Installation, Operation & Maintenance Manual

®
Form No: MM0422A
Products That Perform . . .By People Who Care
INSTALLATION, ROTARY
OPERATION & SCREW
MAINTENANCE
WATER
MANUAL
CHILLERS
MODEL:
WCFX Series R134a
50/60 Hz
TABLE OF CONTENTS
DESCRIPTION PAGE NO DESCRIPTION PAGE NO
1.0 GENERAL INFORMATION 4.4.5 Technician Key and Menu ........................................... 48
1.1 RECEIVING AND INSPECTION.............................................. 4 4.4.5.1 Technician status key .................................. 48
4.4.5.2 Technician status key- main menu.............. 48
1.2 RIGGING AND MOVING .......................................................... 4 4.4.5.3 Compressor FLA calibration....................... 49
1.3 DIMENSIONAL DATA. .............................................................. 4 4.4.5.4 To perform sensor calibration ..................... 49
1.4 APPLICATION PRECAUTIONS. ............................................. 4 4.4.5.5 Manual control ............................................ 49
1.4.1 Water Connections .............................................................. 4 4.4.5.6 Compressor control ..................................... 50
1.4.2 Chilled Water Flow ............................................................. 4 4.4.6 Control Functions......................................................... 51
1.4.3 Water Cooled Condenser .................................................... 5 4.4.6.1 Chilled water pump interlock and flow
1.4.4 Water Treatment.................................................................. 5 switch .......................................................... 51
4.4.6.2 Customer control interlock.......................... 51
2.0 INSTALLATION 4.4.6.3 Anti-recycle timer ....................................... 51
4.4.6.4 On Delay Timer........................................... 51
2.1 FOUNDATION ........................................................................... 10 4.4.6.5 Load control ................................................ 51
2.2 VIBRATION ISOLATION........................................................ 10 4.4.6.6 Ramp control ............................................... 51
2.3 UNMOUNTED ACCESSORIES............................................... 10 4.4.6.7 Staging control ............................................ 52
2.4 WATER PIPING CONNECTIONS.......................................... 10 4.4.6.8 Modmotor setback control .......................... 52
2.5 ELECTRICAL WIRING ........................................................... 10 4.4.6.9 Evaporator pressure control ........................ 52
4.4.6.10 Sump Heater Control................................... 52
2.6 CONTROLS ................................................................................ 28 4.4.6.11 Low pressure cut-off ................................... 53
2.6.1 Connections....................................................................... 28 4.4.6.12 Evaporator Freeze Shutoff .......................... 53
2.6.2 Settings.............................................................................. 28 4.4.6.13 High pressure cut-off................................... 53
2.7 REQUEST FOR START-UP REPRESENTATIVE ............... 28 4.4.6.14 Optical oil level sensor................................ 53
4.4.6.15 High oil temperature thermostat ................. 53
3.0 OPERATION 4.4.6.16 Overload protector....................................... 53
4.4.6.17 Phase control relay ...................................... 53
3.1 SYSTEM WATER FLOW RATE............................................. 29
4.4.6.18 Sensor alarm ................................................ 54
3.2 SEASONAL SHUT-DOWN PROCEDURE ............................ 29 4.4.6.19 No-stop alarm.............................................. 54
3.3 SEASONAL START-UP PROCEDURE.................................. 29 4.4.6.20 Low differential pressure alarm .................. 54
3.4 SAFETY RELIEF VALVES...................................................... 29 4.5 Calibration Of Screw Compressor Capacity Amps At Full
3.5 REFRIGERATION CYCLE ..................................................... 29 Load & Minimum Load Percentage ......................................... 54
3.6 OIL MANAGEMENT SYSTEMS ............................................ 30 4.6 Master/ Slave Control Sequence................................................ 54
4.6.1 Sensor Principle of Operation VIA DBLAN
3.7 HYDRAULIC CAPACITY CONTROL SYSTEM................. 30
Communication Bus..................................................... 55
3.8 FREEZE PROTECTION........................................................... 34 4.6.2 Sequence of Operation ................................................. 56
3.8.1 Standby At Low Ambient Temperatures .................... 34
4.7 Vision 2020i Local Area Network (DBLAN)............................ 56
3.8.2 In Operation................................................................. 34
3.8.3 During Maintenance .................................................... 34 4.8 Network Connection Diagram ................................................... 57
4.9 Hardware Setting ........................................................................ 57
4.9.1 Addressing the Vision 2020i Controller ...................... 57
4.0 ELECTRICAL
4.9.2 Addressing the Vision 2020i Terminal ........................ 58
4.1 ELECTRICAL DATA ................................................................ 35 4.9.3 Vision 2020i Controller LED Status............................ 59
4.2 WIRING DIAGRAM.................................................................. 35
4.3 TYPICAL OPERATION ........................................................... 35 5.0 MAINTENANCE
4.4 Vision 2020i Controller and Terminal ...................................... 45 5.1 GENERAL ................................................................................... 60
4.4.1 Operator Keypad............................................................. 45
4.4.1.1 The fifteen polycarbonate buttons ................... 45 5.2 PERIODIC INSPECTION......................................................... 60
4.4.2 Status Reading ................................................................ 46 5.3 MONTHLY INSPECTION........................................................ 60
4.4.2.1 Input status key ................................................ 46 5.4 WATER SIDE CLEANING OF VESSELS ............................. 60
4.4.2.2 Output status key.............................................. 46 5.5 ELECTRICAL MALFUNCTION ............................................ 61
4.4.2.3 Compressor status key ..................................... 46
5.6 CHARGING. ............................................................................... 61
4.4.2.4 Setpoint key...................................................... 46
5.6.1 Refrigerant Charge ............................................................ 61
4.4.2.5 Clock key.......................................................... 47
5.6.2 Oil Charge ......................................................................... 61
4.4.2.6 Alarm history key............................................. 47
4.4.3 Authorization .................................................................. 48 5.7 TROUBLESHOOTING ............................................................. 63
4.4.3.1 Authorization key............................................. 48 5.8 SAMPLE LOG SHEET.............................................................. 64
4.4.4 Advanced user key and menu......................................... 48
4.4.4.1 User key............................................................ 48
SCHEMATIC DIAGRAM, GRAPH AND TABLE

Figure 1.2 Rigging Diagram ...................................................... 5 Figure 4.2 Typical Wiring Schematic........................................ 36
Figure 1.3 Dimensional Data..................................................... 7 Figure 4.3.1 Vision 2020i Keypad................................................. 48
Table 2.1 Floor Loading Diagram........................................... 11
Table 4.4.6.6 Ramp Rates For Several Setpoints (In Minutes).... 51
Figure 2.4 Pressure Drop ........................................................... 12
Table 4.9.3 LED Status ............................................................... 59
Figure 3.5 Piping Schematic...................................................... 31 Table 5.4 R134a Pressure/Temperature Properties................ 62
Figure 3.7 Continuous Capacity Control System ..................... 34
-2-
INTRODUCTION
This equipment is a factory built and tested packaged chiller designed for the
purpose of cooling water or other non-corrosive liquid. The liquid to be cooled is
circulated through the tubes of a evaporator where the temperature is reduced to
the desired level. The heat absorbed by the refrigerant in the evaporator is rejected
via the condenser where it raises the temperature of another liquid stream (usually
water) being circulated through the tubes. This heat is usually rejected by a cooling
tower or closed circuit evaporator.
To assure satisfactory operation and to avoid damage to the unit, the installation
should be made by a qualified refrigeration mechanic. The reader of this manual
and those who install, operate and maintain this equipment should have 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 tested for performance at the factory at specified field
operating conditions as a final verification of reliability. If it is installed, operated
and maintained with care and attention, it will give many years of satisfactory
service.
NOMENCLATURE
WC F X 18 AR D2R B1R NN B
Water-Cooled Chiller Generation
Heat Recovery
Flooded Evaporator
Condenser Code
X = Screw Compressor
Evaporator Code
Compressor Code Electrical Code

