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    Technical Training 2007Technical Training 2007Technical Training 2007

    5ACV30 CR5ACV30 CR

    5ACV55/75 CR5ACV55/75 CR

    5ACV100/135/210 CR5ACV100/135/210 CR

    Chilled Water System :

    Air-Cooled Inverter Mini Chiller

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    Technical Training 2007Technical Training 2007Technical Training 2007

    System Schematic DiagramSystem Schematic Diagram

    Advantages of Chilled Water SystemAdvantages of Chilled Water System

    Product LineupProduct Lineup Design & ApplicationDesign & Application

    Content

    Product FeaturesProduct Features

    Schematic Diagram & ComponentsSchematic Diagram & Components

    Installation & CommissioningInstallation & Commissioning Self Diagnosis & TroubleshootingSelf Diagnosis & Troubleshooting

    Smart ManagerSmart Manager

    Selection SoftwareSelection Software

    CompetitorCompetitors Products Comparisons Products Comparison

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    Technical Training 2007Technical Training 2007Technical Training 2007

    System Schematic Diagram

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    Technical Training 2007Technical Training 2007Technical Training 2007

    System Schematic Diagram

    Brazed Plate Heat Exchanger(cooler)

    Water

    45oF

    55oF

    Refrigerant Cycle CompressorTXV

    Liquid receiver

    FCU

    StorageTank

    Pump

    Chilledwater out

    Chilled

    water in

    Water Circuit

    Condenser

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Advantages of

    Chilled WaterSystem

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Quiet Operation

    Simple on Site

    Installation

    Versatility in

    System Coupling

    Flexible in Installation

    And Commissioning

    Low Cost of

    Installation

    Chilled WaterChilled Water

    AdvantagesAdvantages

    Long PipingApplication

    Centralized

    ControlMultiple Zone

    Temperature

    Control

    Advantages of Chilled Water System

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Offers flexibility

    during installation

    Advantages of Chilled Water System

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Advantages of Chilled Water System

    No on-site refrigerant charge

    No time consuming refrigerant balancing

    and adjustment

    Eliminate accident or malfunction

    Light weight and compact size for ease of

    handling

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Advantages of Chilled Water System

    Quiet operation due to minimized

    outdoor units and mini chiller can

    be placed far away from room

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Advantages of Chilled Water System

    One to One

    One to many

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Advantages of Chilled Water System

    versus

    Chilled Water System DX System

    Water

    PVC

    Refrigerant

    Copper

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Advantages of Chilled Water System

    Year Round Comfort

    Multiple Temperature Zone Control

    ack To Content

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Product Lineup

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Product Lineup

    Cooling Only/ Heat Pump Model Cooling Only/ Heat Pump Model

    Cooling Only/ Heat Pump Model Cooling Only/ Heat Pump Model

    Heat Pump

    055

    MAC- CSeries

    M4AC-CSeries

    120100 150

    M5AC- CSeries

    080060050040030025020000

    Btu/h

    055

    MAC- CSeries

    M4AC-CSeries

    120100 150

    M5AC- CSeries

    080060050040030025020000

    Btu/h

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Product Lineup

    M5ACV- CSeries

    210135100075055030000

    Btu/h

    M5ACV- CSeries

    210135100075055030000

    Btu/h

    Heat Pump Model

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    Understand Clients requirement Application - feasible Installation/service-able Budget Inspection of job site

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    Site survey Building Load Calculation

    - equipment size Equipment Selection

    - type of system & equipment

    system design:- piping; pump; controls; storage tank;

    installation and service maintenance;

    water treatment.

    cost of equipment operation cost

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    Where to install the chiller and fan coil units

    Determine the pipe route and installation / servicing /

    maintenance consideration

    Building Load estimation for both chiller and Fan coil units (building orientation/size/application,

    i.e. pub; restaurant; office.....)

    Access to the building for delivery and maintenance

    location of other building services

    1. Site Survey

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    OYL MANUFACTURING CO. SDN BHD

