PACKAGED AIR COOLED FREE COOLING CHILLER

APPLIED CHILLER PRODUCTS

PACKAGED AIR COOLED FREE COOLING CHILLER

New

YSFC

200 - 1700

kW

14 ModelsYork Screw Free Cooling


Market Introduction

PackagedAir Cooled

Free Cooling


What is a Free Cooling?Free Cooling has become an established technology recognised throughout

Eastern and Northern Europe by End Users, Architects & Building Services Engineers.

Reducing Global Energy Consumption and CO2 emissions is a Clients key driver for his Buildings & Cooling Processes, reducing operating costs and

environmental impact.

Free Cooling Chiller offers a sustainable alternative, to reduce electrical energy consumption during “winter” ambient periods.

The Free Cooling concept switches off compressors when operating conditions allow, to utilise Natural Cooling provided from Low Ambient

Air passing across a finned coil containing the process liquid. Client’s consider this as an attractive solution.

Ideal applications benefit from having a high 24/7 base load and operate with elevated system return liquid temperatures typically above 15ºC and where the ambient is predicted to be below 5ºC

many operating hours each year.


Our survey revealed this technology is increasing in demand by many users.Although a niche Air Cooled Chiller variant, specifications for such products in most European regions is rapidly increasing and the JCI Sales Teams request the ability to support this technology alternative with their Clients.

There are a number of various applications in which our traditional Clients are currently specifying and Installing such products:-

Locations, Long Cold Winters, Northern Latitudes or Eastern Europe, High Altitude.24/7 Chiller Operating Applications Data Centres, Switch Rooms and Industrial Processes. Chilled Beam and Medium Temperature Air Conditioning.Theatres, Cinemas and Night-Clubs.Hospital Operating Theatres.

As Free Cooling is seen as a progressive “Green” product solution.

Market Requirements For Free Cooling Chiller’s.


Sales Forecasts & Market Assessment

• The Free Cooling project investigated the potential for JCI Systems to offer Packaged Air Cooled Free Cooling Chillers, following requests originating mainly from Central and Eastern Europe.

• Initial forecast reviews for 2008 indicated a likely requirement for 40 units.

• 2010 Product AOP review (April 09) revised this forecast downward to 26 units

• Following PS&S review of the European market indicates there is a wide range of clients applying the principals of Free Cooling to their processes. We have concluded that there is a legitimate market for this product variation as the vast majority of Chiller manufactures offer such products. Unfortunately there are no official statistics to support sales volumes to this market. However have seen many enquires for multiple units. (One project for 18 x 750 kw units which we are specified.)

• It is Product Managements assessment that this market has the ability (in normal market conditions) to generate higher volumes than indicated and we believe we have identified a product to meet this demand.


Alternative Approaches To Free Cooling Chillers?

There are 4 design variations for Free Cooling Systems applied to packaged Air Cooled Chillers available in Europe’s market.

1) Stand Alone Dry Air Cooler. Technically the best solution.Most efficient and flexible option, high installation costs. JCI current solution.

2) Built-in separate Dry Air Cooler. Exclusive applications.Good efficiency levels and often with very high levels of specification, but greater foot print and high cost.

3) Thermosyphen system. Carrier’s Approach.Utilises refrigerant circuitry, has low capital cost and low efficiency. Only two modes of operation restricting mid season application.

4) Dual Function - Free Cooling and Condenser Coil. Commercial.Compact \ Price competitive solution preferred by European MAC team as a product gap filler.

JCI new YSFC solution.


Review of the alternative design concepts determined this technology could not be simply applied to our current Product range.

The stand alone dry air cooler is the most obvious Energy efficient solution. JCI has been successful in winning such projects. Many Clients now requesting packaged units to reduce installation costs and space.

The built-in Dry Air Cooler & Thermosyphen systems both require major equipment redesign.

The Dual Function coil block requires less modification to the existing product’s. Adding the additional coils into the current

condenser design the unit’s width would Increase, prohibiting JCI from loading units

into containers for Global shipment’s.

Why JCI chose to use an OEM Supplier?


