General

Dear Customer Receiving

Thank you for choosing PETRA’s chillers On arrival, inspect the unit before signing
Unit with Semi Hermetic Compressor An IMPORTANT is used to focus on the delivery note. Specify any damage on
(APSa) unit. Please read this manual information that must be noted. the delivery note and send a letter of
thoroughly since it contains valuable protest to the last carrier of the goods.
information on installation, operation and
maintenance of the unit. This will ensure a This manual covers the installation,
longer life time for the unit operation and maintenance of PETRA’s
Chillers Unit with Semi Hermetic Inspection
The following symbols will be used in this Compressor (APSa) unit.
operational manual to alert you to areas of Check the shipment received according to
potential hazard: This will ensure proper operation and a the shipping list to make sure that
long-life service for the unit. shipment is complete. After inspecting the
unit, protect properly during storage or
while moving it to the actual installation
site. This step is important to maintain
warranty to protect unit against adverse
A NOTE is used to highlight additional weather, theft or vandalism on job-site.
data that may be helpful to you.
For more information please contact your
local service center or refer to PETRA
Factory.
Damage to Units
Be sure to inspect the unit upon receipt for
damage. If the unit has been damaged in
A CAUTION is used to identify a hazard transit, file a claim with the transportation
which could lead to personal or machine company immediately and check your
injury. If you need any further information about insurance company immediately.
PETRA’s chillers Units or other Units,
please do not hesitate to contact us at
your nearest sales office.

A WARNING is used to identify a hazard

which could lead to personal death or
machine destruction or break down.
All procedures presented in this manual,
such as installation, operation and
maintenance must be performed by
trained and qualified personnel.

Safety considerations

Keep all doors and screws installed on unit

Installation, start up and service of air PETRA’s Chillers Unit with Semi Hermetic
while moving unit and installing ductwork.
conditioning equipment can be hazardous Compressor (APSa) units are equipped
This will help ensure that the unit stays
due to system pressures, electrical with unsurpassed features microprocessor
square allowing for easier removal of
components and equipment location controller to manage the unit performance
doors after the ductwork is attached.
[roofs, elevated structure...,etc.]. Therefore for optimum efficiency at both full load and
only trained and qualified installation and part load values.
service technicians should install, start up
or service this equipment.

Follow all safety codes.

When working with the equipment,
observe precautions in the literature as
This manual covers the installation, well as the tags, stickers and labels placed
operation and maintenance of PETRA’s on the units.
Chillers Unit with Semi Hermetic
Compressor (APSa) unit.

1
APSa
Safety considerations

Be sure to disconnect power before Wear safety glasses and work gloves. Before driving screws into the cabinet,
servicing this equipment. check the inside of the unit to be sure the
screw will not hit electrical or water lines.

Be careful when handling, rigging and

Before operating, be sure the unit is setting bulky equipment.
properly grounded to prevent injury or The unit must not be operated outside the
death from electrical shock. design limits specified in this manual.

Keep quenching cloth and extinguishers

nearby when brazing.
DO NOT VENT refrigerant relief valves
within a building. Relief valves outlet must The manufacturer will not be liable for any
be vented outdoors. injury or damage caused by incorrect
installation, operation or maintenance
resulting from a failure to follow the
Do not tip units on their side during procedures and instructions detailed in the
transportation or installation, otherwise manuals.
Ulmost care has been taken in the design severe internal damage may occur.
and the manufacture of the units to ensure
that they meet safety requirements.
However, the individual operating or
working on any machinery is primarily
responsible for:
personal safety, safety of other personnel,
and the machinery.

Warranty
Petra parts only warranty
PETRA Product(s) is warranted to be free from defects in material and workmanship for twelve months after the date of installation or
eighteen months after the date of delivery, whichever occurs first, if such defect arises from normal usage of the product in accordance
with the instructions of the manufacturer.
In the event that any part becomes or is shown to be defective under normal usage within the warranty period, expect parts that
customarily require replacement such as air filters, the manufacturer shall repair or replace such part ,at the sole discretion of the
manufacturer.
The manufacturer's obligation under this warranty is limited to:
Repairing the defective part
Or
Furnishing a replacement part provided that the defective part is returned
to the manufacturer

The warranty will be void if the product has been altered, applied to a different application that those it is designed for ,damaged
,misused ,subjected to abnormal use or service; or if the serial number has been altered, defaced or removed from the product.
The warranty will not cover any failure or improper function of any product due to misapplication or improper installation, inadequate or
incorrect wiring, incorrect voltage conditions ;excessive oversize or undersize of product selection ,unauthorized service, or operation at
abnormal conditions such as excessive temperatures or inadequate water flow rates.
In addition, the warranty does not include defects resulting from natural disasters, wars, riots, thefts, fires, earthquakes, floods, lightning
bolts and sudden electrical surges.

For warranty purposes, the following

conditions must be satisfied:
! The initial start of the unit must be carried
The warranty is void if the equipment is
out by trained personnel from an
repaired or modified due to misuse, lack of
Authorized Petra Service Center.
maintenance or failure to comply with
! All the scheduled maintenance PETRA’s instructions or recommendations.
operations detailed in this manual must If the user does not conform to the above
be performed at the specified time by mentioned general notes, it may result in
suitably trained and qualified personnel. the cancellation of the warranty.
! Failure to satisfy any of these
conditions will automatically void the
warranty.
2
APSa
Nomenclature

APSa 100-2 AC 1

A P S a XXX X AC 1

Air-Cooled Option Code:

0 : Without Wire Mesh
Around Chiller

Packaged Chiller 1 : With Wire Mesh

Around Chiller

Semi Hermetic
Screw Compressor Coil Corrosion Protection Material:
AC : Aluminum Fin-Copper Tube
PC : Pre - Coat Aluminum Fin-Copper Tube
Refrigerant 134a
CC : Copper Fin -Copper Tube
BC : Coated Copper Fin - Copper Tube

Nominal sizes:
XXX ; 050 175 415

No. Of Compressors; X 1,2,3 or 4

Name plate description

Nameplate Description
A : The code identification of the machine model.
Nameplate description B : Reference number of the project.
C : The serial number of the machine.
D : The nominal operating power supply voltage over frequency over
the number of phases required.
Ea, Eb : The quantity of compressors installed.
Fa, Fb : The voltage required for the compressors with ±10% tolerance.
Ga, Gb : Locked rotor ampere (starting current) for each compressor.
Ha, Hb : Rated load ampere for each compressor.
Ia, Ib : The maximum running current.
Ja, Jb : Horse power of motor.
Ka, Kb : The quantity of condenser motors installed.
La, Lb : The voltage required for the condenser motor with ± 10% tolerance.
Ma, Mb : The number of the phases of the condenser motor.
Na, Nb : Motor Kilowatt .
Oa, Ob : Full load ampere for each condenser motor.
P : The quantity of evaporator motors installed.
Q : The voltage required for the evaporator motor with ±10%tolerance.
R : The number of the phases of the evaporator motor.
S : Motor Kilowatt.
T : Full load ampere for each evaporator motor.
U : The quantity /stages of electric heater in stalled.
Minimum water loop Chiller minimum water V : The voltage required for the electric heater with ±10%tolerance.
volume (GAL) flow rate (GBM) W : The number of the phases of the electric heater.
X : Kilowatt capacity of the heater.
Y : Full load ampere for electric heater.
Z : The type of refrigerant

3
APSa
Description of components

Refrigeration components Diagnostic alarms:

The driver is able to recognize various
Thermostatic expansion valve ! 1 current analog input (0-20 mA or 4- alarm situations, including probe error,
This device controls the superheat of 20mA) for measuring the evaporation LAN error, Valve connection error and
refrigerant vapor at the outlet of the ! 4 current outputs for piloting the valve's inability of the valve to close after power
evaporator. It acts as a throttle device stepper motor failure.
between the high pressure and low
! 1 alarm relay
pressure sides of a refrigeration system Advanced Flow Control
! 5 LEDs for indicating operating status
and ensures that the rate of refrigerant The driver controls the opening of
flow into the evaporator exactly matches ! Connection to an optional back-up
electrostatic expansion valve according to
the rate of evaporation of liquid refrigerant battery pressure
the desired superheat. There will be no
in the evaporator. Thus, the evaporator is Electronic Expansion Valve Control flow through the expansion valve as long
fully utilized and no liquid refrigerant may The regulation algorithm offers the as the compressor is not running. Once the
reach the compressor. following functions: compressor start up the driver will be
Super heat control: Under near static informed, through a digital input, and will
plant operating conditions. The following start to control the refrigerant mass flow.
figure the calculated mass flow in relation This control is stand alone by precise
to the measured heat exchange capacity positioning of the electronic expansion
of evaporator. valve under different operating conditions
such as compressor start up, start of
further compressor, high/low head
pressure, high/low load and partial load
operation.
Mass Flow

