Installation, Operation & Maintenance Manual

Form No: M-M-0488A-0510
Products that perform...By people who care
INSTALLATION, AIR COOLED

OPERATION & SCROLL
DIRECT
MAINTENANCE
EXPANSION
MANUAL CHILLERS
MODEL:
ACDS R410A
60Hz 10 to 180 Tons
(35 to 633 kW)
MANUAL INDEX
Description Page Description Page
1.0 INTRODUCTION .............................................. 3 4.2.1 Typical Control Sequence With 2 Stage

Operating Thermostat At 10°C Return Water
1.1 Physical Specifications ....................................... 4 Setpoint, 3.0°C Differential .............................. 34
4.2.2 Keypad Operation ........................................... 35
4.2.3 IR32 Electronic Thermostat Parameter List ... 35
2.0 INSTALLATION 4.2.4 IR32 Electronic Thermostat Troubleshooting .. 37
2.1 General ..................................................................... 6 4.3 Vision 2020i Controller and Terminal ............ 38
2.2 Inspection ................................................................ 6 4.3.1 DBG1 Operator Keypad .................................. 38
4.3.2 Status Reading ................................................ 39
2.3 Rigging ..................................................................... 6 4.3.3 Authorization ................................................... 41
2.3.1 General ............................................................. 6
4.3.4 Advanced user key and menu ......................... 41
2.3.2 Rigging and Moving ......................................... 6
4.3.5 Technician Key and Menu ............................... 41
2.4 Space Requirements And Clearance ............... 7 4.3.6 Control Functions ............................................ 44
2.4.1 General ............................................................. 7 4.4 Condenser Fan Control Logic.......................... 47
2.4.2 ACDS ................................................................ 7
4.4.1 Air-Cooled Condenser Control Setpoints ........ 47
2.5 Foundation ............................................................ 18 4.4.2 Increasing Condenser Pressure ...................... 48
2.5.1 Air Cooled Units .............................................. 18 4.4.3 Decreasing Condenser Pressure .................... 48
2.6 Vibration Isolation ............................................... 18 4.5 Master/ Slave Control Sequence ..................... 48
4.5.1 Principle of Operation VIA DBLAN
2.7 Piping Connection .............................................. 21 Communication Bus ........................................ 49
2.7.1 Water Connections Chilled Water 4.5.2 Sequence of Operation ................................... 50
Piping .............................................................. 21
2.7.2 Water Connections Multiple Packaged 4.6 Vision 2020i Local Area Network (DBLAN) .. 50
Chillers ............................................................ 21
4.7 Network Connection Diagram .......................... 51
2.7.3 Water Quality .................................................. 23
4.8 Hardware Setting ................................................. 51
2.8 Electrical Connections....................................... 23
4.8.1 Addressing the Vision 2020i Controller ........... 51
2.9 Request For Start-Up Representative ........... 23 4.8.2 Addressing the Vision 2020i DBG1 Terminal .. 52
4.8.3 Vision 2020i Controller LED Status ................. 53
3.0 OPERATION 4.9 TYPICAL WIRING SCHEMATIC ........................ 54
3.1 General ........................................................... 24

5.0 MAINTENANCE
3.2 Unit Piping ..................................................... 24
5.1 General ................................................................... 88
3.3 Air Cooled Package Start-Up ....................... 24
5.2 Periodic Inspection ............................................. 88
3.4 System Start-Up ............................................ 24
5.3 Monthly Inspection.............................................. 88
3.5 Lubrication .................................................... 24
3.5.1 Oil Level .......................................................... 24 5.4 PHE Maintenance ................................................ 88
3.5.2 Oil Type ........................................................... 30 5.4.1 General ............................................................ 88
5.4.2 Evaporator Cleaning ....................................... 88
3.6 System Flow Rate................................................ 30
5.5 Air Cooled Condenser Cleaning ..................... 89
3.7 System Control .................................................... 30
3.7.1 Capacity Control .............................................. 30 5.6 Electrical Malfunction......................................... 89
3.7.2 Solid-State operating Thermostat ................... 30 5.7 Refrigerant Charging .......................................... 89
5.7.1 General ........................................................... 89
5.7.2 Air Cooled Package ........................................ 89
4.0 ELECTRICAL
5.8 Trouble Shooting ................................................. 91
4.1 Electrical Data ...................................................... 33
5.9 Sample Log Sheet ............................................... 92
4.2 IR32 Electronic Thermostat Front Panel ...... 34
-2-
1.0 INTRODUCTION
This manual is prepared to provide all the necessary information of

installation, operation and maintenance of the latest generation of
Dunham-Bush air-cooled chillers with scroll compressors.
In order to be able to make full use of the manual, you must first determine
your unit model number from the unit name plate.
Dunham-Bush package has been manufactured under a stringent quality

control system. Each packaged chiller is performance tested at the factory
at the specified field operating conditions as a final verification of reliability.
If the package is installed, operated and maintained with care and attention
to the instructions contained here in, it will yield many years of satisfactory
service.
It is assumed that the reader of this manual and those who install, operate
and maintain the equipment have a basic understanding of the principles of
air conditioning, refrigeration and electrical controls.
TABLE 1.1 PRODUCTION IDENTIFICATION
AC D S 030 - AR G S
Air Cooled Packaged Chiller S- Standard Fan

F- Low Noise Fan
V- Compressor Jacket
Direct Expansion Evaporator M- Low Noise Fan &
Compressor Jacket
Scroll Compressor R410A
Nominal Capacity in Tons AN- 208-230V/3pH/60Hz

(ARI Condition) AR- 460V/3pH/60Hz
-3-
1.0 INTRODUCTION
1.1 PHYSICAL DATA

MODEL ACDS 010 020 030 040 050 060 070 080
NOMINAL CAPACITY TONS 10.0 20.9 26.9 41.3 53.2 62.0 71.1 81.4
NOMINAL POWER INPUT KW 10.9 22.5 28.0 45.8 56.8 68.9 80.4 90.7
COMPRESSOR
RPM 3500 3500 3500 3500 3500 3500 3500 3500
MIN. % UNIT CAPACITY REDUCTION 50% 50% 50% 25% 25% 25% 25% 25%
NO. OF REFRIGERANT CIRCUIT 1 1 1 2 2 2 2 2
EVAPORATOR
WATER CONNECTOR INCH[MM] 1.6 [41.3] 1.6 [41.3] 1.6 [41.3] 2.5[63.5] 2.5[63.5] 2.5[63.5] 2.5[63.5] 2.5[63.5]
NOM. WATER FLOW / PD 24.9/ 10.6 49.8/ 10.8 66.5/ 12.7 93.0/ 13.5 121.1/ 14.4 157.0/ 14.4 165.1/ 14.8 189/ 15.0
(GPM)/(FT IN WG) [m³/hr / kPa] [5.7/ 31.7] [11.3/ 32.3] [15.1/ 38] [21.1/ 40.4] [27.5/ 43.0] [35.7/ 43.0] [37.5/ 44.2] [42.9/ 44.8]
MIN/MAX. WATER FLOW (GPM)/[m³/hr] 23.0/ 73.0 42.0/ 131.0 53.0/ 161.0 72.0/ 216.0 90.0/ 272.0 116.0/ 351.0 121.0/ 363.0 136.0/ 410.0
[5.2/ 16.9] [9.5/ 29.8] [12.0/ 36.6] [16.4/ 49.1] [20.4/ 61.8] [26.3/ 79.7] [27.5/ 82.4] [30.9/ 93.1]
MIN/MAX. WATER PD 9.5/ 78.7 8.1/ 65.6 8.3/ 72.0 8.8/ 62.6 8.7/ 63.0 8.6/ 63.0 8.7/ 62.6 8.5/ 61.9
(FT IN WG) / [kPa] [28.4/ 235.2] [24.2/ 196.1] [24.8/ 215.2] [26.3/ 187.1] [26.0/ 188.3] [25.7/ 188.3] [26.0/ 187.1] [25.4/ 185.0]
CONDENSER
COIL ROWS DEEP/ TOTAL FA FT²[M²] 3/ 3/ 4/ 3/ 3/ 4/ 4/ 4/

20.0[1.9] 38.5[3.6] 42.8[4.0] 64.2[6.0] 105.0[9.8] 105.0[9.8] 105.0[9.8] 133.0[12.4]
TOTAL CFM 10150 20200 25000 38000 60300 54798 54798 71400
NO OF FAN 1 2 4 4 6 6 6 6
FAN DIA INCH[MM] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 30.0[762] 31.5[800.0]
MOTOR HP (QTY) 1.5 (1) 1.5 (2) 1.5 (4) 1.5 (4) 1.5 (6) 1.5 (6) 1.5 (6) 2.0 (6)
FAN FLA , AMP (QTY) 2.7 (1) 2.7 (2) 2.7 (4) 2.7 (4) 2.7 (6) 2.7 (6) 2.7 (6) 3.4 (6)
MIN. OPERATING AMBIENT °F[°C] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2]
ELECTRICAL
NOM. VOLTAGE 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60
RLA/COMPRESSOR (QTY), AMPS 12 (2) 21 (2) 26 (2) 21 (4) 26 (4) 26 (2) 36 (4) 36 (2)
36 (2) 46 (2)
UNIT MAX. INRUSH, AMPS 102 173 197 221 254 319 339 398
GENERAL
UNIT LENGTH INCH[MM] 58[1473] 96[2438] 98[2489] 98[2489] 142[3607] 142[3607] 142[3607] 148[3759]
UNIT WIDTH INCH[MM] 43[1092] 43[1092] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235]
UNIT HEIGHT INCH[MM] 51[1295] 51[1295] 57[1448] 57[1448] 76[1930] 76[1930] 76[1930] 88[2235]
SHIPPING WEIGHT LB[KG] 929[421] 1503[682] 2350[1066] 2603[1181] 3950[1792] 4153[1884] 4364[1979] 4865[2207]
OPERATING WEIGHT LB[KG] 934[424] 1515[687] 2365[1073] 2629[1193] 3984[1807] 4193[1902] 4409[2000] 4918[2231]
OPERATING CHARGE R410A LB[KG] 26[12] 51[23] 77[35] 101[46] 128[58] 152[69] 179[81] 203[92]
Note: Nominal capacity is based on evaporator LFT 44°F and condenser ambient 95°F, actual capacity depends on the specified operating
conditions.
-4-
1.0 INTRODUCTION
MODEL ACDS 090 100 120 135 150 165 180
NOMINAL CAPACITY TONS 89.8 100.8 108.4 125.4 138.5 153.0 163.7
NOMINAL POWER INPUT KW 103.7 108.7 118.7 130.8 150.0 160.4 176.5
COMPRESSOR
RPM 3500 3500 3500 3500 3500 3500 3500
MIN. % UNIT CAPACITY REDUCTION 25% 25% 25% 16.7% 16.7% 16.7% 16.7%
NO. OF REFRIGERANT CIRCUIT 2 2 2 2 2 2 2
EVAPORATOR
WATER CONNECTOR INCH[MM] 2.5[63.5] 2.5[63.5] 2.5[63.5] 3.0[76.2] 3.0[76.2] 3.0[76.2] 3.0[76.2]
NOM. WATER FLOW / PD 206.8/ 15.2 230.2/ 15.4 272.0/ 15.8 351.2/ 15.2 345.9/ 14.8 404.6/ 17.5 414.5/ 14.8
(GPM) /(FT IN WG) [m³/hr / kPa] [47.0/ 45.4] [52.3/ 46.0] [61.8/ 47.2] [79.8/ 45.4] [78.6/ 44.2] [91.9/ 52.3] [94.1/ 44.2]
MIN/MAX. WATER FLOW (GPM)/[m³/hr] 147.0/ 443.0 161.0/ 484.0 185.0/ 551.0 210.0/ 400.0 210.0/ 400.0 250.0/ 450.0 270.0/ 480.0
[33.4/ 100.6] [36.6/ 109.9] [42.0/ 125.1] [47.7/ 90.8] [47.7/ 90.8] [56.8/ 102.2] [61.3/ 109.0]
MIN/MAX. WATER PD 8.4/ 61.2 8.3/ 60.0 8.0/ 57.5 5.1/ 30.0 5.1/ 30.0 5.1/ 30.0 5.1/ 30.0
(FT IN WG) / [kPa] [25.1/ 182.9] [24.8/ 179.3] [23.9/ 171.9] [15.2/ 89.7] [15.2/ 89.7] [15.2/ 89.7] [15.2/ 89.7]
CONDENSER
COIL ROWS DEEP/ TOTAL FA FT²[M²] 4/ 4/ 4/ 4/ 4/ 4/ 4/

133.0[12.4] 177.3[16.5] 177.3[16.5] 235.6[21.9] 235.6[21.9] 282.6[26.3] 282.6[26.3]
TOTAL CFM 71400 96960 95200 124140 122850 147420 147420
NO OF FAN 6 8 8 10 10 12 12
FAN DIA INCH[MM] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0] 31.5[800.0]
MOTOR HP (QTY) 2.0 (6) 2.0 (8) 2.0 (8) 2.0 (10) 2.0 (10) 2.0 (12) 2.0 (12)
FAN FLA , AMP (QTY) 3.4 (6) 3.4 (8) 3.4 (8) 3.4 (10) 3.4 (10) 3.4 (12) 3.4 (12)
MIN. OPERATING AMBIENT °F[°C] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2] 45 [7.2]
ELECTRICAL
NOM. VOLTAGE 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60
RLA/COMPRESSOR (QTY), AMPS 46 (4) 46 (2) 56 (4) 36 (3) 46 (6) 46 (3) 56 (6)
56 (2) 46 (3) 56 (3)
UNIT MAX. INRUSH, AMPS 418 495 515 494 524 611 641
GENERAL
UNIT LENGTH INCH[MM] 148[3759] 189[4801] 189[4801] 225.5[5728] 225.5[5728] 267.5[6795] 267.5[6795]
UNIT WIDTH INCH[MM] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235] 88[2235]
UNIT HEIGHT INCH[MM] 88[2235] 88[2235] 88[2235] 93[2362] 93[2362] 93[2362] 93[2362]
SHIPPING WEIGHT LB[KG] 5231[2373] 6196[2811] 6309[2862] 7336[3328] 7888[3578] 9120[4137] 9844[4465]
OPERATING WEIGHT LB[KG] 5290[2400] 6264[2841] 6383[2895] 7454[3381] 8005[3631] 9251[4196] 10007[4539]
OPERATING CHARGE R410A LB[KG] 229[104] 254[115] 304[138] 342[155] 381[173] 419[190] 456[207]
Note: Nominal capacity is based on evaporator LFT 44°F and condenser ambient 95°F, actual capacity depends on the specified operating
conditions.
-5-
2.0 INSTALLATION
2.1 GENERAL 2.3.2 RIGGING AND MOVING

