Water-cooled Chiller Systems
Contents
1. Blue Star s Dealer s Engineer to fill above details before handing over this manual to Customer December 2010 5k2. CONTROL ALvE RELIEF 72 _ weuweusscroucuuen comeron ron comeram ea 2 _ 7 2 TTT mseommboeemws TTT owo O _ CNTRLR LCD XWC2S 011 1 7 _ m m N N gt 82 TECHNICAL MANUAL BLUE STAR Water cooled Chiller Model XWC2S 026A SAPCODE DESCRIPTION HECD BCH011 00 YCD14 amp T CONDENSER HEDX BCH013 00 VAPK 13D002 00 FBAN GT004 00 CMSCB154L3120 HTFL BL100006 00 RODR 00 ROM 15001 00 00 ROPR 00001 00 ELCN 040001 00 FTON WBB006 00 HANU I6FL05 01 FTON FOM15001 00 EATF20040 20050 RCPR LCB DA80 00 PRESSURE CONTROL YK 01L 400 035G050G ROPR ACB DB162 00 83 BLUE STAR SCROLL CHILLER SYSTEMS Water cooled Chiller Model XWC3S 039A SAPCODE DESCRIPTION HECD BCH011 00 YCD14 amp T CONDENSER FBAN GT00400 GP VALVEANGLE 14MXIM4M CMSCB154L31201 comp scrousmiss4nm HIFLBLI0000500 CRANKCASE HEATER SM185 0VI F urERDRERONDOLSS s ROMI 15001 00 MOISTURE INDICATOR SA155S 8 RomvrDExmo0 EXPANVALVETDEX1Y doe ROPRICB DABD00 PRESSURE CONTROL YK O1L 400 03560506 RCPR ACB DB162 00 PRE CONTROL WIC YK 01H 400 290P230X 86
3. 7X H3MOd TW 38V AZt NOLLAVD SNIMIM M3MOd OL Aldd 53002 8 0102 2 SON WNIWH31 OL QNOdS3HHOO OST A3HL 1108 01 0 38 TWHS SHOSS3HdWOO 9NUMVIS 380338 SI JHL 1 38NSN3 INNIA 59 38M M 318V JYV SINN OL INBOVPOV SH3BMN SION wonooiddo euuq eqooiiddo ejoN DU 9 ELS EIS ID B EI Es iie e MUS GID 8 8 mos 9 a c 3 a 2 y 8 Bae I a L09 08 990 ZH OS Hd OVAGIY AlddnS 9NIWWOONI V6S0 SVOMX I9POIN J9 IuS 63 SCROLL CHILLER SYSTEMS VC05V08 99C BLUE STAR HN 211 L 13170 M31VM 1 30 HUM 19II 1009 B N 2 1 1 NJA 395 H X fc 055344 Vv HIV I pOIN V 64 BLUE STAR TECHNICAL MANUAL 66 909 990 1 15 247 010 580 1 T on wear E 3007109 0V18 A389 NI ANV HIM LJJNNOO LON 00 3M8 NI SI 20 AZt TIV NOLLNVD 3 1108 OL 66404 990 03 M NIEVUNS
4. 9MV9M 0134 303 38 Ol SH38MON 318YO ANO 1108 ML SNIHLNV3 OL 4 OL AlddY 3009 80709 M3MOd AYOLA TWHS 5405539 0 SON WNIMH3L OL ONOdS3NNOO 05 A3HL oz 7 ONUNVIS 380438 318YO SINN Ol INSOW OY SH3OWON L AVHL 3HnSN3 any os Wena LJ anv 00 wna WHOS 9 i 90 8 mwos 9 OROF B ZH OG Hd OWASLY AlddNS 9NINWOONI V 802204 990 ON 9NIMYHO V9c0 ScCOMX I PON I III 59 BLUE STAR SCROLL CHILLER SYSTEMS DRAWING NO 366 B07558C WATER COOLED SCROLL CHILER URET T T 366 B07558C ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED COOLER WATER OUTLET SIZE 3 NB VICTAULIC JOINT Model GA XWC3S 039A 9 9 D gt a lt COOLER WATER 14 HOLES 6 FOR FOUNDATION BOLTS INLET SIZE 3 NB VICTAULIC JOINT FRONT WALL 1 25 COND CLEANING REF amp COND WATER CONN END REAR TO WALL 2 5 M 0 6 M AILO EN CONTROL NOTES COMMENDED MINIMUM CLEARANCES ARE AS FOLLOWS 60 BLUE ST
5. HOVA 6Y 099 v HOLVIOSI 399 MHL WIN 6L AHOLOVJ WOYJ GILVINSNI 431009 iit W080 SATOVX 090 SAZOWX Z WBPO SAZOVX ALD 935 V080 SAZOVX 090 SAZOVX 7 80 NNO2 oio LIINI H31VM W3TIIHO NOILWA313 AIND 1311 0 H31VM YATIIHO 8N F 080 090 SAZOVX L 8 0 5 2 866 SACOVX 19III 09 00 IIV V I PON 70 BLUE STAR TECHNICAL MANUAL 8 0 5 20 1 RI OV ANY HIM 193NN09 LON 00 SI 104 20 AZL TIV S HdWOO SSIMS 804 03M0 034 LON 5 AlddnS dWr dMWi 30 350 9 8 0 990 OS 314405 9NINWOONI V8tT0 SACOVX I300IV I III 09 00 IIV 71 SCROLL CHILLER SYSTEMS BLUE STAR 8 816808 990 090 SAZOVX 827108109 071 HIA AVEDVIC INTAI MMV DG 304 gl P 380438 CINI SI UNN 340583 m 01 MBU xxu MO 01 TORINO AYOLA z lt x 8 090 SACOVX 303 816808 0990 ON 9MMV90 TANVd 108103 OG Hd WASIY AlddNS 9NINWOONI 090 SAZOVX
6. 9NUMVIS 380438 SI UNN 1VHL 380SN3 aioW3H 9NUO3NNOO N3HW TNVd 7081N00 3lOKGu 68 28 NLHOHS MONIY m a no mros 51 no mwos 09 TWO SETS 6 soum CU Ezany W Ps E r 4 E 1350 QVdA35 OS Hd i LJ Aldd iS 9NIAWOONI VIN9 0 SEDVX I9PoIN I III Bu AA SCROLL CHILLER SYSTEMS BLUE STAR AN3SNUJ INOHLIA 3S0 38 LON ISDW 0111 SVIS 3 8 30 153408 JHL SI IM3 SIMI 39NVH2 ONIN33NION3 9 vtcesog ooc i A3 ON qu zavogozuvosozuverowosoosowero sazovx gt YATIHONGONYL TONS OOO YYY sm mes 031419345 3SIAM3HIU SSIINN WH NI SNDISN3HII TW EO VI5 3118 NOLL 442530 Peppe 090 8 91051 SSV19 89 8 VSV 33d SV SSONV14 NO dl 1S SNOLLO3NNOO YILYM LINN JHL 90 01 JHL NVH L YSHSIH 38 NVO TIVM 3HOW ON 0072 SLINN 1 N33AAL38 1510 0 05 0 6 TIVM OL 7031405 0 8 TIVM OL HVIH 40 8 TIVM OL 3018 SMOTIOH SV 38V SLINN 30 ALINVA ONY H3SN3ONOO 1 OL SHONVHV3T1O Q30N3AWOO3MH 3015 0705 La 1641
7. KOCHI 2nd Floor Millennium Plaza Nair Road Alinchuvadu Junction Kochi 682 024 Tel 0484 4499000 4499043 SECUNDERABAD 207 Sikh Road Bantia Estate Secunderabad 500 003 Tel 040 44004000 TRIVANDRUM 1X 1490 Chandrika Sasthamangalam Trivandrum 695 010 Tel 0471 2720025 2720065 VISAKHAPATNAM D No 49 24 65 1 Near Sankarmattam Road Madhura Nagar Visakhapatnam 530 016 Tel 0891 2748405 2748433 WEST AHMEDABAD 2nd Floor Shivalik Il Near Shivranjani Cross Roads 132 Feet Ring Road Satellite Ahmedabad 380 015 Tel 079 40224000 BHOPAL Star Arcade 2nd Floor Plot No 165A amp 166 Zone Maharana Pratap Nagar Bhopal 462 011 Tel 0755 2553378 4273378 79 GOA 1st Floor Buddhaseth Apartments Tonca Caranzalem Goa 403 002 Tel 0832 2461671 2462087 MUMBAI Blue Star House 9A Ghatkopar Link Road Saki Naka Mumbai 400 072 Tel 022 66684200 66684000 NAGPUR 219 Bajaj Nagar 1st Floor South Ambazari Road Nagpur 440 010 Tel 0712 6624000 2249000 PUNE 201 A Nityanand Complex 1st Floor 247 A Bund Garden Road Pune 411 011 Tel 020 41044000 26169332 VADODARA Ramakrishna Chambers 7th Floor Productivity Road Alkapuri Vadodara 390 005 Tel 0265 2332021 22 2330334 6614000 89 For any assistance CALL Blue Star Service Blue Star Regional Manager
8. Red COMPRESSOR2 If Compressor2 is ON this LED indicator is Green else Red COMPRESSORS3 II Compressor is ON this LED indicator is Green else Red COMPRESSORS f Compressor4 is ON this LED indicator is Green else Red only for 4 compressor model ON OFF This indicator is Green if the unit is ON and Red if the unit is OFF SET When the user or supervisor enters into the program mode this indicator becomes Green Operational Keys INC Key This key is used to increment any value of the selected digit If you press this key continuously then selected digit value will increment from 0 to 9 SELECT Key This key is used to set any parameter like EWT or Cooling range This acts like the Enter key ON OFF Key This key is used to switch the unit ON or OFF RESET Key This key is used for resetting fault or for restarting the unit after removing an existing fault 29 BLUE STAR SCROLL CHILLER SYSTEMS Display of Parameters By default the unit shows the Entering Water Temperature EWT and Leaving Water Temperature LWT Other parameters can be viewed by pressing INC key At any time of operation if no key is pressed for 10 seconds the display will return to Show EWT amp LWT KEY PRESSED DISPLAY ON LCD DESCRIPTION No Key Pressed EWT 25 7 Display of actual Entering amp Leaving for 10 sec LWT 25 5 Water Temp This is a default display of the controller
9. 00001 00 PRE CONTROL VALVE RELIEF 0220188700 LC M040001 00 CONTACTOR HARTLAND 40AMP3P INC s FTCN WBB006 00 WELL BULB SCROLL CHILLER 2 HANU 16FL05 01 NUT DIAS 8 IN FLAREBRASS __ _ McB 060H3P50A0 J oe FUSECARTRIDGE 2APS TOGGLE SWITCH SPST 10AKAYCEE 1 eu 35 84 TECHNICAL MANUAL BLUE STAR Water cooled Chiller Model XWC4S 052A EACOZ0080 DX CNTRLR LCD XWC4S 052 085 1 4 1 85 BLUE STAR SCROLL CHILLER SYSTEMS Water cooled Chiller Model XWC4S 085A remeron GPYALVEANGLE van xun 5 _ smsne memosmres gt _ crankcase HEATER cowsvew cor oreroot00 Cree Kma PRESSURE CONTROL Vai 81 00 PE CONTROL we YK 400 2900280X a moemoneroo PRE CONTROL VALVE RELIEF 02201687000 eon wesoosco weu steevecouruncan l4 eowmcrmtoncowmamss TTT mewemsumo mon TTT weomwmmommws TT TTT Eo EACOZ0080 DX CNTRLR LCD XWC4S 052 085 86 TECHNICAL MANUAL BLUE STAR Purchase Details The following purchase information will be required by Blu
10. DEC Key This key is used to scroll the display in lower direction as well as to decrement any parameter value SELECT This key is used to select any parameter like EWT SET CR value etc Enter Key This key is used to store any parameter value MODE This key is used to change the ON Mode to OFF Mode and vice versa Display of Parameters By default display will show Entering Water Temperature EWT and Leaving Water Temperature LWT in Chiller and Actual Room Temperature in Condensing Unit Other parameters can be viewed by pressing select key and Enter Key If no key is pressed for 10 seconds the display will show EWT LWT in Chiller and Actual Room Temperature in Condensing Unit Note on Parameters Illustrative Parameters 20 TECHNICAL MANUAL BLUE STAR Operation LCD Description Screen Display Number Power ON BLUE STAR This is the welcome screen for the Cond Unit Controller of the Condensing Unit VERSION This screen displays the software Kpd 3 00 version of the keypad VERSION This screen displays the software Bs1 3 00 version of the Base Unit 1 VERSION This screen displays the software Bs 2 3 00 version of the Base Unit 2 VERSION This screen displays the software Bs 3 3 00 version of the Base Unit 3 VERSION This screen displays the software Bs 4 3 00 version of the Base Unit 4 This screen displays the details of SYSTEMS 2 the number of systems in the Chiller Condensing Unit On the se
