AQUA LinkTM. Advanced hydronic module. General. Quick facts

Transcription

1 TM Advanced hydronic module The cover image is based on AQUA Link LN version. General AQUA Link is a pioneering hydronic module designed to optimise connection between the chiller and the users in plants featuring both an air handling unit (for air ventilation and humidity control) and chilled beams (for ambient temperature control). AQUA Link always produces and distributes the exact right amount of water at the exact required temperature to both cooling coils and for example chilled beams. AQUA Link contains all you need in a water circuit between a Swegon chiller and GOLD air handling unit. The former time-consuming and expensive process is now replaced with Plug and Play! Quick facts One single interlocutor for the entire plant eliminates possible inconveniences relating to identification of responsibilities and difficult communications with the various parties involved; The system only requires hydronic and electrical connection between the chiller, the users and the AQUA Link to operate. All equipment and components are condensed in one unique volume and AQUA Link can be placed outdoor. Energy efficient through demand controlled operation and energy efficient pumps.

2 Contents Features and operating principle 3 Technical characteristics 4 Technical data 6 Operating limits 7 Energy analysis 10 Overall dimensions, weights and hydronic 18 connections Single-line hydronic diagram 26 Installation tips 28 Summary of unique selling points 29 2

3 Features and operating principle The hydronic module AQUA Link is designed to optimise connection between the chiller and the users in plants featuring both an air handling unit (for air ventilation and humidity control) and chilled beams for ambient temperature control (or other elements like fan coils for example). The control algorithm gives high benefits in terms of energy consumption, which is minimised through the control of several parameters at a time. These parameters are: temperature setpoint of chilled water produced by the chiller, pump rotation (both in primary and secondary circuits, if any), opening of the water flow control valves. Some additional benefits are granted at installation: the module, in fact, already features all the required elements, which consequently do not need to be provided for separately and are governed by one single controller. Temperature setpoint modulation The temperature at which chilled water is produced to the chiller (mix of water and glycol for glycol version and pure water for No Glycol version), that is directly connected to the refrigerant evaporation temperature, is essential for the determination of the energy efficiency coefficient of the chiller (EER or ESEER when considered in seasonal terms). In traditional plants where one chiller feeds both the air handling units and the chilled beams, the cold fluid is supplied at one temperature only (typically 7 C) and is blended with the fluid returning from the chilled beams so that the correct water supply temperature is guaranteed. Actually, the production of fluid at such low temperature is not always required. Consider, for instance, that the correct water supply temperature to the chilled beams is normally around 14 C: forced dehumidification is not always necessary in air handling units, especially in climate conditions such as those in Northern European countries, and free cooling may be adopted frequently. This enables feeding the users with water at a temperature that is often above 7 C, which consequently leads to a direct increase in the chiller energy efficiency. The variable chiller setpoint and continuous transfer of operating parameter data between the controllers on the users side and the chiller keep the fluid production temperature as high as possible and, in any case, such as to fully meet the users requirements. This operating logic offers a substantial benefit in terms of energy consumption minimisation thanks to enhanced chiller operating efficiency. Water flow rate modulation The amount of energy used to pump the fluid is linked to the flow rate required by the users. A decrease in the amount of pumped water causes a proportional reduction of the energy spent for this purpose. The water flow rate required to the users basically depends on the water load to be supplied. This is substantially variable according to, for instance, the number of chilled beams to be fed against the total number of chilled beams installed, which need to be served in full load conditions. The water flow rate is modulated, and energy consumption for pumping is consequently reduced, thanks to inverters and variable pumps which are operated by a signal detected by a probe fitted in the hydronic piping. 2-way valve opening modulation The primary circuit features two 2-way valves that control the destined flow to the AHU and to the plate heat exchanger (or mix manifold for No Glycol version) respectively. This arrangement allows for the use of one single pump in the primary circuit, which leads to a reduction in both installation and plant management costs. The valves are modulated according to the actual requirements of each user. The modulation speed of these valves is such as to provide a quick and accurate response to the users requirements. 3

4 AQUA Link An evolved hydraulic module designed to optimise the energy specifications of chilled water production and distribution systems requiring the simultaneous presence of a primary air treatment unit and internal end elements for the treatment of secondary air. The module is available in two main configurations suitable for operation: --with a percentage of Glycol between 20% and 40% in the primary circuit --without Glycol in the primary circuit (AQUA Link NG; the secondary circuit never contains Glycol) The range of power available to the various utilities (UTA and Chilled Beams) varies based on the version that is being examined, as the two configurations (with and without Glycol) are suitable for operation in different climatic conditions where the powers intended for fresh air and secondary air treatment differ greatly. For further information on this topic please refer to the data provided in the attached tables. STRUCTURE Indoor version structure The load bearing frame is built with polished, pickled sheet steel with textured epoxy-polyester powder coating (Colour RAL 7035). Stainless steel screws Outdoor version structure The load-bearing frame is built with galvanised sheet metal, painted with textured polyester powders RAL 7035 at 180 C, which confer high resistance to atmospheric agents. Stainless steel screws. Panelling Built from sheet metal coated with textured RAL The removable doors are fitted with handles to make them easier to take out. HYDRONIC CIRCUIT Common standard parts include: primary circuit pump, 2-way regulation valve on the primary circuit to regulate the temperature to the secondary circuit, gate valves, expansion vessel, relief valve. The version with Glycol also includes: inertial tank, plate exchanger The NO Glycol version also includes: mixing manifold HEAT EXCHANGER (only for the version with Glycol) AISI 316 stainless-steel braze-welded plate evaporator, housed inside a closed-cell insulating casing. The exchanger can be single or double. Double exchangers are already supplied complete with manifold to guarantee a single hydraulic fitting. MIXING MANIFOLD (only for the NO Glycol version) It has an adequate diameter to ensure the water flows are mixed correctly and is supplied with a relief valve and drainage valve to promote drainage. PRIMARY CIRCUIT ELECTRIC CIRCULATION PUMP (Gold supply + plate exchanger or mixing manifold) One-piece impeller pump with direct motor-pump coupling using a single shaft in chrome-plated steel. Cast iron body and impeller, mechanical seal, two-pole three-phase electric motor with electric protection IP 54. Variable-operatinon pump controlled by external inverter. It is possible to choose the single or double-circulation pump version managed with rotation logic and assistance in case of failure. The pumping unit in the version with Glycol is suitable for operation with elevated glycol percentages, between (20% and 40%). SECONDARY CIRCUIT ELECTRIC CIRCULATION PUMP (Chilled Beams supply, optional) One-piece impeller pump with direct motor-pump coupling using a single shaft in chrome-plated steel. Cast iron body and impeller, mechanical seal, two-pole three-phase electric motor with electric protection IP 54. Variable-operating pump controlled by external inverter. It is possible to choose the single or double-circulation pump version managed with rotation logic and assistance in case of failure. CIRCULATION PUMP ROTATION SPEED REGULA- TION INVERTER Each pump (or pair of pumps) is governed by a dedicated inverter controlled by customised regulating logic. The inverters are contained inside the electric control panel which is accordingly cooled by installed fans and shutters for air circulation. TWO-WAY MODULATED VALVE INSTALLED ON THE PRIMARY CIRCUIT TO REGULATE THE TEM- PERATURE OF THE SECONDARY CIRCUIT Motorised automatic regulation valve to control the flow of water to the plate exchanger or to the mixing manifold. The valve is regulated by a temperature signal sent by a probe on the water flow pipe downstream of the plate exchanger. The temperature probe is installed on the secondary branch when the unit is configured with circulation pumps on the secondary branch. Alternatively, the probe is supplied and must be installed according to the instructions provided in the user and maintenance manual. ELECTRIC CONTROL BOARD The board includes: main isolating switch thermal magnetic circuit breakers for the pumps 4

