Installation, Operation & Maintenance Manual

Standard Air Cooled Range

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Proprietary Notice

This publication contains information proprietary and confidential to Smardt-PowerPax Pty Ltd (hereafter
referred to as Smardt-PowerPax). Any reproduction, disclosure or unauthorized use of this publication is
expressly prohibited without written approval from Smardt-PowerPax. Smardt-PowerPax reserves the right
to make changes without notice in product or component design as warranted by evolution in user needs
or progress in engineering or manufacturing technology.

Smardt-PowerPax has exercised its best efforts to ensure that the information contained in this manual is
correct. However, no warranty of reliability or accuracy is given with respect to the information and
Smardt-PowerPax shall not be responsible or liable for the correctness or suitability of the information or
for any error or omission. If you encounter any difficulty in using this manual, please forward your query
to Smardt-PowerPax or its authorized sales agent.

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

© 2014, Smardt-PowerPax Pty Ltd & Smardt Inc. All rights reserved.

For product support issues, corrections, or enquiries contact:

Product Support
[email protected]
Smardt-PowerPax
144 Colchester Road
PO Box 2021
Bayswater North, Vic, 3153
Australia
+61 3 9761 5055
www.powerpax.com.au

Smardt Chillers Pte Ltd

108 Pasir Panjang Road
#04-10 Golden Agri Plaza
Singapore, 118535
+65 6273 1129

www.powerpax.com.au

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Table of Contents
Installation, Operation & Maintenance Manual ......................................................................... 1
Proprietary Notice ............................................................................................................................. 2
List of Acronyms / Definitions .................................................................................................... 5
Installation ................................................................................................................................. 7
General ............................................................................................................................................... 7
Safety Precautions ............................................................................................................................. 7
Safety Guidelines ............................................................................................................................... 7
Warranty, Commissioning & Maintenance ..................................................................................... 8
Spare Parts ......................................................................................................................................... 8
Training............................................................................................................................................... 8
General Description........................................................................................................................... 9
Customer Service............................................................................................................................... 9
Heat Exchangers .............................................................................................................................. 10
Evaporator.........................................................................................................10

Air Cooled Condenser ........................................................................................10

Refrigeration Components ................................................................................10

Controls .............................................................................................................10

Safeties ..............................................................................................................11

Information on Welding .................................................................................................................. 11

Foundation ....................................................................................................................................... 11
Clearance and Maintenance Access............................................................................................... 11
Nameplates ...................................................................................................................................... 12
Unpacking and Inspection............................................................................................................... 13
Unit Placement ................................................................................................................................ 15
Rigging Requirements ..................................................................................................................... 17
Dimensional Drawings..................................................................................................................... 18
Piping Configurations and Flow Connections ................................................................................ 23
Minimum Water Loop Volumes ..................................................................................................... 23
Evaporator Water Circuits .............................................................................................................. 23
Flow Detection Devices ................................................................................................................... 24

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Relief Valves ..................................................................................................................................... 25

Control Field Wiring ........................................................................................................................ 25
Disconnects and Power Wiring....................................................................................................... 26
Circuit Breakers................................................................................................................................ 27
Line Reactor / RFI Filters ................................................................................................................. 27
Wiring Diagram ................................................................................................................................ 28
Pre-Commissioning.......................................................................................................................... 30
Operation ................................................................................................................................. 34
System Checks before Start Up ...................................................................................................... 34
Powering up Compressors .............................................................................................................. 36
Smardt-PowerPax Controller .......................................................................................................... 37
Maintenance ............................................................................................................................ 38
Appendix 1 – Recommended Spare Parts List ............................................................................... 45
Appendix 2 – Wiring Schematic...................................................................................................... 46

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.
List of Acronyms / Definitions

BACnet Proprietary High Level Protocol

BMCC Bearing Motor Compressor Controller
COM Communications (RS232) Serial Port
EXV Electronic Expansion Valve
HLI High Level Interface
IGBT Insulated Gate Bipolar Transistor (Inverter)
IGV Inlet Guide Vane
I/O Board Compressor Interface Module
LBV Load Balancing Valve
LED Light Emitting Diode
ModBus Proprietary High Level Protocol
PCB Printed Circuit Board
PCO3 Chiller Controller with Smardt-PowerPax Software
PGD3 Color Touchscreen Display
PWM Pulse Width Modulation – Bearing Amplifier
RFI Radio Frequency Interference
SCR Silicon Controller Rectifier

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Smardt-PowerPax
Installation Manual

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Installation

General

This manual is intended to inform contractors, building owners, and engineers of the installation, commissioning,
operation, and maintenance requirements for the Smardt-PowerPax air cooled centrifugal chiller range. It is
intended that this document be used alongside the applicable chiller general assembly drawing and wiring diagrams,
supplied with the chiller.

Prior to installation and set-up of this chiller, it is intended that those involved in the installation, set-up, operation
and maintenance of this chiller familiarize themselves with the procedures in this manual. This manual contains the
information necessary to become familiar with the controls system prior to working on this system.

