Design guide for DVM Chiller. Design guide for DVM Chiller

Transcription

1 Design guide for DVM Chiller 1

2 Modification history Date Ver. Modifier Modified detail 30 May Junho Lim - New 23 Mar F Weddington - North American Market 27 Mar J McCloskey - Table added, minor changes

3 Contents 1. Introduction Air-cooled chiller vs Water-cooled chiller What is DVM Chiller? Basic configurations Pump system Chiller arrangement Water piping Water piping elements Water pipes Pumps Expansion tank (vessel) Maintenance Water pipe installation Water quality Freeze prevention of water pipe Chilled water management External contact connection A-Terminal block B-Terminal block C-Terminal block Check before use Module or group operation Operation pattern for modules Product configuration DVM Chiller configuration Module controller

4 ` ` ` Design guide for DVM Chiller 1. Introduction Please note that this document is for reference only and is not an actual design manual. In practice, construction and plumbing methods may vary according to the project requirements and local code. To complete design and installation of the system, please consult your local engineer. 1-1 Air-cooled chiller vs Water-cooled chiller An air-cooled chiller has a condenser that uses air for heat transfer. Air-cooled chillers are preferred for small or medium installations but recently the quality improvement in their structure allows the use in modular setups for large installations as well. An air-cooled chiller is preferred especially in cases where there is not enough water or the water is very expensive. Water-cooled chillers have a water cooled condenser connected with a cooling tower and are usually preferred for medium and large installations where there is a sufficient amount of water. In addition, they are also preferred in cases where there is a demand for constant operation of the system, independently of the ambient temperature (industrial air conditioning, air conditioning of digital systems etc.), because the capacity of the water-cooled chillers are less affected by the ambient temperature conditions. ( Air-cooled chiller ) ( Water-cooled chiller ) Condenser Water Pump Cooling Tower Cooling Tower Circuit Chiller Chilled Water Circuit Chilled Water Pump AHU Chilled Water Circuit Chiller AHU Chilled Water Pump 4

5 1. Introduction 1-2 What is DVM Chiller? DVM Chiller is a air-cooled chiller. It is a machine that exchanges heat from water via vapor-compression. DVM Chiller makes chilled water or hot water and can be used in various applications such as commercial, industrial, and institutional facilities. DVM Chiller uses Inverter driven scroll type compressors manufactured by SAMSUNG. The efficiency of the DVM Chiller is higher than conventional water cooled chiller. Also, DVM Chiller can be installed and configured into a module system for large installations. On the water side of the system, the heat source (water) is supplied to DVM Chiller units throughout the building via the water circuit, which incorporates ancillary elements such as heat exchangers, pumps, valves, strainers, expansion tanks, air vents and water treatment equipment etc. Work scope Design - Outdoor unit (Chiller) : Samsung - Water plumbing including pump : MEP company (Mechanical Engineer) 5

6 Approved Modular Combinations Nominal Tons Standard AG010KSVA*H/AA AG015KSVA*H/AA Recommended Pipe Diameter " " " High Efficiency AG010KSVA*H/AA AG015KSVA*H/AA Recommended Pipe Diameter /2" 3 2 1/2" /2" " " " 6 3" /2" /2" " " 9 4" " " " " 12 4" " " " " 15 5" " " " " " " " 6

7 2. Basic configurations 2-1 Pump system 3 common chilled water system configuration 1) Constant primary flow 2) Primary secondary flow 3) Variable primary flow Constant primary flow Primary secondary flow Variable primary flow Multiple chiller and Multiple chiller and -Small plants multiple loads where operator multiple loads with high Application (Few coils serving is not existed loads like data center similar loads) (Many coils serving similar (Many coils serving similar loads or dissimilar loads) loads or dissimilar loads) Pump energy Pump energy is wasted 50~60% less than constant primary flow 60~75% less than constant primary flow S y s t e m Primary Fixed speed pump Fixed speed pump Variable speed pump Secondary - Variable speed pump - Control valve 3Way valve 2Way valve 2Way valve Remark Simple Common Control complex 7

8 2. Basic configurations 2-1 Pump system 1) Constant primary flow The chilled water pumps are constant speed. For constant flow rate, a 3way valve is placed on the outlet of each coil. A 3way valve is maintaining the set point of the air leaving temperature. T 8

9 2. Basic configurations 2-1 Pump system 2) Primary secondary flow A decoupler pipe separates the two loops hydronically. Primary circuit must contain minimum water volume as stated in the installation guide. T ΔP 9

10 2. Basic configurations 2-1 Pump system 2) Primary secondary flow Decoupler sizing and location Decoupler pipe size should cover the flow rate of the largest primary pump. The pressure drop less than 1.5 ft. The higher the pressure drop, the more the pumps tend to act like they are in series instead of independent loops. Proper decoupler size will prevent this from occuring. Buffer tank Generally buffer tank is recommended to ensure proper water volume to chillers. Because if secondary pump stops and primary pump continues running, then water volume of the system with a decoupler may be too low. Chiller requires minimum flow rates. 10

11 2. Basic configurations 2-1 Pump system 3) Variable primary flow Variable primary flow design uses variable pump instead of constant speed pump. A bypass valve ensures minimum flow rates. The valve should be automatically controlled by using flow meter in primary circuit or secondary P. T ΔP 11