11. SCROLL CHILLER SYSTEMS AIR COOLED XAC2S 010 XAC2S 024MA XAC3S 036MA XAC2YS 048A XAC2YS 060 XAC2YS 080A WATER COOLED XWC2S 011 XWC2S 026A XWC3S 039A XWC4S 052A XWC4S 085A I 7 6 7 7 2 First Print June 2006 Revised July 2008 Revised November 2010 Printed and published by R M lyengar General Manager Technical Support amp Training Dept Blue Star Ltd 9 Bazullah Road Chennai 600 017 Designed for customer use One manual per site irrespective of number of Chillers installed TECHNICAL MANUAL BLUE STAR CONTENTS Basics 3 Liquid Chilling Systems 3 Scroll Chiller Nomenclature 4 Common Liquid Chilling Systems 5 Control 6 Air Handling Equipment 7 Typical Foundation Details 10 Operation Entire System 11 Water cooled Chiller Systems 11 Air cooled Chiller Systems 13 The Micro Computer Panel Controller 15 Air cooled Chiller Systems 15 Water cooled Chiller Systems 16 Using the Micro controller Modular 2 amp 3 Compressor 17 Non Modular Chiller 2 3 amp 4 Compressor Air cooled and Water cooled 28 Operating Instructions 1 35 Operating Instructions 2 3 Compressor Protection Module 43 Inspection amp Routine Maintenance 44 Troubleshooting 46 Technical Specifications 50 G A Drawings amp Wiring Diagrams 53 List of Spares 74 Purchase Details 87 Terms of Warranty 88 Blur Star Service Centres 89 BLUE STAR SCROLL CHILLER SYSTEM
12. gt OND conearPraRwoouan gt BRASS FLARENUFDASENGH VALVE SHUTOFF SEN RarcHETOR e 00M68000LC5MI664 CTFUBL1000050O GRANKCASEHEATERSMI TN gt lt FILTER DRER UDKEK DOLE gt SIGHT GLASS amp MOISTURE 2 D13800 PRESSURE CONTROL 0 400684 X 2 ermeno ALNABADEINDA wormsamesonm J gt FANGUARD 66M26MIIL J e __ 4 GP BRKTSMHPMOTORZONDA FAN 6 _ sieevecouenean 2 CONTACTOR COMPRESSOR AMP SPINE 2 1 2 COMPR MODULAR CONTROLLER SET 00 CT 60AMPS MODULAR CONTROLER gt ELOT T016 01 PCB FOR MODULAR CONTROLLER 2 N N MX I I 1 1 1 1 1 N N gt 1 1 10 75 BLUE STAR SCROLL CHILLER SYSTEMS Aircooled Chiller Model XAC3S 036MA HEDX BCH008 00 DX COOLER BCH 036U 3 8 IN 3 IN 1 VASF 12T001 00 VALVE SHUTOFF 5 8 IN RATCHET OP RCMI 16001 00 SIGHT GLASS amp MOISTURE INDICATOR 5 8 IN 76 TECHNICAL MANUAL BLUE STAR Aircooled Chiller Model XAC2YS
13. paqdipee N8 Ad 06 Hd OVASI AlddNS 9NIWWOONI 67 oz Wamani 7 anv os C anv oi wei E 1439084 51 UNN IM 3H0SN3 I SNINSVM 1350 QVdA33 1L 1 VINtCO SCOVX PON I IIV 09 00 IIV VIIIVVI BLUE STAR SCROLL CHILLER SYSTEMS COOLER CONNECTION SIZE 3 NB CONTROLLER FRONT VIEW XAC3S 036MA Model 5 o 0 z 9 a lt O COMPRESSOR SIDE VIEW RIGGING SLOTS 68 BLUE STAR TECHNICAL MANUAL E29 LL 2 eS s te 2 gt 69 anv oz 7 any os O wen 01 1051409 0134 01 71051409 CBU 9MMM N3MOd ANOIOV4 NOUVNINH31 03490852 318 05 38 TIVHS HINY3 N3MOd TIV 0134 904 38 Ol SN38ADN NEVI ANO N3MOd OL 53002 310109 Z SON WNIMH3L 01 ONOdS3M300 OSW A3HL 5 38M M NEVO SINN OL IN3OV OY SION 300100 XOv1B X3N9 HOIHM ONIMIM OV ANY HUM LO3NNOD LON 00 IME SI INANI 20 AZL ILON 3 WNIMH3L 9NIHDSY3 01 38 TIVHS 58 055384
14. BLOWER Fan motor not starting Check power supply fuses Restore power supply Tripping on over load Fuse blown 3 OVERALL UNIT Noisy operation Unit operates continuously Check overload relay Check electrical circuit Blower touching scroll Bearing noise Belt loose Loose panels Shortage of refrigerant Defective thermostat Unit undersized Reset relay and replace Realign blower Lubricate bearings Tighten the belt Check amp tighten screws Charge gas Replace thermostat Recheck heatload 47 SYMPTOMS 4 CONDITIONED AREA Discomfort in the conditioned area Too warm in conditioned space CAUSE Less air flow High humidity Poor cooling Excess heat load Inadequate cooling SCROLL CHILLER SYSTEMS REMEDY Check air filter belt Regulate fresh air Check refrigeration circuit Check amp regulate heat load Check compressor ON Check filter choke up Less airflow Check reversal of blower fan Compressor trips soon after start Change incoming supply phase polarity on any two phases for scroll compressor Too cold in conditioned space 48 Defective thermostat Contactor stuck up Replace thermostat Replace contactor TECHNICAL MANUAL Troubleshooting the water circuit SYMPTOMS A COOLING TOWER Excessive water drift CAUSE Faulty drift elimination REMEDY Check to be sure all louvers eliminator sections or slats a
15. HUM 38 TIVHS 9MMVM TW 503 38 OL SY38NNN 318YO ANO MMVM M3MOd OL 53002 8N0100 2 SON WNIMH31 OL QNOdS3HN00 OSW A3HL NIVO SINN 01 1 71 AlddAS SNINNOONI 0L0 ScCOVX 9 I IIV 65 BLUE STAR SCROLL CHILLER SYSTEMS CONTROLLER 1 COOLER WATER CONNECTION FRONT VIEW COOLER WATER INLET O 5 5 5 lt SS ET Si I we UL 165 n a fe COMPRESSOR SIDE VIEW RIGGING SLOTS SWITCHGEAR BOX t OUTLET COOLER WATER 66 BLUE STAR TECHNICAL MANUAL 29 a we xm HUM Q30WONd 38 TWHS 9MMM HLAV3 83M0 TW ONRIM 0134 38 OL 318YO AINO OL V 53002 HNO 72 SON OL ONOdS3NNOO OST A3HL SH38M N NEVI JYV SINN OL INGOVTOV SH38W N 1 S3ION 5300709 X9V18 A3N9 NI 33V HOIHM OV ANY HLM LI 193NNOO LON 00 3078 SI 1 20 AZL TIV 310N 310M39 9NUO3NNOO TOMIN00 310738 8 Z8 ONUYOHS MONIY save we LA Wage 5 mm al N WHOS SE 8 Nw
16. Open Act 22 System 1 2 3 4 overload Act 22 System1 2 3 4 Underload Act 22 Reset LED Indicator will flash Green Press Reset key to restart the system Reset LED Indicator will flash Green Press Reset key to restart the system Reset LED Indicator will flash Green Single Phasing on Current Fault Communication between Master chiller base and Keypad failed Individual Switch of System 1 2 3 4 is Off System 1 2 3 4 Single Phasing Communication Error System 1 2 3 4 Switched OFF Press Reset key to restart the system When connection breaks or gets shorted then Communication Error fault will scroll on the Display That particular system switches OFF immediately showing Red LED indication 25 BLUE STAR SCROLL CHILLER SYSTEMS Functional Logic of Compressor Tripping ON Current Fault 1 26 60A Current Transformer C T is placed in B Phase of each compressor power wiring to measure actual compressor current System Tripping on Single Phasing If R or Y phase to compressor is off then current through B phase will go up If it exceeds 125 of Set Max Compressor current then compressor will trip within 2 seconds and LCD will display Single Phasing If B phase is off then current through B phase will be zero and compressor will trip within 2 seconds and LCD will display System Single Phasing System Tripping on Overload If B phase current exceeds 110 of Set Max Compress
17. Press INC SET 12 7 Display of only Set value of Key once CR 5 5 Entering Water Temp amp Cooling Range You can not change value Press INC Comp1 Display of actual value of Compressor 1 Key once 24 Amps current in Amps Press INC Comp2 Display of actual value of Compressor 2 Key once 23 Amps current in Amps Press INC Comp3 Display of actual value of Compressor 3 Key once 25 Amps current in Amps Press INC Comp4 Display of actual value of Compressor 4 Key once 24 Amps current in Amps only for 4 compressors model Press INC Comp1 Display of actual value of Compressor 1 Key once 021 Hrs run time in hours Press INC Comp2 Display of actual value of Compressor 2 Key once 023 Hrs run time in hours Press INC Comp3 Display of actual value of Compressor 3 Key once 025 Hrs run time in hours Press INC Comp4 Display of actual value of Compressor 4 Key once 022 Hrs run time in hours only for 4 compressors model Press INC Fant Display of actual value of Condenser Key once 034 Hrs Fan 1 run time in hours Press INC 7 Fan2 Display of actual value of Condenser Key once 036 Hrs Fan 2 run time in hours only for 4 compr Tandem model 30 TECHNICAL MANUAL BLUE STAR Setting of Parameters The user or supervisor can enter into the PROGRAMME MODE to set various parameters by pressing the SELECT key when the display is showing the Set Temperature and Cooling R
18. 657 8x2 Character LCD Display LED indications 1 C 8 25 C Normal chiller 21 to 5 C Brine Chiller 19 32 C Condensing unit 6 42 Amps NTC Thermistor with 5 metre cable TECHNICAL MANUAL BLUE STAR Description of LED Indicators amp Keypad 8 CHARACTERS X 2 LINE LCD DISPLAY POWER ON OFF MODE m BLUE STAR SPPR STATUS FAULT STATUS LED 4 FS STATUS POWER ON OFF MODE KEY COMPS STATUS UP KEY SELECT KEY DOWN KEY ENTER KEY MODE SELECTION eee e OK RESET KEY LED Indication Power Green Unit is RED Unit is OFF ON Blue Unit is OFF Blue Unit is OFF SPPR Green presence of Power Blinking RED SPPR fault FS AHU Green Flow switch input is OK Blinking RED Flow Switch AHU fault Compressor Green Compressor 1 2 3 4 is ON 1 2 3 4 Red Compressor 1 2 3 4 is OFF RESET Blinking Green fault is cleared or any key is pressed Communication Blinking Green communication is OK 19 BLUE STAR SCROLL CHILLER SYSTEMS ll Keys POWER This key is used to switch ON OFF the system In OFF Mode display light goes OFF and the screen shows POWER DOWN RESET This key is used to reset Fault Alarm or to restart the system after clearing the fault INC Key This key is used to scroll the display in upper direction as well as to increment any parameter value
19. current exceeds 110 of set max compressor current then compressor will trip within 10 seconds and LCD will display Compr Overload 4 Compressor Tripping on Underload If B phase current is less than Set Min compressor current then compressor will trip within 2 seconds and LCD will display Compr Underload 34 TECHNICAL MANUAL BLUE STAR Operating Instructions 1 These operating instructions pertain to Compressor Water cooled Scroll Chillers Compressor Air cooled Scroll Chillers 2 Compressor Air cooled Scroll Chillers Switching ON Chiller Switch ON the unit by pressing ON OFF key on keypad unit The ON OFF LED should glow Green After chilled water pump is running Flow Switch input will be on then CHW FLOW LED will glow Green After preset delay of 10 seconds fans will start amp FAN LED will glow Green If HP LP MP FS SPPR AFT amp CF inputs are OK then compressors will start depending on set temp cooling range amp actual EWT after preset 180 sec delay for 1 compressor then 10 seconds delay for 2 compressor and another 10 seconds delay for 39 compressor and 10 seconds incase of 4th compressor Functional Logic of Compressor switching Controllers will Load Unload number of compressors based on Actual Entering Water Temp set temp and cooling range a Actual EWT gt Set Value all the compressors will be ON b For 4 Compressor Tandem Systems If actual EWT Set Va
