R134a. WCFX Series 60Hz. Water Cooled Screw Flooded Chillers Cooling Capacity: 68 to 374 TR (239 to 1315 kw)

Transcription

1 WCFX Series 60Hz Water Cooled Screw Flooded Chillers Cooling Capacity: 68 to 374 TR (239 to 35 kw) R34a Products that perform...by people who care

2 INTRODUCTION For more than 0 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. WCFX, Water Cooled Screw Flooded Chillers, have a cooling capacity range from 68 to 374 TR [239 to 35 kw] in 60Hz version using Dunham-Bush unique vertical screw compressors with environmentally sound HFC-34a refrigerant. The entire product line features energy efficiency, installation ease, control flexibility, high reliability and advanced 2020i controller. The WCFX range is AHRI certified and ETL listed. TABLE OF CONTENTS Page No Introduction... 2 Nomenclature... 2 Components... 3 Standard Features... 3 Unit Features... 4 Operating Benefits... 9 Typical Sequence of Operation... Physical Specifications... Performance Data... 4 Dimensional Data... 6 Floor Loading Diagram... 9 Pressure Drop Sound Pressure Data Electrical Data Typical Wiring Schematic Application Data Equipment Guide Specifications NOMENCLATURE WC F X 8 AR D2R BR NN B Water Cooled Chiller Generation Flooded Evaporator Heat Recovery X = Screw Compressor Condenser Code Evaporator Code Compressor Code (Nominal TR/ ) Single -,2,5,8 Dual - 20, 22, 24, 27, 30, 33, 36 Triple - 39, 42, 45, 48, 5, 54 Electrical Code AK 200/3/60 AN 230/3/60 AR 460/3/60 AS 575/3/60 CS 400/3/60-2 -

3 COMPONENTS Economiser for improved efficiency Compact, quiet Dunham-Bush Medium Screw compressors Controller for precise and reliable control Bolted construction for easy knockdown Heat exchangers with cleanable and removable enhanced copper tubes Vessels designed according to ASME code STANDARD FEATURES Size/Range 7 Models from 68 to 374 TR [239 to 35 kw]. Multiple compressor units provide redundancy, and favorable part load efficiency. Compressor Quiet, reliable MSC Rotary Screw Compressors. Multiple rotary screw compressor for fail-safe reliability and redundancy. Hermetic Design eliminates shaft seals, inspections, teardowns, alignments, etc. Consistent unloading with dependable slide valve mechanism. Evaporator/Condenser Cleanable and Removable Integral Fin Copper Tubes. One, Two or Three Water Passes Available. Removable Water Heads. Victaulic Groove Water Connections. Vessel designed according to ASME Code, approved and certified by JKKP. Relief Valves(s) standard - 3/4"[9mm] FPT. Full Pump Down Capacity in Condenser. Controller/ Electrical Proactive Advanced Controller adapts to abnormal operating conditions. Tolerant and accommodating of extreme conditions at start-up. Capable of controlling multiple chillers, cooling towers, pumps, etc. Circuit Breaker on each compressor. Unit Mounted Contactors and Time Delay for reduced Inrush Start. Current and Voltage transformers. Under Voltage Phase Failure Relay. Indicator lights for Compressor Overloads, Micro Alarm, Control Power, Compressor Control Circuit

4 UNIT FEATURES Oil Deflection Plate Oil Separator Element Discharge Port Hermetic Motor Housing Main Inlet Bearings Rotors Suction Service Valve Suction Port Slide Valve Suction Check Valve Unloader Piston Oil Strainer Suction Filter 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 female drive rotor and a male 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 an 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 % without HGBP by stepless movement of slide valves away from their stops. 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 an integral oil separator/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 the sump and the discharge gas passes around the deflection plate. An oil drain valve is located near the bottom of the oil sump. Oil is also returned to the compressor after it is separated from the refrigerant at the oil separator located at the discharge of the compressor. Main Bearings Each rotor is fitted with a set of anti-friction tapered roller bearings. They carry both radial and thrust loads. 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. Castings All housings are manufactured of high grade, low porosity cast iron

5 UNIT FEATURES FIG. A FIG. B FIG. C FIG. D 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 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. Compressor Fully UnLoaded 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 electrically 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

