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bull ACWC-SD
bull Screw Typebullbullbull Air-Cooled Packaged Chillers bullbull Installation Operation and bullbull Maintenance Manualbullbullbullbullbullbull DESCRIPTION
TABLE OF CONTENTS
Inspection amp Handling
bull Location and Mounting Wiring Chiller Pipingbullbull Start-Up
bull Maintenance
bull Slide Valve Unloading System Low Ambient Operation Control Settings Unit Operating Limitations Sequence of Operation
bull Safety Controls Field Wiring Star Delta Startbull Control Wiring Diagramsbull ACWC 40 thru 70 ACWC 90 thru 135 ACWC 145 thru 200 ACWC 215 thru 265 Power Wiring Diagrams ACWC 40 thru 70 ACWC 90 thru 135 ACWC 145 thru 200 ACWC 215 thru 265 Electrical Data Cooler Pressure Drops Unit LoadingSuspension Points Troubleshooting Guide Causes amp Prevention of Freeze-Up bull Start-up Check Listbull Operating Data Maintenance
bullbullbullForm No 6184
PAGE NO 2 2 2 2
2 amp 3 3 4 5 5 5
6 amp 7 7
8 amp 9 10 amp 11 12 amp 13 14 amp 15
16 16 17 17
18 amp 19 20 21 22 22 23 24 24
DUNHAM-BUSH USA
INSPECTION amp HANDLING CHILLER PIPING
When unit is received it is the responsibility of the contractor to inspect the unit for shipping damage at time of off loading and make note of damage on carriers freight bill
ACWC units are factory mounted on (2) carbon steel angle beams Sizes 45 thru 90 have three lifting holes per side Sizes 110 thru 215 have four lifting holes per side and sizes 240 thru 265 have five lifting holes per side to facilitate lifting
Spreader bars must be used between rigging lines to prevent damage to the unit Rollers may be used under the skids to facilitate moving the unit a short distance
Models ACWC-40DF thru 22DC are factory mounted on two permanent angle beam carbon steel skids A minimum of four 2 78 lifting eyes are provided in the skids to allow rigging Physical damage to the unit after acceptance is not the responsibility of the factory
LOCATION amp MOUNTING
Model ACWC Air Cooled Packaged Water Chillers are designed for outdoor application and may be mounted on roof or at ground level Air lIow through the condenser is vertical and the unit may be located adjacent to outside of building or on roof without regard for prevailing wind direction
Since these units are air cooled the flow of air to and from the condenser coil must not be impeded There must be no obstruction above the unit that would tend to dellect discharge air downward where it could be recirculated back to the inlet of the unit The required overhead air space should be a minimum of eight feet Ductwork must not be applied to the fan outlets
The unit must be installed with sufficient clearance for air entrance to the condenser coil and for servicing access The unit should be located no closer than four feet from any wall or other obstruction Clearance must be provided at either end of the unit to permit removal of tubes from the chiller
Unit must be set on a solid and level foundation
On roof installations the unit should be mounted on support beams which span load-bearing walls to prevent excessive vibration
On ground level installations the unit should be mounted on a substantial base that will not settle A one-piece concrete slab with footings extended below the frost line is recommended A space should be left between the slab and the building to prevent the transmission of sound and vibration
Vibration mounts may be used for roof-mounted units or other locations where noise might be objectionable
WIRING
A unit wiring diagram showing the required power supply characteristics and all factory supplied wiring details are provided with unit Separate field supplied disconnects must be installed for the power and control circuits and should be within the sight of the unit
Separate 115-volt power source must be field supplied to provide power for control and heater circuits if optional control circuit transformer is not provided All electrical connections should be periodically tightened
The chiller inlet (return) water pipe should be connected to the water connection closest to the control panel end of the unit and the outlet (supply) water pipe connected to the water connection on the opposite end of the cooler(s)
A flow switch must be installed in a straight horizontal section of the chilled water piping This is to be field installed
Gauges should be installed in the piping to and from the chiller to measure the pressure drop and to insure the proper (GPM) flow rate in accordance with submittal data A strainer should be installed in the piping on the inlet side of the chiller and vibration eliminators should be employed on both the inlet and outlet pipes Air vents should be located at all high points in the piping system Vents should be located to be accessible to servicing Drain connections should be provided at all low points to permit complete drainage of chiller and piping system
The chilled water piping should be insulated to reduce heat pickup and to prevent condensation If the system is for year-round operation or if it will not be drained in the winter the chilled water piping should be protected against freezing by electric heating cable or other suitable means
Upon completion of chiller piping start the system water pump and purge air from the system Air purging should be done from the high points in the water circuit Purging of the chiller barrel may be accomplished through the vent pipe located on the top of the chiller compartment Failure to purge air from the water circuit will result in inadequate water flow and may cause the unit to cutout
STARTmiddotUP Refer to start test and check list included with this manual
2
CAUTION
The discharge line valve must be open before starting the compressor Liquid line valves must also be open for sustained operation
All compressors are solid mounted on isopads therefore compressor hold-down bolts must not be loosened Loosening these bolts will cause excessive vibration of the compressor and may result in refrigerant line breakage Prior to start-up check all compressor hold-down bolts for tightness
MAINTENANCE
CONDENSER Units are equipped with direct drive fans that have inherently protected motors with permanently lubricated bearings
The air inlet of the condenser coil should be kept clean through a regular maintenance program
COMPRESSOR
1 OIL LEVEL - The oil level in the compressor(s) should be checked periodically with the compressor either running or stopped If the oil level is below one-half (12) the sight glass oil must be added
2 RECOMMENDED OIL -- The unit 4 factory-charged with DB SR-30 refrigeration 01
Do not add any other type of oil to this factory charge
Do not operate compressor If 011 level Is below one-half (12) sight glass
If the oil level is below the minimum specified above and DB SR-30 is not on hand you may drain the entire factory oil charge then refill with SUNISO 4GS refrigeration oil The factory (DB) oil is of the synthetic type and will not mix with SUNISO 4GS Do not attempt to operate the screw compressor with any oil other than these two specified above
It is suggested that a gallon or mom of DB SR-30 oil be obtained and kept on hand at the job site The substitution of SUNISO 4GS oil as outlined above will result in a 2 to 491 capacity loss and no reduction in input KW
PROCEDURE FOR ADDING OIL
Install temporary jumper wire around LPcontrol contacts of circuit to be serviced Manually close liquid line service valve Lower return water T-STAT (T1) setting to start compressor Run compressor until minimum positive pressure reading on suction service gauge (Do not run compressor in vacuum) Place the system onoff switch in the off position Close the line valve in the discharge line between compressor amp condenser Equalized pressure should now be a minimum of refrigerant vapor Reopen discharge line valve Remove jumper wire from pressure control Open liquid line service valve
3 COMPRESSOR REPAIRS (internal) - Contact factory or an authorized DB Service Agency if a compressor malfunction is suspected
4 COMPRESSOR REPAIRS (External) - Proper operation of unloaded ban loading and unloading is controlled by solenoid valves UL-1 UL-2 and UL-3 Any of these three (3) solenoid valves may be repaired or replaced in the field as required
5 Standard oil acid test kit is not compatible with synthetic oil See DB color chart for oil condition
HIGHPRESSURE PORT
SIGHT GLASS I
CRANKCASE HEATER
3
SLIDE VALVE UNLOADING SYSTEM
The Rotary screw compressor capacity control system for infinite modulation consists of a slide valve and hydraulic pistoncylinder operator intemal to the compressor plus three hydraulic solenoid valves (UL-1 UL-2 amp UL-3)
The slide valve forms a portion of the chamber wall in which the rotors turn thus its position with respect to the rotors determines the effective rotor length and thereby the percent of full load capacity
Upon compressor start-up UL-3 is opened This allows oil pressure to act upon the hydraulic piston holding it in the fully unloaded position After 30 seconds during which time full oil flow is established to all bearings surfaces UL-3 is closed At this point the temperature controller is free to open and close UL-1 or UL-2 in response to the supply water temperature
The slide valve will move to the left (loading) by force of discharge pressure whenever UL-1 opens to permit flow to the oil return (low
Load
centJ
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Slide Valve
Unload
~ Oil Pressure
Oil Pressure Lines
Hydraulic Piston
pressure) line The slide valve will move to the right (unloading) whenever UL-2 opens the oil supply (high pressure) line since the force of the oil exceeds that of the discharge gas
The temperature controller sends a series of power (energizing) pulses to the appropriate solenoid to adjust to load conditions The further the supply water temperature is from the controller set point the longer is the duration of the pulses The series of pulses will continue until the controller is satisfied As the water temperature approaches the set point the pulses become quite brief to prevent overshooting the set point
This method of compressor unloading in conjunction with supply water sensing minimizes actionreaction lag time and overshoot resulting in an exceptionally precise and stable control of supply water temperature
Oil Oil Return Supply
The following table lists solenoid valve position for all three operating modes
UL-1 UL-2 UL-3 Starting Close Close Open Loadinq Open Close Close Unloading Close Open Close
4
LOW AMBIENT OPERATION
Due to the wide range of applications it is sometimes necessary to operate the Air Cooled Packaged Water Chillers at ambients below summer conditions Without proper control when ambients drop below 60degF the pressure differential between the condenser and the evaporator is below the level to insure proper thermal expansion valve operation As a result the unit may cycle off Two types of system control are available allowing the units to operate at the ambients indicated
FAN CYCLING MEDIUM AMBIENT CONTROL TO 30degF
(STANDARD EQUIPMENT-FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water Chillers to provide proper operating head pressures in ambient conditions to 30degF
This is an automatic operation in which the condenser fans are cycled on and off as required in response to head pressure This arrangement provides positive start-up control down to +30degF by delaying the condenser fan operation until a predetermined head pressure is obtained
LOW AMBIENT CONTROL TO OdegF
In conjunction with the standard fan cycling feature all compressors are enclosed in individual housings This housing assures adequate compressor oil temperature for lubrication A five minute time delay relay provides a bypass around the low pressure control to prevent nuisance trip-out during cold start up
COOLER FREEZE PROTECTION-LOW AMBIENT
Cooler freeze protection is a major concern with air cooled chillers To protect against freeze-up a heater cable is provided as standard which protects the cooler to -12degF However there is no freeze protection in the event of power failure or heater cable burnout so the following should be considered for additional protection
1 Drain the cooler and chilled water piping if the chiller is not to be operated over the winter months Drain connections are provided on the coolers
2 Add ethylene glycol to the chilled water system Freeze point should be approximately 10degFbelow minimum design ambient temperature See Page 11 for Glycol Performance
The cooler heater is wired to the control panel and is operational from the factory offered control transformer or field supplied control power
COOLER FREEZE PROTECTION-oPERATION
The ACWC-SD chiller is provided with a temperature sensing freezstat (38deg set point) and a field installed flow switch shutting off the compressors on loss of water flow is also required
Optional low pressure or hot gas bypass freeze protection is also available on the ACWC-SD If these options have not been purchased it is extremely important to guarantee proper chiller water gpm as well as double checking the temperature sensing freezstat calibration
ACWC-SD CONTROL SETTINGS
CUT-INCUT-OUT (PSIG)
UNIT FLP1 FLP2 FLP3 FLP4 FLP5 FLP6 FLP7 FLP8 FLP9 FLP10 FLP11 FLP12 FLP13 FLP14 ISM 44-55 280170 295180
70 260160 275175 2901215
90 260160 275175 2901215 260160 275175 2901215
110-135 260160 2751175 2851210 2951235 2601160 275175 285210 2951235
