AFHX Series 60Hz. Air Cooled Screw Flooded Chillers Cooling Capacity: 77 to 191 TR (271 to 672 kw) R134a. Products that perform...

Transcription

1 AFHX Series 60Hz Air Cooled Screw Flooded Chillers Cooling Capacity: 77 to 191 TR (271 to 672 kw) R134a Products that perform...by people who care

2 INTRODUCTION For more than 100 years, Dunham-Bush has focused on innovative product development. Today, we provide a full portfolio of HVAC/R products from Fan Coil Units to large centrifugal chillers as well as many other innovative green solutions. Our commitment to innovation, matched with an aggressive attitude toward growth, makes Dunham-Bush a leader in global markets. Our product development is tailored to meet the specific needs of customers, building-by-building, country-by-country and region-byregion. No other HVAC/R manufacturer takes this approach to meeting your performance expectations. AFHX, Air Cooled Screw Flooded Chillers, have a cooling capacity range from 77 to 191 TR [271 to 672 kw] in 60Hz version using environmentally sound HFC-134a refrigerant. The entire product line features energy efficiency, installation ease, control flexibility, high reliability and advanced 2020i controller. The AFHX range is AHRI certified and ETL listed. TABLE OF CONTENT Page No Introduction... 2 Nomenclature... 2 Advantages of Flooded Chiller... 3 Unit Features... 5 Operating Benefits... 8 Typical Sequence of Operation... 9 Application Data Physical Specifications Performance Data Dimensional Data Floor Loading Diagram Dimensional Clearance Evaporator Water Pressure Drop Sound Pressure Data Condenser Fan Electrical Data Typical Wiring Schematic Guide Specifications NOMENCLATURE A F HX 150 T - 6 S R - HR Air Cooled Chiller HR LN = Heat Recovery = Low Noise Flooded Evaporator Horizontal Screw Compressor Nominal TR Blank = R22 R = R134a S Q = Standard = Special 5 = 50Hz 6 = 60Hz T = Optional Two Compressors Blank = Standard - 2 -

3 ADVANTAGES OF FLOODED CHILLER In a flooded evaporator the refrigerant surrounds the tubes in the shell and the water to be cooled flows through the tubes. The level of liquid refrigerant in the shell is maintained by the combined action of an electronic level controller and mod-motor actuated ball valves which regulates the subcooled liquid refrigerant into the evaporator. This ensures that all the evaporator tubes are completely immersed in the liquid refrigerant for better heat transfer efficiency. For a Direct Expansion (DX) Evaporator the refrigerant is expanded into the tubes while the chilled water is circulated through the shell. A thermostatic expansion valve is used to throttle the refrigerant in maintaining constant superheat of suction gas to the compressor. The following are the advantages of using a flooded chiller: 1. Higher Capacity and Higher EER achievable with the Same Compressor The flooded evaporator with all the copper tubes immersed in the boiling liquid refrigerant enables a small approach temperature between the boiling liquid refrigerant temperature in the shell and the outlet chilled water temperature in the evaporator tubes to be achieved. This approach temperature or temperature difference between the evaporating temperature of the boiling liquid refrigerant and the chilled water outlet temperature, for a flooded evaporator, is typically less than 3 F [1.7 C]. On the contrary, for a DX or Direct Expansion Evaporator, the typical approach temperature is between 8 F [4.4 C] to 10 F [5.5 C]. This simply means that the same compressor in a flooded evaporator system will operate at a higher saturated evaporating temperature when compared to the same compressor in a DX Evaporator system, when outlet chilled water temperatures in both cases are set at the same temperature. Figure 1 shows the typical screw compressor capacity performance curve at a particular condensing temperature over saturated evaporating temperature of between 30 F [-1.1 C] to 50 F [10 C], and the typical power input curve over the same conditions. It can be noted that the same compressor when operating with a flooded evaporator will generate approximately 8% more cooling capacity while kw input increases by approx 1.8%. Therefore, the same compressor, when coupled to a flooded evaporator, will typically achieve higher cooling capacity with correspondingly higher Energy Efficiency Ratio (EER) i.e. (BTU/Watt) or lower kw/tr. FIGURE 1 A DX Evaporator uses TXV throttling to maintain about 10 F [5.5 C] to 15 F [8.3 C] suction superheat to prevent liquid flood back to the compressor. In a flooded evaporator, the refrigerant boils off in the shell and gas can be sucked out from the top of evaporator back to compressor. The suction superheat is usually about 2 F [1.1 C] to 3 F [1.7 C]. Reduction in suction superheat will further increase the capacity performance of the compressor. DX Evaporators are typically designed with higher tube velocities to ensure proper oil return to compressor both at full load and at reduced load. This will contribute to higher refrigerant pressure drop through the evaporator. On the contrary, there is very little shell side pressure losses for a flooded evaporator. Therefore, lower suction pressure drop in the flooded design will impose less capacity penalty on the compressor and this will further enable the compressor in a flooded evaporator to generate more capacity than one with a DX Evaporator

