50 Hz ACS MODEL: R22 R407c AIR COOLED CHILLERS INSTALLATION, OPERATION & MAINTENANCE MANUAL WITH SCROLL COMPRESSORS

Transcription

1 Products That Perform...By People Who Care Form No: MM0423C INSTALLATION, OPERATION & MAINTENANCE MANUAL AIR COOLED CHILLERS WITH SCROLL COMPRESSORS MODEL: ACS R22 R407c 50 Hz

2 MANUAL INDEX Description Page 1.0 INTRODUCTION PHYSICAL SPECIFICATIONS INSTALLATION 2.1 GENERAL INSPECTION RIGGING General ACS Rigging and Moving SPACE REQUIREMENTS AND CLEARANCE General ACS FOUNDATION Air Cooled Units VIBRATION ISOLATION PIPING CONNECTION Water Connections Chilled Water Piping Water Connections Multiple Packaged Chillers Parallel Chilled Water Flow Units Series Chilled Water Flow Units Water Quality ELECTRICAL CONNECTIONS General REQUEST FOR START-UP REPRESENTATIVE OPERATION 3.1 GENERAL UNIT PIPING AIR COOLED PACKAGE START-UP SYSTEM START-UP LUBRICATION Oil Level Oil Type SYSTEM FLOW RATE SYSTEM CONTROL Capacity Control Solid-State operating Thermostat General Opstat Setting ELECTRICAL CONTROLS Electronic Thermostat IR32 Electronic Thermostat IR32 Electronic Thermostat Troubleshooting ACS Typical Wiring Schematic MAINTENANCE 4.1 GENERAL PERIODIC INSPECTION MONTHLY INSPECTION VESSEL MAINTENANCE General Evaporator Cleaning AIR COOLED CONDENSER CLEANING ELECTRICAL MALFUNCTION REFRIGERANT CHARGING General Air Cooled Package TROUBLE SHOOTING SAMPLE LOG SHEET SCHEMATIC DIAGRAM, GRAPH AND TABLE Figure ACS Rigging Figure 2.4.2A ACS Space Requirements Figure 2.4.2B ACS Dimensional Data Figure ACS Weight Distribution Figure ACS Typical Piping Schematic Figure 3.6 Water Side Pressure Drop Figure Controller Front Panel Table 1.1 Product Identification... 3 Table Capacity Control Table 4.4 Pressure/ Temperature Properties

3 1.0 INTRODUCTION This manual is prepared to provide all the necessary information of installation, operation and maintenance of the latest generation of Dunham- Bush air-cooled chillers with scroll compressors. In order to be able to make full use of the manual, you must first determine your unit model number from the unit name plate. Your Dunham-Bush package has been manufactured under a stringent quality control system. Each packaged chiller is performance tested at the factory at the specified field operating conditions as a final verification of reliability. If the package is installed, operated and maintained with care and attention to the instructions contained here in, it will yield many years of satisfactory service. It is assumed that the reader of this manual and those who install, operate and maintain the equipment have a basic understanding of the principles of air conditioning, refrigeration and electrical controls. TABLE 1.1 PRODUCTION IDENTIFICATION AC S 30-5 E P Air Cooled Packaged DX Chiller Blank - R22 P - R407C Scroll Compressor H - High Efficiency E - Energy Saving Nominal Capacity 5-50Hz 6-60Hz - 3 -

4 1.0 INTRODUCTION 1.1 PHYSICAL SPECIFICATIONS ENERGY SAVING R22 MODEL ACS 10-5-E 13-5-E 15-5-E 20-5-E 23-5-E 26-5-E COMPRESSOR MODEL (QTY) SPA (2) SPB (2) SPC (2) SPD (2) SPE (2) SPBB (2) RPM MIN. % UNIT CAPACITY REDUCTION 50% 50% 50% 50% 50% 25% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDD03 HDD03 HDD04 HDE03 HDE04 HDF03 WATER CONNECTOR INCH[MM] 3[76.2] 3[76.2] 3[76.2] 3[76.2] 3[76.2] 3[76.2] NOM. WATER FLOW / PD (GPM)/(FT IN WG) [m³/hr / kpa] 24.7 / 8.7 [5.6 / 26.0] 29.8 / [6.8 / 36.2] 34.6 / 7.5 [7.9 / 22.4] 42.8 / 7.6 [9.7 / 22.8] 52.9 / 14.2 [12.0 / 42.3] 61.3 / 12.2 [13.9 / 36.6] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 19.5 / 58.1 [4.43 / 13.2] 19.3 / 58.1 [4.4 / 13.2] 29.1 / 87.2 [6.6 / 19.9] 37.2 / [8.5 / 25.3] 37.2 / [8.5 / 25.3] 42.0 / [9.5 / 28.6] MIN/MAX. WATER PD (FT IN WG) / [kpa] 5.66 / [16.9 / 120.5] 5.6 / [16.7 / 120.4] 5.48 / [17.3 / 118.9] 5.93 / [17.7 / 128.6] 7.53 / 54.7 [22.5 / 163.5] 6.2 / 44.5 [18.6 / 133.0] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 2 / 19.25[1.8] 3 / 19.25[1.8] 3/ 19.25[1.8] 3 / 26.5[2.5] 4 / 26.5[2.5] 3 / 44.4[4.1] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] MOTOR HP (QTY) 5/8 (2) 5/8 (2) 5/8 (2) 5/8 (3) 5/8 (3) 5/8 (4) FAN FLA, AMP (QTY) 2 (2) 2 (2) 2 (2) 2 (3) 2 (3) 2 (4) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 25.3 (1) 29.8 (1) 34.3 (1) 40.3 (1) 48.2 (1) 29.8 (2) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 87.5[2222] 87.5[2222] 87.5[2222] 117.5[2984] 117.5[2984] 102[2591] UNIT WIDTH INCH[MM] 36[914] 36[914] 36[914] 38[965] 38[965] 88[2235] UNIT HEIGHT INCH[MM] 67.5[1714] 67.5[1714] 67.5[1714] 70[1778] 70[1778] 71[1803] SHIPPING WEIGHT LB[KG] 1920[873] 2032[924] 2062[937] 2880[1309] 3043[1383] 3742[1701] OPERATING WEIGHT LB[KG] 1942[883] 2052[933] 2081[946] 2935[1334] 3100[1409] 3789[1722] OPERATING CHARGE R22 LB[KG] 22[10] 29[13] 33[15] 44[20] 51[23] 57[26] - 4 -

5 1.0 INTRODUCTION ENERGY SAVING R22 MODEL ACS 30-5-E 40-5-E 46-5-E 55-5-E 60-5-E 70-5-E COMPRESSOR MODEL (QTY) SPCC (2) SPDD (2) SPEE (2) SPDD (3) SPDE (3) SPEE (3) RPM MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 16.7% 16.7% 16.7% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDF03 HDF04 HDH04 XTK08 XTK08 XTM09 WATER CONNECTOR INCH[MM] 3[76.2] 3[76.2] 4[101.6] 4[101.6] 4[101.6] 5[127.0] NOM. WATER FLOW / PD (GPM) /(FT IN WG) [m³/hr / kpa] 69.3 / 15.3 [15.8 / 45.6] 84.6 / 26.8 [19.2 / 79.9] / 13.2 [23.4 / 39.5] / 7.5 [29.9 / 22.5] / 8.9 [33.0 / 26.9] 163.4/ 10.6 [37.1/ 31.7] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 42.0 / [9.5 / 28.6] 42.0 / [9.5 / 28.6] 62.5 / [14.2 / 42.3] / [26.2 / 78.4] / [26.2 / 78.4] / [23.2 / 69.8] MIN/MAX. WATER PD (FT IN WG) / [kpa] 6.23 / 44.5 [18.6 / 133.0] 7.62 / [22.8 / 163.0] 5.41 / [16.2 / 114.9] 6.0 / 41.7 [ / 124.6] 6.0 / 41.7 [ / 124.6] 4.6 / 32.3 [13.7 / 96.5] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 3 / 53.3[5.0] 3 / 53.3[5.0] 4 / 62.2[5.8] 2 / 102.7[9.5] 3 / 102.7[9.5] 3 / 102.7[9.5] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 26.0[660.4] 30.0 [762] 30.0 [762] 30.0 [762] MOTOR HP (QTY) 5/8 (4) 5/8 (4) 5/8 (4) 1.5(6) 1.5(6) 1.5(6) FAN FLA, AMP (QTY) 2 (4) 2 (4) 2 (4) 3.2 (6) 3.2 (6) 3.2 (6) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 34.3 (2) 40.3 (2) 48.2 (2) 40.3 (3) 44.9 (3) 48.2 (3) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 102[2591] 102[2591] 102[2591] 136[3454] 136[3454] 136[3454] UNIT WIDTH INCH[MM] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] UNIT HEIGHT INCH[MM] 71[1803] 71[1803] 71[1803] 78.5[1994] 78.5[1994] 78.5[1994] SHIPPING WEIGHT LB[KG] 3962[1801] 4319[1963] 4481[2037] 6257[2838] 6389[2898] 6527[2961] OPERATING WEIGHT LB[KG] 4026[1830] 4398[1999] 4560[2073] 6499[2948] 6651[3017] 6770[3071] OPERATING CHARGE R22 LB[KG] 66[30] 88[40] 102[46] 122[55] 132[60] 154[70] - 5 -

