DM KEEP KOOL 903-081 DM E 2-00 28 PAGE - Mircli is at the forefront of R407C development and offers...

K E E P K O O L

Application Guide &System Design Manual

KEEP KOOL SYSTEM Comfort Range

Comfort RangeApplication Guide & System Design Manual2

About Airedale

Airedale participates in Eurovent Certification as a founder member. The EuroventCertification programme verifies product performance by managing independent testingof certified products.

We participate in certification programmes for Air Conditioners, Chillers and Fan Coilunits, which enable consultants, specifiers and End Users to compare and selectproducts with assurance that the catalogue data is accurate.

EUROVENT

All new products are tested by Eurovent before being Certified. For certified productsonly the Eurovent symbol appears alongside the certified product performance data.

THE ENVIRONMENT -R407C – THE NATURALREPLACEMENT FORR22

Protecting the environment is a priority and we take care to ensure our products aredeveloped and manufactured with this in mind. Airedale introduced R407C refrigerantin 1992 and now has the most extensive in-field experience in the air conditioningindustry. R407C is offered on all Airedale products and all new products are developedto provide optimum efficiency with this refrigerant ensuring maximum customer choice.

WARRANTY,COMMISSIONING &MAINTENANCE

Our standard warranty package guarantees all parts for 24 months. Additionalcustomised warranty packages are also available covering either parts only or parts andlabour.

Having chosen your Airedale product, a full commissioning service is now available onall products and is charged on a daily rate variable by location.

To further protect your investment in Airedale products, we have also introduced ourown Airedale Service. This includes nation-wide service cover 24 hours a day, 365days a year, plus regular planned maintenance visits. For a free quotation contact ourAiredale Service or your Local Sales Engineer.

TRAINING As well as our comprehensive range of products, Airedale offers a modular range ofRefrigeration and Air Conditioning Training courses, for further information pleasecontact our Training Co-ordinator.

CUSTOMER SERVICES For further assistance or information please telephone:UK Sales Enquiries .............................Tel: + 44 (0) 113 238 7789 & 7799Contracts Manager..............................Tel: + 44 (0) 113 238 7759Projects Managers ..............................Tel: + 44 (0) 113 238 7770 & 7785Overseas Enquiries .............................Tel: + 44 (0) 113 239 1000Spares Enquiries .................................Tel: + 44 (0) 113 238 7723 & 7727Order Processing Enquiries ...............Tel: + 44 (0) 113 238 7751 & 7788Literature Enquiries .............................Tel: + 44 (0) 113 238 7713Airedale Service...................................Tel: + 44 (0) 113 238 7704, 7746 & 7748Training Enquiries ...............................Tel: + 44 (0) 113 238 7738

AIAC Ltd endeavours to ensure that the information in this document is correct and fairlystated, but none of the statements are to be relied upon as a statement orrepresentation of fact. AIAC Ltd does not accept liability for any error or omission, or forany reliance placed on the information contained in this document.

The development of Airedale products and services is continuous and the information inthis document may not be up to date. It is important to check the current position withAIAC Ltd at the address stated. This document is not part of a contract or licenceunless expressly agreed.

No part of this document may be reproduced or transmitted in any form or by anymeans, electronic or mechanical, including photocopying, recording, or informationstorage and retrieval systems, for any purpose other than the purchaser's personal use,without the express written permission of AIAC Ltd.

2000 Airedale International Air Conditioning Limited. All rights reserved. Printed in the UK.

Comfort Range KEEP KOOL SYSTEM

3Comfort Range

3Application Guide & System Design Manual

Contents

INTRODUCTION Page 4

THE KEEP KOOL SYSTEM Page 5General Statement Page 6

SYSTEM DESIGN STEP 1 – COOLING OR COOLING & HEATING Page 6Option 1 - Cooling Only Page 6Option 2 - Cooling with Remote Heating Page 7Option 3 - Cooling & Heating Page 7

SYSTEM DESIGN STEP 2 – SYSTEM TYPE Page 8Option 1 - Single System Page 8Option 2 - Multi Unit System Page 9Option 3 - Zone Control System Page 10

SYSTEM DESIGN STEP 3 – ROOM / ZONE SUMMARY Page 11

SYSTEM DESIGN STEP 4 – INDOOR UNIT SELECTION Page 12

SYSTEM DESIGN STEP 5 – CHILLER UNIT SELECTION Page 13

KEEP KOOL SYSTEM SIZING Page 14Indoor Units Page 14Selection Example Page 14Outdoor Unit Page 14Water Pipework Page 15Design Considerations Page 15

SYSTEM DESIGN STEP 6 – PIPE SIZING Page 16Keep Kool Pipe Sizing Chart Page 16

SYSTEM DESIGN STEP 7 – SYSTEM ACCESSORIES Page 17Regulating Devices Page 17Measuring Devices Page 18Bypass Valves Page 19Shut Off / Strainer Devices Page 19Controls Page 20

WHERE TO INSTALL THE INDOOR UNITS Page 21

WHERE TO INSTALL THE OUTDOOR UNIT Page 22

PIPEWORK SCHEMATIC LAYOUTS Page 23General Plumbing Page 23Installation Page 23Standard Components Page 23

SELECTION DATA SHEETS



Introduction

Airedale’s range of packaged air conditioning systems are designed to generate a morecomfortable climate in shopping areas, offices, hotels and schools.