4 ADVANTAGES OF FLOODED CHILLER 2. Better Part Load Performance The Dunham-Bush Air Cooled Flooded Chiller with its sophisticated advanced controller and patented oil management system has all evaporator tubes completely immersed in the boiling liquid refrigerant to achieve superior heat transfer efficiency while ensuring adequate oil return to the compressor(s). This ensures superior full-load efficiency and even better part-load efficiency as the full heat transfer surface areas of the evaporator tubes are utilized even at part-load conditions. In Direct Expansion Evaporators, because of the need to maintain adequate refrigerant gas velocities in the evaporator tubes for proper oil return, it is typical for certain bundles of evaporator tubes to be blocked or baffled off at part-load conditions. Therefore not utilizing the full heat transfer surface of the evaporator tubes means lower efficiency when compared with a flooded evaporator chiller at part-load conditions. 3. Flash Economizer/ Vapor Injection Cycle for Increase Capacity and Higher EER The renowned Dunham-Bush screw compressor allows for flash economizer vapor injection cycle to be incorporated, increasing capacity by as much as 25% with marginal 10% to 15% increase in kw-input. Most of Dunham-Bush s competitors who produce Rotary Screw Chillers do not incorporate flasheconomizer vapor injection cycle- not to mention flooded evaporator! 4. Excellent Capacity Modulation in Response to Building Loads Dunham-Bush utilizes its state-of-the-art advanced controller in combination with the electronic level controller and modulating motor actuated ball valves to ensure precise control of liquid refrigerant to the flooded evaporator in response to changes in cooling load. While maintaining leaving chilled water temperatures even at very low load. Whereas most of Dunham-Bush s competitors utilize orifice plates to modulate refrigerant feed to the evaporator, resulting in lower efficiency at low-load and less reliable oil return. 5. Maximum Reliability and Redundancy Today, the Dunham-Bush screw compressors are increasingly accepted for its reliability. The 2-compressor, 3-compressor and 4- compressor models are designed to have 2 independent refrigerant circuits for redundancy. For the refrigerant circuits with 2- compressors (i.e. 3-compressor and 4- compressor models), individual compressor is provided with suction stop valve, suction check valve, discharge check valve and other isolating valves in the oil management system to allow complete isolation of an unlikely faulty compressor without contaminating the refrigerant system and further allows other compressors to continue to operate - thus ensuring maximum redundancy 6. Cleanable Evaporator For a single pass evaporator join in a row, the end plates at both ends of the water boxes (2 pass only at return end and 1 pass u arrangement only at u elbow end) can be removed easily without dismantling the chilled water piping connections, for inspection and for mechanical tubes cleaning with brushes or auto-brush. This will enable low tube fouling factor in the evaporator to be ensured, thus maintaining system efficiency. 7. Lower Water Side Pressure Drop In a DX Evaporator, the water flows transversely over the outside of the tubes. The water flow is guided with vertical baffles. This will have a higher-pressure drop compared to the water flow in the tubes of a flooded evaporator. In other words, the equivalent flooded chiller will require smaller water pump to operate at lower power consumption. 8. Commonly Used In Large Tonnage Chillers Where Efficiency Is Critical As a general rule, DX Evaporators are typically used in small and medium tonnage chillers where efficiency may not be a primary consideration but cost is important. However, with increasing energy cost and the drive to reduce global warming, flooded evaporator chillers will increasingly become more popular not only in the large tonnage chillers but also in the small and medium tonnage chillers. Dunham-Bush, again, leads the industry in this respect! - 4 -

5 UNIT FEATURES with the controller through a telephone cable. The terminal allows carrying out of all program operations and also allows the unit working conditions, compressor run times and alarm history to be displayed. Set points and other parameters can be modified via the user terminal. The display has an automatic self-test of the controller on system start-up. Multiple messages will be displayed automatically by scrolling from each message to the next. All of these messages are spelled out in English on the display terminal. There are 15 dedicated buttons to enable the user to access information, based on the security level of the password. For more detail operation of the DBG1 Display Terminal, please refer to the Unit Operation Manual. Vision 2020i a flexible and advance programmable electronic controller designed specifically for the application and precise control of Dunham-Bush Rotary Screw compressor chillers. The controller board is provided with a set of terminals that connect to various devices such as temperature sensors, pressure and current transducers, solenoid valves, compressors and fans contactors, control relays etc. Three sizes of controller boards are provided to handle different number of input and output requirements: DB3-S small, DB3-M medium and DB3-L large board. The unit algorithm program and operating parameters are stored in FLASH-MEMORY that does not require a back-up battery. The program can be loaded through PC or programming key. Vision 2020i controller is equipped with a user friendly terminal with a semi-graphic display and dedicated keys that provides easy access to the unit operating conditions, control set points and alarm history. Each unit s controller can be configured and connected to the local DBLAN network that allows multiple units sequencing control without additional hardware. The DBLAN is local area network made up of several chillers controller. Display and User Terminal The Vision 2020i controller is designed to work with a user friendly back-lit 132 by 64 pixels DBG1 Semi-Graphic Display panel connected Easily accessible measurements include: Leaving chilled water temperature Entering chilled water temperature Compressor discharge temperature Leaving chiller water temperature derivative Evaporator Pressure Condenser Pressure Compressor amp draw of each compressor Compressor elapsed run time of each compressor Compressor starts status Oil level sensor status Water temperature reset value Water flow switch status External start/stop command status Optional ambient temperature is available. With this option the operator can quickly and accurately read all significant temperatures and eliminate the need for thermometers. Voltmeter is also offered as an optional feature. Capacity Control Leaving chilled water temperature control is accomplished by entering the water temperature setpoint and placing the controller in automatic control. The unit will monitor all control functions and move the slide valve to the required operating position. The compressor ramp (loading) cycle is programmable and may be set for specific building requirements. Remote adjustment of the leaving chilled water setpoint is accomplished either through direct BMS protocols connection to - 5 -

