WATER COOLED CENTRIFUGAL CHILLER
Contents
1. Capacity 80 0 x 0 94 75 2 tons kW 59 4 x 0 99 58 8 kW GPM 192 x 1 10 211 2 GPM 6 0 x 1 22 7 32 ft of water 5 To determine condenser water pressure drops first determine GPM Condenser GPM 2 4 75 2 0 285 59 4 221 GPM 6 Condenser pressure drops are read from Figure 2 as follows Condenser pressure drop 6 5 feet Pressure drop MULTISTACK WATER COOLED CENTRIFUGAL CHILLER End Elevation 36 MIN RECOMMENDED SERVICE CLEARANCE D MASTER CONTROL GAUGE PANEL 657 LEAVING CONDENSER WATER 14 ENTERING CONDENSER WATER 0 MINIMUM SIZE OF VIBRATION CUSTOMER TO SUPPLY 4 X 4 X 7 GAUGE ISOLATORS 4 X 4 X 3 8 STRUCTURAL FOOT RAILS RESTING ON WAFFLE VIBRATION ISOLATORS RAILS MUST BE LOCATED DIRECTLY UNDER VERTICAL SUPPORTS AS SHOWN CONTROL PANEL BUSS BAR MODULE SENSOR PANEL ENTERING CHILLED WATER 8 625 0 D SCH 40 PIPE TYP LEAVING CHILLED WATER MULTISTACK WATER COOLED CENTRIFUGAL ELECTRICAL DATA External Input Output Connections 1 Components and wiring by others 18 AWG Min wire vA MINIMUM 2 Inputs to terminals 4 through 8 of TB11 must be wired closed if not used I External inputs Closed to operate sux OA EX1 Manual reset required to resume operation wan 4 lt 1 EX2 Auto reset Remote start stop E EX4 Auto reset Power phase monitor input MP P2. tons to convert tons to 10 F at equivalent for use with capacity tables Tons 450 1 012 444 7 tons 2 Select the appropriate performance table based on module to be used Read the Capacity and kW of a single module at the water temperature specified Capacity 80 0 tons kW 53 6 3 To find the number of modules required divide equivalent tons required at 10 F temperature drop by single module capacity from table Modules required 444 7 80 5 6 or 6 modules Chiller capacity 80 0 6 480 tons Power input 53 6 6 321 6 kW 4 At 12 F evaporator temperature drop applying Figure 1 performance adjustment factors result in Tons 480 0 1 012 485 8 tons vs system load 5 determine evaporator and condenser water pressure drops first determine GPM Fvaporator GPM 24 485 8 12 971 6 GPM Condenser GPM 2 4 485 8 0 285 321 6 1385 9 GPM MULTISTACK WATER COOLED CENTRIFUGAL SELECTION GUIDE 6 With a six module chiller evaporator and condenser pressure drops are read from Figure 2 as follows Evaporator GPM modules 971 6 6 162 GPM Pressure drop 4 3 feet Condenser GPM modules 1385 9 6 231 GPM Pressure drop 7 2 feet Note The above calculations represent theoretical changes in performance based on well established empirical data In reality these calculated points may never be observed in operation since the MS80T will modulate to meet the required capacity and achieve its le
3. 6 The control system shall monitor entering and leaving chilled water temperatures to determine system load and select the number of compressor circuits required to operate Response times and set points shall be adjustable The system shall provide for variable time between compressor Sequencing and temperature sensing so as to fine tune the chiller to different existing building conditions 7 Each module shall have a dedicated sub controller and hand off auto switch such that in the event of loss of communications with the master controller each module is capable of operating independently to meet chilled water load Power Connections Chiller shall have a single point power connection and external inputs and outputs to be compatible with the building management system Inputs Outputs include 1 Remote Start Stop 2 Cooling Alarm Additionally chiller shall be integrateable with building management systems through BacNet ModBus N2 or LON Inlet Headers Each inlet header shall incorporate a built in 30 mesh in line Strainer system to prevent heat exchanger fouling This system Shall include an automatic self cleaning debris blow down system MultiFlush for on line cleaning of the in line Strainers System Interface Portal Integrates chiller with building management system through BacNet ModBus N2 or LON Module Controller and Hand Off Auto Control Receives direction from the master controller and prov
