FL4338-IPCX

INSTALLATION/ OPERATION/ MAINTENANCE

MANUAL

MODEL NUMBER

IPCX 345-HFWWXN(M/P)
FACTORY ORDER NUMBER

L4338
PROJECT:

FPG CHILLER
LOCATION

KUANTAN, MALAYSIA
WATER-COOLED PACKAGED CHILLERS
WITH HELICAL ROTARY SCREW
COMPRESSORS
R134a
50Hz

TABLE OF CONTENTS
DESCRIPTION
1.0

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8

2.0

DESCRIPTION
3.6
3.7
3.8

Introduction ........................................................ 2
Shipping ............................................................. 2
Receiving Inspection .......................................... 2
Rigging and Moving ........................................... 2
Dimensional Data ............................................... 3
Rigging Diagram ................................................ 4
Nameplate Data Sheet ....................................... 4
Certification Data Sheet ..................................... 5

4.0

Location ............................................................. 7
Mounting ............................................................ 7
Leveling ............................................................. 7
Unmounted Accessories .................................... 7
External Connections ......................................... 7
Request For Start-up Representative ................. 8

3.1
3.2
3.3
3.4
3.5

General ............................................................ 15
Periodic Maintenance ....................................... 15
Water Conditions.............................................. 19
Component Maintenance ................................. 22
Maintenance Records ...................................... 23

5.0

TROUBLESHOOTING

6.0

FORMS

5.1
6.1
6.2
6.3

OPERATION

PAGE

High/Low Side Component Operation .............. 12

Optional Subsystem Operation ......................... 12
IPCX 345-HFWWXN(M/P) Schematic Piping
Diagram ........................................................... 13

MAINTENANCE
4.1
4.2
4.3
4.4
4.5

INSTALLATION
2.1
2.2
2.3
2.4
2.5
2.6

3.0

PAGE

GENERAL INFORMATION

General .............................................................. 9
Systems ............................................................. 9
Component Operation ...................................... 10
Lubrication System Operation And Charge ...... 11
Oil Cooling System Operation .......................... 12

General ............................................................ 25
Condition of unit Sheet ..................................... 27
Sample Log Sheet............................................ 28
Request For Start-up Supervision on Chiller and
Condensing Units ............................................. 29

1.0 GENERAL INFORMATION

1.1

INTRODUCTION

1.3

Each unit was designed to meet specific criteria

and must be operated within conditions specified
when ordered.
Refrigerant must be handled with caution and
release to the atmosphere should be minimized.
Instructions for charging and retrieving refrigerant
from these units can be found in the maintenance
section of this manual.
These instructions and the drawings supplied with
the IPCX Unit must be followed carefully to
insure proper installation, operation, and
maintenance.
This manual is written and illustrated for a single
IPCX Unit installation. For instructions
concerning a multiple unit installation, consult
Dunham-Bush.

1.2

SHIPPING

The unit is shipped with base frame and lifting

holes for ease in rigging. Refrigerant and oil
systems are fully charged. Chiller and condenser
water connections have covers to prevent
contamination of the vessels. Check the unit
nameplate to be sure the power supply meets the
unit requirements. The wiring diagram number
and type of refrigerant can also be found on the
unit nameplate.
-2-

RECEIVING/INSPECTION

The unit should be inspected immediately, in the

presence of the carriers representative, for any
evidence of damage during shipping. Any damage
should be noted on the carriers delivery receipt
before it is signed. A damage claim should then
be filed by the purchaser against the delivering
carrier as all shipments are made at the
purchasers risk.

1.4

RIGGING AND MOVING

The Riggers and installers must use every

precaution to prevent damage while moving the
unit from the point of shipment to its permanent
location. Pushing, pulling or climbing on any of
the unit components or piping can easily create
damage that will result in costly repairs of leaks
and malfunctioning components. The only places
it is safe to apply hoisting, jacking, pushing, or
pulling forces are to base frame and lifting holes.
Cables are to be attached only to the lifting holes,
spreaders must be used with the lifting cables to
prevent damage to the unit.
Skidding may be done directly on the base frame
or on properly spaced rollers under the base
frame. Pushing and pulling should only be
directed against the base frame and lifting holes.

1.0 GENERAL INFORMATION

1.5

IPCX 345-HFWWXN(M/P) DIMENSIONAL DATA

-3-

1.0 GENERAL INFORMATION

1.6

IPCX 345-HFWWXN(M/P) RIGGING DIAGRAM

1.7

NAMEPLATE DATA SHEET

-4-

1.0 GENERAL INFORMATION

1.8

CERTIFICATION DATA SHEET

CERTIFICATION DATA SHEET

PAGE: 1 of 2

INDUSTRIAL REFRIGERATION SCREW PROCESS CHILLER

CUSTOMER:

FPG CHILLER

SALES OFFICE:

Dunham-Bush Industrial Sdn Bhd

(Malaysia) .

ORDER NO.:
FACTORY ORDER NO.:
UNIT MODEL NO.:

00

L4338

DATE: 10.4.2012

IPCX-345-HFWWXN(M/P)

REQUIRED QTY:

CONDITIONS OF SERVICE:
MAXIMUM
344 TR
CAPACITY:
29.9 oF
DESIGN EVAP.
TEMP.:
29.9 oF
DESIGN COMP.
SUCT.:
3300V/3PH/50HZ
POWER:

PROCESS FLUID:
FLOW RATE (GPM):
ENT. TEMP. (F):
LVG. TEMP. (F):
PRESS. DROP (PSI):
FOULING FACTOR:

PROJECT:
Proposal NO.:
REV. NO.:

REFRIGERANT:
R134a
DESIGN COND.
TEMP.:
DESIGN COMP.
DISCH.:
CONTROL:

EVAPORATOR
Water

BHP:

57
40
4.15
0.0001 hr.ft2.oF/Btu

104.4 oF
115V/1PH/50HZ

PROCESS FLUID PROPERTIES:

Water @ 50 F (10.0 C)
Sp. Gr.:
Sp. Ht.:
Therm. Cond.:
1.000
1.005 Btu/lb/F
3.2 Cp
3.9 Cp
Visc. Bulk:
Visc. Wall:
Freeze Pt.:
UNIT LOCATION:

Outdoors

ELECT. AREA CLASSIFICATION:

183 HP

104.4 oF

CONDENSER
Water
1052.8
91
101
8.6
0.00025 hr.ft2.oF/Btu

482.3

OIL COOLER
Water
30
91
101
2.5
0.00025 hr.ft2.oF/Btu

0.339 Btu/hr.ft.F/ft
32 F (0 0C)

230L x 100W x 140H

27643 LBS# Shipping / 29076 LBS# Operating
Classified (Hazardous) Location Class I, Division II
UNIT DIM'S:

MAJOR EQUIPMENT SPECIFICATIONS:

COMPRESSOR
EVAPORATOR
EXS22149402H
MODEL: 2516/3.60
Dunham-Bush
Dunham-Bush
MFG:
Horiz. Rotary Screw
DX, 1-pass, 1-circ, 19 bffls, 22
TYPE:
2950 rpm
x 149L x 402T, 3/4 0.028
OTHER:
1.65 L/D, CCW, 3.60 Vi
With copper tbs w/innerfin,
OTHER:
Section VIII, Div. 1, ASME code
OTHER:
refri side, U-stamp, 200/250 psi,
8-150#RF flgd conns

-5-

CONDENSER
CD20147H326HAG
Dunham-Bush
Wtr Cooled, 2-pass, 20
x 147L x 326T, 3/4 0.028
Turbo-CII copper tbs, TEMA-C,
Section VIII, Div. 1, ASME code
Refri side, U-stamp, 200/150 psi
6-150#RF flgd conns