6 UNIT FEATURES the controller communication ports, or from an external hardwired control signal from BMS to supply a chilled water reset 4 to 20mA analog input signal. Remote reset of compressor current limiting function may be accomplished in a similar fashion. System Control The unit may be started or stopped manually, or through the use of an external signal from a Building Automation System. In addition, the controller may be programmed with seven-day operating cycle or other Dunham-Bush control packages may start and stop the system through inter-connecting wiring. System Protection The following system protection controls will automatically act to ensure system reliability: Low suction pressure High discharge pressure Freeze protection Low differential pressure Low oil level Compressor run error Power loss Chilled water flow loss Sensor error Compressor over current Compressor Anti-recycle The controller can retain up to 99 alarm conditions complete with time of failure together data stamping on critical sensor readings in an alarm history. This tool will aid service technicians in troubleshooting tasks enabling downtime and nuisance trip-outs to be minimized. Remote Monitoring Vision 2020i controller can be completed with an optional RS485 communications card and NETVISOR software for remote monitoring and controlled from a PC terminal and optional phone modem. With various optional add-on cards the Vision2020i controller can also be interfaced directly to the Building Management System (BMS) with the standard communication protocols using MODBUS, LONWORKS, BACNET MSTP as well as over IP. This sophisticated feature makes servicing easier and more convenient to the system. The controller as standard is additionally equipped with history files which can be used to take logs and which may be retrieved via the phone modem or internet connection periodically. Now owners of multiple buildings have a simple and inexpensive method of investigating potential problems quickly and in a highly cost effective manner. REFRIGERATION CYCLE The refrigerant management system, is shown in the refrigerant cycle diagram below. Liquid refrigerant enters the flooded evaporator uniformly where it absorbs heat from water flowing through the evaporator tubes. The vaporized refrigerant is then drawn into the suction port of the compressor where the compression begins. This partially compressed gas is then combined with additional gas from the flash economizer as the vapor injection port at an intermediate pressure is exposed to each interlobe space. Compressed gaseous refrigerant is then discharged into the integral oil separator where oil, which is contained in the refrigerant vapor, is removed and returned to the oil sump. High pressure superheated refrigerant is then discharged into the condenser, where air is drawn across the condenser by propeller fans which cool and condense the refrigerant. This liquid refrigerant then passes through the first expansion device and into the flash economizer where flash gas and liquid refrigerant are separated

7 UNIT FEATURES The flash gas is drawn into the vapor injection port of the compressor. The remaining liquid refrigerant then passes through a second expansion device which reduces the pressure further and it is introduced into the bottom of the flooded evaporator via an integral distributor. By removing the flash gas from the flash economizer at an intermediate pressure, the enthalpy of the refrigerant flowing into the evaporator is reduced. This increases the refrigeration effect and improves the efficiency of the refrigeration cycle. Refrigerant flow into and out of the flash economizer is controlled by modulating valves which eliminate the energy wasting hot gas bypass effect inherent with fixed orifices. PART-LOAD PERFORMANCE Through the use of flash economizer modulating flow control and multiple compressors, Dunham- Bush air cooled chillers have some of the best part-load performance characteristics in the industry when measured in accordance with AHRI Standard 550/ In most cases, actual building system loads are significantly less than full load design conditions, therefore chillers operate at part load most of the time. Dunham-Bush air cooled chillers combine the efficient operation of multiple compressors with an economizer cycle and advanced controller to yield the best total energy efficiency and significant operating saving under any load. When specifying air conditioning equipment, it is important to consider the system load characteristics for the building application. In a typical city, the air conditioning load will vary according to changes in the ambient temperature. Weather data compiled over many years will predict the number of hours that equipment will operate at various load percentages

8 OPERATING BENEFITS EFFICIENCY AND RELIABILITY Energy Efficiency Designed to provide the greatest amount of cooling for the least power input over the entire operating range of your building. Delivers outstanding efficiency and total energy savings through the utilization of economizer cycle and advanced controller staging producing greater capacity with fewer compressors. Maximized performance through computermatched components and multiple compressors on a single refrigerant circuit. High efficiency oil recovery system guarantees removal of oil carried over in the refrigerant and maintains the heat exchangers at their maximum efficiency at both full and part load. Operational Advantages Dramatic payback in reduced maintenance and overhaul costs both in downtime and in labor expenditures. Ease of troubleshooting through controller retention of monitored functions. Factory run tested. Safety Code ASME Boiler and Pressure Vessel Code, Section VIII Division 1 "Unfired Pressure Vessels". JKKP Code. ASME Standard B31.5 Refrigeration Piping. IEEE. Safety quality license for import boiler and pressure vessel, China. Refrigerant Compatibility Designed to operate with environmentally sound and economically smart HFC-134a with proven efficiency and reliability. Consult Factory for use of other HFC refrigerants. Control Flexibility Controller-based with DDC (direct digital control) features precise push button control over every aspect of operation with built-in standard features that allow extra energy savings on start-up and throughout the life of your equipment. Ensured uniform compressor loading and optimal energy efficiency through controller to controls which utilize pressure transducers to measure evaporator and condenser pressure. Lower energy costs resulting from automatic load monitoring and increased accuracy and efficiency in compressor staging. Monitor your chiller's key functions from a remote location with a simple, low cost, phone modem option. Proactive control anticipates problems and takes corrective action before they occur. Controls will unload compressor(s) if head or suction pressure approach limits. This will enable unit to stay on line while warning operator of potential problems. ASHRAE Standard 15 Safety Code for Mechanical Refrigeration

