INSTALLATION, WATER OPERATION & MAINTENANCE ......Model B3R B4R B5R C2R E5R 4AR 5AR 5BR 5CR Water Flow Rate USgpm[m³/hr] 179.4[40.8] 224.1[50.9] 271.2[61.6] 333.3[75.8] 411.3[93.5]

Form No: MM0490A-0713 (Superior)

Products that perform...By people who care

R134aR22R407CWCFX-E Series

ORIGINAL INSTRUCTIONS

50Hz60Hz

INSTALLATION,OPERATION &MAINTENANCE

MANUAL

INSTALLATION,OPERATION &MAINTENANCE

MANUAL

MODEL:

WATERCOOLEDSCREW

FLOODEDCHILLERS

R410A

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TABLE OF CONTENTS PAGE NO PAGE NO

INTRODUCTION ..................................................................... 2 1.0 GENERAL INFORMATION 1.1 RECEIVING AND INSPECTION. ......................................... 6 1.2 APPLICATION PRECAUTIONS. ......................................... 6

1.2.1 Water Connections .................................................... 6 1.2.2 Chilled Water Flow .................................................... 6 1.2.3 Water Cooled Condensers ........................................ 6 1.2.4 Condensing Water Treatment .................................... 7

1.3 RIGGING AND MOVING ..................................................... 7 1.4 SPACE REQUIREMENTS AND CLEARANCE ................... 7 2.0 INSTALLATION 2.1 FOUNDATION ................................................................... 14 2.2 VIBRATION ISOLATION ................................................... 14 2.3 UNMOUNTED ACCESSORIES ......................................... 14 2.4 WATER PIPING CONNECTIONS...................................... 14 2.5 ELECTRICAL WIRING ...................................................... 14 2.6 CONTROLS ....................................................................... 22

2.6.1 Connections ............................................................. 22 2.6.2 Settings ................................................................... 22

2.7 REQUEST FOR START-UP REPRESENTATIVE ............. 22 2.8 SOUND .............................................................................. 22 2.9 WARNING LABEL ............................................................. 22 3.0 OPERATION 3.1 SYSTEM WATER FLOW RATE. ....................................... 23 3.2 SEASONAL SHUT-DOWN PROCEDURE ........................ 23 3.3 SEASONAL START-UP PROCEDURE ............................ 23 3.4 REFRIGERATION CYCLE ................................................ 23 3.5 OIL MANAGEMENT SYSTEMS ........................................ 28 3.6 SYSTEM START UP .......................................................... 28 3.7 SYSTEM STANDSTILL ..................................................... 28 3.8 SHUT-DOWN ..................................................................... 28 3.9 SAFETY RELIEF VALVES ................................................ 28 3.10 PIPING JOINTS ................................................................. 28 3.11 ANTI-FREEZE PROTECTION ........................................... 29

3.11.1 Desuperheaters ..................................................... 29 3.11.2 Water Circuit ......................................................... 29 3.11.3 Glycol Freeze Protection ....................................... 29

3.12 HYDRAULIC CAPACITY CONTROL SYSTEM................. 30 3.13 FREEZE PREVENTION ..................................................... 30

3.13.1 Standby At Low Ambient Temperatures ................ 30 3.13.2 In Operation ........................................................... 30 3.13.3 During Maintenance .............................................. 30

4.0 ELECTRICAL 4.1 ELECTRICAL DATA .......................................................... 31

4.2 WIRING DIAGRAM ............................................................ 31 4.3 TYPICAL OPERATION...................................................... 31 4.4 VISION 2020I CONTROLLER AND TERMINAL ............... 45

4.4.1 Touch Screen Terminal Display............................... 45 4.4.2 Status Reading ........................................................ 46 4.4.3 Authorization ........................................................... 48 4.4.4 Advanced user key and menu ................................. 48 4.4.5 Technician Key and Menu ....................................... 49 4.4.6 Control Functions .................................................... 52

4.5 CALIBRATION OF SCREW COMPRESSOR CAPACITY AMPS AT FULL LOAD & MINIMUM LOAD PERCENTAGE ................................................................. 54

4.6 MASTER/ SLAVE CONTROL SEQUENCE ...................... 54 4.6.1 Principle of Operation VIA DBLAN Communication

Bus .......................................................................... 55 4.6.2 Sequence of Operation ............................................ 56

4.7 VISION 2020I LOCAL AREA NETWORK (DBLAN) ......... 56 4.8 NETWORK CONNECTION DIAGRAM .............................. 56 4.9 HARDWARE SETTING ..................................................... 57

4.9.1 Vision 2020i Controller with DBG2/DBG3 Display ... 57 4.9.2 Vision 2020i Controller LED Status ......................... 59

5.0 MAINTENANCE 5.1 GENERAL .......................................................................... 60 5.2 PERIODIC INSPECTION. .................................................. 60 5.3 MONTHLY INSPECTION. .................................................. 60 5.4 WATER SIDE CLEANING OF VESSELS .......................... 60 5.5 SHUT OFF VALVES .......................................................... 60 5.6 CHARGES OF GLAND SEAL. .......................................... 60 5.7 SAFETY PROTECTIVE MEASURE .................................. 60

5.7.1 General Safety Instructions ..................................... 60 5.7.2 Installation/ Operation Of Equipment ....................... 61 5.7.3 Service Instructions For Draining Used

Refrigerant Oil ......................................................... 61 5.8 ELECTRICAL MALFUNCTION ......................................... 62 5.9 CHARGING ........................................................................ 62

5.9.1 Refrigerant Charge .................................................. 62 5.9.2 Refrigerant Discharge .............................................. 62 5.9.3 Oil Charge ............................................................... 62

5.10 TROUBLESHOOTING ....................................................... 64 5.11 SAMPLE LOG SHEET ....................................................... 65 5.12 COMMON DEFECTS AND MEASURES ........................... 65 DECLARATION OF CONFORMITY CE ..................................... 66

SCHEMATIC DIAGRAM, GRAPH AND TABLE Figure 1.3.1 Moving Unit With Fork Lift ................................................................................................................................................ 7 Figure 1.3.2 Rigging Diagram .............................................................................................................................................................. 8 Figure 1.4 Dimensional Data ............................................................................................................................................................. 9 Figure 2.3 Flow Switch .................................................................................................................................................................... 14 Figure 2.4 Water Pressure Drop ..................................................................................................................................................... 16 Figure 3.4 Typical Piping Schematic ............................................................................................................................................... 24 Figure 3.12 Hydraulic Control System .............................................................................................................................................. 30 Figure 4.2 Typical Wiring Schematic ............................................................................................................................................... 32 Figure 4.4.1 Vision 2020i Keypad ..................................................................................................................................................... 45

Table 2.1 Floor Loading Diagram .............................................................................................................................................. 15 Table 2.8 Sound Pressure Data ................................................................................................................................................. 22 Table 4.4.6.6 Ramp Rates For Several Setpoints (In Minutes) ....................................................................................................... 53 Table 4.9.2 LED Status ................................................................................................................................................................. 59 Table 5.4 R134a Pressure/Temperature Properties .................................................................................................................. 63

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INTRODUCTION This manual is designed to provide essential information for installation, operation and maintenance of Dunham-Bush medium screw compressor flooded water cooled package chiller(s).

Dunham-Bush equipments are manufactured under careful quality control and performance pretested at specific filed operating conditions to ensure reliability and performance.

When Installed, operated and maintained with care and attention, your investment will give many years of satisfactory service. It is assumed that the user(s) of this manual is(are) experienced and qualified air conditioning equipment personnel and have read this manual and fully understood the contents before commencing with installation / operating or maintenance work on the equipment. SAFETY CONSIDERATION & PERSONAL PROTECTIVE EQUIPMENT (PPE) When working with chiller(s) there is always a risk of exposure to electrical / mechanical or chemical hazards during installation and service work.

The right Personal Protective Equipment (PPE) should always be used during installation, repair or service work. Reference should be made to appropriate Material Safety Data Sheets (MSDS) and Occupational Safety and Health Administration (OSHA) guidelines for PPE.

Refrigerant are classified as hazardous chemical, reference should be made to MSDS and OSHA guidelines for proper PPE when handling refrigerant. Refrigerant should be handle, reclaimed, recovered and recycled in accordance to The Federal Clean Air Act. Personal safety and the safety of others should never be compromised. Failure to follow recommendations could result in death or serious injuries. NOMENCLATURE

WC F X 10 S AU B3R A4R Q E

Generation E = WCFX-E B = WCFX-B

Q = Options outside the scope of spec

Blank = Options within the scope of spec

Condenser Code

Water Cooled Chiller

Flooded Evaporator

Screw Compressor

S = Single Compressor T = Two Compressors Blank = Three Compressors

Electrical Code AT = 380V/3ph/50Hz AU = 400V/3ph/50Hz

Evaporator Code Model

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INTRODUCTION PHYSICAL SPECIFICATIONS

Model WCFX-E 10S 12S 15S 18S 20S 23S 24S 27S 30S

Cooling Capacity RT 59.8 74.7 90.4 111.1 137.1 156.2 169.0 185.2 209.4 kW 210.3 262.7 317.9 390.7 482.2 549.4 594.4 651.3 736.5

104kcal/h 18.1 22.6 27.4 33.7 41.5 47.3 51.2 56.1 63.5 Min % Unit Capacity 25% 25% 25% 25% 25% 25% 25% 25% 25% Power 400V/3P/50Hz