1.0 GENERAL INFORMATION

PAGE: 2 of 2
MAJOR EQUIPMENT SPECIFICATIONS (CONTINUED):
OIL SEPARATOR
OIL PUMP
TBA
MODEL:
30135
Dunham-Bush
TBA
MFG:
Horizontal
TBA
TYPE:
30 , s. mesh
TBA
OTHER:
Bed, ASME code,
TBA
OTHER:
U-stamp, 400 psi
TBA
OTHER:

ELECTRICAL EQUIPMENT SPECIFICATIONS:

COMP. MOTOR

OIL COOLER
1201050011
Dunham-Bush
Wtr cooled, 2-pass, 5 x 80L
x 18T, 3/4 0.052 w 40 fpi
Trufin copper tbs,TEMA-C,
ASME code both sides, U-stamp, 400/150 psi, 2150#RF flgd conns

OIL PUMP MOTOR

Units STARTER
MFG:
MODEL:
TYPE:
HP:
RPM:
POWER:
OTHER:
OTHER:

ABB
HXR 400LE2
Ex Na II T3 (IEC 60079-15)
450
2971
3300V/3PH/50HZ
Clock Wise Rotation,
F insul, 45 C amb,
IEC Design

TBA
TBA
TBA
TBA
TBA
TBA

By Others
Direct on line

3300V/3PH/50HZ
-

CONTROL PANEL SPECIFICATIONS:

TBA
NEMA-4X s.s., purged
Rigid/Sealtite
MFG:
TYPE:
CONDUIT TYPE:
DB Vision 2020i controller with touch screen display & Nema-4Xss window/door cover
CONTROL:
Suct Press/Temp, Disch Press/Temp, Oil Press, Oil Sump Temp, Ent/Lvg Water Temp, Comp SV Pos,
SENSORS:
Comp Motor Amps (Signal from starter-By Others)
UNIT FEATURES:
Compressor suction and discharge stop/check valves; Oil separator discharge stop/check valve; Hot gas
bypass
Dual relief valves (oil separator, condenser & evaporator), single relief valves (oil cooler)
Liquid line incl. filter/drier, isolation valves, TXVs & sight glass
Oil line (incl. pump suct strainer, iso. valves, dual oil filters w/iso. valves & oil diff. press. regulator)
Oil cooler 3-way temperature actuated, oil regulating valve
Liquid refrig. inlet to evaporator to have an isolation ball valve
Operating Lights, common alarm light, control switches, hour meter, alarms displayed in display
Units of measure on display to be dual (F, psig, psid, etc. & also C, kg/cm,etc.)
Initial charge of R134a refrigerant & DB18 oil; Factory standard gray paint finish
Insulflex insulation of cold surfaces
Unit piped, wired, leak checked, evacuated, charged & run tested on water @ conditions
INSULATION:

Yes

ASME
APPRVL REQD:
STD DOCS REQD:

Charge in Unit
(DB18 Oil)
Std Run (Non-Witnessed)
TESTING:
PAINT: Standard 2 coat system
Pkg Layout Dwg, P&ID, Wiring Dgm, Spare Part Lists, I&O Manuals

REFRIG.:

Charge in Unit (R134a)

-6-

OIL:

2.0 INSTALLATION
2.1

LOCATION

The location of the unit may be any foundation or

deck that is generally level within 1/8 inch
[3.175mm] and structurally capable of supporting
the weight of the unit. A cleared area should be
left around the unit to aid in operation
maintenance and removal of components. See
dimensional drawing to obtain minimum
clearance requirements.

2.2

accompanying the unit for the electrical

connections to interlock the flow switch with the
control panel.

FIGURE 2.4

FLOW SWITCH

MOUNTING

For installations, Dunham-Bush can provide

whatever type of vibration isolator the customer
specifies. They must be installed and adjusted in
accordance with the isolator manufacturers
instructions. The unit may be cemented or lagged
to the foundation if desired.

2.5
2.3

LEVELING

When the unit is at its final location, it should be

jacked or hoisted, by the lifting holes and the unit
let down on the isolator equipment supplied
(optional). It should then be checked for level
longitudinally at the top center of the condenser
shell and laterally across the compressor motor
feet. Steel shims should be installed under the
isolator pads, if necessary to level the unit.

2.4 UNMOUNTED
ACCESSORIES
A chiller flow switch, which is shipped in a
separate container accompanying the unit, must
be installed in the external chilled water outlet
piping. It must be located in a horizontal section
on the pipe where there is at least five (5) pipe
diameters on both sides of the flow switch before
any other connections, as indicated in Fig. 1. The
flow switch paddle must be adjusted to the size of
pipe in which the paddle is installed, and the
switch set to trip at approximately 50% of the
design flow. Consult the wiring diagram

-7-

EXTERNAL CONNECTIONS

2.5.1 Water Connection

After the unit has been leveled, the
external water piping to the chiller and
condenser may be made up. Air vent
valves should be installed at all high
points to bleed the system of entrapped
air. Drain valves or plugs should be
installed at low points to gravity drain the
system. The unit drain plugs for the
chiller, condenser and oil cooler (if
equipped) must be installed prior to
filling the system. Insulation should be
installed on all external piping to prevent
sweating and if the chiller (vessel) and
associated piping was not equipped with
the optional factory insulation, it too must
be insulated.
All external plumbing should have
manual shut-off valves installed near the
unit for ease in servicing and
maintenance. Strainers should also be
mounted in the piping before the unit to

2.0 INSTALLATION
prevent dirt and other contaminants from
entering and damaging the unit and its
satellite equipment.
The external plumbing must be carefully
located and adequately supported by pipe
hangers to prevent twisting or bending
stresses on the unit when the flanges or
grooved pipe connections are bolted. It is
recommended that flanged elbows be
used at the connection to the condenser so
that the external piping will not interfere
with servicing of the condenser tubes.
Flexible connections on water lines
throughout the machinery room are
recommended for chiller and condenser
piping, where sound or vibration
transmission may be a problem.
Following make up of the external
plumbing, a check should be made for
piping stresses at the IPCX unit, as
follows:
Remove condenser and chiller connecting
bolts. If any bolts are misaligned, adjust
external piping or hangers to properly
align the connections, if it is necessary to
reshape and anneal the external piping,
the inside of the piping must be cleaned
of the resulting scale before reassembly.
The piping should then be thoroughly
flushed to remove all foreign material,
connected to the unit, filled, vented and
tested for leaks.
IPCX units are designed for a fixed
evaporator water flow, and means should
be employed to assure a relatively
constant flow at all loads.
2.5.2 Pressure Transmitters
Schroeder valves are installed to isolate
the pressure transmitters.

-8-

The locations are marked in Figure 3.8.

2.6 REQUEST FOR START-UP

REPRESENTATIVE
After the installation has been completed and
checked, request for the services of a DunhamBush authorized start-up representative to perform
the initial start-up of the Dunham-Bush chiller,
Section 6.3. 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 chiller.
(During the warranty period the manufacturer is
responsible for parts only upon proof of defective
workmanship or manufacture).
Following receipt of this request, a representative
will be sent to the customer. He will inspect the
installation to determine whether it meets
Dunham-Bush requirements, perform the initial
start-up of the installation to 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 a

minimum of 24 hours prior to arrival of start-up
representative. This will insure that the oil is
warm enough to vaporize any refrigerant in the oil
and is in the normal operating temperature range.

3.0 OPERATION
which meters the refrigerant into the
evaporator chiller. There it changes its
state back to a gas as it absorbs heat and
evaporates. It is during this change of
state that the refrigerant will extract heat
from the medium being cooled. This low
density cool gas then flows to the
compressor where the cycle is repeated.

3.1 GENERAL
WARNING: The compressor and oil pump are
NOT to be started initially except under the
direct supervision of an Authorized DunhamBush, Inc. Start-up Representative. Be sure
that oil sump heaters are turned on for a
minimum of twenty-four hours prior to initial
start-up. Couplings and motors have been
aligned with the compressor at the factory.
During shipment they may become misaligned.
Alignment and motor pining at initial start-up
must be done by a Dunham-Bush, Inc. StartUp Representative.