KEEP KOOL®PACKAGED SYSTEM

The Airedale Keep Kool packaged air cooled chillers are available in two model ranges.The Keep Kool chillers, for cooling only applications (KKCS) and the Keep Kool heatpump chiller (KKHS) which incorporates both cooling and heating operating modes. Bothmodels are based on a range of fully packaged liquid chillers having integral watercirculating pump, buffer tank (models 15-60) and expansion vessel.

Available in 12 model sizes, this full range of packaged air cooled chillers offer between7.0 – 138.0 kW in cooling mode and 8.0 – 131.0 kW in heating mode.

Both chiller ranges are designed as rugged outdoor units and are compact, weatherproofand quiet. The Keep Kool design concept combines efficient capacity control withminimal refrigerant volumes, fully independent microprocessor controls are standardacross the ranges of efficient, low profile, small footprint outdoor units.

The Airedale range of indoor units includes floor, wall and ceiling mounted fan coilvariants which can be matched to the cooling or heating output of all Keep Kool unitsystems thereby offering maximum flexibility where floor or wall area is at a premium.

The Keep Kool concept is to provide a range of chilled water equipment that can beselected and specified to suit a wide range of applications. Unlike most traditionalcooling systems, the Airedale Keep Kool system retains refrigerant in the chiller only. Asa result, the overall amount of system refrigerant is reduced and the inside of the buildingis left free from any refrigerant making this design an environmentally friendly alternativeto VRV systems.

Airedale is at the forefront of R407C development and offers this as standard across thefull range of Keep Kool chillers.

Keep Kool is a registered trade mark.


5Comfort Range


The Keep Kool System - Overview

Easy to use main controlunitA programmable seven daytime clock that enables theoperation of the chiller.

High Wall UnitsFor installation at high level wherefloor space is at a premium.

Aerovent Fan Coil UnitsThe fan coil unit is available ina horizontal and verticalversions. The vertical unit canbe wall or floor mounted as canthe Concept 2000 unit.

Answer Cassette UnitThe Answer Cassette unit isdesigned for installation in theframe-work of a false ceiling.

Ready to use Chiller UnitBoth the cooling only and heatpump chillers are factory fittedwith the expansion vessel,circulating pump and differentialpressure switch.

Pre sized pipeworkJust follow the designguidelines.

Differential pressure valvefor maintaining the waterflow (2 pipe system)When a majority of the watervalves are closed, the differentialpressure valve will ensure thatthe required flow for the chiller ismaintained.

DESIGN MADE SIMPLEThroughout this system design manualthere is a step by step approachshowing how to design a system to suita particular need.

A worked example shows the ease withwhich a system can be sized. Combinethis with the pre-sized pipework dataand the design is almost complete.

EASE OF INSTALLATION• No need for a refrigeration

installation specialist as all pipingcan be installed by a competentheating installer.

• Easy to install TWO pipe systemleads to quicker and simplerinstallation.

• Pre-sized pipework to suit everycombination of unit.

TECHNICAL FEATURES• Each indoor unit can be fitted with

its own local controls. This provideslocal control of the conditionedspace.

• The use of a TWO pipe systemensures that as the cooling/heatingload on an indoor unit is satisfied,the control valve will close. Theadditional pump pressure providedis then available to provideincreased flow to the indoor unitsthat need it.

• If supplementary heating is required(KKC systems only) then the indoorunits can be fitted with electric orlow pressure hot water heating.



The Keep Kool System

GENERAL STATEMENT This Keep Kool manual is intended to offer the Design Engineer, Consultant, BuildingService Engineer or End User a step by step approach to designing and selecting acomplete Chilled Water system.

Having selected the equipment required additional components such as pipework,controls and valves can be identified and applied where necessary.

Before embarking on a detailed design, there are some fundamental decisions to bemade very early in the selection process.

This manual can be read in conjunction with the “Selection Data Sheets”. Workingexamples of the sheets can be found under System Design Steps 3 – 5 of this manual.Please refer to the appropriate Indoor Unit Technical Manual for capacity details.

