Smardt Oil Free chiller

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REVOLUTIONARY ENERGY SAVINGS

Air-cooled oil-free centrifugal chillers from Smardt Chiller Group

TD – 0081B16Dec2011



Table of Contents _____________________________________________________________________________

______________________________________________________________________

SMARDTCHILLERGROUP.TD – 0081B 3

INTRODUCTION AND OVERVIEW ............................................................................................................... 4

SMARDTChillerGroup-WorldLeaderInOil-FreeChillerEfficiency...........................................................4Certification....................................................................................................................................................4StrongLEEDContribution.............................................................................................................................4StrongSupportForTheEPAResponsibleUseVision..................................................................................4

SMARDT PRODUCT BENEFITS .......................... ........................... .......................... .......................... .......... 5SMARDTAirCooledChillerRange...............................................................................................................5ChillerCostComparison................................................................................................................................6 AQuantumLeapInEnergyEfficiency...........................................................................................................7

PRODUCT DESCRIPTION ........................................................................................................................... 9

GeneralDescription.......................................................................................................................................9CompressorTechnology.............................................................................................................................10UserFriendlyControls.................................................................................................................................12 AirCooledChiller – PrincipalComponents..................................................................................................14GeneralPipingSchematic...........................................................................................................................15

CHILLER NOMENCLATURE ........................... ........................... .......................... .......................... ............. 16

CHILLER DIMENSIONS CLEARANCES ........................ .......................... ........................... ..................... 17MinimumPlacementClearances.................................................................................................................18OverallDimensions,Weights,&PhysicalData...........................................................................................19

ELECTRICAL .............................................................................................................................................. 20

FieldWiring..................................................................................................................................................20ElectricalRatings.........................................................................................................................................21

ELECTRICAL, INSTALLATION ................................................................................................................... 25

General........................................................................................................................................................25ElectricalWiring...........................................................................................................................................25

DESCRIPTION OF OPERATION ................................................................................................................ 26

ChillerCycle.................................................................................................................................................26EvaporatorDescription................................................................................................................................26CompressorDescription..............................................................................................................................26CondenserDescription................................................................................................................................28HotGasValveControl.................................................................................................................................28

CHILLED WATER SYSTEM ........................................................................................................................ 30

EvaporatorWaterCircuits...........................................................................................................................30ChilledWaterPumps...................................................................................................................................30WaterVolume..............................................................................................................................................31VariableWaterFlow....................................................................................................................................31OperatingLimits...........................................................................................................................................31FlowSwitch..................................................................................................................................................32HighPressure&LowPressureSwitches....................................................................................................32ReliefValves................................................................................................................................................32

ReliefValveCharacteristics.........................................................................................................................32ReliefValveApplication...............................................................................................................................33VentLineSizing...........................................................................................................................................33

CONTROLS ................................................................................................................................................ 35

ControlsWiring............................................................................................................................................35ControlPanelWiring....................................................................................................................................36

SPECIFICATIONS SMARDT AIR COOLED CHILLERS .......................... .......................... ......................... 38



Introduction Overview

_____________________________________________________________________________

SMARDTCHILLERGROUPTD – 0081B 4

INTRODUCTION AND OVERVIEW

SMARDT CHILLER GROUP - WORLD LEADER IN OIL-FREE CHILLER EFFICIENCY

ThePowerPaxandSMARDTcompaniesjoinedforcesin2005tomergetheirglobaloperationsin engineering, development, testing and certification, supply chain, technical services andcustomersupport.

PowerPax, basedinMelbourne,Australia,was founded in2000bya teamofHVAC industryexperts,tospecializeinhigh-efficiencyshell-and-tubeheatexchangersandtheiroptimizationinoil-freecentrifugalchillers.

SMARDT,basedinMontreal,Quebec,wasfoundedin2005byateamofTurbocorveterans,toproduce chillerswhich optimized the energyefficiencypotential of theTurbocor compressortechnology.

TheSMARDTChillerGroupnowhaswell over2000operatingchiller installationsacross the

world,alldeliveringhighreliability,outstandingpart-loadefficiencies,andtheoveralllowestcostofownershipinthemarkettoday.AchievingthesegoalsconsistentlyremainstheGroup’scorepurpose,andclearlydifferentiatesitfromcompetitorswithconventionalmachines.

CERTIFICATION

AllSMARDTchillers are ETL listed, have lifetimeelectricalsafety coverage, and incorporateevaporatorsandcondensersthatfullycomplywithASMEpressurevesselcodes.

SMARDTchillerenergyefficiencyperformanceiscertifiedaccordingtoAHRIstandard500/590(ref: www.ahrinet.org). IPLV performancealways farexceeds theminimumlevelssetoutby ASHRAEstandard90.1,CSA743,Eurovent,Australia’sMEPS,andothergoverningbodies.

STRONG LEED CONTRIBUTION

Use of SMARDT chiller technology can significantly contribute to achieving Leadership inEnergy&EnvironmentalDesign(LEED™)certificationforabuilding,beitinexistingbuildings,coreandshellconstructions,ornewconstruction,becauseitcanhelpwincriticalpointsintheEnergy&Atmospherecategory.MarketresearchbytheU.S.GreenBuildingCouncil(USGBC)findsthatthestreamlinedLEEDprocess is secondonly torisingenergycostsasadriver forstrongeradoptionofgreenbuildingpracticesandthetransformationofthebuiltenvironmenttosustainability.SMARDTisamemberoftheUSGBC.STRONG SUPPORT FOR THE EPA RESPONSIBLE USE VISION

TheEPA’sResponsibleUsevision,encouragesmanufacturers,systemdesigners,andowners,toinvestinproductsandtechnologieswhichdocumentsustainabilityofthehighestefficiencies,intandemwiththe lowestemissions.SMARDT is astrongsupporterofthevisionandoftheEPA.



SMARDT Product Benefits _____________________________________________________________________________


SMARDT PRODUCT BENEFITS

SMARDT AIR COOLED CHILLER RANGE

60 TR to 300 TR

Lowest Lifetime Operating Costs

SMARDT works hard to minimizecomplexity in chiller design and operation,andSMARDT simplicity is reflected in lowproductoperatingcosts.Thethinkingmakessimplesense:nooil, floodedshell-and-tubeevaporation, soft start, low powerconsumption, low maintenance costs andhigh reliability,with only onemain movingpart.

SMARDT field reliability has beenoutstanding, and not surprising when oneconsiders that some 80% of all chillerproblems in the field are dueto failures incompressoroilreturn.AndSMARDTchillersusenooil.

The growing fraternity of turbocor-trainedengineers and technicians often suggeststhat total maintenance costs for oil-freechillers run at well under half the costs oftraditionallubricatedchillers.

Serviceability

Always important in minimizing operatingcosts, is ease of serviceability. Serviceaccess is swift and simple with SMARDTchillers, as is access to operating historythrough remote monitoring. Operatinghistory and compressor and chiller setpointsareallaccessibleremotelybytrainedandauthorizedservicepersonnel.

Simple BAS IntegrationIntegration with Modbus, Bacnet andLONworksbuildingmanagementsystemsisstandard, as is connectivity with mostindustry-standardprotocols.

Custom Design and Problem Solving

SMARDT design engineers are alwaysready and willing to resolve particularequipmentdesignchallenges.Forexample,high-efficiency heat recovery and free-cooling applications can all be customdesigned and supplied competitively, andcorrosion protection and other options arealsoavailable.

Redundancy

Theuseofmultiplecompressorsallowsforbuilt-in redundancy safeguards.SMARDT’sredundancy potential can offer systemdesignersuniqueopportunities toeliminatemultiple chillers, multiple controls, andmultiple pumps, thus bringing furthersavingsforowners.

Multiple compressors also allow systemdesigners to save on low-load or ponychillers,becausewithaVFDintegratedinto

each compressor control, a chiller whichusesmultiplecompressorscanbeefficientlydriven right down below 10% or even 5%load.Optimization in DesignCondenser coils use aW configuration tooptimize heat rejection and footprint. Coilsare baked and double-coated and withsealededgesasstandard,soastoextendthe coil’s physical protection from

environmentalcorrosion.Remote Air-Cooled Condensing

Remotelocationofthecondensercanbeapreferred option in some applications.SMARDT can supply either a full packageasdesired,or,onacondenser-lessbasis.





CHILLER COST COMPARISON

Theabovediagramshowsa2yeartotalchillercostcomparison,forahotelinSanDiego,CA.Theleft-handoptionisacompetitorlow-costlubricatedscrewchiller.Theright-handoptionisan

oil-free300TRSMARDTair-cooledchiller.





A QUANTUM LEAP IN ENERGY EFFICIENCY

AllSMARDTchillers,whether air-cooledorwater-cooled, aredesigned to optimize theperformance of thehighlyefficientDanfoss

Turbocor oil-free centrifugal compressor.Oil-free magnetic bearing technology andvariable-speed drives deliver better IPLVefficiencies than conventional oil-lubricatedcentrifugal, reciprocating, scroll, and screwcompressors.Theyarealsohigh-speed – upto 48,000 rpm, very compact, very quiet,rugged,andreliable.ThePowerFactorisahigh.92.