5 pump relays three-phase inverter rpm regulator for each hydraulic circuit protective thermal magnetic circuit breakers for the inverter/s IQnomic module to manage I/O signals from the utilities cut-off transformer cooling fan Electrical power supply 400V/3~/50Hz. CHECKS AND SAFETY DEVICES temperature probe in the flow water to the Chilled Beams circuit probe to control the rate of pump operation on the primary circuit (if there are pumps on the circuit a probe will also be installed on the secondary circuit). motorised two-way infeed valve to the heat exchanger or the mixing manifold. the standard version for outdoor installation is equipped with frost-protection heating elements for the plate exchanger, when included (version with Glycol), and for the main parts when the temperatures make it necessary. INSPECTION The units are inspected in factory to check the hydraulic seal and correct electrical cabling of the parts. VERSIONS and ACCESSORIES Single circulation pump for primary circuit (standard- AQUA Link 1P) The design includes only one circulation pump on the primary circuit. The same pump supplies the thermal exchange coil inside the air treatment unit, as well as the plate exchanger or the mixing manifold on the Chilled Beams circuit. The circulation pump is controlled by an inverter that regulates the speed of rotation based on the real request from the utilities. There are two types of useful pump head: standard head and increased head. Double circulation pump on the primary circuit (optional AQUA Link 2P) The design includes 2 circulation pumps on the primary circuit. The operating logic controls timed operation of the 2 pumps and the automatic intervention of the operating pump if one of the two breaks down. It is possible to choose between two types of useful pump head: standard head and increased head. Circulation pumps to the secondary circuit on the Chilled Beams circuit (optional AQUA Link 1P-1P/2P-2P) The standard unit does not require the use of circulation pumps to supply the Chilled Beams. It is possible to select either a single or double circulation pump accessory for the secondary circuit. It is possible to choose between two types of useful pump head: standard head and increased head. The double pump to the secondary circuit can only be selected if there is a double pump to the primary circuit. The possible versions, with reference to the number of pumps only, are therefore: 1 pump to the primary (AQUA Link 1P) 1 pump to the primary and one pump to the secondary (AQUA Link 1P-1P) 2 Pumps to the primary (AQUA Link 2P) 2 pumps to the primary and 2 pumps to the secondary ( AQUA Link 2P-2P) Version for indoor installation (standard AQUA Link IN) This version does not have closing panels along its perimeter or a cover on top (supplied separately as an option). Any electrical resistance is provided to protect the components, regardless of the percentage of glycol. Version with Glycol for outdoor installation (optional AQUA Link OD) This version is designed with closing panels around the entire perimeter and cover on top. The structural work is built with galvanised sheet steel painted with textured polyester powders in RAL The electrical control panel is designed to provide protection IP 55. Plate exchanger and circulation pumps (if included) on the Chilled Beams circuit will always be protected from low temperatures by a heating cable. The installer must be careful to protect sections of pipes that send supply water for the secondary circuit to the AQUA link unit inside the building from frost. For glycol percentages up to 30%, at a minimum outdoor temperature of -10 C, no other additional form of protection is required. With glycol percentages between 30% and 40% heating cables are added to protect the pumps, the servo-control for the 2-way valve and the electric control panel. No Glycol version NG (optional- AQUA Link NG) The No Glycol version requires both primary and secondary pumps to operate on pure water, without the addition of ethylene Glycol. This version is therefore suitable for operation in mild climatic conditions where the temperatures never subject the system to the risk of frost (for example: completely indoor installation). The last two digits of the machine s alphanumeric identification code indicate the percentage of Glycol required for the primary circuit. In the No Glycol version, these two digits are replaced by the acronym NG. If this version is used for outdoor installation, a series of heating cables will need to be set up accordingly to protect: pump volutes, mixing manifolds, pipes inside the machine. WARN- ING: it is the installer s responsibility to protect the sections of machine infeed and outfeed pipes that lead to the chilled beam circuit and chiller, including the inertial tank. 5

