WATER-COOLED Process CHILLERS SCROLL R407C, PACKAGED, Tankless PZW1S Legacy Chiller Systems, Inc. www.legacychillers.com
Example: P Z W 1 S E 5 P P = Packaged IE = Indoor Evaporator OC = Outdoor Condenser Z Z = Scroll Compressor S = Semi-Hermetic Compressor W A = Air-cooled Condenser W = Water-cooled Condenser T = Integrated Stainless Steel Tank PT = Integrated Poly Tank N = Nexus Technology 1 Nominal Capacity Tons Ex.: 1.5 x 12,000 BTUH = 18,000 BTUH, etc. S S = Single Compressor D = Dual Compressor E Electrical Requirement: E = 208/230-1-60 F = 208/230-3-60 G = 460-1-60 H = 460-3-60 I = 575-3-60 J = 220-1-50 K = 200/208-3-50 L = 380-3-50 5 Refrigerant: *4 = R134A 5 = R407C 6 = R404A * Special order refrigerant class Page 2
Page 3
Legacy Chiller Model: PZW1S Industrial grade process chiller 1 to 20 tons Series Standard Options ETL listed IDEC Pentra PLC control System with 5.7 inch ultra bright touch screen. Copeland Scroll compressor(s) STAINLESS STEEL brazed plate evaporator with insulation, and secured in a steel bracket Compressor and hot gas valve time delays 24V control transformer Suction accumulator Water flow switch, Pump differential sensor Hot gas by-pass capacity control Return fluid sensing thermostat Liquid line drier, sight glass, solenoid, TEV MICRO - High-pressure refrigerant control MICRO- Low-pressure refrigerant control with time MICRO - inlet and outlet realtime readouts. Compressor motor contactor Hard start kit (single phase units only) Painted galvanized steel sheet metal cabinet (30 tons and larger systems are GALVANIZED).5 in insulation on all water and refrigerant lines Micro - Processor On - Off switch for control circuit operation Micro - Processor automatic compressor lead lag on dual circuit units Full refrigerant charge from factory (407C) Standard Computerized factory run testing under load conditions Basic Technical Support Standard LTL crating - Pallet, Foam vertical corners with platic wrap. Optional Enhanced Packaging is available for most models. Five Year Extended Warranty Program Page 4
Factory offered options for this chiller model - Check mark indicates inclusion of this item Process drop assemblies, one inch copper, wall mounted and ready to install 115 volt service outlet, rain-tight (Requires external ckt) BACnet Gateway and Router, BB2-7030, IP to MS/TP, factory installed Compressor fusing (230V) Electrical system upgrade (575V 3ph 60HZ) EWON - VPN access anywhere - Click (?) for more information Fused disconnect (230V) MOXA Five Port Unmanaged Network Switch - Factory Installed Remote Chiller Controller Touchscreen - Shipped Loose Voltage - phase monitor with touchscreen HMI indicator. Process water flow meter (20-100 gpm) Process water flow meter (2-20 gpm) Process water pressure gauge set in-out Add-on package for Glycol applications Evaporator heat tape freeze protection thermostatically controlled Casters (Factory mounted) for easy chiller re-location Condenser water regulating valve - Shipped Loose Enhanced LTL Crating - Pallet, hard wood slats enclosure and plastic wrap Special evaporator, interconnecting piping and components for de-ionized and reverse osmosis water systems. ** Call Factory For Availability and Pricing ** Low flow bypass valve (System pump required) Pump suction side isolation valves (For two pumps max) System Pump Option -.50 horse power - Standard On/Off control System Pump Option -.75 horse power - Standard On/Off control System Pump Option -.75 horse power - VFD pump control adder controlled by PLC. System Pump Option - 1.0 horse power - Standard On/Off control System Pump Option - 1.0 horse power - VFD pump control adder controlled by PLC. System Pump Option - 1.5 horse power - Standard On/Off control System Pump Option - 1.5 horse power - VFD pump control adder controlled by PLC. Basic Technical Support Five Year Extended Warranty Program Page 5
Page 6
1S Page 7
Page 8
PART 1 - GENERAL 1.1 SUMMARY Section includes design, performance criteria, refrigerants, controls, and installation requirements for Air-cooled chillers for process cooling applications. 1.2 REFERENCES Comply with the following codes and standards: AHRI 550/590 NEC, ANSI/ASHRAE 15, ASME Section VIII, ETL Listed, ANSI UL 1995, CSA C22.2 No. 236. 1.3 SUBMITTALS Submittals shall include the following: A. Product dimensions, dry weights and plumbing connection information. B. Summaries of electrical and water utility requirements during operation. C. Control system diagram showing points for field interface and connection to external BMS systems. 1.4 QUALITY ASSURANCE A. Regulatory Requirements: Comply with the standards in Section 1.2. B. Prior to shipment, product will be run tested under load confirming that all features of the products are fully operational and performing to factory specifications. Performance data shall be provided in electronic format and shipped with the product. 