DCLC Series 50Hz Water Cooled Centrifugal Chillers Cooling Capacity: 300 to 1500 TR (1055 to 5274 kw) R134a Products that perform...by people who care
1.0 GENERAL For most of the 20 th Century, DB has been providing innovative solutions for the heating, air conditioning and refrigeration needs of its customers. Today s global company has a proud heritage that began over a 100 years ago. In the 1960s, DB introduced a revolutionary compressor technology for air conditioning and refrigeration applications the twin helical screw compressor. Highly efficient, durable and very reliable, DB s experience of more than 50 years in the application of twin screw compressors in the HVAC industry is unrivalled. Customers demand high efficiency products with exceptional value and DB s new range of DCLC centrifugal chillers satisfy modern market requirements with outstanding energy efficiency and proven technology, designed specifically for environmentally safe refrigerants. This combination ensures the most cost-effective, reliable solution for comfort cooling and process cooling applications. DB continues to deliver performance with reliability packaged in the most energy efficient way with the introduction of the DCLC range of centrifugal water chillers. The major advantages of the DCLC: High reliability Simple operation and maintenance Low sound levels Simplified structure and compact size High efficiency at a competitive market price Designed to use environmentally friendly R134a refrigerant. The DCLC range of chillers is ideal for offices, hospitals, hotels and retail stores as well as industrial applications. The chiller offers a full range of Evaporator/Condenser/Compressor combinations, permitting precise matching of the machine capacity to system requirements. With such a wide range of available combinations, DCLC units can be configured to provide lowest first cost, lowest operating cost or choice of several criteria important for a particular application. The centrifugal chiller selection software is certified in accordance with the latest AHRI standard 550/ 590. DB Sales Engineers are available to assist in selecting the optimum machine needed to satisfy the particular project requirements. The DCLC centrifugal chiller from DB offers superior value and application flexibility, a wide range of options and accessories and the peace of mind that more than 100 years of industry experience is behind this product can be ideally configured to suit your project. TABLE OF CONTENTS 1.0 GENERAL... 2 2.0 WORKING PRINCIPLE AND STRUCTURE... 3 2.1 Refrigeration cycle... 3 2.2 Chiller selection sample... 4 2.3 DCLC Chiller Dimensions... 5 3.0 SYSTEM COMPONENTS... 6 3.1 Compressor major components... 8 3.1.1 Characteristics of the Components... 8 3.1.2 Oil lubrication System... 11 3.1.3 Motor refrigerant-cooled system... 12 3.1.4 Emergency oil supply... 13 3.1.5 How to avoid the surge... 13 3.2 Heat-exchanger major components... 13 3.2.1 Heat-exchanger structure... 14 3.3 Electrical control Equipment... 18 3.3.1 PLC Microcomputer Control software... 18 3.3.2 Control hardware... 18 4.0 APPENDIX... 24 4.1 Unit Selection sample... 24 4.2 Standard DCLC chiller supply scope... 25 4.3 Test issue... 26 4.4 Safe application... 28 4.5 DCLC mechanical specifications... 28 NOMENCLATURE DCLC 1000 B DCLC - Dunham-Bush Centrifugal Water Chiller DCLCR - Dunham-Bush Heat recovery Centrifugal Chiller DCLCV - Dunham-Bush VFD Centrifugal Chiller Design Level : B Nominal Cooling Capacity TR - 2 -
2.0 WORKING PRINCIPLE AND STRUCTURE 2.1 REFRIGERATION CYCLE The compressor on a centrifugal chiller utilizes Single-stage compression circulating diagram the Vapour Compression cycle in the much the same way as any positive displacement compressor. The Vapour compression cycle uses a medium such as refrigerant to absorb heat at one part of the cycle and reject that heat at a different part of the cycle. The centrifugal compressor is a dynamic machine which raises the pressure and temperature of the circulating refrigerant by imparting velocity or dynamic energy through an electric motor driven impeller discharging into a volute or diffuser plate to convert this velocity energy to pressure energy. As with all vapour compression systems, there are four major components: compressor, condenser, expansion device and evaporator. The evaporator absorbs heat from its surrounding and the condenser rejects the heat collected plus any system losses to its surroundings. The cycle will continue to operate all the time the compressor is operating and a system load exists. The following is the principle in details: Compressor: The refrigerant vapour enters the compressor in a low pressure, low temperature but