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wchx-a-r134a-815
wchx-a-r134a-815
wchx-a-r134a-815
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
ECONOMIZER
D The economizer circuit consists of plate type heat
exchanger, expansion valve and solenoid valve on
a dedicated models
D Refrigerant is sub-cooled at economizer before
entering the evaporator; the flash refrigerant from
economizer is fed into compressor at intermediate
pressure and increase the cooling capacity
significantly
Display and User Terminal
The Vision 2020i controller is designed to work with a
user friendly back-lit 132 by 64 pixels PGDE Semi-
Graphic Display panel connected with the controller
CONTROL PANEL through a telephone cable. The terminal display allows
D Electrical enclosure fabricated by heavy gauge carrying out of the unit operations, and also allows the
sheet steel with powder coated baked finishing. unit working conditions, compressor run times and
D Single point power connection for all models alarm history to be displayed. Set points and other
D Main incoming isolator for compressor motor parameters can be modified via the user terminal. The
D Unit mounted reduced inrush starter for compressor display has an automatic self-test of the controller on
system start-up. Multiple messages will be displayed
D Compressor overload protection
automatically by scrolling from each message to the
D Step down transformer for control circuit
next. All of these messages are spelled out in English
D Main power supply monitoring module provide on the display terminal.
protection on under or over voltage, phase reversal,
phase losses and imbalance
-3-
UNIT FEATURES
Easily accessible measurements include: stamping on critical sensor readings in an alarm
D Leaving and entering chilled water temperature condition. This tool will aid service technicians in
D Rate of Change for leaving chilled water troubleshooting tasks enabling downtime and nuisance
temperature trip-outs to be minimized.
D Evaporator and condenser pressure
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 Dunham-Bush, the leader of HVAC solution provider
Amps) 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 water 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
advanced controllers monitor and control equipments in
Leaving chilled water temperature control is chiller plant such as chillers, primary and secondary
accomplished by entering the water temperature chilled water pumps, variable frequency drives (VFD),
setpoint and placing the controller in automatic control. motorized valves, bypass modulating valves, and etc.
Vision 2020i monitors all control functions and moves Field devices such as flow meters, BTU meters, digital
the compressors slide valve to the required position to power meters, sensors & transducers can be interfaced
match the building cooling load demand. 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
NetVisorPRO – Monitoring software of CPM system
is accomplished either through High Level Interfacing
which allows system monitoring, historical trending, and
(HLI) via BMS communication, or Low Level Interfacing
alarm logging to be carry out at a PC terminal.
(LLI) via an external hardwired, 4 to 20mA chilled water
Graphical animations on system operation, temperature
reset control signal. Remote reset of compressor
and flow rate trend graphs, historical data and alarm
current limiting function can be accomplished in a
history logs, settings changes are all available with
similar fashion.
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. In addition, the controller may be
programmed with seven-day operating cycle or other DB-LAN Master Slave Sequencing Control
Dunham-Bush control packages may start and stop the
(MSS)
system through inter-connecting wiring.
In a chiller system with multiple Dunham-Bush chillers,
System Protection Vision 2020i controller of each chiller can be connected
to the DB-LAN network via a communication bus
The following system protection controls will without additional controller, to enable Master-Slave
automatically act to ensure system reliability: Sequencing Control of this chiller system. MSS will
D Low evaporator pressure stage in/out chiller in operation to match building
D High condenser pressure required cooling capacity. Chiller Lead-lag, duty-
D Freeze protection standby and alarm changeover controls are come with
D Compressor oil flow MSS, as well as the chilled water pumps control. Each
D Compressor run error MSS DB-LAN network can be connected up to 8
numbers of chillers.
