Blue star chillers manual

Blue Star has introduced a wide range of air cooled and water cooled scroll chillers with R and RC refrigerant options. Manufactured using world-class capabilities at it's own ISO certified factory, these chillers are available in a wide range of capacities. Blue Star is a pioneer in manufacturing air cooled scroll chillers. Unlike in a manual control where tolerances are much higher, the digital. It has been a pioneer in manufacturing a wide range of Screw Chillers.

Manufactured at its own ISO certified factory with world-class capabilities, these energy efficient green chillers are robust in construction and have been developed with the latest technology screw compressors specially designed for Ra refrigerant. The user password is and the supervisor password is By using these two keys, the password can be selected. 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 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. Then the display will return to the default window. The second line of the LCD is used to display the faults.

The LCD will show all the faults which have occurred as follows. The messages for the various faults are as follows. If the communication Communication ———————- between chiller base Error and keypad is broken. KEY: This indicator flashes green if any key is pressed. Note : 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.

Dry the filter in the shade and re-install it. General compressor Once a week Crankcase heater: Touch the heater body to checks verify that it is warm. Twice a year Oil leaks: Verify that there are no oil leaks. Twice a year Vibration isolation rubber: Inspect the vibration isolation rubber for wear. Control panel Four times inspection a year Inspect the circuits in the control panel and tighten loose wires.

Water line strainers Vibration Isolating pipe hangers Cond. 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. Problems due to power supply quality must be sorted out with concerned electricity board.

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. 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. 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. Motor Disconnect load and operate motor. If motor still vibrates, check for bent shaft or unbalanced rotor. Replace shaft or rebalance rotor. AV, 18A. Hence kindly ensure the following details are filled in. Phone Model Nomenclature Invoice No. Date of Despatch Date of Commissioning Warranty Commencement Date Warranty Expiry Date The warranty is valid only if: 3. The above said warranty does not cover the following: 4.

This warranty is not valid in case the serial number is defaced or altered. 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. Bangalore Plot No. Phase - II, Chandigarh Jaipur Pune Tel: Lucknow New Delhi Hence full load is achieved. Step Capacity Control System No.

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 backwardin 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. 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 specified oil and do not mix with different brands of oil. Different kinds of refrigerant should match with different kinds of oil. Note that some synthetic oils are incompatible with mineral oil.

Prior to fillery oil in the compressor, the system should be totally cleaned up during the initial startup and ensure that it is clean completely. 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. The table below shows the oil replacement standard. 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 acidic 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.

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 are the probable problems existing in the system that should be faced: 1. Contamination of oil by debris causes clogging in the oil filter. Acidified system due to the moisture causes corrosion in the motor. Spoiled oil due to the compressor running at long duration of high discharge temperature reduces life of bearing. Refer to the following oil change intervals to ensure normal running of the compressor. Change the oil periodically: Check the oil for after every 10, hours of running periodically for the first operation cleaning of filter and oil change is recommends after 20, hours of operation hours is recommended.

Due to the piping debris could be accumulated inside the system after operation, check the oil after 2, hours or after one year of running. Check the system whether clean or not and then change the oil after every 20, hours or after 4 years running while the system is operated under good condition.

Prevent debrics from getting clogged in the oil filter. Clogging can cause fearing failure. Installing an optional oil pressure differential switch is recommended 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 to bearingsdue to lack oil. 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, hours of running which reaches first.

Acidity in lubrication oil shortens life of bearing and motor. 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. Refer to the oil changing procedures especially after the system overhaul owing to the motor burn out. Check the oil monthly or periodically and change the oil if it is if bad quality, it is necessary to take care of the oil quality and system cleanness and dryness in the system periodically. 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 overheating, 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. C , the compression ratio will be high at this condition and also the discharge temperature. Hence the use of liquid injection system is essential. Items 1. Accessories Things to be checked 1. Oil level Standard Values 1. Higher than the middle line of oil level sight glass.

Turn on the oil heater at least 8 hrs. Opened 4. No distortion or damage 1. Standard voltage is V. Maximum voltage is V. Insulation resistance value should be above 5 M ohms. Voltage of the control circuit. Insulation Resistance value of the motor between phase to phase and phase to ground.

Power terminals and wire cables terminal connections. Earthling 6. Settings of switches, sensors and controllers. Piping system 1. External piping 2. Leakage test 3. Compressor fixed tightly Leakage test 1. Motor winding sensor Discharge temp. Power terminals are firmly fixed on terminal block and well insulated.

Keep wire cables away from heat source and sharpened metal. Terminal screw and block, both are required. As per local Electricity regulations. Properly set. Fixed properly 2. No leakage 3. Check up the tightness. Pre-Start Up 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. 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. 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. Establish flow through the water cooled condenser for water cooled chillers. Adjust the flow rate to the designed rated flow. Connect the condenser water flow switch with the control panel. Check if all the stop valves in the system are already opened 6. Check if the setting on each timer relay is correct. 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. Starting Current of the compressor The starting current of different model compressor is as given below LRA.

This will be approximately 3. The starting for the Y start is usually set at 4 1 second, and the maximum allowable shift time from Y to 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.

The running restraint of compressor 1. C to 55 Deg. C The control voltage is normally V Protection switch. The table below shows the list of protection switches, which are essential to protect the compressor and operate safely Protection Switch Motor winding temperature protector High discharge temperature protector Phase reversal protector Hi Low pressure protector Phase failure protector Motor overload relay Set Point Cut out Deg. C Cut in 75 Deg. Cut out Deg. C Cut in 60 Deg. Operation of Micro Controller The control circuit for the Chiller comprises of analog sensor inputs such as suction pressure s , discharge pressure s , entering and leaving water temperatures etc.

