Dunham-Bush WCFX Series Installation, Operation & Maintenance Manual
  1. Manuals
  2. Brands
  3. Dunham-Bush Manuals
  4. Chiller
  5. WCFX Series
  6. Installation, operation & maintenance manual
Dunham-Bush WCFX Series Installation, Operation & Maintenance Manual

Dunham-Bush WCFX Series Installation, Operation & Maintenance Manual

Rotary screw water chillers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Products That Perform . . .By People Who Care
INSTALLATION,
INSTALLATION,
OPERATION &
OPERATION &
MAINTENANCE
MAINTENANCE
MANUAL
MANUAL
MODEL:
WCFX Series
50/60
50/60
®
ROTARY
SCREW
WATER
CHILLERS
R134a
R134a
Form No: MM0422A

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the WCFX Series and is the answer not in the manual?

Questions and answers

Mark B Kadehjian
May 14, 2025

Can you tell me what this alarm is: mtrMODfault

0

Related Manuals for Dunham-Bush WCFX Series

Summary of Contents for Dunham-Bush WCFX Series

  • Page 1 ® Form No: MM0422A Products That Perform . . .By People Who Care INSTALLATION, INSTALLATION, ROTARY OPERATION & OPERATION & SCREW MAINTENANCE MAINTENANCE WATER MANUAL MANUAL CHILLERS MODEL: R134a R134a WCFX Series 50/60 50/60...

  • Page 2: Table Of Contents

    ABLE OF CONTENTS DESCRIPTION PAGE NO DESCRIPTION PAGE NO GENERAL INFORMATION 4.4.5 Technician Key and Menu ........... 48 4.4.5.1 Technician status key ........48 RECEIVING AND INSPECTION..........4 4.4.5.2 Technician status key- main menu....48 RIGGING AND MOVING ............4 4.4.5.3 Compressor FLA calibration.......
  • Page 3 These instructions are general in nature and are for standard catalog units. Non-standard units may vary in some respects from these instructions. Dunham-Bush packaged chiller has been manufactured under a careful quality control system. It has been tested for performance at the factory at specified field operating conditions as a final verification of reliability.

  • Page 4: General Information

    Dunham-Bush Industries, M & E Service for failure of tubes or tube sheets due to Department.

  • Page 5: Water Cooled Condenser

    GENERAL INFORMATION 1.4.3 Water Cooled Condensers Tower fan staging in response 1.4.3.2 The water-cooled condenser is also to a thermostat in the tower designed for constant water flow rate, sump. Fan thermostat should and should be supplied with the design have a differential of at least GPM [m³/hr] ±10%.
  • Page 6 0 GENERAL INFORMATION WCFX 20, 22, 24, 27, 30, 33, 36 52" [1321mm] LIFT LIFT SPREADERS CONTROL BOX IF EVAPORATOR 126" [3200mm] IS INSULATED FLAP MUST BE RAISED TO EXPOSE LIFTING HOLE WCFX 39, 42, 45, 48, 51, 54 61" [1549mm] LIFT LIFT SPREADERS...
  • Page 7 0 GENERAL INFORMATION FIGURE 1.3 DIMENSIONAL DATA WCFX 10, 12, 15, 18 - 7 -...
  • Page 8 0 GENERAL INFORMATION WCFX 20, 22, 24, 27, 30, 33, 36 - 8 -...
  • Page 9 0 GENERAL INFORMATION WCFX 39, 42, 45, 48, 51, 54 - 9 -...