SYSTEM DESIGN STEP 1 - Cooling or Cooling & Heating,Selection of Best System

OPTION 1 Does the application require Cooling only in which case a KKCS unit will be required.

COOLING ONLY CHILLER KKCS 2 PIPESYSTEM(COOLING)

INDOOR AHU / CASSETTE

RETURN

FLOW


7Comfort Range


SYSTEM DESIGN STEP 1 - Cooling or Cooling & Heating,Selection of Best System

There maybe a need for heating to be provided by a separate heating system such as aremote boiler, in which case the indoor unit selection will need to be selectedaccordingly. A KKCS chiller will still provide the cooling for this application.

OPTION 2

COOLING with REMOTEHEATING

CHILLER KKCS4 PIPE

SYSTEM(COOLING OR

HEATING)

FLOW

RETURN

REMOTEBOILER

FLOW

RETURN

INDOOR AHU / CASSETTE

Note: Remote boiler to be supplied by others

OPTION 3

COOLING & HEATING

Where a need for cooling and heating is required from the same capital equipment aKKHS unit will be selected to provide cooling when necessary to the indoor units andheating when conditions apply.

It should be noted that the Keep Kool system can only provide cooling to allindoor units and or heating, not both at the same time.

For this reason it is important to try and select all indoor units that require coolingsimultaneously together or conversely all indoor units that require heating at thesame time. This can normally be achieved by zoning the units as detailed later inthis manual.

CHILLER KKHS INDOOR AHU / CASSETTE2 PIPESYSTEM

(COOLING ORHEATING)

FLOW

RETURN

Notes:

1. The above cooling / heating system applies a single reverse cycle heat pump chiller(KKHS) unit.

2. The system design flow rate must be selected in the cooling mode, hence thesystem flow will be the same when switched to the heating mode.



SYSTEM DESIGN STEP 2 - System Type

There are three basic top level systems that can be applied. By following the detailscontained within this manual the necessary decisions can be made in the correct order.

OPTION 1

SINGLE SYSTEM

The Keep Kool single system comprises of one outdoor unit (KKCS/KKHS Chiller)matched to an indoor unit of similar capacity. The circuit is completed by connecting thecorrect size of pipework and supporting valves. A dedicated control scheme controls thissystem which can be either cooling only or cooling and heating.

Single System with2 way valve

Single System with4 way valve

CHILLER UNIT

FILTER-BALL

FILTERMATE

INDOOR UNITS

BYPASS VALVE(ONLY REQUIRED

WITH 2 WAYVALVE)

CHANGE-OVER

THERMO-STAT (KKHSYSTEMS

ONLY)

FILTERBALL

CONTROLVALVE (2 WAY

VALVE SHOWN)CASSETTE / AHU

FILTERMATE

DOUBLEREGULATING

VALVE

CHILLER UNIT

FILTER-BALL

FILTERMATE

INDOOR UNITS

CHANGE-OVER

THERMO-STAT (KKHSYSTEMS

ONLY)

FILTERBALL

CONTROL VALVE 4 WAY VALVE

CASSETTE / AHU

FILTERMATE

DOUBLEREGULATING

VALVE

The above Single System is normally recommended for use with models KKCS / KKHS 3- 11 when applied to Airedale indoor units.


9Comfort Range



OPTION 2

MULTI UNIT SYSTEM

Keep Kool multi unit system comprises of one outdoor unit (KKCS/KKHS Chiller)matched to various indoor units of similar size and capacity. The circuit is completed byconnecting the correct size of pipework and supporting valves. A dedicated controlscheme controls this system which can be either cooling only or cooling and heating.

It should be noted that the indoor units can only be either on cooling and orheating not both at the same time.

CHILLER UNIT INDOOR UNITS

ISOLATINGVALVES

4 WAYVALVE

CASSETTES / AHUS

FILTERMATE

FILTERBALL

The above Multi System is normally recommended for use with models KKCS / KKHS 3 –20 when applied to Airedale indoor units.

Note: The above system type can also be used with 3 way valves if preferred.




OPTION 3

ZONE CONTROLSYSTEM

The Keep Kool zone control system comprises of one or more outdoor units(KKCS/KKHS Chiller) matched to various indoor units of any type, size and capacity.The circuit is completed by connecting the correct size of pipework and supportingvalves. A dedicated control scheme controls this system which can be either coolingonly or cooling and heating.

It should be noted that the indoor units can only be either on cooling and orheating not both at the same time. The zone control system should also beselected using zones requiring only all indoor units on cooling or all on heating.

BYPASSVALVE

BYPASSVALVE

BYPASSVALVE

The above Zone Control System is normally recommended for use with modelsKKCS/KKHS 20 – 60 when applied to Airedale indoor units.

