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Hyperchill precision chilled water

Engineering Data Manual

Index

1. Water cooling..............................................................................................................................................12. Water chillers .............................................................................................................................................23. Hyperchill: general description..................................................................................................................34. Product description ....................................................................................................................................34.1 Refrigeration circuit ...................................................................................................................................34.1.1 Compressor ................................................................................................................................................44.1.2 Condenser...................................................................................................................................................4

4.1.2.1 Air-cooled models..........................................................................................................................44.1.2.2 Water-cooled models.....................................................................................................................5

4.1.3 Expansion device ........................................................................................................................................54.1.4 Evaporator ..................................................................................................................................................64.1.5 Refrigerant..................................................................................................................................................64.2 Water circuit ...............................................................................................................................................74.2.1 Water tank ..................................................................................................................................................74.2.2 Circulation pump ........................................................................................................................................74.2.3 Water by-pass.............................................................................................................................................84.3 Microprocessor control ..............................................................................................................................84.3.1 Connectivity ................................................................................................................................................94.4 Electrical panel...........................................................................................................................................94.5 External frame..........................................................................................................................................105 Options and kits ........................................................................................................................................115.1. Circulation pumps ....................................................................................................................................125.1.1 Low pressure pump (P15) ........................................................................................................................125.1.2 Medium pressure pump (P30)..................................................................................................................125.1.3 High pressure pump (P50)........................................................................................................................125.1.4 Twin pumps...............................................................................................................................................125.1.5 Without pump ...........................................................................................................................................125.2. Filling kits .................................................................................................................................................125.2.1 Manual filling kit (ambient pressure).......................................................................................................135.2.2 Automatic filling kit (ambient pressure) ..................................................................................................135.2.3 Automatic filling kit (pressurized)............................................................................................................135.3. Low water temperature option (LW) ........................................................................................................145.4. Low ambient temperature option (LA).....................................................................................................145.5. Remote control kits ..................................................................................................................................145.5.1 Base remote control kit:...........................................................................................................................145.5.2 Advanced remote control kit ....................................................................................................................155.6. “Non-ferrous” version (LF).......................................................................................................................155.7. Close control version (LD) ........................................................................................................................155.8. Low noise version (LN) .............................................................................................................................155.9 Antifreeze tank heater..............................................................................................................................155.10 Outlet water heater ..................................................................................................................................155.11 Protective control panel cover .................................................................................................................165.12 Transport wheels kit.................................................................................................................................166. Manufacturing and testing .......................................................................................................................167. Hyperchill general data ............................................................................................................................178. Operating limits ........................................................................................................................................189. Hyperchill selection ..................................................................................................................................199.1. Refrigerating capacity ..............................................................................................................................199.2. Flow rate ...................................................................................................................................................209.3. Example calculation .................................................................................................................................21

Hyperchill - Engineering Data ManualRelease 2 - 06/13/06 RT

Hyperchill—Engineering Data Manual Release 2—061506 RT

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1. Water Cooling

In modern industry the optimization of production processes has become a major priority. This has led to a need for cold water, a resource which can sim-plify, improve and speed up industrial processed. Cold water can be used to reduce the time required for products to cool, and therefore can make a signifi-cant contribution towards increased productivity and improved product quality. It can also be used to cool machinery, thereby improv-ing its performance and increasing its working lifetime. In general, water is the medium most commonly used to remove or transmit thermal energy from or to a body, irrespective of whether this is a solid, liquid or gaseous.

There are many reasons why water is the most commonly used medium: it is not dangerous, it is easily sourced and it has a very high thermal capacity. But water, though still readily available, is a critical resource which is becoming ever scarcer and, as a consequence, more costly. In order to ensure the availability of the necessary amount of water, while at the same time avoiding unnecessary wastage and problems of compliance with stringent environmental regulation, the best solution is to use a closed circuit system in which the same water is continuously recirculated, flowing first to the user, where it absorbs heat and fulfills its cooling function, and from there to the cooling system, where the heat is removed from the water so that it is ready to begin the cycle again. The use of a closed circuit also makes it easier to both control the quality of the water and, where necessary, to use additives. The choice of cooling system depends first and foremost on the water temperature required. If the water temperature required is higher than the maximum ambient air temperature, then the air itself can be used as the cooling medium. Systems such as free cooling coils or cooling towers are based on this concept, which, when possible, are certainly economical solutions. However, when the required water temperature is below the maximum ambient air temperature, the best system for cooling water is a water chiller. A chiller allows you to cool water to the temperature required, regardless of surrounding ambient temperature, and with a high degree of accuracy. The integration of a circulation pump and an accumulation tank renders a water chiller a machine which not only cools water, but also pumps it around the closed circuit in which it is installed and offers a form of buffer to cater for varying loads.


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2. Water Chillers

A water chiller is a machine designed and built to cool water or water mixtures in a closed circuit. The system uses a refrigeration circuit to remove the heat from the water. A water chiller comprises a refrigeration circuit and a water circuit. The refrigeration circuit contains refrigerant, while the water circuit contains water. The two fluids, which never come into direct contact with each other, exchange heat in the evaporator, where the liquid refrigerant evaporates as it absorbs the heat removed from the water. The water leaving the chiller is therefore colder that that entering it. When integrated in a closed water circuit, the chiller cools, circulates and re-uses the same water. In this way the system ensures a constant supply of water at the required temperature.

