WCFX-V Danfoss R134a 50-60Hz MM04100A-0822D R1 Lo

CONTENT
1. INTRODUCTION 5.9.1 Chilled Water Pump Control............................51

1.1 General......................................................................... 3 5.9.2 Condenser Water Pump Control .....................51
1.2 Safety Consideration & Personal Protective 5.9.3 Common Alarm ..............................................51
Equipment (PPE) .......................................................... 3 5.9.4 Chilled Water Pump Interlock And Flow Switch
1.3 General Safety Instructions ........................................... 3 ......................................................................51
1.4 Warning Labels ............................................................. 3 5.9.5 Condenser Water Pump Interlock And Flow
1.5 Warranty ....................................................................... 3 Switch ............................................................51
5.9.6 Customer Control Interlock / Unit Enable
2. PRODUCT DESCRIPTION (Remote) ........................................................51
2.1 General – Nomenclature .............................................. 5 5.9.7 Compressor Oil Sump Heater .........................51
2.2 Components ................................................................. 5 5.9.8 Compressor Start Delay Timer .......................51
2.3 Technical Data .............................................................. 6 5.9.9 Compressor Stage Delay Timer ......................51
2.3.1 Physical Specifications ..................................... 6 5.9.10 Compressor Anti-Recycle Timer .....................51
2.3.2 Electrical Data .................................................. 7 5.9.11 Load Control ..................................................51
2.3.3 Sound Pressure Dat ......................................... 7 5.9.12 Ramp Control .................................................52
2.4 Dimensional Data.......................................................... 8 5.9.13 Staging Control ..............................................52
2.5 Power Entry Location .................................................. 10 5.9.14 Compressor Rotation......................................52
2.6 Water Pressure Drop Data .......................................... 11 5.9.15 Electronic Expansion Valve (EEV)
2.7 Electrical Schematic Diagram...................................... 14 – Refrigerant Flow Control ..............................52
5.9.16 Compressor Unloaded Stop............................52
3. INSTALLATION 5.9.17 Hotgas Bypass Control ...................................52
3.1 Application Precautions............................................... 22 5.9.18 Discharge Superheat Control..........................53
3.2 Inspection ................................................................... 22 5.9.19 Chilled Water Reset .......................................53
3.3 Delivery and Storage .................................................. 22 5.9.20 Demand Limiting ............................................53
3.4 Rigging and Moving .................................................... 22 5.10 Safeties and Alarms ....................................................53
3.5 Location ...................................................................... 23 5.10.1 Low Pressure Limiting ....................................53
3.6 Foundation.................................................................. 23 5.10.2 High Pressure Limiting ...................................53
5.10.3 High Current Limiting ......................................53
3.7 Clearance For Service ................................................ 26
5.10.4 Suction-Discharge Pressure Differential (SDD)
3.7.1 Unit Clearance.................................................... 26
Control ...........................................................53
3.8 Unit Isolation ............................................................... 27
5.10.5 Low Pressure Safety ......................................53
3.9 Noise Consideration.................................................... 28
5.10.6 High Pressure Safety......................................53
3.10 Water Piping ............................................................... 28
5.10.7 Low Differential Pressure Alarm......................53
3.10.1 Piping connections ......................................... 28
5.10.8 Evaporator Freeze Safety ...............................54
3.10.2 Water Quality & Water Treatment ................... 28
5.10.9 Compressor Low Oil Safety ............................54
3.10.3 Water Flow Switch .......................................... 29 5.10.10 Sensor Failure Alarm ......................................54
3.10.4 Evaporator Pump Interlock ............................. 29 5.10.11 Compressor No-Stop Alarm ............................54
3.10.5 System Water Flow Rate ................................ 29 5.10.12 Compressor No-Run Alarm ............................54
3.10.6 Evaporator Fluid Circuit .................................. 29 5.10.13 Compressor Starter Alarm ..............................54
3.10.7 Condenser Fluid Circuit .................................. 31 5.10.14 Low Chilled Water Flow Alarm ........................54
3.11 Evaporator Freeze Protection...................................... 31 5.10.15 Power Loss Reset ..........................................54
3.12 Unit Thermal Insulation ............................................... 31 5.10.16 High Motor Temperature Thermostat ..............54
3.13 Safety Relief Valves .................................................... 31 5.10.17 Compressor Overload Protector .....................54
3.14 Electrical ..................................................................... 32 5.10.18 Volt-Phase Control Relay (PCR) .....................54
3.14.1 Power Wiring .................................................. 32 5.11 Master-slave Sequencing Control ................................55
3.14.2 Control Power ................................................ 32 5.12 Electrical Malfunction ..................................................57
3.14.3 Control Wiring / Field Supplied Interlocking ..... 32 5.13 Shutdown (Overnight or Weekend)..............................57
5.14 Seasonal Shut-Down Procedure .................................57
4. COMMISSIONING
5.15 Seasonal Start-up Procedure ......................................57
4.1 Request for Start-Up Representative ........................... 34 5.16 Freeze Prevention .......................................................58
4.2 Water-Cooled Chiller Start-Up ..................................... 34 5.16.1 Standby At Low Ambient Temperatures ............58
5. OPERATION 5.16.2 In Operation......................................................58
5.16.3 During Maintenance..........................................58
5.1 Operating Principles – The Refrigerant Cycle .............. 35
5.2 Typical Operation ........................................................ 35 6. MAINTENANCE
5.3 Compressor Capacity Control ..................................... 35
6.1 General .......................................................................59
5.4 Oil Management Systems ........................................... 36 6.2 Periodic Inspection ......................................................59
5.3.1 Oil Level ......................................................... 36 6.3 Monthly Inspection ......................................................59
5.3.2 Oil Return System .......................................... 36 6.4 Condenser Maintenance .............................................59
5.3.3 Oil Balancing System ..................................... 36 6.5 Evaporator Maintenance .............................................59
5.5 Variable Frequency Drive ............................................ 36 6.6 Refrigerant Charge .....................................................59
5.5.1 VFD user interface ......................................... 36 6.7 Refrigerant Recovery ..................................................61
5.5.2 VFD Setup and Configuration ......................... 39 6.8 Compressor Oil Charge...............................................61
5.5.3 Warnings and Alarms ..................................... 40 6.9 Recovery And Disposable Of Used Compressor Oil ....61
5.6 Electronic Expansion Valve ......................................... 42 6.10 Unit Schematic Diagram..............................................62
5.6.1 Display Panel for EEV Driver .......................... 42
5.6.2 Modifying the Manufacturer parameters .......... 43 7. TROUBLESHOOTING ...................................................83
5.6.3 EEV Setting Lists............................................ 43
5.6.4 Table of Alarm ................................................ 44 8. APPENDIXES
5.7 Vision 2020i Controller and Interface ........................... 45 8.1 Maintenance Log Sheet ..............................................84
5.7.1 DBGX Graphical User Interface ...................... 45 8.2 Refrigerant Property Chart – R134a ............................85
5.7.2 Status Reading ............................................... 45 8.3 Signals For Pressure Transducer ...............................86
5.7.3 Authorization .................................................. 49 8.4 Signals For Current Transducer .................................89
5.8 Addressing The Vision 2020i Controller And Terminal . 49 8.5 Signals For Voltage Transducer .................................90
5.8.1 Vision 2020i Controller (DB5+) Addressing ..... 49 8.6 Signals For NTC Temperature Sensor ........................92
5.8.2 DBGX Touch Screen Display Panel Setup ...... 50 8.7 Signals For Refrigerant Level Sensors ........................94
5.9 Control Functions ........................................................ 51 8.8 Pre-Testing And Commissioning Check List ................95
-2-
1.0 INTRODUCTION
1.1 GENERAL a. Smoking is prohibited in the refrigeration machinery

Dunham-Bush Poseidon, WCFX-V Variable Speed room.
Water-Cooled Screw Flooded Chillers, have a cooling b. Any work on units and chillers may only be carried
capacity range from 133 to 750 TR [467 to 2637 kW] in out by appropriately trained and instructed staff.
both 50 & 60Hz version using environmentally sound c. The refrigeration units must not be operated unless
R134a refrigerant. The entire product line features high full functional and operational safety and reliability
energy efficiency, installation ease, control flexibility, of all components, safety devices and circuits
high reliability and advanced Vision 2020i controller. (refrigerant and oil circuits, secondary refrigerant
The WCFX-V series is certified in accordance with and cooling water circuits) and of the electrical
AHRI Standard 550/590, meets/ exceeds ASHRAE switchgear is ensured.
Standard 90.1 requirements.
The elements of the safety chain, the alarm sensors,
WCFX-V chillers are manufactured under a careful pilot lamps and controllers shall be adjusted according
quality control system to ensure delivery of high to the designed values and must not be set out of
performance and reliability products. operation, not in part either.
This manual is authored to provide all necessary and
correct information for installation, operation and
maintenance of the latest generation of the Dunham- 1.4 WARNING LABELS
Bush Water-Cooled Screw packaged chillers,
Poseidon, WCFX-V series. All procedures and tasks
specified in this manual for installation, commissioning, Electric Shock
operating and maintenance of the unit shall be
performed by qualified trained personnel. The manual
shall be read thoroughly before attempting to install,
commission, operate or service the unit. Hot Surface
1.2 SAFETY CONSIDERATION & Wear Ear Protective Device

PERSONAL PROTECTIVE
EQUIPMENT (PPE)
When working with chiller(s) which relatively a Do Not Step
complicated equipment, individuals may exposed to
electrical, mechanical or chemical hazards during
installation, operation, maintenance or servicing the
chiller.
Personal Protective Equipment (PPE) should always be 1.5 WARRANTY
used during installation, repair or service work. WCFX-V units are covered by Dunham-Bush’s
Reference should be made to appropriate Material warranty term for a period of 12 months from the date
Safety Data Sheets (MSDS) and Occupational Safety of start-up or 18 months from the date of shipment
and Health Administration (OSHA) guidelines for PPE. whichever comes first. The warranty is limited to part
PERSONAL SAFETY AND THE SAFETY OF replacement excluding labour and consumables such
OTHERS SHOULD NEVER BE COMPROMISED. as refrigerant, oil & filter driers, etc.
Failure to follow recommendations could result in death The unit warranty will be void if any modification to the
or serious injuries. unit is carried out without prior written approval from
Dunham-Bush Industries Sdn. Bhd.
1.3 GENERAL SAFETY

INSTRUCTIONS
Always ensure that all required safety measures are
followed, including those in this document, such as:
PPE, using appropriate tools, employing qualified and
skilled technicians (electricians, refrigeration engineers)
and following local regulations.
The following safety instructions shall be followed when

handling the machine.
-3-
1.0 INTRODUCTION
Figure 1.1 Typical Unit Label
-4-
2.0 PRODUCT DE
ESCRIPTION
2.1 GENERAL – NOMENCLATURE

WC F X 19 S R V E AU EAR 5BR Q
Water Cooled Chiller Blank - Sttandard

Q - Special
Flooded Evaporator
Condense
er Code
Screw Compressor
Evaporato
or Code
Model
Electrical Code
S - Single Compressor AT - 380VV/3ph/50Hz
T - Two Compressors AU - 400VV/3ph/50Hz
CB - 380VV/3ph/60Hz
AR - 460VV/3ph/60Hz
R134a AS - 575VV/3ph/60Hz
Variable Frequency Blank - No Economizer

Compressor E - Econoomizer
2.2 COMPONENTS
E
Economizer to enhance performance
VFD for optimized

d and improved part
Compact, quiet MSC compressor load performance
Controller for precise

and
d reliable control
Bolted
B construction
fo
or easy knockdown
Heat exchangers
with cleanable
copper tubes
and removable
water heads for
easy
serviceability Vessels design
ned in accordance
with ASME codde
-5-
2.0 PRODUCT DESCRIPTION
2.3 TECHNICAL DATA

2.3.1 Physical Specifications
Model WCFX-V 19S 20S 23S 24S 27S 30S 36S 38T 40T 41S
Nominal Capacity TR 133.3 164.5 186.6 202.4 220.8 249.0 292.9 271.3 331.1 332.8
[kW] [468.8] [578.5] [656.3] [711.8] [776.6] [875.7] [1030.1] [954.2] [1164.5] [1170.5]
Nominal Power Input kW 78.8 96.0 106.7 117.7 126.0 145.7 166.2 154.0 189.5 188.1
Energy efficiency kW/TR 0.591 0.584 0.572 0.582 0.571 0.585 0.567 0.568 0.572 0.565
COP 5.95 6.03 6.15 6.05 6.16 6.01 6.20 6.20 6.15 6.22
Min. % Unit Capacity 20% 20% 20% 20% 20% 20% 20% 10% 10% 20%
Power Supply V/PH/Hz 380-415/3/50, 380/3/60, 460/3/60, 575/3/60
Compressor
Model (Qty) 1220(1) 1222(1) 1222(1) 1227(1) 1227(1) 1230(1) 2233(1) 1220(2) 1222(2) 2236 (1)
Oil Charge Approx (Each) Liter 55 50 50 46 46 46 62 55/55 50/50 60
Evaporator
Model FAR EAR JAR JBR 6DR 6ER 7CR 6CR 8BR 7BR
Water Connection Inch 8 6 8 8 8 8 8 8 10 10
Design Press. Water Side 150[1034]
psig [kPa]
Flow rate USgpm [m3/h] 319.2[72.5] 393.8[89.4] 446.9[101.4] 484.7[110.0] 528.8[120.0] 596.1[135.3] 701.3[159.1] 649.5[147.4] 792.8[180.0] 796.9[180.9]
Pressure Drop ft wg [kPa] 4.4 [13.1] 9.5 [28.3] 9.7 [29.0] 9.9 [29.6] 8.5 [25.5] 9.5 [28.3] 10.1 [30.3] 11.1 [33.1] 10.1 [30.3] 10.4 [31.0]
Condenser
Model D2R 5BR 5BR 5CR 6CR 1KR RAR K5R M3R M1R
Water Connection Inch 6 6 6 6 6 8 8 8 10 10
psig [kPa]
Flow rate USgpm [m3/h] 402.3[91.3] 495.6[112.5] 560.7[127.3] 609.5[138.4] 663.2[150.5] 750.3[170.3] 879.0[199.5] 814.1[184.8] 994.8[225.8] 998.3[226.6]
Pressure Drop ft wg [kPa] 7.8 [23.4] 10.6 [31.7] 12.9 [38.6] 11.5 [34.5] 12.0 [35.9] 11.5 [34.5] 12.5 [37.2] 15.2 [45.5] 14.1 [42.1] 12.0 [35.9]
General
Unit Length Inch [mm] 117 7/8 149 7/8 149 7/8 149 7/8 150 3/8 156 1/8 174 7/16 169 1/8 170 5/8 174 7/16
[2990] [3810] [3810] [3810] [3820] [3970] [4430] [4300] [4330] [4430]
Unit Width Inch [mm] 56 1/16 53 3/8 55 5/8 55 5/8 56 1/8 57 1/8 70 56 15/16 63 11/16 70
[1420] (1360] [1410] [1410] [1430] [1450] [1780] [1450] [1620] [1780]
Unit Height Inch [mm] 99 [2520] 99 [2520] 99 [2520] 99 [2520] 99 [2520] 99 [2520] 92 1/8 [2340] 99 [2520] 99 [2520] 94 1/8 [2390]
Unit Shipping Weight lbs [kg] 7224 [3276] 7475 [3390] 8028 [3641] 8363 [3793] 9009 [4086] 9890 [4485] 12928 [5863] 12582 [5706] 14597 [6620] 13891 [6300]
Unit Operating Weight lbs [kg] 7971 [3615] 8336 [3780] 8949 [4058] 9359 [4245] 10108 [4584] 11117 [5042] 14487 [6570] 14006 [6352] 16413 [7444] 15654 [7099]
R134a Charge (Approx) lbs [kg] 353 [160] 435 [197] 494 [224] 536 [243] 584 [265] 659 [299] 775 [351] 718 [326] 876 [397] 881 [399]
Model WCFX-V 46S 46T 50T 54T 57T 60T 73T 75T 81T 87T 90T
Nominal Capacity TR 376.6 375.7 410.2 445.0 475.0 504.6 583.4 623.2 666.5 708.6 748.8
[kW] [1324.5] [1321.3] [1442.7] [1565.1] [1670.6] [1774.7] [2051.8] [2191.8] [2344.1] [2492.1] [2633.5]
Nominal Power Input kW 210.0 210.9 230.0 249.7 267.5 285.6 334.1 356.0 377.1 395.0 425.5
Energy efficiency kW/TR 0.558 0.561 0.561 0.561 0.563 0.566 0.573 0.571 0.566 0.557 0.568
COP 6.31 6.27 6.27 6.27 6.25 6.21 6.14 6.16 6.22 6.31 6.19
Min. % Unit Capacity 20% 10% 10% 10% 10% 10% 10% 10% 10% 10% 10%
Power Supply V/PH/Hz 380-415/3/50, 380/3/60, 460/3/60, 575/3/60
Compressor
1222 (1) 1227 (1) 2233 (1) 2236(1)
Model (Qty) 2246 (1) 1222 (2) 1227 (2) 1230 (2) 2233 (2) 2236 (2) 2246 (2)
1227 (1) 1230 (1) 2236 (1) 2246(1)
Oil Charge Approx (Each) Liter 60 50/50 50/46 46/46 46/46 46/46 62/62 62/60 60/60 60/60 60/60
Evaporator
Model 8DR 8DR KBR YAR YBR YCR MAR MBR NAR PAR PAR
Water Connection Inch 10 10 10 10 10 10 12 12 12 12 12
psig [kPa]
Flow rate USgpm [m /h]3 901.7 899.7 982.1 1065.5 1137.3 1208.3 1397.0 1492.2 1595.9 1696.7 1792.8
[204.7] [204.2] [222.9] [241.8] [258.2] [274.3] [317.2] [338.7] [362.3] [385.2] [406.8]
Pressure Drop ft wg [kPa] 13.4 [40.0] 11.3 [33.8] 10.8 [32.4] 11.1 [33.1] 11.3 [33.8] 11.8 [35.2] 12.2 [36.5] 12.7 [37.9] 11.3 [33.8] 13.6 [40.7] 15.0 [44.8]
Condenser
Model M5R M5R T5R YAR YBR YCR JAR JBR KAR 7CR 8AR
Water Connection Inch 10 10 10 10 10 10 12 12 12 12 12
psig [kPa]
Flow Rate USgpm [m3/h] 1127.4 1125.8 1228.9 1333.4 1423.9 1513.8 1753.1 1871.9 1999.4 2121.3 2247.4
[255.9] [255.6] [280.0] [302.7] [323.2] [343.6] [398.0] [424.9] [453.9] [481.5] [510.2]
Pressure Drop ft wg [kPa] 13.1 [39.3] 12.0 [35.9] 12.7 [37.9] 12.2 [36.5] 12.7 [37.9] 12.9 [38.6] 14.5 [43.4] 13.4 [40.0] 12.5 [37.2] 15.2 [45.5] 15.5 [46.2]
General
Unit Length Inch [mm] 174 7/16 170 5/8 196 3/4 196 3/4 196 3/4 196 3/4 206 11/16 206 11/16 206 11/16 213 3/4 213 3/4
[4430] [4330] [5000] [5000] [5000] [5000] [5250] [5250] [5250] [5430] 5430]
Unit Width Inch [mm] 75 3/16 64 11/16 80 80 80 80 88 3/16 88 3/16 88 3/16 90 3/16 90 3/16
[1910] [1640] [2030] [2030] [2030] [2030] [2240] [2240] [2240] [2290] [2290]
Unit Height Inch [mm] 96 7/8 99 92 97 97 97 99 3/16 99 3/16 96 1/16 98 13/16 98 13/16
[2460] [2520] [2340] [2460] [2460] [2460] [2520] [2520] [2440] [2510] [2510]
Unit Shipping Weight lbs [kg] 14873 15173 17576 19131 19642 20197 24065 24607 27320 29256 30269
[6745] [6881] [7971] [8676] [8908] [9160] [10914] [11160] [12390] [13268] [13727]
Unit Operating Weight lbs [kg] 16864 17183 19730 21565 22164 22824 26948 27680 30796 33222 34385
[7648] [7793] [8948] [9780] [10052] [10351] [12221] [12553] [13966] [15067] [15594]
R134a Charge (Approx) lbs [kg] 996 [452] 994 [451] 1085 [492] 1177 [534] 1257 [570] 1335 [606] 1544 [700] 1649 [748] 1764 [800] 1875 [850] 1981 [899]
Notes: 1. The above data are for Superior models with 2-pass evaporator and condenser which rated in accordance with AHRI Standard 550/590 (I-P)-2015 at
standard conditions. The standard rating conditions are as below:
Chilled Water Inlet/Outlet Temperature 54/44°F [12.2/6.7°C]; Cooling Water Inlet/Outlet Temperature 85/94.3°F [29.4/34.6°C]; evaporator fouling factor
0.0001hr.ft².°F/Btu [0.018 m²·K/kW]; condenser fouling factor 0.00025 hr.ft².°F/Btu [0.044 m2·K/kW].
2. 3 passes and flanges water connection may increase unit length up to 6”.
3. Please consult factory for unit dimensions with different side of water connections and Marine Water Box options.
-6-
2.3.2 Electrical Data

50/60Hz
Power Supply 380Vac ± 10% -3Ph-50Hz 400Vac ± 10% -3Ph-50Hz
Model Compressor Unit Compressor Unit Compressor

WCFX-V Model RLA MCA MFS RLA LRA RLA MCA MFS RLA LRA
19S 1220 (1) 146 183 250 146 733 140 175 300 140 696
20S 1222 (1) 180 225 350 180 929 175 218 350 175 883
23S 1222 (1) 200 250 400 200 929 190 237 400 190 883
24S 1227 (1) 219 274 400 219 1140 208 260 450 208 1083
27S 1227 (1) 236 295 450 236 1140 225 281 500 225 1083
30S 1230 (1) 271 339 500 271 1320 254 317 500 254 1254
36S 2233 (1) 310 388 600 310 1477 292 365 600 292 1403
38T 1220 (2) 290 326 400 145 733 278 312 450 139 696
40T 1222 (2) 354 398 500 177 929 348 391 500 174 883
41S 2236 (1) 352 440 700 352 1762 337 421 700 337 1674
46S 2246 (1) 392 490 800 392 2111 384 480 800 384 2005
46T 1222 (2) 394 443 500 197 929 376 423 600 188 883
1222 (1) 233 929 223 883
50T 424 482 630 411 467 700
1227 (1) 191 1140 188 1083
54T 1227(2) 468 527 630 234 1140 448 504 700 224 1083
1227 (1) 266 1140 253 1083
57T 502 569 700 477 541 800
1230 (1) 236 1320 224 1254
60T 1230 (2) 534 601 700 267 1320 507 570 800 253 1254
73T 2233 (2) 618 695 800 309 1477 586 659 800 293 1403
2233 (1) 356 1477 338 1403
75T 663 752 800 631 716 1000
2236 (1) 307 1762 293 1674
81T 2236 (2) 704 792 1000 352 1762 676 761 1000 338 1674
2236 (1) 403 1762 383 1674
87T 756 857 1000 719 815 1200
2246 (1) 353 2111 336 2005
90T 2246 (2) 792 891 1000 396 2111 768 864 1200 384 2005
60Hz
Power Supply 460Vac ± 10% -3Ph-60Hz 575Vac ± 10% -3Ph-60Hz
Model Compressor Unit Compressor Unit Compressor

WCFX-V Model RLA MCA MFS RLA LRA RLA MCA MFS RLA LRA
19S 1220 (1) 122 153 250 122 608 88 110 175 88 484
20S 1222 (1) 153 191 300 153 771 108 135 225 108 613
23S 1222 (1) 166 207 350 166 771 120 150 250 120 613
24S 1227 (1) 182 227 400 182 946 131 164 250 131 752
27S 1227 (1) 196 245 400 196 946 142 178 300 142 752
30S 1230 (1) 221 277 500 221 1096 162 302 350 162 871
36S 2233 (1) 254 317 500 254 1226 186 233 400 186 975
38T 1220 (2) 243 273 350 121 608 174 196 250 87 484
40T 1222 (2) 304 342 450 152 771 214 241 320 107 613
41S 2236 (1) 293 367 600 293 1462 211 264 400 211 1163
46S 2246 (1) 335 419 700 335 1752 235 294 500 235 1393
46T 1222 (2) 328 369 500 164 771 238 268 350 119 613
1222 (1) 194 771 118 613
50T 358 407 600 258 293 400
1227 (1) 164 946 140 752
54T 1227(2) 391 440 600 195 946 282 317 400 141 752
1227 (1) 221 946 141 752
57T 416 471 700 302 342 450
1230 (1) 195 1096 161 871
60T 1230 (2) 442 497 700 221 1096 320 360 500 160 871
73T 2233 (2) 510 574 800 255 1226 372 419 500 186 975
2233 (1) 295 1226 185 975
75T 550 623 800 396 449 630
2236 (1) 255 1462 211 1163
81T 2236 (2) 589 663 800 295 1462 422 475 630 211 1163
2236 (1) 334 1462 205 1163
87T 627 710 1000 443 503 700
2246 (1) 293 1752 238 1393
90T 2246 (2) 669 753 1000 335 1752 476 536 700 238 1393
Notes: 1.) RLA – Rated Load Amps MCA – Minimum Circuit Amps MFS – Maximum Fuse Size LRA – Locked Rotor Amps
2.) The above data are are for Superior models, which rated in accordance with AHRI Standard 550/590 (I-P)-2015 at standard conditions.
2.3.3 Sound Pressure Data

Model Octave Band (Hz) Total Model Octave Band (Hz) Total
WCFX-V 63 125 250 500 1000 2000 4000 8000 dB (A) WCFX-V 63 125 250 500 1000 2000 4000 8000 dB (A)
19S 68 57 63 68 75 72 72 54 79 46T 70 59 65 70 77 74 74 56 81
20S 68 57 63 68 75 72 72 54 79 50T 71 60 66 70 78 75 75 57 82
23S 68 57 63 68 75 72 72 54 79 54T 71 61 66 70 78 75 76 58 82
24S 69 59 64 68 76 73 74 56 80 57T 71 62 66 70 79 76 76 60 83
27S 69 59 64 68 76 73 74 56 80 60T 72 63 67 71 80 77 76 61 83
30S 70 61 65 69 78 75 74 59 81 73T 72 63 67 71 80 77 76 61 83
36S 70 61 65 69 78 75 74 59 81 75T 72 63 67 71 80 77 76 61 83
38T 71 60 66 71 78 75 75 57 82 81T 72 63 67 71 80 77 76 61 83
40T 70 59 65 70 77 74 74 56 81 87T 74 65 69 73 82 79 78 63 86
41S 70 61 65 69 78 75 74 59 81 90T 75 66 70 74 83 80 79 64 87
46S 73 64 68 72 81 78 77 62 85 Note: Sound Pressure Level dB(A) @ 3.3ft [1m] (free field) ± 2dBA.
-7-
2.4 DIMENSIONAL DATA

WCFX-V 19S, 20S, 23S, 24S, 27S, 30S
Water Connector –
Model Dimensions- inches [mm] inches
Evap. Cond.
WCFX-V Length Width Height A B C D E F G YØ ZØ
19S FAR D2R 117 7/8 [2990] 56 1/16[1420] 99 [2520] 5 5/8 [143] 29 1/4 [743] 6 7/8 [175] 19 3/16 [487] 15 1/4 [387] 13 1/4 [337] 2 7/16 [62] 6 8
20S EAR 5BR 149 7/8 [3810] 53 3/8[1360] 99 [2520] 5 5/8 [143] 27 3/8 [695] 5 5/8 [143] 18 3/16 [462] 15 1/4 [387] 12 3/8 [314] 2 1/2 [64] 6 6
23S JAR 5BR 149 7/8 [3810] 55 5/8[1410] 99 [2520] 5 5/8 [143] 29 3/16 [742] 6 7/8 [175] 19 3/16 [487] 15 1/4 [387] 13 3/8 [400] 1 15/16 [49] 6 8
24S JBR 5CR 149 7/8 [3810] 55 5/8[1410] 99 [2520] 5 5/8 [143] 29 3/16 [742] 6 7/8 [175] 19 3/16 [487] 15 1/4 [387] 13 3/8 [400] 1 15/16 [49] 6 8
27S 6DR 6CR 150 3/8 [3820] 56 1/8[1430] 99 [2520] 5 5/8 [143] 29 [737] 6 7/8 [175] 20 3/16 [513] 15 1/4 [387] 14 1/2 [368] 1 1/2 [38] 6 8
30S 6ER 1KR 156 1/8 [3970] 57 1/8[1450] 99 [2520] 6 1/16 [155] 28 13/16[732] 6 7/8 [175] 20 3/16 [513] 16 1/4 [412] 14 7/16 [367] 1 1/2 [38] 8 8
WCFX-V 36S, 41S, 46S
Cond. Water Connector –

