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WCHX-A - R134a - 50Hz - MS04107A-0917 - Lo (004) New
WCHX-A - R134a - 50Hz - MS04107A-0917 - Lo (004) New
WCHX-A - R134a - 50Hz - MS04107A-0917 - Lo (004) New
For more than 100 years, Dunham-Bush has focused on innovative product development. Today, we provide a full
portfolio of HVAC/R products from Fan Coil Units to large centrifugal chillers as well as many other innovative green
solutions. Our commitment to innovation, matched with an aggressive attitude toward growth, makes Dunham-Bush
a leader in global markets. Our product development is tailored to meet the specific needs of customers, building-by-
building, country-by-country and region-by-region. No other HVAC/R manufacturer takes this approach to meeting
your performance expectations.
The Dunham-Bush name is synonymous worldwide with the Rotary Screw Compressor Chillers technology. With
over 45 years of proven experience and track records in manufacturing and installation of Rotary Screw
Compressors and chillers, thousands of our Chillers have clocked more than 100,000 operating hours without any
compressor tear-out or overhaul! As a pioneer and industry leader in the Rotary Screw compressor technology for
HVAC/R systems, Dunham-Bush now introduces the Water Cooled Rotary Screw Flooded Chillers with unsurpassed
performance and reliability.
WCHX-A Water Cooled Screw Chillers, using environmentally sound R134a refrigerant. The entire product line
features high energy efficiency, compact construction, installation ease, control flexibility, high reliability and
advanced controller. The WCHX-A series are certified to AHRI Standard 550-590, meets ASHRAE Standard 90.1.
TABLE OF CONTENTS
Page
Introduction .......................................................................................................................................................................................... 2
Nomenclature ....................................................................................................................................................................................... 2
Unit Features ........................................................................................................................................................................................ 3
Option And Accessories ....................................................................................................................................................................... 5
Operating Benefits ............................................................................................................................................................................... 6
Physical Specifications ......................................................................................................................................................................... 8
Electrical Data ...................................................................................................................................................................................... 9
Sound Pressure Data ........................................................................................................................................................................... 9
Dimensional Data .............................................................................................................................................................................. 10
Floor Loading Diagram ....................................................................................................................................................................... 15
Unit Clearance ................................................................................................................................................................................... 16
Typical Wiring Schematic ................................................................................................................................................................... 17
Application Data ................................................................................................................................................................................. 19
Guide Specifications .......................................................................................................................................................................... 20
NOMENCLATURE
WC HX - A 140 S AU G8B HER Q
Product Generation
Evaporator Code
Model
Electrical Code
S = Single Compressor AT = 380V/3ph/50Hz
T = Two Compressors AU = 400V/3ph/50Hz
-2-
UNIT FEATURES
-3-
UNIT FEATURES
D Compressor discharge temperature and superheat Remote Monitoring And Control
D Current drawn by each compressor
(Option)
D Compressor capacity (percentage of FLA, Full Load
Amps) Dunham-Bush, the leader of HVAC solution provider
understands the arising focus on chiller plant
D Run hours of each compressor
performance and optimization. Several solutions as
D Number of starts of each compressor below are offered to the building owner to achieved
D Electronic Expansion Valve (EEV) Opening optimized chiller plant room controls, operation and
Percentage performance.
D Compressors and condenser fans motors status
D Oil Flow Status, Water Flow Switch Status, Remote Dunham-Bush Chiller Plant Manager (CPM)
Start/Stop Command Status
DB Chiller Plant Manager (CPM) is a trustworthy and
headache-free solution for building owners and users
Capacity Control on chiller plant control and automation system. CPM’s
Leaving chilled water temperature control is advanced controllers monitor and control equipments in
accomplished by entering the water temperature chiller plant such as chillers, primary and secondary
setpoint and placing the controller in automatic control. chilled water pumps, variable frequency drives (VFD),
Micro Vision monitors all control functions and moves motorized valves, bypass modulating valves, and etc.
the compressors slide valve to the required position to Field devices such as flow meters, BTU meters, digital
match the building cooling load demand. power meters, sensors & transducers can be interfaced
with CPM via HLI or LLI. CPM controls chillers and
The compressor ramp (loading) cycle is programmable
pumps sequencing, as well as lead-lag, duty-standby
and may be set for specific building requirements.
and alarm changeover operations.
Remote adjustment of the leaving chilled water setpoint
is accomplished either through High Level Interfacing NetVisorPRO – Monitoring software of CPM system
(HLI) via BMS communication, or Low Level Interfacing which allows system monitoring, historical trending, and
(LLI) via an external hardwired, 4 to 20mA chilled water alarm logging to be carry out at a PC terminal.
reset control signal. Remote reset of compressor Graphical animations on system operation, temperature
current limiting function can be accomplished in a and flow rate trend graphs, historical data and alarm
similar fashion. history logs, settings changes are all available with
NetVisorPRO.
