WFC Applications Manual PDF

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APPLICATIONS MANUAL FOR WFC SERIES

WATER-FIRED CHILLERS/CHILLER-HEATERS
Yazaki WFC-SC Series water-fired chillers are available with nominal cooling capacities of 5, 10,
20, 30, and 50 rated tons. WFC-SH water-fired chiller-heaters are available with nominal capacities of 10,
20, and 30 rated tons. WFC-M water-fired chillers are available with a nominal cooling capacity of 100
rated tons. All are energized by heat medium with allowable temperature range of 158-203°F (70-95°C).
This document is intended to offer information which is expected to be used when applying the
WFC Series units and offers more-detailed information as to why certain items are recommended or
required. It also offers insight gained from past applications and installations without going into detail on
specific projects. This document is intended to be used alongside the Installation Instructions and the
Sales and Design Brochure.
The primary purpose of this document is to help steer designs and installations away from certain
application design features that have been known to fail or ideas that may be valid on older Yazaki systems
or other manufacturer designs, but that will interfere with the logic used in the WFC Series controls or
that may lead to unintended consequences.
TABLE OF CONTENTS
Page
GENERAL INSTALLATION 2
CLEARANCE 3
CHILLED/HOT WATER CIRCUIT 5
Using Glycol in Chilled/Hot Water Circuit 6
Using the Heat Medium to Directly Provide Hydronic Heating 6
Varying the Flow Rate by Use of a VFD 7
COOLING WATER CIRCUIT 8
Controlling the Cooling Water Inlet Temperature 11
Using Glycol in the Cooling Water Circuit 12
Water Conservation Options 12
HEAT MEDIUM CIRCUIT 13
Using Glycol in the Heat Medium Circuit 16
Using the Heat Medium to Provide Hydronic Heating 16
Varying the Heat Medium Temperature by Use of a Mixing Valve 17
USING GLYCOL 18
Ethylene Glycol Charts 18
Propylene Glycol Charts 21
COOLING AND HEATING COIL SELECTION 23
ELECTRICAL REQUIREMENTS 24
For informational purposes only. Yazaki assumes no responsibility for application of this data, for WFCSUL-AM1-2A-0318
actual designs created, nor for service decisions made while using this data. Yazaki reserves the right
to discontinue or change, at any time, specifications, offerings, or designs without notice and without
incurring obligation or liability.
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CONTROL WIRING 24
WFC-SC5 Control Wiring Options 24
WFC-SC/SH Control Wiring Options 25
WFC-M100 Control Wiring Options 30
Changing the Chilled Water Set Point 32
REMOTE LEAVING WATER TEMPERATURE CONTROL 33
CHARTS, DIAGRAMS, AND GRAPHS 34
SPECIFIC APPLICATIONS 41
Cogeneration Applications 41
Solar Applications 42
Auxiliary Boilers 44
Buffer Tanks 44
EXAMPLE PIPING DIAGRAMS 45
Cogeneration 46
Microturbine 50
Solar 52
ABBREVIATION DEFINITIONS & INDEX 55
GENERAL INSTALLATION
While this document attempts to these tubing bundles. As such, it is critically
address most concerns, it is not expected to be important that the unit be within 5° of
able to address every conceivable concern. If a perfectly level. Therefore, it is NEVER
question or application is not addressed by this recommended that the unit be mounted on
manual, please contact Yazaki Energy Systems, inertia springs or other similar vibration
Inc., at 469-229-5443 for further assistance. absorption devices. If vibration is an issue,
Some general installation notes follow: mount the unit on a high-density rubber pad.
Any other method has been proven in past
• In order to maintain the warranty status of
installations to cause issues with proper
the unit, it must be started by an
leveling of the unit. The only vibrating
Authorized Service Provider (ASP). Future
device on the unit is the solution pump,
service should also be done only by on-site
which has almost no vibration at all.
trained personnel or by an ASP.
• The WFC-S units may be laid over onto the
• It is recommended that a hose bib and a
back side (see the Installation Instructions for
120vac duplex outlet be located near the
details) for horizontal movement to its final
WFC unit for ease of future service. An
position, but the WFC unit may not travel by
evacuation should be pulled on the unit 2-3
vehicle to the installation site while in any
times per year, so easy access to power is
position but vertical.
helpful in keeping maintenance costs down.
• Do not mount any electrical disconnects,
• Future maintenance primarily consists of
switches, etc. directly to the WFC unit
evacuation every 4-6 months and adding
panels. Every panel on the unit has the
inhibitor every 3-5 years.
potential to need to be pulled for service
• The WFC units have tubing bundles with drip
access. More importantly, mounting items
trays above them that deliver measured
to the cabinet violates the unit’s UL50E
amounts of fluid to flow over the outside of
Type 3R rating.
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CLEARANCE
The WFC-S units need 39” (1m) clearance wire the controls even if access to the
to the front and to the rear. Side clearance is Junction Box cannot be accommodated.
more flexible. Standard clearance requirements Other service items behind the left side
are 28” (700mm) to the right and left sides, and it panel can be reached from the rear or the
is a good idea to accommodate this requirement. front panels, but not as easily. Any clearance
However, some job sites simply cannot allow for on the left side that is less than 10” (254mm)
such clearance. In such cases, give as much will not allow for removal of the panels at all.
clearance as possible, trying to accommodate • Right Side Clearance – 28” (700mm)
the recommended minimums. Use the following recommended. On all size WFC-S units,
data to guide position selection when clearance there is nothing behind the right side panel
simply cannot be accommodated no matter that requires service access. As such, if side
what is tried: clearance cannot be maintained, this side is
the one that can most afford to be shorted
• Front Clearance – 39” (1m) recommended.
in clearance. Still, any clearance on the right
Almost all regular maintenance is done
side that is less than 10” (254mm) will not
through the front panels. It is not a good
allow for removal of the panels at all.
idea to give this side less than recommended
clearance, but any clearance less than 32” • Top – 18” (457mm) recommended. The
(812mm) will result in great difficulty with
clearance for the top panel is primarily to
service and maintenance. service the fusible plug. The recommended
clearance allows for reasonably easy access.
• Rear Clearance – 39” (1m) recommended. All
However, it could be reached from the side
fluid circuit connections are made at the rear
with relative ease on most units, except the
of the unit. All the fluid circuit thermisters
WFC-SC50. However, any top clearance less
are also accessed through the rear of the
than 12” (305mm) will result in severe
unit. On all units over 20 tons, the flow
difficulty in accessing the fusible plug.
switch is accessed through the rear of the
unit. On the WFC-SC50, the Junction Box is
also located at the rear of the unit. Because
The WFC-M has the main control panel
of all the piping and the need for access in
located on the right side of the unit, so clearance
the future, anything less than 39” (1m)
requirements are quite different.
clearance to the rear is unwise.
• Left Side Clearance – 28” (700mm) • Front Clearance – Since the WFC-M uses
recommended. On all 10, 20, and 30 ton straight tube bundles, there is a need for
WFC-S units, the Junction Box is located on tube pull clearance. This clearance is 115”
the left side. 28” (700mm) is barely enough (2920mm). This clearance is not needed at all
clearance to access the Junction Box. It is times. So long as walls or other items in the
recommended that this side not be given any way can be removed when the clearance is
less than recommended clearance. If, needed, the actual minimum clearance for
however, it cannot be accommodated, be the front of the WFC-M unit is 28” (700mm).
aware that every wire in the Junction Box Very little is accessed through the front of
goes to a terminal strip in the unit’s Control the unit, but solution sampling valves are
Panel. It will be more difficult to wire to located here so less than 28” (700mm) will
these terminals since this terminal strip is make solution sampling rather difficult in the
not anticipated to be used as a Junction Box future.
terminal, but it is possible to still properly
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• Rear Clearance – 39” (1m) is recommended located on the right side of the unit. Most
and that is the absolute minimum. Piping is regular maintenance is done through the
so large that it can barely fit in the minimum right side of the unit as well. Any less than
clearance. It is impractical to provide less. 32” (812mm) will make regular maintenance
• Left Side Clearance – 28” (700mm) is difficult.
recommended. The solution pump and • Top – There is no need to access the top of
several other components including the flow the unit except to access the lifting lugs. 18”
switch are accessed through this side. (457mm) is recommended but anything less
Having less than this clearance will make than 12” (305mm) will make top removal
future maintenance difficult. difficult.
• Right Side Clearance – 39” (1m)
recommended. The main control panel is
Multiple Unit Arrangement

