Screw Type Air-Cooled Packaged Chillers ACWC - Dunham

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ACWC-SD
Screw Type
Air-Cooled Packaged Chillers
Installation, Operation, and
Maintenance Manual
TABLE OF CONTENTS
DESCRIPTION
Inspection & Handling
PAGE NO.
2
Location and Mounting
Wiring
Chiller Piping
Start-Up
Maintenance
Slide Valve Unloading System
Low Ambient Operation
Control Settings
Unit Operating Limitations
Sequence of Operation
Safety Controls, Field Wiring, Star Delta Start
Control Wiring Diagrams
ACWC 40 thru 70
ACWC 90 thru 135
ACWC 145 thru 200
ACWC 215 thru 265
Power Wiring Diagrams
ACWC 40 thru 70
ACWC 90 thru 135
ACWC 145 thru 200
ACWC 215 thru 265
Electrical Data
Cooler Pressure Drops
Unit Loading/Suspension Points
Troubleshooting Guide
Causes & Prevention of Freeze-Up
Start-up Check List
Operating Data
Maintenance
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Form No. 6184
2
2
2
2&3
3
4
5
5
5
6 & 7
7
8 & 9
10 & 11
12 & 13
14 & 15
16
16
17
17
18 & 19
20
21
22
22
23
24
24
DUNHAM-BUSH
USA
INSPECTION & HANDLING
CHILLER PIPING
When unit is received, it is the responsibility of the contractor to inspect
the unit for shipping damage at time of off loading and make note of
damage on carrier's freight bill.
The chiller inlet (return) water pipe should be connected to the water
connection closest to the control panel end of the unit and the outlet
(supply) water pipe connected to the water connection on the opposite
end of the cooler(s).
ACWC units are factory mounted on (2) carbon steel angle beams.
Sizes 45 thru 90 have three lifting holes per side. Sizes 110 thru 215
have four lifting holes per side and sizes 240 thru 265 have five lifting
holes per side to facilitate lifting.
Spreader bars must be used between rigging lines to prevent damage
to the unit. Rollers may be used under the skids to facilitate moving
the unit a short distance.
Models ACWC-40DF thru 22DC are factory mounted on two permanent
angle beam, carbon steel skids. A minimum of four 2 7/8" lifting eyes
are provided in the skids to allow rigging. Physical damage to the unit,
after acceptance, is not the responsibility of the factory.
LOCATION & MOUNTING
Model ACWC Air Cooled Packaged Water Chillers are designed for
outdoor application and may be mounted on roof or at ground level.
Air lIow through the condenser is vertical and the unit may be located
adjacent to outside of building or on roof without regard for prevailing
wind direction.
Since these units are air cooled, the flow of air to and from the
condenser coil must not be impeded. There must be no obstruction
above the unit that would tend to dellect discharge air downward where
it could be recirculated back to the inlet of the unit. The required
overhead air space should be a minimum of eight feet. Ductwork must
not be applied to the fan outlets.
A flow switch must be installed in a straight horizontal section of the
chilled water piping. This is to be field installed.
Gauges should be installed in the piping to and from the chiller to
measure the pressure drop and to insure the proper (GPM) flow rate
in accordance with submittal data. A strainer should be installed in the
piping on the inlet side of the chiller and vibration eliminators should
be employed on both the inlet and outlet pipes. Air vents should be
located at all high points in the piping system. Vents should be located
to be accessible to servicing. Drain connections should be provided
at all low points to permit complete drainage of chiller and piping
system.
The chilled water piping should be insulated to reduce heat pickup
and to prevent condensation. If the system is for year-round operation
or if it will not be drained in the winter, the chilled water piping should
be protected against freezing by electric heating cable or other suitable
means.
Upon completion of chiller piping, start the system water pump and
purge air from the system. Air purging should be done from the high
points in the water circuit. Purging of the chiller barrel may be
accomplished through the vent pipe located on the top of the chiller
compartment Failure to purge air from the water circuit will result in
inadequate water flow and may cause the unit to cutout.
START·UP
Refer to start, test, and check list included with this manual.
The unit must be installed with sufficient clearance for air entrance to
the condenser coil and for servicing access. The unit should be located
no closer than four feet from any wall or other obstruction. Clearance
must be provided at either end of the unit to permit removal of tubes
from the chiller.
Unit must be set on a solid and level foundation.
On roof installations the unit should be mounted on support beams
which span load-bearing walls to prevent excessive vibration.
On ground level installations, the unit should be mounted on a
substantial base that will not settle. A one-piece concrete slab with
footings extended below the frost line is recommended. A space should
be left between the slab and the building to prevent the transmission
of sound and vibration.
Vibration mounts may be used for roof-mounted units or other locations
where noise might be objectionable.
WIRING
A unit wiring diagram showing the required power supply characteristics
and all factory supplied wiring details are provided with unit. Separate,
field supplied, disconnects must be installed for the power and control
circuits and should be within the sight of the unit.
Separate 115-volt power source must be field supplied to provide power
for control and heater circuits if optional control circuit transformer is
not provided. All electrical connections should be periodically tightened.
2
CAUTION:
The discharge line valve must be open before starting the compressor.
Liquid line valves must also be open for sustained operation.
3. COMPRESSOR REPAIRS (internal) - Contact factory or an
authorized DB Service Agency if a compressor malfunction is
suspected.