6 UNIT FEATURES ADVANCED CONTROLLER Vision 2020i a flexible and advance programmable electronic controller designed specifically for the applications and precise control of Dunham-Bush Rotary Screw compressor chillers. The controller board is provided with a set of terminals that connects 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 a programming key. Vision2020i controller is equipped with a user friendly terminal with 320 x 240 pixel, 256 color LCD graphical display and dedicated touch keys that provide easy access to the unit s 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 Vision2020i controller is designed to work with a user friendly 320 x 240 pixel, 256 color DBG3 graphical display panel connected with controller through shielded twisted pair cable. The terminal carrys out all program operations and displays the unit operating conditions, compressor run times, alarm history and is the interface for modifying the control parameters. The display also has an automatic self-test of the controller on system start-up. Multiple messages will be displayed by automatically scrolling from each message to the next. All of these messages are spelled out in English on the display terminal. There are 7 dedicated physical buttons and 3 touch keys that enable the user to access information, based on the security level of the password. For more detailed operating instructors for the DBG3 Display Terminal, please refer to the Unit Operation Manual. Easily accessible measurements include Leaving chilled water temperature Leaving chiller water temperature derivative Evaporator Pressure Condenser Pressure Compressor amp draw of each compressor Compressor elapsed run time of each compressor Compressor starts status Oil level sensor status Water temperature reset value Water flow switch status External start/stop command status Trend graph for leaving chilled water temperature Optional entering chilled water temperature, leaving and entering condenser water temperature are available. With this option the operator can quickly and accurately read all significant water temperatures and eliminate the need for thermometers. Voltage readout 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 through either direct connection of other Dunham-Bush control packages to the controller through either the RS485 long distance differential communications port, via terminal or modem connected to the RS232 communication port, or from an external Building Automation System supplying a simple 4 to 20mA signal. Remote reset of compressor current limit may be accomplished in a similar fashion. System Control The unit may be started or stopped manually, or through the use of an external signal from a Building Automation System. In addition, the 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 able to retain up to 99 alarm conditions complete with time of failure together with data stamping on critical sensor readings in alarm history masks. This tool will aid Service technicians in troubleshooting tasks, enabling downtime and nuisance trips to be minimized

7 UNIT FEATURES 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 open 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 equipped with additional history files which may be used to take logs which can 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 Dunham-Bush Water Cooled Screw Flooded 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 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 resumed to the oil sump. Fully compressed and superheated refrigerant is then discharged into the condenser, where water in the condenser tubes cools and condenses the refrigerant. Liquid refrigerant then passes through the first expansion device and into the flash economizer where flash gas and liquid refrigerant are separated. The gaseous refrigerant is then drawn out of the flash economizer and into the vapor injection port of the compressor. The remaining 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. By removing the flash gas from the flash economizer at an intermediate pressure, the enthalpy of the refrigerant flowing into the evaporator is reduced which 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

8 UNIT FEATURES PART LOAD PERFORMANCE Through the use of flash economizer modulating flow control and multiple compressors, Dunham-Bush Water Cooled Screw Flooded 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 Rotary Screw Water Chillers combine the efficient operation of multiple rotary screw compressors with an economizer cycle and controller control to yield the best total energy efficiency and significant operating savings 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. The Air Conditioning and Refrigeration Institute (AHRI) has established a system, in AHRI Standard 550/ , for measuring total chiller performance over full and part-load conditions. It defines the Integrated Part- Load Value (IPLV) as an excellent method of comparing diverse types of equipment on an equal basis. The IPLV is a single number estimate of a chiller's power use weighted for the number of hours the unit might spend at each part-load point. IPLV's are based on Standard Rating Conditions. The formula for calculating an IPLV is: IPLV = where: A = kw/tr at 0% load point B = kw/tr at 75% load point C = kw/tr at 50% load point D = kw/tr at 25% load point A B C D GLYCOL FREEZE PROTECTION If the chiller or fluid piping is liable to exposure to temperatures below freezing, glycol protection is recommended if the water is not drained. The recommended protection is F [5.6 C] below the minimum ambient temperature in the equipment room and around piping. Use only glycol solutions approved for heat exchanger duty. DO NOT use automotive antifreezing. If the equipment is being used for applications below 38 F [3.3 C] glycol should be used to prevent freeze damage. The freeze protection level should be F [5.6 C] lower than the leaving brine temperature. Table and 2 are to be used to calculate performance and power input with the addition of glycol. Table 3 and 4 are to be used to calculate performance and power input with different fouling factor. Table : Ethylene Glycol % E. G. By Weight Freeze Point F C C Capacity Factor K kw Rate G Flow Factor P P.D. Factor Table 2 : Propylene Glycol % P. G. By Weight Freeze Point F C C2 Capacity Factor K2 kw Rate G2 Flow Factor P2 P.D. Factor Table 3: hr.ft. - F/BTU Fouling Factor Evaporator Fouling Factor M² C kw Capacity Correction Factor kw Correction Factor Table 4: hr.ft. - F/BTU Fouling Factor Condenser Fouling Factor M² C kw Capacity Correction Factor kw Correction Factor

