ACDS-B Air-Cooled Chillers with Tandem Scroll Compressors 14 to 100 Tons aaaaa Features • March 2004 Form No.
INTRODUCTION Direct Drive Fans PC Windows® Based Microcomputer Standard All Models Optional Unit Disconnect Modular Design with common components throughout the line Optional Electronic Expansion Valves Replaceable Filter Drier Tandem Scroll Compressors The Dunham-Bush Commitment...
TABLE OF CONTENTS Page No. Introduction ................................................................................................................................................... 2 Nomenclature ....................................................................................................................................................... 3 Standard Features and Owner Benefits .......................................................................................................
STANDARD FEATURES AND OWNER BENEFITS Size Range • 19 Models from 14 to 100 Tons • High Unit EER at ARI Standard Conditions • Rated with HCFC-22 Quiet Operation • Standard quiet Scroll operation with 1140 RPM fans • Optional Extra Quiet Operation with Scroll Compressors and Extra Quiet 855 RPM Fans Compressor • • • • • Reliable Hermetic Tandem Scroll Type at 3500 RPM (2) Refrigerant Circuits over 25 Tons for Redundancy Compressor Cycling of 2 compressors on single circuit units up to 30 tons Compressor
UNIT FEATURES: SCROLL COMPRESSORS Unit Base Sub-Assembly with Tandem-Scroll Compressor Set Piped and Wired Figure 2 ACDS-B Packaged Chillers use Tandem Scroll Scroll Compressor Technology has developed Compressors. These rugged Commercial / Industrial Grade Scroll Compressors are designed and manufactured to meet the duty that our equipment demands. The construction includes cast iron frame and scroll sets, Teflon impregnated bearings and oil filtration devices internal to each compressor.
UNIT FEATURES: SCROLL COMPRESSORS (CONT.) Scroll Compressor Design is based around two identical spirals or scrolls that, when inserted together, form crescent-shaped compression pockets. During a compression cycle, one scroll remains stationary while the other orbits around the first. As this motion occurs, gas is drawn into the scrolls and moved in increasingly smaller pockets toward the center.
UNIT FEATURES: SCROLL COMPRESSORS (CONT.) Scroll Compressors have much better liquid Capacity Control Modulation is managed by the refrigerant handling capability than other types of compressors due to the nature of scroll design. Microcomputer Controller in units response to system load requirements. The system load requirements are measured by sensing the chiller's leaving fluid temperature and staging the compressors accordingly.
UNIT FEATURES: SCROLL COMPRESSORS (CONT.
UNIT FEATURES: AIR COOLED CONDENSERS All units have direct drive propeller fans and motors. Close blade tip clearance with the fan venturi assure smooth, quiet operation. All air cooled condensers are formed of 3/8 inch diameter copper tubes mechanically expanded into aluminum fins for maximum efficiency of heat transfer between the circulating refrigerant and air. The fins have full self-spacing collars which completely cover each tube.
WINDOWS® BASED MICROCOMPUTER CONTROLLER Full Function Microcomputer Controller with Windows® Based PC Interface Figure 5 Complementing our high-energy efficient product is a Full Function Microcomputer Controller designed to keep your system running at its most Energy Efficient Level, based on current load. This system is designed as a Control ‘State’ (control status) microcomputer providing the user with the current Control State for the exact information on what the microcomputer is doing.
WINDOWS® BASED MICROCOMPUTER CONTROLLER (CONT.) Display Information Capacity Control All information is displayed using common terms that are easy to understand. It is a simple procedure to determine the actual status of the system and the individual circuits, as they are displayed in common terms that are meaningful. The 2 line by 16 extra large character alphanumeric liquid crystal display (LCD) utilizes easy to understand menu-driven software.
Remote Monitoring The Microcomputer is equipped with a high speed RS232 communications port and two high speed RS485 communications ports, to allow for a variety of different remote monitoring operations. The RS232 communications port allows for remote communications at distances of up to 100 feet over a 4-wire shielded cable. The RS485 communication system allows for remote communications at up to 6000 feet (1829 meters) with a 2-wire shielded cable connection.
