SCROLL COMPRESSORS TYPE AIR COOLED PACKAGE CHILLERS

Transcription

1 SCROLL COMPRESSORS TYPE AIR COOLED PACKAGE CHILLERS SCODA-1216A Smartech International Sdn. Bhd. ( P) No.15, Jalan PJS 1/27, (Jalan Petaling Utama 6), Petaling Utama, Batu 7, Off Jalan Klang Lama, Petaling Jaya, Selangor. T: / F: W: Specifications in this catalogue are subject to change without notice in order that SMARTECH may bring the latest innovations to their customer. Smartwise Innovations... Towards Green, Quality & Reliability Solutions SCOD_A SERIES

2 AIR-COOLED SCROLL COMPRESSORS CHILLERS WITH R410A REFRIGERANT This series of R410a, air-cooled scroll compressors chillers with a capacity size from 10 R.tons to 128 R.tons, were designed and manufactured to provide an economical, and yet efficient and highly reliable, system of air conditioning for residential, commercial and industrial buildings. The same type of chillers, can also be adapted for use in industrial process cooling purpose. Each chiller consists of 2 or 4 numbers of hermetic scroll compressors offering exceptional redundancy in the event of a compressor failure. Installations & Applications Guidelines With 2 or 4 equal size compressors, each chiller has two or four equal steps of capacity modulation. Each chiller, from capacity of 10.0 R.tons to 31.0 R tons, is fitted with a compact size brazed plate heat exchanger (BPHE) as cooler to reduce overall size of chiller. Each chiller, larger than 40.0 R.tons of cooling capacity, has a single shell and tubes direct expansion cooler, with dual refrigerant circuits; selected to optimize chiller efficiency at full load and partial load points; and to ensure adequate compressor oil return to compressors at partial loads. The condenser coil is constructed from staggered rows of inner ridge copper tubes mechanically expanded into die-formed hydrophilic aluminium fins, circuited for low refrigerant pressure loss and incorporate integral subcooling circuit to enhance system efficiency and stability. Each chiller is fitted with one or multiple axial propellers, selected to deliver high condenser air flow rate, with low noise level and low motor power consumption. Each air-cooled scroll chiller has an outdoor weather proof casing, constructed from heavy gauge galvanized steel sheets, coated with oven-baked epoxy polyester paint, and mounted on a structural steel base-frame which is hot-dipped galvanized to prevent corrosion. Each chiller is factory pre-piped, pressure tested to prevent leakage, internal system evacuated and fully charged with refrigerant R410a, prewired to power and microprocessor control panel, factory run tested and ready for easy field installation. Nomenclature SCOD SMARTECH Chiller Scroll Compressor Direct Expansion cooler 79 A R4 Nominal Cooling capacity in tons Air Cooled R4 - R410a refrigerant Direct Drive Axial Propeller Fans at Max. Speed of 950RPM Fan Motors with Min. IP54 protection Weather Proof Casing Compressors compartment Condenser coil Factory Packaged and Pre-wired Power and Control Panel Smart-Advance SA-33 Microprocessor Based Controller Shell N tubes cooler Glycol Freeze Protection If the chiller and its chilled water pipings are to be exposed to temperatures below the freezing point of water (i.e. 32 F), then an anti-freeze solution or glycol solution needs to be added to the chilled fluid. The recommended freeze protection should be at least 15 F below the freezing temperature of the glycol chilled water mixture. It is recommended to use only anti-freeze glycol, with inhibitors, which are strictly recommended for heat exchanger duty. However, if the chiller and its chilled water pipings are exposed to freezing ambient temperature, but not being used, then it is recommended to drain all water out of vessels and its pipings. For application when leaving chilled water temperature and return chilled water temperature is below 40 F, glycol solution is also required to be added to the chilled fluid. The freeze point temperature of the glycol-chilled fluid mixture shall be at least 20 F below the operating chilled fluid temperature. Ethylene Glycol, Freeze points & correction factor % E.G. By Freeze Point K1 Kw C1 Capacity Factor Weight F C Rate G1 Flow Factor P1 P.D. Factor Propylene Glycol, Freeze points & correction factor % P.G. By Freeze Point K2 Kw C2 Capacity Factor Weight F C Rate G2 Flow Factor P2 P.D. Factor

