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FORM NO: MS0452A
WATER-COOLED SEMI-HERMETICSCREW COMPRESSOR WATER CHILLERS
HXWC SERIESHXWC SERIES
50Hz50Hz50Hz
Products That Perform...By People Who Care
R
200 to 740 Tons
R134a
INTRODUCTION
Dunham-Bush’s HXWC water cooled chillers are available from 200 to 740 tons.
Dunham-Bush, the world’s acknowledge leader in Screw Compressor chillers has a
proven track record of superior performance and high reliability, unmatched by others!
All chillers are factory run tested before shipment.
TABLE OF CONTENTS
Page
Introduction....................................................................................................................................... 2Nomenclature.................................................................................................................................... 2Unit Features .................................................................................................................................... 3Microcomputer Control....................................................................................................................... 5Physical Specifications ...................................................................................................................... 7Dimensional Data.............................................................................................................................. 8Typical Wiring Schematic................................................................................................................... 9
NOMENCLATURE
HXWC i 550 - 5 N R
Water Cooled HorizontalRotary Screw PackagedChiller
i - c/w Vapor Injection
Blank - w/o Vapor Injection
Models: 240, 310, 370,440, 480, 550,610, 650, 750
50Hz
R-134a
N - StandardP - PremiumS - Superior
- 2 -
UNIT FEATURES
ARI CERTIFICATION
ARI Certification ProgramThe performance of Dunham-Bush Water-Cooled
R134a Rotary Screw Water Chillers has beencertified by the Air Conditioning and Refrigeration
Institute (ARI) in accordance with ARI Standard
550/590-98.
Full load ratings. part load ratings, and water
pressure drop data are regularly tested under this
certification program. This provides anindependent, third party verification of water
chiller performance with a laboratory-rated
performance test utilizing calibratedinstrumentation.
The ARI Seal of Certification shows the
commitment to quality and to our customer'speace of mind. You will get the industry's
standard for efficiency and reliability when you
purchase a Dunham-Bush water chiller.
This certification program does not include low
temperature applications (Ice Bank) or units
utilizing glycol.
Computer Performance RatingsDunham-Bush HXWC, the many combinations of
heat exchangers make it impractical to publishtabular ratings for each combination. A chiller may
be custom matched to certain building
requirements by your Dunham-Bush SalesRepresentative utilizing the Dunham-Bush
Selection Program or Electronic Catalogue which
has performance rated in accordance to ARIStandard 550/590-98. Data which can be
provided to you will include:
] Chiller Capacity
] KW Input
] Evaporator and Condenser Water PressureDrop
] Evaporator and Condenser Tube WaterVelocities
] IPLV/ APLV
] Part-Load Performance
Contact your local Dunham-Bush SalesRepresentative to discuss what Real Solutions
Dunham-Bush can offer to solve your chiller
selection questions.
PART LOAD PERFORMANCEThe Air Conditioning and Refrigeration Institute
(ARI) has established a system, in ARI Standard
550/590-98, for measuring total chillerperformance over full and part-load conditions. It
defines the Integrated Part-Load Value (IPLV) as
an excellent method of comparing diverse typesof equipment on an equal basis. The IPLV is a
single number estimate of a chiller's power use
weighted for the number of hours the unit mightspend at each part-load point. IPLV's are based
on Standard Rating Conditions.
The formula for calculating an IPLV is:
IPLV =
where: A = kW/ton at 100% load pointB = kW/ton at 75% load pointC = kW/ton at 50% load pointD = kW/ton at 25% load point
STANDARD FEATURES
Size/Range] 9 Models from 200 to 740 tons.
] Multiple compressor units provide redundancy,and favorable part load efficiency.
] One-year parts warranty at no extra cost.
Compressor] Quiet, reliable Semi-Hermetic Screw
Compressors.
] Multiple rotary screw compressor for fail-safe
reliability and redundancy.
] Stepless loading and unloading withdependable slide valve mechanism.
] Insured continuous oil flow with high efficiencyexternal oil separator.
1
0.01 + 0.42 + 0.45 + 0.12
A B C D
- 3 -
UNIT FEATURES
Evaporator/Condenser
] Cleanable and Removable Integral Fin CopperTubes.
] Removable Water Heads.
] Victaulic Groove Water Connections.
] Vessels designed and constructed according
to ASME Code, vessels can be constructed to
comply and certified with ASME, JKKP andPED Standards.
] Relief Valve(s) standard - 3/4" FPT.
] Full Pump Down Capacity in Condenser.
Microcomputer/Electrical
] Proactive Microcomputer Controller adapts toabnormal operating conditions.
] Tolerant and accommodating of extreme
conditions at start-up.
] Capable of controlling multiple chillers, cooling
towers, pumps, etc.
] Circuit Breaker on each multiple compressorunit.
] Unit Mounted Contactor and Time Delay for
reduced Inrush Start.
] Current transformer.
] Under Voltage Phase Failure Relay.
] Indicator lights for Compressor Overloads,Micro Alarm, Control Power, Compressor
Control Circuit.
