Post on 06-Jan-2016
description
APPLIED CHILLER PRODUCTS
PACKAGED AIR COOLED FREE COOLING CHILLER
New
YSFC
200 - 1700
kW
14 ModelsYork Screw Free Cooling
APPLIED CHILLER PRODUCTS
Market Introduction
PackagedAir Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
What is a Free Cooling?Free Cooling has become an established technology recognised throughout
Eastern and Northern Europe by End Users, Architects & Building Services Engineers.
Reducing Global Energy Consumption and CO2 emissions is a Clients key driver for his Buildings & Cooling Processes, reducing operating costs and
environmental impact.
Free Cooling Chiller offers a sustainable alternative, to reduce electrical energy consumption during “winter” ambient periods.
The Free Cooling concept switches off compressors when operating conditions allow, to utilise Natural Cooling provided from Low Ambient
Air passing across a finned coil containing the process liquid. Client’s consider this as an attractive solution.
Ideal applications benefit from having a high 24/7 base load and operate with elevated system return liquid temperatures typically above 15ºC and where the ambient is predicted to be below 5ºC
many operating hours each year.
APPLIED CHILLER PRODUCTS
Our survey revealed this technology is increasing in demand by many users.Although a niche Air Cooled Chiller variant, specifications for such products in most European regions is rapidly increasing and the JCI Sales Teams request the ability to support this technology alternative with their Clients.
There are a number of various applications in which our traditional Clients are currently specifying and Installing such products:-
Locations, Long Cold Winters, Northern Latitudes or Eastern Europe, High Altitude.24/7 Chiller Operating Applications Data Centres, Switch Rooms and Industrial Processes. Chilled Beam and Medium Temperature Air Conditioning.Theatres, Cinemas and Night-Clubs.Hospital Operating Theatres.
As Free Cooling is seen as a progressive “Green” product solution.
Market Requirements For Free Cooling Chiller’s.
APPLIED CHILLER PRODUCTS
Sales Forecasts & Market Assessment
• The Free Cooling project investigated the potential for JCI Systems to offer Packaged Air Cooled Free Cooling Chillers, following requests originating mainly from Central and Eastern Europe.
• Initial forecast reviews for 2008 indicated a likely requirement for 40 units.
• 2010 Product AOP review (April 09) revised this forecast downward to 26 units
• Following PS&S review of the European market indicates there is a wide range of clients applying the principals of Free Cooling to their processes. We have concluded that there is a legitimate market for this product variation as the vast majority of Chiller manufactures offer such products. Unfortunately there are no official statistics to support sales volumes to this market. However have seen many enquires for multiple units. (One project for 18 x 750 kw units which we are specified.)
• It is Product Managements assessment that this market has the ability (in normal market conditions) to generate higher volumes than indicated and we believe we have identified a product to meet this demand.
APPLIED CHILLER PRODUCTS
Alternative Approaches To Free Cooling Chillers?
There are 4 design variations for Free Cooling Systems applied to packaged Air Cooled Chillers available in Europe’s market.
1) Stand Alone Dry Air Cooler. Technically the best solution.Most efficient and flexible option, high installation costs. JCI current solution.
2) Built-in separate Dry Air Cooler. Exclusive applications.Good efficiency levels and often with very high levels of specification, but greater foot print and high cost.
3) Thermosyphen system. Carrier’s Approach.Utilises refrigerant circuitry, has low capital cost and low efficiency. Only two modes of operation restricting mid season application.
4) Dual Function - Free Cooling and Condenser Coil. Commercial.Compact \ Price competitive solution preferred by European MAC team as a product gap filler.
JCI new YSFC solution.
APPLIED CHILLER PRODUCTS
Review of the alternative design concepts determined this technology could not be simply applied to our current Product range.
The stand alone dry air cooler is the most obvious Energy efficient solution. JCI has been successful in winning such projects. Many Clients now requesting packaged units to reduce installation costs and space.
The built-in Dry Air Cooler & Thermosyphen systems both require major equipment redesign.
The Dual Function coil block requires less modification to the existing product’s. Adding the additional coils into the current
condenser design the unit’s width would Increase, prohibiting JCI from loading units
into containers for Global shipment’s.
Why JCI chose to use an OEM Supplier?
APPLIED CHILLER PRODUCTS
JCI Selected OEM SupplierFollowing an extensive Market Review we identify the alternative
market suppliers and product solutions. We finalised an OEM agreement with an Italian producer specialising in the process
cooling market for a Unique Branded JCI Design Dual Function - Free Cooling /
Condenser Coil
A reciprocal agreement exists that if either JCI or Hitema’s existing distributors has a product specified the other party should not chase down the order.