Note: The above system shows each loop fitted with a bypass valve for use with 2 wayvalve systems. If preferred the 4 way valve system can be used.

(Control valves and other system accessories not shown).


11Comfort Range


? SYSTEM DESIGN STEP 3 – Room / Zone Summary

Open Plan Office (Example)

Room/Zone Details:

Length x Width x Height 25 x 10 x 3

Room Volume 750 m³

Windows 1 Quantity 1 Area 7.5 m2

Type S.G. Y D.G.

Room Temperature 24 °C 50 %RH

Summer Conditions 30 °C

Winter Conditions -5 °C

Room/Zone Loads:

Sensible LatentRoom 25 kW(Includes Solar & Conduction)

Lighting 10 kW

Equipment 20 kW

People 2.5 kW 0.5 kW

Infiltration (Fresh Air) 3.5 kW 1.0 kW(Based on 10 l/s per person)

L

W

N

E

S

W

Total Room Load 62.5 kW

Sensible Room Load 61.0 kW

Latent Loads 1.5 kW

Notes:

1. Windows for reference only. Data used in Heat Load calculations. Please also note orientation of room as this has aneffect on solar heat gains.



? SYSTEM DESIGN STEP 4 – Indoor Unit Selection


Duty Loads1:

Cooling 61.0 kW

Heating N/A kW

Unit Type Model / Duty / Quantity / Duty x Quantity

Cassette CACW12 / 6.3 kW 10 / 63 kW

Wall _________ / _________ kW _________ / _________ kW

Floor _________ / _________ kW _________ / _________ kW

Ceiling _________ / _________ kW _________ / _________ kW

Fan Coil (Ducted) _________ / _________ kW _________ / _________ kW

Design Conditions:

Room Temperature 24 °C Humidity 50 %RH

Chilled Water Flow 7.0 °C

Chilled Water Return 12.0 °C

Heating Flow N/A °C

Heating Return N/A °C

Notes:

1. Use sensible room load to select equipment.


13Comfort Range


? SYSTEM DESIGN STEP 5 – Chiller Unit Selection


Total Duty Loads1:

Cooling 62.5 kW

Heating _________ kW

Unit Type Model / Duty / Quantity / Duty x Quantity

Cooling Only (KKCS) KKCS25D / 67.5 kW 1 / 67.5 kW

Cooling & Heating (KKHS) _________ / _________ kW _________ / _________ kW

Chiller Flow3 3.22 L/s (Q = M X CP X ∆T)

Design Conditions:

Summer Temperature 30 °C

Winter Temperature -5 °C

Cooling WaterTemperature Flow 7.0 °C Return 12.0 °C

Heating WaterTemperature Flow N/A °C Return N/A °C

GENERAL:

Chiller Supply Required 400 V 3 / 50 Hz Amps 54.1 A

Glycol Percentage 20 % Ethylene Type **See KKCS / KKHS Technical Manual.

Unit Type Model / Duty2 / Quantity / Duty x Quantity

Cooling Only (KKCS) KKCS25D / 66.82 kW 1 / 66.82 kW

Cooling & Heating (KKHS) _________ / _________ kW _________ / _________ kW

Chiller Flow4 3.12 L/s (Q = M X CP X ∆T)

Glycol Data:

Ethylene Glycol Correction Factors Propylene Glycol Correction Factors% Glycol in System 10 20 30 40 % Glycol in System 10 20 30 40Freezing Point ºC -4 -9 -15 -23 Freezing Point ºC -2 -6 -10 -17Output Duty kW 1.00 0.99 0.98 0.97 Output Duty kW 0.99 0.98 0.96 0.93Input Power kW 1.00 1.00 0.99 0.99 Input Power kW 1.00 0.99 0.99 0.98Equivalent Glycol Flow L/s 1.01 1.03 1.06 1.09 Equivalent Glycol Flow L/s 0.99 0.99 1.00 1.01Equivalent Head Available kPa 0.96 0.93 0.89 0.85 Equivalent Head Available kPa 0.94 0.89 0.81 0.74

Notes:

1. Use Room Total Load to select chiller.2. To calculate chiller capacity multiply load by Glycol factor (if applicable).3. Chiller flow based on Cooling Only Duty.4. Revised chiller flow based on chiller selected and revised duty available.



Keep Kool System Sizing

INDOOR UNITS It is normal practice to size a system based on the cooling rather than the heating load. Itis on this premise that we will size a system on the cooling load requirement. If, however,it is the heating load that has to be matched then simply select on heating duty in place ofcooling duty.

Once this is known it is simply a matter of determining the type, size and number ofindoor units required.

In both existing and new buildings it is basically a question of practicality as to which unitscan be installed. Where a false ceiling is available the Cassette unit provides the bestsolution. It offers the most advantageous pattern of air currents and does not take upvaluable floor or wall space.