(Nominal Tons/10) AK 200/3/60
Single - 10,12,15,18 AN 230/3/60
Dual - 20, 22, 24, 27, 30, AU 400/3/50
33, 36 AR 460/3/60
Triple - 39, 42, 45, 48, 51, AS 575/3/60
54 CS 400/3/60
-3-
1.0 GENERAL INFORMATION
1.1 RECEIVING AND model WCFX chillers is copper tubes
with steel tube sheets and liquid heads.
INSPECTION
These materials are generally suitable for
The unit should be inspected immediately, in the use with clean fresh water found in most
presence of the carrier's representative, for any localities. However, minerals and other
evidence of damage during shipping. Any damage contaminants found in some water
should be noted on the carrier's delivery receipt systems may promote aggressive attack
before it is signed. A damage claim should then on the tubes or tube sheets, resulting in
be filed by the purchaser against the delivering failure with serious consequences for the
carrier as all shipments are made at the entire package chiller.
purchaser's risk. The receiving inspection
instructions, sent with the installation instructions, Since Dunham-Bush has no control over
should also be filled at this time and forwarded to the condition of the water used in these
the Dunham-Bush Industries, M & E Service machines, we can take no responsibility
Department. for failure of tubes or tube sheets due to
water corrosion or erosion. It is
recommended that the buyer obtain the
services of local water treatment
1.2 RIGGING AND MOVING specialists to prescribe water treatment.
Each unit has been carefully tested and inspected
at the factory where every precaution was taken to 1.4.2 Chilled Water Flow
ensure that it reaches its destination in perfect The Dunham-Bush WCFX Packaged
condition. It is very important that the installers, Water Chiller is designed for a constant
movers, and riggers use the same care in handling chilled water flow rate, even when the
the unit. The unit is designed to be lifted from the cooling load is varying. The machine
(4) lifting holes in the tube sheets. It can also be will generally perform satisfactorily with
moved on skids placed under the tube sheets. For steady flow rates deviating from design
proper rigging, see Figure 1.2. by as much as +10% / -50%. However,
It is important to protect the unit from damage varying water flow rates can cause
during storage, rigging and installation. Particular control instability, which will result in
care should be given to avoid damage to controls undesirable system effects, particularly
and piping. Do not allow the unit to be used as a poor control of leaving chilled water
ladder or scaffold! temperature. If two-way valves are used
to control flow through cooling coils,
some means such as an automatic
1.3 DIMENSIONAL DATA modulating valve should be provided in
Dimensional outline drawings of the packages are the system to maintain steady flow
shown in Figures 1.3. Note especially the space through the evaporator.
and clearance requirements necessary for If chilled water flow rate and/ or load
servicing the unit. vary, the variation must be controlled so
that return water temperature does not
vary at a rate exceeding 2°F [1.1°C] per
1.4 APPLICATION minute.
PRECAUTIONS If the chilled water system is arranged
for the dual purpose of cooling and
The following instructions are intended to help heating, the evaporator must incorporate
assure proper and successful application of your valves to prevent the flow of hot water
water chilling machines. through it. This can be done with either
manual or automatic shutoff valves, but
1.4.1 Water Conditions water temperature entering the
Standard construction of the evaporator evaporator must never exceed 90°F
and condenser used in Dunham-Bush [32°C].
-4-
1.4.3 Water Cooled Condensers 1.4.3.2 Tower fan staging in response
The water-cooled condenser is also to a thermostat in the tower
designed for constant water flow rate, sump. Fan thermostat should
and should be supplied with the design have a differential of at least
GPM [m³/hr] ±10%. The condenser must 20°F [11.1°C] to avoid short
be protected from rapid changes in cycling.
temperature as well. The maximum
allowable rate of change in condenser 1.4.3.3 A modulating three-way valve
entering water is 1°F [0.6°C] per minute. which bypasses the cooling
Fluctuating flow rate or temperature will tower to blend warm leaving
cause unstable control of the machine, condenser water with cold
resulting in poor control of leaving tower water.
chilled water temperature. If a cooling
tower is used to reject heat from the 1.4.4 Condensing Water
condensing water loop, it must be Treatment
controlled to provide an entering
Condensing water tends to leave silt,
condensing water temperature which
algae and mineral deposits in the
does not change more rapidly than 1°F
condenser tubes. This fouling gradually
[0.6°C] per minute and does not go
decreases unit efficiency. For this reason,
below 60°F [15.6°C]. One or more of the
a program of water treatment should be
following methods may be used to
employed. Also, at regular intervals
control the tower:
depending on water quality, the unit
1.4.3.1 A modulating three-way valve should be shut down, condenser heads
which bypasses tower sprays removed and tubes cleaned. See Section
at low load and low ambient 5.4.
temperature.
FIGURE 1.2 RIGGING DIAGRAM

Rigging should be done in a manner so that no strain is placed on unit components other than at cable
connection points
WCFX 10, 12, 15, 18
42" [1067mm]
LIFT LIFT
SPREADERS
126"
IF EVAPORATOR [3200mm]
IS INSULATED
FLAP MUST
BE RAISED
TO EXPOSE
LIFTING HOLE
Note: Project unit from cables.
-5-
WCFX 20, 22, 24, 27, 30, 33, 36
52" [1321mm]
LIFT LIFT
SPREADERS
CONTROL BOX
IF EVAPORATOR 126"
IS INSULATED [3200mm]
FLAP MUST
BE RAISED
TO EXPOSE
LIFTING HOLE
WCFX 39, 42, 45, 48, 51, 54
61" [1549mm]
LIFT LIFT
SPREADERS
IF EVAPORATOR 126"
IS INSULATED [3200mm]
FLAP MUST
BE RAISED
TO EXPOSE
LIFTING HOLE
Note: Project unit from cables.
-6-
FIGURE 1.3 DIMENSIONAL DATA
WCFX 10, 12, 15, 18
TWO PASS RIGHT HAND ARRANGEMENT SHOWN
-7-
WCFX 20, 22, 24, 27, 30, 33, 36
TWO PASS RIGHT HAND ARRANGEMENT SHOWN
-8-
WCFX 39, 42, 45, 48, 51, 54
-9-
2.0 INSTALLATION
2.1 FOUNDATION 2.4 WATER PIPING
A flat, level concrete foundation or floor capable CONNECTIONS
of supporting the weight of the unit must be Refer to Figures 1.3. for water piping connection
provided. Weights are given in Table 2.1. The locations. Note that the condenser water inlet
unit must be leveled to within 1/16" per foot must be on the bottom. If necessary, evaporator or
[5.2mm per meter] for proper operation. condenser headers can be reversed, left to right or
vice versa. Leaving chilled water temp sensor
2.2 VIBRATION ISOLATION must be located in leaving chilled water stream.
After the unit has been leveled and isolators (if
In case of structure-borne vibration may be of any) has been installed and adjusted, evaporator
concern, it is recommended that the unit be and condenser water piping are connected. Piping
mounted on vibration isolators. Rubber-in-shear must be properly supported to avoid stress on unit
isolators or spring isolators are available for this water connections. Install air vent valves in all
unit as optional equipment. If spring isolators are high connections on evaporator and condenser
installed, it is also necessary to provide isolation headers. Drain valves shall be installed in similar
in condenser water and chilled water pipes by low points to facilitate gravity draining of the
means of flexible connectors and in main power system. It is important that water systems should
supply conduit through use of flexible conduit. be cleaned before start-up to avoid collecting
Isolation of piping and electrical conduit is debris in evaporator and condenser. The best
desirable in any event, to avoid noise transmission. solution is to install wye strainers in both systems
upstream of the unit. After the systems are filled
2.3 UNMOUNTED with water, trapped air shall be bled from the
various vent valves. Check for proper flow rates
ACCESSORIES by measuring water pressure drop across heat
A chiller flow switch, which is shipped in a exchangers and reading flow rates from charts,
separate container accompanying the unit, must Figure 2.4. Compare measured flow rates with
be installed in the external chilled water outlet values specified on purchase order. Check in
piping. It must be located in a horizontal section Table 2.1. to see that evaporator and condenser
on the pipe where there is at least five (5) pipe flow rates fall between min. and max. limits.
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 2.5 ELECTRICAL WIRING
pipe in which the paddle is installed, and the In connecting power wiring to the unit, the
switch set to trip at approximately 50% of the following precautions should be taken:
design flow. Consult the wiring diagram - All field wiring shall be in accordance with the
accompanying the unit for the electrical National Electric Code and must comply with
connections to interlock the flow switch with the state and local codes.
control panel. - Check unit wiring for damage and all terminal
connections for tightness. Unit terminal blocks
are connected with copper conductors only,
FIGURE 2.3 FLOW SWITCH and are sized according to ampacity listed on
unit data plate.
- Connections to unit should match the unit
name plate in volts, phase and Hertz. Voltage
must not vary beyond ±10% of name plate
value and voltage imbalance between phases
must not exceed 2% at any time during
operation of the unit.
- Phase sequence to connections L1, L2, L3
shall be in that order. Check with Amprobe
phase sequence adapter PSA-1 or equivalent.
- 10 -
2.0 INSTALLATION
TABLE 2.1 FLOOR LOADING DIAGRAM
WCFX 10, 12, 15 & 18
C B
D CONTROL PANEL A
WCFX 20, 22, 24, 27, 30, 33, 36, 39, 42, 45, 48, 51 & 54
C B
CONTROL PANEL
D A
Point Loading, Lbs [kg]

50Hz 60Hz
UNIT MODEL A B C D UNIT MODEL A B C D
WCFX WCFX
10AUB1RA1R 827 [1823] 328 [723] 1468 [3236] 899 [1982] 10ARB1RA1R 834 [1839] 334 [736] 1477 [3256] 905 [1995]
12AUC1RA2R 966 [2130] 378 [833] 1710 [3770] 1058 [2332] 12ARC1RA2R 978 [2156] 384 [847] 1721 [3794] 1055 [2326]
15AUD1RA3R 1139 [2511] 458 [1010] 2017 [4447] 1234 [2721] 15ARD1RA3R 1147 [2529] 454 [1001] 2037 [4491] 1244 [2743]
18AUD2RB1R 1186 [2615] 469 [1034] 2108 [4647] 1287 [2837] 18ARD2RB1R 1197 [2639] 484 [1067] 2120 [4674] 1300 [2866]
20AUJ1RH1R 1243 [2740] 1865 [4112] 2249 [4958] 1257 [2771] 20ARJ1RH1R 1291 [2846] 1930 [4255] 2150 [4740] 1290 [2844]
22AUK1RH2R 1353 [2983] 2030 [4475] 2447 [5395] 1369 [3018] 22ARK1RH2R 1383 [3049] 2102 [4634] 2349 [5179] 1416 [3122]
24AUK2RH3R 1376 [3034] 2064 [4550] 2488 [5485] 1390 [3064] 24ARK2RH3R 1430 [3153] 2130 [4696] 2381 [5249] 1429 [3150]
27AUL1RH4R 1547 [3411] 2322 [5119] 2799 [6171] 1559 [3437] 27ARL1RH4R 1600 [3527] 2404 [5300] 2686 [5922] 1600 [3527]
30AUL2RJ1R 1887 [4160] 2839 [6259] 3415 [7529] 1897 [4182] 30ARL2RJ1R 1980 [4365] 2930 [6460] 3270 [7209] 1925 [4244]
33AUL3RJ1R 1932 [4259] 2883 [6356] 3476 [7663] 1934 [4264] 33ARL3RJ1R 1997 [4403] 2981 [6572] 3320 [7319] 1997 [4403]
36AUM1RJ3R 2019 [4451] 3014 [6645] 3634 [8012] 2020 [4453] 36ARM1RJ3R 2090 [4608] 3144 [6931] 3446 [7597] 2088 [4603]
39AUT2RP1R 2289 [5046] 3199 [7053] 3681 [8115] 2337 [5152] 39ART2RP1R 2319 [5113] 3247 [7158] 3711 [8181] 2319 [5112]
42AUT3RQ1R 2585 [5699] 3593 [7921] 4133 [9112] 2578 [5683] 42ART3RQ1R 2596 [5723] 3635 [8014] 4154 [9158] 2596 [5723]
45AUU1RQ2R 2788 [6146] 3892 [8580] 4480 [9877] 2838 [6257] 45ARU1RQ2R 2820 [6217] 3948 [8704] 4512 [9947] 2820 [6217]
48AUV1RR1R 3031 [6682] 4255 [9381] 4892 [10785] 3048 [6720] 48ARV1RR1R 3058 [6742] 4281 [9438] 4893 [10787] 3058 [6742]
51AUV2RR2R 3145 [6933] 4363 [9619] 5009 [11043] 3137 [6916] 51ARV2RR2R 3154 [6953] 4414 [9731] 5044 [11120] 3153 [6951]
54AUV3RR2R 3203 [7061] 4484 [9885] 5125 [11299] 3204 [7064] 54ARV3RR2R 3222 [7103] 4509 [9941] 5154 [11363] 3221 [7101]
Notes: 1.) Refer to dimensional drawings for location of mounting points.