It consists of relay outputs that drive the compressor s , condenser fans, economizer s etc. The crankcase heater should be ON for a period of min. The unit goes in power up mode. In this state, all relay outputs are turned OFF. Switch ON individual system toggle switches mounted in control section to enable demand for respective compressors.

Controller checks for any anti-cycle fault timers leftovers and then generates demand for the first compressor based on set point and actual chilled water temperature. Applicable in case of Air Cooled Chillers 6 Depending on difference between the leaving water temperature and set point, the system shall load or unload.

Unless any of the compressors goes in safety hold. To shut down complete chiller switch off rotary switch provided in panel. To switch OFF a particular compressor, respective toggle switch should be switched off. During normal shut-down through controller, Compressor runs for preset time to enable unloading of slide to minimum position before switching OFF Run Time Equalization. Controller has minimum run time equalization logic option set point should be 0 and set point should be 1.

Compressor which runs for minimum time shall start first during next operation cycle. Safety Parameters During normal running of compressor s following safety Parameters are monitored : Sr. Operating Specifications The following are the Operating Specifications and default set points: 1. Leaving water temperature is set at 45F with a control of 0. Applicable for air cooled chillers only The delay between the Star and Delta connection is preset at 3 seconds.

Anti Freeze Thermostat setting is at 39F. Capacity Control Method The capacity control method is based upon to develop the control zone on both side of Water leaving temperature set point, and accordingly add or subtract the capacity control stages of chiller. To accomplish this system will constantly monitor the set point, trend of load and slide position in relationship to the control zone.

This will be the base of developing the control zone. The lower limit is obtained by subtracting the dead band - set point from the control target Once the control zone has been established, the system will attempt to keep the control sensor reading with in this range.

The capacity control stage calculation is in hold if the chiller running in control zone. Controlling Sensor This is the sensor that has been specified as leaving temperature. Trend of Load The Trend of Load is how fast the control value is changing over a period of time.

If the control value is increasing the rate will be positive, if decreasing the rate will be a negative value. How fast the input is changing, its direction and where the current input reading is in relationship to the control zone will determine what action the system will take. The speed that it is decrement by is based upon the Trend of Load of control input value and the slide Response that has been specified.

Slide Response The purpose of the Slide Response value is to limit or dampen how fast the slide reacts to changes indicated by the control sensor. The lower the number, the faster the system will react to changes of the control sensor.

The Control Status portion of the Status screen is shown below. Chiller information:. Slide Valve Countdown - value that is counted down. The Slide Response and where the control temperature is in relationship to the control zone will determine the speed of the count down. When the value decrements to zero, the system will determine if a change in the systems capacity is required. Circuit information all active circuits will be displayed :. Circuit Number and State - Circuit number and state.

Oil Diff - Oil differential pressure. Oil differential pressure is calculated as follows: Semi hermetic screws; Oil psi Suction psi or Discharge psi Suction psi. Lead - indicates the lead compressor. In this state all points ROs are turned off. This is a time delay to insure the controller has stable power before starting the algorithm.

Items such as freeze protect and emergency stop will force the system into this state. Lockouts can be reset with user level authorization from the keypad; however if the lockout condition has not been corrected, the system will again be forced into the LOCKOUT state.

NOTE: If the Lockout reset is pressed more than 10 times in a day the unit cannot be reset till Factory authorization.

When this state is entered the system will generate an off line alarm, which locks out the unit. The controller will generate the alarm in this condition and not required to be reset if alarm is clear. The control sensor reading is being maintained with in the control zone. Control sensor reading is above the control zone but the Trend Of Load is less than the value in the set point.

This indicates that the temperature is decreasing toward the target at an acceptable speed. Therefore, no additional cooling is needed at this time. The temperature is below the control zone but the Trend of Load is greater than the set point. This indicates that the temperature is increasing toward the target.

Therefore, no reduction in cooling is needed at this time. This state indicates that there is no need to adjust the cooling capacity of the chiller package. This state will be exited when more or less capacity is required. Circuit Control States The action of the circuit control states actually result in more, less or no change in the amount of cooling capacity. An alarm is generated but the system will restart after the delay specified in the corresponding set point.

In this state the circuit is ready to provide cooling capacity if needed. The circuit will remain in this state for a minimum of 60 seconds. The compressor is on and the liquid line solenoid is closed. The circuit will then move to the OFF State. The system will remain in this state for 60 seconds while the fast unloader and unload points are on.

It has been a pioneer in manufacturing a wide range of Screw Chillers. Manufactured at its own ISO certified factory with world-class capabilities, these energy efficient green chillers are robust in construction and have been developed with the latest technology screw compressors specially designed for Ra refrigerant. These chillers have very low power consumption at full load as well as part load conditions.

They are tested in our fully automated test labs to validate their performance. This guarantees reliability and long life of bearings; more than 1 lakh hours under heavy operating conditions. The external oil separator is provided to effectively separate oil from the refrigerant. Embed Size px x x x x No part of this publication may be reproduced in anymanner whatsoever without permission in writing from theExecutive 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 consequenceof any action taken, on the basis of this publication. Technical Specifications Rigging and Installation.