3.2.2 Water Systems

While this unit is greatly simplified and

incorporates features to protect it against damage,
it does represent a considerable investment and
deserves the attention and care normally given to
any fine piece of equipment. Reliable and
economical operation will be achieved if the
instructions in this manual are followed.
CAUTION: Operate
this
equipment
in
accordance with the instructions of this manual.
DO NOT alter control settings to other than
those specified on the wiring diagram
accompanying the unit.

This equipment has been tested prior to shipment

and found satisfactory for the conditions under
which it was sold. Operation in excess of these
conditions will subject this equipment to stresses
for which it was not designed. Failure to heed this
warning may result in injury to operating
personnel and may jeopardize the warranty under
which the equipment was sold.

3.2

SYSTEMS

3.2.1 Refrigerant System

The compressor takes the refrigerant gas
at low density and compresses it to a
higher density. The temperature of the
refrigerant gas is also increased. The
dense refrigerant gas flows to the
condenser where heat is removed, causing
a change in the state of the refrigerant
from a gas to a liquid. The refrigerant in a
liquid state then flows through the
filter/drier, through an expansion valve

-9-

The condenser water system on an IPCX

unit is an open end system and the water
in the system is used to condense hot
refrigerant gas into a liquid. Water is
pumped through the tubes of the
condenser where it picks up heat
condensing the refrigerant. It then flows
to a water tower, evaporative water
cooler, or other cooling service, where
the heat is dissipated to the atmosphere.
Cooled water is picked up here and is
pumped to the condenser to absorb more
heat from the refrigerant.
Some units have water cooled oil
coolers. The water used to cool the oil is
either diverted from the input of the
condenser to the oil cooler or is supplied
from an interior source. A thermally
actuated valve monitors the leaving oil
temperature and modulates the water
flow through the cooler.
The chilled water system is a closed
system and the flow pattern varies for a
flooded system versus a direct expansion
system. Both systems use shell and tube
heat exchangers, but in a flooded system
the water is pumped through the tubes
while in a direct expansion system, water
is pumped through the shell. As the
chilled water leaves from either of these
systems, it is monitored by electronic
arrangement
which
controls
the
operation of the unit. The chilled water
then flows to the cooling coils where it
picks up heat from the space or item
being cooled. The water is then
circulated back to the pump and chiller.

3.0 OPERATION
3.2.3 Lubricating System And
Charge

Note:

3.3

The oil in an IPCX system is used to

lubricate the compressor and is
additionally used to dissipate heat
generated within the compressor,
provide a seal between the male and
female rotors during compression of the
refrigerant, as a hydraulic medium for
capacity control, and to provide quiet
operation.
There are a number of variations of
lubricating systems. The choice of each
system is dependent upon the type of
unit and its purpose.
The system is charged with 35 gallons
[132.5L] of DB 18 oil. Only DB 18 oil
may be used in this package. Use of
other oil is not approved by DunhamBush, and will result in poor
performance of the package.

into the compressor. Just prior to the

point at which the interlobe space leaves
the inlet port, the entire length of the
interlobe space is completely filled with
drawn in gas Fig. 3.3.2C.

FIGURE 3.3.2A

FIGURE 3.3.2B

FIGURE 3.3.2C

FIGURE 3.3.2D

COMPONENT OPERATION

3.3.1 Compressor/ Motor Assembly

The compressor used on the DunhamBush packaged chiller is a positive
displacement,
helical-axial
flow
compressor designed for use with high
pressure refrigerants. Unlike centrifugal
compressors, no purge system is needed.
For clarity reasons, the following
account of the IPCX compressor
operation will be limited to one lobe on
the male rotor and one interlobe space of
the female rotor. In actual operation, as
the rotors revolve, all of the male lobes
and female interlobe spaces interact
similarly with resulting uniform, nonpulsating gas flow.

3.3.2 Suction Phase

As a lobe of the male rotor begins to
unmesh from an interlobe space in the
female rotor, a void is created and gas is
drawn in through the inlet port Fig.
3.3.2A as the rotors continue to turn the
interlobe space increases in size
Fig.3.3.2B and gas flows continuously
- 10 -

3.3.3 Compression Phase

As rotation continues, the gas in the
interlobe
space
is
carried
circumferentially around the compressor
housing. Further rotation meshes a male
lobe with the interlobe space on the
suction end and squeezes (compresses)
the gas in the direction of the discharge
port. Thus the occupied volume of the
trapped gas within the interlobe space is
decreased and the gas pressure
consequently increased.

3.3.4 Discharge Phase

At a point determined by the designed
built-in compressor ratio, the discharge
port is uncovered and the compressed gas
is discharged by further meshing of the
lobe and interlobe space Fig. 3.3.2D.
While the meshing point of a pair of lobes
is moving axially, the next charge is
being drawn into the unmeshed portion
and the working phases of the compressor
cycle are repeated.

3.0 OPERATION
3.3.5 Capacity Control
Compressor vapor displacement is
controlled to balance the flow rate of
liquid refrigerant entering the evaporator
with the changing cooling demand.

FIGURE 3.3.5A

Slide Valve/ Rotor

Housing Inlet End

FIGURE 3.3.5B

Slide Valve/ Rotor

Housing Inlet End

The capacity control valve is located in

the rotor housing as shown in Fig. 3.3.5A
and 3.3.5B. The movement of this valve
along the axes of the rotors is
programmed by a solid state, temperature
initiated, hydraulically actuated control
arrangement. When the compressor is
fully loaded the slide valve is in theclosed
position against the valve stop as shown
in Fig. 3.3.5A, and all gas flows through
the rotor housing as described previously.
When the compressor starts to unload, as
shown in Fig. 3.3.5B, the compressor
slide valve will move away from the
valve stop. The movement of the slide
valve creates an opening in the bottom of
the rotor housing through which suction
gas can pass back to the inlet port. As no
significant amount of work has been done
on the returned suction gas, no
appreciable losses have been incurred.
Reduced capacity is obtained from the
gas remaining in the interlobe, which is
compressed in the ordinary manner. In
principle, as the opening in the rotor
housing is enlarged, the compressor
displacement is reduced. Optional
capacity control system information can
be found under Optional Sub-System
Operation.

- 11 -

3.4 LUBRICATION SYSTEM

OPERATION
3.4.1 Oil Separation and Collection
Prior to entering the condenser, the
discharge refrigerant vapor and the oil a0.
re mechanically separated. The oil/vapor
mixture is discharged from the
compressor to a separator, or combination
sump/separator (depending upon the unit
model).

Open Drive Units - Units featuring a
direct drive compressor incorporate a
combination oil/sump separator in a
single vessel. The upper portion of the
shell contains mesh beds which serve to
remove the oil from the discharge
vapor. The bottom portion of the shell
acts as a sump for the collected oil. The
discharge refrigerant vapor is piped
from the upper portion of the
sump/separator to the condenser.

Oil Sump Heaters - Electric resistance
heaters are located in the lower portion
of the sump vessel and serve to
vaporize excess refrigerant that may
have diluted the oil during shutdown,
and heat the oil to a suitable
temperature for start-up. Normally the
heaters must be energized a minimum
of 24 hours and the oil sump
temperature must be at a minimum of
100F (38C) prior to start-up of the
unit.

Oil Sump Sight Glasses - Sight glasses
are provided in the sump vessel to
monitor the oil level. When the unit is
shut-down and the oil is at design
discharge temperature, the normal oil
level is 1/2 to 1/3 visible in the (top)
sight glass.

