AFVXB Series 50Hz. Air Cooled Screw Flooded Chillers Cooling Capacity: 100 to 520 TR (352 to 1830 kw) Products that perform...

Transcription

1 AFVXB Series 50Hz Air Cooled Screw Flooded Chillers Cooling Capacity: 100 to 520 TR (352 to 1830 kw) 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-bybuilding, country-by-country and region-by-region. No other HVAC/R manufacturer takes this approach to meeting your performance expectations. The Dunham-Bush name is synonymous worldwide with the Rotary Screw Compressor Chillers technology. With over 40 years of proven experience and track records in manufacturing and installation of Rotary Screw Compressors and chillers, thousands of our Chillers have clocked more than 100,000 operating hours without any compressor tear-out or overhaul! As a pioneer and industry leader in the Rotary Screw compressor technology for HVAC/R systems, Dunham-Bush now introduces the Air Cooled Rotary Screw Flooded Chillers with unsurpassed performance and reliability. AFVXB-5SR, Air Cooled Screw Flooded Chillers, have a cooling capacity range from 100 to 520 TR [352 to 1830 kw] in 50Hz version using environmentally sound R134a refrigerant. The entire product line features high energy efficiency, installation ease, control flexibility, high reliability and advanced 2020i controller. TABLE OF CONTENT Page No Introduction... 2 Nomenclature... 2 Advantages of Flooded Chiller... 3 Components... 5 Standard Features... 5 Unit Features... 6 Operating Benefits Unit Options Unit Accessories Typical Sequence of Operation Application Data Page No Physical Specifications Performance Data Dimensional Data Floor Loading Diagram Dimensional Clearance Condenser Fan Sound Pressure Data Electrical Data Typical Wiring Schematic Guide Specifications NOMENCLATURE A F V X B 95-5 S R Air Cooled Chiller R134a Flooded Evaporator Vertical Screw Compressor Standard 5-50Hz 6-60Hz Generation Nominal TR - 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 electronic expansion valve which modulates the subcooled liquid refrigerant into the evaporator. Thus ensure 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. 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 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 enable 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]. 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 compressor. In a flooded evaporator, the refrigerant boils off in the shell and gas only 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 flooded design will impose less capacity penalty on the compressor and this further enable the compressor in a flooded evaporator to generate more capacity than one in a DX Evaporator. FIGURE 1 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 for the same compressor in a flooded evaporator system will operate at a higher saturated evaporating temperature when compare 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 Dunham-Bush 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 generates approximately 13.1% more cooling capacity while kw input increases negligibly of less than 3.6%. Therefore, same compressor when coupled to a flooded evaporator will typically achieve higher cooling capacity with correspondingly higher Energy Efficiency Ratio (EER) or (BTU/Watt) or lower kw/tr

4 ADVANTAGES OF FLOODED CHILLER 2. Better Part Load Performance The Dunham-Bush Air Cooled Flooded Chiller with its sophisticated controller control and patented oil management system ensure all evaporator tubes are 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. On the contrary, in the direct expansion evaporator, because of the need to maintain adequate refrigerant gas velocities in the evaporator tubes for proper oil return, it is typical for certain bundle of evaporator tubes to be blocked or baffled off at part-load conditions. Therefore not utilizing the fullload transfer surface of the evaporator tubes means lower efficiency when compared with flooded evaporator chiller at part-load conditions. 5. Maximum Reliability and Redundancy Today, the Dunham-Bush vertical screw compressors are increasingly accepted for its reliability. The 2-compressor models are designed to have 2 independent refrigerant circuits for redundancy. Individual compressor is provided with suction stop valve, discharge stop valve and other isolating valves in the oil management system to allow complete isolation of an unlikely faulty compressor without contaminating the refrigerant system. 6. Cleanable Evaporator Evaporator water heads can be removed easily without dismantling the chilled water piping connections, for inspection and for mechanical tubes cleaning with brushes. This will enable low tube fouling factor in the evaporator to be ensured, thus maintaining system efficiency. 3. Economizer/ Vapor Injection Cycle for Increase Capacity and Higher EER The renowned Dunham-Bush vertical screw compressor allows for 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 economizer 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 Vision 2020i controller in combination with the electronic level controller and electronic expansion valves to ensure instantaneous and precise feeding of liquid refrigerant to the flooded evaporator in response to changes in building loads demand; and maintains precise (±1/2 F) preset outlet chilled water temperatures even at very low load conditions; whereas most of Dunham-Bush s competitors, in screw chillers, still utilizes the conventional centrifugal chiller method of using orifice plates to modulate refrigerant feed to the evaporator; and as such their machines does at function efficiently at low-load conditions and can encounter oil return problem! 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 higherpressure drop as compared with the water flow in the tubes of a flooded evaporator. In other words, the flooded chillers will require smaller water pumps to operate at lower power consumption. 8. Commonly Use In Large Tonnage Chillers Where Efficiency Is Critical As a general rule, the DX Evaporator are typically used in small and medium tonnage chillers where efficiency is not important and the low initial cost is the main consideration! 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 but also in the small and medium tonnage chillers. Dunham-Bush, again, leads the industry in this respect! - 4 -