1.5 DELIVERY AND HANDLING A. Product shall be delivered to the job site completely assembled with full factory refrigerant charge. B. Comply with the manufacturer's instructions for transporting and rigging. 1.6 WARRANTY and MAINTENANCE A. The chiller manufacturer's limited warranty shall be for a period of five years from date of shipment. For more information please consult the latest product IOM document. B. Maintenance of the product shall be the responsibility of the owner. PART 2 - PRODUCTS 2.1 ACCEPTABLE MANUFACTURERS: Legacy Chiller Systems, Inc. 2.2 PRODUCT DESCRIPTION A. Provide and install as shown on the plans a factory assembled Air-cooled packaged chiller. B. Each unit shall include single, dual, triple or quad refrigerant compressor configuration depending on design requirements. Standard On/Off or Digital Scroll compressors shall be used depending on design requirements. Chillers shall operate with R407C refrigerant for medium temp and R404A for low temp process chiller operations. C. The evaporator, condenser, and expansion valve shall be configured to operate as one refrigerant circuit. 2.3 DESIGN REQUIREMENTS A. Chiller shall be equipped for single-point power connection. B. Plumbing Fluid System(s): Only Type L grade copper or schedule 80 PVC (on special order systems) shall be used to interconnect the chillers various fluid systems. C. Plumbing Refrigeration System(s): Only Type L grade copper shall be used to interconnect the chillers various refrigeration systems. D. Plumbing assembly: For all copper plumbing joints, silfoss with a minimum silver content of 15% shall only be used. For PVC plumbing joints, primer shall be used. Grade of PVC cement shall be equal to Weld-on brand "705" grade of equal. E. Plumbing bends: In both fluid and refrigeration systems (when copper tubing is used), majority of piping bends shall be machine bent. Use of interconnecting fittings shall be kept to a minimum reducing the potential for braze Page 9
joint leaks. 2.4 CHILLER COMPONENTS A. Sheet metal cabinet: Based metal shall consist if galvanized steel with a minimum thickness of 22ga. B. Paint: On applicable models, protective coating (Paint) shall be electro (powder) coated. Protective coating shall be applied to metal POST PRODUCTION to allow for maximum long term protection of cabinetry. C. Compressor(s) Brand: Shall be Copeland Brand Scroll, Copeland Digital Scroll or Copeland Discus type. D. Refrigerant Evaporator : Evaporator shall be manufactured by Alfa Laval or Gea or approve equal. Evaporators shall be designed, constructed, tested and stamped according to the requirements of the ASME Code, Section VIII. E. Refrigerant Condenser (Air or Water cooled): Shall be designed, constructed, tested and stamped according to the requirements of the ASME Code, Section VIII. F. Suction line accumulator: Chillers refrigeration system shall be equipped with a suction line accumulator to prevent compressor damage in the event of a thermal expansion valve failure increasing the potential life of the compressor. G. Liquid Line Solenoid: Chillers refrigeration system shall be equipped with a liquid line solenoid. Solenoid valve shall be closed during compressors off cycle preventing migration of liquid refrigerant, and potential evaporator flooding that can reduce the chiller's compressor life cycle. H. Refrigerant sight glass: Chiller's refrigeration system shall be equipped with a sight class (with moisture indicator) to be used for technical diagnostics during initial commissioning and on-going maintenance operations. I. Refrigerant filter drier: Chiller's refrigeration system shall be equipped with a liquid line filter dryer to maintain the lowest moisture levels as possible during on-going maintenance operations. J. Non OEM components: No more than 5% of the chiller's internal components shall be Original Equipment Manufacture (OEM) components. At least 95% of the total number of components used shall be available at local HVACR supply wholesalers reducing users lifetime cost of ownership. K. Scroll compressor with crankcase heater: On applicable compressors, Scroll shall be equipped with an electric crank case heater. Heater shall be wired to only operate in the compressors OFF cycle. L. Water flow switch: A factory installed digital contact flow sensor shall be used. Materials in contact with process fluid shall be stainless steel or a durable plastic compound. M. Hot gas by-pass capacity control: Each refrigeration circuit shall be equipped with one 24 vac controlled hot gas bypass solenoid and one hot gas bypass solenoid regulator valve. The regulator valve shall be set up and tested by the factory to open at approximately 33 F suction temperature. Note: Systems requiring a fluid/glycol set-point lower than 45 F will require field calibration. See Legacy KB for more information. Chiller PLC shall provide a hot gas deployment delay of 90 seconds standard. Chiller PLC shall also provide the ability to