Selection Procedure of Air Conditioners SE08-01

Checklist for Chilled Water Facility

„ Cooling load calculation Customer

Sales channel/Delivery date

Check the heat generated by the substance to be
cooled, supply chilled water temperature and Name

Substance to be cooled
water flow rate. Cooling equipment

Initial temp. (˚C) Final temp. (˚C) Process amount (kg/h) Load fluctuation (%)
Load conditions

Allow for an extra 10 to 15% in terms of load after Specific heat (kcal/kg˚C) Specific gravity (kg/m3) Process amount (kg/h) Load fluctuation (%)

also considering the heat generated by the pump and Physical properties

the piping heat loss.

Chilled water conditions

Temp. conditions Supply ˚C Return ˚C Pressure loss mH O 2

Not specified
Flow rate L/min precision
Q = (Q1 + Q2 + Q3) × 1.05~1.1 · Net cooling load
Specified

Load fluctuation (%)

Cooling load · Total load (incl. pump-generated and kcal/h

= Q1 × 1.1~1.15 miscellaneous heat)

Power supply Three phase V Hz

• Q: Required capacity (Flow rate × Temp. diff.) (kW)

Chiller specifications
Operating period Time Period ___ ~ __
__
Mo Mo
• Q1: Net load (kW) Water-
Air-cooled/Water-cooled Air-cooled Outdoor ˚C Cooling water inlet ˚C
cooled
• Q2: Heat generated by the pump (kW) … Motor output Yes
Special atmosphere
Location Indoor/Outdoor
(corrosion/explosion)
• Q3: Piping heat loss (kW) Laws and regulations, specified colors, start-up method, contamination factor, etc.
No

Remarks

Other remarks (e.g., use of brine)

[Note]
The calculation above assumes that a sufficient amount
of time has passed.
Depending on the substance to be cooled, a load can
instantaneously be put on the system. For this reason,
actual measurement data and the like are used in
determinations in some cases.
(E.g.: Reactor vessel cooling often results in
instantaneous load on the system.)

4.5.2 Basic configuration of cooling system (overview)

„ Cooling systems are configured based on various conditions for use.
[e.g., load fluctuation, holding water quantity within the circuit, water temperature accuracy, water quality]

When
When load
load fluctuation
fluctuation is
is small
small
<Examples of use>
• General air conditioning • Computer room air conditioning
• Fermentation tank cooling • Constant temperature, constant
• Precision forming equipment humidity facilities
cooling • Printing equipment cooling
Installation of an intermediate heat exchanger at the equipment side is
required for the following uses:

• Cold bath • Tofu cooling

Systems that do not use cushion tanks • Plating tank cooling • Electrolyte cooling
• Quenching liquid cooling
Expansion tank
Chiller Cooling load

„ When load fluctuation is relatively small

„ For closed piping
„ When the minimum holding water quantity
P in the circuit has been secured

Cooling load (open)

Intermediate heat
exchanger
„ When load fluctuation is relatively small
„ When water quality is poor and direct
cooling is not possible
„ When the minimum holding water
P P quantity in the circuit has been secured

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SE08-01 Selection Procedure of Air Conditioners

When
When load
load fluctuation
fluctuation is
is relatively
relatively large
large

Cooling systems that use a cushion tank <Examples of use>

• Compressor cooling
• Dry cleaning equipment cooling
• Resin forming machine cooling
Chiller Cooling load • Reactor vessel cooling

Cushion tank

„ When load fluctuation is relatively large

„ For closed piping
„ When the minimum holding water
P quantity in the circuit cannot be secured

25°C „ When load fluctuation is large

„ When the chilled water supply
12°C temperature to the load side must be
accurately controlled
„ When the minimum holding water
7°C P P quantity in the circuit cannot be
15°C secured

High temperature Low temperature

3-way
tank tank
motor-operated valve

4.5.3 Precautions when selecting a chiller and discussing the system with a client

Simple comparison between air-cooled and water-cooled
Comparison between air-cooled and water-cooled