  • Page 10: Installation

    0 INSTALLATION 2.1 FOUNDATION 2.4 WATER PIPING CONNECTIONS A flat, level concrete foundation or floor capable of supporting the weight of the unit must be Refer to Figures 1.3. for water piping connection provided. Weights are given in Table 2.1. The locations.
  • Page 11 0 INSTALLATION TABLE 2.1 FLOOR LOADING DIAGRAM WCFX 10, 12, 15 & 18 CONTROL PANEL WCFX 20, 22, 24, 27, 30, 33, 36, 39, 42, 45, 48, 51 & 54 CONTROL PANEL Point Loading, Lbs [kg] 50Hz 60Hz UNIT MODEL UNIT MODEL WCFX WCFX...
  • Page 12 0 INSTALLATION FIGURE 2.4 PRESSURE DROPS WCFX 10, 12, 15, 18 – METRIC UNITS 1.) Evaporator 1 & 2 Pass 1 00 2 PASS 1 PASS 1 00 1 000 1 0000 WATER FLOW RATE - GPM 2.) Evaporator 3 Pass 1 00 1 00 1 000...
  • Page 13 0 INSTALLATION WCFX 10, 12, 15, 18 – METRIC UNITS 3.) Condenser 1 & 2 Pass 1 00 2 PASS 1 PASS 1 00 1 000 1 0000 WATER FLOW RATE - GPM 4.) Condenser 3 Pass 1 00 1 00 1 000 WATER FLOW RATE - GPM - 13 -...
  • Page 14 0 INSTALLATION WCFX 20, 22, 24, 27, 30, 33, 36 – METRIC UNITS 1.) Evaporator 1 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM 2.) Evaporator 2 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM - 14 -...
  • Page 15 0 INSTALLATION WCFX 20, 22, 24, 27, 30, 33, 36 – METRIC UNITS 3.) Evaporator 3 Pass 1 00 1 00 1 000 WATER FLOW RATE - GPM 4.) Condenser 1 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM - 15 -...
  • Page 16 0 INSTALLATION WCFX 20, 22, 24, 27, 30, 33, 36 – METRIC UNITS 5.) Condenser 2 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM 6.) Condenser 3 Pass 1 00 1 00 1 000 WATER FLOW RATE - GPM - 16 -...
  • Page 17 0 INSTALLATION WCFX 39, 42, 45, 48, 51, 54 – METRIC UNITS 1.) Evaporator 1 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM 2.) Evaporator 2 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM - 17 -...
  • Page 18 0 INSTALLATION WCFX 39, 42, 45, 48, 51, 54 – METRIC UNITS 3.) Evaporator 3 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM 4.) Condenser 1 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM - 18 -...
  • Page 19 0 INSTALLATION WCFX 39, 42, 45, 48, 51, 54 – METRIC UNITS 5.) Condenser 2 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM 6.) Condenser 3 Pass 1 00 1 00 1 000 1 0000 WATER FLOW RATE - GPM - 19 -...
  • Page 20 0 INSTALLATION WCFX 10, 12, 15, 18 – S. I. UNITS 1.) Evaporator 1 & 2 Pass 1 00 2 PASS 1 PASS 1 00 1 000 WATER FLOW RATE - m³/hr 2.) Evaporator 3 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr...
  • Page 21 0 INSTALLATION WCFX 10, 12, 15, 18 – S. I. UNITS 3.) Condenser 1 & 2 Pass 1 00 2 PASS 1 PASS 1 00 1 000 WATER FLOW RATE - m³/hr 4.) Condenser 3 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr...
  • Page 22 0 INSTALLATION WCFX 20, 22, 24, 27, 30, 33, 36 – S. I. UNITS 1.) Evaporator 1 Pass 1 00 1 00 1 000 WATER FLOW RATE - m³/hr 2.) Evaporator 2 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr - 22 -...
  • Page 23 0 INSTALLATION WCFX 20, 22, 24, 27, 30, 33, 36 – S. I. UNITS 3.) Evaporator 3 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr 4.) Condenser 1 Pass 1 00 1 00 1 000 WATER FLOW RATE - m³/hr - 23 -...
  • Page 24 0 INSTALLATION WCFX 20, 22, 24, 27, 30, 33, 36 – S. I. UNITS 5.) Condenser 2 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr 6.) Condenser 3 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr - 24 -...
  • Page 25 0 INSTALLATION WCFX 39, 42, 45, 48, 51, 54 – S. I. UNITS 1.) Evaporator 1 Pass 1 00 1 00 1 000 WATER FLOW RATE - m³/hr 2.) Evaporator 2 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr - 25 -...
  • Page 26 0 INSTALLATION WCFX 39, 42, 45, 48, 51, 54 – S. I. UNITS 3.) Evaporator 3 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr 4.) Condenser 1 Pass 1 00 1 00 1 000 WATER FLOW RATE - m³/hr - 26 -...
  • Page 27 0 INSTALLATION WCFX 39, 42, 45, 48, 51, 54 – METRIC UNITS 5.) Condenser 2 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr 6.) Condenser 3 Pass 1 000 1 00 1 00 1 000 WATER FLOW RATE - m³/hr - 27 -...

