model selection & design manual

BROAD PACKAGED POWER-EFFICIENT CHILLER

MODEL SELECTION & DESIGN MANUAL

BROAD CENTRAL AIR CONDITIONING

2016 08 SI

Application· Provide chilled / heating water for

central air conditioning system· Produce chilled water over 3℃ and

heating water below 60℃

Cooling capacity 420～4,650kW （120～1,329RT）

（CY90 Packaged Chiller）

Global internet monitoring system for BROAD users since 1996

Global Market

VALUES OF BROAD POWER-EFFICIENT CHILLER

ENERGY SAVINGThe Integrated Part Load Value (IPLV) of the chiller can reach 11. This high IPLV can reduce energy consumption by 40% when compared to traditional electric chillersA BROAD Packaged Water Distribution System can reduces electricity consumption up to 76% when

compared to conventional field-built systems

ADDITIONAL COST SAVINGSThe magnetic oil free and zero friction technology can save up to 40% energy cost and 90% of maintenance cost when compared with traditional electric chillers. BROAD PLC “Smart anti-surge control” module insures the chiller always operate in a safe range. The integrated design of the BROAD chiller, water distribution system and stainless steel metal

enclosure reduce design cost and field installation costs for customers

SPACE SAVING Compared with the traditional electric chillers, A BROAD chiller package reduces volume by 30~50% and the weight by 30%BROAD Packaged Water Distribution System and stainless steel metal enclosures can be installed outside

which reduces mechanical room footprint requirements

WORRY-FREEBROAD Packaged Water Distribution System and stainless steel metal enclosure eliminate risk and reduce system design, procurement and installation errorsBROAD Intelligent Control System (ICS) can be automated for operator free operation of the chiller and water distribution system. BROAD Global Internet Monitoring System provides customers with 24/7/365 fault prediction, analysis and energy-saving management tools

AS THE GLOBAL LEADER OF NON-ELECTRIC CHILLER, WHY BROAD ALSO MAKES ELECTRIC CHILLER？

The BROAD non-electric chiller is the world’s most efficient method to produce chilled water when evaluating original source “primary energy fuels”. A BROAD Direct Fired Absorption Chiller/Heater is able to generate chilled, heating and domestic hot water simultaneously. These three outputs from a single absorption unit is the most reliable system when looking at potential points of failure. The BROAD Generation XI Absorption Chiller provides the longest life span and the quietest operation available in the market today.With the emergence of growing CHP, wind and solar PV power systems we are now manufacturing the power-efficient chiller.Markets for the new power-efficient chiller are as follows:1. Locations of the developing world where there is no access to natural gas or waste energy sources2. Applications for small cooling only requirements3. Site specific locations powered by only wind, hydro or solar PV has great potential to reduce CO2 emissions4. A BROAD Power-efficient Chiller is more efficient than traditional electric chillers5. A BROAD Packaged Water Distribution System is more efficient than traditional distribution systems6. A BROAD Power-efficient Chiller can be combined with a BROAD CHP system, which has higher

efficiency and energy flexibility than a non-hybrid or single energy source plant

CONTENTS

Power-efficient Chiller 1

8

Working Principle

Power-efficient Chiller Cooling Performance Data

Power-efficient Chiller General Conditions

Packaged Power-efficient Chiller Performance Data

Power-efficient Heat Pump Performance Data

Performance Curves

Model Selection Curves

Nomenclature

Combination of Non-electric Power-efficient Chillers

Model Selection & Ordering

Supply Scope

1

3

3

3

3

4

4

4

5

6

7

Dimensions

P&I Diagram

Control System Diagram

Exterior Wiring Diagram

List of Control System Site Engneering

Scope of Supply/Work

Machine Room Construction Tips

Transportation Tips

Lifiting & Leveling Tips

8

11

12

13

14

15

16

16

17

Design & Construction Tips

1

12℃

7℃

magnetic bearing compressor

water d

istribution systemcooling tow

er

water softener

city water

chilled W

. pump

cooling W. pum

p

pumpset

chiller

auto dosing

chilled water

evaporator

throttle valve

condenser

The compressor compresses 7℃ low-temp. & low-pressure refrigerant vapor to 45℃ high temp. & high pressure vapor