High Wall units offer a solution where lower wall space is at a premium such as modernoffices.

Aerovent units can be provided in a wide range of configurations for either recess orsurface mounting fitted with an optional decorative cover or as chassis only. Aeroventunits are available in horizontal or vertical modes for maximum versatility.

Concept 2000 units offer a wide range of duties for low floor and wall mountedapplications.

SELECTION EXAMPLE A small building requires air conditioning. The cooling requirements have beendetermined as follows:

OFFICE ROOM SENSIBLE LOAD (kW) FALSE CEILINGMeeting Room 1 5.8 YesMeeting Room 2 4.0 YesAccounts 2.6 NoPurchasing 2.6 NoSales 2.6 No

As meeting Rooms 1 and 2 both have false ceilings a Cassette unit might well be thebest solution.

The remaining offices all have the same cooling duty but no false ceilings. Selection ofthe required units is now a matter of practicality and personal preference. In this examplewe shall assume that Concept 2000 units have been selected.

Looking at the performance data of the indoor units the following selection can be made:

OFFICE ROOM LOAD (kW) UNIT SELECTED UNIT DUTY (kW)TC SC

Meeting Room 1 5.8 CACW10 6.85 5.80Meeting Room 2 4.0 CACW7 4.69 4.09Accounts 2.6 CCW18 3.13 2.71Purchasing 2.6 CCW18 3.13 2.71Sales 2.6 CCW18 3.13 2.71Total Duty 20.93 kW

OUTDOOR UNIT Now that the indoor units have been selected it is a matter of matching the total duty ofthe indoor units (sum of the total cooling capacity TC) to the chiller (outdoor unit).

The total duty of the indoor units is 20.93kW.

Looking at the performance data for the outdoor units it can be seen that the duty of thechiller is ambient dependent. In this example we will assume an ambient of 35°C.

The following selection can be made:

TOTAL COOLING DUTY UNIT SELECTED UNIT DUTY20.93 kW KKCS7 21.80 kW


15Comfort Range


Keep Kool System Sizing

WATER PIPEWORK Once the size of the chiller has been determined, it is recommended that the pipe sizingdata on the following page is referred to. By following the guidelines specified the correctflow rates can be maintained at all operating conditions.

IMPORTANT NOTE Pipework designs other than those shown can be applied quite successfully toKeep Kool. Where this is undertaken the responsibility for the design is with theinstaller.

DESIGNCONSIDERATIONS

When selecting indoor and outdoor units the following design considerations areappropriate:

Q1: Are all indoor units required to operate at a maximum capacity at the same time?

A1: If the answer to this is no, then it may be possible to select a smaller chiller.

Q2: Is it best to undersize or oversize the chiller?

A2: A slightly undersized chiller will allow operation at very stable conditions. Onlywith a very high cooling demand will performance be stretched.

An oversized chiller on the other hand will always have spare capacity in hand,but may be subject to increased compressor cycling.

Q3: What about partial load operation?

A3: Both KKCS and KKHS chillers feature capacity control so partial load operation isvery stable.

Q4: Can the indoor units on a KKH heat pump system be fitted with electric heating orLPHW heating coils?

A4: No - the heating stage from the indoor control unit is needed to control the watervalve in heat pump mode.

It is very unlikely however that there would be a localised heating demand whenthe system is operating in cooling mode.



SYSTEM DESIGN STEP 6 - Pipe SizingKEEP KOOL PIPE SIZING CHART

MODELSIZE

NOMINALFLOW L/S

AVAILABLEPUMP

PRESSURE(KPA)

PRIMARYLOOP PIPE

SIZE (MM)

TYPICALPIPE LENGTH

(M)

SECONDARYLOOP PIPE

SIZE (MM)

TYPICALPIPE LENGTH

(M)

KK 3 0.41 50 35 200 28 200KK 5 0.65 48 35 200 28 150KK 7 1.04 66 42 200 35 150KK 9 1.25 52 54 200 35 100KK 11 1.65 228 54 200 42 100KK 15 2.15 261 54 200 42 200KK 20 2.74 109 67 200 54 150KK 25 3.21 172 67 200 54 150KK 30 3.73 151 67 200 54 200KK 40 4.79 185 76 200 67 150KK 50 5.65 132 76 200 67 150KK 60 6.96 116 108 200 67 100

Notes:

1. The above typical pipe lengths are to be used as maximum equivalent lengths only.2. The above typical pipe lengths should not be exceeded.3. The above table is to be used as a guide only. Please ensure each application is checked in accordance with

CIBSE guide.4. The above available pump pressures are based on standard size pumps. See Technical Manual for other options.

