Dunham-Bush ACDS Installation, Operation & Maintanance Manual
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Dunham-Bush ACDS Installation, Operation & Maintanance Manual

Dunham-Bush ACDS Installation, Operation & Maintanance Manual

R410a 60hz 10 to 180 tons (35 to 633 kw) air cooled scroll direct expansion chillers
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Products that perform...By people who care
INSTALLATION,
INSTALLATION,
OPERATION &
OPERATION &
MAINTENANCE
MAINTENANCE
MANUAL
MANUAL
MODEL:
ACDS
60Hz
Form No: M-M-0488A-0510
AIR COOLED
SCROLL
DIRECT
EXPANSION
CHILLERS
R
410A
10 to 180 Tons
(35 to 633 kW)

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Summary of Contents for Dunham-Bush ACDS

  • Page 1 Form No: M-M-0488A-0510 Products that perform...By people who care INSTALLATION, INSTALLATION, AIR COOLED SCROLL OPERATION & OPERATION & DIRECT MAINTENANCE MAINTENANCE EXPANSION MANUAL MANUAL CHILLERS MODEL: 410A ACDS 60Hz 10 to 180 Tons (35 to 633 kW)

  • Page 2: Table Of Contents

    ....7 Space Requirements And Clearance 2.4.1 General ............. 7 ......47 Condenser Fan Control Logic 2.4.2 ACDS ..............7 4.4.1 Air-Cooled Condenser Control Setpoints ..47 4.4.2 Increasing Condenser Pressure ...... 48 ............18 Foundation 4.4.3 Decreasing Condenser Pressure ....48 2.5.1 Air Cooled Units ..........

  • Page 3: Introduction

    In order to be able to make full use of the manual, you must first determine your unit model number from the unit name plate. Dunham-Bush package has been manufactured under a stringent quality control system. Each packaged chiller is performance tested at the factory at the specified field operating conditions as a final verification of reliability.

  • Page 4: Physical Specifications

    1.0 INTRODUCTION 1.1 PHYSICAL DATA MODEL ACDS 10.0 20.9 26.9 41.3 53.2 62.0 71.1 81.4 NOMINAL CAPACITY TONS 10.9 22.5 28.0 45.8 56.8 68.9 80.4 90.7 NOMINAL POWER INPUT COMPRESSOR 3500 3500 3500 3500 3500 3500 3500 3500 MIN. % UNIT CAPACITY REDUCTION NO.
  • Page 5 1.0 INTRODUCTION MODEL ACDS 89.8 100.8 108.4 125.4 138.5 153.0 163.7 NOMINAL CAPACITY TONS 103.7 108.7 118.7 130.8 150.0 160.4 176.5 NOMINAL POWER INPUT COMPRESSOR 3500 3500 3500 3500 3500 3500 3500 16.7% 16.7% 16.7% 16.7% MIN. % UNIT CAPACITY REDUCTION NO.

  • Page 6: Installation

    2.3.2 RIGGING AND MOVING 2.1 GENERAL Any unit mounted on skids may be moved The ACDS chiller is designed to cool water or with a forklift, but care must be taken not other non-corrosive liquids. Water is circulated to damage the unit with forks. The skids...

  • Page 7: General

    2.0 INSTALLATION FIGURE 2.3.2 ACDS RIGGING ACDS 010 ACDS 020 - 7 -...
  • Page 8 2.0 INSTALLATION ACDS 030, 040, 050, 060, 070 ACDS 080, 090, 100, 120, ACDS 135, 150, 165, 180 - 8 -...
  • Page 9 2.0 INSTALLATION FIGURE 2.4.2B DIMENSIONAL DATA ACDS 010 - 9 -...
  • Page 10 2.0 INSTALLATION ACDS 020 - 10 -...
  • Page 11 2.0 INSTALLATION ACDS 030 - 11 -...
  • Page 12 2.0 INSTALLATION ACDS 040 - 12 -...
  • Page 13 2.0 INSTALLATION ACDS 050, 060, 070 - 13 -...
  • Page 14 2.0 INSTALLATION ACDS 080, 090 - 14 -...
  • Page 15 2.0 INSTALLATION ACDS 100, 120 - 15 -...
  • Page 16 2.0 INSTALLATION ACDS 135, 150 - 16 -...
  • Page 17 2.0 INSTALLATION ACDS 165, 180 93 [2353.719 mm] - 17 -...