3.4.2 Oil Pump

A screw type oil pump is used to provide
oil at sufficient pressure to lubricate the
compressor and actuate the capacity
control slide valve. The pump is open
drive and located exterior of the oil sump.
The open pump is coupled to a motor. To
avoid circulation of solid contaminants, a
strainer is located at the pump suction.
Shut off valves are provided for ease of
maintenance.

3.0 OPERATION
balance port design provides stable and
accurate control over wide load and
evaporator temperature ranges.

3.5 OIL COOLING SYSTEM

OPERATION
Water cooled oil cooler is supplied for oil cooling.

3.6.4 Filter Drier

3.5.1 Water Cooled Oil Coolers

Constructed with an externally finned
tube bundle mounted in a steel shell, the
heat exchanger provides the required oil
cooling capacity under all operating
conditions. A thermostatically actuated
three-way valve regulates the oil flow
through the shell, as the sensing element
monitors the leaving oil temperature. The
baffle arrangement in the shell side
channels the oil flow a more effective
heat transfer.

3.6

The filter drier is composed of a housing

and replaceable cores which removes
contaminants acid and moisture from the
refrigerant.

3.6.5 Evaporator
Designed for a fixed flow rate, the shell
and tube heat exchanger transfers heat
from the medium being cooled to the
refrigerant, causing the refrigerant to
vaporize.
The refrigerant enters the chiller through
a distributor where it is directed into the
tubes (the evaporating refrigerant is at a
rate depending upon the cooling load).
The tubes are of the patented Inner-Fin
extended surface design which improves
heat transfer while minimizing refrigerant
pressure drop, permitting a compact and
efficient chiller design. The refrigerant
vapor passes through an effective filter
built into the suction head of the chiller
(for additional system protection). The
chiller is provided with dual relief valve
to protect it from refrigerant over
pressure.

HIGH/LOW SIDE
COMPONENT OPERATION

3.6.1 Discharge Check Valve

To prevent migration of refrigerant from
the condenser into the compressor during
shutdown, a discharge check valve may
be used. Located between the compressor
and condenser, the check valve also
prevents excessive spin-down of the
compressor, and allows the unit to be
pumped down for servicing.

3.6.2 Condenser
The condenser is a shell and tube heat
exchanger which serves to condense the
discharge refrigerant vapor by removing
heat. Water is circulated through the tubes
absorbing heat from the discharge vapor
condensing in the shell side of the
externally finned copper tube bundle. The
water flow rate or temperature will have a
significant
effect
on
refrigerant
condensing pressures under all operating
conditions. Dual refrigerant relief valves
are mounted on the condenser vessel
serving as a protection device.

3.6.3 Throttling
Throttling liquid refrigerant serves to
regulate the refrigerant flow into the
chiller while maintaining the required
evaporating temperature. Throttling is
accomplished by an thermo statically
operated expansion valve for accurate
liquid injection into the evaporator. The

- 12 -

3.6.6 Suction Check Valve

Located in the piping between the
compressor and the evaporator, they are
used to prevent excessive spin-down,
equalization of pressure between the
compressor and evaporator, and to
prevent migration of oil into the chiller.

3.6.7 Suction Filter

Chiller has a dacron felt filter located in
the suction head of the cooler.

3.7

OPTIONAL
SUB-SYSTEM
OPERATION

3.7.1 Hot Gas Bypass Capacity

Control
Hot gas bypass capacity control is used to
feed hot gas into the evaporator when the
compressors load falls to 25% or less.

3.0 OPERATION
When this occurs, a solenoid valve in
the capacity control line is energized.
The introduction of hot gas provides a

3.8

stable refrigerant flow and keeps the

machine from short cycling under low load
conditions.

IPCX 345-HFWWXN(M/P) SCHEMATIC PIPING DIAGRAM

- 13 -

3.0 OPERATION

- 14 -

4.0 MAINTENANCE
4.1

GENERAL

Maintenance
personnel
should
become
thoroughly familiar with the unit and the contents
of this manual in order to properly diagnose and
rapidly correct and prevent minor difficulties.
Routine or periodic maintenance should be
followed to insure a comprehensive preventive
maintenance program minimizing costly repairs.

4.2

PERIODIC MAINTENANCE

4.2.1 Pre-Initial Start-Up

Maintenance
a. Insure unit is level.
b. Check for any piping stresses on unit.
c. Check coupling alignment. (Direct
drive compressor and oil pump
motors).
d. Tighten all wiring connections.
e. Check tripping of safety controls for
grounding.
f. Check oil sump heaters for proper
operation.
g. Check all control and starter wiring
connections for grounding.
h. Sump oil level must be visible in sump
sight glass, sump oil temperature must
be at a minimum of 100F (37.8C).
i Hydronic system must be vented free
from entrapped air, and the piping
properly supported to the unit.
j. All satellite equipment and associated
control devices must be operationally
checked and capable of handling their
design capacities.
k. Inspect for external refrigerant leaks
with an electronic leak tester or halide
torch.
l. Check refrigerant indicators for
evidence of moisture.
NOTE:
If moisture is evident
prior to initial start-up, the refrigerant
indicators should be monitored after
start-up to insure that the moisture is
removed. If moisture is evident after
minimal running time, the unit must be
shut-down and the filter drier elements
replaced.
m. Adjust limit switches.
- 15 -

It is important that water systems be

cleaned before start-up to avoid collecting
debris in cooler and condenser. The best
way to do this is to install wye strainers in
both systems upstream of the unit. After
filling systems with water, bleed trapped
air from the various vent valves. Check
for proper flow rates by measuring water
pressure drop across heat exchangers and
reading from charts, Figure 4.2.1.
Compare measured with values specified
on purchase order. Check in Certification
Data Sheet, Section 1.7. to see that
evaporator and condenser fall between
min. and max. limits.

4.2.2 Post Initial Start-up and

Daily Maintenance
NOTE: A log of daily readings should be
maintained.
a. Check suction superheat conditions
after start-up for proper adjustment at
expansion valve.
b. Inspect sight glass for liquid line.
Inspect for a full glass free from
bubbles.
CAUTION: All valve caps, packing glands and pipe
plugs must be tightened securely after performing
maintenance and/or periodically, to prevent
refrigerant leakage.
WARNING: All inspection, maintenance, or repairs
should be done by an authorized, qualified,
Dunham-Bush Service Representative. Failure to
comply may jeopardize the warranty.

c. Check and record the following:

Suction,
discharge
and
oil
pressures.

Condenser inlet and outlet water
temperatures.

Evaporator inlet and outlet cooling
medium temperatures.

Compressor motor amps.

Oil Temperature.

Compressor motor voltage.

Discharge Temperature.
d. Initial seal drainage collection (direct
drive compressor) can be 0.31 cubic
inches per hour (5 cc per hour) after
start-up. After the unit has run a seven

4.0 MAINTENANCE
FIGURE 4.2.1A

EVAPORATOR WATER PRESSURE DROP

EXS22149402H

- 16 -

4.0 MAINTENANCE
FIGURE 4.2.1B

CONDENSER WATER PRESSURE DROP

CD20147H326HAG

- 17 -

4.0 MAINTENANCE
day break-in period, the normal seal
drainage is 0.06 to 0.24 cubic inches per
hour (1 cc to 4 cc per hour).
e. Rotate capacity control hot gas bypass
(optional) throttling valve to proper
adjustment after initial start-up.
f. Check refrigerant indicators for
evidence of moisture. Change filter
drier elements if required.