5 COMPONENTS V-coils configuration for small floor space requirement Direct driven fans Controller for safety protections, precise and reliable control Hermetic rotary screw compressors Rigid structural steel base to prevent unit deflection and coils and piping damage during hoisting Flooded evaporator with cleanable and removable enhanced copper tubes Vapor injection cycle for increase capacity and improve efficiency Bolted construction for easy semi knockdown assembly at site in case of hoisting problem STANDARD FEATURES Size / Range 14 models from 100 to 520 TR [352 to 1830kW] at AHRI standard conditions. Multiple compressor models provide redundancy, and superior part load efficiency. Compressor(s) Improved, quiet, reliable MSC Vertical Rotary Screw Compressors with up to 2 integral oil separators. Optimized for R134a and optimized volume ratio for best efficiency. Improved rpm and noise level. Optimized rotor drive. Improved rotor and anti-reverse rotation bearing design. Optimized VI port position and geometry. Compartmentalized to reduce noise breakout. Multiple rotary screw compressors design for better reliability and redundancy. Welded hermetic design with no requirement for internal parts service, no periodic compressor tear down and overhaul, and eliminates casing leakages. Consistent loading and unloading with dependable slide valve mechanism. No external oil pump required. Double-delta motor winding with 1/3 lock-rotor amps at start-up. Star-delta motor winding for MSC 226 mm series. Faulty or damaged compressors reworkable at minimal cost at various Dunham-Bush s authorized compressors reworked facilities. To ensure minimum downtime during rework of faulty or damaged compressor, Dunham-Bush can arrange to provide a substitute reworked compressors while the faulty compressor is being reworked or repaired. Vapor injection cycle to increase capacity and improve efficiency. Evaporator Two pass for all models. Cleanable and removable integral fin copper tubes for easy serviceability. For a wide variety of applications. Removable water heads for service. Flange/victaulic water connections for quick installation or service (refer Dimensional Data). Build according to ASME code, PED whenever required. JKKP approval. Relief valves(s) standard 3/4 [19mm] FPT

6 STANDARD FEATURES Controller/ Factory Packaged Power Panel Proactive advanced controller adapts to any abnormal operating conditions and for safety protections. Tolerant and accommodating of extreme conditions at start-up. Capable of controlling multiple chillers, pumps, and etc. Circuit breaker on each multiple compressors unit. Unit mounted step-start contactors and delay for reduced inrush starting current. Under and over voltage phase protection relay. Indicator lights for compressor overloads, controller alarm, control power, compressor control circuit, and etc. Condenser Coil/ Fans Constructed with seamless inner-grooved copper tubes expanded into die-formed aluminum fins in staggered configuration. Leaked and pressure tested to 450psig [31bar]. High efficiency low-noise condenser fan. V coil design to increase condensing surface area. V coil with internal baffle for fan cycling and fan staging. UNIT FEATURES ADVANCED CONTROLLER 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. Vision 2020i a flexible and advance programmable microprocessor 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: DB5-S small, DB5-M medium and DB5-L large board. 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 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

7 UNIT FEATURES 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. 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 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

8 UNIT FEATURES The Revolutionary Dunham-Bush Vertical Screw Compressor Dunham-Bush introduced the revolutionary Vertical Screw Compressors in the early 1970 s. Since then, the compressor has undergone several design changes to improve efficiency, and reliability! Today, The Dunham-Bush vertical screw compressors is not only the most efficient and reliable screw compressor in its capacity range; but it is the most completely packaged rotary Screw Compressors for use in flooded chillers! The Dunham-Bush vertical screw compressor and motor assembly is completely housed in an integral oil separator heavy-duty steel casing -- therefore eliminating the need for an external oil separator and its associated piping connections. Now the compressor oil separator is improved to 2. The compressor does not require an external oil pump as it lubricates the bearing and rotors by use of the pressure differential between the discharge and suction cavities of the compressor. Thus, there is also no need for an external compressor oil cooler and its associated piping connections. The compressor is completely sealed to prevent leakage and there is no need to service the few internal moving parts of the compressor. 2 ND OIL SEPARATOR 1 ST OIL SEPARATOR MOTOR REPLACEABLE SUCTION FILTER SUCTION CHECK VALVE SUCTION MALE (DRIVE) ROTOR DISCHARGE OIL DEFLECTOR CAP OIL STRAINER Compressor Assembly The Dunham-Bush rotary screw compressor is a positive displacement helical-axial design optimised for use with specific refrigerants. The compressor consists of two intermeshing helical grooved rotors, a male drive rotor and a female driven rotor, in a stationary housing with suction and discharge gas ports. Uniform gas flow, even torque and positive displacement, all provided by pure rotary motion contributes to vibration-free operation over a wide range of operating conditions. Intake and discharge cycles overlap, effectively producing a smooth, continuous flow of gas. No oil pump is required for lubrication or sealing purposes. Oil is distributed throughout the compressor by the pressure differential between the suction and the discharge cavities. Simplified Capacity Control The slide valve mechanism for capacity modulation and part load operation is outstanding feature: The moving parts are simple, rugged and troublefree. The slide mechanism is hydraulically actuated. Package capacity reduction can be down to as low as 12.5% without HGBP by stepless movement of slide valves. Capacity reduction is programmed by an exclusive electronically initiated, hydraulically actuated control arrangement. Positive Displacement Direct Drive The compressor is directly connected to the motor without any complicated gear systems to speed up the compressor and thus detract from the overall unit reliability. Oil Separation Each compressor is provided with up to 2 integral oil separators/impingement plate located below the discharge gas port. The separator is a multi-layered mesh element which effectively separates oil from the gas stream. The oil drains into sump and discharge gas passes around the deflection plate. An oil drain valve is located near the bottom of the oil sump. Each rotor is fitted with a set of anti-friction tapered roller bearings. They carry both radial and thrust loads. Anti-reverse rotation bearings are used. Rotors The latest asymmetrical rotor profiles of patented Dunham-Bush design assure operation at highest efficiencies. Rotors are precision machined from high strength alloy steel and precision ground, in- house. Castings All housings are manufactured of high grade and low porosity cast iron

