An environmentally conscious, low carbon footprint chiller solution for HVAC, IT and process cooling

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Cool SolutionIndigochiller is a quiet revolution in refrigeration technology. Designed and engineered by Star Refrigeration for unrivalled performance in process cooling and air conditioning, this compact packaged chiller offers the ultimate cooling solution to forward-thinking operators.

Cool DesignIndigochiller was developed in direct response to f-gas regulations and the design aims to eliminate refrigerant leakage. It features bellows seal valves, sealed expansion valves and welded steel pipework.Refrigerant charge is monitored by the chiller’s PLC control system to provide early warning of any potential refrigerant loss. Indigochiller is engineered to have minimal effect on the global environment. It provides an alternative ‘responsible use’ chilling solution.

Cool PowerIndigochiller is a low charge, high performance chiller for medium to large scale operations. Available as an air-cooled or water-cooled unit, Indigochiller has capacity options ranging from 250kW to 1,650kW.All air and water-cooled chillers are factory run tested at our production facility prior to dispatch and client witness testing is also available.

Cool TechnologyIndigochiller features the revolutionary Turbocor compressor. It operates on electromagnetic bearings and uses the synthetic refrigerant R134a. The unique oil-free system offers reliable, hassle free performance. This ensures Indigochiller requires minimal installation, service and maintenance.

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Cool LooksIndigochiller is compact and provides an ideal solution where space constraints are paramount. The air-cooled packaged unit has all major components internally housed. Options are available for white wipe clean cladding finish on the evaporator and pipework.

Cool SoundsIndigochiller is engineered to ensure minimal vibration and low noise. The water-cooled unit is ideally suited to populated production areas and commercial environments due to the noise from each compressor being a mere 73dB(A) @ 1m. The air-cooled Indigochiller is available in a range of noise levels to suit all applications including an ultra-quiet night mode.

Cool ControlIndigochiller features a control system which continuously monitors efficiency and compares real time data against a predetermined performance map stored within the PLC. Deviation of performance is reported on the PLC HMI and can be relayed via modem to our local support office so that any necessary action can be planned. This helps ensure Indigochiller retains optimum performance throughout its operating life. Options include:

Supervisor control for multiple chillers Data and trend logging Remote access Alarm monitoring via Star’s 24/7 call out facility Interface with site BMS and other monitoring systems

Cool RunningIndigochiller is highly energy efficient. Star’s research shows it uses only 60% of the energy required by a standard chiller operating on typical load and ambient profiles. This offers end users a significant saving in energy and running costs.

Cool CareThe refrigeration system is oil-free and so routine maintenance has been reduced to a minimum. There are no requirements for regular inspection or intervention within the compressor and so the risk of refrigerant loss during routine maintenance is also minimised. The leak detection requirements of the f-gas regulations have been reduced to a few simple checks.

Cool CoverIndigochiller is manufactured from the highest quality components to produce a chiller with a life expectancy of 20+ years. Our confidence in the quality and reliability of Indigochiller means we offer a 3 year maintenance backed warranty package on parts, efficiency and refrigerant loss with an option to extend to up to 5 years.

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Cool RevolutionIndigochiller features a revolutionary Turbocor centrifugal compressor. The compressor is low maintenance by design, ensuring lifelong trouble-free running.

The compressor is oil-free and operates on electromagnetic bearings. This ensures minimal vibration and noise, even when running at very high speed.

Compressor - key features: Oil-free

High speed system

Electromagnetic bearings

Integral inverter

Stepless capacity control

One moving part

Low weight and component size

Low maintenance

High efficiency operation

Low noise and vibration

High speed reliability

Excellent part load performance

Low starting current

Zero burnout risk

Inside an IA750S air-cooled Indigochiller

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Electrical panel ventilation Electrical panel anti-condensation heaters Integral unit and panel lighting for safe

maintenance (air-cooled Indigochiller) PID temperature control Continuous efficiency monitoring. This is displayed on the PLC HMI and provides a visual warning of deviation from design performance Lifetime refrigerant charge logging facility in PLC

Indigochiller is mounted on a robust welded baseframe with:

Fully welded construction

Permanent lifting lugs Aluminium floor for ease of maintenance (option

on air-cooled Indigochiller) Easy access to condenser coils for cleaning Petrochemical standard epoxy paint finish

Cool ComponentsAll Indigochiller components have been selected to minimise the risk of refrigerant leakage, optimise performance, reduce maintenance costs and enhance the chiller’s operating life. The result is a chiller that delivers low life-cycle cost to end users.