4.2.3 Monthly Interval

Maintenance
NOTE: A log of monthly interval
readings should be maintained, and the
data compared to daily values for
evidence of operational changes, i.e.
condensing
pressure,
superheat
temperatures, compressor/oil pump motor
current amps, etc. (refer to maintenance
records).
a. Check oil sump sight glass to be at
proper level.
b. Check oil filter pressure drop and
replace filter elements if necessary. A
clean filter will have 1 to 2 psid (6.9 to
13.8 kPa). The oil filter should be
changed at 6 psid (41.4 kPa) pressure
drop across the filter.
c. Check gages and controls for proper
operation and calibration.
d. For other than water chiller
applications, field test chiller cooling
medium for proper freeze point. (Brine
applications, check pH)
e. Inspect all motor starter control relay
contacts for arcing and replace if
required. Check thermal switch heaters
and starter linkages for proper
operation.
f. Check oil sump heaters for proper
operation.
g. Check and record the following
additional items:

Oil temperature at manifold

Oil pump motor current

Oil pump motor voltage

Suction superheat
- 18 -

Discharge superheat
Evaporator and condenser pressure
drop

h. Check filter drier pressure drop.

(Maximum operational pressure drop
across filter is 5 psid (34.5 kPa)
i. Check unloaders for proper loading
and unloading speed. For a full stroke
a maximum of two (2) minutes should
elapse.
j. Check all sub-systems for proper
operation, i.e. evaporator oil return,
water cooled oil cooler.
k. Check condenser water regulating
valve (s) for proper adjustment.

4.2.4 Half Yearly Interval

Maintenance
a. Check coupling alignment (direct
drive compressors, oil pump).
b. Field test oil for acidity. Take action if
required. Low temperature and heat
reclaim require professional analysis at
half yearly interval.
NOTE: PH factor and total acid number
(TAN) are highly responsive to moisture.

4.2.5 Annual Maintenance

a. Send sample of oil to laboratory for
thorough analysis. Record of the
analyses will provide a continuous
case history, and insight, as to what
system components have contributed
to the quality of the oil. Change oil if
required.
b. Send sample of evaporator medium
and condenser water to laboratory for
analysis. This will provide insight as
to what maintenance may be
performed to prevent corrosive
chemical activities.
c. Send sample of refrigerant to
manufacturer for professional analysis
of contamination. Water content
should not exceed 20 PPM.
d. Check, recalibrate operating and safety
controls. Design settings are noted on
the particular job wiring diagram.

4.0 MAINTENANCE
e.
f.

g.

h.
i.
j.

k.

Inspect and clean all satellite equipment

per manufacturers recommendations.
Check compressor seal for refrigerant and
excessive oil leakage. If a maintenance
action is necessary, refer to the latest
edition of the LSC Compressor Manual
6136. If necessary, an update to the latest
seal design is recommended.
Check compressor thrust bearings by
loosening coupling center and checking
male rotor for axial float. If axial float
exists, refer to Compressor Service
Manual 6136 for thrust bearing
service/replacement.
Insure compressor coupling is aligned.
Lubricate compressor motor (direct drive)
per manufacturers recommendations.
Remove condenser heads, and have tubes
inspected for corrosion by a professional
agency. Clean condenser and heat
exchanger(s) as outlined in this manual.
Failure to comply may result in system
problems. Plug or replace tubes if
required.
Check, re-adjust oil pump and clearance.
Align oil pump motor coupling (direct
drive oil pump).

4.2.6 Three Years Interval

Maintenance
a.
b.
c.

d.

e.

f.

Perform annual maintenance.

Replace compressor shaft seal with latest
version.
Inspect/replace compressor unloader,
injection tube, and slipper seal parts if
abnormal operation exists.
Inspect/replace compressor unloader
guide block if wear is evident. Check
slide valve guide and spindle snap rings
for security.
Check compressor balance piston/sleeve
clearance. Replace if beyond limits or if
there has been any changes in unit oil
pressure.
Check rotors for radial and lateral
movement. If movement is beyond pre
selected limits, take appropriate action or
consult factory.

4.2.7 Six Years Interval

Maintenance

- 19 -

a. Repeat three years interval

maintenance.
b. Replace thrust bearing.

4.2.8 Nine Years Interval

Maintenance
A major disassembly and inspection of
the compressor is to be made. The
compressor condition will determine if it
should be field rebuilt or scheduled for a
factory exchange rebuild.
4.2.9 Seasonal Shut-Down

Maintenance
a. Shut down IPCX Unit in normal
manner and partially pumpdown
system.
b. Perform annual maintenance.
c. If unit is located where ambient
temperature will be below freezing,
drain all water thoroughly and blow
out vessel (direct expansion chiller)
with compressed air.
NOTE: Simply draining is not sufficient.
d. Open disconnect switches.
e. Run the oil pump periodically to fill
the pump seal cavity with oil. This will
prevent refrigerant from leaking.
(Direct Drive Units).

4.3 Water Conditions

Standard construction of the evaporator and
condenser used in Dunham-Bush model IPCX
units are copper tubes with steel tube sheets and
header.
These materials are generally suitable for use with
clean fresh water found in most localities.
However, minerals and other contaminants found
in some water systems may promote aggressive
attack on the tubes or tube sheets, resulting in
failure with serious consequences for the entire
package chiller.
Because Dunham-Bush has no control over the
condition of the water used in these machines, we
can take no responsibility for failure of tubes or
tube sheets due to water corrosion or erosion. It is
recommended that the buyer obtain the services of
local water treatment specialists to prescribe
water treatment. Copper-nickel tubes and stainless
tube sheets are however available as an option.

4.0 MAINTENANCE
4.3.1 Water Treatment
Water tends to leave silt, algae and
mineral deposits in the tubes. This fouling
gradually decreases unit efficiency. For
this reason, a program of water treatment
should be employed. At regular intervals
depending on the water quality, the unit
should be shut down to have the tubes
cleaned.

4.3.2 Vessel Maintenance

4.3.2.1 General
The efficient performance of the
vessel tubes heat transfer surfaces
are essential for efficient
performance of the unit. If these
surfaces accumulate a film of
dirt, scale or slime, their
performance
will
degrade
substantially. The heat transfer
surfaces on the refrigerant side
does not foul since refrigerant is a
good solvent and it is in a closed,
filtered cycle. Water side 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.
4.3.2.2 Water Side Cleaning Of Vessels
The effects of fouling of the
vessel's heat transfer surfaces can
be detected by recording full load
performance data on a log sheet.
The best measure of performance
is approach, which is the
difference between leaving water
temperature
and
saturated
refrigerant temperature at the
pressure in the vessel.
At full load, read refrigerant
pressure in the vessel and the
leaving
chilled/hot
water
temperature on the computer. Use
table
4.5
to
find
the
corresponding
saturated
temperature for the proper
refrigerant at the pressure
measured.
- 20 -

Then calculate approaches as

follows:
Approach = leaving chilled water temperature evaporator saturation temperature
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 water side surfaces at
least annual 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.
Condenser vessel shall be of
cleanable shell and tube type with
integral finned copper tubes
mechanically expanded into
heavy fixed steel tube sheets. The
condenser shall be sized for full
pump down capacity. Water
heads are removable for tube
cleaning. Vent and drain plugs
are to be provided in each head.

4.3.3 Condenser Cleaning

To assure optimum efficiency, the
condenser water tubes should be cleaned
of scale, sludge, and slime deposits.
Individual water conditions will
determine how often the
tubes are cleaned. One indication of tube
fouling, is rising condensing pressures
not attributed to air or other causes.
There are two methods of tube cleaning.
1. Mechanical - Using brushes to remove
loose material deposits.
2. Chemical - Flushing solvent to remove
scale deposits.
NOTE: It is recommended that only a reputable
professional chemical cleaning

4.0 MAINTENANCE
organization be used for the cleaning of
the condenser. Damage could result to
the heat exchanger from the use of an
improper, solution or from exposure for
too long a period.
Mechanical Cleaning of Condenser
NOTE: Head gaskets need not be
renewed after each head disassembly
operation. Gasket must to replaced if it is
physically disfigured or otherwise
deteriorated.
1. Isolate water side of condenser, vent,
drain and remove heads.
2. Remove loose material which has
settled in the tubing with brushes.
Flush thoroughly with fresh water,
drain and restore heads and piping to
vessel, torquing nuts evenly. Insure
no entrapped air exists by venting high
points of water system.
Condenser Relief Valves
The condenser relief valve is adjusted and
sealed at the factory. No maintenance is
anticipated. However, if the relief valves
do blow off at the design pre-set
pressure, the cause should be
determined and the relief valves should
be replaced if they do not properly reseat.

