Gas Fired Double-Effect Chiller-Heater CH-MG Series: 150 and 200 RT Capacities W E A R E F R I E N D L Y T O T H E E A R T H
Gas Fired DOUBLE-EFFECT Chiller-Heater Absorption Principle Yazaki MG-Series gas fired DOUBLE-EFFECT chiller-heaters, with cooling capacities of 150 and 200 tons of refrigeration, are designed for commercial applications where chilled water and hot water are used in a central air conditioning system. The condenser is water cooled and heat is rejected through a cooling tower. The Yazaki absorption chiller-heater uses a solution of lithium bromide and water, under a vacuum, as the working fluid. is the refrigerant and lithium bromide, a nontoxic salt, is the absorbent. The double-effect absorption cycle has two generators - one directly heated by a gas burner and the other heated by hot refrigerant vapor. Refrigerant, liberated by heat from the solution, produces a refrigerating effect in the evaporator when cooling water is circulated through the condenser and absorber. Cycle LOW TEMP GENERATOR Refrigerant Vapor CHANGEOVER VALVE (Refrigerant) SEPARATOR HIGH TEMP GENERATOR CONDENSER ORIFICE EVAPORATOR Chilled ABSORBER Dilute Solution Concentrated Solution Refrigerant Vapor Refrigerant Liquid Chilled Gas Supply BURNER HEAT EXCHANGER SOLUTION PUMP CHANGEOVER VALVE (Solution) High-Temperature Generator The gas burner heats dilute lithium bromide solution in the high-temperature generator and, as the solution boils vigorously under a vacuum, droplets of concentrated solution are carried with refrigerant vapor to the separator. After separation, hot refrigerant vapor flows to the low-temperature generator and concentrated solution is precooled in the heat exchanger before flowing to the absorber. Low-Temperature Generator Hot refrigerant vapor from the separator heats dilute lithium bromide solution in the lowtemperature generator. Refrigerant vapor, liberated from this solution, flows to the condenser while solution, which is now concentrated, is precooled in the heat exchanger before flowing to the absorber. Condenser In the condenser, refrigerant vapor is condensed on the surface of the coil and latent heat, removed by the cooling water, is rejected to a cooling tower. Refrigerant liquid accumulates in the condenser and then passes through an orifice into the evaporator. 2
Evaporator In the evaporator, refrigerant liquid is exposed to a substantially deeper vacuum than in the condenser due to the influence of the absorber. As refrigerant liquid flows over the surface of the evaporator coil it boils and removes heat, equivalent to the latent heat of the refrigerant, from the chilled water circuit. The recirculating chilled water is cooled to 44.6 F and the refrigerant vapor is attracted to the absorber. Absorber A deep vacuum in the absorber is maintained by the affinity of the concentrated solution from the generator with the refrigerant vapor formed in the evaporator. Refrigerant vapor is absorbed by concentrated lithium bromide solution flowing across the surface of the absorber coil. Heat of condensation and dilution are removed by the cooling water and rejected to a cooling tower. The resulting dilute solution is preheated in the heat exchanger before returning to the generator where the cycle is repeated. Heating Cycle LOW TEMP GENERATOR CHANGEOVER VALVE (Refrigerant) SEPARATOR HIGH TEMP GENERATOR CONDENSER ORIFICE EVAPORATOR Hot ABSORBER Dilute Solution Concentrated Solution Refrigerant Vapor Refrigerant Liquid Hot Gas Supply BURNER HEAT EXCHANGER SOLUTION PUMP CHANGEOVER VALVE (Solution) High-Temperature Generator Dilute lithium bromide solution is heated in the high-temperature generator by the gas burner in the same manner as the cooling cycle. The solution boils vigorously and droplets of concentrated solution are carried with refrigerant vapor to the separator. Hot refrigerant vapor flows through the refrigerant changeover valve into the evaporator and concentrated solution flows through the solution changeover valve into the absorber sump. Evaporator Hot refrigerant vapor condenses on the surface of the evaporator coil and heat, equivalent to the latent heat of the refrigerant, is transferred to the hot water circuit. The recirculating water is heated to 140 F. Absorber Refrigerant liquid mixes with concentrated lithium bromide solution and the resulting dilute solution returns to the generator where the cycle is repeated. 3