then flows into condenser. In condenser cooling water absorbs the heat from refrigerant vapor condensation process

and its temperature raises from 30℃ to 35℃. Then the heat will be discharged to air through cooling tower. After

condensation, 33℃ refrigerant becomes into 6℃ low-temp. & low-pressure liquid after throttle valve. The refrigerant

enters evaporator and evaporates immediately. It absorbs heat from the chilled water and makes chilled water drop

from 12℃ to 7℃. After evaporation, the refrigerant gasifies into 7℃ vapor and sucked into compressor. Then next

cycle begins

The cooling principle

mid-temp. & high-pressure refrigerant

low-temp. & low-pressure refrigerant

low-temp. & low-pressure refrigerant vapor

chilled water

high-temp. & high-pressure refrigerant vapor

cooling water

BROAD Packaged Power-efficient Chiller

2

heating water

40℃

45℃

condenser

evaporator

throttle valve

heating W. pum

p

low-tem

p. W. pum

p


The compressor compresses 4℃ low-temp. & low-pressure refrigerant

vapor to 55℃ high temp. and high pressure vapor then flows into

condenser. In condenser heating water is heated from 40℃ to 45℃, then

provided to users. After condensation, 43℃ refrigerant becomes into 3℃

low-temp. & low-pressure liquid after throttle valve. The refrigerant enters

evaporator and evaporates immediately. It absorbs heat from the low-

temp. water and makes low-temp. water drop from 10℃ to 5℃. After

evaporation, the refrigerant becomes into low temp. & low-pressure

vapor and sucked to compressor. Then next cycle begins

Heating principle

mid-temp. & high-pressure refrigerant

low-temp. & low-pressure refrigerant

low-temp. & low-pressure refrigerant vapor

heating water

high-temp. & high-pressure refrigerant vapor

low-temp. water

heat source inputDFA

45℃ 55℃ above

from power-efficiency chiller

If higher temp. heating water is required, an extra DFA can be added

to users

3

Mode CY 35 90 180 400

Cooling capacity kW 420 1045 2090 4650

Pump

set

Chilled water pump

External head mH2O 18 20 20 20

Power demand kW 8 22 44 90

Cooling water pump

External head mH2O 10 9 9 9


Total power

demand

kW 14 37 81 150

Shipment wt. kg 2000 2600 5400 8000

Operation wt. kg 3000 3900 7000 10000

Power demand kW 5.5 11 15 37

Operation wt. kg 2960 7600 14300 28700

Power-efficient Chiller Cooling Performance Data

Packaged Power-efficient Chiller Performance Data

General Conditions

Mode C 35 90 180 400

Cooling capacity kW 420 1045 2090 4650

104kcal/h 36 90 180 400

RT 120 300 600 1329


Rated COP 5.70 6.20 6.40 6.46

COP（IPLV） 9.32 10.6 10.7 11.5

Starting current A A 2 4 8 8

Maximum operation current

A 160 360 740 1500

Evaporator

Flow rate m3/h 72 180 360 800

Pressure drop kPa 40 65 65 75

Connection diameter DN 150 200 250 350

Condenser

Flow rate m3/h 90 225 450 1000

Pressure drop kPa 30 60 60 70

Connection diameter DN 150 200 300 400

Refrigerant wt. kg 260 550 1100 2000

Shipment wt. kg 2800 4800 9600 16500

Operation wt. kg 3200 5400 10800 18500

Power-efficient Heat Pump Performance Data

Notes：

1. Rated low temp. heating W. outlet/inlet temp：15/20℃

2. Rated A/C heating W. outlet/inlet temp.: 45/40℃

（Highest permitted outlet temp. 60℃）

3. Please contact BROAD for solution for non-rated conditions

Model C35-R

Heating capacity 628kW

Power demand 110kW

Rated COP 5.71

Starting current 2A

Maximum operation current 190A

Maximum input power 115kW

Evaporator

Flow rate 72m3/h

Pressure drop 40kPa

Connection diameter DN150

Condenser

Flow rate 108m3/h

Pressure drop 40kPa

Connection diameter DN150

Refrigerant 260kg

1. Rated chilled W. outlet/inlet temp：7/12℃

