Air Cooled Flooded Screw Chillers

Form No: MM0463A
Products that perform...By people who care
INSTALLATION,
SCREW
OPERATION & COMPRESSOR
MAINTENANCE
AIR
MANUAL
COOLED
FLOODED
CHILLERS
MODEL:
AFHX Series
60Hz
R134a
TABLE OF CONTENTS
DESCRIPTION
PAGE NO
DESCRIPTION
1.0 INTRODUCTION
1.1
Product Identification. ......................................................... 3
2.0 INSTALLATION
General................................................................................... 6
2.1.1 Application Precautions ............................................ 6
2.1.2 Chilled Water Flow ................................................... 6
2.2
Inspection. ............................................................................. 6
2.3
Rigging ................................................................................... 6
2.3.1 General ...................................................................... 6
2.3.2 Rigging & Moving .................................................... 6
2.4
Space Requirements and Clearance ................................... 8
2.4.1 General ...................................................................... 8
2.4.2 AFHX ........................................................................ 8
2.5
Foundation .......................................................................... 13
2.6
Vibration Isolation.............................................................. 13
2.7
Piping connections. ............................................................. 13
2.8
Electrical Wiring. ............................................................... 13
2.9
Controls ............................................................................... 16
2.9.1 Connections............................................................. 16
2.9.2 Settings .................................................................... 16
2.10 Request For Start-Up Representative .............................. 16
2.1
3.0 OPERATION
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
General................................................................................. 17
Unit piping ........................................................................... 17
System Water Flow Rate ................................................... 17
Unit Operation Including Overnight Shut Down and
Morning Restart ................................................................. 17
3.4.1 Air Cooled Package Chiller Start-Up ..................... 17
System Start Up .................................................................. 17
Shut-Down (Overnight Or Weekend) .............................. 22
Seasonal Shut-Down Procedure ........................................ 22
Seasonal Start-up Procedure ............................................. 22
Safety Relief Valves ............................................................ 22
Refrigeration Cycle- Multiple Compressor AFHX ......... 22
Fan Cycling ......................................................................... 23
Liquid Injection .................................................................. 23
Hydraulic Capacity Control System................................. 23
4.5
4.6
4.7
4.8
4.9
4.0 ELECTRICAL
4.1
4.2
4.3
4.4
Electrical Data..................................................................... 24
Wiring Diagram .................................................................. 24
Typical Operation ............................................................... 24
Vision 2020i Controller and Terminal ............................. 29
4.4.1 Operator Keypad ....................................................... 29
4.4.1.1 The fifteen polycarbonate buttons ............... 29
4.4.2 Status Reading ........................................................... 29
4.4.2.1 Input status key ............................................ 29
4.4.2.2 Output status key ......................................... 30
4.4.2.3 Compressor status key ................................. 30
4.4.2.4 Setpoint key ................................................. 31
4.4.2.5 Clock key ..................................................... 31
4.4.2.6 Alarm history key ........................................ 31
4.4.3 Authorization............................................................. 32
4.4.3.1 Authorization key ........................................ 32
4.4.4 Advanced user key and menu ................................... 32
4.4.4.1 User key ....................................................... 32
4.4.5 Technician Key and Menu ...................................... 32
4.4.5.1 Technician status key .............................. 32
PAGE NO
4.4.5.2 Technician status key- main menu ......... 32

4.4.5.3 Compressor FLA calibration .................. 33
4.4.5.4 To perform sensor calibration ................. 33
4.4.5.5 Manual control ........................................ 33
4.4.5.6 Compressor control ................................. 34
4.4.5.7 Sensors Override ..................................... 35
4.4.6 Control Functions ................................................... 35
4.4.6.1 Chilled water pump interlock and flow
switch ..................................................... 35
4.4.6.2 Customer control interlock ..................... 35
4.4.6.3 Anti-recycle timer ................................... 36
4.4.6.4 On delay timer......................................... 36
4.4.6.5 Load control ............................................ 36
4.4.6.6 Ramp control ........................................... 36
4.4.6.7 Staging control ........................................ 36
4.4.6.8 Modmotor setback control ...................... 36
4.4.6.9 Sump Heater Control .............................. 36
4.4.6.10 Suction/ Discharge Pressure Differential
control ..................................................... 37
4.4.6.11 Evaporator Freeze Shutoff ...................... 37
4.4.6.12 Low pressure cut-off ............................... 37
4.4.6.13 High pressure cut-off .............................. 37
4.4.6.14 Optical oil level sensor ........................... 37
4.4.6.15 High oil temperature thermostat ............. 37
4.4.6.16 Overload protector .................................. 37
4.4.6.17 Phase control relay .................................. 37
4.4.6.18 Sensor alarm............................................ 38
4.4.6.19 No-stop alarm.......................................... 38
4.4.6.20 Low differential pressure alarm .............. 38
Condenser Fan Control Logic ........................................... 38
4.5.1 Air-Cooled Condenser Control Setpoints............... 38
4.5.2 Increasing Condenser Pressure ............................... 39
4.5.3 Decreasing Condenser Pressure.............................. 39
4.5.3.1 Adaptive Control Logic .......................... 39
Master/ Slave Control Sequence ....................................... 39
4.6.1 Sensor Principle of Operation VIA DBLAN
Communication Bus ............................................... 40
4.6.2 Sequence of Operation ............................................ 41
Vision 2020i Local Area Network (DBLAN) ................... 41
Network Connection Diagram .......................................... 42
Hardware Setting ............................................................... 42
4.9.1 Addressing the Vision 2020i Controller ................. 42
4.9.2 Addressing the Vision 2020i DBG1 Terminal ....... 43
4.9.3 Vision 2020i Controller LED Status ...................... 44
5.0 MAINTENANCE
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
General ................................................................................ 45
Periodic Inspection ............................................................. 45
Monthly Inspection............................................................. 45
Vessel Maintenance ............................................................ 45
5.4.1 General .................................................................... 45
5.4.2 Water Side Cleaning Of Evaporator ....................... 45
Air Cooled Condenser Cleaning ....................................... 45
Electrical Malfunction ....................................................... 47
Refrigerant Charge ............................................................ 47
5.7.1 General .................................................................... 47
5.7.2 Air Cooled Packages............................................... 47
Oil Charge ........................................................................... 47
Troubleshooting .................................................................. 48
Sample Log Sheet ............................................................... 49
SCHEMATIC DIAGRAM, GRAPH AND TABLE

DESCRIPTION
Figure 2.3.2
Figure 2.4.1
Figure 2.4.2
Figure 2.5A
Figure 2.5B
Figure 3.2
Figure 3.3
PAGE NO
DESCRIPTION
Typical Rigging ......................................................... 7

Typical Space Requirements ....................................... 8
Dimensional Data ...................................................... 10
Isolator Location ....................................................... 14
Isolator Point Load Data ........................................... 14
Typical Piping Schematic ......................................... 18
Evaporator Water Pressure Drop .............................. 21
PAGE NO
Figure 4.2
Typical Wiring Schematic ........................................ 25
Figure 4.3.1 Vision 2020i keypad ................................................ 29
Table 1.1
Table 4.4.6.5
Table 4.9.3
Table 5.4.2
-2-
Physical Specifications ............................................... 5

Sample Ramp For Several Setpoint (In Minutes)..... 36
LED Status ................................................................ 44
R134a Pressure/Temperature Properties................... 46
AFHX Standard R134a 60Hz IOM Manual
1.0 INTRODUCTION
This manual is designed to provide all the necessary information for
installation, operation and maintenance of the latest generation of the
Dunham-Bush horizontal screw compressor air-cooled packaged
chillers.
To use this manual effectively, you must first identify your unit model
from the unit nameplate.
Your Dunham-Bush package has been manufactured under a careful
quality control system. If the package is installed, operated and
maintained with care and attention to the instructions contained herein,
it will give many years of satisfactory service.
It is assumed the user of this manual and those who install, operate and
maintain this equipment are experienced and qualified air conditioning
equipment personnel.
1.1 PRODUCT IDENTIFICATION
A F HX 210 T - 5 S R HR
HR
LN
Air Cooled Chiller

Flooded Evaporator
= Heat Recovery
= Low Noise
Blank = R22
R
= R134a
Horizontal Screw Compressor

Nominal Tons
= Optional Two
Compressors
Blank = Standard
C
H
S
Q
= Compact
= High Ambient
= Standard
= Special
5
6
= 50Hz
= 60Hz
-3-
1.0 INTRODUCTION
TABLE 1.1 PHYSICAL SPECIFICATIONS
MODEL AFHX
210-6SR
220-6SR
235-6SR
260-6SR
280-6SR
310-6SR
COMPRESSOR
MODEL (QTY)
RPM
NOMINAL CAPACITY
TR
MIN. % UNIT CAPACITY REDUCTION
HX 1817 X 1
HX 1709 X 1
HX 1711 X 1
HX 1711 X 2
HX 1711 X 1
HX 1811 X 1
HX 1811 X 2
HX 1813 X 2
3550
3550
3550
3550
3550
3550
208
220
235
257
280
309
25%
12.5%
12.5%
12.5%
12.5%
12.5%
EVAPORATOR
MODEL (QTY)
WATER CONNECTOR
NOM. WATER FLOW / PD
INCH[MM]
GPM / FT IN WG
MIN/ MAX WATER FLOW
GPM
MIN/ MAX WATER PD
FT IN WG.
L1R (1)
D2R (2)
J1R (2)
J1R (2)
K1R (2)
K2R (2)
8[203]
8[203]
8[203]
8[203]
8[203]
8[203]
499/ 14.67
529/ 7.2
565/ 9.63
618/ 11.16
673/ 11.25
743/ 11.53
159/ 787
235/ 1174
236/ 1174
236/ 1174
257/ 1281
283/ 1409
1.89/ 33.28
1.65/ 30.52
1.96/ 35.56
1.96/ 35.56
1.99/ 36.06
2.02/ 36.77
CONDENSER
COIL ROWS DEEP/ TOTAL FA (SQ.FT)
4/ 282.3
4/ 282.3
4/ 282.3
4/ 141.2, 3/ 188.2
3/ 376.4
4/ 188.2, 3/ 188.2
12
12
12
14
16
16
800(12)
800(12)
800(12)
860(14)
860(16)
860(16)
MOTOR kWI (QTY)
2.0(12)
2.0(12)
2.0(12)
3.0(14)
3.0(16)
3.0(16)
FLA, AMP (QTY)
3.8(12)
3.8(12)
3.8(12)
4.9(14)
4.9(16)
4.9(16)
TOTAL CFM
157500
156177
153594
230034
265944
257460
45
45
45
45
45
45
NO. OF FAN
FAN DIA.
MM
MIN. AMBIENT TEMP. (F) AT MIN. LOAD
ELECTRICAL
NOM. VOLTAGE
460/3/60
460/3/60
460/3/60
460/3/60
460/3/60
460/3/60
UNT RLA
341.3
366.5
394.5
449.8
488.5
508.3
UNIT MAX. INRUSH
530.1
416.2
444.2
494.5
524.3
653.1
GENERAL
UNIT LENGTH
INCH[MM]
276[7010]
276[7010]
276[7010]
318[8077]
360[9144]
381[9677]
UNIT WIDTH
INCH[MM]
88[2235]
88[2235]
88[2235]
88[2235]
88[2235]
88[2235]
UNIT HEIGHT
INCH[MM]
96.5[2451]
96.5[2451]
96.5[2451]
96.5[2451]
96.5[2451]
96.5[2451]
SHIPPING WEIGHT
LBS[KG]
17199[7801]
18690[8478]
19596[8889]
21328[9674]
23645[10725]
25162[11413]
OPERATING WEIGHT
LBS[KG]
17542[7957]
19107[8667]
20099[9117]
21831[9827]
24205[10979]
25768[11688]
OPERATING CHARGE R134a
LBS[KG]
567[257]
600[272]
642[291]
703[319]
794[360]
877[398]
-4-
1.0 INTRODUCTION
MODEL AFHX
355-6SR
405-6SR
435-6SR
460-6SR
515-6SR
555-6SR
COMPRESSOR
MODEL (QTY)
RPM
NOMINAL CAPACITY
TR
MIN. % UNIT CAPACITY REDUCTION
HX 1813 X 1
HX 1816 X 1
HX 1816 X 2
HX 1817 X 2
HX 1813 X 3
HX 1816 X 1
HX 1813 X 2
HX 1816 X 2
HX 1813 X 1
3550
3550
3550
3550
3550
3550
355
402
434
460
512
557
12.5%
12.5%
12.5%
8.33%
8.33%
8.33%
EVAPORATOR
MODEL (QTY)
WATER CONNECTOR
NOM. WATER FLOW / PD
INCH[MM]
GPM / FT IN WG
L2R (2)
L3R (2)
M1R (2)
L2R (1), M2R (1)
L3R (1), M2R (1)
L3R (1), M3R (1)
10[254]
10[254]
12[305]
12[305]
12[305]
12[305]
852/ 9.02
966/ 10.03
1042/ 9.17
1104/ 11.89
1231/ 14.45
1337/ 14.95
MIN/ MAX WATER FLOW
GPM
365/ 1810
390/ 1948
436/ 2173
411/ 2040
423/ 2109
439/ 2184
MIN/ MAX WATER PD
FT IN WG.
1.96/ 35.14
1.96/ 35.59
1.93/ 34.47
1.95/ 34.81
1.94/ 35.04
1.97/ 35.22
CONDENSER
COIL ROWS DEEP/ TOTAL FA (SQ.FT)
4/ 188.2, 3/ 235.3
4/ 235.3, 3/ 235.3
4/ 470.6
3/ 256.7, 4/ 385
4/ 641.7
4/ 641.7
18
20
20
20
20
20
860(18)
860(20)
860(20)
860(20)
860(20)
860(20)
MOTOR kWI (QTY)
3.0(18)
3.0(20)
3.0(20)
3.0(20)
4.0(20)
4.0(20)
FLA, AMP (QTY)
4.9(18)
4.9(20)
4.9(20)
4.9(20)
6.5(20)
6.5(20)
TOTAL CFM
289863
316260
309225
347340
381612
373422
45
45
45
45
45
45
NO. OF FAN
FAN DIA.
MM
MIN. AMBIENT TEMP. (F) AT MIN. LOAD
ELECTRICAL
NOM. VOLTAGE
460/3/60
460/3/60
460/3/60
460/3/60
460/3/60
460/3/60
UNIT RLA
585.4
655.8
695.7
755.4
827.8
896.9
UNIT MAX. INRUSH
726.7
781.4
883.7
896
974.7
1023.6
GENERAL
UNIT LENGTH
INCH[MM]
423[10744]
465[11811]
465[11811]
444[11278]
444[11278]
444[11278]
UNIT WIDTH
INCH[MM]
88[2235]
88[2235]
88[2235]
88[2235]
88[2235]
88[2235]
UNIT HEIGHT
INCH[MM]
96.5[2451]
96.5[2451]
96.5[2451]
120.5[3061]
120.5[3061]
120.5[3061]
SHIPPING WEIGHT
LBS[KG]
27977[12690]
32270[14637]
33567[15226]
34716[15747]
36759[16673]
37994[17234]
OPERATING WEIGHT
LBS[KG]
28749[13040]
33091[15010]
34492[15646]
35582[16140]
37648[17077]
38912[17651]
OPERATING CHARGE R134a
LBS[KG]
1005[456]
1140[517]
1228[557]
1303[591]
1453[659]
1576[715]
-5-
2.0 INSTALLATION
2.1 GENERAL
1.) Check all crates and cartons received against

