Dunham-Bush Manual

Form No: M-M-0489A-0410
Products that perform...By people who care
INSTALLATION, Water
OPERATION & Cooled
MAINTENANCE Screw
Flooded
MANUAL
Chillers
MODEL:
HXWC Series
R134a
65 to 200 Tons
(229 to 703 kW)
60Hz
TABLE OF CONTENTS
DESCRIPTION PAGE NO DESCRIPTION PAGE NO

1.0 GENERAL INFORMATION 4.4.5.1 Technician status key ........................... 25
1.1 RECEIVING AND INSPECTION. ....................................... 4 4.4.5.2 Technician status key- main menu ....... 25
1.2 RIGGING AND MOVING ................................................... 4 4.4.5.3 Compressor FLA calibration ................. 25
1.3 DIMENSIONAL DATA. ...................................................... 4 4.4.5.4 To perform sensor calibration............... 26
1.4 APPLICATION PRECAUTIONS. ....................................... 4 4.4.5.5 Manual control...................................... 26
1.4.1 Water Connections .................................................. 4 4.4.5.6 Compressor control .............................. 27
1.4.2 Chilled Water Flow .................................................. 4 4.4.5.7 Sensors Override ................................. 28
1.4.3 Water Cooled Condenser ........................................ 7 4.4.6 Control Functions ................................................ 28
1.4.4 Water Treatment ..................................................... 7 4.4.6.1 Chilled water pump interlock and flow
switch .................................................. 28
2.0 INSTALLATION 4.4.6.2 Customer control interlock.................... 28
4.4.6.3 Anti-recycle timer ................................. 28
2.1 FOUNDATION ................................................................... 8
4.4.6.4 On Delay Timer .................................... 28
2.2 UNMOUNTED ACCESSORIES ......................................... 8
4.4.6.5 Load control ......................................... 29
2.3 WATER PIPING CONNECTIONS ..................................... 8
4.4.6.6 Ramp control ........................................ 29
2.4 ELECTRICAL WIRING ...................................................... 8
4.4.6.7 Staging control ..................................... 29
2.5 CONTROLS ..................................................................... 10
4.4.6.8 Modmotor setback control .................... 29
2.5.1 Connections .......................................................... 10
4.4.6.9 Suction/ Discharge Pressure Differential
2.5.2 Settings ................................................................. 10
Control (SDD Control)l ......................... 29
2.6 VIBRATION ISOLATION ................................................. 11
4.4.6.10 Sump Heater Control ........................... 30
2.7 REQUEST FOR START-UP REPRESENTATIVE ........... 11
4.4.6.11 Low pressure cut-off ............................. 30
4.4.6.12 Evaporator Freeze Shutoff ................... 30
3.0 OPERATION 4.4.6.13 High pressure cut-off ............................ 30
3.1 SYSTEM WATER FLOW RATE. ..................................... 12 4.4.6.14 Optical oil level sensor ......................... 30
3.2 SEASONAL SHUT-DOWN PROCEDURE ...................... 12 4.4.6.15 High oil temperature thermostat ........... 30
3.3 SEASONAL START-UP PROCEDURE .......................... 12 4.4.6.16 Overload protector ............................... 30
3.4 SAFETY RELIEF VALVES .............................................. 12 4.4.6.17 Phase control relay .............................. 30
3.5 REFRIGERATION CYCLE .............................................. 13 4.4.6.18 Sensor alarm ........................................ 31
3.6 OIL MANAGEMENT SYSTEMS ...................................... 13 4.4.6.19 No-stop alarm....................................... 31
3.7 CONTINUOUS CAPACITY CONTROL SYSTEM ........... 13 4.4.6.20 Low differential pressure alarm ............ 31
3.8 FREEZE PROTECTION .................................................. 13 4.5 Calibration Of Screw Compressor Capacity Amps At
3.8.1 Standby At Low Ambient Temperatures ................ 13 Full Load & Minimum Load Percentage ....................... 31
3.8.2 In Operation........................................................... 15 4.6 Master/ Slave Control Sequence................................... 31
3.8.3 During Maintenance .............................................. 15 4.6.1 Sensor Principle of Operation VIA DBLAN
Communication Bus ............................................ 32
4.0 ELECTRICAL 4.6.2 Sequence of Operation ....................................... 33
4.1 ELECTRICAL DATA ....................................................... 16 4.7 Vision 2020i Local Area Network (DBLAN) .................. 33
4.2 WIRING DIAGRAM.......................................................... 16 4.8 Network Connection Diagram ....................................... 34
4.3 TYPICAL OPERATION ................................................... 16 4.9.1 Vision 2020i Controller with DBG2/DBG3
4.4 VISION 2020I CONTROLLER AND TERMINAL ............. 21 Display ................................................................ 34
4.4.1 Touch Screen Terminal Display ............................ 21 4.9.1.1 Description of the menu ......................... 35
4.4.1.1 The fourteen touch keys ........................... 21 4.9.2 Vision 2020i Controller LED Status ..................... 37
4.4.1.2 The seven physical keys .......................... 21
4.4.2 Status Reading ...................................................... 22
4.4.2.1 Input status key ........................................ 22 5.0 MAINTENANCE
4.4.2.2 Output status key...................................... 22 5.1 GENERAL.......................................................................... 38
4.4.2.3 Compressor status key ............................. 22 5.2 PERIODIC INSPECTION. .................................................. 38
4.4.2.4 Setpoint key .............................................. 23 5.3 MONTHLY INSPECTION................................................... 38
4.4.2.5 Clock key .................................................. 23 5.4 WATER SIDE CLEANING OF VESSELS.......................... 38
4.4.2.6 Alarm history key ...................................... 24 5.5 ELECTRICAL MALFUNCTION ......................................... 40
4.4.3 Authorization ......................................................... 24 5.6 CHARGING........................................................................ 40
4.4.3.1 Authorization key ...................................... 24 5.6.1 Refrigerant Charge .................................................. 40
4.4.4 Advanced user key and menu ............................... 24 5.6.2 Oil Charge ............................................................... 40
4.4.4.1 User key ................................................... 24 5.7 TROUBLESHOOTING ....................................................... 41
4.4.5 Technician Key and Menu ................................... 25 5.8 SAMPLE LOG SHEET....................................................... 42
SCHEMATIC DIAGRAM, GRAPH AND TABLE

DESCRIPTION PAGE NO
Figure 1.2 Rigging Diagram ........................................................................................................................................................................ 5

Figure 1.3 Dimensional Data ...................................................................................................................................................................... 6
Figure 2.1 Floor Loading Diagram ............................................................................................................................................................. 8
Figure 2.2 Flow Switch................................................................................................................................................................................ 8
Figure 2.4 Pressure Drop............................................................................................................................................................................ 9
Figure 3.5 Typical Piping Schematic ....................................................................................................................................................... 15
Figure 3.7 Continuous Capacity Control System ................................................................................................................................... 16
Figure 4.2 Typical Wiring Diagram........................................................................................................................................................... 17
Figure 4.4.1 Vision 2020i Keypad ................................................................................................................................................................ 21
Table 2.1 Floor Loading Diagram ........................................................................................................................................................... 10
Table 4.4.6.6 Ramp Rates for Several Setpoints (In Minutes) .................................................................................................................... 29
Table 4.9.3 LED Status ............................................................................................................................................................................... 37
Table 5.4 R134a Pressure/Temperature Properties .............................................................................................................................. 39
HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

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INTRODUCTION
To assure satisfactory operation and to avoid damage to the unit,

the installation should be made by a qualified refrigeration
mechanic. It is assumed that the reader of this manual and those
who install, operate and maintain this equipment have a basic
understanding of the principles of air conditioning, refrigeration
and electrical controls. These instructions are general in nature
and are for standard catalog units. Non-standard units may vary
in some respects from these instructions.
Dunham-Bush packaged chiller has been manufactured under a

careful quality control system. It has been performance tested at
the factory at specified field operating conditions as a final
verification of reliability. If it is installed, operated and maintained
with care and according to these instructions, it will give many
years of satisfactory service.
NOMENCLATURE
HXWC 200 - 6 N R
Water Cooled Horizontal R134a

Rotary Screw Packaged
Chiller
Standard
Nominal Tons
60Hz

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1.0 GENERAL INFORMATION
1.1 RECEIVING AND 1.4 APPLICATION

INSPECTION PRECAUTIONS
The unit should be inspected immediately, in the The following instructions are intended to help
presence of the carrier's representative, for any assure proper and successful application of your
evidence of damage during shipping. Any units.
damage should be noted on the carrier's delivery
receipt before it is signed. A damage claim should 1.4.1 WATER CONDITIONS
then be filed by the purchaser against the
Standard construction of the evaporator
delivering carrier as all shipments are made at the
and condenser used in Dunham-Bush
purchaser's risk. The receiving inspection
model units are copper tubes with steel
instructions, sent with the installation instructions,
tube sheets and header.
should also be filled out at this time and
forwarded to the Dunham-Bush Industries, M & E These materials are generally suitable
Service Department. for use with clean fresh water found in
most localities. However, minerals and
other contaminants found in some water
1.2 RIGGING AND MOVING systems may promote aggressive attack
The unit has been carefully tested and inspected on the tubes or tube sheets, resulting in
at the factory where every precaution was taken failure with serious consequences for the
to ensure that it reaches its destination in perfect entire package chiller.
condition. It is very important that the installers,
Because Dunham-Bush has no control
movers, and riggers use the same care in
over the condition of the water used in
handling the unit. The unit is designed to be lifted
these machines, we can take no
from the lifting holes in the tube sheets. It can
responsibility for failure of tubes or tube
also be moved on skids placed under the tube
sheets due to water corrosion or erosion.
sheets. For proper rigging, see Figure 1.2.
It is recommended that the buyer obtain
It is important to protect the unit from damage the services of local water treatment
during storage, rigging and installation. Particular specialists to prescribe water treatment.
care should be given to avoid damage to controls Copper-nickel tubes and stainless tube
and piping. Do not allow the unit to be used as a sheets are however available as an
ladder or scaffold. option.
1.4.2 CHILLED WATER FLOW

The Dunham-Bush unit is designed for a
1.3 DIMENSIONAL DATA constant chilled water flow rate, even
Dimensional outline drawings of the package are when the load is varying. The machine
shown in Figure 1.3. Note especially the space will generally perform satisfactorily with
and clearance requirements necessary for steady flow rates deviating from design
servicing the unit. by as much as +10% / -50%. However,
varying water flow rates can cause

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FIGURE 1.2 RIGGING DIAGRAM

Rigging To Be Done In A Manner So That No Strain Is Placed On Unit Components Other Than
At Cable Connection Points

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HXWC 65-6NR, 75-6NR, 95-6NR, 110-6NR, 130-6NR
3.) HXWC 150-6NR, 170-6NR, 185-6NR, 200-6NR