9 UNIT FEATURES FIG. A FIG. B FIG. C FIG. D Solid State Motor Protection The motor winding protection module used in conjunction with sensors embedded in the compressor motor windings is designed to prevent the motor from operating at unsafe operating temperatures. The overloads for the motor are also solid state. Compressor Operation Note: For clarity reasons, the following account of the compressor operation will be limited to one lobe on the male rotor and one interlobe space of the female rotor. In actual operation, as the rotors revolve, all of the male lobes and female interlobe spaces interact similarly with resulting uniform, non-pulsating gas flow. Suction Phase As a lobe of the male rotor begins to unmesh from an interlobe space in the female rotor, a void is created and gas is drawn in tangentially through the inlet port-- Fig. A. --as the rotors continue to turn the interlobe space increases in size-- Fig. B. --and gas flows continuously into the compressor. Just prior to the point Compressor Fully Unloaded at which the interlobe space leaves the inlet port, the entire length of the interlobe space is completely filled with drawn in gas -- Fig. C. Compression Phase As rotation continues, the gas in the interlobe space is carried circumferentially around the compressor housing. Further rotation meshes a male lobe with the interlobe space on the suction end and squeezes (compresses) the gas in the direction of the discharge port. Thus the occupied volume of the trapped gas within the interlobe space is decreased and the gas pressure consequently increased. Discharge Phase At a point determined by the designed "built-in" compression ratio, the discharge port is covered and the compressed gas is discharged by further meshing of the lobe and interlobe space--fig D. While the meshing point of a pair of lobes is moving axially, the next charge is being drawn into the unmeshed portion and the working phases of the compressor cycle are repeated. Compressor Fully Loaded Slide Valve Control Movement of the slide valve is programmed by an exclusive Dunham-Bush electronically initiated (by variations in leaving chilled water temperature) hydraulically actuated control arrangement. When the compressor is fully loaded, the slide valve is in the closed position. Unloading starts when the slide valve is moved back away from the valve stop. Movement of the valve creates an opening in the side of the rotor housing. Suction gas can then pass back from the rotor housing to the inlet port area before it has been compressed. Since no significant work has been done on this return gas, no appreciable power losses are incurred. Reduced compressor capacity is obtained from the gas remaining in the rotors which is compressed in the ordinary manner. Enlarging the opening in the rotor housing effectively reduces compressor displacement

10 UNIT FEATURES REFRIGERATION CYCLE Dunham-Bush rotary screw air cooled chillers are designed for efficiency and reliability. The rotary screw compressor is a positive displacement, variable capacity compressor that will allow operation over a wide variety of conditions. Even at high head and low capacity, a difficult condition for centrifugal compressors, the rotary screw performs in a stable manner. It is impossible for this positive displacement compressor to surge. The refrigerant management system, however, is very similar to centrifugal water chillers and 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 positive displacement compression begins. This partially compressed gas is then combined with additional gas from the vapor injection port at an intermediate pressure. 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. Fully compressed and superheated refrigerant is then discharged into the condenser, where air is being drawn through the condenser tube by the propeller fan cools and condenses the refrigerant. The liquid refrigerant then passes through the economizer. A portion of liquid refrigerant is tapped passes through the first expansion device back into the economizer for further subcooling of main liquid refrigerant flow. The gaseous refrigerant is then drawn out of the economizer and into the vapor injection port of the compressor. The remaining subcooled liquid refrigerant then passes through a second expansion device which reduces refrigerant pressure to evaporator levels where it is then distributed evenly into the evaporator. With the additional subcooling, the enthalpy of the refrigerant flowing into the evaporator is reduced which increases the refrigeration effect and improves the efficiency of the refrigeration cycle. PART-LOAD PERFORMANCE Through the use of economizer and electronic expansion valve, Dunham-Bush rotary screw air cooled flooded chillers have some of best part-load performance characteristics in the industry. 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 rotary screw air cooled flooded chillers combine the efficient operation of rotary screw compressors with an economizer cycle and microprocessor control to yield the best total energy efficiency and significant operating saving under any load as the flooded evaporator fully utilize the total heat transfer area of the tubes, where DX evaporators are not able to do so. 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

11 OPERATING BENEFITS EFFICIENCY AND RELIABILITY Compressor Experience 40 years of rotary screw experience and dedicated technological advancements. Compressors are CE listed. Simply designed for high reliability with only two rotating parts. No gears to fail. Ensured continuous oil flow to each compressor through integral high efficiency oil separation for each compressor. Chillers use multiple rotary screw compressors for fail-safe reliability and redundancy. Energy Efficiency Designed to provide the greatest amount of cooling for the least kilowatt input over the entire operating range of your building. Delivers outstanding efficiency and total energy savings through the utilization of economizer cycle and microprocessor controlled staging producing greater capacity with fewer compressors. Maximized performance through computer-matched components. 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. Optional Advantages Dramatic payback in reduced maintenance and overhaul costs both in down time and in labor expenditures. Ease of troubleshooting through microprocessor 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. ASHRAE Standard 15 Safety Code for Mechanical Refrigeration. IEEE. Safety quality license for import boiler and pressure vessel, China. Optional PED Approval. Refrigerant Compatibility Designed to operate with environmentally safe 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 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 microprocessor controller which utilize pressure transducers to measure evaporator and condenser pressure, and current drawn by each compressor. 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 costs, communication card option. Proactive control by controller that anticipates problems and takes corrective action before they occur. Controls will unload compressor(s) if discharge or suction pressure approach limits. This will enable unit to stay on the line while warning operator of potential problems