6 Technical data AQUALink with glycol STANDARD PRIMARY PUMP* OVERSIZED PRIMARY PUMP* STANDARD SECONDARY PUMP* OVERSIZED SECONDARY PUMP* DIMENSIONS AND WEIGHT (1) (2) WATER GLYCOL MIXTURE TANK VOLUME AQUA Link size Chiller reference capacity [kw] da 90 a 110 da 111 a 143 da 144 a 224 da 225 a 293 Nominal absorbed power [kw] 2,2 2,2 4 5,5 Maximum absorbed power permitted (4) [kw] 2,21 2,37 4,06 5,52 Nominal absorbed current [A] 4,7 4,7 7,9 10,6 Nominal absorbed power [kw] 3 3 5,5 7,5 Maximum absorbed power permitted (4) [kw] 3,2 3,02 5,52 7,57 Nominal absorbed current [A] 6,2 6,2 10,6 14,7 Nominal absorbed power [kw] 2,2 2,2 4 5,5 Maximum absorbed power permitted (4) [kw] 2,37 2,37 4,06 5,52 Nominal absorbed current [A] 4,7 4,7 7,9 10,6 Nominal absorbed power [kw] 3 4 5,5 7,5 Maximum absorbed power permitted (4) [kw] 3,02 4,06 5,52 7,57 Nominal absorbed current [A] 6,2 7,9 10,6 14,7 Length [mm] Height [mm] Depth [mm] Weight [kg] (3) [l] * The values in the table are valid for primary loop glycol percentages from 20% to 40% * The values in the table are valid for every allowed pwer distribution between AHU and Chilled Beams (20%-80%; 30%-70%; 40%-60%) (1) (2) The weight values are valid for standard version AQUA Link IN 1P (3) The chiller combined to AQUA Link has to be selected wit pump (s) + storage tank accessory (4) The nominal absorbed power overcoming, within the indicated range, is allowed by the pump manifacturer and it has not to be considered as an overcoming of the limit values. Technical data AQUALink no glycol STANDARD PRIMARY PUMP* OVERSIZED PRIMARY PUMP* STANDARD SECONDARY PUMP FOR AHU-CB POWER DISTRIBUTION: 20%-80%; 30%-70%; 40%-60% OVERSIZED SECONDARY PUMP FOR AHU-CB POWER DISTRIBUTION: 50%-50% DIMENSIONS AND WEIGHT (1) (2) AQUA Link size Chiller reference capacity [kw] da 90 a 110 da 111 a 143 da 144 a 224 da 225 a 293 Nominal absorbed power [kw] 1,5 1,5 2,2 3 Maximum absorbed power permitted (4) 1,52 1,59 2,37 3,01 Nominal absorbed current [A] 3,2 3,2 4,7 6,2 Nominal absorbed power [kw] 2,2 2,2 3 4 Maximum absorbed power permitted (4) 2,21 2,37 3,01 4,06 Nominal absorbed current [A] 4,7 4,7 6,2 7,9 Nominal absorbed power [kw] 0,75 1,1 1,5 1,5 Maximum absorbed power permitted (4) 0,815 1,1 1,58 1,59 Nominal absorbed current [A] 1,7 2,4 3,2 3,2 Nominal absorbed power [kw] 1,5 1,5 1,85 2,2 Maximum absorbed power permitted (4) 1,5 1,5 2,07 2,37 Nominal absorbed current [A] 3,2 3,2 4,65 4,7 Length [mm] Height [mm] Depth [mm] Weight [kg] VOLUME PLANT (3) [l] (3) (3) (3) (3) * The values in the table are valid for every allowed pwer distribution between AHU and Chilled Beams (80%-20%; 70%-30%; 60%-40%) (1) (2) The weight values are valid for standard version AQUA Link IN 1P NG (3) The minimum water volume content of the combined pant has to be identified in the manual of the combined chiller and depends on the tipe and on the size of the chiller. This volume has to be available in the primary circuit (in the calculation the water volume in the secondary -Chilled Beams- circuit has not to be considered) (4) The nominal absorbed power overcoming, within the indicated range, is allowed by the pump manifacturer and it has not to be considered as an overcoming of the limit values. 6

7 OPERATING LIMITS UNITS WITH GLYCOL INDOOR VERSION Units containing Glycol in the primary circuit and made for indoor installation are built to operate at outdoor temperatures between +3 C and +45 C. They therefore do not provide the installation of heating cables to protect the internal components. For operation at temperatures outside of the aforementioned range, it is necessary to contact our Technical Office. OUTDOOR VERSION Units containing Glycol in the primary circuit and made for outdoor installation are built to operate within the following limits, whose values depend on the percentage of glycol in the primary circuit. With a 20% concentration of ethylene glycol, the minimum admissible temperature is -5 C With a 30% concentration of ethylene glycol, the minimum admissible temperature is -10 C With a 40% concentration of ethylene glycol, the minimum admissible temperature is -20 C The overall maximum admissible temperature is 45 C The plate exchanger is always protected by a protective heating cable on the secondary circuit that contains water. If there are pumps installed on the secondary circuit, the volutes are always protected by a heating cable as well as preinstalled pipes. The installer must protect any connecting pipe sections between the indoor system and AQUA Link For temperatures below -15 C (i.e. for glycol percentages between 30% and 40%) a series of heating elements designed to protect the main parts (pump motors, valve bodies...) and the electrical control board must be set up For operation at temperatures outside of the aforementioned range, it is necessary to contact our Technical Office. UNITS WITHOUT GLYCOL Units without Glycol in the primary circuit are designed and built to operate at outdoor air temperatures between +3 C and +45 C. For operation at temperatures outside of the aforementioned range, it is necessary to contact our Technical Office. For outdoor installation it will nevertheless be necessary to set up a series of heating elements against accidental low temperatures to protect: pump volutes, mixing manifolds, pipes inside the machine. WARNING: it is the installer s responsibility to protect the sections of machine infeed and outfeed pipes that lead to the chilled beam circuit and chiller, including the inertial tank. 7