9 TYPICAL SEQUENCE OF OPERATION The Dunham-Bush air cooled water chiller depends mainly on its on-board controller for control. Operation described is for a twocompressor units and is very similar for single compressor units. For initial start-up, the following conditions must be met: Power supply to unit energized. Unit circuit breakers in the on position. Control power switch on for at least 15 minutes. Compressor switches on. Reset pressed on controller keypad. Chilled water pump running and chilled water flow switch made. Leaving chilled water temperature at least 2 F [1.1 C] above setpoint. All safety conditions satisfied. After all above conditions are met, the controller will call for the lead compressor to start. The compressor 15-minute anti-recycle timer is initiated at compressor start. The controller monitors compressor amps, volts, leaving water temperature and suction and discharge pressures. The compressor and cooling capacity is controlled by pulsed signals to load and unload solenoid valves on the compressor. When the compressor starts, it is fully unloaded, reducing about 25% of its full load capacity. As the computer gives it load signals, capacity gradually increases. The rate of compressor loading is governed by ramp control which is adjustable in the computer. The computer responds to leaving chilled water temperature and its rate of change which is proportional and derivative control. If leaving chilled water temperature is within the deadband (+/-0.8 F [0.5 C] from setpoint), no load or unload commands are given. If chilled water temperature is above deadband, the computer will continue loading the compressor until a satisfactory rate of decline is observed. If leaving chilled water temperature is below the deadband, the compressor is commanded to unload. Thus the compressor capacity is continuously modulated to match applied load and hold leaving chilled water temperature at setpoint. If the applied load is greater than one compressor can handle, it will load fully and then the controller will call for a second compressor. After one minute, the second compressor will start in the same manner as the first. Then both compressors will be commanded to adjust load to 50%. They are gradually loaded up together until the applied load is satisfied. In this way the two compressors share the load equally. If the applied load decreases to the point that both compressors are running at about 40% capacity, the computer shuts down the lag compressor and loads the remaining compressor to about 80%. If applied load decreases further, the remaining compressor unloads proportionately. If applied load decreases to less than the minimum capacity of one compressor, the leaving chilled water temperature will decline to 2 F [1.1 C] below setpoint, at which time the lead compressor will shut down. It will restart automatically if leaving chilled water temperature rises to 2 F [1.1 C] above setpoint and both 15 minute anti-recycle and one minute start delay timers are satisfied. During start-up operation, the computer monitors the difference between discharge and suction pressures to ensure that minimum of 30psi [2bar] differential is available for compressor lubrication. If the difference falls below a minimum of 30psi [2bar], the computer closes refrigerant flow control valves, starving the evaporator, causing evaporator pressure to drop, increasing differential pressure. This is especially helpful at startup, when warm chilled water and low ambient temperature would cause a low head situation. This feature is called EPCAS: Evaporator Pressure Control at Startup. It is one of several proactive control features of the controller which overcome potential problems while continuing operation. Two additional proactive features are low suction and high discharge pressure override. If operating pressures approach trip level, compressors are unloaded as necessary to continue operation

10 APPLICATION DATA Low Ambient Operation / Freeze Protection If unit is required to operate below 20 F [-7 C], optional head pressure control is required. Immersion heater and circulating pump need to be provided to be in operation when the chiller is not operating. Glycol is recommended for added protection. If wind in area is over 5 mph [8 kph], a wind barrier is recommended. Desuperheaters A hot gas desuperheater can be factory supplied for field installation. Suitable fittings in refrigerant lines with shut off valves can be supplied. Consult factory for further details. Water Circuit Constant water flow required with a minimum of 3 USgal per TR [3.3 liters / kw ] increasing up to 10 USgal [11 liters] for process, low load applications with small temperature ranges and/or vastly fluctuating load conditions. 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. The use of glycol causes a performance derate as shown below which needs to be included in the unit selection procedure. Ethylene Glycol % E. G. By Weight Freeze Point F C C1 Capacity Factor K1 kw Rate G1 Flow Factor P1 P.D. Factor Propylene Glycol % P. G. By Weight Freeze Point F C C2 Capacity Factor K2 kw Rate G2 Flow Factor P2 P. D. Factor Correction Factor - Elevation Correction Factor - FF Elevation above Sea Level Feet Meters Factor Capacity Correction Factor kw Correction Factor hr.ft². F/BTU Fouling Factor m². C/kW Capacity Correction Factor kw Correction Factor

