PACKAGED AIR COOLED FREE COOLING CHILLER

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PACKAGED AIR COOLED FREE COOLING CHILLER
New YSFC 200 - 1700 kW 14 Models
York Screw Free Cooling
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Packaged Air Cooled Free Cooling
Market Introduction
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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. Clients 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.
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Market Requirements For Free Cooling Chillers.
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.
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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 PSS 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.

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Alternative Approaches To Free Cooling Chillers?

• There are 4 design variations for Free Cooling
  Systems applied to packaged Air
  Cooled Chillers available in Europes 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.
• Thermosyphen system. Carriers
  Approach.
• Utilises refrigerant circuitry, has low capital
  cost and low efficiency.
• Only two modes of operation restricting mid
  season application.
• 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.

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Why JCI chose to use an OEM Supplier?
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 products. Adding the additional
coils into the current condenser design the
units width would Increase, prohibiting JCI
from loading units into containers for Global
shipments.
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JCI Selected OEM Supplier
Following 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 Hitemas 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
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Packaged Air Cooled Free Cooling
Application
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Product Selection and Application
The 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.

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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.

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YSFC Free Cooling Chiller Operation

• During 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 6C 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.

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YSFC Product Schematic Standard Mechanical
Chiller
Compressor
Flow Temp Stat
Evaporator
EEV
Controller
Fans
Fans
Ambient Stat
Condenser
Condenser
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YSFC Product Schematic Free Cooling Chiller in
Mechanical Cooling Mode
Compressor
Flow Temp Stat
Evaporator
EEV
Free Cooling Valve
Inlet Temp Stat
pC03 Controller
Fans
Fans
Ambient Stat
Condenser
Condenser
Free Cooling
Free Cooling
When Ambient is Grater than 6C below the Return
Liquid Temperature
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YSFC Product SchematicPartial Free Mechanical
Cooling
Compressor
Flow Temp Stat
Evaporator
EEV
Free Cooling Valve
Inlet Temp Stat
pC03 Controller
Fans
Fans
Ambient Stat
Condenser
Condenser
Free Cooling
Free Cooling
When Ambient is 6C below the Return Liquid
Temperature
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YSFC Product SchematicPartial Free Mechanical
Cooling
Compressor
Flow Temp Stat
Evaporator
EEV
Free Cooling Valve
Inlet Temp Stat
pC03 Controller
Fans
Fans
Ambient Stat
Condenser
Condenser
Free Cooling
Free Cooling
Free Cooling
Condenser
Condenser Coil Block Profile
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YSFC Product SchematicFree Cooling Mode
Compressor
Flow Temp Stat
Evaporator
EEV
Free Cooling Valve
Inlet Temp Stat
pC03 Controller
Fans
Fans
Ambient Stat
Condenser
Condenser
Free Cooling
Free Cooling
Free Cooling
Condenser
When Ambient is low enough to satisfy system
cooling demand
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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 _at_ 9C Ambient (6C below
EWT.). Full Free Cooling -2C Ambient.
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.
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EER Comparison JCI Chillers
Based upon 100 Cooling load (850 kW) and 5C
ambient steps
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Packaged Air Cooled Free Cooling
YSFC The Product
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Introducing the new YSFC Range Two circuit models
Info Only Please Refer to Eng. Guide
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Introducing the new YSFC Range 2 4 circuit
models
Info Only Please Refer to Eng. Guide
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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 Coils 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.

