Table of Contents
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HRSC - D
Remote Condenser Packaged Chiller
Installation, Operation &
Maintenance Instructions
Table of Contents
Description
Page No.
Introduction & Product Identification ................................................................................. 1
Inspection, Storage & Rigging............................................................................................. 2
Location, and Clearance & Foundation ............................................................................... 2
Vibration Isolation .............................................................................................................. 2
Water Piping ............................................................................................................. 2, 3 & 4
Refrigerant Piping ............................................................................................................... 5
Electrical Connections ......................................................................................................... 5
Operation ..................................................................................................................... 5 & 6
Maintenance ....................................................................................................................... 6
Slide Valve Unloading System ............................................................................................. 7
Control Settings ............................................................................................................ 8 & 9
Sequence of Operation ............................................................................................... 9 & 10
Optional Microcomputer Controller ..................................................................... 10 thru 16
Electrical Data (60 Hz) ............................................................................................... 17 & 18
Typical Power Wiring ......................................................................................................... 19
Typical Control Wiring (Electro-Mechanical ....................................................................... 20
Typical Control Wiring (Optiomal Microcomputer Controller) ................................... 21 & 22
Typical Piping Schematic ................................................................................................... 23
Capacity Control ............................................................................................................... 24
Physical Data ..................................................................................................................... 24
Evaporator Pressure Drop ................................................................................................. 25
Rigging (Sizes 50 thru 150) ............................................................................................... 26
Rigging (Sizes 180 thru 300) ............................................................................................. 27
Spring Vibration Isolation Data ......................................................................................... 28
Rubber-in-Shear Vibration Isolation Data .......................................................................... 29
Troubleshooting Guide ..................................................................................................... 30
Start-up Check List ............................................................................................................ 31
FORM 5504
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Summary of Contents for Dunham-Bush HRSC - D
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Page 1: Table Of Contents
HRSC - D Remote Condenser Packaged Chiller Installation, Operation & Maintenance Instructions Table of Contents Description Page No. Introduction & Product Identification ................. 1 Inspection, Storage & Rigging..................... 2 Location, and Clearance & Foundation ................2 Vibration Isolation ......................2 Water Piping ...................... -
Page 2: Introduction & Product Identification
It is assumed the user of this manual and those who Your Dunham-Bush package has been manufactured install, operate and maintain this equipment are expe- under a careful quality control system. If the package is... -
Page 3: Inspection, Storage & Rigging
LOCATION & CLEARANCE GENERAL Location of the equipment and the size of the equipment Packaged chillers are designed to cool water or other non- room require careful consideration of the following factors: corrosive liquids. Water is circulated through the direct ex- pansion cooler where it is cooled to the desired temperature then circulated to cooling coils for air conditioning, or to 1. - Page 4 For information concerning the installation, operation and ing systems. For various piping arrangements, consult the servicing of Dunham-Bush coolers, consult the latest revision ASHRAE Handbook. of Form 8110. Water Connections - Multiple Packaged Chillers - Mul- tiple unit packaged chillers have been successfully applied to parallel and series piping systems for years.
- Page 5 TYPICAL CHILLED WATER PIPING TYPICAL MULTIPLE PACKAGED CHILLER WATER CONNECTIONS PARALLEL FLOW PARALLEL FLOW SERIES FLOW...
