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126"

[3200mm]

42" [1067mm]

IF EVAPORATOR

IS INSULATED

FLAP MUST

 BE RAISED
TO EXPOSE

LIFTING HOLE

SPREADERS

LIFT

LIFT

1

.

GENERAL INFORMATION 

 

 
 

1.4.3 

Water Cooled Condensers 

The water-cooled condenser is also 
designed for constant water flow rate, 
and should be supplied with the design 
GPM [m³/hr] ±10%. The condenser must 
be protected from rapid changes in 
temperature as well. The maximum 
allowable rate of change in condenser 
entering water is 1°F [0.6°C] per minute. 
Fluctuating flow rate or temperature will 
cause unstable control of the machine, 
resulting in poor control of leaving 
chilled water temperature. If a cooling 
tower is used to reject heat from the 
condensing water loop, it must be 
controlled to provide an entering 
condensing water temperature which 
does not change more rapidly than 1°F 
[0.6°C] per minute and does not go 
below 60°F [15.6°C]. One or more of the 
following methods may be used to 
control the tower: 

1.4.3.1

 A 

modulating 

three-way 

valve 

which bypasses tower sprays 
at low load and low ambient 
temperature. 

1.4.3.2

  Tower fan staging in response 

to a thermostat in the tower 
sump. Fan thermostat should 
have a differential of at least 
20°F [11.1°C] to avoid short 
cycling. 

1.4.3.3

 A modulating three-way valve 

which bypasses the cooling 
tower to blend warm leaving 
condenser water with cold 
tower water. 

 

1.4.4 Condensing Water 

Treatment 

Condensing water tends to leave silt, 
algae and mineral deposits in the 
condenser tubes. This fouling gradually 
decreases unit efficiency. For this reason, 
a program of water treatment should be 
employed. Also, at regular intervals 
depending on water quality, the unit 
should be shut down, condenser heads 
removed and tubes cleaned. See Section 
5.4. 

 

FIGURE 1.2  RIGGING DIAGRAM 

 

Rigging should be done in a manner so that no strain is placed on unit components other than at cable 
connection points 

 

WCFX 10, 12, 15, 18 

 

 
 
 
 
 
 
 
 

 
 
 
 
 
 
 

 

 
 

Note: Project unit from cables.

 

- 5 - 

Summary of Contents for WCFX 10

Page 1: ...OPERATION MAINTENANCE MANUAL Form No MM0422A R134a R134a R134a 50 60 50 60 Hz 50 60 INSTALLATION OPERATION MAINTENANCE MANUAL Products That Perform By People Who Care MODEL WCFX Series ROTARY SCREW WA...

Page 2: ...ions 51 4 4 6 1 Chilled water pump interlock and flow switch 51 4 4 6 2 Customer control interlock 51 4 4 6 3 Anti recycle timer 51 4 4 6 4 On Delay Timer 51 4 4 6 5 Load control 51 4 4 6 6 Ramp contr...

Page 3: ...his equipment should have basic understanding of the principles of air conditioning refrigeration and electrical controls These instructions are general in nature and are for standard catalog units No...

Page 4: ...ator and condenser used in Dunham Bush model WCFX chillers is copper tubes with steel tube sheets and liquid heads These materials are generally suitable for use with clean fresh water found in most l...

Page 5: ...One or more of the following methods may be used to control the tower 1 4 3 1 A modulating three way valve which bypasses tower sprays at low load and low ambient temperature 1 4 3 2 Tower fan stagin...

Page 6: ...TO EXPOSE LIFTING HOLE IF EVAPORATOR IS INSULATED FLAP MUST BE RAISED TO EXPOSE LIFTING HOLE SPREADERS LIFT 61 1549mm 126 3200mm LIFT 52 1321mm 126 3200mm LIFT LIFT 1 0 GENERAL INFORMATION WCFX 20 22...

Page 7: ...TWO PASS RIGHT HAND ARRANGEMENT SHOWN 1 0 GENERAL INFORMATION FIGURE 1 3 DIMENSIONAL DATA WCFX 10 12 15 18 7...

Page 8: ...TWO PASS RIGHT HAND ARRANGEMENT SHOWN 1 0 GENERAL INFORMATION WCFX 20 22 24 27 30 33 36 8...