2. Rated cooling W. outlet/inlet temp：35/30℃

3. Lowest permitted outlet temp. for chilled

water：3℃

4. Lowest permitted inlet temp. for cooling

water：10℃

5. Adjustable chilled water flowrate：30～120%

6. Adjustable cooling water flowrate：20～140%

7. Pressure limit for chilled W. and cooling W.:

≤1.0MPa （high pressure model available）

8. Adjustable load：10～100%

9. Fouling factor for chilled W：0.018m2· K/kW

Fouling factor for cooling W：0.044m2· K/kW

10. Refrigerant：R134a

11. Machine room ambient temperature:

5～43℃，humidity ≤85%

12. Life design: 30 years

13. Operation noise:≤65dB（A）

14. Operation vibration：≤0.30mm

4

Notes: Calculation method of COP

COP= cooling capacity%/electricity consumption%×rated COP

e.g.C90 rated COP is 6.2,chilled water temp. is 7℃ ,cooling

water temp. is 26℃ ,then cooling capacity is 100%, electricity

consumption is 87%, COP=100%/87%×6.2=7.12

Nomenclature

Codes for high pressure type：

Codes for power supply：

Pressure limit

MPa

Chilled

W.

Cooling

W.1.01～1.60 Fb Mb1.61～2.00 Fc Mc2.01～2.40 Fd Md

Power

supply

Voltage Frequency

B1 380V 50HzB2 400～415V B3 460V 60HzB5 380VB6 400～415V B7 575V

C Y 35 A - 35/29 - 6/14 - B3 - R - Fb

High pressure type（details in right table）

Function: R Heat pump type

Power Supply（3phase 460V/60HZ）

（details in right table）

Chilled W. outlet/inlet temp.（ignored for

rated condition）

Cooling W. outlet/inlet temp.（ignored for

rated condition）

Product design serial number

Cooling capacity:104kcal/h

Y: Packaged chiller （including pumpset,

metal enclosure）

C：Magnetic bearing type

Performance Curves Model Selection Curves

Cooling water temp. changes

Cooling water inlet temp. ℃

%

%

Chilled water outlet temp. ℃

Chilled water temp. changes

Cooling capacity changes

Cooling capacity %

Cooling capacity

Electricity consumption

53 7 9 11 13 15 1770

80

202010

60

40

40 50 60 70 80 90 10030

80

100

90

100

110

120

130

70

60

80

90

100

110

120

19

20 22 24 26 28 30 32 34 36

Electricity consumption %

20

30

40

50

60

70

80

90

100

110

120

Cooling water temp.℃

Chilled water temp.℃130

30

40

50

70

60

80

90

100

110

12018 20 22 24 26 28 30 32 34 36

18℃

15℃

13℃

11℃

9℃

7℃

5℃

3℃

18℃15℃13℃11℃9℃7℃5℃3℃

Cooling capacity %

Electricity consumption %

5

Combination of Non-electric Chiller and Power-efficient Chiller

Energy self-sufficient system

Combination of CHP and power-efficient chiller

Exhaust

500℃ Exhaust chiller

Power-efficiency chillerElectricity

NG

Cooling

Electricity

NG Heating

Gas turbine

Most applicable to places

with huge heating and

cooling load difference

Combination of vacuum boiler and power-efficient chiller

Vacuum boiler

Power-efficiency chiller

NG

Electricity

Heating

Cooling

NG

Daily shift or seasonal shift

according to different

energy prices

Combination of direct-fired chiller and power-efficient chiller

Direct-fired chiller


NG

Cooling

Electricity

HeatingNG

Waste heat is priority

power-efficient chiller used

as supplementary

Combination of waste heat chiller and power-efficient chiller

Waste-energy chiller


Cooling

Electricity

HeatingWaste hot waterExhaustWaste steam

6

Model Selection & Ordering

Function selection· Cooling only type

· Heat pump type

· Combination of CHP and power-efficient chiller,

Combination of waste heat chiller and power-

efficient chiller, Combination of direct-fired chiller

and power-efficient chiller, Combination of vacuum

boiler and power-efficient chiller

Load selection· Any building cooling load cannot be estimated

according to the building area, as it is more closely

related to building insulation and room function.

