McQuay Chilled Water Solution
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Transcript of McQuay Chilled Water Solution
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5ACV30 CR5ACV30 CR
5ACV55/75 CR5ACV55/75 CR
5ACV100/135/210 CR5ACV100/135/210 CR
Chilled Water System :
Air-Cooled Inverter Mini Chiller
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System Schematic DiagramSystem Schematic Diagram
Advantages of Chilled Water SystemAdvantages of Chilled Water System
Product LineupProduct Lineup Design & ApplicationDesign & Application
Content
Product FeaturesProduct Features
Schematic Diagram & ComponentsSchematic Diagram & Components
Installation & CommissioningInstallation & Commissioning Self Diagnosis & TroubleshootingSelf Diagnosis & Troubleshooting
Smart ManagerSmart Manager
Selection SoftwareSelection Software
CompetitorCompetitors Products Comparisons Products Comparison
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System Schematic Diagram
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System Schematic Diagram
Brazed Plate Heat Exchanger(cooler)
Water
45oF
55oF
Refrigerant Cycle CompressorTXV
Liquid receiver
FCU
StorageTank
Pump
Chilledwater out
Chilled
water in
Water Circuit
Condenser
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Advantages of
Chilled WaterSystem
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Quiet Operation
Simple on Site
Installation
Versatility in
System Coupling
Flexible in Installation
And Commissioning
Low Cost of
Installation
Chilled WaterChilled Water
AdvantagesAdvantages
Long PipingApplication
Centralized
ControlMultiple Zone
Temperature
Control
Advantages of Chilled Water System
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Offers flexibility
during installation
Advantages of Chilled Water System
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Advantages of Chilled Water System
No on-site refrigerant charge
No time consuming refrigerant balancing
and adjustment
Eliminate accident or malfunction
Light weight and compact size for ease of
handling
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Advantages of Chilled Water System
Quiet operation due to minimized
outdoor units and mini chiller can
be placed far away from room
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Advantages of Chilled Water System
One to One
One to many
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Advantages of Chilled Water System
versus
Chilled Water System DX System
Water
PVC
Refrigerant
Copper
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Advantages of Chilled Water System
Year Round Comfort
Multiple Temperature Zone Control
ack To Content
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Product Lineup
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Product Lineup
Cooling Only/ Heat Pump Model Cooling Only/ Heat Pump Model
Cooling Only/ Heat Pump Model Cooling Only/ Heat Pump Model
Heat Pump
055
MAC- CSeries
M4AC-CSeries
120100 150
M5AC- CSeries
080060050040030025020000
Btu/h
055
MAC- CSeries
M4AC-CSeries
120100 150
M5AC- CSeries
080060050040030025020000
Btu/h
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Product Lineup
M5ACV- CSeries
210135100075055030000
Btu/h
M5ACV- CSeries
210135100075055030000
Btu/h
Heat Pump Model
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Design & Application
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Design & Application
Understand Clients requirement Application - feasible Installation/service-able Budget Inspection of job site
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Design & Application
Site survey Building Load Calculation
- equipment size Equipment Selection
- type of system & equipment
system design:- piping; pump; controls; storage tank;
installation and service maintenance;
water treatment.
cost of equipment operation cost
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Design & Application
Where to install the chiller and fan coil units
Determine the pipe route and installation / servicing /
maintenance consideration
Building Load estimation for both chiller and Fan coil units (building orientation/size/application,
i.e. pub; restaurant; office.....)
Access to the building for delivery and maintenance
location of other building services
1. Site Survey
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Design & Application
OYL MANUFACTURING CO. SDN BHD
COOLING LOAD ESTIMATION
PROJECT NAME : SK Bungalow DATE: 28/2/2001
LOCATION : Penthouse
AREA = 2000 HEIGHT = 15 NO.OF PEOPLE = 4
CFM/PERSON= 15 VENT, CFM = 500 B.F. = 0.15
ROOM TEMP = 75 ROOM RH% =
TEMP DIFF. (ROOM & OUTDOOR) = 20 MOISTURE DIFF. = 80
GAIN/TD BTU/HR GAIN/TD BTU/HR
OUTDOOR TEMP CORRN= -2 0
NE GLASS 600 0.76 45 20,520 22 10,032
E GLASS 0.76 106 0 35 0
SE GLASS 0.76 97 0 32 0
S GLASS 0.76 10 0 8 0
SW GLASS 600 0.76 30 13,680 91 41,496
W GLASS 0.76 44 0 132 0
NW GLASS 0.76 28 0 75 0
N GLASS 0.76 11 0 11 0
SHADED GLASS 0.76 11 0 11 0
N WALL 0.49 1 0 13 0
NE WALL 200 0.49 53 5,194 17 1,666E WALL 0.49 36 0 15 0
SE WALL 600 0.49 16 4,704 16 4,704
S WALL 0.49 1 0 14 0
SW WALL 200 0.49 1 98 30 2,940
W WALL 0.49 2 0 39 0
NW WALL 600 0.49 1 294 33 9,702
ROOF 2,000 0.23 6 2,760 38 17,480
ALL GLS TRANSM 1,200 1.13 -2 (2,712) 0 0
PARTITION 0.45 -2 0 0 0
CEILING 0.3 0 0 0 0
FLOOR 0.49 -7 0 -5 0
PEOPLE,(S) 4 1 245 980 245 980
POWER,KW 4 1 3414 13,656 3414 13,656
LIGHTS,WATTS 2,000 1.25 3.414 8,535 3.414 8,535
MISC.HEAT (S) 1 1 0 1 0
SAFETY % (S) 5 3,385 5,560DT.GN/LK/FAN% 8 0 0
OA HEAT(S)*BF 0 0
PEOPLE,(L) 4 1 205 820 205 820
MISC.HEAT (L) 1 1 0 1 0
SAFETY % (L) 10 82 82
DUCT LEAK% 8 0 0
OA HEAT(L)*BF 4,080 4,080
OA HEAT(S)1-BF 0 0
OA HEAT(L)1-BF 23,120 23,120