Evap.
WCFX-V Length Width Height A B C D E F YØ ZØ
36S 7CR RAR 174 3/16 [4430] 70 [1780] 92 1/8 [2340] 6 7/8 [175] 35 1/4 [895] 8 1/8 [207] 24 5/16 [618] 2 [51] 15 7/8 [403] 8 8
41S 7BR M1R 174 3/16 [4430] 70 [1780] 94 1/8 [2390] 6 7/8 [175] 36 1/4 [920] 7 3/8 [187] 24 5/16 [618] 1 [25] 15 7/8 [403] 10 10
46S 8DR M5R 174 3/16 [4430] 75 [1910] 96 7/8 [2460] 6 7/8 [175] 37 5/16 [948] 8 1/8 [207] 26 5/16 [669] 2 [51] 20 [508] 10 10
WCFX-V 38T, 40T, 46T
Water Connector –
Evap. Cond.
WCFX-V Length Width Height A B C D E F G YØ ZØ
38T 6CR K5R 169 1/8 [4300] 56 15/16[1450] 99 [2520] 6 1/16 [153] 28 13/16 [732] 6 7/8 [175] 20 1/4 [514] 16 1/4 [413] 14 7/16 [367] 1 5/16 [33] 8 8
40T 8BR M3R 170 5/8 [4330] 63 11/16[1620] 99 [2520] 6 7/8 [175] 32 13/16 [833] 8 1/8 [207] 19 1/2 [495] 20 1/4 [515] 16 7/16[418] - 10 10
46T 8DR M5R 170 5/8 [4330] 64 11/16[1640] 99 [2520] 6 7/8 [175] 32 13/16 [833] 8 1/8 [207] 19 7/16 [494] 20 3/16 [513] 16 7/16[418] 1 [25] 10 10
Notes: 1.) Above drawings and dimensions are for Superior models with vessels construction based on flat head and comply with PED/ JKKP/ Chinese
Machinery codes.
2.) Unit layout shown are for reference only. Some orientations may vary.
3.) Consult factory for models with vessels with ASME/ other approvals.
-8-
WCFX-V 50T, 54T, 57T, 60T
Water Connector –
Evap. Cond.
WCFX-V
Length Width Height A B C D E F YØ ZØ
50T KBR T5R 196 3/4 [5000] 80 [2030] 92 [2340] 6 7/8 [175] 36 3/4 [934] 8 1/8 [207] 27 5/16 [694] 3 [76] 20 [508] 10 10
54T YAR YAR 196 3/4 [5000] 80 [2030] 97 [2460] 7 3/8 [187] 39 11/16 [1008] 8 7/8 [226] 28 5/16 [719] 3 7/8 [99] 20 [508] 10 10
57T YBR YBR 196 3/4 [5000] 80 [2030] 97 [2460] 7 3/8 [187] 39 11/16 [1008] 8 7/8 [226] 28 5/16 [719] 3 7/8 [99] 20 [508] 10 10
60T YCR YCR 196 3/4 [5000] 80 [2030] 97 [2460] 7 3/8 [187] 39 11/16 [1008] 8 7/8 [226] 28 5/16 [719] 3 7/8 [99] 20 [508] 10 10
WCFX-V 73T, 75T, 81T, 87T, 90T
Y( Y(
Water Connector –
Evap. Cond.
WCFX-V
Length Width Height A B C D E F YØ ZØ
73T MAR JAR 206 11/16 [5250] 88 3/16 [2240] 99 3/16 [2520] 8 [203] 40 13/16 [1036] 10 3/16 [258] 29 5/16 [744] 3 1/4 [82] 24 1/2 [622] 12 12
75T MBR JBR 206 11/16 [5250] 88 3/16 [2240] 99 3/16 [2520] 8 [203] 40 13/16 [1036] 10 3/16 [258] 29 5/16 [744] 3 1/4 [82] 24 1/2 [622] 12 12
81T NAR KAR 206 11/16 [5250] 88 3/16 [2240] 96 1/16 [2440] 8 1/8 [207] 48 [1219] 10 1/8 [257] 30 1/4 [769] 4 1/4 [108] 24 1/2 [622] 12 12
87T PAR 7CR 213 3/4 [5430] 90 3/16 [2290] 98 13/16 [2510] 9 3/4 [248] 49 [1144] 10 3/16 [259] 32 5/16 [821] 5 1/4 [133] 25 1/2 [648] 12 12
90T PAR 8AR 213 3/4 [5430] 90 3/16 [2290] 98 13/16 [2510] 9 3/4 [248] 47 3/4 [1213] 10 3/16 [259] 32 5/16 [821] 3 3/8 [86] 25 1/2 [648] 12 12
Notes: 1.) Above drawings and dimensions are for Superior models with vessels construction based on flat head and comply with PED/ JKKP/ Chinese
Machinery codes.
2.) Unit layout shown are for reference only. Some orientations may vary.
3.) Consult factory for models with vessels with ASME/ other approvals.
-9-
2.5 POWER ENTRY LOCATION

a.) WCFX-V 19S, 20S, 23S, 24S, 27S, 30S, 38T, 40T, 46T
b.) WCFX-V 36S, 41S, 46S
c.) WCFX-V 50T, 54T, 57T, 60T
d.) WCFX-V 73T, 75T, 81T,87T, 90T
- 10 -
2.6 WATER PRESSURE DROP DATA (IMPERIAL)

1.) EVAPORATOR 2 PASS - PART 1
100
6AR
5BR
5AR
B3R 5CR
B2R 4AR
1AR
Pressure Drop - ft.wg
1BR
2AR
2BR 7BR
2CR 8CR
10 2DR KDR
KCR
LAR
CFR
CGR
7AR MAR
9BR PCR
7CR
6ER
6DR
1
50 500 5000
Water Flow Rate - USgpm

100
Z3R YBR
Z1R CBR DAR
C2R DCR
7DR CER
C3R
6CR
P2R
6BR
D2R
3BR
JAR MBR
E2R N1R
10 JBR N2R
FAR NAR
PBR
SAR
SCR
CDR SDR
KAR
TAR
BBR
TBR
8AR
8BR
1
100 1000
- 11 -

100
P1R 8DR CAR

P3R BAR
EAR
9AR
Z2R
PAR
DBR
YCR
10
KBR
CCR
YAR LBR
1
100 1000
4.)CONDENSER 2 PASS - PART 1

100
K4R
6CR
J5R
F4R V2R
A4R
B2R J4R
E1R 4AR
E2R
E3R
M4R
E4R
10
T3R
H1R
U1R
E5R
Y2R
Y7R
1BR
RAR JAR 8AR
1KR V2R
M1R
1
50 500 5000
- 12 -
5.) CONDENSER 2 PASS - PART 2

100
Y6R
M3R Y5R
X1R Y4R 7AR
L2R X5R 1CR
K5R M2R
B3R
K1R X3R
B4R
K3R
B5R
5AR
C2R
KAR
F2R
10 SDR
5CR
8CR
D2R
9AR
9BR
WAR
7CR WBR
T4R
YBR 7BR
JBR
1
100 1000
6.)CONDENSER 2 PASS - PART 3

100
G2R Y3R
F3R
5BR
V1R
X2R
M5R X4R
T5R
10
Y1R
YAR
YCR
Z1R
8BR
U2R
1
100 1000
- 13 -
2.7 ELECTRICAL SCHEMATIC DIAGRAM

1.) One Compressor Models
- 14 -
∼ ∼
- 15 -
- 16 -
2.) Two Compressors Models
- 17 -
∼ ∼
- 18 -
∼ ∼
Ω
- 19 -
- 20 -
- 21 -
3.0 INSTALLATION
3.1 APPLICATION B. Check the model number and the electrical

characteristics on the nameplate to determine if
PRECAUTIONS they are correct.
Dunham-Bush packaged chillers are designed for C. Check for freight damage, shortages or other
chilled water or other non-corrosive liquids. The liquid discrepancies and note them on the delivery receipt
to be chilled is to be circulated through the tubes of a before signing.
refrigerant evaporator where the temperature is D. In the event that any damage is found, a damage
reduced to the desired level. The heat absorbed by the claim should immediately be filed by the purchaser
refrigerant in the evaporator is rejected via the against the forwarder.
condenser coils where it raises the temperature of
cross flow air.
Care should be taken to ensure that the equipment is
properly installed and adjusted. Only trained and
3.3 DELIVERY AND STORAGE
qualified installers are allowed to carry out the If the unit will be stored for an extended period prior to
installation works. the installation, below precautions shall be observed.
The following regultations shall be observed to ensure A. Store the unit in secured location and protected
the safety and functional reliability of the chiller from construction dirt.
packages: B. Remain the shipping packing until the unit is ready
A. For the installation of refrigeration machines and the for installation.
protection of personnel (EN378-3) C. Close all the refrigerant isolation valves
B. For testing the refrigeration machine prior to its D. Recommended to have periodic inspection during
start-up (EN378-2) the storage period
C. For renewal testing (EN378-2)
D. For testing for corrosion (EN378-2)
E. For taking a plant record (EN378-2 and EN378-4) 3.4 RIGGING AND MOVING
F. For taking measures in case of emergency (EN378-
2) Each unit has been carefully tested and crafted at the
G. For instruction of the competent operating factory where every precaution is taken to assure that
personnel (EN378-4) the unit reaches you in perfect condition. It is very
important that the riggers and movers should use the
H. For maintenance and repair (EN378-4)
same care and precaution in moving the equipment into
I. For recovery, reuse and disposal of refrigerants, oil, place. Make sure that chains, cables, or other moving
secondary refrigerants and parts of the refrigeration equipment are placed so as to avoid damage to the unit
machine (e.g. filters, driers, heat insulation) (EN378- or piping. The refrigerant piping must not be used as a
4) ladder or as a hand hold. Do not attach a chain hoist
J. For handling and storage of refrigerants (EN378-4) sling to the piping or equipment. Move the unit in an
upright position and let it down gently from trucks or
IMPORTANT: Dunham Bush is not liable for
rollers.
damage resulting from the operator’s
infringement of the mentioned rules Any unit mounted on skids may be moved with a forklift,
or other laws and regulations binding but care must be taken not to damage the unit with
at the respective place of installation. forks. The skids should not be removed until the unit is
at its final location. Refer to Rigging Instrutions on
Figure 3.4A
3.2 INSPECTION The unit is to be rigged through the holes in the base
side rails. In all cases, spreader bars must be used
Packaged units are fully assembled in factory and between rigging lines to prevent coil or fan deck
charged with refrigerant. Units are tested and inspected damage. The unit must be lifted using All Rigging
before it leaves the factory. Points. Refer to Rigging Instructions on Figure 3.4B.
When the equipment is received, it is important that the All models can be pushed or pulled (with chains)
following inspections to be completed in the presence from the unit end only. Truck forks must be kept
of the forwarder’s representative. level and not tilted back. Do not raise the end of the
A. Check all crates and cartons received against the unit more than 2" [51mm] off the floor.
Bill of Lading/ Shipping Papers to be sure they
agree.
- 22 -
3.0 INSTALLATION
3.5 LOCATION 3.6 FOUNDATION

The units are designed for indoor operation and shall The foundations must have adequate structural
be installed on suitable flat level foundation, which strength to fully support the unit’s operating weight as
capable to support weight of the unit. Installation shown in section 2.3.1 Physical Specifications.
location shall comply to local authorities’ requirements, Foundations must be levelled for proper operation and
as well as with restricted access to authorized trained functioning of controls and provision must be made for
personnel only. Unit shall be installed at area where the supporting the individual load points as shown in Figure
o
surrounding ambient temperature is 40 to 104 F [4.4 to 3.6 Floor Loading Diagram. The unit must be levelled to
o
40 C] within 1/16” per foot [5.2mm per meter] for proper
operation.
Another consideration which must be taken into
account is that the unit should be mounted away from Unit shall not be secured on building’s foundation to
noise sensitive spaces and must have adequate avoid noise and vibration transmission. Vibration
support to avoid vibration and noise transmission into isolators are recommended for unit installation at
the building. Units should be mounted over corridors, rooftop.
utility areas, rest rooms or other auxiliary areas where
sound levels are not an important factor. Sound and
structural consultants should be retained for
recommendations on critical installations.
Figure 3.4A Moving Unit With Fork Lift
USE SKID TO AVOID DAMAGE TO

THE UNIT
- 23 -
3.0 INSTALLATION
FIGURE 3.4B RIGGING DIAGRAM

Rigging should be done in a manner so that no strain is placed on unit components other than at cable connection
points
Sample 1
Sample 2
Note: Spreader bar supplied by others.

Please contact Dunham-Bush if further
information about the spreader bar is
required.
- 24 -
3.0 INSTALLATION
Figure 3.6: Floor Loading Diagram

WCFX-V 19S, 20S, 23S, 24S, 27S, 30S, 38T, WCFX-V 36S, 41S, 46S, 50T, 54T, 57T, 60T,
40T, 46T 73T, 75T, 81T, 87T, 90T
1.) Point Load Location - Inches[mm]

Model
L1 L2 L3 L4 L5 W1 W2
WCFX-V
19S 3 3/8 [86] 105 7/8 [2689] 8 5/8 [219] - - 6 [152] 8 7/16 [214]
20S 3 3/8 [86] 137 7/8 [3502] 8 5/8 [219] - - 6 [152] 8 1/2 [216]
23S 3 3/8 [86] 137 7/8 [3502] 8 5/8 [219] - - 6 [152] 7 11/16 [202]
24S 3 3/8 [86] 137 7/8 [3502] 8 5/8 [219] - - 6 [152] 7 11/16 [202]
27S 3 5/8 [92] 137 7/8 [3502] 8 7/8 [225] - - 6 [152] 7 1/2 [191]
30S 3 5/8 [92] 137 7/8 [3502] 14 5/8 [371] - - 6 [152] 7 1/2 [191]
36S 20 [508] 40 11/16 [1033] 40 11/16 [1033] 50 11/16 [1287] 20 [508] 11/16 [17] 11/16 [17]
38T 3 5/8 [92] 150 7/8 [3832] 14 5/8 [371] - - 6 [152] 7 5/16 [186]
40T 4 7/8 [124] 150 7/8 [3832] 14 5/8 [371] - - 6 [152] 6 [152]
41S 20 [508] 40 11/16 [1033] 40 11/16 [1033] 50 11/16 [1287] 20 [508] 11/16 [17] 11/16 [17]
46S 20 [508] 40 11/16 [1033] 40 11/16 [1033] 50 11/16 [1287] 20 [508] 11/16 [17] 1 1/2 [38]
46T 4 7/8 [124] 150 7/8 [3832] 14 5/8 [371] - - 6 [152] 7 [178]
50T 15 [381] 55 [1397] 55 [1397] 55 [1397] 15 [381] 1 1/2 [38] 1 1/2 [38]
54T 15 [381] 55 [1397] 55 [1397] 55 [1397] 15 [381] 1 1/2 [38] 1 1/2 [38]
57T 15 [381] 55 [1397] 55 [1397] 55 [1397] 15 [381] 1 1/2 [38] 1 1/2 [38]
60T 15 [381] 60 [1524] 60 [1524] 45 [1143] 15 [381] 1 1/2 [38] 1 1/2 [38]
73T 15 [381] 53 11/16 [1363] 60 11/16 [1541] 60 11/16 [1541] 15 [381] 1 1/2 [38] 1 1/2 [38]
75T 15 [381] 53 11/16 [1363] 60 11/16 [1541] 60 11/16 [1541] 15 [381] 1 1/2 [38] 1 1/2 [38]
81T 15 [381] 53 11/16 [1363] 60 11/16 [1541] 60 11/16 [1541] 15 [381] 1 1/2 [38] 1 1/2 [38]
87T 15 [381] 60 11/16 [1541] 60 11/16 [1541] 60 11/16 [1541] 15 [381] 1 1/2 [38] 1 1/2 [38]
90T 15 [381] 60 11/16 [1541] 60 11/16 [1541] 60 11/16 [1541] 15 [381] 1 1/2 [38] 1 1/2 [38]
2.) Point Load Data - Lbs [kg]

Model Operating
P1 P2 P3 P4 P5 P6 P7 P8
WCFX-V Weight
19S 1762 [799] 2499 [1134] 1851 [839] 1859 [843] - - - - 7971 [3615]
20S 2094 [950] 2711 [1229] 1837 [833] 1695 [769] - - - - 8336 [3780]
23S 2101 [953] 2868 [1301] 1993 [904] 1987 [901] - - - - 8949 [4058]
24S 2212 [1003] 3018 [1369] 2082 [944] 2048 [929] - - - - 9359 [4245]
27S 2384 [1081] 3235 [1467] 2220 [1007] 2269 [1029] - - - - 10108 [4584]
30S 2032 [921] 4164 [1888] 2073 [940] 2848 [1291] - - - - 11117 [5042]
36S 1543 [700] 2320 [1052] 1480 [671] 2222 [1008] 1417 [643] 2124 [963] 1354 [614] 2026 [919] 14484 [6569]
38T 3075 [1395] 3994 [1811] 3160 [1433] 3777 [1713] - - - - 14006 [6352]
40T 3759 [1705] 4259 [1931] 4089 [1854] 4307 [1953] - - - - 16413 [7444]
41S 1626 [738] 2550 [1156] 1558 [706] 2443 [1108] 1489 [675] 2336 [1059] 1420 [644] 2229 [1011] 15651 [7098]
46S 1915 [868] 2590 [1174] 1830 [830] 2482 [1126] 1744 [791] 2375 [1077] 1659 [752] 2267 [1028] 16861 [7647]
46T 3970 [1800] 4765 [2161] 3966 [1799] 4482 [2033] - - - - 17183 [7793]
50T 2203 [999] 2710 [1229] 2154 [977] 2771 [1257] 2105 [955] 2832 [1284] 2056 [933] 2893 [1312] 19726 [8946]
54T 2353 [1067] 2981 [1352] 2316 [1050] 3055 [1386] 2280 [1034] 3129 [1419] 2243 [1017] 3204 [1453] 21561 [9778]
57T 2444 [1108] 3052 [1384] 2399 [1088] 3126 [1418] 2355 [1068] 3200 [1451] 2310 [1048] 3274 [1485] 22160 [10050]
60T 2511 [1139] 3124 [1417] 2478 [1124] 3203 [1453] 2446 [1109] 3283 [1489] 2413 [1094] 3362 [1525] 22820 [10349]
73T 3317 [1505] 3547 [1609] 3134 [1421] 3644 [1653] 2951 [1338] 3742 [1697] 2768 [1255] 3839 [1741] 26943 [12219]
75T 3396 [1540] 3651 [1656] 3209 [1455] 3752 [1702] 3022 [1371] 3853 [1747] 2835 [1286] 3954 [1793] 27674 [12550]
81T 3650 [1655] 4099 [1859] 3483 [1580] 4232 [1919] 3316 [1504] 4364 [1979] 3149 [1428] 4496 [2039] 30790 [13963]
87T 3715 [1685] 4471 [2028] 3646 [1653] 4619 [2095] 3576 [1622] 4767 [2162] 3506 [1590] 4915 [2229] 33215 [15064]
90T 3809 [1727] 4642 [2105] 3746 [1699] 4800 [2177] 3684 [1671] 4958 [2249] 3622 [1642] 5116 [2320] 34378 [15591]
Note: Unit must be lowered onto mounting springs in a level fashion or spring damage may occur.
- 25 -
3.0 INSTALLATION
trouble and result in higher costs for operation,
3.7 CLEARANCE FOR SERVICE maintenance and repair.
Sufficient clearance around the unit is required to
Front – 45” [1143mm]
ensure proper unit operation, and as space for service
and maintenance works. Rear – 18” [457mm]
Below clearance requirements are general guideline, Top – 18” [457mm]
where local health and safety regulations, and other End – Tube length at one side for tube servicing; 36”
practical considerations shall be taken into account. [914mm] at the other end.
Failure to allow these clearances will cause serious
3.7.1 Unit Clearance

1.) WCFX-V 19S, 20S, 23S, 24S, 27S, 30S, 38T, 40T, 46T
2.) WCFX-V 36S, 41S, 46S
3.) WCFX-V 50T, 54T, 57T, 60T, 73T, 75T, 81T, 87T, 90T
- 26 -
3.0 INSTALLATION
3.8 UNIT ISOLATION 3. Lift up the chiller as per the instructions in Section 3.4
Rigging, and position the chiller on top of the upper
In case of structure-borne vibration may be of concern, housing of the spring isolators.
it is recommended to install vibration isolators under
(For spring isolator models DHB only)
the base of the Packaged Chiller.
4. Align mounting hole of the chiller base with the
Rubber-in-shear or spring vibration isolators are offered leveling screw bolt hole of the upper housing of the
as optional items. When spring isolators are used, spring isolators.
flexible connections must be installed in the water 5. Pass through leveling screw bolt & turn Clock-Wise
piping system and in the refrigerant lines if it is a split (CW) to load spring until desired level (FH & OH) is
system. achieved. Leave the locking nut loose for moment.
Note: These flexible connectors must be suitable 6. After completing level adjustment of all spring
for the fluid and pressures involved. isolators, lock the locking nut of the spring isolators
tight. (CW)
All piping which is external to the chiller must be 7. Bolt down the spring isolators to the floor.
supported by spring mounted hangers and any piping 8. Spring isolator can be installed at either hole of
which goes through the wall, ceiling or floor should be each vessel skidlet (valid for compact foot print
properly sheathed to prevent transmission of piping design only).
vibration to the structure.
(For spring isolator models YRS only)
When spring isolators are used, electrical service to the 4. Align mounting hole of the chiller base with the
unit must also be connected by means of a 36" [914mm] tapped hole of the upper housing of the spring
section of flexible conduit. isolators.
The installation of spring isolators shall follow the 5. Adjust the leveling screw bolt until desired level (FH &
instructions as below: OH) is achieved. Turn clock-wise (CW) to load spring
or counter-clockwise (CCW) to unload spring.
1. Place all the spring isolators in place on the 6. After completing level adjustment of all spring
foundation, according to the isolator models and isolators, lock the tapped bolt tight (CW) to fix the
locations in the provided GA drawing. spring isolators to the chiller.
2. (For spring isolator models DHB only) Unscrew 7. Bolt down the spring isolators to the floor.
leveling screw bolt (assembled with spring isolator) 8. Spring isolator can be installed at either hole of
by turning counter-clockwise, (CCW) from the spring each vessel skidlet (valid for compact foot print
isolator. design only).
Figure 3.8 Spring Vibration Isolators

DHB-S-1 DHB-S-2
YRS-2 YRS-4 YRS-6
FH & OH = Free Height and Operating Height
- 27 -
3.0 INSTALLATION
3.9 NOISE CONSIDERATION It is important that the water system be cleaned before
start up to avoid collecting debris in the heat
Another consideration is the chiller must not be located exchangers. After filling the system with water (or a
near noise sensitive spaces. The chiller must have glycol solution), start pump, bleed off trapped air, and
adequate support to avoid vibration and noise check for proper flow rate by measuring water pressure
transmission into the building. Chiller could be mounted drop across evaporator and condenser.
over corridors, utility areas, rest rooms or other auxiliary Note: Cleanable strainer, preferably of 20 mesh
areas where sound level is not an important factor. shall be installed as close as possible to the
Sound and Structural consultants should be consulted evaporator and condenser water inlet
for critical installations connection, to remove impurities and debris
Refer to section 2.4.4 for unit sound pressure data. before they reach the evaporator.
3.10.2 Water Quality & Water

3.10 WATER PIPING Treatment
3.10.1 Piping connections Evaporators and condensers used in these packages
are made of steel, copper and brass and are suitable
Refer to the dimensional drawings for water piping for operation with well-maintained water systems.
connection locations. Note that the However, if the water used in evaporator or condenser
evaporator/condenser water inlet must be connected to is corrosive, high in mineral content or entrained solids,
the bottom (condenser water inlet). If necessary, the foreign particles in the water can cause increases in
evaporator or condenser headers can be swapped, heat exchanger pressure drop and fouling factor, and
from the left to the right end of the vessel or vice versa subsequently reduced the unit performance and even
to suit site water piping conditions. failure of heat exchangers. Therefore, it may be
necessary to obtain the services of a water treatment
Note: Leaving chilled water temp sensor must be
consultant and to provide and maintain water treatment.
located at leaving chilled water stream.
This is particularly important with glycol solution
After the unit has been levelled and isolators (if any) systems.
installed & adjusted, connect evaporator and
Fouling factor correction factor as shown in below table
condenser water piping, keeping in mind that the
may need to be included due to level of water quality.
evaporator and condenser tubes may require cleaning
or replacement at some future date, and removable
sections of piping will be required to permit evaporator Table 3.10.2A Correction Factor – FF
and condenser head removal. (Evaporator)
Piping must be supported to avoid excess stress on the Fouling Factor Capacity
kW Correction
Correction
evaporator and condenser heads. Cut piping holes in Hr.ft².°F/BTU m².°C/kW Factor
Factor
the panel at the end of the unit, if there is any. Install air
vent points to permit complete air purging of the water 0.00010 0.018 1.000 1.000
circuits. Install drain valves in similar low points to 0.00025 0.044 0.992 0.998
facilitate complete water system drainage. Install 0.00050 0.088 0.979 0.995
temperature & pressure indicators in the water piping at
0.00075 0.132 0.967 0.991
the unit to monitor water flow. Install shut-off valves to
isolate the unit from the piping system during unit 0.00100 0.176 0.955 0.987
servicing.
Water pressure gauges are recommended to check the Table 3.10.2B Correction Factor – FF
water pressure and flow rate in the system, before and (Condenser)
after the evaporator and condenser, and to determine if
Fouling Factor Capacity
variations occur in the evaporator, condenser and kW Correction
Correction
system. When installing pressure taps to measure the Factor
Hr.ft².°F/BTU m².°C/kW Factor
amount of pressure drop across the water side of the
0.00025 0.044 1.000 1.000
heat exchangers, the taps should be located at least 24
inches [610mm] downstream from any connections 0.00050 0.088 0.992 1.018
(flange, elbow, etc.) in the water piping. 0.00075 0.132 0.983 1.036
Note: Due to possible high pressures resulting 0.00100 0.176 0.973 1.054
from rising temperatures, do not close shut-

off valves with cold water in the heat
exchangers.
- 28 -
3.0 INSTALLATION
3.10.3 Water Flow Switch and water velocity may contribute to a greater fouling.
The quality of the water could be maintained by
A flow switch must be installed at evaporator outlet to chemical treatment and periodical cleaning. The curve
proof the chilled liquid flow through the evaporator. This plotted is based on a clean water system.
is to prevent damage to the evaporator resulted by unit
operation with insufficient fluid flow.
3.10.6 Evaporator Fluid Circuit
Evaporator flow switch can be supplied as an optional
item. The flow switch is factory shipped loose, field Operating Limits - Leaving Evaporator
installed item. There are three options available.
Fluid Temperature
Part Number Description Leaving Fluid Temperature Minimum Maximum
3101100020 Weather tight flow switch with CE mark Standard 39.2 oF [4 oC] 50 oF [10 oC]
3101100003 NEMA 1 rated flow switch Dual Mode / Low Temp. Operation 18 oF [-7.8 oC] 50 oF [10 oC]
H021129A3 NEMA 4 rated flow switch
The flow switch must be located in a horizontal section 3.10.6.1 Wide Range ΔT - Low Flow
on the pipe where there is at least five (5) pipe Applications
diameters on both sides of the flow switch before any Multiple smaller chillers may be applied in
other connections, as indicated in Figure 3.10.3. The series, each providing a portion of the
flow switch paddle must be adjusted to the size of pipe
design temperature range typical 10°F
in which the paddle is installed, and the switch set to
[5.5°C] each.
trip at approximately minimum operating flow rate.
Refer to the unit wiring diagram for the electrical Chilled fluid may be recirculated through the
connections to interlock the Chilled Water Flow evaporator as shown below to allow the
Switch (CWFS) with the control panel. chiller to operate with acceptable flow rates
and temperature ranges (Figure 3.10.6.1).
Figure 3.10.3 Flow Switch
Figure 3.10.6.1
The same flow switch can be also supplied as an

optional item for condenser water flow detection.
This may help to prevent high condenser pressure
alarm which caused by condenser water flow loss.
The mixed fluid temperature range through the evaporator for units with
standard evaporators, should not be less than 7.5°F [4.2°C].
3.10.4 Evaporator Pump Interlock
A chilled water pump starter interlock must be 3.10.6.2 Narrow Range ΔT - High Flow
connected to the controller (as shown in the field wiring Applications
diagram). For chillers installed with common header
water piping design, this interlock can be connected to For Narrow Range ΔT applications, a
the motorized valve interlock. This served as secondary partial evaporator bypass piping and valve
protection to proof chilled liquid flow through the configuration can be used as shown below.
evaporator. This permits a higher ΔT and lower ΔP
(pressure drop) through the evaporator
(Figure 3.10.6.2).
3.10.5 System Water Flow Rate
The quantity of liquid being circulated can be measured Figure 3.10.6.2
quite accurately ( ± 5%) by determining the water
pressure drop through the heat exchangers and
reading flow rate from the heat exchanger pressure
drop curve. Connect reliable pressure gauges to valves
installed in heat exchangers entering and leaving water
vent connections and read pressure difference with
pumps in operation. An alternative method of
determining flow rate is to measure pressure difference
from pump inlet to outlet and read flow rate from pump
curve.
However due to the quality of water at the jobsite, the
accuracy of the curve might vary. Conditions such as
The fluid mixes after the evaporator.
water hardness, organic material, suspended solids
- 29 -
3.0 INSTALLATION
3.10.5.3 Minimum Chilled Fluid Loop capacity is required or the load profile
Volume dictates, multiple chillers may be piped in
parallel. Units of equal size help to ensure
The evaporator fluid circuit requires a
fluid flow balance, but balancing valves
minimum system fluid volume of 3 US
ensure balanced flows even with dissimilar
gallons per Ton [3.3 liters/ cooling kW] for
sized chillers.
stable operation. The minimum system
fluid volume may increasing up to 10 US Temperature controller sensors may or may
gallons per Ton [11 liters/ cooling kW] for not need to be moved to the common fluid
process cooling, low load applications with piping depending on the specific application.
small temperature range and/or vastly Parallel Chiller Applications – Both units
fluctuating load conditions. operate simultaneously modulating with
load variations. Each unit operates
independently sensing its own leaving fluid
3.10.6.4 Tanks for System Volume temperature. The set point of each
Enhancement thermostat is set to maintain the desired
It may be necessary to install a tank in the loading scheme. (Figure 3.10.6.5A)
system to provide sufficient system fluid
volume, as shown below. The tank should Figure 3.10.6.5A
be baffled and piped for proper fluid mixing
to prevent stratification.
Figure 3.10.6.4A
Figure 3.10.6.4B Single Loop System with Storage