UNIT FEATURES: OPTIONAL ENCLOSURES AND FEATURES Optional plastic coated wire finguard. Available for upper half of unit (FGT) as shown on page 2, lower half of unit (FGB), or both. Figure 7a Optional full length painted aluminum grilles (GRL) to protect condenser fins and mechanical components. This option also includes sheet metal enclosure panels for the unit ends. Figure 7b Optional full length painted steel louvers (LUV) for the maximum protection for condenser fins and mechanical components.
OPTIONS Options are installed at the factory. Accessories are shipped unmounted. Low Ambient Control (LAC) TO 0°F (-17.8°C) Minimum Ambient—units use variable speed fans in conjunction with standard fan cycling. Extra Quiet Fan Operation (EQF)—using 855 RPM Fans and Scroll Compressors, provide the quietest operating refrigeration equipment possible.
OPTIONS (CONT.) Fin Guard Bottom (FGB) (1" x 4" Coated Wire)—encloses the bottom compressor, condenser Remote Monitoring Modem (MOD2)—for and cooler section of the unit only. Use FGT and FGB for full unit protection. multiple chiller network long distance communication with the same features as MOD1, with the addition of a gateway to convert the RS485 ports for network operation.
ACCESSORIES (SHIPPED LOOSE FOR FIELD MOUNTING) Water Flow Switch (WFS) - paddle type field PC Connection Basic (PCCB) - Provides adjustable flow switch. Must be tied into the unit safety circuit so that the package will remain off until water flow is proved. Helps prevent cooler freeze up. NEMA 3R enclosure, for use on water, ethylene or propylene glycol circuits.
APPLICATION DATA Cooler Design Data 6. Narrow Range !T - High Flow Applications Maximum - Leaving chilled fluid temperature (LCFT) is 60°F (18°C). The unit can start and pull down with up to 80°F (27°C) entering-water temperature. For sustained operation, it is recommended that the entering water temperature not exceed 70°F (21°C). 2. Minimum - LCFT is 42°F (5.5°C) for all models except ACDSB 025D, 030D, 035D and 040D for water applications with standard coolers. Oversized coolers CH2 for 42°F (5.
APPLICATION DATA (CONT.
APPLICATION DATA (CONT.) Multiple Chillers Per Chilled Water System 1. Where the load is greater than one ACDS-B can supply or where standby capacity is required or the load profile dictates, multiple chillers may be piped in parallel. Units of equal size help to ensure fluid flow balance, but balancing valves ensure balanced flows even with dissimilar sized chillers. Temperature controller sensors may or may not need to be moved to the common fluid piping depending on the specific application. 2.
APPLICATION DATA (CONT.) Glycol Freeze Protection If the chiller or fluid piping may be exposed to temperatures below freezing, glycol protection is recommended. The recommended protection is 15°F (8.3°C) below the minimum ambient temperature. Use only glycol solutions approved for heat exchanger duty. The use of automotive anti-freeze is not recommended because they have short-lived inhibitors and fouling of the vessels will occur.
SELECTION PROCEDURE: ENGLISH I.P. UNITS 60 HZ EXAMPLE Select an air cooled packaged chiller for the following conditions of service: TABLE 5 Elevation above Sea Level (ft.) 0 2000 4000 6000 8000 10000 50 Tons at 54°F entering, 44°F leaving chilled water. Design ambient is 95°F using R22 refrigerant. Minimum operating ambient is 50°F. Altitude is 6000 feet. Evaporator fouling is .00025. Electrical characteristics are 460/3/60. Unit to use 40% ethylene glycol by weight.
SELECTION PROCEDURE: S.I. UNITS 60 HZ EXAMPLE Select an air cooled packaged chiller for the following conditions of service: TABLE 8 Elevation above Sea Level (M) 0 600 1200 1800 2400 3000 175 kWo at 12.5°C entering, 6.5°C leaving chilled water. Design ambient is 35°C. Minimum operating ambient is 10°C. Altitude is 1800 meters. Evaporator fouling is .044. Electrical characteristics are 460/3/60. Unit to use 40% ethylene glycol by weight.
