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DCLC

Centrifugal water chiller

Installation Manual

Version Number：2010-4-23

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Contents

1 - SAFETY CONSIDERATIONS.........................................................................................................................................3

1.1 - Installation safety considerations..............................................................................................................................3

1.2 - Maintenance safety considerations ..........................................................................................................................4

1.3 - Operating checks.......................................................................................................................................................4

1.4 - Equipment and components under pressure............................................................................................................4

1.5 - Repair safety considerations .....................................................................................................................................5

2 –INSTALLATION .................................................................................................................................................................6

2.1 - Introduction...............................................................................................................................................................6

2.2 - Receiving the chiller ..................................................................................................................................................6

2.2.1 - Inspect shipment.........................................................................................................................................6

2.2.2 - Provide chiller protection ...........................................................................................................................7

2.3 - Lift the chiller.............................................................................................................................................................8

2.3.1 –Rig the entire DCLC chiller........................................................................................................................8

2.3.2 - Rig chiller components ..............................................................................................................................9

2.3.3 - Lifting ............................................................................................................................................................9

2.3.4 - Physical data .............................................................................................................................................14

2.4 - Install chiller supports .............................................................................................................................................14

2.5 - General drawings of piping and electrical connection............................................................................................16

2.6 – Connect water piping..............................................................................................................................................18

2.6.1 - Install water piping to heat exchanger...................................................................................................19

2.6.2 - Install vent piping to safety valves .........................................................................................................21

2.7 - Make electrical connection .....................................................................................................................................22

2.7.1 - The electrical characteristics of the DCLC units. .................................................................................22

2.7.2 - Installation standards and precautions..................................................................................................25

2.7.3 Electrical characteristics ............................................................................................................................25

2.7.4 - Connect the starting cabinet ...................................................................................................................27

2.7.5 - Connect the starting cabinet to the control box ...................................................................................28

2.7.6 - Connect Power Wires to Oil Pump Starter ...........................................................................................28

2.7.7 - Make the necessary connections for the outgoing control signals ...................................................28

2.7.8 - Motor connections ....................................................................................................................................29

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The DCLC series centrifugal chillers are applicable for air conditioning system or technology

process in need of the chilled water. And the owner must provide cooling system by themselves.

Please refer to the specifications of the chiller on the name plate.

1 - SAFETY CONSIDERATIONS

DCLC liquid chillers are designed to provide safe and reliable service when operated within design

specifications. When operating these chillers, use good judgment and safety precautions to avoid

damage to equipment and property or injury to personnel.

Be sure you understand and follow the procedures and safety precautions contained in the chiller

instructions as well as those listed in this guide.

1.1 - Installation safety considerations

In certain cases the safety valves are installed on stop valves. These valves are factory-supplied

lead-sealed in the open position. This system permits isolating and removing the safety valves for

checking and replacing. The safety valves are designed and installed to ensure protection against

high pressure and fire risk.

All factory-installed safety valves are lead-sealed to prevent any calibration change. If a safety

valve is removed for checking or replacement please ensure that there is always an active safety

valve on each of the reversing valves installed in the unit.

The safety valves must be connected to discharge pipes. These pipes must be installed in a way

that ensures that people and property are not exposed to refrigerant leaks. These fluids may be

diffused in the air, but far away from any building air intake, or they must be discharged in a

quantity that is appropriate for a suitably absorbing environment. Periodic check of the safety

valves: See “Maintenance safety considerations”.

DANGER:

� DO NOT VENT safety valves into a building. Outlet from valves must be vented outdoors.

PROVIDE adequate ventilation, especially for enclosed and low overhead spaces. Inhalation of

high concentrations of vapor is harmful and may cause heart irregularities, unconsciousness,

or death. Misuse can be fatal. Vapor is heavier than air and reduces the amount of oxygen

available for breathing. Product causes eye and skin irritation. Decomposition products are

hazardous.

� DO NOT USE OXYGEN to purge lines or to pressurize a chiller for any purpose. Oxygen gas

reacts violently with oil, grease, and other common substances.

� NEVER EXCEED specified test pressures, verify the allowable test pressure by checking the

instruction literature and the design pressures on the chiller nameplate.

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� DO NOT USE air for leak testing. Use only refrigerant or dry nitrogen.

� DO NOT VALVE OFF any safety device. BE SURE that all pressure safety valves are properly,

installed and functioning before operating any chiller.

1.2 - Maintenance safety considerations

Engineers working on the electric or refrigeration components must be authorized, trained and fully

qualified. All refrigerant circuit repairs must be carried out by an authorize engineer, fully qualified

to work on these units. He must be familiar with the equipment and the installation.

NOTE:

During any handling, maintenance and service operations the engineers working on the unit must

be equipped with safety gloves, glasses, shoes and protective clothing.

WARNING:

� DO NOT WELD OR FLAMECUT any refrigerant line or vessel until all refrigerant (liquid and

Vapor) has been removed from chiller. Traces of Vapor should be displaced with dry air

nitrogen and the work area should be well ventilated. Refrigerant in contact with an open flame

produces toxic gases.

� DO NOT work on high-voltage equipment unless you are qualified.

� DO NOT WORK ON electrical components, including control panels, switches, relays etc, until

you ensure ALL POWER IS OFF; residual voltage can leak from capacitors or solid state

components.

� LOCK OPEN AND TAG electrical circuits during servicing. IF WORK IS INTERRUPTED,

confirm that all circuits are de-energized before resuming work.

1.3 - Operating checks

During the life-time of the system, inspection and tests must be carried out against the national

standards. The safety devices on site must be checked each year. And every five years for external

overpressure devices (safety stop valves). If the chiller operates in a corrosive environment,

inspect the protection devices more frequently.

NOTE:

� DO NOT ATTEMPT TO REPAIR OR RECONDITION any safety devices when corrosion or

build-up of foreign material (rust, dirt, scale, etc.) is found within the valve body or mechanism.

� DO NOT install safety valves in series or backwards.

� PROVIDE A DRAIN connection in the vent line near each pressure relief device to prevent a

build-up of condensate or rain water.