Safety Precautions

Access to the Smardt-PowerPax chiller must be reserved for authorized personnel. Only those trained in
maintenance and service are authorized to access the unit.

Safety precautions must be observed during installation, start-up and all service of the chiller due to the presence of
high pressure refrigerant charge and high voltage hazards. Only qualified personnel should install, start-up and
service this equipment. Failure to use qualified personnel to work on Smardt-PowerPax equipment will affect the
equipment warranty and may result in serious injury.

Always ensure that all required safety measures are followed such as:

 Wearing protective clothing (gloves, shoes etc.)

 Wearing safety glasses
 Wearing a grounding wrist strap
 Using appropriate tools
 Employing qualified electricians
 Employing Smardt-PowerPax trained and certified refrigeration technicians
 Following local regulations and codes

Safety Guidelines

The evaporator is a pressure vessel. Ensure that it is installed, inspected, registered and maintained in accordance
with local code requirements over its lifetime.

Never cover or obstruct any safety device, including the relief valves in the refrigerant circuits. Ensure that all relief
valves are vented outside the building/plant area in accordance with safety regulations. High concentration levels of
refrigerant in enclosed spaces can displace oxygen and cause asphyxiation and lead to heart irregularities,
unconsciousness, or death. Do not disable any safety devices.

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WARNING!
High voltage electrical equipment is potentially lethal! Isolate incoming electrical power before attempting
installation of the equipment. If work is interrupted, ensure that all circuits are de-energized and power is still
isolated before continuing work. Only a qualified electrician should work on high-voltage electrical equipment.

Wait a minimum of 15 minutes after isolating power before removing compressor access covers as
capacitors can store sufficient charge to cause electrocution within this time frame.

Warranty, Commissioning & Maintenance

Commissioning and maintenance of all Smardt-PowerPax chillers is to be undertaken by Smardt-PowerPax or by a

Smardt-PowerPax certified service provider. Failure to comply with this requirement will void the chiller warranty.
Smardt-PowerPax chillers come with a unit parts and labour warranty in respect to all non-consumable parts (when
installed within Australia, International warranty may vary), for a period of 12 months from the date of
commissioning or 18 months from the date of dispatch from Smardt-PowerPax – whichever is sooner.

Warranty is not a substitute for maintenance. Warranty cover is conditional upon maintenance being carried out
according to the Smardt-PowerPax recommendations during the warranty period. Failure to follow the designated
maintenance procedures and schedules will void the chiller warranty and remove any liability from Smardt-
PowerPax. Please consult the Smardt-PowerPax Terms and Conditions for a warranty statement.

Spare Parts

Smardt-PowerPax has a recommended spare parts list. Stocking the recommended spare parts can reduce service
response times. See Appendix 1 the recommended spare parts list. For the recommended spare parts price list please
contact the Smardt-PowerPax service department [email protected].

Training

Smardt-PowerPax offers a range of training courses on the complete range of Smardt-PowerPax products. For
further information on the training courses available please see our website (www.powerpax.com.au) or contact
Smardt-PowerPax directly [email protected].

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General Description

Smardt-PowerPax make a range of air cooled chillers from 200 to 1580 kWR. The Smardt-PowerPax air cooled chiller
range consists of Danfoss Turbocor centrifugal compressor(s), a flooded R134a shell and tube evaporator, and an air
cooled condenser. Liquid control is via an Electronic Expansion Valve (EXV).

The compressors are semi-hermetic, two stage, direct drive, variable speed centrifugal type. This is a high speed
centrifugal machine which employs advanced magnetic bearing technology and direct drive to eliminate the need
for oil within the system.

Capacity control is provided by variable speed drive and inlet guide vanes, capable of reducing compressor capacity
to 10% of full load (at ARI550/590 standard part load conditions).

To accommodate loads below 25% there is a provision for discharge gas to be injected into the evaporator. This
provision is implemented by the controller only after the maximum turn down has been achieved by compressor
speed reduction. This ensures that the maximum efficiency is maintained at all times. This load balancing valve
feature is integral to load low load operation and is managed to achieve optimum performance at low load via our
proprietary chiller control logic.

The compressor starts unloaded and current is limited to less than 2 amps per compressor. The maximum amps are
also limited to a preset value by the compressors inbuilt control software. Motor cooling is provided by an integrated
liquid refrigerant injection system controlled by the compressor. The compressor is equipped with discharge and
suction shutoff (isolating) valves, and fitted check valves to prevent reverse spin on shutdown.

As a guide, a number of units from 200 to 1580 kWR at nominal conditions with low-noise fans have been
pre-selected and used throughout the manual for information purposes only.

Please contact Smardt-PowerPax with your specific requirements or specific technical data.

Customer Service

For additional product support please contact the Smardt-PowerPax service department at:
[email protected] or call +61 3 9761 5055.

