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Design guide for DVM Chiller

1

Design guide

for DVM Chiller

Modification history

Date Ver. Modifier Modified detail

30 May 17 1.0 Junho Lim - New

23 Mar 18 1.5 F Weddington - North American Market

27 Mar 18 1.6 J McCloskey - Table added, minor changes

Contents

1. Introduction -------------------------------------------------------------------- 04

1-1 Air-cooled chiller vs Water-cooled chiller ------------------------------------------ 04

1-2 What is DVM Chiller ? ------------------------------------------------------------------ 05

2. Basic configurations ---------------------------------------------------------- 06

2-1 Pump system ------------------------------------------------------------------------------ 06

2-2 Chiller arrangement ---------------------------------------------------------------------- 11

2-3 Water piping ------------------------------------------------------------------------------- 13

3. Water piping elements ------------------------------------------------------- 15

3-1 Water pipes -------------------------------------------------------------------------------- 16

3-2 Pumps --------------------------------------------------------------------------------------- 22

3-3 Expansion tank (vessel) ---------------------------------------------------------------- 27

4. Maintenance -------------------------------------------------------------------- 29

4-1 Water pipe installation ------------------------------------------------------------------- 29

4-2 Water quality ------------------------------------------------------------------------------- 32

4-3 Freeze prevention of water pipe ------------------------------------------------------ 33

4-4 Chilled water management ------------------------------------------------------------- 34

5. External contact connection ------------------------------------------------ 37

5-1 A-Terminal block --------------------------------------------------------------------------- 37

5-2 B-Terminal block -------------------------------------------------------------------------- 38

5-3 C-Terminal block -------------------------------------------------------------------------- 45

6. Check before use ------------------------------------------------------------- 56

6-1 Module or group operation ------------------------------------------------------------- 56

6-2 Operation pattern for modules -------------------------------------------------------- 57

7. Product configuration --------------------------------------------------------- 61

7-1 DVM Chiller configuration --------------------------------------------------------------- 61

7-2 Module controller -------------------------------------------------------------------------- 64


4

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.

Cooling Tower

`

Chiller

` AHU

Cooling

Tower

Circuit

Condenser

Water

Pump

Chilled

Water

Circuit

Chilled Water Pump

( Air-cooled chiller ) ( Water-cooled chiller )

Chiller

` AHU

Chilled Water Pump

Chilled Water

Circuit


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)


6

Approved Modular Combinations

Nominal Tons

Standard High Efficiency

AG010KSVA*H/AA AG015KSVA*H/AARecommended

Pipe DiameterAG010KSVA*H/AA AG015KSVA*H/AA

Recommended

Pipe Diameter

10 1 2"

15 1 2"

20 2 2"

30 2 2 1/2" 3 2 1/2"

40 4 2 1/2"

45 3 3"

50 5 3"

60 4 3" 6 3"

70 7 3 1/2"

75 5 3 1/2"

80 8 4"

90 6 4" 9 4"

100 10 4"

105 7 4"

110 11 4"

120 8 4" 12 4"

130 13 4"

135 9 4"

140 14 5"

150 10 5" 15 5"

160 16 5"

165 11 5"

180 12 5"

195 13 5"

210 14 5"

225 15 5"

240 16 5"


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

Application

-Small plants

(Few coils serving

similar loads)

Multiple chiller and

multiple loads where operator

is not existed

(Many coils serving similar

loads or dissimilar loads)

Multiple chiller and

multiple loads with high

loads like data center

(Many coils serving similar

loads or dissimilar loads)

Pump energy Pump energy is wasted50~60% 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


8


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


9


2-1 Pump system


A decoupler pipe separates the two loops hydronically.

Primary circuit must contain minimum water volume as stated in the installation guide.

T

ΔP


10


2-1 Pump system


✓ 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.


11


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


12


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.

`


13


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 14.04 ]

T

T

Upstream chiller Downstream chiller

Parallel chiller Series chiller

63.46 GPMSystem pressure drop : 7.25 psi

126.8 GPMSystem pressure drop : 26.1 psi

Upstream chiller starts first. When upstream chiller can not achieve

target water set temperature, downstream chiller is operated.


14


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.

Pump

Modular Chillers

(installed in parallel)

Fan Coil Units


Profile of Pressure Drop between inlet and outlet

CCCC

C

C

C

C

100%75%50%25%

Flow rates of each load

100%

75%

50%

25%

ΔP

ΔP

: Flow control valveC


15


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.

