HHP FOUR PRIVATE LIMITED

0.553MWh Battery Energy Storage

System (BESS)
Replus Engitech Private Limited
Document No: Pune, INDIA
REPL-23-083-OM-MAN- Operation & Maintenance Manual HVAC
200 Page 1 of 21
system

Document Title: Operation & Maintenance Manual HVAC system

Document No:
REPL Document No: REPL-23-083-OM-MAN-200

Approvals

Revision Date Reason for Revision Prepared By Checked By Approved By

R0 19-12-2024 Noted for Information AG Amit A Amit A

R1 04-01-2025 Noted for Information AG Amit A Amit A

 HHP FOUR PRIVATE LIMITED
0.553MWh Battery Energy Storage
System (BESS)
Replus Engitech Private Limited
Document No: Pune, INDIA
REPL-23-083-OM-MAN- Operation & Maintenance Manual HVAC
200 Page 2 of 21
system

1. CRS
HVAC QAP
Sr.No Page no. Hygenco Comment Replus response
To segregate Installation,
The documents have
1 Operation & Maintenance
been segregated.
manuals.
NATIONAL
COOLING SYSTEM

OPERATION &
MAINTENANCE MANUAL FOR
CONTAINER COOLING UNIT
1
❖ CONTENTS:

1) WARRANTY CERTIFICATE

2) PRINCIPLE OF WORKING

3) SPECIFICATIONS OF SYSTEM

4) STANDARD SETTING

5) MAINTENANCE INSTRUCTION

6) TROUBLE SHOOTING CHART

7) LEAKAGE DETECTION

8) CHARGING PROCEDURE

9) WIRING DIAGRAM

2
 NATIONAL COOLING SYSTEM
Plot No.57/1/05, F-II Block, Woman Entrepreneurs Industrial Premises Co-Op
Society Ltd, MIDC, Bhosari, Pune 411 026, Cell No.: + 91 9371009096, +91 9922962652!
Email ID: - sales@nationalcoolingsystems.in, Tel No.: 7756939160
http://www.nationalcoolingsystems.in
WARRANTY CERTIFICATE

Date : 02/12/2024
Description : Container Cooling Unit ( NPC 7.0 )
Order No : REPL/2-25/0544, Dated 01.10.2024
Machine No : NPC/437/12/2024
Customer : REPLUS ENGITCH PVT LTD

The company warrants the Cooling Unit manufactured by us to be free from defects in
workmanship & material, under normal use and service. Equipment returned to our factory,
transportation prepaid and insured, within 12 months from the date of dispatch and found to be
defective in workmanship or material by us will be repaired or replaced, at free of charge and
returned, freight prepaid and insured, by most economical mode of transport. The warranty will be 12
months from the date of dispatch, for electrical parts and switchgear. If our inspection does not
disclose any defect in the workmanship of the material, the company reserves the right to charge for
repairs conducted or parts replaced.

This warranty is in lieu of all other warranties, expressed or implied. In no other event the
company will be responsible for consequential damage of any nature whatsoever.

The equipment not manufactured by us but procured by other sources & supplied, will not be subject
to the above warranty. For such items, the manufacturer/supplier’s standard warranty as force at the
time of supply will apply.

Yours Faithfully,

For NATIONAL COOLING SYSTEM

Sd/xx/xx
PROPRIETOR
Mr. R.R. Bagwan

3
 2. PRINCIPLE OF WORKING:
It works on Simple Vapor Compression Refrigeration Cycle. The hermetically sealed
compressor compresses the refrigerant to a higher temperature and pressure. A Fin and tube type
condenser extract heat from the refrigerant with the help of ambient air and liquefies it. The liquid
refrigerant then passes through a drier/filter to an expansion device i.e., a capillary tube. The
capillary tube reduces the pressure of refrigerant and injects it into the evaporator. The refrigerant in
the evaporator evaporates by absorbing heat from the hot air inside the electronic panel. To enable
this operation with high Co-efficient of Performance

The ambient air is continuously cooled by refrigeration system and circulated at the required
operating temperature along with cool, clean and moisture free flow of air to process.