Refrigeration and water circuits within a chiller

evaporator

refrigeration circuit

water circuit


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3. Hyperchill: General Description

Hyperchill is domnick hunter’s answer to the specific needs of the industrial user, offering precise water temperature control in a package which is compact and easy to use. With a choice of 16 models, the range meets cooling capacity needs between 6500 - 648,980 BTU (2 - 360 kW); each model is designed to work safely and reliably in all conditions. In the manufacturing industry, where operating conditions vary widely, flexibility becomes an essential requirement: regardless of whether the incoming water temperature is 41˚ F - 86˚ F (5˚ C - 30˚ C). Hyperchill, thanks to advanced technical solutions and a wide range of accessories, is always ready to operated continuously and efficiently. Over and above this extreme flexibility of use, Hyperchill’s advanced technical solutions offer reliability, efficiency, energy savings, compact dimensions and low weight, making Hyperchill the ideal solution for all industrial users. Compliant scroll compressors (PCW 060 - 650), an evaporator integrated in the water tank (PCW 007 - 650) and an advanced

microprocessor controller make Hyperchill the perfect solution for every chilled water need.

The four main components of the refrigeration circuit are the compressor, the condenser, the expansion device and the evaporator. These components are connected by pipes made entirely from high quality copper, through which the refrigerant flows. The refrigeration circuit also includes a refrigerant filter, flow and humidity indicators (from PCW 040), high pressure switch, low pressure switch (from PCW 040), fan pressure switch (air-cooled models) and service valves for charging / discharging the refrigerant. From PCW 040 Hyperchill is equipped with refrigerant pressure gauges on both the high and low pressure sides. From PCW 210 Hyperchill features a dual refrigeration circuit: this offers increased safety, in that one circuit can continue to operate eve if there is a fault on the other circuit.

4. Product Description

4.1 Refrigeration Circuit


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4.1.1 Compressor

All models are equipped as standard with hermetic refrigeration compressors, which are maintenance free and installed on rubber vibration damping mountings. PCW 007 - 040 feature hermetic piston compressors. PCW 060 - 650 are fitted with compliant scroll type compressors. Compliant scroll compressor offer significant advantages in terms of energy savings, high efficiency and quiet operation. The exclusive “compliant” technology, combined with a reduced number of moving parts, makes these compressors very reliable and practically indestructible. Compliant scroll compressors do not require pre-heating on start up and are more ecological in that they allow a smaller quantity of refrigerant to by used. The scroll’s very low level of vibration reduces the risks of breakage and increases the life of the chiller. PCW 007 - 160 have a single compressor; PCW 210 - 330 feature two scroll compressors installed within two separate refrigeration circuits; PCW 420 - 650 feature four scroll compressors within two separate refrigeration circuits, with

two compressors per circuit. Multiple compressors offer improved water temperature control as well as increased safety in the unlikely event where a compressor fails. The compressors are automatically rotated to share the load. The electric motors on all the compressors are protected by thermal and overcurrent relays.

The air cooled condenser comprises of one or more finned coils (copper pipes, aluminum fins) across which air is blown by one or more fans. On models PCW 020 upwards, the condensing coils feature a wire mesh pre filter. This significantly reduces dirt accumulation on the condenser, thereby reducing the risk of a sudden chiller cut out, while at the same time reducing both energy consumption and maintenance. From model PCW 025, the condensing section is completely separated from the rest of the chiller, thereby allowing maintenance even when the chiller is in operation. Air cooled models offer two differing fan selections, according to the customers’ needs:

Condensing coil with protective wire mesh pre filter and axial fans Axial fan versions: The axial fans are supplied with external rotor electric motors and die cast aluminum blades, complete with protection grilles. Models from PCW 040 are equipped with fans offering wing profile blades which guarantee high performance and low noise levels. The electric motors of the fans are protected by thermal and overcurrent relays.

4.1.2 Condenser

4.1.2.1 Air Cooled Models

Compliant Scroll Compressors


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Centrifugal fan versions: The centrifugal version is used in those cases where the chiller needs to be ducted (axial fans do not allow ducting of the treated air, in that the discharge pressure of the air expelled from the fan is practically zero). Centrifugal fans, on the other hand, impart a significant discharge pressure to the air, thus allowing the chiller to be ducted. The centrifugal fan version can also be used in those applications where the warm discharge air is to be used for ambient or process heating. The centrifugal version is offered on PCW 040 - 650. Centrifugal fans cannot operate without ducting since they need a certain counter pressure to avoid damage to the fan motor. When ducted, it is important to ensure that each fan is individually ducted in order to avoid warm outlet air from recirculating from the operating fans to non operating fans, with a consequent warm air flow in the condenser and a subsequent decrease in the chillers condensing capacity.

PCW 080 - 510 are available as water cooled models, used in those cases in which air cooled models would create difficulties (i.e. installation in enclosed or warm areas), or where the production of warm water is desired. The shell & tube heat exchanger features copper tubes within a carbon steel shell. All models are supplied standard with pressostatic valves which modulate the incoming water flow according to the water temperature and consequent condensing pressure.