The ACDS chiller is designed to cool water or Any unit mounted on skids may be moved
with a forklift, but care must be taken not
other non-corrosive liquids. Water is circulated
to damage the unit with forks. The skids
through the direct expansion evaporator where it
should not be removed until the unit is at
is cooled to the desired temperature and then its final location.
circulated to cooling coils for air conditioning, or to
The ACDS model can be lifted by the
other types of heat exchangers for process
method showing in Figure 2.3.2.
cooling.
Care should be taken to ensure that the
equipment is properly installed and adjusted. An 2.4 SPACE REQUIREMENTS
installer or operator should first be familiar with AND CLEARANCE
the information in this manual.
2.4.1 GENERAL
The dimensional data and clearances that
2.2 INSPECTION
follow are useful for determining space
When the equipment is delivered, it is important requirements. The unit should be placed
that the following inspection be completed in the to make the clearance noted available for
presence of the carrier's representative: proper servicing. Failure to allow such
1. Check all crates and cartons received against clearance will cause serious problems
the Bill of Lading/Shipping Papers to be sure and result in higher costs for operation,
they tally. maintenance and repair.
2. Check the model number and the electrical
characteristics on the nameplate to determine 2.4.2 ACDS
if they are correct. The dimensional data are shown in
3. Check for freight damage, shortages or other Figure 2.4.2B and space requirements
discrepancies and take note of them on the are shown in Figure 2.4.2A. The most
delivery receipt before signing. important consideration which must be
taken into account when deciding on the
Should any damage be found, a damage
location of an air cooled equipment, is the
claim should immediately be filed by the
provision for supply of ambient air to the
purchaser against the delivering carrier as all
condenser, and removal of heated air
shipments are made at the purchaser's risk.
from the condenser area. When this
essential requirement is not provided, it
will result in higher condensing
2.3 RIGGING temperatures, which will cause poor
2.3.1 GENERAL operation, higher power consumption and
eventually failure of equipment. Units
Each unit has been carefully tested and
must not be located in the vicinity of
packed at the factory where every care is
taken to ensure that the unit reaches you steam, hot air or fume exhausts.
in perfect condition. It is very important Another consideration which must be
that the riggers and movers use the same taken into account is that the unit should
care and precaution in moving the be mounted away from noise sensitive
equipment into place. Make sure that spaces and must have adequate support
chains, cables, or other moving to avoid vibration and noise transmission
equipment are placed so as to avoid into the building. Units should be
damage to the unit or piping. The
mounted over corridors, utility areas, rest
refrigerant piping should not be used as a
rooms or other auxiliary areas where
ladder or as a handle. Do not attach a
chain hoist sling to the piping or sound levels are not an important factor.
equipment. Move the unit in an upright Sound and structural experts should be
position and let it down gently from trucks consulted for recommendations on critical
or rollers. installations.
-6-
2.0 INSTALLATION
FIGURE 2.3.2 ACDS RIGGING

ACDS 010
ACDS 020
-7-
2.0 INSTALLATION
ACDS 030, 040, 050, 060, 070
ACDS 080, 090, 100, 120,
ACDS 135, 150, 165, 180
-8-
2.0 INSTALLATION
FIGURE 2.4.2B DIMENSIONAL DATA

ACDS 010
-9-
2.0 INSTALLATION
ACDS 020
- 10 -
2.0 INSTALLATION
ACDS 030
- 11 -
2.0 INSTALLATION
ACDS 040
- 12 -
2.0 INSTALLATION
ACDS 050, 060, 070
- 13 -
AIR FLOW
ACDS 080, 090
60.5 [1537.400 mm]

24 [609.600 mm]
48 [1219.200 mm]
POWER ENTRY
(BOTTOM)
DOOR SWING
88 [2235.600 mm]
2.0 INSTALLATION
- 14 -
AIR FLOW
48 [1218.800 mm]
AIR FLOW
TOP VIEW CONTROL BOX ACCESS
88 [2236.711 mm]
6 NOS OF 3/4" (19) 84 [2134]
MOUNTING HOLES 6 NOS OF n 2.9 [73mm] LIFTING
12 [300.300 mm] 88
FOR SPRING ISOLATORS HOLES ON BOTH SIDE OF THE FRAME
66 [1675.100 mm] 58 [1467.100 mm] 12 [304.800 mm]
148 [3747.000 mm]
REAR VIEW LEFT VIEW FRONT VIEW

2.0 INSTALLATION
ACDS 100, 120
- 15 -
NOTES: WATER IN CONNECTION [3.5"] NOMINAL DIA
OPTIONAL-WELDED FLANGE CONNECTION
1. ALL DIMENSIONS ARE IN INCHES AND MILIMETERS.
2. ALLOW 60 [ 1254 ] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICES.
3. USE MINIMUM 36 [ 914 ] FLEXIBLE CONDUIT TO CONTROL BOX TO ISOLATE UNIT.
4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT.
33 [836.000 mm]
ACDS 135, 150
9 [219.500 mm]
DETAIL A
Approx.
WATER OUT CONNECTION [3.5"] NOMINAL DIA

OPTIONAL WELDED FLANGE CONNECTION
44 [1119.700 mm]
Approx.
24 [609.200 mm] 60.5 [1536.600 mm]

AIR FLOW 48 [1216.800 mm]
POWER ENTRY
(BOTTOM)
88 [2237.600 mm] DOOR SWING

2.0 INSTALLATION
- 16 -
48 [1219.200 mm]
AIR FLOW
AIR FLOW TOP VIEW .

CONTROL BOX ACCESS
93 [2357.500 mm]
A
POWER ENTRY
(BOTTOM)
6 NOS OF 3/4" (19) 6 NOS OF ? 2.9 [? 73.200 mm] LIFTING 84 [2134]

MOUNTING HOLES HOLES ON BOTH SIDE OF THE FRAME 88 [2235]
FOR SPRING ISOLATORS
30 [762.000 mm] 83 [2101.850 mm] 83 [2101.850 mm] 30 [762.000 mm]
226 [5740]

NOTES: WATER IN CONNECTION [3.5"] NOMINAL DIA
1. ALL DIMENSIONS ARE IN INCHES AND MILIMETERS.
2. ALLOW 60 [ 1254 ] CLEARANCE AT CONTROL PANEL END OF UNIT FOR SERVICES.
3. USE MINIMUM 36 [ 914 ] FLEXIBLE CONDUIT TO CONTROL BOX TO ISOLATE UNIT.
4. WATER PIPING TO BE SUPPORTED TO MINIMIZE LOAD ON UNIT.
33 [836.000 mm]
12 [294.900 mm]
Approx.
DETAIL A
WATER OUT CONNECTION [3.5"] NOMINAL DIA
ACDS 165, 180
44 [1116.050 mm]
Approx.
24 [609.600 mm] 60 [1524.000 mm]
AIR FLOW 48 [1219.200 mm]
POWER ENTRY
88 [2237.600 mm]
DOOR SWING
2.0 INSTALLATION
- 17 -
48 [1216.800 mm]
AIR FLOW
AIR FLOW TOP VIEW

.
CONTROL BOX ACCESS
93 [2353.719 mm]
POWER ENTRY
(BOTTOM)
84 [2134]
88 [2235]
8 NOS OF 3/4" (19)
MOUNTING HOLES 8 NOS OF n 2.9 [73mm] LIFTING
FOR SPRING ISOLATORS HOLES ON BOTH SIDE OF THE FRAME
30 [762.000 mm] 69 [1756.830 mm] 69 [1756.830 mm] 69 [1756.830 mm] 30 [762.000 mm]
267.5 [6794.500 mm]

2.0 INSTALLATION
2.5 FOUNDATION Rubber-in-shear or spring vibration isolators are

offered as optional items. When spring isolators
2.5.1 AIR COOLED UNITS are used, flexible connectors must be installed in
The foundation must be level for proper the water piping system and in the refrigerant
operation and functioning of controls and lines of split systems. Kindly note that: These
provision must be made for supporting flexible connectors must be suitable for the fluid
the individual load points as shown in and pressures involved.
Figure 2.5.1, Roof mounted units must be When using flexible connectors in refrigerant
supported on adequate steel structures. If piping, they must be mounted in the refrigerant
units are located on the ground level, a discharge and liquid lines close to the packaged
concrete plinth is recommended. chiller, in a horizontal position and parallel to the
compressor crankshaft.
2.6 VIBRATION ISOLATION All piping which is external to the packaged chiller
must be supported by spring mounted hangers
Under certain critical conditions, it may be and any piping which goes through the wall,
necessary to install vibration isolators under the ceiling or floor should be properly pivoted to
base of the Packaged Chiller. prevent transmission of piping vibration to the
structure.
FIGURE 2.5.1 FLOOR LOADING DIAGRAM
ACDS 010 ACDS 020
POINT LOAD LOCATION

MODEL DIMENSIONS – INCH [MM]
ACDS A B C D
010 31 (787) 2 (51) 54 (1372) 2 (51)
020 31 (787) 2 (51) 92 (2337) 2 (51)
POINT LOAD DATA

LOADS – LBS [KG] TOTAL
MODEL OPERATING
ACDS P1 P2 P3 P4 WEIGHT
LBS [KG]
010 208 [94] 213 [97] 247 [112] 267 [121] 934 [424]
020 348 [158] 410 [186] 410 [186] 348 [158] 1515 [687]
- 18 -
2.0 INSTALLATION
ACDS 030, 040, 050, 060, 070
ACDS 080, 090, 100, 120, 135, 150
ACDS 165, 180
- 19 -
2.0 INSTALLATION
POINT LOAD LOCATION

DIMENSIONS – INCH [MM]
MODEL
ACDS
A B C D E F
030 84 [2134] 16 [406] 76 [1930] 16 [406] - -
040 84 [2134] 16 [406] 76 [1930] 16 [406] - -
050 84 [2134] 20 [508] 102 [2600] 20 [508] - -
060 84 [2134] 20 [508] 102 [2600] 20 [508] - -
070 84 [2134] 20 [508] 102 [2600] 20 [508] - -
080 84 [2134] 12 [305] 58[1467] 66 [1675] 12 [305] -
090 84 [2134] 12 [305] 58[1467] 66 [1675] 12 [305] -
100 84 [2134] 16 [406] 86 [2172] 71 [1803] 16 [406] -
120 84 [2134] 16 [406] 86 [2172] 71 [1803] 16 [406] -
135 84 [2134] 30 [762] 83 [2102] 83 [2102] 30 [762] -
150 84 [2134] 30 [762] 83 [2102] 83 [2102] 30 [762] -
165 84 [2134] 30 [762] 69 [1757] 69 [1757] 69 [1757] 30 [762]
180 84 [2134] 30 [762] 69 [1757] 69 [1757] 69 [1757] 30 [762]
POINT LOAD DATA

LOADS - LBS [KG] TOTAL
MODEL OPERATING
ACDS WEIGHT
P1 P2 P3 P4 P5 P6 P7 P8 LBS [KG]
030 470 [213] 713 [323] 713 [323] 470 [213] - - - - 2365 [1073]
040 611 [277] 704 [319] 704 [319] 611 [277] - - - - 2629 [1193]
050 1060 [481] 932 [423] 932 [423] 1060 [481] - - - - 3984 [1807]
060 1133 [514] 963 [437] 963 [437] 1133 [514] - - - - 4193 [1902]
070 1207 [548] 998 [452] 998 [452] 1207 [548] - - - - 4409 [2000]
080 836 [379] 819[372] 804[365] 804[365] 819[372] 836 [379] - - 4918 [2231]
090 904 [410] 881 [400] 860 [390] 860 [390] 881 [400] 904 [410] - - 5290 [2400]
100 1026 [465] 1043 [473] 1064 [482] 1064 [482] 1043 [473] 1026 [465] - - 6264 [2841]
120 1049 [476] 1063 [482] 1080 [490] 1080 [490] 1063 [482] 1049 [476] - - 6383 [2865]
135 1137 [516] 1242 [564] 1348 [611] 1348 [611] 1242 [564] 1137 [516] - - 7454 [3381]
150 1225 [556] 1334 [605] 1443 [655] 1443 [655] 1334 [605] 1225 [556] - - 8005 [3631]
165 1110 [504] 1141 [518] 1172 [532] 1202 [545] 1202 [545] 1172 [532] 1141 [518] 1110 [504] 9251 [4196]
180 1225 [556] 1242 [564] 1260 [571 1277 [579] 1277 [579] 1260 [571] 1242 [564] 1225 [556] 10007 [4539]
- 20 -
2.0 INSTALLATION
2.7 PIPING CONNECTIONS 2.7.2 WATER CONNECTIONS -