20. ir 2 Password Press key w for shifting to the next digit to the left 0001 2 Password Press key 4 till the desired value of second last digit 0011 of password 2 the screen If the is incorrect following message appears Password Invalid 22 TECHNICAL MANUAL BLUE STAR Following Parameters can be set after Entering Correct Password LCD Description Parameter Display Limits Set Temp To set the desired temperature Press INC key till Max 32 C 19 the desired value appears amp press key to confirm it Option To set the parameters from local keypad make the option Local option as LOCAL and to set the parameters from remote keypad change the option to REMOTE Power ON To set the Power On Delay press key 4 till the Max 120 sec Delay 30 desired value appears amp press key to confirm it Min 30 sec Set Amps To set the Max Current value press key 4 till the Max 42 Amps Max 25 desired value appears amp press key to confirm it Min 6 Amps Set Amps To set the Min Current value press key v till the Max 42 Amps Max 6 desired value appears amp press key to confirm it Min 6 Amps Set Unit The unit address can be set by using and key Max 9 Addr 1 Min 1 VERSION Displays the software version of the Controller Base Bs 1 3 00 VERSION Displays the software version of the Keypad Local Kpd 3 00 Master Description of Status Windows LCD D
21. 048A INCOMER SWITCH 175 AMPS 1 77 BLUE STAR SCROLL CHILLER SYSTEMS Aircooled Chiller Model XAC2YS 048A soans 21 40 sure sesr 01 10 2544 78 TECHNICAL MANUAL BLUE STAR Aircooled Chiller Model XAC2YS 060 SAPCODE Net Qty COCD1021648001 COCD1021648002 COCD1041448001 0 01041448002 HEDX BCH101 00 CMSCB250L31201 HTFL BL130007 00 RCSL EVR25 00 RCSC EVR3 00 RCDR 098F 001 00 RCTXV TDEBX19 00 RCTXV TDEBX 30 00 RCMI 28001 00 RCPR LCB DA80 00 PRESSURE CONTROL YK 01L 400 035G050G SPPC T011 00 HI PR SWITCH SAGINO 450 AUTO GUFA GISO02 00 HAPRRB004 00 FBCL GT006 00 BFAX ALF003 00 MOAC 02502 00 FBAR MTOO1 00 GUFA GIR003 00 GUFA GIR004 00 FTCN WBB005 00 FBAN GT004 00 HASI CS8264000 00002 00 EATFZ0040 FTCN FCM 4001 00 2 CONTROLLER TANDEM SCROLL 60TR 79 BLUE STAR SCROLL CHILLER SYSTEMS Aircooled Chiller Model XAC2YS 080A Tcocorosrseanis MII46I 665 861660 gt Dx cooLen ge nenny 1 cowscmousram aT CRAWONSEHENTRHSONSERS 4 1 sotwoDvawEEWES e SOENODCOLEWGEWE 57 Lmoomowrowus rss e EXP VALVE TDEBX30 1 3 8 1 1 Nm Lowe MOISTURE NOWATORSAIIS IBN 2 PRESSU
22. 3 SCROLL CHILLER SYSTEMS Inspection amp Routine Maintenance Regular inspection of all the chilling unit equipments reduces failures and ensures continuous operation A healthy supply CHECK IF INCOMING POWER IS AS PER THE RATED POWER SUPPLY VOLTS 380 420V PHASE THREE PHASE CYCLES 50Hz TYPE AC ONLY Regular Inspection Regular inspection must be carried out as follows Item Period Filter cleaning Once a week Air Handling Equipment General compressor Once a week checks Twice a year Twice a year 44 Inspection Procedure Filter Water hose Remove the internal filter and wash it with water Dry the filter in the shade and re install it Crankcase heater Touch the heater body to verify that it is warm Oil leaks Verify that there are no oil leaks Vibration isolation rubber Inspect the vibration isolation rubber for wear TECHNICAL MANUAL Item Inspection Procedure Gas leak check Four times a year Conduct test for gas leaks in all refrigerant pipe joints Control panel Four times inspection a year u lt 12 Inspect the circuits in the control panel and tighten loose wires Water line strainers Vibration Isolating pipe hangers Cond water circuit Four times a year IC 5 Shutoff valve Check Valve 411 Flex connector Chilled water circuit Once a year Concrete in
23. AMS SCROLL CHILLER SYSTEMS XWC4S 085A O Drawing Model 54 BLUE STAR BLUE STAR TECHNICAL MANUAL VS80 SVOMX I PON 1 55 BLUE STAR SCROLL CHILLER SYSTEMS 366 B04591 B 8 Yr 1 EX 2 2 ISOMETRIC VIEW SIDE VIEW N O gt lt 5 o CALLER WATER NLET 1 1 2 N8 WH SUPON FLANGE ANSI B 18 5 01508 i o Q 9 0 E a Son c AE LH Dore a ELEVATION FOR PROPER MAINTENENCE SERVICE TUBE CLEANING AND REMOVAL 2750 9 07 OF THE UNIT REAR TO WALL 915 3 07 RECOMMENDED CLEARANCES WATER OUTLET 1 9 NB WITH SUPON E ANS B 155 CL 1508 D NOTE 56 BLUE STAR TECHNICAL MANUAL y 908908 990 t 908609 990 SNIMYNG 1 Ov AW HIA oa 9 0 ST IME SI TW HUM 38 N3MOd TIV 83M0 N3MOd Aol G3MOTIO4 OL TVD ANO aw oz LI wer N3MOd OL XlddY 53000 310109 SON
24. AR TECHNICAL MANUAL 9208 Odd V Y0220H 990 L Lm qousoo quu 3ngvins HUM 38 TVHS HIVE 93M0 TW C3MOTIO4 38 01 318 2 NO M3MOd OL 51444 S3000 HNO 7 SON OL ONOdS3NNOO OSW A3HL TEVI 3VV SINN OL INGOVIOY SUBANAN s kd 5 e gt 8 mos 9 JINN Vd A33 1 180d Sg m 1304 NN 3 8 NOUNY G 01 ZH OG Hd OVASLY AlddNS SNINNOONI 702208 990 650 55 SJ9 IU 61 SCROLL CHILLER SYSTEMS BLUE STAR V6S0 SYOMX I9polN Jolly V 9 62 BLUE STAR TECHNICAL MANUAL ala 106 08 990 2 15 x CHV V SEO SHFOMX V CGO SYOMX WVYYOVIG 9NINIM 7051405 01314 SNIMIM 1041NOO AMOIOV 33MOd 0133 Y3MOd AHOLOVI 5 905539 M0 STOMINOD ISNA HOUMS 38055384 01 HOLMS 38055384 V3X3 8 LINIUID VOSSIYNOI HOLIVINOD 905539 M0 oz war 7 o9 DJ any wet E 700709 X9v18 A389 NI OV ANY HLM 1I 193NNOO NOUYNIWH3L 2 318 5 00 310702 ama HUM 03010848 38 TIVHS
25. Air Cooled Scroll Chillers SCROLL CHILLER SYSTEMS Description Units XAC2S 010 XAC2S 024MA XAC3S 036MA XAC2YS 048A XAC2YS 060 XAC2YS 080A Nominal Cooling Capacity kW TR 35 16 10 84 40 24 126 57 36 168 8 48 211 60 281 28 80 Electrical Power Supply A Power Supply V Ph Hz 380 420V 3 Ph 50Hz AC B Total Current at Rated Load Amp 25 5 492 73 101 122 162 C Power Consumption at Rated Load kW 11 26 5 39 8 54 0 69 8 92 0 Overall Dimensions A Length mm 1775 2234 3355 2980 2980 2980 B Width mm 935 1147 1147 2040 2040 2040 C Height mm 1505 1696 1696 2460 2460 2460 Refrigerant Charge R22 kg 9 18 27 42 50 70 Unit Weight kg 625 925 1375 2090 2200 2400 Compressor A Quantity No 2 2 as 4 3 4 Condenser 0 of coils No 2 4 6 4 4 4 A Total Face Area sq m sq ft 2 23 04 3 75 40 5 57 60 8 24 88 7 8 24 88 7 8 24 88 7 Tube Material Material Inner Grooved Copper Tubes C OD x Thickness mmxmm 9 5 x 0 28 9 5 x 0 28 9 5 x 0 28 9 5 x 0 28 9 5 x 0 28 9 5 x 0 28 D Type of Fin SLIT E Fin Material Material ALUMINIUM F Rows Deep No 2 3 as 2 244 3 Condenser Fan Motor A Quantity No 2 2 3 2 3 4 B Power Supply V Ph Hz 400 415 3 50 C Speed RPM 910 910 910 910 910 910 D Power 0 37 0 5 0 56 0 75 0 56 0 75 1 9 2 5 19 25 19 25 Fan
26. Chassis Chassis design Revision X Direct Expansion Water cooled Air cooled 2 No of Refrigeration circuit 3 No of Refrigeration circuit 4 No of Refrigeration circuit S Scroll YS Tandem Scroll 010 10TR 024 24 036 36 048 48 060 60 080 80 011 11 TR 026 26 039 39 052 52 TR 085 85 Modular Revision Version if applicable TECHNICAL MANUAL BLUE STAR Common Liquid Chilling Systems The refrigeration cycle of a basic system is shown in the figure below aA WYN SUCTION LINE L HOT GAS REFRIGERANT LIQUID CHILLING SYSTEM Refrigeration Cycle Chilled water enters the cooler at 12 C for example and leaves at 7 C Condenser water leaves a cooling tower at 32 C enters the condenser and returns to the cooling tower at 37 C Condensers may also be cooled by air or through evaporation of water This system with a single compressor and one refrigerant circuit with a water cooled condenser is used extensively to chill water for airconditioning because itis relatively simple and compact Multiple chilled water circuits can be connected to achieve higher capacity BLUE STAR SCROLL CHILLER SYSTEMS Control The chilled liquid temperature sensor sends an electrical signal electronic control to the control circuit which then modulates compressor capacity in response t
27. D LED Indication Message SPPR SPPR Trip Both Power amp SPPR LED indicators will blink Red if the fault exists Press Reset key to restart the system after the fault is cleared and Reset LED blinks Green In case of Chiller both FS AHU amp Power indicators will Flow Switch blink Red if the fault exists Press Reset key to restart the system after the fault is cleared and Reset LED blinks Green In case of Condensing Unit both FS amp Power indicators AHU will flash Red if the fault exists Press Reset key to restart the system after the fault is cleared and Reset LED blinks Green Compressor Compressor LED will blink Red if the fault exists in a 1 2 3 4 Trip on particular compressor This fault is Auto Reset Motor Protector Compressor 1 2 3 4 on High Pressure Compressor 1 2 3 4 Trip on Low Pressure Room Temperature sensor is open or bad System 1 2 3 4 overload on Current Fault System 1 2 3 4 Underload on Current Fault System 1 2 3 4 Display of Alarms and Reset Procedure MP1 2 3 4 Trip Power amp Compressor LEDs will blink Red if the fault exists Press Reset key to restart the system after the fault is cleared and Reset LED blinks Green Power amp Compressor 1 indicators will flash Red if the fault exists Press Reset key to restart the system after the fault is cleared and Reset LED blinks Green All compressors become OFF This fault is Auto Reset HP1 2 3 4 Trip LP1 2 3 4 Trip Room Thermister
28. I300IV I III 72 BLUE STAR TECHNICAL MANUAL guv v 080 SAZOVX A 4271081409 021 HILA AVEDVIC U 1 lt 380438 SI ININIM 99 nll 1 8 0 990 ON 09 Hd OWASLY AlddAS SNINWOONI 73 V080 SAZOVX I9POIN I III BLUE STAR SCROLL CHILLER SYSTEMS List of Spares Aircooled Chiller Model XAC2S 010 CONDENSER COIL RH XAC2S 010 EE CONDENSER COIL LH XAC2S 010 TE For coupnEssORAVITa TEMPS 2 TTT cono moromavias en 1 TTT TTT TT TTT a LI MN DX CNTRLR LCD XAC2S 010 pee _ 74 TECHNICAL MANUAL BLUE STAR Aircooled Chiller Model XAC2S 024MA 6X600L66 we nany GP VALVEANGLE VAN sce TDEXH 00 e WcmiceDwsoo PRESSURE CONTROL 40005808 2 weu Bucs soron omer Gur amowo WIRE GUARD MODULAR Guramweo GUARDMODULARGHLLER wemmon RUBBER CUSHION PacKNG