Tank to Increase Loop Volume
Series Chiller Applications – Where a

large temperature range is required (over 25
°F [13.9 °C]), the chiller may be piped in
series. In this case the units are controlled
independently. The load is progressive by
Figure 3.10.6.4C Primary and Secondary Loop temperature so the chiller selections are
Systems are normally used where critical. (Figure 3.10.6.5B)
the secondary system has variable
flow and/or multiple loads. See
Figure 3.10.6.5B
example below.
3.11.5.5 Multiple Chillers In A Chilled

Water System
Where the load is greater than available
from one packaged chiller, where standby
- 30 -
3.0 INSTALLATION
3.10.6.6 Variable Evaporator Flow The use of glycol causes a derated performance as
shown below which needs to be included in the unit
Dunham-Bush chillers are capable for
selection procedure.
variable evaporator flow system. The chiller
may operate to maintain constant leaving
Table 3.11A : Ethylene Glycol
fluid temperature with evaporator flow rate
changes, with below conditions fulfilled. % E. G. Freeze Point C1 K1 G1 P1
By Capacity kW Flow P.D.
D Evaporator fluid flow rate is within Weight °F °C Factor Rate Factor Factor
minimum and maximum flow rate of the
10 26.2 -3.2 0.995 0.998 1.019 1.050
unit at all time during the operation
15 22.4 -5.3 0.991 0.997 1.030 1.083
D Rate of flow changed shall not exceeded
10% per minute 20 17.8 -7.9 0.988 0.996 1.044 1.121
Failure to comply with the above conditions 25 12.6 -10.8 0.984 0.995 1.060 1.170
will cause problem to the chiller operation 30 6.7 -14.1 0.981 0.994 1.077 1.219
and may cause the chiller to shutdown.
Table 3.11B : Propylene Glycol
3.10.7 Condenser Fluid Circuit
% P. G. Freeze Point C2 K2 G2 P2
The unit is designed to work with constant condenser By Capacity kW Flow P.D.
Weight °F °C Factor Rate Factor Factor
flow, variable condenser flow is not recommended.
Variable condenser flow will keep condenser pressure 10 26.1 -3.3 0.988 0.994 1.005 1.019
high at the chiller, and thus, decreases chiller’s 15 22.8 -5.1 0.984 0.992 1.008 1.031
efficiency and increase power consumption of the
20 19.1 -7.2 0.978 0.990 1.010 1.051
system. In addition, variable condenser flow increases
25 14.5 -9.7 0.970 0.988 1.015 1.081
rate of fouling of condenser, which will de-rating chiller
performance and increases unit maintenance cost. 30 8.9 -12.8 0.962 0.986 1.021 1.120
The unit can be operated with condenser inlet water

temperature above 55°F [12.8°C] up to 105°F [40.6°C],
with minimum pressure differential of 25PSID between 3.12 UNIT THERMAL
evaporator and condenser. If a cooling tower is used to INSULATION
reject heat from the condenser water loop, it shall be
controlled to maintain condenser water temperature WCFX-V units are pre-insulated in factory. WCFX-V’s
above minimum allowed temperature, minimized evaporators and cold surfaces are insulated with 1”
temperature fluctuation, as well as the minimum [25mm] thick closed cell insulation.
pressure differential. This control can be achieved by Double thick insulation can be supplied as optional item.
the mean of fan speed control or fan staging. If the unit 2” [50mm] closed cell insulation is applied on
is required to operate with condenser inlet water evaporator for extra resistance to condensation.
temperature lower than 55°F [12.8°C], a bypass control Condenser insulation can be supplied as optional item
at condenser water loop is recommended to maintain for heat recovery chillers. 1” [25mm] thick closed cell
condenser inlet water temperature is always higher insulation is provided to discharge piping and
than 55°F [12.8°C]. condenser to reduce heat losses during heat recovery
operation, and to prevent unpleasant human contact
with hot surface.
3.11 EVAPORATOR FREEZE
PROTECTION
3.13 SAFETY RELIEF VALVES
If the chiller or fluid piping may be exposed to
temperatures below freezing, glycol protection is The evaporators and condensers are protected against
recommended if the water is not drained. The overpressure by safety refrigerant relief valves, in
recommended protection is 10°F [5.6°C] below the accordance to ASME Boiler and Pressure Vessel Code.
minimum ambient temperature in the equipment room The compressors are also installed with refrigerant
and around piping. Use only glycol solutions approved relief valve which connected to its high pressure
for heat exchanger duty. DO NOT use automotive anti- chamber.
freezing.
If the equipment is being used to supply chilled fluid
39.2°F [4°C] or below, glycol should be used to prevent
freeze damage. The freeze protection level should be
15°F [8.3°C] lower than the leaving brine temperature.
- 31 -
3.0 INSTALLATION
Relief valve venting shall be installed for federal, state, 3.14.2 Control Power
local codes and regulations conformity. Vent pipe sizing
shall be in accordance to ANSI/ASHRAE Standard 15 The main supply voltage to 115Vac step down
(Safety Standard for Refrigeration Systems) when is transformer is supplied as standard with the unit. Power
installed. Never install any kind of shut-off valve in the supply to step down transformer is taken from main
safety relief vent line. power supply of chiller, with fuse protection.
115Vac control voltage is used by controls, solenoid

valves, compressor crankcase heaters, motor starters,
3.14 ELECTRICAL etc.
3.14.1 Power Supply Wiring

3.14.3 Control Wiring / Field Supplied
Power supply to the unit must conformed and match Interlocking
the unit nameplate in volts, phase, and Hertz. Power Control wiring for below unit inputs/outputs should be
supply voltage MUST NOT vary beyond ±10% of made where applicable to ensure stable unit operation.
nameplate rated value. Voltage imbalance between
phases MUST NOT exceed 2% and current imbalance D Chilled Water Pump Interlock (24Vac; Mandatory)
between phases MUST NOT exceed 10% at any time D Chilled Water Flow Switch Interlock (24Vac;
during operation of the unit. Correct phasing of power Mandatory)
supply shall be check and confirm. D Remote Start/Stop (24Vac)
All field power wiring shall be carried out in accordance D Alarm Relay Output (Volt-free contact)
with the National Electric Code (NEC) and comply with D Chilled Water Pump Control (Volt-free contact,
local codes and regulations. Refer to electrical data and Optional)
wiring diagram shipped with the unit or the unit D Chilled Water Reset (4-20mA; Optional)
submittals for unit MCA (Minimum Circuit Amps), MFS D Demand Limiting (4-20mA; Optional)
(Maximum Fuse Size), and field wiring terminations.
MCA shall be used for wire sizing and MFS shall be Unit digital inputs, analogue inputs and outputs shall be
used for overcurrent device sizing. run with shielded cable, with the shielded grounded at
WCFX-V series is designed with single power point one end only. The unit digital outputs with volt-free
termination requires single set electrical power supply contacts are rated AC 240V 5A, DC 30V 5A.
with disconnect to the unit. Overcurrent protection To ensure stable operation of control system, DO NOT
device or disconnect switch shall be field supplied
run low voltage (< 30V) wiring together with cables with
between main incoming and unit terminal blocks, in
higher voltage (> 30V) in the same cable tray or conduit.
accordance to NEC and local codes and regulations.
Main disconnect switch at unit is available as option. Important: Do not use chilled water pump operation
via the flow switch or auxiliary chilled water pump
Field wires shall be sized as per NEC current ampacity
contacts to start & stop this unit. These are safety
rating for conductors with conductor temperature rating
o
of 75 C. controls, not operational controls.
The unit is ready for start-up when the following
Units require 3-phase power supply, and earth (E) only.
procedures have been completed.
Cables of each 3-phase power supply shall be routing
in the same cable tray or conduit, and enter the unit via
same power entry to minimized the electromagnetic
interference.
Refer to Figure 3.14.1 for field wiring termination.
- 32 -
3.0 INSTALLATION
Figure 3.14.1 Typical Field Wiring Diagram

WCFX-V 19S, 20S, 23S, 24S, 27S, 30S, 36S, 41S, 46S
WCFX-V 38T, 40T, 46T, 50T, 54T, 57T, 60T, 73T, 75T, 81T, 87T, 90T
- 33 -
4.0 COMMISSIONING
4.1 REQUEST FOR START-UP D. Compressor crankcase heater(s) has been

REPRESENTATIVE energized for a minimum of 24 hours.
E. Calibrated refrigerant gauges have been
After the installation has been completed and checked, connected to the suction and discharge.
Form 9180 (APENDIX 8.10) shall be filled in and sent F. Turn on the chilled water pump, check direction of
to the Dunham-Bush Service Department for rotation and adjust the water flow through the
authorized start-up representative to perform the initial evaporator to the specified flow rate. Bleed off all
start-up of the Dunham-Bush packaged chiller. entrained air.
Competent service and operating personnel shall be in
G. Apply same procedures as stated in (F) for
attendance to assist in the work involved, and also to
condenser pump.
be trained in the service and maintenance of this unit.
Following receipt of the signed Form 9180, a H. Check all refrigerant valves to be sure they are
representative will be sent to the customer. He will opened.
inspect the installation to determine whether it meets I. Check all three phases of supply voltage, of all
Dunham-Bush’s requirements; perform the initial start- legs of the motor. They must be within ±10% of the
up of the installation; determine whether it is in nameplate voltage.
satisfactory operating condition; and instruct the J. Check and confirm the power supply phasing is
specified customer personnel in its operation and correct to ensure the compressor will not running
maintenance for the length of time specified in the backwards.
purchase contract.
Start the chiller by either local start command with ROL
NOTE: Oil sump heaters should be energized for selector switch on position “L”; or with ROL selector
a minimum of 24 hours and the oil sump switch on position “R” and the remote start signal is ON.
temperature must be at a minimum of
100°F [38°C] prior to arrival of start-up A. Compressor #1 will start in about 1 minute &
representative. This will ensure that the proceed to load up if leaving water temperature is
oil is warm enough to vaporize any above setpoint. Compressor #2 will follow as the
dissolved refrigerant and that the oil is demand dictates
within the normal operating temperature B. When compressor starts, check the gauges and
range. note if the pressures are within the prescribed
WARNING: The compressor(s) should be started limits.
initially ONLY under the direct C. The electrical control settings should be checked
supervision of an Authorized Dunham- and if necessary, reset to those settings indicated
Bush Start-Up Representative. on the wiring diagram. Safety controls are factory
set and must be maintained at settings indicated
on the wiring diagram.
D. The temperatures of the chilled water both in and
4.2 WATER-COOLED CHILLER out, should be checked to insure the unit is
START-UP operating within the desired temperatures.
Caution: These units may equipped with factory

installed service or shut off valves that
must be opened before attempting to start.
The unit is ready for start-up when the following

procedures have been completed
A. Water piping for the evaporator and condenser are
is installed and tested.
B. Electrical connections are made and properly
fused.
C. Unit has been leak tested. Leaks corrected, and
charge completed.
- 34 -
5.0 OPERATION
5.1 OPERATING PRINCIPLES – This delivers outstanding efficiency and total energy
savings through utilization of economizer cycle. Unit
THE REFRIGERANT CYCLE EER is improved with economizer cycle.
Dunham-Bush variable speed water-cooled chillers,
WCFX-V series are designed for high efficiency and
reliability. The variable speed screw compressor is a 5.2 TYPICAL OPERATION
positive displacement, variable capacity compressor
that will allow operation over a wide variety of In order to start a compressor, the following conditions
conditions. must be met:
The typical refrigerant management system is shown in D Unit power supply is within preset range of Volt-
the refrigerant cycle diagram. Phase Control Relay (PCR)
D Compressor circuit breakers on
D Chilled water pump running
D Chilled water flow switch made
D Control switch and compressor switches on
D “Start” command is enabled
D All safety conditions satisfied
D Leaving chilled water temperature is 2°F [1.1°C] or
more above setpoint
D Start delay timer has elapsed (default = 1 minute)
First compressor is started after all the above are
fulfilled. Anti-recycle timer of 15 minutes is initiated
when the compressor is started.
Power supply to the unit is always monitored by the
PCR. The controller monitors compressor current
drawn by means of CT (current transformer &
transducer), leaving and entering chilled water
temperature using TS (temperature sensors),
evaporator and condensing pressure by PT (pressure
transducer). These inputs are used to control the
loading and staging of the compressor.
Liquid refrigerant enters the flooded evaporator To shut down the unit automatically, the customer
uniformly where it absorbs heat from water flowing control contacts “remote start” signal must be opened.
through the evaporator tubes, and vaporized. The To shut down the unit manually, simply turn the ROL
vaporized refrigerant is drawn into the compressor selector switch to position “O”.
suction port where the positive displacement
compression begins.
This partially compressed refrigerant gaseous is then
mixed with additional flash refrigerant from the 5.3 COMPRESSOR CAPACITY
economizer in the compression camber. The CONTROL
compressed gaseous refrigerant is now discharged into
the integral oil separator, to separate lubrication oil Each compressor has a Variable Speed Drive (VFD) as
from the gaseous refrigerant, and recovers lubrication compressor starter, as well as to modulating
oil back to the oil sump. compressor speed for capacity modulation.
The fully compressed and superheated refrigerant is Dunham-Bush WCFX-V series are incorporated with
discharged into the condenser, where water in the Hybrid Variable Speed Screw Compressors which
condenser tubes cools and condenses the refrigerant. combined variable speed screw operation together with
Liquid refrigerant leaves the condenser is further sub- hydraulically actuated slide valve mechanism for
cooled by the economizer. optimum performance and system stability. Table 5.3.
The gaseous refrigerant is drawn out from the below shows capacity control of the compressor.
economizer and injected into compressor through the Vision 2020i controls the compressor capacity by a 0-
vapor injection port. The remaining liquid refrigerant 10Vdc control signal to the Variable Frequency Drive.
shall passes through the Electronic Expansion Valve The control signal is between 4 to 10Vdc reflecting 25
(EEV) which throttles the refrigerant flow into to 60Hz variable speed operation. Slide valve
evaporator depending on cooling load demand. mechanism is used for capacity control below 40%.
- 35 -
5.0 OPERATION
Table 5.3. Capacity Control of VSD Screw The hot gas valve should be opened enough only to
Compressor allow good oil return when the unit is fully unloaded.
20~40% (1/8 to 1/2 turn). Excessive oil return will lower
Compressor %
Capacity
40~100% discharge superheat un-desirably. The oil return valve
Unloading Loading Hold should be left wide open. Refer section 5.4.1 for oil
Compressor
level observation via oil level sight glass on the
25Hz 25~60Hz
Frequency (Hz) compressor.
Solenoid Valve A
Closed Open Closed Open
(Normally Closed)
Label –SV-CnLD
(De-Energized) (Energized) (De-Energized) (Energized) 5.4.3 Oil Balancing System
Solenoid Valve B WCFX-V units with twin compressors are furnished with
Open Closed Closed Closed
(Normally Opened) an oil balancing system which consists of oil balancing
(De-Energized) (Energized) (Energized) (Energized)
Label – SV-CnUL
line and solenoid valves control.
Note : “n” = compressor number
The oil balancing line is connected to oil overflow port,
which will be the source of oil for this balancing system.
A solenoid valve named “Oil Balancing Solenoid Valve”
5.4 OIL MANAGEMENT is installed at the line connecting oil balancing line and
SYSTEMS suction line.
When a compressor is in operation and the controller

5.4.1 Oil Level detects that the oil level switch is opened, the controller
will energized Oil Balancing Solenoid Valve of the
The sight glass installed on the side of the compressor
compressor to allow oil recovery from another
is used to determine the oil level in which the
compressor through the oil balancing line. Solenoid
compressor can safely operate. It is extremely
valve will be de-energied when oil level switch is closed.
important that the compressor is never started with the
If the oil level switch does not closed but the delay
oil level over the sight glass. If the level is above the
timer of “Low Oil Alarm” is elapsed, the compressor will
glass prior to start-up, sufficient oil must be drained
be shut down and lock off with “Compressor Low Oil
until the level is at the center of the sight glass.
Alarm” message is shown on the display panel.
Oil level should be monitored after start-up to ensure oil
returning from the system does not rise above the sight
glass nor trip the oil level sensor. The compressor can 5.5 VARIABLE FREQUENCY
safely operate with the oil level below the sight glass as
the oil level sensor will protect the compressor against DRIVE
a low oil condition.
5.5.1 VFD user interface
5.4.2 Oil Return System
The VFD is equipped with graphical local control panel
The compressor is oil lubricated and discharges a small (LCP) as shown below. All settings and controls of the
amount of oil mist along with refrigerant. This oil is VFD can be access via LCP. The LCD-display is back-
carried into the evaporator. Oil rich refrigerant is lit with a total of 6 alpha-numeric lines. All data is
returned from the evaporator through a tap in the shell, displayed on the LCP which can show up to 5 operating
oil return valve, filter drier, angle valve, sight glass and variables while in [Status] mode.
into jet pump installed on the suction line. The jet pump
is powered by high pressure gas from the compressor
discharge line through hot gas feed valve. This forces
the oil rich mixture from the evaporator through oil
return valve into the suction line where it is carried into
the compressor.
- 36 -
5.0 OPERATION
Figure 5.5.1 The Graphical Local Control about the value/measurement linked to the
Panel (LCP) displayed operating variables (1.1, 1.2, 1.3, 2,
and 3). See the operating variables shown in
the display in this illustration. 1.1, 1.2 and 1.3
are shown in small size. 2 and 3 are shown in
medium size.
Status 1(0) a
1234rpm 10.4Hz 43.5Hz
1. b
43.5Hz
Run OK c
Quick Main Alarm
2. Status
Menu Menu Log
C
ck
an
Ba
Status display II
el
See the operating variables (1.1, 1.2, 1.3, and

Info
3. On OK 2) shown in the display in this illustration. In

the example, Speed, Motor current, motor
Warn.
power and Frequency are selected as
Alarm variables in the first and second lines. 1.1, 1.2
and 1.3 are shown in small size. 2 is shown in
4. Hand
Off
Auto
Reset large size
On On
Referring to Figure 5.5.1, the LCP is divided into four

functional groups and 3 display lines.
1. Graphical display with Status lines.

2. Menu keys and indicator lights (LEDs) – selecting Indicator lights (LEDs)
mode, changing parameters and switching between
display functions. If certain threshold values are exceeded, the
alarm and/or warning LED lights up. A status
3. Navigation keys and indicator lights (LEDs). and alarm text appear on the control panel.
4. Operation keys and indicator lights (LEDs). The On LED is activated when the frequency
converter receives power from mains voltage,
a Top Section – Status line a DC bus terminal, or an external 24 V supply.
Status messages displaying icons and graphics. It At the same time, the back light is on.
shows the status when in status mode or up to 2
variables when not in status mode and in the case Indicating LED Description
of Alarm/Warning On On (Green LED) Control section is working
b Middle Section – Line 1-2 Warn. (Yellow LED) Indicates a warning
Warn.
Operator data lines displaying data and variables
Alarm (Flashing Red LED) Indicates an alarm
defined or selected by the user. It shows up to 5 Alarm
variables with related unit, regardless of status. In
case of alarm/warning, the warning is shown
instead of the variables. 5.5.1.2 Menu keys and indicator lights
c Bottom Section – Status line (LEDs)
Status messages displaying text. It always shows The menu keys are divided into functions. The
the state of the frequency converter in status mode. keys below the display and indicator lights are
used for parameter setup, including choice of
5.5.1.1 Graphical display with Status lines. display indication during normal operation.
Status display I
Quick Main Alarm
This read-out state is standard after start-up or Status
Menu Menu Log
initialisation. Use [INFO] to obtain information
- 37 -
5.0 OPERATION
[Status] [Info]
Indicates the status of the frequency converter Displays information about a command,
and/or the motor. 3 different readouts can be parameter, or function in any display window.
selected by pressing the [Status] key: [Info] provides detailed information when
• 5 line readouts needed. Exit Info mode by pressing either
• 4 line readouts [Info], [Back], or [Cancel]
• Smart Logic Control.
Use [Status] for selecting the mode of display 5.5.1.3 Navigation keys and indicator
or for changing back to Display mode from lights (LEDs).
either the Quick Menu mode, the Main Menu
mode or Alarm mode. Also use the [Status] The 4 navigation keys are used to navigate
key to toggle single or double read-out mode. between the different choices available in
[Quick Menu], [Main Menu] and [Alarm Log].
[Quick Menu] Press the keys to move the cursor. [OK] is
Allows quick set-up of the frequency converter. used for selecting a parameter marked by the
The most common HVAC functions can be cursor and for enabling the change of a
programmed here. The [Quick Menu] consists parameter.
of
Ca
ck
• My Personal Menu
nc
Ba
el
• Quick Set-up
• Function Set-up
• Changes Made
Info
• Loggings On OK
[Main Menu] Warn.

Is used for programming all parameters. The
Main Menu parameters can be accessed Alarm
immediately unless a password has been
created via any of below: 5.5.1.4 Operation keys and indicator lights
• 0-60 Main Menu Password (LEDs).
• 0-61 Access to Main Menu w/o Password
• 0-65 Personal Menu Password Hand Auto
• 0-66 Access to Personal Menu w/o Off Reset
On On
Password.
For most HVAC applications it is not Operation Keys mean for local control are
necessary to access the Main Menu found at the bottom of the control panel.
parameters but instead the Quick Menu, Quick
Set-up and Function Set-up provides the [Hand On]
simplest and quickest access to the typical Enables control of the frequency converter via
required parameters. the GLCP. [Hand On] also starts the motor,
and it is now possible to enter the motor
[Alarm Log] speed data by means of the navigation keys.
Displays an Alarm list of the 10 latest alarms The key can be selected as [1] Enable or [0]
(numbered A1-A10). To obtain additional Disable via 0-40 [Hand on] Key on LCP. The
details about an alarm, press the navigation following control signals are still active when
keys to manoeuvre to the alarm number and [Hand On] is activated:
press [OK]. Information is displayed about the • [Hand On] - [Off] - [Auto On]
condition of the frequency converter before it • Reset
enters the alarm mode. The Alarm log key on • Coasting stop inverse
the LCP allows access to both Alarm log and • Reversing
Maintenance log. • Set-up select LSB (Less Significant Bit) -
Set-up select MSB (Most Significant Bit)
Back Cancel Info • Stop command from serial communication
• Quick stop
[Back] • DC brake
Reverts to the previous step or layer in the
navigation structure [Off]
stops the connected motor. The key can be
[Cancel] selected as:-
Cancels the last change or command as long • [1] Enabled
as the display has not been changed. • [0] Disabled via 0-41
• [Off] Key on LCP.
- 38 -
5.0 OPERATION
If no external stop function is selected and the Table 5.5.2 Parameter list
[Off] key is inactive the motor can only be Parameter Unit of
stopped by disconnecting the mains supply. Description Value
Index Measurement
Compressor
1-03 Torque Characteristics
[Auto On] Torque
Enables the frequency converter to be Follow
controlled via the control terminals and/or 1-20 Motor Power Compressor kW
nameplate
serial communication. When a start signal is
applied on the control terminals and/or the bus, Follow Unit
1-22 Motor Voltage Vac
Power Supply
the frequency converter starts. The key can be
1-23 Motor Frequency 60 Hz
selected as:-
• [1] Enabled Follow
1-24 Motor Current Compressor A
• [0] Disabled via 0-42 nameplate
• [Auto on] Key on LCP. 1-25 Motor Normal 3500 RPM
1-28 Motor Rotation (0)OFF
[Reset]
1-39 Motor Pole 2
is used for resetting the frequency converter
after an alarm (trip). It can be selected as:- 1-62 Slip Compensation 100 %
• [1] Enable 1-71 Start Delay 1 Second
• [0] Disable via 0-43 1-90 Motor Thermal Protection No Protection

• [Reset] Key on LCP 3-15 Reference 1 Source Analog Input 53
The parameter shortcut can be carried out by 3-41 Ramp Up Time 40 Second
holding down the [Main Menu] key for 3 3-42 Ramp Down Time 40 Second
seconds. The parameter shortcut allows direct
4-12 Motor Speed Low Limit 25 Hz
access to any parameter
4-13 Motor Speed High Limit 60 Hz
4-16 Torque Limit Motor Mode set to max
5.5.2 VFD Setup and Configuration 4-18 Current Limit set to max
Parameter Data 4-51 Warning High current set to max

The graphical display (LCP) provides access 5-01 Terminal 27 Mode Input
to all parameters listed under the Quick Menus. 5-10 Terminal 18 Digital Input Start
Settings in [Quick Mena] can be access by 5-11 Terminal 19 Digital Input No operation
following procedures.
**5-12 Terminal 27 Coast inverse
a. Press [Quick Menu]; OR Press [Main Menu]
5-40 Relay 1 Alarm
twice
b. Press [▲] and [▼] to find the parameter to 5-40 Relay 2 Ready
change. 6-10 Terminal 53 Low Voltage 0.07 Vdc
c. Press [OK]. 6-11 Terminal 53 High Voltage 10.00 Vdc
d. Press [▲] and [▼] to select the correct 6-14 Terminal 53 Low Current 0
parameter setting.
6-15 Terminal 53 High Current 60
e. Press [OK].To move to a different digit
14-03 Over Modulation ON
within a parameter setting, use the [◀] and
14-12 Function at Mains Imbalance DISABLE
[▶].
14-25 Trip Delay at Torque Limit set to max
f. Highlighted area indicates digit selected for
change. 14-26 Trip Delay at Inverter Fault set to max
g. Press [Cancel] button to disregard change, 14-51 DC Link Compensation OFF
or press [OK] to accept change and enter 0-50 LCP Copy All To LCP
the new setting 0-60 Main Menu Password 0998
Access to Main Menu w/o
0-61 All Read Only
Password
- 39 -
5.0 OPERATION
5.5.3 Warnings and Alarms CAUTIONS: Alarms that are trip-locked offer
A warning or an alarm is signalled by the relevant LED additional protection, means that the
on the front of the frequency converter and indicated by mains supply must be switched off
a code on the display. A warning remains active until its before the alarm can be reset. After
cause is no longer present. Under certain being switched back on, the VFD is no
circumstances operation of the motor may still be longer blocked and may be reset as
continued. Warning messages may be critical, but are described above once the cause has
not necessarily so. If an alarm occurs, the frequency been rectified. Alarms that are not trip-
converter trips. Alarms must be reset to restart locked can also be reset using the
operation once their cause has been rectified. This may automatic reset function (Warning:
be done in 4 ways: automatic wake-up is possible!)
A. Pressing [Reset] on the LCP If a warning and alarm is marked
B. Via a digital input with the “Reset” function against a code in the table on the
C. Via serial communication/optional fieldbus following table, this means that either
D. By resetting automatically using the [Auto Reset]. a warning occurs before an alarm, or it
This is default setting. can be specified whether it is a
warning or an alarm that is to be
NOTE: After a manual reset using the [RESET] displayed for a given fault.
button on the LCP, the [AUTO ON] or [HAND
ON] button must be pressed to restart the
motor. If an alarm cannot be reset, the
reason may be that its cause has not been
rectified, or the alarm is trip-locked.
Table 5.5.3.1 Alarm / Warning Code List

No Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference
1 10 Volts low X
2 Live zero error (X) (X) 6-01
3 No motor (X) 1-80
4 Mains phase loss (X) (X) (X) 14-12
5 DC link voltage high X
6 DC link voltage low X
7 DC over voltage X X
8 DC under voltage X X
9 Inverter overloaded X X
10 Motor ETR over temperature (X) (X) 1-90
11 Motor thermistor over temperature (X) (X) 1-90
12 Torque limit X X
13 Over Current X X X
14 Earth fault X X X
15 Hardware mismatch X X
16 Short Circuit X X
17 Control word timeout (X) (X) 8-04
18 Start failed X
19 Internal Fan Fault X
20 External Fan Fault X 14-53
21 Brake resistor short-circuited X
22 Brake resistor power limit (X) (X) 2-13
23 Brake chopper short-circuited X X
24 Brake check (X) (X) 2-15
25 Drive over temperature X X X
26 Motor phase U missing (X) (X) (X) 4-58
27 Motor phase V missing (X) (X) (X) 4-58
28 Motor phase W missing (X) (X) (X) 4-58
29 Inrush fault X X
30 Fieldbus communication fault X X
31 Out of frequency range X X
32 Mains failure X X
33 Phase Imbalanc X X
- 40 -
5.0 OPERATION
Table 5.5.3.1 Alarm / Warning Code List (Continue)

No Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference
34 Internal fault X X
35 Heatsink sensor X X
36 Overload of Digital Output Terminal 27 (X) 5-00,5-01
37 Overload of Digital Output Terminal 29 (X) 5-00,5-02
38 Overload of Digital Output On X30/6 (X) 5-32
39 Overload of Digital Output On X30/7 (X) 5-33
40 Pwr. card supply X X
41 24 V supply low X X X
42 1.8 V supply low X X
43 Speed limit X (X) 1-86
44 AMA calibration failed X
45 AMA check Unom and Inom X
46 2AMA low Inom X
47 AMA motor too big X
48 AMA motor too small X
49 AMA Parameter out of range X
50 AMA interrupted by user X
51 AMA timeout X
52 AMA internal fault X X
53 Current limit X
54 External Interlock X
55 Output Frequency at Maximum Limit X
56 Voltage Limit X
57 Control Board Over-temperature X X X
58 Heat sink Temperature Low X
59 Option Configuration has Changed X
60 Safe Stop (X) X¹ 5-19
61 Pwr. Card Temp X X
62 Illegal FC configuration X
63 PTC 1 Safe Stop X X¹
64 Dangerous Failure X¹
65 Safe Stop Auto Restart
66 Power Unit Setup X
67 Illegal PS config X
68 Drive Initialized to Default Value X
69 Analog input 54 wrong settings X
70 NoFlow X X 22-2*
71 Dry Pump X X 22-2*
72 End of Curve X X 22-5*
73 Broken Belt X X 22-6*
74 Start Delayed X 22-7*
75 Stop Delayed X 22-7*
76 Clock Fault X 0-7*
77 Fire M was Active
78 Fire M Limits Exceeded
79 Missing Motor
80 Locked Rotor
81 Brake IGBT X X
82 Heatsink temp X X X
83 Heatsink sensor X X
84 Pwr.card supply X X
85 Pwr.card temp X X
86 Illegal PS config X X
87 New spare parts X
88 New Type Code X X
(X) Dependent on parameter
X¹ Can not be Auto reset via 14-20 Reset Mode
- 41 -
5.0 OPERATION
The front panel now holds the display and the keypad,
5.6 ELECTRONIC EXPANSION made up of 6 buttons that pressed alone or in
VALVE combination, are used to perform all the configuration
and programming operations on the driver.
Electronic Expansion Valves (EEV) are provided to
The graphic display shows 2 system variables, the
AVX-B chillers for refrigerant flow control to achieve
control status of the driver, the activation of the
optimum efficiency. EEV can be also supplied to some protectors, any alarms and the status of the relay
models for superheat control of the PHE economizer. output.
EEV driver(s) is provided to controls the EEV. An EEV
Display Panel is provided for unit with multiple EEV
drivers.
There are 5 LEDs on the face plate of EEV driver that
display the operating status, as described below:
5.6.1 Display Panel for EEV Driver

The display panel for EEV driver, once installed, is
used to perform all the configuration and programming
operations on the driver. It displays the operating status,
the significant values for the type of control that the
driver is performing (e.g. superheat control), the alarms,
the status of the digital inputs and the relay output.
For installation:
• remove the cover, pressing on the fastening
points;
• fit the display board, as shown;
• the display will turn on, and if the driver is being
commissioned, the guided configuration
procedure will start
- 42 -
5.0 OPERATION
5.6.2 Modifying the Manufacturer 5.6.3 EEV Setting Lists

parameters Table 5.6.3A EEV SETTING, refrigerant
The Manufacturer level is used to configure all the liquid level control
driver parameters, and consequently, in addition to the
Description Value Description
Service parameters, the parameters relating to alarm
management, the probes and the configuration of the Network add 198 -
valve. See the table of parameters. Refrigerant 2 R134a
Valve 1 Carel EXV
Probe S1 0 Not Used
Main Control 16 Analog Positioner ( 0-10V)
Probe S2 4 0-10V external signal
Auxiliary Regulation 1 Disabled
Probe S3 0 Not Used
Relay Configuration 0 Disabled
Probe S4 0 Not Used
DI2 Configuration 1 Disabled
Display Main Var.1 1 Valve Opening
Display Main Var. 2 19 S2 Probe Measurement
S1 Probe Alarm Manag. 3 Valve at Fixed Position
S2 Probe Alarm Manag. 3 Valve at Fixed Position
S3 Probe Alarm Manag. 1 No Action
S4 Probe Alarm Manag. 1 No Action
All the driver parameters can be modified by entering Unit Measurement °C/K/barg °C, K, barg
the Manufacturer Level. If when setting a parameter the DI1 Configuration 5 Regulation Start / Stop
value entered is out-of-range, this is not accepted and Language English English
the parameter soon after returns to the previous value.
If no button is pressed, after 5 min the display
automatically returns to the standard mode. Table 5.6.3B EEV SETTING, superheat
control for Economizer
Steps to access to Manufacturer Parameters:
Description Value Description
A. Press [Esc] one or more times to switch to the Network address 198 -
standard display Refrigerant: 2 R134a
B. Press [Prg], the display shows a screen with the Valve: 1 CAREL EXV
PASSWORD request. Probe S1: 4 0…17.3 bar
C. Press [ENTER] and enter the Manufacturer level Main control: Multiplexed / cabinet/cold room
password: 0066, starting from the right-most figure Probe S2: 1 CAREL NTC
and confirming each figure with [ENTER].
Auxiliary control: 1 Disabled
D. If the value entered is correct, the list of parameter Probe S3 0 Not used
categories is shown:
Reversed Alarm relay (closed in
• Configuration Relay configuration: 5
case of alarm)
• Probes Probe S4: 1 CAREL NTC
• Control DI2 configuration: 5 Regulation start/stop
• Special Display main var. 1: 5 Superheat
• Alarm configuration Display main var. 2: 1 Valve opening
• Valve S1 probe alarm manag. 3 Valve at fixed
E. Press the [UP] or [DOWN] buttons to select the S2 probe alarm manag. 3 Valve at fixed
category and [ENTER] to access the first S3 probe alarm manag. 1 No action
parameter in the category. S3 probe alarm manag. 1 No action
F. Press [UP] or [DOWN] to select the parameter to Unit of measure °F/psig °F/psig
be set and [ENTER] to move to the value of the
DI1 configuration 5 Regulation start/stop
parameter.
Language: English English
G. Press [UP] or [DOWN] to modify the value
S1 pressure MINIMUM
0 psig
H. Press ENTER to save the new value of the value
parameter pressure MAXIMUM value 200 psig
I. Repeat steps (f), (g), (h) to modify the other S1 alarm MIN pressure 0 psig
parameters S1 alarm MAX pressure 200 psig
J. Press Esc to exit the procedure for modifying the Superheat set point 12 °F
Manufacturer parameters.
- 43 -
5.0 OPERATION
5.6.4 Table of Alarm
- 44 -
5.0 OPERATION
5.7 VISION 2020i CONT

TROLLER Other buttons which are not sho own are to access
AND INTERFACE different level of setting changes s. These are 'User',
'Technician' and 'Factory' levels.
Vision 2020i controller is equipped withh a user friendly
It can only be access depend on the password level.
DBGX display panel, with 7” TFT, 16.7 7M colors, LED
The higher password can access the lower password
backlight touch screen graphical d display. DBGX
level's setting but not vice versa.
terminal allows carrying out all program operations. The
user terminal allows displaying the e unit working
conditions, compressor run times, alarm m history at any
time and modifying the parameters. Th he terminal also 5.7.1.1 The Touch Keys
has an automatically self-test of the e controller on
Key Description
system start-up. Multiple messages will be displayed by
automatically scrolling from each messa age to the next. Displays thhe analog inputs and
All of these messages are spelled out in English INPUT STATUS digital inpu
uts status measured by
language on the LED screen. the probes s/sensors.
OUTPUT he relay outputs and

Displays th
5.7.1 DBGX Graphical User IInterface STATUS analog outtputs status.
The DBGX display panel is a full toucch screen color

display panel with various touch keys to perform the COMPRESSOR
he status of Compressors
Displays th
command. STATUS
Display the
e active alarms and to
ALARM RESET
perform ala
arm manual resets.
CLOCK /
he date, time and day.
Displays th
SCHEDULE
Keys With Restricted Acce

ess
SETPOINT Displays th
he status of set points.
USER User Contrrol Changeable Settings.
Techniciann Control Changeable

TECHNICIAN
Settings.
There are 5 basic touch keys for unresstricted access,

Factory Coontrol Changeable
while another 4 touch keys with restriccted access by FACTORY
Settings.
authorization password.
5.7.2 STATUS READING

G
5.7.2.1 Input Status Key

To read inputs status, touc
ch the input status
key:
is for password log in to gain autho

orization, to the
access setting menu.
- 45 -
5.0 OPERATION
The display is showing the data as follows: Reading Description
Unit of
Measurement
ANALOGUE READINGS
Compressor 1 Motor Winding

Motor Temp 2 °F / °C
Temperature 2

Temperature 3

Temperature 1

Temperature 2

Temperature 3
Touch the input status key to read other input DIGITAL STATUS
status. Comp 1 Starter Compressor 1 Starter Status Open / Close
Below readings and status are available in Comp 2 Starter Compressor 2 Starter Status Open / Close
Input Status screens. Comp 1 Oil Lvl Compressor 1 Oil Level Open / Close
Unit of Comp 2 Oil Lvl Compressor 2 Oil Level Open / Close

Reading Description
Measurement
Remote Enable Remote Start Enable Open / Close
ANALOGUE READINGS
Local Enable Local Start Enable Open / Close
Supply Temp Chilled water leaving temperature °F / °C
Chilled Water Flow Evaporator Flow Switch Status Open / Close
Rate of change of chilled water °F.min-1 / Condenser Flow Switch Status
Slope Temp Cond. Water Flow Open / Close
leaving temperature °C.min-1 (optional)
Return Temp Chilled water entering temperature °F / °C Comp 1 VFD

Compressor 1 VFD alarm Open / Close
Alarm
Supply COND
Condenser water leaving temperature °F / °C
Temp Comp 2 VFD
Compressor 2 VFD alarm Open / Close
Alarm
Return COND Condenser water entering
°F / °C
Temp temperature Freeze Mode Enable (Optional – Dual
Freeze Mode Open / Close
Mode operation)
C1 Suction
Compressor 1 Suction Pressure PSIG / BAR
Pressure
C1 Discharge
Compressor 1 Discharge Pressure PSIG / BAR
Pressure
5.7.2.2 Output Status Key
C2 Suction
Compressor 2 Suction Pressure PSIG / BAR
Pressure
To read outputs status, touch the output status
C2 Discharge key:
Compressor 2 Discharge Pressure PSIG / BAR
Pressure
Compressor 1
Compressor 1 Operating Current A
Amps
Compressor 2
Compressor 2 Operating Current A
Amps
System Voltage Power Supply Voltage (optional) V The display is showing the data as follows:
Chilled Water
Chilled Water Reset Input (optional) °F / °C
Reset
Demand Limit Demand Limiting Input (optional) %
C1 Discharge
Compressor 1 Discharge Temperature °F / °C
Temp
C2 Discharge
Compressor 2 Discharge Temperature °F / °C
Temp
C1 Discharge
Compressor 1 Discharge Superheat °F / °C
Superheat
C2 Discharge
Compressor 2 Discharge Superheat °F / °C
Superheat
Refrigerant Level Refrigerant level in evaporator mm
Refrigerant Level Touch the input status key to read other input
Rate of change of refrigerant level mm.min-1
Slope
status.
Temperature 1
- 46 -
5.0 OPERATION
Below readings and status are available in 5.7.2.3 Compressor Status Key
Output Status screens.
To read compressor status, touch the
Reading Description Status
compressor status key:
OFF;
ON-LOAD;
ON-HOLD;
ON-UNLOAD;
ON Man Hold;
Compressor 1 Compressor 1 Status
ON Man Load; The display is showing the data as follows:
ON Man Unload;
Oil Level Low;
Starter Fault;
OFF-Alarm
OFF;
ON-LOAD;
ON-HOLD;
ON-UNLOAD;
ON Man Hold;
Compressor 2 Compressor 2 Status
ON Man Load;
ON Man Unload;
Oil Level Low;
Starter Fault;
OFF-Alarm
Alarm Relay General Alarm Status ON / OFF
Control Power Control power of control system ON / OFF

C1 Liquid Compressor 1 Liquid Injection Touch the compressor status key to read other
ON / OFF
Injection Sol Solenoid Valve status of compressor 1.
C2 Liquid Compressor 2 Liquid Injection
ON / OFF
Injection Sol Solenoid Valve
Chilled Water
Evaporator Pump Control (optional) ON / OFF
Pump
Cond. Water
Condenser Pump Control (optional) ON / OFF
Pump
Hotgas Bypass Solenoid Valve
Hotgas Relay ON / OFF
(Optional)
Economizer Solenoid Valve (model
Vapor Injection ON / OFF
dependent)
Comp 1 Oil Compressor 1 Oil Balancing
ON / OFF
Balance Sol. Solenoid Valve
Comp 2 Oil Compressor 2 Oil Balancing
ON / OFF
Balance Sol. Solenoid Valve
Cooling Tower Cooling Tower Fan Stage #1
ON / OFF
Stage 1 (optional) Touch the compressor status key again to
Cooling Tower Cooling Tower Fan Stage #2
ON / OFF read status of compressor 2.
Stage 2 (optional)
Condenser Condenser modulating 3-ways valve
Valve (optional)
0-10Vdc 5.7.2.4 Setpoint Key
EEV 1 Output Compressor 1 EEV Opening
% To read setpoints value, touch the setpoint
Percentage Percentage
EEV 1 Output Control voltage output for key:
0-10Vdc
Voltage Compressor 1 EEV positioning
C1 VFD Output Compressor 1 VFD Output
%
Hz
Hz Frequency The display is showing the data as follows:
EEV 2 Output Compressor 2 EEV Opening
%
EEV 2 Output Control voltage output for
0-10Vdc
Voltage Compressor 2 EEV positioning
%
Hz
Hz Frequency
Enabling next unit (optional master-
Start Next ON / OFF
slave control)
Total Slave units required for
Units Needed operation (optional master-slave ON / OFF
control)
- 47 -
5.0 OPERATION
Below setpoints are available in Setpoint
screens.
Unit of
Setpoint Description Measurement /
Value
Supply Water Temperature
Chilled Water Leaving
Set point °F / °C
Temperature Setpoint
Upper Temperature control
Dead Band + °F / °C
band
Lower Temperature control
Dead Band 1 °F / °C
band
st
Start-Up Dead 1 Compressor restart
°F / °C
Band temperature dead band
Supply Water Temperature
High Leaving Chilled Water
5.7.2.5 Clock Key
High Alarm °F / °C
Temperature Alarm
Low Leaving Chilled Water To read the current day, time and date, unit
Low Alarm °F / °C
Temperature Alarm scheduling and ice-cel mode scheduling
Freeze Alarm Evaporator Freeze alarm °F / °C (optional), touch the clock key
Compressor Rotation
Lead
Preset Lead Compressor 1 or 2
Compressor
None;
By Run Hours;
Rotation Compressor Rotation
By Day;
By Staging
The display is showing the data as follows:
Power Loss Setpoint
Restart of unit and
Manual;
Restart compressor after recover from
Auto
power failure
Compressor Compressor High Discharge
Discharge Temp Temperature Alarm and lock °F / °C
Cutout Limit off
Compressor Compressor High Motor
Motor Temp Temperature Alarm and lock °F / °C
Cutout Limit off
Cooling Tower Control (optional)
Stage 1
Cooling tower fan 1 ON
On Setpoint PSIG / BAR
setpoint
Cooling tower fan 1 OFF Authorization is needed to set the date and
Off Setpoint PSIG / BAR
setpoint time. See the authorization procedure and log
Stage 2 in at least as user level.
On Setpoint
Cooling tower fan 2 ON
PSIG / BAR
Touch on selected set point which contained
setpoint
in rectangle box to change the date, time and
Off Setpoint
Cooling tower fan 2 OFF
PSIG / BAR weekday. Use the popped up keypad to key in
setpoint
the desired setpoint value and touch “Enter”
key to confirm the change.
Authorization is required to alter setpoint data,
See the authorization procedure and shall be
authorized at least as user level to alter the
setpoints.
Touch on the selected set point which
contained in rectangle box. A keypad will pops
up on the screen. Use this keypad to key in
the desired setpoint value and touch “Enter”
key to confirm the change. If the value entered
is out of acceptable range, the setpoint will not
change and the keypad will remain to receive
another value.
- 48 -
5.0 OPERATION
For schedule setup, touch on Schedule key to
access to schedules setting screen.
Use the “left” or “right” touch keys to browse

the alarm histories.
5.7.3 Authorization
To get authorization level, press authorization key:

Touch on “Configuration Zone 1” for schedule
settings.
The display is showing the current access level as view

5.7.2.6 Alarm History Key only:
To check active alarm, touch on Alarm Reset
key once.
Touch on the rectangle box with “****”. A keypad will

pops up. Key in the authorization code and touch on
“Enter” key to gain the authorization access.
5.7 ADDRESSING THE VISION

2020i CONTROLLER AND
DBGX TERMINAL
To clear/reset active alarm, select active alarm 5.7.1 Vision 2020i Controller (DB5+)
and touch button “Ack”, follow by button Addressing
“Reset”.
To view the unit alarm history, touch again on One major different of DB5+ controller with previous
Alarm Reset key, the display is showing the version of Vision controller is that the controller address
data as follows. of DB5+ controllers can be set by using the button and
7-segment display on the controller.
- 49 -
5.0 OPERATION
Refer to below screen, locate button “A” (as shown This will start update the DBGX application software.
below) at bottom middle of controller. Access the button Once done, the display will reboot and start with new
using a pin or screw driver (diameter <3mm) graphic program.
5.7.2.2 System Settings

The menus can be accessed by pressing any point on
the touch screen for few seconds until the menu is
display:
Press and hold button “A” for 3 seconds, the 7-segment

display starts flashing and shows the stored address
(factory default address setting at “1”).
Press the button repeatedly to increment the address Choose Show system settings
value until desired value. Screen with title “System settings” will appeared as
Wait 10 seconds to save the new address, where the below:
display shall flash quickly. Switch off the controller and
restart again to activate the new address.
If the controller is switched off within 7 seconds after
the new address is set, the new address will not be
activated.
5.7.2 DBGX Touch Screen Display

Panel Setup
The DBGX 7” touch screen display panel is
designed to be user friendly, with graphical layout
and quick access to operating parameters.
5.7.2.1 Application Update
The menus can be accessed by pressing any point on
the touch screen for few seconds until the menu is
display:
Choose “Update…” from the menu pop out and next

screen with title “Update wizard ½” will appeared Display Settings:
Choose “Auto select best match” and then select “Next” Settings relating to backlight auto shut off time,
brightness of screen & calibrate screen.
Service Settings:
Select “Set Device Address” to set display address.
- 50 -
5.0 OPERATION
diagram specifies the terminals to which this contact
5.9 CONTROL FUNCTIONS must be wired. The R/O/L selector switch needs to be
The Vision 2020i controller performs the following positioned at “R” to enable this control. To start the unit,
functions on screw chillers. the control contacts must be closed. To stop the unit,
the control contacts must be opened.
5.9.1 Chilled Water Pump Control 5.9.7 Compressor Oil Sump Heater
(Optional) Each compressor is fitted with an oil sump band-heater.
Chilled water pump of the unit can be controlled by The heater is energized at all times when compressor
control output point (volt-free contact) available in the is off and de-energized when the compressor is running.
unit control panel. The chiller will starts chilled water Maintaining compressor oil sump temperature help to
pump upon received start command and remains on minimized potential of refrigerant to dissolved into the
during the entire operation period. Chilled water pump lubrication oil. For this reason, it is essential that
will remains running for 3 minutes after the chiller has heaters be energized for 24 hours before starting a
received stop command and all compressors are compressor. This will ensure refrigerant dissolved in the
stopped. lubrication oil is vaporized and proper oil viscosity for
unit operation.
5.9.2 Condenser Water Pump Control
(Optional) 5.9.8 Compressor Start Delay Timer
Condenser water pump of the unit can be controlled by A compressor start delay of one minute is incorporated
control output point (volt-free contact) available in the into controller before the first compressor is started to
unit control panel. The chiller will starts condenser ensure the system load requires the compressor. A
water pump upon received start command and remains start delay countdown timer is shown at compressor
on during the entire operation period. Condenser water status screen during this timing.
pump will stop after the chiller has received stop
command and all compressors are stopped. 5.9.9 Compressor Stage Delay Timer
A compressor stage delay of one minute is
5.9.3 Common Alarm incorporated into the controller to ensure that the
system load requires another compressor. A stage
Volt-free contact available in unit control panel to delay countdown timer is shown at compressor status
provide indication of unit control alarm status. This screen during stage delay timing.
contact will closed when any of the control alarm is
triggered. Control alarms are those alarms that trip off
compressor or unit. 5.9.10 Compressor Anti-Recycle Timer
The compressor motor requires an anti-recycle time
delay which prevents restart for 15 minutes after a start.
5.9.4 Chilled Water Pump Interlock The purpose of this feature is to avoid frequent starts
And Flow Switch which tend to elevate the motor winding temperature
These are field installed switches; both of them are and impose undue wear on contactors. The controller
used to ensure chilled water flow before the unit is will not restart the compressor motor until the 15
allowed to start. Failure of either one during operation minutes anti-recycle timer have elapsed. An “OFF-SC
will cause the compressor to shut down. Chilled water timer” is displayed at the compressor status during anti-
flow shall be remain in circulation for at least 3 minutes cycle timing.
after the compressors are stopped. This will help to CAUTION: This timer is bypassed by manual
vaporize remaining cool liquid refrigerant in the control of compressors. DO NOT
evaporator to prevent potential of evaporator freeze up. manually start a compressor more than
once every 15 minutes.
5.9.5 Condenser Water Pump Interlock
And Flow Switch (Optional) 5.9.11 Load Control
The controller controls the leaving water temperature
These are field installed switches; both of them are
within a narrow dead band by varying the motor
used to ensure condenser water flow before the unit is
rotation speed of the compressor. The VFD varies the
allowed to start. Failure of either one during operation
operating frequency of the compressor to control its
will cause the compressor to shut down..
capacity. The controller determines a desired level of
loading and varies compressor operating speed
5.9.6 Customer Control Interlock / Unit depending on difference between load target and
Enable (Remote) actual load. The load target is varied based on rate of
approach to desired temperature preventing significant
Control contacts from an external source can be used temperature oscillations. The status of the compressor
to enable or disable operation of the unit. The wiring can be observed at terminal display.
- 51 -
5.0 OPERATION
5.9.12 Ramp Control “By Stage” – Lead compressor is rotated at each

Another feature of the controller is ramp control, which compressors restart cycle
is the ability to vary ramping time of the machine from
start. Often when the machine is started, the water in
the chilled water circuit is warm, and the unit will go to 5.9.15 Electronic Expansion Valve
full load quickly. With ramp control, the user can (EEV) – Refrigerant Flow Control
program the controller so that it loads at a Each unit has one, or up to two EEVs to control the
predetermined rate. This is a valuable tool, since it can volume of refrigerant flow into the evaporator. The EEV
help reduce power consumption and demand charges. control is based on refrigerant liquid level in the
Two variables are used to define the ramp profile: evaporator which feedback by a refrigerant liquid level
Ramp rate and ramp start setpoint. Ramp Rate defines transmitter. Vision 2020i controller output a 0-10Vdc
the maximum amount that can be added to the target control signal to EEV driver(s) to control the refrigerant
each second. Ramp Start point defines the percent flow, in such, maintaining the refrigerant liquid level in
capacity target at which the ramp begins on the first the evaporator. The controller determines a desired
compressor. The Ramp Rate setpoint can be set level of EEV opening target depending on difference
anywhere from 0.1 to 1.0, smaller values producing between Preset Refrigerant Liquid Level and actual
slower loading rates. The Ramp Start setpoint can be refrigerant liquid level feedback by the transmitter. The
set anywhere between 0 and 50%. The compressor will EEV opening target is varied based on rate of approach
load quickly to this value and then follow the ramp to desired refrigerant liquid level precenting significant
slope from there. See Table 5.5.10 for ramp rates at liquid level fluctuation.
various settings with 1-minute compressor start/stage
delay timer. These values are calculated with Besides refrigerant flow control during normal operation,
assumption that the chilled water temperature is not the EEV(s) can be also a preventive action to recover
descending more than slope temperature setpoint, unit operation, and to prevent unit from tripping by
o o
typically -2.0 F (-1.1 C) per minute. alarm
The controller will override the EEV control logic and
Table 5.9.12 Ramp Rates for Several force EEV to closed, to recover from abnormal
Setpoints (In Minutes) operation, such as below:
a. Low suction pressure
1 Comp. 2 Comp. 3 Comp. 4 Comp.
Ramp Start Point Start Point Start Point Start Point b. Low suction-discharge pressure differential
Rate Setpoint Setpoint Setpoint Setpoint
Setpoint
c. Low discharge superheat
30% 50% 75% 30% 50% 75% 30% 50% 75% 30% 50% 75%
EEV(s) in liquid line can be also served as refrigerant
0.1 12 9 4.5 22 18.5 14 29 25.5 21 33 29 25 isolation device. When “R/O/L” selector switch is
0.2 6 5 2 11.5 10 8 16 14 12 18 16 14 switched to position “O” (Off), the EEV driver will close
0.3 4 3 1.5 8 7 5.5 11 10 9 13 12 11 the EEV with additional 120 closing steps after the EEV
0.4 3 2.5 1 6.5 5.5 4.5 9 8 7 11 10 9 is fully closed. This is to ensure that the EEV is “fully
closed” and tight to isolate refrigerant at it’s upstream.
5.9.13 Staging Control

On multiple-compressor machines, when the controller
5.9.16 Compressor Unloaded Stop
determines that a compressor is fully loaded and This optional control feature can be enabled via
temperature is not being maintained, another terminal display panel when this operation is required.
compressor is added. When unloading, a compressor This control feature permits compressor unloading
is taken off line when the controller determines that the before each stop (normal and healthy stop, except stop
remaining compressor can manage the load. by alarm). Compressor(s) will be unloaded to minimum
capacity as preset before stop, or stops after the preset
5.9.14 Compressor Rotation unloaded stop timer is elapsed.
For multiple compressors models, besides unit

operation with manually preset lead compressor, the 5.9.17 Hotgas Bypass Control
controller is able to automatically rotate the lead (Optional)
compressor to balance up total running of all the
When hot gas bypass has been supplied with the unit,
compressors. Three types of automatic compressor
an output from the controller controls the solenoid valve.
lead/lag rotation are available, which are “By Running
The hotgas bypass solenoid valve is energized when
Hours”, “By Day” or “By Stage”.
the only running compressor is unloaded to minimum
“By Running Hours” – Compressor with least running [Hotgas Bypass ON Setpoint]. The solenoid valve will
hours will starts first be de-energized when the running compressor has
been loaded up [Hotgas Bypass OFF Setpoint].
“By Day” – Lead compressor is rotated everyday
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5.0 OPERATION
5.9.18 Discharge Superheat Control 5.10.3 High Current Limiting