Multiple Packaged Chillers
2.7.1 WATER CONNECTIONS Multiple unit package chillers have been
CHILLED WATER PIPING successfully applied to parallel and series
After the unit has been leveled, the piping systems for years. Special
external water piping may be set up. Be attention, however, must be given to the
sure that the water piping is connected to particulars involved for each application
the corresponding connectors. The water- or serious operational problems can
outlet connection of the evaporator is result. The following guidelines should be
closest to the expansion valve (refrigerant followed for multiple unit application.
circuit) end.
It is assumed that the chilled water flow
Water flow through the evaporator must rate is constant.
remain constant for proper chiller
operation. Water pressure gauges are 2.7.2.1 Parallel Chilled Water Flow Units
recommended to check the water
Method A: Both units operate
pressure and flow rate in the system,
simultaneously, modulating with load
before and after the evaporator, and to
variations. Each packaged chiller
determine if variations occur in the
operating thermostat senses the return
evaporator and system. When installing
water temperature using standard
pressure taps to measure the amount of
controls (See Figure 2.7C). The set point
pressure drop across the water side of
of each thermostats will be set to
the evaporator, the taps should be
maintain the desired unloading. In
located at least twenty-four (24) inches
addition to that, for each chiller package,
[610mm] downstream from any
the suction sensing hot gas by-pass
connections (flange, elbow, etc.) in the
valve provides modulating capacity
water piping.
reduction from 100% to approximately
There are many piping and control 30% on single compressor models with
systems which may be used to ensure hot gas by-pass.
constant water flow through the
Method B: Install units the same as
evaporator. A typical system is shown in
Method A, but add a third thermostat in
Figure 2.7A. A three-way motorized
the return water, as shown in Figure
valve, which operates in response to the
2.7E. This thermostat will be set to cycle
discharge air temperature of the cooling
off one of the units when the load drops
coil, is used.
below 50%. When this condition is
Another system which is sometimes used reached, the leaving mixed water
consists of a two-way modulating control temperature will rise, causing the return
valve, which also responds to the water temperature to rise and the unit
discharge air temperature of the cooling operating will load up. The "off" unit is
coil, used with a spring loaded bypass sequencing to start again before full
regulating valve as shown in Figure 2.7B system load temperature is reached.
The bypass valve must be set to ensure
This system will be as stable as Method
full flow of circulating chilled water when
A, in operation, but in normal air-
the modulating valve is completely
conditioning applications, this is not
closed.
detrimental. The advantage of Method B
Other systems are noted in the ASHRAE is a better part load efficiency. Also a
Handbook and may operate equally well. lead-lag control can be added.
Whatever the system is selected, the
water flow must be constant.
- 21 -
2.0 INSTALLATION
FIGURE 2.7A
FIGURE 2.7B
FIGURE 2.7C FIGURE 2.7D
FIGURE 2.7E
- 22 -
2.0 INSTALLATION
2.7.2.2 Series Chilled Water Flow Units

- All field wirings are to be in accordance
Units should be equally sized. The with the National Electrical Code and
upstream unit will carry a larger load state and local codes.
because it cools higher temperature
- All wirings are to be checked for damage
water. The thermostats sense inlet
and all terminal connections are to be
water temperatures. (See figure 2.7D).
tested for tightness. Unit terminal blocks
The number 1 unit thermostat will
are to be connected with copper
unload or cycle off the packaged chiller
conductors only and sized per ampacity
before unloading occurs of the Number
listed on unit data plate.
2 unit.
- The power supply should match the unit
2.7.3 WATER QUALITY nameplate in volts, phase and Hertz.
Voltage must be within ±10% of
Evaporators used in this packages is
nameplate value and voltage imbalance
made of steel and copper and are
between phases must not exceed 2%
suitable for operation with well-
maintained water systems. However, if
the water used in evaporator is corrosive,
high in mineral content or entrained
2.9 REQUEST FOR START-UP
solids, the water can reduce the
performance and even damage the heat
REPRESENTATIVE
exchangers. Therefore, it may be
Start-up service is an option upon request when
necessary to obtain the service of a water
an order for the unit is placed. If you request for
treatment consultant and to provide and
start-up service, then after the installation has
maintain water treatment. This is
been completed and checked, a written notice
particularly important with glycol systems
shall be given to the Dunham-Bush
and with cooling tower loops.
representative. Following receipt of written notice,
a representative will be sent to the customer. The
purchaser should have competent service and
2.8 ELECTRICAL operating personnel in attendance to assist in the
CONNECTIONS work involved, and also to be trained in the
operation and maintenance of this unit.
2.8.1 GENERAL The representative will inspect the installation to
All units are wired as completely as determine whether it meets Dunham-Bush
possible at the factory prior to delivery. requirements, perform the initial start-up of the
The connections which must be made by installation determine whether it is in satisfactory
the installer are to the main power operating condition, and instruct specified
source, starting equipment and customer personnel in its operation and
interlocking the satellite equipment. In maintenance for the length of time specified in the
connecting power wiring to the unit, the purchase contract.
following precautions should be taken:
- 23 -
3.0 OPERATION
3.1 GENERAL 3.4 SYSTEM START-UP

The unit should be started up only by a 1. Before starting the compressor(s), check all
refrigeration technician who is familiar with the three phases of supply voltage, of all legs of
accepted operation practices for refrigeration the motor. They must be within ±10% of the
systems. nameplate voltage.
Use the scroll unit start-up report, to record all 2. Start compressor(s), check the gauges and
temperature, pressure, electrical readings and note if the pressures are within the prescribed
control settings. A copy must be forwarded to limits.
Dunham-Bush service department, before
warranty will be honored. 3. Check the refrigerant sight glass to be sure it
is free of bubbles. If not, charge as specified
per section 4.8 Charging.
4. Shut the compressor down and check the
3.2 UNIT PIPING compressor crankcase sight glass for oil level.
It should be between 1/2 to 3/4 of the
See Figure 3.2.1 for typical unit piping
schematics. complete sightglass. If not, see Section 3.5
Lubrication.
5. Restart the compressor. After an hour of
operation the expansion valve superheat
3-3 AIR COOLED PACKAGES setting should be checked, it should be
START-UP between 8°F [4.4°C] and 10°F [5.6°C] at full
load design conditions. In some instances, it
The unit is ready for start-up when the following will be necessary to lower the superheat
procedures have been completed: setting to ensure proper distribution. Turn the
1. Water piping for the evaporator is installed TX valve adjustment stem clockwise to
and tested. increase the superheat setting and
counterclockwise to decrease the setting. Be
2. Electrical connections are made and properly
sure and allow ample time between each
fused.
adjustment for the system to rebalance.
3. Unit has been leak tested, leaks corrected
6. The temperature of the chilled water both in
and charge completed.
and out, should be checked to insure the unit
4. Compressor crankcase heater(s) has been is operating within the desired temperatures.
energized for a minimum of 24 hours.
5. Calibrated refrigerant gauges have been
connected to the suction and discharge ports. 3.5 LUBRICATION
6. Turn On the chilled water pump, check 3.5.1 OIL LEVEL
direction of rotation and adjust the water flow
through the evaporator to the specified flow A properly operated unit should run with
rate. Bleed off all entrained air. the compressor crankcase warm to touch.
Check oil level frequently to see that a
7. Manually energize the fan starters and check sufficient amount of oil remains in the
the fan rotation. Fans should pull air through crankcase. Compressor oil level can be
the condenser coil and discharge vertically checked by the sight glass. To make sure
upwards. Rotation can be changed on 3- that proper oil level is observe, operate
phase motors by interchanging only two wires the compressor for 15 minutes, then stop
on the main terminal block. the compressor. Oil should appear from
8. Check all refrigerant valves to be sure they 1/2 to 3/4 in the sight glass with the
are open. compressor stopped.
9. Proceed to section 3.4 System Start-Up.
- 24 -
3.0 OPERATION
FIGURE 3.2.1 TYPICAL PIPING SCHEMATIC

ACDS 010, 020, 030
- 25 -
3.0 OPERATION
ACDS 040, 050, 060, 070
- 26 -
3.0 OPERATION
ACDS 080, 090, 100, 120
- 27 -
3.0 OPERATION
ACDS 135, 150
- 28 -
3.0 OPERATION
ACDS 165, 180
- 29 -
3.0 OPERATION
3.5.2 OIL TYPE - Variation of unit capacity in response to

If the oil becomes discolored indicating system load requirements is controlled
contamination, the contamination can be by an operating thermostat, which
take care of by installing a new filter-drier monitors the return water temperature.
in the liquid line and changing the oil. - On multiple compressor units, capacity
WARNING: is controlled by compressor staging.
Use Only Dunham-Bush Approved Refer to Table 3.7.1 to determine the
Refrigeration Oil, Warranty Will Be capacity control scheme for your
Void If Other Than Approved Oil Is specific unit.
Used. It is recommended to change oil
annually to prolong the compressor TABLE 3.7.1 CAPACITY CONTROL
life-time. COMPRESSOR CYLINDER UNLOADING
ACDS CAPACITY
AND STAGING SCHEDULE
Oil charge for a complete recharge shown ACDS 010, 020, 030
in the following table. Oil type and COMPRESSOR OFF 0.0%
COMPRESSOR 1 ON 100% 50.0%
approved oils are also listed for each
ACDS 040, 050, 060, 070, 080, 090, 100, 120
compressor. After recharge the oil level
COMPRESSOR OFF 0.0%
should be maintained per section 3.5.2. COMPRESSOR 1 ON 100% 25.0%
COMPRESSOR MODEL OIL CHARGE (L) APPROVED OIL COMPRESSOR 3 ON 100% 75.0%
HLH 068 1.6 PVE COMPRESSOR 4 ON 100% 100.0%
ACDS 135, 150, 165, 180
SH 140 3.3
COMPRESSOR OFF 0.0%
SH 180
POE COMPRESSOR 2 ON 100% 33.3%
SH 240 6.7
(160SZ)
SH 300
SH 380 7.2 COMPRESSOR 5 ON 100% 83.4%
3.6 SYSTEM FLOW RATE

3.7.2 SOLID-STATE OPERATING
The quantity of chilled water being circulated can THERMOSTAT
be estimated by determining the water pressure
3.7.2.1 General
drop through the evaporator by reading GPM
[L/S] from the appropriate pressure drop curve. A four-stage solid-state operating
(See Figure 3.6) thermostat, FSE, is used on all AC
packages. The opstat senses return
An alternate method of determining GPM [L/S]is
chilled water or air temperature and by
to measure pressure difference from pump inlet to
staging and/or unloading compressors is
outlet and read GPM [L/S] from pump curve.
able to control leaving chilled water or air
Water flow rate must not vary more than ±10% temperature to a narrow band of
from design flow rate. temperature.
3.7.2.2 Opstat Settings

3.7 SYSTEM CONTROL
Each four-stage electronic opstat is
3.7.1 CAPACITY CONTROL factory, adjusted to your specified
conditions, A field check of the controller
The standard system capacity control
may be made by first determining your
operates as follows:
design range (R). To determine the
- As the chiller load initially drops, the range of a water chiller, subtract the
suction of the compressor(s) starts design leaving water temperature (TLW)
dropping proportionately, thus from the return water temperature
balancing minor load variations. (TRW) (R =TRW-TLW).
- 30 -
3.0 OPERATION
The standard range is 10°F [5.6°C]. To rated to handle both rated load amp and locked
determine the range of a condensing rotor amps.
unit, subtract the design no load return
air temperature (TNL) from the design CR - Relays (Miscellaneous Control)
full load return air temperature (TFL) (R= These relays provide the necessary circuit logic
TFL- TNL). The standard range is 6°F for lock-in, lock -out and transfer functions.
[3.3°C].
Set point of the opstat should be your HTR - Crankcase Heater
design leaving chilled water temperature Energized continuously as long as control circuit
(TLW) for water chillers. The standard power disconnect switch (not supplied with the
adjustment range for AC units is 32 to unit) is closed and compressor is off. This heater
104°F [0° to 40°C]. maintains crankcase temperature above the
The location of setting knob is shown in system temperature during the compressor off
Figure 3.7.2A. cycle, preventing refrigerant migration into the
Step Temp adjusts the temperature crankcase and consequent compressor damage.
range per stage in degrees F. To
determine TRB. For a standard
SOL-
condensing unit TRB= 0.25 x R. Check i.) Liquid Line Solenoid Valve
the dial setting on the opstat. The
Closes when the compressor(s) is off to
approximate setting of Step Temp is
prevent any liquid refrigerant from
shown in the Figure 3.7.2B by the Step
accumulating in the chiller during the off
Temp should be changed by an
cycle.
authorized serviceman only.
ii.) Discharge Solenoid Control (Optional)
This function is used in low ambient
application. Discharge solenoid is turn off to
3.8 ELECTRICAL CONTROLS
reduce condensing surface and to increase
head pressure.
MCCB/MCB/MMS - Main Circuit Breaker
This is an automatic, calibrated, ambient OL - Motor Overload
compensated, magnetic trip circuit breaker, which (Manual Reset)
provides both direct line-break compressor
For AC the compressor is protected by overload
branch circuit. short circuit locked rotor and
relays utilizing quick trip, ambient compensated
overload protection. It has a manually operable
heaters. The overload relays are manually reset.
handle for compressor circuit disconnect, and an
auxiliary NO. switch (optional) which interrupts the OUVR - Over Under Voltage Relay
115V compressor control circuit when the breaker (Optional)
opens.
Protects the unit from the following electric supply
malfunctions: over voltage, under voltage, please
M- Contactor (Compressor and Fan
reversal, single phasing and phase imbalance. If
Motor)
the OUVR trips, a control relay will de-energize
The contactor, operated by the control circuit, and open the control circuit. A red LED trip light,
provides power individually to the compressor and located on the OUVR, will indicate a supply
fan motors. Contactors are used either singly or in malfunction. Tile OUVR is a manual reset control
parallel pairs for across-the-line start device.
(simultaneous operation). These devices are amp
- 31 -
3.0 OPERATION
FIGURE 3.6 WATER SIDE PRESSURE DROP

1a.) IMPERIAL UNITS
100
ACDS 010
ACDS 020
ACDS 030
ACDS 040 ACDS 100
ACDS 050 ACDS 120
.
ACDS 060 ACDS 090

ACDS 070
PRESSURE DROP - FT.WG.
ACDS 080
10
ACDS 135
ACDS 150
ACDS 165
ACDS 180
1
10 100 1000
WATER FLOW RATE - GPM
1b.) SI UNITS
1000
ACDS 010
.
ACDS 020
PRESSURE DROP - kPa.
ACDS 030
ACDS 040
ACDS 090
ACDS 050
100 ACDS 100
ACDS 060
ACDS 120
ACDS 070
ACDS 080
ACDS 135
ACDS 150
ACDS 165
ACDS 180
10
1 10 100 1000
WATER FLOW RATE - m³/hr
- 32 -
4.0 ELECTRICAL
4.1 ELECTRICAL DATA

Power Supply Standard Unit Electrical Data Each Compressor Condenser Fan Motors
MODEL
V-Ph-Hz RLA MCA MFS/HACR Qty RLA LRA-XL Qty HP FLA/Mtr
208/230-3-60 61 68 90 2 27 145 1 2 7.2

