installation, air cooled operation & scroll maintenance direct expansion manual ...€¦ ·...

Form No: M-M-0488A-0510

Products that perform...By people who care

R134a

R22

R407C ACDS

50Hz 60Hz

INSTALLATION,OPERATION &MAINTENANCE

MANUAL

INSTALLATION,OPERATION &MAINTENANCE

MANUAL

MODEL:

AIR COOLEDSCROLLDIRECT

EXPANSIONCHILLERS

R410A

10 to 180 Tons(35 to 633 kW)

- 2 -

MANUAL INDEX Description Page

Description Page

1.0 INTRODUCTION .............................................. 3

1.1 Physical Specifications ....................................... 4

2.0 INSTALLATION 2.1 General ..................................................................... 6

2.2 Inspection ................................................................ 6

2.3 Rigging ..................................................................... 6 2.3.1 General ............................................................. 6 2.3.2 Rigging and Moving ......................................... 6

2.4 Space Requirements And Clearance ............... 7 2.4.1 General ............................................................. 7 2.4.2 ACDS ................................................................ 7

2.5 Foundation ............................................................ 18 2.5.1 Air Cooled Units .............................................. 18

2.6 Vibration Isolation ............................................... 18

2.7 Piping Connection .............................................. 21 2.7.1 Water Connections Chilled Water

Piping .............................................................. 21 2.7.2 Water Connections Multiple Packaged

Chillers ............................................................ 21 2.7.3 Water Quality .................................................. 23

2.8 Electrical Connections ....................................... 23

2.9 Request For Start-Up Representative ........... 23

3.0 OPERATION 3.1 General ........................................................... 24

3.2 Unit Piping ..................................................... 24

3.3 Air Cooled Package Start-Up ....................... 24

3.4 System Start-Up ............................................ 24

3.5 Lubrication .................................................... 24 3.5.1 Oil Level .......................................................... 24 3.5.2 Oil Type ........................................................... 30

3.6 System Flow Rate ................................................ 30

3.7 System Control .................................................... 30 3.7.1 Capacity Control .............................................. 30 3.7.2 Solid-State operating Thermostat ................... 30

4.0 ELECTRICAL 4.1 Electrical Data ...................................................... 33

4.2 IR32 Electronic Thermostat Front Panel ...... 34

4.2.1 Typical Control Sequence With 2 Stage Operating Thermostat At 10°C Return Water Setpoint, 3.0°C Differential .............................. 34

4.2.2 Keypad Operation ........................................... 35 4.2.3 IR32 Electronic Thermostat Parameter List ... 35 4.2.4 IR32 Electronic Thermostat Troubleshooting .. 37

4.3 Vision 2020i Controller and Terminal ............ 38 4.3.1 DBG1 Operator Keypad .................................. 38 4.3.2 Status Reading ................................................ 39 4.3.3 Authorization ................................................... 41 4.3.4 Advanced user key and menu ......................... 41 4.3.5 Technician Key and Menu ............................... 41 4.3.6 Control Functions ............................................ 44

4.4 Condenser Fan Control Logic.......................... 47 4.4.1 Air-Cooled Condenser Control Setpoints ........ 47 4.4.2 Increasing Condenser Pressure ...................... 48 4.4.3 Decreasing Condenser Pressure .................... 48

4.5 Master/ Slave Control Sequence ..................... 48 4.5.1 Principle of Operation VIA DBLAN

Communication Bus ........................................ 49 4.5.2 Sequence of Operation ................................... 50

4.6 Vision 2020i Local Area Network (DBLAN) .. 50

4.7 Network Connection Diagram .......................... 51

4.8 Hardware Setting ................................................. 51 4.8.1 Addressing the Vision 2020i Controller ........... 51 4.8.2 Addressing the Vision 2020i DBG1 Terminal .. 52 4.8.3 Vision 2020i Controller LED Status ................. 53

4.9 TYPICAL WIRING SCHEMATIC ........................ 54

5.0 MAINTENANCE 5.1 General ................................................................... 88

5.2 Periodic Inspection ............................................. 88

5.3 Monthly Inspection .............................................. 88

5.4 PHE Maintenance ................................................ 88 5.4.1 General ............................................................ 88 5.4.2 Evaporator Cleaning ....................................... 88

5.5 Air Cooled Condenser Cleaning ..................... 89

5.6 Electrical Malfunction ......................................... 89

5.7 Refrigerant Charging .......................................... 89 5.7.1 General ........................................................... 89 5.7.2 Air Cooled Package ........................................ 89

5.8 Trouble Shooting ................................................. 91

5.9 Sample Log Sheet ............................................... 92

- 3 -

1.0 INTRODUCTION This manual is prepared to provide all the necessary information of installation, operation and maintenance of the latest generation of Dunham-Bush air-cooled chillers with scroll compressors. In order to be able to make full use of the manual, you must first determine your unit model number from the unit name plate. Dunham-Bush package has been manufactured under a stringent quality control system. Each packaged chiller is performance tested at the factory at the specified field operating conditions as a final verification of reliability. If the package is installed, operated and maintained with care and attention to the instructions contained here in, it will yield many years of satisfactory service. It is assumed that the reader of this manual and those who install, operate and maintain the equipment have a basic understanding of the principles of air conditioning, refrigeration and electrical controls. TABLE 1.1 PRODUCTION IDENTIFICATION

AC D S 030 - AR G S

Air Cooled Packaged Chiller S- Standard Fan F- Low Noise Fan V- Compressor Jacket M- Low Noise Fan &

Compressor Jacket

AN- 208-230V/3pH/60Hz AR- 460V/3pH/60Hz

Scroll Compressor

Direct Expansion Evaporator

R410A

Nominal Capacity in Tons (ARI Condition)

- 4 -

1.0 INTRODUCTION 1.1 PHYSICAL DATA

MODEL ACDS 010 020 030 040 050 060 070 080

NOMINAL CAPACITY TONS 10.0 20.9 26.9 41.3 53.2 62.0 71.1 81.4

NOMINAL POWER INPUT KW 10.9 22.5 28.0 45.8 56.8 68.9 80.4 90.7

COMPRESSOR

RPM 3500 3500 3500 3500 3500 3500 3500 3500

MIN. % UNIT CAPACITY REDUCTION 50% 50% 50% 25% 25% 25% 25% 25%

NO. OF REFRIGERANT CIRCUIT 1 1 1 2 2 2 2 2

EVAPORATOR

WATER CONNECTOR INCH[MM] 1.6 [41.3] 1.6 [41.3] 1.6 [41.3] 2.5[63.5] 2.5[63.5] 2.5[63.5] 2.5[63.5] 2.5[63.5]

NOM. WATER FLOW / PD (GPM)/(FT IN WG) [m³/hr / kPa]

24.9/ 10.6 [5.7/ 31.7]

49.8/ 10.8[11.3/ 32.3]

66.5/ 12.7[15.1/ 38]

93.0/ 13.5[21.1/ 40.4]

121.1/ 14.4[27.5/ 43.0]

157.0/ 14.4 [35.7/ 43.0]

165.1/ 14.8 [37.5/ 44.2]

189/ 15.0 [42.9/ 44.8]

MIN/MAX. WATER FLOW (GPM)/[m³/hr] 23.0/ 73.0 [5.2/ 16.9]

42.0/ 131.0[9.5/ 29.8]

53.0/ 161.0[12.0/ 36.6]

72.0/ 216.0[16.4/ 49.1]

90.0/ 272.0 [20.4/ 61.8]

116.0/ 351.0 [26.3/ 79.7]

121.0/ 363.0 [27.5/ 82.4]

136.0/ 410.0[30.9/ 93.1]

MIN/MAX. WATER PD (FT IN WG) / [kPa]

9.5/ 78.7 [28.4/ 235.2]

8.1/ 65.6 [24.2/ 196.1]

8.3/ 72.0 [24.8/ 215.2]

8.8/ 62.6 [26.3/ 187.1]

8.7/ 63.0 [26.0/ 188.3]

8.6/ 63.0 [25.7/ 188.3]

8.7/ 62.6 [26.0/ 187.1]

8.5/ 61.9 [25.4/ 185.0]

CONDENSER

COIL ROWS DEEP/ TOTAL FA FT²[M²] 3/ 20.0[1.9]

3/ 38.5[3.6]

4/ 42.8[4.0]

3/ 64.2[6.0]

3/ 105.0[9.8]

4/ 105.0[9.8]

4/ 105.0[9.8]

4/ 133.0[12.4]

TOTAL CFM 10150 20200 25000 38000 60300 54798 54798 71400

NO OF FAN 1 2 4 4 6 6 6 6

FAN DIA INCH[MM] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 31.5[800.0]

MOTOR HP (QTY) 1.5 (1) 1.5 (2) 1.5 (4) 1.5 (4) 1.5 (6) 1.5 (6) 1.5 (6) 2.0 (6)

FAN FLA , AMP (QTY) 2.7 (1) 2.7 (2) 2.7 (4) 2.7 (4) 2.7 (6) 2.7 (6) 2.7 (6) 3.4 (6)

MIN. OPERATING AMBIENT °F[°C] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2]

ELECTRICAL

NOM. VOLTAGE 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60

RLA/COMPRESSOR (QTY), AMPS 12 (2) 21 (2) 26 (2) 21 (4) 26 (4) 26 (2) 36 (2)

36 (4) 36 (2) 46 (2)

UNIT MAX. INRUSH, AMPS 102 173 197 221 254 319 339 398

GENERAL

UNIT LENGTH INCH[MM] 58[1473] 96[2438] 98[2489] 98[2489] 142[3607] 142[3607] 142[3607] 148[3759]

UNIT WIDTH INCH[MM] 43[1092] 43[1092] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235]

UNIT HEIGHT INCH[MM] 51[1295] 51[1295] 57[1448] 57[1448] 76[1930] 76[1930] 76[1930] 88[2235]

SHIPPING WEIGHT LB[KG] 929[421] 1503[682] 2350[1066] 2603[1181] 3950[1792] 4153[1884] 4364[1979] 4865[2207]

OPERATING WEIGHT LB[KG] 934[424] 1515[687] 2365[1073] 2629[1193] 3984[1807] 4193[1902] 4409[2000] 4918[2231]

OPERATING CHARGE R410A LB[KG] 26[12] 51[23] 77[35] 101[46] 128[58] 152[69] 179[81] 203[92]

Note: Nominal capacity is based on evaporator LFT 44°F and condenser ambient 95°F, actual capacity depends on the specified operating conditions.

- 5 -

1.0 INTRODUCTION

MODEL ACDS 090 100 120 135 150 165 180

NOMINAL CAPACITY TONS 89.8 100.8 108.4 125.4 138.5 153.0 163.7

NOMINAL POWER INPUT KW 103.7 108.7 118.7 130.8 150.0 160.4 176.5

COMPRESSOR

RPM 3500 3500 3500 3500 3500 3500 3500

MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 16.7% 16.7% 16.7% 16.7%

NO. OF REFRIGERANT CIRCUIT 2 2 2 2 2 2 2

EVAPORATOR

WATER CONNECTOR INCH[MM] 2.5[63.5] 2.5[63.5] 2.5[63.5] 3.0[76.2] 3.0[76.2] 3.0[76.2] 3.0[76.2]

NOM. WATER FLOW / PD (GPM) /(FT IN WG) [m³/hr / kPa]

206.8/ 15.2 [47.0/ 45.4]

230.2/ 15.4 [52.3/ 46.0]

272.0/ 15.8 [61.8/ 47.2]

351.2/ 15.2 [79.8/ 45.4]

345.9/ 14.8 [78.6/ 44.2]

404.6/ 17.5 [91.9/ 52.3]

414.5/ 14.8 [94.1/ 44.2]

MIN/MAX. WATER FLOW (GPM)/[m³/hr] 147.0/ 443.0 [33.4/ 100.6]

161.0/ 484.0[36.6/ 109.9]

185.0/ 551.0[42.0/ 125.1]

210.0/ 400.0[47.7/ 90.8]

210.0/ 400.0 [47.7/ 90.8]

250.0/ 450.0 [56.8/ 102.2]

270.0/ 480.0[61.3/ 109.0]

MIN/MAX. WATER PD (FT IN WG) / [kPa]

8.4/ 61.2 [25.1/ 182.9]

8.3/ 60.0 [24.8/ 179.3]

8.0/ 57.5 [23.9/ 171.9]

5.1/ 30.0 [15.2/ 89.7]

5.1/ 30.0 [15.2/ 89.7]

5.1/ 30.0 [15.2/ 89.7]

5.1/ 30.0 [15.2/ 89.7]

CONDENSER

COIL ROWS DEEP/ TOTAL FA FT²[M²] 4/ 133.0[12.4]

4/ 177.3[16.5]

4/ 177.3[16.5]

4/ 235.6[21.9]

4/ 235.6[21.9]

4/ 282.6[26.3]

4/ 282.6[26.3]

TOTAL CFM 71400 96960 95200 124140 122850 147420 147420

NO OF FAN 6 8 8 10 10 12 12

FAN DIA INCH[MM] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0]

MOTOR HP (QTY) 2.0 (6) 2.0 (8) 2.0 (8) 2.0 (10) 2.0 (10) 2.0 (12) 2.0 (12)

FAN FLA , AMP (QTY) 3.4 (6) 3.4 (8) 3.4 (8) 3.4 (10) 3.4 (10) 3.4 (12) 3.4 (12)

MIN. OPERATING AMBIENT °F[°C] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2]

ELECTRICAL

NOM. VOLTAGE 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60

RLA/COMPRESSOR (QTY), AMPS 46 (4) 46 (2) 56 (2)

56 (4) 36 (3) 46 (3)

46 (6) 46 (3) 56 (3)

56 (6)

UNIT MAX. INRUSH, AMPS 418 495 515 494 524 611 641

GENERAL

UNIT LENGTH INCH[MM] 148[3759] 189[4801] 189[4801] 225.5[5728] 225.5[5728] 267.5[6795] 267.5[6795]

UNIT WIDTH INCH[MM] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235]

UNIT HEIGHT INCH[MM] 88[2235] 88[2235] 88[2235] 93[2362] 93[2362] 93[2362] 93[2362]

SHIPPING WEIGHT LB[KG] 5231[2373] 6196[2811] 6309[2862] 7336[3328] 7888[3578] 9120[4137] 9844[4465]

OPERATING WEIGHT LB[KG] 5290[2400] 6264[2841] 6383[2895] 7454[3381] 8005[3631] 9251[4196] 10007[4539]

OPERATING CHARGE R410A LB[KG] 229[104] 254[115] 304[138] 342[155] 381[173] 419[190] 456[207]

Note: Nominal capacity is based on evaporator LFT 44°F and condenser ambient 95°F, actual capacity depends on the specified operating conditions.

