Model decoding ........................................................................................................................................ 4
Unit features, standard specifications & options.................................................................................... 5-8
Physical data ....................................................................................................................................... 9-12
Performance data .............................................................................................................................. 15-20
Electrical data ......................................................................................................................................... 21
Water side pressure drop ....................................................................................................................... 22
Unit dimensions ................................................................................................................................ 23-28
Load distribution ................................................................................................................................ 47-48
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
3
Page 4
13 & 14
OPTIONS
&
ACCESSORIES
SEE NOTE # 2
BELOW
12
HGBP
OPTIONS
WITHOUT HGBP
B : HGBP (OPTIONAL)
A : STANDARD UNIT
11
COOLER
OPTIONS
10
OPTIONS
CIRCUIT BREAKER
9
MODEL DECODING
CONDENSER COIL
VICTAULIC CONN.
(OPTIONAL)
A : STANDARD WITH
B : FLANGE CONN.
CIRCUIT
BREAKER
COMPRESSOR
A : STANDARD
B :
PRE-COATED
ALUMINUM FIN
ALUMINUM FIN
A :
B :
C : COPPER FIN
WITH VICTAULIC
CONN. (OPTIONAL)
C : ASME STAMPED
BELOW)
(SEE NOTE # 1
WITH FLANGE
CONN.(OPTIONAL)
D : ASME STAMPED
- COOLER GUARD
- UNIT DISCONNECT SWITCH
- COMPRESSOR ENCLOSURE
- WATER FLOW SWITCH
- SPRING ISOLATOR etc...
8
SUPPLY
( V-Ph-Hz )
ELECTRICAL
L : 380/415-3-50
(4 WIRE)
7
ANT
B : R-134a
REFRIGER-
4, 5 & 6
UNIT SIZE
BASIC
1, 2 & 3
045
ASQ
(SERIES)
050
055
060
COOLINE
AIR COOLED
070
SCREW WATER
080
090
100
CHILLERS
115
130
140
150
160
170
180
190
200
220
230
240
250
260
270
280
4
300
320
330
340
350
360
380
400
420
440
NOTES:
1. FOR OTHER COATING, SPECIFY YOUR REQUIREMENTS IN WRITING.
2. COMPUTER SELECTED DIGITS (FROM 'AA' TO 'ZZ') DESCRIBING OTHER OPTIONS & ACCESSORIES OR COMBINATIONS THEREOF, SUCH AS: - CONDENSER COIL GUARD
Page 5
FEATURES
These ASQ air cooled screw water chillers offer the ultimate combination of energy saving design, superior engineering
features and flexibility of application as required by today’s market.
These chillers incorporate the newest advanced microprocessor controller. This controller monitors analog and digital
*
inputs to achieve precise control & protective functions of the air cooled water chiller units. This microprocessor
controller is complete with all the hardware and software necessary to control the chiller unit and insures its efficiency
and reliability.
Designed to conform to ARI standard 550/590 water chilling packages using the vapor compression cycle.
*
Designed to conform to ANSI/ASHRAE 15-1994 Safety code for Mechanical Refrigeration.
*
Compact unit design and excellent serviceability.
*
All packaged chillers incorporate compact water coolers with enhanced inner grooved copper tubes bundled into a
*
"U" shaped and expanded into a steel tubular sheet which offer efficient water flow as well as heat transfer design
resulting in optimal unit performance.
High Energy Efficiency Ratio (EER) semi-hermetic compact twin screw compressors provided in these units.
*
Single point power connection to minimize job site installation cost and time.
*
Completely wired control panel with
*
safety controls.
Compressors are with part winding start.
*
Low noise condenser fans, direct drive at 860 RPM with rolled form venturi design to eliminate short circuiting of
*
airflow.
the advanced microprocessor
controller provides all the necessary operating and
All fans are die cast aluminum propeller type with aerodynamic design, top discharge, provided with protective
*
grille mounted on top panel within the unit casing.
All condenser fan motors are totally enclosed air over type (TEAO) with class ''F'' winding insulation and ball bearings.
*
Inherent thermal protection of the automatic reset type and specially designed for outdoor application.
STANDARD SPECIFICATIONS
CAPACITY CONTROL
A. Standard settings:
These chillers are equipped with stepless capacity control system as standard for very accurate response to load
requirements and best part load efficiency. Each compressor is equipped with a slider controller that enables to modulate
capacity between 25% to 100%, thus giving a broad range to control total chiller capacity between 10% to 100% on an
average. This system has following advantages:
1. Infinite capacity modulation allows the compressor capacity to exactly match the cooling load.
2. Reduce compressor cycling that leads to better operational reliability.
3. Reduce operating cost.
B. Optional settings:
The COOLINE packaged chillers incorporate stepped load shedding as required by some energy management systems.
Modulation of capacity in response to system load requirements is affected by a microprocessor controller which monitors the leaving water temperature.
Capacity control is achieved by cycling compressor ON/OFF and slider capacity pre-set control valve. The use of slider
control valve provides excellent part load capacities.
On multiple compressor units, capacity is controlled by a combination of slider capacity control valve and compressor
staging. For such optional stepped load shading, please see the following table.
5
Page 6
MODEL NUMBER
ASQ045B - ASQ070B
ASQ080B- ASQ150B
ASQ160B - ASQ200B
ASQ220B - ASQ280B
ASQ300B - ASQ440B
100-50-OFF
100-75-63-50-25-OFF
100-83-66-50-33-16-OFF
100-87-75-63-50-37-25-12-OFF
100-92-83-75-66-58-50-42-33-25-16-8-OFF
100-75-63-50-25-HGBP-OFF
100-83-66-50-33-16-HGBP-OFF
100-87-75-63-50-37-25-12-HGBP-OFF
100-92-83-75-66-58-50-42-33-25-16-8-HGBP-OFF
OPTION-2 OPTION-1
100-50-HGBP-OFF
NOTES: 1. All models have slider capacity control valve on all compressors.
2. HGBP = Hot gas bypass available on lead compressor for all models (option).
3. HGBP modulates to approximately 50% of its compressor lowest unloaded capacity.
SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORS
% FULL LOAD CAPACITY CONTROL
All compressors are compact semi-hermetic twin screw of the high capacity and efficiency due to its perfect profile form
ratio 5:6. Simple and robust construction with slider control valve for capacity unloading, suction/discharge shut-off valves,
check valve in discharge gas outlet, oil sight glass, oil fill/drain service valve, directly flanged-on three stage oil separator
with long-life fine filter 10 microns mesh size, robust axial bearings in tandem configuration, suction gas filter, internal
pressure relief valve and manual lock-out electronic protection system for thermal motor winding temperature, phase
reversal, discharge gas temperature protection controls.
CONDENSER COILS
W-configuration condenser coils are corrugated fin and tube type, constructed of seamless 3/8" dia. & 0.014" (0.35 mm)
thick copper tubes, mechanically bonded to aluminum fins for maximum heat transfer efficiency. As an option, copperfins or acrylic coated aluminum fins or other coated coils may be provided. The fins have full self spacing collars
which completely cover each tube. The staggered tube design improve the thermal efficiency. End plates support
sheets are 14 gauge galvanized steel, formed to provide structural strength. Each coil is pressure tested in the factory
at not less than 450 psi air pressure.