System Control Chiller plantroom control and automation by Dunham-
Bush CPM provides the owners with a chiller system in
The unit may be started or stopped manually, or stable operation, optimized performance and energy
through the use of an external signal from a Building efficiency.
Automation System.
DB-LAN Master Slave Sequencing Control
System Protection (MSS)
The following system protection controls will In a chiller system with multiple Dunham-Bush ACHX-B
automatically act to ensure system reliability: chillers, Micro Vision controller of each chiller can be
D Low evaporator pressure connected to the DB-LAN network via a communication
D High condenser pressure bus without additional controller, to enable Master-
Slave Sequencing Control of this chiller system. MSS
D Freeze protection
will stage in/out chiller in operation to match building
D Compressor oil flow required cooling capacity. Chiller Lead-lag, duty-
D Compressor run error standby and alarm changeover controls are come with
D Power loss MSS, as well as the chilled water pumps control. Each
D Chilled water flow loss MSS DB-LAN network can be connected up to 8
D Sensor error numbers of chillers.
D Compressor over current
D Compressor Anti-recycle Building Management System (BMS)
D High motor temperature Communication
Micro Vision is able to communicate to BMS through
the add-on communication card via various common
protocols as:
D Modbus RTU RS485, ModBus TCPIP
D BACnet over IP, MS/TP, or PTP
D LONworks FTT 10
-4-
OPTIONS AND ACCESSORIES
D Compressor Isolation Valve (Suction & D Condenser Water Pump Control – Condenser
Discharge) – For the ease of servicing water pump is controlled by chiller for enhanced
D Evaporator and Condenser Flanged Connection stable operation
– Flanged connection is available on request D Complete Temperature Monitoring – Entering
D Marine Water Box – Marine water box for evaporator water temperature sensor, leaving and
condenser, for ease of condenser tube cleaning entering condenser water temperature sensors can
without interfere with field water piping be included for complete temperature monitoring of
the unit
D 250 psig Evaporator and Condenser – Evaporator
and condenser vessels with 250 psig working D IP54 Control Panel – IP54 rated control panel can
pressure at water side is available to suite site be supplied for harsh working environment
installation D BMS Communication – Various add-on
D Double Insulation – Evaporator with double think communication cards provide BMS communication
2” [50mm] closed cell insulation, for extra resistance via common protocols: Modbus RTU RS485 /
to condensation TCPIP, LONworks FTT10, BACnet over IP / MSTP /
PTP
D Hotgas Bypass – To maintain unit operation below
minimum unloaded capacity
D ASME / JKKP Compliance – Evaporator,
Factory Supplied - Field Installed by
condenser and desuperheater with ASME / JKKP
approval is available on request
Customer
D Extended Warranty Period for Compressors – D Water Flow Switch – Flow switch to be installed at
Extended compressor warranty is available on evaporator and condenser outlet piping as safety
request interlock to evaporator and condenser water flow
status. Three options are available: Weather tight
flow switch with CE mark; NEMA 3R, and NEMA 4
Electrical Options And Controls rated flow switch
D Rubber-In-Shear Isolators – Designed for ease of
D Ground Fault Interrupt (GFI) – Provides installation. These one-piece molded rubber
equipment with ground fault protection isolators are applicable for most installations.
D Ammeter / Voltmeter – Analog ammeter and D Spring Isolators – These housed spring
voltmeter with 3 phase selector switch for indication; assemblies have a neoprene friction pad at the
located on the control panel bottom to prevent the passage of noise, and a
D Refrigerant Leak Detector – A refrigerant spring locking levering bolt at the top. Neoprene
detection sensor module is connected to micro inserts prevent contact between the steel upper and
vision controller to monitor refrigerant concentration lower housings. Suitable for more critical application
around the unit. Alarm is triggered and unit is shut as compared to rubber-in-shear isolator
down when the refrigerant concentration has D DB-LAN Master Slave Sequencing Control (MSS)
exceeded the preset safety limit Pre-programmed at factory; field supplied and
D Chilled Water Reset / Demand Limiting – Low installed inter-connection wiring between chillers to
level interfacing with Building Automation System provide communication bus among chillers’
(BAS). Chilled Water Reset allows controlled controllers to enable Master-Slave Sequencing
temperature setpoint to be reset by a 4-20mA signal Control
from BAS; while Demand Limiting will limit the D Chiller Plant Manager (CPM) – Factory supplied
maximum current drawn by the compressors by 4- control panel; field supplied and installed
20mA signal from BAS interconnection wiring and field devices; for
D Chilled Water Pump Control – Primary chilled complete chiller plantroom automation
water pump is controlled by chiller’s micro vision
controller for enhanced safety operation
-5-
OPERATING BENEFITS
D Dramatic payback in reduced maintenance and The refrigerant management system is shown in the
overhaul costs both in downtime and in labor refrigerant cycle diagram below.