-6-
control instability, which will result in used to reject heat from the condensing
undesirable system effects, particularly water loop, it must be controlled to
poor control of leaving chilled water provide an entering condensing water
temperature. If two-way valves are used temperature which does not change
to control flow through cooling coils, more rapidly than 1°F/min. [0.6°C/min.]
some means such as an automatic and does not go below 60°F [15.6°C].
modulating valve should be provided in One or more of the following methods
the system to maintain steady flow may be used to control the tower:
through the evaporator.
1.4.3.1 A modulating three-way valve
If chilled water flow rate and/ or load
which bypasses tower sprays at
vary, the variation must be controlled so
low load and low ambient
that return water temperature does not
temperature.
vary at a rate exceeding 2°F [1.1°C] per
minute. 1.4.3.2 Tower fan staging in response
If the chilled water system is arranged to a thermostat in the tower
for the dual purpose of cooling and sump. Fan thermostat should
heating, the evaporator must incorporate have a differential of at least

valves to prevent the flow of hot water 20°F [11.1°C] to avoid short
through it. This can be done with either cycling.
manual or automatic shutoff valves, but

1.4.3.3 A modulating three-way valve,
the method of control must be such that
which bypasses the cooling,
water temperature entering the
tower to blend warm leaving
evaporator never exceeds 90°F [32.2°C].
condenser water with cold
tower water.
1.4.3 WATER COOLED
CONDENSERS
1.4.4 WATER TREATMENT
The water-cooled condenser is also
designed for constant water flow rate, Water tends to leave silt, algae and
and should be supplied with the design mineral deposits in the tubes. This
flow rate ±10%. The condenser must be fouling gradually decreases unit
protected from rapid changes in efficiency. For this reason, a program of
temperature as well. The maximum water treatment should be employed. At
allowable rate of change in condenser regular intervals depending on the water
entering water is 1°F [0.6°C] per minute. quality, the unit should be shut down to
Fluctuating flow rate or temperature will have the tubes cleaned. See Chapter 5
cause unstable control of the machine, “Water Side Vessels Cleaning”.
resulting in poor control of leaving chilled
water temperature. If a cooling tower is

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2.0 INSTALLATION
2.1 FOUNDATION switch set to trip at approximately 50% of the

design flow. Consult the wiring diagram
A flat, level concrete foundation or floor capable accompanying the unit for the electrical
of supporting the weight of the unit must be connections to interlock the flow switch with the
provided. Weights are given in Figure 2.1. The control panel.
unit must be leveled to within 1/16" per foot [5mm
per meter] for proper operation.
FIGURE 2.2 FLOW SWITCH
2.2 UNMOUNTED
ACCESSORIES
A chiller flow switch, which is shipped in a
separate container accompanying the unit, must
be installed in the external chilled water outlet
piping. It must be located in a horizontal section
on the pipe where there is at least five (5) pipe
diameters on both sides of the flow switch before
any other connections, as indicated in Fig. 1. The
flow switch paddle must be adjusted to the size of
pipe in which the paddle is installed, and the
TABLE 2.1 FLOOR LOADING DIAGRAM
D C
COMPRESSOR
A CONTROL PANEL B
Point Load Data- Lbs

Model HXWC A B C D Operating Weight Shipping Weight
65 -6NR 1045 1248 1247 1641 5181 4505
75-6NR 1210 1288 1347 1850 5696 4953
95-6NR 1420 1488 1572 2164 6644 5777
110-6NR 1480 1680 1728 2271 7159 6225
130-6NR 1839 1932 2043 2670 8484 7377
150 -6NR 1705 2158 2977 1792 8633 7507
170-6NR 2150 2834 3197 1980 10162 8837
185-6NR 2181 2882 3291 2033 10387 9032
200-6NR 2404 3233 3331 2062 11029 9590

-8-
2.0 INSTALLATION
FIGURE 2.4 PRESSURE DROPS

Evaporator 2 Pass
100
PRESSURE DROP - FT.WG.
B1R
C1R
D1R
10
J1R
K1R
K2R
L1R
E1R
1
10 100 1000
WATER FLOW - GPM
Condenser 2 Pass
100
PRESSURE DROP - FT.WG.
A1R
A2R
A3R
10
G1R
H2R
B1R
H4R
C1R
1
100 1000
WATER FLOW RATE- GPM

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2.0 INSTALLATION
2.3 WATER PIPING - Connections to unit should match the unit

CONNECTIONS nameplate in volts, phase and Hertz. Voltage
Refer to Figure 1.3 for water piping connection must not vary beyond ±10% of nameplate
value and voltage imbalance between phases
locations. Note that the condenser water inlet
must not exceed 2% at any time during
must be on the bottom. If necessary, evaporator
operation of the unit.
or condenser heads can be reversed, left to right
or vice versa. Leaving chilled water temp sensor Phase sequence to connections L1, L2, L3 shall
must be located in leaving chilled water stream. be in that order. Check with Amprobe phase
After the unit has been leveled and isolators (if sequence adapter PSA-1 or equivalent.
any) installed and adjusted, connect evaporator
and condenser water piping. Piping must be
properly supported to avoid stress on unit water
2.5 CONTROLS
connections. Install air vent valves in all high
connections on evaporator and condenser heads.
2.5.1 CONNECTIONS
Install drain valves in similar low points to
facilitate gravity draining of the system. It is Controls, which are to be field installed,
important that water systems be cleaned before should be connected in accordance with
start-up to avoid collecting debris in cooler and the appropriate wiring diagram
condenser. The best way to do this is to install accompanying the unit. The following
wye strainers in both systems upstream of the connections should be made where
unit. After filling the system with water, bleed applicable:
trapped air from the various vent valves. Check
2.5.1.1 Connect a set of normally open
for proper flow rates by measuring water pressure
auxiliary contacts from chilled
drop across heat exchangers and reading the flow
water pump contactor into unit
rate from charts, Figure 2.3. Compare measured
controls as shown on unit
flow rate with values specified on purchase order.
wiring diagram.
Check in Figure 2.3 to see that evaporator and
condenser flow rate fall between min. and max.
2.5.1.2 Install a chilled water flow
limits.
switch (paddle type
recommended) in straight
length of chilled water piping to
avoid turbulence. Connect in
2.4 ELECTRICAL WIRING same electrical circuit as
In connecting power wiring to the unit, the 2.5.1.1.
following precautions should be taken:
2.5.1.3 For control of condensing water
- All field wiring is to be in accordance with the
pumps, connect contacts
National Electric Code and must comply with
supplied in unit in series with
state and local codes.
condensing water pump starter
- Check unit wiring for damage and all terminal coil.
connections for tightness. Unit terminal blocks
are to be connected with copper conductors 2.5.1.4 Connect an enable/disable
only, sized per ampacity listed on unit data contact into the unit controls as
plate. shown on the wiring diagram.
Closure of this contact enables
the unit to operate.

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2.0 INSTALLATION
2.5.2 SETTINGS
Following this contact a representative will be
All controls are factory set. However sent to the customer. He will inspect the
operating control settings are not always installation to determine whether it meets
applicable under all operating conditions. Dunham-Bush Industries requirements, perform
For recommended control settings, refer the initial start-up of the installation, determine
to the wiring diagram accompanying the whether it is in satisfactory operating condition,
unit. Safety controls must be set and instruct the specified customer personnel in
according to factory recommendations. its operation and maintenance for the length of
time specified in the purchase contract.
NOTE:
2.6 VIBRATION ISOLATION
Sump oil heaters should be energized for a
Where structure-borne vibration may be of
minimum of 24 hours and the oil sump
concern, it is recommended that the unit be
temperature must be at a minimum of 100°F
mounted on vibration isolators. Rubber-in-shear
[38°C] prior to arrival of start-up representative.
isolators or spring isolators are available for this
This will ensure that the oil is warm enough to
unit as optional equipment. If spring isolators are
vaporize any dissolved refrigerant and that the oil
installed, it is also necessary to provide isolation
is within the normal operating temperature range.
in condenser water and chilled water pipes by
Sump oil heaters are energized simply by turning
means of flexible connectors and in main power
on the control power switch.
supply conduit through use of flexible conduit.
Isolation of piping and electrical conduit is
desirable in any event, to avoid noise WARNING:
transmission.
The compressor(s) should be started initially
ONLY under the direct supervision of an
Authorized Dunham-Bush Industries Start-Up
2.7 REQUEST FOR START-UP Representative.
REPRESENTATIVE
After the installation has been completed and
checked, contact the M&E Service Department of
Dunham-Bush Industries for an authorized start-
up representative to perform the initial start-up of
the Dunham-Bush packaged chiller. The
purchaser must have competent service and
operating personnel in attendance to assist in the
work involved, and also to be trained in the
service and maintenance of this unit. (During the
warranty period, the manufacturer is responsible
for parts only upon proof of defective
workmanship or manufacture).

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3.0 OPERATION
3.1 SYSTEM WATER FLOW 3.3 SEASONAL START-UP

RATE PROCEDURE
The quantity of water being circulated can be When the unit is to be started up after being shut
measured quite accurately (±5%) by determining down for a prolonged period:
the water pressure drop through the vessels and
3.3.1 Check unit for evidence of rust or
reading the flow rate from the pressure drop
corrosion. Clean surfaces and repaint as
curves, Figure 2.3. Connect reliable pressure
necessary. Repair insulation if necessary.
gauges to valves installed in the vessels entering
and leaving water vent connections and read 3.3.2 Energize power supply to unit. Unit must
pressure difference with chilled water pump in be energized for 24 hours in order to
operation. An alternate method of determining warm up compressor oil sump before
flow rate is to measure the pressure difference starting. Control circuit power switch
from pump inlet to outlet and read the flow rate should be off during this period to prevent
from the pump curve. compressor operation. Clean waterside
heat transfer surface of condenser and
evaporator by removing heads and
3.2 SEASONAL SHUT-DOWN brushing tubes.
PROCEDURE 3.3.3 Check water circuits to see that cooling
3.2.1 If the unit is to be shut down for a tower is ready for operation, and both
prolonged period (a month or more), the circuits are filled. Start pumps and check
power supply to the unit may be de- for flow in both cooler and condenser.
energized to conserve energy.
3.3.4 Turn control circuit power switches on,
3.2.2 The cooling tower may be drained to turn compressor switch on, and press
avoid freezing. If the unit is located in an reset on computer keyboard. Compressor
area where the ambient temperature should start after start-up clock times out
constantly remains above freezing, the and leaving water temperature should be
condenser need not be drained. It is automatically controlled. Check
better to leave the condenser and refrigerant charge and check for normal
evaporator filled with water during a suction and discharge pressures.
shutdown period. If the unit is located
where ambient temperature will be below 3.3.5 Have a trained service mechanic check
freezing, drain all water thoroughly, the function of all control setpoints. Check
removing all vent and drain plugs from signal lights for proper operation.
both heads of each vessel, and blow out 3.3.6 Take oil sample from each compressor
tubes with compressed air. and submit it for laboratory analysis.
NOTE: Simply draining is not sufficient.
Stagnant water may cause serious
corrosion. 3.4 SAFETY RELIEF VALVES
3.2.3 It is recommended that an oil sample be Each pressure vessel is protected by a safety
taken from each compressor and relief valve as required by ASME Code. On some
submitted for laboratory analysis. units, the condenser has a dual manifold. One
Dunham-Bush offers this service in its Oil valve in this manifold is active, the other standby.
Kare Program. This analysis should be If the active valve starts to leak, simply screw the
done at the beginning and end of each
manifold valve to the opposite extreme, which will
operating season, or every six months if
activate the standby valve. Local codes may
the unit is used year round.
require that all safety relief valves be piped to the
Important: Discontinue chilled water pump outdoors. Never install a hand valve in a safety
operation when unit is not relief vent line.
operational.