  • Page 28: Controls

    After the installation has been completed and Controls, which are to be field installed, checked, contact the M&E Service Department of should be connected in accordance with Dunham-Bush Industries for an authorized start- appropriate wiring diagram up representative to perform the initial start-up of accompanying the unit.

  • Page 29: Operation

    Local codes may require that all Dunham-Bush offers this service in its safety relief valves be piped to the outdoors. Oil Kare Program. This analysis should Never install a hand valve in a safety relief vent be done at the beginning and end of each line.

  • Page 30: Oil Management Systems

    0 OPERATION pump installed on the suction line. The for the piping schematics. Each vertical screw jet pump is powered by high pressure compressor discharges hot and high pressure gas gas from the compressor discharge line through a discharge service valve (or check valve through hot gas feed valve.
  • Page 31 0 OPERATION FIGURE 3.5 PIPING SCHEMATIC 1.) 1 COMPRESSOR - WCFX 10, 12, 15 & 18 - 31 -...
  • Page 32 0 OPERATION 2.) 2 COMPRESSORS - WCFX 20, 22, 24, 27, 30, 36 - 32 -...
  • Page 33 0 OPERATION 3 COMPRESSORS - WCFX 39, 42, 45, 48, 51 & 54 - 33 -...

  • Page 34: Freeze Protection

    0 OPERATION With valves A and B both energized (A open, B severe damage will result; e.g. split and leaking closed) during normal compressor operation, high tubes and cracked and leaking headers. Since this pressure oil is directed to the slide valve. The damage can be extremely costly and is not pressure acting on the surface of the slide valve covered by warranty, it is important to be mindful...

  • Page 35: Electrical

    0 ELECTRICAL 4.1 ELECTRICAL DATA UNIT MODEL NOM. VOLTS UNIT EACH COMPRESSOR 50 HZ 60 HZ 50 HZ 60 HZ WCFX 10 WCFX 12 WCFX 15 WCFX 18 WCFX 20 73 (2) 200 (2) 498 (2) WCFX 22 73 / 85 200 / 200 498 / 498 WCFX 24...

  • Page 36: Typical Wiring Schematic

    0 ELECTRICAL FIGURE 4.2 TYPICAL WIRING SCHEMATIC A.) 1 COMPRESSOR Ω Ω - 36 -...
  • Page 37 0 ELECTRICAL - 37 -...
  • Page 38 0 ELECTRICAL B.) 2 COMPRESSORS Ω - 38 -...
  • Page 39 0 ELECTRICAL - 39 -...
  • Page 40 0 ELECTRICAL - 40 -...
  • Page 41 0 ELECTRICAL C.) 3 COMPRESSORS - 41 -...
  • Page 42 0 ELECTRICAL Ω Ω Ω - 42 -...
  • Page 43 0 ELECTRICAL - 43 -...
  • Page 44 0 ELECTRICAL - 44 -...