12 UNIT OPTIONS Options Installed At The Factory Heat reclaim condensers (desuperheaters) are available for special applications. Main Incoming Isolator Factory installed main disconnect for entire unit. Copper Condenser Fins - Copper fins offer better corrosion protection for severe conditions. In more corrosive environments, hydrophilic or Adsil-coated fins would be more appropriate. Hot Gas Bypass - Consists of hot gas bypass regulator(s) and solenoid valve(s) for each circuit for applications with a minimum load which may dip below the unit s minimum unloaded capacity. 115V Convenience Outlet - Duplex outlet located inside the control panel and protected by a 15 amp fuse. Low Ambient Controls (LAC option) - Kindly refer to Low Ambient Operation/ Freeze Protection. Compressor Start Counter - One start counter provided for each compressor, located inside the control panel. Compressor Elapsed Time Meter - One elapsed time meter to register run hours per compressor, located inside the control panel. Three Phase Ammeter - Single analog ammeter with a 3 phase selector switch for indication, located inside the control panel. Three Phase Voltmeter - Single analog voltmeter installed with a 3 phase selector switch for indication, located inside the control panel. UNIT ACCESSORIES Accessories Shipped Unmounted Water Flow Switch - Paddle type field adjustable flow switch available for all units, installed into the unit safety circuit so that the chiller will remain off until there is water flow. Helps to prevent evaporator from freezing. Vapor-proof enclosure, for use on water or glycol systems. The flow switch is to be shipped loose and installed at site. Rubber-in-shear Isolators - Designed for ease of installation, these rubber, one-piece, molded isolators are applicable for most installations. Spring Isolators - These housed spring assemblies have a neoprene friction pad at the bottom to prevent the passage of noise, and a spring locking levering bolt at the top. Neoprene inserts prevent contact between the steel upper and lower housings. Suitable for more critical applications as compared to rubber-in-shear isolators

13 TYPICAL SEQUENCE OF OPERATION The Dunham-Bush air cooled water chiller depends mainly on its on-board controller for control. Operation described is for two-compressor units and is very similar for single compressor unit. 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. After a one-minute delay, the first contactor (e.g. 1M-1) is energized followed by the second contactor (e.g. 1M-2) after onesecond-time delay. This provides reduced inrush stepped 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, 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 controller. The controller 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 controller will continue loading the compressor until a satisfactory rate of temperature 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 compressors will start in the same manner as the first. Then both compressors will be commanded to adjust load to approximately 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 90%. If applied load decreases further, the remaining compressor unloads proportionally. If applied load decreases to less than the minimum capacity of one compressor, the leaving chilled water temperature will gradually decline to 2 F [1.1 C] below setpoint, and then 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 controller 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 controller closes refrigerant flow control valves, starving the evaporator, causing evaporator pressure to drop, hence 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

14 APPLICATION DATA Low Ambient Operation / Freeze Protection If unit is required to operate below 65 F [18.3 C], optional head pressure control is required. 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. Desupperheater reclaim the desuperheated gas energy for hot water utility. Consult factory for further details. Water Circuit Constant water flow required with a minimum of 3 gallons per TR [3.3 liters/kw] increasing up to 10 gallons per TR [11 liters/kw] for process, low load applications with small temperature ranges and/or vastly fluctuating load conditions. Glycol Freeze Protection If the chiller or fluid piping is to 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 water in 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 Note: The Correction Factor is for LWT down to 44 F only. Propylene Glycol % P. G. By Weight Freeze Point F C C2 Capacity Factor K2 kw Rate G2 Flow Factor P2 P. D. Factor Note: The Correction Factor is for LWT down to 44 F only. 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

15 PHYSICAL SPECIFICATIONS Model AFVXB 95-5SR 110-5SR 135-5SR 160-5SR 200-5SR 225-5SR 250-5SR Cooling Capacity TR kw Power Input kw Energy efficiency kw/tr COP [kw o /kwi] Compressor Model (Qty) 1218 (1) 1222 (1) 1222 (1) 1227 (1) 1230 (1) 2233 (1) 2236 (1) RPM Min. % Unit Capacity Reduction 25% 25% 25% 25% 25% 25% 25% Compressor Power kw Compressor Rated Current amp Compressor Starting Current amp Evaporator Model (Qty) C4R (1) 1CR (1) 1DR (1) 2ER (1) 2 FR (1) EBR (1) JCR (1) Water Connector inches[mm] 4[101.6] 5[127] 5[127] 6[152.4] 6[152.4] 6[152.4] 8[203.2] Nom. Water Flow USgpm[l/s] [15.1] [16.8] [21.4] [25.8] [29.4] [34.5] [39.4] Nom. Water Pressure Drop ft.wg[kpa] 12.0 [36] 25.4 [76] 27.4 [82] 29.4 [88] 29.1 [87] 28.8 [86] 28.4 [85] Condenser Coil Row Total Face Area sq.ft[sq.m] 117.9[11] 165[15.3] 165[15.3] 212.2[19.7] [24.1] 259.3[24.1] 306.5[28.5] No of Fans Fan Dia inches[mm] Fan Motor HP Fan Motor FLA amp Electrical Nom. Voltage Unit RLA amp Unit MCA amp Unit MFS amp Unit Max. Inrush amp General Unit Length inches[mm] 140.2[3560] 185.4[4710] 185.4[4710] 230.7[5860] [7210] 283.9[7210] 329.1[8360] Unit Width inches[mm] 88[2235] 88[2235] 88[2235] 88[2235] 88 [2235] 88[2235] 88[2235] Unit Height inches[mm] 88[2235] 88[2235] 88[2235] 88[2235] 93.2 [2368] 93.2[2368] 93.2[2368] Shipping Weight lbs[kg] 7480[3400] 9273[4215] 9570[4350] 11220[5100] [5650] 14300[6500] 15620[7100] Operating Weight lbs[kg] 7744[3520] 9636[4380] 9988[4540] 11660[5300] [5850] 14784[6720] 16170[7350] Operating Charge R134a lbs[kg] 253[115] 275[125] 275[125] 440[ 200] 539[245] 539[245] 550[250] Model AFVXB 280-5SR 310-5SR 340-5SR 360-5SR 400-5SR 450-5SR 500-5SR Cooling Capacity TR kw Power Input kw Energy efficiency kw/tr COP [kw o /kwi] Compressor Model (Qty) 1222 (2) 1227 (1), 1230 (1), 1227 (2) 1222 (1) 1227 (1) 1230 (2) 2233 (2) 2236 (2) RPM Min. % Unit Capacity Reduction 12.5% 12.5% 12.5% 12.5% 12.5% 12.5% 12.5% Compressor Power kw Compressor Rated Current amp / / / / / / / Compressor Starting Current amp 645 / / / / / / / 1571 Evaporator Model (Qty) Q1R (1) S1R (1) S1R (1) S2R (1) 2FR(2) EBR(2) JCR (2) Water Connector inches[mm] 8 [203.2] 8 [203.2] 8 [203.2] 8 [203.2] 6 [152.4] 6 [152.4] 8[203.2] Nom. Water Flow USgpm[l/s] [42.8] [47.2] [51.6] [55.2] [58.8] [68.9] [78.8] Nom. Water Pressure Drop ft.wg[kpa] 30.1 [90] 30.4 [91] 30.8 [92] 31.1 [93] 29.1 [87] 28.8 [86] 28.4 [85] Condenser Coil Row 5 4/5 5 4/ Total Face Area sq.ft[sq.m] 330.1[30.7] 377.2[35] 377.2[35] 424.4[39.4] [48.2] [48.2] 613[ 56.9] No of Fans Fan Dia inches[mm] Fan Motor HP Fan Motor FLA amp Electrical Nom. Voltage Unit RLA amp / / / Unit MCA amp / / / 559 Unit MFS amp / / / 800 Unit Max. Inrush amp / / / 1571 General Unit Length inches[mm] 362.6[9210] 407.9[10360] 407.9[10360] 453.1[11510] [14420] [14420] [16720] Unit Width inches[mm] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] Unit Height inches[mm] 93.2[2368] 93.2[2368] 93.2[2368] 93.2[2368] 93.2[2368] 93.2[2368] 93.2[2368] Shipping Weight lbs[kg] 18700[8500] 19822[9010] 20790[9450] [10410] [11300] [13000] 31240[14200] Operating Weight lbs[kg] 19250[8750] 20482[9310] 21450[9750] [10810] [11700] [13440] 32340[14700] Operating Charge R134a lbs[kg] 561[255] 715[325] 880[400] 946[430] 1012[460] 1089[495] 1100[500] Note: Nominal data is based on LWT 44 F and condenser ambient 95 F. Actual capacity depends on the specified operating conditions

