Oil-Free

Chiller Manual Centrifugal Chiller

Installation, Operation &

IOM-WC rev1
Maintenance Manual
This publication contains information proprietary and confidential to Smardt Inc. (“Smardt”). Any
reproduction, disclosure or unauthorized use of this publication is expressly prohibited without
written approval from Smardt. Smardt reserves the right to make changes without notice in product
or component design as warranted by evolution in user needs or progress in engineering of
manufacturing technology.

Smardt has exercised its best efforts to ensure that the information contained in the manual is
correct. However, no warranty or reliability or accuracy is given with respect to the information and
Smardt is not and shall not be responsible or liable for the correctness or suitability of the information
or for any effort or omission.

All brand names and product names used in the manual are trademarks, registered trademarks, or
trade names of their respective holders.

TERMS AND DEFINITIONS

BMS Building Management System

EXV Electronic Expansion Valve

HP / LP High Pressure / Low Pressure

MCA Minimum Circuit Ampacity

MOCP Maximum Over Current Protection

PLC Programmable Logic Controller

RH Relative Humidity

VFD Variable Frequency Drive

For product support issues, corrections, or enquiries, contact :

Product Support
[email protected]

Smardt Inc.
1800 Trans Canada Hwy
Dorval, QC, Canada H9P 1H7
Tel : +1 514 426 8989
Fax: +1 514 426 5757
TABLE OF CONTENTS

Terms and Definitions ……………………………………………………………………… 2

Installation and Safety Guidelines ………………………………………………..………. 4

Rigging ……………………………………………………………………………………….. 7

Commissioning ………………………………………………………………………………. 11

Control Wiring Reference …………………………………………………………………… 12

Sequence of Operation …………………………………………………………………….. 13

Maintenance …………………………………………………………………………………. 17

Troubleshooting Guide ……………………………………………………………………… 19

Service Procedures ………………………………………………………………………….. 20

Removal and Installation of Compressors ………………………………………………… 25

Heat Exchanger Service ……………………………………………………………………... 28

Incident Report Procedure …………………………………………………………………… 29

Downloadable Forms:

http://interactions.smardt.com/Docs/SmardtCommissioningForm.pdf

http://interactions.smardt.com/Docs/SmardtControlWiringConnections.pdf

http://interactions.smardt.com/Docs/Smardt_RequestStartUp_AcrobatForm.pdf

http://interactions.smardt.com/Docs/Smardt_IncidentReport_AcrobatForm.pdf
 INSTALLATION and SAFETY GUIDELINES

General
The purpose of this manual is to inform contractors, building owners, and engineers of
installation, sequence of operation and service requirements for the Smardt oil-free
water-cooled centrifugal chiller. It is intended that this document be used with the
applicable installation and wiring drawings.

The water-cooled centrifugal chiller consists of an evaporator, condenser, twin-turbine

centrifugal compressor, compressor controller, and interconnecting refrigerant piping.
The chiller set is a packaged unit, requiring connection to the condenser and chilled
water circuits, as well as the main electrical supply and control wiring.

Safety Precautions
Safety precautions must be observed during installation, start-up, and service of the
chiller due to the presence of refrigerant charge and low voltage hazards.
Only qualified personnel should install, start up, and service this equipment.

Safety Guidelines
Ensure that relief valves vent outside the building in accordance with safety regulations.
Concentrations of refrigerant in enclosed spaces can displace oxygen and cause
asphyxiation.

Do not disable any safety devices.

This instruction manual contains the generally valid safety regulations that are of
the most importance to the operator of refrigeration units.

• Always ensure that the Smardt chiller is operated by qualified staff only.
• Provide suitable, fully operational fire extinguishing equipment.

Environmentally friendly handling

• Observe the instructions on handling and storing refrigerant (see safety
data sheet).
• Ensure that refrigerant does not escape into the air, the ground or the
sewage system.
• Ensure that installation, set-up, maintenance and cleaning are only carried
out by certified companies that specialize in refrigeration units. Smardt
recommends having the service department install, set up, service and
clean the system.

Safe handling – staff

Staff involved with operation of the Smardt chiller should receive instruction with
regard to the following points at regular intervals a minimum of once a year.
• Risks involved in dealing with refrigeration units
• Safety stipulations
• Conduct in the event of accidents and malfunctions
• Measures in the event of accidents and malfunctions
Personal safety equipment
Operator’s obligations:
• To provide equipment to protect against the effects of refrigerants and
coolants.
• To store fully operational personal safety equipment outside of the at-risk
areas, within easy reach.

Personal safety equipment consists of:

• Protective gloves made from leather

• Protective goggles (for use with chemicals)

RISK of SUFFOCATION
R-134a is ASPHYXIATING

Common name of the substance: 1,1,1,2 tetrafluoroethane

Chemical name: CF3-CH2F

In the event that refrigerant escapes, please observe the following

• Have first aid equipment on hand
• Have emergency shower on hand
• Wear self-contained breathing apparatus – R134a is asphyxiating.
• Ensure that everyone leaves the danger area immediately.
• Follow first aid measures relevant to refrigerant
• Inform the local safety personnel.
• Only enter rooms where refrigerant has escaped if wearing the
appropriate safety equipment.
• Ventilate rooms in which refrigerant has escaped.
• Ventilate the hazardous area.
• Stop the gas escaping.
• Ensure that the refrigerant does not escape into the sewage system or
into the environment.

If the refrigerant concentration is more than 0.25 kg/m³:

• Wear self-contained breathing apparatus.
• Ensure that at least one person with the necessary safety equipment is
standing by to come to your aid. If the following are possible without
putting yourself at further risk:
• Switch off the Smardt chilling system using the emergency-stop button or
the master switch.
• Close the valves on the suction and liquid pipes.

5
 • Observe instructions on the safety data sheet.
In case of contact with refrigerant observe the following

Cause Symptoms Measures

Gaseous refrigerant Rinse with plenty of clean water
has come into contact Eye irritation immediately. Consult a doctor
with the eyes immediately.

Liquid refrigerant has Extreme eye irritation, watery Rinse with plenty of clean water
come into contact with eyes, redness and swollen immediately. Consult a doctor
the eyes eyelids. immediately.

Gaseous refrigerant
has come into contact No risk
with the skin
Liquid refrigerant has Rinse with plenty of clean water
Frostbite with burn-like skin
come into contact with immediately. Consult a doctor
problems (redness, blistering)
the skin immediately.
Take person out into the fresh
Inability to move, air immediately. Consult a
Inhalation of gaseous unconsciousness Risk of doctor immediately.
refrigerant suffocation! If patient stops breathing:
artificial resuscitation. Inform
the poison control center.

Storage and Handling

• Only use refrigerant in ventilated areas.

• Ensure that the container is sealed appropriately (cap, chain).
• Only use containers which are suitable for Refrigerant R 134a and for the
intended pressure and temperature
• Store containers at a temperature of less than 50 °C in a ventilated area.
• Avoid long periods of exposure to heat.