the Bill of Lading/ Shipping Papers to be sure
they agree.
2.) Check the model number and the electrical
characteristics on the nameplate to determine
if they are correct.
3.) Check for freight damage, shortages or other
discrepancies and note them on the delivery
receipt before signing.
In the event that any damage is found, a damage
claim should immediately be filed by the
purchaser against the delivering carrier as all
shipments are F.O.B. Factory.
Packaged chillers are designed to cool water or

other non-corrosive liquids. The liquid to be
cooled is to be circulated through the tubes of a
refrigerant evaporator where the temperature is
reduced to the desired level. The heat absorbed by
the refrigerant in the evaporator is rejected via the
condenser where it raises the temperature of
another liquid stream (usually water) being
circulated through the tubes. This heat is usually
rejected by a cooling tower or closed circuit
cooled.
Care should be taken to see that the equipment is
properly installed and adjusted. An installer or
operator should first become familiar with the
information contained in this manual.
2.3 RIGGING
2.1.1 APPLICATION PRECAUTIONS

The following instructions are intended to
help assure proper and successful
application of your water chilling machine.
2.1.2 CHILLED WATER FLOW

The Dunham-Bush AFHX Packaged
Water Chiller is designed for a constant
chilled water flow rate, even when the
cooling load is varying. The machine will
generally perform satisfactorily with
steady flow rates deviating from design by
as much as 10%. However, varying water
flow rates can cause control instability
which will result in undesirable system
effects, particularly poor control of leaving
chilled water temperature. If two-way
valves are used to control flow through
cooling coils, some means such as an
automatic modulating valve should be
provided in the system to maintain steady
flow through the evaporator.
If the chilled water system is arranged for
the dual purpose of cooling and heating,
the evaporator must incorporate valves to
prevent the flow of hot water through it.
This can be done with either manual or
automatic shutoff valves, but the method
of control must be that water temperature
entering the evaporator never exceeds
90F[32.2C].
2.3.1 GENERAL
Each unit has been carefully tested and
crafted at the factory where every
precaution is taken to assure that the unit
reaches you in perfect condition. It is very
important that the riggers and movers
should use the same care and precaution in
moving the equipment into place. Make
sure that chains, cables. or other moving
equipment are placed so as to avoid
damage to the unit or piping. The
refrigerant piping must not be used as a
ladder or as a handhold. Do not attach a
chain hoist sling to the piping or
equipment. Move the unit in an upright
position and let it down gently from trucks
or rollers.
2.3.2 RIGGING AND MOVING

Any unit mounted on skids may be moved
with a forklift, but care must be taken not
to damage the unit with forks. The skids
should not be removed until the unit is at
its final location.
The AFHX model is to be rigged through
the holes in the base side rails. In all cases,
spreader bars must be used between
rigging lines to prevent coil or fan deck
damage. The unit must be lifted using All
Rigging Points. Refer to Rigging
Instructions on Figure 2.3.2.
All models can be pushed or pulled (with
chains) from the control box end only.
Truck forks must be kept level and not
tilted back. Do not raise the end of the unit
more than 2"[51mm] off the floor.
2.2 INSPECTION
When the equipment is delivered, it is important
that the following inspection be completed in the
presence of the carrier's representative.
-6-
2.0 INSTALLATION
FIGURE 2.3.2
TYPICAL RIGGING
-7-
2.0 INSTALLATION
2.4 SPACE REQUIREMENTS
AND CLEARANCE
2.4.1
GENERAL
The dimensional data and clearances that
follow are useful for determining space
requirements. The unit should be placed
to make the clearance noted available for
servicing properly. Failure to allow these
clearances will cause serious trouble and
result in higher costs for operation,
maintenance and repair.
2.4.2
AFHX
The dimensional data are shown in
Figure 2.4.2 and space requirements are
shown in Figure 2.4.1. The most
important consideration which must be
taken into account when deciding upon
location of air-cooled equipment, is
provision for a supply of ambient air to
the condenser, and removal of heated air

from the condenser area. Where this
essential requirement is not provided, it
will result in higher condensing
temperatures,
which
cause
poor
operation, higher power consumption and
possibly, eventual failure of equipment.
Units must not be located in the vicinity
of steam, hot air or fume exhausts.
Another consideration which must be
taken into account is that the unit should
be mounted away from noise sensitive
spaces and must have adequate support to
avoid vibration and noise transmission
into the building. Units should be
mounted over corridors, 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 2.4.1 TYPICAL SPACE REQUIREMENTS

WALLS OR OBSTRUCTIONS
The unit should be located so that air may circulate freely and not be recirculated. For proper airflow
and access all sides of the unit must be a minimum of eight feet [2438mm] away from any wall or
obstruction. It is preferred that this distance be increased whenever possible. Care should be taken to
see that ample room is left for maintenance work through access doors and panels. Overhead
obstructions are not permitted. When the unit is in an area where it is enclosed by three walls the unit
must be installed as indicated for units in a pit.
-8-
2.0 INSTALLATION
FIGURE 2.4.1 TYPICAL SPACE REQUIREMENTS
Single Pit (See Note 2)
Double Pit (See Note 2)
Multi Pit
Notes:
1.) All dimensions are minimal, unless
otherwise noted.
Corner Wall
2.) Pit installations are not recommended. Re-circulation of hot

condenser air in combination with
surface air turbulence cannot be
predicted. Hot air re-circulation will
severely affect unit efficiency (EER)
and can cause high pressure or fan
motor temperature trips. DunhamBush will not be responsible for
ducting fans to a higher level to
alleviate the above mentioned
conditions.
-9-
2.0 INSTALLATION
FIGURE 2.4.2
DIMENSIONAL DATA
AFHX 210-6SR
AFHX 220-6SR, 235-6SR
AFHX 260-6SR
NOTE : ALL DIMENSIONS ARE IN INCHES(MM).
- 10 -
2.0 INSTALLATION
AFHX 280-6SR
AFHX 310-6SR
AFHX 355-6SR
- 11 -
2.0 INSTALLATION
AFHX 405-6SR, 435-6SR
AFHX 460-6SR, 515-6SR, 555-6SR
- 12 -
2.0 INSTALLATION
2.5 FOUNDATION
Refer to index for unit dimensions and load
points. Foundations must be level for proper
operation and functioning of controls and
provision must be made for supporting the
individual load points as shown in the unit
dimensions. Roof mounted units must be
supported on adequate steel structure. If units are
located on the ground level, a concrete base is
recommended.
2.6 VIBRATION ISOLATION

Under certain critical conditions. It may be
necessary to install vibration isolators under the
base of the Packaged Chiller.
Rubber-in-shear or spring vibration isolators are
offered as optional items. When spring isolators
are used, flexible connections must be installed in
the water piping system and in the refrigerant
lines of split systems. Note: These flexible
connectors must be suitable for the fluid and
pressures involved.
All piping which is external to the packaged
chiller must be supported by spring mounted
hangers and any piping which goes through the
wall, ceiling or floor should be properly sheathed
to prevent transmission of piping vibration to the
structure.
When spring isolators are used, electrical service
to the unit must also be flexibly connected. By
means of a 36" section of flexible conduit.
2.7 PIPING CONNECTIONS

Refer to the dimensional drawings for water
piping connection locations. After the unit has
been leveled and isolators (if any) installed &
adjusted, connect evaporator water piping,
keeping in mind that the evaporator tubes may
require cleaning or replacement at some future
date, and removable sections of piping will be
required to permit evaporator head removal.
Piping must be supported to avoid excess stress
on the evaporator heads. Cut piping holes in the
removable access panel at the end of the unit.

Opening the hole to the left-hand side of the panel
so that it can still be removed after piping is in
place. Holes can also be cut down through the
floor of the unit providing no cross-members are
cut out. Install air vent points to permit complete
air purging of the chilled water circuit. Install
drain valves in similar low points to facilitate
complete water system drainage. Install
temperature & pressure indicators in the water
piping at the unit to monitor water flow. Install
shut-off valves to isolate the unit from the piping
system during unit servicing.
Note: Due to possible high pressures resulting
from rising temperatures, do not close shut-off
valves with cold water in the evaporator.
It is important that the chilled water system be
cleaned before startup to avoid collecting debris
in the evaporator. After filling the system with
water (or a glycol solution), start pump, bleed off
trapped air, and check for proper flow rate by
measuring water pressure drop across evaporator.
2.8 ELECTRICAL WIRING

In connecting power wiring to the unit, the
following precautions should be taken:
1.) All field wiring is to be in accordance with
the National Electric Code and must comply
with state and local codes. See Electrical Data
for minimum circuit ampacity and fuse size.
2.) Check unit wiring for damage and all terminal
connections for tightness. Unit terminal
blocks are to be connected with copper
conductors only, sized per ampacity listed on
unit data plate.
3.) Connections to unit should match the unit
nameplate in volts, phase, and Hertz. Voltage
must not vary beyond 10% of nameplate
value and voltage imbalance between phases
must not exceed 2% at any time during
operation of the unit.
4.) Phase sequence to connectors L1, L2 and L3
shall be in that order. Check with Amprobe
phase sequence adapter PSA-1 or equivalent.
- 13 -
2.0 INSTALLATION
FIGURE 2.5 ISOLATOR LOCATION AND POINT LOAD DATA
1.) AFHX 210-6SR, 220-6SR, 235-6SR, 260-6SR
2.)
AFHX 280-6SR, 310-6SR
a.) Point Load Location Inches [mm]

Unit Model
AFHX
A Dim.
B Dim.
C Dim.
D Dim.
E Dim.
F Dim.
210-6SR
86 [2184]
21 [533]
117 [2972]
117 [2972]
21 [533]
220-6SR
86 [2184]
21 [533]
117 [2972]
117 [2972]
21 [533]
235-6SR
86 [2184]
21 [533]
117 [2972]
117 [2972]
21 [533]
260-6SR
86 [2184]
21 [533]
138 [3505]
138 [3505]
21 [533]
280-6SR
86 [2184]
28 [711]
101 [2565]
102 [2591]
101 [2565]
28 [2565]
310-6SR
86 [2184]
33 [839]
105 [2667]
105 [2667]
105 [2667]
33 [839]
b.) Point Load Data lbs [kg]