Proprietary magnetic bearings replaceconventional oil lubricated bearings, which

eliminate high friction losses, mechanicalwear, and high-maintenance oilmanagement systems, to deliver chillerenergysavingsof35percentandmoreoverconventional chillers, while ensuring long-term reliability. Over 75,000 magneticbearingmachinesareoperatinginthefield,mainlyinhigh-endvacuumpumpsandCNCspindles - any innovation risk having beenlongovercome.

Turbocor’s one main moving part (rotorshaft and impellers) is levitated duringrotation by a digitally-controlled magneticbearing system. Position sensors at eachmagnetic bearing, provide real-timefeedback to the bearing control system at120 times each revolution, thus ensuringconstantlycenteredrotation.Key benefits of SMARDT chillers can besummarizedas:

Heat transfer optimization through

oil-freedesign

Extraordinarysoft-startefficiency

Rugged & built-in defense againstpowerfailure

HFC-134aozonefriendlyrefrigerant

Significantnoisereduction

Spectacularenergycostsavings

Improvedpartloadefficiencies

Heat Transfer Optimization Through Oil-

Free Design

The well-known ASHRAE study (researchProject 361) concluded that typicallubricatedchillercircuitsshowreductionsindesign heat transfer efficiency of 15-25%,as lubricant accumulates on heat transfersurfaces, denatures and blocks normalthermodynamic transfer processes.Logically,nooilinyourchillermeansnooilcontamination over time, so designefficiencyismaintainedeffortlessly.Extraordinary Soft-Start Efficiency

Thecompressor’spowerelectronics,furtherenhancedbySMARDT’s chillercontrollers,requireonly2 ampsfor start-up,comparedwith 500-600 amps for conventionalmachines. This means further savings forowners, who can reduce maximum powerloads and reduce backup generator size,costandcapacity.Rugged Built-in Defense Against Power

Failure

Each compressor hasabankofcapacitorsfor energystorage andto filter DC voltagefluctuations.Incaseofapowerfailure,thecapacitors provide continuity power to thebearings to keep the shaft levitated,allowing themotor to turn into a generatorandtopoweritselfdowntoastop.Extendedlife testing confirms the system’sremarkabledurability.HFC-134a Ozone Friendly Refrigerant

R134ahasnoozonedepletionpotentialandnophase-outscheduleunder theMontrealProtocol;ithasanA1ratingunderASHRAEstandard 34 (no flame propagation, lowertoxicity). Positive pressure chiller designs(comparedwithnegativepressuredesigns





using R123, for example) enhancesustainable performance, as neither air ormoisturecanleakintothechiller.Nopurgeunit is required – a further saving. LiquidR134a refrigerant is used in SMARDT

chillers to cool critical electronic andelectromechanical components, to assuremaximumefficiencyandsafeoperation.Significant Noise Reduction

Very low sound and vibration levels areachieved, because there is no physicalcontact between moving metal parts,eliminating the need for expensiveattenuation.TestingofSMARDTaircooledchillers, with reference to AHRI standard

575, yields readingsas lowas77dBAat1meter.

Spectacular Energy Cost Savings

Compared with a new screw chiller,SMARDTIPLVenergyefficiencyisroutinelymorethan32%better.Comparedwitholder

lubricated reciprocating, screw, scroll, orcentrifugal chillers, year round energysavings with SMARDT chillers can be aspectacular 50% and more. Under AHRIconditions,SMARDTIPLVperformancecanbe as low as .33 kW/TR while part-loadefficiencycanbeunder.30kW/TR.Improved Part Load Efficiencies

Thegraphbelow(datasource:AHRI2005)showsverysimplythatawiderangeoflarge

US cities all demand the vast bulk of theirchiller operations at part load – enablingmuchloweroperatingcostswithaSMARDToil free chiller, compared with a lubricatedalternative.



Product Description _____________________________________________________________________________


PRODUCT DESCRIPTION

GENERAL DESCRIPTION

The SMARDT range of chillers offer thesmallest footprint, the quietest operation,and some of the highest operatingefficienciesonthemarket.SMARDT’s Air-Cooled centrifugal chillerconsistsofashell&tubeevaporator,twin-turbine centrifugal compressor(s),compressor controller(s), hot gas bypassvalves, air cooled condenser coils,condenser fans, refrigerant level sensor(s),electronic expansion valve(s),interconnecting refrigerant piping, and

safety features such as triple freezeprotection. Condenser coils use a Wconfigurationtooptimizeheatrejectionandfootprint, sealed edge coils arebakedanddouble-coated as standard to extend thecoil’s protection from environmentalcorrosion, and all SMARDT chillers aredesignedtooptimizetheperformanceofoil-

free centrifugal compressors fromDanfossTurbocorCompressorsInc.TheSMARDTchillersetisapackagedunit,requiring connection to the chilled watercircuit, main electrical supply, andintegration with the building automationsystem(BAS)ifapplicable.The following protocol interfaces areavailable on SMARDT chillers for BAS:LON, BACNET, BACNET/IP, N2, andMODBUS/IP, and these interfaces are

usually installed within the SMARDT maincontrolpanel.SMARDT chillers deliver a high level ofreliability, outstanding part-load efficiency,andthelowestoverallcostofownershiponthemarket.

SMARDTAir-CooledChillersofferthesmallestfootprint,thequietestoperation,andthehighestair-cooledoperatingefficienciesonthemarket,andserviceaccessisalsooutstandinglysimple.





COMPRESSOR TECHNOLOGY

SMARDT chillers optimize the benefits ofthe revolutionaryDanfossTurbocor oil-freecentrifugal compressor technology. The

TT300compressordelivers60to90TRandtheTT400delivers120to150TR. Advancedelectronicsmeanthatmechanicalforces can bemanaged with extraordinary

tolerancesandachieveaveryhighdegreeofreliability.Theintegral2stagecentrifugalcompressor and shaft is levitated utilizing

state of the art magnetic bearingtechnology,whichpositionsandadjuststheassembly automatically, 120 times perrevolution.

Cutawayviewoftheadvancedoil-lessmagneticbearingtechnologyoftheDanfossTurbocorCompressorusedintheSMARDTrangeofChillers.

TheonecombinedmovingpartintheSMARDTChiller – themagneticallylevitated2stage

centrifugalcompressorandshaftoftheTurbocorCompressor.





300kWR(85tR)floodedchillerwith3%oilinrefrigerant

AsthiscomparativeAHRIstudyshowed,over20%ofalubricatedchiller’soperatingefficiencyis

routinelylostinitsearlyyears,asaresultofoilcloggingofheattransfersurfaces.

-

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

900,000

1,000,000

- 5 10 15 20 25

Turbocor Screw Centrifugal Screw

YEARS





USER FRIENDLY CONTROLS

SMARDT’s Kiltech controller is very user-friendly, highly intuitive, and allowsoptimization of both single and multiple

compressoroperationwhilstenablinga richarrayofcommunicationoptions.SMARDT chiller controllers have beendevelopedfromthegroundupusingprimarycompressorperformancemaps,maximizingtheperformancepotentialwithinthese,thenoptimizing the whole chiller’s operation tominimizeenergyconsumptionThecompressor’son-boarddigitalcontrollerproactivelymanagescompressoroperation,

while allowing external control and web-enabled monitoring of performance andreliabilityinformation.

ThePowerPaxmicroprocessorsystemhasbeenusedonmanychillersites,andthein-field experiencegained has resulted inthe

generation of state-of-the-art controlssoftware that both maximizes operatingefficienciesandminimizesmaintenanceandoperatingcosts.

TheSMARDTKiltechcontrollerprovidesforseveral access levels for plant operatorsand for commissioning, and offers a widevarietyofoptions for flexibleoperationandoptimizationofpowerconsumption,therebymaximizing time spent operating atcompressorsweetspots.





CondensingTempvEvaporatorMassFlowRate

PowerInput(kW)vEvaporatorMassFlowRateSMARDTchillercontrollershavebeendevelopedfromthegroundup,usingprimarycompressorperformancemaps,maximizingtheperformancepotentialwithinthesemaps,thenoptimizing

thewholeofthechiller’soperationtominimizeenergyconsumption.

RemoteMonitoringApplication-CompressorOverviewScreenCapture

TheSMARDTchillerremotemonitoringapplicationbringsnumerousadditionalbenefits,includingsuperiorprotectionofHVACassets,earlydiagnosticsassistance,&enhancedrapid

responseinthedetectionofalarmsorfaults.





AIR COOLED CHILLER PRINCIPAL COMPONENTS

Figure1:ExplodedView-AirCooledChiller-PrincipalComponents





GENERAL PIPING SCHEMATIC

Figure2:GeneralPipingSchematic



Chiller Nomenclature

_____________________________________________________________________________


CHILLER NOMENCLATURE

Figure3:ChillerNomenclature

AirCooledFanType

ChillerType(AirCooled)

DesignSeries(Software)(“A”-std/“__”non-std)

EvaporatorTubeSizeA=Ø3/4",B=Ø1"

NominalCoolingCapacity÷10(027→270kW)

CompressorTypeB=TT300,E=TT350

H=TT400,L=TT500

NumberofCompressors

NumberofEvaporatorPasses

FanSections

AA027.1BH6.4A2X



Chiller Dimensions Clearances

_____________________________________________________________________________


CHILLER DIMENSIONS CLEARANCES

Figure4:ChillerDimensions&Clearances

(Ref.Table2)



Chiller Dimensions Clearances

_____________________________________________________________________________


MINIMUM PLACEMENT CLEARANCES

UNIT PLACEMENT SIDE CLEARANCE

Singleunit,floorlevel 1830mm(6'-0")

Singleunit,pitinstallationnodeeperthanheightofunit

2440mm(8'-0")

Unitssidebyside,floorlevel3660mm(12'-0")betweenunits,

1830mm(6'-0")onothersides

Unitssidebyside,pitinstallationnodeeperthanheightofunit

4880mm(16'-0")betweenunits,2440mm(8'-0")onothersides

Table1:MinimumPlacementClearances



Overall Dimensions, Weights Physical Data

_____________________________________________________________________________


OVERALL DIMENSIONS, WEIGHTS, PHYSICAL DATA

ModelNo.

