETS
SEL NEXT OPTION
ECT
User's Manual 19
Wiring Guide Notes
• Relay Outputs (RO) 230 VAC 10 amps.
• SI 1-4 factory set for 4 wire differential inputs.
(0 to 100 milli volts dc)
• SI 5-8 factory set for MCS-T100 temperature inputs.
(0 to 5 volts dc)
• All analog inputs must have shield tied to GND.
• Mircro Control Panel-I/O factory set address to
Mircro Control Panel I/O Items refer page 21.
High Voltage Wireway Relay Ouptus & 220 VAC 50/60 hertz Input
Preferred direction of wire
220 VAC
Low Voltage Wireway Sensor Input, Analog Output & Communications

Terminals Shielded cable only, preferred direction of wire

Detail of Micro Control Panel and I/O Key Items
220
220 VAC
User's Manual 21
IB Series interface boards (IB 6)
These interface boards are used to accept 0 to 10 V DC analog input signals and are designed to allow
externally supplied control signals to control one or two Sporlon step motor valves including electronic expansion
valves. IB 6 boards are used on valves with 6386 steps.
CN4 CN2
+4-20
-4-20
Black
White
Green
Red
IN
GND
24V-1
24V-2
CN3
Configure the Board power should be applied to these terminals.
When used with a 0-10 volt input signal, a jumper OPERATION and TROUBLESHOOTING
should be placed on the pins labelled CN3 as shown When properly configured and installed the IB Series
in the above Figure 1. This is the default jumper requires no maintenance. They incorporate a number
position. The impedence for this input is 40 k ohms. of operational features to assure trouble free service.
Choose “Open on Rise” or “Close on Rise” operation On power-up the board will initialize by giving the valve
using the middle two pins on jumper CN2. The jumper a large number of steps to assure that the valve is
is stored on one pin only and will cause the valve to fully shut. The routine will require approximately 8
open as input signal rises, i.e. valve is closed at 0 seconds for the IB1, 16 seconds for the IB3 and 32
volts or 4 milliamps and fully open at 10 volts or 20 seconds for the IB6. The valve will not respond to
milliamp input. By placing the jumper on both pins, the input signals during this time.
operation is reversed so that the valve will be fully If the valve is required to shut during operation, the
open at 0 volts or 4 milliamps. Other pins on CN2 pumpdown terminals should be used. When given a
have been clipped at the factory and are not used for pumpdown signal, the board will shut the valve
operation of the valve. immediately and overdrive by 250 steps to reset valve
Wiring Instructions and Cautions position. On removal of the pumpdown signal the valve
Use the chart given next page No.24 as a guide for will resume position as dictated by the external control
wire connections. Certain precautions must be taken signal.
in wiring and operation of the IB Series. If power is lost to the IB or wire to the valve severed,
1. The 24 volts must be supplied by a transformer not the valve will remain in its last position. Solenoid valves
used for any other purpose. In addition, the may be desired before the step motor valve on critical
secondary winding of the transformer must not be applications.
connected to chassis ground. To force the valve shut during operation for test
2. The primary input of the transformer should be purpose, simply remove the jumper from CN4 or CN3,
protected by Metal Oxide Varister (MOV) surge depending on configuration. To resume normal
suppressors, supplied with the IB. For protection operation, replace the jumper.
from electrical transients, connect one MOV To allow for component tolerances, the IB will shut the
between one leg of the input voltage of the 24 valve when the input signal reaches 4.25 milliamps or
VAC transformer and earth ground. Connect a .015 volts depending on the configuration.
second MOV between the other leg of the input The IB can power one or two valves. The valves will
voltage of the 24 VAV transformer and earth operate simultaneously and will open and close by the
ground. same number of steps. Valve wires must be connected
3. The pumpdown terminals must be supplied with a exactly the same for both valves.
“dry” contact from a switch or relay. No external

Wiring Connections
From left to right when the board is oriented with the terminal strip across
the bottom.
+4-20 - connection for the positive leg of a 4-20 milliamp or 0-10 volt signal
-4-20 - connection for negative leg of a 4-20 milliamp or 0-10 volt signal
B - black wire from valve, or both valves when two valves are used
W - white wire from valve, or both valves when two valves are used
G - green wire from valve, or both valves when two valves are used
R - red wire from valve, or both valves when two valves are used
IN - from external pumpdown switch or relay. See wiring instructions.
GND - to external pumpdown switch or relay. See wiring instructions.
24V-1 - from 24 volt, 15 VA transformer. See wiring instructions.
24V-2 - from 24 volt, 15 VA transformer. See wiring instructions.
3.0 inches
Dia. 0.125 typical & places Jumper for close on

input rise
4-20 mA. 1000 ohms

4-20 mA. 600 ohms
.0 inches 4-20 mA. 300 ohms
0-10 VDC
4-20 mA or valve digital 24 vac

B-in VDC b wg r input input
025 typical input
4 places
0.25 typical
4 places + Lead Ground Lead Pump down 24 VAC Power
Signal In
User's Manual 23
MCS Panel Troubleshooting
TROUBLE SHOOTING FOR SPORLAN IB6
INTERFACE CARD
TEST THE VALVE:
The resistance of the motor winding may be tested without operating

the system as follows:
1) Check voltage (24V) at IB or Transformer
2) Remove power from the external controller and /or IB
3) Remove the valve leads from IB
4) Measure the resistance between the black and white leads of
the valve. The resistance should be 75 Ohms with the valve at
room temperature or approximately 65 Ohms if the valve is at
-40 deg F.
5) Measure the resistance between green and red leads this value
should be between +/-5 %of the resistance between black and
white leads
6) Measure the resistance from any lead to valve body. Resistance
should be infinite, that is to say, open

TEST THE IB:
SR. PARAMETER IF NO IF YES

NO.
1 Is there 24VAC at terminal? Repair or replace power Go for 2
supply or supply wiring
2 Is the valve connected to Shut off power to IB and Go for 3
terminal (B,W,G,R)with correct wiring
wire colors correct ?
3 Connect voltmeter on Check the step motor. Go for 4
AC scale to the black If operational replace the IB
and white terminal.
Interrupt and restore power
to IB. Does the meter read
12 VAC±1?
4 Repeat test using red and Same as in 4 Go for 5
green terminal.
Does the meter read
12VAC +/-1?
5 Are wires for external Shut off power to IB and Go for 6
signal connected to external controller and correct
terminal +4-20 and -4-20 input signal observing polarity
6 Is external signal present? Shut off power Go for 7
Signal should be Test or correct wiring
0-10VDC?
7 Is polarity of signal correct? Shut off power. Go for 8
Terminal (+) to terminal +4-20 If not correct wiring
and (-) to terminal -4-20
8 Pin jumper in not required Shut off power. And correct Go for 9
on CN2 & CN4; jumper position
but required in CN3
9 IB IS FUNCTIONAL,TEST EXTERNAL CONTROLLER
User's Manual 25
The Micro Control Panel Troubleshooting
Quick Reference Sheet
PROBLEM POTENTIAL SOLUTION
No Sensor + 5 V D C Indicates a possible shorted input sensor

Remove all sensor + 5 V DC wires.
Wait about 30 to 60 seconds. If + 5 V DC returns,
replace one sensor wire at a time until the + 5 V
DC is lost again. This will be the shorted sensor.
A sensor input reads -99.9 This indicates an open sensor input signal or
5 VDC problem.
Check sensor wiring for missing wire or poor
connection.
Check sensor for bad sensor
Check + 5 V DC on sensor input to ground.
If less than 5 VDC is on the sensor 5 VDC
terminal block, the problem is with probably a
shorted sensor. (A poly fuse protects the board)
Remove all sensor input terminals.
Wait about 1 min. or until 5 VDC restored at
sensor input.
Connect terminals 1 at time until short reappears
& fix bad sensor.
A sensor input reads +999.9 This indicates a shorted sensor input signal.
Check sensor wiring for +5VDC shorted to signal etc.
Check sensor for bad sensor.
A pressure sensor is reading This indicates the transducer sensor input needs
more than 1 psi off to be calibrated via the offset capability in the
(The temperature & humidity software. (Transducers by design need to be
sensors do not require calibrated based on construction and altitude.)
calibration.) You need to have a valid Auth code to change
sensor offsets
You must use the Windows based software
package P Conn
See P Conn Interactive section for instructions.
(Change SI Status, Manual Value and / or offset.)
Invalid reading on one This indicates an input problem with 1 sensor.

sensor input. Verify jumper settings correct for that SI.
MCS CONTROLLER Indicates Micro in constant reset.