ACDS-010
460-3-60 27 30 40 2 12 87 1 2 3.4
208/230-3-60 103 114 150 2 46 304 2 1.5 5.4

ACDS-020
460-3-60 47 53 70 2 21 147 2 1.5 2.7
208/230-3-60 134 148 200 2 56 320 4 1.5 5.4

ACDS-030
460-3-60 63 69 90 2 26 160 4 1.5 2.7
208/230-3-60 206 217 250 4 46 304 4 1.5 5.4

ACDS-040
460-3-60 95 100 110 4 21 147 4 1.5 2.7
208/230-3-60 256 270 300 4 56 320 6 1.5 5.4

ACDS-050
460-3-60 120 127 150 4 26 160 6 1.5 2.7
2 56 320
208/230-3-60 294 313 350 6 1.5 5.4
2 75 485
ACDS-060
2 26 160
460-3-60 140 149 175 6 1.5 2.7
2 36 215
208/230-3-60 332 351 400 4 75 485 6 1.5 5.4

ACDS-070
460-3-60 160 169 200 4 36 215 6 1.5 2.7
2 75 485
208/230-3-60 381 405 450 6 2 7.2
2 94 560
ACDS-080
2 36 215
460-3-60 184 196 225 6 2 3.4
2 46 260
208/230-3-60 419 443 500 4 94 560 6 2 7.2

ACDS-090
460-3-60 204 216 250 4 46 260 6 2 3.4
2 94 560
208/230-3-60 486 516 600 8 2 7.2
2 120 680
ACDS-100
2 46 260
460-3-60 231 245 300 8 2 3.4
2 56 320
208/230-3-60 538 568 600 4 120 680 8 2 7.2

ACDS-120
460-3-60 251 265 300 4 56 320 8 2 3.4
3 75 485
208/230-3-60 579 603 700 10 2 7.2
3 94 560
ACDS-135
3 36 215
460-3-60 280 292 300 10 2 3.4
3 46 260
208/230-3-60 636 660 700 6 94 560 10 2 7.2

ACDS-150
460-3-60 310 322 350 6 46 260 10 2 3.4
3 94 560
208/230-3-60 728 758 800 12 2 7.2
3 120 680
ACDS-165
3 46 260
460-3-60 347 361 400 12 2 3.4
3 56 320
208/230-3-60 806 836 900 6 120 680 12 2 7.2

ACDS-180
460-3-60 377 391 400 6 56 320 12 2 3.4
Note: MCA - Minimum Circuit Ampacity MFS - Maximum Fuse Size RLA - Running Load Amps
FLA – Full Load Amps LRA - Locked Rotor Amps
- 33 -
4.0 ELECTRICAL
4.2 IR32 ELECTRONIC THERMOSTAT FRONT PANEL
1- Display: shows the value measured by the connected sensor. In the event of alarm condition the
sensor value will be displayed alternately with the codes of the active alarms. When programming the
instrument, the display shows the parameter codes being introduced and their values.
2- Decimal Point LED: lights up when the controlled parameter is displayed.
3- Reverse LED: flashes when at least one relay working in the "Reverse" mode is active. The Led
flashes as many times as the number of active 'reverse' relays. There is a two seconds' pause
between a flashing stage and the next one.
4- Direct LED: flashes when at least one relay working in the "Direct" mode is active. Its working logic is
the same as the "Reverse" LED.
5- SEL Button: displays and/or allows you to select the Set-point. If pressed for 5 seconds together with
PRG/MUTE it allows you to enter the password and the configuration parameters (having a "Cxx" type
code).
6- PRG/Mute Button: if pressed for 5 seconds it allows you to access the menu of the more frequently
used parameters (having a "Pxx" type code). In the event of alarm condition, it silences the buzzer
and, if pressed after the cause that determined the alarm has disappeared, it resets any other alarm. It
completes the programming procedure storing all the values of the modified parameters.
7- Button Δ: increases the value of the set-point or that of any other selected parametel:
8 - Button ∇ : decreases the value of the set-point or that of any other selected parametel: In NTC input
versions it can display the value of the second sensor (holding "Down" pressed while the display
shows the value of the main sensor).
Note: for Infrared Universal, Series models, please refer to the table at the end of the manual
4.2.1 TYPICAL CONTROL SEQUENCE WITH 2 STAGE OPERATING

THERMOSTAT AT 10°C RETURN WATER SETPOINT, 3.0°C DIFFERENTIAL
- 34 -
4.0 ELECTRICAL
4.2.2 KEYPAD OPERATION 4) "C" Parameters modification:

Press [SEL] key + PRG/mute] key for 5
1) Set-point display: sec allows you to enter password and
Press [SEL] key to display set-point. configuration parameters ("Cxx" type
code). Display show 0. Select password
2) Set-point modification: by pressing [up arrow] key until 22 or 77
Press [SEL] key for few sec to change display. Press [SEL] key to confirm. Code
St1 setpoints. Release [SEL] key, actual C0 displayed if password is correct else
set-point value flashes. Use [up arrow] or repeat procedure. Use [up arrow] or
[down arrow]key to change value. Press [down arrow] key to desire parameter.
[SET] key to confirm new value. Press [SEL] to confirm. Use [up arrow] or
[down arrow] key to desire value. Press
3) "P" Parameters modification: [SEL] to confirm. Repeat procedure for
other parameters. Press [PRG/mute] key
Press [PRG/mute] key for 5 sec allows
to exit.
you to access the most frequent used
parameters ("Pxx" type code).Use [up 5) Alarm Handling:
arrow] or [down arrow] key to require
In the event of alarm condition, press
parameter. Press [SEL] key to display this
[PRG/mute] key to silence the buzzer. If
parameter. Use [up arrow] or [down
pressed after the cause of alarm
arrow] key to set value. Press [SEL] key
disappeared, it resets any other alarm.
to confirm. Repeat procedure for other
parameters. Press [PRG/mute] key to 6) Second Probe Display:
store modified data and go back to
normal operation. For NTC input versions, 2nd probe value
can be displayed by pressing [down
arrow] key while the main probe value is
displayed.
4.2.3 IR32 ELECTRONIC THERMOSTAT PARAMETERS LIST

Par. Description Min. Max. Default Fac. Set
St1 Set Point 1 min probe max probe 20 6
St2 Set Point 2 (Modes 6,7,8,9) min probe max probe 40 NA
CO Operation Mode 1 9 2 1
Setting Differentials
P1 Set Point 1 Differential (absolute value) 0.1 99.9 2 2
P2 Set Point 2 Differential 0.1 99.9 2 NA
P3 Dead Zone Differential (Modes 3,4,5) (absolute value) 0 99.9 2 NA
C4 Authority. NTC models only with Mode 1or 2 and
-2 2 0.5 0.5
C19 = 2, 3 or 4
C5 Control Action: 0=Proportional (P) 1=Prop+Integral (P+I) 0 1 0 0
Outputs
C6 Delay time (sec) btw energization of different relays 0 999 5 120
C7 Min time (min) btw energization of the same relay 0 15 0 5
C8 Min off time (min) of the same relay 0 15 0 3
C9 Min on time (min) of the same relay 0 15 0 0
Outputs Status in the event of sensor alarm:
0 = All relays de-energized
C10 1 = All relays energized 0 3 0 0
2 = DA relays energized, all others de-energized
3 = RA relays energized, all others de-energized
Output Rotation: (Modes 1,2,6,7,8 only)
0 = No rotation
C11 1 = Standard rotation 0 7 0 0
2 = 2+2 rotation (compressor on relays 1 & 3)
3 = 2+2 rotation (valve normal open)
- 35 -
4.0 ELECTRICAL
Par. Description Min. Max. Default Fac. Set

C11 Output models only (A and Z) 0 7 0 0
4 = Rotation of relays 3 & 4 (No rotation for 1 & 3)
5 = Rotation of relays 1 & 2 (No rotation for 3 & 4)
6 = Separate rotation of coupled relays 1-2 & 3-4
7 = Rotation on relays 2,3,4 (No rotation for 1)
C12 PWM cycle time (sec) 0.2 999 20 NA
Sensor
C13 Probe type: 0 = 4-20, 1 = 0-20; 0 = K tc 1 = J tc 0 1 0 0
NTC probe : 0 = normal function, 1= invert function,
(instrument display NTC2 and control on NTC1)
P14 Probe calibration or offset -99 99.9 0 0
C15 Analog Input min.scaling value -99 C16 0 NA
C16 Analog Input max.scaling value C15 999 100 NA
C17 Probe response time (noise filter) 1 14 5 5
C18 Temperature unit: 0 = C, 1 = F 0 1 0 0
C19 2nd Probe: NTC only, Mode 1 or 2 0 4 0 0
0 = no modification on std. Mode
1 = differential mode (NTC1 - NTC2)
2 = summer offset
3 = winter offset
4 = active offset with Dead zone P2
C21 Set point 1 min. limit -99 C22 min. probe -50
C22 Set point 1 max. limit C21 999 max. probe 90
C23 Set point 2 min. limit -99 C24 min. probe -50
C24 Set point 2 max. limit C23 999 max. probe 90
Alarms
P25 Low temp. alarm set point -99 P26 min. probe -50
P26 High temp. alarm set point P25 999 max. probe 90
P27 Alarm hysteresis 0.1 99 2 2
P28 Alarm delay, min 0 120 60 60
C29 Digital input 1 configuration (CO different from 6,7,8) 0 4 0 4
In case of alarm the status of relays depends on C31
0 = non active input
1 = immediate alarm with automatic reset
2 = immediate alarm with manual reset
3 = delay alarm (P28) with manual reset
4 = on/off of the control
C30 Digital input 2 configuration (IRDR only) 0 4 0 NA
option as for C29
C31 Outputs Status in case of alarm condition detected 0 3 0 0
via digital input:
0 = All relays de-energized
1 = All relays energized
2 = DA relays energized, all others de-energized
3 = RA relays energized, all others de-energized
Others
C32 Unit address (for serial connection) 1 16 1 1
Special Parameters
C33 Special mode of operation: 0 = No, 1 = Yes 0 1 0 0
DO NOT MODIFY THIS PARAMETER
Set and programmed starting mode C0 before
modifying C33
C50 Keypad(KP) and Remote Control(RC) activation: 0 4 4 3
0 = KP off, RC on (only type P parameters)
1 = KP on, RC on (only type P parameters)
2 = KP off, RC off
3 = KP on, RC off
4 = KP on, RC on (all parameters)
C51 Remote IR controller activation code 0 120 0 0
- 36 -
4.0 ELECTRICAL
4.2.4 IR32 ELECTRONIC THERMOSTAT TROUBLESHOOTING
Code Description Cause Control Action Reset Remedies
Er0 Sensor error faulty sensor depends on C10 R: automatic Check connection. Check
V: manual sensor signal
Er1 Sensor NTC2 faulty sensor if C19=1 & Mode R: automatic Check connection. Check
error =1 or 2 V: manual sensor signal
see Er0
Er2 Memory error voltage drop Stoppage R: automatic Reset factory-set values.
during V: manual
programming Turn off controller, turn on
stage, again holding [PRG/mute]
key
memory
damaged by
electromagnetic
interference
Er3 Alarm via contact linked to depends on C31 R: depends Check C29, C30, C31 &
external contact digital input is on C29 & P28.
on digital input open C30
Check the external contact
V: manual Er4
Er4 High temp > P26 for a Nil R: automatic Check P26, P27 & P28.
temperature time interval > V: manual
alarm P28
Er5 Low temp < P25 for a Nil R: automatic Check P26, P27 & P28.
temperature time interval > V: manual
alarm P28
NOTE:
R = Control action
Resetting the instrument means to restore normal operating conditions after the cause that determinied the alarm has been cleared.
V = Display
Display and buzzer. Display reset means that normal display of usual values is restored.
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4.0 ELECTRICAL
4.3 VISION 2020i 4.3.1.1 The fifteen polycarbonate buttons:

CONTROLLER AND a) Seven polycarbonate buttons at top
row
TERMINAL
Button Description
Vision2020i controller is equipped with a user
Displays the analog inputs and
friendly 132x64 pixels back-lit graphic display INPUT STATUS digital inputs status measured by
terminal. It is connected with controller through the probes/sensors.
telephone cable. This terminal allows carrying out

OUTPUT Displays the relay outputs and
all program operations. The user terminal allows STATUS analog outputs status.
displaying the unit working conditions,
compressor run times, alarm history at any time COMPRESSOR Displays the status of Compressor
STATUS 1, 2 and so on.
and modifying the parameters. The terminal also
has an automatically self-test of the micro-
SETPOINT Displays the status of set points.
controller on system start-up. Multiple messages
will be displayed by automatically scrolling from
each message to the next. All of these messages CLOCK/
Displays the date, time and day.
SCHEDULE
are spelled out in English language on the LCD
screen.
ALARM HISTORY Display the alarm history.
4.3.1 DBG1 OPERATOR KEYPAD

AUTHORIZATION To log in the level of passwords.
The DBG1 operator keypad consists of
15 polycarbonate buttons:
b) Eight polycarbonate buttons at
Figure 4.3.1 : Vision 2020i keypad bottom row
Button Description
USER User Control Changeable Settings.
Technician Control Changeable

TECHNICIAN
Settings.
The top right ‘Authorization’ button is for
password log in to gain authorization, to
FACTORY Factory Control Changeable Settings.
the access setting menu.
The top left six operator buttons Unit information / Compressor
MENU
Information.
functions are to view status only, except
the ‘Setpoint’ button also allows setting
Display the active alarms and to
changes after gained authorization. ALARM RESET
perform alarm manual resets.
The three buttons at the bottom left are Scroll the various screens when the
cursor is in the top left of the display.
to access different level of setting If the cursor is inside a numeric field,
changes. UP the button increases or decreases
the corresponding value. If the field is
a selection, pressing the button
These are 'User', 'Technician' and displays the available options.
'Factory' levels, from left.
DOWN See the UP arrow
It can only be access depend on the
password level. The higher password To move the cursor around the
can access the lower password level's ENTER screens and to save the values of the
set parameters
setting and not vice versa.
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4.0 ELECTRICAL
4.3.2 STATUS READING Press down arrow key or output key to

go to next screen:
4.3.2.1 Input status key
To read inputs status press input status
key:
The display is showing the data as
follows:

follows:
Hot Gas Bypass OFF
ANALOG INPUTS
Supply Temp 044.8 °F [07.1°C]