DX COOLER: WATER SIDE PRESSURE DROP ENGLISH I.P. Figure 13 AND S.I. UNITS TABLE 11 Cooler Curve No. Model *Conn. Size I.P. Units Minimum Maximum GPM GPM S.I. Units Min. Max. Lit./Sec. Lit./Sec. Single Circuit Coolers 1 2 3 4 CHS006601B CHS007601A CHS007601B CHS008601A 3" NPTE 3" NPTE 3" NPTE 3" NPTE 29 37 50 56 97 101 164 168 1.83 2.34 3.16 3.54 6.13 6.39 10.38 10.63 50 56 70 62 78 69 86 101 112 140 188 164 168 227 205 315 206 304 407 365 380 459 3.16 3.54 4.42 3.92 4.93 4.37 5.44 6.39 6.
PERFORMANCE DATA: ENGLISH I. P. UNITS R22 - 60 HZ - Standard Unit - 1140 RPM Fans Table 12a LWT °F 40 42 44 NOTES: 24 ACDS-B MODEL 015S **020S **025S **027S 030S **025D **030D **035D **040D 045D **050D **055D **057D 060D 065D 070D 080D 090D 100D 015S 020S 025S 027S 030S *025D *030D *035D *040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D 015S 020S 025S 027S 030S 025D 030D 035D 040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D (1) (2) (3) (4) (5) (6) (7) TONS 85°F KW EER NPLV TONS 12.
PERFORMANCE DATA: ENGLISH I. P. UNITS R22 - 60 HZ - Standard Unit - 1140 RPM Fans Table 12b LWT °F 45 46 48 NOTES: ACDS-B MODEL TONS 015S 020S 025S 027S 030S 025D 030D 035D 040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D 015S 020S 025S 027S 030S 025D 030D 035D 040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D 015S 020S 025S 027S 030S 025D 030D 035D 040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D 13.8 18.8 24.4 28.5 32.2 26.7 32.5 35.5 40.2 49.1 52.9 58.7 60.8 62.7 69.7 77.1 83.
PERFORMANCE DATA: S. I. UNITS R22 - 60 HZ - Standard Unit - 1140 RPM Fans Table 13a LWT °C 6.5 6.5 ACDS-B MODEL 015S 020S 025S 027S 030S 025D 030D 035D 040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D NOTES: (1) (2) (3) (4) 26 kWo 30°C kWi COP 47.1 63.9 83.1 97.1 109.9 93.1 113.5 121.7 140.0 167.0 180.0 199.7 206.9 212.8 236.3 261.5 283.8 315.6 340.8 12.6 17.1 23.1 27.4 31.3 24.7 31.0 33.2 37.6 45.8 50.4 56.5 56.0 56.9 65.6 74.3 81.0 91.4 93.2 3.17 3.19 3.20 3.21 3.21 3.20 3.21 3.24 3.
PERFORMANCE DATA: S. I. UNITS R22 - 60 HZ - Standard Unit - 1140 RPM Fans Table 13b LWT 6.5 6.5 ACDS-B 015S 020S 025S 027S 030D 025D 030D 035D 040D 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D NOTES: (1) (2) (3) (4) (5) 45°C 40.4 54.1 69.7 80.9 91.9 80.0 96.2 103.0 118.3 139.5 150.2 166.8 174.3 178.7 202.4 223.4 246.5 275.0 297.7 17.1 23.2 31.0 36.4 41.5 33.4 41.9 44.9 50.8 61.3 67.3 75.1 75.0 76.2 87.2 97.9 107.2 120.9 122.8 ENTERING CONDENSER AIR TEMPERATURE 49°C (See Note 4) 2.10 2.07 2.
PHYSICAL SPECIFICATIONS: ENGLISH I.P. & S.I. UNITS ACDS-B 015S, 020S, 025S, 027S, 030S Table 14a ACDS-B MODEL Nominal Capacity in Tons (kW) Quantity of Compressors 015S 020S 025S 027S 030S 15 (52) 20 (70) 25 (88) 27 (95) 30 (105) 2 2 2 2 2 CHS006601B CHS006601B CHS007601B CHS007601B CHS008601A Water Volume, Gallons (Liters) 3.4 (12.9) 3.4 (12.9) 5.5 (20.8) 5.5 (20.8) 7.0 (26.5) Minimum Flow Rate, GPM (L/S) 29 (1.83) 29 (1.83) 50 (3.15) 50 (3.15) 56 (3.
