PACKAGED AIR COOLED FREE COOLING CHILLER
New
YSFC
200 - 1700 kW
14 Models
York Screw Free Cooling
APPLIED CHILLER PRODUCTS
Packaged
Air Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
Market
Introduction
What is a Free Cooling?
Free Cooling has become an established technology recognised throughout Eastern
and Northern Europe by End Users, Architects & Building Services Engineers.
Reducing Global Energy Consumption and CO2 emissions is a Clients key driver for his
Buildings & Cooling Processes, reducing operating costs and environmental impact.
Free Cooling Chiller offers a sustainable alternative, to reduce electrical energy
consumption during “winter” ambient periods.
The Free Cooling concept switches off compressors when operating conditions allow,
to utilise Natural Cooling provided from Low Ambient Air passing across a finned coil
containing the process liquid. Client’s consider this as an attractive solution.
Ideal applications benefit from having a high 24/7 base load and operate with
elevated system return liquid temperatures typically above 15ºC and where the
ambient is predicted to be below 5ºC many operating hours each year.
APPLIED CHILLER PRODUCTS
Market Requirements For Free Cooling Chiller’s.
Our survey revealed this technology is increasing in demand by many users.
Although a niche Air Cooled Chiller variant, specifications for such products in most
European regions is rapidly increasing and the JCI Sales Teams request the ability
to support this technology alternative with their Clients.
There are a number of various applications
in which our traditional Clients are currently
specifying and Installing such products:-
Locations, Long Cold Winters, Northern
Latitudes or Eastern Europe, High Altitude.
24/7 Chiller Operating Applications
Data Centres, Switch Rooms and Industrial Processes.
Chilled Beam and Medium Temperature Air Conditioning.
Theatres, Cinemas and Night-Clubs.
Hospital Operating Theatres.
As Free Cooling is seen as a progressive “Green” product solution.
APPLIED CHILLER PRODUCTS
Sales Forecasts & Market Assessment
•
The Free Cooling project investigated the potential for JCI Systems to offer
Packaged Air Cooled Free Cooling Chillers, following requests originating
mainly from Central and Eastern Europe.
•
Initial forecast reviews for 2008 indicated a likely requirement for 40 units.
•
2010 Product AOP review (April 09) revised this forecast downward to 26 units
•
Following PS&S review of the European market indicates there is a wide
range of clients applying the principals of Free Cooling to their processes.
We have concluded that there is a legitimate market for this product
variation as the vast majority of Chiller manufactures offer such products.
Unfortunately there are no official statistics to support sales volumes to this
market. However have seen many enquires for multiple units.
(One project for 18 x 750 kw units which we are specified.)
•
It is Product Managements assessment that this market has the ability (in
normal market conditions) to generate higher volumes than indicated and
we believe we have identified a product to meet this demand.
APPLIED CHILLER PRODUCTS
Alternative Approaches To Free Cooling Chillers?
There are 4 design variations for Free Cooling Systems applied
to packaged Air Cooled Chillers available in Europe’s market.
1) Stand Alone Dry Air Cooler.
Technically the best solution.
Most efficient and flexible option, high installation costs.
JCI current solution.
2) Built-in separate Dry Air Cooler.
Exclusive applications.
Good efficiency levels and often with very high levels of specification,
but greater foot print and high cost.
3) Thermosyphen system.
Carrier’s Approach.
Utilises refrigerant circuitry, has low capital cost and low efficiency.
Only two modes of operation restricting mid season application.
4) Dual Function - Free Cooling and Condenser Coil.
Commercial.
Compact \ Price competitive solution preferred by European MAC team as a
product gap filler.
JCI new YSFC solution.
APPLIED CHILLER PRODUCTS
Why JCI chose to use an OEM Supplier?
Review of the alternative design concepts
determined this technology could not be
simply applied to our current Product range.
The stand alone dry air cooler is the most obvious
Energy efficient solution. JCI has been successful in
winning such projects. Many Clients now requesting
packaged units to reduce installation costs and space.