4. COMPRESSOR REPAIRS (External) - Proper operation of
All compressors are solid mounted on isopads, therefore, compressor
hold-down bolts must not be loosened. Loosening these bolts will cause
excessive vibration of the compressor and may result in refrigerant
line breakage. Prior to start-up check all compressor hold-down bolts
for tightness.
unloaded ban, loading, and unloading is controlled by solenoid
valves UL-1, UL-2 and UL-3. Any of these three (3) solenoid valves
may be repaired or replaced in the field, as required.
5. Standard oil acid test kit is not compatible with synthetic oil. See
DB color chart for oil condition.
MAINTENANCE
CONDENSER
Units are equipped with direct drive fans that have inherently protected
motors with permanently lubricated bearings.
HIGHPRESSURE
PORT
The air inlet of the condenser coil should be kept clean through a
regular maintenance program.
COMPRESSOR
1.
2.
OIL LEVEL - The oil level in the compressor(s) should be checked
periodically, with the compressor either running or stopped. If
the oil level is below one-half (1/2) the sight glass, oil must be
added.
I
SIGHT GLASS
CRANKCASE HEATER
RECOMMENDED OIL -- The unit 4 factory-charged with DB
SR-30 refrigeration 01.
Do not add any other type of oil to this factory charge.
Do not operate compressor If 011 level Is below one-half (1/2)
sight glass.
If the oil level is below the minimum specified above, and DB
SR-30 is not on hand, you may drain the entire factory oil
charge, then refill with SUNISO 4GS refrigeration oil. The factory
(DB) oil is of the synthetic type and will not mix with SUNISO
4GS. Do not attempt to operate the screw compressor with any
oil other than these two specified above.
It is suggested that a gallon or mom of DB SR-30 oil be obtained
and kept on hand at the job site. The substitution of SUNISO
4GS oil, as outlined above, will result in a 2% to 491 capacity
loss, and no reduction in input K.W.
PROCEDURE FOR ADDING OIL
Install temporary jumper wire around L.P.control contacts of circuit
to be serviced. Manually close liquid line service valve. Lower
return water T-STAT (T1) setting to start compressor. Run
compressor until minimum positive pressure reading on suction
service gauge. (Do not run compressor in vacuum!) Place the
system on/off switch in the off position. Close the line valve in
the discharge line between compressor & condenser. Equalized
pressure should now be a minimum of refrigerant vapor. Reopen
discharge line valve. Remove jumper wire from pressure control.
Open liquid line service valve.
3
SLIDE VALVE
UNLOADING SYSTEM
The Rotary screw compressor capacity control system for infinite
modulation consists of a slide valve and hydraulic piston/cylinder
operator intemal to the compressor; plus three hydraulic solenoid
valves (UL-1, UL-2 & UL-3).
pressure) line. The slide valve will move to the right (unloading)
whenever UL-2 opens the oil supply (high pressure) line, since the
force of the oil exceeds that of the discharge gas.
The temperature controller sends a series of power (energizing)
"pulses" to the appropriate solenoid to adjust to load conditions. The
further the supply water temperature is from the controller set point,
the longer is the duration of the pulses. The series of pulses will
continue until the controller is satisfied. As the water temperature
approaches the set point, the pulses become quite brief to prevent
overshooting the set point.
The slide valve forms a portion of the chamber wall in which the rotors
turn; thus, its position with respect to the rotors determines the effective
rotor length and thereby the percent of full load capacity.
Upon compressor start-up, UL-3 is opened. This allows oil pressure
to act upon the hydraulic piston, holding it in the fully unloaded position.
After 30 seconds, during which time full oil flow is established to all
bearings surfaces, UL-3 is closed. At this point the temperature
controller is free to open and close UL-1 or UL-2 in response to the
supply water temperature.
This method of compressor unloading in conjunction with supply water
sensing minimizes action/reaction lag time and overshoot resulting in
an exceptionally precise and stable control of supply water temperature.
The slide valve will move to the left (loading) by force of discharge
pressure, whenever UL-1 opens to permit flow to the oil return (low
Hydraulic Piston
Load
Unload
~
¢::J
Oil Pressure
Slide Valve
Oil Pressure Lines
Screw Rotor
Oil
Return
Oil
Supply
The following table lists solenoid valve position for all three operating modes.
Starting
Loadinq
Unloading
4
UL-1
Close
Open
Close
UL-2
Close
Close
Open
UL-3
Open
Close
Close
LOW AMBIENT OPERATION
Due to the wide range of applications, it is sometimes necessary to
operate the Air Cooled Packaged Water Chillers at ambients below
summer conditions. Without proper control, when ambients drop below
60°F. the pressure differential between the condenser and the
evaporator is below the level to insure proper thermal expansion valve
operation. As a result, the unit may cycle off. Two types of system
control are available allowing the units to operate at the ambients
indicated:
COOLER FREEZE PROTECTION-LOW AMBIENT
Cooler freeze protection is a major concern with air cooled chillers. To
protect against freeze-up, a heater cable is provided as standard,
which protects the cooler to -12°F. However, there is no freeze
protection in the event of power failure or heater cable burnout, so the
following should be considered for additional protection:
1. Drain the cooler and chilled water piping if the chiller is not to be
operated over the winter months. Drain connections are provided
on the coolers.
FAN CYCLING
MEDIUM AMBIENT CONTROL TO 30°F.
(STANDARD EQUIPMENT-FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water
Chillers to provide proper operating head pressures, in ambient
conditions to 30°F.
This is an automatic operation in which the condenser fans are cycled
on and off, as required, in response to head pressure. This arrangement
provides positive start-up control down to +30°F by delaying the
condenser fan operation until a predetermined head pressure is
obtained.