PRIMARYLOOP

SECONDARYLOOP

DIAGRAM SHOWINGPRIMARY ANDSECONDARYLOOPS


17Comfort Range


SYSTEM DESIGN STEP 7 - System Accessories

REGULATING DEVICES TWO WAY CONTROL VALVES

Two-way control valves offer the system the option of ON / OFF control being openedand closed by means of an electrical signal. Fully modulating versions are available onlarger sized valves, i.e. 0% to 100%.

THREE WAY CONTROL VALVES

Three way valves are normally used in conjunction with a bypass leg to achieve completewater flow modulation. The water flow path is either around the cooling / heating circuitor open to bypass under times of reduced load.

This modulating flow to bypass allows the pump to operate against a consistent pumpinghead, which leads to improved valve control and temperature control.

FOUR WAY CONTROL VALVES

Used on smaller chilled water systems where modulation is required at times when lowload is relevant. The four way valves modulate the water flow to bypass by opening up aflow path internally within the valve.




MEASURING DEVICES ORIFICE PLATE

Orifice plates are commonly used for the measurement of main branch water flows. Theyuse an accurate method of flow measurement but are very difficult to install without apressure tapped carrier ring. The carrier fits in between the pipe flanges and the orificeplate.

Red Strap -HP Test Point

Blue Strap -LP Test Point

The orifice plate and carrier ring system is reasonably expensive, however MeteringStations which incorporate an orifice plate and a regulating valve prove more accurateand economical both from an initial and commissioning cost than any of the currentmethods of flow measurements.

SHORT VENTURI

Whilst their accuracy is approximately the same as that for orifice plates they tend to bemore expensive. For this reason Short Venturi devices are not normally used oncommercial chilled water systems.

VARIABLE ORIFICE DOUBLE REGULATING VALVES (vodr)

Variable Orifice Double Regulating valves are being used extensively at present. Theymeasure and regulate the water flow by means of a variable orifice device installed withinthe valve body. Flow adjustment is achieved by turning the hand wheel to reveal agraduated scale.

Accuracy’s vary dependent on the amount they are closed. Fully open they will give anaccuracy of ± 5% typically. As they are closed down to a smaller orifice opening (lessthan 50% of fully open), the accuracy will decrease typically to ± 15%.

DOUBLE REGULATING VALVE

Double Regulating Valves (DRV) can only be used in conjunction with a fixed orifice, or inthe bypass line of a cooling coil three-way valve where it is used to provide an equivalentpressure drop to the cooling coil such that the overall coil & valve resistance is the samewhatever the position of the three-way valve.


19Comfort Range



BYPASS VALVES A pressure sensing Bypass valve is offered to limit the maximum pressure and at thesame time ensure a minimum flow of water through the cooling unit. The pressuresensing Bypass valve should be installed at the end of the circuits down stream of thelast indoor unit in the loop. The valve should be set at 300mbar (30 kPa) as shown bythe scale on the valve.

FILTERBALL VALVESHUT OFF / STRAINERDEVICES A water strainer is a necessary fitment on all installations. Required on the supply water

pipework to all indoor units and on the return water pipework just before the chiller. The'Filterball' valve is an on/off spherical valve containing a 0.7 mm removable (700 micron)strainer which is easy to inspect and remove for normal maintenance operations withoutdraining the system down.

FILTERMATE VALVE

The 'Filtermate' is a high quality spherical isolation valve. It is recommended on returnpipelines from the air handling units and leaving pipeline just after the chiller unit. Thefiltermate is supplied coupled with the filterball valve in kit form.

WATER STRAINER

A water filter with a minimum 20 mesh screen is a necessary fitment on all installations.The appropriate filter can be supplied loose for site installation and should be fitted in thereturn water pipework just before the chiller.




CONTROLS CONTROL UNIT

A programmable time clock based controller is utilised to synchronise the operation ofboth the KKC and KKH based system.

The 103E7A timeclock is used to enable the outdoor chiller on KKC systems.

The 102E7A timeclock is used to enable the outdoor heat pump chiller on KKH systems.

The change from cooling to heating is achieved by a manually operated changeoverswitch.

This timeclock has an additional switched output to select either cooling or heatingoperation on the chiller.

Each control unit can be programmed to provide 7 day or weekday/weekend operationand incorporates 3 daily ON/OFF control periods.

Override buttons enable the system to run outside the pre-set operating periods.

The control unit operates from a 230VAC 50HZ power supply.

CHANGEOVER THERMOSTAT

A changeover thermostat is required on every indoor unit on heat pump chiller systems.This pipe mounted thermostat is supplied loose for installation on the main pipework flowto the indoor unit. This thermostat reverses the operation of the indoor unit control valveto suit the operating mode of the chiller. This thermostat should be set at 20°C.