16 PERFORMANCE DATA Model AFVXB LWT F Ambient Temperature F Cap TR Comp kw Cap TR Comp kw Cap TR Comp kw Cap TR Comp kw SR SR SR SR SR SR SR

17 PERFORMANCE DATA Model AFVXB LWT F Ambient Temperature F Cap TR Comp kw Cap TR Comp kw Cap TR Comp kw Cap TR Comp kw SR SR SR SR SR SR SR

18 DIMENSIONAL DATA AFVXB 95-5SR SWING DOOR COMPARTMENT ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO CONTROL BOX TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. CONTROL SWING DOOR SERVICE CLEARANCE OF 24" [610] SERVICE CLEARANCE OF 60" [1524] AIR OUT WATER OUTLET Ø4" [101] 88 [2235] WATER INLET Ø4" [101] 5 [130] 17 [439] 4 NOS OF 2" [50]Ø LIFTING HOLES 14 [350] 56 [1430] 56 [1430] 140 [3560] 6 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 24 [598] AFVXB 110-5SR, 135-5SR SWING DOOR COMPARTMENT ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO CONTROL BOX TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. CONTROL SWING DOOR SERVICE CLEARANCE OF 24" [610] SERVICE CLEARANCE OF 60" [1524] AIR OUT 88 [2235] WATER OUTLET Ø4" [101] WATER INLET Ø4" [101] 5 [130] 17 [439] 4 NOS OF 2" [50]Ø LIFTING HOLES 10 [255] 55 [1400] 55 [1400] 55 [1400] 185 [4710] 8 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 24 [598]

19 DIMENSIONAL DATA AFVXB 160-5SR SWING DOOR COMPARTMENT ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. SERVICE CLEARANCE OF 24" [610] CONTROL SWING DOOR SERVICE CLEARANCE OF 60" [1524] AIR OUT 88 [2235] WATER OUTLET Ø6" [152] WATER INLET Ø6" [152] 6 [143] 18 [469] 4 NOS OF 2" [50]Ø 21 [545] LIFTING HOLES 63 [1590] 63 [1590] 63 [1590] 231 [5860] 8 NOS OF 3/4" [19]Ø MOUNTING HOLES 24 [597] 86 [2187] 88 [2233] AFVXB 200-5SR, 225-5SR SWING DOOR COMPARTMENT ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. SERVICE CLEARANCE OF 24" [610] CONTROL SWING DOOR SERVICE CLEARANCE OF 60" [1524] AIR OUT 93 [2368] WATER OUTLET Ø6" [152] WATER INLET Ø6" [152] 6 [143] 22 [570] 4 NOS OF 2" [50]Ø LIFTING HOLES 19 [485] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 284 [7210] 10 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 26 [663]