145-160 280170 2951180 260160 275175 2901215 260160 275175 2901215
185-200 280170 295180 260160 275175 2951235 2951235 260160 275175 285210 2951235 215 260160 275175 2901215 260160 2901215 2901215 260160 275175 290215 260160 275175 290215
240 260160 260160 275175 275175 2901215 2901215 260160 260160 275175 275175 2851210 2851210 295235 2951235
265 260160 260160 275175 275175 2851210 2851210 295235 2951235 260160 260160 275175 275175 285210 2851210 2951235
TEMPERATURE ACTUATED LEGEND FACTORY SETTING
Chiller Low Water Temperature Thermostat T2 Cut-Out 3rF Chiller Heater Thermostat
I(Non-Adiustable) Included With CBH1 Heater
Cut-In Cut-Out
40degF 45degF
Oil Temperature Safety Control (Adjustable) Manual Reset
OTS 1 OTS 2 OTS3
Cut-Out 240degF
Capacity Control Thermostat (Adj) Mode Control Position T1 Dial Set At 44degF
UNIT OPERATING LIMITATIONS
1 Maximum ambient air to condenser is 110degF (60 Hertz operation) 2 Maximum allowable cooler water pressure is 150 PSIG 3 Maximum allowable water temperature to cooler is 75degF 4 Units must not have leaving water temperatures of 42degF or lower unless used with a glycol solution
5
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory The following key shows how the indexing system can be used
12 Line number on wiring diagram
[12] Line number in text
(R5) Component identification symbol in text (Relay 5)
[E] Normally open contact - line number location
[E] Normally closed contact - line number location
Holding coil - line number location
amp Note number
SEQUENCE OF OPERATION (TYPICAL) MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models Refer to the wiring diagram furnished with the unit for specific information ( ) Control Identification Symbol [ ] Circuit Line Number
Important Notel With all the control circuit switches (SW1-SW3) in the off position and the staging thermostat (T1) to its highest temperature Terminals 2 and 4 on the Terminal Board (TER5) must have 115 volts supshyplied for a minimum of 24 hours to energize the compressor crankshycase heaters (CCH1 2) [6 8]
Preliminary Sequence Close the main power disconnect switch Check to see that the red indicating light on the phase loss monitor (PLM 1) is lit (Note There will be two phase loss monitors (PLM1) and (PLM2) on dual power block models) This light must be on to indicate proper phase rotation for the compressors If the light is not on disconnect the main power and reverse any two phase legs at the Main Incoming Power Terminal Block (WARNING DO NOT REVERSE THE LEADS ON THE PHASE LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS TO RUN BACKWARDS CAUSING SEVERE DAMAGE AND WILL VOID THE COMPRESSOR WARRANTY)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed and are supplying power to the compressor crankcase heaters Power is also supplied to the chiller barrel heater (CBH1) [13) the optional receiver heaters (RH1 2 [1011] and the optional convenience outlet (CO) [14]
Control power goes through the control panel circuit breaker (CB1) [8] and field supplied remote time clock [36] Check to make sure time clock contacts close during occupied modes
Start up the chilled water pump The water flow is confirmed when the water flow switch completes the electrical circuit across Terminals 15 and 16 [38] on Terminal Board (TER5) Terminals 17 [47] and 18 [49] provide an interlock for the water pump starter(s) when either compressor is in operation Set the thermostat (T1) to the desired leaving water temperature (eg 44degF) Set point adjustment is acshycomplished directly on the control
Place the three (3) control circuit switches (SW1-SW3) in the On position thus energizing the balance of the control circuit [23] [33] [36] The system will be in the Time-In mode for five minutes before the first compressor will start
The low ambient lockout thermostat (LAT1) [38] and temperature freezestat (T2) [38] must also be satisfied to allow compressor operashytion
Stage 1 Starting Upon demand for cooling thefirst stepof the staging thermostat (T1) will be to close energizing relays (R1) [61] time delay (TD1) [60] and the optional time delay (TD3) [62] If all the safety controls and switches are closed (see Safety Controls section for more detail) the control
circuit for Compressor No1 will energize allowing the compressor to start Relay (R5) [20] will energize closing the normally open (NO) set of contacts [23] which energize the liquid line solenoid valve (SOL1) [23] Another set of NO contacts on (R5) [20) provide a series intershylock with all the safety and operating controls which will lock out the compressor if any safety trips during normal operation (See Note 6 on Wire Diagram) The last set of NO contacts on (R5) [48) provides an interlock circuit for the water circuiting pump(s)
The fan contactor (C13) [23] will also close supplying power to the side of the fan cycling pressure controls (See Power Wiring Diagram)
Note The fan motors are controlled by their own fan cycling controls and will cut in at different factory set head pressures
Time Delay (TD1) [601) has two (2) sets of contacts the first set of (TD1) [19] normally closed (NC) contacts provide a 30 second jumper around the low pressure control (LP1) [20] to prevent short cycling during start-up The second set of (TD1) [24) contacts in the NC posishytion power the unloader solenoid (UL3-1) [24] which hold the comshypressor in the full unload position for 30 seconds After (TD1) [60] times out (30 seconds) the contacts for the unloader solenoid (UL3-1) open and the NO set close which energize the relay (R3) [25]
Stage 1 Modulation Upon energizing relay (R3) [25) the crankcase heater (CCH 1) [6] is de-energized and the NO contacts of relay (R3) [45 48] are closed allowing the thermostat (T1) to energize the load solenoid (UL1-1) [45) and the unload solenoid (UL2-1) [481] upon demand The opshytional time delay (TD3) [62] is used to bypass low pressure control (LP1) [20] for five minutes for low ambient starts
Stage 2 Starting Subsequent to the start of Compressor No1 an approximate five minute time delay is incorporated into the microprocessor After this time delay and a further call for cooling the second step of the stagshying thermostat (T1) will close This will energize relay (R2) [58] time delay (TD2) [57] and the optional time delay (TD4) [59] If all the safety controls and switches are closed (see Safety Control section for more details) the control circuit for Compressor No2 will energize allowing the compressor to start Relay (R6) [3D] will energize allowshying the liquid line solenoid valve (SOL2) [331] to energize Relay (R6) [3D]will also interlock the water pump starters and the safety controls the same as Compressor No 1 circuit
The fan contactor (C14) [33] will close supplying power to the line side of the fan cycling pressure controls (See Power Wiring Diagram)
Time delay (TD2) will provide a 30 second jumper around the low pressure control (LP2) [30] and will energize the full unload solenoid (UL 3-2) [34] for 30 seconds then energize relay (R4) [35]
Upon energizing relay (R4) [35] the crankcase heater (CCH2) [8] is de-energized and the NO contacts of relay (R4) [46 49) are closed allowing the thermostat (T1) to energize the load solenoid (UL2-1) [46] and the unload solenoid (UL2-2) [49] upon demand
6
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
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Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
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1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
INSPECTION amp HANDLING CHILLER PIPING
When unit is received it is the responsibility of the contractor to inspect the unit for shipping damage at time of off loading and make note of damage on carriers freight bill
ACWC units are factory mounted on (2) carbon steel angle beams Sizes 45 thru 90 have three lifting holes per side Sizes 110 thru 215 have four lifting holes per side and sizes 240 thru 265 have five lifting holes per side to facilitate lifting
Spreader bars must be used between rigging lines to prevent damage to the unit Rollers may be used under the skids to facilitate moving the unit a short distance
Models ACWC-40DF thru 22DC are factory mounted on two permanent angle beam carbon steel skids A minimum of four 2 78 lifting eyes are provided in the skids to allow rigging Physical damage to the unit after acceptance is not the responsibility of the factory
LOCATION amp MOUNTING
Model ACWC Air Cooled Packaged Water Chillers are designed for outdoor application and may be mounted on roof or at ground level Air lIow through the condenser is vertical and the unit may be located adjacent to outside of building or on roof without regard for prevailing wind direction
Since these units are air cooled the flow of air to and from the condenser coil must not be impeded There must be no obstruction above the unit that would tend to dellect discharge air downward where it could be recirculated back to the inlet of the unit The required overhead air space should be a minimum of eight feet Ductwork must not be applied to the fan outlets
The unit must be installed with sufficient clearance for air entrance to the condenser coil and for servicing access The unit should be located no closer than four feet from any wall or other obstruction Clearance must be provided at either end of the unit to permit removal of tubes from the chiller
Unit must be set on a solid and level foundation
On roof installations the unit should be mounted on support beams which span load-bearing walls to prevent excessive vibration
On ground level installations the unit should be mounted on a substantial base that will not settle A one-piece concrete slab with footings extended below the frost line is recommended A space should be left between the slab and the building to prevent the transmission of sound and vibration
Vibration mounts may be used for roof-mounted units or other locations where noise might be objectionable
WIRING
A unit wiring diagram showing the required power supply characteristics and all factory supplied wiring details are provided with unit Separate field supplied disconnects must be installed for the power and control circuits and should be within the sight of the unit
Separate 115-volt power source must be field supplied to provide power for control and heater circuits if optional control circuit transformer is not provided All electrical connections should be periodically tightened
The chiller inlet (return) water pipe should be connected to the water connection closest to the control panel end of the unit and the outlet (supply) water pipe connected to the water connection on the opposite end of the cooler(s)
A flow switch must be installed in a straight horizontal section of the chilled water piping This is to be field installed
Gauges should be installed in the piping to and from the chiller to measure the pressure drop and to insure the proper (GPM) flow rate in accordance with submittal data A strainer should be installed in the piping on the inlet side of the chiller and vibration eliminators should be employed on both the inlet and outlet pipes Air vents should be located at all high points in the piping system Vents should be located to be accessible to servicing Drain connections should be provided at all low points to permit complete drainage of chiller and piping system
The chilled water piping should be insulated to reduce heat pickup and to prevent condensation If the system is for year-round operation or if it will not be drained in the winter the chilled water piping should be protected against freezing by electric heating cable or other suitable means
Upon completion of chiller piping start the system water pump and purge air from the system Air purging should be done from the high points in the water circuit Purging of the chiller barrel may be accomplished through the vent pipe located on the top of the chiller compartment Failure to purge air from the water circuit will result in inadequate water flow and may cause the unit to cutout
STARTmiddotUP Refer to start test and check list included with this manual
2
CAUTION
The discharge line valve must be open before starting the compressor Liquid line valves must also be open for sustained operation
All compressors are solid mounted on isopads therefore compressor hold-down bolts must not be loosened Loosening these bolts will cause excessive vibration of the compressor and may result in refrigerant line breakage Prior to start-up check all compressor hold-down bolts for tightness
MAINTENANCE
CONDENSER Units are equipped with direct drive fans that have inherently protected motors with permanently lubricated bearings
The air inlet of the condenser coil should be kept clean through a regular maintenance program
COMPRESSOR
1 OIL LEVEL - The oil level in the compressor(s) should be checked periodically with the compressor either running or stopped If the oil level is below one-half (12) the sight glass oil must be added
2 RECOMMENDED OIL -- The unit 4 factory-charged with DB SR-30 refrigeration 01
Do not add any other type of oil to this factory charge
Do not operate compressor If 011 level Is below one-half (12) sight glass
If the oil level is below the minimum specified above and DB SR-30 is not on hand you may drain the entire factory oil charge then refill with SUNISO 4GS refrigeration oil The factory (DB) oil is of the synthetic type and will not mix with SUNISO 4GS Do not attempt to operate the screw compressor with any oil other than these two specified above