12 2. Basic configurations 2-2 Chiller arrangement 1) Parallel chillers configuration Parallel configuration is more common than series configuration. Parallel configuration use usually same capacity and type of chiller. ` ` ` When only one chiller is operating, supply chilled water temperature rises. Operating chiller can be reset to produce target water temperature. (Increasing chiller energy consumption) * To avoid this problem, primary pump must be variable speed. This can solve the flow mixing problem. *But below 50% load, only on chiller pump is operating. All of coils receive less water flow rate. Also to avoid short circuit problem, a check valve or isolation valve should be installed. *ASHRAE Standard 90.1 : When a parallel chiller is shut down, flow rate must be reduced. 12

13 2. Basic configurations 2-2 Chiller arrangement 2) Series chillers configuration The mixing problem and less flow can be solved in series chiller system. But each chiller must accommodate double flow rate. This increases pressure drop. To compensate pressure drop, series chiller applies to low flow system. [higher ΔT than ] Upstream chiller Downstream chiller T T Parallel chiller GPM System pressure drop : 7.25 psi Series chiller GPM System pressure drop : 26.1 psi Upstream chiller starts first. When upstream chiller can not achieve target water set temperature, downstream chiller is operated. 13

14 2. Basic configurations 2-3 Water piping 1) Direct return piping When designed with direct return piping, the pressure drop and flow rates will be uneven between near and far side from the pump due to different piping lengths. Because of different friction loss the water flow rate of each chiller and load will not be same. It requires to install additional flow control valves near the inlet side of each load to balance water flow. Flow rates of each load 25% 50% 75% 100% 100% C Fan Coil Units (installed in parallel) Modular Chillers (installed in parallel) 75% 50% C C C C C C 25% C ΔP Pump C : Flow control valve ΔP Profile of Pressure Drop between inlet and outlet 14

15 2. Basic configurations 2-3 Water piping 2) Reverse return piping If the pipe length between supply and return is the same, it has approximately the same friction loss, which will produce approximately the same flow rate. Fan Coil Units (installed in parallel) Modular Chillers (installed in parallel) Equal ΔP Pump Equal ΔP Profile of Pressure Drop between inlet and outlet Although reverse return system is closer to self-balancing than direct return systems, make sure each load is similar to balance water flow 15

16 3. Water piping elements When designing a water piping system, the following should be considered : Water must be supplied to the required locations according to the needs of each DVM Chiller. Head and friction losses should be kept minimum. Water velocity should be properly controlled to avoid water flow noise, pipe vibration, and pipe expansion/contraction issues due to temperature differences. Attention should be paid to water management : Impact of the water quality, corrosion prevention, freeze prevention etc. Proper arrangements should be provided for easy service and maintenance. Process Pipe design Direct or reverse return Pipe route design Minimization of pipe length Flow rate calculation Head loss, friction loss calculation Select pipe size Select other parts Calculation total head loss Select water pump 16

17 3. Water piping elements 3-1 Water pipes 1) Constant water flow a. Constant flow valve The constant flow valve maintains a steady flow rate for the stable operation. This constant water flow valve is required for each DVM Chiller C C C C C : Constant flow valve b. Reverse return piping If the pipe length between supply and return is the same, it has approximately the same friction loss, which it makes the same flow rate. 17

18 3. Water piping elements 3-1 Water pipes 2) Friction losses In order to force a fluid through a pipe, pressure is required to overcome the viscous friction forces. Friction loss occurs when water flow through a pipe. Note The Darcy equation is the basis of all fluid flow equations and relates the pipe pressure drop required to overcome the fluid viscous friction forces : P = ( ρ * f * l * v² ) / ( 2 * d ) Where : P = friction losses (Pa) ρ = fluid density (kg/m³) f = friction factor, depending on the roughness of the internal surface of the pipe l = pipe length (m) v = fluid velocity (m/s) d = internal pipe diameter (m) Most air conditioning systems use steel pipe or copper tubing. Based on the Darcy equation, the pipe friction / flow tables are made. 18

19 3. Water piping elements 3-1 Water pipes 2) Friction losses Example (By Hazen-Williams Equation chart) 19

20 3. Water piping elements 3-1 Water pipes 3) Water velocity The recommended water velocity through the piping is depending on two conditions : Pipe diameter Effect of erosion Pipe selection guide Velocity High Low Reliability Erosion accelerating, vibration and noise Damaging wear and tear of pipes and fittings Laminar flow reduces the chiller efficiency * Design water velocity must be decided by the design engineer as erosion is a function of time [ Recommended velocity range ] Pipe diameter [inch] *Velocity range [ft/s] 5 or more 6.9 ~ 8.9 2~4 3.9 ~ 6.9 About ~ 3.9 [ Max allowable velocity to minimize erosion ] Running time (hr/year) Velocity(ft/s) 1, , , , , , * 1 year = 8,760 hr 20

21 Flow rate Design guide for DVM Chiller 3. Water piping elements 3-1 Water pipes 4) Example of sizing water pipes : * Condition - Type : Stainless steel pipe, Water flow : 200 l/min, Friction loss : less than 1.2 kpa Case #1 Pipe size : 50 A, Velocity : 1.99 m/s, Friction loss : 1.05 kpa Case #2 Pipe size : 60 A, Velocity : 1.28 m/s, Friction loss : 0.36 kpa (Lower than 0.4 kpa Not efficiency) 40 mm high friction loss (2.04 kpa/m) 75 mm low velocity (0.79 m/s) Friction loss 21