JCI Selected OEM SupplierFollowing an extensive Market Review we identify the alternative

market suppliers and product solutions. We finalised an OEM agreement with an Italian producer specialising in the process

cooling market for a Unique Branded JCI Design Dual Function - Free Cooling /

Condenser Coil

A reciprocal agreement exists that if either JCI or Hitema’s existing distributors has a product specified the other party should not chase down the order.

No other Hitema product may be ordered from them without Product Management Authorisation


ApplicationPackagedAir Cooled

Free Cooling


Product Selection and ApplicationThe YSFC is not seen as a replacement for the YCIV. Both models have their unique benefits for the client.

You select which one is best.

YCIV YSFC• High Summer efficiency 3.2 EER. • High 4 ESEER mid season performance.• Continuous VSD Cooling for extended low ambient efficiencies throughout the year.

• Lower Summer efficiency EER 2.6• 3.7 ESEER performance

• 100% Free Cooling EER 26 At an ambient approximately 16C below the return chilled liquid temperature there is no Mechanical Cooling required.


Free Cooling Chiller Operating Modes

Free Cooling units operate in 3 modes.

• Mechanical Cooling Chiller operates in refrigerating mode in summer ambient conditions.

• Partial Free & Mechanical Cooling (excluding Thermosyphen system)

Where Free Cooling works in series (up-stream) of Mechanical Cooling to reduce compressor load when lower ambient temperatures allow.

• Total Free Cooling (Condenser fans running) When the ambient air is cool enough to reject the full heat load from the system.


YSFC Free Cooling Chiller OperationDuring Summer Ambients the unit operates as a typical chiller,

albeit at a reduced efficiency level. This is due to the additional coil rows required for the Free Cooling circuit placed in front of the condenser.

As the ambient falls 6°C below the return system liquid temperature.• The 3-way valve redirects the flow through to the Free Cooling Coil

in series with the evaporator enabling the partial Free Cooling / Mechanical Refrigeration mode.

• To maximise unit efficiency each circuit is unloaded and disabled in sequence as the ambient falls.

• Whilst a refrigerant circuit is operating the fans continue to maintain the minimum condensing pressure.

• As each refrigerant circuit stops, fan control changes to maintain leaving liquid temperature.

Winter Ambients, where full free cooling is achieved (without mechanical cooling) the leaving chilled liquid temperature is maintained at the desired

temperature by fan control.


YSFC Product Schematic Standard Mechanical Chiller

Evaporator

Controller

Compressor

Condenser

Fans Fans

EEV

Flow TempStat

AmbientStat

Condenser


Free Cooling

YSFC Product Schematic Free Cooling Chiller in Mechanical

Cooling Mode

Evaporator

pC03Controller

Compressor

Condenser

Fans Fans

Free Cooling Valve EEV

Flow TempStat

AmbientStat

Inlet Temp Stat

Condenser

Free Cooling

When Ambient is Grater than 6°C below the Return Liquid Temperature


Evaporator

pC03Controller

Compressor

Fans Fans


Flow TempStat

AmbientStat

Inlet Temp Stat

YSFC Product SchematicPartial Free & Mechanical Cooling

CondenserCondenser

Free Cooling Free Cooling

When Ambient is 6°C below the Return Liquid Temperature


Evaporator

pC03Controller

Compressor

Fans Fans


Flow TempStat

AmbientStat

Inlet Temp Stat

YSFC Product SchematicPartial Free & Mechanical Cooling

Condenser

FreeCooling

CondenserCondenser


Condenser Coil Block Profile


Evaporator

Condenser

pC03Controller

Compressor

Condenser

Fans Fans


Flow TempStat

AmbientStat

Inlet Temp Stat

YSFC Product SchematicFree Cooling Mode

Condenser

FreeCooling


When Ambient is low enough to satisfy system cooling demand


YSFC Free Cooling mW Hours operation

Data based on

YSFC 850SB 860 kW.

Constant load 365 Day 24/7.

24hr Average Daily Temperature.

15 – 7 Chilled Glycol split.

Partial Free Cooling enabled @

9°C Ambient (6°C below EWT.).

