Auds B

ACDS-B/AUDS-B
Air-Cooled Chillers
with Tandem Scroll Compressors
ACDS-B/AUDS-B 015S-100D
Installation, Operation &
Maintenance Manual
Form No. 6109B

January 2004
TABLE OF CONTENTS
Page
1.0 General Information
1.1
1.2
1.3
Introduction ................................................................................................................................ 5
Product Identification ............................................................................................................... 5
Physical Specifications - English I.P. and S. I. Units .................................................................. 6-9
2.0 Installation
2.1
2.2
2.3
General Installation Instructions ............................................................................................... 10

Inspection .................................................................................................................................. 10
Handling, Storage and Rigging .................................................................................................. 10
2.3.1
2.3.2
2.3.3
2.4
Space and Clearance Requirements

2.4.1
2.4.2
2.4.3
2.5
General Space and Clearance Requirements ....................................................................................... 11

Location and Installation Clearance ................................................................................................... 12
ACDS-B and AUDS-B Dimensional Data ......................................................................................... 13-21
Foundation and Mounting Structure

2.5.1
2.5.2
2.5.3
2.5.4
2.6
General Handling Instructions ........................................................................................................... 10

Storage ............................................................................................................................................. 10
Rigging and Moving ......................................................................................................................... 10
2.3.3.1
Rigging Instruction Drawing ............................................................................................ 10
ACDS-B Unit Weights and Point Loading - Aluminum Fin Condenser Unit ........................................... 22
ACDS-B Unit Weights and Point Loading - Copper Fin Condenser Unit ................................................ 22
AUDS-B Unit Weights and Point Loading - Aluminum Fin Condenser Unit .......................................... 23
AUDS-B Unit Weights and Point Loading - Copper Fin Condenser Unit ................................................ 23
Vibration Isolation Requirement

2.6.1
2.6.2
2.6.3
2.6.4
2.6.5
2.6.6
2.6.7
2.6.8
2.7
2.8
2.9
ACDS-B Rubber-in-Shear - with Aluminum Fin Condenser .................................................................. 24

ACDS-B Rubber-in-Shear - with Copper Fin Condenser ....................................................................... 24
ACDS-B Spring Isolators - with Aluminum Fin Condenser ................................................................... 25
ACDS-B Spring Isolators - with Copper Fin Condenser ........................................................................ 25
AUDS-B Rubber-in-Shear - with Aluminum Fin Condenser ................................................................. 26
AUDS-B Rubber-in-Shear - with Copper Fin Condenser ...................................................................... 26
AUDS-B Spring Isolators - with Aluminum Fin Condenser ................................................................... 27
AUDS-B Spring Isolators - with Copper Fin Condenser ........................................................................ 27
Piping Connections: ACDS-B / AUDS-B ...................................................................................... 28
2.7.1 ACDS-B Chilled Water Piping ........................................................................................................ 28-29
2.7A
Typical Chilled Water Piping - Three Way Bypass ............................................................... 30
2.7B
Typical Chilled Water Piping - Two Way Bypass ................................................................. 30
2.7.2 Multiple Chiller Water Piping ............................................................................................................. 28
2.7.2.1
Parallel Multiple Chiller Water Piping ................................................................................ 28
2.7C
Typical Parallel Chiller Chilled Water Piping ....................................................................... 28
2.7.2.2
Series Multiple Chiller Water Piping .................................................................................. 28
2.7D
Typical Series Chiller Chilled Water Piping ......................................................................... 28
2.7.3 ACDS-B Chilled Water Quality ............................................................................................................ 28
2.7.4 AUDS-B Condensing Unit Connections .............................................................................................. 29
2.7.4.1
General Condensing Unit Connections Applications ......................................................... 29
2.7E
Condensing Unit Typical Hot Gas Bypass Piping ................................................................ 30
Electrical Connections: ACDS-B / AUDS-B .................................................................................. 31
2.8.1 Electrical Data Table - Unit ............................................................................................................ 32-33
2.8.2 Electrical Data Table - Field ........................................................................................................... 34-35
2.8.3 General Electrical Notes ..................................................................................................................... 36
Refrigerant Charging Procedure ................................................................................................. 37
2.9.1
General Refrigerant Charging Procedures .......................................................................................... 37
2.9A
Refrigerant Line Capacities ............................................................................................................... 37
2.9.2
AUDS-B Refrigerant Charge Calculation ............................................................................................. 37
2.9.3
AUDS-B Refrigerant Charging Procedure ........................................................................................... 37
TABLE OF CONTENTS
Page
3.0 Operation
3.1
3.2
Qualified Unit Start-up Report (Required for Warranty) ........................................................... 38

Typical Refrigerant Piping .......................................................................................................... 38
3.2A
3.2B
3.2C
3.2D
3.3
3.4
3.5
3.6
3.7
3.8
3.9
Typical ACDS-B 015S - 030S Packaged Chiller Refrig. Piping ................................................................

Typical ACDS-B 025D - 060D Packaged Chiller Refrig. Piping ...............................................................
Typical AUDS-B 015S - 030S Condensing Unit Refrig. Piping ................................................................
Typical AUDS-B 025D - 060D Condensing Unit Refrig. Piping ..............................................................
39
39
40
40
Pre-start-up Procedure for ACDS-B and AUDS-B Systems ............................................................ 41
Start-up and Reporting for ACDS-B and AUDS-B Systems ........................................................... 41
Lubrication - ACDS-B / AUDS-B ................................................................................................... 42
3.5.1 General ............................................................................................................................................. 42
3.5.2 Oil Level ............................................................................................................................................ 42
3.5.3 Oil Type ............................................................................................................................................. 42
Chilled Fluid Flow Rate ACDS-B or Split-System Chillers ........................................................... 42
3.6A Unit Cooler Reference Table - DX Coolers ............................................................................................ 42
3.6B
Water Side Pressure Drop Curves - DX Coolers ..................................................................................... 43
System Control ACDS-B and AUDS-B .......................................................................................... 44
3.7.1 Capacity Control System .................................................................................................................... 44
3.7.2 Capacity Control Staging for Single Circuit Units ................................................................................. 45
3.7.3 Capacity Control Staging for Dual Circuit Units ................................................................................... 45
3.7.4 Condenser Fan Cycling ....................................................................................................................... 46
Electrical Controls Description .............................................................................................. 47-48
DB Director - Microcomputer System Control ............................................................................ 48

3.9.1 Precautions .......................................................................................................................... 48
3.9.2 Computer Operation ...................................................................................................... 48-49
3.9.2.1
3.9.2.2
3.9.2.3
3.9.2.4
3.9.2.5
3.9.2.6
3.9.2.7
3.9.2.8
Keypad Display Quick Reference - Display Status ............................................................. 50

Keypad Display Quick Reference - Entry Keys ................................................................... 51
Display Data ................................................................................................................... 52
Read and Enter Data ........................................................................................................ 53
Capacity Control States ................................................................................................... 54
Circuit Control States ...................................................................................................... 55
Alarms Section .......................................................................................................... 56-57
Control States Quick Reference - Chiller Applications ....................................................... 58
3.9.3 Control Functions and Operations ....................................................................................... 59

3.9.3.1
3.9.3.2
3.9.3.3
3.9.3.4
3.9.3.5
3.9.3.6
3.9.3.7
3.9.3.8
3.9.3.9
3.9.3.10
3.9.3.11
3.9.3.12
3.9.3.13
Compressor and Unloader Staging .................................................................................. 59

Condenser Fan Control .................................................................................................... 60
Pumpdown Control ........................................................................................................ 60
Anti-Recycle ................................................................................................................... 60
Lead / Lag (optional feature) ........................................................................................... 60
Chilled Water / Air Reset .................................................................................................. 60
Customer Control Interlock ............................................................................................. 60
Low Pressure Unload ...................................................................................................... 61
High Pressure Unload ...................................................................................................... 61
High Amp Unload (optional Load Limiting) ..................................................................... 61
Low Ambient Temperature Limit (optional) ..................................................................... 61
Power-up Delay .............................................................................................................. 61
Electronic Expansion Valve Control (optional) .................................................................. 61
3.9.4 General Servicing Procedure .......................................................................................... 61

3.9.5ATypical Power Wiring (Two Compressor Model) ............................................................. 62
3.9.5B Typical Control Wiring (Two Compressor Model) ...................................................... 63-64
TABLE OF CONTENTS
Page
3.10 DB Director - Circuit Operation
for ACDS-B or AUDS-B Split-System Chiller ............................................................ 65
or AUDS-B Leaving Air Control with DX Coil ......................................................... 65
3.10.1 Unit on Standby ................................................................................................................. 65
3.10.2 Unit Run Cycle Sequence - (Increasing Load) ...................................................................... 65
3.10.2.1
3.10.2.2
3.10.2.3
3.10.2.4
Step 1 Increasing Load ..........................................................................................

Step 4 Increasing Load .........................................................................................
65
65
65
65
3.10.3 Unit Run Cycle Sequence - (Decreasing Load) ..................................................................... 66

3.10.3.1
3.10.3.2
3.10.3.3
3.10.3.1
Step 4
Step 3
Step 2
Step 1
Decreasing Load
Decreasing Load
Decreasing Load
Decreasing Load
........................................................................................
........................................................................................
........................................................................................
........................................................................................
66
66
66
66
3.11 DB Director - Circuit Operation for AUDS-B Return Air Control

of Constant Volume with DX Coil 84
3.11.1 Unit on Standby ................................................................................................................. 67
3.11.2.1
3.11.2.2
3.11.2.3
3.11.2.4
Step 1
Step 2
Step 3
Step 4
Increasing Load
Increasing Load
Increasing Load
Increasing Load
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
67
67
67
67

3.11.3.1
3.11.3.2
3.11.3.3
3.11.3.4
Step 4
Step 3
Step 2
Step 1
Decreasing Load
Decreasing Load
Decreasing Load
Decreasing Load
........................................................................................
........................................................................................
........................................................................................
........................................................................................
68
68
68
68
3.12 DB Director - Circuit Operation

for AUDS-B Suction Pressure Control for multiple evaporators ................................................. 69
3.12.1 Unit on Standby ................................................................................................................. 69
3.12.2.1
3.12.2.2
3.12.2.3
3.12.2.4
Step 1 Increasing Load

..........................................................................................
..........................................................................................
..........................................................................................
..........................................................................................
69
69
69
69

3.12.3.1
3.12.3.2
3.12.3.3
3.12.3.4
Step 4 Decreasing Load

.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
70
70
70
70
4.0 Maintenance
4.1
4.2
4.3
4.4
General Maintenance ................................................................................................................. 71

Periodic Inspection .................................................................................................................... 71
Monthly Inspection ................................................................................................................... 71
Vessel Maintenance ................................................................................................................... 71
4.4.1 General Unit Efficiency and Performance ........................................................................... 71
4.4.2 Cooler Cleaning .................................................................................................................. 71
4.5 Air Cooled Condenser Cleaning ................................................................................................. 71
4.6 Electrical Malfunction ............................................................................................................... 71
4.7 Compressor Maintenance ......................................................................................................... 72
4.8 Refrigerant Charge ................................................................................................................... 72
4.9 Troubleshooting ........................................................................................................................ 73
4.9.1 Unit will not start ............................................................................................................... 73
4.9.2 Compressor hums but does not start ................................................................................. 73
4.9.3 Compressor cycles on low pressure control ........................................................................ 73
4.9.4 Compressor cycles on high pressure control ................................................................................... 73
4.10 Start-Up and Maintenance Log Sheet .................................................................................... 74-75
4.11 Temperature and Pressure Table ................................................................................................. 76
4
1.0 GENERAL INFORMATION
1.1 Introduction
This manual is designed to provide all necessary
information for installation, operation and
maintenance of the latest generation of Dunham-Bush
scroll compressor package units. These packages
include air cooled water chiller machines, and air cooled
condensing units.
To use this manual effectively, you must first determine
your unit model number from the unit nameplate.
Since this manual is comprehensive for a wide variety
of units, you should be careful to use only those
sections which apply to your model. Note that each
section is clearly marked as to the applicable models.
The AUDS-B is a condensing unit without a mounted
evaporator. It is designed for remote DX water chiller
or air cooling coil applications. Due to the evaporator
being remotely mounted, the AUDS-B machine is given
a factory electrical test only.
To assure satisfactory operation and to avoid damage

to the unit, the installation should be made by a
qualified refrigeration mechanic. It is assumed that
the reader of his manual and those who install, operate
and maintain this equipment have a basic
understanding of the principles of air conditioning,
refrigeration and electrical controls. These instructions
are general in nature and are for standard catalog units.
Non-standard units may vary in some respects from
these instructions.
Your Dunham-Bush package has been manufactured
under a careful quality control system and has been
factory run tested as a final verification of reliability. If
it is installed, operated and maintained with care and
attention to these instructions, it will give many years
of satisfactory service.
Air Cooled Packaged Chiller Models and Condensing Units for Use with
DX Coil Banks or Remote Coolers for Split-System Chillers
MODEL
ACDS-B / AUDS-B
UNIT SIZE
015S,020S,025S,027S,030S
025D,030D,035D,040D,045D
050D,055D,057D,060D,065D
070D,080D,090D,100D
DESCRIPTION
1 Tandem Scroll Compressor - 1 Refrigerant Circuit
2 Tandem Scroll Compressors - 2 Refrigerant Circuits
1.2 Product Identification

A
C D
B 060 D AR Z B
Microcomputer Control
Air Cooled Condenser

R22 Base Refrigerant
Packaged Chiller (C)
Condensing Unit (U)
Direct Expansion Evaporator
Tandem Scroll Compressor
Unit Vintage
Nominal Capacity in Tons
CD 208/3/60 Main Power

AN 230/3/60 Main Power
AR 460/3/60 Main Power
AS 575/3/60 Main Power
Refrigerant Circuits
(S) Single - 015S, 020S, 025S, 027S, 030S
(D) Dual - 025D, 030D, 035D, 040D, 045D
050D, 055D, 057D, 060D, 065D,
070D, 080D, 090D, 100D
5
1.0 GENERAL INFORMATION (CONT.)
1.3 Physical Specifications: English I.P. & S.I. Units

ACDS-B & AUDS-B 021S, 024S, 027S, 030S, 035S
UNIT MODEL
Quantity of Compressors / Circuit
STANDARD COOLER for ACDS-B or
Remote Mounted Cooler (RCH1 Option)
for AUDS-B Split-System Chiller
Water Volume, Gallons (Liters)
Minimum Flow Rate, GPM (L/S)
Maximum Flow Rate, GPM (L/S)
Water Conn. Size In/Out (Type)
OPTIONAL COOLER for 42F (5.5C) LWT
CH2 Option(1) for ACDS-B or
Remote Mounted Cooler (RCH2) Option
CONDENSER
Fan Quantity - All 30" (766mm) Diameter
Motor Quantity(3)
Standard Fans - Nominal RPM
Standard Fans - HP (4)
Standard Fans - (kW) (4)
Opt. Extra Quiet Fans - Nominal RPM
Opt. Extra Quiet Fan Motor - HP (kW) (4)
GENERAL DATA
Min.Starting/Operating AmbientF (C) (4)
with HGBP, F (C) (4)
Low Ambient Option, F (C) (5)
Extra Low Ambient Option, F (C) (6)
Number of Circuits
Approximate Refrig. Chg. lbs. (kgs) R22
Approximate Refrig. Chg. lbs. (kgs) R407C
ACDS-B Weights
Shipping Wt., lbs. (kgs) Alum. Fin Cond.
Shipping Wt., lbs. (kgs) Copper Fin Cond.
Operating Wt., lbs.(kgs) Alum. Fin Cond.
Operating Wt., lbs.(kgs) Copper Fin Cond.
AUDS-B Weights
NOTES:
(1)
(2)
(3)
(4)
(5)
(6)
015S
2/1
020S
2/1
025S
2/1
CHS006601B CHS006601B CHS007601B
027S
2/1
030S
2/1
CHS007601B
CHS008601A
3.4 (12.9)
29 (1.83)
97 (6.12)
3"NPTE
3.4 (12.9)
29 (1.83)
97 (6.12)
3"NPTE
5.5 (20.8)
50 (3.15)
168 (10.60)
3"NPTE
5.5 (20.8)
50 (3.15)
168 (10.60)
3"NPTE
7.0 (26.5)
56 (3.53)
172 (10.85)
3"NPTE
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
CHS008601A
NR
NR
CHS007601A CHS007601A
NR
NR
NR
NR
L216
2
(1) 2
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
27 (102.2)
37 (2.33)
101 (6.37)
3"NPTE
L216
2
(1) 2
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
27 (102.2)
37 (2.33)
101 (6.37)
3"NPTE
L216
2
(1) 2
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
35 (132.5)
56 (3.53)
168 (10.60)
3"NPTE
L216
2
(1) 2
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
NR
NR
NR
NR
L216
2
(1) 2
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
1
33 (15.0)
33 (15.0)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
1
45 (20.4)
45 (20.4)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
1
57 (25.9)
57 (25.9)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
1
62 (28.1)
62 (28.1)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
1
70 (31.8)
70 (31.8)
1636 (743)
1865 (847)
1668 (757)
1897 (861)
1674 (760)
1903 (864)
1720 (781)
1949 (885)
1722 (782)
1952 (886)
1768 (803)
1998 (907)
1807 (820)
2037 (925)
1866 (847)
2096 (952)
1957 (888)
2304 (1046)
2016 (915)
2363 (1072)
1398 (635)
1628 (739)
1431 (650)
1661 (754)
1386 (629)
1616 (734)
1431 (650)
1661 (754)
1422 (646)
1651 (750
1479 (671)
1708 (775)
1444 (656)
1669 (758)
1501 (681)
1731 (786)
1580 (717)
1927 (875)
1650 (749)
1997 (907)
CH2 or RCH2 - Oversized cooler required where indicated for 42F (5.5C) LWT.
NR - Not Required
NPTE - National Pipe Thread External
Units with Low Ambient Option use (1) 1.0 HP (0.76 kW) in lieu of (1) 1.5 HP (1.15kW) fan motor per circuit
Minimum Starting/Operation Ambient with a maximum of 5 MPH wind across coil & minimum 25% load
Low Ambient Option requires (1) 1 HP (0.76 kW) variable speed fan, motor per circuit
Extra Low Ambient Option requires electronic expansion valve(s), variable speed fan, 50% glycol, 50%
minimum load and maximum 5 MPH wind across coil
6

ACDS-B & AUDS-B 025D, 030D, 035D, 040D, 045D
UNIT MODEL
CONDENSER
Motor Quantity(3)
GENERAL DATA
Number of Circuits
Approximate Refrig. Chg, lbs. (kgs) R22
Approximate Refrig. Chg, lbs. (kgs) R407C
ACDS-B Weights
AUDS-B Weights
NOTES:
(1)
(2)
(3)
(4)
(5)
(6)
025D
4/2
030D
4/2
035D
4/2
CHD007601B CHD007601B CHD008601B