COMPACT DESIGN SHELL AND TUBE WATER COOLERS
The DX shell & tube cooler with removable ‘U’ shaped bundled tubes are made of internally grooved copper tubes
expanded into a heavy steel tubular sheets.
The chiller cooler & baffles are constructed of steel and brass respectively. The coolers are insulated with heavy closed
cellular foam insulation (3/4" thick). All chiller barrels are fitted with vent, drain connection and victaulic water pipe
connection as standard.
SHELL & TUBE
HEAT
EXCHANGER
(COOLER)
DESIGN PRESSURE,
(BAR/PSIG)
16/23522.8/33529/42641.5/610STD
10/14711.3/16515.5/22823.3/342ASME (option)
WATER SIDEREFRIGERANT SIDE
TEST PRESSURE,
(BAR/PSIG)
DESIGN PRESSURE,
(BAR/PSIG)
TEST PRESSURE,
(BAR/PSIG)
CABINET
All units are of heavy gauge (G-90) galvanized steel. Steel sheet panels are zinc coated and galvanized by hot dip
process of lock-forming quality conforming to ASTM A 653 commercial weight G-90 followed by air dry paint or backed on
electrostatic polyester dry powder coat.
CONTROL PANEL
The control panel design is equivalent to NEMA 4 (IP55) with hinged door for easy access ensuring dust and weather-
proof construction. Internal power and control wiring is neatly routed, adequately anchored and all wires identified with
cable markers as per NEC standards applicable to HVAC industry.
The electrical controls used in the control panel are UL approved which are reliable in operation at high ambient conditions for a long period.
6
Page 7
CONDENSER FANS
Condenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phase
with class ''F'' winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosed
air over type (TEAO) with inherent thermal protection of automatic reset type.
MICROPROCESSOR CONTROLLER
The microprocessor controller works on the state of art microprocessor technology. This controller monitors analog and
digital inputs to achieve precise control & safety functions of the unit.
The Software works on the Proportional Integral Derivative (PID) algorithm for precise control logic.
The simple to use push button keyboard allows accessing to the operating conditions, control set points & alarm history
that are clearly displayed on a multi-line back illuminated LCD panel.
An easy to install serial port/modem option allows remote monitoring of the operating parameters. With corresponding
windows software, the system allows data to be viewed in tabular or graphic format as well as interact with system set up.
This chiller controller is compatible with the Building Management System (BMS) BACNET/MODBUS protocols through
corresponding optional gateway interfaces.
It is also compatible with GSM protocol through GSM optional gateway that sends up to 3 mobile phone SMS messages
whenever alarm take place, indicating the type of alarm, the corresponding compressor, the related chiller and which
location.
The microprocessor consists of the following hardware:
1. User Interface Board: Provided with simple to use push button keyboard and menu driven software to access operating conditions, control set points & alarm history that are clearly displayed on the LCD panel.
2. Main Board: This controls up to two (2) compressor system.
3. Auxiliary Boards: Required for controlling an additional two (2) or more compressors.
4. Remote Monitoring System [Optional]: The micro controller is complete with all hardware and software necessary to
remotely monitor and control the chiller unit.
Display Information:
In the normal operating mode the 20 x 4 characters LCD panel display the system status, the temperature of the water
inlet & outlet, the set point, run time of the compressor & the alarm history.
Easily accessible measurements for each circuit include the following:
Suction and discharge temperatures
·
Suction, discharge and oil pressures
·
Water inlet/outlet temperatures
·
Compressor status
·
Fan status
·
Liquid line solenoid status
·
Unit/Compressor run time
·
The control temperature is continuously displayed on the 3 Digit 7 segments LED Display. The 3 LED lights indicate the
Power ON, Menu adjustment and Fault.
System Protection:
The following system protection is provided to ensure system reliability:
compressor winding overheating
·
Low suction pressure
·
High discharge pressure
·
Freeze protection
·
Low oil pressure
·
Sensor error
·
Time delay – Anti recycle time for compressor
·
Serial communication error
·
7
Page 8
STANDARD CONTROL & SAFETY DEVICES
MICROPROCESSOR CONTROLLER: This controller monitors analog and digital inputs to achieve precise control &
safety functions of the unit.
COMPRESSOR IN-BUILT PROTECTION DEVICE: Protect the compressor by monitoring:
A) Motor winding temperature in case of overload.
B) Discharge gas temperature in case of overheating.
C) Phase reversal for direction of rotation.
STARTERS: The starter is operated by the control circuit and provides power to the compressor motors. These devices
are rated to handle safely both RLA and LRA of motors.
CRANKCASE HEATERS: Each compressor has immersion type crankcase heater. The compressor crankcase heater is always on when
the compressors are de-energized. This protect the system against refrigerant migration, oil dilution and potential compressor failure.
HIGH PRESSURE SWITCH: This switch provides an additional safety protection in the case of excessive discharge pressure.
STANDARD ACCESSORIES
UNIT ON-OFF SWITCH: ON-OFF switch is provided for manually switching the unit control circuit.
INDICATOR LIGHTS: LED lights indicates power ON to the units, MENU adjustment and FAULT indications due to trip on safety devices.
ELECTRONIC EXPANSION VALVE: Electronic expansion valve is used to regulate the refrigerant flow to the water
cooler and maintain a constant superheat and load optimization.
FILTER DRIER (REPLACEABLE CORE TYPE): Refrigerant circuits are kept free of harmful moisture, sludge, acids
and oil contaminating particles by the filter drier.
SIGHT GLASS: A moisture indicating sight glass installed in the liquid line. An easy-to-read color indicator shows
moisture contents and provides a mean for checking the system refrigerant charge.
LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from accumulating
in the water cooler during the off cycle.
UNDER VOLTAGE AND PHASE PROTECTION: Protects against low incoming voltage as well as single phasing, phase reversal
and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it can be set up for manual reset.
OPTIONS
(All options are at extra cost. Please check with your nearest dealer/sales office)
HOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50%
of its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor
on and off, ensuring narrow temperature swing and lengthen the life span of the compressor.
WATER FLOW SWITCH: Paddle type field adjustable flow switch for water cooler circuits. Interlock into unit safety
circuits so that the unit will remain off until water flow is determine.
UNIT MOUNT SPRING ISOLATORS: This housed spring assemblies have a neoprene friction pad on the bottom to
prevent vibration transmission.
COMPRESSOR CIRCUIT BREAKERS: Protects against compressor branch circuit fault. When tripped (manually or
automatically), the breaker opens the power supply to the compressor and control circuit through auxiliary contacts.
LIQUID COOLERS: ASME code stamped liquid cooler.
PRESSURE GAUGES: Suction & discharge pressures gauges.
NON-FUSED MAIN DISCONNECT SWITCHES: De-energize power supply during servicing/repair works as well as with door interlock.
CONDENSER COIL GUARD: Protect the condenser coil from physical damage.
COMPRESSOR/COOLER GUARD: Protect the compressor from vandalism.