3 MECHANICAL SPECIFICATIONS AND FEATURES Installations & Applications Guidelines Chilled Liquid Piping The chilled liquid piping shall be laid out such that the circulating chilled water pump discharges into the cooler. A check valve shall be installed at the discharge side of pump. A strainer of 40 mesh is recommended to be installed at pump inlet and before discharging into the inlet line of the cooler. Manual stop valves shall be installed in all lines to facilitate servicing and replacement of faulty pump strainers, check valves, etc. Drain connections, with ¾ stop valves, should be provided at all low points to permit complete drainage of the cooler and system piping. Pressure-gauge connections are recommended for installation in the inlet and outlet water lines. Gauges are not provided with the unit and are to be furnished by others. Chilled liquid lines exposed to the weather should be wrapped with a supplemental heater cable and insulated or glycol should be added to the chilled liquid to protect against freezing if low-ambient periods are expected. A flow switch is available as an accessory on all units. A flow switch must be installed in the leaving water piping of the cooler and must not be used to start and stop the unit. Minimum Chilled Water Loop Volume Depending on whether the chiller is used for airconditioning application or for process cooling application, it is necessary to ensure there is adequate system volume of chilled water to prevent frequent and rapid cycling on/off of compressors or unstable operation of the chillers. In most application, especially for process cooling application, it may be necessary to install a tank in the piping system to provide sufficient system fluid volume. MODEL MINIMUM SYSTEM FLUID VOLUMES AIR CONDITIONING APPLICATION, US GALLONS PROCESS COOLING APPLICATION, US GALLONS SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD SCOD Application Limitations DESCRIPTION MAXIMUM MINIMUM Ambient Air Tempreture F Chilled Water ΔT, F 14 6 Leaving Chilled Water, F Return Chilled Water, F Water Side Pressure, F 200 psig N.A. Notes: i) For ambient air above 120 F, the unit may operate at reduced load with optional current limiter ii) For ambient air temperature between 25 F to 65 F, low ambient head pressure control is required by varying condenser fan motor speeds, cycling off condenser fans and adding of solenoid valves control to partially block off parts of condenser tubed circuitry. CASING The casing which is constructed from heavy gauge galvanized steel sheets, degreased, bonderised and coated with oven-baked epoxy polyester paint, is designed and manufactured for outdoor, weather-proof installation. The complete casing, with all the components of the chiller, are mounted on a rigid structural welded steel based frame, which is hot-dipped galvanized and coated with two layers of marine paint to prevent corrosions. The baseframe has either rigging holes or lifting ears for ease of lifting. TWIN COMPRESSORS IN TANDEM BPHE COOLER HERMETIC SCROLL COMPRESSORS Each unit has either two or four hermetic scroll compressors. Each scroll compressor has a suction gas-cooled motor, operating at 2950 rpm at 50Hz electrical supply, with internal line break motor protection or solid state motor protection. The no-contact scroll design of the compressor has a proven reliability, low noise and high efficiency performance. The compressors are compartmentalized to reduce noise break-out to surrounding areas. BPHE EVAPORATOR SHELL & TUBES EVAPORATOR The compact brazed plates Heal Exchanger acts as a evaporator or cooler, cooling a secondary fluid (water) as it losses heat to the liquid refrigerant which boils and convert to vapor and absorbing more energy to superheated gas. BPHE evaporator provides a good, stable boiling process with a small temperature difference between the boiling liquid refrigerant and the secondary fluid (water) to be cooled. This results in a higher evaporation temperature which increases the compressor cooling capacity and improves the total system efficiency. The BPHE are used for chillers of cooling capacity from 10 R.tons to 30 R.tons due to its compact size, lighter weight, less refrigerant charge required compared to shell and tubes evaporator of the same capacity. A water strainer shall be installed at the return chilled water inlet pipe prior to the BPHE, to prevent entry of any particles larger than 1mm, which could block the internal channels, causing poor performance, increase water side pressure drop and the risk of freezing. The shell and tubes direct expansion evaporator or cooler; with its shell, tube-sheets, headers and water piping connectors are constructed from high carbon steel; while internally it consists of a bundle of inner-finned copper tubes which penetrate through staggered pieces of baffle plates which are rigidly held together by multiple steel rods. The baffle plates are configured to allow the warm return water to cross-flow through the tubes-bundle in multi-passes to improve heat transfers; while the liquid refrigerant boils to vapor as it absorbs heat, and travel within the inner copper tubes, as the warm return water cools down to the required outlet chilled water temperature. Copper fins condenser coil AIR-COOLED CONDENSER COIL Constructed from staggered rows of inner ridged copper tubes mechanically expanded into die-formed aluminium fins for positive bonding and efficient heat rejection. The pre-coated aluminium fins improve corrosion resistance and maintains the fins surface for efficient heat rejection. The condenser coil is pressure tested up to 450psig with dry nitrogen under water for leaks. Optional copper fins condenser coil. Copper tubes bundle Steel rod Tube-sheet Shell Baffle plate 21 2