INITIALIZATION on LCD display. Check incoming power > 220 VAC
Top row of LCD display all Indicates software chip problem possible.
bars & 2nd row blank. Possible U11 software version incorrect or
chip bad.
Possible U13 GAL chip incorrect or chip bad.
Possible bad connection or cable between
LCD and Micro Control Panel

PROBLEM POTENTIAL SOLUTION
LCD blank. Indicates bad connection.

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

Verify RS485 LED blinking.
Verify termination jumper
J6 only on at Micro Control Panel & last I/O.
Verify Micro Control Panel & I/O addresss set
correctly.
Verify wiring from Micro Control Panel to
each I/O correct.
Check fuses/220 VAC on I/O units
Changes to MCS not being This indicates inability to write to chip U10.
made from the units keypad. Verify EEP WRITE ENABLE jumper W6 is on.
Not authorized
P Conn cannot make changes This indicates you are not at a proper
authorization level.
Follow steps below for proper authorization.
From either the SYSTEM INFO or STATUS screen,
under P Conn, click on the AUTH button on the
lower right of your LCD display.
Follow prompts and enter a valid 4-digit
authorization number.
The authorization level is displayed at the
top of the display and is reflected via the
colour of the AUTH button.
RED = view only
YELLOW = service level
BLUE = Supervisor level
Green = Factory level
Invalid authorization This indicates an invalid auth number.

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

CFG layout for different version than
software chip U11.
User's Manual 27
Problem Potential Solution
INVALID CONFIG TYPE Indicates U10 CFG incompatible with U11 software.
Example U10 CFG for home while U11 for chiller.
INVALID CONFIG Indicates Checksum invalid Reload CFG
Sensor input believed invalid Verify Berg jumpers using Quick Reference Sheets
(Under Sensor Diagnostic Check board version number Check wiring of sensor
Sub Menu)
Communications to Micro The Verify red LED (located just to the

Control Panel left of the RS-485 connector) on the gate way
485-GATEWAY from PC- blinking indicates that the PC-Connect program is
Connect not working. talking to the gateway. Verify that the two wire
shielded cable is properly wired from the RS-485
connector to the gateway.
If both of LEDs are blinking, check the address of

the Micro Control Panel and any other
Micro Control Panels that are on the network.
Each must have a unique address.
This address can be changed from the Micro Control
Panel Proper authorization is required. Enter the
UNIT INFORMATION screen by depressing the
SERVICE DIAGNOSTIC key and scrolling to this item.
Depress the ENTER key and scroll to the NETWORK
ADDRESS screen. Change address if needed.
Verify +12 V DC to Micro Control Panel RS485.
GATEWAY INVALID CONFIG indicates Checksum

invalid. Either set to factory defaults or reset
settings.
NOTE : All sensosr inputs should be shielded cable with shield tied to ground on Micro
Control Panel Sensor Input Groung Terminal.

Rigging and Installation
Rigging
When the chiller arrives at Warehouse/Site, proper rigging and
handling is mandatory during unloading and leading the unit into
position.
Care must be taken to keep the unit upright during rigging. Avoid
unnecessary jerking or rough handling.
Proper hoisting straps should be used when rigging (nylon flat rope).
It is also mandatory that an experienced and reliable rigger be
selected to handling unloading and final placement of the equipment.
The rigger must be advised that the unit contains internal components
that require to be kept in an upright position. Care must be exercised
to avoid twisting of the equipment.
Storage
Check for transportation damages if any and take up with factory
for any damages.
In case the site is not ready to install the chiller, proper care should
be taken to store the chiller in a covered space. Check up the
pressure of the unit when received. If the pressure is not holding in
the system, the system should be pressure tested immediately,
repair the leakages if any and charge the system with Nitrogen.
Never keep the system without pressure.
User's Manual 29
Installation
Proper care should be taken to make the foundation for the Chiller.
In case the Chiller is located on rooftop, ensure that the same is
located in such a way that the load of the same is transferred to
the columns and not to the slab directly. The foundation should be
properly levelled.
Install the Chiller on the Foundation/Pedestal and grout by using

foundation bolts. The Chiller should be levelled on the foundation.
The unit should not be located nearer to any heat source or any
high tension line running above.
Adequate space around the Chiller as recommended in the G A

Drawing should be made available for maintenance purpose.
The chilled water and condenser water piping connections to the

cooler and condenser should be terminated preferably with flexible
connections to avoid transmission of vibration if any. The piping
shall be supported external to the unit as per the recommended
practice.
Use recommended size of power cable to be terminated to the

MCCB of the Panel of the unit. Use 3 ½ core Aluminium cable
along with double earthing and terminate through proper lugs. Avoid
any sharp bend for the cable at the termination point. The cable
shall be adequately supported.

Legend for Control & Power Wiring Diagram for
Water Cooled Screw Chiller
Sr. no Acronym Description
1 CB Circuit breaker
2 EMG Emergency Off Mushroom Type
3 INT-69 Motor protector module
4 OCTH Oil cooler thermostat
5 1M, 2M, 3M, 4M, 5M Contactors
6 G Ground terminal
7 S1 Sensor input terminal
8 C Common connection for relay output
9 NO Normally open connection for
relay output
10 NC Normally closed connection for relay
output
11 L Phase Line
12 N Neutral
13 TB Terminal Block
14 SP/PR Single phasing preventer / Phase reversal
protector
15 OL Overload relay
16 MCCB Molded Case Circuit Breaker
17 CT Current transformer
18 RLY Relay output
19 SI8 Sensor Input card
20 MCS Micro Control Main Board
21 LCD Touch key pad for MCS
22 OCF Oil Cooler Fan
23 MP Compressor Motor Protector
24 HTR Oil Heater
25 SV Solenoid Valve
26 TR Transformer
27 EEV Card Interface Board for EEV
28 EEV Electronic Expansion Valve
User's Manual 31
Screw Compressor

Construction of Compressor
Fig. 1
1. Compressor casing 19. Disc spring

2. Motor casing 20. α-Balance piston
3. Oil separator 21. Bearing slot nut
4. Motor rotor assembly 22. Male rotor
5. Motor stator assembly 23. Suction bearings
6. Motor rotor washer 24. Suction bearings inner/outer
7. Motor rotor spacer ring spacer ring
8. Oil Separator Baffle 25. Oil guiding ring
9. Oil separator cartridge 26. Oil level sight glass
10. Piston 27. Oil filler cartridge
11. Piston spring 28. Suction filter
12. Piston rod 29. Oil heater
13. Bearing sets cover plate 30. Refrigeration Lubricant
14. Modulation solenoid valve 31. Suction flange
15. Modulation slide valve 32. Discharge flange
16. Slide valve key 33. Cable box
17. Discharge bearings 34. Power bolt
18. Discharge fixed ring 35. Thermostat terminals

36. Motor cable cover plate
User's Manual 33
Capacity control system
The BSC series screw compressors are equipped with continuous
(step less) capacity control system, which consist of a slide valve,
piston rod, cylinder, piston and its rings. The slide valve and the
piston are connected by the piston rod. The principle of operation
is by using the oil pressure to drive the piston in the cylinder. See
figure on next page. The lubrication oil flows from the oil tank
through the oil filter cartridge and capillary then fills into the piston
cylinder due to the positive oil pressure higher than the right side
of spring force plus the high pressure gas. The positive pressure
differential causes the piston to move towards the right side in the
cylinder. When the slide valve moves towards the right side; the
effective compression volume in the compression chamber is
increasing thereby increasing the displacement of refrigerant gas
and hence increase in the refrigeration capacity.
The piston spring is to force the piston back to its original position,
i.e. 25% position to reduce the starting current during the next
startup. The compressor started at full load, will result in a larger
starting current that could damage the compressor motor seriously.
The capillary is provided to maintain and restrain a stable amount
of oil flow to cylinder. The modulation (step less) solenoid valves
(SV1 & SV2) that are controlled by micro controller with the
temperature sensor to modulate the piston position smoothly with
stable output of capacity.
If the oil filter cartridge, capillary, or modulation solenoid valves are
not working very well in the capacity control system; will result in
the abnormality and ineffectiveness of the capacity control system.
In continuous (step less) capacity control system, a normally open
solenoid valve (SV2) and a normally close solenoid valve (SV1)
are equipped to the inlet and outlet of piston cylinder respectively.
These two solenoid valves are controlled by the Chiller temperature
controller or micro controller, refrigeration capacity control and hence
can be modulated at anywhere within 25% - 100%. Therefore, it is
available to control the capacity output stably by modulating the
inlet of SV2 and outlet of SV1 alternatively.