Air-cooled Water-cooled Comments

Cooling capacity { {

Power consumption* ∆ {

COP* ∆ {

Cooling water piping work is necessary/

Ease of installation { ∆ Cooling water temp. control is
necessary
Maintenance of cooling water circuit is
Ease of maintenance ~ ∆
necessary
Necessity of a machine Should essentially be installed indoors
~ ∆
room for the water-cooled
Water quality management, chemical
Maintenance costs ~ ∆
infusion, air blow
Cooling water temp. control is
Year-round cooling { {
necessary
* "Water-cooled" does not include cooling tower fans and water-cooled pumps.

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Selection Procedure of Air Conditioners SE08-01

The selection of chiller models

‹ Model selection (C/O)

The capacity of refrigerating units (chillers) is essentially determined by the following:

„ Air-cooled… Chilled water outlet temperature, (Chilled water outlet/inlet temperature difference),
Outdoor temperature, Power supply frequency
„ Water-cooled… Chilled water outlet temperature, (Chilled water outlet/inlet temperature difference),
Cooling water outlet temperature, Power supply frequency

[ °C (Return water temp.) – °C (Supply water temp.)] × Water flow rate (L/h) × Specific heat × Specific gravity
Q (kW) =
860 kcal/kW

Operable temperature range for chillers

Based on Maker's Limitation

Year-round chiller operation

Many process cooling systems are used in intermediate and winter seasons, requiring measures to allow for
operation even when outdoor air temperatures are relatively low at the chiller side and/or facility side.

„ Air-cooled… Airflow (high pressure) control with fan; Installation of a windshield; Prevention of chilled
water freezing
„ Water-cooled… Control of cooling water temp.; (Control of cooling tower fan, 3-way valve control, etc.)

Chiller flow range

For the water heat exchanger, a flow range (circulating water velocity) is predetermined in order to prevent
corrosion of the heat transmission tube.
Maximum flow rate… A high flow rate can ultimately cause corrosion due to friction of the liquid on the inner
surface of the piping (Erosion). (The maximum is approximately 2.0 m/sec, though this
depends on the model.)

Minimum flow rate… A low flow rate increases the amount of scale that adheres to the inner surface of the piping,
resulting in corrosion and the development of pinholes (Pitting). Moreover, this can have a
significant adverse effect on capacity. (The minimum is approximately 0.4 m/sec, though this
depends on the model.)
Water flow usage range [Example] UWAP-G (DAIKIN domestic models)
Model UWAP1180G6 (K) UWAP1500G6 (K) UWAP1800G6 (K) UWAP2360G6 (K) UWAP3000G6 (K) UWAP3550G6 (K)

Maximum 680 850 1,030 1,350 1,720 2,030

Water
flow Minimum 169 215 258 339 430 509
(L/min)
Rated 338 430 516 677 860 1,018

[Note] When selecting a differential of 1°C, be sure to use a chiller with more than the rated water flow to prevent compressor hunting.

[Reference] FAQ
Q: Can a chiller be operated when the temperature difference is ∆t = 10°C?
A: A response to the effect of "It can be easily addressed according to the operable water flow range as per
the engineering material" would be incorrect.
∆t = 10°C is possible in relation to the machine's rated capacity. (It is best to respond by citing the
minimum flow rate.)

«Example»
Q: Does the UWAP3550G6 allow for operation when ∆t = 10°C for chilled water?
A: Confirm the capacity required by the customer.
If the required capacity is 320 kW, the flow rate is 459 L/min at ∆t =10°C. Therefore, ∆t = 10°C cannot
be addressed. The minimum flow rate that would allow the chiller to address ∆t = 10°C is 509 L/min.