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Page 6: Water Piping
• Lines must be sized according to latest edition of ASHRAE Handbook. Liquid lines should be sized based on 100°F liquid subcooling at the condenser. • Maximum of 50 linear feet of refrigerant line length (contact factory if application requires longer runs). • All installations require authorized Dunham-Bush start up. • Factory is to review all field piping. ELECTRICAL CONNECTIONS... -
Page 7: Maintenance
7. The representative will inspect the installation to deter- mine whether it meets Dunham-Bush, Inc. requirements, 6. Restart the compressor. After an hour of operation, the perform the initial start-up of the installation, determine... -
Page 8: Slide Valve Unloading System
SLIDE VALVE UNLOADING SYSTEM The DB screw compressor capacity control system for infinite the oil return (low pressure) line. The slide valve will move modulation consists of a slide valve and hydraulic piston/ to the right (unloading) whenever UL-2 opens the oil supply cylinder operator internal to the compressor, plus three hy- (high pressure) line, since the force of the oil exceeds that of draulic solenoid valves (UL-1, UL-2, &... -
Page 9: Control Settings
HRSC CONTROL SETTINGS PRESSURE ACTUATED LEGEND FACTORY SETTING High Pressure Control HP 1-4 Cut-Out 365 PSIG (Manual Reset) Low Pressure Control LP 1-4 Cut-In 55 PSIG (Auto Reset) Cut-Out 35 PSIG Low Pressure Freeze Control LPF 1-4 Cut-Out 54 PSIG PRESSURE ACTUATED LEGEND FACTORY SETTING... -
Page 10: Sequence Of Operation
CONDENSER HEAD PRESSURE CONTROL General he minimum ambient shown above reflects the performance of the condenser surface exposed to the operational fan(s) as well as that portion of the surface rejecting heat by natu- All units require some means to keep the condensing pres- ral convection with related fans “off”. - Page 11 MICROCOMPUTER CONTROLLER 1. General Description (Electrically Programmable Read Only Memory) store gen- Your Dunham-Bush HRSC is controlled by an NC25 micro- eral operating procedures (algorithms) and are the same for computer system. The computer system is composed of a all packages. The EAROM chip (Electrically Alterable Read...
- Page 12 2.4. Do not allow the component boards to get wet, TOTAL CYCLES gives the number of cycles (direct contact with water or condensation). since a memory clear was performed. This Disconnect power to the NC25 when plugging records up to 65,000 cycles. in or unplugging a ribbon cable connector.
- Page 13 3. Use the up or down arrow keys to select the WARNING: Setting the clock will cause a system setpoint to be changed. Press ENTER. A reset. The entire unit will shut down and start over cursor will flash over the setpoint A value. again.
- Page 14 A description of each of the functions follows: not have to be earlier than the turn off time. Schedules turn on by time and day, but turn off 4.1. Capacity Control of Screw Compressors by time alone. For example, a schedule from The capacity of a compressor can be controlled 1900 to 0700 Saturdays would turn on at 7:00 PM manually or automatically.
- Page 15 2. Manually load the compressor(s) to full load. CAUTION: Anti-recycle timer is bypassed by manual control. DO NOT start a compressor more This can be done one compressor at a time if than once every 15 minutes. necessary. 3. Locate the amps and full load amps (FLA) NOTE: All compressors will revert back to auto- analog locations from the analog input menu matic control if the computer is not given a...
- Page 16 A formula for calculating ramp time in minutes is sors on the circuit are locked off. The high pressure T = [(# compressors x 100) - start pt.] x Compressor alarm will be recorded by the computer. Typical setpoint value is 360 psig. Control Interval/(Ramp rate x 60)] 4.11 Freeze Safety The compressor control interval can be determined by...
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Page 17: Optional Microcomputer Controller
4.16 Hot Gas Bypass Control (option) not operating if the associated digital input When hot gas bypass has been supplied with from the compressor contactor does not the package, an output from the computer indicate that the contactor is pulled in (digital controls the solenoid. -
Page 18: Electrical Data (60 Hz)
60 Hz HRSC ELECTRICAL DATA (50 - 150) COMPRESSORS RATED LOAD AMPS LOCKED ROTOR AMPS Volts Type MOTOR NO. Minimum MOTOR NO. Model 60 Hz Circuit Max Fuse HRSC 3 Ph. Start Ampacity Size 208/230 1040 208/230 208/230 1228 208/230 208/230 1415 208/230... - Page 19 60 Hz HRSC ELECTRICAL DATA (50 - 150) COMPRESSORS Minimum Maximum Circuit Fuse LOCKED ROTOR AMPS RATED LOAD AMPS Type Volts Ampacity Size MOTOR NO. MOTOR NO. Model 60 Hz. Cir. 1 Cir. 2 Cir. 1 Cir. 2 Unit HRSC 3 PH.