5.5 (20.8)
50 (3.15)
164 (10.35)
3" NPTE
5.5 (20.8)
50 (3.15)
164 (10.35)
3" NPTE
7 (26.5)
70 (4.42)
227 (14.32)
4" NPTE
CHD008601A CHD008601A CHD010601B
7.7 (29.1)
56 (3.53)
168 (10.60)
3" NPTE
7.7 (29.1)
56 (3.53)
168 (10.60)
3" NPTE
10.7 (40.5)
78 (4.92)
315 (19.87)
4" NPTE
CHD008601A CHD010601A CHD011601A
040D
4/2
045D
4/2
CHD008601B
CHD010601B
7 (26.5)
70 (4.42)
227 (14.32)
4" NPTE
10.7 (40.5)
78 (4.93)
315 (19.23)
4" NPTE
CHD010601B
NR
10.7 (40.5)
78 (4.92)
315 (19.87)
4" NPTE
NR
NR
NR
NR
CHD011601B
CHD011601A
7.7 (29.1)
56 (3.53)
168 (10.60)
3" NPTE
L216
4
(2) 4
1140
1.0
(.76) 1.15
855
1.0 (0.76)
10.7 (40.5)
62 (3.91)
205 (12.93)
4" NPTE
L216
4
(2) 4
1140
1.0
(.76) 1.15
855
1.0 (0.76)
12.9 (48.8)
69 (4.35)
206 (12.99)
4" NPTE
L216
4
(2) 4
1140
1.0
(.76) 1.15
855
1.0 (0.76)
12.9 (48.8)
86 (5.42)
304 (19.18)
4" NPTE
L216
4
(2) 4
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
12.9 (48.8)
69 (4.35)
206 (12.99)
4" NPTE
L216
4
(2) 4
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
62 (28.1)
62 (28.1)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
75 (34.0)
75 (34.0)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
83 (37.6)
83 (37.6)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
93 (42.2)
93 (42.2)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
109 (49.4)
109 (49.4)
3424 (1554)
3877 (1760)
3844 (1584)
3941 (1789)
3517 (1597)
3968 (1802)
3606 (1637)
4058 (1842)
3604 (1636)
4057 (1842)
3712 (1685)
4165 (1891)
3629 (1648)
4081 (1853)
3737 (1697)
4189 (1902)
3702 (1681)
4154 (1886)
3810 (1730)
4262 (1935)
3061 (1390)
3513 (1595)
3123 (1418)
3575 (1623)
3048 (1384)
3500 (1589)
3123 (1418 )
3575 (1623)
3040 (1380)
3492 (1585)
3123 (1418)
3575 (1623)
3055 (1387)
3506 (1592)
3148 (1429)
3599 (1634)
3111 (1412)
3563 (1613)
3220 (1462)
3672 (1667)
NR - Not Required
7

ACDS-B & AUDS-B 050D, 055D, 057D, 060D
UNIT MODEL
CONDENSER
Motor Quantity(3)
GENERAL DATA
Number of Circuits
Approximate Refrig. Chg. lbs. (kgs) R22
Approximate Refrig. Chg. lbs. (kgs) R407C
ACDS-B Weights
AUDS-B Weights
NOTES:
(1)
(2)
(3)
(4)
(5)
(6)
050D
4/2
055D
4/2
057D
4/2
060D
4/2
CHD011601B
CHD011601B
CHD011601B
CHD013601B
12.9 (49.0)
86 (5.44)
315 (19.23)
4" NPTE
12.9 (49.0)
86 (5.44)
315 (19.23)
4" NPTE
12.9 (49.0)
86 (5.44)
315 (19.23)
4" NPTE
18.1 (68.5)
101 (6.39)
420 (25.76)
4" NPTE
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
CHD013601B
CHD013601B
CHD013601B
NR
18.1 (68.5)
101 (6.39)
420 (25.76)
4" NPTE
L216
4
(2) 4
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
18.1 (68.5)
101 (6.39)
420 (25.76)
4" NPTE
L312
4
(2) 4
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
18.1 (68.5)
101 (6.39)
420 (25.76)
4" NPTE
L216
6
(2) 6
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
NR
NR
NR
NR
L216
6
(2) 6
1140
(1.0) 1.5
(.76) 1.15
855
1.0 (0.76)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
119 (54.0)
119 (54.0)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
130 (59.0)
130 (59.0)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
136 (61.7)
136 (61.7)
30 (-1.1)
40 (4.4)
0 (-18)
-20 (-29)
2
140 (63.5)
140 (63.5)
3910 (1775)
4362 (1980)
4061 (1844)
4513 (2049)
4228 (1920)
4926 (2236)
4379 (1988)
5077 (2305)
4649 (2111)
5325 (2418)
4800 (2179)
5476 (2486)
4649 (2111)
5325 (2418)
4800 (2179)
5476 (2486)
3123 (1418)
3575 (1623)
3242 (1472)
3694 (1677)
3430 (1557)
4128 (1874)
3560 (1616)
4258 (1933)
3845 (1746)
4520 (2052)
3981 (1807)
4656 (2114)
3841 (1744)
4516 (2050)
3981 (1807)
4656 (2114)
NR - Not Required
8

ACDS-B & AUDS-B 065D, 070D, 080D, 090D, 100D
UNIT MODEL
CONDENSER
Motor Quantity(3)
GENERAL DATA
Number of Circuits
Approximate Refrig. Chg, lbs. (kgs) R22
Approximate Refrig. Chg, lbs. (kgs) R407C
ACDS-B Weights
AUDS-B Weights
NOTES:
(1)
(2)
(3)
(4)
(5)
(6)
065D
4
CXD1209F09
070D
4
080D
4
CXD1209F09 CXD1209F09
090D
4
100D
4
CXD1209B07
CXD12120B07
28 (106)
112/6.94
365/22.63
4" VIC
28 (106)
112/6.94
365/22.63
4" VIC
28
112/6.94
365/22.63
4" VIC
23 (87.1)
140/8.68
380/23.56
4" VIC
30 (1136)
188/11.65
459/28.45
4" VIC
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
L216
6
(2) 6
1140
(1) 1.5
(0.76) 1.15
855
1.0 (0.76)
NR
NR
NR
NR
L216
6
(2) 6
1140
(1) 1.5
(0.76) 1.15
855
1.0 (0.76)
NR
NR
NR
NR
L312
6
(2) 6
1140
(1) 1.5
(0.76) 1.15
855
1.0 (0.76)
NR
NR
NR
NR
L312
6
(2) 6
1140
(1) 1.5
(0.76) 1.15
855
1.0 (0.76)
NR
NR
NR
NR
L216
8
(2) 8
1140
(1) 1.5
(0.76) 1.15
855
1.0 (0.76)
30 (-1.1)
49 (4.4)
0 (-18)
-20 (-29)
2
125
30 (-1.1)
49 (4.4)
0 (-18)
-20 (-29)
2
103
30 (-1.1)
49 (4.4)
0 (-18)
-20 (-29)
2
150
30 (-1.1)
49 (4.4)
0 (-18)
-20 (-29)
2
160
30 (-1.1)
49 (4.4)
0 (-18)
-20 (-29)
2
165
NR - Not Required
9
2.0 INSTALLATION
2.1
General ACDS-B/AUDS-B
Models ACDS-B packaged chillers are designed to cool

water or other non-corrosive liquids. Water is circulated
through the direct expansion cooler where it is cooled
to the desired temperature then circulated to cooling
coils for air conditioning, or to other types of heat
exchangers for process cooling.
AUDS-B Model condensing units are designed to serve
a wide variety of field-installed evaporators, with
interconnecting piping to be connected in the field.
When connected to a direct expansion cooler, the model
AUDS-B condensing unit operates the same as an ACDSB packaged chiller. When connected to one or more
DX coil banks, the unit is used to cool and dehumidify
ducted air.
Care should be taken to see that the equipment is
properly installed and adjusted. An installer or operator
should first become familiar with the information
contained in this manual. Installation of models AUDSB requiring field-installed refrigeration piping should
only be made by a qualified refrigeration technician.
2.2
Inspection ACDS-B/AUDS-B
When the equipment is delivered, it is important that

the following inspection be completed in the presence
of the carriers representative:
1. Check all crates and cartons received against the Bill
of Lading/Shipping Papers to be sure they agree.
2. Check the model number and the electrical
characteristics on the nameplate to determine if they
are correct.
3. Check for freight damage, shortages or other

discrepancies and note them on the delivery receipt
before signing.
In the event that any damage is found, a damage claim
should immediately be filed by the purchaser against
the delivering carrier as all shipments are made at the
purchasers risk.
2.3
2.3.1
Handling Storage & Rigging

General ACDS-B/AUDS-B Handling
Instructions
Each unit has been carefully tested at the factory where

every precaution is taken to assure that the unit reaches
you in perfect condition. It is very important that the
riggers and movers should use the same care and
precaution in moving the equipment into place. Make
sure that chains, cables, or other moving equipment
are placed so as to avoid damage to the unit or piping.
The refrigerant piping must not be used as a ladder or
as a hand hold. Do not attach a chain hoist sling to the
piping or equipment. Move the unit in an upright
position and let it down gently from trucks or rollers.
2.3.2 Storage
This equipment is designed for outdoor use but must
be protected from physical damage if stored before
installation.
2.3.3
ACDS-B/AUDS-B Rigging and

Moving
This equipment is too large to be carried by a forklift

without serious damage so rigging is required.
Figure 2.3.3.1
10
2.0 INSTALLATION
2.4
2.4.1
Space and Clearance

Requirements
ACDS-B/AUDS-B
General Space and Clearance
Requirements
The dimensional data and space requirements are given

on pages 13 thru 21. Refer to 2.4.2 for location and
installation clearances and 2.4.3 for dimensional
requirements. The most important consideration which
must be taken into account when deciding upon the
location of air cooled equipment, is the provision for a
supply of ambient air to the condenser, and removal of
heated air from the condenser area. Where this essential
requirement is not provided, it will result in higher
condensing temperatures, which cause poor operation,
higher power consumption and possibly, eventual
failure of equipment. Units must not be located in the
vicinity of steam, hot air or fume exhausts.
Another consideration which must be taken is that the

unit should be mounted away from noise sensitive
spaces and must have adequate support to avoid
vibration and noise transmission into the building. Units
should be mounted over corridors, utility areas, rest
rooms or other auxiliary areas where sound levels are
not as important a factor. Sound and structural
consultants should be retained for recommendations
on critical installations.
11
2.0 INSTALLATION (CONT.)
2.4.2 Location and Installation Clearance - ACDS-B & AUDS-B 015S-100D
12
2.4.3 Dimensional Data: ACDS-B 015S to 030S
022508ABCAT
13
2.4.3 Dimensional Data: ACDS-B & AUDS-B 025D to 055D
022509ABCAT
14
2.4.3 Dimensional Data: ACDS-B 057D and 060D
022510ABCAT1
15

2.4.3 Dimensional Data: ACDS-B 065D and 100D
024613AACAT
16
2.4.3 Dimensional Data: AUDS-B 015S to 030S
022555ABCAT
17
2.4.3 Dimensional Data: AUDS-B 025D to 055D
022556ABCAT
18

024302AACAT
19

2.4.3 Dimensional Data: AUDS-B 100D
024303ABCAT
20
022557ABCAT
21
2.5 Foundation or Mounting Structure

Foundations must be level within 1/16" per foot, for proper
operation and functioning of controls. Provision must be
made for supporting the individual load points as shown in
the unit dimensions on 2.4.3 and unit weight and point
2.5.1
loading charts 2.5.1 - 2.5.4. Roof mounted units must be

supported on adequate steel structures. If units are located
on the ground level, a concrete base is recommended.
ACDS-B Unit Weights and Point Loading

Aluminum Fin Condenser Unit
UNIT
#
MODEL FANS
#1
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
446
465
476
509
543
864
908
948
951
960
1049
1123
771
771
1160
1177
1226
1244
1299
2
2
2
2
2
4
4
4
4
4
4
4
6
6
6
6
6
6
8
POS (WEIGHT IN LBS)

#2
#3
#4
558
565
591
613
661
1006
1021
1034
1044
1071
1108
1198
877
877
1012
1075
1125
1191
1194
324
343
346
376
405
738
782
822
825
834
923
991
928
928
1465
1484
1540
1560
1817
340
347
355
368
407
880
895
908
917
945
981
1067
1052
1052
1107
1179
1279
1355
1797
#5
#6
TOTAL
LBS
--1668
--1720
--1768
--1866
--2016
--3488
--3606
--3712
--3737
--3810
--4061
--4379
586
586 4800
586
586 4800
981
952 6678
981
952 6849
1055 1088 7314
1055 1088 7494
1222 919 8248
CNT
BOX
END
#1
202
211
216
231
247
392
412
430
432
436
476
510
350
350
527
534
557
565
590
FIELD:
POS (WEIGHT IN KGS)

#2 #3
#4
#5
#6
TOTAL
KGS
253
257
268
278
300
457
464
469
474
486
503
544
398
398
460
488
511
541
542
------------266
266
432
432
494
494
417
757
781
803
847
915
1584
1637
1685
1697
1730
1844
1988
2179
2179
3033
3109
3322
3403
3745
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
147
156
157
171
184
335
355
373
375
379
419
450
421
421
666
674
700
709
825
154
158
161
167
185
400
406
412
416
429
445
484
478
478
503
536
581
615
816
------------266
266
445
445
479
479
555
DIMENSIONS
B
C
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
43.00
43.00
43.00
43.00
43.00
43.00
59.50
------------46.00
46.00
49.00
49.00
49.00
49.00
68.50
40.00
40.00
40.00
40.00
40.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
INSTALL ISOLATORS AT THE

CORRESPONDING LOAD POINTS.
Drawing No. 024397AACAT
TOP VIEW
2.5.2
ACDS-B Unit Weights and Point Loading

Copper Fin Condenser Unit
UNIT
#
MODEL FANS
#1
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
532
588
636
415
424
1049
1093
1093
1189
1199
1208
1208
1107
1116
1274
1291
1336
1354
1408
2
2
2
2
2
4
4
4
4
4
4
4
6
6
6
6
6
6
8
POS (WEIGHT IN LBS)

#2
#3
#4
646
719
771
524
544
1161
1176
1176
1209
1240
1269
1269
1077
1106
1126
1189
1235
1301
1303
405
459
494
557
565
914
958
958
1053
1064
1073
1073
1541
1556
1559
1578
1631
1651
2021
CNT
BOX
END
417
486
509
591
609
1026
1041
1041
1074
1105
1134
1134
1408
1451
1201
1273
1369
1445
2001
#5
#6
TOTAL
LBS
#1
------------868
871
1101
1101
1171
1171
1346
------------766
775
1072
1072
1204
1204
1043
1897
1949
1997
2096
2363
3941
4058
4165
4190
4262
4512
5076
5476
5476
7333
7504
7946
8126
9122
242
267
289
188
192
476
496
496
540
544
548
548
503
507
579
586
607
615
639
FIELD:
POS (WEIGHT IN KGS)

#2 #3
#4
#5
293
326
350
238
247
527
534
534
549
563
576
576
489
502
512
540
561
591
592
184
208
224
253
257
415
435
435
478
483
487
487
700
706
708
717
741
750
918
189
221
231
268
276
466
473
473
488
502
515
515
639
659
545
578
622
656
909
------------394
395
500
500
532
532
611
#6
TOTAL
KGS
------------348
352
487
487
547
547
473
861
885
907
952
1073
1789
1842
1891
1902
1935
2048
2305
2486
2486
3331
3408
3610
3691
4142
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
DIMENSIONS
B
C
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
43.00
43.00
43.00
43.00
43.00
43.00
59.50
------------46.00
46.00
49.00
49.00
49.00
49.00
68.50
40.00
40.00
40.00
40.00
40.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00

TOP VIEW
22

2.5.3
AUDS-B Unit Weights and Point Loading

Aluminum Fin Condenser Unit
UNIT
#
MODEL FANS
#1
POS (WEIGHT IN LBS)

#2
#3
#4
#5
#6
TOTAL
LBS
#1
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
359
359
371
376
410
727
727
727
730
739
742
816
612
612
771
787
837
854
786
526
526
552
563
611
961
961
961
970
997
1005
1096
809
809
909
972
1022
1088
1067
------------470
470
629
629
703
703
654
------------537
537
863
863
1000
1000
779
1431
1431
1479
1501
1650
3123
3123
3123
3148
3220
3242
3560
3981
3981
4650
4821
5286
5466
5887
163
163
168
171
186
330
330
330
331
336
337
370
278
278
350
357
380
388
357
2
2
2
2
2
4
4
4
4
4
4
4
6
6
6
6
6
6
8
238
238
241
243
272
601
601
601
604
613
616
684
629
629
578
597
653
673
1001
308
308
315
319
357
834
834
834
844
871
879
964
924
924
900
972
1072
1148
1600
CNT
BOX
END
POS (WEIGHT IN KGS)

#2
#3
#4
#5
239
239
251
256
277
436
436
436
440
453
456
498
367
367
413
441
464
494
484
108
108
109
110
123
273
273
273
274
278
280
311
286
286
262
271
296
305
455
FIELD:
140
140
143
145
162
379
379
379
383
395
399
438
419
419
409
442
487
521
727
------------213
213
285
285
319
319
297
#6
TOTAL
KGS
DIMENSIONS
B
C
------------244
244
392
392
454
454
354
650
650
671
681
749
1418
1418
1418
1429
1462
1472
1616
1807
1807
2111
2188
2400
2481
2674
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
43.00
43.00
43.00
43.00
43.00
43.00
59.50
------------46.00
46.00
49.00
49.00
49.00
49.00
68.50
40.00
40.00
40.00
40.00
40.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00

UNIT TOP VIEW

2.5.4
AUDS-B Unit Weights and Point Loading

Copper Fin Condenser Unit
UNIT
#
MODEL FANS
#1
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
411
411
422
427
487
845
845
845
848
857
859
997
700
700
885
901
947
964
895
2
2
2
2
2
4
4
4
4
4
4
4
6
6
6
6
6
6
8
POS (WEIGHT IN LBS)

#2
#3
#4
591
591
617
629
710
1078
1078
1078
1087
1115
1123
1277
897
897
1023
1086
1132
1198
1176
288
288
291
293
347
709
709
709
712
721
724
852
777
777
671
690
743
763
1205
371
371
378
382
453
943
943
943
952
979
988
1132
1073
1073
994
1066
1162
1238
1804
CNT
BOX
END
#5
#6
------------571
571
749
749
819
819
777
------------638
638
983
983
1116
1116
903
TOTAL
LBS
1661
1661
1708
1731
1997
3575
3575
3575
3599
3672
3694
4258
4656
4656
5306
5477
5919
6099
6761
#1
187
187
192
194
221
384
384
384
385
389
390
453
318
318
402
409
430
438
406
POS (WEIGHT IN KGS)