Page 9: ...1 0 GENERAL INFORMATION WCFX 39 42 45 48 51 54 9...

Page 10: ...versed left to right or vice versa Leaving chilled water temp sensor must be located in leaving chilled water stream After the unit has been leveled and isolators if any has been installed and adjuste...

Page 11: ...2799 6171 1559 3437 27ARL1RH4R 1600 3527 2404 5300 2686 5922 1600 3527 30AUL2RJ1R 1887 4160 2839 6259 3415 7529 1897 4182 30ARL2RJ1R 1980 4365 2930 6460 3270 7209 1925 4244 33AUL3RJ1R 1932 4259 2883...

Page 12: ...ROP FT WG B1R C1R D1R D2R E1R B1R C1R D1R D2R E1R 1 PASS 2 PASS 1 1 0 1 00 1 0 1 00 1 000 WATER FLOW RATE GPM PRESSURE DROP FT WG B1R C1R D1R D2R E1R 2 0 INSTALLATION FIGURE 2 4 PRESSURE DROPS WCFX 10...

Page 13: ...GPM PRESSURE DROP FT WG A1R A2R A3R B1R C1R A1R A2R A3R B1R C1R 1 PASS 2 PASS 1 1 0 1 00 1 0 1 00 1 000 WATER FLOW RATE GPM PRESSURE DROP FT WG A1R A2R A3R B1R C1R 2 0 INSTALLATION WCFX 10 12 15 18 ME...

Page 14: ...URE DROP FT WG J1R K1R K2R L1R L2R L3R M1R M2R M3R 1 1 0 1 00 1 00 1 000 1 0000 WATER FLOW RATE GPM PRESSURE DROP FT WG J1R K1R K2R L1R L2R L3R M1R M2R M3R 2 0 INSTALLATION WCFX 20 22 24 27 30 33 36 M...

Page 15: ...RE DROP FT WG J1R K1R K2R L1R L2R L3R M1R M2R M3R 1 1 0 1 00 1 00 1 000 1 0000 WATER FLOW RATE GPM PRESSURE DROP FT WG H1R H2R H3R H4R J1R J2R J3R K1R K2R 2 0 INSTALLATION WCFX 20 22 24 27 30 33 36 ME...

Page 16: ...RE DROP FT WG H1R H2R H3R H4R J1R J2R J3R K1R K2R 1 1 0 1 00 1 00 1 000 1 0000 WATER FLOW RATE GPM PRESSURE DROP FT WG H1R H2R H3R H4R J1R J2R J3R K1R K2R 2 0 INSTALLATION WCFX 20 22 24 27 30 33 36 ME...

Page 17: ...SURE DROP FT WG T2R T3R U1R V1R V2R V3R W1R W2R Y1R 1 1 0 1 00 1 00 1 000 1 0000 WATER FLOW RATE GPM PRESSURE DROP FT WG T2R T3R U1R V1R V2R V3R W1R W2R Y1R 2 0 INSTALLATION WCFX 39 42 45 48 51 54 MET...

Page 18: ...SSURE DROP FT WG T2R T3R U1R V1R V2R V3R W1R W2R Y1R 1 1 0 1 00 1 00 1 000 1 0000 WATER FLOW RATE GPM PRESSURE DROP FT WG P1R Q1R Q2R R1R R2R R3R T1R T2R T3R 2 0 INSTALLATION WCFX 39 42 45 48 51 54 ME...

Page 19: ...SSURE DROP FT WG P1R Q1R Q2R R1R R2R R3R T1R T2R T3R 1 1 0 1 00 1 00 1 000 1 0000 WATER FLOW RATE GPM PRESSURE DROP FT WG P1R Q1R Q2R R1R R2R R3R T1R T2R T3R 2 0 INSTALLATION WCFX 39 42 45 48 51 54 ME...

Page 20: ...SSURE DROP kPa B1R C1R D1R D2R E1R B1R C1R D1R D2R E1R 1 PASS 2 PASS 1 1 0 1 00 1 000 1 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa B1R C1R D1R D2R E1R 2 0 INSTALLATION WCFX 10 12 15 18 S I...