Unit Model
AFHX
Pos. #1
Pos. #2
Pos. #3
Pos. #4
Pos. #5
Pos. #6
Pos. #7
Pos. #8
Total Operating
Weight
210-6SR
2414 [1095]
2652 [1203]
2890 [1311]
3067 [1391]
3195 [1449]
3323 [1507]
17542 [7957]
220-6SR
3092 [1403]
3179 [1442]
3265 [1481]
3258 [1478]
3190 [1447]
3123 [1417]
19107 [8667]
235-6SR
3272 [1484]
3330 [1511]
3389 [1537]
3428 [1555]
3370 [1529]
3311 [1502]
20099 [9117]
260-6SR
3733 [1694]
3667 [1663]
3600 [1633]
3506 [1591]
3610 [1638]
3714 [1685]
21831 [9903]
280-6SR
3272 [1484]
3098 [1405]
2924 [1326]
2749 [1247]
2779 [1261]
2953 [1340]
3128 [1419]
3302 [1498]
24205 [10979]
310-6SR
3412 [1548]
3275 [1486]
3137 [1423]
3000 [1361]
3030 [1374]
3167 [1437]
3304 [1499]
3442 [1561]
25768 [11688]
- 14 -
2.0 INSTALLATION
3.) AFHX 355-6SR, 405-6SR, 435-6SR, 460-6SR, 515-6SR, 555-6SR
a.) Point Load Location Inches [mm]

Unit Model
AFHX
A Dim.
B Dim.
C Dim.
D Dim.
E Dim.
F Dim.
G Dim.
H Dim.
355-6SR
86 [2184]
40.75 [1035]
68.25 [1734]
68.25 [1734]
68.5 [1740]
68.25 [1734]
68.25 [1734]
40.75 [1035]
405-6SR
86 [2184]
40.75 [1035]
76.5 [1944]
76.5 [1943]
77.5 [1969]
76.5 [1943]
76.5 [1943]
40.75 [1035]
435-6SR
86 [2184]
40.75 [1035]
76.5 [1944]
76.5 [1943]
77.5 [1969]
76.5 [1943]
76.5 [1943]
40.75 [1035]
460-6SR
86 [2184]
40.75 [1035]
72.5 [1842]
72.5 [1842]
72.5 [1842]
72.5 [1842]
72.5 [1842]
40.75 [1035]
515-6SR
86 [2184]
40.75 [1035]
72.5 [1842]
72.5 [1842]
72.5 [1842]
72.5 [1842]
72.5 [1842]
40.75 [1035]
555-6SR
86 [2184]
40.75 [1035]
72.5 [1842]
72.5 [1842]
72.5 [1842]
72.5 [1842]
72.5 [1842]
40.75 [1035]
b.) Point Load Data lbs [kg]

Unit Model
AFHX
Pos.
#1
Pos.
#2
Pos.
#3
Pos.
#4
Pos.
#5
Pos.
#6
Pos.
#7
Pos.
#8
Pos.
#9
Pos.
#10
Pos.
#11
Pos.
#12
Total
Operating
Weight
355-6SR
2437
[1105]
2393
[1086]
2350
[1066]
2307
[1046]
2264
[1027]
2220
[1007]
2234
[1013]
2326
[1055]
2417
[1096]
2509
[1138]
2600
[1179]
2692
[1221]
28749
[13040]
405-6SR
2810
[1275]
2781
[1262]
2752
[1249]
2723
[1235]
2694
[1222]
2665
[1209]
2705
[1227]
2734
[1240]
2763
[1253]
2792
[1266]
2821
[1280]
2850
[1293]
33091
[15010]
435-6SR
2974
[1349]
2926
[1327]
2878
[1306]
2831
[1284]
2783
[1262]
2735
[1241]
2745
[1259]
2823
[1280]
2870
[1302]
2918
[1324]
2966
[1345]
3013
[1367]
34492
[15646]
460-6SR
2937
[1332]
2938
[1333]
2939
[1333]
2940
[1334]
2941
[1334]
2942
[1335]
2999
[1360]
2996
[1359]
2992
[1357]
2989
[1356]
2986
[1354]
2983
[1353]
35582
[16140]
515-6SR
2984
[1354]
3035
[1377]
3086
[1400]
3137
[1423]
3188
[1446]
3240
[1470]
3296
[1495]
3243
[1471]
3190
[1447]
3136
[1423]
3083
[1398]
3030
[1374]
37648
[17077]
555-6SR
3368
[1528]
3308
[1500]
3247
[1473]
3187
[1446]
3126
[1418]
3066
[1391]
3122
[1416]
3181
[1443]
3239
[1469]
3297
[1496]
3356
[1522]
3414
[1549]
38912
[17651]
- 15 -
2.0 INSTALLATION
2.9 CONTROLS
2.10 REQUEST FOR STARTUP REPRESENTATIVE
2.9.1 CONNECTIONS
Controls which are to be field installed
should be connected in accordance with
the
appropriate
wiring
diagram
accompanying the unit. The following
connections should be made where
applicable:
1.) Connect a set of normally open
auxiliary contacts from chilled water
pump contactor into unit controls as
shown on unit wiring diagram.
2.) Install a chilled water flow switch
(paddle type recommended) (or
differential pressure switch) in straight
length of chilled water piping to avoid
turbulence. Connect in same electrical
circuit as ( 1.)
2.9.2 SETTINGS
All controls are factory set, however
operating control settings are not always
applicable under all operating conditions.
For recommended control settings, see
wiring diagram accompanying unit. Safety
controls must be set to factory
recommendations.
NOTE: WATER QUALITY - AFHX
Evaporators used in these packages are
made of steel, copper and brass and are
suitable for operation with wellmaintained water systems. However, if
the water used in evaporator is corrosive,
high in mineral content or entrained
solids, the water can cause reduced
performance and even failure of heat
exchangers. Therefore, it may be
necessary to obtain the services of a
water treatment consultant and to
provide and maintain water treatment.
This is particularly important with glycol
systems.
After the installation has been completed and

checked, Form 9180 must be filled out and sent to
the Dunham-Bush Service Department for
authorized start-up representative to perform the
initial start-up of the Dunham-Bush packaged
chiller. The purchaser will have competent
service and operating personnel in attendance to
assist in the work involved, and also to be trained
in the service and maintenance of this unit.
(During the warranty period, the manufacturer is
responsible for parts only upon proof of defective
workmanship or manufacture).
Following receipt of the signed Form 9180, a
representative will be sent to the customer. He
will inspect the installation to determine whether
it meets Dunham-Bush, Inc. requirements;
perform the initial start-up of the installation;
determine whether it is in satisfactory operating
condition; and instruct the specified customer
personnel in its operation and maintenance for the
length of time specified in the purchase contract.
NOTE: Sump oil heaters should be energized for
a minimum of 24 hours and the oil sump
temperature must be at a minimum of
100F [38C] prior to arrival of start-up
representative. This will ensure that the
oil is warm enough to vaporize any
dissolved refrigerant and that the oil is
within the normal operating temperature
range.
WARNING: The compressor(s) should be
started initially ONLY under the
direct supervision of an Authorized
Dunham-Bush,
Inc.,
Start-Up
Representative.
- 16 -
3.0 OPERATION
3.1 GENERAL
The unit should be started up only by a
refrigeration technician who is familiar with
accepted operation practices for refrigeration
systems.
Use small screw unit start-up report to record all
temperature, pressure, electrical readings and
control settings. A copy must be forwarded to
Dunham-Bush, Inc., before the warranty will be
honored.
pump contacts to start & stop this unit. These are

safety controls, not operational controls.
3.4.1 AIR COOLED PACKAGE

CHILLER START-UP
The unit is ready for start-up when the
following
procedures
have
been
completed.
1. Water piping for the evaporator is
installed and tested.
2. Electrical connections are made and
properly fused.
3. Unit has been leak tested. Leaks
corrected, and charge completed.
4. Compressor crankcase heater(s) has
been energized for a minimum of 24
hours.
5. Calibrated refrigerant gages have been
connected to the suction and discharge.
6. Turn on the chilled water pump, check
direction of rotation and adjust the
water flow through the evaporator to
the specified flow rate. Bleed off all
entrained air.
7. Manually energize the fan starters and
check the fan rotation. Fans should pull
air through the condenser coil and
discharge vertically upwards.
8. Check all refrigerant valves to be sure
they are open.
9. Proceed to System Start-up.
Compressor #1 will start in about 15
minutes & proceed to load up if leaving
water temperature is above setpoint.
Compressor #2 will follow as the demand
dictates.
3.2 UNIT PIPING

Each unit has a separate refrigerant circuit for
each compressor. See Figure 3.2 for typical unit
piping schematic.
3.3 SYSTEM
RATE
WATER
FLOW
The quantity of chilled water being circulated can

be measured quite accurately (5%) by
determining the water pressure drop through the
evaporator and reading GPM [m/hr] from the
evaporator pressure drop curve, Figure 3.3.
Connect reliable pressure gauges to valves
installed in evaporator entering and leaving water
vent connections and read pressure difference
with chilled water pump in operation. An
alternative method of determining GPM [m/hr] is
to measure pressure difference from pump inlet to
outlet and read GPM [m/hr] from pump curve.
However due to the quality of water at the jobsite,
the accuracy of the curve might vary. Conditions
such as water hardness, organic material,
suspended solids and water velocity may
contribute to a greater fouling. The quality of the
water could be maintained by chemical treatment
and periodical cleaning. The curve plotted is
based on a clean water system.
3.4 UNIT OPERATION

INCLUDING OVERNIGHT
SHUT-DOWN AND
MORNING RESTART
Caution: These units may equipped with
manifold installed manual discharge valve that
must be opened before attempting to start.
Important: Do not use chilled water pump
operation via the flow switch or Aux chilled water
3.5 SYSTEM START UP

1. Before starting the compressor(s), check all
three phases of supply voltage, of all legs of
the motor. They must be within 10% of the
nameplate voltage. Check to be sure
compressor is not running backwards.
2. Start compressor(s), check the gages and note
if the pressures are within the prescribed
limits.
3. Stage unit down until all compressors are off
and check the compressor crankcase sight
glass for oil level. It should be 1/2 to 3/4 of the
compressor sight glass.
- 17 -
3.0 OPERATION
FIGURE 3.2
1.)
TYPICAL PIPING SCHEMATIC
1 Compressor, 1 Evaporator
- 18 -
3.0 OPERATION
2.)
2 Compressors, 2 Evaporators
- 19 -
3.0 OPERATION
3.)
3 Compressors, 2 Evaporators
- 20 -
3.0 OPERATION
FIGURE 3.3
EVAPORATOR WATER PRESSURE DROP
AFHX 210-6SR
AFHX 220-6SR
AFHX 235-6SR
AFHX 260-6SR
AFHX 280-6SR
AFHX 310-6SR
AFHX 355-6SR
AFHX 405-6SR
AFHX 435-6SR
AFHX 555-6SR
AFHX 460-6SR
AFHX 515-6SR
- 21 -
3.0 OPERATION
4. The electrical control settings should be
checked and if necessary, reset to those
settings indicated on the wiring diagram.
Safety controls are factory set and must be
maintained at settings indicated on the wiring
diagram.
5. The temperatures of the chilled water both in
and out, should be checked to insure the unit is
operating within the desired temperatures.
3.6 SHUT-DOWN (OVERNIGHT

OR WEEKEND)
To shut down in the unit with compressors on or
off, turn each individual compressor switch. Do
not close any valve. The chilled water pump shall
then be turned off. Finally, do not open the main
unit disconnect. Main power is required to keep
the sump heaters.
Important: Discontinue chilled water
pump operation when unit is not
operational.
Note: For chillers operating in low
ambient, if it is possible that the overnight
ambient will drop below 45F [7C], it is
preferable to leave the chilled water pump
on.
3.7 SEASONAL SHUT-DOWN

PROCEDURE
Standard Ambient Units
1. Follow standard overnight shutdown procedure
2. Turn off chilled water pump
3. Close manual discharge valve
4. Close liquid valve on sealpot
5. If ambient temperature during the extended
shut-down period will not get below freezing,
the chilled water system may be left filled, If
the ambient temperature will be below
freezing, drain all water thoroughly, removing
all vent & drain plugs from both heads of the
evaporator, and blow out tubes will
compressed air to avoid serious stagnant water
corrosion.
6. Finally, it is recommended that an oil sample
be taken from each compressor & submitted
for lab analysis. Dunham-Bush offers this
service in its "Oil Kare" program. This
analysis should be done at the end of each
operating season or every 6 months if the unit

is used year round
The power supply to the unit may be deenergized to conserve energy. Just remember
that all heaters will now be inactive, and the
evaporator could freeze-up if not properly
drained.
3.8 SEASONAL
PROCEDURE
START-UP
l. Check fan drives for wear, rust, propeller

clearance, etc. and make necessary repairs &
adjustments. Grease main fan shaft bearings
with a good grade of EP ball bearing grease.
2. Check & clean condenser fin surface if
necessary. Use a warm water soap solution,
being careful not to bend fins. Comb out bent
fin areas.
3. Check all power supply connections at all
points, and all control terminal screws for
tightness.
4. Energize main power to unit & leave on for at
least 24 hours in order for compressors to
thoroughly warm up.
5. Start chilled water pump and verify correct
flow-rate glycol % if required. Bleed-off
system air if necessary.
6. Open main discharge valve in discharge
header.
7. Open liquid valve on sealpot.
8. Turn control circuit power switch on, and all
individual compressor circuit switches. Press
computer keyboard reset key (RST).
Compressors should start after start-up clock
times out and will come on in sequence to
satisfy the existing load.
3.9 SAFETY RELIEF VALVES