20 DIMENSIONAL DATA AFVXB 250-5SR SERVICE CLEARANCE OF 24" [610] SWING DOOR COMPARTMENT ELECTRICAL CONTROL SWING DOOR SERVICE CLEARANCE OF 60" [1524] NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. AIR OUT 93 [2368] WATER OUTLET Ø8" [203] WATER INLET Ø8" [203] 7 [175] 24 [620] 4 NOS OF 2" [50]Ø LIFTING HOLES 18 [455] 59 [1490] 59 [1490] 59 [1490] 59 [1490] 59 [1490] 12 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 26 [663] 329 [8360] AFVXB 280-5SR SERVICE CLEARANCE OF 60" [1524] SWING DOOR COMPARTMENT CONTROL SWING DOOR ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. SERVICE CLEARANCE OF 24" [610] SERVICE CLEARANCE OF 24" [610] AIR OUT 93 [2368] WATER OUTLET Ø8" [203] WATER INLET Ø8" [203] 7 [175] 24 [620] 8 NOS OF 2" [50]Ø LIFTING HOLES 19 [492] 65 [1645] 65 [1645] 65 [1645] 65 [1645] 65 [1645] 363 [9210] 12 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 18 [468]

21 DIMENSIONAL DATA AFVXB 310-5SR SERVICE CLEARANCE OF 24" [610] SERVICE CLEARANCE OF 60" [1524] SWING DOOR COMPARTMENT CONTROL SWING DOOR ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. SERVICE CLEARANCE OF 24" [610] AIR OUT WATER OUTLET Ø8" [203] 93 [2368] WATER INLET Ø8" [203] 7 [175] 25 [630] 20 [500] 8 NOS OF 2" [50]Ø LIFTING HOLES 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 408 [10360] 14 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2186] 88 [2236] 18 [468] AFVXB 340-5SR SERVICE CLEARANCE OF 24" [610] SERVICE CLEARANCE OF 60" [1524] SWING DOOR COMPARTMENT CONTROL SWING DOOR ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. SERVICE CLEARANCE OF 24" [610] AIR OUT 93 [2368] WATER OUTLET Ø8" [203] WATER INLET Ø8" [203] 7 [175] 25 [630] 8 NOS OF 20 [500] 2" [50]Ø LIFTING HOLES 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 14 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2186] 88 [2236] 18 [468] 408 [10360]

22 DIMENSIONAL DATA AFVXB 360-5SR SERVICE CLEARANCE OF 24" [610] SERVICE CLEARANCE OF 60" [1524] SWING DOOR COMPARTMENT CONTROL SWING DOOR ELECTRICAL NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. SERVICE CLEARANCE OF 24" [610] AIR OUT WATER OUTLET Ø8" [203] 93 [2368] WATER INLET Ø8" [203] 7 [175] 25 [630] 17 [435] 8 NOS OF 2" [50]Ø LIFTING HOLES 60 [1520] 60 [1520] 60 [1520] 60 [1520] 60 [1520] 60 [1520] 60 [1520] 453 [11510] 16 NOS OF 3/4" [19]Ø MOUNTING HOLES 18 [468] 86 [2185] 88 [2235] AFVXB 400-5SR, 450-5SR SERVICE CLEARANCE OF 60" [1524] CONTROL SWING DOOR SWING DOOR COMPARTMENT ELECTRICAL CONTROL SWING DOOR NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. ELECTRICAL SERVICE CLEARANCE OF 60" [1524] COMPARTMENT SWING DOOR AIR OUT 93 [2368] WATER OUTLET Ø6" [152] WATER INLET Ø6" [152] 6 [143] 22 [570] 10 NOS OF 3/4" [19]Ø MOUNTING HOLES 61 [1560] 4 NOS OF 2" [50]Ø LIFTING HOLES 61 [1560] 61 [1560] 284 [7210] 19 [485] 61 [1560] 4 NOS OF 19 [485] 2" [50]Ø LIFTING HOLES 61 [1560] 61 [1560] 61 [1560] 61 [1560] 284 [7210] 10 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 26 [663] 568 [14427] AFVXB 500-5SR SERVICE CLEARANCE OF 60" [1524] CONTROL SWING DOOR SWING DOOR COMPARTMENT ELECTRICAL CONTROL SWING DOOR NOTES: 1. ALL DIMENSIONS ARE IN INCHES AND MILLIMETERS. 2. ALLOW 60in [1524mm] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICE. 3. USE MINIMUM 36in [914mm] FLEXIBLE CONDUIT TO CONTROL BOX TO ISOLATE UNIT. 4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT. ELECTRICAL COMPARTMENT SWING DOOR SERVICE CLEARANCE OF 60" [1524] AIR OUT 93 [2368] WATER OUTLET Ø8" [203] WATER INLET Ø8" [203] 7 [175] 24 [620] 12 NOS OF 3/4" [19]Ø MOUNTING HOLES 59 [1490] 59 [1490] 4 NOS OF 2" [50]Ø LIFTING HOLES 59 [1490] 329 [8360] 59 [1490] 18 [455] 59 [1490] 4 NOS OF 2" [50]Ø 18 [455] LIFTING HOLES 59 [1490] 59 [1490] 59 [1490] 59 [1490] 59 [1490] 329 [8360] 12 NOS OF 3/4" [19]Ø MOUNTING HOLES 86 [2185] 88 [2235] 26 [663] 658 [16713]