Standard components include: EC condenser fans (air-cooled Indigochiller) Bellows seal valves Welded interconnecting steel pipework Epoxy coated condenser fins (air-cooled Indigochiller) Low pressure drop discharge non-return valve

design Steel bodied expansion valve with precision

controlled hermetically sealed magnetic drive, manual control override, UPS back up and position feedback for assurance of correct operation

Dual relief valves for ease of maintenance, with bursting discs for leak-free operation and standard three-way changeover valve for ease of cost effective maintenance

Powder coated mild steel electrical panel (option for stainless steel)

Mitsubishi PLC with HMI user interface

Indigochiller HMI user interface

EC Condenser Fans

Magnetically driven expansion valve

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Cool AirThe air-cooled Indigochiller is a complete refrigeration package housed in one unit. Typical applications include new and retrofit systems in the building services and process cooling industries.

The Indigochiller is available in two noise ranges, S and R. The S model’s low sound levels make it suitable for most applications. Industry standard chillers would typically require acoustic attenuation packages to achieve similar sound levels. The R model of Indigochiller achieves residential noise levels without the requirement for expensive, heavy and unsightly acoustic attenuation packages.

Indigochiller avoids the reduction in chiller performance and efficiency, as well as the increase in maintenance and access time associated with the use of external attenuation.

Each unit comprises Turbocor centrifugal compressor(s), shell and tube heat exchanger evaporator, air-cooled condenser, electrical control panel and all interconnecting pipework, valves and wiring.

Calculating the integrated part load value (IPLV)coefficient of performance using the ARI550/590standard indicates that Star’s Indigochiller uses 60% of the energy of a standard air-cooled chiller.

Air-cooled Indigochiller utilises EC fan techonology coupled with floating head pressure to enhance part load chiller efficiency. The PLC control system integrates fan speed, head pressure and compressor control to optimise chiller efficiency during periods of low ambient temperature and reduced cooling load.

Maintaining chiller performance throughout its operating life was a key requirement during the development of Indigochiller. To ensure this is the case, all air-cooled chillers include epoxy coated fins as standard and our quoted performance figures are based upon this design. Fin protection is also included as standard both internally and externally to prevent damage during installation and future operation.

The condenser frame forms a walk-in maintenance space. Components are readily accessible for maintenance and the condenser coil arrangement has been designed for ease of cleaning.

The air-cooled condenser has been designed for efficiency, reliability and safety. Key features include:

Copper tubes, aluminium fins

Epoxy coated fins

Fin protection (internal and external)

Variable speed EC type condenser fans

Top and bottom fan guards

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* For R models at design conditions the FLC will never be reached due to lower fan speed.Indigochiller starting currents never exceed the full load current, even momentarily and regardless of the operating conditions. This allows a smaller power supply system to be used as the Indigochiller avoids the inrush current normally associated with starting compressors. Information in the table above is subject to change. Please contact Star Refrigeration for current technical specification.Revision - September 2010.

250 kW Units 500 kW Units 750 kW Units 1000 kW Units

IA250S IA250R IA500S IA500R IA750S IA750R IA1000S

GEN

ERAL

Capacity (kW) 250 250 500 500 750 750 1000

Dry Bulb Temperature (°C)

35 35 35 35 35 35 35

Power Supply 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50

Sound Pressure Level (dB(A) @ 10m) 61 56 64 59 65 61 67

Dimensions (m)(L x W x H)

3.4 x 2.3 x 2.35 4.4 x 2.3 x 2.35 5.9 x 2.3 x 2.35 8.3 x 2.3 x 2.35 9.1 x 2.3 x 2.35 10.1 x 2.3 x 2.92 10.1 x 2.3 x 2.92

Dry Weight (kg) 3740 4164 5896 7222 9482 11,248 12,661

Operating Weight (kg) 4055 4479 6404 7729 10,197 11,963 13,881

Refrigerant R134a R134a R134a R134a R134a R134a R134a

Full Load Current (A)* 150 155 300 310 450 455 600

Water Pipes Size 100NB 100NB 125NB 125NB 150NB 150NB 150NB

CEN

TRIF

UG

AL

COM

PRES

SORS Quantity 1 2 3 4

Max. Absorbed Power(kW)

86 86 each 86 each 86 each

Enclosure IP54 IP54 IP54 IP54

AIR

COO

LED

CON

DEN

SER No. of Fans 6 8 12 16 18 20 20

Air Flow Volume (m3/s) 26.5 24.8 52.0 49.6 75.0 68.0 88.0

Max Absorbed Fan Power (kW)

8.1 4.3 16.2 9.6 24.3 12.0 27.0

SHEL

L AN

D TU

BE E

VAPO

RATO

R

Shell Side Medium R134a R134a R134a R134a

Tube Side Medium Water Water Water Water

Tube Temp In/Out (°C) 12/7 12/7 12/7 12/7

Chiller Max Absorbed Power (kW)

88.5 85.2 177.0 170.4 265.5 253.2 348.6

Tube Temp In/Out (°C) 12/6 12/6 12/6 12/6

Chiller Max Absorbed Power (kW)

92.4 89.1 184.8 178.2 277.2 264.9 364.2

Water Flow (m3/h)(min/design/max)

30 / 36 / 55 61 / 72 / 111 82 / 108 / 150 103 / 144 / 187

Water Pressure Drop (kPa)

19 / 26 / 58 19 / 25 / 56 24 / 39 / 73 30 / 55 / 90

Technical Schedule

HEIG

HT “H

”

WIDTH “W”

LENGTH

“L”

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The water-cooled unit features a shell and tube evaporator and condenser to cut the risk of refrigerant loss. This style of evaporator is highly reliable and provides excellent chilling capacity in a small footprint.