    COOLING LOAD ESTIMATION

    PROJECT NAME : SK Bungalow DATE: 28/2/2001

    LOCATION : Penthouse

    AREA = 2000 HEIGHT = 15 NO.OF PEOPLE = 4

    CFM/PERSON= 15 VENT, CFM = 500 B.F. = 0.15

    ROOM TEMP = 75 ROOM RH% =

    TEMP DIFF. (ROOM & OUTDOOR) = 20 MOISTURE DIFF. = 80

    GAIN/TD BTU/HR GAIN/TD BTU/HR

    OUTDOOR TEMP CORRN= -2 0

    NE GLASS 600 0.76 45 20,520 22 10,032

    E GLASS 0.76 106 0 35 0

    SE GLASS 0.76 97 0 32 0

    S GLASS 0.76 10 0 8 0

    SW GLASS 600 0.76 30 13,680 91 41,496

    W GLASS 0.76 44 0 132 0

    NW GLASS 0.76 28 0 75 0

    N GLASS 0.76 11 0 11 0

    SHADED GLASS 0.76 11 0 11 0

    N WALL 0.49 1 0 13 0

    NE WALL 200 0.49 53 5,194 17 1,666E WALL 0.49 36 0 15 0

    SE WALL 600 0.49 16 4,704 16 4,704

    S WALL 0.49 1 0 14 0

    SW WALL 200 0.49 1 98 30 2,940

    W WALL 0.49 2 0 39 0

    NW WALL 600 0.49 1 294 33 9,702

    ROOF 2,000 0.23 6 2,760 38 17,480

    ALL GLS TRANSM 1,200 1.13 -2 (2,712) 0 0

    PARTITION 0.45 -2 0 0 0

    CEILING 0.3 0 0 0 0

    FLOOR 0.49 -7 0 -5 0

    PEOPLE,(S) 4 1 245 980 245 980

    POWER,KW 4 1 3414 13,656 3414 13,656

    LIGHTS,WATTS 2,000 1.25 3.414 8,535 3.414 8,535

    MISC.HEAT (S) 1 1 0 1 0

    SAFETY % (S) 5 3,385 5,560DT.GN/LK/FAN% 8 0 0

    OA HEAT(S)*BF 0 0

    PEOPLE,(L) 4 1 205 820 205 820

    MISC.HEAT (L) 1 1 0 1 0

    SAFETY % (L) 10 82 82

    DUCT LEAK% 8 0 0

    OA HEAT(L)*BF 4,080 4,080

    OA HEAT(S)1-BF 0 0

    OA HEAT(L)1-BF 23,120 23,120

    GRAND TOTAL HEAT = 99,196 144,853

    COOLING TONS = 8.27 12.07

    ROOM SENSIBLE HEAT = 71,094 116,751

    TOTAL OA HEAT = 27,200 27,200

    4.00PM SEP/MARAREA/QTYITEM FACTORS

    10.00 AM SEP/MAR

    2. Building Load Estimation

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    am 4.0 kW

    pm 3.0 kW

    am 3.5 kW

    pm 5.0 kW

    am 3.5 kW

    pm 5.5 kW

    am 3.5 kW

    pm 2.5 kW

    am 4.5 kW

    pm 3.0 kW

    am 4.5 kW

    pm 3.0 kWam 3.8 kW

    pm 3.5 kW

    am 9.0 kW

    pm 8.0 kW

    am 3.5 kW

    pm 5.0 kW

    am 3.8 kW

    pm 3.5 kW

    am 3.8 kW

    pm 3.5 kW

    Room 9

    Room 11

    Room 10

    Room 8

    Room 7

    Room 6Room 5

    Room 4

    Room 3

    Room 2

    Room 1

    UU2. Building Load Estimation

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    am 4.0 kW

    pm 3.0 kW

    am 3.5 kW

    pm 5.0 kW

    am 3.5 kW

    pm 5.5 kW

    am 3.5 kW

    pm 2.5 kW

    am 4.5 kW

    pm 3.0 kW

    am 4.5 kW

    pm 3.0 kWam 3.8 kW

    pm 3.5 kW

    am 9.0 kW

    pm 8.0 kW

    am 3.5 kW

    pm 5.0 kW

    am 3.8 kW

    pm 3.5 kW

    am 3.8 kW

    pm 3.5 kW

    Room 9

    Room 11

    Room 10

    Room 8

    Room 7

    Room 6Room 5

    Room 4

    Room 3

    Room 2

    Room 1

    am 4.0 kW

    pm 3.0 kW

    am 3.5 kW

    pm 5.0 kW

    am 3.5 kW

    pm 5.5 kW

    am 3.5 kW

    pm 2.5 kW

    am 4.5 kW

    pm 3.0 kW

    am 4.5 kW

    pm 3.0 kWam 3.8 kW

    pm 3.5 kW

    am 9.0 kW

    pm 8.0 kW

    am 3.5 kW

    pm 5.0 kW

    am 3.8 kW

    pm 3.5 kW

    am 3.8 kW

    pm 3.5 kW

    Room 9

    Room 11

    Room 10

    Room 8

    Room 7

    Room 6Room 5

    Room 4

    Room 3

    Room 2

    Room 1

    U2. Building Load Estimation Diversity Factor

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Design & Application

    Room a.m. p.m. DX

    Room 1 4.0 2.5 4.0

    Room 2 4.5 3.0 4.5Room 3 4.5 3.0 4.5

    Room 4 9.0 8.0 9.0

    Room 5 3.8 3.5 3.8

    Room 6 3.8 3.5 3.8

    Room 7 3.8 3.5 3.8Room 8 3.5 4.5 4.5

    Room 9 3.5 5.0 5.0

    Room 10 3.5 5.5 5.5

    Room 11 3.5 5.5 5.5

    Total 47.4 47.5 53.9

    Chiller Capacity : 45.7 kW

    DX unit capacity(total) : 53.9 kW

    Saving ~ 6.4 kW(11.9 % in this case)

    Room a.m. p.m. DX

    Room 1 4.0 2.5 4.0

    Room 2 4.5 3.0 4.5Room 3 4.5 3.0 4.5

    Room 4 9.0 8.0 9.0

    Room 5 3.8 3.5 3.8

    Room 6 3.8 3.5 3.8

    Room 7 3.8 3.5 3.8Room 8 3.5 4.5 4.5

    Room 9 3.5 5.0 5.0

    Room 10 3.5 5.5 5.5

    Room 11 3.5 5.5 5.5

    Total 47.4 47.5 53.9

    Chiller Capacity : 45.7 kW

    DX unit capacity(total) : 53.9 kW

    Saving ~ 6.4 kW(11.9 % in this case)

    2. Building Load Estimation Diversity Factor

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    Technical Training 2007Technical Training 2007Technical Training 2007

    Criteria to select a mini chiller: capacity required

    water entering condition

    water leaving condition

    ambient condition

    cooling/ heating mode required?

    3. Chiller Selection

    Design & Application

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    If the chiller is operate under nonstandard condition, the capacity canbe calculated from the performancecharacteristic, flow rate and pressure

    drop then being determined.

    Samp

    leofpe

    rform

    ance

    chart

    3. Chiller Selection

    Design & Application

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    Upon chiller units being selected, water flowrate of chiller and pressure drop also need tobe determined.

    Water flow rate,

    Liters/Min = Total Capacity, W70 x Temp. Diff. O C

    3. Chiller Selection

    Design & Application

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    From Water flow rate,

    the pressure dropacross the chiller unitsneed to bedetermined for pumpselection.

    Find the pressure

    drop from the datatable ->

    3. Chiller Selection

    Design & Application

    &

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    Example 1

    Please select a cooling only chiller operate at ambient

    temperature 35 o C, leaving water temperature 5 o C.

    Minimum capacity required is 25 kW. Determine the

    required flow rate and the internal pressure loss.

    Entering water temperature is 12 o C.

    3. Chiller Selection

    Design & Application

    D i & A li ti

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    From performance chart, AC100 C selected. Thecapacity at 35 o C at 5 o C leaving water temperatureis 25.90 kW.

    Hence the flow rate, liters/min : 2590070 x 5

    = 74 liters/min

    = 1.23 liters/s= 4.44 m3/hr

    3. Chiller Selection

    Design & Application

    Solution:

    D i & A li ti

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    From 4.44 m

    3

    /hr and the table above, the pressure drop forAC100C is 47.5 kPa

    3. Chiller Selection

    Design & Application

    Solution:

    D i & A li ti

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    From the total cooling capacity shown in the Table 1,

    calculate the water flow rate by using the following

    formula:

    Liters/Min = Total Cooling Capacity, W70 x Temperature Rise o C

    USGPM = Total Cooling Capacity, Btu/H500 x Temperature Rise o F

    4. FCU Selection

    Design & Application

    Example 2:

    D i & A li ti

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    Table 1: Total Cooling Capacity

    Room am Load, kW pm Load , kW Fan Coil Unit, kW

    Room 1 4.0 2.5 4.0Room 2 4.5 3.0 4.5Room 3 4.5 3.0 4.5Room 4 9.0 8.0 9.0Room 5 3.8 3.5 3.8

    Room 6 3.8 3.5 3.8Room 7 3.8 3.5 3.8Room 8 3.5 4.5 4.5Room 9 3.5 5.0 5.0Room 10 3.5 5.5 5.5

    Room 11 3.5 5.5 5.5

    4. FCU Selection

    Design & Application

    Fan Coil units Capacity can be determined by Cooling

    Capacity Performance Chart as below:

    Design & Application

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    Line A

    Line D Line C

    Line B

    Point 1

    Point 4 Point 3

    Point 2

    Water temperature rise o C

    E n

    t e r i n g

    W a t e r

    o C

    Total Cooling & Sensible Capacity, kW

    Entering Air WB oC

    Entering Air DB oC

    4. FCU Selection

    Design & Application

    Design & Application

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    Line A

    Line D Line C

    Line B

    Point 1

    Point 4 Point 3

    Point 2

    Water temperature rise o C

    E n

    t e r i n g

    W a t

    e ro

    C

    Total Cooling & Sensible Capacity, kW

    Entering Air WB oC

    Entering Air DB oC

    Point 1 - Temperature Rise in o C Line A - Determine the temperature rise

    Point 2 - Entering water temperature o C and entering water temperature

    Point 3 - Entering air temperature (WB) o C Line B - To cross on coil condition, I.e.