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Page 20: Typical Power Wiring
TYPICAL HRSC 150 POWER WIRING (460/3/60) COMPRESSOR MOTORS 1-2 SEE NOTE 5... -
Page 21: Typical Control Wiring
TYPICAL HRSC 150 CONTROL WIRING (Electrical Mechanical) -
Page 22: Typical Control Wiring (Optiomal Microcomputer Controller)
TYPICAL HRSC 150 CONTROL WIRING (Optional Micro-Computer Controller) -
Page 24: Typical Piping Schematic
HRSC 050 TO 300 PIPING SCHEMATIC Shown Typical for Each Separate Refrigerant Circuit CIRG - 050. 060, 075 2 CIRC - 100, 110. 120, 135, 150 3 CIRC - 180, 210, 225 4 CIRC - 240. 255, 270, 300 ACCESS VALVE CHECK COUPLING VALVE... -
Page 25: Capacity Control
CAPACITY CONTROL Further reduction is possible on all units through use of Each compressor can modulate from 100% to 30% of full load by slide valve operation. This provides reduction down the hot gas bypass option which reduces compressor capac- to 7.5% on four-compressor units. -
Page 26: Evaporator Pressure Drop
EVAPORATOR WATER PRESSURE DROP MODEL HRSC-D CHILLER MODEL CURVE NO. MIN. GPM MAX. GPM CHS008601B* CHS010601B* CHS011601B* CHD013601B* 110, 120 EXD12102J07DVTO 135, 150 EXD14102J07DVTO 180, 220, 225 EXT18122J07DFRO 1060 240, 255, 270, 300 EXT20122J07DFRO 1140 *These chillers have welded heads. All other chillers have removable heads. NOTE: Constant water flow through the evaporator is required with a minimum of three gallons per ton of system water loop volume. -
Page 27: Rigging (Sizes 50 Thru 150)
HRSC 50-150 RIGGING INSTRUCTIONS SPREADER BAR ASSEMBLY (SUPPLIED BY OTHERS) POWER KNOCKOUT 2 1/2" DIA. LIFTING HOLES 3/4" DIA MOUNTING HOLES (9) SPREADER BAR HRSC 50-150 ISOLATOR INSTRUCTIONS MIDPOINT (9) 3/4 DIA. HOLES SUPPLIED 13 3/8 FRONT (CONTROL BOX) UNIT FRAME RAIL UNIT ISOLATOR (OPTIONAL) ISOLATOR CROSS RAIL ISOLATOR ASSEMBLY (FRONT VIEW) -
Page 28: Rigging (Sizes 180 Thru 300)
HRSC 180-300 RIGGING INSTRUCTIONS SPREADER BAR ASSEMBLY (SUPPLIED BY OTHERS) 3/4 DIA HOLES ISOLATOR MOUNTING 2 1/2 DIA. LIFTING HOLES (4) SPREADER BARS HOLES-6 SUPPLIED BY OTHERS HRSC 180-300 ISOLATOR INSTRUCTIONS (6) 3/4 DIA. HOLES SUPPLIED CONDENSER BUMPER RAIL 12 1/2 3 1/2... -
Page 31: Troubleshooting Guide
TROUBLESHOOTING GUIDE POSSIBLE CAUSE REMEDY CHILLER UNIT WILL NOT START 1. Power off 1. Check main disconnect switch 2. Main line open Check main fuses 3. Incorrect wiring Check the wiring diagram 4. Loose terminals Tighten all terminals 5. Control circuit open Check phase loss monitor, flow switch, circuit breakers, temperature control, low ambient thermostat, low temperature, thermostat,... -
Page 32: Start-Up Check List
START-UP CHECK LIST Date ______________ Unit Model No. _________________________ a. Vibration isolator used _________ _________ Setting Unit: b. Spring isolator adjusted for equal heiqht _________ _________ c. If rubber-in-shear isolators are used, is unit leveled by shimming _________ _________ Wiring: a.
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Questions and answers
If the chiller compressors is not able to cut out and the targets is still up to 100percent what is the course of it
The Dunham-Bush HRSC - D chiller compressor may not cut out while the targets remain at 100 percent if the leaving chilled water temperature (TLW) stays above the setpoint by 20°F or more. The system increases or maintains target percent capacity based on how far TLW is from the setpoint and how fast it is approaching. If TLW is not within the temperature deadband or is rising, the compressor will continue running at high capacity.
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