4 AXIAL PROPELLER FANS The patented and unique designed axial propellers are selected to deliver high condenser air flow rates, with low noise level and low motor power consumption. The 3-phase, high starting torque, direct drive condenser fan motors run at maximum speed of 950 rpm for low noise operation. All condenser fan motors are provided with either internal line break motor protection or external mounted overload protector; and are suitable for outdoor installations with minimum IP54 protection. Optional variable fan speed control or fan cycling in response to condensing head pressures, during low ambient condition. Optional EC motors available to reduce fan motor power input and enable variable operation of fan speeds. Installations & Applications Guidelines POWER AND CONTROL PANEL Each chiller is packaged with a power and control panel which is ready to accept rated 3 phase 50Hz electrical supply from a remote mounted isolator. The power panel is furnished with factory pre-wired and mounted DOL starters for compressors, DOL starters for condenser fan motors. MCBs for compressors and fan motors, external overload protectors for compressors and/or fan motors. Power, alarm and compressor run lights to indicate unit operation status. The Heart of the control panel is the highly reliable Smart-Advance SA-33 microprocessor based controller with advance compressor management logic for scroll compressors in response to required chilled water inlet set-point temperature. The Smart-Advance SA-33 controller provides the following safety-protection controls and features:- Display featuring 3 digits with decimal point, minus sign and icons, making it easier to read the values and check the operating status. Monitors in/out temperature High discharge pressure cut-out protection Low suction pressure cut-out protection Chilled water anti-freeze protection Staggered starting of compressors to reduce current inrush Compressors short cycling (on and off repeatedly) prevention which cause overheating of compressors and premature failures or burnt-compressors For multiple units placed side by side where condenser coils air-intake sides face each other, to ensure there is a minimum distance of D ft between units. MODEL SIZE H ft D ft 10 to to to There should be a minimum clearance above the condenser air discharge outlet, not to impede condenser fan performance and not to cause air to deflect downwards and recirculate through condenser coils. H D Lead-lag control of compressors operation and auto-balancing of compressors run-hours A historical alarms save in a FIFO list Can be furnished with optional RS485 adaptor for local / remote monitoring OPTIONAL ACCESSORIES UNDER VOLTAGE AND PHASE PROTECTION RELAY It protects against low incoming voltage conditions as well as single phase reversal and phase unbalance by opening the control circuit. HEAT RECOVERY / DESUPERHEATERS O This can be factory supplied and installed to get free hot water up to as high as 55 C. OTHER OPTIONAL ACCESSORIES Coated or uncoated copper fin coils in lieu of pre-coated aluminium fins coils. Suction and discharge pressure gauges. Discharge or suction stop valves for each compressor. Water flow switches to be shipped loose. Spring isolators to be shipped loose. Rubber-in-shear isolators to be shipped loose. Remote keyboard (up to 100m). Hydraulic package and pump(s). 3. Avoid locating units near neighbour s windows or in building airwell where normal operating sound may be objectionable to building occupants. 4. The standard condenser fans are propeller-type and are not recommended for use with ductwork, filters or other inpedements to air-flow in the condenser air stream. 5. When it is desirable to surround the unit(s), it is recommended that the screening be able to pass the required condenser air-flows without exceeding 0.1 external static pressure. 6. Protection against corrosive environments is available by supplying the units with either copper fins, or cured epoxy-coating on the condenser coils. Epoxy-coated coils should be utilized with any units being installed at the seashore, or where salt spray may hit the units, or where avid rain is prevalent (Copper condenser coils are not recommended where they may be exposed to acid rain). 7. On installations where winter operation is intended and snow accumulations are expected, additional elevation must be provided to insure normal condenser air flow. 3 20

