FORM NO: MS0452A

WATER-COOLED SEMI-HERMETICSCREW COMPRESSOR WATER CHILLERS

HXWC SERIESHXWC SERIES

50Hz50Hz50Hz

Products That Perform...By People Who Care

R

200 to 740 Tons

R134a

INTRODUCTION

Dunham-Bush’s HXWC water cooled chillers are available from 200 to 740 tons.

Dunham-Bush, the world’s acknowledge leader in Screw Compressor chillers has a

proven track record of superior performance and high reliability, unmatched by others!

All chillers are factory run tested before shipment.

TABLE OF CONTENTS

Page

Introduction....................................................................................................................................... 2Nomenclature.................................................................................................................................... 2Unit Features .................................................................................................................................... 3Microcomputer Control....................................................................................................................... 5Physical Specifications ...................................................................................................................... 7Dimensional Data.............................................................................................................................. 8Typical Wiring Schematic................................................................................................................... 9

NOMENCLATURE

HXWC i 550 - 5 N R

Water Cooled HorizontalRotary Screw PackagedChiller

i - c/w Vapor Injection

Blank - w/o Vapor Injection

Models: 240, 310, 370,440, 480, 550,610, 650, 750

50Hz

R-134a

N - StandardP - PremiumS - Superior

- 2 -

UNIT FEATURES

ARI CERTIFICATION

ARI Certification ProgramThe performance of Dunham-Bush Water-Cooled

R134a Rotary Screw Water Chillers has beencertified by the Air Conditioning and Refrigeration

Institute (ARI) in accordance with ARI Standard

550/590-98.

Full load ratings. part load ratings, and water

pressure drop data are regularly tested under this

certification program. This provides anindependent, third party verification of water

chiller performance with a laboratory-rated

performance test utilizing calibratedinstrumentation.

The ARI Seal of Certification shows the

commitment to quality and to our customer'speace of mind. You will get the industry's

standard for efficiency and reliability when you

purchase a Dunham-Bush water chiller.

This certification program does not include low

temperature applications (Ice Bank) or units

utilizing glycol.

Computer Performance RatingsDunham-Bush HXWC, the many combinations of

heat exchangers make it impractical to publishtabular ratings for each combination. A chiller may

be custom matched to certain building

requirements by your Dunham-Bush SalesRepresentative utilizing the Dunham-Bush

Selection Program or Electronic Catalogue which

has performance rated in accordance to ARIStandard 550/590-98. Data which can be

provided to you will include:

] Chiller Capacity

] KW Input

] Evaporator and Condenser Water PressureDrop

] Evaporator and Condenser Tube WaterVelocities

] IPLV/ APLV

] Part-Load Performance

Contact your local Dunham-Bush SalesRepresentative to discuss what Real Solutions

Dunham-Bush can offer to solve your chiller

selection questions.

PART LOAD PERFORMANCEThe Air Conditioning and Refrigeration Institute

(ARI) has established a system, in ARI Standard

550/590-98, for measuring total chillerperformance over full and part-load conditions. It

defines the Integrated Part-Load Value (IPLV) as

an excellent method of comparing diverse typesof equipment on an equal basis. The IPLV is a

single number estimate of a chiller's power use

weighted for the number of hours the unit mightspend at each part-load point. IPLV's are based

on Standard Rating Conditions.

The formula for calculating an IPLV is:

IPLV =

where: A = kW/ton at 100% load pointB = kW/ton at 75% load pointC = kW/ton at 50% load pointD = kW/ton at 25% load point

STANDARD FEATURES

Size/Range] 9 Models from 200 to 740 tons.

] Multiple compressor units provide redundancy,and favorable part load efficiency.

] One-year parts warranty at no extra cost.

Compressor] Quiet, reliable Semi-Hermetic Screw

Compressors.

] Multiple rotary screw compressor for fail-safe

reliability and redundancy.

] Stepless loading and unloading withdependable slide valve mechanism.

] Insured continuous oil flow with high efficiencyexternal oil separator.

1

0.01 + 0.42 + 0.45 + 0.12

A B C D

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UNIT FEATURES

Evaporator/Condenser

] Cleanable and Removable Integral Fin CopperTubes.

] Removable Water Heads.

] Victaulic Groove Water Connections.

] Vessels designed and constructed according

to ASME Code, vessels can be constructed to

comply and certified with ASME, JKKP andPED Standards.

] Relief Valve(s) standard - 3/4" FPT.

] Full Pump Down Capacity in Condenser.

Microcomputer/Electrical

] Proactive Microcomputer Controller adapts toabnormal operating conditions.

] Tolerant and accommodating of extreme

conditions at start-up.

] Capable of controlling multiple chillers, cooling

towers, pumps, etc.

] Circuit Breaker on each multiple compressorunit.

] Unit Mounted Contactor and Time Delay for

reduced Inrush Start.

] Current transformer.

] Under Voltage Phase Failure Relay.

] Indicator lights for Compressor Overloads,Micro Alarm, Control Power, Compressor

Control Circuit.