Each pressure vessel is protected by a safety relief
valve as required by ASME Code. Each
compressor is protected by a relief valve which is
vented to atmosphere. Never install any kind of
shut-off valve in a safety relief vent line.
3.10 REFRIGERATION CYCLE

-MULTIPLE COMPRESSOR
AFHX
Following is the normal sequence of operation for
a unit installed in a typical air conditioning
system. Refer to Figure 3.2, the typical piping
- 22 -
3.0 OPERATION
schematic for multiple compressor AFHX unit.
Each horizontal screw compressor discharges hot,
high pressure gas into a hot gas manifold through
an oil separator and is then split and routed into
the left-hand and right-hand side condenser where
it condenses, rejecting heat to the outdoor air
drawn through the coil by fans. The liquid
refrigerant from the condenser is drain out from
bottom of the condenser coil through liquid stop
valve into the economizer feed line.
The refrigerant flows through the economizer
feed ball valve, dropping its pressure, causing it to
flash. It then flows into the flash economizer tank
which is at an intermediate pressure between
condenser and evaporator Liquid is centrifugally
separated from the flash gas and the liquid drains
to the bottom of the tank, exits via the economizer
drain line, and passes through the economizer
drain ball valve. Both economizer ball valves are
actuated by a Modutrol motor that adjusts flow to
maintain an appropriate refrigerant level in the
evaporator, determined by a liquid level float
switch.
From the drain line, liquid refrigerant flows into
the flooded evaporator, where it boils, cooling the
water flowing inside evaporator tubes. Vapor
from the boiling refrigerant flows up the suction
pipes through a shut-off valve (optional), suction
check valve and suction filter (inside compressor)
into the compressor where it is compressed and
starts the cycle again.
Vapor flows from the top of flash economizer into
the compressor at the vapor injection port, which
feeds it into the compressor part way through the
compression process. Check valve prevents
backflow at shutdown in multi-compressor units.
All compressors operate in parallel on a common
evaporator and condenser.
3.11 FAN CYCLING

On start-up, all fan will remain off (some units
may have base fans which run together with
compressor). As the head pressure builds up, next
fan stage will start. Subsequently fan stage will
start if the head pressure continues to rise. Refer
wiring circuit diagram for number of fan stage.
system designed to feed refrigerant liquid into the

compressor to provide additional motor cooling as
required. The liquid injection control the
compressor discharge gas temperature below
158F[70C], the maximum discharge operating
temperature of these compressors.
3.13 HYDRAULIC CAPACITY

CONTROL SYSTEM
Each compressor has a hydraulic control system
to supply the proper force necessary to actuate the
slide valve, thereby regulating compressor
loading for maximum unit capacity. It is
composed of a normally closed solenoid valve
(SV1), a normally closed solenoid valve (SV2), a
slide valve, rod, cylinder and piston. The slide
valve and the piston are connected by the rod.
During start up, valve SV1 is energized while
valve SV2 is not energized. There will not be a
sufficient oil pressure in the cylinder to overcome
the opposing spring force. This starting position
of the side valve allows the maximum amount of
refrigerant to bypass the compression chamber i.e
25% of full load. This minimum load will require
low starting current which is important in
protecting the compressor motor. When loading,
valve SV1 is not energized while valve SV2 is
energized. Oil will flow into the cylinder, building
sufficient pressure to overcome the opposing
spring force causing the slide valve moving to the
right. This will increase the effective compression
volume in the compression chamber and hence
the refrigeration flow rate. As a result,
refrigeration capacity increases. When the
compressor is given a hold command, valve SV1
and SV2 are not energized. This will prevent oil
flow into or out of the cylinder causing the piston
to halt. During unloading, valve SV1 is energized
while valve SV2 is not energized. The spring
force will cause oil to bleed from the cylinder and
push the slide valve towards its original position.
3.12 LIQUID INJECTION

Each compressor is fitted with a liquid injection
- 23 -
SOLENOID
VALVE 1
SOLENOID
VALVE 2
Start
Energize
Not Energize
Loading
Not Energize
Energize
Unloading
Energize
Not Energize
Stable
Not Energize
Not Energize
4.0 ELECTRICAL
4.1 ELECTRICAL DATA
COMPRESSOR DATA
COND. FAN MOTOR DATA
UNIT ELECTRICAL DATA
AFHX
MODEL
MODEL
QTY
RLA
LRA
QTY
HP
FLA
FLA
MCA
MFS
210-6SR
HX1817
296
1635
12
4.3
348
422
700
220-6SR
HX1709
HX1711
1
1
149
177
730
845
6
6
2
2
4.3
4.3
378
422
500
235-6SR
HX1711
HX1711
1
1
177
177
845
845
6
6
2
2
4.3
4.3
406
450
600
260-6SR
HX1711
HX1811
1
1
177
205
845
915
6
8
3
3
5.5
5.5
459
510
700
280-6SR
HX1811
HX1811
1
1
205
205
915
915
8
8
3
3
5.5
5.5
498
549
700
310-6SR
HX1813
HX1813
1
1
217
217
1400
1400
8
8
3
3
5.5
5.5
522
576
700
355-6SR
HX1813
HX1816
1
1
217
281
1400
1495
8
10
3
3
5.5
5.5
597
667
800
405-6SR
HX1816
HX1816
1
1
281
281
1495
1495
10
10
3
3
5.5
5.5
672
742
1000
435-6SR
HX1817
HX1817
1
1
296
296
1635
1635
10
10
3
3
5.5
5.5
702
776
1000
460-6SR
HX1813
HX1813
1
2
217
217
1400
1400
8
12
3
3
5.5
5.5
761
815
1000
515-6SR
HX1816
HX1813
1
2
281
217
1495
1400
8
12
4
4
7.1
7.1
857
927
1200
555-6SR
HX1816
HX1816
HX1813
1
1
1
281
281
217
1495
1495
1400
8
12
4
4
7.1
7.1
921
991
1200
NOTES:
MCA MINIMUM CIRCUIT AMPACITY

MFS MAXIMUM FUSE SIZE
RLA - RATED LOAD AMPS AT ARI CONDITIONS
INR INRUSH AMPS
LRA - LOCKED ROTOR AMPS
4.2 WIRING DIAGRAM

Figure 4.2 are wiring diagrams for 2-compressor
unit control by Vision 2020i controller. This may
not be an accurate representation of your unit. It is
best to use the wiring diagram mounted in the
package control panel. A copy of that diagram is
furnished with the unit owners manual.
4.3 TYPICAL OPERATION

In order to start a compressor, the following
conditions must be met:
- system voltage above phase control relay (PCR)
setting
- chilled water pump running
- chilled water flow switch made
- compressor circuit breakers on
- customer unit control contact closed
- control switch and compressor switches on
- reset pressed on controller keypad
- power has been on the controller for 15 minutes

- all safety conditions satisfied
- leaving chilled water temperature 2F [1.1C]
or more above setpoint
A compressor is started by first energizing 1MC
followed by 1DC and 1SC. Anti-recycle time of
15 minutes is initiated within the computer at
start.
When the compressor starts, the controller
monitors amperage by means of 1CT, voltage
using 3T, leaving water temperature using TS,
and condensing pressure. These inputs are used to
control the loading and staging of the compressor.
The compressor's loading is controlled by pulsing
signals to the load and unload solenoids.
To shut down the unit automatically, the customer
control contacts must be opened. To shut down
the unit manually, simply shut off the compressor
switches. This will cause a no-run alarm that must
be reset to restart the compressor.
- 24 -
4.0 ELECTRICAL
FIGURE 4.2
TYPICAL WIRING DIAGRAM 2 Compressors
- 25 -
4.0 ELECTRICAL
- 26 -
4.0 ELECTRICAL
- 27 -
4.0 ELECTRICAL
- 28 -
4.0 ELECTRICAL
4.4 VISION 2020i
CONTROLLER AND
TERMINAL
4.4.1.1 The fifteen polycarbonate buttons:

a) Seven polycarbonate buttons at top
row
Vision 2020i controller is equipped with a user

friendly 132x64 pixels back-lit graphic display
terminal. It is connected with controller through
telephone cable. This terminal allows carrying out
all program operations. The user terminal allows
displaying the unit working conditions,
compressor run times, alarm history at any time
and modifying the parameters. The terminal also
has an automatically self-test of the controller on
system start-up. Multiple messages will be
displayed by automatically scrolling from each
message to the next. All of these messages are
spelled out in English language on the LCD
screen.
4.4.1
OPERATOR KEYPAD
The operator keypad consists of 15
polycarbonate buttons:
Figure 4.4.1 : Vision 2020i keypad
Button
Description
INPUT STATUS
Displays the analog inputs and

digital inputs status measured by
the probes/sensors.
OUTPUT
STATUS
Displays the relay outputs and

analog outputs status.
COMPRESSOR
STATUS
Displays the status of Compressor

1, 2 and so on.
SETPOINT
Displays the status of set points.
CLOCK/
SCHEDULE
Displays the date, time and day.
ALARM HISTORY
Display the alarm history.
AUTHORIZATION
To log in the level of passwords.
b) Eight polycarbonate
bottom row
Button
The top right Authorization button is

for password log in to gain authorization,
to the access setting menu.
The top left six operator buttons
functions are to view status only, except
the Setpoint button also allows setting
changes after gained authorization.
The three buttons at the bottom left are
to access different level of setting
changes.
These are 'User', 'Technician'
'Factory' levels, from left.
- 29 -
at
Description
USER
User Control Changeable Settings.
TECHNICIAN
Technician
Settings.
FACTORY
Factory Control Changeable Settings.
MENU
Unit information
Information.
ALARM RESET
Display the active alarms and to

perform alarm manual resets.
UP
Scroll the various screens when the

cursor is in the top left of the display.
If the cursor is inside a numeric field,
the button increases or decreases
the corresponding value. If the field is
a selection, pressing the button
displays the available options.
DOWN
See the UP arrow
ENTER
To move the cursor around the

screens and to save the values of the
set parameters
and
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.
buttons
Control
Changeable
Compressor
4.0 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:
The display is showing the data as
follows:
follows:
C1 Vapor Inj
Hot Gas Bypass
ANALOG INPUTS
Supply Temp
Return Temp
Suction Pres
Disch Press
044.8 F [07.1C]
055.6 F [13.2C]
073 PSI [05.2BAR]
179 PSI [12.9BAR]
Repeat the same steps to go to other

relay outputs screen:
Press down arrow key or input key to

go to next screen:
4.4.2.3 Compressor status key

follows:
ANALOG INPUTS
C1 Amps
C1 Disc T
OFF
OFF
101A
125.2F [51.8C]
To read compressor
compressor status key:
status
press

follows:
COMPRESSOR 1 STATUS

sensor inputs screen:
4.4.2.2 Output status key

To read relay outputs status press
output status key:

follows:
RELAY OUTPUTS
Comp 1 ON-LOAD
Alarm Status
OFF
Control Power
ON
SDD Control
OFF
C1 Liquid Inj
OFF
CW Pump
ON
- 30 -
Comp 1 OK
Amps= 100A
FLA1= 230A
Capacity= 025.5%
Status=ON-LOAD
Press down arrow key or press
compressor key to go to next screen:

follows:
COMPRESSOR 1 HISTORY 1
Today
Total
Run Hour
05
0006
Cycle
02
0006
Last On
04/24
19:06
Last Off
04/24
19:03
4.0 ELECTRICAL
4.4.2.4 Setpoint key:
REAL TIME CLOCK
To read the setpoint value press

setpoint key
Day
Time
Date

follows:
MONDAY
16:10
05/12/05
To set the date and time, you must be

authorized. See the authorization
procedure and log in at least as user
level.
Press enter key to select the date or
time to alter and use the up-down arrow
key to change the value and press enter
key to confirm.
SETPOINT 1
Supply Water Temp
Set point=
44.0 F [06.7C]
Dead band=
0.8 F [0.5C]
To alter setpoint data, you must be

authorized. See the authorization
procedure and you must be authorized
at least as user level.
Press enter key to select the setpoint to
alter and use the up-down arrow key to
change the value and press enter key to
confirm.
>
>
>
4.4.2.6 Alarm history key:

To view the unit alarm history press
alarm history key:

follows:
Press down arrow key or press

setpoint key to go to next screen:

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
ALARM HISTORY
001-C1 Starter
19:03
05/12/05
TR: 030.2 LWT: 64.3 [17.9]
DP: 191 [13.6]
SP: 076 [5.4]
Press down arrow key or press alarm
key to go to next screen for other alarm
history:
To clear alarm history, press input key

and authorization key together and then
press the alarm key again. Now the
display should be showing No alarm

follows:
- 31 -
4.0 ELECTRICAL
4.4.3 Authorization
Press down arrow key or user key to go

to next screen for other setpoint:
4.4.3.1 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
and press enter key to confirm.
The display is showing the current

access level as view only:
AUTHORIZATION
Please Enter your
Password
Repeat the above steps for others

setpoints.
PASSWORD= 0000
Status=View
Press enter key and use the up-down
arrow key to change the password
settings and press enter key to confirm.
4.4.5 TECHNICIAN KEY and MENU

4.4.5.1 Technician status key
This key is use to view and change the
compressor FLA setpoint, sensors
calibration, manually control digital
inputs and outputs, manually control
compressor. In order to gain access to
this button, you must be authorized and
log in at least as user level. See the
authorization section about this
procedure.
Now the authorization status change to

different access level.
4.4.4
Advanced user key and

menu
4.4.4.1 User Key

User key is use to view and change the
pressure, ampere safety limits and
liquid injection temperature setpoints,
unit of measurements. In order to gain
access to this button, you must be
authorized and log in at least as user
level.
4.4.5.2 Technician status key main

menu
Press technician key to go to
technician setpoints main menu:

follows:
Press the user key and display is
showing the data as follows:
USER SETPOINT 1
High Pressure Safety
Limits
Hold=
246PSI [17.0BAR]
Unload=
256PSI [17.7BAR]
Cutout=
270PSI [18.6BAR]
Technician Setpoints
Main Menu
Comp FLA Calibration
Sensor Calibration
Manual Control
Compressor Control
Sensors Override
Press enter key to move the cursor

to the sub-menu.
- 32 -
4.0 ELECTRICAL
follows:
Use up or down arrow key to move the

cursor to the desired 'Sensor
Calibration',
Main Menu
Sensor Calibration
Manual Control
Compressor Control
Sensors Override

follows:
Sensor Offset 1
Suction Press
Current =
076PSI [5.4BAR]
Average =
187PSI [8.6BAR]
24Hrs MAX = 200PSI [11.4BAR]
24Hrs MIN = 074PSI [4.6BAR]
Calibration = 00PSI [0.0BAR]
4.4.5.3 Compressor FLA Calibration:
To calibrate compressor FLA, press

down arrow key to go the sub-menu
'Comp FLA Calibration',
Press enter key to move the cursor to

calibrate the desired sensor and use the
up-down arrow key to change the value

follows:
Technician Setpoint 1
Comp 1 FLA CALIBRATION
211x00.66+97.80
FLA = 237A
Capacity C1 = 000.0%
Min. Percent Cal = 25.0%
Max. Percent Cal = 00A
Repeat the above steps for others

sensors calibrations.
4.4.5.5 Manual Control:
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:
A digital input sensor or relay output

can be controlled manually with the
keypad. Digital input sensor or relay
output can be turned on, off manually
and placed back to auto mode.
To place a digital input or relay output
in manual control, the operator must be
authorized at technician level or higher.
key three times to move the cursor to
the manual control sub-menu:

follows:

follows:

calibrate the comp FLA and use the updown arrow key to change the value
4.4.5.4 To perform Sensor Calibration:
Main Menu
Sensor Calibration
Manual Control
Compressor Control
Sensors Override
Main Menu
Sensor Calibration
Manual Control
Compressor Control
Sensors Override
- 33 -
4.0 ELECTRICAL
key four times to move the cursor to the
manual control sub-menu:

cursor to the desired digital input or
relay output,

follows:

follows:
Digital Inputs
Manual Control
C1 Starter=
Auto
C1 Oil Lvl=
Auto
Unit Enable=
Auto
Flow Switch=
Auto
Main Menu
Sensor Calibration
Manual Control
Compressor Control
Sensors Override

the desired point for manual control and
use the up or down arrow key to change
the status of the digital input or relay
output to AUTO/CLOSE/OPEN or
AUTO/ON/OFF.
Use down arrow key to move the cursor

to the desired compressor control
screen, then press enter key to move the
cursor to compressor status position,
AUTO /MAN/OFF

follows:

follows:
Compressor Control
Manual Override
COMPRESSOR 1=AUTO
St= 0005
Amps= 071.8
Capacity= 025.0%
Status = OFF
Relay Outputs
Manual Control
Alarm Relay
Auto
SDD Relay
Auto
Liquid Inj C1
Auto
CW Pump
Auto
Vap Inj Relay
Auto
Use up or down arrow key to select

MAN and press enter key to confirm
the change. The compressor will start
or continue to run in hold state. Press
the user key to continue hold, press the
technician key to load and factory key
to unload.
Press enter key to confirm the change.
4.4.5.6 Compressor Control:

Screw compressors can be controlled
manually with the keypad. A
compressor can be turned on, off, or
placed in computer control. When a
compressor is controlled manually, it
can be commanded to load, hold, or
unload. If safety limiting condition is
active, it will not accept a load
command.
To place a compressor in manual
control, the operator must be authorized
and log in as technician level and
higher.
Manual Hold
- 34 -
Manual Load
Manual Unload
If a safety condition is exceeded while

operating manually, the compressor
will shutdown.
CAUTION: Anti-recycle timer is
bypassed by manual control. DO NOT
start a compressor more than once
every 15 minutes.
4.0 ELECTRICAL
NOTE: All compressors will revert
back to automatic control if the
computer is the computer is not given a
load, unload, or hold command at least
once every 15 minutes. A command
can be repeated to meet the 15 minute
requirement for manual control.
To the change the settings of
compressor load/Unload, follow the
above steps and go to compressor
control. Use down arrow key to move
the following and press to change the
settings.
Sensors Manual
Override
Supply Water Temp
Man Reading = 45.0 F [7.2C]
Manual Override = NO

the Man Reading and use the up or
down arrow key to change the value of
the analog reading, press enter key
move the cursor to the Manual
Override to enable, or disable the
manual override control.
Load/Unload Control
Manual Pulse Settings
Pulse Rate=
001sec
Pulse Width=
001sec
Repeat the above steps for other sensors

override.
4.4.5.7 Sensors Override

Value of analog readings can be
temporary override during sensor
failure.
To override the analog readings, the
operator must be authorized at
technician level or higher.
key five times to move the cursor to the
Sensors Override sub-menu:
Caution: Sensors override require continuous

monitoring and observation by the field service
personnel at all time during the unit operation.
Faulty sensor shall be replaced as soon as possible
in order to allow the unit to be running in
automatic mode.
4.4.6
4.4.6.1 Chilled Water Pump Interlock

And Flow Switch (CWP And
CWFS)
These are field installed switches, both
of which are used to ensure chilled
water flow before the unit is allowed to
start. Failure of either one during
operation will cause the compressor to
shut down.
A water flow alarm will be generated
and Rest Alarm must be pressed to
clear the alarm.

follows:
Main Menu
Sensor Calibration
Manual Control
Compressor Control
Sensors Override
Control Functions
4.4.6.2 Customer Control Interlock

cursor to the desired analog reading,

follows:
- 35 -
Control contacts from an external

controller can be used to enable or
disable operation of the unit. The
wiring 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.
4.0 ELECTRICAL
that it loads at a predetermined rate.
This is a valuable tool, since it can help
reduce power consumption and demand
charges. Two variables are used to
define the ramp profile: Ramp rate and
start point. Ramp rate defines the length
of time the unit takes to load from start
point to full load. Start point is the
percent of full load at which the ramp
begins. The ramp rate A setpoint can be
set anywhere from 0.1 to 1.0, smaller
values producing slower loading rates.
The ramp start B setpoint can be set
anywhere between 0 and 50%. The
compressor will load quickly to this
value and then follow the ramp slope
from there. See Table 4.4.6.6 for ramp
rates at various settings.
4.4.6.3 Anti-Recycle Timer
The compressor motor requires an antirecycle time delay which prevents

restart for 15 minutes after a start. The
purpose of this feature is to avoid
frequent starts which tend to elevate the
motor winding temperature and impose
undue wear on contactors. The
controller will not restart the
compressor motor until the 15 minutes
have elapsed.
4.4.6.4 On Delay Timer
A Compressor on delay timer of one or

two minutes is incorporated to prevent
two compressors from starting at the
same time and ensures that the system
load requires another compressor. The
compressor output status will display
the timer count-down during this
timing.
4.4.6.7 Staging Control
On multiple-compressor machines,
when the controller 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 remaining compressors can control
water temperature.
4.4.6.5 Load Control
The controller controls the leaving

water temperature within a narrow
deadband by pulsing load and/ or
unload solenoids on the compressor.
The load and unload solenoids position
the slide valve within the compressor to
control its capacity. The controller
determines a desired level of loading
and varies pulse duration depending on
difference between load target and
actual load. The load target is varied
based on rate of approach to desired
temperature preventing significant
temperature oscillations. The status of
the compressor can be observed by
displaying the compressor control
point.
4.4.6.8 Modmotor Setback Control
A computer contact and a resistor are

wired in parallel in the modmotor
control circuit. The contact is controller
controlled to open under light load
conditions. This lowers liquid level
slightly, preventing excessive liquid
level in the evaporator.
4.4.6.9 Sump Heater Control
Each compressor is fitted with an oil

sump band-heater. The heater is
energized at all times when compressor
is off and de-energized when the
compressor is running.
Its purpose is to prevent refrigerant
migration into the oil during shut down.
For this reason, it is essential that
heaters be energized for 24 hours
before starting a compressor.
4.4.6.6 Ramp Control
Another feature of the controller is

ramp control, which is the ability to
vary load 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
full load quickly. With ramp control,
the user can program the computer so
TABLE 4.4.6.6 Ramp Rates for Several Setpoints (In Minutes)

Ramp
Rate
Setpoint
0.1
0.2
0.3
0.4
1 Comp.
Start Point Setpoint
2 Comp.
3 Comp
4 Comp
30%
50%
75%
30%
50%
75%
30%
50%
75%
30%
50%
75%
12.0
6.0
4.0
3.0
9.0
5.0
3.0
2.5
4.5
2.0
1.5
1.0
22.0
11.5
8.0
6.5
18.5
10.0
7.0
5.5
14.0
8.0
5.5
4.5
29.0
16.0
11.0
9.0
25.5
14.0
10.0
8.0
21.0
12.0
9.0
7.0
33.0
18.0
13.0
11.0
29.0
16.0
12.0
10.0
25.0
14.0
11.0
9.0
- 36 -
4.0 ELECTRICAL
pressure alarm will be recorded by the
controller. Reset by pressing the Reset
Alarm button on the controller.
Standard setpoint is 270psig[18.6BAR].
4.4.6.10 Suction/ Discharge Pressure

Differential Control
(SDD Control)
This control function seeks to prevent a
low differential pressure alarm. It
monitors the difference between
condenser and evaporator pressure. If
this difference is less than 25 psid
[1.7BAR] for more than 10 seconds,
and evaporator pressure is above 39
psig [2.7BAR], the controller will open
a set of contacts in the modmotor
circuit, causing valves to travel in the
closed direction. This starves the
evaporator, which increases pressure
difference. When this difference
exceeds 25 psid [1.7BAR], modmotor
control returns to normal.
CAUTION: Do not start compressor
manually more than once every 15
minutes. Verify that chilled water flow
switch is closed.
4.4.6.14 Optical Oil Level Sensor (LS)

An optical oil level sensor is located in
each compressor. If low oil indication
(digital input is OFF) persists for 60
seconds during compressor operation,
the controller 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 computer.
4.4.6.15 High Oil Temperature

Thermostat (12TAS)
A thermostat is located in each
compressor which will open the
compressor run circuit if oil
temperature exceeds 203F [95C]. The
high oil temperature pilot light will
indicate an excessive oil temperature
and a No-Run error will be recorded by
the computer. Reset is activated by
pressing the Reset Alarm button on
controller.
4.4.6.11 Evaporator Freeze Shutoff

If the leaving chilled water temperature
drops below the freeze setpoint, the
controller will shut down the unit and
store the freeze alarm. After solving the
problem, press Reset Alarm on the
controller to clear the alarm.
4.4.6.12 Low Pressure Cut-off

This function protects the unit from
operating at abnormally low evaporator
refrigerant pressure. The controller will
shut down the compressor when
evaporator pressure falls below the low
pressure setpoint and turn on the alarm
pilot light.
A low pressure alarm will be recorded
by the controller. Reset by pressing the
Reset Alarm button on the controller.
Standard setpoint is 28 psig [1.9BAR].
4.4.6.16 Overload Protector (M2OL)

A solid state overload protects each
compressor by three phase current
monitoring to prevent high current
draw. The trip setting is factory set and
is reset by pressing button on overload
after correcting problem. The Reset
Alarm button on controller must also
be pressed to clear the alarm. A no-run
error is stored in the controller.
4.4.6.17 Phase Control Relay (PCR)
4.4.6.13 High Pressure Cut-off

