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030-050

Water-Cooled Packaged Chillers


with Helical Rotary Screw Compressors
Installation, Operation & Maintenance Manual


Form No. 6168

TABLE OF CONTENTS

Page
1.0 General Information
1.1
1.2
1.3
1.4
1.5
1.6

1.7

Introduction ................................................................................................................................................ 5
Product Identification ................................................................................................................................. 5
Physical Specifications: 60 HZ ................................................................................................................ 6-8
Physical Specifications: 50 HZ .............................................................................................................. 9-11
Dimensional Data ................................................................................................................................ 12-16
Application & Location Requirements
1.6.1
Chilled Water Flow .......................................................................................................................... 17
1.6.2
Ice Storage ...................................................................................................................................... 17
1.6.3
Multiple Unit Control ...................................................................................................................... 17
1.6.4
Water Cooled Condensers ............................................................................................................... 17
1.6.5
Condensing Water Treatment .......................................................................................................... 18
1.6.6
Foundation ...................................................................................................................................... 18
1.6.7
Vibration Isolation ........................................................................................................................... 18
1.6.8
Location and Installation Suggestions ............................................................................................. 18
1.6.9
Equipment Location and Unit Security ............................................................................................ 18
1.6.10 Cooler - Freeze Protection ............................................................................................................... 18
1.6.11 Electrical Connection Options ......................................................................................................... 18
1.6.12 Low Voltage Units ........................................................................................................................... 18
1.6.13 Medium Voltage Units .................................................................................................................... 18
1.6.14 Power Sources ................................................................................................................................. 18
1.6.15 Unit and Field Mount Disconnects .................................................................................................. 18
1.6.16 Control Circuits ............................................................................................................................... 18
Starter & Control Panels
1.7.1
Solid State Reduced Voltage Starters .......................................................................................... 19-21
1.7.2
Wye-Delta Starters ........................................................................................................................... 21
1.7.3
Across-The-Line Starters .................................................................................................................. 21

2.0 Installation
2.1
2.2
2.3

2.4

2.5

2.6
2.7

General Installation ................................................................................................................................... 22


Inspection .................................................................................................................................................. 22
Handling, Storage & Rigging .................................................................................................................... 22
2.3.1
General 2+:E Handling Instructions ............................................................................................ 22
2.3.2
Storage ........................................................................................................................................... 22
2.3.3
2+:E Rigging and Moving ........................................................................................................... 22
Space and Clearance Requirements .......................................................................................................... 23
2.4.1
General Space and Clearance Requirements .................................................................................... 23
2.4.2
Location and Clearance Drawing ..................................................................................................... 23
Foundation or Mounting Structure .......................................................................................................... 24
2.5.1
2+:E Unit Weights, Point Loading and Center of Gravity English I.P. Units ............................. 24
2.5.2
2+:E Unit Weights, Point Loading and Center of Gravity S.I. Units ......................................... 25
Sound and Vibration Isolation .................................................................................................................. 26
2.6.1
2+:E Spring Vibration Isolators and Locations ............................................................................ 26
Water Piping Connections ......................................................................................................................... 27
2.7.1
2+:E Chilled Water Piping ........................................................................................................... 27
Figure 27A Chilled Water Piping - Three-Way Load Side By-Pass ..................................................... 27
Figure 27B Chilled Water Piping - Two-Way Load Side By-Pass ....................................................... 27
2.7.2
Multiple Chillers Per Chilled Water System ...................................................................................... 28
2.7.2.1
Load is Greater than one 2+:E can Handle .............................................................. 28
2.7.2.2
Parallel Chiller Applications ........................................................................................ 28
Figure 28A Parallel Chiller Chilled Water Piping Schematic ........................................................... 28
2.7.2.3
Series Chiller Applications .......................................................................................... 28
Figure 28B Series Chiller Chilled Water Piping Schematic ............................................................. 28
2.7.2.4
Oversizing Chillers ...................................................................................................... 28
2.7.2.5
Water (Fluid) Strainers ................................................................................................ 28
2.7.3
Cooler Design Data Guidelines ........................................................................................................ 29
2.7.3.1
Maximum Leaving Fluid Temperature ......................................................................... 29
2.7.3.2
Minimum Leaving Fluid Temperature .......................................................................... 29
2.7.3.3
Operating Leaving Temperature Range ....................................................................... 29
2.7.3.4
Minimum/Maximum Flow Rates ................................................................................. 29
2.7.3.5a
Two Pass Coolers ........................................................................................................ 29
2.7.3.5b
Single Pass Coolers ..................................................................................................... 29
2.7.3.5c
Three Pass Coolers ...................................................................................................... 29

TABLE OF CONTENTS

Page

2.8
2.9

2.7.3.6
Wide Range - Low Flow Chiller Operation .................................................................. 29
2.7.3.7
Extra Narrow and Wide Range Applications ............................................................... 29
Figure 29A Wide Range - Low Flow By-Pass Piping Schematic ...................................................... 29
Figure 29B Extra Narrow and Wide Range By-Pass Piping Schematic ........................................... 29
2.7.4
Chilled Fluid Loop Volume (CFLV) Guidelines ................................................................................... 30
Table 30
Minimum Chilled Loop Volume Quick Reference Table ............................................... 30
Figure 30A Single Loop System with Storage Tank ....................................................................... 30
Figure 30B Primary and Secondary Loop Systems with Storage Tank ........................................... 30
2.7.5
Flooded Cooler Water Side Pressure Drop Curves ............................................................................ 31
2.7.6
Condenser Water Side Pressure Drop Curves ................................................................................... 32
2.7.7
Cooling Tower Control and Condenser Application Design Data ..................................................... 33
2.7.7.1
Cooling Tower Head Pressure Control ......................................................................... 33
2.7.7.2
Condenser Water Temperature ................................................................................... 33
2.7.7.3
Condenser Water Regulating Valves ........................................................................... 33
2.7.7.4
Cooling Tower and Head Pressure Control .................................................................. 33
2.7.7.5
Condenser Water Pump .............................................................................................. 33
2.7.7.6
Fan Cycling Tower Control .......................................................................................... 33
2.7.7.6.1
Minimum Entering Condenser Water Temperature ..................................................... 33
2.7.7.6.2
Maximum Entering Condenser Water Temperature .................................................... 33
2.7.7.6.3
Unit Operating Efficiency ............................................................................................ 33
2.7.7.6.4
Minimum/Maximum Flow Rate Data .......................................................................... 34
2.7.7.6.5
Condenser Water Pressure Drop Data ......................................................................... 34
2.7.7.6.6
Wide Condenser Water Temperature Ranges .............................................................. 34
2.7.7.6.7
Narrow Condenser Water Temperature Ranges .......................................................... 34
2.7.8
Glycol Freeze Protection .................................................................................................................. 34
Table 34A
Ethylene Glycol ........................................................................................................... 34
Table 34B
Propylene Glycol ......................................................................................................... 34
2.7.9
Water Quality .................................................................................................................................. 34
Typical Refrigerant Piping Diagram .......................................................................................................... 35
Electrical Connections ............................................................................................................................... 35
2.9.1
Unit Electrical Data .......................................................................................................................... 36
2.9.2
Electrical Field Connection Data ...................................................................................................... 37
2.9.3
Power Wiring Diagram: Typical Solid State Unit Mounted Starter ............................................... 38-39
2.9.4
Power Wiring Diagram: Typical Wye-Delta unit Mounted Starter ................................................ 40-41
2.9.5
Typical Control Wiring Diagram .................................................................................................. 42-44
2.9.6
Typical Optional Interconnection Wiring Diagram ........................................................................... 45

3.0 Operation: Mechanical


3.1
3.2
3.3
3.4
3.5
3.6
3.7

3.8
3.9

General Mechanical Unit Operation .......................................................................................................... 46


System Water Flow Rate ............................................................................................................................ 46
Seasonal Shut-Down Procedure ................................................................................................................ 46
Seasonal Start-Up Procedure .................................................................................................................... 46
Safety Relief Valves ................................................................................................................................... 46
Refrigerant Cycle ....................................................................................................................................... 46
Oil System .................................................................................................................................................. 47
3.7.1
Oil Supply System ............................................................................................................................ 47
3.7.2
Oil Return System ............................................................................................................................ 47
Hydraulic Capacity Control System ........................................................................................................... 47
Freeze Protection ....................................................................................................................................... 47
3.9.1
Standby at Low Ambient Temperature ............................................................................................ 47
3.9.2
In Operation .................................................................................................................................... 47
3.9.3
During Maintenance ........................................................................................................................ 47

4.0 Operation: Control System


4.1
4.2
4.3

Typical Wiring Diagram ............................................................................................................................. 48


Typical Operation ...................................................................................................................................... 48
Microcomputer Controller ........................................................................................................................ 48
4.3.1
To display Data From the Menu ....................................................................................................... 48
4.3.2
To Reset All Control Points to Computer Control ............................................................................. 48
4.3.3
To Display Alarms ............................................................................................................................ 48
4.3.4
to Become Authorized ..................................................................................................................... 48
4.3.5
To Alter Setpoints Data .................................................................................................................... 48

TABLE OF CONTENTS

Page
4.3.6
4.3.7
4.3.8

4.4

To Calibrate Temperature and Pressure Sensors ............................................................................... 49


To Set Date and Time ...................................................................................................................... 49
To Display Data without Accessing Menu ........................................................................................ 49
Figure 49 Microcomputer Keypad .................................................................................................. 49
Figure 50 Microcomputer Instruction Label ..................................................................................... 50
4.3.9
To Revise Schedules ......................................................................................................................... 50
4.3.10 To Set Holidays ................................................................................................................................ 50
Control and Safety Functions ................................................................................................................... 50
4.4.1
Chilled Water pump Interlock and Flow Switch ............................................................................... 50
4.4.2
Customer Control Interlock ............................................................................................................. 50
4.4.3
Anti-Recycle Timer (Microcomputer) ............................................................................................... 50
4.4.4
Load Control (Microcomputer) ........................................................................................................ 51
4.4.5
Ramp Control (Microcomputer) ....................................................................................................... 51
4.4.6
Current Limiting (Microcomputer) ................................................................................................... 51
4.4.7
Hot Gas Bypass (Factory Installed Option) ....................................................................................... 51
4.4.8
Refrigerant Management ................................................................................................................ 51
4.4.9
High Oil Sump Temperature Alarm .................................................................................................. 51
4.4.10 Control Power Loss .......................................................................................................................... 51
4.4.11 Low Pressure Cutoff (Microcomputer) ............................................................................................. 51
4.4.12 Cooler Freeze Shut-off (Microcomputer) ......................................................................................... 52
4.4.13 High Pressure Cutoff (Microcomputer) ............................................................................................ 52
4.4.14 Low Oil Pressure Alarm (Microcomputer) ........................................................................................ 52
4.4.15 Sump Heater Control ....................................................................................................................... 52
4.4.16 Compressor Starter Failure .............................................................................................................. 52
4.4.17 Compressor Power Control (No Stop Alarm) ................................................................................... 52
4.4.18 Sensor Alarm Shutdown .................................................................................................................. 52
4.4.19 Slide Valve Error (Microcomputer) ................................................................................................... 52
4.4.20 Liquid Line Mod Motor Error (Microcomputer) ............................................................................... 53
4.4.21 Oil Sump Starter Error (Microcomputer) .......................................................................................... 53
4.4.22 Chilled Water Reset (Optional) ........................................................................................................ 53
4.4.23 Demand Limiting Input (Optional) ................................................................................................... 53
4.4.24 Pressure Load Limiting .................................................................................................................... 53
4.4.25 Unit Schedule of Operation (Optional) ............................................................................................ 53
4.4.26 Low Chiller Flow Alarm ................................................................................................................... 54
4.4.27 External Shutdown (No-Run Alarm) ................................................................................................. 54
4.4.28 Low Discharge Superheat (DSH) Alarm ............................................................................................ 54
4.4.29 Proactive Warning Contact .............................................................................................................. 54
4.4.30 Condenser Flow Alarm and Interlock ............................................................................................... 54
4.4.31 Chiller Pump Interlock ..................................................................................................................... 54
4.4.32 Ice Build Mode ................................................................................................................................ 54

5.0 Maintenance
5.1
5.2
5.3
5.4
5.5
5.6

5.7
5.8

General Maintenance ................................................................................................................................ 55


Periodic Inspection .................................................................................................................................... 55
Monthly Inspection ................................................................................................................................... 55
Water Side Cleaning of Vessels ................................................................................................................. 55
Electrical Malfunction ............................................................................................................................... 55
Charging .................................................................................................................................................... 55
5.6.1
Refrigerant Charge .......................................................................................................................... 55
5.6.2
Oil Charge ....................................................................................................................................... 55
Troubleshooting .................................................................................................................................. 56-57
Sample Log Sheet ...................................................................................................................................... 58

1.0 GENERAL INFORMATION

1.1 Introduction
This manual is designed to provide all necessary
information for installation, operation and
maintenance of the latest generation of 2+: E
Dunham-Bush Helical Rotary Screw compressor
package units.
To use this manual effectively, you must first determine
your unit model number from the unit nameplate.
Since this manual is comprehensive for a wide variety
of units, you should be careful to use only those
sections which apply to your model. Note that each
section is clearly marked as to the applicable models.
This equipment is a factory built and tested packaged
chiller designed for the purpose of cooling water or
other non-corrosive liquid. The liquid to be cooled is
to be circulated through the tubes of a refrigerant
evaporator (hereafter referred to as a cooler) where
the temperature is reduced to the desired level. The
heat absorbed by the refrigerant in the cooler is rejected
via the condenser where it raises the temperature of

another liquid stream (usually water) being circulated


through the tubes. This heat is usually rejected via a
cooling tower or closed circuit cooler.
To assure satisfactory operation and to avoid damage
to the unit, the installation should be made by a
qualified refrigeration mechanic. It is assumed that
the reader of his manual and those who install, operate
and maintain this equipment have a basic
understanding of the principles of air conditioning,
refrigeration and electrical controls. These instructions
are general in nature and are for standard catalog units.
Non-standard units may vary in some respects from
these instructions.
Your Dunham-Bush package has been manufactured
under a careful quality control system and has been
factory run tested as a final verification of reliability. If
it is installed, operated and maintained with care and
attention to these instructions, it will give many years
of satisfactory service.

1.2 Product Identification


2+:E 030 B

AR ZP

F6, E6

F1S

Open Drive Rotary Screw


Packaged Water-Cooled
Water Chiller
Nominal Capacity (Tons x 10)
Unit Vintage
Single Refrigerant Circuit
Unit Voltage
AR460/3/60
AU400/3/50
AS575/3/60
CT3300/3/50
AX2300/3/60
AY 4160/3/60
W - Water
Z - Refrigerant (R22), P - Propylene Glycol
E - Ethylene Glycol
Microcomputer Controller
Evaporator Designation
Condenser Designation
Compressor Motor Designation

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: 60 Hz


2+:E 030
2+:E 030 - 60 HZ

Model No.

Nominal Capacity: tons/(kWo)


Compressor Model
Motor RPM

Standard
Vessel Set
English
S. I. Units
276
942
2010
3550

Flooded Cooler - (Code)


Cooler Shell Diameter in./(cm)
Cooler Tube Length: in./(cm)
Design Working Pressure:
Water Side: psig(kPa)
Refrigerant Side: psig/(kPa)
Water Volume (2 Pass): gal./(Litres)
Optional Single Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water (kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Standard Two Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Optional Three Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

F6

Double Oversized
Vessel Set
English
S. I. Units
279
952
2010
3550

G6

H6

22
144

559
3658

24
144

610
3658

26
144

660
3658

150
300
60.8

1034
2069
230

150
300
71.6

1034
2069
271

150
300
88.2

1034
2069
334

481
1.16
2406
21.58

30.3
3.47
151.8
64.5

555
1.14
2777
20.87

35
3.41
175.2
62.4

671
1.16
3354
21.49

42.3
3.47
211.6
64.2

243
2.23
1193
39.56

15.3
6.67
75.3
118.2

278
2.22
1389
40.6

17.5
6.64
87.6
121.4

344
2.29
1633
37.94

21.7
6.84
103
113.4

164
3.56
733
52.81

10.3
10.64
46.2
157.8

192
3.49
861
52.2

12.1
10.43
54.3
156

227
3.7
997
53.36

14.3
11.06
62.9
159.5

Condenser Code
Condenser Shell Diameter: in./(cm)
Condenser Tube Length: in./(cm)
Design Working Pressure
Water Side: psig/(kPa)
Refrigerant Side: psig/(kPa)
Water Volume: Gal/(Litres)
Standard Two Pass Condenser:
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

Single Oversized
Vessel Set
English
S. I. Units
278
949
2010
3550

E6

E7

F6

20
144

508
3658

20
144

508
3658

22
144

559
3658

150
300
66.9

1034
2069
253

150
300
73.9

1034
2069
280

150
300
93.2

1034
2069
353

291
2.44
1435
37.96

18.4
7.29
90.5
113.5

349
2.8
1495
34.32

22
8.37
94.3
102.6

409
2.55
1983
39.26

25.8
7.62
125.1
117.3

13720
14780
14870
15930
572

6223
6704
6745
7226
260

14515
15725
15665
16875
624

6584
7133
7106
7655
283

15980
17500
17135
18650
780

7249
7938
7772
8460
354

General Data
Shipping Wt. w/ Low Volt Motor: lbs/(kg)
Operating Wt. w/ Low Volt Motor: lbs/(kg)
Shipping Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Charge R-22: lbs/(kg)

Note:
Low Voltage Motor: 460/3/60 and 575/3/60
Medium Voltage Motor: 2300/3/60 and 4160/3/60

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: 60 Hz


2+:E 040
2+:E 040 - 60 HZ

Model No.

Nominal Capacity: tons/(kWo)


Compressor Model
Motor RPM

Standard
Vessel Set
English
S. I. Units
400
1365
2015
3550

Flooded Cooler - (Code)


Cooler Shell Diameter in./(cm)
Cooler Tube Length: in./(cm)
Design Working Pressure:
Water Side: psig(kPa)
Refrigerant Side: psig/(kPa)
Water Volume (2 Pass): gal./(Litres)
Optional Single Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water (kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Standard Two Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Optional Three Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

H6

Double Oversized
Vessel Set
English
S. I. Units
408
1392
2015
3550

K6

L6

26
144

660
3658

30
144

762
3658

32
144

813
3658

150
300
88.2

1034
2069
334

150
300
109.2

1034
2069
413

150
300
133.4

1034
2069
505

671
1.16
3354
21.49

42.3
3.47
211.6
64.2

794
1.16
3970
20.39

50.1
3.47
250.5
63.9

994
1.12
4968
22.43

62.7
3.59
313.4
67.0

344
2.29
1633
37.94

21.7
6.84
103.0
113.4

407
2.3
1936
38.43

25.7
6.87
122.1
114.9

507
2.31
2435
39.51

32.0
6.90
153.6
118.1

227
3.7
997
53.36

14.3
11.06
62.9
159.5

284
3.75
1232
53.04

17.9
11.21
77.7
158.5

329
3.53
1535
57.08

20.8
10.55
96.8
170.6

22
144

559
3658

24
144

610
3658

26
144

660
3658

150
300
93.2

1034
2069
353

150
300
111.4

1034
2069
422

150
300
135.6

1034
2069
513

409
2.55
1983
39.26

25.8
7.62
125.1
117.3

500
2.64
2262
35.33

31.5
7.89
142.7
105.6

602
2.69
2710
36.0

38.0
8.04
171.0
107.6

17010
18530
17710
19235
780

7716
8405
8033
8725
354

19105
20945
19805
21650
1137

8666
9501
8984
9820
516

20755
23000
21455
23705
1336

9414
10433
9732
10753
606

Condenser Code
Condenser Shell Diameter: in./(cm)
Condenser Tube Length: in./(cm)
Design Working Pressure
Water Side: psig/(kPa)
Refrigerant Side: psig/(kPa)
Water Volume: Gal/(Litres)
Standard Two Pass Condenser:
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

Single Oversized
Vessel Set
English
S. I. Units
404
1378
2015
3550

F6

G6

H6

General Data
Shipping Wt. w/ Low Volt Motor: lbs/(kg)
Operating Wt. w/ Low Volt Motor: lbs/(kg)
Shipping Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Charge R-22: lbs/(kg)

Note:
Low Voltage Motor: 460/3/60 and 575/3/60
Medium Voltage Motor: 2300/3/60 and 4160/3/60

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: 60 Hz


2+:E 050
2+:E 050 - 60 HZ

Model No.

Nominal Capacity: tons/(kWo)


Compressor Model
Motor RPM

Standard
Vessel Set
English
S. I. Units
477
1628
2018
3550

Flooded Cooler - (Code)


Cooler Shell Diameter in./(cm)
Cooler Tube Length: in./(cm)
Design Working Pressure:
Water Side: psig(kPa)
Refrigerant Side: psig/(kPa)
Water Volume (2 Pass): gal./(Litres)
Optional Single Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water (kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Standard Two Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Optional Three Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

K6

Double Oversized
Vessel Set
English
S. I. Units
N/A
N/A
N/A
N/A

L6

N/A

30
144

762
3658

32
144

813
3658

N/A
N/A

N/A
N/A

150
300
109.2

1034
2069
413.4

150
300
133.4

1034
2069
505

N/A
N/A
N/A

N/A
N/A
N/A

794
1.16
3970
21.39

50.1
3.47
250.5
63.9

994
1.16
4968
22.43

62.7
3.47
313.4
67.0

N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A

407
2.30
1936
38.43

25.7
6.87
122.1
114.9

507
2.31
2435
39.51

32.0
6.90
153.6
118.1

N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A

284
3.75
1232
53.04

17.9
11.21
77.7
158.5

329
3.53
1535
5708

20.8
10.55
96.8
170.6

N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A

24
144

610
3658

26
144

660
3658

N/A
N/A

N/A
N/A

150
300
111.4

1034
2069
422

150
300
135.6

1034
2069
513

N/A
N/A
N/A

N/A
N/A
N/A

504
2.68
2243
34.86

31.8
8.01
141.5
104.2

602
2.69
2710
36.0

38.0
8.04
171.0
107.6

N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A

19675
21515
20355
22195
1137

8925
9759
9233
10068
516

21330
23560
22000
24245
1336

9675
10687
9979
10998
606

N/A
N/A
N/A
N/A
N/A

N/A
N/A
N/A
N/A
N/A

Condenser Code
Condenser Shell Diameter: in./(cm)
Condenser Tube Length: in./(cm)
Design Working Pressure
Water Side: psig/(kPa)
Refrigerant Side: psig/(kPa)
Water Volume: Gal/(Litres)
Standard Two Pass Condenser:
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

Single Oversized
Vessel Set
English
S. I. Units
483
1648
2018
3550

G6

H6

N/A

General Data
Shipping Wt. w/ Low Volt Motor: lbs/(kg)
Operating Wt. w/ Low Volt Motor: lbs/(kg)
Shipping Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Charge R-22: lbs/(kg)

Note:
Low Voltage Motor: 460/3/60 and 575/3/60
Medium Voltage Motor: 2300/3/60 and 4160/3/60

1.0 GENERAL INFORMATION (CONT.)

1.4 Physical Specifications: 50 Hz


2+:E 030
2+:E 030 - 50 HZ

Model No.