Features & Benefits n Each Chiller-Heater Serves a Dual Purpose: and Heating This compact chiller-heater reduces floor space and installation costs because it replaces the traditional chiller-boiler combination and simplifies piping, pumps, valves and controls. n High COP of 1.2 Reduces fuel consumption and operating costs by up to 17% compared with other double-effect absorption units. n Part Load IPLV Rating >1.3 Reduces seasonal fuel consumption because the chiller operates more efficiently at part load for most of the time. n Low NOx Gas Burner <30 ppm Advanced Riello low NOx gas burners are used to meet the strict air quality requirements of California and other states. n Hermetic Integrity Strict quality control and testing with a mass spectrometer ensures the vacuum section is airtight and eliminates the need for an onboard mechanical purge pump. Hydrogen, a by-product of the absorption cycle, is continuously removed through a palladium cell or stored with other noncondensible gases in an external purge tank n PID Microprocessor PID (proportional, integral and differential) controls are utilized to optimize the absorption cycle performance and provide stable chilled water and hot water outlet temperatures under all load conditions. n Burner Firing is Modulated 30% to 100% The burner is proportionally controlled to match the output capacity of the chillerheater and reduce operating costs. n Safe, Odorless, Non-toxic Working Fluids Ozone safe and CFC free. Working fluids of non-toxic lithium bromide and water operate safely under a vacuum at all times. n A Single VFD Hermetic Solution Pump One variable speed pump circulates solution and reduces electrical consumption at part load. Additional pumps are not required because gravity feed drippers are used to distribute refrigerant and solution instead of spray nozzles. This eliminates the need for periodic nozzle maintenance. n Low Temperature operation allowed down to 65 F inlet cooling water without the need for cooling tower bypass control. n Weatherproof Cabinet Equipment room is not required because the chiller-heater is enclosed in a weatherproof cabinet suitable for indoor or outdoor installation. n Low Electrical Consumption Since less than 19.3 VA/RT is required to operate the chiller-heater, it is not neccessary to upgrade the existing electrical service. 4
Features & Benefits (Continued) n Built-In Shutdown Controls Safely shuts down the chiller-heater under abnormal operating conditions. n Ideal for a Two Pipe Hydronic System Installation costs reduced because only two pipes are required to transport chilled or hot water to a central air handling unit or multiple fan-coil units. n 30 Minute Changeover /heating changeover only requires a 30 minute delay. n Simple Mode Selection or heating operation can be selected at the chiller-heater or remotely from the building management system. n Built-In Digital Display Panel Used for mode selection, operating status and troubleshooting. n Remote Chilled and Hot Reset Raise chilled water setpoint or lower hot water setpoint to reduce operating costs during unoccupied hours. n Hinged Marine Boxes Allow easy access to the condenser and absorber for tube cleaning and maintenance without disconnecting piping. n Factory Installed Crossover Pipe and Insulation Eliminates site fabrication and installation of crossover pipe between the absorber and condenser and site insulation of cold and hot surfaces. n Simplified Transportation and Lifting Each modular chiller-heater is mounted on a steel frame and anchor points are provided for lifting. n Quiet Operation Since the chiller-heater has relatively few moving parts, the noise level is typically less than 74idB(A) and there is no vibration. The chiller-heater is ideal for installation adjacent to occupied spaces because it does not compromise occupant comfort. n Simple Maintenance Only two routine service calls are required per year to evacuate noncondensible gases and check other operating conditions. Start-up, routine maintenance and troubleshooting are provided by a network of independent Yazaki authorized service providers with backup from the factory. n Factory Charged and Performance Tested Since each chiller-heater is shipped completely assembled and tested, installation and start-up are simplified. n ISO9001 and ISO14001 Factory Certification Quality control is assured by compliance with strict manufacturing and industry standards. n UL Listed for USA and Canada 5