6 1.0 INTRODUCTION HIGH EFFICIENCY R22 MODEL ACS 10-5-H 13-5-H 15-5-H 20-5-H 23-5-H 26-5-H COMPRESSOR MODEL (QTY) SPA (2) SPB (2) SPC (2) SPD (2) SPE (2) SPBB (2) RPM MIN. % UNIT CAPACITY REDUCTION 50% 50% 50% 50% 50% 25% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDD03 HDD03 HDD04 HDE03 HDE04 HDF03 WATER CONNECTOR INCH[MM] 3[76.2] 3[76.2] 3[76.2] 3[76.2] 3[76.2] 3[76.2] NOM. WATER FLOW / PD (GPM)/(FT IN WG) [m³/hr / kpa] 25.7 / 9.31 [5.8 / 27.8] 31.0 / 6.2 [7.0 / 18.4] 35.6 / 21.5 [8.1 / 64.3] 45.2 / 10.7 [10.3 / 32.0] 53.6 / 9.6 [12.2 / 28.7] 60.9/ 12.1 [13.8 / 36.1] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 19.5 / 58.1 [4.4 / 13.2] 29.1 / 87.2 [6.6/ 19.8] 19.5 / 58.1 [4.4 / 13.2] 37.2 / [8.5 / 25.4] 42.0 / [9.5 / 28.6] 42 / [9.5 / 28.6] MIN/MAX. WATER PD (FT IN WG) / [kpa] 5.7 / 40.3 [17.0 / 120.5] 5.5 / 39.8 [16.4 / 119.0] 7.3 / 52 [21.8 / 155.4] 7.5 / 54.7 [22.4 / 163.5] 6.2 / 44.5 [18.5 / 133.0] 6.2 / 44.5 [18.5 / 133.0] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 3 / 19.25[1.8] 3 / 19.25[1.8] 4 / 19.25[1.8] 4 / 26.5[2.5] 4 / 26.5[2.5] 3 / 44.4[4.1] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] MOTOR HP (QTY) 5/8 (2) 5/8 (2) 5/8 (2) 5/8 (3) 5/8 (3) 5/8 (4) FAN FLA, AMP (QTY) 2 (2) 2 (2) 2 (2) 2 (3) 2 (3) 2 (4) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 24.4 (1) 28.6 (1) 32.9 (1) 38.5 (1) 46.0 (1) 28.6 (2) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 87.5[2222] 87.5[2222] 87.5[2222] 117.5[2984] 117.5[2984] 102[2591] UNIT WIDTH INCH[MM] 36[914] 36[914] 36[914] 38[965] 38[965] 88[2235] UNIT HEIGHT INCH[MM] 67.5[1714] 67.5[1714] 67.5[1714] 70[1778] 70[1778] 71[1803] SHIPPING WEIGHT LB[KG] 2085[948] 2207[1003] 2239[1018] 3128[1422] 3305[1502] 3742[1701] OPERATING WEIGHT LB[KG] 2109[959] 2228[1013] 2260[1027] 3187[1449] 3367[1530] 3789[1722] OPERATING CHARGE R22 LB[KG] 22[10] 29[13] 33[15] 44[20] 51[23] 58[26] - 6 -

7 1.0 INTRODUCTION HIGH EFFICIENCY R22 MODEL ACS 30-5-H 40-5-H 46-5-H 55-5-H 60-5-H 70-5-H COMPRESSOR MODEL (QTY) SPCC (2) SPDD (2) SPEE (2) SPDD (3) SPDE (3) SPEE (3) RPM MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 16.7% 16.7% 16.7% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDF03 HDF04 HDH04 XTK08 XTK08 XTM09 WATER CONNECTOR INCH[MM] 3[76.2] 4[101.6] 4[101.6] 4[101.6] 4[101.6] 5[127.0] NOM. WATER FLOW / PD (GPM) /(FT IN WG) [m³/hr / kpa] 71.6 / 9.9 [16.3 / 29.6] 88.9 / 10.2 [20.2 / 30.4] / 7.5 [25.1 / 22.3] / 8 [31.9 / 23.9] / 13.2 [33.8 / 39.5] / 6.6 [37.7 / 19.7] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 56.0 / [12.7 / 38.1] 62.0 / [14.1 / 42.4] 85.3 / [19.4 / 58.2] / [26.2 / 78.4] 96.1 / [21.8 / 65.5] / [26.4 / 78.9] MIN/MAX. WATER PD (FT IN WG) / [kpa] 6.4 / 46.0 [19.1 / 137.5] 5.3 / 38.6 [16.0 / 115.4] 4.7 / 33.7 [14.0 / 100.7] 6 / 41.7 [17.9 / 124.6] 6.1 / 43 [18.4 / 128.5] 5.1 / 35.3 [15.2 / 105.6] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 3 / 53.3[5.0] 4 / 62.2[5.8] 4 / 62.2[5.8] 3 / [9.5] 3 /102.7 [9.5] 3 / [9.5] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 30 [762] 30 [762] 30 [762] 30 [762] MOTOR HP (QTY) 5/8 (4) 5/8 (4) 1.5(4) 1.5(6) 1.5(6) 1.5(6) FAN FLA, AMP (QTY) 2 (4) 2 (4) 3.2 (4) 3.2 (6) 3.2 (6) 3.2 (6) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 32.9 (2) 38.5 (2) 46 (2) 40.3 (3) 44.9 (3) 48.2 (3) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 102[2591] 102[2591] 102[2591] 136[3454] 136[3454] 136[3454] UNIT WIDTH INCH[MM] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] UNIT HEIGHT INCH[MM] 71[1803] 71[1803] 71[1803] 76.5[1943] 76.5[1943] 76.5[1943] SHIPPING WEIGHT LB[KG] 4303[1956] 4690[2132] 4866[2212] 6257[2838] 6389[2898] 6527[2961] OPERATING WEIGHT LB[KG] 4372[1987] 4776[2171] 4952[2251] 6499[2948] 6651[3017] 6770[3071] OPERATING CHARGE R22 LB[KG] 66[30] 88[40] 102[46] 122[55] 132[60] 154[70] - 7 -

8 1.0 INTRODUCTION ENERGY SAVING R407c MODEL ACS 10-5-E-P 13-5-E-P 15-5-E-P 20-5-E-P 23-5-E-P 26-5-E-P COMPRESSOR MODEL (QTY) SPAE (2) SPBE (2) SPCE (2) SPDE (2) SPEE (2) SPBBE (2) RPM MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 25% 25% 25% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDD03 HDD03 HDD04 HDE03 HDE04 HDE04 WATER CONNECTOR INCH[MM] 3 [76.2] 3 [76.2] 3 [76.2] 3 [76.2] 3 [76.2] 3 [76.2] NOM. WATER FLOW / PD (GPM)/(FT IN WG) [m³/hr / kpa] 25.0 / 8.85 [5.7 / 26.5] 29.6 / 22.1 [6.8 / 66.1] 34.2 / 7.4 [7.8 / 22.1] 42 / 7.37 [9.6 / 22.0] 51.2 / 5.6 [11.6 / 16.7] 59.7 / 17.6 [13.6 / 52.6] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 19.4 / 58.1 [4.4 / 13.3] 14.7 / 43.7 [3.3 / 9.9] 29.1 / 87.2 [6.6 / 19.9] 37.2 / [8.5 / 25.5] 49.7 / [11.3 / 33.9] 37.2 / [8.5 / 25.4] MIN/MAX. WATER PD (FT IN WG) / [kpa] 5.63 / [16.8 / 120.5] 6.3 / 44.6 [18.8 / 133.3] 5.48 / [17.3 / 118.9] 5.93 / [17.7 / 128.6] 5.3 / 38.8 [15.8 / 116.0] 7.5 / 54.7 [22.4 / 163.5] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 2 / 19.25[1.8] 3 / 19.25[1.8] 3/ 19.25[1.8] 3 / 26.5[2.5] 4 / 26.5[2.5] 3 / 44.4[4.1] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] MOTOR HP (QTY) 5/8 (2) 5/8 (2) 5/8 (2) 5/8 (3) 5/8 (3) 5/8 (4) FAN FLA, AMP (QTY) 2 (2) 2 (2) 2 (2) 2 (3) 2 (3) 2 (4) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 25.3 (1) 29.8 (1) 34.3 (1) 40.3 (1) 48.2 (1) 29.8 (2) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 87.5[2222] 87.5[2222] 87.5[2222] 117.5[2984] 117.5[2984] 102[2591] UNIT WIDTH INCH[MM] 36[914] 36[914] 36[914] 38[965] 38[965] 88[2235] UNIT HEIGHT INCH[MM] 67.5[1714] 67.5[1714] 67.5[1714] 70[1778] 70[1778] 71[1803] SHIPPING WEIGHT LB[KG] 1920[873] 2032[924] 2062[937] 2880[1309] 3043[1383] 3742[1701] OPERATING WEIGHT LB[KG] 1942[883] 2052[933] 2081[946] 2935[1334] 3100[1409] 3789[1722] OPERATING CHARGE R407C LB[KG] 22[10] 29[13] 33[15] 44[20] 51[23] 58[26] - 8 -