ENERGY EFFICIENCY

] Designed to provide the greatest amount ofcooling for the least kilowatt input over the

entire operating range of your building.

] Delivers outstanding efficiency and totalenergy savings through the use of

microcomputer controlled slide valve and

evaporator leaving water temperature control.

] High efficiency external oil separator

guarantees removal of oil carried over in the

refrigerant and maintains the heat exchangers

at their maximum efficiency at both full and

part load.

] Rating according to ARI Standard 550/590-98"Centrifugal or Rotary Screw Liquid Chilling

Packages".

GLYCOL FREEZEPROTECTIONIf the chiller or fluid piping may be exposed to

temperatures below freezing, glycol protection is

recommended if the water is not drained. Therecommended protection is 10°F (5.6°C) below

the minimum ambient temperature in the

equipment room and around piping. Use onlyglycol solutions approved for heat exchanger

duty. DO NOT use automotive anti- freeze.

If the equipment is being used for applicationsbelow 38°F (3.3°C), glycol should be used to

prevent freeze damage. The freeze protection

level should be 10°F (5.6°C) lower than theleaving brine temperature.

Table 1: Ethylene Glycol%E. G. By Mass Freeze Point

°F °C

10 26.2 -3.2

15 22.2 -5.3

20 17.9 -7.9

25 12.7 -10.8

30 6.7 -14.1

35 -0.2 -17.8

40 -8.1 -25.8

45 -17.5 -27.5

50 -28.9 -33.8

Table 2: Propylene Glycol%P. G. By Mass Freeze Point

°F °C

10 26.1 -3.3

15 22.9 -5.1

20 19.2 -7.2

25 14.7 -9.7

30 9.2 -12.8

35 2.4 -16.6

40 -6.0 -21.3

45 -16.1 -27.0

50 -28.3 -33.8

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MICROCOMPUTER CONTROL

Vision2020i a flexible and advance programmable

electronic microcontroller designed specifically for

the applications and precise control of Dunham-

Bush Rotary Screw compressor chillers.

The controller board is provided with a set of

terminals that connected to various devices such

as temperature sensors, pressure and current

transducers, solenoid valves, compressors and

fans contactors, control relays and etc. Three

sizes of controller boards are provided to handle

different number of input and output

requirements: DB2-S small board, DB2-M

medium board and DB2-L large board.

The unit algorithm program and operating

parameters are stored in FLASH-MEMORY that

does not require a back-up battery. The program

can be loaded through PC or programming key.

Vision2020i controller is equipped with a user

friendly terminal with a graphic display and

dedicated keys that provides easy access to the

unit operating conditions, control set points and

alarm history.

Each unit’s controller can be programmed and

connected to the local DBLAN network that allows

multiple units sequencing control without

additional hardware. The DBLAN is local area

network made up of several chillers’ controller.

Display and User Terminal

Vision2020i controller is design to work with a

user friendly back-lit 132 by 64 pixels DBG1

Graphic Display panel connected with controller

through telephone cable. The terminal allows

carrying out all program operations. The user

terminal allows displaying the unit working

conditions, compressor run times, alarm history

and modifying the parameters. The display also

has an automatically self-test of the

microprocessor 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 display terminal.

There are 15 dedicated buttons enable user to

access information, base on the security level of

the password. For more detail operation of the

DBG1 Display Terminal, please refer to the Unit

Operation Manual.

Easily accessible measurements include:

] Leaving chilled water temperature

] Leaving chiller water temperature derivative

] Evaporator Pressure

] Condenser Pressure

] Compressor amp draw of each compressor

] Compressor elapsed run time of each

compressor

] Compressor starts status

] Oil level sensor status

] Water temperature reset value

] Water flow switch status

] External start/stop command status

Optional entering chilled water temperature,

leaving and entering condenser water

temperature are available. With this option the

operator can quickly and accurately read all

significant water temperatures and eliminate the

need for often-inaccurate thermometers.

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MICROCOMPUTER CONTROL

Capacity Control

Leaving chilled water temperature control is

accomplished by entering the water temperature

setpoint and placing the microcomputer in

automatic control. The unit will monitor all control

functions and move the slide valve to the required

operating position. The compressor ramp

(loading) cycle is programmable and may be set

for specific building requirements. Remote

adjustment of the leaving chilled water setpoint is

accomplished through either direct connection of

other Dunham-Bush control packages to the

microcomputer through either the RS485 long

distance differential communications port, via

terminal or modem connected to the RS232

communication port, or from an external Building

Automation System supplying a simple 4 to 20mA

signal. Remote reset of compressor current limit

may be accomplished in a similar fashion.

System Control

The unit may be started or stopped manually, or

through the use of an external signal from a

Building Automation System. In addition, the

microcomputer may be programmed with seven-

day operating cycle or other Dunham-Bush

control packages may start and stop the system

through inter-connecting wiring.

System Protection

The following system protection controls will

automatically act to insure system reliability:

] Low suction pressure

] High discharge pressure

] Freeze protection

] Low differential pressure

] Low oil level

] Compressor run error

] Power loss

] Chilled water flow loss

] Sensor error

] Compressor over current

] Compressor Anti-recycle

The microcomputer will retain the latest up to 99

alarm conditions complete with time of failure

together data stamping on critical sensor readings

in an alarm history. This tool will aid service

technicians in troubleshooting tasks enabling

downtime and nuisance trip-outs to be minimized.