superheated state. The compression process increases the pressure and the temperature and the now high pressure, high temperature superheated gas is discharged into a condenser, a heat exchanger where due to its high temperature the refrigerant can be condensed using cooling tower water or ambient air. Condenser: The high pressure hot vapour is condensed into a high pressure hot liquid, or saturated liquid as its pressure corresponds to its condensing temperature. This now high pressure liquid refrigerant discharges from the bottom of the condenser and is passed through an expansion valve or some other restrictive device. Expansion valve: The downstream side of this expansion device is exposed to the low pressure part of the system which causes the refrigerant to expand rapidly as it passes through the device, as it expands; adiabatic cooling of the gas/liquid mixture occurs to the point where it is then colder than the water (or other liquid to be cooled) in the evaporator. Evaporator: This is a second heat exchanger where the medium ultimately to be cooled by this process, the chilled water, is circulated on one side and the cold refrigerant mixture is circulated through the other side where it absorbs heat, thereby cooling down the chilled water. Cooling the chilled water is the fundamental purpose of the equipment. The refrigerant then continues to circulate in the system and after going through the compression process again the heat absorbed will be rejected by the condenser to the tower water or ambient air. The cooling capacity of a system is directly proportional to refrigerant gas flow through the compressor. An adjustable guide vane regulating device can be installed at the inlet of centrifugal compressors to control the suction flow of compressor, matching the system cooling capacity to that of the building cooling load in a regulated and step less manner across a defined range. Maximum outside temperature for transport and storage of the DCLC units the minimum and maximum allowable temperatures are -20 C and +50 C. Unit (Standard type) operating temp range: Evaporator Condenser Min. Max. Inlet water temp. C 8 25 Outlet water temp. C 4 15 Inlet water temp. C 15.6 34 Outlet water temp. C 22 41-3 -
2.0 WORKING PRINCIPLE AND STRUCTURE 2.2 CHILLER SELECTION SAMPLE Sample Specification(300TR-1500TR, 400V-3P-50Hz,star delta start) Chiller Chiller current Evaporator Condenser Dimension Weight Model Cooling capacity Power input COP IPLV Rated current Locked-rotor current Chilled water flow volume Chilled water pressure drop Water pipe in/outlet dia. Cooling water flow volume Cooling water pressure drop Water pipe in/outlet dia. Length Width Height Running weight Shipping weight R134a injection kw TR kw kwo/kwi kwo/kwi A A l/s kpa mm l/s kpa mm mm mm mm kg kg kg DCLC300 1055 300 179 5.91 5.76 297 691 46 72 DN200 54 58 DN200 4994 1994 2250 11375 9539 666 DCLC350 1231 350 201 6.11 6.08 334 779 53 70 DN200 63 57 DN200 4994 1994 2250 11375 9539 666 DCLC400 1406 400 222 6.34 6.78 369 861 61 68 DN200 72 73 DN200 4994 1994 2250 11068 9395 617 DCLC450 1582 450 261 6.06 6.34 434 1011 68 66 DN200 81 71 DN200 4423 1994 2250 10480 8972 521 DCLC500 1758 500 288 6.11 6.35 481 1120 76 75 DN200 89 66 DN200 4994 1994 2250 11167 9457 617 DCLC550 1934 550 318 6.08 6.55 530 1235 83 61 DN200 98 47 DN200 4994 1994 2250 10962 9331 617 DCLC600 2110 600 343 6.15 6.60 571 1330 91 79 DN250 106 71 DN200 4994 1994 2250 11068 9395 617 DCLC650 2285 650 370 6.18 6.24 615 1432 99 77 DN250 115 62 DN200 4994 1994 2250 11295 9507 648 DCLC700 2461 700 394 6.25 6.48 658 1533 106 79 DN250 124 71 DN200 4994 1994 2250 11375 9539 666 DCLC750 2637 750 427 6.18 6.35 715 1665 114 72 DN250 133 72 DN250 4959 2096 2270 12120 10154 693 DCLC800 2813 800 454 6.20 6.38 760 1771 121 81 DN250 142 73 DN250 4959 2096 2270 12321 10261 712 DCLC850 2989 850 469 6.37 6.59 786 1831 129 67 DN300 150 52 DN300 5065 2426 3010 18757 16139 907 DCLC900 3164 900 502 6.31 6.48 842 1962 136 74 DN300 159 57 DN300 5065 2426 3010 18757 16139 907 DCLC1000 3516 1000 565 6.23 6.01 949 2211 152 90 DN300 176 69 DN300 5675 2426 2903 20427 17267 1103 DCLC1100 3868 1100 613 6.31 6.17 1029 2397 167 87 DN300 194 82 DN300 5675 2426 2903 20589 17312 1157 DCLC1200 4219 1200 679 6.21 6.39 1139 2655 182 78 DN350 212 73 DN350 5675 2426 2903 20589 17312 1157 DCLC1300 4571 1300 718 6.37 6.59 1210 2818 197 102 DN350 229 95 DN350 5737 2712 2965 23214 19675 1156 DCLC1400 4922 1400 773 6.37 6.66 1300 3029 212 101 DN350 246 94 DN350 5737 2712 2965 26520 22765 1215 DCLC1500 5274 1500 825 6.40 6.61 1387 3231 227 101 DN350 264 93 DN350 5737 2712 2965 23832 19948 1270 Notes: 1. Nominal Cooling capacities are based on following conditions: Chilled water inlet/outlet temperature 12.2/6.6 C; Condenser water inlet/outlet temperature 29.4/35 C; The rated current data as listed for DCLC chiller models 300-1500 is based on 400V/3P/50Hz power supply. 