Refrigerant mass flow control has a fast

response with a wide range capacity, high
resolution, highly linear flow capacity and
continuous modulation of mass flow with
Electronic Expansion Valve no stress in the refrigeration circuit.
It is a device for precise control of 0 List of Alarms
refrigerant mass flow. This valve consists The four LEDs, located at the front cover
of two main internal assemblies; the valve Super Heat of the driver, have a primary function of
body and the stepper motor. indicating whenever an alarm should
The housing of body and motor is hermetic occur. The following table illustrates the
Suction pressure control:
utilizing exclusively brazing and welding different alarms:
Under operating conditions of over/under
technologies and elementary all gas kits,
load. These conditions are detected when
The design offers several technical
the pressure exceeds the set limits MOP
advantages such as direct coupling of
(Maximum Operating Pressure) or LOP
motor and valve assembly for easy and
(Lowest Operating Pressure). In these
reliable movement of the valve assembly.
situations, super heat is still controlled. POWER
There is no need for any other seals,
The following figure illustrates capacity
eliminating the use of bellows and
variation of compressors and expansion ALARM
diaphragms which could be subject to life
time limitations, the body is stainless steel. valves at 2.8°C evaporating temperature:
For the motor, the amount of rotation is
dependent on the number of pulses, one
pulse will move by ( a =1.8°). A load trains 230
TXV2
oil will lead to continuous rotation. 230
The drive shaft of the rotor is connected to 190 EXV1 TXV1
Capacity kw

a spindle to transform the rotation in 170

conjunction with a cage assembly into a 150
line motion for moving of the valve slides. 130 Compresseor
The gate valve is specially designed for 110
linear flow characteristics in order to 90
provide a wide range of capacity with a
70
linear rotation between flow and 86 95 104 113 122 131
positioning of the valve. Condensing TemperatureoC
Driver
The driver for the EEV is a programmable
device, which regulates the expansion in
one refrigeration circuit with the aim of
maintaining constant superheat. Status of LEDs Type of Reset
Alarm
This function is achieved by regulating the Open LED Close LED Power LED Alarm LED
opening of the valve using a PID self- Open Valve At Power Failure Blink Blink On Blink Manual
adjusting algorithm. Probe Error Off Blink On On Automatic
The driver features: Stepper Motor Error Blink Blink On On Automatic
EEPROM Error At Start Off Off On Blink Manual
— 24 VAC power ± 10%
EEPROM Error At Working ** ** On On Automatic
— 1 NTC analog input for measuring the
**: Shows the Valve Status
temperature of the superheated vapor

4
APSa
Description of components

Crankcase Heater Pressure Switches Replaceable core drier

The heater minimizes the absorption of the Moisture will enter a system any time it is
High Pressure Switch operated for field services. A filter drier is a
liquid refrigerant by the oil in the crankcase
The switch has fixed non-adjustable very effective method for removing small
during brief or extended shutdown periods.
settings, and is mounted in the discharged amounts of moisture and contamination. It
side of the compressor. The switch is is installed in the refrigerant liquid line, so
provided to protect the compressor and that all the refrigerant in the circulation
the refrigeration system from unsafe high passes through the drier, each time it
pressure conditions. If an unsafe high circulates through the system.
pressure condition should exist, the switch
The heater is located in the bottom cover
opens and shuts OFF the compressor. The
of the compressor. The heater fixture must
unit control module prevents the unit from
be tight to prevent it from backing out of
restarting. Don’t operate the unit on high
the heater well. The heater eventually
pressure more than 2825 kpa).
burns out if exposed to air for an extended
period.

Never open any switch that de-energizes

the crankcase heater unless unit is being
serviced or is to be shut down for a
prolonged period. After a prolonged
shutdown on a service job, energize the
crankcase.

Shut off Valve

This is a manual valve located in the liquid Low Pressure Switch
line used for pump down applications and This switch, which is mounted on the
for liquid line accessories repair or compressor has fixed non-adjustable
maintenance. settings. It is of the automatic reset type.

Solenoid Valve
This is normally closed with a de-
energized coil solenoid valve and is fitted
on the liquid line. The solenoid valve is Unit should be in continuous operation for
opened when the compressor is ON and at least 10 minutes prior to checking the
closed when the compressor is OFF. low pressure switch.

Pressure Switches Limit Table Cut Out Cut In

Manual
High Pressure kpa 2825 (with differential)
Low Pressure kpa
(for cooling) 140 280

Low Pressure kpa

(for heat pump) 140 70

5
APSa
Description of components

Power And Control Components Power Circuit Breaker (PCB) (Optional) Upon confirmation of healthy 3 phase
Control Circuit Breaker (CCB) (Option) The function of the power circuit breaker is supply, system will monitor the power
to provide protection from short circuit for supply constantly according to the DIP
This device is incorporated in the unit as
the whole unit or for each motor. switch settings. Should there be failure
part of the control circuit to protect the
occurred, system will flash the red LED
control circuit from a short circuiting.
slowly until the error delay time out and
relay will be turn off. If power supply is
recovered before the error delay time out,
red LED will be off and system operate as
normal. System will lock the error if this
failure happens > 5 times within 2 hours.
This fault can be reset by manually turn off
the power supply only.

All PETRA units can work using the nominal

power supply 10%
Voltage Monitor/Phase Failure Relay (PFR)
Feature
1. Phase reversal.
The crankcase heater of each three phase 2. Over or under voltage.
compressor can be energized when this 3. Multiple type of fault auto recovery and
control circuit breaker is switched ON. It is lock function. 1. PFR Factory setting must be adjusted with
highly recommended to energize the
factory approval
crankcase heaters of the compressors 24 PFR Adjustment procedure 2. Adjustment of PFR below or over 10%
hours before operating the unit for the first There is a 8 way DIP switch to program the will void the unit warranty
time or if the unit was out of use for a long 3 phase monitor to the table below.
period of time. Upon power up, the controller will blink the
red LED quickly indicating at warm up
Contactor stage. This process may take a few
The contactors are mainly used for seconds [0 - 20 sec depends on the
controlling 3-phase motors. voltage supply and monitor settings]. Red
LED will be off once the power supply is
stable. Green LED and relay will turn on 5
sec later.
Should the controller is unable to read the
healthy 3 phase supply after 20 seconds, it
will lock the error and flash the red LED
according to the alarm code. It will check
the power supply again 280 sec later.

SW 1 SW 2 SW 3 SW 4 SW 5 SW 6 SW 7 SW 8
Fault time delay Voltage tolerance Reserved Voltage measuring 3 phase input
00 - 5 sec 00 - 5 % 0 - Monitor 00 - 380 V
01 - 10 sec 01 - 10 % 1 - Bypassed 01 - 400 V
10 - 15 sec 10 - 15 % 10 - 415 V
11 - 20 sec 11 - 20 % 11 - 440 V
The unit should contain all the required To select time Check according When set to '1 ', no Select accoriding
contactors to start all motors such as delay to confirm to SW 7 SW 8 under/ over voltage to power supply
compressors and pumps. (Evaporator fan fault settings checking will be done
motors and electric heaters if available)