Stability and Reactivity

Stability Stable under normal conditions

Refrigerant reacts strongly with alkali metals

and alkaline earth metals Pulverized aluminum
Substances to be avoided
and pulverized zinc catalyzes the
decomposition of the refrigerant.

If escaping vapors come into contact with fire

or very hot objects, they form decomposition
products which produce a high degree of
Other information irritation and have strong thermal effects. It is
possible that an explosive mixture could be
formed under high pressure and with a high
proportion of air.
 WARNING!
Low voltage in electrical equipment is potentially lethal. Isolate incoming electrical power
before attempting installation or service of the equipment.

When AC power is first removed from the compressor, the capacitors store enough
energy to cause injury. It is essential to allow sufficient time for the capacitors to
discharge before proceeding. Only a qualified electrician should work on low-voltage
electronic equipment.

Wait at least 10 minutes after isolating power

before opening compressor access covers.

Foundation
Before installing the chiller set, ensure that the supporting floor meets the load bearing
requirements. Smardt is not responsible for the load bearing capacity of the floor.

Clearance
Adequate clearance around the chiller set is essential to facilitate maintenance and
service. Required minimum clearances are tabulated under Dimensions and clearances
on page 8.

Relief Valves
Ensure relief valves vent outside a building in accordance with national safety
regulations and Jurisdictional requirements. Concentrations of refrigerant in enclosed
spaces can displace oxygen and lead to asphyxiation.
Unpacking and inspection
When unpacking the unit, carefully inspect it for visible signs of damage. Check for
damaged evaporator insulation, broken wires, and loose piping and bolts. Any damage
should be reported to the shipping company immediately.

Open all containers and verify all parts against the packing list.

Report any shortages to Smardt.

RIGGING

Care must be exercised at all times when rigging or handling the chiller set to protect it
from damage. Four rigging points (two at each end) are provided on the evaporator tube
sheet corners. The chiller’s high center of gravity must be considered when rigging to
ensure that the chiller is secure and balanced when suspended. A spreader bar / I-beam
combination should be used to safely position the chiller set into its final location. The
typical rigging details are shown below in
Figure 1.

Smardt is not responsible for the rigging and placement of the unit. Arrangements can
be made through a local equipment mover.

7
Figure 1: Rigging Diagram

Unit Placement
Install the chiller set on approved anti-vibration mounts. Each corner should be
supported on vibration eliminators and steel plate or suitably isolated from the plant
room floor. Generally waffle pads are considered suitable as the Smardt chiller is
virtually vibration free. The chiller should be protected from excessive ground or pipe
borne vibration from external sources such as pumps.

Once installed, remove the rigging equipment and check for longitudinal and transverse
alignment. Add shims, if necessary, to level the unit along both axes.

Table 1 Dimensions and clearances

MODEL H W L Lbs * Clearances
Tube removal Controls access Service top side
SW840S-3A 81.4” 41.53” 165” 19000 150” from tubesheet 36” min side 12” min above

*Includes full refrigerant charge – water circuits empty. Weights may vary with individual tube count.
NOTE: Values shown are typical. Refer to Smardt for product specific values.
Local codes may apply - ensure clearances comply with local codes/standards.
Figure 2: Dimensions and Clearances

The condenser and evaporator connections are grooved-type stubs (Victaulic®,

Shurjoint®, or other equivalent) for interconnection to the external water circuits. All
external piping must be adequately supported and aligned to prevent strain and
distortion on the chiller headers and couplings.

Pressure drops and flows

Table 2 Pressure drops and Flows
Design flow Pressure drop No. of Conn. Size (nominal)
( GPM ) ( PSI ) Passes (inch )
Evaporator 957 3.3 2 8
Condenser 1153 5.9 2 8
NOTE: Values shown are typical. Refer to Smardt for product specific values.
r circuits
The chiller set performance and efficiency can be adversely affected by contaminants in
the water circuits. Such contaminants may impede or block the flow of water through the
circuits or reduce heat exchanger performance.

Strainers should be located on the inlet side of the evaporator and condenser. Water
inlets to the chiller must be connected to the lower headers of the evaporator and
condenser. All external water piping must be cleaned or flushed before being connected
to the chiller set.

The water circuits should be arranged so that the pumps discharge through the
evaporator and condenser, and should be controlled as necessary to maintain
essentially constant chilled and condenser water flows through the unit at all load
conditions.

9
Figure 3 Piping Schematic
Control wiring
The primary chiller control functions are implemented either via a Carel® PLC, or the Kiltech
controller which looks after the control of chilled water temperature, interlocks, and interfacing
to the building system.

http://interactions.smardt.com/Docs/SmardtControlWiringConnections.pdf

Disconnects and power wiring

The mains power input connection for the Smardt range of chillers is a single point
termination via a mains termination box (supplied as standard) on each chiller unit. From
the mains termination box, each compressor control box (power and controls) is pre-
wired to the individual compressors. All power wiring upstream of this point is the
responsibility of the installing contractor.

All wiring must be installed in accordance with appropriate local, and national electrical
codes and will require a circuit breaker or fuses to protect the main wiring run from the
final distribution sub-board to the unit. A neutral and an earth are essential.
Electrical data
Table 3 Pressure drops and Flows

MODEL Voltage MCA MOCP

SW series 460 v 60 Hz 3 Phases 260 300

NOTE: Values shown are maximum. Refer to Smardt for product specific values.

Compressor motors are designed to operate satisfactorily over a range of ± 10 percent

of the standard design voltage.
Note:
A Neutral is required for control purposes. The load is essentially a balanced 3 phase
load and the neutral may be run in the minimum allowable cable size relative to the three
phase mains.

COMMISSIONING

NOTE: Smardt requires equipment to be commissioned according to a detailed

procedure and by a Smardt and Turbocor trained and certified technician. In
order to activate the warranty, the commissioning form must be completed and
submitted to Smardt. An interactive Adobe Acrobat Form is available on-line at:

http://interactions.smardt.com/Docs/SmardtCommissioningForm.pdf

If Smardt is conducting the commissioning, or you request a factory supervised

start-up, please submit the Smardt request for Start-Up Form available on-line at:

http://interactions.smardt.com/Docs/Smardt_RequestStartUp_AcrobatForm.pdf

Before commissioning

• Obtain the Smardt Commissioning Form and understand its requirements

• Ensure that all the electrical connections and any pneumatic connections
have been set up in accordance with the plans and the local regulations.
• Ensure that the PLC control system is available and is in working order.
• Ensure that all communication links to higher-level control systems and
process control systems have been connected.
• Ensure that the cold water/brine circuit has been filled and is operational.
• Ensure that the refrigerating capacity is at 100%.
• Ensure that test operation is possible at a minimum of half capacity over a
number of hours.
• Ensure that the cooling water circuit has been filled, purged and is
operational.
• Check that a heat load is available during start-up.
• Check that insulation work has been completed.
• Clean dust and rubbish from the unit.
• Ensure that the unit is accessible from all directions.
• Check refrigerant or protective gas filling at least once a month if
commissioning does not take place within 4 weeks after delivery. If this is
the case, instruct the relevant service office to do this.
• Inform the relevant service office of any damages, prior to commissioning.
• Agree on the commissioning date with the Smardt service office.