    Point 4 - Entering air temperature (DB)

    o

    C WB and DBPoint 5 - Total Cooling Capacity Line C- Intersection point at WB

    Point 6 - Sensible Capacity determine the total cooling capacity

    Line D- Intersection point at DB determine

    Sensible Capacity

    4. FCU Selection

    Design & Application

    Design & Application

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    Assumption, if cooling capacity of 8.4 kW andentering water at 5 o C, leaving water at 10 o C,then :

    Liters/Min = Total Cooling Capacity, W70 x Temperature Rise o C= 8,400 = 24 liters/ min

    70 x 5

    4. FCU Selection

    Design & Application

    Solution:

    Design & Application

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    4. FCU Selection

    Design & Application

    Find pressure drop at this flow rate fromTable ofpressure drop

    Design & Application

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    With pre-determine flow rate, pressure drop of

    the fan coil can be determined interpolation methodusing data given in the pressure drop table :

    Assumption: Pressure Drop for CC30 CW at flow rate of

    24 liters/Min = XX - 7,72 = 24.00 - 20.14

    11.55 - 7,72 25.21 - 20.14

    Water pressure drop, X = 7.83kPa

    4. FCU Selection

    Design & Application

    Design & Application

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    With pre-determine flow rate, Heating Capacity can beestimated from the heating Capacity Performance Chart

    4. FCU Selection

    Design & Application

    Design & Application

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    Standard heating capacity is based on EWT at 60 o C and EAT at21.1 o C, if operating temperature different from the standard, then

    correction factor need to apply based on table below:

    37.8 43.3 45.0 48.8 54.4 60.0 65.5 71.1 76.7 82.2 87.7

    4.4 0.838 0.980 1.021 1.122 1.265 1.406 1.552 1.698 1.845 1.988 2.134

    7.2 0.771 0.913 0.954 1.055 1.198 1.379 1.485 1.631 1.778 1.920 2.067

    10.0 0.700 0.843 0.885 0.986 0.130 1.272 1.417 1.563 1.710 1.853 2.000

    12.7 0.631 0.773 0.817 0.918 1.062 1.205 1.349 1.495 1.639 1.786 1.931

    15.5 0.562 0.705 0.748 0.848 0.992 1.137 1.281 1.427 1.572 1.719 1.865

    18.3 0.493 0.636 0.679 0.779 0.923 1.070 1.212 1.358 1.504 1.650 1.799

    21.1 0.424 0.567 0.610 0.711 0.855 1.000 1.146 1.290 1.438 1.583 1.730

    23.9 0.354 0.498 0.541 0.642 0.786 0.932 1.078 1.222 1.369 1.515 1.664

    26.7 0.284 0.428 0.471 0.573 0.717 0.863 1.008 1.155 1.302 1.449 1.597

    WATER ENTERING TEMPERATURE , C

    HEATING CAPACITY CORRECTION FACTORS

    EAT oC

    Adjusted heating capacity, W ( @ Nominal air Flow ) = base heating capacity ( @ nominal. 60C EWT, 21.1C EAT) x Heating Capacity Correction Factor

    Example at 54.4 o C water entering temperature and 23.9 o C air enteringtemperature, the correction factor is o.786

    4. FCU Selection

    Design & Application

    Design & Application

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    2 basic categories of water pipe worksystems, i.e.

    Close System Open System

    5. Water Piping Design

    Design & Application

    Design & Application

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    Close System

    Pipe installation forms a close circuit minimum

    water loss in these type of system. Expansion

    tank / make up water tank is sufficient to top upthe loss water

    5. Water Piping Design

    Design & Application

    Design & Application

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    Mini chiller is designed with applicationof a close water piping system.

    Possible to use the unit with an opensystem by adding a buffer / intermediate

    tank and pump.

    5. Water Piping Design

    Design & Application

    Design & Application

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    Open System

    Pipe works form an open loop. Usually

    use for cooling tower, formation of alga /bacteria is normal. Water treatment required

    5. Water Piping Design

    Design & Application

    Design & Application

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    If buffer tank being used, Baffle plate install to prevent return water mixing with

    chilled water Suitable to use for multiple chiller operation Water tank can be sized accordingly as storage to allow

    longer cycled off period for chiller, hence saving energy Care to ensure no air leakage along pump suction line

    to prevent air trap - automatic air vent Take care of the water quality, water treatment

    required

    Use only when necessary, i.e. total water volume isinsufficient and need buffer storage to take care ofactual requirement / multiple chiller / standard built inpump head insufficient

    5. Water Piping Design

    g pp

    Design & Application

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    Open System

    5. Water Piping Design

    g pp

    Water out

    Water inMini Chiller Unit

    Return water from fan coil units

    Supply water tofan coil units

    Secondary pump

    TankAir vent

    Baffle plate

    Design & Application

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    Type of piping system

    Series

    Diverting Parallel direct return

    Parallel reverse return

    5. Water Piping Design

    g pp

    Design & Application

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    Type of piping system - Series

    5. Water Piping Design

    g pp

    FCU 1 FCU 2

    FCU 4 FCU 3

    Water out

    Water inMini Chiller Unit

    Design & Application

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    Advantages Low pipe cost

    5. Water Piping Design

    Disadvantages Each fan coil cannot be control individually

    High pressure drop

    Type of piping system - Series

    Design & Application

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    Type of piping system - Diverting

    5. Water Piping Design

    Mini Chiller Unit

    Water out

    Water in FCU 4 FCU 3

    FCU 2FCU 1

    Design & Application

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    Advantages Individual control of each fan coils

    5. Water Piping Design

    Disadvantages Only fan coil units with low pressure drops suitable Low water velocity, air vent required

    Entering water temperature to fan coil units different.

    Type of piping system - Diverting

    Design & Application

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    Horizontal Installation

    Type of piping system - Parallel Direct Return

    5. Water Piping Design

    Mini Chiller Unit

    Water out

    Water in

    Fan Coil Uni

    Design & Application

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    5. Water Piping Design

    Type of piping system - Parallel Direct Return

    Mini Chiller Unit

    Water out

    Water in

    Fan Coil Units

    Vertical Installation

    Design & Application

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    1st in 1st out

    Supply and return pipe length uneven

    Proper balancing of water flow required

    More economical compare to reverse return type

    5. Water Piping Design

    Type of piping system - Parallel Direct Return

    Design & Application

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    Horizontal Installation

    Type of piping system - Parallel Reverse Return

    5. Water Piping Design

    Mini Chiller Unit

    Water out

    Water in

    Fan Coil Units

    Design & Application

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    5. Water Piping Design

    Type of piping system - Parallel Reverse Return

    Vertical Installation

    Mini Chiller Unit

    Water out

    Water in

    Fan Coil Units

    Design & Application

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    1st in - Last out concept

    Supply and return pipes equal length simple balancing

    Use for fan coil units that have same or nearly thesame pressure drop

    High rise building required extra length and weight ofpipe - not economical

    5. Water Piping Design

    Type of piping system - Parallel Reverse Return

    Design & Application

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    Type of pipes and fitt ings

    There are several types of pipe that normally use in for

    water piping

    Black carbon steel pipe Copper pipe

    PVC pipe

    5. Water Piping Design

    Design & Application

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    Black carbon steel pipe

    Joint by arc welding; thread; flange with gasket Most commonly used in chiller installation

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    Copper pipe

    High resistance to corrosion and ease installation High cost Can be joint by brazing; soldering; flare joint

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    PVC pipes

    Light weight Corrosion resistance Not suitable for high temperature application

    Installed with more support(shorter span)

    UPVC generally up to 60 oC usage CPVC higher temperature application Method to joint : solvent cementing / welding; thread