  • Page 18: Foundation

    Packaged Chiller. prevent transmission of piping vibration to the structure. FIGURE 2.5.1 FLOOR LOADING DIAGRAM ACDS 010 ACDS 020 POINT LOAD LOCATION DIMENSIONS – INCH [MM] MODEL ACDS 31 (787)
  • Page 19 2.0 INSTALLATION ACDS 030, 040, 050, 060, 070 ACDS 080, 090, 100, 120, 135, 150 ACDS 165, 180 - 19 -...
  • Page 20 2.0 INSTALLATION POINT LOAD LOCATION DIMENSIONS – INCH [MM] MODEL ACDS 84 [2134] 16 [406] 76 [1930] 16 [406] 84 [2134] 16 [406] 76 [1930] 16 [406] 84 [2134] 20 [508] 102 [2600] 20 [508] 84 [2134] 20 [508] 102 [2600]...

  • Page 21: Piping Connection

    2.0 INSTALLATION 2.7.2 WATER CONNECTIONS - 2.7 PIPING CONNECTIONS Multiple Packaged Chillers 2.7.1 WATER CONNECTIONS Multiple unit package chillers have been CHILLED WATER PIPING successfully applied to parallel and series piping systems years. Special After the unit has been leveled, the attention, however, must be given to the external water piping may be set up.
  • Page 22 2.0 INSTALLATION FIGURE 2.7A FIGURE 2.7B FIGURE 2.7C FIGURE 2.7D FIGURE 2.7E - 22 -...

  • Page 23: Water Quality

    Dunham-Bush and with cooling tower loops. representative. Following receipt of written notice, a representative will be sent to the customer. The purchaser should have competent service and 2.8 ELECTRICAL...

  • Page 24: Operation

    2. Start compressor(s), check the gauges and temperature, pressure, electrical readings and note if the pressures are within the prescribed control settings. A copy must be forwarded to limits. Dunham-Bush service department, before 3. Check the refrigerant sight glass to be sure it warranty will be honored.
  • Page 25 3.0 OPERATION FIGURE 3.2.1 TYPICAL PIPING SCHEMATIC ACDS 010, 020, 030 - 25 -...
  • Page 26 3.0 OPERATION ACDS 040, 050, 060, 070 - 26 -...
  • Page 27 3.0 OPERATION ACDS 080, 090, 100, 120 - 27 -...
  • Page 28 3.0 OPERATION ACDS 135, 150 - 28 -...
  • Page 29 3.0 OPERATION ACDS 165, 180 - 29 -...

  • Page 30: Oil Type

    COMPRESSOR OFF 0.0% COMPRESSOR 1 ON 100% 50.0% approved oils are also listed for each ACDS 040, 050, 060, 070, 080, 090, 100, 120 compressor. After recharge the oil level COMPRESSOR OFF 0.0% should be maintained per section 3.5.2. COMPRESSOR 1 ON 100% 25.0%...
  • Page 31 3.0 OPERATION The standard range is 10°F [5.6°C]. To rated to handle both rated load amp and locked determine the range of a condensing rotor amps. unit, subtract the design no load return air temperature (TNL) from the design CR - Relays (Miscellaneous Control) full load return air temperature (TFL) (R= These relays provide the necessary circuit logic TFL- TNL).
  • Page 32 3.0 OPERATION FIGURE 3.6 WATER SIDE PRESSURE DROP 1a.) IMPERIAL UNITS ACDS 010 ACDS 020 ACDS 030 ACDS 100 ACDS 040 ACDS 120 ACDS 050 ACDS 090 ACDS 060 ACDS 070 ACDS 080 ACDS 135 ACDS 150 ACDS 165 ACDS 180...