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YSFC Component Selection
When the Clients design characteristics are
finalised component selection is then Optimised
for the specific project design.
Design Cooling Capacity
Condensing Requirement Free Cooling load
We use simulator software, to confirm the
dimensions compressors of evaporator condenser
coil and fans
Condensing duty Sound performance
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YSFC Unit Construction - Mount Components
After selecting the components a study final of
the optimum layout for the base.
3 WAY VALVE
TANK (Option)
HYDRAULIC PIPING (Manifold) Inlet Outlet
EVAPORATOR
COMPRESSORS
PUMP (Option)
SUPPLEMENTARY PANEL (Option)
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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.
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YSFC Unit Construction - Final Assembly
Condenser module
With the mechanical component location finalised,
the Control panel is positioned
Control Panel
Base
The 3D module is complete and the 2D drawings
are produced automatically for production.
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YSFC Product, Wiring, Pressure / Instrument
Drawings are issued for Client Approval before
production release and lead time conformation.
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Components Around the YSFC
Optional Pumps and Acoustic Compressor Enclosur
e
Dual relief (option)
3 Way Valve and Hydraulic pipe connections from
manifold to Free Cooling Coils
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Components Around the YSFC
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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 Designers
  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.

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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 contactors 4.03 Compressor
rephasing 4.04 Main Auxiliary Panel Heaters for
-10C 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.
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YSFC Product Hydraulic Pump Options.
Single pump 2.5 bar head option with internal
wiring to panel mounted contactors Optional
Acoustic boxes for Either Compressors and or
Pumps for Low noise versions. Dual pump 2.5
bar head option with internal wiring to panel
mounted contactors Additional Dual Pump
Electronic Management Controls.
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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
Compressors and or Pumps, Low noise version.
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YSFC End-of-line functional run test
After assembly the chiller is run tested at
prevailing ambient conditions 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.
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YSFC Recorded Test Data
AIR FLOW
AIR FLOW
AIR FLOW
WATER FLOW
ELECTRICAL POWER
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YSFC System Hydraulic Calculations
Caution when calculating the chilled liquid
pressure drop.
In mechanical cooling mode the total pressure
drop calculation is the 3 way valve and
interconnecting Hydraulic pipes Evaporator.
In partial or total Free Cooling modes the
pressure drop calculation is the 3 way valve,
distribution header, interconnecting hydraulic
pipes Free Cooling Coil Evaporator.
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.
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.
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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.
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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 flow
8. Factory Order Form
9. Factory Collections Form
10. Warranty Process flow
11. Warranty Standard Hours List.
12. Typical Wiring Diagrams Standard unit with
    available options (pdf).
13. Typical Product Drawings (pdf)
14. Launch Presentation (ppt)

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Packaged Air Cooled Free Cooling
Competition
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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. Thermosyph
en 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.
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YSFC Free Cooling Chiller Competition
GeoClima, Emicon, Cosfi, Uniflair, YSFC,
Climaveneta.
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YSFC Free Cooling Chiller Competition
GeoClima, Emicon, Cosfi, Uniflair, YSFC,
Climaveneta.
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YSFC Free Cooling Chiller Competition
GeoClima, Emicon, Cosfi, Uniflair, YSFC,
Climaveneta.
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Servicing Renewal Parts Contacts
Packaged Air Cooled Free Cooling
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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 and YLCS 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 Evaporators Plus
many common refrigeration, electrical components.
New components include The Carel PCO3 controller
with the Free Cooling Software. Hydronic system
and Three way Valve.
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YSFC Service Training and Replacement Parts.

• 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.

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

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YSFC JCI-Hitema Contract Special Variations

• 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.

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YSFC Communications Product Process

• JCI Sales and the Product Supply Sourcing will
  jointly work with Hitema.
• Responsibilities are as follows.
• Product Supply Sourcing.
• Product Manager Roger.J.Smeed_at_JCI.com
  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 Roger.J.Smeed_at_JCI.com
  00441268246198.
• Order Entry Processing and Commissioning
  registration and Warranty management.
• Centralised through Customer Services
  Basildon.
• Orderentry CG-EUR-Basildon_at_jci.com
  00441268246266.
• After Sales Technical Operation support.
• Tim.Jennings_at_jci.com 00447976196714.
• Renewal Parts
• hvacparts.cg-eur_at_jci.com 0044126824600.

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Have Your Say Any Questions?
Have Confidence in Free Cooling and our New
YSFC. Thank you.