· 30~50W/m2 is recommended for energy-efficiency

building, 60~90W/m2 for normal building, 100~150W/m2

for high occupant density and high space building

Flowrate selection· BROAD designs the distr ibution system head

according to its profound experiences

· BROAD is open for special head design

Pressure selection· The standard pressure limit for chilled/heating/cooling

water is 1.0MPa. Information about high pressure type

please see Code for high pressure type· >2.0MPa system: secondary heat exchange

recommended

Control· BROAD power-efficient chillers are equipped with

complete control function including internet monitoring

· If users have a building management system（BMS）,

the BMS control interface can be selected as an

optional supply. If the BMS interface is not ordered

along with the chiller, it can be purchased later

· BROAD BMS is recommended to customers （for the

whole building）

Machine room location· On the floor or on building rooftop

· chiller can also be installed in the basement

· Cooling tower should be installed on the floor, on

stilt or on building rooftop

Packaged selection· Packaged power-efficient chiller includes chiller,

water distribution system, metal enclosure as

machine room, etc.

· If the packaged system is installed in the building,

metal enclosure can be selected as an option

· Cooling tower is an option for international

Lead time· ≤CY90: 4 months

· ≥CY180: 6 months

Warranty Free warranty is to cover 12 months from commissioning

or 18 months from shipment,whichever comes earlier

Technical specification is based upon· GB 25131 Safety Requirements For Water Chillers

（Heat Pump） Using The Vapor Compression Cycle

· GB 19577 Minimum Allowable Values Of Energy Efficiency

And Energy Efficiency Grades For Water Chillers

· ANSI/AHRI 551-591（SI） with Addendum Performance

Rating of Water-Chilling and Heat Pump Water-Heating

Packages Using the Vapor Compression Cycle

· GB/T18430 Water Chilling（Heat Pump） Packages

Using The Vapor Compression Cycle. Part 1: Water

Chilling（Heat Pump） Packages For Industrial &

Commercial And Similar Application

· GB/T 19409 Water-Source （Ground-Source） Heat Pumps

7

Supply Scope

Products Category Item Remarks

Chiller Chiller Heat exchanger Include condenser, evaporator （cold insulation included）

Compressor Magnetic bearing, VFD centrifugal type ,oil free operation

Throttling set Include electronic expansion valve, drying filter, shut-off valve, regulating valve

Check valve Prevent refrigerant vapor flow-back to protect compressor

Motor cooling device Include drying filter, control valve set etc

Control system

Low voltage control cabinet Include low voltage electric parts, control board, PLC, etc

Power control cabinet Includes switch gear, instant, reactor etc

Touch screen For operation

External control elements Include temperature & pressure sensors, flow switches, solution level probes and actuators

BMS interface （optional） Connect to BMS system through dry contact or serial communication

Refrigerant R134a Used for cooling or heating

Pumpsetsystem

Pumpset A/C water pump Two units

Cooling water pump Two units

Accessories Include zero resistance filter, check valve, soft connectors, valves and vibration isolator etc

Piping ＊ Include all piping between pumpset and chiller

Piping accessories Include flow switches, auto air vent & its socket, soft connectors

Motor drain valve When water quality becomes poor, this valve automatically drains the cooling water. It also drains cooling water automatically in winter to avoid freeze

A/C W. flowmeter For precise management of chiller load and efficiency

Water softener Improve A/C water and cooling water quality

Auto dosing device Automatically charge biocide corrosion inhibitor and anti-sludge to the cooling water

Pumpset control cabinet Include inverters for A/C W. pump, cooling W. pump, cooling fan soft starter, low voltage electric parts, etc

Electric wiring ＊ Include wires, cables, cable conduit, cable supporters, etc.