4.1.3 Expansion device On PCW 007 - 025 the expansion device is of the capillary type. The capillary’s calibration has been established in the test room in order to ensure the required cooling capacity for which the chiller has been designed. From model PCW 040 upwards, the expansion device is a thermostatic expansion valve. This adjustable valve has already been factory calibrated to ensure optimum operation. The thermostatic valve is self regulating (according to the demand for cooling power), and thus allows the chiller to effortlessly operate with high water temperatures.

4.1.2.2 Air Cooled Models


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The evaporator, a component that is common to both the refrigeration circuit and the water circuit, performs the function of cooling the incoming water to the desired temperature, using the cold refrigerant to do so. On PCW 007—260 the evaporator is positioned inside the (standardly supplied) water tank itself. This design solution offers many advantages: the evaporator is protected and thermally isolated; the exchange of heat between the evaporator and the surrounding water further improves the cooling capacity of the chiller; the space saved means that the already compact dimensions of the chiller are reduced even further. All evaporators used on Hyperchill have been designed to offer high efficiency, while minimizing pressure drops and the risk of deposited material causing clogging. For PCW 007—025 the evaporator is of the coaxial tube type, with the outer tube is plastic to allow it to expanded without rupturing in case there is any ice formation. For PCW 040—650 the evaporator is of the finned coil type, with copper pipes and aluminum fins. This type of evaporator offers a high efficiency together with a special design which creates a wide water flow path with a consequent low water velocity; the upside of this is a low water side pressure drop and a significantly lower susceptibility to clogging up. An antifreeze sensor ( standard from PCW 020), inserted inside the evaporator, stops the chiller in the event of ice formation.

The refrigerant is the medium used to transfer energy. By changing pressure and temperature and changing from a liquid to a gaseous state it effectively transforms the input energy (e.g. compressor electrical energy, condenser cooling energy) to output energy (i.e. cooling of the chilled water). All Hyperchill standard models feature refrigerant R407C. R407C is classified as an environmentally friendly refrigerant, and offers an ODP (Ozone Depletion Potential) of zero; as a consequence R407C has no planned phase out date and can be used without restrictions. It also offers a very low GWP (Global Warming Potential) level. R407C also features a high COP (Coefficient of Performance), thereby ensuring that the chiller’s power consumption is kept to a minimum.

4.1.5 Refrigerant

4.1.4 Evaporator

Configuration for PCW 007 - 025 Configuration for PCW 040 - 650


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On PCW 007—650 the standard water circuit comprises a water accumulation tank, in which the evaporator is inserted. The tank acts as a thermal energy store; it allows the system to accumulate chilled water and thereby not only reduces the number of times the compressor stops and restarts (consequently increasing its service life) but also permits a smaller differential value to be set (the differential is the difference between the temperature at which the compressor stops and that at which it restarts), thereby improving outlet water temperature control. A pressure gauge monitoring the pressure of the outlet water is fitted, as standard, on every model. The temperature control sensor is positioned after the evaporator in the water circuit; as a consequence it is possible to control the water outlet temperature, as opposed to as in most cases, the inlet temperature. This allows for an improved chilled water outlet temperature control. The tank itself offers a generous capacity, thereby maximizing its advantage. It is made from carbon steel plate, with a maximum operating pressure of 87 psi (6 bar) (suitable for operation in pressurized circuits). The tank is designed, manufactured and tested in compliance with all applicable regulations. The outer walls are insulated in expanded polyurethane for improved insulation and efficiency. An air bleed valve at the top of the tank and a drain valve at the bottom are fitted as standard. The water level, which must be constant and sufficiently high to cover the evaporator inside the tank, is controlled by a level sensor (from PCW 020). The level sensor’s float design allows it to also be used with high glycol percentages and with de-mineralized water. The tank does not form part of the structural framework of the chiller and is therefore easily removable (from model PCW 040), offering an important maintenance advantage.

The circulation pump is standard on PCW 007—650. The pump has an average discharge pressure of 43 psi (3 bar) and is installed on the inlet side of the tank. On PCW 007 - 025 the pump is of the peripheral type, with a cast iron body and brass impeller. The impeller consists of a series of radial blades. On PCW 040 - 650 the pump is of the centrifugal type, with a cast iron body and impeller, a motor keyed directly onto the pump shaft, mechanical seals with ceramic / carbon rings and NBR elastomers.

4.2.2 Circulation Pump

4.1.2 Water Tank


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The pump is protected by thermal and overcurrent relays. A polyurethane thermal insulation is applied to the pump. Twin pumps and pumps with differing available head pressures are available as an option (see para 5.1) 4.2.3 Water By-pass PCW 007 - 650 features a by-pass between the water outlet and inlet sides. The water by-pass comprises a small bore pipe, which ensures that there is always a minimal recirculation flow, even if the water flow to the user machine is shut off. The by-pass offers several important advantages: • in the event of an interruption in the water flow to the user machine, it protects the pump against

potential damage caused by the sudden absence of water. • In the event of an interruption in the water flow to the user machine, it prevents the chiller from

stopping (with the consequent need for manual restarting). The chiller will be able to continually recirculate the water, chilling the water in the accumulation tank to the required temperature; on reaching this temperature it will stop as programmed, ready to start again as soon there is a demand from the chiller outlet.