8 Capacities data AQUALink with glycol STANDARD PRIMARY PUMP OVERSIZED PRIMARY PUMP STANDARD SECONDARY PUMP OVERSIZED SECONDARY PUMP INTERMEDIATE HEAT EXCHANGER WATER PRES- SURE DROP 100% capacity (12/7 C) - 40% ethylen glycol 100% capacity (12/7 C) - 30% ethylen glycol 100% capacity (12/7 C) - 20% ethylen glycol 100% capacity (12/7 C) - 40% ethylen glycol 100% capacity (12/7 C) - 30% ethylen glycol 100% capacity (12/7 C) - 20% ethylen glycol 60% capacity (14/17 C) - Water 70% capacity (14/17 C) - Water 80% capacity (14/17 C) - Water 60% capacity (14/17 C) - Water 70% capacity (14/17 C) - Water 80% capacity (14/17 C) - Water 60% capacity (14/17 C) 70% capacity (14/17 C) AQUA Link size Maximum cooling capacity of combined chiller [kw] 110,7 143,5 224,5 293,1 Maximum head (1) (2) [kpa] 118,9 98,3 96,6 117,8 (3) [kw] 1,7 1,78 3,47 4,39 Maximum head (1) (2) [kpa] 132,7 106,8 119,7 131,8 (3) [kw] 1,65 1,72 3,38 4,22 Maximum head (1) (2) [kpa] 144,1 113,8 128,2 143,1 (3) [kw] 1,59 1,65 3,28 4,07 Maximum head (1) (2) [kpa] 186,6 154,9 175,2 168,9 (3) [kw] 2,41 2,59 4,02 5,98 Maximum head (1) (2) [kpa] 201,3 163,5 182,4 185,6 (3) [kw] 2,33 2,49 3,86 5,76 Maximum head (1) (2) [kpa] 213,7 170,6 188,2 199,1 (3) [kw] 2,24 2,4 3,7 5,55 Maximum head (1) (4) [kpa] 185,3 161,1 161,4 200,5 (5) [kw] 1,98 2,14 3,37 5,07 Maximum head (1) (4) [kpa] 163,7 131,3 132,2 151,8 (5) [kw] 2,08 2,23 3,57 5,3 Maximum head (1) (4) [kpa] 139,1 97,1 96,1 93,4 (5) [kw] 2,16 2,3 3,74 5,44 Maximum head (1) (4) [kpa] 251,4 293,9 231,2 283,4 (5) [kw] 2,47 3,44 4,59 6,5 Maximum head (1) (4) [kpa] 228,9 261,9 196,7 237,3 (5) [kw] 2,61 3,64 4,88 6,87 Maximum head (1) (4) [kpa] 202,8 224,6 155,8 181,5 (5) [kw] 2,73 3,79 5,11 7,17 Pressure drop on Chilled Beams side exchanger [kpa] 24,3 23,7 36,9 24,6 32,6 31,9 49,9 33,2 42,1 41,2 64,7 42,9 (1) Maximum allowable frequency: 50 Hz (2) Available that can be obtained if the pump should transfer to the users the maximum permissible power for that size with water temperature in / out from the chiller 12 / 7 C (3) Power absorbed by the pump if it should transfer to the users the maximum permissible power for that size with water temperature in / out from the chiller 12 / 7 C and the maximum static under the same conditions (4) Static that can be obtained if the pump should transfer to the Chilled Beams the indicated percent capacity with water temperature in / out 14/17 C from Chilled Beams (5) Power absorbed by the pump if it should transfer to the Chilled Beams the indicated percent capacity with water temperature in / out 14/17 C from Chilled Beams and the maximum static under the same conditions 8

9 Capacities data AQUALink no glycol STANDARD PRIMARY PUMP OVERSIZED PRIMARY PUMP STANDARD SECONDARY PUMP OVERSIZED SECONDARY PUMP 100% capacity (12/7 C) 100% capacity (12/7 C) 20% capacity (14/17 C) - CB 30% capacity (14/17 C) - CB 40% capacity (14/17 C) - CB 20% capacity (14/17 C) - CB 30% capacity (14/17 C) - CB 40% capacity (14/17 C) - CB AQUA Link size Maximum cooling capacity of combined chiller [kw] 110,7 143,5 224,5 293,1 Maximum head (1) (2) [kpa] (3) [kw] 1,47 1,48 2,35 2,9 Maximum head (1) (2) [kpa] (3) [kw] 2,06 2,14 3,01 3,71 Maximum head (1) (4) [kpa] 149,0 172,0 169,0 152,0 (5) [kw] 0,53 0,77 1,08 1,27 Maximum head (1) (4) [kpa] (5) [kw] 0,63 0,94 1,34 1,49 Maximum head (1) (4) [kpa] (5) [kw] 0,72 1,06 1,51 1,57 Maximum head (1) (4) [kpa] 231,0 223,0 207,0 212,0 (5) [kw] 0,85 0,98 1,34 1,91 Maximum head (1) (4) [kpa] (5) [kw] 1,06 1,21 1,62 2,15 Maximum head (1) (4) [kpa] (5) [kw] 1,23 1,39 1,87 2,31 (1) Maximum allowable frequency: 50 Hz (2) Available that can be obtained if the pump should transfer to the users the maximum permissible power for that size with water temperature in / out from the chiller 12 / 7 C (3) Power absorbed by the pump if it should transfer to the users the maximum permissible power for that size with water temperature in / out from the chiller 12 / 7 C and the maximum static under the same conditions (4) Static that can be obtained if the pump should transfer to the Chilled Beams the indicated percent capacity with water temperature in / out 14/17 C from Chilled Beams (5) Power absorbed by the pump if it should transfer to the Chilled Beams the indicated percent capacity with water temperature in / out 14/17 C from Chilled Beams and the maximum static under the same conditions 9