Nominal Capacity: tons/(kWo)


Compressor Model
Motor RPM

Standard
Vessel Set
English
S. I. Units
246
840
2010
2960

Flooded Cooler - (Code)


Cooler Shell Diameter in./(cm)
Cooler Tube Length: in./(cm)
Design Working Pressure:
Water Side: psig(kPa)
Refrigerant Side: psig/(kPa)
Water Volume (2 Pass): gal./(Litres)
Optional Single Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Standard Two Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Optional Three Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

F5

Double Oversized
Vessel Set
English
S. I. Units
251
857
2010
2960

F6

G6

22
144

559
3658

22
144

559
3658

24
144

610
3658

150
300
51.6

1034
2069
195

150
300
60.8

1034
2069
230

150
300
71.6

1034
2069
271

389
1.14
1946
20.88

34.5
3.41
122.8
62.4

481
1.16
2406
21.58

30.3
3.47
151.8
64.5

555
1.14
2777
20.87

35.0
3.41
175.2
62.4

201
2.33
939
37.29

12.7
6.96
59.2
111.5

243
2.23
1193
39.56

15.3
6.67
75.3
118.2

278
2.22
1389
40.6

17.5
6.64
87.6
121.4

135
3.5
606
52.41

8.5
10.46
38.2
156.7

164
3.56
733
52.81

10.3
10.64
46.2
157.8

192
3.49
861
52.2

12.1
10.43
54.3
156

18
144

457
3658

20
144

508
3658

20
144

508
3658

150
300
55.4

1034
2069
210

150
300
66.9

1034
2069
253

150
300
73.9

1034
2069
280

251
2.71
1435
37.96

15.8
8.10
90.5
113.5

291
2.44
1435
37.96

18.4
7.29
90.5
113.5

349
2.8
1495
34.32

22.0
8.37
94.3
102.6

12885
13770
14035
14926
520

5845
6246
6366
6770
236

13645
14705
14790
15855
572

6189
6670
6709
7192
260

14435
15650
15590
16795
624

6548
7099
7072
7618
283

Condenser Code
Condenser Shell Diameter: in./(cm)
Condenser Tube Length: in./(cm)
Design Working Pressure
Water Side: psig/(kPa)
Refrigerant Side: psig/(kPa)
Water Volume: Gal/(Litres)
Standard Two Pass Condenser:
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

Single Oversized
Vessel Set
English
S. I. Units
249
850
2010
2960

D6

E6

E7

General Data
Shipping Wt. w/ Low Volt Motor: lbs/(kg)
Operating Wt. w/ Low Volt Motor: lbs/(kg)
Shipping Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Charge R-22: lbs/(kg)
Note:
Low Voltage Motor: 400/3/50
Medium Voltage Motor: 3300/3/50

1.0 GENERAL INFORMATION (CONT.)

1.4 Physical Specifications: 50 Hz


2+:E 040
2+:E 040 - 50 HZ

Model No.

Nominal Capacity: tons/(kWo)


Compressor Model
Motor RPM

Standard
Vessel Set
English
S. I. Units
357
1218
2015
2960

Flooded Cooler - (Code)


Cooler Shell Diameter in./(cm)
Cooler Tube Length: in./(cm)
Design Working Pressure:
Water Side: psig(kPa)
Refrigerant Side: psig/(kPa)
Water Volume (2 Pass): gal./(Litres)
Optional Single Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Standard Two Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Optional Three Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

G6

Double Oversized
Vessel Set
English
S. I. Units
364
1242
2015
2960

H6

K6

24
144

610
3658

26
144

660
3658

30
144

762
3658

150
300
71.6

1034
2069
271

150
300
88.2

1034
2069
334

150
300
109.2

1034
2069
413

555
1.14
2777
20.87

35.0
3.41
175.2
62.4

671
1.16
3354
21.49

42.3
3.47
211.6
64.2

794
1.16
3970
21.39

50.1
3.47
250.5
63.9

278
2.22
1389
40.6

17.5
6.64
87.6
121.4)

344
2.29
1633
37.94

21.7
6.84
103.0
113.4

407
2.3
1936
38.43

25.7
6.87
122.1
114.9

192
3.49
861
52.2

12.1
10.43
54.3
156.0

227
3.7
997
53.36

14.3
11.06
62.9
159.5

284
3.75
1232
53.04

17.9
11.21
77.7
158.5

20
144

508
3658

22
144

559
3658

24
144

610
3658

150
300
73.9

1034
2069
280

150
300
93.2

1034
2069
353

150
300
111.4

1034
2069
422

349
2.8
1495
34.32

22.0
8.37
94.3
102.6

409
2.55
1983
39.26

25.8
7.62
125.1
117.3

500
2.64
2262
35.33

31.5
7.89
142.7
105.6

15170
16380
16115
17325
624

6881
7430
7310
7859
283

16630
18155
17585
19105
780

7543
8235
7977
8666
354

18730
20565
19680
21520
1137

8496
9328
8927
9761
516

Condenser Code
Condenser Shell Diameter: in./(cm)
Condenser Tube Length: in./(cm)
Design Working Pressure
Water Side: psig/(kPa)
Refrigerant Side: psig/(kPa)
Water Volume: Gal/(Litres)
Standard Two Pass Condenser:
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

Single Oversized
Vessel Set
English
S. I. Units
361
1232
2015
2960

E7

F6

G6

General Data
Shipping Wt. w/ Low Volt Motor: lbs/(kg)
Operating Wt. w/ Low Volt Motor: lbs/(kg)
Shipping Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Charge R-22: lbs/(kg)
Note:
Low Voltage Motor: 400/3/50
Medium Voltage Motor: 3300/3/50

10

1.0 GENERAL INFORMATION (CONT.)

1.4 Physical Specifications: 50 Hz


2+:E 050
2+:E 050 - 50 HZ

Model No.

Nominal Capacity: tons/(kWo)


Compressor Model
Motor RPM

Standard
Vessel Set
English
S. I. Units
427
1457
2018
2960

Flooded Cooler - (Code)


Cooler Shell Diameter in./(cm)
Cooler Tube Length: in./(cm)
Design Working Pressure:
Water Side: psig(kPa)
Refrigerant Side: psig/(kPa)
Water Volume (2 Pass): gal./(Litres)
Optional Single Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Standard Two Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Optional Three Pass Cooler
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

H6

Double Oversized
Vessel Set
English
S. I. Units
437
1491
2018
2960

K6

L6

26
144

660
3658

30
144

762
3658

32
144

813
3658

150
300
88.2

1034
2069
334

150
300
109.2

1034
2069
413

150
300
133.4

1034
2069
505

671
1.16
3354
21.49

42.3
3.47
211.6
64.2

794
1.16
3970
21.39

50.1
3.47
250.5
63.9

994
1.2
4968
22.43

62.7
3.59
313.4
67.0

344
2.29
1633
37.94

21.7
6.84
103.0
113.4

407
2.30
1936
38.43

25.7
6.87
122.1
114.9

507
2.31
2435
39.51

32.0
6.90
153.6
118.1

227
3.7
997
53.36

14.3
11.06
62.9
159.5

284
3.75
1232
53.04

17.9
11.21
77.7
158.5

329
3.53
1535
57.08

20.8
10.55
96.8
170.6

22
144

559
3658

24
144

610
3658

26
144

660
3658

150
300
93.2

1034
2069
353

150
300
111.4

1034
2069
422

150
300
135.6

1034
2069
513

409
2.55
1983
39.26

25.8
7.62
125.1
117.3

500
2.64
2262
35.23

31.5
7.89
142.7
105.6

602
2.69
2710
36.0

38.0
8.04
171.0
107.6

17400
18915
18075
19595
780

7893
8580
8199
8888
354

19500
21340
20175
22015
1137

8845
9680
9151
9986
516

21145
23380
21825
24065
1336

9591
10605
9900
10916
606

Condenser Code
Condenser Shell Diameter: in./(cm)
Condenser Tube Length: in./(cm)
Design Working Pressure
Water Side: psig/(kPa)
Refrigerant Side: psig/(kPa)
Water Volume: Gal/(Litres)
Standard Two Pass Condenser:
Minimum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)
Maximum Flow Rate: GPM/(L/s)
Pressure Drop: Ft. Water/(kPa)

Single Oversized
Vessel Set
English
S. I. Units
432
1474
2018
2960

F6

G6

H6

General Data
Shipping Wt. w/ Low Volt Motor: lbs/(kg)
Operating Wt. w/ Low Volt Motor: lbs/(kg)
Shipping Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Wt. w/ Medium Volt Motor: lbs/(kg)
Operating Charge R-22: lbs/(kg)
Note:
Low Voltage Motor: 400/3/50
Medium Voltage Motor: 3300/3/50

11

1.0 GENERAL INFORMATION (CONT.)

1.5 Dimensional Data


82" [2083]
ELECTRICAL SERVICE
ENTRANCE

60" [1524]

144[3658]
OUTSIDE OF TUBESHEETS
C
2 PASS WITH SAME HAND WATER CONNECTIONS
C1
2 PASS WITH OPPOSITE HAND WATER CONNECTIONS
C2
2 PASS CONDENSER 1 PASS COOLER
C3
2 PASS CONDENSER 3 PASS COOLER

MINIMUM REQUIRED FOR TUBE


CLEANING or REPLACEMENT EITHER END
RECOMMEND 175[4445] SEE NOTE 1 & 2

CONTROL BOX DOOR


MUST HAVE A MINIMUM OF
32" [813] FOR OPENING

M
SEE NOTE 5

14 [356]

LEAVING WATER

COOLER

ENTERING
WATER

CONDENSER

ENTERING WATER
K

LEAVING WATER
L
A

RIGHT SIDE WHEN VIEWING CONTROL BOX

12

152 [3861]

6 [152]
TYP

NOTES
1 - IF A DOORWAY OR OTHER PROPERLY LOCATED
OPENING IS USED FOR TUBE REMOVAL THE
SUGGESTED MINIMUM CLEARANCE IS 36"
2 - SUGGESTED CLEARANCES AROUND THE MACHINE
ARE MINIMUM REQUIREMENTS. IT IS STRONGLY
RECOMMENDED THAT AT LEAST ONE OF THESE
CLEARANCE REQUIREMENTS EXCEED THE MINIMUM
TO ALLOW FOR COMPRESSOR OR MOTOR SERVICING.
3 - WHEN LOOKING AT 2 PASS COOLER HEAD
CONNECTIONS, WATER OUTLET IS LEFT CONNECTION,
WATER INLET IS RIGHT CONNECTION AS SUPPLIED BY
FACTORY. CUSTOMER MAY REVERSE THIS
ARRANGEMENT BUT LEAVING WATER TEMPERATURE
SENSOR MUST BE RELOCATED TO WATER OUTLET.
4 - SEE PAGE 34 FOR VESSEL CONNECTION SIZES
5 - ' A ' DIMENSION(OVERALL WIDTH) IS USING THE
STANDARD LOW VOLTAGE MOTOR, WHEN MEDIUM
VOLTAGE MOTOR IS USED ADD ' M ' DIMENSION TO
' A ' FOR OVERALL WIDTH.

1.0 GENERAL INFORMATION (CONT.)

1.5 Dimensional Data


Model

2+:E03060 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

Cooler
F6-22"
G6-24"
H6-26"

Cond.

Cl

C2

C3

E6,E7-20" 65-1/2[1664] 169-5/8[4308] 174-5/8[4435] 174-1/8[4423] 174-3/8[4429]


E6,E7-20"
70[1778]
170-1/8[4321] 175-1/8[4448] 174-5/8[4436] 176-1/2[4483]
F6-22"
71[1803]
171-3/4[4362] 176-3/4[4489]
168[4267]
173-7/8[4417]

2+:E04060 Hz
Standard Vessel Set
Single Oversized Vessel Set
Double Oversized Vessel Set

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

71[1803]
171-3/4[4362] 176-3/4[4489]
168[4267]
173-7/8[4417]
73-7/8[1877] 171-3/4[4362] 179-3/8[4556] 175-5/8[4461] 179-1/8[4550]
75[1905]
171-1/8[4347] 179-7/8[4569] 176-1/8[4474] 179-5/8[4563]

K6-30"
L6-32"

G6-24"
H6-26"

73-7/8[1877] 171-3/4[4362] 179-3/8[4556] 175-5/8[4461] 179-1/8[4550]


75[1905]
171-1/8[4347] 179-7/84569] 176-1/8[44741 179-5/8[4563]

2+:E05060 Hz
Standard Vessel Set
Single Oversized Vessel Set

2+:E03050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E04050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E05050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

Model

2+:E03060 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

F5,F6-22"
F5,F6-22"
G6-24"

D6-18" 64-3/4[1645] 164-1/2[4169 168-1/4[4274] 168-1/8[4271] 168-5/8[4283]


E6,E7-20" 65-1/2[1664] 169-5/8[4308] 174-5/8[4435] 174-1/8[4423] 174-3/8[4429]
E6,E7-20"
70[1778]
170-1/8[4321] 175-1/8[4448] 174-5/8[4436] 176-1/2[4483]

G6-24"
H6-26"
K6-30"

E7-20"
F6-22"
G6-24"

70[1778]
170-1/8[4321] 175-1/8[4448] 174-5/8[4436] 176-1/2[4483]
71[1803]
171-3/4[4362] 176-3/4[4489]
168[4267]
173-7/8[4417]
73-7/8[1877] 171-3/4[4362] 179-3/8[4556] 175-5/8[446] 179-1/8[4550]

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

71[1803]
171-3/4[4362] 176-3/4[4489]
168[4267]
173-7/8[4417]
73-7/8[1877] 171-3/4[4362] 179-3/8[4556] 175-5/8[4461] 179-1/8[4550]
75[1905]
171-1/8[4347] 179-7/8[4569] 176-1/8[4474] 179-5/8[4563]

Cooler

Cond.

F6-22"
G6-24"
H6-26"

E6,E7-20"
E6,E7-20"
F6-22"

16-5/8[422]
16-5/8[422]
17-5/8[448]

18-1/4[464]
19-1/4[489]
20-1/4[514]

11-3/4[298]
11-3/4[298]
12-3/4[324]

12-3/4[324]
14[356]
15[381]

14-7/8[378]
13-1/2[343]
12-3/8[314]

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

17-5/8[448]
18-5/8[473]
19-5/8[499]

20-1/4[514]
22-1/4[565]
23-1/4[591]

12-3/4[324]
14[356]
15[381]

15[381]
16-5/8[422]
18[457]

12-3/8[314]
10-5/8[270]
13-3/8[340]

K6-30"
L6-32"

G6-24"
H6-26"

18-5/81473]
19-5/8[499]

22-1/4[565]
23-1/4[591]

14[356]
15[381]

16-5/8[422]
18[457]

10-5/8[270]
13-3/8[340]

F5,F6-22"
F5,F6-22"
G6-24"

D6-18"
E6,E7-20"
E6,E7-20"

15-5/8[397]
16-5/8[422]
16-5/8[422]

18-1/4[464]
18-1/4[464]
19-1/4[489]

10-1/2[267]
11-3/4[298]
11-3/4[298]

12-3/4[324]
12-3/4[324]
14[356]

14-3/4[375]
14-7/8[378]
13-1/2[343]

G6-24"
H6-26"
K6-30"

E7-20"
F6-22"
G6-24"

16-5/8[422]
17-5/8[448]
18-5/8[473]

19-1/4[489]
20-1/4[514]
22-1/4[565]

11-3/4[298]
12-3/4[324]
14[356]

14[356]
15[381]
16-5/8[422]

13-1/2[343]
12-3/8[314]
10-5/8[270]

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

17-5/8[448]
18-5/8[473]
19-5/8[499]

20-1/4[514]
22-1/4[565]
23-1/4[591]

12-3/4[324]
14[356]
15[381]

15[381]
16-5/8[422]
18[457]

12-3/8[314]
10-5/8[270]
13-3/8[340]

2+:E04060 Hz
Standard Vessel Set
Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E05060 Hz

Standard Vessel Set


Single Oversized Vessel Set

2+:E03050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E04050 Hz
Standard Vessel Set
Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E05050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

13

1.0 GENERAL INFORMATION (CONT.)

1.5 Dimensional Data


COOLER RELIEF VALVE SIZE
VESSEL
F5,F6-22",G6-24",H6-26"
K6-30",L6-32"

3/4" MPT
1" MPT

COOLER RELIEF VALVE


LOCATED ON VERTICAL CENTERLINE

6 [152]
TYP

23[584]
2 [51]
TYP

COOLER

SEPARATOR

CONDENSER
SEPARATOR RELIEF VALVES
(2)1/2" MPT

148 [3759]
MOUNTING HOLES CENTER TO CENTER

12 [305]

6 [152]

0.813 [21]
12 [305]

24 [610]
SUGGESTED CLEARANCE
SEE NOTE 6

12-1/4[311]
SEE DETAIL 10-A
COND RELIEF VALVES

CONTROL BOX DOOR SWING


IS A MAXIMUM OF 32" [813]

4 [102]
TYP
MOUNTING PAD DETAIL

60

40

20

CONDENSER RELIEF VALVES


(2)3/4" MPT

45.00

DETAIL 10-A
CONDENSER RELIEF VALVE DETAIL

36 [914]
SEE NOTE 6

36 [914] - 48 [1219]
SEE NOTE 8

LEFT SIDE VIEW WHEN VIEWING CONTROL BOX


RIGHT HAND VESSEL CONNECTIONS SHOWN

14

1.0 GENERAL INFORMATION (CONT.)

1.5 Dimensional Data


WATER CONNECTION SELECTION
COOLER

CONDENSER
2 PASS, LH
2 PASS, RH

1 PASS, LH
1 PASS, RH
2 PASS, LH
2 PASS, RH
3 PASS, LH
3 PASS, RH

HAND = LEAVING WATER CONNECTION LOCATION


WHEN VIEWED FACING CONTROL BOX

NOTES
1 - WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT
2 - ALL DIMENSIONS ARE IN INCHES AND [MILLIMETERS]
3 - VENT AND DRAIN CONNECTIONS PROVIDED ON COOLER AND CONDENSER HEADS
4 - SUFFICIENT ROOM MUST BE ALLOWED FOR COOLER & CONDENSER CONNECTIONS
5 - IF UNIT IS EQUIPPED WITH SKID OPTION ADD AN ADDITIONAL 1/2"[13] TO ALL VERTICAL DIMENSIONS THAT
BEGIN AT THE FLOOR
6 - SUGGESTED CLEARANCES AROUND THE MACHINE ARE MINIMUM REQUIREMENTS. IT IS STRONGLY
RECOMMENDED THAT AT LEAST ONE OF THESE CLEARANCES REQUIREMENTS EXCEED THE MINIMUM TO ALLOW
FOR COMPRESSOR OR MOTOR SERVICING.
7 - WATER CONNECTIONS OF 1 PASS VESSELS ARE ON CENTER LINE OF VESSEL. FOR COOLER USE
DIMENSIONS `G' & `L'.
8 - CONSULT NEC and LOCAL CODES FOR REQUIRED ELECTRICAL PANEL CLEARANCES.

Model

Cooler

Cond.

89-1/8[2264]
89-1/8[2264]
91-1/8[2315]

53-1/2[1359]
58[1473]
59[1499]

2+:E03060 Hz
Standard Vessel Set
Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E04060 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E05060 Hz

Standard Vessel Set


Single Oversized Vessel Set

2+:E03050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

F6-22"
G6-24"
H6-26"

E6,E7-20" 93-3/4[2381]
E6,E7-20" 93-1/2[2375]
F6-22"
93-3/4[2381]

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

94-3/4[2407]
95[2413]
97-1/2[2477]

91-1/8[2315]
93-1/8[2366]
95-1/8[2416]

59[1499]
61-7/8[1572]
63[1600]

K6-30"
L6-32"

G6-24"
H6-26"

95-3/4[2432]
98-1/2[2502]

93-1/8[2366]
95-1/8[2416]

61-7/8[1572]
63[1600]

D6-18" 92-1/8[2340]
E6,E7-20" 93-1/4[2369]
E6,E7-20"
93[2362]

87-1/8[2213]
89-1/8[2264]
89-1/8[2264]

52-3/4[1340]
53-1/2[1359]
58[1473]

F5,F6-22"
F5,F6-22"
G6-24"

2+:E04050 Hz
Standard Vessel Set
Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E05050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

G6-24"
H6-26"
K6-30"

E7-20"
F6-22"
G6-24"

94[2388]
94-1/4[2394]
94-1/2[2400]

89-1/8[2264]
91-1/8[2315]
93-1/8[2366]

58[1473]
59[1499]
61-7/8[1572]

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

94-3/4[2407]
95[2413]
97-1/2[2477]

91-1/8[2315]
93-1/8[2366]
95-1/8[2416]

59[1499]
61-7/8[1572]
63[1 600]

15

1.0 GENERAL INFORMATION (CONT.)


1.5 Dimensional Data
S

N=COOLER
P=COND

D1

RETURN HEAD

1 PASS HEAD(COOLER ONLY)


3 PASS HEAD(COOLER ONLY)

H
TYP
2 PASS COOLER HEAD

NOTE WHEN VIEWING 2 PASS COOLER HEAD


IF CONN'S ARE DIFFERENT LENGTHS THE
LONGEST CONN. IS ALWAYS ON THE RIGHT

NOTE WHEN VIEWING 3 PASS COOLER HEAD


CONN IS ALWAYS TO THE LEFT OF CENTER

E
WATER CONNECTION SIZES(SHOWN IN INCHES ONLY)
COOLER
CONDENSER
VESSEL
VESSEL
1 PASS
1 PASS 2 PASS 3 PASS
2 PASS 3 PASS
8"
6"
D6-18" NOT AVAIL
6" NOT AVAIL
F5-22" 10"
8"
8"
E6-20" NOT AVAIL
8" NOT AVAIL
F6-22" 10"
8"
8"
E7-20" NOT AVAIL
8" NOT AVAIL
G6-24" 12"
10"
8"
F6-22" NOT AVAIL
8" NOT AVAIL
H6-26" 12"
10"
8"
G6-24" NOT AVAIL 10" NOT AVAIL
K6-30" 14"
L6-32" 14"
10"
8"
H6-26" NOT AVAIL 10" NOT AVAIL

Model

Cooler

2+:E03060 Hz

E1
2 PASS COND HEAD
NOTE WHEN VIEWING COND HEAD, IF CONN'S
ARE DIFFERENT LENGTHS THE LONGEST
CONN. IS ALWAYS ON THE BOTTOM

D1

E1

F6-22"
G6-24"
H6-26"

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

20-1/8[5111 15-1/8[384] 12-1/2[318] 12-1/2[318]


15-5/8[397] 15-5/8[397] 14-5/8[372] 19-5/8[499]
15-5/8[397] 15-5/8[397] 15-1/8[384] 20-1/8[511]

7-3/8[187]
8-1/8[207]
8-7/8[226]

6-7/8[175]
6-7/8[175]
7-3/8[187]

Standard Vessel Set


Single Oversized Vessel Set

K6-30"
L6-32"

G6-24"
H6-26"

15-5/8[397] 15-5/8[397] 14-5/8[372] 19-5/8[499]


15-5/8[397] 15-5/8[397] 15-1/8[384] 20-1/8[511]

8-1/8[207]
8-7/8[226]

6-7/8[175]
7-3/8[187]

F5,F6-22" D6-18" 12-1/2[318] 12-1/2[318] 11-5/8[295] 11-5/8[295]


F5,F6-22" E6,E7-20" 12-1/2[318] 12-1/2[318]
12[305]
18[457]
G6-24" E6,E7-20"
13[330]
13[330]
12[305]
18[457]

6-7/8[175]
6-7/8[175]
6-7/8[175]

5-5/8[143]
6-1/8[156]
6-1/8[156]

2+:E05060 Hz
2+:E03050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E04050 Hz

E6,E7-20" 12-1/2[318] 12-1/2[318]


12[305]
18[457]
E6,E7-20"
13[330]
13[330]
12[305]
18[457]
F6-22"
20-1/8[511] 15-1/8[384] 12-1/2[318] 12-1/2[318]

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E04060 Hz

6-7/8[1751] 6-1/8[156]
6-7/8[175] 6-1/8[156]
7-3/8[187] 6-7/8[175]

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

G6-24"
H6-26"
K6-30"

E7-20"
F6-22"
G6-24"

13[330]
13[330]
12[305]
18[457]
120-1/8[511] 15-1/8[384] 12-1/2[318] 12-1/2[318]
15-5/8[397] 15-5/8[397] 14-5/8[372] 19-5/8[499]

6-7/8[175]
7-3/8[187]
8-1/81207]

6-1/8[156]
6-7/8[175]
6-7/8[175]

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

20-1/8[511] 15-1/8[384] 12-1/2[318] 12-1/2[318]


15-5/8[397] 15-5/8[397] 14-5/8[372] 19-5/8[499]
15-5/8[3971] 15-5/8[397]] 15-1/8[384] 20-1/8[511]

7-3/8[187]
8-1/8[207]
8-7/8[226]

6-7/8[175]
6-7/8[175]
7-3/8[187]

2+:E05050 Hz

Model

Cooler

Cond.