2.) Unit must be lowered onto mounting springs in a level fashion or spring damage may occur.
- 11 -
2.0 INSTALLATION
FIGURE 2.4 PRESSURE DROPS
WCFX 10, 12, 15, 18 – METRIC UNITS
1.) Evaporator 1 & 2 Pass
100
2 PASS
B1R
C1R
PRESSURE DROP - FT.WG. .
D1R
D2R
10
E1R
B1R
1 C1R
D1R
1 PASS D2R
E1R
0.1
10 100 1000 10000
WATER FLOW RATE - GPM
2.) Evaporator 3 Pass

100
B1R
C1R
D1R
D2R
E1R
10
1
10 100 1000
- 12 -
2.0 INSTALLATION
WCFX 10, 12, 15, 18 – METRIC UNITS
3.) Condenser 1 & 2 Pass
100
2 PASS
A1R
A2R
A3R
10 B1R
C1R
A1R
A2R
1
A3R
B1R
1 PASS
C1R
0.1
10 100 1000 10000
4.) Condenser 3 Pass

100
A1R
A2R
A3R
B1R
C1R
10
1
10 100 1000
- 13 -
2.0 INSTALLATION
WCFX 20, 22, 24, 27, 30, 33, 36 – METRIC UNITS
100
J1R
K1R
K2R
L1R
L2R
10
L3R
M1R
M2R
M3R
1
100 1000 10000

100
J1R
K1R
.
K2R
PRESSURE DROP - FT.WG.
L1R
L2R
10
L3R
M1R
M2R
M3R
1
100 1000 10000
- 14 -
2.0 INSTALLATION
100
J1R
K1R
.
K2R
L1R
L2R
10
L3R
M1R
M2R
M3R
1
10 100 1000

100
H1R
.
H2R
H3R
H4R
J1R
10
J2R
J3R
K1R
K2R
1
100 1000 10000
- 15 -
2.0 INSTALLATION
100
H1R
H2R
.
H3R
H4R
J1R
10
J2R
J3R
K1R
K2R
1
100 1000 10000

100
H1R
H2R
H3R
.
H4R
J1R
10
J2R
J3R
K1R
K2R
1
10 100 1000
- 16 -
2.0 INSTALLATION
WCFX 39, 42, 45, 48, 51, 54 – METRIC UNITS
100
.
T2R
T3R
U1R
V1R
V2R
10
V3R
W1R
W2R
Y1R
1
100 1000 10000

100
T2R
T3R
U1R
V1R
V2R
10
V3R
W1R
W2R
Y1R
1
100 1000 10000
- 17 -
2.0 INSTALLATION
100
T2R
T3R
U1R
V1R
V2R
10 V3R
W1R
W2R
Y1R
1
100 1000 10000

100
P1R
Q1R
.
Q2R
R1R
R2R
10
R3R
T1R
T2R
T3R
1
100 1000 10000
- 18 -
2.0 INSTALLATION
100
P1R
Q1R
Q2R
.
R1R
R2R
10
R3R
T1R
T2R
T3R
1
100 1000 10000

100
P1R
Q1R
Q2R
R1R
.
R2R
10
R3R
T1R
T2R
T3R
1
100 1000 10000
- 19 -
2.0 INSTALLATION
WCFX 10, 12, 15, 18 – S. I. UNITS
1.) Evaporator 1 & 2 Pass
100
B1R
C1R
D1R
D2R
.
E1R
PRESSURE DROP - kPa
10
B1R
C1R
D1R
2 PASS
D2R
E1R
1 PASS
1
10 100 1000
WATER FLOW RATE - m³/hr

1000
B1R
C1R
PRESSURE DROP - kPa .
D1R
100 D2R
E1R
10
1
1 10 100 1000
- 20 -
2.0 INSTALLATION
WCFX 10, 12, 15, 18 – S. I. UNITS
3.) Condenser 1 & 2 Pass
100
A1R
A2R
A3R
B1R
C1R
10
A1R
A2R
A3R
2 PASS
B1R
C1R
1 PASS
1
10 100 1000

1000
A1R
A2R
A3R
B1R
100 C1R
10
1
10 100 1000
- 21 -
2.0 INSTALLATION
WCFX 20, 22, 24, 27, 30, 33, 36 – S. I. UNITS
100
J1R
PRESSURE DROP- kPa .
K1R
K2R
L1R
L2R
10
L3R
M1R
M2R
M3R
1
10 100 1000

1000
.
J1R
PRESSURE DROP - kPa
100 K1R
K2R
L1R
L2R
10 L3R
M1R
M2R
M3R
1
10 100 1000
- 22 -
2.0 INSTALLATION
WCFX 20, 22, 24, 27, 30, 33, 36 – S. I. UNITS
1000
J1R
K1R
.
K2R
L1R
PRESSURE DROP - kPa
100
L2R
L3R
M1R
M2R
10
M3R
1
10 100 1000

100
H1R
H2R
H3R
.
H4R
PRESSURE DROP - kPa
J1R
10
J2R
J3R
K1R
K2R
1
10 100 1000
- 23 -
2.0 INSTALLATION
WCFX 20, 22, 24, 27, 30, 33, 36 – S. I. UNITS
1000
H1R
.
H2R
PRESSURE DROP - kPa
100
H3R
H4R
J1R
J2R
10
J3R
K1R
K2R
1
10 100 1000

1000
H1R
H2R
H3R
H4R
.
J1R
PRESSURE DROP - kPa
100
J2R
J3R
10 K1R
K2R
1
10 100 1000
- 24 -
2.0 INSTALLATION
WCFX 39, 42, 45, 48, 51, 54 – S. I. UNITS
100
T2R
T3R
U1R
.
V1R
PRESSURE DROP - kPa
V2R
10 V3R
W1R
W2R
Y1R
1
100 1000

1000
T2R
T3R
U1R
100
V1R
V2R
V3R
W1R
10 W2R
Y1R
1
10 100 1000
- 25 -
2.0 INSTALLATION
WCFX 39, 42, 45, 48, 51, 54 – S. I. UNITS
1000
T2R
T3R
U1R
100 V1R
V2R
V3R
W1R
W2R
10 Y1R
1
10 100 1000

100
P1R
Q1R
Q2R
.
R1R
PRESSURE DROP - kPa
R2R
10
R3R
T1R
T2R
T3R
1
100 1000
- 26 -
2.0 INSTALLATION
1000
P1R
.
Q1R
PRESSURE DROP - kPa
100 Q2R
R1R
R2R
R3R
T1R
10
T2R
T3R
1
10 100 1000