Page 21: ...m hr PRESSURE DROP kPa A1R A2R A3R B1R C1R 1 1 0 1 00 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa A1R A2R A3R B1R C1R A1R A2R A3R B1R C1R 1 PASS 2 PASS 2 0 INSTALLATION WCFX 10 12 15 18 S I...

Page 22: ...URE DROP kPa J1R K1R K2R L1R L2R L3R M1R M2R M3R 1 1 0 1 00 1 000 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa J1R K1R K2R L1R L2R L3R M1R M2R M3R 2 0 INSTALLATION WCFX 20 22 24 27 30 33 36 S...

Page 23: ...r PRESSURE DROP kPa J1R K1R K2R L1R L2R L3R M1R M2R M3R 1 1 0 1 00 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa H1R H2R H3R H4R J1R J2R J3R K1R K2R 2 0 INSTALLATION WCFX 20 22 24 27 30 33 36...

Page 24: ...RESSURE DROP kPa H1R H2R H3R H4R J1R J2R J3R K1R K2R 1 1 0 1 00 1 000 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa H1R H2R H3R H4R J1R J2R J3R K1R K2R 2 0 INSTALLATION WCFX 20 22 24 27 30 33...

Page 25: ...URE DROP kPa T2R T3R U1R V1R V2R V3R W1R W2R Y1R 1 1 0 1 00 1 000 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa T2R T3R U1R V1R V2R V3R W1R W2R Y1R 2 0 INSTALLATION WCFX 39 42 45 48 51 54 S I...

Page 26: ...m hr PRESSURE DROP kPa T2R T3R U1R V1R V2R V3R W1R W2R Y1R 1 1 0 1 00 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa P1R Q1R Q2R R1R R2R R3R T1R T2R T3R 2 0 INSTALLATION WCFX 39 42 45 48 51 54 S I...

Page 27: ...RESSURE DROP kPa P1R Q1R Q2R R1R R2R R3R T1R T2R T3R 1 1 0 1 00 1 000 1 0 1 00 1 000 WATER FLOW RATE m hr PRESSURE DROP kPa P1R Q1R Q2R R1R R2R R3R T1R T2R T3R 2 0 INSTALLATION WCFX 39 42 45 48 51 54...

Page 28: ...E Service Department of Dunham Bush Industries for an authorized start up representative to perform the initial start up of the Dunham Bush packaged chiller The purchaser must have competent service a...

Page 29: ...iscontinue chilled water pump operation when unit is not operational 3 3 SEASONAL START UP PROCEDURE When the unit is to be started up after being shut down for a prolonged period 3 3 1 Check unit for...

Page 30: ...5 3 6 1 WCFX 10 18 The compressor is oil lubricated and discharges a small amount of oil mist along with refrigerant This oil is carried into the evaporator Oil rich refrigerant is returned from the e...

Page 31: ...3 0 OPERATION FIGURE 3 5 PIPING SCHEMATIC 1 1 COMPRESSOR WCFX 10 12 15 18 31...

Page 32: ...3 0 OPERATION 2 2 COMPRESSORS WCFX 20 22 24 27 30 36 32...

Page 33: ...3 0 OPERATION 3 3 COMPRESSORS WCFX 39 42 45 48 51 54 33...

Page 34: ...and is not covered by warranty it is important to be mindful of freeze prevention Three cases deserve particular attention 3 8 1 Standby at Low Ambient Temperatures If the unit is to stand idle at amb...

Page 35: ...ram mounted in the package control panel A copy of that diagram is furnished with the unit owner s manual 4 3 TYPICAL OPERATION In order to start a compressor the following conditions must be met Corr...

Page 36: ...4 0 ELECTRICAL FIGURE 4 2 TYPICAL WIRING SCHEMATIC A 1 COMPRESSOR 36...

Page 37: ...4 0 ELECTRICAL 37...

Page 38: ...4 0 ELECTRICAL B 2 COMPRESSORS 38...

Page 39: ...4 0 ELECTRICAL 39...

Page 40: ...4 0 ELECTRICAL 40...

Page 41: ...4 0 ELECTRICAL C 3 COMPRESSORS 41...

Page 42: ...4 0 ELECTRICAL 42...