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    Galvanized iron(GI) is not recommended as Zinc coating on

    the GI pipe will have an electrolytic reaction with the copper

    components in the system, i.e. BPHE; fan coil heat

    exchanger. The zinc will be sacrificial metal and deposit itself

    on the copper surface

    Zinc surface slowly eroded Zinc deposit on the copper surface will retard heat transfer

    process

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    Fitting for steel pipe, treaded

    90 o elbow tee joint reducer connector

    union nipple flange

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    Fitting for Copper pipes - expanded end for brazing or

    threaded end

    90 o elbow Reducer Tee joint Connector

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    Fitting for PVC pipes (with treaded end-can joint tosteel pipe of fitting

    90 o elbow Tee joint Connector Adapter

    Socket Union Reducer

    5. Water Piping Design

    Type of pipes and fitt ings

    Design & Application

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    Type of pipes and valves

    Valves- One of the important component in a water piping

    system with the following functions:

    To isolate a component from the system - enableeasy servicing/maintenance

    To regulate water flow rate To divert / mix flow direction To prevent back flow To relieve / regulate pressure

    5. Water Piping Design

    Design & Application

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    Gate valve - to be fully open / fully close; not suitable forregulate or control flow; for isolation / shutoff purposes

    Isolation is important for maintenance purposes. The minimumrequirement is : Chiller supply and return connection; pump

    suction and discharge connection; fan coil unit supply andreturn connection; cooling coil bypass( if 3-way motorized valveis fitted at the coil

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Globe valves - for throttling duty where positive shutoff isrequired

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Ball valve - for throttling duty, used with smaller pipe diameter

    Butterfly valve - has low pressure drops; easy and fastoperation; can be used for throttling duty

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Balancing valve - for throttling duty to regulate water flowrate for balancing purposes. Pressure tapping port provided for

    pressure drop measurement

    Check valve - prevent back flush

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Actuators

    - Automatic valves operate for automatic controller to

    control the fluid flow. Common actuators are :

    Solenoid valve electric motorized valve pneumatic valve

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Solenoid valve - allows wither totally open or closeposition. A magnetic coil will lifts or drops a plunger to open orclose the flow of water

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Electric motorized valve - usually this actuator hasa built in 24V motor to produce a rotary motion to open orclose the valve. Flexible in opening position(depends onexternal signal); high cost

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Pneumatic valve - valve has a flexible diaphragm -operate by injecting air pressure in to the valve to position thevalve open / close. High cost

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    In the chilled water pipe system, automatic control valves usedmay be either 2-way or 3-way. All three types of actuatorabove may be used.

    2-way valve - water flows into the inlet port and exits fromthe outlet port. Actuator used to vary the flow rate

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    3-way valves - 3 ports are available

    1. Mixing valve

    B

    A

    A + B

    2 stream of water blends into 1 stream

    2. Diverting valve

    A + B

    A

    B

    Split 1 stream into 2 different streams

    5. Water Piping Design

    Type of pipes and valves

    Design & Application

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    Installation sample of 2-way valves

    FCU

    Supply Return

    5. Water Piping Design

    Design & Application

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    Installation sample of 3-way valves

    FCU

    FCU

    Supply Return

    Diverting

    Mixing

    5. Water Piping Design

    Design & Application

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    Wrong Installation sample of 2-way valves

    5. Water Piping Design

    FCU

    Mini Chiller Unit

    FCU

    Problem : both FCU off, solenoid valve off, no water flow.

    However pump still running, pressure built up, pump

    problem

    Design & Application

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    Add bypass pipe to relief pressure

    5. Water Piping Design

    Mini Chiller Unit

    FCU

    FCU

    FCU

    P

    Differential pressure transmitter to monitor the

    amount of water used. If pressure goes higherthan preset value, will activate relief valve and

    bypass water

    Installation sample of 2-way valves pre-cautions

    Design & Application

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    5. Water Piping DesignInstallation sample of 2-way valves pre-cautions

    Mini Chiller Unit

    FC

    U

    FC

    U

    FC

    U

    P

    INV

    When differential pressure become higher, the Inverter will

    slow down the water pump to maintain the heap pressure.

    If no demand, water pump stop running

    Use a variable speed drive for secondary pump

    Design & Application

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    Modify control wiring for chiller and fan coil unit

    The above method of 2-way valves installation incur high cost due toextra piping, fittings, pressure transmitter...... There is possible to

    change the control wiring of the system. Normally when the fan coilunit thermostat cut-off, the power supply to control the 2-way valvewill be off. It is possible to run a line from the thermostat to the chillerremote switch whereby when the thermostat cut-off, the chiller andpump will also cut-off.

    5. Water Piping DesignInstallation sample of 2-way valves pre-cautions

    Design & Application

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    Installation sample of 3-way valves5. Water Piping Design

    Mini Chiller Unit

    FC

    U

    FC

    U

    FC

    U

    3-Way valve gives constant flow rate, when no demand,the water bypass through the valve. Energy wastage is

    the disadvantage.

    Use 3-way diverting valves

    Design & Application

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    Other type of valves and fittings

    Thermometer- glass thermometers are installed on the inletand outlet pipes of either the chiller unit or fan coil units. Thisis to measure the water temperature differential to determine

    the capacity performance.

    Thermometer bulb

    measuring correct

    water flow

    temperature

    Thermometer

    too high up,

    stagnant

    water

    5. Water Piping Design

    Design & Application

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    Pressure gauge cock - Used to isolate pressure gaugesalong the water pipe line. When not in use, the valve is closed toprevent prolonged pressurizing to the gauge, and damage the gauge

    Pressure gauge

    Impulse tubing loop

    Gauge cock (ball valve)

    Main pipe line

    5. Water Piping Design

    Other type of valves and fittings

    Design & Application

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    Pressure gauge and thermometer as the previous 2 slides

    should be included in the design stage - consideration for

    commissioning. The measuring devices should be installed

    at the following location :

    Main supply and return pipe Main branch supply/return pipe

    Cooling coils Heating coils Chiller (chilled water side)

    5. Water Piping Design

    Other type of valves and fittings

    Design & Application

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    Safety relief valve - valve will open when pressure exceed setvalue to prevent over pressuring the system. Normally used inhot water system. Should be installed near an expansion tank orpump discharge line.

    Air vent valve - OYL mini chiller has an automatic air vent

    located on top of the buffer tank. Air vent valve used to releaseany trapped air in the tank. Additional air vent should beinstalled at the highest position of the piping network

    5. Water Piping Design

    Other type of valves and fittings

    Pipe Pipe

    Air vent

    Air vent

    5 W Pi i D i

    Design & Application

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    Water outlet

    Water inlet

    Strainer

    Strainer- Strainer are a type of filter for water pipe systems. At leastone strainer should be installed at the location just before the pump.Strainer should be fitted in the return water connection to chiller priorto brazed plate heat exchanger to prevent dirt/particle trapped withinthe heat exchanger.