9 OPERATING BENEFITS EFFICIENCY & RELIABILITY Compressor Experience 40 years of rotary screw experience and dedicated technological advancements. 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 kw input over the entire operating range of your building. Delivers outstanding efficiency and total energy savings through the utilization of economizer cycle and optimised compressor staging producing greater capacity with fewer compressors. Maximized performance through computer matched 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. Installation Ease Side-by-side evaporator/condenser plus compact arrangement of rotary screw compressors result in minimised unit dimensions. Units feature optional split design to allow easy fit through any standard commercial doorway. Dramatic payback from reduced maintenance and overhaul costs both in down time and in labor expenditures. Ease of troubleshooting through controller history retention of monitored functions. Factory run tested. Safety Code Compliance: ASME Boiler and Pressure Vessel Code, Section VlIl Division "Unfired Pressure Vessels" ASME Standard B3.5 Refrigeration Piping ASHRAE Standard 5 Safety Code for Mechanical Refrigeration National Electric Code Refrigerant Compatibility Designed to operate with environmentally sound and economically smart HFC-34a with proven efficiency and reliability. Consult factory for use with new 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 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, phone modem. Proactive control by controller that anticipates problems and takes corrective action before they occur. Controls will unload compressor(s) if head or suction pressure approach limits. This will enable the unit to stay on line while warning operator of potential problems. Computer Performance Ratings Dunham-Bush WCFX Water Cooled Screw Flooded Chillers are available from 68 to 374 TR [239 to 35 kw]. The vast number of combinations of heat exchangers, compressors and motors make it impractical to publish tabular ratings for each combination. A chiller may be custom matched to certain building requirements by your Dunham-Bush Sales Representatives utilizing the WCFX Computer Selection Program. Data which can be provided to you will include: Chiller Capacity kw Input Evaporator and Condenser Water Pressure Drop Evaporator and Condenser Tube Water Velocities Motor Electrical Data Part-Load Performance Contact our local Dunham-Bush Sales Representative to discuss what custom solutions Dunham-Bush can offer to solve your chiller selection questions

10 TYPICAL SEQUENCE OF OPERATION The Dunham-Bush Water Cooled Screw Flooded Chiller depends mainly on its on-board controller for control. Operation described is for a two- compressor unit and is very similar for single or three-compressor units. For initial start-up, the following conditions must be met: Power supply to unit energized Compressor circuit breakers in the "on" position Control power switch on for at least 5 minutes. Compressor switches on Reset pressed on controller key pad Chilled water pump running and chilled water flow switch made Leaving chilled water temperature at least 2 F [. C] above setpoint All safety conditions satisfied After all above conditions are met, the controller will call for the lead compressor and the condenser water pump to start. After a one-minute delay, the first contactor (e.g. M-) is energized followed by the second contactor (e.g. M-2) after one second time delay. This provides reduced inrush stepped start. The compressor 5-minute anti-recycle timer is initiated at compressor start. The controller monitors compressor amps, volts, leaving water temperature, and evaporator and condenser pressures. The compressor cooling capacity is controlled by pulsed signals to load and unload solenoid valves on the compressor. When the compressor starts, it is fully unloaded, yielding 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. 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 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 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 unloadsproportionately. If applied load decreases to less than the minimum capacity of one compressor, the leaving chilled water temperature will decline to 2 F [. C] below setpoint, at which time the lead compressor will shut down. It will restart automatically if leaving chilled water temp rises to 2 F [. C] above setpoint and both 5 minute anti-recycle and one minute start delay timers are satisfied. During operation, the controller monitors the difference between condenser and evaporator pressures to ensure that a minimum of 30 psi [2 bar] differential is available for compressor lubrication. If the difference falls below a minimum of 30 psi [2 bar], 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 cold condensing water 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. - -

11 PHYSICAL SPECIFICATIONS One Compressor Models WCFX, 2, 5, 8 MODEL WCFX AR BRAR 2AR CRA2R 5AR DRA3R 8AR D2RBR Unit Nominal Capacity* TR[kW] 68[239] 85[299] 5[369] 24[436] Unit Nominal Power Input kw COMPRESSOR Model (Qty) 2 () 22 () 25 () 28 () RPM Electrical Information AR- 460V AR- 460V AR- 460V AR- 460V Compressor : RLA, Each ST Step Inrush, Each LRA, Each Unit : MCA (Min. Circuit Amps) MFS (Max. Allow. Fuse Size) EVAPORATOR Model BR CR DR D2R Design Press. Water Side psig[bar] 50[.3] 50[.3] 50[.3] 50[.3] Design Press. Refrig. Side psig[bar] 200[3.8] 200[3.8] 200[3.8] 200[3.8] Water Volume USgal[liters] [38] 2[45] 7[64] 8[68] Min. Water Flow ( Pass) USgpm[m³/hr] 49[34] 92[44] 250[57] 282[64] Min. Water Flow (2 Pass) USgpm[m³/hr] 74[7] 96[22] 25[28] 4[32] Min. Water Flow (3 Pass) USgpm[m³/hr] 50[] 64[5] 83[9] 94[2] Max. Water Flow ( Pass) USgpm[m³/hr] 743[69] 958[27] 252[284] 408[320] Max. Water Flow (2 Pass) USgpm[m³/hr] 372[84] 479[9] 626[42] 704[60] Max. Water Flow (3 Pass) USgpm[m³/hr] 248[56] 39[72] 47[95] 469[6] CONDENSER Model AR A2R A3R BR Design Press. Water Side psig[bar] 50[.3] 50[.3] 50[.3] 50[.3] Design Press. Refrig. Side psig[bar] 200[3.8] 200[3.8] 200[3.8] 200[3.8] Water Volume USgal[liters] 2[45] 4[53] 8[68] 22[83] Min. Water Flow ( Pass) USgpm[m³/hr] 83[42] 227[52] 273[62] 330[75] Min. Water Flow (2 Pass) USgpm[m³/hr] 92[2] 4[26] 37[3] 65[37] Min. Water Flow (3 Pass) USgpm[m³/hr] 6[4] 76[7] 9[2] [25] Max. Water Flow ( Pass) USgpm[m³/hr] 900[204] 900[204] 366[3] 500[34] Max. Water Flow (2 Pass) USgpm[m³/hr] 390[89] 390[89] 570[29] 570[29] Max. Water Flow (3 Pass) USgpm[m³/hr] 306[69] 325[74] 455[3] 550[25] GENERAL INFORMATION Shipping Weight lbs[kg] 3229[465] 3762[706] 4439[204] 4634[22] Operating Weight lbs[kg] 355[6] 438[877] 4882[224] 5097[232] Approx. Refrig. R34a Charge lbs[kg] 209[95] 248[2] 32[42] 376[7] *Actual capacities will depend on the specified operating conditions. Consult nearest Dunham-Bush sales office for computer selections. - -