When several units are set next to each cabinet panels must be removed so that service
other, the recommended clearance between access is maximized. In such a modular
them is not cumulative. For example, with 28” configuration, clearance between two units is
(700mm) space between two units, each unit has essentially zero. It will be necessary to cover the
its minimum recommended clearance gap between the two units with custom-made
requirement satisfied without the need to space sheet metal panels to maintain the weather-
them 56” (1400mm) apart. resistant characteristic of the cabinet. An
optional Modular Configuration Cabinet
The singular exception is the WFC-SC50.
accessory may also be available at the time of
This unit has its Junction Box located at the rear
order. Be aware, modular configuration may
of the unit. Therefore, it is possible to set these
result in loss of the UL50E Type 3R rating on the
units right next to each other in what is called a
cabinet. Modular Configuration is not supported
“Modular Configuration”. To do so, the side
on any other size WFC unit model.
Equipment
WFC-SC5 WFC-SC/H10 WFC-SC/H20 WFC-SC/H30 WFC-SC50 WFC-M100
Dimensions
23.4 29.9 41.7 54.3 70.3 59.4
Width Inches (mm) (594) (760) (1060) (1380) (1785) (1510)
29.3 38.2 51.2 60.8 77.2 144.0
Depth Inches (mm) (744) (970) (1300) (1545) (1960) (3654)
69.1 74.8 79.1 80.5 82.1 86.6
Height Inches (mm) (1755) (1900) (2010) (2045) (2085) (2200)
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CHILLED/HOT WATER CIRCUIT

1. The chilled/hot water circuit is a copper WFC unit can generate. This negative effect
tubing bundle. This circuit is comprised of will become even greater if glycol is also
copper tubing, brass fittings, and associated used in multiple fluid circuits.
solders. Any chemicals that are used in this 3. Allowable chilled/hot water flow rate is 80
circuit should bear this component make-up – 120% of nominal flow rate. The flow is not
in mind. required to be particularly stable, but should
2. No more than a 50% mixture of glycol by never leave these limits.
weight should be used. Bear in mind that 4. The maximum pressure allowed in the
glycol will have a significant negative impact chilled/hot water circuit is 150 PSI (1070 kPa).
on the amount of heat that can be If the chilled/hot water circuit will be a
transferred which will, in turn, have a closed loop, a properly charged expansion
negative impact on the cooling capacity the tank will be required.
TYPICAL CHILLED/HOT WATER PIPING

A balance valve/circuit setter is WFC unit to help ensure a solid mass of fluid in
recommended to be used when a VFD is not the fluid circuit.
being used since some method of flow control
If used, Pressure and Temperature test
must be available. Isolation valves should be
ports (Pete’s Plugs) should be located at the inlet
present at both the inlet and the outlet of the
and outlet of the chilled/hot water circuit in the
WFC chilled/hot water circuit. The balance valve
WFC unit. A pressure relief valve should be
may double as an isolation valve, depending
installed that will open if the pressure within the
upon design. It is always recommended that the
chilled/hot water circuit rises above 150 PSI (1070
balance valve be located downstream of the
kPa). The circuit will also need a properly-
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charged expansion tank unless the chilled/hot Freeze protection for the circuit can be
water circuit is not a closed loop. A pressure provided by the WFC unit by installing a field-
regulating valve should be installed at the make- supplied thermostat to the IF1 terminals located
up water inlet if the make-up water pressure on the I/O Board inside the WFC control panel.
exceeds 150 PSI (1070 kPa). In any case, a check The thermostat should be sensing the
valve should be installed on the make-up water temperature of the fluid in the chilled/hot fluid
inlet to prevent fluid from within the circuit from circuit. It is recommended this thermostat close
pushing back out into the municipal water if it senses the temperature of the fluid to be
supply. Drain valve(s) should be placed so that lower than 35.6°F (2°C). Make sure the
when the isolation valves are closed, the WFC thermostat opens again around 37.2°F (3°C).
unit’s fluid circuit can be drained. Finally, a When the circuit is closed, the IF RUN light will
strainer with clean-out should be positioned illuminate on the front panel and the P contacts
upstream of the chilled/hot water pump itself. If will be closed in an attempt to run the
desired, a check valve may be placed chilled/hot water pump.
downstream of the chilled/hot water pump.
SPECIFIC CHILLED/HOT WATER CIRCUIT OBJECTIVES

Using Glycol in Chilled/Hot Water Circuits using water. This could cause unexpected action
of the pressure relief valve in certain cases.
The chilled/hot water circuit is made of
copper and brass parts with appropriate welding Consult the “Using Glycol” section of this
materials at joints. Any chemicals used in the manual for further information.
circuit should bear these materials in mind. As
far as the WFC unit is concerned, the primary use Using the Heat Medium to Directly Provide
for glycol in the chilled/hot water circuit is for
Hydronic Heating
freeze protection. The anti-boil characteristics
should never be needed for the sake of the This method is really intended to be
chiller. employed on cooling-only models. The
advantage of using this method is the ability to
It is usually preferable to use Propylene
deliver heated water at a temperature above
Glycol (PG) rather than Ethylene Glycol (EG). PG
140°F (60°C). By necessity, it will mix the fluids of
is non-toxic. Further, the heat transfer and fluid
the heat medium and chilled/hot water circuits,
motion characteristics of PG are closer to those
so additional care must be taken when choosing
of water than those of EG. The only real
chemical makeup of the fluid, especially where
functional advantage EG has over PG is in the
glycol may be concerned.
anti-boil characteristic, which is meaningless in
regard to the chilled/hot water circuit. To use this method, an additional heat
medium bypass valve must be used. However,
No matter what form of glycol is chosen,
rather than bypassing the heat medium into a
no more than 50% by weight should be used. Be
heating coil, it passes the heat medium around
aware that the detrimental effects on heat
into the chilled/hot water circuit, or into a heat
transfer and subsequent unit cooling and/or
exchanger which, in turn, heats the chilled/hot
heating capacities are cumulative when glycol is
water circuit. Mixing fluids from two circuits is a
used in other circuits as well. Be aware that the
legitimate method of providing heating, but this
higher viscosity of glycol will also cause the
is not a method preferred by Yazaki. It is,
pressure in the loop while the chilled/hot water
however, one of the available methods to allow
pump is running to be higher than it would be
a WFC-SC50 or WFC-M100 unit to be used to
provide heating and cooling in a 2-pipe system.
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The WFC-SH units can produce either the thermal cycle. The absorption process itself
heated or chilled water in a 2-pipe system, but in means that changes in heat medium input take
the heat mode, it normally delivers 131°F (55°C) 1-3 minutes before the chilled water output
heated water. The highest temperature it can responds in kind. In addition, the internal logic
produce is about 140°F (60°C). If the system of the WFC-S has a tendency to conflict with this
requires hotter water than 140°F (60°C), then the out-board strategy which almost inevitably
WFC-SH unit is inappropriate for use as the heat causes the VFD to “hunt” as the WFC-S capacity
source. control energizes or de-energizes various valves
and functions to match the load demands. It is
It should be noted that WFC-SH units
recommended, therefore, that the normal
produce 131°F (55°C) heated water because it has
capacity control strategy not be circumvented.
been found that heating with this temperature
Actual application results on installations that
of heated water requires a coil, fan speed, and
have tried this have all been unfavorable (as of
flow rate that is the almost the same as the coil,
this writing).
fan speed, and flow rate required for cooling
with 44.6°F (7°C) chilled water. This allows the
same fan coil used in a 2-pipe cooling system to
also be used in heating mode without need for
varying fan speeds or complicated changeover
controls.
Varying the Flow Rate by Use of VFDs