expenditures
D Ease of troubleshooting through controller retention
of monitored functions
Factory Testing
D Each chiller undergoes the factory testing prior to
unit shipment. This assures consistencies of
workmanship at highest quality
D Thus, all units shipped are completely factory
tested; charged and adjusted according to the
design parameters, for ease of installation and
minimal field start-up adjustments
Control Flexibility
D Controller-based with DDC controller (direct digital
control) features precise push button control over
every aspect of operation with built-in standard
features that maximized energy savings on start-up
and throughout the life of your equipment
D Ensured uniform compressor loading and optimal
energy efficiency through controller to controls
-6-
OPERATING BENEFITS
Liquid refrigerant enters the flooded evaporator PART LOAD PERFORMANCE
uniformly where it absorbs heat from water flowing
through the evaporator tubes, and vaporized. The Through the use of multiple compressors and
vaporized refrigerant is drawn into the compressor economizer on a dedicated model, Dunham-Bush
suction port where the positive displacement WCHX-A Chillers offer a performances meeting most of
compression begins. the industrial requirements when measured in
accordance with AHRI Standard 550/590.
This partially compressed refrigerant gaseous is then
mixed with additional flash refrigerant from the In most cases, actual building system loads are
economizer in the compression chamber. The significantly less than full load design conditions,
compressed gaseous refrigerant is now discharged into therefore chillers operate at part load most of the time.
the internal oil separator, to separate lubrication oil from Dunham-Bush WCHX-A Chillers having multiple rotary
the gaseous refrigerant. screw compressors, economizer and advanced
controller to yield the best total energy efficiency and
The fully compressed and superheated refrigerant is
significant operating savings at part loads.
discharged into the condenser, where water in the
condenser tubes cools and condenses the refrigerant. When specifying air conditioning equipment, it is
Liquid refrigerant leaves the condenser in further sub- important to consider the system load characteristics of
cooled condition by the economizer on a dedicated the building.
chiller models. In a typical city, the air conditioning load varies
according to the changes in the ambient temperature.
The gaseous refrigerant is drawn out from the
Weather data compiled over the years could predict the
economizer and is injected into compressor through the
number of hours that equipment operate at various load
vapor injection port. The remaining liquid refrigerant
percentages.
shall passes through the Electronic Expansion Valve
(EEV) which reduces refrigerant pressure to evaporator The Air Conditioning and Refrigeration Institute (AHRI)
levels where it is then distributed evenly into the has established a system, under AHRI Standard
evaporator. 550/590, for measuring total chiller performance over
full and part-load conditions. It defines the Integrated
Part-Load Value (IPLV) as an excellent method of
comparing equipment for their efficiency on equal
basis. The IPLV is a single number that estimate power
consumption by chiller weighted over number of hours
the unit might operate at each part-load point. IPLV's
are based on AHRI Standard Rating Conditions.
The formula for calculating an IPLV is:
1
IPLV =
0.01 + 0.42 + 0.45 + 0.12
A B C D
-7-
PHYSICAL SPECIFICATIONS
Model 110S 120T 140S 160S 170T 190S 200T 210S 220T 240T 250S 270S 280T
TR 110.0 116.0 135.0 160.0 165.0 187.0 195.0 205.0 215.0 240.0 245.0 268.0 275.0
Nominal Capacity
kW 386.9 408.0 474.8 562.7 580.3 657.7 685.8 721.0 756.2 844.1 861.7 942.6 967.2
Nominal Power Input kW 65.6 69.4 81.6 96.5 99.4 108.0 117.1 121.1 128.0 142.7 147.4 155.7 162.6
kW/TR 0.596 0.598 0.604 0.603 0.602 0.577 0.601 0.591 0.595 0.594 0.602 0.581 0.591