Air Cooling Unit manufactured by us simply works on the principle of Vapor Compression
Refrigeration Cycle. It is described briefly as below: -

The vapor-compression uses a circulating liquid refrigerant as the medium which absorbs and
removes heat from the space to be cooled and subsequently rejects that heat elsewhere. Figure 1
depicts a typical, single-stage vapor-compression system. All such systems have four components: a
compressor, a condenser, a Thermal expansion valve (also called a throttle valve), and an
evaporator. Circulating refrigerant enters the compressor in the thermodynamic state known as a
4
saturated vapor and is compressed to a higher pressure, resulting in a higher temperature as well.
The hot, compressed vapor is then in the thermodynamic state known as a superheated vapor and it
is at a temperature and pressure at which it can be condensed with typically available cooling water
or cooling air. That hot vapor is routed through a condenser where it is cooled and condensed into a
liquid by flowing through a coil or tubes with cool water or cool air flowing across the coil or tubes.
This is where the circulating refrigerant rejects heat from the system and the rejected heat is carried
away by either the water or the air (whichever may be the case).

The condensed liquid refrigerant, in the thermodynamic state known as a saturated liquid, is
next routed through an expansion valve where it undergoes an abrupt reduction in pressure. That
pressure reduction results in the adiabatic flash evaporation of a part of the liquid refrigerant. The
auto-refrigeration effect of the adiabatic flash evaporation lowers the temperature of the liquid and
vapor refrigerant mixture to where it is colder than the temperature of the enclosed space to be
refrigerated.

The cold mixture is then routed through the coil or tubes in the evaporator. A fan circulates the
warm air in the enclosed space across the coil or tubes carrying the cold refrigerant liquid and vapor
mixture. That warm air evaporates the liquid part of the cold refrigerant mixture. At the same time,
the circulating air is cooled and thus lowers the temperature of the enclosed space to the desired
temperature. The evaporator is where the circulating refrigerant absorbs and removes heat which is
subsequently rejected in the condenser and transferred elsewhere by the water or air used in the
condenser. To complete the refrigeration cycle, the refrigerant vapor from the evaporator is again
saturated vapor and is routed back into the compressor.

3. SPECIFICATIONS OF SYSTEM: -

MODEL CONTAINER COOLING UNIT (NPC 7.0)

TYPE AIR COOLED

DIMENSION OF UNIT L 1200 X W 1100 X H 2300 MM

CAPACITY 2800 CMH (Free Flow)

MEDIUM TO BE COOLED Clean Air

TEMPERATURE RANGE 24 TO 26 Deg Cent

SUPPLY VOLTAGE 3 Ph, 415 Volt, 50 Hz, with Neutral

CONTROL VOLTAGE 230 Volt

GAS (REFRIGERANT) R - 407 C (Eco Friendly Gas)

5
4. STANDARD SETTING:
Temp Controller Ideal Setting: -
LILYTECH (ZL – 630A – R)
Para. Description Setting

Set Temp 24
U10 Time Delay for Cooling Cut Off 0
U11 Time Delay for Cooling Initial Start / Restart 0
U12 Cooling Run Frequency in case Probe Failure 5
U20 Room Sensor Calibration 0
U21 Pipe Sensor Calibrations 0
U22 Hysteresis 2
U23 Energy Saving Mode 2 (NA)
U30 Defrost Period 0 (Disable)
U31 Defrost Time 5 (NA)
U32 Defrost Finish Time 12 (NA)
U33 Dripping Time 5 (NA)
U34 Over Temp Warning Delay After Defrost 0 (Disable)
U35 Defrost After Turn to Online 0 (Disable)
U36 Delay to Defrost after turn to Online 0 (Disable)
U37 Remote Force Defrost 0 (NA)
U38 Defrost Type 0 (NA)
U39 Defrost Finish Sensor 1 (NA)
U40 Cooling Blower/ Fan Start Temp 0 (NA)
U41 Cooling Blower/ Fan Start Delay 0 (NA)
U42 Cooling Blower/ Fan Stop Delay 0 (NA)
U43 Cooling Blower/ Fan Control Mode 4
U44 Cooling Blower/ Fan Running Time when Compressor is Off 0 (NA)
U45 Cooling Blower/ Fan Stop Time when Compressor is Off 0 (NA)
U50 Deviation For High Temp Alarm 15
U51 Deviation For Low Temp Alarm 10
U52 Over Temp Warning Delay 0
U53 Over Temp Warning Delay After Power Supply 0 (Disable)
U60 DI 1
U61 Warning Delay time to DI 0 (Disable)
U62 Buzzer Warning 0 (Disable)
U63 DI Function 0
U64 Output Status During Door Open 0 (NA)
U65 DI Door Open, outputs restart after U61 time (when U64=1/2/3) 1
U70 Display during defrosting 0
U71 Time to keep the display during defrost, after defrosting is finished 30 (NA)
U90 Working Mode Cooling
U91 On/Offline Status On
U96 Controller ID code 0
U97 Baud rate 2
U98 Modbus slave address 1
U99 Password 1111