6
APSa
Standard features
Construction
! Galvanized C-channel chiller base with turn increases system reliability. ! Control voltage is 220-240V for all
lifting lugs painted with Acrylic ! Components of each refrigeration circuit: components.
Polyurethane paint. - Expansion valve. ! Power supply monitor
! V-shaped, air-cooled condenser allows - Liquid line solenoid valve. (phase failure relay)
less installation space requirements - Liquid line shut off valve. ! Single point power connection for each
! Modular design with multiple compressor - Liquid line moisture indicator sight electrical panel (refer to electrical
execution provides flexibility for varying glass. data tables).
load conditions and avoids total shut - Replaceable core type filter ! Starting contactors for compressors and
down of the chiller during servicing of - Fully charged unit with R134-a condenser fan motors
any of the refrigeration circuits. refrigerant. ! Automatic pump down control.
! Easily accessible system components - High safety pressure switches (capsule ! ON/OFF switch for each compressor.
! Weather proof with ample space for easy type; factory pre-set). ! Control circuit breaker for short circuit
access power and control panels ! Epoxy paint for all exposed copper piping protection.
! Heavy duty mounting chassis for the system of the refrigeration circuit ! Circuit breaker for each compressor.
whole unit coated with weatherproof, ! Liquid injection kit ! Short cycling protection for compressors
polyester powder electrostatic ! Stepless capacity control for each (time delay).
paint, oven-baked to ensure maximum compressor (25-100)% ! Control transformer sized to supply the
gloss and hardness. needs of the control circuit, sourcing
! Anti-vibration mounts under compressor Electrical power from the main unit power
(rubber pad type). ! Inherent motor protection for each connection.
compressor Part winding start ! Microprocessor control for full
Refrigeration ! Inherent motor protection for each management of the chiller operation and
condenser fan motor safety circuits
! Independent refrigeration circuit per
! Smart lead-lag operation for ! Control terminal strip for easy connection
compressor.
compressors with electrical board and easy field
! Liquid, discharge and suction pipes are installation.
all of hard copper pipes. They are ! Free terminal for remote ON/OFF
connection ! Head pressure control by the simple.
formed using the highly accurate CNC
! Free terminal for general alarm output ON/OFF condenser fan motor according
pipe bending machines in order to
! High ambient kit to ambient temperature down to 7°C.
minimize pipe-brazed joints which in

Optional features
Construction Electrical
! Chiller sound enhancement Options The following options are available for ! Low ambient head pressure control
There are 3 options to enhance the chiller vibration isolation: If the chiller is intended for use in low
chiller sound pressure level: a- Neoprene rubber pads ambient conditions (below 7°C), low
a- Compressor compartment with b- 1 inch Spring isolator ambient control must be added. This can
standard fan be achieved by varying the speed of the
b- Ultra low fan speed720 rpm/900 rpm Refrigeration condenser fan motor by using a variable
(50/60Hz) and compressor with ! Cooler tape heater: Factory installed frequency drive. The speed of the
compartment heater to protect cooler from freeze-up at condenser fan motor can be regulated with
c- Special design fan blades with external low ambient down to (-20°F). reference to the high-pressure sensor to
rotor motor and compressor with ! Ice storage option: Special chillers are maintain constant condensing pressure in
compartment. available for this option, please consult the condenser.
d- Insulation jacket around compressor. the factory for more details. ! Unit mounted fused or non-fused
! Coils protection material ! Glycol option: Used for applications disconnect service switch with external
There are 3 options for coils material: requiring water outlet temperature below handle to isolate unit from power for
40°F. servicing.
a- Polyurethane precoated aluminum
! Suction valves for compressors larger ! Ground current protection for whole unit
fins with copper tubes
than 90 HP. power supply. The current is monitored by
b- Copper fins with copper tubes
! Suction accumulator. toroidal coils around the power leads.
c- Polyurethane post coat copper fins
! Liquid receiver. ! Building automation system connection.
with copper tubes
! High pressure relief valve. ! External overload for each compressor.
! Galvanized steel wire mesh guard
around the chiller’s perimeter ! Pressure gauges (High + Low). ! External overload for condenser fans.
! Cooler cladding can be aluminum, ! Water flow switch: Required as a safety ! Ampere meter and/or voltmeter installed on
stainless steel or polyester painted (22 interlock to prevent operation of the unit the electric panel door.
gauge) galvanized steel without evaporator flow (available for ! Circuit breaker for condenser fan motors.
! Cooler insulation: field installation only). ! Main power circuit breaker for the whole
! Cooler can be insulated with 1.5 inch or ! Electronic expansion valve. unit with door isolator.
more thickness closed cell foam ! Capablity of connecting two chillers to
insulation. operate as one unit by using one controller.
! Chiller Vibration Isolation: ! Chiller plant manager for multiple chillers to
control chillers operation and operate their
respective pumps and valves.
! Soft starter for Compressors.
7
APSa
Microprocessor controller

A screen shot showing various status information

MS-Windows © by Microsoft Corporation.

Displayed Data Capacity Control Strategy

 Leaving/Entering water temperature This control strategy is based on hours for each compressor. Also, manual
 Ambient temperature developing a control zone and then to step selection is possible.
 Compressor discharge the compressor(s) through their stages to In addition, the compressor’s advanced
maintain the control sensor reading within time delay management avoids frequent
pressure/temperature this zone. To accomplish this, the system ON/OFF switching for the compressor
 Compressor suction will constantly monitor the control value, its which ensures long life operation.
pressure/temperature rate of change and position in relation to
 Compressor drawn current the control zone. Head Pressure Control
 Suction/Discharge super heat PETRA provides analog output signals for
 Compressor load percentage Soft Load Function fan speed controller (Option)
 The compressors will start un-loaded to
Saturated suction/discharge
 ensure soft start function, and then it will System Protections
Compressor oil diff start loading gradually and according to
 Compressor timers PETRA provides special advanced
load request, to prevent sudden load
 software designed to be proactive; that is,
Digital input status changing and save energy.
to take corrective action to keep a safety
 Output relays status condition from occurring. If a safety does
 Compressor Efficiency
Protections status occur, the software attempts to restart the
 Historical alarm Because the most efficient compressor unit when the system returns to normal.
 performance is at 100% load, PETRA has This approach eliminates most, if not all of
Schedule developed its own load/un-load strategy to
 the nuisance alarms that occur.
Adjustable setpoint provide an efficient performance. The
number of compressors operating and the
System Control load percentage of each compressor will be Alarms and Safeties
The unit may be started or stopped monitored to achieve what is called the  Cutout and Un-loading:
manually, or through the use of an external Optimum Capacity Limit to switch off  High discharge pressure
signal from a Building Automation System. compressors. Action will be taken after a 
In addition, the controller may be High discharge temperature
certain programmable time delay.
programmed with daily and yearly start-  Low suction pressure
stop schedule management. Capacity Control Strategy  Low suction temperature
Compressor selection (activation) will  Freeze state
depend on operating hours (automatic  High ampere state
lead-lag management) to maintain the
same operating

8
APSa
Microprocessor controller

Other Alarms and Safeties

 Low discharge pressure B. Hard Wire
 Unsafe suction pressure MCS 485 Network with local Remote Within the hard wire structure there are six
 Unsafe discharge pressure modem communications: features as follows:
 Flow switch (No flow protection) Controller Controller Controller 1. RUN / STOP - (BMS to controller)
addr #1 addr #2 addr #3 2. EMER. STOP - (BMS to controller)
 Phase loss protection 3. CHILLED WATER RESET - (BMS to controller)
 Low differential oil pressure 4. DEMAND LIMITING - (BMS to controller)
 Unsafe oil pressure 5. COMPRESSOR RUN - (controller to BMS)
 Low oil level 6. ALARM - (controller to BMS)
 Motor temperature
 Low motor amps
 Probe error alarm

Communications & Building Management

System
PETRA provides the user with two
options in communicating with a Building
Management system, as follows:
Remote PC with
Windows & MCS- Connect
MCS 485 Network with local Rs232
communications:

Controller Controller Controller

addr #1 addr #2 addr #3 A. Communications
Within the communications structure there
are two options as follows:
1. RS-232
This is usually used to connect to:
RS 485 - A PC communicating at 19,200 baud
via the MS Windows© based software
package,'PC- Connect’.
- A modem communicating remotely over
the telephone network at 14,400 baud.
RS 232
2. RS-485
A three-position terminal block used to
communicate with a Building Management
System. As part of this capability BacNet,
MODBUS, Johnson
Local PC with Controls N2 built in controllers and LON
Windows & MCS- Connect
Talk Communications capabilities are
available Through Lon card option

9
APSa
Installation

Unloading
These units are designed for overhead rigging. So for proper supplied with lifting lugs on base sides. Spreader bars should be
unloading and handling, a suitable crane is needed. Use wear flex used to keep cables or slings clear from the unit sides to avoid
slings as shown in figure below. All units are damage to unit frame.

Place the unit gently and without shock hazard

When installing the units consider the following points:

— Foundation should be made of flat-levelled concrete. — Free space of not less than 3000mm above the condenser fans
— Minimum free space beside the condenser coil. should be available to prevent air short-circuiting.
— Minimum free space on both sides of the unit for service — Once the unit is in place, check again that the unit is leveled, so
and maintenance. that oil equalizes properly.