It is suggested that a gallon or mom of DB SR-30 oil be obtained and kept on hand at the job site The substitution of SUNISO 4GS oil as outlined above will result in a 2 to 491 capacity loss and no reduction in input KW
PROCEDURE FOR ADDING OIL
Install temporary jumper wire around LPcontrol contacts of circuit to be serviced Manually close liquid line service valve Lower return water T-STAT (T1) setting to start compressor Run compressor until minimum positive pressure reading on suction service gauge (Do not run compressor in vacuum) Place the system onoff switch in the off position Close the line valve in the discharge line between compressor amp condenser Equalized pressure should now be a minimum of refrigerant vapor Reopen discharge line valve Remove jumper wire from pressure control Open liquid line service valve
3 COMPRESSOR REPAIRS (internal) - Contact factory or an authorized DB Service Agency if a compressor malfunction is suspected
4 COMPRESSOR REPAIRS (External) - Proper operation of unloaded ban loading and unloading is controlled by solenoid valves UL-1 UL-2 and UL-3 Any of these three (3) solenoid valves may be repaired or replaced in the field as required
5 Standard oil acid test kit is not compatible with synthetic oil See DB color chart for oil condition
HIGHPRESSURE PORT
SIGHT GLASS I
CRANKCASE HEATER
3
SLIDE VALVE UNLOADING SYSTEM
The Rotary screw compressor capacity control system for infinite modulation consists of a slide valve and hydraulic pistoncylinder operator intemal to the compressor plus three hydraulic solenoid valves (UL-1 UL-2 amp UL-3)
The slide valve forms a portion of the chamber wall in which the rotors turn thus its position with respect to the rotors determines the effective rotor length and thereby the percent of full load capacity
Upon compressor start-up UL-3 is opened This allows oil pressure to act upon the hydraulic piston holding it in the fully unloaded position After 30 seconds during which time full oil flow is established to all bearings surfaces UL-3 is closed At this point the temperature controller is free to open and close UL-1 or UL-2 in response to the supply water temperature
The slide valve will move to the left (loading) by force of discharge pressure whenever UL-1 opens to permit flow to the oil return (low
Load
centJ
Screw Rotor
Slide Valve
Unload
~ Oil Pressure
Oil Pressure Lines
Hydraulic Piston
pressure) line The slide valve will move to the right (unloading) whenever UL-2 opens the oil supply (high pressure) line since the force of the oil exceeds that of the discharge gas
The temperature controller sends a series of power (energizing) pulses to the appropriate solenoid to adjust to load conditions The further the supply water temperature is from the controller set point the longer is the duration of the pulses The series of pulses will continue until the controller is satisfied As the water temperature approaches the set point the pulses become quite brief to prevent overshooting the set point
This method of compressor unloading in conjunction with supply water sensing minimizes actionreaction lag time and overshoot resulting in an exceptionally precise and stable control of supply water temperature
Oil Oil Return Supply
The following table lists solenoid valve position for all three operating modes
UL-1 UL-2 UL-3 Starting Close Close Open Loadinq Open Close Close Unloading Close Open Close
4
LOW AMBIENT OPERATION
Due to the wide range of applications it is sometimes necessary to operate the Air Cooled Packaged Water Chillers at ambients below summer conditions Without proper control when ambients drop below 60degF the pressure differential between the condenser and the evaporator is below the level to insure proper thermal expansion valve operation As a result the unit may cycle off Two types of system control are available allowing the units to operate at the ambients indicated
FAN CYCLING MEDIUM AMBIENT CONTROL TO 30degF
(STANDARD EQUIPMENT-FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water Chillers to provide proper operating head pressures in ambient conditions to 30degF
This is an automatic operation in which the condenser fans are cycled on and off as required in response to head pressure This arrangement provides positive start-up control down to +30degF by delaying the condenser fan operation until a predetermined head pressure is obtained
LOW AMBIENT CONTROL TO OdegF
In conjunction with the standard fan cycling feature all compressors are enclosed in individual housings This housing assures adequate compressor oil temperature for lubrication A five minute time delay relay provides a bypass around the low pressure control to prevent nuisance trip-out during cold start up
COOLER FREEZE PROTECTION-LOW AMBIENT
Cooler freeze protection is a major concern with air cooled chillers To protect against freeze-up a heater cable is provided as standard which protects the cooler to -12degF However there is no freeze protection in the event of power failure or heater cable burnout so the following should be considered for additional protection
1 Drain the cooler and chilled water piping if the chiller is not to be operated over the winter months Drain connections are provided on the coolers
2 Add ethylene glycol to the chilled water system Freeze point should be approximately 10degFbelow minimum design ambient temperature See Page 11 for Glycol Performance
The cooler heater is wired to the control panel and is operational from the factory offered control transformer or field supplied control power
COOLER FREEZE PROTECTION-oPERATION
The ACWC-SD chiller is provided with a temperature sensing freezstat (38deg set point) and a field installed flow switch shutting off the compressors on loss of water flow is also required
Optional low pressure or hot gas bypass freeze protection is also available on the ACWC-SD If these options have not been purchased it is extremely important to guarantee proper chiller water gpm as well as double checking the temperature sensing freezstat calibration
ACWC-SD CONTROL SETTINGS
CUT-INCUT-OUT (PSIG)
UNIT FLP1 FLP2 FLP3 FLP4 FLP5 FLP6 FLP7 FLP8 FLP9 FLP10 FLP11 FLP12 FLP13 FLP14 ISM 44-55 280170 295180
70 260160 275175 2901215
90 260160 275175 2901215 260160 275175 2901215
110-135 260160 2751175 2851210 2951235 2601160 275175 285210 2951235
145-160 280170 2951180 260160 275175 2901215 260160 275175 2901215
185-200 280170 295180 260160 275175 2951235 2951235 260160 275175 285210 2951235 215 260160 275175 2901215 260160 2901215 2901215 260160 275175 290215 260160 275175 290215
240 260160 260160 275175 275175 2901215 2901215 260160 260160 275175 275175 2851210 2851210 295235 2951235
265 260160 260160 275175 275175 2851210 2851210 295235 2951235 260160 260160 275175 275175 285210 2851210 2951235
TEMPERATURE ACTUATED LEGEND FACTORY SETTING
Chiller Low Water Temperature Thermostat T2 Cut-Out 3rF Chiller Heater Thermostat
I(Non-Adiustable) Included With CBH1 Heater
Cut-In Cut-Out
40degF 45degF
Oil Temperature Safety Control (Adjustable) Manual Reset
OTS 1 OTS 2 OTS3
Cut-Out 240degF
Capacity Control Thermostat (Adj) Mode Control Position T1 Dial Set At 44degF
UNIT OPERATING LIMITATIONS
1 Maximum ambient air to condenser is 110degF (60 Hertz operation) 2 Maximum allowable cooler water pressure is 150 PSIG 3 Maximum allowable water temperature to cooler is 75degF 4 Units must not have leaving water temperatures of 42degF or lower unless used with a glycol solution
5
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory The following key shows how the indexing system can be used
12 Line number on wiring diagram
[12] Line number in text
(R5) Component identification symbol in text (Relay 5)
[E] Normally open contact - line number location
[E] Normally closed contact - line number location
Holding coil - line number location
amp Note number
SEQUENCE OF OPERATION (TYPICAL) MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models Refer to the wiring diagram furnished with the unit for specific information ( ) Control Identification Symbol [ ] Circuit Line Number
Important Notel With all the control circuit switches (SW1-SW3) in the off position and the staging thermostat (T1) to its highest temperature Terminals 2 and 4 on the Terminal Board (TER5) must have 115 volts supshyplied for a minimum of 24 hours to energize the compressor crankshycase heaters (CCH1 2) [6 8]
Preliminary Sequence Close the main power disconnect switch Check to see that the red indicating light on the phase loss monitor (PLM 1) is lit (Note There will be two phase loss monitors (PLM1) and (PLM2) on dual power block models) This light must be on to indicate proper phase rotation for the compressors If the light is not on disconnect the main power and reverse any two phase legs at the Main Incoming Power Terminal Block (WARNING DO NOT REVERSE THE LEADS ON THE PHASE LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS TO RUN BACKWARDS CAUSING SEVERE DAMAGE AND WILL VOID THE COMPRESSOR WARRANTY)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed and are supplying power to the compressor crankcase heaters Power is also supplied to the chiller barrel heater (CBH1) [13) the optional receiver heaters (RH1 2 [1011] and the optional convenience outlet (CO) [14]
Control power goes through the control panel circuit breaker (CB1) [8] and field supplied remote time clock [36] Check to make sure time clock contacts close during occupied modes
Start up the chilled water pump The water flow is confirmed when the water flow switch completes the electrical circuit across Terminals 15 and 16 [38] on Terminal Board (TER5) Terminals 17 [47] and 18 [49] provide an interlock for the water pump starter(s) when either compressor is in operation Set the thermostat (T1) to the desired leaving water temperature (eg 44degF) Set point adjustment is acshycomplished directly on the control
Place the three (3) control circuit switches (SW1-SW3) in the On position thus energizing the balance of the control circuit [23] [33] [36] The system will be in the Time-In mode for five minutes before the first compressor will start
The low ambient lockout thermostat (LAT1) [38] and temperature freezestat (T2) [38] must also be satisfied to allow compressor operashytion
Stage 1 Starting Upon demand for cooling thefirst stepof the staging thermostat (T1) will be to close energizing relays (R1) [61] time delay (TD1) [60] and the optional time delay (TD3) [62] If all the safety controls and switches are closed (see Safety Controls section for more detail) the control
circuit for Compressor No1 will energize allowing the compressor to start Relay (R5) [20] will energize closing the normally open (NO) set of contacts [23] which energize the liquid line solenoid valve (SOL1) [23] Another set of NO contacts on (R5) [20) provide a series intershylock with all the safety and operating controls which will lock out the compressor if any safety trips during normal operation (See Note 6 on Wire Diagram) The last set of NO contacts on (R5) [48) provides an interlock circuit for the water circuiting pump(s)
The fan contactor (C13) [23] will also close supplying power to the side of the fan cycling pressure controls (See Power Wiring Diagram)
Note The fan motors are controlled by their own fan cycling controls and will cut in at different factory set head pressures
Time Delay (TD1) [601) has two (2) sets of contacts the first set of (TD1) [19] normally closed (NC) contacts provide a 30 second jumper around the low pressure control (LP1) [20] to prevent short cycling during start-up The second set of (TD1) [24) contacts in the NC posishytion power the unloader solenoid (UL3-1) [24] which hold the comshypressor in the full unload position for 30 seconds After (TD1) [60] times out (30 seconds) the contacts for the unloader solenoid (UL3-1) open and the NO set close which energize the relay (R3) [25]
Stage 1 Modulation Upon energizing relay (R3) [25) the crankcase heater (CCH 1) [6] is de-energized and the NO contacts of relay (R3) [45 48] are closed allowing the thermostat (T1) to energize the load solenoid (UL1-1) [45) and the unload solenoid (UL2-1) [481] upon demand The opshytional time delay (TD3) [62] is used to bypass low pressure control (LP1) [20] for five minutes for low ambient starts
Stage 2 Starting Subsequent to the start of Compressor No1 an approximate five minute time delay is incorporated into the microprocessor After this time delay and a further call for cooling the second step of the stagshying thermostat (T1) will close This will energize relay (R2) [58] time delay (TD2) [57] and the optional time delay (TD4) [59] If all the safety controls and switches are closed (see Safety Control section for more details) the control circuit for Compressor No2 will energize allowing the compressor to start Relay (R6) [3D] will energize allowshying the liquid line solenoid valve (SOL2) [331] to energize Relay (R6) [3D]will also interlock the water pump starters and the safety controls the same as Compressor No 1 circuit
The fan contactor (C14) [33] will close supplying power to the line side of the fan cycling pressure controls (See Power Wiring Diagram)
Time delay (TD2) will provide a 30 second jumper around the low pressure control (LP2) [30] and will energize the full unload solenoid (UL 3-2) [34] for 30 seconds then energize relay (R4) [35]
