R- 410A Series Zero Ozone Depletion

Size: px

Start display at page:

Download "R- 410A Series Zero Ozone Depletion"

Edgar Francis
5 years ago
Views:

1 Form: WR-GS-0705 GENERAL SPECIFICATION Compact Connectable Reversing 10-30HP Water to Water Geothermal Heat Pump R- 410A Series Zero Ozone Depletion Chiller Solutions LLC, 2008

2 General Description The WR Series is an R-410a extended range packaged water to water reversing geothermal heat pump designed to operate at standard ISO geothermal conditions. Each modular GHP is neatly packaged within a compact aluminum structural frame with stainless steel removable service panels. Modules from 10 to 30 HP utilize a single R-410a scroll compressor and are packaged in the same sized cabinet with the same piping connections to allow the modules to be stacked and/or placed side by side. The modules can be interconnected using a piping header kit which includes standard ball valves and P/T ports. These header kits will connect up to four modules in a row to allow simple common piping to the supply and return of each of the water to refrigerant heat exchangers. While each module is able to operate individually, the controls can be packaged to link multiple units into a unit control group that operates though a GCM (geothermal control module). The GCM serves to control unit staging, operation, and pumping controls for a totally packaged solution which is flexibly applied to the number of WR series modules, tanks, and pumps. Reverse refrigerant cycle operation of each of the modules provides the ability to switch from a chiller function to a heating function. This allows for simple hydronic design of the building piping system. Modules are designed to be easily maneuvered through any standard door. General Design Parameters Each module contains a single high efficiency scroll compressor with R-410a refrigerant providing minimum global warming impact and zero ozone depletion. Additionally, the module is packaged with an oversized stainless steel refrigerant to water evaporator and condenser to maximize efficiencies into extended range applications. Other refrigeration controls include high and low refrigerant pressure controls, electronic expansion valve, dual bi-flow liquid line filter driers, and refrigerant pressure transducers. Each module includes a control system that can be linked to a Master Control Module - either independently or in groups of up to six modules. High Efficiency Scroll Compressors Refrigeration System The scroll compressors are a nominal 3500 rpm at 60 Hz and 2900 rpm at a 50 Hz hermetically sealed with a vibration isolated mounting assembly. The compressor is unidirectional and will only pump refrigerant when the compressor motor is wired in the proper electrical phase sequence. The compressor has as standard features an oil sight glass and an oil charging valve. Each compressor comes with an overload module which monitors motor winding temperature, phase, and voltage. The compressor is installed just behind the front mechanical access panel to allow for simple service or maintenance. 2 Chiller Solutions LLC, 2008

3 Evaporator and Condenser The evaporator and condenser are compact 316L stainless steel heat exchangers. The heat exchangers consist of stainless steel embossed plates stacked so that every other plate is rotated 180. The spaces between the plates form the channels for the refrigerant and the coolant. Between every two plates is a thin foil of copper. When heat in a vacuum is applied to the heat exchanger the copper is melted and is drawn into all the plate contact points and seams. The heat exchanger is fully pressure tested and rated for use with R410a refrigerant. Each heat exchanger shall be fully insulated to guard against radiation transmission as well as condensation. Reversing Valve (RSV) The 4 way reversing solenoid valve is an on/off type valve which operates when the energized solenoid coil uncovers a port inside the valve allowing it to shift from the heating to the cooling function. This valve is designed to redirect refrigerant flow, thus reversing the functions of both of the water to refrigerant heat exchangers. The RSV is pressure tested and rated for use with R410a refrigerant. Liquid Line Filter Dryer (LLFD) The liquid line filter dryer is a hermetically sealed type designed to assist in screening and dehydrating the liquid refrigerant returning from the condenser. The filter dryer is installed upstream of the expansion valve for additional protection. Two filter driers are provided in a parallel configuration in modules over 15 HP to allow for the appropriate surface area. The LLFD is pressure tested and rated for use with R410a refrigerant. Electronic Expansion Valve (EXV) The Electronically Operated Step Motor flow control valve is used for the precise control of liquid refrigerant flow. Synchronized signals to the motor provide discrete angular movement, which translates into precise linear positioning of the valve piston for refrigerant. Valve pistons and ports are uniquely characterized, providing improved flow resolution and performance. The EXV is easily interfaced with the microprocessor based controller. This unique expansion valve design allows precision refrigerant control in either heating or cooling mode. The EXV is pressure tested and rated for use with R410a refrigerant. 3 Chiller Solutions LLC, 2008