※ Although reverse return system is closer to self-balancing than direct return systems,

make sure each load is similar to balance water flow

Pump

Modular Chillers


Fan Coil Units (installed in parallel)

Profile of Pressure Drop between inlet and outlet

Equal ΔP

Equal ΔP


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

Select pipe size

Select other parts

Calculation total head loss

Select water pump

Head loss, friction loss calculation


17


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

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.

C C C C

C

: Constant flow valve


18


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.


19


3-1 Water pipes

2) Friction losses

✓ Example (By Hazen-Williams Equation chart)


20


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 Reliability

High Erosion accelerating, vibration and noise

LowDamaging 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

Pipe diameter

[inch] *Velocity range [ft/s]

5 or more 6.9 ~ 8.9

2~4 3.9 ~ 6.9

About 1 2.0 ~ 3.9

Running time (hr/year) Velocity(ft/s)

1,500 9.8

2,000 9.5

3,000 9.0

4,000 8.0

6,000 7.0

8,000 5.9

[ Recommended velocity range ]

[ Max allowable velocity to minimize erosion ]

* 1 year = 8,760 hr


21


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

Flo

w r

ate

Friction loss

40 mm

high friction loss

(2.04 kPa/m)

75 mm

low velocity

(0.79 m/s)

(Lower than 0.4 kPa → Not efficiency)


22


3-1 Water pipes

4) Example of sizing water pipes :

* Example (By Hazen-Williams Equation chart)

Flow

rate

Friction loss

Model 15HP

Water Flow 120 LPM

Diameter 40 A

Velocity 1.35 m/s

Friction loss 0.58 kPa/m

Model 20HP

Water Flow 160 LPM

Diameter 40 A

Velocity 1.82m/s


Model 25HP

Water Flow 200 LPM

Diameter 50 A

Velocity 1.99m/s



23


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 suction

Actual head of

Delivery

H_a

Actual head

of suction

Actual head

of Delivery H_a

Water head

Actual head

of Delivery


24


3-2 Pumps


▶ Equivalent length of friction loss by fitting [ft]

**Above chart is for reference only**

▶ Resistance of valves and fittings to flow of fluids

Pipe size ¾” 1” 1.25” 1.5” 2” 2.5” 3” 4”

Elbow (Long Radius) 2.3 2.7 3.2 3.4 3.6 3.6 4.0 4.6

Tee (line flow) 2.4 3.2 4.6 5.6 7.7 9.3 12 17

Tee (branch flow) 5.3 6.6 8.7 9.9 12 13 17 21

Globe valve 24 29 37 42 54 62 79 110


25


3-2 Pumps


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


26


3-2 Pumps


▶ Example

DVM Chiller 15 Ton

FCU 24k Btu/h * 4 EA Supply Return

Required flow rate : 120 l/min

Pressure loss

PHE of DVM Chiller : 60 kPa

FCU : 25 kPa

Flow rate : 120 l/min

Length : 25 m

Pipe diameter : 40 A

Velocity : 1.35 m/s

Friction loss : 59 mmAq/m

Flow rate : 120 l/min

Length : 20 m

Pipe diameter : 40 A

Velocity : 1.35 m/s

Friction loss : 59 mmAq/m

Pump

Efficiency : 60%

DVM Chiller

FCU

32.8 feet

Elbow : 4 ea

T-connection straight through : 1 ea

Globe valve : 1 ea

- Flow rate : 120 l/min = 7.2m3/hr

- Total head pressure(H_t) = 0 + 26.0 + 12.8 + 85.0 = 123.8 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 : 60 + 25 = 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

[ Pump catalogue ]


27


3-2 Pumps


▶ Use selection software of the pump manufacturer

- Input flow rate & Head pressure

* Reference site : www.grundfos.com


28


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

Pump off

PE

PExpansion tank

14.5 psi 14.5 psi

Pump on

PE

P

0 psi 14.5 psi

✓ It may occur cavitation

Pump off

PE

P

Pump on

PE

P

✓ It can prevent cavitation

14.5 psi 14.5 psi

14.5 psi 29 psi


29


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 volume @ highest water temp

* v_low(ℓ/kg) : water specific volume @ 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 volume @ highest water temp

* v_low(ℓ/kg) : water specific volume @ lowest water temp

* Pa(kgf/cm2) : Atmospheric pressure – 1.03

* P0(kgf/cm2) : System initial pressure @ cold pressure

* P1(kgf/cm2) : System operating pressure @ hot pressure

* α : Safety factor


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.


