DCLC Series 50Hz

Water Cooled Centrifugal Chillers

Cooling Capacity: 300 to 1500 TR (1055 to 5274 kW)

R134a

Products that perform...By people who care

1.0 GENERAL
For most of the 20th Century, DB has been providing innovative solutions for the heating, air conditioning
and refrigeration needs of its customers. Today’s global company has a proud heritage that began over a
100 years’ ago.
In the 1960s, DB introduced a revolutionary compressor technology for air conditioning and refrigeration
applications – the twin helical screw compressor. Highly efficient, durable and very reliable, DB’s
experience of more than 50 years in the application of twin screw compressors in the HVAC industry is
unrivalled.
Customers demand high efficiency products with exceptional value and DB’s new range of
DCLC centrifugal chillers satisfy modern market requirements with outstanding energy efficiency and
proven technology, designed specifically for environmentally safe refrigerants. This combination ensures
the most cost-effective, reliable solution for comfort cooling and process cooling applications.
DB continues to deliver performance with reliability packaged in the most energy efficient way with the
introduction of the DCLC range of centrifugal water chillers.
The major advantages of the DCLC:
D High reliability
D Simple operation and maintenance
D Low sound levels
D Simplified structure and compact size
D High efficiency at a competitive market price
D Designed to use environmentally friendly R134a refrigerant.
The DCLC range of chillers is ideal for offices, hospitals, hotels and retail stores as well as industrial
applications. The chiller offers a full range of Evaporator/Condenser/Compressor combinations,
permitting precise matching of the machine capacity to system requirements. With such a wide range of
available combinations, DCLC units can be configured to provide lowest first cost, lowest operating cost
or choice of several criteria important for a particular application. The centrifugal chiller selection software
is certified in accordance with the latest AHRI standard 550/ 590.
DB Sales Engineers are available to assist in selecting the optimum machine needed to satisfy the
particular project requirements.
The DCLC centrifugal chiller from DB offers superior value and application flexibility, a wide range of
options and accessories and the peace of mind that more than 100 years of industry experience is
behind this product can be ideally configured to suit your project.

TABLE OF CONTENTS
1.0 GENERAL ............................................................. 2
2.0 WORKING PRINCIPLE AND STRUCTURE ......... 3
2.1 Refrigeration cycle ................................................. 3
2.2 Chiller selection sample ......................................... 4
2.3 DCLC Chiller Dimensions ...................................... 5
3.1.5 How to avoid the surge ............................... 13
3.2 Heat-exchanger major components .................... 13
3.2.1 Heat-exchanger structure............................ 14
3.3 Electrical control Equipment ................................ 18
3.3.1 PLC Microcomputer Control software ........ 18
3.3.2 Control hardware ........................................ 18

3.0 SYSTEM COMPONENTS...................................... 6 4.0 APPENDIX .......................................................... 24

3.1 Compressor major components ............................. 8
3.1.1 Characteristics of the Components ................ 8
3.1.2 Oil lubrication System ................................. 11
3.1.3 Motor refrigerant-cooled system .................. 12
3.1.4 Emergency oil supply................................... 13
4.1 Unit Selection sample.......................................... 24
4.2 Standard DCLC chiller supply scope ................... 25
4.3 Test issue ............................................................ 26
4.4 Safe application ................................................... 28
4.5 DCLC mechanical specifications ......................... 28

NOMENCLATURE
DCLC 1000 B

DCLC - Dunham-Bush Centrifugal Water Chiller Design Level : B

DCLCR - Dunham-Bush Heat recovery
Centrifugal Chiller Nominal Cooling Capacity TR
DCLCV - Dunham-Bush VFD Centrifugal Chiller

-2-
2.0 WORKING PRINCIPLE AND STRUCTURE

2.1 REFRIGERATION CYCLE

The compressor on a centrifugal chiller utilizes Single-stage compression circulating diagram
the Vapour Compression cycle in the much the
same way as any positive displacement
compressor. The Vapour compression cycle
uses a medium such as refrigerant to absorb
heat at one part of the cycle and reject that heat
at a different part of the cycle. The centrifugal
compressor is a dynamic machine which raises
the pressure and temperature of the circulating
refrigerant by imparting velocity or dynamic
energy through an electric motor driven impeller
discharging into a volute or diffuser plate to
convert this velocity energy to pressure energy.
As with all vapour compression systems, there
are four major components: compressor,
condenser, expansion device and evaporator.
The evaporator absorbs heat from its
surrounding and the condenser rejects the heat
collected plus any system losses to its surroundings. The cycle will continue to operate all the time the
compressor is operating and a system load exists.
The following is the principle in details:

Compressor: The refrigerant vapour enters the compressor in a low pressure, low temperature but
superheated state. The compression process increases the pressure and the temperature and the now
high pressure, high temperature superheated gas is discharged into a condenser, a heat exchanger
where due to its high temperature the refrigerant can be condensed using cooling tower water or ambient
air.

Condenser: The high pressure hot vapour is condensed into a high pressure hot liquid, or saturated
liquid as its pressure corresponds to its condensing temperature. This now high pressure liquid
refrigerant discharges from the bottom of the condenser and is passed through an expansion valve or
some other restrictive device.