22 3. Water piping elements 3-1 Water pipes 4) Example of sizing water pipes : * Example (By Hazen-Williams Equation chart) Model 15HP Model 20HP Model 25HP Water Flow 120 LPM Water Flow 160 LPM Water Flow 200 LPM Diameter 40 A Diameter 40 A Diameter 50 A Velocity 1.35 m/s Velocity 1.82m/s Velocity 1.99m/s Friction loss 0.58 kpa/m Friction loss 0.95 kpa/m Friction loss 1.05 kpa/m Flow rate Friction loss 22

23 3. Water piping elements 3-2 Pumps Water pump selection 3 Factors for pump selection 1) Flow rate, 2) Total Head, 3) Power 1) Flow rate Sum of required flow rate of each DVM Chiller 2) Total Head H_t = H_a + H_p + H_f + H_u H_a : Head pressure by level difference ( H_a value is 0 in closed loop as no level difference ) H_p : Friction loss by straight pipes H_f : Equivalent length of friction loss by fittings H_u : Friction loss from the condenser / evaporator in the units ( PHE of DVM Chiller) H_a Actual head of Delivery H_a Actual head of Delivery H_a Actual head of Delivery Actual head of suction Actual head of suction Water head 23

24 3. Water piping elements 3-2 Pumps Water pump selection Equivalent length of friction loss by fitting [ft] Pipe size ¾ Elbow (Long Radius) Tee (line flow) Tee (branch flow) Globe valve **Above chart is for reference only** Resistance of valves and fittings to flow of fluids 24

25 3. Water piping elements 3-2 Pumps Water pump selection 3) Power Motor power calculation : This value will be used to select motor of water pump Power[kW] = q x ρ x g x h / (3.6 x 10^6) / η q = Flow rate (m3/h) ρ = Density of fluid (kg/m3), * 1,000 for water g = Gravity (9.81 m/s2) h = Differential head (m) η = Pump efficiency 25

26 3. Water piping elements 3-2 Pumps Water pump selection Example DVM Chiller 15 Ton FCU 24k Btu/h * 4 EA Required flow rate : 120 l/min Pressure loss PHE of DVM Chiller : 60 kpa FCU : 25 kpa Supply Flow rate : 120 l/min Length : 25 m Pipe diameter : 40 A Velocity : 1.35 m/s Friction loss : 59 mmaq/m Return Flow rate : 120 l/min Length : 20 m Pipe diameter : 40 A Velocity : 1.35 m/s Friction loss : 59 mmaq/m DVM Chiller Elbow : 4 ea T-connection straight through : 1 ea Globe valve : 1 ea [ Pump catalogue ] Pump Efficiency : 60% FCU 32.8 feet - Flow rate : 120 l/min = 7.2m3/hr - Total head pressure(h_t) = = kpa (12,6 maq) * H_a : 0, * H_p : (25+20) x 59 = 2,655 mmaq = 26.0 kpa, * H_f : (1.3x4)x59 +( 0.9x1)x59+(16x1)x59 = 1,304 mmaq = 12.8 kpa, * H_u : = 85.0 kpa Refer to the table about equivalent length of friction loss by fitting - Power = 5.76 x 1,000 x 9.81 x 12.6 / (3.6 x 10^6) / 0.6 = 0.33 kw 26

27 3. Water piping elements 3-2 Pumps Water pump selection Use selection software of the pump manufacturer - Input flow rate & Head pressure * Reference site : 27

28 3. Water piping elements 3-3 Expansion tank (vessel) The purpose of the expansion tank is to maintain system pressure by allowing the water to expand when the water temperature increases in order to prevent pipe and equipment damage. The tank is partially filled with air, whose compressibility cushions shock caused by water hammer and absorbs excess water pressure caused by thermal expansion. An expansion tank is required in a closed system. In an open system, the reservoir acts as the expansion tank. The expansion tank can be of the open or closed type. The open expansion tank (reservoir) is located at the suction side of the pump, above the highest point in the system. At this location, the tank provides atmospheric pressure equal to or higher than the pump suction, preventing air from leaking into the system. The closed expansion tank is used in small systems and is designed larger than open expansion tanks. The tank is located at the suction side of the pump. Expansion tank (vessel) location It may occur cavitation It can prevent cavitation 14.5 psi 14.5 psi P P E Expansion tank E 14.5 psi 14.5 psi P P Pump off Pump off 0 psi 14.5 psi P P E E 14.5 psi 29 psi P P Pump on Pump on 28

29 3. Water piping elements 3-3 Expansion tank (vessel) Expansion tank (vessel) sizing Open expansion tank In the case of open expansion tanks, corrosion prevention is required. - Size(l) = Vw x (v_high - v_low) x α * Vw(l) : Total water amount in the system * v_high(l/kg) : water specific highest water temp * v_low(l/kg) : water specific lowest water temp * α : Safety factor Closed expansion tank - Size(l) = Vw x (v_high - v_low) / [(Pa / P0) (Pa / P1)] x α * Vw(l) : Total water amount in the system * v_high(l/kg) : water specific highest water temp * v_low(l/kg) : water specific lowest water temp * Pa(kgf/cm2) : Atmospheric pressure 1.03 * P0(kgf/cm2) : System initial cold pressure * P1(kgf/cm2) : System operating hot pressure * α : Safety factor 29