  • Page 33: Electrical

    4.0 ELECTRICAL ELECTRICAL DATA Power Supply Standard Unit Electrical Data Each Compressor Condenser Fan Motors MODEL V-Ph-Hz MFS/HACR LRA-XL FLA/Mtr 208/230-3-60 ACDS-010 460-3-60 208/230-3-60 ACDS-020 460-3-60 208/230-3-60 ACDS-030 460-3-60 208/230-3-60 ACDS-040 460-3-60 208/230-3-60 ACDS-050 460-3-60 208/230-3-60 ACDS-060 460-3-60 208/230-3-60 ACDS-070...

  • Page 34: Ir32 Electronic Thermostat Front Panel

    4.0 ELECTRICAL IR32 ELECTRONIC THERMOSTAT FRONT PANEL 1- Display: shows the value measured by the connected sensor. In the event of alarm condition the sensor value will be displayed alternately with the codes of the active alarms. When programming the instrument, the display shows the parameter codes being introduced and their values.

  • Page 35: Keypad Operation

    4.0 ELECTRICAL 4) "C" Parameters modification: 4.2.2 KEYPAD OPERATION Press [SEL] key + PRG/mute] key for 5 1) Set-point display: sec allows you to enter password and Press [SEL] key to display set-point. configuration parameters ("Cxx" type code). Display show 0. Select password by pressing [up arrow] key until 22 or 77 2) Set-point modification: display.
  • Page 36 4.0 ELECTRICAL Par. Description Min. Max. Default Fac. Set Output models only (A and Z) 4 = Rotation of relays 3 & 4 (No rotation for 1 & 3) 5 = Rotation of relays 1 & 2 (No rotation for 3 & 4) 6 = Separate rotation of coupled relays 1-2 &...

  • Page 37: Ir32 Electronic Thermostat Troubleshooting

    4.0 ELECTRICAL 4.2.4 IR32 ELECTRONIC THERMOSTAT TROUBLESHOOTING Code Description Cause Control Action Reset Remedies Sensor error faulty sensor depends on C10 R: automatic Check connection. Check V: manual sensor signal Sensor NTC2 faulty sensor if C19=1 & Mode R: automatic Check connection.

  • Page 38: Vision 2020I Controller And Terminal

    4.0 ELECTRICAL 4.3.1.1 The fifteen polycarbonate buttons: VISION 2020i a) Seven polycarbonate buttons at top CONTROLLER AND TERMINAL Button Description Vision2020i controller is equipped with a user Displays the analog inputs and friendly 132x64 pixels back-lit graphic display INPUT STATUS digital inputs status measured by terminal.

  • Page 39: Status Reading

    4.0 ELECTRICAL Press down arrow key or output key to 4.3.2 STATUS READING go to next screen: 4.3.2.1 Input status key To read inputs status press input status key: The display is showing the data as follows: The display is showing the data as follows: Hot Gas Bypass ANALOG INPUTS...
  • Page 40 4.0 ELECTRICAL 4.3.2.4 Setpoint key: REAL TIME CLOCK To read the setpoint value press setpoint key > MONDAY Time > 16:10 Date > 05/12/05 The display is showing the data as follows: To set the date and time, you must be authorized.

  • Page 41: Authorization

    4.0 ELECTRICAL Press down arrow key or user key to go 4.3.3 AUTHORIZATION to next screen for other setpoint: 4.3.3.1 Authorization key 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 The display is showing the current value and press enter key to confirm.
  • Page 42 4.0 ELECTRICAL Use up or down arrow key to move the The display is showing the data as cursor to the desired 'Sensor follows: Calibration', Technician Setpoints Main Menu Comp FLA Calibration ■ Sensor Calibration The display is showing the data as Manual Control follows: Compressor Control...
  • Page 43 4.0 ELECTRICAL Use up or down arrow key to move the Press technician key to go to technician cursor to the desired digital input or setpoints main menu and press enter relay output, key four times to move the cursor to the manual control sub-menu: The display is showing the data as The display is showing the data as...