4. E FS1 Flow switch Chilled water ee pn 1 FS2 Flow switch Condenser water Va MS1 Aux interlock Chilled water pump starter MS2 Aux interlock Condenser water pump starter gray EDE AT _ T 4 RS Reset signal Software selectable 0 10VDC 4 20 TE ONES NNNM _ _ RS Reset signal Software selectable 0 10VDC 4 20mA peg Bt 2 RESE SIGNAL BB aa 4 External outputs mp 2 9 10 RESET SIGNAL R CAR Customer alarm relay 24 VAC 5 CPR Condenser pump relay 24 VAC 5 VA max FLR X Full load relay 24 VAC 5 VA max DRSV Debris removal solenoid valve 24 VAC 6 W 16VA Max of 2 DRSV in this circuit Sensor Inputs ECW Entering condenser water LCW Leaving condenser water ECHW Entering chilled water LCHW Leaving chilled water For additional information see installation manual and master control user manual 3 Conductor 6 Conductor 1 Conduit 2 Conduit 8 EN 1 0 2 0 LCW C ECHW 3 0 4 0 250 MCM 300 MCM System Wire amp Fuse Sizing Specifications Model No Volts Hz PH Tons Compressor RLA LRA MS80T H W 460 03 8 6 132 Wiring Sizing Fuse Sizing MCA minimum circuit ampacity MF maximum fuse size MCA 1 25 x RLA1 RLA2 2 25 x RLA1 RLA2 RLA3 Where MF does not equal a standar
5. TISTACK MS80T Centrifugal Water Cooled Chiller the following information is requested 1 Load in tons of refrigeration 2 Chilled water temperature drop 3 Leaving chilled water temperature 4 Entering condenser water temperature Capacity Tables Capacity tables are based on a 10 F temperature drop through the evaporator and a capacity of 80 Tons at all chilled and condenser water temperatures The module is optimized to provide 80 tons at the maximum efficiency If the system load is less than 80 Tons the chiller will unload to provide the smaller required capacity at a theoretically higher efficiency For other than 10 F temperature drop apply the respective performance adjustment factors from Figure 1 to determine the theoretical improvements resulting from a broader temperature difference Water Flow Rates Evaporator water flow can be determined as follows GPM 24 Tons Temperature Drop F Condenser water flow should always be determined using a 10 F temperature rise as follows GPM 2 4 Tons 0 285 Compressor kW Waterside Pressure Drop Evaporator and condenser waterside pressure drops are provided in Figure 2 To use Figure 2 divide the total water GPM by the number of modules in the chiller Chilled Water Selection Example system load 450 tons Chilled water drop of 12 F Leaving water temperature of 45 F Entering condensed water temperature of 85 F 1 Use Figure 1 adjustment factor for
6. WATER COOLED CENTRIFUGAL CHILLER Product Data Catalog MODELS MSSOT_W MULTISTACK CID The Leader in Modular Chillers Listed MULTISTACK WATER COOLED CENTRIFUGAL CHILLER MODULES Side View Control box Compressor Circuit breaker hidden Gauges a PA c Em gm c Buss bar Condenser water Module sensor panel Chilled water Cutting Edge Compressor Easy Installation Technology e Compact modules fit through most doorways and e MagLev magnetic bearings no metal to metal into freight elevators contact e Modules connect quickly and easily Quieter than typical background noise Factory charged and run tested e Soft start pulls only 2 amps at 415V e Micro refrigerant charge compliant with AS HRAE 15 Oil Free design in most cases e Superior part load efficiency High Flexibility Integrated VFD control e Service can be performed a convenient non e Uses environmentally friendly R 134A refrigerant emergency basis Superior Dependability Install only the capacity required at the time e Multiple independent systems for redundancy Operates only the capacity required by the load e Integrates fully with building management through e Comprehensive computer monitoring BACnet ModBus or LON net O US OF e Automatic lead lag e Automatic fault recording MULTISTACK WATER COOLED CENTRIFUGAL DATA amp PERFORMANCE TABLES General Data Table MODEL Compressor Type Dry weig
7. alves Supplied and installed by others 411 8 Dad Standard Y Flow Switch Supplied and installed by Others To cooling flower From cooling VC tower Strainer 3 Way Condenser Strainer Isolation Valve Condenser By pass Valve Supplied and installed Supplied and Water Pump Recommended by others Note Select installed by Supplied and supplied and strainer based on others installed by installed in the water quality others building by others MULTISTACK WATER COOLED CENTRIFUGAL SCHEMATICS Pian View s e v aperi e E sam a o M LM 42 Minimum required clearance 32 gt Recommended 64 service clearance 7 Recommended service clearance 42 Recommended service clearance ee p eee E Se ee EMT a Front Elevation Number of Modules x 32 3 20 32 Master control Eri MULTISTACK MULTISTACK T MULTISTACK W Note Main power connection for a single module chiller is located inside module 22 Union Ya F P T 4 Blank ends Pressure taps Drain hose X n 7 32 Drain with mm hose bibb 2 JL aS LE T i e Rail length Number of Modules x 32 8 S i T fe 9 Condenser water and 4 x wall structural foot RT chilled water connections 4 DDRS 210A rails resting Minimum s