2. Add ethylene glycol to the chilled water system. Freeze point should
be approximately 10°F.below minimum design ambient temperature.
See Page 11 for Glycol Performance.
The cooler heater is wired to the control panel and is operational
from the factory offered control transformer or field supplied control
power.
COOLER FREEZE PROTECTION-oPERATION
The ACWC-SD chiller is provided with a temperature sensing freezstat
(38° set point) and a field installed flow switch, shutting off the
compressors on loss of water flow, is also required.
LOW AMBIENT CONTROL TO O°F.
In conjunction with the standard fan cycling feature, all compressors
are enclosed in individual housings. This housing assures adequate
compressor oil temperature for lubrication. A five minute time delay
relay provides a bypass around the low pressure control to prevent
nuisance trip-out during cold start up.
Optional low pressure or hot gas bypass freeze protection is also
available on the ACWC-SD. If these options have not been
purchased it is extremely important to guarantee proper chiller
water gpm as well as double checking the temperature sensing
freezstat calibration.
ACWC-SD
CONTROL SETTINGS
CUT-IN/CUT-OUT (PSIG)
UNIT
FLP1
44-55
70
280/170
260/160
90
110-135
260/160
145-160
185-200
215
260/160
280/170
280/170
240
260/160
260/160
265
260/160
FLP2
295/180
FLP3
275/175
275/175
2751175
2951180
295/180
275/175
260/160
260/160
2901215
FLP4
FLP5
FLP6
FLP7
FLP8
FLP9
FLP10
FLP11
FLP12
FLP13
2901215 260/160 275/175 2901215
2851210 2951235 2601160 275/175 285/210 2951235
260/160 275/175 2901215 260/160 275/175 2901215
260/160 275/175 2951235 2951235 260/160 275/175 285/210 2951235
2901215 260/160 2901215 2901215 260/160 275/175 290/215 260/160 275/175 290/215
275/175 275/175 2901215 2901215 260/160 260/160 275/175 275/175 2851210 2851210 295/235
275/175 275/175 2851210 2851210 295/235 2951235 260/160 260/160 275/175 275/175 285/210
TEMPERATURE ACTUATED
LEGEND
Chiller Low Water Temperature Thermostat
Chiller Heater Thermostat
I(Non-Adiustable)
Oil Temperature Safety Control
(Adjustable)
Manual Reset
Capacity Control Thermostat (Adj.) Mode Control Position
T2
Included With
CBH1 Heater
OTS 1
OTS 2
OTS3
T1
FLP14
ISM
2951235
2851210 2951235
FACTORY SETTING
Cut-Out
Cut-In
Cut-Out
3rF
40°F
45°F
Cut-Out
240°F
Dial Set At
44°F
UNIT OPERATING LIMITATIONS
1.
2.
3.
4.
Maximum ambient air to condenser is 110°F. (60 Hertz operation)
Maximum allowable cooler water pressure is 150 PSIG.
Maximum allowable water temperature to cooler is 75°F.
Units must not have leaving water temperatures of 42°F or lower unless used with a glycol solution.
5
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit
theory. The following key shows how the indexing system can be used.
12
Line number on wiring diagram
[12]
Line number in text
(R5)
Component identification symbol in text (Relay #5)
[E]
[E]
Normally open contact - line number location
Normally closed contact - line number location
@
Holding coil - line number location
.&
Note number
SEQUENCE OF OPERATION (TYPICAL)
MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models.
Refer to the wiring diagram furnished with the unit for specific
information.
(
) Control Identification Symbol
[
]
Circuit Line Number
Important Notel
With all the control circuit switches (SW1-SW3) in the "off' position
and the staging thermostat (T1) to its highest temperature, Terminals
#2 and #4 on the Terminal Board (TER5) must have 115 volts sup­
plied for a minimum of 24 hours to energize the compressor crank­
case heaters (CCH1, 2) [6, 8].
Preliminary Sequence
Close the main power disconnect switch. Check to see that the red
indicating light on the phase loss monitor (PLM 1) is lit. (Note: There
will be two phase loss monitors, (PLM1) and (PLM2) on dual power
block models.) This light must be on to indicate proper phase rotation
for the compressors. If the light is not on, disconnect the main power
and reverse any two phase legs at the Main Incoming Power Terminal
Block. (WARNING! DO NOT REVERSE THE LEADS ON THE PHASE
LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS
TO RUN BACKWARDS, CAUSING SEVERE DAMAGE, AND WILL
VOID THE COMPRESSOR WARRANTY!)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed
and are supplying power to the compressor crankcase heaters. Power
is also supplied to the chiller barrel heater (CBH1) [13). the optional
receiver heaters (RH1, 2 [10,11] and the optional convenience outlet
(CO) [14].
Control power goes through the control panel circuit breaker (CB1) [8]
and field supplied remote time clock [36]. Check to make sure time
clock contacts close during occupied modes.
Start up the chilled water pump. The water flow is confirmed when the
water flow switch completes the electrical circuit across Terminals
#15 and #16 [38] on Terminal Board (TER5). Terminals #17 [47] and
#18 [49] provide an interlock for the water pump starter(s) when either
compressor is in operation. Set the thermostat (T1) to the desired
leaving water temperature (e.g. 44°F.). Set point adjustment is ac­
complished directly on the control.
Place the three (3) control circuit switches (SW1-SW3) in the "On"
position, thus energizing the balance of the control circuit. [23], [33],
[36]. The system will be in the "Time-In" mode for five minutes before
the first compressor will start.