Full Free Cooling -2°C Ambient.0%

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100%

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Calculated Percentage Energy Saving per Month

Moscow

Stockholm

Warsaw

Berlin

Paris

Madrid

This graph shows the potential to save energy as a % comparing the YFSC modes either operating thought the year in Mechanical Cooling or Partial / Total Free Cooling.


0

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EER

Ambient / Leaving Liquid

100% Load 365 Day EER 850kW

YSFC 850

YCIV 930 HE Opt

EER Comparison JCI Chillers

Based upon 100% Cooling load (850 kW) and 5°C ambient steps


YSFC The Product

PackagedAir Cooled

Free Cooling


Introducing the new YSFC Range Two circuit models

Info Only Please Refer to Eng. G

uide


Introducing the new YSFC Range 2 & 4 circuit models

Info Only Please Refer to Eng. G

uide


YSFC Standard Features

• R407c standard options exist via SQ for R134a. • Light grey RAL 7035 polyester epoxy powder paint.• Two or four fixed speed step control part wind Hermitic Screw Compressor(s)

optional Open or Closed transition Star Delta Starters. • Carel microprocessor controller including specific Free Cooling software.• Electronic Expansion Valves (increased performance in partial mechanical /

free cooling mode).• Axial speed controlled condenser fans various options for differing control and

drive(s).• Aluminium Fin & Copper Tube Condenser / Free Cooling Ambient Coil’s options

for alternative materials / coatings.• Shell & Tube Direct Expansion Evaporator 19mm closed cell insulation.• PN16 inlet manifold and outlet evap. stub for Chilled Liquid flange

connections.• 6 Bar Three Way Free Cooling Mixing Valve, Heater and Auto Daily Rotation. • EPDM Flexible reinforced helix wire compound rubber Hydraulic Tubes.


YSFC Component Selection

We use simulator software, to confirm the

dimensions compressor’s of evaporator condenser

coil and fans

Design Cooling Capacity

Condensing Requirement & Free Cooling load

Condensing duty & Sound performance

When the Clients designcharacteristics are finalisedcomponent selection is thenOptimised for the specific project design.


After selecting the components a study final of the optimum layout for the base.

TANK (Option)

EVAPORATOR

PUMP (Option)

3 WAY VALVE

HYDRAULIC PIPING

(Manifold)Inlet

Outlet

YSFC Unit Construction - Mount Components

COMPRESSORS

SUPPLEMENTARYPANEL (Option)


YSFC Unit Construction - The Condenser Module

Coils and Fans are selected initially from the standard unit design configuration. Cost Performance and Sound Optimisation.

JCI Offer Special Quotation variations on Coil lengths, Coil Rows, Fin Pitch, and Fan Performance to meet Project requirements.


With the mechanical component location finalised, the Control panel is positioned

The 3D module is complete and the 2D drawings are produced automatically for production.

Control Panel

Condenser module

Base

YSFC Unit Construction - Final Assembly


YSFC Product, Wiring, Pressure / Instrument Drawings are issued forClient Approval before production release and lead time conformation.


Components Around the YSFC

Dual relief (option)

OptionalPump’s andAcoustic CompressorEnclosure

3 Way Valve and Hydraulic pipe connections from manifold to Free Cooling Coils


Components Around the YSFC


YSFC Product Options and Accessories.

Enhanced Free Cooling Performance.The Base unit configuration of unit size and performance

has been selected to offer a competitive all round package.

For specific applications where the Designer’s requirement is to increase the potential Free Cooling Performance, the factory can

offer alternatives through the Special Quotation procedure.

Potential variations include:-• Reduced Fin Pitch (additional Fins to the Coils).

• Increased Air Flow Fans.• Extended Coil length with additional Fans.

Building Chilled Liquid Glycol Free option available as SQ Option (Limiting the Glycol circulation loop within the unit). Ideal for use in

moderate climates where the ambient falls below zero for only a small number of hours a year.