This control function is to prevent the discharge This function prevents the unit from tripping at
superheat reached a low level which may be an compressor overload alarm. When compressor draws
indication of liquid flood back to compressor. Discharge higher current than the rated full load current, the
superheat is the temperature difference between the controller will override the capacity control command of
discharge temperature and the corresponding the compressor. The compressor will be forced to hold
condenser saturated temperature to the condenser or unload to reduce its operating current to bring the
pressure. The controller will force the compressor to compressor operation back to normal and safe zone.
unload if the discharge superheat is low. EEV will be
forced to close to increase suction superheat and bring 5.10.4 Suction-Discharge Pressure
unit operation back to normal and safe zone.
Differential (SDD) Control
5.9.19 Chilled Water Reset This control function seeks to maintain pressure
differential across evaporator and condenser for proper
When Chilled Water Reset option is furnished, the lubrication and to prevent low suction-discharge
desired chilled water temperature can be raised pressure differential alarm. If the controller detects a
automatically by an external signal provided by an refrigerant system is operating in low suction-discharge
external controller, or BAS (Building Automation pressure differential, the SDD control will force the EEV
System). The external signal can be 0–5Vdc, or 4– to closes. This starves the evaporator, which shall
20mA. Chilled Water Reset control can perform increases the pressure differential. When the pressure
o o
maximum temperature reset (increase) of 10 F [5 C]. differential has built-up and back to safe zone, SDD
control will off and EEV will regulates according to load
5.9.20 Demand Limiting demand.
When Demand Limiting option is furnished, a 4-20mA,
or 0-5Vdc signal must be supplied to the Demand 5.10.5 Low Pressure Safety
Limit analog input as shown on the wiring diagram. This function protects the unit from operating at
Supplying 4mA, or 0Vdc will have no limiting effect, and abnormally low evaporator pressure. When the
20mA, or 5Vdc will have maximum limiting. evaporator pressure of a refrigeration circuit drops
below the Low Pressure Cut-off safety setpoint, the
controller will shut down all compressors in that
refrigerant circuit and turn on the alarm light. Alarm
5.10 SAFETIES AND ALARMS message “System Low Pressure – System Off” will
be displayed at DBGX display panel. Manual reset at
The Vision 2020i controller performs the following
display panel is required to clear this alarm.
safety limiting and protection on screw compressor
chillers
5.10.6 High Pressure Safety
5.10.1 Low Pressure Limiting This function protects the unit from operating at
abnormally high condensing pressure. When the
This function prevents the unit from tripping at low
condensing pressure of a refrigeration circuit exceeded
evaporator pressure alarm. When evaporator pressure
the High Pressure Cut-off safety setpoint, the controller
is approaching low suction pressure cut-off safety
will shut down all compressors in that refrigerant circuit
setpoint, the controller will override the capacity control
and turn on the alarm light. Alarm message “System
command of the compressor. The compressor will be
High Pressure- System Off” will be displayed at
forced to hold or unload, and EEV will be forced to
DBGX display panel. Manual reset at display panel is
open to bring the unit operation back to normal and
required to clear this alarm.
safe zone.
5.10.7 Low Differential Pressure Alarm

5.10.2 High Pressure Limiting This function protects the unit from operating at
This function prevents the unit from tripping at high abnormally low suction-discharge pressure differential
condenser pressure alarm. When condensing pressure for pro-long period. If the controller detects a refrigerant
is approaching high discharge pressure cut-off safety circuit is operating with SDD lower than Low SDD Cut
setpoint, the controller will override the capacity control off safety setpoint for a period of time, the controller will
command of the compressor. The compressor will be shut down all compressors in that refrigerant circuit and
forced to hold or unload to bring the unit operation back turn on the alarm light. Alarm message Pressure
to normal and safe zone. Differential System Off” will be displayed at DBGX
display panel. Manual reset at display panel is required
to clear this alarm.
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5.0 OPERATION
5.10.8 Evaporator Freeze Safety 5.10.14 Low Chilled Water Flow Alarm
If the leaving chilled water temperature drops below the This alarm is activated when chilled water flow switch
freeze setpoint, the controller will shut down the unit status is opened when compressor is running. The unit
and turn on the alarm light. Alarm message “Freeze will be stopped and alarm light is turn on. Alarm
Protection” will be displayed at DBGX display panel. message “Loss of Water Flow” will be displayed at
Manual reset at display panel is required to clear this DBGX display panel. Manual reset at display panel is
alarm. required to clear this alarm.
5.10.9 Compressor Low Oil Safety 5.10.15 Power Loss Reset

Oil level sensor is located in each compressor to Power Loss Restart Setting is available in Setpoint
monitor the oil level status in the compressor. If the menu to determine unit restart characteristic after
controller detects compressor is operating with low oil recover from a power failure.
level for a period of time, the controller will shut down If Power Loss Restart Setting is set to “Auto”, the unit
the compressor and turn on the alarm light. Alarm will restart automatically after power is resumed, with
message “Compressor Low Oil Level” will be alarm history recorded. No active alarm message is
displayed at DBGX display panel. Manual reset at shown.
If Power Loss Restart Setting is set to “Manual”, alarm
message “Power Loss” with power loss and resumed
5.10.10 Sensor Failure Alarm time are be displayed at DBGX display panel when
If the controller measures an analogue sensor power supply to the unit is resumed. Manual reset at
(temperature, pressure, or Amp sensor.) with the display panel is required to clear this alarm and put the
reading is beyond its measuring range, the associated unit back into operation.
compressors or system are shutdown. Alarm light is
turned on and alarm message “Sensor Failure” will be 5.10.16 High Compressor Motor
displayed at DBGX display panel. Manual reset at
Temperature Protection
Three motor winding temperature sensors are
furnished at each compressor which will trips the
5.10.11 Compressor No-Stop Alarm compressor when any of these sensor detects high
If the controller turns off a compressor, but the motor winding temperature. Alarm message
compressor’s starter status does not turn off, all “Compressor High Motor Temp” will be displayed at
compressors will be turned off and alarm light is turned DBGX display panel. Manual reset at display panel is
on. Alarm message “Compressor Did Not Stop” will required to clear this alarm.
be displayed at DBGX display panel. Manual reset at
display panel is required to clear this alarm. This alarm
indicates a wiring or hardware error.
5.10.17 Compressor Overload
Protection
5.10.12 Compressor No-Run Alarm A solid state overload protects each compressor by
three phase current monitoring to prevent high current
When the controller has started a compressor but did draw. The trip setting is factory set and is reset by
not received feedback on compressor operating current, pressing button on overload after correcting problem.
alarm will be triggered and alarm light will turn on. “No Run – Compressor OFF” alarm message will be
Alarm message “Compressor Did not Run” will be displayed at DBGX display panel. Manual reset at
displayed at DBGX display panel. Manual reset at display panel is required to clear this alarm.
5.10.18 Volt-Phase Control Relay (PCR)

5.10.13 Compressor Starter Alarm
The PCR protects the unit from the following electric
When the controller starts a compressor but did not supply malfunctions: under or over-voltage, phase
received feedback on compressor’s starter status, reversal, phase imbalance and phase loss. If the PCR
alarm will be triggered and alarm light will turn on. trips, control circuit will be de-energized and the unit
Alarm message “Compressor Starter Error” will be will be shut down. PCR is auto-reset when power
displayed at DBGX display panel. Manual reset at supply has back to pre-set range. Control circuit is re-
display panel is required to clear this alarm. energized again after PCR is reset. Controller treats
this protection as “Power Loss”. Refer to section
5.10.15 Power Loss Reset for the unit restart
characteristic.
- 54 -
5.0 OPERATION
5.11 MASTER-SLAVE SEQUENCING Vision2020i Controller offers this feature with

CONTROL (MSS) minimized field wiring cost compare to conventional
method that involves lots of hardware cost. It is carried
The optional Master-Slave Sequencing Control is used out this control function via the advanced DBLAN
to sequence multiple chillers in one installation communication bus to implement the network
according to the building load demand. It also controls management for multiple chillers lead/lag
the dedicated chilled water pump or motorized valve. communication, sequencing and monitoring.
Figure 5.11A Typical DBLAN Network (3 Chillers)
Graphic
Display
(option)
Twisted Pair Shielded Cable

DBLAN
DBGX Display DBGX Display DBGX Display

DB5+ DB5+ DB5+
DB1 DB1 DB1
DB1 DB1 DB1
Unit #1 Unit #2 Unit #3
Notes
a) Each chiller has a stand-alone Vision 2020i controller and dedicated display (DBGX)
b) Each chiller’s Vision 2020i will be connected to DBLAN network through J11 connector using twisted pair
shielded cable
c) The MSS chiller lead/lag selection can be determined by
D Manual lead/lag setpoint
D Schedule and holiday setup
D Alarm conditions
d) The lead/lag selection determine the chiller operation sequence as follows, The following is an example of three
chillers network with two units on-duty and one unit standby.
Lead chiller selection Chiller operation sequence
1 & 2 on duty
1
3 standby
2 & 3 on duty,
2
1 standby
1 & 3 on duty,
3
2 standby
e) If the lead/lag selection is changed over to a different chiller, the sequence of operation will be rotated
f) Each chiller will use a network address setpoint to determine individual chiller network address
g) Master-slave control can be extended up to maximum eight (8) chillers in the DBLAN network.
A typical sequence of operation of MSS is shown Figure 5.11B Flow Chart – Master-Slave Control Sequence.
- 55 -
5.0 OPERATION
Figure 5.11B Flow Chart – Master-Slave Control Sequence
- 56 -
5.0 OPERATION
5.12 ELECTRICAL both heads of the condenser to drain water in the

condenser, and blow through the tubes with
MALFUNCTION compressed air to avoid stagnant water that
potentially causes serious corrosion. The power
The unit has four devices designed to protect
supply to the unit may be de-energized to conserve
compressor motors and manual motor controllers from
energy.
electrical malfunctions: Circuit breakers, starter
overload relays, under voltage relay, and motor over 5. It is recommended to that an oil sample is taken
temperature protectors. from each compressor and submitted for laboratory
analysis during the seasonal shut-down to check for
If the under voltage relay trips, it is a sign of trouble in moisture level and impurities. Oil analysis should be
incoming power. If it trips again after resetting, call your done at the beginning and end of each operating
electric utility to investigate the problem. If circuit season, or every six months if the unit is used year
breaker or motor overload relay or motor over round.
temperature protector trip, this is a sign of possible
motor trouble. DO NOT reset and try to run compressor
again. Call authorized service representative to check
for motor trouble. Resetting these safety devices and
5.15 SEASONAL START-UP
repeated starting could turn a minor motor problem into PROCEDURE
a costly major motor burnout.
When the unit is to be started up after being shut down
for a prolonged period:
5.13 SHUTDOWN (OVERNIGHT 1. Check unit for evidence of rust or corrosion. Clean
surfaces and repaint as necessary. Repair
OR WEEKEND) insulation if necessary.
To shut down the unit for overnight or weekend, turn 2. Clean waterside heat transfer surface of condenser
ROL selector switch to “O” position; or make the remote and evaporator by removing headers and brushing
start signal to “OFF”. If there is running compressor, the tubes.
compressor shall stops. The evaporator water pump 3. Check all power supply connections at all points,
shall be turned off 3 minutes later to vaporize the cool and all control terminal screws for tightness.
liquid refrigerant left in the evaporator. 4. If the water was drained out from system previously,
DO NOT close any valve and DO NOT turn off the main re-install the drain plugs and refill water into the
incoming power supply. Main power supply is required system. After all air has been purged out from the
to energize the compressor heater(s) to maintain water circuit, re-install the vent plugs.
compressor oil sump temperature. 5. Check water circuits to ensure cooling tower is
ready for operation. Start pumps and check for flow
Important: Discontinue chilled water pump in both evaporator and condenser.
operation when unit is not operational.
6. Energize main power to unit & leave on for at least
Note: For installation in some regions that chillers 24 hours in order for compressors to thoroughly
may leave idle in the plantroom with warm up. Compressor oil sump temperature must
overnight ambient will drop below 45°F be at a minimum of 100°F [38°C].
[7.2°C], it is preferable to leave the chilled 7. Start water pump and verify correct flow-rate. Bleed-
water pump on. off system air if necessary.
8. Open all refrigerant isolation valves (liquid line shut
off valve, compressor discharge and suction service
5.14 SEASONAL SHUT-DOWN valves).
PROCEDURE 9. Turn control circuit power switch on.
1. Follow all steps as discussion in section 5.12 10. Start the chiller by either local start command with
Shutdown (Overnight or Weekend) ROL selector switch on position “L”; or with ROL
selector switch on position “R” and the remote start
2. Close the refrigerant isolation valves (liquid line shut
signal is ON.
off valve, compressor discharge and suction service
11. First compressor will starts after the countdown
valves)
timer
3. Check and verify that chilled water and condenser
water pumps are stopped. Turn off main power
supply to the pumps, if desired.
4. Drain water in condenser piping and cooling tower,
if desired. Remove the drain and vent plugs from
- 57 -
5.0 OPERATION
5.16 FREEZE PREVENTION 5.16.2 IN OPERATION

Freezing of water in evaporator tubes is a possibility if
If water (or brine) is allowed to freeze within the tubes chilled water flow stops and if the low suction pressure
and headers of the evaporator or condenser, severe cutout (normally set for 28 psig [1.9BAR], or 32°F [0°C]
damage will result; e.g. split and leaking tubes and saturation) and evaporator freeze alarm cutout both fail.
cracked and leaking headers. Since this damage can If the chilled water flow switch and pump interlock are
be extremely costly and is not covered by warranty, it is properly applied (See Section 5.8.4), the unit has four
important to be mindful of freeze prevention. Three protective devices which must all fail in order to freeze
cases deserve particular attention: the evaporator in operation. While this is unlikely, it is
important to see that all these devices are functional
and properly calibrated.
5.16.1 STANDBY AT LOW AMBIENT
TEMPERATURES
If the unit is to stand idle at ambient temperatures 5.16.3 DURING MAINTENANCE
below 32°F [0°C], the water should be drained from In transferring refrigerant within the unit, or removing
evaporator and condenser. A header should be refrigerant from the unit for maintenance purposes, it is
removed from each vessel and the tubes should be possible to freeze evaporator or condenser tubes.
blown dry with compressed air. Gravity draining the Remember that whenever the pressure in a vessel is
vessel through drains in headers may not be sufficient. reduced below 28 psig [1.9BAR], if water is not flowing,
If evaporator or condenser is served with a glycol it is possible to freeze the tubes. For this reason, it is a
solution, make sure the freeze temperature of the good precaution to have water flowing in both vessels
solution is lower than the expected minimum ambient whenever transferring refrigerant.
temperature.
- 58 -
6.0 MAINTENANCE
6.1 GENERAL Vessel tubes may be physically cleaned by first

As with all mechanical equipment, a program of regular draining the water, then removing the headers and
inspection, cleaning and preventive maintenance by brushing each tube individually with a tube cleaning
trained personnel will contribute greatly to the long brush until it is clean. The brush should have stiff nylon
satisfactory service life of this product. bristles. For best results, always remove both headers
before cleaning the tubes. Replace the headers, being
careful to properly position gaskets, and refill the
system with water.
6.2 PERIODIC INSPECTION Head gaskets need not be renewed after each head
Read essential temperatures and pressures disassembly operation. Gaskets should and must be
periodically to see that they indicate normal operation. renewed if they are physically disfigured or otherwise
It is a good idea to record these readings on a log deteriorated. New gaskets are available from the
sheet. If any abnormal operation is observed, try to factory.
remedy it. See Trouble Shooting Guide Section.
6.5 EVAPORATOR
6.3 MONTHLY INSPECTION MAINTENANCE
Remote dirt and debris from condenser coil. Shut unit
As the evaporator is typically part of a closed circuit,
down, open main disconnect, inspect control panel,
accumulation of scale or sludge are insignificant.
checking for loose wires, burned contacts, signs of
However, if cleaning is deemed necessary, use the
overheated wires, etc. Restart unit and check
same procedures as described for condenser tube
performance of controls. Check sight glasses for proper
cleaning.
refrigerant charge, see section 6.5 Refrigerant Charge.
Calculation of evaporator approaches as follows:
Evaporator Approach = Leaving Chilled Water
Temperature – Evaporator Saturated Temperature
6.4 CONDENSER
MAINTENANCE
The effects of fouling of the condenser heat transfer 6.6 REFRIGERANT CHARGE
surfaces can be detected by recording full load
All packaged chiller units are given a complete charge
performance data on the log sheet. The best measure
of refrigerant at the factory. The type and amount of
of performance of condenser is approach temperature,
refrigerant required is in Physical Specifications. The
which is the difference between leaving water
total refrigerant shown is for the entire system.
temperature and saturated refrigerant temperature at
the pressure in the vessel. At full load, read evaporator In order to check proper refrigerant charge, look in
pressure and leaving chilled water temperature each liquid line sight glass with the aid of a flashlight
readings on the display panel. Then use Appendix 8.2 during system operation. At all operating conditions, the
to find saturated temperature in condenser. Then sight glass should be clear. If bubbles are visible at any
calculate approaches as follows: operating condition, the circuit is short of charge.
Condenser Approach = Saturated Discharge BE CAREFUL: NOT TO OVERCHARGE THE
Temperature – Leaving Condenser Water Temperature. MACHINE. Overcharging will result in considerable
liquid logging in the condenser, and excessive
If the approach increases by more than 2°F [1.1°C]
condensing pressure.
above the approach recorded at clean conditions, the
tubes should be cleaned. It is generally advisable to To add refrigerant, connect a refrigerant vessel to the
clean the water side surfaces at least annually and 1/4"[6mm] back seating port of the suction valve. Purge
more often if severely foul water is used. In chemical the air from the tube with refrigerant gas before
cleaning, a caustic solution is pumped through the heat connecting. With the unit running, open the refrigerant
exchanger, which attacks dirt, slime and mineral vessel vapor connection slightly. If the refrigerant
deposits and flushes then away. Chemicals can be vessel is warmer than the cooler, refrigerant will more
recommended by water treatment specialists, but it is readily flow from the vessel into the unit.
important to rinse the system thoroughly after cleaning
to remove the chemicals before they attack the metal
surfaces.
- 59 -
6.0 MAINTENANCE
Figure 6.3: Recommended Preventive Maintenance Schedule

Tasks Daily Monthly Bi-Yearly Yearly
Monitor and record chiller's operating parameters in log sheet X
Check oil level in oil level sight glass X
Observe unit operation sound X
Check and verify proper oil heater operation X
Check and verify proper oil return system operation X
Check for proper refrigerant levels X
Check for any trace of oil stain and sign of refrigerant leakage, repair as
X
necessary
Carry out refrigerant leak test with a halide torch or an electronic leak
X
detector
Oil analysis for acidity level, moisture content and dissolved solids.
X
Replace if necessary (1)
Check liquid line sight glass for sign of excessive moisture content and
filter drier for sign of excessive pressure drop. Replace filter drier as X
necessary (2)
Check Suction Filter for excessive pressure drop (3) X
Verify Evaporator and Condenser liquid flow, and check flow switch
X
operation
Water analysis to verify that both the water loop are properly treated (4) X
Check for evaporator and condenser temperature approach X

(5)
Evaporator and Condenser tube cleaning X
(6)
Check for proper concentration of antifreeze solution, if applicable X
Perform Eddy Current testing and inspect tubes (7)
Check strainer, clean as necessary X
Check for any loose mechanical valves and parts, and tighten as
X
necessary
Check for any loose cable termination and tighten as necessary X
Check and verify accuracy of transducers, thermistors, etc., calibrate as

X
necessary
Check Electronic Expansion Valve (EEV) operation X
Check Accuracy of Temperature sensors X
Check 3-phase voltage and current balance X
Check operation of motor starter X
Check Motor Winding Resistance X
Check programmable operating setpoints and safety cutouts X

Notes: 1) Change oil after first year or 3000 hours of operation (whichever comes first). Subsequent oil change should be done as per oil analysis result.
2) Replace filter if pressure different between inlet and outlet ends is more than 3PSID [0.21Bar].
3) Replace filter if pressure different between inlet and outlet ends is more than 2.5PSID [0.17Bar].
4) More frequent water analysis may be needed for condenser water loop when it is an open loop system. Monthly water analysis is recommended.
5) More frequent cleaning may be required depending on site operating conditions.
6) For process cooling application where the brine solution may be drained out from the system, the fluid concentration shall be checked in daily basis.
7) To perform as required by performance.
- 60 -
6.0 MAINTENANCE
6.7 REFRIGERANT RECOVERY 6.9 RECOVERY AND

If service and maintenance task required refrigerant to DISPOSABLE OF USED
be removed from the system, refrigerant shall be COMPRESSOR OIL
recovered using approved refrigerant recovery
techniques and equipment and then safely stored, in Used refrigerant oil can be drained from compressor oil
accordance to local regulations. Any refrigerant transfer sump, oil separator, receiver or any part of the
and recovery operations must be carried out using a refrigeration machine. Draining of used refrigerant oil
transfer unit. A 1/2” SAE connector on the manual shall be done with minimum refrigerant release to the
liquid line valve is supplied with all units for connection environment in accordance with CE requirements.
to the transfer station.
1. Connect a refrigerant hose between oil drain valve
CAUTION: Refrigerant SHALL NOT be discharged and external receiver.
directly into the atmosphere. 2. Connect a refrigerant transfer pump between
external receiver and refrigeration machine.
IMPORTANT: Never re-use disposable (non-
3. Drain used refrigerant oil from compressor oil
returnable) cylinders or attempt to
sump, oil separator, receiver or refrigeration
refill them. It is dangerous and illegal.
machine by virtue of pressure difference.
When cylinders are empty, evacuate
the remaining gas pressure, and 4. Evacuate external receiver and transfer refrigerant
move the cylinders to a place vapor back into the refrigerant machine through
designated for their recovery refrigerant transfer pump. The refrigerant pressure
within the external receiver must be of positive
Before opening a refrigerant circuit, purge and consult pressure in order to prevent inward leakage from
the pressure gauges. Be sure pressure is at 0 kPa the atmosphere.
before removing components and opening a circuit. 5. Heat external receiver with trace heaters in order
to facilitate boiling of dissolved refrigerant within
the used refrigerant oil.
6.8 COMPRESSOR OIL CHARGE 6. Drain and dispose used refrigerant oil through the
oil drain valve located at the bottom of the external
The proper oil charge is in the unit as supplied from the receiver in accordance with CE requirement and
factory. Any operating compressor should show oil other local directives.
return and oil overflow at all time. Refer Section 5.4
which describe proper oil management system of the
chiller. It is typical that Dunham-Bush vertical screw
compressor is operating with oil level runs below the
bottom of the compressor oil sight glass. If for some
reason, a compressor runs low on oil, a low oil level
switch in the compressor will shut it down before any
damage is done.
In the event of a low oil shutdown, call a DB authorized
service agent to correct the problem. DO NOT ADD
OIL TO THE SYSTEM.
Note: Only DHB-021 oil may be used in this package.

Use of other oil is not approve by Dunham-Bush, and
will result in poor performance of the package. It is
required to change oil after first year or 3000 hours
of operation (whichever comes first). Oil analysis
shall be done for the subsequent years to ensure the oil
is within its characteristic.
- 61 -
6.0 MAINTENANCE
6.10 UNIT SCHEMATIC DIAGRAM