For additional sales support please contact the Smardt-PowerPax sales department at: [email protected] or call
+61 3 9761 5010.

For additional product support, or Sales Support throughout Asia-Pacific, please contact the Singapore Office at:
[email protected] or call +65 6273 1129

Or visit the Smardt-PowerPax website at: www.powerpax.com.au

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Heat Exchangers

Evaporator
The evaporator is flooded shell and tube design using enhanced surface finned copper tubes. It is designed and
constructed in accordance with either ASME or AS1210 pressure vessel codes for a refrigerant side working pressure
of 1320 kPa and a maximum waterside working pressure of 1000 kPa. 2000 kPa water side working pressure is
available as an optional extra.

The evaporator shell is insulated with 19mm closed-cell foam (max k factor of 0.038W/mK) with a vapor barrier
skin as standard. Further insulation is available as an optional extra.

Correct operating refrigerant level is maintained in the evaporator by a control feedback loop based upon the signal
from a refrigerant liquid level sensor. The control function is built into the Smardt-PowerPax EXV controller which
maintains the liquid level in the condenser by modulating the position of the stepper motor driven EXV. Similarly,
the hot gas injection is controlled by the chiller controller via a stepper motor driven load balancing valve. The set
points and control terms for these functions can be adjusted if necessary at commissioning via the chiller controller
interface, on an EXV controller software interface.

Air Cooled Condenser

Compressor discharge gas is piped into an air cooled condenser, condensing through the coil where it free drains
into a liquid header. The liquid refrigerant is then piped to a common liquid line from where it returns to the
evaporator via the EXV.

Refrigeration Components
Refrigerant circuit components include:
 suction line valves
 discharge line stop / check valves
 motor cooling line filter drier
 refrigerant level chamber
 sight glasses
 electronic expansion and load balancing valves
 compressor staging valves
 pressure relief valves
Isolation valves are provided in the refrigeration piping to allow replacement of components without removing the
entire refrigeration charge. The refrigeration system does not contain oil.

Controls
The chiller controller utilizes a microprocessor based controller running on Smardt-PowerPax proprietary software.
It handles the basic functions of chilled water temperature control, and condenser head pressure control. Also
incorporated is a function to trip the circuit breaker in the event of a compressor controls failure. The controls also
protect the chiller against freezing by monitoring for low leaving water temperature and loss of water flow (via
pressure differential switch and external interlocks). The controller also monitors the compressor status signal which
indicates the state of various production functions built into the compressor controller.

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In-built compressor control functions protect against high head pressure, low suction pressure, power supply faults
(voltage and imbalance), excess power input, excess amps input, excess motor temperature, and excessive
electronics temperature.

The controller fitted to the Smardt-PowerPax air cooled chiller is a PLC based device utilizing imbedded control
software written specifically by Smardt-PowerPax for Smardt-PowerPax chiller applications. It utilizes a color touch
screen interface and provides access to settings via a combination of touch screen and button controls.

The various applications are selectable through user interface screens to the touch screen interface. The status of
the compressors and various system parameters can be viewed on these screens as we have the capability to log up
to 100 past alarms and events. The program is stored in non-volatile memory and can be upgraded in the field.

The compressor controller also ensures compressor operation is between the limits (eg. surge) of its operational
envelope at all times.

Safeties
Smardt-PowerPax air cooled units are equipped to provide the following protection:

 Low chilled water temperature

 Power supply errors
 Compressor motor thermal or electrical overload
 Phase loss
 High pressure
 Low pressure
 Loss of chiller water flow via an interlock to an external flow switch

Information on Welding

Smardt-PowerPax vessels are designed and manufactured in accordance with either ASME or AS1210. Welding
should never be performed on the vessels or tube sheets as such a practice would be considered a field
modification and would render the documentation provided with the chiller invalid. Refer to local for pressure
vessel regulations and codes for further information. Do not weld on any part of the chiller under any
circumstances as current can travel through the chiller earth if the welder earth is not satisfactory unnecessarily
damaging chiller/compressor electronics and voiding the unit warranty.

Foundation

Before installing the chiller set, ensure that the supporting floor meets the load bearing requirements. Consult the
Dimensions and Weight Table on page 15 and 16 to determine the load bearing requirements. Four point supports
must be installed along the length of the chiller base frame. Mid base frame struts do not require direct support.

Smardt-PowerPax is not responsible for the load bearing capacity of the floor.

Clearance and Maintenance Access

Adequate clearance around the chiller set is essential to facilitate maintenance and service. Required minimum
clearances are tabulated under “Air Cooled Chiller Clearances” on page 18, please ensure that adequate space for
all installation and service operations is allowed. Check that the minimum clearance complies with all local electrical
codes.

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Air intake, wall clearances, and fan discharge clearances are dependent on the height of the adjacent walls and best
practice design principles. Contact Smardt-PowerPax for further guidance if uncertain.

Note: Short Cycling air discharge will impede the unit’s performance and capacity.