#2
#3
#4
#5
268
268
280
286
322
489
489
489
493
506
510
580
407
407
465
493
514
544
534
131
131
132
133
158
322
322
322
323
327
329
387
353
353
305
313
337
346
547
FIELD:
168
168
172
173
206
428
428
428
432
444
449
514
487
487
451
584
528
562
820
------------259
259
340
340
372
372
353
#6
TOTAL
KGS
------------290
290
447
447
507
507
410
754
754
775
786
907
1623
1623
1623
1634
1667
1677
1933
2114
2114
2410
2486
2688
2769
3070
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
20.00
DIMENSIONS
B
C
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
57.00
43.00
43.00
43.00
43.00
43.00
43.00
59.50
------------46.00
46.00
49.00
49.00
49.00
49.00
68.50
40.00
40.00
40.00
40.00
40.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00
83.00

UNIT TOP VIEW
23
2.6 Vibration Isolation ACDS-B/AUDS-B

Under certain critical conditions, it may be necessary to install
vibration isolators under the base of the Packaged Chiller and
the Air Cooled Condenser.
Rubber-in-shear or spring vibration isolators are offered as
optional items. See 2.6.1 or 2.6.2 on pages 24 (ACDS-B / AUDS-B)
for mounting location. When spring isolators are used, flexible
connectors must be installed in the water piping system and in
the refrigerant lines of split systems. Note: These flexible
connectors must be suitable for the fluid and pressures involves.
When using flexible connectors in refrigerant piping, they must
be mounted in the refrigerant discharge and liquid lines close
to the packaged chiller, in a horizontal position and parallel to the

compressor crankshaft.
All piping which is external to the packaged chiller must be
supported by spring mounted hangers and any piping which
goes through the wall, ceiling or floor should be properly
sheathed to prevent transmission of piping vibration to the
structure.
When spring isolators are used, electrical service to the unit
must also be flexibly connected, by means of a 36" section of
flexible conduit.
2.6.1
ACDS-B Rubber-in-Shear Vibration Isolators and Locations

For Units with Aluminum Fin Condensers
2.6.2
ACDS-B Rubber-in-Shear Vibration Isolators and Locations

For Units with Copper Fin Condensers
024398AACAT
024398AACAT
24
2.6.3
ACDS-B Spring Vibration Isolators and Locations

2.6.4
ACDS-B Spring Vibration Isolators and Locations


25

2.6.5
AUDS-B Rubber-in-Shear Vibration Isolators and Locations

2.6.6
AUDS-B Rubber-in-Shear Vibration Isolators and Locations


26

2.6.7
AUDS-B Spring Vibration Isolators and Locations

024404AACAT
2.6.8
AUDS-B Spring Vibration Isolators and Locations


27

2.7
2.7.1
Piping Connections
ACDS-B/AUDS-B
when both heating and cooling are required. This

should also be considered when designing heating and
cooling systems. For various piping arrangements
consult the ASHRAE Handbook.
ACDS-B Chilled Water Piping
After the unit has been leveled, the external water piping
may be made up. Be sure water piping is connected to
the correct fittings. The water out connection is closest
to the expansion valve (Refrigerant-in) end. A chilled
water flow switch must be installed.
Water flow through the cooler must remain constant
for proper chiller operation. Water pressure gauges
are recommended to check the water pressure and flow
rate in the system, before and after the cooler, and to
determine if variations occur in the cooler and system.
The cooler must be freeze protected with the correct
percentage of glycol if ambient temperatures are
expected to be below 32F. If sub-freezing ambient
temperatures are possible, all exposed field water piping
should have heater tape and insulation or a glycol
mixture to prevent freezing. Main power is required to
keep the sump heaters and cooler heaters on.
When installing pressure taps to measures the amount
of pressure drop across the water side of the cooler,
the taps should be located in the water piping a
minimum of twenty-four (24) inches downstream from
any connections (flange, elbow, etc.).
There are many piping and control systems which may
be used to assure constant water flow through the
cooler. A typical system is shown in Figure 2.7A. It
uses a three way motorized valve which operates in
response to the discharge air temperature of the cooling
coil.
Another system which is sometimes used consists of a
two way modulating control valve, which also responds
to the discharge air temperature of the cooling coil,
used in conjunction with a spring loaded bypass
regulating valve as shown in Figure 2.7B. The bypass
valve must be set to assure the full flow of circulating
chilled water when the modulating valve is completely
closed.
Other systems are noted in the ASHRAE Handbook and
may serve equally well. Whatever system is selected,
water flow must be constantly maintained through the
chiller.
If the system is arranged for the dual purpose of cooling
in the summer and heating in the winter, the cooler
must be valved off during the heating season so that
hot water will not pass through the cooler. This may
be either a manual or automatic change-over operation.
There are also times, such as early spring and late fall,
2.7.2 Water Connections

Multiple Packaged Chillers
Multiple unit packaged chillers have been successfully
applied to parallel and series piping systems for years.
Special attention, however, must be given to the
particulars involved for each application or serious
operational problems can result.
The following are guidelines which should be followed
for multiple unit application.
NOTE: A constant chilled water flow rate is assumed to
be maintained through all coolers.
2.7.2.1 Parallel Chilled Water Flow Units
Both units operate simultaneously, modulating with
load variations. Each packaged chiller operating
thermostat senses leaving water temperature using
standard controls (See Figure 2.7C). The set point of
each thermostat will be set to maintain the desired
unloading. In addition, for each chiller package, the
optional suction sensing hot gas by-pass valve provides
modulating capacity reduction to approximately 10%
on single compressor models with hot gas bypass.
2.7.2.2 Series Chilled Water Flow Units
Units should be equally sized. The upstream unit will
carry a larger load because it cools higher temperature
water. The thermostats sense leaving fluid temperatures
(See Figure 2.7D). The Number 1 unit thermostat will
unload or cycle off the packaged chiller before
unloading occurs on the Number 2 unit.
2.7.3 Water Quality
ACDS-B
Coolers used in these packages are made of steel, copper

and brass and are suitable for operation with wellmaintained water systems. However, if the water used
in cooler is corrosive, high in mineral content or
entrained solids, the water can cause reduced performance and even failure of heat exchangers. Therefore,
it may be necessary to obtain the services of a water
treatment consultant and to provide and maintain water
treatment. This is particularly important with glycol
systems.
See Maintenance Section 4.0 Paragraph 4.4 for
maintenance of heat exchangers.
28

2.7.4
Condensing Unit Connections

AUDS-B
2.7.4.1 General
The AUDS-B condensing unit may be connected to either
a cooling coil or a remote cooler. When making
connections, all refrigerant piping should be installed
in accordance with local or state codes and the latest
issue of ANSI/ASHRAE Standard 15 Safety Code for
Mechanical Refrigeration. Hard drawn type L or K
copper tubing should be used. Soft tubing, where
bending is required, may be used providing it is
protected in accordance with the local code restrictions.
Careful considerations must always be given to sizing
the liquid line and suction line. For sizing lines, refer to
Compressor Piping Manual, Form No. 4120.1 or ASHRAE
Handbook.
A suction to liquid heat exchanger must be used if the

evaporator is installed more than 30 ft. above the
condensing unit or if the pressure drop in the liquid
line exceeds 15 psi. This is necessary to prevent flashing
gas at the expansion valve.
When a unit is provided with the hot gas bypass option,
a hot gas regulator and solenoid will be mounted at
the condensing unit. The contractor must furnish an
insulated hot gas line with check valve. The line must
be piped for an evaporator coil or cooler as shown in
Figure 2.7E.
For information concerning the installation, operation
and servicing of Dunham-Bush coolers, consult the latest
revision of Form 8110.
29
Figure 2.7A
EXPANSION
TANK
PUMP
THREE
WAY VALVE
R-OUT
CHILLER
R-IN
COOLING
COIL
Figure 2.7B
EXPANSION
TANK
TWO
WAY VALVE
PUMP
R-OUT
CHILLER
R-IN
COOLING
COIL
BYPASS REG.
VALVE
Figure 2.7C
R-OUT
Figure 2.7D
CHILLER
R-IN
R-OUT
FLUID-IN
No. 1
CHILLER
T
FLUID-OUT
W-IN
R-IN
W-OUT
R-OUT
CHILLER
R-IN
R-OUT
No. 2
CHILLER
R-IN
Figure 2.7E
30

2.8
Electrical Connections
ACDS-B/AUDS-B
All units are wired as completely as possible at the factory

prior to delivery. The connections which must be made
by the installer are to the main power source, control
power source, separate chiller heater power source and
interlocking the satellite equipment. In connecting
power wiring to the unit, the following precautions
should be taken:
The power supply should match the unit nameplate

in volts, phase and Hertz. Voltage must be within
10% of nameplate value and voltage imbalance between phases must not exceed 2%.
For minimum circuit ampacity and maximum fuse
size, see Unit Nameplate.
All field wiring is to be in accordance with the National Electrical Code and state and local codes.
All wiring is to be checked for damage and all terminal connections tested for tightness. Unit terminal
blocks are to be connected with copper conductors
only, sized per ampacity listed on unit data plate.
31

2.8.1
Electrical Data (60Hz/3PH)
ACDS-B
Model
015S
020S
025S
027S
030S
025D
030D
035D
040D
60 Hz
Nom.
Volts
Standard Unit
Electrical Data
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
62
62
33
24
82
82
41
33
97
97
51
40
104
104
53
44
111
111
55
48
68
68
36
26
90
90
45
36
107
107
57
45
116
116
59
49
123
123
61
53
MFS/
HACR
90
90
45
30
110
110
60
45
125
125
70
60
150
150
80
70
150
150
80
70
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
127
127
68
50
146
146
75
57
158
158
80
63
168
168
85
69
133
133
71
53
154
153
79
60
167
167
84
67
179
178
90
73
150
150
80
60
175
175
90
70
200
200
100
80
200
200
110
90
NOTES: RLA
MCA
MFS / HACR
LRA-XL
RLA
MCA
Each Compressor
Qty./
Circuit
2
2
2
2
2
2
2
2
2
2
2
2
1/1
1/1
1/1
1/1
2
2
2
2
4
4
4
4
4
4
4
4
2/2
2/2
2/2
2/2
3/1
3/1
3/1
3/1
LRA-XL
RLA
23.8
23.8
12.6
9.2
33.6
33.6
16.5
13.7
41.1
41.1
21.8
17.4
41.1/48.1
41.1/48.1
21.8/23.8
17.4/21.2
48.1
48.1
23.8
21.2
189
189
94
74
278
278
127
100
350
350
158
125
350/425
350/425
158/187
125/148
425
425
187
148
25.1
25.1
13.6
10.1
29.9
29.9
15.3
11.9
31.1/34.8
31.2/34.9
16/17.2
12.3/14.5
33.6/41.1
33.6/41.1
16.5/21.8
13.8/17.5
189
189
94
74
232
232
125
100
232/278
232/278
125/127
100/100
278/350
278/350
127/158
100/125
Standard 1140 RPM

Condenser
Fan Motors
Total FLA
Qty.
HP
KW
Each
2* 1.5
5.9
2* 1.5
2.2
5.9
2* 1.5
3
2* 1.5
2.1
2* 1.5
5.9
2* 1.5
2.9
5.9
2* 1.5
3
2* 1.5
2.1
2* 1.5
5.9
2* 1.5
2.9
5.9
2* 1.5
3
2* 1.5
2.1
2* 1.5
5.9
2* 1.5
2.9
5.9
2* 1.5
3
2* 1.5
2.1
2* 1.5
5.9
2* 1.5
2.9
5.9
2* 1.5
3
2* 1.5
2.1
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
4*
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
4.4
4.4
4.4
5.8
5.9
5.9
3
2.1
5.9
5.9
3
2.1
5.9
5.9
3
2.1
5.9
5.9
3
2.1
- Rated Load Amps at ARI Conditions of Service

*Replace (1) 1.5 HP motor with (1) 1 HP motor
- Minimum Circuit Ampacity
per circuit on units with Low Ambient Option
- Maximum fuse or HACR breaker size, protective device
- Locked Rotor Amps Standard Across the Line Starting
IMPORTANT: See additional notes on pages 36.
32

2.8.1
ACDS-B
Model
045D
050D
055D
057D
060D
065D
070D
080D
085D
090D
100D
60 Hz
Nom.
Volts
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
NOTES: RLA
MCA
MFS / HACR
LRA-XL
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
Standard Unit
Electrical Data
MCA
RLA
191
201
191
201
103
107
80
85
198
210
198
210
103
109
83
88
212
224
212
224
121
128
91
96
249
263
249
262
127
132
101
106
249
263
249
262
127
132
101
106
287
305
286
304
139
147
118
125
323
341
323
341
142
150
121
128
352
374
352
373
162
172
130
137
361
382
361
381
182
192
138
146
361
382
361
381
182
192
138
146
373
393
373
393
188
198
143
150
MFS/
HACR
225
225
125
100
250
250
125
100
250
250
150
110
300
300
150
125
300
300
150
125
350
350
175
150
400
400
175
150
450
450
200
150
450
450
225
175
450
450
225
175
450
450
225
175
Each Compressor
Qty./
Circuit
4
4
4
4
3/1
3/1
3/1
3/1
1/3
1/3
1/3
1/3
4
4
4
4
4
4
4
4
2/2
2/2
2/2
2/2
4
4
4
4
2/2
2/2
2/2
2/2
4
4
4
4
4
4
4
4
4
4
4
4
RLA
41.1
41.1
22
17.6
41.1/48.1
41.1/48.1
21.8/23.8
17.4/21.2
41.1/48.1
41.1/48.1
25.4/27.3
17.4/21.2
52.8
52.8
26.5
21.7
52.8
52.8
26.5
21.7
52.8/71.1
52.8/71.1
26.5/33.0
24.8/27.2
71.1
71.1
30.7
26.8
71.1/85.6
71.1/85.6
30.7/40.6
26.8/31.1
80.6
80.6
40.6
31.1
80.6
80.6
40.6
31.1
80.6
80.6
40.6
31.1
LRA-XL
350
350
158
125
350/425
350/425
158/187
125/148
350/425
350/425
158/187
125/148
425
425
187
148
425
425
187
148
425/480
425/480
187/225
148/180
480
480
225
180
480/500
480/500
225/2500
180/200
500
500
250
200
500
500
250
200
500
500
250
200
Standard 1140 RPM

Condenser
Fan Motors
Total FLA
Qty.
HP
KW
Each
4*
1.5
5.9
4*
1.5
5.8
5.9
4*
1.5
3
4*
1.5
2.1
4*
1.5
5.9
4*
1.5
5.8
5.9
4*
1.5
3
4*
1.5
2.1
4*
1.5
5.9
4*
1.5
5.8
5.9
4*
1.5
3
4*
1.5
2.1
6*
1.5
5.9
6*
1.5
8.7
5.9
6*
1.5
3
6*
1.5
2.1
6*
1.5
5.9
6*
1.5
8.7
5.9
6*
1.5
3
6*
1.5
2.1
6*
1.5
5.9
6*
1.5
8.7
5.9
6*
1.5
3.0
6*
1.5
2.1
6*
1.5
8.7
5.9
6*
1.5
5.9
6*
1.5
3.0
6*
1.5
2.1
6*
1.5
5.9
6*
1.5
8.7
5.9
6*
1.5
3.0
6*
1.5
2.1
6*
1.5
5.9
6*
1.5
8.7
5.9
6*
1.5
3.0
6*
1.5
2.1
6*
1.5
5.9
6*
1.5
8.7
5.9
6*
1.5
3.0
6*
1.5
2.1
8*
1.5
5.9
8*
1.5
11.6
5.9
8*
1.5
3.0
8*
1.5
2.1
- Rated Load Amps at ARI Conditions of Service

*Replace (1) 1.5 HP motor with (1) 1 HP single phase
- Minimum Circuit Ampacity
motor per circuit on units with Low Ambient Option
- Maximum fuse or HACR breaker size, protective device
- Locked Rotor Amps Standard Across the Line Starting
IMPORTANT: See additional notes on page 36.
33

2.8.2
Field Wiring Electrical Data (60Hz/3PH)

Single Source Power - Wire Size Range and Quantity
Supply Voltage
60 Hz.
ACDS-B
Model
015S
020S
025S
027S
030S
025D
030D
035D
040D
NOTE:
Code
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
Nom.
Volts
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
1
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
Standard Terminal Block
Optional - Unit Mtd. Disconnect Switch
Qty. Wires
Per Pole
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Wire
Size Range
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
Qty. Wires
Per Pole
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Wire
Size Range
#14 TO 1/0
#14 TO 1/0
#14 TO 1/0
#14 TO 1/0
#14 TO 1/0
#14 TO 1/0
#14 TO 1/0
#14 TO 1/0
#4 TO 4/0
#4 TO 4/0
#14 TO 1/0
#14 TO 1/0
#4 TO 4/0
#4 TO 4/0
#14 TO 1/0
#14 TO 1/0
#4 TO 4/0
#4 TO 4/0
#14 TO 1/0
#14 TO 1/0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
#4 TO 4/0
#4 TO 4/0
#14 TO 1/0
#14 TO 1/0
#4 TO 350MCM
#4 TO 350MCM
#14 TO 1/0
#14 TO 1/0
#4 TO 350MCM
#4 TO 350MCM
#14 TO 1/0
#14 TO 1/0
#4 TO 350MCM
#4 TO 350MCM
#14 TO 1/0
#14 TO 1/0
Single point power is standard for all models ACDSB 015S to ACDSB 100D.
34