No.ofComp’

No.ofFans

Length

ServiceLength

No.of

LiftingLugs

Empty

Weight

Shipping

Weight(Charged)

Operating

Weight

Weight

atFootFR

mm(ft-in) mm(ft-in) Kg(lbs) Kg(lbs) Kg(lbs) Kg(lbs)A027 1 4 3680

(12’-8”)8458(27’-9”)

4 3038(6698)

3230(7120)

3348(7382)

899(1983)

A030 1 6 5010(16’-5¼”)

8458(27’-9”)

4 3745(8256)

4000(8820)

4144(9137)

1195(2635)

A054 2 8 6150(20’-21/8”)

8458(27’-9”)

4 4798(10578)

5150(11360)

5323(11735)

1528(3368)

A059 2 10 7315(24’-0”)

8458(27’-9”)

6 5358(11812)

5750(12680)

5952(13123)

1758(3876)

A073 3 10 7315(24’-0”)

8458(27’-9”)

6 5846(12888)

6250(13780)

6467(14258)

1903(4195)

A082 3 12 8458(27’-9”) 8458(27’-9”) 6 6396(14100) 6850(15100) 7092(15636) 2122(4678)

WeightatFootFL

WeightatFootBR

WeightatFootBL

CenterofGravity

R134aCharge

WaterContent

FlowRange**

No.ofTubePasses

WaterConn.Sizes(Victualic)

Kg(lbs) kg(lbs) kg(lbs) mm(ft-in) kg(lbs) kg(lbs) L/s(gpm)943(2079)

736(1623)

770(1697)

2060(6’-9”)

191(422)

119(262)

8-18(127-285)

2 4

1238(2729)

840(1852)

871(1921)

2870(9’-5”)

256(564)

144(317)

10-20(127-285)

2 4

1570(3461) 1099(2422) 1127(2484) 3505(11’-6”) 356(782) 170(375) 12-30(127-285) 2 5

1800(3969)

1224(2698)

1211(2670)

4300(14’-1”)

394(868)

201(443)

21-48(333-713)

3 6

1945(4289)

1295(2856)

1324(2918)

3680(14’-1”)

405(892)

217(478)

26-54(412-856)

2 6

2169(4782)

1387(3057)

1415(3119)

5260(17’-3”)

454(1000)

243(536)

26-54(412-856)

2 6

Theabovetableappliesto460VAC-variablespeed.For575VACrefertoSMARDTmodelspecificequipmentspec.

*Valuesdifferbychillermodel.ReferalsotoSMARDTmodelspecificequipmentspecforfurtherdetails.**gpmareU.S.gallonsperminute

Table2:OverallDimensions,Weights,&PhysicalData*Includesfullrefrigerantcharge – watercircuitsempty.

Weightsmayvarywithindividualtubecount.



Electrical

_____________________________________________________________________________


ELECTRICAL

FIELD WIRING

Figure5:FieldWiringfor460VAirCooledChiller

Figure6:FieldWiringfor575VAirCooledChiller



Electrical

_____________________________________________________________________________


ELECTRICAL RATINGS

QTY MODEL QTY MODEL MCA (A) MOP (A) MDS (A) MFW/9

0°C

MFW/

75°C

A027.1BG6.X2V CI01-03 170 250 161 1/0 2/0

A027.1BG6.X2E CH03-03 164 250 154 1/0 2/0

A027.1BG6.X2F SDQ.6N.V7 D 167 250 157 1/0 2/0

A027.1BG6.X2S SDQ.6N.V7 Y 159 250 148 1/0 2/0

A027.1BG7.X2V CI01-03 188 300 178 2/0 3/0

A027.1BG7.X2E CH03-03 182 300 171 2/0 3/0

A027.1BG7.X2F SDQ.6N.V7 D 186 300 175 2/0 3/0

A027.1BG7.X2S SDQ.6N.V7 Y 178 300 165 2/0 3/0

A030.1BG6.X3V CI01-03 179 250 172 2/0 3/0

A030.1BG6.X3E CH03-03 170 250 161 1/0 2/0

A030.1BG6.X3F SDQ.6N.V7 D 175 250 167 2/0 2/0

A030.1BG6.X3S SDQ.6N.V7 Y 163 250 153 1/0 2/0

A030.1BG7.X3V CI01-03 198 300 189 3/0 3/0

A030.1BG7.X3E CH03-03 189 300 179 2/0 3/0

A030.1BG7.X3F SDQ.6N.V7 D 194 300 184 2/0 3/0

A030.1BG7.X3S SDQ.6N.V7 Y 182 300 170 2/0 3/0

A044.2BG6.X3V CI01-03 299 400 310 300 350

A044.2BG6.X3E CH03-03 290 400 299 250 350

A044.2BG6.X3F SDQ.6N.V7 D 295 400 305 300 350

A044.2BG6.X3S SDQ.6N.V7 Y 283 400 291 250 300

A044.2BG7.X3V CI01-03 333 450 344 350 400

A044.2BG7.X3E CH03-03 324 450 334 350 400

A044.2BG7.X3F SDQ.6N.V7 D 329 450 339 350 400

A044.2BG7.X3S SDQ.6N.V7 Y 317 450 326 300 400

A054.2BG6.X4V CI01-03 309 400 321 300 350

A054.2BG6.X4E CH03-03 297 400 307 300 350

A054.2BG6.X4F SDQ.6N.V7 D 304 400 315 300 350

A054.2BG6.X4S SDQ.6N.V7 Y 288 400 296 250 350

A054.2BG7.X4V CI01-03 343 450 356 350 500

A054.2BG7.X4E CH03-03 331 450 342 350 400

A054.2BG7.X4F SDQ.6N.V7 D 337 450 349 350 500

A054.2BG7.X4S SDQ.6N.V7 Y 321 450 331 350 400

G7

2

G6

8

G7

2

G6

6

G7

1

G6

6

1

G6

ELECTRICAL RATING - AIRCOOLED - TT300 460V 60Hz FOR USA

CHILLER

COMP. - TT300 FAN CHILLER

4

G7

Table3:ElectricalRatings



Electrical

_____________________________________________________________________________


ElectricalRatings(cont’d)

QTY MODEL QTY MODEL MCA (A) MOP (A) MDS (A) MFW/

90°C

MFW/

75°C

A059.2BG6.X5V CI01-03 319 400 332 300 400

A059.2BG6.X5E CH03-03 304 400 315 300 350

A059.2BG6.X5F SDQ.6N.V7 D 312 400 324 300 400

A059.2BG6.X5S SDQ.6N.V7 Y 292 400 301 300 350

A059.2BG7.X5V CI01-03 353 450 367 400 500

A059.2BG7.X5E CH03-03 338 450 350 350 500

A059.2BG7.X5F SDQ.6N.V7 D 346 450 359 350 500

A059.2BG7.X5S SDQ.6N.V7 Y 326 450 336 350 400

A073.3BG6.X5V CI01-03 439 500 470 2 x 3/0 2 x 4/0

A073.3BG6.X5E CH03-03 424 500 453 2 x 3/0 2 x 4/0

A073.3BG6.X5F SDQ.6N.V7 D 432 500 462 2 x 3/0 2 x 4/0

A073.3BG6.X5S SDQ.6N.V7 Y 412 500 439 2 x 3/0 2 x 4/0

A073.3BG7.X5V CI01-03 488 600 522 2 x 4/0 2 x 250

A073.3BG7.X5E CH03-03 473 600 505 2 x 4/0 2 x 250

A073.3BG7.X5F SDQ.6N.V7 D 481 600 514 2 x 4/0 2 x 250

A073.3BG7.X5S SDQ.6N.V7 Y 461 500 491 2 x 4/0 2 x 250

A082.3BG6.X6V CI01-03 449 500 482 2 x 3/0 2 x 4/0

A082.3BG6.X6E CH03-03 431 500 461 2 x 3/0 2 x 4/0

A082.3BG6.X6F SDQ.6N.V7 D 440 500 472 2 x 3/0 2 x 4/0

A082.3BG6.X6S SDQ.6N.V7 Y 416 500 444 2 x 3/0 2 x 4/0

A082.3BG7.X6V CI01-03 498 600 533 2 x 4/0 2 x 250

A082.3BG7.X6E CH03-03 480 600 513 2 x 4/0 2 x 250

A082.3BG7.X6F SDQ.6N.V7 D 489 600 524 2 x 4/0 2 x 250

A082.3BG7.X6S SDQ.6N.V7 Y 465 600 496 2 x 4/0 2 x 250

G7

3

G6

12

G7

3

G6

10

G7

2

G6

10

ELECTRICAL RATING - AIRCOOLED - TT300 460V 60Hz FOR USA

CHILLER


Table3:ElectricalRatings(cont’d)