COMPRESSOR ENCLOSURE BOX: Reduce compressor operating noise and keep the compressor clean.
FLANGED COOLER CONNECTION: Easy on-site piping connections.
COOLER HEATER WRAPPED: Prevent freezing up of water on low ambient temperature.
COPPER FINS/TUBES CONDENSER COILS: For seashore salty corrosive environments.
COATED COPPER/ALUMINUM FINS CONDENSER COILS: For seashore or acid corrosive environments.
BMS: BACNET, MODBUS, GSM and remote monitoring.
The following design requirements must be known to select a package chiller.
1. Required cooling capacity in tons
2. Leaving chilled water temperature in 0F (LCWT)
3. Chilled water flow rate in GPM
4. Chilled water cooling range in 0F (water in temp. _ water out temp.)
5. Design ambient temperature
6. Minimum ambient temperature
7. Altitude
8. Electrical power supply
SAMPLE SELECTION
Select an Air Cooled Packaged chiller for the following conditions:
Required system capacity is 110 tons at 540F entering chilled water
and 440F leaving water. Design ambient temperature is 950F.
Altitude is 2000 feet above sea level.
Water cooler fouling factor is 0.00010. Power supply: 380/415V-3Ph-50Hz.
STEP-1: UNIT SELECTION
Entering the capacity performance data at given LCWT and ambient temperature.
ASQ115B chiller unit at sea level will produce 115.3 tons and 120.3 kW compressor
0
power input at 44
F leaving chilled water temperature with 100F water temperature
difference and 950F ambient temperature.
For the conditions required, the unit actual cooling capacity when corrected for
altitude (0.99) and fouling factor (1.0).
Capacity = 115.3x0.99x1.0 = 114.1 Tons, which then exceeds the requirements.
So the selection is correct.
STEP-2: CHILLED WATER FLOW (GPM):
Water GPM =
Required capacity (Tons) x 24 = 110 x 24
Cooling Range, ∆T 100F
= 264 GPM
EVAPORATOR FOULING
FACTOR (HR-FT
2-0
0.00010
0.00025
0.00050
0.00075
0.00100
ELEVATION ABOVE
SEA LEVEL (FT.)
CAPACITY
CORRECTION
F/BTU)
FACTOR
1.000
0.992
0.978
0.965
0.951
TABLE - 2
+0.6
F)
0
+0.4
+0.2
CORRECTION FACTOR (
-0.2
-0.4
CAPACITY
CORRECTION
FACTOR
0
2000
4000
6000
8000
10000
1.00
0.99
0.98
0.97
0.96
0.95
TABLE - 1
POWER
INPUT
FACTOR
1.000
0.997
0.990
0.984
0.978
0
510
CHILLED WATER TEMPERATURE RISE (0F)
STANDARDS
ARI-550/590-98
ARI-590-86
ARI-590-81
1520
TABLE - 3
ARI
Referring to pressure drop chart (page # 22), pressure drop at 264 GPM = 13.3 ft. of water for selected model.
NOTE: The total flow rate should be divided by 2 for models ASQ220B - ASQ440B to find out the total pressure drop.
STEP-3: ELECTRICAL
Refer to electrical data at
380/415V-3Ph-50Hz
, the main power wire size for ASQ115B is to be sized for a minimum circuit
ampacity (MCA) of 292 Amps and maximum over current protection (MOCP) of 411 Amps.
STEP-4: CHILLED WATER PUMP SELECTION
For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop
calculated in step 2.
STEP-5: LCWT CORRECTION
Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water tempera-
0
ture range is above 10
F and subtract correction from design leaving chilled water temperature (LCWT) when water
temperature range is below 100F.
EXAMPLE:
0
If LCWT rise is 12.5
F, enter correction curve at 12.50F and read the correction factor of 0.2. The corrected LCWT is
44+0.2 = 44.20F.
NOTE: 1.When the chilled water temperature rise is less than 50F, the high water flow rate will result to excessive
pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.
2.Please refer to water pressure drop curves.
13
Page 14
SELECTION PROCEDURE (Metric units)
DESIGN REQUIREMENTS
The following design requirements must be known to select a proper package chiller.
1. Required cooling capacity in kilowatt (kW)
2. Leaving chilled water temperature in 0C (LCWT)
3. Chilled water flow rate in LPS
4. Chilled water cooling range in 0C (water in temp. _ water out temp.)
5. Design ambient temperature
6. Minimum ambient temperature
7. Altitude
8. Electrical power supply
SAMPLE SELECTION
Select an Air Cooled Packaged chiller for the following conditions:
Required system capacity is 395 kW at 120C entering chilled water
and 60C leaving water. Design ambient temperature is 350C.
EVAPORATOR FOULING
FACTOR (M
0.000018
0.000044
0.000088
0.000132
0.000176
Altitude is 600 meter above sea level.
Water cooler fouling factor is 0.000018. Power supply:
380/415V-3Ph-50Hz.
2-0
ELEVATION ABOVE
SEA LEVEL (Meter)
CAPACITY
C/W)
CORRECTION
FACTOR
TABLE - 2
1.000
0.992
0.978
0.965
0.951
0
600
1200
1800
2400
3000
TABLE - 1
POWER
INPUT
FACTOR
STEP-1: UNIT SELECTION
Entering the capacity performance data at given LCWT and ambient temperature.
ASQ115B chiller unit at sea level will produce 403.6 kW and 120.1 kW compressor
0
power input at 6
C leaving chilled water temperature with 60C water temperature
difference and 350C ambient temperature.
0
C)
+0.33
+0.22
+0.11
For the conditions required, the unit actual cooling capacity when corrected for
altitude (0.99) and fouling factor (1.0).
CORRECTION FACTOR (
Capacity = 403.6x0.99X1.0 = 399.5 kW, which then exceeds the requirements.
So the selection is correct.
STEP-2: CHILLED WATER FLOW (LPS):
Water LPS =
Required capacity (kW) x 0.239 = 395 x 0.239
Cooling Range, ∆T 60C
= 15.7 LPS
-0.11
-0.22
CHILLED WATER TEMPERATURE RISE (0C)
TABLE - 3
Referring to pressure drop chart (page # 22), pressure drop at 15.7 LPS = 36 kPa for selected model.
NOTE: The total flow rate should be divided by 2 for models ASQ220B - ASQ440B to find out the total pressure drop.
CAPACITY
CORRECTION
FACTOR
1.00
0.99
0.98
0.97
0.96
0.95
STANDARDS
1.000
ARI-550/590-98
0.997
0.990
0.984
0.978
546780109
ARI-590-86
ARI-590-81
ARI
STEP-3: ELECTRICAL
Refer to electrical data at
380/415V-3Ph-50Hz
ampacity (MCA) of 292 Amps and maximum over current protection (MOCP) of 411 Amps.
STEP-4: CHILLED WATER PUMP SELECTION
For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop
calculated in step 2.
STEP-5: LCWT CORRECTION
Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water tempera-
0
ture range is above 6
C and subtract correction from design leaving chilled water temperature (LCWT) when water
temperature range is below 60C.
EXAMPLE:
0
If LCWT rise is 7.4
C, enter correction curve at 7.40C and read the correction factor of 0.11. The corrected LCWT is
60C+0.11 = 6.110C.