12 PHYSICAL SPECIFICATIONS Two Compressor Models WCFX 20, 22, 24, 27, 30, 33, 36 UNIT MODEL 20AR JRHR 22AR KRH2R 24AR K2RH3R 27AR LRH4R 30AR L2RJR 33AR L3RJ2R 36AR MRJ3R Unit Nominal Capacity* TR[kW] 37[482] 53[538] 70[598] 90[668] 2[738] 230[809] 250[879] Unit Nominal Power Input kw COMPRESSORS Model (Qty) 2 (2) 2 (), 22 () 22 (2) 22 (), 25 () 25 (2) 25 (), 28 () 28 (2) RPM Electrical Information AR-460V AR-460V AR-460V AR-460V AR-460V AR-460V AR-460V Compressor : RLA, Each / / / ST Step Inrush, Each / / / LRA, Each / / / Unit : MCA (Min. Circuit Amps) MFS (Max. Allow. Fuse Size) EVAPORATOR MODEL MODEL JR KR K2R LR L2R L3R MR Design Press. Water Side psig[bar] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] Design Press. Refrig. Side psig[bar] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] Water Volume USgal[liters] 2[80] 23[87] 26[99] 29[] 33[25] 36[36] 40[52] Min. Water Flow ( Pass) USgpm[m³/hr] 282[64] 309[70] 340[77] 39[89] 434[99] 479[9] 524[9] Min. Water Flow (2 Pass) USgpm[m³/hr] 4[32] 55[35] 70[39] 96[44] 27[49] 240[54] 262[59] Min. Water Flow (3 Pass) USgpm[m³/hr] 94[2] 3[23] 3[26] 30[30] 45[33] 60[36] 75[40] Max. Water Flow ( Pass) USgpm[m³/hr] 408[320] 545[35] 70[386] 965[446] 27[493] 2396[544] 2620[595] Max. Water Flow (2 Pass) USgpm[m³/hr] 704[60] 773[75] 85[93] 978[222] 86[247] 98[272] 3[297] Max. Water Flow (3 Pass) USgpm[m³/hr] 469[6] 55[7] 567[29] 652[48] 724[64] 799[8] 873[98] CONDENSER MODEL MODEL HR H2R H3R H4R JR J2R J3R Design Press. Water Side psig[bar] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] Design Press. Refrig. Side psig[bar] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] Water Volume USgal[liters] 30[4] 33[25] 37[40] 4[55] 45[7] 5[93] 57[26] Min. Water Flow ( Pass) USgpm[m³/hr] 325[74] 36[82] 396[90] 449[2] 504[4] 550[25] 598[36] Min. Water Flow (2 Pass) USgpm[m³/hr] 63[37] 8[4] 98[45] 225[5] 252[57] 275[62] 299[68] Min. Water Flow (3 Pass) USgpm[m³/hr] 8[25] 20[27] 32[30] 50[34] 68[38] 83[42] 99[45] Max. Water Flow ( Pass) USgpm[m³/hr] 500[34] 560[354] 98[450] 2247[5] 2500[568] 2500[568] 2500[568] Max. Water Flow (2 Pass) USgpm[m³/hr] 82[84] 870[97] 903[205] 960[28] 80[245] 376[32] 495[339] Max. Water Flow (3 Pass) USgpm[m³/hr] 54[23] 602[37] 660[50] 749[70] 84[9] 900[204] 900[204] GENERAL INFORMATION Shipping Weight lbs[kg] 6056[2747] 659[2990] 6700[3039] 7537[349] 987[467] 9358[4245] 9785[4438] Operating Weight lbs[kg] 666[302] 7250[3289] 7370[3343] 8290[3760] 5[4584] 295[4670] 768[4884] Approx. Refrig. R34a Charge lbs[kg] 46[89] 458[208] 497[225] 56[254] 623[283] 686[3] 748[339] *Actual capacities will depend on the specified operating conditions. Consult nearest Dunham-Bush sales office for computer selections