The continuous (step less) capacity control system needs to be
associated by a micro controller such as the Micro Control Panel as
well as PLC with LCD displayer etc.
It is very important for any controller to control the load and unload
stably. For a smooth modulation, it is suggested to install an
additional orifice valve in the oil line while a fast speed of loading
and unloading is happening.
Continuous capacity control system
No. Component No. Component
1 Suction filter 10 Lubricant

2 Gas in (low pressure) 11 Oil separator cartridge
3 Motor 12 Gas out(high pressure without oil)
4 Oil filter cartridge 13 Capillary
5 Suction bearings 14 Solenoid valve (normally open), SV2
(Loading)
6 Male rotor 15 Solenoid valve (normally closed), SV1
(Un Loading)
7 Discharge bearings 16
8 Discharge silencer 17 Slide valve
9 Gas out (high pressure with oil)
SV1 (Unload) SV2 (Load)
Start On On/Off
Loading Off Off
Unloading On On
Stable Off On
User's Manual 35
Lubricant
The main functions of the lubrication oil in screw compressor are
lubrication, internal sealing, cooling and capacity control. The positive
oil pressure in the cylinder pushes the piston and the slide valve,
which is connected by a piston rod to move forward and backward
in the compression chamber. The design with positive pressure
differential lubrication system in the BSC series is available to
eleminate an extra oil pump in the compressor.
The bearings used in BSC compressor require a small but steady
quantity of oil for lubrication; the oil injection into the compression
chamber creates an oil sealing film in the compression housing for
increasing the efficiency and absorbing a portion of heat of
compression.
In order to separate the oil from the mixed refrigerant gas, an oil
separator is required to ensure the least amount of oil carried into
the system. Pay more attention to the oil temperature, which is a
very significant factor for the compressor bearings’ life. High oil
temperature will reduce the oil viscosity and cause poor lubrication
and heat absorption in the compressor as well. It is recommended
to keep the oil viscosity above 15mm2/s at any temperature. If the
compressor is operated under the critical conditions, (high discharge
pressure) then extra oil cooler is required. Some high viscosity oil
is recommended for applications with high working condition. It
happens often that the return oil from the evaporator is insufficient
due to the high viscosity of oil, which is difficult to be carried back,
that causes the loss of oil in compressor. If the system encounters
the oil return problem then it is recommended to install extra 2nd oil
separator between the compressor discharge connection and
condenser.
Each of BSC series of compressors are equipped with two oil sight
glasses as a standard; one is the oil high level sight glass and the
other is the oil low level sight glass. The normal oil level in the
compressor oil tank should be maintained above the top of the low
oil sight glass and in the middle level of high oil sight glass when
compressor is running. It is recommended strongly to install the
optional accessory of oil level switch to prevent from low oil level
in compressor.
Warnings:
a. Use the qualified oil and do not mix with different brand of oil.
Different kinds of refrigerant should match with different kinds of
oil. Note that some synthetic oil is incompatible with mineral oil.
Prior to the oil is filled into the compressor, the system should be
totally cleaned up during the initial startup and ensure that it is
clean completely.

b. For the chiller system using synthetic oil, avoid the exposure of
oil to the atmosphere too long, it is also necessary to vacuum the
system completely when installing the compressor.
c. The table below shows the oil replacement standard. Each
compressor at HANBELL charges standard quantity of oil.
d. In order to take out the moisture from the system, it is suggested
to clean the system by hot air or Nitrogen, thereafter vacuum the
system as long as possible. It is essential to change new oil into
the system especially after the motor burn out, the acidity debris
will still remain inside the system, hence follow the above
mentioned procedures to overhaul the system. Check the oil
acidity after 72 hours operating and then change it again and
again if the limit is still over the oil acidity standard until been
qualified.
Oil Replacement Standards
Item Value Item Value
Color, ASTM Above 6.0 Total acid Above0.5
number
mg KOH/g
Particle Matters Above 5.0 Copper Strip Above 2.0
mg/100ml 100 Deg C /3hrs
Viscosity Variation ±10% of Moisture Above 100
40 Deg. C 15mm2 / Sec or more ppm
Changing oil
Lubrication oil is the most important factor to maintain the operating,
lubricating, cooling, sealing and driving the capacity piston of the
compressor. Following is the probable problems existing in the
system that should be faced:
1. Contamination of oil by debris causes the oil filter clogged.
2. Acidified system due to the moisture causes the motor corroded.
3. Spoiled oil due to the compressor running at long duration of high
discharge temperature causes the bearings’ life shortened.
Refer to the following oil change timing to ensure the compressor
runs normally:
1. Change the oil periodically: Check the oil for every 10,000 hours
of running periodically for the first operation, to change oil and
clean oil filter after running 20,000 hours is recommended. Due
to the piping debris could be accumulated inside the system after
operation, check the oil after 2,500 hours or after one year of
running. Check the system whether clean or not and then change
the oil after every 20,000 hours or after 4 years running while the
system is operated under good condition.
User's Manual 37
2. Avoid the debris clogged in the oil filter causing the bearings
failure, an optional oil pressure differential switch is recommended
to be installed. The switch will trip when the oil pressure differential
reaches the set point between the primary and secondary sides
and the compressor, will shut down to prevent the bearings
damage due to lack of oil.
3. If the compressor discharge temperature often keeps high
approaching to the set point, then the oil will be spoiled gradually
in short time, hence check the oil characterestic every 2 months
if possible. It is necessary to change the oil if the character of the
oil is out of the standard. In case oil characterestic could not
be checked periodically, then change the oil after 4 years’ of
installation or after 20,000 hours’ of running which reaches first.
4. Acidity in lubrication oil causes the reduction of bearing’s life and
motor’s life. Check the oil acidity periodically and change the oil
if the oil acidity value measured is lower than PH 6. Change the
deteriorated drier periodically if possible to keep the system dry.
Check the acidity of oil after 72 hours of initial of operation.
5. Refer to the oil changing procedures especially after the system
overhaul owing to the motor burn out. Check the oil quality monthly
or periodically and change the oil if the oil is not qualified, it is
necessary to take care of the oil quality and system cleanness
and dryness in the system periodically.
The Compressors are charged with Blue Star ACS oil for the Water Cooled application
and for R22.