  • Page 45: Vision 2020I Controller And Terminal

    0 ELECTRICAL 4.4 VISION 2020i 4.4.1.1 The fifteen polycarbonate buttons: a) Seven polycarbonate buttons at top CONTROLLER AND TERMINAL Button Description Vision 2020I controller is equipped with user Displays the analog inputs and friendly 132x64 pixels back-lit graphic display INPUT STATUS digital inputs status measured by the probes/sensors.

  • Page 46: Status Reading

    0 ELECTRICAL 4.4.2 STATUS READING Press down arrow key or output key to go to next screen: 4.4.2.1 Input status key To read inputs status press input status key: Repeat the same steps to go to other relay outputs screen: The display is showing the data as follows: 4.4.2.3 Compressor status key...

  • Page 47: Clock Key

    0 ELECTRICAL The display is showing the data as REAL TIME CLOCK follows: > MONDAY SETPOINT 1 Time > 16:10 Date > 05/12/05 Supply Water Temp Set point= 44.0 °F [06.7°C] Dead band= 0.8 °F [0.5°C] To set the date and time, you must be authorized.

  • Page 48: Authorization

    0 ELECTRICAL 4.4.3 Authorization Press down arrow key or user key to go to next screen for other setpoint: 4.3.3.1 Authorization key To get authorization level, press authorization key: To alter setpoint data, press enter key to select the setpoint to alter and use the up-down arrow key to change the value The display is showing the current and press enter key to confirm.

  • Page 49: Compressor Fla Calibration

    0 ELECTRICAL The display is showing the data as Technician Setpoints follows: Main Menu Technician Setpoints Comp FLA Calibration Sensor Calibration Main Menu Manual Control Comp FLA Calibration Compressor Control Sensor Calibration Manual Control Use up or down arrow key to move the Compressor Control cursor to the desired 'Sensor Calibration',...

  • Page 50: Compressor Control

    0 ELECTRICAL The display is showing the data as given a command at least once every 15 follows: minutes. 4.4.5.6 Compressor Control: Technician Setpoints Screw compressors can be controlled manually with keypad. Main Menu compressor can be turned on, off, or Comp FLA Calibration placed in computer control.

  • Page 51: Control Functions

    0 ELECTRICAL Use up or down arrow key to select controller can be used to enable or MAN and press enter key to confirm disable operation of the unit. The the change. The compressor will start wiring diagram specifies the terminals or continue to run in hold state.

  • Page 52: Ramp Control

    0 ELECTRICAL 4.4.6.6 Ramp Control unloading, a compressor is taken off line when the computer determines that Another feature of the controller is the remaining compressors can control ramp control, which is the ability to water temperature. vary load time of the machine from start.

  • Page 53: Low Pressure Cut-Off

    0 ELECTRICAL Failure is indicated on the alarm pilot 4.4.6.11 Low Pressure Cut-off light. The low oil alarm will be This function protects the unit from recorded by the controller. operating at abnormally low evaporator refrigerant pressure. The controller will 4.4.6.15 High Oil Temperature shut down the compressor when cooler Thermostat (12TAS)

  • Page 54: Sensor Alarm

    0 ELECTRICAL etc.). All calibration on sensors shall be done 4.4.6.18 Sensor Alarm in this step. If the controller measures an analog 2. Load the compressor to full load. If the amps value (temperature, pressure.) that is far reading do not match with calculated FLA beyond normal operating values, the value within 2-3A, do this calculation: Amps associated compressors are shutdown.

  • Page 55: Communication Bus

    0 ELECTRICAL 4.6.1 Principle of Operation via DBLAN communication bus Example: 6 chillers network with 4 units on duty and 2 units standby Graphic Display (option) DBLAN DBG1 DBG1 DBG1 DBG1 DBG1 DBG1 Notes a) Each chiller has a stand-alone master DB2 board and dedicated display panel DBG1 with multiple DB1 expanders board connected to J23 on DB2 b) Each chiller DB2 will be connected to DBLAN network through J11 connector c) The chiller lead/lag selection can be determined by...