Each compressor weighs approximately 140 kilograms. It is advised that sufficient access be allowed for a small
trolley to easily be brought alongside the chiller, to allow for future service and maintenance needs.

Nameplates
Nameplates are located in various locations on the chiller.

The chiller unit nameplate is located on the outside of the control cabinet and contains both
the model and serial number along with the original design condition. The serial number
and model number should be used to identify the chiller for service, parts and warranty
enquiries. Check that the information on the chiller nameplate is consistent with the
chiller ordered.
Figure 1: Chiller Nameplate

The evaporator has a nameplate. This plate has a serial number which identifies the
vessel, but not the entire unit. This plate also provides the year of manufacture, the
rated pressures, and operating temperature ranges of the vessel.

Figure 2: Evaporator Nameplate

Each compressor also has a nameplate. These nameplates help identify the individual
compressors. The serial number on these plates should be used when identifying the
compressor in question for any service, parts or warranty enquiries.

To obtain some replacement parts, it may be necessary to quote the Model Number,
Serial Number, and Part Number which are found on the above three plates.

Figure 3: Location Compressor Nameplate

Figure 4: Compressor Nameplate

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Unpacking and Inspection

Upon receipt of the chiller it should be inspected immediately for any possible damage and checked thoroughly to
ensure that everything is complete. The unit should be carefully inspected for damage to the evaporator insulation,
condenser coils, broken wires, loose piping and bolts. If damage is suspected immediately perform a leak test, and
repair any leaks if found. If damage is detected, or the shipment is incomplete, immediately file a claim with the
shipping company and notify Smardt-PowerPax.

Do not remove any packing materials until the chiller is in its final position as moving the unit without the packaging
may result in damage, which will not be covered by the Smardt-PowerPax warranty.

Inspect all piping and control cabinet for external damage.

Figure 5: Side views of the air-cooled chiller

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Unit Placement

Before placing the unit, consult the Chiller Dimensions and Weight Table (table 1 ) and Chiller Clearances Table
(Table 2) to confirm that there is adequate room for all connections and to service the chiller.

Install the chiller on approved anti-vibration mounts. Each chiller should have a minimum four supports per side
down length of the base frame (a minimum total of eight) and should be suitably isolated from the plant room floor.
Generally waffle pads are considered suitable as the Smardt-PowerPax chiller is virtually vibration free. It is not
necessary to secure the chiller down the centre rails, only the outside rails should be secured to the anti-vibration
mounts. 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 axis. Obtaining a 0 x and y axis is important.

The following are dimensions and clearances required for the standard Smardt-PowerPax air cooled range.
Table 1: Air Cooled Dimensions and Weights

Air Cooled Chiller Dimensions and Weights

Operating
Model Height (mm) Width (mm) Length (mm) No. of Fans
Weight (kg)
AC028.1B 2550 2330 2800 3110 4
AC028.1B
2550 2330 4000 3730 6
6 fans
AC028.1B
2550 2330 5200 4350 8
8 fans
AC040.1E 2550 2330 4000 4250 6
AC040.1E
2550 2330 5200 4870 8
8 fans
AC040.1E
2550 2330 6400 5490 10
10 fans
AC054.2B 2550 2330 5200 5280 8
AC054.2B
2550 2330 6400 5900 10
10 fans
AC054.2B
2550 2330 7600 6520 12
12 fans
AC065.2E 2550 2330 6400 6360 10
AC065.2E
2550 2330 7600 6980 12
12 fans
AC065.2E
2550 2330 8800 7600 14
14 fans
AC080.2E 2550 2330 7600 7120 12
AC080.2E
2550 2330 8800 7740 14
14 fans
AC080.2E
2550 2330 10000 8360 16
16 fans
AC086.3B 2550 2330 8800 8080 12
AC086.3B
2550 2330 10000 8700 14
14 fans
AC086.3B
2550 2330 11200 9320 16
16 fans
AC110.4B 2550 2330 10200 10560 16
AC110.4B
2550 2330 12600 11800 20
20 fans

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AC110.4B
2550 2330 15000 13040 24
24 fans
AC120.3E 2550 2330 10000 9490 16
AC120.3E
2550 2330 11200 10110 18
18 fans
AC120.3E
2550 2330 12400 10730 20
20 fans
AC150.4E
2550 2330 12600 12720 20
20 fans
AC150.4E
2550 2330 15000 13960 24
24 fans
AC150.4E
2550 2330 17400 15200 28
28 fans
AC160.4E
2550 2330 12600 13130 20
20 fans
AC150.4E
2550 2330 15000 14370 24
24 fans
AC150.4E
2550 2330 17400 15610 28
28 fans
*option “Economizer”: add 75kg per compressor to the operating weight

Table 2: Air Cooled Chiller Clearances

Minimum Clearances - Air Intake/Output (mm)