30 4. Maintenance 4-1 Water pipe installation Example of water pipe installation No. Name No. Name 01 Drain pipe 07 Valve 02 Flange 08 Air vent valve 03 Strainer 09 Check valve 04 Drain valve 10 Pump 05 Temperature gauge 11 Flexible joint 06 Pressure gauge 12 Expansion tank If the hydronic pipe is not managed periodically, it may affect the operation and may cause noise, maintenance, and service difficulty. Hydronic pipe should be insulated per local code. If water piping is not insulated, or poorly installed, there may be heat loss, and may cause frozen damage during cold weather. When using indoor units such as two or more fan coil units, make sure each unit is installed with valving to maintain proper balanced water flow. Install the expansion tank that can absorb expansion and contraction of water due to temperature change. Location of tank based on type used, open or closed. Install automatic air vents at high points in the piping to aid in the removal of air When using expansion tanks or automatic air vents, give 1/250 slant to horizontal pipes. 30

31 4. Maintenance 4-1 Water pipe installation Install drain valves at low points of the loop. If the system is large, install drain valves for each of the main pipes so that draining is easier for maintenance. Water pump should be installed on the inlet side of DVM Chiller heat exchanger. A stainless steel strainer (50 Mesh or more) is mandatory at heat exchanger inlet. Use flexible joint at inlet/outlet of heat DVM Chiller heat exchanger connections pipe to aid in absorption of vibration and stress. Install temperature gauge and pressure gauge at inlet/outlet of DVM Chiller heat exchanger connections for monitoring, maintenance, and service. Connect water pipes to the product by cut and groove coupling. Install the pipe and the product in a manner it can be easily disconnected if needed for service. Install valves at inlet/outlet of pipes, drain valve at inlet, and air purge valve at outlet of water pipe. Maintain the water volume as listed in technical documents. If the volume is too low, compressor may short cycle with light load on the system. Such operation may result in shortening the life of the product and/or product malfunction due to repetition of compressor operation. Be aware of the volume, if water temperature and capacity control is done by a bypass system. There is a possibility of scale generated on plate type heat exchanger, periodical chemical cleaning may be necessary to remove scale. Install chemical input between valve and the product. If the product is stopped for a long periods of time during winter, or stops operation for unoccupied times, take appropriate countermeasures (water drain, circulating pump operation, heater, etc.) to prevent freezing in cold regions where outdoor temperature falls below 32. When water in the system freezes, it will cause damage to the plate type heat exchanger and therefore preventive measure must be taken. Example: Pumping heat exchanger with glycol is a preventative measure. 31

32 4. Maintenance 4-1 Water pipe installation Water maintenance is standard for chilled/heating water with circulating water. Using untreated water may cause corrosion and performance issues. Also, avoid autofill water systems that do not have chemical treatment. Water storage must be used within the range listed in installation manuals. 50 ~ 200 % of rated water storage can be used, but using rated water storage is recommended. - If water volume is low, it may cause performance decrease due to scale accumulation, thermal protection operation to prevent freezing, and potential gas leakage. - If water storage is over, it may cause corrosion. Be aware of any cavitation when checking flow rate of water system, installation of expansion tank, and air purging placed in the middle of the loop. In case of semi-closed chilled/heating water system with thermal storage, exchange water (once every 1 ~ 2 years), clean and maintain thermal storage periodically. New concrete thermal storage may elute foreign substances, so ph of thermal storage water may be affected. If ph is over the standard, copper may corrode faster. Exchange the water periodically in this situation. Also, over time if thermal storage is used water leakage may occur due to cracks. - In case of using sea water or contaminated underground water, corrosion may occur by slime generated by microbes or calcium carbonate. Installation of chemical pot feeder is recommended for ease of water treatment maintenance. 32

33 4. Maintenance 4-2 Water quality If chilled/heating water is not maintained by the following standard, corrosion and scale accumulation may occur. It may decrease the performance of heat exchange, and may also cause product malfunction due to heat exchanger damage by freezing. Extra care is necessary, and water should be maintained to keep the water within the standards. Item Chilled water system Circulation water (below 68 ) Supply water Heating water system Low level medium temp. heating gauge Circulation water (68 ~140 ) Supply water Corrosion effect Forming scale ph (77 ) 6.8~ ~ ~ ~8.0 O O Electric conductivity (ms/m, 77 ) {μs/cm, 77 } Below 40 {Below 400} Below 30 {Below 300} Below 30 {Below 300} Below 30 {Below 300} O O Chloride ion (mgcl-/l) Below 50 Below 50 Below 50 Below 50 O Basic Sulfate ion (mgso42-/l) Below 50 Below 50 Below 50 Below 50 O item Acid consumption (ph4.8, mgcaco3/l) Below 50 Below 50 Below 50 Below 50 O Full hardness (mgcaco3/l) Below 70 Below 70 Below 70 Below 70 O Calcium hardness (mgcaco3/l) Below 50 Below 50 Below 50 Below 50 O Ion-like silica (mgsio2/l) Below 30 Below 30 Below 30 Below 30 O Iron (mgfe/l) Below 1.0 Below 0.3 Below 1.0 Below 0.3 O Copper (mgcu/l) Below 1.0 Below 0.1 Below 1.0 Below 0.1 O Reference item Sulfide ion (mgs2-/l) Not detected Not detected Not detected Not detected O Ammonium ion (mgnh4+/l) Below 1.0 Below 0.1 Below 0.3 Below 0.1 O Chlorine residual (mgcl/l) Below 0.3 Below 0.3 Below 0.25 Below 0.3 O Free carbon (mgco2/l) Below 4.0 Below 4.0 Below 0.4 Below 4.0 O 33