Figure 6.10: Typical System Schematic Diagram
1.) WCFX-V 19S, 20S, 23S, 24S, 27S, 30S
- 62 -
6.0 MAINTENANC
CE
2.) WCFX-V 36S, 41S, 46S
- 63 -
6.0 MAINTENANCE
3.) WCFX-V 38T, 40T, 46T, 50T, 54T, 57T, 60T
- 64 -
6.0 MAINTENANCE
4.) WCFX-V 73T, 75T, 81T, 87T, 90T
- 65 -
6.0 MAINTENANCE
5.) Optional
- 66 -
6.0 MAINTENANCE
- 67 -
6.0 MAINTENANC
CE
- 68 -
6.0 MAINTENANC
CE
- 69 -
6.0 MAINTENANCE
6.) Recommended Spare Part List – Mechanical
Bubble No 19SR 20SR
WCFX-V Part No Description Part No Description
M01a 1003200045 COMP MSC1220NHL6V5KOEMCS9C-CE 1003220027 COMP MSC1222NHL6V5KOEMCS9C-CE
M02a 1090009027 VAL-SER 4-1/8 SCT (053572A6) 1090009027 VAL-SER 4-1/8 SCT (053572A6)
M03a 1090009219 SV VALVE 5" SUCT /DIS 1090009219 SV VALVE 5" SUCT /DIS
M04a - - - -
M05a - - - -
-
M01b - - - -
M02b - - - -
M03b - - - -
M04b - - - -
M05b - - - -
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
M06 3003300026 PRV, 300PSI, 3/4"MPT*FPT 3003300026 PRV, 300PSI, 3/4"MPT*FPT
M07 3012061005 VAL,ANG 1/4"MPT*3/8" 3012061005 VAL,ANG 1/4"MPT*3/8"
M08 3201106002 SI-GLS 3/8” (SYJ10H11) 3201106002 SI-GLS 3/8” (SYJ10H11)
M09 3005003003 VAL-SOL 3/8 ODF HV3M3T 110V 3005003003 VAL-SOL 3/8 ODF HV3M3T 110V
M10 3203163079 DRI,FTR 3/8" DCL163S 3203163079 DRI,FTR 3/8" DCL163S
M11 H006381B2 VAL-ANG 0.375ODS*0.375ODS H006381B2 VAL-ANG 0.375ODS*0.375ODS
-
M13 H200P135 VAL-ANG 0.500FL*0.38MPT H200P135 VAL-ANG 0.500FL*0.38MPT
-
M14a - - - -
M15a - - - -
M16a - - - -
M17a - - - -
M18a - - - -
M19a - - - -
M20a 3201100001 SI-GLS W/O BASE (SGRN M24X1) 3201100001 SI-GLS W/O BASE (SGRN M24X1)
M21a 3001275001 EEV, E6VA8ASV00, 1-5/8x1-5/8 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8
M21c - - - -
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24a H006381B4 VAL-ANG 0.625ODS*0.625ODS 3012140012 VAL,ANG 7/8" x 7/8"
M24b - - - -
M25a 3204107009 DRI-SHL 487,7/8,1-BLK,UL 3204107009 DRI-SHL 487,7/8,1-BLK,UL
M25b - - - -
M26 3204904020 DRI-CRE SH48-A00 3204904020 DRI-CRE SH48-A00
M27a 3012140012 VAL,ANG 7/8" x 7/8" 3012140012 VAL,ANG 7/8" x 7/8"
M27b - - - -
M28 - - - -
M29a 3201114001 SI-GLS 7/8" (SYJ22H11) 3201114001 SI-GLS 7/8" (SYJ22H11)
M29b - - - -
M30 1290001005 JET PMP-INL 1290001005 JET PMP-INL
M31 1290001006 JET PMP-OTL 1290001006 JET PMP-OTL
M32 - - - -
M34 - - - -
M35 - - - -
M36 - - - -
M37 - - - -
M38 - - - -
M39 - - - -
M40 3190200003 SWT-LIQ LEVEL,200MM (L), WIKA 3190200003 SWT-LIQ LEVEL,200MM (L), WIKA
Oil 7101002021 OIL, DHB-021 7101002021 OIL, DHB-021
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
MD1 3003450016 PRV, 450PSI, 3/4"MPT*FPT 3003450016 PRV, 450PSI, 3/4"MPT*FPT
-
MH1 3005020002 VAL-SOL 7/8 ODF HV20M7T 110V 3005020002 VAL-SOL 7/8 ODF HV20M7T 110V
MH2 3012140012 VAL,ANG 7/8” x 7/8” 3012140012 VAL,ANG 7/8” x 7/8”
-
-
-
MC1 HVAL453 VAL-3WAY DUAL RELIEF VALVE HVAL453 VAL-3WAY DUAL RELIEF VALVE
-
ML1a H006381B4 VAL-ANG 0.625ODS*0.625ODS H006381B4 VAL-ANG 0.625ODS*0.625ODS
ML2a 3203305081 DRI,FTR 5/8" DCL305S(SDR) 3203305081 DRI,FTR 5/8" DCL305S(SDR)
ML3a - - - -
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML4 H006381B4 VAL-ANG 0.625ODS*0.625ODS H006381B4 VAL-ANG 0.625ODS*0.625ODS
ML5 3005010004 VAL-SOL 5/8 ODF HV10M5T 110V 3005010004 VAL-SOL 5/8 ODF HV10M5T 110V
ML6 3201110001 SI-GLS 5/8" ((SYJ12H11)) 3201110001 SI-GLS 5/8" ((SYJ12H11))
ML7 - - - -
-
MBa - - - -
MBb - - - -
MBc - - - -
-
ME1 HVAL453 VAL-3WAY DUAL RELIEF VALVE HVAL453 VAL-3WAY DUAL RELIEF VALVE
- 70 -
6.0 MAINTENANCE
Bubble No 23SR 24SR
M04a - - - -
M05a 3020026021 VAL,CHK 1-5/8"(SUPERIOR) - -
-
M01b - - - -
M02b - - - -
M03b - - - -
M04b - - - -
M05b - - - -
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M14a 1212029151 PLT H/EX V80Hx66 - -
M15a 3012140012 VAL,ANG 7/8" x 7/8" - -
M16a 3203757082 DRI,FTR 7/8" DCL757S(SDR) - -
M17a - - - -
M18a 3005020002 VAL-SOL 7/8 ODF HV20M7T 110V - -
M19a 3001037277 TXV TGEN17 7/8 x 1 3/8 - -
M21a 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8
M21c - - - -
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M28 - - - -
M29b - - - -
M32 - - - -
M34 - - - -
M35 - - - -
M36 - - - -
M37 - - - -
M38 - - - -
M39 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML3a - - - -
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBa 3050005029 VAL-BAL 1-5/8 (SR-17313) - -
MBb - - - -
MBc - - - -
-
- 71 -
6.0 MAINTENANCE
Bubble No 27SR 30SR
M04a - - - -
M05a 3020026021 VAL,CHK 1-5/8"(SUPERIOR) 3020026021 VAL,CHK 1-5/8"(SUPERIOR)
-
M01b - - - -
M02b - - - -
M03b - - - -
M04b - - - -
M05b - - - -
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M14a 1212035152 PLT H/EX V80Hx82 1212043153 PLT H/EX V120THx54
M15a 3012140012 VAL,ANG 7/8" x 7/8" H006381A7 VAL-ANG STL 1-1/8*1-1/8
M16a 3203757082 DRI,FTR 7/8" DCL757S(SDR) 3203757082 DRI,FTR 7/8" DCL757S(SDR)
M17a - - - -
M18a 3005020002 VAL-SOL 7/8 ODF HV20M7T 110V 3005025007 VAL-SOL 1-1/8 ODF HV25M9T 110V
M19a 3001037277 TXV TGEN17 7/8 x 1 3/8 3001037278 TXV TGEN25 1 1/8 x 1 3/8
M21a 3001927001 EEV, E7VB4ASZ00, 2-1/8 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8
M21c - - - -
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M28 - - - -
M29b - - - -
M32 - - - -
M34 - - - -
M35 - - - -
M36 - - - -
M37 - - - -
M38 - - - -
M39 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML3a - - - -
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBa 3050005029 VAL-BAL 1-5/8 (SR-17313) 3050005029 VAL-BAL 1-5/8 (SR-17313)
MBb - - - -
MBc - - - -
-
- 72 -
6.0 MAINTENANCE
Bubble No 36SR 41SR
M02a 1090009181 VAL SERV 5" MSC 226 DIS 1090009181 VAL SERV 5" MSC 226 DIS
M03a 1090009182 VAL SERV 6" MSC 226 SUC 1090009182 VAL SERV 6" MSC 226 SUC
M04a - - - -
-
M01b - - - -
M02b - - - -
M03b - - - -
M04b - - - -
M05b - - - -
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M14a 1212052154 PLT H/EX V120THx68 1212052154 PLT H/EX V120THx68
M15a H006381A7 VAL-ANG STL 1-1/8*1-1/8 H006381A7 VAL-ANG STL 1-1/8*1-1/8
M16a 3203757082 DRI,FTR 7/8" DCL757S(SDR) 3203757082 DRI,FTR 7/8" DCL757S(SDR)
M17a - - - -
M18a 3005025007 VAL-SOL 1-1/8 ODF HV25M9T 110V 3005025007 VAL-SOL 1-1/8 ODF HV25M9T 110V
M19a 3001037278 TXV TGEN25 1 1/8 x 1 3/8 3001037278 TXV TGEN25 1 1/8 x 1 3/8
M21a 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8
M21c - - - -
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M28 - - - -
M29b - - - -
M32 - - - -
M34 - - - -
M35 - - - -
M36 - - - -
M37 - - - -
M38 - - - -
M39 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML3a - - - -
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBb - - - -
MBc - - - -
-
- 73 -
6.0 MAINTENANCE
Bubble No 46SR 38TR
M02a 1090009181 VAL SERV 5" MSC 226 DIS 1090009027 VAL-SER 4-1/8 SCT (053572A6)
M03a 1090009182 VAL SERV 6" MSC 226 SUC 1090009219 SV VALVE 5" SUCT /DIS
M04a - - 3020066039 VALVE, CHECK 4 1/8' ASSY (CHIN
M05a 3020026021 VAL,CHK 1-5/8"(SUPERIOR) - -
-
M01b - - 1003200045 COMP MSC1220NHL6V5KOEMCS9C-CE
M02b - - 1090009027 VAL-SER 4-1/8 SCT (053572A6)
M03b - - 1090009219 SV VALVE 5" SUCT /DIS
M04b - - 3020066039 VALVE, CHECK 4 1/8' ASSY (CHIN
M05b - - - -
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M14a 1212064156 PLT H/EX V120THx90 - -
M15a H006381A7 VAL-ANG STL 1-1/8*1-1/8 - -
M16a 3204107009 DRI-SHL 487,7/8,1-BLK,UL - -
M17a 3204904020 DRI-CRE SH48-A00 - -
M18a 3005025007 VAL-SOL 1-1/8 ODF HV25M9T 110V - -
M19a 3001904175 TXV,TRAE40MC,15',1-1/8*1-3/8 - -
M21c - -
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25a 3204207010 DRI-SHL 967,7/8,2-BLK,UL 3204207044 DRI-SHL 967,7/8,2-BLK
M25b - - - -
M27b - - - -
M28 - - 3020010001 VAL,CHK 5/8" (YCVS13)
M29a 3201114001 SI-GLS 7/8" (SYJ22H11) 3201110001 SI-GLS 5/8" ((SYJ12H11))
M29b - - - -
M32 - - - -
M34 - - HVAL977T4 VAL RTL 3/8 ODS X 3/4 HEX
M35 - - 3201106002 SI-GLS 3/8" (SYJ10H11)
M36 - - HVAL387 VAL-CHK LIF 0.375ODS
M37 - - 3005003003 VAL-SOL 3/8 ODF HV3M3T 110V
M38 - - HVAL387 VAL-CHK LIF 0.375ODS
M39 - - H006381B2 VAL-ANG 0.375ODS*0.375ODS
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML1a H006381B4 VAL-ANG 0.625ODS*0.625ODS 3012140012 VAL,ANG 7/8" x 7/8"
ML2a 3203305081 DRI,FTR 5/8" DCL305S(SDR) 3204107009 DRI-SHL 487,7/8,1-BLK,UL
ML3a - - 3204904020 DRI-CRE SH48-A00
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBa 3050005029 VAL-BAL 1-5/8 (SR-17313) - -
MBb - - - -
MBc - - - -
-
- 74 -
6.0 MAINTENANCE
Bubble No 40TR 46TR
M04a 3020066039 VALVE, CHECK 4 1/8' ASSY (CHIN 3020066039 VALVE, CHECK 4 1/8' ASSY (CHIN
M05a - - 3020026021 VAL,CHK 1-5/8"(SUPERIOR)
-
M01b 1003220027 COMP MSC1222NHL6V5KOEMCS9C-CE 1003220027 COMP MSC1222NHL6V5KOEMCS9C-CE
M02b 1090009027 VAL-SER 4-1/8 SCT (053572A6) 1090009027 VAL-SER 4-1/8 SCT (053572A6)
M03b 1090009219 SV VALVE 5" SUCT /DIS 1090009219 SV VALVE 5" SUCT /DIS
M04b 3020066039 VALVE, CHECK 4 1/8' ASSY (CHIN 3020066039 VALVE, CHECK 4 1/8' ASSY (CHIN
M05b - - 3020026021 VAL,CHK 1-5/8"(SUPERIOR)
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M14a - - 1212064156 PLT H/EX V120THx90
M15a - - H006381A7 VAL-ANG STL 1-1/8*1-1/8
M16a - - 3204209002 DRI-SHL 969,1-1/8,2-BLK
M17a - - 3204904020 DRI-CRE SH48-A00
M18a - - 3005025007 VAL-SOL 1-1/8 ODF HV25M9T 110V
M19a - - 3001904175 TXV,TRAE40MC,15',1-1/8*1-3/8
M21c - -
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25a 3204309011 DRI-SHL P1449,1-1/8,3-BLK 3204309011 DRI-SHL P1449,1-1/8,3-BLK
M25b - - - -
M27b - - - -
M28 3020010001 VAL,CHK 5/8" (YCVS13) 3020010001 VAL,CHK 5/8" (YCVS13)
M29a 3201110001 SI-GLS 5/8" ((SYJ12H11)) 3201110001 SI-GLS 5/8" ((SYJ12H11))
M29b - - - -
M32 - - - -
M34 HVAL977T4 VAL RTL 3/8 ODS X 3/4 HEX HVAL977T4 VAL RTL 3/8 ODS X 3/4 HEX
M35 3201106002 SI-GLS 3/8" (SYJ10H11) 3201106002 SI-GLS 3/8” (SYJ10H11)
M36 HVAL387 VAL-CHK LIF 0.375ODS HVAL387 VAL-CHK LIF 0.375ODS
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML1a 3012140012 VAL,ANG 7/8" x 7/8" 3012140012 VAL,ANG 7/8" x 7/8"
ML2a 3204107009 DRI-SHL 487,7/8,1-BLK,UL 3204107009 DRI-SHL 487,7/8,1-BLK,UL
ML3a 3204904020 DRI-CRE SH48-A00 3204904020 DRI-CRE SH48-A00
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBa - - 3050005029 VAL-BAL 1-5/8 (SR-17313)
MBb - - 3050005029 VAL-BAL 1-5/8 (SR-17313)
MBc - - - -
-
- 75 -
6.0 MAINTENANCE
Bubble No 50TR 54TR
-
M05b 3020026021 VAL,CHK 1-5/8"(SUPERIOR) 3020026021 VAL,CHK 1-5/8"(SUPERIOR)
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M16a 3204209002 DRI-SHL 969,1-1/8,2-BLK 3204309011 DRI-SHL P1449,1-1/8,3-BLK
M17a 3204904020 DRI-CRE SH48-A00 3204904020 DRI-CRE SH48-A00
M19a 3001904175 TXV,TRAE40MC,15',1-1/8*1-3/8 3001500067 TXV,TRAE50MC,1-1/8*1-3/8 ODF,
M21c - - 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M29b - - - -
M32 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBb 3050005029 VAL-BAL 1-5/8 (SR-17313) 3050005029 VAL-BAL 1-5/8 (SR-17313)
MBc - - - -
-
- 76 -
6.0 MAINTENANCE
Bubble No 57TR 60TR
-
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M17a 3204904020 DRI-CRE SH48-A00 3204904020 DRI-CRE SH48-A00
M19a 3001500067 TXV,TRAE50MC,1-1/8*1-3/8 ODF, 3001500067 TXV,TRAE50MC,1-1/8*1-3/8 ODF,
M21c 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M29b - - - -
M32 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBc - - - -
-
- 77 -
6.0 MAINTENANCE
Bubble No 73TR 75TR
M04a 3020080001 VALVE CHK 5" ASSY YANTAI 3020080001 VALVE CHK 5" ASSY YANTAI
-
M02b 1090009181 VAL SERV 5" MSC 226 DIS 1090009181 VAL SERV 5" MSC 226 DIS
M03b 1090009182 VAL SERV 6" MSC 226 SUC 1090009182 VAL SERV 6" MSC 226 SUC
M04b 3020080001 VALVE CHK 5" ASSY YANTAI 3020080001 VALVE CHK 5" ASSY YANTAI
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M15a H006381A8 VAL-ANG 1.375ODS * 1.375ODS H006381A8 VAL-ANG 1.375ODS * 1.375ODS
M16a - - - -
M17a - - - -
M18a - - - -
M19a 3001085292 EEV,E5VA5AST00, 1-3/8 x 1-3/8 3001085292 EEV,E5VA5AST00, 1-3/8 x 1-3/8
M21c 3001156293 EEV,E6VB2ASV00, 1-5/8 1-5/8 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M29b - - - -
M32 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBc - - - -
-
- 78 -
6.0 MAINTENANCE
Bubble No 81TR 87TR
M04a 3020080001 VALVE CHK 5" ASSY YANTAI 3020080001 VALVE CHK 5" ASSY YANTAI
-
M02b 1090009181 VAL SERV 5" MSC 226 DIS 1090009181 VAL SERV 5" MSC 226 DIS
M03b 1090009182 VAL SERV 6" MSC 226 SUC 1090009182 VAL SERV 6" MSC 226 SUC
M04b 3020080001 VALVE CHK 5" ASSY YANTAI 3020080001 VALVE CHK 5" ASSY YANTAI
-
M01c - - - -
M02c - - - -
M03c - - - -
M04c - - - -
M05c - - - -
-
-
-
M15a H006381A8 VAL-ANG 1.375ODS * 1.375ODS H006381A8 VAL-ANG 1.375ODS * 1.375ODS
M16a - - - -
M17a - - - -
M18a - - - -
M19a 3001085292 EEV,E5VA5AST00, 1-3/8 x 1-3/8 3001085292 EEV,E5VA5AST00, 1-3/8 x 1-3/8
M21c 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8
-
M14b - - - -
M15b - - - -
M16b - - - -
M17b - - - -
M18b - - - -
M19b - - - -
M20b - - - -
M21b - - - -
-
M24b - - - -
M25b - - - -
M27b - - - -
M29b - - - -
M32 - - - -
Ref 7102134002 RFG-R134A 7102134002 RFG-R134A
-
-
-
-
-
-
-
-
-
ML1b - - - -
ML2b - - - -
ML3b - - - -
ML7 - - - -
-
MBc - - - -
-
- 79 -
6.0 MAINTENANCE
Bubble No 90TR
WCFX-V Part No Description
M01a 1003460028 COMP MSC2246NHL6V5KOEMCS9C-CE
M02a 1090009181 VAL SERV 5" MSC 226 DIS
M03a 1090009182 VAL SERV 6" MSC 226 SUC
M04a 3020080001 VALVE CHK 5" ASSY YANTAI
M05a 3020026021 VAL,CHK 1-5/8"(SUPERIOR)
-
M01b 1003460028 COMP MSC2246NHL6V5KOEMCS9C-CE
M02b 1090009181 VAL SERV 5" MSC 226 DIS
M03b 1090009182 VAL SERV 6" MSC 226 SUC
M04b 3020080001 VALVE CHK 5" ASSY YANTAI
M05b 3020026021 VAL,CHK 1-5/8"(SUPERIOR)
-
M01c - -
M02c - -
M03c - -
M04c - -
M05c - -
-
M06 3003300026 PRV, 300PSI, 3/4"MPT*FPT
M07 3012061005 VAL,ANG 1/4"MPT*3/8"
M08 3201106002 SI-GLS 3/8” (SYJ10H11)
M09 3005003003 VAL-SOL 3/8 ODF HV3M3T 110V
M10 3203163079 DRI,FTR 3/8" DCL163S
M11 H006381B2 VAL-ANG 0.375ODS*0.375ODS
-
M12 3003200023 PRV, 200PSI, 3/4"MPT*FPT
M13 H200P135 VAL-ANG 0.500FL*0.38MPT
-
M14a 1212121162 PLT H/EX V200THx152
M15a H006381A8 VAL-ANG 1.375ODS * 1.375ODS
M16a - -
M17a - -
M18a - -
M19a 3001085292 EEV,E5VA5AST00, 1-3/8 x 1-3/8
M20a 3201100001 SI-GLS W/O BASE (SGRN M24X1)
M21a 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8
M21c 3001312294 EEV,E7VC1ASZ00, 2-1/8 x 2-1/8
-
M14b - -
M15b - -
M16b - -
M17b - -
M18b - -
M19b - -
M20b - -
M21b - -
-
M22 H200P135 VAL-ANG 0.500FL*0.38MPT
M23 3003200023 PRV, 200PSI, 3/4"MPT*FPT
M24a H006381A7 VAL-ANG STL 1-1/8*1-1/8
M24b - -
M25a 3204309011 DRI-SHL P1449,1-1/8,3-BLK
M25b - -
M26 3204904020 DRI-CRE SH48-A00
M27a H006381A7 VAL-ANG STL 1-1/8*1-1/8
M27b - -
M28 3020010001 VAL,CHK 5/8" (YCVS13)
M29a 3201110001 SI-GLS 5/8" ((SYJ12H11))
M29b - -
M30 1290001005 JET PMP-INL
M31 1290001006 JET PMP-OTL
M32 - -
M34 HVAL977T4 VAL RTL 3/8 ODS X 3/4 HEX
M35 3201106002 SI-GLS 3/8” (SYJ10H11)
M36 HVAL387 VAL-CHK LIF 0.375ODS
M38 HVAL387 VAL-CHK LIF 0.375ODS
M40 3190200003 SWT-LIQ LEVEL,200MM (L), WIKA
Oil 7101002021 OIL, DHB-021
Ref 7102134002 RFG-R134A
-
-
-
-
MD1 3003450016 PRV, 450PSI, 3/4"MPT*FPT
-
MH1 3005020002 VAL-SOL 7/8 ODF HV20M7T 110V
MH2 3012140012 VAL,ANG 7/8” x 7/8”
-
-
-
MC1 HVAL453 VAL-3WAY DUAL RELIEF VALVE
-
ML1a 3012140012 VAL,ANG 7/8" x 7/8"
ML2a 3204107009 DRI-SHL 487,7/8,1-BLK,UL
ML3a 3204904020 DRI-CRE SH48-A00
ML1b - -
ML2b - -
ML3b - -
ML4 H006381B4 VAL-ANG 0.625ODS*0.625ODS
ML5 3005010004 VAL-SOL 5/8 ODF HV10M5T 110V
ML6 3201110001 SI-GLS 5/8" ((SYJ12H11))
ML7 - -
-
MBa 3050005029 VAL-BAL 1-5/8 (SR-17313)
MBb 3050005029 VAL-BAL 1-5/8 (SR-17313)
MBc - -
-
ME1 HVAL453 VAL-3WAY DUAL RELIEF VALVE
- 80 -
6.0 MAINTENANCE
Hermetic Compressor Hermetic Compressor
Model 380/3/50 460/3/60
PN Description PN Description
1220 1003200042 1220NHL6V5KOEMCB9C-CE 1003200048 1220NHL6V5KOEMBJ9C-UL
Semi Hermetic Compressor Semi Hermetic Compressor
Model 380/3/50 460/3/60
PN Description PN Description
1220 1003200043 1220BHL6V5KOEMCB9C-CE 1003200049 1220BHL6V5KOEMBJ9C-UL
Semi Hermetic Compressor
Model 400/3/50
PN Description
1220 1003200047 1220BHL6V5KOEMCS9C-CE
1222 1003220028 1222BHL6V5KOEMCS9C-CE
1227 1003270844 1227BHL6V5KOEMCS9C-CE
1230 1003300844 1230BHL6V5KOEMCS9C-CE
2233 1003330024 2233BHL6V5KOEMCS9C-CE
2236 1003360027 2236BHL6V5KOEMCS9C-CE
2246 1003460029 2246BHL6V5KOEMCS9C-CE
Note: Please contact factory for the details of spare part with different voltage as listed above.
- 81 -
7.0 TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
1. Unit will not start. a.) Power off. a.) Check main disconnect switch and main line fuses.
b.) No control power. b.) Check control transformer fusing.
c.) Compressor circuit breakers c.) Close circuit breakers. If trip, check compressor.
open. d.) Check for power supply problems (low voltage, phase
d.) Undervoltage relay open. imbalance). When corrected, press reset button.
e.) Flow Switch open. e.) Start pumps, check flow switch.
f.) Compressor switch open. f.) Turn switch on. Check alarm status. Correct problem.
g.) Controller shutdown not reset. g.) Press reset button.
h.) Pressure switch fault. h.) Check and reset the pressure switch
2. Compressor hums a.) Low voltage. a.) Check at main incoming power supply entrance and at unit.
but does not start. Consult power company if voltage is low and increase wire
size to the unit if voltage is normal at main and low at unit.
b.) No power on one phase of 3 Voltage must be within 10% of motor nameplate rating.
phase unit. b.) Check fuses and wiring.
c.) Faulty starter or contactor. c.) Check the contacts and time delay on starter. Check if the
pressure switch is trpped as it is linked to the starter.
3. Compressor will not a.) Cooling not required. a.) Apply load.
start when reset b.) Controller's time delay active. b.) Wait 15 minutes max.
button is pushed. c.) Undervoltage relay open. c.) See 1 ( d.) above.
Alarm light: off d.) Flow switch open. d.) See 1 ( e.) above.
e.) Compressor switch open. e.) See 1 ( f.) above.
f.) Burned out signal light. f.) Check signal light bulbs.
i.) Wiring problem i.) Check wiring against drawing.
4. Compressor a.) Compressor drawing high a.) Check motor winding insulation. Reset overloads, run
overload. amps. compresssor and check amps. Do not exceed RLA x
1.25. Call D/B service representative.
5. High motor a.) Motor windings failing. a.) Check motor winding insulation. Reset by turning
temperature compressor switch off and then on.
6. Low evaporator a.) Inadequate refrigerant feed to a.) Check to see EEV response. Check liquid level setpoint.
pressure evaporator. b.) See information on charging in Section 6.6.
b.) Inadequate refrigerant charge. c.) At high load, check evaporator approach (See Section
c.) Fouling of water side of 6.5). If approach is more than 2°F [1.1°C] above clean
evaporator. valve, fouling is probably the trouble. Clean tube.
d.) Measure pressure drop across vessel and determine
d.) Inadequate chilled water flow. flowrate from Section 2.7. If flowrate is low, check chilled
water pump, valves and strainers.
e.) If all oil level sight glasses are full at all times, remove oil
e.) Too much oil in system. until oil level shows at top of glass on a compressor.
7. High condenser a.) Fouling of water side of a.) At high load, check condenser approach (See Section
pressure. condenser 6.4). If approach is more than 2°F [1.1°C] above clean
valve, fouling is probably the trouble. Clean tube.
b.) Inadequate condenser water
flow. d.) Measure pressure drop across vessel and determine
flowrate from Section 2.7. If flowrate is low, check
condenser water pump, valves and strainers.
8. Oil low in sump. a.) Low oil level in compressor. a.) Low oil level in compressor sight glass is acceptable.
9. Low oil shutdown. a.) Low oil in compressor. a.) See Section 6.8.
10. Freeze warning. a.) Operating setpoint too low. a.) Check leaving water setpoint on controller.
b.) Load changing too rapidly. b.) Load on package must drop at reasonable rate for
automatic control to work properly.
11. Improper capacity a.) Ramp rate incorrect. a.) See Section 5.5.10.
control.
- 82 -
8.0 APPENDIXES
8.1 MAINTENANCE LOG SHEET

JOB NAME : UNIT NO. : SHEET NO. :
UNIT MODEL : COMP. MODEL :
SERIAL NO. : COMP. FLA / VOLT / HZ :
DATE :
Time
Circuit 1 bar
%FLCP Power Superheat Sys Temperature Sys Pressure
Cooler Pressure
Circuit 2 bar
Circuit 1 bar
Condenser Pressure
Circuit 2 bar
Circuit 1 bar
Liquid Line Pressure
Circuit 2 bar
Suction Temp. Comp'r 1 °C
Suction Temp. Comp'r 2 °C
Discharge Temp. Comp'r 1 °C
Discharge Temp. Comp'r 2 °C
Liquid Line Temp. Circuit 1 °C
Liquid Line Temp. Circuit 2 °C
Suction Superheat Comp'r 1 °C
Suction Superheat Comp'r 2 °C
Discharge Superheat Comp'r 1 °C
Discharge Superheat Comp'r 2 °C
System Voltage V
Amperage Comp'r 1 A
Amperage Comp'r 2 A
Target %
% FLCP Comp'r 1 %
% FLCP Comp'r 2 %
°C
Chilled Water Supply
Cooler
bar
°C
Chilled Water Return
bar
Condenser On Coil °C
Cond
Circuit 1 °C
Condenser Off Coil
Circuit 2 °C
Circuit 1 °C
Cooler Approach
Circuit 2 °C
Approach
Circuit 1 °C
Condenser Approach
Circuit 2 °C
Circuit 1 °C
Liquid Subcooling
Circuit 2 °C
Circuit 1 %
EEV Opening
Circuit 2 %
Circuit 1 V
EEV Output Voltage
Circuit 2 V
Circuit 1 mm
Refrigerant Level
Circuit 2 mm
Others
Oil Level Comp'r 1 *

Oil Level Comp'r 2 *
Circuit 1 *
Liquid Level (BT/AT)
Circuit 2 *
Noise Level (N-Normal, AN-Abnormal) *
Circuit 1 Hz
VFD
Circuit 2 Hz
REMARKS:
- 83 -
8.0 APPENDIXES
8.2 REFRIGERANT PROPERTY CHART – R134a