    5. Water Piping Design

    Other type of valves and fittings

    5 W t Pi i D i

    Design & Application

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    Flow switch - to switch off the chiller unit when low waterflow rate is detected in the piping, possible due to :

    pump failure

    blocked BPHE

    accidental closing of valve

    failure of control valves

    Water outlet

    Water inlet

    BPHE Flow switch

    5. Water Piping Design

    Other type of valves and fittings

    5 W t Pi i D i

    Design & Application

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    Fan coil pressure loss Chiller pressure loss

    Pipe pressure loss - pipe, fittings & component

    5. Water Piping Design

    System Pressure Loss

    5 Water Piping Design

    Design & Application

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    Pipe friction looses are dependent on the following factors :

    Water velocity

    Pipe internal diameter Pipe length Type of material - affect the internal wall roughness

    5. Water Piping Design

    Pipe and Fitting Sizing

    5 Water Piping Design

    Design & Application

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    Water velocity limits are set to take care of noise; erosion andinstallation cost. Recommended guidelines :

    Pipe friction loss should be between 1 to 4 ft / 100 ft ofequivalent pipe length (100 Pa/m to 400 Pa/m)

    Water velocity range for different servicesService Velocity

    fps m/sPump discharge 8-12 2.4-3.6Pump suction 4-7 1.2-2.1

    Drain line 4-7 1.2-2.1Header 4-15 1.2-4.6Riser 3-10 0.9-3.0City water 3-7 0.9-2.1

    5. Water Piping Design

    5 Water Piping Design

    Design & Application

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    Calculation of System Loss Step by Step GuideStep 1 - Draw up a schematic layout, c/w chiller; fan coil units and

    accurately reflect the length of pipe work

    Step 2 - Decide the position and numbers of valves, control valves,

    balancing valves; measuring stations; strainers and mark them on the

    sketch.

    Step 3 - Label each section of the pipe with an identifying letter.Carefully select the pipe route that gives the highest resistance to

    water flow.

    Step 4 - Fill in the water volume flow rate and pipe length for the firstsection on the pipe sizing chart. Use the pressure loss factor from

    Friction Loss Chart and equivalent length by using the equivalent

    length factors from all types of fitting

    5. Water Piping Design

    C l l ti f S t L St b St G id5 Water Piping Design

    Design & Application

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    Calculation of System Loss Step by Step Guide

    Step 5 - Enter type of fitting and their quantity, multiply the quantity

    be the velocity pressure loss factor by the equivalent length for each

    type of fitting to get the total fitting equivalent length,

    Step 6 - Add the total fitting equivalent length to the straight pipe

    length to give total pipe length. Multiply the total pipe length by the

    pipe pressure drop per meter length to obtain a total pressure loss ofthe pipe section

    Step 7 - Repeat step 5 - 7 for other section of pipes. Summarize the

    total pressure drop for all the section. Take into consideration aminimum of 10% safety factor.

    Step 8 - Use the result of step 8 to select the pump

    5. Water Piping Design

    5 Water Piping Design

    Design & Application

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    Example 3Determine the pressure loss of the pipe system below c/w chiller and FCU.If the standard built in pump has external head of 20m, is the pump

    able to handle the pressure loss?

    5. Water Piping Design

    5 Water Piping Design

    Design & Application

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    Pressure loss for copper pipe- close / open system

    5. Water Piping Design

    5 Water Piping Design

    Design & Application

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    Pressure loss for steel pipe- close system

    5. Water Piping Design

    5 Water Piping Design

    Design & Application

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    Pressure loss for steel pipe- open system

    5. Water Piping Design

    5. Water Piping Design

    Design & Application

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    Definition :The equivalent pipe length of a component in the pipesystem is the length of a straight pipe which will give thesame friction losses as the components itself.

    The concept of equivalent pipe length is used incalculating friction losses along the water pipe system,equivalent pipe length can be obtained from tables.

    5. Water Piping Design

    Equivalent pipe length

    5. Water Piping Design

    Design & Application

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    5. Water Piping Design

    5. Water Piping Design

    Design & Application

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    p g g

    P l i t5. Water Piping Design

    Design & Application

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    Fitting : 10 x 90 elbow; 4 tee joint; 2x gate valve; 1 strainer - 1 1/4 steel pipe2 gate valve; 2 tee joint; 1 glove valve 1 1/8 copper

    Pressure loss pipe systemp g g

    5 Copper pipe1 1/8 SB75BW5. Water Piping Design

    Design & Application

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    Fitting : 10 x 90 elbow; 4 tee joint; 2x gate valve; 1 strainer - 1 1/4 steel pipe2 gate valve; 2 tee joint; 1 glove valve 1 1/8 copper

    10 10

    15

    15

    3

    1 1/4 steel pipe

    AC80C

    p g g

    5. Water Piping Design

    Design & Application

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    Pressure loss - OYL fan coil unit data

    Model Nominal Water flow rate Unit Friction loss at nominal flow rate

    L/min USGPM PSI (unit internal components)

    SB75BW 57.00 15.08 6.08

    SB100BW 73.48 19.44 1.83

    SB125BW 97.49 25.79 2.46

    Please refer to relevant technical manual AFCU-2004, page 70

    p g g

    5. Water Piping Design

    Design & Application

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    Pressure loss - OYL mini chiller data

    Note : Unit internal losses take care of friction loss through Brazed plate

    heat exchanger (BPHE); internal pipe work; pump fittings, flow switch, etc.Please refer to relevant technical manual

    Steel pipe 1 1/4 diameter :5. Water Piping Design

    Design & Application

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    Steel pipe 1 1/4 diameter :

    Flow rate : 15.08 usgpm (57.00 Liters/min)

    Straight pipe length : 55 x 2 = 110Equivalent length for fittings : 10 x 3.3 = 33 (elbow)

    4 x 2.3 = 9.2 (tee joint)2 x 1.5 = 3.0 (gate valve)1 x 9.0 = 9.0 (strainer)

    Total equivalent pipe length = 164.2

    From Friction loss for closed piping system, at 15.08 usgpm, forsteel pipe, the friction loss is 3.8 / 100 of pipe, hence friction lsteel pipe = 3.8 x 164.2/100 = 6.24

    5. Water Piping Design

    Design & Application

    Copper pipe 1 1/8 diameter :

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    Total external pipe and fitting loose = 11.87

    Flow rate : 15.08 usgpm

    Straight pipe : 3x2 = 6 Equivalent pipe length for fitting : 2 x 1.4 = 2.8(gate valve)2 x 0.9 = 1.8 (tee joint)1 x 22 = 22 (globe valve)

    1 x 1 = 11 x 1.5 = 1.5

    Total equivalent pipe length copper : 33.1friction loss for copper pipe(1 1/8 at 15.08 usgpm) = 17/100hence 33.1 gives : 17 x 33.1/100 = 5.63

    5. Water Piping Design

    Design & Application

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    Fan coil loose : 6.08

    mini chiller internal loose : 8.7Total external pipe and fitting loose = 11.87

    Total system friction loose : 6.08+8.7+11.87 = 26.65

    = 8.125m

    6. Pump Selection

    Design & Application

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    Pump is one of the fundamental component in the system. It

    circulates water through all the components in the system.

    Pump is a built in component in OYL mini chiller. Basic

    understanding about the pump characteristic is important.