34 4. Maintenance 4-3 Freeze prevention of water pipe (If not using Anti-freeze) When outdoor temperature is low or during winter months, water in pump and piping may freeze and may cause damage to the product and the piping system. Insulate piping and all accessories to help prevent freezing. Use of heat trace is recommended. In low ambient conditions operate the pump while the product is off or if possible, drain the system. Stopping during winter Do not cut-off the power supply. - This may result in water leakage or pipe damage because pump will not operate to prevent freezing. Do not cut-off the power supply for the pump. Stop the operation with water pipe valve opened. - Stop the operation with valve opened to make water circulate when the pump operates. If the water does not circulate, it may freeze and cause product malfunction. Stopping for an extended time Drain water from water pipes and water side heat exchanger. - Open drain valves on water pipe system and drain plug in DVM CHILLER when draining water. - Product may be damaged if water freezes inside the piping and water side of the heat exchanger when temperatures are below 32 F. Cut-off the power supply after draining water. - Pump may operate for protection even there is no water when power is supplied and it may cause pump malfunction. 34

35 4. Maintenance 4-4 Chilled water management If the chilled water storage exceeds optimal range, stop the operation until cause is taken care before re-start the operation. * Range: 50 ~ 200 % of rated flow rate Item Water flow rate working range (GPM) Rated condition Working range Model AG010* AG015* AG010* AG015* Cooling / Heating ~ ~

36 4. Maintenance 4-4 Chilled water management Water temperature range - Operate the product within the following range. For product protection, compressor operation may be limited. Rated condition Range(Water Outlet) Classification (Inlet / Outlet) Water Brine Cooling 53.6 / ~ ~ 77 Heating 104 / ~ 131 When using in brine condition in cooling mode, maintain concentration of brine properly. The product should be set in low temperature usage. * To use low temperature function, hydro controller option No. 34 and Seg 23 of advanced option 05 = "E" should be all set. * Anti-freeze standard data Water outlet temperature, 14 ~ 23 23~32 32~ ~ ~ 68 Ethylene glycol, % Propylene glycol, % Minimum water outlet temperature,

37 4. Maintenance 4-4 Chilled water management Minimum water storage - If the length of water pipe is too short, water volume within the system becomes lower and ON/OFF operation of the compressor occurs more often. For stable operation, maintain certain water volume by applying header or Buffer tank. - If total water volume is under the minimum volume, install another tank to retain more water volume. Model name Minimum water volume (gal) AG010KSV Series 72 AG015KSV Series Total water volume in the system = water volume within the water pipe + water volume in DVM CHILLER + water volume in AHU (or fan coil) Minimum capacity of buffer tank = Minimum water volume - water volume within the water pipe system 37

38 5. External contact connection Configuration of terminal block T/B : Terminal Block A-T/B B-T/B C-T/B DVM Chiller 5-1 A-Terminal block Hydro control box - Purpose is to check the status of product in control room. Cooling/Heating display Operation display Freeze protection display * A-T/B : Output contact * Output contact can be connected neutral contact and open/short only * Apply dry contact(no current) Warning display Defrost operation display Pump operation display Pump operation Comp operation display 38

39 5. External contact connection No. Name Function Contact short Contact open signal 1-2 Cooling/Heating display Display when operating in heating mode Heat 3-4 Operation display Display when operation ON Operate Stop 5-6 Warning display Display when error occurs Error occurred No error Cool A-T/B 7-8 Defrost operation display Display when in defrost Defrost On Defrost Off 9-10 Pump operation display Display when pump is operating Pump On Pump Off Comp operation display Display when compressor is operating Compressor On Compressor Off Pump operation Signal of pump operation Pump signal On Pump signal Off Freeze protection display Display when in freeze protection Pump On for Freeze protection Others Dry contact 5-2 B-Terminal block Pump interlock Operation On/Off * B-T/B : Input contact * Input contact can be connected neutral contact and open/short only * Apply dry contact(no current) Operation On/Off Operation mode Hot water(cool storage) mode Hot water(cool storage) Thermostat signal Standard for Hot water (Cool storage) control 39

40 5. External contact connection 1 Pump interlock (Mandatory) - Prevents operating DVM Chiller without pump operation. If DVM Chiller operates without pump operation, it may be cause product damage. - Works by contact signal between DVM Chiller and pump. - After checking for pump operation, the product operates.(apply interlock system) If pump does not operate, the product will not operate. - The power of pump should be supplied separately. DVM Chiller provides only a dry contact for reliability of product. Product can be damaged because of problem of a pump which is installed in field. Operation on signal to pump Feedback signal from the pump for delay time? Yes Detect the water flow for 10sec? Yes DVM Chiller Operation On No No Operation OFF Error display *E918 Operation OFF Error display *E911/E913 Hydro option setting - Delay time of pump operation signal feedback is determined in the No. 13 of hydro option setting. *E911 : Dose not detect the signal of flow switch E913 : Six times detection of E911 (Operation is not possible) *E918 : No feedback interlock signal of pump operation Option No. Option Item Option value Factory default Definition Setting unit 13 Delay time of pump operation signal feedback 10~ Second unit Main unit of module ** Pump interlock may be proven by means of flow switch or control interlock. 40

41 5. External contact connection 1 Pump interlock Wiring connection Dry Contact or flow proving device Relay Input signal Voltage supply Power supply (Field supplied) Relay Pump Caution * Some voltage is necessary to activate relay * Input cannot be connected by jumper No. Function Contact short Contact open Setting unit A-T/B Pump operation Pump signal ON Pump signal OFF Each unit B-T/B 7-8 Pump interlock Pump on Pump off Each unit 41