The low ambient lockout thermostat (LAT1) [38] and temperature
freezestat (T2) [38] must also be satisfied to allow compressor opera­
tion.
Stage 1 Starting
Upon demand for cooling, the first stepof the staging thermostat (T1)
will be to close energizing relays (R1) [61], time delay (TD1) [60] and
the optional time delay (TD3) [62]. If all the safety controls and switches
are closed, (see "Safety Controls" section for more detail) the control
6
circuit for Compressor No.1 will energize, allowing the compressor to
start. Relay (R5) [20] will energize, closing the normally open (NO) set
of contacts [23], which energize the liquid line solenoid valve (SOL1)
[23]. Another set of NO contacts on (R5) [20) provide a series inter­
lock with all the safety and operating controls, which will lock out the
compressor if any safety trips during normal operation. (See Note 6
on Wire Diagram.) The last set of NO contacts on (R5) [48) provides
an interlock circuit for the water circuiting pump(s).
The fan contactor (C13) [23] will also close, supplying power to the
side of the fan cycling pressure controls. (See Power Wiring Diagram.)
Note: The fan motors are controlled by their own fan cycling controls
and will cut in at different factory set head pressures.
Time Delay (TD1) [601) has two (2) sets of contacts: the first set of
(TD1) [19] normally closed (NC) contacts provide a 30 second jumper
around the low pressure control (LP1) [20] to prevent short cycling
during start-up. The second set of (TD1) [24) contacts in the NC posi­
tion power the unloader solenoid (UL3-1) [24], which hold the com­
pressor in the full unload position for 30 seconds. After (TD1) [60]
times out (30 seconds), the contacts for the unloader solenoid (UL3-1)
open and the NO set close, which energize the relay (R3) [25].
Stage 1 Modulation
Upon energizing relay (R3) [25), the crankcase heater (CCH 1) [6] is
de-energized and the NO contacts of relay (R3) [45, 48] are closed,
allowing the thermostat (T1) to energize the load solenoid (UL1-1)
[45) and the unload solenoid (UL2-1) [481] upon demand. The op­
tional time delay (TD3) [62] is used to bypass low pressure control
(LP1) [20] for five minutes for low ambient starts.
Stage 2 Starting
Subsequent to the start of Compressor No.1 an approximate five
minute time delay is incorporated into the microprocessor. After this
time delay, and a further call for cooling, the second step of the stag­
ing thermostat (T1) will close. This will energize relay (R2) [58], time
delay (TD2) [57] and the optional time delay (TD4) [59]. If all the safety
controls and switches are closed, (see "Safety Control" section for
more details) the control circuit for Compressor No.2 will energize,
allowing the compressor to start. Relay (R6) [3D] will energize, allow­
ing the liquid line solenoid valve (SOL2) [331] to energize. Relay (R6)
[3D] will also interlock the water pump starters and the safety controls
the same as Compressor No. 1 circuit.
The fan contactor (C14) [33] will close, supplying power to the line
side of the fan cycling pressure controls. (See Power Wiring Diagram.)
Time delay (TD2) will provide a 30 second jumper around the low
pressure control (LP2) [30] and will energize the full unload solenoid
(UL 3-2) [34] for 30 seconds then energize relay (R4) [35].
Upon energizing relay (R4) [35], the crankcase heater (CCH2) [8] is
de-energized and the NO contacts of relay (R4) [46, 49) are closed,
allowing the thermostat (T1) to energize the load solenoid (UL2-1)
[46] and the unload solenoid (UL2-2) [49] upon demand.
SHUTDOWN SEQUENCE
Stage 2 Shutdown
Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water
temperature is still lower than the setpoint, the second step of the
thermostat (T1) will open and de-energize relay (R2) [58], providing
an approximate five minute time delay again integral with the micro­
processor has expired subsequent to the start of Compressor No.2.
This will close the liquid line solenoid (SOL2) [33] and turn off Com­
pressor No.2. Compressor No. 1 will load and unload as required.
Compressor No.2 will not be able to restart for five minutes due to
integral time delays.
If the leaving water temperature is still lower than the setpoint, the first
step of the thermostat (T1) will open and de-energize relay(RI) [61].This
will close the liquid line solenoid (SOL 1) [23] and turn off Compressor
NO.1 as long as it has run for approximately three minutes. Compres­
sor NO.1 will not be able to restart for five minutes.
SAFETY CONTROLS
FIELD CONTROL WIRING
The unit is protected by the following safety controls:
1.
2.
3.
4.
5.
6.
7.
8.
9.
High Pressure (HP)
Low Pressure (LP) (automatic reset)
High Discharge Temperature (OTS)
Compressor Solid State Module (CSTM)
Low Water Temperature (T2)
Low Ambient Thermostat (LAT)
Compressor Starter Overloads (OLH) (optional)
Phase Loss Monitor (PLM)
Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions, the
compressor(s) will automatically stop. All controls must be manually
reset, except low ambient thermostat (LAT) and phase loss monitor
(PLM). The individual compressor safeties (HP, LP, OTS and CSTM)
contacts are found on Lines 20 (CTT1) or Line 30 (CTT1). The other
safeties, listed above, are discussed in the "preliminary sequence
section.
In addition to 3 phase power (and optional 115 volt control) wiring
described above, the following control interlock wiring is recommended.
The "as built" control schematic, provided with the unit, provides
detailed information. Typical control schematics are as shown on pages
8-15.
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can
be used to trigger remote failure lights or alarm bells in the
event of a refrigeration failure.
2) Time Clock - All unit on-off control should be done through
terminals 15 and 16. An open contact shuts down the unit.