Legend
1 Electric box NO OBSTA
CLES
< 20 Feet
2 Free space for service
3 Flat leveled foundation
4 Compressor
1

2
5 Feet

4.5 Feet 8 Feet

7 Feet
4.5 Feet
4
3

10
APSa
Installation

Connection
Chilled Water Piping
Once the unit has been located in its final
position, the chiller water piping may be
connected. A typical water piping diagram
for a water cooler is illustrated in figures on - For more details, please refer to:
the next page. This diagram shows main Petra catalogue (general data, performance table, chiller’s layout, pressure drop curves, ..etc.).
components which should be used as - For chilled water piping and cooler connections, please refer to the figures on the next page.
follows: - Pipe connection could be NPT up to 76 mm flange or flexible pipe victulic pipe joint on other.
— Refer to “Cooler Connections” section
for right size of piping.
— Stop valves should be installed in all
lines to facilitate servicing.
— Flexible connections should be installed Don't flush any foreign material into or through the cooler.
on the cooler inlet and outlet to ensure This should be done without cooler connection to the system.
against transmission of water pipe
vibration.
— Drain connections should be provided at Site fitting
(by contractor)
drain connection of the cooler for
complete drainage of the cooler.
— Air vent or small valves should be
installed at the cooler.
— A strainer must be installed in the cooler
inlet line just ahead of the cooler. This is Thermometer Flow switch
Pressuer gauge
Pressuer gauge
important to protect the cooler from
entrance of large particles which could Water in
Air vent
Air vent FS
Water Out
cause damage to the evaporator.
Drain Drain Globe (balancing) valve
(Recommended 40 mesh strainer) Gate valve
Strainer Thermometer
Flexible connectin
— Thermometers and pressure gauges Flexible connectin

should be installed in the inlet and outlet

water lines. Flange pipe connection

— A chilled water flow switch must be

installed in the leaving water piping of
the cooler. There should be a straight
horizontal run of at least 5 diameters on Site fitting
each side of the switch. Choose the right (by contractor)

size of the flow switch blade which

complies with the pipe in which it is
installed. The switch to be wired to the
specified terminals which are shown in
the unit’s wiring diagram.
Thermometer Flow switch
— All piping works to and from the cooler Pressuer gauge Pressuer gauge
must be designed taking into
consideration the following: Water in Air vent FS
Water Out

- Piping should be kept free of all Globe (balancing) valve

Gate valve Drain
foreign matters. Strainer Flexible connectin
Air vent Thermometer

- Avoid elbows, tees, and valves Flexible connectin

which decrease the pump capacity.

Flange pipe connection
All piping should be kept as
straight as possible.
- All piping must be supported
independent of the chiller.
- The chilled water piping system
should be laid out so that the
circulating pump discharges
directly into the cooler. The suction
for this pump should be taken from
the piping system return line.
- Flushing the chilled water piping
from any foreign material before
the system is placed into operation
should be done without cooler
connection to the system.

11
APSa
Application data

Altitude correction factors Condenser Airflow

Capacity correction factors must be Any restrictions on the unit’s fan airflow will
applied to standard ratings at altitudes Cooler protection: A protection against low
affect the unit’s capacity, condenser head ambient freeze-up is required for ambient
above sea level using the multipliers on pressure, and compressor power input.
the right: temperatures below 32ºF .
Such restrictions (i.e. not providing vertical
clearance or lateral clearance, insufficient Protection should be in the form of:
High Ambient Temperature unit-to-unit clearance ) will cause warm air 1- Inhibited ethylene glycol or any other
High outdoor ambient chiller start-up and re-circulation or coil starvation. Minimum suitable glycol (Option).
operation is possible for chillers at ambient required operational and maintenance 2- Cooler is equipped with an electric
temperatures up to 125°F at nominal clearances around the unit are shown in heater tape that helps prevent
voltage (for standard units). For higher the figure below. freeze-up (Option).
ambient temperature, please refer to
PETRA factory. Cooler Flow Range
Chiller ratings and performance data Altitude Correction
Capacity Correction (Antifreeze) pertain to a cooling temperature rise of [ft] Factor
Inhibited ethylene glycol (or any other 10°F. Chillers may be suitable for
suitable glycol or brine) should be used operation in a range from 5.4 to 14.5°F Sea level 1
in installations where sub-freezing temperature rise without adjustment,
temperatures are expected (If this provided flow limits are within minimum 1000 0.995
application is needed, please contact limits on outlined in table below. High flow 2000 0.99
PETRA factory). rate is limited by pressure drop that can be
tolerated. 3000 0.985
Unit Leveling Minimum Cooler Flow: Based on the 4000 0.98
Unit must be leveled when installed to maximum permissible T across the
ensure proper oil return to the compressors. cooler 14.5°F. 5000 0.973
Maximum Cooler Flow: Based on Minimum
Permissible T across the cooler 5.4°F. 6000 0.967
Fluid Temperature
Fluid loop volume: To obtain proper 7000 0.96
1. Maximum leaving chilled fluid
temperature for unit is 50ºF. For temperature control,the loop fluid volume 8000 0.95
continuous operation, it is must be at least 2.4 GPM/Ton based on a
recommended that inlet fluid 10ºF difference in water/fluid temperature for
temperature does not exceed 60ºF (If chiller nominal capacity in air conditioning
continuous operation is required for inlet applications, taking into consideration the
water temperature above 60ºF, please minimum system volume.
refer to PETRA factory).
2. Minimum leaving chilled fluid
temperature for a standard unit is 40ºF
(for lower leaving temperature contact
PETRA factory).

Minimum cooler flow rate Minimum loop volume Minimum cooler flow rate Minimum loop volume
MODEL (GPM) (Gallon) MODEL (GPM) (Gallon)

50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz 50 Hz 60 Hz
APSa 50-1 78.2 89.2 562.8 642.0 APSa 200-2 292.2 332.0 2103.6 2390.4
APSa 55-1 85.2 96.7 613.2 696.0 APSa 210-2 305.8 347.0 2202.0 2498.4
APSa 60-1 84.8 98.5 610.8 709.2 APSa 220-2 318.7 363.5 2294.4 2617.2
APSa 65-1 93.7 108.0 674.4 777.6 APSa 235-2 341.8 387.5 2461.2 2790.0
APSa 70-1 101.5 116.2 730.8 836.4 APSa 245-2 362.5 408.0 2610.0 2937.6
APSa 70-2 103.5 118.0 745.2 849.6 APSa 250-2 374.5 422.5 2696.4 3042.0
114.7 132.2 825.6 951.6 APSa 260-2 389.2 440.8 2802.0 3174.0
APSa 75-1
APSa 275-2 402.7 456.8 2899.2 3289.2
APSa 80-1 126.0 144.5 907.2 1040.4
APSa 290-2 408.2 461.7 2938.8 3324.0
APSa 95-2 137.7 157.5 991.2 1134.0
APSa 300-2 423.3 481.2 3048.0 3464.4
APSa 95-1 138.2 158.2 994.8 1138.8
APSa 310-3 464.7 528.2 3345.6 3802.8
APSa 100-1 153.8 175.0 1107.6 1260.0
APSa 325-2 504.7 574.0 3633.6 4132.8
APSa 100-2 154.2 175.2 1110.0 1261.2
APSa 345-4 518.2 585.8 3730.8 4218.0
APSa 110-2 164.7 188.5 1185.6 1357.2 APSa 360-4 535.5 607.0 3855.6 4370.4
APSa 120-2 172.8 197.5 1244.4 1422.0 APSa 380-4 564.3 637.8 4063.2 4592.4
APSa 125-2 181.0 205.8 1303.2 1482.0 APSa 385-3 567.8 643.2 4088.4 4630.8
APSa 135-2 199.5 227.8 1436.4 1640.4 APSa 390-4 578.2 651.8 4162.8 4693.2
APSa 140-2 212.3 241.5 1528.8 1738.8 APSa 400-4 584.3 663.8 4207.2 4779.6
APSa 145-2 222.0 254.7 1598.4 1833.6 APSa 410-4 599.5 678.7 4316.4 4886.4
APSa 160-2 235.0 268.0 1692.0 1929.6 APSa 415-4 611.7 693.8 4404.0 4995.6
APSa 165-2 244.8 278.5 1762.8 2005.2 APSa 465-4 637.3 727.0 4588.8 5234.4
APSa 175-2 259.2 293.0 1866.0 2109.6 APSa 470-4 671.5 756.5 4834.8 5446.8
APSa 190-2 267.7 303.5 1927.2 2185.2 APSa 480-4 683.5 775.0 4921.2 5580.0
APSa 195-2 282.2 318.8 2031.6 2295.6 APSa 500-4 753.8 853.6 5407.8 6123.6