No other Hitema product may be ordered from them without Product Management Authorisation
APPLIED CHILLER PRODUCTS
ApplicationPackagedAir Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
Product Selection and ApplicationThe YSFC is not seen as a replacement for the YCIV. Both models have their unique benefits for the client.
You select which one is best.
YCIV YSFC• High Summer efficiency 3.2 EER. • High 4 ESEER mid season performance.• Continuous VSD Cooling for extended low ambient efficiencies throughout the year.
• Lower Summer efficiency EER 2.6• 3.7 ESEER performance
• 100% Free Cooling EER 26 At an ambient approximately 16C below the return chilled liquid temperature there is no Mechanical Cooling required.
APPLIED CHILLER PRODUCTS
Free Cooling Chiller Operating Modes
Free Cooling units operate in 3 modes.
• Mechanical Cooling Chiller operates in refrigerating mode in summer ambient conditions.
• Partial Free & Mechanical Cooling (excluding Thermosyphen system)
Where Free Cooling works in series (up-stream) of Mechanical Cooling to reduce compressor load when lower ambient temperatures allow.
• Total Free Cooling (Condenser fans running) When the ambient air is cool enough to reject the full heat load from the system.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller OperationDuring Summer Ambients the unit operates as a typical chiller,
albeit at a reduced efficiency level. This is due to the additional coil rows required for the Free Cooling circuit placed in front of the condenser.
As the ambient falls 6°C below the return system liquid temperature.• The 3-way valve redirects the flow through to the Free Cooling Coil
in series with the evaporator enabling the partial Free Cooling / Mechanical Refrigeration mode.
• To maximise unit efficiency each circuit is unloaded and disabled in sequence as the ambient falls.
• Whilst a refrigerant circuit is operating the fans continue to maintain the minimum condensing pressure.
• As each refrigerant circuit stops, fan control changes to maintain leaving liquid temperature.
Winter Ambients, where full free cooling is achieved (without mechanical cooling) the leaving chilled liquid temperature is maintained at the desired
temperature by fan control.
APPLIED CHILLER PRODUCTS
YSFC Product Schematic Standard Mechanical Chiller
Evaporator
Controller
Compressor
Condenser
Fans Fans
EEV
Flow TempStat
AmbientStat
Condenser
APPLIED CHILLER PRODUCTS
Free Cooling
YSFC Product Schematic Free Cooling Chiller in Mechanical
Cooling Mode
Evaporator
pC03Controller
Compressor
Condenser
Fans Fans
Free Cooling Valve EEV
Flow TempStat
AmbientStat
Inlet Temp Stat
Condenser
Free Cooling
When Ambient is Grater than 6°C below the Return Liquid Temperature
APPLIED CHILLER PRODUCTS
Evaporator
pC03Controller
Compressor
Fans Fans
Free Cooling Valve EEV
Flow TempStat
AmbientStat
Inlet Temp Stat
YSFC Product SchematicPartial Free & Mechanical Cooling
CondenserCondenser
Free Cooling Free Cooling
When Ambient is 6°C below the Return Liquid Temperature
APPLIED CHILLER PRODUCTS
Evaporator
pC03Controller
Compressor
Fans Fans
Free Cooling Valve EEV
Flow TempStat
AmbientStat
Inlet Temp Stat
YSFC Product SchematicPartial Free & Mechanical Cooling
Condenser
FreeCooling
CondenserCondenser
Free Cooling Free Cooling
Condenser Coil Block Profile
APPLIED CHILLER PRODUCTS
Evaporator
Condenser
pC03Controller
Compressor
Condenser
Fans Fans
Free Cooling Valve EEV
Flow TempStat
AmbientStat
Inlet Temp Stat
YSFC Product SchematicFree Cooling Mode
Condenser
FreeCooling
Free Cooling Free Cooling
When Ambient is low enough to satisfy system cooling demand
APPLIED CHILLER PRODUCTS
YSFC Free Cooling mW Hours operation
Data based on
YSFC 850SB 860 kW.
Constant load 365 Day 24/7.
24hr Average Daily Temperature.
15 – 7 Chilled Glycol split.
Partial Free Cooling enabled @
9°C Ambient (6°C below EWT.).
Full Free Cooling -2°C Ambient.0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Ja
nu
ary
Fe
bru
ary
Ma
rch
Ap
ril
Ma
y
Ju
ne
Ju
ly
Au
gu
st
Se
pte
mb
er
Octo
be
r
No
ve
mbe
r
De
ce
mbe
r
Calculated Percentage Energy Saving per Month
Moscow
Stockholm
Warsaw
Berlin
Paris
Madrid
This graph shows the potential to save energy as a % comparing the YFSC modes either operating thought the year in Mechanical Cooling or Partial / Total Free Cooling.