Model
Right of Chiller Above Chiller* Left of Chiller
AC028.1B 2000 2000 2000
AC040.1E 2000 2000 2000
AC054.2B 2000 2000 2000
AC065.2E 2000 2000 2000
AC080.2E 2000 2000 2000
AC086.3B 2000 2000 2000
AC110.4B 2000 2000 2000
AC120.3E 2000 2000 2000
AC150.4E 2000 2000 2000
AC160.4E 2000 2000 2000
*Clearance above the chiller, and air intake side, is dependent on the height and type of the adjacent wall. Please contact Smardt-PowerPax for
guidelines/recommendations. Clearances valid for all fan combinations

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Rigging Requirements

Care must be exercised at all times when rigging or handling the new chiller to protect it from damage. Where
possible, all packaging and protection should be left in place until the chiller is in its final position. Care should be
taken to ensure that slings do not crush the casework or coils.

Up to six rigging points (three per side) are provided on the base rails of the chiller. The chiller’s centre 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 into its final location. When lifting the unit always
ensure that the slings are of the correct lifting capacity. The Smardt-PowerPax units should not be lifted from any
points other than the lifting points on the base frame.

Smardt-PowerPax is not responsible for the rigging and placement of the unit. Smardt-PowerPax strongly
recommends that a specialized company unloads the machine.

Local codes and regulations regarding the lifting of this equipment may apply. Always ensure that these codes are
adhered to.

The rigging details and centre of gravity information are shown below in Figure 6. Refer to table 2: Air Cooled
Clearances on page 16 for the required chiller clearances.

Figure 6: Lifting Diagram

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Dimensional Drawings
Figure 7: Dimensional Drawing AC028.1B

Figure 8: Dimensional Drawings AC040.1E

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Figure 9: Dimensional Drawings AC054.2B

Figure 10: Dimensional Drawings AC065.2E

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Figure 11: Dimensional Drawings AC080.2E

Figure 12: Dimensional Drawings AC086.3B

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Figure 13: Dimensional Drawing AC110.4B

Figure 14: Dimensional Drawing AC120.3E

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Figure 15: Dimensional Drawing AC150.4E

Figure 16: Dimensional Drawing AC160.4E

Note: Above are the typical dimensional drawings for standard Smardt-PowerPax chillers. Due to Smardt-PowerPax policy of continuous development dimensions
are subject to change without notice. Please contact Smardt-PowerPax for specific dimensions and drawings with optional fans and economizers.

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Piping Configurations and Flow Connections

The evaporator has Victaulic Type grooved stubs (unless specified as flanged) for connection to the external water
circuit.

All external piping must be adequately supported and aligned to prevent strain and distortion on the chiller headers
and couplings. Flexible bellows shall be used to ensure no loads are transferred from the field piping to the nozzles
of the evaporator.

See table 3 for piping connections and typical flow configurations. Please consult the specific chillers specification
sheet for exact Flows and Pressure Drops.

Table 3: Piping Connections and Flow Configurations

Evaporator
Model
No. of Passes Nominal Cooling Capacity (kWR) Flow Rate (l/s)* Size (inch vict.)
AC028.1B 4 280 12.1 6
AC040.1E 4 400 17.3 6
AC054.2B 2 540 23.35 6
AC065.2E 2 700 30.26 6
AC080.2E 2 800 34.58 6
AC086.3B 2 850 36.74 6
AC110.4B 1 1100 47.54 8
AC120.3E 2 1200 51.87 6
AC150.4E 1 1500 64.83 8
AC160.4E 1 1580 6 8
*at AHRI conditions nominal cooling capacity, 12.2/6.7 35ºC AT

Minimum Water Loop Volumes

In the evaporator water circuit there is a minimum water volume requirement of 3.5 litres per cooling kilowatt (kWR)
for all air conditioning applications and 7 litres per cooling kilowatt (kWR) for all process cooling applications. This
water volume needs to be ‘useful’ during periods where bypass valve is open at 100%, meaning the quantity of water
available in the bypass loop must be as per the volume specification above. The bypass loop can be defined as being
the return leg from the chilled water bypass valve to the chiller water inlet.

Evaporator Water Circuits

The chiller performance and efficiency can be adversely affected by contaminants in the water circuit. Such
contaminants may impede or block the flow of water through the circuit or reduce heat exchanger performance.

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PUMP EVAPORATOR
STRAINER

Figure 17: Water Circuit

Strainers should be located on the inlet side of the evaporator. Return water to the chiller must be connected to the
lower connection of the evaporator. 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 should be controlled
as necessary to maintain essentially constant chiller water flows through the unit at all load conditions. For projects
designed with variable water flow through the chiller the flow rate may be modulated between the minimum and
maximum flow rates provided on the pressure drop curve. Any change in flow rate should not exceed 10% per
minute to maintain leaving chilled water temperature control and avoid tripping of the safety devices.

Operating below the minimum flow rate laminar flow may lead to fouling, increase risk of freeze up and poor control.
Flow rates exceeding the stated maximum may result in tube erosion.