11
 • All materials needed for commissioning (refrigerant etc.) are to be
requested or made available.

Clearances
Adequate clearance around the chiller set is essential to facilitate maintenance and
service. Note and report if clearances are considered inadequate (re: Installation
Guidelines).

Damage inspection
Inspect it for visible signs of damage. Check for damaged evaporator insulation, broken
wires, and loose piping and bolts. Note any damage and report it to the appropriate
personnel on site.

Piping connections
All external piping must be adequately supported and aligned to prevent strain and
distortion on the chiller headers and couplings. Provision should be made to measure
pressure drop across each heat exchanger.

Evaporator and condenser water circuits

Strainers should be located on the inlet side of the evaporator and condenser. Water
inlets to the chiller must be connected to the lower headers of the evaporator and
condenser. The water circuits should be arranged so that the pumps discharge through
the evaporator and condenser, and controlled as necessary to maintain essentially
constant chilled and condenser water flows through the unit at all load conditions.

Control wiring reference data

The primary chiller control functions are implemented via a Carel ® PLC or the Kiltech
Controller which looks after the control of chilled water temperature, interlocks, and
interfacing to the building system. These connections are made at a 24 v terminal strip
inside the control cubicle. The Smardt Control Wiring Connections Form is on-line at:

http://interactions.smardt.com/Docs/SmardtControlWiringConnections.pdf

Chiller Controller I/O Functions for water cooled chillers (1~6 Compressors)

Temperature 1 EnChW_temp Entering chilled water temperature for control and monitoring
Temperature 2 LvgChW_temp Leaving chilled water temperature for control and monitoring
Temperature 3 EntCw_temp Entering condenser water temperature for control and monitoring
Temperature 4 LvgCw_temp Leaving condenser water temperature for control and monitoring
Temperature 5 LiquidRefrig_temp Liquid refrigerant temperature before the expansion valve.
Temperature 6 OutsideAirTemp Optional outside air temperature for data logging only
Temperature 7 Not used
Temperature 8 Not used

Digital Input 1 BMS Enable BMS Enable contact – starts and stops the chiller
Digital Input 2 ChW Flow Proof Chilled water flow proof switch
Digital Input 3 Cw Flow proof Condenser water flow proof switch
Digital Input 4 Not used
Digital Input 5 Ext LP Switch External low pressure switch
Digital Input 6 Ext HP Switch External high pressure switch
Digital Input 7 Gas Leak sensor Gas leakage sensor
Digital Input 8 Ext FreezeStat External Freezestat input
Digital Output 1 Comp Interlock Relay Compressor interlock relay output
Digital Output 2 Tower VFD Enable Cooling tower VFD enable
Digital Output 3 Chw Pump or vfd Relay Chilled water pump enable output
Digital Output 4 Cw pump or vfd Relay Condenser water pump enable output
Digital Output 5 Maximum capacity reached Maximum capacity reached output, calls additional chillers
Digital Output 6 Chiller Ready Closed when chiller is ready to run but not yet running
Digital Output 7 Chiller Fault Closed when chiller is in fault state
Digital Output 8 Chiller Run Closed when chiller is running

Analog Input 1 Tower fan VFD Feedback Tower or condenser fan VFD feedback (4-20mA)
Analog Input 2 Chw Pump VFD Feedback Chilled water pump VFD feedback ( 4-20 mA)
Analog Input 3 Cw Pump VFD Feedback Condenser water pump VFD feedback (4-20mA)
Analog Input 4 BAS Load Limit Input Building Automation System Amp Input feedback (4-20mA)
Analog Input 5 Set Point Reset Input Set Point reset input , 0-5 VDC, 0-10 VDC or 4-20mA
Analog Input 6 Level Sensor or EXV Input Refrigerant level sensor input for EXV, 0-5 VDC, 0-10 VDC, 4-20mA
Analog Input 7 Combo RH/Temp Sensor T in Outside air temp input for tower control 0-5VDC, 0-10VDC or 4-20mA
Analog Input 8 Combo RH/Temp Rh in Outside RH input for tower control. 0-5 VDC, 0-10 VDC or 4-20mA

Analog Output 1 Tower Fan VFD or 3-Way Valve VFD cooling tower fan output. Controls Cw inlet temp. (4-20mA)
Analog Output 2 Cw Pump VFD Output VFD condenser pump output (4-20mA)
Analog Output 3 ChW Pump VFD Output VFD chilled water pump output (4-20mA)
Analog Output 4 Expansion Valve Output Stepper motor output. Same loop for level control (4-20 mA)
Analog Output 5 Hot Gas Bypass Output Hot gas bypass capacity control output. 4-20mA or 0-10VDC
Analog Output 6 Power Output 0-600 kW Chiller power output power

Power Wiring

All wiring must be installed in accordance with appropriate local, and national electrical
codes and will require a circuit breaker or fuses to protect the main wiring run from the
final distribution sub-board to the unit.

SEQUENCE OF OPERATION
General
The purpose of this section is to provide guide on the sequence of operation for the
Smardt oil-free centrifugal chiller. It is intended that this document be used with the
applicable installation
Starting with stopped chiller (chiller at idle)
1. Enable signal sent from BAS sets digital input on chiller control to true.
a. Chiller controller waits 5 seconds before acting on BAS enable.
2. If the leaving chilled water temperature is greater than or equal to the “set point
temperature” plus the “∆T over set point” and there are compressors available to
run the chiller is set to “PULL DOWN STATE”.
3. Depending on the number of compressors configured to start up initially and the
number of compressors available to run – compressors interlocks are closed and
15% demand is sent to each of the selected compressors.

13
4. Once the selected compressors are started up and begin to run the chiller
demand is increased at a fixed ramp rate of 5% per minute until a demand of
100% is reached or the temperature is less than or equal to the set point.
a. At any point during this demand ramp up (temperature pull down) if the
chiller demand goes over the “%Demand Stage Up” setting and a
compressor is available to run a new compressor will be turned on.
OR
b. At any point during this demand ramp up (temperature pull down) if the
chiller power goes over a calculated optimum number to switch on
another compressor and a compressor is available to run a new
compressor will be turned on.