The water-cooled Indigochiller is also available with a sophisticated cascade control system. This allows total control of flow temperature in process cooling applications, even under varying load conditions.

The flooded shell and tube evaporators and condensers have been designed to minimise the potential for leakage and optimise reliablility. Evaporator features on both the air-cooled and water-cooled Indigochiller include:

Enhanced tubes

Integral helical fins Enhanced boiling effect Close temperature approach (1.5K) Variable evaporating temperature

Cool WaterIndigochiller is available as a compact unit with a water-cooled condenser. Typical applications include HVAC and process cooling in dairy, pharmaceutical and petrochemical facilities.

Water-cooled units have nominal capacities of 275kW to 1,650kW, chilling water from 12°C to 6°C. The entry level model offers 275kW of cooling capacity from a unit less than 4m² (2.8m x 1.3m).

Water-cooled units have noise levels of 73dB(A) at 1m for each compressor. This makes them ideal for use within a populated production area, without the need for sound attenuation.

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* Indigochiller starting currents never exceed the full load current, even momentarily and regardless of the operating conditions. This allows a smaller power supply system to be used as the Indigochiller avoids the inrush current normally associated with starting compressors. Information in the table above is subject to change. Please contact Thermo Tech for current technical specification.Revision - September 2010.

250 kW Unit 500 kW Unit 750 KW Unit 1000 kW Unit 1250 kW Unit 1500 kW Unit

IW250 IW500 IW750 IW1000 IW1250 IW1500

GEN

ERAL

Capacity (kW) 275 550 825 1100 1375 1650

Power Supply 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50

Sound Pressure Level dB(A) @ 1m 73 76 78 79 80 81

Dimensions (m) – (L x W x H) 2.65 x 1.3 x 1.75 4.25 x 1.3 x 1.75 5.4 x 1.5 x 1.75 5.92 x 1.55 x 1.95 5.6 x 2.0 x 2.2 5.6 x 2.0 x 2.2

Dry Weight (kg) 2116 3093 5165 6787 9284 9862

Operating Weight (kg) 2369 3610 5910 7923 10,862 11,676

Refrigerant R134a R134a R134a R134a R134a R134a

Full Load Current (A)* 140 280 420 560 700 840

CEN

TRIF

UG

AL

COM

PRES

SORS

Quantity 1 2 3 4 5 6

Max. Absorbed Power (kW) 86 86 each 86 each 86 each 86 each 86 each

Enclosure IP54 IP54 IP54 IP54 IP54 IP54

SHEL

L AN

D TU

BE C

ON

DEN

SER Tube Side Medium Water Water Water Water Water Water

Shell Side Medium R134a R134a R134a R134a R134a R134a

Tube Temp In/Out (°C) 29/35 29/35 29/35 29/35 29/35 29/35

Water Flow (m3/h) (min/design/max) 35 / 49 / 83 56 / 98 / 134 76 / 147 / 183 101 / 197 / 242 122 / 244 / 295 144 / 293 / 329

Water Pressure Drop (kPa) 9 / 17 / 47 11 / 33 / 58 12 / 39 / 59 11 / 40 / 59 13 / 50 / 73 13 / 55 / 69

Water Pipe Size 100NB 125NB 150NB 150NB 200NB 200NB

SHEL

L AN

D TU

BE E

VAPO

RATO

R

Shell Side Medium R134a R134a R134a R134a R134a R134a

Tube Side Medium Water Water Water Water Water Water

Tube Temp In/Out (°C) 12/7 12/7 12/7

Chiller Absorbed Power (kW) 60.0 120.0 180.0 240.0 300.0 360.0

Tube Temp In/Out (°C) 12/6 12/6 12/6

Chiller Absorbed Power (kW) 62.8 125.6 188.4 251.2 344.0 376.8

Water Pipe Size 100NB 125NB 150NB 150NB 200NB 200NB

Water Flow (m3/h) (min/design/max) 30 / 39 / 55 61 / 79 / 111 82 / 118 / 150 103 / 158 / 187 117 / 197 / 237 140 / 236 / 284

Water Pressure Drop (kPa) 19 / 31 / 58 19 / 30 / 56 24 / 47 / 73 30 / 66 / 90 21 / 58 / 83 21 / 60 / 87

Technical Schedule

”H“

TH

GIE

H

WIDTH “W”

LENGTH “L”