29. OL ONOdS3HOO OSTY 09 O 9 3HL 154 5938M M 318VO SINN OL IN3OVTOV L any wir VMVMV DG 303 wm Z 52 vd Jaos f LUNN 35 8 NOUNV G 01 ZH 05 Hd OWASLY AlddNS SNIWWOONI LL0 SCOMX I300IV 57 BLUE STAR SCROLL CHILLER SYSTEMS NO PROJECTION DRAWING NO 366 B07557C ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE SPECIFIED BLUE STAR Model XWC2S 026A LH SIDE VIEW MIL aid gt gt O Q 2 0 ER a 14 HOLES 6 FOR FOUNDATION BOLTS 1 5 CONTROL END FRONT TO WALL 1 25 COND CLEANING 1 0 M REF amp COND WATER CONN END REAR TO WALL 2 5 M RECOMMENDED MINIMUM CLEARANCES ARE AS FOLLOWS RH SIDE TO WALL LH SIDE TO WALL NOTE 58 BLUE STAR TECHNICAL MANUAL 90 9 6 04404 990 96 OGU no 03 3603 HIMES 00100 3OV18 A389 NI wa 1OMIN09 1 ANY HUM 193NNOO LON 00 Q3dWiH2 NIGVUNS OGU 2 JA 03 3018 SI 00 21 TY 38 TIYHS HINY3 TW SNIMIM TOHINOO AXOLI
30. Quantity No 2 2 3 4 4 Condenser A Model Qty No YCD 10 1 YCD 14 2 YCD 14 3 YCD 14 4 YCD 21 4 B No of Pass Water Side No 8 8 8 8 8 0 No of Pass Refrig Side No 1 1 1 1 1 D Water Connection Size IN OUT inch 1 1 4 BSP DX Cooler A Model Qty No YCH 10 BCH 024U BCH 036U BCH 024U BCH 048U 2 IN 1 1 2 IN 1 1 3 IN 1 1 2 IN 1 2 2 IN 1 2 B No of Pass Each Crt No 4 Pass 2 Pass 2Pass 2 Pass 2 Pass C Water Connection Size IN OUT 1 EACH 11 2 NB 1EACH 3 NB 3 NB 1 EACH 3 NB 1 EACH 4 NB D No of Refrig Circuit No 2 2 3 4 4 Remarks Rating of Units The ratings are based on 6 7 C 44 F chilled water outlet temperature and 2 4 USGPM TR water flow for cooler with 0 0001 F ft hr Btu fouling factor and 29 4 C 85 F entering water temperature and 3 0 USGPM TR water flow for condensor with 0 00025 F ft hr Btu fouling factor Note Specifications subject to change due to continuous product development 51 BLUE STAR SCROLL CHILLER SYSTEMS SFU Rating amp Cable Size for Hermetic Scroll Chillers 2720 DES XACSS XACBYS 048A xAcavs o6 XAC2YS 080A 0A XWC2S 01 4C x 16 sq mm AL XWC2S 026A 3v 35 sq mm AL XWC3S 039A 100A 3 C x 50 sq mm AL XWC4S 052A 125A 37 C x 95 sq mm AL XWC4S 085A 200A 37 C 185 sq mm AL 52 TECHNICAL MANUAL BLUE STAR GA DRAWINGS amp WIRING DIAGR
31. RE CONTROL e _ 66061560 PRESSURE CONTROL ADAM 2 _ sNrANBRDWNGSRADE MOTOR2SHPRRPWASHMND LGumommes GUARD HEADER 40750665588 a LGumommio GUARD HEADER 20200 06635845 gt Fronwes00500 Bus sm 57 reanaro0e00 GPVALVE ANGLE va 47 SPRING Tron enaoo00200 ALUMINUM CONNECTOR FOR a conTacTOR COMPRAS contacto cono MOTOR avira wa e 21 10 1 5 1 1 1 1 1 14 N IN I N 80 TECHNICAL MANUAL BLUE STAR De Aircooled Chiller Model XAC2YS 080A SAPCODE DESCRIPTION Net Qty C60H3P63AC 63 AMPS FUSE CARTRIDGE 2 AMPS 81 BLUE STAR SCROLL CHILLER SYSTEMS Water cooled Chiller Model XWCS2011 anemose wseomwero 2 _ emm crankcase WenTen 2 women THERM De VANE 2 _ Cremar MOISTURE 2 moemicsowoo PRESSURE 2 D16200 PRE CONTROL We 2 cor overoce0o Furen 0 006400 2 2 _
32. Range as follows Set CR 5 0 By pressing INC key the required Cooling Range can be set and can be confirmed by pressing the SELECT key If the unit is in user mode the display will return to the default window If the unit is in supervisor mode the display will show the maximum current limit of each compressor Set Amps Max 036 By pressing INC key the Maximum current limit can be set and can be confirmed by pressing the SELECT key Then the display will show the following Set Amps Min 012 By pressing INC key the Minimum current limit can be set and can be confirmed by pressing the SELECT key Then the display will return to the default window Also please note that the Set indicator will be ON throughout the program mode 39 SCROLL CHILLER SYSTEMS Fault Alarms Display Both LCD and LED indicators display the various faults occurring in the unit The second line of the LCD is used to display the faults The LCD will show all the faults which have occurred as follows It also displays multiple faults if they exist The messages for the various faults are as follows Fan1 Overload Fan2 Overload Compressor 1 Overload Compressor 2 Overload Compressor 3 Overload Compressor 4 Overload Compressor 1 or 2 High Pressure OF1 Trip OF2 Trip OC1 Trip OC2 Trip OC3 Trip OC4 Trip HP1 Trip Fault Scrolling LCD LED Indication Message SPPR Fault SPPR Trip Both Power a
33. S TECHNICAL MANUAL BLUE STAR Basics Liquid Chilling Systems A liquid chilling system chills water brine or other secondary coolant for airconditioning or refrigeration purposes The system may be either factory assembled and wired or shipped in sections for erection in the field The most frequent liquid chilling application for airconditioning is water chilling although brine cooling for low temperature refrigeration and chilling of fluids in industrial processes are also common The basic components of a vapour compression liquid chilling system include a compressor a liquid cooler evaporator a condenser a compressor drive a liquid refrigerant expansion or flow control device and a control centre The system may also include a receiver or accumulator an economiser and other ancillary components as part of the operating system Principle of operation Liquid usually water enters the cooler where it is chilled by liquid refrigerant at a lower temperature The refrigerant vapourises and is drawn into the compressor which increases the pressure and temperature of the gas so that it may be condensed at the higher temperature in the condenser The condenser cooling medium is warmed in the process The condensed liquid refrigerant then flows back to the evaporator through an expansion device SCROLL CHILLER SYSTEMS Scroll Chiller Nomenclature Number Compressor Type S Capacity
34. WT Set Value CR 2 one compressor will be unloaded If actual EWT Set Value CR both the Compressors will be unloaded For 3 Compressor System If actual EWT Set Value CR 3 one Compressor will be unloaded If actual EWT Set Value 2CR 3 two Compressors will be unloaded Ill If actual EWT Set Value CR 3rd Compressor will be unloaded in compressor model IV If actual EWT Set Value 3CR 4 three Compressors will be unloaded 3 Switching OFF Chiller i Power Key Press Power Key on keypad unit it will show you System Down message and all Systems go OFF i Mode Key You can switch OFF the Systems by pressing the MODE key to select OFF Mode LCD indicates the System 1 System 2 and System 3 OFF Mode iii You can also switch off the Systems by putting ON OFF Toggle switch in OFF Mode Units will be switched OFF and message on screen is System 1 2 3 S W OFF 27 BLUE STAR SCROLL CHILLER SYSTEMS Using the Micro Controller Non Modular Chiller 2 3 8 4 Compressors Air cooled amp Water cooled Salient Features Digital control and setting of temperature values in 0 1 C steps Display of actual compressor current in Amps with underload amp overload protection Auto loading unloading of compressors with run time equalisation Non volatile memory backup for all set value parameter Automatic starting of unit in case of power failure Built in tim
35. ange The user Password is 0851 KEY PRESSED DISPLAY ON LCD DESCRIPTION Press SELECT Password For changing set parameter Entry of Password Key once 0000 can be made by pressing SELECT key Press INC Password For changing last digit of password go on pressing Key 0001 INC key till you get the desired value Press RESET Password Now by pressing Reset key you can go to the Key once 0021 27 digit of your Password to change it Press INC Password Now go on pressing INC key till you get the Key 0051 desired value of 2 digit of your Password Press RESET Password Now by pressing Reset key you can go to the Key once 0451 35 digit of your Password to change it Press INC Password Now go on pressing INC key till you get the Key 0851 desired value 0851 is correct Password OBSL Press SELECT Password After pressing SELECT key for correct Key Invalid Password it will show Set Temp otherwise Invalid Press INC Set Temp Now go on pressing INC key till you get the Key 12 5 desired value of Set Temp Press SELECT Set CR Press SELECT key to store setting of Set Key 3 4 Temp amp go to next parameter setting i e Set CR Press INC Set CR Now go on pressing INC key till you get the Key 5 4 desired value of Set CR Press SELECT OPTION Press SELECT key to store setting amp go to Key LOCAL next parameter setting i e Local or Remote mo
36. as specified above During the warranty period BSL BSL Dealer will render free of cost service as follows 9 1 4 Quarterly Preventive Maintenance Checks 9 2 Attend to all breakdown calls or performance related to complaints promptly and diligently 9 3 Repair replace components when necessary within the overall Warranty Policy explained as above TECHNICAL MANUAL 24x7 Customer Care 1800 209 1177 Service to 57007 customerservice bluestarindia com EAST BHUBANESHWAR 3A Satya Nagar 2nd Floor Bhubaneshwar 751 007 Tel 0674 2572403 2573670 GUWAHATI 13 K C Patowari Road Ulubari Guwahati 781 007 Tel 0361 2468496 KOLKATA 7 Hare Street Kolkata 700 001 Tel 033 22134200 22106609 NORTH CHANDIGARH Adarsh Mall 4th Floor Plot No 50 Industrial amp Business Park Phase Il Chandigarh 160 002 Tel 0172 2790482 5024000 JAIPUR A 19 Main Sahakar Path Near Sahakar Bhawan Jaipur 302 001 Tel 0141 2744033 35 LUCKNOW 177 4 Faizabad Road Lucknow 226 007 Tel 0522 4034000 NEW DELHI E 44 12 Okhla Ind Area Phase II Okhla New Delhi 110 020 Tel 011 41494200 41494000 SOUTH BANGALORE Ozone Manay Technology Park Sy No 56 18 amp 55 9 Hongasandra Village Begur Hobli Garvebhavipalya Bangalore 560 068 Tel 41854000 CHENNAI 104 Garuda Building Cathedral Road Chennai 600 086 Tel 044 28124000 42444200