This function protects the compressor
from operating at abnormally high
discharge refrigerant pressures. The
controller will shut down the
compressor when condenser pressure
reaches the high pressure set point, and
turn on the alarm indicator lamp on the
control box. The high discharge
- 37 -
The PCR protects the unit from the

following electric supply malfunctions:
Undervoltage, phase reversal and single
phasing. If the PCR trips, a control
relay (lCR) will de-energize and open
the control circuit. A green LED
indicates presence of power supply.
The yellow LED indicates a good
voltage supply. The power loss setpoint
is factory set to AUTO to allow
4.0 ELECTRICAL
automatic start after PCR failure.
Compressor will not start for 15
minutes after failure. To select manual
reset, set power loss setpoint to
MANUAL. In this case, a power loss
alarm will be stored by the controller
and Reset Alarm must be pressed to
start.
4.4.6.18 Sensor Alarm

If the computer measures an analog
value (temperature, pressure.) that is far
beyond normal operating values, the
associated compressors are shutdown.
The computer then stores the alarm
code corresponding to the sensor alarm.
A sensor alarm indicates a problem in
the analog measurement system.
4.4.6.19 No-Stop Alarm

If the controller turns off a compressor,
but the compressor digital input does
not turn off, a No-Stop alarm is
generated. The computer will turn off
the control power relay which disables
all compressor control circuits and will
turn on the alarm light. This alarm
indicates a wiring or hardware error.
1. Adaptive Individual Air-cooled Condenser

Control
This type of control is based upon a single
compressor per circuit. The individual
discharge pressure on that circuit will be the
controlling pressure.
2. Adaptive
Air
Combined
Air-cooled
Condenser Control
This type of control is based upon a condenser
that is controlled by the highest discharge
pressure from any one of the compressors
sharing that circuit (compressor 1&2 - share;
compressor 3&4 - share). The highest
discharge pressure between the sharing
compressors will be the controlling pressure.
4.5.1
Air Cooled Condenser

Control Setpoints
The air-cooled condenser setpoints are as follows:

Setpoint COND Stage 1 ON - Condenser stage 1
on.
4.4.6.20 Low Differential Pressure

Alarm
For proper lubrication, a compressor
requires a 25 psid [1.7BAR] differential
pressure between condenser and
evaporator pressures. If the differential
pressure is less than 25 psid [1.7BAR]
for 3 minutes while a compressor is
operating, all compressors will be shut
down. The controller will store the low
differential pressure alarm code and
turn on the alarm light. The Reset
Alarm key must be pressed to clear the
alarm.
4.5
method of control is enhanced with adaptive, selflearning, fan control logic. The end result is
condenser control that offers significantly reduced
fan cycling and improved efficiency. The two
types of air-cooled condenser control logic are
explained as follows:
CONDENSER FAN
CONTROL LOGIC
If the differential pressure is less, the controller

provides two types of control logic for air-cooled
condensers. The type of control will be governed
by the physical condenser layout of the unit. Each
Setpoint COND Stage 2 OFF - Condenser stage 2

off.
Setpoint COND DIFF ON -
Differential
pressure for
additional
condenser stages.
Setpoint COND DIFF OFF -
Differential
pressure for
subtracting
condenser stages.
A compressor must be operating for the condenser

fans to operate. The condenser points (i.e. fans)
will turn on based upon the value in setpoint
COND Stage 1 ON. When the discharge pressure
exceeds this value, the first condenser point is
turned on. If additional condenser points exist,
they will be turned on when the pressure exceeds
the previous cut in value (COND Stage 1 ON for
the first stage) plus the value contained in COND
DIFF ON setpoint.
- 38 -
4.0 ELECTRICAL
Condenser points (i.e. fans) will be turned off
based upon the value in the setpoint COND ST2
OFF (COND Stage 2 turn OFF point). As the
discharge pressure is reduced, the condenser
points will be turned off based upon the COND
ST2 OFF setpoint, plus the value in the COND
DIFF OFF setpoint for each stage number above
stage 2. Stage 2 of condenser staging will be
turned off based upon the value in the setpoint
(COND ST2 OFF). See below for an example of
condenser staging.
4.5.2
4.5.3.1 Adaptive Control Logic

The controller enhances the condenser
control logic above with a unique,
adaptive, self-learning fan control logic.
These enhancement results in a control
scheme that offers reduced fan cycling
and improved efficiency. Adaptive
Control Logic automatically adjusts the
fan cut-in offset based upon the
following criteria:
1. If the last fan turned on (including
FAN 1) is cycled off in 10 minutes
or less, then a COND ON OFFSET
value will be incremented by 5 psig
[0.3 BAR]. This increases the fan 1
turn on value (COND ST1 ON plus
COND ON OFFSET) which in turn
increases all of the fan turn on
settings. This process will continue
until fan cycling ceases or the
adjusted turn on point for the last fan
stage is 217 psig [15.0BAR]. This
will also be a setpoint.
Increasing Condenser
Pressure
(Example of 4 stage fan cycling)

COND FAN1 ON when discharge pressure is >
140psig [9.7BAR] (COND Stage 1 ON setpoint)
156psig [10.8BAR] (COND Stage 1 ON plus
1xCOND DIFF ON setpoint values)
2. The cut-in offset (COND ON

OFFSET) will be decreased by 5
psig [0.3 BAR] if the last fan to be
turned on has not cycled off within 1
hour. The offset will continue to
decrease by 5 psig [0.3 BAR] every
10 minutes unless fan cycling begins
again.

And so on for the number of condenser fans
supplying the circuit.
4.5.3
The Adaptive Control Logic will only

affect the condenser fan turn on logic, it
will not affect the fan turn off logic.
Decreasing Condenser
Pressure
(4 fan example "continued")

COND FAN4 OFF when discharge pressure is <
124psig [8.5BAR] (COND Stage 2 OFF plus
2xCOND DIFF OFF setpoint values)
118psig [8.1BAR] (COND Stage 2 OFF plus
1xCOND DIFF OFF setpoint values)
112psig [7.7BAR] (COND Stage 2 OFF setpoint
value)
105psig [7.2BAR] (COND Stage 1 OFF setpoint
value)
4.6 Master/Slave Control

Sequence
The optional master/slave control sequence is
used to sequence multiple chillers in one
installation according to the building load
demand. It also controls the dedicated chilled
water pump or motorized valve.
Vision 2020i Controller offers this feature with
minimized field wiring cost compare to
conventional method that involves lots of
hardware cost. It is carried out this control
function
via
the
advanced
DBLAN
communication bus to implement the network
management for multiple chillers lead/lag
communication, sequencing and monitoring.
- 39 -
4.0 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
DB3
DBG1
DB3
DBG1
DBG1
DB3
DB3
DBG1
DB3
DBG1
DBG1
DB3
DB1
DB1
DB1
DB1
DB1
DB1
DB1
DB1
DB1
DB1
DB1
DB1
#1
#3
#2
#4
#5
#6
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
Manual lead/lag setpoint
Schedule and holiday setup
Alarm conditions
d) The lead/lag selection determine the chiller operation sequence as follows,
Lead chiller
selection
Normal chillers operation sequence
When DBLAN fails
1, 2 & 3 on duty, 4, 5 & 6 standby
1, 2 & 3 on duty
2, 3 & 4 on duty, 5, 6 & 1 standby
2, 3 & 4 on duty
3, 4 & 5 on duty, 6, 1 & 2 standby
3, 4 & 5 on duty
4, 5 & 6 on duty, 1, 2 & 3 standby
4, 5 & 6 on duty
5, 6 & 1 on duty, 2, 3 & 4 standby
5, 6 & 1 on duty
6, 1 & 2 on duty, 3, 4 & 5 standby
6, 1 & 2 on duty
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) Each chiller will require a dedicated chilled water pump or motorized valve digital output, unit
enable and chilled flow status digital inputs as well as enable next output command.
- 40 -
4.0 ELECTRICAL
4.6.2
Sequence Of Operation
1. When the customer enable input is on to

start the lead unit, the chilled water pump
starter or motorized valve control point will
close and water will start to flow through the
evaporator, this will activate the flow switch.
The flow switch and water pump status are
interlocked and feedback as digital input to
the chiller and upon receipt of a valid 'on'
signal, the lead chiller will begin to execute
its running program.
2. The controller will start and load the
compressor(s), upon achieving full load; it
will send an output signal via the DBLAN to
enable second unit (lag 1)
3. The second unit will now command its chilled
water pump to start if the customer unit
enable is activated. The second chiller will
start and load the compressor(s) until it
reaches full load
4. When the second chiller or lag 1 unit reaches
full load, it will enable the third chiller.
5. The chiller will keep cascading until all
chillers on duty are at full load.
6. If the leaving water temperature falls below
setpoint, all of the chillers will begin to
unload evenly.
7. If the load drops below 45% total capacity,
delay the last unit (lag 3) will be disabled, and
the remaining three units will load up to
compensate if necessary. The pump for chiller
4 will be shut off.
8. As the load demand falls, the lag 2 unit will
be disabled 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 having critical alarm, the lag 1
will take over as the master unit
automatically.
10. In order to enable next unit, the following
conditions must met
a) LWT (LWT Setpoint + Enable Next

deadband)
b) After a enable next time delay of 3
minutes (adjustable) and
c) When the lead units packaged capacity is
higher than Next on setpoint,
for example, WCFX2, %FLCP C1 & %FLCP C2
Next on setpoint
or it is being lockout by an alarm.
4.7
VISION 2020i LOCAL

AREA NETWORK
(DBLAN)
A DBLAN network is made up of several

chillers controller. Each units controller can be
programmed and connected to the local DBLAN
network that allows multiple units sequencing
control without additional hardware.
Every DBLAN node must be addressed to be
identified by the other nodes. Each address (an
integer number) must be unique in the network
for avoiding messages mismatch: in case two or
more nodes have the same identifying address the
network cannot work.
The max address number selectable is in the 1-16
for the Vision 2020i controller boards and 17-32
range for the Vision 2020i User terminal.
The three chiller unit combinations:
Controller with address of 1 connect to Terminal
with address of 17
with address of 18
with address of 19
Follow the following steps:
- 41 -
4.0 ELECTRICAL
4.8 NETWORK CONNECTION DIAGRAM
Adr:17
Vision 2020i
Terminal
Adr:18
Adr:19
Vision 2020i
Terminal
Vision 2020i
Terminal
Telephone Cable
Telephone Cable
Telephone Cable
J10
J10
J10
Adr:1
Vision 2020i
Controller
Adr:2
Vision 2020i
Controller
J11
J11
Adr:3
Vision 2020i
Controller
RS 485 Cable
J11
RS 485 Cable
max 500 meters
max 500 meters
The 6 core telephone cables (to J10 socket) are supply by the manufacturer.
The 3 core RS 485 data cables (to J11 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 SETTINGS

4.9.1
Change the display address setting to 0 as follow.
Addressing the Vision

2020i controller
Display address
Setting
At
the
Vision
2020i
terminal,
push
simultaneously the last three keys on the lower
right corner of the Vision 2020i terminal
keyboard. Push them for at least 5 seconds.
Vision 2020i
5 sec
Turn off DB3 controller.

At the Vision 2020i DBG1 terminal, hold
simultaneously the Alarm key and Up arrow
key, turn on DB3 controller and hold these keys
until Self Test mask is appeared.
This display will appear:

Display address
Setting
I/O Board address:
17
Vision 2020i
01
- 42 -
4.0 ELECTRICAL
controller address (for first chiller, it is 01) that
you 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 arrow key. Press Enter key to save and
exit.
PLAN Address : 1
Up : Increase
Down : Decrease
Enter : Save & Exit
Push enter to continue.

Then the display appears:
P:01
Trm1
Trm2
Trm 3
The terminal display will become blank after

Enter key is pressed. Please proceed to next
section on Addressing the Vision 2020i DBG1
Terminal.
4.9.2
Addressing the Vision

2020i DBG1 terminal
At the Vision 2020i DBG1 terminal, hold

simultaneously the last three keys on the lower
right corner of the Vision 2020i terminal
keyboard. Hold them for at least 5 seconds.
Display address
Setting
I/o Board address:
Display address
Setting
I/o Board address:
The display will appears:

:
Priv/Shared
Pr
Sh
--- OK? NO
Set Trm1, Trm2 and Trm3 to 17 Pr,32 Sh

and None ---, change the 'NO' to 'YES'(to
confirm and save) and press enter.
Note: Pr = Private, Sh = Share.
For multiple units with master-slave sequencing
control features, at the second chiller unit Vision
2020i terminal; repeat step 1 by holding the three
keys again. The display will appears:
Vision 2020i
5 sec
Adr
17
32
None
18
02
The address display (18) is the correct setup for

the second chiller unit with the controller address
of two (P:02).Press enter to confirm the settings
and the display will appears:
17
01
Terminal config
Press ENTER
To continue
The first line is the address of the terminal display

that you are using, (for first chiller, it is 17). The
next line allows you to select the Vision 2020i
- 43 -
4.0 ELECTRICAL
P:02
Trm1
Trm2
Trm 3
Adr
18
32
None
Priv/Shared
Pr
Sh
--- OK? NO
P:02
Trm1
Trm2
Trm 3
At the third chiller unit Vision 2020i terminal:

Press the three keys again, the display will
appears:
Display address
Setting
: 19
I/o Board address:

Adr
19
32
None
Priv/Shared
Pr
Sh
--- OK? NO
With the above settings, terminal with address 17

will only work with the controller with address 1,
terminal 18 will only work with the controller
with address 2, terminal 19 will only work with
the controller with address 3 and a terminal with
address 32 will work with both.
03
4.9.3
The address display (19) is the correct setup for
the third chiller unit with the controller address of
three(P:03).Press enter to confirm the setting
and the display will appears:
Terminal config
Press ENTER
To continue
Vision 2020i
LED Status
Controller
Vision 2020i controller have three LEDs between

the J3 and J4 connectors 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,
then LED configuration is among those listed
below.
Table 4.9.3
LED
LED Status
STATUS
DESCRIPTION
ON
Vision 2020i controller is synchronized with all the other DBLAN nodes.
The node is working correctly.
OFF
Vision 2020i controller is not network connected or it doesnt receive any signal from the DBLAN
GREEN
BLINKING
Vision 2020i controller is transmitting data to other network nodes.
YELLOW
RED
OFF
Vision 2020i controller is not transmitting messages.
OFF
No hardware and software problem.
ON
Vision 2020i controller software not compatible or variables database not correct, contact DunhamBush Service Personnel.
BLINKING
Vision 2020i hardware is not compatible - Ram is smaller than 32 KB.