Each time a new compressor is turned on the chiller controller is placed into a
“STAGE UP” state, initially in this state the demand to each of the operating
compressors is reduced in order to lower the ∆P across the evaporator and
condenser such that a new compressor easily without risk of surging – This may
last for roughly 120seconds. When a new compressor is started it is started at
the same demand as the other operating compressors, once this new
compressor has reached the same RPM as the other operating compressors the
“STAGE UP” sequence finishes and the fixed ramp to set point continues again.
5. Once the set point temperature is reached the chiller control mode is changed
from “PULL DOWN” to “RUN MODE”. When the chiller is placed in “RUN
MODE” the fuzzy pid loop takes over control of supplying demand to the
compressors based on the error between the set point and leaving chilled water
temperature.
a. If the chilled water temperature drops below the set point temperature for
a period greater than 5 continuous seconds the chiller controller starts to
look if it should shut down a compressor. The prerequisites for shutting
down a compressor are:
i. The compressor RPM must be reduced to within 5% of the
compressors lowest speed for the existing suction and discharge
pressure.
ii. The minimum time between compressor turn offs has expired
(generally set to 120seconds).
 iii. The inlet guide vane must have remained at a position lower than the
chiller controller IGV STAGE DOWN% for 60 seconds
OR
iv. The chiller demand has reduced to less than or equal to 10%
(Minimum chiller loading).
6. If while the chiller is in the “RUN MODE” the heat load on the chiller increases again
the compressors are turned back on as detailed in the pull down sequence.
7. While in “RUN MODE” if the chiller is unloaded where only one compressor is
operational and the chilled water temperature drops to the chiller controller
configured “SHUT DOWN TEMP” the chiller is turned off. A 180 second anti-recycle
timer is started once this timer has expired the chiller control state is returned to
“IDLE” and the chiller may be re-started.
Abnormal operation sequences:

Chiller in alarm avoidance:

Chiller Management System continuously monitors for abnormal system conditions such
as low suction pressure, high discharge pressure, low leaving temperature, high amp
draw and others.
The controller implements a three stage alarm management strategy in order to stay
online as long as possible. The alarm management routine operates as follows:

ALARM STATE ACTION REQUIRED

All monitored values No Action Required
Normal
One or more monitored If system is loading the system stops loading.
values is within 5% of the
alarm setting
One or more monitored System demand is reduced by 0.5% per second until
values is equal to or demand reaches 10% or compressors ride to the surge
greater than the alarm speed. If the alarm is still present and the compressors are
setting at the surge speed the controller will enter stage down state
turning compressors off every 120seconds until the last
compressor is left online.
One or more monitored Chiller is turned off, all compressors shutdown. The Fault
values is equal to or will be automatically reset after the time value setup in the
greater than the trip advanced setting screen (default = 180sec).
setting Once the fault has been reset the system is set back to idle
state where it must wait for 180sec anti-recycle timer before
starting the chiller again.

15
Discharge Pressure

Chiller detected fault:

If at any time whilst the chiller is running a fault condition is detected the chiller is placed
into fault state. The chiller will remain in the fault state for a pre-configured period of not
less than 180seconds after which time the fault will be automatically reset and the chiller
placed back to “IDLE” where the 180second anti-recycle timer is started again.

Compressor faults:
If a fault is generated inside the compressor:
• If the fault is reset able such as a suction pressure, bearing displacement or
motor over temperature fault the chiller controller attempts to automatically reset
the fault and make the compressor useful again.
• If the fault is not able to be reset such as a compressor over current trip or
system component failure the chiller controller places that compressor in a not-
useable state and flags on touch screen that the compressor is “LOCKED OUT”.

A maximum of three compressor faults per hour are tolerated, if more than three faults in
an hour are generated the compressor is placed offline for a 20minute period (until fault
time expires).
If compressor does fault while the chiller is running and then reset that
compressor is then selected as the last compressor to startup when the load
increases.
 MAINTENANCE
Maintenance inspections
The following list of preventative maintenance items must be carried out by authorized
and qualified personal in a timely fashion.

Owner's responsibilities:
• Report any damage to the chiller set.
• Report any faults that occur with the chiller set.
• Turn off the chiller if fault condition persists.
• Maintain a safe working environment in the plant room, free from obstructions
and debris.
• Provide adequate lighting.
• Ensure plant room ventilation is adequate and as per government regulations.
• Maintain water treatment to the chiller as per government regulations and
maintain water quality to prevent premature failure of the system.

Smardt recommends that on-site operational checks be carried out as per Table
Operational checks evaluate the system performance, fault history and trends.

Table 1. Frequency of maintenance for Smardt chillers:

ITEM TASK Frequency

3mths 6mths 12mths
Electrical
Check Main power supply voltages
checks
Check Electrical terminals are tight
Check Hot spots / discoloration on power cables
Check Amperages are as per design
Electronic Check communication cables are secure
inspections Check pressure and temperature sensor
connections are secure.
Check there are no signs of physical damage /
discoloration on printed circuit boards.

Check the printed circuit boards are free of dust

Check EXV winding resistance (do NOT disturb
connections unless repair is required)
Check all mounting bolts are secure
Compressor Check for refrigerant leaks
refrigeration Check for mechanical damage
circuit Check operating temperatures and pressures
inspections
Chilled water Check for Insulation damage.
circuit
inspection Check chilled water sensors are secure and installed
with adequate heat transfer medium.
Check water flow / pressure drops are as per design.
Check flow switch operation.
Check for water leaks.
Check water strainers.
17
Condenser
Check condenser water sensors are secure and
water circuit
installed with adequate heat transfer medium.
inspection
(if fitted) Check water flow / pressure drops are as per design.
Check flow switch operation.
Check for water leaks.
Check water strainers.
Clean condenser tubes
Check cooling tower operation (refer manufacturers
specification(s))
Check airflow is not obstructed.
Air cooled
Check fin surfaces are clean
condenser
Check fans rotation (direction).
inspection (if
Check fan motor overload devices
fitted)

Table 2. Frequency of Maintenance – Turbocor compressor

Item Task Frequency
6 mths `12 mths 60 mths
General Check for visible mechanical damage to
inspections compressor
Check for excessive vibration from other
rotating equipment
Electrical Check main power supply voltages (refer to p
inspections 47 Turbocor service manual)
Check electrical terminals are tight
Check for signs of hotspots / discoloration on
power cables
Check amperages as per design
Check DC Bus voltage
Check capacitor mid bus voltage
Replace capacitor set
Check operation of all system safety devices
and interlocks
Electronic Check all communications cables are secure
inspections and tight
Check all electronic modules are secure
Check physical condition of all exposed Printed
Circuit Boards (PCB’s)
Check all exposed PCB’s for dust build-up and
clean if necessary
Check calibration pressure / temperature
sensors
Refrigeration Check operation of IGV assembly
Check system refrigeration charge
Check superheat level / control, if applicable
Check system and motor cooling liquid line to
ensure sufficient subcooling
Check operating conditions external to the
compressor
Clean / inspect motor-cooling strainers (if
service has taken place) As Required
 TROUBLESHOOTING
The performance of the chiller set is largely dependent on the correct operation of the
water circuits and the refrigeration system. When evaluating the refrigeration system, it
is important to check the operation of the water circuits first. Failure to do this may lead
to misdiagnosis of the refrigeration circuit. Ensure that the chiller has sufficient water
flows in both the evaporator and condenser, as per specifications.