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3.0 OPERATION
3.5 REFRIGERATION CYCLE Oil is also returned to the compressor after it is

separated from the refrigerant at the oil separator
Refer to Figure 3.5 for the piping schematics.
located at the discharge of the compressor.
Each screw compressor discharges hot, high
pressure gas through a discharge check valve
into the condenser, where it condenses outside
the tubes, rejecting heat to the water flowing 3.7 CONTINUOUS CAPACITY
inside the tubes. The condensed liquid refrigerant
exits the condenser and goes into the liquid feed
CONTROL SYSTEM
line. Continuous capacity control for each compressor
The refrigerant flows through the liquid ball valve is achieve by using a normally close solenoid
for throttling and experience a pressure drop valve (SV2) and a normally close solenoid valve
causing it to condensate. The liquid ball valve is (SV1) which are equipped to the inlet and outlet of
actuated by a Modutrol motor that adjusts flow to piston cylinder respectively. These two solenoid
maintain an appropriate refrigerant level in the valves are controlled by the chiller temperature
evaporator, determined by a liquid level float controller. Refrigeration capacity hence can be
switch. modulated anywhere within 25% to 100% for
each compressor. Therefore, it is possible to
From the liquid line, liquid refrigerant flows into control the capacity output stably by modulating
the flooded evaporator, where it boils, absorbing the inlet of SV2 and outlet of SV1 alternatively.
heat from the water flowing inside evaporator
tubes and thus cooling it. Vapor from the boiling
refrigerant flows up the suction piping through a
suction service valve and suction filter (inside 3.8 FREEZE PREVENTION
compressor) into the compressor where it is
compressed and starts the cycle again. If water (or brine) is allowed to freeze within the
tubes and heads of the evaporator or condenser,
severe damage will result; split and leaking tubes
3.6 OIL MANAGEMENT and cracked and leaking heads. Since this
damage can be extremely costly and is not
SYSTEMS covered by warranty, it is important to be mindful
The compressors are oil lubricated and a small of freeze prevention. Three cases deserve
amount of oil is discharged along with the particular attention:
refrigerant. This oil is carried back into the
evaporator. Oil rich refrigerant is returned to the 3.8.1 STANDBY AT LOW AMBIENT
compressor from the evaporator through a oil TEMPERATURES
return line which consist of an oil return valve, a
If the unit is to stand idle at ambient
filter drier, sight glass and check valves before
temperatures below 32°F [0°C], the
going to a jet pump at each compressor. From the
water should be drained from evaporator
jet pump, this oil rich liquid feeds through service
and condenser. One water header
valve into the compressor suction port. Gas from
should be removed from each vessel
each compressor which drives the jet pump flows
and the tubes blown dry with
through an angle valve and solenoid valve.
compressed air. Gravity draining the
For multiple-compressor units, an extra oil vessel through drains in heads may not
balancing line is required between the be sufficient. If evaporator or condenser
compressors. This piping ensures oil is not is served with a glycol solution, make
trapped in a single compressor when some of the sure the freeze temperature of the
compressors are not operating. Any excess oil in solution is lower than expected minimum
a compressor will flow into the other compressors ambient temperature.
through this line. The flow is controlled through
solenoid valves.

- 13 -
3.0 OPERATION
FIGURE 3.5 SCHEMATIC PIPING DIAGRAM

- 14 -
3.0 OPERATION
FIGURE 3.7 CONTINUOUS CAPACITY CONTROL SYSTEMS

SV1 SV2
Start Energize Not Energize
Loading Not Energize Energize
Unloading Energize Not Energize
Stable Not Energize Not Energize
3.8.2 IN OPERATION 3.8.3 DURING MAINTENANCE

Freezing of water in cooler tubes is a In transferring refrigerant within the unit,
possibility if chilled water flow stops and or removing refrigerant from the unit for
if the low suction pressure cutout
maintenance purposes, it is possible to
(normally set for 28 psig [1.9 BAR], or
freeze evaporator or condenser tubes.
32°F [0°C] saturation) and the low water
temperature cutout both fail. If the chilled Remember that whenever the pressure
water flow switch and pump interlock are in a vessel is reduced below 28 psig [1.9
properly applied (See chapter 2 bar], if water is not flowing, it is possible
“Control”) the unit has four protective to freeze tubes. For this reason, it is a
devices which must all fail for the good precaution to have water flowing in
evaporator to hall freeze. While this is
both vessels whenever transferring
unlikely, it is important to see that all
these devices are functional and refrigerant.
properly calibrated.

- 15 -
4.0 ELECTRICAL
4.1 ELECTRICAL DATA

Unit Each Compressor
Model
Voltage
HXWC MCA MFS RLA (Qty) INR (Qty) LRA (Qty)
A A A A A
65-6NR 460V-3PH-60Hz 76 125 61(1) 165(1) 500(1)
75-6NR 460V-3PH-60Hz 93 150 74(1) 206(1) 625(1)
95-6NR 460V-3PH-60Hz 120 200 96(1) 241(1) 730(1)
110-6NR 460V-3PH-60Hz 134 225 107(1) 279(1) 845(1)
130-6NR 460V-3PH-60Hz 159 250 127(1) 302(1) 915(1)
150-6NR 460V-3PH-60Hz 173 300 138(1) 462(1) 1400(1)
170-6NR 460V-3PH-60Hz 201 350 161(1) 462(1) 1400(1)
185-6NR 460V-3PH-60Hz 224 400 179(1) 493(1) 1495(1)
200-6NR 460V-3PH-60Hz 233 400 186(1) 540(1) 1635(1)
NOTES: MCA - MINIMUM CIRCUIT AMPACITY

MFS - MAXIMUM FUSE SIZE
RLA - RATED LOAD AMPS AT ARI COS
INR - INRUSH AMPS
LRA - LOCKED ROTOR AMPS
4.2 WIRING DIAGRAM - Reset pressed on controller keypad

Figure 4.2 are typical wiring diagrams for a 1 - All safety conditions satisfied
compressor unit control by Vision 2020i controller. - Leaving chilled water temperature 2°F [1.1°C]
This may not be an accurate representation of or more above setpoint
your unit. It is best to use the wiring diagram
A compressor is started by first energizing 1M1
mounted in the package control panel. A copy of
followed by 1M2 after 1 second if step start is
that diagram is furnished with the unit owner’s
activated (See Section 4.5.4). Otherwise, both
manual.
contactors energize together. Anti-recycle time of
15 minutes is initiated within the computer at start.
4.3 TYPICAL OPERATION When the compressor starts, the micro-computer
In order to start a compressor; the following monitors amperage by means of 1CT, leaving
conditions must be met: water temperature using TS, and condensing
- Correct system voltage and phase sequence pressure. These inputs are used to control the
such that phase control relay (PCR) is in normal loading and staging of the compressor. The
state compressor's loading is controlled by pulsing
signals to the load and unload solenoids.
- Chilled water pump running
- Chilled water flow switch made To shut down the unit automatically, the customer
control contacts must be opened. To shut down
- Compressor circuit breakers on
the unit manually, simply shut off the compressor
- Customer unit control contact closed switches. This will cause a no-run alarm that must
- Control switch and compressor switches on be reset to restart the compressor.
- Power has been on the microcomputer for 15
minutes
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FIGURE 4.2 TYPICAL WIRING DIAGRAM
∼ ∼

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∼ ∼

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4.4 VISION 2020i 4.4.1.1 THE FOURTEEN TOUCH KEYS:

CONTROLLER AND Key Description
TERMINAL MAIN Display the main screen
Vision 2020i controller is equipped with user USER User Control Changeable Settings.
friendly 5.7” touch screen display with 256 colors
Technician Control Changeable
TECHNICIAN
and 320 × 240 pixel on graphic resolution. It is Settings.
connected with controller through twisted pair FACTORY
Factory Control Changeable
Settings.
shielded cable. The graphic display terminal
allows carrying out all program operations. The SETPOINT Displays the status of set points.
user terminal allows displaying the unit working AUTHORIZATIO

To log in the level of passwords
conditions, component run times, alarm history at N
any time and modifying the parameters. The MENU

Unit information / Compressor
Information.
terminal also has an automatically self-test of the
CLOCK/SCHED
controller on system start-up. Multiple messages ULE
Displays the date, time and day.
will be displayed by automatically scrolling from Display the active alarms and to
ALARM RESET
each message to the next. All of these messages perform alarm manual resets.
are spelled out in English language on the screen. Scroll the various screens when the
cursor is in the top left of the
display. If the cursor is inside a
numeric field, the button increases
LEFT
or decreases the corresponding
4.4.1 TOUCH SCREEN TERMINAL value. If the field is a selection,
pressing the button displays the
DISPLAY available options.
RIGHT See the LEFT arrow

The touch screen keypad consists of 14 touch
Displays the analog inputs and
keys, and 7 physical keys: digital
INPUT STATUS
inputs status measured by the
probes/sensors.
OUTPUT Displays the relay outputs and
Model E0000 STATUS analog outputs status.
COMPRESSOR Displays the status of Compressor
Unit No : 01 STATUS 1, 2 and so on.
Date : 09/06/08 4.4.1.2 THE SEVEN PHYSICAL KEYS:

Time : 03:33
Key Description
Program Date : 09/05/08 Scroll the various screens when the

cursor is in the top left of the
display. If the cursor is inside a
numeric field, the button increases
UP
or decreases the corresponding
value. If the field is a selection,
pressing the button displays the
available options.
To move the cursor around the
Figure 4.4.1 Vision 2020i keypad ENTER screens and to save the values of
the set parameters
The top right ‘Authorization’ button is for DOWN See the UP arrow
password log in to gain authorization, to the

Unit information / Compressor
access setting menu. MENU
Information.
The three buttons at the top row which is to ALARM RESET

Display the active alarms and to
perform alarm manual resets.
access different level of setting changes. These
are 'User', 'Technician' and 'Factory' levels. AUTHORIZATION To log in the level of passwords
It can only be access depend on the password Displays the analog inputs and
INPUT STATUS digital inputs status measured by
level. The higher password can access the lower the probes/sensors.
password level's setting and not vice versa.