Energy efficiency
COP 5.90 5.88 5.82 5.83 5.84 6.09 5.85 5.95 5.91 5.92 5.85 6.05 5.95
Compressor
Evaporator
Model G7B G8B G8B G9B G8B K5B J4B K6B M1B R3B R3B R4B S2B
USgpm 262.5 276.9 322.2 381.7 394.3 446.3 465.4 489.2 513.0 572.7 584.6 639.6 656.2
Water Flow Rate
L/s 16.6 17.5 20.3 24.1 24.9 28.2 29.4 30.9 32.4 36.1 36.9 40.4 41.4
Psig 3.8 2.7 3.6 4.2 7.3 4.1 8.2 3.8 8.2 6.4 7.1 6.1 8.1
Pressure Drop
kPa 25.9 18.3 25.1 29.2 50.1 28.4 56.5 26.0 56.8 44.0 49.0 41.9 55.9
Condenser
Model D7R HDR HER FCR AHR GCR AHR GBR AJR BLR QDR QFR T7R
USgpm 332.5 350.9 408.9 484.4 500.1 562.8 590.1 618.9 649.7 725.1 741.5 807.2 830.3
Water Flow Rate
L/s 21.0 22.1 25.8 30.6 31.6 35.5 37.2 39.1 41.0 45.8 46.8 50.9 52.4
Psig 4.8 3.6 4.7 8.9 9.7 6.2 12.1 6.0 13.4 10.4 11.6 9.8 12.9
Pressure Drop
kPa 32.8 24.8 32.1 61.6 67.2 43.0 83.3 41.5 92.3 71.4 80.0 67.5 88.7
General
Inch 117 1/2 130 123 3/4 117 3/4 155 1/2 124 1/4 155 3/4 124 1/4 156 4/5 150 4/5 157 1/4 157 1/4 165 1/4
Unit Length
mm 2980 3300 3140 2990 3950 3160 3960 3160 3980 3830 3990 3990 4200
Inch 45 3/7 47 3/5 49 1/5 47 2/5 51 1/2 47 3/5 51 1/2 47 3/5 51 1/2 51 1/2 66 66 62 3/4
Unit Width
mm 1150 1210 1250 1200 1310 1210 1310 1210 1310 1310 1680 1680 1590
Inch 80 78 84 84 78 88 82 88 81 87 81 81 86 1/2
Unit Height
mm 2030 1980 2130 2130 1980 2240 2080 2240 2060 2210 2060 2060 2200
Lbs 5839 7190 7050 7552 8896 8478 9082 8683 9505 10739 10833 11181 12094
Unit Shipping Weight
Kg 2651 3264 3201 3429 4039 3849 4123 3942 4315 4876 4918 5076 5491
Lbs 6396 7871 7738 8232 9727 9334 9927 9598 10427 11895 12082 12562 13416
Unit Operating Weight
Kg 2904 3573 3513 3737 4416 4238 4507 4357 4734 5400 5485 5703 6091
Lbs 291 307 357 423 437 495 516 542 569 635 648 709 728
Approx. R134a Charge
kg 132 139 162 192 198 225 234 246 258 288 294 322 330
Notes: 1. The above data are for premium models with 2-pass evaporator and condenser which rated in accordance with AHRI Standard 550/590 (I-P)-2015
at standard conditions. The standard rating conditions are as below:
Chilled Water Inlet/Outlet Temperature 54/44°F [12.2/6.7oC]; Cooling Water Inlet Temperature 85°F [29.4oC]; Cooling Water Flow Rate 3Usgpm/ton
[0.054 l/s.kW]; Evaporator fouling factor 0.0001hr.ft².°F/Btu [0.000018 m2.oC/W]; condenser fouling factor 0.00025hr.ft².°F/Btu [0.0000144 m2.oC/W];
2-pass evaporator and condenser.
2. To consult nearest Dunham-Bush sales office for computer selections other than above operating conditions.
-8-
ELECTRICAL DATA
Unit Compressor
Model
110S 87 76 82 87 94 91 91 73 98
120T 91 76 80 88 96 93 83 74 99
140S 87 76 82 87 94 91 91 73 98
160S 87 76 82 87 94 91 91 73 98
190S 88 78 83 87 95 92 93 75 99
200T 91 79 84 91 99 96 92 77 102
210S 89 80 84 88 97 94 93 78 100
220T 90 79 85 90 97 94 94 76 101
240T 90 79 85 90 97 94 94 76 101
250S 91 82 86 90 99 96 95 80 102
270S 91 82 86 90 99 96 95 80 102
280T 90 79 85 90 97 94 94 76 101
Note: Sound Pressure Level dB(A) @ 3.3ft [1m] (free field) ± 2dBA.
-9-
DIMENSIONAL DATA
5.13 [130]
HEIGHT
26.29 [668]
52.00 [1321]
102.00 [2591] WIDTH
LENGHT
WCHX-A 120T
5.13 [130]
78.00 [1980]
23.40 [594]
5.63 [143]
15.86 [403]
- 10 -
DIMENSIONAL DATA
WCHX-A 170T
5.13 [130]
78.00 [1980]
23.40 [594]
6.09 [155]
15.86 [403]
WCHX-A 190S
5.63 [143]
88.00 [2240]
25.81 [656]
6.88 [175]
17.86 [454]
- 11 -
DIMENSIONAL DATA
HEIGHT D
23.66 [601]
6.09 [155]
15.86 [403]
5.25 [133]
2.00 [51] TYP
68.00 [1727] 27.90 [709]
134.00 [3404] 16.50 [419]
WIDTH]
LENGTH
WCHX-A 210S
5.63 [143]
88.00 [2240]
25.81 [656]
6.88 [175]
17.86 [454]
- 12 -
DIMENSIONAL DATA
WCHX-A 240T
6.08 [154]
87.00 [2210]
26.89 [683]
6.88 [175]
16.86 [428]
5.25 [133]
2.00 [51] TYP
6.31 [160] 68.00 [1727] 43.50 [1105] 27.90 [709]
134.00 [3404] 10.50 [267]
51.48 [1310]
150.81 [3830]
WCHX-A 250S
81.00 [2060]
8.13 [207]
6.09 [155]
6.75 [171]
16.00 [406] 6.00 [153] TYP
2.00 [51] TYP
33.02 [839] 12.40 [315]
138.00 [3505]
66.00 [1680] MAX.