YSFC Product Options and Accessories.1.01 Low Noise (Compressor Enclosure).1.02 Super Low Noise (Compressor boxes and reduced sound fans).SQ Extend coils + extra modifications to achieve minimal possible sound.1.03 Unit Wire Enclosure (Lower Section).1.04 Epoxy Coated Ambient Coil.1.05 Rubber type anti-vibration mounts.1.06 Spring Anti-vibration mounts.2.- - Hydronic pump options (see next slides)2.06 Pressure Regulation Valve (between 3-way-valve and Evaporator).2.14-15 Double evaporator insulation 38mm – Evaporator heater mat.2.16 Y mechanical water filter (supplied lose)3.01 Compressor Suction Valves.3.02 Dual relief change over valves.4.01-4.09 Star Delta compressor motor starters (Open & Closed Transition)4.02 Compressor remote run monitoring contactors4.03 Compressor rephasing4.04 Main – Auxiliary Panel Heaters for ≤-10°C ambient.4.05 Individual fan fuses.4.06-7-8 Serial card BACNET MODBUS (RS485) or Echelon.Std Carrel controller languages, English, French, German, Italian, Spanish.SQ Glycol Free Process System.


Single pump 2.5 bar head optionwith internal wiring to panel mounted contactors

Optional Acoustic boxes forEither Compressors and or Pumps for Low noise versions.

Dual pump 2.5 bar head optionwith internal wiring to panel mounted contactors

Additional Dual Pump Electronic Management Controls.

YSFC Product Hydraulic Pump Options.


Dual VSD pump option with internal wiring to a panel mounted Single Inverter.With electronic pump Management Controls.

Storage Weir Tank.Various additional options

Dependant on requirement. Internal constant speed circulation Pump.

Optional Acoustic boxes available for Compressor’s and or Pumps,Low noise version.

YSFC Product Hydraulic Pump Options.


After assembly the chiller is run tested at prevailing ambientconditions to verify the Mechanical cooling operation and Safety sequences. (Larger capacity units tests are performed separately on individual circuits.)Controlled ambient testing is not available at the Factory.

YSFC End-of-line functional run test


AIR FLOW AIR FLOW

AIR FLOW

WATER FLOW

ELECTRICAL POWER

waterm iT

oT

fVIabs ,,

airT airT

airT

YSFC Recorded Test Data


In mechanical cooling mode the total pressure drop calculation isthe 3 way valve and interconnecting Hydraulic pipes + Evaporator.

In partial or total Free Cooling modes the pressure drop calculation isthe 3 way valve, distribution header, interconnecting hydraulic pipes

+ Free Cooling Coil + Evaporator.

YSFC System Hydraulic CalculationsCaution when calculating the chilled liquid pressure drop.

System Working Pressure.Due to the limitation of the three way valve and Hydraulic pipes

the chilled liquid static system pressure is limited to 6 Bar.

There is obviously a difference in system resistance between the two modes.Discuss this with the client and introduce the option of a pressure regulating

valve to equalise the system pressure drop for each mode.This is installed in the Hydraulic pipe between the 3-way-valve and Evaporator.


YSFC Documentation and selection process.The engineering guide allows for manual selection for both the Mechanical and Free Cooling Modes. As the free cooling chiller application is more suited to specific regions we plan not translate Documents unit specific requests are received.

A selection program is in development and will be distributed Q4 2009. In the interim period please submit SQ for electronic selections. We will have to pay the software house an operator licence of €80 for each user. Please email R Smeed to confirm your licence requirement.

Pricing is a manual operation using the Master List Price, That will be included in the intranet price pages, with the Multiplier distributed to the Sales Managers as usual.

The OEM supplier is happy to work on special applications and options. Please submit a detailed SQ request for review & potential quote.


YSFC Intranet

information 1. Single Page Product

Information Sheet.2. Engineering Guide.3. Installation Commissioning

Operation and Maintenance Manuel.

4. PCO3 Controller Operators Manuel.

5. MLP Price Pages and Words.6. SQ Process flow.7. Order Process flow8. Factory Order Form9. Factory Collections Form10.Warranty Process flow11. Warranty Standard Hours

List.12.Typical Wiring Diagrams

Standard unit with available options (pdf).