Cooling tower （option）

Cooling tower Include auto water makeup device, spraying device, anti-drifting device, fillings, water makeup and draining pipe /valve

Cooling tower fan Cooling fan cable & control wiring not included

Option Enclosure Enclosure Include stainless steel panel, roof cover, structural frame, baseframe, as well as accessories

Notes：1. ＊ only for standard size. Special offer is available

2. If the customer does not order cooling tower, only linkage control signal to cooling fan will be. provided

CY90BROAD Packaged Power-efficiency Chiller

2016.05.27Friday

10:16:18

Time on

Temp. setting

A/C W. pump

Compressor

Cooling W. pump

Cooling tower fan

Anti-sludge pump

Biocide pump

Cooling W.drain

Cooling w. outlet

Chilled water

48.0 Hz

48.0 Hz

HzHz

48.048.0

℃6.9

℃7.0℃30.0

℃11.8

6.40

6.97

8.09

m3/h181.0

R. level

%80

%50

REV rpm25000

Cooling W. inlet

Instant COP

Hour COP

Daily COP

Cooling water

℃35.0℃30.2

Time off

1#

1#

1#2#

2#

1#

REV rpm250002#

2#

Mon Tue Wed Thu Fri Sat Sun

07 303017

Monitor

Monitor

Setting

Check-up

Expense

Information

Profession

Language

ON OFF


8DESIGN & CONSTRUCTION TIPS

CY35 Dimensions

3960 1880

1880

3960

565

200

Control cabinet

Strong current cabinet

Cont

rol c

abine

t for

wat

er

distr

ibut

ion

syste

m

Left

Right

Maintenance space in the

Tube cleaning space in the front or rear

≥2000

Anchor bolt6-M24

Anchor bolt hole Concrete plinths made at site120×120×400

Chilled W. outletDN150

Chi

lled

W. in

letD

N150

Coo

ling

W. in

letD

N150

Cooling W. outletDN150

right and left≥800,1200 suggested

Front Rear

DN25Drainage DrainageDrainageDrainage

DN25

1780 1780

400 1380 1380400 400

2351690

DN40 DN40Dragging hole

Φ50

660 1140 745

2200

1880

2200

655

780

640

2080

100～

200

1840

380

100

9

CY90 Dimensions

5520 2130

2130

5520

1425200

Control cabinet



Contr

ol ca

binet

for w

ater

distrib

ution

syste

m

Left

RightMaintenance space in

Tube cleaning space in the front or rear≥4000

Anchor bolt6-M24


Chilled W. outlet DN200

Chi

lled

W. in

let D

N200

Coo

ling

W. o

utle

tDN2

00

Cooling W. outlet DN200

the right and left≥800, 1200 suggested

DN25Drainage DrainageDrainageDrainage

DN25

2560 2560

400 2160 2160400 400

2502390


Φ50

660 1500 940

2130

2500

775

810

700

2330

100 ～

200

2090

380

100

2500

RearFront

10

Cooling W. outlet L

Cooling W. inlet L

Chilled W. inlet KSplit lifting is available

A

EG

F

a d

BC

D

100

≥NChilled W. outlet K

H I


Φ50

Tube cleaning space in the rear

≥JRight

Left

e e f f400

400 400 400800 400b b c c

FrontRear

Maintenance space in the front≥4000

Maintenance space in the right and left

Control cabinet





Anchor bolt 12-M24

100～

200


Drainage Drainage

CY180、CY400Dimensions

Mode A B C D E F G H I J

CY180 10210 2130 2500 590 1510 300 1545 2885 820 4000

CY400 11410 2140 3000 625 1975 600 1000 2280 1095 5000

Mode K L M N a b c d e f

CY180 DN250 DN300 1600 1200 2330 2090 1765 2090 2490 2165

CY400 DN350 DN400 2000 1200 2360 2480 2025 2100 2880 2425

11

P&I Diagram

PM PMF4 F3F5

T2

T1

B1

T4

T3

B2

P1

YKP2

F6F7

F4 F3F5

F6F7

F1 F1EXV

G F2 G F2

TS

KFEKD

G F2

F2

F2

LBV LBV

F9

FE

YE YF

F8