11 PHYSICAL SPECIFICATIONS Model AFHX 75-6SR 80T-6SR 90T-6SR 100-6SR 115-6SR Unit Nominal Capacity TR[kW] 70 [246] 74 [260] 84 [295] 88 [311] 103 [362] Unit Nominal Power Input kw COMPRESSOR Model (Qty) HX 1512 (1) HX 1309 (2) HX 1311 (2) HX 1709 (1) HX 1711 (1) RPM Min. % Unit Capacity 25% 12.5% 12.5% 25% 25% EVAPORATOR Model (Qty) B1R (1) B1R (1) C1R (1) C1R (1) D1R (1) Water Connector inches[mm] 5 [127] 5 [127] 5 [127] 5 [127] 6 [152] Nominal Water Flow / Pressure Drop USgpm/ ft.wg[m³/hr/ kpa] 168.7/ 9.3 [38.3/ 27.8] 177.3/ 10.2 [40.3/ 30.5] 201.2/ 8.4 [45.7/ 25.1] 212.3/ 9.3 [48.2/ 27.8] 247.1/ 7.4 [56.1/ 22.1] Min/ Max Water Flow USgpm[m³/hr] 63.0/ [14.3/ 71.1] 63.0/ [14.3/ 71.1] 79.0/ [17.9/ 90.0] 79.0/ [17.9/ 90.0] 105.0/ [23.8/ 118.7] Min/ Max Water Pressure Drop ft.wg[kpa] 1.6/ 28.3 [4.8/ 84.6] 1.6/ 28.3 [4.8/ 84.6] 1.6/ 28.7 [4.8/ 85.8] 1.6/ 28.7 [4.8/ 85.8] 1.6/ 28.5 [4.8/ 85.2] CONDENSER Coil Rows Deep/ Total Face Area ft²[m²] 3/ [11.3] 3/ [11.3] 4/ [11.3] 4/ [11.3] 4/ [15.1] No. Of Fan Fan Diameter (Qty) inches[mm] 31.5 [800](6) 31.5 [800](6) 31.5 [800](6) 31.5 [800](6) 31.5 [800](8) Motor kw i (Qty) 2(6) 2(6) 2(6) 2(6) 2(8) FLA, AMP (Qty) 3.8(6) 3.8(6) 3.8(6) 3.8(6) 3.8(8) Total Air Flow cfm[m³/hr] [130386] [126532] [123963] [123963] [172136] Min. Operating Ambient F[ C] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] ELECTRICAL Nominal Voltage 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 Unit RLA A Unit Max. Inrush A GENERAL Unit Length inches[mm] 150 [3810] 150 [3810] 150 [3810] 150 [3810] 192 [4877] Unit Width inches[mm] 88 [2235] 88 [2235] 88 [2235] 88 [2235] 88 [2235] Unit Height inches[mm] 87.5 [2222] 87.5 [2222] 87.5 [2222] 87.5 [2222] 87.5 [2222] Shipping Weight lbs[kg] 8526 [3867] 9063 [4111] 9601 [4355] 9322 [4228] [4953] Operating Weight lbs[kg] 8641 [3920] 9179 [4164] 9749 [4422] 9470 [4295] [5040] Operating Charge R134a lbs[kg] 205 [93] 216 [98] 245 [111] 260 [118] 302 [137] Note: Nominal capacity is based on evaporator LWT 44 F and condenser ambient 95 F, actual capacity depends on the specified operating conditions

12 PHYSICAL SPECIFICATIONS Model AFHX 125T-6SR 135-6SR 150-6SR 150T-6SR 175T-6SR 190-6SR Unit Nominal Capacity TR [kw] 110 [387] 121 [427] 132 [466] 137 [482] 158 [556] 171 [603] Unit Nominal Power Input kw COMPRESSOR Model (Qty) HX 1509 (2) HX 1811 (1) HX 1813 (1) HX 1512 (2) HX 1709 (1) HX 1512 (1) HX 1816 (1) RPM Min. % Unit Capacity 12.5% 25% 25% 12.5% 12.5% 25% EVAPORATOR Model (Qty) D2R (1) D2R (1) J1R (1) J1R (1) K1R (1) K2R (1) Water Connector inches[mm] 6 [152] 6 [152] 6 [152] 6 [152] 6 [152] 6 [152] Nominal Water Flow / Pressure Drop USgpm / ft.wg [m³/hr / kpa] 264.3/ 6.8 [60.0/ 20.3] 291.6/ 8.1 [66.2/ 24.2] 318.0/ 11.2 [72.2/ 33.5] 329.3/ 11.9 [74.8/ 35.6] 380.1/ 13.3 [86.3/ 39.8] 411.7/ 13.0 [93.5/ 38.9] Min/ Max Water Flow USgpm[m³/hr] 117.0/ [26.6/ 133.2] 117.0/ [26.6/ 133.2] 117.0/ [26.6/ 133.4] 117.0/ [26.6/ 133.4] 128.0/ [29.1/ 145.3] 142.0/ [32.2/ 160.0] Min/ Max Water Pressure Drop ft.wg[kpa] 1.6/ 28.8 [4.8/ 86.1] 1.6/ 28.8 [4.8/ 86.1] 1.9/ 33.8 [5.7/ 101.1] 1.9/ 33.8 [5.7/ 101.1] 1.9/ 33.9 [5.7/ 101.4] 1.9/ 34.3 [5.7/ 102.6] CONDENSER Coil Rows Deep/ Total Face Area ft²[m²] 4/ [15.1] 4/ [15.1] 4/ [17.5] 4/ [17.5] 4/ [21.9] 4/ [21.9] No. Of Fan Fan Diameter (Qty) inches[mm] 31.5 [800](8) 31.5 [800](8) 31.5 [800](8) 31.5 [800](8) 31.5 [800](10) 31.5 [800](10) Motor kw i (Qty) 2(8) 2(8) 2(8) 2(8) 2(10) 2(10) FLA, AMP (Qty) 3.8(8) 3.8(8) 3.8(8) 3.8(8) 3.8(10) 3.8(10) Total Air Flow cfm[m³/hr] [165285] [165285] [175419] [172278] [215348] [219273] Min. Operating Ambient F[ C] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] ELECTRICAL Nominal Voltage 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 Unit RLA A Unit Max. Inrush A GENERAL Unit Length inches[mm] 192 [4877] 192 [4877] [5144] 192 [4877] 234 [5944] 234 [5944] Unit Width inches[mm] 88 [2235] 88 [2235] 88 [2235] 88 [2235] 88 [2235] 88 [2235] Unit Height inches[mm] 87.5 [2222] 87.5 [2222] 96.5 [2451] 96.5 [2451] 96.5 [2451] 96.5 [2451] Shipping Weight lbs[kg] [5458] [5214] [5593] [5850] [6968] [6613] Operating Weight lbs[kg] [5555] [5311] [5707] [5964] [7095] [6750] Operating Charge R134a lbs[kg] 322 [146] 355 [161] 388 [176] 401 [182] 483 [219] 522 [237] Note: Nominal capacity is based on evaporator LWT 44 F and condenser ambient 95 F, actual capacity depends on the specified operating conditions