  • Page 44: Control Functions

    4.0 ELECTRICAL NOTE: All compressors will revert back The display is showing the data as to automatic control if the computer is follows: the computer is not given a load, Sensors Manual unload, or hold command at least once Override every 15 minutes.
  • Page 45 4.0 ELECTRICAL consumption and demand charges. 4.3.6.3 Anti-Recycle Timer Two variables are used to define the The compressor motor requires an anti- ramp profile: Ramp rate and start point. recycle time delay which prevents Ramp rate defines the length of time restart for 15 minutes after a start.
  • Page 46 4.0 ELECTRICAL 4.3.6.8 Liquid Line Solenoid Control 4.3.6.11 Evaporator Freeze Shutoff When compressors starts, the liquid If the leaving chilled water temperature line solenoid will energize when suction drops below the freeze setpoint, the pressure falls below the pumpout controller will shut down the unit and setpoint or a time delay of 5 seconds is store the freeze alarm.

  • Page 47: Condenser Fan Control Logic

    4.0 ELECTRICAL 1. Adaptive Individual Air-cooled Condenser 4.3.6.14 Sensor Alarm Control If the computer measures an analog This type of control is based upon a single value (temperature, pressure.) that is compressor circuit. individual far beyond normal operating values, the discharge pressure on that circuit will be the associated compressors are shutdown.

  • Page 48: Increasing Condenser Pressure

    4.0 ELECTRICAL ST2 OFF setpoint, plus the value in the COND improved efficiency. Adaptive DIFF OFF setpoint for each stage number above Control Logic automatically adjusts the stage 2. Stage 2 of condenser staging will be fan cut-in offset based upon the turned off based upon the value in the setpoint following criteria: (COND ST2 OFF).

  • Page 49: Principle Of Operation Via Dblan Communication Bus

    4.0 ELECTRICAL 4.5.1 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 DB3 board and dedicated graphic display with multiple DB1 expanders board connected to J23 on DB3 b) Each chiller DB3 will be connected to DBLAN network through J11 connector c) The chiller lead/lag selection can be determined by...

  • Page 50: Sequence Of Operation

    4.0 ELECTRICAL 4.5.2 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 51: Network Connection Diagram

    4.0 ELECTRICAL NETWORK CONNECTION DIAGRAM Adr:17 Adr:18 Adr:19 Vision 2020i Vision 2020i Vision 2020i 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 The 6 core telephone cables (to J10 socket) are supply by the manufacturer.

  • Page 52: Addressing The Vision 2020I Dbg1 Terminal

    4.0 ELECTRICAL want to configure. Once you select the address *********************************** then press ‘enter’ button SELF TEST PLEASE WAIT The display will appears: ************************************ Terminal config Press ENTER To continue The following mask will appear. Set pLAN address to 1 (or accordingly) using “Up” and “Down”...

  • Page 53: Vision 2020I Controller Led Status

    4.0 ELECTRICAL Set Trm1, Trm2 and Trm3 to ’19 Pr’,’32 Sh’ and Set Trm1, Trm2 and Trm3 to ’18 Pr’,’32 Sh’ and ‘None ---’, change the 'NO' to 'YES'(to confirm ‘None ---’, change the 'NO' to 'YES'(to confirm and save) and press enter. and save) and press enter.