2.8.2
Field Wiring Electrical Data (60Hz/3PH)

Single Source Power - Wire Size Range and Quantity
Supply Voltage
60 Hz.
ACDS-B
Model
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
NOTE:
Standard Terminal Block
Code
Nom.
Volts
Per Pole
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
AK
AN
AR
AS
CD
AN
AR
AS
CD
AN
AR
AS
CD
AN
AR
AS
CD
AN
AR
AS
CD
AN
AR
AS
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
208
230
460
575
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
1
Qty. Wires
Optional - Unit Mtd. Disconnect Switch
Wire
Qty. Wires
Wire
Size Range
Per Pole
Size Range
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#12 TO 2/0
#6 TO 400 MCM
#6 TO 400 MCM
#6 TO 400 MCM
#12 TO 2/0
#4 TO 500 MCM
#4 TO 500 MCM
#6 TO 400 MCM
#12 TO 2/0
#4 TO 500 MCM
#4 TO 500 MCM
#6 TO 400 MCM
#12 TO 2/0
#4 TO 500 MCM
#4 TO 500 MCM
#6 TO 400 MCM
#6 TO 400 MCM
#4 TO 500 MCM
#4 TO 500 MCM
#6 TO 400 MCM
#6 TO 400 MCM
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
1
1
#4 TO 350MCM
#4 TO 350MCM
#4 TO 4/0
#14 TO 1/0
#4 TO 350MCM
#4 TO 350MCM
#4 TO 4/0
#14 TO 1/0
#4 TO 350MCM
#4 TO 350MCM
#4 TO 4/0
#4 TO 4/0
3/0 TO 250MCM
3/0 TO 250MCM
#4 TO 4/0
#4 TO 4/0
3/0 TO 250MCM
3/0 TO 250MCM
#4 TO 4/0
#4 TO 4/0
2/0 to 600MCM
2/0 to 600MCM
#4 TO 350MCM
#4 TO 4/0
2/0 to 600MCM
2/0 to 600MCM
#4 TO 350MCM
#4 TO 4/0
2/0 to 600MCM
2/0 to 600MCM
#4 TO 350MCM
#4 TO 4/0
2/0 to 600MCM
2/0 to 600MCM
#4 TO 350MCM
#4 TO 350MCM
2/0 to 600MCM
2/0 to 600MCM
#4 TO 350MCM
#4 TO 350MCM
Single point power is standard for all models ACDSB 015S to ACDSB 100D.
35

2.8.1
General Electrical Notes

1. Main power must be supplied from a single power source
field-supplied fused disconnect(s) using dual element time
delay fuses or a HACR rated circuit breaker. Power supply is
three phase unless otherwise shown.
2. The maximum terminal block incoming wire size is shown in
the electrical field wiring data table.
3. Compressor starting is XL only.
4. Control circuit transformer (115VAC) is supplied as standard
feature.
6. Crankcase heaters are wired in the control circuit. The main

unit power field disconnect and local safety switch must be
closed (on) at all times for heater operation.
7. The compressor crankcase heaters must be energized for 24
hours before the unit is initially started or after a prolonged
open disconnect.
8. All field wiring must be in accordance with all applicable local
and national codes.
9. Minimum and maximum unit supply voltages are shown in the
following tabulated data.
Supply Voltage:
5. Cooler heater power (115VAC) must be field-supplied from a

separate field-mounted fused disconnect (15 amp max. fuse
size).
TABLE 30A
Nominal
208V
230V
460V
575V
Voltage Code
CD
AN
AR
AS
Minimum
187V
207V
414V
518V
Maximum
220V
253V
506V
632V
Cooler Heater Wattage

Unit
Model
ACDS-B
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
CH2
Optional Cooler
Standard Cooler
for 44F (6.7C)
280
280
280
280
280
280
280
280
280
420
420
420
420
560
560
560
560
560
420
FLA ea.
2.4
2.4
2.4
2.4
2.4
2.4
2.4
2.4
2.4
3.7
3.7
3.7
3.7
4.9
4.9
4.9
4.9
4.9
3.7
for 42F (5.5C)

280
280
280
280
280
280
280
420
420
420
420
420
420
560
560
560
560
560
420
FLA ea.
2.4
2.4
2.4
2.4
2.4
2.4
2.4
3.7
3.7
3.7
3.7
3.7
3.7
4.9
4.9
4.9
4.9
4.9
3.7
CH3
Optional Cooler
for 40F (4.5C)
280
280
280
280
280
280
420
420
420
420
560
560
560
560
560
560
560
560
420
FLA ea.
2.4
2.4
2.4
2.4
2.4
2.4
3.7
3.7
3.7
3.7
4.9
4.9
4.9
4.9
4.9
4.9
4.9
4.9
3.7
Cooler
Heater
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
TABLE 30B
Unit Model
ASDS-B
Qty.
Total Watts (70 Watts each)
Total FLA (0.61 FLA each)
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
140
140
140
140
140
280
280
280
280
280
280
280
280
280
440
600
600
600
600
1.22
1.22
1.22
1.22
1.22
2.44
2.44
2.44
2.44
2.44
2.44
2.44
2.44
2.44
3.82
5.24
5.24
5.24
5.24
Belt or Strap Type - Crankcase Heater Data
36

2.9
2.9.1
Refrigerant Charging
Procedure ACDS-B/AUDS-B
General Refrigerant Charging
Procedures
The ACDS-B units are charged at the factory with the

refrigerant for which they were designed. The type
and amount of refrigerant are shown on the nameplate.
The AUDS-B units have a gas holding charge of the
refrigerant type shown on the nameplate.
Prior to charging an AUDS-B split system and after all

piping has been completed, the system must be pressure
tested and the system evacuated. For the procedures
to follow, consult the latest revision of Form 4232.
Table 2.9A Refrigerant Line Capacities
Line Size, in.

5/8 OD
7/8 OD
1 1/8 OD
1 3/8 OD
1 5/8 OD
2 1/8 OD
2 5/8 OD
2.9.2
R-22 Refrigerant Line Charge Lbs./100 Ft.

Liquid
Discharge
Suction
@ 90F
@ 105 F
@ 40F
12.0
.72
.30
24.0
1.35
.51
42.0
2.30
.87
59.0
3.50
1.33
74.0
4.96
1.88
146.0
8.61
3.26
225.0
13.70
5.03
Charge Calculation: Condensing

Unit AUDS-B
Prior to charging your AU condensing unit with field

installed lowside, you must first determine the amount
of refrigerant required for your system.
Determine the estimated amount for each circuit and
charge each circuit with this amount. To estimate
the amount of charge for one circuit?
1. Multiply the nominal capacity of the circuit by 2.5 to
obtain refrigerant charge in pounds.
2. Determine the length of the liquid line. Refer to Table
2.9A which gives the refrigerant charge for different
line sizes per 100 ft. Multiply your length per 100 ft.
by the amount shown in the table for your line size
and saturated temperature conditions.
3. Determine the length of the suction line for one
circuit. Refer to Table 2.9A. Multiply your length
per 100 ft. by the amount shown in the table for
your line size and saturated temperature conditions.
4. Consult the manufacturer of your low side to obtain
the operating charge.
2.9.3
Charging
AUDS-B
Once the estimated amount of charge required for your

system has been determined and the system is leak free,
you are ready to begin charging the system.
To charge the unit, attach a drum of refrigerant to the
backseating port of the liquid line valve. Purge the
charging line to remove air, invert the drum and open
it to the system. A set of scales should be used to
weigh the drum before and after charging to determine
the amount of refrigerant charged into the system.
After the system has been charged and the machine is
running, the system should once again be checked for
leaks to make sure that no leaks have occurred during
the handling of the equipment.
The unit, if possible, should be operated at full load
design conditions and the sight glass at the evaporator
should be checked. When the sight glass for each circuit
clears, compare the temperature of liquid leaving the
subcooler with that leaving the condenser. The
temperature differernce, subcooling, should be 15F to
20F.
5. Add the amount from steps 1, 2, 3, 4 to obtain an

estimated refrigerant charge per circuit.
37
3.0 OPERATION
3.1
Qualified Unit Start-up Report
The unit should be started up only by a refrigeration

technician who is familiar with accepted operation
practices for refrigeration systems.
Use reciprocating unit start-up report, Form NS1001F,
July 1985, to record all temperature, pressure, electrical
readings and control settings. A copy must be
forwarded to Dunham-Bush, Inc., North American
Service, Harrisonburg, Virginia before the warranty will
be honored.
3.2
Typical ACDS-B Refrigerant Piping
ACDS-B 015S thru 030S have a tandem scroll compressor

set and a single circuit unit.
ACDS-B 025D thru 1000D have (2) tandem scroll
compressor sets and dual circuit unit
See Figure 3.2A, 3.2B, 3.2C for typical ACDS-B packaged
chiller refrigerant piping.
See Figure 3.2D, 3.2E, 3.2F for typical AUDS-B
condensing unit piping.
NOTE: When the unit is spring mounted, care should
be taken to insure that piping is not excessively rigid.
See Section 2.6.
38
3.0 OPERATION - MECHANICAL SYSTEMS (CONT.)

Figure 3.2A
Typical ACDS-B 015S-030S Packaged Chiller Refrigerant Piping

Single Tandem Scroll Compressor Set Single Circuit Unit
OUTLET FACING DOWN
OR HORIZONTAL.
OUTLET FACING DOWN

OR HORIZONTAL.
HG
HP SW (REF.)
HP TRD
HG
COND
(HORIZ)
COND
(VERT)
SC-IN
C1A
C1B
LIQ.
LIQ.
TEE (DOWN)
7/8 ON ALL
MODELS
HAND
VALVE
HG
REG
W/ SOL
HAND VALVES
NEAR END OF UNIT IN
LOW PART OF LINE. VALVE
TO BE HORIZONTAL WITH
OUTLET FACING DOWN.
FILTER DRIER
CHR
LP TRD TYP.
WATER
IN
Figure 3.2B
WATER
OUT
Typical ACDS-B 025D-100D Packaged Chiller Refrigerant Piping

Two Tandem Scroll Compressor Sets Two Circuit Unit
OUTLET FACING DOWN

OR HORIZONTAL
OUTLET FACING DOWN
OR HORIZONTAL
HP SW (REF)
C1A
HOT GAS
HOT GAS
HP TRD
RIGHT HAND
CONDENSER
(HORIZONTAL)
C1B
HOT GAS
RIGHT HAND
CONDENSER
(VERTICAL)
SC-IN
LEFT HAND
CONDENSER
(HORIZONTAL)
LIQ.
LIQ.
TEE
(DOWN)
LIQUID CIRCUIT 2
ALL MODELS
C2B
HAND
VALVE
HOT GAS
REGULATOR
W/ SOL
LP TRD TYP.
WATER
IN
TXV's
LIQ.
TEE
(DOWN)
7/8
7/8
7/8
CHILLER
LEFT HAND
CONDENSER
(VERTICAL)
SC-IN
LIQ.
C2A
HOT GAS
LIQUID CIRCUIT 1
ALL MODELS
NEAR END OF UNIT IN LOW PART

OF LINE. VALVE TO BE HORIZONTAL
WITH OUTLET FACING DOWN.
FILTER DRIERS
CIRCUIT 2
TXV's
CIRCUIT 1
WATER
OUT
39
3.0 OPERATION (CONT.)

Figure 3.2C
Typical AUDS-B 015S-030S Packaged Chiller Refrigerant Piping

Single Tanem Scroll Compressor Set Single Circuit Unit
OUTLET FACING DOWN

OR HORIZONTAL.
OUTLET FACING DOWN

OR HORIZONTAL.
HOT GAS
HP SW (REF)
HOT GAS
COND
(VERT)
COND
(HORIZ)
HP TRD
SC-IN
C1A
C1B
LIQ.
1 1/8
HAND
VALVE
LIQ.
TEE (DOWN)
HG
REG
W/ SOL
022577AACAT
Figure 3.2D
Typical AUDS-B 025D-100D Packaged Chiller Refrigerant Piping

Two Tandem Scroll Compressor Set Two Circuit Unit
022578ABCAT
40

3.3
Pre-Start-Up Procedure for

ACDS-B Packaged Chillers &
AUDS-B Split Systems
whether it is in satisfactory operating condition, and

instruct 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 and the oil sump temperature must be at a
minimum of 100F (38C) prior to arrival of start-up
representative. This will ensure that the oil is warm
enough to vaporize any dissolved refrigerant and that
the oil is within the normal operating temperature range.
The unit is ready for start-up when the following procedures

have been completed.
1.
2.
3.
Water piping for the cooler is installed and tested.

Electrical connections are made and properly fused.
Unit has been leak tested, leaks corrected, and charge
completed.
4. Compressor crankcase heater(s) has been energized for
a minimum of 24 hours.
5. Calibrated refrigerant gages have been connected to the
suction and discharge pressure ports.
6. Turn on the chilled water pump, check direction of
rotation and adjust the water flow through the cooler
to the specified flow rate. Bleed off all entrained air.
7. Manually energize the fan starters and check the fan
rotation. Fans should pull air through the condenser
coil and discharge vertically upwards. Rotation can be
changed on 3-phase motors by interchanging only two
wires on the main terminal block.
8. Check all refrigerant valves to be sure they are open.
9. Scroll compressors, like several other types of
compressors, will only compress in one rotational
direction. Three phase compressors will rotate in either
direction depending upon phasing of the power. Since
there is a 50-50 chance of connecting power in such a
way as to cause rotation in the reverse direction, it is
important to ensure proper rotation direction is
achieved when the system is installed and operated.
There is no negative impact on durability caused by
operating three phase Compliant Scroll compressors in
the reversed direction for a short period of time (under
one hour). However, after several minutes of operation,
the compressors internal protector will trip.
10. Proceed to System Start-up.
2.
3.
4.
5.
3.4
1.
System Start-Up & Reporting

for ACDS-B Packaged Chillers
& AUDS-B Split-Systems
Request for Start-Up Representative ACDS-B/AUDS-B

Start-up service is an option for these units and is requested
when the unit is ordered. If you purchased start-up service,
then after the installation has been completed and checked,
Form 9180 must be filled out and sent to the local DunhamBush representative who sold the unit. Following receipt
of this signed form, a representative will be sent to the
customer. The purchaser should have competent service
and operating personnel in attendance to assist in the work
involved, and also to be trained in the operation and
maintenance of this unit.
The representative will inspect the installation to determine
whether it meets Dunham-Bush, Inc. requirements,
perform the initial start-up of the installation, determine
6.
7.
8.
Scroll Compressor Rotation

Scroll compressors, like several other types of compressors,
will only compress in one rotational direction. Three-phase
compressors will rotate in either direction depending upon
phasing of the power to L1, L2 and L3. Since there is a 50/
50 chance of connecting power in such a way as to cause
rotation in the reverse direction, it is important to ensure
proper rotation direction is achieved when the system is
installed and operated. Verification of proper rotation
direction is made by observing that suction pressure drops
and discharge pressure rises when the compressor is
energized. Reverse rotation results in a sound level above
that with correct rotation direction, as well as
substantially reduced current draw compared to
tabulated values and after several minutes of operation,
the compressors internal protector will trip. All threephase compressors are wired identically internally. As a
result, once the correct phasing is determined for a
specific system or installation, connecting properly
phased power leads to the same terminals should
maintain proper rotation direction.
Before starting the compressor(s), check all three phases
of supply voltage, of all legs of the motor. They must be
within 10% of the nameplate voltage.
Start compressor(s), check the gages and note if the
pressures are within the prescribed limits.
Check the refrigerant sight glass at the TX Valve to be
sure it is free of bubbles. If not, charge as specified per
section 4.8 Charging.
Shut the compressor down and check the compressor
shell sight glass for oil level. It should be visible in the
sight glass. If not, see Section 3.7 Lubrication.
Restart the compressor. After an hour of operation the
expansion valve superheat setting should be checked, it
should be between 10 and 14F at full load design
conditions. In some instances, it will be necessary to
raise the superheat setting to prevent expansion valve
hunting. Turn the TX valve adjustment stem clockwise
to increase the superheat setting and counterclockwise
to decrease the setting. Be sure and allow 10 minutes
between each adjustment for the system to rebalance.
The electrical control settings should be checked and, if
necessary, reset to those settings indicated on the wiring
diagram. Safety controls are factory set and must be
maintained at settings indicated on the wiring diagram.
The temperatures of the chilled water both in and out,
should be checked to insure the unit is operating within
the desired temperatures.
41
3.0 OPERATION - MECHANICAL SYSTEMS (CONT.)

3.5
Lubrication ACDS-B/AUDS-B
3.5.1
General
All scroll compressors have an internal system for positive

lubrication.
3.5.2
Oil Level
Observe oil during operation to see that oil is visible in the

sight glass.
1.
2.
There is a Shrader valve fitting at the oil level to remove

or add oil if necessary.
NOTE: The scroll compressor is a single direction
compressor and must not be run in the reverse direction.
3.5.3
If the oil becomes discolored indicating contamination, the

contamination can be eliminated by installing a new filterdrier in the liquid line and changing the oil.
WARNING: USE ONLY DUNHAM-BUSH OR COPELAND
APPROVED REFRIGERATION OIL. WARRANTY WILL BE VOID IF
OTHER THAN APPROVED OIL IS USED.
Oil charge for a complete recharge is shown in the following
table. Oil type and approved oils are also listed for the
compressor. After recharge, the oil level should be maintained
visible in the sight glass.
ZZ18
thru
ZZ38
Tandem
Scrolls
Oil Charge*
(Ounces)
280
280
280
280
280
System Flow Rate ACDS-B
The quantity of chilled water being circulated can be

estimated by determining the water pressure drop through
the cooler and reading GPM from the appropriate pressure
drop curve, Table 3.6A.
An alternate method of determining GPM is to measure
pressure difference from pump inlet to outlet and read GPM
from pump curve.
Water flow rate must not vary more than 10% from design
flow rate.
TABLE 3.6A
Oil Type
Compressor
3.6
Oil Type
Approved Oils
150SUS
150SUS
150SUS
150SUS
150SUS
CALUMET R015
or
TEXACO WF-32
"
"
*Oil charge is total for both compressors of the scroll tandem.
NOTE: To remove contaminated oil from the compressor,

first reclaim the refrigerant from the compressor with the
compressor isolated by closing the system shutoff valves.
With the compressor at 0 pressure, remove the oil equalizer
line at the oil level. Allow the oil to drain into a catch pan. To
remove the remaining oil below the sight glass level, bend a
12-inch piece of 1/4 inch plastic tubing to fit thru the open
equalizer fitting on the compressor to reach to the bottom
of the compressor sump. Seal the opening between the tubing
and the equalizer fitting with a rag.
Attach a service manifold to the Schrader fitting on the
compressor housing at the oil level. Insert 1-2 psig of nitrogen
into the compressor using the above Schrader fitting to force
the oil in the sump out thru the small plastic tube into the
catch pan. Change liquid line filter drier cores using special
acid removing type cores.
Unit
Model
Size
015S
020S
025S
027S
030S
025D
030D
035D
040D
045D
050D
055D
057D
060D
065D
070D
080D
090D
100D
Cooler Curve No. for Table 23

Std
Optional
Optional
CH1
CH2
CH3
44F(CLR) 42F (CLR) 40F (CLR)
1
1
1
1
1
2
3
3
2
3
3
4
4
4
4
3
4
4
3
4
6
5
7
8
5
7
9
7
7
8
9
9
12
9
9
12
9
9
12
12
12
12
11
11
11
11
11
11
11
11
11
12
12
12
13
13
13
NOTES:
1. A constant water flow rate is required with a minimum of
3 gallons per ton (3.25 L/kW) water loop volume increasing
up to 10 gallons per ton (10.8 L/kW) for process, low load
applications with small temperature ranges and/or vastly
fluctuating load conditions.
2. AUDS-B 160-270 split system chillers use the same coolers
as the ACDS-B 160-270 packaged chillers.
3. AUDS-B 160-270 split-system remote coolers are supplied
insulated with the refrigeration specialty parts shipped
loose for field installation. (No cooler heaters supplied
since the remote cooler option is intended for indoor
installation.
42
DX COOLER: WATER SIDE PRESSURE DROP