5 PERFORMANCE TABLE Installations & Application Guidelines Location The Smartech SCOD-AR4 1. Installations may either be on ground level or on a roof On Ground Level, the unit must be installed on a concrete slab, with footers extending below the frost line. The base slab shall not settle and cause strain on the refrigerant lines and the chilled water piping lines. Precautions shall be taken to prevent the unit from tampering by unauthorised persons or cause injury to unauthorised persons. A fenced-in enclosure is recommended. Rubber-in- Shear isolators shall be placed below the unit. On Roof location, it is necessary to ensure the roof structure can carry the entire operating weight of the chiller and equipment for service and maintenance. Spring type vibration isolators shall be used to reduce vibration and noise from transmitting through the building structure to cause nuisance to occupants. MIN 12" L 2. Clearance Space The installation place shall have adequate free flow of fresh air for the air-cooled condensers. To ensure there are no obstacles or structures that will restrict fresh air intake and cause re-circulation of hot condenser air. Adequate clearance space of minimum L ft around the unit shall be provided for service and to ensure unrestricted flow of fresh air to condensers. (Refer to Fig 1 & Fig 2 below). If unit has to be placed near a wall, to maintain minimum L ft clearance and ensure the top of condenser fan discharge outlet is at least 12 inches over the wall height. Alternatively, a condenser discharge air hood shall be installed to ensure hot condenser air discharge at least 12 inches above the wall height. MIN 12" Model Size 10 to to to 128 Minimum Clearance L 1 1/2 ft 2 ft 3 ft Lvg Water Temp ( F) Ambient Temp ( F) Model SCOD AR4 R.Ton kwi R.Ton kwi R.Ton kwi R.Ton kwi Fig 1 Fig 2 L Note: Kwi is compressor power input 19 4

6 PERFORMANCE TABLE TYPICAL WIRING DIAGRAM - SCOD79AR4 ~ SCOD128AR4 ( To continue from previous page ) Lvg Water Temp ( F) Ambient Temp ( F) Model SCOD AR4 R.Ton kwi R.Ton kwi R.Ton kwi R.Ton kwi Note: Kwi is compressor power input

7 TYPICAL WIRING DIAGRAM - SCOD79AR4 ~ SCOD128AR4 ( To continue from previous page ) PHYSICAL SPECIFICATIONS Model - AR Nominal Capacity Ton Nominal Power Input kwi Scroll Compressor(s) No. Of Compressors Qty No. Of Refrigerant Circuits Qty % Step Capacity Reduction Qty 100%, 50% Condenser Coil Row/Total Face Area FT² 2/20.0 2/24.7 2/29.6 2/32.7 2/35.8 2/42.5 2/43.3 2/61.4 Total CFM CFM No. Of Fans/motor Qty Fan Model ODS850 ODS850 ODS900 TFZ880 TFZ880 TFZ880 ODS850 ODS900 Motor Input Power each kw Evaporator Evaporator Type Water Connection Sizes inch (mm) BRAZED PLATES HEAT EXCHANGER 1 1/2 1 1/ /2 Nominal Water Flow Rate USGPM Evaporator Pressure Drop Psi Optional Built-In Pump Pump Type HORIZONTAL END SUCTION - VERTICAL DISHAREG Available External Head ft.wg Power Input kw Speed RPM Electrical Data NRA Compressor(each) MTA LRA NRA Unit Electrical Data excluding optional pump MCA MF General Unit Length inch 41 1/2 41 1/2 42 5/8 42 5/8 42 5/8 42 5/ Unit Width inch 41 1/2 41 1/ Unit Height inch 62 1/2 62 1/2 71 3/8 71 3/8 71 3/8 75 3/8 70 1/2 76 1/2 Unit Operating Weight lbs Notes: (I) NRA - running amperes at nominal conditions (ii) MTA - must trip amperes of compressor (iii) MCA - Minimum Circuit Ampacity (iv) MFS - Maximum Fuse Size (v) Unit electrical data excludes optional chilled water pump 17 6