adjust hot gas deployment time delay as needed. N. 24V control transformer: An industrial grade control transformer shall be factory installed. O. Direct drive condenser fan motor: On air-cooled process chiller models, an industrial grade bracket mounted condenser fan motor shall be used. Fan motor shall have sealed bearings requiring limited maintenance. P. Rust resistant, high CFM, aluminum condenser fan blade: On air-cooled process chiller models, an industrial grade aluminum condenser fan blade shall be used. Q. Condenser(s): Air-cooled SCROLL compressor condenser models shall use all copper tubing aluminum fins condenser(s) with a minimum of 14 fins per inch. Water-Cooled SCROLL compressor condenser models shall use tube in tube. R. Compressor motor contactor: Only industrial grade compressor contactors shall be used. S. Condenser motor and control circuit fusing: On air-cooled process chiller models condenser fan motors shall be independently fused. T. Insulation on all water and refrigerant lines: All internal water, refrigeration suction lines and tanks (on tank model chillers) shall be insulated with a minimum of 1/2" insulation. Insulation shall be properly installed and fitted as to no allow air space between the pipe and insulation to prevent condensate buildup. U. Chiller Controls: This chiller control system shall provide the following features: 1. Ultra bright 5.7" Color LCD OI Touch Screen with auto screen saver 2. Simple navigation. 3. Real-time Pressure and Temperature readings 4. Automatic COMPRESSOR Lag/Lead with the ability to program modified lag/lead operations Page 10
5. Automatic SYSTEM PUMP Lag/Lead with the ability to program modified lag/lead operations 6. Manual and auto system pump control 7. Control operates to a +/- 1 F accuracy 8. Operates and displays in F or C 9. Controls cooling on inlet or outlet temperature 10. Monitors and logs compressor/pump run hours 11. USB update slot for IN-PLACE HMI and PLC software updates. Manufacturer shall NOT charge for software updates and shall make such updates available for download. 12. Only CE, UL Listed control components shall be used. 13. HMI shall provide built in web server features standard. 14. HMI shall offer an SD slot for additional operational data storage and data logging. 15. All operational activity and alarm occurrences shall be downloadable from SD card in.csv format. 16. Only removable control relays shall be used. PLC shall NOT contain hard soldered relays that will require replacement of the PLC should a relay fail. 17. Modbus TCP, RTU and ASCII for integration with most Building Automation Systems (BAS) 18. Preconfigured (Optional) BacNet and LONWORKS communication gateways shall be offered for integration of the most popular building automation systems. 19. Modbus I/O table shall be available for download from manufactures website. 20. PLC I/O shall be both modular and expandable. 21. PLC shall have the optional feature to generate text or email alerts for potential maintenance or service issues. 22. PLC shall be capable of trouble free field operation from -10 F to 120 F. 23. Touch screen shall provide basic onboard help with troubleshooting tips. 2.5 SPECIAL QUALIFICATIONS A. Weights are based on models with standard features only. Weights will increase with each added option. Consult factory. B. The calculations for the MCA and MOP are based on requirements of NFPA 70, the National Electrical Code (NEC) and CSA C22.1, the Canadian Electrical Code (CEC). The MCA is the minimum wire size needed to guarantee that the wiring will not overheat under any operating conditions. The MOP is the maximum allowable circuit breaker size that will properly disconnect power to the equipment under any anticipated fault condition. C. Low ambient, or lower leaving water temperatures, can require the recirculation of glycol solutions or other fluid blends. These solutions can effect unit capacities. Please consult the factory on these or other special applications for proper sizing. 2.6 OPTIONAL FEATURES - Please "Optional Features" section of this document for to select. PART 3 - EXECUTION 3.1 INSTALLATION A. Process chillers must be installed by a qualified and licensed installer familiar with such installation work. Installer should follow all local codes and refer to the IOM Booklet provided with all Legacy equipment. 3.2 START-UP A. Process chillers must be started-up by a licensed service provider familiar with such work. Technician should follow all local codes and refer to the IOM Booklet provided with all Legacy equipment. Note: Legacy Chiller Systems offers a fee based start-up service available upon request. Please contact for more information. For detailed information on Installation, Operation and Maintenance (IOM) of this product, please Page 11
download and review the latest version of Legacy's IOM booklet from our Knowledgebase at www.legacychillers.com. Page 12
Page 13
Page 14