ENGLISH I.P.
Figure 3.6B
AND
METRIC S.I. UNITS
TABLE 3.6B
Cooler
Curve
No.
Model
*Conn. Size
English I.P. Units

Minimum
Maximum
GPM
GPM
Metric S.E. Units

Min.
Max.
Lit./Sec.
Lit./Sec.
Single Circuit Coolers

1
2
3
4
CHS006601B
CHS007601A
CHS007601B
CHS008601A
3" NPTE
3" NPTE
3" NPTE
3" NPTE
29
37
50
56
97
101
164
168
1.83
2.34
3.16
3.54
6.13
6.39
10.38
10.63
50
56
70
62
78
69
86
101
112
140
188
164
168
227
205
315
206
304
407
365
380
459
3.16
3.54
4.42
3.92
4.93
4.37
5.44
6.39
6.94
8.68
11.65
10.38
10.63
14.32
12.97
19.23
13.03
19.23
25.75
22.63
23.56
28.45
Dual Circuit Coolers

3
4
5
6
7
8
9
10
11
12
13
CHD007601B
CHD008601A
CHD008601B
CHD010601A
CHD010601B
CHD011601A
CHD011601B
CHD013601B
CXD12090F09
CXD12090B07
CXD12120B07
3" NPTE
3" NPTE
3" NPTE
4" NPTE
4" NPTE
4" NPTE
4" NPTE
4" NPTE
4" NPTE
4" NPTE
4" NPTE
*Non-Metric compliance
43

3.7
3.7.1
System Control
ACDS-B/AUDS-B
Capacity Control
The standard system capacity control operates as

follows:
Staging of unit capacity in response to system load
requirements is controlled by the microcomputer, which
monitors the leaving water temperature.
ACDS-B/AUDS-B 015S, 020S, 025S and 030S have two
steps capacity control.
ACDS-B/AUDS-B 027S has three steps capacity control.
ACDS-B/AUDS-B 025D to 100D have four capacity control
steps.
All models are equipped with tandem scroll compressors
per refrigerant circuit and capacity is controlled by
compressor staging.
As the chiller load initially drops, the suction pressure
of the compressor(s) starts dropping proportionately,
thus balancing minor load variations.
Hot gas by-pass capacity control is used (as an option)

to lower the "first on/last off" step of capacity control
to roughly 50%. This effectively provides an additional
step of capacity control. The use of multiple small
compressors gives good part load performance energy
efficiency ratios (EER). Hot gas by-pass operates by
imposing an artificial load on the evaporator. Discharge
gas from the compressor is introduced to the liquidvapor mixture of refrigerant downstream of the
expansion valve. The discharge gas is cooled by the
liquid refrigerant present in the turbulence of the
evaporator so that the final temperature does not rise.
Hot gas by-pass does not offer any energy savings, but
does allow the cooling capacity of the equipment to
vary precisely with the load requirements.
Refer to Table 3.7.2 or Table 3.7.3 to determine the
capacity control scheme for your specific unit.
44

3.7.2
ACDS-B/AUDS-B Capacity Control Staging for Single Circuit Units

Compressor Staging - Single Refrigerant Circuit Units
Percent of Full Capacity
ACDS-B
& AUDS-B
Unit Model
015S
Off
0
First Stage
w/HGBP
Min. Cap.
w/HGBP
Option
25
020S
25
50
NA
100
025S
25
50
NA
100
027S
23
46
54
100
030S
25
50
NA
100
3.7.2
First
Stage
Single Circuit
Compressor
#1 - On
50
Second
Stage
Single Circuit
Compressor
#2 - On
NA
Full
Capacity
Single Circuit
Compressor
#1 & #2 - On
100
ACDS-B/AUDS-B Capacity Control Staging for Dual Circuit Units

Compressor Staging - Dual Refrigerant Circuit Units
Percent of Full Capacity
ACDS-B
& AUDS-B
Unit Model
025D
First Stage
First
w/HGBP
Stage
Min. Cap.
Compressor
w/HGBP
1-On
Off
Off
Option
Circ. 1 Circ. 2
0
13
25
Second
Stage
Compressors
1-On
3-On
Circ. 1
Circ. 2
50
Third
Stage
Compressors
1, 2-On 3-On
Circ. 1 Circ. 2
75
Full
Capacity
Compressors
1, 2-On 3, 4-On
Circ. 1 Circ. 2
100
030D
13
25
50
75
100
035D
12
24
50
74
100
040D
12
23
46
69
100
045D
13
25
50
75
100
050D
12
24
48
72
100
055D
11
22
48
74
100
057D
13
25
50
75
100
060D
065D
0
0
13
13
25
25
50
50
75
75
100
100
070D
15
25
50
75
100
080D
14
25
50
75
100
090D
14
25
50
75
100
100D
16
25
50
75
100
NOTE: Hot gas bypass modulates to approximately one-half of the capacity of the first step.
45

3.7.4
Fan Cycling Control

ACDS-B/AUDS-B
Fan cycling control is based on the discharge pressure

of the refrigerant circuit being cooled by the fans. See
section 3.9.3.2. The following two versions of fan
control are used.
NOTE: The variable speed motor is applied in place of

the motors indicated in Step 1 of the table
below and operates as described under SCR in
section 3.8.
1) Standard Unit - Fan Cycling only

2) Low Ambient Option - Combination fan cycling and
variable speed motor control to reach low ambients
ACDS-B/AUDS-B
Fan Cycling Control Chart
ACDS-B/AUDS-B
Refrig.
Fan Number on at Each Step
Model
Circuit
015S-030S
#1
#2
#1
#3
025D-055D
#2
#4
057D-090D
#1
#3
#5
#2
#4
#6
#1
#3
#5
#7
#2
#4
#6
#8
100D
46

3.8
Electrical Controls Description

ACDS-B/AUDS-B
M-
Contactor (Compressor and Fan Motor) The

contactor, operated by the control circuit,
provides power to the compressors and fan
motors. Compressor contactors are used either
singly or in parallel pairs. These devices are
amp rated to handle both rated load amps and
locked rotor amps.
3PS -
Compressor Oil Failure Switch (Manual Reset)

This is a differential pressure switch that
continuously compares oil pressure with suction
pressure to provide protection against low net
oil pressure. It is equipped with a 120 second
time delay feature to avoid nuisance shutdown
due to momentary low fluctuations of oil
pressure due to oil foaming, etc.
S1 -
Power Switch (115V Control Circuit)

This switch energizes the control circuit and
must be left on at all times (except for
temporary control circuit service work) to allow
off cycle pumpdown and normal on cycle
operation. (Compressor sump heaters are
connected before this switch and are not
affected by switch position).
S2 -
Unit Enable Switch - This switch selects "ON",

"OFF", or "Remote" for the unit enable. If set to
"ON", the unit will be allowed to provide
cooling. If set to "OFF", the unit will only start
to maintain pumpdown and will not provide
cooling. When the switch is set to "Remote",
an external set of contacts must close to allow
the unit to provide cooling.
S3-S6
Compressor Switch. This switch disconnects

power from the corresponding compressor
control circuit. These switches should only be
used for service work, since pumpdown is
disabled when switch is off.
SCR -
Fan Speed Control (Optional)

The fan speed control varies the speed of the
fan, depending on head pressure. With the
discharge pressure of 140 psig or below, the
fan is at minimum speed. As discharge pressure
rises, the fan speed is increased proportionally
until it reaches full speed at 200 psig. See fan
cycling control section.
SOL -
Liquid Line Solenoid Valve

Closes when the compressor(s) is off to prevent
any liquid refrigerant from accu-mulating in the
chiller during the off cycle.
ChillerLINK - This module converts the communication protocol

of the microcomputer to an industry standard protocol.
Typically the standard protocols available are BACnet or
MODBUS.
CR -
Relays (Miscellaneous Control)

These relays provide the necessary circuit logic
for lock-in, lock-out and transfer functions.
CT -
Current Transformer - This device is used by the

microcomputer to measure the current being
drawn by a compressor.
CWP - Chilled Water Pump Interlock.

It is recommended that an interlock between
the chilled water pump and the package be
provided to prevent the unit from operating
with the chilled water pump off. Connect the
interlock to the terminals shown on the
diagram.
FLS -
Flow Switch. The chilled water flow switch must

be installed at the job site to ensure chilled
water flow while the package is in operation.
Gateway - This board converts RS485 information from

the microcomputer to RS232 data for a modem
or PC computer.
GFI -
HTR -
Ground Fault Interrupt - The ground fault sensor

monitors the compressor and fan motor current
for leakage to ground. If the leakage exceeds
the setting of the device (4-12 amps), the
control circuit power will be turned off.
Crankcase Heater
Energized continuously as long as control circuit
power is on and compressor is off. This heater
maintains crankcase temperature above the
system temperature during the compressor off
cycle, preventing refrigerant migration into the
crankcase and consequent compressor damage.
Chiller Heater and Thermostat (Water Chillers
only)-The chiller heater with integral thermostat
is powered by a separate customer supplied
115VAC source. The heater turns on when the
shell temperature drops to 38F. This helps
prevent a chiller freeze-up under low ambient
conditions.
47

For units with Electronic Expansion Valve option,
this valve pulses open to meter refrigerant into
the vessel and maintain desired suction
superheat.
Unload Solenoid - This solenoid will unload the
compressor cylinder bank when the solenoid is
energized.
SSR -
Solid State Relay Board (Optional) - This board

provides the pulsing signal to an electronic
expansion valve.
1TAS - Motor Overload Protection

Compressor overload protection is afforded by
solid state device (1TAS) that monitors internal
motor temperature. If the maximum motor
temperature is exceeded, the compressor will
shutdown. To reset 1TAS, open the associated
compressor switch for 5 seconds.
10TR - Timer (Optional) - This timer provides a 1 second
delay between closing of compressor contactors
for part wind starting.
UVR -
3.9
Undervoltage Relay (Optional)

Protects the unit from the following electric
supply malfunctions: under-voltage, phase
reversal and single phasing. If the UVR trips, a
control relay will de-energize and open the
control circuit. A LED light, located on the UVR,
will indicate a normal power supply.
DB Director Microcomputer
System Control
Dunham-Bush ACDS-B/AUDS-B reciprocating packages

are controlled by a microcomputer system. The
computer system is composed of a main microcomputer
board (MCB), several types of input/output (I/O) boards,
and sensors. The I/O boards are connected to the
microcomputer by RS485 shielded cables. These
hardware components are controlled by the software
program in the microcomputer. The software
determines the state of the output relays based on the
input values.
Another type of sensor input is an analog input. An

analog value is one that varies continuously, such as a
temperature or pressure. An analog input must be
converted to a digital value before the computer
software can process the data.
The computer system outputs are relays that switch the
115 VAC control devices such as contactors and
solenoids. There are eight outputs on the main
microcomputer board and eight outputs on each relay
output board.
The software for the computer is stored in three
different types of computer memory chips. The EPROM
chip (Electrically Programmable Read Only Memory)
stores general operating procedures (algorithms). The
EEROM chip (Electronically Erasable Read Only Memory)
stores the program that defines the configuration for a
particular unit. This software is called the configurator.
Both of these chips retain their content when power is
removed. The third type of memory is RAM (Random
Access Memory) and is battery backed and is used for
storing non-essential information.
3.9.1
Precautions
The following precautions must be taken while working

with the microcomputer system.
1.
Cover the computer components completely

when drilling sheet metal near the computer.
2.
Strip wires away from microcomputer to

prevent strands from falling on components.
3.
Do not allow the component boards to get wet.
4.
Route control and power wires away from

RS485 cables and sensor wires.
5.
Handle boards with care.
6.
Use shielded cables for all digital and analog

sensor inputs.
3.9.2 Computer Operation

The keypad and display are used to display data and
alter setpoints. The display has 2 lines with 16 characters
per line and the keypad has 16 keys. See figure 3.9.2
for the outline of the keypad and display.
There are two types of sensor inputs to the computer

system. A digital input indicates whether or not 5VDC
voltage is present at the input. This could be used to
determine whether or not the unit is enabled, a water
flow switch is made, or the status of other on/off
devices.
48

3.9.2
Computer Operation (cont.)
The keypad has 8 DISPLAY STATUS keys and 8 ENTRY

keys. The number keys, with corresponding function,
are:
The ENTRY keys are:
1 - COMPRESSOR STATUS
SERVICE DIAGNOSTIC
2 - CONDENSER STATUS
SET POINTS (SAFETIES)
3 - EVAPORATOR STATUS
MANUAL (AUTO)
4 - ALARM STATUS
LOCKOUT RESET
5 - SYSTEM PRESSURE
PROGRAM OPTIONS
6 - SYSTEM TEMPERATURE
INCREASE (+)
7 - ADDITIONAL STATUS INFO
DECREASE (-)
8 - LOCKOUT STATUS
ENTER
Figure 3.9.2
ENTRY
DISPLAY STATUS
COMPRESSOR
STATUS
SYSTEM
PRESSURE
CONDENSOR
STATUS
SYSTEM
TEMPERATURE
EVAPORATOR
STATUS
ADDITIONTAL
STATUS INFO.
LOCKOUT
STATUS
ALARM
STATUS
SERVICE
DIAGNOSTI
PROGRAM
OPTIONS
SETPOINTS
(SAFETIES)
INCREASE
(+)
MANUAL
(AUTO)
DECREASE
(-)
LOCKOUT
RESET
ENTER
49
3.9.2.1 Keypad Display Quick Reference -Display Status

To display data from the DISPLAY STATUS keypad, press the desired key to show the first two lines of data.
Repressing the same key selects the next two lines, etc. The keypad has 8 numbered Display Status keys. The
number keys, with corresponding function are:
1 COMPRESSOR STATUS
2 CONDENSER STATUS
3 EVAPORATOR STATUS
4 ALARM STATUS
5 SYSTEM PRESSURE
6 SYSTEM TEMPERATURE
7 ADDITIONAL STATUS INFO
8 LOCKOUT STATUS
COMP1
LLS 1
LOADED
ON
FAN 1
FAN 3
ON
ON
COMP2
LLS2
LOADED
ON
FAN 2
FAN 4
ON
ON
COMP1
LLS1
ON
ON
1 SP
AMP 1
+46.5A
UNIT CTL
RUN
OFF
2 SP
CHIL FLW
CHIL RST
COND ON OFFSET
CIRCUIT #1
ULS1-1
COND ON OFFSET
CIRCUIT #2
P
COMP2
CHIL OUT +44.8F

CHIL IN
+54.2F
DP OPD AMP
82 243
24 46
DP OPD AMP
83 233
26 57
ON
AMP2
YES
+0.0F
+57.2A
DISPLAY STATUS
CHIL OUT 44.8F

CHIL IN 54.2F
COMPRESSOR
STATUS
SYSTEM
PRESSURE
CONDENSOR
STATUS
SYSTEM
TEMPERATURE
EVAPORATOR
STATUS
ADDITIONTAL
STATUS INFO.
ALARM
STATUS
LOCKOUT
STATUS
COMP1 = 1015H
STARTS=0000210
LLS1
= 1010H
STARTS =000200
ULS1-1 = 0080H
STARTS = 00230
1 APR 26 0028:37
LOW SUCTION #1
Chiller Configuration Example
2 APR 24 1025:4
NO RUN #2
3 APR 20 0815:01
POWER RETURNED
4 APR 20 0710:20
POWER FAILED
Two reciprocating compressors

One unloader solenoid on compressor
#1
One liquid line solenoid per compressor
Four condenser fans
Suction & discharge pressure per
compressor
Oil pressure per compressor
Leaving liquid temperature sensor
Return liquid temperature sensor
1 APR 26 0027:37
LOW SUCTION #1
1 5P DP OPD AMP
52 215 25 42
2 APR 24 1025:40
NO RUN #2
50
3.9.2.2 Keypad Display Quick Reference -ENTRY KEYS

The ENTRY keys are:
SERVICE DIAGNOSTIC
SETPOINTS (SAFETIES)
MANUAL (AUTO)
LOCKOUT RESET
PROGRAM OPTIONS
INCREASE (+)
DECREASE (-)
ENTER
#1 CHIL OUT TARG
ENTR CHG +45.0F
CONTROL STATUS
ENTR CHG OPTION
CLEAR PT INFO
ENTR CHG OPTION
DATE DISPLAY
ENTR CHG OPTION
#8 PMP DN CUT IN
ENTR CHG +70.0P
AUTHORIZATION
ENTR CHG OPTION
UNIT INFORMATION
ENTR CHG OPTION
TIME DISPLAY
ENTR CHG OPTION
#9 PMP DN COUT
ENTR CHG +40.0P
SENSOR OFFSETS
ENTR CHG OPTION
DATE & TIME SET

ENTR CHG OPTION
#27 CND STG1 ON

ENTR CHG + 190.0P
SENSOR DIAGNOSTIC
ENTR CHG OPTION
DAY OF WEEK SET

ENTR CHG OPTION
#28 CND STG2 OFF

ENTR CHG + 140.0P
CLEAR ALRM HSTRY

ENTR CHG OPTION
OPERATING SCHEDS
ENTR CHG OPTION
#35 FLA CIRCUIT 1

ENTR CHG + 55.0A
#36 FLA CIRCUIT 2
ENTR CHG + 65.0A
ENTRY
RELAY OUTS MANAL

ENTR CHG OPTION
SERVICE
DIAGNOSTIC
PROGRAM
OPTIONS
SETPOINTS
(SAFETIES)
INCREASE
(+)
MANUAL
(AUTO)
DECREASE
(-)
LOCKOUT
RESET
ENTER
ANALG OUTS MANAL

ENTR CHG OPTION
SENSOR INS MANAL
ENTR CHG OPTION
RESET LOCKTS?
ENTER KEY=YES
ENTER KEY
Selects options or enters
changes after adjustments
have been made.
INCREASE (+)
KEY &
DECREASE (-)
KEY
Used To adjust
values or change
options selected.
(SERVICE,
SETPOINTS,
MANUAL, &
PROGRAM keys.)
51