Table 2. Fault diagnosis chart

SYMPTOMS POSSIBLE CAUSE ACTION

Low suction pressure Low chilled water flow Check flow as per design
Chilled water temperature too low Check set points
Faulty pressure transducer Check transducer
Insufficient refrigerant charge Check evaporator liquid level
Check sub-cooling
Check discharge temperature
Restricted refrigerant flow Check EXV operation
Check filter driers
Suction valve closed Check valve position
Compressor IGV stuck open Check indicated position and
carry out standard IGV checks.
High discharge pressure (water- Condenser water temp. too high Check tower set point
cooled machines)
Low condenser water flow Check flow as per design

Fouled water tubes Clean tubes

Blocked water strainer Clean strainer

Faulty pressure transducer Non- Replace transducer

condensable in system.
Dehydrate system

System overcharged Adjust charge

Discharge valve closed Check valve position

Restriction in pipe work Correct pipe work

High discharge pressure (air-

Blocked / restricted airflow Remove obstructions
cooled machines)
Air re-circulation Remove cause of re-circulation
Fans reversed Electrical Correct power supply connection
overload(s) tripped Reset / investigate cause
Motor failure Repair / replace
Replace transducer Dehydrate
Faulty pressure transducer Non-
system
condensable in system
System overcharged Adjust charge

Discharge valve closed Check valve position

Restriction in pipe work Correct pipe work

19
 SYMPTOMS POSSIBLE CAUSE ACTION
Chilled water temperature too Check temperature sensor.
High-evaporator pressure high
Check for excessive water flow.
Pressure sensor faulty
Replace transducer
IGV failure
Check operation (refer procedure)

Insufficient refrigerant charge. Check refrigerant charge.

Low refrigerant temperature
cutout Faulty sensor. Water temperature Replace sensor.
too low. Water flow blocked
Check set points.

Find / repair blockage

No motor cooling. Check pipe work / valves.

Drive temperature too high
Insufficient sub-cooling. Faulty Check compressor solenoids
sensor (refer service manual).

Check refrigerant charge.

Check liquid line for restrictions.

Replace sensor

Compressor does not start No cooling demand. Check temperature set points.

Faulty chilled water temperature Replace faulty sensors.

sensors.
Replace faulty sensors.
Faulty pressure sensors.
Check power at mains terminal
No mains power block.

No chiller controller power Check control circuit fuses / CB’s

SERVICE PROCEDURES
The following tools are required for servicing the chiller:

Service tools

Allen key set up to 14mm

Torx screwdriver #25
Manifold set
Thermometer
+1000VDC Multimeter
Computer with Turbocor Monitoring Software
Grounding wrist-strap
Connecting refrigerant gauges

It is extremely important that the manifold set is free of moisture and dust. It is also
important that the gauge set is not contaminated with other refrigerants or oil. When
performing any service procedure that requires the addition of refrigerant, do not use
reclaimed refrigerant unless it is of guaranteed quality and oil-free.

1. Connect the low pressure hose (blue hose) to the access valve provided at
the suction ball valve.

2. Connect the high pressure hose (red hose) to the access valve provided at
the discharge ball valve.

3. Purge both gauge lines to ensure that non-condensables, which can lead to
false pressure readings, are removed from the line. Once this is complete,
the service technician can evaluate the refrigeration system.

Removing refrigerant

Whenever removing refrigerant from the evaporator and condenser vessels, water flow
must be established prior to carrying out this procedure. Water flow prevents a freeze-up
condition that will cause leaks between the water and refrigerant circuits, leading to
major component failure. This procedure may vary, depending on the type of service
required.

1. Install the gauge manifold set or refrigerant recovery lines to the chiller set in
the appropriate area of service. Connect the common refrigerant hose to the
suction side of an approved refrigerant recovery system.

2. Connect a hose between the discharge side of the recovery system and the
recovery container.

3. Purge all lines of non-condensables.

4. Switch on the recovery system and transfer the refrigerant. (The time of
transfer depends on the type of transfer system and the volume of
refrigerant.) To assist the transfer, it is important to maintain a cool recovery
cylinder. Once the system pressure is approximately 10 kPa, the system can
be opened up to atmosphere and the necessary repairs carried out.

Once the system is open for inspection, turn the water pumps off or isolate flow if the
system is in parallel with other chillers. If the water circuits are not shut down,
condensation will occur in the refrigeration pipe work, leading to longer than normal
evacuation times due to the presence of moisture in the system.

Refrigerant leak testing

Leak testing can be performed by the following means:

• Electronic leak detector
• Soapy water

21
Both of the above methods are adequate to locate leaks. Once the leak is isolated, the
system should be shut down and the affected component(s) repaired

Machine not operating - no charge

1. Connect the service manifold set to the chiller as per procedure 4.2

2. Connect gauge set-up to the R134A refrigerant cylinder and add a trace gas
(only required if electronic detection device is used).

3. Connect the gauge set-up to an industrial grade nitrogen cylinder and

increase the pressure in the system to 1500 kpa.

4. Carry out leak detection as per the above procedure.

Once the leak has been repaired, pressurize the system with nitrogen and leave
undisturbed for 24 hrs. Check the pressure gauge noting any change in pressure and
ambient temperatures from the previous day. (There may be slight pressure changes if
the ambient temperature has changed dramatically.) If the pressure in the system is
maintained, the nitrogen can be removed and the dehydration procedure (4.5) can be
performed on the chiller.

Dehydration procedure

When the system has been open for a lengthy period and contamination has occurred, it
is important to dehydrate the system to remove any moisture.

ATTENTION: Never apply power to the unit while under a vacuum.

NOTE:
Use the same hoses as in the leak testing procedure, making sure the lines are free of
leaks. If possible, use copper lines to minimize potential leaks between the chiller and
the vacuum pump.

1. Install the evacuation hoses between the chiller and the vacuum pump.

2. Start the vacuum pump.

3. Open all isolation valves on the chiller to ensure that there is a vacuum
achieved throughout the system.
4. Once a vacuum has been achieved, connect an approved vacuum testing
device and check the results. If the vacuum reading is less than 500 microns,
isolate the vacuum hoses in the event that the reading is affected by the
running vacuum pump.

5. Let the chiller remain under vacuum for approx.1 hour. Recheck the vacuum
reading. If the reading does not increase by 50 microns within this time, the
chiller is ready to be recharged with refrigerant. If the system was severely
contaminated by an internal electrical failure or by the presence of moisture,
a triple dehydration procedure should be carried out, breaking the vacuum
each time with refrigerant or nitrogen to remove all contamination.
During operation, carry out refrigerant analysis on a regular basis and change filter driers
as required.