31


▶ 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.

4. Maintenance


32


▶ 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.

4. Maintenance


33

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

Heating water system

effect

Low level medium temp. heating gauge

Circulation water

(below 68 )Supply water

Circulation water

(68 ~140 )Supply water Corrosion

Forming

scale

Basic

item

pH (77 ) 6.8~8.0 6.8~8.0 7.0~8.0 7.0~8.0 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

Sulfate ion (mgSO42-/ℓ) Below 50 Below 50 Below 50 Below 50 O

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

Reference

item

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

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

4. Maintenance


34

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.

4. Maintenance


35

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

4. Maintenance

Item

Water flow rate working range (GPM)

Rated condition Working range

Model AG010* AG015* AG010* AG015*

Cooling / Heating 24 33.6 15.8 ~ 48 16.8 ~ 67.2


36


▶ Water temperature range

- Operate the product within the following range.

For product protection, compressor operation may be limited.

✓ 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

4. Maintenance

ClassificationRated condition

(Inlet / Outlet)

Range(Water Outlet)

Water Brine

Cooling 53.6 / 44.6 41 ~ 77 14 ~ 77

Heating 104 / 113 77 ~ 131

Water outlet temperature, 14 ~ 23 23~32 32~ 35.6 35.6 ~ 41 41 ~ 68

Ethylene glycol, % 40 30 20 10 0

Propylene glycol, % 40 35 25 15 0

Minimum water outlet temperature, 14 23 32 35.6 41


37


▶ 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.

✓ 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

4. Maintenance

Model name Minimum water volume (gal)

AG010KSV Series 72

AG015KSV Series 100.8


38

5. External contact connection

▶ Configuration of terminal block

DVM Chiller

Hydro control box

A-T/B B-T/B

C-T/B

※ T/B : Terminal Block

5-1 A-Terminal block

Cooling/Heating

display

Operation

display

Warning

display

Defrost operation

display

Pump operation

display

Comp operation

display

Pump operation

Freeze protection

display

* A-T/B : Output contact

* Output contact can be connected

neutral contact and open/short only

* Apply dry contact(No current)

- Purpose is to check the status of product in control room.


39


No. Name Function Contact short Contact open signal

A-T/B

1-2 Cooling/Heating displayDisplay when operating

in heating modeHeat Cool

Dry

contact

3-4 Operation display Display when operation ON Operate Stop

5-6 Warning display Display when error occurs Error occurred No error

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

11-12 Comp operation displayDisplay when compressor is

operatingCompressor On Compressor Off

13-14 Pump operation Signal of pump operation Pump signal On Pump signal Off

15-16 Freeze protection displayDisplay when in freeze

protection

Pump On for

Freeze protectionOthers

5-2 B-Terminal block

Pump interlock

Operation

On/Off

Operation

On/Off

Operation mode Standard for Hot water

(Cool storage) control

Hot water(Cool storage)

mode

Hot water(Cool storage)

Thermostat signal* B-T/B : Input contact

* Input contact can be connected




40


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.

✓ Hydro option setting

- Delay time of pump operation signal feedback is determined in the No. 13 of hydro

option setting.

Operation on

signal to pumpFeedback signal from

the pump for delay

time?

Operation OFF

Error display

*E918

No

Yes DVM Chiller

Operation On

*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

Detect the water

flow for 10sec?

Yes

Operation OFF

Error display

*E911/E913

No

Option No. Option Item Option value Factory default Definition Setting unit

13Delay time of pump

operation signal feedback10~240 30 Second unit Main unit of module

** Pump interlock may be proven by means of flow switch or

control interlock.


41


① Pump interlock – Wiring connection

No. Function Contact short Contact open Setting unit

A-T/B 13-14 Pump operation Pump signal ON Pump signal OFF Each unit

B-T/B 7-8 Pump interlock Pump on Pump off Each unit

PumpRelay

(Field supplied)

Power supplyVoltage

supply

Input signal

Relay

※ Caution

* Some voltage is necessary to activate relay

* Input cannot be connected by jumper

Dry Contact orflow proving

device


42


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)


- The input signal pattern is determined in the No. 28 of hydro option setting at first.

- To use this external contact, the input method of operation on/off in hydro setting needs

to be set to 1.