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

F6-22"
G6-24"
H6-26"

E6,E7-20"
E6,E7-20"
F6-22"

7-1/2[191]
8[203]
6-3/8[162]

7[178]
7[178]
7-1/2[191]

12[305]
12-1/4[311]
12-1/2[318] 14-3/8[365]
11-3/8[289] 14-7/8[378]

6-3/4[171]
7-5/8[194]
8-1/8[207]

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

6-3/8[162]
6-7/8[175]
6-7/8[175]

7-1/2[191] 11-3/8[289] 14-7/8[378]


8[203]
11-7/8[302] 15-3/8[391]
6-3/8[162] 111-7/8[302] 15-3/8[391]

8-1/8[207]
9-1/2[241]
10-1/8[257]

Standard Vessel Set


Single Oversized Vessel Set

K6-30"
L6-32"

G6-24"
H6-26"

6-7/8[175]
6-7/8[175]

8[203]
6-3/8[162]

11-7/8[302] 15-3/8[391]
11-7/8[302] 15-3/8[391]

9-1/2[241]
10-1/8[257]

7-1/2[191]
7-1/2[191]
8[203]

6-1/2[165]
7[178]
7[178]

12[305]
12-1/4[311]
12[305]
12-1/4[311]
12-1/2[318] 14-3/8[365]

6-3/4[171]
6-3/4[171]
7-5/8[194]
7-5/8[194]
8-1/8[207]
9-1/2[241]

2+:E03060 Hz

2+:E04060 Hz

2+:E05060 Hz
2+:E03050 Hz

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

2+:E04050 Hz

F5,F6-22" D6-18"
F5,F6-22" E6,E7-20"
G6-24" E6,E7-20"

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

G6-24"
H6-26"
K6-30"

E7-20"
F6-22"
G6-24"

8[203]
6-3/8[162]
6-7/8[175]

7[178]
112-1/2[318] 14-3/8[365]
7-1/2[191] 11-3/8[289] 14-7/8[378]
8[203]
11-7/8[302] 15-3/8[391]

Standard Vessel Set


Single Oversized Vessel Set
Double Oversized Vessel Set

H6-26"
K6-30"
L6-32"

F6-22"
G6-24"
H6-26"

6-3/8[162]
6-7/8[175]
6-7/8[175]

7-1/2[191]
8[203]
6-3/8[162]

2+:E05050 Hz

16

Cond.

J
TYP

11-3/8[289] 14-7/8[378] 8-1/8[207]


11-7/8[302] 15-3/8[391] 9-1/2[241]
11-7/8[302] 115-3/8[391] 10-1/8[257]

1.0 GENERAL INFORMATION (CONT.)


1.6

Application & Location


Requirements

1.6.1 Chilled Water Flow


The Dunham-Bush 2+:E Packaged Water Chiller is
designed for a constant chilled water flow rate even when
the cooling load is varying. The machine will generally
perform satisfactorily with steady flow rates deviating from
design by as much as +10% to -50%. However, varying
water flow rates can cause control instability which will
result in undesirable system effects, particularly poor
control of leaving chilled water temperature. If two-way
valves are used to control flow through cooling coils, some
means such as an automatic modulating valve should be
provided in the system to maintain steady flow through
the cooler.
If the chilled water system is arranged for the dual purpose
of cooling and heating, the cooler must incorporate valves
to prevent the flow of hot water through it. This can be
done with either manual or automatic shutoff valves, but
the method of control must be such that water
temperature entering the cooler never exceeds 90F (32C).

1.6.2 Ice Storage


With a positive displacement rotary screw compressor, the
Dunham-Bush water chiller can easily cool low temperature
glycol down to 22F (-6C) with entering condenser water
of 85F (29C). The same chiller can also produce warmer
(40F (4C) to 45F (7C) leaving glycol for those building
systems designed for only peak shaving. This can be
accomplished by an external signal to the unit
microcomputer. No matter what your ice storage needs,
the Dunham-Bush Rotary Screw Water-Cooled Chiller can
handle the application.
When used with Dunham-Bush Ice-Cels, the microcomputer can be specially programmed to provide dual
mode leaving chilled liquid set points for both air
conditioning and ice freezing duty, plus start and stop of
chilled liquid and condenser pumps.
In addition, the following thermal storage controls can be
provided.
a.
b.
c.
d.
e.
f.

Freeze only
Freeze plus cooling
Cooling with ice only
Cooling with chiller plus ice
Cooling with chiller only
Off

The microcomputer can provide daily scheduling of above


modes in as many different daily schedules as desired.
These schedules can be assigned to days of the week and
holidays.

1.6.3 Multiple Unit Control


One of the most perplexing problems to system designers
is control of multiple chillers on the same water loop. The
first decision is whether to put the chillers in parallel or
series on the chilled water side. If lower pumping cost is
paramount, then putting chillers in series is often
preferable. If primary/secondary pumping is utilized with
normal 10F (6C) range, then putting chillers in parallel is
normally used. In either case, the Dunham-Bush

microcomputer (with special programming) can control


up to three chillers. This eliminates the need for external
control interface which often becomes difficult. Contact
the factory if more than three chillers need to be
networked.

1.6.4 Water Cooled Condensers


The water-cooled condenser can accommodate varying
flow rates such as occurs with the use of two-way water
regulating valves or variable speed pumps. The condenser
must be protected from rapid changes in temperature. A
rapid change in temperature or flow rate will cause
unstable operation resulting in poor control of the leaving
chilled water temperature and possible nuisance trips.
If the cooling tower is used to reject the heat from the
condensing water loop, it must be controlled to provide
an entering condensing water temperature, which does
not go below 60F. The rate of temperature change must
not exceed 20F 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 cooler and
condenser. This varies the refrigerant flow and, therefore,
the capacity. If this occurs faster then the machine can
accommodate it, the head pressure or suction pressure
will soon exceed their safety setpoints and the unit will
shut down.
One or more of the following methods may be used to
control head pressure:
1.6.4.1

Tower fan starting in response to a thermostat


in the tower sump. The fan thermostat should
have a differential of at least 20 to avoid short
cycling.

1.6.4.2

A modulating three-way valve which bypasses


the cooling tower to blend warm leaving
condenser water with the cold tower water.

1.6.4.3

Variable speed pumps controlled by an analog


output signal (0 to 5 volt) from the chiller
microprocessor based on the condenser head
pressure.

It is further recommend that the condenser water pump


be cycled by the chiller. This is to prevent potentially very
cold water from going through the condenser while the
chiller is shutdown. At the same time it is probable that
relatively warmer chilled water is in the cooler (an
inversion). Refrigerant tends to migrate if there is a
difference in pressure within the components of the chiller.
It will seek the lowest pressure area of the chiller, which in
this case would be the condenser.
Starting a chiller where the refrigerant has migrated to
the condenser is not desirable. The presence of highly
subcooled liquid refrigerant in the condenser could cause
possible low suction pressure and liquid slugging of the
compressor.
17

1.0 GENERAL INFORMATION (CONT.)


If the condenser water pump is off until the machine starts,
the water in the condenser is at room ambient which is usually
much closer to the cooler water temperature.

water flow switch must be supplied and mounted in the


water piping to protect the unit from low or no flow, which
can cause cooler freezing.

1.6.5 Condensing Water Treatment

1.6.11 Electrical Connection Options

Condensing water tends to leave silt, algae and mineral


deposits in the condenser tubes. This fouling gradually
decreases unit efficiency. For this reason, a program of
water treatment should be employed. Also, at regular
intervals, depending on water quality, the unit should be
shut down, condenser heads removed and tubes cleaned.

Refer to the Electrical Data Tables for specific electrical


data requirements. All wiring must be done in accordance
with the National Electric Code (NEC) and all local and
state codes. Typical power, control and interconnection
wiring diagrams are found on pages 48 through 55. A
complete set of wiring diagrams for all units is available
from our Dunham-Bush Sales Representative.

1.6.6 Foundation
A flat, level concrete foundation or floor capable of
supporting the weight of the unit must be provided. The
unit must be levelled to within 1/16 inch per foot (1.6mm
per 30.5cm) for proper operation.

1.6.7

Vibration Isolation

Where structure-borne vibration may be of concern, it is


recommended that the unit be mounted on vibration
isolators. Spring isolators are available for this unit as
optional equipment. If spring isolators are installed, it is
also necessary to provide isolation in condenser water and
chilled water pipes by means of flexible connectors and in
main power supply conduit through use of flexible conduit.
Isolation of piping and electrical conduit is desirable in
any event to avoid noise transmission.

1.6.8

Location and Installation


Suggestions

2+:E  Packaged Chillers are designed for indoor

application. Proper locations and installation procedures


for this equipment are very important for successful trouble
free operation. It is desirable to install these units with
sufficient service space on all sides of the Unit. Tube
cleaning and unit servicing require considerable space at
the ends of the units as shown in the dimensional outline
section of this manual. Compressor and motor servicing
require space at the rear of the unit. NEC and Local Codes
require a minimum of 36 to 48 inches in front of the unit
depending on the application location.

1.6.9

Equipment Location and Unit


Security

The 2+:E is a quiet operating chiller but sound sensitivity


should be considered when locating this equipment.
Equipment and equipment rooms need to be located in
areas of the building that will not disturb surrounding
occupied spaces. Equipment rooms can be acoustically
designed for sound sensitive installations to minimize
sound transmission into occupied spaces. It is suggested
that an acoustical Engineer be consulted on critical sound
and vibration applications before, rather than after, the
equipment is installed. Unit security and personal safety
should also be considered when locating this equipment.
All state and local sound and safety codes should be
considered when laying out or installing mechanical
equipment.

1.6.10 Cooler - Freeze Protection


The leaving water sensor mounted on the Cooler will shut
down the unit if a cooler freeze condition should occur. A
18

The unit will be shipped with wiring diagrams located in


the electrical panel.

1.6.12 Low Voltage Units


460/3/60, 575/3/60 & 400/3/50 voltage applications are
supplied with unit-mounted, Solid State Reduced Voltage
or Wye-Delta starter panel. An optional remote-mountable
Wye-Delta starter panel can also be supplied. All three
low voltage starter panels are for single point power
source. Refer to the Electrical Data Tables for detailed
information.

1.6.13 Medium Voltage Units


2300/3/60, 4160/3/60 & 3300/3/50 applications are
supplied with remote-mounted across-the-line starter
panel.

1.6.14 Power Sources


The term Power Source refers to the unit main power
supply.
The Control Power includes the oil sump heater power.
For unit mounted starters, control power is supplied by a
unit mounted control transformer. Dunham-Bush supplied
remote mounted starters also include a control circuit
transformer to provide 115 VAC.
Medium voltage units require a separate 460/3/60 or 400/
3/50 power source for the oil pump and control power
transformer.

1.6.15 Unit and Field Mounted


Disconnects
Disconnecting means are described in Article 440 of the
National Electric Code (NEC) which requires disconnecting
means capable of disconnecting air conditioning and
refrigeration equipment including motor-compressors, and
controllers from the circuit feeder. If the fused disconnect
option is not supplied, then the disconnects by others
should be selected and located within the NEC guidelines.
Location requirements per NEC, indicate that the
disconnect be located in a readily accessible position within
sight (50 feet) of the unit. Maximum recommended fuse
or CB breaker sizes are found in the Electrical Data Tables
in this catalog. Maximum wire sizes that the unit can
accept, are listed in the Electrical Data Table in this catalog.

1.6.16 Control Circuits


115 volt control circuit terminals are clearly marked on
the electrical diagram found in the control panel for control
power.

1.0 GENERAL INFORMATION (CONT.)


1.7 Starter & Control Panels
The 2+:E is available with several types of compressor
motor starting methods, depending on voltage, for Unit
Mounted and Remote Mounted applications. All models
are supplied in NEMA 1 enclosures. The unit controller
and all other options are in a separate section of the
electrical enclosure with the exception of the remote
mounted starter.
Unit mounted Solid State reduced voltage and WYEDelta Starters are available for 460/3/60, 575/3/60 and
400/3/50 voltage applications and are supplied fully
installed and wired with all starter options ordered. All
unit mounted starters include control transformer with
primary and secondary fuses, oil pump starter, oil pump
overloads, undervoltage relay, and current transformer
for compressor motor load control.

Solid State Starters are an excellent method of soft motor


starting, through solid state ramp control of voltage,
current, speed and torque. The effect/benefit of the soft
start is a reduction of both electrical and mechanical system
stress. This special solid state ramp control is shown in the
following diagrams.

Programmable Ramp Profiles


Motor
Current

600%

Max. Adjusted
Current

300%
Initial Current

100%
0

Remote mounted WYE-Delta Starters are supplied for


460/3/60, 575/3/60 and 400/3/50. Across-The-Line Starters
are supplied for medium voltage 2300/4160/3/60 and
3300/3/50 applications.

Time
(Sec)

0
15
Ramp Time (sec)

Accel

Full
Speed

Programmable Speed / Torque Curves

1.7.1 Solid State Reduced Voltage


Starters

Torque
Full Voltage

Unit Mounted
Solid State Starters are unit mounted and wired in a NEMA
1 enclosure, and offer many standard features:

Microprocessor controller
Bypass contactor for eliminating SCR heat generation
Programmable starting profiles
Controlled inrush current and torque
Stepless acceleration to full speed
Adjustable acceleration rate
Programmable motor protection
Under/over voltage and phase monitoring
Electronic overloads
Motor short circuit protection
Instant over current protection
Current imbalance
Ground fault interrupt
Embedded diagnostics
Integral display
Digital metering
Built-in self testing
Pending fault indicator

Options

Unit Mounted Circuit Breakerwith disconnect


handle extended through the door
Unit Mounted Fused Disconnecthandle extends
through the door
Door Latch Solenoidfor power and control panels

Solid State Starters DBRSM6B are microprocessorcontrolled solid state reduced voltage with easy-to-use
keypad interface. They operate on a user-programmed
closed-loop current ramp for optimum motor control and
protection.

Full
Load
Torque

Programmable
Acceleration
Torque

DBRSM6B
"Soft Start"

Typical Load

Speed (RPM)

Standard Features of the DBRSM6B Starter

Electronic Motor Overloads are Class 10, with 115%


overload service factor for the DBRSM starters.
Initial Current is the starting point for the current
ramp. It can be set between 50-400% of the motor
FLA. This must be set so the motor starts turning when
a start command is given.
Current Limit is the maximum motor current limit
with an adjustable current range from 200-600% of
the full load current. This reduces the starting current
to limit brownout conditions during starting.

Percent
Voltage

100%

Initial
Torque

Run

Start

Time (Seconds)
19

1.0 GENERAL INFORMATION (CONT.)

Latched Fault Relay Output, switches and is latched,


if any fault occurs that will not allow the motor to
start or operate properly.
Programmable Relay Outputs are supplied to
indicate overload trip, overload lock, overload
warning, starter operating, motor up-to-speed,
shorted SCR, ground fault, or under current trip.
Programmable Metering for each of two display
meters may be set to measure amps(A), volts(V),
frequency(Hz), motor overload content(OL), power
factor(pf), elapsed time meter(etm), kilowatts(KW),
kilowatt-hours(KWH), kilovolt-amps reactive(Kvar).
When measuring current or voltage, "avg" indicates
an average of all three lines, "scr" will give a scrolling
meter, and 1, 2, or 3 indicates a specific line
measurement. For example, selecting "Vavg" will
display the average voltage of all three lines.
Starts Per Hour Limiter sets the number of starts
allowed per hour.
Start Interval Limiter sets the minimum allowed time
between starts. The motors used on this equipment
should not be started more than three times per hour.
Adjustable Acceleration Ramp Profiles are the
profiles of the motor starting current. The starting
point of each current ramp is the initial current setting,
which is adjustable from 50 to 400%. The maximum
current is adjustable from 200 to 600% and sets the
endpoint for the current ramp. The ramp time is
adjustable form 0 to 120 seconds. This sets the amount
of time the starter spends smoothly ramping from the
initial current to the maximum current value. Typical
values are 150% for initial current; 250% for maximum
current, and 15 seconds for ramp time.
Closed Loop Current Ramp function of the starter
operates on a user-programmed current ramp for
optimal motor control and protection. The motor is
accelerated from the initial current setting to the
maximum current setting during the defined ramp
time.

Max
Current

Time
(Sec)

Ramp Time

20

120

Stall Time

Bypass
Energizes

Initial
Current

Motor
Current (%)
600

Up To
Speed

Single Phase Protection, protects against one of the


three phases being lost, the starter will shut down
the motor, if running, and refuse to start until the
phase is restored. The starter will report the condition
and register a fault.
Phase Rotation Protection for the starter can be
selected to be ABC sensitive. If the incoming line

phasing is detected to be out of sequence, a fault is


registered.
Line to Line Current Imbalance is monitored and if
the current in any phase differs from the average by a
programmable setting (10 to 40%), the starter will
shut down, and report the condition and register a
fault.
Over / Under Voltage Protection monitors the line
voltage and if any phase varies above or below the
base line voltage by more than a programmable
percentage (10 to 30%), a fault is recorded and the
motor is shut down.
Adjustable Stalled Motor Protection monitors the
current of the motor for an up-to-speed condition. If
the motor does not reach up-to-speed before the ramp
time plus the set stall time expires, the starter will
consider the motor stalled. An Up-To-Speed fault will
be registered.
Ground Fault Detection monitors the motor and
wiring for ground faults. The starter performs the
Ground Fault Protection by monitoring the
instantaneous sum of the three phase currents. The
user can set a predetermined trip point or alarm for
when a ground fault is detected.
Instantaneous Electronic Over-Current Trip for
situations where the current level suddenly increases
to > 8 x FLA due to a power system or motor fault.
The starter registers a fault and shuts the motor down
immediately.
Under Current Protection allows the user to select a
low current trip level (10 to 100% of FLA) and delay
time (0.1 to 90.0 seconds). This allows the user to set
a predetermined trip point that can indicate an under
current condition or cause a starter trip to detect loss
of motor load.
Low / High Frequency Trips protect against any of
the phases going above or below the programmed
range, and the starter will register a fault. The
Maximum range of the Frequency Trips is 23 to 72 HZ.
Shorted SCR Detection detects shorted SCRs during
acceleration. The starter will then shut down, report
the condition and register a fault.
Protection Modules are Metal Sintered-Oxide
Varistors (SIOVs) that protect electronic components
against external voltage spikes.
Passcode Protection provides protection against
unauthorized changes and when enabled, most
programmable menu parameters may only be viewed
and not changed. A three digit passcode between 001
and 999 may be chosen.
Battery Back-Up Menu Parameters are protected by
an 10 year life battery.
Full Fault Annunciation when a motor fault occurs,
the fault code and description are displayed on the
LCD display and recorded in the event recorder.
The LCD and LED Status and Diagnostics comes
standard with programmable keypad, plain English
LCD display and status LEDs. The keypad is doormounted for viewing and programming from outside
the enclosure.
Accumulated Event Recorder provides information
for each time an event occurs, the code, condition,
and time of the event will be recorded in the revolving

1.0 GENERAL INFORMATION (CONT.)

99-event recorder. An event is considered anything


that changes the present state which the starter is in,
including faults, starts, stops, overload warnings, and
overload trips.
Programmable Service Factor is set to the service
factor of the motor.
Real Time Clock with battery backup is included in
the starter. This allows the starter to track motor
thermal overload content, enforce starter lockout
times, and time stamp faults in the event recorder. It
will track lockouts even when the power is removed.
Emergency Restart Provision has the ability to
override the starter lockouts if it is necessary to start
the motor. This feature should only be used in the
event of an emergency.

1.7.2 Wye-Delta Starters


Unit Mounted
Wye Delta Starters are unit mounted for 460/3/60, 575/3/
60 and 400/3/50 applications and offer many standard
features mounted and wired in a NEMA 1 enclosure:

Closed Transition controller in a NEMA 1 enclosure


Controlled inrush current and torque to 33%
Two Step acceleration speed control
Ambient compensated overload relay
Under voltage, phase monitoring relay

WYE Delta Wiring Configuration


1M

Step 1, Y Start
Contactors 1M and S close
2M is open

T1

Step 1, Delta Run

2M

Contactor 2S opens
1R closes

T4

2M

T5

T2
T1

T3

S
T6

1M
T3

1M
2M

T1

T4

T6

T6

T5

Winding pattern "Y"


33% torque, 33% current
T2

Winding pattern "Delta"


Full torque, Full current T4
T2

T3
T5

This method is superior to Across-The-Line motor starting


due to the reduced electrical demand, in areas with high
electrical rates and utility demand charges.

Remote Mounted
Remote Mounted WYE Delta Starters offer the same
standard features and options as the Unit Mounted
Starters, and are supplied in a stand alone NEMA 1
enclosure, for contractor mounting and wiring. Terminals
are marked for interconnecting wiring, from the remote
starter to the
chiller, for ease of wiring.

1.7.3 Across-The-Line Starters

Options

Unit Mounted Circuit Breakerswith disconnect


handles extended through the door
Unit Mounted Fused Disconnecthandles extended
through the door
Ground Fault Interrupt Relay
Under and Over Voltage, Phase Loss, and Phase
Imbalance Relay
Volt and Amp Meterswith selector switches for
three phase meter reading
Door Latch Solenoidfor power and control panels

WYE Delta Closed Transition Starters (also called Star Delta


Starters) - offer a reduced voltage/reduce inrush current
method of starting motors. WYE Delta starters utilize
special wound motors that can be connected to the "Y"
pattern for reduced starting torque. In the "Y"
configuration, each set of phase windings is brought
together at a common point. This increases the impedance
of the motor itself, reducing the current and torque to
33% of normal. Three contactors and a timer are used to
switch the six leads brought out of the motor into the Ythen-Delta configuration in a two-step starting process.
"Closed Transition" WYE Delta starters utilize shunt resisters
in the circuit during the transition phase of starting to
prevent motor stalls or current spikes. This scheme uses
four contactors in three steps and large starting resisters.

Remote Mounted
Remote Mounted Starters are available for medium voltage
2300/4160/3/60 and 3300/3/50 voltage applications. Other
voltages are available by contacting our Sales
Representative or Application Engineering Department.
Across-The-Line Starters are supplied in NEMA 1 enclosures
and have the many standard features:

Control Power Transformer with primary and


secondary fusing
Ambient compensated overloads
Current transformers
4-20mA load signal
Oil Pump Starter with overload protection
Under voltage and phase monitoring relay
Draw out contactor with fused isolation switch

Options

Ground Fault Interrupt Relay


Under and Over Voltage, Phase Loss, and Phase
Imbalance Relay
Volt and Amp Meterswith selector switches for
three phase meter reading
Door Latch Solenoidfor power and control panels

21

2.0 INSTALLATION

2.1 General 2+:E


2+:Epackaged chillers are designed to cool water or
other non-corrosive liquids. Water is circulated through
the flooded cooler where it is cooled to the desired
temperature then circulated to cooling coils for air
conditioning, or to other types of heat exchangers for
process cooling.

2.2 Inspection 2+:E


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 agree.

the delivering carrier as all shipments are made at the


purchaser's risk.

2.3 Handling, Storage & Rigging


2.3.1 General 2+:E Handling Instructions
Each unit has been carefully tested at the factory where
every precaution is taken to assure that the unit reaches
you in perfect condition. It is very important that the
riggers and movers should 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 must not be used as a ladder or
as a hand hold. 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.

2. Check the model number and the electrical


characteristics on the nameplate to determine if
they are correct.

2.3.2 Storage

3. Check for freight damage, shortages or other


discrepancies and note them on the delivery receipt
before signing.

2.3.3 2+:E Rigging and Moving

In the event that any damage is found, a damage claim


should immediately be filed by the purchaser against

This equipment is designed for outdoor use but must


be protected from damage if stored before installation.

This equipment is too large to be carried by a forklift


without serious damage so rigging is required.

Figure 2.3.3.1

RIGGING INSTRUCTIONS
LIFT FROM OUTSIDE LIFTING HOLES ONLY !

NOTES
1-DO NOT SKID UNIT UNLESS UNIT IS EQUIPPED WITH FACTORY
INSTALLED SKID OPTION.
2-USE SPREADER BARS TO INSURE CABLES DO NOT DAMAGE
MACHINE COMPONENTS.