It should be noted that the WFC-S unit is
designed with constant flow in mind. There is
little value in varying the flow rate on any circuit.
All that is accomplished by varying the flow rate
is changing the temperature difference through
the chilled/hot water circuit. It will have little
appreciable effect on the actual capacity.
If a VFD is used, its primary values are for
soft-start and to ensure a particular flow rate is
maintained, regardless of the condition of
strainers or other factors. The VFD control
points must be set to no less than 80% of rated
flow rate and no more than 120% of rated flow
rate. The flow rate range will allow a
temperature difference range of 8.3 - 12.4°F (4.6
- 6.9°C) when cooling at full capacity. This
temperature difference range will change
slightly when glycol is being used in the
chilled/hot water circuit, but the flow rate
limitation of 80-120% still applies.
Finally, be aware that there is NO
reliable method of using a VFD on the heat
medium circuit to control or fine-tune the chilled
water outlet temperature due to the nature of
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COOLING WATER CIRCUIT
1. The cooling water circuit is a copper tubing 3. Install flow balancing valves in each
circuit for non-standard crossover piping
bundle that is broken into two circuits. One designs.
circuit is the Condenser and the other circuit 4. Install cooling water flow and/or isolation
is the Absorber. On all units except the WFC- valves at least 5 pipe diameters
SC/SH10 and the WFC-M100 units, these are upstream and downstream of their
respective “T” fittings.
two completely separate circuits with their 5. The crossover pipe configuration must
own connection points located at the back of provide clear access to the rear of the
the chiller. A cooling water crossover must chiller for maintenance.
be field-supplied for proper cooling water
piping to these units, as shown below: On the WFC-SC/SH10 and WFC-M100 units,
however, there is an internal crossover
incorporated as part of the unit design.
Therefore, WFC-SC/SH10 and WFC-M100
units only have one cooling water inlet and
one cooling water outlet, both still located at
the back of the unit. These circuits are
comprised of copper tubing, brass fittings,
and associated solders. Any chemicals other
than water that are used in this circuit
should bear this component make-up in
mind.
2. No more than a 50% mixture of glycol by
weight should be used. Bear in mind that
glycol will have a significant negative impact
on the amount of heat that can be
transferred which will, in turn, have a
negative impact on the cooling capacity the
MODEL COPPER TUBING STEEL TUBING WFC-S unit can generate.
WFC- A B A B 3. Allowable cooling water flow rate is 100 –
SC5 2” 1-1/2” 2” 1-1/2” 120% of nominal flow rate. The flow rate of
SC/SH20 3" 2" 3-1/2" 2-1/2" the cooling water should never fall below the
SC/SH30 3" 2-1/2" 4" 3" rated flow rate. If the flow rate should fall
SC50 4" 3" 5" 3-1/2" below the rated flow rate, the unit could face
If piping size reduction is required, it should be done at the unit. a situation where there is not enough
All sizes listed are minimum sizes. thermal capacity in the cooling water to be
able to reject the total of the heat medium
input and the heat taken in by the
CROSSOVER PIPING NOTES:
evaporator. The effect of such a deficiency
1. WFC-SC/SH10 and WFC-M100 units is a direct loss cooling capacity. This loss is
have an internal crossover and do not
require this assembly.
practically 1 BTU deficiency in the cooling
2. Each standard crossover pipe has similar water = 1 BTU loss in cooling capacity.
pressure losses for balanced cooling NEVER UNDERSIZE THE COOLING TOWER
water flow through the Absorber and OR COOLING WATER PUMP!
Condenser.
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4. The maximum pressure allowed in the are taken when isolation valves create a
cooling water is 150 PSI (1070 kPa). closed loop in the tubing within the unit
5. A properly charged expansion tank will be during Heating mode.
required on closed loop systems. Such a 6. The unit is designed for constant flow;
tank may not be required if the cooling water therefore, the only benefit derived from use
circuit is an open-loop system. For WFC-SH of VFD pumps is soft start and an assured
units, ensure that proper expansion steps flow rate.
TYPICAL COOLING WATER PIPING
A balance valve/circuit setter is If used, Pressure and Temperature test

recommended to be used when a VFD is not ports (Pete’s Plugs) should be located at the inlet
being used since some method of flow control and outlet of the cooling water circuit in the WFC
must be available. A balance valve/circuit setter unit. If the cooling tower is closed loop, a
will be needed on the outlet side of both the pressure relief valve should be installed that will
condenser and absorber cooling water circuits open if the pressure within the cooling water
on all sizes except for the WFC-SC/SH10 and circuit rises above 150 PSI (1070 kPa).
WFC-M100 so that each circuit can be set
The circuit will also need a properly-
independently of the other. Isolation valves
charged expansion tank unless the cooling water
should be present at both the inlet and the outlet
circuit is not a closed loop. A pressure regulating
of the WFC cooling water circuit(s). The balance
valve should be installed at the make-up water
valve may double as an isolation valve,
inlet if the make-up water pressure exceeds 150
depending upon design. It is always
PSI (1070 kPa). In any case, a check valve should
recommended that the balance valve(s) be
be installed on the make-up water inlet to
located downstream of the WFC unit to help
prevent fluid from within the circuit from
ensure a solid mass of fluid in the fluid circuit.
pushing back out into the municipal water
supply. Drain valve(s) should be placed so that
P a g e | 10
when the isolation valves are closed, the WFC BTU (44 kw), but a 10-ton WFC-S series will have
unit’s fluid circuit can be drained. Finally, a to reject about 292,000 BTU (85.4 kW) [(171.4
strainer with clean-out should be positioned MBTU (50.2 kW) heat input plus 120 MBTU (35.2
upstream of the cooling water pump itself. A kW) cooling capacity)]. When contacting cooling
check valve should be placed downstream of the tower sales departments, be aware that they
cooling water pump. In cases where the cooling never think in terms of the needs of absorption
tower is below the level of the chiller, this check systems. If they are only told that it’s for a 10-
valve is not optional. ton chiller, they will provide a cooling tower that
rejects only 150,000 BTU (44 kW) which isn’t even
A diverting valve, typically designated
enough to remove the total heat input, much
CWV, can be used in the cooling water return
less provide any cooling capacity.
circuit to the cooling tower. This valve can divert
the cooling water return directly into the cooling When choosing a cooling tower, do not
tower sump when conditions warrant. Typically provide the salesman with the capacity in tons.
for WFC-S units, this would be set to dump into Instead, using the 10-ton WFC-S as an example,
the sump on start of a cycle when the cooling ask for a bid for a tower that can reject 292,000
water is being supplied at a temperature colder BTU (85.4 kW) and can handle an 80 GPM (5 l/sec)
than 75.2°F (24°C). WFC-M units can handle flow rate at a 10°F (5.5°C) approach. Each portion
temperatures down to 64.4°F (18°C) before the of this statement is important and must not be
water should be diverted to the sump. The CWV left out. WFC units use a much higher flow rate
would also be used to dump directly into the than any compression system, so a tower that
cooling tower sump at the beginning of a cooling can handle the BTU component may not be able
cycle that is following the Heat/Cool changeover to handle the through-put of up to 8 GPM (0.5
in order to prevent a slug of hot water from l/sec) per ton. The approach is another factor that
being directed over the cooling tower fill media, the cooling tower vendor will need in order to
thus preventing possible thermal damage to the determine proper sizing, but the approach does
fill media. not differ between compression systems and the
WFC requirements.
Freeze protection for the circuit can be
provided by the WFC unit by installing a field- Other methods of heat rejection are
supplied thermostat at the IF2 terminals located available and acceptable so long as they can
on the I/O Board inside the WFC-S control panel. reject the necessary amount of heat at the
The thermostat should be sensing the required water flows and the unit is protected
temperature of the fluid in the cooling water from potentially negative effects from using the
circuit. It is recommended this thermostat close other method. Those methods include but are
if it senses the temperature of the fluid to be not limited to ground loops, rejection to water
lower than 35.6°F (2°C). Make sure the (stream, pond, lake, or ocean), adiabatic coolers,
thermostat opens again around 37.2°F (3°C). evaporative dry coolers, closed loop cooling
When the circuit is closed, the IF RUN light will towers, etc.
illuminate on the front panel and the CP contacts
The advantage of ground loop or closed
will be closed in an attempt to run the cooling
loop systems is that they typically do not require
water pump.
all the maintenance that the typical cooling
Cooling towers are the typical method of tower does. This could give a significant life-
heat rejection. Always keep in mind that, when cycle cost advantage.
compared to compression systems, absorption
systems typically require 200% or more of the
cooling capacity in the tower. A 10-ton
compression system typically rejects 150,000
P a g e | 11
SPECIFIC COOLING WATER CIRCUIT OBJECTIVES