10 ENERGY ANALYSIS Introducing AQUA link combined with chiller set point variable and the SMART Link of advanced management of set point allows to obtain significant benefits in terms of reduced fuel consumption. As evidence of this below shows the results of simulations made for both energy systems with glycol for Northern European climates for both systems without glycol for southern European climates. NO GLYCOL SYSTEM, LOCATION IN NORD EUROPE (STOCKHOLM) 1. TRADITIONAL SYSTEM: (see diagram below) GOLD air handling unit Extract air Exhaust air Outdoor air Air cooler Regulating 2-way valve Supply air On/off 2-way valve Bypass valve i On/off 2-way valve i = Inverters Heat exchanger i i Regulating 2-way valve Climate beams Collector 40% water/glycol primary circuit Chiller Integrator inertial tank Inertial tank This system consists of the following components: 1. A fixed setpoint chiller with a known total power. The chiller is supplied with a water-glycol blend circulation pump and a small capacity inertial tank complete with an expansion vessel. In addition, the chiller features multiple compressors giving the possibility to reduce the supplied power according to the required power, still producing water at the same temperature; 2. An inertial tank complete with an expansion vessel to achieve the min. volume required in the plant proportionally to the chiller capacity and number of steps; 3. A manifold used to mismatch the users feeding circuits; 4. A variable pump feeding the air handling unit coil; 5. A variable feed pump on the glycol side of the plate heat exchanger; 6. An inspectable plate heat exchanger to mismatch the section working with a blend of water and glycol from the section fed with pure water; 7. A variable feed pump to the chilled beams; 8. A complete air handling unit with a rotary heat exchanger (enthalpy rotor) and a air cooler complete with a 2-way modulating control valve; 9. A chilled beam system equipped with a 2-way valve to shut off the water supply; 10. Taps, valves and hydronic piping to connect the various components. 10

11 2. AQUA Link SYSTEM: (see diagram below) GOLD air handling unit Extract air Exhaust air Outdoor air Air cooler Supply air AQUA Link Regulating 2-way valve On/off 2-way valve Chiller Regulating 2-way valve Inertial tank i Heat exchanger Bypass valve On/off 2-way valve 40% water/glycol primary circuit Integrator inertial tank i = Inverters i Climate beams This system consists of the following components: 1. A variable setpoint chiller with a known total power. The chiller is supplied with a circulation pump for water-glycol blending and a small capacity inertial tank. In addition, the chiller features multiple compressors giving the possibility to reduce the supplied power according to the required power. The temperature of the output chilled water is connected to the user s requirements and may vary continuously between two setpoints. 2. The AQUA Link module, which comprises: --An additional inertial tank complete with an expansion vessel to achieve the min. volume required in the plant proportionally to the chiller capacity and number of capacity steps; --A variable circulation pump feeding the primary circuit; --Pressure probes for pump rotation speed control; --A plate heat exchanger to mismatch the section working with a blend of water and glycol from the section fed with pure water; --A 2-way motor-driven modulating valve designed to control the flow rate to the users; --Taps, valves and hydronic piping to connect the various components; 3. A complete air handling unit with a rotary heat exchanger (enthalpy rotor) and an air cooler complete with a 2-way modulating control valve; 4. A variable feed pump to the chilled beams; 5. Pressure probes to control rotation speed of the pump; 6. A chilled beam system equipped with a 2-way valve to shut off the water supply. 11

12 The simulation was made keeping the same operating conditions in both systems. Below is a list of operating conditions that are fundamental to identify the test context. Location of installation Max. total required power Stockholm 200 kw Power distribution to 2 users: Air handling unit 60 kw (30%) Chilled Beams 140 kw (70%) Temperature below which the chilled beams do not require feeding with chilled water 0 C Temperature below which the air handling unit can operate in free cooling conditions 16 C Air delivery temperature to chilled beams 16 C Outdoor temperature Outdoor enthalpy Outdoor air volume treated by the AHU from weather file covering 8760 hours from weather file covering 8760 hours 3,6 m 3 /s ( m 3 /h) No. of chilled beams 241 An iterative method was used to calculate the following values for each hour of operation of the chiller serving the plant: The hourly COP values; The power absorbed on an hourly basis and the absorbed energy, as a consequence. The analysis has enabled identification of: The energy consumed by the variable setpoint system (supposing that the water temperature delivered by the chiller varies according to the chill request); The energy consumed by the same system, but with a fixed setpoint, producing water at a constant temperature of 7 C for the GOLD air handling unit and chilled beams regardless of fluctuations in the required power. The trends of the COP value measured every hour throughout the annual 8760 hours is illustrated below. 8,00 7,00 EER Fixed set point Variable set point 6,00 5,00 EER 4,00 3,00 2,00 1,00 0, Temperature C 12

13 The analysis was conducted considering real chiller operating conditions and the actual energy consumption of the axial fans serving the condensing section. 70,00 60,00 Absorbed energy Fixed set point Variable set point Absorbed energy (hourly) kw 50,00 40,00 30,00 20,00 10,00 0, Temperature C Reduction coefficient fans Fixed set point chiller Variable set point chiller Absorbed energy (annual) [kwh] 81,913 71,027 Consumption reduction [kwh] Consumption reduction % 0,0% 13,3% Electricity rata [ /kwh] 0,07 0,07 Economic Saving [ ] 0 805,5 13

14 NO GLYCOL SYSTEM, LOCATION IN CENTRAL ITALY (ROME) 1. TRADITIONAL SYSTEM: (see diagram below) GOLD air handling unit Exit air Exhaust air Outdoor air Cold Coil exchanger Regulating 2-way valve Primary air On/off 2-way valve On/off 2-way valve i i = Inverters i Regulating 3-way valve Climate beams Collector No glycol primary circuit Chiller Integrator inertial tank The system is assumed to be composed of the following parts: 1. a chiller with a known overall power and fixed set point. The chiller is equipped with a water circulation pump. The chiller is built in a multi compressor version, with the possibility of lowering the power supply based on the power request, to always produce water at the same temperature. 2. outdoor inertial tank complete with expansion vessel, used to obtain the minimum volume of the system in proportion with the capacity and number of steps in the chiller 3. decoupling manifold supplying the utilities 4. supply pump with variable flow rate for the AHU coil 5. chilled beams circuit supply pump with variable flow rate 6. AHU equipped with heat recovery system (enthalpy wheel) and finned-coil thermal exchanger complete with 2-way modulating regulation valve 7. chilled beam system equipped with two-way water supply shut-off valve 8. taps, valves and hydraulic connecting pipes for the various components. 14