Electrical

_____________________________________________________________________________



QTY MODEL QTY MODEL MCA (A) MOP (A) MDS (A) MFW/90°C

MFW/75°C

A027.1BF6.X2V CI01-03 146 225 139 1/0 1/0

A027.1BF6.X2E CH03-03 139 225 132 1 1/0

A027.1BF6.X2F SDQ.6N.V7 D 139 225 132 1 1/0

A027.1BF6.X2S SDQ.6N.V7 Y 134 225 125 1 1/0

A027.1BF7.X2V CI01-03 159 250 151 2/0 2/0

A027.1BF7.X2E CH03-03 152 250 143 1/0 2/0

A027.1BF7.X2F SDQ.6N.V7 D 152 250 143 1/0 2/0

A027.1BF7.X2S SDQ.6N.V7 Y 146 250 136 1/0 1/0

A030.1BF6.X3V CI01-03 154 250 148 1/0 2/0A030.1BF6.X3E CH03-03 146 225 139 1/0 1/0

A030.1BF6.X3F SDQ.6N.V7 D 146 225 139 1/0 1/0

A030.1BF6.X3S SDQ.6N.V7 Y 139 225 132 1 1/0

A030.1BF7.X3V CI01-03 166 250 160 2/0 2/0

A030.1BF7.X3E CH03-03 159 250 151 2/0 2/0

A030.1BF7.X3F SDQ.6N.V7 D 159 250 151 2/0 2/0

A030.1BF7.X3S SDQ.6N.V7 Y 152 250 143 1/0 2/0

A044.2BF6.X3V CI01-03 254 350 263 250 250

A044.2BF6.X3E CH03-03 246 300 254 250 250

A044.2BF6.X3F SDQ.6N.V7 D 246 300 254 250 250A044.2BF6.X3S SDQ.6N.V7 Y 239 300 247 250 250

A044.2BF7.X3V CI01-03 276 350 286 300 300

A044.2BF7.X3E CH03-03 269 350 277 300 300

A044.2BF7.X3F SDQ.6N.V7 D 269 350 277 300 300

A044.2BF7.X3S SDQ.6N.V7 Y 262 350 270 250 300

A054.2BF6.X4V CI01-03 268 350 280 300 300

A054.2BF6.X4E CH03-03 254 350 263 250 250

A054.2BF6.X4F SDQ.6N.V7 D 254 350 263 250 250

A054.2BF6.X4S SDQ.6N.V7 Y 239 300 247 250 250

A054.2BF7.X4V CI01-03 291 400 303 300 350

A054.2BF7.X4E CH03-03 276 350 286 300 300

A054.2BF7.X4F SDQ.6N.V7 D 276 350 286 300 300

A054.2BF7.X4S SDQ.6N.V7 Y 262 350 270 250 300

2

F6 8

F7 8

2

F6 6

F7 6

1

F6 6

F7 6

ELECTRICAL RATING - AIRCOOLED - TT300 575V 60Hz - FANS 460V FOR CANADA

CHILLER


4

F7

F6

4

1




Electrical

_____________________________________________________________________________



QTY MODEL QTY MODEL MCA (A) MOP (A) MDS (A) MFW/90°C

MFW/75°C

A059.2BF6.X5V CI01-03 273 350 285 300 300

A059.2BF6.X5E CH03-03 254 350 263 250 250

A059.2BF6.X5F SDQ.6N.V7 D 268 350 280 250 250

A059.2BF6.X5S SDQ.6N.V7 Y 246 300 254 250 250

A059.2BF7.X5V CI01-03 296 400 308 300 350

A059.2BF7.X5E CH03-03 276 350 286 300 300

A059.2BF7.X5F SDQ.6N.V7 D 291 400 303 300 300

A059.2BF7.X5S SDQ.6N.V7 Y 269 350 277 250 300

A073.3BF6.X5V CI01-03 373 450 400 500 500

A073.3BF6.X5E CH03-03 354 450 378 500 500

A073.3BF6.X5F SDQ.6N.V7 D 368 450 395 500 500

A073.3BF6.X5S SDQ.6N.V7 Y 346 400 369 500 500

A073.3BF7.X5V CI01-03 406 500 435 2 x 3/0 2 x 4/0

A073.3BF7.X5E CH03-03 386 450 413 2 x 3/0 2 x 3/0

A073.3BF7.X5F SDQ.6N.V7 D 401 500 429 2 x 3/0 2 x 4/0

A073.3BF7.X5S SDQ.6N.V7 Y 379 450 404 500 500

A082.3BF6.X6V CI01-03 373 450 400 500 500

A082.3BF6.X6E CH03-03 368 450 395 500 500

A082.3BF6.X6F SDQ.6N.V7 D 373 450 400 500 500

A082.3BF6.X6S SDQ.6N.V7 Y 346 400 369 500 500

A082.3BF7.X6V CI01-03 406 500 435 2 x 3/0 2 x 4/0

A082.3BF7.X6E CH03-03 401 500 429 2 x 3/0 2 x 4/0

A082.3BF7.X6F SDQ.6N.V7 D 406 500 435 2 x 3/0 2 x 4/0

A082.3BF7.X6S SDQ.6N.V7 Y 379 450 404 500 500

MDS: MINIMUM DISCONNECT SIZE RATING

MFW: MINIMUM FIELD WIRING SIZE: BASED ON COPPER (AWG / kcmil)

3

F6

12

12

F7

3

F6 10

F7 10

2

F6 10

F7 10

ELECTRICAL RATING - AIRCOOLED - TT300 575V 60Hz - FANS 460V FOR CANADA

CHILLER





Electrical Installation

_______ __________________________________________________________________


ELECTRICAL, INSTALLATION

GENERAL

Allapplicablecodes shouldbe adhered to.The Limited Product Warranty does notcoverdamagedequipmentcausedbywiringnon-compliance, an open fuse resultingfrom an overload, a short, or a ground.Correct the causeof the open fuse beforereplacing the fuse and restarting thecompressor.Compressormotorsaredesignedtooperatesatisfactorilyoverarangeof±10percentofthestandarddesignvoltage.

ELECTRICAL WIRING

All electrical wiring connecting to the unitshouldbemadeofcopper. All wiring must be installed in accordancewithappropriatelocalandnationalelectricalcodes, andwill require a circuitbreaker orfusestoprotectthemainwiringrunfromthefinaldistributionsub-boardtotheunit. According to specific model and/or option

selected, field wiring connections willrequireeitheroneortwosupplyconductorsinparallel.EachSMARDTChilleris providedwitha 3pole power distribution block or busbarsystem, splitting field supply main powerintomultiplesecondarycircuits.

Groundlugsarelocatednexttofieldwiringterminalsforequipmentgrounding.Minimum required bending space atterminals and means for strain relief ofsupply conductors, shall be provided byinstallation contractor to prevent leadsseparating from their terminations, orsubjecting them to damage from sharpedges.All electrical wiring connecting to the unitshallonlybemadeofcopperand shall be

shieldedand grounded. It isassumed thatsupply conductors rated 75 C (167 F) willbeusedindeterminingthesizeofterminals.The main power input connection for theSMARDTrangeofchillers is asinglepointtermination via a main termination box(suppliedasstandard)oneachchillerunit. All power wiring from this point on, is theresponsibility of the installation contractor.From the main termination box, eachcompressor control box (power and

controls) is pre-wired to the individualcompressors. All wiring must be installed in accordancewithappropriatelocalandnationalelectricalcodes, andwill require a circuit breaker orfusestoprotectthemainwiringrunfromthefinaldistributionsub-boardtotheunit.



Operation

________________________________________________________________________________


DESCRIPTION OF OPERATION

CHILLER CYCLE

Controls Cooling Cycle Operation:

WhentheSMARDTchillercontrolsystemissetto“HVAC_COOL”mode ,indicatingthechilleristo beused to control the leaving chilledwatertemperature (LCWT) to a desired value, thefollowingdescriptionofoperationistrue:EVAPORATOR DESCRIPTION

Whenthechillerisoperatedincoolingmode,thecondensed liquid refrigerantexits theelectronicexpansion valve (4) Figure 7, and enters the

bottom of the flooded evaporator, where it isevenly dispersed along the length of theevaporator bythe use ofadistributorplate (3).Liquid refrigerant inside the evaporator at lowpressure then makes contact with the coppertubes that the building’s water runs through,exchangesheattotherefrigerant,andvaporizesit(2)atthesuctionpressureof thecompressor(1).Asaresultofthelowerdensityofthevaporandthesuctionofthecompressor,thevaporizedrefrigerant gas is then drawn to the top of theevaporatorthroughthemisteliminators(5).(Mist

eliminators inhibit minute liquid particlesentrained in the vaporized refrigerant, fromentering the compressor). Passing through the(pre-rotation)inletguidevanes(6),thevaporizedrefrigerantthen enters thecompressorinlet (7),where the angleof incidence of the refrigeranthittingthefirststageimpeller,isaltered,therebyallowing a higher compression efficiency for agivencompressorrotorspeed.