Liquid injection
The liquid injection to the suction side of the compressor, is carried
out by providing a separate thermostatic expansion valve in the
system. (Low-temp type expansion valve)
The flow of liquid refrigerant is controlled through the expansion
valve by the suction superheat directly.
Application of liquid injection
The compressor motor temperature and its compression chamber
temperature will be very high almost approaching the setting of
motor thermister and discharge temperature thermister, which often
result in the trip of the sensors under the above working conditions
causing the chillers to shut down.
The purpose of installing a liquid injection system is to prevent the
compressor motor from overheat, an expansion valve is installed in
the system with tube piped between the liquid line and compressor
for cooling down the compression chamber and motor to ensure
that the compressor can be run continuously and safely.
The suction superheat should be controlled between 5 to 10 deg.
C for the application of water cooled screw chillers by means of the
expansion valve devices. During the initial start up, the loading of
the chillers will be heavy due to the higher temperature of return
chilled water, hence the liquid injection devices of adequate capacity
should be selected to reduce the overheat of the compressor.
When the compressor is operated for low temperature system (E.T
=< -10 deg. C), the compression ratio will be high at this condition
and also the discharge temperature. Hence the use of liquid injection
system is essential.
User's Manual 39
Pre-Start up,
Testing, Commissioning
& Operation
Prior to starting of the unit, check up the procedure detailed herein
Items Things To be checked Standard Values
1. Accessories 1. Oil level 1. Higher than the middle

line of oil level sight
glass.
2. Time for heating the oil 2. Turn on the oil heater at
least 8 hrs. before
starting.
3. System valve status. 3. Opened
4. Capillary 4. No distortion or damage
2. Electrical 1. Voltage of the main power. 1. Electricity voltage should be

System kept within +_15% to the
rated voltage. Instant
maximum voltage drop
while starting should be
less than 10% to the rated
voltage.
2. Voltage of the control 2. Standard voltage is 220 V.
circuit. Maximum voltage is 230 V.
3. Insulation Resistance value 3. Insulation resistance value
of the motor between should be above 5 M ohms
phase to phase and phase 4. Power terminals are firmly
to ground. fixed on terminal block and
4. Power terminals and wire well insulated. Keep wire
cables terminal cables away from heat
connections. source and sharpened
metal. Terminal screw and
block, both are required.
5. Earthling
5. As per local Electricity
6. Settings of switches, regulations.
sensors and controllers.
6. Properly set.
3. Piping system 1. External piping 1. Fixed properly

2. Leakage test 2. No leakage
3. Compressor fixed tightly 3. Check up the tightness
Leakage test
4. Safety devices 1. Motor winding sensor 1. Connected properly

Discharge temp. sensor 2. Connected properly

Operation
1) In addition to above pre start-up check up, it is also necessary
to pay attention to the auxiliary facilities while the chiller is
commissioned at the job site and the periodic maintenance
after the initial start up.
2) In order to keep the capacity control smoothly under the low
ambient temperature with the normal viscosity of oil, it is required
to heat the oil by heater at least 8 hours before next starting.
The lower the ambient temperature is, the longer the time of
heating of oil should be. The oil temperature should be over 50
Deg. C before starting the compressor. Keep the oil heater
energised after the compressor is shutdown for preparation of
next start-up, to keep the oil temperature over the minimum
required value, which is essential especially under low ambient
condition.
3) Recheck the settings on each controls
4) Establish the chilled water flow through the cooler. Adjust the
water flow rate to the designed rated flow. Connect the Chilled
water flow switch with Micro Control Panel.
5) Check if all the stop valves in the system are already opened
6) Check if the setting on each timer relay is correct.
7) Check up the idle pressure of the system
8) Recheck the wiring to the compressor motor is as per the
wiring diagram with Star – Delta connection given below.
MCS
MCD
User's Manual 41
Following are the start up limitations
1) Lowest Starting Voltage: The power voltage cannot be lower
than 10% of rated voltage during start-up period of compressor.
2) Maximum Discharge Pressure: 18 kg/cm2 g
3) Minimum Suction Pressure: 6~8 kg/cm2 g
4) Maximum designed discharge pressure: 28 kg/cm2 g
5) Maximum designed discharge temperature: 110 Deg. C
Starting Procedure:
Operation of Micro-Controller for Single / Twin System
The MCS control circuit for Blue Star Water Cooled (DX) Screw
Chiller comprises of analog sensor inputs such as System Pressures,
System Temperatures, Chilled Water Temperatures etc. and digital
sensor inputs such as flow switch, External Anti-freeze interlock,
Single Phase/ Phase Reversal fault, etc.. It consists of various relay
outputs that drive the compressor, liquid line solenoid valve, liquid
injection control etc. Analog outputs (0-10V DC) are used to drive
the Electronic Expansion Valves.
Before switching ON the chiller, ensure that the flow switch is
connected between points 7 and 8 in the wiring diagram and there
is sufficient water flow. The crankcase heater should be ON for a
period of 8 hours before starting the compressor.
In the OFF state, the condition of the outputs is as follows:
System 1
Relay output Condition
Main1 OFF
Delta1 OFF
Loadsol1 OFF
Unloadsol1 ON
LLS1 OFF
LIQinjct 1 OFF
System 2
Main2 OFF
Delta 2 OFF
Loadsol2 OFF
Unloadsol2 ON
LLS2 OFF
LIQinjct 2 OFF
§ Starting Specifications:
(1) Switch on power supply. The unit goes in power up

mode. System stays in this mode for a time period as
specified in MCS set point 23(factory set=90s). In
this state, all relay outputs are turned OFF.
(2) After the power up delay, the system-1 goes in ON
state. Controller will initialise & monitor Power Supply
stability for 90 seconds. When this happens, the
condition of the relay outputs is as follows:

Main1 ON
Delta1 OFF,ON after time
corresponding to set
point factory set=3s
Loadsol1 OFF
Unloadsol1 ON
LLS1 OFF
LIQinjct 1 OFF
(3) Controller will check for any anti-cycle (fault) timers

leftovers
(4) During start-up, the MCS Controller will monitor

cooling demand as per Leaving water temperature
(set point 1), condition of Flow Switch, Anti Freeze
and other Compressor Safeties and start compressor
of the first system with fast unloading control logic
for initial 30 seconds.
(5) Compressor will pump down till the suction pressure

reaches 60 psig. During pump down the liquid line
solenoid is kept de-energized (closed). Once suction
pressure drops to 60 psig Liquid Line Solenoid (LLS)
valve is opened. Even though the suction pressure
does not reach the set value, the LLS will be opened
after 5 seconds.
(6) Depending on set point and actual leaving water

temperature, the system shall load or unload. The
operation of the load or unload solenoid valves is as
under:
User's Manual 43
SV1 (Unload) SV2 (Load)
Start ON ON/OFF
Loading OFF OFF
Unloading ON ON
Stable OFF ON
(7) When compressor-1 is at 100 % load, then demand

for the second system will be activated based on
load requirement. Compressor-2 shall be ON when
compressor-1 is at 100% load or even if compressor-
1 is unable to load further due to any of the safeties.
(8) Compressor-2 is started as per the sequence given

in steps 4 to 7.
(9) Compressor-1 will get unloaded and then both the

compressors will load/ unload simultaneously
approximately at the same percentage (unless any
of the compressors goes in safety hold).
(10) To shut down chiller switch off rotary switch provided

in panel. Initially system-2 & then system –1 will go
into shutdown mode.
(11) MCS has ‘minimum run time equalization’ logic option

(set point 103 should be 0 and set point 104 should
be 1). The compressor, which runs for minimum time,
will be stat first during next operation.
During normal running of compressors, following

safety parameters are monitored:
Sr. Set Point Trip Delay Default Setting

No. Description (Seconds)
1 Hi amps 2 110 %
2 Low amps 5 15 %
3 Low suction 90 48 psig
4 Low gas / LSV FLT 10 20 psig
5 High discharge 1 275 psig
6 Low discharge 40 100 psig
7 Low oil differential 180 50 psig
8 Unsafe Oil 4 25 psig
9 Anti freeze * 5 39oF

* In case of Anti Freeze, both Circuits of the Chiller
will be locked out.
To avoid nuisance tripping during compressor start

up, following Initial Bypass/ Time Delay adjustment
procedure is observed:
Set Point Bypass Time Delay