22

2.0 INSTALLATION (CONT.)


2.4
2.4.1

Space and Clearance


Requirements 2+:E
General Space and Clearance
Requirements

The dimensional data and space requirements are given


on pages 12 thru 16. Refer to 2.4.2 for location and
installation clearances and 2.4.3 for dimensional
requirements. The most important consideration which
must be taken into account when deciding upon the
location of water cooled equipment is the provision for
sufficient space for servicing, including electrical panel
code clearance compliance and cooler and condenser
tube cleaning and potential tube replacement.
Figure 2.4.2

Another consideration which must be made 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 under corridors, utility areas, rest
rooms or other auxiliary areas where sound levels are
not as important a factor. Sound and structural
consultants should be retained for recommendations
on critical installations.

Location and installation Clearance 2+:E 030-050


ELECTRICAL SERVICE
ENTRANCE

NOTES
36 [914]

152 [3861]

1 - IF A DOORWAY OR OTHER PROPERLY LOCATED


OPENING IS USED FOR TUBE REMOVAL THE
SUGGESTED MINIMUM CLEARANCE IS 36"
2 - SUGGESTED CLEARANCES AROUND THE MACHINE
ARE MINIMUM REQUIREMENTS. IT IS STRONGLY
RECOMMENDED THAT AT LEAST ONE OF THESE
CLEARANCE REQUIREMENTS EXCEED THE MINIMUM
TO ALLOW FOR COMPRESSOR OR MOTOR SERVICING.
3 - CONSULT NEC and LOCAL CODES FOR REQUIRED
ELECTRICAL PANEL CLEARANCES.

SEE NOTE 1 & 2

MINIMUM REQUIRED FOR TUBE


CLEANING or REPLACEMENT EITHER END
RECOMMEND 175[4445] SEE NOTE 1 & 2

CONTROL BOX DOOR SWING


IS A MAXIMUM OF 32" [813]

CONTROL BOX DOOR SWING


IS A MAXIMUM OF 32" [813]
SEE NOTE 3

60

40

20

CONDENSER

RIGHT SIDE WHEN VIEWING CONTROL BOX


LEFT SIDE VIEW WHEN VIEWING CONTROL BOX
RIGHT HAND VESSEL CONNECTIONS SHOWN

23

2.0 INSTALLATION (CONT.)


2.5

Foundation or Mounting
Structure

Foundations must be level within 1/16" per foot, for


proper operation and functioning of controls.
Provisision must be made for supporting the individual
load points as shown in the unit dimensions on 2.4.3

and unit weight and point loading chart 2.5.1. Roof


mounted units must be supported on adequate steel
structures. If units are located on the ground level, a
concrete base is recommended.

2.5.1 2+:E Unit Weights, Point Loading and Center of Gravity


A

ENGLISH I.P. UNITS

F
Y

Cooler Cond.
Code Code Comp.

Model

Motor

A
lbs.

Operating Weight
Shipping
B
C
D
Total Weight
X
lbs.
lbs.
lbs.
lbs.
lbs.
in.

Y Z
in. in.

E
in.

F
in.

2+:E030
60Hz, STD
60Hz, STD
60Hz, Single O.S. Clr.
60Hz, Single O.S. Clr.
60Hz, DBL O.S. Clr.
60Hz, DBL O.S. Clr.
50Hz, STD
50Hz, STD
50Hz, Single O.S. Clr.
50Hz, Single O.S. Clr.
50Hz, DBL O.S. Clr.
50Hz, DBL O.S. Clr.

F6
F6
G6
G6
H6
H6
F5
F5
F6
F6
G6
G6

E6
E6
E7
E7
F6
F6
D6
D6
E6
E6
E7
E7

2010
2010
2010
2010
2010
2010
2010
2010
2010
2010
2010
2010

Low Volt Motor


Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor

3115
3040
3305
3235
3715
3655
2835
2770
3085
3015
3280
3210

3710
3910
3965
4160
4450
4635
3450
3645
3680
3875
3935
4125

3630
3930
3845
4150
4250
4565
3375
3675
3620
3920
3835
4140

4325
5050
4610
5330
5085
5795
4110
4835
4320
5045
4600
5320

14780
15930
15725
16875
17500
18650
13770
14925
14705
15855
15650
16795

13720
14870
14515
15665
15980
17135
12885
14035
13645
14790
14435
15590

80
84
80
84
79
83
81
85
80
84
80
84

25
24
27
26
28
27
24
23
25
24
27
26

36
38
35
37
34
36
36
38
35
37
35
37

148
148
148
148
148
148
148
148
148
148
148
148

53.50
53.50
58.00
58.00
59.00
59.00
52.75
52.75
53.50
53.50
58.00
58.00

60Hz, STD
60Hz, STD
60Hz, Single O.S. Clr.
60Hz, Single O.S. Clr.
60Hz, DBL O.S. Clr.
60Hz, DBL O.S. Clr.
50Hz, STD
50Hz, STD
50Hz, Single O.S. Clr.
50Hz, Single O.S. Clr.
50Hz, DBL O.S. Clr.
50Hz, DBL O.S. Clr.

H6
H6
K6
K6
L6
L6
G6
G6
H6
H6
K6
K6

F6
F6
G6
G6
H6
H6
E7
E7
F6
F6
G6
G6

2015
2015
2015
2015
2015
2015
2015
2015
2015
2015
2015
2015

Low Volt Motor


Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor

3800
3755
4430
4390
5065
5025
3370
3315
3785
3735
4410
4365

4675
4780
5250
5355
5660
5760
4120
4280
4605
4760
5180
5335

4510
4710
5155
5365
5800
6020
4000
4245
4405
4665
5045
5320

5545
5990
6110
6540
6475
6900
4890
5485
5360
5945
5930
6500

18530
19235
20945
21650
23000
23705
16380
17325
18155
19105
20565
21520

17010
17710
19105
19805
20755
21455
15170
16115
16630
17585
18730
19680

81
83
80
82
80
81
81
84
80
83
79
82

27
27
29
29
31
31
27
26
27
27
30
29

36
37
35
36
35
36
36
37
35
37
34
36

148
148
148
148
148
148
148
148
148
148
148
148

59.00
59.00
61.88
61.88
63.00
63.00
58.00
58.00
59.00
59.00
61.88
61.88

60Hz, STD
60Hz, STD
60Hz, Single O.S. Clr.
60Hz, Single O.S. Clr.
50Hz, STD
50Hz, STD
50Hz, Single O.S. Clr.
50Hz, Single O.S. Clr.
50Hz, DBL O.S. Clr.
50Hz, DBL O.S. Clr.

K6
K6
L6
L6
H6
H6
K6
K6
L6
L6

G6
G6
H6
H6
F6
F6
G6
G6
H6
H6

2018
2018
2018
2018
2018
2018
2018
2018
2018
2018

Low Volt Motor


Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor

4535
4510
5170
5150
3835
3810
4470
4445
5100
5080

5390
5510
5795
5915
4750
4870
5330
5445
5730
5850

5295
5480
5940
6135
4615
4790
5265
5450
5910
6105

6295
6695
6655
7045
5715
6125
6275
6675
6640
7030

21515
22195
23560
24245
18915
19595
21340
22015
23380
24065

19675
20355
21330
22000
17400
18075
19500
20175
21145
21825

80
82
80
81
81
83
81
82
80
81

29
29
31
30
27
27
29
29
31
30

36
36
36
37
36
37
35
36
36
37

148
148
148
148
148
148
148
148
148
148

61.88
61.88
63.00
63.00
59.00
59.00
61.88
61.88
63.00
63.00

2+:E 040

2+:E050

Notes:

24

Low Voltage Motor - 460/3/60, 575/3/60 and 400/3/50


Medium Voltage Motor - 2300/3/60, 4160/3/60 and 3300/3/50
X, Y, and Z Designates Location for Center of Gravity

2.0 INSTALLATION (CONT.)

2.5.2 2+:E Unit Weights, Point Loading and Center of Gravity

S.I. UNITS

F
Y

Cooler Cond.
Code Code Comp.

Model

Motor

A
kgs.

Operating Weight
Shipping
B
C
D
Total Weight
X
Y Z
E
F
kgs. kgs. kgs. kgs.
kgs.
cm. cm. cm. cm. cm.

2+:E 030
60Hz, STD
60Hz, STD
60Hz, Single O.S. Clr.
60Hz, Single O.S. Clr.
60Hz, DBL O.S. Clr.
60Hz, DBL O.S. Clr.
50Hz, STD
50Hz, STD
50Hz, Single O.S. Clr.
50Hz, Single O.S. Clr.
50Hz, DBL O.S. Clr.
50Hz, DBL O.S. Clr.
2+:E040
60Hz, STD
60Hz, STD
60Hz, Single O.S. Clr.
60Hz, Single O.S. Clr.
60Hz, DBL O.S. Clr.
60Hz, DBL O.S. Clr.
50Hz, STD
50Hz, STD
50Hz, Single O.S. Clr.
50Hz, Single O.S. Clr.
50Hz, DBL O.S. Clr.
50Hz, DBL O.S. Clr.

F6
F6
G6
G6
H6
H6
F5
F5
F6
F6
G6
G6

E6
E6
E7
E7
F6
F6
D6
D6
E6
E6
E7
E7

2010
2010
2010
2010
2010
2010
2010
2010
2010
2010
2010
2010

Low Volt Motor


Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor

1413
1379
1499
1467
1685
1658
1286
1256
1399
1368
1488
1456

1683
1774
1799
1887
2019
2102
1565
1653
1669
1758
1785
1871

1647
1783
1744
1882
1928
2071
1531
1667
1642
1778
1740
1878

1962
2291
2091
2418
2307
2629
1864
2193
1960
2288
2087
2413

6704
7226
7133
7655
7938
8460
6246
6770
6670
7192
7099
7618

6223
6745
6584
7106
7249
7772
5845
6366
6189
6709
6548
7072

203
214
203
213
202
211
205
216
204
214
204
214

64
61
69
66
70
68
62
59
64
61
69
66

91
96
89
93
87
91
91
96
90
95
88
93

376
376
376
376
376
376
376
376
376
376
376
376

136
136
147
147
150
150
134
134
136
136
147
147

H6
H6
K6
K6
L6
L6
G6
G6
H6
H6
K6
K6

F6
F6
G6
G6
H6
H6
E7
E7
F6
F6
G6
G6

2015
2015
2015
2015
2015
2015
2015
2015
2015
2015
2015
2015

Low Volt Motor


Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor

1724
1703
2009
1991
2297
2279
1529
1504
1717
1694
2000
1980

2121
2168
2381
2429
2567
2613
1869
1941
2089
2159
2350
2420

2046
2136
2338
2434
2631
2731
1814
1926
1998
2116
2288
2413

2515 8405
2717 8725
2771 9501
2967 9820
2937 10433
3130 10753
2218 7430
2488 7859
2431 8235
2697 8666
2690 9328
2948 9761

7716
8033
8666
8984
9414
9732
6881
7310
7543
7977
8496
8927

205
211
204
208
202
207
205
213
204
211
202
208

69
68
75
74
79
78
68
66
70
68
75
73

91
93
89
91
90
92
91
95
89
93
87
91

376
376
376
376
376
376
376
376
376
376
376
376

150
150
157
157
160
160
147
147
150
150
157
157

60Hz, STD
60Hz, STD
60Hz, Single O.S. Clr.
60Hz, Single O.S. Clr.
50Hz, STD
50Hz, STD
50Hz, Single O.S. Clr.
50Hz, Single O.S. Clr.
50Hz, DBL O.S. Clr.
50Hz, DBL O.S. Clr.

K6
K6
L6
L6
H6
H6
K6
K6
L6
L6

G6
G6
H6
H6
F6
F6
G6
G6
H6
H6

2018
2018
2018
2018
2018
2018
2018
2018
2018
2018

Low Volt Motor


Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor
Low Volt Motor
Med Volt Motor

2057
2046
2345
2336
1740
1728
2028
2016
2313
2304

2445
2499
2629
2683
2155
2209
2418
2470
2599
2654

2402
2486
2694
2783
2093
2173
2388
2472
2681
2769

2855
3037
3019
3196
2592
2778
2846
3028
3012
3189

8925
9233
9675
9979
7893
8199
8845
9151
9591
9900

204
208
202
206
206
211
205
209
203
207

75
73
79
77
69
67
75
73
78
77

91
93
91
93
91
94
90
92
91
93

376
376
376
376
376
376
376
376
376
376

157
157
160
160
150
150
157
157
160
160

2+:E 050

Notes:

9759
10068
10687
10998
8580
8888
9680
9986
10605
10916

Low Voltage Motor - 460/3/60, 575/3/60 and 400/3/50


Medium Voltage Motor - 2300/3/60, 4160/3/60 and 3300/3/50
X, Y, and Z Designates Location for Center of Gravity

25

2.0 INSTALLATION (CONT.)

Sound and Vibration Isolation 2+:E

2.6

Sound and vibration of mechanical equipment inside


buildings is often critical and it may be necessary to install
vibration isolators under the base of the Packaged Chiller.

which goes through the wall, ceiling or floor should be


properly sheathed to prevent transmission of piping
vibration to the structure.

Spring vibration isolators are offered as optional items.


See 2.6.1 for mounting location. When spring isolators
are used, flexible connectors must be installed in the water
piping system. Note: These flexible connectors must be
suitable for the fluid and pressures involved.

When spring isolators are used, electrical service to the


unit must also be flexibly connected, by means of a 36"
section of flexible conduit.
Refer to pages 24 and 25 for dimensional information
required for locating isolators.

All piping which is external to the packaged chiller must


be supported by spring mounted hangers and any piping

2.6.1 2+:E Spring Vibration Isolators and Locations


MODEL

UNIT MAKEUP

DIM
`F'

SPRING ISOLATOR LOCATIONS


B
C
D
CD-4200
CD-4200
CD-4770
CD-4770
CD-4770
CD-5870
CD-4770
CD-4770
CD-5300
CD-4770
CD-4770
CD-5870
CD-5300
CD-4770
CD-5870
CD-5300
CD-5300
CE-7000

PCXi030 STD 60Hz MACHINE


PCXi030 STD 60Hz MACHINE
SINGLE OVERSIZE VESSEL SET
SINGLE OVERSIZE VESSEL SET
DOUBLE OVERSIZED VESSEL SET
DOUBLE OVERSIZED VESSEL SET

F6 COOLER/E6 COND - 460/575/3/60 VOLT MOTOR


F6 COOLER/E6 COND - 2300/4160/3/60 VOLT MOTOR
G6 COOLER/E7 COND - 460/575/3/60 VOLT MOTOR
G6 COOLER/E7 COND - 2300/4160/3/60 VOLT MOTOR
H6 COOLER/F6 COND - 460/575/3/60 VOLT MOTOR
H6 COOLER/F6 COND - 2300/4160/3/60 VOLT MOTOR

53.50
53.50
58.00
58.00
59.00
59.00

[1359]
[1359]
[1473]
[1473]
[1499]
[1499]

A
CD-3500
CD-3500
CD-4200
CD-4200
CD-4200
CD-4200

PCXi040 STD 60Hz MACHINE


PCXi040 STD 60Hz MACHINE
SINGLE OVERSIZE VESSEL SET
SINGLE OVERSIZE VESSEL SET
DOUBLE OVERSIZED VESSEL SET
DOUBLE OVERSIZED VESSEL SET

H6 COOLER/F6 COND - 460/575/3/60 VOLT MOTOR


H6 COOLER/F6 COND - 2300/4160/3/60 VOLT MOTOR
K6 COOLER/G6 COND - 460/575/3/60 VOLT MOTOR
K6 COOLER/G6 COND - 2300/4160/3/60 VOLT MOTOR
L6 COOLER/H6 COND - 460/575/3/60 VOLT MOTOR
L6 COOLER/H6 COND - 2300/4160/3/60 VOLT MOTOR

59.00
59.00
61.88
61.88
63.00
63.00

[1499]
[1499]
[1572]
[1572]
[1600]
[1600]

CD-4200
CD-4200
CD-5300
CD-5300
CD-5870
CD-5870

CD-5300
CD-5300
CD-5870
CE-7000
CE-7000
CE-7000

CD-5300
CD-5300
CD-5870
CE-7000
CE-7000
CE-7000

CE-7000
CE-7000
CE-7000
CE-8400
CE-8400
CE-8400

PCXi050 STD 60Hz MACHINE


PCXi050 STD 60Hz MACHINE
SINGLE OVERSIZE VESSEL SET
SINGLE OVERSIZE VESSEL SET

K6 COOLER/G6 COND - 460/575/3/60 VOLT MOTOR


K6 COOLER/G6 COND - 2300/4160/3/60 VOLT MOTOR
L6 COOLER/H6 COND - 460/575/3/60 VOLT MOTOR
L6 COOLER/H6 COND - 2300/4160/3/60 VOLT MOTOR

61.88 [1572]
61.88 [1572]
63.00 [1600]
63.00 [1600]

CD-5300
CD-5300
CD-5870
CD-5870

CE-7000
CE-7000
CE-7000
CE-7000

CD-5870
CE-7000
CE-7000
CE-7000

CE-7000
CE-8400
CE-8400
CE-8400

PCXi030 STD 50Hz MACHINE


PCXi030 STD 50Hz MACHINE
SINGLE OVERSIZE VESSEL SET
SINGLE OVERSIZE VESSEL SET
DOUBLE OVERSIZED VESSEL SET
DOUBLE OVERSIZED VESSEL SET

F5 COOLER/D6 COND - 400/3/50 VOLT MOTOR


F5 COOLER/D6 COND - 3300/3/50 VOLT MOTOR
F6 COOLER/E6 COND - 400/3/50 VOLT MOTOR
F6 COOLER/E6 COND - 3300/3/50 VOLT MOTOR
G6 COOLER/E7 COND - 400/3/50 VOLT MOTOR
G6 COOLER/E7 COND - 3300/3/50 VOLT MOTOR

52.75
52.75
53.50
53.50
58.00
58.00

[1340]
[1340]
[1359]
[1359]
[1473]
[1473]

CD-3500
CD-3500
CD-3500
CD-3500
CD-4200
CD-4200

CD-4200
CD-4200
CD-4200
CD-4770
CD-4770
CD-4770

CD-4200
CD-4200
CD-4200
CD-4770
CD-4770
CD-4770

CD-4770
CD-5870
CD-4770
CD-5870
CD-5300
CD-5870

PCXi040 STD 50Hz MACHINE


PCXi040 STD 50Hz MACHINE
SINGLE OVERSIZE VESSEL SET
SINGLE OVERSIZE VESSEL SET
DOUBLE OVERSIZED VESSEL SET
DOUBLE OVERSIZED VESSEL SET

G6 COOLER/E7 COND - 400/3/50 VOLT MOTOR


G6 COOLER/E7 COND - 3300/3/50 VOLT MOTOR
H6 COOLER/F6 COND - 400/3/50 VOLT MOTOR
H6 COOLER/F6 COND - 3300/3/50 VOLT MOTOR
K6 COOLER/G6 COND - 400/3/50 VOLT MOTOR
K6 COOLER/G6 COND - 3300/3/50 VOLT MOTOR

58.00
58.00
59.00
59.00
61.88
61.88

[1473]
[1473]
[1499]
[1499]
[1572]
[1572]

CD-4200
CD-4200
CD-4200
CD-4200
CD-5300
CD-5300

CD-4770
CD-4770
CD-5300
CD-5300
CD-5870
CD-5870

CD-4770
CD-4770
CD-5300
CD-5300
CD-5870
CD-5870

CD-5870
CE-7000
CE-7000
CE-7000
CE-7000
CE-8400

PCXi050 STD 50Hz MACHINE


PCXi050 STD 50Hz MACHINE
SINGLE OVERSIZE VESSEL SET
SINGLE OVERSIZE VESSEL SET
DOUBLE OVERSIZED VESSEL SET
DOUBLE OVERSIZED VESSEL SET

H6 COOLER/F6 COND - 400/3/50 VOLT MOTOR


H6 COOLER/F6 COND - 3300/3/50 VOLT MOTOR
K6 COOLER/G6 COND - 400/3/50 VOLT MOTOR
K6 COOLER/G6 COND - 3300/3/50 VOLT MOTOR
L6 COOLER/H6 COND - 400/3/50 VOLT MOTOR
L6 COOLER/H6 COND - 3300/3/50 VOLT MOTOR

59.00
59.00
61.88
61.88
63.00
63.00

[1499]
[1499]
[1572]
[1572]
[1600]
[1600]

CD-4770
CD-4200
CD-5300
CD-5300
CD-5870
CD-5870

CD-5300
CD-5870
CD-5870
CE-7000
CE-7000
CE-7000

CD-5300
CD-5300
CD-5870
CE-7000
CE-7000
CE-7000

CE-7000
CE-7000
CE-7000
CE-8400
CE-8400
CE-8400

TOP ACCESS ADJUSTMENT BOLT


Turn clockwise to load spring and maintain
Free & Operating Height. Bolt length is suitable
for 1" maximum Equipment Base thickness

NOTES
1-DIMENSIONS ARE TO ISOLATOR MOUNTING HOLES

TO INSTALL SPRING ISOLATORS


- REMOVE JACK BOLT, OIL IT AND RUN THE NUT BACK AGAINST THE BOLTHEAD
- SET THE ISOLATOR UNDER BRACKET ON UNIT.
- INSERT BOLT THRU CLEARANCE HOLE IN BRACKET AND THREAD INTO TOP
PLATE OF ISOLATOR UNTIL IT PULLS UP FLUSH TO BOTTOM OF BRACKET
- ADJUST INDIVIDUAL ISOLATORS AS NECESSARY TO LEVEL UNIT.
- LOCK NUTS DOWN AGAINST BRACKET AT ALL (4) POSITIONS
'MBD'
MAXIMUM BOLT DIAMETER

FREE and
OPERATING HEIGHT
L

HCW

SW `W'

T
RIBBED NEOPRENE PAD
ISOLATOR
CCCDCE-

26

Illustration shows single spring C-A, C-B


or C-C mount. C-D & C-E have 2 & 4
springs each respectively

DIMENSION
HCL
HCW
SBC
SW
7-1/4" [184] 1-3/4" [44] 7-7/8" [200] 7/16" [11]
10-3/8" [264] 1-3/4" [44]
11" [279] 7/16" [11]
11-3/8" [289] 5-1/8" [130]
-------

HCL
SBC

MBD
A
T
L
3/8'
6-5/8" [168] 9/16" [14]
8-7/8" [225]
3/8"
9-3/4" [248] 9/16" [14]
12" [305]
1/2" 12-1/8" [308] 5/8" [16] 12-3/4" [324]

FREE and
OPERATING HEIGHT
W
3-1/2" [89]
5-1/2" [140]
3-1/2" [89]
6" [152]
6-5/8" [168]
6" [152]

2-ISOLATOR SELECTIONS ARE A MINIMUM OF 10%


ABOVE FLOOR LOADING WEIGHTS.
3-UNITS ARE IN ENGLISH AND [S.I.]

DUNHAM BUSH
MASON
PART NUMBER PART NUMBER
010416A1
010416A2
010416A3
010416A4
010416A5
010416A6
010416A7
010416A8
010416A9
010416B1
010416B2
010416B3
010416B4
010416B5

CC-1750
CC-2100
CC-2935
CD-3500
CD-4200
CD-4770
CD-5300
CC-2385
CC-2650
CD-5870
CE-7000
CC-1000
CC-1350
CE-8400

SPRING COLOR
BLACK
YELLOW W/RED INSIDE
RED W/GREEN INSIDE
BLACK W/RED INSIDE
YELLOW W/RED INSIDE
YELLOW W/GREEN INSIDE
RED W/RED INSIDE
YELLOW W/GREEN INSIDE
RED W/RED INSIDE
RED W/GREEN INSIDE
BLACK W/RED INSIDE
BLACK
YELLOW
YELLOW W/RED INSIDE

2.0 INSTALLATION (CONT.)


2.7

Water Piping Connections


2+:E

2.7.1 2+:E Chilled Water Piping

After the unit has been levelled and isolators (if any)
installed and adjusted, connect cooler and condenser
water piping. Piping must be properly supported to
avoid stress on unit water connections. Install air vent
valves in all high connections on cooler and condenser
heads. Install drain valves in similar low points to
facilitate gravity draining of the system. It is important
that water systems be cleaned before start-up to avoid
collecting debris in cooler and condenser.

piping a minimum of twenty-four (24) inches


downstream from any connections (flange, elbow, etc.).
There are many piping and control systems which may
be used to assure constant water flow through the
cooler. A typical system is shown in Figure 2.7A. It
uses a three way motorized valve which operates in
response to the discharge air temperature of the cooling
coil.