Time clock, night shut down, and energy management shut
down should all be done from these terminals and contacts
should be applied in series.
3) Flow Switch - The flow switch contacts should be installed
between terminals 15 and 16 and be in series with time clock
contacts.
4) Chilled Water Pump - The control of the chilled water pump
must be worked out by the system designer. It is necessary for
the pump to be on during any compressor operation and
terminals 17 and 18 should be used to energize the pump starter.
However it is likely that the pump should remain on throughout
all occupied operation or even at night for freeze protection.
Terminals 17 and 18 should not be the sole means of controlling
pump operation.
STAR·DELTA STARTING
OPEN TRANSITION (OPTIONAL)
Typical For All Compressors
On initial call for cooling staging relay (R1) holding coil will energize.
The (R1) contacts 7-4 close, energizing star contactor (S1) and the
five second transition timer (TD5). Transition contactor (S1) power
contacts close, tying the center legs of the compressor motor windings
together into "Star" (WYE) configuration. At the same time (S1) N.C.
(Normally Closed) auxiliary contacts open preventing (C2) from closing,
(S1) N.O. (Normally Open) auxiliary contacts then close, energizing
contactor (C1). The (C1) power contacts close, applying power to the
compressor winding. (C1) N.O. (Normally Open) auxiliary contacts
close locking (C1) in the energized position. The compressor operates
in the "Star" mode until (TD5) transition timer times out (five seconds)
at which time contacts N.C. open and de-energize (S1). Star contactor
(S1) N.C. auxiliary contacts close, (TD5) timer N.O. contacts close,
energizing compressor contactor (C2), power contacts close, thereby
completing the "Delta" wiring configuration. Compressor contactor (C2)
N.C. auxiliary contacts open, preventing (S1) star contactor from
energizing until the next starting sequence.
7
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17
ELECTRICAL DATA
Model
ACWC
SC
Volts
60 Hz
3 Ph.
Type
of
Start
45
208/230
208/230
208
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
YO
XL
208
YO
230
XL
230
YO
460
XL
460
YO
208
208
230
230
460
460
208
XL
YO
XL
YO
XL
YO
XL
208
YO
230
XL
230
YO
460
XL
460
YO
208
208
230
230
460
460
XL
YO
XL
YO
460
460
55
208/230
208/230
460
460
70
90
110
208/230
208/230
460
460
208
208
230
230
460
460
208
208
230
230
460
460
125
I
135
145
160
XL
YO
COMPRESSOR
Qty.
RLA
Starting
Curro Ea.
HP
Ea.
1040
178.8
(1) 50
178.8
347
73.7
422
73.7
141
205.1
1228
205.1
(1) 60
409
90.4
485
90.4
162
208.3
1415
(1) 75
208.3
472
97.4
539
97.4
180
178.8
1040
178.8
347
(2) 50
178.8
1040
178.8
347
73.7
422
73.7
141
205.1
1228
205.1
409
(2) 60
205.1
1228
205.1
409
914
485
90.4
162
(1) 60
205.1
1228
(1) 75
208.3
1415
205.1
(1) 60
409
(1) 75
208.3
472
(1) 60
205.1
1228
(1) 75
208.3
165
(1) 60
409
205.1
(1) 75
208.3
472
(1) 60
90.4
485
(1 \ 75
97.4
539
(1) 60
90.4
162
(1) 75
180
97.4
208.3
1415
208.3
472
(2) 75
208.3
1415
208.3
472
97.4
539
97.4
180
(2) SO
178.8
1040
(1) 60
205.1
1228
(2) 50
178.8
347
(1\ 60
205.1
409
(2) 50
178.8
1040
(1) 60
2011
1228
(2) 50
178.8
347
(1) 60
205.1
409
(2) 50
73.7
422
(1) 60
90.4
485
(2) SO
731
141
(1)60
90.4
162
205.1
1228
205.1
409
(3) 60
205.1
1228
205.1
409
90.4
485
90.4
167
FAN MOTORS
FLA
LRA
Ea.
Ea.