1.4 - Equipment and components under pressure

These products incorporate equipment or components under pressure, manufactured by

Dunham-Bush or other manufacturers. Consult your appropriate national trade association or the

owner of the equipment or components under pressure (declaration, re-qualification, retesting, etc).

The characteristics of this equipment/these components are given on the nameplate or in the

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required documentation, supplied with the products.

1.5 - Repair safety considerations

All installation parts must be maintained by the personnel in charge, in order to avoid material

deterioration and injuries to people. Faults and leaks must be repaired immediately. The authorized

technician must have the responsibility to repair the fault immediately. Each time repairs have been

carried out to the unit, the operation of the safety devices must be re-checked. If a leak occurs or if

the refrigerant becomes polluted (e.g. by a short circuit in a motor) remove the complete charge

using a recovery unit and store the refrigerant in mobile containers. Repair the leak detected and

recharge the circuit with the total R134a charge, as indicated on the unit name plate.

NOTE:

� DO NOT siphon refrigerant. AVOID SPILLING liquid refrigerant on skin or getting it into the

eyes. USE SAFETY GOGGLES AND SAFETY GLOVES. Wash any spills from the skin with

soap and water. If liquid refrigerant enters the eyes, IMMEDIATELY FLUSH EYES with water

and consult a physician.

� NEVER APPLY an open flame or live steam to refrigerant cylinder. Dangerous overpressure

can result. If it is necessary to heat refrigerant, use only warm water.

� DO NOT REUSE disposable (non-returnable) cylinders or attempt to refill them. It is

DANGEROUS AND ILLEGAL. When cylinders are emptied, evacuate remaining gas pressure,

loosen the collar and unscrew and discard the valve stem. DO NOT INCINERATE.

� During refrigerant operations, CHECK THE REFRIGERANT TYPE before adding refrigerant to

the chiller. Wrong refrigerant can cause damage or malfunction to the chiller.

� Periodically monitor and repair or if necessary replace any component or piping that shows

signs of damage.

� DO NOT climb over a chiller. Use platform, or staging.

� USE MECHANICAL EQUIPMENT (crane, hoist, etc.) to lift or move heavy components. Even if

components are light, use mechanical equipment when there is a risk of slipping or losing your

balance.

� DO NOT USE eyelets to lift any part of the chiller or the complete chiller.

� BE AWARE that certain automatic start arrangements CAN ENGAGE TOWER FAN, OR

PUMPS. Open the disconnect ahead of the tower fans, or pumps.

� USE only repair or replacement parts that meet the code requirements of the original

equipment.

� DO NOT VENT OR DRAIN water boxes containing industrial brines, without the permission of

your process control group.

� DO NOT LOOSEN water box bolts until the water box has been completely drained.

� DO NOT LOOSEN a packing gland nut before checking that the nut has a positive thread

engagement.

� PERIODICALLY INSPECT all valves, fittings, and piping for corrosion, rust, leaks, or damage.

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2 –INSTALLATION

2.1 - Introduction

The DCLC chiller is factory assembled, wired, leak tested and electrically tested. Installation (not

by Dunham-Bush) consists primarily of establishing water and electrical services to the chiller. The

rigging, installation, site wiring, site piping, and insulation of water box covers are the responsibility

of the contractor and/or customer. Dunham-Bush will provide necessary guideline for the chiller

installation.

2.2 - Receiving the chiller

NOTE:

� Do not open any valves or loosen any connections. The standard DCLC chiller is shipped with

a nitrogen holding charge. Inspect for shipping damage while chiller is still on shipping

conveyance. If chiller appears to be damaged or has been torn loose from its anchorage, have

it examined by transportation inspectors before removal. Forward claim papers directly to

transport companies. Manufacturer is not responsible for any damage incurred in transit.

� Installation unit should be carried out by Professionals. Water chilling unit should be grounded

well. Moreover, the grounding wire can’t join to gas pipe, telephone line. Otherwise, there may

be an electric shock accident.

2.2.1 - Inspect shipment

Compare the name plate data with the order. Confirm that the unit received is the one ordered.

A. The unit nameplate must include the following information:

� Model number

� Cooling capacity

� Rated power consumption

� Refrigerant and charge amount

� Cooling/chilled water flow

� Chilled water in/outlet temperature

� Unit weight and outline dimensions

� Product no.

� COP value

� Power supply

� Cooling water in/outlet temperature

� Manufacturing date

� Production license no.

B. The cooler & condenser name plate

Check if there is any damage to the surface of delivered unit and accessories after unpackaged;

Fig.1 Chiller Name Plate

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then count the delivered goods according to the unit package list to see if there is anything missed

(including accessories and standbys). Immediately notify the nearest Dunham-Bush representative

if any item lost. (Safety valve discharge pipe) to connect to the outside

1-Vane actuator 2-Suction elbow 3- Condenser safety valve 4- Compressor motor

5-Motor sight glass 6- Heat exchangers connection plate 7- Cooler sight glass I

8- R134a enter valve 9-Oil pump 10-Chiller nameplate 11- Cooler sight glass II

12- Cooler safety valve 13- Micro-computer controller

2.2.2 - Provide chiller protection

To prevent loss or damage, leave all parts in original packages until the installation. In order to

prevent dirt and debris from entering chiller components during shipping, all opens should be

closed with covers or plugs. A full operating oil charge is placed in the oil sump before shipment.

Do not keep the DCLC units outside where they are exposed to the weather, as the sensitive

control mechanism and the electronic modules may be damaged. The unit should also be away

from fire source and flammable substance. If it is paralleled with heating elements such as boiler,

pay sufficient attention to the influence of heat radiation.

Fig.2 Typical DCLC Unit profile

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Choose places with indoor temperature below 45℃ and good ventilation. The unit should not be

installed and stored outdoors or in the open air, or in environments with corrosive gas.

The location of the unit should have good lighting for good maintenance and checking. And there

should be enough space for drawing out heat exchange pipes in the unit to meet the need of

maintaining, checking and cleaning the heat exchanger. The room should be longer than the length

of the unit.