GRAND TOTAL HEAT = 99,196 144,853
COOLING TONS = 8.27 12.07
ROOM SENSIBLE HEAT = 71,094 116,751
TOTAL OA HEAT = 27,200 27,200
4.00PM SEP/MARAREA/QTYITEM FACTORS
10.00 AM SEP/MAR
2. Building Load Estimation
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Design & Application
am 4.0 kW
pm 3.0 kW
am 3.5 kW
pm 5.0 kW
am 3.5 kW
pm 5.5 kW
am 3.5 kW
pm 2.5 kW
am 4.5 kW
pm 3.0 kW
am 4.5 kW
pm 3.0 kWam 3.8 kW
pm 3.5 kW
am 9.0 kW
pm 8.0 kW
am 3.5 kW
pm 5.0 kW
am 3.8 kW
pm 3.5 kW
am 3.8 kW
pm 3.5 kW
Room 9
Room 11
Room 10
Room 8
Room 7
Room 6Room 5
Room 4
Room 3
Room 2
Room 1
UU2. Building Load Estimation
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Design & Application
am 4.0 kW
pm 3.0 kW
am 3.5 kW
pm 5.0 kW
am 3.5 kW
pm 5.5 kW
am 3.5 kW
pm 2.5 kW
am 4.5 kW
pm 3.0 kW
am 4.5 kW
pm 3.0 kWam 3.8 kW
pm 3.5 kW
am 9.0 kW
pm 8.0 kW
am 3.5 kW
pm 5.0 kW
am 3.8 kW
pm 3.5 kW
am 3.8 kW
pm 3.5 kW
Room 9
Room 11
Room 10
Room 8
Room 7
Room 6Room 5
Room 4
Room 3
Room 2
Room 1
am 4.0 kW
pm 3.0 kW
am 3.5 kW
pm 5.0 kW
am 3.5 kW
pm 5.5 kW
am 3.5 kW
pm 2.5 kW
am 4.5 kW
pm 3.0 kW
am 4.5 kW
pm 3.0 kWam 3.8 kW
pm 3.5 kW
am 9.0 kW
pm 8.0 kW
am 3.5 kW
pm 5.0 kW
am 3.8 kW
pm 3.5 kW
am 3.8 kW
pm 3.5 kW
Room 9
Room 11
Room 10
Room 8
Room 7
Room 6Room 5
Room 4
Room 3
Room 2
Room 1
U2. Building Load Estimation Diversity Factor
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Design & Application
Room a.m. p.m. DX
Room 1 4.0 2.5 4.0
Room 2 4.5 3.0 4.5Room 3 4.5 3.0 4.5
Room 4 9.0 8.0 9.0
Room 5 3.8 3.5 3.8
Room 6 3.8 3.5 3.8
Room 7 3.8 3.5 3.8Room 8 3.5 4.5 4.5
Room 9 3.5 5.0 5.0
Room 10 3.5 5.5 5.5
Room 11 3.5 5.5 5.5
Total 47.4 47.5 53.9
Chiller Capacity : 45.7 kW
DX unit capacity(total) : 53.9 kW
Saving ~ 6.4 kW(11.9 % in this case)
Room a.m. p.m. DX
Room 1 4.0 2.5 4.0
Room 2 4.5 3.0 4.5Room 3 4.5 3.0 4.5
Room 4 9.0 8.0 9.0
Room 5 3.8 3.5 3.8
Room 6 3.8 3.5 3.8
Room 7 3.8 3.5 3.8Room 8 3.5 4.5 4.5
Room 9 3.5 5.0 5.0
Room 10 3.5 5.5 5.5
Room 11 3.5 5.5 5.5
Total 47.4 47.5 53.9
Chiller Capacity : 45.7 kW
DX unit capacity(total) : 53.9 kW
Saving ~ 6.4 kW(11.9 % in this case)
2. Building Load Estimation Diversity Factor
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Criteria to select a mini chiller: capacity required
water entering condition
water leaving condition
ambient condition
cooling/ heating mode required?
3. Chiller Selection
Design & Application
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If the chiller is operate under nonstandard condition, the capacity canbe calculated from the performancecharacteristic, flow rate and pressure
drop then being determined.
Samp
leofpe
rform
ance
chart
3. Chiller Selection
Design & Application
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Upon chiller units being selected, water flowrate of chiller and pressure drop also need tobe determined.
Water flow rate,
Liters/Min = Total Capacity, W70 x Temp. Diff. O C
3. Chiller Selection
Design & Application
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From Water flow rate,
the pressure dropacross the chiller unitsneed to bedetermined for pumpselection.
Find the pressure
drop from the datatable ->
3. Chiller Selection
Design & Application
&
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Example 1
Please select a cooling only chiller operate at ambient
temperature 35 o C, leaving water temperature 5 o C.
Minimum capacity required is 25 kW. Determine the
required flow rate and the internal pressure loss.
Entering water temperature is 12 o C.
3. Chiller Selection
Design & Application
D i & A li ti
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From performance chart, AC100 C selected. Thecapacity at 35 o C at 5 o C leaving water temperatureis 25.90 kW.
Hence the flow rate, liters/min : 2590070 x 5
= 74 liters/min
= 1.23 liters/s= 4.44 m3/hr
3. Chiller Selection
Design & Application
Solution:
D i & A li ti
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From 4.44 m
3
/hr and the table above, the pressure drop forAC100C is 47.5 kPa
3. Chiller Selection
Design & Application
Solution:
D i & A li ti
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From the total cooling capacity shown in the Table 1,
calculate the water flow rate by using the following
formula:
Liters/Min = Total Cooling Capacity, W70 x Temperature Rise o C
USGPM = Total Cooling Capacity, Btu/H500 x Temperature Rise o F
4. FCU Selection
Design & Application
Example 2:
D i & A li ti
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Table 1: Total Cooling Capacity
Room am Load, kW pm Load , kW Fan Coil Unit, kW
Room 1 4.0 2.5 4.0Room 2 4.5 3.0 4.5Room 3 4.5 3.0 4.5Room 4 9.0 8.0 9.0Room 5 3.8 3.5 3.8
Room 6 3.8 3.5 3.8Room 7 3.8 3.5 3.8Room 8 3.5 4.5 4.5Room 9 3.5 5.0 5.0Room 10 3.5 5.5 5.5
Room 11 3.5 5.5 5.5
4. FCU Selection
Design & Application
Fan Coil units Capacity can be determined by Cooling
Capacity Performance Chart as below:
Design & Application
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Line A
Line D Line C
Line B
Point 1
Point 4 Point 3
Point 2
Water temperature rise o C
E n
t e r i n g
W a t e r
o C
Total Cooling & Sensible Capacity, kW
Entering Air WB oC
Entering Air DB oC
4. FCU Selection
Design & Application
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Line A
Line D Line C
Line B
Point 1
Point 4 Point 3
Point 2
Water temperature rise o C
E n
t e r i n g
W a t
e ro
C
Total Cooling & Sensible Capacity, kW
Entering Air WB oC
Entering Air DB oC
Point 1 - Temperature Rise in o C Line A - Determine the temperature rise
Point 2 - Entering water temperature o C and entering water temperature
Point 3 - Entering air temperature (WB) o C Line B - To cross on coil condition, I.e.