(4) 7.0
(4) 38.0
(4) 7.0
(4) 380
(4) 3.5
(4) 19.0
(4) 35
(4) 19.0
(4) 7.0
(4) 38.0
(4) 7.0
(4) 38.0
(4) 3.5
(4) 19.0
(4) 3.5
(4) 19.0
(6) 7.0
(6) 38.0
(6) 7.0
(6) 380
(6) 35
(6) 19.0
(6) 3.5
(6\ 19.0
(6) 7.0
(6) 38.0
(6) 7.0
(6) 38.0
(6) 7.0
(6) 38.0
(6) 7.0
(6) 38.0
(6) 3.5
(6) 19.0
(6) 3.5 . (6) 19.0
(8) 7.0
(8) 38.0
(8) 7.0
(8) 38.0
(8) 7.0
(8) 38.0
(8) 7.0
(8) 38.0
(8) 3.5
(8) 19.0
(8) 3.5
(8) 19.0
MIN. CIRCUIT
AMPACITY
Circ.2
Circ.1
252
252
106
106
284
284
127
127
302
302
143
143
266
266
266
266
187
187
312
312
312
312
231
231
-
RECOMMENDED
WIRE SIZE
Circ.2
Circ.1
-
250
250
2
2
300
300
1
1
350
350
0
0
300
300
300
300
000
000
400
400
350
350
0000
0000
-
-
--
-
224
224
224
224
-
-
256
256
256
256
-
-
MAXIMUM
FUSESIZE
eire. 2
Circ.1
400
400
175
175
450
450
200
200
500
500
225
225
400
400
400
400
400
400
-
-
-
-
0000
0000
0000
0000
-
300
300
300
300
400
250
250
250
500
SOO
=1
:;g
450
450
-
500
300
300
(8) 7.0
(8) 38.0
312
260
400
300
500
450
(8) 7.0
(8) 38.0
312
260
400
300
500
450
(8) 7.0
(8) 38.0
312
260
350
300
500
450
(8) 70
(8) 38.0
02
260
350
300
500
450
(8) 3..5
(8) 19.0
240
-
250
-
300
-
-
300
-
500
500
500
500
300
300
450
450
450
450
500
(8) 3.5
(8) 19.0
240
(8) 7.0
(8) 7.0
(8) 7.0
(8) 7.0
(8) 35
(8i 3.5
(8)
(8)
(8)
(8)
(8)
(8)
316
316
316
316
247
247
38.0
38.0
38.0
38.0
19.0
19.0
260
260
260
260
-
250
400
400
400
400
250
250
-
300
300
300
300
-
-
(10) 7.0
(10) 38.0
326
402
400
0000
(10) 7.0
(10) 38.0
326
402
400
0000
500
500
(10) 7.0
(10) 38.0
326
402
400
0000
500
500
(10) 7.0
(10) 38.0
326
402
400
0000
500
500
(10) 35
(10) 19.0
295
-
350
350
-
10 (3.5)
(10)19.0
295
-
350
-
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(10)
(10)
326
326
326
326
329
329
462
462
462
462
400
400
400
400
400
400
(2)250
(2)250
(2)250
(2)250
500
500
500
500
400
400
38.0
38.0
38.0
38.0
19.0
19.0
-
-
350
I
-
500
7.0
7.0
7.0
7.0
3.5
3.5
I
400
600
600
600
600
-
NOTES:
1. XL: Across the Line;YO:Star Delta
2. RLA: Rated LoadAmps (rated in accordance with ARI Standard 590.) LRA: LockedRotorAmps
3. Wire Size Amps equal125%of the ratedloadampsfor the largestmotorin the circuitplus 100%of the ratedloadamps for all other motorsin the circuit, per
N.E.C.
4.
Wire size based on copperconductorswith75'C. insulation, perN.E.C.Table310-16. Terminal block lugs are sizedaccordingly. Use of oversize wiring may
not lit in terminal blocks.
5. Maximum fuse size is basedon 175%to 225%of the rated load ampsfor the largestmotorin the circuit plus 100%of the rated loadampsfor a other motors
in the circuit per N.E.C.
VOLTAGE TOLERANCES:
208V-230V: min. 187V.,Max 253V
480V: Min.414V., Max.506V.
18
I
'I
ELECTRICAL DATA
Model
ACWC
SC
Volts
3 Ph.
Type
of
Start
208
XL
208
YO
230
XL
230
YO
460
XL
460
YO
208
208
230
230
460
460
208
208
230
230
460
460
208
XL
YO
208
YO
230
XL
230
YO
460
XL
460
YO
60 Hz
185
200
215
COMPRESSOR
Oty.
RLA
Starting
Curro Ea.
HP
Ea.
(1) 60
(2) 75
(1) 60
(2) 75
(1) 60
12\ 75
(1) 60
(2) 75
(1) 60
(2) 75
(1) 60
(2) 75
XL
XL
YO
XL
265
(4) 60
YO
XL
YO
XL
240
208
208
230
230
460
460
(3) 75
YO
XL
YO
(2) 60
(2) 75
(2) 60
(2) 75
(2) 60
(2) 75
(2) 60
(2) 75
(2) 60
12\ 75
(2) 60
(2) 75
XL
YO
XL
XL
XL
YO
(4) 75
205.1
208.3
205.1
208.3
205.1
208.3
205.1
208.3
90.4
97.4
90.4
97.4
208.3
208.3
208.3
208.3
97.4
97.4
205.1
205.1
205.1
205.1
90.4
90.4
205.1
208.3
205.1
208.3
205.1
208.3
2011
208.3
90.4
97.4
90.4
97.4
208.3
208.3
208.3
208.3
97.4
97.4
FAN MOTORS
FLA
LRA
Ea.
Ea.
1228
(12) 7.0
1415
409
(12) 7.0
472
1228
(12)7.0
1415
409
(12) 7.0
472
485
(12) 3.5
539
162
(12)
180
1415
(12) 7.0
472
(12) 7.0
1415
(12) 7.0
472
(12) 7.0
539
(12) 3.5
180 1(12) 3.5
1228
(12) 7.0
409
(12) 7.0
1228
(12) 7.0
409
(12) 7.0
485
(12) 3.5
(12) 3.5
162
1228
(14) 7.0
1415
409
(14) 7.0
472
1228
(14) 7.0
1415
409
(14) 7.0
472
485
(14) 3.5
539
162
(14) 3.5
180
1415
(16) 7.0
1415
(16) 7.0
(16) 7.0
1415
472
(16) 7.0
539
(16) 3.5
(16) 3.5
539
MIN.CIRCUIT
AMPACITY
Cire.1 Cire.2
RECOMMENDED
WIRESIZE
Cire.1
Cire.2
MAXIMUM
FUSE SIZE
Cire.1
Cire.2
(12) 38.0
341
469
500
(2) 250
500
600
(12) 38.0
341
469
500
(2) 250
500
600
(12) 38.0
341
469
500
(2) 250
500
600
(12) 38.0
341
469
500
(2) 250
500
600
(12) 19.0
352
-
500
-
400
-
.5(12)19.