15 2. AQUA Link SYSTEM: (see diagram below) GOLD air handling unit Exit air Exhaust air Outdoor air Cold Coil exchanger Regulating 2-way valve Primary air i AQUA Link Chiller i Regulating 2-way valve Vertical collector Bypass valve On/off 2-way valve No glycol primary circuit On/off 2-way valve Climate beams Integrator inertial tank The system is assumed to be composed of the following parts: 1. a chiller with a known overall power and variable set point. The chiller is equipped with a water circulation pump. The chiller is built in a multi compressor version, with the possibility, therefore, of lowering the power supply based on the power request. The temperature of the chilled water being produced depends on the request from the utilities and varies continuously between the two set values. 2. The AQUA Link module, in turn, is composed of: --variable flow-rate circulation pump to supply the primary circuit -- probe to control pump rotation speed --decoupling and mixing manifold to supply the chilled beams --motorised modulating two-way valve to control the manifold supply flow rate --taps, valves and hydraulic connecting pipes for the various components 3. AHU equipped with heat recovery system (enthalpy wheel) and finned-coil thermal exchanger complete with 2-way modulating regulation valve 4. chilled beams supply pump with variable operating rate and relative probe 5. chilled beam system equipped with two-way water supply shut-off valve. 15

16 Simulation is obviously achieved by maintaining the same operating conditions for the two systems. The basic conditions to identify this trial context are provided below. Location of installation Max. total required power Rome 200 kw Power distribution to 2 users: Air handling unit 140 kw (70%) Chilled Beams 60 kw (30%) Temperature below which the chilled beams do not require feeding with chilled water 0 C Temperature below which the air handling unit can operate in free cooling conditions 16 C Air delivery temperature to chilled beams 16 C Outdoor temperature Outdoor enthalpy from weather file covering 8760 hours from weather file covering 8760 hours Outdoor air volume treated by the AHU ( m 3 /h) No. of chilled beams 70 In terms of the previous analysis carried out on Stockholm, the overall chiller power therefore remained unchanged. Accordingly, the two analyses refer to buildings of different sizes. The distribution of powers between AHU and chilled beams changes due to the different climatic conditions in southern European areas with a high dehumifidying requirement. Through an interactive procedure for each single hour of chiller operation serving the system, the following were evaluated: --the hourly EER values --the hourly rate of power absorption and consequently the absorbed energy The analysis determined: the energy consumed by the system with a variable set (assuming that the water supply temperature from the chiller varies based on the request for cold). the energy consumed by the system, at a fixed set however, that produces water at a constant temperature of 7 C for Gold and chilled beams, regardless of the change in required power. The progress of the EER value read at an hourly rate for 8760 hours per annum is provided below. 8,00 7,00 EER Fixed set point Variable set point 6,00 5,00 EER 4,00 3,00 2,00 1,00 0, Temperature C 16

17 The analysis took into account real chiller operation and therefore also the energy consumption of the axial fans serving the condensing unit. 80,00 70,00 Absorbed energy Fixed set point Variable set point Absorbed energy (hourly) kw 60,00 50,00 40,00 30,00 20,00 10,00 0, Temperature C Reduction coefficient fans Fixed set point chiller Variable set point chiller Absorbed energy (annual) [kwh] 104, Consumption reduction [kwh] Consumption reduction % 0,0% 10,2% Electricity rata [ /kwh] 0,15 0,15 Economic Saving [ ] ,8 17

18 Overall dimensions, weights and hydronic connections AQUA Link 100/140 A4E027-C Ep W.in Gold out W out Gold in Chiller in W out Chiller out A * Rp Es Lh CLEARANCES A Chiller.in G 2"1/2 F Ep ELECTRICAL PANEL Chiller.out G 3"F Es ELECTRICAL SUPPLY INLET W.in G 2"1/2 F Lh Rp LIFTING HOLES REMOVABLE PANEL * OPTIONAL A OPTIONAL WATER PUMP W.out Gold.in Gold.out G 2"1/2 F G 3"F G 2"1/2 F 18

19 Overall dimensions, weights and hydronic connections AQUA Link 100/140 A4E027-C 60 G1 G1 G2 G G4 G4 G3 G MODELLO MODEL PESO (kg) WEIGHT(kg) PESO IN FUNZIONE (kg) OPERATING WEIGHT (kg) G1 (kg) G2 (kg) G3 (kg) G4 (kg) AQUALINK 110 2P2P AQUALINK 140 2P2P AQUALINK 110 2P2P_LN AQUALINK 140 2P2P_LN AQUALINK 110 1P AQUALINK 140 1P AQUALINK 110 1P_LN AQUALINK 140 1P_LN AQUALINK 110 1P1P AQUALINK 140 1P1P AQUALINK 110 1P1P_LN AQUALINK 140 1P1P_LN AQUALINK 110 2P AQUALINK 140 2P AQUALINK 110 2P_LN AQUALINK 140 2P_LN Fh G.. FORI DI FISSAGGIO FIXING HOLES PUNTI DI APPOGGIO ANTIVIBRANTI VIBRATION DAMPER FOOT HOLDS Ø16 19

20 Overall dimensions, weights and hydronic connections AQUA Link 220/300 A4E024-C Gold out W.in W.out * 1773 W.out Chiller in Gold in Chiller out Ep -AQUALINK 220- Rp Es Gold out W.in W.out * W.out Chiller in Gold in Chiller out Lh -AQUALINK 300- Ep Es Lh CLEARANCES ELECTRICAL PANEL ELECTRICAL SUPPLY INLET LIFTING HOLES Chiller.in Chiller.out W.in W.out G 2"1/2 F G 3"F G 3" F G 3"F Rp REMOVABLE PANEL * OPTIONAL WATER PUMP Gold.in Gold.out G 3"F G 3"F 20

21 Overall dimensions, weights and hydronic connections AQUA Link 220/300 A4E024-C 60 G1 G1 G2 G G4 G4 G3 G MODELLO MODEL PESO (kg) WEIGHT(kg) PESO IN FUNZIONE (kg) OPERATING WEIGHT (kg) G1 (kg) G2 (kg) G3 (kg) G4 (kg) AQUALINK 220 1P AQUALINK 300 1P AQUALINK 220 1P_LN AQUALINK 300 1P_LN AQUALINK 220 2P2P AQUALINK 300 2P2P AQUALINK 220 2P2P_LN AQUALINK 300 2P2P_LN AQUALINK 220 1P1P AQUALINK 300 1P1P AQUALINK 220 1P1P_LN AQUALINK 300 1P1P_LN AQUALINK 220 2P AQUALINK 300 2P AQUALINK 220 2P_LN AQUALINK 300 2P_LN Fh G.. FORI DI FISSAGGIO FIXING HOLES PUNTI DI APPOGGIO ANTIVIBRANTI VIBRATION DAMPER FOOT HOLDS Ø16 21