42 5. External contact connection 2 Operation contact signal - It is possible to control operation by contact signal. You can select the operation method by either Module control/dms or external contact. - Hydro option setting is required for this function. (Option No. 1 / Option No. 28) Value of hydro option No. 28? 1 0 Is there input signal? (B-T/B, 9/10) No Operation OFF (Contact : Open) Yes DVM Chiller Operation ON (Contact : Short) Is there input signal? (B-T/B, 13/14) No Cooling operation start (Contact : Open) Yes Heating operation start (Contact : Short) No No Is there input signal? (B-T/B, 9/10) Is there input signal? (B-T/B, 11/12) Yes Yes DVM Chiller Operation ON (Contact : Short) DVM Chiller Operation OFF (Contact : Short) Is there input signal? (B-T/B, 13/14) No Cooling operation start (Contact : Open) Yes Heating operation start (Contact : Short) Hydro option setting - The input signal pattern is determined in the No. 28 of hydro option setting at first. Option No. Option Item Option value Factory default Option Definition Setting unit 28 Signal pattern of operation ON/OFF by external contact 0/1 0 0 Usual input signal Main unit 1 Instant input signal of group - To use this external contact, the input method of operation on/off in hydro setting needs to be set to 1. Option No. Option Item Option value Factory default Option Definition Setting unit 1 Input method of operation ON/OFF 0/1 0 0 Module control/dms Main unit 1 External contact of group 42

43 5. External contact connection 2 Operation contact signal Wiring connection Operation ON contact signal Operation mode contact signal DDC DDC Dry contact Dry contact Dry contact DDC External controller (DDC : Direct Digital Control) Input signal Input signal (Field supplied) (Field supplied) Input signal No. Function Contact short Contact open Signal type Setting unit B-T/B 9-10 Operation on/off Refer to the below or Instant input signal Operation mode Heat Cool Usual input Main unit of group Signal type No. 9~10 No. 11~12 Signal type Short(Operation on) Open(Operation off) - Usual input signal (Open/short) Short(Operation on) Short(Operation off) Instant input signal (Pulse input) 43

44 5. External contact connection 3 Hot water / Cool storage - Able to store the thermal energy in water tank for later use. DVM Chiller Thermo on (Contact : Short) DVM Chiller Operation ON Is there input signal? (B-T/B, 15/16) Yes Cool storage (Hot water) operation (Contact : Short) Is there input signal? (B-T/B, 19/20) Yes B-T/B 9-10 : on No Cooling(Heating) operation (Contact : Open) - Cool storage operation B-T/B 13/14 : open - Hot water signal : B-T/B 13/14 : short No DVM Chiller Thermo off (Contact : Open) Hydro option setting - To use this external contact, the input method of operation mode in hydro setting have to be set to 1. Option No. Option Item Option value Factory default Option Definition Setting unit 3 Input method of operation mode (Cool/Heat, Cool storage/hot water) 0/1 0 0 Module control/dms Main unit 1 External contact of group Module control setting - Service mode setting of Module control is required for this function. Main menu 9 Sub menu Function Option value Factory default 4 Use Cool storage mode 0/1-5 Use Hot water mode 0/1 - Option Definition Save 0 Disable 1 Enable 0 Disable 1 Enable Save at DVM Chiller 44

45 5. External contact connection 3 Hot water / Cool storage Wiring connection (Field supplied) Dry contact Dry contact DDC DDC Dry contact DDC Input signal Input signal External controller(ddc : Direct Digital Control) Input signal No. Function Contact short Contact open Signal type Setting unit Hot water(cool storage) mode Cool storage or Hot water Cool or Heat Usual input B-T/B Hot water(cool storage) control method Control by set temperature Control by thermostat Usual input Main unit of group Hot water(cool storage) Thermostat signal Thermo on Thermo off Usual input 45

46 5. External contact connection 5-3 C-Terminal block T/B : Terminal Block Silent mode function Demand function * C-T/B : Input contact * Input contact can be connected neutral contact and open/short only * Apply dry contact(no current) except C-T/B No. 17~20 Forced fan function Unusual condition reset Water law function External water outlet Temperature (4~20mA) Set temperature / Room temperature Sensor(4~20mA) Sensor Type: PT100 1 Silent mode function - Reduces the noise of outdoor unit in night time during low demand. - When silent mode function is enabled by module control, only cooling mode is possible. - If silent mode is enabled by external contact, both Cooling and Heating mode are possible by signal of external contact. 46

47 5. External contact connection By module control DVM Chiller Operation ON After 6hr from highest ambient temp? Yes Hydro option value of No. 12? 1~3 Silent mode operation (Only Cooling mode) No 0 No Yes Normal operation Normal operation After 12hr from mode entry or mode off? By external contact DVM Chiller Operation ON Is there input signal? (C-T/B, 1/2) Yes Hydro option value of No. 12? 1~3 Silent operation (Cooling or Heating mode) No 0 Normal operation (Contact : Open) Normal operation Hydro option setting - Silent mode function level is determined in the No. 12 of hydro option setting at first. Option No. Option Item Option value Factory default 12 Silent mode function level 0~3 1 Option Definition 0 Default(100%) 1 Level 1 2 Level 2 3 Level 3 Setting unit Main unit of module - To use external contact, the input method of silent mode function in hydro setting have to be set to 1. Option No. Option Item Option value Factory default Option Definition Setting unit 6 Input method of silent mode function 0/1 0 0 Module control/dms Main unit 1 External contact of group 47