13 PHYSICAL SPECIFICATIONS Three Compressor Models WCFX 39, 42, 45, 48, 5, 54 UNIT MODEL 39AR T2RPR 42AR T3RQR 45AR URQ2R 48AR VRRR 5AR V2RR2R 54AR V3RR2R Unit Nominal Capacity* TR[kW] 272[957] 292[27] 33[] 333[7] 354[245] 374[35] Unit Nominal Power Input kw COMPRESSORS Model (Qty) 22 (2), 25 () 22 (), 25 (2) 25 (3) 25 (2), 28 () 25 () 28 (2) 28 (3) RPM Electrical Information AR- 460V AR- 460V AR- 460V AR- 460V AR- 460V AR- 460V Compressor : RLA, Each 85 / / / / ST Step Inrush, Each 200 / / / / LRA, Each 498 / / / / Unit : MCA (Min. Circuit Amps) MFS (Max. Allow. Fuse Size) EVAPORATOR Model T2R T3R UR VR V2R V3R Design Press. Water Side psig[bar] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] Design Press. Refrig. Side psig[bar] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] Water Volume USgal[liters] 4[55] 44[67] 50[90] 53[20] 56[22] 58[220] Min. Water Flow ( Pass) USgpm[m³/hr] 556[26] 598[36] 657[49] 700[59] 739[68] 773[75] Min. Water Flow (2 Pass) USgpm[m³/hr] 278[63] 299[68] 329[75] 350[79] 370[84] 387[88] Min. Water Flow (3 Pass) USgpm[m³/hr] 85[42] 99[45] 29[50] 233[53] 246[56] 258[59] Max. Water Flow ( Pass) USgpm[m³/hr] 2777[630] 2992[679] 3285[746] 3500[795] 3540[804] 3540[804] Max. Water Flow (2 Pass) USgpm[m³/hr] 389[35] 496[340] 643[373] 750[397] 848[49] 93[438] Max. Water Flow (3 Pass) USgpm[m³/hr] 926[2] 997[226] 95[249] 67[265] 232[280] 287[292] CONDENSER Model PR QR Q2R RR R2R R2R Design Press. Water Side psig[bar] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] 50[.3] Design Press. Refrig. Side psig[bar] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] 200[3.8] Water Volume USgal[liters] 57[26] 63[239] 68[258] 74[280] 8[307] 8[307] Min. Water Flow ( Pass) USgpm[m³/hr] 647[47] 7[6] 756[72] 803[82] 85[93] 899[204] Min. Water Flow (2 Pass) USgpm[m³/hr] 324[74] 355[8] 378[86] 402[9] 426[97] 450[2] Min. Water Flow (3 Pass) USgpm[m³/hr] 26[49] 237[54] 252[57] 268[6] 284[64] 300[68] Max. Water Flow ( Pass) USgpm[m³/hr] 3237[735] 3500[795] 3500[795] 3500[795] 3500[795] 3540[804] Max. Water Flow (2 Pass) USgpm[m³/hr] 500[34] 500[34] 560[354] 650[375] 650[375] 650[375] Max. Water Flow (3 Pass) USgpm[m³/hr] 79[245] 83[269] 259[286] 339[304] 48[322] 498[340] GENERAL INFORMATION Shipping Weight lbs[kg] 542[4782] 80[5353] 289[585] 3900[6305] 4332[650] 4642[6642] Operating Weight lbs[kg] 596[5260] 298[5888] 40[6396] 5290[6935] 5765[75] 66[7306] Approx. Refrig. R34a Charge lbs[kg] 8[367] 873[396] 935[424] 994[45] 58[480] 22[509] * Actual capacities will depend on the specified operating conditions. Consult nearest Dunham-Bush sales office for computer selections

14 PERFORMANCE DATA Model WCFX Leaving Chilled Water Temp F Entering Condenser Water Temp F TR kw TR kw TR kw Notes:. Ratings in accordance with AHRI Standard 550/ Shaded ratings are at AHRI standard conditions. 3. Ratings based on R-34a, evaporator fouling factor of 0.000, evaporator water flow of 2.4 USgpm/TR, degree F. Delta-T, and condenser fouling factor of , and condenser water flow of 3.0 USgpm/TR

15 PERFORMANCE DATA Model WCFX Leaving Chilled Water Temp F Entering Condenser Water Temp F TR kw TR kw TR kw Notes:. Ratings in accordance with AHRI Standard 550/ Shaded ratings are at AHRI standard conditions. 3. Ratings based on R-34a, evaporator fouling factor of 0.000, evaporator water flow of 2.4 USgpm/TR, degree F. Delta-T, and condenser fouling factor of , and condenser water flow of 3.0 USgpm/TR