12
APSa
Operation

Unit Check Before Starting Before Starting the Unit

— Insure that all piping has been - Check the electrical connection for tightness.
completed. - Switch on the main power supply.
— Check for refrigerant piping leak.
— Open suction, discharge and liquid line Use the following formula to determine the present voltage imbalance:
valve for each system.
— The compressor oil level should be
maintained so that an oil level is visible
in the sight glass The oil level can only Example: Present Voltage Imbalance
be tested when the compressor is
running in a stabilized conditions. In this Max. Voltage Deviation
100 x
case, the oil should be between ¼ and Average Voltage
¾ in the sight glass. At shut down oil
level can fall to the bottom limit of the oil
sight glass. Supply voltage = 380 volt/3ph/50Hz
— Insure that the water pumps are ON. AB = 383 volt
— Check and adjust water pump flow and BC = 376 volt
pressure drop across the cooler. Verify AC = 378 volt
flow switch operation.
383 + 376 + 378
— Check the control panel and compressor Average Voltage =
electrical box to assure it's free of 3
foreign material. =379 volt
— Be certain all water temperature sensors Determine maximum deviation from average voltage:
are inserted completely in their
respective wells and are coated with AB = 383 - 379 = 4v
heat conductive compound. BC = 379 - 376 = 3v
AC = 379 - 378 = 1v
— The main cable for the power supply of
the unit is as the manufacturer
recommendation (refer to the electrical B
A C
data table for unit ampacity to select the
main power supply cable).
— Proper disconnect switch is installed
beside the unit for emergency or for
maintenance purposes. (Refer to MOTOR
electrical data tables for proper size).
— The chiller is supplied through main
power circuit breaker or non fused Maximum deviation is [4v]. Determine present
disconnect switch (refer to the electrical voltage imbalance:
data table for the proper selection of the
circuit breaker size). Voltage imbalance = 100 x 4 = 1.0%
379
— All field connection wiring is connected
properly to the control terminal such as: The amount of phase imbalance is satisfactory, as it
- Water flow switch signal is below the maximum allowable phase imbalance
- Pump inter lock signal value [2%]
- General alarm signal
- Remote switch signal
— Refer to electrical field wiring for more
information. Also it is important to refer
to the wiring diagram for the exact field
wiring connection. (Field connection is
represented by dash dot lines on the Check that the voltage monitor [Phase Failure Relay Lamp] is giving a green LED. If
wiring diagram) hot, the device will give a red LED to indicate failure with the main power supply.
— Make sure that there are no obstacles
available that may stop the condenser
fan(s).
— Inspect visually for any loose wires.
— Check CFM rotation direction after
commitioning. Contact your local electric utility company immediately if supply voltage phase
imbalance is more than ± 2%.

13
APSa
Operation

Unsafe Suction Pressure High Discharge Temperature Low Motor Amp

This safety is similar to the low suction If the discharge temperature analog input !f the ampere analog input drops below the
pressure safety except this set point can rises above the value of the set point or value of the set point and it remains there
be set up with a lower value and a very the digital input turns ON and it remains for the time specified in the safety time of
short safety time. If the suction pressure there for the time specified in the safety that set point. the compressor will be
drops below the value of the set point or time, the compressor will be locked out locked out and a low motor amp alarm
the digital input turns ON and it remains and a high temperature alarm generated. generated. This alarm can be used to
there for the time specified in the safety indicate low refrigerant. This safety is
time of that set point, the compressor will bypassed for the firsts seconds after a
Hi Motor Temperature or Motor Fault compressor has started.
be locked out and a low suction alarm
generated. This safety will always cause a If the high motor temperature input rises
lock out on the first trip requiring a manual above the value of the set point or the
digital input turns ON and it remains there No Compress Proof
reset to restart the compressor. For the
firsts minutes after the compressor has for the time specified in the safety time, the If a compressor is called to be on and the
started the safety time is extend by twice compressor will be looked out and a high compressor proof input is OFF (this is a
the normal time delay, this enables the set motor temperature or motor fault alarm digital input), a NO COMP PROOF alarm
point safety time to be set much tighter for generated. will be generated.
normal operation.
Hi Oil Temperature Operation Limitations
Low Discharge Pressure !f the oil temperature rises above the value
of the set point or the digital input turns Temperature
If the discharge pressure drops below the If the unit is to be used in an area with high
ON and it remains there for the time
value of the set point and it remains there solar radiation, it should be mounted so
specified in the safety time of that set
for the time specified in the safety time of that the control box is not exposed to direct
point, the compressor will be locked out
that set point, the compressor will be solar radiation. (Refer to the Temperature
and a high oil temperature alarm
locked out and a low discharge alarm Table below)
generated.
generated.
Temperature Table °C
Hi Motor Amp Maximum Ambient Temp 52.0
High Discharge Pressure
If the ampere analog input rises above the Maximum Cooler [EWT]* 15.5
If the discharge pressure raised above the value of the set point or the digital in put Minimum Cooler [LWT]** 3.3
value of the set point or the digital input turns ON and it remains there for the time
turns ON and it remains there for the time specified in the safety time of that set
specified in the safety time of that set point, the compressor will be locked out * EWT: Entering Water Temperature
point, the compressor will be locked out and a high motor amp alarm generated. ** LWT: Leaving Water Temperature
and a high discharge alarm generated. This safety is bypassed for the first 3 [But for brine chiller application the
seconds after a compressor has started. minimum cooler LWT will be lower]

Maintenance

Preventive Maintenance
Perform all maintenance procedures and — refrigerant shortage, measure the ! Inspect all piping components for
inspections at the recommended intervals. system superheat and system sub- leakage and damage.
This will prolong the life of the equipment cooling. ! Clean and repaint any areas that show
and minimize the possibilty of costly — If operating conditions indicate a signs of corrosion.
failures. refrigerant overcharge, remove ! Inspect electrical wiring condition and
refrigerant at the liquid line service tighten any loose connections.
valve. Allow refrigerant to escape
Weekly ! Clean the condenser coils.
slowly, to minimize oil loss. Do not
discharge refrigerant into the ! Clean the condenser fans, check the fan
After the unit has been operating for
atmosphere. assemblies for proper clearance in the
approximately 30 minutes and the system
— Measure the power supply voltage, fan openings and for motor shaft
has stabilized, check the operating
compressor and fan running amperes. misalignment, abnormal and play,
conditions & complete the procedures
— Inspect the entire system for unusual vibration & noise.
below:
conditions and inspect the condenser ! Check the oil level.
— Check the evaporator refrigerant
pressure & the condenser refrigerant coils for dirt and debris.
pressure. Leak Test System
— Check the liquid line sight glasses. Annual Maintenance All units should be under sufficient pressure
The refrigerant flow past the sight to conduct a leak test after installation. If
! Perform all weekly maintenance
glasses should be clear. Bubbles in there is no system pressure, admit nitrogen
procedures.
the refrigerant indicate either low into the system until some pressure is
! Have a qualified service technician to
refrigerant charge or excessive observed and then proceed to test for leaks.
check the setting & function of each
pressure drop in the liquid line. After leaks are repaired the system must be
control.
— If operating pressure and sight glass dehydrated.
conditions seem to indicate. ! Inspect the condition of compressor & Use dry nitrogen and refrigerant to raise the
control contactors and replace as system pressure up to 1035kPa. The
required. procedure
14
APSa
Maintenance