NOTE: 1.When the chilled water temperature rise is less than 3
pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.
2.Please refer to water pressure drop curves.
, the main power wire size for ASQ115B is to be sized for a minimum circuit
0
C, the high water flow rate will result to excessive
14
Page 15
F AMBIENT TEMPERATURE
0
F AMBIENT TEMPERATURE 130
0
F AMBIENT TEMPERATURE 125
0
WATER
COMP.
CAP.
WATER
COMP.
CAP.
WATER
COMP.
CAP.
FLOW
(GPM)
EER
kW
(Tons)
FLOW
(GPM)
EER
kW
(Tons)
FLOW
(GPM)
EER
kW
(Tons)
4. Direct interpolation is permissible. Do not extrapolate.
5. kW power input is for compressor only.
6. EER for entire unit. Refer to electrical data for fan kW.
1. Customer to specify the exact nominal power supply available at site so that electrical components are selected accurately, failing to do so will affect unit
5. Under compressor type 1 are the big compressors or compressor with economizer, and type 2 are the small compressors or compressor without economizer.
6. All field wiring must be in accordance with NEC and local standards.
7. Minimum and maximum unit supply voltages are shown in the tabulated data above.
8. Neutral line required on 380/415V-3Ph-50Hz (4 wires) power supply.
2. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker.
3. The maximum incoming wire size is 500 MCM. On units having MCA greater than 500 MCM wire, the factory supplied power terminal block will accept
4. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection.
9. The ±10% voltage variation from the nominal is allowed for a short time only, not permanent.
SBSLAVE BOARD
S1CONTROL SWITCH
SSPS SOLID STATE PROTECTION SYSTEM
TMCB
THERMAL MAGNETIC CIRCUIT BREAKER
TRANS TRANSFORMER
TDSTIME DELAY SWITCH
D7 (MB)23B
TSTEMPERATURE SENSOR
ULUNLOADER
UVMUNDER VOLTAGE MONITOR
2
2
UVRUNDER VOLTAGE RELAY
TERMINAL BLOCK
- - - - - FIELD WIRING
LEGEND ON MAIN BOARD
D1DIGITAL INPUT 1
C/1CCOMMON
1ODIGITAL OUT 1
DCDIGITAL COMMON
T1THERMISTOR 1
SHSHIELD
X52/X53 SERIAL COMMUNICATION PORT
PEPOTENTIAL EARTH
JU/TU/TD/TL
BOARD JUMPERS
NOTES
1. POWER SUPPLY,
ALL FIELD WIRING TO COMPLY WITH LOCAL CODES.
2. FUSES TO DUAL ELEMENT TYPE.
3. USE COPPER CONDUCTORS ONLY.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY END USER WITH
RATING AS RECOMMENDED BY MANUFACTURER.
5. POWER MUST BE SUPPLIED TO CRANKCASE
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
HEATER MUST BE ON FOR 12 HOURS BEFORE
OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN COMPRESSOR DAMAGE.
6. MARK IN THE BOX FOUND AT THE UPPER RIGHT OF
THE RESPECTIVE OPTIONAL ITEM, IF THE OPTIONAL
ITEM IS INCLUDED IN THE UNIT.
380/415V-3Ph-50Hz
.
IF THE COLLER HEATER TAPE IS EN ABLE HGBS IS NOT POSSIBLE
30
Page 32
MICROPROCESSOR CONTROLLER
Sequence of Operation
The following describes the sequence of operation for a two screw compressor chiller unit.
Operation is similar for a one or four compressor unit.
For initial start-up, the following conditions must be met:
All power supplied to the unit shall be energized for 12 hours.
·
Control power switch on for at least 5 minutes.
·
All safety conditions satisfied.
·
Press ESC on the microcomputer keypad.
·
Chilled water pump running and chilled water flow switch contact closed.
·
Customer interlock contact closed, if any.
·
STAGE - ON SEQUENCE
Staging ON & OFF sequence, shall be accomplished by the Leaving water temperature control selection.
Stage #1:
If the Leaving Water Temperature is greater than the Stage 1- ON water temperature set point value, the Compressor #1
liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloaded
capacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.
As discharge pressure of Compressor #1 rises, the corresponding fans are energize accordingly to the fan stage-ON set
point. If the discharge pressure falls below the fan stage-OFF set point value, the corresponding fans will turn off.
Stage #2:
If the Leaving Water Temperature is greater than the Stage 2- ON water temperature set point value, the Compressor #2
liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloaded
capacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.
As discharge pressure of Compressor #2 rises, the corresponding fans are energize accordingly to the fan stage-ON set
point. If the discharge pressure falls below the fan stage-OFF set point value, the corresponding fans will turn off.
STAGE - OFF SEQUENCE
During the staging OFF, the first-in last-out sequence is adopted, if equalization of compressor timing is not selected.
Else the more used is switched off.
As the applied load decreases and when the leaving water temperature falls below the stage 2 -OFF water temperature
set point value, stage 2 is turned off.
If the leaving water temperature falls below the stage 1-OFF water temperature set point value, the stage 1 is turned off.
31
Page 33
TROUBLESHOOTING GUIDE
1) No LED display lit or erratic display behavior
a) Check serial cable integrity.
b) Check serial cable connections on both the User Interface Board and the Main Board.
c) Check correct and tight insertion of jumpers JU1 and JU2 on the Main Board.
d) Check correct and tight insertion of jumpers TU1 and TD1 on the User Interface Board and on the last board of the
network.
2) Controller does not respond to keypad
a) Check serial cable integrity.
b) Check serial cable connections on both the User Interface Board and the Main Board.
c) Check correct and tight insertion of jumpers TU1 and TD1 on the User Interface Board, main and/or auxiliary
board.
d) Check dip switches and integrity on the User Interface Board.
3) Several analog values reading incorrectly
a) Check correct and tight connection of the probes to the board.
b) Check the probe cable: test for short-circuit.
c) The pressure transducer probe is a 4-20mA transmitter check the polarity of the connection on the Board.
d) Check if the power supply voltage is into the specified limits: 24Vac +/- 10%.
e) The temperature probe is a PTC sensor disconnect it from the board and measure its resistance that is 1000 ohm
0
C or 1200 ohm at 500C.
at 25
4) Digital input reading incorrectly
a) Check if the auxiliary 220 Vac voltage is present in the electrical box.
b) Check if the AC input on the Board is correctly connected to one of the 220 Vac terminals in the electrical box.
c) Check if A1/A14 inputs are correctly connected with respect to the cabling diagram of the electrical box.
5) No LCD display lit or erratic display behavior
a) Check serial cable integrity.
b) Check serial cable connections on both the User Interface Board and the Main Board.
c) Check correct and tight insertion of jumpers JU1 and JU2 on the Main Board.
d) Check correct and tight insertion of jumpers TU1 and TD1 on the User Interface Board, main and/or auxiliary
board.
e) Adjust display intensity by rotating trimmer RV1 counter-clockwise (from the back side of the board).