APPLIED CHILLER PRODUCTS
0
5
10
15
20
25
30
EER
Ambient / Leaving Liquid
100% Load 365 Day EER 850kW
YSFC 850
YCIV 930 HE Opt
EER Comparison JCI Chillers
Based upon 100% Cooling load (850 kW) and 5°C ambient steps
APPLIED CHILLER PRODUCTS
YSFC The Product
PackagedAir Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
Introducing the new YSFC Range Two circuit models
Info Only Please Refer to Eng. G
uide
APPLIED CHILLER PRODUCTS
Introducing the new YSFC Range 2 & 4 circuit models
Info Only Please Refer to Eng. G
uide
APPLIED CHILLER PRODUCTS
YSFC Standard Features
• R407c standard options exist via SQ for R134a. • Light grey RAL 7035 polyester epoxy powder paint.• Two or four fixed speed step control part wind Hermitic Screw Compressor(s)
optional Open or Closed transition Star Delta Starters. • Carel microprocessor controller including specific Free Cooling software.• Electronic Expansion Valves (increased performance in partial mechanical /
free cooling mode).• Axial speed controlled condenser fans various options for differing control and
drive(s).• Aluminium Fin & Copper Tube Condenser / Free Cooling Ambient Coil’s options
for alternative materials / coatings.• Shell & Tube Direct Expansion Evaporator 19mm closed cell insulation.• PN16 inlet manifold and outlet evap. stub for Chilled Liquid flange
connections.• 6 Bar Three Way Free Cooling Mixing Valve, Heater and Auto Daily Rotation. • EPDM Flexible reinforced helix wire compound rubber Hydraulic Tubes.
APPLIED CHILLER PRODUCTS
YSFC Component Selection
We use simulator software, to confirm the
dimensions compressor’s of evaporator condenser
coil and fans
Design Cooling Capacity
Condensing Requirement & Free Cooling load
Condensing duty & Sound performance
When the Clients designcharacteristics are finalisedcomponent selection is thenOptimised for the specific project design.
APPLIED CHILLER PRODUCTS
After selecting the components a study final of the optimum layout for the base.
TANK (Option)
EVAPORATOR
PUMP (Option)
3 WAY VALVE
HYDRAULIC PIPING
(Manifold)Inlet
Outlet
YSFC Unit Construction - Mount Components
COMPRESSORS
SUPPLEMENTARYPANEL (Option)
APPLIED CHILLER PRODUCTS
YSFC Unit Construction - The Condenser Module
Coils and Fans are selected initially from the standard unit design configuration. Cost Performance and Sound Optimisation.
JCI Offer Special Quotation variations on Coil lengths, Coil Rows, Fin Pitch, and Fan Performance to meet Project requirements.
APPLIED CHILLER PRODUCTS
With the mechanical component location finalised, the Control panel is positioned
The 3D module is complete and the 2D drawings are produced automatically for production.
Control Panel
Condenser module
Base
YSFC Unit Construction - Final Assembly
APPLIED CHILLER PRODUCTS
YSFC Product, Wiring, Pressure / Instrument Drawings are issued forClient Approval before production release and lead time conformation.
APPLIED CHILLER PRODUCTS
Components Around the YSFC
Dual relief (option)
OptionalPump’s andAcoustic CompressorEnclosure
3 Way Valve and Hydraulic pipe connections from manifold to Free Cooling Coils
APPLIED CHILLER PRODUCTS
Components Around the YSFC
APPLIED CHILLER PRODUCTS
YSFC Product Options and Accessories.
Enhanced Free Cooling Performance.The Base unit configuration of unit size and performance
has been selected to offer a competitive all round package.
For specific applications where the Designer’s requirement is to increase the potential Free Cooling Performance, the factory can
offer alternatives through the Special Quotation procedure.
Potential variations include:-• Reduced Fin Pitch (additional Fins to the Coils).
• Increased Air Flow Fans.• Extended Coil length with additional Fans.
Building Chilled Liquid Glycol Free option available as SQ Option (Limiting the Glycol circulation loop within the unit). Ideal for use in
moderate climates where the ambient falls below zero for only a small number of hours a year.