The best way to do this is to install wye strainers in


both systems upstream of the unit. After filling systems
with water, bleed trapped air from the various vent
valves. Check for proper flow rates by measuring water
pressure drop across heat exchangers and reading GPM
from charts, Figures 31 and 32. Compare measured
GPM's with values specified on purchase order.

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 in conjunction with a spring loaded bypass
regulating valve as shown in Figure 2.7B. The bypass
valve must be set to assure the full flow of circulating
chilled water when the modulating valve is completely
closed.

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 cooler and system.

Other systems are noted in the ASHRAE Handbook and


may serve equally well. Whatever system is selected,
water flow must be constantly maintained through the
chiller.

The cooler must be freeze protected with the correct


percentage of glycol if ambient temperatures are
expected to be below 32F. If sub-freezing ambient
temperatures are possible, the unit cooler, condenser
and all exposed field water piping should be drained or
have a glycol mixture to prevent freezing.
When installing pressure taps to measure the amount
of pressure drop across the water side of the cooler
and condenser, the taps should be located in the water

If the system is arranged for the dual purpose of cooling


in the summer and heating in the winter, the cooler
must be valved off during the heating season so that
hot water will not pass through the cooler. This may
be either a manual or automatic change-over operation.
There are also times, such as early spring and late fall,
when both heating and cooling are required. This
should also be considered when designing heating and
cooling systems. For various piping arrangements,
consult the ASHRAE Handbook.

Figure 2.7A - Three-Way Load Side Bypass


EXPANSION
TANK

COOLER

RETURN
FLUID

FLOW
SWT

THREE-WAY
VALVE

COOLING CORE

SUPPLY
FLUID

Figure 2.7B- Two-Way Load Side Bypass


EXPANSION
TANK

COOLER

FLOW
SWT

BYPASS
REG. VALVE

TWO-WAY
VALVE

RETURN
FLUID

COOLING CORE

SUPPLY
FLUID

27

2.0 INSTALLATION (CONT.)

2.7.2 Multiple Chillers Per Chilled Water


System
2.7.2.1

2.7.2.2

Where the load is greater than one


can supply or where standby capacity is
required or the load profile dictates, multiple
chillers may be piped in parallel. Units of
equal size help to ensure fluid flow balance,
however, balancing valves will ensure
balanced flows even with dissimilar chillers.
Temperature controller sensors may or may
not need to be moved to the common fluid
piping depending on the specific application.
Parallel Chiller Applications (Figure 28A)
Both units operate simultaneously
modulating with load variations. Each unit
operates independently sensing its own
leaving water temperature. The set point of
each sensor is set to maintain the desired
loading scheme.
If unit sequencing is required, special
programming and interconnecting wiring are
required. Additional water control piping
may also be required.

Figure 28A

COOLER

FLUID - IN

TEMPERATURE
SENSORS

COOLER

Figure 28B
FLUID IN

TEMPERATURE
SENSOR

COOLER
No. 2

COOLER
No. 1

TEMPERATURE
SENSOR
FLUID OUT

2.7.2.4

Oversizing Chillers

Oversizing of chillers more than 10-15% is not


recommended. Oversizing causes energy inefficiency
and shortened compressor life due to excessive
compressor cycling. Larger future load requirements
may cause temporary oversizing of equipment which
will require careful unit selection. It may be better to
properly size for the present load and add another unit
later for future expansion. It is also recommended using
multiple units where operation at minimum load is
critical. Fully loaded equipment operates better and
more efficiently than large equipment running at or
near minimum capacity.
Hot gas bypass should not be a means to allow
oversizing of chillers. Hot gas bypass should only be
used where the equipment is sized properly for full
load but the load turn down is less than the minimum
unloading capacity available.

FLUID - OUT
CONTACT FACTORY FOR ADDITIONAL SENSOR
AND CONTROL SCHEME

2.7.2.3

Series Chiller Applications (Figure 28B)


Where a large temperature range is required
(generally over 15F [8.4C]), the chiller may
be piped in series. If load balancing is not
required, the units are controlled
independently. Chiller Number 1 will operate
up to full load when the system requirements
are within its capability.
If load balancing is required, special
programming and interconnecting wiring are
required. The load is progressive by
temperature so the chiller selections are
critical.

28

2.7.2.5

Water (Fluid) Strainers

It is recommended that 40-mesh strainers be installed


in the fluid piping as close to unit cooler as possible to
prevent plugging or damage to the tubes.

2.0 INSTALLATION (CONT.)


2.7.3

Cooler Design Data Guidelines

2.7.3.1

MaximumLCFT (Leaving Chilled Fluid


Temperature) is 50F (10C). The unit can start
and pull down with up to 90F (32.2C)
entering water temperature.

2.7.3.2

MinimumLCFT is 38F (3.3C) for all unit


models being applied to water applications
using standard coolers. Consult factory for
other operating conditions below 38F
(3.3C) or use ethylene or propylene glycol.

2.7.3.3

Operating
Leaving
Temperature
Applications using ethylene or propylene
glycol can be applied from 50 to 20F (10.0
to -6.7C).

2.7.3.4

Minimum/Maximum Flow Rates Data and


vessel fluid volume are found on page 31.

2.7.3.5c Three Pass Coolers are used for Wide Range


Applications, and have an effective chiller
operating chilled fluid temperature
difference range from 10 to 20F (5.6 to
11.1C).
2.7.3.6

Wide Range - Low Flow Chiller Operation


can be accomplished with a by-pass
recirculation method of piping, to allow the
chiller to operate with acceptable flow rates
as shown in Figure 26A. This is a suggested
arrangement and special engineering of
piping, valving, and sensor locations is
required to ensure proper operation.

2.7.3.7

For Extra Narrow and Wide Range


Applications a by-pass piping arrangement
can be used similar to Figure 26B. This is a
suggested arrangement and special
engineering of piping, valving, and sensor
locations is required to ensure proper
operation.

2.7.3.5a Two Pass Coolers are considered Standard


and are used for most Air Conditioning and
Process Applications. They have a chilled
fluid temperature difference range from 8
to 14F (4.4 to 7.8C).
2.7.3.5b Single Pass Coolers are used for Narrow
Temperature Range Applications, and have
a chilled fluid temperature difference range
from 3 to 10F (1.7 to 5.6C).

Figure 29A
RETURN
FLUID
COOLER

RECIRCULATED
PORTION OF FLOW

SUPPLY
FLUID

THERMOSTAT SENSOR

The mixed fluid temperature range through the cooler, for units with standard coolers, should not be less than 6F
(3.3C).
Figure 29B
RETURN
FLUID
COOLER

COOLER BYPASS
PORTION OF FLOW

SUPPLY
FLUID

ADDITIONAL SYSTEM
THERMOSTAT SENSOR

This fluid mixes after the cooler.


29

2.0 INSTALLATION (CONT.)


2.7.4

Chilled Fluid Loop Volume (CFLV)


Guidelines

Careful consideration needs to be given to the Chilled


Fluid Loop Volume (CFLV) or System / Inertia to
maintain an acceptable leaving fluid temperature.

will re-start and the chiller will again load up possibly


to 100% and pull the loop down again repeating the
short cycle pattern.

Small Loop Volume Systems may have temperature


control problems due to the small fluid volume in the
system. This System Inertia Problem is exaggerated
at low load conditions and causes chiller to short cycle.
The small fluid volume in the system will be pulled down
to setpoint in a very short period of time, and the chiller
will be shut down. The chiller's anti-recycle timer limits
the number of starts to three per hour. The system loop
temperature will warm up during this off cycle and may
require cooling before the anti- recycle timer has timed
out. Once the anti-recycle timer has timed out the unit

The System Loop Volume should be sized to limit the


temperature rise that can occur during the off cycle.
Air Conditioning Applications
The chilled fluid loop volume must be at least 3 gallons
per nominal ton of cooling (3.25 L per kW).
Process & Special Air Conditioning Applications
Where leaving fluid temperature is often more critical,
the chilled fluid loop volume should be increased to 6
to 10 gallons per ton (6.5 to 10.8 L per KW).

Quick ReferenceMinimum Chilled Fluid Loop Volume*

Table 30A
Model
030
040
050

Air Conditioning Applications


Gallons
Liters
900
3406
1200
4542
1500
5677

Gallons
1800
2400
3000

Process Applications
Liters
Gallons
6813
To
3000
9084
To
4000
11355
To
5000

Liters
11355
15140
18925

*Values based on nominal capacity at 10F (5.6C) chilled fluid temperature range.
Type of Application
Normal Air Conditioning
Process Cooling

Gal/Ton
3
6 - 10

L/KW
3.25
6.5 - 10.8

Gallons = Gal/Ton x ARI Capacity in Tons


Liters = L/KW x ARI capacity in KW

Tanks for System Volume Enhancement


It may be necessary to install a tank in the system to provide sufficient system fluid volume, as shown below.
Figure 30A

Single Loop System with Storage Tank to Increase Loop Volume


PUMP
COOLER

LOAD
TANK

Figure 30B

Primary and Secondary Loop Systems are normally used where the secondary system has variable
flow and/or multiple loads. See example below.
PUMP

COOLER

PERFORATED
DIVIDER

LOAD
PUMP

TANK

30

SINGLE or MULTIPLE LOAD SOURCES


WITH SINGLE or MULTIPLE PUMPS

LOAD

2.0 INSTALLATION (CONT.)


2.7.5

Flooded Cooler Water Side Pressure Drop

Figure 31

ENGLISH I.P. UNITS AND S. I. UNITS


FT of
KPa WATER
180 60
150

50

120

40

90

30

60

20

45

15

30
27
24

10
9
8

21

18

15

12

F5

F5

H6

F6 G6

K6

F5

GPM 100
L/S 6.3

200
12.6

Vessel
Code

Water Connection
Size (*)

F5
F6
G6
H6
K6
L6

10" VIC
10" VIC
12" VIC
12" VIC
14" VIC
14" VIC

F5
F6
G6
H6
K6
L6

8" VIC
8" VIC
8" VIC
10"VIC
10"VIC
10"VIC

F5
F6
G6
H6
K6
L6

6" VIC
8" VIC
8" VIC
8" VIC
8" VIC
8" VIC

300
19

400
25

F6

G6 H6

L6

K6

L6

F6 G6

H6

K6

L6

500 600 700 800 9001000


32 38 44 50 57 63

1500
95

Minimum
Maximum
GPM
GPM
Single Pass - Flooded Cooler
389
1946
481
2406
555
2777
671
3354
794
3970
994
4968
Two Pass - Flooded Cooler
201
939
243
1193
278
1389
344
1633
407
1936
507
2435
Three Pass - Flooded Cooler
135
606
164
733
192
861
227
997
284
1232
329
1535

2000
126

3000
189

Minimum
L/s

4000 5000 6000


252 315 379

Maximum
L/s

24.6
30.4
35.0
42.3
50.1
62.7

122.8
151.7
175.2
211.6
250.4
313.4

12.7
15.3
17.5
21.7
25.7
32.0

59.2
75.3
87.6
103.0
122.1
153.6

8.5
10.4
12.1
14.3
17.9
20.7

38.5
46.3
54.3
62.9
77.7
96.8

* Non-Metric Compliant
31

2.0 INSTALLATION (CONT.)


2.7.6

Condenser Water Side Pressure Drop

Figure 32

ENGLISH I.P. UNITS AND S. I. UNITS


FT of
KPa WATER
180 60
150

50

120

40

90

30

60

20

45

15

30
27
24

10
9
8

21

18

15

12

3
E7

D6
E6

G6

400
25

500 600 700 800 900 1000


32 38 44 50 57 63

1
GPM 100
L/S 6.3

200
12.6

Vessel
Code

Water Connection
Size (*)

D6
E6
E7
F6
G6
H6

6" VIC
8" VIC
8" VIC
8" VIC
10" VIC
10" VIC

* Non-Metric Compliant

32

H6

F6

300
19

Minimum
Maximum
GPM
GPM
Two Pass - Condenser
251
1146
291
1435
349
1495
409
1983
500
2262
602
2711

1500
95

2000
126

3000
189

Minimum
L/s
15.8
18.4
22.0
25.8
31.6
38.0

4000 5000 6000


252 315 379

Maximum
L/s
72.3
90.5
94.3
125.1
142.7
171.0

2.0 INSTALLATION (CONT.)

2.7.1

Cooling Tower Control and Condenser Application Design Data

2.7.7.1

Cooling Tower and Head Pressure Control


is imperative for proper trouble free chiller
operation. There are several methods of
tower and head pressure that we will discuss
below.

2.7.7.2

Condenser Water Temperature should


never go below 60F (15.6C) and its rate of
change should not be rapid. Rapid is defined
as not exceeding 2F (1.1C) per minute. If
this cannot be guaranteed, then other
controls such as tower dampers, tower sump
heater, 3-way tower bypass valve, 2-way
tower throttling valve or variable speed
condenser pumping must be utilized. 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 dynamics of
rapidly varying condenser water temperature
subjects the machine to fluctuating pressure
differentials across the cooler and condenser.
This varies the refrigerant flow and,
therefore, the capacity and efficiency of the
chiller. If this occurs faster than the machine
can accommodate, the head pressure or
suction pressure will soon exceed their safety
setpoints and the machine will shut down.
Through an optional analog output board,
the microcomputer can control the bypass
or throttling valve directly from condenser
pressure, by sending a 0 to 10 VDC signal to
a direct current, valve motor actuator.
The Dunham-Bush microcomputer can
provide a digital signal to enable the control
circuit of the tower.

2.7.7.3

Condenser Water Regulating Valves are a


desirable method of head pressure control,
because they respond directly to changes in
head pressure and provide the most stable
method of head pressure control. Stable
head pressure control allows the chiller to
operate at the best efficiency for the load
conditions.

2.7.7.4

Cooling Tower and Head Pressure Control


can be attained via fan cycling if the tower is
rated at the same capacity as the chiller, and
the machine will operate at design conditions
under heavy load. On multiple chiller
installations, a single tower may be sized,
for a multiple of the individual chillers. If this
is true and only one machine is running, the

tower is then oversized, relative to the


individual chiller needs, and head pressure
control becomes a challenge. On other
installations, the tower/chiller might be
oversized to the design load and the machine
and tower frequently cycle under light loads.
Under these conditions, fan cycling might
result in very rapid temperature swings,
which creates a dynamic situation that
occurs faster than the chiller control system
can accommodate. Variable speed fans or
modulating valve control should be used to
maintain system stability.
2.7.7.5

Condenser Water Pump must be controlled


by the chiller to ensure there is no condenser
water flow until start-up.

2.7.7.6

Fan Cycling Tower Control is one method


of head pressure control, but this type of
control does not work for all systems. We
recommend that the condenser water pump
control through the unit interlock, in the
chiller control panel, be used to enable and
disable the condenser water pumps. We
further recommend that the designer
carefully evaluate the system to determine a
precise method of tower fan and water pump
temperature control for the most efficient
method of head pressure control.

2.7.7.6.1 MinimumECWT (Entering Condenser


Water Temperature) is 60F (15.6C) to start
the unit, and maintain head pressure control
for proper unit operation. The water
temperature change rate must be less than
2F (1.1C) per minute to assure proper chiller
operating stability. This is necessary because
it operates in a dynamic environment. Head
pressure through water regulating control
valves or bypass piping should be used where
lower ECWT is expected.
2.7.7.6.2 MaximumECWT (Entering Condenser
Water Temperature) is 95F (35C) without
loss of unit capacity or potential high
condensing temperature/pressure shutdown.
The water temperature change rate must be
less than 2F (1.1C) per minute to assure
proper chiller operating stability. For higher
condenser entering water temperature,
consult the factory.
2.7.7.6.3 Unit Operating Efficiency and trouble free
operation is greatly influenced by the
entering condenser water temperature,
proper flow, and the mean temperature of
the condenser water.

33

2.0 INSTALLATION (CONT.)

2.7.7.6.4 Minimum/Maximum Flow Rates Data and


vessel fluid volume are shown on page 32.

Table 34A

Ethylene Glycol

2.7.7.6.5 Condenser Water Pressure Drop Data is


shown on page 32.
2.7.7.6.6 Wide Condenser Water Temperature
Ranges for units operating with 95 ECWT
(35C) and higher, and wider than 10F
(5.6C) range, increases the unit condensing
temperature and decreases the unit
efficiency. This situation is usually found in
applications with undersized condenser
water towers.

FREEZE POINT
% E.G.
By Mass

10

26.2

-3.2

15

22.2

-5.3

20

17.9

-7.9

25

12.7

-10.8

30

6.7

-14.1

35

-0.2

-17.8

40

-8.1

-25.8

45

-17.5

-27.5

50

-28.9

-33.8

2.7.7.6.7 Narrow Condenser Water Temperature


Ranges are desirable for unit efficiency,
because it reduces the mean condensing
temperature.

2.7.8

Glycol Freeze Protection

If the chiller or fluid piping may be exposed to


temperatures below freezing, glycol protection is
recommended if the water is not drained. The
recommended protection is 10F (5.6C) 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 antifreeze.
If the equipment is being used for applications below
38F (3.3C), glycol should be used to prevent freeze
damage. The freeze protection level should be 10F
(5.6C) lower than the leaving brine temperature.

2.7.9

Water Quality

Coolers used in these packages are made of steel, copper


and brass and are suitable for operation with wellmaintained water systems. However, if the water used
in cooler is corrosive, high in mineral content or
entrained solids, the water can cause reduced
performance and even failure of heat exchangers.
Therefore, it may be necessary to obtain the services of
a water treatment consultant and to provide and
maintain water treatment. This is particularly important
with glycol systems.
See Maintenance Section 4.0 Paragraph 4.4 for
maintenance of heat exchangers.

34

Table 34B

Propylene Glycol
FREEZE POINT
% P.G.
by Mass

10

26.1

-3.3

15

22.9

-5.1

20

19.2

-7.2

25

14.7

-9.7

30

9.2

-12.8

35

2.4

-16.6

40

-6.0

-21.3

45

-16.1

-27.0

50

-28.3

-33.8

2.0 INSTALLATION (CONT.)


2.8

Typical Refrigerant Piping

LEGEND
12
11

CONDENSER

13

10
2

1
9

OIL
SEPARATOR

21

LOAD/UNLOAD BLOCK

COMPRESSOR

DISCHARGE LINE

20

LIQUID LINE

19

COMPRESSOR OIL SUPPLY


OIL RETURN LINE

18
7

16

15

14

SUCTION LINE

17

DISCHARGE CHECK VALVE

SERVICE VALVE

MODULATING BALL VALVE

MODUTROL MOTOR

CHARGING VALVE

LIQUID LEVEL FLOAT SWITCH

SUCTION CHECK VALVE

ISOLATION VALVE

SUCTION STRAINER

10

OIL PUMP

11

FILTER

12

ISOLATION VALVE

13

PRESSURE REGULATOR

14

OIL RETURN VALVE

15

FILTER DRIER

16

ISOLATION VALVE

17

CHECK VALVE

18

SIGHT GLASS

19

JET PUMP

20

HOT GAS VALVE

21

LOAD/UNLOAD BLOCK ASSEMBLY

UNLOAD SOLENOID VALVE

LOAD SOLENOID VALVE

COOLER

2.9

Electrical Connections

All units are wired as completely as possible at the


factory prior to deliver. The connections which must be
made by the installer are to the main power source,
control power source, starting equipment and
interlocking the satellite equipment. In connecting
power wiring to the unit, the following precautions
should be taken:
All field wiring is to be in accordance with the
National Electrical Code and state and local codes.

terminal blocks are to be connected with copper


conductors only, 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 valve and voltage
imbalance between phases must not exceed 2%.
For minimum circuit ampacity and maximum fuse
size, see Unit Nameplate.

All wiring is to be checked for damage and all


terminal connections tested for tightness. Unit
35

2.0 INSTALLATION (CONT.)


2.9.1

Unit Electrical Data

Motor Size (HP)


Motor Class
Compressor Motor Code
460/3/60
FLA
LRA
Y-D START
S S START
MFS
MCA
FL EFF
575/3/60
FLA
LRA
Y-D START
S S START
MFS
MCA
FL EFF
2300/3/60
FLA
LRA
MFS
MCA
FL EFF
460V - oil pump
MFS
460V - oil pump
MCA
4160/3/60
FLA
LRA
MFS
MCA
FL EFF
460V - oil pump
MFS
460V - oil pump
MCA
400/3/50
FLA
LRA
Y-D START
S S START
MFS
MCA
FL EFF
3300/3/50
FLA
LRA
MFS
MCA
FL EFF
400V - oil pump
MFS
400V - oil pump
MCA
Oil Pump Data
400/3/50
FLA
460/3/60
FLA
575/3/60
FLA
Notes:
a.
b.
c.
d.

36

200
STD
E
221
1580
527
442
350
280
94.7
177
1264
421
354
300
224
94.7
45.2
326
70
57
94.0
15
13
25
196
40
32
94.0
15
13
259
1620
540
518
450
329
94.6
32
186
50
40
93.0
15
13

200
PREM
E
225
1450
483
450
350
285
95.7
178
1160
387
356
300
226
95.7
45
340
70
57
94.6
15
13
25
205
40
32
94.6
15
13
232
1523
508
464
400
295
94.7
32
195
50
40
93.6
15
13

250
STD
F
283
1644
548
566
450
358
94.0
226
1315
438
453
350
286
94.0
56
364
90
70
94.0
15
13
31
218
50
39
94.0
15
13
323
1680
560
646
500
409
94.0
40
204
70
50
93.0
15
13

250
PREM
F
277
1825
608
554
450
350
95.8
224
1440
480
448
350
283
95.8
55
380
90
69
94.6
15
13
30.5
228
50
39
94.6
15
13
285
1916
639
570
500
361
94.8
40
212
70
50
93.6
15
13

4.6
3.7
2.72

4.6
3.7
2.72

4.6
3.7
2.72

4.6
3.7
2.72

300
300
STD PREM
G
G
335
325
2197 2200
732
733
670
650
500
500
423
410
94.6 96.1
268
260
1760 1760
587
587
536
520
450
450
338
328
94.6 96.1
67
66
459
485
110
110
84
83
94.1 94.8
15
15
13
13
37.1 36.6
276
291
60
60
47
46
94.1 94.8
15
15
13
13
390
335
2240 2310
747
770
780
670
600
500
493
424
94.2 95.1
48
48
270
285
80
80
60
60
93.1 93.8
15
15
13
13

350
350
STD PREM
H
H
387
378
2501 2550
834
850
774
756
600
600
488
477
95.3 96.2
309
302
2000 2040
667
680
618
605
500
500
389
381
95.3 96.2
77.3
77
520
580
125
125
97
97
94.2 95.2
15
15
13
13
42.8
42
312
350
70
70
54
53
94.2 95.0
15
15
13
13
450
389
2540 2678
847
893
900
778
700
600
568
491
94.3 95.2
56
55
280
320
90
90
70
69
93.2 94.1
15
15
13
13

400
STD
J
440
3110
1037
880
700
554
94.9
352
2490
830
704
600
443
94.9
87.7
575
150
110
94.5
15
13
48.4
345
80
61
94.5
15
13
512
3150
1050
1024
800
645
94.3
63
305
110
79
93.8
15
13

400
PREM
J
428
2900
967
856
700
539
96.1
342
2320
773
685
600
431
96.1
87
616
150
109
95.2
15
13
48
370
80
60
95.2
15
13
441
3045
1015
882
700
556
95.1
62
350
100
78
94.4
15
13

450
STD
K
494
3550
1183
988
800
622
95.0
395
2840
947
790
600
497
95.0
98.5
653
150
124
94.8
15
13
54.5
392
90
69
94.8
15
13
580
3580
1193
1160
1000
730
94.6
71
374
110
89
94.0
15
13

450
PREM
K
476
3220
1073
952
800
599
96.2
380
2600
867
760
600
478
96.2
98
691
150
123
95.2
15
13
54
415
90
68
95.2
15
13
491
3381
1127
982
800
619
95.2
70
400
110
88
94.4
15
13

4.6
3.7
2.72

4.6
3.7
2.72

4.6
3.7
2.72

4.6
3.7
2.72

4.6
3.7
2.72

4.6
3.7
2.72

400V, 460V, and 575V units will be provided with control power
transformers in the starter for single power connection.
400/460/575 Volt Motors, the 84 dba Motor is standard
2300V and 4160V units will require a separate 460/3/60 service
for oil pump and control transformer.
3300V units will require a separate 400/3/50 service for oil
pump and control transformer.