6
Temp Controller Description: -
1.1 Power-on Display
After power on, all LED unit will be on, then model
name, and firmware version:

1.2 Display Icon

Icon Function On Off Blink
Temp. Output Energized Deenergized Delay protecting
Defrost Defrosting Not defrosting Dripping water
Mode Cooling mode ---- DI energy saving
Mode Heating mode ---- DI energy saving
Maintenance Need maintenance No failure found ----
Warning Has warning No warning ----

Digital Display
Four digits display values in normal condition. They also display warnings as below:
Displa Remark Displa Remark
y y
E01 Room sensor failure (short or open) Err Password error
E02 Pipe sensor failure (short or open) dEF Defrosting
Hi Room temperature. Is higher than dr DI door open warning
the high limit
Lo Room temperature. Is lower than Frd Forced cooling or heating
the low limit
EE Memory error UnL Restore to factory password “1111”
Set Setpoint
Keep 〖S〗 depressed for 3 seconds to enter the setting setpoint status.
Press〖▲〗or〖▼〗 to set the value (keeping depressed can fast set).
Press 〖S〗 to exit and save the setting.
The status will exit without saving the setting if no key operation within 30 seconds.

Set Parameters
Password:
Keep 〖P〗 depressed for 3 seconds, digits show “---0”.
Press〖▼〗to select the digit of the password, press〖▲〗to set the value of the digit.
Press 〖S〗 to confirm.
If the password is correct, enter the parameter setting status, else display “Errs,” and exit.
Parameter Set:
The display will be “U10”. Press〖▲〗or〖▼〗to select the parameter code (see table below).
Press 〖S〗 to display the value of the code, press〖▲〗or〖▼〗to set its value.
Press 〖S〗 to return.
So, all the codes could be set.
Keep 〖P〗 depressed for 3 seconds to exit and save the settings.
The status will exit without saving the settings if no key operation for 30 seconds.