9 1.0 INTRODUCTION ENERGY SAVING R407C MODEL ACS 30-5-E-P 40-5-E-P 46-5-E-P 55-5-E-P 60-5-E-P 70-5-E-P COMPRESSOR MODEL (QTY) SPCCE (2) SPDDE (2) SPEEE (2) SPDDE (3) SPDEE (3) SPEEE (3) RPM MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 16.7% 16.7% 16.7% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDF04 HDH03 HDH04 XTK08 XTK08 XTM09 WATER CONNECTOR INCH[MM] 3 [76.2] 4 [101.6] 4 [101.6] 4 [101.6] 4 [101.6] 5 [127.0] NOM. WATER FLOW / PD (GPM) /(FT IN WG) [m³/hr / kpa] 69.7 / 9.4 [15.8 / 28.2] 83.6 / 17.3 [19.0 / 51.7] / 13.0 [23.1 / 38.9] / 10.4 [29.5 / 31.1] 143 / 12.4 [32.5 / 37.1] / 10.4 [36.9 / 31.1] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 56.0 / [12.7 / 38.2] 46.6 / [10.6 / 31.8] 62.5 / [14.2 / 42.4] 96.1 / [21.8 / 65.5] 96.1 / [21.8 / 65.5] / [23.3 / 69.8] MIN/MAX. WATER PD (FT IN WG) / [kpa] 6.4 / 46.2 [19.0 / 138.1] 6.1 / 43.3 [18.2 / 129.5] 5.4 / 38.6 [16.1 / 115.3] 6.1 / 43 [18.4 / 128.5] 6.1 / 43 [18.4 / 128.5] 4.6 / 32.3 [13.7 / 96.5] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 3 / 53.3[5.0] 4 / 53.3[5.0] 4 / 62.2[5.8] 2 / [9.5] 3 /102.7 [9.5] 3 / [9.5] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 26.0[660.4] 30 [762] 30 [762] 30 [762] MOTOR HP (QTY) 5/8 (4) 5/8 (4) 5/8 (4) 1.5(6) 1.5(6) 1.5(6) FAN FLA, AMP (QTY) 2 (4) 2 (4) 2 (4) 3.2 (6) 3.2 (6) 3.2 (6) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 34.3 (2) 40.3 (2) 48.2 (2) 40.3 (3) 44.9 (3) 48.2 (3) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 102[2591] 102[2591] 102[2591] 136[3454] 136[3454] 136[3454] UNIT WIDTH INCH[MM] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] UNIT HEIGHT INCH[MM] 71[1803] 71[1803] 71[1803] 76.5[1943] 76.5[1943] 76.5[1943] SHIPPING WEIGHT LB[KG] 3962[1801] 4319[1963] 4481[2037] 6257[2838] 6389[2898] 6527[2961] OPERATING WEIGHT LB[KG] 4026[1830] 4398[1999] 4560[2073] 6499[2948] 6651[3017] 6770[3071] OPERATING CHARGE R407C LB[KG] 66[30] 88[40] 102[46] 122[55] 132[60] 154[70] - 9 -

10 1.0 INTRODUCTION HIGH EFFICIENCY R407c MODEL ACS 10-5-H-P 13-5-H-P 15-5-H-P 20-5-H-P 23-5-H-P 26-5-H-P COMPRESSOR MODEL (QTY) SPAE (2) SPBE (2) SPCE (2) SPDE (2) SPEE (2) SPBBE (2) RPM MIN. % UNIT CAPACITY REDUCTION 50% 50% 50% 50% 50% 25% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDD03 HDD03 HDD04 HDE03 HDE04 HDE04 WATER CONNECTOR INCH[MM] 3 [76.2] 3 [76.2] 3 [76.2] 3 [76.2] 3 [76.2] 3 [76.2] NOM. WATER FLOW / PD (GPM)/(FT IN WG) [m³/hr / kpa] 25.9 / [5.9 / 52.4] 31.2 / 17 [7.1 / 50.8] 36.5 / 16.0 [8.3 / 47.7] 44.5 / 22.7 [10.1 / 67.9] 53.3 / 9.5 [12.1 / 28.5] 63.7 / 19.8 [14.5 / 59.1] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 14.7 / 43.6 [3.4 / 10.0] 19.5 / 58.1 [4.5 / 13.3] 25.0 / 74.6 [5.7 / 17.0] 25.0 / 74.6 [5.7 / 17.0] 42.0 / [9.5 / 28.6] 37.2 / [8.5 / 25.4] MIN/MAX. WATER PD (FT IN WG) / [kpa] 6.33 / [18.9 / 132.6] 7.28 / [21.8 / 155.3] 8.1 / 57.7 [24.2 / 172.4] 8.1 / 57.7 [24.2 / 172.4] 6.2 / 44.5 [18.6 / 133.1] 7.5 / 54.7 [22.4 / 163.5] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 3 / 19.25[1.8] 3 / 19.25[1.8] 4 / 19.25[1.8] 4 / 26.5[2.5] 4 / 26.5[2.5] 3 / 44.4[4.1] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] 26.0[660.4] MOTOR HP (QTY) 5/8 (2) 5/8 (2) 5/8 (2) 5/8 (3) 5/8 (3) 5/8 (4) FAN FLA, AMP (QTY) 2 (2) 2 (2) 2 (2) 2 (3) 2 (3) 2 (4) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 24.4 (1) 28.6 (1) 32.9 (1) 38.5 (1) 46.0 (1) 28.6 (2) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 87.5[2222] 87.5[2222] 87.5[2222] 117.5[2984] 117.5[2984] 102[2591] UNIT WIDTH INCH[MM] 36[914] 36[914] 36[914] 38[965] 38[965] 88[2235] UNIT HEIGHT INCH[MM] 67.5[1714] 67.5[1714] 67.5[1714] 70[1778] 70[1778] 71[1803] SHIPPING WEIGHT LB[KG] 2085[948] 2207[1003] 2239[1018] 3128[1422] 3305[1502] 3742[1701] OPERATING WEIGHT LB[KG] 2109[959] 2228[1013] 2260[1027] 3187[1449] 3367[1530] 3789[1722] OPERATING CHARGE R407C LB[KG] 22[10] 29[13] 33[15] 44[20] 51[23] 58[26]