13 PERFORMANCE DATA LWT F Model AFHX Ambient Temperature, F TR kw kw I TR kw kw I TR kw kw I TR kw kw I 75-6SR T-6SR T-6SR SR SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR SR SR T-6SR T-6SR SR Notes: 1.) Ratings based on 10 F water range in evaporator and.0001 hr.ft². F/BTU fouling factor. 2.) Interpolation between ratings is permissible but extrapolation is NOT. 3.) kw I is for compressor input. 4.) Unit is running on part load for ambient temperature 115 F and above due to current limiter

14 PERFORMANCE DATA LWT F Model AFHX Ambient Temperature, F TR kw kw I TR kw kw I TR kw kw I TR kw kw I 75-6SR T-6SR T-6SR SR SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR T-6SR SR SR T-6SR SR SR T-6SR T-6SR SR Notes: 1.) Ratings based on 10 F water range in evaporator and.0001 hr.ft². F/BTU fouling factor. 2.) Interpolation between ratings is permissible but extrapolation is NOT. 3.) kw I is for compressor input. 4.) Unit is running on part load for ambient temperature 115 F and above due to current limiter

15 DIMENSIONAL DATA AFHX 75-6SR, 100-6SR AFHX 80T-6SR, 90T-6SR AFHX 115-6SR, 135-6SR Note : All dimensions are in inches[mm]

16 DIMENSIONAL DATA AFHX 125T-6SR, 150T-6SR AFHX 150-6SR Note : All dimensions are in inches[mm]

17 DIMENSIONAL DATA AFHX 175T-6SR AFHX 190-6SR Note : All dimensions are in inches[mm]

18 FLOOR LOADING DIAGRAM a.) POINT LOAD LOCATION inches[mm] Model AFHX A Dim. B Dim. C Dim. D Dim. E Dim. 75-6SR 86[2184] 18[457] 57[1448] 57[1448] 18[457] 80T-6SR 86[2184] 18[457] 57[1448] 57[1448] 18[457] 90T-6SR 86[2184] 18[457] 57[1448] 57[1448] 18[457] 100-6SR 86[2184] 18[457] 57[1448] 57[1448] 18[457] 115-6SR 86[2184] 18[457] 78[1981] 78[1981] 18[457] 125T-6SR 86[2184] 18[457] 78[1981] 78[1981] 18[457] 135-6SR 86[2184] 18[457] 78[1981] 78[1981] 18[457] 150-6SR 86[2184] 18[457] 83-1/4[2115] 83-1/4[2115] 18[457] 150T-6SR 86[2184] 18[457] 78[1981] 78[1981] 18[457] 175T-6SR 86[2184] 18[457] 99[2515] 99[2515] 18[457] 190-6SR 86[2184] 18[457] 99[2515] 99[2515] 18[457] b.) POINT LOAD DATA lbs [kg] Model AFHX Pos. #1 Pos. #2 Pos. #3 Pos. #4 Pos. #5 Pos. #6 Total Operating Weight 75-6SR 1297 [588] 1464 [664] 1630 [739] 1465 [665] 1416 [642] 1368 [621] 8641 [3919] 80T-6SR 1633 [741] 1578 [716] 1523 [691] 1462 [663] 1482 [672] 1501 [681] 9179 [4164] 90T-6SR 1737 [788] 1675 [760] 1612 [731] 1550 [703] 1575 [714] 1599 [725] 9749 [4422] 100-6SR 1415 [642] 1614 [732] 1813 [822] 1598 [725] 1543 [700] 1487 [674] 9470 [4296] 115-6SR 1607 [729] 1849 [839] 2091 [948] 1795 [814] 1855 [841] 1915 [869] [5040] 125T-6SR 2169 [984] 2094 [950] 2020 [916] 1819 [825] 1987 [901] 2156 [978] [5555] 135-6SR 1700 [771] 1954 [886] 2208 [1002] 1886 [855] 1949 [884] 2011 [912] [5311] 150-6SR 1794 [814] 2102 [953] 2411 [1094] 2057 [933] 2091 [948] 2125 [964] [5707] 150T-6SR 2323 [1054] 2258 [1024] 2192 [994] 1994 [904] 2125 [964] 2256 [1023] [5964] 175T-6SR 3046 [1382] 2787 [1264] 2528 [1147] 2145 [973] 2427 [1101] 2708 [1228] [7095] 190-6SR 2056 [933] 2257 [1024] 2458 [1115] 2715 [1232] 2704 [1227] 2692 [1221] [6750]