8. aving chilled water setpoint Operation with Glycol Ethylene glycol adjustment factors Figure 3 should be used to adjust performance depending on the percent of glycol used in the evaporator circuit The factors in Table 3 are based on a 10 F change in fluid temperature through the evaporators Capacity and kW should be obtained by extrapolating no more than 10 F from the lowest leaving chilled water temperature shown in the capacity tables MULTISTACK should be contacted if leaving glycol temperatures below 40 F are required Adjustment factors for propylene glycol are shown in Figure 4 and are used in the same way given in the following example Glycol Selection Example Determine Capacity GPM Pressure Drop and kW for a MS80 module cooling 30 ethylene glycol from 50 F to 40 F with an entering condensing temperature of 85 F and 100 water 1 By extrapolating from the Performance Tables Capacity 80 0 tons kW 59 4 2 Evaporator water flow and pressure drops are determined for water as in the previous example Evaporator GPM 24 80 10 192 GPM Fvaporator pressure drop 6 feet 3 To convert performance for water to performance with ethylene glycol read adjustment factors from Figure 3 at 30 glycol Capacity adjustment 0 94 kW adjustment 0 99 Evaporator GPM adjustment 1 10 Pressure drop adjustment 1 22 4 Calculate performance with 30 ethylene glycol by multiplying performance for water by adjustment factors
9. ber of modules For selection procedures see selection example Modules are designed tested and rated in accordance with ARI 550 590 MULTISTACK WATER COOLED CENTRIFUGAL CAPACITY TABLES AE AAA LI PERFORMANCE ADJUSTMENT FACTOR s CHILLED WATER TEMPERATURE DROP degrees F Figure 1 Performance Adjustment Factor A MS80T Condenser B MS80T Evaporator 100 n 90 80 70 60 50 Lu 40 LLJ LL e cc eO uu 20 cc o o LLJ cc 10 9 8 7 6 5 4 O OO O oOo ooo LO O ex co 7 0 FLOW RATE GPM A Figure 2 Water Pressure Drop 1 60 1 40 pem No ADJUSTMENT FACTOR 1 00 0 90 0 80 10 20 30 40 50 ETHYLENE GLYCOL Figure 3 Ethylene Glycol Adjustment Factors m m L iif ecc e er Li E o i i PROPYLENE GLYCOL Propylene Glycol Adjustment Factors Figure 4 Selection To select a MUL
10. ble Frequency Drive The chiller shall be equipped with a fully integrated Variable Frequency Drive VFD to automatically regulate compressor speed in response to cooling load and compressor pressure lift The chiller control shall coordinate compressor speed and guide vane position to optimize chiller efficiency a digital regulator shall provide V Hz control b The VFD shall have 110 continuous overload of continuous amp rating with no time limit PWM pulse width modulated output IGBT insulated gate bipolar transistors power technology full power rating at 2kHz DC bus inductor choke and wireless construction The inverter unit shall be refrigerant cooled and shall be fully integrated into the compressor package Central Control System 1 Scheduling of the various compressors shall be performed by a microprocessor based control system Master Controller A new lead compressor is selected every 24 hours to assure even distribution of compressor run time 2 The Master Controller shall monitor and report the following on each refrigeration system Discharge Pressure Fault suction Pressure Fault Compressor Winding Temperature suction Temperature c Evaporator Leaving Chilled Water Temp 3 The Master Controller shall monitor and report the following system parameters a Chilled Water Entering and Leaving Temperature b Condenser Water Entering and Leaving Temperature c Chilled Water and Condenser Wat