1000
P1R
Q1R
.
Q2R
R1R
PRESSURE DROP - kPa
100
R2R
R3R
T1R
10
T2R
T3R
1
10 100 1000
- 27 -
2.0 INSTALLATION
2.6 CONTROLS 2.7 REQUEST FOR START-
UP REPRESENTATIVE
2.6.1 Connections
After the installation has been completed and
Controls, which are to be field installed, checked, contact the M&E Service Department of
should be connected in accordance with Dunham-Bush Industries for an authorized start-
the appropriate wiring diagram up representative to perform the initial start-up of
accompanying the unit. The following the Dunham-Bush packaged chiller. The
connections should be made where purchaser must have competent service and
applicable: operating personnel in attendance to assist in the
work involved. They must also be trained in the
2.6.1.1 Connect a set of normally open
service and maintenance of this unit. (During the
auxiliary contacts from chilled
warranty period, the manufacturer is responsible
water pump contactor into unit
for parts only upon proof of defective
controls as shown on unit
workmanship or manufacture).
wiring diagram.
Subsequently a representative will be sent to the
2.6.1.2 Install a chilled water flow
customer. He will inspect the installation to
switch (paddle type
determine whether it meets Dunham-Bush
recommended) in straight
Industries requirements, perform the initial start-
length of chilled water piping to
up of the installation, determine whether it is in
avoid turbulence. Connect in
satisfactory operating condition, and instruct the
same electrical circuit as 2.5.1.1.
specified customer personnel in its operation and
2.6.1.3 For control of condensing water maintenance for the length of time specified in the
pumps, connect contacts purchase contract.
supplied in unit in series with
condensing water pump starter NOTE:
coil. Sump oil heaters should be energized for a
2.6.1.4 Connect an enable/disable minimum of 24 hours and the oil sump
contact into the unit controls as temperature must be at a minimum of 100°F
shown on the wiring diagram. [38°C] prior to arrival of start-up representative.
Closure of this contact enables This will ensure that the oil is warm enough to
the unit to operate. vaporize any dissolved refrigerant and that the oil
is within the normal operating temperature range.
Sump oil heaters are energized simply by turning
2.6.2 Settings on the control power switch.
All controls are factory set however
operating control settings are not always WARNING:
applicable under all operating conditions. The compressor(s) should be started initially
For recommended control settings, see ONLY under the direct supervision of an
wiring diagram accompanying unit. Authorized Dunham-Bush Industries Start-Up
Safety controls must be set in accordance Representative.
with factory recommendations.
- 28 -
3.0 OPERATION
3.1 SYSTEM WATER FLOW 3.3 SEASONAL START-UP
RATE PROCEDURE
The quantity of chilled water being circulated can When the unit is to be started up after being shut
be measured quite accurately (±5%) by down for a prolonged period:
determining the water pressure drop through the 3.3.1 Check unit for evidence of rust or
evaporator and reading flow rates from evaporator corrosion. Clean surfaces and repaint as
pressure drop curve, Figures 2.3. Connect reliable necessary. Repair insulation if necessary.
pressure gauges to valves installed in evaporator 3.3.2 Energize power supply to unit.
entering and leaving water vent connections and Compressor oil sump heater must be
read pressure difference with chilled water pump energized for at least 24 hours prior to
in operation. Condenser water flow rate can be compressor start-up. Clean waterside heat
measured in the same way. An alternate method transfer surface of condenser and
of determining flow rates is to measure pressure evaporator by removing headers and
difference from pump inlet to outlet, and read brushing tubes.
flow rates from the pump curve. 3.3.3 Check water circuits to see if cooling
tower is ready for operation, and both
circuits are filled with water. Start pumps
3.2 SEASONAL SHUT-DOWN and check for flow in both evaporator and
PROCEDURE condenser.
3.2.1 If the unit is to be shut down for a 3.3.4 Turn on control circuit power switches,
prolonged period (a month or more), the turn on compressor switch, and press reset
power supply to the unit may be de- on computer keyboard. Compressor should
energized to conserve energy. start after start-up clock times out and
3.2.2 The cooling tower may be drained to leaving water temperature should be
avoid freezing. If the unit is located in an automatically controlled. Check refrigerant
area where the ambient temperature charge and check for normal suction and
constantly remains above freezing, the discharge pressures.
condenser need not be drained. It is better 3.3.5 Have a trained service mechanic check the
to leave the condenser and evaporator function of all control setpoints. Check
filled with water during a shutdown signal lights for proper operation.
period. If the unit is located where 3.3.6 Take oil sample from each compressor and
ambient temperature will be below submit it for laboratory analysis.
freezing, drain all water thoroughly and
remove all vent and drain plugs from both 3.4 SAFETY RELIEF VALVES
headers of each vessel. Blow out tubes Each pressure vessel is protected by a safety relief
with compressed air. valve as required by ASME Code. Single
NOTE: Simply draining is not sufficient. compressor units also have a compressor relief
Stagnant water may cause serious valve. On some units, the condenser has a dual
corrosion. manifold. One valve in this manifold is active,
3.2.3 It is recommended that an oil sample is while the other is on stand-by. If the active valve
taken from each compressor and starts to leak, simply switch the manifold valve to
submitted for laboratory analysis. the opposite extreme, which will activate the
Dunham-Bush offers this service in its stand-by valve. Local codes may require that all
Oil Kare Program. This analysis should safety relief valves be piped to the outdoors.
be done at the beginning and end of each Never install a hand valve in a safety relief vent
operating season, or every six months if line.
the unit is used year round.
Important: Discontinue chilled water 3.5 REFRIGERATION CYCLE
pump operation when unit is Refer to Figure 3.5A for WCFX 10-18, Figure
not operational. 3.5B for WCFX 20-36 or 3.5C for WCFX 39-54,
- 29 -
3.0 OPERATION
for the piping schematics. Each vertical screw pump installed on the suction line. The
compressor discharges hot and high pressure gas jet pump is powered by high pressure
through a discharge service valve (or check valve gas from the compressor discharge line
in multiple compressor units) into the condenser, through hot gas feed valve. This forces
where it condenses by rejecting heat to water the oil rich mixture from the evaporator
inside the tubes. The liquid refrigerant drains to through oil return valve into the suction
the bottom of the condenser and exits via the line where it is carried into the
economizer feed line. compressor.
The refrigerant flows through the economizer The hot gas valve should be opened
feed ball valve, in which its pressure drops, and enough only to allow good oil return
thus it flashes. It then flows into the flash when the unit is fully unloaded. (1/8 to
economizer tank which is at an intermediate 1/2 turn). Excessive oil return will lower
pressure between condenser and evaporator. discharge superheat un-desirably. The oil
Liquid refrigerant is centrifugally separated from return valve should be left wide open.
the flash gas and the liquid drains to the bottom of In normal operation, no oil level will be
the tank, exits via the economizer drain line, and visible in the compressor sight glass.
passes through the economizer drain ball valve.
Both economizer ball valves are actuated by a 3.6.2 WCFX 20-54
Modutrol motor that adjusts flow to maintain an The compressors are oil lubricated and
appropriate refrigerant level in the evaporator, discharge a small amount of oil mist
which is determined by a liquid level float switch. along with refrigerant. This oil is carried
From the drain line, liquid refrigerant flows into into the evaporator. Oil rich refrigerant is
the flooded evaporator, where it boils, by returned from the evaporator through
absorbing heat from the water flowing inside two taps in the shell, a filter-drier and
evaporator tubes. Vapor from the boiling isolation valve, and into a manifold that
refrigerant flows up the suction pipes through a serves all compressors. At each
shut-off valve (optional), suction check valve and compressor, this oil rich liquid flows
suction filter (inside compressor) into the through a check valve, sight glass, and
compressor where it is compressed and starts the into a jet pump which feeds through an
cycle again. isolation valve then into the compressor
Vapor flowing from the top of flash economizer suction line.
will be injected into the compressor at the vapor Oil overflow feeds from the C4 port on
injection port, which feeds it into the compressor the compressor through an overflow
part way through the compression process. Check valve, sightglass, and check valve, and is
valve prevents backflow at shutdown in multi- shared between compressors by feeding
compressor units. All compressors operate in through the overflow feed solenoid
parallel on a common evaporator and condenser. valves into the operating compressors.
3.6 OIL MANAGEMENT 3.7 HYDRAULIC CAPACITY

SYSTEMS (See Fig. 3.5.) CONTROL SYSTEM
(See Fig. 3.7.)
3.6.1 WCFX 10-18
Each compressor has a hydraulic control system
The compressor is oil lubricated and
to position the capacity control slide valve, in
discharges a small amount of oil mist
order to regulate compressor capacity. It is
along with refrigerant. This oil is carried
composed of a normally closed solenoid valve, a
into the evaporator. Oil rich refrigerant is
normally open solenoid valve and internal
returned from the evaporator through a
pressure regulating valve.
tap in the shell, oil return valve, filter
drier, angle valve, sight glass and into jet
- 30 -
3.0 OPERATION
FIGURE 3.5 PIPING SCHEMATIC
1.) 1 COMPRESSOR - WCFX 10, 12, 15 & 18
- 31 -
3.0 OPERATION
2.) 2 COMPRESSORS - WCFX 20, 22, 24, 27, 30, 36
- 32 -
3.0 OPERATION
3.) 3 COMPRESSORS - WCFX 39, 42, 45, 48, 51 & 54
- 33 -
3.0 OPERATION
With valves A and B both energized (A open, B severe damage will result; e.g. split and leaking
closed) during normal compressor operation, high tubes and cracked and leaking headers. Since this
pressure oil is directed to the slide valve. The damage can be extremely costly and is not
pressure acting on the surface of the slide valve covered by warranty, it is important to be mindful
piston creates a force which is sufficient to of freeze prevention. Three cases deserve
overcome the opposing spring force and to move particular attention:
the valve in the direction of increasing capacity.
When the compressor is given a "hold" command, 3.8.1 Standby at Low Ambient
valve A is de-energized (closed) and slide valve Temperatures
movement is halted. The internal pressure If the unit is to stand idle at ambient
regulating valve allows oil to bleed from the slide temperatures below 32°F [0°C], the
valve chamber during the hold condition. If valve water should be drained from evaporator
B is then de-energized (open), the high pressure and condenser. A header should be
oil acting on the slide valve will be vented to removed from each vessel and the tubes
suction, and the pressure in the slide valve should be blown dry with compressed air.
chamber will be reduced. The slide valve spring Gravity draining the vessel through
will now move the piston back toward the drains in headers may not be sufficient.
minimum capacity position. If evaporator or condenser is served with
Under standard conditions, the compressor will a glycol solution, make sure the freeze
load in 60 seconds and unload in 55 seconds. temperature of the solution is lower than
the expected minimum ambient
FIGURE 3.7 HYDRAULIC CONTROL temperature.
SYSTEM
3.8.2 In Operation
SLIDE VALVE POSITION
Freezing of water in evaporator tubes is
UNLOADING LOADING HOLD
a possibility if chilled water flow stops
SOLENOID VALVE A CLOSED OPEN CLOSED
(NORMALLY CLOSED) (DE-ENERGIZED) (ENERGIZED) (DE-ENERGIZED) and if the low suction pressure cutout
SOLENOID VALVE B OPEN CLOSED CLOSED (normally set for 28 psig [1.9BAR], or
(NORMALLY OPEN) (DE-ENERGIZED) (ENERGIZED) (ENERGIZED)
32°F [0°C] saturation) and the low water
temperature cutout both fail. If the
chilled water flow switch and pump
interlock are properly applied (See
2.6.1.1 and 2.6.1.2) the unit has four
protective devices which must all fail in
order to freeze the evaporator in
operation. While this is unlikely, it is
important to see that all these devices are
functional and properly calibrated.
3.8.3 During Maintenance

In transferring refrigerant within the unit,
or removing refrigerant from the unit for
maintenance purposes, it is possible to
freeze evaporator or condenser tubes.
Remember that whenever the pressure in
a vessel is reduced below 28 psig
[1.9BAR], if water is not flowing, it is
possible to freeze the tubes. For this
3.8 FREEZE PREVENTION reason, it is a good precaution to have
If water (or brine) is allowed to freeze within the water flowing in both vessels whenever
tubes and headers of the evaporator or condenser, transferring refrigerant.
- 34 -
4.0 ELECTRICAL
4.1 ELECTRICAL DATA
UNIT MODEL NOM. VOLTS UNIT EACH COMPRESSOR
50 HZ 60 HZ 50 HZ 60 HZ MCA MFS RLA INR LRA
WCFX 10 AU AR 400 460 94 150 75 200 498