R-134a PRESSURE / TEMPERATURE PROPERTIES (PSIG-F)
Pressure Temp. Pressure Temp. Pressure Temp. Pressure Temp. Pressure Temp.
0 -14.7 53 56.9 106 90.9 159 115.0 212 134.1
1 -12.0 54 57.7 107 91.5 160 115.4 213 134.4
2 -9.5 55 58.5 108 92.0 161 115.8 214 134.7
3 -7.1 56 59.3 109 92.5 162 116.2 215 135.1
4 -4.8 57 60.1 110 93.0 163 116.6 216 135.4
5 -2.6 58 60.9 111 93.5 164 117.0 217 135.7
6 -0.5 59 61.6 112 94.0 165 117.4 218 136.0
7 1.5 60 62.4 113 94.5 166 117.7 219 136.4
8 3.5 61 63.1 114 95.0 167 118.1 220 136.7
9 5.3 62 63.9 115 95.5 168 118.5 221 137.0
10 7.2 63 64.6 116 96.0 169 118.9 222 137.3
11 8.9 64 65.3 117 96.5 170 119.3 223 137.6
12 10.6 65 66.0 118 97.0 171 119.7 224 138.0
13 12.3 66 66.8 119 97.5 172 120.0 225 138.3
14 13.9 67 67.5 120 98.0 173 120.4 226 138.6
15 15.5 68 68.2 121 98.4 174 120.8 227 138.9
16 17.0 69 68.9 122 98.9 175 121.2 228 139.2
17 18.5 70 69.5 123 99.4 176 121.5 229 139.5
18 20.0 71 70.2 124 99.9 177 121.9 230 139.8
19 21.4 72 70.9 125 100.3 178 122.3 231 140.1
20 22.8 73 71.6 126 100.8 179 122.6 232 140.4
21 24.1 74 72.2 127 101.3 180 123.0 233 140.8
22 25.4 75 72.9 128 101.7 181 123.4 234 141.1
23 26.7 76 73.5 129 102.2 182 123.7 235 141.4
24 28.0 77 74.2 130 102.7 183 124.1 236 141.7
25 29.2 78 74.8 131 103.1 184 124.5 237 142.0
26 30.5 79 75.5 132 103.6 185 124.8 238 142.3
27 31.7 80 76.1 133 104.0 186 125.2 239 142.6
28 32.8 81 76.7 134 104.5 187 125.5 240 142.9
29 34.0 82 77.3 135 104.9 188 125.9 241 143.2
30 35.1 83 78.0 136 105.3 189 126.3 242 143.5
31 36.2 84 78.6 137 105.8 190 126.6 243 143.8
32 37.3 85 79.2 138 106.2 191 127.0 244 144.1
33 38.4 86 79.8 139 106.7 192 127.3 245 144.4
34 39.5 87 80.4 140 107.1 193 127.7 246 144.7
35 40.5 88 81.0 141 107.5 194 128.0 247 145.0
36 41.5 89 81.5 142 108.0 195 128.4 248 145.3
37 42.5 90 82.1 143 108.4 196 128.7 249 145.6
38 43.5 91 82.7 144 108.8 197 129.1 250 145.9
39 44.5 92 83.3 145 109.2 198 129.4 251 146.2
40 45.5 93 83.9 146 109.7 199 129.7 252 146.4
41 46.4 94 84.4 147 110.1 200 130.1 253 146.7
42 47.4 95 85.0 148 110.5 201 130.4 254 147.0
43 48.3 96 85.6 149 110.9 202 130.8 255 147.3
44 49.2 97 86.1 150 111.3 203 131.1 256 147.6
45 50.1 98 86.7 151 111.8 204 131.4 257 147.9
46 51.0 99 87.2 152 112.2 205 131.8 258 148.2
47 51.9 100 87.8 153 112.6 206 132.1 259 148.5
48 52.7 101 88.3 154 113.0 207 132.4 260 148.7
49 53.6 102 88.8 155 113.4 208 132.8 261 149.0
50 54.4 103 89.4 156 113.8 209 133.1 262 149.3
51 55.3 104 89.9 157 114.2 210 133.4 263 149.6
52 56.1 105 90.4 158 114.6 211 133.8 264 149.9
- 84 -
8.0 APPENDIXES
8.3 SIGNALS FOR PRESSURE TRANSDUCER

a.) Pressure Transducer (Range: 0 - 200PSIG)
Feedback: 0.5 - 4.5Vdc or 4 – 20mA
PRESSURE Signal PRESSURE Signal PRESSURE Signal PRESSURE Signal
PSIG BAR Vdc mA PSIG BAR Vdc mA PSIG BAR Vdc mA PSIG BAR Vdc mA
0 0.00 0.50 4.00 50 3.45 1.50 8.00 100 6.90 2.50 12.00 150 10.34 3.50 16.00
1 0.07 0.52 4.08 51 3.52 1.52 8.08 101 6.97 2.52 12.08 151 10.41 3.52 16.08
2 0.14 0.54 4.16 52 3.59 1.54 8.16 102 7.03 2.54 12.16 152 10.48 3.54 16.16
3 0.21 0.56 4.24 53 3.66 1.56 8.24 103 7.10 2.56 12.24 153 10.55 3.56 16.24
4 0.28 0.58 4.32 54 3.72 1.58 8.32 104 7.17 2.58 12.32 154 10.62 3.58 16.32
5 0.34 0.60 4.40 55 3.79 1.60 8.40 105 7.24 2.60 12.40 155 10.69 3.60 16.40
6 0.41 0.62 4.48 56 3.86 1.62 8.48 106 7.31 2.62 12.48 156 10.76 3.62 16.48
7 0.48 0.64 4.56 57 3.93 1.64 8.56 107 7.38 2.64 12.56 157 10.83 3.64 16.56
8 0.55 0.66 4.64 58 4.00 1.66 8.64 108 7.45 2.66 12.64 158 10.90 3.66 16.64
9 0.62 0.68 4.72 59 4.07 1.68 8.72 109 7.52 2.68 12.72 159 10.97 3.68 16.72
10 0.69 0.70 4.80 60 4.14 1.70 8.80 110 7.59 2.70 12.80 160 11.03 3.70 16.80
11 0.76 0.72 4.88 61 4.21 1.72 8.88 111 7.66 2.72 12.88 161 11.10 3.72 16.88
12 0.83 0.74 4.96 62 4.28 1.74 8.96 112 7.72 2.74 12.96 162 11.17 3.74 16.96
13 0.90 0.76 5.04 63 4.34 1.76 9.04 113 7.79 2.76 13.04 163 11.24 3.76 17.04
14 0.97 0.78 5.12 64 4.41 1.78 9.12 114 7.86 2.78 13.12 164 11.31 3.78 17.12
15 1.03 0.80 5.20 65 4.48 1.80 9.20 115 7.93 2.80 13.20 165 11.38 3.80 17.20
16 1.10 0.82 5.28 66 4.55 1.82 9.28 116 8.00 2.82 13.28 166 11.45 3.82 17.28
17 1.17 0.84 5.36 67 4.62 1.84 9.36 117 8.07 2.84 13.36 167 11.52 3.84 17.36
18 1.24 0.86 5.44 68 4.69 1.86 9.44 118 8.14 2.86 13.44 168 11.59 3.86 17.44
19 1.31 0.88 5.52 69 4.76 1.88 9.52 119 8.21 2.88 13.52 169 11.66 3.88 17.52
20 1.38 0.90 5.60 70 4.83 1.90 9.60 120 8.28 2.90 13.60 170 11.72 3.90 17.60
21 1.45 0.92 5.68 71 4.90 1.92 9.68 121 8.34 2.92 13.68 171 11.79 3.92 17.68
22 1.52 0.94 5.76 72 4.97 1.94 9.76 122 8.41 2.94 13.76 172 11.86 3.94 17.76
23 1.59 0.96 5.84 73 5.03 1.96 9.84 123 8.48 2.96 13.84 173 11.93 3.96 17.84
24 1.66 0.98 5.92 74 5.10 1.98 9.92 124 8.55 2.98 13.92 174 12.00 3.98 17.92
25 1.72 1.00 6.00 75 5.17 2.00 10.00 125 8.62 3.00 14.00 175 12.07 4.00 18.00
26 1.79 1.02 6.08 76 5.24 2.02 10.08 126 8.69 3.02 14.08 176 12.14 4.02 18.08
27 1.86 1.04 6.16 77 5.31 2.04 10.16 127 8.76 3.04 14.16 177 12.21 4.04 18.16
28 1.93 1.06 6.24 78 5.38 2.06 10.24 128 8.83 3.06 14.24 178 12.28 4.06 18.24
29 2.00 1.08 6.32 79 5.45 2.08 10.32 129 8.90 3.08 14.32 179 12.34 4.08 18.32
30 2.07 1.10 6.40 80 5.52 2.10 10.40 130 8.97 3.10 14.40 180 12.41 4.10 18.40
31 2.14 1.12 6.48 81 5.59 2.12 10.48 131 9.03 3.12 14.48 181 12.48 4.12 18.48
32 2.21 1.14 6.56 82 5.66 2.14 10.56 132 9.10 3.14 14.56 182 12.55 4.14 18.56
33 2.28 1.16 6.64 83 5.72 2.16 10.64 133 9.17 3.16 14.64 183 12.62 4.16 18.64
34 2.34 1.18 6.72 84 5.79 2.18 10.72 134 9.24 3.18 14.72 184 12.69 4.18 18.72
35 2.41 1.20 6.80 85 5.86 2.20 10.80 135 9.31 3.20 14.80 185 12.76 4.20 18.80
36 2.48 1.22 6.88 86 5.93 2.22 10.88 136 9.38 3.22 14.88 186 12.83 4.22 18.88
37 2.55 1.24 6.96 87 6.00 2.24 10.96 137 9.45 3.24 14.96 187 12.90 4.24 18.96
38 2.62 1.26 7.04 88 6.07 2.26 11.04 138 9.52 3.26 15.04 188 12.97 4.26 19.04
39 2.69 1.28 7.12 89 6.14 2.28 11.12 139 9.59 3.28 15.12 189 13.03 4.28 19.12
40 2.76 1.30 7.20 90 6.21 2.30 11.20 140 9.66 3.30 15.20 190 13.10 4.30 19.20
41 2.83 1.32 7.28 91 6.28 2.32 11.28 141 9.72 3.32 15.28 191 13.17 4.32 19.28
42 2.90 1.34 7.36 92 6.34 2.34 11.36 142 9.79 3.34 15.36 192 13.24 4.34 19.36
43 2.97 1.36 7.44 93 6.41 2.36 11.44 143 9.86 3.36 15.44 193 13.31 4.36 19.44
44 3.03 1.38 7.52 94 6.48 2.38 11.52 144 9.93 3.38 15.52 194 13.38 4.38 19.52
45 3.10 1.40 7.60 95 6.55 2.40 11.60 145 10.00 3.40 15.60 195 13.45 4.40 19.60
46 3.17 1.42 7.68 96 6.62 2.42 11.68 146 10.07 3.42 15.68 196 13.52 4.42 19.68
47 3.24 1.44 7.76 97 6.69 2.44 11.76 147 10.14 3.44 15.76 197 13.59 4.44 19.76
48 3.31 1.46 7.84 98 6.76 2.46 11.84 148 10.21 3.46 15.84 198 13.66 4.46 19.84
49 3.38 1.48 7.92 99 6.83 2.48 11.92 149 10.28 3.48 15.92 199 13.72 4.48 19.92
- 85 -
8.0 APPENDIXES
b.) Pressure Transducer (Range: 0 - 500PSIG)

Feedback: 0.5 - 4.5Vdc or 4 - 20mA
Pressure Signal Pressure Signal Pressure Signal Pressure
PSIG BAR Vdc mA PSIG BAR Vdc mA PSIG BAR Vdc mA PSIG BAR
0 0.00 0.50 4.00 100 6.90 1.30 7.20 200 13.79 2.10 10.40 300 20.69
2 0.14 0.52 4.06 102 7.03 1.32 7.26 202 13.93 2.12 10.46 302 20.83
4 0.28 0.53 4.13 104 7.17 1.33 7.33 204 14.07 2.13 10.53 304 20.97
6 0.41 0.55 4.19 106 7.31 1.35 7.39 206 14.21 2.15 10.59 306 21.10
8 0.55 0.56 4.26 108 7.45 1.36 7.46 208 14.34 2.16 10.66 308 21.24
10 0.69 0.58 4.32 110 7.59 1.38 7.52 210 14.48 2.18 10.72 310 21.38
12 0.83 0.60 4.38 112 7.72 1.40 7.58 212 14.62 2.20 10.78 312 21.52
14 0.97 0.61 4.45 114 7.86 1.41 7.65 214 14.76 2.21 10.85 314 21.66
16 1.10 0.63 4.51 116 8.00 1.43 7.71 216 14.90 2.23 10.91 316 21.79
18 1.24 0.64 4.58 118 8.14 1.44 7.78 218 15.03 2.24 10.98 318 21.93
20 1.38 0.66 4.64 120 8.28 1.46 7.84 220 15.17 2.26 11.04 320 22.07
22 1.52 0.68 4.70 122 8.41 1.48 7.90 222 15.31 2.28 11.10 322 22.21
24 1.66 0.69 4.77 124 8.55 1.49 7.97 224 15.45 2.29 11.17 324 22.34
26 1.79 0.71 4.83 126 8.69 1.51 8.03 226 15.59 2.31 11.23 326 22.48
28 1.93 0.72 4.90 128 8.83 1.52 8.10 228 15.72 2.32 11.30 328 22.62
30 2.07 0.74 4.96 130 8.97 1.54 8.16 230 15.86 2.34 11.36 330 22.76
32 2.21 0.76 5.02 132 9.10 1.56 8.22 232 16.00 2.36 11.42 332 22.90
34 2.34 0.77 5.09 134 9.24 1.57 8.29 234 16.14 2.37 11.49 334 23.03
36 2.48 0.79 5.15 136 9.38 1.59 8.35 236 16.28 2.39 11.55 336 23.17
38 2.62 0.80 5.22 138 9.52 1.60 8.42 238 16.41 2.40 11.62 338 23.31
40 2.76 0.82 5.28 140 9.66 1.62 8.48 240 16.55 2.42 11.68 340 23.45
42 2.90 0.84 5.34 142 9.79 1.64 8.54 242 16.69 2.44 11.74 342 23.59
44 3.03 0.85 5.41 144 9.93 1.65 8.61 244 16.83 2.45 11.81 344 23.72
46 3.17 0.87 5.47 146 10.07 1.67 8.67 246 16.97 2.47 11.87 346 23.86
48 3.31 0.88 5.54 148 10.21 1.68 8.74 248 17.10 2.48 11.94 348 24.00
50 3.45 0.90 5.60 150 10.34 1.70 8.80 250 17.24 2.50 12.00 350 24.14
52 3.59 0.92 5.66 152 10.48 1.72 8.86 252 17.38 2.52 12.06 352 24.28
54 3.72 0.93 5.73 154 10.62 1.73 8.93 254 17.52 2.53 12.13 354 24.41
56 3.86 0.95 5.79 156 10.76 1.75 8.99 256 17.66 2.55 12.19 356 24.55
58 4.00 0.96 5.86 158 10.90 1.76 9.06 258 17.79 2.56 12.26 358 24.69
60 4.14 0.98 5.92 160 11.03 1.78 9.12 260 17.93 2.58 12.32 360 24.83
62 4.28 1.00 5.98 162 11.17 1.80 9.18 262 18.07 2.60 12.38 362 24.97
64 4.41 1.01 6.05 164 11.31 1.81 9.25 264 18.21 2.61 12.45 364 25.10
66 4.55 1.03 6.11 166 11.45 1.83 9.31 266 18.34 2.63 12.51 366 25.24
68 4.69 1.04 6.18 168 11.59 1.84 9.38 268 18.48 2.64 12.58 368 25.38
70 4.83 1.06 6.24 170 11.72 1.86 9.44 270 18.62 2.66 12.64 370 25.52
72 4.97 1.08 6.30 172 11.86 1.88 9.50 272 18.76 2.68 12.70 372 25.66
74 5.10 1.09 6.37 174 12.00 1.89 9.57 274 18.90 2.69 12.77 374 25.79
76 5.24 1.11 6.43 176 12.14 1.91 9.63 276 19.03 2.71 12.83 376 25.93
78 5.38 1.12 6.50 178 12.28 1.92 9.70 278 19.17 2.72 12.90 378 26.07
80 5.52 1.14 6.56 180 12.41 1.94 9.76 280 19.31 2.74 12.96 380 26.21
82 5.66 1.16 6.62 182 12.55 1.96 9.82 282 19.45 2.76 13.02 382 26.34
84 5.79 1.17 6.69 184 12.69 1.97 9.89 284 19.59 2.77 13.09 384 26.48
86 5.93 1.19 6.75 186 12.83 1.99 9.95 286 19.72 2.79 13.15 386 26.62
88 6.07 1.20 6.82 188 12.97 2.00 10.02 288 19.86 2.80 13.22 388 26.76
90 6.21 1.22 6.88 190 13.10 2.02 10.08 290 20.00 2.82 13.28 390 26.90
92 6.34 1.24 6.94 192 13.24 2.04 10.14 292 20.14 2.84 13.34 392 27.03
94 6.48 1.25 7.01 194 13.38 2.05 10.21 294 20.28 2.85 13.41 394 27.17
96 6.62 1.27 7.07 196 13.52 2.07 10.27 296 20.41 2.87 13.47 396 27.31
98 6.76 1.28 7.14 198 13.66 2.08 10.34 298 20.55 2.88 13.54 398 27.45
- 86 -
8.0 APPENDIXES
b.) Pressure Transducer (Range: 0 - 500PSIG)

Feedback: 0.5 - 4.5Vdc or 4 - 20mA
Pressure Signal Pressure Signal
PSIG BAR Vdc mA PSIG BAR Vdc mA
300 20.69 2.90 13.60 400 27.59 3.70 16.80

302 20.83 2.92 13.66 402 27.72 3.72 16.86
304 20.97 2.93 13.73 404 27.86 3.73 16.93
306 21.10 2.95 13.79 406 28.00 3.75 16.99
308 21.24 2.96 13.86 408 28.14 3.76 17.06
310 21.38 2.98 13.92 410 28.28 3.78 17.12
312 21.52 3.00 13.98 412 28.41 3.80 17.18
314 21.66 3.01 14.05 414 28.55 3.81 17.25
316 21.79 3.03 14.11 416 28.69 3.83 17.31
318 21.93 3.04 14.18 418 28.83 3.84 17.38
320 22.07 3.06 14.24 420 28.97 3.86 17.44
322 22.21 3.08 14.30 422 29.10 3.88 17.50
324 22.34 3.09 14.37 424 29.24 3.89 17.57
326 22.48 3.11 14.43 426 29.38 3.91 17.63
328 22.62 3.12 14.50 428 29.52 3.92 17.70
330 22.76 3.14 14.56 430 29.66 3.94 17.76
332 22.90 3.16 14.62 432 29.79 3.96 17.82
334 23.03 3.17 14.69 434 29.93 3.97 17.89
336 23.17 3.19 14.75 436 30.07 3.99 17.95
338 23.31 3.20 14.82 438 30.21 4.00 18.02
340 23.45 3.22 14.88 440 30.34 4.02 18.08
342 23.59 3.24 14.94 442 30.48 4.04 18.14
344 23.72 3.25 15.01 444 30.62 4.05 18.21
346 23.86 3.27 15.07 446 30.76 4.07 18.27
348 24.00 3.28 15.14 448 30.90 4.08 18.34
350 24.14 3.30 15.20 450 31.03 4.10 18.40
352 24.28 3.32 15.26 452 31.17 4.12 18.46
354 24.41 3.33 15.33 454 31.31 4.13 18.53
356 24.55 3.35 15.39 456 31.45 4.15 18.59
358 24.69 3.36 15.46 458 31.59 4.16 18.66
360 24.83 3.38 15.52 460 31.72 4.18 18.72
362 24.97 3.40 15.58 462 31.86 4.20 18.78
364 25.10 3.41 15.65 464 32.00 4.21 18.85
366 25.24 3.43 15.71 466 32.14 4.23 18.91
368 25.38 3.44 15.78 468 32.28 4.24 18.98
370 25.52 3.46 15.84 470 32.41 4.26 19.04
372 25.66 3.48 15.90 472 32.55 4.28 19.10
374 25.79 3.49 15.97 474 32.69 4.29 19.17
376 25.93 3.51 16.03 476 32.83 4.31 19.23
378 26.07 3.52 16.10 478 32.97 4.32 19.30
380 26.21 3.54 16.16 480 33.10 4.34 19.36
382 26.34 3.56 16.22 482 33.24 4.36 19.42
384 26.48 3.57 16.29 484 33.38 4.37 19.49
386 26.62 3.59 16.35 486 33.52 4.39 19.55
388 26.76 3.60 16.42 488 33.66 4.40 19.62
390 26.90 3.62 16.48 490 33.79 4.42 19.68
392 27.03 3.64 16.54 492 33.93 4.44 19.74
394 27.17 3.65 16.61 494 34.07 4.45 19.81
396 27.31 3.67 16.67 496 34.21 4.47 19.87
398 27.45 3.68 16.74 498 34.34 4.48 19.94
- 87 -
8.0 APPENDIXES
8.4 SIGNALS FOR CURRENT TRANSDUCER

a.) Current Transducer
CT Ratio: 0 - 250A/ 0-5A Range: 0 - 250A Feedback: 0 - 20mA
Measured Signal Measured Signal Measured Signal Measured Signal Measured Signal
Current (A) (mA) Current (A) (mA) Current (A) (mA) Current (A) (mA) Current (A) (mA)
0 0.00 50 4.00 100 8.00 150 12.00 200 16.00

1 0.08 51 4.08 101 8.08 151 12.08 201 16.08
2 0.16 52 4.16 102 8.16 152 12.16 202 16.16
3 0.24 53 4.24 103 8.24 153 12.24 203 16.24
4 0.32 54 4.32 104 8.32 154 12.32 204 16.32
5 0.40 55 4.40 105 8.40 155 12.40 205 16.40
6 0.48 56 4.48 106 8.48 156 12.48 206 16.48
7 0.56 57 4.56 107 8.56 157 12.56 207 16.56
8 0.64 58 4.64 108 8.64 158 12.64 208 16.64
9 0.72 59 4.72 109 8.72 159 12.72 209 16.72
10 0.80 60 4.80 110 8.80 160 12.80 210 16.80
11 0.88 61 4.88 111 8.88 161 12.88 211 16.88
12 0.96 62 4.96 112 8.96 162 12.96 212 16.96
13 1.04 63 5.04 113 9.04 163 13.04 213 17.04
14 1.12 64 5.12 114 9.12 164 13.12 214 17.12
15 1.20 65 5.20 115 9.20 165 13.20 215 17.20
16 1.28 66 5.28 116 9.28 166 13.28 216 17.28
17 1.36 67 5.36 117 9.36 167 13.36 217 17.36
18 1.44 68 5.44 118 9.44 168 13.44 218 17.44
19 1.52 69 5.52 119 9.52 169 13.52 219 17.52
20 1.60 70 5.60 120 9.60 170 13.60 220 17.60
21 1.68 71 5.68 121 9.68 171 13.68 221 17.68
22 1.76 72 5.76 122 9.76 172 13.76 222 17.76
23 1.84 73 5.84 123 9.84 173 13.84 223 17.84
24 1.92 74 5.92 124 9.92 174 13.92 224 17.92
25 2.00 75 6.00 125 10.00 175 14.00 225 18.00
26 2.08 76 6.08 126 10.08 176 14.08 226 18.08
27 2.16 77 6.16 127 10.16 177 14.16 227 18.16
28 2.24 78 6.24 128 10.24 178 14.24 228 18.24
29 2.32 79 6.32 129 10.32 179 14.32 229 18.32
30 2.40 80 6.40 130 10.40 180 14.40 230 18.40
31 2.48 81 6.48 131 10.48 181 14.48 231 18.48
32 2.56 82 6.56 132 10.56 182 14.56 232 18.56
33 2.64 83 6.64 133 10.64 183 14.64 233 18.64
34 2.72 84 6.72 134 10.72 184 14.72 234 18.72
35 2.80 85 6.80 135 10.80 185 14.80 235 18.80
36 2.88 86 6.88 136 10.88 186 14.88 236 18.88
37 2.96 87 6.96 137 10.96 187 14.96 237 18.96
38 3.04 88 7.04 138 11.04 188 15.04 238 19.04
39 3.12 89 7.12 139 11.12 189 15.12 239 19.12
40 3.20 90 7.20 140 11.20 190 15.20 240 19.20
41 3.28 91 7.28 141 11.28 191 15.28 241 19.28
42 3.36 92 7.36 142 11.36 192 15.36 242 19.36
43 3.44 93 7.44 143 11.44 193 15.44 243 19.44
44 3.52 94 7.52 144 11.52 194 15.52 244 19.52
45 3.60 95 7.60 145 11.60 195 15.60 245 19.60
46 3.68 96 7.68 146 11.68 196 15.68 246 19.68
47 3.76 97 7.76 147 11.76 197 15.76 247 19.76
48 3.84 98 7.84 148 11.84 198 15.84 248 19.84
49 3.92 99 7.92 149 11.92 199 15.92 249 19.92
- 88 -
8.0 APPENDIXES
b.) Current Transducer

CT Ratio: 0 - 500A/ 0 - 5A Range: 0 - 500A Feedback: 0 - 20mA
Measured Signal Measured Signal Measured Signal Measured Signal Measured Signal
Current (A) (mA) Current (A) (mA) Current (A) (mA) Current (A) (mA) Current (A) (mA)
0 0.00 100 4.00 200 8.00 300 12.00 400 16.00

2 0.08 102 4.08 202 8.08 302 12.08 402 16.08
4 0.16 104 4.16 204 8.16 304 12.16 404 16.16
6 0.24 106 4.24 206 8.24 306 12.24 406 16.24
8 0.32 108 4.32 208 8.32 308 12.32 408 16.32
10 0.40 110 4.40 210 8.40 310 12.40 410 16.40
12 0.48 112 4.48 212 8.48 312 12.48 412 16.48
14 0.56 114 4.56 214 8.56 314 12.56 414 16.56
16 0.64 116 4.64 216 8.64 316 12.64 416 16.64
18 0.72 118 4.72 218 8.72 318 12.72 418 16.72
20 0.80 120 4.80 220 8.80 320 12.80 420 16.80
22 0.88 122 4.88 222 8.88 322 12.88 422 16.88
24 0.96 124 4.96 224 8.96 324 12.96 424 16.96
26 1.04 126 5.04 226 9.04 326 13.04 426 17.04
28 1.12 128 5.12 228 9.12 328 13.12 428 17.12
30 1.20 130 5.20 230 9.20 330 13.20 430 17.20
32 1.28 132 5.28 232 9.28 332 13.28 432 17.28
34 1.36 134 5.36 234 9.36 334 13.36 434 17.36
36 1.44 136 5.44 236 9.44 336 13.44 436 17.44
38 1.52 138 5.52 238 9.52 338 13.52 438 17.52
40 1.60 140 5.60 240 9.60 340 13.60 440 17.60
42 1.68 142 5.68 242 9.68 342 13.68 442 17.68
44 1.76 144 5.76 244 9.76 344 13.76 444 17.76
46 1.84 146 5.84 246 9.84 346 13.84 446 17.84
48 1.92 148 5.92 248 9.92 348 13.92 448 17.92
50 2.00 150 6.00 250 10.00 350 14.00 450 18.00
52 2.08 152 6.08 252 10.08 352 14.08 452 18.08
54 2.16 154 6.16 254 10.16 354 14.16 454 18.16
56 2.24 156 6.24 256 10.24 356 14.24 456 18.24
58 2.32 158 6.32 258 10.32 358 14.32 458 18.32
60 2.40 160 6.40 260 10.40 360 14.40 460 18.40
62 2.48 162 6.48 262 10.48 362 14.48 462 18.48
64 2.56 164 6.56 264 10.56 364 14.56 464 18.56
66 2.64 166 6.64 266 10.64 366 14.64 466 18.64
68 2.72 168 6.72 268 10.72 368 14.72 468 18.72
70 2.80 170 6.80 270 10.80 370 14.80 470 18.80
72 2.88 172 6.88 272 10.88 372 14.88 472 18.88
74 2.96 174 6.96 274 10.96 374 14.96 474 18.96
76 3.04 176 7.04 276 11.04 376 15.04 476 19.04
78 3.12 178 7.12 278 11.12 378 15.12 478 19.12
80 3.20 180 7.20 280 11.20 380 15.20 480 19.20
82 3.28 182 7.28 282 11.28 382 15.28 482 19.28
84 3.36 184 7.36 284 11.36 384 15.36 484 19.36
86 3.44 186 7.44 286 11.44 386 15.44 486 19.44
88 3.52 188 7.52 288 11.52 388 15.52 488 19.52
90 3.60 190 7.60 290 11.60 390 15.60 490 19.60
92 3.68 192 7.68 292 11.68 392 15.68 492 19.68
94 3.76 194 7.76 294 11.76 394 15.76 494 19.76
96 3.84 196 7.84 296 11.84 396 15.84 496 19.84
98 3.92 198 7.92 298 11.92 398 15.92 498 19.92
- 89 -
8.0 APPENDIXES
8.5 SIGNALS FOR VOLTAGE TRANSDUCER

Voltage Transducer
Range: 0 - 500Vac Feedback: 0 - 5Vdc
Measured Signal Measured Signal MEasured Signal Measured Signal Measured Signal
Voltage (V) (Vdc) Voltage (V) (Vdc) Voltage (V) (Vdc) Voltage (V) (Vdc) Voltage (V) (Vdc)
0 0.00 100 1.00 200 2.00 300 3.00 400 4.00