Point 4 - Entering air temperature (DB)
o
C WB and DBPoint 5 - Total Cooling Capacity Line C- Intersection point at WB
Point 6 - Sensible Capacity determine the total cooling capacity
Line D- Intersection point at DB determine
Sensible Capacity
4. FCU Selection
Design & Application
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Assumption, if cooling capacity of 8.4 kW andentering water at 5 o C, leaving water at 10 o C,then :
Liters/Min = Total Cooling Capacity, W70 x Temperature Rise o C= 8,400 = 24 liters/ min
70 x 5
4. FCU Selection
Design & Application
Solution:
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4. FCU Selection
Design & Application
Find pressure drop at this flow rate fromTable ofpressure drop
Design & Application
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With pre-determine flow rate, pressure drop of
the fan coil can be determined interpolation methodusing data given in the pressure drop table :
Assumption: Pressure Drop for CC30 CW at flow rate of
24 liters/Min = XX - 7,72 = 24.00 - 20.14
11.55 - 7,72 25.21 - 20.14
Water pressure drop, X = 7.83kPa
4. FCU Selection
Design & Application
Design & Application
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With pre-determine flow rate, Heating Capacity can beestimated from the heating Capacity Performance Chart
4. FCU Selection
Design & Application
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Standard heating capacity is based on EWT at 60 o C and EAT at21.1 o C, if operating temperature different from the standard, then
correction factor need to apply based on table below:
37.8 43.3 45.0 48.8 54.4 60.0 65.5 71.1 76.7 82.2 87.7
4.4 0.838 0.980 1.021 1.122 1.265 1.406 1.552 1.698 1.845 1.988 2.134
7.2 0.771 0.913 0.954 1.055 1.198 1.379 1.485 1.631 1.778 1.920 2.067
10.0 0.700 0.843 0.885 0.986 0.130 1.272 1.417 1.563 1.710 1.853 2.000
12.7 0.631 0.773 0.817 0.918 1.062 1.205 1.349 1.495 1.639 1.786 1.931
15.5 0.562 0.705 0.748 0.848 0.992 1.137 1.281 1.427 1.572 1.719 1.865
18.3 0.493 0.636 0.679 0.779 0.923 1.070 1.212 1.358 1.504 1.650 1.799
21.1 0.424 0.567 0.610 0.711 0.855 1.000 1.146 1.290 1.438 1.583 1.730
23.9 0.354 0.498 0.541 0.642 0.786 0.932 1.078 1.222 1.369 1.515 1.664
26.7 0.284 0.428 0.471 0.573 0.717 0.863 1.008 1.155 1.302 1.449 1.597
WATER ENTERING TEMPERATURE , C
HEATING CAPACITY CORRECTION FACTORS
EAT oC
Adjusted heating capacity, W ( @ Nominal air Flow ) = base heating capacity ( @ nominal. 60C EWT, 21.1C EAT) x Heating Capacity Correction Factor
Example at 54.4 o C water entering temperature and 23.9 o C air enteringtemperature, the correction factor is o.786
4. FCU Selection
Design & Application
Design & Application
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2 basic categories of water pipe worksystems, i.e.
Close System Open System
5. Water Piping Design
Design & Application
Design & Application
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Close System
Pipe installation forms a close circuit minimum
water loss in these type of system. Expansion
tank / make up water tank is sufficient to top upthe loss water
5. Water Piping Design
Design & Application
Design & Application
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Mini chiller is designed with applicationof a close water piping system.
Possible to use the unit with an opensystem by adding a buffer / intermediate
tank and pump.
5. Water Piping Design
Design & Application
Design & Application
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Open System
Pipe works form an open loop. Usually
use for cooling tower, formation of alga /bacteria is normal. Water treatment required
5. Water Piping Design
Design & Application
Design & Application
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If buffer tank being used, Baffle plate install to prevent return water mixing with
chilled water Suitable to use for multiple chiller operation Water tank can be sized accordingly as storage to allow
longer cycled off period for chiller, hence saving energy Care to ensure no air leakage along pump suction line
to prevent air trap - automatic air vent Take care of the water quality, water treatment
required
Use only when necessary, i.e. total water volume isinsufficient and need buffer storage to take care ofactual requirement / multiple chiller / standard built inpump head insufficient
5. Water Piping Design
g pp
Design & Application
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Open System
5. Water Piping Design
g pp
Water out
Water inMini Chiller Unit
Return water from fan coil units
Supply water tofan coil units
Secondary pump
TankAir vent
Baffle plate
Design & Application
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Type of piping system
Series
Diverting Parallel direct return
Parallel reverse return
5. Water Piping Design
g pp
Design & Application
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Type of piping system - Series
5. Water Piping Design
g pp
FCU 1 FCU 2
FCU 4 FCU 3
Water out
Water inMini Chiller Unit
Design & Application
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Advantages Low pipe cost
5. Water Piping Design
Disadvantages Each fan coil cannot be control individually
High pressure drop
Type of piping system - Series
Design & Application
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Type of piping system - Diverting
5. Water Piping Design
Mini Chiller Unit
Water out
Water in FCU 4 FCU 3
FCU 2FCU 1
Design & Application
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Advantages Individual control of each fan coils
5. Water Piping Design
Disadvantages Only fan coil units with low pressure drops suitable Low water velocity, air vent required
Entering water temperature to fan coil units different.