22 Overall dimensions, weights and hydronic connections AQUA Link No Glicole 100/140 A4E302-A 1986 Gold out W.in Ep W.out Gold in Chiller in A W.out * Chiller out Es Rp Rp Lh Rp Rp Chiller.in G 2"1/2 F SPAZI DI INSTALLAZIONE CLEARANCES Chiller.out W.in G 2"F G 3"F Ep QUADRO ELETTRICO ELECTRICAL PANEL W.out * G 2"F Es Lh Rp INGRESSO ALIMENTAZIONE ELETTRICA ELECTRICAL SUPPLY INLET FORI DI SOLLEVAMENTO LIFTING HOLES PANNELLO ASPORTABILE REMOVABLE PANEL * OPTIONAL A POMPE CIRCUITO SECONDARIO SECONDARY CIRCUIT PUMP W.out G 3"F Gold.in Gold.out 110 Gold.out 140 G 2"1/2F G 2"F G 2"1/2F 22

23 Overall dimensions, weights and hydronic connections AQUA Link No Glicole 100/140 A4E302-A Fh G1 G4 G2 G MODELLO MODEL PESO (kg) WEIGHT(kg) PESO IN FUNZIONE (kg) OPERATING WEIGHT (kg) G1 (kg) G2 (kg) G3 (kg) G4 (kg) AQUALINK NG 110 2P2P AQUALINK NG 140 2P2P AQUALINK NG 110 2P2P_LN AQUALINK NG 140 2P2P_LN AQUALINK NG 110 1P AQUALINK NG 140 1P AQUALINK NG 110 1P_LN AQUALINK NG 140 1P_LN AQUALINK NG 110 1P1P AQUALINK NG 140 1P1P AQUALINK NG 110 1P1P_LN AQUALINK NG 140 1P1P_LN AQUALINK NG 110 2P AQUALINK NG 140 2P AQUALINK NG 110 2P_LN AQUALINK NG 140 2P_LN Fh G.. FORI DI FISSAGGIO FIXING HOLES PUNTI DI APPOGGIO ANTIVIBRANTI VIBRATION DAMPER FOOT HOLDS Ø16 23

24 Overall dimensions, weights and hydronic connections AQUA Link No Glicole 220/300 A4E306-A Gold out W.in VERSIONE Ep W.out Gold in Chiller in W.out * Chiller out Es Gold out W.in VERSIONE W.out * W.out 140 Gold in Chiller in Chiller out Rp Rp Lh Rp Rp Ep SPAZI DI INSTALLAZIONE CLEARANCES QUADRO ELETTRICO ELECTRICAL PANEL Chiller.in Chiller.out G 2"1/2 F G 3" F Es Lh Rp INGRESSO ALIMENTAZIONE ELETTRICA ELECTRICAL SUPPLY INLET FORI DI SOLLEVAMENTO LIFTING HOLES PANNELLO ASPORTABILE REMOVABLE PANEL * CON POMPE LATO ACQUA OPTIONAL WATER PUMP W.in W.out Gold.in Gold.out G 3" F G 3"F G 2"1/2 F G 3"F 24

25 Overall dimensions, weights and hydronic connections AQUA Link No Glicole 220/300 A4E306-A Fh 80 G1 G G4 G MODELLO MODEL PESO (kg) WEIGHT(kg) PESO IN FUNZIONE (kg) OPERATING WEIGHT (kg) G1 (kg) G2 (kg) G3 (kg) G4 (kg) AQUALINK NG 220 2P2P AQUALINK NG 300 2P2P AQUALINK NG 220 2P2P_LN AQUALINK NG 300 2P2P_LN AQUALINK NG 220 1P AQUALINK NG 300 1P AQUALINK NG 220 1P_LN AQUALINK NG 300 1P_LN AQUALINK NG 220 1P1P AQUALINK NG 300 1P1P AQUALINK NG 220 1P1P_LN AQUALINK NG 300 1P1P_LN AQUALINK NG 220 2P AQUALINK NG 300 2P AQUALINK NG 220 2P_LN AQUALINK NG 300 2P_LN Fh G.. FORI DI FISSAGGIO FIXING HOLES PUNTI DI APPOGGIO ANTIVIBRANTI VIBRATION DAMPER FOOT HOLDS Ø16 25

26 Single-Line hydronic diagram AQUALink A4D921 - C INLET FROM GOLD OUTLET TO CHILLER INLET FROM CHILLER SF SB ØC ØA CR A25 SC ØC A B ØC INLET FROM CHILLED BEAMS ØC PA(BT13) WITH 2 PUMPS VERSION WITH 2 PUMPS VERSION ØA M14 EL VR 03 CR M16 VR EL BPW20 CR CR VE BPW1 CR ØM ØA BPW10 BPW2 M13 VR M15 EL ØM ØA CR EL VR PA(BTT) ØA ØA CR ØM CR BPW20 OUTLET TO CHILLED BEAMS M13 EL PA(BTT) M15 EL WITH 1 PUMP ONLY VERSION WITH 1 PUMP ONLY VERSION SECONDARY CIRCUIT OUTLET TO GOLD MODELLO /MODEL Ø M Ø A OPTIONAL WITH SECONDARY LOOP PUMP 110 2"1/2 2"1/2 2"1/2 Ø C PRIMARY CIRCUIT 140 2"1/2 2"1/2 2"1/ " 2"1/2 3" 300 3" 2"1/2 3" Rev. Data-Date Dis.-Draftman Visto - Checked by Descrizione revisione - Revision description C 24/10/12 R.Crivellaro F.Cappon Aggiunte sonde antigelo,sigle pompe,trasduttori di pressione B 28/02/12 R.Crivellaro F.Cappon Convert to solid edge format Denominazione-Denomination Disegno-Drawing Rev. HYDRAULIC CIRCUIT AQUALINK Scala-Scale Data-Date Dis.-Draftsman Visto-Checked by Foglio di N. 1 27/02/2012 Crivellaro F.Cappon Sheet of Sost. il dis.-replace draw. Sost. dal dis.-replaced by draw. - Proprietà riservata, riproduzione vietata a termini di legge.copyright. / / - Reserved property, reproduction prohibited accordin to existent laws.copyright. 1 A4D921 C MTE 56 rev. 04 date: 07/04/11 / 26