2 0.02 102 1.02 202 2.02 302 3.02 402 4.02
4 0.04 104 1.04 204 2.04 304 3.04 404 4.04
6 0.06 106 1.06 206 2.06 306 3.06 406 4.06
8 0.08 108 1.08 208 2.08 308 3.08 408 4.08
10 0.10 110 1.10 210 2.10 310 3.10 410 4.10
12 0.12 112 1.12 212 2.12 312 3.12 412 4.12
14 0.14 114 1.14 214 2.14 314 3.14 414 4.14
16 0.16 116 1.16 216 2.16 316 3.16 416 4.16
18 0.18 118 1.18 218 2.18 318 3.18 418 4.18
20 0.20 120 1.20 220 2.20 320 3.20 420 4.20
22 0.22 122 1.22 222 2.22 322 3.22 422 4.22
24 0.24 124 1.24 224 2.24 324 3.24 424 4.24
26 0.26 126 1.26 226 2.26 326 3.26 426 4.26
28 0.28 128 1.28 228 2.28 328 3.28 428 4.28
30 0.30 130 1.30 230 2.30 330 3.30 430 4.30
32 0.32 132 1.32 232 2.32 332 3.32 432 4.32
34 0.34 134 1.34 234 2.34 334 3.34 434 4.34
36 0.36 136 1.36 236 2.36 336 3.36 436 4.36
38 0.38 138 1.38 238 2.38 338 3.38 438 4.38
40 0.40 140 1.40 240 2.40 340 3.40 440 4.40
42 0.42 142 1.42 242 2.42 342 3.42 442 4.42
44 0.44 144 1.44 244 2.44 344 3.44 444 4.44
46 0.46 146 1.46 246 2.46 346 3.46 446 4.46
48 0.48 148 1.48 248 2.48 348 3.48 448 4.48
50 0.50 150 1.50 250 2.50 350 3.50 450 4.50
52 0.52 152 1.52 252 2.52 352 3.52 452 4.52
54 0.54 154 1.54 254 2.54 354 3.54 454 4.54
56 0.56 156 1.56 256 2.56 356 3.56 456 4.56
58 0.58 158 1.58 258 2.58 358 3.58 458 4.58
60 0.60 160 1.60 260 2.60 360 3.60 460 4.60
62 0.62 162 1.62 262 2.62 362 3.62 462 4.62
64 0.64 164 1.64 264 2.64 364 3.64 464 4.64
66 0.66 166 1.66 266 2.66 366 3.66 466 4.66
68 0.68 168 1.68 268 2.68 368 3.68 468 4.68
70 0.70 170 1.70 270 2.70 370 3.70 470 4.70
72 0.72 172 1.72 272 2.72 372 3.72 472 4.72
74 0.74 174 1.74 274 2.74 374 3.74 474 4.74
76 0.76 176 1.76 276 2.76 376 3.76 476 4.76
78 0.78 178 1.78 278 2.78 378 3.78 478 4.78
80 0.80 180 1.80 280 2.80 380 3.80 480 4.80
82 0.82 182 1.82 282 2.82 382 3.82 482 4.82
84 0.84 184 1.84 284 2.84 384 3.84 484 4.84
86 0.86 186 1.86 286 2.86 386 3.86 486 4.86
88 0.88 188 1.88 288 2.88 388 3.88 488 4.88
90 0.90 190 1.90 290 2.90 390 3.90 490 4.90
92 0.92 192 1.92 292 2.92 392 3.92 492 4.92
94 0.94 194 1.94 294 2.94 394 3.94 494 4.94
96 0.96 196 1.96 296 2.96 396 3.96 496 4.96
98 0.98 198 1.98 298 2.98 398 3.98 498 4.98
- 90 -
8.0 APPENDIXES
8.6 SIGNALS FOR NTC TEMPERATURE SENSORS

a.) WH, WF & HP Type
Range: -50 to 105oC
(-58 to 221oF)
Temperature Resistance Value (kΩ) Temperature Resistance Value (kΩ) Temperature Resistance Value (kΩ)
o o o o o o
C F Max. Typical Min. C F Max. Typical Min. C F Max. Typical Min.
-50 -58.0 344.60 329.50 314.90 1 33.8 26.65 26.13 25.62 56 132.8 3.50 3.43 3.35
-49 -56.2 325.00 310.90 297.30 2 35.6 25.52 25.03 24.55 57 134.6 3.39 3.32 3.25
-48 -54.4 306.60 293.50 280.90 3 37.4 24.44 23.99 23.54 58 136.4 3.28 3.22 3.15
-47 -52.6 289.40 277.20 265.40 4 39.2 23.42 23.00 22.57 59 138.2 3.18 3.12 3.05
-46 -50.8 273.40 262.00 251.00 5 41.0 22.45 22.05 21.66 60 140.0 3.09 3.02 2.95
-45 -49.0 258.30 247.70 237.40 6 42.8 21.53 21.15 20.78 61 141.8 2.99 2.93 2.86
-44 -47.2 244.20 234.30 224.70 7 44.6 20.64 20.30 19.95 62 143.6 2.90 2.84 2.77
-43 -45.4 231.00 221.70 212.80 8 46.4 19.81 19.48 19.15 63 145.4 2.82 2.75 2.69
-42 -43.6 218.60 209.90 201.60 9 48.2 19.01 18.70 19.39 64 147.2 2.73 2.67 2.61
-41 -41.8 207.00 198.90 191.00 10 50.0 18.25 17.96 17.67 65 149.0 2.65 2.59 2.53
-40 -40.0 196.00 188.50 181.10 11 51.8 17.51 17.24 16.97 66 150.8 2.57 2.51 2.45
-39 -38.2 185.50 178.50 171.60 12 53.6 16.81 16.56 16.30 67 152.6 2.50 2.44 2.38
-38 -36.4 175.60 169.00 162.60 13 55.4 16.14 15.90 15.67 68 154.4 2.42 2.36 2.31
-37 -34.6 166.30 160.20 154.20 14 57.2 15.50 15.28 15.06 69 156.2 2.35 2.30 2.24
-36 -32.8 157.60 151.90 146.30 15 59.0 14.89 14.69 14.48 70 158.0 2.28 2.23 2.17
-35 -31.0 149.40 144.10 138.80 16 60.8 14.31 14.12 13.92 71 159.8 2.22 2.16 2.11
-34 -29.2 141.70 136.70 131.80 17 62.6 13.75 13.58 13.39 72 161.6 2.15 2.10 2.05
-33 -27.4 134.50 129.80 125.20 18 64.4 13.22 13.06 12.89 73 163.4 2.09 2.04 1.99
-32 -25.6 127.70 123.30 119.00 19 66.2 12.72 12.56 12.40 74 165.2 2.03 1.98 1.93
-31 -23.8 121.20 117.10 113.10 20 68.0 12.24 12.09 11.94 75 167.0 1.98 1.92 1.87
-30 -22.0 115.20 111.30 107.50 21 69.8 11.77 11.63 11.50 76 168.8 1.92 1.87 1.82
-29 -20.2 109.40 105.70 102.20 22 71.6 11.32 11.20 11.07 77 170.6 1.87 1.82 1.77
-28 -18.4 103.90 100.50 97.20 23 73.4 10.90 10.78 10.66 78 172.4 1.81 1.77 1.72
-27 -16.6 98.68 95.52 92.45 24 75.2 10.49 10.38 10.27 79 174.2 1.76 1.72 1.67
-26 -14.8 93.80 90.84 87.97 25 77.0 10.10 10.00 9.90 80 176.0 1.72 1.67 1.62
-25 -13.0 89.20 86.43 83.73 26 78.8 9.73 9.63 9.53 81 177.8 1.67 1.62 1.58
-24 -11.2 84.85 82.26 79.74 27 80.6 9.38 9.28 9.18 82 179.6 1.62 1.58 1.53
-23 -9.4 80.76 78.33 75.96 28 82.4 9.04 8.94 8.84 83 181.4 1.58 1.53 1.49
-22 -7.6 76.89 74.61 72.39 29 84.2 8.72 8.62 8.52 84 183.2 1.54 1.49 1.45
-21 -5.8 73.23 71.10 69.01 30 86.0 8.41 8.31 8.21 85 185.0 1.49 1.45 1.41
-20 -4.0 69.77 67.77 65.82 31 87.8 8.11 8.01 7.92 86 186.8 1.45 1.41 1.37
-19 -2.2 66.44 64.57 62.74 32 89.6 7.83 7.73 7.63 87 188.6 1.42 1.37 1.33
-18 -0.4 63.30 61.54 59.83 33 91.4 7.55 7.45 7.36 88 190.4 1.38 1.34 1.30
-17 1.4 60.32 58.68 57.07 34 93.2 7.29 7.19 7.10 89 192.2 1.34 1.30 1.26
-16 3.2 57.51 55.97 54.46 35 95.0 7.04 6.94 6.85 90 194.0 1.31 1.27 1.23
-15 5.0 54.85 53.41 51.99 36 96.8 6.79 6.70 6.61 91 195.8 1.27 1.23 1.19
-14 6.8 52.33 50.98 49.65 37 98.6 6.56 6.47 6.37 92 197.6 1.24 1.20 1.16
-13 8.6 49.95 48.68 47.43 38 100.4 6.34 6.25 6.15 93 199.4 1.21 1.17 1.13
-12 10.4 47.69 46.50 45.32 39 102.2 6.12 6.03 5.94 94 201.2 1.17 1.14 1.10
-11 12.2 45.55 44.43 43.33 40 104.0 5.92 5.83 5.74 95 203.0 1.14 1.11 1.07
-10 14.0 43.52 42.47 41.43 41 105.8 5.72 5.63 5.54 96 204.8 1.12 1.08 1.04
-9 15.8 41.55 40.57 39.60 42 107.6 5.53 5.44 5.35 97 206.6 1.09 1.05 1.02
-8 17.6 39.69 38.77 37.86 43 109.4 5.34 5.26 5.17 98 208.4 1.06 1.02 0.99
-7 19.4 37.92 37.06 36.21 44 111.2 5.17 5.08 4.99 99 210.2 1.03 1.00 0.97
-6 21.2 36.25 35.44 34.64 45 113.0 5.00 4.91 4.83 100 212.0 1.01 0.97 0.94
-5 23.0 34.66 33.90 33.15 46 114.8 4.83 4.75 4.67 101 213.8 0.98 0.95 0.92
-4 24.8 33.15 32.44 31.73 47 116.6 4.68 4.59 4.51 102 215.6 0.96 0.92 0.89
-3 26.6 31.72 31.05 30.39 48 118.4 4.52 4.44 4.36 103 217.4 0.93 0.90 0.87
-2 28.4 30.36 29.73 29.11 49 120.2 4.38 4.30 4.22 104 219.2 0.91 0.88 0.85
-1 30.2 29.06 28.48 27.89 50 122.0 4.24 4.16 4.08 105 221.0 0.89 0.86 0.83
0 32.0 27.83 27.28 26.74 51 123.8 4.10 4.03 3.95 106 222.8 0.87 0.84 0.81
52 125.6 3.97 3.90 3.82 107 224.6 0.84 0.82 0.79
53 127.4 3.85 3.77 3.70 108 226.4 0.82 0.80 0.77
54 129.2 3.73 3.65 3.58 109 228.2 0.80 0.78 0.75
55 131.0 3.61 3.54 3.46 110 230.0 0.79 0.76 0.73
- 91 -
8.0 APPENDIXES
b.) HT Type
Range: -10 to 150oC
(14 to 302oF)
Temperature Resistance Value (kΩ) Temperature Resistance Value (kΩ) Temperature Resistance Value (kΩ)
o o o o o o
C F Max. Typical Min. C F Max. Typical Min. C F Max. Typical Min.
0 32.0 165239 161638 158036 51 123.8 17760 17401 17042 102 215.6 3293 3176 3058
1 33.8 157036 153694 150352 52 125.6 17109 16757 16405 103 217.4 3199 3084 2969
2 35.6 149288 146187 143086 53 127.4 16485 16140 15795 104 219.2 3108 2995 2883
3 37.4 141965 139088 136211 54 129.2 15887 15549 15211 105 221.0 3019 2909 2799
4 39.2 135043 132375 129706 55 131.0 15314 14982 14651 106 222.8 2934 2826 2719
5 41.0 128498 126023 123548 56 132.8 14764 14439 14114 107 224.6 2851 2746 2641
6 42.8 122307 120012 117717 57 134.6 14236 13918 13600 108 226.4 2771 2668 2565
7 44.6 116449 114321 112194 58 136.4 13730 13418 13107 109 228.2 2694 2593 2492
8 46.4 110904 108932 106961 59 138.2 13244 12939 12634 110 230.0 2619 2520 2422
9 48.2 115654 103827 102001 60 140.0 12778 12479 12181 111 231.8 2547 2450 2354
10 50.0 100682 98990 97298 61 141.8 12330 12038 11746 112 233.6 2477 2382 2288
11 51.8 95971 94405 92838 62 143.6 11901 11615 11329 113 235.4 2409 2316 2224
12 53.6 91507 90057 88608 63 145.4 11488 11208 10928 114 237.2 2343 2252 2162
13 55.4 87276 85934 84593 64 147.2 11092 10818 10544 115 239.0 2279 2191 2102
14 57.2 83263 82022 80782 65 149.0 10711 10443 10175 116 240.8 2218 2131 2044
15 59.0 79456 78310 77163 66 150.8 10345 10083 9821 117 242.6 2158 2073 1988
16 60.8 75845 74786 73727 67 152.6 9993 9737 9481 118 244.4 2100 2017 1934
17 62.6 72417 71440 70462 68 154.4 9655 9405 9154 119 246.2 2044 1962 1881
18 64.4 69163 68261 67359 69 156.2 9330 9085 8840 120 248.0 1989 1910 1830
19 66.2 66073 65241 64410 70 158.0 9018 8778 8538 121 249.8 1937 1859 1781
20 68.0 63137 62372 61606 71 159.8 8717 8483 8248 122 251.6 1886 1809 1733
21 69.8 60348 59643 58939 72 161.6 8428 8199 7969 123 253.4 1836 1761 1687
22 71.6 57697 57049 56401 73 163.4 8150 7926 7701 124 255.2 1788 1715 1642
23 73.4 55177 54582 53987 74 165.2 7882 7663 7443 125 257.0 1742 1670 1598
24 75.2 52780 52234 51688 75 167.0 7625 7410 7195 126 258.8 1697 1626 1556
25 77.0 50500 50000 49500 76 168.8 7377 7167 6957 127 260.6 1653 1584 1515
26 78.8 48373 47873 47373 77 170.6 7138 6933 6726 128 262.4 1610 1643 1476
27 80.6 46348 45848 45349 78 172.4 6908 6707 6506 129 264.2 1569 1503 1437
28 82.4 44417 43920 43422 79 174.2 6686 6490 6294 130 266.0 1529 1465 1400
29 84.2 42577 42082 41587 80 176.0 6473 6281 6089 131 267.8 1490 1427 1364
30 86.0 40823 40332 39840 81 177.8 6267 6080 5892 132 269.6 1453 1391 1329
31 87.8 39151 38663 38174 82 179.6 6069 5886 5702 133 271.4 1416 1355 1295
32 89.6 37556 37072 36588 83 181.4 5878 5699 5520 134 273.2 1381 1321 1262
33 91.4 36034 35554 35075 84 183.2 5694 5519 5343 135 275.0 1346 1288 1230
34 93.2 34581 34107 33633 85 185.0 5517 5345 5174 136 276.8 1313 1256 1199
35 95.0 33195 32726 32258 86 186.8 5346 5178 5010 137 278.6 1280 1224 1168
36 96.8 31871 31408 30945 87 188.6 5181 5017 4853 138 280.4 1249 1194 1139
37 98.6 30607 30150 29694 88 190.4 5022 4861 4701 139 282.2 1218 1164 1111
38 100.4 29400 28949 28499 89 192.2 4868 4711 4554 140 284.0 1189 1136 1083
39 102.2 28246 27802 27358 90 194.0 4720 4566 4413 141 285.8 1160 1108 1056
40 104.0 27143 26706 26269 91 195.8 4577 4427 4277 142 287.6 1132 1081 1030
41 105.8 26090 25659 25229 92 197.6 4439 4292 4145 143 289.4 1104 1055 1005
42 107.6 25082 24659 24235 93 199.4 4306 4162 4019 144 291.2 1078 1029 980
43 109.4 24118 23702 23286 94 201.2 4177 4037 3896 145 293.0 1052 1004 956
44 111.2 23197 22787 22378 95 203.0 4053 3916 3778 146 294.8 1027 980 933
45 113.0 22315 21913 21511 96 204.8 3933 3799 3664 147 296.6 1003 957 911
46 114.8 21471 21076 20681 97 206.6 3817 3686 3554 148 298.4 979 934 889
47 116.6 20663 20275 19888 98 208.4 3705 3577 3448 149 300.2 956 912 868
48 118.4 19890 19509 19129 99 210.2 359 3471 3346 150 302.0 933 890 847
49 120.2 19149 18776 18402 100 212.0 3492 3369 3246
50 122.0 18440 18074 17707 101 213.8 3391 3271 3151
- 92 -
8.0 APPENDIXES
8.7 SIGNALS FOR REFRIGERANT LEVEL SENSORS

LIQUID LEVEL SENSOR
Part Number: 3190200001
Range : 0 - 200mm Feedback : 4 - 20mA
MEASURED Signal MEASURED Signal MEASURED Signal MEASURED Signal MEASURED Signal
LEVEL (MM) (mA) LEVEL (MM) (mA) LEVEL (MM) (mA) LEVEL (MM) (mA) LEVEL (MM) (mA)
0 4.00 40 7.20 80 10.40 120 13.60 160 16.80
1 4.08 41 7.28 81 10.48 121 13.68 161 16.88
2 4.16 42 7.36 82 10.56 122 13.76 162 16.96
3 4.24 43 7.44 83 10.64 123 13.84 163 17.04
4 4.32 44 7.52 84 10.72 124 13.92 164 17.12
5 4.40 45 7.60 85 10.80 125 14.00 165 17.20
6 4.48 46 7.68 86 10.88 126 14.08 166 17.28
7 4.56 47 7.76 87 10.96 127 14.16 167 17.36
8 4.64 48 7.84 88 11.04 128 14.24 168 17.44
9 4.72 49 7.92 89 11.12 129 14.32 169 17.52
10 4.80 50 8.00 90 11.20 130 14.40 170 17.60
11 4.88 51 8.08 91 11.28 131 14.48 171 17.68
12 4.96 52 8.16 92 11.36 132 14.56 172 17.76
13 5.04 53 8.24 93 11.44 133 14.64 173 17.84
14 5.12 54 8.32 94 11.52 134 14.72 174 17.92
15 5.20 55 8.40 95 11.60 135 14.80 175 18.00
16 5.28 56 8.48 96 11.68 136 14.88 176 18.08
17 5.36 57 8.56 97 11.76 137 14.96 177 18.16
18 5.44 58 8.64 98 11.84 138 15.04 178 18.24
19 5.52 59 8.72 99 11.92 139 15.12 179 18.32
20 5.60 60 8.80 100 12.00 140 15.20 180 18.40
21 5.68 61 8.88 101 12.08 141 15.28 181 18.48
22 5.76 62 8.96 102 12.16 142 15.36 182 18.56
23 5.84 63 9.04 103 12.24 143 15.44 183 18.64
24 5.92 64 9.12 104 12.32 144 15.52 184 18.72
25 6.00 65 9.20 105 12.40 145 15.60 185 18.80
26 6.08 66 9.28 106 12.48 146 15.68 186 18.88
27 6.16 67 9.36 107 12.56 147 15.76 187 18.96
28 6.24 68 9.44 108 12.64 148 15.84 188 19.04
29 6.32 69 9.52 109 12.72 149 15.92 189 19.12
30 6.40 70 9.60 110 12.80 150 16.00 190 19.20
31 6.48 71 9.68 111 12.88 151 16.08 191 19.28
32 6.56 72 9.76 112 12.96 152 16.16 192 19.36
33 6.64 73 9.84 113 13.04 153 16.24 193 19.44
34 6.72 74 9.92 114 13.12 154 16.32 194 19.52
35 6.80 75 10.00 115 13.20 155 16.40 195 19.60
36 6.88 76 10.08 116 13.28 156 16.48 196 19.68
37 6.96 77 10.16 117 13.36 157 16.56 197 19.76
38 7.04 78 10.24 118 13.44 158 16.64 198 19.84
39 7.12 79 10.32 119 13.52 159 16.72 199 19.92
- 93 -
8.0 APPENDIXES
8.8 PRE-TESTING AND

COMMISSIONING
CHECK LIST
- 94 -
Dunham‐Bush Industries Sdn Bhd (166302‐K)
Lot 5755‐6, Kidamai Industrial Park
Bukit Angkat, 43000 Kajang
Selangor Darul Ehsan, Malaysia
T: +603 89249000
W: www.dunham‐bush.com
COMMISSIONING REQUEST AND PRE-START-UP CHECK LIST
Request for start-up and commissioning of Dunham-Bush Air and Water Cooled Chillers
Job Name : Unit Model

Address & Location : Unit Serial
Number of Units
Kindly complete, officially stamp, sign and return this form to Dunham-Bush (DB) should you require DB to dispatch
technicians or supervision to jobsite. Failure to complete and check all the below items may result in additional
charges to your company. Additional charges will result if the start-up and commissioning exercise is delayed, or
additional days are required due to site delays/problems, or if there is in-complete preparations on your scope of
work.
A. Dunham-Bush Unit
1. Essential electrical power to the Chiller is available
Measured Voltage: L1-L2: L1-L3: L2-L3:
1. Erected on foundation
2. Spring isolators or Neoprene Rubber pads installed and adjusted to level unit
3. Cooler / Chiller vessel insulated
4. Chiller leveled within ± 1/16” per foot
5. Visually check for leaks (oil dripping etc.)
6. Standing Pressure of each refrigerant circuit Refrigerant
7. Inspect chillers or condensing units for damage
8. Check for enough clearance for proper airflow and servicing of unit
B. Air Handling Unit/ Fan Coil / Process System
1. All units tested, commissioned and operating without problem
2. All process system ready and completed for Operation
C. Piping
1. Cleaned , flushed and pressure tested for leaks
2. Properly supported – vibration eliminators installed
- 95 -
3. Air vents, thermometers and pressure gauges installed
4. All water balancing and isolating valves installed and tested
5. All chilled and condenser water flow switches installed, tested and calibrated
6. All modulating valves and flow controls checked and calibrated
7. All modulating valves and flows set at design flow requirement
8. Water piping system properly purged of air and no air lock in system
D. Units with Cooling Tower
1. Cleaned, tested and operational
2. Tower fan tested and balanced
3. Tower water flow balanced
4. Water treatment services performed, auto chemical Feed has flow interlock
E. Water Pump
1. All condenser and chilled water pump tested operational and balanced
Condenser Pump FLA : Pump Running Amp:
Chilled Water Pump FLA : Pump Running Amp:
2. All pumps properly primed and no air lock in pumping system
3. Adequate and constant water supply available
4. Required flow ratio must be maintained prior to start-up the chillers
(Follow water flow curve on I.O.M.)
F. Electrical Wiring
1. Adequate and constant power supply available
2. All power wiring and control completed to all of the system components
3. All circuit breakers and overload relays properly sized and installed
4. All wiring and grounding conforms to National Electrical Codes
5. All automatic control devices checked, tested and operational
6. All field supplied main electrical boards, switch boards, starter boards and
controls checked, tested and operational.
Customer interlocks only as indicated on wiring diagram

7.
(shielded cable as required )
8. Energize crank case heater for 24 hours prior to start-up of the compressors
- 96 -
G. Units with Remote Refrigerant Condenser Piping
1. Required amount of refrigerant for system charging at job site
2. Entire system properly dehydrated – must hold vacuum at 700 microns for a minimum
half an hour.
3. All fan cycling, damper control systems checked and operational
4. All control wiring installed
H. Remote Evaporator Systems
1. Liquid line solenoid interlocked with Dunham-Bush unit control panel
2. Entire system properly dehydrated – must hold vacuum at 700 microns
microns for a minimum half an hour.
3. All expansion valves properly sized and properly installed
4. All refrigerant piping installed in accordance With standard good practice
and design criteria
5. All terminal equipment properly sized and properly installed
6. All automatic control devices checked and operational
I. Condition
1. Essential electrical power to the equipment is available as designed
2. Essential water supply for city usage and conditions is available
3. Full load available for proper test and balance of Dunham-Bush equipment
Services To Be Rendered
Dunham-Bush engineers, supervisors, technicians and service representative will check, test, start-up and
commission the chiller and condensing units in accordance to standard Dunham-Bush procedures and re-
commendation and standard commercial good practices.
Dunham-Bush Rendered Services Above Do Not Include Any Responsibility For The Following:-
1. Installation and operating of the temperature control system external to the chillers or condensing units - Other
wise agreed upon by both parties prior to performance of works.
a. Balancing of the air distributor side of this system.

b. Balancing of the water side of the system other than the chillers or condensing units
c. Balancing of refrigerant systems.
2. Electrical wiring performed by others.
- 97 -
We (the dealer/contractor) request the present of
Dunham-Bush personnel at the job site on or about (date) to check, test
start-up and commission the equipment / system as required.
On receipt of this form, Dunham-Bush will schedule their service personnel to this job within seven to fourteen
days (7-14 days) of the requested date.
It is understood that Dunham-Bush personnel will be at site to perform start- up and commissioning exercise for
a period not exceeding normal working days.
We the undersigned agree that we will pay a free for such time that is spent on this over the specific normal
working days agreed upon, due to delays and in-complete preparations on our part and scope of
works/responsibilities. To cover this contingency, our contingency Purchase Order No.
be issued with the assurance that if no addition time is required, this purchase order will be cancelled.
An overtime charge will be rendered for work executed on Saturday, Sunday and Public Holidays
Dealer /
Contractor:
Address: Authorized
Signatory:
Full Name :
Company Stamp:
Position:
- 98 -
Malaysia China United Kingdom
Lot 5755-6, No. 1 Dunham-Bush Road, 8 Downley Road,

Kidamai Industrial Park, Laishan District, Havant,
Bukit Angkat, Yantai, Hampshire,
43000 Kajang, Shandong Province, England PO9 2JD
Selangor, Malaysia China 264003
Tel : +44-23-9247 7700
Tel: +603-8924 9000 Tel: +86-535-739 7888 Fax: +44-23-9245 0396
Fax: +603-8739 5020 Fax: +86-535-739 7999
United States of America United Arab Emirates South Africa
1800 SE 38th Avenue, Office # 2606, No. 57 Sovereign Drive

Homestead, Fortune Executive Towers, Route 21 Corporate Park
Florida 33035 Cluster T1, Jumeirah Lake Tower Irene, Pretoria
United States of America Dubai, UAE South Africa
Tel: +1(786)-800 9999 Tel: +971-4-443 9207 Tel: +27-12-345 4202

Fax: +1(786)-527 3539 Fax: +971-4-443 9208 Fax: +27-12-345 4203
India Indonesia Thailand
Unit No : 804-805 , 8th Floor, The Boulevard Office, 48/39 Soi Praditmanutham 19
Spaze Platinum Tower, 3F2 Jl. Fachrudin No.5, Praditmanutham Road,
Sohna Road, Sector-47, Gurgaon Kp. Bali, Tanah Abang Lat Pharo, Bangkok 10230
Haryana-122018, India Jakarta Pusat - 10250, Indonesia Thailand
Tel: +91-124-414 4430 Tel: +62-21-2123 1392 Tel: +662-002 2125
Singapore Vietnam
2 Kallang Pudding Road 10th Floor, Nam A Bank Tower,

#07-07 Mactech Building 201-203 Cach Mang Thang 8 Street,
Singapore 349307 Ward 4, District 3, Ho Chi Minh City,
Vietnam
Tel: +65-6842 2012
Fax: +65-6842 2013 Tel: +84-8-6290 3108
Fax: +84-8-6290 3109
[email protected]
www.dunham-bush.com
Products that perform...By people who care
Manufacturer reserves the right to change specifications without prior notice. M-M-04100A-0822D

WCFX-V Danfoss R134a 50-60Hz MM04100A-0822D R1 Lo

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CONTENT

1. INTRODUCTION 5.9.1 Chilled Water Pump Control............................51

1.1 GENERAL a. Smoking is prohibited in the refrigeration machinery

1.2 SAFETY CONSIDERATION & Wear Ear Protective Device

1.3 GENERAL SAFETY

The following safety instructions shall be followed when

Figure 1.1 Typical Unit Label

2.1 GENERAL – NOMENCLATURE

Water Cooled Chiller Blank - Sttandard

Variable Frequency Blank - No Economizer

VFD for optimized

Controller for precise

2.3 TECHNICAL DATA

2.3.2 Electrical Data

Model Compressor Unit Compressor Unit Compressor

Model Compressor Unit Compressor Unit Compressor

2.3.3 Sound Pressure Data

2.4 DIMENSIONAL DATA

WCFX-V 36S, 41S, 46S

Cond. Water Connector –

WCFX-V 38T, 40T, 46T

WCFX-V 50T, 54T, 57T, 60T

WCFX-V 73T, 75T, 81T, 87T, 90T

2.5 POWER ENTRY LOCATION

b.) WCFX-V 36S, 41S, 46S

c.) WCFX-V 50T, 54T, 57T, 60T

d.) WCFX-V 73T, 75T, 81T,87T, 90T

2.6 WATER PRESSURE DROP DATA (IMPERIAL)

Water Flow Rate - USgpm

2.) EVAPORATOR 2 PASS - PART 2

Water Flow Rate - USgpm

3.) EVAPORATOR 2 PASS - PART 3

P1R 8DR CAR

4.)CONDENSER 2 PASS - PART 1

Water Flow Rate - USgpm

5.) CONDENSER 2 PASS - PART 2

6.)CONDENSER 2 PASS - PART 3

Water Flow Rate - USgpm

2.7 ELECTRICAL SCHEMATIC DIAGRAM

2.) Two Compressors Models

3.1 APPLICATION B. Check the model number and the electrical

3.5 LOCATION 3.6 FOUNDATION

Figure 3.4A Moving Unit With Fork Lift

USE SKID TO AVOID DAMAGE TO

FIGURE 3.4B RIGGING DIAGRAM

Note: Spreader bar supplied by others.

Figure 3.6: Floor Loading Diagram

1.) Point Load Location - Inches[mm]

2.) Point Load Data - Lbs [kg]

3.7.1 Unit Clearance

2.) WCFX-V 36S, 41S, 46S

Figure 3.8 Spring Vibration Isolators

YRS-2 YRS-4 YRS-6

FH & OH = Free Height and Operating Height

3.10.2 Water Quality & Water

from rising temperatures, do not close shut-

The same flow switch can be also supplied as an

Figure 3.10.6.4B Single Loop System with Storage