    6. Pump Selection

    Design & Application

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    Primary - secondary pump

    If the built in pump in the mini chiller is not able to deliver the

    head pressure required to the load even in a close loop system :

    Change the existing pump to a higher head pump

    Install a booster pump - primary - secondary pump system

    6. Pump Selection

    Design & Application

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    Primary - secondary pump

    Water out

    WaterinMini Chiller Unit

    Booster pump (secondary)

    Bypassloop

    A

    B

    Fan Coil Units

    Built in pump(primary)

    6. Pump Selection

    Design & Application

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    Disadvantages of this system

    Extra cost for pump Unused bypass chilled water - wastage

    Cautions Bypass loop short(but sufficient to prevent turbulence) to

    minimize pressure loss between the entry and exit point of

    loop

    Do not use any valve in the bypass loop

    Primary - secondary pump

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    6. Pump Selection

    Design & Application

    P i d

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    Case 3: Capacity of primary pump < secondary pumpa net flow up the loop from B. A become a mixing point and B

    become diverting T. Water temperature entering FCU will be in

    between the water temperature leaving the chiller and the watertemperature entering Chiller

    Primary - secondary pump

    Primary - secondary pump in series

    6. Pump Selection

    Design & Application

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    Primary secondary pump in series

    Water out

    Water in

    Mini Chiller Unit

    FCU

    Built in pump(primary)

    Booster pump (secondary)

    6. Pump Selection

    Design & Application

    Primary - secondary pump in series

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    This installation is not recommended :

    risky - wrong pump sizing can caused damage to pump

    if this design need to be used, primary pump capacitymust be equal to the secondary pump, otherwise :

    cavitations problem to the smaller pump pressure drop across pump high head loss - harmful to the chiller

    a y seco da y pu p se es

    7. Multiple Chiller Selection

    Design & Application

    Primary - secondary pump in series

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    y y p p

    In the cases of multiple chiller need to be used,there are few possible installation method :

    Common supply and return headers Primary - secondary system Common tank system

    Common supply and return headers

    7. Multiple Chiller Selection

    Design & Application

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    Chiller 1

    Chiller 2

    Chiller 3

    Check Valve

    Supply Header

    Return Header

    Chilled water supply

    Chilled water return

    7. Multiple Chiller Selection

    Design & Application

    Common supply and return headers

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    Chiller 1

    Chiller 2

    Chiller 3

    Check Valve

    Chilled water supply to FCU

    Chilled water return from FCU

    7. Multiple Chiller Selection

    Design & Application

    Common supply and return headers

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    Most common and preferred

    Low installation cost Chiller set at different return water temperature - load staging Check valve to prevent back flush of water Drawbacks

    proper balancing of water flow rate through each chiller iscrucial

    Any chiller off, water flow rate to the FCU will be affected.To overcome this, it is necessary to wire the chillercontrols for continuos pump running as long as one fan

    coil is in operation One supply line, less flexibility in water distribution

    control, i.e. the highest pressure losses zone might beaffected

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    Common supply and return line

    7. Multiple Chiller Selection

    Design & Application

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    Common supply and return line

    No common header used, higher pressure dropalong common pipe lines - can use larger pipe sizeat this common line to reduce pressure lost.

    Proper balancing is crucial

    1st in last out arrangement at the supply and returnlines is useful to reduce the problem of distribution

    Primary - secondary pump system

    7. Multiple Chiller Selection

    Design & Application

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    Chiller 1

    Chiller 2

    Chiller 3

    Check Valve

    Chilled water supply

    Chilled water returnBypass Loop

    Secondary Pumps

    Primary Pump

    7. Multiple Chiller Selection

    Design & Application

    Primary - secondary pump system

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    Chiller of different capacities can be installed together

    without much balancing

    Balancing valve required

    Secondary pump alone handle the flow and pressure

    requirements of FCU - if one of the primary pump off,the water supply to FCU not affected

    7. Multiple Chiller Selection

    Design & Application

    Primary - secondary pump system

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    Chiller 1

    Chiller 2

    Chiller 3

    Check Valve

    Chilled water supply

    Chilled water return

    Secondary Pumps

    Auxiliary tank

    Primary Pump

    Common tank system - Open System

    7. Multiple Chiller Selection

    Design & Application

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    Chiller 1

    Chiller 2

    Chiller 3

    Chilled water to FCU

    Secondary Pumps

    Primary Pump

    Tank

    Return from FCU

    7. Multiple Chiller Selection

    Design & Application

    Common tank system - Open System

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    Each chiller and secondary pump forms own pipe circuit

    Common tank act as buffer storage tank

    No check valve required, normal globe valve is sufficientto ensure proper water flow

    Tank at higher level - to allow gravity feed of water tothe chillers and pumps

    Refer to earlier slide for open system for all cautionsduring installation and operation

    Multiple chiller-single fan coil load with

    lti l i it h d

    7. Multiple Chiller Selection

    Design & Application

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    multiple circuits - common header

    Chiller 1

    Chiller 2

    Chiller 3

    Check ValveSupply Header

    Return Header

    Circuit 2

    Circuit 1

    Circuit 3

    7. Multiple Chiller Selection

    Design & Application

    Multiple chiller-single fan coil load with

    lti l i it h d

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    multiple circuits - common header

    Chiller 1

    Chiller 2

    Chiller 3

    Circuit 2

    Circuit 1

    Circuit 3

    Minimum compressor run time : 3 minutes(PCB design)

    8. Water Storage Tank and Expansion Tank

    Design & Application

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    Minimum off time of compressor : 4 minutes(PCB design)~ compressor possible cycle on/off 8 times/hour.

    Total volume of water in the system must be able to pull-down by 5 C temperature within 3 minutes

    Total volume of water = volume of storage tank +volume of pipe length +volume of expansion tank

    Water Volume = Time * flow rate for 5 C Temp. Diff. Water Volume = 3* flow rate (liters/min)

    Volume = Time * flow rate for 5 o C Temp. Diff.Volume = 3* flow rate (liters/min)

    8. Water Storage Tank and Expansion Tank

    Design & Application

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    Volume = 3* flow rate (liters/min)

    Example : A mini chiller has a cooling capacity of 40,000Btu/hr (11.72 kW)

    Flow rate USGPM = Capacity, Btu/hr500 * 9

    or Flow rate Liters/min = Capacity, W70 * 5Flow rate = 11720/350 = 33.6 liters/min

    Volume of system = 3 * 33.6 = 100.8 liters

    Assuming the storage tank capacity is 1/3 of the total system watervolume, storage tank capacity = 100.8/3 = 33.6 liters

    For simple calculation, the following tables can be used to estimate the volume of water in

    a system by simply mult iply the length of pipes with the factor:

    Pipe type Pipe Size Water Volume, liters/min

    Steel SCH 40(ST) 1/2 0 196

    Design & Application

    8. Water Storage Tank and Expansion Tank

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    Steel, SCH. 40(ST) 1/2 0.196

    3/4 0.344

    1 0.558

    1 1/4 0.9651 1/2 1.313

    2 2.165

    2 1/2 3.098

    Copper, type L 1/2 0.094

    5/8 0.151

    3/4 0.2257/8 0.312

    1 18 0.532

    1 3/8 0.811

    1 5/8 1.148

    2 1/8 1.997

    2 5/8 3.079PVC, DIN 8062 20mm 0.227

    25mm 0.353

    32mm 0.581

    40mm 0.908

    50mm 1.425

    Expansion tankExpansion tank provide a space into which water can expand or

    8. Water Storage Tank and Expansion Tank

    Design & Application

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    p p p p

    from which it can contract as the water go under volumetric

    changes with respect to temperature change. This device iscompulsory in heat pump units.