16 DIMENSIONAL DATA One Compressor Models WCFX, 2, 5, 8 TWO PASS RIGHT HAND ARRANGEMENT SHOWN - 6 -

17 DIMENSIONAL DATA Two Compressor Models WCFX 20, 22, 24, 27, 30, 33, 36 TWO PASS RIGHT HAND ARRANGEMENT SHOWN - 7 -

18 DIMENSIONAL DATA Three Compressor Models WCFX 39, 42, 45, 48, 5,

19 FLOOR LOADING DIAGRAM WCFX, 2, 5 & 8 C B D CONTROL PANEL A WCFX 20, 22, 24, 27, 30, 33, 36, 39, 42, 45, 48, 5 & 54 C B D CONTROL PANEL A Point Load Data, LBS UNIT MODEL A B C D WCFX ARBRAR 834[378] 334[52] 477[670] 905[4] WCFX 2ARCRA2R 978[444] 384[74] 72[78] 55[479] WCFX 5ARDRA3R 47[520] 454[206] 2037[924] 244[564] WCFX 8ARD2RBR 97[543] 484[220] 220[962] 300[590] WCFX 20ARJRHR 29[586] 930[875] 250[975] 290[585] WCFX 22ARKRH2R 383[627] 22[953] 2349[65] 46[642] WCFX 24ARK2RH3R 430[649] 230[966] 238[80] 429[648] WCFX 27ARLRH4R 600[726] 2404[90] 2686[28] 600[726] WCFX 30ARL2RJR 980[898] 2930[329] 3270[483] 925[873] WCFX 33ARL3RJ2R 997[906] 298[352] 3320[506] 997[906] WCFX 36ARMRJ3R 2090[948] 344[426] 3446[563] 2088[947] WCFX 39ART2RPR 239[52] 3247[473] 37[683] 239[52] WCFX 42ART3RQR 2596[78] 3635[649] 454[884] 2596[78] WCFX 45ARURQ2R 2820[279] 3948[79] 452[2047] 2820[279] WCFX 48ARVRRR 3058[387] 428[942] 4893[229] 3058[387] WCFX 5ARV2RR2R 354[43] 444[2002] 5044[2288] 353[430] WCFX 54ARV3RR2R 3222[46] 4509[2045] 554[2338] 322[46] Notes:.) Refer to dimensional drawings for location of mounting points. 2.) Unit must be lowered onto mounting springs in a level fashion or spring damage may occur

20 PRESSURE DROP IMPERIAL UNITS WCFX, 2, 5, 8.) Evaporator & 2 Pass 0 PRESSURE DROP - ft.wg. BR CR DR D2R ER PASS 2 PASS BR CR DR D2R ER WATER FLOW RATE - USgpm 2.) Evaporator 3 Pass 0 PRESSURE DROP - ft.wg. BR CR DR D2R ER 0 00 WATER FLOW RATE - USgpm

21 PRESSURE DROP IMPERIAL UNITS WCFX, 2, 5, 8 3.) Condenser & 2 Pass 0 2 PASS PRESSURE DROP - ft.wg. AR A2R A3R BR CR PASS AR A2R A3R BR CR WATER FLOW RATE - USgpm 4.) Condenser 3 Pass 0 PRESSURE DROP - ft.wg. AR A2R A3R BR CR 0 00 WATER FLOW RATE - USgpm - 2 -

22 PRESSURE DROP IMPERIAL UNITS WCFX 20, 22, 24, 27, 30, 33, 36.) Evaporator Pass 0 PRESSURE DROP - ft.wg. JR KR K2R LR L2R L3R MR M2R M3R WATER FLOW RATE - USgpm 2.) Evaporator 2 Pass PRESSURE DROP - ft.wg. 0 JR KR K2R LR L2R L3R MR M2R M3R WATER FLOW RATE - USgpm 3.) Evaporator 3 Pass 0 PRESSURE DROP - ft.wg. JR KR K2R LR L2R L3R MR M2R M3R 0 00 WATER FLOW RATE - USgpm

23 PRESSURE DROP IMPERIAL UNITS WCFX 20, 22, 24, 27, 30, 33, 36 4.) Condenser Pass 0 PRESSURE DROP - ft.wg. HR H2R H3R H4R JR J2R J3R KR K2R WATER FLOW RATE - USgpm 5.) Condenser 2 Pass 0 PRESSURE DROP - ft.wg. HR H2R H3R H4R JR J2R J3R KR K2R WATER FLOW RATE - USgpm 6.) Condenser 3 Pass 0 PRESSURE DROP - ft.wg. HR H2R H3R H4R JR J2R J3R KR K2R 0 00 WATER FLOW RATE - USgpm

24 PRESSURE DROP IMPERIAL UNITS WCFX 39, 42, 45, 48, 5, 54.) Evaporator Pass 0 PRESSURE DROP- ft.wg. T2R T3R UR VR V2R V3R WR W2R YR WATER FLOW RATE - USgpm 2.) Evaporator 2 Pass 0 PRESSURE DROP - ft.wg. T2R T3R UR VR V2R V3R WR W2R YR WATER FLOW RATE - USgpm 3.) Evaporator 3 Pass 0 PRESSURE DROP - ft.wg. T2R T3R UR VR V2R V3R WR W2R YR WATER FLOW RATE - USgpm