Charging the refrigeration system

Use pure refrigerant from non-contaminated cylinders.

1. Turn on the chilled water and condenser water pumps.

2. Connect up charging lines to the bottom of the evaporator vessel and the
charging cylinder.

3. Purge lines, removing non-condensables.

4. Add the correct amount of refrigerant charge to the evaporator vessel as

indicated by the name plate.

In the event that a minimum of 75% of the total refrigerant charge cannot be added to
the chiller, use an approved refrigerant pump to attain the minimum charge. The
machine will require restarting and the gas charge added during operation.

NOTE: The Turbocor compressors rely upon liquid refrigerant for the cooling of their
mechanical, electro-mechanical, and electronic components. Therefore in order to bring
the system to the correct operational refrigerant charge it may be necessary to connect
your charging lines onto the bypass port on the operational compressor, and provide
liquid to it during is operation. This will ensure adequate cooling for the compressor
whilst completing the charging of the system.

Refer to procedures 4.7 and 4.8 to determine the operational refrigerant charge, to
ensure system does not become over charged. During this procedure, it may be
necessary to bypass some control functions in order to maintain chiller operation and
thereby reach the desired refrigerant charge.

Check sub-cooling
Sub-cooling measurement procedure:
1. Set up the service manifold as per procedure 4.2; however, connect the
discharge hose (red) to the liquid line upstream of the electronic expansion
valve (EXV).

2. Note the corresponding saturation temperature of the refrigerant at the

pressure indicated. (In order to have sub-cooling, the measured value must
be less than the saturation temperature.)

3. With a temperature probe, measure the temperature on the liquid line

upstream of the EXV.

4. Calculate the difference between the saturated temperature and the

measured temperature. This difference is the amount of sub-cooling.
Design spec: 9-15° F (5-8° C).

23
Check superheat
Superheat Measurement Procedure:
1. Connect up the service manifold as per procedure 4.2.

2. Note the corresponding saturation temperature of the refrigerant at the

pressure indicated. (In order to have superheat, the measured value must be
greater than the saturation temperature.)

3. With a temperature probe, measure the temperature on the suction line.

4. Calculate the difference between the saturated temperature and the

measured temperature. This difference is the amount of superheat.
Design spec: 0-5° F (0-3° C).

Soldering procedure
When components in the refrigeration system require replacement, soldering or
sweating will be required to either remove or replace the components. To protect the
internal pipe work, the use of industrial grade nitrogen must be used at all times during
any procedure where a naked flame is applied to the pipe-work. The use of nitrogen
prevents copper oxide formation in the internal pipe work during the soldering process.
(This keeps the internal pipe work clean and free of contamination.)
1. Connect the gauge manifold set as per procedure 4.2.

2. Connect the common gauge line (yellow hose) to the nitrogen regulator.

3. Set the regulator to provide a positive pressure of 5 psig.

4. Open the nitrogen cylinder and manifold set to purge the area to be soldered.
(Nitrogen displaces any oxygen present in the pipe work.) During the
soldering process, be sure that any component that may be affected by the
addition of heat to the area be cooled by means of a wet rag wrapped around
the component.

5. Once the soldering process is complete, cool down the pipe work and shut off
the nitrogen supply. Once cool, the system can be reassembled and tested
for leaks.

Checking IGV operation

During compressor ramp-up, the inlet guide

vanes open depending on load conditions,
as indicated by the ball bearing on the
outside of the IGV housing; refer to Figure
4. If the ball does not move, further testing
will be required; refer to the Compressor
Service Manual. When the Turbocor
compressor is not in operation the Inlet
Guide Vanes will move to the closed
position.
Checking Electronic Expansion Valve operation

During operation, the EXV modulates, maintaining the pre-set liquid level in the
evaporator. The EXV responds to the liquid level sensor via the chiller controller. Refer
to procedure 4.12 to verify the operation of the liquid level sensor. If the liquid level
sensor is operating correctly, use the chiller controller interface to manually drive the
EXV. Verify that the liquid level fluctuates according to the drive signal, as observed
through the sight glass on the cooler. If the EXV fails to respond to the manual input, the
EXV is defective and requires replacement.

Checking liquid level sensor operation

Be sure control type: Level is selected in the

controller. The level sensors have a display on
the back of the sensor. Observe the indicated
level to see that it varies (particularly during
startup). At stable conditions the level should
be maintained within 5 % of the set point
(normally 45 to 55 %). The sensor is a 0 to 90
ohm resistive element (45 ohms at indicated
50%).

REMOVAL AND INSTALLATION OF COMPRESSORS

DANGER
Before performing any service on the compressor, electrical power must be isolated. To
ensure safe and clear access to the compressor, follow these procedures:

1. Switch off the AC mains at the disconnect switch. Install a lock-out device or
place a placard at the switch alerting others that compressor servicing is in
progress. Wait at least 10 minutes before opening any of the compressor
access covers.

When AC power is first removed from the compressor, the DC link capacitors
store enough energy to cause electrocution. Allow sufficient time for the capacitors to
discharge before proceeding.

2. Using a #25 bit, remove the four Torx screws that secure the mains input cover
to the main compressor housing. Refer to Figure 5.
3. NOTE: Ensure the removal of all four Torx screws, paying special attention to the
removal of the screw in the top left of the mains input cover, as failure to remove
may result in damage to the cover

25
 4. Lift away the mains input cover and set aside.
5. With a voltmeter, verify that there is no voltage present on all three phases.
6. Using a #25 bit, remove the Torx screws that secure the top cover to the main
compressor housing.
7. Lift away the top cover and set aside.
8. With a voltmeter, verify that there is no voltage present on the DC bus.
9. Remove the screws that secure the service-side cover.
10. Lift away the service-side cover and set aside.

Refrigerant Containment
Isolation and recovery of the refrigerant must be performed by a qualified service
technician.

1. Close the suction butterfly valve.

2. Close the discharge ball valve.

3. Close the inter-stage ball valve (if fitted).

4. Close the motor cooling shut-off valve.

5. Connect the service gauge as per procedure 4.2.

6. Connect an approved refrigerant recovery system to the compressor as per procedure

4.3 and transfer the refrigerant into a clean cylinder.

Compressor Removal
Refer to 5.1 "Preparation for Service" steps 1 through 7 prior to commencing the
removal procedures.

1. Remove the terminal nuts from the terminal block using a 16mm socket and wrench.
2. Remove the AC mains cables from the terminals.

3. Loosen the gland nut on the mains input bracket and pull the power cable through the
opening until it is completely detached from the compressor.

4. Disconnect the communication/interlock cables from the compressor I/O connector

module. Make sure that there is no secondary power source connected to the terminal
block before disconnecting any sensors or relay inputs/outputs. Once the transfer of
refrigerant is complete, disconnect the service isolation valves.