Controlling the Cooling Water Inlet unit itself will adjust to the cooling water inlet
Temperature temperature that is provided so no further
interface will be required.
The cooling water inlet temperature is
extremely important to the proper function of Another method of control is by use of a
the unit. However, the WFC-S series units can cooling water bypass valve in the return circuit
handle a fairly wide range of cooling water inlet to the tower, usually indicated by the
temperatures. In general, the colder the cooling designation CWV. If the tower fan cannot be
water inlet temperature, the greater the cooling controlled, the CTF circuit of the WFC unit could
capacity that can be achieved. Under no be used to control the field-supplied CWV in
circumstances should the cooling water inlet order to achieve cooling water inlet temperature
temperature be set to hold a temperature below control.
75.2°F (24°C). Doing so will result in a LOSS of Some sources of heat rejection
capacity due to action of crystallization- consistently allow for cooling water inlet
prevention procedures and solution dilution temperatures below the allowable 75.2°F (24°C).
functions. The WFC-M series is different in that These include ground loops as well as lake-pond-
it has more sophisticated logic and can handle river water loops and well water systems. In
cooling water temperatures down to 64.4°F these cases, a mixing valve must be used in the
(18°C) before it begins crystallization-prevention circuit that will allow a portion of the cooling
procedures. water outlet fluid that is exiting the WFC unit to
The most common method of be diverted back into the WFC unit’s cooling
controlling the cooling water inlet temperature water inlet. The WFC unit has no function that
is by use of cooling tower fan cycling or cooling can control this, so all control in such cases must
tower fan speed control. For fan speed control, be outboard. Set the mixing valve to control at
a VFD cooling tower fan is most commonly used. 80.6°F (27°C) so that there is plenty of room for
The WFC unit will have no interaction with the valve to modulate as necessary without
control of the VFD cooling tower fan since the leaving the allowable temperature range of
VFD will take its cue from the actual temperature 75.2°F (24°C) – 89.6°F (32°C). If used, the mixing
of the cooling tower sump. valve should divert to a point upstream of the
cooling water pump as shown below.
Another common method of cooling
water inlet temperature control is by fan cycling.
The WFC unit CAN control the fan starter control
signal in order to cycle the fan. If this is utilized,
the dry contact circuit between CM1 and CTF.
On WFC-S units, this circuit is opened when the
cooling water inlet temperature falls below
80.6°F (27°C) and is closed when the temperature
rises above 84.2°F (29°C). On WFC-M units, this
circuit is opened when the cooling water inlet
temperature falls below 75.1°F (24°C) and is
closed when the temperature rises above 81.5°F
(27.5°C). It is NOT necessary to use the onboard
fan cycling capability if an outboard fan cycler is
desired. Regardless of the method used, the
P a g e | 12
Using Glycol in the Cooling Water Circuit temperature difference range of 7.2 – 9.0°F (4 -
5°C) when running at full capacity. This
The cooling water circuit is made of
temperature difference range will change
copper and brass parts with appropriate welding
slightly when glycol is being used in the cooling
materials at joints. Any chemicals used in the
water circuit, but the flow rate limitation of 100-
circuit should bear these materials in mind. As
120% still applies.
far as the WFC unit is concerned, the primary use
for glycol in the cooling water circuit is for freeze
protection. The anti-boil characteristics should
Water Conservation Options
never be needed for the sake of the chiller.
Since the system requires cooling water
It is usually preferable to use Propylene
inlet temperatures below 89.6°F (32°C), air-
Glycol (PG) rather than Ethylene Glycol (EG). PG
cooled condensers are not a viable option. The
is non-toxic. Further, the heat transfer and fluid
only practical method to achieve the required
motion characteristics of PG are closer to water
temperatures is by use of evaporative cooling.
than those of EG. The only real functional
The most common method of evaporative
advantage EG has over PG is in the anti-boil
cooling is achieved through use of a cooling
characteristic, which is meaningless in regard to
tower. However, these towers require chemical
the cooling water circuit.
maintenance and consume a great deal of water.
No matter what form of glycol is chosen, As a result, water conservation may become a
no more than 50% by weight should be used. Be higher priority.
aware that the detrimental effects on heat
Bar none, the most effective method of
transfer and subsequent unit cooling capacity is
water conservation is by use of a ground loop.
cumulative when glycol is used in other circuits
This closed loop system completely eliminates all
as well. Be aware that the higher viscosity of
chemical maintenance and doesn’t regularly
glycol will also cause the pressure in the loop
need make-up water. However, the sheer cost
while the cooling water pump is running to be
of drilling and burying the required length of
higher than it would be using water. This could
cooling water loop could make this an
cause unexpected action of the pressure relief
undesirable option. Another complication is the
valve in certain cases.
amount of area the loop will require. Vertical
Consult the “Using Glycol” section of this loops require less acreage, but it tends to cost
document for further information. more to drill such deep holes. Horizontal loops
are cheaper per foot, but the acreage
Varying the Flow Rate by Use of VFDs requirements skyrocket. As wonderful of an
option as this is overall, and for all its significant
It should be noted that the WFC-S unit is benefits, this option is rarely used due to the
designed with constant flow in mind. There is area restrictions.
little value in varying the flow rate on any circuit.
In terms of water conservation, typically
All that is accomplished by varying the flow rate
the first step is to minimize the loss of water in
is changing the temperature difference through
blow-down. This can also help save in chemical
the circuit.
costs. Closed loop cooling towers are the typical
If a VFD is used, its primary values are for method of controlling blow down. They also
soft-start and to ensure a particular flow rate is grant the benefit of practically eliminating the
maintained, regardless of the condition of need to ever descale the cooling water circuit of
strainers or other factors. The VFD control the WFC unit.
Another method of water conservation
flow rate and no more than 120% of rated flow
is by use of adiabatic coolers. These are air-
rate. The flow rate range will allow a cumulative
P a g e | 13
cooled condensers that spray water out in front media in front of the coils. This dry fluid cooler
of their coils in order to achieve a measure of allows for the scale to build up on replaceable
evaporative cooling for the incoming air mass. media pads, eliminating completely any
This reduces the temperature of that incoming chemical maintenance requirement due to the
air mass to a temperature closer to dew point, water. Even the dirt and fuzz typically gather on
allowing the air-cooled coil to function at a the replaceable evaporative media instead of the
temperature below the ambient dry bulb coil. Water savings is considerable since only as
temperature. The down side seems to be scale much water as is needed to wet the pads is ever
buildup on the coil fins and subsequently used, and those pads are only wetted when the
shortened coil life due to the scale and chemicals evaporative dry cooler cannot produce the
necessary to remove the scale. However, the temperature of cooling water without
advantages of not needing regular chemical evaporative assistance. The pads typically need
maintenance coupled with the use of water only to be replaced on an annual basis, but have been
when needed and no blow down loss at all may known to last as long as three years before
more than compensate. Often, however, dirt replacement is required.
and fuzz in the air will gather and cake up on the
Adiabatic coolers and evaporative dry
surface of the coil, reducing its effectiveness.
coolers are the most cost-effective methods of
This dirt and fuzz may need a chemical wash of
water conservation to date. Each has its issues,
its own.
however, and these options are typically more
A new form of fluid cooler is gaining expensive as a capital cost than normal cooling
ground. This new fluid cooler is called the towers. Both of these options also usually
“evaporative dry cooler”. It is essentially an air- require far more fan energy than a typical
cooled condenser with evaporative cooling cooling tower.
HEAT MEDIUM CIRCUIT