25 PRESSURE DROP IMPERIAL UNITS WCFX 39, 42, 45, 48, 5, 54 4.) Condenser Pass 0 PRESSURE DROP - ft.wg. PR QR Q2R RR R2R R3R TR T2R T3R WATER FLOW RATE - USgpm 5.) Condenser 2 Pass 0 PRESSURE DROP - ft.wg. PR QR Q2R RR R2R R3R TR T2R T3R WATER FLOW RATE - USgpm 6.) Condenser 3 Pass 0 PRESSURE DROP - ft.wg. PR QR Q2R RR R2R R3R TR T2R T3R WATER FLOW RATE - USgpm

26 PRESSURE DROP S. I. UNITS WCFX, 2, 5, 8.) Evaporator & 2 Pass 0 PRESSURE DROP - kpa BR CR DR D2R ER 2 PASS BR CR DR D2R ER PASS 0 00 WATER FLOW RATE - m³/hr 2.) Evaporator 3 Pass 00 PRESSURE DROP - kpa 0 BR CR DR D2R ER 0 00 WATER FLOW RATE - m³/hr

27 PRESSURE DROP S. I. UNITS WCFX, 2, 5, 8 3.) Condenser & 2 Pass 0 PRESSURE DROP - kpa AR A2R A3R BR CR 2 PASS AR A2R A3R BR CR PASS 0 00 WATER FLOW RATE - m³/hr 4.) Condenser 3 Pass 00 PRESSURE DROP - kpa 0 AR A2R A3R BR CR 0 00 WATER FLOW RATE - m³/hr

28 PRESSURE DROP S. I. UNITS WCFX 20, 22, 24, 27, 30, 33, 36.) Evaporator Pass 0 PRESSURE DROP - kpa JR KR K2R LR L2R L3R MR M2R M3R 0 00 WATER FLOW RATE - m³/hr 2.) Evaporator 2 Pass 00 PRESSURE DROP - kpa 0 JR KR K2R LR L2R L3R MR M2R M3R 0 00 WATER FLOW RATE - m³/hr 3.) Evaporator 3 Pass 00 PRESSURE DROP - kpa 0 JR KR K2R LR L2R L3R MR M2R M3R 0 00 WATER FLOW RATE - m³/hr

29 PRESSURE DROP S. I. UNITS WCFX 20, 22, 24, 27, 30, 33, 36 4.) Condenser Pass PRESSURE DROP - kpa 0 HR H2R H3R H4R JR J2R J3R KR K2R 0 00 WATER FLOW RATE - m³/hr 5.) Condenser 2 Pass 00 PRESSURE DROP - kpa 0 HR H2R H3R H4R JR J2R J3R KR K2R 0 00 WATER FLOW RATE - m³/hr 6.) Condenser 3 Pass 00 PRESSURE DROP -kpa 0 HR H2R H3R H4R JR J2R J3R KR K2R 0 00 WATER FLOW RATE - m³/hr

30 PRESSURE DROP S. I. UNITS WCFX 39, 42, 45, 48, 5, 54.) Evaporator Pass PRESSURE DROP- kpa 0 T2R T3R UR VR V2R V3R WR W2R YR 0 00 WATER FLOW RATE - m³/hr 2.) Evaporator 2 Pass 00 PRESSURE DROP - kpa 0 T2R T3R UR VR V2R V3R WR W2R YR 0 00 WATER FLOW RATE - m³/hr 3.) Evaporator 3 Pass 00 PRESSURE DROP - kpa 0 T2R T3R UR VR V2R V3R WR W2R YR 0 00 WATER FLOW RATE - m³/hr

31 PRESSURE DROP S. I. UNITS WCFX 39, 42, 45, 48, 5, 54 4.) Condenser Pass PRESSURE DROP - kpa 0 PR QR Q2R RR R2R R3R TR T2R T3R 0 00 WATER FLOW RATE - m³/hr 5.) Condenser 2 Pass 00 PRESSURE DROP - kpa 0 PR QR Q2R RR R2R R3R TR T2R T3R 0 00 WATER FLOW RATE - m³/hr 6.) Condenser 3 Pass 00 PRESSURE DROP - kpa 0 PR QR Q2R RR R2R R3R TR T2R T3R 0 00 WATER FLOW RATE - m³/hr - 3 -