No

Yes DVM Chiller

Operation ON

(Contact : Short)

Operation OFF

(Contact : Open)

Is there input signal?(B-T/B, 13/14)

Yes

Heating

operation

start

(Contact :

Short)

Cooling

operation start

(Contact : Open)


Yes DVM Chiller

Operation ON

(Contact : Short)


Yes

Cooling

operation start

(Contact : Open)


Value of hydro option No. 28?

0

1


Yes DVM Chiller

Operation OFF

(Contact : Short)

No

No

No

No

Heating

operation

start

(Contact :

Short)

Option No. Option ItemOption

value

Factory

defaultOption Definition

Setting

unit

28Signal pattern of operation ON/OFF by

external contact 0/1 0

0 Usual input signal Main unit

of group1 Instant input signal


value

Factory


Setting

unit

1 Input method of operation ON/OFF 0/1 00 Module control/DMS Main unit

of group1 External contact


43


② Operation contact signal – Wiring connection

Operation ON

contact signal

Operation mode

contact signal

Input signal

DDC

Dry contact

(Field supplied)

※ External controller

(DDC : Direct Digital Control)

DDC

Dry contact

DDC

Dry contact

Input signalInput signal(Field supplied)

No. Function Contact short Contact open Signal type Setting unit

B-T/B

9-10Operation on/off Refer to the below

Usual input

or

Instant input signal Main unit of group11-12

13-14 Operation mode Heat Cool Usual input

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)


44


③ Hot water / Cool storage

- Able to store the thermal energy in water tank for later use.


- To use this external contact, the input method of operation mode in hydro setting have

to be set to 1.

✓ Module control setting

- Service mode setting of Module control is required for this function.

No

Yes Cool storage

(Hot water) operation

(Contact : Short)

DVM Chiller

Operation ON

Cooling(Heating)

operation

(Contact : Open)


Yes

DVM Chiller

Thermo on

(Contact : Short)

DVM Chiller

Thermo off

(Contact : Open)


No- Cool storage operation B-T/B 13/14 : open

- Hot water signal: B-T/B 13/14 : short

B-T/B 9-10 : on


value

Factory


Setting

unit

3Input method of operation mode

(Cool/Heat, Cool storage/Hot water)0/1 0

0 Module control/DMS Main unit


Main

menu

Sub

menuFunction

Option

value

Factory

defaultOption Definition Save

9

4 Use Cool storage mode 0/1 -0 Disable

Save at

DVM

Chiller

1 Enable

5 Use Hot water mode 0/1 -0 Disable

1 Enable


45


③ Hot water / Cool storage – Wiring connection

Input signal

DDC

Dry contact

※ External controller(DDC : Direct Digital Control)

DDC

Dry contact

DDC

Dry contact

Input signalInput signal

(Field supplied)


B-T/B

15-16Hot water(Cool storage)

mode

Cool storage or

Hot waterCool or Heat Usual input

Main unit of group17-18Hot water(Cool storage)

control method

Control by

set temperature

Control by

thermostatUsual input

19-20Hot water(Cool storage)

Thermostat signalThermo on Thermo off Usual input


46


5-3 C-Terminal block

* C-T/B : Input contact

* Input contact can be connected



except C-T/B No. 17~20

Silent mode

function

Demand

function

Forced

fan

function

Unusual

condition

reset

Set temperature /

Room temperature

Sensor(4~20mA)

Water law function

External water outlet

Temperature

(4~20mA)

※ T/B : Terminal Block

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.

Sensor Type: PT100


47


✓ By module control

DVM Chiller

Operation ON

After 6hr from

highest ambient

temp?

Normal

operation

No

Silent mode operation

(Only Cooling mode)

YesHydro option

value of No. 12?

1~3

0

After 12hr from

mode entry or

mode off?

YesNo

Normal

operation

✓ By external contact

DVM Chiller

Operation ON

Yes Hydro option

value of No. 12?1~3

0

Normal

operation

(Contact : Open)

No

Is there

input signal?

(C-T/B, 1/2)

Normal

operation

Silent operation

(Cooling or Heating mode)


- Silent mode function level is determined in the No. 12 of hydro option setting at first.

- To use external contact, the input method of silent mode function in hydro setting have

to be set to 1.


value

Factory


Setting

unit

12 Silent mode function level 0~3 1

0 Default(100%)

Main unit

of module

1 Level 1

2 Level 2

3 Level 3


value

Factory


Setting

unit

6 Input method of silent mode function 0/1 00 Module control/DMS Main unit



48


① Silent mode function – Wiring connection

Input signal

DDC

Dry contact

(Field supplied)




C-T/B 1-2 Silent mode function On Off Usual input Main unit of group


49


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?