WCFX 12 AU AR 400 460 106 200 85 200 498
WCFX 15 AU AR 400 460 156 250 125 325 885
WCFX 18 AU AR 400 460 163 250 130 325 885
WCFX 20 AU AR 400 460 164 225 73 (2) 200 (2) 498 (2)
WCFX 22 AU AR 400 460 176 250 73 / 85 200 / 200 498 / 498
WCFX 24 AU AR 400 460 191 275 85 (2) 200 (2) 498 (2)
WCFX 27 AU AR 400 460 228 300 85 / 122 200 / 325 498 / 885
WCFX 30 AU AR 400 460 275 350 122 (2) 325 (2) 885 (2)
WCFX 33 AU AR 400 460 283 400 122 / 130 325 / 325 885 / 885
WCFX 36 AU AR 400 460 293 400 130 (2) 325 (2) 885 (2)
WCFX 39 AU AR 400 460 313 400 (2)85 / 122 (2)200 / 325 (2)498 / 885
WCFX 42 AU AR 400 460 350 425 85 / 122(2) 200 / 325(2) 498 / 885(2)
WCFX 45 AU AR 400 460 397 500 122 (3) 325 (3) 885 (3)
WCFX 48 AU AR 400 460 405 500 (2)122 / 130 (2)325 / 325 (2)885 / 885
WCFX 51 AU AR 400 460 413 525 122 / 130(2) 325 / 325(2) 885 / 885(2)
WCFX 54 AU AR 400 460 423 550 130 (3) 325 (3) 885 (3)
NOTE: MCA – MINIMUM CIRCUIT AMPACITY

MFS – MAXIMUM FUSE SIZE
RLA – RATED LOAD AMPS ARI COS
INR FIRST STEP INRUSH AMPS
LRA – LOCKED ROTOR AMPS
4.2 WIRING DIAGRAM - Reset pressed on microcomputer keypad

Figure 4.2 shows the typical wiring diagram for 1, - All safety conditions satisfied
2 & 3 compressors unit. It is best to use the - Leaving chilled water temperature 2°F [1.1°C]
wiring diagram mounted in the package control or more above setpoint
panel. A copy of that diagram is furnished with A compressor is started by first energizing 1M1
the unit owner’s manual. followed by 1M2 after 1 second if step start is
activated (See Section 4.5.4). Otherwise, both
contactors energize together. Anti-recycle time of
4.3 TYPICAL OPERATION 15 minutes is initiated within the computer at start.
In order to start a compressor; the following When the compressor starts, the micro-computer
conditions must be met: monitors amperage by means of 1CT, leaving
- Correct system voltage and phase sequence water temperature using TS, and condensing
such that phase control relay (PCR) is in normal pressure. These inputs are used to control the
state loading and staging of the compressor. The
- Chilled water pump running compressor's loading is controlled by pulsing
- Chilled water flow switch made signals to the load and unload solenoids.
- Compressor circuit breakers on To shut down the unit automatically, the customer
- Customer unit control contact closed control contacts must be opened. To shut down
- Control switch and compressor switches on the unit manually, simply shut off the compressor
- Power has been on the microcomputer for 15 switches. This will cause a no-run alarm that must
minutes be reset to restart the compressor.
- 35 -
4.0 ELECTRICAL
FIGURE 4.2 TYPICAL WIRING SCHEMATIC
A.) 1 COMPRESSOR
- 36 -
4.0 ELECTRICAL
- 37 -
4.0 ELECTRICAL
B.) 2 COMPRESSORS
- 38 -
4.0 ELECTRICAL
- 39 -
4.0 ELECTRICAL
- 40 -
4.0 ELECTRICAL
C.) 3 COMPRESSORS
- 41 -
4.0 ELECTRICAL
Ω
- 42 -
4.0 ELECTRICAL
- 43 -
4.0 ELECTRICAL
- 44 -
4.0 ELECTRICAL
4.4 VISION 2020i 4.4.1.1 The fifteen polycarbonate buttons:
CONTROLLER AND a) Seven polycarbonate buttons at top
row
TERMINAL
Button Description
Vision 2020I controller is equipped with user Displays the analog inputs and
friendly 132x64 pixels back-lit graphic display INPUT STATUS digital inputs status measured by
the probes/sensors.
terminal. It is connected with controller through
telephone cable. The terminal allow carrying out OUTPUT Displays the relay outputs and
STATUS analog outputs status.
all program operations. The user terminal allows
displaying the unit working conditions, COMPRESSOR Displays the status of Compressor
component run times, alarm history at any time STATUS 1, 2 and so on.
and modifying the parameters. The terminal also

has an automatically self-test of the controller on SETPOINT Displays the status of set points.
system start-up. Multiple messages will be
displayed by automatically scrolling from each CLOCK/
Displays the date, time and day.
message to the next. All of these messages are SCHEDULE
spelled out in English language on the LCD

screen. ALARM HISTORY Display the alarm history.
4.4.1 DBG1 OPERATOR KEYPAD AUTHORIZATION To log in the level of passwords.
The DBG1 operator keypad consists of

15 polycarbonate buttons: b) Eight polycarbonate buttons at
bottom row
Figure 4.3.1 : Vision 2020i keypad Button Description
USER User Control Changeable Settings.
Technician Control Changeable

TECHNICIAN
Settings.
The top right ‘Authorization’ button is

for password log in to gain authorization, FACTORY Factory Control Changeable Settings.
to the access setting menu.
The top left six operator buttons MENU
Unit information / Compressor
Information.
functions are to view status only, except
the ‘Setpoint’ button also allows setting
Display the active alarms and to
changes after gained authorization. ALARM RESET
perform alarm manual resets.
The three buttons at the bottom left are Scroll the various screens when the
to access different level of setting cursor is in the top left of the display.
If the cursor is inside a numeric field,
changes. UP the button increases or decreases
the corresponding value. If the field is
These are 'User', 'Technician' and a selection, pressing the button
displays the available options.
'Factory' levels, from left.
It can only be access depend on the DOWN See the UP arrow
password level. The higher password can

access the lower password level's setting ENTER
To move the cursor around the
screens and to save the values of the
and not vice versa. set parameters
- 45 -
4.0 ELECTRICAL
4.4.2 STATUS READING Press down arrow key or output key to
go to next screen:
4.4.2.1 Input status key
To read inputs status press input status
key:
Repeat the same steps to go to other
relay outputs screen:
The display is showing the data as
follows: 4.4.2.3 Compressor status key
To read compressor status press
ANALOG INPUTS
compressor status key:
Supply Temp 044.8 °F [07.1°C]
Return Temp 055.6 °F [13.2°C]
Suction Pres 073 PSI [05.2BAR]
Disch Press 179 PSI [12.9BAR] The display is showing the data as
follows:
COMPRESSOR 1 STATUS
Press down arrow key or input key to
go to next screen: Comp 1 OK
Amps= 100A
FLA1= 230A
Capacity= 025.5%
follows: Status=ON-LOAD
ANALOG INPUTS
Press down arrow key or press
C1 Amps 101A compressor key to go to next screen:
C1 Disc T 125.2°F [51.8°C]

follows:
Repeat the same steps to go to other
sensor inputs screen: COMPRESSOR 1 HISTORY 1
4.4.2.2 Output status key Today Total
To read relay outputs status press Run Hour 05 0006
output status key: Cycle 02 0006
Last On 04/24 19:06

The display is showing the data as Last Off 04/24 19:03
follows:
RELAY OUTPUTS
Comp 1 ON-LOAD 4.4.2.4 Setpoint key:
Alarm Status OFF To read the setpoint value press
Control Power ON setpoint key
SDD Control OFF
C1 Liquid Inj OFF
CW Pump ON
- 46 -
4.0 ELECTRICAL
follows: REAL TIME CLOCK
Day > MONDAY

SETPOINT 1 Time > 16:10
Date > 05/12/05
Supply Water Temp
Set point= 44.0 °F [06.7°C]
Dead band= 0.8 °F [0.5°C]
To set the date and time, you must be
authorized. See the authorization
procedure and log in at least as user
level.
To alter setpoint data, you must be
Press enter key to select the date or
authorized. See the authorization time to alter and use the up-down arrow
procedure and you must be authorized key to change the value and press enter
at least as user level. key to confirm.
Press enter key to select the setpoint to
alter and use the up-down arrow key to
change the value and press enter key to
confirm.
4.4.2.6 Alarm history key:
To view the unit alarm history press
alarm history key:
Press down arrow key or press

setpoint key to go to next screen: The display is showing the data as
follows:
ALARM HISTORY
001-C1 Starter
Repeat the same steps to go to other 19:03 05/12/05
setpoints screen and perform setpoint TR: 030.2 LWT: 64.3 [17.9]
DP: 191 [13.6]
modification.
SP: 076 [5.4]
4.4.2.5 Clock key: Press down arrow key or press alarm

key to go to next screen for other alarm
To read the current day, time and date, history:
unit scheduling and ice-cel mode
scheduling (optional), press the clock
key
To clear alarm history, press input key
and authorization key together and then
press the alarm key again. Now the
display should be showing “No alarm”
follows:
- 47 -
4.0 ELECTRICAL
4.4.3 Authorization Press down arrow key or user key to go
to next screen for other setpoint:
4.3.3.1 Authorization key
To get authorization level, press
authorization key:
To alter setpoint data, press enter key to
select the setpoint to alter and use the
The display is showing the current up-down arrow key to change the value
access level as view only: and press enter key to confirm.
AUTHORIZATION
Please Enter your

Repeat the above steps for others
Password
setpoints.
PASSWORD= 0000
Status=View
4.4.5 TECHNICIAN KEY and MENU
Press enter key and use the up-down
arrow key to change the password 4.4.5.1 Technician status key
settings and press enter key to confirm.
This key is use to view and change the
compressor FLA setpoint, sensors
calibration, manually control digital
Now the authorization status change to inputs and outputs, manually control
different access level. compressor. In order to gain access to
this button, you must be authorized and
4.4.4 Advanced user key and log in at least as user level. See the
menu authorization section about this
procedure.
4.4.4.1 User Key
User key is use to view and change 4.4.5.2 Technician status key –main
the pressure, ampere safety limits menu
and liquid injection temperature Press technician key to go to technician
setpoints, unit of measurements. In setpoints main menu:
order to gain access to this button,
you must be authorized and log in at
least as user level.
follows:
Press the user key and display is Technician Setpoints

showing the data as follows:
Main Menu
USER SETPOINT 1 Comp FLA Calibration
Sensor Calibration
High Pressure Safety Manual Control
Limits Compressor Control
Hold= 360PSI [23.4BAR]
Unload= 370PSI [24.1BAR]
Cutout= 400PSI [24.8BAR] Press enter key to move the cursor to
the sub-menu.
- 48 -
4.0 ELECTRICAL
follows: Technician Setpoints
Main Menu
Technician Setpoints Comp FLA Calibration
Sensor Calibration
Main Menu Manual Control
Comp FLA Calibration Compressor Control
Sensor Calibration
Manual Control Use up or down arrow key to move the
Compressor Control cursor to the desired 'Sensor
Calibration',
4.4.5.3 Compressor FLA Calibration:

To calibrate compressor FLA, press The display is showing the data as
down arrow key to go the sub-menu follows:
'Comp FLA Calibration',
Sensor Offset 1
Suction Press
Current = 076PSI [5.4BAR]
The display is showing the data as Average = 187PSI [8.6BAR]
follows: 24Hrs MAX = 200PSI [11.4BAR]
24Hrs MIN = 074PSI [4.6BAR]
Calibration = 00PSI [0.0BAR]
Technician Setpoint 1
Comp 1 FLA CALIBRATION
211x00.66+97.80 Press enter key to move the cursor to
FLA = 237A calibrate the desired sensor and use the
Capacity C1 = 000.0 % up-down arrow key to change the value
Min Percent Cal = 25.0 % and press enter key to confirm.
Max Percent Cal = 00 A
Press enter key to move the cursor to Repeat the above steps for others
calibrate the comp FLA and use the up- sensors calibrations.
down arrow key to change the value
and press enter key to confirm.
4.4.5.5 Manual Control:
A digital input sensor or relay output
can be controlled manually with the
keypad. Digital input sensor or relay
output can be turned on, off manually
4.4.5.4 To perform Sensor Calibration: and placed back to auto mode.
To place a digital input or relay output
Press technician key to go to technician
in manual control, the operator must be
setpoints main menu and press enter
authorized at technician level or higher.
key twice to move the cursor to the
sensor calibration sub-menu:
key three times to move the cursor to
the manual control sub-menu:

follows:
- 49 -
4.0 ELECTRICAL
The display is showing the data as given a command at least once every 15
follows: minutes.
Technician Setpoints 4.4.5.6 Compressor Control:

Screw compressors can be controlled
Main Menu manually with the keypad. A
Comp FLA Calibration compressor can be turned on, off, or
Sensor Calibration placed in computer control. When a
Manual Control ■ compressor is controlled manually, it
Compressor Control can be commanded to load, hold, or
unload. If safety limiting condition is
Use up or down arrow key to move the active, it will not accept a load
cursor to the desired digital input or command.
relay output, To place a compressor in manual
control, the operator must be authorized
and log in as technician level and
higher.
follows:
key four times to move the cursor to the
manual control sub-menu:
Digital Inputs
Manual Control
C1 Starter= Auto
C1 Oil Lvl= Auto The display is showing the data as
Unit Enable= Auto follows:
Flow Switch= Auto
Technician Setpoints
Press enter key to move the cursor to Main Menu

the desired point for manual control and Comp FLA Calibration
use the up or down arrow key to change Sensor Calibration
the status of the digital input or relay Manual Control
output to AUTO/CLOSE/OPEN or Compressor Control ■
AUTO/ON/OFF.
Use down arrow key to move the cursor
to the desired compressor control
screen, then press enter key to move the
The display is showing the data as cursor to compressor status position,
follows: AUTO /MAN/OFF
Relay Outputs
Manual Control
Alarm Relay Auto The display is showing the data as
SDD Relay Auto follows:
Liquid Inj C1 Auto Compressor Control
CW Pump Auto
Vap Inj Relay Auto Manual Override
COMPRESSOR 1=AUTO
Press enter key to confirm the change. St= 0005
NOTE: All manual control will revert back to Amps= 071.8
automatic control if the keypad is not Capacity= 025.0%
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4.0 ELECTRICAL
Use up or down arrow key to select controller can be used to enable or
MAN and press enter key to confirm disable operation of the unit. The
the change. The compressor will start wiring diagram specifies the terminals
or continue to run in hold state. Press to which the contacts must be wired. To
the user key to continue hold, press the enable the unit, the contacts must be
technician key to load and factory key closed. To disable the unit, the contacts
to unload. must be opened.
4.4.6.3 Anti-Recycle Timer

The compressor motor requires an anti-
Manual Hold Manual Load Manual Unload recycle time delay which prevents
restart for 15 minutes after a start. The
If a safety condition is exceeded while
purpose of this feature is to avoid
operating manually, the compressor
frequent starts which tend to elevate the
will shutdown.
motor winding temperature and impose
CAUTION: Anti-recycle timer is bypassed by undue wear on contactors. The
manual control. DO NOT start a controller will not restart the
compressor more than once every 15 compressor motor until the 15 minutes
minutes. have elapsed.
NOTE: All compressors will revert back to
automatic control if the keypad is not 4.4.6.4 On Delay Timer
given a load, unload, or hold command A Compressor on delay timer of one or
at least once every 15 minutes. A two minutes is incorporated to prevent
command can be repeated to meet the
two compressors from starting at the
15 minute requirement for manual
same time and ensures that the system
control.
load requires another compressor. The
compressor output status will display
the timer count-down during this timing.
4.4.6 Control Functions
4.4.6.5 Load Control
4.4.6.1 Chilled Water Pump Interlock The controller controls the leaving
And Flow Switch (CWP And water temperature within a narrow
CWFS) deadband by pulsing load and/ or
These are field installed switches, both unload solenoids on the compressor.
of which are used to ensure chilled The load and unload solenoids position
water flow before the unit is allowed to the slide valve within the compressor to
start. Failure of either one during control its capacity. The controller
operation will cause the compressor to determines a desired level of loading
shut down. and varies pulse duration depending on
difference between load target and
A water flow alarm will be generated
actual load. The load target is varied
and ‘Rest Alarm’ must be pressed to
clear the alarm. based on rate of approach to desired
temperature preventing significant
temperature oscillations. The status of
4.4.6.2 Customer Control Interlock the compressor can be observed by
Control contacts from an external displaying the compressor output status.
- 51 -
4.0 ELECTRICAL
4.4.6.6 Ramp Control unloading, a compressor is taken off
Another feature of the controller is line when the computer determines that
ramp control, which is the ability to the remaining compressors can control
vary load time of the machine from water temperature.
start. Often when the machine is started,
the water in the chilled water circuit is 4.4.6.8 Modmotor Setback Control
warm, and the unit will go to full load A computer contact and a resistor are
quickly. With ramp control, the user wired in parallel in the modmotor
can program the computer so that it control circuit. The contact is controller
loads at a predetermined rate. This is a controlled to open under light load
valuable tool, since it can help reduce conditions. This lowers liquid level
power consumption and demand slightly, preventing excessive liquid
charges. Two variables are used to level in the evaporator.
define the ramp profile: Ramp rate and
start point. Ramp rate defines the length 4.4.6.9 Evaporator Pressure Control
of time the unit takes to load from start This control function seeks to prevent a
point to full load. Start point is the low differential pressure alarm. It
percent of full load at which the ramp monitors the difference between
begins. The ramp rate setpoint can be condenser and evaporator pressure. If
set anywhere from 0.1 to 0.4, smaller this difference is less than 30 psig
values producing slower loading rates. [2.1BAR] for more than 60 seconds,
The ramp start setpoint can be set and evaporator pressure is above 75
anywhere between 10 and 50%. The psig [5.1BAR], the computer will open
compressor will load quickly to this a set of contacts in the modmotor
value and then follow the ramp slope circuit, causing valves to travel in the
from there. See Table 4.4.6.6 for ramp closed direction. This starves the
evaporator, which increases pressure
rates at various settings.
difference. When this difference
exceeds 30 psig [2.1BAR], modmotor
TABLE 4.4.6.6 Ramp Rates for Several control returns to normal.
Setpoints (In Minutes) CAUTION: Do not start compressor
manually more than once every 15
Ramp 1 Comp. 2 Comp. 3 Comp
minutes. Verify that chilled water flow
Rate Start Point
Setpoint
Start Point
Setpoint
Start Point
Setpoint switch is closed.
Setpoint 25% 50% 75% 25% 50% 75% 25% 50% 75%
0.1 25 17 8 58 50 42 91 83 75
4.4.6.10 Sump Heater Control
0.2 13 8 4 29 25 21 46 42 37 Each compressor is fitted with an oil
0.3 8 6 3 19 17 14 30 28 25 sump heater. The heater is energized at
0.4 6 4 2 15 12 10 23 21 19 all times when compressor is off and
de-energized when the compressor is
running.
4.4.6.7 Staging Control
Its purpose is to prevent refrigerant
On multiple-compressor machines, migration into the oil during shut down.
when the controller determines that a For this reason, it is essential that
compressor is fully loaded and heaters be energized for 24 hours
temperature is not being maintained, before starting a compressor.
another compressor is added. When
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4.0 ELECTRICAL
4.4.6.11 Low Pressure Cut-off Failure is indicated on the alarm pilot
This function protects the unit from light. The low oil alarm will be
operating at abnormally low evaporator recorded by the controller.
refrigerant pressure. The controller will
shut down the compressor when cooler 4.4.6.15 High Oil Temperature
pressure falls below the low pressure Thermostat (12TAS)
setpoint and turn on the alarm pilot A thermostat is located in each
light. compressor which will open the
A low pressure alarm will be recorded compressor run circuit if oil
by the controller. Reset by pressing the temperature exceeds 203°F [95°C]. The
‘Reset Alarm’ on the controller. high oil temperature pilot light will
indicate an excessive oil temperature
Standard setpoint is 28 psig [1.9BAR]
and a No-Run error will be recorded by
for water-cooled systems.
the computer. Reset is activated by
pressing the ‘Reset Alarm’ button on
4.4.6.12 Evaporator Freeze Shutoff
microcomputer.
If the leaving chilled water temperature
drops below the freeze setpoint, the
4.4.6.16 Overload Protector (M2OL)
controller will shut down the unit and
store the freeze alarm. After solving the
A solid state overload protects each
compressor by three phase current
problem, press ‘Reset Alarm’ on the
monitoring to prevent high current
controller to clear the alarm.
draw. The trip setting is factory set and
is reset by pressing button on overload
4.4.6.13 High Pressure Cut-off
after correcting problem. The ‘Reset
This function protects the compressor Alarm’ button on controller must also
from operating at abnormally high be pressed to clear the alarm. A no-run
discharge refrigerant pressures. The error is stored in the controller.
controller will shut down the
compressor when condenser pressure 4.4.6.17 Phase Control Relay (PCR)
reaches the high pressure set point, and
The PCR protects the unit from the
turn on the alarm indicator lamp on the
following electric supply malfunctions:
control box. The high discharge Undervoltage, phase reversal and single
pressure alarm will be recorded by the phasing. If the PCR trips, a control
controller. Reset by pressing the ‘Reset relay (lCR) will de-energize and open
Alarm’ button on the micro-computer. the control circuit. A green LED
Setpoint for water-cooled system is 164 indicates presence of power supply.
psig [11.3BAR]. The yellow LED indicates a good
voltage supply. The power loss setpoint
4.4.6.14 Standard Oil Level Sensor (LS) is factory set to AUTO to allow
An standard oil level sensor is located automatic start after PCR failure.
in each compressor. If low oil Compressor will not start for 15
indication (digital input is OFF) persists minutes after failure. To select manual
for 60 seconds during compressor reset, set power loss setpoint to
operation, the controller will then shut MANUAL. In this case, a power loss
down the compressor. The status of the alarm will be stored by the
oil level sensor can be seen on the microcomputer and ‘Reset Alarm’ must
computer display. be pressed to start.
- 53
30 -
4.0 ELECTRICAL
4.4.6.18 Sensor Alarm etc.). All calibration on sensors shall be done
If the controller measures an analog in this step.
value (temperature, pressure.) that is far 2. Load the compressor to full load. If the amps
beyond normal operating values, the reading do not match with calculated FLA
associated compressors are shutdown. value within 2-3A, do this calculation: Amps
The controller then stores the alarm – FLA
code corresponding to the sensor alarm. For example, FLA = 150A, however the max
A sensor alarm indicates a problem in amps at full load is 130A, so, do the
the analog measurement system. calculation
130 – 150 = -20
4.4.6.19 No-Stop Alarm 3. Key in this value into “Max Percent Cal” of
If the controller turns off a compressor, the compressor in “COMPRESSOR FLA
but the compressor digital input does CALIBRATION” mask under technician key.
not turn off, a No-Stop alarm is 4. Therefore, the value of FLA will change.
generated. The controller will turn off Verify that amps and FLA now match closely.
the control power relay which disables 5. Manually unload the compressor all the way.
all compressor control circuits and will 6. Locate the minimum percentage of capacity
turn on the alarm light. This alarm for the compressor. If this value is 25% ± 3%,
indicates a wiring or hardware error. no change required. Else, enter this value into
“Min Percent Cal” in the same mask. The
4.4.6.20 Low Differential Pressure default value of “Min Percent Cal” is 25%.
Alarm
For example, the minimum percentage of
For proper lubrication, a compressor capacity for the compressor is 32.2%,
requires a 30 psig [2.1BAR] differential therefore, enter 32.2 at “Min Percent Cal”.
pressure between condenser and
7. Repeat this procedure for each compressor.
evaporator pressures. If the differential
pressure is less than 30 psig [2.1BAR]
for 3 minutes while a compressor is
operating, all compressors will be shut 4.6 Master/Slave Control
down. The controller will store the low
differential pressure alarm code and
Sequence
turn on the alarm light. The ‘Reset The optional master/slave control sequence is
Alarm’ key must be pressed to clear the used to sequence multiple chillers in one
alarm. installation according to the building load demand.
It also controls the dedicated chilled water pump
or motorized valve.
Vision2020i Controller offers this feature with
4.5 CALIBRATION OF minimized field wiring cost compare to
SCREW COMPRESSOR conventional method that involves lots of
CAPACITY AMPS AT hardware cost. It is carried out this control
FULL LOAD & MINIMUM function via the advanced DBLAN
LOAD PERCENTAGE communication bus to implement the network
management for multiple chillers lead/lag
1. Check calibration of all sensors (pressure communication, sequencing and monitoring.
sensors, current transducers, temp sensors and
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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
DB2 DBG1 DB2 DBG1 DB2 DBG1 DB2 DBG1 DB2 DBG1 DB2 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 DB2 board and dedicated display panel DBG1 with multiple
DB1 expanders board connected to J23 on DB2
b) Each chiller DB2 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
- 55 -
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 is
The flow switch and water pump status are higher than “Next on setpoint”,
interlocked and feedback as digital input to for example, WCFX2, %Capacity C1 &
the chiller and upon receipt of a valid 'on' %Capacity C2 ≥ Next on setpoint
signal, the lead chiller will begin to execute
its running program. or it is being lockout by an alarm.
2. The controller will start and load the