4 Fluid Piping Piping The primary refrigerant piping for the chiller shall be copper type L. All copper piping shall be brazed with 5% Sil-Fos. All piping is to be assembled using Chiller Solutions piping and brazing procedures. Fluid side connections shall be Victaulic style roll groove to the manufacture supplied headers. The patented Style 607 rigid coupling joins 2-4 ( mm) rolled grooved, harddrawn copper tubing (CTS). The joint is assembled without disassembling the bolts, nuts, gasket and housings. The Style 607 coupling requires lubrication be applied to the sealing lips of the gasket before sliding the coupling on pipe grooved to Victaulic specifications. Insulation All components subject to operation below dew-point shall be insulated with ¾ inch closed cell elastomeric insulation. The expanded closed-cell structure of the pipe insulation makes it an efficient heat and vapor barrier. It is manufactured without the use of CFC's, HFC's or HCFC's. It is also formaldehyde free, low VOCs, fiber free, dust free and resists mold and mildew. The insulation has a flame-spread index of less than 25 and a smoke-developed index of less than 50 as tested by ASTM E and CAN/ULC S-102. Insulation shall be further vapor sealed using a silicone or butyl based sealant. Pipe Header Assembly Modules can easily be connected to common piping using factory provided header assemblies. These header kits provide easy attachment of 2 to 4 modules in a parallel piping arrangement. Each unit header can utilize Victaulic connection style ball or butterfly valves with hand or motorized actuators to allow flow control or service isolation of the entire fluid side of each module. Each inlet/outlet also is provided with a ¼ P/T port to allow for accurate pressure and temperature measurement of the fluid side of each module. Each header kit is supplied with base insulation, leaving only the actual connection points to be field insulated. Field Victaulic connections are available in Australian Standard (Request 22.10) British Standard (Request 22.08) and DIN Standard (Request 22.09). Electrical Electrical Enclosure The module shall be complete with a self contained operating and safety panel mounted inside an approved enclosure. This panel will include the compressor starter/motor protector along with the module control board. The electrical panel is accessible from a cover panel mounted on the front access side of the module. This cover panel may only be removed through the use of appropriate tooling, standard for HVAC and refrigeration servicing. The unit electrical diagram and process/instrumentation diagram is laser engraved onto a coated aluminum plate then securely fastened to the interior of the access panel. Each panel also contains laser engraved placards for 4 Chiller Solutions LLC, 2008

5 each component for simple reference to the spare parts list, 3D model, or unit diagrams. Field electrical connection is on the rear facing side of the module. High/Low Pressure Transducers Each module utilizes suction and discharge pressure transducers to provide +/- 1.2% accurate readings of the refrigerant pressures. The transducers are rated for use in R-410a applications including all extended range temperatures included in the module performance chart. The pressure transducers provide a 4-20 ma signal to the control board to monitor the safe operation of the refrigerant system. The suction pressure transducer also provides accurate sensing of the saturated evaporating temperature of the refrigerant to control the electronic expansion valve. Motor Protection Each motor and the control circuit on the system will be protected with an independent breaker sized to provide over-current and thermal protection. Each breaker shall be capable of isolating each motor or control circuit for service. Each breaker shall also provide the appropriate branch circuit protection as prescribed by CE & NEC. Each breaker shall be rated to operate at 50 C in the D x magnetic release performance range in approximately one tenth of one second. Breakers are tropicalized to 55 C and 95% RH (Acc. IEC ) Primary Module Control (PMC) Control System The primary control system is a simple control board to provide I/O analog and digital, along with relay outputs to the compressor contactor and reversing valve solenoid. Each module has room for expansion for additional accessories, although the primary control system provides all safety and operating controls, such as suction and discharge pressure safety lockouts, operational sequence control- including compressor time delay, and electronic expansion valve monitoring or adjustment. The control provides 30 second data logging prior to any safety lockout. One module in each group will be designated the master control module. The master control module simply replaces the standard unit control module by unplugging the unit control board and replacing it with the master control board. Up to six modules can be grouped under this platform. Geothermal Control Module (GCM) The Geothermal Control Module is the same control as the master control used on each group. The GCM is configured to control the overall system operation. This could include algorithmic staging of the compressors, loop pump VFD controls, temperature/pressure monitoring, and alarm points. The GCM is configurable to meet specific building requirements and can communicate with several building automation system protocols including BACnet (MS/TP, PTP or ARC 156), LonWorks, Modbus, and Johnston N2. 5 Chiller Solutions LLC, 2008