Expansion valve: The downstream side of this expansion device is exposed to the low pressure part of
the system which causes the refrigerant to expand rapidly as it passes through the device, as it expands;
adiabatic cooling of the gas/liquid mixture occurs to the point where it is then colder than the water (or
other liquid to be cooled) in the evaporator.

Evaporator: This is a second heat exchanger where the medium ultimately to be cooled by this process,
the ‘chilled water’, is circulated on one side and the cold refrigerant mixture is circulated through the other
side where it absorbs heat, thereby cooling down the chilled water. Cooling the chilled water is the
fundamental purpose of the equipment. The refrigerant then continues to circulate in the system and after
going through the compression process again the heat absorbed will be rejected by the condenser to the
tower water or ambient air.
The cooling capacity of a system is directly proportional to refrigerant gas flow through the compressor.
An adjustable guide vane regulating device can be installed at the inlet of centrifugal compressors to
control the suction flow of compressor, matching the system cooling capacity to that of the building
cooling load in a regulated and step less manner across a defined range.

Maximum outside temperature — for transport and storage of the DCLC units the minimum and
maximum allowable temperatures are -20°C and +50°C.
Unit (Standard type) operating temp range:
Min. Max.
Inlet water temp. °C 8 25
Evaporator
Outlet water temp. °C 4 15
Inlet water temp. °C 15.6 34
Condenser
Outlet water temp. °C 22 41

-3-
2.0 WORKING PRINCIPLE AND STRUCTURE

2.2 CHILLER SELECTION SAMPLE

Sample Specification（300TR-1500TR, 400V-3P-50Hz,star delta start）
Chiller
Chiller Evaporator Condenser Dimension Weight
current

pressure drop

pressure drop
Cooling water

Cooling water
Rated current

Chilled water

Chilled water
Locked-rotor

in/outlet dia.