compressor(s), upon achieving full load; it
will send an output signal via the DBLAN to 4.7 VISION 2020i LOCAL
enable second unit (lag 1) AREA NETWORK
3. The second unit will now command its chilled (DBLAN)
water pump to start if the customer unit
enable is activated. The second chiller will A DBLAN network is made up of several
start and load the compressor(s) until it chillers’ controller. Each unit’s controller can be
reaches full load programmed and connected to the local DBLAN
4. When the second chiller or lag 1 unit reaches network that allows multiple units sequencing
full load, it will enable the third chiller. control without additional hardware.
5. The chiller will keep cascading until all Every DBLAN node must be addressed to be
chillers on duty are at full load. identified by the other nodes. Each address (an
integer number) must be unique in the network
6. If the leaving water temperature falls below for avoiding messages mismatch: in case two or
setpoint, all of the chillers will begin to more nodes have the same identifying address the
unload evenly. network cannot work.
7. If the load drops below 45% total capacity, The max address number selectable is in the 1-16
delay the last unit (lag 3) will be disabled, and for the Vision 2020i controller boards and 17-32
the remaining three units will load up to range for the Vision 2020i DBG1 User terminal.
compensate if necessary. The pump for chiller
4 will be shut off.
8. As the load demand falls, the lag 2 unit will The three chiller unit combinations:
be disabled below 45% total capacity, and so Controller with address of 1 connect to Terminal
on until the load falls enough to shut off the with address of 17
lead chiller.
Controller with address of 2 connect to Terminal
9. Each unit in the network can monitor the with address of 18
operation of other units via DBLAN. If the
Controller with address of 3 connect to Terminal
master unit is having critical alarm, the lag 1
with address of 19
will take over as the master unit automatically.
10. In order to enable next unit, the following Follow the following steps:
conditions must met
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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 Addressing the Vision 2020i controller
1. Set the dip switches respective to the DBLAN address. You can find the DIP switches in between the
J11 AND J12.
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4.0 ELECTRICAL
4.9.2 Addressing the Vision Set Trm1, Trm2 and Trm3 to ’17 Pr’,’32 Sh’
2020i DBG1 terminal and ‘None ---’, change the 'NO' to 'YES'(to
confirm and save) and press ‘enter’.
At the Vision 2020i DBG1 terminal, hold Note: Pr = Private, Sh = Share.
simultaneously the last three keys on the lower For multiple units with master-slave sequencing
right corner of the Vision 2020i terminal control features, At the second chiller unit Vision
keyboard. Hold them for at least 5 seconds. 2020i terminal; repeat step 1 by holding the three
keys again. The display will appears:
Vision 2020i
5 sec Display address
Setting……… : 18
I/o Board address: 02
The display will appears:
Display address
Setting……… : 17 The address display (18) is the correct setup for
the second chiller unit with the controller address
I/o Board address: 01 of two (P:02).Press ‘enter’ to confirm the settings
and the display will appears:
Terminal config
Press ENTER
The first line is the address of the terminal display To continue
that you are using, (for first chiller, it is 17). The
next line allows you to select the Vision 2020i
controller address (for first chiller, it is 01) that
you want to configure. Once you select the
address then press ‘enter’ button
Set Trm1, Trm2 and Trm3 to ’18 Pr’,’32 Sh’
The display will appears: and ‘None ---’, change the 'NO' to 'YES'(to
confirm and save) and press enter.
Terminal config
P:02 Adr Priv/Shared
Press ENTER
Trm1 18 Pr
To continue
Trm2 32 Sh
Trm 3 None --- OK? NO
Push ‘enter’ to continue. At the third chiller unit Vision 2020i terminal:
Then the display will appears: Press the three keys again. Then the display will
appears:
P:01 Adr Priv/Shared Display address
Trm1 17 Pr Setting……… : 19
Trm2 32 Sh
Trm 3 None --- OK? NO I/o Board address: 03
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4.0 ELECTRICAL
The address display (19) is the correct setup for With the above settings, terminal with address 17
the third chiller unit with the controller address of will only work with the controller with address 1,
three(P:03).Press ‘enter’ to confirm the setting terminal 18 will only work with the controller
and the display will appears: with address 2, terminal 19 will only work with
the controller with address 3 and a terminal with
Terminal config address 32 will work with both.
Press ENTER
To continue
4.9.3 Vision 2020i Controller

LED Status
Vision 2020i controller have three LEDs beside

Set Trm1, Trm2 and Trm3 to ’19 Pr’,’32 Sh’ the DIP switches for indicating basic node status.
and ‘None ---’, change the 'NO' to 'YES'(to They are Red, Yellow and Green coloured.
confirm and save) and press enter.
P:02 Adr Priv/Shared

Trm1 19 Pr Red Yellow Green
Trm2 32 Sh
Trm 3 None --- OK? NO At the start-up all LEDs are ON and after few
seconds OFF again. After 5 – 15 seconds elapse,
then LED configuration is among those listed
below.
Table 4.9.3 LED Status
LED STATUS DESCRIPTION
Vision 2020i controller is synchronized with all the other DBLAN nodes.
ON
The node is working correctly.
GREEN
OFF Vision 2020i controller is not network connected or it doesn’t receive any signal from the DBLAN
BLINKING Vision 2020i controller is transmitting data to other network nodes.
YELLOW
OFF Vision 2020i controller is not transmitting messages.
OFF No hardware and software problem.
RED
Vision 2020i controller software not compatible or variables database not correct, contact Dunham-
ON
Bush Service Personnel.
Vision 2020i hardware is not compatible - Ram is smaller than 32 KB.