Compressor Model(Qty.) 1210(1) 1212(1) 1215(1) 1218(1) 1222(1) 1222(1) 1227(1) 1227(1) 1230(1) Power Input kW 37.4 44.3 53.1 65.7 80.6 88.7 96.2 104.6 119.5 RLA, Each 74 99 123 146 146 146 183 183 213 LRA, Each 403 559 611 730 711 711 876 876 968

Evaporator Model C2R C3R D2R E2R 2CR 2DR EAR JAR JBR Water Flow Rate USgpm[m³/hr] 143.5[32.6] 179.3[40.7] 217.0[49.3] 266.6[60.6] 329.0[74.8] 374.9[85.2] 405.6[92.2] 444.5[101.0] 502.6[114.2] Pressure Drop psi[kPa] 1.6[11.0] 1.8[12.4] 1.8[12.4] 1.6[11.0] 3.9[26.9] 4.5[31.1] 4.4[30.4] 4.4[30.4] 4.6[31.7] Design Pressure psi 150 Connection Size inches[mm] 4[102] 5[127] 6[152] 6[152] 6[152] 6[152] 6[152] 8[203] 8[203]

Condenser Model B3R B4R B5R C2R E5R 4AR 5AR 5BR 5CR Water Flow Rate USgpm[m³/hr] 179.4[40.8] 224.1[50.9] 271.2[61.6] 333.3[75.8] 411.3[93.5] 468.6[106.5] 507[115.2] 555.6[126.3] 628.2[142.8] Pressure Drop psi[kPa] 2.1[14.5] 2.2[15.2] 2.3[15.9] 2.4[16.6] 4.4[30.4] 5.1[35.2] 4.9[33.8] 5.0[34.5] 5.0[34.5] Design Pressure psi 150 Connection Size inches[mm] 4[102] 5[127] 5[127] 6[152] 6[152] 6[152] 6[152] 8[203] 8[203]

General Information Length Inches[mm] 118 1/4 [3003]

124 1/4 [3157]

123 7/8[3147]

124 7/16[3160]

164 3/16[4171]

164 3/16[4171]

164 3/16 [4171]

164 3/16 [4171]

164 3/16[4171]

Width Inches[mm] 41 13/16 [1062] 42 3/16 [1072]

48 1/8[1222]

52 3/16[1326]

63[1600]

63[1600]

63 [1600]

63 [1600]

63[1600]

Height Inches[mm] 72 15/16 [1852] 72 15/16 [1852]

83 1/4[2115]

83 1/4[2115]

67 9/16[1716]

67 9/16[1716]

67 15/16 [1725]

70 3/16 [1783]

72 3/4[1847]

Shipping Weight lbs[kg] 6574[2982] 6946[3151] 7627[3460] 8729[3959] 8466[3840] 8896[4035] 10675[4842] 11202[5081] 11885[5391] Operating Weight lbs[kg] 6835[3100] 7263[3294] 8008[3632] 9198[4172] 9025[4094] 9485[4302] 11317[5133] 11918[5406] 12678[5751] Approx. R134a Ref. Charge lbs[kg] 220[100] 254[115] 320[145] 364[165] 441[200] 485[220] 573[260] 529[240] 562[255]

Model WCFX-E 33T 36S 36T 41S 41T 46T 50T 54T

Cooling Capacity RT 202.1 245.9 223.7 279.2 264.3 315.0 343.6 371.7 kW 710.8 864.8 786.8 981.9 929.5 1107.9 1208.4 1307.3

104kcal/h 61.2 74.5 67.8 84.6 80.1 95.5 104.1 112.6 Min % Unit Capacity 12.5% 25% 12.5% 25% 12.5% 12.5% 12.5% 12.5% Power 400V/3P/50Hz

Compressor Model(Qty.) 1218(1) 1215(1) 2233(1) 1218(2) 2236(1)

1222(1)1218(1) 1222(2)

1227(1) 1222(1) 1227(2)

Power Input kW 118.0 135.9 129.0 154.0 150.9 173.7 189.9 206.3 RLA, Each 146/123 246 146(2) 294 146/146 146(2) 183/146 183(2) LRA, Each 730/611 1311 730(2) 1730 730/711 711(2) 876/711 876(2)

Evaporator Model 5AR 6AR 5BR 6CR 6CR 7DR 8BR 8CR Water Flow Rate USgpm[m³/hr] 485.0[110.2] 590.2[134.1] 536.7[122.2] 670.1[152.3] 634.3[144.2] 756.0[171.8] 824.6[187.4] 892.1[202.7] Pressure Drop psi[kPa] 4.8[33.1] 4.9[33.8] 4.9[33.8] 4.8[33.1] 4.3[29.7] 4.8[32.9] 5[34.5] 5.2[35.9] Design Pressure psi 150 Connection Size inches[mm] 8[203] 8[203] 8[203] 8[203] 8[203] 8[203] 10[254] 10[254]

Condenser Model J5R K4R K3R K5R K5R L1R M3R M4R Water Flow Rate USgpm[m³/hr] 606.3[137.8] 737.7[167.7] 671.1[152.5] 837.6[190.4] 792.9[180.2] 945.0[214.8] 1030.8[234.3] 1115.1[253.4] Pressure Drop psi[kPa] 5.1[35.2] 5.1[35.2] 5.1[35.2] 4.9[33.8] 4.5[31.1] 5.2[35.9] 5.2[35.9] 5.1[35.2] Design Pressure psi 150 Connection Size inches[mm] 8[203] 8[203] 8[203] 8[203] 8[203] 8[203] 10[254] 10[254]

General Information Length Inches[mm] 196 3/4[4997] 174 3/16[4425] 196 3/4[4997] 174 3/16[4425] 196 3/4[4997] 196 3/4[4997] 196 3/4[4997] 196 3/4[4997] Width Inches[mm] 75[1905] 70[1778] 75[1905] 70[1778] 80[2032] 80[2032] 80[2032] 80[2032] Height Inches[mm] 78[1981] 85 5/8[2175] 78[1981] 85 5/8[2175] 78 11/16[1999] 80 7/16[2044] 84 7/16[2145] 84 7/16[2145] Shipping Weight lbs[kg] 12304[5580] 12960[5879] 13415[6085] 13569[6155] 14519[6586] 17322[7857] 17955[8144] 18591[8433] Operating Weight lbs[kg] 14004[6352] 14004[6352] 14378[6522] 14768[6699] 15718[7129] 18678[8472] 19413[8805] 20167[9147] Approx. R134a Ref. Charge lbs[kg] 639[290] 761[345] 683[310] 838[380] 882[400] 970[440] 1014[460] 1080[490]

Notes: 1. This physical specifications table is based on Superior vessel models with the following operation condition: inlet/outlet cooled water temperature 54/44°F, inlet/outlet cooling water temperature 85/95°F, Fouling factor of evaporator 0.0001hr.ft2.°F/Btu, Fouling factor of condenser 0.00025hr.ft2.°F/Btu, 2 pass vessels

2. Actual capacity will depend on the specified conditions. To consult nearest Dunham-bush sales office for computer selections. 3. Non-standard chillers can be designed according to different requirements.

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INTRODUCTION

Model WCFX-E 57T 60T 69 73 73T 75T 77 81


104kcal/h 120.5 128.4 144.2 152.8 148.7 158.6 161.4 170.1 Min % Unit Capacity 12.5% 12.5% 8.5% 8.5% 12.5% 12.5% 8.5% 8.5% Power 400V/3P/50Hz

Compressor

Model(Qty.) 1230(1) 1227(1) 1230(2) 1222(3) 1227(1) 1222(2) 2233(2)

2236(1) 2233(1)

1227(2) 1222(1) 1227(3)

Power Input kW 220.8 235.3 267.3 283.9 273.2 292.1 300.4 316.4 RLA, Each 213/183 213(2) 146(3) 183/146(2) 246(2) 294/246 183(2)/146 183(3) LRA, Each 968/876 968(2) 711(3) 876/711(2) 1311(2) 1730/1311 876(2)/711 876(3)

Evaporator Model 8DR KBR Z3R CBR LAR LBR CFR CGR Water Flow Rate USgpm[m³/hr] 954.7[217.0] 1016.7[231.1] 1141.9[259.5] 1210.3[275.1] 1177.4[267.6] 1256.2[285.5] 1278.5[290.6] 1348.0[306.2] Pressure Drop psi[kPa] 5.5[38.0] 5.3[36.6] 6.0[41.4] 6.1[42.1] 5.7[39.3] 5.8[40.0] 6.1[42.1] 6.2[42.8] Design Pressure psi 150 Connection Size inches[mm] 10[254] 10[254] 10[254] 10[254] 12[305] 12[305] 10[254] 10[254]

Condenser Model M5R T5R X3R Y6R U1R U2R Y7R Z1R Water Flow Rate USgpm[m³/hr] 1193.4[271.2] 1271.1[288.9] 1427.4[324.4] 1512.9[343.8] 1471.8[334.5] 1570.2[356.9] 1598.1[363.2] 1684.2[382.8] Pressure Drop psi[kPa] 5.2[35.9] 5.4[37.3] 5.9[40.7] 6.1[42.1] 6.0[41.4] 5.6[38.6] 5.9[40.7] 5.8[40.0] Design Pressure psi 150 Connection Size inches[mm] 10[254] 10[254] 10[254] 10[254] 12[305] 12[305] 10[254] 12[305]