D Power loss
D Chilled water flow loss Building Management System (BMS)
D Sensor error Communication
D Compressor over current
Vision 2020i is able to communicate to BMS through
D Compressor Anti-recycle
the add-on communication card via various common
D High motor temperature protocols as:
The controller can retain up to 99 alarm histories D Modbus RTU RS485, ModBus TCPIP
complete with time of failure together with data
D BACnet over IP, MS/TP, or PTP
-4-
OPTIONS AND ACCESSORIES
D LONworks FTT10 D Condenser Water Pump Control – Condenser
D Compressor Isolation Valve (Suction & water pump is controlled by chiller for enhanced
Discharge) – For the ease of servicing stable operation
D Evaporator and Condenser Flanged Connection D Complete Temperature Monitoring – Entering
– Flanged connection is available on request evaporator water temperature sensor, leaving and
D 250 psig Evaporator and Condenser – Evaporator entering condenser water temperature sensors can
and condenser vessels with 250 psig working be included for complete temperature monitoring of
pressure at water side is available to suite site the unit
installation D IP54 Control Panel – IP54 rated control panel can
D Double Insulation – Evaporator with double think be supplied for harsh working environment
2” [50mm] closed cell insulation, for extra resistance D BMS Communication – Various add-on
to condensation communication cards provide BMS communication
D Hotgas Bypass – To maintain unit operation below via common protocols: Modbus RTU RS485 /
minimum unloaded capacity TCPIP, LONworks FTT10, BACnet over IP / MSTP /
D ASME / JKKP Compliance – Evaporator, PTP
condenser and desuperheater with ASME / JKKP
approval is available on request
D Extended Warranty Period for Compressors –
Factory Supplied - Field Installed by
Extended compressor warranty is available on Customer
request
D Water Flow Switch – Flow switch to be installed at
evaporator and condenser outlet piping as safety
interlock to evaporator and condenser water flow
Electrical Options And Controls status. Three options are available: Weather tight
flow switch with CE mark; NEMA 1, and NEMA 4
D Ground Fault Interrupt (GFI) – Provides
rated flow switch
equipment with ground fault protection
D Rubber-In-Shear Isolators – Designed for ease of
D Ammeter / Voltmeter – Analog ammeter and
installation. These one-piece molded rubber
voltmeter with 3 phase selector switch for indication;
isolators are applicable for most installations.
located on the control panel
D Spring Isolators – These housed spring
D Refrigerant Leak Detector – A refrigerant
assemblies have a neoprene friction pad at the
detection sensor module is connected to vision
bottom to prevent the passage of noise, and a
2020i controller to monitor refrigerant concentration
spring locking levering bolt at the top. Neoprene
around the unit. Alarm is triggered and unit is shut
inserts prevent contact between the steel upper and
down when the refrigerant concentration has
lower housings. Suitable for more critical application
exceeded the preset safety limit
as compared to rubber-in-shear isolator
D Chilled Water Reset / Demand Limiting – Low
D DB-LAN Master Slave Sequencing Control (MSS)
level interfacing with Building Automation System
Pre-programmed at factory; field supplied and
(BAS). Chilled Water Reset allows controlled
installed inter-connection wiring between chillers to
temperature setpoint to be reset by a 4-20mA signal
provide communication bus among chillers’
from BAS; while Demand Limiting will limit the
controllers to enable Master-Slave Sequencing
maximum current drawn by the compressors by 4-
Control
20mA signal from BAS
D Chiller Plant Manager (CPM) – Factory supplied
D Chilled Water Pump Control – Primary chilled control panel; field supplied and installed
water pump is controlled by chiller’s vision 2020i interconnection wiring and field devices; for
controller for enhanced safety operation complete chiller plantroom automation
-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 90S 110S 120T 140S 160S 170T 190S 200T 210S