11. d size 250 MCM fuse the next larger fuse should be used Notes 1 RLA1 of the largest motor in the system RLA2 amp RLA3 RLA of other motors in the system 2 Wire sizing is based on National Electrical Code NEC rating for 75 C wire with 3 wires per conduit 3 Wiring distance from branch circuit shall not exceed 100 feet MULTISTACK WATER COOLED CENTRIFUGAL SCHEMATICS Required Chilled Water Piping Pressure Taps Supplied and installed by Multistack lt MULTISTACK Chiller SP Strainer 1 2 Sensor Isolation Valve Pockets Standard Y Supplied and Supplied by Strainer installed by Multistack Supplied and others Installation of sensor pocket 1 Chilled Water Weld a Let is Select strainer Pump recommended at based on water Supplied and 30 from end of quality installed by chiller supplied others and installed by others Sk X lt From building ON load gt lt Z gt To building FS L load Chiller Isolation Valves Supplied and installed by others Flow Switch Supplied and installed by others Condenser Schematic with Head Pressure Control MULTISTACK Chiller DX Supplied and installed by Multistack 1 2 Sensor Pockets Supplied by Multistack Installation of sensor pocket Weld a Let is recommended at 30 from end of chiller supplied and installed by others Condenser Isolation V
12. er Flow 4 An out of tolerance indication from these controls or sensors shall cause a fault indication at the Master Controller and shutdown of that compressor with the transfer of load requirements to the next available compressor In the case of a System Fault the entire chiller will be shut down When a fault occurs the Master Controller shall record conditions at the time of the fault and store the data for recall This information shall be capable of being recalled through the keypad of the Master Controller and displayed on the Master Controller s 2 line by 40 character back lit LCD A history of faults shall be maintained including date and time of day of each fault up to the last 20 occurrences 5 Individual monitoring of leaving chilled water temperatures from each refrigeration system shall be programmed to protect against freeze up Master Controller Stages and monitors the status of up to 8 modules Provides interface with all system variables and set points LCD Display 4X20 character backlit LCD displays system and chiller variables A complete picture of both compressor and chiller system performance is available at the display This includes but is not limited to refrigerant temperatures and pressures water temperatures compressor speeds actual and desired detailed fault information compressor run hours and theoretical system capacity MULTISTACK WATER COOLED CENTRIFUGAL MECHANICAL SPECIFICATIONS
13. he compressors operating speed and a movable inlet guide vane shall only be used in the case of a surge or choke condition arising during normal operation The moveable inlet guide vane shall be of the electro mechanical type 4 Bearing System The compressor shall use an oil free bearing system of the digitally controlled homo polo magnetic bearing type The bearings shall have an fully integrated back up bearing system and shall have a self generating power system so that the bearings shall be able to stay levitated in the case of a power failure No sump heater is to be required The bearing system shall use no more than 500 watts of energy during its normal operation and it must also have an auto balance capability in the case of any external vibration or out of balance event occurring 5 Prime Mover A direct drive synchronous permanent magnet brushless DC motor of the hermetic type of sufficient size to efficiently fulfill compressor horsepower requirements Motor shall be liquid refrigerant cooled with internal thermal overload protection devices embedded in the winding of each phase 6 Motor Starter The main motor starter is to be fully integrated into the compressor and shall be of the soft Start type with a maximum starting current of 20 of the full load current of the compressor It must be fully integrated with the motors variable speed control system and it must be factory tested during the run test of the unit 7 Varia
14. ht Kg each Normal capacity each Quanti Oil charge pints Evaporator Weight Kg each Water storage litres each Quanti Header system litres Condenser Weight Kg each Water storage litres each Quanti Header system litres Refrigerant type Refrigerant charge Kg circuit Number of circuits Operating weights Kg Shipping weight Kg MS80 MagLev Centrifugal 120 45 281 kW 1 Brazed Plate 189 54 43 8 1 57 2 Brazed Plate 220 47 7 1 57 2 R 134A 20 45 1 1 205 997 72 Performance Table All performance at 80 tons net Capacity SINGLE MODULE 580 1 ENTERING CONDENSER WATER TEMPERATURE Sa NE 27C 33 C 35 aw 1000 kW EER 1000 kW EER 1000 kW EER 1000 kW EER 1000 kW ER 30 9 98 58 3 33 60 4 2 i 6 1 72 352 62 2 Vi 8 2 1 52 8 E 4 333 4 35 7 15 46 68 340 49 365 1477 71 5 0 2 i 8 6 4 2 6 41 3 9 5 8 5 0 5 5 9 0 5 6 2 9 53 5 16 11 9 6 14 6 5 Quoted capacity at all points is 281 kW As long as compressor is not limited by demand or control parameters it will adjust speed to meet demand provided the required operational point is on the compressor map All performance data is based on a 10 Cchilled water temperature drop through the evaporator and condenser For total chiller performance multiply outputs Tons and input kW by the num