352
-
500
-
400
-
(12) 38.0
(12) 38.0
(12) 38.0
(12) 19.0
(12) 19.0
(12) 19.0
(12) 38.0
(12) 38.0
(12) 38.0
(12) 38.0
(12) 19.0
(12) 19.0
(14) 38.0
345
345
345
345
359
359.
504
504
504
504
225
225
504
469
469
469
469
600
600
600
600
(14) 38.0
(2) 250
(2) 250
(2) 250
(2) 250
504
504
504
504
225
225
525
500
500
500
500
500
500
(2) 250
(2) 250
(2) 250
(2) 250
0000
0000
(2}250
(2) 250
(2) 250
(2) 250
(2) 250
0000
0000
(2)300
500
500
500
500
450
450
700
700
700
700
300
300
700
504
525
(2) 250
(2)300
700
700
(14) 38.0
504
525
(2)250
(2)300
700
700
(14) 38.0
504
525
(2) 250
(2)300
700
700
(14) 19.0
225
248
0000
250
300
300
(14) 19.0
225
248
410
250
300
300
(16)
(16)
(16)
(16)
(16)
(16\
525
525
525
525
248
248
525
525
525
525
248
248
(2)300
(2)300
(2}300
(2}300
250
250
(2)300
(2)300
(2}300
(2}300
250
250
700
700
700
700
300
300
700
700
700
700
300
300
38.0
38.0
38.0
38.0
38.0
38.0
-
-
-
-
-
700
700
700
700
300
300
700
NOTES:
1.
2.
3.
4.
5.
XL: Across the Line; YO: Star Delta
RLA: Rated Load Amps (rated in accordance with ARI Standard 590.) LRA: Locked Rotor Amps
Wire Size Amps equal 125% of the rated load amps for the largest motor in the circuit plus 100% of the rated load amps for all other motors in the circuit, per
N.E.C.
Wire size based on copper conductors with 75°G. insulation. per N.E.G. Table 310-16. Terminal block lugs are sized accordingly. Use of oversize wiring may
not fit in terminal blocks.
Maximum fuse size is based on 175% to 225% of the rated load amps for the largest motor in the circuit plus 100% of the rated load amps for a other motors
in the circuit per N.E.G.
VOLTAGE TOLERANCES:
208V-230V: min. 187V., Max 253V.
480V: Min.414V., Max.506V.
19
006
009
00"
0;;:
(Wd~) 3.lV~ M01::1 ~3.1VM
OOt
OOl:
OS L.
00 L.
os
0"
Ot
'V
::D
m
(I)
(I)
c:
m
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c
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o'V
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m
m
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~
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m
:D
aoao
3~nSS3~d ~3100~
APPLICATION DATA
POINT LOADING
rMi
I
A
*,
1
5
*1
ACWC 45 THRU 10 SC
COMPRESSOR
SECTION
13'10
CONDENSER SECTION
._ 2
• *1
*4
~
1
•
A
....
*,
COMPREIlOfl
IECnoN
*2
, *J
I'·'
.
CONDENSER SECTION
,
-,
*4
.,
A
45
55
70
90
110
125
135
145
160
185
200
215
240
265
91
91
145
145
60
60
60
138%
1383/0
138%
138%
106
106
133%
Dimensions
B
C
D
-
-
-
-
-
-
-
40
40
40
74
74
129
129
82%
82%
110
160
160
160
107%
107%
107%
107%
106%
134
134
-
-
80
107%
107%
C
ACwe 110 THRU 200 Ie
13'10
Model
Size
*5
1:..1
Model
Size
45
55
70
90
110
125
135
145
160
185
200
215
240
265
Loadlnu (LBS)
1&2 3&4
765
585
705
810
660
890
1025 1500
1195
635
1255
690
1255
665
1330 2380
1330 2440
1235 2575
1275 2635
1010 2270
1115 2550
1380 2980
5&6
550
635
700
1175
1525
1835
1880
2160
2280
2980
3020
2590
2870
3515
7&8 9 &10
-
-
995
1115
1105
1450
1515
1360
1380
2240
2715
2750
-
-
-
-
-
840
1125
1175
... ,
ACWC 2t5 THRU 215 SC
13'10
L "
· .. 2
,,4
lIf'
11"
to I..I i,
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START
REMEDY
1. Check main disconnect switch
2. Check main fuses
3. Check the wiring diagram
4. Tiqhten all terminals
5. Check phase loss monitor, flow switch, circuit breakers,
temperature control, low ambient thermostat, low temperature
thermostat, remote switch, etc.
6. Wait
POSSIBLE CAUSE
1. Power off
2. Main line open
3. Incorrect wiring
4. Loose terminals
5. Control circuit open
6. Time delay
COMPRESSOR HUMS BUT DOES NOT START
REMEDY
POSSIBLE CAUSE
1 a. Check at service and unit for loss
1. Low voltage
b. Consult power company
POSSIBLE CAUSE
1. Refrigerant shortage
2. Restriction in liquid line
3. Low water flow thru cooler
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL
REMEDY
1. Check for leaks -- add refrigerant
2a. Plugged strainer - dean or replace
b. Liquid line valve partially closed - open valves fully
c. Expansion valve clogged or inoperative - clean or replace as
required
d. Solenoid valve partially open - clean or replace as required
3. Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL
REMEDY
POSSIBLE CAUSE
1. Compressor discharge valve partially closed
1. Open valve fully
2. Operate condenser fans with compressors off. If condenser
2. Non-condensible gases in system
pressure exceeds saturated pressure corresponding to condenser
entering air temperature, then purge air from discharge line.