The Vision 2020i controller is just for working in stand-alone mode.
- 44 -
5.0 MAINTENANCE
5.1 GENERAL
heat transfer surfaces can be detected by

recording full load performance data on
the log sheet. The best measure of
performance of evaporator is approach,
which is the difference between leaving
water
temperature
and
saturated
refrigerant temperature at the pressure in
the vessel. At full load, read evaporator
pressure and leaving chilled water
temperature on the computer. Then use
Table 5.4.2 to find saturated temperature
in evaporator. Then calculate approaches
as follows:
As with all mechanical equipment, a program of

regular inspection, cleaning and preventive
maintenance by trained personnel will contribute
greatly to the long satisfactory service life of this
product.
5.2 PERIODIC INSPECTION

Read essential temperatures and pressures
periodically to see that they indicate normal
operation. It is a good idea to record these
readings on a log sheet. If any abnormal operation
is observed, try to remedy it. See Trouble
Shooting Guide Section.
Evaporator Approach = T lvg chilled

water - T sat evaporator
If the approach increases by more than
2F [1.1C] above the approach recorded
at clean conditions, the tubes should be
cleaned. It is generally advisable to clean
the waterside surfaces at least annually
and more often if severely foul water is
used. In chemical cleaning, a caustic
solution is pumped through the heat
exchanger, which attacks dirt, slime and
mineral deposits and flushes then away.
Chemicals can be recommended by water
treatment specialists, but it is important to
rinse the system thoroughly after cleaning
to remove the chemicals before they
attack the metal surfaces.
5.3 MONTHLY INSPECTION

Remote dirt and debris from condenser coil. Shut
unit down, open main disconnect, inspect control
panel, checking for loose wires, burned contacts,
signs of overheated wires, etc. Restart unit and
check performance of controls. Check sight
glasses for proper refrigerant charge, see
charging.
5.4 VESSEL MAINTENANCE

5.4.1 GENERAL
The efficient performance of the
evaporator and condenser heat transfer
surfaces is essential for efficient
performance of your packaged water
cooling machine. If these surfaces
accumulate a film of dirt, scale or slime,
their performance efficiency will degrade
substantially. The refrigerant side of heat
transfer surfaces does not foul since
refrigerant is a good solvent and it is in a
closed, filtered cycle. Waterside surfaces
can foul from the water system. A
program of water treatment can slow the
rate of fouling on heat transfer surfaces,
but not eliminate it.
5.4.2 WATER SIDE CLEANING OF

EVAPORATOR
The effects of fouling of the evaporator
5.5 AIR COOLED

CONDENSER CLEANING
The face of the condenser should be cleaned at
least once month during operation. If conditions
are bad and condensers pick up dirt very quickly,
it is suggested that they can be cleaned more
frequently. If the condenser is allowed to get too
dirty, the unit will run at high head pressure and
will not give satisfactory performance.
Dirty coils can be cleaned using a soft brush or by
flushing with cool water or commercially
available coil cleaners. DO NOT USE HOT
WATER OR STEAM. To do so will cause
excessive pressure in the system. The face of the
condenser should be cleaned at the beginning of
the season and periodically thereafter if
conditions require.
- 45 -
5.0 MAINTENANCE
TABLE 5.4.2 R134a PRESSURE/ TEMPERATURE PROPERTIES
PRESS
PSIG
KPA
TEMP.
F
PRESS
PSIG
KPA
TEMP.
F
PRESS
PSIG
TEMP.
KPA
PRESS
PSIG
KPA
TEMP.
F
PRESS
PSIG
KPA
TEMP.
F
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
46.11
212.00
1563.45 134.10 56.72
1.00
108.28 -12.00
-24.44
54.00
473.79 57.70
14.28 107.00 839.31
91.50
33.06
160.00 1204.83 115.40
46.33
213.00
1570.34 134.40 56.89
2.00
115.17
-9.50
-23.06
55.00
480.69 58.50
14.72 108.00 846.21
92.00
33.33
161.00 1211.72 115.80
46.56
214.00
1577.24 134.70 57.06
3.00
122.07
-7.10
-21.72
56.00
487.59 59.30
15.17 109.00 853.10
92.50
33.61
162.00 1218.62 116.20
46.78
215.00
1584.14 135.10 57.28
4.00
128.97
-4.80
-20.44
57.00
494.48 60.10
15.61 110.00 860.00
93.00
33.89
163.00 1225.52 116.60
47.00
216.00
1591.03 135.40 57.44
5.00
135.86
-2.60
-19.22
58.00
501.38 60.90
16.06 111.00 866.90
93.50
34.17
164.00 1232.41 117.00
47.22
217.00
1597.93 135.70 57.61
6.00
142.76
-0.50
-18.06
59.00
508.28 61.60
16.44 112.00 873.79
94.00
34.44
165.00 1239.31 117.40
47.44
218.00
1604.83 136.00 57.78
7.00
149.66
1.50
-16.94
60.00
515.17 62.40
16.89 113.00 880.69
94.50
34.72
166.00 1246.21 117.70
47.61
219.00
1611.72 136.40 58.00
8.00
156.55
3.50
-15.83
61.00
522.07 63.10
17.28 114.00 887.59
95.00
35.00
167.00 1253.10 118.10
47.83
220.00
1618.62 136.70 58.17
9.00
163.45
5.30
-14.83
62.00
528.97 63.90
17.72 115.00 894.48
95.50
35.28
168.00 1260.00 118.50
48.06
221.00
1625.52 137.00 58.33
10.00 170.34
7.20
-13.78
63.00
535.86 64.60
18.11 116.00 901.38
96.00
35.56
169.00 1266.90 118.90
48.28
222.00
1632.41 137.30 58.50
11.00 177.24
8.90
-12.83
64.00
542.76 65.30
18.50 117.00 908.28
96.50
35.83
170.00 1273.79 119.30
48.50
223.00
1639.31 137.60 58.67
12.00 184.14
10.60
-11.89
65.00
549.66 66.00
18.89 118.00 915.17
97.00
36.11
171.00 1280.69 119.70
48.72
224.00
1646.21 138.00 58.89
13.00 191.03
12.30
-10.94
66.00
556.55 66.80
19.33 119.00 922.07
97.50
36.39
172.00 1287.59 120.00
48.89
225.00
1653.10 138.30 59.06
14.00 197.93
13.90
-10.06
67.00
563.45 67.50
19.72 120.00 928.97
98.00
36.67
173.00 1294.48 120.40
49.11
226.00
1660.00 138.60 59.22
15.00 204.83
15.50
-9.17
68.00
570.34 68.20
20.11 121.00 935.86
98.40
36.89
174.00 1301.38 120.80
49.33
227.00
1666.90 138.90 59.39
16.00 211.72
17.00
-8.33
69.00
577.24 68.90
20.50 122.00 942.76
98.90
37.17
175.00 1308.28 121.20
49.56
228.00
1673.79 139.20 59.56
17.00 218.62
17.50
-8.06
70.00
584.14 69.50
20.83 123.00 949.66
99.40
37.44
176.00 1315.17 121.50
49.72
229.00
1680.69 139.50 59.72
18.00 225.52
20.00
-6.67
71.00
591.03 70.20
21.22 124.00 956.55
99.90
37.72
177.00 1322.07 121.90
49.94
230.00
1687.59 139.80 59.89
19.00 232.41
21.40
-5.89
72.00
597.93 70.90
21.61 125.00 963.45 100.30
37.94
178.00 1328.97 122.30
50.17
231.00
1694.48 140.10 60.06
20.00 239.31
22.80
-5.11
73.00
604.83 71.60
22.00 126.00 970.34 100.80
38.22
179.00 1335.86 122.60
50.33
232.00
1701.38 140.40 60.22
21.00 246.21
24.10
-4.39
74.00
611.72 72.20
22.33 127.00 977.24 101.30
38.50
180.00 1342.76 123.00
50.56
233.00
1708.28 140.80 60.44
22.00 253.10
25.40
-3.67
75.00
618.62 72.90
22.72 128.00 984.14 101.70
38.72
181.00 1349.66 123.40
50.78
234.00
1715.17 141.10 60.61
23.00 260.00
26.70
-2.94
76.00
625.52 73.50
23.06 129.00 991.03 102.20
39.00
182.00 1356.55 123.70
50.94
235.00
1722.07 141.40 60.78
24.00 266.90
28.00
-2.22
77.00
632.41 74.20
23.44 130.00 997.93 102.70
39.28
183.00 1363.45 124.10
51.17
236.00
1728.97 141.70 60.94
25.00 273.79
29.20
-1.56
78.00
639.31 74.80
23.78 131.00 1004.83 103.10
39.50
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
27.00 287.59
31.70
-0.17
80.00
653.10 76.10
24.50 133.00 1018.62 104.00
40.00
186.00 1384.14 125.20
51.78
239.00
1749.66 142.60 61.44
28.00 294.48
32.80
0.44
81.00
660.00 76.70
24.83 134.00 1025.52 104.50
40.28
187.00 1391.03 125.50
51.94
240.00
1756.55 142.90 61.61
29.00 301.38
34.00
1.11
82.00
666.90 77.30
25.17 135.00 1032.41 104.90
40.50
188.00 1397.93 125.90
52.17
241.00
1763.45 143.20 61.78
30.00 308.28
35.10
1.72
83.00
673.79 78.00
25.56 136.00 1039.31 105.30
40.72
189.00 1404.83 126.30
52.39
242.00
1770.34 143.50 61.94
31.00 315.17
36.20
2.33
84.00
680.69 78.60
25.89 137.00 1046.21 105.80
41.00
190.00 1411.72 126.60
52.56
243.00
1777.24 143.80 62.11
32.00 322.07
37.30
2.94
85.00
687.59 79.20
26.22 138.00 1053.10 106.20
41.22
191.00 1418.62 127.00
52.78
244.00
1784.14 144.10 62.28
33.00 328.97
38.40
3.56
86.00
694.48 79.80
26.56 139.00 1060.00 106.70
41.50
192.00 1425.52 127.30
52.94
245.00
1791.03 144.40 62.44
34.00 335.86
39.50
4.17
87.00
701.38 80.40
26.89 140.00 1066.90 107.10
41.72
193.00 1432.41 127.70
53.17
246.00
1797.93 144.70 62.61
35.00 342.76
40.50
4.72
88.00
708.28 81.00
27.22 141.00 1073.79 107.50
41.94
194.00 1439.31 128.00
53.33
247.00
1804.83 145.00 62.78
36.00 349.66
41.50
5.28
89.00
715.17 81.50
27.50 142.00 1080.69 108.00
42.22
195.00 1446.21 128.40
53.56
248.00
1811.72 145.30 62.94
37.00 356.55
42.50
5.83
90.00
722.07 82.10
27.83 143.00 1087.59 108.40
42.44
196.00 1453.10 128.70
53.72
249.00
1818.62 145.60 63.11
38.00 363.45
43.50
6.39
91.00
728.97 82.70
28.17 144.00 1094.48 108.80
42.67
197.00 1460.00 129.10
53.94
250.00
1825.52 145.90 63.28
39.00 370.34
44.50
6.94
92.00
735.86 83.30
28.50 145.00 1101.38 109.20
42.89
198.00 1466.90 129.40
54.11
251.00
1832.41 145.20 62.89
40.00 377.24
45.50
7.50
93.00
742.76 83.90
28.83 146.00 1108.28 109.70
43.17
199.00 1473.79 129.70
54.28
252.00
1839.31 146.40 63.56
41.00 384.14
46.40
8.00
94.00
749.66 84.40
29.11 147.00 1115.17 110.10
43.39
200.00 1480.69 130.10
54.50
253.00
1846.21 146.70 63.72
42.00 391.03
47.40
8.56
95.00
756.55 85.00
29.44 148.00 1122.07 110.50
43.61
201.00 1487.59 130.40
54.67
254.00
1853.10 147.00 63.89
43.00 397.93
48.30
9.06
96.00
763.45 85.60
29.78 149.00 1128.97 110.90
43.83
202.00 1494.48 130.80
54.89
255.00
1860.00 147.30 64.06
44.00 404.83
49.20
9.56
97.00
770.34 86.10
30.06 150.00 1135.86 111.30
44.06
203.00 1501.38 131.10
55.06
256.00
1866.90 147.60 64.22
45.00 411.72
50.10
10.06
98.00
777.24 86.70
30.39 151.00 1142.76 111.80
44.33
204.00 1508.28 131.40
55.22
257.00
1873.79 147.90 64.39
46.00 418.62
51.00
10.56
99.00
784.14 87.20
30.67 152.00 1149.66 112.20
44.56
205.00 1515.17 131.80
55.44
258.00
1880.69 148.20 64.56
47.00 425.52
51.90
11.06
100.00 791.03 87.80
31.00 153.00 1156.55 112.60
44.78
206.00 1522.07 132.10
55.61
259.00
1887.59 148.50 64.72
48.00 432.41
52.70
11.50
101.00 797.93 88.30
31.28 154.00 1163.45 113.00
45.00
207.00 1528.97 132.40
55.78
260.00
1894.48 148.70 64.83
49.00 439.31
53.60
12.00
102.00 804.83 88.80
31.56 155.00 1170.34 113.40
45.22
208.00 1535.86 132.80
56.00
261.00
1901.38 149.00 65.00
50.00 446.21
54.40
12.44
103.00 811.72 89.40
31.89 156.00 1177.24 113.80
45.44
209.00 1542.76 133.10
56.17
262.00
1908.28 149.30 65.17
51.00 453.10
55.30
12.94
104.00 818.62 89.90
32.17 157.00 1184.14 114.20
45.67
210.00 1549.66 133.40
56.33
263.00
1915.17 149.60 65.33
52.00 460.00
56.10
13.39
105.00 825.52 90.40
32.44 158.00 1191.03 114.60
45.89
211.00 1556.55 133.80
56.56
264.00
1922.07 149.90 65.50
NOTE : PRESSURE AND TEMPERATURE ARE STATED IN PSIA(KPA) AND F(C) RESPECTIVELY.
- 46 -
5.0 MAINTENANCE
5.6 ELECTRICAL
MALFUNCTION
any operating condition, the circuit is short
The unit has four devices designed to protect
Be careful not to overcharge the machine.
compressor motors and manual motor controllers
overcharging will result in considerable
from electrical malfunctions: Circuit breakers,
liquid logging in the condenser, and
starter overload relays, under voltage relay, and
excessive condensing pressure.
of charge.
motor over temperature protectors (optional).
To add refrigerant, connect a refrigerant
If the under voltage relay trips, it is a sign of
vessel to the 1/4" back seating port of the
trouble in incoming power. If it trips again after
suction valve. Purge the air from the tube
resetting, call your electric utility to investigate
with refrigerant gas before connecting.
the problem. If circuit breaker or motor overload
With the unit running, open the refrigerant
relay or motor over temperature protectors trip,
vessel vapor connection slightly. If the
this is a sign of possible motor trouble. DO NOT
refrigerant vessel is warmer than the
reset and try to run compressor again. Call
evaporator, refrigerant will more readily
authorized service representative to check for
flow from the vessel into the unit.
motor trouble. Resetting these safety devices and