S

city water

chilled water

pumpset control cabinet

PLC control cabinet

internet

F8 F8

YDYD

YAYAYB

YC YC INV1INV2

cooling W. pum

p

chilled W

. pump

auto dosing d

evice

water softener

F8

V F

YCYE YF

YC

FE

F9 F9 F9LQFJ LQFJ

Control devices:

EKDINV1INV2PLCTS

Controlled objects:

EXVKFLBVLQFJPMYB

Sensors:

T1T2T3T4B1B2P1P2SV

Others:

F1F2F3F4F5F6F7F8F9FEYAYCYDYEYFYKG

electronic throttle valve controller

cooling tower fan inverter

cooling water pump inverter

Programmable Logic Controller

TS touch screen

electronic throttle valve

control cabinet fan

load balancing valve

cooling tower fan

compressor

motor drain valve

chilled W. inlet temp. sensor

chilled W. outlet temp. sensor

cooling W. inlet temp. sensor

cooling W. outlet temp. sensor

chilled W. flow switch

cooling W. flow switch

evaporation pressure sensor

condensation pressure sensor

conductivity sensor

A/C W. flowmeter

check valve

shutoff valve

safety valve

purge valve

vent valve

drain valve

refrigerant discharge valve

shutoff valve

balance valve

auto water makeup valve

auto vent valve

manual drain valve

pollution discharge valve

water makeup valve

manual water makeup valve

level probe

dry filter

Notes:1.Chiller scope 2.Line type: actuator signal output

sensor signal input

communication

12

Control System

Notes:

1. BROAD packaged chiller control system includes interfaces for chiller、

pumpset、cooling tower fan、internet, BMS etc

2. Pumpset and cooling tower control interface and water distribution system

control cabinet are supplied with pumpset

3. BMS control interface includes Serial communication and Dry contact

options. Serial Communication interface can be ModBus、ProfiBus、BACnet

or Lonwork

4. Only control interfaces will be provided to customers who only order chiller

without pumpset and cooling tower

cable：

power cable

control wire

communication cable

internet connection

BROA

D chiller

packaged w

ater distribution system

control cabinet

control cabinet

control interfaces for pumpset and cooling tower

power

internet

sensor interfaces

power

1#chilled W. pump

1# cooling W. pump

2# cooling W. pump

anti-sludge agent pump

biocide pump

cooling W. drain valve

1#cooling tower fan

n#cooling tower fan

2#chilled W. pump

dry contact（optional）

serial communication（optional）ProfiBusModBusBACnetLonwork or other communica-tion protocols

38

4

9

（optional）

13

Power control cabinet 1

1# compressor power power

power

power

L11L12L13N10PE

L11L1 L2 L3 N PEL12

L13N10PE

Ln1 LK1ULK1V MK1

MK2

MQ1

MQ2

MT

MS

MF1

MF2

LK1W

LQ1ULQ1VLQ1W

LF1ULF1VLF1W

LF2ULF2VLF2W

LQ2ULQ2V

MT02NO1

MS02NO1

FP03FP02

NO1

LQ2W

LK2ULK2VLK2W

Ln2Ln3Nn0PE

Ln1Ln2Ln3Nn0PE

LNPE

600620

601621602622 I2+ I2-

I1+ I1-

603623604624 I3+ I3-605625606626607627628629608614634615635V1+221

n#compressor power

Low voltage cabinet power

1# chilled W. pump

1#chilled W. pump operation feedback2222#chilled W. pump operation feedback

V1+216217

RS485 RS485

SON

SOFF

2231# cooling W. pump operation feedback2242#cooling W. pump operation feedback2251# cooling tower fan operation feedback2262# cooling tower fan operation feedback227anti-sludge agent level228biocide level230cooling W. drain valve feedback