27 Single-Line hydronic diagram AQUALink No Glycol A4E512 - B INLET FROM GOLD OUTLET TO CHILLER INLET FROM CHILLER SF SB MADE BY THE PLUMBER ØC ØA CR A25 SC ØC A B ØC ØC INLET FROM CHILLED BEAMS PA(BT13) WITH 2 PUMPS VERSION WITH 2 PUMPS VERSION ØA EL HS VR EL VR BPW20 VE ØA BPW1 ØA CR CR EL M14 VR ØM BPW10 ØM BPW2 CR CR EL M16 VR PA(BTT) ØA CR ØM ØA CR BPW20 OUTLET TO CHILLED BEAMS PA(BTT) EL M13 EL M15 WITH 1 PUMP ONLY VERSION WITH 1 PUMP ONLY VERSION OUTLET TO GOLD MODELLO /MODEL Ø M Ø A Ø C 110 2"1/2 2"1/2 2"1/ "1/2 2"1/2 2"1/ " 2"1/2 3" OPTIONAL WITH SECONDARY LOOP PUMP 300 3" 2"1/2 3" Rev. Data-Date Dis.-Draftman Visto - Checked by Descrizione revisione - Revision description B 23/11/2012 R.Crivellaro F.Cappon Aggiunte sigle pompe,sigle sonde,trasduttori di pressione Denominazione-Denomination Disegno-Drawing Rev. HYDRAULIC CIRCUIT AQUALINK NG Scala-Scale Data-Date Dis.-Draftsman Visto-Checked by Foglio di N. 1 30/07/12 R.Crivellaro F.Cappon Sheet of Sost. il dis.-replace draw. Sost. dal dis.-replaced by draw. / / 1 A4E512 B - Proprietà riservata, riproduzione vietata a termini di legge.copyright. - Reserved property, reproduction prohibited accordin to existent laws.copyright. MTE 56 rev. 04 date: 07/04/11 / 27

28 Installation tips Check that the location where the unit is installed provides for easy connection of the hydronic piping coming from the chiller and the terminal units. Refer to the dimension drawings attached to this Technical Booklet to locate the connections. Place the unit so that a minimum distance is left, as shown in the dimension drawings. Place the unit in a manner that assures the lowest environmental impact (noise emissions, integration with nearby structures, etc.). 700 mm 700 mm 28

29 Summary Advantages for the fitter The construction of a hydronic system serving the air conditioning unit in a building is undoubtedly a complex operation both hydronically and in terms of easy management and control, first of all because the main elements making up the system (chiller, UTA, chilled beams) must be selected and, secondly, because they must be networked. Besides the main parts mentioned above, a hydronic system also comprises a series of accessory components such as pumps, tanks, shut-off valves, control valves, filling units, manifolds for circuit mismatching, etc. that must be selected, installed in a dedicated compartment (distribution box) and interconnected. The operating logic at the design stage may be affected by the features of these components and their capacity to respond to control signals originating from the system constituting elements. AQUA Link was designed to simplify commissioning of the plant, thus reducing both installation and plant management costs. This is why it is complete with all the elements required for the hydronic circuit, which are normally excluded from the supply of the main units and must be procured from the fitter. Provision of these elements in one single shell, that is sized by the manufacturer at earlier stages, offers a number of advantages: One single interlocutor for the entire plant eliminates possible inconveniences relating to identification of responsibilities and difficult communications with the various parties involved; Accurate sizing that can be tested at any time against complete documentation; Quick commissioning compared to other solutions: the system only requires hydronic and electrical connection between the chiller, the users and AQUA Link to operate; One individual standardised communication protocol between the various elements; Well-organised, compact and easy-to-find location of components; No dedicated compartment required to contain all the featured elements (when the outdoor version is selected); Operating options to adapt AQUA Link to the different plant engineering requirements (high heads, mismatching of primary and secondary circuits, installation outdoors or indoors, etc.); A dedicated selection software to check the performances of the unit according to the features of the served plant. Advantages for the end user After implementation, the system must operate smoothly without downtimes and with minimised energy consumption, yet meeting the users requirements. High chiller and terminal unit performances are no guarantee that the second objective above be achieved, especially if, as is the case with all traditional plants, the production temperature of chilled water is established univocally at the design stage and is determined according to the heaviest work conditions envisaged for system operation. As a matter of fact, the operating conditions of the system vary according to different parameters: --indoor temperature; --outdoor temperature; --outdoor air humidity; --number of people in the room(s); --exposure of various areas to sun radiation; --possibility to go for free cooling; --etc. This said, it is fundamental that the system responds to the users requirements in real time. Thanks to this option, for instance, the unit heavily consumes energy only when the operating conditions are heavy. This results into a decrease in global energy consumption that derives from improved energy efficiency for the chiller and reduced energy requirements for water-glycol blend pumping. The awareness of the end user on matters regarding energy consumption is undeniable and self-evident. AQUA Link can play a major role in this thanks to: Reduced indirect consumption: the consumption of energy supplied to the chiller and used to produce chilled water is reduced through a setpoint that varies continuously and according to the users requirements; Reduced direct consumption: the consumption of energy used to pump water to the primary and secondary circuits (version 1P-1P or 2P-2P) is reduced through inverter-controlled variable pumps that only absorb the min. amount of energy required by the plant; Reduced indirect consumption: the consumption of energy required for water pumping is reduced through the use of one single pump to the primary circuit to serve both users. Decreasing of footprint: all equipment and components are condensed in one unique volume, AQUA Link can be placed outdoor. 29