General Information Length Inches[mm] 196 3/4[4997] 196 3/4[4997] 213 3/4[5429] 213 3/4[5429] 206 3/4[5251] 206 3/4[5251] 213 3/4[5429] 213 3/4[5429] Width Inches[mm] 80[2032] 80[2032] 86[2184] 86[2184] 86[2184] 86[2184] 86[2184] 86[2184] Height Inches[mm] 84 7/16[2145] 86 7/16[2196] 87 3/8[2219] 87 3/8[2219] 82 3/4[2102] 82 3/4[2102] 87 3/8[2219] 86 7/8[2206] Shipping Weight lbs[kg] 19367[8785] 21126[9583] 24358[11049] 24927[11307] 23122[10488] 23705[10753] 25509[11571] 27056[12272] Operating Weight lbs[kg] 21019[9534] 22886[10381] 26488[12015] 27156[12318] 25055[11365] 25784[11695] 27847[12631] 29544[13401] Approx. R134a Ref. Charge lbs[kg] 1113[505] 1312[595] 1521[690] 1587[720] 1301[590] 1389[630] 1653[750] 1731[785]

Model WCFX-E 81T 84 87 90 108 113 118 123


104kcal/h 169.6 177.7 185.2 192.2 223.7 234.2 244.4 255.3 Min % Unit Capacity 12.5% 8.5% 8.5% 8.5% 8.5% 8.5% 8.5% 8.5% Power 400V/3P/50Hz

Compressor

Model(Qty.) 2236(2) 1230(1) 1227(2) 1230(2) 1227(1) 1230(3) 2233(3)

2236(1) 2233(2)

2236(2) 2233(1) 2236(3)

Power Input kW 308.7 329.8 343.6 359.2 411.9 430.6 448.2 465.7 RLA, Each 294(2) 213/183(2) 213(2)/183 213(3) 246(3) 294/246(2) 294(2)/246 294(3) LRA, Each 1730(2) 967/876(2) 968(2)/876 968(3) 1311(3) 1730/1311(2) 1730(2)/1311 1730(3)

Evaporator Model MAR DBR DCR DCR PBR PBR SAR SCR Water Flow Rate USgpm[m³/hr] 1343.0[305.2] 1407.2[319.8] 1467.1[333.4] 1522.6[346.0] 1771.7[402.7] 1855.2[421.6] 1935.8[440.0] 2022.2[459.6] Pressure Drop psi[kPa] 5.2[35.9] 5.5[38.0] 5.6[38.6] 6.1[42.1] 5.8[40.0] 5.8[40.0] 5.7[39.3] 5.2[35.9] Design Pressure psi 150 Connection Size inches[mm] 12[305] 12[305] 12[305] 12[305] 12[305] 12[305] 12[305] 12[305]

Condenser Model JAR 1BR 1CR 1CR 8CR 8BR 9AR 9BR Water Flow Rate USgpm[m³/hr] 1678.8[381.5] 1758.9[399.8 1833.9[416.8] 1903.2[432.5] 2214.6[503.3] 2319.0[527.0] 2419.8[550.0] 2527.8[574.5] Pressure Drop psi[kPa] 5.3[36.6] 5.8[40.0] 5.6[38.6] 6.0[41.4] 5.1[35.2] 5.2[35.9] 4.6[31.74] 4.4[30.36] Design Pressure psi 150 Connection Size inches[mm] 12[305] 10[254] 10[254] 10[254] 12[305] 12[305] 12[305] 12[305]

General Information Length Inches[mm] 206 3/4[5251] 213 3/4[5429] 213 3/4[5429] 213 3/4[5429] 201 3/4[5124] 201 3/4[5124] 201 3/4[5124] 201 3/4[5124] Width Inches[mm] 86[2184] 86[2184] 86[2184] 86[2184] 99[2515] 99[2515] 99[2515] 99[2515] Height Inches[mm] 86 7/4[2206] 87 11/16[2228] 87 11/16[2228] 87 11/16[2228] 117 7/16[2984] 117 7/16[2984] 126 11/16[3217] 126 11/16[3217]Shipping Weight lbs[kg] 27213[12344] 30186[13692] 30976[14050] 31288[14192] 37663[17083] 38532[17478] 41519[18833] 42996[19503] Operating Weight lbs[kg] 29537[13398] 32826[14890] 33769[15317] 34080[15459] 39922[18108] 40844[18526] 44010[19963] 45576[20673] Approx. R134a Ref. Charge lbs[kg] 1455[660] 1940[880] 2017[915] 2017[915] 2006[910] 2011[912] 2238[1015] 2253[1022]

Notes: 1. This physical specifications table is based on Superior vessel models with the following operation condition: inlet/outlet cooled water temperature 54/44°F, inlet/outlet cooling water temperature 85/95°F, Fouling factor of evaporator 0.0001hr.ft2.°F/Btu, Fouling factor of condenser 0.00025hr.ft2.°F/Btu, 2 pass vessels

2. Actual capacity will depend on the specified conditions. To consult nearest Dunham-bush sales office for computer selections. 3. Non-standard chillers can be designed according to different requirements.

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1.0 GENERAL INFORMATION 1.1 RECEIVING AND INSPECTION The unit should be inspected immediately, in the presence of the carrier's representative, for any evidence of damage during shipping. Any damage should be noted on the carrier's delivery receipt before it is signed. A damage claim should then be filed by the purchaser against the delivering carrier as all shipments are made at the purchaser's risk. The receiving inspection instructions, sent with the installation instructions, should also be filled at this time and forwarded to the Dunham-Bush Industries, M & E Service Department. 1.2 APPLICATION PRECAUTIONS The following instructions are intended to help assure proper and successful application of your water chilling machines. 1.2.1 WATER CONDITIONS

Dunham-Bush’s WCFX-E chiller(s) are engineered and designed with liquid heads together with steal shell and copper tube type heat ex-changes for extended heat transfer surface as well as straightforward cleaning advantages (shell and tube evaporator and condenser).

The materials used in fabrication are generally suitable for clean fresh water found in most localities. However, minerals and other contaminants found in some water systems may promote aggressive attack on the tubes or tube sheets, resulting in failure with serious consequences for the entire package chiller.

Since Dunham-Bush has no control over the condition of the water used in these machines, Dunham-Bush is not liable for failure of tubes or tube sheets due to water corrosion or erosion. It is recommended that the end user/owner obtain the services of local water treatment specialists to prescribe the correct water treatment.

1.2.2 CHILLED WATER FLOW

Dunham-Bush WCFX-E flooded water cooler packaged chillers are designed for a constant chilled water flow rate, even when the cooling load is varying. The machine will generally perform satisfactorily with steady flow rates deviating from design by as much as +10% / -50%. However, varying water flow rates will cause control instability, which will result in undesirable system effects, particularly poor control of leaving chilled water temperature. If two-way valves are used to control flow through cooling coils, some means of control (for example automatic modulating valve)

should be installed in the system to maintain steady flow through the evaporator. If either the chilled water flow rate or/and load varies, the variation must be controlled so that return water temperature does not vary at a rate exceeding 2°F [1.1°C] per minute. If the chilled water system is designed for the dual purpose of cooling and heating, the evaporator must incorporate valves to prevent the flow of hot water through it. This can be done with either manual or automatic shutoff valves, but water temperature entering the evaporator must never exceed 90°F [32°C].

1.2.3 WATER COOLED CONDENSERS The water cooled condenser is also designed for constant water flow rate, and should be supplied with the design flow rate ±10%. The condenser must be protected from rapid changes in temperature as well. The maximum allowable rate of change in condenser entering water is 1°F [0.6°C] per minute. Fluctuating flow rate or temperature will cause unstable control of the machine, resulting in poor control of leaving chilled water temperature. If a cooling tower is used to reject heat from the condensing water loop, it must be controlled to provide an entering condensing water temperature which does not change more rapidly than 1°F [0.6°C] per minute and does not go below 60°F [15.6°C]. One or more of the following methods may be used to control the tower: 1.2.3.1 A modulating three-way valve

which bypasses tower sprays at low load and low ambient temperature.

1.2.3.2 Tower fan staging in response to a thermostat in the tower sump. Fan thermostat should have a differential of at least 20°F [11.1°C] to avoid short cycling.

1.2.3.3 A modulating three-way valve which bypasses the cooling tower to blend warm leaving condenser water with cold tower water.

1.2.4 CONDENSING WATER TREATMENT

Condensing water tends to leave silt, algae and mineral deposits in the condenser tubes. This fouling gradually decreases unit efficiency. For this reason, a program of water treatment should be employed. Also, at regular intervals depending on water quality, the unit should be shut down, condenser heads removed and tubes cleaned. See Section 5.4.

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1.0 GENERAL INFORMATION 1.3 RIGGING AND MOVING Each unit is carefully designed and built in the factory; every precaution has been taken into consideration to assure that the unit reaches you in perfect condition. It is very important that the riggers and movers use the same care and precaution when moving the equipment into place. Make sure that chains, cables or other moving equipment are placed or position correctly to avoid damage to the unit or piping. The refrigerant piping must not be used as a ladder or as a hand hold. 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.

Unit(s) mounted on skids may be moved with a forklift, but care must be taken so that the fork of the forklift does not to damage the unit. The skids should not be removed until the unit is at its final location.

The WCFX model is to be rigged through the provided rigging holes. It is highly recommended that spreader

bars be used between rigging lines to prevent damage to the unit. The unit must be lifted using all rigging points. It can also be moved on skids placed under the tube sheets. Refer to Figure 1.3.1 and 1.3.2 for rigging instructions. 1.4 SPACE REQUIREMENTS AND

CLEARANCE 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 servicing properly. Failure to allow these clearances will cause serious trouble and result in higher costs for operation, maintenance and repair. The dimensional data and space requirement are shown in Figure 1.4.