Figure7:EvaporatorRefrigerantFlow

COMPRESSOR DESCRIPTION

SMARDT oil free chillers exclusively useTurbocor variable speed magnetic bearingcompressors(Figure8)onallchillers.AlloftheTurbocor compressorsarea two stage design,meaning the compression of the vaporrefrigeranttakesplacethroughtwoimpellers.

Figure8:TurbocorCompressor-ExternalViewThe refrigerant enters the suction side of thecompressorasalow-pressure,low-temperature,super-heated gas - ref Figure 9, (1). Therefrigerant gas passes through a set ofadjustable inlet guide vanes (IGV) (2) that are

3

5

6

7



Operation

________________________________________________________________________________


used tocontrol thecompressor capacityat lowloadconditions.The first compression element that the gasencountersisthefirst-stageimpeller(3),andthecentrifugal force produced by the rotating

impeller results in an increase in both gasvelocity and pressure. The high-velocity gasdischarging from the impeller isdirected to thesecondstageimpeller(4)throughde-swirlvanes(5). The gas is further compressed by thesecond stage impeller and then dischargedthroughavolute(6)viaavane-lessdiffuser(7).(Avoluteisacurvedfunnelincreasinginareatothe discharge port. As the area of the cross-sectionincreases,thevolutereducesthespeedof the gas and increases its pressure.) Fromthere, the high-pressure/high temperature gas

exitsthecompressoratthedischargeport(8).

Figure9:TurbocorCompressorCrossSection

Figure10:PressurevEnthalpyCapacity control on SMARDT chillers isachievedbyvaryingthespeed,inletguidevaneposition,andnumberofoperatingcompressors.Figure11providesagraphicalrepresentationofthe centrifugal compressor’s response todemandandoperatingconditions.

Rotating

Speed

Control Only

C o n d e n s i n g T e m p e r a t u r e ( ˚ C )

IGV

Control

+

Speed

Control

Inlet Guide Vane + Hot gas + Speed Control

Refrigerating Capacity (%)

100%80%60%40%20%

20 C

30 C

40 C

50 C

60 C

Figure11:GraphicRepresentationofCapacityControl

3

2 4

5

7

1

6

8



Operation

________________________________________________________________________________


CONDENSER DESCRIPTION

Superheated refrigerant from the compressorentersatthetopofthecondenserbarrelwhereitis dispersed by a deflection plate. As therefrigerant is moving around the tubes in the

condenser, heat is being constantly removedfromtherefrigerantanddissipatedtothecoolingwater that is moving through the condensertubes.HOT GAS VALVE CONTROL

The hot gas valve provides the followingfunctionality:

Capacitycontrolatlowload.

Assistedpressure ratio relief for starting

newcompressors.

Head pressure relief for heat pump andaircooledchillersoperatingabovedesignconditions.

Low Load Capacity Control Functionality

Hot gas control of leaving water temperature(LWT) is a last resort method of control whenspeedcontrolandinletguidevanecontrolisnolongeranoption.Thehotgasvalvecontrolusesthecompressor’sIGV%surge.Chokeandactual

rpmdeterminewhentousethehotgasvalveforcapacitycontrol.The set point for the hot gas control is adifferential temperature below the leavingtemperature set point. By using a differentialtemperature, the hot gas control set pointautomatically adjusts with a change in supplytemperaturesetpointforthechiller,suchthatitis easy to implement alongside set point resetstrategies. AsthediagraminFigure11shows,thehotgasvalve is only used once the compressors haveusedupallspeedand IGV controlenvelopes.Ifthechiller’scapacitymustbeincreased,andthehotgasvalveis in the openposition, the valvewill close before adjustment is made forincreasedcompressordemand.

It should be noted that the hot gas capacitycontrolofSMARDTaircooledchillers,onlytakesplace when the last compressor is operating.The chiller control system makes best use of

compressor stagingbefore resorting tohot gascontrol. Under normal air conditioning loadswheretheoutsideair temperatureand theheatloadappliedtothechillerarecloselyrelated,itisnot uncommon for the hotgas capacitycontrolvalvenevertobeused.Assisted Pressure Ratio Relief

Major reasons forrequiringpressure ratio reliefwhen turning on one or more additionalcompressors within a refrigerant circuit where

compressorsarealreadyoperating,are:• Toavoidrapidrotordisplacement-which

isaninherentweaknessofallcentrifugalcompressors which do not incorporatepressureratiounloading.To reduce the potential of rotatingcomponentdamage.High dynamic forces can impacttraditional bearing technologysignificantly.Withtheincorporationoftherevolutionary magnetic bearing designused in the Turbocor compressor onSMARDT chillers, the potential forrotating component damage is greatlyreduced, in that shutdown can occurbeforeanysurfaceimpacttakesplace.

• Instability,asthecompressorovercomesthesystempressureandbeginstoopenthedischargecheckvalve.Thedangerofholdingrampupconditions

without flow, for an extended period of

time:

– All energy transferred to thecompressor, has no outlet, andresults in high internaltemperatures.



Operation

________________________________________________________________________________


– Large sudden amperage spikesontheinvertercanbedangerous,duetolowthermalinertiaonInertGateBy-polarTransistors(IGBT).Thehighertheheadthatmustbeovercome, the higher the

amperagespikes.

Control Strategy

Theassistedhotgasbypassstartupisenabledwhenever the chiller enters the “STAGE UP”mode,andthepressureratiocalculatedfromthehighest discharge pressure and lowest suctionpressure of all compressors online, isabove aconfiguredlimitdefaultpressureratioof2.2.

If hotgaspressureratio assistance is required,the hot gas valve is forced open at 1% persecond,untilthepressureratioisreducedbelowthe limit at which the next compressor is startenabled.Oncethenewcompressorhasstartedand is runningwithin 10% of the speed of theother compressors, the hot gas valve isclosedslowlyatarateof0.5%persecond.

Return Water Control

Occasionally, insteadofsupplying chilledwatercontrol,SMARDTchillersareselectedtoprovidereturn water temperature control in a plant.Return water temperature control allows theleaving chilled water set point to automaticallyfloat with the actual building load. Runninghigher leaving chilled water temperatures

permits a higher chiller performance – anefficiency increase of approximately 3% per0.5°C(1°F)increaseinsetpointispossible.Selecting “HVAC_RET” mode on the chiller’sgraphicaltouchpadinterfacewillenablecontrolfromthereturnwatertemperature.Allalarmandfaulttrippointsareactiveinthismode,andextracare must be taken when selecting a returnwater temperature to run, to avoid driving thechiller into low suction pressure or low leavingchilled water faults. SMARDT suggests a set

pointof10°C(50°F)to15.5°C(60°F).



Chilled Water System _____________________________________________________________________________


CHILLED WATER SYSTEM

EVAPORATOR WATER CIRCUITS

Chiller performance and efficiency can beadversely affected by contaminants in thewatercircuits,andsuchcontaminantscouldimpede or block the flow of water throughthecircuitorreducetheperformanceoftheheatexchanger.Strainersshouldbelocatedontheinletsideoftheevaporator,returnwatertothechillermustbeconnectedto thelowerconnectionof the evaporator, and all external waterpiping must be cleaned or flushed beforebeingconnectedtothechillerset.

Water circuits should be arranged so thatpumps discharge through the evaporatorandarecontrolledasnecessary,tomaintainessentially constant chiller water flowsthroughtheunitatallloadconditions.To ensure the chiller’s performance andlongevity, air must be purged from bothwaterboxesontheevaporator,andfromtheentirewatercircuit.CHILLED WATER PUMPS

Make all connections prior to filling withwater.Runapreliminaryleakcheckbeforeinsulating the pipes and filling with water.SMARDT recommends consultingauthorities in order to be compliant withlocalbuildingcodesandsafetyregulations. Additionalconsiderations,asfollows,shouldbemadewhendesigningthepipingsystem:

All piping systems should include

temperatureandpressuremeasuresat the evaporator. Make these

connectionspriortofillingwithwater.

Water pressure should be

maintained throughout the system.

Install regulating valves or

comparable pressure maintenance

devices.

The piping system should be

designedwithaminimumnumberof

elevationanddirectionalchangesin

order to minimize system pressure

drop.

Toprohibitdebris fromentering the

pump,astrainershouldbeinstalled

at thewatersupply line,andahead

of(before)thepump.

Pipingmade toand from the chiller

water connections and pressure

reliefvalves,mustbemadeinsuch

a way that weight and strain is

removed from the chiller

connections.Allchilledwater

piping attached to chiller

connections, should be adequately

insulated. Strainers with 20 mesh

filters,shouldbeinstalled

upstreamoftheevaporator.

Adequatevalvingshouldbesupplied

topermit drainingofwater fromthe

evaporator.

Installvibrationeliminatorstoreduce

vibration transmission to the

building.

Installair valvesat the systemhigh

points and drain valves at the

system low points. Additionally,

shutoffvalvesshouldbeinstalledfor

unitservicing.





Protect water from freezing by

insulatingwaterpiping.Ensurethere

is a vapor barrier on theoutsideof

the insulation, in order to protect

from pipe condensation within theinsulation.

Note: If glycol or propylene is added forfreezeprotection,thiswillcauseapressuredrop, whichmay then result in the loss ofperformance. Only use glycol with factoryapproval.WATER VOLUME

When designing the chilled water system,consider:

Theminimumcoolingload.