Upon energizing relay (R4) [35] the crankcase heater (CCH2) [8] is de-energized and the NO contacts of relay (R4) [46 49) are closed allowing the thermostat (T1) to energize the load solenoid (UL2-1) [46] and the unload solenoid (UL2-2) [49] upon demand
6
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
7
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
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472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
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(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
CAUTION
The discharge line valve must be open before starting the compressor Liquid line valves must also be open for sustained operation
All compressors are solid mounted on isopads therefore compressor hold-down bolts must not be loosened Loosening these bolts will cause excessive vibration of the compressor and may result in refrigerant line breakage Prior to start-up check all compressor hold-down bolts for tightness
MAINTENANCE
CONDENSER Units are equipped with direct drive fans that have inherently protected motors with permanently lubricated bearings
The air inlet of the condenser coil should be kept clean through a regular maintenance program
COMPRESSOR
1 OIL LEVEL - The oil level in the compressor(s) should be checked periodically with the compressor either running or stopped If the oil level is below one-half (12) the sight glass oil must be added
2 RECOMMENDED OIL -- The unit 4 factory-charged with DB SR-30 refrigeration 01
Do not add any other type of oil to this factory charge
Do not operate compressor If 011 level Is below one-half (12) sight glass
If the oil level is below the minimum specified above and DB SR-30 is not on hand you may drain the entire factory oil charge then refill with SUNISO 4GS refrigeration oil The factory (DB) oil is of the synthetic type and will not mix with SUNISO 4GS Do not attempt to operate the screw compressor with any oil other than these two specified above
It is suggested that a gallon or mom of DB SR-30 oil be obtained and kept on hand at the job site The substitution of SUNISO 4GS oil as outlined above will result in a 2 to 491 capacity loss and no reduction in input KW
PROCEDURE FOR ADDING OIL
Install temporary jumper wire around LPcontrol contacts of circuit to be serviced Manually close liquid line service valve Lower return water T-STAT (T1) setting to start compressor Run compressor until minimum positive pressure reading on suction service gauge (Do not run compressor in vacuum) Place the system onoff switch in the off position Close the line valve in the discharge line between compressor amp condenser Equalized pressure should now be a minimum of refrigerant vapor Reopen discharge line valve Remove jumper wire from pressure control Open liquid line service valve
3 COMPRESSOR REPAIRS (internal) - Contact factory or an authorized DB Service Agency if a compressor malfunction is suspected
4 COMPRESSOR REPAIRS (External) - Proper operation of unloaded ban loading and unloading is controlled by solenoid valves UL-1 UL-2 and UL-3 Any of these three (3) solenoid valves may be repaired or replaced in the field as required
5 Standard oil acid test kit is not compatible with synthetic oil See DB color chart for oil condition
HIGHPRESSURE PORT
SIGHT GLASS I
CRANKCASE HEATER
3
SLIDE VALVE UNLOADING SYSTEM
The Rotary screw compressor capacity control system for infinite modulation consists of a slide valve and hydraulic pistoncylinder operator intemal to the compressor plus three hydraulic solenoid valves (UL-1 UL-2 amp UL-3)
The slide valve forms a portion of the chamber wall in which the rotors turn thus its position with respect to the rotors determines the effective rotor length and thereby the percent of full load capacity
Upon compressor start-up UL-3 is opened This allows oil pressure to act upon the hydraulic piston holding it in the fully unloaded position After 30 seconds during which time full oil flow is established to all bearings surfaces UL-3 is closed At this point the temperature controller is free to open and close UL-1 or UL-2 in response to the supply water temperature
The slide valve will move to the left (loading) by force of discharge pressure whenever UL-1 opens to permit flow to the oil return (low
Load
centJ
Screw Rotor
Slide Valve
Unload
~ Oil Pressure
Oil Pressure Lines
Hydraulic Piston
pressure) line The slide valve will move to the right (unloading) whenever UL-2 opens the oil supply (high pressure) line since the force of the oil exceeds that of the discharge gas
The temperature controller sends a series of power (energizing) pulses to the appropriate solenoid to adjust to load conditions The further the supply water temperature is from the controller set point the longer is the duration of the pulses The series of pulses will continue until the controller is satisfied As the water temperature approaches the set point the pulses become quite brief to prevent overshooting the set point
This method of compressor unloading in conjunction with supply water sensing minimizes actionreaction lag time and overshoot resulting in an exceptionally precise and stable control of supply water temperature
Oil Oil Return Supply
The following table lists solenoid valve position for all three operating modes
UL-1 UL-2 UL-3 Starting Close Close Open Loadinq Open Close Close Unloading Close Open Close
4
LOW AMBIENT OPERATION
Due to the wide range of applications it is sometimes necessary to operate the Air Cooled Packaged Water Chillers at ambients below summer conditions Without proper control when ambients drop below 60degF the pressure differential between the condenser and the evaporator is below the level to insure proper thermal expansion valve operation As a result the unit may cycle off Two types of system control are available allowing the units to operate at the ambients indicated
FAN CYCLING MEDIUM AMBIENT CONTROL TO 30degF
(STANDARD EQUIPMENT-FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water Chillers to provide proper operating head pressures in ambient conditions to 30degF
This is an automatic operation in which the condenser fans are cycled on and off as required in response to head pressure This arrangement provides positive start-up control down to +30degF by delaying the condenser fan operation until a predetermined head pressure is obtained
LOW AMBIENT CONTROL TO OdegF
In conjunction with the standard fan cycling feature all compressors are enclosed in individual housings This housing assures adequate compressor oil temperature for lubrication A five minute time delay relay provides a bypass around the low pressure control to prevent nuisance trip-out during cold start up
COOLER FREEZE PROTECTION-LOW AMBIENT
Cooler freeze protection is a major concern with air cooled chillers To protect against freeze-up a heater cable is provided as standard which protects the cooler to -12degF However there is no freeze protection in the event of power failure or heater cable burnout so the following should be considered for additional protection
1 Drain the cooler and chilled water piping if the chiller is not to be operated over the winter months Drain connections are provided on the coolers
2 Add ethylene glycol to the chilled water system Freeze point should be approximately 10degFbelow minimum design ambient temperature See Page 11 for Glycol Performance
The cooler heater is wired to the control panel and is operational from the factory offered control transformer or field supplied control power
COOLER FREEZE PROTECTION-oPERATION
The ACWC-SD chiller is provided with a temperature sensing freezstat (38deg set point) and a field installed flow switch shutting off the compressors on loss of water flow is also required
Optional low pressure or hot gas bypass freeze protection is also available on the ACWC-SD If these options have not been purchased it is extremely important to guarantee proper chiller water gpm as well as double checking the temperature sensing freezstat calibration
ACWC-SD CONTROL SETTINGS
CUT-INCUT-OUT (PSIG)
UNIT FLP1 FLP2 FLP3 FLP4 FLP5 FLP6 FLP7 FLP8 FLP9 FLP10 FLP11 FLP12 FLP13 FLP14 ISM 44-55 280170 295180
70 260160 275175 2901215
90 260160 275175 2901215 260160 275175 2901215
110-135 260160 2751175 2851210 2951235 2601160 275175 285210 2951235
145-160 280170 2951180 260160 275175 2901215 260160 275175 2901215
185-200 280170 295180 260160 275175 2951235 2951235 260160 275175 285210 2951235 215 260160 275175 2901215 260160 2901215 2901215 260160 275175 290215 260160 275175 290215
240 260160 260160 275175 275175 2901215 2901215 260160 260160 275175 275175 2851210 2851210 295235 2951235
265 260160 260160 275175 275175 2851210 2851210 295235 2951235 260160 260160 275175 275175 285210 2851210 2951235
TEMPERATURE ACTUATED LEGEND FACTORY SETTING
Chiller Low Water Temperature Thermostat T2 Cut-Out 3rF Chiller Heater Thermostat
I(Non-Adiustable) Included With CBH1 Heater
Cut-In Cut-Out
40degF 45degF
Oil Temperature Safety Control (Adjustable) Manual Reset
OTS 1 OTS 2 OTS3
Cut-Out 240degF
Capacity Control Thermostat (Adj) Mode Control Position T1 Dial Set At 44degF
UNIT OPERATING LIMITATIONS
1 Maximum ambient air to condenser is 110degF (60 Hertz operation) 2 Maximum allowable cooler water pressure is 150 PSIG 3 Maximum allowable water temperature to cooler is 75degF 4 Units must not have leaving water temperatures of 42degF or lower unless used with a glycol solution
5
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory The following key shows how the indexing system can be used
12 Line number on wiring diagram
[12] Line number in text
(R5) Component identification symbol in text (Relay 5)
[E] Normally open contact - line number location
[E] Normally closed contact - line number location
Holding coil - line number location
amp Note number
SEQUENCE OF OPERATION (TYPICAL) MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models Refer to the wiring diagram furnished with the unit for specific information ( ) Control Identification Symbol [ ] Circuit Line Number
Important Notel With all the control circuit switches (SW1-SW3) in the off position and the staging thermostat (T1) to its highest temperature Terminals 2 and 4 on the Terminal Board (TER5) must have 115 volts supshyplied for a minimum of 24 hours to energize the compressor crankshycase heaters (CCH1 2) [6 8]
Preliminary Sequence Close the main power disconnect switch Check to see that the red indicating light on the phase loss monitor (PLM 1) is lit (Note There will be two phase loss monitors (PLM1) and (PLM2) on dual power block models) This light must be on to indicate proper phase rotation for the compressors If the light is not on disconnect the main power and reverse any two phase legs at the Main Incoming Power Terminal Block (WARNING DO NOT REVERSE THE LEADS ON THE PHASE LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS TO RUN BACKWARDS CAUSING SEVERE DAMAGE AND WILL VOID THE COMPRESSOR WARRANTY)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed and are supplying power to the compressor crankcase heaters Power is also supplied to the chiller barrel heater (CBH1) [13) the optional receiver heaters (RH1 2 [1011] and the optional convenience outlet (CO) [14]
Control power goes through the control panel circuit breaker (CB1) [8] and field supplied remote time clock [36] Check to make sure time clock contacts close during occupied modes
Start up the chilled water pump The water flow is confirmed when the water flow switch completes the electrical circuit across Terminals 15 and 16 [38] on Terminal Board (TER5) Terminals 17 [47] and 18 [49] provide an interlock for the water pump starter(s) when either compressor is in operation Set the thermostat (T1) to the desired leaving water temperature (eg 44degF) Set point adjustment is acshycomplished directly on the control
Place the three (3) control circuit switches (SW1-SW3) in the On position thus energizing the balance of the control circuit [23] [33] [36] The system will be in the Time-In mode for five minutes before the first compressor will start
The low ambient lockout thermostat (LAT1) [38] and temperature freezestat (T2) [38] must also be satisfied to allow compressor operashytion
Stage 1 Starting Upon demand for cooling thefirst stepof the staging thermostat (T1) will be to close energizing relays (R1) [61] time delay (TD1) [60] and the optional time delay (TD3) [62] If all the safety controls and switches are closed (see Safety Controls section for more detail) the control
circuit for Compressor No1 will energize allowing the compressor to start Relay (R5) [20] will energize closing the normally open (NO) set of contacts [23] which energize the liquid line solenoid valve (SOL1) [23] Another set of NO contacts on (R5) [20) provide a series intershylock with all the safety and operating controls which will lock out the compressor if any safety trips during normal operation (See Note 6 on Wire Diagram) The last set of NO contacts on (R5) [48) provides an interlock circuit for the water circuiting pump(s)
The fan contactor (C13) [23] will also close supplying power to the side of the fan cycling pressure controls (See Power Wiring Diagram)
Note The fan motors are controlled by their own fan cycling controls and will cut in at different factory set head pressures