11 1.0 INTRODUCTION HIGH EFFICIENCY R407C MODEL ACS 30-5-H-P 40-5-H-P 46-5-H-P 55-5-H-P 60-5-H-P 70-5-H-P COMPRESSOR MODEL (QTY) SPCCE (2) SPDDE (2) SPEEE (2) SPDDE (3) SPDEE (3) SPEEE (3) RPM MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 16.7% 16.7% 16.7% NO. OF REFRIGERANT CIRCUIT EVAPORATOR MODEL HDF04 HDH03 HDH04 XTK08 XTK08 XTM09 WATER CONNECTOR INCH[MM] 3 [76.2] 4 [101.6] 4 [101.6] 4[101.6] 4[101.6] 5[127.0] NOM. WATER FLOW / PD (GPM) /(FT IN WG) [m³/hr / kpa] 73.7 / 10.4 [16.8 / 31.1] 90.9 / 10.6 [20.7 / 31.6] 110.1/ 7.4 [25.0 / 22.1] / 7.8 [31.6 / 23.3] / 9 [33.0 / 26.9] / 9.6 [37.8 / 28.7] MIN/MAX. WATER FLOW (GPM)/[m³/hr] 56.0 / [12.7 / 38.1] 62.0 / [14.1 / 42.4] 85.5 / [19.4 / 58.2] / [26.2 / 78.4] / [26.2 / 78.4] / [26.4 / 78.9] MIN/MAX. WATER PD (FT IN WG) / [kpa] 6.4 / 46.0 [19.1 / 137.5] 5.3 / 38.6 [16.0 / 115.4] 4.7 / 33.7 [14.0 / 100.7] 6 / 41.7 [17.9 / 124.6] 6 / 41.7 [17.9 / 124.6] 5.1 / 35.3 [15.2 / 105.6] CONDENSER COIL ROWS DEEP/ TOTAL FA FT²[M²] 3 / 53.3[5.0] 4 / 62.2[5.8] 4 / 62.2[5.8] 3 / [9.5] 3 /102.7 [9.5] 4 / [9.5] TOTAL CFM NO OF FAN FAN DIA INCH[MM] 26.0[660.4] 26.0[660.4] 30 [762] 30 [762] 30 [762] 30 [762] MOTOR HP (QTY) 5/8 (4) 5/8 (4) 1.5(4) 1.5(6) 1.5(6) 1.5(6) FAN FLA, AMP (QTY) 2 (4) 2 (4) 3.2 (4) 3.2 (6) 3.2 (6) 3.2 (6) MIN. AMBIENT TEMP. ( F) (WITH FAN CYCLING AND SOLENOID CONTROL) ELECTRICAL NOM. VOLTAGE 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 RLA/CIRCUIT (QTY), AMPS 32.9 (2) 38.5 (2) 46 (2) 40.3 (3) 44.9 (3) 48.2 (3) UNIT MAX. INRUSH GENERAL UNIT LENGTH INCH[MM] 102[2591] 102[2591] 102[2591] 136[3454] 136[3454] 136[3454] UNIT WIDTH INCH[MM] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] UNIT HEIGHT INCH[MM] 71[1803] 71[1803] 71[1803] 76.5[1943] 76.5[1943] 76.5[1943] SHIPPING WEIGHT LB[KG] 4303[1956] 4690[2132] 4866[2212] 6257[2838] 6389[2898] 6527[2961] OPERATING WEIGHT LB[KG] 4372[1987] 4776[2171] 4952[2251] 6499[2948] 6651[3017] 6770[3071] OPERATING CHARGE R407C LB[KG] 66[30] 88[40] 102[46] 122[55] 132[60] 154[70]

12 2.0 INSTALLATION 2.1 GENERAL The ACS chiller is designed to cool water or other non-corrosive liquids. Water is circulated through the direct expansion evaporator where it is cooled to the desired temperature and then circulated to cooling coils for air conditioning, or to other types of heat exchangers for process cooling. Care should be taken to ensure that the equipment is properly installed and adjusted. An installer or operator should first be familiar with the information in this manual. 2.2 INSPECTION When the equipment is delivered, it is important that the following inspection be completed in the presence of the carrier's representative: 1. Check all crates and cartons received against the Bill of Lading/Shipping Papers to be sure they tally. 2. Check the model number and the electrical characteristics on the nameplate to determine if they are correct. 3. Check for freight damage, shortages or other discrepancies and take note of them on the delivery receipt before signing. Should any damage be found, a damage claim should immediately be filed by the purchaser against the delivering carrier as all shipments are made at the purchaser's risk. 2.3 RIGGING GENERAL Each unit has been carefully tested and packed at the factory where every care is taken to ensure that the unit reaches you in perfect condition. It is very important that the riggers and movers use the same care and precaution in moving the equipment into place. Make sure that chains, cables, or other moving equipment are placed so as to avoid damage to the unit or piping. The refrigerant piping should not be used as a ladder or as a handle. Do not attach a chain hoist sling to the piping or equipment. Move the unit in an upright position and let it down gently from trucks or rollers RIGGING AND MOVING Any unit mounted on skids may be moved with a forklift, but care must be taken not to damage the unit with forks. The skids should not be removed until the unit is at its final location. The ACS model can be lifted by the method showing in Figure SPACE REQUIREMENTS AND CLEARANCE GENERAL The dimensional data and clearances that follow are useful for determining space requirements. The unit should be placed to make the clearance noted available for proper servicing. Failure to allow such clearance will cause serious problems and result in higher costs for operation, maintenance and repair ACS The dimensional data are shown in Figure 2.4.2B and space requirements are shown in Figure 2.4.2A. The most important consideration which must be taken into account when deciding on the location of an air cooled equipment, is the provision for supply of ambient air to the condenser, and removal of heated air from the condenser area. When this essential requirement is not provided, it will result in higher condensing temperatures, which will cause poor operation, higher power consumption and eventually failure of equipment. Units must not be located in the vicinity of steam, hot air or fume exhausts. Another consideration which must be taken into account is that the unit should be mounted away from noise sensitive spaces and must have adequate support to avoid vibration and noise transmission into the building. Units should be mounted over corridors, utility areas, rest rooms or other auxiliary areas where sound levels are not an important factor. Sound and structural experts should be consulted for recommendations on critical installations

13 2.0 INSTALLATION FIGURE ACS RIGGING ACS 10-5, 13-5, 15-5 ACS 20-5,

14 2.0 INSTALLATION ACS 26-5, 30-5, 40-5, 46-5 ACS 55-5, 60-5,

15 2.0 INSTALLATION FIGURE 2.4.2A ACS SPACE REQUIREMENTS Walls or Obstructions The unit should be located so that air may circulate freely and not be recirculated. For proper air flow and access all sides of the unit must be a minimum of four feet away from any wall or obstruction. It is preferred that this distance be increased whenever possible. Make sure that there is ample room for maintenance work through access doors and panels. Overhead obstructions are not permitted. When the unit is in an area where it is enclosed by three walls the unit must be installed as indicated for units in a pit. Multiple Units For units placed side by side, the minimum distance between units is 8 feet [2438mm]. If units are placed end to end, the minimum distance between units is 4 feet [1219mm]. Units in Pits The top of the unit should be level with the top of the pit, and side distance increased to 8 feet [2438mm]. If top of the unit is not level with the top of pit, discharge cones or stacks must be used to raise discharge air to the top of the pit. This is a minimum requirement. Stacks cannot be used on direct driven unit. Belt driven units must be reinforced internally to support the weight of stacks, and larger fan motors may be required. Contact your local Dunham-Bush representative for details. Decorative Fences Fences must have 50% free area, with a 1 foot [305mm] undercut, a 4 foot [1219mm] minimum clearance, and it must not exceed the top of unit. If these requirements are not met, unit must be installed as indicated for "Units in a Pit"

16 2.0 INSTALLATION FIGURE 2.4.2B ACS DIMENSIONAL DATA ACS 10-5, 13-5, 15-5 ACS 20-5, 23-5 NOTE: ALL DIMENSIONS ARE IN INCHES [MM]

17 2.0 INSTALLATION ACS 26-5, 30-5, 40-5, 46-5 ACS 55-5, 60-5, 70-5 NOTE: ALL DIMENSIONS ARE IN INCHES [MM]

18 2.0 INSTALLATION 2.5 FOUNDATION AIR COOLED UNITS The foundation must be level for proper operation and functioning of controls and provision must be made for supporting the individual load points as shown in Figure 2.5.1, Roof mounted units must be supported on adequate steel structures. If units are located on the ground level, a concrete plinth is recommended. 2.6 VIBRATION ISOLATION Under certain critical conditions, it may be necessary to install vibration isolators under the base of the Packaged Chiller. Rubber-in-shear or spring vibration isolators are offered as optional items. When spring isolators are used, flexible connectors must be installed in the water piping system and in the refrigerant lines of split systems. Kindly note that: These flexible connectors must be suitable for the fluid and pressures involved. When using flexible connectors in refrigerant piping, they must be mounted in the refrigerant discharge and liquid lines close to the packaged chiller, in a horizontal position and parallel to the compressor crankshaft. All piping which is external to the packaged chiller must be supported by spring mounted hangers and any piping which goes through the wall, ceiling or floor should be properly pivoted to prevent transmission of piping vibration to the structure. FIGURE ACS WEIGHT DISTRIBUTION ACS 10-5, 13-5, 15-5 NOTE: ALL DIMENSIONS ARE IN INCHES [MM]. MODEL LOADS LBS [KG] A B C D TOTAL OPERATING WEIGHT LBS [KG] ACS [238] 447 [203] 447 [203] 524 [238] 1942 [882] ACS [251] 472 [215] 472 [215] 554 [251] 2052 [933] ACS [255] [218] [218] 562 [255] 2081 [946]