Theminimumplantcapacityduringa

lowloadperiod.

The desired cycle time for the

compressor.

Ifthechillerplanthasa reasonableturndown, the water volume should

be two to three times the chilled

water gpm flow rate. If the system

components do not provide the

required water volume, add a

storagetank.

VARIABLE WATER FLOW

A large rangeofSMARDTchillersarewellsuited to installations where the chilledwater and condenser water flow rates arechanged in the chiller, relative to theinstantaneous building load and outdoorconditions.WhenapplyingSMARDTchillersto variable volume (variable speed)pumping applications, the designer mustmake sure SMARDT’s design parametersaremetasfollows:

1. Thatwaterflowshallnotbealtered

atarategreaterthan10%per

minute.

2.

That the water flow rates shall notexceed themaximumandminimum

flowsdetailedinthechillerselection

sheet.

Variablespeedpumpingisadesignfeatureof the SMARDT air-cooled chiller, whichreduces the water flow through theevaporator as the load decreases. Thisfeature will function successfully if thedesign and minimum flow rates are notexceeded.Checkindividualratingsheetsformaximumandminimumflowrates.OPERATING LIMITS

Maximum standby ambient

temperature=54 C(130 F)

Maximum operating ambient


Minimum operating ambient

temperature(standard)=3 C(38 F)

Minimum operating ambient

temperature (operational low-

ambientcontrol)=-10 C(14 F)

Leaving chilled water temperature

(LCWT) = 3 C to 16 C (38 F to

60 F)

Operating ΔT = 3K to 9K (6 F to

16 F)

Maximum operating inlet fluid


Maximum startup inlet fluid






Maximum non-operating inlet fluid


FLOW SWITCH

Aflowswitchfor thechilledwatersystemisnecessarytoensureadequatewaterflowtotheevaporatorbeforestartingtheunit.Priortostartingtheunit,andtoensureadequatewaterflowtotheevaporator,itisnecessarytoinstallaflowswitchforthechilledwatersystem. A flow switch will guard againstpossible evaporator freezing, should waterflowbeinterrupted.Theflowswitchistobefieldinstalledinthechilledwaterpipingandwiredtothecontrolpanelbythe installationcontractor.

HIGH PRESSURE LOW PRESSURE

SWITCHES

The High Pressure (HP) & Low Pressure(LP) switches provide an additional safetyfeature, which prevents overpressure or

waterfreezing.Thecut-offpressuresfortheHPandLPswitchesareasfollows:

HP:1586kPa(230psig)(≈60 C/140 F),

reset at 1276 kPa (185 psig) (≈ 52 C /

125 F)(installedondischargeheader)

LP: 179 kPa (26 psig) (≈ -1.7 C / 29 F),

resetat345kPa(50psig)(≈12.2 C/54 F),(installedon theevaporator,except for lowambient/glycol applications, where the LPswitchisnotinstalled).

RELIEF VALVES

Ensurereliefvalvesventoutsideabuildingin accordance with national safetyregulations and jurisdictional requirements.

Concentrations of refrigerant in enclosedspaces can displace oxygen and lead toasphyxiation. Do not displace any safetydevices.

RELIEF VALVE CHARACTERISTICS

ThefollowingtablegivesSMARDTPressureReliefValveparametersforthenotedchillermodel.

RefertoSMARDTspecificationforothermodelspecificvalues.

SMARDT Pressure Relief Valves

EVAPORATOR

Dualreliefvalves(2)Setpressure1310kPa(190psig)

TAG DischargeRates(Cr)minkg/min(lbs/min)

Outletsize(NPT)

AA031.1BXX.44N 8.7 (19.1) 19 mm (3/4

")

Table4:PressureReliefValveParametersSMARDT Air Cooled chillers are suppliedwithdualpressurereliefvalvesmountedontheevaporator.Thevalvesareconnectedtoa changeover manifold. Using a commonbody chamber that serves as the base for

twoindependentreliefvalves,asystemcanremain fully operational when valves needtobeservicedandreplaced.





All pressure relief valves on SMARDTchillers have been sized, selected andsupplied in accordance with ASHRAE 15and the ASME unfired pressure vesselcode.AlldischargeratesarecertifiedbytheNationalBoardofBoiler

andPressureVesselInpectors.RELIEF VALVE APPLICATION

The ASHRAE 15 Safety Standard forRefrigeration Systems provides guidelinesfor sizing refrigerant relief valves and ventpiping. Without attempting to provide acomplete and thorough interpretation, thisdocument provides the necessary data toproperlydeterminepipingrequirements.

VENT LINE SIZINGPiping. ASHRAE 15-2004, Section 9.7.8outlines acceptable relief piping locationsand sizing. Summarized, the relief pipingshould vent R-134a refrigerant at least 15feetabovegroundlevelandatleast20 1feetfrom any window, ventilation opening, orbuilding exit. The discharge piping shouldpreventadischargedrefrigerantfrombeingsprayed directly on personnel and preventforeignmaterialordebrisfromenteringthepiping. Additionally, discharge piping for afusible plug or rupture disc shall haveprovisions to prevent plugging the pipe intheeventofadischargebytheplugordisc. As indicated in SMARDT InstallationInstructions (Form 160.73-N1), each ventlinemust contain a dirt trap in the verticalsection to allow collection and removal forany stack condensation or debris. ThepipingMUSTbearrangedtoavoidstrainonthe relief valves – SMARDT recommendstheuseofaflexibleconnector .Theventline

should be sized in accordance with ANSI/ASHRAE 15, and local codes, butshouldneverbesmallerthanthereliefvalveoutlet sizes provided in specific chillerdocumentation.Common Header

. ASHRAE 15 section9.7.8.4allowsformultiplereliefdevices(on

thesameormultipleunits)tobeconnectedintoacommonlineorheader.Thesizingofthe common discharge header and ventpiping for relief devices - expected tooperatesimultaneously-shallbebasedonthe sum of their outlet areas, with due

allowance for the pressure drop in alldownstreamsectionsandback-pressure resulting from thedischargeofmultiplereliefdevices.

Maximum Length. ASHRAE 15 section9.7.8.5 and Appendix H define themaximum length of discharge pipingdownstreamofthepressure-reliefdeviceas:

f

P P d

fC

P P d

Lr 6

)/ln()(2146.0 20

2

2

2

2

0

5

[feet]Eq.(2)a

f

P P d

fC

P P d L

r 500

)/ln()(104381.7 20

2

2

2

2

0

515

[meters]Eq.(2)bWhere:L=equivalentlengthofdischargepiping,m

(ft)Cr= rated capacity as stamped on thedeviceinkg/sec(lb/min)f= moody friction factor in fully turbulentflowd= inside diameter of pipe or tube, mm(inches)ln=naturallogarithmP2= absolute pressure at the outlet ofdischargepiping,kPa(psia)P0=allowedbackpressure(absolute)attheoutletofpressurereleasedevice,kPa(psi)

= (0.15 x relief valve set pressure +atmosphericpressure)The ASHRAE15usersmanual states thatwhen the length of the vent pipe exceedsapproximately 220 diameters (L/d > 220),thefirstterminequation(2)aor(2)bmaybeusedtosolveforthediameter,d.





2.0

2

2

2

0

2

36.1 P P

fLC d r [inches]Eq.(3)a

2.0

2

2

2

0

2

2521

P P

fLC d r [millimeters]Eq.

(3)b Anaveragefrictionfactorf=0.02,maybeusedwhenthepipesizeisnotknown.Thissectiononthedischargeventlineistobe used as a guide only. For a completedescriptionof the relief valve vent line sizing, pleaserefer to ASHRAE Standard 15 or localoverridingcodes.

1CSAB-52requires25’fromanyopening.



Controls

_______________________________________________________________________


CONTROLS

CONTROLS WIRING

Figure12:G3ControlsWiringDiagram – OpticalIsolatedConverter – G3TouchPanel



Controls

_______________________________________________________________________


CONTROL PANEL WIRING

Figure13:ControlPanelWiringSchematic – 460V/575V



Controls

_______________________________________________________________________


ControlPanelWiring(cont’d)

Figure14:ControlPanelWiringSchematic(cont’d)– 460V/575V



Specifications

______ _________________________________________________________________


SPECIFICATIONS SMARDT AIR COOLED CHILLERS

GENERAL

1.1 SUMMARY

This Section includes design,performance criteria, refrigerants,controls, and installation requirementsforaircooledcentrifugalchillers.1.2 REFERENCES

Complianceiswiththefollowingcodesandstandards: ARI550/590NEC

ANSI/ASHRAE15 ASMESectionVIIIETLListed ANSIUL1995CSAC22.2No.236(Canada)OSHAasadoptedbytheState

1.3 SUBMITTALS

Submittalsshallincludethefollowing:

A. Dimensioned plan and elevationdrawings, including required serviceclearancesandlocationofallfieldpipingandelectricalconnections.B. Electrical and water qualityrequirements during operation, standbyandshutdown.C. Control system diagram showingpointsforfieldinterfaceandconnectionto external BMS systems. Drawingsshallshowfieldandfactorywiring.

D.InstallationandOperationManuals.E. Manufacturers certified performancedataasperAHRIatfullloadandIPLVorNPLV.