• It smooths out peaks in the thermal load by mixing the incoming warm water with a small amount of the chilled water from the chiller outlet.

• It facilitates system start up, when the incoming water temperature is very high, without the need to reduce the flow rate.

All Hyperchill models offer, as standard, a microprocessor which is both simple to use and allows for precise, reliable control of the chiller. PCW 007 - 013 are fitted with the base microprocessor, with programming, control and alarm functions. PCW 020 - 025 are fitted with the “plus” microprocessor, allowing use in a wide variety of industrial refrigeration applications. It allows the user to set the operating parameters and monitor chiller operation, as well as featuring an extensive set of alarms. PCW 040 - 650, which are more complex in their operation, are equipped with the “advanced” microprocessor, with a larger quantity of inputs and outputs. The advanced microprocessor can be customized by the user: it is possible to create a control program specifically for the application in which the chiller is used. This offers many advantages for “intelligent” control which often cannot be obtained with standard microprocessors, buy which nonetheless are essential to optimize the operation of complex refrigeration machines.

4.3 Microprocessor Control

O

I

sel

I

O

X 100

comp

SEL

mute

PRG

clear

O

I

I

O

Advanced Microprocessor Controller PCW 040 - PCW 650

Base Microprocessor PCW 007 - 013 Plus Microprocessor PCW 020 - 025


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4.2.1 Connectivity Over and above the remote control kits offered (see para. 5.5), PCW 040 - 650 can be simply connected to an external supervisor system (otherwise known as BMS or Building Management System). For connecting to a BMS using the MODBUS protocols the connection is direct, while for selected other protocols a Gateway can be supplied to allow connection. 4.4 Electrical Panel The electrical panel is located inside the chiller and positioned at the front for easy access. It is designed in accordance with all applicable regulations and is suitable for installation outdoors. The power section comprises a main isolator switch, protection against motor overcurrents (automatic and / or fused), thermal protection for the pump and a series of contactors. The power supply is 230V/1 ph/60Hz for PCW 007 - 013 and 460V/3ph/60Hz for PCW 020 - 650.

Microprocessor Features

Base Plus Advanced

Digital Display x x x

Main Switch x x x

On / Off Button & Lamp x x x

Alarm Siren & Lamp x x x

Password Protected x x x

Programmable Parameters x x x

Programmable Alarms x x x

Hour Counter / Service Alarm x x x

Automatic Restart x x x

Powered General Alarm Contact x x x

Volt Free General Alarm Contact

Remote On / Off x x

Synoptic Panel x x

Status Report x

Water • Pump (from PCW 020) • Low water level • Antifreeze • High water temperature • Low water temperature

Refrigerant • High pressure (from PCW 020) • Low pressure (from PCW 040) • Compressor fault (PCW 040)

Others • Service requires • Microprocessor error • Voltage outside of limits • Sensor fault

List of Alarms


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4.5 External Frame The frame has been designed to allow easy access to all the chiller’s components. PCW 007 - 013 are designed for installation in a protected area, while all other models can be installed outdoors. PCW 007 - 013, the external frame is made up of self-supporting carbon steel panels with an epoxy polyester paint finish. On PCW 020 - 650 the external structure consists of galvanized carbon steel panels with a polyester paint finish. All models feature fasteners made in stainless steel.


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5 Options and Kits The needs of industry are widely varied and typically a chiller used in industrial applications needs to be adaptable to far more specific uses than is usual in generic chilling applications. As a consequence Hyperchill offers a wide range of options which allow the chiller to be customized to the requirements of an extensive quantity of specific user applications. For options availability according to model, please refer to Table 1. Table 1 - Options Availability by Model

PCW Models with Axial Fans PCW007-013 PCW020-025 PCW040-160 PCW210-330 Options

Water Circulation Pump

Without Pump X X X P15 22 psi (1.5 bar) X X X P30 43 psi (3 bar) Standard Standard Standard Standard P50 72 psi (5bar) X X X Double Pump X

Water Tank Standard Standard Standard Standard Close Control X X

Non-Ferrous Copper - Aluminum X X Copper - Copper X X X

Low Ambient Temperature 0 to 14˚F (-18 to -10˚C) X X X Low Water Temperature 14˚F (-10˚C) X X X Antifreeze Tank Heater X X X Low Noise X X X Aggressive Ambient Treatment X X X Kits

Filling Kit Ambient manual Standard X X X Ambient automatic X X X Pressurized automatic X X X X

Remote Control Base X X X X Advanced X X X

Wheels X X Control Panel Cover X X

PCW Models with Centrifugal Fans and Water Cooled Models PCW040-060 PCW080-650 Options

Water Circulation Pump

Without Pump X X P15 22 psi (1.5 bar) X X P30 43 psi (3 bar) Standard Standard P50 72 psi (5bar) X X Double Pump X

Water Tank Standard Standard Close Control X X

Non-Ferrous Copper - Aluminum X X Copper - Copper X X

Low Ambient Temperature 0 to 14˚F (-18 to -10˚C) X X Low Water Temperature 14˚F (-10˚C) X X Antifreeze Tank Heater X X Low Noise X X Kits