in/outlet dia.
flow volume

flow volume
Power input

Water pipe

Water pipe

Shipping

injection
Running
capacity
Cooling

current

Length

weight

weight
Height

R134a
Width
IPLV
COP

Model

kW TR kW kWo/kWi kWo/kWi A A l/s kPa mm l/s kPa mm mm mm mm kg kg kg

DCLC300 1055 300 179 5.91 5.76 297 691 46 72 DN200 54 58 DN200 4994 1994 2250 11375 9539 666

DCLC350 1231 350 201 6.11 6.08 334 779 53 70 DN200 63 57 DN200 4994 1994 2250 11375 9539 666

DCLC400 1406 400 222 6.34 6.78 369 861 61 68 DN200 72 73 DN200 4994 1994 2250 11068 9395 617

DCLC450 1582 450 261 6.06 6.34 434 1011 68 66 DN200 81 71 DN200 4423 1994 2250 10480 8972 521

DCLC500 1758 500 288 6.11 6.35 481 1120 76 75 DN200 89 66 DN200 4994 1994 2250 11167 9457 617

DCLC550 1934 550 318 6.08 6.55 530 1235 83 61 DN200 98 47 DN200 4994 1994 2250 10962 9331 617

DCLC600 2110 600 343 6.15 6.60 571 1330 91 79 DN250 106 71 DN200 4994 1994 2250 11068 9395 617

DCLC650 2285 650 370 6.18 6.24 615 1432 99 77 DN250 115 62 DN200 4994 1994 2250 11295 9507 648

DCLC700 2461 700 394 6.25 6.48 658 1533 106 79 DN250 124 71 DN200 4994 1994 2250 11375 9539 666

DCLC750 2637 750 427 6.18 6.35 715 1665 114 72 DN250 133 72 DN250 4959 2096 2270 12120 10154 693

DCLC800 2813 800 454 6.20 6.38 760 1771 121 81 DN250 142 73 DN250 4959 2096 2270 12321 10261 712

DCLC850 2989 850 469 6.37 6.59 786 1831 129 67 DN300 150 52 DN300 5065 2426 3010 18757 16139 907

DCLC900 3164 900 502 6.31 6.48 842 1962 136 74 DN300 159 57 DN300 5065 2426 3010 18757 16139 907

DCLC1000 3516 1000 565 6.23 6.01 949 2211 152 90 DN300 176 69 DN300 5675 2426 2903 20427 17267 1103

DCLC1100 3868 1100 613 6.31 6.17 1029 2397 167 87 DN300 194 82 DN300 5675 2426 2903 20589 17312 1157

DCLC1200 4219 1200 679 6.21 6.39 1139 2655 182 78 DN350 212 73 DN350 5675 2426 2903 20589 17312 1157

DCLC1300 4571 1300 718 6.37 6.59 1210 2818 197 102 DN350 229 95 DN350 5737 2712 2965 23214 19675 1156

DCLC1400 4922 1400 773 6.37 6.66 1300 3029 212 101 DN350 246 94 DN350 5737 2712 2965 26520 22765 1215

DCLC1500 5274 1500 825 6.40 6.61 1387 3231 227 101 DN350 264 93 DN350 5737 2712 2965 23832 19948 1270

Notes:
1. Nominal Cooling capacities are based on following conditions:
Chilled water inlet/outlet temperature 12.2/6.6°C; Condenser water inlet/outlet temperature 29.4/35°C;
The rated current data as listed for DCLC chiller models 300-1500 is based on 400V/3P/50Hz power supply.
60Hz performance data is available upon request.
2. For DCLC chiller models 300-1000, low-voltage 400V is standard and recommended (high voltage optional); for DCLC models 1100-1500, High
Voltage 3kV/6kV/10kV is recommended (low voltage optional);
3. The design fouling factor for evaporator and condenser are 0.0176 and 0.044 m2/kW, respectively for alternative fouling factors please contact DB
4. The design working pressure of the water (tube) side for both evaporator and condenser is 10 bar, higher pressure designs are available upon
request.
5. The Sample Specification above is for reference only. According to a variety of main parts combination, the same cooling capacity can have many
different models.
Contact local DB office to choose the appropriate chiller for the User’s practical requirements. Due to possible product improvement, we reserve the
right to make changes in design and construction at any time without notice.

-4-
2.0 WORKING PRINCIPLE AND STRUCTURE

2.3 DCLC CHILLER DIMENSIONS

Model A B C D E F G H J K Y Z

DCLC300 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200

DCLC350 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200

DCLC400 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200

DCLC450 4423 1994 2250 3800 637 1067 483 853 997 489 DN200 DN200

DCLC500 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200

DCLC550 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200

DCLC600 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN250

DCLC650 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN250

DCLC700 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN250

DCLC750 4959 2096 2270 4300 689 1119 490 920 1048 521 DN250 DN250

DCLC800 4959 2096 2270 4300 689 1119 490 920 1048 521 DN250 DN250

DCLC850 5065 2426 3010 4300 969 1519 786 1336 1213 610 DN300 DN300

DCLC900 5065 2426 3010 4300 969 1519 786 1336 1213 610 DN300 DN300

DCLC1000 5675 2426 2903 4900 969 1519 786 1336 1213 610 DN300 DN300

DCLC1100 5675 2426 2903 4900 969 1519 786 1336 1213 610 DN300 DN300

DCLC1200 5675 2426 2903 4900 969 1519 786 1336 1213 610 DN350 DN350

DCLC1300 5737 2712 2965 4900 885 1485 695 1295 1356 678 DN350 DN350

DCLC1400 5737 2712 2965 4900 885 1485 695 1295 1356 678 DN350 DN350

DCLC1500 5737 2712 2965 4900 885 1485 695 1295 1356 678 DN350 DN350
Notes:
1. The above dimensions are based on standard water side design pressure of 10 bar, and Victaulic connections. Dimension A is for unit
configurations with two pass evaporator and condenser, left hand configuration when viewed from compressor and electrical box side of unit.
2. Service access should be provided in accordance with American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 15,
latest edition, National Fire Protection Association (NFPA) 70, and local safety code.
3. Allow at least 1350mm overhead clearance for service rigging for the compressor.
4. Certified drawings available upon request. Drawings included in this section are for preliminary layout purposes only. Detailed certified drawings are
available from the local DB sales office. Do not use for final construction drawings.
The above dimensions are for the standard chillers, if other than standard vessel configuration is selected please consult local DB Sales office.
5. All dimensions are in mm.

-5-
Americas Europe Africa

United States of America United Kingdom South Africa

175 South Street, 8 Downley Road, No. 57 Sovereign Drive

West Hartford, Havant, Hampshire, Route 21 Corporate Park
CT 06110, USA England PO9 2JD Irene, Pretoria
South Africa
Tel: 1-860-249 8671 Tel : 44-23-9247 7700
Fax: 1-860-953 3300 Fax: 44-23-9245 0396 Tel: 27-12-345 4202
Fax: 27-12-345 4203

China Asia Middle East & North Africa

No. 1 Dunham-Bush Road, Singapore United Arab Emirates

Laishan District,
Yantai, 2, Kallang Pudding Road #07-07, Al Murad Tower, Office 506
Shandong Province, Mactech Industrial Building, Al-Barsha 1,
China 264003 Singapore 349307 P. O. Box # 30922,
Dubai, UAE
Tel: 86-535-658 8999 Tel: 65-6842 2012
Fax: 86-535-658 1999 Fax: 65-6842 2013 Tel: 971-4-451 9899
Fax: 971-4-451 9881

Russia & CIS Malaysia

Russia Lot 5755-6, Kidamai Industrial Park,

Bukit Angkat,
Lot 11, Novinskiy Boulevard, 43000 Kajang,
Moscow, Selangor Darul Ehsan,
121099 Russian Federation Malaysia

Tel: 7-499-255 6953 Tel: 603-8924 9000

Fax: 7-499-255 6953 Fax: 603-8739 5020

info@dunham-bush.com
www.dunham-bush.com Products that perform...By people who care

Manufacturer reserves the right to change specifications without prior notice. M-S-0489A-0112