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4.4.2 STATUS READING

4.4.2.1 Input status key OUTPUT STATUS 1
To read inputs status, touch on input Comp 1 ON-HOLD

status key: Comp 2 ON-LOAD
Alarm Status OFF
Control Power ON
SDD Control OFF
The display is showing the data as
follows:
Touch on right arrow key or output key

ANALOG SENSORS 1 to go to next screen:
Supply Temperature 44.6°F [7.0°C]
Suction Pressure 68PSI[4.7BAR] The display is showing the data as

Discharge Pressure 195PSI[13.4BAR] follows:
OUTPUT STATUS 2
Setback Control OFF

Touch on right arrow key or input key to
C1 Liquid Injection Sol ON
go to next screen:
C2 Liquid Injection Sol OFF

follows:
Repeat the same steps to go to other

relay outputs screen:
ANALOG SENSORS 2
Compressor 1 Amps 125 A

4.4.2.3 Compressor status key
To read compressor status, touch on
Compressor 2 Amps 135 A
compressor status key:

follows:

sensor inputs screen: COMPRESSOR 1 STATUS
4.4.2.2 Output status key Comp 1 OK

Amps = 125 A
To read relay outputs status, touch
FLA1 = 125 A
output status key:
Target = 100.0%
Capacity = 100.0%
Status = ON-HOLD

follows:

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Touch on right arrow key or compressor

key to go to next screen:
44.0

follows:
COMPRESSOR 1 HISTORY
Today Total
Run Hour 12 156
Cycle 01 20 Touch on right arrow key or setpoint
key to go to next screen:
Last On 05/23 07:00
Last Off 05/22 22:15

setpoints screen and perform setpoint
modification.
4.4.2.4 Setpoint key:
To read the setpoint value, touch on 4.4.2.5 Clock key:
setpoint key To read the current day, time and date,
unit scheduling and Ice-cel mode
scheduling (optional), touch on the
clock key
follows:

follows:
SETPOINT 1
Supply Water Temp

REAL TIME CLOCK
Set point = 44°F [6.7°C]
Dead Band = 0.8°F [0.5°C]
Day > MONDAY
Time > 15 : 30
Date > 12 / 05 / 08
To alter set point data, you must be

authorized. See the authorization
procedure and you must be authorized To set the date and time, you must be
at least as user level. authorized. See the authorization
procedure and log in at least as user
Touch on the selected set point which level.
written in blue color and underlined.
Use the keypad to key in the desired Touch on the date or time which is
setpoint and press OK key to confirm written in blue color and underlined to
the change. If the value you key in is change the setpoint. Use the up or
out of acceptable range, the setpoint down keys of the keypad below to
will not change and the keypad will change the value and touch on OK key
remain to receive another value. to confirm.

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Touch on left arrow key or alarm history

key to go to next screen for other alarm
history:
To clear alarm history, press “Prg” key

and “Esc” key together at the right hand
side of the terminal and then press the
alarm key again. Now the display
should be showing “No alarm”
Touch on right arrow key or clock key to

go to next screen:
4.4.3 AUTHORIZATION
4.4.3.1 Authorization key

To get authorization level, touch on
The display is showing the data as authorization key:
follows:
Schedule 1 Setpoint
Time On = 08 : 00 The display is showing the current
Time Off = 20 : 00 access level as view only
Days Thursday
Monday Friday
Tuesday Saturday AUTHORIZATION
Wednesday Sunday Please Enter Your Password
****
Status = View
1 2 3 4 5 C
6 7 8 9 0
4.4.2.6 Alarm history key:
To view the unit alarm history, touch on
Main key to go to main menu, and then
touch on alarm history key:
Key in the password by using the touch
keys and touch on Enter key to confirm.

follows:
Now the authorization status changes
to different access level.
ALARM HISTORY
4.4.4 ADVANCED USER KEY AND
001-C1 Starter
15:31 12/05/08
MENU
TR: 030.2 LWT: 55.5°F [13.1°C]
DP1: 180PSI [12.4BAR] 4.4.4.1 User Key
SP1: 80PSI [5.5BAR] User key is use to view and change the
C1: 068 A C2: 080 A pressure, ampere safety limits and
liquid injection temperature set points,
unit of measurements. In order to gain
access to this button, you must be

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4.0 ELECTRICAL
authorized and log in at least as user compressor FLA setpoint, sensors

level. calibration, manually control digital
inputs and outputs, manually control
compressor and override sensor
reading. In order to gain access to this
Touch on the user key and display is button, you must be authorized and log
showing the data as follows: in at least as technician level. See the
authorization section about this
procedure.
USE SETPOINT 1
4.4.5.2 Technician status key - main
High Pressure Safety menu
Limit
Hold = 240 PSI [16.5BAR] Touch on technician key to go to
Unload = 245 PSI [16.9BAR] technician set points main menu:
Cutout = 250 PSI [17.2BAR]

follows:
Touch on right arrow key or user key to
go to the next screen or setpoints.
TECHNICIAN SETPOINTS
MAIN MENU
To alter setpoint data, press on the COMP FLA CALIBRATION

setpoint which in written in blue color
and underlined. Use the keypad below SENSOR CALIBRATION
to change the value and press OK key MANUAL CONTROL
to confirm. If the value you key in is out
of acceptable range, the setpoint will COMPRESSOR CONTROL
not change and the keypad will remain
to receive another value. SENSORS OVERRIDE
Touch on on the selected sub-menu to

245 move the next page to the sub menu.
4.4.5.3 Compressor FLA Calibration:

To calibrate compressor FLA, touch on
the sub-menu 'Comp FLA Calibration',
follows:
TECHNICIAN SETPOINT 1
Repeat the above steps for other Comp 1 FLA CALIBRATION
setpoints. 157 × 00.90 + 028.50
FLA1 = 181A
Capacity Comp 1 = 000.0%
Min Percent Cal = 25.0%
4.4.5 TECHNICIAN KEY and MENU Max Percent Cal = 00A
4.4.5.1 Technician status key

This key is use to view and change the

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4.0 ELECTRICAL
Touch on the desired setpoint with blue Touch on technician key to go to

color and underlined to calibrate the technician set points main menu and
comp FLA and use the keypad shown touch on the ‘Manual Control’ sub-
as below to change the value and press menu:
OK key to confirm.
follows:
90
DIGITAL INPUTS
MANUAL CONTROLS
Comp 1 Starter = Auto
Comp 2 Starter = Auto
Comp 1 Oil Level = Auto
Comp 2 Oil Level = Auto
Unit Enable = Auto
Flow Switch = Auto
Touch on desired point with blue color

4.4.5.4 To Perform Sensor and underlined for manual control.
Calibration: Use the keypad shown as below to
change to the desired digital input to
To perform sensor calibration, touch on AUTO/CLOSE/OPEN. Touch on OK to
the ‘Sensor Calibration’ sub-menu: confirm.
follows:
SENSOR OFFSET 1
Suction Pressure 1
Current = 078 PSI [5.4BAR]
Average = 187 PSI [12.9BAR]
24Hrs Max = 200 PSI [13.8BAR]
24Hrs Min = 074 PSI [5.1BAR]
Calibration = 00 PSI [0.0BAR]
Touch on the selected sensor The display is showing the data as

calibration and key in the calibration follows:
value by using the keypad.
Press OK to confirm. Repeat the above
steps for others sensors calibrations. DIGITAL INPUTS
MANUAL CONTROLS
4.4.5.5 Manual Control: Comp 1 Starter = Close

A digital input sensor or relay output Comp 2 Starter = Auto
can be controlled manually with the Comp 1 Oil Level = Auto
keypad. Digital input sensor or relay
output can be turned on, off manually
and placed back to auto mode. To
place a digital input or relay output in
manual control, the operator must be
authorized at technician level or higher.

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For manual control of digital outputs, Use the keypad shown as below to
use the following keypad to change the change to the compressor control to
desired digital output to AUTO/MANUAL/OFF. Touch on OK to
AUTO/ON/OFF. Touch on OK to confirm.
confirm.
If the compressor control is placed on

4.4.5.6 Compressor Control: MANUAL control, the display is
showing data as follow:
Screw compressors can be controlled
manually with the keypad. A
compressor can be turned on, off, or
placed in computer control. When a COMPRESSOR CONTROL
compressor is controlled manually, it Manual Override
can be commanded to load, hold, or
unload. If safety limiting condition is Compressor 1 = AUTO
active, it will not accept a load St = 0000
command. Amps = 000.0 A
Capacity = 000.0 %
To place a compressor in manual
Status = OFF
control, the operator must be
authorized and log in as technician
level and higher.
Touch on technician key to go to
technician setpoints main menu and Touch on HOLD, LOAD or UNLOAD
touch on the ‘Compressor Control’ sub- key to manually control the compressor
menu: running status.
The display is showing the data as If a safety condition is exceeded while
follows: operating manually, the compressor will
shutdown.
CAUTION: Anti-recycle timer is
COMPRESSOR CONTROL bypassed by manual control. DO NOT
Manual Override starts a compressor more than once
every 15 minutes.
Compressor 1 = AUTO
St = 0000 NOTE: All compressors will revert back
Amps = 000.0 A to automatic control if the computer is
Capacity = 000.0 % the computer is not given a load,
Status = OFF unload, or hold command at least once
every 15 minutes. A command can be
repeated to meet the 15 minute
requirement for manual control.

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4.0 ELECTRICAL
To the change the settings of Faulty sensor shall be replaced as soon as

compressor load/Unload, follow the possible in order to allow the unit to be running in
above steps and go to compressor automatic mode.
control. Use right arrow key to move to
the following page as shown:
4.4.6 CONTROL FUNCTIONS
LOAD / UNLOAD CONTROL
4.4.6.1 Chilled Water Pump Interlock
Manual Pulse Settings And Flow Switch (CWP And
Pulse Rate = 001 sec
Pulse Width = 001 cyc
CWFS)
These are field installed switches, both
of which are used to ensure chilled
water flow before the unit is allowed to
start. Failure of either one during
operation will cause the compressor to
shut down.
4.4.5.7 Sensors Override A water flow alarm will be generated

and ‘Rest Alarm’ must be pressed to
Value of analog readings can be
temporary override during sensor clear the alarm.
failure.
To override the analog readings, the 4.4.6.2 Customer Control Interlock
operator must be authorized at Control contacts from an external
technician level or higher. controller can be used to enable or
Touch on technician key to go to disable operation of the unit. The wiring
technician setpoints main menu and diagram specifies the terminals to
touch on ‘Sensors Override’ sub-menu:
which the contacts must be wired. To
follows: enable the unit, the contacts must be
closed. To disable the unit, the contacts
must be opened.
Sensors Manual
Override 4.4.6.3 Anti-Recycle Timer
The compressor motor requires an anti-
Supply Water Temp
Man Reading = 45.0°F [7.2°C] recycle time delay which prevents
Manual Override = NO restart for 15 minutes after a start. The
purpose of this feature is to avoid
frequent starts which tend to elevate
the motor winding temperature and
impose undue wear on contactors. The
controller will not restart the
Touch on the value to key in the compressor motor until the 15 minutes
override reading. Then, touch on have elapsed.
NO/YES key with blue color and
underlined to enable, or disable the 4.4.6.4 On Delay Timer
manual override control. A Compressor on delay timer of one or
Repeat the above steps for other two minutes is incorporated to prevent
sensors override. two compressors from starting at the
same time and ensures that the system
CAUTION: Sensors override require continuous
load requires another compressor. The
monitoring and observation by the field service
compressor output status will display
personnel at all time during the unit operation.
the timer count-down during this timing.