48 5. External contact connection 1 Silent mode function Wiring connection Dry contact DDC External controller (DDC : Direct Digital Control) (Field supplied) Input signal No. Function Contact short Contact open Signal type Setting unit C-T/B 1-2 Silent mode function On Off Usual input Main unit of group 48

49 5. External contact connection 2 Demand function - Used to limit power consumption of the product to manage efficiency. - Hydro option setting is required for this function. (Option No. 5 : Demand control level) It can be set as no limit or range of 50 ~ 100%. (Interval : 5%) - If it is enabled by external contact, Hydro option setting is required for this function (Option No. 4 : Input method of Demand control) DVM Chiller Operation ON Demand control On by Module control or DMS? Yes Demand control operation No Normal operation No Demand control Off by Module control or DMS? Yes Normal operation Use of external contact Is there input signal? (C-T/B, 3/4) Yes Demand control operation No Normal operation (Contact : Open) 49

50 5. External contact connection Hydro option setting - Demand control level is determined in the No. 5 of hydro option setting at first. Option No. Option Item Option value Factory default 5 Demand control level 0~11 3 Option Definition 0 Default(100%) 1 95% 2 90% 3 85% 4 80% 5 75% 6 70% 7 65% 8 60% 9 55% 10 50% 11 Not applied(no Limit) Setting unit Main unit of module - To use external contact, the input method of Demand control in hydro setting have to be set to 1. Option No. Option Item Option value Factory default Option Definition Setting unit 4 Input method of Demand control 0/1 0 0 Module control/dms Main unit 1 External contact of group 50

51 5. External contact connection 2 Demand function Wiring connection External controller (DDC : Direct Digital Control) Dry contact DDC (Field supplied) Input signal No. Function Contact short Contact open Signal type Setting unit C-T/B 3-4 Demand function On Off Usual input Main unit of group 51

52 5. External contact connection 3 Water law function - Used to optimize the operation state of product depending on ambient conditions to save power cost. - Leaving water temperature of product is set automatically by ambient or room temperature. - If it is enabled by external contact, Hydro option setting is required for this function. (Option No. 8 : Input method of Water law function) - Water law control method is determined by No. 15 of hydro option setting. (Based on ambient temperature or room temperature) - In case of using water law by room temperature, The room temperature sensor must be installed connected at No.17/18 of C-T/B. Leaving water temp.[ F] [Cooling / Heating Mode] Tcool1 or Theat1 Tcool2 or Theat2 AirCool1 or AirHeat1 AirCool2 or AirHeat2 Ambient temp.[ F] Leaving water temp. F] [Cooling / Heating Mode] Tcool1 or Theat1 Tcool2 or Theat2 RoomCool1 or RoomHeat1 RoomCool2 or RoomHeat2 Room temp.[ F] 52

53 5. External contact connection Hydro option setting - Water law control standard is determined in the No. 15 of hydro option setting. Option No. Option Item Option value Factory default Option Definition Setting unit 15 Water law control standard 0/1 0 0 Ambient temperature Main unit 1 Room temperature of group - To use external contact, the input method of Water law in hydro setting have to be set to 1. Option No. Option Item Option value Factory default Option Definition Setting unit 8 Input method of Water law function 0/1 0 0 Module control/dms Main unit 1 External contact of group - The value of parameters are determined by No. 16~27 of hydro option setting. Option No. Option Item Option value Factory default Definition 16 AirCool1(For Water law) 0~20 10 Standard1 outdoor temperature for cooling 17 AirCool2(For Water law) 30~40 35 Standard2 outdoor temperature for cooling 18 RoomCool1(For Water law) 15~24 20 Standard1 room temperature for cooling 19 RoomCool2(For Water law) 25~35 30 Standard2 room temperature for cooling 20 Tcool1(For Water law) -10~25 15 Standard1 set temperature for cooling 21 Tcool2(For Water law) -10~25 7 Standard1 set temperature for cooling 22 AirHeat1(For Water law) -20~5-10 Standard1 outdoor temperature for heating 23 AirHeat2(For Water law) 10~20 15 Standard2 outdoor temperature for heating 24 RoomHeat1(For Water law) 15~24 20 Standard1 room temperature for heating 25 RoomHeat2(For Water law) 25~35 30 Standard2 room temperature for heating 26 Theat1(For Water law) 35~55 45 Standard1 set temperature for heating 27 Theat2(For Water law) 35~55 35 Standard1 set temperature for heating Setting unit Main unit of group ** All values are in ºC 53

54 5. External contact connection 3 Water law function Wiring connection Dry contact DDC Input signal (Field supplied) Sensor SMPS 24V External controller(ddc : Direct Digital Control) (Field supplied) No. Function Contact short Contact open Signal type Setting unit C-T/B Water law Water law control Set temp. input / Room temp. sensor Water outlet set Temp. control Usual input Main unit of group 4 ~ 20mA Current input Main unit of group Correlation of both room temp. sensor and current (Room temperature sensor for water law( ) = 6.25 x Current(mA) 75) Current(mA) Temperature( ) Temperature( F)

55 5. External contact connection 4 External water temperature sensor - External water temperature sensor is used for control instead of product s water outlet temperature sensor - Hydro option setting is required for this function. (Option No. 14 : External water outlet temperature sensor) - The external water temperature sensor should be installed in the common building return header. This will allow the mixed temperature of water to be accurately read. - It must be connected at No. 19/20 of C-T/B External water temp. sensor use? Yes Operation pattern of DVM Chiller is not standard control? Yes External water temp. sensor control No No Water outlet temp. sensor control of each product Water outlet temp. sensor control of each product Hydro option setting - It has to be set to 1, when an external water temp. sensor is used instead of individual unit s water outlet temp. sensor. Option No. Option Item Option value Factory default Option Definition Setting unit 14 External water outlet temperature sensor 0/1 0 0 Disuse Main unit 1 Use of group 55