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Understanding minimum holding water quantity within the circuit

• If the quantity of holding water within the chilled water circuit is too low, the following problems will occur:

(1) The ON/OFF frequency of the chiller will increase, which shortens the machine life.
(2) Load fluctuation disrupts the temperature of the supply water. In a particular case, it may activate the anti-
freezing mechanism.
(3) A drastic decrease in the hot water temperature occurs during defrosting, which causes a cold draft by
the secondary unit (if using a heat pump).

How to obtain holding water quantity

Holding water quantity (L) =
Chiller holding water quantity (L) + Total holding water quantity in secondary unit (e.g.,FCU) + Water quantity within chilled
water piping circuit (L)

„ Rationale behind the calculations of the minimum holding water quantity within chilled water circuit

<Basic theory for DAIKIN domestic model> (Note) Values may differ depending on the model.

In order to protect the compressor, the compressor ON/OFF

frequency should be kept within 6 times per hour. This assumes that there is no
(The continuous operation time of the compressor should be sudden change in the load.
approximately 5 minutes though it can differ depending on the model.)
Q: For cooling capacity at a minimum load (kW) × 860 [kcal/h]
Q – 1/2Q = W × Diff. × 60/5 1/2Q: For the load at the highest ON/OFF frequency (kW) × 860 [kcal/h]
W: Holding water quantity within the circuit (L)
Diff: Thermo differential 1, 2 or 4 (°C)

Example: Model UWYP1180G6 (Accuracy priority mode: Minimum load of 12%)

118 × 0.225 × 860 – 1/2 × 118 × 0.225 × 860 = W × 2 × 60/4 Therefore, W = 380 L 400 L
(Value in the engineering material)

Capacity at the minimum Diff. = 2 °C Minimum continuous operation time

load of 12% (as listed in the engineering material)

In the case of process cooling

Although load fluctuation according to use in process cooling is not

understood completely, it is wise to determine a holding water quantity A cushion tank is necessary when
that allows for an ON or OFF time of at least 5 minutes even in cases it cannot sufficiently contain the
where the load changes from 0 to 100% in a short period of time.
minimum holding water quantity
in the circuit!
Roughly 4- to 5-fold the standard
holding water quantity

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Selection Procedure of Air Conditioners SE08-01

„ Water quality management

Understanding minimum holding water quantity within the circuit

„ Even if the minimum holding water quantity in a circuit is secured, other measures may become necessary depending
on how the water-side system is set up.

[In the case of 2-way valve control at the secondary unit]

When the load becomes 0, the chilled water stops running into the secondary unit and all the water returns
back to the chiller via the header bypass.
• Do not consider the holding water quantity of the secondary unit when
calculating the minimum holding water quantity within the circuit. (The
holding water quantity must be calculated within the area encased in red
below.)

Air If the chiller does not have a tank, it is either necessary to use a 3-way
conditioner
valve in one place in a circuit that allows for securing the holding water
quantity or set up a circuit that allows for constant circulation of a certain
quantity of water.
Air
conditioner
If the system has a header bypass only, it can easily cause
insufficient holding water quantity during a low load period.

The holding water quantity must be

Chiller Tank calculated within the area encased in thick dot line.

Chiller water quality standards (JRA water quality guideline)

The water quality standards for chilled/hot water circuits have been added to the conventional standards for cooling water circuits specified in the Guideline of
Water Quality for Refrigeration and Air Conditioning Equipment (JRA-GL-02-1994) issued by the Japan Refrigeration and Air Conditioning Industry Association
(JRA) in 1994. In order to prevent corrosion of the cooling tubes as well as scale buildup within them, be sure to provide water chilling units with cooling water,
chilled water and hot water of a water quality according to the table below.
Table 3.1 Water quality standards for cooling water, chilled water, hot water and make-up water (5)
Item (1) (6) Cooling water circuits (4) Hot water circuits (3)
Chilled water circuits Tendencies (2)
Once-thru- Low-quality medium temp. water High-quality medium temp. water
Circulation type
water type circuits circuits