The built-in Dry Air Cooler & Thermosyphen
systems both require major equipment redesign.
The Dual Function coil block requires
less modification to the existing product’s.
Adding the additional coils into the current
condenser design the unit’s width would
Increase, prohibiting JCI from loading units
into containers for Global shipment’s.
APPLIED CHILLER PRODUCTS
JCI Selected OEM Supplier
Following an extensive Market Review we identify the alternative
market suppliers and product solutions. We finalised an OEM agreement
with an Italian producer specialising in the process cooling market for a
Unique Branded JCI Design Dual Function - Free Cooling / Condenser Coil
A reciprocal agreement exists that if either JCI or Hitema’s existing distributors
has a product specified the other party should not chase down the order.
No other Hitema product may be ordered from them without Product Management Authorisation
APPLIED CHILLER PRODUCTS
Packaged
Air Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
Application
Product Selection and Application
The YSFC is not seen as a replacement for the YCIV.
Both models have their unique benefits for the client.
You select which one is best.
YCIV
• High Summer efficiency 3.2 EER.
• High 4 ESEER mid season
performance.
• Continuous VSD Cooling for
extended low ambient efficiencies
throughout the year.
APPLIED CHILLER PRODUCTS
YSFC
• Lower Summer efficiency EER 2.6
• 3.7 ESEER performance
• 100% Free Cooling EER 26
At an ambient approximately 16C below
the return chilled liquid temperature there
is no Mechanical Cooling required.
Free Cooling Chiller Operating Modes
Free Cooling units operate in 3 modes.
• Mechanical Cooling
Chiller operates in refrigerating mode
in summer ambient conditions.
•
Partial Free & Mechanical Cooling
(excluding Thermosyphen system)
Where Free Cooling works in series
(up-stream) of Mechanical Cooling to
reduce compressor load when lower
ambient temperatures allow.
•
Total Free Cooling (Condenser fans running)
When the ambient air is cool enough to reject the full heat load from the system.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Operation
During Summer Ambients the unit operates as a typical chiller,
albeit at a reduced efficiency level. This is due to the additional coil rows
required for the Free Cooling circuit placed in front of the condenser.
As the ambient falls 6°C below the return system liquid temperature.
• The 3-way valve redirects the flow through to the Free Cooling Coil
in series with the evaporator enabling the partial Free Cooling /
Mechanical Refrigeration mode.
• To maximise unit efficiency each circuit is unloaded and disabled
in sequence as the ambient falls.
• Whilst a refrigerant circuit is operating the fans continue to maintain
the minimum condensing pressure.
• As each refrigerant circuit stops, fan control changes to maintain
leaving liquid temperature.
Winter Ambients, where full free cooling is achieved (without mechanical
cooling) the leaving chilled liquid temperature is maintained at the desired
temperature by fan control.
APPLIED CHILLER PRODUCTS
YSFC Product Schematic
Standard Mechanical Chiller
Compressor
Flow
Temp
Stat
Evaporator
EEV
Controller
Ambient
Stat
APPLIED CHILLER PRODUCTS
Fans
Fans
Condenser
Condenser
YSFC Product Schematic
Free Cooling Chiller in Mechanical Cooling Mode
Compressor
Flow
Temp
Stat
Evaporator
Free Cooling Valve
Inlet Temp Stat
EEV
pC03
Controller
Ambient
Stat
Fans
Fans
Condenser
Condenser
Free Cooling
Free Cooling
APPLIED CHILLER PRODUCTS
When Ambient is Grater than 6°C below the Return Liquid Temperature
YSFC Product Schematic
Partial Free & Mechanical Cooling
Compressor
Flow
Temp
Stat
Evaporator
Free Cooling Valve
Inlet Temp Stat
EEV
pC03
Controller
Ambient
Stat
APPLIED CHILLER PRODUCTS
Fans
Fans
Condenser
Condenser
Free Cooling
Free Cooling
When Ambient is 6°C below the Return Liquid Temperature
YSFC Product Schematic
Partial Free & Mechanical Cooling
Compressor
Flow
Temp
Stat
Evaporator
Free Cooling Valve
Inlet Temp Stat
pC03
Controller
Ambient
Stat
Free
Cooling
Fans
Fans
Condenser
Condenser
Free Cooling
Free Cooling
Condenser
APPLIED CHILLER PRODUCTS
Condenser Coil Block Profile
EEV
YSFC Product Schematic
Free Cooling Mode
Compressor
Flow
Temp
Stat
Evaporator
Free Cooling Valve
Inlet Temp Stat
EEV
pC03
Controller
Ambient
Stat
Free
Cooling
Fans
Fans
Condenser
Condenser
Free Cooling
Free Cooling
Condenser
APPLIED CHILLER PRODUCTS
When Ambient is low enough to satisfy system cooling demand
YSFC Free Cooling mW Hours operation
Calculated Percentage Energy Saving per Month
100%
Data based on
YSFC 850SB 860 kW.