56 5. External contact connection 4 External water temperature sensor Wiring connection Sensor SMPS 24V (Field supplied) No. Function Contact short Contact open Signal type Setting unit C-T/B External water outlet temperature 4~20mA Current input Main unit of group Correlation of both external water outlet temp. sensor and current (The value of water outlet set temp.( ) = 6.25 x Current(mA) 55) Current(mA) Temperature( ) Temperature( F)

57 6. Check List 6-1 Module or group operation Module/group operation is to combine multiple units in modules or groups of a single water pipe system and to operate depending on the working condition. A single module control can control a maximum of 16 DVM CHILLERs (0 ~ 15). - DVM CHILLER can have a maximum of 8 modules (1 ~ 8) and 4 groups (1 ~4). - A maximum of 8 units can be connected to a module, and a maximum of 16 units (module) can be connected to a group. Depending on the working condition below, set modules or groups. - A module or a group must be connected to a single water pipe. - When modules are controlled by a group, the modules cannot operate themselves and the display will not show the modules during the module operation. You can select an operation mode, a pattern operation (according to distribution method of compressor capacity) and an applied operation by each module or group. 57

58 6. Check List 6-2 Operation pattern for modules - The default is Standard control. This is can be changed at Module Controller. Contact a service center for further details. - When the current water temperature reaches the set temperature, On/Off control will be performed by each unit. 1) Standard control - All units connected to each module start operating at the same time, and then they control the water outlet temperature and the capacity of compressor separately. Standard control is suited to the site that has always a high cooling and heating load factor. 58

59 6. Check List 6-2 Operation pattern for modules 2) Rotation control - DVM CHILLER s water outlet temperature is controlled according to the water outlet temperature average value of all units which operates by pumps in a module. However, if you set Use for an external water temperature sensor, it controls the water outlet temperature according to a temperature value from the sensor. - Only one unit with the highest priority operates, and if the unit has the full load, a unit with the following priority will operate. - The unit with the lowest priority operates at the minimum capacity, and if the water outlet temperature reaches the set temperature, it performs On/Off control. The rotation control is suited to the site that has small capacity at load side during starting a DVM CHILLER and has a small fluctuation in momentary load. 59

60 6. Check List 6-2 Operation pattern for modules 3) Efficiency control - DVM CHILLER s water outlet temperature is controlled according to the water outlet temperature average value of all units which operates by pumps in a module. However, if you set Use for an external water temperature sensor, it controls the water outlet temperature according to a temperature value from the sensor. - The unit with the highest priority operates, and if that unit operates with optimum efficiency, a unit with the following priority will operate. - When all units reach efficient operating condition, each unit operates at capacity between efficient operating condition and the maximum capacity condition. - When all units reach efficient operating condition and the water outlet temperature reaches close to the set temperature, the unit with the lowest priority decreases compressor operating capacity. 60

61 6. Check List 6-2 Operation pattern for modules 3) Efficiency control The efficiency control is suited to the site that has both an operating section with the low load and a focused operating time. When all units operate with the optimum efficiency, they control the pressure of their compressors in a range between higher than *efficient Hz and lower than full load Hz separately. * Efficient Hz means the best efficient Hz of inverter. 61

62 7. Product configuration 7-1 DVM Chiller configuration 1) Product dimension Anchor Bolt 65 3/16 * Unit :inches Anchor Bolt 30 5/ / /8 9 1/ / /8 31 5/8 34 7/8 No Part Name Specification 1 Water Connections 50 A Cut Groove 2 Power Hole (front) 6 1/3 in*6 3/16 in 3 Power Hole (side) Left Φ 2 in, Right Φ 1 ¾ in 4 Communication Hole (Front) Φ 1 3/8 in 5 Monitoring Window 7 in* 5 1/16 in 62

63 7. Product configuration 7-1 DVM Chiller configuration 2) Part exploded view No Part Name No Part Name No Part Name 1 Air Heat Exchanger 10 Fan Motor 19 Water Connection 2 Water Heat Exchanger 11 Oil Return Valve 20 Water Pressure Sensor 3 4way Valve 12 High Pressure Sensor 21 PHE EEV 4 Accumulator 13 Hot Gas Bypass Valve 22 Air Vent 5 EVI Bypass Valve 14 Low Pressure Sensor 23 Water Temp. Sensor 6 Oil Separator 15 Vapor Injection Valve 24 EVI EEV 7 Receiver Tank 16 High Pressure Switch 25 Sub Cooler 8 Scroll Compressor 17 Accum. Return Valve 26 Fusible Plug 9 Propeller Fan 18 Main EEV 63

64 7. Product configuration 7-1 DVM Chiller configuration 2) Part exploded view (Hydro parts) [ AG010/015KSVA*H/AA ] 64

65 7. Product configuration 7-2 Module controller (MCM-A00N, Mandatory) 1) Function - A module controller controls DVM Chillers by each group or module. 2) Features - DVM Chiller On/Off control (Module / Group) - Operation mode, water outlet temperature setting - Optional operation setting - Module / Group setting - Weekly / Holiday operation schedule setting - Summer time (Daylight saving) support - Back light screen - User settings / Service mode support - Forced fan function (Anti snow accumulation) 65