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4.4.6.5 Load Control 4.4.6.7 Staging Control

The controller controls the leaving On multiple-compressor machines,
water temperature within a narrow when the controller determines that a
deadband by pulsing load and/ or compressor is fully loaded and
unload solenoids on the compressor. temperature is not being maintained,
The load and unload solenoids position another compressor is added. When
the slide valve within the compressor to unloading, a compressor is taken off
control its capacity. The controller line when the computer determines that
determines a desired level of loading the remaining compressors can control
and varies pulse duration depending on water temperature.
difference between load target and
actual load. The load target is varied
based on rate of approach to desired 4.4.6.8 Modmotor Setback Control
temperature preventing significant A computer contact and a resistor are
temperature oscillations. The status of wired in parallel in the modmotor
the compressor can be observed by control circuit. The contact is controller
displaying the compressor output controlled to open under light load
status. conditions. This lowers liquid level
slightly, preventing excessive liquid
4.4.6.6 Ramp Control level in the evaporator.
Another feature of the controller is ramp
control, which is the ability to vary load 4.4.6.9 Suction/ Discharge Pressure
time of the machine from start. Often Differential Control
when the machine is started, the water (SDD Control)
in the chilled water circuit is warm, and
the unit will go to full load quickly. With This control function seeks to prevent a
ramp control, the user can program the low differential pressure alarm. It
computer so that it loads at a monitors the difference between
predetermined rate. This is a valuable condenser and evaporator pressure. If
tool, since it can help reduce power this difference is less than 30 psid
consumption and demand charges. [2.1BAR] for more than 10 seconds,
Two variables are used to define the and evaporator pressure is above 75
ramp profile: Ramp rate and start point. psig [5.2BAR], the controller will open a
Ramp rate defines the length of time set of contacts in the modmotor circuit,
the unit takes to load from start point to causing valves to travel in the closed
full load. Start point is the percent of full direction. This starves the evaporator,
load at which the ramp begins. The which increases pressure difference.
ramp rate setpoint can be set anywhere When this difference exceeds 30 psid
from 0.1 to 1.0, smaller values [2.1BAR], modmotor control returns to
producing slower loading rates. The normal.
ramp start setpoint can be set CAUTION: Do not start compressor
anywhere between 0 and 50%. The manually more than once every 15
compressor will load quickly to this minutes. Verify that chilled water flow
value and then follow the ramp slope switch is closed.
from there. See Table 4.4.6.6 for ramp
rates at various settings.
TABLE 4.4.6.6 Ramp Rates for Several Setpoints (In Minutes)

1 Comp. 2 Comp. 3 Comp 4 Comp
Ramp
Rate Start Point Setpoint Start Point Setpoint Start Point Setpoint Start Point Setpoint
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
4.4.6.10 Sump Heater Control (digital input is OFF) persists for 60

Each compressor is fitted with an oil seconds during compressor operation,
sump heater. The heater is energized the controller will then shut down the
at all times when compressor is off and compressor. The status of the oil level
de-energized when the compressor is sensor can be seen on the computer
running. display.
Its purpose is to prevent refrigerant Failure is indicated on the alarm pilot
migration into the oil during shut down. light. The low oil alarm will be recorded
For this reason, it is essential that by the controller.
heaters be energized for 24 hours
before starting a compressor. 4.4.6.15 High Oil Temperature
Thermostat (12TAS)
4.4.6.11 Low Pressure Cut-off A thermostat is located in each
This function protects the unit from compressor which will open the
operating at abnormally low evaporator compressor run circuit if oil temperature
refrigerant pressure. The controller will exceeds 203°F [95°C]. The high oil
shut down the compressor when cooler temperature pilot light will indicate an
pressure falls below the low pressure excessive oil temperature and a No-
setpoint and turn on the alarm pilot Run error will be recorded by the
light. computer. Reset is activated by
A low pressure alarm will be recorded pressing the ‘Reset Alarm’ button on
by the controller. Reset by pressing the controller.
‘Reset Alarm’ on the controller.
Standard setpoint is 28psig [1.9BAR] 4.4.6.16 Overload Protector (M2OL)
for water-cooled systems. A solid state overload protects each
compressor by three phase current
4.4.6.12 Evaporator Freeze Shutoff monitoring to prevent high current
If the leaving chilled water temperature draw. The trip setting is factory set and
drops below the freeze setpoint, the is reset by pressing button on overload
controller will shut down the unit and after correcting problem. The ‘Reset
store the freeze alarm. After solving the Alarm’ button on controller must also be
problem, press ‘Reset Alarm’ on the pressed to clear the alarm. A no-run
controller to clear the alarm. error is stored in the controller.
4.4.6.13 High Pressure Cut-off 4.4.6.17 Phase Control Relay (PCR)

This function protects the compressor The PCR protects the unit from the
from operating at abnormally high following electric supply malfunctions:
discharge refrigerant pressures. The Undervoltage, phase reversal and
controller will shut down the single phasing. If the PCR trips, a
compressor when condenser pressure control relay (lCR) will de-energize and
reaches the high pressure set point, open the control circuit. A green LED
and turn on the alarm indicator lamp on indicates presence of power supply.
the control box. The high discharge The yellow LED indicates a good
pressure alarm will be recorded by the voltage supply. The power loss setpoint
controller. Reset by pressing the ‘Reset is factory set to AUTO to allow
Alarm’ button on the controller. Setpoint automatic start after PCR failure.
for water-cooled system is 164psig Compressor will not start for 15 minutes
[11.3BAR]. after failure. To select manual reset, set
power loss setpoint to MANUAL. In this
4.4.6.14 Standard Oil Level Sensor (LS) case, a power loss alarm will be stored
An standard oil level sensor is located by the controller and ‘Reset Alarm’
in each compressor. If low oil indication must be pressed to start.

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4.0 ELECTRICAL
4.4.6.18 Sensor Alarm 2. Load the compressor to full load. If the amps
If the controller measures an analog reading do not match with calculated FLA
value (temperature, pressure.) that is value within 2-3A, do this calculation: Amps –
far beyond normal operating values, the FLA
associated compressors are shutdown. For example, FLA = 150A, however the max
The controller then stores the alarm amps at full load is 130A, so, do the
code corresponding to the sensor calculation
alarm. A sensor alarm indicates a
130 – 150 = -20
problem in the analog measurement
system. 3. Key in this value into “Max Percent Cal” of the
compressor in “COMPRESSOR FLA
4.4.6.19 No-Stop Alarm CALIBRATION” mask under technician key.
If the controller turns off a compressor, 4. Therefore, the value of FLA will change.
but the compressor digital input does Verify that amps and FLA now match closely.
not turn off, a No-Stop alarm is 5. Manually unload the compressor all the way.
generated. The controller will turn off 6. Locate the minimum percentage of capacity
the control power relay which disables for the compressor. If this value is 25% ± 3%,
all compressor control circuits and will no change required. Else, enter this value into
turn on the alarm light. This alarm “Min Percent Cal” in the same mask. The
indicates a wiring or hardware error. default value of “Min Percent Cal” is 25%.
4.4.6.20 Low Differential Pressure For example, the minimum percentage of

Alarm capacity for the compressor is 32.2%,
therefore, enter 32.2 at “Min Percent Cal”.
For proper lubrication, a compressor
requires a 30 psid [2.1BAR] differential 7. Repeat this procedure for each compressor.
pressure between condenser and
evaporator pressures. If the differential
4.6 MASTER/ SLAVE
pressure is less than 30 psid [2.1BAR]
for 3 minutes while a compressor is
CONTROL SEQUENCE
operating, all compressors will be shut The optional master/slave control sequence is
down. The controller will store the low used to sequence multiple chillers in one
differential pressure alarm code and installation according to the building load demand.
turn on the alarm light. The ‘Reset It also controls the dedicated chilled water pump
Alarm’ key must be pressed to clear the or motorized valve.
alarm.
Vision2020i Controller offers this feature with
minimized field wiring cost compare to
4.5 CALIBRATION OF SCREW conventional method that involves lots of
hardware cost. It is carried out this control
COMPRESSOR CAPACITY
function via the advanced DBLAN communication
AMPS AT FULL LOAD & bus to implement the network management for
MINIMUM LOAD multiple chillers lead/lag communication,
PERCENTAGE sequencing and monitoring.
1. Check calibration of all sensors (pressure
sensors, current transducers, temp sensors
and etc.). All calibration on sensors shall be
done in this step.