Circulating water Circulating water

Circulating Make-up Once-thru- Circulating water Make-up Make-up Scale
Make-up water [Between 20°C [Between 20°C Corrosion
water water water [20°C or lower] water water generation
and 60 °C] and 90 °C]

pH (25°C) 6.5-8.2 6.0-8.0 6.8-8.0 6.8-8.0 6.8-8.0 7.0-8.0 7.0-8.0 7.0-8.0 7.0-8.0 { {

Electrical conductivity (mS/m) (25°C) Up to 80 Up to 30 Up to 40 Up to 40 Up to 30 Up to 30 Up to 30 Up to 30 Up to 30

{ {
{µS/m} (25°C) (1) {Up to 800} {Up to 300} {Up to 400} {Up to 400} {Up to 300} {Up to 300} {Up to 300} {Up to 300} {Up to 300}
Standard items

Chloride ion (mg Cl–/L) Up to 200 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 30 Up to 30 {

Sulfate ion (mg SO42–/L) Up to 200 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 30 Up to 30 {

Acid consumption (pH4.8) (mg CaCO2/L) Up to 100 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 {

Total hardness (mg CaCO3/L) Up to 200 Up to 70 Up to 70 Up to 70 Up to 70 Up to 70 Up to 70 Up to 70 Up to 70 {

Calcium hardness (mg CaCO3/L) Up to 150 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 Up to 50 {

Ionic silica (mg SIO2/L) Up to 50 Up to 30 Up to 30 Up to 30 Up to 30 Up to 30 Up to 30 Up to 30 Up to 30 {

Iron (mg Fe/L) Up to 1.0 Up to 0.3 Up to 1.0 Up to 1.0 Up to 0.3 Up to 1.0 Up to 0.3 Up to 1.0 Up to 0.3 { {

Copper (mg Cu/L) Up to 0.3 Up to 0.1 Up to 1.0 Up to 1.0 Up to 0.1 Up to 1.0 Up to 0.1 Up to 1.0 Up to 0.1 {
Reference items

Not to be Not to be Not to be Not to be Not to be Not to be Not to be Not to be Not to be

Sulfide ion (mg S2–/L) {
detected detected detected detected detected detected detected detected detected

Ammonium ion (mg NH4+/L) Up to 1.0 Up to 0.1 Up to 1.0 Up to 1.0 Up to 0.1 Up to 1.0 Up to 0.1 Up to 1.0 Up to 0.1 {

Residual chlorine (mg Cl/L) Up to 0.3 Up to 0.3 Up to 0.3 Up to 0.3 Up to 0.3 Up to 0.25 Up to 0.3 Up to 0.1 Up to 0.3 {

Free carbon dioxide (mg CO2/L) Up to 4.0 Up to 4.0 Up to 4.0 Up to 4.0 Up to 4.0 Up to 0.4 Up to 4.0 Up to 0.4 Up to 4.0 {

Stability index 6.0-7.0 - - - - - - - - { {

Note: (1) The nomenclature of items, definition of terms and units of items are based on JIS K0101. Incidentally, the units and numerals in { } are conventional
figures inserted for reference purposes.
(2) The circle ({) in the table indicates factors affecting the corrosion or scale-generation tendency.
(3) If the temperature is high (over 40°C), the corrosion tendency is usually high. Especially, when iron material with no protective coating comes in direct
contact with water, it is preferable to take anti-corrosion measures such as the application of anti-corrosive agents or deaeration.
(4) In regard to a cooling water circuit that employs a closed type cooling tower, the water quality standards for the medium temperature water circuits
should be applied to closed circuit circulating water and its make-up water and the water quality standards for circulating type cooling water circuits
should be applied to sprinkling water and its make-up water.
(5) City water, industrial water and ground water should be used as source water to be supplied/replenished, and deionized water, miscellaneous water, softened
water and the like should be avoided.
(6) The 15 items listed above show typical factors of corrosion and scale problems.

66 The Basic Knowledge of Air Conditioner