Type of piping system - Diverting
Design & Application
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Horizontal Installation
Type of piping system - Parallel Direct Return
5. Water Piping Design
Mini Chiller Unit
Water out
Water in
Fan Coil Uni
Design & Application
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5. Water Piping Design
Type of piping system - Parallel Direct Return
Mini Chiller Unit
Water out
Water in
Fan Coil Units
Vertical Installation
Design & Application
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1st in 1st out
Supply and return pipe length uneven
Proper balancing of water flow required
More economical compare to reverse return type
5. Water Piping Design
Type of piping system - Parallel Direct Return
Design & Application
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Horizontal Installation
Type of piping system - Parallel Reverse Return
5. Water Piping Design
Mini Chiller Unit
Water out
Water in
Fan Coil Units
Design & Application
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5. Water Piping Design
Type of piping system - Parallel Reverse Return
Vertical Installation
Mini Chiller Unit
Water out
Water in
Fan Coil Units
Design & Application
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1st in - Last out concept
Supply and return pipes equal length simple balancing
Use for fan coil units that have same or nearly thesame pressure drop
High rise building required extra length and weight ofpipe - not economical
5. Water Piping Design
Type of piping system - Parallel Reverse Return
Design & Application
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Type of pipes and fitt ings
There are several types of pipe that normally use in for
water piping
Black carbon steel pipe Copper pipe
PVC pipe
5. Water Piping Design
Design & Application
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Black carbon steel pipe
Joint by arc welding; thread; flange with gasket Most commonly used in chiller installation
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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Copper pipe
High resistance to corrosion and ease installation High cost Can be joint by brazing; soldering; flare joint
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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PVC pipes
Light weight Corrosion resistance Not suitable for high temperature application
Installed with more support(shorter span)
UPVC generally up to 60 oC usage CPVC higher temperature application Method to joint : solvent cementing / welding; thread
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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Galvanized iron(GI) is not recommended as Zinc coating on
the GI pipe will have an electrolytic reaction with the copper
components in the system, i.e. BPHE; fan coil heat
exchanger. The zinc will be sacrificial metal and deposit itself
on the copper surface
Zinc surface slowly eroded Zinc deposit on the copper surface will retard heat transfer
process
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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Fitting for steel pipe, treaded
90 o elbow tee joint reducer connector
union nipple flange
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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Fitting for Copper pipes - expanded end for brazing or
threaded end
90 o elbow Reducer Tee joint Connector
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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Fitting for PVC pipes (with treaded end-can joint tosteel pipe of fitting
90 o elbow Tee joint Connector Adapter
Socket Union Reducer
5. Water Piping Design
Type of pipes and fitt ings
Design & Application
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Type of pipes and valves
Valves- One of the important component in a water piping
system with the following functions:
To isolate a component from the system - enableeasy servicing/maintenance
To regulate water flow rate To divert / mix flow direction To prevent back flow To relieve / regulate pressure
5. Water Piping Design
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Gate valve - to be fully open / fully close; not suitable forregulate or control flow; for isolation / shutoff purposes
Isolation is important for maintenance purposes. The minimumrequirement is : Chiller supply and return connection; pump
suction and discharge connection; fan coil unit supply andreturn connection; cooling coil bypass( if 3-way motorized valveis fitted at the coil
5. Water Piping Design
Type of pipes and valves
Design & Application
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Globe valves - for throttling duty where positive shutoff isrequired
5. Water Piping Design
Type of pipes and valves
Design & Application
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Ball valve - for throttling duty, used with smaller pipe diameter
Butterfly valve - has low pressure drops; easy and fastoperation; can be used for throttling duty
5. Water Piping Design
Type of pipes and valves
Design & Application
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Balancing valve - for throttling duty to regulate water flowrate for balancing purposes. Pressure tapping port provided for
pressure drop measurement
Check valve - prevent back flush
5. Water Piping Design
Type of pipes and valves
Design & Application
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Actuators
- Automatic valves operate for automatic controller to
control the fluid flow. Common actuators are :
Solenoid valve electric motorized valve pneumatic valve
5. Water Piping Design
Type of pipes and valves
Design & Application
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Solenoid valve - allows wither totally open or closeposition. A magnetic coil will lifts or drops a plunger to open orclose the flow of water
5. Water Piping Design
Type of pipes and valves
Design & Application
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Electric motorized valve - usually this actuator hasa built in 24V motor to produce a rotary motion to open orclose the valve. Flexible in opening position(depends onexternal signal); high cost
5. Water Piping Design
Type of pipes and valves
Design & Application
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Pneumatic valve - valve has a flexible diaphragm -operate by injecting air pressure in to the valve to position thevalve open / close. High cost
5. Water Piping Design
Type of pipes and valves
Design & Application
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In the chilled water pipe system, automatic control valves usedmay be either 2-way or 3-way. All three types of actuatorabove may be used.
2-way valve - water flows into the inlet port and exits fromthe outlet port. Actuator used to vary the flow rate
5. Water Piping Design
Type of pipes and valves
Design & Application
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3-way valves - 3 ports are available
1. Mixing valve
B
A
A + B
2 stream of water blends into 1 stream
2. Diverting valve
A + B
A
B
Split 1 stream into 2 different streams
5. Water Piping Design
Type of pipes and valves
Design & Application
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Installation sample of 2-way valves
FCU
Supply Return
5. Water Piping Design
Design & Application
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Installation sample of 3-way valves
FCU
FCU
Supply Return
Diverting
Mixing
5. Water Piping Design
Design & Application
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Wrong Installation sample of 2-way valves
5. Water Piping Design
FCU
Mini Chiller Unit
FCU
Problem : both FCU off, solenoid valve off, no water flow.
However pump still running, pressure built up, pump
problem
Design & Application
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Add bypass pipe to relief pressure
5. Water Piping Design
Mini Chiller Unit
FCU
FCU
FCU
P
Differential pressure transmitter to monitor the
amount of water used. If pressure goes higherthan preset value, will activate relief valve and
bypass water
Installation sample of 2-way valves pre-cautions
Design & Application
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5. Water Piping DesignInstallation sample of 2-way valves pre-cautions
Mini Chiller Unit
FC
U
FC
U
FC
U
P
INV
When differential pressure become higher, the Inverter will
slow down the water pump to maintain the heap pressure.
If no demand, water pump stop running
Use a variable speed drive for secondary pump
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Modify control wiring for chiller and fan coil unit
The above method of 2-way valves installation incur high cost due toextra piping, fittings, pressure transmitter...... There is possible to
change the control wiring of the system. Normally when the fan coilunit thermostat cut-off, the power supply to control the 2-way valvewill be off. It is possible to run a line from the thermostat to the chillerremote switch whereby when the thermostat cut-off, the chiller andpump will also cut-off.
5. Water Piping DesignInstallation sample of 2-way valves pre-cautions
Design & Application
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Installation sample of 3-way valves5. Water Piping Design
Mini Chiller Unit
FC
U
FC
U
FC
U
3-Way valve gives constant flow rate, when no demand,the water bypass through the valve. Energy wastage is
the disadvantage.
Use 3-way diverting valves
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Other type of valves and fittings
Thermometer- glass thermometers are installed on the inletand outlet pipes of either the chiller unit or fan coil units. Thisis to measure the water temperature differential to determine
the capacity performance.
Thermometer bulb
measuring correct
water flow
temperature
Thermometer
too high up,
stagnant
water
5. Water Piping Design
Design & Application
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Pressure gauge cock - Used to isolate pressure gaugesalong the water pipe line. When not in use, the valve is closed toprevent prolonged pressurizing to the gauge, and damage the gauge
Pressure gauge
Impulse tubing loop
Gauge cock (ball valve)
Main pipe line
5. Water Piping Design
Other type of valves and fittings
Design & Application
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Pressure gauge and thermometer as the previous 2 slides
should be included in the design stage - consideration for
commissioning. The measuring devices should be installed
at the following location :
Main supply and return pipe Main branch supply/return pipe
Cooling coils Heating coils Chiller (chilled water side)
5. Water Piping Design
Other type of valves and fittings
Design & Application
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Safety relief valve - valve will open when pressure exceed setvalue to prevent over pressuring the system. Normally used inhot water system. Should be installed near an expansion tank orpump discharge line.
Air vent valve - OYL mini chiller has an automatic air vent
located on top of the buffer tank. Air vent valve used to releaseany trapped air in the tank. Additional air vent should beinstalled at the highest position of the piping network
5. Water Piping Design
Other type of valves and fittings
Pipe Pipe
Air vent
Air vent
5 W Pi i D i
Design & Application
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Water outlet
Water inlet
Strainer
Strainer- Strainer are a type of filter for water pipe systems. At leastone strainer should be installed at the location just before the pump.Strainer should be fitted in the return water connection to chiller priorto brazed plate heat exchanger to prevent dirt/particle trapped withinthe heat exchanger.