1.4 QUALITY ASSURANCE

A. Regulatory Requirements:Compliance with the standards inSection1.2.1.5 DELIVERY AND HANDLING

A. Chillers shall bedelivered tothe jobsite completely assembled (unlessotherwisespecified).

B. Compliance shall be with themanufacturer’s instructions fortransportationandrigging.

1.6 WARRANTY and MAINTENANCE

A. The chiller manufacturer’s warrantyshall be for a period of one year fromdateofequipmentstartupor18monthsfrom the date of shipment, whicheveroccursfirst.B.Thewarrantyshall includepartsandlaborcostsfortherepairorreplacementofpartsfoundtobedefectiveinmaterialorworkmanship.C.Maintenanceofthechillerequipmentwhileunderwarranty,ismandatoryandshall be the responsibility of thepurchaser, unless supplied by themanufacturer.Optional:

1. Extended chiller parts and laborwarranty.

2. 2-5-yearcompressorpartsandlabor.

3. 2-5 year chiller parts and laborwarranty.



Specifications

______ _________________________________________________________________


PRODUCTS

2.1 ACCEPTABLE MANUFACTURERS

A.SmardtInc.

B. Approved Equal. Note approvedequal does not automatically imply thealternate product matches thisspecification, functionality or deliveredquality.2.2 PRODUCT DESCRIPTION

A. Provideandinstall asshownon theplans, a factory assembled air-cooledpackagedchiller.

B. Eachunit shall includeone ormoreTurbocor oil-freemagnetic bearing andvariable-speedcentrifugalcompressors.Integratedvariablefrequencydriveshalloperate with inlet guide vanes tooptimize part load efficiency. ChillersshalloperatewithHCF-134arefrigerant- not subject to phase-out by theMontreal Protocol and the U.S. EPAcleanairact.C. The evaporator, condenser, andexpansion valve shall be configured tooperate as a single refrigerant circuitunless otherwise specified. The chillerunit compressors shall bedesigned formechanical and electrical isolation tofacilitateserviceandremoval.

2.3 DESIGN REQUIREMENTS

A. Unit shall consist of one or moremagnetic bearing oil-free centrifugalcompressors with integrated variablefrequency drive, refrigerant flooded

evaporator, air cooled condenser, andoperating controls with equipmentprotection.B. Performance: Refer to schedule forspecific operating conditions. Whenutilizing Turbocor model TT300compressorsthechillershallbecapable

of stable operation down to 20 tons.When utilizing Turbocor model TT350compressors, the chiller shall becapableofstableoperationdownto35tons.All these ratingsaremeasuredatstandard AHRI entering condenser

watertemperaturesandwithoututilizinghotgasbypass.

C. Acoustics: Sound pressure for theunitshallnotexceed83dBA,measuredat1meter(3.28ft).Sounddatashallbemeasured according to AHRI Standard370.

Global 63 125 250 500 1k 2k 4k 8k

D. Chiller shall beequipped for single-pointpowerconnection.2.4 CHILLER COMPONENTS

A.Compressors:

1. Compressors shall be of semi-hermeticcentrifugaldesignandoperateoil-freewithtwo-stagesofcompression,magnetic bearings,movable inlet guidevanesandintegratedvariablefrequency

drivesystem.2. Automatically positioned andcontrolled inlet guide vanes shalloperatewithcompressorspeedcontrols.3. The compressor shall be capable ofcomingtoacontrolledstopintheeventof a power failure. The unit shall becapable of initializing an automaticrestartinthecaseofpowerfailure.

4. Each compressor shall haveintegrated microprocessor controlcapableofcapacityandsafetycontrol.5. Each compressor shall be installedwith individual suction, discharge andmotor cooling refrigerant line isolationvalves. Chillers without discharge lineisolation valves that rely on non-return



Specifications

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valves in the discharge line forcompressor removal, shall not beaccepted.6. Each compressor shall have anindividualdisconnectswitch.Onchillers

that are provided with more than onecompressor, each compressor shallhavemechanicalandelectrical isolationto allow the chiller to operate when acompressorisremoved.Optional:

1. EMI filters installed for eachcompressor.B.Evaporator:

1. Evaporator shall be shell-and-tubetypeandshallbedesigned,constructed,tested and stamped according to therequirements of the ASME Code,Section VIII Code Case 1518-5.Refrigerant shall be in the shell andwaterinsidethetubes.Thewatersidesshallbedesignedforaminimumof150psig or as specified. Vents and drainsshall be provided. The refrigerant sideshall bear the ASME Code stamp.Vesselsshallpassatestpressureof1.1timestheworkingpressurebutnotlessthan 689 kPa (100 psig). Provideintermediate tube supports spaced toenableequalliquidandgasflowacrossmultiple compressor suction ports. Theevaporatorwaterconnectionsshallalsobeequippedwithright-handor left-handconnection,interchangeable.

2.Aperforatedplatedesignedforvapordisengagementshallbe installed insidethe evaporator above the tubing, to

ensure effective liquid droplet removal,to prevent liquid damage tocompressors, and to equalize suctionpressure across evaporators withmultiplecompressors.3.

Tubes shall be individuallyreplaceable and have internally and

externally enhanced surfaces designedfor refrigeration duty.Tubes shall havesmooth full tube wall landings at thetube-sheet ends and at intermediatetube supports. Tubes shall bemechanically roller expanded intosteel

tube sheets containing a minimum ofthreeconcentricgrooves.4. Minimum evaporator exiting watertemperature shall be 3.3°C (38°F).Minimum entering condenser airtemperature shall be 0°C (32°F).Minimum inlet condenser air to outletchilledwaterdifferenceshallbe-11.1°C(12°F).5. The evaporator, including chilled

water boxes, compressor suction line,compressor end bell, and all othercomponents, subject to condensingmoisture, shall be insulated with ULrecognized¾inchclosedcellinsulation. All jointsand seams shallbe sealed toformavaporbarrier.Optional:

1. Marinewaterboxes.

2. Epoxy-coating of inside surfaces ofwaterboxesandtubesheets.

3. Water sidevessel design for of 300psioperation.

4. Double insulation, 1½ inch, onevaporator,waterboxes,suctionpiping.

C. Air-CooledCondenser:

1. Air cooled packaged chillers andcontrols shall be capable of reliable

operation between 0°C (32°F) and40.6°C(105°F)ambientairtemperature.2. Air-cooled condensers shall utilizemill-coated hydrophilic-blue aluminumfinswithrefrigerationdutycoppertubesmechanically expanded into fin collars.Condenser coilsshallbearranged ina



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W-configuration to reduce equipmentfootprint.3. Condenser coils and fans shall bearranged such that one fan operateswithonecoilsectionsothatthefailureof

afanwillnotaffecttheCFMacrossanycoil beyond that fan. The standardcoating shall meetASTMB117 2000hrsaltspraytest.4.Thecondensershallbeequippedwithanoversizedliquid lineandmechanicalfloat to ensure liquid sub-coolingnecessary for effective cooling of thecompressor.5.Thecondensershallbeequippedwith

packaged fixed or variable speed fanscapable of delivering specified CFM ofairaccordingtoARIstandardoperatingconditions.Thefanmotorsshallbehighefficiency, direct drive, 3-phase,insulation class “F”, current protected,Totally Enclosed Air Over (TEAO),double sealed and with permanentlylubricatedballbearings.6. The fans shall be low sound. Theyshall be balanced dynamically andstatically and direct drive. Also, theblades shall be corrosion resistantdesignedfor lownoise, full airfoil crosssection, providingvertical air dischargefromextendedorifices.Theguardsshallbeconstructedofheavyduty14gaugesteelandpainted.Optional:

1. The coating system for HVAC coilcorrosion resistanceprovidesa lifetimeprotection against micro-organism

contamination that causes unwantedodors,andshallpassa10,000hoursaltspray test. Next to anti-corrosionprotection and energy conservation ofthe total system, the coating shallprevent adhesion of dirt and growth ofmicro-organisms,andshallalsoprevent

chemical, galvanic, and microbialcorrosion.

2.Lowambientkitshallallowoperationdownto9.4°C(15⁰F).

D.RefrigerationComponentsLiquidLevelControls:

1.

Controlofrefrigerantflowshallutilizeasingleormultiple6,000stepelectronicexpansionvalve(EXV),tooperatewithinthefullrangefromfullloadtothelowestloading capacity for the chiller. Fixedorificemeteringdevicesorfloatcontrolsusing hot gas bypass are not

acceptable. The EXV liquid line shallhave a sight glass with moistureindicator and temperature sensorconnected to the control system forvalidationofsub-cooling.2.Thecondensershallbeprovidedwithacapacitivetypeliquidleveltransducerwitha resolutionofnot less than 1024discretesteps. The transducer shall bewired to the chiller control system.Condenser liquid level measurementshallbeusedintheelectronicexpansionvalve controlalgorithmwith aminimumlevelsetpointtoensureadequateliquidseal ismaintained inthe condenser, toprovide compressor motor coolingduringoperation.Condenserliquidlevelshall be clearly displayed on thegraphical operator interface in aminimum of two screens. Chillerswithout direct level measurement areprohibited,duetopossibleoverheatingdamagethatmayoccurincompressorswhenliquidsealislost.