6 Remote Access of Controls As long as a porthole can be established, either the master control or GCM can be accessed remotely through a PC connect or even a modem. This enhanced service allows the factory or service personnel to remotely access, monitor, or troubleshoot a module or system. Base Frame Structural The base frame shall be constructed of heavy gauge welded stainless steel. This base frame contains engineered mounting systems for each of the components. When set in place, the frame distributes the entire weight of the components uniformly across the base allowing the modules to be stacked up to two high. Module Enclosure The module enclosure shall be constructed of heavy duty extruded aluminum structural members connected together using cast aluminum corners. This modular framing system provides superior structural integrity to allow the removal of any of the access panels for service. Lifting attachment points are provided on each of the four corners. Only a qualified rigging professional should attempt moving this unit. 6 Chiller Solutions LLC, 2008

7 Physical Data WR-25-1Z5 Electrical Data Dimensions L W H Module (cm) Crated (cm) Dry Weight 270 kg Volts Phase HZ Compressor Total Unit MFS MCA Qty HP FLA FLA Operating Weight Oil Weight Refrigerant Weight Victaulic Connections Electrical Connections 295 kg 6.7 litre 9 kg 5.4 cm 4.8 cm FLA is at 5 C LCT and 36 C Leaving Fluid Temp WR-25-1Z5 ***Capacity (Watts)*** Leaving Coolant Temperature ºC LFT ºC WR-25-1Z5 ***Power (Watts)*** Leaving Coolant Temperature ºC LFT ºC WR-25-1Z5 ***Coefficient of Performance (COP)*** Leaving Coolant Temperature ºC LFT ºC Chiller Solutions LLC, 2008

284.3 mm A. B. C. D. E. F. 48.3 mm ELECTRICAL CONNECTION 54.

7 mm A F LEFT TOP FRONT WITH COMPRESSOR PANEL REMOVED 762.0 mm 914.4 mm E D FRONT 914.4 mm 312.7 mm 658.6 mm 804.6 mm 156.6 mm 109.

8 284.3 mm A. B. C. D. E. F mm ELECTRICAL CONNECTION 54.0 mm VICTAULIC CONNECTIONS COMPRESSOR COMPRESSOR ACCESS PANEL ELECTRICAL ACCESS PANEL REMOVABLE PANEL E F mm C B B BACK B B mm A F LEFT TOP FRONT WITH COMPRESSOR PANEL REMOVED mm mm E D FRONT mm mm mm mm mm mm F RIGHT PRODUCTION DRAWING CHILLER SOLUTIONS, LLC. 101 ALEXANDER AVE. - UNIT 3 - POMPTON PLAINS, N.J PHONE:(973) FAX: (973) STANDARD MODEL: WR SERIES SERIAL NO : STOCK BY: CHKD: CA DATE: NONE SCALE: DWG. NO: MAIN

9 395.3 mm mm mm mm TOP VIEW mm mm mm mm mm mm mm mm mm mm.0 mm PRODUCTION DRAWING CHILLER SOLUTIONS, LLC. 101 ALEXANDER AVE. - UNIT 3 - POMPTON PLAINS, N.J PHONE:(973) FAX: (973) STANDARD MODEL: WR SERIES FRONT VIEW SERIAL NO : STOCK BY: CHKD: CD CA DATE: SCALE: NONE DWG. NO: MAIN JOB ASSEMBLY

10 FULL PORT 54 mm BALL VALVE mm mm mm 19.1 mm ARMAFLEX INSULATION 54 mm VICTAULIC CONNECTION mm 4" VICTAULIC CONNECTION PRODUCTION DRAWING CHILLER SOLUTIONS, LLC. 101 ALEXANDER AVE. - UNIT 3 - POMPTON PLAINS, N.J PHONE:(973) FAX: (973) STANDARD MODEL: WR SERIES SERIAL NO : STOCK BY: CHKD: CD CA DATE: SCALE: NONE DWG. NO: HEADER

B. Unit construction shall comply with ASHRAE 15 Safety Code, NEC, and ASME applicable codes (U.S.A. codes).

B. Unit construction shall comply with ASHRAE 15 Safety Code, NEC, and ASME applicable codes (U.S.A. codes). Guide Specifications PART 1 GENERAL 1.01 SYSTEM DESCRIPTION Microprocessor controlled, air-cooled liquid chiller utilizing scroll compressors, low sound fans, hydronic pump system and optional fluid storage