TR 85.0 110.0 116.0 135.0 160.0 165.0 187.0 195.0 205.0
Nominal Capacity
kW 298.9 386.9 408.0 474.8 562.7 580.3 657.7 685.8 721.0
Nominal Power Input kW 51.6 65.6 69.4 81.6 96.5 99.4 108.0 117.1 121.1
kW/TR 0.606 0.596 0.598 0.604 0.603 0.602 0.577 0.601 0.591
Energy efficiency
COP 5.80 5.90 5.88 5.82 5.83 5.84 6.09 5.85 5.95
Min % Unit Capacity % 25 25 12.5 25 25 12.5 25 12.5 25
Power Supply 400V/ 3Ph/ 50Hz
Compressor
1612 (1)
Model (Qty) 1612 (1) 1616 (1) 1315 (2) 1912 (1) 1915 (1) 1612 (2) 1917 (1) 1917 (1)
1616 (1)
Evaporator
Model D7B G7B G8B G8B G9B G8B K5B J4B K6B
USgpm 202.8 262.5 276.9 322.2 381.7 394.3 446.3 465.4 489.2
Water Flow Rate
L/s 12.8 16.6 17.5 20.3 24.1 24.9 28.2 29.4 30.9
Psig 3.4 3.8 2.7 3.6 4.2 7.3 4.1 8.2 3.8
Pressure Drop
kPa 23.2 25.9 18.3 25.1 29.2 50.1 28.4 56.5 26.0
Design Press. Water Side Psig[kPa] 150 [1034]
Water Connection Size Inch 5 5 5 5 5 5 6 5 6
Condenser
Model D9R D7R HDR HER FCR AHR GCR AHR GBR
USgpm 257.5 332.5 350.9 408.9 484.4 500.1 562.8 590.1 618.9
Water Flow Rate
L/s 16.3 21.0 22.1 25.8 30.6 31.6 35.5 37.2 39.1
Psig 4.4 4.8 3.6 4.7 8.9 9.7 6.2 12.1 6.0
Pressure Drop
kPa 30.5 32.8 24.8 32.1 61.6 67.2 43.0 83.3 41.5
Design Press. Water Side Psig[kPa] 150 [1034]
Water Connection Size Inch 6 6 8 8 8 8 10 8 10
General
Inch 124 1/4 117 1/2 130 1/16 123 3/4 117 3/4 155 1/2 124 1/4 155 3/4 124 1/4
Unit Length
mm 3160 2980 3300 3140 2990 3950 3160 3960 3160
Inch 44 45 7/16 47 1/2 49 3/16 47 3/8 51 1/2 47 9/16 51 1/2 47 9/16
Unit Width
mm 1120 1150 1210 1250 1200 1310 1210 1310 1210
Inch 78 80 78 84 84 78 88 82 88
Unit Height
mm 1980 2030 1980 2130 2130 1980 2240 2080 2240
Lbs 5013 5839 7190 7050 7552 8896 8478 9082 8683
Unit Shipping Weight
Kg 2273 2648 3261 3197 3425 4035 3846 4120 3939
Lbs 5476 6396 7871 7738 8232 9727 9334 9927 9598
Unit Operating Weight
Kg 2483 2901 3570 3509 3733 4411 4233 4502 4353
Lbs 255 291 307 357 423 437 495 516 542
Approx. R134a Charge
kg 102 132 139 162 192 198 225 234 246
-8-
ELECTRICAL DATA
Unit Compressor
Model
WCHX-A Min. Circuit
Power Supply Max. Fuse Size Model (Qty) RLA (Qty) LRA (Qty)
Ampacity
90S 69 58 64 69 76 73 73 55 80
110S 69 58 64 69 76 73 73 55 80
120T 73 58 62 70 78 75 65 56 81
140S 69 58 64 69 76 73 73 55 80
160S 69 58 64 69 76 73 73 55 80
170T 73 61 65 73 81 78 68 59 84
190S 69 59 64 68 76 73 74 56 81
200T 72 61 66 72 80 77 73 58 83
210S 70 61 65 69 78 75 74 59 82
220T 71 60 66 71 78 75 75 57 82
240T 71 60 66 71 78 75 75 57 82
250S 72 63 67 71 80 77 76 61 83
270S 72 63 67 71 80 77 76 61 83
280T 71 60 66 71 78 75 75 57 82
300T 71 60 66 71 78 75 75 57 81
330T 70 59 65 70 77 74 74 56 81
380T 73 64 68 72 81 78 77 62 84
Note: Sound Pressure Level dB(A) @ 3.3ft [1m] (free field) ± 2dBA.
-9-
DIMENSIONAL DATA
WCHX-A 90S
78 [1980] 4 [102]
21 [532]
5 3/4 [143]
14 3/4 [377]
7/8"[22] MOUNTING
6 1/2 [165] HOLES X 4 NOS 2 [51] TYP
24 3/4 [630]
52 [1321]
15 3/4 44 [1120]
102 [2591]
[400]
124 1/4 [3160]
5 1/4 [130]
HEIGHT
2 [51] TYP
5 1/4 [133]
26 1/4 [668]
52 [1321]
102 [2591] WIDTH
LENGHT
- 10 -
DIMENSIONAL DATA
WCHX-A 120T
5 1/4 [130]
78 [1980]
23 1/2 [594]
5 3/4 [143]
15 3/4 [403]
WCHX-A 170T
5 1/4 [130]
78 [1980]
23 1/2 [594]
6 [155]
15 3/4 [403]
- 11 -
DIMENSIONAL DATA
WCHX-A 190S
5 3/4 [143]
88 [2240]
25 3/4 [656]
7 [175]
17 3/4 [454]
HEIGHT D
23 11/16 [601]
6 1/16 [155]
15 7/8 [403]
- 12 -
DIMENSIONAL DATA
WCHX-A 210S
5 5/8 [143]
88 [2240]
25 13/16 [656]
6 7/8 [175]
17 7/8 [454]
WCHX-A 240T
87 [2210]
6 1/16 [154]
26 7/8 [683]
6 7/8 [175]
16 7/8 [428]
5 1/4 [133]
68 [1727] 43 1/2 [1105] 2 [51] TYP
6 5/16 [160]
134 [3404] 10 1/2 [267] 27 7/8 [709]
150 13/16 [3830] 51 7/16 [1310]
- 13 -
DIMENSIONAL DATA
WCHX-A 250S
81 [2060]
8 1/8 [207]
6 1/16 [155]
WCHX-A 270S
81 [2060]
8 1/8 [207]
6 1/16 [155]
- 14 -
DIMENSIONAL DATA
WCHX-A 280T
86 1/2
[2200]
6 7/8
[175] 6 1/16
[155]
20 1/4 18 1/4
[514] [463]
WCHX-A 300T
CONTROL PANEL
Ø8[203]
COMPRESSOR
Ø10[254] Ø8 [Ø203]
Ø10[254]
88
[2240]
7 3/8
[187] 6 7/8
[175]
21 3/16 19 3/16
[539] [488]
- 15 -
DIMENSIONAL DATA
WCHX-A 330T
CONTROL PANEL
Ø8[203]
COMPRESSOR
Ø8[203]
Ø10[254]
Ø10[254]
91