FIGURE 1.3.1 MOVING UNIT WITH FORK LIFT

USE SKID TO AVOID DAMAGE TO THE UNIT

Note: Skid supplied by others. Please contact Dunham-Bush if further information about skid is required.

- 8 -

1.0 GENERAL INFORMATION FIGURE 1.3.2 RIGGING DIAGRAM

Rigging should be done in a manner so that no strain is placed on unit components other than at cable connection points

Sample 1 Sample 2 Note: Spreader bar supplied by others. Please contact Dunham-Bush if further information about the spreader bar is required.

- 9 -

MODEL

AB

CD

EF

GHEIGHT

IJ

KLENGTH

MWIDTH

Y (Ø)

Z (Ø)

WCFX‐E 10S

2 1/16

[53]

10 5/8

[270

]101 15/16

[258

9]6

[153]

2 1/2

[63]

10 1/16

[256]

5 1/8

[130

]72

15/16

[185

2]23

1/4

[591]

14 3/4

[374

]12

5/8

[321

]118 1/4

[300

3]4 5/8

[118]

41 13/16

[106

2]4

[102]

5[127]

WCFX‐E 12S

2 1/16

[53]

16 11/16

[424

]101 7/8

[258

8]6

[153]

2 1/2

[63]

10 1/16

[256]

5 1/8

[130

]72

15/16

[185

2]22

13/16

[580]

14 3/4

[374

]14

7/16

[366

]124 1/4

[315

7]4

[102]

42 3/16

[107

2]5

[127]

5[127]

WCFX‐E 15S

2 1/16

[53]

16 11/16

[424

]101 7/8

[258

8]6

[153]

2 7/8

[72]

11 1/8

[282]

5 5/8

[143

]83

1/4

[211

5]24

13/16

[630]

16 7/16

[417

]14

7/16

[366

]123 7/8

[314

7]4

[102]

48 1/8

[122

2]5

[127]

6[152]

WCFX‐E 18S

2 1/16

[53]

16 7/8

[429

]101 7/8

[258

8]6

[153]

1 9/16

[40]

12 3/8

[315]

5 5/8

[143

]83

1/4

[211

5]28

1/8

[715]

18 3/16

[462

]15

3/8

[391

]124 7/16

[316

0]4 1/2

[115]

52 3/16

[132

6]6

[152]

6[152]

1.0 GENERAL INFORMATION FIGURE 1.4 DIMENSIONAL DATA

WCFX-E 10S, 12S, 15S, 18S

Notes : 1.) All dimensions are in inches[mm].

2.) Above drawing is for Superior model. Consult factory for Standard and Premium model dimension.

- 10 -

MODEL

AB

CD

EF

GHEIGHT

IJ

KLENGTH

MN

OP

QR

SWIDTH

Y (Ø)

Z (Ø)

WCFX‐E 20S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]40

11/16

[1033]

25 [635]

58 1/2

[148

6]53

1/2

[1359]

67 9/16

[1716]

1 1/8

[28]

1 3/8

[35]

21 1/8

[536]

164 3/16

[417

1]11

/16

[17]

1 3/4

[44]

5 5/8

[143

]14

7/8

[377

]19

5/16

[491]

25 1/4

[642

]4

[102]

63[160

0]5

[127

]6

[152

]

WCFX‐E 23S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]40

11/16

[1033]

25 [635]

58 1/2

[148

6]53

1/2

[1359]

67 9/16

[1716]

1 1/8

[28]

1 3/8

[35]

20 7/8

[530]

164 3/16

[417

1]11

/16

[17]

3/4

[19]

5 5/8

[143

]14

7/8

[377

]19

5/16

[491]

26 1/4

[668

]4 1/2

[115]

63[160

0]6

[152

]6

[152

]

WCFX‐E 24S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]40

11/16

[1033]

25 [635]

58 1/2

[148

6]53

1/2

[1359]

67 15/16

[1725]

1 1/8

[28]

1 3/8

[35]

21 1/8

[536]

164 3/16

[417

1]11

/16

[17]

1 3/8

[35]

5 5/8

[143

]14

7/8

[377

]20

5/16

[516]

28 1/2

[725

]5 5/8

[143]

63[160

0]6

[152

]6

[152

]

WCFX‐E 27S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]40

11/16

[1033]

25 [635]

58 1/2

[148

6]53

1/2

[1359]

70 3/16

[1783]

1 1/8

[28]

1 3/8

[35]

20 7/8

[530]

164 3/16

[417

1]11

/16

[17]

2 1/2

[64]

6 7/8

[175

]14

7/8

[377

]21

5/16

[542]

29 3/4

[756

]5 5/8

[143]

63[160

0]6

[152

]8

[203

]

WCFX‐E 30S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]40

11/16

[1033]

25 [635]

58 1/2

[148

6]53

1/2

[1359]

72 3/4

[1847]

1 1/8

[28]

1 3/8

[35]

20 7/8

[530]

164 3/16

[417

1]11

/16

[17]

2 1/2

[64]

6 7/8

[175

]14

7/8

[377

]21

5/16

[542]

29 3/4

[756

]5 5/8

[143]

63[160

0]6

[152

]8

[203

]

WCFX‐E 36S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]50

11/16

[1287]

30 11/16

[780]

60[152

4]60

[1524]

85 5/8

[2175]

1 1/8

[28]

1 3/8

[35]

21 1/8

[536]

174 3/16

[442

5]11

/16

[17]

2 1/4

[57]

6 7/8

[175

]15

7/8

[403

]22

5/16

[567]

31 3/4

[807

]6 7/8

[175]

70[177

8]8

[203

]8

[203

]

WCFX‐E 41S

20 [508]

40 11/16

[1033]

40 11/16

[103

3]50

11/16

[1287]

30 11/16

[780]

60[152

4]60

[1524]

85 5/8

[2175]

1 1/8

[28]

1 3/8

[35]

21 1/8

[536]

174 3/16

[442

5]11

/16

[17]

2 1/4

[57]

6 7/8

[175

]15

7/8

[403

]22

5/16

[567]

31 3/4

[807

]6 7/8

[175]

70[177

8]8

[203

]8

[203

]

1.0 GENERAL INFORMATION WCFX-E 20S, 23S, 24S, 27S, 30S, 36S, 41S



- 11 -

MODEL

AB

CD

EF

GHEIGHT

IJ

KLENGTH

MN

OP

QR

SWIDTH

Y (Ø)

Z (Ø)

WCFX‐E 33T

15 [381]

60[1524]

60[1524]

45[1143]

24 [610]

68 1/2

[1740]

78 1/2

[1994]

78[1981]

7/8

[22]

1 7/8

[48]

21 1/8

[537]

196 3/4

[4997]

1 1/2

[38]

2 1/2

[64]

6 7/8

[175]

17 1/2

[445]

23 5/16

[592]

29 3/4

[756]

5 11/16

[144]

75[190

5]8

[203]

8[203]

WCFX‐E 36T

15 [381]

60[1524]

60[1524]

45[1143]

24 [610]

68 1/2

[1740]

78 1/2

[1994]

78[1981]

7/8

[22]

1 7/8

[48]

21 1/8

[537]

196 3/4

[4997]

1 1/2

[38]

2 1/2

[64]

6 7/8

[175]

17 1/2

[445]

23 5/16

[592]

29 3/4

[756]

5 11/16

[144]

75[190

5]8

[203]

8[203]

WCFX‐E 41T

15 [381]

60[1524]

60[1524]

45[1143]

24 [610]

68 1/2

[1740]

78 1/2

[1994]

78 11/16

[1999]

7/8

[22]

1 7/8

[48]

21 1/8

[537]

196 3/4

[4997]

1 1/2

[38]

2 1/4

[57]

6 7/8

[175]

20 [508]

24 5/16

[618]

31 3/4

[807]

6 1/16

[155]

80[203

2]8

[203]

8[203]

WCFX‐E 46T

15 [381]

55[1397]

55[1397]

55[1397]

26 [660]

64 1/2

[1638]

64 1/2

[1638]

80 7/16

[2044]

7/8

[22]

1 7/8

[48]

18 15/16

[480]

196 3/4

[4997]

1 1/2

[38]

2 [51]

8 1/8

[207]

20 [508]

25 5/16

[643]

33 3/4

[858]

6 7/8

[175]

80[203

2]8

[203]

8[203]

WCFX‐E 50T

15 [381]

55[1397]

55[1397]

55[1397]

26 [660]

64 1/2

[1638]

64 1/2

[1638]

84 7/16

[2145]

7/8

[22]

1 7/8

[48]

18 15/16

[480]

196 3/4

[4997]

1 1/2

[38]

2 [51]

8 1/8

[207]

20 [508]

26 5/16

[669]

35 3/4

[909]

6 7/8

[175]

80[203

2]10 [254]

10 [254]

WCFX‐E 54T

15 [381]

55[1397]

55[1397]

55[1397]

26 [660]

64 1/2

[1638]

64 1/2

[1638]

84 7/16

[2145]

7/8

[22]

1 7/8

[48]

18 15/16

[480]

196 3/4

[4997]

1 1/2

[38]

2 [51]

8 1/8

[207]

20 [508]

26 5/16

[669]

35 3/4

[909]

6 7/8

[175]

80[203

2]10 [254]

10 [254]

WCFX‐E 57T

15 [381]

55[1397]

55[1397]

55[1397]

26 [660]

64 1/2

[1638]

64 1/2

[1638]

84 7/16

[2145]

7/8

[22]

1 7/8

[48]

18 15/16

[480]

196 3/4

[4997]

1 1/2

[38]

2 [51]

8 1/8

[207]

20 [508]