    Air

    Water

    Tank

    Diaphragm

    Threaded end

    Tee Joint

    Pump suction lineWater Flow from Mini Chiller

    Spacing between the plates is small, no debris, fouling orli i th t i i t t t t i t i

    9. Water Treatment

    Design & Application

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    scaling in the system is important to ensure no restrict inwater flow and thus performance not affected.

    Strainer along water suction line will remove debris likesand, metal debris, etc..

    It is good practice to install filter at the make up water

    supply line. Filter elements required periodical service to remove

    trapped particles.

    Flushing the pipe with water during initial start up and

    commissioning of the min chiller is necessary

    Fouling refers to the tendency of water form a film onthe heat transfer surfaces Fouling can be organic or

    9. Water Treatment

    Design & Application

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    the heat transfer surfaces. Fouling can be organic orinorganic surface fouling.

    Organic fouling includes microbiological growth. Algaemay also form on these surfaces. This is moresignificant in open system

    Scaling is inorganic fouling. It is normally caused bydeposit inorganic salts

    Symptoms: sudden increase in pressure drop andgradual drop in heat transfer performance

    Remedy : Chemical cleaning

    Organic fouling can be removed by use of alkaline cleaningagent like sodium hydroxide at 5% concentration. Refer toh i l f f d il i i k

    9. Water Treatment

    Design & Application

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    chemical manufacturer for more details instruction. Makesure the excess chemical is fully clean up from the system

    Inorganic fouling most commonly need acidic based cleaningagent. Mineral acids has strong ability to dissolve scales, butattack/corrode stainless steel and copper parts, hence is not

    recommended. Organic acids at 2 - 5% concentration ismore ideal when used to clean BPHE.

    Refer to chemical manufacturer recommendation on thedosage requirement. Upon completion, flush with clean water

    to remove excess acids. It is recommended that the water to be replaced at least

    once a year to prevent fouling on the BPHE

    Glycol Solutions

    9. Water Treatment

    Design & Application

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    y

    Entering water temperature - operating range

    EWT 0C EWT 0C Max EWT 0C

    Factory Setting Minimum maximumCooling Mode 12 3 15

    Heating Mode 40 35 50

    Antifreeze 2 -4 3

    9. Water Treatment

    Design & Application

    Glycol Solutions

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    SW2 Setting(for cool mode)

    SET TEMP. SW20C SW2-3 SW2-2 SW2-1

    Set by VR3 off off off

    3 off off on

    4 off on off5 off on on

    6 on off off

    7 on off on

    8 on on off

    9 on on on

    If DIP switch is set to (off,off ,off), the set temperature is determine

    by VR3 setting, otherwise setting above will override the VR3 setting

    y

    9. Water Treatment

    Design & Application

    Glycol Solutions

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    For Commissioning, it is recommended to observe

    and adjust the setting if necessary :

    For cooling mode, press SW1 once in PCB Green LED will bl inks for few seconds Adjust VR3 to the required water entering temperature by using

    suitable tools

    If glycol added, the entering water temperature (3 0C-9 0C) canbe set by adjusting DIP switch (SW2)

    For heating mode, press SW1 twice, red LED wil l bl inks for fewseconds

    Adjust VR1 to set the required water temperature for heatingmode

    VR2 is adjusted to set antifreeze temperature

    y

    9. Water Treatment

    Design & Application

    Glycol Solutions

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    If sensor setting has been adjust for process cooling - to operateat lower temperature, precaution must be taken to prevent waterfreeze up. For sub zero application, the water must mix with antifreeze glycol solution.

    2 commonly used glycol : ethylene glycol and propylene glycol.Ensure the quantity mixed with water is sufficient to cater for theoperating temperature requirement. The more glycol added, thecapacity loss is higher.

    Make sure water pump is on all the time to ensure continuouswater flow through BPHE to prevent formation of ice.

    y

    9. Water Treatment

    Design & Application

    Glycol Solutions

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    Correction factors with Glycol added to water

    Glycol % Capacity Water flow Pressure drop

    10 0.990 1.015 1.06

    20 0.980 1.040 1.12

    30 0.970 1.080 1.18

    40 0.965 1.135 1.24

    9. Water Treatment

    Design & Application

    Glycol Solutions

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    Pipe being insulated for the following purposes :

    Prevent heat gain / loss from the water in the pipe

    10. Pipe Insulation Requirement

    Design & Application

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    Prevent heat gain / loss from the water in the pipe

    Prevent condensation when chilled water flow in the pipe Prevent injury due to hot water flow in the pipe

    To do a calculation of insulation thickness, one must know :

    Insulation material thermal conductivity coefficient (K) Pipe size Air condition at the site of installation (Dry bulb and humidity) Convective heat transfer coefficient (H)

    A simplify spread sheet is provided to estimate the insulationthickness

    PIPING INSULATION THICKNESS CALCULATION:

    Air condi tion:

    DB/C 25 Dew point

    RH/% 75 DP/C 20.26

    10. Pipe Insulation Requirement

    Design & Application

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    Pipe specification:

    Pipe dia. 1.25 in 31.8 mm

    Radius, r1 15.879 mm

    Pipe surface temperature/C 7

    Insulation material:

    Material: Armarflex

    Thermal conductivity, k 0.0374 W/mK

    Surface convective heat transfer 9 W/m2K

    coefficient, h

    Insulation selection:

    Calculated insulation size

    r2 25.181 mm

    Insulation thickness 9.3 mm

    (Minimum) 0.4 in

    USE THENEXT SIZE THICKNESS

    AVAILABLE OR THICKER FOR

    SAFETY FACTOR

    Few application samples will be provided, however with thefollowing considerations:

    Th ti Al LED f t i l AL1 d AL2 i i i

    10. Pipe Insulation Requirement

    Design & Application

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    The option Alarm LED from terminal AL1 and AL2 in minichiller is meant to be installed into the external control switchboard - to indicate if an abnormal operation has occur. ThePCB will give out a signal to light up the LED when any of theprotection devices trip.

    The option Remote Switch may be located at a convenientplace for easy access to the user. It may be placed inside theswitchboard. It can also act as an emergency switch to stopthe chiller

    The power supply for the fan coil units are separated from themini chiller

    ack To Content

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    Product Features

    Product Features

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    Less foot print occupied

    Less space required.

    Product Features

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    Made of AISI 316 Stainless Steel

    High heat exchange efficiency

    Conventional Back to Back Circuits BPHE

    New Technology BPHE- True Dual Circuits

    Product Features

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    Primary Circuit 1 Primary Circuit 2

    Secondary Circuit

    Primary Circuit 1 Primary Circuit 2

    Inverter Mini Chiller True Dual Circuits BPHE

    Product Features

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    Support up to 50 chiller and 120 fan coil units

    through chiller bus

    Product Features

    A network up to 50 chillers Operation control on chillers done

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    Operation control on chillers donethrough microprocessor controller.

    Additional chiller can be added on by jusextend the water piping.