4.3.4 Liquid Injection Oil Cooling

System
The water cooled oil coolers require
periodic cleaning of the waterside to
assure maximum efficiency. It is
recommended that the tubes are cleaned
out at the same time that the condenser is
cleaned. (Refer to 4.3.3)

4.3.5 Cleaning Chiller

Because the chiller water or brine is a
closed system, less frequent cleaning of
the chiller tubes is required.
NOTE: It is recommended that only a reputable
professional
chemical
cleaning
organization be used for the cleaning
of the chiller. Damage could result to the
heat exchanger from the use of an
improper solution, or from exposure
for too long a period.
- 21 -

Chiller relief valve(s)

The chiller relief valve is adjusted and sealed
at the factory, no maintenance is anticipated.
However, if the relief valve does blow-off at
the design pre-set pressure, the cause should
be determined and the relief valve should be
replaced if it does not properly re-seat.
4.3.5.1 Brine Maintenance
The chiller cooling medium
must be periodically checked
and maintained at design percent
concentration, for a freeze point
at least 10F (6C) below
minimum saturated evaporator
temperature. The actual freeze
point may be determined by
obtaining the specific gravity
(with a hydrometer) and the
temperature of the brine. With
this data obtained, the percent
concentration and freeze point
may be determined from curves
available
from
the
brine
manufacturer.
WARNING: The factory is not responsible for
damage due to chiller freeze-up
as a result of negligent
periodic maintenance of brines.
Chloride Brines
In addition to proper freeze point,
chloride
brines
require
special
precautions. A rust inhibitor must be
used in adequate quantity and the brine
PH must be checked and adjusted
periodically to prevent potential chiller
corrosion. Brine PH must be maintained
between 7.5 and 8.0 and must be
adjusted before filling chiller.
NOTE: Consult brine manufacturer or a
professional agency for mixing the
solution,
adjusting
PH,
and
proportioning the rust inhibitor.
4.3.5.2 Suction Filter
The suction filter should
normally be inspected, cleaned
or the element replaced only
when a major overhaul is
performed.

4.0 MAINTENANCE
specifications
and
periodic
insulation resistance tests are also
recommended.

1. Transfer refrigerant to the condenser or

remove the charge completely. Isolate
the chiller and insure chiller is at
atmospheric pressure.

4.4.1.3. Coupling Alignment

2. Remove insulation at chiller suction

head and suction flange. Remove flange
bolts at chiller head and suction piping
flange.

Shafts become misaligned as a

result of many natural and
unavoidable
causes.
Heat,
vibration, bearing wear, the
settling of foundations, etc., all
tend to alter alignment. Periodic
checks of the compressor coupling
is recommended.

3. Remove chiller head and pipe assembly,

head flange 0-Ring and suction pipe
flange gasket.
4. Disassemble filter element and inspect.
Clean filter element with compressor or
replace if necessary.

NOTE: The coupling should be hot when

making alignment adjustments.
Also the motor should be
aligned to the compressor.

5. Reassemble filter element to head with

felt facing chiller.
6. Install chiller head assembly using new
flange gaskets and head 0-ring.

SP-16
(Compressor Coupling Alignment)

7. Add refrigerant as required and test for

any refrigerant leakage.

1. To check angular misalignment

(Figure B) mount indicator (as shown
on left flange) with stem on face of right
flange. Rotate equipment noting
maximum and minimum indicator
reading. Move equipment as
necessary to reduce the total indicator
reading to that shown below.

4.4 COMPONENT MAINTENANCE

4.4.1 Compressor/Motor Assembly
4.4.1.1 Compressor
All inspection, maintenance, or
repairs of the compressor, must be
done by an authorized, qualified
Dunham-Bush,
Inc.
Service
Representative as listed in the latest
edition of Form Number 9822. If
the customer has any reason to
suspect a problem, he should
contact the Dunham-Bush Service
Representative
for
assistance.
Failure to comply may jeopardize
the warranty. Repair information
may be found in the latest edition
of the LSC Compressor Service
Manual, Form No. 6136.
4.4.1.2 Compressor Motor
Direct drive motors must be
lubricated per manufacturer's
- 22 -

2. To check parallel misalignment (Figure

C) set indicator stem on outer surface
of flange. Rotate equipment noting
maximum and minimum indicator
reading. Move equipment as necessary
to reduce indicator reading to that shown
below. Be careful not to disturb the
setting of Step 1.
NOTE:

If it is necessary to remove the motor

alignment pins, the motor should be
repinned after the alignment corrections
are made.
3. Repeat Steps 1 and 2 as necessary.
4. Coupling hubs to be spaced to
dimension C, as shown in the table
below.

4.0 MAINTENANCE
5. This coupling should be rotated several
revolutions to make sure no "endwise
creep" in connected shafts is measured.
6. Tighten all bolts as shown in chart
below.

7. When operating at full speed, both

laminated rings should have a distinct
and clearly defined appearance not
blurred when viewed from top and
side.

FIGURE 4.4 COUPLING ALIGNMENT

A.) COUPLING IN ALIGNMENT

B.) TEST FOR ANGULAR MISALIGNMENT

BOLT TORQUE
THOMAS
COUPLING
SERIES

FORMFLEX
COUPLIN
G SERIES

THOMAS

C.) TEST FOR PARALLEL MISALIGNMENT

DIMENSION C
(SEE FIG. A)

MISALIGNMENT (TIR)

FORM-FLEX

PARALLEL

ANGULAR

ft.lb.

kg.m.

ft.lb.

kg.m.

Inch

mm

Inch

mm

Inch

cm

163 DBZ-B

13

1.8

0.003

0.076

0.003

0.076

2 7/16

6.19

201 DBZ-B

25

3.5

0.005

0.127

0.005

0.127

2 15/16

7.46

226 DBZ-B

AK 30

43

6.0

40

5.5

0.005

0.127

0.005

0.127

3 13/16

9.68

263 DBZ-B

AK 35

63

8.7

40

5.5

0.007

0.178

0.007

0.178

4 5/16

11.00

301 DBZ-B

AK 40

95

13.1

80

11.1

0.007

0.178

0.007

0.178

4 7/8

12.38

351 DBZ-B

AK 45

175

24.2

80

11.1

0.007

0.178

0.007

0.178

5 7/8

14.90

350-51

95

13.1

0.007

0.178

0.007

0.178

15.24

1. Consult factory for complete engineering specification ASY-ES-1, if additional information is required.
2. TIR = Total Indicator Reading.
3. Compressor alignment data is subject to periodic change. Consult latest North American Service Bulletin SR-109

4.5

MAINTENANCE RECORDS

4.5.1 Logs
It is recommended that permanent daily
records of system operating conditions be
recorded at least once a day. The records
should be retained as they are invaluable
in determining patterns of operational

- 23 -

change that will indicate the need for

maintenance or service. System design
conditions are established by the readings
entered when the unit is first installed.
NOTE: In addition to the Daily/Monthly
log sheets, annual and seasonal
maintenance is required. (See periodic
Maintenance Section)

4.0 MAINTENANCE
R134a PRESSURE/TEMPERATURE PROPERTIES

TABLE 4.5
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.

- 24 -

5.0 TROUBLESHOOTING
5.1

entered in the current Daily Log with those

entered immediately following installation of the
unit will be of considerable assistance in locating
trouble areas.