19 2.0 INSTALLATION ACS 20-5, 23-5 ACS 26-5, 30-5, 40-5, 46-5 ACS 55-5, 60-5, 70-5 NOTE: ALL DIMENSIONS ARE IN INCHES [MM]. MODEL LOADS - LBS [KG] A B C D E F TOTAL OPERATING WEIGHT LBS [KG] ACS [334] 734 [333] 734 [333] 736 [334] [1334] ACS [353] 774 [351] 774 [351] 778 [353] [1408] ACS [379] 1063 [482] 1063 [482] 836 [379] [1722] ACS [403] 1129 [512] 1129 [512] 888 [403] [1830] ACS [440] 1232 [559] 1232 [559] 970 [440] [1998] ACS [456] 1279 [580] 1279 [580] 1005 [456] [2072] ACS [796] 1349 [612] 944 [428] 848 [385] 817 [371] 787 [357] 6499 [2948] ACS [814] 1381 [626] 966 [438] 868 [394] 836 [379] 805 [366] 6651 [3017] ACS [828] 1406 [658] 983 [446] 883 [401] 851 [386] 820 [ [3071]

20 2.0 INSTALLATION 2.7 PIPING CONNECTIONS WATER CONNECTIONS CHILLED WATER PIPING After the unit has been leveled, the external water piping may be set up. Be sure that the water piping is connected to the corresponding connectors. The wateroutlet connection of the cooler is closest to the expansion valve (refrigerant circuit) end. Water flow through the cooler must remain constant for proper chiller operation. Water pressure gauges are recommended to check the water pressure and flow rate in the system, before and after the cooler, and to determine if variations occur in the coole r and system. When installing pressure taps to measure the amount of pressure drop across the water side of the cooler, the taps should be located at least twenty-four (24) inches [610mm] downstream from any connections (flange, elbow, etc.) in the water piping. There are many piping and control systems which may be used to ensure constant water flow through the cooler. A typical system is shown in Figure 2.7A. A three-way motorized valve, which operates in response to the discharge air temperature of the cooling coil, is used. Another system which is sometimes used consists of a two-way modulating control valve, which also responds to the discharge air temperature of the cooling coil, used with a spring loaded bypass regulating valve as shown in Figure 2.7B The bypass valve must be set to ensure full flow of circulating chilled water when the modulating valve is completely closed. Other systems are noted in the ASHRAE Handbook and may operate equally well. Whatever the system is selected, the water flow must be constant WATER CONNECTIONS - Multiple Packaged Chillers Multiple unit package chillers have been successfully applied to parallel and series piping systems for years. Special attention, however, must be given to the particulars involved for each application or serious operational problems can result. The following guidelines should be followed for multiple unit application. It is assumed that the chilled water flow rate is constant Parallel Chilled Water Flow Units Method A: Both units operate simultaneously, modulating with load variations. Each packaged chiller operating thermostat senses the return water temperature using standard controls (See Figure 2.7C). The set point of each thermostats will be set to maintain the desired unloading. In addition to that, for each chiller package, the suction sensing hot gas by-pass valve provides modulating capacity reduction from 100% to approximately 30% on single compressor models with hot gas by-pass. Method B: Install units the same as Method A, but add a third thermostat in the return water, as shown in Figure 2.7E. This thermostat will be set to cycle off one of the units when the load drops below 50%. When this condition is reached, the leaving mixed water temperature will rise, causing the return water temperature to rise and the unit operating will load up. The "off" unit is sequencing to start again before full system load temperature is reached

21 2.0 INSTALLATION FIGURE 2.7A FIGURE 2.7B FIGURE 2.7C FIGURE 2.7D FIGURE 2.7E

22 2.0 INSTALLATION This system will be as stable as Method A, in operation, but in normal air-conditioning applications, this is not detrimental. The advantage of Method B is a better part load efficiency. Also a lead-lag control can be added Series Chilled Water Flow Units WATER QUALITY Units should be equally sized. The upstream unit will carry a larger load because it cools higher temperature water. The thermostats sense inlet water temperatures. (See figure 2.7D). The number 1 unit thermostat will unload or cycle off the packaged chiller before unloading occurs of the Number 2 unit. Coolers used in this packages is made of steel and copper and are suitable for operation with well-maintained water systems. However, if the water used in cooler is corrosive, high in mineral content or entrained solids, the water can reduce the performance and even damage the heat exchangers. Therefore, it may be necessary to obtain the service of a water treatment consultant and to provide and maintain water treatment. This is particularly important with glycol systems and with cooling tower loops. 2.8 ELECTRICAL CONNECTIONS GENERAL All units are wired as completely as possible at the factory prior to delivery. The connections which must be made by the installer are to the main power source, starting equipment and interlocking the satellite equipment. In connecting power wiring to the unit, the following precautions should be taken: - All field wirings are to be in accordance with the National Electrical Code and state and local codes. - All wirings are to be checked for damage and all terminal connections are to be tested for tightness. Unit terminal blocks are to be connected with copper conductors only and sized per ampacity listed on unit data plate. - The power supply should match the unit nameplate in volts, phase and Hertz. Voltage must be within ±10% of nameplate value and voltage imbalance between phases must not exceed 2% 2.9 REQUEST FOR START-UP REPRESENTATIVE Start-up service is an option upon request when an order for the unit is placed. If you request for start-up service, then after the installation has been completed and checked, a written notice shall be given to the Dunham-Bush representative. Following receipt of written notice, a representative will be sent to the customer. The purchaser should have competent service and operating personnel in attendance to assist in the work involved, and also to be trained in the operation and maintenance of this unit. The representative will inspect the installation to determine whether it meets Dunham-Bush requirements, perform the initial start-up of the installation determine whether it is in satisfactory operating condition, and instruct specified customer personnel in its operation and maintenance for the length of time specified in the purchase contract

23 3.0 OPERATION 3.1 GENERAL The unit should be started up only by a refrigeration technician who is familiar with the accepted operation practices for refrigeration systems. Use the scroll unit start-up report, to record all temperature, pressure, electrical readings and control settings. A copy must be forwarded to Dunham-Bush service department, before warranty will be honored. 3.2 UNIT PIPING See Figure for typical unit piping schematics. 3-3 AIR COOLED PACKAGES START-UP The unit is ready for start-up when the following procedures have been completed: 1. Water piping for the evaporator is installed and tested. 2. Electrical connections are made and properly fused. 3. Unit has been leak tested, leaks corrected and charge completed. 4. Compressor crankcase heater(s) has been energized for a minimum of 24 hours. 5. Calibrated refrigerant gauges have been connected to the suction and discharge ports. 6. Turn On the chilled water pump, check direction of rotation and adjust the water flow through the cooler to the specified flow rate. Bleed off all entrained air. 7. Manually energize the fan starters and check the fan rotation. Fans should pull air through the condenser coil and discharge vertically upwards. Rotation can be changed on 3-phase motors by interchanging only two wires on the main terminal block. 8. Check all refrigerant valves to be sure they are open. 9. Proceed to section 3.4 System Start-Up. 3.4 SYSTEM START-UP 1. Before starting the compressor(s), check all three phases of supply voltage, of all legs of the motor. They must be within ±10% of the nameplate voltage. 2. Start compressor(s), check the gauges and note if the pressures are within the prescribed limits. 3. Check the refrigerant sight glass to be sure it is free of bubbles. If not, charge as specified per section 4.8 Charging. 4. Shut the compressor down and check the compressor crankcase sight glass for oil level. It should be between 1/2 to 3/4 of the complete sightglass. If not, see Section 3.5 Lubrication. 5. Restart the compressor. After an hour of operation the expansion valve superheat setting should be checked, it should be between 8 F [4.4 C] and 10 F [5.6 C] at full load design conditions. In some instances, it will be necessary to lower the superheat setting to ensure proper distribution. Turn the TX valve adjustment stem clockwise to increase the superheat setting and counterclockwise to decrease the setting. Be sure and allow ample time between each adjustment for the system to rebalance. 6. The temperature of the chilled water both in and out, should be checked to insure the unit is operating within the desired temperatures. 3.5 LUBRICATION OIL LEVEL A properly operated unit should run with the compressor crankcase warm to touch. Check oil level frequently to see that a sufficient amount of oil remains in the crankcase. Compressor oil level can be checked by the sight glass. To make sure that proper oil level is observe, operate the compressor for 15 minutes, then stop the compressor. Oil should appear from 1/2 to 3/4 in the sight glass with the compressor stopped