This section does not address the negative impact on the cooling capacity the
specific needs of heat sources. Consult the WFC unit can produce. Many heat sources
manufacturer or design engineer for the details actually specify the need for some amount of
and requirements of the heat source. ethylene glycol as an anti-boil agent.
4. Allowable heat medium flow rate is 30 –
1. The allowable temperature range of the
120% of nominal flow rate. The flow is not
heat medium is 158-203°F (70-95°C). The
required to be particularly stable, but should
temperature is not required to be
never leave these limits.
particularly stable, but should never leave
5. The maximum pressure allowed in the heat
these limits while the unit is attempting to
medium circuit is 150 PSI (1070 kPa).
satisfy the load demand.
6. When the WFC unit has satisfied the
2. The heat medium circuit is a stainless-steel
temperature demand in the chilled water
tubing bundle inside the WFC generator.
loop (or the hot water loop in heating mode on
Any chemicals other than water that are
WFC-SH units) then the WFC unit must stop
introduced into this circuit should bear this
receiving heat from the heat medium. No
component make-up in mind.
wild flow is permitted! This is usually
3. No more than a 50% mixture of glycol by
accomplished by use of a Heat Medium
weight should be used. Bear in mind that
Bypass Valve for WFC-S units or for WFC-M
glycol will have a significant negative impact
units, a Heat Medium Proportional Valve.
on the amount of heat that can be utilized by
the WFC unit which will, in turn, generate a
P a g e | 14
7. The unit has logic that will trim its capacity process simply does not allow it to respond
to match the load demand, and therefore, it fast enough for modulation to work.
is not necessary to use a mixing valve to Therefore, it’s always best to let the WFC-S
control the heat medium temperature unit regulate itself. This is not the case for
unless the heat medium temperature could the WFC-M series. The WFC-M unit comes
possibly rise above 203°F (95°C). If a mixing standard with a modulating heat medium
valve is to be used to control heat medium valve to control flow through the chiller. The
temperature, it MUST NOT also be used as chiller always wants the hottest water it can
the Heat Medium Bypass Valve. Always use get without going above 203°F (95°C).
separate valves for separate functions. 9. Bear in mind that whatever heat content is
Every known attempt to use a single valve transferred from the heat medium will be
for both functions has failed to produce the used by the WFC-S unit to generate a cooling
desired results (as of this writing). capacity approximately equal to 70% of
8. Varying the heat medium flow rate and that transferred heat capacity. Likewise,
temperature will have a direct impact on the the heating capacity in a WFC-SH unit should
potential cooling or heating capacity of the be approximately equal to 97% of the
WFC-S unit. However, it is NOT transferred heat capacity.
recommended that any external controls be
installed to control flow and/or For example: If 100,000 BTU of heat is
temperature for the purpose of regulating transferred from the heat medium, it can be
WFC-S unit capacity. Such attempts (as of reasonably expected that a cooling capacity
of approximately 70,000 BTU can be
this writing) have all failed. The primary
generated in a properly maintained and
reason for the failure of this concept is that operating WFC-S unit. Likewise, it can be
the unit will be delayed about 1-3 minutes reasonably expected that a heating capacity
when responding to changes in the heat of 97,000 BTU can be expected in a properly
input due to the thermal wheeling of the maintained and operating WFC-SH unit.
process. Simply put, the nature of the
TYPICAL HEAT MEDIUM PIPING
P a g e | 15
A balance valve/circuit setter is on this in the section covering the WFC unit
recommended to be used when a VFD is not controls.
being used since some method of flow control
When selecting a Heat Medium Bypass
must be available. Isolation valves should be
Valve, ensure the valve and the actuator motor
present at both the inlet and the outlet of the
are capable of sustained temperatures of
WFC heat medium circuit. The balance valve
204.8°F (96°C). The actuator motor should have a
may double as an isolation valve, depending
stroke time no greater than 90 seconds and
upon design. It is always recommended that the
spring-return is preferred. The heat medium
balance valve be located downstream of the
bypass line should have a balancing/ball valve
WFC unit to help ensure a solid mass of fluid in
installed in it. This valve should be adjusted so
the fluid circuit.
that the pressure drop through the bypass is
If used, Pressure and Temperature test equal to the pressure drop through the
ports (Pete’s Plugs) should be located at the inlet generator of the WFC-S unit in order to minimize
and outlet of the heat medium circuit in the WFC stress on the heat medium fluid circuit, the heat
unit. A pressure relief valve should be installed medium pump, and other components.
that will open if the pressure within the heat
Freeze protection for the heat medium
medium circuit rises above 150 PSI (1070 kPa). The
loop is expected to be provided by the heat
circuit will also need a properly-charged
source itself. There is no provision for freeze
expansion tank unless the heat medium circuit is
protection for the heat medium loop within the
not a closed loop. A pressure regulating valve
unit itself. On the wiring diagram for the unit,
should be installed at the make-up water inlet if
there may be reference to a circuit labeled IF3,
the make-up water pressure exceeds 150 PSI
which is control of freeze protection logic for the
(1070 kPa). In any case, a check valve should be
heat medium circuit. In UL models, this circuit is
installed on the make-up water inlet to prevent
not enabled and does not work!
fluid from within the circuit from pushing back
out into the municipal water supply. Drain WFC-M units can use Heat Medium
valve(s) should be placed so that when the Bypass Valves for On/Off usage like the WFC-S
isolation valves are closed, the WFC unit’s fluid units. However, the WFC-M unit is intended for
circuit can be drained. Finally, a strainer with use with a proportional control valve which
clean-out should be positioned upstream of the comes standard with the unit. The Heat Medium
heat medium pump itself. If desired, a check Proportional Valve is shipped separately for
valve may be positioned downstream from the field-installation.
heat medium pump.
The Heat Medium Bypass Valve should
be controlled by the WFC unit itself, using the
P3A (accept) and P3B (bypass) terminals. If some
external control will be operating the Heat
Medium Bypass Valve, that control MUST
monitor these terminals for demand and bypass
requests from the chiller and act appropriately in
accordance with these request signals. Be aware
that the voltage to control the Heat Medium
Bypass Valve is NOT provided by the WFC-S
unit. The WFC unit simply utilizes dry contacts
to control field-supplied voltage to the Heat
Medium Bypass Valve. There will be more detail
P a g e | 16
SPECIFIC HEAT MEDIUM CIRCUIT OBJECTIVES

Using Glycol in the Heat Medium Circuit
The heat medium circuit is made of the heating coils. Physically, the valve would be
stainless steel with appropriate welding identical to the one chosen as the Heat Medium
materials at joints. Any chemicals used in the Bypass Valve since the temperature endurance
circuit should bear these materials in mind. As and stroke time requirements are the same for
far as the WFC unit is concerned, the primary use both applications. This method is really intended
for glycol in the heat medium circuit is for freeze to be employed on cooling only units. The
protection. The anti-boil characteristics should advantage of using this method is the ability to
never be needed for the sake of the chiller. deliver heated water at a temperature above
However, that does not mean that anti-boil 140°F (60°C).
characteristics may not have an important role
The WFC-SH units can produce either
elsewhere in the circuit.
heated or chilled water in a 2-pipe system, but in
It is usually preferable to use Propylene the heat mode, it normally delivers 131°F (55°C)
Glycol (PG) rather than Ethylene Glycol (EG). PG heated water. The highest temperature it can
is non-toxic. Further, the heat transfer and fluid produce is about 140°F (60°C). If the system
motion characteristics of PG are closer to water requires hotter water than 140°F (60°C), then the
than those of EG. The only real functional WFC-SH unit is inappropriate for use as the heat
advantage EG has over PG is in the anti-boil source.
characteristic, which in the case of CHP, may be
It should be noted that WFC-SH units
a key influencing factor.
produce 131°F (55°C) heated water because it has
No matter what form of glycol is chosen, been found that heating with this temperature
no more than 50% by weight should be used. Be of heated water requires a coil, fan speed, and
aware that the detrimental effects on heat flow rate that is almost the same as the coil, fan
transfer and subsequent unit cooling and/or speed, and flow rate required for cooling with
heating capacities are cumulative when glycol is 44.6°F (7°C) chilled water. This allows the same
used in other circuits as well. Be aware that the fan coil used in a 2-pipe cooling system to also be
higher viscosity of glycol will also cause the used in heating mode without need for varying
pressure in the loop while the heat medium fan speeds or complicated changeover controls.
pump is running to be higher than it would be
using water. This could cause unexpected action
Varying the Flow Rate by Use of VFDs
of the pressure relief valve in certain cases.
It should be noted that the WFC unit is
Consult the “Using Glycol” section of this
designed with constant flow in mind. There is
document for further information.
little value in varying the flow rate on any circuit,
including the heat medium circuit. All that is
Using the Heat Medium to Directly Provide accomplished by varying the flow rate is
Hydronic Heating changing the heat transfer into the WFC unit.
The unit can adjust itself to match the load
A second Heat Medium Bypass Valve can
demand, so the only value in varying the flow
be used to allow the heat medium to provide
rate is to control the heat medium inlet
heated water in systems designed for hydronic
temperature from the source. The WFC unit
heating. A valve used for this purpose is usually
reduces capacity quickly when the temperature
called the Heating Coil Bypass Valve. It will divert
of the heat medium falls. Therefore, in order to
heat medium from the WFC unit and direct it to
maximize the cooling capacity, a heat source
P a g e | 17
with low BTU content may still be able to conflict with this strategy, usually causing the
produce usable chilled water capacity by moving mixing valve to “hunt” as it tries to find a balance
the heat medium at lower flow rates (no less than point between the temperature it allows
30% of rated flow) in order to produce higher through to the WFC-S unit and the chilled water
temperatures (no greater than 203°F (95°C)). outlet temperature. A mixing valve may be used
upstream of the Heat Medium Bypass Valve to
If a VFD is used, its primary values are for
limit the heat medium temperature if it could
soft-start and to ensure a particular flow rate is
potentially rise above 203°F (95°C). However,
maintained, regardless of the condition of
there is little reason to try to purposely mix a
strainers or other factors. The VFD control
temperature lower than 200°F (93°C).
flow rate and no more than 120% of rated flow In the case of WFC-M units, it is always
rate. If higher temperature is the goal, then the best to provide it the hottest water possible
VFD can be used to vary the flow rate in order to without exceeding 200°F (93°C). The Heat
provide heat medium supply at a minimum Medium Proportional Valve which comes
temperature, usually recommended to be no standard with the WFC-M unit varies the flow
less than 176°F (80°C). through the generator to match building load.
Therefore, regulating temperature is of
There is NO reliable method of using a
secondary importance for WFC-M units.
VFD on the heat medium circuit to control or
fine-tune the chilled water outlet temperature
due to the nature of the thermal cycle, typically
referred to as “thermal wheeling”. The process
itself means that changes in heat medium input
take 1-3 minutes before the chilled water output
responds in kind. In addition, the internal logic
of the WFC-S has a tendency to conflict with this
out-board strategy which almost inevitably
causes the VFD to “hunt” as the WFC-S capacity
control energizes or de-energizes various valves
and functions to match the load demands.
Therefore, it is recommended that the normal
WFC-S unit capacity control not be
circumvented. Actual application results on jobs
that have tried this have all been unfavorable (as
of this writing).
Varying the Heat Medium Temperature by