APPLIED CHILLER PRODUCTS
YSFC Product Options and Accessories.1.01 Low Noise (Compressor Enclosure).1.02 Super Low Noise (Compressor boxes and reduced sound fans).SQ Extend coils + extra modifications to achieve minimal possible sound.1.03 Unit Wire Enclosure (Lower Section).1.04 Epoxy Coated Ambient Coil.1.05 Rubber type anti-vibration mounts.1.06 Spring Anti-vibration mounts.2.- - Hydronic pump options (see next slides)2.06 Pressure Regulation Valve (between 3-way-valve and Evaporator).2.14-15 Double evaporator insulation 38mm – Evaporator heater mat.2.16 Y mechanical water filter (supplied lose)3.01 Compressor Suction Valves.3.02 Dual relief change over valves.4.01-4.09 Star Delta compressor motor starters (Open & Closed Transition)4.02 Compressor remote run monitoring contactors4.03 Compressor rephasing4.04 Main – Auxiliary Panel Heaters for ≤-10°C ambient.4.05 Individual fan fuses.4.06-7-8 Serial card BACNET MODBUS (RS485) or Echelon.Std Carrel controller languages, English, French, German, Italian, Spanish.SQ Glycol Free Process System.
APPLIED CHILLER PRODUCTS
Single pump 2.5 bar head optionwith internal wiring to panel mounted contactors
Optional Acoustic boxes forEither Compressors and or Pumps for Low noise versions.
Dual pump 2.5 bar head optionwith internal wiring to panel mounted contactors
Additional Dual Pump Electronic Management Controls.
YSFC Product Hydraulic Pump Options.
APPLIED CHILLER PRODUCTS
Dual VSD pump option with internal wiring to a panel mounted Single Inverter.With electronic pump Management Controls.
Storage Weir Tank.Various additional options
Dependant on requirement. Internal constant speed circulation Pump.
Optional Acoustic boxes available for Compressor’s and or Pumps,Low noise version.
YSFC Product Hydraulic Pump Options.
APPLIED CHILLER PRODUCTS
After assembly the chiller is run tested at prevailing ambientconditions to verify the Mechanical cooling operation and Safety sequences. (Larger capacity units tests are performed separately on individual circuits.)Controlled ambient testing is not available at the Factory.
YSFC End-of-line functional run test
APPLIED CHILLER PRODUCTS
AIR FLOW AIR FLOW
AIR FLOW
WATER FLOW
ELECTRICAL POWER
waterm iT
oT
fVIabs ,,
airT airT
airT
YSFC Recorded Test Data
APPLIED CHILLER PRODUCTS
In mechanical cooling mode the total pressure drop calculation isthe 3 way valve and interconnecting Hydraulic pipes + Evaporator.
In partial or total Free Cooling modes the pressure drop calculation isthe 3 way valve, distribution header, interconnecting hydraulic pipes
+ Free Cooling Coil + Evaporator.
YSFC System Hydraulic CalculationsCaution when calculating the chilled liquid pressure drop.
System Working Pressure.Due to the limitation of the three way valve and Hydraulic pipes
the chilled liquid static system pressure is limited to 6 Bar.
There is obviously a difference in system resistance between the two modes.Discuss this with the client and introduce the option of a pressure regulating
valve to equalise the system pressure drop for each mode.This is installed in the Hydraulic pipe between the 3-way-valve and Evaporator.
APPLIED CHILLER PRODUCTS
YSFC Documentation and selection process.The engineering guide allows for manual selection for both the Mechanical and Free Cooling Modes. As the free cooling chiller application is more suited to specific regions we plan not translate Documents unit specific requests are received.
A selection program is in development and will be distributed Q4 2009. In the interim period please submit SQ for electronic selections. We will have to pay the software house an operator licence of €80 for each user. Please email R Smeed to confirm your licence requirement.
Pricing is a manual operation using the Master List Price, That will be included in the intranet price pages, with the Multiplier distributed to the Sales Managers as usual.
The OEM supplier is happy to work on special applications and options. Please submit a detailed SQ request for review & potential quote.
APPLIED CHILLER PRODUCTS
YSFC Intranet
information 1. Single Page Product
Information Sheet.2. Engineering Guide.3. Installation Commissioning
Operation and Maintenance Manuel.
4. PCO3 Controller Operators Manuel.
5. MLP Price Pages and Words.6. SQ Process flow.7. Order Process flow8. Factory Order Form9. Factory Collections Form10.Warranty Process flow11. Warranty Standard Hours
List.12.Typical Wiring Diagrams
Standard unit with available options (pdf).
13. Typical Product Drawings (pdf)
14.Launch Presentation (ppt)
APPLIED CHILLER PRODUCTS
CompetitionPackagedAir Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
Stand Alone Dry Air Cooler. With thought all Packaged Air Cooled Chillers and Dry Air
Cooler manufactures can provide the solution.
Thermosyphen system.Carrier.