24 3.0 OPERATION FIGURE ACS TYPICAL PIPING SCHEMATIC ACS 10-5, 13-5, 15-5, 20-5,

25 3.0 OPERATION ACS 26-5, 30-5, 40-5,

26 3.0 OPERATION ACS 55-5, 60-5,

27 3.0 OPERATION OIL TYPE If the oil becomes discolored indicating contamination, the contamination can be take care of by installing a new filter-drier in the liquid line and changing the oil. WARNING: Use Only Dunham-Bush Approved Refrigeration Oil, Warranty Will Be Void If Other Than Approved Oil Is Used. It is recommended to change oil annually to prolong the compressor life-time. Oil charge for a complete recharge shown in the following table. Oil type and approved oils are also listed for each compressor. After recharge the oil level should be maintained per section COMPRESSOR OIL CHARGE (l) APPROVED OIL SPAE SPBE SPCE SPDE SPEE SPBBE SPCCE SPDDE SPDEE SPEEE DB26 (R22 Refrigerant) / DB02 (R407c Refrigerant) 3.6 SYSTEM FLOW RATE The quantity of chilled water being circulated can be estimated by determining the water pressure drop through the cooler by reading GPM [L/S] from the appropriate pressure drop curve. (See Figure 3.6) An alternate method of determining GPM [L/S]is to measure pressure difference from pump inlet to outlet and read GPM [L/S] from pump curve. Water flow rate must not vary more than ±10% from design flow rate. 3.7 SYSTEM CONTROL CAPACITY CONTROL The standard system capacity control operates as follows: - As the chiller load initially drops, the suction of the compressor(s) starts dropping proportionately, thus balancing minor load variations. - Variation of unit capacity in response to system load requirements is controlled by an operating thermostat, which monitors the return water temperature. - On multiple compressor units, capacity is controlled by compressor staging. Refer to Table to determine the capacity control scheme for your specific unit. TABLE CAPACITY CONTROL COMPRESSOR CYLINDER UNLOADING AND STAGING SCHEDULE ACS 10-5, 13-5, 15-5, 20-5, 23-5 ACS CAPACITY COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100 % 50% ACS 26-5, 30-5, 40-5, 46-5 COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100 % 25% COMPRESSOR 2 ON 100 % 50% COMPRESSOR 3 ON 100 % 75% COMPRESSOR 4 ON 100 % 100% ACS 55-5, 60-5, 70-5 COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100 % 16.67% COMPRESSOR 2 ON 100 % 33.33% COMPRESSOR 3 ON 100 % 50.0% COMPRESSOR 4 ON 100 % 66.7% COMPRESSOR 5 ON 100 % 83.4% COMPRESSOR 6 ON 100 % 100% SOLID-STATE OPERATING THERMOSTAT General A four-stage solid-state operating thermostat, FSE, is used on all AC packages. The opstat senses return chilled water or air temperature and by staging and/or unloading compressors is able to control leaving chilled water or air temperature to a narrow band of temperature Opstat Settings Each four-stage electronic opstat is factory, adjusted to your specified conditions, A field check of the controller may be made by first determining your design range (R). To determine the range of a water chiller, subtract the design leaving water temperature (TLW) from the return water temperature (TRW) (R =TRW-TLW)

28 3.0 OPERATION FIGURE 3.6 WATER SIDE PRESSURE DROP 1a.) ENERGY SAVING IMPERIAL UNITS 100 R22 ACS 10 ACS 13 ACS 46 PRESSURE DROP - FT.WG.. 10 ACS 15 ACS 23 ACS 40 ACS 20 ACS 26 ACS 30 ACS 55 ACS 60 ACS CHILLED WATER FLOW RATE - GPM 1b.) HIGH EFFICIENCY - IMPERIAL UNITS R ACS 15 ACS 10 PRESSURE DROP - FT.WG.. 10 ACS 13 ACS 20 ACS 23 ACS 26 ACS 30 ACS 40 ACS 60 ACS 46 ACS 55 ACS CHILLED WATER FLOW RATE - GPM

29 3.0 OPERATION 1c.) ENERGY SAVING IMPERIAL UNITS R407c 100 ACS 13 ACS 10 ACS 30 ACS 15 ACS 26 PRESSURE DROP - FT.WG.. 10 ACS 20 ACS 40 ACS 23 ACS 46 ACS 55 ACS 60 ACS CHILLED WATER FLOW RATE - GPM 1d.) HIGH EFFICIENCY - IMPERIAL UNITS R407c 100 ACS 10 ACS 13 ACS 30 PRESSURE DROP - FT.WG.. 10 ACS 15 ACS 20 ACS 26 ACS 23 ACS 40 ACS 46 ACS 55 ACS 60 ACS CHILLED WATER FLOW RATE - GPM

30 3.0 OPERATION 2a.) ENERGY SAVING S. I. UNITS R PRESSURE DROP - kpa ACS 10 ACS 13 ACS 15 ACS 23 ACS 40 ACS 20 ACS 46 ACS 26 ACS 30 ACS 55 ACS 60 ACS CHILLED WATER FLOW RATE - m³/hr 2b.) HIGH EFFICIENCY S. I. UNITS R PRESSURE DROP - kpa ACS 15 ACS 10 ACS 13 ACS 20 ACS 23 ACS 26 ACS 30 ACS 40 ACS 60 AC S 46 ACS 55 ACS CHILLED WATER FLOW RATE - m³/hr

31 3.0 OPERATION 2c.) ENERGY SAVING S. I. UNITS R407c 1000 PRESSURE DROP - kpa. 100 ACS 13 ACS 10 ACS 15 ACS 26 ACS 20 ACS 40 ACS 23 ACS 30 ACS 55 ACS 60 ACS 70 ACS CHILLED WATER FLOW RATE - m³/hr 2d.) HIGH EFFICIENCY - S. I. UNITS R407c 1000 PRESSURE DROP - kpa. 100 ACS 10 ACS 13 ACS 15 ACS 20 ACS 26 ACS 23 ACS 30 ACS 55 ACS 60 ACS ACS 40 ACS CHILLED WATER FLOW RATE - m³/hr

32 3.0 OPERATION The standard range is 10 F [5.6 C]. To determine the range of a condensing unit, subtract the design no load return air temperature (TNL) from the design full load return air temperature (TFL) (R= TFL- TNL). The standard range is 6 F [3.3 C]. Set point of the opstat should be your design leaving chilled water temperature (TLW) for water chillers. The standard adjustment range for AC units is 32 to 104 F [0 to 40 C]. The location of setting knob is shown in Figure 3.7.2A. Step Temp adjusts the temperature range per stage in degrees F. To determine TRB. For a standard condensing unit TRB= 0.25 x R. Check the dial setting on the opstat. The approximate setting of Step Temp is shown in the Figure 3.7.2B by the Step Temp should be changed by an authorized serviceman only. 3.8 ELECTRICAL CONTROLS MCCB/MCB - Main Circuit Breaker This is an automatic, calibrated, ambient compensated, magnetic trip circuit breaker, which provides both direct line-break compressor branch circuit. short circuit locked rotor and overload protection. It has a manually operable handle for compressor circuit disconnect, and an auxiliary NO. switch (optional) which interrupts the 230V compressor control circuit when the breaker opens. M - Contactor (Compressor and Fan Motor)- Optional The contactor, operated by the control circuit, provides power individually to the compressor and fan motors. Contactors are used either singly or in parallel pairs for across-the-line start (simultaneous operation). These devices are amp rated to handle both rated load amp and locked rotor amps. CR - Relays (Miscellaneous Control) These relays provide the necessary circuit logic for lock-in, lock -out and transfer functions. HTR - Crankcase Heater Energized continuously as long as control circuit power disconnect switch (not supplied with the unit) is closed and compressor is off. This heater maintains crankcase temperature above the system temperature during the compressor off cycle, preventing refrigerant migration into the crankcase and consequent compressor damage. SOL- i.) Liquid Line Solenoid Valve Closes when the compressor(s) is off to prevent any liquid refrigerant from accumulating in the chiller during the off cycle. ii.) Discharge Solenoid Control (Optional) This function is used in low ambient application. Discharge solenoid is turn off to reduce condensing surface and to increase head pressure. OL - Motor Overload (Manual Reset) For AC the compressor is protected by overload relays utilizing quick trip, ambient compensated heaters. The overload relays are manually reset. OUVR - Over Under Voltage Relay (Optional) Protects the unit from the following electric supply malfunctions: over voltage, under voltage, please reversal, single phasing and phase imbalance. If the OUVR trips, a control relay will de-energize and open the control circuit. A red LED trip light, located on the OUVR, will indicate a supply malfunction. Tile OUVR is a manual reset control device