Remote Monitoring

The microcomputer is complete with an optional

RS485 communications card and NETVISOR

software necessary for remote monitoring and

controlled from a PC terminal and optional phone

modem.

With various optional add-on cards the

Vision2020i controller can also be interfaced

directly to the BMS with the standard

communication protocols using MODBUS,

LONWORKS, BACNET MSTP as well as over IP.

This sophisticated feature makes servicing easier

and more convenient to the system. The

microcomputer as standard is additionally

equipped with history files which may be used to

take logs which may be retrieved via the phone

modem or internet connection periodically. Now

owners of multiple buildings have a simple and

inexpensive method of investigating potential

problems quickly and in a highly cost effective

manner. Dunham-Bush has various open

protocols on its microcomputer to allow direct

interface with Building Management Systems.

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PHYSICAL SPECIFICATIONS

MODEL HXWC 240-5NR 310-5NR 370-5NR 440-5NR 480-5NR 520-5NR 550-5NR 610-5NR 650-5NR 750-5NR

NOMINAL CAPACITY (TONS) 203 254 307 365 406 414 459 513 559 626

MIN % UNIT CAPACITY REDUCTION 12.5% 12.5% 12.5% 8.33% 8.33% 8.33% 8.33% 5.9% 5.9% 5.9%

COMPRESSOR

MODEL (QTY) HX1811(2)

HX1813(1)

HX 1816(1)

HX1817(2)

HX1813(2)

HX1816(1)

HX1813(1)

HX 1816(2)

HX1816(3)

HX1816(1)

HX 1817(2)

HX 1813(2)

HX 1816(2)

HX 1813(1)

HX 1816(3)

HX1817(4)

RPM 2900 2900 2900 2900 2900 2900 2900 2900 2900 2900

ELECTRICAL INFORMATION

COMPR. RLA, EACH 123 135/174 188 135/174 135/174 174 174/188 135/174 135/174 188

LRA, EACH 745 910/1160 1400 910/1160 910/1160 1160 1160/1400 910/1160 910/1160 1400

UNIT MIN CIRCUIT AMPS 277 353 423 488 527 550 600 662 701 800

MAX. ALLOW. FUSE SIZE 400 500 600 600 700 700 700 800 800 800

EVAPORATOR

MODEL X1R X2R X3R X4R X5R X5R X6R X8R X10R X11R

WATER CONNECTION (INCH) 8 8 8 10 10 10 10 10 12 12

NOMINAL WATER FLOW (GPM) 489 611 738 878 977 1047 1103 1235 1345 1505

NOMINAL PRESSURE DROP(FT WG) 7.3 7.5 8.1 8.2 7.6 8.7 8.8 8.6 6.5 5.9

CONDENSER

MODEL Z1R Z2R Z3R Z4R Z5R Z5R Z6R Z8R Z10R Z11R

WATER CONNECTION (INCH) 6 6 8 8 8 8 8 8 12 12

NOMINAL WATER FLOW (GPM) 587 734 887 1059 1170 1255 1323 1480 1603 1800

NOMINAL PRESSURE DROP(FT WG) 7.6 8.0 7.4 7.7 8.0 9.0 8.1 8.3 7.2 7.1

GENERAL INFORMATION

UNIT LENGTH (INCH) 171 171 171 171 171 171 171 210 210 210

UNIT WIDTH (INCH) 56 5/8 58 5/8 62 5/8 82 82 82 82 82 94 100

UNIT HEIGHT (INCH) 86 1/8 86 1/8 88 1/8 86 1/8 88 1/2 88 1/2 88 1/2 90 1/2 97 1/2 102 1/2

SHIPPING WEIGHT (KG) 5065 5970 6800 8190 9020 9290 9600 11390 14135 17190

OPERATING WEIGHT (KG) 5470 6445 7345 8845 9740 10035 10400 12530 15545 18910

APPROX. R134a REF. CHARGE (KG) 265 330 400 475 530 570 600 670 730 815

Notes: 1.) Nominal capacity is based on standard condition, actual capacity depends on the specified operating conditions.2.) Evaporator and condenser models are based on standard condition and are both 2 pass. Model might change for non-standard conditions

or application.3.) This physical specifications table is for standard vessels only, premium and superior vessels’ data are available in electronic catalog.

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DIMENSIONAL DATA

1.) HXWC 240-5NR, 310-5NR, 370-5NR

2.) HXWC 440-5NR, 480-5NR, 520-5NR, 550-5NR

3.) HXWC 610-5NR, 650-5NR, 750-5NR

NOTE: ALL DIMENSIOS ARE IN INCHES.

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TYPICAL WIRING SCHEMATIC

2 COMPRESSORS

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Ω

Ω

TYPICAL WIRING SCHEMATIC

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TYPICAL WIRING SCHEMATIC

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TYPICAL WIRING SCHEMATIC