Constant load 365 Day 24/7.
24hr Average Daily Temperature.
15 – 7 Chilled Glycol split.
Partial Free Cooling enabled @
9°C Ambient (6°C below EWT.).
Full Free Cooling -2°C Ambient.
90%
Moscow
Stockholm
80%
Warsaw
Berlin
70%
Paris
Madrid
60%
50%
40%
30%
20%
10%
0%
December
November
October
September
August
July
June
May
April
March
February
January
This graph shows the potential to save energy as a % comparing the YFSC modes
either operating thought the year in Mechanical Cooling or Partial / Total Free Cooling.
APPLIED CHILLER PRODUCTS
EER Comparison JCI Chillers
100% Load
365 Day
EER
850kW
Based upon 100% Cooling
load
(850
kW)
and 5°C ambient steps
30
YSFC 850
25
YCIV 930 HE Opt
20
EER 15
10
5
Ambient / Leaving Liquid
APPLIED CHILLER PRODUCTS
Av
er
ag
e
-5
/7
0/
7
5/
7
10
/7
15
/7
20
/7
25
/7
30
/7
0
Packaged
YSFC
Air Cooled
The
Product
Free Cooling
APPLIED CHILLER PRODUCTS
Introducing the new YSFC Range Two circuit models
APPLIED CHILLER PRODUCTS
Introducing the new YSFC Range 2 & 4 circuit models
APPLIED CHILLER PRODUCTS
YSFC Standard Features
•
•
•
•
R407c standard options exist via SQ for R134a.
Light grey RAL 7035 polyester epoxy powder paint.
Two or four fixed speed step control part wind Hermitic Screw Compressor(s)
optional Open or Closed transition Star Delta Starters.
Carel microprocessor controller including specific Free Cooling software.
Electronic Expansion Valves (increased performance in partial mechanical /
free cooling mode).
Axial speed controlled condenser fans various options for differing control and
drive(s).
Aluminium Fin & Copper Tube Condenser / Free Cooling Ambient Coil’s
options for alternative materials / coatings.
Shell & Tube Direct Expansion Evaporator 19mm closed cell insulation.
•
•
•
PN16 inlet manifold and outlet evap. stub for Chilled Liquid flange connections.
6 Bar Three Way Free Cooling Mixing Valve, Heater and Auto Daily Rotation.
EPDM Flexible reinforced helix wire compound rubber Hydraulic Tubes.
•
•
•
•
APPLIED CHILLER PRODUCTS
YSFC Component Selection
When the Clients design
characteristics are finalised
component selection is then
Optimised for the specific
project design.
Design Cooling Capacity
Condensing Requirement
& Free Cooling load
Condensing duty
& Sound performance
APPLIED CHILLER PRODUCTS
We use simulator software,
to confirm the dimensions
compressor’s of evaporator
condenser coil and fans
YSFC Unit Construction - Mount Components
After selecting the components a study
final of the optimum layout for the base.