37. cond line the model type is scrolled This is the default screen of the controller Act Room under healthy condition which displays the 1 Actual Room Temperature This is the screen of the controller under any faulty condition It also displays the 1 room temperature and the fault is scrolled on the second line Press SEL Set This screen displays the value 2 key once Temp 25 of the set temperature Press SEL System 1 shows the ON OFF status of system 1 3 key once On Press SEL It shows ON OFF status of next systems key once up to 4 systems up to 4 compressors after each in multicompressor system screen Press SEL Act Room After displaying the status of all the systems key once Temp 25 the controller will return to the default screen 1 21 BLUE STAR SCROLL CHILLER SYSTEMS Parameters Setting with Password Sr No Password Parameters 1 0851 Set Temperature Local Remote Option Power Delay 2 Set Temperature Local Remote Option Power On Delay Minimum amp Maximum Current Setting Address Setting 3 Programming mode for Chiller Condensing Unit is factory set Password Entering Procedure Operation LCD Description Display Press SEL Set This screen displays the value of the set temperature Key Temp 25 This is the screen where you can enter the desired password 0000 Password Press key 4 till the desired value of last digit of 0001 password 2 the screen
38. d if the FS fault is present This indicator flashes green if any key is pressed If Fani is ON this indicator is Green and Red if the Fan1 is OFF If Fan2 is ON this indicator is Green and Red if the Fan2 is OFF If Compressor1 is ON this indicator is Green and Red if it is OFF If Compressor2 is ON this indicator is Green and Red if it is OFF If Compressor3 is ON this indicator is Green and Red if it is OFF If Compressor4 is ON this indicator is Green and Red if it is OFF This indicator is Green if the unit is in ON mode and Red if the unit is in OFF mode When the user or supervisor enters into the program mode this indicator becomes Green All preset programs on the controller should not to be disturbed or changed for site convenience as it may result in total operational failure of the chillers Please contact authorised Blue Star Executive only for changes faults on the controller performance 42 TECHNICAL MANUAL BLUE STAR Compressor Protection Module SM Series CONTROL CIRCUIT ET Flas Control relay External overload protector Safety lock oul relay Compressor contactor LP switch Optional short cycle timer 3 min ewilch Dacharge gas thennecstat Fused diconneci Compressor motor TH Control device Motor safety thermostat Wiring Diagram without Pump down Cycle SY Series 4
39. de Press INC OPTION Press INC key to change the mode from Local Key REMOTE to Remote amp then press SELECT Key to store it By using same procedure as above you can set the maximum minimum current limit of compressor for overload amp underload protection by entering the supervisor password Similarly you can set the type of unit air cooled or water cooled brine or standard AFT by entering the factory password 31 Fault amp Alarms Display SCROLL CHILLER SYSTEMS Both LCD and LED indicators display various faults that may occur in the unit The second line of the LCD displays the faults The LCD shows faults as follows It also displays multiple faults if they exist Nature of Fault LCD DISPLAY LED indication on Keypad Phase Reversal Fault EWT 25 7 Reset amp Power LED will flash Red if the fault if RYB phase sequence SPPR Trip exists After the fault is cleared Power LED is not correct flashes Green but unit to be restarted by pressing Reset key Flow Switch EWT 25 7 Reset amp CHW Flow LED will flash Red if the Sensor Fault FS Trip fault exists After fault is cleared CHW Flow If no water flow LED flashes Green but unit to be restarted by pressing Reset key Fan Overload EWT 25 7 FAN LED indicator will flash Red if the fault Relay Fault CF Trip exists FAN overload fault is Auto reset Comp1 Trips EWT 25 7 COMPRESSOR 1 LED indicator wil
40. e Star Dealer in case of any warranty claims or service requests Hence kindly ensure the following details are filled in 1 Customer s Name amp Address Model Nomenclature M Date of Commissioning Warranty Expiry Date Signature amp Seal of Signature amp Seal of Customer BSL Engineer or Dealer Date of Filling 87 BLUE STAR SCROLL CHILLER SYSTEMS Terms of Warranty Blue Star extends a comprehensive warranty on its Packaged Airconditioners PCPA VRF and Chiller Systems which entitles the customer to the following 1 88 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 Free after sales service during the above mentioned period as and when necessary within the Municipal limits of the city or town where the Blue Star dealer office is situated Note For units installed beyond the Municipal Limits of the juridiction of the authorised Service Agent Dealer of Blue Star all expenses incurred in collection of the unit or parts thereof from the company s authorised service station or the service personnel technicians towards to and fro travel conveyance and othe
41. e delays for compressor and condenser fan Current sensing single phase phase reversal protection 3 level data entry password protection User Supervisor amp Factory n built anti freeze safety Optional Remote Control Using Group Controller Specifications 1 Power supply Single phase Voltage 180 to 260V AC Frequency 50 Hz 3 Operating temperature limit 0 65 C 3 Display 8 Character X 2 Lines Backlit LCD LED indicators and touch key pad 4 Temperature control accuracy 1 5 Entering water temperature range 8 25 C 6 Cooling range 2 10 7 Antifreeze setting 5 C cut out and 8 C cut in 8 Temperature sensors NTC thermistor sensor SS enclosure with 5m long cable 9 LCD Display amp Keypad unit Door mounting 10 Micro Computer Base unit Base mounting 28 TECHNICAL MANUAL BLUE STAR LED Indicators POWER This LED indicator indicates the presence of power and flashes Red if SPPR fault occurs CHW FLOW If flow switch input is OK this LED flashes Green else flashes Red KEY This LED indicator flashes Green if any key is pressed FAN If Fan is ON this LED indicator is Green else Red FAN 1 2 If Fan is ON this LED indicator is Green else Red only for 4 compressor Tandem model AFT 1 2 If AFT is OK this LED indicator is Green else Red if the AFT trips only for 4 compressor water cooled model COMPRESSOR1 If Compressor is ON this LED indicator is Green else
42. e operated in manual mode All alarms amp faults are indicated only on the LCD control panel TECHNICAL MANUAL Air cooled Chiller Systems Starting the system Ensure that the crankcase heater is always ON when the compressor is OFF 1 2 3 4 10 11 12 13 14 Ensure input voltage is within specified range 380 420 volts Ensure all valves on the waterlines are in open condition Check water level in expansion tank Be certain all control sensor bulbs are inserted completely in their respective thermo wells Check that the recommended fuses are in the power circuit disconnect switch and then close the switch Ensure crankcase heater supply is connected before disconnect switch as shown in wiring diagram Start the chilled water pumps Start AHUs or other airhandling equipments Set chilled water thermostat to the desired water temperature Switch on the chiller from the micro computer panel located on the chiller Follow operational instructions provided in the following pages In case of scroll compressors if an unusual noise is heard on starting and there is no change in suction pressure and discharge pressure the direction of rotation of compressor is wrong Reverse the wiring terminals of the compressor and again check for noise and suction amp discharge pressures This can be eliminated with the provision of a safety electrical device on the control panel which pro
43. ely in their respective thermo wells 7 Check that the recommended fuses are in the power circuit disconnect switch and then close the switch 8 Ensure crankcase heater supply is connected before disconnect switch as shown in wiring diagram 9 Start the cooling tower fan 10 Start the condenser water pumps 11 Start the chilled water pumps 12 Start AHUS or other air handling equipments 13 Set chilled water thermostat to the desired water temperature 14 Switch on the chiller from the micro computer panel Follow operational instructions provided in the following pages 15 In case of scroll compressors if an unusual noise is heard on starting and there is no change in suction pressure and discharge pressure the direction of rotation of compressor is wrong Reverse the wiring terminals of the compressor and again check for noise and suction amp discharge pressures This can be eliminated with the provision of a safety electrical device on the control panel which provides the unit reverse polarity protection and single phase protection 16 When compressor starts a flow of liquid will be noted in the liquid indicator After several minutes of operation the bubbles disappear and full flow of liquid occurs when the unit is operating normally 11 BLUE STAR SCROLL CHILLER SYSTEMS 12 17 Check the operation of the safety control switches and indicating lights on the control panel to be sure that they f