5. Using a 24mm wrench, remove the suction ball valve bolts.

6. Using a 8mm hex key, remove the discharge ball valve bolts.

7. Using a 8 mm hex key, remove the inter-stage ball valve bolts.

8. Remove the motor cooling connection at the rear of the compressor.

9. Replace the top cover and secure it using Torx screws.

10. Replace the main input cover and secure it using Torx screws.

11. Remove the four compressor mounting bolts using a 9/16” socket.

12. Connect an approved lifting device, such as a mobile hydraulic lifter, to the eyebolts
provided on each side of the compressor.

13. Remove the compressor.

14. Using the blanking plates provided with the new compressor, seal up the compressor
in preparation for shipment to the supplier; this will prevent moisture and foreign material
from entering the compressor, possibly affecting the compressor strip-down and analysis
procedures.

Compressor installation
Install new o-rings only when reattaching the ball valves to the compressor.

1. Remove the blanking plates provided with the new compressor.

2. Connect an approved lifting device, such as a mobile hydraulic lifter, to the eyebolts
provided on each end of the compressor.

3. Position and align the compressor over the mounting base.

4. Insert the four compressor mounting bolts that secure the compressor to the chiller.
Tighten the screws using a 16mm socket.

5. Attach the motor cooling connection at the front of the compressor.

6. Using a 8 mm hex key, tighten the inter-stage valve bolts.

27
7. Using a 8mm hex key, tighten the discharge service valve bolts.

8. Using a 14mm hex key, tighten the suction service valve bolts.

9. Connect the communication/interlock cables to the compressor I/O connector module.

10. Using a #25 bit, remove the four Torx screws that secure the main input cover. Lift
away cover. Make sure that electrical power is isolated from the AC mains cables before
handling them.

11. Route the power cable through the opening in the mains input bracket.

12. Attach the AC mains cables to the terminals, and the grounding cable to the
grounding lug.

13. Attach the terminal nuts to the terminal block using a 16mm socket and wrench.

14. Tighten the gland nut on the mains input bracket.

15. Replace the main input cover and secure it using Torx screws.

NOTE: Suction and discharge valves are meant to be used for service only. Do not run
the unit or leave open for extended periods of time. If it is intended it will be open for
extended periods use planking plates with gaskets and test of leaks.

HEAT EXCHANGER SERVICE

Air-Cooled Condenser
The Smardt condenser is a vertical air flow cross finned coil heat exchanger design. The
coil is horizontal and incorporates a separate sub cooling circuit and may have a liquid
receiver located between the main and sub cooling circuits to ensure that the main
circuit does not liquid lock.

No regular service is required; however the following checks should be made on a

regular basis:
• Ensure that the motors protection devices (in the main cubicle) are not tripped.
• Check the general state of the fin surfaces for built up soiling. A build up of dust
adhering to the fins in greasy environments can lead to air flow reduction and
poor heat exchange. Generally steam or pressure spray cleaning in the most
appropriate cleaning method.

Evaporator – shell-and-tube type

Shell-and-tube type evaporators should be treated as described for condensers above.

Evaporator – shell-and-plate type

An alternative Smardt flooded shell-and-plate evaporator may be fitted. This type is not
mechanically cleanable. Chemical cleaning methods may be used but it is essential to
ensure that the chemicals used are compatible with and will result in no harm to the
materials of construction.

Materials are:
Copper (coating – heat exchange plates)
Stainless steel (heat exchange plates)
Low carbon steel (water connections)

Proceed generally as follows:

1. Shut down the chiller set and isolate from the power.

2. Isolate and drain down the cooler water circuit, including the pump and inlet filter.

3. Remove the inlet filter and inspect it for the possible cause of the problem.

4. Replace the filter.

5. Follow the chemical suppliers procedure to introduce the chemicals only to the cooler.

6. Flush thoroughly afterwards, then seal the water circuit and refill the system. Bleed
the water circuit.

7. Re-connect power and monitor the chiller operation at startup.

INCIDENT REPORT PROCEDURE

Smardt strives for product excellence and maintains a competent staff of professionals in
application design and service to serve our customers. If you have a problem with a
Smardt chiller, we want to know about it. To report an incident and request an RMA,
please submit a Chiller Incident Report. This form is available on-line at:

http://interactions.smardt.com/Docs/Smardt_IncidentReport_AcrobatForm.pdf

29
 FUSE – 6A

24V
24VAC 24V
110 VAC
(Not Grounded)
24V

24N

24N

24N

TC T1 T-1, Entering Chilled Water Temp

TC T2 T-2, Leaving Chilled Water Temp
TC T3 T-3, Entering Cond Water Temp
TC T4 T-4, Leaving Cond Water Temp
TC T5 T-5, Liquid Refrigerant Temp (Single Ckt Chillers Only)
TC T6
Wiring Diagram

TC T7

TC T8

COM DI-1 DI-1, BAS Enable Input – Normally Open, Close to enable chiller
COM DI-2 DI-2, Chw Flow Input – Chiller Faults if opens while running
COM DI-3 DI-3, Cw Flow Input – Chiller Faults if opens while running
COM DI-4 DI-4, Not Used
COM DI-5 DI-5, HP Safety Switch – External manual reset high pressure switch
COM DI-6 DI-6, LP Safety Switch – External low pressure switch Compressor I/O PCB’s –
24vac relays Modular Single Compressor
COM DI-7 DI-7, Gas Leakage Input Same fro each module
Used to close Chillers Only!
COM DI-8 DI-8, Ext Freeze Stat compr interlocks
RLY-1 RLY-1
LVG T
+ -

RLY-1 Compressor Interlock Relay

RUN Leaving Water Temp Of
RLY-2 RLY-2 RLY-2 Tower Fan or Evap Condenser VFD Enable Signal
Module
RLY-3 RLY-3 RLY-3 Chilled Water Pump Enable or Pump VFD Enable
+ - I-LOCK
RLY-4 RLY-4 RLY-4 Condenser Water Pump Enable or Pump VFD Enable Compr Interlock #1
RLY-5 RLY-5 RLY-5 Maxim Capacity Reached ~ Call for help M
RLY-6 RLY-6 RLY-6 Chiller Ready relay Compr Interlock #2 RS485 Electronic
RLY-7 RLY-7
c + -

RLY-7 Chiller Faulted relay Expansion

RLY-8 RLY-8 RLY-8 Chiller Running relay Compr Interlock #3 Valve
AI-1 +
_ AI–1, Tower / Condenser Fan VFD Feedback (4-20mA) Compr Interlock #4 -
AI-1 Level
s
AI-2 + Liquid Level
_ AI–2, Chw Pump VFD Feedback (4-20mA) Sensor
AI-2