Control Characteristics 57.2 PID COOLING CONTROL Chilled Temp. ( F) 53.6 50.0 46.4 42.8 39.2 35.6 0 80% Load 10 20 50% Load 30 40 50 60 Time (min) 80% Load 70 80 Chilled Inlet Temp. Chilled Outlet Temp. Proportional Control Digital PID Control 143.6 PID HEATING CONTROL Hot Temp. ( F) 141.8 138.2 134.6 131.0 80% 127.4 50% Load Load 123.8 0 10 20 30 40 50 60 Time (min) 80% Load 70 80 Hot Outlet Temp. Hot Inlet Temp. Proportional Control Digital PID Control 55.4 53.6 COOLING SETPOINT Maximum Setpoint 147.5 145.4 HEATING SETPOINT Maximum Setpoint Chilled Outlet Temp. ( F) 51.8 50.0 48.2 46.4 44.6 42.8 41.0 Minimum Setpoint Hot Outlet Temp. ( F) 143.6 141.8 140.0 138.2 136.4 134.6 132.8 39.2 0 5 10 Time (min) 15 20 25 Standard Rating Point Digital PID Control 131.0 105.8 104.0 102.2 0 Minimum Setpoint 5 10 15 20 25 Time (min) 6
Application (Gas Fired & Heating System Operation) FAN COIL UNIT COOL AIR Gas Supply GAS FIRED DOUBLE-EFFECT CHILLER-HEATER COOLING TOWER Dilute Solution Concentrated Solution Refrigerant Vapor Refrigerant Liquid Chilled Standard Specification NOTES: 1. Fuel input is based on HIGHER HEATING VALUE of gas. 2. Specifications are based on water in all circuits and fouling factor of 0.0005 ft 2 hr. F/Btu. 3. Do not exceed 114 psi operating pressure in any water circuit. 4. Chilled/hot water flow limits are 80~120% of standard rating. 5. water flow limits are 100~120% of standard rating. 6. Two or more modules may be installed in parallel for larger capacities. 7. Standard natural gas supply pressure is 7.0 in. wc. 8. Sound pressure noise level measured in a free field at a point 39 in. in front of the chiller-heater and 59 in. above the ground. MODEL CH-MG150 CH-MG200 Capacity (Btu/hr x 1000) 1,800 2,400 Chilled Temp. ( F) 44.6 Outlet, 53.6 Inlet Heating Capacity (Btu/hr x 1000) 1,245 1,660 Hot Temp. ( F) 140.0 Outlet, 132.8 Inlet Chilled/Hot Rated Flow (gpm) 399.4 532.6 Evap. Press. Loss (psi) 10.5 9.2 Retention Volume (gal) 48 69 Heat Rejection (Btu/hr x 1000) 3,045 4,060 Temp. ( F) 85.1 Inlet, 94.3 Outlet *Rated Flow (gpm) 658.6 878.1 Cond./Abs. Press. Loss (psi) 7.5 7.2 Retention Volume (gal) 114 153 Type Natural Gas Fuel Input (Btu/hr 1,500 2,000 x 1000) Heating 1,500 2,000 Power Supply 208V or 230V, 60Hz, 3ph Electrical Consumption 2.9 3.3 (kva) Heating 2.9 3.3 Control and Heating 30% - 100% PID Control Type Low NOx Forced Draft Burner Combustion Flame Detection UV Scanner Ignition Intermittent Spark Noise Level Sound Pressure db(a) 74 74 Chilled/Hot (in) 4 Flange 5 Flange Piping (in) 5 Flange 6 Flange Gas Supply (in) 2 NPT 2 NPT Exhaust Vent (in) 13.8 x 9.8 (inside) Weight Dry (lb) 12,346 14,330 Operating (lb) 13,698 16,183 Type Weatherproof Cabinet Material Pre-painted hot dipped galvanized steel Finish Silver metallic * Minimum cooling water flow 7
Expanded Performance NOTES: 1. Capacities are based on standard gas input ratings. 2. Standard water flow rates used in all circuits. 3. Fouling factor of 0.0005 ft 2 hr. F/Btu in the condenser/absorber and evaporator. 4. Performance data may be interpolated but must not be extrapolated. 5. Expanded performance data is provided for reference only. Contact Yazaki Energy Systems, Inc. for certified data or performance at other conditions. TEMPERATURE ( F) COOLING CAPACITY & HEAT REJECTION (Btu/hr x 1000) Inlet 80 85.1 90 Chilled Outlet 41.0 42.8 44.6 46.4 48.2 41.0 42.8 44.6 46.4 48.2 41.0 42.8 44.6 46.4 48.2 Capacity 1,582 1,743 1,831 1,862 1,877 1,477 1,679 1,800 1,830 1,853 1,305 1,584 1,750 1,796 1,836 CH-MG150 Heat Rejection 2,827 2,988 3,076 3,107 3,122 2,722 2,924 3,045 3,075 3,098 2,550 2,829 2,995 3,041 3,081 NOTE: Data highlighted is based on standard rated conditions. Capacity 2,110 2.324 2,442 2,483 2,503 1,969 2,238 2,400 2,440 2,470 1,740 2,112 2,334 2,395 2,448 CH-MG200 Heat Rejection 3,770 3,984 4,102 4,143 4,163 3,629 3,898 4,060 4,100 4,130 3,400 3,772 3,994 4,055 4,108 Part Load Performance Normally, for comfort cooling applications the chiller-heater will operate at part load cooling for most of the time. Since less heat is rejected through the cooling tower during part load cooling operation, the lower cooling water temperature improves the cooling performance by increasing the Coefficient of Performance (COP) and reducing the gas input. The chiller-heater can operate with 65 F minimum cooling water inlet temperature without the need for cooling tower bypass control. NOTES: 1. Fuel Input (%) is gas consumption as percentage of full load rated fuel input. 2. Capacity (%) is percentage of full load rated cooling capacity. 3. Broken line indicates part load characteristics at full load rated COP. Fuel Input (%) 100 90 80 70 60 50 40 30 20 20 44.6 F Chilled Outlet ARI 560-2000 Part Load Inlet Temperatures A (85.0 F), B (77.5 F), C (70.0 F) C 30 40 50 60 8 Capacity (%) B A 70 80 90 100