44. ertia base may be required Dead leg mounted on Vibration isolator on steel frame 1 vibration isolated frame 4 45 SCROLL CHILLER SYSTEMS Troubleshooting Faults and complaints in chilled water AC systems can be broadly classified under three areas The first step in troubleshooting is to identify the area and diagnose the fault Diagnosing faults Malfunctions can be classified under any of the following A THE ELECTRICAL CIRCUIT The malfuntioning of electrical circuit is due to LOW or HIGH voltage variations frequent power failures loose electrical contacts defective electrical components etc Problems due to power supply quality must be sorted out with concerned electricity board B THE REFRIGERATION CIRCUIT Improper cooling usually indicates poor performance of the refrigeration circuit Reasons may be poor servicing low high gas in the system non condensible gases and lower efficiency of the compressor C THE CONDITIONED AIR CIRCUIT Less air flow poor cooling uneven temperature excessive airleaks are complaints that come under this classification Most of the above faults can be eliminated by periodical servicing The troubleshooting chart that follows will help isolate the exact fault and suggest remedies Quick check Troubleshooting Chart SYMPTOMS 1 COMPRESSOR High discharge pressure Non condensible gases Over charged refrigerant Cho
45. escription Display Power ON Displays the Power On Delay left for the system in seconds Dely 120 Syst1 TM Displays the Anti Recycle Time for the Compressor in seconds Recy 180 System 1TM Displays the ON OFF status of the complete system Dely 10 System 1 Displays the ON OFF staus of the individual system Off Mode To view the parameter of any particular system press SEL key until the desired System appears on the screen and then press key 23 BLUE STAR SCROLL CHILLER SYSTEMS Following are the parameters that can be viewed for a system OK Healthy Trip fault Ok Healthy Trip fault System 1 MP Ok This window shows the status of the MP input of system 1 Ok Healthy Trip fault System 1 OFF This window shows the ON OFF status of the System 1 No System is ON Yes System is OFF Configuration of Dip Switch Selection Dip switch no 1 for Termination Resistance must be ON in the last System 1 Setting for 2 Compressor System HANDSET CABLE COMMUNICATION CABLE HANDSET COM II 2 COMMUNICATION CABLE m SLAVE BASE p lt lt GGG LEOLE 24 TECHNICAL MANUAL LEDs on the display panel will indicate the faults The alarm message indicating the fault type will be scrolled on the LCD Various system fault alarms are as follows Scrolling LC
46. for Condenser Unit A Quantity No 2 2 3 2 3 4 B Fan Dia mm 610 660 660 915 C Material Aluminium Galvanised Steel D Hub Bore Dia mm 15 87 25 4 With One Keyway DX Cooler A Model YCH 10 21N 1 0240 BCH 036U BCH 048U BCH 075U BCH 080U Twin Circuit Three Circuit Twin Circuit Twin Circuit B Water Connection Size IN OUT inch 11 2 NB 3 NB 3 NB 4 NB 4 NB 4 NB C No of Refrig Circuit No 2 2 3 2 2 2 Remarks Rating of Units The ratings are based on 6 7 C 44 F chilled water outlet temperature and 2 4 USGPM TR water flow for cooler with 0 0001 F ft hr Btu fouling factor and 35 C 95 F ambient air temperature Note Specifications subject to change due to continuous product development 50 TECHNICAL MANUAL Water Cooled Hermetic Scroll Chiller Description UNITS XWC2S 011 XWC2S 026A XWC3S 039A XWC4S 052A XWC4S 085A Nominal Cooling Capacity kW 38 7 91 4 137 1 182 8 298 9 TR 11 26 39 52 85 Electrical Power Supply Power Supply V Ph Hz 380 420V 3 Ph 50Hz AC B Total Current At Rated Load Amp 20 42 63 84 128 C Power Consumption At Rated Load kW 9 22 33 44 70 4 Overall Dimensions A Length mm 1700 2250 2250 2250 2496 B Width mm 550 1234 1234 1234 1234 C Height mm 1415 1607 1956 1956 2087 Refrigerant Charge R22 kg 9 18 27 36 76 Unit Weight Approx kg 650 960 1350 1780 2510 Compressor
47. ities ranging from 2000 cfm to 51000 cfm and with single skin and double skin insulation Single Skin Air Handling Unit Double Skin Air Handling Unit Note Technical specifications for the above products are available in their respective catalogues BLUE STAR SCROLL CHILLER SYSTEMS Typical Foundation Details Air cooled Chillers Provide R C C pedestal of 250mm x 250mm height For installation on terrace provide 250mm x 250mm high beam minimum Actual length of beam shall be as per span of beam Alternately ISMB girder of suitable height can be provided Water cooled Chillers I XX stai Provide R C C pedestal of 250mm x 250mm height For installation on terrace provide 250mm x 250mm high beam minimum Actual length of beam shall be as per span of beam 10 TECHNICAL MANUAL BLUE STAR Operation Entire System Water cooled Chiller Systems Starting the system Ensure that the crankcase heater is always ON when the compressor is OFF 1 Ensure input voltage is within specified range 380 420 volts Ensure all valves on the water lines are in open condition Check water level in expansion tank Check water level in cooling tower and make up tanks Ensure water quality is within recommended parameters Oog e qe m Be certain all control sensor bulbs are inserted complet
48. ked condenser fins Less ODU airflow REMEDY Purge the system Remove excess Clean the ODU coil Reverse fan direction Low discharge pressure Low compression efficiency Low refrigerant charge and recharge Replace compressor Check for leaks repair High suction pressure Excessive load Defective suction valves Reduce fresh air amp load Replace compressor Anti freeze thermostat Faulty freeze protection control or improper adjustment Readjust control or replace follow setting standards 46 TECHNICAL MANUAL CAUSE REMEDY Clogged suction strainer dryer SYMPTOMS Low suction pressure Clean replace strainer Compressor short cycles on low pressure Compressor trips on high pressure dryer No cooling load Choked air filter Thermostat erratic Air in the system Overcharged gas Condenser fan not working Check thermostat Clean air filter Check thermostat Purge the system Remove excess charge Check ODU performance Compressor noisy Liquid knock Check for coil chokeup Defective valve reeds Check return air filter Replace compressor Scroll compressor Compressor pressure does not build up to high pressure Compressor motor working in reverse rotation Interchange any two phases of polarity for changing direction Compressor pressure Do Do does not go down on low pressure Compressor noisy Do 2
49. l flash Red MP Relay OC1 Trip if the fault exists This fault is Auto reset Comp Trips EWT 25 7 COMPRESSOR 2 LED indicator will flash Red MP Relay OC2 Trip if the fault exists This fault is Auto reset Comp3 Trips on EWT 25 7 COMPRESSOR 3 LED indicator will flash Red MP Relay OC3 Trip if the fault exists This fault is Auto reset 4 Trips EWT 25 7 COMPRESSOR 4 LED indicator will flash Red MP Relay OC4 Trip if the fault exists This fault is Auto reset only for 4compressor model 1 Trips on EWT 25 7 Reset amp COMPRESSOR 1 LED indicators will High Press Sw HP1 Trip flash Red if the fault exists After the fault is cleared Reset LED indicator flashes Green but Comp1 Trips on EWT 25 7 to be restarted by the user by pressing Reset Low Press Sw LP1 Trip key Comp Trips on EWT 25 7 Reset amp COMPRESSOR 2 LED indicators will High Press Sw HP2 Trip flash Red if the fault exists After the fault is cleared Reset LED indicator flashes Green but Comp2 Trips on EWT 25 7 to be restarted by the user by pressing Reset Low Press Sw LP2 Trip key Comp3 Trips on EWT 25 7 Reset amp COMPRESSOR 3 LED indicators will High Press Sw Trip flash Red if the fault exists After the fault is cleared Reset LED indicator flashes Green but Comp3 Trips on EWT 25 7 to be restarted by the user by pressing Reset Low Press Sw LP3 Trip key Trips EWT 25 7 Reset amp COMPRESSOR 4 LED indicator
50. load EWT 25 7 on Current Fault Comp3Overload COMPRESSOR 3 LED Indicator will flash Red amp Comp3 Underload EWT 25 7 Reset LED Indicator will flash Green Press on Current Fault Comp3Underload Reset key to restart the unit Comp3 Single EWT 25 7 Phasing on Current Comp3Single Ph Comp4 Overload EWT 25 7 on Current Fault Comp4Overload COMPRESSOR 4 LED Indicator will flash Red amp Comp4 Underload EWT 25 7 Reset LED Indicator will flash Green Press on Current Fault Comp4Underload Reset key to restart the unit only for 4 Comp4 Single EWT 25 7 compressors model Phasing on Current Comp4Single Ph Communication EWT 25 7 If the communication between Chiller Error Fault Communic Error Base Unit amp Keypad is broken then LCD will display Fault 33 BLUE STAR SCROLL CHILLER SYSTEMS Functional Logic of Compressor Tripping on Current Fault 1 A100A Current Transformer C T is placed in line on the B Phase of each compressor power wiring to measure actual compressor current 2 Compressor Tripping on Single Phasing If R or Y phase to compressor is off then current through B phase will go up If it exceeds 125 of set max compressor current then compressor will trip within 2 seconds and LCD will display Single Phasing If B phase is off then current through B phase will be zero and compressor will trip within 2 seconds LCD will display Single Phasing 3 Compressor Tripping on Overload If B phase
51. lue CR 4 three comp ON any one Comp OFF If actual EWT Set Value 3CR 4 two comp ON one from each Group If actual EWT Set Value 2CR 4 any one compressor will be ON For 4 Compressor Systems If actual EWT Set Value CR 4 only three compressors will be ON If actual EWT Set Value 3CR 4 only two compressors will be ON If actual EWT Set Value 2CR 4 only one compressor will be ON 35 BLUE STAR SCROLL CHILLER SYSTEMS 36 For 3 Compressor Systems If actual EWT Set Value CR 3 only two compressors will be ON If actual EWT Set Value 2CR 3 only one compressor will be ON For 2 Compressor Systems If actual EWT Set Value CR 2 only one compressor will be ON c If actual EWT lt Set Value CR all the compressors will be OFF Switching OFF Chiller 1 Press ON OFF key on keypad unit Unit will go into OFF Mode if it is in ON mode All the compressors will be switched OFF Compressor 1 2 3 amp 4 and Fan LED indicators will glow Red 2 You can also switch off the unit by putting ON OFF toggle switch on OFF mode Unit will be switched off The control phase i e R Phase will be cut off hence LCD display amp all LED indicators will go blank TECHNICAL MANUAL BLUE STAR Operating Instructions 2 These operating instructions pertain to Tandem Chiller Twin Circuit Air Cooled Viewing the Parameters By default the u