6) No LED H1 blinking light on NG3 Board
a) Check power supply cable an connection.
b) Check if the power supply voltage is into the specified limits: 24Vac +/- 10%.
c) Check for fuse F1, replace with 1AT/250V if blown.
7) No display of leds on User Interface Board
a) Check serial cable integrity.
b) Check serial cable connections on both the User Interface Board and the Main Board.
c) Check correct and tight insertion of jumpers JU1 and JU2 on the Main Board.
d) Check correct and tight insertion of jumpers TU1 and TD1 on the User Interface Board, main and/or auxiliary
board.
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8) Auxilliary board not responding to commands
a) Check if LED H1 on Auxilliary board is blinking , if not go to point (6).
b) Check serial cable integrity.
c) Check serial cable connections on both the Main and the Auxilliary boards.
d) Check that jumpers JU1 and JU2 on the Auxilliary boards are not installed.
e) Check correct and tight insertion of jumpers TU1 and TD1 on the User Interface Board, main and/or auxiliary
board.
9) Analog Outputs not responding
a) Check Analog Output cables integrity (for short-circuit).
b) Check Analog Output cabling and connections.
c) Check if the power supply voltage is into the specified limits: 24VAC +/- 10%.
d) Check the fuse F1, replace with 1AT/250V if blown.
10) Digital Outputs not responding
a) Check Digital Output cables integrity (no short-circuit, no open-circuit).
b) Check digits Output cabling and connections.
c) Check if the power supply voltage is into the specified limits: 24VAC +/- 10%.
d) Check the fuse F1, replace with 1AT/250V if blown.
11) Serial Communication with Remote Monitoring Control not Functioning
a) Check the serial cable connected on plug-in board IS-485 mounted on the Main Board.
b) Check if the plug-in board is correctly mounted on the Main Board.
c) Check if jumpers X5 and X6 on the plug-in board IS-485 are correctly installed.
d) Check if jumpers X17 and X18 on the GATEWAY board are correctly installed.
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APPLICATION GUIDELINES
INTRODUCTION
These guidelines should be considered when designing systems and their installation utilizing COOLINE ASQ series
liquid chillers. Stable operation, performance and reliability of units is often dependent upon proper compliance with
these recommendations. When any application varies from these guidelines, it should be referred with Cooline Air Conditioners for specific recommendations.
UNIT SELECTION/SIZING
Unit selection procedure and capacities are provided in this catalog for proper selection. The COOLINE electronic selection program may also be utilized for this purpose.
Over sizing chillers beyond a maximum limit of 5 – 10 % in order to assure adequate capacity or considering future
expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operation
and excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operate
more efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized
unit is usually more costly to purchase, install and operate.
When over sizing is desired due to anticipation of future plant expansion, consider using multiple units. For example,
install a single chiller for the present load requirement and install a second chiller for the foreseen additional load demand
due to expansion. Further, it is also recommended that installing two chillers instead of a single chiller be considered in
applications where partial load operation at low capacities is necessary.
Operation of two chillers at higher loading is preferred to operating a single chiller at or near its minimum possible capacity.
FOULING FACTOR AND WATER REQUIREMENT
The tabulated performance data provided in this catalog are based on a fouling factor of 0.00010 hr-ft2-0F/Btu (0.000018
m2-0C/W). As fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other
fouling factors, apply appropriate correction factor from the table provided in this catalog.
These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water may
result in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading to
possible equipment damage. The more scale forming material and suspended solids in the system water, the greater the
chances of scale and deposit formation and fouling. These include calcium, magnesium, biological growth (algae, fungi
and bacteria), dirt, silt, clays, organic contaminants (oils), silica, etc. which should be kept to the minimum to retard scale
and deposit formation. In order to prevent corrosion and pitting, the pH value of the water flowing through the cooler must
be kept between 7 and 8.5. COOLINE recommends that a water treatment specialist is consulted to provide and maintain
water treatment, this is particularly critical with glycol systems.
EFFECT OF ALTITUDE ON UNIT CAPACITY
The tabulated performance data provided in this catalog are for use at or near sea level altitude application.
substantially above sea level, the decreased air density will reduce condenser capacity and therefore unit capacity. For unit
selection at these higher altitudes, apply appropriate correction factor from the table provided in this catalog.
At altitudes
HIGH AMBIENT CONSIDERATION
These chillers are designed for year round operation over a range of ambient temperatures. As a standard, these chillers
can start and operate satisfactorily up to 1250F (520C) ambient temperature at rated nominal voltage.
WATER FLOW RATES AND COOLER PRESSURE DROP
The maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog.
The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminar
flow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessive pressure drop and severe tube erosion.
During unit operation, water flow rate must not vary more than ± 5% from the design flow rate. The water flow switch should be
calibrated accordingly. The piping and pumping layout should be right for the application and must assure proper water return
and circulation. When using glycol solution, flow rate and pressure drop are higher than with water, therefore care must be
taken not to exceed the limits. In such applications, consult Cooline Air Conditioners for specific recommendations.
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COOLER FLUID (WATER OR GLYCOL) TEMPERATURES RANGE
Unit can start and pull down from 950F (350C) entering fluid temperature. The design leaving chilled fluid temperature
(LCWT) range as mentioned earlier in the tabulated performance data is 40 to 500F. The design entering chilled fluid
temperature range is 50 to 600F. The design cooler temperature drop (∆T) range is 5 to 150F.
The tabulated performance data provided in this catalog is based on a chilled water temperature drop of 100F. Units may
be operated at any desired temperature drop within the range of 5 to 150F as long as the temperature and flow limits are
not violated and appropriate correction factors are applied on the capacity and power input. The COOLINE electronic
selection program can be very handy in selecting equipment at different temperature drops.
It should be noted that temperature drop outside the aforesaid range is not permitted as it is beyond the optimum range of
control and could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the
equipment.
FLOW RATES AND/OR WATER TEMPERATURES OUT OF RANGE
Certain applications (particularly process cooling jobs) call for flow rates and/or water temperatures that are outside the
above mentioned limits/range. Our chillers can be utilized for these applications by selecting the chiller based on the
specific process load and making a suitable piping and mixing arrangement in order to bring the flow rates and/or water
temperatures relevant to the chiller within acceptable limits.
Example 1:
An application requires 240 GPM of water at 450F and the return water temperature is 650F.
A standard chiller can be used for this application as shown in the following basic schematic layout (single mixing arrangement).
45°F
500 GPM
45°F
240 GPM
200 TR
Chiller
45°F
260 GPM
54.6°F
500 GPM
65°F
240 GPM
Load
200 TR
Example 2:
An application requires 192 GPM of water at 650F and the return water temperature is 800F.
A standard chiller can be used for this application as shown in the following basic schematic layout (dual mixing arrangement).
45°F
340 GPM
45°F
82.2 GPM
65°F
192 GPM
120 TR
Chiller
340 GPM
53.4°F
45°F
257.8 GPM
80°F
109.8 GPM
Load
120 TR
53.4°F
340 GPM
80°F
82.2 GPM
35
80°F
192 GPM
Page 37
COOLER FREEZE PROTECTION
If the unit is located in an area where ambient temperatures fall below 320F (00C), cooler protection in the form of Ethylene
Glycol Solution is required to protect the cooler and fluid piping from low ambient freeze-up. This glycol solution must be
0
added to the water system loop to bring down the freezing point of water to a difference of 15
F (8.30C) below minimum
operating ambient temperature.