13. Typical Product Drawings (pdf)

14.Launch Presentation (ppt)


CompetitionPackagedAir Cooled

Free Cooling


YSFC Free Cooling Chiller Competition

Stand Alone Dry Air Cooler. With thought all Packaged Air Cooled Chillers and Dry Air

Cooler manufactures can provide the solution.

Thermosyphen system.Carrier.

Built-in separate Dry Air Cooler.Cosfi, Liebert Hiross, MTA, Uniflar.

Dual Function - Free Cooling and Condenser Coil.ACM, Aermec, Airwell, Blue Box, Ciat, Clivet, Climaveneta,Emicom, Euroklimat, Daikin-McQuay, Geoclima, Galletti, Lennox, Matri Clima, Rhoss, RC, Trane, Venco.



GeoClima, Emicon, Cosfi, Uniflair, YSFC, Climaveneta.

Free Cooling Std units Mechanical Cooling vs Power input

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550

0 200 400 600 800 1000 1200 1400Duty kW

Input k

W

Free Cooling Std units FC mode vs Power input

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kW



Free Cooling Std units Mechanical cooling vs Sound Pressure

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@ 5 m

Free Cooling Std unit Mechanical Cooling vs Length

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Leng

th mm




Free Cooling Std units Mechanical Cooling vs Weight

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Free Cooling std unit vs Euro

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Servicing Renewal

Parts Contacts

PackagedAir Cooled

Free Cooling


YSFC JCI Products and Service Departments have experience of many shared Component suppliers

The Design of the YSFC has many similarities to our own YAES – YCAS andYLCS models. Using many common components that our Service Engineers and Renewal Parts Group are familiar with their availability and use.

For example:- Hanbell Compressors, Ziehl Fans, pumps, Alfa-Laval or Heatcraft Evaporator’s Plus many common refrigeration, electrical components.

New components include The Carel PCO3 controller with the Free Cooling Software.Hydronic system and Three way Valve.


YSFC Service Training and Replacement Parts.

Replacement Parts

• Must be purchased through JCI Renewal Parts Organisation who will have access to Hitema’s detailed bills of material’s for each product supplied. • Please ensure Model Number & Serial Number is given along with details of the Components requested.

Service Training

A Service Trainer Course will be organised at the Factory near Venice.During Q4 FY 2009 The course will consist of:-

• Product Overview (General Refrigeration system)• Theory of operation of the Free Cooling System.• Detail review of the PCO3 Carrel controller and software.• Review end of line test and the Commissioning procedures.


Drawing Approvals• Upon receipt of order the Factory will review the unit configuration and produce project specific physical & electrical drawings.• These will require Client approval before components purchase and manufacture commences. (Early reply would be required to ensure shortest possible lead times.) Typical lead times 6 – 8 weeks after drawing approvals. Email communication of documentation and approvals is to be co-ordinated through Customer Services Group in Basildon.Commissioning registration• To initiate the warranty coverage the unit commissioning Completion date must be registered with the Basildon Customer Services team along with a copy of completed commissioning log report. • Specified system fill / commissioning procedures must be followed• Hitema reserves the right to request that any failed component be returned for analysis.• An agreed standard hours and labour rates repair times for replacement of faulty items. Warranty• In line with the current European standard policy of 18 months from factory collection. • All parts are with a full 18 month warranty with the exemption of the liquid Pump options.

YSFC JCI-Hitema Contract Special Variations


YSFC Communications Product ProcessJCI Sales and the Product Supply & Sourcing will jointly work with Hitema.Responsibilities are as follows.

• Product Supply & Sourcing. Product Manager [email protected] 00441268246198. Account management, Maintain documentation and price list, Product Training, Product Management and application and special quotation support.• Factory will provide Engineering Support Through The Existing SQ System. Review requests for Special Quotation's. Specific product Technical / Engineering support. Product Manager [email protected] 00441268246198.• Order Entry & Processing and Commissioning registration and Warranty management. Centralised through Customer Services Basildon. Orderentry [email protected] 00441268246266.• After Sales Technical Operation support. [email protected] 00447976196714.• Renewal Parts [email protected] 0044126824600.


Have Your Say Any Questions?

Have Confidence in Free Cooling and our New YSFC.

Thank you.

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