    Water InWater Out

    ChillerBus

    Up to 50Chillers

    Product Features

    Can be done through Chiller ControlPanel

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    User friendly and versatile controls Main menu includes:Operation Timer Display

    Setting Alarm

    Whole system configuration

    Unique system configuration

    Product Features

    1. Less Start & Stop

    2. Fast Cooling/ Heating 4. Low Starting Surge

    3. Precise Temperature Control

    RunningRunning Conventional air conditioner:

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    Running

    current

    Hours of operation

    Running

    current

    Hours of operation

    Conventional air conditioner:

    High starting currentFrequent on/off cycle

    Inverter air conditioner:

    Low starting currentSmooth operation

    Inverter air conditioner:

    Low starting currentSmooth operation

    Product Features

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    Conventional System

    Inverter System

    Product Features

    High & Low Pressure Switches Anti Freeze Protection Sensor

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    Discharge Temperature Sensor Over Pressure Relief Valve Water Pressure Differential Switch

    Anti Freeze Heater on BPHE Compressor, Water Pump Overload Protector

    ack To Content

    Schematic Diagram

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    Schematic Diagram

    &

    Components

    Schematic diagram

    Condenser Coil 1

    Disch

    Temp 1

    (Disch Comp 1)Suct

    HP1

    LP1

    Cond In

    Temp 1

    (Condenser)

    Cond Out

    Temp 1

    (Def Comp 1)

    Filter

    Drier

    EXV

    O/A Temp

    5ACV100CR

    4WV

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    Acc

    Acc

    Liq Rvr

    Liq

    Rvr

    BPHE FS

    Condenser Coil 2

    Disch

    Temp 2

    (Disch Comp 2)

    Inv

    Comp

    Std

    Comp

    Temp

    (Suction)

    HP2

    LP2

    BPHE Out

    Temp

    (BPHE Out)

    BPHE In

    Temp

    (BPHE In)

    EWT (Water In)

    LWT (Water Out)

    Pump

    Cond Out

    Temp 2

    (Def Comp 2)

    Filter

    Drier

    Heating Cap Tube

    Check valve

    Cooling Cap Tube

    Check valve

    O/A Temp

    (Outdoor Ai r)

    Summary Pages-

    Screen 3

    Display Menu-

    Defros t Sensor

    Display Menu-

    Inverter Chiller

    Display Menu-

    Discharge Sensor

    4WV

    Components

    Variable speedfan motors(100%, 70% &50%)

    Coil guardsFan guards

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    Heat exchangerswith gold fin asstandard

    Water pump

    True dual circuits BPHE(Brazed plate heatexchanger)

    Expansiontank ( 8L)

    Control boxassembly

    Components

    IPM board(Intelligent power module)Uni-

    directionalbridge diode

    3 phaserectifierbridge diode

    Fancapacitors

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    Main board Magneticcontactors

    EMI filter

    Capacitorboard

    PFC capacitor(Power factor correction)

    Power board

    Components

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    For Model 55, 75, 100 & 135 For Model 30

    Components

    To convert rectif ied DC current+500VDC to respective desired

    voltages

    - 12VDC relay

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    - MCU +5VDC- IPM +15VDC

    Ensure stabili ty of above voltageswithin power supply voltage

    fluctuation range (304-480 VAC)

    Over voltage feedback

    Output short circuit protection

    Components

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    Components

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    Components

    High pressure switch

    (NC) 600 psi open,480psi close.

    Low pressure switch(NC) 18 psi open,28 psi close.

    Chiller panelcontroller

    EXV (Electronicsexpansion valve

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    Variable drive systemcompartment

    Fixed drive systemcompartment

    Pump OLP (overloadprotector)

    Differential pressureswitch

    Over pressure reliefvalve

    Anti freeze heater on

    BPHE

    Compressor OLP(overload protector)

    Fixed speedscrollcompressor(R410A)

    Variablespeed scrollcompressor

    (R410A)

    4 Way valve

    Installation

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    &

    Commissioning

    Installation & Commissioning

    Unit Handling

    Unit Placement

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    Maintenance Access

    Water Piping & Fitting

    Power Supply & Electrical Connection

    Preliminary Checking before Start-up

    General Control Flow Chart

    Installation & Commissioning

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    5ACV 100/135/210 CR

    Air Cooled Chiller are cooled by air, space restriction will reduces theair flow, decrease the cooling capacity, increase the power input and,

    in come cases, prevent the unit from operating because of an excess

    Installation & Commissioning

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    of condensation pressure.

    5ACV equipped with propeller fan, which doesnt need ductwork on fanoutlet.

    Direct effect of the wind on the discharge surface of the fan should beavoided.

    Enough clearance around the unit for maintenance works.

    Installation & Commissioning

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    Minimum clearances

    5ACV100/135/210CR5ACV30/55/75CR

    Installation & Commissioning

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    Installation & Commissioning

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    5ACV 30 / 55 / 75 CR

    Installation & Commissioning

    5ACV 100 / 135 CR

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    Installation & Commissioning

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    5ACV 210 CR

    Install piping with minimum bends and changes in elevation tominimize pressure drop. Consider the following:!

    Vibration eliminators to reduce vibration and noise transmissionh b ildi

    Installation & Commissioning

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    to the building.

    Shut off valves to isolate the unit from the piping system duringunit servicing.

    Manual or automatic air vent valves at the highest points of thechilled water piping.

    A means of maintaining adequate system water pressure

    (expansion tank or regulating valve) Temperature and pressure indicators located at the unit to air in

    unit servicing.

    Water connection could be damaged by an excessive stresswhen screwing them. Use a second spanner to compensatethe stress of tightening.

    S f t diff ti l it h i d t

    Installation & Commissioning

    !

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    Safety differential pressure switch is used to ensureadequate water flow to evaporator before starting up the

    unit.

    Balancing valve to regulate the amount of water flow ratethrough the unit.

    It is mandatory to install a strainer at the inlet of the unit.!

    Recommended Piping Connection

    Installation & Commissioning

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    Recommended Fuses & Cable Size

    101010Power Supply Cable Size (mm2

    ) *

    1006040Recommended Fuse (A) *

    380 415 / 3 / 50Voltage Range **

    5ACV210CR5ACV135CR5ACV100CRModel

    Installation & Commissioning

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    10

    5

    10

    5

    10

    3

    Power Supply Cable Size (mm2) *

    Number of Conductor

    1.51.51.5Interconnection Cable Size (mm2) *

    102536Recommended Fuse (A) *

    415 / 3 / 50415 / 3 / 50230 / 1 / 50Voltage Range **

    5ACV75CR5ACV55CR5ACV30CRModel

    105

    105

    103

    Power Supply Cable Size (mm ) Number of Conductor

    1.51.51.5Interconnection Cable Size (mm2) *

    IMPORTANT:

    The figures shown in the table are for information purpose only. They should be checked and selected to comply

    with local/national codes of regulation. This is also subject to the type of installation and conduct ion used.

    * The appropriate voltage range should be checked with label data on the unit.

    Before carrying out any operations on the electrical system, make

    sure that the unit is de-energized.!

    It i i t t th t th li i d d!

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    It is important that the appliance is grounded.!

    Before connecting the power supply lines, check that the available

    voltage value does not exceed the range specified in the electricaldata being provided in Installation Manual.!

    Its recommended to check the correct sequence of the 3 supply

    phases R-S-T before the unit start up.!

    Check the power supply and grounding cable.

    Check that any voltage and phase variation in the power supply doesnot exceed the prefixed thresholds.

    Check that components of the external water circuit have been

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    Check that components of the external water circuit have beeninstalled properly, and according to the manufacturers instructions.

    Check that the filling of the hydraulic circuits, and make sure that thefluid circulation is correct, withou