- 6 -

2.0 INSTALLATION 2.1 GENERAL

The ACDS chiller is designed to cool water or other non-corrosive liquids. Water is circulated through the direct expansion evaporator where it is cooled to the desired temperature and then circulated to cooling coils for air conditioning, or to other types of heat exchangers for process cooling. Care should be taken to ensure that the equipment is properly installed and adjusted. An installer or operator should first be familiar with the information in this manual. 2.2 INSPECTION

When the equipment is delivered, it is important that the following inspection be completed in the presence of the carrier's representative: 1. Check all crates and cartons received against

the Bill of Lading/Shipping Papers to be sure they tally.

2. Check the model number and the electrical characteristics on the nameplate to determine if they are correct.

3. Check for freight damage, shortages or other discrepancies and take note of them on the delivery receipt before signing. Should any damage be found, a damage claim should immediately be filed by the purchaser against the delivering carrier as all shipments are made at the purchaser's risk.

2.3 RIGGING 2.3.1 GENERAL

Each unit has been carefully tested and packed at the factory where every care is taken to ensure that the unit reaches you in perfect condition. It is very important that the riggers and movers use the same care and precaution in moving the equipment into place. Make sure that chains, cables, or other moving equipment are placed so as to avoid damage to the unit or piping. The refrigerant piping should not be used as a ladder or as a handle. Do not attach a chain hoist sling to the piping or equipment. Move the unit in an upright position and let it down gently from trucks or rollers.

2.3.2 RIGGING AND MOVING Any unit mounted on skids may be moved with a forklift, but care must be taken not to damage the unit with forks. The skids should not be removed until the unit is at its final location. The ACDS model can be lifted by the method showing in Figure 2.3.2.

2.4 SPACE REQUIREMENTS AND CLEARANCE

2.4.1 GENERAL

The dimensional data and clearances that follow are useful for determining space requirements. The unit should be placed to make the clearance noted available for proper servicing. Failure to allow such clearance will cause serious problems and result in higher costs for operation, maintenance and repair.

2.4.2 ACDS The dimensional data are shown in Figure 2.4.2B and space requirements are shown in Figure 2.4.2A. The most important consideration which must be taken into account when deciding on the location of an air cooled equipment, is the provision for supply of ambient air to the condenser, and removal of heated air from the condenser area. When this essential requirement is not provided, it will result in higher condensing temperatures, which will cause poor operation, higher power consumption and eventually failure of equipment. Units must not be located in the vicinity of steam, hot air or fume exhausts. Another consideration which must be taken into account is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building. Units should be mounted over corridors, utility areas, rest rooms or other auxiliary areas where sound levels are not an important factor. Sound and structural experts should be consulted for recommendations on critical installations.

- 7 -

2.0 INSTALLATION FIGURE 2.3.2 ACDS RIGGING

ACDS 010 ACDS 020

- 8 -

2.0 INSTALLATION ACDS 030, 040, 050, 060, 070 ACDS 080, 090, 100, 120, ACDS 135, 150, 165, 180

- 9 -

2.0 INSTALLATION FIGURE 2.4.2B DIMENSIONAL DATA ACDS 010

- 10 -

2.0 INSTALLATION ACDS 020

- 11 -


- 12 -


- 13 -

2.0 INSTALLATION ACDS 050, 060, 070

- 14 -

LEFT

VIE

WFR

ON

T VI

EWREA

R VI

EW

TOP

VIEW

84 [

2134

]

POW

ER E

NTR

Y(B

OTT

OM

)

DO

OR S

WIN

G

48 [1218.800 mm]

60.5

[15

37.4

00 m

m]

48 [1219.200 mm]

24 [

609.

600

mm

]

88 [2235.600 mm]

AIR F

LOW

AIR F

LOW

AIR F

LOW

CON

TRO

L BO

X AC

CESS

6 N

OS

OF

n2.

9 [7

3mm

] LI

FTIN

GH

OLE

S O

N B

OTH

SID

E O

F TH

E FR

AME

6 N

OS

OF

3/4"

(19

)M

OU

NTI

NG

HO

LES

FOR S

PRIN

G I

SOLA

TORS

12 [

304.

800

mm

]58

[14

67.1

00 m

m]

66 [

1675

.100

mm

]

12 [

300.

300

mm

]88

88 [2236.711 mm]

148

[374

7.00

0 m

m]

2.0 INSTALLATION ACDS 080, 090

- 15 -


- 16 -

TOP

VIEW

LEFT

VIE

WFR

ON

T VI

EWRE

AR V

IEW

84 [

2134

]

88 [

2235

]

.

AIR

FLO

W

226

[574

0]

1. A

LL D

IMEN

SIO

NS

ARE

IN I

NCH

ES A

ND

MIL

IMET

ERS.

2. A

LLO

W 6

0 [

1254

] C

LEAR

ANCE

AT

CON

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L PA

NEL

EN

D O

F U

NIT

FO

R SE

RVI

CES.

3. U

SE M

INIM

UM

36

[ 91

4 ]

FLEX

IBLE

CO

ND

UIT

TO

CO

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BOX

TO I

SOLA

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.4.

WAT

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IPIN

G T

O B

E SU

PPO

RTED

TO

MIN

IMIZ

E LO

AD O

N U

NIT

.

NO

TES:

6 N

OS

OF

3/4"

(19

)M

OU

NTI

NG

HO

LES

FOR

SPR

ING

ISO

LATO

RS

AIR

FLO

W

6 N

OS

OF

?2.

9 [?

73.2

00 m

m]

LIFT

ING

HO

LES

ON

BO

TH S

IDE

OF

THE

FRAM

E

POW

ER E

NTR

Y(B

OTT

OM

)

POW

ER E

NTR

Y(B

OTT

OM

)

30 [

762.

000

mm

]83

[21

01.8

50 m

m]

83 [

2101

.850

mm

]30

[76

2.00

0 m

m]

CON

TRO

L BO

X AC

CESS

88 [

2237

.600

mm

]D

OO

R S

WIN

G

AIR

FLO

W

9 [2

19.5

00 m

m]

Appr

ox.

33 [

836.

000

mm

]

44 [

1119

.700

mm

]Ap

prox

.

WAT

ER O

UT

CON

NEC

TIO

N [

3.5"

] N

OM

INAL

DIA

OPT

ION

AL W

ELD

ED F

LAN

GE

CON

NEC

TIO

N

48 [

1216

.800

mm

]

48 [

1219

.200

mm

]

60.5

[15

36.6

00 m

m]

24 [

609.

200

mm

]

93 [

2357

.500

mm

]

WAT

ER I

N C

ON

NEC

TIO

N [

3.5"

] N

OM

INAL

DIA

OPT

ION

AL-W

ELD

ED F

LAN

GE

CON

NEC

TIO

N

DET

AIL

A

A


- 17 -

LEFT

VIE

WFR

ON

T VI

EWREA

R V

IEW

TOP

VIEW

69 [

1756

.830

mm

]

84 [

2134

]88

[22

35]

.DO

OR

SW

ING

POW

ER E

NTR

Y

8 N

OS

OF

n2.

9 [7

3mm

] LI

FTIN

GH

OLE

S O

N B

OTH

SID

E O

F TH

E FR

AME

8 N

OS

OF

3/4"

(19

)M

OU

NTI

NG

HO

LES

FOR

SPR

ING

ISO

LATO

RS

NO

TES:

1. A

LL D

IMEN

SIO

NS

ARE

IN I

NCH

ES A

ND

MIL

IMET

ERS.

2. A

LLO

W 6

0 [

1254

] C

LEAR

ANCE

AT

CON

TRO

L PA

NEL

EN

D O

F U

NIT

FO

R SE

RVIC

ES.

3. U

SE M

INIM

UM

36

[ 91

4 ]

FLEX

IBLE

CO

ND

UIT

TO

CO

NTR

OL

BOX

TO I

SOLA

TE U

NIT

.4.

WAT

ER P

IPIN

G T

O B

E SU

PPO

RTED

TO

MIN

IMIZ

E LO

AD O

N U

NIT

.

WAT

ER I

N C

ON

NEC

TIO

N [

3.5"

] N

OM

INAL

DIA

OPT

ION

AL W

ELD

ED F

LAN

GE

CON

NEC

TIO

N

WAT

ER O

UT

CON

NEC

TIO

N [

3.5"

] N

OM

INAL

DIA

OPT

ION

AL W

ELD

ED F

LAN

GE

CON

NEC

TIO

N

33 [

836.

000

mm

]

12 [

294.

900

mm

]Ap

prox

.

44 [

1116

.050

mm

]Ap

prox

.

DET

AIL

A

A

48 [

1219

.200

mm

]

60 [

1524

.000

mm

]

48 [

1216

.800

mm

]

88 [

2237

.600

mm

]

24 [

609.

600

mm

]

93 [2353.719 mm]

30 [

762.

000

mm

]69

[17

56.8

30 m

m]

69 [

1756

.830

mm

]30

[76

2.00

0 m

m]

POW

ER E

NTR

Y(B

OTT

OM

)

CON

TRO

L BO

X AC

CESS

AIR F

LOW

AIR F

LOW

AIR

FLO

W

267.

5 [6

794.

500

mm

]


- 18 -

2.0 INSTALLATION 2.5 FOUNDATION 2.5.1 AIR COOLED UNITS

The foundation must be level for proper operation and functioning of controls and provision must be made for supporting the individual load points as shown in Figure 2.5.1, Roof mounted units must be supported on adequate steel structures. If units are located on the ground level, a concrete plinth is recommended.

2.6 VIBRATION ISOLATION Under certain critical conditions, it may be necessary to install vibration isolators under the base of the Packaged Chiller.

Rubber-in-shear or spring vibration isolators are offered as optional items. When spring isolators are used, flexible connectors must be installed in the water piping system and in the refrigerant lines of split systems. Kindly note that: These flexible connectors must be suitable for the fluid and pressures involved.

When using flexible connectors in refrigerant piping, they must be mounted in the refrigerant discharge and liquid lines close to the packaged chiller, in a horizontal position and parallel to the compressor crankshaft.

All piping which is external to the packaged chiller must be supported by spring mounted hangers and any piping which goes through the wall, ceiling or floor should be properly pivoted to prevent transmission of piping vibration to the structure.