1# chilled W. pump

2# chilled W. pump

1#cooling W. pump

2#cooling W. pump

anti-sludge pump

anti-sludge pump


1#cooling tower fan

2#cooling tower fan

231 power metering pulse

RJ45internet interface

BMS communication interface (optional)2-core communication cable

shielded cable

non-shielded cable

BROAD supply scope

connect to internet

sensors interface

（option）

Dry-contacttion)

（option）

A3+A3-

cooling W. conductivity

A4+A4-

chilled W. flow meter

640641BMS

642643chiller on

644645fault

BMS onBMS off

2# chilled W. pump on/off

2# cooling W. pump on/off

2#cooling tower fan on /off

anti-sludge pump

biocide pump


water system fault

water system fault reset

1#cooling W. pump

1#cooling tower fan

operation

frequency

operation

frequency

operation

frequency

Power control cabinet n

Low voltage control cabinet

BMS

BROA

D packaged

distribution system

control cabinet

Exterior Wiring Diagram

Notes：

1. Instead of a control cabinet, only control interfaces will be provided to customers

who only order chiller without pumpset and cooling tower

2. DC4-20mA signal is provided for frequency control and sensors

14

Item Object Installation position

and requirement

Material Source BROAD scope Customer scope

chiller Chiller power Chiller control cabinet

and water system

5-core cable Customer / Cable installation

and wiring inside

chiller control

cabinet

Touch screen Built-in / BROAD / /

Ambient temperature

sensor

Ventilation and avoid

direct sunlight

3-core shielded

cable(10m standard

supple)

BROAD Wiring inside

chiller control

cabinet

Temperature sensor

installation and

cable installation

Network monitor Built-in Network cable Customer Wiring inside

chiller control

cabinet

Cable installation

Wiring at building

side

BMS

interface(optional)

Chiller control cabinet Communication

cable(for serial

communication), 11-

core cable(for dry

contact)

Customer Wiring inside

chiller control

cabinet

Cable installation

wiring at building

side

Chiller and pumpset

grounding

Grounding resistance

≤4Ω

Grounding

wire

Customer / Grounding setup

and wiring

pumpset Main power supply

connection

Water distribution

system control cabinet

5-core cable Customer Wiring inside

chiller control

cabinet

Cable installation

Wire between chiller

and water distribution

system cabinet

Between chiller and

water distribution

system cabinet

Cable supply as per

package chiller

BROAD installation and

wiring inside

chiller control

cabinet

/

List of Control System Installation

15

Scope of Supply/Work

Category Item BROAD Customer Remarks

Transportation &

Location

Factory to port √ BROAD can arrange transportation upon request

Jobsite settlement（eg. erection） √ BROAD provides free guidance

Electric engineering Power supply to enclosure √ 3 phase, 4 wires

Internet connection √ Network cable to the enclosure is to be provided by

customer

Grounding √

Construction & Instal-

lation

Foundation √

Pipe connection between chiller

and pumpset for order with

pumpset

√ A crane must be provided by customer

External piping installation √ Include chilled water pipes, water make-up and

drain pipes

Chiller insulation and chilled water

pumps insulation

√ Factory-mounted

Piping insulation in enclosure √ For order with pumpset

Pipeline insulation √

Anti-freezing √ Water anti-freeze treatment is recommended when

the ambient temp. is below 0℃

Commissioning Jobsite chiller commissioning √ Customer provides energy and air conditioning load

Operation & Mainte-

nance

Operator training on site √ BROAD provides free professional site training;

the customer pays the accommodations and

transportation for BROAD engineer

Regular maintenance √ Service contract can be signed after the warranty

period

16

Machine Room Construction Transportation Tips

BROAD Packaged Power-exfficiency Chiller can be

placed outdoor directly, no additional construction of

machine room. Make the foundation in accordance

with the drawings

· Please refer to dimension drawings for plinth dimensions

· Load capacity:

①The machine room foundation load is recommended

as 1.5 times of the operation weight

②Make sure that the foundation is level without

sinking or overload（for rooftop installation）

③Chiller load should be evenly distributed on the

contact surface between the frame base rolling

steel and the plinth

· Anchor bolts:

①Anchor bolts must be pre-installed in foundation

per dimension drawings

②Place the chiller on the foundation directly and fix

it with anchor bolts

Machine Room Shipping Status

Foundation

Machine room built by customer

· Ventilation: poor ventilation leads to high humidity

in the machine room, which may erode the unit.