  • Page 54: Typical Wiring Schematic

    4.0 ELECTRICAL 4.9 TYPICAL WIRING SCHEMATIC ACDS 010 - 54 -...
  • Page 55 4.0 ELECTRICAL - 55 -...
  • Page 56 4.0 ELECTRICAL ACDS 020 - 56 -...
  • Page 57 4.0 ELECTRICAL - 57 -...
  • Page 58 4.0 ELECTRICAL ACDS 030 - 58 -...
  • Page 59 4.0 ELECTRICAL - 59 -...
  • Page 60 4.0 ELECTRICAL ACDS 040 - 60 -...
  • Page 61 4.0 ELECTRICAL - 61 -...
  • Page 62 4.0 ELECTRICAL ACDS 050, 060, 070 - 62 -...
  • Page 63 4.0 ELECTRICAL - 63 -...
  • Page 64 4.0 ELECTRICAL ACDS 080, 90 - 64 -...
  • Page 65 4.0 ELECTRICAL - 65 -...
  • Page 66 4.0 ELECTRICAL - 66 -...
  • Page 67 4.0 ELECTRICAL - 67 -...
  • Page 68 4.0 ELECTRICAL ACDS 100 - 68 -...
  • Page 69 4.0 ELECTRICAL - 69 -...
  • Page 70 4.0 ELECTRICAL - 70 -...
  • Page 71 4.0 ELECTRICAL - 71 -...
  • Page 72 4.0 ELECTRICAL ACDS 120 - 72 -...
  • Page 73 4.0 ELECTRICAL - 73 -...
  • Page 74 4.0 ELECTRICAL - 74 -...
  • Page 75 4.0 ELECTRICAL - 75 -...
  • Page 76 4.0 ELECTRICAL ACDS 135 - 76 -...
  • Page 77 4.0 ELECTRICAL - 77 -...
  • Page 78 4.0 ELECTRICAL - 78 -...
  • Page 79 4.0 ELECTRICAL - 79 -...
  • Page 80 4.0 ELECTRICAL ACDS 150 - 80 -...
  • Page 81 4.0 ELECTRICAL - 81 -...
  • Page 82 4.0 ELECTRICAL - 82 -...
  • Page 83 4.0 ELECTRICAL - 83 -...
  • Page 84 4.0 ELECTRICAL ACDS 165, 180 - 84 -...
  • Page 85 4.0 ELECTRICAL - 85 -...
  • Page 86 4.0 ELECTRICAL - 86 -...
  • Page 87 4.0 ELECTRICAL - 87 -...

  • Page 88: Maintenance

    5.0 MAINTENANCE b.) Use anti-freeze when 5.1 GENERAL evaporation temperature is close to As with all mechanical equipment, a program of liquid-side freezing regular inspection, cleaning preventive c.) Use a freeze protection thermostat maintenance by trained personnel will contribute and flow switch to guarantee a greatly to the long satisfactory service life of this constant water flow before, during product.

  • Page 89: Air Cooled Condenser Cleaning

    5.0 MAINTENANCE sign of possible motor trouble. DO NOT reset and 5.4.2.2. Strainers try to run compressor again. Call authorized If any of the media contains particle service representative to check for motor trouble. larger 1mm (0.04 inch), we recommend Resetting these safety devices and repeated that a strainer with a size of 16-20 starting could turn a minor motor problem into a...
  • Page 90 5.0 MAINTENANCE TABLE 5.4 R410A PRESSURE/ TEMPERATURE PROPERTIES Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature psig °F °C psig °F °C psig °F °C psig °F °C 10.8 74.5 -40.0 -40.0 62.2 428.9 10.0 -12.2 169.6 1169.4 60.0 15.6 364.1 2510.4 110.0...

  • Page 91: Trouble Shooting

    5.8 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY 1. Unit will not 1. Power off 1. Check main disconnect switch. start 2. Main line open 2. Check main fuses. 3. Incorrect wiring 3. Check with wiring diagrams. 4. Loose terminals 4. Tighten terminals. 5.

  • Page 92: Sample Log Sheet

    5.0 MAINTENANCE 5.9 SAMPLE LOG SHEET SHEET NO......... DUNHAM-BUSH SCROLL COMPRESSOR PACKAGED CHILLER NAMEPLATE DATA: UNIT MODEL NO............UNIT NO........VOLTS: ......Hz ....UNIT SERIAL NO............COMPRESSOR MODEL NOS..............DATE .......... TIME ............ START UP :...
  • Page 93 Products that perform...By people who care Corporate Head Office DUNHAM-BUSH HOLDING BHD (Formerly known as Dunham-Bush (Malaysia) Bhd) (129358-X) Lot 5755-6, Kidamai Industrial Park, Bukit Angkat 43000 Kajang, Selangor Darul Ehsan, Malaysia. Tel: 603-8733 9898 Fax: 603-8739 5020 E-Mail: info@dunham-bush.com.my...

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