ENERGY EFFICIENCY
] Designed to provide the greatest amount ofcooling for the least kilowatt input over the
entire operating range of your building.
] Delivers outstanding efficiency and totalenergy savings through the use of
microcomputer controlled slide valve and
evaporator leaving water temperature control.
] High efficiency external oil separator
guarantees removal of oil carried over in the
refrigerant and maintains the heat exchangers
at their maximum efficiency at both full and
part load.
] Rating according to ARI Standard 550/590-98"Centrifugal or Rotary Screw Liquid Chilling
Packages".
GLYCOL FREEZEPROTECTIONIf the chiller or fluid piping may be exposed to
temperatures below freezing, glycol protection is
recommended if the water is not drained. Therecommended protection is 10°F (5.6°C) below
the minimum ambient temperature in the
equipment room and around piping. Use onlyglycol solutions approved for heat exchanger
duty. DO NOT use automotive anti- freeze.
If the equipment is being used for applicationsbelow 38°F (3.3°C), glycol should be used to
prevent freeze damage. The freeze protection
level should be 10°F (5.6°C) lower than theleaving brine temperature.
Table 1: Ethylene Glycol%E. G. By Mass Freeze Point
°F °C
10 26.2 -3.2
15 22.2 -5.3
20 17.9 -7.9
25 12.7 -10.8
30 6.7 -14.1
35 -0.2 -17.8
40 -8.1 -25.8
45 -17.5 -27.5
50 -28.9 -33.8
Table 2: Propylene Glycol%P. G. By Mass Freeze Point
°F °C
10 26.1 -3.3
15 22.9 -5.1
20 19.2 -7.2
25 14.7 -9.7
30 9.2 -12.8
35 2.4 -16.6
40 -6.0 -21.3
45 -16.1 -27.0
50 -28.3 -33.8
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MICROCOMPUTER CONTROL
Vision2020i a flexible and advance programmable
electronic microcontroller designed specifically for
the applications and precise control of Dunham-
Bush Rotary Screw compressor chillers.
The controller board is provided with a set of
terminals that connected to various devices such
as temperature sensors, pressure and current
transducers, solenoid valves, compressors and
fans contactors, control relays and etc. Three
sizes of controller boards are provided to handle
different number of input and output
requirements: DB2-S small board, DB2-M
medium board and DB2-L large board.
The unit algorithm program and operating
parameters are stored in FLASH-MEMORY that
does not require a back-up battery. The program
can be loaded through PC or programming key.
Vision2020i controller is equipped with a user
friendly terminal with a graphic display and
dedicated keys that provides easy access to the
unit operating conditions, control set points and
alarm history.
Each unit’s controller can be programmed and
connected to the local DBLAN network that allows
multiple units sequencing control without
additional hardware. The DBLAN is local area
network made up of several chillers’ controller.
Display and User Terminal
Vision2020i controller is design to work with a
user friendly back-lit 132 by 64 pixels DBG1
Graphic Display panel connected with controller
through telephone cable. The terminal allows
carrying out all program operations. The user
terminal allows displaying the unit working
conditions, compressor run times, alarm history
and modifying the parameters. The display also
has an automatically self-test of the
microprocessor 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 display terminal.
There are 15 dedicated buttons enable user to
access information, base on the security level of
the password. For more detail operation of the
DBG1 Display Terminal, please refer to the Unit
Operation Manual.
Easily accessible measurements include:
] Leaving chilled water temperature
] Leaving chiller water temperature derivative
] Evaporator Pressure
] Condenser Pressure
] Compressor amp draw of each compressor
] Compressor elapsed run time of each
compressor
] Compressor starts status
] Oil level sensor status
] Water temperature reset value
] Water flow switch status
] External start/stop command status
Optional entering chilled water temperature,
leaving and entering condenser water
temperature are available. With this option the
operator can quickly and accurately read all
significant water temperatures and eliminate the
need for often-inaccurate thermometers.
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MICROCOMPUTER CONTROL
Capacity Control
Leaving chilled water temperature control is
accomplished by entering the water temperature
setpoint and placing the microcomputer in
automatic control. The unit will monitor all control
functions and move the slide valve to the required
operating position. The compressor ramp
(loading) cycle is programmable and may be set
for specific building requirements. Remote
adjustment of the leaving chilled water setpoint is
accomplished through either direct connection of
other Dunham-Bush control packages to the
microcomputer through either the RS485 long
distance differential communications port, via
terminal or modem connected to the RS232
communication port, or from an external Building
Automation System supplying a simple 4 to 20mA
signal. Remote reset of compressor current limit
may be accomplished in a similar fashion.
System Control
The unit may be started or stopped manually, or
through the use of an external signal from a
Building Automation System. In addition, the
microcomputer may be programmed with seven-
day operating cycle or other Dunham-Bush
control packages may start and stop the system
through inter-connecting wiring.
System Protection
The following system protection controls will
automatically act to insure system reliability:
] Low suction pressure
] High discharge pressure
] Freeze protection
] Low differential pressure
] Low oil level
] Compressor run error
] Power loss
] Chilled water flow loss
] Sensor error
] Compressor over current
] Compressor Anti-recycle
The microcomputer will retain the latest up to 99
alarm conditions complete with time of failure
together data stamping on critical sensor readings
in an alarm history. This tool will aid service
technicians in troubleshooting tasks enabling
downtime and nuisance trip-outs to be minimized.