3 WAY
VALVE
TANK
(Option)
EVAPORATOR
COMPRESSORS
SUPPLEMENTARY
PANEL (Option)
APPLIED CHILLER PRODUCTS
HYDRAULIC PIPING
(Manifold)
Inlet
Outlet
PUMP
(Option)
YSFC Unit Construction - The Condenser Module
Coils and Fans are selected initially from the standard unit design
configuration. Cost Performance and Sound Optimisation.
JCI Offer Special Quotation variations on Coil lengths, Coil Rows,
Fin Pitch, and Fan Performance to meet Project requirements.
APPLIED CHILLER PRODUCTS
YSFC Unit Construction - Final Assembly
Condenser module
With the mechanical
component location
finalised, the Control
panel is positioned
Control Panel
The 3D module is complete and the 2D drawings
are produced automatically for production.
APPLIED CHILLER PRODUCTS
Base
YSFC Product, Wiring,
Pressure / Instrument
Drawings are issued for
Client Approval before
production release and
lead time conformation.
APPLIED CHILLER PRODUCTS
Components Around the YSFC
Optional
Pump’s
and
Acoustic
Compressor
Enclosure
Dual relief (option)
APPLIED CHILLER PRODUCTS
3 Way Valve and Hydraulic
pipe connections from manifold
to Free Cooling Coils
Components Around the YSFC
APPLIED CHILLER PRODUCTS
YSFC Product Options and Accessories.
Enhanced Free Cooling Performance.
The Base unit configuration of unit size and performance
has been selected to offer a competitive all round package.
For specific applications where the Designer’s requirement is to
increase the potential Free Cooling Performance, the factory can
offer alternatives through the Special Quotation procedure.
Potential variations include:• Reduced Fin Pitch (additional Fins to the Coils).
• Increased Air Flow Fans.
• Extended Coil length with additional Fans.
Building Chilled Liquid Glycol Free option available as SQ Option (Limiting the
Glycol circulation loop within the unit). Ideal for use in moderate climates
where the ambient falls below zero for only a small number of hours a year.
APPLIED CHILLER PRODUCTS
YSFC Product Options and Accessories.
1.01
Low Noise (Compressor Enclosure).
1.02
Super Low Noise (Compressor boxes and reduced sound fans).
SQ
Extend coils + extra modifications to achieve minimal possible sound.
1.03
Unit Wire Enclosure (Lower Section).
1.04
Epoxy Coated Ambient Coil.
1.05
Rubber type anti-vibration mounts.
1.06
Spring Anti-vibration mounts.
2.- Hydronic pump options (see next slides)
2.06
Pressure Regulation Valve (between 3-way-valve and Evaporator).
2.14-15 Double evaporator insulation 38mm – Evaporator heater mat.
2.16
Y mechanical water filter (supplied lose)
3.01
Compressor Suction Valves.
3.02
Dual relief change over valves.
4.01-4.09 Star Delta compressor motor starters (Open & Closed Transition)
4.02
Compressor remote run monitoring contactors
4.03
Compressor rephasing
4.04
Main – Auxiliary Panel Heaters for ≤-10°C ambient.
4.05
Individual fan fuses.
4.06-7-8 Serial card BACNET MODBUS (RS485) or Echelon.
Std
Carrel controller languages, English, French, German, Italian, Spanish.
SQ
Glycol Free Process System.
APPLIED CHILLER PRODUCTS
YSFC Product Hydraulic Pump Options.
Single pump 2.5 bar head option
with internal wiring to
panel mounted contactors
Optional Acoustic boxes for
Either Compressors and or
Pumps for Low noise versions.
Dual pump 2.5 bar head option
with internal wiring to
panel mounted contactors
Additional Dual Pump
Electronic Management Controls.
APPLIED CHILLER PRODUCTS
YSFC Product Hydraulic Pump Options.
Dual VSD pump option with internal wiring to a panel mounted Single Inverter.
With electronic pump Management Controls.
Storage Weir Tank.
Various additional options
Dependant on requirement.
Internal constant speed circulation Pump.
Optional Acoustic boxes available for Compressor’s and or Pumps,
Low noise version.