Use a traveling crane or derrick crane for unit hoisting and checking. Make sure there is enough

overhead service clearance.

Water drainage can be thoroughly realized around the unit and in the entire chiller room.

If chiller is exposed to freezing temperature after water circuits have been installed, open water

drains in the waterbox and remove all water from Cooler and condenser. Leave drains open until

there is no water in the system.

Refrigerant detection systems(not by Dunham-bush) shall be fitted in chiller rooms for refrigerants

with ODP>0 or GWP>0 if the system charge is more than 25 kg. Refrigerant detection systems

shall be fitted in chiller rooms for any refrigerants in order to raise alarms and initiate ventilation if

the refrigerant’s level rises to 25 % of the LFL or 50 % of the ATEL/ODL.

The unit must be checked periodically during its operating life to ensure that no shocks (handling

accessories, tools etc.) have damaged it. If necessary, the damaged parts must be repaired or

replaced. See also “DCLC Operation and Maintenance Manual”.

2.3 - Lift the chiller

The entire DCLC chiller can be lifted as default. The flange connections allow the compressor,

cooler and condenser sections to be separated and lifted individually.

2.3.1 – Rigging the entire DCLC chiller

See rigging instructions on the label attached to chiller. Lift chiller only from the points indicated in

the instructions supplied and in the chiller rigging drawings. Each lifting cable or chain must be

capable of supporting the entire weight of the chiller.

NOTE:

� Lifting chiller from points other than those specified may result in serious damage to the unit

and personal injury. Rigging equipment and procedures must be adequate for chiller weight.

� These weights are broken down into component sections for use when installing the unit in

sections. For the complete chiller weight, add all component sections and refrigerant charge

together.

� Make sure that rigging cable is over the rigging bar before lifting.

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2.3.2 - Rig chiller components

Refer to instructions below:

� Only a qualified service technician should perform this operation.

� Do not attempt to disconnect flanges while the chiller is under pressure. Failure to relieve

pressure can result in personal injury or damage to the chiller.

� Wiring must also be disconnected, before rigging the compressor. In order to disconnect the

starter from the chiller, remove wiring for the oil pump, oil heater, control wiring at the control

box, and the main motor leads at the starter lugs. Remove all transducer and sensor wires with

the sensor. Clip all wire ties necessary to pull heat exchangers apart.

� If the Cooler and condenser vessels must be separated, the heat exchangers should be kept

level by placing a support plate under the tube sheets. The support plate will also help to keep

the vessels level and aligned when the vessels are bolted back together.

2.3.3 - Lifting

A. Packaged lifting: Before lifting, make sure the steel wire connect to the sheet hole and load

well-distributed. Be careful not to damage the other parts.

Pay more attention to following points:

� Lift the units horizontal as far as possible. If it has to be oblique, make sure the tilt angle less

than 20 °.

� Damage will happen when impact, be sure that the units will be transported smoothly and

safely.

� When transporting the module with rolling bars, do protect the units from overturning. Lifting pointLifting beam

1. Each sling should bear the whole chiller weight.2. Each sling can be adjusted according to the actual need.3. Moving or lifting the chiller by the forklift is Prohibited. Fig.3 Machine Rigging Guide

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“ ”

“ ”

“ ”

Length

A

Width

B

Height

C

Pipe

clearance

D

Transportation

weight

Operating

weight

R134a

weight Model

mm mm mm mm kg kg kg

DCLC300 4375 1600 2030 3800 5518 6201 227

DCLC350 4375 1600 2030 3800 5610 6391 258

DCLC400 4375 1600 2030 3800 5634 6479 290

DCLC450 4399 1879 2120 3800 7184 8221 337

DCLC500 4920 1879 2120 4300 8039 9329 402

DCLC550 4423 1994 2230 3800 8231 9651 467

DCLC600 4944 1994 2230 4300 9440 10996 542

DCLC650 4944 1994 2230 4300 9646 11334 548

DCLC700 4944 1994 2230 4300 9564 11195 541

DCLC750 4959 2096 2305 4300 10320 12236 643

DCLC800 4959 2096 2305 4300 10383 12338 643

DCLC850 5065 2426 2989 4300 15569 18049 769

DCLC900 5065 2426 2989 4300 15571 18051 769

DCLC1000 5065 2426 2989 4300 15615 18095 769

DCLC1100 5065 2426 2989 4300 16085 18671 804

DCLC1200 5127 2712 3030 4300 18311 21289 902

Fig.4 DCLC Unit dimensions

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DCLC1300 5737 2712 3030 4900 19198 22551 1056

DCLC1400 5737 2712 3030 4900 19422 22941 1065

DCLC1500 5737 2712 3030 4900 19923 23607 1070

B. Separate lifting: Lift the unit component disassembly at the job site if the client insists.

a) Remove and lift the motor-compressor as a whole.

The motor-compressor weights are as follows:

Motor-compressor Weight Weight

Unit 380V Unit

(kg)

6000V Unit

(kg)

10000V Unit

(kg)

DCLC300 2200 2280 2295

DCLC350 2230 2310 2325

DCLC400 2270 2350 2365

DCLC450 2470 2550 2565

DCLC500 2550 2630 2645

DCLC550 2570 2650 2665

DCLC600 3120 3200 3215

DCLC650 3000 3060 3075

DCLC700 3050 3110 3125

DCLC750 3080 3140 3155

DCLC800 3110 3170 3185

DCLC850 5200 5280 5295

DCLC900 5230 5310 5325

DCLC1000 5340 5410 5425

DCLC1100 5400 5470 5485

DCLC1200 5500 5570 5585

DCLC1300 5640 5710 5725

DCLC1400 5740 5810 5825

Fig.5 Lift the motor-compressor

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DCLC1500 5890 5960 5975

Note:

The motor-compressor weight includes the weight of the motor, the compressor and the pipe

supports. For each unit the weight given is that of the nearest (based on voltage).

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b) Remove and lift the cooler and condenser together.