Using this glycol solution causes a variation in unit performance, flow rate and pressure drop, therefore appropriate
correction factors from the aforementioned table in this catalog should be applied.
MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATION
A multiple chiller system has two or more chillers connected by parallel or series piping to a common distribution system.
Multiple chiller arrangements offer the advantage of operational flexibility, standby capacity and less disruptive maintenance. Also, they offer some standby capacity if repair work must be done on a chiller from a set of duty chillers. Starting
in-rush current is reduced, as well as power costs at partial-load conditions.
A multiple chiller arrangement should be provided if the system load is greater than a single chiller capacity, standby
0
capability is desired, large temperature drop (greater than 15
F) is desired or application calls for splitting the total
capacity for better part load operation.
In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced water
flow. It is mandatory that cooler flow rates must be balanced to ensure proper flow to each chiller based on its respective
capacity. As mentioned above, two basic multiple chiller systems are used: parallel and series chilled water flow.
In the parallel arrangement, liquid to be chilled is divided among the liquid chillers; the multiple chilled streams are
combined again in a common line after chilling. Water temperatures (EWT or LWT) can be used to cycle units On and Off
based on the cooling demand. Parallel arrangements permit adding chillers in the future for plant expansion with the
appropriate considerations beforehand.
In the series arrangement, the chilled liquid pressure drop may be higher unless coolers with fewer liquid-side passes or
baffles are used. No over chilling by either unit is required, and compressor power consumption is lower than it is for the
parallel arrangement at partial loads. It is also possible to achieve higher overall entering to leaving temperature drops,
which may in turn provide the opportunity for lower chilled water design temperature, lower design flow and resulting
installation and operational cost savings. Series chiller arrangements can be controlled in several ways based on the
water temperatures depending on cooling demand.
A valved piping bypass is suggested around each chiller to facilitate future servicing as it gives the personnel an option
for service without a complete shutdown.
0
COOLINE recommends the parallel arrangement for design temperature drops (∆T) up to 15
0
ment beyond that i.e., 16 to 20
F. Complete design details on these parallel and series chilled water flow arrangements
F and the series arrange-
can be found in the ASHRAE handbooks and other design literature which should be referred by the designer in preparing
his detailed designs.
PIPING ARRANGEMENTS AND PLANT LAYOUT
Our chillers are suitable for incorporating in ‘Two Pipe’ single temperature systems or ‘Four Pipe’ independent load
systems. The system piping circuit (load distribution circuit) should be basically parallel piping either Direct Return or
Reverse Return system with a good pumping arrangement.
The method of circuiting and pumping is a judgment decision by the designer. The designer must weigh the pros and
cons of cost, nature of load and configuration of building, energy economics, flexibility, installation requirements and
others to determine the best arrangement for his project. In all cases, it must be ensured that the design water flow is
constantly maintained through the chillers at all stages of operation. Some suggested arrangements with basic schematic layouts are as follows:
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Page 38
A. Single or multiple chillers with constant water flow through chillers and load system:
CHWS
Chiller
LoadLoad
3-Way
Valve
3-Way
Valve
CHWR
Constant Speed Pump
In this type of arrangement, constant water flow through the chillers and load distribution piping circuit is maintained.
Before proceeding further, a brief explanation on the operation of a typical chilled water system / valves which is fundamental to the design or analysis of a system.
Where multiple zones of control are required, the various load devices are controlled first; then the source (chillers)
system capacity is controlled to follow the capacity requirement of the loads. Control valves are commonly used to control
loads. These valves control the capacity of each load by varying the amount of water flow through the load device.
Control valves for these applications are two-way (straight-through) and three-way valves. The effect of either valve is to
vary the amount of water flowing through the load device. With a two-way valve, as the valve strokes from full-open to fullclosed, the quantity of water flowing through the load gradually decreases from design flow to no flow. The three-way
mixing valve has the same effect on the load as the two way valve - as the load reduces, the quantity of water flowing
through the load decreases in proportion to the load and the difference amount is directed through a bypass.
In terms of load control, a two-way valve and a three-way valve perform identical functions—they both vary the flow
through the load as the load changes. The fundamental difference between the two-way valve and the three-way valve is
that as the source or distribution system sees the load, the two-way valve provides a variable flow load response and the
three-way valve provides a constant flow load response.
Referring to the foregoing schematic layout, this is a conventional system and is not as energy efficient as the two-way
valve systems especially on the pumping side due to constant water circulation in the system. On multiple chiller installations, pumps are required to operate continuously and the sequencing of chillers is dependent on water temperatures.
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B. Single or multiple chillers with constant water flow through chillers and variable water flow through load system:
FM-1
CHWS
Bypass
Line
Variable Speed Pump
Chiller
Bypass
Control
Valve
FM-2
System
Controller
CHWR
Load
2-Way
Valve
P
Load
2-Way
Valve
In this type of arrangement, constant water flow through the chillers is maintained, however the quantity of water flowing
through the load distribution piping system decreases in proportion to the load and the difference amount is directed
through a bypass pipe that connects the supply and return headers. Brief sequence of operation is as follows:
The bypass with its control valve and flow meter provides the design flow required through the chillers. Flow meter FM1
measures the actual flow to the chilled water system. The system flow is compared with the required flow for the chillers.
The difference is made up through the bypass and is monitored by flow meter FM2. This flow meter controls the bypass
valve to maintain the desired flow in the bypass based on the set points in the system controller (the valve is positioned
by sum of flow meters FM1 and FM2).
The speed of the chiller pumps is controlled by the differential pressure sensor/transmitter, maintaining the desired
differential pressure (∆P) across the cooling coils, their control valves and the branch piping. The pump speed is modulated within a certain range in order to reduce the pumping head and not to alter the water flow rate (the duty flow rate of
the pumps remains constant). Each chiller-pump combination operates independently from the remaining chillers and
each pump is shutdown when the respective chiller is stopped. Instead of using water temperature as an indicator of
demand, the sequencing of chillers is dependent on water flow. The chillers are rated in gallons per minute; the actual
flow to the system determines the number of chillers that should be in operation.
Energy is saved because the system head is reduced appreciably when there are light cooling loads on the system and
due to cycling of pumps.
Note: Some designers may consider installing constant speed pumps and utilize pressure relief bypass control valves
controlled by a differential pressure sensor/controller to maintain a fixed differential pressure between the supply and
return mains of the chilled water system in order to accommodate for the required chiller flow and to achieve some form
of variable volume system. This method is not recommended as it’s a wasteful practice because a considerable amount
of energy is lost, an almost constant volume system results and the pumping energy remains substantially that required
at full system flow and head.
Also, the problem with this system is improper control of the bypass valve which does not guarantee proper flow through
the chillers and high differential pressures in the control valves on the cooling coils when the system friction subsides at
low loads which can cause lifting of the valve stems or wire cutting of the valve seats. Further, as all the water must be
pumped at a head equal to or greater than the design head, the pump or pumps are forced to run up the pump head
capacity curve, which increases the overpressure on the system and also increases the wear on the pumps, since they
are forced to operate with high radial thrusts.