FIGURE 2.5.1 FLOOR LOADING DIAGRAM

ACDS 010 ACDS 020

POINT LOAD LOCATION MODEL ACDS

DIMENSIONS – INCH [MM]

A B C D

010 31 (787) 2 (51) 54 (1372) 2 (51)

020 31 (787) 2 (51) 92 (2337) 2 (51)

POINT LOAD DATA

MODEL ACDS

LOADS – LBS [KG] TOTAL OPERATING

WEIGHT LBS [KG]

P1 P2 P3 P4

010 208 [94] 213 [97] 247 [112] 267 [121] 934 [424]

020 348 [158] 410 [186] 410 [186] 348 [158] 1515 [687]

- 19 -

2.0 INSTALLATION ACDS 030, 040, 050, 060, 070

ACDS 080, 090, 100, 120, 135, 150

ACDS 165, 180

- 20 -

2.0 INSTALLATION POINT LOAD LOCATION

MODEL ACDS

DIMENSIONS – INCH [MM]

A B C D E F

030 84 [2134] 16 [406] 76 [1930] 16 [406] - -

040 84 [2134] 16 [406] 76 [1930] 16 [406] - -

050 84 [2134] 20 [508] 102 [2600] 20 [508] - -

060 84 [2134] 20 [508] 102 [2600] 20 [508] - -

070 84 [2134] 20 [508] 102 [2600] 20 [508] - -

080 84 [2134] 12 [305] 58[1467] 66 [1675] 12 [305] -

090 84 [2134] 12 [305] 58[1467] 66 [1675] 12 [305] -

100 84 [2134] 16 [406] 86 [2172] 71 [1803] 16 [406] -

120 84 [2134] 16 [406] 86 [2172] 71 [1803] 16 [406] -

135 84 [2134] 30 [762] 83 [2102] 83 [2102] 30 [762] -

150 84 [2134] 30 [762] 83 [2102] 83 [2102] 30 [762] -

165 84 [2134] 30 [762] 69 [1757] 69 [1757] 69 [1757] 30 [762]

180 84 [2134] 30 [762] 69 [1757] 69 [1757] 69 [1757] 30 [762]

POINT LOAD DATA

MODEL ACDS

LOADS - LBS [KG] TOTAL OPERATING

WEIGHT LBS [KG] P1 P2 P3 P4 P5 P6 P7 P8

030 470 [213] 713 [323] 713 [323] 470 [213] - - - - 2365 [1073]

040 611 [277] 704 [319] 704 [319] 611 [277] - - - - 2629 [1193]

050 1060 [481] 932 [423] 932 [423] 1060 [481] - - - - 3984 [1807]

060 1133 [514] 963 [437] 963 [437] 1133 [514] - - - - 4193 [1902]

070 1207 [548] 998 [452] 998 [452] 1207 [548] - - - - 4409 [2000]

080 836 [379] 819[372] 804[365] 804[365] 819[372] 836 [379] - - 4918 [2231]

090 904 [410] 881 [400] 860 [390] 860 [390] 881 [400] 904 [410] - - 5290 [2400]

100 1026 [465] 1043 [473] 1064 [482] 1064 [482] 1043 [473] 1026 [465] - - 6264 [2841]

120 1049 [476] 1063 [482] 1080 [490] 1080 [490] 1063 [482] 1049 [476] - - 6383 [2865]

135 1137 [516] 1242 [564] 1348 [611] 1348 [611] 1242 [564] 1137 [516] - - 7454 [3381]

150 1225 [556] 1334 [605] 1443 [655] 1443 [655] 1334 [605] 1225 [556] - - 8005 [3631]

165 1110 [504] 1141 [518] 1172 [532] 1202 [545] 1202 [545] 1172 [532] 1141 [518] 1110 [504] 9251 [4196]

180 1225 [556] 1242 [564] 1260 [571 1277 [579] 1277 [579] 1260 [571] 1242 [564] 1225 [556] 10007 [4539]

- 21 -

2.0 INSTALLATION 2.7 PIPING CONNECTIONS 2.7.1 WATER CONNECTIONS

CHILLED WATER PIPING After the unit has been leveled, the external water piping may be set up. Be sure that the water piping is connected to the corresponding connectors. The water-outlet connection of the evaporator is closest to the expansion valve (refrigerant circuit) end.

Water flow through the evaporator must remain constant for proper chiller operation. Water pressure gauges are recommended to check the water pressure and flow rate in the system, before and after the evaporator, and to determine if variations occur in the evaporator and system. When installing pressure taps to measure the amount of pressure drop across the water side of the evaporator, the taps should be located at least twenty-four (24) inches [610mm] downstream from any connections (flange, elbow, etc.) in the water piping.

There are many piping and control systems which may be used to ensure constant water flow through the evaporator. A typical system is shown in Figure 2.7A. A three-way motorized valve, which operates in response to the discharge air temperature of the cooling coil, is used.

Another system which is sometimes used consists of a two-way modulating control valve, which also responds to the discharge air temperature of the cooling coil, used with a spring loaded bypass regulating valve as shown in Figure 2.7B The bypass valve must be set to ensure full flow of circulating chilled water when the modulating valve is completely closed.

Other systems are noted in the ASHRAE Handbook and may operate equally well. Whatever the system is selected, the water flow must be constant.

2.7.2 WATER CONNECTIONS - Multiple Packaged Chillers Multiple unit package chillers have been successfully applied to parallel and series piping systems for years. Special attention, however, must be given to the particulars involved for each application or serious operational problems can result. The following guidelines should be followed for multiple unit application.

It is assumed that the chilled water flow rate is constant.

2.7.2.1 Parallel Chilled Water Flow Units

Method A: Both units operate simultaneously, modulating with load variations. Each packaged chiller operating thermostat senses the return water temperature using standard controls (See Figure 2.7C). The set point of each thermostats will be set to maintain the desired unloading. In addition to that, for each chiller package, the suction sensing hot gas by-pass valve provides modulating capacity reduction from 100% to approximately 30% on single compressor models with hot gas by-pass.

Method B: Install units the same as Method A, but add a third thermostat in the return water, as shown in Figure 2.7E. This thermostat will be set to cycle off one of the units when the load drops below 50%. When this condition is reached, the leaving mixed water temperature will rise, causing the return water temperature to rise and the unit operating will load up. The "off" unit is sequencing to start again before full system load temperature is reached.

This system will be as stable as Method A, in operation, but in normal air- conditioning applications, this is not detrimental. The advantage of Method B is a better part load efficiency. Also a lead-lag control can be added.

- 22 -

2.0 INSTALLATION

FIGURE 2.7A

FIGURE 2.7B

FIGURE 2.7C

FIGURE 2.7D

FIGURE 2.7E

- 23 -

2.0 INSTALLATION 2.7.2.2 Series Chilled Water Flow Units

Units should be equally sized. The upstream unit will carry a larger load because it cools higher temperature water. The thermostats sense inlet water temperatures. (See figure 2.7D). The number 1 unit thermostat will unload or cycle off the packaged chiller before unloading occurs of the Number 2 unit.

2.7.3 WATER QUALITY

Evaporators used in this packages is made of steel and copper and are suitable for operation with well-maintained water systems. However, if the water used in evaporator is corrosive, high in mineral content or entrained solids, the water can reduce the performance and even damage the heat exchangers. Therefore, it may be necessary to obtain the service of a water treatment consultant and to provide and maintain water treatment. This is particularly important with glycol systems and with cooling tower loops.

2.8 ELECTRICAL

CONNECTIONS 2.8.1 GENERAL

All units are wired as completely as possible at the factory prior to delivery. The connections which must be made by the installer are to the main power source, starting equipment and interlocking the satellite equipment. In connecting power wiring to the unit, the following precautions should be taken:

- All field wirings are to be in accordance with the National Electrical Code and state and local codes.

- All wirings are to be checked for damage and all terminal connections are to be tested for tightness. Unit terminal blocks are to be connected with copper conductors only and sized per ampacity listed on unit data plate.

- The power supply should match the unit nameplate in volts, phase and Hertz. Voltage must be within ±10% of nameplate value and voltage imbalance between phases must not exceed 2%

2.9 REQUEST FOR START-UP REPRESENTATIVE

Start-up service is an option upon request when an order for the unit is placed. If you request for start-up service, then after the installation has been completed and checked, a written notice shall be given to the Dunham-Bush representative. Following receipt of written notice, a representative will be sent to the customer. The purchaser should have competent service and operating personnel in attendance to assist in the work involved, and also to be trained in the operation and maintenance of this unit.

The representative will inspect the installation to determine whether it meets Dunham-Bush requirements, perform the initial start-up of the installation determine whether it is in satisfactory operating condition, and instruct specified customer personnel in its operation and maintenance for the length of time specified in the purchase contract.

- 24 -

3.0 OPERATION 3.1 GENERAL The unit should be started up only by a refrigeration technician who is familiar with the accepted operation practices for refrigeration systems. Use the scroll unit start-up report, to record all temperature, pressure, electrical readings and control settings. A copy must be forwarded to Dunham-Bush service department, before warranty will be honored. 3.2 UNIT PIPING See Figure 3.2.1 for typical unit piping schematics. 3-3 AIR COOLED PACKAGES

START-UP The unit is ready for start-up when the following procedures have been completed:

1. Water piping for the evaporator is installed and tested.

2. Electrical connections are made and properly fused.

3. Unit has been leak tested, leaks corrected and charge completed.

4. Compressor crankcase heater(s) has been energized for a minimum of 24 hours.

5. Calibrated refrigerant gauges have been connected to the suction and discharge ports.

6. Turn On the chilled water pump, check direction of rotation and adjust the water flow through the evaporator to the specified flow rate. Bleed off all entrained air.

7. Manually energize the fan starters and check the fan rotation. Fans should pull air through the condenser coil and discharge vertically upwards. Rotation can be changed on 3-phase motors by interchanging only two wires on the main terminal block.

8. Check all refrigerant valves to be sure they are open.

9. Proceed to section 3.4 System Start-Up.

3.4 SYSTEM START-UP 1. Before starting the compressor(s), check all

three phases of supply voltage, of all legs of the motor. They must be within ±10% of the nameplate voltage.

2. Start compressor(s), check the gauges and note if the pressures are within the prescribed limits.

3. Check the refrigerant sight glass to be sure it is free of bubbles. If not, charge as specified per section 4.8 Charging.

4. Shut the compressor down and check the compressor crankcase sight glass for oil level. It should be between 1/2 to 3/4 of the complete sightglass. If not, see Section 3.5 Lubrication.

5. Restart the compressor. After an hour of operation the expansion valve superheat setting should be checked, it should be between 8°F [4.4°C] and 10°F [5.6°C] at full load design conditions. In some instances, it will be necessary to lower the superheat setting to ensure proper distribution. Turn the TX valve adjustment stem clockwise to increase the superheat setting and counterclockwise to decrease the setting. Be sure and allow ample time between each adjustment for the system to rebalance.

6. The temperature of the chilled water both in and out, should be checked to insure the unit is operating within the desired temperatures.

3.5 LUBRICATION 3.5.1 OIL LEVEL

A properly operated unit should run with the compressor crankcase warm to touch. Check oil level frequently to see that a sufficient amount of oil remains in the crankcase. Compressor oil level can be checked by the sight glass. To make sure that proper oil level is observe, operate the compressor for 15 minutes, then stop the compressor. Oil should appear from 1/2 to 3/4 in the sight glass with the compressor stopped.

- 25 -

3.0 OPERATION FIGURE 3.2.1 TYPICAL PIPING SCHEMATIC ACDS 010, 020, 030

- 26 -

3.0 OPERATION ACDS 040, 050, 060, 070

- 27 -

3.0 OPERATION ACDS 080, 090, 100, 120

- 28 -

3.0 OPERATION ACDS 135, 150

- 29 -

3.0 OPERATION ACDS 165, 180

- 30 -

3.0 OPERATION 3.5.2 OIL TYPE

If the oil becomes discolored indicating contamination, the contamination can be take care of by installing a new filter-drier in the liquid line and changing the oil. WARNING: Use Only Dunham-Bush Approved Refrigeration Oil, Warranty Will Be Void If Other Than Approved Oil Is Used. It is recommended to change oil annually to prolong the compressor life-time. Oil charge for a complete recharge shown in the following table. Oil type and approved oils are also listed for each compressor. After recharge the oil level should be maintained per section 3.5.2.

COMPRESSOR MODEL OIL CHARGE (L) APPROVED OIL

HLH 068 1.6 PVE

SH 140 3.3

POE (160SZ)

SH 180

6.7 SH 240

SH 300

SH 380 7.2

3.6 SYSTEM FLOW RATE

The quantity of chilled water being circulated can be estimated by determining the water pressure drop through the evaporator by reading GPM [L/S] from the appropriate pressure drop curve. (See Figure 3.6) An alternate method of determining GPM [L/S]is to measure pressure difference from pump inlet to outlet and read GPM [L/S] from pump curve. Water flow rate must not vary more than ±10% from design flow rate. 3.7 SYSTEM CONTROL 3.7.1 CAPACITY CONTROL

The standard system capacity control operates as follows: - As the chiller load initially drops, the

suction of the compressor(s) starts dropping proportionately, thus balancing minor load variations.

- Variation of unit capacity in response to system load requirements is controlled by an operating thermostat, which monitors the return water temperature.

- On multiple compressor units, capacity is controlled by compressor staging. Refer to Table 3.7.1 to determine the capacity control scheme for your specific unit.

TABLE 3.7.1 CAPACITY CONTROL COMPRESSOR CYLINDER UNLOADING

AND STAGING SCHEDULE ACDS CAPACITY

ACDS 010, 020, 030

COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100% 50.0%

ACDS 040, 050, 060, 070, 080, 090, 100, 120

COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100% 25.0% COMPRESSOR 2 ON 100% 50.0% COMPRESSOR 3 ON 100% 75.0% COMPRESSOR 4 ON 100% 100.0%

ACDS 135, 150, 165, 180

COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100% 16.7% COMPRESSOR 2 ON 100% 33.3% COMPRESSOR 3 ON 100% 50.0% COMPRESSOR 4 ON 100% 66.7% COMPRESSOR 5 ON 100% 83.4% COMPRESSOR 6 ON 100% 100.0%

3.7.2 SOLID-STATE OPERATING

THERMOSTAT

3.7.2.1 General A four-stage solid-state operating thermostat, FSE, is used on all AC packages. The opstat senses return chilled water or air temperature and by staging and/or unloading compressors is able to control leaving chilled water or air temperature to a narrow band of temperature.

3.7.2.2 Opstat Settings

Each four-stage electronic opstat is factory, adjusted to your specified conditions, A field check of the controller may be made by first determining your design range (R). To determine the range of a water chiller, subtract the design leaving water temperature (TLW) from the return water temperature (TRW) (R =TRW-TLW).

- 31 -

3.0 OPERATION

The standard range is 10°F [5.6°C]. To determine the range of a condensing unit, subtract the design no load return air temperature (TNL) from the design full load return air temperature (TFL) (R= TFL- TNL). The standard range is 6°F [3.3°C].

Set point of the opstat should be your design leaving chilled water temperature (TLW) for water chillers. The standard adjustment range for AC units is 32 to 104°F [0° to 40°C].

The location of setting knob is shown in Figure 3.7.2A.

Step Temp adjusts the temperature range per stage in degrees F. To determine TRB. For a standard condensing unit TRB= 0.25 x R. Check the dial setting on the opstat. The approximate setting of Step Temp is shown in the Figure 3.7.2B by the Step Temp should be changed by an authorized serviceman only.