26 5/16

[669]

35 3/4

[909]

6 7/8

[175]

80[203

2]10 [254]

10 [254]

WCFX‐E 60T

15 [381]

55[1397]

55[1397]

55[1397]

26 [660]

64 1/2

[1638]

64 1/2

[1638]

86 7/16

[2196]

7/8

[22]

1 7/8

[48]

18 15/16

[480]

196 3/4

[4997]

1 1/2

[38]

3 [76]

8 5/8

[219]

20 [508]

27 5/16

[694]

36 3/4

[934]

6 7/8

[175]

80[203

2]10 [254]

10 [254]

WCFX‐E 73T

15 [381]

53 11/16

[1363]

60 11/16

[1541]

60 11/16

[1541]

25 [635]

74[1880]

81[2057]

82 3/4

[2102]

7/8

[22]

1 7/8

[48]

20 5/8

[524]

206 3/4

[5251]

1 1/2

[38]

3 7/8

[99]

9 3/4

[248]

23 [584]

28 5/16

[719]

39 11/16

[1008]

7 3/8

[187]

86[218

4]10 [254]

12 [305]

WCFX‐E 75T

15 [381]

53 11/16

[1363]

60 11/16

[1541]

60 11/16

[1541]

25 [635]

74[1880]

81[2057]

82 3/4

[2102]

7/8

[22]

1 7/8

[48]

20 5/8

[524]

206 3/4

[5251]

1 1/2

[38]

3 7/8

[99]

9 3/4

[248]

23 [584]

28 5/16

[719]

39 11/16

[1008]

7 3/8

[187]

86[218

4]10 [254]

12 [305]

WCFX‐E 81T

15 [381]

53 11/16

[1363]

60 11/16

[1541]

60 11/16

[1541]

25 [635]

74[1880]

81[2057]

86 7/4

[2206]

7/8

[22]

1 7/8

[48]

20 5/8

[524]

206 3/4

[5251]

1 1/2

[38]

3 3/4

[95]

10 1/8

[258]

23 [584]

29 5/16

[745]

41 1/2

[1055]

8[203]

86[218

4]12 [305]

12 [305]

1.0 GENERAL INFORMATION WCFX-E 33T, 36T, 41T, 46T, 50T, 54T, 57T, 60T, 73T, 75T, 81T



- 12 -

MODEL

AB

CD

EF

GHEIGHT

IJ

KLENGTH

MN

OP

QR

SWIDTH

Y (Ø)

Z (Ø)

WCFX‐E 69

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

87 3/8

[221

9]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

3 7/8

[99]

8 5/8

[219]

23 [584]

24 5/16

[618]

39 11/16

[100

8]7 3/8

[187

]86

[218

4]10 [254]

10 [254]

WCFX‐E 73

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

87 3/8

[221

9]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

3 7/8

[99]

8 5/8

[219]

23 [584]

24 5/16

[618]

39 11/16

[100

8]7 3/8

[187

]86

[218

4]10 [254]

10 [254]

WCFX‐E 77

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

87 3/8

[221

9]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

3 7/8

[99]

8 5/8

[219]

23 [584]

24 5/16

[618]

39 11/16

[100

8]7 3/8

[187

]86

[218

4]10 [254]

10 [254]

WCFX‐E 81

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

86 7/8

[220

6]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

2 7/8

[74]

8 5/8

[219]

23 [584]

24 5/16

[618]

38 3/16

[970]

8[203

]86

[218

4]12 [305]

10 [254]

WCFX‐E 84

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

87 11/16

[222

8]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

3 3/4

[95]

10 1/8

[258]

23 [584]

24 5/16

[618]

39 [991]

8 1/8

[207

]86

[218

4]10 [254]

12 [305]

WCFX‐E 87

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

87 11/16

[222

8]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

3 3/4

[95]

10 1/8

[258]

23 [584]

24 5/16

[618]

39 [991]

8 1/8

[207

]86

[218

4]10 [254]

12 [305]

WCFX‐E 90

15 [381

]60

11/16

[1541]

60 11/16

[1541]

60 11/16

[154

1]25 [635

]81

[205

7]81

[2057]

87 11/16

[222

8]7/8

[22]

1 7/8

[48]

20 5/8

[524]

213 3/4

[542

9]1 1/2

[38]

3 3/4

[95]

10 1/8

[258]

23 [584]

24 5/16

[618]

39 [991]

8 1/8

[207

]86

[218

4]10 [254]

12 [305]

1.0 GENERAL INFORMATION WCFX-E 69, 73, 77, 81, 84, 87, 90



- 13 -

MODEL

AB

CD

EF

GHEIGHT

IJ

KLENGTH

MN

OP

QR

SWIDTH

Y (Ø)

Z (Ø)

WCFX‐E 108

20 [508]

53 5/16

[1355]

53 5/16

[1355]

53 5/16

[135

5]25 [635]

76[1930]

74[1880]

117 7/16

[2984]

7/8

[22]

1 7/8

[48]

19 1/4

[489]

201 3/4

[5124]

1 1/2

[38]

3 3/8

[85]

10 3/16

[259]

92[2337]

32 5/16

[821]

47 1/2

[1207]

8 7/8

[226]

99[2515]

12 [305]

12 [305]

WCFX‐E 113

20 [508]

53 5/16

[1355]

53 5/16

[1355]

53 5/16

[135

5]25 [635]

76[1930]

74[1880]

117 7/16

[2984]

7/8

[22]

1 7/8

[48]

17 7/8

[454]

201 3/4

[5124]

1 1/2

[38]

3 3/8

[85]

10 3/16

[259]

92[2337]

32 5/16

[821]

47 1/2

[1207]

8 7/8

[226]

99[2515]

12 [305]

12 [305]

WCFX‐E 118

20 [508]

53 5/16

[1355]

53 5/16

[1355]

53 5/16

[135

5]25 [635]

76[1930]

74[1880]

126 11/16

[3217]

7/8

[22]

1 7/8

[48]

19 1/4

[489]

201 3/4

[5124]

1 1/2

[38]

3 1/2

[89]

10 3/4

[273]

92[2337]

35 5/16

[897]

51 11/16

[1312]

10 3/4

[273]

99[2515]

14 [356]

14 [356]

WCFX‐E 123

20 [508]

53 5/16

[1355]

53 5/16

[1355]

53 5/16

[135

5]25 [635]

76[1930]

74[1880]

126 11/16

[3217]

7/8

[22]

1 7/8

[48]

17 7/8

[454]

201 3/4

[5124]

1 1/2

[38]

3 1/2

[89]

10 3/4

[273]

92[2337]

35 5/16

[897]

51 11/16

[1312]

10 3/4

[273]

99[2515]

14 [356]

14 [356]

1.0 GENERAL INFORMATION WCFX-E 108, 113, 118, 123



- 14 -

2.0 INSTALLATION 2.1 FOUNDATION A flat, level concrete foundation or floor capable of supporting the weight of the unit must be provided. Weights are given in Table 2.1. The unit must be leveled to within 1/16" per foot [5.2mm per meter] for proper operation. 2.2 VIBRATION ISOLATION In case of structure-borne vibration may be of concern, it is recommended that the unit be mounted on vibration isolators. Rubber-in-shear isolators or spring isolators are available for this unit as optional equipment. If spring isolators are installed, it is also necessary to provide isolation in condenser water and chilled water pipes by means of flexible connectors and in main power supply conduit through use of flexible conduit. Isolation of piping and electrical conduit is desirable in any event, to avoid noise transmission. 2.3 UNMOUNTED ACCESSORIES A chiller water flow switch (option item), which is shipped separately accompanying the unit must be field installed in the external chilled water outlet piping. It must be located in a horizontal section on the pipe where there is at least five (5) pipe diameters on both sides of the flow switch before any other connections, as indicated in Figure 2.3. The flow switch paddle must be adjusted to the size of pipe in which the paddle is installed, and the switch set to trip at approximately -50% of the design flow. Refer to the unit wiring diagram for the electrical connections to interlock the Chilled Water Flow Switch (CWFS) with the control panel. Figure 2.3 Flow Switch

2.4 WATER PIPING CONNECTIONS Refer to Figures 1.4. for water piping connection locations. Note that the condenser water inlet must be connected to the bottom (condenser water inlet). If necessary, evaporator or condenser headers can be swapped, from the left to the right end of the vessel or vice versa to suit site water piping conditions. Leaving

chilled water temp sensor must be located at leaving chilled water stream. After the unit has been leveled and isolators (if any) have been installed and adjusted, evaporator and condenser water piping are connected. Piping must be properly supported to avoid stress on unit water connections. Install air vent valves in all high connections on evaporator and condenser headers. Drain valves should be installed in similar low points to facilitate gravity draining of the system. It is important that water systems should be cleaned before start-up to avoid debris getting trapped in evaporator and condenser. The best solution is to install wye strainers upstream (before the chiller) on both systems of the unit.

After the systems are filled with water, trapped air should be bled from the various vent valves. Check for proper flow rates by measuring water pressure drop across heat exchangers and reading flow rates from charts, Figure 2.3. Compare measured flow rates with values specified on purchase order. Refer and check Table 2.1. to see if evaporator and condenser flow rates fall between min. and max. limits. CAUTION: WATER QUALITY - WCFX Evaporators used in these packages are made of steel, copper and brass 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 cause reduced performance and even failure of heat exchangers. Therefore, it may be necessary to obtain the services of a water treatment consultant and to provide and maintain water treatment. This is particularly important with glycol solution systems. 2.5 ELECTRICAL WIRING In connecting power wiring to the unit, the following precautions should be taken:

- All field wiring shall be in accordance with the National Electric Code and must comply with state and local codes.