Part Load IPLV Rating ARI 560-2000 Integrated Part Load Value (IPLV) is a single number measure of part load cooling performance based on a w e i g h t e d a v e r a g e o f c o m m o n b u i l d i n g t y p e s, operating hours and average U.S.A. weather data. Part load performance is often expressed as Coefficient of Performance (COP): COP = Net Output Net Input IPLV = 0.01A+0.42B+0.45C+0.12D COP 1.34 1.32 1.30 1.28 1.26 1.24 C 70.0 F Inlet 77.5 F Inlet 85.0 F Inlet B Where A, B, C and D are part load COP s at the following conditions: POINT COOLING COOLING CAPACITY (%) WATER TEMP ( F) A B C D 100 75 50 25 85.0 77.5 70.0 70.0 Since the minimum gas input to the chiller-heater is 30%, the corresponding cooling capacity at 70.0 F cooling water inlet is 33.6%. The equivalent COP at 25% cooling capacity (Point D) is calculated from this condition to account for cycling. Part Load Heating Performance During part load operation, the heating efficiency of the chiller-heater increases. As the firing rate is reduced, the burner modulates both fuel and air; and the ratio of heat exchanger surface area to fuel input increases. NOTE: Fuel Input (%) is gas consumption as percentage of full load rated fuel input. POINT Thermal Efficiency (%) A B C D 1.22 1.20 86.0 85.0 84.0 20 COOLING CAPACITY (%) 100 75 50 25 83.0 20 30 40 50 60 COOLING WATER TEMP ( F) 85.0 77.5 70.0 70.0 * Calculated as per ARI 560-2000 Capacity (%) COP 1.200 1.283 1.346 *1.300 30 40 50 60 9 Fuel Input (%) A 70 80 90 100 ARI WEIGHTED FACTOR 0.01 0.42 0.45 0.12 IPLV WEIGHTED AVERAGE COP 0.012 0.539 0.606 0.156 1.313 70 80 90 100
Typical Piping SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION SYMBOL DESCRIPTION T Temp. gauge P Pressure gauge F Gas meter Reducing valve Check valve Expansion joint COOLING TOWER LS (Optional) CTS CWV M Strainer Flush Valve Inlet IF2 (Optional) CWTS P P T Relief valve Outlet T CHILLER-HEATER Expansion tank T T Manual valve Chilled/Hot Outlet Chilled/Hot Intlet Air Vent P P T P T P Supply AIR HANDLING UNIT FAN COIL UNIT FAN COIL UNIT Return Drain COOLING WATER PUMP Supply Flush Valve Drain F Gas Inlet IF1 (Optional) Drain Drain CHILLED/HOT WATER PUMP Supply Drain Typical Field Wiring COOLING TOWER CWV M LS (Optional) CTS COOLING WATER PUMP CHILLED/HOT WATER PUMP CWTS POWER BOX (Supplied by Others) OPTIONAL CONTROL BOX CONNECTIONS OPTIONAL JUNCTION BOX CONNECTIONS JB CHILLER- HEATER CB WIRING (Number of Conductors) FUSED DISCONNECTS SYMBOL DESCRIPTION SYMBOL DESCRIPTION IF1 Chilled/hot water freeze switch CTS tower switch IF2 water freeze switch LS Level switch CWTS water temperature switch CWV water control valve Power Supply (208V or 230V, 60Hz, 3ph) IF1 (Optional) IF2 (Optional) STANDARD JUNCTION BOX (JB) CONNECTIONS Power supply. Chilled/hot water and cooling water pump control. Thermal overload interlocks from chilled/hot water pump, cooling water pump and cooling tower fan. OPTIONAL JUNCTION BOX (JB) CONNECTIONS Remote cooling/heating mode selection. Remote start/stop selection. tower fan control output (Alternative to CTS). OPTIONAL CONTROL BOX (CB) CONNECTIONS /heating mode status. Chiller-heater operating status. Chiller-heater standby status. Dilution cycle status. Burner operating status. General shutdown alarm output. External fault alarm output. Main fault alarm output. Burner flame failure alarm. External fault interlock (Additional control supplied by others). Earthquake switch shutdown. Remote temperature control 4.5 F setup/setback. 10 water flow switch (FS2) input (Flow switch supplied by others). Freeze protection switch (IF1) input for chilled/hot water (Temp. switch supplied by others). Freeze protection switch (IF2) input for cooling water (Temp. switch supplied by others). Exhaust fan control output. Exhaust fan interlock. tower sump level switch (LS).