3.8 ELECTRICAL CONTROLS MCCB/MCB/MMS - Main Circuit Breaker This is an automatic, calibrated, ambient compensated, magnetic trip circuit breaker, which provides both direct line-break compressor branch circuit. short circuit locked rotor and overload protection. It has a manually operable handle for compressor circuit disconnect, and an auxiliary NO. switch (optional) which interrupts the 115V compressor control circuit when the breaker opens. M - Contactor (Compressor and Fan

Motor) The contactor, operated by the control circuit, provides power individually to the compressor and fan motors. Contactors are used either singly or in parallel pairs for across-the-line start (simultaneous operation). These devices are amp

rated to handle both rated load amp and locked rotor amps. CR - Relays (Miscellaneous Control) These relays provide the necessary circuit logic for lock-in, lock -out and transfer functions. HTR - Crankcase Heater Energized continuously as long as control circuit power disconnect switch (not supplied with the unit) is closed and compressor is off. This heater maintains crankcase temperature above the system temperature during the compressor off cycle, preventing refrigerant migration into the crankcase and consequent compressor damage. SOL- i.) Liquid Line Solenoid Valve

Closes when the compressor(s) is off to prevent any liquid refrigerant from accumulating in the chiller during the off cycle.

ii.) Discharge Solenoid Control (Optional)

This function is used in low ambient application. Discharge solenoid is turn off to reduce condensing surface and to increase head pressure.

OL - Motor Overload

(Manual Reset) For AC the compressor is protected by overload relays utilizing quick trip, ambient compensated heaters. The overload relays are manually reset. OUVR - Over Under Voltage Relay

(Optional) Protects the unit from the following electric supply malfunctions: over voltage, under voltage, please reversal, single phasing and phase imbalance. If the OUVR trips, a control relay will de-energize and open the control circuit. A red LED trip light, located on the OUVR, will indicate a supply malfunction. Tile OUVR is a manual reset control device.

- 32 -

10

100

1000

1 10 100 1000

PRES

SUR

E D

RO

P -k

Pa.

.

WATER FLOW RATE - m³/hr

1

10

100

10 100 1000

PRES

SUR

E D

RO

P -F

T.W

G.

.

WATER FLOW RATE - GPM

3.0 OPERATION FIGURE 3.6 WATER SIDE PRESSURE DROP 1a.) IMPERIAL UNITS 1b.) SI UNITS

ACDS 010 ACDS 020 ACDS 030 ACDS 040 ACDS 050 ACDS 060 ACDS 070

ACDS 080

ACDS 135 ACDS 150 ACDS 165

ACDS 180

ACDS 100 ACDS 120

ACDS 090

ACDS 010 ACDS 020 ACDS 030 ACDS 040 ACDS 050 ACDS 060 ACDS 070

ACDS 080

ACDS 135 ACDS 150 ACDS 165

ACDS 180

ACDS 090 ACDS 100

ACDS 120

- 33 -

4.0 ELECTRICAL 4.1 ELECTRICAL DATA

MODEL Power Supply Standard Unit Electrical Data Each Compressor Condenser Fan Motors

V-Ph-Hz RLA MCA MFS/HACR Qty RLA LRA-XL Qty HP FLA/Mtr

ACDS-010 208/230-3-60 61 68 90 2 27 145 1 2 7.2

460-3-60 27 30 40 2 12 87 1 2 3.4

ACDS-020 208/230-3-60 103 114 150 2 46 304 2 1.5 5.4

460-3-60 47 53 70 2 21 147 2 1.5 2.7

ACDS-030 208/230-3-60 134 148 200 2 56 320 4 1.5 5.4

460-3-60 63 69 90 2 26 160 4 1.5 2.7

ACDS-040 208/230-3-60 206 217 250 4 46 304 4 1.5 5.4

460-3-60 95 100 110 4 21 147 4 1.5 2.7

ACDS-050 208/230-3-60 256 270 300 4 56 320 6 1.5 5.4

460-3-60 120 127 150 4 26 160 6 1.5 2.7

ACDS-060

208/230-3-60 294 313 350 2 2

56 75

320 485 6 1.5 5.4

460-3-60 140 149 175 2 2

26 36

160 215 6 1.5 2.7

ACDS-070 208/230-3-60 332 351 400 4 75 485 6 1.5 5.4

460-3-60 160 169 200 4 36 215 6 1.5 2.7

ACDS-080

208/230-3-60 381 405 450 2 2

75 94

485 560 6 2 7.2

460-3-60 184 196 225 2 2

36 46

215 260 6 2 3.4

ACDS-090 208/230-3-60 419 443 500 4 94 560 6 2 7.2

460-3-60 204 216 250 4 46 260 6 2 3.4

ACDS-100

208/230-3-60 486 516 600 2 2

94 120

560 680 8 2 7.2

460-3-60 231 245 300 2 2

46 56

260 320 8 2 3.4

ACDS-120 208/230-3-60 538 568 600 4 120 680 8 2 7.2

460-3-60 251 265 300 4 56 320 8 2 3.4

ACDS-135

208/230-3-60 579 603 700 3 3

75 94

485 560 10 2 7.2

460-3-60 280 292 300 3 3

36 46

215 260 10 2 3.4

ACDS-150 208/230-3-60 636 660 700 6 94 560 10 2 7.2

460-3-60 310 322 350 6 46 260 10 2 3.4

ACDS-165

208/230-3-60 728 758 800 3 3

94 120

560 680 12 2 7.2

460-3-60 347 361 400 3 3

46 56

260 320 12 2 3.4

ACDS-180 208/230-3-60 806 836 900 6 120 680 12 2 7.2

460-3-60 377 391 400 6 56 320 12 2 3.4

Note: MCA - Minimum Circuit Ampacity MFS - Maximum Fuse Size RLA - Running Load Amps FLA – Full Load Amps LRA - Locked Rotor Amps

- 34 -

4.0 ELECTRICAL 4.2 IR32 ELECTRONIC THERMOSTAT FRONT PANEL 1- Display: shows the value measured by the connected sensor. In the event of alarm condition the

sensor value will be displayed alternately with the codes of the active alarms. When programming the instrument, the display shows the parameter codes being introduced and their values.

2- Decimal Point LED: lights up when the controlled parameter is displayed. 3- Reverse LED: flashes when at least one relay working in the "Reverse" mode is active. The Led

flashes as many times as the number of active 'reverse' relays. There is a two seconds' pause between a flashing stage and the next one.

4- Direct LED: flashes when at least one relay working in the "Direct" mode is active. Its working logic is the same as the "Reverse" LED.

5- SEL Button: displays and/or allows you to select the Set-point. If pressed for 5 seconds together with PRG/MUTE it allows you to enter the password and the configuration parameters (having a "Cxx" type code).

6- PRG/Mute Button: if pressed for 5 seconds it allows you to access the menu of the more frequently used parameters (having a "Pxx" type code). In the event of alarm condition, it silences the buzzer and, if pressed after the cause that determined the alarm has disappeared, it resets any other alarm. It completes the programming procedure storing all the values of the modified parameters.

7- Button Δ: increases the value of the set-point or that of any other selected parametel: 8 - Button ∇ : decreases the value of the set-point or that of any other selected parametel: In NTC input

versions it can display the value of the second sensor (holding "Down" pressed while the display shows the value of the main sensor).

Note: for Infrared Universal, Series models, please refer to the table at the end of the manual 4.2.1 TYPICAL CONTROL SEQUENCE WITH 2 STAGE OPERATING

THERMOSTAT AT 10°C RETURN WATER SETPOINT, 3.0°C DIFFERENTIAL

- 35 -

4.0 ELECTRICAL 4.2.2 KEYPAD OPERATION

1) Set-point display: Press [SEL] key to display set-point. 2) Set-point modification: Press [SEL] key for few sec to change St1 setpoints. Release [SEL] key, actual set-point value flashes. Use [up arrow] or [down arrow]key to change value. Press [SET] key to confirm new value. 3) "P" Parameters modification: Press [PRG/mute] key for 5 sec allows you to access the most frequent used parameters ("Pxx" type code).Use [up arrow] or [down arrow] key to require parameter. Press [SEL] key to display this parameter. Use [up arrow] or [down arrow] key to set value. Press [SEL] key to confirm. Repeat procedure for other parameters. Press [PRG/mute] key to store modified data and go back to normal operation.

4) "C" Parameters modification: Press [SEL] key + PRG/mute] key for 5 sec allows you to enter password and configuration parameters ("Cxx" type code). Display show 0. Select password by pressing [up arrow] key until 22 or 77 display. Press [SEL] key to confirm. Code C0 displayed if password is correct else repeat procedure. Use [up arrow] or [down arrow] key to desire parameter. Press [SEL] to confirm. Use [up arrow] or [down arrow] key to desire value. Press [SEL] to confirm. Repeat procedure for other parameters. Press [PRG/mute] key to exit. 5) Alarm Handling: In the event of alarm condition, press [PRG/mute] key to silence the buzzer. If pressed after the cause of alarm disappeared, it resets any other alarm. 6) Second Probe Display: For NTC input versions, 2nd probe value can be displayed by pressing [down arrow] key while the main probe value is displayed.

4.2.3 IR32 ELECTRONIC THERMOSTAT PARAMETERS LIST

Par. Description Min. Max. Default Fac. Set

St1 Set Point 1 min probe max probe 20 6

St2 Set Point 2 (Modes 6,7,8,9) min probe max probe 40 NA

CO Operation Mode 1 9 2 1

Setting Differentials

P1 Set Point 1 Differential (absolute value) 0.1 99.9 2 2

P2 Set Point 2 Differential 0.1 99.9 2 NA

P3 Dead Zone Differential (Modes 3,4,5) (absolute value) 0 99.9 2 NA C4 Authority. NTC models only with Mode 1or 2 and

C19 = 2, 3 or 4 -2 2 0.5 0.5

C5 Control Action: 0=Proportional (P) 1=Prop+Integral (P+I) 0 1 0 0

Outputs

C6 Delay time (sec) btw energization of different relays 0 999 5 120

C7 Min time (min) btw energization of the same relay 0 15 0 5

C8 Min off time (min) of the same relay 0 15 0 3

C9 Min on time (min) of the same relay 0 15 0 0

C10

Outputs Status in the event of sensor alarm: 0 = All relays de-energized 1 = All relays energized 2 = DA relays energized, all others de-energized 3 = RA relays energized, all others de-energized

0 3 0 0

C11

Output Rotation: (Modes 1,2,6,7,8 only) 0 = No rotation 1 = Standard rotation 2 = 2+2 rotation (compressor on relays 1 & 3) 3 = 2+2 rotation (valve normal open)

0 7 0 0

- 36 -

4.0 ELECTRICAL

Par. Description Min. Max. Default Fac. Set

C11 Output models only (A and Z) 4 = Rotation of relays 3 & 4 (No rotation for 1 & 3) 5 = Rotation of relays 1 & 2 (No rotation for 3 & 4) 6 = Separate rotation of coupled relays 1-2 & 3-4 7 = Rotation on relays 2,3,4 (No rotation for 1)

0 7 0 0

C12 PWM cycle time (sec) 0.2 999 20 NA

Sensor

C13 Probe type: 0 = 4-20, 1 = 0-20; 0 = K tc 1 = J tc NTC probe : 0 = normal function, 1= invert function, (instrument display NTC2 and control on NTC1)

0 1 0 0

P14 Probe calibration or offset -99 99.9 0 0 C15 Analog Input min.scaling value -99 C16 0 NA C16 Analog Input max.scaling value C15 999 100 NA C17 Probe response time (noise filter) 1 14 5 5 C18 Temperature unit: 0 = C, 1 = F 0 1 0 0 C19 2nd Probe: NTC only, Mode 1 or 2

0 = no modification on std. Mode 1 = differential mode (NTC1 - NTC2) 2 = summer offset 3 = winter offset 4 = active offset with Dead zone P2

0 4 0 0

C21 Set point 1 min. limit -99 C22 min. probe -50 C22 Set point 1 max. limit C21 999 max. probe 90 C23 Set point 2 min. limit -99 C24 min. probe -50 C24 Set point 2 max. limit C23 999 max. probe 90

Alarms P25 Low temp. alarm set point -99 P26 min. probe -50 P26 High temp. alarm set point P25 999 max. probe 90 P27 Alarm hysteresis 0.1 99 2 2 P28 Alarm delay, min 0 120 60 60 C29 Digital input 1 configuration (CO different from 6,7,8)

In case of alarm the status of relays depends on C31 0 = non active input 1 = immediate alarm with automatic reset 2 = immediate alarm with manual reset 3 = delay alarm (P28) with manual reset 4 = on/off of the control

0 4 0 4

C30 Digital input 2 configuration (IRDR only) option as for C29

0 4 0 NA

C31 Outputs Status in case of alarm condition detected via digital input: 0 = All relays de-energized 1 = All relays energized 2 = DA relays energized, all others de-energized 3 = RA relays energized, all others de-energized

0 3 0 0

Others C32 Unit address (for serial connection) 1 16 1 1 Special Parameters

C33 Special mode of operation: 0 = No, 1 = Yes DO NOT MODIFY THIS PARAMETER Set and programmed starting mode C0 before modifying C33

0 1 0 0

C50 Keypad(KP) and Remote Control(RC) activation: 0 = KP off, RC on (only type P parameters) 1 = KP on, RC on (only type P parameters) 2 = KP off, RC off 3 = KP on, RC off 4 = KP on, RC on (all parameters)

0 4 4 3

C51 Remote IR controller activation code 0 120 0 0

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4.0 ELECTRICAL 4.2.4 IR32 ELECTRONIC THERMOSTAT TROUBLESHOOTING

Code Description Cause Control Action Reset Remedies

Er0 Sensor error faulty sensor depends on C10 R: automaticV: manual

Check connection. Check sensor signal

Er1 Sensor NTC2 error

faulty sensor if C19=1 & Mode =1 or 2

see Er0

R: automaticV: manual

Check connection. Check sensor signal

Er2 Memory error voltage drop during programming stage,

memory damaged by electromagnetic interference

Stoppage R: automaticV: manual

Reset factory-set values.