33 3.0 OPERATION FIGURE 3.7.2A CONTROLLER FRONT PANEL 1- Display: shows the value measured by the connected sensor. In the event of alarm condition the sensor value will be displayed alternately with the codes of the active alarms. When programming the instrument, the display shows the parameter codes being introduced and their values. 2- Decimal Point LED: lights up when the controlled parameter is displayed. 3- Reverse LED: flashes when at least one relay working in the "Reverse" mode is active. The Led flashes as many times as the number of active 'reverse' relays. There is a two seconds' pause between a flashing stage and the next one. 4- Direct LED: flashes when at least one relay working in the "Direct" mode is active. Its working logic is the same as the "Reverse" LED. 5- SEL Button: displays and/or allows you to select the Set-point. If pressed for 5 seconds together with PRG/MUTE it allows you to enter the password and the configuration parameters (having a "Cxx" type code). 6- PRG/Mute Button: if pressed for 5 seconds it allows you to access the menu of the more frequently used parameters (having a "Pxx" type code). In the event of alarm condition, it silences the buzzer and, if pressed after the cause that determined the alarm has disappeared, it resets any other alarm. It completes the programming procedure storing all the values of the modified parameters. 7- Button : increases the value of the set-point or that of any other selected parametel: 8 - Button : decreases the value of the set-point or that of any other selected parametel: In NTC input versions it can display the value of the second sensor (holding "Down" pressed while the display shows the value of the main sensor). Note: for Infrared Universal, Series models, please refer to the table at the end of the manual FIGURE 3.7.2B TYPICAL CONTROL SEQUENCE WITH 2 STAGE OPERATING THERMOSTAT AT 10 C RETURN WATER SETPOINT, 3.0 C DIFFERENTIAL

34 3.0 OPERATION ELECTRONIC THERMOSTAT Keypad Operation 1) Set-point display: Press [SEL] key to display set-point. 2) Set-point modification: Press [SEL] key for few sec to change St1 setpoints. Release [SEL] key, actual set-point value flashes. Use [up arrow] or [down arrow]key to change value. Press [SET] key to confirm new value. 3) "P" Parameters modification: Press [PRG/mute] key for 5 sec allows you to access the most frequent used parameters ("Pxx" type code).use [up arrow] or [down arrow] key to require parameter. Press [SEL] key to display this parameter. Use [up arrow] or [down arrow] key to set value. Press [SEL] key to confirm. Repeat procedure for other parameters. Press [PRG/mute] key to store modified data and go back to normal operation. 4) "C" Parameters modification: Press [SEL] key + PRG/mute] key for 5 sec allows you to enter password and configuration parameters ("Cxx" type code). Display show 0. Select password by pressing [up arrow] key until 22 or 77 display. Press [SEL] key to confirm. Code C0 displayed if password is correct else repeat procedure. Use [up arrow] or [down arrow] key to desire parameter. Press [SEL] to confirm. Use [up arrow] or [down arrow] key to desire value. Press [SEL] to confirm. Repeat procedure for other parameters. Press [PRG/mute] key to exit. 5) Alarm Handling: In the event of alarm condition, press [PRG/mute] key to silence the buzzer. If pressed after the cause of alarm disappeared, it resets any other alarm. 6) Second Probe Display: For NTC input versions, 2nd probe value can be displayed by pressing [down arrow] key while the main probe value is displayed IR32 ELECTRONIC THERMOSTAT PARAMETERS LIST Par. Description Min. Max. Default Fac. Set St1 Set Point 1 min probe max probe 20 6 St2 Set Point 2 (Modes 6,7,8,9) min probe max probe 40 NA CO Operation Mode Setting Differentials P1 Set Point 1 Differential (absolute value) P2 Set Point 2 Differential NA P3 Dead Zone Differential (Modes 3,4,5) (absolute value) NA C4 Authority. NTC models only with Mode 1or and C19 = 2, 3 or 4 C5 Control Action: 0=Proportional (P) 1=Prop+Integral (P+I) Outputs C6 Delay time (sec) btw energization of different relays C7 Min time (min) btw energization of the same relay C8 Min off time (min) of the same relay C9 Min on time (min) of the same relay C10 Outputs Status in the event of sensor alarm: = All relays de-energized 1 = All relays energized 2 = DA relays energized, all others de-energized 3 = RA relays energized, all others de-energized C11 Output Rotation: (Modes 1,2,6,7,8 only) 0 = No rotation 1 = Standard rotation 2 = 2+2 rotation (compressor on relays 1 & 3) 3 = 2+2 rotation (valve normal open)

35 3.0 OPERATION Par. Description Min. Max. Default Fac. Set C11 Output models only (A and Z) = Rotation of relays 3 & 4 (No rotation for 1 & 3) 5 = Rotation of relays 1 & 2 (No rotation for 3 & 4) 6 = Separate rotation of coupled relays 1-2 & = Rotation on relays 2,3,4 (No rotation for 1) C12 PWM cycle time (sec) NA Sensor C13 Probe type: 0 = 4-20, 1 = 0-20; 0 = K tc 1 = J tc NTC probe : 0 = normal function, 1= invert function, (instrument display NTC2 and control on NTC1) P14 Probe calibration or offset C15 Analog Input min.scaling value -99 C16 0 NA C16 Analog Input max.scaling value C NA C17 Probe response time (noise filter) C18 Temperature unit: 0 = C, 1 = F C19 2nd Probe: NTC only, Mode 1 or = no modification on std. Mode 1 = differential mode (NTC1 - NTC2) 2 = summer offset 3 = winter offset 4 = active offset with Dead zone P2 C21 Set point 1 min. limit -99 C22 min. probe -50 C22 Set point 1 max. limit C max. probe 90 C23 Set point 2 min. limit -99 C24 min. probe -50 C24 Set point 2 max. limit C max. probe 90 Alarms P25 Low temp. alarm set point -99 P26 min. probe -50 P26 High temp. alarm set point P max. probe 90 P27 Alarm hysteresis P28 Alarm delay, min C29 Digital input 1 configuration (CO different from 6,7,8) In case of alarm the status of relays depends on C31 0 = non active input 1 = immediate alarm with automatic reset 2 = immediate alarm with manual reset 3 = delay alarm (P28) with manual reset 4 = on/off of the control C30 Digital input 2 configuration (IRDR only) NA option as for C29 C31 Outputs Status in case of alarm condition detected via digital input: 0 = All relays de-energized 1 = All relays energized 2 = DA relays energized, all others de-energized 3 = RA relays energized, all others de-energized Others C32 Unit address (for serial connection) Special Parameters C33 Special mode of operation: 0 = No, 1 = Yes DO NOT MODIFY THIS PARAMETER Set and programmed starting mode C0 before modifying C33 C50 Keypad(KP) and Remote Control(RC) activation: = KP off, RC on (only type P parameters) 1 = KP on, RC on (only type P parameters) 2 = KP off, RC off 3 = KP on, RC off 4 = KP on, RC on (all parameters) C51 Remote IR controller activation code

36 3.0 OPERATION IR32 ELECTRONIC THERMOSTAT TROUBLESHOOTING Code Description Cause Control Action Reset Remedies Er0 Sensor error faulty sensor depends on C10 R: automatic V: manual Check connection. Check sensor signal Er1 Sensor NTC2 faulty sensor if C19=1 & Mode R: automatic Check connection. Check error =1 or 2 V: manual sensor signal see Er0 Er2 Memory error voltage drop stoppage R: automatic Reset factory-set values. during programming stage, V: manual Turn off controller, turn on again holding [PRG/mute] key memory damaged by electromagnetic interference Er3 Alarm via contact linked to depends on C31 R: depends Check C29, C30, C31 & external contact digital input is on C29 & P28. on digital input open C30 Check the external contact V: manual Er4 Er4 High temp > P26 for a nil R: automatic Check P26, P27 & P28. temperature time interval > V: manual alarm P28 Er5 Low temp < P25 for a nil R: automatic Check P26, P27 & P28. temperature time interval > V: manual alarm P28 NOTE: R = Control action Resetting the instrument means to restore normal operating conditions after the cause that determinied the alarm has been cleared. V = Display Display and buzzer. Display reset means that normal display of usual values is restored