19 DIMENSIONAL CLEARANCE SPACE REQUIREMENTS Single Pit (See Note 2) Double Pit (See Note 2) Multi Pit Corner Wall Notes: 1.) All dimensions are minimal, unless otherwise noted. 2.) Pit installations are not recommended. Re-circulation of hot condenser air in combination with surface air turbulence cannot be predicted. Hot air re-circulation will severely affect unit efficiency (EER) and can cause high pressure or fan motor temperature trips. Dunham- Bush will not be responsible for ducting fans to a higher level to alleviate the above mentioned conditions

20 EVAPORATOR WATER PRESSURE DROP IMPERIAL UNITS 100 PRESSURE DROP - ft.wg AFHX 75-6SR AFHX 80T-6SR AFHX 90T-6SR AFHX 100-6SR AFHX 115-6SR AFHX 150-6SR AFHX 150T-6SR AFHX 125T-6SR AFHX 135-6SR AFHX 175T-6SR AFHX 190-6SR WATER FLOW RATE - USgpm S. I. UNITS PRESSURE DROP - kpa AFHX 75-6SR AFHX 80T-6SR AFHX 90T-6SR AFHX 100-6SR AFHX 115-6SR AFHX 150-6SR AFHX 150T-6SR AFHX 125T-6SR AFHX 135-6SR AFHX 175T-6SR AFHX 190-6SR WATER FLOW RATE - m³/hr SOUND PRESSURE DATA Model Octave Band (Hz) K 2K 4K 8K AFHX 75-6SR AFHX 80T-6SR AFHX 90T-6SR AFHX 100-6SR AFHX 115-6SR AFHX 125T-6SR AFHX 135-6SR AFHX 150-6SR AFHX 150T-6SR AFHX 175T-6SR AFHX 190-6SR Note: Unit Sound Pressure Level 33 ft [10m] (free field), ± 2 db tolerance. Total db (A)

21 CONDENSER FAN FAN POSITION NUMBER & CYCLING SEQUENCE AFHX 75-6SR, 100-6SR, 80T-6SR, 90T-6SR AFHX 115-6SR, 135-6SR, 150-6SR, 125T-6SR, 150T-6SR BASE FANS 2, 4, 6 BASE FANS 2, 4, 6, 8 STAGE 1 1, 5 STAGE 1 1, 5 STAGE 2 3 STAGE 2 3, 7 AFHX 175T-6SR, 190-6SR BASE FANS 2, 4, 6, 8, 10 STAGE 1 1, 5 STAGE 2 3, 7 STAGE 3 9 ELECTRICAL DATA MODEL AFHX COMPRESSOR DATA COND. FAN MOTOR DATA UNIT ELECTRICAL DATA MODEL QTY RLA LRA QTY HP FLA FLA MCA MFS 75-6SR HX T-6SR HX T-6SR HX SR HX SR HX T-6SR HX SR HX SR HX T-6SR HX T-6SR HX1709 HX SR HX Note: MCA - Minimum Circuit Ampacity MFS - Maximum Fuse Size RLA - Running Load Amps FLA Full Load Amps LRA - Locked Rotor Amps