Built-in separate Dry Air Cooler.Cosfi, Liebert Hiross, MTA, Uniflar.
Dual Function - Free Cooling and Condenser Coil.ACM, Aermec, Airwell, Blue Box, Ciat, Clivet, Climaveneta,Emicom, Euroklimat, Daikin-McQuay, Geoclima, Galletti, Lennox, Matri Clima, Rhoss, RC, Trane, Venco.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.
Free Cooling Std units Mechanical Cooling vs Power input
50
150
250
350
450
550
0 200 400 600 800 1000 1200 1400Duty kW
Input k
W
Free Cooling Std units FC mode vs Power input
0
10
20
30
40
50
60
0 200 400 600 800 1000 1200 1400
Duty kW
Input
kW
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
Free Cooling Std units Mechanical cooling vs Sound Pressure
55
60
65
70
75
80
85
0 200 400 600 800 1000 1200 1400
Duty kW
Soun
d Pres
sure
@ 5 m
Free Cooling Std unit Mechanical Cooling vs Length
2000
4000
6000
8000
10000
12000
14000
16000
0 200 400 600 800 1000 1200 1400
Duty kW
Leng
th mm
GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
Free Cooling Std units Mechanical Cooling vs Weight
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
0 200 400 600 800 1000 1200 1400
Duty kW
Free Cooling std unit vs Euro
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
0 200 400 600 800 1000 1200 1400
Duty kW
Euros
GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.
APPLIED CHILLER PRODUCTS
Servicing Renewal
Parts Contacts
PackagedAir Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
YSFC JCI Products and Service Departments have experience of many shared Component suppliers
The Design of the YSFC has many similarities to our own YAES – YCAS andYLCS models. Using many common components that our Service Engineers and Renewal Parts Group are familiar with their availability and use.
For example:- Hanbell Compressors, Ziehl Fans, pumps, Alfa-Laval or Heatcraft Evaporator’s Plus many common refrigeration, electrical components.
New components include The Carel PCO3 controller with the Free Cooling Software.Hydronic system and Three way Valve.
APPLIED CHILLER PRODUCTS
YSFC Service Training and Replacement Parts.
Replacement Parts
• Must be purchased through JCI Renewal Parts Organisation who will have access to Hitema’s detailed bills of material’s for each product supplied. • Please ensure Model Number & Serial Number is given along with details of the Components requested.
Service Training
A Service Trainer Course will be organised at the Factory near Venice.During Q4 FY 2009 The course will consist of:-
• Product Overview (General Refrigeration system)• Theory of operation of the Free Cooling System.• Detail review of the PCO3 Carrel controller and software.• Review end of line test and the Commissioning procedures.
APPLIED CHILLER PRODUCTS
Drawing Approvals• Upon receipt of order the Factory will review the unit configuration and produce project specific physical & electrical drawings.• These will require Client approval before components purchase and manufacture commences. (Early reply would be required to ensure shortest possible lead times.) Typical lead times 6 – 8 weeks after drawing approvals. Email communication of documentation and approvals is to be co-ordinated through Customer Services Group in Basildon.Commissioning registration• To initiate the warranty coverage the unit commissioning Completion date must be registered with the Basildon Customer Services team along with a copy of completed commissioning log report. • Specified system fill / commissioning procedures must be followed• Hitema reserves the right to request that any failed component be returned for analysis.• An agreed standard hours and labour rates repair times for replacement of faulty items. Warranty• In line with the current European standard policy of 18 months from factory collection. • All parts are with a full 18 month warranty with the exemption of the liquid Pump options.
YSFC JCI-Hitema Contract Special Variations
APPLIED CHILLER PRODUCTS
YSFC Communications Product ProcessJCI Sales and the Product Supply & Sourcing will jointly work with Hitema.Responsibilities are as follows.
• Product Supply & Sourcing. Product Manager Roger.J.Smeed@JCI.com 00441268246198. Account management, Maintain documentation and price list, Product Training, Product Management and application and special quotation support.• Factory will provide Engineering Support Through The Existing SQ System. Review requests for Special Quotation's. Specific product Technical / Engineering support. Product Manager Roger.J.Smeed@JCI.com 00441268246198.• Order Entry & Processing and Commissioning registration and Warranty management. Centralised through Customer Services Basildon. Orderentry CG-EUR-Basildon@jci.com 00441268246266.• After Sales Technical Operation support. Tim.Jennings@jci.com 00447976196714.• Renewal Parts hvacparts.cg-eur@jci.com 0044126824600.
APPLIED CHILLER PRODUCTS
Have Your Say Any Questions?
Have Confidence in Free Cooling and our New YSFC.
Thank you.