Time Delay (TD1) [601) has two (2) sets of contacts the first set of (TD1) [19] normally closed (NC) contacts provide a 30 second jumper around the low pressure control (LP1) [20] to prevent short cycling during start-up The second set of (TD1) [24) contacts in the NC posishytion power the unloader solenoid (UL3-1) [24] which hold the comshypressor in the full unload position for 30 seconds After (TD1) [60] times out (30 seconds) the contacts for the unloader solenoid (UL3-1) open and the NO set close which energize the relay (R3) [25]
Stage 1 Modulation Upon energizing relay (R3) [25) the crankcase heater (CCH 1) [6] is de-energized and the NO contacts of relay (R3) [45 48] are closed allowing the thermostat (T1) to energize the load solenoid (UL1-1) [45) and the unload solenoid (UL2-1) [481] upon demand The opshytional time delay (TD3) [62] is used to bypass low pressure control (LP1) [20] for five minutes for low ambient starts
Stage 2 Starting Subsequent to the start of Compressor No1 an approximate five minute time delay is incorporated into the microprocessor After this time delay and a further call for cooling the second step of the stagshying thermostat (T1) will close This will energize relay (R2) [58] time delay (TD2) [57] and the optional time delay (TD4) [59] If all the safety controls and switches are closed (see Safety Control section for more details) the control circuit for Compressor No2 will energize allowing the compressor to start Relay (R6) [3D] will energize allowshying the liquid line solenoid valve (SOL2) [331] to energize Relay (R6) [3D]will also interlock the water pump starters and the safety controls the same as Compressor No 1 circuit
The fan contactor (C14) [33] will close supplying power to the line side of the fan cycling pressure controls (See Power Wiring Diagram)
Time delay (TD2) will provide a 30 second jumper around the low pressure control (LP2) [30] and will energize the full unload solenoid (UL 3-2) [34] for 30 seconds then energize relay (R4) [35]
Upon energizing relay (R4) [35] the crankcase heater (CCH2) [8] is de-energized and the NO contacts of relay (R4) [46 49) are closed allowing the thermostat (T1) to energize the load solenoid (UL2-1) [46] and the unload solenoid (UL2-2) [49] upon demand
6
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
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Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
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COMPREIlOfl CONDENSER SECTION IECnoN
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ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
SLIDE VALVE UNLOADING SYSTEM
The Rotary screw compressor capacity control system for infinite modulation consists of a slide valve and hydraulic pistoncylinder operator intemal to the compressor plus three hydraulic solenoid valves (UL-1 UL-2 amp UL-3)
The slide valve forms a portion of the chamber wall in which the rotors turn thus its position with respect to the rotors determines the effective rotor length and thereby the percent of full load capacity
Upon compressor start-up UL-3 is opened This allows oil pressure to act upon the hydraulic piston holding it in the fully unloaded position After 30 seconds during which time full oil flow is established to all bearings surfaces UL-3 is closed At this point the temperature controller is free to open and close UL-1 or UL-2 in response to the supply water temperature
The slide valve will move to the left (loading) by force of discharge pressure whenever UL-1 opens to permit flow to the oil return (low
Load
centJ
Screw Rotor
Slide Valve
Unload
~ Oil Pressure
Oil Pressure Lines
Hydraulic Piston
pressure) line The slide valve will move to the right (unloading) whenever UL-2 opens the oil supply (high pressure) line since the force of the oil exceeds that of the discharge gas
The temperature controller sends a series of power (energizing) pulses to the appropriate solenoid to adjust to load conditions The further the supply water temperature is from the controller set point the longer is the duration of the pulses The series of pulses will continue until the controller is satisfied As the water temperature approaches the set point the pulses become quite brief to prevent overshooting the set point
This method of compressor unloading in conjunction with supply water sensing minimizes actionreaction lag time and overshoot resulting in an exceptionally precise and stable control of supply water temperature
Oil Oil Return Supply
The following table lists solenoid valve position for all three operating modes
UL-1 UL-2 UL-3 Starting Close Close Open Loadinq Open Close Close Unloading Close Open Close
4
LOW AMBIENT OPERATION
Due to the wide range of applications it is sometimes necessary to operate the Air Cooled Packaged Water Chillers at ambients below summer conditions Without proper control when ambients drop below 60degF the pressure differential between the condenser and the evaporator is below the level to insure proper thermal expansion valve operation As a result the unit may cycle off Two types of system control are available allowing the units to operate at the ambients indicated
FAN CYCLING MEDIUM AMBIENT CONTROL TO 30degF
(STANDARD EQUIPMENT-FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water Chillers to provide proper operating head pressures in ambient conditions to 30degF
This is an automatic operation in which the condenser fans are cycled on and off as required in response to head pressure This arrangement provides positive start-up control down to +30degF by delaying the condenser fan operation until a predetermined head pressure is obtained
LOW AMBIENT CONTROL TO OdegF
In conjunction with the standard fan cycling feature all compressors are enclosed in individual housings This housing assures adequate compressor oil temperature for lubrication A five minute time delay relay provides a bypass around the low pressure control to prevent nuisance trip-out during cold start up
COOLER FREEZE PROTECTION-LOW AMBIENT
Cooler freeze protection is a major concern with air cooled chillers To protect against freeze-up a heater cable is provided as standard which protects the cooler to -12degF However there is no freeze protection in the event of power failure or heater cable burnout so the following should be considered for additional protection
1 Drain the cooler and chilled water piping if the chiller is not to be operated over the winter months Drain connections are provided on the coolers
2 Add ethylene glycol to the chilled water system Freeze point should be approximately 10degFbelow minimum design ambient temperature See Page 11 for Glycol Performance
The cooler heater is wired to the control panel and is operational from the factory offered control transformer or field supplied control power
COOLER FREEZE PROTECTION-oPERATION
The ACWC-SD chiller is provided with a temperature sensing freezstat (38deg set point) and a field installed flow switch shutting off the compressors on loss of water flow is also required
Optional low pressure or hot gas bypass freeze protection is also available on the ACWC-SD If these options have not been purchased it is extremely important to guarantee proper chiller water gpm as well as double checking the temperature sensing freezstat calibration
ACWC-SD CONTROL SETTINGS
CUT-INCUT-OUT (PSIG)
UNIT FLP1 FLP2 FLP3 FLP4 FLP5 FLP6 FLP7 FLP8 FLP9 FLP10 FLP11 FLP12 FLP13 FLP14 ISM 44-55 280170 295180
70 260160 275175 2901215
90 260160 275175 2901215 260160 275175 2901215
110-135 260160 2751175 2851210 2951235 2601160 275175 285210 2951235
145-160 280170 2951180 260160 275175 2901215 260160 275175 2901215
185-200 280170 295180 260160 275175 2951235 2951235 260160 275175 285210 2951235 215 260160 275175 2901215 260160 2901215 2901215 260160 275175 290215 260160 275175 290215
240 260160 260160 275175 275175 2901215 2901215 260160 260160 275175 275175 2851210 2851210 295235 2951235
265 260160 260160 275175 275175 2851210 2851210 295235 2951235 260160 260160 275175 275175 285210 2851210 2951235
TEMPERATURE ACTUATED LEGEND FACTORY SETTING
Chiller Low Water Temperature Thermostat T2 Cut-Out 3rF Chiller Heater Thermostat
I(Non-Adiustable) Included With CBH1 Heater
Cut-In Cut-Out
40degF 45degF
Oil Temperature Safety Control (Adjustable) Manual Reset
OTS 1 OTS 2 OTS3
Cut-Out 240degF
Capacity Control Thermostat (Adj) Mode Control Position T1 Dial Set At 44degF
UNIT OPERATING LIMITATIONS
1 Maximum ambient air to condenser is 110degF (60 Hertz operation) 2 Maximum allowable cooler water pressure is 150 PSIG 3 Maximum allowable water temperature to cooler is 75degF 4 Units must not have leaving water temperatures of 42degF or lower unless used with a glycol solution
5
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory The following key shows how the indexing system can be used
12 Line number on wiring diagram
[12] Line number in text
(R5) Component identification symbol in text (Relay 5)
[E] Normally open contact - line number location
[E] Normally closed contact - line number location
Holding coil - line number location
amp Note number
SEQUENCE OF OPERATION (TYPICAL) MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models Refer to the wiring diagram furnished with the unit for specific information ( ) Control Identification Symbol [ ] Circuit Line Number
Important Notel With all the control circuit switches (SW1-SW3) in the off position and the staging thermostat (T1) to its highest temperature Terminals 2 and 4 on the Terminal Board (TER5) must have 115 volts supshyplied for a minimum of 24 hours to energize the compressor crankshycase heaters (CCH1 2) [6 8]
Preliminary Sequence Close the main power disconnect switch Check to see that the red indicating light on the phase loss monitor (PLM 1) is lit (Note There will be two phase loss monitors (PLM1) and (PLM2) on dual power block models) This light must be on to indicate proper phase rotation for the compressors If the light is not on disconnect the main power and reverse any two phase legs at the Main Incoming Power Terminal Block (WARNING DO NOT REVERSE THE LEADS ON THE PHASE LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS TO RUN BACKWARDS CAUSING SEVERE DAMAGE AND WILL VOID THE COMPRESSOR WARRANTY)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed and are supplying power to the compressor crankcase heaters Power is also supplied to the chiller barrel heater (CBH1) [13) the optional receiver heaters (RH1 2 [1011] and the optional convenience outlet (CO) [14]
Control power goes through the control panel circuit breaker (CB1) [8] and field supplied remote time clock [36] Check to make sure time clock contacts close during occupied modes
Start up the chilled water pump The water flow is confirmed when the water flow switch completes the electrical circuit across Terminals 15 and 16 [38] on Terminal Board (TER5) Terminals 17 [47] and 18 [49] provide an interlock for the water pump starter(s) when either compressor is in operation Set the thermostat (T1) to the desired leaving water temperature (eg 44degF) Set point adjustment is acshycomplished directly on the control
Place the three (3) control circuit switches (SW1-SW3) in the On position thus energizing the balance of the control circuit [23] [33] [36] The system will be in the Time-In mode for five minutes before the first compressor will start
The low ambient lockout thermostat (LAT1) [38] and temperature freezestat (T2) [38] must also be satisfied to allow compressor operashytion
Stage 1 Starting Upon demand for cooling thefirst stepof the staging thermostat (T1) will be to close energizing relays (R1) [61] time delay (TD1) [60] and the optional time delay (TD3) [62] If all the safety controls and switches are closed (see Safety Controls section for more detail) the control
circuit for Compressor No1 will energize allowing the compressor to start Relay (R5) [20] will energize closing the normally open (NO) set of contacts [23] which energize the liquid line solenoid valve (SOL1) [23] Another set of NO contacts on (R5) [20) provide a series intershylock with all the safety and operating controls which will lock out the compressor if any safety trips during normal operation (See Note 6 on Wire Diagram) The last set of NO contacts on (R5) [48) provides an interlock circuit for the water circuiting pump(s)
The fan contactor (C13) [23] will also close supplying power to the side of the fan cycling pressure controls (See Power Wiring Diagram)
Note The fan motors are controlled by their own fan cycling controls and will cut in at different factory set head pressures
Time Delay (TD1) [601) has two (2) sets of contacts the first set of (TD1) [19] normally closed (NC) contacts provide a 30 second jumper around the low pressure control (LP1) [20] to prevent short cycling during start-up The second set of (TD1) [24) contacts in the NC posishytion power the unloader solenoid (UL3-1) [24] which hold the comshypressor in the full unload position for 30 seconds After (TD1) [60] times out (30 seconds) the contacts for the unloader solenoid (UL3-1) open and the NO set close which energize the relay (R3) [25]
Stage 1 Modulation Upon energizing relay (R3) [25) the crankcase heater (CCH 1) [6] is de-energized and the NO contacts of relay (R3) [45 48] are closed allowing the thermostat (T1) to energize the load solenoid (UL1-1) [45) and the unload solenoid (UL2-1) [481] upon demand The opshytional time delay (TD3) [62] is used to bypass low pressure control (LP1) [20] for five minutes for low ambient starts