37 3.0 OPERATION ACS TYPICAL WIRING SCHEMATIC ACS 10-5, 13-5,

38 3.0 OPERATION ACS 20-5, 23-5 Ω Ω

39 3.0 OPERATION ACS 26-5, 30-5, 40-5,

40 3.0 OPERATION ACS 55-5, 60-5,

41 3.0 OPERATION Ω Ω Ω Ω Ω Ω

42 4.0 MAINTENANCE 4.1 GENERAL As with all mechanical equipment, a program of regular inspection, cleaning and preventive maintenance by trained personnel will contribute greatly to the long satisfactory service life of this product. 4.2 PERIODIC INSPECTION Read essential temperatures and pressures periodically to see that they indicate normal operation. It is a good idea to record these readings on a log sheet. If any abnormal operation is observed, try to remedy it. See Trouble Shooting Guide Section. 4.3 MONTHLY INSPECTION Check cooling tower water treatment system, Wipe down external surfaces of unit. Shut unit down, open main disconnect, inspect control panel, checking for loose wires, burned contacts, signs of overheated wires, etc. Restart unit and check performance of controls. Check sight glasses for proper refrigerant charge. 4.4 VESSEL MAINTENANCE GENERAL The efficient performance of the cooler and condenser heat transfer surfaces is essential for efficient performance of your packaged water cooling machine. If these surfaces accumulate a film of dirt, scale or slime, their performance efficie ncy will degrade substantially. The refrigerant side of heat transfer surfaces does not foul since refrigerant is a good solvent and it is in a closed, filtered cycle. Water side surfaces can foul from the water system. A program of water treatment can slow the rate of fouling on heat transfer surfaces, but not eliminate it COOLER CLEANING The effects of fouling can be detected by recording full load performance data on the log sheet. If the difference between the leaving water from the cooler and saturated suction temperature at the compressor is 2 F [1.1 C] greater than the difference recorded at clean conditions, the tubes should be cleaned. It is generally advisable to clean the cooler water side surfaces at least annually, and more often if severely foul water is used. This cleaning must be done chemically. In chemical cleaning, a caustic solution is pumped through the heat exchanger, which attacks dirt, slime, and mineral deposits and flushes them away. Chemicals can be recommended by water treatment specialists, but it is important to rinse the system thoroughly after cleaning to remove the chemicals before they attack the metal surfaces. The cooler water side (shell side) cannot be physically cleaned because of the crossflow baffle construction. 4.5 AIR COOLED CONDENSER CLEANING The face of the condenser should be cleaned at least once month during operation. If conditions are bad and condensers pick up dirt very quickly, it is suggested that they can be cleaned more frequently

43 4.0 MAINTENANCE TABLE 4.4 PRESSURE/ TEMPERATURE PROPERTIES 1.) R22 psig Pressure Temperature Pressure Temperature Pressure Temperature kpa o F o C psig kpa o F o C psig kpa o F o C

44 4.0 MAINTENANCE 2.) R407C Pressure Temperature Temperature Temperature Pressure Pressure Bubble Dew Bubble Dew Bubble Dew psig kpa F C F C psig kpa F C F C psig kpa F C F C

45 4.0 MAINTENANCE If the condenser is allowed to get too dirty, the unit will run at high head pressure and will not give satisfactory performance. Dirty coils can be cleaned using a soft brush or by flushing with cool water or commercially available coil cleaners. DO NOT USE HOT WATER OR STEAM. To do so will cause excessive pressure in the system. The face of the condenser should be cleaned at the beginning of the season and periodically thereafter if conditions require. 4.6 ELECTRICAL MALFUNCTION The unit has four devices designed to protect compressor motors and manual motor controllers from electrical malfunctions: Circuit breakers. starter overload relays, under voltage relay (optional), and motor over temperature protectors. If the under voltage relay trips, it is a sign of trouble in incoming power. If it trips again after resetting, call your electric utility to investigate the problem. If circuit breaker or motor overload relay or motor over temperature protectors trip, this is a sign of possible motor trouble. DO NOT reset and try to run compressor again. Call authorized service representative to check for motor trouble. Resetting these safety devices and repeated starting could turn a minor motor problem into a costly major motor burnout. 4.7 REFRIGERANT CHARGE GENERAL All packaged chiller units are given a complete charge of refrigerant at the factory. The type and amount of refrigerant required is in Physical Specifications. The total refrigerant shown is for the entire system. Since these units have separate circuits, each circuit should be considered separately for charging. In order to check proper refrigerant charge, look in each liquid line sight glass with the aid of a flashlight during system operation. At all operating conditions, the sight glass should be clear. If bubbles are visible at any operating condition, the circuit is short of charge. Be careful not to overcharge the machine. overcharging will result in considerable liquid logging in the condenser, and excessive condensing pressure. To add refrigerant, connect a refrigerant vessel to the 1/4" [6.4mm] back seating port of the suction valve. Purge the air from the tube with refrigerant gas before connecting. With the unit running, open the refrigerant vessel vapor connection slightly. If the refrigerant vessel is warmer than the cooler, refrigerant will more readily flow from the vessel into the unit AIR COOLED PACKAGES To determine the proper refrigerant charge, check the amount of subcooling if possible. The amount of subcooling at the liquid line (liquid line saturation temperature corresponding to liquid line pressure minus liquid line temperature) should be between 15 F [8.3 C] and 20 F [11.1 C]. Subcooling at the condenser out-subcooler inlet trap should not exceed 5 F [2.8 C]. This sight glass should be clear with no bubbles

46 4.0 MAINTENANCE 4.8 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY 1. Unit will not start 1. Power off 2. Main line open 3. Incorrect wiring 4. Loose terminals 5. Control circuit open 1. Check main disconnect switch. 2. Check main fuses. 3. Check with wiring diagrams. 4. Tighten terminals. 5. Check pump fuses, starter heater elements, pressure and temperature controls. 2. Compressor hums but does not start 1. Low voltage 2. No power on one phase of 3 phase unit 3. Faulty starter or contactor 1. Check at main entrance and at unit. Consult power company if voltage is low and increase wire size to the unit if voltage is normal at main and low at unit. Voltage must be within 10% of motor nameplate rating. 2. Check fuses and wiring. 3. Check the contacts and time delay on part wind start. 3. Compressor cycles on low pressure control 1. Refrigerant shortage 2. No load on chiller 3. Restriction in liquid line 4. Head pressure too low 1. Check for leaks and add refrigerant. 2. Check pump operation and water flow. 3. a.) Plugged drier. If temperature drop exists across the drier remove and replace cores. b.) Liquid line or suction valve partially closed. Open valves fully and close in one full turn. c.) Expansion valve clogged or inoperative. Check superheat setting. Check charge and thermo bulb. 4. Restrict water flow to condenser by adjusting the water regulating valve or cycle cooling tower fan. 4. Compressor cycles on high pressure control 1. Compressor discharge valve partially closed. 2. Air in system 3. Overcharge of refrigerant 4. High pressure control improperly set 5. Main water valve closed 6. Water regulating valve set high or defective 7. Condenser fan inoperative 8. Dirty condenser 9. Fan cycle switches inoperative, or set too high 10.Fan motors not running 11.Fan motor reverse rotation 1. Open valve fully and close with one turn 2. Flush water valve. If pressure in system exceeds the pressure corresponding to the water temperature purge air from compressor gauge connection. 3. Purge system while in operation until bubbles show in sight glass. Close valve and add small amount of refrigerant until sight glass just clears. 4. Adjust the control. 5. Open the water valve. 6. Reset or replace valve. 7. Check, replace or repair set screw (pulley), fan motor, or inoperative fan control. 8. Clean condenser surfaces with brush and/or vacuum. 9. Check and readjust. 10.Check contactor, thermal overload relay, check motor, check capacitor. (If single phase) 11.Reverse two fan motor leads. (3 phase only)

47 4.0 MAINTENANCE 4.9 SAMPLE LOG SHEET SHEET NO... DUNHAM-BUSH SCROLL COMPRESSOR PACKAGED CHILLER NAMEPLATE DATA: UNIT MODEL NO.... UNIT NO.... VOLTS:... Hz... UNIT SERIAL NO.... COMPRESSOR MODEL NOS... START UP : DATE... TIME... DATE TIME ELAPSED TIME METERS COMP. NO. 1. SUCTION 2. PRESSURE 3. DISCHARGE 2. PRESSURE 3. DISCHARGE 2. TEMPERATURE 3. DISCHARGE SUPERHEAT 2. (DISC. TEMP.-SAT. DISCH.)* 3. DISCHARGE SUPERHEAT 2. (DISC. TEMP.-SAT. SUCT.)* 3. EVAPORATOR WATER TEMPERATURE-IN EVAPORATOR WATER TEMPERATURE-OUT EVAPORATOR PRESSURE DROP Ft.wg. [KPa] EVAPORATOR WATER FLOW gpm[m³/hr] CONDENSER AIR TEMPERATURE-IN (AMBIENT) AC ONLY ACTUAL VOLTAGE 2. COMPRESSOR AMPS 3. FAN AMPS VOLTS *USE TABLE 4.4 FOR OBTAINING SATURATED TEMPERATURE THIS LOG SHEET IS PROVIDED AS A RECOMMENDATION OF THE READINGS THAT SHOULD BE TAKEN ON A PERIODIC BASIS. THE ACTUAL READINGS TAKEN AND THE FREQUENCY WILL DEPEND UPON THE UNITS APPLICATION, HOURS OF USE, ETC. THIS TYPE OF INFORMATION CAN PROVE VERY USEFUL IN PREVENTING AND/ OR SOLVING PROBLEMS THAT MIGHT OCCUR DURING THE LIFE OF THE UNIT

48