- Check unit wiring for damage and all terminal connections for tightness. Unit terminal blocks are connected with copper conductors only, and are sized according to ampacity listed on unit data plate.

- Connections to unit should match the unit name plate in volts, phase and Hertz. Voltage must not vary beyond ±10% of name plate value and voltage imbalance between phases must not exceed 2% at any time during operation of the unit.

- Phase sequence to connections L1, L2, L3 shall be in that order. Check with Amprobe phase sequence adapter PSA-1 or equivalent.

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2.0 INSTALLATION Table 2.1 Floor Loading Diagram

WCFX-E 10S, 12S, 15S, 18S WCFX-E 108, 113, 118, 123 WCFX-E 20S, 23S, 24S, 27S, 30S, 36S, 41S, 33T, 36T, 41T, 46T, 50T, 54T, 57T, 60T, 73T, 75T, 81T, 69, 73, 77, 81, 84, 87, 90

POINT LOAD DATA

Model WCFX-E

P1 P2 P3 P4 P5 P6 P7 P8 P9 Operating Weight

lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg lbs kg

10S 3262 1480 1369 621 1043 473 1160 526 - - - - - - - - - - 6835 3100 12S 3335 1513 1529 694 1116 506 1283 582 - - - - - - - - - - 7263 3294 15S 3534 1603 1787 810 1264 573 1423 646 - - - - - - - - - - 8008 3632 18S 3840 1742 2159 979 1496 679 1703 772 - - - - - - - - - - 9198 4172 20S 1147 520 1456 660 1041 472 1331 604 934 424 1206 547 828 375 1081 491 - - 9025 4094 23S 1184 537 1547 702 1077 488 1414 642 969 440 1282 581 862 391 1150 521 - - 9485 4302 24S 1350 612 1939 879 1217 552 1766 801 1083 491 1593 722 950 431 1420 644 - - 11317 5133 27S 1399 635 2055 932 1265 574 1873 850 1131 513 1691 767 996 452 1508 684 - - 11918 5406 30S 1521 690 2163 981 1371 622 1970 894 1220 553 1778 807 1069 485 1586 719 - - 12678 5751 33T 1645 746 2297 1042 1555 705 2155 978 1465 664 2014 914 1375 624 1873 850 - - 14378 6522 36S 1546 701 2316 1051 1454 660 2167 983 1363 618 2018 915 1272 577 1868 848 - - 14004 6352 36T 1645 746 2297 1042 1555 705 2155 978 1465 664 2014 914 1375 624 1873 850 - - 14378 6522 41S 1624 736 2449 1111 1527 693 2292 1040 1430 649 2135 968 1334 605 1977 897 - - 14768 6699 41T 1961 889 2319 1052 1857 842 2189 993 1753 795 2059 934 1649 748 1929 875 - - 15718 7129 46T 2232 1012 2839 1288 2133 967 2671 1211 2034 922 2502 1135 1934 877 2334 1059 - - 18678 8472 50T 2332 1058 2945 1336 2224 1009 2770 1256 2117 960 2595 1177 2010 912 2420 1098 - - 19413 8805 54T 2415 1096 3043 1380 2315 1050 2866 1300 2215 1005 2688 1219 2114 959 2510 1139 - - 20167 9147 57T 2526 1146 3130 1420 2431 1102 2958 1342 2335 1059 2786 1264 2240 1016 2613 1185 - - 21019 9534 60T 2691 1221 3453 1566 2600 1180 3262 1480 2509 1138 3071 1393 2418 1097 2880 1306 - - 22886 10381 69 3388 1537 3964 1798 3139 1424 3726 1690 2891 1311 3488 1582 2642 1198 3250 1474 - - 26488 12015 73 3509 1592 4057 1840 3237 1468 3810 1728 2966 1345 3564 1617 2695 1222 3318 1505 - - 27156 12318

73T 3399 1542 4055 1840 2940 1334 3721 1688 2481 1125 3386 1536 2023 917 3051 1384 - - 25055 11365 75T 3484 1580 4173 1893 3019 1369 3831 1738 2554 1158 3488 1582 2089 947 3146 1427 - - 25784 11695 77 3599 1632 4148 1882 3326 1508 3898 1768 3053 1385 3647 1654 2779 1261 3397 1541 - - 27847 12631 81 3759 1705 4430 2009 3489 1583 4165 1889 3218 1460 3900 1769 2948 1337 3635 1649 - - 29544 13401

81T 3808 1727 4890 2218 3322 1507 4500 2041 2837 1287 4109 1864 2351 1066 3719 1687 - - 29537 13398 84 4097 1859 4983 2260 3807 1727 4691 2128 3516 1595 4399 1995 3226 1463 4107 1863 - - 32826 14890 87 4214 1911 5116 2321 3921 1778 4817 2185 3628 1645 4519 2050 3334 1512 4220 1914 - - 33769 15317 90 4250 1928 5130 2327 3972 1802 4834 2193 3694 1676 4539 2059 3416 1550 4244 1925 - - 34080 15459

108 4182 1897 4476 2030 4337 1967 4769 2163 4260 1932 4623 2097 4313 1956 4536 2057 4425 2007 39922 18108 113 4261 1933 4577 2076 4446 2017 4892 2219 4354 1975 4735 2148 4402 1997 4651 2110 4527 2053 40844 18526 118 4549 2063 4958 2249 4764 2161 5314 2410 4657 2112 5136 2330 4735 2148 5020 2277 4878 2212 44010 19963 123 4718 2140 5148 2335 4912 2228 5502 2496 4816 2184 5326 2416 4914 2229 5189 2354 5051 2291 45576 20673

Notes: 1.) Refer to dimensional drawings for location of mounting points. 2.) Unit must be lowered onto mounting springs in a level fashion or spring damage may occur. 3.) Data for Superior models. Consult factory for Standard and Premium model point load data.

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20S 23S 18S 27S 30S 41S

10S12S15S24S

33T36T41T46T50T54T57T60T

73T 75T 81T

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18S 27S 30S 36S 41S

12S10S20S23S24S15S

36S

33T36T41T46T 50T

54T 57T 60T 73T 75T 81T

2.0 INSTALLATION Figure 2.4 Water Pressure Drop IMPERIAL UNITS

1A.) Evaporator 1 Pass a.) Single Compressor

b.) Twin Compressors

c.) Three Compressors

1B.) Evaporator 2 Pass a.) Single Compressor



Note : Above water pressure drop is for Superior model. Consult factory for Standard and Premium model.

6977817384

87,90108, 113118 123

6973778184

87, 90108, 113118 123

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gWATER FLOW RATE - USgpm

WATER PRESSURE DROP IMPERIAL UNITS

1C.) Evaporator - 3 Pass a.) Single Compressor



2A.) Condenser - 1 Pass a.) Single Compressor




27S 30S 18S 36S 41S

10S12S20S23S15S24S

54T 57T 60T 73T 75T 81T

33T36T41T46T50T

6973778184

87,90 108, 113 118 123

24S 18S 27S 30S 36S 41S

10S12S15S20S23S

33T36T41T46T50T54T57T60T

73T 75T 81T

6973778481

87,90 108 113 118 123

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WATER PRESSURE DROP IMPERIAL UNITS

2B.) Condenser 2 Pass a.) Single Compressor



2C.) Condenser 3 Pass a.) Single Compressor




24S 27S 30S 36S 41S

10S12S15S20S23S18S

33T36T41T46T

50T54T60T57T73T75T81T

69778184

87, 90108113118123

24S 18S 27S 30S 36S 41S

10S12S20S15S23S

54T 57T 60T 73T 75T 81T

33T36T41T46T50T

6973778184

87,90108 113 118 123

73

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18S 27S 30S 36S 41S

12S10S20S23S24S15S

33T36T41T46T50T54T

57T 60T 73T 75T 81T

23S 24S 18 27S 30S 41S

10S12S20S15S

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36S

33T36T41T46T 50T

54T 57T 60T 73T 75T 81T

WATER PRESSURE DROP SI Units

1A.) Evaporator 1 Pass a.) Single Compressor



1B.) Evaporator 2 Pass a.) Single Compressor




6977817384

87,90 108,113 118 123

6973778184

87,90 108,113 118 123

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WATER PRESSURE DROP SI Units

1C.) Evaporator - 3 Pass a.) Single Compressor



2A.) Condenser - 1 Pass a.) Single Compressor




27S30S18S36S41S

10S12S20S23S15S24S

54T 57T 60T 73T 75T 81T

33T36T41T46T50T

6973778184

87,90 108,113 118 123

18S 27S 30S 36S 41S

10S12S15S20S23S24S

33T36T41T46T50T54T57T

60T 73T 75T 81T

6973778184

87,90108 113 118 123

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WATER PRESSURE DROP SI Units 2B.) Condenser 2 Pass a.) Single Compressor

b.) Twin Compressors c.) Three Compressors

2C.) Condenser 3 Pass a.) Single Compressor




24S 27S 30S 36S 41S

10S12S15S20S23S18S

33T36T41T46T

50T54T60T57T73T75T81T

69778184

87,90 108113118123

24S18S 27S 30S 36S 41S

10S12S20S15S23S

54T57T60T73T75T81T

33T36T41T46T50T

6973778184

87,90108 113 118 123

73

- 22 -

2.0 INSTALLATION 2.6 CONTROLS

2.6.1 CONNECTIONS Controls, which are to be field installed, should be connected in accordance with the appropriate wiring diagram accompanying the unit. The following connections should be made where applicable: 2.6.1.1 Connect a set of normally open

auxiliary contacts from chilled water pump contactor into unit controls as shown on unit wiring diagram.