GENERAL

Operating personnel must be completely familiar

with the equipment and this manual. This will be
necessary for correct diagnosis of any troubles
and will permit immediate correction of minor
difficulties. It is important that operators be able
to quickly distinguish conditions requiring expert
service in order to minimize down-time and
maintenance expense. Comparison of the readings
SYMTOM
A. Unit shuts
down on
compressor
starter
overload

B. Unit shuts
down on oil
pump starter
overload

To determine and isolate common problems

which might occur, the following chart was made
which lists symptoms, possible causes and
remedies.

POSSIBLE CAUSE

REMEDY

1. Faulty compressor or motor

2. Overloads trip below 105% of full load
amperage
3. Low voltage
4. Load limit relay out of adjustment
5. Check and adjust for proper operation

1. Contact Dunham-Bush Service Representative

2. Install properly sized overloads
3. Check line voltage. Must be 10% of rated voltage

1. Cold oil

1. Check oil sump heaters for proper operation, repair and

replace as necessary
2. Check line voltage must be 10% of rated voltage
3. Clean and repair as necessary
4. Clean and replace as necessary
5. Repair or replace as necessary
6. Open service valve

2.
3.
4.
5.
6.

Low voltage
Bound Pump
Plugged oil filter
Faulty motor
Closed service valve

1. High Discharge Pressure

a. Poor or no condensing water flow

1.
a. Clean strainers, check setting of flow valve, check
condenser pump - clean and repair as necessary
b. Clean tubes, have water checked by water treatment
specialist
c. Remove excess refrigerant
d. Purge air or non condensables

b. Condenser tubes fouled

C. Unit shuts
down on
High-Low
pressure
switch

c. Refrigerant overcharge
d. Air or non-condensables in
refrigerant system
e. Water supply to condenser is too
warm
f. Pressure switch out of calibration
2. Low Suction Pressure
a. Plugged filter/drier
b. Low refrigerant charge

e. Check, repair and adjust condenser water cooling

facilities
f. Reset or replace as necessary
2.
a. Replace elements if pressure drop is above limits
b. Check sight glass for flashing gas, check for leaks,
repair leaks. Add refrigerant as necessary
c. Check control valves for proper settings, check for
dirty strainer, adjust clean and repair as necessary
d. Clean chiller, consult water treatment specialist
e. Check and reset or replace free-up switch as
necessary, check brine for proper % solution
f. Reset or replace as necessary
g. Adjust condenser water regulating valve (if
applicable). Check tower temperature controls

c. Low water flow thru chiller

d. Fouled chiller
e. Frozen chiller
f. Pressure switch out of calibration
g. Low condenser water temperature
Units with Liquid Injection:
1. Low refrigerant charge
2. Inoperative liquid injection TX valve
3. Inoperative liquid injection solenoid
D. Shutdown on 4. Discharge temperature thermostats out
of adjustment
high temp
Units with Water Cooled Oil Cooler:
5. Oil cooler water valve out of adjustment
6. Inadequate water supply to oil cooler
7. Dirty oil cooler

1. Check sight glass for flashing gas, check for leaks,

repair leaks and add refrigerant as necessary
2. Replace valve
3. Check oil for burnout
4. Reset to lower temperature
5. Readjust
6. Check condenser water pump and clean strainer
7. Check and clean tubes if necessary, check condenser
water treatment installation

- 25 -

5.0 TROUBLESHOOTING
SYMTOM

POSSIBLE CAUSE

REMEDY

1. Low refrigerant charge

E. Shutdown of
unit on seal
oil temp

F. Unit shuts
down on
freezestat

1. Check sight glass for flashing gas, check for leaks.

Repair leaks add refrigerant as necessary
2. Replace valve
3. Check coil for burnout
4. Clean or replace as necessary

2. Inoperative TX valve
3. Inoperative seal oil cooler solenoid
4. Filter drier plugged
1. Inadequate flow of chilled water

1. Check settings of valves, clean strainers, check chiller

pump, clean and repair as necessary
2. Reset or replace as necessary
3. Readjust to desired leaving chilled water temperature

2. Malfunctioning freezestat
3. Incorrect TLC temperature setting

1. Pump malfunctioning
G. Unit shuts
2. Strainers plugged
down on flow 3. Valves not set properly
switch
4. Air in system
5. Flow switch inoperable
H. Unit shuts
down on
chilled water
pump

1.
2.
3.
4.
5.

1. Overload on pump

1.
a. Pump malfunctions, repair or replace as necessary
b. Plugged
c. Closed system valves, reset as necessary

1. Sump heaters not functioning during off

period
2. Maladjusted expansion valves
J. Low
discharge/oil
temperature

Check pump, clean and repair as necessary

Clean strainers
Reset valves
Bleed system
Replace

1. Repair and replace as necessary

2. Readjust superheat settings of main expansion valves,

liquid injection and seal oil cooler expansion valves
3. Discharge temperature thermostat out of 3. Reset to lower temperature
adjustment
Water Cooled Oil Coolers
Water Cooled Oil Coolers
4. Oil cooler water valve out of adjustment 4. Readjust
5. High water pressure
5. Readjust water pressure regulator
1. Maladjusted expansion valve

K. High
discharge/oil
temperature

1. Readjust superheat settings of main expansion valves,

liquid injection and seal oil cooler expansion valves
2. Discharge temperature thermostat out of 2. Reset to lower temperature
adjustment
3. Liquid injection solenoid valve
3. Check coil for burnout
malfunction
Water Cooled Oil Coolers
Water Cooled Oil Coolers
4. Oil cooler water valve out of adjustment 4. Readjust
5. Inadequate water supply to oil cooler
5. Check condenser water pump and clean strainer
6. Dirty oil cooler
6. Check and clean tubes
1. Check unit visually for leaks, repair as necessary
2. Readjust superheat as necessary

L. Unit
periodically
running low
or losing oil

1. External oil leak

2. Low discharge superheat and or suction
superheat
3. Units with jet pump not picking up oilclogged lines or maladjusted valves
4. Discharge temperature thermostat out of
adjustment
5. Liquid injection solenoid valve
malfunction
6. Liquid injection TX valve malfunction
1. Oil filter plugged
2. Low oil pressure safety switch
malfunction
3. Low discharge superheat and/or suction
superheat

1. Clean and replace as necessary

2. Repair or readjust as necessary

M. Shut down
on low oil
pressure

3. Repair or readjust as necessary

4. Reset to lower temperature
5. Repair or readjust as necessary
6. Repair or readjust as necessary

3. Readjust superheat as necessary

- 26 -

6.0

FORMS

6.1 CONDITION OF UNIT SHEET

JOB NAME
ADDRESS
MODEL NO.
SERIAL NO.
*Essential Information

It is Dunham-Bushs objective to manufacture quality products that arrive at the buyer site in good
condition. You can help us serve you if you will fill out this report upon receipt of the unit you
purchased. Please complete this form fully and return to Dunham-Bush immediately in the postage paid
self-addressed envelope attached.

A. CONDITION OF UNIT

YES

NO

COMMENTS

1. All components intact

2. Insulation damage
3. Piping damage
4. Condition of painted surfaces
5. Welding damage
6. Evidence of oil leaks
7. Evidence of refrigerant leaks
8. Has claim been made against carrier
for shipping damage?
B. OWNERS MANUAL
(In Control Panel)
1. Problem with rigging or moving
C. MISCELLANEOUS PARTS RECEIVED:
1. Vibration pads (or) isolators
(when called for)
2. Flow switch (when called for)
3. Cooler / Condenser
4. Drain Flugs
5. Keys
D. EQUIPMENT IS TO BE STORED ON
A LEVEL SURFACE IN A PROTECTED
AREA FREE FROM JOBSITE DAMAGE

CONTRACTOR
ADDRESS
CITY

STATE

PHONE

DATE

ZIP

SIGNED
TITLE

- 27 -

6.0

FORMS

6.2 SAMPLE LOG SHEET

SHEET NO. .............................