5. Water Piping Design
Other type of valves and fittings
5 W t Pi i D i
Design & Application
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Flow switch - to switch off the chiller unit when low waterflow rate is detected in the piping, possible due to :
pump failure
blocked BPHE
accidental closing of valve
failure of control valves
Water outlet
Water inlet
BPHE Flow switch
5. Water Piping Design
Other type of valves and fittings
5 W t Pi i D i
Design & Application
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Fan coil pressure loss Chiller pressure loss
Pipe pressure loss - pipe, fittings & component
5. Water Piping Design
System Pressure Loss
5 Water Piping Design
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Pipe friction looses are dependent on the following factors :
Water velocity
Pipe internal diameter Pipe length Type of material - affect the internal wall roughness
5. Water Piping Design
Pipe and Fitting Sizing
5 Water Piping Design
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Water velocity limits are set to take care of noise; erosion andinstallation cost. Recommended guidelines :
Pipe friction loss should be between 1 to 4 ft / 100 ft ofequivalent pipe length (100 Pa/m to 400 Pa/m)
Water velocity range for different servicesService Velocity
fps m/sPump discharge 8-12 2.4-3.6Pump suction 4-7 1.2-2.1
Drain line 4-7 1.2-2.1Header 4-15 1.2-4.6Riser 3-10 0.9-3.0City water 3-7 0.9-2.1
5. Water Piping Design
5 Water Piping Design
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Calculation of System Loss Step by Step GuideStep 1 - Draw up a schematic layout, c/w chiller; fan coil units and
accurately reflect the length of pipe work
Step 2 - Decide the position and numbers of valves, control valves,
balancing valves; measuring stations; strainers and mark them on the
sketch.
Step 3 - Label each section of the pipe with an identifying letter.Carefully select the pipe route that gives the highest resistance to
water flow.
Step 4 - Fill in the water volume flow rate and pipe length for the firstsection on the pipe sizing chart. Use the pressure loss factor from
Friction Loss Chart and equivalent length by using the equivalent
length factors from all types of fitting
5. Water Piping Design
C l l ti f S t L St b St G id5 Water Piping Design
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Calculation of System Loss Step by Step Guide
Step 5 - Enter type of fitting and their quantity, multiply the quantity
be the velocity pressure loss factor by the equivalent length for each
type of fitting to get the total fitting equivalent length,
Step 6 - Add the total fitting equivalent length to the straight pipe
length to give total pipe length. Multiply the total pipe length by the
pipe pressure drop per meter length to obtain a total pressure loss ofthe pipe section
Step 7 - Repeat step 5 - 7 for other section of pipes. Summarize the
total pressure drop for all the section. Take into consideration aminimum of 10% safety factor.
Step 8 - Use the result of step 8 to select the pump
5. Water Piping Design
5 Water Piping Design
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Example 3Determine the pressure loss of the pipe system below c/w chiller and FCU.If the standard built in pump has external head of 20m, is the pump
able to handle the pressure loss?
5. Water Piping Design
5 Water Piping Design
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Pressure loss for copper pipe- close / open system
5. Water Piping Design
5 Water Piping Design
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Pressure loss for steel pipe- close system
5. Water Piping Design
5 Water Piping Design
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Pressure loss for steel pipe- open system
5. Water Piping Design
5. Water Piping Design
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Definition :The equivalent pipe length of a component in the pipesystem is the length of a straight pipe which will give thesame friction losses as the components itself.
The concept of equivalent pipe length is used incalculating friction losses along the water pipe system,equivalent pipe length can be obtained from tables.
5. Water Piping Design
Equivalent pipe length
5. Water Piping Design
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5. Water Piping Design
5. Water Piping Design
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p g g
P l i t5. Water Piping Design
Design & Application
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Fitting : 10 x 90 elbow; 4 tee joint; 2x gate valve; 1 strainer - 1 1/4 steel pipe2 gate valve; 2 tee joint; 1 glove valve 1 1/8 copper
Pressure loss pipe systemp g g
5 Copper pipe1 1/8 SB75BW5. Water Piping Design
Design & Application
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Fitting : 10 x 90 elbow; 4 tee joint; 2x gate valve; 1 strainer - 1 1/4 steel pipe2 gate valve; 2 tee joint; 1 glove valve 1 1/8 copper
10 10
15
15
3
1 1/4 steel pipe
AC80C
p g g
5. Water Piping Design
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Pressure loss - OYL fan coil unit data
Model Nominal Water flow rate Unit Friction loss at nominal flow rate
L/min USGPM PSI (unit internal components)
SB75BW 57.00 15.08 6.08
SB100BW 73.48 19.44 1.83
SB125BW 97.49 25.79 2.46
Please refer to relevant technical manual AFCU-2004, page 70
p g g
5. Water Piping Design
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Pressure loss - OYL mini chiller data
Note : Unit internal losses take care of friction loss through Brazed plate
heat exchanger (BPHE); internal pipe work; pump fittings, flow switch, etc.Please refer to relevant technical manual
Steel pipe 1 1/4 diameter :5. Water Piping Design
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Steel pipe 1 1/4 diameter :
Flow rate : 15.08 usgpm (57.00 Liters/min)
Straight pipe length : 55 x 2 = 110Equivalent length for fittings : 10 x 3.3 = 33 (elbow)
4 x 2.3 = 9.2 (tee joint)2 x 1.5 = 3.0 (gate valve)1 x 9.0 = 9.0 (strainer)
Total equivalent pipe length = 164.2
From Friction loss for closed piping system, at 15.08 usgpm, forsteel pipe, the friction loss is 3.8 / 100 of pipe, hence friction lsteel pipe = 3.8 x 164.2/100 = 6.24
5. Water Piping Design
Design & Application
Copper pipe 1 1/8 diameter :
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Total external pipe and fitting loose = 11.87
Flow rate : 15.08 usgpm
Straight pipe : 3x2 = 6 Equivalent pipe length for fitting : 2 x 1.4 = 2.8(gate valve)2 x 0.9 = 1.8 (tee joint)1 x 22 = 22 (globe valve)
1 x 1 = 11 x 1.5 = 1.5
Total equivalent pipe length copper : 33.1friction loss for copper pipe(1 1/8 at 15.08 usgpm) = 17/100hence 33.1 gives : 17 x 33.1/100 = 5.63
5. Water Piping Design
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Fan coil loose : 6.08
mini chiller internal loose : 8.7Total external pipe and fitting loose = 11.87
Total system friction loose : 6.08+8.7+11.87 = 26.65
= 8.125m
6. Pump Selection
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Pump is one of the fundamental component in the system. It
circulates water through all the components in the system.
Pump is a built in component in OYL mini chiller. Basic
understanding about the pump characteristic is important.