BLINKING
The Vision 2020i controller is just for working in stand-alone mode.
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5.0 MAINTENANCE
5.1 GENERAL the difference between leaving water temperature
and saturated refrigerant temperature at the
As with all mechanical equipment, a program of
pressure in the vessel. At full load, read
regular inspection, cleaning and preventive
evaporator and condenser pressures on the
maintenance by trained personnel will contribute
computer. Then use Table of Refrigerant
greatly to the long satisfactory service life of this
Pressure/ Temperature Properties to find
product. Some of this care can easily be provided
corresponding saturated temperature for each
by owner personnel. However, a Dunham-Bush
pressure. Read leaving chilled water temperature
authorized service mechanic should inspect the
on the computer. Read leaving condenser water
unit at least annually and evaluate the unit
temperature on computer if option is provided, or
performance.
with field installed thermometer. Then calculate
approaches as follows:
5.2 PERIODIC INSPECTION Condenser Approach = T sat condenser - T lvg

cond. water
Read essential temperatures and pressures
periodically to see that they indicate normal Evaporator Approach = T lvg chilled water - T
sat evaporator
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 more
in Section 5.8. If any abnormal operation is
than 2°F [1.1°C] above the approach recorded at
observed, try to determine cause and remedy it.
clean conditions, the tubes should be cleaned. It is
See Trouble-shooting Guide, Section 5.7.
generally advisable to clean the waterside
surfaces at least annually and more often if
severely foul water is used. This cleaning can be
5.3 MONTHLY INSPECTION done chemically or physically. In chemical
Check water treatment system. Wipe down cleaning, a caustic solution is pumped through the
external surfaces of unit. Shut unit down, open heat exchanger, which attacks dirt, slime and
main disconnect, inspect control panel, checking mineral deposits and flushes them away.
for loose wires, burned contacts, signs of Chemicals can be recommended by water
overheated wires, etc. Restart unit and check treatment specialists, but it is important to rinse
performance of controls and time rate of loading the system thoroughly after cleaning to remove
and unloading. Check flash tank feed line sight the chemicals before the chemicals attack the
glass for proper refrigerant charge level. See metal surfaces.
Charging, Section 5.6. Vessel tubes may be physically cleaned by first
draining the water, then removing the headers and
brushing each tube individually with a tube
5.4 WATER SIDE CLEANING cleaning brush until it is clean. The brush should
OF VESSELS have stiff nylon bristles. Brush kits are available
from D/B North American Service. For best
The effects of fouling on the evaporator or
results, always remove both headers before
condenser heat transfer surfaces can be detected
cleaning the tubes. Replace the headers, being
by recording full load performance data on the log
careful to properly position gaskets, and refill the
sheet. The best measure of performance of
system with water.
evaporator and condenser is approach, which is
- 60 -
5.0 MAINTENANCE
Head gaskets need not be renewed after each head In order to check proper refrigerant charge, check
disassembly operation. Gaskets should and must flash economizer feed line sightglass (refer to
be renewed if they are physically disfigured or Figure 3.5,) during unit operation. If bubbles are
otherwise deteriorated. New gaskets are available visible in sight glass, unit is undercharged.
from the factory. INSPECT CAREFULLY. Refrigerant should be added through the charging
valve on the evaporator feed line until the
condenser drain sight glass is clears. Sight glass
should be clear at all operating conditions. When
5.5 ELECTRICAL
operating at full load, the evaporator tube bundle
MALFUNCTION
(visible through sight glass on evaporator shell)
The unit has four devices designed to protect the should be immersed. At light load, tubes may be
compressor motor from electrical malfunctions: visible. To add refrigerant, connect a refrigerant
computer current limiting function, motor vessel to the liquid line charging valve under the
overload relay, phase control relay, and circuit evaporator. Purge the air from the tube. With the
breaker. unit running, open the refrigerant vessel liquid
If the phase control relay trips, it is a sign of connection slightly. If the refrigerant vessel is
trouble in incoming power. If it trips again after warmer than the evaporator, refrigerant will flow
resetting, call your electric utility to investigate from the vessel into the unit. The need for
the problem. If the circuit breaker or motor additional refrigerant is an indication of
overload relay trips, this is a sign of possible refrigerant leakage. In the interest of
motor trouble. DO NOT reset and try to run environmental protection as well as operating cost,
compressor again. Call authorized service the leak should be found and corrected.
representative to check for motor trouble.
Resetting these safety devices and repeated
5.6.2 Oil Charge
starting could turn a minor motor problem into a
costly major motor burnout. The proper oil charge is in the unit as supplied
from the factory. The compressor should show oil
return at all times. If for some reason, the
compressor runs low on oil, a low oil level switch
5.6 CHARGING in the compressor will shut it down before any
damage is done. In the event of a low oil
5.6.1 Refrigerant Charge
shutdown, call a D/B authorized service agent to
The WCFX unit is given a complete charge of correct the problem. DO NOT ADD OIL TO
refrigerant at the factory. All standard units use THE SYSTEM.
refrigerant and the amount necessary to change
NOTE: Only DB 18 oil may be used in this
the unit can be found in the physical
package. Use of other oil is not approved by
specifications.
Dunham-Bush, and will result in poor
If the unit must be charged on the jobsite, it performance of the package. It is
should be done by a qualified refrigeration recommended to change oil annually to
mechanic. prolong the compressor life-time.
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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.
- 62 -
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 c.) Close circuit breakers. If trip, check compressor.
breakers 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 g.) Press reset button.
not 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 normal
does not at main and low at unit. Voltage must be within 10% of motor
start. name plate rating.
b.) No power on one phase b.) Check fuses and wiring.
of 3 phase unit.
c.) Faulty starter or c.) Check the contacts and time delay on part wind start.
contactor.
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. Do not exceed RLA x 1.25. Call D/B serviceman.
5. High oil a.) Motor windings failing. a.) Check megohms.
temperature b.) Insufficient motor cooling. b.) Open liquid injection valve slightly.
6. Low suction a.) Inadequate feed to a.) Check to see that liquid line ball valve is open.
pressure evaporator.
b.) Inadequate refrigerant b.) See information on charging in Section 5.6.
charge.
c.) Fouling of waterside of c.) At high load, check evaporator approach (See Section 5.4). If
evaporator. 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 2.3. 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.
7. High a.) Inadequate air flow a.) Check condenser flow rate, either with condenser pressure drop
discharge across condenser curve or with pump curve.
pressure. b.) Fouling of waterside of b.) At high load, check difference between saturated refrigerant temp.
condenser. and leaving water temp. If 2°F [1.1°C] or more above start-up
conditions, remove headers and clean tubes.
8. Oil low in a.) Low oil level in a.) Low oil level in compressor sight glass is acceptable.
sump. compressor.
9. Low oil a.) Low oil in compressor. a.) See Section 5.6.2.
shutdown.
10. Freeze a.) Operating setpoint too a.) Check leaving water setpoint on microcomputer.
warning. low.
b.) Load changing too b.) Load on package must drop at reasonable rate for automatic
rapidly. control to work properly.
11. Improper a.) Ramp rate incorrect. a.) See Section 4.4.6.6.
capacity
control.
- 63 -
5.0 MAINTENANCE
5.8 SAMPLE LOG SHEET SHEET NO. .......................
DUNHAM-BUSH ROTARY SCREW COMPRESSOR PACKAGED CHILLER
NAME PLATE DATA:
UNIT MODEL NO. WCFX :............. 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
EVAPORATOR WATER TEMPERATURE-IN
EVAPORATOR WATER TEMPERATURE-
OUT
EVAPORATOR WATER PRESSURE DROP
ftwg [kPa]
EVAPORATOR WATER FLOW

gpm [m³/hr]
CONDENSER WATER PRESSURE DROP

ftwg [kPa]
CONDENSER WATER FLOW gpm [m³/hr]
ACTUAL VOLTAGE (NOT NOMINAL)
COMPRESSOR AMPS 2
3
TONS = GPME X UTE
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.
- 64 -

Installation, Operation & Maintenance Manual

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Form No: MM0422A

Products That Perform . . .By People Who Care

SCHEMATIC DIAGRAM, GRAPH AND TABLE

Dunham-Bush packaged chiller has been manufactured under a careful quality

Water-Cooled Chiller Generation

Compressor Code Electrical Code

FIGURE 1.2 RIGGING DIAGRAM

Note: Project unit from cables.

WCFX 39, 42, 45, 48, 51, 54

Note: Project unit from cables.

TWO PASS RIGHT HAND ARRANGEMENT SHOWN

TWO PASS RIGHT HAND ARRANGEMENT SHOWN

WCFX 10, 12, 15 & 18

Point Loading, Lbs [kg]

Notes: 1.) Refer to dimensional drawings for location of mounting points.

2.) Evaporator 3 Pass

WATER FLOW RATE - GPM

WATER FLOW RATE - GPM

4.) Condenser 3 Pass

WATER FLOW RATE - GPM

2.) Evaporator 2 Pass

WATER FLOW RATE - GPM

WATER FLOW RATE - GPM

4.) Condenser 1 Pass

WATER FLOW RATE - GPM

WATER FLOW RATE - GPM

6.) Condenser 3 Pass

WATER FLOW RATE - GPM

WATER FLOW RATE - GPM

2.) Evaporator 2 Pass

WATER FLOW RATE - GPM

4.) Condenser 1 Pass

WATER FLOW RATE - GPM

WATER FLOW RATE - GPM

6.) Condenser 3 Pass

WATER FLOW RATE - GPM

2.) Evaporator 3 Pass

WATER FLOW RATE - m³/hr

WATER FLOW RATE - m³/hr

4.) Condenser 3 Pass

WATER FLOW RATE - m³/hr

2.) Evaporator 2 Pass

WATER FLOW RATE - m³/hr

4.) Condenser 1 Pass

WATER FLOW RATE - m³/hr

WATER FLOW RATE - m³/hr

6.) Condenser 3 Pass

WATER FLOW RATE - m³/hr

WATER FLOW RATE - m³/hr

2.) Evaporator 2 Pass

WATER FLOW RATE - m³/hr

4.) Condenser 1 Pass

WATER FLOW RATE - m³/hr

WATER FLOW RATE - m³/hr

6.) Condenser 3 Pass

WATER FLOW RATE - m³/hr

3.6 OIL MANAGEMENT 3.7 HYDRAULIC CAPACITY

3.8.3 During Maintenance