Filling Kit Ambient manual X X Ambient automatic X X Pressurized automatic X X

Remote Control Base X X Advanced X X

Control Panel Cover X X


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There are many applications in which the user has differing pump requirements, or the head pressure demand from the user’s machine differs significantly from the available head pressure around 43 psi (3 bar) offered by the standard pump fitted on the chiller (PCW 007 - 650). As a consequence Hyperchill offers several pump options. 5.1.1 Low Pressure Pump (P15) If the standard available head pressure is too high, this might cause, for example, excessive vibration in the circuit. In this case the customer can choose the optional low pressure pump P15, approximately 22 psi (1.5 bar) 5.1.2 Medium Pressure Pump (P30) Standard on PCW 007 - 650 installed within the chiller itself P30, approximately 43 psi (3 bar). 5.1.3 High Pressure Pump (P50) The standard pump’s available head pressure may not be sufficient to overcome the pressure drop within the circuit and thus ensure a sufficient water flow. In this case the high pressure pump P50, approximately 72 psi (5 bar). 5.1.4 Twin Pumps A supplementary P30 circulation pump is available, which works in parallel to the main pump as a stand-by pump (DP). Each pump covers the full operating needs of the chiller; only one pump operates at a time, the second is purely a safety stand by. From PCW 080 the stand by pump is installed inside the unit itself. 5.1.5 Without Pump Hyperchill can be supplied without a circulation pump, in those applications where this is already supplied by the user. 5.2 Filling Kits Hyperchill offers various kits to allow filling or topping up of the water circuit, both at ambient pressure or in pressurized circuits. The automatic filling kits avoid the need for periodic water level checks and protect the chiller against potential damage caused by the water circuit running dry. It is important to underline that the standard versions of the models PCW 007 - PCW 013 are designed for operation in a circuit at ambient pressure and are supplied with an integral filling tank. However, on request and at no extra cost, they may be supplied in versions for operation in a pressurized circuit.

5.1 Circulation Pumps


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5.2.1 Manual Filling Kit (ambient pressure) This can be installed on chillers which operate with water circuits at ambient pressure. It is made up of a clear plastic tank fixed to the rear of the chiller using an additional mounting frame, and connected to the chiller’s accumulation tank by a plastic pipe. This simple accessory allows a quick check of the water level in the circuit as well as an easy top-up if necessary; the addition of additives such as antifreeze is also rendered straight forward using this kit. The fill tank also acts as an expansion tank. PCW 007 - 013 are supplied standard with a manual fill tank installed within the chiller itself. This tank is removed if the pressurized fill kit is ordered. The manual ambient pressure filling kit CANNOT be installed in those circuits where the chiller is positioned at a lower level than the user or the water piping. This not only to avoid the tank from being under pressure with the water flowing out of the bleed valve, but also because the fill kit could not be used as a water fill and level control device. 5.2.2 Automatic Filling Kit (ambient pressure) This kit consists of a manual filling kit as described in para.4.2.1, with an additional fitting at the top of the tank for connection to a filling pipe, and a float controlled switch. The addition of these components transforms the kit into a filling tank which can automatically refill itself with water. 5.2.3 Automatic Filling Kit (pressurized) This kit is used for chillers operating with pressurized water circuits. It comprises a pressure reducer, a pressure gauge, an automatic breather valve, a drain valve and a pressure relief valve. This kit allows the water circuit pressure to be maintained at a value equal to or less than the mains water pressure. Installation of this kit exempts the user from the need to install a safety valve in the water circuit 73 psi (6 bar). For PCW 007 - 013 field installation of this kit is complicated, as such it is recommended that this is requested when ordering so it can be installed in the factory.

Ambient Pressure Fill Kit

Pressurized Fill Kit


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5.3 Low Water Temperature Option (LW) For those applications requiring a chilled water temperature of less than the standard chiller’s 32˚ F (0˚ C) limit, Hyperchill offers an option which enables the production of water at temperatures of down to 14˚ F (-10˚ C). 1. In these application glycol must be added to the water 2. When operating with low water outlet temperatures the refrigerating capacity decreases

and as a consequence the condensing section (on air cooled models) may effectively become oversized. To ensure correct operation it is recommended that when ordering the low water temperature option the low ambient temperature option be ordered as well.

5.4 Low Ambient Temperature Option (LA) When Hyperchill is to be installed in environments where the minimum ambient temperature falls below 41˚ F (5˚ C), the low ambient temperature option will be required (this is to prevent the condensing temperature from dropping below the minimum level required to guarantee correct operation). On PCW 013 - 130 and PCW 420 - 650 this option allows operation down to ambient temperatures of 14˚ F (-10˚ C), while for PCW 160 - 330 the temperature limit is reduced still further to 0˚ F (-18˚ C). 5.5 Remote Control Kits These kits allow Hyperchill to be controlled from a remote location. 5.5.1 Base Remote Control Kits: This kit displays the chiller’s operating status, signals the presence of any alarms and allows remote switching (on and off) of the chiller. 5.5.2 Advanced Remote Control Kits: This remote control board is an exact replica of that mounted on the chiller itself, and as a consequence it allows remote function of all activities on the chiller itself, including full status visualization, programming of all parameters, etc.