Use of a Mixing Valve
The unit itself will adapt to the heat
medium inlet temperature without need of
external controls. Further, this is not a reliable
method to control or fine-tune the chilled water
outlet temperature due to the inherent 1-3
minute delay between varying the heat medium
input temperature and the resulting chilled
water outlet temperature. Further still, the
internal logic of the WFC-S has a tendency to
P a g e | 18
USING GLYCOL
WFC units are optimized around the use Beware! Using glycol in more than one
of water in all fluid loops. When using an anti- loop will have a cumulative effect on the capacity
freeze agent, all aspects of the differences must of the unit. Therefore, it is recommended that
be considered. The glycol solution used won’t glycol use be limited and used only when needed
have the same heat capacity, nor will the heat and only in the lowest concentration necessary
transfer rates be the same as water. Viscosity to achieve the desired temperature protection.
differences will change the pressure drop ratings
Propylene Glycol (PG) is recommended
and can affect pump selection. Additives in the
over Ethylene Glycol (EG). PG performance is
glycol should be considered carefully due to their
closer to water than EG in both thermal capacity
possible corrosive effects on the fluid loop
and heat transfer characteristics. PG is safe and
tubing.
non-toxic whereas EG is a toxic substance. The
When using a glycol solution, the two only reason to ever choose EG over PG is when
primary concerns will be the impact on required the anti-boil characteristic is important.
flow rate and the resulting thermal transfer,
both of which will affect the cooling and/or
heating capacity of the WFC unit. Charts are Freezing Point
provided in this section for use in determining EG PG
the effects of glycol. However, it must be kept in 10% 23°F 26°F
20% 14°F 18°F
mind that under no circumstances should the
30% 2°F 7°F
flow rate ever be greater than 120% of the rated 40% -13°F -8°F
flow rate. Likewise, the pressure limit of 150 PSI 50% -36°F -29°F
(1070 kPa) also still applies.
ETHYLENE GLYCOL CHARTS

The following charts are for use with The third chart is the Pressure Drop
Ethylene Glycol. Adjustment Chart. This chart shows the
adjustment factor that should be applied to the
The first chart is the Capacity
Pressure Drop through a particular fluid loop so
Adjustment Chart. This chart indicates the loss
that the correct measured value may be attained
of heat transfer due to the reduced thermal
for use when setting flow rates through the loop.
capacity of ethylene glycol. This chart shows the
resulting capacity adjustment factor when the For example: 30% EG in the 44.6°F (7°C) chilled water
EG is flowing at the unit’s rated flow rate. loop will result in a Capacity Adjustment
Factor of 0.92. This means that only 92% of
The second chart is the Flow Rate the expected cooling capacity will be
Adjustment Chart. This chart shows what available due to the presence of EG. It will
percent of rated flow rate is required in order to also require the flow rate to be 109% greater
maximize capacity when using ethylene glycol. than the Rated Flow Rate and will produce a
Any flow rate greater than what is indicated by corrected pressure drop value that is
the chart will have no additional positive effect approximately 125% of the Rated Pressure
on thermal transfer due to surface area Drop.
limitations within the WFC unit. Any less and
there may be a slightly greater loss of capacity
than shown by the Capacity Adjustment Chart.
P a g e | 19
Exercises: The presence of 30% EG in the cooling water

loop has no direct effect on cooling capacity.
#1 Given: All three loops have 30% EG. The
The thermal capacity of the loop is indeed
chilled water loop is at 44.6°F (7°C), the
lowered by 4%, but there is still more than
cooling water loop is at 87.8°F (31°C), and the
enough thermal capacity in the loop to be
heat medium loop is at 190.4°F (88°C).
able to accept all the heat input by the
Calculations: The process begins with the heat generator and the evaporator.
medium loop. The capacity adjustment
#2 Given: WFC-SC10. Everything at rated
factor in this loop is 0.975. This means there
conditions except 30% EG is present in the
is 2.5% less heat available to drive the
cooling water circuit.
process than if water were used. The effect
on cooling capacity is the amount of lost Calculations: The total heat for rejection is
input heat divided by the COP - In this case, 291,400 BTU. The total thermal capacity of
2.5% / 0.70 = 3.6%. So the unit is the cooling water loop is equal to the flow
automatically going to produce 3.6% less rate * ΔT * 500. So the thermal capacity of
cooling capacity due to the presence of 30% the loop is: 80.8 * 7.25 * 500 = 292,400. If
EG in the heat medium loop. 30% EG is present in this loop, then the
thermal capacity is 292,400 * 0.96 = 280,704
The next process is the direct effect of 30%
BTU. This means a deficiency of 10,696 BTU.
EG in the chilled water loop. As seen in the
Therefore, unit will potentially lose 9% of its
example above, the capacity adjustment
cooling capacity simply because it can no
factor is 0.92, so 8% of the cooling capacity
longer reject all the heat brought in through
is lost due to the presence of 30% EG in the
the generator and the evaporator. Since the
chilled water loop. This loop has already had
generator is so much hotter than the
COP figured into its capacity so that is a
evaporator, almost all the loss effect will be
direct 8% loss.
on the evaporator, meaning a direct loss of
Therefore, the total capacity loss in the unit capacity rather than a reduction on the
is 11.6% due to the presence of 30% EG in amount of heat drawn from the heat
both loops. So a 10-ton unit at rated medium loop.
conditions, but using 30% EG in both loops
will produce only 8.84 tons of cooling effect.
P a g e | 20
P a g e | 21
PROPYLENE GLYCOL CHARTS

The following charts are for use with input heat divided by the COP - In this case,
Propylene Glycol. 2.5% / 0.70 = 3.6%. So the unit is
automatically going to produce 3.6% less
The first chart is the Capacity cooling capacity due to the presence of 30%
Adjustment Chart. This chart indicates the loss PG in the heat medium loop.
of heat transfer due to the reduced thermal
The next process is the direct effect of 30%
capacity of propylene glycol. This chart shows PG in the chilled water loop. As seen in the
the resulting capacity adjustment factor when example above, the capacity adjustment
the PG is flowing at the unit’s rated flow rate. factor is 0.96, so 4% of the cooling capacity
The second chart is the Flow Rate is lost due to the presence of 30% PG in the
chilled water loop. This loop has already had
Adjustment Chart. This chart shows what
COP figured into its capacity so that is a
percent of rated flow rate is required in order to direct 4% loss.
maximize the use of propylene glycol. Any flow
rate greater than what is indicated by the chart Therefore, the total capacity loss in the unit
will have no additional positive effect on thermal is 7.6% due to the presence of 30% PG in both
loops. So a 10-ton unit at rated conditions,
transfer. Any less and there may be a slightly
but using 30% PG in both loops will produce
greater loss of capacity than shown by the only 9.24 tons of cooling effect.
Capacity Adjustment Chart.
The presence of 30% PG in the cooling water
The third chart is the Pressure Drop loop has no direct effect on cooling capacity.
Adjustment Chart. This chart shows the The thermal capacity of the loop is indeed
adjustment factor that should be applied to the lowered by 3%, but there is still more than
Pressure Drop through a particular fluid loop so enough thermal capacity in the loop to be
that the correct measured value may be able to accept all the heat input by the
attained. generator and the evaporator.
For example: 30% PG in the 44.6°F (7°C) chilled water #2 Given: WFC-SC10. Everything at rated
loop will result in a Capacity Adjustment conditions except 30% glycol is present in the
Factor of 0.96. This means that only 96% of cooling water circuit.
the expected cooling capacity will be Calculations: The total heat for rejection is
available due to the presence of PG. It will 291,400 BTU. The total thermal capacity of
also require the flow rate to be 104% greater the cooling water loop is equal to the flow
than the Rated Flow Rate and will produce a rate * ΔT * 500. So the thermal capacity of
pressure drop that is approximately 120% of the loop is: 80.8 * 7.25 * 500 = 292,400. If
the Rated Pressure Drop. 30% PG is present in this loop, then the
Exercises: thermal capacity is 292,400 * 0.97 = 283,628
BTU. This means a deficiency of 7,772 BTU.
#1 Given: All three loops have 30% PG. The Therefore, unit will potentially lose 6.5% of
chilled water loop is at 44.6°F (7°C), the its cooling capacity simply because it can no
cooling water loop is at 87.8°F (31°C), and the longer reject all the heat brought in through
heat medium loop is at 190.4°F (88°C). the generator and the evaporator. Since the
Calculations: The process begins with the heat generator is so much hotter than the
medium loop. The capacity adjustment evaporator, almost all the loss effect will be
factor in this loop is 0.975. This means there on the evaporator, meaning a direct loss of
is 2.5% less heat available to drive the capacity rather than a reduction on the
process than if water were used. The effect amount of heat drawn from the heat
on cooling capacity is the amount of lost medium loop.
P a g e | 22
P a g e | 23
COOLING AND HEATING COIL SELECTION