6. Pump Selection
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Primary - secondary pump
If the built in pump in the mini chiller is not able to deliver the
head pressure required to the load even in a close loop system :
Change the existing pump to a higher head pump
Install a booster pump - primary - secondary pump system
6. Pump Selection
Design & Application
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Primary - secondary pump
Water out
WaterinMini Chiller Unit
Booster pump (secondary)
Bypassloop
A
B
Fan Coil Units
Built in pump(primary)
6. Pump Selection
Design & Application
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Disadvantages of this system
Extra cost for pump Unused bypass chilled water - wastage
Cautions Bypass loop short(but sufficient to prevent turbulence) to
minimize pressure loss between the entry and exit point of
loop
Do not use any valve in the bypass loop
Primary - secondary pump
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6. Pump Selection
Design & Application
P i d
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Case 3: Capacity of primary pump < secondary pumpa net flow up the loop from B. A become a mixing point and B
become diverting T. Water temperature entering FCU will be in
between the water temperature leaving the chiller and the watertemperature entering Chiller
Primary - secondary pump
Primary - secondary pump in series
6. Pump Selection
Design & Application
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Primary secondary pump in series
Water out
Water in
Mini Chiller Unit
FCU
Built in pump(primary)
Booster pump (secondary)
6. Pump Selection
Design & Application
Primary - secondary pump in series
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This installation is not recommended :
risky - wrong pump sizing can caused damage to pump
if this design need to be used, primary pump capacitymust be equal to the secondary pump, otherwise :
cavitations problem to the smaller pump pressure drop across pump high head loss - harmful to the chiller
a y seco da y pu p se es
7. Multiple Chiller Selection
Design & Application
Primary - secondary pump in series
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y y p p
In the cases of multiple chiller need to be used,there are few possible installation method :
Common supply and return headers Primary - secondary system Common tank system
Common supply and return headers
7. Multiple Chiller Selection
Design & Application
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Chiller 1
Chiller 2
Chiller 3
Check Valve
Supply Header
Return Header
Chilled water supply
Chilled water return
7. Multiple Chiller Selection
Design & Application
Common supply and return headers
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Chiller 1
Chiller 2
Chiller 3
Check Valve
Chilled water supply to FCU
Chilled water return from FCU
7. Multiple Chiller Selection
Design & Application
Common supply and return headers
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Most common and preferred
Low installation cost Chiller set at different return water temperature - load staging Check valve to prevent back flush of water Drawbacks
proper balancing of water flow rate through each chiller iscrucial
Any chiller off, water flow rate to the FCU will be affected.To overcome this, it is necessary to wire the chillercontrols for continuos pump running as long as one fan
coil is in operation One supply line, less flexibility in water distribution
control, i.e. the highest pressure losses zone might beaffected
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Common supply and return line
7. Multiple Chiller Selection
Design & Application
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Common supply and return line
No common header used, higher pressure dropalong common pipe lines - can use larger pipe sizeat this common line to reduce pressure lost.
Proper balancing is crucial
1st in last out arrangement at the supply and returnlines is useful to reduce the problem of distribution
Primary - secondary pump system
7. Multiple Chiller Selection
Design & Application
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Chiller 1
Chiller 2
Chiller 3
Check Valve
Chilled water supply
Chilled water returnBypass Loop
Secondary Pumps
Primary Pump
7. Multiple Chiller Selection
Design & Application
Primary - secondary pump system
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Chiller of different capacities can be installed together
without much balancing
Balancing valve required
Secondary pump alone handle the flow and pressure
requirements of FCU - if one of the primary pump off,the water supply to FCU not affected
7. Multiple Chiller Selection
Design & Application
Primary - secondary pump system
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Chiller 1
Chiller 2
Chiller 3
Check Valve
Chilled water supply
Chilled water return
Secondary Pumps
Auxiliary tank
Primary Pump
Common tank system - Open System
7. Multiple Chiller Selection
Design & Application
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Chiller 1
Chiller 2
Chiller 3
Chilled water to FCU
Secondary Pumps
Primary Pump
Tank
Return from FCU
7. Multiple Chiller Selection
Design & Application
Common tank system - Open System
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Each chiller and secondary pump forms own pipe circuit
Common tank act as buffer storage tank
No check valve required, normal globe valve is sufficientto ensure proper water flow
Tank at higher level - to allow gravity feed of water tothe chillers and pumps
Refer to earlier slide for open system for all cautionsduring installation and operation
Multiple chiller-single fan coil load with
lti l i it h d
7. Multiple Chiller Selection
Design & Application
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multiple circuits - common header
Chiller 1
Chiller 2
Chiller 3
Check ValveSupply Header
Return Header
Circuit 2
Circuit 1
Circuit 3
7. Multiple Chiller Selection
Design & Application
Multiple chiller-single fan coil load with
lti l i it h d
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multiple circuits - common header
Chiller 1
Chiller 2
Chiller 3
Circuit 2
Circuit 1
Circuit 3
Minimum compressor run time : 3 minutes(PCB design)
8. Water Storage Tank and Expansion Tank
Design & Application
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Minimum off time of compressor : 4 minutes(PCB design)~ compressor possible cycle on/off 8 times/hour.
Total volume of water in the system must be able to pull-down by 5 C temperature within 3 minutes
Total volume of water = volume of storage tank +volume of pipe length +volume of expansion tank
Water Volume = Time * flow rate for 5 C Temp. Diff. Water Volume = 3* flow rate (liters/min)
Volume = Time * flow rate for 5 o C Temp. Diff.Volume = 3* flow rate (liters/min)
8. Water Storage Tank and Expansion Tank
Design & Application
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Volume = 3* flow rate (liters/min)
Example : A mini chiller has a cooling capacity of 40,000Btu/hr (11.72 kW)
Flow rate USGPM = Capacity, Btu/hr500 * 9
or Flow rate Liters/min = Capacity, W70 * 5Flow rate = 11720/350 = 33.6 liters/min
Volume of system = 3 * 33.6 = 100.8 liters
Assuming the storage tank capacity is 1/3 of the total system watervolume, storage tank capacity = 100.8/3 = 33.6 liters
For simple calculation, the following tables can be used to estimate the volume of water in
a system by simply mult iply the length of pipes with the factor:
Pipe type Pipe Size Water Volume, liters/min
Steel SCH 40(ST) 1/2 0 196
Design & Application
8. Water Storage Tank and Expansion Tank
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Steel, SCH. 40(ST) 1/2 0.196
3/4 0.344
1 0.558
1 1/4 0.9651 1/2 1.313
2 2.165
2 1/2 3.098
Copper, type L 1/2 0.094
5/8 0.151
3/4 0.2257/8 0.312
1 18 0.532
1 3/8 0.811
1 5/8 1.148
2 1/8 1.997
2 5/8 3.079PVC, DIN 8062 20mm 0.227
25mm 0.353
32mm 0.581
40mm 0.908
50mm 1.425
Expansion tankExpansion tank provide a space into which water can expand or
8. Water Storage Tank and Expansion Tank
Design & Application
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p p p p
from which it can contract as the water go under volumetric
changes with respect to temperature change. This device iscompulsory in heat pump units.