Description Adjustment *
Hi amps For first
3 seconds —-
Low amps For first
3 seconds —-
Low suction During pump 2 minutes 45 seconds
down for first 5 minutes of
Compressor running.
Low gas / LSV FLT —- 4 seconds, for first 5
inutes of compressor.
Low oil differential First 5 seconds 25 psig for next
30 seconds.
• All the above parameters for time delay adjustment

are as per default set points.
§ Operating Specifications:
The following are the Operating Specifications and default set points:
- Leaving water temperature is set at 45°F with a control
of ±0.5 °F.
- Liquid injection system switches on at Discharge
Temperature of 165 °F
- The delay between the Star and Delta connection is
set at 3 seconds.
- Low-pressure setting is at 48 psig and High-pressure
setting is at 275 psig.
- Anti Freeze Thermostat setting is at 39 °F.
NOTE:
Lock out delay: If any critical fault reoccurs within 2 hours of
running, the controller will trip the unit and would go in lock out,
after which manual intervention is required to diagnose and rectify
the fault.
User's Manual 45
FAST UNLOADING
For screw compressors, this state is entered when the compressor
is turned on. The system will remain in this state for 45 seconds
while the “fast unloader” and unload points are on. This is to ensure
that the screw is unloaded.
COMPRESSOR IS LOADING
For screw compressors, this state is when the load solenoid is
being pulsed to increase the cooling capacity of the circuit.
COMPRESSOR IS UNLOADING
For screw compressors, this state is when the unload solenoid is
being pulsed to reduce the cooling capacity of the circuit by moving
the slide valve.
Starting Current of the compressor

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

Current (LRA), A current, A
BSC-075A 685 230
BSC-105A/ BSC-105W 735 245
BSC-125W 965 325
BSC-145A/ BSC-145W 1100 370
BSC-160A/ BSC-160W 1480 495
BSC-210A/ BSC-210W 1760 590
A. The starting for the Y start is usually set at 4 ± 1 second, and

the maximum allowable shift time from Y to D is 40 milliseconds.
It is advisable to change the Y starting time prior to different working
condition in the job site in accordance with the current variation of
Y starting. It is recommended that the duration of Y starting is not
over 15 seconds at the step of 25% capacity.
The running restraint of compressor

1) Compressor restart frequency
The restart counts for the models BSC - 125W, BSC - 105W,
BSC - 145W, BSC - 160W and BSC - 210W are recommended
below 2 times in one hour
2) The starting for the Y start is usually set at 3 seconds and the
maximum allowable shift time from Star to Delta is 40 Sec.
However it is recommended that the duration of the Y starting
is not over 15 seconds at the step of 25% capacity.
3) Supply power
Long term running => +5%
Instant Running => +10%
Frequency: +2 %
Phase current unbalance: The difference in phase current between
the biggest phase current differential and smallest phase current
differential is required to be less than 3 %
4) Phase voltage unbalance: +2.25 %
5) Range of ambient temperature: -10 Deg. C to 55 Deg. C
6) The control voltage is normally 220 V
7) Protection switch
The table below shows the list of protection switches, which are
essential to protect the compressor and operate safely
Protection Switch Set Point

Motor winding Cut out 120 Deg. C
temperature protector Cut in 75 Deg.
High discharge Cut out 110 Deg. C
temperature protector Cut in 60 Deg. C
Phase reversal protector Phase reversal when power on
Hi Low pressure protector Highest pressure 25 Kg/Sq.cmg
Phase failure protector Phase failure when compressor
starting or running
Motor overload relay Set by a related application
value, any setting should be
tripped in 15 sec.
Hi-Low Voltage protector Rated Voltage + 15 %
Oil level switch Oil level lower than the
floating ball
Oil pressure differential switch Cut out 2.5 Kg/Sq.cmg
User's Manual 47
Troubleshooting
Shut Down of Compressor
1) Shut down the Chiller by switching off the required switch provided in the Panel.
2) Stop the chilled water supply to the Cooler.
In case of long term shutdown required because of the retrofit of the system or overhauling
of the compressor follow the above instructions after reinstallation of the system before
starting up again to ensure the safety and good running condition of the compressor
Troubleshooting
SR. PROBLEMS PROBLEM CAUSE
NO.
1 Sudden trip of motor 1) Low suction pressure or high suction temperature
thermister / Sensor (lack of refrigerant or clogged suction filter) or high
suction superheat.
2) Motor overload. Liquid injection system failure.
3) Motor winding thermister failure.
4) Unstable electrical system or failure.
5) Bad motor coil winding causing the motor
temperature to rise rapidly.
2 Compressor unable 1) Low ambient temperature or High oil viscosity.

to load
2) Capillary clogged
3) Modulation solenoid valve clogged or burnt.
4) Internal built in oil lines clogged.- Clean the oil line.
5) Oil filter cartridge clogged. - Clean Oil
filter cartridge.
6) Piston stuck up
3 Compressor unable 1) Modulation solenoid valve clogged or burnt.-

to unload repair Solenoid valve.
2) Piston rings worm off or broken, or Cylinder
damaged resulting leakage.
3) Insufficient lubricant. Add Lubricant
4) Leakage at discharge cover plate end side.
5) Solenoid valve voltage incorrect.
6) Capacity control logic unsuitable piston stuck-up.

NO
4 Poor insulation value 1) Bad compressor motor coil
of motor 2) Motor power terminal or bolt wet of frosty
3) Motor power terminal or bolt bad or dusty
4) Bad insulation of magnetic contactors
5) Acidified internal refrigeration system
6) Motor coil running for a long time continuously
under High Temperature
7) Compressor restart counts too many times
5 Compressor starting 1) Slide valve piston unable to back to its 25 %

failure or star-delta original position.
starter shifting failure
2) Voltage incorrect
3) Voltage drop too high when starting the
compressor or Magnetic contactor failure.
4) Motor broken down
5) Phase failure or phase reversal.
6) Motor thermistor sensor trip.
7) Incorrect power supply connection.
8) Star delta starter timer failure.
9) Discharge stop valve closed.
10) Improper connection between the terminal
of star delta wiring.
11) In anti recycling period.
6 High Suction Pressure 1) Cooler water flow rate is higher than the rated
flow rate - Maintain the rated flow rate.
2) Cooler water inlet temperature is higher than rated
- Supply the rated temperature cooling water at
cooler inlet.
3) System is overcharged - Remove the excess
refrigerant.
User's Manual 49
NO.
7 High discharge 1) Condenser problem.- Check cooling water

temperture temperature or Condenser Tubes clogged.
2) Refrigerant overcharged - Remove excess refrigerant.
3) Air in refrigeration syste - Air should be vented
during start-up and periodically.
4) Insufficient lubrication oil.-Add the lubrication Oil.
5) Damaged bearing, mutual friction of rotors.
6) High compression ratio.
7) Improper expansion valve.
8) Improper Vi value. No system extra cooling devices.
(Liquid Injection or oil cooler)
8 Low suction pressure 1) Cooler water flow rate is lower than the rated flow
2) Cooler water inlet temperature is lower than the

rated temperature.
3) System is undercharged. Charge the refrigerant
9 High suction 1) High suction Pressure.- Refer Sr. No.-6

temperature
10 Abnormal vibration 1) Damaged bearings

and noise of compressor
2) Phenomenon of liquid compression
3) Friction between rotors or between rotor

and compression chamber
4) Insufficient lubrication oil
5) Loosen internal parts
6) Electromagnetic sound of the solenoid valve
7) External debris fallen into the compressor.