32 SOUND PRESSURE DATA WCFX Octave Band (Hz) K 2K 4K 8K Total dba Note: Sound Pressure Level 3.3ft [m] (free field) +/- 2dBA. ELECTRICAL DATA UNIT MODEL NOMINAL VOLTS-PH-HZ UNIT EACH COMPRESSOR MCA MFS RLA INR LRA WCFX Hz WCFX Hz WCFX Hz WCFX Hz WCFX Hz (2) 200 (2) 498 (2) WCFX Hz / / / 498 WCFX Hz (2) 200 (2) 498 (2) WCFX Hz / / / 885 WCFX Hz (2) 325 (2) 885 (2) WCFX Hz / / / 885 WCFX Hz (2) 325 (2) 885 (2) WCFX Hz (2)85 / 22 (2)200 / 325 (2)498 / 885 WCFX Hz / 22(2) 200 / 325(2) 498 / 885(2) WCFX Hz (3) 325 (3) 885 (3) WCFX Hz (2)22 / 30 (2)325 / 325 (2)885 / 885 WCFX Hz / 30(2) 325 / 325(2) 885 / 885(2) WCFX Hz (3) 325 (3) 885 (3) NOTE: MCA - MINIMUM CIRCUIT AMPACITY MFS - MAXIMUM FUSE SIZE RLA - RATED LOAD AMPS INR - FIRST STEP INRUSH AMPS LRA - LOCKED ROTOR AMPS

33 TYPICAL WIRING SCHEMATIC Two Compressors Unit Ω

34 TYPICAL WIRING SCHEMATIC

35 TYPICAL WIRING SCHEMATIC

36 APPLICATION DATA HEAT RECOVERY The Dunham-Bush Water Cooled Screw Flooded Chiller can significantly reduce building operating costs when the heat recovery option is selected. Any building which requires simultaneous heating and cooling may be an excellent candidate for this system. Hotter Hot Water Most centrifugal water chillers are limited in producing leaving condenser water temperatures to 5 F [40.6 C] or below. Dunham-Bush Water Cooled Screw Flooded Chillers are able to provide leaving water temperatures over 20 F [48.9 C] allowing for the installation of smaller heating coils at a lower first cost than systems utilizing centrifugal water chillers. The warmer supply air temperatures available will also improve tenant comfort. Greater Design Flexibility Centrifugal water chillers must be selected carefully in order to accomplish a successful installation. They are susceptible to surge conditions during part-load operation and are more suited for application within a closely defined operating envelope. The heat recovery Dunham-Bush Water Cooled Screw Flooded Chiller, on the other hand, utilizes a positive displacement compressor which cannot surge. This chiller is capable of unloading its compressors to their minimum capacity at all head pressure conditions, both cooling and heat recovery, for greater design flexibility. The unit can be modified for Heat Reclaim use. Lower Energy Consumption The efficient unloading characteristics of the Dunham- Bush Water Cooled Screw Flooded Chiller compressor make it ideal for heat recovery duty. Heat recovery chillers must be selected to operate at various operating conditions, not just full load heating and full load cooling duties. Heat recovery chillers operate at low load much of the time, conditions at which centrifugal chillers would be operating inefficiently and possibly with hot gas bypass. In addition, no penalty will be paid when operating the Dunham-Bush heat recovery chiller in the cooling mode, unlike a centrifugal which, when selected for the higher heat recovery temperatures will not perform as well at the lower cooling only temperatures. Free Cooling Not Free Heating Even greater energy savings can be achieved when the Dunham-Bush Rotary Screw Water Cooled Heat Recovery Chillers are utilized to their maximum benefit. Typically heat recovery chillers had been thought to supply "free heat" while cooling a constant load within a building. The higher head conditions for heat recovery however cause the compressor to draw more power than for cooling only duty. The ideal way to utilize a heat recovery chiller would be to have it operate at only the capacity required for the variable-heating load. This would enable the remainder of the base-cooling load to be handled by a separate chiller for greater energy efficiency. Although this may not be an ideal application for centrifugal chiller, Dunham-Bush Rotary Screw Compressor characteristics, on the other hand, allow the heat recovery chiller to unload to very low load capacities at the high head conditions created in heat recovery operation. To utilize the Dunham-Bush Rotary Screw Heat Recovery Chillers to their fullest potential, the designer must change his way of thinking to providing chillers that are unloaded to provide only the heating load required and simultaneously supply a portion of free cooling to cover the base cooling load. Controls Units can also be provided with optional dual controls so they can control leaving chilled water or leaving condenser water. A double bundle condenser is provided on a Heat Recovery Water Chiller which minimizes space requirements. Consult your local Dunham-Bush Sales Representative for additional details. Head Pressure Control Cooling tower control is increasingly becoming an overlooked subject, and it causes problems. The following is a general recommendation that is applicable to all standard packaged chillers. Virtually all chiller manufacturers recommend that condenser water be controlled so that its temperature never goes below 60 F [5.6 C] (even when the machine is off) and that its rate of change is not rapid. Rapid can be defined as not exceeding 2 F [. C] per minute. This is necessary because a chiller operates in a dynamic environment and is designed to maintain a precise leaving chilled water temperature under varying entering conditions. The additional dynamic of rapidly varying condenser water temperature subjects the machine to fluctuating pressure differentials across the evaporator and condenser. This varies the refrigerant flow and therefore, the capacity. If this occurs faster than the machine can accommodate it, the head pressure or suction pressure will soon exceed safety setpoints and the machine will shut down