Return Temp 055.6 °F [13.2°C]
Suction Pres 073 PSI [05.2BAR]
Disch Press 179 PSI [12.9BAR]
Repeat the same steps to go to other
relay outputs screen:
Press down arrow key or input key to
go to next screen: 4.3.2.3 Compressor status key
To read compressor status press
compressor status key:

follows:
ANALOG INPUTS follows:
C1 Amps 101A COMPRESSOR 1 STATUS
C1 Disc T 125.2°F [51.8°C]
Comp 1 OK
Amps= 100A
FLA1= 230A
Capacity= 025.5%
Repeat the same steps to go to other Status=ON-LOAD
sensor inputs screen:
Press down arrow key or press
4.3.2.2 Output status key compressor key to go to next screen:
To read relay outputs status press
output status key:

follows:
follows:
COMPRESSOR 1 HISTORY 1
RELAY OUTPUTS Today Total
Comp 1 ON-LOAD Run Hour 05 0006
Alarm Status OFF Cycle 02 0006
Control Power ON Last On 04/24 19:06
C1 Liquid Inj OFF Last Off 04/24 19:03
CW Pump ON
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4.0 ELECTRICAL
4.3.2.4 Setpoint key:

REAL TIME CLOCK
To read the setpoint value press
setpoint key Day > MONDAY
Time > 16:10
Date > 05/12/05

follows:
To set the date and time, you must be
SETPOINT 1 authorized. See the authorization
procedure and log in at least as user
Supply Water Temp level.
Set point= 44.0 °F [06.7°C] Press enter key to select the date or
Dead band= 0.8 °F [0.5°C] time to alter and use the up-down arrow
key to change the value and press
enter key to confirm.
To alter setpoint data, you must be

authorized. See the authorization
procedure and you must be authorized 4.3.2.6 Alarm history key:
at least as user level.
To view the unit alarm history press
Press enter key to select the setpoint to alarm history key:
alter and use the up-down arrow key to
change the value and press enter key
to confirm.
follows:
ALARM HISTORY
Press down arrow key or press setpoint
key to go to next screen: 001-C1 Starter
19:03 05/12/05
TR: 030.2 LWT: 64.3 [17.9]
DP: 191 [13.6]
SP: 076 [5.4]
Repeat the same steps to go to other
setpoints screen and perform setpoint
modification. Press down arrow key or press alarm
key to go to next screen for other alarm
history:
4.3.2.5 Clock key:
To read the current day, time and date,
unit scheduling and ice-cel mode
scheduling (optional), press the clock To clear alarm history, press input key
key and authorization key together and then
press the alarm key again. Now the
display should be showing “No alarm”

follows:
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4.0 ELECTRICAL
4.3.3 AUTHORIZATION Press down arrow key or user key to go

to next screen for other setpoint:
4.3.3.1 Authorization key
To get authorization level, press
authorization key:
To alter setpoint data, press enter key
to select the setpoint to alter and use
the up-down arrow key to change the
The display is showing the current
value and press enter key to confirm.
access level as view only:
AUTHORIZATION
Please Enter your Repeat the above steps for others

Password setpoints.
PASSWORD= 0000
Status=View
4.3.5 TECHNICIAN KEY AND MENU
Press enter key and use the up-down 4.3.5.1 Technician status key
arrow key to change the password This key is use to view and change the
settings and press enter key to confirm. compressor FLA setpoint, sensors
calibration, manually control digital
inputs and outputs, manually control
compressor. In order to gain access to
Now the authorization status change to this button, you must be authorized and
different access level. log in at least as user level. See the
authorization section about this
4.3.4 ADVANCED USER KEY AND procedure.
MENU
4.3.4.1 User Key 4.3.5.2 Technician status key –main

User key is use to view and change the menu
pressure, ampere safety limits and Press technician key to go to technician
liquid injection temperature setpoints, setpoints main menu:
unit of measurements. In order to gain
access to this button, you must be
authorized and log in at least as user
level. The display is showing the data as
follows:
Technician Setpoints
Press the user key and display is Main Menu
showing the data as follows: Comp FLA Calibration
Sensor Calibration
USER SETPOINT 1 Manual Control
Compressor Control
High Pressure Safety Sensors Override
Limits
Hold= 360PSI [23.4BAR]
Unload= 370PSI [24.1BAR] Press enter key to move the cursor to
Cutout= 400PSI [24.8BAR]
the sub-menu.
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4.0 ELECTRICAL
The display is showing the data as Use up or down arrow key to move the
follows: cursor to the desired 'Sensor
Calibration',
Main Menu
Comp FLA Calibration ■
Sensor Calibration The display is showing the data as
Manual Control follows:
Compressor Control
Sensors Override
Sensor Offset 1
Suction Press
Current = 076PSI [5.4BAR]
4.3.5.3 Compressor FLA Calibration: Average = 187PSI [8.6BAR]
To calibrate compressor FLA, press 24Hrs MAX = 200PSI [11.4BAR]
down arrow key to go the sub-menu 24Hrs MIN = 074PSI [4.6BAR]
'Comp FLA Calibration', Calibration = 00PSI [0.0BAR]
Press enter key to move the cursor to

calibrate the desired sensor and use
The display is showing the data as the up-down arrow key to change the
follows: value and press enter key to confirm.
Technician Setpoint 1
Comp 1 FLA CALIBRATION
211x00.66+97.80
FLA = 237A Repeat the above steps for others
Capacity C1 = 000.0% sensors calibrations.
Min. Percent Cal = 25.0%
Max. Percent Cal = 00A 4.3.5.5 Manual Control:
A digital input sensor or relay output
can be controlled manually with the
Press enter key to move the cursor to
keypad. Digital input sensor or relay
calibrate the comp FLA and use the up-
output can be turned on, off manually
down arrow key to change the value
and placed back to auto mode.
and press enter key to confirm.
To place a digital input or relay output
in manual control, the operator must be
authorized at technician level or higher.
Press technician key to go to technician
4.3.5.4 To perform Sensor Calibration: setpoints main menu and press enter
Press technician key to go to technician key three times to move the cursor to
setpoints main menu and press enter the manual control sub-menu:
key twice to move the cursor to the
sensor calibration sub-menu:

The display is showing the data as follows:
follows:
Technician Setpoints Main Menu
Main Menu Comp FLA Calibration
Comp FLA Calibration Sensor Calibration
Sensor Calibration ■ Manual Control ■
Manual Control Compressor Control
Compressor Control Sensors Override
Sensors Override
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4.0 ELECTRICAL
Use up or down arrow key to move the Press technician key to go to technician
cursor to the desired digital input or setpoints main menu and press enter
relay output, key four times to move the cursor to the
manual control sub-menu:

follows: The display is showing the data as
follows:
Digital Inputs Technician Setpoints
Manual Control
Main Menu
C1 Starter= Auto Comp FLA Calibration
C1 Oil Lvl= Auto Sensor Calibration
Unit Enable= Auto
Manual Control
Flow Switch= Auto Compressor Control ■
Sensors Override
Press enter key to move the cursor to Use down arrow key to move the cursor
the desired point for manual control and to the desired compressor control
use the up or down arrow key to screen, then press enter key to move
change the status of the digital input or the cursor to compressor status
relay output to AUTO/CLOSE/OPEN or position, AUTO /MAN/OFF
AUTO/ON/OFF.

The display is showing the data as follows:
follows:
Compressor Control
Relay Outputs
Manual Control Manual Override
Alarm Relay Auto COMPRESSOR 1=AUTO
Liquid Inj C1 Auto St= 0005
CW Pump Auto Amps= 071.8
Vap Inj Relay Auto Capacity= 025.0%
Use up or down arrow key to select

Press enter key to confirm the change. MAN and press enter key to confirm the
change. The compressor will start or
continue to run in hold state. Press the
4.3.5.6 Compressor Control: user key to continue hold, press the
Screw compressors can be controlled technician key to load and factory key
manually with the keypad. A to unload.
compressor can be turned on, off, or
placed in computer control. When a
compressor is controlled manually, it
can be commanded to load, hold, or Manual Hold Manual Load Manual Unload
unload. If safety limiting condition is
active, it will not accept a load If a safety condition is exceeded while
command. operating manually, the compressor will
To place a compressor in manual shutdown.
control, the operator must be CAUTION: Anti-recycle timer is
authorized and log in as technician bypassed by manual control. DO NOT
level and higher. start a compressor more than once
every 15 minutes.
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4.0 ELECTRICAL
NOTE: All compressors will revert back The display is showing the data as
to automatic control if the computer is follows:
the computer is not given a load,
unload, or hold command at least once Sensors Manual
every 15 minutes. A command can be Override
repeated to meet the 15 minute
requirement for manual control. Supply Water Temp
Man Reading = 45.0°F [7.2°C]
To the change the settings of Manual Override = NO
compressor load/Unload, follow the
above steps and go to compressor
control. Use down arrow key to move
the following and press to change the
settings. Press enter key to move the cursor to
the “Man Reading” and use the up or
down arrow key to change the value of
Load/Unload Control the analog reading, press enter key
move the cursor to the “Manual
Manual Pulse Settings Override” to enable, or disable the
Pulse Rate= 001sec manual override control.
Pulse Width= 001sec
Repeat the above steps for other

sensors override.
4.3.5.7 Sensors Override Caution: Sensors override require continuous
Value of analog readings can be monitoring and observation by the field service
temporary override during sensor personnel at all time during the unit operation.
failure. Faulty sensor shall be replaced as soon as
To override the analog readings, the possible in order to allow the unit to be running in
operator must be authorized at automatic mode.
technician level or higher.
Press technician key to go to technician
setpoints main menu and press enter 4.3.6 CONTROL FUNCTIONS
key five times to move the cursor to the
‘Sensors Override’ sub-menu: 4.3.6.1 Chilled Water Pump Interlock
And Flow Switch (CWP And
CWFS)
These are field installed switches, both
The display is showing the data as of which are used to ensure chilled
follows: water flow before the unit is allowed to
start. Failure of either one during
operation will cause the compressor to
Technician Setpoints shut down.
Main Menu
Comp FLA Calibration A water flow alarm will be generated
Sensor Calibration and ‘Rest Alarm’ must be pressed to
Manual Control clear the alarm.
Compressor Control
Sensors Override 4.3.6.2 Customer Control Interlock
Control contacts from an external
controller can be used to enable or
Use up or down arrow key to move the disable operation of the unit. The wiring
cursor to the desired analog reading, 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.
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4.0 ELECTRICAL
4.3.6.3 Anti-Recycle Timer consumption and demand charges.

The compressor motor requires an anti- Two variables are used to define the
recycle time delay which prevents ramp profile: Ramp rate and start point.
restart for 15 minutes after a start. The Ramp rate defines the length of time
purpose of this feature is to avoid the unit takes to load from start point to
frequent starts which tend to elevate full load. Start point is the percent of full
the motor winding temperature and load at which the ramp begins. The
impose undue wear on contactors. The ramp rate A setpoint can be set
controller will not restart the anywhere from 0.1 to 1.0, smaller
compressor motor until the 15 minutes values producing slower loading rates.
have elapsed. The ramp start B setpoint can be set
anywhere between 0 and 50%. The
4.3.6.4 Load Control compressor will load quickly to this
value and then follow the ramp slope
The controller controls the leaving
from there. See Table 4.3.6.5 for ramp
water temperature within a narrow
rates at various settings.
deadband by pulsing load and/ or
unload solenoids on the compressor.
4.3.6.6 Staging Control
The load and unload solenoids position
the slide valve within the compressor to On multiple-compressor machines,
control its capacity. The controller when the controller determines that a
determines a desired level of loading compressor is fully loaded and
and varies pulse duration depending on temperature is not being maintained,
difference between load target and another compressor is added. When
actual load. The load target is varied unloading, a compressor is taken off
based on rate of approach to desired line when the computer determines that
temperature preventing significant the remaining compressors can control
temperature oscillations. The status of water temperature.
the compressor can be observed by
4.3.6.7 Pumpdown Control
displaying the compressor control point.
This feature is to stored refrigerant in
4.3.6.5 Ramp Control condenser when compressor is
Another feature of the controller is ramp stopped. Pumpdown control will take
control, which is the ability to vary load place when temperature set point is
time of the machine from start. Often achieved before compressor is being
when the machine is started, the water cycled off or unit enable input is off.
in the chilled water circuit is warm, and The compressor will stop when suction
the unit will go to full load quickly. With pressure is lower than pumpdown
ramp control, the user can program the setpoint, 65PSI [4.5BAR] (for R22) or
computer so that it loads at a 15 seconds (setpoint) delay timer is
predetermined rate. This is a valuable elapsed.
tool, since it can help reduce power
TABLE 4.3.6.5 Ramp Rates for Several Setpoints (In Minutes)

1 Comp. 2 Comp. 3 Comp 4 Comp
Ramp
Start Point Setpoint Start Point Setpoint Start Point Setpoint Start Point Setpoint
Rate
Setpoint
30% 50% 75% 30% 50% 75% 30% 50% 75% 30% 50% 75%
0.1 12.0 9.0 4.5 22.0 18.5 14.0 29.0 25.5 21.0 33.0 29.0 25.0
0.2 6.0 5.0 2.0 11.5 10.0 8.0 16.0 14.0 12.0 18.0 16.0 14.0
0.3 4.0 3.0 1.5 8.0 7.0 5.5 11.0 10.0 9.0 13.0 12.0 11.0
0.4 3.0 2.5 1.0 6.5 5.5 4.5 9.0 8.0 7.0 11.0 10.0 9.0
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4.0 ELECTRICAL
4.3.6.8 Liquid Line Solenoid Control 4.3.6.11 Evaporator Freeze Shutoff