Maintenance
Maintain the Chiller periodically in accordance with the schedule shown in table below
Water Cooled Screw Chiller Maintenance Schedule

Check Points Daily Weekly Monthly Quarterly Annually
General
Log parameters X
Check Water Level in expansion tank X
Check Water Level in the Cooling Tower Sump X
Check for any refrigerant leaks through X
flare joints, valve glands etc
Check and clean refrigerant strainer X
Check condition of refrigerant drier X
Clean Cooling tower sump X
Clean water line strainers X
Check quality of water X
Check healthy operation of safety devices X
Check tightness of all electrical terminations X
Top up grease for all motors X
Apply thermal paste on the temperature sensors X
Check for any abnormal noise and vibration X
Check liquid line sight glass/moisture indicator X
Check water pressure drop in Cooler X
Check water pressure drop in Condenser X
Analyse Oil sample X
Check suction superheat X
Check crank case heater X
MCS Panel
Check program settings X
Check fault history X
Check load/unload furnction X
Check pump down function X
Check Clock X
User's Manual 51
Maintenance schedule : Compressor
Check Points Time period
Compressor 1000 2500 5000 10000 15000 20000 25000 30000

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

Spare Parts Lists
SPARES FOR LCWX1-104
Item BAAN Description QTY. Specification
CODE Nos.
Compressor Spares
CDHAI0140 BSC-105W (RC16) Screw Compressor for R 22 1
3105-1143A Oil Filter 1 φ56*200L
3101-1051B Oil Heater (220V) 1 220V, 150W
3105-1146A Inner Gasket of Oil Filter Flange 1 TEFLON 1.5t
3101-1148A-3 Outer Gasket of Oil Filter Flange 1 REINZ-AFM 34, 1.5t
4401-30 Solenoid Coil 2 220V
4401-30 Solenoid Valve (Stepless Control) 2 2743K0R30-4344
SDH12223DS
3101-1003A Solenoid Valve Gasket 2 NOK,1515SPS
4804-01 Oil Sight Glass (O-Ring Included) 1 ALCO
3105-1004A-3 4" Gasket 1 REINZ-AFM 34, 1.5t
3105-1024C Suction Filter 1 φ110*103L
3105-1004A-3 Gasket for 4" Flange 1 REINZ-AFM 34, 1.5t
4405-56 Oil Level Switch 1 RFS-8-2, 1200mm
CDSPI0710 Blue Star ACS Oil 15 Litres
Controls & Accessories spares
EAECI0010 Sporlan SEH-100 Electronic Expansion Valve 1
EAGAI0040 Sporlan Interface Board IB6 1
EASBI0140 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection 1
EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil for Liquid Injection 1
FEDBI0140 CTG Dehydrator (Core) 3
SAMAI0010 Indicator Moisture 1
VAAAZ2106 Sporlan Expansion Valve BBIVE-4 for Liquid Injection 1
Electrical spares
EAMAZ0470 MCCB Siemens - 3VL3720, 200A 1
EAMAZ0480 Siemens Contactor, 3TF50,110A, 220 VAC 2
EAMAZ0490 Coil for Contactor, 3TF50,110A 2
EAMAZ0510 Coil for Siemens Contactor, 3TF47, 70A ,220 V 1
EAMAZ0520 SPPR, GIC SM-101 1
EASHZ0060 4 Positionn Selector Switch - Salzer 61198 ON/OFF 1
EAMAZ0205 MCB - 4A, 2 Pole, 415V, 3KA, for controller 1
Micro Control Panel spares
EATFZ0010 Constant Voltage Transformer, 150 VA 1
EBMBI0040 MCS Board Panel Mount Type- MCS 8 (230v.) 1
EBMBI0140 SI-16 Extension Board, 230V. 1
SATAI0075 Pressure Transducer with 20' Cable (0-200psig)- TI 200-20 1
SATAI0080 Temp. Sensor with 20' Cable -MCS- T100-20 4
EATDI0060 Current Sensor (CT) 0 to 250 amps. - CT-250 1
EAMAZ0550 INT 69 module 1
EAMAZ0560 E PROM chip 1
EAGAI0050 Control Panel Fuse 1
User's Manual 53
Item BAAN Description Qty. Specification
CODE Nos.
Compressor Spares
CDSAI0145 BSC-125W (RC17) Screw Compressor for R 22 1
3105-1143A Oil Filter 1 φ56*200L
3101-1051B Oil Heater (220V) 1 220V, 150W
SDH12223DS
SAMAI0010 Indicator Moisture 1
Electrical spares

CODE Nos.
Compressor spares
CDSAI0150 BSC-145W (RC18) Screw Compressor for R22 1
3105-1143A Oil Filter 1
3101-1051B Oil Heater (220V) 1 220V,150W
3101-1006A-3 Gasket (For Motor Cable Cover Plate) 1 REINZ-AFM 34, 1.5t
SDH12223DS
4804-01 Oil Sight Glass (O-Ring included) 1 ALCO
4404-056 Oil Level switch 1 RFS-8-2, 1200 mm
Controls & Accessories Spares
EASBI0145 Sporlan SV B10 S2 Solenoid Valve Coil 1
Electrical Spares
EAMAZ0470 MCCB 3VL3725, 250A 1
EAMAZ0480 Siemens Contactor 3TF49 / 85A ., 220 VAC 1
EAMAZ0490 Coil for Contactor,3TF49/85A ,220 V 1
EAMAZ0500 Siemens Contactor,3TF51,140A , 220 VAC 2
EAMAZ0510 Coil for Contactor, 3TF51, 140A ,220 V 2
Micro Control Panel Spares
EBMBI0040 MCS Board Panel Mount Type- MCS 8 (230V.) 1
EBMBI0140 SI-16Extension Board, 230V. 1
SATAI0070 Pressure Sensor with 20' Cable (0-500psig)- TI 500-20 2
SATAI0080 Temperature Sensor with 20' Cable -MCS- T100-20 4
User's Manual 55
Item BAAN Description Qty.Nos. Specification
CODE
Compressor spares
3101-1051B Oil Heater (220V) 1 220V,150W
SDH12223DS
Electrical Spares

Item BAAN Description Qty. SPECIFICATION
CODE Nos.
Compressor spares
CDSAI0180 BSC-210W (RC-20) Screw Compressor for R22 1
3105-1004a-3 4"Gasket For Discharge Flange 1 Reinz-Afm 34, 1.5t
3107-1143a Oil Filter 1
3101-1051B Oil Heater (220V) 1 220V,150W
3107-1146a Inner Gasket Of Oil Filter Flange 1 Teflon 1.5t
3101-1006a-3 Gasket (For Motor Cable Cover Plate) 1 Reinz-Afm 34, 1.5t
4401-30 Solenoid Coil 2 220v
4401-30 Solenoid Valve (Stepless Control) 2 2743k0r30-4344
Sdh12223ds
3101-1003a Solenoid Valve Gasket 2 Nok,1515sps
3107-1054a Gasket For Suction Filter 1 φ161.5*1.5t
3107-1024c Suction Filter 1 φ159*210l
Electrical Spares
MCCB 3VL 4731, 315 A 1
EASHZ0060 4 Position Selector Switch - Salzer 61198 ON/OFF 1
EAMAZ0480 Siemens Contactor 3TF53, 205A ., 220 VAC 2
EAMAZ0500 Siemens Contactor,3TF52, 170 A , 220 VAC 1
EAMAZ0510 Coil for Siemens Contactor, 3TF52,170A, 220 V 1
User's Manual 57
CODE Nos.
Compressor Spares
CDSAI0140 BSC-105W (RC16) Screw Compressor for R 22 2
3105-1143A Oil Filter 2 φ56*200L
3101-1051B Oil Heater (220V) 2 220V, 150W
SDH12223DS
EASBI0145 Sporlan SV B10 S2 Solenoid Valve for Liquid Injection Coil 2
FEDBI0140 CTG Dehydrator (Core) ( L Type Strainer) 6
Electrical spares
EBMBI0040 MCS Board Panel Mount Type- MCS 8 (230V) 1
SATAI0075 Pr. Transducer with 20' Cable (0-200psig)- TI 200-20 2
EAGAI0040 Interface board IB6Q Sporlan 2
EBMBI0050 MCS I/O Expansion Board (230 V) 1

CODE Nos.
Compressor Spares
CDHAI0140 BSC-105W (RC16) Screw Compressor for R 22 1
3105-1143A Oil Filter 1 φ56*200L
3101-1051B Oil Heater (220V) 1 220V, 150W
SDH12223DS
3101-1051B Oil Heater (220V) 1 220V,150W
SDH12223DS
Electrical spares
User's Manual 59
CODE Nos.
Compressor Spares