Stage 2 Starting Subsequent to the start of Compressor No1 an approximate five minute time delay is incorporated into the microprocessor After this time delay and a further call for cooling the second step of the stagshying thermostat (T1) will close This will energize relay (R2) [58] time delay (TD2) [57] and the optional time delay (TD4) [59] If all the safety controls and switches are closed (see Safety Control section for more details) the control circuit for Compressor No2 will energize allowing the compressor to start Relay (R6) [3D] will energize allowshying the liquid line solenoid valve (SOL2) [331] to energize Relay (R6) [3D]will also interlock the water pump starters and the safety controls the same as Compressor No 1 circuit
The fan contactor (C14) [33] will close supplying power to the line side of the fan cycling pressure controls (See Power Wiring Diagram)
Time delay (TD2) will provide a 30 second jumper around the low pressure control (LP2) [30] and will energize the full unload solenoid (UL 3-2) [34] for 30 seconds then energize relay (R4) [35]
Upon energizing relay (R4) [35] the crankcase heater (CCH2) [8] is de-energized and the NO contacts of relay (R4) [46 49) are closed allowing the thermostat (T1) to energize the load solenoid (UL2-1) [46] and the unload solenoid (UL2-2) [49] upon demand
6
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
LOW AMBIENT OPERATION
Due to the wide range of applications it is sometimes necessary to operate the Air Cooled Packaged Water Chillers at ambients below summer conditions Without proper control when ambients drop below 60degF the pressure differential between the condenser and the evaporator is below the level to insure proper thermal expansion valve operation As a result the unit may cycle off Two types of system control are available allowing the units to operate at the ambients indicated
FAN CYCLING MEDIUM AMBIENT CONTROL TO 30degF
(STANDARD EQUIPMENT-FACTORY INSTALLED)
A fan cycling control is standard on all Air Cooled Packaged Water Chillers to provide proper operating head pressures in ambient conditions to 30degF
This is an automatic operation in which the condenser fans are cycled on and off as required in response to head pressure This arrangement provides positive start-up control down to +30degF by delaying the condenser fan operation until a predetermined head pressure is obtained
LOW AMBIENT CONTROL TO OdegF
In conjunction with the standard fan cycling feature all compressors are enclosed in individual housings This housing assures adequate compressor oil temperature for lubrication A five minute time delay relay provides a bypass around the low pressure control to prevent nuisance trip-out during cold start up
COOLER FREEZE PROTECTION-LOW AMBIENT
Cooler freeze protection is a major concern with air cooled chillers To protect against freeze-up a heater cable is provided as standard which protects the cooler to -12degF However there is no freeze protection in the event of power failure or heater cable burnout so the following should be considered for additional protection
1 Drain the cooler and chilled water piping if the chiller is not to be operated over the winter months Drain connections are provided on the coolers
2 Add ethylene glycol to the chilled water system Freeze point should be approximately 10degFbelow minimum design ambient temperature See Page 11 for Glycol Performance
The cooler heater is wired to the control panel and is operational from the factory offered control transformer or field supplied control power
COOLER FREEZE PROTECTION-oPERATION
The ACWC-SD chiller is provided with a temperature sensing freezstat (38deg set point) and a field installed flow switch shutting off the compressors on loss of water flow is also required
Optional low pressure or hot gas bypass freeze protection is also available on the ACWC-SD If these options have not been purchased it is extremely important to guarantee proper chiller water gpm as well as double checking the temperature sensing freezstat calibration
ACWC-SD CONTROL SETTINGS
CUT-INCUT-OUT (PSIG)
UNIT FLP1 FLP2 FLP3 FLP4 FLP5 FLP6 FLP7 FLP8 FLP9 FLP10 FLP11 FLP12 FLP13 FLP14 ISM 44-55 280170 295180
70 260160 275175 2901215
90 260160 275175 2901215 260160 275175 2901215
110-135 260160 2751175 2851210 2951235 2601160 275175 285210 2951235
145-160 280170 2951180 260160 275175 2901215 260160 275175 2901215
185-200 280170 295180 260160 275175 2951235 2951235 260160 275175 285210 2951235 215 260160 275175 2901215 260160 2901215 2901215 260160 275175 290215 260160 275175 290215
240 260160 260160 275175 275175 2901215 2901215 260160 260160 275175 275175 2851210 2851210 295235 2951235
265 260160 260160 275175 275175 2851210 2851210 295235 2951235 260160 260160 275175 275175 285210 2851210 2951235
TEMPERATURE ACTUATED LEGEND FACTORY SETTING
Chiller Low Water Temperature Thermostat T2 Cut-Out 3rF Chiller Heater Thermostat
I(Non-Adiustable) Included With CBH1 Heater
Cut-In Cut-Out
40degF 45degF
Oil Temperature Safety Control (Adjustable) Manual Reset
OTS 1 OTS 2 OTS3
Cut-Out 240degF
Capacity Control Thermostat (Adj) Mode Control Position T1 Dial Set At 44degF
UNIT OPERATING LIMITATIONS
1 Maximum ambient air to condenser is 110degF (60 Hertz operation) 2 Maximum allowable cooler water pressure is 150 PSIG 3 Maximum allowable water temperature to cooler is 75degF 4 Units must not have leaving water temperatures of 42degF or lower unless used with a glycol solution
5
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory The following key shows how the indexing system can be used
12 Line number on wiring diagram
[12] Line number in text
(R5) Component identification symbol in text (Relay 5)
[E] Normally open contact - line number location
[E] Normally closed contact - line number location
Holding coil - line number location
amp Note number
SEQUENCE OF OPERATION (TYPICAL) MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models Refer to the wiring diagram furnished with the unit for specific information ( ) Control Identification Symbol [ ] Circuit Line Number
Important Notel With all the control circuit switches (SW1-SW3) in the off position and the staging thermostat (T1) to its highest temperature Terminals 2 and 4 on the Terminal Board (TER5) must have 115 volts supshyplied for a minimum of 24 hours to energize the compressor crankshycase heaters (CCH1 2) [6 8]
Preliminary Sequence Close the main power disconnect switch Check to see that the red indicating light on the phase loss monitor (PLM 1) is lit (Note There will be two phase loss monitors (PLM1) and (PLM2) on dual power block models) This light must be on to indicate proper phase rotation for the compressors If the light is not on disconnect the main power and reverse any two phase legs at the Main Incoming Power Terminal Block (WARNING DO NOT REVERSE THE LEADS ON THE PHASE LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS TO RUN BACKWARDS CAUSING SEVERE DAMAGE AND WILL VOID THE COMPRESSOR WARRANTY)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed and are supplying power to the compressor crankcase heaters Power is also supplied to the chiller barrel heater (CBH1) [13) the optional receiver heaters (RH1 2 [1011] and the optional convenience outlet (CO) [14]
Control power goes through the control panel circuit breaker (CB1) [8] and field supplied remote time clock [36] Check to make sure time clock contacts close during occupied modes
Start up the chilled water pump The water flow is confirmed when the water flow switch completes the electrical circuit across Terminals 15 and 16 [38] on Terminal Board (TER5) Terminals 17 [47] and 18 [49] provide an interlock for the water pump starter(s) when either compressor is in operation Set the thermostat (T1) to the desired leaving water temperature (eg 44degF) Set point adjustment is acshycomplished directly on the control
Place the three (3) control circuit switches (SW1-SW3) in the On position thus energizing the balance of the control circuit [23] [33] [36] The system will be in the Time-In mode for five minutes before the first compressor will start
The low ambient lockout thermostat (LAT1) [38] and temperature freezestat (T2) [38] must also be satisfied to allow compressor operashytion
Stage 1 Starting Upon demand for cooling thefirst stepof the staging thermostat (T1) will be to close energizing relays (R1) [61] time delay (TD1) [60] and the optional time delay (TD3) [62] If all the safety controls and switches are closed (see Safety Controls section for more detail) the control
circuit for Compressor No1 will energize allowing the compressor to start Relay (R5) [20] will energize closing the normally open (NO) set of contacts [23] which energize the liquid line solenoid valve (SOL1) [23] Another set of NO contacts on (R5) [20) provide a series intershylock with all the safety and operating controls which will lock out the compressor if any safety trips during normal operation (See Note 6 on Wire Diagram) The last set of NO contacts on (R5) [48) provides an interlock circuit for the water circuiting pump(s)
The fan contactor (C13) [23] will also close supplying power to the side of the fan cycling pressure controls (See Power Wiring Diagram)
Note The fan motors are controlled by their own fan cycling controls and will cut in at different factory set head pressures
Time Delay (TD1) [601) has two (2) sets of contacts the first set of (TD1) [19] normally closed (NC) contacts provide a 30 second jumper around the low pressure control (LP1) [20] to prevent short cycling during start-up The second set of (TD1) [24) contacts in the NC posishytion power the unloader solenoid (UL3-1) [24] which hold the comshypressor in the full unload position for 30 seconds After (TD1) [60] times out (30 seconds) the contacts for the unloader solenoid (UL3-1) open and the NO set close which energize the relay (R3) [25]
Stage 1 Modulation Upon energizing relay (R3) [25) the crankcase heater (CCH 1) [6] is de-energized and the NO contacts of relay (R3) [45 48] are closed allowing the thermostat (T1) to energize the load solenoid (UL1-1) [45) and the unload solenoid (UL2-1) [481] upon demand The opshytional time delay (TD3) [62] is used to bypass low pressure control (LP1) [20] for five minutes for low ambient starts
Stage 2 Starting Subsequent to the start of Compressor No1 an approximate five minute time delay is incorporated into the microprocessor After this time delay and a further call for cooling the second step of the stagshying thermostat (T1) will close This will energize relay (R2) [58] time delay (TD2) [57] and the optional time delay (TD4) [59] If all the safety controls and switches are closed (see Safety Control section for more details) the control circuit for Compressor No2 will energize allowing the compressor to start Relay (R6) [3D] will energize allowshying the liquid line solenoid valve (SOL2) [331] to energize Relay (R6) [3D]will also interlock the water pump starters and the safety controls the same as Compressor No 1 circuit
The fan contactor (C14) [33] will close supplying power to the line side of the fan cycling pressure controls (See Power Wiring Diagram)
Time delay (TD2) will provide a 30 second jumper around the low pressure control (LP2) [30] and will energize the full unload solenoid (UL 3-2) [34] for 30 seconds then energize relay (R4) [35]
Upon energizing relay (R4) [35] the crankcase heater (CCH2) [8] is de-energized and the NO contacts of relay (R4) [46 49) are closed allowing the thermostat (T1) to energize the load solenoid (UL2-1) [46] and the unload solenoid (UL2-2) [49] upon demand
6
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
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Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
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COMPREIlOfl CONDENSER SECTION IECnoN
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ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
KEY TO WIRING DIAGRAM INDEXING SYSTEM
The wiring diagrams and sequence instructions on the following pages have been devised to simplify the understanding and tracing of circuit theory The following key shows how the indexing system can be used
12 Line number on wiring diagram
[12] Line number in text
(R5) Component identification symbol in text (Relay 5)
[E] Normally open contact - line number location
[E] Normally closed contact - line number location
Holding coil - line number location
amp Note number
SEQUENCE OF OPERATION (TYPICAL) MODELS ACWC 90-135 SO
The following sequence of operation is typical for all ACWC SD Models Refer to the wiring diagram furnished with the unit for specific information ( ) Control Identification Symbol [ ] Circuit Line Number
Important Notel With all the control circuit switches (SW1-SW3) in the off position and the staging thermostat (T1) to its highest temperature Terminals 2 and 4 on the Terminal Board (TER5) must have 115 volts supshyplied for a minimum of 24 hours to energize the compressor crankshycase heaters (CCH1 2) [6 8]
Preliminary Sequence Close the main power disconnect switch Check to see that the red indicating light on the phase loss monitor (PLM 1) is lit (Note There will be two phase loss monitors (PLM1) and (PLM2) on dual power block models) This light must be on to indicate proper phase rotation for the compressors If the light is not on disconnect the main power and reverse any two phase legs at the Main Incoming Power Terminal Block (WARNING DO NOT REVERSE THE LEADS ON THE PHASE LOSS MONITOR FOR THIS WILL ALLOW THE COMPRESSORS TO RUN BACKWARDS CAUSING SEVERE DAMAGE AND WILL VOID THE COMPRESSOR WARRANTY)