[2310]
8 1/8
6 7/8
[207]
[175]
20 3/4 19 3/16
[527] [488]
6 [152]
6 3/4 [171]
11 [279] TYP
2 [51] TYP 16 7/16 13 3/8
32 3/8 [822]
151 [3835] [417] [339]
164 1/2 [4180] 70 [1780] MAX
WCHX-A 380T
CONTROL PANEL
Ø10[254]
Ø12[305]
99
[2510]
MAX
24 3/16
[615] 23 1/4 [590]
- 16 -
FLOOR LOADING DIAGRAM
Single Compressor P2 P4
CONTROL PANEL
P1 P3
Two Compressors
P2 P4
CONTROL PANEL
P1 P3
90S 1359 [616] 1385 [628] 1243 [564] 1490 [676] 5476 [2483]
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]
300T 3660 [1796] 3835 [1739] 4136 [1876] 4250 [1927] 16181 [7338]
330T 4215 [1912] 4062 [1842] 4409 [2000] 4550 [2063] 17236 [7817]
380T 5946 [2696] 7366 [3340] 5626 [2552] 6463 [2931] 25400 [11519]
- 17 -
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
- 18 -
TYPICAL WIRING SCHEMATIC
- 19 -
TYPICAL WIRING SCHEMATIC
∼ ∼
- 20 -
APPLICATION DATA
- 21 -
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
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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
water leaving temperature, evaporator and condenser
The compressor starter contactors shall be wired
pressure; compressor amp draw; and discharge
securely to the main incoming terminal block. External
refrigerant temperature.
compressor over load protector, over heating
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,
service personnel and for the critical manufacturer D Programmable with Seven day operation cycle
settings in order to protect the chiller controller from D [Optional] chilled liquid and condenser water
unauthorized access. pump 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
and oil by manufacturer. When delivered, machine shall
valves
be stored indoors, away from construction dirt, dust ,
moisture or any other hazardous material that would
INDICATOR LIGHTS harm the chillers. Inspect under shipping tarps, bags, or
D System common alarm 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
be carried out by a authorized service personnel and
D Leaving chilled water temperature
the warranty is limited to part replacement excluding
D Leaving chilled water temperature derivative labor and consumables such as refrigerant, oil & filter
D Evaporator pressure driers etc.
D Condenser pressure
D Compressor amps draw for each compressor
D Operating supply Voltage [optional]
D Compressor elapsed run time of each
EXECUTION
compressor
D Compressor start status INSTALLATION
D Oil flow status Chiller shall be installed strictly according to
D Water temperature re-set value [optional] manufacturer’s recommendations as stipulated in the
D Water flow switch status installation manual, drawings and tender documents.
D External start/stop command status Care should be taken to provide necessary service
D Percentage of compressor capacity clearance as required in the manufacturer’s drawing.
D Electronic expansion valve percentage of opening Install the strainers at the inlet to the evaporator to
prevent debris or other particles entering to the
evaporator during piping work and initial flushing the
SAFETY PROTECTIONS system. Required coordination to be done with the
D Compressor motor over load protection (3 phase) electrical contractor and the control contractors to
D Compressor motor overheat protection ensure electrical supply and required communications
D High discharge temperature protection links are established.
D Under voltage phase failure relay
D Low oil flow
START-UP/COMMISSIONING
D High condenser pressure
D Low evaporator pressure Chiller shall be commissioned by a service
D Freeze protection (low chilled liquid leaving representative from manufacturer or by their local
temperature ) representative. The service personnel shall be trained
D Chilled water flow loss and authorized by the manufacturer for start up of the
D Compressor run error supplied units. The start-up shall include briefing
D Power loss operators on chiller operations and maintenance as
D Sensor error well.
D Refrigerant loss
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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