4.6
3.7
2.72

4.6
3.7
2.72

500
500
STD PREM
L
L
544
526
3900 3600
1300 1200
1088 1052
800
800
684
662
95.3 96.5
435
421
3120 2900
1040
967
870
842
700
700
547
529
95.3 96.5
108.2
108
738
766
175
175
136
135
95.3 95.2
15
15
13
13
59.8
59
443
460
100
100
75
74
95.3 95.6
15
15
13
13

4.6
3.7
2.72

4.6
3.7
2.72

Legend:
FLA - Full Load Amps
LRA - Locked Rotor Amps
MCA - Minimum Circuit Ampacity
MFS - Maximum Fuse Size
FL EFF - Full Load Efficiency
SS Start - Solid State Starting (Standard Starting Method)
Y-D Start - Y Delta Starting (Optional Starting Method)

2.0 INSTALLATION (CONT.)


2.9.2

Electrical Field Connection Data

Motor Size (HP) (Standard [S] and Premium [P])


Compressor Motor Code

200 250 [S] 250 [P] 300 [S] 300 [P]


350 400 [S] 400 [P] 450 [S] 450 [P]
500
ES & EP
FS
FP
GS
GP
HS & HP
JS
JP
KS
KP
LS & LP

Unit Mounted - Solid State Starters ONLY


460/3/60

Terminal Block
"Standard"
Circuit Breaker
"Optional"
Fused Disconnect
"Optional"

575/3/60

Terminal Block
"Standard"
Circuit Breaker
"Optional"
Fused Disconnect
"Optional"

400/3/50

Terminal Block
"Standard"
Circuit Breaker
"Optional"
Fused Disconnect
"Optional"

# of Conductors (4)
Wire Range
Trip Amps
# of Conductors (4)
Wire Range
Rating in amps
# of Conductors (4)
Wire Range
# of Conductors (4)
Wire Range
Trip Amps
# of Conductors (4)
Wire Range
Rating in amps
# of Conductors (4)
Wire Range
# of Conductors (4)
Wire Range
Trip Amps
# of Conductors (4)
Wire Range
Rating in amps
# of Conductors (4)
Wire Range

2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
250A
1
#6-350
400A
1
#2-600
2
#6-350
400A
2
3/0-500
400A
1
#2-600

2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
600A
2
3/0-500
600A
2
#2-600

2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
400A
2
3/0-500
400A
1
#2-600

2
#6-350
600A
2
3/0-500
600A
2
#2-600
2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
600A
2
3/0-500
600A
2
#2-600

2
#6-350
600A
2
3/0-500
600A
2
#2-600
2
#6-350
400A
2
3/0-500
400A
1
#2-600
2
#6-350
600A
2
3/0-500
600A
2
#2-600

2
#6-350
600A
2
3/0-500
600A
2
#2-600
2
#6-350
600A
2
3/0-500
600A
2
#2-600
2
#2-600
600A
2
3/0-500
600A
2
#2-600

2
#2-600
600A
2
3/0-500
600A
2
#2-600
2
#2-600
600A
2
3/0-500
600A
2
#2-600
2
#2-600
800A
3
#1-500
600A
3
#1-500

2
#2-600
600A
2
3/0-500
600A
2
#2-600
2
#2-600
600A
2
3/0-500
600A
2
#2-600
2
#2-600
600A
2
3/0-500
600A
2
#2-600

2
#2-600
800A
3
#1-500
800A
3
#1-500
2
#2-600
600A
2
3/0-500
600A
2
#2-600
2
#2-600
800A
3
#1-500
800A
3
#1-500

2
#2-600
800A
3
#1-500
800A
3
#1-500
2
#2-600
600A
2
3/0-500
600A
2
#2-600
2
#2-600
800A
3
#1-500
800A
3
#1-500

2
#2-600
800A
3
#1-500
800A
3
#1-500
2
#2-600
600A
2
3/0-500
600A
2
#2-600
NA
NA
NA
NA
NA
NA
NA
NA

2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600

2
#1-500
800A
3
#1-500
CF
CF
CF
2
#1-500
600A
2
3/0-500
600A
2
#2-600
4
#2-600
800A
3
#1-500
CF
CF
CF

2
#1-500
800A
3
#1-500
CF
CF
CF
2
#1-500
600A
2
3/0-500
600A
2
#2-600
4
#2-600
800A
3
#1-500
CF
CF
CF

2
#2-600
800A
3
#1-500
CF
CF
CF
2
#1-500
600A
2
3/0-500
600A
2
#2-600
NA
NA
NA
NA
NA
NA
NA
NA

4
#4-500
600A
2
250-500
600A
2
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600

4
#4-500
800A
3
2/0-400
800A
4
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600
4
#4-500
800A
3
2/0-400
800A
4
#2-600

4
#4-500
800A
2
250-500
800A
2
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600
4
#4-500
800A
3
2/0-400
800A
4
#2-600

4
#4-500
800A
3
2/0-400
800A
4
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600
NA
NA
NA
NA
NA
NA
NA
NA

Unit Mounted - Wye Delta Starters ONLY


460/3/60

Terminal Block
"Standard"
Circuit Breaker
"Optional"
Fused Disconnect
"Optional"

575/3/60

Terminal Block
"Standard"
Circuit Breaker
"Optional"
Fused Disconnect
"Optional"

400/3/50

Terminal Block
"Standard"
Circuit Breaker
"Optional"
Fused Disconnect
"Optional"

# of Conductors (4)
Wire Range
Trip Amps
# of Conductors (4)
Wire Range
Rating in amps
# of Conductors (4)
Wire Range
# of Conductors (4)
Wire Range
Trip Amps
# of Conductors (4)
Wire Range
Rating in amps
# of Conductors (4)
Wire Range
# of Conductors (4)
Wire Range
Trip Amps
# of Conductors (4)
Wire Range
Rating in amps
# of Conductors (4)
Wire Range

2
#2-300
400A
2
3/0-500
400A
1
#2-600
2
#3-2/0
250A
1
#6-350
400A
1
#2-600
2
#2-300
400A
2
3/0-500
400A
1
#2-600

2
#1-500
400A
2
3/0-500
400A
1
#2-600
2
#2-300
400A
2
3/0-500
400A
1
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600

2
#1-500
400A
2
3/0-500
400A
1
#2-600
2
#2-300
400A
2
3/0-500
400A
1
#2-600
2
#2-300
400A
2
3/0-500
400A
1
#2-600

2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#2-300
400A
2
3/0-500
400A
1
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600

2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#2-300
400A
2
3/0-500
400A
1
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600

2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600

2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#1-500
600A
2
3/0-500
600A
2
#2-600
2
#1-500
800A
3
#1-500
CF
CF
CF

Remote Mounted - Wye Delta Starters ONLY


460/3/60

Terminal Block
"Standard"
Circuit Breaker
"Optional"

# of Conductors (4)
2
2
2
2
4
Wire Range
#6-250 #6-250 #6-250 #6-250 #4-500
Trip Amps
400A
400A
400A
600A
600A
# of Conductors (4)
2
2
2
2
2
Wire Range
3/0-250 3/0-250 3/0-250 250-500 250-500
Fused Disconnect
Rating in amps
400A
400A
400A
600A
600A
"Optional"
# of Conductors (4)
1
1
1
2
2
Wire Range
#2-600 #2-600 #2-600 #2-600 #2-600
575/3/60
Terminal Block
# of Conductors (4)
2
2
2
2
2
"Standard"
Wire Range
#6-250 #6-250 #6-250 #6-250 #6-250
Circuit Breaker
Trip Amps
250A
400A
400A
400A
400A
"Optional"
# of Conductors (4)
1
2
2
2
2
Wire Range
#6-350 3/0-250 3/0-250 3/0-250 3/0-250
Fused Disconnect
Rating in amps
400A
400A
400A
400A
400A
"Optional"
# of Conductors (4)
1
1
1
1
1
Wire Range
#2-600 #2-600 #2-600 #2-600 #2-600
400/3/50
Terminal Block
# of Conductors (4)
2
2
2
4
4
"Standard"
Wire Range
#6-250 #6-250 #6-250 #4-500 #4-500
Circuit Breaker
Trip Amps
400A
600A
400A
600A
600A
"Optional"
# of Conductors (4)
2
2
2
2
2
Wire Range
3/0-250 250-500 3/0-250 3/0-500 250-500
Fused Disconnect
Rating in amps
400A
600A
400A
600A
600A
"Optional"
# of Conductors (4)
1
2
1
2
2
Wire Range
#2-600 #2-600 #2-600 #2-600 #2-600
Notes:
1.
All field wiring used to connect the
Chillers must be Copper.
2.
Wire sizes 250 and larger are Kcmil.
3.
Remote mounted Medium Voltage Starters provided with Buss-Bar connections.
4.
Number of conductors per pole.

4
#4-500
600A
2
250-500
600A
2
#2-600
2
#6-250
400A
2
3/0-250
600A
2
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600

4
#4-500
600A
2
250-500
600A
2
#2-600
4
#4-500
600A
2
250-500
600A
2
#2-600
4
#4-500
800A
3
2/0-400
800A
4
#2-600

NA = Not Available
CF = Consult Factory

37

2.0 INSTALLATION (CONT.)

2.9.3 Power Wiring Diagram: Typical Solid State Unit Mounted Starter

FURNISHED
NOT FURNISHED

FURNISHED
NOT FURNISHED

JUMPERS DENOTED AS IN/OUT ARE 2 PIN JUMPERS.

022343 SH 5 OF 8

38

2.0 INSTALLATION (CONT.)

2.9.3 Power Wiring Diagram: Typical Solid State Unit Mounted Starter

022343 SH 6 OF 8

39

2.0 INSTALLATION (CONT.)

2.9.4 Power Wiring Diagram: Typical Wye-Delta Unit Mounted Starter

40

2.0 INSTALLATION (CONT.)

2.9.4 Power Wiring Diagram: Typical Wye-Delta Unit Mounted Starter

MECHANICAL INTERLOCK

LEGEND
1A
AM
CB
CR
CT
DIS
FU
GF
J
M
O/L
OV
S
T
TR
UV

96

RESISTOR
CONTACTOR
AMMETER
CIRCUIT
BREAKER
CONTROL
RELAY
CURRENT
TRANSFORMER
DISCONNECT
FUSE
GROUND
FAULT
JUMPER
CONTACTOR
OVER
LOAD
OVER
VOLTAGE
SHORTING
CONFACTOR
TRANSFORMER
TRANSITION
TIMER
UNDER
VOLTAGE

14

84

022343 SH 8 OF 8

41

2.0 INSTALLATION (CONT.)

2.9.5 Typical Control Wiring Diagram


115VAC
1TB
GND
10AWG
1

10AWG

5FU

15A

6FU

15A

4CR-2

SEE NOTE 1

4CR-1

750W

1 HTR

OIL SUMP HTR 1

750W

2 HTR

OIL SUMP HTR 2

2
Y

7FU

20
BLK

S1

10A

CONTROL
POWER

WHT
4T

24V
T1

T2

52

10
11

115VAC
1

12
13

2T
7

15

12VAC

8FU

14
15

12

4A

17

9FU

18

16
DIGITAL
I/O BOARD
(DI\OB)

12 VAC

16

18

20

19

COMP
STARTER
AUX

20

CWP*

RIBBON CABLE
TO MICRO COMPUTER

5TB
65

GND

57

1H

41
SH

1N

1DI

STARTER AUXILIARY

1CPR

SEE NOTE 10

20

J1

+12VDC

TO MICROCOMPUTER

17

11

CWFS

12

2H

21
20

22

21

3H

2DI

3DI

23

CHILLED WATER

2N

FLOW SWITCH

2CPR
3N

UNIT CONTROL CONTACTS

3CPR

4H

24
25

4DI

4N

5DI

5N

6DI

6N

7DI

7N

5H

26
6H

27
28

SEE
LINE 52

12CP

51

BLK

SEE
LINE 54

13CP

WHT

4MTR

LEVEL CONTROL
MOD MOTOR

50

RED

COMP
STARTER
FAILURE

COMP
SWITCH

29

S2

10

OIL
PUMP
OVERLOAD
RELAY
13

OIL
PUMP AUX
14 SWITCH

23

30
28

31

1C

2C

33
34

10K

1CP

25

1NO

1SN

2CR

2SN

32

1RES

7H

2CP

2NO

26

1SOL

3NO

27

2SOL

COMP START RELAY


(39,50)

LOAD SOLENOID

3SN

3C

35
36

3CP

5C

5CP

5NO

4C

4CP

4NO

UNLOAD SOLENOID

28

37
38

2CR-1

COMP
STARTER

39
14

40

34

41
20

42

6C

6CP

6NO

8C

45

20

8H

101

2CR-2

20
102

19

9H

20

CONDENSER PUMP
INTERLOCK

103

5CR

105

6CR

9C
10C

60
61
62

42

9DI

9N

9CP

9NO

35

10NO

36

10CP

7SN

4CR
1LT

104

CONDENSER FLOW
SWITCH
HEATER CONTROL
(2,4)
ALARM LIGHT
ALARM RELAY (54)

8SN
11C

11CP

11NO

6CR

37
9SN

106

57

59

ICE BUILD MODE

5CR

ALARM

55

58

HOT GAS BYPASS


(OPTION)

5CPR

52

56

CHILLER PUMP INTERLOCK


(60)

33

8N

8DI

48

54

8NO

4CPR

47

53

OIL PUMP STARTER

5SN

8CP

46

51

3CR

29

6SN

44

50

COMP STARTER CIRCUIT

4SN

43

49

WARNING

2 RELAY (57)

10SN

PROACTIVE WARNING
NOTE 14
107

3CR

50

13C

13NO

52

14NO

51

11SN

108
14C

CHILLER PUMP
INTERLOCK

13CP

14CP

4MTR OPEN
SEE LINE 9

4MTR CLOSE

022343 SH 1 OF 8

2.0 INSTALLATION (CONT.)

2.9.5 Typical Control Wiring Diagram


RIBBON CABLE
TO DIGITAL I/O BOARDS

RIBBON CABLE
TO ANALOG I/O BOARDS

63
64

J3

65

J2

MICROCOMPUTER
(MCB)

RS485
J5

DISPLAY

RS232

66

J6

67

NAME

1 TLW TEMP.
2 RAMP UP
3 AMP LIMIT
4 PWR LOSS
5 HI/LO PRESSURE
6 ICE/FREEZE
7 H.G. BYPASS
8 OIL PRESSURE

TLW
F
0.1
(UNLOAD)

20.0%
(HOLD)
0.0
SEE TABLE
SEE TABLE
10.0%
25.0 PSID

245 PSIG
25.0%
26.0 PSID

9
10 CWR MAX. 0-5VDC
11 DEMAND LIMIT
15 LEAK DETECT
16 CND VALVE

190 PSIG

ANTIRECYCLE

20 MIN.

17

0.0
0.0
1900 PPM
160 PSIG

2000 PPM

18

KEYBOARD

69
70

INSTRUCTIONS

71

PRESS HELP KEY FOR BASIC


OPERATION INSTRUCTIONS.

72

TO DISPLAY CONTROL VALUE

73

1) PRESS MENU KEY TO DISPLAY


MENU ITEM.
2) USE UP OR DOWN ARROW TO
MOVE TO DESIRED MENU ITEM.
3) PRESS ENTER KEY TO SELECT
DESIRED MENU ITEM.
4) USE UP OR DOWN ARROW TO
DISPLAY DESIRED CONTROL VALUE.

74
75
76

SET POINT TABLE

12VAC

J7

68

SET POINTS

FOR MORE INFORMATION

77

SEE OWNERS MANUAL.

78
79
AI BOARD #1
(1AIB)
5AI

80
81
82

SI. SOFTWARE OPTION


FURNISHED
NOT FURNISHED

83

1
2
3
4
5
6
7
8
9
10
11
15
16

85

20.0%
(HOLD)
0.0
SEE TABLE
SEE TABLE
10.0%
1.80 BARS

86

A
TLW C
0.1
(UNLOAD)

TLW TEMP
RAMP UP
AMP LIMIT
POWER LOSS
HI/LO PRESSURE
ICE/FREEZE
H.G. BYPASS
OIL PRESSURE

16.90 BARS
-5.5 C
25.0%
1.90 BARS

CWR MAX. 0-5VDC


DEMAND LIMIT
LEAK DETECT
CNDVALVE
ANTIRECYCLE

2000 PPM
13.10 BARS
20 MIN.

64

BLK

66

0.0
0.0
1900 PPM
11.00 BARS

SET POINT TABLE

1PT
COOLER
PRESSURE
(0-200 PSIG)

GRN

67

WHT 41

2PT
DISCHARGE
PRESSURE
(0-500 PSIG)

(4TB)
64
(3TB)

GRN

68

SH

94
95

RED 64
3PT
OIL
PRESSURE
(0-500 PSIG)

GRN

2AI

WARNING

7TS
DISCHARGE
TEMP

100

(3TB)

3AI
7AI

(4TB)

(3TB)
(4TB)

64

BLK

WHT

70

BLK

41

WHT

4AI

(4TB)

102

9AI
(#1)
6RES
100K

GND

103
1LS
REFRIGERANT
LEVEL
SENSOR

106

65

RED

BLK

WHT
SH

GND

(5TB)

83
41

12AI
(#4)

RED
BLK

41

WHT

3TB
64

WHT

41

SH

(5TB)

5ZD

(5TB)

GND

3ZD

4ZD

LAST WIRE NUMBER 87, 101-108

41 (-)

WHT

(3TB)

JUMPER ON
ADDRESS #2

80 (+)

BLK

(#5)

GND

(4TB)

64

RED

82

BLK

41

WHT

NOTES

45678-

FUSES SHALL BE TIME DELAY TYPE.


ALL FIELD WIRING SHALL COMPLY WITH LOCAL, STATE AND NATIONAL CODES.
WHEN CONTROL TSF IS NOT SUPPLIED, A DIRECT CONNECTED
115VAC CONTROL CIRCUIT WITH OVERCURRENT PROTECTION AT 30A OR LESS
(FIELD SUPPLIED) IS REQUIRED. USE #10 AWG COPPER
CONDUCTORS. WIRE TO 1TB. USE TERMINAL #2 FOR CONNECTION OF THE
GROUND SUPPLY CONDUCTOR.
DISCONNECT MEANS AND BRANCH CIRCUIT PROTECTION SHALL BE PROVIDED
BY INSTALLER
IF POWER SUPPLY HAS BEEN INTERRUPTED FOR A PROLONGED PERIOD,
OIL SUMP HEATERS MUST BE ENERGIZED FOR 24 HOURS MINIMUM BEFORE
STARTING COMPRESSORS.
USE COPPER CONDUCTORS ONLY. CONTROL WIRING 14AWG.

CUSTOMER CONTROL CONTACTS MUST BE WIRED BETWEEN 20 & 21.


THE CONTACTS MUST CLOSE TO START THE UNIT.
IF 0-5VDC CWR IS USED, SET SETPOINT 10B
TO RESET DESIRED AT 5VDC INPUT.

CAUTION: DO NOT SUPPLY OVER 5.0VDC TO 11AI.


9-

IF 0-5VDC DEMAND LIMIT IS USED, SET


SETPOINT 11B BETWEEN 0.0 AND 10.0. MAX
DEMAND LIMIT OCCURS WITH A 10.0 SETTING

CAUTION: DO NOT SUPPLY OVER 5.0VDC


TO 12AI.

10- ALL FIELD CONTROL WIRING SHOULD UTILIZE


SHIELDED WIRE. GROUND SHIELD TO
SUBPANEL OR SH TERMINAL (IF SHOWN) ONLY.
DO NOT ROUTE WITH HIGH VOLTAGE WIRES.
11-

VALUES OF % GLYCOL ARE BY


MASS OF ETHYLENE
OR PROPYLENE GLYCOL.

12- IF CONDENSER FLOW SWITCH IS


USED, FLOW MUST BE ESTABLISHED
WITHIN 20 SEC. OF COMP. START
IF NOT USED, JUMPER TERMINAL 19 & 20.
13- CLOSE CONTACTS FOR ICE BUILD MODE.
UNIT WILL GO TO FULL LOAD UNTIL LEAVING
BRINE REACHES SETPOINT 6A. THEN UNIT WILL
SHUT DOWN UNTIL CONTACTS ARE OPENED.
14- PROACTIVE WARNING CONTACT CLOSES WHEN
UNIT IS UNLOADING DUE TO HIGH DISCHARGE
PRESSURE, LOW SUCTION PRESSURE, HIGH
COMP MOTOR AMPS, OR REFRIGERANT LEAK
DETECT.