Turn off controller, turn on again holding [PRG/mute] key

Er3 Alarm via external contact on digital input

contact linked to digital input is open

depends on C31 R: depends on C29 & C30

V: manual

Check C29, C30, C31 & P28.

Check the external contact Er4

Er4 High temperature alarm

temp > P26 for a time interval > P28

Nil R: automaticV: manual

Check P26, P27 & P28.

Er5 Low temperature alarm

temp < P25 for a time interval > P28

Nil R: automatic V: manual

Check P26, P27 & P28.

NOTE: R = Control action Resetting the instrument means to restore normal operating conditions after the cause that determinied the alarm has been cleared. V = Display Display and buzzer. Display reset means that normal display of usual values is restored.

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4.0 ELECTRICAL 4.3 VISION 2020i

CONTROLLER AND TERMINAL

Vision2020i controller is equipped with a user friendly 132x64 pixels back-lit graphic display terminal. It is connected with controller through telephone cable. This terminal allows carrying out all program operations. The user terminal allows displaying the unit working conditions, compressor run times, alarm history at any time and modifying the parameters. The terminal also has an automatically self-test of the micro-controller on system start-up. Multiple messages will be displayed by automatically scrolling from each message to the next. All of these messages are spelled out in English language on the LCD screen.

4.3.1 DBG1 OPERATOR KEYPAD The DBG1 operator keypad consists of 15 polycarbonate buttons:

Figure 4.3.1 : Vision 2020i keypad

The top right ‘Authorization’ button is for password log in to gain authorization, to the access setting menu.

The top left six operator buttons functions are to view status only, except the ‘Setpoint’ button also allows setting changes after gained authorization.

The three buttons at the bottom left are to access different level of setting changes.

These are 'User', 'Technician' and 'Factory' levels, from left.

It can only be access depend on the password level. The higher password can access the lower password level's setting and not vice versa.

4.3.1.1 The fifteen polycarbonate buttons:

a) Seven polycarbonate buttons at top row

Button Description

INPUT STATUS Displays the analog inputs and digital inputs status measured by the probes/sensors.

OUTPUT STATUS

Displays the relay outputs and analog outputs status.

COMPRESSOR STATUS

Displays the status of Compressor 1, 2 and so on.

SETPOINT Displays the status of set points.

CLOCK/ SCHEDULE

Displays the date, time and day.

ALARM HISTORY Display the alarm history.

AUTHORIZATION To log in the level of passwords.

b) Eight polycarbonate buttons at bottom row

Button Description

USER User Control Changeable Settings.

TECHNICIAN Technician Control Changeable Settings.

FACTORY Factory Control Changeable Settings.

MENU Unit information / Compressor Information.

ALARM RESET Display the active alarms and to perform alarm manual resets.

UP

Scroll the various screens when the cursor is in the top left of the display. If the cursor is inside a numeric field, the button increases or decreases the corresponding value. If the field is a selection, pressing the button displays the available options.

DOWN See the UP arrow

ENTER To move the cursor around the screens and to save the values of the set parameters

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ANALOG INPUTS C1 Amps 101A C1 Disc T 125.2°F [51.8°C]

RELAY OUTPUTS

Comp 1 ON-LOAD Alarm Status OFF Control Power ON C1 Liquid Inj OFF CW Pump ON

COMPRESSOR 1 STATUS Comp 1 OK Amps= 100A FLA1= 230A Capacity= 025.5% Status=ON-LOAD

Hot Gas Bypass OFF

COMPRESSOR 1 HISTORY 1

Today Total Run Hour 05 0006 Cycle 02 0006

Last On 04/24 19:06 Last Off 04/24 19:03

ANALOG INPUTS Supply Temp 044.8 °F [07.1°C] Return Temp 055.6 °F [13.2°C] Suction Pres 073 PSI [05.2BAR]Disch Press 179 PSI [12.9BAR]

4.0 ELECTRICAL 4.3.2 STATUS READING

4.3.2.1 Input status key

To read inputs status press input status key: The display is showing the data as follows: Press down arrow key or input key to go to next screen: The display is showing the data as follows: Repeat the same steps to go to other sensor inputs screen:

4.3.2.2 Output status key

To read relay outputs status press output status key: The display is showing the data as follows:

Press down arrow key or output key to go to next screen: The display is showing the data as follows: Repeat the same steps to go to other relay outputs screen:

4.3.2.3 Compressor status key To read compressor status press compressor status key: The display is showing the data as follows: Press down arrow key or press compressor key to go to next screen: The display is showing the data as follows:

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SETPOINT 1 Supply Water Temp Set point= 44.0 °F [06.7°C] Dead band= 0.8 °F [0.5°C]

REAL TIME CLOCK Day > MONDAY Time > 16:10 Date > 05/12/05

ALARM HISTORY 001-C1 Starter 19:03 05/12/05 TR: 030.2 LWT: 64.3 [17.9] DP: 191 [13.6] SP: 076 [5.4]

4.0 ELECTRICAL 4.3.2.4 Setpoint key:

To read the setpoint value press setpoint key

The display is showing the data as follows: To alter setpoint data, you must be authorized. See the authorization procedure and you must be authorized at least as user level.

Press enter key to select the setpoint to alter and use the up-down arrow key to change the value and press enter key to confirm. Press down arrow key or press setpoint key to go to next screen: Repeat the same steps to go to other setpoints screen and perform setpoint modification.

4.3.2.5 Clock key: To read the current day, time and date, unit scheduling and ice-cel mode scheduling (optional), press the clock key The display is showing the data as follows:

To set the date and time, you must be authorized. See the authorization procedure and log in at least as user level. Press enter key to select the date or time to alter and use the up-down arrow key to change the value and press enter key to confirm.

4.3.2.6 Alarm history key: To view the unit alarm history press alarm history key: The display is showing the data as follows: Press down arrow key or press alarm key to go to next screen for other alarm history: To clear alarm history, press input key and authorization key together and then press the alarm key again. Now the display should be showing “No alarm”

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AUTHORIZATION

Please Enter your Password

PASSWORD= 0000 Status=View

USER SETPOINT 1

High Pressure Safety Limits

Hold= 360PSI [23.4BAR] Unload= 370PSI [24.1BAR] Cutout= 400PSI [24.8BAR]

Technician Setpoints Main Menu

Comp FLA Calibration Sensor Calibration Manual Control Compressor Control Sensors Override

4.0 ELECTRICAL 4.3.3 AUTHORIZATION 4.3.3.1 Authorization key

To get authorization level, press authorization key: The display is showing the current access level as view only: Press enter key and use the up-down arrow key to change the password settings and press enter key to confirm. Now the authorization status change to different access level.

4.3.4 ADVANCED USER KEY AND

MENU 4.3.4.1 User Key

User key is use to view and change the pressure, ampere safety limits and liquid injection temperature setpoints, unit of measurements. In order to gain access to this button, you must be authorized and log in at least as user level. Press the user key and display is showing the data as follows:

Press down arrow key or user key to go to next screen for other setpoint: To alter setpoint data, press enter key to select the setpoint to alter and use the up-down arrow key to change the value and press enter key to confirm. Repeat the above steps for others setpoints.

4.3.5 TECHNICIAN KEY AND MENU 4.3.5.1 Technician status key

This key is use to view and change the compressor FLA setpoint, sensors calibration, manually control digital inputs and outputs, manually control compressor. In order to gain access to this button, you must be authorized and log in at least as user level. See the authorization section about this procedure.

4.3.5.2 Technician status key –main

menu Press technician key to go to technician setpoints main menu: The display is showing the data as follows: Press enter key to move the cursor to the sub-menu.

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Comp FLA Calibration ■ Sensor Calibration Manual Control Compressor Control Sensors Override

Technician Setpoint 1 Comp 1 FLA CALIBRATION

211x00.66+97.80 FLA = 237A Capacity C1 = 000.0% Min. Percent Cal = 25.0% Max. Percent Cal = 00A


Comp FLA Calibration Sensor Calibration ■ Manual Control Compressor Control Sensors Override

Sensor Offset 1 Suction Press Current = 076PSI [5.4BAR] Average = 187PSI [8.6BAR] 24Hrs MAX = 200PSI [11.4BAR] 24Hrs MIN = 074PSI [4.6BAR] Calibration = 00PSI [0.0BAR]


Comp FLA Calibration Sensor Calibration Manual Control ■ Compressor Control Sensors Override

4.0 ELECTRICAL

The display is showing the data as follows:

4.3.5.3 Compressor FLA Calibration: To calibrate compressor FLA, press down arrow key to go the sub-menu 'Comp FLA Calibration', The display is showing the data as follows: Press enter key to move the cursor to calibrate the comp FLA and use the up-down arrow key to change the value and press enter key to confirm.

4.3.5.4 To perform Sensor Calibration: Press technician key to go to technician setpoints main menu and press enter key twice to move the cursor to the sensor calibration sub-menu: The display is showing the data as follows:

Use up or down arrow key to move the cursor to the desired 'Sensor Calibration', The display is showing the data as follows: Press enter key to move the cursor to calibrate the desired sensor and use the up-down arrow key to change the value and press enter key to confirm. Repeat the above steps for others sensors calibrations.

4.3.5.5 Manual Control:

A digital input sensor or relay output can be controlled manually with the keypad. Digital input sensor or relay output can be turned on, off manually and placed back to auto mode. To place a digital input or relay output in manual control, the operator must be authorized at technician level or higher. Press technician key to go to technician setpoints main menu and press enter key three times to move the cursor to the manual control sub-menu: The display is showing the data as follows:

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Digital Inputs Manual Control

C1 Starter= Auto C1 Oil Lvl= Auto Unit Enable= Auto Flow Switch= Auto

Relay Outputs Manual Control

Alarm Relay Auto Liquid Inj C1 Auto CW Pump Auto Vap Inj Relay Auto

Compressor Control

Manual Override COMPRESSOR 1=AUTO St= 0005 Amps= 071.8 Capacity= 025.0%


Comp FLA Calibration Sensor Calibration Manual Control Compressor Control ■ Sensors Override

4.0 ELECTRICAL

Use up or down arrow key to move the cursor to the desired digital input or relay output, The display is showing the data as follows: Press enter key to move the cursor to the desired point for manual control and use the up or down arrow key to change the status of the digital input or relay output to AUTO/CLOSE/OPEN or AUTO/ON/OFF. The display is showing the data as follows: Press enter key to confirm the change.

4.3.5.6 Compressor Control: Screw compressors can be controlled manually with the keypad. A compressor can be turned on, off, or placed in computer control. When a compressor is controlled manually, it can be commanded to load, hold, or unload. If safety limiting condition is active, it will not accept a load command. To place a compressor in manual control, the operator must be authorized and log in as technician level and higher.

Press technician key to go to technician setpoints main menu and press enter key four times to move the cursor to the manual control sub-menu: The display is showing the data as follows: Use down arrow key to move the cursor to the desired compressor control screen, then press enter key to move the cursor to compressor status position, AUTO /MAN/OFF The display is showing the data as follows: Use up or down arrow key to select MAN and press enter key to confirm the change. The compressor will start or continue to run in hold state. Press the user key to continue hold, press the technician key to load and factory key to unload.

Manual Hold Manual Load Manual Unload If a safety condition is exceeded while operating manually, the compressor will shutdown. CAUTION: Anti-recycle timer is bypassed by manual control. DO NOT start a compressor more than once every 15 minutes.

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Load/Unload Control Manual Pulse Settings Pulse Rate= 001sec Pulse Width= 001sec


Comp FLA Calibration Sensor Calibration Manual Control Compressor Control Sensors Override

Sensors Manual Override

Supply Water Temp Man Reading = 45.0°F [7.2°C] Manual Override = NO

4.0 ELECTRICAL

NOTE: All compressors will revert back to automatic control if the computer is the computer is not given a load, unload, or hold command at least once every 15 minutes. A command can be repeated to meet the 15 minute requirement for manual control. To the change the settings of compressor load/Unload, follow the above steps and go to compressor control. Use down arrow key to move the following and press to change the settings.

4.3.5.7 Sensors Override Value of analog readings can be temporary override during sensor failure. To override the analog readings, the operator must be authorized at technician level or higher. Press technician key to go to technician setpoints main menu and press enter key five times to move the cursor to the ‘Sensors Override’ sub-menu: The display is showing the data as follows: Use up or down arrow key to move the cursor to the desired analog reading,

The display is showing the data as follows:

Press enter key to move the cursor to the “Man Reading” and use the up or down arrow key to change the value of the analog reading, press enter key move the cursor to the “Manual Override” to enable, or disable the manual override control. Repeat the above steps for other sensors override.