Air
Water
Tank
Diaphragm
Threaded end
Tee Joint
Pump suction lineWater Flow from Mini Chiller
Spacing between the plates is small, no debris, fouling orli i th t i i t t t t i t i
9. Water Treatment
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scaling in the system is important to ensure no restrict inwater flow and thus performance not affected.
Strainer along water suction line will remove debris likesand, metal debris, etc..
It is good practice to install filter at the make up water
supply line. Filter elements required periodical service to remove
trapped particles.
Flushing the pipe with water during initial start up and
commissioning of the min chiller is necessary
Fouling refers to the tendency of water form a film onthe heat transfer surfaces Fouling can be organic or
9. Water Treatment
Design & Application
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the heat transfer surfaces. Fouling can be organic orinorganic surface fouling.
Organic fouling includes microbiological growth. Algaemay also form on these surfaces. This is moresignificant in open system
Scaling is inorganic fouling. It is normally caused bydeposit inorganic salts
Symptoms: sudden increase in pressure drop andgradual drop in heat transfer performance
Remedy : Chemical cleaning
Organic fouling can be removed by use of alkaline cleaningagent like sodium hydroxide at 5% concentration. Refer toh i l f f d il i i k
9. Water Treatment
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chemical manufacturer for more details instruction. Makesure the excess chemical is fully clean up from the system
Inorganic fouling most commonly need acidic based cleaningagent. Mineral acids has strong ability to dissolve scales, butattack/corrode stainless steel and copper parts, hence is not
recommended. Organic acids at 2 - 5% concentration ismore ideal when used to clean BPHE.
Refer to chemical manufacturer recommendation on thedosage requirement. Upon completion, flush with clean water
to remove excess acids. It is recommended that the water to be replaced at least
once a year to prevent fouling on the BPHE
Glycol Solutions
9. Water Treatment
Design & Application
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y
Entering water temperature - operating range
EWT 0C EWT 0C Max EWT 0C
Factory Setting Minimum maximumCooling Mode 12 3 15
Heating Mode 40 35 50
Antifreeze 2 -4 3
9. Water Treatment
Design & Application
Glycol Solutions
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SW2 Setting(for cool mode)
SET TEMP. SW20C SW2-3 SW2-2 SW2-1
Set by VR3 off off off
3 off off on
4 off on off5 off on on
6 on off off
7 on off on
8 on on off
9 on on on
If DIP switch is set to (off,off ,off), the set temperature is determine
by VR3 setting, otherwise setting above will override the VR3 setting
y
9. Water Treatment
Design & Application
Glycol Solutions
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For Commissioning, it is recommended to observe
and adjust the setting if necessary :
For cooling mode, press SW1 once in PCB Green LED will bl inks for few seconds Adjust VR3 to the required water entering temperature by using
suitable tools
If glycol added, the entering water temperature (3 0C-9 0C) canbe set by adjusting DIP switch (SW2)
For heating mode, press SW1 twice, red LED wil l bl inks for fewseconds
Adjust VR1 to set the required water temperature for heatingmode
VR2 is adjusted to set antifreeze temperature
y
9. Water Treatment
Design & Application
Glycol Solutions
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If sensor setting has been adjust for process cooling - to operateat lower temperature, precaution must be taken to prevent waterfreeze up. For sub zero application, the water must mix with antifreeze glycol solution.
2 commonly used glycol : ethylene glycol and propylene glycol.Ensure the quantity mixed with water is sufficient to cater for theoperating temperature requirement. The more glycol added, thecapacity loss is higher.
Make sure water pump is on all the time to ensure continuouswater flow through BPHE to prevent formation of ice.
y
9. Water Treatment
Design & Application
Glycol Solutions
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Correction factors with Glycol added to water
Glycol % Capacity Water flow Pressure drop
10 0.990 1.015 1.06
20 0.980 1.040 1.12
30 0.970 1.080 1.18
40 0.965 1.135 1.24
9. Water Treatment
Design & Application
Glycol Solutions
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Pipe being insulated for the following purposes :
Prevent heat gain / loss from the water in the pipe
10. Pipe Insulation Requirement
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Prevent heat gain / loss from the water in the pipe
Prevent condensation when chilled water flow in the pipe Prevent injury due to hot water flow in the pipe
To do a calculation of insulation thickness, one must know :
Insulation material thermal conductivity coefficient (K) Pipe size Air condition at the site of installation (Dry bulb and humidity) Convective heat transfer coefficient (H)
A simplify spread sheet is provided to estimate the insulationthickness
PIPING INSULATION THICKNESS CALCULATION:
Air condi tion:
DB/C 25 Dew point
RH/% 75 DP/C 20.26
10. Pipe Insulation Requirement
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Pipe specification:
Pipe dia. 1.25 in 31.8 mm
Radius, r1 15.879 mm
Pipe surface temperature/C 7
Insulation material:
Material: Armarflex
Thermal conductivity, k 0.0374 W/mK
Surface convective heat transfer 9 W/m2K
coefficient, h
Insulation selection:
Calculated insulation size
r2 25.181 mm
Insulation thickness 9.3 mm
(Minimum) 0.4 in
USE THENEXT SIZE THICKNESS
AVAILABLE OR THICKER FOR
SAFETY FACTOR
Few application samples will be provided, however with thefollowing considerations:
Th ti Al LED f t i l AL1 d AL2 i i i
10. Pipe Insulation Requirement
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The option Alarm LED from terminal AL1 and AL2 in minichiller is meant to be installed into the external control switchboard - to indicate if an abnormal operation has occur. ThePCB will give out a signal to light up the LED when any of theprotection devices trip.
The option Remote Switch may be located at a convenientplace for easy access to the user. It may be placed inside theswitchboard. It can also act as an emergency switch to stopthe chiller
The power supply for the fan coil units are separated from themini chiller
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Product Features
Product Features
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Less foot print occupied
Less space required.
Product Features
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Made of AISI 316 Stainless Steel
High heat exchange efficiency
Conventional Back to Back Circuits BPHE
New Technology BPHE- True Dual Circuits
Product Features
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Primary Circuit 1 Primary Circuit 2
Secondary Circuit
Primary Circuit 1 Primary Circuit 2
Inverter Mini Chiller True Dual Circuits BPHE
Product Features
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Support up to 50 chiller and 120 fan coil units
through chiller bus
Product Features
A network up to 50 chillers Operation control on chillers done
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Operation control on chillers donethrough microprocessor controller.
Additional chiller can be added on by jusextend the water piping.