16.50 [419]
157.25 [3990]
- 13 -
DIMENSIONAL DATA
WCHX-A 270S
81.00 [2060]
8.13 [207]
6.09 [155]
6.75 [171]
16.50 [419] 6.00 [152] TYP
2.00 [51] TYP
16.00 [406] 33.02 [839] 12.40 [315]
138.00 [3505]
157.25 [3990] 66.00 [1680] MAX.
WCHX-A 280T
86.50 [2200]
6.88 [175]
6.09 [155]
- 14 -
FLOOR LOADING DIAGRAM
Single Compressor
P2 P4
CONTROL PANEL
P1 P3
Two Compressors
P2 P4
CONTROL PANEL
P1 P3
110S 1770 [803] 1853 [841] 1187 [538] 1585 [719] 6396 [2901]
120T 2444 [1108] 2345 [1064] 1384 [628] 1698 [770] 7871 [3570]
140S 2394 [1085] 2243 [1017] 1466 [665] 1636 [742] 7738 [3509]
160S 2467 [1119] 2527 [1146] 1464 [664] 1774 [805] 8232 [3733]
170T 2633 [1194] 2611 [1184] 2105 [955] 2378 [1078] 9727 [4411]
190S 2876 [1304] 2987 [1355] 1570 [712] 1901 [862] 9334 [4233]
200T 2680 [1215] 2672 [1212] 2149 [975] 2426 [1100] 9927 [4502]
210S 2844 [1290] 3194 [1449] 1533 [695] 2027 [919] 9598 [4353]
220T 2893 [1312] 2870 [1301] 2175 [986] 2490 [1129] 10427 [4729]
240T 3249 [1473] 3269 [1482] 2507 [1137] 2871 [1302] 11895 [5395]
250S 2960 [1342] 3175 [1440] 2724 [1235] 3224 [1462] 12082 [5480]
270S 3057 [1386] 3282 [1488] 2879 [1306] 3344 [1517] 12562 [5697]
280T 3211 [1456] 3391 [1583] 3281 [1488] 3534 [1603] 13416 [6084]
- 15 -
UNIT CLEARANCE
trouble and result in higher costs for operation,
CLEARANCE FOR SERVICE maintenance and repair.
Sufficient clearance around the unit is required to
Front – 45” [1143mm]
ensure proper unit operation, and as space for service
and maintenance works. Rear – 18” [457mm]
Below clearance requirements are general guideline, Top – 18” [457mm]
where local health and safety regulations and other End – Tube length at one side for tube servicing;
practical considerations shall be taken into account. 36” [914mm] at the other end
Failure to allow these clearances will cause serious
- 16 -
TYPICAL WIRING SCHEMATIC
- 17 -
TYPICAL WIRING SCHEMATIC
∼ ∼
- 18 -
APPLICATION DATA
- 19 -
APPLICATION DATA
necessary control can sometimes be attained via fan refrigerant in the condenser will cause low suction
cycling if the tower is rated at the same capacity as the pressures and possibly liquid slugging of the
chiller’s heat rejection. On multiple chiller jobs, a single compressor. If the condenser water pump is off until
tower is oversized relative to the chiller. On other jobs prior to the chiller starts, the water in the condenser is
the tower/chiller might be oversized to the design load at the chiller room ambient, which is usually much
and the chiller and tower frequently cycle under light closer to the evaporator water temperature.
load. Under these conditions, fan cycling might result in Further to condenser pump control, a 0-10 Vdc analog
very rapid temperature swings, which creates a signal can be output from the chiller’s controller to
dynamic situation to condenser, that potentially cause bypass some of the condenser water flow to maintain
unstable operation. Thus, in this case, either variable chiller’s condenser pressure. Cooling tower fans control
speed fans or modulating valve control should be used is also available to achieve better system efficiency.
to regain control of the condenser water. Either type of
control provides precise modulating control of the Thus, even though there has been a trend toward fan
condenser water rather than on-off step control. The cycling control of cooling towers, it is not a device that
control can be initiated either by a condenser water is suitable to every installation. We recommend that the
temperature sensor/controller or, even better, by direct designer carefully evaluate the system to determine if a
control from the chiller's controller based upon the more precise method of control is indicated. If there is
chiller's condenser pressure. any doubt, the more precise control is required.