3. Each compressor shall be installedwith individual suction, discharge, andmotor cooling refrigerant line isolationvalves. Chillers without discharge lineisolation valves that rely on non-returnvalves in the discharge line for



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compressor removal, shall not beaccepted.4. To prevent unit operation with nowater flow, factory mounted and wiredthermal dispersion water flow switches

shallbeprovidedonthecondenser.5.Thecondensershallbeequippedwitha mechanical stainless steel float forelectronicactuationoftheEXV,soastoprovide a positive liquid seal toensureeffectivecoolingofthecompressor6.Theevaporatorshallbeprovidedwithspring loaded reseating type pressurerelief valves, in accordance with ASHRAE-15. Rupture discs are not

acceptable.7. Load balancing valves shall beprovided for capacity control andadditionaltemperaturestability.8. There shall be a backup superheatcontrolontheinletofthecompressor,inordertocontroltheEXVintheeventofafailure of the primary level sensingdevice.E.PrimeMover:

1. A permanent-magnet, synchronoushermetically sealed motor of sufficientsize to effectively provide compressorhorsepower requirements. The motorshall include soft-start capabilities withan in-rush current of no more than 2amps (TT300 models) and 4 amps(TT400 models). The motor shall beliquid refrigerant cooled with internalthermal overload protection devicesembeddedinthewindingofeachphase.

2.Thecompressormotorandchillerunitshall include variable frequency speedcontrols tomatchcooling load demandto compressor speed and inlet guidevaneposition.

3. Each compressor shall be equippedwith an AC line reactor and individualdisconnect.F.ChillerFrame&Housing

1. All components shall be mountedonto a unitized construction, having agalvanized welded steel frame suitableforoutdoorinstallation.2. Compressors and controls shall becontained within a sheet metalenclosuretoprotectcriticalcomponentsfromtheweather.G.ChillerControls

The controller fitted to the oil-freecentrifugal chiller package shall be anembedded real time microprocessordevice that utilizes control softwarewritten specifically for chillerapplications. User operation shall beaccomplished using a panel mountedcolortouch-screeninterface.Thestatusof the compressors and all systemparameters, including compressoralarmsandtemperaturetrends,shallbeviewable.G1.Thechillercontrolsystemshallhavethe capability of storing one year ofoperationaldata.Nolessthan60pointsof information shall be sampled at amaximumof15minuteintervals.G2.Thechillercontrolsystemshallhavefullwebbasedremotecontrolcapability;including the capability of remoteoperationandsoftwareupdates.Controller features must include the

following:

1. Selectable control mode – leavingchilledwater, entering chilled water, orsuctionpressurecontrol.2.

10.4-inch or 12.1-inch or 15-inch,65,000 colors, touch panel operator



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interface operating windows XPembedded.3. Chiller documentation shall beviewableviatouchpanelinpdfformat.

4.

Operatorinterfaceshallbecapableofconnecting directly to compressors viaserial communication protocol anddisplay compressor information usingTurbocor compressor monitoring /commissioningsoftware.5. Chiller control panel shall contain aminimumofthreeprocessors;allcontrolfunctionality shall be carried out on adedicatedreal timeprocessoranddataserved to a remote graphical user

interfaceviaanopenEthernetprotocol.Proprietary protocols between any pcbased or micro based processor arestrictlyprohibited.6. ChillercontrolsshallbenativeBacNetcapable via MSTP or IP. Addition ofgateway devices or additionalprocessors or pluggable PCBs toachieveBacNet communications to theBASisstrictlyprohibited.7. CompleteconfigurationofnativeBAScommunications via Modbus RTU,Modbus TCP/IP, BacNet MSTP andBacNet IP shall be made via standardchillercontrollergraphicaluserinterface.Chiller controls that utilize externalsoftwareconfigurationtoolstoconfiguretheseprotocolsareexplicitlyprohibited.8. Chiller control shall be capable ofcontrolling up to eight Turbocorcompressors on up to eight individualrefrigerant circuits serving the same

chilledwaterstream.9. Chiller control panel user interfaceshallbecapableofremotecontrolviaaninternet connection without the use ofany third party gateway device oradditionalhardwareorsoftware.

10. Chiller control shall be capable ofoperating in headless mode (no touchpanel connected) and utilize standardwindows XP or higher computer todisplay user interface via Ethernetconnection.

11. Real time chiller control processorshall be capable of e-mailing apredefined list of recipients, should afault occur. E-mail shall include detailsof fault, possible reason for fault,attachmentofmonthlydatalogof195ormore compressor and chiller variables,andataminimumintervalof30secondsandwithindicationofseverityoffault.12. Ability to place all outputs in a

manual state (hand, off, auto) viagraphicaluserinterface.13. Alarm screen shall be capable offiltering faults into specific categoriessuchascompressor,chillerandsystemfaultsinordertoproviderapiddiagnosis,andseparationoffailuremodes.14. Variable speed cooling towercontrol.15.

Optional variable speed condenserwaterpumpingcontrol.16. Optional ability to turn on/off dutystandbychilledwaterpumps.17. Optional ability to turn on/off dutystandbycondenserwaterpumps.18. Optional ability to operate chillerisolationvalvesforbothevaporatorandcondenser.

19.

Multiple compressor stagingalgorithmshalloperateattheoptimizedpower curves of each compressorsimultaneously, and shall resetautomatically every second duringoperation.Compressorstagingmethodsthat operate using simple incremental



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percent of demand shall not beaccepted.20. Continuous data logging foroperational trending and bin analysisshallbeexportableto“CSV”format.(12

monthsdatastored).21. EmbeddedWebandFTPserverstoenable remote encrypted control, logdownload,softwareversionupload,andoperationalmonitoring.22. Built-in stepper motor controls forEXVs.23. Controlslockupprotection.

24.

Ramp rate control - Peak energydemandlimitingalgorithms.25. Three levels of alarm safety forminimumchillerdowntime.26. Chillercontrolsoftwareshallemployan active fault avoidance algorithm toreduce chiller capacity and/or powerlevel in the case of the chillerapproachingwithin10%ofanytriplimitvalue such as suction pressure,discharge pressure, chiller amp limit,leaving chilled water temperature limit,etc...27. Store up to 32,000 alarm and faulteventsstoredwithdate/timestamp.28. Realtimedatatrendingviewableviatouchpanel.29. Chiller load profile charts viewableviatouchpanel.

30.

Chiller control graphical userinterfaceshall be capable of displayingdata inSIor I-P unitswithoutaffectingcontrolorBASprotocolunits.

Optional:

1. BMS interface module for theinterfacewith BacNETMSTP, BacNETIPorLonTalkFT10isstandard.

Data on Main Display Screen shall

include:

a) Entering and leaving chilled water

temperatures.b)

Enteringandleavingcondenserwatertemperatures.c)

Currentoperatingstateofchiller.d) Activetimers.

e)

Chillerenablestatus.f)

Chillerwaterflowproofstatus.g)

Condenserwaterflowproofstatus.h)

Indicationofcompressorreadiness.i)

Indicationofclearancetorun. j)

Chillersetpoint.

k)

TotalchillerkW.l)

Totalchillercurrentinput.m)

Three pages of data trends withzoomfunctionality.n)

Graphical dial indicators that clearlyindicate safe and unsafe operatingvalues.o)

Graphical representation ofevaporatorandcondensershowinggasmovementwhenchillerisrunning.p)

Current alarms (announce andmanualresetprovision).q)

Compressor actual rpm, maximumrpm,minimumrpm.



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r)

Compressoralarmdescription&faultdescription.s)

Compressor percentage motordemand.

t)

Compressorsafetyinterlockstatus.u) Compressor modbus communicationhealthstatus.v)

Compressor suction and dischargepressures.w)

Compressor suction and dischargetemperatures.

x)

Compressor internal cooling systemtemperaturesandstatus.y)

CompressormotorkWandamps.z)

Compressorpressureratio.EXECUTION

3.1 INSTALLATION

A. Install per manufacturer’s IOM

documentation, shop drawings, andsubmittaldocuments.

B. Align chiller on foundations ormountingrailsasspecifiedondrawings.

C.

Arrangepipingtoenabledismantlingand permit head removal for tubecleaning.

D.Coordinateelectricalinstallationwithelectricalcontractor.

E. Coordinate controls and BMSinterfacewithcontrolscontractor.

F.

Provideallmaterialrequiredforafullyoperationalandfunctionalchiller.

3.2 START-UP

A. Unitsshallbe field chargedwithant.HFC-134arefrigerant.

B. Factory Start-Up Services: Providefactorysupervised start-upon-site foraminimum of two working days andensure proper operation of theequipment.Duringtheperiodofstart-up,the factory authorized technician shallinstruct the owner’s representative inproper care and operation of theequipment.



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SMARDTCHILLERGROUP.TD – 0081B 46

SmardtInc.,1800TransCanadaHwy,Dorval,QC,H9P1H7,CanadaTel:+15144268989Fax:+15144265757

[email protected]

SmardtChillersInc.,22ColoradoAvenue,Plattsburgh,NewYork,12903USATel:+15144268989Fax:+15144265757

[email protected]

SMARDTChillers(Asia-Pacific)PtyLtd.,144ColchesterRoad,P.O.Box2021,BayswaterNorth,Victoria3153, Australia

Tel:+61397617905Fax:[email protected]

Smardt Oil Free chiller

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