The crankcase heater relay contacts (R3) [6] and (R4) [8] are closed and are supplying power to the compressor crankcase heaters Power is also supplied to the chiller barrel heater (CBH1) [13) the optional receiver heaters (RH1 2 [1011] and the optional convenience outlet (CO) [14]
Control power goes through the control panel circuit breaker (CB1) [8] and field supplied remote time clock [36] Check to make sure time clock contacts close during occupied modes
Start up the chilled water pump The water flow is confirmed when the water flow switch completes the electrical circuit across Terminals 15 and 16 [38] on Terminal Board (TER5) Terminals 17 [47] and 18 [49] provide an interlock for the water pump starter(s) when either compressor is in operation Set the thermostat (T1) to the desired leaving water temperature (eg 44degF) Set point adjustment is acshycomplished directly on the control
Place the three (3) control circuit switches (SW1-SW3) in the On position thus energizing the balance of the control circuit [23] [33] [36] The system will be in the Time-In mode for five minutes before the first compressor will start
The low ambient lockout thermostat (LAT1) [38] and temperature freezestat (T2) [38] must also be satisfied to allow compressor operashytion
Stage 1 Starting Upon demand for cooling thefirst stepof the staging thermostat (T1) will be to close energizing relays (R1) [61] time delay (TD1) [60] and the optional time delay (TD3) [62] If all the safety controls and switches are closed (see Safety Controls section for more detail) the control
circuit for Compressor No1 will energize allowing the compressor to start Relay (R5) [20] will energize closing the normally open (NO) set of contacts [23] which energize the liquid line solenoid valve (SOL1) [23] Another set of NO contacts on (R5) [20) provide a series intershylock with all the safety and operating controls which will lock out the compressor if any safety trips during normal operation (See Note 6 on Wire Diagram) The last set of NO contacts on (R5) [48) provides an interlock circuit for the water circuiting pump(s)
The fan contactor (C13) [23] will also close supplying power to the side of the fan cycling pressure controls (See Power Wiring Diagram)
Note The fan motors are controlled by their own fan cycling controls and will cut in at different factory set head pressures
Time Delay (TD1) [601) has two (2) sets of contacts the first set of (TD1) [19] normally closed (NC) contacts provide a 30 second jumper around the low pressure control (LP1) [20] to prevent short cycling during start-up The second set of (TD1) [24) contacts in the NC posishytion power the unloader solenoid (UL3-1) [24] which hold the comshypressor in the full unload position for 30 seconds After (TD1) [60] times out (30 seconds) the contacts for the unloader solenoid (UL3-1) open and the NO set close which energize the relay (R3) [25]
Stage 1 Modulation Upon energizing relay (R3) [25) the crankcase heater (CCH 1) [6] is de-energized and the NO contacts of relay (R3) [45 48] are closed allowing the thermostat (T1) to energize the load solenoid (UL1-1) [45) and the unload solenoid (UL2-1) [481] upon demand The opshytional time delay (TD3) [62] is used to bypass low pressure control (LP1) [20] for five minutes for low ambient starts
Stage 2 Starting Subsequent to the start of Compressor No1 an approximate five minute time delay is incorporated into the microprocessor After this time delay and a further call for cooling the second step of the stagshying thermostat (T1) will close This will energize relay (R2) [58] time delay (TD2) [57] and the optional time delay (TD4) [59] If all the safety controls and switches are closed (see Safety Control section for more details) the control circuit for Compressor No2 will energize allowing the compressor to start Relay (R6) [3D] will energize allowshying the liquid line solenoid valve (SOL2) [331] to energize Relay (R6) [3D]will also interlock the water pump starters and the safety controls the same as Compressor No 1 circuit
The fan contactor (C14) [33] will close supplying power to the line side of the fan cycling pressure controls (See Power Wiring Diagram)
Time delay (TD2) will provide a 30 second jumper around the low pressure control (LP2) [30] and will energize the full unload solenoid (UL 3-2) [34] for 30 seconds then energize relay (R4) [35]
Upon energizing relay (R4) [35] the crankcase heater (CCH2) [8] is de-energized and the NO contacts of relay (R4) [46 49) are closed allowing the thermostat (T1) to energize the load solenoid (UL2-1) [46] and the unload solenoid (UL2-2) [49] upon demand
6
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
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ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
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19
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APPLICATION DATA
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Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
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Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
SHUTDOWN SEQUENCE
Stage 2 Shutdown Stage 1 Shutdown
After both compressors have unloaded fully and the leaving water temperature is still lower than the setpoint the second step of the thermostat (T1) will open and de-energize relay (R2) [58] providing an approximate five minute time delay again integral with the microshyprocessor has expired subsequent to the start of Compressor No2 This will close the liquid line solenoid (SOL2) [33] and turn off Comshypressor No2 Compressor No 1 will load and unload as required Compressor No2 will not be able to restart for five minutes due to integral time delays
SAFETY CONTROLS
The unit is protected by the following safety controls
1 High Pressure (HP) 2 Low Pressure (LP) (automatic reset) 3 High Discharge Temperature (OTS) 4 Compressor Solid State Module (CSTM) 5 Low Water Temperature (T2) 6 Low Ambient Thermostat (LAT) 7 Compressor Starter Overloads (OLH) (optional) 8 Phase Loss Monitor (PLM) 9 Control Circuit Breaker (CB1)
If any of these devices should open due to abnormal conditions the compressor(s) will automatically stop All controls must be manually reset except low ambient thermostat (LAT) and phase loss monitor (PLM) The individual compressor safeties (HP LP OTS and CSTM) contacts are found on Lines 20 (CTT1) or Line 30 (CTT1) The other safeties listed above are discussed in the preliminary sequence section
If the leaving water temperature is still lower than the setpoint the first step of the thermostat (T1) will open and de-energize relay(RI) [61]This will close the liquid line solenoid (SOL 1) [23] and turn off Compressor NO1 as long as it has run for approximately three minutes Compresshysor NO1 will not be able to restart for five minutes
FIELD CONTROL WIRING
In addition to 3 phase power (and optional 115 volt control) wiring described above the following control interlock wiring is recommended The as built control schematic provided with the unit provides detailed information Typical control schematics are as shown on pages 8-15
1) Alarm Circuit -Terminals 6-13 (2 per compressor circuit) can be used to trigger remote failure lights or alarm bells in the event of a refrigeration failure
2) Time Clock - All unit on-off control should be done through terminals 15 and 16 An open contact shuts down the unit Time clock night shut down and energy management shut down should all be done from these terminals and contacts should be applied in series
3) Flow Switch - The flow switch contacts should be installed between terminals 15 and 16 and be in series with time clock contacts
4) Chilled Water Pump - The control of the chilled water pump must be worked out by the system designer It is necessary for the pump to be on during any compressor operation and terminals 17 and 18 should be used to energize the pump starter However it is likely that the pump should remain on throughout all occupied operation or even at night for freeze protection Terminals 17 and 18 should not be the sole means of controlling pump operation
STARmiddotDELTA STARTING OPEN TRANSITION (OPTIONAL)
Typical For All Compressors On initial call for cooling staging relay (R1) holding coil will energize The (R1) contacts 7-4 close energizing star contactor (S1) and the five second transition timer (TD5) Transition contactor (S1) power contacts close tying the center legs of the compressor motor windings together into Star (WYE) configuration At the same time (S1) NC (Normally Closed) auxiliary contacts open preventing (C2) from closing (S1) NO (Normally Open) auxiliary contacts then close energizing contactor (C1) The (C1) power contacts close applying power to the
compressor winding (C1) NO (Normally Open) auxiliary contacts close locking (C1) in the energized position The compressor operates in the Star mode until (TD5) transition timer times out (five seconds) at which time contacts NC open and de-energize (S1) Star contactor (S1) NC auxiliary contacts close (TD5) timer NO contacts close energizing compressor contactor (C2) power contacts close thereby completing the Delta wiring configuration Compressor contactor (C2) NC auxiliary contacts open preventing (S1) star contactor from energizing until the next starting sequence
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ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
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TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
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ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
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19
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
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ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
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Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
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Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
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ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
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Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
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ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
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19
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Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
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ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
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19
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Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
0
(Wd~) 3lV~ M011 ~31VM
006 009 00 OOt OOl OS L 00 L os 0 Ot
V D m (I) (I)
c D m c D o V
- m m -t o
~
~ m D-
aoao 3~nSS3~d ~3100~
APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
-------
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TYPICAL POWER WIRING Models 45 thru 70 SC
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
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APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
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Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
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21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
---
----------
TYPICAL POWER WIRING Models 145 thru 200 SC
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17
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
0
(Wd~) 3lV~ M011 ~31VM
006 009 00 OOt OOl OS L 00 L os 0 Ot
V D m (I) (I)
c D m c D o V
- m m -t o
~
~ m D-
aoao 3~nSS3~d ~3100~
APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
ELECTRICAL DATA Model Volts Type COMPRESSOR FAN MOTORS MIN CIRCUIT RECOMMENDED MAXIMUM ACWC 60 Hz of Qty RLA Starting FLA LRA AMPACITY WIRESIZE FUSESIZE
SC 3 Ph Start HP Ea Curro Ea Ea Ea Circ1 Circ2 Circ1 Circ2 Circ1 eire 2
208230 XL 1788 1040 (4) 70 (4) 380 252 - 250 - 400 -45 208230 YO (1) 50 1788 347 (4) 70 (4) 380 252 - 250 - 400 -
460 XL 737 422 (4) 35 (4) 190 106 - 2 - 175 -460 YO 737 141 (4) 35 (4) 190 106 - 2 - 175 -
208230 XL 2051 1228 (4) 70 (4) 380 284 - 300 - 450 -55 208230 YO (1) 60 2051 409 (4) 70 (4) 380 284 - 300 - 450 -
460 XL 904 485 (4) 35 (4) 190 127 - 1 - 200 -460 YO 904 162 (4) 35 (4) 190 127 - 1 - 200 -
208230 XL 2083 1415 (6) 70 (6) 380 302 350 500 -70 208230 YO (1) 75 2083 472 (6) 70 (6) 380 302 350 500 -
460 XL 974 539 (6) 35 (6) 190 143 0 225 -460 YO 974 180 (6) 35 (6 190 143 0 225 -208 XL 1788 1040 (6) 70 (6) 380 266 224 300 0000 400 400 208 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400
90 230 XL (2) 50 1788 1040 (6) 70 (6) 380 266 224 400 I300 0000 400 400 230 YO 1788 347 (6) 70 (6) 380 266 224 300 0000 400 400 460 XL 737 422 (6) 35 (6) 190 187 - 000 - 250 460 YO 737 141 (6) 35 (6) 190 187 - =1000 - 250 208 XL 2051 1228 (8) 70 (8) 380 312 256 400 300 250 208 YO 2051 409 (8) 70 (8) 380 312 256 400 300 500
110 230 XL (2) 60 2051 1228 (8) 70 (8) 380 312 256 g I350 300 SOO 450 230 YO 2051 409 (8) 70 (8) 380 312 256 350 300 500 450 460 XL 914 485 (8) 35 (8) 190 231 - 0000 - 300 460 YO 904 162 (8) 35 (8) 190 231 - 0000 - 300 -