APPLIED CHILLER PRODUCTS
YSFC End-of-line functional run test
After assembly the chiller is run tested at prevailing ambient
conditions to verify the Mechanical cooling operation and Safety
sequences. (Larger capacity units tests are performed separately
on individual circuits.)
Controlled ambient testing is not available at the Factory.
APPLIED CHILLER PRODUCTS
YSFC Recorded Test Data
AIR FLOW
Tair
AIR FLOW
WATER
FLOW
 water
m
Tair
Tair
AIR FLOW
To
ELECTRICAL
POWER
Ti
APPLIED CHILLER PRODUCTS
I abs ,V , f
YSFC System Hydraulic Calculations
Caution when calculating the chilled liquid pressure drop.
In mechanical cooling mode the total pressure drop calculation is
the 3 way valve and interconnecting Hydraulic pipes + Evaporator.
In partial or total Free Cooling modes the pressure drop calculation is
the 3 way valve, distribution header, interconnecting hydraulic pipes
+ Free Cooling Coil + Evaporator.
There is obviously a difference in system resistance between the two modes.
Discuss this with the client and introduce the option of a pressure regulating
valve to equalise the system pressure drop for each mode.
This is installed in the Hydraulic pipe between the 3-way-valve and Evaporator.
System Working Pressure.
Due to the limitation of the three way valve and Hydraulic pipes
the chilled liquid static system pressure is limited to 6 Bar.
APPLIED CHILLER PRODUCTS
YSFC Documentation and selection process.
The engineering guide allows for manual selection for both the
Mechanical and Free Cooling Modes. As the free cooling chiller
application is more suited to specific regions we plan not translate
Documents unit specific requests are received.
A selection program is in development and will be distributed Q4
2009. In the interim period please submit SQ for electronic
selections. We will have to pay the software house an operator
licence of €80 for each user. Please email R Smeed to confirm
your licence requirement.
Pricing is a manual operation using the Master List Price,
That will be included in the intranet price pages, with the Multiplier
distributed to the Sales Managers as usual.
The OEM supplier is happy to work on special applications and
options. Please submit a detailed SQ request for review & potential
quote.
APPLIED CHILLER PRODUCTS
YSFC
Intranet
information
APPLIED CHILLER PRODUCTS
1. Single Page Product Information
Sheet.
2. Engineering Guide.
3. Installation Commissioning
Operation and Maintenance
Manuel.
4. PCO3 Controller Operators
Manuel.
5. MLP Price Pages and Words.
6. SQ Process flow.
7. Order Process flow
8. Factory Order Form
9. Factory Collections Form
10. Warranty Process flow
11. Warranty Standard Hours List.
12. Typical Wiring Diagrams
Standard unit with available
options (pdf).
13. Typical Product Drawings (pdf)
14. Launch Presentation (ppt)
Packaged
Air Cooled
Free Cooling
APPLIED CHILLER PRODUCTS
Competition
YSFC Free Cooling Chiller Competition
Stand Alone Dry Air Cooler.
With thought all Packaged Air Cooled Chillers and Dry Air Cooler
manufactures can provide the solution.
Thermosyphen system.
Carrier.
Built-in separate Dry Air Cooler.
Cosfi, Liebert Hiross, MTA, Uniflar.
Dual Function - Free Cooling and Condenser Coil.
ACM, Aermec, Airwell, Blue Box, Ciat, Clivet, Climaveneta,
Emicom, Euroklimat, Daikin-McQuay, Geoclima, Galletti,
Lennox, Matri Clima, Rhoss, RC, Trane, Venco.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
Free Cooling Std units Mechanical Cooling vs
Power input
Free Cooling Std units FC mode vs
Power input
550
60
50
450
Input kW
Input kW
40
350
250
30
20
150
10
0
50
0
200
400
600 Duty kW 800
1000
1200
1400
0
200
400
600
800
1000
1200
1400
Duty kW
GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
Free Cooling Std unit Mechanical Cooling
vs Length
85
16000
80
14000
75
12000
Length mm
Sound Pressure @ 5 m
Free Cooling Std units Mechanical cooling vs
Sound Pressure
70
65
10000
8000
6000
60
4000
55
0
200
400
600
800
Duty kW
1000 1200 1400
2000
0
200
400
600
800
1000
1200
1400
Duty kW
GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.