The cooler and condenser weights are as follows:

Model Cooler weight

(kg)

Cooler with

water weight

(kg)

Condenser

weight (kg)

Condenser

with water

weight (kg)

DCLC300 1450 350 1470 350

DCLC350 1480 350 1420 350

DCLC400 1510 350 1540 360

DCLC450 2050 409 2070 448

DCLC500 2150 492 2150 598

DCLC550 2350 529 2400 643

DCLC600 2850 581 3020 662

DCLC650 2940 637 3135 761

DCLC700 3000 673 3230 761

DCLC750 3330 733 3400 830

DCLC800 3330 733 3470 879

DCLC850 4550 928 4570 1167

DCLC900 4550 928 4570 1167

DCLC1000 4550 928 4570 1167

DCLC1100 4700 1014 4570 1167

DCLC1200 5700 1187 5770 1359

DCLC1300 6000 1311 5900 1507

DCLC1400 6170 1397 6100 1615

DCLC1500 6240 1487 6300 1723

Note:

Assemble the unit immediately after lifting. Make sure the lifting and exposed time after splitting the

chiller as short as possible to avoid internal corrosion.

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2.3.4 - Physical data

The maximum and minimum water flow rates in the cooler and condenser are as follows:

Flow rates

Model Standard Minimum Maximal Standard Minimum Maximal

DCLC300 45 23 59 54 28 70

DCLC350 53 28 69 63 33 82

DCLC400 61 32 79 72 37 94

DCLC450 68 35 88 81 42 105

DCLC500 76 40 99 89 46 116

DCLC550 83 43 108 98 51 127

DCLC600 91 47 118 106 55 138

DCLC650 99 51 129 115 60 150

DCLC700 106 55 138 124 64 161

DCLC750 114 59 148 133 69 173

DCLC800 121 63 157 142 74 185

DCLC850 129 67 168 150 78 195

DCLC900 136 71 177 159 83 207

DCLC1000 152 79 198 176 92 229

DCLC1100 167 87 217 194 101 252

DCLC1200 182 95 237 212 110 276

DCLC1300 197 102 256 229 119 298

DCLC1400 212 110 276 246 128 320

DCLC1500 227 118 295 264 137 343

Standard Cooler (l/s) Standard Condenser (l/s)

2.4 - Install chiller supports

Note:

Typical applications of these units are in refrigeration systems, and do not require earthquake

resistance. Earthquake resistance has not been verified.

The stator of centrifugal refrigerating compressor has very little dynamic load to the base after

strict static balance and dynamic balance. Refer to general drawing of the chiller for detailed

base dimension. The base surface against the steel plate as seat of the unit should be

horizontal and smooth. If the base surface is uneven, it may be necessary to use the accessory

spring isolators. Spring isolators are purchased as an accessory from Dunham-Bush. It can be

field supplied and installed. The spring isolators should be placed directly under chiller support

plates or located under chiller soleplates.

The installation requirements are as follows:

� Ensure that the base dimension is exactly the same as that in the general drawing.

� Place the base plate where it is required. Then place the chiller on the base plate.

� Ensure no interspace between the base plate and chiller soleplates. Fill a leveling pad

between the base plate and concrete base to adjust the chiller to water level (the height

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difference should be within 0.5mm/meter).

� Hoist the chiller to place shock-absorption rubber pad on the base plate, then place the

chiller on the shock-absorption rubber pad.

� Guarantee that the level gradient of the chiller is no more than 1/1000.

� Adopt drainage channel around the chiller unit. The drainage around the unit must be good

to prevent the unit from erosion.

In order to provide adequate, long-lasting support for the chiller, it is essential to choose the

right concrete and to apply it properly. Dunham-Bush advise using an epoxy-type, pre-mixed,

non-shrinking concrete only.

Follow the manufacturer’s instructions for applying the concrete:

� Check the unit layout drawing to determine the concrete thickness required.

� The concrete must be applied up to the top of the base of the spring isolator, and there

must be no gap in the concrete below the spring isolators.

� Dry the concrete in accordance with the manufacturer’s instructions before starting the unit.

Note:1. There are 4 base plates，16 adjuster bolts and 16 leveling pads ineach chiller.Foundation materials are supplied by the client.2. After the solidification of concrete, spin out the adjuster bolts.3. The thickness of the secondary cement layer can be adjustedaccording to the chiller level, determined by the client.FG

A

H D DBF45

1-1 2-2

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二次浇灌armoured concrete >400100 outdoor ground>25Adjuster bolt 4-M20*150Leveling Pad 4-100*100*10Base plate

EC

E105 10525 254-M20 throughout

A B C D E F G H Model

mm

DCLC300 3746 1600 190 440 390 650 670 3156

DCLC350 3746 1600 190 440 390 650 670 3156

DCLC400 3746 1600 190 440 390 650 670 3156

DCLC450 3746 1879 190 440 390 650 879 3156

DCLC500 4267 1879 190 440 390 650 879 3677

DCLC550 3746 1994 190 440 390 650 994 3156

DCLC600 4267 1994 190 440 390 650 994 3677

DCLC650 4267 1994 190 440 390 650 994 3677

Fig.6 Unit Installation dimensions

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DCLC700 4267 1994 190 440 390 650 994 3677

DCLC750 4267 2096 190 440 390 650 1096 3677

DCLC800 4267 2096 190 440 390 650 1096 3677

DCLC850 4267 2426 310 590 540 800 1126 3437

DCLC900 4267 2426 310 590 540 800 1126 3437

DCLC1000 4267 2426 310 590 540 800 1126 3437

DCLC1100 4267 2426 310 590 540 800 1126 3437

DCLC1200 4267 2712 310 590 540 800 1412 3437

DCLC1300 4877 2712 310 590 540 800 1412 4047

DCLC1400 4877 2712 310 590 540 800 1412 4047

DCLC1500 4877 2712 310 590 540 800 1412 4047

2.5 - General drawings of piping and electrical connection

图图图图 12 DCLC 机组外部接线图机组外部接线图机组外部接线图机组外部接线图

⑴air switch ⑵free starter ⑶motor

terminal box

⑷oil pump

control box ⑸control box

⑹air vent ⑺pressure

gauge

⑻chilled water

pump

⑼cooling water

pump

⑽chilled pump

starter

⑾cooling pump

starter

⑿cooling tower

starter ⒀air switch

⒁oil pump air

switch

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Cable

NO. Application Specification

1# Main power entering

starting cabinet

380V AC: three phases, one Neutral line, one earth line;

6KV,10KV: three phases, one earth line;

2# Control box ~ cooling

tower starter Two control lines(option)

3# Control box ~ cooling

pump starter Two control lines(option)

4# Control box ~ chilled

pump starter Two control lines(option)

5# Main power ~ oil pump

control box 380V AC: three phases, one Neutral line, one earth line;

6# Starter cabinet ~

control box

220V AC: single phase, one Neutral line, one earth line; 10

shield control lines, 600V, 80℃, grounding in the starter

cabinet.