Caution: Sensors override require continuous monitoring and observation by the field service personnel at all time during the unit operation. Faulty sensor shall be replaced as soon as possible in order to allow the unit to be running in automatic mode. 4.3.6 CONTROL FUNCTIONS 4.3.6.1 Chilled Water Pump Interlock

And Flow Switch (CWP And CWFS) These are field installed switches, both of which are used to ensure chilled water flow before the unit is allowed to start. Failure of either one during operation will cause the compressor to shut down. A water flow alarm will be generated and ‘Rest Alarm’ must be pressed to clear the alarm.

4.3.6.2 Customer Control Interlock Control contacts from an external controller can be used to enable or disable operation of the unit. The wiring diagram specifies the terminals to which the contacts must be wired. To enable the unit, the contacts must be closed. To disable the unit, the contacts must be opened.

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4.0 ELECTRICAL 4.3.6.3 Anti-Recycle Timer

The compressor motor requires an anti-recycle time delay which prevents restart for 15 minutes after a start. The purpose of this feature is to avoid frequent starts which tend to elevate the motor winding temperature and impose undue wear on contactors. The controller will not restart the compressor motor until the 15 minutes have elapsed.

4.3.6.4 Load Control The controller controls the leaving water temperature within a narrow deadband by pulsing load and/ or unload solenoids on the compressor. The load and unload solenoids position the slide valve within the compressor to control its capacity. The controller determines a desired level of loading and varies pulse duration depending on difference between load target and actual load. The load target is varied based on rate of approach to desired temperature preventing significant temperature oscillations. The status of the compressor can be observed by displaying the compressor control point.

4.3.6.5 Ramp Control Another feature of the controller is ramp control, which is the ability to vary load time of the machine from start. Often when the machine is started, the water in the chilled water circuit is warm, and the unit will go to full load quickly. With ramp control, the user can program the computer so that it loads at a predetermined rate. This is a valuable tool, since it can help reduce power

consumption and demand charges. Two variables are used to define the ramp profile: Ramp rate and start point. Ramp rate defines the length of time the unit takes to load from start point to full load. Start point is the percent of full load at which the ramp begins. The ramp rate A setpoint can be set anywhere from 0.1 to 1.0, smaller values producing slower loading rates. The ramp start B setpoint can be set anywhere between 0 and 50%. The compressor will load quickly to this value and then follow the ramp slope from there. See Table 4.3.6.5 for ramp rates at various settings.

4.3.6.6 Staging Control On multiple-compressor machines, when the controller determines that a compressor is fully loaded and temperature is not being maintained, another compressor is added. When unloading, a compressor is taken off line when the computer determines that the remaining compressors can control water temperature.

4.3.6.7 Pumpdown Control This feature is to stored refrigerant in condenser when compressor is stopped. Pumpdown control will take place when temperature set point is achieved before compressor is being cycled off or unit enable input is off. The compressor will stop when suction pressure is lower than pumpdown setpoint, 65PSI [4.5BAR] (for R22) or 15 seconds (setpoint) delay timer is elapsed.

TABLE 4.3.6.5 Ramp Rates for Several Setpoints (In Minutes)

Ramp Rate

Setpoint

1 Comp. Start Point Setpoint

2 Comp. Start Point Setpoint

3 Comp Start Point Setpoint

4 Comp Start Point Setpoint

30% 50% 75% 30% 50% 75% 30% 50% 75% 30% 50% 75%

0.1 12.0 9.0 4.5 22.0 18.5 14.0 29.0 25.5 21.0 33.0 29.0 25.0

0.2 6.0 5.0 2.0 11.5 10.0 8.0 16.0 14.0 12.0 18.0 16.0 14.0

0.3 4.0 3.0 1.5 8.0 7.0 5.5 11.0 10.0 9.0 13.0 12.0 11.0

0.4 3.0 2.5 1.0 6.5 5.5 4.5 9.0 8.0 7.0 11.0 10.0 9.0

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4.0 ELECTRICAL 4.3.6.8 Liquid Line Solenoid Control

When compressors starts, the liquid line solenoid will energize when suction pressure falls below the pumpout setpoint or a time delay of 5 seconds is elapsed. For unit with two liquid lines per refrigerant circuit, the second liquid line solenoid will energize when suction pressure falls below low pressure cutout setpoint or a time delay of 25 seconds is elapsed and unit target is above 40%. The second liquid line solenoid will be de-energized when the unit target is less than 35%.

4.3.6.9 Sump Heater Control Each compressor is fitted with an oil sump band-heater. The heater is energized at all times when compressor is off and de-energized when the compressor is running.

Its purpose is to prevent refrigerant migration into the oil during shut down. For this reason, it is essential that heaters be energized for 24 hours before starting a compressor.

4.3.6.10 Low Pressure Cut-off

This function protects the unit from operating at abnormally low evaporator refrigerant pressure. The controller will shut down the compressor when evaporator pressure falls below the low pressure setpoint and turn on the alarm pilot light.

A low pressure alarm will be recorded by the controller. Reset by pressing the ‘Reset Alarm’ button on the controller. Standard setpoint is 58 psig [4.0BAR].

4.3.6.11 Evaporator Freeze Shutoff If the leaving chilled water temperature drops below the freeze setpoint, the controller will shut down the unit and store the freeze alarm. After solving the problem, press ‘Reset Alarm’ on the controller to clear the alarm.

4.3.6.12 High Pressure Cut-off This function protects the compressor from operating at abnormally high discharge refrigerant pressures. The controller will shut down the compressor when condenser pressure reaches the high pressure set point, and turn on the alarm indicator lamp on the control box. The high discharge pressure alarm will be recorded by the controller. Reset by pressing the ‘Reset Alarm’ button on the controller. Setpoint is 400 psig [27.6BAR].

4.3.6.13 Phase Control Relay (PCR) - Optional The PCR protects the unit from the following electric supply malfunctions: Undervoltage, phase reversal and single phasing. If the PCR trips, a control relay (lCR) will de-energize and open the control circuit. A green LED indicates presence of power supply. The yellow LED indicates a good voltage supply. The power loss setpoint is factory set to AUTO to allow automatic start after PCR failure. Compressor will not start for 15 minutes after failure. To select manual reset, set power loss setpoint to MANUAL. In this case, a power loss alarm will be stored by the controller and ‘Reset Alarm’ must be pressed to start.

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4.0 ELECTRICAL 4.3.6.14 Sensor Alarm

If the computer measures an analog value (temperature, pressure.) that is far beyond normal operating values, the associated compressors are shutdown. The computer then stores the alarm code corresponding to the sensor alarm. A sensor alarm indicates a problem in the analog measurement system.

4.3.6.15 No-Stop Alarm If the controller turns off a compressor, but the compressor digital input does not turn off, a No-Stop alarm is generated. The computer will turn off the control power relay which disables all compressor control circuits and will turn on the alarm light. This alarm indicates a wiring or hardware error.

4.3.6.16 Low Differential Pressure Alarm For proper lubrication, a compressor requires a 30 psid [2.1BAR] differential pressure between condenser and evaporator pressures. If the differential pressure is less than 30 psid [2.1BAR] for 3 minutes while a compressor is operating, all compressors will be shut down. The controller will store the low differential pressure alarm code and turn on the alarm light. The ‘Reset Alarm’ key must be pressed to clear the alarm.

4.4 CONDENSER FAN CONTROL LOGIC

If the differential pressure is less, the controller provides two types of control logic for air-cooled condensers. The type of control will be governed by the physical condenser layout of the unit. Each method of control is enhanced with adaptive, self-learning, fan control logic. The end result is condenser control that offers significantly reduced fan cycling and improved efficiency. The two types of air-cooled condenser control logic are explained as follows:

1. Adaptive Individual Air-cooled Condenser Control This type of control is based upon a single compressor per circuit. The individual discharge pressure on that circuit will be the controlling pressure.

2. Adaptive Air Combined Air-cooled Condenser Control This type of control is based upon a condenser that is controlled by the highest discharge pressure from any one of the compressors sharing that circuit (compressor 1&2 - share; compressor 3&4 - share). The highest discharge pressure between the sharing compressors will be the controlling pressure.

4.4.1 Air Cooled Condenser Control

Setpoints The air-cooled condenser setpoints are as follows: Setpoint COND Stage 1 ON - Condenser stage

1 on. Setpoint COND Stage 2 OFF - Condenser stage

2 off. Setpoint COND DIFF ON - Differential

pressure for additional condenser stages.

Setpoint COND DIFF OFF - Differential pressure for subtracting condenser stages.

A compressor must be operating for the condenser fans to operate. The condenser points (i.e. fans) will turn on based upon the value in setpoint COND Stage 1 ON. When the discharge pressure exceeds this value, the first condenser point is turned on. If additional condenser points exist, they will be turned on when the pressure exceeds the previous cut in value (COND Stage 1 ON for the first stage) plus the value contained in COND DIFF ON setpoint. Condenser points (i.e. fans) will be turned off based upon the value in the setpoint COND ST2 OFF (COND Stage 2 turn OFF point). As the discharge pressure is reduced, the condenser points will be turned off based upon the COND

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4.0 ELECTRICAL ST2 OFF setpoint, plus the value in the COND DIFF OFF setpoint for each stage number above stage 2. Stage 2 of condenser staging will be turned off based upon the value in the setpoint (COND ST2 OFF). See below for an example of condenser staging.

4.4.2 INCREASING CONDENSER

PRESSURE (Example of 4 stage fan cycling)

COND FAN1 ON when discharge pressure is > 230psig [15.9BAR] (COND Stage 1 ON setpoint)

COND FAN2 ON when discharge pressure is > 250psig [17.2BAR] (COND Stage 1 ON plus 1xCOND DIFF ON setpoint values)



And so on for the number of condenser fans supplying the circuit.

4.4.3 DECREASING CONDENSER

PRESSURE (4 fan example "continued")

COND FAN4 OFF when discharge pressure is < 200psig [13.8BAR] (COND Stage 2 OFF plus 2xCOND DIFF OFF setpoint values) COND FAN3 OFF when discharge pressure is < 190psig [13.1BAR] (COND Stage 2 OFF plus 1xCOND DIFF OFF setpoint values) COND FAN2 OFF when discharge pressure is < 180psig [12.4BAR] (COND Stage 2 OFF setpoint value) COND FAN1 OFF when discharge pressure is < 170psig [11.7BAR] (COND Stage 1 OFF setpoint value) 4.4.3.1 Adaptive Control Logic

The controller enhances the condenser control logic above with a unique, adaptive, self-learning fan control logic. These enhancement results in a control scheme that offers reduced fan cycling

and improved efficiency. Adaptive Control Logic automatically adjusts the fan cut-in offset based upon the following criteria: 1. If the last fan turned on (including

FAN 1) is cycled off in 10 minutes or less, then a COND ON OFFSET value will be incremented by 5 psig [0.3BAR]. This increases the fan 1 turn on value (COND ST1 ON plus COND ON OFFSET) which in turn increases all of the fan turn on settings. This process will continue until fan cycling ceases or the adjusted turn on point for the last fan stage is 320 psig [22.1BAR]. This will also be a setpoint.

2. The cut-in offset (COND ON

OFFSET) will be decreased by 5 psig [0.3BAR] if the last fan to be turned on has not cycled off within 1 hour. The offset will continue to decrease by 5 psig [0.3BAR] every 10 minutes unless fan cycling begins again.

The Adaptive Control Logic will only affect the condenser fan turn on logic, it will not affect the fan turn off logic.

4.5 Master/Slave Control

Sequence The optional master/slave control sequence is used to sequence multiple chillers in one installation according to the building load demand. It also controls the dedicated chilled water pump or motorized valve.

Vision2020i Controller offers this feature with minimized field wiring cost compare to conventional method that involves lots of hardware cost. It is carried out this control function via the advanced DBLAN communication bus to implement the network management for multiple chillers lead/lag communication, sequencing and monitoring.

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Graphic Display (option)

DB3 DB3 DB3 DB3

DB1

DB1

DB1

DB1 DB1

DB1 DB1

DB1

DBG1 DBG1 DBG1 DBG1

DBLAN

#1 #2 #3 #4 #5 #6

DB3

DB1

DB1

DBG1 DB3 DBG1

DB1

DB1

4.0 ELECTRICAL 4.5.1 PRINCIPLE OF OPERATION VIA DBLAN COMMUNICATION BUS Example: 6 chillers network with 4 units on duty and 2 units standby

Notes

a) Each chiller has a stand-alone master DB3 board and dedicated graphic display with multiple DB1 expanders board connected to J23 on DB3

b) Each chiller DB3 will be connected to DBLAN network through J11 connector

c) The chiller lead/lag selection can be determined by

Manual lead/lag setpoint

Schedule and holiday setup

Alarm conditions

d) The lead/lag selection determine the chiller operation sequence as follows,

Lead chiller selection

Normal chillers operation sequence When DBLAN fails

1 1, 2 & 3 on duty, 4, 5 & 6 standby 1, 2 & 3 on duty






e) If the lead/lag selection is changed over to a different chiller, the sequence of operation will be rotated

f) Each chiller will use a network address setpoint to determine individual chiller network address

g) Each chiller will require a dedicated chilled water pump or motorized valve digital output, unit enable and chilled flow status digital inputs as well as enable next output command.

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4.0 ELECTRICAL 4.5.2 Sequence Of Operation 1. When the customer enable input is ‘on’ to

start the lead unit, the chilled water pump starter or motorized valve control point will close and water will start to flow through the evaporator, this will activate the flow switch. The flow switch and water pump status are interlocked and feedback as digital input to the chiller and upon receipt of a valid 'on' signal, the lead chiller will begin to execute its running program.