When compressors starts, the liquid If the leaving chilled water temperature
line solenoid will energize when suction drops below the freeze setpoint, the
pressure falls below the pumpout controller will shut down the unit and
setpoint or a time delay of 5 seconds is store the freeze alarm. After solving the
elapsed. For unit with two liquid lines problem, press ‘Reset Alarm’ on the
per refrigerant circuit, the second liquid controller to clear the alarm.
line solenoid will energize when suction
pressure falls below low pressure
4.3.6.12 High Pressure Cut-off
cutout setpoint or a time delay of 25
seconds is elapsed and unit target is This function protects the compressor
above 40%. The second liquid line from operating at abnormally high
solenoid will be de-energized when the discharge refrigerant pressures. The
unit target is less than 35%. controller will shut down the
compressor when condenser pressure
reaches the high pressure set point,
4.3.6.9 Sump Heater Control and turn on the alarm indicator lamp on
the control box. The high discharge
Each compressor is fitted with an oil
pressure alarm will be recorded by the
sump band-heater. The heater is
controller. Reset by pressing the ‘Reset
energized at all times when compressor
Alarm’ button on the controller. Setpoint
is off and de-energized when the
is 400 psig [27.6BAR].
compressor is running.
Its purpose is to prevent refrigerant
migration into the oil during shut down. 4.3.6.13 Phase Control Relay (PCR)
For this reason, it is essential that - Optional
heaters be energized for 24 hours The PCR protects the unit from the
before starting a compressor. following electric supply malfunctions:
Undervoltage, phase reversal and
4.3.6.10 Low Pressure Cut-off single phasing. If the PCR trips, a
control relay (lCR) will de-energize and
This function protects the unit from
open the control circuit. A green LED
operating at abnormally low evaporator
indicates presence of power supply.
refrigerant pressure. The controller will
The yellow LED indicates a good
shut down the compressor when
voltage supply. The power loss setpoint
evaporator pressure falls below the low
is factory set to AUTO to allow
pressure setpoint and turn on the alarm
automatic start after PCR failure.
pilot light.
Compressor will not start for 15 minutes
A low pressure alarm will be recorded
after failure. To select manual reset, set
by the controller. Reset by pressing the
power loss setpoint to MANUAL. In this
‘Reset Alarm’ button on the controller.
case, a power loss alarm will be stored
Standard setpoint is 58 psig [4.0BAR].
by the controller and ‘Reset Alarm’
must be pressed to start.
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4.0 ELECTRICAL
4.3.6.14 Sensor Alarm 1. Adaptive Individual Air-cooled Condenser

Control
If the computer measures an analog
value (temperature, pressure.) that is This type of control is based upon a single
far beyond normal operating values, the compressor per circuit. The individual
associated compressors are shutdown. discharge pressure on that circuit will be the
The computer then stores the alarm controlling pressure.
code corresponding to the sensor
2. Adaptive Air Combined Air-cooled
alarm. A sensor alarm indicates a Condenser Control
problem in the analog measurement
This type of control is based upon a condenser
system.
that is controlled by the highest discharge
pressure from any one of the compressors
4.3.6.15 No-Stop Alarm
sharing that circuit (compressor 1&2 - share;
If the controller turns off a compressor, compressor 3&4 - share). The highest
but the compressor digital input does discharge pressure between the sharing
not turn off, a No-Stop alarm is compressors will be the controlling pressure.
generated. The computer will turn off
the control power relay which disables
all compressor control circuits and will 4.4.1 Air Cooled Condenser Control
turn on the alarm light. This alarm Setpoints
indicates a wiring or hardware error. The air-cooled condenser setpoints are as
follows:
4.3.6.16 Low Differential Pressure Alarm
Setpoint COND Stage 1 ON - Condenser stage
For proper lubrication, a compressor 1 on.
requires a 30 psid [2.1BAR] differential
Setpoint COND Stage 2 OFF - Condenser stage
pressure between condenser and
2 off.
evaporator pressures. If the differential
pressure is less than 30 psid [2.1BAR] Setpoint COND DIFF ON - Differential
for 3 minutes while a compressor is pressure for
operating, all compressors will be shut additional
down. The controller will store the low condenser stages.
differential pressure alarm code and Setpoint COND DIFF OFF - Differential
turn on the alarm light. The ‘Reset pressure for
Alarm’ key must be pressed to clear the subtracting
alarm. condenser stages.
A compressor must be operating for the
condenser fans to operate. The condenser points
(i.e. fans) will turn on based upon the value in
4.4 CONDENSER FAN
setpoint COND Stage 1 ON. When the discharge
CONTROL LOGIC pressure exceeds this value, the first condenser
If the differential pressure is less, the controller point is turned on. If additional condenser points
provides two types of control logic for air-cooled exist, they will be turned on when the pressure
condensers. The type of control will be governed exceeds the previous cut in value (COND Stage 1
by the physical condenser layout of the unit. Each ON for the first stage) plus the value contained in
method of control is enhanced with adaptive, self- COND DIFF ON setpoint.
learning, fan control logic. The end result is Condenser points (i.e. fans) will be turned off
condenser control that offers significantly reduced based upon the value in the setpoint COND ST2
fan cycling and improved efficiency. The two OFF (COND Stage 2 turn OFF point). As the
types of air-cooled condenser control logic are discharge pressure is reduced, the condenser
explained as follows: points will be turned off based upon the COND
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4.0 ELECTRICAL
ST2 OFF setpoint, plus the value in the COND and improved efficiency. Adaptive
DIFF OFF setpoint for each stage number above Control Logic automatically adjusts the
stage 2. Stage 2 of condenser staging will be fan cut-in offset based upon the
turned off based upon the value in the setpoint following criteria:
(COND ST2 OFF). See below for an example of
condenser staging. 1. If the last fan turned on (including
FAN 1) is cycled off in 10 minutes
or less, then a COND ON OFFSET
4.4.2 INCREASING CONDENSER value will be incremented by 5 psig
PRESSURE [0.3BAR]. This increases the fan 1
(Example of 4 stage fan cycling) turn on value (COND ST1 ON plus
COND ON OFFSET) which in turn
COND FAN1 ON when discharge pressure is >
increases all of the fan turn on
230psig [15.9BAR] (COND Stage 1 ON setpoint)
settings. This process will continue
COND FAN2 ON when discharge pressure is > until fan cycling ceases or the
250psig [17.2BAR] (COND Stage 1 ON plus adjusted turn on point for the last
1xCOND DIFF ON setpoint values) fan stage is 320 psig [22.1BAR].
COND FAN3 ON when discharge pressure is > This will also be a setpoint.
270psig [18.6BAR] (COND Stage 1 ON plus
2xCOND DIFF ON setpoint values) 2. The cut-in offset (COND ON
OFFSET) will be decreased by 5
COND FAN4 ON when discharge pressure is >
psig [0.3BAR] if the last fan to be
290psig [20.0BAR] (COND Stage 1 ON plus
turned on has not cycled off within
3xCOND DIFF ON setpoint values)
1 hour. The offset will continue to
And so on for the number of condenser fans decrease by 5 psig [0.3BAR] every
supplying the circuit. 10 minutes unless fan cycling
begins again.
4.4.3 DECREASING CONDENSER The Adaptive Control Logic will only

PRESSURE affect the condenser fan turn on logic, it
(4 fan example "continued") will not affect the fan turn off logic.
COND FAN4 OFF when discharge pressure

is < 200psig [13.8BAR] (COND Stage 2 OFF plus
2xCOND DIFF OFF setpoint values) 4.5 Master/Slave Control
COND FAN3 OFF when discharge pressure Sequence
is < 190psig [13.1BAR] (COND Stage 2 OFF plus
1xCOND DIFF OFF setpoint values) The optional master/slave control sequence is
COND FAN2 OFF when discharge pressure used to sequence multiple chillers in one
is < 180psig [12.4BAR] (COND Stage 2 OFF installation according to the building load demand.
setpoint value) It also controls the dedicated chilled water pump
COND FAN1 OFF when discharge pressure or motorized valve.
is < 170psig [11.7BAR] (COND Stage 1 OFF Vision2020i Controller offers this feature with
setpoint value) minimized field wiring cost compare to
conventional method that involves lots of
4.4.3.1 Adaptive Control Logic hardware cost. It is carried out this control
The controller enhances the condenser function via the advanced DBLAN communication
control logic above with a unique, bus to implement the network management for
adaptive, self-learning fan control logic. multiple chillers lead/lag communication,
These enhancement results in a control sequencing and monitoring.
scheme that offers reduced fan cycling
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4.0 ELECTRICAL
4.5.1 PRINCIPLE OF OPERATION VIA DBLAN COMMUNICATION BUS

Example: 6 chillers network with 4 units on duty and 2 units standby
Graphic
Display
(option)
DBLAN
DB3 DBG1 DB3 DBG1 DB3 DBG1 DB3 DBG1 DB3 DBG1 DB3 DBG1
DB1 DB1 DB1 DB1 DB1 DB1
DB1 DB1 DB1 DB1 DB1 DB1
#1 #2 #3 #4 #5 #6
Notes
a) Each chiller has a stand-alone master DB3 board and dedicated graphic display with multiple DB1
expanders board connected to J23 on DB3
b) Each chiller DB3 will be connected to DBLAN network through J11 connector
c) The chiller lead/lag selection can be determined by
D Manual lead/lag setpoint
D Schedule and holiday setup
D Alarm conditions
d) The lead/lag selection determine the chiller operation sequence as follows,
Lead chiller Normal chillers operation sequence When DBLAN fails

selection
1 1, 2 & 3 on duty, 4, 5 & 6 standby 1, 2 & 3 on duty
e) If the lead/lag selection is changed over to a different chiller, the sequence of operation will be
rotated
f) Each chiller will use a network address setpoint to determine individual chiller network address
g) Each chiller will require a dedicated chilled water pump or motorized valve digital output, unit enable
and chilled flow status digital inputs as well as enable next output command.
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4.0 ELECTRICAL
4.5.2 Sequence Of Operation

a) LWT ≥ (LWT Setpoint + Enable Next
1. When the customer enable input is ‘on’ to deadband)
start the lead unit, the chilled water pump
starter or motorized valve control point will b) After a enable next time delay of 3
close and water will start to flow through the minutes (adjustable) and
evaporator, this will activate the flow switch. c) When the lead unit’s packaged capacity
The flow switch and water pump status are is higher than “Next on setpoint”,
interlocked and feedback as digital input to
for example, WCFX2, %FLCP C1 & %FLCP C2 ≥
the chiller and upon receipt of a valid 'on'
Next on setpoint
signal, the lead chiller will begin to execute its
running program. or it is being lockout by an alarm.
2. The controller will start and load the
compressor(s), upon achieving full load; it will
send an output signal via the DBLAN to 4.6 VISION 2020i LOCAL AREA
enable second unit (lag 1)
NETWORK (DBLAN)
3. The second unit will now command its chilled
water pump to start if the customer unit A DBLAN network is made up of several chillers’
enable is activated. The second chiller will controller. Each unit’s controller can be
start and load the compressor(s) until it programmed and connected to the local DBLAN
reaches full load network that allows multiple units sequencing
4. When the second chiller or lag 1 unit reaches control without additional hardware.
full load, it will enable the third chiller. Every DBLAN node must be addressed to be
5. The chiller will keep cascading until all chillers identified by the other nodes. Each address (an
on duty are at full load. integer number) must be unique in the network for
avoiding messages mismatch: in case two or
6. If the leaving water temperature falls below
more nodes have the same identifying address
setpoint, all of the chillers will begin to unload
the network cannot work.
evenly.
7. If the load drops below 45% total capacity, The max address number selectable is in the 1-16
delay the last unit (lag 3) will be disabled, and for the Vision 2020i controller boards and 17-32
the remaining three units will load up to range for the Vision 2020i User terminal.
compensate if necessary. The pump for
chiller 4 will be shut off. The three chiller unit combinations:
8. As the load demand falls, the lag 2 unit will be Controller with address of 1 connect to Terminal
disabled below 45% total capacity, and so on with address of 17
until the load falls enough to shut off the lead
Controller with address of 2 connect to Terminal
chiller.
with address of 18
9. Each unit in the network can monitor the
Controller with address of 3 connect to Terminal
operation of other units via DBLAN. If the
master unit is having critical alarm, the lag 1 with address of 19
will take over as the master unit automatically.
Follow the following steps:
10. In order to enable next unit, the following
conditions must met
- 50 -
4.0 ELECTRICAL
4.7 NETWORK CONNECTION DIAGRAM

Adr:17 Adr:18 Adr:19
Vision 2020i Vision 2020i Vision 2020i

Terminal Terminal Terminal
Telephone Cable Telephone Cable Telephone Cable
J10 Adr:1 J10 Adr:2 J10 Adr:3
Vision 2020i Vision 2020i Vision 2020i

Controller Controller Controller
J11 J11 J11

RS 485 Cable RS 485 Cable
max 500 meters max 500 meters

The 6 core telephone cables (to J10 socket) are supply by the manufacturer.
The 3 core RS 485 data cables (to J11 socket) are supply by the customer.
Pay attention to the network polarity:
RX+/TX+ on one controller must be connected to RX+/TX+ on the other controller; the same is true for
RX-/TX- and GND.
4.8 HARDWARE SETTINGS Change the display address setting to 0 as follow.
4.8.1 ADDRESSING THE VISION 2020i Display address

CONTROLLER Setting……… : 0
At the Vision 2020i terminal, push simultaneously

the last three keys on the lower right corner of the
Vision 2020i terminal keyboard. Push them for at
least 5 seconds.
Vision 2020i
5 sec
Turn off DB3 controller.
At the Vision 2020i DBG1 terminal, hold

simultaneously the “Alarm” key and “Up arrow”
key, turn on DB3 controller and hold these keys
This display will appear:
until “Self Test” mask is appeared.
Display address
Setting……… : 17 Vision 2020i
I/O Board address: 01
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4.0 ELECTRICAL
want to configure. Once you select the address

*********************************** then press ‘enter’ button
SELF TEST
PLEASE WAIT
************************************ The display will appears:
Terminal config
Press ENTER
To continue
The following mask will appear. Set pLAN

address to 1 (or accordingly) using “Up” and
“Down” arrow key. Press “Enter” key to save and
exit.
PLAN Address : 1 Push ‘enter’ to continue.
Up : Increase Then the display appears:
Down : Decrease
Enter : Save & Exit P:01 Adr Priv/Shared
Trm1 17 Pr
Trm2 32 Sh
Trm 3 None --- OK? NO
The terminal display will become blank after