Water InWater Out
ChillerBus
Up to 50Chillers
Product Features
Can be done through Chiller ControlPanel
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User friendly and versatile controls Main menu includes:Operation Timer Display
Setting Alarm
Whole system configuration
Unique system configuration
Product Features
1. Less Start & Stop
2. Fast Cooling/ Heating 4. Low Starting Surge
3. Precise Temperature Control
RunningRunning Conventional air conditioner:
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Running
current
Hours of operation
Running
current
Hours of operation
Conventional air conditioner:
High starting currentFrequent on/off cycle
Inverter air conditioner:
Low starting currentSmooth operation
Inverter air conditioner:
Low starting currentSmooth operation
Product Features
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Conventional System
Inverter System
Product Features
High & Low Pressure Switches Anti Freeze Protection Sensor
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Discharge Temperature Sensor Over Pressure Relief Valve Water Pressure Differential Switch
Anti Freeze Heater on BPHE Compressor, Water Pump Overload Protector
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Schematic Diagram
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Schematic Diagram
&
Components
Schematic diagram
Condenser Coil 1
Disch
Temp 1
(Disch Comp 1)Suct
HP1
LP1
Cond In
Temp 1
(Condenser)
Cond Out
Temp 1
(Def Comp 1)
Filter
Drier
EXV
O/A Temp
5ACV100CR
4WV
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Acc
Acc
Liq Rvr
Liq
Rvr
BPHE FS
Condenser Coil 2
Disch
Temp 2
(Disch Comp 2)
Inv
Comp
Std
Comp
Temp
(Suction)
HP2
LP2
BPHE Out
Temp
(BPHE Out)
BPHE In
Temp
(BPHE In)
EWT (Water In)
LWT (Water Out)
Pump
Cond Out
Temp 2
(Def Comp 2)
Filter
Drier
Heating Cap Tube
Check valve
Cooling Cap Tube
Check valve
O/A Temp
(Outdoor Ai r)
Summary Pages-
Screen 3
Display Menu-
Defros t Sensor
Display Menu-
Inverter Chiller
Display Menu-
Discharge Sensor
4WV
Components
Variable speedfan motors(100%, 70% &50%)
Coil guardsFan guards
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Heat exchangerswith gold fin asstandard
Water pump
True dual circuits BPHE(Brazed plate heatexchanger)
Expansiontank ( 8L)
Control boxassembly
Components
IPM board(Intelligent power module)Uni-
directionalbridge diode
3 phaserectifierbridge diode
Fancapacitors
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Main board Magneticcontactors
EMI filter
Capacitorboard
PFC capacitor(Power factor correction)
Power board
Components
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For Model 55, 75, 100 & 135 For Model 30
Components
To convert rectif ied DC current+500VDC to respective desired
voltages
- 12VDC relay
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- MCU +5VDC- IPM +15VDC
Ensure stabili ty of above voltageswithin power supply voltage
fluctuation range (304-480 VAC)
Over voltage feedback
Output short circuit protection
Components
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Components
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Components
High pressure switch
(NC) 600 psi open,480psi close.
Low pressure switch(NC) 18 psi open,28 psi close.
Chiller panelcontroller
EXV (Electronicsexpansion valve
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Variable drive systemcompartment
Fixed drive systemcompartment
Pump OLP (overloadprotector)
Differential pressureswitch
Over pressure reliefvalve
Anti freeze heater on
BPHE
Compressor OLP(overload protector)
Fixed speedscrollcompressor(R410A)
Variablespeed scrollcompressor
(R410A)
4 Way valve
Installation
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&
Commissioning
Installation & Commissioning
Unit Handling
Unit Placement
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Maintenance Access
Water Piping & Fitting
Power Supply & Electrical Connection
Preliminary Checking before Start-up
General Control Flow Chart
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5ACV 100/135/210 CR
Air Cooled Chiller are cooled by air, space restriction will reduces theair flow, decrease the cooling capacity, increase the power input and,
in come cases, prevent the unit from operating because of an excess
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of condensation pressure.
5ACV equipped with propeller fan, which doesnt need ductwork on fanoutlet.
Direct effect of the wind on the discharge surface of the fan should beavoided.
Enough clearance around the unit for maintenance works.
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Minimum clearances
5ACV100/135/210CR5ACV30/55/75CR
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5ACV 30 / 55 / 75 CR
Installation & Commissioning
5ACV 100 / 135 CR
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Installation & Commissioning
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5ACV 210 CR
Install piping with minimum bends and changes in elevation tominimize pressure drop. Consider the following:!
Vibration eliminators to reduce vibration and noise transmissionh b ildi
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to the building.
Shut off valves to isolate the unit from the piping system duringunit servicing.
Manual or automatic air vent valves at the highest points of thechilled water piping.
A means of maintaining adequate system water pressure
(expansion tank or regulating valve) Temperature and pressure indicators located at the unit to air in
unit servicing.
Water connection could be damaged by an excessive stresswhen screwing them. Use a second spanner to compensatethe stress of tightening.
S f t diff ti l it h i d t
Installation & Commissioning
!
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Safety differential pressure switch is used to ensureadequate water flow to evaporator before starting up the
unit.
Balancing valve to regulate the amount of water flow ratethrough the unit.
It is mandatory to install a strainer at the inlet of the unit.!
Recommended Piping Connection
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Recommended Fuses & Cable Size
101010Power Supply Cable Size (mm2
) *
1006040Recommended Fuse (A) *
380 415 / 3 / 50Voltage Range **
5ACV210CR5ACV135CR5ACV100CRModel
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10
5
10
5
10
3
Power Supply Cable Size (mm2) *
Number of Conductor
1.51.51.5Interconnection Cable Size (mm2) *
102536Recommended Fuse (A) *
415 / 3 / 50415 / 3 / 50230 / 1 / 50Voltage Range **
5ACV75CR5ACV55CR5ACV30CRModel
105
105
103
Power Supply Cable Size (mm ) Number of Conductor
1.51.51.5Interconnection Cable Size (mm2) *
IMPORTANT:
The figures shown in the table are for information purpose only. They should be checked and selected to comply
with local/national codes of regulation. This is also subject to the type of installation and conduct ion used.
* The appropriate voltage range should be checked with label data on the unit.
Before carrying out any operations on the electrical system, make
sure that the unit is de-energized.!
It i i t t th t th li i d d!
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It is important that the appliance is grounded.!
Before connecting the power supply lines, check that the available
voltage value does not exceed the range specified in the electricaldata being provided in Installation Manual.!
Its recommended to check the correct sequence of the 3 supply
phases R-S-T before the unit start up.!
Check the power supply and grounding cable.
Check that any voltage and phase variation in the power supply doesnot exceed the prefixed thresholds.
Check that components of the external water circuit have been
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Check that components of the external water circuit have beeninstalled properly, and according to the manufacturers instructions.
Check that the filling of the hydraulic circuits, and make sure that thefluid circulation is correct, withou