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C. Single or multiple chillers with constant water flow through chillers and variable water flow through load
system (primary/secondary pumping arrangement):
A
CHWS
Flow Sensor
Variable
CHWR
Load
2-Way
Valve
Load
P
2-Way
Valve
Constant Speed
Primary Pump
Speed Secondary Pump
Chiller
B
System
Controller
This system is called a Primary – Secondary System and in this arrangement, the generation zone is separated from the
transportation or distribution zone. In this type of arrangement also, constant water flow through the chillers is maintained, however the quantity of water flowing through the load distribution pump/piping system decreases in proportion to
the load and the difference amount is directed through a bypass pipe that connects the supply and return headers. This
bypass pipe forms a ‘Hydraulic Coupling’ between the points A – B and is also called as Common Bridge or Decoupling
Line. The sequence of operation is similar as the foregoing system with the following explanation:
The speed of the secondary chiller pump is controlled by the differential pressure sensor/transmitter, maintaining the
desired differential pressure (∆P) across the cooling coils, their control valves and the branch piping. This pump speed is
modulated within a broad range in order to reduce the pumping head and alter the water flow rate based on the changing
load conditions.
The primary pumps are constant speed pumps and the design flow rate through the chillers remains constant. Each
chiller-pump combination operates independently from the remaining chillers and each pump is shutdown when the
respective chiller is stopped. The sequencing of chillers is dependent on water flow. If greater flow is demanded than that
supplied by the chiller-pumps, return water is forced through the bypass into the supply header. This flow indicates a
need for additional chiller capacity and another chiller-pump starts. Excess bypass flow with reference to the set points in
the system controller in the opposite direction i.e., into the return header indicates overcapacity and the chiller-pumps are
turned off.
Energy is saved because the system head and water flow rate are reduced on the Secondary Pump when there are
partial cooling loads on the system and due to cycling of Primary Pumps.
UNIT LOCATION AND INSTALLATION
These chillers are designed for outdoor installation and can be installed at ground level or on a suitable rooftop location.
In order to achieve good operation, performance and trouble-free service, it is essential that the proposed installation
location and subsequent installing procedures meet the following requirements:
• The most important consideration while deciding upon the location of air cooled chillers is the provision for supply of
adequate ambient air to the condenser and removal of heated discharge air from the condenser. This is accomplished
by maintaining sufficient clearances which have been specified in this Catalog around the units and avoiding obstructions in the condenser air discharge area to prevent the possibility of warm air circulation. Further, the condenser fans
are propeller type and are not recommended for use with ductwork or other hindrances in the condenser air stream.
Where these requirements are not complied, the supply or discharge airflow restrictions or warm air recirculation will
cause higher condensing temperatures resulting in poor unit operation, higher power consumption and possible eventual failure of equipment.
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•
The unit’s longitudinal axis should be parallel to the prevailing wind direction in order to ensure a balanced air flow
through the condenser coils. Consideration should also be given to the possibility of down-drafts caused by adjacent
buildings, which may cause recirculation or uneven unit airflow. For locations where significant cross winds are expected, an enclosure of solid or louver type is recommended to prevent wind turbulence interfering with the unit airflow.
When units are installed in an enclosure, the enclosure height should not exceed the height of the unit.
•
The location should be selected for minimum sun exposure and away from hot air sources, steam, exhaust vents and
sources of airborne chemicals that could attack the condenser coils and steel parts of the unit. Avoid locations where
the sound output and air discharge from the units may be objectionable.
•
If the location is an area which is accessible to unauthorized persons, steps must be taken to prevent access to the unit
by means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage or possible
harm caused by unauthorized removal of panels or protective guards exposing rotating or high voltage components.
•
The clearance requirements prescribed above are necessary to maintain good airflow and provide access for unit
operation and maintenance. However, it is also necessary to consider access requirements based on practical considerations for servicing, cleaning and replacing large components.
•
The unit must be installed on a ONE-PIECE, FLAT and LEVELLED {within 1/2'' (13 mm) over its length and width} /
CONCRETE BASE that extends fully to support the unit. The carrying or supporting structure should be capable of
handling complete operating weight of the unit as given in the Physical Data tables in this Catalog.
•
For ground level installations, it must be ensured that the concrete base is stable and does not settle or dislocate upon
installation of the unit which can strain the refrigerant lines resulting in leaks and may also cause compressor oil return
problems. It is recommended that the concrete slab is provided with appropriate footings. The slab should not be
connected to the main building foundation to avoid noise and vibration transmission.
•
For rooftop installations, choose a place with adequate structural strength to safely support the entire operating weight
of the unit. The unit shall be mounted on a concrete slab similar to ground installations. The roof must be reinforced for
supporting the individual point loads at the mounting isolator locations. It must be checked and ensured that the
concrete base is perfectly horizontal and levelled, especially if the roof has been pitched to aid in water removal. It
should be determined prior to installation if any special treatment is required to assure a levelled installation else it
could lead to the above mentioned problems.
•
Vibration isolators are necessary for installing these chillers in order to minimize the transmission of vibrations. The
two types of vibration isolators generally utilized for mounting these units are Neoprene Pads and Spring Isolators.
Neoprene Pads are recommended for ground level normal installations jobs where vibration isolation is not critical and
job costs must be kept to a minimum. Spring Isolators are recommended for ground level installations which are noisesensitive areas or exposed to wind loads and all roof top installations. For critical installations (extremely noise and
vibration sensitive areas), follow the recommendations of structural and acoustical consultants.
•
Based on the specific project requirements, choose the type of vibration isolators best suited for the application. Carefully select the vibration isolators’ models / configuration based on the respective point loads and place each mount in
its correct position following the Load Distribution Data and Mounting Drawings provided in this Catalog. Refer to the
Schematic Mounting Layout drawings provided in the IOM manual of these chillers for further details in this regard.
COOLER PIPING CONNECTIONS
The following pertinent guidelines are served to ensure satisfactory operation of the units. Failure to follow these recommendations may cause improper operation and loss of performance, damage to the unit and difficulty in servicing and
maintenance:
•
Water piping must be connected correctly to the unit i.e., water must enter from the inlet connection on the cooler and
leave from the outlet connection.
•
A flow switch must be installed in the field piping at the outlet of the cooler (in horizontal piping) and wired back to the unit
control panel using shielded cable. There should be a straight run of piping of at least five pipe diameters on either side
of the flow switch. Paddle type flow switches can be obtained from COOLINE which are supplied as optional items.
•
The chilled water pump(s) installed in the piping system should discharge directly into the unit cooler. The pump(s)
may be controlled external to the unit - but an interlock must be wired to the unit control panel (as shown in the wiring
diagram) so that the unit can start only upon proof of pump operation.
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•
Flexible connections suitably selected for the fluid and pressure involved should be provided as mandatory in order to
minimize transmission of vibrations to the piping / building as some movement of the unit can be expected during
normal operation. The piping and fittings must be separately supported to prevent any loading on the cooler.