22 TYPICAL WIRING SCHEMATIC TWO COMPRESSORS UNIT

23 TYPICAL WIRING SCHEMATIC

24 TYPICAL WIRING SCHEMATIC Ω Ω

25 TYPICAL WIRING SCHEMATIC

26 GUIDE SPECIFICATIONS 1. The contractor shall in accordance with the plans, furnish and install Dunham-Bush packaged liquid chiller(s). The unit(s) shall be completely factory packaged including rotary screw compressor(s), evaporator, condenser, and controller control center. The packaged chiller shall be factory assembled, charged and tested with a full operating refrigerant and oil charge. The refrigerant type shall be R134a. 2. Capacity of each chiller shall be not less than TR (kw output) cooling USgpm (liters/min.) of water from F[ C] to F[ C]. Power input requirements for the unit(s), incorporating all appurtenances necessary for unit operation, including but not limited to the control accessories and oil pump or pumps, if required, shall not exceed kw input at design conditions. The unit shall be able to unload to % of cooling (refrigeration) capacity when operating with leaving chilled water and entering condenser temperature at full load design temperatures. The unit shall be capable of continuous operation at this point, with stable compressor operation, without the use of hot gas bypass. 3. Heat transfer surfaces shall be selected to reflect the incorporation of a fouling factor of hr.ft². F/BTU [ m². C/W] for the evaporator. Water pressure drop at design conditions shall not exceed feet of water through the evaporator. 4. The packaged chiller shall be furnished with singlestage direct connected positive displacement rotary screw compressor(s) as required, of the oil injected type, driven by a 3500 RPM (2900 RPM-50Hz) motor. Each compressor shall include an integral oil separation system, oil sump and oil filter. The oil temperature shall be controlled during operation to maintain proper oil temperatures throughout the lubrication system. An electric oil heater shall be supplied with each compressor to maintain oil temperature during shutdown period. Each compressor shall have a suction filter, suction service valve and a discharge check valve. Compressor capacity control shall be obtained by an electrically initiated, hydraulically actuated slide valve within each compressor housing. (Provide isolation valves on all connections to compressor to allow condenser to be used as a pump down receiver.) 5. Evaporator vessels shall all be cleanable shell and tube type with integral finned copper water tubes mechanically expanded into heavy fixed steel tube sheets. They are to be available in one, two or three pass design as required on the drawings with Victaulic connections. Flanges or stub out connections optional. The shell side of the evaporator is to have a single relief valve with provision for refrigerant venting. Evaporators shall be designed, constructed in accordance with the ASME Code for Unfired Pressure Vessels. The flooded evaporator shall have a built in distributor for feeding refrigerant evenly under the tube bundle to produce a uniform boiling action and baffle plates shall be provided to ensure vapor separation. Water headers are to be removable for tube cleaning. Vent and drain plugs are to be provided in each head. (All low temperature surfaces shall be factory insulated.) 6. The flooded evaporator shall be fitted with an oil recovery system. The oil recovery system will ensure that the evaporator is operating at peak efficiency at all times and provide optimal energy efficiency during extended periods of part load. Units without oil recovery systems mounted on the evaporator will not be acceptable. 7. The condenser coil is to be constructed of copper tubes and die formed aluminum fins having selfspacing collars. Fins shall be mechanically bonded to the tubes. An integral sub-cooling loop shall be incorporated into the coil. Condenser divider baffles shall fully separate each condenser fan section to control the airflow to maintain proper head pressure control. The condenser shall be sized for pump down capacity. 8. To maximize energy efficiency, the packaged chiller shall be equipped with a flash economizer cycle and modulating refrigerant expansion devices. Refrigerant vapor from the flash economizer shall be fed back into an intermediate compressor stage, reducing the enthalpy of the refrigerant and increasing the net refrigeration effect of the evaporator

27 GUIDE SPECIFICATIONS 9 The fans shall be heavy duty, polypropylene blade, direct drive propeller type. Motors shall be three phase with internal overloads and are to be permanently lubricated. 10. The packaged chiller shall be furnished with a modulating refrigerant control system to optimize efficiency and compressor protection. This refrigerant control system will reduce the flow of efficiency robbing refrigerant vapor in the condenser from entering the evaporator at reduced load by directly modulating a motorized refrigerant valve in the liquid line entering the evaporator. In addition, the refrigerant control system shall measure the level of liquid refrigerant in the flooded evaporator and restrict refrigerant flow entering the evaporator upon a rise in the level, protecting the compressor from liquid slugging. Fixed orifice control systems will not be acceptable. (Hot gas bypass shall be factory installed for operation below minimum percent of unit capacity.) 11. The packaged chiller shall be equipped with controller control. The control shall provide for compressor loading based on leaving chilled water temperature. It shall provide for high and low refrigerant pressure protection, low oil level protection, evaporator water freeze protection, sensor error protection, and motor load control (demand limiter) based on amp draw. Anti-recycle protection shall also be provided. The controller shall have a simple keypad accessed input system and be complete with a two-line 80 character alphanumeric display. Input shall be accomplished through simple menu driven display screens, with on-line help available by pressing a help button at anytime during operation. The controller shall continuously monitor evaporator leaving water temperature; evaporator and condenser pressure; compressor amp draw; and refrigerant. The controller shall be complete with all hardware and software necessary to enable remote monitoring of all data through the addition of only a simple, phone modem and terminal. The controller shall be complete with an RS232 "local" communications port and an RS485 long distance differential communications port. The controller shall also accept a remote start and stop signal, 0 to 5VDC chilled water temperature reset signal and (0 to 5VDC compressor current limit reset signal). Terminal or PC with communication software installed to enable remote monitoring. 12. The electrical control panel shall be wired to permit fully automatic operation during - initial start-up, normal operation, and shutdown conditions. The control system shall contain the following control and safety devices: MANUAL CONTROLS Control circuit stop and start switches Compressor enable switch SAFETY CONTROLS Solid state compressor motor starter overloads (3 phase) Low oil level optical sensor High condenser pressure Low evaporator pressure Freeze protection Chilled water flow loss Under voltage phase failure relay AUTOMATIC CONTROLS Compressor motor increment contactors Increment start timer Anti-recycle timer Oil sump heater interlock relays REFRIGERANT CONTROLS Motorized refrigerant flow control Liquid refrigerant level sensor for evaporator Compressor load and unload solenoid valves INDICATOR LIGHTS Power on Compressor high oil temperature Compressor motor overload System common alarm 13. The control system shall be provided with an antirecycle device. The control shall limit compressor starting to a minimum of 15 minutes between starts. 14. The packaged chiller shall be furnished with unit mounted reduced inrush starting system for each compressor. The starters shall be factory mounted and wired, with individual circuit breakers on multiple compressor units. The unit shall be wired so that the only field electrical connection to the packaged chiller shall be to a single three-phase power terminal. Optional items in ( )