requires a separate relief valve with gauge 10. Disconnect the hose from the cylinder. The process used most often to determine
set and a gas cylinder. 11. Open the gauge manifold hand valves the correct refrigerant quantity is by
With the compressed gas cylinder in the and purge the pressure from the observing the refrigerant flow in the sight
upright position, admit the dry nitrogen system. glass in the liquid line. Since an
slowly until the desired pressure is 12. Repeat steps 3 through 13. uninterrupted supply of liquid is necessary
obtained. Carefully check the complete 13. Repeat steps 3 through 9 only. for the proper functioning of expansion
system for leaks by means of soap 14. Open the gauge manifold hand valves valves, it may be assumed that the unit has
bubbles. Where bubbles appear, a leak and admit refrigerant into the system been correctly filled when a clear flow of
exists. cylinder. Pressure is indicated on the liquid refrigerant is visible. Bubbles or foam
Check at all points that are expected to gauges. usually indicate insufficient refrigerant.
leak, such as flare connections, flanges, 15. Close the high side gauge manifold However, care should be taken that no
quick coupling, brazing, joints..etc. Leave hand valves. bubbles are seen in the sight glass, even
the system for a certain time and watch 16. Start the unit and add the proper though, the unit has been fully filled.
the gauge for any drop in reading. When charge of refrigerant. Additionally the temperature in the
the test is complete, system pressure condenser could also lead to sudden
should be reduced to 0KPa the evaporation, e.g. by switching the fan ON at
compressor is evacuated and charged Refrigerant Charge the condenser. Thus, the sight glass is a
with the proper kind of refrigerant. valuable device in determining the correct
Pressure Regulator
The unit is charged with the refrigerant for filling quantity.
Cylinder Pressure
Gauge System Pressure Gauge
which it is designed. Efficient operation of After all field connections (electrical and
an air-conditioning unit depends on the mechanical) have been completed and the
correct charge of refrigerant by weight. In system has been evacuated, the system
case of an under charged unit, the can be fully charged with refrigerant in two
To System evaporator is starved of refrigerant, which ways as shown below.
leads to low compressor suction pressure,
Pressure Relief Valve loss in output and perhaps overheating of
the compressor motor, in case of suction Importance of proper charging
gas cooled compressors (high superheat). The main job of a service engineer is to
Compressed Gas Cylinder Leak Test System
Overcharging the unit can lead to upkeep modern, mechanical cooling
condenser overflow and thus too high system running. It is essential to know the
condenser pressure, to evaporator proper way to handle refrigerant to all
System Evacuation flooding and possibly to compressor types of systems. All systems do not use
System evacuation is considered the most damage due to liquid coming into the the same refrigerant. All systems do not
important process to prepare the unit for compressor. use the same amount of charge even
charging and to remove both air and Sudden pressure in the condenser when capacities may be entirely
moisture from the system. indicates exceeding the pumping capacity comparable.
of the unit and filling of the condenser with
Gauge Manifold Check the name-plate on
liquid, increased cooling of suction line as
factory - assembled systems
well as an increase in noise of the working
Vacuum Pump All manufacturers include a name-plate
valve in the compressor. Liquid knocking
that clearly lists the refrigerants for which
also indicates unit overcharge or incorrect
the system was designed. How much
adjustment and/or incorrect function of
Suc Dis charge to use will vary widely from system
the control system. Gaseous refrigerant is
to system. This makes it doubly important
only
always to check the catalogues & service
Charged if small quantities are intended.
bulletins.
Screw Compressor
System Evacuation
Refrigerant bottles with double or single
valves stand
1. Connect gauge manifold to the system. Upright and refrigerant is charged by Vapor Charging
2. Purge all pressure from the system by means of the pressure gauge connection Do not charge blends in vapor phase.
opening the system service valve[s] and in the compressor suction shutoff valve. This means that the refrigerant should be
the gauge manifold hand valves. When doing so, check condenser removed from the cylinder as a liquid
3. Connect the center hose on the gauge pressures when charging liquid refrigerant (either from the dip tube in a two valve
manifold to the vacuum pump. and determine charging weight. If cylinder cylinder or by inverting the cylinder). The
4. Start the vacuum pump. pressure drops too low for further charging liquid is allowed to evaporate (flash) in
5. Close OFF the gauge manifold hand before the job is finished, place cylinder in the charging lines. Small systems with a
valve. a bucket of warm (25° - 45°C) water, or single component refrigerant such as
6. Stop the vacuum pump but not before use a heat lamp to increase pressure. Do 134a are usually charged through the
closing the gauge manifold hand valves. not apply heat with a torch. Never heat gauge port of the compressor suction
7. Disconnect the center hose of the cylinder above 50°C. service valve.
gauge from the vacuum pump and Normal procedure is:.
connect it to a cylinder containing the 1. Back-seat suction service valve as for
proper type of refrigerant. normal operation.
8. Open cylinder valves and loosen the 2. Loosely connect line from service
center hose at gauge manifold. Purge Never heat bottles with the flame of the manifold to suction service valve
the hose for a few seconds then tighten lamp such as a Bunsen or welding burner. gauge port.
the connection.
9. Close the refrigerant cylinder valves and
admit refrigerant into the system until a
pressure of about 35kPa is
indicated on the gauges.
15
APSa
Maintenance

3. Connect center line from manifold to the Liquid Charging Watch the discharge pressure
refrigerant cylinder. Charging the refrigerant in the liquid phase Watch the discharge pressure. A rapid rise
4. Back-seat discharge service valve has always been customary for larger in pressure indicates, that the condenser is
5. Loosely connect remaining line from systems. It is essential for charging blend filling with liquid. If this is the case, the
service manifold to discharge service refrigerants. If a complete charge is to be system pump-down capacity still seems
valve gauge port. added to an evacuated system the liquid is low on charge, an auxiliary receiver may
6. Slightly open cylinder valve to purge frequently charged through the be needed.
vapor up to the compressor discharge compressor discharge service valve. The When the proper weight of refrigerant has
service valve. compressor is not operated while been added, close the cylinder valve and
7. Tighten discharge service valve charging. The procedure for attaching the let the low-pressure control stop the
connection at gauge port. manifold and purging the lines is similar to compressor.
8. Purge vapor from cylinder up to that described for vapor charging. On most Close the charging port valve and vent
compressor suction service valve. systems, a charging port is located on the refrigerant vapour from the hose by
9. Tighten suction service valve connection liquid line downstream from the receiver. loosening connection.
gauge port. Open both compressor In this case, refrigerant can be added Open the liquid line valve or receiver outlet
service valve. while the system is not operating. General valve and check the operation of the
10. Place cylinder of refrigerant on suggestions will not always apply to system.
weighing scale. specific operations but the following Replace cap on cylinder valve and
11. Pressurize system to full cylinder outline may be helpful. charging valve. Plug both ends of the
pressure and make final leak check. charging hose or manifold so it will be
12. Start compressor. Run unit head Connect the refrigerant cylinder to the clean for the next use.
pressure and suction pressure charging port
stabilize. Open the cylinder valve Connect the refrigerant cylinder to the
completely and control the flow of charging port. Use as short a line as
refrigerant from the manifold. possible to minimize water contamination
From time to time, note suction or use a drier if indicated by conditions. 1- Never charge the liquid in the low
pressure with the cylinder valve The cylinder should be upside down if it pressure side of the system.
closed. From time to time note does not have a liquid/ vapor valve. 2- Don't overcharge. Overcharging results
discharge pressure to see that it does Install a pressure gauge so that the in higher pressure, possible compressor
not rise above the level normally compressor discharge pressure can be damage and higher power consumption.
expected under operating conditions. observed. 3- During charging or removal of
For air-cooled system, the discharge refrigerant, be sure water/fluid is
pressure should be approximately the continually circuiting through the cooler
pressure corresponding to ambient Crack cylinder valve and purge to prevent freezing. Damage caused by
temperature plus 10°C (refrigeration) to charging line freezing is considered abuse and may
17°C (air conditioning). With the connection to the charging port void PETRA warranty.
13. When correct weight of refrigerant has loose, crack cylinder valve and purge
been introduced, close cylinder valve charging line with refrigerant using the
and disconnect charging line. VAPOUR hand wheel of a cylinder fitted
14. When satisfied that the system is with a liquid/ vapor valve. Tighten System Pump Down
operating as it should, back-seat both connection, open cylinder valve and check This procedure is used to isolate the
suction and discharge service valve. for leaks. refrigerant in the condenser coil. This
Bleed pressure from both gauge lines process can be utilized for maintenance,
through the manifold charging port. repairs and long periods of shutdown.
15. Replace cylinder valve cap and fit flare Close the valve at the receiver outlet Pump down procedure:
plugs in open ends of charging and Close the valve at the receiver outlet or if ! Install pressure gauge in the unit, if not
gauge lines. Replace plugs in gauge there is no receiver close the valve in the installed.
ports of compressor service valve. liquid line upstream from the charging ! Install a jumper across the terminals of
port. This is necessary to prevent the the low pressure cutout.
condensing pressure from forcing liquid ! Operate the unit.
into the cylinder. ! Start closing the shut off valve while the
unit is operating.
Slowly open the charging port valve and ! When low pressure gauge reaches about
charge liquid 4.5 Kpa shut down the unit.
1) If possible, refrigerant should always be With the compressor running , slowly open ! Immediately close the compressor
charged by weight, using a good scale. the charging port valve and charge liquid suction valve.
2) If cylinder pressure drops too low for using the LIQUID hand wheel at a rate fast ! Remove the jumper from the low
further charging before the job is enough to keep the compressor from pressure cutout.
finished, place cylinder in a bucket of cutting out on low-pressure control if ! Repeat the above for 2 or 3 times.
warm (25-45°C) water, or use a heat possible. The refrigerant flow can also be ! Repeat the above for 2 or 3 times.
lamp to increase pressure. Do not apply controlled by the cylinder valve to avoid
heat with a torch. Never heat cylinder ending up with a hose full of liquid
above 52°C. refrigerant, The same result can be
obtained by closing the cylinder valve first
when charging is finished.