8 PHYSICAL SPECIFICATIONS Model - AR TYPICAL WIRING DIAGRAM - SCOD79AR4 ~ SCOD128AR4 ( To continue from previous page ) Nominal Capacity Ton Nominal Power Input kwi Scroll Compressor(s) No. Of Compressors Qty No. Of Refrigerant Circuits Qty % Step Capacity Reduction Qty 100%, 50% 100%, 75%, 50%, 25% Condenser Coil Row/Total Face Area FT² 3/56.2 2/93.3 2/ / / / / /197.3 Total CFM CFM No. Of Fans/motor Qty Fan Model TFZ880 ODS900 ODS900 ODS900 ODS850 ODS900 TFZ880 TFZ880 Motor Input Power each kw Evaporator Evaporator Type Water Connection Sizes inch (mm) SHELL & TUBES DX COOLER Nominal Water Flow Rate USGPM Evaporator Pressure Drop Psi Optional Built-In Pump Pump Type HORIZONTAL END SUCTION - VERTICAL DISCHARGE VERTICAL IN-LINE Available External Head ft.wg Power Input kw Speed RPM Electrical Data based on 400V-3-50HZ NRA Compressor(each) MTA LRA NRA Unit Electrical Data excluding optional pump MCA MF General Unit Length inch Unit Width inch Unit Height inch Unit Operating Weight lbs Notes: (I) NRA - running amperes at nominal conditions (ii) MTA - must trip amperes of compressor (iii) MCA - Minimum Circuit Ampacity (iv) MFS - Maximum Fuse Size (v) Unit electrical data excludes optional chilled water pump 7 16

9 TYPICAL WIRING DIAGRAM - SCOD79AR4 ~ SCOD128AR4 DIMENSION DATA SCOD AR4 MODEL A B C D E F G H SCOD 10-AR4 41 1/2 41 1/2 48 1/2 30 1/2 14 1/2 14 1/2 1 1/2 12 SCOD 12-AR4 41 1/2 41 1/2 48 1/2 30 1/2 21 1/2 21 1/2 1 1/2 12 SCOD 14-AR4 42 5/ / /4 21 3/ /8 SCOD 16-AR4 42 5/ / /4 25 3/ /8 SCOD 19-AR4 42 5/ / /4 29 3/ /8 SCOD 21-AR4 42 5/ / /4 36 3/ /8 SCOD 24 & 31 AR4 MODEL A B C D E F G P SCOD 24-AR / / SCOD 31-AR / /

10 DIMENSION DATA SCOD 40 AR4 TYPICAL WIRING DIAGRAM - SCOD40AR4 ~ SCOD64AR4 ( To continnue from previous page) SCOD 52, 55 & 64 AR4 9 14

11 TYPICAL WIRING DIAGRAM - SCOD40AR4 ~ SCOD64AR4 DIMENSION DATA SCOD SCOD 79, 79, 103, 103, & AR4 AR4 MODEL A B C D E G SCOD 79-AR SCOD 103-AR / SCOD 110-AR / SCOD 128-AR /

12 TYPICAL WIRING DIAGRAM - SCOD10AR4 ~ SCOD31AR4 TYPICAL WIRING DIAGRAM - SCOD10AR4 ~ SCOD31AR4 ( To continue from previous page ) 11 12