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4.0 ELECTRICAL
4.6.1 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 display panel DBG1 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

¾ Manual lead/lag setpoint
¾ Schedule and holiday setup
¾ Alarm conditions
d) The lead/lag selection determine the chiller operation sequence as follows,
Lead chiller selection Normal chillers operation sequence When DBLAN fails
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
4.6.2 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 b) After a enable next time delay of 3
starter or motorized valve control point will minutes (adjustable) and
close and water will start to flow through the
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, %Capacity C1 & %Capacity
the chiller and upon receipt of a valid 'on' C2 ≥ Next on setpoint
signal, the lead chiller will begin to execute its
or it is being lockout by an alarm.
running program.
2. The controller will start and load the

compressor(s), upon achieving full load; it will
send an output signal via the DBLAN to 4.7 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
control without additional hardware.
4. When the second chiller or lag 1 unit reaches
full load, it will enable the third chiller. Every DBLAN node must be addressed to be
identified by the other nodes. Each address (an
5. The chiller will keep cascading until all chillers integer number) must be unique in the network for
on duty are at full load. 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. The max address number selectable is in the 1-16
for the Vision 2020i controller boards and 17-32
7. If the load drops below 45% total capacity,
range for the Vision 2020i DBG1 User terminal.
delay the last unit (lag 3) will be disabled, and
the remaining three units will load up to
compensate if necessary. The pump for
The three chiller unit combinations:
chiller 4 will be shut off.
Controller with address of 1 connect to Terminal
8. As the load demand falls, the lag 2 unit will be with address of 17
disabled below 45% total capacity, and so on
until the load falls enough to shut off the lead Controller with address of 2 connect to Terminal
chiller. with address of 18
Controller with address of 3 connect to Terminal
9. Each unit in the network can monitor the
with address of 19
operation of other units via DBLAN. If the
master unit is having critical alarm, the lag 1 Follow the following steps:
will take over as the master unit automatically.
10. In order to enable next unit, the following

conditions must met

- 33 -
4.0 ELECTRICAL
4.8 NETWORK CONNECTION DIAGRAM

Adr:17 Adr:18 Adr:19
Vision 2020i Vision 2020i Vision 2020i
DBG1 DBG1 DBG1
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.
4.9 HARDWARE SETTINGS

4.9.1 VISION 2020i CONTROLLER
WITH DBG2/ DBG3 DISPLAY
The menus can be accessed by pressing
any point on the touch screen together
with the (up) and Prg buttons for at
least one second. Alternatively, press the
(up) / (down), (enter) buttons
together for at least one second.
The following operations exit the menu:
1. Pressing the Esc button; To access an item, simply press the touch
2. Automatically 1 minute after a button screen on the corresponding indication, or
was pressed or the touch screen press the (up) / (down) buttons until
touched; selecting it and then confirm by pressing
3. Pressing the “X” symbol when (enter).
displayed at the top right. To modify the value of a field, after having
As shown in the following figure, the activated it (a field is active when the
buttons that can be used during the cursor is flashing inside), press the (up)
configuration phase are also visible on the / (down) buttons to change the value
right side of the display:
and press (enter) to save it. Pressing
Esc before (enter) cancel the
modifications made to the field.
- 34 -
4.0 ELECTRICAL
4.9.1.1 Description of the menu “Network Configuration” menu
Main menu
The main menu, visible in the previous
image “Display Configuration”, is used
to select the main three configuration
categories, that is:
• Screen Settings: Settings relating to
the screen
• Network Configuration: Settings
relating to the RS485 network
• General Options: Various settings
“Screen Settings” menu The following options are possible:

• Terminal Address: Used to set the
address of the terminal (from 1 to 32,
default: 32). If the value “--” is set
(two dashes are displayed) the
terminal will communicate with the
Vision 2020i board using the “Point-
Point” protocol : the “Baud Rate”,
“Network Monitor” and “Setup I/O
Board” fields will then disappear, as
they have no meaning.
• Baud Rate: Used to set the DBLAN
communication baud rate. The
The following options are available: possible values are 62500 (default) or
• Contrast: Used to set the contrast of 115200 (used only if all the devices in
the display (from 0 to 100, default: the network are configured for this
50). speed). Note that not all the DBLAN
• Normal Brightness After: Used to set devices support the 115200 setting.
the time after the touch screen or the • Network Monitor: This is used to
buttons are last pressed that the display the status of the network (see
display switches from “high next paragraph)
brightness” to “normal brightness”. • Setup I/O Board Setup: These fields
The possible values range from 30 s are used to modify the list of
to 15 min, default: 1 min. terminals associated with each
• Screen Saver Timeout: Used to set individual Vision 2020i board.
the time after the touch screen or the
buttons are last pressed that the Network Monitor
display switches off, after having
switched to “normal brightness”. The
possible values range from 30 s to 4
hours (4 hrs), default: 15 min.
• Calibrate Touch Screen: The touch
screen can be calibrated if it is
evidently misaligned. To align the
touch screen, press the exact centre
of the crosses displayed in sequence.
The message “Done: touch the
screen to ESC” indicates that the
operation has been completed
correctly. If, on the other hand, the This screen is used to display the status
message “Bad: touch to ESC and of the network when master-slave
repeat” is displayed, the operation will sequencing control is furnished,
need to be repeated. indicating graphically which devices

- 35 -
4.0 ELECTRICAL
are connected for each address. The 4. To exit the configuration procedure
meaning of the symbols is the and save the data, select the “OK ?”
following: field, set “Yes” and confirm by
pressing (enter). Alternatively, if
Vision 2020i controller active in the
the terminal remains inactive (no
network
button is pressed) for more than 30
Any type of terminal active in the network s, the configuration procedure is
automatically ended without saving
Current terminal the changes.
Important: the DBG2/3 terminals
Device not connected
cannot be configured as “Sp” (shared
printer) as the printer output is not
featured. Selecting this mode has no
If activity is detected on the network, effect on the management of printed
the message “Online” is displayed. To messages sent via DBLAN.
exit the screen, press the Esc button.
Assigning the I/O Board Address of
Assigning the list of private and the Controller
shared terminals In order to configure the I/O board
The list of terminals associated with address of the Vision 2020i controller,
each individual Vision 2020i board can the terminal address must set to “--”.
be modified from the “Network Please refer to “Network Configuration
Configuration” menu, as follows: Menu” for procedures to configure the
1. Select the address of the required terminal address. The following display
board using the (up) / (down) will appear:
buttons in the “Setup I/O Board” field
(only the boards that are effectively
on-line can be selected) and confirm
by pressing (enter). If the DBLAN
network is not working correctly, or
no Vision 2020i board is present,
the field is not modifiable, and “--
“(two dashes) will be displayed.
2. Press the “Setup” button: the
following screens will be displayed in
sequence:
Switch off power supply of the

controller now. Disconnect connectors
at J11 and J23 on the controller. Press
and hold “alarm reset” and “up” key,
then resume power supply of the
controller.
After a few seconds, the controller
commences the start-up sequence, and
then the following display is shown.
3. Now the (enter) button is used to ***********************************

move the cursor from one field to the SELF TEST
PLEASE WAIT
next, and (up) / (down) change ************************************
the value of the current field. The
“P:xx” field shows the address of the
selected board (in the example,
board number 12 has been
selected);

- 36 -
4.0 ELECTRICAL
When this screen appears, wait 10 The possible values are “off”, “low”,
seconds and then release the buttons. “high”. Default: high.
The controller stops the start-up This parameter has no effect on the
sequence and the following display is alarm signal, which is activated or
shown. deactivated by the Vision 2020i.
2. Beep On: Used to set when the
pLAN Address : 1 “Beep” sounds. The possible values
Up : Increase are: “active items” (associates a
Down : Decrease sound with the active area of the
Enter : Save & Exit display), “screen” (associates a
sound with any point on the touch
screen) and “screen & keys”
(associates a sound with both the
touch screen and the keypad).
Default: “screen & keys”.
Then, set the “pLAN Address” using the 3. Download Bar: activates (“yes”) or
“Up” and “Down” buttons on the deactivates (“no”) the display of the
terminal. Confirm the setting by status bar that indicates the
pressing “Enter” button. The controller progress of the page. Default: “yes”.
completes the start-up sequence and 4. Clear Cache Memory: deletes the
uses the specified address. cache memory used to accelerate
Now, configure the “Terminal Address” the display of the screens. This
to its desired setting. Terminal display function may be useful if there are
address shall be set to “17” if it is errors in the graphics. Pressing the
connected to a Vision 2020i controller button displays a window that
with I/O address “01”. If the terminal is prompts for confirmation. Press
connected to a Vision 2020i controller “yes” to confirm the operation or “no”
with I/O address “02”, terminal display to abort it.
address shall be set to “18”. 5. Display Firmware Update: starts the
DBG2/3 firmware update procedure.
“General Options” menu
4.9.2 Vision 2020i Controller LED
Status
Vision 2020i controller have three LEDs between
the J3 and J4 connectors for indicating basic
node status. They are Red, Yellow and Green
coloured.
Red Yellow Green
At the start-up all LEDs are ON and after few

The following options are possible:
seconds OFF again. After 5 – 15 seconds elapse,
1. Beep Volume: Used to set the
then LED configuration is among those listed
volume associated of the “Beep”
below.
with the buttons and the touch
screen pressing.
Table 4.9.2 LED Status

LED STATUS DESCRIPTION
ON Vision 2020i controller is synchronized with all the other DBLAN nodes. 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
ON Vision 2020i controller software not compatible or variables database not correct, contact Dunham-Bush Service Personnel.
Vision 2020i hardware is not compatible - Ram is smaller than 32 KB.
1
The Vision 2020i controller is just for working in stand-alone mode.

- 37 -
5.0 MAINTENANCE
5.1 GENERAL and condenser is approach, which is the

difference between leaving water temperature
As with all mechanical equipment, a program of
and saturated refrigerant temperature at the
regular inspection, cleaning and preventive
pressure in the vessel. At full load, read cooler
maintenance by trained personnel will contribute
and condenser pressures on the computer. Then
greatly to the long satisfactory service life of this
use Table 5.4 to find corresponding saturated
product. Some of this care can easily be provided
temp. for each. Read leaving chilled water
by owner personnel. However, a Dunham-Bush
temperature on the computer. Read leaving
authorized service mechanic should inspect the
condenser water temperature on computer if
unit at least annually and evaluate unit
option is provided, or with field installed
performance.
thermometer. Then calculate approaches as
follows:
5.2 PERIODIC INSPECTION Condenser Approach = T sat condenser -

T lvg cond. water
Read essential temperatures and pressures Cooler Approach = T lvg chilled water -
periodically to see that they indicate normal T sat cooler
operation. It is a good idea to record these
readings on a log sheet. See sample record sheet If the approach for either vessel increases by
in Section 5.8. If any abnormal operation is more than 2°F [1.1°C] above the approach
observed, try to determine cause and remedy it. recorded at clean conditions, the tubes should be
See Trouble-shooting Guide, Section 5.7. cleaned. It is generally advisable to clean the
waterside surfaces at least annually and more
often if severely foul water is used. This cleaning
5.3 MONTHLY INSPECTION can be done chemically or physically. In chemical

cleaning, a caustic solution is pumped through the
Check water treatment system. Wipe down
heat exchanger, which attacks dirt, slime and
external surfaces of unit. Shut unit down, open
mineral deposits and flushes them away.
main disconnect, inspect control panel, checking
Chemicals can be recommended by water
for loose wires, burned contacts, signs of
treatment specialists, but it is important to rinse
overheated wires, etc. Restart unit and check
the system thoroughly after cleaning to remove
performance of controls and time rate of loading
the chemicals before they attack the metal
and unloading. Check flash tank feed line sight
surfaces.
glass for proper refrigerant charge level. See
Charging, Section 5.6.
Vessel tubes may be physically cleaned by first
draining the water, then removing the heads and
brushing each tube individually with a tube
5.4 WATER SIDE CLEANING cleaning brush until clean. The brush should have
OF VESSELS stiff nylon bristles. Brush kits are available from
The effects of fouling on the cooler or condenser D/B North American Service. For best results,
heat transfer surfaces can be detected by always remove both heads before cleaning the
recording full load performance data on the log tubes. Replace the heads, being careful to
sheet. The best measure of performance of cooler properly position gaskets, and refill the system
with water.