2.6.1.2 Install a chilled water flow switch (paddle type recommended) in straight length of chilled water piping to avoid turbulence. Connect in same electrical circuit as 2.6.1.1.

2.6.1.3 For control of condensing water pumps, connect contacts supplied in unit in series with condensing water pump starter coil.

2.6.1.4 Connect an enable/disable contact into the unit controls as shown on the wiring diagram. Closure of this contact enables the unit to operate.

2.6.2 SETTINGS

All controls are factory set however operating control settings are not always applicable under all operating conditions. For recommended control settings, see wiring diagram accompanying unit. Safety controls must be set in accordance with factory recommendations.

2.7 REQUEST FOR START-UP

REPRESENTATIVE After completion of installation and system checking, contact Dunham-Bush Industries Service Department to an engage the services of authorized start-up representative to perform the first (1st) initial start-up of the Dunham-Bush chiller. Start-up should be performed in the presences of service and operational representative from the end user side, representative are encourage to participate and assist in the work to get acquainted with the new equipment. Subsequently Dunham-Bush’s representative will be sent to the installation site to carry out a final inspection on the installation work to determine if Dunham-Bush Industries requirements are met. Perform an equipment pre-handover start-up; review and check required operation condition and parameters. Provide guidance to the specified customer personnel in its operation and basic maintenance procedure for the length of time indicated in the purchase contract (If any). For extensive equipment training is required please contact Dunham-Bush Sales and Service department for arrangements

NOTE: Sump oil heaters should be energized for a minimum of 24 hours and the oil sump temperature must be at a minimum of 100°F [38°C] prior to arrival of start-up

representative. This will ensure that the oil is warm enough to vaporize any dissolved refrigerant and that the oil is within the normal operating temperature range. Sump oil heaters are energized simply by turning on the control power switch.

WARNING: Initial compressor(s) start-up should ONLY be carried out under the direct supervision of an Authorized Dunham-Bush Industries Start-Up Representative.

2.8 SOUND Other consideration to be made when installing the chiller is the location of the chiller. Chiller should not be located near noise sensitive areas. Adequate support / precaution should be put into place to avoid vibration and noise transmission into the building. Sound and Structural consultants should be consulted for critical installations Table 2.8 Sound Pressure Data

ModelWCFX-E

Octave Band (Hz) Total dB (A) 63 125 250 500 1000 2000 4000 8000

10S 71 55 59 67 75 72 62 53 78 12S 71 56 60 67 75 72 62 53 78 15S 72 57 61 69 77 74 64 55 82 18S 72 57 61 69 77 74 64 55 83 20S 71 59 63 71 79 76 66 57 82 23S 71 59 63 71 79 76 66 57 82 24S 72 60 63 72 79 76 66 57 83 27S 72 60 63 72 79 76 66 57 83 30S 72 60 63 72 79 76 66 57 83 33T 74 61 65 73 81 78 68 59 84 36S 72 57 61 69 77 74 64 55 83 36T 74 61 65 73 81 78 68 59 85 41S 72 57 61 69 77 74 64 55 83 41T 74 61 65 73 81 78 68 59 85 46T 73 61 65 73 81 78 68 59 84 50T 73 61 65 73 81 78 68 59 84 54T 73 61 65 73 81 78 68 59 84 57T 74 61 65 73 81 78 68 59 85 60T 74 61 65 73 81 78 68 59 85 69 75 63 67 75 83 80 70 61 86 73 75 63 67 75 83 80 70 61 86

73T 75 63 67 75 83 80 70 61 86 75T 75 63 67 75 83 80 70 61 86 77 75 63 67 75 83 80 70 61 86 81 75 63 67 75 83 80 70 61 86

81T 75 63 67 75 83 80 70 61 86 84 75 63 67 75 83 80 70 61 86 87 75 63 67 75 83 80 70 61 86 90 75 63 67 75 83 80 70 61 86 108 76 64 68 76 84 81 71 62 87 113 76 64 68 76 84 81 71 62 87 118 76 64 68 76 84 81 71 62 87 123 76 64 68 76 84 81 71 62 87

Note: Sound Pressure Level dB(A) @ 3.3ft [1m] (free field) ± 2dBA.

2.9 WARNING LABEL Electric shock Hot surface Wear ear protective device Do not step

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3.0 OPERATION 3.1 SYSTEM WATER FLOW RATE The volume of chilled water being circulated can be measured quite accurately (±5%) by determining the water pressure drop through the evaporator and reading flow rates from evaporator pressure drop curve, Figures 2.3. Connect reliable pressure gauges to valves installed in evaporator entering and leaving water vent connections and read pressure difference with chilled water pump in operation. Condenser water flow rate can be measured in the same way. An alternate method of determining flow rates is to measure pressure difference from pump inlet to outlet, and read flow rates from the pump curve. 3.2 SEASONAL SHUT-DOWN

PROCEDURE 3.2.1 If the unit is to be shut down for a prolonged

period (a month or more), the power supply to the unit may be de-energized to conserve energy.

3.2.2 The cooling tower may be drained to avoid freezing. If the unit is located in an area where the ambient temperature constantly remains above freezing, the condenser need not be drained. It is better to leave the condenser and evaporator filled with water during a shutdown period. If the unit is located where ambient temperature will be below freezing, drain all water thoroughly and remove all vent and drain plugs from both headers of each vessel. Blow out tubes with compressed air.

NOTE: Simply draining is not sufficient. Stagnant water may cause serious corrosion.

3.2.3 It is recommended to that an oil sample is taken from each compressor and submitted for laboratory analysis during the seasonal shut-down to check for moisture level and impurities. Dunham-Bush offers this service in its Oil Kare Program. Oil analysis should be done at the beginning and end of each operating season, or every six months if the unit is used year round.

Important: Discontinue chilled water pump operation when unit is not operational.

3.3 SEASONAL START-UP

PROCEDURE When the unit is to be started up after being shut down for a prolonged period:

3.3.1 Check unit for evidence of rust or corrosion. Clean surfaces and repaint as necessary. Repair insulation if necessary.

3.3.2 Clean waterside heat transfer surface of condenser and evaporator by removing headers and brushing tubes.

3.3.3 Check water circuits to see if cooling tower is ready for operation, and both circuits are filled with water remove airlocks (if any). Start pumps and check for flow in both evaporator and condenser.

3.3.4 Energize compressor oil sump heater for at least 24 hours prior to compressor start-up, oil sump temperature must be at a minimum of 100°F [38°C]. Turn on control circuit power switches, turn on compressor switch, and press on computer keyboard. Compressor should start after start-up clock time count down 3.3.5 Have a trained service mechanic check the function of all control setpoints. Check signal lights for proper operation.

3.3.7 Take oil sample from each compressor and submit it for laboratory analysis.

3.4 REFRIGERATION CYCLE Refer to Figure 3.4 Typical Piping Schematic for:

1 compressor - WCFX 10S, 12S, 15S, 18S, 20S, 23S, 24S, 27S, 30S.

2 compressors - WCFX 33T, 36T, 41T, 46T, 50T, 54T, 57T, 60T.

3 compressors - WCFX 69, 73, 77, 81, 84, 87, 90. 108, 113, 118, 123

Dual condition units have same cycle as standard units.

Each vertical screw compressor discharges hot and high pressure gas through a discharge service valve (or check valve in multiple compressor units) into the condenser, where it condenses by rejecting heat to water inside the tubes. The liquid refrigerant drains to the bottom of the condenser and exits from the bottom side, then the liquid line separate to two lines, one line refrigerant feed TXV before economizer, absorb heat from the other line refrigerant inside economizer which is at an intermediate pressure between condenser and evaporator, and turn to gas back to compressor vapor injection port, the other line refrigerant get some subcooling and drain to ball valve before evaporator. Ball valve is actuated by a motor that adjusts flow to maintain an appropriate refrigerant level in the evaporator, which is determined by a liquid level float switch. liquid refrigerant flows into the flooded evaporator, where it boils, by absorbing heat from the water flowing inside evaporator tubes. Vapor from the boiling refrigerant flows up the suction pipes through a shut-off valve (optional), suction check valve and suction filter (inside compressor) into the compressor where it is compressed and starts the cycle again.

Economizer return vapor will feeds it into the compressor part way through the compression process. Check valve prevents backflow at shutdown in multi- compressor units. All compressors operate in parallel on a common evaporator and condenser.

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3.0 OPERATION Figure 3.4 Typical Piping Schematic 1.) 1 Compressor - WCFX 10S, 12S, 15S, 18S, 20S, 23S, 24S, 27S, 30S

- 25 -

3.0 OPERATION 2.) 2 Compressors - WCFX 33T, 36T, 41T, 46T, 50T, 54T, 57T, 60T

- 26 -

3.0 OPERATION 3.) 3 Compressors - 69, 73, 77, 81, 84, 87, 90, 108, 113, 118, 123

- 27 -

3.0 OPERATION 4.) PIPING SCHEMATIC DATA

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3.0 OPERATION 3.5 OIL MANAGEMENT SYSTEMS

(See Figure 3.5.) The compressor is oil lubricated and discharges a small amount of oil mist along with refrigerant. This oil is carried into the evaporator. Oil rich refrigerant is returned from the evaporator through a tap in the shell, oil return valve, filter drier, angle valve, sight glass and into jet pump installed on the suction line. The jet pump is powered by high pressure gas from the compressor discharge line through hot gas feed valve. This forces the oil rich mixture from the evaporator through oil return valve into the suction line where it is carried into the compressor.