  • Page 56: Sequence Of Operation

    0 ELECTRICAL 4.6.2 Sequence Of Operation a) LWT ≥ (LWT Setpoint + Enable Next 1. When the customer enable input is ‘on’ to deadband) start the lead unit, the chilled water pump b) After a enable next time delay of 3 starter or motorized valve control point will minutes (adjustable) and close and water will start to flow through the...

  • Page 57: Network Connection Diagram

    0 ELECTRICAL 4.8 NETWORK CONNECTION DIAGRAM Adr:17 Adr:18 Adr:19 Vision 2020i Vision 2020i Vision 2020i DBG1 DBG1 DBG1 Terminal Terminal Terminal Telephone Cable Telephone Cable Telephone Cable Adr:1 Adr:2 Adr:3 Vision 2020i Vision 2020i Vision 2020i Controller Controller Controller RS 485 Cable RS 485 Cable max 500 meters max 500 meters...

  • Page 58: Addressing The Vision 2020I Terminal

    0 ELECTRICAL 4.9.2 Addressing the Vision Set Trm1, Trm2 and Trm3 to ’17 Pr’,’32 Sh’ and ‘None ---’, change the 'NO' to 'YES'(to 2020i DBG1 terminal confirm and save) and press ‘enter’. At the Vision 2020i DBG1 terminal, hold Note: Pr = Private, Sh = Share. simultaneously the last three keys on the lower For multiple units with master-slave sequencing right corner of the Vision 2020i terminal...

  • Page 59: Vision 2020I Controller Led Status

    0 ELECTRICAL The address display (19) is the correct setup for With the above settings, terminal with address 17 the third chiller unit with the controller address of will only work with the controller with address 1, three(P:03).Press ‘enter’ to confirm the setting terminal 18 will only work with the controller and the display will appears: with address 2, terminal 19 will only work with...

  • Page 60: Maintenance

    Some of this care can easily be provided corresponding saturated temperature for each by owner personnel. However, a Dunham-Bush pressure. Read leaving chilled water temperature authorized service mechanic should inspect the on the computer. Read leaving condenser water...

  • Page 61: Electrical Malfunction

    NOTE: Only DB 18 oil may be used in this unit found physical package. Use of other oil is not approved by specifications. Dunham-Bush, will result poor If the unit must be charged on the jobsite, it performance package.

  • Page 62: R134A Pressure/Temperature Properties

    0 MAINTENANCE TABLE 5.4 R134a PRESSURE/TEMPERATURE PROPERTIES PRESS TEMP. PRESS TEMP. PRESS TEMP. PRESS TEMP. PRESS TEMP. PSIG °F °C PSIG °F °C PSIG °F °C PSIG °F °C PSIG °F °C 0.00 101.38 -14.70 -25.94 53.00 466.90 56.90 13.83 106.00 832.41 90.90 32.72 159.00 1197.93 115.00...

  • Page 63: Troubleshooting

    0 MAINTENANCE 5.7 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY 1. Unit will not a.) Power off. a.) Check main disconnect switch and main line fuses. start. b.) No control power. b.) Check control transformer fusing. c.) Compressor circuit c.) Close circuit breakers. If trip, check compressor. breakers open.

  • Page 64: Sample Log Sheet

    0 MAINTENANCE 5.8 SAMPLE LOG SHEET SHEET NO......DUNHAM-BUSH ROTARY SCREW COMPRESSOR PACKAGED CHILLER NAME PLATE DATA: UNIT MODEL NO. WCFX :..... UNIT NO.:...... VOLTS: ....Hz ....UNIT SERIAL NO.: ........................JOB NAME: ............LOCATION: ............ START DATE: ..........................

This manual is also suitable for:

Wcfx 10Wcfx 12Wcfx 15Wcfx 18Wcfx 20Wcfx 22 ... Show all

Table of Contents

Save PDF