- 38 -
5.0 MAINTENANCE
TABLE 5.4 R134A PRESSURE/TEMPERATURE PROPERTIES

PRESS TEMP. PRESS TEMP. PRESS TEMP. PRESS TEMP. PRESS TEMP.
PSIG KPA °F °C PSIG KPA °F °C PSIG KPA °F °C PSIG KPA °F °C PSIG KPA °F °C
0.00 101.38 -14.70 -25.94 53.00 466.90 56.90 13.83 106.00 832.41 90.90 32.72 159.00 1197.93 115.00 46.11 212.00 1563.45 134.10 56.72
1.00 108.28 -12.00 -24.44 54.00 473.79 57.70 14.28 107.00 839.31 91.50 33.06 160.00 1204.83 115.40 46.33 213.00 1570.34 134.40 56.89
2.00 115.17 -9.50 -23.06 55.00 480.69 58.50 14.72 108.00 846.21 92.00 33.33 161.00 1211.72 115.80 46.56 214.00 1577.24 134.70 57.06
3.00 122.07 -7.10 -21.72 56.00 487.59 59.30 15.17 109.00 853.10 92.50 33.61 162.00 1218.62 116.20 46.78 215.00 1584.14 135.10 57.28
4.00 128.97 -4.80 -20.44 57.00 494.48 60.10 15.61 110.00 860.00 93.00 33.89 163.00 1225.52 116.60 47.00 216.00 1591.03 135.40 57.44
5.00 135.86 -2.60 -19.22 58.00 501.38 60.90 16.06 111.00 866.90 93.50 34.17 164.00 1232.41 117.00 47.22 217.00 1597.93 135.70 57.61
6.00 142.76 -0.50 -18.06 59.00 508.28 61.60 16.44 112.00 873.79 94.00 34.44 165.00 1239.31 117.40 47.44 218.00 1604.83 136.00 57.78
7.00 149.66 1.50 -16.94 60.00 515.17 62.40 16.89 113.00 880.69 94.50 34.72 166.00 1246.21 117.70 47.61 219.00 1611.72 136.40 58.00
8.00 156.55 3.50 -15.83 61.00 522.07 63.10 17.28 114.00 887.59 95.00 35.00 167.00 1253.10 118.10 47.83 220.00 1618.62 136.70 58.17
9.00 163.45 5.30 -14.83 62.00 528.97 63.90 17.72 115.00 894.48 95.50 35.28 168.00 1260.00 118.50 48.06 221.00 1625.52 137.00 58.33
10.00 170.34 7.20 -13.78 63.00 535.86 64.60 18.11 116.00 901.38 96.00 35.56 169.00 1266.90 118.90 48.28 222.00 1632.41 137.30 58.50
11.00 177.24 8.90 -12.83 64.00 542.76 65.30 18.50 117.00 908.28 96.50 35.83 170.00 1273.79 119.30 48.50 223.00 1639.31 137.60 58.67
12.00 184.14 10.60 -11.89 65.00 549.66 66.00 18.89 118.00 915.17 97.00 36.11 171.00 1280.69 119.70 48.72 224.00 1646.21 138.00 58.89
13.00 191.03 12.30 -10.94 66.00 556.55 66.80 19.33 119.00 922.07 97.50 36.39 172.00 1287.59 120.00 48.89 225.00 1653.10 138.30 59.06
14.00 197.93 13.90 -10.06 67.00 563.45 67.50 19.72 120.00 928.97 98.00 36.67 173.00 1294.48 120.40 49.11 226.00 1660.00 138.60 59.22
15.00 204.83 15.50 -9.17 68.00 570.34 68.20 20.11 121.00 935.86 98.40 36.89 174.00 1301.38 120.80 49.33 227.00 1666.90 138.90 59.39
16.00 211.72 17.00 -8.33 69.00 577.24 68.90 20.50 122.00 942.76 98.90 37.17 175.00 1308.28 121.20 49.56 228.00 1673.79 139.20 59.56
17.00 218.62 17.50 -8.06 70.00 584.14 69.50 20.83 123.00 949.66 99.40 37.44 176.00 1315.17 121.50 49.72 229.00 1680.69 139.50 59.72
18.00 225.52 20.00 -6.67 71.00 591.03 70.20 21.22 124.00 956.55 99.90 37.72 177.00 1322.07 121.90 49.94 230.00 1687.59 139.80 59.89
19.00 232.41 21.40 -5.89 72.00 597.93 70.90 21.61 125.00 963.45 100.30 37.94 178.00 1328.97 122.30 50.17 231.00 1694.48 140.10 60.06
20.00 239.31 22.80 -5.11 73.00 604.83 71.60 22.00 126.00 970.34 100.80 38.22 179.00 1335.86 122.60 50.33 232.00 1701.38 140.40 60.22
21.00 246.21 24.10 -4.39 74.00 611.72 72.20 22.33 127.00 977.24 101.30 38.50 180.00 1342.76 123.00 50.56 233.00 1708.28 140.80 60.44
22.00 253.10 25.40 -3.67 75.00 618.62 72.90 22.72 128.00 984.14 101.70 38.72 181.00 1349.66 123.40 50.78 234.00 1715.17 141.10 60.61
23.00 260.00 26.70 -2.94 76.00 625.52 73.50 23.06 129.00 991.03 102.20 39.00 182.00 1356.55 123.70 50.94 235.00 1722.07 141.40 60.78
24.00 266.90 28.00 -2.22 77.00 632.41 74.20 23.44 130.00 997.93 102.70 39.28 183.00 1363.45 124.10 51.17 236.00 1728.97 141.70 60.94
25.00 273.79 29.20 -1.56 78.00 639.31 74.80 23.78 131.00 1004.83 103.10 39.50 184.00 1370.34 124.50 51.39 237.00 1735.86 142.00 61.11
26.00 280.69 30.50 -0.83 79.00 646.21 75.50 24.17 132.00 1011.72 103.60 39.78 185.00 1377.24 124.80 51.56 238.00 1742.76 142.30 61.28
27.00 287.59 31.70 -0.17 80.00 653.10 76.10 24.50 133.00 1018.62 104.00 40.00 186.00 1384.14 125.20 51.78 239.00 1749.66 142.60 61.44
28.00 294.48 32.80 0.44 81.00 660.00 76.70 24.83 134.00 1025.52 104.50 40.28 187.00 1391.03 125.50 51.94 240.00 1756.55 142.90 61.61
29.00 301.38 34.00 1.11 82.00 666.90 77.30 25.17 135.00 1032.41 104.90 40.50 188.00 1397.93 125.90 52.17 241.00 1763.45 143.20 61.78
30.00 308.28 35.10 1.72 83.00 673.79 78.00 25.56 136.00 1039.31 105.30 40.72 189.00 1404.83 126.30 52.39 242.00 1770.34 143.50 61.94
31.00 315.17 36.20 2.33 84.00 680.69 78.60 25.89 137.00 1046.21 105.80 41.00 190.00 1411.72 126.60 52.56 243.00 1777.24 143.80 62.11
32.00 322.07 37.30 2.94 85.00 687.59 79.20 26.22 138.00 1053.10 106.20 41.22 191.00 1418.62 127.00 52.78 244.00 1784.14 144.10 62.28
33.00 328.97 38.40 3.56 86.00 694.48 79.80 26.56 139.00 1060.00 106.70 41.50 192.00 1425.52 127.30 52.94 245.00 1791.03 144.40 62.44
34.00 335.86 39.50 4.17 87.00 701.38 80.40 26.89 140.00 1066.90 107.10 41.72 193.00 1432.41 127.70 53.17 246.00 1797.93 144.70 62.61
35.00 342.76 40.50 4.72 88.00 708.28 81.00 27.22 141.00 1073.79 107.50 41.94 194.00 1439.31 128.00 53.33 247.00 1804.83 145.00 62.78
36.00 349.66 41.50 5.28 89.00 715.17 81.50 27.50 142.00 1080.69 108.00 42.22 195.00 1446.21 128.40 53.56 248.00 1811.72 145.30 62.94
37.00 356.55 42.50 5.83 90.00 722.07 82.10 27.83 143.00 1087.59 108.40 42.44 196.00 1453.10 128.70 53.72 249.00 1818.62 145.60 63.11
38.00 363.45 43.50 6.39 91.00 728.97 82.70 28.17 144.00 1094.48 108.80 42.67 197.00 1460.00 129.10 53.94 250.00 1825.52 145.90 63.28
39.00 370.34 44.50 6.94 92.00 735.86 83.30 28.50 145.00 1101.38 109.20 42.89 198.00 1466.90 129.40 54.11 251.00 1832.41 145.20 62.89
40.00 377.24 45.50 7.50 93.00 742.76 83.90 28.83 146.00 1108.28 109.70 43.17 199.00 1473.79 129.70 54.28 252.00 1839.31 146.40 63.56
41.00 384.14 46.40 8.00 94.00 749.66 84.40 29.11 147.00 1115.17 110.10 43.39 200.00 1480.69 130.10 54.50 253.00 1846.21 146.70 63.72
42.00 391.03 47.40 8.56 95.00 756.55 85.00 29.44 148.00 1122.07 110.50 43.61 201.00 1487.59 130.40 54.67 254.00 1853.10 147.00 63.89
43.00 397.93 48.30 9.06 96.00 763.45 85.60 29.78 149.00 1128.97 110.90 43.83 202.00 1494.48 130.80 54.89 255.00 1860.00 147.30 64.06
44.00 404.83 49.20 9.56 97.00 770.34 86.10 30.06 150.00 1135.86 111.30 44.06 203.00 1501.38 131.10 55.06 256.00 1866.90 147.60 64.22
45.00 411.72 50.10 10.06 98.00 777.24 86.70 30.39 151.00 1142.76 111.80 44.33 204.00 1508.28 131.40 55.22 257.00 1873.79 147.90 64.39
46.00 418.62 51.00 10.56 99.00 784.14 87.20 30.67 152.00 1149.66 112.20 44.56 205.00 1515.17 131.80 55.44 258.00 1880.69 148.20 64.56
47.00 425.52 51.90 11.06 100.00 791.03 87.80 31.00 153.00 1156.55 112.60 44.78 206.00 1522.07 132.10 55.61 259.00 1887.59 148.50 64.72
48.00 432.41 52.70 11.50 101.00 797.93 88.30 31.28 154.00 1163.45 113.00 45.00 207.00 1528.97 132.40 55.78 260.00 1894.48 148.70 64.83
49.00 439.31 53.60 12.00 102.00 804.83 88.80 31.56 155.00 1170.34 113.40 45.22 208.00 1535.86 132.80 56.00 261.00 1901.38 149.00 65.00
50.00 446.21 54.40 12.44 103.00 811.72 89.40 31.89 156.00 1177.24 113.80 45.44 209.00 1542.76 133.10 56.17 262.00 1908.28 149.30 65.17
51.00 453.10 55.30 12.94 104.00 818.62 89.90 32.17 157.00 1184.14 114.20 45.67 210.00 1549.66 133.40 56.33 263.00 1915.17 149.60 65.33
52.00 460.00 56.10 13.39 105.00 825.52 90.40 32.44 158.00 1191.03 114.60 45.89 211.00 1556.55 133.80 56.56 264.00 1922.07 149.90 65.50
NOTE : PRESSURE AND TEMPERATURE ARE STATED IN PSIA(KPA) AND °F(°C) RESPECTIVELY.