CODE Nos.
Compressor spares
3101-1051B Oil Heater (220V) 2 220V,150W
SDH12223DS
Control & Accessories Spares
Electrical Spares
User's Manual 61
Item Baan Description Qty. Specification
CODE Nos.
3101-1051B Oil Heater (220V) 2 220V,150W
3107-1005A-3 3'’ Gasket For Discharge Flange 2 REINZ-AFM 34, 1.5t
SDH12223DS
3107-1024C Suction Filter 2 60mesh
3107-1004A-3 Gasket for Suction Filter Flange 2 REINZ-AFM 34, 1.5t
3101-1052C Oil Heater 2 φ12.7,220V*300w
Electrical Spares

CODE Nos.
3101-1051B Oil Heater (220V) 1 220V,150W
SDH12223DS
3105-1004a-3 4"Gasket For Discharge Flange 1 Reinz-Afm 34, 1.5t
3107-1143a Oil Filter 1
3107-1146a Inner Gasket Of Oil Filter Flange 1 Teflon 1.5t
3101-1006a-3 Gasket (For Motor Cable Cover Plate) 1 Reinz-Afm 34, 1.5t
4401-30 Solenoid Coil 2 220v
4401-30 Solenoid Valve (Stepless Control) 2 2743k0r30-4344
Sdh12223ds
3101-1003a Solenoid Valve Gasket 2 Nok,1515sps
3107-1054a Gasket For Suction Filter 1 φ161.5*1.5t
3107-1024c Suction Filter 1 φ159*210l
Electrical Spares
User's Manual 63
CODE
MCCB 3VL 4731, 315 A 1
EAMAZ0480 Siemens Contactor 3TF53, 205A ., 220 VAC 2
EAMAZ0500 Siemens Contactor,3TF52, 170 A , 220 VAC 1
EAMAZ0510 Coil for Siemens Contactor, 3TF52,170A, 220 V 1

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

Return To : Manufacturing Unit - Thane
Product : Water cooled Screw Chiller
Chiller Model :
Sr. No. :
Customer Name : Location :
Date :
Observation Comments Details Of Defects
Quality Of Packing OK / Damaged
Receipt of Documents
- Packing List Yes / No
- Test Report Yes / No
- Truck No.
Condition Of Parts :
- Frame Work Ok /
- Compressor Ok /
- Condenser Ok /
- Cooler Ok /
- Electrical Panel Ok /
- Refrigerant Piping Ok /
- Controls Ok /
- Idle Pressure Ok /
Remarks :
Checked By
For Factory Use :
- Date Of Receipt : - Action By :
- Comments :
User's Manual 65
The field feed back card as per the format below shall be send to factory
after Commisioning of the Chiller
Field Feed Back Card - Commissioning of Chiller at Site

Product : Water cooled Screw Chiller
Chiller Model :
Sr. No. :
Customer Name : Location :
Engineer’s Name :
Observation Comments Remarks
Installation/Precommissioning Checks :
- Unit Installed and levelled Ok /
- Installation Ok /
- Condenser water connection terminated Ok /
properly with isolation required
- Chilled water connection terminated
properly with isolation required Ok /
- Electrical connection with Earthing
terminated properly Ok /
- Condenser water and Chilled water system
properly flushed Ok /
- Water Quality checked Ok /
- Meggering of Cabling done Ok /
- Condenser water and Chilled water Pump
commissioned Ok /
Water flow adjusted to the design flow by
checking pressure drop Ok /
Water flow switches connected with
electrical panel Ok /
Check up Voltage Ok / Starting 400 ± 10% Running 400 ± 10%
Commissoned the Chiller Ok / Long term running 400 ± 5%
Noise Level Ok /
Vibration Ok /
Check Current Ok /
Testing done at site Ok /
Performance data as per format Ok /
- Commissioning Date
- Commissioning By
Remarks :
Note : Warranty will be valid only after receipt of this card at the factory
For Factory Use :
- Date Of Receipt : - Action By :
- Comments :

Hand over the Chiller to the Customer as per the format and establish Warranty
COMMISSIONING & HANDING OVER REPORT
Our Ref: Date:
BLUE STAR LIMITED Cust. Ref.
PURCHASE ORDER Date:
Date:
Equipment : Blue Star make Cooled Screw Chillers
Model:
Sl.No.
Customer Name & Address Programme Place Date Time
Departure
Arrival
Work started
Work completed
Departure
Equipment location : Arrival
Call made by Received by: Date Time
Nature of service Materials used Qty.
COMMISSIONING
Service rendered
Supplied,Installed,Tested and commissioned Blue Star make Water Cooled Screw Chillers and they are
put into regular operation. The Model No. & Serial Nos. of the units are given below :
CHILLER MODEL :
SERIAL NO. OF MACHINE NO.1 :
SERIAL NO. OF MACHINE NO.2 :
The chillers are handed over to the customer for the beneficial use.
Equipment warranty expires on : Attended by: Blue Star Ltd. Signature:

For office use: The above equpiment has been installed &
commissioned to our satisfaction.
Other comments (if any).
o To bill o Not to bill Date : Customer’s Stamp & Signature

5091-10C Registered Office : Kasthuri Buildings, Jamshedji Tata Road, Mumbai 400 020
User's Manual 67
Recommended water quality standards:
Test items Chilled water Cooling Tower Make up
quality water quality water quality
pH 7.2 - 8.5 7.2 - 8.5 6.0 - 8.0

Total hardness
(CACO3) ppm Max. 80 Less than 200 Max. 50
Total Alkalinity
(CACO3) ppm Less than 100 Less than 100 Less than 80
Chloride Ion (ppm) Less than 50 Less than 200 Less than 50
Total Ion (Fe) ppm Less than 0.3 Less than 1.0 Less than 0.3
Silica (SiO2) ppm Less than 30 Less than 50 Less than 30
Ammonium Ion
Less than 0.2 Less than 1.0 Less than 0.2
ppm

Log report
Customer's Name
Date:
Time
S.No Description Units 10.00 12.00 14.00 16.00 18.00
1 Voltage R-Y Volts
Voltage Y-B Volts
Voltage R-B Volts
2 Current - R Amps.
Current - Y Amps.
Current - B Amps.
3 Supply Frequency Hz
4 Suction Pressure comp. PSIG
5 Discharge Pressure comp. PSIG
6 Compressor Current. Amps.
0
7 Cooler Entering Water temp. F
0
8 Cooler Leaving Water temp. F
9 Cooler Pressure drop PSIG
10 Cooler water Flow rate US GPM
0
11 Condenser Entering water temp. F
0
12 Condenser Leaving water temp. F
13 Condenser Pressure drop PSIG
14 Condenser water Flow rate US GPM
0
15 Refri. System temp. - Suction F
0
16 Refri. System temp.-Discharge. F
0
17 Refri. System temp. - Liquid F
User's Manual 69
WARRANTY CLAIM FORM
For Blue Star Water Cooled Screw Chillers
A copy of this form is to be filled in case of the Chiller failure, by BSL Engineer)
Location(City) ....... Date ....

Chiller Model No: Chiller Serial No.
Date of despatch Date of commissioning
Warranty commencing date Warranty expiry date
Application in which equipment is used
Customers Name and Address Dealers Name and Address
Starting Problem o Yes o No
Noise at Starting o Yes o No
Noise while running o Yes o No

Compressor: o High Noise o Vibration o Condenser/Oil cooler o Unbalanced
Fan: o High Noise o Vibration o Shaft bend

Any mounting bolts loose: o Yes o No
Electrical problem o Yes o No
Voltage o Yes No o
Insulation resistance (Megger test)…………….....…….. Ohms
Motor o Jammed Bearing noise o Burnt out o

Any leakage in the condenser coil o Yes o No
Any vibration in piping o Yes o No
Less cooling in cooler o Yes o No
Checked Water flow rate o Yes o No
Checked Compressor working in full Load o Yes o No
High Ambient Temperature o Yes o No
Operating pressure checked o Yes o No
Shortage of refrigerant o Yes o No
Air cooled condenser coils clogged o Yes o No
All the fans working o Yes o No
Signature & Seal of Customer Signature & Seal of BSL Engineer

Date . Date .
(For factory use only)

Claim settled o Credit advice No. ........................... Claim rejected o
Reasons for rejection ....................................................................................
Settlement authorised by: .. Date .