•
The cooler must be protected by a strainer, preferably of 20 mesh, fitted as close as possible to the liquid inlet connection, and provided with a means of local isolation.
•
Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler.
Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if any
variations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop
across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstream
from any connection (flange etc.) but as near to the cooler as possible.
•
Drain and air vent connections should be provided at all low and high points in the piping system to permit complete
drainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for use
in all lines to facilitate servicing.
•
The system water piping must be flushed thoroughly before connecting to the unit cooler. The cooler must not be
exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and
valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance to
isolate the cooler without disrupting flow to other units.
•
The following is a suggested piping arrangement at the chiller for single unit installations. For multiple chiller installations, each unit should be piped as shown:
Isolating Valve - Normally Open
Isolating Valve - Normally Closed
Balancing Valve
Flow meter
Strainer
OUT
IN
Pressure tapping
Flow Switch
Connection (flanged / Victaulic)
Pipe work
Flexible connection
Note: For chillers with two coolers, the connecting pipes for entering and leaving water on one cooler must be joined to
the corresponding pipes on the other cooler before connecting to the main headers in the system piping.
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CHILLED FLUID VOLUME REQUIREMENT
The volume of water in a piping system loop is critical to the smooth and proper operation of a chilled water system. If
sufficient volume of water is not there in the system, the temperature control can be lost resulting in erratic system
operation and excessive compressor cycling. Therefore, to prevent this effect of a ‘Short Water Loop’ ensure that total
volume of water in the piping system loop equals or exceeds 3 Gallons per Nominal Ton of cooling capacity for standard
air conditioning applications and 6 Gallons per Nominal Ton of cooling capacity for process cooling jobs where accuracy
is vital and applications requiring operation at very low ambient temperatures and low loading conditions.
For example, chiller model ASQ100B operating with a design water flow rate of 205 GPM for a standard air conditioning
application would require 100 (Nom. Cap.) x 3 = 300 Gallons of water in the piping system loop.
To achieve the aforementioned water volume requirements, it may be necessary to install a tank in the piping system loop to
increase the volume of water in the system and therefore, reduce the rate of change of return water temperature. This tank
should be provided on the return water side to the chiller and the tank should be baffled to ensure that there is no stratification
and the entering stream thoroughly mixes with the tank water. See recommended tank design schematics below:
TANK SCHEMATIC
SUGGESTIONS ON SYSTEM DESIGN AND PIPING PRACTICES
The prospective chilled water system should be designed to the specific requirements of the owner and to achieve the
most efficient system possible. Following are some recommendations:
•
The first decision a designer of a chilled water system must make is the selection of the temperature differential.
Temperature differential is the difference between the supply water and the return water temperatures. There is no one
temperature difference for all chilled water systems. The actual temperature difference that is selected for a specific
installation is determined by the cost of the cooling coils for various temperature differences and the effect that higher
differences may have on the operating cost of the chillers. A careful balance between energy savings and first cost
should be made by the designer. These are the decisions that must be made by the designer for each application and
only experienced designers should entertain water temperature differences in excess of 12
tems. A number of conditions must be recognized before making the final selection of temperature differential:
a) An increase in temperature differential decreases water flow and therefore saves pumping energy.
b) An increase in temperature differential may increase the cost of cooling coils that must operate with a higher mean
temperature difference.
c) Higher temperature differentials increase the possibilities of loss of temperature difference in coils due to dirt on the
air side and chemical deposits on the water side of them.
d) Laminar flow on the water side due to lower velocities at low loads on a coil is always a concern of the water system
designer. The possibility of laminar flow is greater with higher temperature differences. Laminar flow reduces the
heat-transfer rate and should not occur in a coil at any point in its load range. Many systems operate inefficiently
because of coils that were selected at too low a friction loss through them at design load; therefore, at reduced
loads and flows, they operate with laminar flow.
0
F on chilled water sys-
42
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•
Control of Return Water Temperature: Return water temperature is one of the most important operating values for a
chilled water system. It tells the operator just how good a job the control system and coils are doing in converting
energy from the chillers to the air or water systems that are cooling the building. This is such a basic criterion that it
should be addressed early in the design of a chilled water system. The proper method of controlling return temperature
is through the correct selection of control valves and cooling coils. In conclusion, one of the designer’s most important
tasks is the selection of a sound temperature differential that will provide maximum possible system efficiency. The
second step in this process is to ensure that the differential is maintained after the system is commissioned.
•
The water system should be configured to distribute the water efficiently with a minimum use of energy-wasting
devices. These devices are listed here:
a) Three-way temperature control valves
b) Balancing valves, manual or automatic
c) Pressure-reducing or pressure-regulating valves
•
The piping should be designed without
a) Reducing flanges or threaded reducing couplings
b) Bullhead connections (e.g., two streams connected to the run connections of a tee with the discharge on the branch
of the tee)
•
The friction for the piping should be calculated for all pipe runs, fittings and valves.
•
Cooling coils should be selected with a high enough water velocity in the tubes to avoid laminar flow throughout the
normal load range imposed on the coils.
•
Coil control valves and their actuators should be sized to ensure that they can operate at all loads on the system
without lifting the valve head off the valve seat.
•
Expansion tank should be provided to so that water volume changes can be accommodated. Expansion tanks are
generally connected to the suction side of the pump - lowest pressure point.
•
Pumps in parallel must always operate at the same speed. There may be some exceptional cases where parallel
pumps are operated at different speeds, but only experienced designers should make evaluations for such a proposed
operation. Also, it is better to use pumps of the same size when operating them in parallel. Variable speed pumps
should be controlled so that pumps operating in parallel never have more than one percent difference in actual operating speed. Mixing of constant and variable speed pumps in parallel operation is wrong and leads to disastrous
results.
•
Distribution pumps should be selected for maximum efficiency at the design condition and within the economic constraints of the project. Distribution pumps should be added and subtracted to avoid operation of pumps at points of
high thrust and poor efficiency. Pump sequencing should achieve maximum possible system efficiency.
•
Differential pressure control (bypass) valves should never be installed at the pump discharges.
•
Check valves should be provided in pump discharges when pumps are operating in parallel. Pump discharge check
valves should be center guided, spring loaded, disc type check valves and should be sized so that the check valve is
full open at design flow rate. Generally this will require the check valve to be one pipe size smaller than the connecting
piping.
•
Circuiting Chilled water to Multiple Chillers : There are fundamentals for the circuiting of chillers that should not be
violated in order to achieve maximum efficiency. Some of these are:
a) Design the piping arrangement so that energy consumption of chillers is not increased.
b) Arrange the piping so that all chillers receive the same return water temperature.
c) Ensure that the required design water flow through the coolers is always maintained.
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RIGGING INSTRUCTIONS
ATTENTION TO RIGGERS
Hook rigging sling thru holes in base rail, as shown below.
Holes in base rail are centered around the unit center of gravity.
Center of gravity is not unit center line.
Ensure center of gravity aligns with the main lifting point before lifting.
Use spreader bar when rigging, to prevent the slings from damaging the unit.
CAUTION
All panels should be in place when rigging.
Care must be taken to avoid damage to the coils during handling.
Insert packing material between coils & slings as necessary.