23 FLOOR LOADING DIAGRAM AFVXB 95-5SR, 110-5SR, 135-5SR, 160-5SR, 200-5SR, 225-5SR, 250-5SR AFVXB 280-5SR, 310-5SR, 340-5SR, 360-5SR COMPARTMENT POINT LOAD LOCATION Model AFVXB Dimensions - inches[mm] A Dim. B Dim. C Dim. D Dim. E Dim. F Dim. G Dim. H Dim. I Dim. 95-5SR 86 [2184] 14 [350] 56 [1430] 56 [1430] SR 86 [2184] 10 [255] 55 [1400] 55 [1400] 55 [1400] SR 86 [2184] 10 [255] 55 [1400] 55 [1400] 55 [1400] SR 86 [2184] 21 [545] 63 [1590] 63 [1590] 63 [1590] SR 86 [2184] 19 [485] 61 [1560] 61 [1560] 61 [1560] 61 [1560] SR 86 [2184] 19 [485] 61 [1560] 61 [1560] 61 [1560] 61 [1560] SR 86 [2184] 18 [455] 59 [1490] 59 [1490] 59 [1490] 59 [1490] 59 [1490] SR 86 [ 2184] 19 [492] 65 [1645] 65 [1645] 65 [1645] 65 [1645] 65 [1645] SR 86 [ 2184] 20 [500] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] SR 86 [ 2184] 20 [500] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] 61 [1560] SR 86 [ 2184] 17 [435] 60 [1520] 60 [1520] 60 [1520] 60 [1520] 60 [1520] 60 [1520] 60 [1520] POINT LOAD DATA Model AFVXB 95-5SR 110-5SR 135-5SR 160-5SR 200-5SR 225-5SR 250-5SR 280-5SR 310-5SR 340-5SR 360-5SR Point Load - lbs[kg] P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P [559] 1160 [526] 1195 [542] 1303 [591] 1097 [498] 1268 [575] 1147 [520] 1809 [821] 1528 [693] 1586 [719] 1643 [745] 1019 [462] 931 [422] 1000 [454] 1071 [486] 935 [424] 1070 [485] 1014 [460] 1513 [687] 1369 [621] 1426 [647] 1454 [660] 1317 [597] 1197 [543] 1227 [556] 1414 [641] 1187 [538] 1370 [621] 1225 [555] 1756 [796] 1517 [688] 1579 [716] 1613 [732] 1270 [576] 1109 [503] 1173 [532] 1325 [601] 1119 [508] 1281 [581] 1152 [523] 1524 [691] 1391 [631] 1453 [659] 1450 [658] 1401 [636] 1234 [560] 1258 [571] 1526 [692] 1277 [579] 1471 [667] 1302 [591] 1702 [772] 1507 [683] 1571 [713] 1584 [718] 1520 [690] 1288 [584] 1346 [611] 1578 [716] 1302 [591] 1492 [677] 1291 [585] 1534 [696] 1413 [641] 1480 [671] 1446 [656] [576] 1289 [585] 1637 [743] 1367 [620] 1573 [713] 1379 [626] 1648 [748] 1496 [679] 1564 [709] 1554 [705] 1467 [665] 1519 [689] 1832 [831] 1486 [674] 1703 [772] 1429 [648] 1545 [701] 1436 [651] 1507 [684] 1442 [654] [661] 1674 [759] 1457 [661] 1595 [723] 1486 [674] 1556 [706] 1524 [691] 1669 [757] 1914 [868] 1568 [711] 1555 [706] 1458 [662] 1534 [696] 1438 [652] [696] 1541 [699] 1475 [669] 1548 [702] 1495 [678] [774] [710] 1481 [672] 1561 [708] 1434 [650] [664] 1541 [699] 1465 [665] 1503 [682] 1588 [720] 1429 [648] [651] 1425 [646] Total Operating Weight 7760 [3520] 9656 [4380] [4540] [5300] [5850] [6720] [7350] [8750] [9310] [9750] [10810]

24 DIMENSIONAL CLEARANCE Single Pit (See Note 2) Double Pit (See Note 2) Multi Pit Corner Wall Notes: 1) All dimensions are minimum unless otherwise noted. 2) Overhead obstructions are not permitted. 3) Pit installations are not recommended. Re-circulation of hot condenser air in combination with surface air turbulence cannot be predicted. Hot air recirculation will severely affect unit efficiency (EER) and can cause high pressure or fan motor temperature trips. Contractor shall be responsible for ducting fans to a higher level to alleviate the discharge air and prevent backflow of air, consult Dunham-Bush or our Representative for the correct design recommendation

25 CONDENSER FAN FAN POSITION NUMBER & CYCLING SEQUENCE AFVXB 95-5SR AFVXB 110-5SR, 135-5SR System System Stage 1 1 Stage 1 1 Stage 2 2 & 5 Stage 2 2 & 5 Stage 3 4 & 7 Stage 3 3 & 4 Stage 4 3 & 6 AFVXB 160-5SR AFVXB 200-5SR, 225-5SR System System Stage 1 1 Stage 1 1 & 3 Stage 2 2 & 5 Stage 2 2 & 5 Stage 3 4 & 7 Stage 3 4 & 7 Stage 4 6 & 9 Stage 4 6, 8 & 10 Stage 5 3 & 8 Stage 5 9 & 11 AFVXB 250-5SR AFVXB 280-5SR System Stage 1 1 & 3 System 1 System 2 Stage 2 2 & 5 Stage Stage 3 4, 6 & 7 Stage 2 2 & 5 10 & 11 Stage 4 8, 10 & 12 Stage 3 4 & 7 12 & 13 Stage 5 9, 11 & 13 Stage 4 3 & 6 9 & 14 AFVXB 310-5SR AFVXB 340-5SR System 1 System 2 System 1 System 2 Stage Stage Stage 2 2 & 5 10 & 11 Stage 2 2 & 5 10 & 11 Stage 3 4 & 7 12 & 13 Stage 3 4 & 7 12 & 13 Stage 4 3 & 6 14 & 15 Stage 4 3 & 6 14 & 15 Stage 5-9 & 16 Stage 5-9 & 16 AFVXB 360-5SR System 1 System 2 Stage Stage 2 2 & 5 12 & 13 Stage 3 4 & 7 14 & 15 Stage 4 6 & 9 16 & 17 Stage 5 3 & 8 11 &