7# Starter cabinet ~ main

motor

380V AC: 6 motor lead lines(the minimum current of it is

0.721 times of the rated current), two earth lines;

6KV,10KV: 3 motor lead lines, one earth line;

Install the alignment according to the attachment electric schematic diagram. Equipment,

installation, and all starting and control devices must comply with details in equipment

submittal drawings and literature.

NOTE:

� User supports the cables not only from distribution cabinet to the starter cabinet but also

from starter cabinet to the compressor motor, oil pump box and control cabinet.

� Do not use the regulating transformer to supply the pilot relays.

� High-voltage motor has two kinds of start methods: start main motor directly or reduced

voltage to start. The start method must comply with the relevant national electrical

standards, and meet Dunham-Bush relevant regulations.

� When the section switch is chosen as a main circuit breaker device, it is necessary to

install a protection against short circuits upstream of the cabinet.

� Wiring and piping shown are for general point-of connection only and are not intended to

show details for a specific installation.

� All wiring must comply with applicable codes. Wiring not shown for optional devices such

as:

remote start-stop

remote alarm

optional safety device

optional remote sensors

� The routing of field-installed conduit and conductors and the location of field-installed

devices must not interfere with equipment access or the reading, adjusting, or servicing of

any component.

� The starters must be designed and manufactured in accordance with Dunham-Bush

instruction for the DCLC. Installer is responsible for any damage caused by improper

wiring between starter and compressor motor.

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� To the low-voltage unit, those compressor motor terminals, wire terminal and wire should

be insulated to prevent condensation of water and the electric arc. To the high- voltage

units, a specialized terminal is necessary. And the high voltage insulation is also

necessary in accordance with the local electrical standards.

2.6 – Connect water piping

The water supply must be analyzed and appropriate filtering, treatment, control devices,

isolation and bleed valves and circuits built in, to prevent corrosion, fouling and deterioration of

the pump fittings. Consult either a water treatment specialist or appropriate literature on the

subject.

Circulating chilled water quality standards

Item Unit Requirements and conditions of

use Allowed values

Suspended

matter mg/L

according to the production

process requirements ≤10

pH values mg/L according to pharmaceutical

formulations 6.8---8.0

Methyl

orange

alkalinity

mg/L

according to pharmaceutical

formulations and operating

conditions

≤150

Ca3+ mg/L

according to pharmaceutical

formulations and operating

conditions

30---120

Fe2+ mg/L ＜0.5

CI- mg/L Carbon steel heat exchanger ≤200

SO42- mg/L [SO42-] ≤200

silica mg/L ≤50

Free

Chlorine mg/L return line 0.5---1.0

Petroleum mg/L ＜5（should not

exceed）

Circulating cooling water quality standards

Item Unit Requirements and conditions of

use Allowed values

Suspended

matter mg/L

according to the production

process requirements ≤20

pH values mg/L according to pharmaceutical

formulations 6.8--8.2

Methyl

orange

alkalinity

mg/L

according to pharmaceutical

formulations and operating

conditions

≤500

Ca3+ mg/L according to pharmaceutical

formulations and operating 30---200

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conditions

Fe2+ mg/L ＜0.5

CI- mg/L Carbon steel heat exchanger ≤200

SO42- mg/L [SO42-] ≤200

silica mg/L ≤175

Free Chlorine mg/L return line 0.5---1.0

Petroleum mg/L ＜5（should not

exceed）

2.6.1 - Install water piping to heat exchanger

For size and position of the heat exchanger water inlet and outlet connections, refer to the

certified dimensional drawings supplied with the chiller from Dunham-Bush. Connect the

pipeline of chilled water and cooling water (flange connection) according to the general

drawing.

NOTE:

� Factory-supplied insulation is not flammable but can be damaged by welding sparks and

open flame. Protect insulation with a wet canvas cover.

� Remove chilled and cooling water sensors and probes before welding connecting piping to

the connections. Replace them after welding.

� Offset pipe flanges to permit removal of waterbox cover for maintenance and to provide

clearance for pipe cleaning. However, water pipe should not cross in front of the waterbox

or access will be blocked.

� The water piping must not transmit any radial or axial force to the heat exchangers.

Provide openings in water piping for required pressure gages and thermometers. For thorough

mixing and temperature stabilization, wells in the leaving water pipe should extend at least

50mm inside the pipe.

Install air vents at all high points in piping to remove air and prevent water hammer.

Install waterbox vent and drain piping in accordance with individual job data. The connections

are 3⁄4NPT. And then, fill the unused waterbox drains and vent openings with plugs.

Adopt a filter at the water inlet. Do not exert burden from connected pipeline or other load on

the cooler and condenser (take measures of pipe supporting and so on). Install pipe hangers

where needed. Make sure no weight or stress is placed on waterbox nozzles or flanges.

The direction of the water pipe inlet and outlet are decided by users according to actual

conditions. It is advised that entering water is always the lower of the 2 nozzles. Leaving water

is always the upper nozzle for cooler or condenser.

The outlet temperature of chilled water and cooling water will be mixed thoroughly after a

flowing distance. There are two temperature sensor probe connectors, for fixing the

water-outlet temperature sensor probe of chilled water and cooling water respectively. The

connectors should be installed according to the diagram below.