The air must be purged from both water boxes on the evaporator and from the entire water circuit to ensure the
chiller’s performance and longevity.

Using untreated or improperly treated water in these units can result in inefficient chiller operation and possible
tube damage. The available water supply must be analyzed and treated appropriately to prevent corrosion, erosion,
or fouling and deterioration of the evaporator. Consult a qualified water treatment specialist familiar with local
water conditions, to assist in this development and implementation of a proper water treatment program.

Flow Detection Devices

An external pump interlock is required to be hard wired into the chiller terminal strip (X4), or alternatively a status
wire from a variable speed drive can be hard-wired into the chiller. Using a HLI status is not acceptable, hard-wiring
of an interlock/status wire is mandatory on all chillers. This is done to prevent the chiller from starting without
confirmation that the chiller water pump is running, alleviating the potential of freezing the water in the vessel. If
either of the above options are not installed, warranty on the chiller will be void. Smardt-PowerPax chillers come

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standard with a Differential Pressure Transmitter (DPT) fitted; this enables the chiller controller to shut down in the
event of low flow, or high flow through the evaporator. You can obtain a vessel pressure drop curve from your local
Smardt-PowerPax representative to allow the full vessel flow range to be utilized, and set the chillers DPT to use the
full vessel flow range.
A flow switch or differential pressure switch can be fitted and hard-wired to the chiller terminal strip as above in lieu
of the interlock or status wire as long as it is set to stop the chiller in either a low or no flow condition. This is best
set-up with the use of the vessel flow curve as detailed above.

Relief Valves

To meet the safety code requirements, each Smardt-PowerPax air cooled chiller has pressure relief valves fitted to
the evaporator vessel to relieve excess refrigerant pressure to the atmosphere in case of emergency. Most codes
require that pressure relief valves be vented to the outside of a building to prevent oxygen displacement which can
lead to asphyxiation. At least two valves are provided, with a change over manifold for service. Refer to local
installation codes for specific requirements.

Figure 18: Smardt-PowerPax Controller

Control Field Wiring

The primary chiller control functions are implemented via a chiller

controller with Smardt-PowerPax proprietary software, which controls
the chiller water temperature, interlocks, and provides an interface to
the building system.

Field wiring connections for the chiller controller only are tabulated in
Figure 19 for wiring diagram (page 28).

Table 4: Wiring Connections for the chiller controller

Field
Reference Signal Function
Terminal

T3F Field wiring supply, 24VDC Field wiring use only

T4F Field wiring supply, 0VDC Field wiring use only

X2 Close to run Remote Start/Stop

X4 Close to run External CHW Flow Protection

X6 Voltage free inputs to be connected to the 24VDC Close to run External COW Flow Protection
from T3F ONLY
Open to initiate Refrigerant
Reclaim.
X8 Refrigerant Leak Detection

X10 Voltage free outputs, recommended to be Chiller Running status Closed between X10 & X11 = running

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Installation

X11 connected to the 24VDC Common Point for X10 & X12

X12 Chiller Faulty status Closed between X12 & X11 = faulty

X14 0 – 10 VDC input External Set Point Offset SP offset from BAS

X16 Ground input Ground Ground for X14

X18 0 – 10 VDC input External Demand Limit Signal External demand limit signal

X20 Ground input Ground Ground for X18

X26 24VDC output CHW water pump enable Enables the CHW pump by Powerpax

X28 24VDC output COW water pump enable Enables the COW pump by Powerpax

Speed control of the CHW pump by

X30 0 – 10 VDC output Speed control for CHW pump
Powerpax

Speed control of the COW pump by

X32 0 – 10 VDC output Speed control for COW pump
Powerpax

X34 24VDC input No. of comps run limit Consult Powerpax service engineer

X36 24VDC input Mains power loss detection Consult Powerpax service engineer

X38 24VDC input All start Consult Powerpax service engineer

X40 24VDC output Daisy Chain Consult Powerpax service engineer

X42 24VDC output Refrigerant recovery Consult Powerpax service engineer

Note: Control wiring must be run separately to power wiring

Power Wiring and Disconnect Means

All wiring must be installed in accordance with appropriate local and national electrical codes.
ALL prescribed electrical works must be carried out by a qualified electrician at ALL times.
The mains power of the chiller in most of cases is 3phase + Earth; it is introduced to PowerPax’s electrical panel at a
single connection point. It is the customer’s (or site electrical contractor’s) responsibility to install the upstream
wiring according to the local electrical standards and rules. A Main disconnect switch is mandatory to be installed by
the customer from the upstream switch board (this is also an option and can be ordered at PowerPax);

WARNING!
To prevent injury or death, disconnect and isolate all electrical power sources before attempting connections to
the unit.

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Installation

The mains power supply is introduced from either the top or the bottom of the electrical cabinet and, then to be
connected to the mains bus bar provided. Install the three phase cable in the correct order according to the local
standard. Earth cable MUST be connected to earth bar in the same cavity of the electrical cabinet.