It is further recommended that the condenser water Dunham-Bush WCHX-A Chillers have as standard a
pump be cycled by the chiller. This is to eliminate control feature called EPCAS (Evaporator Pressure
potentially very cold water from going through the Control at Start) which will allow for an inverted start.
condenser while the chiller is shut down. At the same This occurs when the chilled water loop in a building is
time it is probable that relatively warmer chilled water is at a higher temperature than the condenser/tower loop.
in the evaporator (an inversion). Refrigerant tends to This occurs in many buildings after a weekend shut
migrate if there is a difference in pressures within the down. The chilled water loop can be as high as 90°F
components of the chiller. It will seek the lowest and the condenser/tower loop as low as 60°F. With the
pressure area of the packaged chiller which, in this EPCAS feature, the valve feeding the evaporator will
case, would be the condenser. Starting of a chiller be throttled to create a pressure differential to help load
where the refrigerant has migrated to the condenser is the compressor.
not desirable. The presence of highly subcooled liquid
GUIDE SPECIFICATIONS
design temperatures. The unit shall be capable of
SCOPE continuous operation at this point, with stable
Supply and commissioning of complete factory compressor operation, without the use of hot gas
assembled water cooled rotary screw chiller(s). The bypass.
rotary screw chiller(s) shall contain rotary screw Heat transfer surfaces shall be selected to reflect the
compressor(s), evaporator, condenser, interconnecting incorporation of a fouling factor of 0.00025
refrigerant piping, electronic expansion valve, control hr.sq.ft.°F/BTU [0.000044m².°C/W] for the water
panel, chilled liquid connections, condenser water condenser and 0.0001 hr.sq.ft.°F/BTU [0.0000176
connections. The control panel shall be fully wired by m².°C/W] for evaporator. Water pressure drop at design
the manufacturer connecting & interlocking controller, conditions shall not exceed ___________ feet of water
starter, electrical protection devices with electrical through the condenser, and ____________ feet of
power and control connections. Packaged chiller shall water through the evaporator.
be factory assembled, charged and tested with a full
operating refrigerant and oil charge. The refrigerant
type shall be R134a. and shall not have phasing out QUALITY ASSURANCE
schedule. D Chiller performance shall be certified by AHRI as
Capacity of each chiller shall be not less than per AHRI 550/590 standard latest edition
_________refrigerant tons (kW output) cooling at D [Optional] ASHRAE Standard 15 safety code for
________ USGPM (liters/min.) of water from mechanical refrigeration
_______°F[°C] to ________°F[°C]. Power input D ASME standard B31.5 for Refrigerant piping
requirements for the unit(s), incorporating all D Vessels shall be fabricated and pressure tested in
appurtenances necessary for unit operation, including
compliance with ASME Boiler and Pressure vessel
but not limited to the control accessories and pumps, if code, Section VIII, Division 1 “Unfired Pressure
required, shall not exceed _______kW input at design
Vessels”
conditions. The unit shall be able to unload to _____%
of cooling (refrigeration) capacity when operating with D [Optional] JKKP code for vessels required in
leaving chilled water and entering condenser water at Malaysia market place
- 20 -
GUIDE SPECIFICATIONS
D Manufacturer shall have experience of minimum 10 be designed, constructed in accordance with the ASME
years in manufacturing water cooled screw chillers Code for Unfired Pressure Vessels. Evaporator shell
in their facility side shall undergo pneumatic pressure test at 220psi,
D Unit shall be manufactured in ISO9001 registered shall be designed for working pressure up to 200psi.
manufacturing facility Tube side shall undergo hydrostatic pressure test at
D Factory run test: Chiller shall be pressure tested, 195psi, shall be designed for 150psi working pressure.
evacuated and fully charged with refrigerant and oil. The flooded evaporator shall have an efficient and
The chiller shall be run tested with water flowing reliable oil recovery system. The oil recovery system
through the vessels will insure the evaporator is operating at peak efficiency
D Manufacturer shall have a service organization with at all times and provide optimal energy efficiency during
trained service personal extended periods of part load. Units without such oil
recovery systems will not be acceptable.
All low temperature surfaces shall be factory insulated
OPERATING REQUIREMENT with 25mm thick Polyethylene resin having K factor of
The unit shall be capable of starting up with entering 0.26 btu-in / hr – ft² – °F.
fluid temperature to the cooler at 95°F. Unit shall be
able to operate with 3-phase 50Hz with unit rated CONDENSER
voltage +/-10%. Control Voltage shall be
115V/1ph/50Hz. Condenser vessel shall be cleanable shell and tube .