PHYSICAL SPECIFICATIONS: ENGLISH I.P. & S.I. UNITS ACDS-B 025D, 030D, 035D, 040D, 045D Table 14b ACDS-B MODEL Nominal Capacity in Tons (kW) Quantity of Compressors STANDARD EVAPORATOR Water Volume, Gallons (Liters) 025D 030D 035D 040D 045D 25 (88) 30 (105) 35 (120) 40 (140) 45 (150) 4 4 4 4 4 CHD007601B CHD007601B CHD008601B CHD008601B CHD010601B 5.5 (20.8) 5.5 (20.8) 7 (26.5) 7 (26.5) 10.7 (40.5) Minimum Flow Rate, GPM (L/S) 50 (3.15) 50 (3.15) 70 (4.42) 70 (4.42) 78 (4.
PHYSICAL SPECIFICATIONS: ENGLISH I.P. & S.I. UNITS ACDS-B 050D, 055D, 057D, 060D Table 14c ACDS-B MODEL Nominal Capacity in Tons (kW) Quantity of Compressors STANDARD EVAPORATOR Water Volume, Gallons (Liters) 050D 055D 057D 060D 50 (175) 55 (190) 57 (200) 60 (210) 4 4 4 4 CHD011601B CHD011601B CHD011601B CHD013601B 12.9 (49.0) 12.9 (49.0) 12.9 (49.0) 18.1 (68.5) Minimum Flow Rate, GPM (L/S) 86 (5.44) 86 (5.44) 86 (5.44) 101 (6.39) Maximum Flow Rate, GPM (L/S) 315 (19.23) 315 (19.
PHYSICAL SPECIFICATIONS: ENGLISH I.P. & S.I. UNITS ACDS-B 065D, 070D, 080D, 090D, 100D Table 14d ACDS-B MODEL 065D 070D 080D 090D 100D Nominal Capacity in Tons (kW) Quantity of Compressors 65 (235) 4 70 (240) 4 80 (280) 4 90 (300) 4 100 (350) 4 STANDARD EVAPORATOR Water Volume, Gallons (Liters) CXD1209F09 28 (106) CXD1209F09 28 (106) Minimum Flow Rate, GPM (L/S) Maximum Flow Rate, GPM (L/S) 112/6.94 365/22.63 112/6.94 365/22.63 112/6.94 365/22.63 140/8.68 380/23.56 188/11.65 459/28.
DIMENSIONAL DATA: ACDS-B 015S TO 030S Figure 14a 022508ABCAT 32
DIMENSIONAL DATA: ACDS-B 025D TO 055D Figure 14b 022509ABCAT 33
DIMENSIONAL DATA: ACDS-B 057D TO 060D Figure 15a 022510ABCAT1 34
DIMENSIONAL DATA: ACDS-B 065D TO 100D Figure 15b 024613AACAT 35
ELECTRICAL DATA: (60HZ/3PH) Table 15a ACDS-B Model 015S 020S 025S 027S 030S 025D 030D 035D 040D 60 Hz Nom.
ELECTRICAL DATA: (60HZ/3PH) Table 15b ACDS-B Model 045D 050D 055D 057D 060D 065D 070D 080D 085D 090D 100D AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS 60 Hz Nom.
ELECTRICAL DATA: FIELD WIRING (60HZ/3PH) Table 16a Single Source Power - Wire Size Range and Quantity Supply Voltage 60 Hz. ACDS-B Model 015S 020S 025S 027S 030S 025D 030D 035D 040D NOTE: 38 Standard Terminal Block Optional - Unit Mtd. Disconnect Switch Code AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS Nom. Volts 208 230 460 575 208 230 460 575 208 230 460 575 208 230 460 575 208 230 460 575 Qty.
ELECTRICAL DATA: FIELD WIRING (60HZ/3PH) Table 16b Single Source Power - Wire Size Range and Quantity Supply Voltage 60 Hz. ACDS-B Model 045D 050D 055D 057D 060D 065D 070D 080D 090D 100D NOTE: Code AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS AK AN AR AS CD AN AR AS CD AN AR AS CD AN AR AS CD AN AR AS CD AN AR AS Standard Terminal Block Nom.
ELECTRICAL DATA: (60HZ/3PH) General Electrical Notes 1. Main power must be supplied from a single power source field-supplied fused disconnect(s) using dual element time delay fuses or a HACR rated circuit breaker. Power supply is three phase unless otherwise shown. 6. Crankcase heaters are wired in the control circuit. The main unit power field disconnect and local safety switch must be closed (on) at all times for heater operation. 7.