3.9.2.3
Display Data
To Display Data from the DISPLAY STATUS keys

.1 General Information:
Pressing a key selects the first two lines of
data as shown in Figure 3.9.2.1. Repressing
the same key selects the next two lines, etc.
The "+" and "_" keys may be used with alarm

and lockout status to allow scrolling.
.2 COMPRESSOR STATUS key

The data from this key is divided into two
sections. The first section provides the circuit
control state of each of the compressors. The
second section is the ON/OFF state of the relay
outputs related to compressor circuit control.
When the button is first pressed, compressor 1
state is shown on the first line and liquid line
solenoid or electronic expansion valve status is
shown on the second line. Subsequent key
presses display the status for the remaining
compressors. Refer to section 3.9.2.8 for the
Circuit Control States. The status for the liquid
line is either ON or OFF, whereas for the
electronic expansion valve, the valve percentage
of opening and the current superheat value is
displayed.
After the compressor control states are all
displayed, subsequent key presses display the
ON / OFF state of each of the relay outputs
related to compressor control such as
compressor, liquid line, and unloaders.
.3 CONDENSER STATUS key
The data from this key is divided into two
sections. The first section provides the ON /
OFF state of each of the fan control relays. The
second section displays the calculated offset to
the fan turn on pressure for each circuit. These
values are labeled "Cond ON Offset" and are
added to the fan turn on setpoint to determine
the actual pressure at which the fan will turn
on. See fan control logic description.
.4 EVAPORATOR STATUS key
When this key is first pressed, the leaving water
temperature (Chil Out) and the entering water
temperature (Chil In) are displayed. If the chilled
water pump control option is furnished and the
key is pressed again, the On/Off status of the
pump and chilled water flow is displayed.
.5 ALARM STATUS key

The alarm status key displays the most recent
32 alarms and lockouts. When the key is first
pressed, the most recent alarm (#1) is
displayed. The alarm number is displayed in
the upper left corner followed by the month,
day, and time of the alarm. The second line
shows the name of the alarm. The Increase
(+) and Decrease (-) keys can be used to scroll
through the alarm listing. See the alarm
description Section 3.9.2.7.
.6 SYSTEM PRESSURE key
The system pressure key displays the operating
pressures and amps for each compressor. The
following values are displayed:
1. SP = Suction Pressure
2. DP = Discharge Pressure
3. OPD = Oil Pressure Differential (optional)
4. AMP = Amps of the compressor
When the key is first pressed, these values are
shown for compressor 1. Subsequent key
presses display the value of the other
compressors. The compressor number is shown
in the upper left corner of the display.
.7 SYSTEM TEMPERATURE key
When this key is first pressed, the chiller leaving
water temperature (Chil Out) and chiller
entering water temperature (Chil In) values are
displayed. Subsequent key presses, display all
the sensor input values except the pressures.
This includes amps, flow switch, unit control
input, chilled water reset, and suction
temperature, if applicable. The sensor inputs
related to pressure are displayed with the
System Pressure key.
.8 ADDITIONAL STATUS INFO key
This key provides the total run hours and
number of starts for each relay output. When
first pressed, the name of RO #1 (Typically
Comp 1) is shown followed by the total run
hours. The second line shows the number of
starts for that relay output. Subsequent key
presses, scroll through all of the relay outputs
and provide the same information.
.9 LOCKOUT STATUS key
The Lockout Status key is a subset of the Alarm
Status key. Only the chiller setpoint safety
alarms are displayed. These relate to protecting
the machine from abnormal operation. The
information displayed for each alarm is the
same as described in the Alarm Status section.
52

3.9.2.4
Read and Enter Data
To Read and Enter Data from the ENTRY keys

.1 General Information:
Pressing a key selects the first two lines of data
as shown in the Figure 3.9.2.2. Repressing the
same key selects the next two lines, etc.
Different items will appear depending on the
package configuration, options selected, and
authorization level.
.2 SERVICE DIAGNOSTICS key
This key cycles through the following menu
items. When the desired menu item is reached,
press the ENTER key to display the data.
CONTROL STATUS
This menu item displays the Capacity Control
State and the Evaporator Control State. The
display toggles between these displays every
two seconds. Refer to the Control States
Section 3.9.2.8.
AUTHORIZATION
This menu item is used to enter the
Authorization required to access and make
changes to the microcomputer. When selected,
the display shows "ENTER AUTH #XXXX" as a
prompt or the four digit code from the number
keys. As each digit is entered, the Xs change
to 0. When complete, press enter, and the
authorization level is displayed. Four levels of
authorization are used.
1. VIEW - No authorization is needed to view
data or reset a lockout.
2. SERVICE - Authorization to access and
change setpoints that are needed for setting
up the unit to customer conditions. Typical
authorization code is #3224.
3. SUPERVISOR - Authorization to access and
change setpoints that are not normally
needed for configuration of a unit.
4. FACTORY - Allows access to all parameters
with the ability to change the values.
adjust the offset value. Use the (+) or (-) keys

to change the offset and then press ENTER. This
offset value is added to the measured value to
obtain the calibrated value used by the
program.
SENSOR DIAGNOSTIC
This menu item displays the analog to digital
conversion counts and the volts for each of the
sensor inputs. The conversion varies between
0 and 1023, and the volts change between 0V
and 5.012V. Use the (+) or (-) keys to scroll
between sensor numbers.
UNIT INFORMATION
This menu item displays the following
information. Use the (+) or (-) keys to scroll
through the data.
Software version and Configuration number

Hardware version
Unit name
Unit serial number
Model name
Manufacturer
Network address - The network address can
be changed by pressing the ENTER key,
followed by (+) or (-) to change the number
and then ENTER.
.3 SETPOINTS (SAFETIES) key

This key is used to display the setpoints and
allows modifications if authorized. When first
pressed, setpoint #1 is displayed. Use the (+)
or (-) keys to scroll through the setpoints. When
the desired setpoint is displayed, press the
ENTER key to enter the change mode as
indicated by a "+/-" symbol. Use the (+) or (-)
keys to alter the setpoint value and then press
ENTER when done.
.4 MANUAL (AUTO) key
This key is used only by authorized service
personnel for manual control of the unit.
.5 LOCKOUT RESET key
This key is used to clear a lockout. Press ENTER
after the safety problem is resolved to reset all
relay outputs to computer control.
SENSOR OFFSET
This menu item allows sensors to be calibrated.
CAUTION: This function should only be
performed by a serviceman with a certified
accurate meter. After ENTER is pressed, the
sensor can be selected with the Increase/
Decrease keys. Then press ENTER again to
53
.6 PROGRAM OPTIONS key

This key displays the following information. Use
the (+) or (-) keys to scroll through the menu
items and then press ENTER to select the desired
screen.
DATE DISPLAY - shows the current day of
week, month, date and year.
TIME DISPLAY - shows the current day of
week, and time of day.
DATE & TIME SET -allows adjustment of
month, date, year, hour, and minute. The
"+/-" symbol is shown below the field to be
adjusted. Use the (+) or (-) keys to change
the field and then press ENTER to move to
the next field.
DAY OF WEEK SET - allows the day of week
to be changed by pressing the (+) or (-) keys.
OPERATING SCHEDs - allows the 7 day
operating schedule to be set up. When
ENTER is pressed, a day of the week is
displayed followed by the Turn On time and
then the Turn Off time in 24:00 format. Use
the (+) or (-) keys to select the day of week
desired and then press ENTER. The "+/-"
symbol is shown below the field to be
adjusted. Use the (+) or (-) keys to change
the field and the press ENTER to move to
the next field.
.7 INCREASE (+) and DECREASE (-) keys
These keys are used to scroll through menus or
data values or to select the desired information.
The keys are also used to increase or decrease
values that are being adjusted. When making
value changes, the key may be held down for
continuous adjustments.
.8 ENTER key
This key is used to select an option being
displayed on the screen or to confirm the new
value after a data change has been made.
3.9.2.5
Capacity Control States
.1 POWERUP
This state is entered when the microcomputer
is powered up or the system has been reset.
The system will remain in this state for
approximately 2 minutes with all relay outputs
off. This is a time delay to insure the micro has
stable power before turning any points on and
to allow external devices to close.
are moved to the OFF state through the normal

states. One step of capacity will be decreased
per second.
.3 SCH OFF
This state is entered when the active Operating
Schedule is false. When the chiller is in this
state, the individual circuit states, if active, are
moved to the OFF state through the normal
per second.
.4 EVP FLW (No Evaporator Flow)
This state is entered when the flow switch
sensor input is OFF. When the chiller is in this
state the individual circuit states, if active, are
moved to the OFF state through the normal
per second.
.5 AMB OFF (Low Ambient Temp Off)
This state is entered if the ambient temperature
falls below the low ambient setpoint. When
the chiller is in this state, the individual circuit
states, if active, are moved to the OFF state
through the normal states. One step of capacity
will be decreased per second. When ambient
increases by 5F above the setpoint, the unit
will be allowed to run.
.6 LOST IO
This state will be entered whenever the
microcomputer loses communications with any
one of the I/O boards that are connected. When
this state is entered, the system will generate a
LOST I/O alarm which identifies which I/O is offline. The LOCKOUT RESET key must be pressed
to reset the system, after the LOST I/O has been
corrected. In this state, all RO's except the
ALARM RO are turned OFF.
.7 LOCKOUT
This state is entered whenever a critical situation
is encountered that could cause harm to the
chiller package. Items such as freeze protection,
low pressure, high pressure or high amps will
force the system into this state. Lockouts can
be reset without authorization from the keypad,
however, if the lockout condition has not been
corrected, the system will again be forced into
the LOCKOUT state. In this state, all RO's except
the ALARM RO are turned OFF.
.2 STOPPED
This state is entered when the Unit Control
sensor input switch is off. When the chiller is
in this state, the individual circuit states if active
54
.8 OFF
This state is entered when the system has been
cleared from the above shutdown states. The
chiller is now ready to move into an active state
to meet the needed capacity.
safety. Lockouts can be reset without

authorization from the keypad, however, if the
lockout condition has not been corrected, the
circuit will again be forced into the LOCKOUT
state.
.9 HOLDING
This state is entered when one of three
conditions exists:
.3 PUMP DWN (Pump Down)

This state is entered whenever the circuit is no
longer wanted on or if the compressor is off
with chiller flow on and suction pressure rises
above the Pumpdown Cutin setpoint. The
compressor is on and the liquid line solenoid is
closed. This state is active until the suction
pressure reaches the value in the Pumpdown
cutout setpoint. The circuit will then move to
the ANTICYC state.
1) The liquid being cooled is being maintained

at a temperature in the control zone.
2) The temperature is above the target
temperature plus the control zone but the
temperature is decreasing sufficiently. This
indicates that the temperature is decreasing
toward the target.
3) The temperature is below the control zone
but the slope is increasing sufficiently. This
indicates that the temperature is increasing
toward the target. This state indicates that
there is no need to add or subtract from
the cooling capacity of the chiller package.
This state will be exited when more or less
capacity is required.
.10 UNLDING (Unloading)
This state is entered when less capacity is
required. During this state a variable time delay
is implemented, after which the capacity of the
package will be decreased by one step.
.11 LOADING
This state is entered when more capacity is
required. During this state a variable time delay
is implemented, after which the capacity of the
package will be increased by one step.
3.9.2.6 Circuit Control States

The action of the circuit control states actually results
in more, less or no change in the amount of cooling
capacity. The CAPACITY CONTROL STATES enable the
individual circuits to move within their states.
.1 LOST IO
This state is entered when the CAPACITY
CONTROL STATE is LOST IO. This indicates a
loss of communication between microcomputer
boards. The Lockout reset key will move the
circuit to the OFF state.
.4 ANTICYC
This state is entered when the PMP DWN state
has been successfully completed. The circuit
will stay in this state with all circuit points off
for the anti-cycle time delay. The circuit will
then move to the OFF state.
.5 OFF
This state is entered when no cooling capacity
is required from this circuit or if the prior state
was holding the circuit off line. In this state
the circuit is ready to attempt to provide cooling
capacity if needed.
.6 UNLDED
In this state all unloaders on the compressor
are on and the compressor is supplying the
minimum amount of capacity.
.7 U1 LOAD
This state only exists for compressors with two
unloaders. This state is in effect when the first
unloader solenoid is off and the second
unloader solenoid is on.
.8 LOADED
This state is when the compressor is fully
loaded. In this state, the circuit is providing
the maximum amount of cooling capacity.
.9 SUC HLD (Suction Pressure Hold)
This state is entered when one unloader has
been turned off due to low suction pressure.
.2 LOCKOUT
This state is entered when the CAPACITY
CONTROL STATE is LOCK OUT or a safety for
this circuit has indicated that a critical situation
has been encountered. Alarms such as (LOW
SUCTION) or (HI DISCH PSI) are examples of a
55
.10 DIS HLD (Discharge Pressure Hold)

This state is when a fully loaded circuit that has
more than one step has encountered a
discharge pressure that is close to the high
pressure trip. In this state, one step of cooling
capacity will be turned off. The circuit will
remain in this state for a minimum of five
minutes before returning to the LOADED state
if the high pressure condition has been
corrected.
.11 SAFETY
This state is entered when a safety trips but a
lockout is not to be generated. An alarm is
generated but the system will restart after a
time delay (typically 15 minutes). One safety
trip is allowed every 2 hours. If 2nd trip occurs
within 2 hours of the first trip, then the circuit
goes to the LOCK OUT state.
3.9.2.7
SI Manual
Point Info Clear
Clock Set
CFG Downloaded
.3 Alarms generated by the control algorithm

The following alarms indicate that action taken
by the control algorithm:
Rotated Lead
Daylight Savings
3.9.2.7.2 MCS-8 System Alarms
Alarms are generated by the MCS-8 control algorithm:
.1 Configuration problem alarms
These alarms indicate a problem with the
configuration file that has been loaded into the
system. The system is not operational, a
configuration must be transmitted to the unit
form PConn or the config ship must be replaced
with a valid one.
ALARMS SECTION
There are three types of alarms that are generated by

the MCS-8 control logic:
Information only alarms
MCS-8 system alarms and
Chiller set point safety alarms.
All of the alarms have the same format. The alarm is
identified and it is date time stamped. Alarms can be
viewed from the MCS-8 by pressing the ALARM STATUS
(4) key or from the PConn program.
3.9.2.7.1 Information only alarms
.1 System generated alarms
The following alarms are generated to provide
information. They will not cause a change in
the control algorithm such as a lock out
condition or a relay output being forced off.
Power Failed
Power Returned
Computer Reset
Battery Failed
LCD Failure
HW Date Invalid
HW Time Invalid
SW Date Invalid
SW Time Invalid
Ram Integrity
Watchdog Reset
.2 Alarms as a result of individual action

Alarms Cleared
STPT Changed
RO Manual
AO Manual
.2 Missing (3) INVALID alarms and description

MCS-RO8 #1 Lost
MCS-RO8 #2 Lost
MCS-RO8 #3 Lost
MCS-SI8 #1 Lost
MCS-SI8 #2 Lost
MCS-SI8 #3 Lost
Lost IO Shutdown
.3 Key sensors problem alarms
This alarm indicates a problem with a key
sensor; it is either shorted or open. The alarm
will contain ALARM followed by the 8 character
name of the sensor.
Sensor Fault
The following sensors related to the entire
system are tested:
leaving liquid, if failed: lock out the chiller
system
returning liquid, if failed: alarm only, no
lock out
ambient temperature, if failed: alarm only,
no lock out
The following circuit sensors are tested. If they
fail, that circuit only is locked out.
suction pressure and temperature
discharge pressure and temperature
oil pressure and temperature
56
3.9.2.7.3 Chiller Setpoint Safety Alarms

The chiller algorithm incorporates a number of safety
checks to ensure that the various components that make
up the chiller package are not damaged. These types
of safeties are based upon setpoints. If this type of
safety trips, the circuit or system state becomes SAFETY.
The state will remain as SAFETY for a time delay and
then the system will attempt to run. If the system safety
trips for a second time within two hours, the circuit or
system state becomes LOCK OUT. By this method the
microcomputer attempts to ride through a transient
system problem while still protecting the chiller package.
.1 Freeze Protection
If the leaving liquid temperature drops below
the "FREEZE TEMP" set point value, the system,
and all circuits, will enter a lockout state and a
freeze notification alarm will be generated.
.2 No Chiller Flow Protection
If the chiller flow sensor input turns off and a
liquid line solenoid output stays ON, all circuits
will be locked off and a No Flow alarm will be
generated.
.3 Low Differential Oil Pressure (optional)
If the oil differential pressure drops below the
low oil setpoint value, and it remains there for
the time specified in the safety time of that set
point, the circuit will be locked out and a low
oil alarm generated. This safety is active only
when the compressor is on.
.4 Low Suction Pressure
If the suction pressure drops below the Low
Suction set point value, and it remains there
for the time specified as follows, the circuit will
be locked out and a low suction alarm
generated. If the unit does not have an ambient
temperature sensor, the low pressure time delay
is two minutes from the time that the
compressor starts. If the unit does have an
ambient temperature sensor and ambient is
above 40F, the time delay is also two minutes.
Below 40F, however, the time delay at
compressor start is extended to four minutes.
After this initial time delay, the delay before
lockout is 45 seconds from the time that suction
pressure falls below the setpoint.
.6 Hi Motor Amp
The full load amps (FLA) of each compressor
are stored in FLA COMP # setpoints. If the
compressor amps sensor input rises above the
FLA setpoint times the HI AMP % setpoint
divided by 100 for 10 seconds, the circuit will
be locked out and a high motor amp alarm
generated.
.7 No Compressor Proof (No-Run Alarm)
If the microcomputer relay output for
compressor control is ON but the amps sensor
input measures a value less than the FLA
setpoint times the LO AMP % setpoint dived by
100 for 2 seconds, the compressor is locked
out and No Comp Proof alarm is generated.
Typical value for the LO AMP % setpoint is 20%.
.8 Unsafe Suction Pressure
If the suction pressure falls below the Unsafe
Suction setpoint (typically 10 psig) for 10
seconds, the affected circuit will be locked off,
and an Unsafe Suction alarm will be generated.
.9 Pumpdown Alarm
If a pumpdown (Compressor ON with liquid line
solenoid OFF) requires more time to complete
than the Pump Down Delay (PMP DN DLAY)
setpoint, then the circuit will be locked off. A
Pumpdown alarm will be generated.
.10 No-Stop Alarm
If the computer commands a compressor to
turn OFF but the amp feedback stays higher
than the LO AMP % setpoint times the
compressor FLA setpoint divided by 100, for 5
seconds, then the entire unit will be locked off
and the control power relay will be turned off.
A No-Stop alarm will be generated.
.11 Low Discharge Pressure
If discharge pressure is below the LO DISC PSI
setpoint for 30 seconds while the compressor
is operating, the circuit will be locked off on a
Low Discharge pressure alarm.
.5 High Discharge Pressure

If the discharge pressure rises above the HI
DISCH PSI set point value and it remains there
for one second, the circuit will be locked out
and a high discharge alarm generated.
57
3.9.2.8 Control States Quick Reference - Chiller Applications

Control States tell the user what the system is doing, this information is critical in determining the chillers status!
Capacity Control States
State
Circuit Control States
Description
State
POWERUP
System Reset or Power Returned (delay

of 120 seconds or set point value)
STOPPED
Description
LOST IO
Lost communication
Chiller is off because Unit Control sensor

input is in STOP
LOCKOUT
Safety tripped twice within half hour,

circuit locked off
SCH OFF
Unit schedule of operation is holding the

unit OFF.
STOPPED
Capacity control state is STOPPED
Chiller is off because Chiller Flow sensor

input status is NO.
PMP DWN
Pumping down
EVP FLOW
ANTICYC
Delay after turning off circuit
AMB OFF
Chiller is off because Ambient Temp is

below Low Ambient setpoint
OFF
Circuit ready but not required
LOST IO
Lost communication to other boards.