2. The controller will start and load the compressor(s), upon achieving full load; it will send an output signal via the DBLAN to enable second unit (lag 1)

3. The second unit will now command its chilled water pump to start if the customer unit enable is activated. The second chiller will start and load the compressor(s) until it reaches full load

4. When the second chiller or lag 1 unit reaches full load, it will enable the third chiller.

5. The chiller will keep cascading until all chillers on duty are at full load.

6. If the leaving water temperature falls below setpoint, all of the chillers will begin to unload evenly.

7. If the load drops below 45% total capacity, delay the last unit (lag 3) will be disabled, and the remaining three units will load up to compensate if necessary. The pump for chiller 4 will be shut off.

8. As the load demand falls, the lag 2 unit will be disabled below 45% total capacity, and so on until the load falls enough to shut off the lead chiller.

9. Each unit in the network can monitor the operation of other units via DBLAN. If the master unit is having critical alarm, the lag 1 will take over as the master unit automatically.

10. In order to enable next unit, the following conditions must met

a) LWT ≥ (LWT Setpoint + Enable Next deadband)

b) After a enable next time delay of 3 minutes (adjustable) and

c) When the lead unit’s packaged capacity is higher than “Next on setpoint”,

for example, WCFX2, %FLCP C1 & %FLCP C2 ≥ Next on setpoint

or it is being lockout by an alarm.

4.6 VISION 2020i LOCAL AREA

NETWORK (DBLAN) A DBLAN network is made up of several chillers’ controller. Each unit’s controller can be programmed and connected to the local DBLAN network that allows multiple units sequencing control without additional hardware.

Every DBLAN node must be addressed to be identified by the other nodes. Each address (an integer number) must be unique in the network for avoiding messages mismatch: in case two or more nodes have the same identifying address the network cannot work.

The max address number selectable is in the 1-16 for the Vision 2020i controller boards and 17-32 range for the Vision 2020i User terminal. The three chiller unit combinations:

Controller with address of 1 connect to Terminal with address of 17

Controller with address of 2 connect to Terminal with address of 18

Controller with address of 3 connect to Terminal with address of 19 Follow the following steps:

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Vision 2020i5 sec

Display address Setting……… : 17 I/O Board address: 01

Display address Setting……… : 0

Vision 2020i

4.0 ELECTRICAL 4.7 NETWORK CONNECTION DIAGRAM

Adr:17 Adr:18 Adr:19 Telephone Cable Telephone Cable Telephone Cable J10 Adr:1 J10 Adr:2 J10 Adr:3

J11 J11 J11 RS 485 Cable RS 485 Cable max 500 meters max 500 meters

The 6 core telephone cables (to J10 socket) are supply by the manufacturer. The 3 core RS 485 data cables (to J11 socket) are supply by the customer. Pay attention to the network polarity: RX+/TX+ on one controller must be connected to RX+/TX+ on the other controller; the same is true for RX-/TX- and GND. 4.8 HARDWARE SETTINGS 4.8.1 ADDRESSING THE VISION 2020i

CONTROLLER At the Vision 2020i terminal, push simultaneously the last three keys on the lower right corner of the Vision 2020i terminal keyboard. Push them for at least 5 seconds.

This display will appear:

Change the display address setting to 0 as follow. Turn off DB3 controller. At the Vision 2020i DBG1 terminal, hold simultaneously the “Alarm” key and “Up arrow” key, turn on DB3 controller and hold these keys until “Self Test” mask is appeared.

Vision 2020i Terminal

Vision 2020i Controller





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*********************************** SELF TEST

PLEASE WAIT ************************************

PLAN Address : 1 Up : Increase Down : Decrease Enter : Save & Exit

Display address Setting……… : 17 I/o Board address: 01

P:01 Adr Priv/Shared Trm1 17 Pr Trm2 32 Sh Trm 3 None --- OK? NO


Terminal config Press ENTER To continue


Vision 2020i5 sec

4.0 ELECTRICAL The following mask will appear. Set pLAN address to 1 (or accordingly) using “Up” and “Down” arrow key. Press “Enter” key to save and exit. The terminal display will become blank after “Enter” key is pressed. Please proceed to next section on Addressing the Vision 2020i DBG1 Terminal. 4.8.2 ADDRESSING THE VISION

2020I DBG1 TERMINAL At the Vision 2020i DBG1 terminal, hold simultaneously the last three keys on the lower right corner of the Vision 2020i terminal keyboard. Hold them for at least 5 seconds.

The display will appears:

The first line is the address of the terminal display that you are using, (for first chiller, it is 17). The next line allows you to select the Vision 2020i controller address (for first chiller, it is 01) that you

want to configure. Once you select the address then press ‘enter’ button The display will appears: Push ‘enter’ to continue. Then the display appears: Set Trm1, Trm2 and Trm3 to ’17 Pr’,’32 Sh’ and ‘None ---’, change the 'NO' to 'YES'(to confirm and save) and press ‘enter’. Note: Pr = Private, Sh = Share. For multiple units with master-slave sequencing control features, at the second chiller unit Vision 2020i terminal; repeat step 1 by holding the three keys again. The display will appears: The address display (18) is the correct setup for the second chiller unit with the controller address of two (P:02).Press ‘enter’ to confirm the settings and the display will appears:

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4.0 ELECTRICAL Set Trm1, Trm2 and Trm3 to ’18 Pr’,’32 Sh’ and ‘None ---’, change the 'NO' to 'YES'(to confirm and save) and press enter. At the third chiller unit Vision 2020i terminal: Press the three keys again, the display will appears: The address display (19) is the correct setup for the third chiller unit with the controller address of three(P:03).Press ‘enter’ to confirm the setting and the display will appears:

Set Trm1, Trm2 and Trm3 to ’19 Pr’,’32 Sh’ and ‘None ---’, change the 'NO' to 'YES'(to confirm and save) and press enter. With the above settings, terminal with address 17 will only work with the controller with address 1, terminal 18 will only work with the controller with address 2, terminal 19 will only work with the controller with address 3 and a terminal with address 32 will work with both. 4.8.3 Vision 2020i Controller LED

Status Vision 2020i controller have three LEDs between the J3 and J4 connectors for indicating basic node status. They are Red, Yellow and Green coloured. Red Yellow Green At the start-up all LEDs are ON and after few seconds OFF again. After 5 – 15 seconds elapse, then LED configuration is among those listed below.

Table 4.8.3 LED Status

LED STATUS DESCRIPTION

GREEN ON Vision 2020i controller is synchronized with all the other DBLAN nodes.

The node is working correctly.

OFF Vision 2020i controller is not network connected or it doesn’t receive any signal from the DBLAN

YELLOW BLINKING Vision 2020i controller is transmitting data to other network nodes.

OFF Vision 2020i controller is not transmitting messages.

RED OFF No hardware and software problem.

ON Vision 2020i controller software not compatible or variables database not correct, contact Dunham-Bush Service Personnel.

BLINKING Vision 2020i hardware is not compatible - Ram is smaller than 32 KB. The Vision 2020i controller is just for working in stand-alone mode.

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4.0 ELECTRICAL 4.9 TYPICAL WIRING SCHEMATIC ACDS 010

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4.0 ELECTRICAL

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4.0 ELECTRICAL ACDS 020

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4.0 ELECTRICAL

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4.0 ELECTRICAL

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4.0 ELECTRICAL

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4.0 ELECTRICAL ACDS 050, 060, 070

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4.0 ELECTRICAL

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∼∼∼

∼∼∼

4.0 ELECTRICAL ACDS 080, 90

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∼∼∼ ∼4.0 ELECTRICAL

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∼∼

4.0 ELECTRICAL

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4.0 ELECTRICAL

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∼∼∼

∼∼∼


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- 70 -

∼∼

4.0 ELECTRICAL

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4.0 ELECTRICAL

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∼∼∼

∼∼∼


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∼∼

4.0 ELECTRICAL

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4.0 ELECTRICAL

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∼∼∼

∼∼∼


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∼∼

4.0 ELECTRICAL

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4.0 ELECTRICAL

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∼∼∼

∼∼∼


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∼∼

4.0 ELECTRICAL

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4.0 ELECTRICAL

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∼∼∼

∼∼∼

4.0 ELECTRICAL ACDS 165, 180

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∼∼

4.0 ELECTRICAL

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4.0 ELECTRICAL

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5.0 MAINTENANCE 5.1 GENERAL As with all mechanical equipment, a program of regular inspection, cleaning and preventive maintenance by trained personnel will contribute greatly to the long satisfactory service life of this product. 5.2 PERIODIC INSPECTION Read essential temperatures and pressures periodically to see that they indicate normal operation. It is a good idea to record these readings on a log sheet. If any abnormal operation is observed, try to remedy it. See Trouble Shooting Guide Section. 5.3 MONTHLY INSPECTION Check cooling tower water treatment system, Wipe down external surfaces of unit. Shut unit down, open main disconnect, inspect control panel, checking for loose wires, burned contacts, signs of overheated wires, etc. Restart unit and check performance of controls. Check sight glasses for proper refrigerant charge. 5.4 PHE MAINTENANCE 5.4.1 GENERAL

The efficient performance of the evaporator and condenser heat transfer surfaces is essential for efficient performance of your packaged water cooling machine. If these surfaces accumulate a film of dirt, scale or slime, their performance efficiency will degrade substantially. The refrigerant side of heat transfer surfaces does not foul since refrigerant is a good solvent and it is in a closed, filtered cycle. Water side surfaces can foul from the water system. A program of water treatment can slow the rate of fouling on heat transfer surfaces, but not eliminate it.

5.4.1.1 Freezing Protection For BPHE

a.) Use a filter <1mm, 16 mesh (see previous chapter on BPHE maintenance)

b.) Use an anti-freeze when the evaporation temperature is close to liquid-side freezing

c.) Use a freeze protection thermostat and flow switch to guarantee a constant water flow before, during and after compressor operation.

d.) Avoid "pump-down" function e.) When starting up a system, wait a

moment before starting the condenser (or have reduced flow through it)

5.4.2 EVAPORATOR CLEANING 5.4.2.1. Cleaning BPHE

Normally very high degree of turbulence in BPHE there is a self-cleaning effect in the channels. However, in some applications the fouling tendency can be very high. In such cases, it is always possible to clean the exchanger by circulating a cleaning liquid (CIP-Cleaning In Place). Use a tank with weak acid or, if the exchanger is frequently cleaned, 5% oxalic acid. Pump the cleaning through the exchanger. For optimum cleaning, the cleaning solution flow rate should be a minimum of 1.5times the normal flow rate, preferably in a back-flush mode. After use, do not forget to rinse the heat exchanger carefully with clean water. A solution of 1-2% sodium hydroxide (NaOH) or sodium bicarbonate (NaHCO₂) before the last rinse ensure that all acid is neutralized. Clean at regular intervals.

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5.0 MAINTENANCE 5.4.2.2. Strainers

If any of the media contains particle larger 1mm (0.04 inch), we recommend that a strainer with a size of 16-20 mesh (number of openings pe inch) is installed before the exchanger. The particles could otherwise block the channels, causing bad performance, increased pressure drop and risk of freezing.

5.5 AIR COOLED CONDENSER

CLEANING The face of the condenser should be cleaned at least once month during operation. If conditions are bad and condensers pick up dirt very quickly, it is suggested that they can be cleaned more frequently. If the condenser is allowed to get too dirty, the unit will run at high head pressure and will not give satisfactory performance. Dirty coils can be cleaned using a soft brush or by flushing with cool water or commercially available coil cleaners. DO NOT USE HOT WATER OR STEAM. To do so will cause excessive pressure in the system. The face of the condenser should be cleaned at the beginning of the season and periodically thereafter if conditions require. 5.6 ELECTRICAL

MALFUNCTION The unit has four devices designed to protect compressor motors and manual motor controllers from electrical malfunctions: Circuit breakers. starter overload relays, under voltage relay (optional), and motor over temperature protectors. If the under voltage relay trips, it is a sign of trouble in incoming power. If it trips again after resetting, call your electric utility to investigate the problem. If circuit breaker or motor overload relay or motor over temperature protectors trip, this is a

sign of possible motor trouble. DO NOT reset and try to run compressor again. Call authorized service representative to check for motor trouble. Resetting these safety devices and repeated starting could turn a minor motor problem into a costly major motor burnout. 5.7 REFRIGERANT CHARGE 5.7.1 GENERAL

All packaged chiller units are given a complete charge of refrigerant at the factory. The type and amount of refrigerant required is in Physical Specifications. The total refrigerant shown is for the entire system. Since these units have separate circuits, each circuit should be considered separately for charging. In order to check proper refrigerant charge, look in each liquid line sight glass with the aid of a flashlight during system operation. At all operating conditions, the sight glass should be clear. If bubbles are visible at any operating condition, the circuit is short of charge. Be careful not to overcharge the machine. overcharging will result in considerable liquid logging in the condenser, and excessive condensing pressure. To add refrigerant, connect a refrigerant vessel to the 1/4" [6.4mm] back seating port of the suction valve. Purge the air from the tube with refrigerant gas before connecting. With the unit running, open the refrigerant vessel vapor connection slightly. If the refrigerant vessel is warmer than the evaporator, refrigerant will more readily flow from the vessel into the unit.

5.7.2 AIR COOLED PACKAGES

To determine the proper refrigerant charge, check the amount of subcooling if possible. The amount of subcooling at the liquid line (liquid line saturation temperature corresponding to liquid line pressure minus liquid line temperature) should be between 15°F [8.3°C] and 20°F [11.1°C]. Subcooling at the condenser out-subcooler inlet trap should not exceed 5°F [2.8°C]. This sight glass should be clear with no bubbles.