- 39 -
5.0 MAINTENANCE
Head gaskets need not be renewed after each the cooler feed line until the condenser drain sight
head disassembly operation. Gaskets should and glass clears. Sight glass should be clear at all
must be renewed if they are physically disfigured operating conditions. When operating at full load,
or otherwise deteriorated. New gaskets are the cooler tube bundle (visible through sight glass
available from the factory. INSPECT on cooler shell) should be immersed. At light load,
CAREFULLY. tubes may be visible. To add refrigerant, connect
a refrigerant vessel to the liquid line charging
valve under the cooler. Purge the air from the
5.5 ELECTRICAL tube. With the unit running, open the refrigerant
MALFUNCTION vessel liquid connection slightly. If the refrigerant
vessel is warmer than the cooler, refrigerant will
The unit has four devices designed to protect the
flow from the vessel into the unit. The need for
compressor motor from electrical malfunctions:
additional refrigerant is indication of refrigerant
computer current limiting function, motor overload
leakage. In the interest of environmental
relay, phase control relay, and circuit breaker.
protection as well as operating cost, the leak
If the phase control relay trips, it is a sign of should be found and corrected.
trouble in incoming power. If it trips again after
resetting, call your electric utility to investigate the 5.6.2 OIL CHARGE
problem. If the circuit breaker or motor overload
The proper oil charge is in the unit as supplied
relay trips, this is a sign of possible motor trouble.
from the factory. The compressor should show oil
DO NOT reset and try to run compressor again.
return at all times. If for some reason, the
Call authorized service representative to check for
compressor runs low on oil, a low oil level switch
motor trouble. Resetting these safety devices and
in the compressor will shut it down before any
repeated starting could turn a minor motor
damage is done. In the event of a low oil
problem into a costly major motor burnout.
shutdown, call a D/B authorized service agent to
correct the problem. DO NOT ADD OIL TO THE
SYSTEM.
5.6 CHARGING
NOTE: Only DB 18 oil may be used in this
5.6.1 REFRIGERANT CHARGE package. Use of other oil is not
The unit is given a complete charge of refrigerant approved by Dunham-Bush, and will
at the factory. The refrigerant charge for the unit result in poor performance of the
is stated on the serial number sticker attached to package. It is recommended to
the unit. change oil annually to prolong the
compressor life-time.
If the unit must be charged on the jobsite, it
should be done by a qualified refrigeration
mechanic.
In order to check proper refrigerant charge, check
liquid feed line sight glass (refer to Figure 3.5,)
during unit operation. If bubbles are visible in
sight glass, unit is undercharged. Refrigerant
should be added through the charging valve on

- 40 -
5.0 MAINTENANCE
5.7 TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
1. Unit will not a.) Power off. a.) Check main disconnect switch and main line fuses.
start. b.) No control power. b.) Check control transformer fusing.
c.) Compressor circuit breakers c.) Close circuit breakers. If trip, check compressor.
open.
d.) Phase control relay open. d.) Check for power supply problems (low voltage, phase
imbalance). When corrected, press reset button.
e.) Flow Switch open. e.) Start pumps, check flow switch.
f.) Compressor switch open. f.) Turn switch on. Check alarm status. Correct problem.
g.) Microcomputer shutdown not g.) Press reset button.
reset.
2. Compressor a.) Low voltage. a.) Check at main entrance and at unit. Consult power company if
hums but voltage is low and increase wire size to the unit if voltage is
does not normal at main and low at unit. Voltage must be within 10% of
start. motor nameplate rating.
b.) No power on one phase of 3 b.) Check fuses and wiring.
phase unit.
c.) Faulty starter or contactor. c.) Check the contacts and time delay on part wind start.
3. Compressor a.) Cooling not required. a.) Apply load.

will not start b.) Computer's time delay b.) Wait 15 minutes max.
when reset active.
button is c.) Phase control relay open. c.) See 1.( d.) above.
pushed. d.) Flow switch open. d.) See 1.( e.) above.
e.) Compressor switch open. e.) See 1.( f.) above.
Check light: f.) Burned out signal light. f.) Check signal light bulbs.
None g.) Wiring problem g.) Check wiring against drawing.
4. Compressor a.) Compressor drawing high a.) Check motor megohms. Reset overloads; run compressor an
overload. amps. check amps. Call D/B serviceman.
5. Low suction a.) Inadequate feed to cooler. a.) Check to see that liquid line ball valve is open.
pressure b.) Inadequate refrigerant b.) See information on charging in Section 5.6.
charge.
c.) Fouling of waterside of c.) At high load, check cooler approach (See Section 5.4). If
cooler. approach is more than 2°F [1.1°C] above clean valve, fouling
is probably the trouble. Clean tube.
d.) Inadequate chilled water d.) Measure pressure drop across vessel and determine flow rate
flow. from Figure 2.4. If flow rate is low, check chilled water pump,
valves and strainers.
e.) Too much oil in system. e.) If all oil level sight glasses are full at all times, remove oil until
oil level shows at top of glass on a compressor.
6. High a.) Inadequate air flow across a.) Check condenser flow rate, either with condenser pressure
discharge condenser drop curve or with pump curve.
pressure. b.) Fouling of waterside of b.) At high load, check difference between saturated refrigerant
condenser. temp. and leaving water temp. If 2°F [1.1°C] or more above
start-up conditions, remove heads and clean tubes.
7. Oil low in a.) Low oil level in compressor. a.) Low oil level in compressor sight glass is acceptable.
sump.
8. Low oil a.) Low oil in compressor. a.) See Section 5.6.2.
shutdown.
9. Freeze a.) Operating setpoint too low. a.) Check leaving water setpoint on microcomputer.
warning. b.) Load changing too rapidly. b.) Load on package must drop at reasonable rate for automatic
control to work properly.
10. Improper a.) Ramp rate incorrect. a.) See Section 4.4.6.6.
capacity
control.

- 41 -
5.0 MAINTENANCE
5.8 SAMPLE LOG SHEET SHEET NO. ............................
DUNHAM-BUSH ROTARY SCREW COMPRESSOR PACKAGED CHILLER

NAMEPLATE DATA:
UNIT MODEL NO.: ...................................... UNIT NO.: ............................... VOLTS: ..................... Hz.....................
UNIT SERIAL NO.: ....................................................................................................................................................
JOB NAME: .......................................................................... LOCATION:....................................................................
START DATE: ...........................................................................................................................................................
DATE
TIME
ELAPSED TIME METERS
COMPRESSORS OPERATING
EVAPORATOR REFRIGERANT
PRESSURE
CONDENSER REFRIGERANT
PRESSURE
1.
DISCHARGE TEMPERATURE 2.
3.
CONDENSER REFRIGERANT DRAIN

TEMPERATURE
CONDENSER WATER TEMPERATURE-

IN
CONDENSER WATER TEMPERATURE-

OUT
COOLER WATER TEMPERATURE-IN
COOLER WATER TEMPERATURE-OUT
COOLER WATER PRESSURE DROP

FT.WG.[kPa]
COOLER WATER FLOW GPM [m³/hr]
CONDENSER WATER PRESSURE

DROP FT.WG.[kPa]
CONDENSER WATER FLOW

GPM [m³/hr]
ACTUAL VOLTAGE (NOT NOMINAL)
COMPRESSOR AMPS 2
TONS = GPME X ΔTE

24
NOTE: COMPRESSOR ARE NUMBERED FROM LEFT TO RIGHT AS YOU FACE CONTROL / STARTER PANEL. 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.

- 42 -
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

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DESCRIPTION PAGE NO DESCRIPTION PAGE NO

SCHEMATIC DIAGRAM, GRAPH AND TABLE

Figure 1.2 Rigging Diagram ........................................................................................................................................................................ 5

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

To assure satisfactory operation and to avoid damage to the unit,

Dunham-Bush packaged chiller has been manufactured under a

Water Cooled Horizontal R134a

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

1.1 RECEIVING AND 1.4 APPLICATION

1.4.2 CHILLED WATER FLOW

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

FIGURE 1.2 RIGGING DIAGRAM

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

HXWC 65-6NR, 75-6NR, 95-6NR, 110-6NR, 130-6NR

3.) HXWC 150-6NR, 170-6NR, 185-6NR, 200-6NR

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

heating, the evaporator must incorporate have a differential of at least

manual or automatic shutoff valves, but

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

2.1 FOUNDATION switch set to trip at approximately 50% of the

TABLE 2.1 FLOOR LOADING DIAGRAM

Point Load Data- Lbs

65 -6NR 1045 1248 1247 1641 5181 4505

75-6NR 1210 1288 1347 1850 5696 4953

95-6NR 1420 1488 1572 2164 6644 5777

110-6NR 1480 1680 1728 2271 7159 6225

130-6NR 1839 1932 2043 2670 8484 7377

150 -6NR 1705 2158 2977 1792 8633 7507

170-6NR 2150 2834 3197 1980 10162 8837

185-6NR 2181 2882 3291 2033 10387 9032

200-6NR 2404 3233 3331 2062 11029 9590

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

FIGURE 2.4 PRESSURE DROPS

WATER FLOW - GPM

WATER FLOW RATE- GPM

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

2.3 WATER PIPING - Connections to unit should match the unit

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

3.1 SYSTEM WATER FLOW 3.3 SEASONAL START-UP

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

3.5 REFRIGERATION CYCLE Oil is also returned to the compressor after it is

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

FIGURE 3.5 SCHEMATIC PIPING DIAGRAM

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

FIGURE 3.7 CONTINUOUS CAPACITY CONTROL SYSTEMS

3.8.2 IN OPERATION 3.8.3 DURING MAINTENANCE

HXWC Series ♦ R134a ♦ 60Hz ♦ IOM Manual

4.1 ELECTRICAL DATA

65-6NR 460V-3PH-60Hz 76 125 61(1) 165(1) 500(1)

75-6NR 460V-3PH-60Hz 93 150 74(1) 206(1) 625(1)

95-6NR 460V-3PH-60Hz 120 200 96(1) 241(1) 730(1)

110-6NR 460V-3PH-60Hz 134 225 107(1) 279(1) 845(1)

130-6NR 460V-3PH-60Hz 159 250 127(1) 302(1) 915(1)

150-6NR 460V-3PH-60Hz 173 300 138(1) 462(1) 1400(1)

170-6NR 460V-3PH-60Hz 201 350 161(1) 462(1) 1400(1)