All penetrations into the control enclosure for wiring must be sealed with IP-56 UV rated glands to maintain the
integrity of the enclosure. Any damage from water ingress will result in void of warranty.

It is important that the voltage to the Smardt-PowerPax units is within +/-10% of the nameplate voltage, and the
voltage unbalance between phases must not exceed 2%. Any imbalance between phase voltage of more than 2% or
more than 10% of the current will be considered neglect and will void the Smardt-PowerPax chiller warranty. If this
occurs, contact your local electricity supplier and ensure that the chiller is turned off until this has been rectified.

To prevent control interference/malfunctions, do not run low voltage wiring (<30V) with high voltage wiring, i.e. AC
voltage. Recommended control wiring should be screened cable, with the screen to be terminated 360° at the entry
point of the control panel.

Table 5: Lug Sizes

Actives Neutral Earth

Main Lug Size 10mm 10mm 8mm

Circuit Breakers

WARNING!
To prevent injury or death, disconnect and isolate all electrical power sources before attempting connections to
the unit. Wait at least 15 minutes after isolating power before removing compressor access covers.

Protective circuit breakers are provided for each compressor. Isolating these circuit breakers does not isolate the
incoming power supplied to the chiller.

Line Reactor / RFI Filters

Smardt-PowerPax provides a line reactor and harmonic filter for each compressor. They are located electrically
between the circuit breakers and the compressor. The use of the line reactor and harmonic filter improve the
power quality going to the compressors.

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Installation

Wiring Diagram
Figure 19: Wiring Diagram

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ACIM1.7
Installation

Figure 20: Wiring Schematic

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Installation

Pre-Commissioning

Smardt-PowerPax requires equipment to be commissioned according to a detailed procedure and by a Smardt-

PowerPax trained and certified technician. In order to activate the warranty, the commissioning form must be
completed and submitted to Smardt-PowerPax.

Prior to commissioning, obtain the current pre-commissioning form (example shown on the following pages) either
by contacting the Smardt-PowerPax service department or by downloading the form at www.powerpax.com.au and
ensure that all requirements have been met to commission the Chiller. Please allow 7 days for the coordination of
commissioning from the date the pre-commissioning form is submitted. Forms can be submitted to:
[email protected] or by faxing +61 3 9761 6707.

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Operation

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Smardt-PowerPax
Operation Manual

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Operation

Operation

System Checks before Start Up

Chiller Checks

Before powering up the Smardt-PowerPax chiller check for any signs of damage. If damage is discovered, contact
your local Smardt-PowerPax representative immediately to report it.

Ensure that all refrigerant valves are open including suction, discharge, motor cooling and liquid line valves.

Turn all fan circuit breakers on. Ensure that the fans on the chiller are rotating in the correct direction. Fans should
be pulling air through the coils and discharging it vertically upwards. If the fans are turning in the wrong direction,
reversing of the phases will be required.

If the fans are not operating check that the 3 phase power supply is within the design voltage range and check that
the circuit breakers are not tripped. Check the wiring diagram for control wiring.

Electrical Checks:

Note: Below checks must be performed with the power OFF. Removal of covers with power applied
will result in exposure to high voltages. It is important to ensure adequate time has been allowed for the
capacitors to completely discharge the DC Voltage stored before the top cover is removed for any
reason, this generally takes at least 20 to 30 minutes. Failure to follow these instructions may result in
electrocution, the voltage present at the capacitors is >500VDC.

Check if all control connections in control cabinet are tight, secure and making good connection.

Check all incoming mains electrical connections for tightness and security. Ensure that there is an earth present and
it has been connected to the appropriate bus bar in the electrical cabinet as it is essential for correct operation of
the unit. Tighten terminals if needed.

Remove the line reactor enclosure covers and check electrical connections for tightness. Replace line reactor
enclosure covers.

Compressor Checks:

Note: The below checks must be performed with the power OFF. Removal of covers with power
applied will result in exposure to high voltages. Failure to have power off may result in electrocution,
please follow the steps detailed above in ‘Electrical Checks’.

Remove the top cover from the compressor, remove the four screws, near the motor bus bars, holding the soft start
board in place. Turn the soft start over and check the four fuses are securely in place and in good working order (see
Figure 21 on the following page).

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Operation

Figure21: Softstart Fuse Locations

Check all screws for tightness and check all electrical plugs are fitted correctly. Refit top cover when all checks have
been completed.

Remove the side covers from the compressors and check the serial driver and BMCC boards are firmly seated onto
the backplane board (see Figure 22), check all electrical plugs are fitted correctly. Refit the compressor side covers
once the compressor tests have been completed.

Figure 22: Backplane Board

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Operation

Powering up Compressors

Check with the electrical contractor and request that power be turned on to the chiller. Once all the covers have
been replaced on the compressor, and the electrician has turned on the power, power can be turned on to the
compressors.