AI-3 +
_ AI-3, Cw Pump VFD Feedback (4-20mA)
AI-3

AI-4 +
_ AI-4, BAS Load Limiter 0-100% (4-20mA)
AI-4 Compr Interlock #5
AI-5 +
_ AI-5, BAS Set point reset (4-20mA, 0-5VDC, 0-10VDC)
AI-5 Compr Interlock #6
AI-6 +
_ AI-6, Refrigerant Level Sensor (4-20mA, 0-5VDC, 0-10VDC)
AI-6 Compr Interlock #7
AI-7 +
_ AI-7, Remote outside air temperature (4-20mA, 0-5VDC, 0-10VDC)
AI-7 Compr Interlock #8
AI-8 +
AI-8, Remote outside air RH% (4-20mA, 0-5VDC, 0-10VDC)
Wiring diagram

_
AI-8

AO-1 +
_ AO-1, Tower/ Condenser Fan VFD Speed Signal (4-20mA)
AO-1

AO-2 + RS485 COMMS TO TOUCH

_ AO-2, Condenser Pump VFD Speed Signal (4-20mA)
AO-2
PANEL
AO-3 +
_ AO-3, Chilled Water Pump VFD Speed Signal (4-20mA)
AO-3

AO-4 +
_ AO-4, Refrigerant Level Control Output (4-20mA)
AO-4

AO-5 +
_ AO-5, HotGas Valve Output (4-20mA)
AO-5

AO-6 +
_ AO-6, Electrical Power Output 0 to 600kW (4-20mA)
AO-6

FUSE – 2A Power to Touch

Panel
110

110

110
Touch Screen Power
N
Supply
N

Gnd
 Controller Default and Custom Settings

SETTING DESCRIPTION Default Setting COMMENT

Temperature Regulation Settings
Chilled air/water set point 45˚F
Leaving or entering air/water control Leaving
Dead Band 0.1˚F
Proportional band 18
Integral Gain 2500
Derivative Gain 5000
Control Min 5%
Max Slew Rate 5%
∆T Above Set point to Start 4˚F
Stop Chiller Temp (Safe shut down~ Set above alarm) 42˚F
Condenser Control Settings
Minimum Set point temperature 65˚F
Maximum Set point temperature 85˚F
Starting% 25%
Starting Timer 120sec
Starting Set point 75˚F
Set point change per minute 0.5˚F
Proportional Band 20˚F
Integral Gain 2500
Control Min 0%
Max Slew Rate 5%
Alarm Settings
Suction pressure alarm 30 psig
Suction pressure trip 26 psig
Suction trip timer 15 sec
Discharge pressure alarm 150 psig
Discharge pressure trip 160 psig
Discharge trip timer 15 sec
System amp alarm (Chiller specific) Xxx
System amp trip (Chiller specific) Xxx
Over amp trip timer 45 sec
Leaving temperature alarm 38˚F
Leaving temperature trip 36˚F
Leaving high temp limit while running 55˚F
Leaving high temp time limit 30 min
Condenser water high temp alarm 95˚F
Condenser water high temp trip 100˚F
Auto fault reset delay timer 180 sec
Compressor Staging Settings
%Demand Stage Up 90%
% RPM Stage Up 60%
% RPM Stage Down 5%
Power Stage Up % 100%
Stage up time delay 240 sec
Stage down time delay 120 sec

31
Pressure ratio limit 2.2
IGV% before stage down 75%
Number of compressor to start (Chiller/ Site
Xxx
dependent)
Look forward time 1 sec
Temperature Reset (upper) (only works if reset 0˚R /
based on return temp is selected as reset mode) 54˚F
Temperature Reset (lower) (only works if reset 4˚R /
based on return temp is selected as reset mode) 45˚F
Display Units Imperial
Comp Mode Modbus
Pass Code 0
Chiller Address 1
RS485Baud (Chiller to BAS comms) 19200
Evaporator VFD Tuning 35
Condenser VFD Tuning 45
Design kW input (Chiller dependent) Xxx
System Setup
Number of compressors (chiller dependent) Xxx
Number of refrigerant circuits (chiller dependent) Xxx
Three phase VAC (Site dependent) Xxx
Compressor Type TT300
Evaporator Type Flooded
Water
Condenser Type
Cooled
PID
Control Mode
Leaving
Cond
Condenser Control Mode Water
In
Equal
Stage Mode
run time
Chiller model (chiller dependent) Xxx
Temperature reset mode AI #5
Hot Gas Valve Settings
Proportional Band 2˚F
Integral gain 1500
Control Min 0%
Max Slew Rate 5%
Starting % 50%
Starting Timer 180 sec
Set point (∆T Below the set point) 1˚F
Manual Valve % 0%
Step Count 24000
Sensor & Analogue Input Settings
Temperature Input#1 Offset 0˚R
Temperature Input#2 Offset 0˚R
Temperature Input#3 Offset 0˚R
Temperature Input#4 Offset 0˚R
Temperature Input#5 Offset 0˚R
Temperature Input#6 Offset 0˚R
Temperature Input#7 Offset 0˚R
Temperature Input#8 Offset 0˚R
 Analogue Input Scaling
AI-1 Cond Fan VFD Speed Feed Back 0/0/100
AI – 2 Chilled Water Pump VFD Speed Feed Back 0/0/100
AI – 3 Condenser Water Pump VFD Speed Feed Back 0/0/100
AI – 4 BAS Load Limit input 0/50/100
AI – 5 Set point Reset 0/0/10
AI – 6 Refrigerant Level Sensor 0/0/100
AI – 7 Remote Temp Sensor 0/32/150
AI- 8 Remote RH% Sensor 0/0/95
Electronic Expansion Valve Settings
Proportional Band 5˚R
Integral gain 500
Control Minimum (min valve position per compressor) 7%
Max Slew Rate 5%
Starting % 25%
Starting Timer 120sec
Min SH Set point -2˚R
Max SH Set point 1˚R
Minimum Sub-cooling 2.5˚R
Manual Valve % 0%
Step Count 24000

Record of compressor controller settings

SETTING DESCRIPTION Default Setting COMMENT
Compressor Alarm and Trip Settings
Compressor Control Mode Modbus
Display Units Imperial
Discharge pressure alarm limit 155
Discharge temperature alarm limit 90
Suction pressure alarm limit 28psig
Leaving temperature alarm limit 38˚F
Current alarm limit (Chiller dependant) Xxx
Discharge pressure trip limit 170
Discharge temperature trip limit 95
Suction pressure trip limit 25psig
Leaving temperature trip limit 36˚F
Current trip limit (Chiller dependant) Xxx
Electronic Expansion Valve Settings (Modular Chillers Only)
Liquid
Control Mode
Level 1
Auto/Manual Auto
Stepper Startup% 25%
Stepper Startup position delay 120 sec
Stepper control set point 35%
Stepper control loop speed 45%
Stepper minimum count 10%
Maximum step count 6000
RS485 Modbus Settings

33
Slave Address (Compressor dependent 1~6) Xxx
Baud Rate 38400
Stop bits 2