GROUND

CW (OPEN)

4MTR
INDICATOR
CCW (CLOSED)

SH

LEGEND
AI
CND
COMP
CP
CPR
CR
CW
CWFS
CWP
CWR
DI
ETM

123-

4TB

79 (+)

GRN

13AI

2TS
SUMP
TEMPERATURE (HI)

SH
BLK

(3TB)

10AI
(#2)

CCW (0%)

71

+5

11AI
(#3)

SLIDE POSITION
INDICATOR

64

GND

(3TB)

CW (100%)
W

SH

AI BOARD #2
(2AIB)

81

SH

101

105

RED

(4TB)

(3TB)
69

64

RIBBON CABLE

99

104

6AI
(3TB)

97
98

COMPRESSOR CURRENT
SIGNAL FROM
POWER PANEL

(-)

SH

WHT 41
(3TB)
SH
(4TB)

96

GND

(3TB)

RED

92
93

41

WHT

(3TB)

WHT 41
(3TB)

91

(+)
4-20 MA

(3TB)

64
(3TB)

SH

40

BLK

250
2RES

(4TB)

RED

88

90

1AI

SH

87

89

(3TB)

41

WHT

84

SETPOINTS
NAME

1TS
LEAVING
COOLER
WATER
TEMP (LO)

RED

FS
FU
GFI
GND
HTR
I/O
LS
LT
M
MTR
NC
NO
OL
PPM
PT
RES
S
SH
SN
SOL
TAS
TB
TLW
TR
TS
TSF
TSM
ZD

ANALOG INPUT
CONDENSER
COMPRESSOR
CONTROL POINT
CAPACITOR
CONTROL RELAY
CLOCKWISE (POINTER END)
CHILLED WATER FLOW SWITCH
CHILLED WATER PUMP
CHILLED WATER RESET
DIGITAL INPUT
ELAPSED TIME METER
FLOAT SWITCH
FUSE
GROUND FAULT INTERUPT
GROUND
HEATER
INPUT/OUTPUT
LEVEL SENSOR
LIGHT
CONTACTOR
MOTOR
NORMALLY CLOSED
NORMALLY OPEN
OVERLOAD
PARTS PER MILLION
PRESSURE TRANSDUCER
RESISTOR
SWITCH
SHIELD
SNUBBER
SOLENOID
THERMOSTAT
TERMINAL BLOCK
TEMP LEAVING WATER
TIMER
TEMP. SENSOR
TRANSFORMER
TRANSMITTER
(5.1VDC)
ZENER DIODE
MANUAL RESET
FACTORY TERMINAL
FIELD WIRING
FIELD SUPPLIED

022343 SH 2 OF 8

43

2.0 INSTALLATION (CONT.)

2.9.5 Typical Control Wiring Diagram: Options

CHILLER LINK OPTION


FURNISHED
NOT FURNISHED

RS232 CABLE

DOOR LATCH

20

115V

SOLENOID OPTION

TO MCB J6

FURNISHED
NOT FURNISHED
1

8SOL

1B

KEY
SWITCH

PORT
B

3T
CLASS 2

24V
GND
24VAC

CONTROL
DOOR

TO COMMUNICATION

PORT
A

9SOL

SYSTEM

POWER DOOR

CHILLER LINK

MODEM OPTION
FURNISHED
NOT FURNISHED
RS232 CABLE
8
GND

TO MCB J6

2
BLK

CONDENSER WATER
CONTROL OPTION

RIBBON CABLE

WHT

MODEM

TELEPHONE

FURNISHED
NOT FURNISHED

TO MCB J3

LINE

POWER
OUTLET

ANALOG
OUTPUT
BOARD
(AOB)
17

85

2AO

12VAC

41
GND

18

WATER TEMPERATURE OPTION

AI BOARD #2
(2AIB)
4TS
ENTERING
COOLER
WATER
TEMP (LO)

5TS
LEAVING
CONDENSER
WATER
TEMP (HI)

6TS
ENTERING
CONDENSER
WATER
TEMP (HI)

RED

64

BLK

73

WHT

41

RED

64

BLK

74

WHT

41

RED

64

BLK

75

WHT

41

+5

RIBBON CABLE

(-)

0-5 VDC
OR 0-10VDC
SET BY
JUMPER JP2

SH

JUMPER ON
ADDRESS #5

FURNISHED
NOT FURNISHED

(+)

R22 LEAK DETECTOR OPTION


FURNISHED
NOT FURNISHED

TO MCB J3

R22 DETECTOR

14AI
(#1)

AI BOARD #3
(3AIB)

GND

+5

17AI
(#1)

15AI
(#2)

GND
JUMPER ON
ADDRESS #3

GND

(5TB) 65

RED

(5TB) 41

WHT

12VAC/DC
IN

84 BLK

Vo
GND

(5TB) SH

+5
16AI

HOT GAS BYPASS


OPTION

(#3)

GND

ALARM BELL OPTION


FURNISHED
NOT FURNISHED

FURNISHED
NOT FURNISHED
33

7SOL

2
36

ALARM

022343 SH 3 OF 8

44

2.0 INSTALLATION (CONT.)

2.9.6 Typical Optional Interconnection Wiring Diagram

PCXI
1TB
1
2

#10 AWG*

2TB-1
4
9
10

SEE NOTES: 1,2


CWFS
CWP
OPTIONAL
CDFS

OIL PUMP 0/L RELAY

STARTER AUX CONTACT

OIL PUMP AUX SWITCH


OIL PUMP STARTER

(-)
DEMAND
LIMIT
0-5VDC
(+)

(+)

(-)
CWR
0-5VDC

NOTE 5

CONDENSER
PUMP NOTE 4
INTERLOCK
ALARM
CONTACT

AUX
CDFS
CTXD
CWFS
CWP
CWR
GND
O/L

34
40
41
57

79
80
85
101
102
103
104
105

WARNING
CONTACT
CHILLER PUMP
INTERLOCK

STARTER AUX CONTACT

57

(+)

CONDENSER
WATER
CONTROL
OPTION

CTXD 4-20mA DC (-)


NOTE 3

SH

20

23

CTXD 4-20mA DC (+)

40
41
41

10

13
14

OIL PUMP AUX SWITCH

14
19
20
20

34
(-)
0-5VDC
OR
0-10VDC

COMP STARTER O/L RELAYS

11
12
13

115VAC
GND

COMP STARTER CIRCUIT

20
21
23

CUSTOMER
UNIT
CONTROL

1
2

#10 AWG*
#10 AWG*

GND

OPTIONAL
ICE
BUILD
CONTROL

STARTER

*SEE NOTE 6

106
NOTE 8

107
108

LEGEND
AUXILIARY
CONDENSER WATER FLOW SWITCH (OPTIONAL)
CURRENT TRANSDUCER
CHILLED WATER FLOW SWITCH
CHILLED WATER PUMP AUX. SWITCH
CHILLED WATER RESET
GROUND
OVERLOAD

NOTES:
1.

2.

SHIELDED CABLE SHOULD BE


UTILIZED FOR CWFS, CDFS, CWP, CUSTOMER
CONTROL, CWR, DEMAND LIMIT,
CURRENT TRANSDUCER WIRING, AND CONDENSER
WATER CONTROL OPTION.
GROUND ONLY ONE END OF EACH
SHIELDED CABLE IN THE UNIT
CONTROL PANEL OR STARTER PANEL.

3. TERMINAL "SH" IS PROVIDED FOR


WIRING CURRENT TRANSDUCER
SHIELDING ONLY.
INSULATE THE
SHIELD UP TO THE SH TERMINAL.
4. THE CONDENSER PUMP INTERLOCK
MUST BE USED TO ENABLE THE
CONDENSER PUMP CONTROL CIRCUIT.
CONTACT RATING: 125VAC-10A
250VAC-5A

5. DO NOT SUPPLY OVER 5.0VDC.


DEMAND LIMIT AND CWR ARE OPTIONAL.
6. FOR EXTENDED DISTANCE BETWEEN
PCXI AND STARTER, CONDUCTORS
MUST BE SIZED TO ENSURE
115VAC+/-10% AT 1TB.
7. INTERCONNECTING 115VAC WIRING
SHOULD BE 14 AWG MINIMUM EXCEPT
AS NOTED. SHIELDED CABLE CAN BE 16 AWG.
8. THE CHILLER PUMP INTERLOCK CAN BE
USED TO ENABLE THE CHILLER PUMP
CONTROL CIRCUIT, IF DESIRED.
9. REF. 022165

022343 SH 4 OF 8

45

3.0 OPERATION: MECHANICAL SYSTEM


3.1 General Operation Statement

3.4.2

Energize power supply to unit. Unit must be


energized for 24 hours in order to warm up
oil sump before starting. Control circuit power
switch should be off during this period to
prevent compressor operation. Clean water
side heat transfer surface of condenser and
cooler by removing heads and brushing
tubes.

3.4.3

Check water circuits to see that cooling tower


is ready for operation, and both circuits are
filled. Start pumps and check for correct flow
rates in both cooler and condenser.

3.4.4

Turn control circuit power switch on, turn


compressor switch on, and press reset on
computer keyboard. Compressor will start
after start-up clock times out and leaving
water temperature will be automatically
controlled. Check refrigerant charge and
check for normal suction and discharge
pressures.

3.4.5

Have a trained service mechanic check the


function of all control setpoints. Check signal
lights for proper operation.

3.4.6

Take oil sample from the sump and submit it


for laboratory analysis.

The unit operation section of this manual is divided


into mechanical and control system operation, for
clarity. Refer to Section 4 for control information.

3.2 System Water Flow Rate


The quantity of chilled water being circulated can be
measured quite accurately (5%) by determining the
water pressure drop through the cooler and reading
GPM from cooler pressure drop curve, Figure 31.
Connect reliable pressure gauges to cooler entering and
leaving water connections and read pressure difference
with chilled water pump in operation. Condenser water
flow rate can be measured in the same way, using Figure
32. An alternate method of determining GPM is to
measure pressure difference from pump inlet to outlet
and read GPM from pump curve.

3.3 Seasonal Shut-down Procedure


3.3.1

If the unit is to be shut down for a prolonged


period (a month or more), the power supply
to the unit may be de-energized to conserve
energy.

3.3.2

The cooling tower may be drained to avoid


freezing. If the unit is located in an area where
the ambient temperature constantly remains
above freezing, the condenser need not be
drained. It is better to leave the condenser
and cooler filled with water during shutdown
period. If the unit is located where ambient
temperature will be below freezing, drain all
water thoroughly, removing all vent and drain
plugs from both heads of each vessel, and
blow out tubes with compressed air.
NOTE: Simply draining is not sufficient.
Stagnant water may cause serious corrosion.

3.3.3

It is recommended that an oil sample be taken


from the compressor and submitted for
laboratory analysis. Dunham-Bush offers this
service in its Oil Kare Program. This analysis
should be done at the beginning and end of
each operating season, or every six months if
the unit is used year round.

3.4 Seasonal Start-up Procedure


When the unit is to be started up after being shut down
for a prolonged period:

3.4.1

46

Check unit for evidence of rust or corrosion.


Clean surfaces and repaint as necessary.
Repair insulation if necessary.

3.5 Safety Relief Valves


Each pressure vessel is protected by a safety relief valve
as required by ASME Code. The condenser and separator
have a dual manifold. One valve in this manifold is
active, the other standby. If the active valve starts to
leak, simply screw the manifold valve to the opposite
extreme, which will activate the standby valve. Local
codes may require that all safety relief valves be piped
to the outdoors. Never install a hand valve in a safety
relief vent line.

3.6 Refrigerant Cycle


Following is the normal sequence of operation for a
unit installed in a typical air conditioning system and
served by a cooling tower. Refer to Section 2.8 for a
typical piping schematic for a 2+:E 030-050 unit. The
large screw compressor discharges warm, high-pressure
gas into an oil separator. The gas then travels through
a dicharge check valve (1) into the condenser where
the gas is condensed outside tubes, rejecting heat to
cooling tower water flowing inside the tubes. The liquid
refrigerant drains to the bottom of the condenser and
exits into the liquid line. The refrigerant flows by a
service valve (2), through a modulating ball valve (3),
which is driven by a modutrol motor (4) and by a
charging valve (5). The motor adjusts the valve to

3.0 OPERATION: MECHANICAL SYSTEM (CONT.)


maintain an appropriate level in the cooler, determined
by a liquid level float switch (6), and measurement of
compressor discharge superheat.
From the modulating valve, liquid/vapor refrigerant
flows into the flooded cooler, where it boils, cooling
the water flowing inside the cooler tubes. Vapor from
the boiling refrigerant flows up the suction pipe through
a suction check valve (7) into the compressor where it
is compressed and starts the cycle again.

3.7 Oil System


3.7.1

Oil Supply System

The compressors oil is supplied from a sump in the oil


separator by an external pump. This oil is used to
actuate the slide valve and lubricate the bearings, rotors,
and seals in the compressor. Section 2.8, typical piping
schematic, illustrates oil from the oil separator sump
feeds through an isolation valve (8), a suction strainer
(9), and the oil pump (10). From there it passes through
a filter (11), another isolation valve (12), and into the
compressors main oil port. The oil pressure is controlled
by a pressure regulator (13).
Electric resistance heaters are located in the oil sump in
the oil separator and serve to vaporize excess refrigerant
that would otherwise dilute the oil during shutdown
by heating the oil to a suitable temperature. The heaters
must be energized a minimum of 24 hours prior to start
up of the unit.
Two oil sump sight glasses are provided. During normal
oepration or shutdown, the bottom glass should
indicate oil. The top glass should always be empty.

3.7.2

Oil Return System

The oil separator discharges a very small amount of oil


mist along with refrigerant. This oil is carried through
the condenser and into the cooler. As shown in Section
2.8, typical piping schematic, oil-rich refrigerant is
returned from the cooler through taps in the cooler
shell through an oil return valve (14), filter drier (15),
and isoaltion valve (16). From there it passes through
a check valve (17) which prevents back flow, through a
sight glass (18) for observing oil return rate and into a
jet pump (19). The jet pump receives high-pressure
gas from the discharge line through a hot gas valve
(20). This forces the oil-rich mixture from the cooler
into the compressor.

3.8

Hydraulic Capacity Control


System

loading. It is controlled by the units microcomputer,


which provides signals to solenoid valves on load/unload
block assembly (21). The signals are provided to the
load solenoid valve (B) or unload solenoid valve (A) to
provide pressure to move the slide valve. Needle valves
are located on load/unload block assembly (21) for
factory adjustment of control rates.

3.9 Freeze Prevention


If water (or brine) is allowed to freeze within the tubes
and heads of the cooler or condenser, severe damage
will result; split and leaking tubes and cracked and
leaking heads. Since this damage can be extremely costly
and is not covered by warranty, it is important to be
mindful of freeze prevention. Three cases deserve
particular attention:

3.9.1

Standby at Low Ambient


Temperatures

If the unit is to stand idle at ambient temperatures below


32F, the water should be drained from cooler and
condenser. A head should be removed from each vessel
and the tubes blown dry with compressed air. Gravity
draining the vessel through drains in heads may not be
sufficient, stagnant water may cause serious corrosion.
If cooler or condenser are served with a glycol solution,
make sure the freeze temperature of the solution is
lower than expected minimum ambient temperature.

3.9.2

In Operation

Freezing of water in cooler tubes is a possibility if chilled


water flow stops and if the low suction pressure cutout
(normally set for 58 psig, or 32F saturation) and the
low water temp cutout both fail. If the chilled water
flow switch and pump interlock are properly applied
(See 2.5.1.1 and 2.5.1.2) the unit has four protective
devices which must all fail to produce freezing of the
cooler in operation. While this is unlikely, it is important
to see that all these devices are functional and properly
calibrated.

3.9.3

During Maintenance

In transferring refrigerant within the unit, or reclaiming


refrigerant from the unit for maintenance purposes, it
is possible to freeze cooler or condenser tubes.
Remember that whenever the pressure in a vessel is
reduced below 58 psig, if water is not flowing, it is
possible to freeze tubes. For this reason, it is a good
precaution to have water flowing in both vessels
whenever transferring or reclaiming refrigerant.

(See Section 2.8, Typical Piping Schematic)


The compressor has a hydraulic control system to supply
the proper force necessary to actuate the capacity
control slide valve, thereby regulating compressor
47

4.0 OPERATION: SYSTEM CONTROL

4.1 Wiring Diagram

#6372.

Refer to Section 2.9 for Electrical Information and typical


wiring diagrams for a 2+:E 030-050. This may not be an
accurate representation of your unit. It is best to use the
wiring diagram mounted in the package control panel. A
copy of that diagram is furnished with the unit owner's
manual.

4.3.1
1.
2.

4.2 Typical System Control


In order to start a unit, the following conditions must be
met:
chilled water pump running
chilled water flow switch made
customer control contact (optional) closed
control switch and compressor switch on
circuit breakers on
all safety conditions satisfied
reset pressed on microcomputer keypad
the compressor has not started within the last 20
minutes
leaving chilled water temperature 2F or more above
setpoint
oil sump temperature is greater than 70F.

3.
4.

NOTE: When displaying analog sensors, the PAGE MODE


key can be pressed to display two new analog inputs after
each arrow key is pressed. Press PAGE MODE again to
return to displaying one new analog input.

4.3.2
1.

The microcomputer starts the oil pump by energizing 4CP.


Oil pressure and standby discharge pressure are then
monitored to insure that a differential of at least 26 psig
is maintained for 5 seconds. The capacity indicator must
also unload to less than 8% before the microcomputer
energizes 2CR, which starts the compressor motor.
When the compressor starts, the microcomputer monitors
leaving water temperature, ramp schedule, and load
limiting to control load and unload solenoids. The
refrigerant level sensor and discharge temperature are used
to control the refrigerant modulating motor (See 4.4.8).
When minimum compressor capacity exceeds system load
and water temperature falls below setpoint, the
compressor and oil pump shut down.

4.3

The display board has a 20-key keypad and a 2 x 40 LCD


display, refer to Figure 49. The keypad and display can be
used to determine the status of the compressor, oil pump,
and refrigeration system. Various setpoints can also be
displayed and altered.
The status of the machine can also be monitored by a
computer terminal either locally or remotely by a modem.
The terminal must be able to handle RS232

communications. For more information, order Form

48

2.
3.

1.
2.
3.
4.
5.
6.

2.
3.

2.
3.

To Become Authorized

Select AUTHORIZATION on the main memo. Press


ENTER.
If the current status shown is VIEW, press the
authorization code (64) on the number keys.
Press ENTER. The current status will change to PROG
(program) if accepted.

4.3.5
1.

To Display Alarms

Press the MENU key.


Use the up or down arrow to select ALARMS.
Press ENTER.
The day, time, and alarm code is displayed. Alarm 1 is
the most recent alarm.
Press the down arrow to view previous alarms.
Check the computer instruction label to obtain the
name of the alarm. A typical label is shown in Figure
50. If the data label is not available, display the digital
input that corresponds to the alarm number. If the
digital input name SPARE is not available, the label
must be used.

4.3.4
1.

To Reset All Control Points to


Computer Control

Press the RESET key. The display will show RESET ALL
CPs to COM MODE? N Y
Press the right arrow key to select Y.
Press the ENTER key. The reset will not be accepted if
a lockout control point is active. Resolve the problem
and reset again.

4.3.3

Microcomputer Controller

This unit is controlled by a microcomputer control


system. The system is composed of four microcomputer
boards, a display board and analog and digital sensors.
The following sections describe the system and how to
operate it.

To Display Data From the Menu

Press the MENU key.


Use the up or down arrow keys to select the type of
information desired. The main menu items are:
DATE & TIME SET
CONTROL POINTS
ANALOG SENSORS
DIGITAL SENSORS
SETPOINTS A & B
HOLIDAYS
ALARMS
AUTHORIZATION
Press the ENTER key.
Use the up or down arrow keys to select the desired
data. For control points, additional data can be viewed
with the right and left arrow keys.

To Alter Setpoint Data

You must be authorized and in the PROG mode. See


section 4.3.4.
Select SETPOINTS A & B on the main menu. Press
ENTER.
Use the up or down arrow keys to select the setpoint

4.0 OPERATION: SYSTEM CONTROL (CONT.)


4.

5.

to be changed. Press ENTER. A cursor will flash over


the setpoint A value.
a) If you want to change setpoint A, press in the
desired new value and press ENTER. If the new value
is within limits, it will be stored in memory. The cursor
will then move to setpoint B.
b) If you do not want to change setpoint A, press
ENTER.
Repeat #4 for Setpoint B.

4.3.6

To Calibrate Temperature and


Pressure Sensors

NOTE: Temperature and pressure calibration should only


be done by a qualified refrigeration technician.
NOTE: For units with SI display option, the critical
temperature and pressure calibration values are stored in
the setpoints corresponding to the sensor names or
numbers. Enter calibration values in the setpoints.
1. You must be authorized and in the PROG mode. See
Section 4.3.4.
2. Display the analog sensor to be calibrated on the top
line of the display.
3. Press ENTER to show ZERO CALIBRATION value.
4. Use an accurate gauge to measure the analog value
when it is stable and near design conditions.
5. Determine the revised zero calibration required as
follows: Meter Reading - AI Display + Zero Calibration
= New Zero Calibration. The new zero calibration
must be rounded to the nearest whole number.
6. Press ENTER to place the cursor on the zero calibration
value.
7. Enter the new value from #5. Negative values are

8.

entered by pressing LOWER FUNCTION +/- before the


number.
Press ENTER to store the revised zero calibration.
For example, if a suction pressure gauge shows 58
psig and the computer displays 60.3 psig with a zero
calibration of -1, then new calibration would be 58 60.3 + (-1) = -3.3 (-3). So the zero calibration should
be changed to -3.

4.3.7

To Set Date and Time

1.
2.

You must be authorized. See Section 4.3.4.


Select DATE & TIME SET on the main menu. Press
ENTER to display current date and time.
3. Press ENTER key to move cursor to each date/time item.
4. As each item flashes, use the number keys to enter
revised data if necessary. The day of week, SUNday
through SATurday, is selected by number keys 1
through 7, respectively.
5. Press ENTER to continue. The last ENTER will store
the new date and time.
WARNING: Setting the clock will cause a system reset.
The entire unit will shut down and start over again. If the
change was started inadvertently, press MENU key before
completing the change.

4.3.8
1.
2.
3.
4.

To Display Data Without Accessing


Menu

Press LOWER FUNCTION.


Press function desired (blue sub-script)
Press item number to be displayed.
Press ENTER.
EX: To display analog input #5, press LOWER
FUNCTION, ANALOG SENSOR, 5, ENTER.

Figure 49 Microcomputer Keypad

CONTROL
POINTS

4
ALARMS

CLOCK
SET

RESET

ANALOG
SENSORS

SET
POINTS

8
CONFIG

+/-

DIGITAL
SENSORS

HELP

MENU

PAGE
MODE

ENTER

6
AUTH

SYSTEM
TIME

LOWER
FUNCTION

49

4.0 OPERATION: SYSTEM CONTROL (CONT.)

Figure 50 - Microcomputer Instruction Label

(4.3.9
1.

To Revise Schedules

See Section 4.4.25 - Unit Schedule of Operation


(Optional)

4.3.10 To Set Holidays


1.
2.

3.
4.
5.
6.

You must be authorized to make changes to Holiday


settings. See Section 4.3.4.
Up to eight holiday ranges can be set (H1 - H8). Select
the HOLIDAYs item from the main menu and press
ENTER.
Use the up or down arrow to select the holiday number
to change. Press ENTER.
Press ENTER to obtain a cursor over Start month. Enter
revised month number and press ENTER.
Enter revised Start day number and press ENTER.
Repeat 4 and 5 for End month and day.

When a holiday is active, the Time and Date screen show


the holiday number (H1 - H8) that is active rather than the
current day of week. The Holiday numbers are used in
Schedules to modify machine operation (See 4.4.25).

4.4 Control And Safety Functions


4.4.1

Chilled Water Pump Interlock and


Flow Switch (CWP AND CWFS)

The flow switch is field installed, which is used to ensure


chilled water flow before the unit is allowed to start. Failure
during operation will cause the compressor and oil pump
to shutdown. A water flow alarm will be generated and
RESET must be pressed to clear the alarm. NOTE: The
flow switch or pump interlock cannot be used for normal
control of the unit. (See 4.4.2).

50

NOTE: If the switch is located a long distance from the


unit or the wiring is routed near high voltage wiring,
shielded cable should be used. Ground the shield to the
unit sub-panel.

4.4.2

Customer Control Interlock

Control contacts from an external controller can be used


to enable or disable operation of the unit. The wiring
diagram specifies the terminals to which the contacts must
be wired. To enable the unit, the contacts must be closed.
To disable the unit, the contacts must be opened.

4.4.3

Anti-Recycle Timer
(Microcomputer)

The compressor motor requires an anti-recycle time delay


which prevents restart for 20 minutes after a start. The
purpose of this feature is to avoid frequent starts which
tend to elevate the motor winding temperature and impose
undue wear on contactors. The microcomputer will not
restart the compressor motor until the 20 minutes have
elapsed. COFF is displayed when the compressor control
point (1CP) is addressed, and when other conditions for
compressor start are satisfied. See Section 3.2.

4.0 OPERATION: SYSTEM CONTROL (CONT.)


4.4.4

Load Control (Microcomputer)

The microcomputer controls the leaving water temperature


within a narrow deadband by pulsing load and/or unload
solenoids on the compressor. The load and unload
solenoids position the slide valve within the compressor
to control its capacity. The microcomputer determines a
desired level of loading and varies pulse duration
depending on difference between load target and actual
load. The load target is varied based on rate of approach
to desired temperature preventing significant temperature
oscillations. The current limit function (see Section 4.4.6)
overrides the temperature control.
The status of the compressor can be observed by displaying
the compressor control point (1/CONTROL POINT). One of
the following messages will be displayed:
COMP 1 LUBE
COMP 1 LOAD
COMP 1 HOLD
COMP 1 UNLD
COMP 1 OFF
COMP 1 COFF
COMP 1 LOFF

4.4.5

Lubrication cycle
Automatic load
Automatic hold
Automatic unload
Off on temperature or
customer control
Off on timer (C lock off)
Manual off or safety
shutdown

Ramp Control (Microcomputer)

Another feature of the microcomputer is ramp control,


which is the ability to vary load time of the machine from
start. Often when the machine is started, the water in the
chilled water circuit is warm, and the unit will go to full
load quickly. With ramp control, the user can program the
computer so that it loads at a predetermined rate. This is
a valuable tool, since it can help reduce power consumption
and demand charges. Two variables are used to define
the ramp profile: Ramp rate and start point. Ramp rate
defines the length of time the unit takes to load from start
point to full load. Start point is the percent of full load at
which the ramp begins. The ramp rate A setpoint can be
set anywhere from 0.1 to 0.4, smaller values producing
slower loading rates. The ramp start B setpoint can be set
anywhere between 10 and 50%. The compressor will load
quickly to this value and then follow the ramp slope from
there. See Table 4 for ramp rates at various settings.
Table 4 - Ramp Rates for Several Setpoints (in Minutes)
Ramp
Rate
Setpoint
.1
.2
.3
.4

Start Point Setpoint


10%
30
15
10
8

20%
27
13
9
7

50%
17
8
5
4

4.4.6 Current Limiting (Microcomputer)


A maximum desired current is specified by amp limit B
setpoint for the compressor. Above the B setpoint, the
compressor will not load. If the amps rise above the A
setpoint, the computer will give an unload command to
the compressor until the current drops below the A
setpoint. The amp value in the A setpoint should be 10%
of RLA higher than the B setpoint.