The cooling coil used by the WFC unit mode turns out to be exactly the same as the
should be selected in the same manner as a heating coil that would be selected when
cooling coil would be selected for any other type provided 131°F (55°C) heated water.
of chiller. Determine the chilled water
It is possible to heat with the WFC-SC
temperature and the air flow requirements, and
cooling-only models, but it will require either a
then choose coil rows and surface area based on
four-pipe system with dedicated heating coil
the load and noise requirements. The WFC
that is directly fed heat medium, or it will require
chiller provides chilled water in the same
routing heat medium the WFC-SC unit and into
temperatures and for the same use as any other
the chilled/hot water circuit. When mixing the
chiller. However, it is designed for a 10°F (5.5°C)
fluid from the heat medium and chilled/hot
+/- 2°F (1.1°C) temperature rise between chilled
water circuits, particular care must be used
water supply and chilled water return. It is not
when choosing chemicals that will flow within
capable of any greater variance and is certainly
these circuits since there will now be steel and
not capable of a 15°F (8.3°C) temperature rise that
stainless steel tubing in the same circuit where
some of the more modern chillers seem to be
copper and brass tubing is also found. This will
moving toward. This manual will not go into any
restrict the inhibitor chemicals that glycol or
further detail on cooling coil selection.
other additives might be used with. Use of a
In regard to WFC-SH units, a two-pipe heat exchanger between the heat medium and
system is the intended use. The WFC-SH will use hot water circuits will alleviate this issue.
the very same piping and fan coils that the
Also, the fan speed required during heat
cooling side uses. This is why 131°F (55°C) heated
mode will vary depending upon the temperature
water temperature was selected for use during
design point of the heat medium. Be aware that
heat mode. Whatever coil selection was
external controls may also be required for fan
determined to be appropriate for the cooling
speed and mode selection.
P a g e | 24
ELECTRICAL REQUIREMENTS
The WFC-SC5 has a unique power supply Phase converters typically come sized by
that can accept 85-265vac / 50 or 60 Hz / 1-phase “HP”. For the 10, 20, and 30 ton models, a 1-hp
supply power. phase converter is typically sufficient. For the
WFC-SC50 and WFC-M100 units, a 2-hp phase
With exception of the WFC-SC5, all other
converter will likely be needed. Consult the
WFC-S units require a 208vac / 60 Hz / 3-phase
technical specifications of the phase converter
power supply. The power leg that reads highest
that has been chosen for the application for
voltage to ground should terminate on terminal
proper sizing. The voltage provided by the phase
L2. If 3-phase power is not available, there are
converter as the third leg of power should be
aftermarket devices that will convert single-
terminated at terminal L2 in the Junction Box
phase power to three-phase power.
regardless of whether it is the highest voltage to
ground power leg or not.
CONTROL WIRING
WFC-SC5 Control Wiring Options connections, and remote Enable/Disable
connections are here. TB2 contains all the
The I/O Board of the WFC-SC5 unit has
“command” connections. TB2 connections are
two terminal blocks on it. These terminals are
all 24v, 60va max, dry contact connections.
the field interface to all control options on the
unit. TB1 contains all the “feedback” Complete explanation of the TB1 and
connections. Safety overload connections, flow TB2 terminal connections are on the WFC-SC5
switch connections, freeze protection Field Wiring Diagram below:
P a g e | 25
WFC-SC/SH Control Wiring Options

All WFC-S units except for the WFC-SC5 The center section has a terminal strip
use the same control package with the same that is used to control signals for the chilled/hot
connections available for use. In many cases, water pump, the cooling tower pump, the
these connections can be defined in a universal cooling tower fan, and the heat medium bypass
connection device for whichever BMS has been valve. All of these circuits are 24v, 60va max, dry
chosen. Do not use this section when contact circuits. Field-supplied 24v power is
considering wiring for the WFC-SC5 or for the provided to terminal CM1 and is used as source
WFC-M units. voltage for control of each device.
There are several places where controls In the left section of the Junction Box,
can be terminated. This document will start with there are two terminal strips, one at the top and
the Junction Box, since almost all field wiring one at the bottom. The top terminal strip
should be terminated in it. The Junction Box is actually has two sections on it. The left side of
broken up into three sections. the top terminal strip is for heat medium pump
control and feedback terminals. The right side of
The left section is where high voltage
the top terminal strip, labeled A, B, C, D, and E, is
terminates. The center section is for most pump
for BMS interface. The lower terminal strip is for
and valve controls. The right section is for
safety interlock wiring and optional remote
feedback terminal connections, BMS interface,
monitoring packages.
and safety interlock interface.
TYPICAL WFC-SC/SH JUNCTION BOX
P a g e | 26
The center section of the Junction Box is that signal returns to terminal “A”, the unit will
for control of the chilled/hot water pump, enter COOL mode. If that signal returns on
cooling water pump, cooling tower fan, and the terminal “B”, the unit will enter HEAT mode.
heat medium bypass valve. Field-supplied When controlling a WFC-SC cooling-only unit,
power is provided to terminal CM1 and is routed terminals “A” and “B” have no use and do not
through dry contacts within the WFC-S unit so as need to be controlled. If the signal returns to
to indicate a demand. The dry contacts are 24v, terminal “C”, the unit will be Enabled. If the
60va max, so they may not be sufficient for direct signal returns to terminal “D”, the unit will be
control of a starter, but can be used as pilot Disabled. There are no other functions that BMS
voltage for the relay that does actually control can control. Leaving water temperature cannot
the starter coil. Alternatively, BMS could be controlled remotely using the Yazaki controls.
monitor this signal as an indication of demand It is possible to use external devices, however, to
for a pump, fan, or valve. gain some form of remote leaving water
temperature control. Such control is detailed in
Terminal “P” indicates a demand for the
its own section.
chilled/hot water pump. Terminal “CP” indicates
a demand for the cooling water pump. Terminal Please be aware that it is important that
“CTF” indicates a demand for the cooling tower the unit not receive conflicting control signals,
fan. “P3A” indicates a demand for heat medium. i.e., it must not receive Enable and Disable
“P3B” indicates a demand that the heat medium signals simultaneously. That is why SPDT relays
bypass the WFC-S unit. are suggested to be used. However, the unit
CAN use momentary contacts instead. The
The “CTF” contacts cycle based on the
momentary contact signal must last at least 0.5
temperature indicated by the on-board CTI
seconds to be heard and understood by the CPU
thermister. If another form of cooling tower fan
Board. BMS Interface wiring is as follows:
control is being utilized, then the “CTF” contacts
need not be used.
The “P3A” and “P3B” contacts are
unique in that they go through a different type
of relay than all the other dry contacts. As such,
these contacts alone are not limited by the 24v,
60va max restriction that all the other contacts
have. The RP3 relay for these contacts has a
limitation of 5 amps and can handle up to
250vac. NO OTHER CONTACTS in the Junction
Box are capable of this higher rating.
Defining the functions of the left section An example of controlling the
of the Junction Box, the top terminal strip has a Enable/Disable signals using momentary
set of terminals beginning with the letter “S”. contacts is displayed below:
Terminals S3 and S4 control the heat medium
pump. Terminals S13 and S14 are for alarm
condition indication. The other “S” terminals are
for feedback indication. Refer to the Field Wiring
Diagram for more information on those
terminals.
At the right side of the top terminal block
are the BMS interface terminals. The WFC-S unit
sends out a DC voltage signal on terminal “E”. If
P a g e | 27
Finally, the lower terminal strip gives auxiliary contacts for the overloads in them, not
interface to optional remote monitoring even as an option. Motors with imbedded
packages as well as to safety interlocks. thermal safety limits are also practically non-
Terminals 1 and 2 are for digital communication existent in modern times. Therefore, other
connections to the optional LON Adapter. methods must be used.
Terminals 7 and 8 are dummy terminals
First, if the pump is a VFD pump, the
intended for use with the optional LON Adapter.
alarm contacts of the VFD controller could be
Terminals 3, 4, 5, 6, and CM2 are for used instead. Route the CM2 signal through the
safety interlock interface. A DC voltage signal is NC contacts of the VFD alarm circuit and back to
sent out by the WFC-S unit on terminal CM2. the appropriate safety interlock terminal.
This signal MUST return to terminals 3, 4, 5, and Second, there are a number of aftermarket
6, or else immediate error codes will be devices that can monitor overcurrent situations.
generated. The intent of these terminals is to Adding one of those to the starter box could
monitor a set of auxiliary contacts on the provide the feedback desired for proper control
overloads of the pump and fan starters. If those of the safety interlock signal. These would
overloads trip, the auxiliary contacts will open, essentially operate as a second overload sensor
causing the WFC-S unit to respond immediately for the pump or motor in question, except that
according to whichever safety tripped. when it trips, it only affects the chiller. Third,
there are some motors and pumps that have
Terminal 3 is intended for the
accessories for thermal monitors. Using those,
chilled/hot water pump safety overload.
proper feedback could be provided. Lastly, it is
Terminal 4 is intended for the cooling water
possible to use a 4-pole starter overload on a 3-
pump overload. Terminal 5 is intended for the
pole starter and use the extra overload pole as
cooling tower fan overload. Terminal 6 is
the auxiliary contact.
intended for the heat medium pump overload.
This control strategy was devised in the 1970s, If no options for safety interlock wiring
and has remained largely unchanged since that can be found at all, contact Yazaki Energy
time. However, modern starters do not have Systems, Inc. for further assistance.
P a g e | 28
P a g e | 29
Heat Medium Control in Extraordinary Other Control Wiring Options