TYPICAL POWER WIRING DIAGRAM (Four COMPRESSOR MODEL) Figure 16a 024098AACAT 41
TYPICAL CONTROL WIRING DIAGRAM (Four COMPRESSOR MODEL) Figure 16b 024099ACCAT 42
TYPICAL CONTROL WIRING DIAGRAM (Four COMPRESSOR MODEL) Figure 16c 024099BCCAT 43
TYPICAL SEQUENCE OF OPERATION MICROCOMPUTER CONTROLLER The following sequence of operation describes a fourcompressor scroll packaged chiller. Operation is very similar for a two-compressor unit. As discharge pressure of compressor #3 rises, the even numbered fans are activated according to the fan stage setpoints as described above for circuit #1 fans. For initial start-up, the following conditions must be met.
PART LOAD INFORMATION TABLE 19 Capacity Control Steps ( Expressed in %) English ACDS-B Model 015S %CAP %Kw 020S %CAP %Kw 025S %CAP %Kw 027S %CAP %Kw 030S %CAP %Kw 025D %CAP %Kw 030D %CAP %Kw 035D %CAP %Kw 040D %CAP %Kw 045D %CAP %Kw 050D %CAP %Kw 055D %CAP %Kw 057D %CAP %Kw 060D %CAP %Kw 065D %CAP %Kw 070D %CAP %Kw 080D %CAP %Kw 090D %CAP %Kw 100D %CAP (1) (2) (3) (4) (5) % Step 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 10
PRODUCT SPECIFICATION Part 1: General 1.01 Work Included A. Provide complete Microcomputer controlled air-cooled chiller utilizing Tandem Scroll Compressor sets suitable for outdoor installation. Contractor shall furnish and install chillers as shown and scheduled on the drawings. Units shall be installed in accordance with this specification. B. Chillers shall be selected for use with water / ( % ethylene or propylene glycol). 1.02 Quality Assurance A.
B. The start-up date shall be certified by the Mechanical Contractor, and provided to the Manufacturer, Engineer and Owner. C. (Provide an optional extended four (4)-year warranty on the compressors only, 5 years total). D. (During the warranty period, the equipment supplier shall furnish the services of an authorized service agency for all labor associated with parts replacement or repair, and start-up of the refrigeration equipment at the beginning of each cooling season.
B. The compressors shall be fitted with a crankcase heater, large suction filter, oil sight glass, oil strainer and magnetic crankcase plug. The lubrication system shall be centrifugal forced feed type with external oil equalization. C. To maximize reliability, the compressors shall utilize across-the-line start and, to limit start-up current draw, be limited to a maximum of 15 HP with a time delay between compressor starts. 2.
f. 2. 3. 4. 5. Proactive control providing safeties for high pressure, low pressure and freeze protection, to eliminate nuisance trips g. Proactive compressor staging to eliminate overloading during start-up to reduce compressor cycling h. Continuous evaluation of sensors i. (Control of Hot Gas bypass) Microcomputer - Unit Protection shall provide the following: a. Low pressure cutout with Proactive safety b. High pressure cutout with Proactive safety c.
6. Microcomputer Remote Monitoring Capabilities - shall include a complete Full Function communication system through the following means: a. PC Connection - shall provide communications to a 3.1 or higher level Personal Computer, or BMS (Building Automation System) to provide, as a minimum, the following: 1. Dynamic system data update of all outputs, inputs, control states, and alarms 2. Complete History Storage of all data needed for both Static and Dynamic graphing 3.
G. (Low ambient lock-out control requiring a field setpoint.) H. (Gauges include suction and discharge pressure for each refrigerant circuit in addition to the readings through the microcomputer.) I. (Steel Painted Louvers for complete unit enclosure for general mechanical security and unit aesthetics.) J. (Aluminum Painted Grills similar to louvers except manufactured or aluminum with 3/8" x 3 1/2" slots instead of louvers for hail damage protection and unit aesthetics.) K.
INSTALLATION CLEARANCE Figure 17 March 2004 52 P. O. Box 20000, Harrisonburg, VA 22801 Phone: 540-434-0711 FAX: 540-434-2448 www.dunham-bush.com Form No.