16
APSa
Maintenance

Changing Filter Drier Core Coil Cleaning

The main function of the filter dryer is to Periodic verification of coil cleanliness is
eliminate any humidity or deposits inside the required. Dirty coils increase air side
pressure drops and reduce heat transfer Clean the condenser coils at least Once
system. When the filter is blocked, a certain each year, or more frequently if the unit is
pressure drop across the filter occurs and a potential, thus unbalancing the system.
Every six months examine finned surface located in a "dirty" environment. This will
temperature difference between the liquid maintain proper unit operating efficiencies.
in/out and the filter can be sensed. In this for accumulation of dirt or lint. If necessary
wash down the affected areas with a mild To clean the coils, use a soft brush and a
case the filter has to be changed. vacuum cleaner.
The process is as follows: detergent solution and a soft brush. Care
should be taken not to disturb the fin
! System pump down procedure has to be surfaces. A compressed air line may be used to blow
carried out. out any solids between the fins. Clean
! Remove the screws and the filter cover. refrigerant coils with cold water and
! Take out the old core. detergent or one of the commercially
! Clean the filter shell. available chemical coil cleaners.
! System pump down procedure has to be
carried out.
! Remove the screws and the filter cover.
! Take out the old core.
! Clean the filter shell.
Do not probe the coils with a metal
! Use a new core(s) and cover the filter
scrapper as damage may cause tube
tightly.
! Evacuate the low pressure side (do not
forget to open solenoid valve).
! Open all valves. For coil combing:
! The unit is ready to start. Before Cleaning ! Choose proper fin width comb.
! Be careful not to damage tubes and fins.
Compressor Oil
All units are factory charged with oil. The Final Check
approved oils to be added upon need are: Before leaving the unit, check the
For APSa series units: BSE 170 OR following:
Equivalent. ! Oil level can be seen in the sight glass of
the compressor.
! All controls and protective devices
function properly.

Cleaning the Evaporator

Do not re-use drain oil and do not use any The chilled water system is a closed-loop
oil that has been exposed to the After Cleaning and therefore should not accumulate scale
atmosphere. or sludge. If the chiller becomes fouled,
first attempt to dislodge the material by
back flushing the system.

Water Flow Limits

Evaporated flow rates below the tabulated
values will results in laminar flow causing
freeze-up problems, scaling and poor
control. Evaporator water flow rates
exceeding those listed may result in
excessive tube erosion.

The use of improperly treated or untreated

water in this equipment may result in
scaling, erosion, corrosion, algae or slime.

17
APSa
Sequence of operation

The APS chiller depends on its on-board ! Compressor switches-ON.

microprocessor for control. For initial start- ! Control circuit breaker-ON.
up, the following conditions must be met: ! Main system voltage-ON.
! Chilled water pump-running. ! All safety conditions-satisfied.
! Chilled water flow switch-made. ! Compressor time delay-elapsed.
! Customer control contact-closed. ! Leaving chilled water temperature-above setpoint.

Leaving Liquid Value

Setpt Value Description

#2 (3.0 °F) Cntrl Zone+ (46.0°)

#1 (43.0°F) Target (43.0°)

#3 (1.0°F) Cntrl Zone- (42.0°)

The system will attempt to keep the control Safety considerations

value within the control zone that has been Freeze Protection Low Differential Oil Pressure
developed by calculating the required
If the leaving liquid temperature drops This safety is designed to meet the
system capacity. The system’s capacity will
below the set point value the system, and compressor manufacturer requirements on
be based on the number of circuits
all circuits, will enter a lockout state and a oil pressure. For the first 5 seconds
(compressors) that are required to operate.
freeze notification alarm will be generated. following a compressor start this safety is
The system will adjust the required
NOT checked. For the next 30 seconds, if
capacity between the minimum and the Note:you have the option of one freeze protector the
package or individual freeze protections by circuit. This is the oil differential pressure drops below of
maximum values. All the compressors that
selected in the PC-Config program. the value of the set point or the digital input
are operating will be synchronized to meet
turns ON and it remains there for the time
the system’s capacity. When the maximum
specified in the safety time of that set
capacity value has been reached, an
point, the compressor will be locked out
additional compressor, if available, will be No Flow Protection and a low oil alarm generated. After this
required to operate. The number of
If the flow switch is for the chiller system, time period, if the oil differential pressure
compressors required to operate will be
then the entire system will be shut down drops below the value of the set point and
increased by one and the system’s
with the LOCK OUT state if set point it remains there for the time specified in
capacity will be set to the minimum value
“PUMP FAFLURE” is an active lockout the safety time, the compressor will be
and the sequence will begin again.
type of set point. If the set point is inactive, locket out and a low oil alarm generated.
The number of compressors operating and
the system will determine if there is a This enables the set point value and the
the load percentage of each compressor
second pump, if so it will be started. Else, safety time to be much tighter. This safety
will be monitored to achieve what is called
the system will be shut down and is interrogated when the compressor is ON
the Optimum Capacity Limit to switch off
automatically restarted when the flow and not in a pump down state.
compressors. Action will be taken after a
certain programmable time delay. switch is on. indicating that there is flow, If
When the minimum capacity value has the flow switch is for the individual circuit,
been reached, a compressor will be turned then that circuit will be locked out. Low Suction Pressure
off. The number of compressors required If the suction pressure drops below the
to operate will be decreased by one and Phase Loss Protection value of the set point or the digital input
the system’s capacity will be set to the Phase loss, as indicated by the phase loss turns ON and it remains there for the time
maximum value and the sequence will monitor, will result in the system and all specified in the safety time, the
began again. circuits being locked off and a phase loss compressor will be locked out and a low
The compressor slide control is based on notification alarm will be generated. No set suction alarm generated. For the first 3
the current drawn from that compressor. point is required. minutes after the compressor has started
For example, if the current drawn is greater the safety time is extend by 2 minutes, this
than the capacity indicated, then the enables the set point safety time to be set
compressor is unloaded. Conversely, if it is much tighter for normal operation. This
less, then it is loaded. Emergency Stop safety can also be used as a freeze
The compressors that are operating can be Emergency stop, as indicated by the protection based upon the suction kPa.
loaded, where their load solenoids are emergency stop switch, will result in the
pulsed; unloaded where their unload system and all circuits being locked oft and
solenoids are pulsed or in a hold state, an emergency stop notification alarm will
where no action is required. be generated. No set point is required.
(compressor) reflects this action.
When the water temperature falls below
the setpoint, the compressor will shut
down.