“Enter” key is pressed. Please proceed to next
section on Addressing the Vision 2020i DBG1
Terminal. Set Trm1, Trm2 and Trm3 to ’17 Pr’,’32 Sh’ and
‘None ---’, change the 'NO' to 'YES'(to confirm
and save) and press ‘enter’.
4.8.2 ADDRESSING THE VISION Note: Pr = Private, Sh = Share.
2020I DBG1 TERMINAL
For multiple units with master-slave sequencing
At the Vision 2020i DBG1 terminal, hold control features, at the second chiller unit Vision
simultaneously the last three keys on the lower 2020i terminal; repeat step 1 by holding the three
right corner of the Vision 2020i terminal keyboard. keys again. The display will appears:
Hold them for at least 5 seconds.
Display address
Vision 2020i Setting……… : 18
5 sec
I/o Board address: 02
The display will appears:

The address display (18) is the correct setup for
Display address the second chiller unit with the controller address
Setting……… : 17 of two (P:02).Press ‘enter’ to confirm the settings
and the display will appears:
Terminal config
Press ENTER
To continue
The first line is the address of the terminal display

that you are using, (for first chiller, it is 17). The
next line allows you to select the Vision 2020i
controller address (for first chiller, it is 01) that you
- 52 -
4.0 ELECTRICAL
Set Trm1, Trm2 and Trm3 to ’18 Pr’,’32 Sh’ and Set Trm1, Trm2 and Trm3 to ’19 Pr’,’32 Sh’ and
‘None ---’, change the 'NO' to 'YES'(to confirm ‘None ---’, change the 'NO' to 'YES'(to confirm
and save) and press enter. and save) and press enter.
P:02 Adr Priv/Shared P:02 Adr Priv/Shared

Trm1 18 Pr Trm1 19 Pr
Trm2 32 Sh Trm2 32 Sh
Trm 3 None --- OK? NO Trm 3 None --- OK? NO
At the third chiller unit Vision 2020i terminal: With the above settings, terminal with address 17
Press the three keys again, the display will will only work with the controller with address 1,
appears: terminal 18 will only work with the controller with
Display address address 2, terminal 19 will only work with the
Setting……… : 19 controller with address 3 and a terminal with
address 32 will work with both.
4.8.3 Vision 2020i Controller LED

Status
The address display (19) is the correct setup for
Vision 2020i controller have three LEDs between
the third chiller unit with the controller address of the J3 and J4 connectors for indicating basic
three(P:03).Press ‘enter’ to confirm the setting node status. They are Red, Yellow and Green
and the display will appears: coloured.
Terminal config
Press ENTER
To continue Red Yellow Green
At the start-up all LEDs are ON and after few

seconds OFF again. After 5 – 15 seconds elapse,
then LED configuration is among those listed
below.
Table 4.8.3 LED Status

LED STATUS DESCRIPTION
Vision 2020i controller is synchronized with all the other DBLAN nodes.
ON
The node is working correctly.
GREEN
OFF Vision 2020i controller is not network connected or it doesn’t receive any signal from the DBLAN
BLINKING Vision 2020i controller is transmitting data to other network nodes.

YELLOW
OFF Vision 2020i controller is not transmitting messages.
OFF No hardware and software problem.

RED
Vision 2020i controller software not compatible or variables database not correct, contact Dunham-
ON
Bush Service Personnel.
Vision 2020i hardware is not compatible - Ram is smaller than 32 KB.

BLINKING
The Vision 2020i controller is just for working in stand-alone mode.
- 53 -
4.0 ELECTRICAL
4.9 TYPICAL WIRING SCHEMATIC

ACDS 010
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4.0 ELECTRICAL
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4.0 ELECTRICAL
ACDS 020
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4.0 ELECTRICAL
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4.0 ELECTRICAL
ACDS 030
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4.0 ELECTRICAL
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4.0 ELECTRICAL
ACDS 040
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4.0 ELECTRICAL
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4.0 ELECTRICAL
ACDS 050, 060, 070
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4.0 ELECTRICAL
- 63 -
4.0 ELECTRICAL
ACDS 080, 90
∼ ∼∼
∼ ∼∼
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4.0 ELECTRICAL
∼ ∼ ∼ ∼
- 65 -
4.0 ELECTRICAL
∼ ∼
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4.0 ELECTRICAL
- 67 -
4.0 ELECTRICAL
ACDS 100
∼ ∼∼
∼ ∼∼
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4.0 ELECTRICAL
∼ ∼ ∼ ∼
- 69 -
4.0 ELECTRICAL
∼ ∼
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4.0 ELECTRICAL
- 71 -
4.0 ELECTRICAL
ACDS 120
∼ ∼∼
∼ ∼∼
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4.0 ELECTRICAL
∼ ∼ ∼ ∼
- 73 -
4.0 ELECTRICAL
∼ ∼
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4.0 ELECTRICAL
- 75 -
4.0 ELECTRICAL
ACDS 135
∼ ∼∼
∼ ∼∼
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4.0 ELECTRICAL
∼ ∼ ∼ ∼
- 77 -
4.0 ELECTRICAL
∼ ∼
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4.0 ELECTRICAL
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4.0 ELECTRICAL
ACDS 150
∼ ∼∼
∼ ∼∼
- 80 -
4.0 ELECTRICAL
∼ ∼ ∼ ∼
- 81 -
4.0 ELECTRICAL
∼ ∼
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4.0 ELECTRICAL
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4.0 ELECTRICAL
ACDS 165, 180
∼ ∼∼
∼ ∼∼
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4.0 ELECTRICAL
∼ ∼ ∼ ∼
- 85 -
4.0 ELECTRICAL
∼ ∼
- 86 -
4.0 ELECTRICAL
- 87 -
5.0 MAINTENANCE
5.1 GENERAL b.) Use an anti-freeze when the

evaporation temperature is close to
As with all mechanical equipment, a program of liquid-side freezing
regular inspection, cleaning and preventive c.) Use a freeze protection thermostat
maintenance by trained personnel will contribute and flow switch to guarantee a
greatly to the long satisfactory service life of this constant water flow before, during
product. and after compressor operation.
d.) Avoid "pump-down" function
e.) When starting up a system, wait a
5.2 PERIODIC INSPECTION moment before starting the
condenser (or have reduced flow
Read essential temperatures and pressures
through it)
periodically to see that they indicate normal
operation. It is a good idea to record these
5.4.2 EVAPORATOR CLEANING
readings on a log sheet. If any abnormal
operation is observed, try to remedy it. See
5.4.2.1. Cleaning BPHE
Trouble Shooting Guide Section.
Normally very high degree of
turbulence in BPHE there is a self-
cleaning effect in the channels.
5.3 MONTHLY INSPECTION However, in some applications the
Check cooling tower water treatment system, fouling tendency can be very high.
Wipe down external surfaces of unit. Shut unit In such cases, it is always possible to
down, open main disconnect, inspect control clean the exchanger by circulating a
panel, checking for loose wires, burned contacts, cleaning liquid (CIP-Cleaning In Place).
signs of overheated wires, etc. Restart unit and Use a tank with weak acid or, if the
check performance of controls. Check sight exchanger is frequently cleaned, 5%
glasses for proper refrigerant charge. oxalic acid.
Pump the cleaning through the
exchanger.
5.4 PHE MAINTENANCE For optimum cleaning, the cleaning
solution flow rate should be a minimum
of 1.5times the normal flow rate,
5.4.1 GENERAL preferably in a back-flush mode.
The efficient performance of the After use, do not forget to rinse the heat
evaporator and condenser heat transfer exchanger carefully with clean water.
surfaces is essential for efficient A solution of 1-2% sodium hydroxide
performance of your packaged water (NaOH) or sodium bicarbonate
cooling machine. If these surfaces (NaHCO₂) before the last rinse ensure
accumulate a film of dirt, scale or slime, that all acid is neutralized. Clean at
their performance efficiency will degrade regular intervals.
substantially. The refrigerant side of heat
transfer surfaces does not foul since
refrigerant is a good solvent and it is in a
closed, filtered cycle. Water side surfaces
can foul from the water system. A
program of water treatment can slow the
rate of fouling on heat transfer surfaces,
but not eliminate it.
5.4.1.1 Freezing Protection For BPHE

a.) Use a filter <1mm, 16 mesh (see
previous chapter on BPHE
maintenance)
- 88 -
5.0 MAINTENANCE
5.4.2.2. Strainers sign of possible motor trouble. DO NOT reset and

If any of the media contains particle try to run compressor again. Call authorized
larger 1mm (0.04 inch), we recommend service representative to check for motor trouble.
that a strainer with a size of 16-20 Resetting these safety devices and repeated
mesh (number of openings pe inch) is starting could turn a minor motor problem into a
installed before the exchanger. costly major motor burnout.
The particles could otherwise block the
channels, causing bad performance,
increased pressure drop and risk of 5.7 REFRIGERANT CHARGE
freezing.
5.7.1 GENERAL
All packaged chiller units are given a
complete charge of refrigerant at the
factory. The type and amount of
refrigerant required is in Physical
Specifications. The total refrigerant
shown is for the entire system. Since
these units have separate circuits, each
circuit should be considered separately
for charging.
In order to check proper refrigerant
5.5 AIR COOLED CONDENSER charge, look in each liquid line sight glass
CLEANING with the aid of a flashlight during system
operation. At all operating conditions, the
The face of the condenser should be cleaned at
sight glass should be clear. If bubbles are
least once month during operation. If conditions
visible at any operating condition, the
are bad and condensers pick up dirt very quickly,
circuit is short of charge.
it is suggested that they can be cleaned more
frequently. Be careful not to overcharge the machine.
If the condenser is allowed to get too dirty, the overcharging will result in considerable
unit will run at high head pressure and will not liquid logging in the condenser, and
give satisfactory performance. excessive condensing pressure.
Dirty coils can be cleaned using a soft brush or by To add refrigerant, connect a refrigerant
flushing with cool water or commercially available vessel to the 1/4" [6.4mm] back seating
coil cleaners. port of the suction valve. Purge the air
from the tube with refrigerant gas before
DO NOT USE HOT WATER OR STEAM. To do
connecting. With the unit running, open
so will cause excessive pressure in the system.
the refrigerant vessel vapor connection
The face of the condenser should be cleaned at
slightly. If the refrigerant vessel is warmer
the beginning of the season and periodically
than the evaporator, refrigerant will more
thereafter if conditions require.
readily flow from the vessel into the unit.
5.6 ELECTRICAL 5.7.2 AIR COOLED PACKAGES

MALFUNCTION To determine the proper refrigerant
charge, check the amount of subcooling if
The unit has four devices designed to protect
possible. The amount of subcooling at the
compressor motors and manual motor controllers
liquid line (liquid line saturation
from electrical malfunctions: Circuit breakers.
temperature corresponding to liquid line
starter overload relays, under voltage relay
pressure minus liquid line temperature)
(optional), and motor over temperature protectors.
should be between 15°F [8.3°C] and 20°F
If the under voltage relay trips, it is a sign of [11.1°C]. Subcooling at the condenser
trouble in incoming power. If it trips again after out-subcooler inlet trap should not exceed
resetting, call your electric utility to investigate the 5°F [2.8°C]. This sight glass should be
problem. If circuit breaker or motor overload relay clear with no bubbles.
or motor over temperature protectors trip, this is a
- 89 -
5.0 MAINTENANCE
TABLE 5.4 R410A PRESSURE/ TEMPERATURE PROPERTIES

Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature
psig kPa °F °C psig kPa °F °C psig kPa °F °C psig kPa °F °C
10.8 74.5 -40.0 -40.0 62.2 428.9 10.0 -12.2 169.6 1169.4 60.0 15.6 364.1 2510.4 110.0 43.3
11.5 79.3 -39.0 -39.4 63.7 439.2 11.0 -11.7 172.5 1189.4 61.0 16.1 369.1 2544.9 111.0 43.9
12.1 83.4 -38.0 -38.9 65.2 449.5 12.0 -11.1 175.4 1209.3 62.0 16.7 374.2 2580.0 112.0 44.4
12.8 88.3 -37.0 -38.3 66.8 460.6 13.0 -10.6 178.4 1230.0 63.0 17.2 379.4 2615.9 113.0 45.0
13.5 93.1 -36.0 -37.8 68.3 470.9 14.0 -10.0 181.5 1251.4 64.0 17.8 384.6 2651.7 114.0 45.6
14.2 97.9 -35.0 -37.2 69.9 481.9 15.0 -9.4 184.5 1272.1 65.0 18.3 389.9 2688.3 115.0 46.1
14.9 102.7 -34.0 -36.7 71.5 493.0 16.0 -8.9 187.6 1293.5 66.0 18.9 395.2 2724.8 116.0 46.7
15.6 107.6 -33.0 -36.1 73.2 504.7 17.0 -8.3 190.7 1314.8 67.0 19.4 400.5 2761.4 117.0 47.2
16.3 112.4 -32.0 -35.6 74.9 516.4 18.0 -7.8 193.9 1336.9 68.0 20.0 405.9 2798.6 118.0 47.8
17.1 117.9 -31.0 -35.0 76.6 528.1 19.0 -7.2 197.1 1359.0 69.0 20.6 411.4 2836.5 119.0 48.3
17.8 122.7 -30.0 -34.4 78.3 539.9 20.0 -6.7 200.4 1381.7 70.0 21.1 416.9 2874.4 120.0 48.9
18.6 128.2 -29.0 -33.9 80.0 551.6 21.0 -6.1 203.6 1403.8 71.0 21.7 422.5 2913.1 121.0 49.4
19.4 133.8 -28.0 -33.3 81.8 564.0 22.0 -5.6 207.0 1427.2 72.0 22.2 428.2 2952.4 122.0 50.0
20.2 139.3 -27.0 -32.8 83.6 576.4 23.0 -5.0 210.3 1450.0 73.0 22.8 433.9 2991.7 123.0 50.6
21.1 145.5 -26.0 -32.2 85.4 588.8 24.0 -4.4 213.7 1473.4 74.0 23.3 439.6 3031.0 124.0 51.1
21.9 151.0 -25.0 -31.7 87.2 601.2 25.0 -3.9 217.1 1496.9 75.0 23.9 445.4 3070.9 125.0 51.7
22.7 156.5 -24.0 -31.1 89.1 614.3 26.0 -3.3 220.6 1521.0 76.0 24.4 451.3 3111.6 126.0 52.2
23.6 162.7 -23.0 -30.6 91.0 627.4 27.0 -2.8 224.1 1545.1 77.0 25.0 457.3 3153.0 127.0 52.8
24.5 168.9 -22.0 -30.0 92.9 640.5 28.0 -2.2 227.7 1569.9 78.0 25.6 463.2 3193.7 128.0 53.3
25.4 175.1 -21.0 -29.4 94.9 654.3 29.0 -1.7 231.3 1594.8 79.0 26.1 469.3 3235.7 129.0 53.9
26.3 181.3 -20.0 -28.9 96.8 667.4 30.0 -1.1 234.9 1619.6 80.0 26.7 475.4 3277.8 130.0 54.4
27.2 187.5 -19.0 -28.3 98.8 681.2 31.0 -0.6 238.6 1645.1 81.0 27.2 481.6 3320.5 131.0 55.0
28.2 194.4 -18.0 -27.8 100.9 695.7 32.0 0.0 242.3 1670.6 82.0 27.8 487.8 3363.3 132.0 55.6
29.2 201.3 -17.0 -27.2 102.9 709.5 33.0 0.6 246.0 1696.1 83.0 28.3 494.1 3406.7 133.0 56.1
30.1 207.5 -16.0 -26.7 105.0 724.0 34.0 1.1 249.8 1722.3 84.0 28.9 500.5 3450.8 134.0 56.7
31.1 214.4 -15.0 -26.1 107.1 738.4 35.0 1.7 253.7 1749.2 85.0 29.4 506.9 3495.0 135.0 57.2
32.2 222.0 -14.0 -25.6 109.2 752.9 36.0 2.2 257.5 1775.4 86.0 30.0 513.4 3539.8 136.0 57.8
33.2 228.9 -13.0 -25.0 111.4 768.1 37.0 2.8 261.4 1802.3 87.0 30.6 520.0 3585.3 137.0 58.3
34.2 235.8 -12.0 -24.4 113.6 783.2 38.0 3.3 265.4 1829.9 88.0 31.1 526.6 3630.8 138.0 58.9
35.3 243.4 -11.0 -23.9 115.8 798.4 39.0 3.9 269.4 1857.5 89.0 31.7 533.3 3677.0 139.0 59.4
36.4 251.0 -10.0 -23.3 118.1 814.3 40.0 4.4 273.5 1885.7 90.0 32.2 540.1 3723.9 140.0 60.0
37.5 258.6 -9.0 -22.8 120.3 829.4 41.0 5.0 277.6 1914.0 91.0 32.8 547.0 3771.5 141.0 60.6
38.6 266.1 -8.0 -22.2 122.7 846.0 42.0 5.6 281.7 1942.3 92.0 33.3 553.9 3819.0 142.0 61.1
39.8 274.4 -7.0 -21.7 125.0 861.9 43.0 6.1 285.9 1971.2 93.0 33.9 560.9 3867.3 143.0 61.7
40.9 282.0 -6.0 -21.1 127.4 878.4 44.0 6.7 290.1 2000.2 94.0 34.4 567.9 3915.6 144.0 62.2
42.1 290.3 -5.0 -20.6 129.8 894.9 45.0 7.2 294.4 2029.8 95.0 35.0 575.1 3965.2 145.0 62.8
43.3 298.5 -4.0 -20.0 132.2 911.5 46.0 7.8 298.7 2059.5 96.0 35.6 582.3 4014.8 146.0 63.3
44.5 306.8 -3.0 -19.4 134.7 928.7 47.0 8.3 303.0 2089.1 97.0 36.1 589.6 4065.2 147.0 63.9
45.7 315.1 -2.0 -18.9 137.2 946.0 48.0 8.9 307.5 2120.2 98.0 36.7 596.9 4115.5 148.0 64.4
47.0 324.1 -1.0 -18.3 139.7 963.2 49.0 9.4 311.9 2150.5 99.0 37.2 604.4 4167.2 149.0 65.0
48.3 333.0 0.0 -17.8 142.2 980.4 50.0 10.0 316.4 2181.5 100.0 37.8 611.9 4218.9 150.0 65.6
49.6 342.0 1.0 -17.2 144.8 998.4 51.0 10.6 321.0 2213.2 101.0 38.3 - - - -
50.9 350.9 2.0 -16.7 147.4 1016.3 52.0 11.1 325.6 2244.9 102.0 38.9 - - - -
52.2 359.9 3.0 -16.1 150.1 1034.9 53.0 11.7 330.2 2276.7 103.0 39.4 - - - -
53.6 369.6 4.0 -15.6 152.8 1053.5 54.0 12.2 334.9 2309.1 104.0 40.0 - - - -
55.0 379.2 5.0 -15.0 155.5 1072.1 55.0 12.8 339.6 2341.5 105.0 40.6 - - - -
56.3 388.2 6.0 -14.4 158.2 1090.8 56.0 13.3 344.4 2374.6 106.0 41.1 - - - -
57.8 398.5 7.0 -13.9 161.0 1110.1 57.0 13.9 349.3 2408.4 107.0 41.7 - - - -
59.2 408.2 8.0 -13.3 163.8 1129.4 58.0 14.4 354.2 2442.1 108.0 42.2 - - - -
60.7 418.5 9.0 -12.8 166.7 1149.4 59.0 15.0 359.1 2475.9 109.0 42.8 - - - -
5.0 MAINTENANCE
- 90 -
5.8 TROUBLE SHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
1. Unit will not 1. Power off 1. Check main disconnect switch.

start 2. Main line open 2. Check main fuses.
3. Incorrect wiring 3. Check with wiring diagrams.
4. Loose terminals 4. Tighten terminals.
5. Control circuit open 5. Check pump fuses, starter heater elements,
pressure and temperature controls.
2. Compressor 1. Low voltage 1. Check at main entrance and at unit. Consult power
hums but company if voltage is low and increase wire size to
does not the unit if voltage is normal at main and low at unit.
start Voltage must be within 10% of motor nameplate
rating.
2. No power on one phase 2. Check fuses and wiring.
of 3 phase unit
3. Faulty starter or 3. Check the contacts and time delay on part wind
contactor start.
3. Compressor 1. Refrigerant shortage 1. Check for leaks and add refrigerant.

cycles on 2. No load on chiller 2. Check pump operation and water flow.
low 3. Restriction in liquid line 3. a.) Plugged drier. If temperature drop exists across
pressure the drier remove and replace cores.
control b.) Liquid line or suction valve partially closed. Open
valves fully and close in one full turn.
c.) Expansion valve clogged or inoperative. Check
superheat setting. Check charge and thermo
bulb.
4. Head pressure too low 4. Restrict water flow to condenser by adjusting the
water regulating valve or cycle cooling tower fan.
4. Compressor 1. Compressor discharge 1. Open valve fully and close with one turn
cycles on valve partially closed.
high 2. Air in system 2. Flush water valve. If pressure in system exceeds the
pressure pressure corresponding to the water temperature
control purge air from compressor gauge connection.
3. Overcharge of 3. Purge system while in operation until bubbles show
refrigerant in sight glass. Close valve and add small amount of
refrigerant until sight glass just clears.
4. High pressure control 4. Adjust the control.
improperly set
5. Main water valve closed 5. Open the water valve.
6. Water regulating valve 6. Reset or replace valve.
set high or defective
7. Condenser fan 7. Check, replace or repair set screw (pulley), fan
inoperative motor, or inoperative fan control.
8. Dirty condenser 8. Clean condenser surfaces with brush and/or
vacuum.
9. Fan cycle switches in- 9. Check and readjust.
operative, or set too
high
10. Fan motors not running 10. Check contactor, thermal overload relay, check
motor, check capacitor. (If single phase)
11. Fan motor reverse 11. Reverse two fan motor leads. (3 phase only)
rotation
- 91 -
5.0 MAINTENANCE
5.9 SAMPLE LOG SHEET SHEET NO. ................................
DUNHAM-BUSH SCROLL COMPRESSOR PACKAGED CHILLER

NAMEPLATE DATA:
UNIT MODEL NO. ........................................................ UNIT NO. ....................................VOLTS: ............................ Hz ..................
UNIT SERIAL NO. ........................................................ COMPRESSOR MODEL NOS. ....................................................................
START UP : DATE .......................................... TIME....................................................

DATE
TIME
ELAPSED TIME METERS
COMP. NO.
1.
SUCTION 2.
PRESSURE 3.
4.
1.
DISCHARGE 2.
PRESSURE 3.
4.
1.
DISCHARGE 2.
TEMPERATURE 3.
4.
1.
DISCHARGE SUPERHEAT 2.
(DISC. TEMP.-SAT. DISCH.)* 3.
4.
1.
DISCHARGE SUPERHEAT 2.
(DISC. TEMP.-SAT. SUCT.)* 3.
4.
EVAPORATOR WATER TEMPERATURE-IN
EVAPORATOR WATER TEMPERATURE-OUT
EVAPORATOR PRESSURE DROP ftwg[kPa]
EVAPORATOR WATER FLOW gpm [m³/hr]
CONDENSER AIR TEMPERATURE-IN
(AMBIENT) AC ONLY
1.
ACTUAL VOLTAGE 2.
COMPRESSOR AMPS 3.
4.
FAN AMPS
VOLTS
*USE TABLE 5.4 FOR OBTAINING SATURATED TEMPERATURE

THIS LOG SHEET IS PROVIDED AS A RECOMMENDATION OF THE READINGS THAT SHOULD BE TAKEN ON A PERIODIC BASIS. THE
ACTUAL READINGS TAKEN AND THE FREQUENCY WILL DEPEND UPON THE UNITS APPLICATION, HOURS OF USE, ETC. THIS TYPE OF
INFORMATION CAN PROVE VERY USEFUL IN PREVENTING AND/ OR SOLVING PROBLEMS THAT MIGHT OCCUR DURING THE LIFE OF
THE UNIT.
- 92 -
Products that perform...By people who care
Manufacturer reserves the right to change specifications without prior notice.
Corporate Head Office

DUNHAM-BUSH HOLDING BHD
(Formerly known as Dunham-Bush (Malaysia) Bhd) (129358-X)
Lot 5755-6, Kidamai Industrial Park, Bukit Angkat

43000 Kajang, Selangor Darul Ehsan, Malaysia.
Tel: 603-8733 9898 Fax: 603-8739 5020
E-Mail: info@dunham-bush.com.my
www.dunham-bush.com

Installation, Operation & Maintenance Manual

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Installation, Operation & Maintenance Manual

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Form No: M-M-0488A-0510

Products that perform...By people who care

INSTALLATION, AIR COOLED

Description Page Description Page

1.0 INTRODUCTION .............................................. 3 4.2.1 Typical Control Sequence With 2 Stage

3.0 OPERATION 4.9 TYPICAL WIRING SCHEMATIC ........................ 54

3.1 General ........................................................... 24

This manual is prepared to provide all the necessary information of

Dunham-Bush package has been manufactured under a stringent quality

TABLE 1.1 PRODUCTION IDENTIFICATION

Air Cooled Packaged Chiller S- Standard Fan

Scroll Compressor R410A

Nominal Capacity in Tons AN- 208-230V/3pH/60Hz

1.1 PHYSICAL DATA

RPM 3500 3500 3500 3500 3500 3500 3500 3500

NO. OF REFRIGERANT CIRCUIT 1 1 1 2 2 2 2 2

COIL ROWS DEEP/ TOTAL FA FT²[M²] 3/ 3/ 4/ 3/ 3/ 4/ 4/ 4/

MODEL ACDS 090 100 120 135 150 165 180

RPM 3500 3500 3500 3500 3500 3500 3500

NO. OF REFRIGERANT CIRCUIT 2 2 2 2 2 2 2

COIL ROWS DEEP/ TOTAL FA FT²[M²] 4/ 4/ 4/ 4/ 4/ 4/ 4/

TOTAL CFM 71400 96960 95200 124140 122850 147420 147420

NOM. VOLTAGE 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60 460/3/60

2.1 GENERAL 2.3.2 RIGGING AND MOVING

FIGURE 2.3.2 ACDS RIGGING

ACDS 030, 040, 050, 060, 070

ACDS 080, 090, 100, 120,

ACDS 135, 150, 165, 180

FIGURE 2.4.2B DIMENSIONAL DATA

ACDS 050, 060, 070

60.5 [1537.400 mm]

66 [1675.100 mm] 58 [1467.100 mm] 12 [304.800 mm]

148 [3747.000 mm]

REAR VIEW LEFT VIEW FRONT VIEW

ACDS 100, 120

WATER OUT CONNECTION [3.5"] NOMINAL DIA

24 [609.200 mm] 60.5 [1536.600 mm]

88 [2237.600 mm] DOOR SWING

AIR FLOW TOP VIEW .

6 NOS OF 3/4" (19) 6 NOS OF ? 2.9 [? 73.200 mm] LIFTING 84 [2134]

30 [762.000 mm] 83 [2101.850 mm] 83 [2101.850 mm] 30 [762.000 mm]

REAR VIEW LEFT VIEW FRONT VIEW

OPTIONAL WELDED FLANGE CONNECTION

24 [609.600 mm] 60 [1524.000 mm]

AIR FLOW 48 [1219.200 mm]

AIR FLOW TOP VIEW

267.5 [6794.500 mm]

REAR VIEW LEFT VIEW FRONT VIEW

2.5 FOUNDATION Rubber-in-shear or spring vibration isolators are

FIGURE 2.5.1 FLOOR LOADING DIAGRAM

ACDS 010 ACDS 020

POINT LOAD LOCATION

POINT LOAD DATA

ACDS 030, 040, 050, 060, 070

ACDS 080, 090, 100, 120, 135, 150

ACDS 165, 180

POINT LOAD LOCATION

030 84 [2134] 16 [406] 76 [1930] 16 [406] - -

040 84 [2134] 16 [406] 76 [1930] 16 [406] - -

050 84 [2134] 20 [508] 102 [2600] 20 [508] - -

060 84 [2134] 20 [508] 102 [2600] 20 [508] - -

070 84 [2134] 20 [508] 102 [2600] 20 [508] - -

080 84 [2134] 12 [305] 58[1467] 66 [1675] 12 [305] -