Chiller is locked out.
UNLDED
Compressor ON, all unloaders OFF
LOCKOUT
Chiller locked out, all points except alarm

point are OFF.
U1 LOAD
1st unloader is OFF, 2nd unloader is ON
LOADED
OFF
System ready to run but no cooling

capacity required
Circuit is fully loded, all unloaders are

OFF
HOLDING
Unit running with no change in capacity

required.
SUC HLD
Holding 1 unloader off until suction

pressure returns to normal
UNLDING
Count down to reduce capacity
DIS HLD
LOADING
Count down to increase capacity
Holding 1 unloader off until discharge

pressure returns to normal
SAFETY
Safety tripped not LOCKOUT
Evaporator Control States

State
Description
LOCKOUT
Circuit is locked out
CLOSED
Liquid line solenoid (LLS) is closed
PREPUMP
LLS is closed with compressor ON to

pumpout liquid
STARTUP
Electronic expansion valve (EXV) is in

start-up mode
OPENED
Liquid line solenoid is open
HOLDING
EXV is holding at desired opening
OPENING
EXV is opening
CLOSING
EXV is closing
LOW SPR
EXV is closing quickly because superheat

is low
58

3.9.3
Control Functions and Operations
The computer system performs the following control

functions on scroll compressor packages.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Compressor Staging
Fan control
Pumpdown control
Anti-recycle timing
Lead/lag (optional)
Chilled water reset
Customer control interlock
Low pressure unload
High pressure unload
High amp unload (optional)
Low ambient temperature limit (optional)
Power up delay
Electronic expansion valve control (optional)
A description of each of these functions follows:

3.9.3.1 Compressor Staging
Refer to Section 3.7.2 for standard capacity control
staging and to Section 3.7.3 for optional capacity
control staging for a particular unit.
A delay between different compressors starting is
implemented to minimize current inrush and to ensure
that additional capacity is required.
.1 Chiller or DX Coil Control Based on Leaving
Temperature
For chiller control or leaving air DX coil control,
the computer stages the compressors based on
leaving water or air temperature. The control
zone (+) and control zone (-) setpoints are
stored in the computer as a temperature offset
from desired leaving water or air temperature.
The control zone (+) setpoint is where the next
stage of capacity is added, and the control zone
(-) setpoint is where the unit capacity is
decreased by one step. If water temperature is
falling at a substantial rate, the unit may stop
loading or may decrease capacity before
reaching the control zone (-) setting. After a
stage transition, a time delay is activated during
which another stage transition is not allowed.
This lets the system stabilize.
The difference between the control zone
setpoints should be more than the temperature
change caused by one stage transition to
prevent short cycling. Typical control zone
setpoints for a water chiller are control zone
(+) = 3.0 and control zone (-) = -2.0. Setpoints
for an air DX coil should be much wider, possibly
control zone (+) = 6.0 and control zone (-) = 6.0. In this case, the effect of one stage
transition must be less than 12.0F at minimum
air flow to avoid short cycling.
Before the first stage of a package is allowed

to start, the leaving temperature must be above
the setpoint by the amount stored in the Start
Deadband setpoint. This value may be 3F for
a water chiller but may need to be much higher
for a DX coil, possibly 15F.
Some air handler configurations require an
entering air enthalpy sensor to enable/disable
the unit. When enthalpy is above the Enthalpy
Start setpoint, the unit is allowed to start and
then maintain desired leaving air temperature.
If the entering air enthalpy falls below the
Enthalpy Start setpoint minus a small
deadband, the unit is disabled.
.2 DX Coil Control Based on Return Air
Temperature or Enthalpy
The computer stages the compressors based on
return air temperature or enthalpy. The stage
1 shutdown setpoint is stored in the computer
as an offset from desired return air temperature
or enthalpy. The stage deadband setpoint
defines the On to Off differential for each stage.
The inter- stage deadband setpoint defines the
differential between the turn OFF points of each
sequential stage.
A typical setpoint
configuration for a unit with return air
temperature staging is:
Return Air Temp

Stage 1 off
Stage Deadband
Inter-stage D/B
Setpoint
76.0
-4.0
2.0
1.5
Stage 1 would turn on at a return air

temperature of 76 + (-4.0) + 2.0 = 74.0F and
would turn off at 76 + (-4.0) = 72.0F. Stage 2
would turn on at a return air temperature of
76 + (-4.0) + 1.5 + 2.0 = 75.5F and would
turn off at 76 + (-4.0) + 1.5 = 73.5F, etc.
.3 Suction Pressure Control
Suction pressure control may be needed for a
system with two DX coils serving separate air
flows. The building control system must supply
a contact closure to enable/disable each
refrigerant circuit. When the contact is closed,
the first compressor on the unit will start and
stay on until the contacts open. The unloader
and/or second compressor will be staged based
on a circuit suction pressure setpoint and a
control zone around that setpoint. The control
zone staging will operate similarly to the
description in item 1 of this section.
59
3.9.3.2 Fan Control

The fan control is based on the discharge pressures of
the circuits being cooled by the fans. Refer to section
3.7.4 for a correlation of refrigerant circuit to fan
numbers for each model. The computer calculates the
highest discharge pressure of the compressors operating
and uses this value to control fans according to the fan
pressure setpoints and the internally calculated fan turn
on offset.
The Condenser Stage 1 ON setpoint plus the Fan Turn
ON offset is where fan 1 turns on. The Fan Turn ON
offset is normally 0.0 and is only increased if a fan short
cycles. The effect of this is to automatically widen the
on to off differential and reduce fan cycling. The
Condenser Differential ON setpoint defines the
difference between each subsequent fan turn ON
pressure. For example: COND Stage 1 ON = 190.0
Psig, Fan Turn ON offset = 20.0, and COND Differential
ON = 10.0.
Then Fan stage 1 turn on pressure is 190 + 20 = 210,
Fan stage 2 turn on pressure is 190 + 20 + 10 = 220,
and Fan stage 3 turn on pressure is 190 + 20 + (2 * 10)
= 230, etc.
The Condenser Stage 2 OFF setpoint is where fan 2 turns
off. The Condenser Differential OFF setpoint defines
the difference between each subsequent fan turn OFF
pressure. For example: COND stage 2 OFF = 140 Psig,
and COND Differential OFF = 10.0. Then Fan stage 2
turn off pressure is 140, Fan stage 3 turn off pressure is
140 + 10 = 150, and Fan stage 3 turn off pressure is
140 + (2 * 10) = 160, etc.
Condenser Stage 1 turns OFF only if suction pressure
falls below the low suction pressure setpoint for 10
seconds and discharge pressure is less than the Fan stage
1 turn on pressure.
A compressor must be operating (amps above
minimum) for the fans to operate.
3.9.3.3 Pumpdown Control

When the water temperature does not require cooling
or if the unit enable sensor input contacts are open the
computer maintains a cooler pressure lower than the
Pumpdown CUT IN setpoint. When suction pressure
exceeds the pumpdown CUT IN setpoint, the
compressor is turned on without activating the liquid
line solenoid or electronic expansion valve. Then, when
the suction pressure falls below the Pumpdown CUT
OUT setpoint, the compressor is turned off. The
compressor control state displays PMP DWN when the
compressor is pumping down. A pumpdown will only
be performed once every 10 minutes as long as chilled
water flow is on.
When chilled water is not flowing, a maximum of two

pumpdowns will be performed after which the unit will
remain in the OFF state. The pumpdown process is
monitored to protect the cooler. The pumpdown alarm
will lock off the compressor if the pumpdown requires
more than thirty seconds to complete. This usually
indicates a faulty liquid line solenoid.
3.9.3.4 Anti-Recycle Timing
When a compressor is stopped by the computer, a 5
minute time delay is initiated during which the
compressor cannot start. A delay is also implemented
when power is first applied to the computer.
The compressor control state displays ANTICYC when
the anti-recycle timer is timing.
3.9.3.5 Lead/Lag (optional feature)

A factory installed lead/lag option allows the computer
to automatically rotate the lead refrigerant circuit. The
first compressor of each refrigerant circuit (compressors
1 and 3 of a four compressor package) on the unit must
have an unloader for lead/lag to operate. The lead
refrigerant circuit will rotate whenever a refrigerant
circuit shutdown is required or if the time of day passes
through midnight. The effect is that the first refrigerant
circuit to become active is the first to shut down.
3.9.3.6 Chilled Water/Air Reset

The chilled water/air reset (CHIL RST) sensor input allows
the customer to raise the leaving water or air
temperature setpoint based on an external signal.
A 0-5VDC signal can be used, where 0VDC is no reset
and 5VDC is maximum reset. The maximum
temperature reset can be defined by setting the MAX
TRGT RST setpoint to the maximum temperature reset
desired. For example, to obtain a maximum reset of
6F, a 6.0 is stored in MAX TRGT RST.
CAUTION: The voltage input must never exceed 5.0
VDC.
3.9.3.7 Customer Control Interlock

Customer supplied time clock (or other on/off logic)
control contacts can be used to control the package.
The wiring diagram specifies the place to wire the
control contacts. The control contacts signal a sensor
input. If the contacts open, the unit will perform a
pumpdown if needed and then turn off.
Note: This control must be used for automatic control
of the package. Do not use the flow switch to control
the package.
60
3.9.3.8 Low Pressure Unload

After the initial start-up, if a refrigerant circuit
experiences a low pressure condition and the circuit
can be unloaded, the circuit will enter a low pressure
unload mode. If a compressor on the circuit has an
unloader, the unloader will be energized. The circuit
control state will display SUC HLD (suction hold).
The unit stays in this condition for the safety delay time
and then reverts to normal operation.
Caution: If this mode of operation repeats, the unit
requires service by a qualified refrigeration technician.
3.9.3.9 High Pressure Unload

If an operating circuit discharge pressure approaches
the high pressure trip point (typically at 355 psig), and
the compressor has an unloader, the unit will enter a
high pressure unload mode. The unload solenoid will
be energized. This will help prevent a high pressure
trip. The circuit control state will display DIS HLD
(discharge hold).
The unit will stay in this mode for the safety delay time
and then revert to normal operation.
Caution: If this mode of operation occurs, the unit
should be checked immediately for condenser blockage.
Otherwise, contact a qualified refrigeration technician
for service.
3.9.3.11 Low Ambient Temperature Limit

(optional)
If the ambient temperature drops below the Low
Ambient setpoint, the compressors will be put into an
AMB OFF state and will not be allowed to run. The
ambient temperature must rise 5F above this setpoint
before the unit will be enabled.
3.9.3.12 Power-up Delay

When power is first applied to the controls, a two
minute delay is implemented before a compressor is
allowed to start. This allows all external devices to timeout and close their contacts.
3.9.3.13 Electronic Expansion Valve Control

(optional)
When a compressor starts, the microcomputer controls
the electronic expansion valve to maintain the desired
superheat (typically 12F). The expansion valve
percentage of opening and current superheat value are
displayed on the second line of the Compressor Status
display.
3.9.4
(1)
3.9.3.10 High Amp Unload (Load Limit)

The high amp limit is determined by multiplying the HI
AMP % setpoint by the FLA setpoint for the compressor
and then dividing by 100. If a compressor's amp
measurement reaches the high amp limit, and the
compressor has an unloader, the unit will enter a high
amp unload mode. The unloader will be activated to
unload the compressor. The circuit control state will
display AMP HLD (amp hold).
The unit will stay in this mode for the safety delay time
and then revert to normal operation. This mode is
normal if the unit is started with high chiller water
temperature.
General Servicing Procedure
A general troubleshooting procedure is shown below.
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Check compressor status to see if it is locked

off.
If locked off, check alarms to see cause.
Check all sensor inputs for accuracy.
Repair mechanical system problem or
electrical system problem.
Reset alarm by pressing LOCKOUT RESET KEY
followed by ENTER.
Check that all requirements for start-up are
met.
Operate machine over full operating
conditions and observe results.
Verify that all sensor input values are correct.
Caution: If this mode of operation occurs with chiller

temperature near design conditions, the unit should
be checked immediately for condenser blockage or
abnormal system voltage. Otherwise, contact a
qualified refrigeration technician for service.
61

3.9.5A
Typical Power Wiring Diagram (Four Compressor Model)
024098AACAT
62

3.9.5B
Typical Control Wiring Diagram (Four Compressor Model)
024099ACCAT
63

3.9.5B
Typical Control Wiring Diagram (Four Compressor Model) (cont.)
024099BCCAT
64

3.10
Circuit
Operation for ACDS-B or
AUDS-B Split-System Chillers
or AUDS-BLeaving Air Control
for DX Coil
Typical 2 compressor control sequence of operation with

4 steps of capacity control. Refer to 3.9.5B for wiring
diagram.
3.10.1 Unit on standby

Main field disconnect switch closed. 115VAC control
power on. S1 control switch on. Compressor switches
on. Leaving water or air temperature below leaving
temperature setpoint plus Control Zone + setpoint or
unit control contacts open.
Pumpdown during standby -When the flow switch is ON, any of the compressors
may come on for a short time and pump down if there
is any low side pressure build up during the standby
period. Compressors will be held off line for 10 minutes
after a pumpdown. Immediately following a normal
"on" cycle, pumpdowns can be expected as residual
liquid in the low side vaporizes.
3.10.2 Run cycle sequence (increase

load)
Water or air flow switch closes and unit control contacts
are closed.
.4 Compressor #1 unload solenoid is energized

through RO3.
.5 Compressor #1 oil and suction pressure rise to
normal levels, and 3PS-1 terminates the time
open sequence.
1st stage capacity is now On-Line.
3.10.2.2 - STEP 2
.6 Leaving water or air temperature rises above
chiller out setpoint plus Control Zone + setpoint
and stage 1 has been on line for an inter-stage
delay. Compressor #1 unload solenoid is deenergized to LOAD the compressor.
2nd stage capacity is now On-Line.
3.10.2.3 - STEP 3
chiller out setpoint plus Control Zone + setpoint
delay.
.8 Compressor #2 starts 100% loaded. Amp
sensor 2CT indicates current flow. The
microcomputer energizes liquid line solenoid 2
and circuit 2 refrigerant flow starts. Oil failure
switch 3PS-2 starts to time open (120 sec.
delay). Low pressure lockout starts to time open
(120 sec. delay).
NOTE: If either oil pressure or suction pressure
is not established at a normal level within the
above delay times, circuit 2 will shut down.
to unload the compressor.
3.10.2.1 - STEP 1
chiller out temperature setpoint plus Control
Zone + setpoint.
.2 Anti-cycle timer times out or inter-stage delay
times out and RO1 closes (up to a 5 minute
delay).
.3 Compressor #1 starts thru RO1. Amp sensor,
1CT, indicates current flow. RO2 energizes
liquid line solenoid 1SOL and circuit 1
refrigerant flow starts. Oil failure switch 3PS-1
starts to time open (120 sec. delay). Low
pressure lockout starts to time open (120 sec.
delay).
.10 Compressor #2 oil and circuit #2 suction

pressures rise to normal levels, and 3PS-3
terminates the time open sequence.
3rd stage capacity is now On-Line.
3.10.2.4 - STEP 4
setpoint plus Control Zone + setpoint and stage
3 has been on line for an inter-stage delay.
Compressor #1 unload solenoid is de-energized
to load the compressor.
100% capacity is now On-Line.

is not establishing at a normal level within the
above times, circuit 1 will shut down.
65
3.10.3 Run cycle sequence (decreasing

load)
3.10.3.1 - STEP 4
.1 Leaving water or air temperature falls below
chiller out setpoint minus Control Zone setpoint and stage 4 has been on line for an
inter-stage delay. Compressor #1 unload
solenoid is energized to unload the compressor.
3.10.3.2 - STEP 3
chiller out setpoint minus Control Zone setpoint and stage 3 has been on for an interstage delay. Liquid line solenoid for circuit 2 is
de-energized and circuit 2 refrigerant flow
stops. Compressor #2 remains running and
circuit 2 pumpdown begins.
.3 When suction pressure drops to the pumpdown
cutout setpoint, compressor #2 stops. Circuit
#2 pumpdown and unload sequence is now
complete, and all circuit 2 controls are back to
standby status.
3.10.3.3 - STEP 2
chiller out setpoint minus Control Zone setpoint and stage 2 has been on line for an
solenoid is energized to unload the compressor.
3.10.3.4 - STEP 1
chiller out setpoint minus Control Zone setpoint and stage 1 has been on for an interstage delay. Liquid line solenoid for circuit 1 is
de-energized and circuit 1 refrigerant flow
stops. Compressor #1 remains running and
circuit 1 pumpdown begins.
.7 When suction pressure drops to the
pumpdown cutout setpoint, compressor #1
stops. Circuit #1 pumpdown and unload
sequence is now complete, and all circuit 1
controls are back to standby status.
.4 Compressor #1 unload solenoid is de-energized

to load compressor #1 back to full capacity.
66
Unit is off.
3.11
Circuit
Operation for AUDS-B with
Supply Air Temperature or
Enthalpy Control for DX Coil

typical diagram.

on. Return air temperature or enthalpy below desired
return air value plus the stage 1 Off setpoint or unit
control contacts open.

load)
are closed.
3.11.2.1 - STEP 1
.1 Return air temperatue or enthalpy rises above
return air setpoint plus Stage 1 Off setpoint plus
Stage Deadband setpoint.
delay).
delay).
through RO3.
open sequence.
3.11.2.2 - STEP 2
.6 Return air temperature or enthalpy rises above
Stage Deadband setpoint plus Inter-stage
Deadband setpoint and stage 1 has been on
line for an interstage delay. Compressor #1
unload solenoid is de-energized to LOAD the
compressor.
3.11.2.3 - STEP 3
Stage Deadband setpoint plus two times the
Inter-stage Deadband setpoint and stage 2 has
been on line for an interstage delay.
(120 sec. delay).
3.11.2.4 - STEP 4
Stage Deadband setpoint plus three times the
Inter-stage Deadband setpoint and stage 3 has
been on line for an inter-stage delay.
Compressor #1 unload solenoid is de-energized
to load the compressor.