The releasing length of probe conducting wire is 3 meters away from the water outlet flange

20

surface. There are 4 temperature sensors in the chilled/cooling water in/outlet pipes totally. To

see whether the water flow quantity conformed to rated or not, a device is installed in the

chilled water in/outlet pipes to detect the pressure difference after the cooler.

B

F

L

EG

H

K

Chilled water outlet ICooling water outlet J

Cooling water inlet JChilled water inlet I

Fig.7 typical piping installation

Fig.8 Water connection layout parameters

21

B E F G H I J K L Model

mm

DCLC300 1600 570 940 435 805 DN200 DN200 400 800

DCLC350 1600 570 940 435 805 DN200 DN200 400 800

DCLC400 1600 570 940 435 805 DN200 DN200 400 800

DCLC450 1879 626 996 498 868 DN200 DN200 464 940

DCLC500 1879 626 996 498 868 DN200 DN200 464 940

DCLC550 1994 737 1167 483 853 DN200 DN250 489 997

DCLC600 1994 737 1167 483 853 DN200 DN250 489 997

DCLC650 1994 737 1167 483 853 DN200 DN250 489 997

DCLC700 1994 737 1167 483 853 DN200 DN250 489 997

DCLC750 2096 789 1219 490 920 DN250 DN250 521 1045

DCLC800 2096 789 1219 490 920 DN250 DN250 521 1045

DCLC850 2096 1050 1558 807 1315 DN300 DN300 610 1213

DCLC900 2426 1050 1558 807 1315 DN300 DN300 610 1213

DCLC1000 2426 1050 1558 807 1315 DN300 DN300 610 1213

DCLC1100 2426 1050 1558 807 1315 DN300 DN300 610 1213

DCLC1200 2712 1064 1622 757 1315 DN350 DN350 678 1356

DCLC1300 2712 1064 1622 757 1315 DN350 DN350 678 1356

DCLC1400 2712 1064 1622 757 1315 DN350 DN350 678 1356

DCLC1500 2712 1064 1622 757 1315 DN350 DN350 678 1356

2.6.2 - Install vent piping to safety valves

Refrigerant discharged into confined spaces can displace oxygen and cause asphyxiation. It is

advised that the safety valve should discharge outdoors refer to Fig.2 “Typical DCLC Unit

profile”.

If safety valves are manifolded, the cross-sectional area of the relief pipe must at least equal

the sum of the areas required for individual relief pipes.（Standard single valve flow area is

254mm2）Install pipe bracket where needed, ensure no load on the safety valve discharge pipe

line. A length of flexible tubing or piping near the device is essential on spring-isolated chillers.

Cover the outdoor vent with a rain cap and place a condensation drain at the low point in the

vent piping to prevent water build-up on the atmospheric side of the relief device.

The DCLC chiller is factory equipped with safety valves on the cooler and condenser shells.

The opening pressure of the safety valve is 1.28MPa.The safety valves are installed after stop

valves, which are lead-sealed in the open position. These valves permit isolating and removing

the safety valves for calibration and replacement.

NOTE:

� Provide a pipe plug near outlet side of each relief device for leak test. Provide pipe fittings

that allow vent piping to be disconnected periodically for inspection of valve mechanism.

� Equip the piping with connections allowing disconnection for the inspection of the piping.

22

2.7 - Make electrical connection

2.7.1 - The electrical characteristics of the DCLC units.

A. Power requirement

� Control cabinet power supply: Single phase 220V±10%, 1KVA (suggest use 2×1.0mm2

sheathed wire)

� Control oil pump power supply: Three phase 5 wires 380V±5%, 5KVA (suggest use

3×2.5mm2+2×1.5mm2 sheathed wire)

� Starter box: single phase 220V±10%, 1KVA (suggest use 2×1.0mm2 sheathed wire). It is

suggested to use 10×1.0mm2 sheathed wire to connect the control cabinet with starter box.

� Control wire: suggest use 1×1.0mm2 sheathed wire.

� The low-voltage starter cabinet is three phase 5 wires, The mid/high-voltage starter cabinet

is three phase 4 wires.

B. Operating environment requirement

� Ambient temperature range: -5~45℃

� Relative humidity：≤90% without condensation

� Atmospheric pressure：86~106Kpa

� Without corrosive gas and conductive dust. For avoid short circuit broken transformers,

wiring and other electrical equipment, and convenient control unit independent, Each

power supply enter line should be equipped the appropriate short-circuit device.

� No serious vibration around the installation place. And the vertical tilt angle should be less

than 5 degrees.

Note:

Each unit equipped with short-circuit separately and forbid a few generating units connect with

one device together.

C. Supply disconnecting device requirement

� Isolate the electrical equipment from the supply and have OFF and ON marked

� Have an external operating means.

� Be provided with a means permitting it to be locked in the OFF position.

� Disconnect all live conductors of its power supply circuit.

� Have a breaking capacity sufficient to interrupt the current of the largest motor when

stalled together with the sum of the normal running currents of all other motors and/or

loads.

Note:

� Unit that can be customized with a short-circuit device.

� Cut off the main power switch before maintenance unit, and lock the main switch in the

OFF position.

� Field wiring must be installed in accordance with job wiring diagrams and all applicable

electrical local regulations. Wiring diagrams in this publication are for reference only and

are not intended for use during actual installation; follow job specific wiring diagrams.

� The thicknesses and quality of the insulation are, wherever necessary, adapted to the

constraints of the placing and preparation of the wiring, terminal spade tagging, the fitting

23

of specific connectors, etc.

� Equipment, electricity and instrumentation installation comply with the national installation

requirement as other general industrial equipment, electrical, instrumentation installation.