21Comfort Range


Where to install the Indoor Units

INSTALLATIONALTERNATIVES

In existing buildings, it is basically a question of practicality when determining where tofind space to locate the room unit. However, if possible, it is preferable to install the roomunit in the ceiling. This installation alternative will provide the most advantageous patternof air currents in the premises.

CEILING MOUNTED AEROVENT FLOOR MOUNTED AEROVENT/CONCEPT 2000

CASSETTE UNIT MOUNTED HIGH WALL UNIT WALL MOUNTED



Where to install the Outdoor Unit

The chiller must always be installed outdoors. To ensure sufficient condenser airflow andmaintenance access the minimum clearances shown below must always be observed.

AB

CD

KKC/KKH A B C D3-5 150 500 500 5007-11 150 500 800 500

MM1000mm

AIRFLOW &SERVICE

1000mmAIRFLOW &

SERVICE10

00m

mA

IRF

LO

W &

SE

RV

ICE

1000

mm

AIR

FL

OW

&S

ER

VIC

E

1500mmAIRFLOW &

SERVICE

1000

mm

AIR

FL

OW

&S

ER

VIC

E

1000

mm

AIR

FL

OW

&S

ER

VIC

E

1500mmAIRFLOW &

SERVICE

KKCS/KKHS15 – 30D

KKCS/KKHS40 – 60D

KKCS/KKHS3 – 11D


23Comfort Range


Pipework Schematic Layouts

GENERAL PLUMBING Once the size of the chiller has been determined, it is recommended that the pipe sizingdata on page 16 is referred to. By following the guidelines specified the correct flow ratescan be maintained at all operating conditions:

Pipework designs other than those shown can be applied quite successfully toKeep Kool. Where this is undertaken the responsibility for the design is with the installer.

It is recommended that isolation valves are fitted adjacent to both the outdoor and indoorunits for servicing and testing.

Pump head is available for pipework pressure losses and this should not be exceeded,please refer to page 16.

All pipework should be insulated with a minimum of 9mm wall thickness pipe insulationand be correctly clipped to a supporting surface.

Pipe runs to indoor units should be kept as simple as possible with the minimum numberof connections and bends to be used.

An air vent must be fitted at any high point in the system likely to cause an air lock.

Correct piping codes of practice and regulations should be observed at all times withparticular regard to system internal cleanliness.

INSTALLATION The water piping should be arranged as shown in the diagrams. Always use the numberof loops shown and the correct number of bypass valves and control valves, asapplicable. Use the correct diameter copper tubing. All copper piping is to be insulatedand must be vapour sealed.

Steel or plastic tubing can also be used providing that they have the same pressuredrops as those of the recommended copper tubes.

AIR VENTSTANDARDCOMPONENTS If auto air vents are used then we strongly recommend an auto pressurisation unit be

fitted to the system.

EXPANSION VESSEL

Installed as standard on all Keep Kool models. Expansion vessel may require re-selecting for Glycol and system volume, please refer to Airedale.

DRAIN/FILL POINT

Included as standard on all Keep Kool models.

BUFFER TANK

Installed as standard on Keep Kool models KKCS / KKHS 15 – 60. For models 3 – 11ensure the system water volume and control strategy only permits the compressor tostart 6 times per hour. See technical manual .



Pipework Schematic Layouts

OUTDOOR UNIT BELOWINDOOR UNITS

KKCS / KKHS CHILLER

CASSETTE

15m

TYPICAL PIPEWORKSCHEMATIC KKCS / KKHS CHILLER

CASSETTE

75m

OUTDOOR UNIT ABOVEINDOOR UNITS

KKCS / KKHS CHILLER

CASSETTE

75m

Notes:

1. For pipework lengths please read in conjunction with table on page 16.


25Comfort Range


Notes:

SELECTION DATA SHEETKEEP KOOL APPLICATIONS

TO BE COMPLETED IN CONJUNCTION WITH THE RELEVANTTECHNICAL MANUALS AND FOR GUIDANCE, PLEASE REFER TO THE

“APPLICATION GUIDE & SYSTEM DESIGN MANUAL”

Airedale International Air Conditioning LtdLeeds Road, Rawdon, Leeds,

LS19 6JY, ENGLANDTel: + 44 (0) 113 239 1000

Fax: + 44 (0) 113 250 7219e-mail: [email protected]

Web Site: www.airedale.co.uk

Engineer: Date:

Company: Site Ref:

? SELECTION STAGE No 1. – COOLING OR COOLING & HEATINGo Cooling Only (KKCS) o Cooling & Remote Heating (KKCS) o Cooling & Heating (KKHS)

? SELECTION STAGE No 2. – SYSTEM TYPEo Single System o Multi Unit System o Zone Control System

? SELECTION STAGE No 3. – ROOM / ZONE SUMMARY

Room/Zone Details:

Length x Width x Height x x

Room Volume _________ m³

Windows 1 Quantity ________ Area _______ m2

Type S.G. D.G.