Base Remote Control

Advanced Remote Control


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5.6 Non Ferrous Option (CA or CC) In the non-ferrous option, the tank and pipes are made from non-ferrous materials (stainless steel, copper, brass, plastic). This ensures that all parts which come in contact with the water are non-ferrous and therefore do not release particles of iron into the water. This option is designed for those applications which require the use of very pure water (de-mineralized / de ionized water). Two versions are available: • Copper / aluminum version (Al/Cu) with a copper / aluminum evaporator • Copper / copper version (Cu/Cu) with copper / copper evaporator. The Cu/Cu version is used when

the liquid to be treated is corrosive against aluminum On request and depending upon the model, special version with a stainless steel water circuit can be supplied. 5.7 Close Control Option (LD) The standard Hyperchill features a design configuration allowing a very precise chilled water outlet temperature control (typically much more precise than other chillers on the market). If, however an even greater degree of accuracy is required for the temperature of the chilled water produced, Hyperchill is available with the Close Control configuration offering outlet water temperature fluctuations of less than +/- 1˚ F (0.5˚ C). To obtain this degree of accuracy the chiller runs continuously without cycling off / on thereby maintaining a constant water temperature in the accumulation tank. To achieve this twin (for improved precision) hot gas by-pass valves are used allowing partialization of the cooling capacity in the evaporator by injecting a measured quantity of the gas exiting the compressor; in this way the cooling capacity obtained follows the real needs of the inlet water temperature and chiller stoppages are avoided. The Close Control Option furthermore features a P+1 control algorithm for maximum precision as well as twin pressure switch condensing temperature control. 5.8 Low Noise Option (LN) The already reduced noise level of the standard Hyperchill my sometimes still be too high for certain applications. (LN) which allows a noise level reduction of about 3 db. Chiller performance decreases slightly for low noise versions. 5.9 Antifreeze Tank Heater (AH) The antifreeze heater is used in applications where the unit is installed in cold climatic conditions but where the user does not want to add antifreeze additives to the water. 5.10 Outlet Water Heater This is used for all applications where water heating is sometimes also required.


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5.11 Protective Control Panel Cover This metal cover protects the microprocessor control panel against dirt and weather. It is hinged to allow easy access to the controller itself. 5.12 Transport Wheels Kit This allows the unit to be easily moved around and is used in those applications where the chiller needs to be continuously moved during its operating life. 6 Manufacturing and Testing All Hyperchill models are subjected to very sophisticated manufacturing techniques and extensive testing to ensure the very highest quality levels. Every single chiller which leaves the factory undergoes the following tests: • Helium refrigerant leak test • Sniffer refrigerant leak test • Vacuum stability test • Electrical tests (power consumption , earthing, phrases, over voltage) • Microprocessor tests (settings & operation) • Components and safety devices tests (settings & operation) • Water circuit leak test (pressurized) • Refrigerating performance tests at nominal conditions with water flow • Water pressure drop test


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7 Hyperchill General Data Tab. 2 General Data

Model PCW 007 013 020 025 040 060 080 110 130 160 210 260 330 420 510 650

Cooling Capacity (1)

Air Cooled BTU/h 6,513 13,379 18,910 25,267 37,882 60,989 78,783 107,869 128,006 160,021 212,597 253,498 326,242 421,329 513,919 648,981

Water Cooled BTU/h CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF CF

Power Supply V/Ph/Hz 230/1/60 460/3/60

Protection Class IP IP 33 IP 44 IP 54

Compressors

Type Hermetic, Piston Hermetic Compliant Scroll

Compressors / Circuit 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 1/1 2/2 2/2 2/2 4/2 4/2 4/2

Max. Abs. Power - 1 compr kW 0.8 1.7 2.2 3.2 4.9 7.1 9.1 12.6 15.8 19.0 12.6 15.8 19.0 12.6 15.8 19.0

Axial Fans

Quantity 1 1 1 1 1 1 1 2 2 3 3 3 3 2 2 3

Max. Abs. Power - 1 Fan kW 0.1 0.1 0.2 0.2 0.7 0.7 0.9 0.7 0.7 0.7 0.9 0.9 0.9 2.4 2.4 2.4

Air Flow cfm 1,350 1,350 2,590 2,410 4,180 4,000 5,410 7,300 7,060 10,240 15,000 14,710 15,540 27,660 27,070 38,850

Pumps

Type Peripheral Centrifugal

Water Flow nominal GPM 1.3 2.7 3.8 5.1 7.6 12.2 15.8 21.6 25.6 32.0 42.5 50.7 65.2 84.3 102.8 129.8

P30 nominal power hp 0.4 0.4 0.5 0.5 1 1 1 2 2 2 3 3 3 5.5 5.5 5.5

P30 available head pressure psi 44 42 49 41 45 44 41 51 48 45 44 44 41 49 48 44

P50 nominal power hp 0.9 0.9 1.0 1.0 2.0 2.0 2.0 2.5 2.5 2.5 5.5 5.5 5.5 10.0 10.0 10.0