D. Neutral line and ground protection requirements

Below 1kV the neutral point connect ground directly, the neutral line cable cross-section of

three-phase four-wire system should not be less than minimum required cross-section of the

wire which sustained by the maximum unbalanced current. Protection ground wire

cross-section, should meet the circuit protection of device reliable action requirements, and

should conform to the following table:(The smallest cross-section (mm2) of protection of ground

wire meet the thermal stability requirement)

Neutral line cross-section (N)

Three cases Neutral line minimum

cross-section Sn=

General Phase conducting wire

cross-section S S/2

For two-phase circuit, or

single-phase circuit which separate

from three-phase system

Phase conducting wire

cross-section S S

For third-harmonic prominent lines Phase conducting wire

cross-section S >S

Electronic control system and instrument installation are according to chiller automatic control

system wiring diagram. Please prepare connect wire from user control cabinet to the starter

cabinet, oil pump and control cabinet; starter cabinet and control cabinet connect wire, install

the alignment according to the electronic control wiring diagram . Select cable type in

accordance with it’s continuous load capacity. For parallel connection, adopt same

specifications cable (Include length, cross-sectional area and manufacturer). Due to

temperature, environmental difference and cable voltage loss, the following wiring list for

reference only.

To DCLC chiller control cabinet, please select the cable according to a continuous load

capacity. Dunham-Bush recommended cables as following:

Maximum temperature ( )℃ Cable type Voltage (10kV)

Rated load Short circuit

Protection conductor cross-section (PE，PEN)

Phase conducting wire cross-section

S(mm2)

protection conductor minimum

cross-section Sp

S≤16 S

16<S≤35 16

35<S≤400 S/2

400<S≤800 200

800<S S/4

24

Cross linked polyvinyl

chloride insulation ≤10 90 250

Polyvinyl chloride insulation 70 160

At the maximum operating current the connecting loop voltage drop shall not exceed the

allowable value.

E. Standard chiller electronic system distribution

Control system distribution

1 The cable in oil pump control box VV5*2.5

2 The cable in microcomputer control box VV3*2.5

3 The cable between the microcomputer control box and the low voltage

starter cabinet

KVV10*1.5

Power system distribution

No. Incoming cable of the starter

cabinet

The cable between the main motor and the

starter Model

1 2×（YJV3*120+2*70） 6×VVR120 300RT

2 2×（YJV3*120+2*70） 6×VVR120 350RT

3 2×（YJV3*120+2*70） 6×2VVR70 400RT

4 2×（YJV3*150+2*70） 6×2VVR70 450RT

5 2×（YJV3*150+2*70） 6×2VVR70 500RT

6 2×（YJV3*150+2*70） 6×2VVR95 550RT

7 2×（YJV3*185+2*95） 6×2VVR95 600RT

8 2×（YJV3*185+2*95） 6×2VVR95 650RT

9 2×（YJV3*240+2*120） 6×2VVR120 700RT

10 2×（YJV3*240+2*120） 6×2VVR120 750RT

11 3×（YJV3*185+2*95） 6×2VVR120 800RT

12 3×（YJV3*185+2*95） 6×2VVR150 850RT

13 3×（YJV3*240+2*120） 6×2VVR150 900RT

14 3×（YJV3*240+2*120） 6×2VVR185 1000RT

15 3×（YJV3*240+2*120） 6×2VVR185 1100RT

16 4×（YJV3*185+2*95） 6×2VVR185 1200RT

17 4×（YJV3*185+2*95） 6×2VVR240 1300RT

18 4×（YJV3*240+2*120） 6×2VVR240 1400RT

19 4×（YJV3*240+2*120） 6×2VVR240 1500RT

NOTE:

� "Incoming Cable: 3×(YJV3*185+2*95) "means 3 cable groups parallel together, and the

components of each group are 3*185 and 2*95,5 cables total.

� "The cable between the starter and the main motor: 6 × VVR120" means there are 6

cables between the main motor and the starter. Each cable is VVR120;

� "The cable between the main motor and the starter: 6 × 2VVR120" means there are 6

groups cables between the main motor and the starter. Each group consists of 2 VVR120

parallel.

� The control system distribution is applicable to all centrifugal chillers;

� The incoming Cable of the Starter cabinet is applicable to all the low voltage chiller. The

25

cable between the main motor and the starter is applicable to the low voltage delta start

and the soft starter.

� The electrical junction box must be protected by the ground wire.High-voltage product

enter & out wire type is the same.

2.7.2 - Installation standards and precautions

Every starter /control /oil pump cabinet has one power connection point. The starter cabinet

(standard for 380V unit and optional for about 380V unit) features are as follows:

� Motor always powered in the process of start, starting smooth and time is short, no

harmonic interference;

� Adopted Closed Wye Delta switch, impulse current even less than conventional Wye Delta

start current, reduce harmful effects and extend motor electrical endurance;

� Motor protection. Include overload protection, Phase failure, circuit-short protection.

(Reverse phase protection device for 380V chiller and multiple protection for >380V

chiller );

� Siemens used in the secondary circuit. Simple circuit, high precision timing and stable and

reliable control;

� Simple operation, easy maintenance.

� The oil pump control and the oil heater control

Note:

If the supply power is not 220V, user has to add a power transformer in control cabinet.

All connections to the network and the power wiring must be carried out in accordance with the

applicable codes at the place of installation. Protection of power leads against overcurrents is

supplied with the unit.

Note:

If particular aspects of an installation require different characteristics from those listed above

(or not mentioned), contact Dunham-Bush.

2.7.3 Electrical characteristics

Compressor electrical date

Model

Compressor

(kW) Model

Compressor

(kW)

DCLC300 200 DCLC800 498

DCLC350 224 DCLC850 518

DCLC400 259 DCLC900 544

DCLC450 289 DCLC1000 614

DCLC500 307 DCLC1100 671

DCLC550 363 DCLC1200 734

DCLC600 377 DCLC1300 769

DCLC650 398 DCLC1400 816

26

DCLC700 431 DCLC1500 860

DCLC750 472

Compressor voltage

Model Voltage Adopt Voltage Range

DCLC300~DCLC1500 380V 361V-399V

DCLC300~DCLC1500 400V 380V-420V

DCLC300~DCLC1500 415V 395V-435V

DCLC300~DCLC1500 440V 418V-462V

DCLC300~DCLC1500 460V 437V-483V

DCLC300~DCLC1500 3KV/6KV/10KV

2.8 KV-3.2 KV / 5.7 KV-6.3 KV / 9.5

KV-10.5 KV

Note:

Chillers shall not be selected at voltages out of the listed supply voltage range. To the chiller,

300RT-1000RT recommended low-voltage 380V (high voltage optional); 1100RT-1500RT

recommended 3kV/6kV/10kV to high voltage (low voltage optional);

Oil pump electrical data

Item Input power kW Elec. V-PH-Hz MIN/MAX motor voltage

Oil pump 1.1 380-3-50 350/420

Oil pump voltage

Model Voltage Adopt Voltage Range

DCLC300~DCLC1500 380V 361V-399V

DCLC300~DCLC1500 400V 380V-420V

DCLC300~DCLC1500 415V 395V-435V

DCLC300~DCLC1500 440V 418V-462V

DCLC300~DCLC1500 460V 437V-483V

Oil sump heater electrical data

Crankcase heater voltage

Model Voltage

Adopt Voltage

Range Note

DCLC300~DCLC1500 220V 198V-242V User supply 220V

DCLC300~DCLC1500

Oil pump

voltage ±5%

User cannot supply

220V

Item Input power kW Elec. V-PH-Hz

Oil heater control 0.1 220/1/50-60

Oil heater (≤ 800RT chiller) 0.8 (2 heaters*0.4kW) 220/1/50-60

Oil heater (＞800RT chiller) 1.0 (1 heater) 220/1/50-60

27

Note:

If cannot supply 220V power for oil sump heater, please add a transformer.

2.7.4 - Connect the starting cabinet

The compressor motor and the regulating part must be earthed to the starter cabinet.

The DCLC is available with starter cabinet, as the follow picture show:

The chiller which rated power is below 400 kW (include 400 kW) use the Cabinet A; Cabinet B

is available for the chiller which rated power is 400 kW above.

The starter cabinet is a standard low voltage unit (380V) and optional for high voltage (>380V)

unit. There are many types of DB start cabinets to suit different situations. The way to choose

the starter is described in the Starter catalogue. Any questions, please consult Dunham-Bush.

NOTE:

The starter cabinet has the power in/outlet leading brackets. The connections between the

Fig.9 Starter Cabinet dimensions

28

leading-out bracket and the motor terminal need be done by the user themselves.

2.7.5 - Connect the starting cabinet to the control box

Connect the communication cables directly from the control box to the starter cabinet,

including the host closing, host trip, host running, host ready and host current cables. All the

regulating cables must be shielded.

Consult the job wiring diagrams for cable type and number. Ensure that the control circuit is

properly earthed in accordance with electrical standards and with the instructions on the chiller

control wiring label.

2.7.6 - Connect Power Wires to Oil Pump Starter

Connect power wires(380V 3P 50Hz) to oil pump starter mounted in machine power panel.

Use separate fused disconnect or circuit breaker as shown on job wiring diagrams and Fig. 19.

Check that power supply voltage agrees with oil pump voltage. Follow correct phasing for

proper oil motor rotation.

2.7.7 - Make the necessary connections for the outgoing control signals

Connect the auxiliary equipment, the chilled water pump and the condenser water pump, as

well as the additional alarms, as indicated in the job wiring diagrams.

Fig.10 Pump control box schematic

29

2.7.8 - Motor connections

Generally, DCLC compressors have three kinds of main motors: 6kV, 10kV high-voltage

motors and 380V low-voltage motor. To these motors, the electrical wirings are difference.

Connect the wiring by the following guide:

a) If adopted 6KV grade level or 10KV high-voltage motors, control the main motor start

through high-voltage starter cabinet. All field-supplied conductors, devices, field-installation

wiring, and termination of conductors and devices must be in compliance with all applicable

codes and job specifications.

High-voltage motor circuit diagram

(2) If adopted 380V low-voltage motor, controlled with Dunham-Bush standard cabinet,

sub-closed-Star-delta starter or a multi-stage step-down auto-start, by the user choice.

Three-phase five-wire of main power connect with the starter cabinet enter side. Six-line

access to the motor and starter cabinet outlet side, motor should be grounded. (The

terminal studs must not take the weight of the leads, use intermediate supports.)

Starter cabinet has connection terminals which used for connect with control cabinet. The

power of microcomputer Control cabinet is 220 V, and oil pump is 380 V. Other control lines

are connected to the control cabinet corresponding terminals.

30

Low-voltage motor circuit diagram

In addition, because the main motor terminal box inside temperature lower than the outside ,

Insulate compressor motor terminals to prevent moisture condensation and electrical arcing

Main motor terminal insulation treatment

(3) Starter cabinet and main motor connection

The terminal on the main motor marked with the letter (U1、U2； V1、V2； W1、W2)

NOTE:

A cable conduit is provided in the bottom of the control box for field wiring connections.

To 380V low-voltage:

31

A) Adopt closed-delta (QSF) starts. Pls follow the motor marked letter and wiring diagram,

from the start cabinet led to six lines to the motor terminal. (Be likely to used two cables in

one line because the cable capacity limited, notice the specification of cable is the same)

KM4 KM2U1V1W1W2U2V2

U1 V1 W1W2 U2 V2 StarterCompressor

B) For self-coupling reduction voltage (QOF) start, motor terminals have been connected into

a ∆-connection, From the start cabinet led to three lines to the motor terminal. (Be likely to

used two cables in one line because the cable capacity limited, notice the specification of

cable is the same.)

KM1U1V1W1W2U2V2

U V WCompressorStarter

C) For high-voltage direct start (QZF), there are three terminals on the motor, connection

mothed as follow wiring diagram: (Be likely to used two cables in one line because the

cable capacity limited, notice the specifiction of cable is the same)

32

UV WU V WVKMStarterCompressor

NOTE:

Do not insulate terminals until wiring arrangement has been checked and approved by

Dunham-Bush start-up personnel. Also, make sure correct phasing is followed for proper

motor rotation .

33

Dunham-Bush Yantai Co., Ltd.

No.1 Dunham-Bush Road, Laishan District, Yantai

Shandong, China 264003

T: +86 535 6588999

F: +86 535 6581999

W: www.dunham-bush.com.cn