3. Purge system while in operation until head pressure reaches a
3. Overcharge of R-22
normal level
4. Clean the condenser
4. Dirty condenser
5. Replace if necessary
5. Compressor discharge check valve not operating properly
6. Check pressure control setting
6. Fans not running
CAUSES AND PREVENTION OF FREEZE-UP
PREVENTION
1. Charge per manufacturer's recommendation.
2. Check the safety time delay low pressure control for proper setting
at the beginning of each season.
3. Use an ample sized cleanable strainer in the chilled water circuit.
Improper chilled water circulation
Make certain the strainer is clean to insure full flow and velocity of
chilled water. It may sometimes be necessary to treat the water to
prevent formation of deposits.
Not draining for winter shutdown
4. When the system is shut down for the winter, remove the drain
plugs and drain the cooler. Blowout any remaining water with air.
Improper pump shutdown
5. Make sure chiller barrel heater is working and flow switch is
installed per wiring diagrams
Low ambient during air conditioning season
6. Make sure chiller barrel heater is working
CAUSES
1. Improper charging
2. Improperly set safety time delay
3.
4.
5.
6.
NOTE:
If the ambient temperature is below 32°F, freezing can be completely prevented by one of two methods:
1. Drain all water from the equipment.
2. Add antifreeze to the water.
22
START-UP CHECK LIST
Unit Model No.
Setting unit:
Yes
No
a. Vibration isolator used
b. Spring isolator adjusted for equal height
c. If rubber-in-shear isolators are used, is unit leveled by shimming
Wiring:
a. Power wiring complete
b. Control wiring complete
c. Electric service adequate for load
d. Power source voltage correct for motor(s) used
e. Motor circuit has proper size fusetrons
f. System wired per diagram
g. All lead connections tight
h. Wiring complies with local codes
i. Flow switch operation
Piping:
a. Piping complies with applicable codes
b. External piping independently supported
c. Chilled water lines insulated
Alignment:
a. All belts adjusted and checked for tension
b. All pulleys checked and adjusted for proper pitch, tightness and
alignment
Before Start-Up:
a. Open compressor discharge service valve
b. Open liquid valve(s)
c. Open suction, and discharge valves to pressure gauges (if supplied)
d. Check rotation of all fan motors
e. Start auxiliary equipment (pumps, fans, etc.)
f. Is crankcase heater operating? Operate 24 hours prior to unit startup
g. Check the compressor oil level through the crankcase sight glass. The oil
level should be to the top of the glass. If the level is low, add oil in
accordance with the directions in the maintenance instruction
h. Check all control settings as specified in Table 1.
I. Air purged from chilled water system
After Start-Up:
a. Check high pressure control
b. Check oil temperature safety switch
c. Check and adjust low pressure or temperature freeze control
d. Check and adjust operating thermostat
e. Check and adjust low pressure operating control
f. Check and adjust expansion valve superheat
g. Check and adjust capacity control thermostat
23
OPERATING DATA
CHILLER
Voltage: L-1
L-2
L-3
_
Pressure Gauge Readings:
#1 Suction
psig
#1 Discharge
psig; #2 Suction
psig
psig
#3 Suction
psig
#3 Discharge
psig; #4 Suction
High pressure switch setting:
#1 (Cut-in)
psig
psig (Out); #2 (Cut-in)
psig
psig
#3 (Cut-in)
psig
psig (Out); #4 (Cut-In)
Checked Setting - Yes - No (each circuit)
Low Pressure Switch Setting:
#1 (Cut-in)
psig
psig (Out); #2 (Cut-in)
psig
psig
#3 (Cut-In)
psig
psig (Out); #4 (Cut-in)
Checked Setting -Yes -No (each circuit)
#1 Oil Temperature Safety Switch
Cut Out; #2 Oil Temperature Safety Switch
#3 Oil Temperature Safety Switch
Cut Out; #4 Oil Temperature Safety Switch
If Star-Delta start, time delay is
seconds.
Temperature of air entering condenser
"F,
Temperature of air leaving condenser
of.
Temperature of chilled water entering chiller
OF.
Temperature of water (chilled) leaving chiller
"F,
Chilled water pressure entering chiller
psig
Chilled water pressure leaving chiller
psig
#2 Discharge
#4 Discharge
_ psig;
_ psig
psig (Out);
psig (Out)
psig (Out);
psig (Out)
Cut Out;
Cut Out
MAINTENANCE
Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive
service calls.
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble
free operation.
WEEKLY CHECKS- with unit in operation for at least four hours.
1) Check compressor oil level - At least above 1/2 of sight glass
2) Record suction and discharge pressures
Typical Condition: R22
Ambient 95°F: Return water 55°F., Leaving water 45°F.
Suction 62 psig: Discharge 270 psig
3) Record ambient temperature
4) Check liquid sight glass
Make sure liquid is clear - no bubbles
5) Check that all fans are running
6) Check entering face of condenser coil for cleanliness
7) Record voltage at unit
All of the above can be performed by building maintenance personnel. If oil levels are low or any of the above
checked items are questionable consult a qualified serviceman.
At least once a year a qualified serviceman should check unit oil levels, superheat and control operation.
DUNHAM-BUSH
USA
Bmgess RO~, Harrisonburg, VA 22801
Phone: (540) 434-0711 FAX (540) 434-~ 2'1'18
wvvw.dunham-bush.com
P l) • 130 x UtUC t01
Form No. 6184