IPCX PRESSURE / TEMPERATURE LOG

NAMEPLATE DATA: .......................................................................................................................
UNIT MODEL IPCX : ................................... UNIT SERIAL NO. ...................................................
JOB NAME : ................................................. LOCATION :.............................................................
START UP :

DATE .................................. TIME ......................................

COMPRESSOR SLIDE VALVE POSITION

A

SUCTION TEMPERATURE

SATURATED SUCTION TEMPERATURE

SEAL OIL TEMPERATURE

DISCHARGE TEMPERATURE

DISCHARGE PRESSURE

SATURATED DISCHARGE TEMPERATURE

_______%

_______%

_______%

_______%

_______%

_______%

PSI

PSI

PSI

PSI

PSI

PSI

DISCHARGE SUPERHEAT (F-D)

G

OIL & DISCHARGE PRESSURE

NET OIL PRESSURE (G-E)

CONDENSER LIQUID OUT TEMPERATURE

CONDENSER LIQUID OUT PRESSURE/

SATURATED
NET SUBCOOLING (H-I)

EVAPORATOR WATER IN F

EVAPORATOR WATER OUT F

EVAPORATOR APPROACH (B-K)

CONDENSER WATER IN F

CONDENSER WATER OUT F

CONDENSER APPROACH (F-M)
GPM CONDENSER
GPM EVAPORATOR
PRESSURE DROP ACROSS OIL FILTERS MAX
5#
COMPRESSOR VOLTAGE AND AMPERAGE

- 28 -

6.0

FORMS

6.3 REQUEST FOR START-UP SUPERVISION ON

CHILLER AND CONDENSING UNITS
JOB NAME
ADDRESS
UNIT MODEL NO. *
UNIT SERIAL NO. *
CUSTOMER P.O. NUMBER

*ESSENTIAL INFORMATION
A. DUNHAM-BUSH UNIT
1. Erected on foundation --------------------------------------------------------------------------------------------------------------------------------------- AA
2. Spring isolators or ISO pads installed and adjusted to level unit--------------------------------------------------------------------------------- AA
B. PIPING
1. Cleaned and pressure tested for leaks------------------------------------------------------------------------------------------------------------------ AA
2. Properly supported vibration eliminators installed ------------------------------------------------------------------------------------------------- AA
3. Strainers installed to prevent contamination ----------------------------------------------------------------------------------------------------------- AA
4. Air vents thermometers and pressure gauges installed------------------------------------------------------------------------------------------ AA
5. Chill water flow switch and operating thermostat bulb installed (if applicable) --------------------------------------------------------------- AA
6. All level controls modulating flow controls checked and calibrated --------------------------------------------------------------------------- AA
7. All water and brine flows set a design flow requirements ------------------------------------------------------------------------------------------ AA
8. Water treatment system installed ------------------------------------------------------------------------------------------------------------------------- AA
C. ELECTRICAL WIRING
1. Adequate power supply available ------------------------------------------------------------------------------------------------------------------------ AA
2. All power wiring and control wiring completed to all of the system components ------------------------------------------------------------- AA
3. All circuit breakers overload relays properly sized and installed --------------------------------------------------------------------------------- AA
4. All wiring and grounding conforms to National and Local Electrical Codes ------------------------------------------------------------------- AA
5. Unit terminal blocks connected with copper conductors-------------------------------------------------------------------------------------------- AA
D. UNITS WITH REMOTE REFRIGERANT CONDENSER PIPING
1. Required amount of refrigerant for system charging at job site ---------------------------------------------------------------------------------- AA
2. Entire system properly dehydrated must hold vacuum at 800 to 1,000 microns for a minimum of eight hours with vacuum
pump secured-------------------------------------------------------------------------------------------------------------------------------------------------- AA
3. All fan cycling damper control systems checked and operational ----------------------------------------------------------------------------- AA
4. All control and power wiring installed -------------------------------------------------------------------------------------------------------------------- AA
E. REMOTE EVAPORATOR SYSTEMS
1. Liquid line solenoid interlocked with Dunham-Bush unit control panel ------------------------------------------------------------------------- AA
2. Entire system properly dehydrated must hold vacuum at 800 to 1,000 microns for a minimum of eight hours with vacuum
pump secured-------------------------------------------------------------------------------------------------------------------------------------------------- AA
3. All thermal expansion valves properly sized and properly installed ----------------------------------------------------------------------------- AA
4. All refrigerant piping installed in accordance with standard design criteria ASHRAE - RSES ----------------------------------------- AA
5. All terminal equipment properly sized and properly installed ------------------------------------------------------------------------------------- AA
6. All automatic control devices checked and operational--------------------------------------------------------------------------------------------- AA
F. CONDITIONS
1. Full load available for proper test and balance of Dunham-Bush equipment ----------------------------------------------------------------- AA
2. Sign reverse side --------------------------------------------------------------------------------------------------------------------------------------------- AA
FAILURE TO COMPLETE AND CHECK ALL OF THE ABOVE ITEMS MAY RESULT IN CHARGES TO THE CUSTOMER FOR
DISPATCHING SUPERVISION TO JOBSITE

- 29 -

6.0

FORMS

SERVICES TO BE RENDERED
The initial start-up of the Rotary Screw Chillers or Condensing Units will be supervised by a Dunham-Bush Service
Representative. He will supervise the work of the installing contractor on the following items:
1.
2.
3.
4.
5.

Checking the unit for leaks.

Charging the unit with initial refrigerant charge. (Remote refrigerant piped unit)
Checking the unit and its factory-mounted controls.
Check test and start.
Supervise training of operator and contractor personnel.

THE SUPERVISORY SERVICES LISTED ABOVE DO NOT INCLUDE ANY

RESPONSIBILITY FOR THE FOLLOWING:
1. Installation and operation of the temperature control system external to the unit
a. Balancing of the air distribution side of the system.
b. Balancing of the water side of the system. (As required)
c. Balancing of refrigerant systems.
2. Electrical wiring performed by others

THE INSTALLING CONTRACTOR SHALL FURNISH THE FOLLOWING:

1. All materials and labor required to complete the installation.
2. A refrigeration service mechanic to assist Dunham-Bush start-up personnel during the initial start-up to be trained
in unit operation. This training is essential in performing In-Warranty labor incumbent upon installing contractor,
and or end user.
3. A refrigeration service mechanic to repair all refrigerant leaks discovered as well as repair or replace all
refrigerant and parts of the system that may need repair or replacement.
4. A suitable load for tests and adjustments (units cannot be satisfactorily tested with less than full load condition,
the manufacturer cannot assume any responsibility for the operation of the unit until it has been satisfactorily
tested and accepted by the purchaser).
5. Evacuation of the unit and component system.
With reference to the term of this contract, we (the customer)
of the Dunham-Bush Authorized Representative at the job site on or about

are requesting the presence

Month

Day

Year

to supervise start-up of the system and instruct our operating personnel. On receipt of this form, Dunham-Bush will
schedule their representative to this job within ten to fourteen days of the requested date. We, the undersigned, will
have our operating and servicing people at the job site for training, and to assist with the start-up of this equipment,
this training being a requirement to implement servicing the equipment.
It is understood that the services of the Dunham-Bush Service Representative will be furnished per the Terms of
Sale Agreement for a period not to exceed the normal working days as stipulated in the Terms of Sale. We, the
undersigned as purchaser or representative of the purchaser, agree that we will pay a fee for such time that is spent
on this job that is over the specific normal working days agreed to in the purchase contract. *To cover this
contingency our Contingency Purchase Order No.
will be issued with the assurance that if no additional
time is required this purchase order will be canceled.
An overtime charge will be rendered for work executed on Saturday and Sunday.
*Consult Dunham-Bush International (Thailand) Ltd. for current service rates.

CONTRACTOR
ADDRESS
CITY

STATE

PHONE

DATE

ZIP

SIGNED
TITLE

- 30 -