60Hz performance data is available upon request. 2. For DCLC chiller models 300-1000, low-voltage 400V is standard and recommended (high voltage optional); for DCLC models 1100-1500, High Voltage 3kV/6kV/10kV is recommended (low voltage optional); 3. The design fouling factor for evaporator and condenser are 0.0176 and 0.044 m 2 /kw, respectively for alternative fouling factors please contact DB 4. The design working pressure of the water (tube) side for both evaporator and condenser is 10 bar, higher pressure designs are available upon request. 5. The Sample Specification above is for reference only. According to a variety of main parts combination, the same cooling capacity can have many different models. Contact local DB office to choose the appropriate chiller for the User s practical requirements. Due to possible product improvement, we reserve the right to make changes in design and construction at any time without notice. - 4 -
2.0 WORKING PRINCIPLE AND STRUCTURE 2.3 DCLC CHILLER DIMENSIONS Model A B C D E F G H J K Y Z DCLC300 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200 DCLC350 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200 DCLC400 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200 DCLC450 4423 1994 2250 3800 637 1067 483 853 997 489 DN200 DN200 DCLC500 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200 DCLC550 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN200 DCLC600 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN250 DCLC650 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN250 DCLC700 4994 1994 2250 4300 637 1067 483 853 997 489 DN200 DN250 DCLC750 4959 2096 2270 4300 689 1119 490 920 1048 521 DN250 DN250 DCLC800 4959 2096 2270 4300 689 1119 490 920 1048 521 DN250 DN250 DCLC850 5065 2426 3010 4300 969 1519 786 1336 1213 610 DN300 DN300 DCLC900 5065 2426 3010 4300 969 1519 786 1336 1213 610 DN300 DN300 DCLC1000 5675 2426 2903 4900 969 1519 786 1336 1213 610 DN300 DN300 DCLC1100 5675 2426 2903 4900 969 1519 786 1336 1213 610 DN300 DN300 DCLC1200 5675 2426 2903 4900 969 1519 786 1336 1213 610 DN350 DN350 DCLC1300 5737 2712 2965 4900 885 1485 695 1295 1356 678 DN350 DN350 DCLC1400 5737 2712 2965 4900 885 1485 695 1295 1356 678 DN350 DN350 DCLC1500 5737 2712 2965 4900 885 1485 695 1295 1356 678 DN350 DN350 Notes: 1. The above dimensions are based on standard water side design pressure of 10 bar, and Victaulic connections. Dimension A is for unit configurations with two pass evaporator and condenser, left hand configuration when viewed from compressor and electrical box side of unit. 2. Service access should be provided in accordance with American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) 15, latest edition, National Fire Protection Association (NFPA) 70, and local safety code. 3. Allow at least 1350mm overhead clearance for service rigging for the compressor. 4. Certified drawings available upon request. Drawings included in this section are for preliminary layout purposes only. Detailed certified drawings are available from the local DB sales office. Do not use for final construction drawings. The above dimensions are for the standard chillers, if other than standard vessel configuration is selected please consult local DB Sales office. 5. All dimensions are in mm. - 5 -
Americas United States of America 175 South Street, West Hartford, CT 06110, USA Tel: 1-860-249 8671 Fax: 1-860-953 3300 Europe United Kingdom 8 Downley Road, Havant, Hampshire, England PO9 2JD Tel : 44-23-9247 7700 Fax: 44-23-9245 0396 Africa South Africa No. 57 Sovereign Drive Route 21 Corporate Park Irene, Pretoria South Africa Tel: 27-12-345 4202 Fax: 27-12-345 4203 China No. 1 Dunham-Bush Road, Laishan District, Yantai, Shandong Province, China 264003 Tel: 86-535-658 8999 Fax: 86-535-658 1999 Asia Singapore 2, Kallang Pudding Road #07-07, Mactech Industrial Building, Singapore 349307 Tel: 65-6842 2012 Fax: 65-6842 2013 Middle East & North Africa United Arab Emirates Al Murad Tower, Office 506 Al-Barsha 1, P. O. Box # 30922, Dubai, UAE Tel: 971-4-451 9899 Fax: 971-4-451 9881 Russia & CIS Russia Lot 11, Novinskiy Boulevard, Moscow, 121099 Russian Federation Tel: 7-499-255 6953 Fax: 7-499-255 6953 Malaysia Lot 5755-6, Kidamai Industrial Park, Bukit Angkat, 43000 Kajang, Selangor Darul Ehsan, Malaysia Tel: 603-8924 9000 Fax:603-8739 5020 info@dunham-bush.com www.dunham-bush.com Products that perform...by people who care Manufacturer reserves the right to change specifications without prior notice. M-S-0489A-0112