208 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 1415
208 YO (1) 60 2051 409 (8) 70 (8) 380 312 260 400 300 500 450(1) 75 2083 472
230 XL (1) 60 2051 1228 (8) 70 (8) 380 312 260 350 300 500 450(1) 75 2083 165125
230 YO (1) 60 2051 409 (8) 70 (8) 380 02 260 350 300 500 450 (1) 75 2083 472
460 XL (1) 60 904 485 (8) 35 (8) 190 240 - 250 - 300 -(1 75 974 539
460 YO (1) 60 904 162 (8) 35 (8) 190 240 - 250 - 300 -(1) 75 974 180
208 XL 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 208 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
135 230 XL (2) 75 2083 1415 (8) 70 (8) 380 316 260 400 300 500 450 I 230 YO 2083 472 (8) 70 (8) 380 316 260 400 300 500 450
460 XL 974 539 (8) 35 (8) 190 247 - 250 - 300 -460 YO 974 180 (8i 35 (8) 190 247 - 250 - 300 -
208 XL (2) SO 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 1228
208 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1 60 2051 409
230 XL (2) 50 1788 1040 (10) 70 (10) 380 326 402 400 0000 500 500 145 (1) 60 2011 1228
230 YO (2) 50 1788 347 (10) 70 (10) 380 326 402 400 0000 500 500(1) 60 2051 409
460 XL (2) 50 737 422 (10) 35 (10) 190 295 - 350 350 --(1) 60 904 485
460 YO (2) SO 731 141 10 (35) (10)190 295 - 350 350- -(1)60 904 162
208 XL 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 600 208 YO 2051 409 (10) 70 (10) 380 326 462 400 (2)250 500 600
160 230 XL (3) 60 2051 1228 (10) 70 (10) 380 326 462 400 (2)250 500 230 YO 2051 409 (10) 70 (10) 380 326 462 600400 (2)250 500 600 460 XL 904 485 (10) 35 (10) 190 329 - 400 - 400 460 YO 904 167 (10) 35 (10) 190 329 - 400 - 400 - I
NOTES 1 XL Across the LineYOStarDelta 2 RLA Rated LoadAmps(ratedin accordance withARI Standard 590) LRA LockedRotorAmps 3 Wire Size Amps equal125of the ratedloadampsfor the largestmotorin thecircuitplus100of the ratedloadampsfor all othermotorsin the circuit per
NEC 4 Wire size based on copperconductorswith75C insulation perNECTable310-16 Terminal block lugs are sizedaccordingly Use of oversize wiringmay
not lit in terminal blocks 5 Maximumfuse size is basedon 175to 225of the ratedloadampsfor the largestmotorin the circuitplus 100of the rated loadampsfora othermotors
in the circuit per NEC VOLTAGE TOLERANCES 208V-230V min 187VMax 253V
480V Min414V Max506V
I
18
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
0
(Wd~) 3lV~ M011 ~31VM
006 009 00 OOt OOl OS L 00 L os 0 Ot
V D m (I) (I)
c D m c D o V
- m m -t o
~
~ m D-
aoao 3~nSS3~d ~3100~
APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
ELECTRICAL DATA Volts Type COMPRESSORModel FAN MOTORS MINCIRCUIT RECOMMENDED MAXIMUM 60 Hz of Oty RLA Starting FLAACWC LRA AMPACITY WIRESIZE FUSE SIZE 3 Ph Start Curro EaSC HP Ea Ea Ea Cire1 Cire2 Cire1 Cire2 Cire1 Cire2 208 XL 2051(1) 60 1228 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 1415 208 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 230 XL (1) 60 2051 1228 (12)70 (12) 380 341 469 500 (2) 250 500 600
12 75 2083 1415185 230 YO (1) 60 2051 409 (12) 70 (12) 380 341 469 500 (2) 250 500 600
(2) 75 2083 472 460 XL 485 (12) 35 (1) 60 904 (12) 190 352 500 400- - -
(2) 75 974 539 460 YO (1) 60 904 162 (12) 5(12)19 352 500 400- - -
(2) 75 974 180 208 XL 2083 1415 (12) 70 (12) 380 345 469 500 500(2) 250 600
472208 YO 2083 (12) 70 345(12) 380 469 500 (2) 250 500 600 230 XL (3) 75 2083 1415 (12) 70 345(12) 380 469 500 (2) 250 500 600200 230 YO 2083 472 (12) 70 (12) 190 345 469 500 500(2) 250 600 460 XL 539974 (12) 35 (12) 190 359 - 450500 - -
180 1(12) 35 460 YO 974 (12) 190 359 450 -500- -2051 1228208 XL (12) 70 504(12) 380 504 (2) 250 (2) 250 700 700
208 YO 2051 409 (12) 70 (12) 380 504 504 (2) 250 700(2) 250 700 (4) 60 2051 1228 (12) 70 230 XL (12) 380 504 504 (2) 250 (2) 250 700 700215
YO 2051 409230 (12) 70 (12) 380 504 504 (2) 250 (2) 250 700 700 460 904 485 (12) 35 XL (12) 190 225 225 0000 0000 300 300
(12) 35 460 YO 904 162 (12) 190 300225 225 0000 0000 300 2051 1228208 XL (2) 60 (14) 70 (14) 380 504 525 (2250 700 700(2)300
(2) 75 2083 1415 2051 409 (14) 70 700 700208 YO (2) 60 (14) 380 504 525 (2) 250 (2)300
(2) 75 2083 472240 700XL (2) 60 2051 1228 (14) 70 (14) 380 504 525 (2)250 (2)300 700230
(2) 75 2083 1415 2011230 YO (2) 60 409 (14) 70 (14) 380 504 525 (2) 250 (2)300 700 700
(2) 75 2083 472 300460 XL (2) 60 904 485 (14) 35 (14) 190 225 248 0000 250 300
12 75 974 539 904 162 250 300 300460 YO (2) 60 (14) 35 (14) 190 225 248 410
(2) 75 974 180 2083 1415 (2)300 700 700XL (16) 70 (16) 380 525 525 (2)300208 2083 1415 (2)300 700 700208 YO (16) 70 525 525 (2)300(16) 380
700 7002083 1415 (16) 70 (2300230 XL (16) 380 525 525 (2300 700 700(2300(4) 75 2083 472 (16) 70 (16) 380 525 525 (2300230 XL265
300250 300974 539 (16) 35 248 248 250XL (16) 380 460 (16) 35 300 300974 (16 380 248 250 250YO 539 248460
NOTES 1 XL Across the Line YO Star Delta 2 RLA Rated Load Amps (rated in accordance with ARI Standard 590) LRA Locked Rotor Amps 3 Wire Size Amps equal 125 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for all other motors in the circuit per
NEC 4 Wire size based on copper conductors with 75degG insulation per NEG Table 310-16 Terminal block lugs are sized accordingly Use of oversize wiring may
not fit in terminal blocks 5 Maximum fuse size is based on 175 to 225 of the rated load amps for the largest motor in the circuit plus 100 of the rated load amps for a other motors
in the circuit per NEG VOLTAGE TOLERANCES 208V-230V min 187V Max 253V
480V Min414V Max506V
19
0
(Wd~) 3lV~ M011 ~31VM
006 009 00 OOt OOl OS L 00 L os 0 Ot
V D m (I) (I)
c D m c D o V
- m m -t o
~
~ m D-
aoao 3~nSS3~d ~3100~
APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
0
(Wd~) 3lV~ M011 ~31VM
006 009 00 OOt OOl OS L 00 L os 0 Ot
V D m (I) (I)
c D m c D o V
- m m -t o
~
~ m D-
aoao 3~nSS3~d ~3100~
APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
APPLICATION DATA
POINT LOADING
ArMi I 1 5 1
ACWC 45 THRU 10 SC
COMPRESSOR CONDENSER SECTION SECTION
_ 2 4 bull 1
bull CA
J
Model Dimensions Size A B C D 45 91 - - -55 91 - - -70 145 - - -90 145 - - -110 60 40 160 -125 60 40 160 -135 60 40 160 -145 138 74 107 -160 13830 74 107 -185 138 129 107 -200 138 129 107 -215 106 82 106 80 240 106 82 134 107 265 133 110 134 107
1310
1310
~
1
1310
2
ACwe 110 THRU 200 Ie
COMPREIlOfl CONDENSER SECTION IECnoN
4 -
5Imiddot
ACWC 2t5 THRU 215 SC
Model Loadlnu (LBS) Size 1amp2 3amp4 5amp6 7amp8 9 amp10 45 585 765 550 - -55 705 810 635 - -70 660 890 700 - -90 1025 1500 1175 - -110 1195 635 1525 995 -125 1255 690 1835 1115 -135 1255 665 1880 1105 -145 1330 2380 2160 1450 -160 1330 2440 2280 1515 -185 1235 2575 2980 1360 -200 1275 2635 3020 1380 -215 1010 2270 2590 2240 840 240 1115 2550 2870 2715 1125 265 1380 2980 3515 2750 1175
11
II i middot 2 4 lIf 11 to L
21
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
TROUBLESHOOTING GUIDE
CHILLER UNIT WILL NOT START POSSIBLE CAUSE REMEDY 1 Power off 1 Check main disconnect switch
2 Main line open 2 Check main fuses
3 Incorrect wiring 3 Check the wiring diagram
4 Loose terminals 4 Tiqhten all terminals
5 Control circuit open 5 Check phase loss monitor flow switch circuit breakers temperature control low ambient thermostat low temperature thermostat remote switch etc
6 Time delay 6 Wait
COMPRESSOR HUMS BUT DOES NOT START
POSSIBLE CAUSE REMEDY
1 Low voltage 1a Check at service and unit for loss
b Consult power company
COMPRESSOR CUTS OUT ON LOW PRESSURE SAFETY CONTROL POSSIBLE CAUSE REMEDY 1 Refrigerant shortage 1 Check for leaks -- add refrigerant 2 Restriction in liquid line 2a Plugged strainer - dean or replace
b Liquid line valve partially closed - open valves fully c Expansion valve clogged or inoperative - clean or replace as
required d Solenoid valve partially open - clean or replace as required
3 Low water flow thru cooler 3 Check water flow thru cooler and correct as required
COMPRESSOR CYCLES ON HIGH PRESSURE CONTROL POSSIBLE CAUSE REMEDY 1 Compressor discharge valve partially closed 1 Open valve fully 2 Non-condensible gases in system 2 Operate condenser fans with compressors off If condenser
pressure exceeds saturated pressure corresponding to condenser entering air temperature then purge air from discharge line
3 Overcharge of R-22 3 Purge system while in operation until head pressure reaches a normal level
4 Dirty condenser 4 Clean the condenser 5 Compressor discharge check valve not operating properly 5 Replace if necessary 6 Fans not running 6 Check pressure control setting
CAUSES AND PREVENTION OF FREEZE-UP CAUSES PREVENTION 1 Improper charging 1 Charge per manufacturers recommendation
2 Improperly set safety time delay 2 Check the safety time delay low pressure control for proper setting at the beginning of each season
3 Improper chilled water circulation 3 Use an ample sized cleanable strainer in the chilled water circuit Make certain the strainer is clean to insure full flow and velocity of
chilled water It may sometimes be necessary to treat the water to prevent formation of deposits
4 Not draining for winter shutdown 4 When the system is shut down for the winter remove the drain
plugs and drain the cooler Blowout any remaining water with air
5 Improper pump shutdown 5 Make sure chiller barrel heater is working and flow switch is installed per wiring diagrams
6 Low ambient during air conditioning season 6 Make sure chiller barrel heater is working
NOTE If the ambient temperature is below 32degF freezing can be completely prevented by one of two methods
1 Drain all water from the equipment 2 Add antifreeze to the water
22
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
START-UP CHECK LIST
Unit Model No
Setting unit
Wiring
Piping
Alignment
Before Start-Up
After Start-Up
Yes No a Vibration isolator used
b Spring isolator adjusted for equal height c If rubber-in-shear isolators are used is unit leveled by shimming
a Power wiring complete
b Control wiring complete c Electric service adequate for load
d Power source voltage correct for motor(s) used
e Motor circuit has proper size fusetrons f System wired per diagram
g All lead connections tight h Wiring complies with local codes i Flow switch operation
a Piping complies with applicable codes b External piping independently supported c Chilled water lines insulated
a All belts adjusted and checked for tension b All pulleys checked and adjusted for proper pitch tightness and
alignment
a Open compressor discharge service valve b Open liquid valve(s) c Open suction and discharge valves to pressure gauges (if supplied) d Check rotation of all fan motors e Start auxiliary equipment (pumps fans etc) f Is crankcase heater operating Operate 24 hours prior to unit startup g Check the compressor oil level through the crankcase sight glass The oil
level should be to the top of the glass If the level is low add oil in accordance with the directions in the maintenance instruction
h Check all control settings as specified in Table 1 I Air purged from chilled water system
a Check high pressure control b Check oil temperature safety switch c Check and adjust low pressure or temperature freeze control d Check and adjust operating thermostat e Check and adjust low pressure operating control f Check and adjust expansion valve superheat g Check and adjust capacity control thermostat
23
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184
OPERATING DATA CHILLER Voltage L-1 L-2 L-3 _ Pressure Gauge Readings 1 Suction psig 1 Discharge psig 2 Suction psig 2 Discharge _ psig 3 Suction psig 3 Discharge psig 4 Suction psig 4 Discharge _ psig High pressure switch setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-in) psig psig (Out) 4 (Cut-In) psig psig (Out) Checked Setting - Yes - No (each circuit) Low Pressure Switch Setting 1 (Cut-in) psig psig (Out) 2 (Cut-in) psig psig (Out) 3 (Cut-In) psig psig (Out) 4 (Cut-in) psig psig (Out) Checked Setting -Yes -No (each circuit) 1 Oil Temperature Safety Switch Cut Out 2 Oil Temperature Safety Switch Cut Out 3 Oil Temperature Safety Switch Cut Out 4 Oil Temperature Safety Switch Cut Out If Star-Delta start time delay is seconds Temperature of air entering condenser F Temperature of air leaving condenser of Temperature of chilled water entering chiller OF Temperature of water (chilled) leaving chiller F Chilled water pressure entering chiller psig Chilled water pressure leaving chiller psig
MAINTENANCE Good maintenance practice will prolong the chiller life and will reduce the Ask of system breakdown and expensive service calls
A weekly check of the ACWC-SD unit requires only a few minutes and will prove beneficial in insuring long trouble free operation
WEEKLY CHECKS- with unit in operation for at least four hours 1) Check compressor oil level - At least above 12 of sight glass 2) Record suction and discharge pressures
Typical Condition R22 Ambient 95degF Return water 55degF Leaving water 45degF Suction 62 psig Discharge 270 psig
3) Record ambient temperature 4) Check liquid sight glass
Make sure liquid is clear - no bubbles 5) Check that all fans are running 6) Check entering face of condenser coil for cleanliness 7) Record voltage at unit
All of the above can be performed by building maintenance personnel If oil levels are low or any of the above checked items are questionable consult a qualified serviceman
At least once a year a qualified serviceman should check unit oil levels superheat and control operation
DUNHAM-BUSH USA
P l) bull 130 xUtUC t01 Bmgess RO~ Harrisonburg VA 22801 Phone (540) 434-0711 FAX (540) 434-~ 2118
wvvwdunham-bushcom Form No 6184