Page 43: ...4 0 ELECTRICAL 43...

Page 44: ...4 0 ELECTRICAL 44...

Page 45: ...nd Factory levels from left It can only be access depend on the password level The higher password can access the lower password level s setting and not vice versa 4 4 1 1 The fifteen polycarbonate bu...

Page 46: ...s input status key The display is showing the data as follows Press down arrow key or input key to go to next screen The display is showing the data as follows Repeat the same steps to go to other sen...

Page 47: ...r setpoints screen and perform setpoint modification 4 4 2 5 Clock key To read the current day time and date unit scheduling and ice cel mode scheduling optional press the clock key The display is sho...

Page 48: ...surements In order to gain access to this button you must be authorized and log in at least as user level Press the user key and display is showing the data as follows Press down arrow key or user key...

Page 49: ...enter key to confirm 4 4 5 4 To perform Sensor Calibration Press technician key to go to technician setpoints main menu and press enter key twice to move the cursor to the sensor calibration sub menu...

Page 50: ...to AUTO CLOSE OPEN or AUTO ON OFF The display is showing the data as follows Press enter key to confirm the change NOTE All manual control will revert back to automatic control if the keypad is not gi...

Page 51: ...ring diagram specifies the terminals to which the contacts must be wired To enable the unit the contacts must be closed To disable the unit the contacts must be opened 4 4 6 3 Anti Recycle Timer The c...

Page 52: ...determines that a compressor is fully loaded and temperature is not being maintained another compressor is added When unloading a compressor is taken off line when the computer determines that the rem...

Page 53: ...will then shut down the compressor The status of the oil level sensor can be seen on the computer display Failure is indicated on the alarm pilot light The low oil alarm will be recorded by the contr...

Page 54: ...and etc All calibration on sensors shall be done in this step 2 Load the compressor to full load If the amps reading do not match with calculated FLA value within 2 3A do this calculation Amps FLA For...

Page 55: ...conditions d The lead lag selection determine the chiller operation sequence as follows Lead chiller selection Normal chillers operation sequence When DBLAN fails 1 1 2 3 on duty 4 5 6 standby 1 2 3 o...

Page 56: ...abled below 45 total capacity and so on until the load falls enough to shut off the lead chiller 9 Each unit in the network can monitor the operation of other units via DBLAN If the master unit is hav...

Page 57: ...11 socket are supply by the customer Pay attention to the network polarity RX TX on one controller must be connected to RX TX on the other controller the same is true for RX TX and GND 4 9 HARDWARE SE...

Page 58: ...ws you to select the Vision 2020i controller address for first chiller it is 01 that you want to configure Once you select the address then press enter button The display will appears Push enter to co...

Page 59: ...e the DIP switches for indicating basic node status They are Red Yellow and Green coloured Red Yellow Green At the start up all LEDs are ON and after few seconds OFF again After 5 15 seconds elapse th...

Page 60: ...saturated refrigerant temperature at the pressure in the vessel At full load read evaporator and condenser pressures on the computer Then use Table of Refrigerant Pressure Temperature Properties to fi...

Page 61: ...s refer to Figure 3 5 during unit operation If bubbles are visible in sight glass unit is undercharged Refrigerant should be added through the charging valve on the evaporator feed line until the cond...

Page 62: ...184 00 1370 34 124 50 51 39 237 00 1735 86 142 00 61 11 26 00 280 69 30 50 0 83 79 00 646 21 75 50 24 17 132 00 1011 72 103 60 39 78 185 00 1377 24 124 80 51 56 238 00 1742 76 142 30 61 28 27 00 287 5...

Page 63: ...an check amps Do not exceed RLA x 1 25 Call D B serviceman 5 High oil temperature a Motor windings failing b Insufficient motor cooling a Check megohms b Open liquid injection valve slightly 6 Low su...

Page 64: ...URE IN EVAPORATOR WATER TEMPERATURE OUT EVAPORATOR WATER PRESSURE DROP ftwg kPa EVAPORATOR WATER FLOW gpm m hr CONDENSER WATER PRESSURE DROP ftwg kPa CONDENSER WATER FLOW gpm m hr ACTUAL VOLTAGE NOT N...

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