Dimensions (CH-MG Series) SIDE Front Rear Left Right 2.0 CLEARANCE (IN) 115 (Note 4) 40 28 28 NOTES: 1. All pipe connections are ANSI Class 150 flanges. 2. indicates anchor bolt location. 3. Ensure that minimum clearance space is provided for chiller-heater maintenance (length 40 in., above 40 in. and sides 28 in.). 4. Provide maintence clearance for tube removal in front (preferred) or rear of chiller-heater. 2.0 8.3 8.7 88.2 (H) 20.6 73.3 (W) 56.0 76.8 8.7 FRONT VIEW Vent Cap 45.4 16.3 62.2 CH-MG150 87.6 144.2 (L) 2.3 TOP VIEW Exhaust vent flange 62.2 RIGHT SIDE VIEW 3.5 Field wiring junction box water inlet 5 flange Gas inlet 2 flange 75.6 34.7 13.0 13.8 7.7 13.8 Condensate drain 1/2 tube 17.7 17.4 REAR VIEW 11.8 15.7 10 holes 10 mm dia. EXHAUST VENT FLANGE DETAILS Connect Class B venting system to exhaust vent flange for indoor installations water outlet 5 flange 14.3 37.7 Chilled/hot water outlet 4 flange Chilled/hot water inlet 4 flange 50.6 12.9 SIDE Front Rear Left Right 2.0 CLEARANCE (IN) 115 (Note 4) 40 28 28 NOTES: 1. All pipe connections are ANSI Class 150 flanges. 2. indicates anchor bolt location. 3. Ensure that minimum clearance space is provided for chiller-heater maintenance (length 40 in., above 40 in. and sides 28 in.). 4. Provide maintence clearance for tube removal in front (preferred) or rear of chiller-heater. 2.0 8.3 8.7 97.6 (H) 20.5 80.7 8.7 FRONT VIEW 77.2 (W) 58.5 Vent Cap 39.1 16.3 62.2 CH-MG200 89.6 147.0 (L) 2.3 TOP VIEW Exhaust vent flange 62.2 RIGHT SIDE VIEW 11 3.5 Field wiring junction box water inlet 6 flange Gas inlet 2 flange 85.3 25.6 13.0 13.8 7.7 28.1 3.3 17.7 15.7 18.0 11.8 EXHAST VENT FLANGE DETAILS Connect Class B venting system to exhaust vent flange for indoor installations Condensate drain 1/2 tube 10 holes 10 mm dia. water outlet 6 flange Chilled/hot water outlet 5 flange 37.8 55.9 13.0 Chilled/hot water inlet 5 flange REAR VIEW All dimensions in inches
YAZAKI SALES REPRESENTATIVE/DISTRIBUTOR For information concerning sales, operation, application or technical assistance, please contact your Yazaki Sales Representative/Distributor or the following: YAZAKI ENERGY SYSTEMS, INC. 701 E. PLANO PARKWAY, SUITE 305, PLANO, TEXAS 75074 Phone: 469-229-5443 Fax: 469-229-5448 Email: yazaki@yazakienergy.com Web: www.yazakienergy.com Yazaki reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. SB-MGUL-1107