7
Registers: -
Z Z Z
L L L
- - -
6 6 6
Address Name RW Range Remark Function Code 1 2 3
0 0 0
A A A
- - -
R R R
0 Room Temp. R -50.0~130.0℃ real value ×10 0x03 ● ● ●
1 Pipe Temp. R -50.0~130.0℃ real ×10 0x03 / ● ●
7 Temp. output stop protection time RW 0~100 min 0x03/0x06/0x10 ● ● ●
8 Temp. output run protection time RW 0~100 min 0x03/0x06/0x10 ● ● ●
9 Temp. output run frequency RW 0~8 0x03/0x06/0x10 ● ● ●
10 Room sensor calibration RW -9.9~+9.9℃ real ×10 0x03/0x06/0x10 ● ● ●
11 Pipe sensor calibration RW -9.9~+9.9℃ real ×10 0x03/0x06/0x10 / ● ●
12 Hysteresis RW 0.1~30.0℃ real ×10 0x03/0x06/0x10 ● ● ●
0: Room
temperature
1: Room
13 Display during defrosting RW 0~3 temperature before 0x03/0x06/0x10 ● ● ●
defrosting
2: Setpoint
3: “dEF”
Time to keep defrosting display
14 RW 0~255 min 0x03/0x06/0x10 ● ● ●
after defrosting finished
15 Defrost period RW 0~180 hour 0: defrost forbidden 0x03/0x06/0x10 ● ● ●
16 Defrost time RW 1~180 min 0x03/0x06/0x10 ● ● ●
17 Defrost finish temp. RW 0.5~50.0℃ 0x03/0x06/0x10 / ● ●
18 Dripping time RW 0~180 min 0x03/0x06/0x10 ● ● ●
Over temp. warning delay after
19 RW 0~180 hour 0x03/0x06/0x10 ● ● ●
defrosting
20 Defrost after turned to online RW 0~1 0: disable. 1: enable 0x03/0x06/0x10 ● ● ●
Delay for defrost after turned to
21 RW 0~180 min 0x03/0x06/0x10 ● ● ●
online
0: auto. 1: remote
22 Defrost Mode RW 0~1 0x03/0x06/0x10 ● ● ●
control
23 Fan start temp. RW -45~+120℃ real ×10 0x03/0x06/0x10 / / ●
24 Fan start delay RW 0~600秒 0x03/0x06/0x10 / / ●
25 Fan stop delay RW 0~600秒 0x03/0x06/0x10 / / ●
0: Controlled mode,
see 6.4
1: Stop in defrosting,
see 6.4
2: Stop in defrosting,
else
26 Fan control mode RW 0~4 0x03/0x06/0x10 / / ●
running
3: Run in defrosting,
see 6.4
4: Run in defrosting,
else
running
Fan run time when compressor
27 RW 0~60 min 0x03/0x06/0x10 / / ●
stops during cooling mode
Fan stop time when compressor
28 RW 0~60 min 0x03/0x06/0x10 / / ●
stops during cooling mode
0: neglect pipe
temperature.
29 Defrost finish sensor RW 0~1 0x03/0x06/0x10 / ● ●
1: based on pipe
temp.

8
31 Deviation for high temp. warning RW 0~60℃ real ×10 0x03/0x06/0x10 ● ● ●
32 Deviation for low temp. warning RW 0~60℃ real ×10 0x03/0x06/0x10 ● ● ●
33 Over temp. warning delay RW 0~180 min 0x03/0x06/0x10 ● ● ●
1st Over temp. warning delay after
34 RW 0~180 hour 0x03/0x06/0x10 ● ● ●
turned to online
0: electrical heater
35 Defrost type RW 0~1 0x03/0x06/0x10 ● ● ●
1: gas
36 Controller ID code RW 0~31 0x03/0x06/0x10 ● ● ●
39 See U60 RW 0~2 See U60 0x03/0x06/0x10 ● ● ●
40 See U61 RW 0~120 min 0x03/0x06/0x10 ● ● ●
41 Buzzer warning RW 0~1 0: disable. 1: enable 0x03/0x06/0x10 ● ● ●
0x0000 / 0x0000: not forced.
42 Remote forced temp. output on RW 0x03/0x06/0x10 ● ● ●
0xFF00 0xFF00: forced on
-
48 Setpoint RW real ×10 0x03/0x06/0x10 ● ● ●
40.0~+120.0℃
0: cooling. 1:
49 Working mode RW 0~1 0x03/0x06/0x10 ● ● ●
heating
0xFF00: forced
51 Remote (host) forced defrost RW 0x0000 / 0xFF00 0x01/0x05/0x06/0x10 ● ● ●
defrost
0x0000: offline
50 Remote On/Off RW 0x0000 / 0xFF00 0x01/0x05/0x06/0x10 ● ● ●
0xFF00: online
52 Restore to factory default RW 0~1 1: restore settings 0x06/0x10 ● ● ●
53 Password RW 0~9999 0x03/0x06/0x10 ● ● ●
RW -
54 See U23 real ×10 0x03/0x06/0x10 ● ● ●
20.0~+20.0℃
55 See U63 RW 0~2 See U63 0x03/0x06/0x10 ● ● ●
56 See U64 RW 0~3 See U64 0x03/0x06/0x10 ● ● ●
57 See U65 RW 0~1 See U65 0x03/0x06/0x10 ● ● ●

9
5. MAINTENANCE INSTRUCTIONS:
Compressor:
Compressor requires no maintenance. It is hermetically sealed, properly lubricated at the factory & should provide years of satisfactory
operating service.
If the refrigerant is lost, recharging valves are provided on the suction sides of the compressor for recharging and / or checking suction under
no circumstances the refrigerant lines to be loosened, removed or tempered with. They must be dealt with only by trained people. The system contains
refrigerant gases under pressure.