52. mbly amp wiring for multi compressor systems maximum 4 Nos e Condensing Unit Chiller option Wall panel mounted LCD display and keyboard Handset with 5 metre cable Master Controller with 2 relay outputs 230V AC for Compressor amp Alarm 4 Digital Inputs 12V DC amp 2 Analog Inputs for Temp sensors Slave controller with 1 relay output 230V AC for compressor amp 4 Digital Inputs 12V DC Built in SPPR protection circuit e Fuse protection 0 5 Amps for relay and transformer Crankcase Heater circuit with 2 Amps fuse protection e Base mounting Current Transformer 100 Amps for monitoring Compressor current The following are the maximum and minimum current settings Maximum Setting 42 Amps Minimum Setting 6 Amps 2level password protection for parameter setting Individual ON OFF Switch on each controller base Auto loading unloading of compressor systems with runtime equalisation In built Anti Freeze safety e Automatic starting of unit in case of power failure with preset values Optional Group Controller 50 metre cable for Display 17 Specifications 1 Controller power supply 2 Operating temperature limit 3 Display amp Keypad unit Wall mounting 4 Temperature control accuracy 5 Set temperature range 6 Set current range 7 Temperature sensors 18 SCROLL CHILLER SYSTEMS Single phase 180 to 260V AC 50 Hz 3 0
53. mp Reset indicators will flash Red if the fault exists and flash Green after the fault is cleared but not reset by the user through keypad FS Fault FS Trip Both CHW FLOW amp Reset indicators will flash Red if the fault exists and Reset indicator flashes Green after the fault is cleared but not reset by the user through keypad indicator will flash Red if the fault exists 2 indicator will flash Red if the fault exists COMPRESSOR1 indicator will flash Red if the fault exists COMPRESSOR2 indicator will flash Red if the fault exists COMPRESSOR3 indicator will flash Red if the fault exists COMPRESSOR4 indicator will flash Red if the fault exists Reset COMPRESSOR1 and COMPRESSOR2 indicators will flash Red if the fault exists and Reset indicator flashes Green after the fault is cleared but not reset by the user through keypad 40 TECHNICAL MANUAL Compressor 1 or 2 Low Pressure LP1 Trip Reset 5 and COMPRESSOR2 indicators will flash Red if the fault exists and Reset indicator flashes Green after the fault is cleared but not reset by the user through keypad Compressor 3 or 4 High Pressure HP2 Trip Reset COMPRESSOR3 and COMPRESSORA indicators will flash Red if the fault exists and Reset indicator flashes Green after the fault is cleared but not reset by the user through keypad and keypad is broken Com
54. nd splash retainers are in place Top deck assemblies and wood fill splash bars must be intact and level There must be no tendency to channel water Fill packs must be intact and in place with no sagging or gaps between packs Over pumping Reduce water flow to tower to design conditions or use larger metering orifices Unusual fan drive vibration Loose bolts amp cap screws Motor Tighten all bolts and cap screws on all mechanical equipment and support Fan Be sure blades are properly positioned in correct sockets Check match numbers Make certain all blades are as far from centre of fan as safety devices permit All blades must be pitchedthe same Clean off deposit build up on blades Disconnect load and operate motor If motor still vibrates check for bent shaft or unbalanced rotor Replace shaft or rebalance rotor Fan noise Loose fan hub cover Tighten fan hub cover fasteners Scale or foreign Substance in Water system Insufficient blow down Water treatment Check water quality Install water treatment system B CHILLED WATER amp CONDENSER WATER PUMPS Noisy operation on pumps Heavy leakage on pumps Insufficient water flow Defective bearings Replace bearings Gland packing damaged Replace gland pack Pressure doesn t rise on supply gauges Check expansion tank level Check pump direction Check suction strainer 49 Technical specifications
55. nit will show the entering water temperature and leaving water temperature Other parameters can be viewed by pressing INC key At any time of the operation if no key is pressed for 10 seconds the display will return to showing the entering water temperature and leaving water temperature EWT 25 7 LWT 25 5 1 Press INC key once display will show the Set Temperature and Cooling Range The display will be as follows SET 24 0 CR 4 0 2 When the INC key is pressed again the display will show the current through the first compressor Comp 1 24 Amps When the INC key is pressed again the display will show the current through the second compressor Comp 2 23 Amps 4 When the INC key is pressed again the display will show the current through the third compressor Comp 3 24 Amps 5 When the INC key is pressed again the display will show the current through the fourth compressor Comp 4 25 Amps 37 When the INC key is pressed again the display will show the total run time 38 10 11 12 of the first compressor Comp 1 Hr 00024 SCROLL CHILLER SYSTEMS When the INC key is pressed again the display will show the total run time of the second compressor Comp 2 Hr 00023 When the INC key is pressed again the display will show the total run time of the third compressor Comp 3 Hr 00024 When the INC key is pressed again the display will show the total run time of the fourth comp
56. ntrols as under New Saginomia Preset LP Cutout set at 35 psig Check with gauge HP Cutout set at 400 psig Check with gauge Antifreeze set at 5 C Check with thermometer Thermostat set as per requirement Stopping procedure 1 Switch off the chiller by pressing ON OFF key only 2 Stop chilled water pump 3 Stop air handling equipments Note Please note that these units cannot be operated in manual mode All alarms and faults are indicated only on the LCD control panel 14 TECHNICAL MANUAL BLUE STAR The Micro Computer Panel Controller Air cooled Chiller Systems The micro controller facia is shown below for different air cooled chiller systems For 2 amp 3 Compressors only 8 CHARACTERS X 2 LINE LCD DISPLAY POWER ON OFF MODE SPPR STATUS FAULT STATUS LED 4 FS STATUS POWER ON OFF MODE KEY COMPS STATUS UP KEY SELECT KEY DOWN KEY ENTER KEY MODE SELECTION KEY e COMMUNICATION OK LED For 4 Compressors only BLUE STAR CHW FLOW KEY 15 BLUE STAR SCROLL CHILLER SYSTEMS Water cooled Chiller Systems The micro controller facia is shown below for water cooled chiller systems For 2 3 amp 4 Compressors MICRO COMPUTER CONTROL BLUE STAR TECHNICAL MANUAL BLUE STAR Using Micro Controller 2 and 3 Circuits Modular 2 amp 3 Compressors Salient Features e Modular hardware design with modular asse
57. o leaving or return chilled liquid temperature changes from its set point Compressor capacity adjustment is accomplished differently on the scroll chillers as below In a 4 compressor circuit chiller the capacity of the output can be reduced in 4 steps 75 50 25 0 In a triple circuit the capacity can be reduced in three steps 66 33 0 In a twin circuit it can be reduced to 50 or 0 In a single circuit the chiller sensor directly switches the compressor On or Off A typical water cooled chiller TECHNICAL MANUAL BLUE STAR Air Handling Equipment The basic secondary system is an all air single zone airconditioning system consisting of an air handling unit and an air distribution system The airconditioning units are normally designed to supply a constant air volume or a variable air volume for low medium or high velocity air distribution Normally the equipment is located outside the conditioned area If the conditions permit it can be located closer to the conditioned area The cooling equipment used for airconditioning in comfort applications are normally a Direct expansion type using refrigerant fluid b Indirect cooling type using chilled water As this manual discusses only chilling units using water we will consider air handlers used with indirect cooling systems which are classified as follows In room Terminal Systems Fan coil units fixed in individual r
58. ooms can be remotely controlled by the end user Chiller water passes through the coils as the cooling media The indoor air is continuously recirculated through the coil to cool the room FCU capacities are normally limited to 1 1 5 2 2 5 3 or 3 5 TR Fan Coil Unit BLUE STAR SCROLL CHILLER SYSTEMS Floor standing Vertical Units Larger areas such as halls conference rooms and meeting rooms use medium capacity air handling units which could be floor standing or ceiling mounted Floor standing units can be installed in an enclosed room Such units circulate air through a duct above a false ceiling Return air is normally collected from above the false ceiling into the enclosed room Chilled water units are available in 5 7 5 and 10 TR capacities X Floor standing AHU Ceiling suspended Horizontal Units Ceiling suspended units can be installed above the false ceiling to conserve floor space and ducted to supply air Return air is collected directly via the plenum space above the false ceiling around the duct These models are available in 3 5 7 5 and 10 TR capacities Ceiling suspended AHU TECHNICAL MANUAL BLUE STAR Floor mounted Air Handling Units For cooling larger areas stand alone air handling units are installed in a separate plant room Air is supplied through ducts and return air is collected through ducts or ceiling plenum These units are available in capac