repeated starting could turn a minor motor
problem into a costly major motor burnout.
5.8 OIL CHARGE

The proper oil charge is in the unit as supplied
5.7 REFRIGERANT CHARGE
from the factory. Any operating compressor

should show oil return and oil overflow at all
5.7.1 GENERAL
time. If for some reason, a compressor runs low
All packaged chiller units are given a
on oil, a low oil level switch in the compressor
complete charge of refrigerant at the
will shut it down before any damage is done. In
factory.
of
the event of a low oil shutdown, call a D/B
Physical
authorized service agent to correct the problem.
refrigerant
The
type
required
and
is
amount
in
Specifications. The total refrigerant shown

is for the entire system. Since these units
have separate circuits, each circuit should
DO NOT ADD OIL TO THE SYSTEM.

Note:
be considered separately for charging.
Only DB 18 oil may be used in this

package. Use of other oil is not
approved by Dunham-Bush, and will
In order to check proper refrigerant charge,

look in each liquid line sight glass with the
aid of a flashlight during system operation.
At all operating conditions, the sight glass
should be clear. If bubbles are visible at
- 47 -
result in poor performance of the

package. It is recommended to
change oil annually to prolong
the compressor life-time.
5.0 MAINTENANCE
5.9 TROUBLESHOOTING
SYMPTOM
1. Unit will not
start.
POSSIBLE CAUSE
a.) Power off.
b.) No control power.
c.) Compressor circuit
breakers open.
d.) Phase control relay open.
e.) Flow Switch open.
f.) Compressor switch open.
g.) Controller shutdown not
reset.
2. Compressor
hums but does
not start.
a.) Low voltage.
b.) No power on one phase of

3 phase unit.
c.) Faulty starter or contactor.
3. Compressor will
not start when
reset button is
pushed.
REMEDY
a.) Check main disconnect switch and main line fuses.
b.) Check control transformer fusing.
c.) Close circuit breakers. If trip, check compressor.
d.) Check for power supply problems ( low voltage, phase
imbalance). When corrected, press reset button.
e.) Start pumps, check flow switch.
f.) Turn switch on. Check alarm status. Correct problem.
g.) Press reset button.
a.) Check at main entrance and at unit. Consult power
company if voltage is low and increase wire size to the
unit if voltage is normal at main and low at unit.
Voltage must be within 10% of motor nameplate
rating.
b.) Check fuses and wiring.
c.) Check the contacts and time delay on part wind start.
a.) Cooling not required.

b.) Computer's time delay
active.
c.) Phase control relay open.
d.) Flow switch open.
e.) Compressor switch open.
f.) Burned out signal light.
i.) Wiring problem
a.) Apply load.

b.) Wait 15 minutes max.
4. Compressor
overload.
a.) Compressor drawing high

amps.
a.) Check motor megohms. Reset overloads; run

compressor an check amps. Do not exceed RL x 1.25.
Call D/B serviceman.
5. High motor
temperature
a.) Motor windings failing.
a.) Check megohms. Reset by turning compressor switch

off and then on.
6. Low suction
a.) Inadequate feed to

evaporator.
b.) Inadequate refrigerant
charge.
c.) Fouling of waterside of
evaporator.
a.) Check to see that main expansion valve superheat.
Check light:
None
d.) Inadequate chilled water

flow.
e.) Too much oil in system.
c.) See 1.( d.) above.

d.) See 1.( e.) above.
e.) See 1.( f.) above.
f.) Check signal light bulbs.
i.) Check wiring against drawing.
b.) See information on charging in Section 5.7.

c.) At high load, check evaporator approach (See Section
5.4). If approach is more than 2F [1.1C] above clean
valve, fouling is probably the trouble. Clean tube.
d.) Measure pressure drop across vessel and determine
flowrate from Figure 3.3. If flow rate is low, check
chilled water pump, valves and strainers.
e.) If all oil level sight glasses are full at all times, remove
oil until oil level shows at top of glass on a
compressor.
7. High discharge
pressure.
a.) Inadequate air flow across

condenser
a.) Check condenser fan operation and condenser coil for

clogging.
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 5.8.
10. Freeze warning.
a.) Operating setpoint too low.

b.) Load changing too rapidly.
a.) Check leaving water setpoint on controller.

b.) Load on package must drop at reasonable rate for
automatic control to work properly.
11. Improper
capacity control.
a.) Ramp rate incorrect.
a.) See Section 4.4.6.5.
- 48 -
5.0 MAINTENANCE
5.10 SAMPLE LOG SHEET
SHEET NO............................
DUNHAM-BUSH SCREW COMPRESSOR PACKAGED CHILLER

NAMEPLATE DATA:
UNIT MODEL NO. ........................................................ UNIT NO. ....................................VOLTS: ............................ Hz ..................
UNIT SERIAL NO. ........................................................ COMPRESSOR MODEL NOS. ....................................................................
START UP :
DATE .......................................... TIME....................................................
DATE
TIME
ELAPSED TIME METERS
COMP. NO.
1.
2.
SUCTION PRESSURE
3.
4.
1.
2.
DISCHARGE PRESSURE
3.
4.
1.
2.
DISCHARGE TEMPERATURE
3.
4.
1.
2.
DISCHARGE SUPERHEAT
(DISC. TEMP.-SAT. DISCH.)*
3.
4.
1.
2.
DISCHARGE SUPERHEAT
(DISC. TEMP.-SAT. SUCT.)*
3.
4.
EVAPORATOR WATER TEMPERATURE-IN

EVAPORATOR WATER TEMPERATURE-OUT
EVAPORATOR PRESSURE DROP
FTWG [KPA]
EVAPORATOR WATER FLOW
GPM[M/HR]
CONDENSER AIR TEMPERATURE-IN

(AMBIENT) AC ONLY
1.
ACTUAL VOLTAGE
COMPRESSOR AMPS
2.
3.
4.
FAN AMPS
VOLTS
*USE TABLE 5.4.2 FOR OBTAINING SATURATED TEMPERATURE

THIS LOG SHEET IS PROVIDED AS A RECOMMENDATION OF THE READINGS THAT SHOULD BE TAKEN ON A PERIODIC BASIS. THE
ACTUAL READINGS TAKEN AND THE FREQUENCY WILL DEPEND UPON THE UNITS APPLICATION, HOURS OF USE, ETC. THIS TYPE OF
INFORMATION CAN PROVE VERY USEFUL IN PREVENTING AND/ OR SOLVING PROBLEMS THAT MIGHT OCCUR DURING THE LIFE OF
THE UNIT.
- 49 -
Products that perform...By people who care
(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
www.dunham-bush.com
Manufacturer reserves the right to change specifications without prior notice.
Corporate Head Office

DUNHAM-BUSH HOLDING BHD

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Form No: MM0463A

Products that perform...By people who care

Product Identification. ......................................................... 3

4.4.5.2 Technician status key- main menu ......... 32

SCHEMATIC DIAGRAM, GRAPH AND TABLE

Typical Rigging ......................................................... 7

Physical Specifications ............................................... 5

1.1 PRODUCT IDENTIFICATION

Air Cooled Chiller

Horizontal Screw Compressor

AFHX Standard R134a 60Hz IOM Manual

MIN. % UNIT CAPACITY REDUCTION

MIN/ MAX WATER FLOW

MIN/ MAX WATER PD

COIL ROWS DEEP/ TOTAL FA (SQ.FT)

MOTOR kWI (QTY)

FLA, AMP (QTY)

MIN. AMBIENT TEMP. (F) AT MIN. LOAD

UNIT MAX. INRUSH

OPERATING CHARGE R134a

AFHX Standard R134a 60Hz IOM Manual

MIN. % UNIT CAPACITY REDUCTION

L2R (1), M2R (1)

L3R (1), M2R (1)

L3R (1), M3R (1)

MIN/ MAX WATER FLOW

MIN/ MAX WATER PD

COIL ROWS DEEP/ TOTAL FA (SQ.FT)

MOTOR kWI (QTY)

FLA, AMP (QTY)

MIN. AMBIENT TEMP. (F) AT MIN. LOAD

UNIT MAX. INRUSH

OPERATING CHARGE R134a

AFHX Standard R134a 60Hz IOM Manual

1.) Check all crates and cartons received against

Packaged chillers are designed to cool water or

2.1.1 APPLICATION PRECAUTIONS

2.1.2 CHILLED WATER FLOW

2.3.2 RIGGING AND MOVING

AFHX Standard R134a 60Hz IOM Manual

AFHX Standard R134a 60Hz IOM Manual

the condenser, and removal of heated air

FIGURE 2.4.1 TYPICAL SPACE REQUIREMENTS

AFHX Standard R134a 60Hz IOM Manual

Double Pit (See Note 2)

2.) Pit installations are not recommended. Re-circulation of hot

AFHX Standard R134a 60Hz IOM Manual

AFHX 220-6SR, 235-6SR

NOTE : ALL DIMENSIONS ARE IN INCHES(MM).

AFHX Standard R134a 60Hz IOM Manual

NOTE : ALL DIMENSIONS ARE IN INCHES(MM).

AFHX Standard R134a 60Hz IOM Manual

AFHX 460-6SR, 515-6SR, 555-6SR

NOTE : ALL DIMENSIONS ARE IN INCHES(MM).

AFHX Standard R134a 60Hz IOM Manual

2.6 VIBRATION ISOLATION

2.7 PIPING CONNECTIONS

removable access panel at the end of the unit.

2.8 ELECTRICAL WIRING