P50 avialable head power psi 73 68 87 73 86 83 78 84 81 75 68 67 64 78 75 71

Dimensions and Weight

Depth inches 20.9 20.9 38.6 38.6 44.2 44.2 65.0 65.0 65.0 85.6 85.6 85.6 85.6 118.1 118.1 128.7

Width inches 29.5 29.5 21.0 21.0 28.7 28.7 29.3 29.3 29.3 29.3 35.4 35.4 35.4 50.9 50.9 50.9

Height inches 31.5 31.5 48.3 48.3 53.5 53.5 53.5 53.5 53.5 53.5 76.9 76.9 76.9 89.4 89.4 89.4

Connections In / Out inch 1 1 1 1 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2 1 1/2 2 2 2 2 1/2 2 1/2 2 1/2

Tank Capacity gal 6.6 6.6 11.9 11.9 31.7 31.7 47.6 47.6 66.0 79.3 132.0 132.0 132.0 264.0 264.0 264.0

Weight (axial fan version) (2) lbs 230 240 370 400 550 595 840 904 950 1150 1765 1990 2205 3310 3970 4630

Noise Level

Sound Pressure (3) dB (A) 52 52 53 53 50 50 52 52 52 55 58 58 58 62 62 64

(1) at water inlet / outlet temperature = 45˚ F / 55˚ F (7 ˚ C/ 12˚ C), glycol 0%, 95˚ F (35˚ C) (2) weights are inclusive of pallet and refriger-ant charge (3) referred to axial fan version in free field conditions at a distance 32.8 ft (10m) from unit, meas-ured on condenser side


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8 Operating Limits All models in the Hyperchill range offer very wide operating limits. This characteristic not only allows Hyperchill to be easily applied in the majority of industrial applications, but also offers other advantages both as regards reliability and operating safety. These are: • Reliable and safe operation even in demanding conditions • Reduced risk of stoppage, even when the chillers performance is compromised by wear or by dirt

accumulated on the surfaces of the heat exchanger • No start up problems: Hyperchill can be started even with very high initial water temperatures or

ambient air temperature. Hyperchill operating limits are summarized in Table 3 Tab. 3 - Operating limits

Minimum Maximum

Chilled Water Outlet Temperature Standard 32˚F (0˚ C) / Optional 14˚ F (-10˚ C) /

Water Inlet Temperature Standard / 86˚ F(30˚ C) Optional 59˚ F (15˚ C)

Inlet-Outlet Temperature Difference Standard 2˚ F(1˚ C) 59˚ F(15˚ C) Optional

Ambient Temperature Standard 41˚ F(5˚ C) 113˚ F(45˚ C) Optional

Maximum Glycol 50%

Operating Pressure 87 psi (6 bar)

To ensure the operating limits are maintained over time it is important that the chiller is installed correctly and receives correct periodical maintenance.


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Correction Factor f1 Chilled Water Temperature ˚ F 35 40 45 50 55 60 65 70 75 ˚ C 2 4 7 10 13 16 18 21 24

Ambient Temperature ˚ F ˚ C 65 18 1.010 1.095 1.180 1.280 1.380 1.480 1.580 1.605 1.630 70 21 0.980 1.065 1.150 1.250 1.350 1.450 1.550 1.575 1.600 75 24 0.950 1.035 1.120 1.220 1.320 1.420 1.520 1.545 1.570 80 27 0.900 0.985 1.070 1.170 1.270 1.370 1.470 1.495 1.520 85 29 0.850 0.935 1.020 1.120 1.220 1.320 1.420 1.445 1.470 90 32 0.840 0.925 1.010 1.110 1.210 1.310 1.410 1.435 1.460 95 35 0.830 0.915 1.000 1.100 1.200 1.300 1.400 1.425 1.450

100 38 0.800 0.885 0.970 1.070 1.170 1.270 1.370 1.395 1.420 105 40 0.770 0.855 0.940 1.040 1.140 1.240 1.340 1.365 1.390 110 43 0.664 0.749 0.834 0.934 1.034 1.134 1.234 1.259 1.284 113 45 0.600 0.685 0.770 0.870 0.970 1.070 1.170 1.195 1.220

9. Hyperchill Selection The choice of the Hyperchill model which best satisfies the user’s needs depends on the required cooling capacity and the conditions in which the chiller is to operate. The operating conditions also effect the flow rate of chilled water and consequently the pressure drop caused by the passage of the water through the evaporator. To facilitate selection of the appropriate Hyperchill model, domnick hunter offers a software selection program which allows for accurate and easy selection and informs the user of all performance criteria at the given conditions. 9.1 Refrigerating Capacity The choice of the appropriate Hyperchill model depends upon the demand for refrigerating capacity from the load. This capacity must be supplied by the chiller within the specified operating condition limits. The refrigerating capacities indicated in Tab 2 refer to operation at nominal (i.e. standard) conditions. Generally speaking the real operating conditions for any given application will differ from these nominal conditions and as a consequence it is necessary to individually select the chiller. The parameters which determine the refrigerating capacity of a water chiller are: • Maximum ambient temperature in which the chiller is expected to operate • Minimum temperature of the chilled water to be produced by the chiller • Percentage of glycol in the chilled water Tab. 4 lists the correction factors to be applied in order to determine the approximate refrigerating capacity of any Hyperchill model in conditions differing from standard. The correction factor allows the effective refrigerating capacity to be calculated using the following formula:

Effective Refrigerating Capacity (BTU) = P x F1 x F2 =Where: P is the refrigerating capacity of the selected model at standard reference conditions chilled water outlet temperature 45˚ F (7˚ C), ambient temperature 95˚ F (35˚ C), as given in Tab 2 F2 is the correction factor for the glycol % which is to be added according to the minimum water temperature. See Tab. 5


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Correction Factor F3 Chilled Water Temperature ˚ F 35 40 45 50 55 60 65 70 75 ˚ C 2 4 7 10 13 16 18 21 24

Ambient Temperature ˚ F ˚ C 65 18 1.010 1.095 1.180 1.280 1.380 1.480 1.580 1.605 1.630 70 21 0.980 1.065 1.150 1.250 1.350 1.450 1.550 1.575 1.600 75 24 0.950 1.035 1.120 1.220 1.320 1.420 1.520 1.545 1.570 80 27 0.900 0.985 1.070 1.170 1.270 1.370 1.470 1.495 1.520 85 29 0.850 0.935 1.020 1.120 1.220 1.320 1.420 1.445 1.470 90 32 0.840 0.925 1.010 1.110 1.210 1.310 1.410 1.435 1.460 95 35 0.830 0.915 1.000 1.100 1.200 1.300 1.400 1.425 1.450

100 38 0.800 0.885 0.970 1.070 1.170 1.270 1.370 1.395 1.420 105 40 0.770 0.855 0.940 1.040 1.140 1.240 1.340 1.365 1.390 110 43 0.664 0.749 0.834 0.934 1.034 1.134 1.234 1.259 1.284 113 45 0.600 0.685 0.770 0.870 0.970 1.070 1.170 1.195 1.220

9.2 Flow Rate The flow of the treated water and thus of the chilled water produced by the chiller depends upon three factors: • The temperature of the chilled water produced • The ambient temperature • The temperature difference between the water entering the chiller and that leaving it. Tab. 6 Lists the correction factors to be applied in order to determine the water flow of any Hyperchill model in conditions differing from standard. The correction factor allows the effective water flow rate to be calculated, using the following formula:

Effective flow rate (gpm) = Q x F3 x F4 Where: • Q is the nominal water flow rate at standard reference conditions, chilled water outlet temperature

45˚ F (7˚ C) with ambient temperature 95˚ F (35˚ C) as indicated in Tab.2 • F4 is the correction factor for the water inlet / outlet temperature difference—see Tab. 7

Tab. 6—correction factor F3 takes account of chilled water temperature and ambient temperature

Correction Factor F2

Glycol % (by weight) 5 10 15 20 25 30 35 40 45 50

Minimum Water Tem-perature ˚F 28 25 19 14 7 1 -6 -13 -22 -31

Correction Factor F2 0.995 0.990 0.985 0.980 0.975 0.970 0.965 0.960 0.950 0.940

Tab. 5 correction factor F2 takes account of glycol % in chilled water


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9.3 Example Calculation We wish to determine the performance of a PCW 160 when working in the following operating conditions: Chilled water supply temperature 50˚ F (12˚ C) Chilled water return temperature 60˚ F (18˚ C) Maximum ambient temperature 90˚ F (32˚ C) Glycol % in the water 20% From Tab.2 we obtain: P=160021 BTU (47 kW) refrigerating cooling capacity with chilled water 45˚ F (7˚ C) with ambient 95˚ F (35˚ C) and glycol at 0% Q=32 gpm (7m3/hr) nominal flow rate with standard 43 psi (3 bar) pump in the above conditions. The effective refrigerating cooling capacity From Tab. 4 for the stated operating conditions we obtain: F1 = 1.110 From Tab. 5 for the stated operating conditions we obtain: F2 = 0.98

P x F1 x F2 = 160021 x 1.110 x 0.98 = 174071 BTU (51kW) The effective chilled water flow rate produced by the PCW 160 with therefore be: From Tab. 6 for the stated operating conditions we obtain: F1 = 1.110 From Tab. 7 for the stated operating conditions we obtain: F2 = 1.00

Q x F3 x F4 = 32 x 1.110 x 1.00 = 35 gpm (8 m3/hr)

Tab. 7 correction factor F4 takes account of difference between water inlet and outlet temperatures

Correction Factor F4 Temperature Differential Between Inlet and Outlet

2˚ F / 1˚ C

4˚ F / 2˚ C

5˚ F / 3˚ C

7˚ F / 4˚ C

9˚ F / 5˚ C

11˚ F / 6˚ C

13˚ F / 7˚ C

14˚ F / 8˚ C

16˚ F / 9˚ C

18˚ F / 10˚ C

20˚ F / 11˚ C

22˚ F / 12˚ C

23˚ F / 13˚ C

25˚ F / 14˚ C

27˚ F / 15˚ C

Correction Factor f4 5.000 2.500 1.666 1.250 1.000 0.833 0.714 0.625 0.555 0.500 0.454 0.417 0.385 0.357 0.333

hyperchill precision chilled water - sin-can inc · hyperchill precision chilled water ... axial...

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