59. or current then compressor will trip within 10 seconds and LCD will display System Overload System Tripping on Underload If B Phase current is less than Set Min compressor current then compressor will trip within 2 seconds and LCD will display System Underload Operating Instructions 1 Switching On Chiller Switch on the chiller by pressing Power key on keypad unit POWER LED glows Green After chilled water pump is started Flow Switch input will be ON Then FS LED will start glowing Green If HP LP MP FS and SPPR inputs are OK then System will start depending on SET temperature Cooling Range amp Actual EWT after preset delay of 180 seconds for 1st Compressor then 10 seconds delay after each compressor 2 Switching ON Condensing Unit Press Power key on keypad unit to switch on the Condensing Unit Power LED glows Green First AHU Blower will start giving input signal to Controller Then FS AHU LED glows Green If HP LP MP FS and SPPR inputs are OK then System will start depending on SET temperature Differential amp Actual Room Temperature after preset delay of 180 seconds for 1st Compressor then 10 seconds delay after each compressor TECHNICAL MANUAL BLUE STAR Modular Chiller Controller will Load Unload compressors based on Actual Entering Water Temperature Set Value and Cooling range For 2 Compressor System If actual EWT gt Set Value all the compressors will be loaded If actual E
60. pressor 3 or 4 LP2 Trip Reset COMPRESSOR3 and Low Pressure COMPRESSORA indicators will flash Red if the fault exists and Reset indicator flashes Green after the fault is cleared but not reset by the user through keypad If the Leaving Water AFT Trip Temperature goes below AFT limit 5 0 C Entering Water EWT Thermister Temperature sensor Open is open or bad Leaving Water LWT Thermister Temperature sensoris Open open or bad Current through SPPR1 Trip COMPRESSOR1 Compressor 1 is indicator flashes Red and Reset out of range indicator flashes Green Current through SPPR2 Trip COMPRESSOR2 Compressor 2 is indicator flashes Red and Reset out of range indicator flashes Green Current through SPPR3 Trip COMPRESSOR3 Compressor 3 is indicator flashes Red and Reset out of range indicator flashes Green Current through SPPR4 Trip COMPRESSOR4 Compressor 4 is indicator flashes Red and Reset out of range indicator flashes Green If the communication Communication between chiller base Error 41 SCROLL CHILLER SYSTEMS Description of Indicators The various indicators available in the display of the chiller denote the following POWER CHW FLOW KEY FAN1 FAN2 COMPRESSOR1 COMPRESSOR2 COMPRESSORS COMPRESSOR amp 4 ON OFF SET Note This indicator indicates the presence of power and flashes Red if SPPR fault occurs If there is no FS fault this LED is Green and Re
61. r incidentals etc will be borne by the customer The warranty is valid only if 3 1 The equipment operates on AC power supply of 400V 5 and in accordance with the Company s operating instructions 3 2 Service repair or shifting of the airconditioner is carried out only by Blue Star s authorised dealer or by the Company The above said warranty does not cover the following 4 1 Consumables such as refrigerant oil V belts air filters etc 4 2 Scaling Deterioration of condenser water pipes and connected water piping 4 3 Deterioration or failure of equipment amp controls piping due to corrosive atmosphere This warranty is null and void if repair and or modification are carried out by the customer himself or his representative or if non Blue Star products accessories are included in the installation without written concurrence from Blue Star or its dealers This warranty is not valid in case the serial number is defaced or altered The guarantee 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 guarantee in no case shall extend to the payment or any monetary consideration whatsoever of the replacement or return of the airconditioner as a whole Any repair replacement shall not extend the overall warranty period
62. ressor Comp 4 Hr 00024 When the INC key is pressed again the display will show the total run time of the first fan Fan 1 Hr 00025 When the INC key is pressed again the display will show the total run time of the second fan Fan 2 Hr 00024 When the INC key is pressed again the display will show the total run time of the chill water pump ChilPump Hr 00024 Setting the Parameters The user or supervisor can enter into the program mode to set the various parameters by pressing the SELECT key while the display is showing the set temperature and cooling range The user password is 0851 and the supervisor password is 4321 When the SELECT key is pressed the display will show the following Password 0000 TECHNICAL MANUAL BLUE STAR The user has to press INC key to scroll the digit and RESET key to shift the digit By using these two keys the password can be selected SELECT key is used to confirm the password If the entered password is correct the unit will go to the program mode If the password is wrong the display will show an error message and return to main menu after 2 seconds The error message is Password Invalid When the user successfully enters into the program mode the display will be Set Temp 25 0 By pressing INC key the required Set Temperature can be set and can be confirmed by pressing the SELECT key Then the display will show the Cooling
63. s will High Press Sw HP4 Trip flash Red if the fault exists After the fault is cleared Reset LED flashes Green but to be Trips on EWT 25 7 restarted by the user by pressing Reset key Low Press Sw LP4 Trip only for 4 compressors model 32 TECHNICAL MANUAL Anti Freeze Temp EWT 25 7 If LWT goes below AFT limit 5 0 C then AFT fault AFT Trip Compressors will Trip and LCD will display fault LWT lt Set AFT AFT Trip Compressors will restart when LWT goes above 8 0 C EWT sensor is EWT After reconnecting good sensor unit will Auto open or bad EWT Ther Open restart Only LCD will display Fault LWT sensor is EWT 25 7 After reconnecting good sensor unit will Auto restart Only LCD will display Fault open or bad LWT Ther Open Comp1 Overload EWT 25 7 on Current Fault Comp1Overload Comp1Underload EWT 25 7 on Current Fault 1 Underload COMPRESSOR 1 LED Indicator will flash Red amp Reset LED Indicator will flash Green Press Reset key to restart the unit Comp1 Single EWT 25 7Comp1 Phasing on Current Single Ph Comp2 Overload EWT 25 7 on Current Fault Comp2Overload COMPRESSOR 2 LED Indicator will flash Red amp Comp2Underload EWT 25 7 Reset LED Indicator will flash Green Press on Current Fault Comp2Underload Reset key to restart the unit Comp2 Single Ph EWT 25 7 asing on Current Comp2Single Ph Comp3 Over
64. unction to stop compressor motor in case the settings are exceeded 18 Check compressor suction superheat after steady operation and leaving chilled liquid has been pulled down to the required temperature Compressor suction superheat is the difference between the actual temperature of the main refrigerant gas entering the compressor and the saturation temperature corresponding to the suction pressure as shown in a standard pressure temperature table for R22 Compressor suction superheat is directly related to evaporator cooler superheat which is controlled by thermal expansion valve adjustment Alow compressor suction superheat indicates alow cooler superheat approaching flooding condition of the evaporator and vice versa 19 The thermal expansion valve is factory set to control at 5 5 C superheat which in normal operation produces a compressor suction superheat of approx 6 C It is not recommended to adjust thermostatic expansion valve in the field 20 Check setting of controls as under Fixed Preset Type LP Cutout set at 35 psig Check with gauge HP Cutout set at 290 psig Check with gauge Antifreeze set at 5 C Check with thermometer Thermostat set as per requirement Stopping procedure 1 Switch off the chiller by pressing ON OFF key only 2 Stop chilled water pump 3 Stop condenser water pump 4 Stop cooling tower fan 5 Stop air handling equipments Note Please note that these units cannot b
65. vides the unit reverse polarity protection and single phase protection When compressor starts a flow of liquid will be noted in the liquid indicator After several minutes of operation the bubbles disappear and full flow of liquid occurs when the unit is operating normally Check the operation of the safety control switches and indicating lights on the control panel to be sure that they function to stop compressor motor in case the settings are exceeded Check compressor suction superheat after steady operation has been established and leaving chilled liquid has been pulled down to the required temperature Compressor suction superheat is the difference between the actual temperature of the main refrigerant gas entering the compressor and the saturation temperature corresponding to the suction pressure as shown in a standard pressure temperature table for R22 Compressor suction superheat is directly related to evaporator cooler superheat which is controlled by thermal expansion valve adjustment A low compressor 13 BLUE STAR SCROLL CHILLER SYSTEMS suction superheat indicates a low cooler superheat approaching flooding condition of the evaporator and vice versa 15 thermal expansion valve is factory set to control at 5 5 C superheat which in normal operation produces a compressor suction superheat of approx 6 C It is not recommended to adjust thermostatic expansion valve in the field 16 Check setting of co
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