4.4.7

Hot Gas Bypass (Factory-installed


option)

When hot gas bypass has been supplied with the package,
an output from the computer controls the solenoid. The
solenoid is turned on if the slide indicator of the compressor
drops below the hot gas bypass B setpoint. If the slide
indicator then climbs above the hot gas bypass A setpoint,
the solenoid is turned off. Typical setpoints are 10% for
the B setpoint and 25% for the A setpoint.

4.4.8

Refrigerant Management

The liquid line ball valve is controlled by a modulating


motor (4MTR). The mod motor is positioned by the
microcomputer, which is responding to cooler refrigerant
level via a liquid level transducer, and compressor discharge
superheat by means of the discharge pressure and
temperature measurements. If cooler level is sensed to be
low by the transducer, the mod motor is driven open. If
the level is high, the mod motor drives the valve closed. A
drop in discharge superheat below a value determined by
the microcomputer causes the modulating valve to close,
lowering the liquid level in the cooler.

4.4.9

High Sump Temperature Alarm

If sump temperature rises above the sump temperature


limit (145F) for 4 minutes, an alarm is generated. The
compressor is locked off and the alarm light is turned on.
Resolve the problem and press RESET.

4.4.10 Control Power Loss


The microcomputer can be set up to start automatically
or manually after a power failure to the microcomputer.
The power loss B setpoint is factory set to 0.0 to allow
automatic start after a control power loss. To select manual
reset, set power loss B setpoint to 1.0. In this case, a
power loss alarm will be stored by the microcomputer and
RESET must be pressed to start.

4.4.11 Low Pressure Cut-off


(Microcomputer)
This function protects the unit from operating at
abnormally low cooler refrigerant pressure. The
microcomputer will shut down the compressor when
cooler pressure falls below the low pressure setpoint and
turn on the alarm pilot light. A low pressure alarm will be
recorded by the microcomputer. Reset by pressing the
RESET button on the microcomputer. Standard setpoint
is 58 psig for water systems.

51

4.0 OPERATION: SYSTEM CONTROL (CONT.)


4.4.12 Cooler Freeze Shut-off
(Microcomputer)
If the leaving chilled water temperature drops below the
freeze setpoint, the microcomputer will shut down the
unit and store the freeze alarm. After solving the problem,
press RESET on the microcomputer to clear the alarm.

4.4.13 High Pressure Cut-off


(Microcomputer)
This function protects the compressor from operating at
abnormally high discharge refrigerant pressures. The
microcomputer will shut down the compressor when
discharge pressure reaches the high pressure set-point,
and turn on the alarm indicator lamp on the control box.
The high discharge pressure alarm will be recorded by the
microcomputer. Reset by pressing the RESET button on
the microcomputer. Typical setpoint is 250 psig.

4.4.14 Low Oil Pressure Alarm


(Microcomputer)
A low oil pressure alarm is triggered by one of the following
conditions: 1) The compressor is on and oil pressure is
less than 25 psig for 10 seconds, or 2) The oil pump is on
and the compressor has not started within 1 minute.
If either of the above conditions occur, the microcomputer
will lock off the compressor and oil pump, and turn on
the alarm light. The low oil pressure alarm code will be
stored in the microcomputer. When the problem is
resolved, press RESET to clear the alarm. See Section 5.6.2
regarding oil change.

4.4.15 Sump Heater Control


The two oil sump heaters are controlled by the 4CR relay.
When the oil pump is turned on, the sump heaters are deenergized (4CR is energized). When the oil pump turns
off, 4CR is de-energized if sump temperature is less than
Heater Temperature setpoint B (130F). If sump
temperature rises above Heater Temperature setpoint A
(135F), 4CR is energized and the heater turns off.

4.4.16 Compressor Starter Failure


A compressor starter failure is generated if any of the
starter safety contacts open. The contacts must be wired
in series and connected to the control panel as shown on
the wiring diagram. Safety devices on the starter may
include compressor overload, under-voltage/phase failure,
ground fault, shorted SCR detector, etc. When one of these
contacts opens, digital input 5 turns on and the compressor
is locked off on a compressor starter alarm. The alarm
light is turned on. Resolve the problem and press RESET.

4.4.17 Compressor Power Control (No


Stop Alarm)
The control power relay feeds power to the compressor
control circuit. After power-up, the relay is closed to allow
normal compressor control.
The computer will open this relay if it detects that the
52

compressor contactor auxiliary switch stays closed for 15


seconds when the computer is commanding the
compressor to be off. The computer determines that the
auxiliary switch is closed if the compressor contactor digital
input (typically #1) is displaying ON rather than OFF. A
No-Stop alarm would then be stored in the alarm history.
This would indicate that either a hardware problem is
forcing the compressor to run when it should not or that
the contactor status is not being monitored correctly.
When the problem is resolved, press the RESET key to allow
the machine to start.

4.4.18 Sensor Alarm Shutdown


If the computer measures an analog value that is far
beyond normal operating values, the compressor is
shutdown. The computer then stores the alarm code
corresponding to the specific sensor that caused the alarm.
Any of these alarms indicate a problem in the analog
measurement system. After the problem is resolved, the
RESET key must be pressed.
The following is a description of each sensor alarm:
1) Leaving water temperature error is triggered if sensor
reads higher than 190F for 10 seconds.
2) Suction pressure transducer error is activated if sensor
reads less than -20 psig for 10 seconds. It is also
triggered if leaving water temperature is less than 60F
and suction pressure reads higher than 150 psig for
10 seconds.
3) Discharge pressure transducer error is triggered if
discharge pressure reads higher than 390 psig or lower
than 5 psig for 10 seconds.
4) Oil pressure transducer error is generated if the sensor
reads higher than 350 psig, or lower than 5 psig, or if
differential is greater than 120 psid for 5 seconds.
This alarm will also trigger if the oil pump is off and
oil differential is outside of the 05 psid band for 5
minutes.
5) Sump temperature sensor error is triggered if the
sensor reads higher than 280F or lower than 0F for
10 seconds.

4.5.19 Slide Valve Error (Microcomputer)


A slide valve error will be generated if the feedback
potentiometer measures a value below -10% or above
110% for 56 seconds. The alarm will also trigger if the oil
pump is running with the compressor off and the slide
reading does not fall below 8% within 56 seconds. When
this alarm occurs, the compressor will be locked off and
the alarm light turned on. Check for proper operation
and calibration of the potentiometer and load/unload
solenoids. Clear the alarm by pressing RESET.

4.0 OPERATION: SYSTEM CONTROL (CONT.)


4.4.20 Liquid Line Mod Motor Error
(Microcomputer)
A mod motor error will be generated if the feedback
potentiometer measures a value that is more than 8% away
from the target value for 1 minute. This indicates that
there is a problem with the mod motor or feedback
potentiometer reading. When this alarm occurs, the
compressor will be locked off and the alarm light turned
on. Clear the alarm by pressing RESET.

4.4.21 Oil Pump Starter Error


(Microcomputer)
The microcomputer monitors the oil pump starter with
two digital inputs (#6&7). If the oil pump overload relay
opens (digital input 6 turns on), the oil pump starter error
is triggered. This error is also triggered if the oil pump
auxiliary switch does not close (digital input 7 turns off)
within 5 seconds of a pump start command. If this alarm
occurs, the compressor will be locked off and the alarm
light turned on. Clear the alarm by pressing RESET.

4.4.22 Chilled Water Reset (Optional)


If desired, the chilled water temperature can be raised
automatically by a 0-5 VDC analog signal provided by an
external controller. The reset signal must be between 0
VDC and 5 VDC, with 0 VDC being no reset and 5 VDC
being maximum reset. The maximum temperature reset
(increase) desired must be stored in CWR MAX setpoint B.
For example, to raise the chilled water setpoint from 44F
to 50F (6.0 difference) with a 5 VDC input, a 6.0 is stored
in CWR MAX setpoint B.
CAUTION: The voltage input must not exceed 5.0 VDC.
Shielded cable should be used for the signal wires with
the shield connected to ground only at one end.

4.4.23 Demand Limiting Input (Optional)


If demand limiting is desired, a 0 to 5 volt DC signal must
be supplied to the Demand Limit terminals shown on the
wiring diagram. The ground lead of the signal should be
connected to Ground Terminal and the positive lead should
be connected to the Demand Limit Terminal.
Supplying 0 volts will have no limiting effect, and 5 volts
will have maximum limiting. The Demand Limit setpoint
is used to determine the maximum amount of limiting the
voltage supplied to Demand Limit analog input will have.
If the Demand Limit setpoint is set to 0.0, there will be no
limiting, and if set to 10.0, there will be maximum limiting.
The Demand Limit setpoint can be set anywhere between
0.0 and 10.0 depending on the amount of Demand Limit
desired.
The Demand Limit works by automatically lowering the
HOLD and UNLOAD amp limits for the compressors. This
does not change the amp limit setpoints. The
microcomputer takes the signal supplied to the Demand
Limit analog input, the value held in the Demand Limit

setpoint, and the amp limit setpoints to calculate the


amount of limiting to take place. To calculate the value
for the Demand Limit setpoint for a desired Demand
Limiting current with 5 volts supplied to Demand Limit
analog input, use the following equation:
((Amp Limit (B)-Desired Limit Current)/Amp Limit setpoint
(B)) x 10
This Demand Limiting will only unload compressors. It
will not turn them off.
CAUTION: Do not feed in a voltage higher than 5.0 VDC.
Shielded cable should be used for the 5 volt signal with
the shield connected to ground only at one end.

4.4.24 Pressure Load Limiting


If the suction or discharge pressure gets close to the
pressure limits, the microcomputer performs load limiting
to reduce the possibility of a low pressure or high pressure
trip. When suction pressure drops below the low pressure
limit plus 4 psig or if discharge pressure rises above the
high pressure limit minus 10 psig, the compressor will not
be allowed to load. If suction pressure drops below the
low pressure limit plus 2 psig or if discharge pressures
rises above the high pressure limit minus 5 psig, the
compressor will unload.

4.4.25 Unit Schedule of Operation


(Optional)
If a seven day time schedule of unit operation is desired,
the internal real time clock of the microcomputer can be
used. When the SCHEDULE control point is ON, the
compressor is allowed to operate. The following procedure
is used to modify the operating schedule.
1.
2.
3.
4.
5.
6.

Perform the authorization procedure (See 4.3.4).


Press MENU key.
Use Up and Down to select CONTROL POINTS.
Press ENTER.
Use Up and Down to select SCHEDULE control point.
Use the right arrow key to display the first schedule.
The standard display screen would show:
CP 17 SCHEDULE GRP:1 SCH:1 0000 2400 DAYS:
*** ALL DAYS ***
This indicates that control point 17 named SCHEDULE
is controlled by schedule group (GRP) #1. The first
schedule (SCH:1) turns on at 0000 hours and off at
2400 hours (military time) every day of the week. Thus
it is on all the time.
7. To change this schedule, press ENTER. The cursor will
flash over the turn-on time.
8. Use the number keys (0-9) to enter the revised turnon time using military format.
9. Press ENTER. The cursor will move over to the turnoff time.
10. Use the number keys to enter the turn-off time in
military format.

53

4.0 OPERATION: SYSTEM CONTROL (CONT.)


11. Press ENTER. The cursor will move to DAYS during
which this schedule is active.
12. To change the days for this schedule, press one or
more of the following number keys: 0 - Clear all
current days; 1 - Sunday(S); 2 - Monday(M); 3 Tuesday(T); 4 - Wednesday(W); 5 - Thursday(R); 6 Friday(F); 7 - Saturday(A); 8 - *** ALL DAYS ***.
13. Press ENTER. If "ALL DAYS" was not selected, the cursor
will move to HOLS where holiday numbers 1 - 8 may
be entered. If a holiday is not entered, this schedule
will be off during a holiday time range.
14. Press ENTER. The revised schedule number is now
stored.
15. To add another schedule, press the right arrow key
and repeat steps 7-14.
16. To delete a schedule, clear all of the days by pressing
0 at Step 12.
The schedule group turns on when any of the individual
schedules turns on. The turn-on time must be earlier than
the turn off time.
Example: If a unit is to operate at all times except between
the hours of 1:00 AM and 6:00 AM, the following schedules
would be entered:
CP 17 SCHEDULE GRP:1 SCH:1 0000 0100 DAYS: *** ALL
DAYS ***
CP 17 SCHEDULE GRP:1 SCH:2 0600 2400 DAYS: *** ALL
DAYS ***
Another example: A typical building may require cooling
from 6:00 AM to 7:00 PM Monday - Friday and from 7:00
AM - 3:00 PM on Saturdays and on Holidays #1 and #2.
The schedules would be entered as follows:
CP 17 SCHEDULE GRP:1 SCH:1 0600 1900 DAYS: MTWRF
CP 17 SCHEDULE GRP:1 SCH:2 0700 1500 DAYS: A
HOLS:12

4.4.26 Low Chiller Flow Alarm


A low flow alarm will be generated if the oil pump is
operating and flow switch digital input is OFF. The
compressor and oil pump will be locked off and the alarm
light turned on. After resolving the problem, press RESET.

4.4.27 External Shutdown (No-Run


Alarm)
A No-Run alarm is generated if the computer tries to start
(or run) the compressor but the compressor is held off by
an external control or fault. The computer determines
that the compressor is not operating if the digital input
from the compressor contactor does not indicate that the
contactor is pulled in, or if the compressor amps fall below
a minimum value.

54

4.4.28 Low Discharge Superheat (DSH)


Alarm
A low discharge superheat alarm is triggered if the
compressor has been on for 10 minutes and DSH is below
the minimum for 4 minutes. If this occurs, the
microcomputer will lock off the compressor, turn on the
alarm light, and store the low DSH alarm code. When the
problem is resolved, press RESET to clear the alarm.

4.4.29 Proactive Warning Contact


The Proactive Warning Contact closes if the unit is being
load limited due to high discharge pressure, low suction
pressure, or high compressor motor amps. The contact
also closes if the refrigerant leak detector option senses
high refrigerant levels in the air.

4.4.30 Condenser Flow Alarm


The condenser water flow switch is optional. If the switch
is installed, the flow must be established within 20 seconds
of a compressor start.
It is highly recommended that the condenser pump
interlock contacts be used in the control circuit of the pump
starter to enable pump operation.

4.4.31 Chiller Pump Interlock


The chiller pump interlock can be used to enable the chiller
pump control circuit. This output is controlled by the
internal unit operation schedule or the unit control contacts
(digital input #3). The output is turned off if the
compressor is shut down on an alarm.

4.4.32 Ice Build Mode


Caution: Ensure proper glycol concentration for ice build
application.
If the ice build contacts are closed (8 DI turns ON), the
unit will go to full load until leaving brine reaches the Ice
Build setpoint (6A). Then the unit will shut down until the
contacts are opened (8 DI turns OFF).

5.0 MAINTENANCE

5.1 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. Some of this care
can easily be provided by owner personnel. However, a
Dunham-Bush authorized service mechanic should inspect
the unit at least annually and evaluate unit performance.

5.2 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. See sample, Section
5.8. If any abnormal operation is observed, try to determine
cause and remedy it. See Troubleshooting Guide, Section
5.7.

5.3 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. Put compressor
in manual control and time rate of loading and unloading.
Adjust needle valves as necessary to get load and unload
time of 4020 sec., then return to automatic control.
Check subcooling for proper refrigerant charge level. See
Charging, Section 4.6.

5.4 Water Side Cleaning of Vessels


See Section 1.4.3 Condensing Water Treatment
The effects of fouling of the cooler or condenser heat
transfer surfaces can be detected by recording full load
performance data on the log sheet. The best measure of
performance of cooler and condenser is approach, which
is the difference between leaving water temperature and
saturated refrigerant temperature at the pressure in the
vessel. At full load, read suction and discharge pressures
on the computer. Then use a pressure temperature chart
to find saturated temp. for each. Read leaving chilled water
temperature on the computer. Read leaving condenser
water temperature with a field installed thermometer
which must be used if the water temperature option is
not installed. Then calculate approaches as follows:
Condenser Approach = T sat condenser - T lvg cond. water
Cooler Approach = T lvg chilled water - T sat cooler
If the approach for either vessel increases by more than
2F above the approach recorded at clean conditions, the
tubes should be cleaned. It is generally advisable to clean
the water side surfaces at least annually and more often if
severely foul water is used. This cleaning can be done
chemically or physically. In chemical cleaning, a caustic
solution is pumped through the heat exchanger, which
attacks dirt, slime and mineral deposits and flushes then
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.

Vessel tubes may be physically cleaned by first draining


the water, then removing the heads and brushing each
tube individually with a tube cleaning brush until clean.
For best results, always remove both heads before cleaning
the tubes. Replace the heads, being careful to properly
position gaskets, and refill the system with water.
Head gaskets need not be renewed after each head
disassembly operation. Gaskets should and must be
renewed if they are physically disfigured or otherwise
deteriorated. (New gaskets are available from the factory.
See Repair Parts List.) INSPECT CAREFULLY.

5.5 Electrical Malfunction


The unit has two devices designed to protect the
compressor motor from electrical malfunctions: motor
overload relay and undervoltage relay (optional).
If the undervoltage relay trips, it is a sign of trouble with
incoming power. If it trips again after resetting, call your
electric utility to investigate the problem. If the customersupplied fuses or motor overload relay trips, 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.

5.6 Charging
5.6.1

Refrigerant Charge

The 2+: unit is given a complete charge of refrigerant


E
at the factory unless ordered uncharged. The amount
necessary to charge the unit can be found in the physical
specifications, Table 1. If the unit must be charged on the
job-site, a qualified refrigeration mechanic must do it.
To verify proper refrigerant charge, check refrigerant liquid
subcooling while unit is operating at full load. At full load,
read discharge pressure on the computer. Then use a
pressure-temperature chart to find saturated temperature.
Read liquid line temperature leaving the condenser with
field installed temperature sensor. Then calculate liquid
subcooling as follows:
Subcooling =

Saturated discharge temperature - liquid


line temperature

The subcooling is to be between 8 and 10F. If refrigerant


is to be added, it should be added while operating at full
load through the charging valve on the cooler feed line
until the proper subcooling is obtained.

5.6.2 Oil Charge


The proper oil charge is in the unit as supplied from the
factory. If for some reason, the compressor runs low on
oil, the microcomputer will shut off the motor on a low oil
pressure alarm before any damage is done. In the event
of a low oil shutdown, call a D/B authorized service agent
to correct the problem. DO NOT ADD OIL TO THE SYSTEM.
The upper sightglass in the condenser sump should never
indicate an oil level.
55

5.0 MAINTENANCE (CONT.)

5.7 Troubleshooting
Possible Causes

Corrective Action

Indication

5.7.1 Unit will not start


1.

Main power off.

No voltage on unit.

Check main disconnect switch and main line


fuses

2.

No control power.

Control switch on, only high


voltage present.

Check control transformer fusing or customer


supplied source.

3.

Undervoltage relay open

Pilot light on relay off.

Check for power supply problems (low voltage,


phase imbalance). When corrected, press reset
button.

4. Chiller flow switch open.

Chiller pumps off, no flow.

Start pumps, check flow switch.

5.

Customer control off.

Unit control digital input is OFF.

Close contact.

6.

Compressor switch open.

Switch OFF.

Turn switch on.

7.

Microcomputer shutdown, not


reset.

Compressor control point


indicated LOFF.

Check alarm status. Correct problem. Press


reset button.

8.

Oil sump temperature is less


than 70F.

Low oil sump temperature.

Check oil sump heater, and temperature


sensor. Wait for oil to heat up.

5.7.2 Compressor will not start when reset button is pushed. Checked lights: None
1.

Cooling not required

Cooler leaving water temp. less


than 2F above setpoint.

Apply load.

2.

Computers time delay active.

Control point indicates COFF.

Wait 15 minutes max.

3.

Undervoltage relay open.

Chiller pumps off, no flow.

Start pumps, check flow switch.

4.

Flow switch open.

Unit control digital input is OFF.

Close contact.

5. Compressor switch open.

Switch OFF.

Turn switch on.

6.

Burned out signal light.

Check voltage across light.

Check signal light bulbs.

7.

Wiring problem.

Other indications not satisfied.

Check wiring against drawing.

Condenser refrigerant sightglass


bare.

See Refrigerant Charge - 5.6.1.

5.7.3 High sump oil temperature


1.

Insufficient refrigerant charge

2.

Bypass valve closed.

56

Adjust valve

5.0 MAINTENANCE (CONT.)

5.7 Troubleshooting (cont.)


Indication

Possible Causes

Corrective Action

5.7.4 Low suction pressure


1.

Inadequate feed to cooler

Low suction pressure indication


on computer and light on.

Check to see that liquid line ball valve is


open.

2.

Inadequate refrigerant charge

Low suction pressure indication


on computer and light on.

See information on charging in Section 5.6.

3.

Fouling of water side of cooler

Low suction pressure indication


on computer and light on.

At high load, check cooler approach. (See


5.4). If approach is more than 2 F above
clean value, fouling is probably the trouble.
Clean tube bundle. See 5.4.

4.

Inadequate chilled water flow

Low suction pressure indication


on computer and light on.

Measure pressure drop across vessel and


determine gpm from fig. 4. If gpm is low,
check chilled water pump, valves and
strainers.

5.

Fouling of water side of


condenser.

High discharge pressure


indication on computer and
light on.

At high load, check condenser approach (see


5.4) If approach is more than 2 F above
start-up conditions, fouling is probably the
trouble. Clean tube bundle (see 5.4).

Oil low in sight glass on oil


separator

Call a D/B Authorized Service Agent to correct


the problem.

5.7.6 Low oil pressure


1.

Low oil level in compressor

5.7.7 Freeze warning


1.

Operating setpoint too low

Freeze light on. Indication on


computer

Check leaving water setpoint on


microcomputer.

2.

Load changing too rapidly.

Freeze light on. Indication on


computer

Load on package must drop at reasonable


rate for automatic control to work properly.

Observe amps while manually


loading and unloading.

Adjust needle valves for 40 second load/


unload rate when loading/unloading with
microcomputer in manual control mode.

5.7.8 Improper capacity control


1.

Compressor loads/unloads too


fast or slow.

2. Ramp rate incorrect

See 4.5.6.

57

5.0 MAINTENANCE (CONT.)

5.8 Sample Log Sheet

2+:E Pressure/Temperature Log


SERIAL #_______________________

MODEL #________________________

COMPRESSOR SLIDE VALVE POSITION


A

SUCTION PRESSURE

SATURATED SUCTION TEMPERATURE

OIL TEMPERATURE

DISCHARGE TEMPERATURE

DISCHARGE PRESSURE

SATURATED DISCHARGE TEMPERATURE


DISCHARGE SUPERHEAT (D-F)

OIL PRESSURE
NET OIL PRESSURE (G-E)

CONDENSER REFRIGERANT OUT TEMPERATURE


NET SUBCOOLING (F-H)

COOLER WATER IN

COOLER WATER OUT


COOLER APPROACH (J-B)

CONDENSER WATER IN

CONDENSER WATER OUT


CONDENSER APPROACH (F-M)
GPM CONDENSER
GPM COOLER
PRESSURE DROP ACROSS OIL FILTERS MAX. 5#
COMPRESSOR MOTOR VOLTAGE AND AMPERAGE

58

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