Warranty
Blue Star Screw Chillers carry a warranty for a period of 12 months
from the data of commissioning or 15 months from the date of
delivery, whichever is earlier, unless stated otherwise in the contract
of sales.
Terms of Warranty
Blue Star extends a comprehensive warranty on its systems, which
entitles the customer to the following
1. Repair / reconditioning, by BSL / BSL Dealer, through whom
the machine has been purchased, of any part of the equipment
found defective within 12 months from the date of commissioning
or 15 months from the date of despatch whichever is earlier.
2. The warranty is valid only if:
2.1. Installation and commissioning is taken care of by BSL/their
authorised persons.
2.2. The equipment is operated as per the Company’s operating
instructions.
3. The above said warranty does not cover the following:
3.1 Any leakage of Refrigerant due to improper operations
4. This warranty is not valid if any repair and/or modifications are
carried out by the customer himself or his representative without
written concurrence from Blue Star Limited.
5. The warranty extended herein is in lieu of all implied conditions/
warranties under the law and is confined to the repairs or
replacements of defective parts and does not cover any
consequential or resulting liability damage or loss arising from
such defect. Furthermore, the warranty in no case, shall extend
to the payment or any monetary consideration whatever of the
replacement or return of the Screw Chiller as a whole
6. Any repair/ replacement shall not extend the overall warranty
period as specified above.
7. The cost of transportation of material and of persons beyond
Municipal jurisdiction shall be borne by the customer.
8. This warranty may be read in conjunction with any other warranty
on the installation as a whole, if the Screw Chiller is supplied
as part of a Project.
User's Manual 71
For any
assistance,
CALL:
Blue Star Service:
Ph: ............................................................
Cell: ..........................................................
Blue Star Dealer:
Ph: ............................................................
Cell: ..........................................................
Blue Star Regional Manager:
Ph: ............................................................
Fax: ..........................................................
Blue Star’s/Dealer’s engineer to fill

above details before handing over
this Manual to customer.

Service Centres
EAST SOUTH WEST

BHUBANESHWAR BANGALORE BHOPAL
3A, Satya Nagar, Salarpuria Centre II “Star Arcade”, 2nd Floor
2nd Floor, No. 13, Ward No. 67 Plot No.165A & 166, Zone-I
Bhubaneswar - 751 007. Koramangala Industrial Layout Maharana Pratap Nagar
Tel: (0674) 2508270 / 2508239 Koramangala Bhopal - 462 011.
Bangalore 560 095. Tel: (0755) 2553378 /
GUWAHATI
New Star Freeze Building Tel: (080) 51854200 / 51854000 5273378 / 79
2nd Floor,
Opp. Kunjalata Bibah Bhawan, CHENNAI GOA
G. S. Road, 104, ‘Garuda Building’, 1st Floor, Flat No.1
Guwahati - 781 005. Cathedral Road, Vaibhav Apartment
Tel: (0361) 2340619 / 2340620 Chennai 600 086. Vidya Nagar Colony
Tel: (044) 52444200 Miramar, Panjim, Goa 403 001.
KOLKATA 28116707- 8 Tel: (0832) 2461671 / 2462087
7, Hare Street
Kolkata 700 001. KOCHI MUMBAI
Tel: (033) 22134200 / 22106609 39/5766, Tharakandam Estate Blue Star House
Kurisipally Road 9A, Ghatkopar Link Road
NORTH Kochi 682 015. Saki Naka, Mumbai 400 072.
Tel: (0484) 2356139 / Tel: (022) 56684200 / 56684000
CHANDIGARH
2357933 / 2357934
SCO 1, Madhya Marg, Sector 26 NAGPUR
Chandigarh 160 019. 219, Bajaj Nagar, 1st Floor,
Tel: (0172) 2790482 / 5004000 SECUNDERABAD South Ambazari Road,
207, Sikh Road Nagpur 440 010.
JAIPUR Bantia Estates
33, Kiran Path Tel: (0712) 2229244 / 2249000
Secunderabad 500 003.
Suraj Nagar West, Civil Lines Tel: (040) 27847553 /
Jaipur 302 006. PUNE
27842057-58 / 27815469
Tel: (0141) 5179359 / 2225326 201/A, Nityanand Complex
TRIVANDRUM 1st Floor, 247/A
LUCKNOW T.C. IX/1490 Bund Garden Road
B-140, Nirala Nagar ‘Chandrika’, Sasthamangalam Pune 411 011.
Lucknow 226 007. Trivandrum - 695 010. Tel: (020) 26113031 /
Tel: (0522) 2787274 / 2786172s Tel: (0471) 2720025 / 2720065 26127230 / 26122307
NEW DELHI VISAKHAPATNAM VADODARA

E-44/12 Okhla Ind. Area 47-12-6/7 Ramakrishna Chambers
Phase II, Ohkla 2nd Floor 7th Floor, Productivity Road
New Delhi - 110 020. Amaravathi Complex
Tel: (011) 41494200 / 000 Alkapuri, Vadodara 390 005.
Dwarakanagar Tel: (0265) 2338561 /
Visakhapatnam 530 016. 2332021 / 2332022
Tel: (0891) 2748405 / 2748433
* 4 - ) 6 0 - - ) 5 ;
User's Manual 73
* 4 - ) 6 0 - - ) 5 ;

Manual Screw Chiller Water Cooled PDF

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Copyright:

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Manual Screw Chiller Water Cooled PDF

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Water Cooled Screw Chiller

No part of this publication may be reproduced in any

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

Since ASHRAE standards use the FPS system, FPS nomenclature

Published by Blue Star Limited, Airconditioning Projects Division.

For restricted circulation only. Not for sale.

Technical Specification ............................................................................................. 8

Electronic Expansion Valve ...................................................................................10

MCS Panel ..............................................................................................................13

MCS Panel Troubleshooting ..................................................................................24

Rigging and Installation .........................................................................................29

Screw Compressor .................................................................................................32

Pre-Start Check up, Operation and Commissioning ..........................................40

Spare Parts Lists ....................................................................................................53

Field Feedback Card .............................................................................................65

Commissioning and Handing Over .......................................................................67

Water Quality ..........................................................................................................68

Log Report ..............................................................................................................69

Warranty Claim Form .............................................................................................70

GA Drawing..........................................................provided on last inner wrapper

Electrical Wiring Diagrams..................................provided on last inner wrapper

2 Screw Chiller (Water Cooled)

Water Cooled condenser

Refrigerant liquid injection

4 Screw Chiller (Water Cooled)

Micro Control Panel

Single Phasing SPPR module Current sensing

6 Screw Chiller (Water Cooled)

LIQUID NOM. CAP. IN TR

CHILLER NO. OF COMPRESSORS

SR DESCRIPTION UNIT MODEL

SR DESCRIPTION UNIT MODEL

8 Screw Chiller (Water Cooled)

Valve operation Retaining Nut

4-Pin Feed Through

10 Screw Chiller (Water Cooled)

Motor type : 2 phase permanent magnet,

12 Screw Chiller (Water Cooled)

PC Support Software for

Micro Control Panel Network

Micro Control Micro Control Micro Control

Micro Control Panel

14 Screw Chiller (Water Cooled)

Micro Control Micro Control Micro Control

Micro Control Panel

To install and run the program we suggest the following system

Front End System Requirements

Minimum System Required to Run Program

16 Screw Chiller (Water Cooled)

Function View Service Supervisory Factory

Sensor offsets No Yes Yes Yes

Sensor diagostics No Yes Yes Yes

Clear alarm history No No No Yes

Clear point information No No No Yes

Date & time set Yes Yes Yes Yes

Day of week set Yes Yes Yes Yes

Change no flow lockout or shut down No No No Yes

Change rotate yes or no No No No Yes

Change manual/auto settings No No Yes Yes

Change setpoint values* No Yes Yes Yes

Change operating schedules no Yes Yes Yes

Change holiday dates no Yes Yes Yes

Lock out reset Yes Yes Yes Yes

MCS CONTROLLER Indicates Micro in constant reset.

13. Bearing sets cover plate 30. Refrigeration Lubricant