Condenser Cleaning:
Proper maintenance of the Condenser & Evaporator will ensure normal operation of the cooling Unit. If maintenance is delayed or ignored, the
maximum ambient temperature under which the unit is designed to operate will be decreased.

Condenser Fan:
Fan motors require no maintenance. All bearings are self-sealed lubricated during manufacturing for the life of the motor.

Refrigerant Loss:
The Air-Cooled Unit was thoroughly assessed before leaving the factory, to ensure against refrigeration leaks. Transportation damages require
repairs & recharging of the system. This work should be performed by qualified people only, available in any reputable air conditioning repair & service
company.
Before recharging make sure that there are no leaks & that the system has been properly evacuated by a deep vacuum.

10
6. TROUBLE SHOOTING GUIDE

ITEM CONDITION POSSIBLE CAUSE REMEDY

1. All lights Off. No main supply. Control Check all the wires on the main cable, check main switch, Check &
circuit fuses blown. repair short circuit in control circuit.

In-coming fuses are blown Replace Fuse.

In coming power supply is

not correct. Neutral not connected properly.

2. All MCB is ON, but Check the setting of HP switch as per recommendation, if it is Ok
the Cooling unit is HP Trip then check the condition of Air-cooled fins type condenser if
not ON. necessary clean it carefully without damaging the fins also ensure
the right direction & RPM of condenser fan motor.
If the Air Chilling Unit is operated without the cleaning of Air-
cooled condenser periodically the problem of condensation will start
in terms of HP of refrigerant, causing a breakdown. To avoid this,
periodically clean the condenser by blowing the air in between the
fins & straighten the fins.
After conducting the above checks, then reset the HP trip by
pressing manually reset button on switch & monitor the discharge
pressure on the gauge.

SPP Trip Check the phase sequence on VSPD-1 at inside

electrical panel, if it is ok it glows green indication, if it is not ok it
glows red and green both indication on controller and glows the SPP
trip indication on panel door, then change the incoming phase
sequence of any two phase

11
LP Trip Check the setting of LP switch as per recommendation, if it is Ok,
then check the circulation of air flow.
Check the suction pressure & standing pressure of refrigerant it
should be as per the designed value. Otherwise, there might be the
problem of leakage of refrigerant under such condition detect the
location of leak by Nitrogen pressure test & conduct gas charging by
professional technician as per standard procedure. Ref Para 10.

Check the setting & contacts of Overload relay. If maladjusted or

Compressor OLP Trip defective adjust or replace it.
Check the Compressor by resistance & Ground check at the
terminal. Check the condition of condenser Manually reset the OLP
by pressing reset button on OLP. Monitor the LRA & running current
of compressor.

Cond Fan OLP Trip Check the setting & contacts of Overload relay. If maladjusted
or defective adjust or replace it.
Check the Fan motor by resistance & Ground check at the
terminal. Check the condition of pump Manually reset the OLP by
pressing reset button on OLP. Monitor the LRA & running current of
Fan motor.

Cooling Blower Trip Check the setting & contacts of Overload relay. If maladjusted or
defective adjust or replace it.
Check the Compressor by resistance & Ground check at the
terminal. Check the condition of condenser Manually reset the OLP
by pressing reset button on OLP. Monitor the LRA & running current
of Blower.

12
7. LEAKAGE DETECTION:

Leakage detection of any system is normally done by the Soap Bubble Method or with a free on detector.

PROCEDURE:

1.Charge the system with Nitrogen gas through the charging valve.
2.Pressurise the system with Nitrogen only up to 300 P.S.I.
3.Apply soap bubbles at all brazed and flare joints to detect leakage.
4.Rectify the leakage spot by either tightening the Flare Nut or by brazing (System
5.Should not be under pressure when brazing is done.)
6.After rectification, charge Nitrogen to 300 P.S.I. Hold it for 24 Hrs. to make sure that the system is leak proof.