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5.0 MAINTENANCE TABLE 5.4 R410A PRESSURE/ TEMPERATURE PROPERTIES

Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature

psig kPa °F °C psig kPa °F °C psig kPa °F °C psig kPa °F °C

10.8 74.5 -40.0 -40.0 62.2 428.9 10.0 -12.2 169.6 1169.4 60.0 15.6 364.1 2510.4 110.0 43.3

11.5 79.3 -39.0 -39.4 63.7 439.2 11.0 -11.7 172.5 1189.4 61.0 16.1 369.1 2544.9 111.0 43.9

12.1 83.4 -38.0 -38.9 65.2 449.5 12.0 -11.1 175.4 1209.3 62.0 16.7 374.2 2580.0 112.0 44.4

12.8 88.3 -37.0 -38.3 66.8 460.6 13.0 -10.6 178.4 1230.0 63.0 17.2 379.4 2615.9 113.0 45.0

13.5 93.1 -36.0 -37.8 68.3 470.9 14.0 -10.0 181.5 1251.4 64.0 17.8 384.6 2651.7 114.0 45.6

14.2 97.9 -35.0 -37.2 69.9 481.9 15.0 -9.4 184.5 1272.1 65.0 18.3 389.9 2688.3 115.0 46.1

14.9 102.7 -34.0 -36.7 71.5 493.0 16.0 -8.9 187.6 1293.5 66.0 18.9 395.2 2724.8 116.0 46.7

15.6 107.6 -33.0 -36.1 73.2 504.7 17.0 -8.3 190.7 1314.8 67.0 19.4 400.5 2761.4 117.0 47.2

16.3 112.4 -32.0 -35.6 74.9 516.4 18.0 -7.8 193.9 1336.9 68.0 20.0 405.9 2798.6 118.0 47.8

17.1 117.9 -31.0 -35.0 76.6 528.1 19.0 -7.2 197.1 1359.0 69.0 20.6 411.4 2836.5 119.0 48.3

17.8 122.7 -30.0 -34.4 78.3 539.9 20.0 -6.7 200.4 1381.7 70.0 21.1 416.9 2874.4 120.0 48.9

18.6 128.2 -29.0 -33.9 80.0 551.6 21.0 -6.1 203.6 1403.8 71.0 21.7 422.5 2913.1 121.0 49.4

19.4 133.8 -28.0 -33.3 81.8 564.0 22.0 -5.6 207.0 1427.2 72.0 22.2 428.2 2952.4 122.0 50.0

20.2 139.3 -27.0 -32.8 83.6 576.4 23.0 -5.0 210.3 1450.0 73.0 22.8 433.9 2991.7 123.0 50.6

21.1 145.5 -26.0 -32.2 85.4 588.8 24.0 -4.4 213.7 1473.4 74.0 23.3 439.6 3031.0 124.0 51.1

21.9 151.0 -25.0 -31.7 87.2 601.2 25.0 -3.9 217.1 1496.9 75.0 23.9 445.4 3070.9 125.0 51.7

22.7 156.5 -24.0 -31.1 89.1 614.3 26.0 -3.3 220.6 1521.0 76.0 24.4 451.3 3111.6 126.0 52.2

23.6 162.7 -23.0 -30.6 91.0 627.4 27.0 -2.8 224.1 1545.1 77.0 25.0 457.3 3153.0 127.0 52.8

24.5 168.9 -22.0 -30.0 92.9 640.5 28.0 -2.2 227.7 1569.9 78.0 25.6 463.2 3193.7 128.0 53.3

25.4 175.1 -21.0 -29.4 94.9 654.3 29.0 -1.7 231.3 1594.8 79.0 26.1 469.3 3235.7 129.0 53.9

26.3 181.3 -20.0 -28.9 96.8 667.4 30.0 -1.1 234.9 1619.6 80.0 26.7 475.4 3277.8 130.0 54.4

27.2 187.5 -19.0 -28.3 98.8 681.2 31.0 -0.6 238.6 1645.1 81.0 27.2 481.6 3320.5 131.0 55.0

28.2 194.4 -18.0 -27.8 100.9 695.7 32.0 0.0 242.3 1670.6 82.0 27.8 487.8 3363.3 132.0 55.6

29.2 201.3 -17.0 -27.2 102.9 709.5 33.0 0.6 246.0 1696.1 83.0 28.3 494.1 3406.7 133.0 56.1

30.1 207.5 -16.0 -26.7 105.0 724.0 34.0 1.1 249.8 1722.3 84.0 28.9 500.5 3450.8 134.0 56.7

31.1 214.4 -15.0 -26.1 107.1 738.4 35.0 1.7 253.7 1749.2 85.0 29.4 506.9 3495.0 135.0 57.2

32.2 222.0 -14.0 -25.6 109.2 752.9 36.0 2.2 257.5 1775.4 86.0 30.0 513.4 3539.8 136.0 57.8

33.2 228.9 -13.0 -25.0 111.4 768.1 37.0 2.8 261.4 1802.3 87.0 30.6 520.0 3585.3 137.0 58.3

34.2 235.8 -12.0 -24.4 113.6 783.2 38.0 3.3 265.4 1829.9 88.0 31.1 526.6 3630.8 138.0 58.9

35.3 243.4 -11.0 -23.9 115.8 798.4 39.0 3.9 269.4 1857.5 89.0 31.7 533.3 3677.0 139.0 59.4

36.4 251.0 -10.0 -23.3 118.1 814.3 40.0 4.4 273.5 1885.7 90.0 32.2 540.1 3723.9 140.0 60.0

37.5 258.6 -9.0 -22.8 120.3 829.4 41.0 5.0 277.6 1914.0 91.0 32.8 547.0 3771.5 141.0 60.6

38.6 266.1 -8.0 -22.2 122.7 846.0 42.0 5.6 281.7 1942.3 92.0 33.3 553.9 3819.0 142.0 61.1

39.8 274.4 -7.0 -21.7 125.0 861.9 43.0 6.1 285.9 1971.2 93.0 33.9 560.9 3867.3 143.0 61.7

40.9 282.0 -6.0 -21.1 127.4 878.4 44.0 6.7 290.1 2000.2 94.0 34.4 567.9 3915.6 144.0 62.2

42.1 290.3 -5.0 -20.6 129.8 894.9 45.0 7.2 294.4 2029.8 95.0 35.0 575.1 3965.2 145.0 62.8

43.3 298.5 -4.0 -20.0 132.2 911.5 46.0 7.8 298.7 2059.5 96.0 35.6 582.3 4014.8 146.0 63.3

44.5 306.8 -3.0 -19.4 134.7 928.7 47.0 8.3 303.0 2089.1 97.0 36.1 589.6 4065.2 147.0 63.9

45.7 315.1 -2.0 -18.9 137.2 946.0 48.0 8.9 307.5 2120.2 98.0 36.7 596.9 4115.5 148.0 64.4

47.0 324.1 -1.0 -18.3 139.7 963.2 49.0 9.4 311.9 2150.5 99.0 37.2 604.4 4167.2 149.0 65.0

48.3 333.0 0.0 -17.8 142.2 980.4 50.0 10.0 316.4 2181.5 100.0 37.8 611.9 4218.9 150.0 65.6

49.6 342.0 1.0 -17.2 144.8 998.4 51.0 10.6 321.0 2213.2 101.0 38.3 - - - -

50.9 350.9 2.0 -16.7 147.4 1016.3 52.0 11.1 325.6 2244.9 102.0 38.9 - - - -

52.2 359.9 3.0 -16.1 150.1 1034.9 53.0 11.7 330.2 2276.7 103.0 39.4 - - - -

53.6 369.6 4.0 -15.6 152.8 1053.5 54.0 12.2 334.9 2309.1 104.0 40.0 - - - -

55.0 379.2 5.0 -15.0 155.5 1072.1 55.0 12.8 339.6 2341.5 105.0 40.6 - - - -

56.3 388.2 6.0 -14.4 158.2 1090.8 56.0 13.3 344.4 2374.6 106.0 41.1 - - - -

57.8 398.5 7.0 -13.9 161.0 1110.1 57.0 13.9 349.3 2408.4 107.0 41.7 - - - -

59.2 408.2 8.0 -13.3 163.8 1129.4 58.0 14.4 354.2 2442.1 108.0 42.2 - - - -

60.7 418.5 9.0 -12.8 166.7 1149.4 59.0 15.0 359.1 2475.9 109.0 42.8 - - - -

5.0 MAINTENANCE

- 91 -

5.8 TROUBLE SHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

1. Unit will not start

1. Power off 2. Main line open 3. Incorrect wiring 4. Loose terminals 5. Control circuit open

1. Check main disconnect switch. 2. Check main fuses. 3. Check with wiring diagrams. 4. Tighten terminals. 5. Check pump fuses, starter heater elements,

pressure and temperature controls.

2. Compressor hums but does not start

1. Low voltage 2. No power on one phase

of 3 phase unit 3. Faulty starter or

contactor

1. Check at main entrance and at unit. Consult power company if voltage is low and increase wire size to the unit if voltage is normal at main and low at unit. Voltage must be within 10% of motor nameplate rating.

2. Check fuses and wiring. 3. Check the contacts and time delay on part wind

start.

3. Compressor cycles on low pressure control

1. Refrigerant shortage 2. No load on chiller 3. Restriction in liquid line 4. Head pressure too low

1. Check for leaks and add refrigerant. 2. Check pump operation and water flow. 3. a.) Plugged drier. If temperature drop exists across

the drier remove and replace cores. b.) Liquid line or suction valve partially closed. Open

valves fully and close in one full turn. c.) Expansion valve clogged or inoperative. Check

superheat setting. Check charge and thermo bulb.

4. Restrict water flow to condenser by adjusting the water regulating valve or cycle cooling tower fan.

4. Compressor cycles on high pressure control

1. Compressor discharge valve partially closed.

2. Air in system 3. Overcharge of

refrigerant 4. High pressure control

improperly set 5. Main water valve closed 6. Water regulating valve

set high or defective 7. Condenser fan

inoperative 8. Dirty condenser 9. Fan cycle switches in-

operative, or set too high

10. Fan motors not running 11. Fan motor reverse

rotation

1. Open valve fully and close with one turn 2. Flush water valve. If pressure in system exceeds the

pressure corresponding to the water temperature purge air from compressor gauge connection.

3. Purge system while in operation until bubbles show in sight glass. Close valve and add small amount of refrigerant until sight glass just clears.

4. Adjust the control. 5. Open the water valve. 6. Reset or replace valve. 7. Check, replace or repair set screw (pulley), fan

motor, or inoperative fan control. 8. Clean condenser surfaces with brush and/or

vacuum. 9. Check and readjust. 10. Check contactor, thermal overload relay, check

motor, check capacitor. (If single phase) 11. Reverse two fan motor leads. (3 phase only)

- 92 -

5.0 MAINTENANCE 5.9 SAMPLE LOG SHEET SHEET NO. ................................ DUNHAM-BUSH SCROLL COMPRESSOR PACKAGED CHILLER

NAMEPLATE DATA:

UNIT MODEL NO. ........................................................ UNIT NO. .................................... VOLTS: ............................ Hz ..................

UNIT SERIAL NO. ........................................................ COMPRESSOR MODEL NOS. ....................................................................

START UP : DATE .......................................... TIME ....................................................

DATE TIME

ELAPSED TIME METERS COMP. NO.

1. SUCTION 2.

PRESSURE 3. 4. 1.

DISCHARGE 2.

PRESSURE 3. 4. 1.

DISCHARGE 2. TEMPERATURE 3. 4.

1. DISCHARGE SUPERHEAT 2. (DISC. TEMP.-SAT. DISCH.)* 3.

4. 1. DISCHARGE SUPERHEAT 2.

(DISC. TEMP.-SAT. SUCT.)* 3. 4.

EVAPORATOR WATER TEMPERATURE-IN

EVAPORATOR WATER TEMPERATURE-OUT EVAPORATOR PRESSURE DROP ftwg[kPa] EVAPORATOR WATER FLOW gpm [m³/hr]

CONDENSER AIR TEMPERATURE-IN (AMBIENT) AC ONLY

1. ACTUAL VOLTAGE 2.

COMPRESSOR AMPS 3. 4. FAN AMPS

VOLTS

*USE TABLE 5.4 FOR OBTAINING SATURATED TEMPERATURE THIS LOG SHEET IS PROVIDED AS A RECOMMENDATION OF THE READINGS THAT SHOULD BE TAKEN ON A PERIODIC BASIS. THE ACTUAL READINGS TAKEN AND THE FREQUENCY WILL DEPEND UPON THE UNITS APPLICATION, HOURS OF USE, ETC. THIS TYPE OF INFORMATION CAN PROVE VERY USEFUL IN PREVENTING AND/ OR SOLVING PROBLEMS THAT MIGHT OCCUR DURING THE LIFE OF THE UNIT.

Corporate Head OfficeDUNHAM-BUSH HOLDING BHD

(Formerly known as Dunham-Bush (Malaysia) Bhd) (129358-X)

Lot 5755-6, Kidamai Industrial Park, Bukit Angkat43000 Kajang, Selangor Darul Ehsan, Malaysia.

Tel: 603-8733 9898 Fax: 603-8739 5020E-Mail: [email protected]

www.dunham-bush.com

Manufacturer reserves the right to change specifications w

ithout prior notice.

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