67

load)
3.11.3.1 - STEP 4
.1 Return air temperature or enthalpy falls below
three times the Inter-stage Deadband setpoint
delay. Compressor #1 unload solenoid is
energized to unload the compressor.
3.11.3.2 - STEP 3
two times the Inter-stage Deadband setpoint
and stage 3 has been on for an inter-stage delay.
Liquid line solenoid for circuit 2 is de-energized
and circuit 2 refrigerant flow stops. Compressor
#2 remains running and circuit 2 pumpdown
begins.
standby status.
3.11.3.3 - STEP 2
the Inter- stage Deadband setpoint and stage
2 has been on line for an inter-stage delay.
Compressor #1 unload solenoid is energized
3.11.3.4 - STEP 1
return air setpoint plus Stage 1 Off setpoint and
stage 1 has been on for an inter-stage delay.
Liquid line solenoid for circuit 1 is de-energized
and circuit 1 refrigerant flow stops. Compressor
#1 remains running and circuit 1 pumpdown
begins.
Unit is off.

68
through RO3.
3.12
Circuit
Operation for AUDS-B with
Multiple Evaporators
Controlled by Suction
Pressure at the Unit

diagram.

on. Return air temperature or enthalpy below desired
return air value plus the Stage 1 Off setpoint or unit
control contacts open.

load)
are closed.
3.12.2.1 - STEP 1
.1 Building control system closes circuit 1 start
contact.
delay).
delay).

open sequence.
3.12.2.2 - STEP 2
.6 Circuit 1 suction pressure rises above the
Suction Pressure setpoint plus Control Zone +
setpoint and stage 1 has been on line for an
solenoid is de-energized to LOAD the
compressor.
3.12.2.3 - STEP 3
.7 Building control system closes circuit 2 start
contact.
(120 sec. delay).
3.12.2.4 - STEP 4
.11 Circuit 2 suction pressure rises above the
Suction Pressure setpoint plus Control Zone +
setpoint and stage 3 has been on line for an
solenoid is de-energized to load the compressor.

69

load)
3.12.3.1 - STEP 4
.1 Circuit 2 suction pressure falls below the Suction
Pressure setpoint minus Control Zone - setpoint
3.12.3.2 - STEP 3
.2 Building control system opens Circuit 2 start
contact.
standby status.
3.12.3.3 - STEP 2
.5 Circuit 1 suction pressure falls below the Suction
Pressure setpoint minus Control Zone - setpoint
3.12.3.4 - STEP 1
.6 Building control system opens Circuit 1 start
contact.
Unit is off.

70
4.0 MAINTENANCE
4.1
General
As with all mechanical equipment, a program of regular

inspection, cleaning and preventive maintenance by trained
personnel will contribute greatly to the long satisfactory
service life of this product.
4.2
Periodic Inspection
Read essential temperatures and pressures periodically to see

that they indicate normal operation. It is a good idea to
record these readings on a log sheet. See sample, Section
4.10. If any abnormal operation is observed, try to determine
cause and remedy it. See Troubleshooting Guide, Section
4.9.
4.3
Monthly Inspection
Wipe down external surfaces of unit. Shut unit down, open

main disconnect, inspect control panel, checking for loose
wires, burned contacts, signs of overheated wires, etc. Restart
unit and check performance of controls. Check sight glasses
for proper refrigerant charge.
4.4
4.4.1
4.5
Air Cooled Condenser

Cleaning ACDS-B/AUDS-B
The face of the condenser should be cleaned at least once a

month during operation. If conditions are bad the condensers
pick up dirt very quickly, it is suggested that they be cleaned
more frequently. If the condenser is allowed to get too dirty,
the unit will run a high head pressure and will not give
satisfactory performance.
Dirty coils can be cleaned using a soft brush or by flushing
with cool water or commerically available coil cleaners. DO
NOT USE HOT WATER OR STEAM. To do so will cause excessive
pressure in the system. The face of the condenser should be
cleaned at the beginning of the season and periodically
thereafter if conditions require.
Vessel Maintenance
General
The efficient performance of the cooler and condenser heat

transfer surfaces is essential for efficient performance of your
packaged water cooling machine. If these surfaces
accumulate a film of dirt, scale or slime, their performance
efficiency will degrade substantially. The refrigerant side of
heat transfer surfaces does not foul, since refrigerant is a
good solvent and it is in a closed, filtered cycle. 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.
4.4.2
In chemical cleaning, a caustic solution is pumped through

the heat exchanger, which attacks dirt, slime and mineral
deposits and flushes them 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.
The cooler water side (shell side) cannot be physically cleaned
because of the cross-flow baffle construction.
Cooler Cleaning ACDS-B or

Split-System Chiller
The effects of fouling can be detected by recording full load

performance data on the log sheet. If the difference between
the leaving water from the cooler and the saturated suction
temperature at the compressor is greater than the difference
recorded at clean conditions, the tubes should be cleaned.
It is generally advisable to clean the cooler water side surfaces
at least annually, and more often if severely foul water is
used. This cleaning must be done chemically.
4.6
Electrical Malfunction
The unit has four devices designed to protect compressor

motors and motor controllers from electrical malfunction:
customer supplied short circuit protection, circuit breakers
(optional, if available), under voltage relays (optional), solid
state motor over temperature protectors, and microcomputer
high amp protection.
If the undervoltage relay trips, it is a sign of trouble in
incoming power. If it trips again after resetting, call your
electric utility to investigate the problem. If circuit breaker
or motor over temperature protectors trip, this is a sign of
possible motor trouble. DO NOT reset and try to run
compressor again. Call authorized service representative to
check for motor trouble. Resetting these safety devices and
repeated starting could turn a minor motor problem into a
costly major motor burnout.
71
4.0 MAINTENANCE (CONT.)

4.7
Compressor Maintenance
The Discus compressor has four components that may

be replaced. The components are the suction strainer,
oil pump, cylinder heads and valve plates.
If a component, other than that listed below, fails, the
compressor will require replacement. Return the
compressor to your local Copeland distributor for
replacement.
Compressor Bolt Torque Specifications
All Torques in ft.-lb.
Discus
Bottom plate
Housing cover
Oil pump to housing cover
Cylinder head
Oil screen cover
Crankcase heater plug
Discharge valve
Suction valve 1/2"
Suction valve 5/8"
Capacity control valve
Pipe plug, 1/4"
Pipe plug, 1/8"
Oil sight glass
33
33
21
42-50
50
38
42
42
80
35
23
17
3
4.8
Refrigerant Charge
All packaged chiller units are given a complete charge

of refrigerant at the factory. The type and amount of
refrigerant required is in Physical Specifications. The
total refrigerant shown is for the entire system. Since
these units have separate circuits, each circuit should
be considered separately for charging.
In order to check proper refrigerant charge, look in each
liquid line sight glass with the aid of a flashlight during
system operation. At all operating conditions, the sight
glass should be clear. If bubbles are visible at any
operating condition, the circuit is short of charge.
Be careful not to overcharge the machine. Overcharging
will result in considerable liquid logging in the
condenser, and excessive condensing pressure.
To add refrigerant, connect a refrigerant vessel to the
1/4" backseating port of the suction valve. Purge the
air from the tube with refrigerant gas before connecting.
With the unit running, open the refrigerant vessel vapor
connection slightly. If the refrigerant vessel is warmer
than the cooler, refrigerant will more readily flow from
the vessel into the unit.
To determine the proper refrigerant charge, check the
amount of subcooling at design full load conditions, if
possible. The amount of subcooling at the liquid line
(liquid line saturation temperature corresponding to
liquid line pressure minus liquid line temperature)
should be between 15F and 20F.
Subcooling at the condenser out-subcooler inlet trap
should not exceed 5F. This sight glass should be clear
with no bubbles.
72

4.9
Troubleshooting Guide
Corrective Action
Possible Causes
4.9.1 Unit will not start

1.
2.
3.
4.
5.
Power off.
Main line open
No control voltage
Loose terminals
Control circuit open
6. Incorrect phase sequence (UVR option)

7. Microcomputer safety lockout
(if applicable)
Check main disconnect switch

Check main fuses
Check control terminal block for 115VAC
Tighten all terminals
Check fuses, control switches and field installed interlocks, pressure and
temperature controls and readouts.
Reverse incoming power sequence
Resolve problem and press RESET
4.9.2 Compressor hums but does not start

a.
b.
Check at main entrance and at unit

Consult power company if voltage is low and increase wire size to
the unit if voltage is normal at main and low at unit. Voltage must
be within 10% of motor nameplate rating.
1.
Low voltage
2.
No power on one phase of 3 phase

unit
Check fuses and wiring
3.
Faulty starter or contactor
Check the contacts and time delay on part wind start (if applicable)
4.9.3 Compressor cycles on low pressure control

1. Refrigerant shortage
2. No load on chiller
3. Restriction in liquid line
4. Head pressure too low
Check for leaks and add refrigerant

Check pump operation and water flow
a. Plugged filter drier. If temperature drop exists across the drier,
remove and replace cores.
b. Liquid line or suction valve partially closed. Open valves fully and
close in one full turn.
c. Expansion valve clogged or inoperative. Check superheat setting.
Check charge and thermo bulb.
Possible cause - fan cycle switches set too low. Remedy - check and
reset
4.9.4 Compressor cycles on high pressure control

1.
Compressor discharge valve partially

closed
2. Air in system
3. Overcharge of refrigerant
4. High pressure control improperly set
5. Condenser fan inoperative
6. Dirty condenser
7. Fan cycle settings incorrect
8. Fan motors not running
9. Fan motor reverse rotation
Open valve fully and close with one turn

Purge condenser coils
Purge system while in operation until bubbles show in sight glass. Close
valve and add small amount of refrigerant until sight glass just clears
Adjust the control
Check, replace or repair set screw (pulley), fan motor, or inoperative fan
control
Clean condenser surfaces with brush and/or vacuum
Check and re-adjust
Check contactor, check motor, check capacitor (if single phase)
Reverse two fan motor leads (3 phase only)
73
4.10 Sample Log Sheet
Sheet No.
Page 1 of 2
ACDS-B / AUDS-B 015S to 100D

Reciprocating Compressor Packaged Chiller or Condensing Unit
NAMEPLATE DATA:
UNIT MODEL NO.
UNIT SERIAL NO.
UNIT ELECTRICAL DATA:
VOLTS
PHASE
COMPRESSOR MODEL NO.
COMPRESSOR S.N.
COMPRESSOR S.N.
COMPRESSOR S.N.
START UP: DATE
HZ
, TIME
REPORT DATE
REPORT TIME
ELAPSED TIME METER COMPRESSOR 1
COOLER WATER TEMPERATURE - IN

COOLER WATER TEMPERATURE - OUT
COOLER PRESSURE DROP PSI/IN WATER
COOLER WATER FLOW (GPM)
CONDENSER AIR TEMPERATURE - IN (AMBIENT)
ACTUAL VOLTAGE
FAN AMPS
VOLTS
*Use Table 4.11 For Obtaining Saturated Temperature

This log sheet is provided as a recommendation of the readings that should be taken on a periodic basis. The actual readings
taken and the frequency will depend upon the units applications, hours of use, etc. This type of information can prove very
useful in preventing and/or solving problems that might occur during the life of this unit.
74
4.10 Sample Log Sheet
Sheet No.
Page 2 of 2
ACDS-B 015S-030S
Reciprocating Compressor Packaged Chiller
COMPR.
NO.
1
SUCTION PRESSURE
2
3
1
DISCHARGE PRESSURE
2
3
1
DISCHARGE TEMPERATURE
2
3
1
SUCTION TEMPERATURE
2
3
1
DISCHARGE SUPERHEAT
(DISCH. TEMP. SAT. DISCH.)*
2
3
1
SUCTION SUPERHEAT
(SUCT. TEMP. SAT. SUCT.)*
2
3
1
COMPRESSOR AMPS
2
3
75
4.11 Temperature Pressure Table

Refrigerant 22 Pressure/Temperature Properties (PSIG-F)
PRES
TEMP
PRES
TEMP
PRES
TEMP
PRES
TEMP
PRES
TEMP
PRES
TEMP
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
-41.4
-38.8
-36.4
-34.1
-31.8
-29.7
-27.7
-25.7
-23.8
-22.0
-20.2
-18.5
-16.9
-15.3
-13.7
-12.2
-10.7
-9.2
-7.8
-6.4
-5.1
-3.8
-2.5
-1.2
0.0
1.2
2.4
3.6
4.8
5.9
7.0
8.1
9.2
10.2
11.3
12.3
13.3
14.3
15.3
16.2
17.2
18.1
19.1
20.0
20.9
21.8
22.6
23.5
24.4
25.2
26.1
26.9
27.7
28.5
29.3
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
30.1
30.9
31.7
32.4
33.2
33.9
34.7
35.4
36.1
36.9
37.6
38.3
39.0
39.7
40.4
41.0
41.7
42.4
43.0
43.7
44.3
45.0
45.6
46.3
46.9
47.5
48.1
48.7
49.4
50.0
50.6
51.2
51.7
52.3
52.9
53.5
54.1
54.6
55.2
55.8
56.3
56.9
57.5
58.0
58.6
59.1
59.7
60.3
90.8
61.3
61.8
62.4
62.9
63.4
63.9
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
64.4
64.9
65.4
65.9
66.4
66.9
67.4
67.9
68.3
68.8
69.3
69.8
70.2
70.7
71.2
71.7
72.1
72.6
73.0
73.5
74.0
74.4
74.9
75.3
75.8
76.2
76.6
77.1
77.5
78.0
78.4
78.8
79.3
79.7
80.1
80.5
81.0
81.4
81.8
82.2
82.6
83.0
83.4
83.9
84.3
84.7
85.1
85.5
85.9
86.3
86.7
87.1
87.5
87.9
88.3
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
88.6
89.0
89.4
89.8
90.2
90.6
91.0
91.3
91.7
92.1
92.5
92.8
93.2
93.6
93.9
94.3
94.7
95.0
95.4
95.8
96.1
96.5
96.9
97.2
97.6
97.9
98.3
98.6
99.0
99.3
99.7
100.0
100.4
100.7
101.1
101.4
101.7
102.1
102.4
102.8
103.1
103.4
103.8
104.1
104.4
104.8
105.1
105.4
105.7
106.1
106.4
106.7
107.0
107.4
107.7
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
108.0
108.3
108.6
109.0
109.3
109.6
109.9
110.2
110.5
110.8
111.2
111.5
111.8
112.1
112.4
112.7
113.0
113.3
113.6
113.9
114.2
114.5
114.8
115.1
115.4
115.7
116.0
116.3
116.6
116.9
117.2
117.5
117.8
118.1
118.3
118.6
118.9
119.2
119.5
119.8
120.1
120.3
120.6
120.9
121.2
121.5
121.8
122.0
122.3
122.6
122.9
123.1
123.4
123.7
124.0
276
278
280
282
284
286
288
290
292
294
296
298
300
302
304
306
308
310
312
314
316
318
320
322
324
326
328
330
332
334
336
338
340
342
344
346
348
350
352
354
356
358
360
362
364
366
368
370
372
374
376
378
380
124.5
125.1
125.6
126.1
126.7
127.2
127.7
128.3
128.8
129.3
129.8
130.3
130.9
131.4
131.9
132.4
132.9
133.4
133.9
134.4
134.9
135.4
135.9
136.4
136.8
137.3
137.8
138.3
138.8
139.2
139.7
140.2
140.7
141.1
141.6
142.1
142.5
143.0
143.4
143.9
144.3
144.8
145.2
143.7
146.1
146.6
147.0
147.5
147.9
148.3
148.8
149.2
149.6
76
JANUARY 2004
P. O. Box 20000, Harrisonburg, VA 22801

Phone: (540) 434-0711 FAX (540) 434-2448
www.dunham-bush.com
Form No. 6109B

Auds B

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ACDS-B/AUDS-B

Form No. 6109B

General Installation Instructions ............................................................................................... 10

Space and Clearance Requirements

General Space and Clearance Requirements ....................................................................................... 11

Foundation and Mounting Structure

General Handling Instructions ........................................................................................................... 10

Vibration Isolation Requirement

ACDS-B Rubber-in-Shear - with Aluminum Fin Condenser .................................................................. 24

Qualified Unit Start-up Report (Required for Warranty) ........................................................... 38

Typical ACDS-B 015S - 030S Packaged Chiller Refrig. Piping ................................................................

DB Director - Microcomputer System Control ............................................................................ 48

Keypad Display Quick Reference - Display Status ............................................................. 50

3.9.3 Control Functions and Operations ....................................................................................... 59

Compressor and Unloader Staging .................................................................................. 59

3.9.4 General Servicing Procedure .......................................................................................... 61

Step 1 Increasing Load ..........................................................................................

3.10.3 Unit Run Cycle Sequence - (Decreasing Load) ..................................................................... 66

3.11 DB Director - Circuit Operation for AUDS-B Return Air Control

3.11.3 Unit Run Cycle Sequence - (Decreasing Load) ..................................................................... 68

3.12 DB Director - Circuit Operation

Step 1 Increasing Load

3.12.3 Unit Run Cycle Sequence - (Decreasing Load) ..................................................................... 70

Step 4 Decreasing Load

General Maintenance ................................................................................................................. 71

1.0 GENERAL INFORMATION

To assure satisfactory operation and to avoid damage

1.2 Product Identification

Air Cooled Condenser

CD 208/3/60 Main Power

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: English I.P. & S.I. Units

CHS006601B CHS006601B CHS007601B

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: English I.P. & S.I. Units

CHD007601B CHD007601B CHD008601B

CHD008601A CHD008601A CHD010601B

CHD008601A CHD010601A CHD011601A

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: English I.P. & S.I. Units

1.0 GENERAL INFORMATION (CONT.)

1.3 Physical Specifications: English I.P. & S.I. Units

Models ACDS-B packaged chillers are designed to cool

When the equipment is delivered, it is important that

3. Check for freight damage, shortages or other

Handling Storage & Rigging

Each unit has been carefully tested at the factory where

ACDS-B/AUDS-B Rigging and

This equipment is too large to be carried by a forklift

Space and Clearance

The dimensional data and space requirements are given

Another consideration which must be taken is that the

2.0 INSTALLATION (CONT.)

2.4.2 Location and Installation Clearance - ACDS-B & AUDS-B 015S-100D

2.0 INSTALLATION (CONT.)

2.4.3 Dimensional Data: ACDS-B 015S to 030S

2.0 INSTALLATION (CONT.)

2.4.3 Dimensional Data: ACDS-B & AUDS-B 025D to 055D

2.0 INSTALLATION (CONT.)

2.4.3 Dimensional Data: ACDS-B 057D and 060D

2.0 INSTALLATION (CONT.)

2.0 INSTALLATION (CONT.)

2.4.3 Dimensional Data: AUDS-B 015S to 030S