Please ventilate 3X machine rooms every hour

· Drainage:

①Chiller foundation must be on a high level in the

machine room

②All discharge pipes and drainpipes must be visible

above the drainage

③Machine room in basement must be built above a

water ditch, which is equipped with an auto level-

controlled submerged pump

· Temperature:

machine room temperature must be controlled

within 5~43℃. Lower temperature may crack heat

exchange tubes and water box when the chiller is

shut off. Higher temperature may damage electrical

components. Thermometer and over temperature

alarm must be installed in machine room

· Humidity:

machine room humidity must be lower than 85%. Higher

humidity may impair insulation of electrical components

· CY35 & CY90 are to be shipped in one piece, while

CY180 & CY400 in two pieces

· Al l equipment can be container ized as per

Container Arrangement Reference

· BROAD can arrange transportation and insurance

on behalf of customers. If customers manage it by

themselves, please refer to BROAD Chiller Packing &

Transportation Regulations for container arrangement

in advance, so as to make sure safety transportation

17

Lifting & Leveling Tips

Sketch of lifting

<90°

<90°<90°

<90°

<90°

1. Before the chiller is positioned, concrete foundation

plinths must be molded and leveled. The level degree

is <1.5‰, height of foundation is 100~200mm. Then fix

the chiller with anchor bolts on the foundation

2. Lifting must be done by qualified lifting companies

that are properly insured

3. The crane must be supported by crossties and

firm foundation to prevent it from sinking. Check

the crane steel ropes and hooks before lifting to

prevent any accident. The lifting intersection angle

must be less than 90°. It is strictly prohibited to lift

the chiller with a single steel rope. When the chiller

is lifted 20mm above the carriage or the ground, it

should be kept for a little while. Lift the chiller slowly if

everything is fine

4. If l imited by loading height, loading angle or

machine room access, the professional l ifting

company must make special plan with BROAD team

together to avoid any risk

5. The landing of the chiller must be with care. Crash

landing is strictly forbidden

6. When moving the chiller, only round steels or thick

steel tubes can be used as rollers instead of wooden

sticks. Only drag the dragging hole on the rolling

steel. Do not place forces on other part of the

chiller. Lift the unit first with jacks under the rolling

steel before rigging

7. After chiller positioning, please adjust leveling and

lay thin steel plate where it is uneven to guarantee

compact contact between the chiller and base.

Take tube sheet as the leveling point and make

front/rear and left/right leveling （check level height

of every part by acrylic tube）. It should be leveled

within 1‰ both lengthwise and sidewise. Leveling

must be done within 2 hours after locating the chiller;

otherwise the chiller base will be damaged

8. The chiller must be located levelly and its steel frame

bases must match the plinth, the weight of the chiller

must be evenly balanced on the plinth

9. The chiller should be protected by full time personnel

during transportation & installation. No access

for unauthorized persons. Valves of the chiller are

forbidden to be screwed. If the machine room is

still under construction, precautions are essential to

avoid chiller get damaged or dirty. No scraping the

paint or insulation layer

CY35/90 Lifting sketch

CY180/400 Chiller lifting sketch CY180/400 Pumpset lifting sketch

Insert lift ropes after removing

the cover on chiller roof

BROAD power-efficient chillers and packaged water distribution system are ISO、

CE、ETL、ASME certified

To protect forest & water sources, please imitate us to adopt compact layout & thin paper printing

2016.09

The First Edition Quantity:10,000

BY290-16 © 2016

BROAD Town, Changsha, China 410138 www. broad.com

Tel: +86-731-84086688 Fax: +86-731-84610087

100g

model selection & design manual

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