Shell shall be fabricated from rolled carbon steel sheet
with fusion welded seams or carbon steel standard
COMPRESSOR AND MOTOR pipes. End plates shall be of carbon steel with precision
The packaged chiller shall be furnished with single- drilling, reamed in order to accommodate tubes.
stage hermetic direct connected positive displacement Intermediate tube support shall be in place to provide
rotary screw compressor(s) as required, driven by a required tube support between tube sheets. Tubes
2900 RPM 2 pole motor. The oil differential pressure shall be of copper, seamless, high efficient, internally
shall be controlled during operation to maintain proper enhanced and externally finned, mechanically
oil lubrication throughout the lubrication system. Each expanded into fixed steel tube sheets. Tube diameter
compressor shall have a suction filter. Compressor shall be ¾ inch and thickness shall be 0.025 inch.
capacity control shall be obtained by an electrically Water box shall be removable for tube cleaning, shall
initiated, hydraulically actuated slide valve within each have stubout water connections with victaulic grooves
compressor. The bearing shall be heavy duty, anti- in compliance to ANSI / AWWAC-606. They are to be
friction tapered roller type, anti-reverse, shall be able to available in one, two or three pass design as required
carry both radial and thrust loads. on the drawings. Vent and drain plugs are to be
provided in water box. The shell side of the condenser
shall have pressure relief valve with provision for
EVAPORATOR refrigerant venting. Condenser refrigerant side shall be
Evaporator vessel shall be cleanable shell and tube, designed, constructed in accordance with the ASME
flooded type. Shell shall be fabricated from rolled Code for Unfired Pressure Vessels. Condenser shell
carbon steel sheet with fusion welded seams or carbon side shall undergo pneumatic pressure test at 220psi,
steel standard pipes. End plates shall be of carbon shall be designed for working pressure upto 200psi.
steel with precision drilling, reamed in order to Tube side shall undergo hydrostatic pressure test at
accommodate tubes. Intermediate tube support shall 195psi, shall be designed for 150psi working pressure.
be in place to provide required tube support between
The condenser shall be sized for full pump down
tube sheets. Tubes shall be of copper, seamless, high
capacity.
efficient, internally enhanced and externally finned,
mechanically expanded into fixed steel tube sheets.
Tube diameter shall be ¾ inch and thickness shall be REFRIGERANT CIRCUIT
0.025 inch. The flooded evaporator shall have a built in The refrigerant circuit shall include oil filter, replaceable
distributor for feeding refrigerant evenly under the tube filter drier on oil return line, sight glass on liquid line,
bundle to produce a uniform boiling action and baffle pressure relief valves on the cooler and condenser,
plates shall be provided to ensure vapor separation. liquid line angle valve for refrigerant charging. The
Water box shall be removable for tube cleaning, shall packaged chiller shall be furnished with an electronic
have stubout water connections with victaulic grooves expansion valve for precise modulation of refrigerant
in compliance to ANSI / AWWAC-606. They are to be flow control and improve efficiency by optimizing the
available in one, two or three pass design as required suction and discharge superheat while protecting
on the drawings. Vent and drain plugs are to be compressor. Fixed orifice control systems will not be
provided in water box. The shell side of the evaporator acceptable. (Option Hot gas bypass shall be factory
shall have pressure relief valve with provision for installed for operation down to approximately 10% of
refrigerant venting. Evaporators refrigerant side shall full load.)
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GUIDE SPECIFICATIONS
ELECTRICAL AND CONTROL PANEL multiple unit that allow sequencing control without
additional hardware. The controller shall be able to
The electrical switch gears, controller, control sensors
carry out all program operations. It shall be able to
and relays shall be housed in NEMA-1 panel. The
display unit operating parameters, compressor
panel casing shall be of galvanized steel with powder
information, alarm history and shall able to modify the
coating for corrosion resistance.
parameters.
The controller shall be able to carry out its own
ELECTRICAL POWER PANEL diagnose test on the controller and the connected
The chiller manufacturer shall provide suitable starter devices and alarm messages shall be displayed
for the compressor motor in order to minimize the automatically on faulty devices.
starting current. The starter shall be factory mounted, All messages shall be displayed in English language.
wired to the motor and controller. The starter shall be shall be displayed either in Imperial or SI units.
able to provide adequate starting torque and the
required acceleration for the compressor during Leaving chilled water temperature control shall be
starting. accomplished by entering the water temperature set
point with accuracy to 0.8°F and placing the controller
NEMA-1 electrical panel compartment shall include: automatic control mode. The controller shall monitor all
D Main incoming power terminal block suitable to control functions and move the compressor slide valve
receive single entry of three phase 3-wire power to the calibrated position. The compressor loading
supply with specified voltage cycle shall be programmable and shall be adjusted to
D Compressor motor over current protection module the building load requirement. The loading adjustable
for each phase range shall be from 0.1% to 0.4% per increment to
D Compressor motor overheat protection prevent excessive demand hike at start up.
D Under/over voltage phase reversal and imbalance The controller shall continuously monitor evaporator
relay leaving water temperature, rate of change of chilled
The compressor starter contactors shall be wired water leaving temperature, evaporator and condenser
securely to the main incoming terminal block. External pressure; compressor amp draw; and discharge
compressor over load protector, over heating refrigerant temperature.
protection, over/under voltage phase relay shall be The controller shall be complete with all hardware and
interlocked with the compressor starter contactors to software necessary to enable remote monitoring of all
provide adequate protection to the compressor motor. data through the addition of an optional web card if
accessing the controller via web or network cards if
linking chiller to the Building Management Systems.