Remote Monitoring
The microcomputer is complete with an optional
RS485 communications card and NETVISOR
software necessary for remote monitoring and
controlled from a PC terminal and optional phone
modem.
With various optional add-on cards the
Vision2020i controller can also be interfaced
directly to the BMS with the standard
communication protocols using MODBUS,
LONWORKS, BACNET MSTP as well as over IP.
This sophisticated feature makes servicing easier
and more convenient to the system. The
microcomputer as standard is additionally
equipped with history files which may be used to
take logs which may be retrieved via the phone
modem or internet connection periodically. Now
owners of multiple buildings have a simple and
inexpensive method of investigating potential
problems quickly and in a highly cost effective
manner. Dunham-Bush has various open
protocols on its microcomputer to allow direct
interface with Building Management Systems.
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PHYSICAL SPECIFICATIONS
MODEL HXWC 240-5NR 310-5NR 370-5NR 440-5NR 480-5NR 520-5NR 550-5NR 610-5NR 650-5NR 750-5NR
NOMINAL CAPACITY (TONS) 203 254 307 365 406 414 459 513 559 626
MIN % UNIT CAPACITY REDUCTION 12.5% 12.5% 12.5% 8.33% 8.33% 8.33% 8.33% 5.9% 5.9% 5.9%
COMPRESSOR
MODEL (QTY) HX1811(2)
HX1813(1)
HX 1816(1)
HX1817(2)
HX1813(2)
HX1816(1)
HX1813(1)
HX 1816(2)
HX1816(3)
HX1816(1)
HX 1817(2)
HX 1813(2)
HX 1816(2)
HX 1813(1)
HX 1816(3)
HX1817(4)
RPM 2900 2900 2900 2900 2900 2900 2900 2900 2900 2900
ELECTRICAL INFORMATION
COMPR. RLA, EACH 123 135/174 188 135/174 135/174 174 174/188 135/174 135/174 188
LRA, EACH 745 910/1160 1400 910/1160 910/1160 1160 1160/1400 910/1160 910/1160 1400
UNIT MIN CIRCUIT AMPS 277 353 423 488 527 550 600 662 701 800
MAX. ALLOW. FUSE SIZE 400 500 600 600 700 700 700 800 800 800
EVAPORATOR
MODEL X1R X2R X3R X4R X5R X5R X6R X8R X10R X11R
WATER CONNECTION (INCH) 8 8 8 10 10 10 10 10 12 12
NOMINAL WATER FLOW (GPM) 489 611 738 878 977 1047 1103 1235 1345 1505
NOMINAL PRESSURE DROP(FT WG) 7.3 7.5 8.1 8.2 7.6 8.7 8.8 8.6 6.5 5.9
CONDENSER
MODEL Z1R Z2R Z3R Z4R Z5R Z5R Z6R Z8R Z10R Z11R
WATER CONNECTION (INCH) 6 6 8 8 8 8 8 8 12 12
NOMINAL WATER FLOW (GPM) 587 734 887 1059 1170 1255 1323 1480 1603 1800
NOMINAL PRESSURE DROP(FT WG) 7.6 8.0 7.4 7.7 8.0 9.0 8.1 8.3 7.2 7.1
GENERAL INFORMATION
UNIT LENGTH (INCH) 171 171 171 171 171 171 171 210 210 210
UNIT WIDTH (INCH) 56 5/8 58 5/8 62 5/8 82 82 82 82 82 94 100
UNIT HEIGHT (INCH) 86 1/8 86 1/8 88 1/8 86 1/8 88 1/2 88 1/2 88 1/2 90 1/2 97 1/2 102 1/2
SHIPPING WEIGHT (KG) 5065 5970 6800 8190 9020 9290 9600 11390 14135 17190
OPERATING WEIGHT (KG) 5470 6445 7345 8845 9740 10035 10400 12530 15545 18910
APPROX. R134a REF. CHARGE (KG) 265 330 400 475 530 570 600 670 730 815
Notes: 1.) Nominal capacity is based on standard condition, actual capacity depends on the specified operating conditions.2.) Evaporator and condenser models are based on standard condition and are both 2 pass. Model might change for non-standard conditions
or application.3.) This physical specifications table is for standard vessels only, premium and superior vessels’ data are available in electronic catalog.
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DIMENSIONAL DATA
1.) HXWC 240-5NR, 310-5NR, 370-5NR
2.) HXWC 440-5NR, 480-5NR, 520-5NR, 550-5NR
3.) HXWC 610-5NR, 650-5NR, 750-5NR
NOTE: ALL DIMENSIOS ARE IN INCHES.
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TYPICAL WIRING SCHEMATIC
2 COMPRESSORS
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Ω
Ω
TYPICAL WIRING SCHEMATIC
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TYPICAL WIRING SCHEMATIC
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TYPICAL WIRING SCHEMATIC