The hot gas valve should be opened enough only to allow good oil return when the unit is fully unloaded. (1/8 to 1/2 turn). Excessive oil return will lower discharge superheat un-desirably. The oil return valve should be left wide open. In normal operation, no oil level will be visible in the compressor sight glass. 3.6 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. Check to be sure compressor is not running backwards.

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

3. Stage unit down until all compressors are off and check the compressor crankcase sight glass for oil level. It should be 1/2 to 3/4 of the compressor sight glass.

4. The electrical control settings should be checked and if necessary, reset to those settings indicated on the wiring diagram. Safety controls are factory set and must be maintained at settings indicated on the wiring diagram.

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

3.7 SYSTEM STANDSTILL

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

Under steady-state operating conditions, check refrigerant piping or capillary tubes for abnormal vibrations.

After 2-5 hours of operations under established conditions, check the oil level and add oil if necessary. If oil return continues to perform poorly, further investigation of the piping design is required.

When necessary, refrigerant can added in the liquid phase, carefully throttling the refrigerant on the low-

pressure side and as far as possible from the compressor.

Important: Do not overcharge the system. Note: Observe any abnormal running noise;

ensure the absence of any liquid flood-back to the compressor by measuring the return gas superheat and compressor sump temperature.

3.8 SHUT-DOWN (Overnight or

Weekend) To shut down in the unit with compressors on or off, turn each individual compressor switch. Do not close any valve. The chilled water pump shall then be turned off. Finally, do not open the main unit disconnect. Main power is required to keep the sump heaters.

Important: Discontinue chilled water pump operation when unit is not operational.

Note: For chillers operating in low ambient, if it is

possible that the overnight ambient will drop below 45°F [7.2°C], it is preferable to leave the chilled water pump on.

3.9 SAFETY RELIEF VALVES Each pressure vessel is protected by a safety relief valve as required by ASME Code. Each compressor is protected by a relief valve which is vented to atmosphere. Never install any kind of shut-off valve in a safety relief vent line.

Local codes may require that all safety relief valves be piped to the outdoors. 3.10 PIPING JOINTS Joints shall be designed so that they will not be damaged due to the freezing of water on the outside. They shall be suitable for the pipe, the piping material and the pressure, temperature and fluid. Coated (e.g. galvanized) pipes shall not be welded, unless all coating has been completely removed from the joint area. Welded joints shall be suitably protected.

The piping material is copper. The joint material is silver alloy (argentum, copper, cadmium and zinc). The welding joint is used at evaporator steel pipe. Not for piping. The welding joint is protected well with epoxy paint.

In general, detachable joints shall only be used where permanent joints for technical reasons are not appropriate. The detachable joints are included Flanged joint, Flared joints, Taper pipe threads and Compression joints.

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3.0 OPERATION 3.11 ANTI-FREEZE PROTECTION 3.11.1 DESUPERHEATERS

A hot gas desuperheater can be factory supplied for field installation. Tees in refrigerant lines with shut off valves can be supplied. Consult factory for further details.

3.11.2 WATER CIRCUIT

Constant water flow required with a minimum of 3 gallons per ton (3.3 liters/ kWo) increasing up to 10 gallons (11 lifers) for process, low load applications with small temperature ranges and/or vastly fluctuating load conditions.

3.11.3 GLYCOL FREEZE PROTECTION

If the chiller or fluid piping may be exposed to temperatures below freezing, glycol protection is recommended. The re-commended protection is 10°F [5.6°C] below the minimum ambient temperature. Use only glycol solutions approved for heat exchanger duty. The use of automotive anti-freeze is not recommended because they have short-lived inhibitors and fouling of the vessels will occur. If the equipment is exposed to freezing temperature and not being used, the vessels and piping should be drained.

If the equipment is being used for operating conditions below 42°F [5.5°C] with standard vessels or below 40°F [4.4°C] with optional 40°F [4.4°C] vessels, glycol should be used to prevent freeze damage. The freeze protection level should be 10°F [5.6°C] lower than the leaving brine temperature. The use of glycol causes a performance aerate as shown in table for ethylene glycol and table for propylene glycol and needs to be included in the unit selection procedure.

Ethylene Glycol

% E. G. By

Weight

Freeze Point C1 Capacity

Factor

K1 kW

Rate

G1 Flow

Factor

P1 P.D.

Factor °F °C

10 26.2 -3.2 0.995 0.998 1.019 1.050

15 22.4 -5.3 0.991 0.997 1.030 1.083

20 17.8 -7.9 0.988 0.996 1.044 1.121

25 12.6 -10.8 0.984 0.995 1.060 1.170

30 6.7 -14.1 0.981 0.994 1.077 1.219

35 0.0 -17.8 0.977 0.992 1.097 1.275

40 -10.0 -23.3 0.973 0.991 1.116 1.331

45 -17.5 -27.5 0.968 0.990 1.138 1.398

50 -28.9 -33.8 0.964 0.989 1.161 1.466

Propylene Glycol

% P. G.By

Weight

Freeze Point C2 Capacity

Factor

K2 kW

Rate

G2 Flow

Factor

P2 P.D.

Factor °F °C

10 26.1 -3.3 0.988 0.994 1.005 1.019

15 22.8 -5.1 0.984 0.992 1.008 1.031

20 19.1 -7.2 0.978 0.990 1.010 1.051

25 14.5 -9.7 0.970 0.988 1.015 1.081

30 8.9 -12.8 0.962 0.986 1.021 1.120

Evaporator Fouling Factor

Fouling Factor Capacity Correction

Factor

kW Correction

Factor hr.ft².°F/BTU m².°C/kW

0.00010 0.018 1.000 1.000

0.00025 0.044 0.992 0.998

0.00050 0.088 0.979 0.995

0.00075 0.132 0.967 0.991

0.00100 0.176 0.955 0.987

Condenser Fouling Factor

Fouling Factor Capacity Correction

Factor

kW Correction

Factor hr.ft².°F/BTU m².°C/kW

0.00025 0.044 1.000 1.000

0.00050 0.088 0.992 1.018

0.00075 0.132 0.983 1.036

0.00100 0.176 0.973 1.054

IMPORTANT:

Depending on the climatic conditions, add glycol with an adequate concentration as shown in table for ethylene glycol and table for propylene glycol to protect the chiller or the water piping at the installation site.

If the system will not be used during the freezing weather conditions and is not protected by an antifreeze solution, draining of the evaporator and outdoor piping is mandatory.

In cases where it is not possible to apply the recommendations in above paragraph, the circulating pump with immersion heater is another optional item to protect the evaporator against frost.

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3.0 OPERATION 3.12 HYDRAULIC CAPACITY

CONTROL SYSTEM (See Figure 3.12.)

Each compressor has a hydraulic control system to position the capacity control slide valve, in order to regulate compressor capacity. It is composed of a normally closed solenoid valve, a normally open solenoid valve and internal pressure regulating valve.

With valves A and B both energized (A open, B closed) during normal compressor operation, high pressure oil is directed to the slide valve. The pressure acting on the surface of the slide valve piston creates a force which is sufficient to overcome the opposing spring force and to move the valve in the direction of increasing capacity. When the compressor is given a "hold" command, valve A is de-energized (closed) and slide valve movement is halted. The internal pressure regulating valve allows oil to bleed from the slide valve chamber during the hold condition. If valve B is then de-energized (open), the high pressure oil acting on the slide valve will be vented to suction, and the pressure in the slide valve chamber will be reduced. The slide valve spring will now move the piston back toward the minimum capacity position.

Under standard conditions, the compressor will load in 60 seconds and unload in 55 seconds. Figure 3.12 Hydraulic Control System

SLIDE VALVE POSITION

UNLOADING LOADING HOLD

SOLENOID VALVE A (NORMALLY CLOSED)

CLOSED (DE-ENERGIZED)

OPEN (ENERGIZED)

CLOSED (DE-ENERGIZED)

SOLENOID VALVE B (NORMALLY OPEN)

OPEN (DE-ENERGIZED)

CLOSED (ENERGIZED)

CLOSED (ENERGIZED)

3.13 FREEZE PREVENTION If water (or brine) is allowed to freeze within the tubes and headers of the evaporator or condenser, severe damage will result; e.g. split and leaking tubes and cracked and leaking headers. Since this damage can be extremely costly and is not covered by warranty, it is important to be mindful of freeze prevention. Three cases deserve particular attention: 3.13.1 STANDBY AT LOW AMBIENT

TEMPERATURES If the unit is to stand idle at ambient temperatures below 32°F [0°C], the water should be drained from evaporator and condenser. A header should be removed from each vessel and the tubes should be blown dry with compressed air. Gravity draining the vessel through drains in headers may not be sufficient. If evaporator or condenser is served with a glycol solution, make sure the freeze temperature of the solution is lower than the expected minimum ambient temperature.

3.13.2 IN OPERATION Freezing of water in evaporator tubes is a possibility if chilled water flow stops and if the low suction pressure cutout (normally set for 28 psig [1.9BAR], or 32°F [0°C] saturation) and the low water temperature cutout both fail. If the chilled water flow switch and pump interlock are properly applied (See 2.6.1.1 and 2.6.1.2) the unit has four protective devices which must all fail in order to freeze the evaporator in operation. While this is unlikely, it is important to see that all these devices are functional and properly calibrated.

3.13.3 DURING MAINTENANCE In transferring refrigerant within the unit, or removing refrigerant from the unit for maintenance purposes, it is possible to freeze evaporator or condenser tubes. Remember that

Documents

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