Use of

external contact

Is there input signal?(C-T/B, 3/4)

Normal

operation

Normal

operation

(Contact : Open)

Demand control

operation

Demand control Off by

Module control or DMS ?

Normal

operation

Yes

No

Yes

No

No

Demand control

operation

Yes


50



- Demand control level is determined in the No. 5 of hydro option setting at first.

- To use external contact, the input method of Demand control in hydro setting have

to be set to 1.


value

Factory


Setting

unit

5 Demand control level 0~11 3

0 Default(100%)

Main unit

of module

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)


value

Factory


Setting

unit

4 Input method of Demand control 0/1 00 Module control/DMS Main unit



51


② Demand function – Wiring connection

Input signal

DDC

Dry contact

(Field supplied)




C-T/B 3-4 Demand function On Off Usual input Main unit of group


52


③Water 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.

Ambient temp.[°F]

Lea

vin

g w

ate

r te

mp.[°F

]

AirCool1 or AirHeat1

Tcool1 or Theat1

Tcool2 or Theat2

[Cooling / Heating Mode]

AirCool2 or AirHeat2

Room temp.[°F]

Lea

vin

g w

ate

r te

mp. °F

]

RoomCool1 or RoomHeat1

Tcool1 or Theat1

Tcool2 or Theat2

[Cooling / Heating Mode]

RoomCool2 or RoomHeat2


53



- Water law control standard is determined in the No. 15 of hydro option setting.

- To use external contact, the input method of Water law in hydro setting have to be set to 1.

- The value of parameters are determined by No. 16~27 of hydro option setting.


value

Factory


Setting

unit

15 Water law control standard 0/1 00 Ambient temperature Main unit

of group1 Room temperature


value

Factory


Setting

unit

8 Input method of Water law function 0/1 00 Module control/DMS Main unit



value

Factory

defaultDefinition

Setting

unit

16 AirCool1(For Water law) 0~20 10 Standard1 outdoor temperature for cooling

Main unit

of group

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

** All values are in ºC


54


③Water law function – Wiring connection

(Field supplied)

※ External controller(DDC : Direct Digital Control)

DDC

Dry contact

Input signal

(Field supplied) Sensor SMPS 24V


C-T/B

11-12 Water law Water law controlWater outlet set

Temp. controlUsual input Main unit of group

17-18Set temp. input /

Room temp. sensor4 ~ 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) 4 6 8 10 12 14 16 18 20

Temperature(℃) -50.0 -37.5 -25.0 -12.5 0 12.5 25.0 37.5 50.0

Temperature(°F) -58 -35.5 -13 -9.5 32 54.5 77 99.5 122


55


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


- It has to be set to 1, when an external water temp. sensor is used instead of individual

unit’s water outlet temp. sensor.

External water

temp. sensor use?

Water outlet temp.

sensor control of

each product

No

Yes YesOperation pattern of DVM

Chiller is not standard

control?

External water temp.

sensor control

Water outlet temp.

sensor control of

each product

No


value

Factory


Setting

unit

14 External water outlet temperature sensor 0/1 00 Disuse Main unit

of group1 Use


56


④ External water temperature sensor – Wiring connection

(Field supplied)

Sensor SMPS 24V


C-T/B 19-20 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) 4 6 8 10 12 14 16 18 20

Temperature(℃) -30 -17.5 -5 7.5 20 32.5 45 57.5 70

Temperature(°F) -22 0.5 23 45.5 68 90.5 113 135.5 158


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.


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.


59

6. Check List


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.


60

6. Check List


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.


61

6. Check List


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.


62

7. Product configuration

7-1 DVM Chiller configuration

1) Product dimension

1 23

4

5

70 2/3

66 3

/4

30 1/8

7 5/8

10.09 1/16

Anchor Bolt Anchor Bolt

31 5/834 7/8

10.0

30 5/8

65 3/16

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

* Unit :inches


63



2) Part exploded view

3

9

11

7

8

7

8

5321

19

19

8

12

13

22

20

20

22 23

21

18 2517

14

15

6

16

4

20

26

10

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


64



2) Part exploded view

(Hydro parts)

[ AG010/015KSVA*H/AA ]


65


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)

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