15. ides the capability of standalone operation if the master controller fails or if communication with the master controller is lost Each module controller communicates directly with its module s MagLev compressor through ModBus providing a more redundant means of multiple compressor control 11 MULTISTACK WATER COOLED CENTRIFUGAL COMPRESSOR Inverter speed control Permanent magnet motor Motor and bearing control Two stage direct drive hermetic centrifugal compressor Inlet guide vanes 140 Bernard Street Cheltenham VIC Australia 3192 Tel 61 3 8586 8200 Fax 61 3 8586 8202 Email multistack sales dunnair com au Website www multistack com au MULTISTACK The Leader in Modular Chillers Multistack has a policy of continuous product improvement and reserves the right to change designs specifications and data without notice Please see your Multistack representative for the most current information
16. ize vibration stubs each 8 SCH on waffle vibration isolators isolators 4 x 4 x Ye 40 steel pipe for butt welds Solenoid 32 center to center Maximum load 50 P S L or victaulic connections valve N C supplied by others 17 N P S full port MULTISTACK WATER COOLED CENTRIFUGAL MECHANICAL SPECIFICATION 10 System Description Chiller shall incorporate two stage centrifugal Compressor with magnetic bearings and consist of single 80 ton refrigerant circuits Each refrigerant circuit shall consist of an individual compressor condenser evaporator electronic expansion valve and control system Each circuit shall be constructed to be independent of other circuits from a refrigeration and electrical standpoint The chiller system must be able to produce chilled water even in the event of a failure of one or more refrigerant circuits Circuits shall not contain more than 55 Ib of refrigerant 1 Chiller Modules shall be ETLC US listed in accordance with UL Standard 1995 CSA Standard C22 2 236 and bear the ASME UM stamp on all heat exchangers 2 Modules shall ship wired and charged with refrigerant All modules shall be factory run tested prior to shipment 3 Compressors heat exchangers piping and controls shall be mounted on a heavy gauge steel frame Electrical controls and associated components for each module shall be mounted within that module Chilled and Condenser Water Mains Each module shall include supply and
17. return mains for both chilled and condenser water Grooved end connections are provided for interconnection to eight inch standard 8 625 inch outside diameter piping with Victaulic type couplings Evaporators and Condensers Each evaporator and condenser shall be brazed plate heat exchangers constructed of 316 stainless steel designed tested and stamped in accordance with ASME code for 300 psig working pressure on the evaporator and 360 psig working pressure on the condenser Both the condenser and evaporator heat exchanger shall be mounted below the compressor to eliminate the effect of migration of refrigerant to the cold evaporator with consequent liquid slugging on Start up Compressor 1 Unit shall have a direct drive oil free two stage semi hermetic centrifugal compressor complete with an active passive magnetic bearing system Casing shall be constructed from aluminum and shall not weigh more than 300 Ibs each The electronic soft starters compressor controls inverter power electronics bearing and motor control shall be fully integrated into the compressor and Shall be digitally controlled The magnetic bearing system must be fully protected in the case of a power outage with its own inbuilt power generation system 2 The impeller shall be statically and dynamically balanced The compressor shall be vibration tested and not exceed a level of 0 14 IPS 3 The capacity control should primarily be achieved by varying t
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