Room Temperature _________ °C %RH

Summer Conditions _________ °C

Winter Conditions _________ °C

Room/Zone Loads:

Sensible Latent

Room _________ kW

(Includes Solar & Conduction)

Lighting _________ kW

Equipment _________ kW

People _________ kW _________ kW

Infiltration (Fresh Air) _________ kW _________ kW

(Based on 10 l/s per person)

L

W

N

E

S

W

Total Room Load _________ kW

Sensible Room Load_________ kW

Latent Loads _________ kW

Notes:1. Windows for reference only. Data used in Heat

Load calculations. Please also note orientation ofroom as this has an effect on solar heat gains.

? SELECTION STAGE No 4. – INDOOR UNIT SELECTION

Total Duty Loads1:

Cooling _________ kW Heating _________ kW

Unit Type Model / Duty / Quantity / Duty x QuantityCassette _________ / _________ kW _________ / _________ kWWall _________ / _________ kW _________ / _________ kWFloor _________ / _________ kW _________ / _________ kWCeiling _________ / _________ kW _________ / _________ kWFan Coil (Ducted) _________ / _________ kW _________ / _________ kW

Design Conditions: Notes: 1. Use sensible unit duties to match room load.

Room Temperature _________ °C Humidity %RH

Chilled Water Flow _________ °C Chilled Water Return _________ °C

Heating Flow _________ °C Heating Return °C

? SELECTION STAGE No 5. – CHILLER UNIT SELECTION

Total Duty Loads1:Cooling _________ kW Heating _________ kW

Unit Type Model / Duty / Quantity / Duty x QuantityCooling Only (KKCS) _________ / _________ kW _________ / _________ kWCooling & Heating (KKHS) _________ / _________ kW _________ / _________ kW

Chiller Flow3 l/s (Q = M x Cp x ∆T) Notes:

Design Conditions:Summer Temperature _________ °C

Winter Temperature _________ °C

Cooling Water Temperature Flow _________ °C Return °C

Heating Water Temperature Flow _________ °C Return °C

1. Use Room Total Load to select chiller.2. To calculate chiller capacity multiply load by

Glycol factor (if applicable).3. Chiller flow based on Cooling Only Duty.4. Revised chiller flow based on chiller selected and

revised duty available.

General:Chiller Supply Required ______ V ______ / ______ Hz Amps A

Glycol Percentage _________% **See KKCS / KKHS Technical Manual.

Unit Type Model / Duty2 / Quantity / Duty x QuantityCooling Only (KKCS) _________ / _________ kW _________ / _________ kWCooling & Heating (KKHS) _________ / _________ kW _________ / _________ kW

Chiller Flow4 _________ l/s

Glycol Data:

Ethylene Glycol Correction Factors Propylene Glycol Correction Factors

% Glycol in System 10 20 30 40 % Glycol in System 10 20 30 40Freezing Point ºC -4 -9 -15 -23 Freezing Point ºC -2 -6 -10 -17Output Duty kW 1.00 0.99 0.98 0.97 Output Duty kW 0.99 0.98 0.96 0.93Input Power kW 1.00 1.00 0.99 0.99 Input Power kW 1.00 0.99 0.99 0.98Equivalent Glycol Flow L/s 1.01 1.03 1.06 1.09 Equivalent Glycol Flow L/s 0.99 0.99 1.00 1.01Equivalent Head Available kPa 0.96 0.93 0.89 0.85 Equivalent Head Available kPa 0.94 0.89 0.81 0.74

? SELECTION STAGE No 6. – PLUMBING REQUIREMENTS

Pipe Sizing: Please refer to Pipe Sizing Table on page 16.

? SELECTION STAGE No 7. – SYSTEM ACCESSORIES

Type of Valves / Quantity

None _________

2 Port _________

3 Port _________

4 Port _________

Water Strainer:o Filterball Valve o Filtermate Valve o Water Strainer

Options:

Controls:

FOR A COMMERCIAL PROPOSAL PLEASE FAX THE COMPLETED FORM FOR THE ATTENTION OF OURTECHNICAL SALES DEPARTMENT. PLEASE ENSURE THAT ALL SECTIONS ARE COMPLETED.

Airedale International Air Conditioning LtdLeeds Road, Rawdon, Leeds LS19 6JY, England

Tel: +44 (0) 113 239 1000 Fax: +44 (0) 113 250 7219e-mail: [email protected]

website: www.airedale.co.uk

Part No: 903-081 DM E 02/00

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