APPLIED CHILLER PRODUCTS
YSFC Free Cooling Chiller Competition
Free Cooling std unit vs Euro
180000
160000
140000
Euros
120000
100000
80000
60000
40000
20000
0
0
200
400
600
800
1000
1200
1400
Duty kW
GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.
APPLIED CHILLER PRODUCTS
Packaged
Servicing
Air Cooled Renewal Parts
Free Cooling
Contacts
APPLIED CHILLER PRODUCTS
YSFC JCI Products and Service Departments have
experience of many shared Component suppliers
The Design of the YSFC has many similarities to our own YAES – YCAS and
YLCS models. Using many common components that our Service Engineers
and Renewal Parts Group are familiar with their availability and use.
For example:Hanbell Compressors, Ziehl Fans, pumps,
Alfa-Laval or Heatcraft Evaporator’s
Plus many common refrigeration, electrical components.
New components include
The Carel PCO3 controller with the Free Cooling
Software.
Hydronic system and Three way Valve.
APPLIED CHILLER PRODUCTS
YSFC Service Training and Replacement Parts.
Service Training
A Service Trainer Course will be organised at the Factory near Venice.
During Q4 FY 2009
The course will consist of:• Product Overview (General Refrigeration system)
• Theory of operation of the Free Cooling System.
• Detail review of the PCO3 Carrel controller and software.
• Review end of line test and the Commissioning procedures.
Replacement Parts
• Must be purchased through JCI Renewal Parts Organisation who will have
access to Hitema’s detailed bills of material’s for each product supplied.
• Please ensure Model Number & Serial Number is given along with
details of the Components requested.
APPLIED CHILLER PRODUCTS
YSFC JCI-Hitema Contract Special Variations
Drawing Approvals
• Upon receipt of order the Factory will review the unit configuration and produce
project specific physical & electrical drawings.
• These will require Client approval before components purchase and manufacture
commences. (Early reply would be required to ensure shortest possible lead times.)
Typical lead times 6 – 8 weeks after drawing approvals.
Email communication of documentation and approvals is to be co-ordinated through
Customer Services Group in Basildon.
Commissioning registration
• To initiate the warranty coverage the unit commissioning
Completion date must be registered with the Basildon
Customer Services team along with a copy of completed
commissioning log report.
• Specified system fill / commissioning procedures must be followed
• Hitema reserves the right to request that any failed component be returned for analysis.
• An agreed standard hours and labour rates repair times for replacement of faulty items.
Warranty
• In line with the current European standard policy of 18 months from factory collection.
• All parts are with a full 18 month warranty with the exemption of the liquid Pump options.
APPLIED CHILLER PRODUCTS
YSFC Communications Product Process
JCI Sales and the Product Supply & Sourcing will jointly work with Hitema.
Responsibilities are as follows.
• Product Supply & Sourcing.
Product Manager Roger.J.Smeed@JCI.com 00441268246198.
Account management, Maintain documentation and price list, Product Training,
Product Management and application and special quotation support.
• Factory will provide Engineering Support Through The Existing SQ System.
Review requests for Special Quotation's.
Specific product Technical / Engineering support.
Product Manager Roger.J.Smeed@JCI.com 00441268246198.
• Order Entry & Processing and Commissioning registration and Warranty management.
Centralised through Customer Services Basildon.
Orderentry CG-EUR-Basildon@jci.com 00441268246266.
• After Sales Technical Operation support.
Tim.Jennings@jci.com 00447976196714.
• Renewal Parts
hvacparts.cg-eur@jci.com 0044126824600.
APPLIED CHILLER PRODUCTS
Have Your Say Any Questions?
Have Confidence in Free Cooling and our New
YSFC.
Thank you.
APPLIED CHILLER PRODUCTS