WARNING: Risk of Electrocution. Do NOT power up compressors with the compressor top covers
removed.

Compressors should be powered up one at a time. Compressors are turned on by switching the allocated circuit
breaker.

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Operation

Smardt-PowerPax Controller

Please refer to Operating Manual “Smardt Chiller Controller v13_05_A_AA

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Maintenance

Smardt-PowerPax
Maintenance Manual

Maintenance

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Maintenance
The following Smardt-PowerPax maintenance schedule is outlined on the following pages in table 6. It should be
noted however, that Smardt-PowerPax require quarterly maintenances only, however this table provides the
checks based on a monthly schedule should that be your requirement for ongoing maintenance. Please note that
maintenance should only be carried out by a Smardt-PowerPax certified technician. Warranty is not an excuse for
not maintaining the chiller to a sufficient minimum standard. Chiller warranty will only be valid if the service
schedule that has been set for the warranty period has been adhered to. Once a scheduled warranty maintenance
has been completed Smardt-PowerPax requires the Smardt-PowerPax service form be returned to the service
department. The Smardt-PowerPax maintenance form can be found on pages 55 – 60 of the Maintenance Manual.
For the latest maintenance form please contact your local Smardt-PowerPax representative who will give you the
information to contact the Smardt-PowerPax Service Department if required.
.

Note: Maintenance should only be carried out by a Smardt-PowerPax certified technician. Failure to
comply will void chiller warranty.

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Table 6: Smardt-PowerPax Maintenance

Item Task Frequency

Q A
Check main power supply voltages P
Check electrical terminals are tight P
Electrical Checks
Check there are no hot spots / discoloration on power cables P
Check Amperages are as per design P
Check communication cables are secure P
Check pressure and temperature sensor connections are secure P
Electronic Inspections Check PCB’s (printed circuit boards) are free of dust P
Check there are no signs of damage / hot spots on Printed Circuit Boards P
Check EXV winding resistance (do NOT disturb unless repair required) P
Check IGV Assembly operating correctly P
Check compressor fault log P
Compressor Checks Check calibration of pressure and temperature sensors P
Check Backplane voltage test points P
Check all modules and connections are secure P
Check all mounting bolts are secure P
Check for refrigerant leaks P
Compressor Refrigeration Circuit Inspections Check for mechanical damage P
Check operating temperatures and pressures P
Check that the compressor motor cooling line sight glass
is full during operation P
Check for insulation damage P
Check chilled water sensors are secure and installed
with adequate heat transfer medium P
Chilled Water Circuit Inspection
Check water flows and pressure drops are as per design conditions P
Check flow switch/interlock operation P
Check for leaks P
Check water strainers P
Check air flow is not obstructed P
Check fin surfaces are clean P
Air Cooled Condenser inspection Check fan rotation (direction) P
Check fan motor overload devices P
Clean condenser coils P

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Maintenance
Comments & Photos

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Appendix

Appendix

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Appendix

Appendix 1 – Recommended Spare Parts List

Recommendation for
Item Part Description TT300 R134a TT350 R134a No.
Stocking

Compressor Components
Kit – Module – Soft Recommended - All
1.1 X X 1
Start Models
Kit – Module – Recommended - All
1.2 X X 1
Bearing PWM Models
Kit - Module- Serial Recommended - All
1.3 X X 1
Driver Models
KIT-SENSOR-
ASSEMBLY-
1.4 X X Beneficial - All Models 1
TEMPERATURE-
MOTOR ROTOR
KIT -SENSOR-
1.5 PRESSURE/TEMPERA X X Beneficial - All Models 1
TURE -SUCTION
KIT-SENSOR-
PRESSURE/TEMPERA
1.6 X X Beneficial - All Models 1
TURE-DISCHARGE &
ECR
KIT -DC/DC
Recommended – All
1.7 CONVERTER X X 1
Models
ASSEMBLY
KIT-IGBT MANIFOLD
1.8 X X Beneficial – All Models 1
COOLING
KIT -IGV HOUSING
1.9 X X Beneficial – All Models 1
ASSEMBLY
KIT -BEARING
MOTOR Beneficial – All Models
1.10 X X 1
COMPRESSOR Model Specific
CONTROL (BMCC)
KIT-FUSES (FIE) ASIC Recommended - All
1.11 X X 1
SOFT START Models
KIT - FUSE CLASS T Recommended - All
1.12 X X 1
Mains Fuses Models
Chiller Components

2.1 Pressure Sensor X X Recommended 2

Chilled Water
2.2 X X Recommended 2
Temperature Sensor
2.3 PCO3 Controller X X Beneficial 1
2.4 EXV Controller X X Recommended 1
Other Components
3.1 EXV Head X Recommended 1

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Appendix

Appendix 2 – Wiring Schematic

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Appendix

144 Colchester Road

PO Box 2021
Bayswater North, VIC
Australia, 3775
www.powerpax.com.au
Phone: +61 3 9761 7905 Fax: +61 3 9761 6707

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