26 SOUND PRESSURE DATA Model AFVXB Octave Band (Hz) K 2K 4K 8K Total db (A) 95-5SR SR SR SR SR SR SR SR SR SR SR SR SR SR Note: Unit Sound Pressure Level 33 ft[10m] (free field), ± 2 db tolerance. ELECTRICAL DATA Model AFVXB Compressor Data Cond. Fan Motor Data Unit Electrical Data Qty Model RLA STA LRA Qty HP FLA RLA MCA MFS 95-5SR 1 MSC SR 1 MSC SR 1 MSC SR 1 MSC SR 1 MSC SR 1 MSC SR 1 MSC SR 1 1 MSC1222 MSC SR 1 1 MSC1222 MSC SR 1 1 MSC1227 MSC SR 1 1 MSC1227 MSC SR 1 1 MSC1230 MSC SR 1 1 MSC2233 MSC SR 1 1 MSC2236 MSC Notes: 1.) Larger compressor models MSC2233 and MSC2236 are using star-delta starting method. Others compressor models are using doubledelta starting. 2.) MCA - Minimum Circuit Amps. MFS - Maximum Fuse Size RLA - Rated Load Amps LRA - Locked Rotor Amps FLA - Full Load Amps STA - Starting Amps

27 TYPICAL WIRING SCHEMATIC AFVXB 1 (SHEET 1 OF 3)

28 TYPICAL WIRING SCHEMATIC AFVXB 1 (SHEET 2 OF 3) Ω

29 TYPICAL WIRING SCHEMATIC AFVXB 1 (SHEET 3 OF 3)

30 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 panel. 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 Refrigerant Tons (kw output) cooling at 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 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.heat transfer surfaces shall be selected to reflect the incorporation of a fouling factor of hr.sq.ft. F/BTU ( m². C/W) for evaporator. Water pressure drop at design conditions shall not exceed feet of water through the evaporator. 3. The packaged chiller shall be furnished with singlestage direct connected positive displacement rotary screw compressor(s) as required, of vapor injection type, driven by a 2900 RPM (3500 RPM- 60Hz) motor. Each compressor shall comes with built in integral oil separation system, oil sump and oil filter. The oil differential pressure shall be controlled during operation to maintain proper oil lubrication throughout the system. An electric oil heater shall be supplied together with each compressor to maintain oil temperature during shutdown period. Each compressor shall have a suction filter, 127, 192 and 226mm compressor series will come with service valve for both suction and discharge. Compressor capacity control shall be obtained by an electrically initiated, hydraulically actuated slide valve within each compressor. 4. 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 or flange connections. The shell side of the evaporator shall 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 heads 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. The flooded evaporator shall be fitted with an oil recovery system. The oil recovery system will insure 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. 5. 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 e sized for pump down capacity. 6. To maximize energy efficiency, the packaged chiller shall be equipped with an economizer cycle and thermal expansion devices. Refrigerant vapor from the 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. 7. The fans shall be heavy duty, Aluminium blade, direct drive propeller type. Motors shall be three phase with internal overloads and are to be permanently lubricated. 8. The packaged chiller shall be furnished with a electronic refrigerant control system to optimize efficiency and compressor protection. The electronic refrigerant control system should be able to allow a portion of liquid refrigerant to passes through the first expansion device and into the economizer for further sub cooling of main liquid refrigerant flow. The gaseous refrigerant is then drawn out of the economizer and into the vapor injection port of the compressor. The remaining liquid refrigerant then passes through a second expansion device which reduces the refrigerant pressure to evaporator levels where it is then distributed evenly into the evaporator. This shall deliver outstanding efficiency and total energy saving through the utilization of economizer cycle which resulted in increment of capacity by as much as 12% with only 7% additional absorbed power.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 slugging liquid refrigerant. Fixed orifice control systems will not be acceptable. (Hot gas bypass shall be factory installed for operation below minimum percent of unit capacity.)

31 GUIDE SPECIFICATIONS 9. The packaged chiller shall be equipped with controller control. The control shall provide for compressor control 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 compressor 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 LCD display terminal. Input shall be accomplished through simple menu driven display screens. All data, values and alarms shall be spelled in wording, not coding. The controller shall continuously monitor evaporator leaving water temperature; evaporator and condenser pressure; compressor amp draw; and refrigerant condensing temperature. The controller shall be complete with all hardware and software necessary to enable remote monitoring of unit operating status/parameters through the addition of only a simple add-on communication card onto the controller. The controller shall be completed with a RS485 ModBus RTU communication port as standard. The controller shall also accept a remote start and stop signal, 0 to 5VDC or 4 to 20mA analog signal for chilled water temperature reset or compressor demand limit. 11. The controller shall limit compressor starting to be not more than four times in an hour. 12. 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. Modular units shall have individual electrical connection. 10. 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 overload/ Thermal Overload Low oil level optical sensor High condenser pressure Low evaporator pressure Chilled Water Freeze protection Chilled water flow loss under or over voltage, and phase failure relay AUTOMATIC CONTROLS Compressor motor increment contactors Increment start timer Anti-recycle timer Oil sump heater interlock relays REFRIGERANT CONTROLS Electronic expansion devices 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 Optional items in ( )

32 Malaysia Lot , Kidamai Industrial Park, Bukit Angkat, Kajang, Selangor Darul Ehsan, Malaysia Tel: Fax: China No. 1 Dunham-Bush Road, Laishan District, Yantai, Shandong Province, China Tel: Fax: Europe United Kingdom 8 Downley Road, Havant, Hampshire, England PO9 2JD Tel : Fax: Middle East & North Africa United Arab Emirates Al Murad Tower, Office 506 Al-Barsha 1, P. O. Box # 30922, Dubai, UAE Tel: Fax: Asia Singapore 2, Kallang Pudding Road #07-07, Mactech Industrial Building, Singapore Tel: Fax: Africa South Africa No. 57 Sovereign Drive Route 21 Corporate Park Irene, Pretoria South Africa Tel: Fax: Please Scan Here for quick link to Dunham-Bush website info@dunham-bush.com Products that perform...by people who care Manufacturer reserves the right to change specifications without prior notice. M-S-0494B-0213