8. CHARGING THE SYSTEM: ‘Appx B’

This Chilling Unit has been manufactured under strict quality control but if a
need for repair (parts replacement etc.) arises, the following cautions should be observed.
1. Turn both the operation switch and power source OFF.
2. Fire may be used during work so dismount the Chilling Unit from the machine and drain all the water. Furthermore, choose a
place with no danger of fire and a well-ventilated place where there is no danger of fire and a well-ventilated place where there is no
danger of suffocation caused by the release of the refrigerant.

After the system is made leak- proof, the Nitrogen in the system is to be removed. The system should be evacuated by vacuum pump
for at least 4 hours. The evacuation should be done through both charging and discharge valve.
1. Use proper refrigerant for charging.
2. Charge the refrigerant in the system through charging valve. Make sure that the air in the charging tube is fully removed.
3. Charge the refrigerant till the vacuum breaks completely.
4. Put ON the system.
5. After the compressor starts, open the charging valve.
6. Charge system further till the pressure gauge on Suction Valve shows 50 TO 70 P.S.I. for R 407C refrigerant.

13
 MCB 6A REMOTE ON
MCB 4P 50A
R1 GRAY P 1
RED R R1

YELLOW Y Y1

BLUE B B1

N N1 N1
BLACK

EARTHING E 1 1

INCOMING
R1 Y1 B1 E R1 Y1 B1 E E R1 Y1 B1 E
SUPPLY
415V 3PH +N +E

GV2ME08 GV2ME21 GV2ME07

R1 Y1 B1 N1 CB1 CB2 CB3

TS2M1-1-16A-230V
MPD 192 SPP
R Y B N

LC1D09 LC1D32 LC1D09

MPD192
C1 C2 C3
SPP

50 51 52 56 57 58
53 54 55 53 54 55

E E
E E
B B
C M N1 BLACK
BLOWER FAN 2
COMPRESSOR FAN1 MPD TS2M1-1-
192 16A-230V
 SPP EMG TIMER
5 5 5 5
1 3 4

4
TIC
6

5 09
S/W 5 5
2 3 A4 5
4
TIC C1
MANUAL SWITCH 5

8 9
PRESSURE PRESSURE
SW SW
CB1 CB1 CB2
11
10
12

7 6 14
CB2
7
13
R/L1 R2 G C1
R1 ZL-630A-R R3 C2 R4 R5
L3 G
BLACK
8 L5
N1
BLOWER BLOWER ON LP COM/FAN C/F HP COM/FAN
POWER TIC
TRIP TRIP ON ON TRIP TRIP
ON
 GRAY
230V AC 5

C2 CB3

15

PRE/SW 18

16

CB3

17
C3 L7 R6
G

BLACK N1

FAN 2 FAN 2 FAN 2

ON ON TRIP
 GRAY GRAY
230V AC 5 5 230V AC

5 5 5 5 5 5

9 9 9
9 9 9
R1 R2 R3 R4 R5 R6

5 5 5
5 5 5

19 20 21 22 23 24

R L2 R L4 R L9 R L10 R L6 L8

BLACK N1 N1

SPP BLOWER LP HP COM FAN 2

FAULT TRIP TRIP TRIP TRIP TRIP
 5 5

1 RELAY FOR
COM& FAN
PIN NO 25 25
12

N1 5 09 8 5

N/8 L/7 6 5 4/L

12 12 12 12 12 12
ZL-630A-R R1 R2 R3 R4 R5 R6
TIC
8 8 8 8 8 8

14 13 9 10 11 12
26 26 26 26 26 26
RED WHITE

26 27 28 25
A B ORANGE

SPP BLOWER LP HP COM FAN2

SENSOR 1
SENSOR 2
SENSOR

TO PIN NO TRIP TRIP TRIP TRIP TRIP TRIP

COM

9 OF TIC
RS485

21
DI FROM
ALARM
N1 BLACK IN PUT N1
 B
RH 85
A
25
ANY FAULT
26
1
REMOTE ON
P
SENSOR 1 28
SENSOR 2 27
SENSOR COMMON 25
SENSOR COMMON 25
09
10
LP/HP
11
12

HP FAN 15
16
HTR 1
N1
N1

50
51
BLOWER
52
E
53
CONNECTOR DETAILS

54
COMPRESSOR
55
E

53
54
FAN1
55
E
56
57
FAN2HP
58
E