CONTROL PANEL The controller shall be complete with a RS485 long
The packaged chiller shall be equipped with stand distance differential communications port, the remote
along proactive advance controller which adapts to connection shall be established by a twisted pair of
abnormal operation conditions. The unit algorithm wire. The controller shall also accept a remote start and
program and operating parameters shall be stored in stop signal, 0 to 5VDC [optional], chilled water
flash-memory. Battery back-up is not acceptable. 115V temperature reset signal [optional] and 0 to 5VDC
Power supply to the controller shall be provided by a compressor current limit reset signal [optional].
control transformer provided with the panel. External The electrical control panel shall be wired to permit fully
power source to the controller is not acceptable. The automatic operation during - initial start-up, normal
controller shall be equipped with a user friendly operation, and shutdown conditions. The control
terminal with color touch screen LED back lit graphical system shall contain the following control, displays and
display and dedicated touch keys that provides easy safety devices:
access to the unit operating parameters, control set
points and alarm history. There shall be dedicated MANUAL CONTROLS
physical buttons and touch keys enable user to access D Compressor over current
information, based on security level of password. There D Compressor anti-recycle
shall be min three level of password for operator,
D Programmable with Seven day operation cycle
service personnel and for the critical manufacturer
settings in order to protect the chiller controller from D [Optional] chilled liquid and condenser water pump
unauthorized access. on/off control
The controller board shall be provided with a set of AUTOMATIC CONTROLS
terminals that connected to various devices such as
D Compressor motor increment contactors
temperature sensors, pressure transducers, current
D Start delay timer
transducers, solenoid valves, compressor contactors,
D Anti-recycle timer
electronic expansion valve, and controls relays. The
D Oil flow interlock
controller should be able to configured and connected
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GUIDE SPECIFICATIONS
REFRIGERANT FLOW CONTROLS DELIVERY, STORAGE AND HANDLING
D Refrigerant flow control shall be carried out Unit shall be delivered to job site fully assembled with
electronically by a precision electronic expansion all interconnecting refrigerant piping and internal wiring
valve ready for field installation and charged with refrigerant
D Compressor loading and unloading solenoid valves and oil by manufacturer. When delivered, machine shall
be stored indoors, away from construction dirt, dust ,
INDICATOR LIGHTS moisture or any other hazardous material that would
D System common alarm harm the chillers. Inspect under shipping tarps, bags, or
crates to be sure there is no water collected during
The control system shall be provided with an anti- transit. Protective shipping covers shall be kept with the
recycle device. The control shall limit compressor unit until machine is ready for installation.
starting to a minimum of 15 minutes between starts.
WARRANTY
SYSTEM OPERATION INFORMATION
Chiller manufacturer’s warranty shall cover for 12
The chiller display shall provide following operating months from the date of start-up or 18 months from the
information date of shipment whichever is first. The start-up shall
D Leaving chilled water temperature be carried out by a authorized service personnel and
D Leaving chilled water temperature derivative the warranty is limited to part replacement excluding
D Evaporator pressure labor and consumables such as refrigerant, oil & filter
D Condenser pressure driers etc.
D Compressor amps draw for each compressor
D Operating supply Voltage [optional]
D Compressor elapsed run time of each compressor EXECUTION
D Compressor start status
D Oil flow status
D Water temperature re-set value [optional]
INSTALLATION
D Water flow switch status Chiller shall be installed strictly according to
D External start/stop command status manufacturer’s recommendations as stipulated in the
D Percentage of compressor capacity installation manual, drawings and tender documents.
D Electronic expansion valve percentage of opening Care should be taken to provide necessary service
clearance as required in the manufacturer’s drawing.
Install the strainers at the inlet to the evaporator to
SAFETY PROTECTIONS prevent debris or other particles entering to the
D Compressor motor over load protection (3 phase) evaporator during piping work and initial flushing the
D Compressor motor overheat protection system. Required coordination to be done with the
D High discharge temperature protection electrical contractor and the control contractors to
D Under voltage phase failure relay ensure electrical supply and required communications
D Low oil flow links are established.
D High condenser pressure
D Low evaporator pressure START-UP/COMMISSIONING
D Freeze protection (low chilled liquid leaving
Chiller shall be commissioned by a service
temperature )
representative from manufacturer or by their local
D Chilled water flow loss
representative. The service personnel shall be trained
D Compressor run error
and authorized by the manufacturer for start up of the
D Power loss
supplied units. The start-up shall include briefing
D Sensor error operators on chiller operations and maintenance as
D Refrigerant loss well.
D Reverse rotation
Controller shall be able to retain upto 99 alarm
conditions complete with time of failure and all critical
sensor readings. This aids service technicians in their
trouble shooting task enabling downtime and nuisance
trip-outs to be minimized.
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