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Sequence of operation

Unit Operation Check list

Running Check List

Model: Address:
Project No:

OPERATION CONDITIONS READING

Unit Operation Mode
Running Time After Stabilization
Pressure Drop At Cooler (Pa)
Evaporator Flow Rate (CFM)
Condenser Flow Rate (CFM)
Ambient Temperature (°C)
Compressor Running Operation
Frequency (Hz)
Entering Wet Bulb Temp. (°C)
Leaving Wet Bulb Temp. (°C)
Humidity %

REFRIGERATION TEST READING

Refrigerant Charge Type
Refrigerant Charge Weight (Kg)
Condenser Inlet Temperature (°C) (Air/Water)
Condenser Outlet Temperature (°C) (Air/Water)
Evaporator Inlet Temperature (°C) (Air/Water)
Evaporator Outlet Temperature (°C) (Air/Water)
Discharge Pressure (Kpa)
Liquid Line Pressure (At Shut Off Valve) (Kpa)
Suction Pressure (Kpa)
Discharge Temperature (°C)
Liquid Line Temperature (Before Exp. Valve) (°C)
Suction Temperature (°C)
Sub Cooling (°C)
Evaporator Superheat (°C)

ELECTRICAL TEST READING

System Voltage At Test ± 10% R-S: R-T: S-T:
Compressor Running (A)
Condenser. Fan Motor Running (A)
Evaporator Blower Motor Running (Supply) (A)
Evaporator Blower Motor Running (Return) (A)
Earth Continuity Ok: Not Ok:
Insulation Test Ok: Not Ok:

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Sequence of operation

Start Up Check list

Start Up Checklist
(before operating the unit)

Project Name: Date:

Customer Name: Project No.:

Model: Address:
Signature:

Location of Machine YES NO COMMENTS

Check if there is minimum 2 meters distance between the machine

and any restricting surface

Check if all components of machine easily accessible and serviceable

Check the Leveling of machine

Check for any leftover cardboard pieces or packing material on

evaporator coil

Condition of Machine YES NO COMMENTS

Check if any refrigerant line broken

Check if there are any gas or oil leaks in system

Check if protection devices in electric panel operate properly

Check if all mechanical protection devices operate properly

Check if evaporator fans are rotate freely

Check if pulleys are properly fixed in place

Check if pulley belts loose

Electrical Connections YES NO COMMENTS

Check the cable size and compare it with the design

Check wiring system if there is any loose

Water System YES NO COMMENTS

Check the connection between the control circuit and the pump contactor

Check the pump compatible with requirement of unit.

And what is amount of water that pumps is pumping

Check the pressure gauge and globe valve at pump exit

Check the air release valves on water lines

Check the connections between cooler and water circuit

Check the temperature sensors on cooler entering and leaving water lines

Ducting System YES NO COMMENTS

Check if volume dampers are open

Check if there is any leakage in the duct

Check if all ducting properly insulated

Check the external static pressure in the system and compare it to
the design one

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Troubleshooting
Use the tables in this section to assist and help you in identifying the cause or causes of any malfunctions in the unit's operation. The column
headed RECOMMENDED ACTION will suggest repair procedures.

Disconnect electrical power inspection before servicing the unit and allow all rotating equipment to stop completely. Failure to
do so may result in personal injury or death from electrical shock or any moving parts.

Source of Trouble Possible Causes Corrective Steps

1. Compressors fails to start a. Main switch open a. Close switch

b. Thermal lockout relay opened b. See point 11.

c. Defective contactor c. Repair or replace

d. System shut down by safety d. Determine type and cause of
devices shutdown and correct it before
resetting safety switch
e. Thermostat set too high e. Check evaporator temperature.
Lower thermostat setting, if
possible without freezeup
-
f. Liquid line solenoid will not open f. Repair or replace
g. Motor electrical trouble g. Check motor for opens, short
circuits or burn-out
h. Loose wiring h. Check all wire junctions. Tighten
all terminal screws

2. Compressor noisy or vibrating a. Improper isolation a. Check isolator operation

b. Improper piping support b. Relocate, add, or remove hangers.
c. Improper clearances c. Running gear worn. Overhaul
compressor and replace defective
parts
d. Flooding of refrigerant into d. Check rating and setting of
crankcase expansion valve
e. Motor rotor is loose (SRC) e. Check key fit and tightness of
rotor locking bolt

3. High discharge pressure a. Discharge shut

-off valve partially a. Open valve
closed
b. High ambient temperature b. Provide cooler air to condenser
c. System overcharged with c. Remove excess
refrigerant
d. Excessive loading d. Reduce load
e. Non condensibles in system e. Purge the non-condensibles

4. Low discharge pressure a. Suction shut -off valve partially a. Open valve
closed
b. Insufficient refrigerant in system b. Check for leaks. Repair and add
charge
c. Low suction pressure c. See point 6.
d. Compressor operating unloaded d. See corrective steps for failure of
compressor to load up. See point
8.
e. Worn Discharge service e. Ovehaul compressor

5. High suction pressure a. Excessive load a. Reduce load or add equipment

b. Expansion valve over feeding b. Regulate superheat. Check valve
Rating against the application

c. Compressor operating unloaded c. See point 8.

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Troubleshooting

6. Low suction pressure a. Chilled water pump not operating a. Check and start pump
b. Lack of refrigerant b. Check for leaks. Repair and
add charge
c. Evaporator dirty or iced up. c. Clean or defrost
d. Clogged liquid line filter drier d. Replace cartridge(s)

e. Expansion valve malfunctioning e. Check and reset for proper

superheat. Repair or replace if
necessary
f. Condensing temperature too low f. See corrective steps for failure of
compressor to unload. See point 7
g. Chiller pump off g. Check. Add interlock

7. Compressor will not unload a. Defective capacity control a. Replace

b. Unloader mechanism stuck. b. Replace cylinder liner unloader
Unloader lifting pins worn assembly

8. Compressor will not load up a. Defective capacity control a. Replace

9. Compressor loses oil a. Shortage of refrigerant a. Repair leak and recharge system
with refrigerant and oil
b. Low suction pressure b. See entry “low suction pressure”
c. Expansion valve stuck open c. Repair or replcae expansion valve
d. Restriction in refrigeration system d. Locate restriction and remove

10. Internal thermal protection a. High condensing temperature a. See corrective steps for high
lockout opened discharge pressure
b. Low voltage during high load b. Check supply voltage and for
condition excessive line drop
c. Loose power wiring c. Check all connections and tighten
d. Defective relay d. Replace
e. Defective or grounded wiring in e. Repair or rewire
motor or power circuits
f. Power line fault causing single f. Check supply voltage. Notify
phase running or unbalanced power company. Do not restart
voltage until fault is corrected
g. Failure of second starter to pul g. Repair or replace contactor or
up-on partwinding system time delay mechanism

11. Compressor “short cycles” a. Thermostat differential set too a. Check evaporator temp. Reset
close differential ensuring that there is
no freeze up
b. Leaky solenoid valve b. Replace solenoid valve
c. Overcharge of refrigerant c. Remove excess
d. Lack of refrigerant d. Check for leaks. Repair and add
charge

12. Motor overload relays open a. Defective relay assembly a. Repair or replace
b. Low voltage during high load b. Check supply voltage and for
condition excessive line drop
c. Locked compressor c. Overhaul compressor
d. Defective or grounded wiring in d. Repair or rewire
motor
e. Loose power wiring e. Check all connections
and tighten

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Typical wiring diagrams

Control Diagram

RISK OF ELECTRIC SHOCK CAN CAUSE INJURY OR DEATH:

DISCONNECT ALL REMOTE ELECTRIC POWER SUPPLIES
BEFORE SERVICING.

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Typical wiring diagrams

Control Diagram

Microprocessor Controller

F1
3

6
F1
2

Menu
F1

8
5
1

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Typical wiring diagrams

Lists & Tables

PFR INDICATOR LIGHT DIAGNOSTICS

LEGEND RUN GREEN
COMP. Compressor HPS High Pressure Switch.
RESTART DELAY GREEN
CFM Condenser Fan Motor TR Transformer
REVERSE PHASE RED
CCB Control Circuit Breaker. R.S Remote Switch
TMP Thermal Motor Protector. OLS Oil Level Switch UNBALANCE / SINGLE PHASE RED
C Contactor. SV Sliding Valve HIGH / LOW VOLTAGE RED
PFR Phase Failure Relay. WFS Water \flow Switch
CCH Crankcase Heater. LSVi Liquid Solenoid Valve Injection
LSV Liquid Solenoid Valve. Terminal Number.
MP Motor Protector Signal Lamp
PI Pump Interlock Wn Wiring Number.
CT Current Transformer Field Connection.
SW Switch

MCS DISPLAY
ALARM:
1* IN CASE OF “ COMP. PROOF” ALARM MESSAGE FOR ANY CIRCUIT
CHECK: HPS, MP, (EXD ALARM) RELATED TO THAT CIRCUIT
2* IN CASE OF “FREEZE” ALARM IT MEANS ONE OF THE FOLLOWING:
- FREEZE CONDITION
- WATER OUT SENSOR ISN’T CONNECTED OR DOESN’T OPERATE

DISC.P: DISCHARGE PRESSURE

SUC.P: SUCTION PRESSURE
DISC.T: DISCHARGE TEMPERATURE
SUC.T: SUCTION TEMPERATURE

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Typical wiring diagrams

Power Diagram

26
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Refrigeration schematic diagrams

For Cooling Units Only

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