Conditions The I/O Board has a few other options
The WFC-S unit expects to have control available for use by the BMS or other devices.
over every pump, valve, and motor. However, On I/O Board TB1, there is a set of
there are times when a heat medium bypass terminals labeled “ST2”. This is a set of contacts
valve is available, but heat medium pump that is used for Emergency Shutdown. If this
control is not or vice versa. In such cases, wire electrical circuit is broken, the unit will come to
the control of the heat medium pump and the a complete halt within 6 seconds. Once stopped,
heat medium bypass valve in series. A spring- it will cease all pump, valve, and fan motor calls
return-closed actuator should be used and wired as well. Usually, a fire safety panel controls this
as follows: feature. This feature can be set to use either NC
or NO contacts for its reaction. These are NOT
dry contacts, so do not apply any voltage of any
kind to these terminals or else permanent
damage could result to both the I/O Board and
to the CPU Board. Such damage is not covered
by the unit warranty. ALSO, DO NOT USE THIS
FEATURE AS REMOTE “ENABLE/DISABLE”
CONTROL! Repeated instances of ST2 action
could harm the system. As the name suggests, it
is for Emergency Shutdown only.
On I/O Board TB4, there is one more set
of 24v, 60va max dry contacts that can be used
Control of Heat Medium Bypass as well. “CHSTN” at TB4 terminals 7 and 8 closes
to indicate the unit has been Disabled.
Valve When the WFC-S Unit Does
Not Control the Heat Medium Pump No other contacts on the I/O Board are
enabled for use by the logic on UL Model WFC-S
units.
There is a provision for a flow switch for
the cooling water circuit. There is a jumper at
Molex connection CN11 in the Control Panel that
has a jumper wire labeled “FS2”. If a cooling
water flow switch is to be added, cut this jumper
and wire the flow switch in series with these
wires. A cooling water flow switch is always
recommended if safety interlocks for the cooling
water pump and/or cooling tower fan motor
cannot be provided in a normal manner.
Finally, there is no need to ever employ
Control of the Heat Medium Pump a Lead/Lag strategy. However, if it simply must
be used, just set the leaving water set points of
When the WFC-S Unit Does Not
each chiller to be 0.9-1.8°F (0.5-1.0°C) apart. The
Control or Does Not Utilize a Heat unit logic will automatically stage units in an out
Medium Bypass Valve as necessary.
P a g e | 30
WFC-M100 Control Wiring Options sequence that will divert heat away from the
chiller when this contact closes.
The new logic and control box of the
WFC-M100 has allowed for more control options S11-S12 is a dry contact that closes when
that have been available in the WFC-S series the chiller is Enabled.
units. Some terminal designations have been S13-S14 is a dry contact that closes when
changed between the WFC-S and WFC-M units. the unit goes into alarm condition.
The WFC-M series has two options of S15-S16 is a dry contact intended to
control: On/Off (like the WFC-S uses) or Fully control an auxiliary boiler or some other auxiliary
Modulating (only available for the WFC-M units). heat source. This contact closes when the Heat
As such, all the terminals for pump control and Medium Temperature falls below 185°F (85°C)
P3A and P3B are still available but are really only and opens when the Heat Medium Temperature
to offer a unified control strategy in case there rises to 194°F (90°C).
are other WFC-S units on the same job. On/Off
strategy for the WFC-M includes something that S17-S18 is a dry contact that closes when
is missing in the logic of older WFC-S. The dead the chiller generates a Maintenance Alert Code.
band on the WFC-S is 7.2°F (4°C) and cannot be Maintenance Alert Codes will not interfere with
changed. On the WFC-M, the dead band can be the unit’s operation but will indicate that
set to 3.8°F (2°C), 5.4°F (3°C), or 7.2°F (4°C) by using maintenance will be required soon.
the new Infinity ∞ S1 control program that was IF1, IF2, and IF3 terminals are for use
developed for the next generation of Yazaki with freeze protection thermostats. These are
equipment. NOT dry contacts. Do NOT apply external
The modulating logic has been voltage these terminals. If the dry contacts of
developed over years and presents several the freeze protection thermostat close, then the
advantages over the older On/Off strategy. This appropriate pump will be energized. IF1 is for
new logic is designed to hold the leaving chilled the chilled water pump, IF2 is for the cooling
water set point +/- 0.5°F (0.3°C). If the load is less tower pump, and IF3 is for the heat medium
than 25% of the unit’s cooling capacity, the pump.
chiller will overshoot 1.8°F (1°C) and then shut S34-S35 are for the Emergency
off. Once the leaving chilled water temperature Shutdown function ST2. These are NOT dry
rises back up to set point, the unit will turn back contacts. Do NOT apply external voltage these
on. In this way, the WFC-M series maximizes the terminals. This is intended for integration into a
use of waste heat even better than the WFC-S fire panel.
did.
S36-S37 are for Economy Mode. BMS
Terminals DCP and 24V are used to usually controls this function. These are NOT dry
provide power for and to communicate with the contacts. Do NOT apply external voltage these
Optional LON Adapter. Currently, there is no terminals. When this circuit closes, the unit will
other protocol that can interface with the WFC- apply a 5.4°F (3°C) offset to the current leaving
M software. chilled water set point.
S3-S4 is a dry contact that signals Finally, C, D, and E are for BMS interface
demand for the Heat Medium Pump. to remotely Enable or Disable the chiller. These
S5-S6 is a dry contact that closes when are NOT dry contacts. Do NOT apply external
the WFC-M needs the heat to stop coming to the voltage these terminals. When the voltage
unit. Its intention is to be used to turn off the supplied by terminal E returns to C, the chiller
heat source, but the signal can be used by BMS Enables. When it returns to D, the chiller
to control a bypass valve or a logic-based Disables.
P a g e | 31
P a g e | 32
Changing the Chilled Water Set Point point than it is the factory standard. As such, the
apparent cooling capacity changes based on set
The chilled water set point from the
point. The chart below indicates the capacity
factory on all WFC-S units is 43.7°F (6.5°C). This
adjustment factor for various set points, taking
can be adjusted to be as low as 41.9°F (5.5°C) or
into account the Heat Medium Inlet
as high as 59.9°F (15.5°C). Dead band is always
Temperature.
7.2°F (4°C) and cannot be changed. Be aware that
the temperature set points cannot be set The reason for two charts is that the
remotely. design temperature for WFC-S units is 190.4°F
(88°C) whereas the design temperature for the
The chilled water set point from the
WFC-M is 194°F (90°C).
factory on all WFC-M units is 44.0°F (6.7°C). In
On/Off mode, this can be adjusted to be as low Example: A 10-ton unit set to 48F that receives 190F
as 41.9°F (5.5°C) or as high as 59.9°F (15.5°C). heat medium has about a 1.1 adjustment factor
for an apparent capacity of 11 tons. Change the
However, the WFC-M units are designed for
heat medium temperature to 200F and the
modulating operation. In modulating mode, the
capacity adjustment factor will change to about
set point can be set as low as 39.2°F (4°C) or as
1.18 or 11.8 apparent tons.
high as 51.8°F (11°C).
Changing the set point from factory
standard simulates changing the cooling capacity
of the unit. It is easier to hold a 59.9°F (15.5°C) set
P a g e | 33
REMOTE LEAVING WATER TEMPERATURE CONTROL

There are occasions when remote able to accommodate any dead band desired as
control of the leaving water temperature or a well as being chosen for remote set point
dead band different than 7.2°F (4°C) is required. adjustment capability. Wire the control as
The WFC-S unit is not capable of altering its dead shown here:
band nor can its leaving water temperature set
points be altered remotely. However, there is a
method that can be employed to satisfy these
desires.
Both methods require the use of a field-
supplied external water temperature control.
This control must use its own leaving water
temperature sensor. This temperature control
must be wired into the BMS terminals and will
control the WFC-S unit by Enabling and Disabling
the unit in accordance with its needs. The WFC- TYPICAL WIRING OF AN EXTERNAL
S unit’s on-board leaving chilled water set point WATER TEMPERATURE CONTROL
must be set as low as it can be, and in case of a
WFC-SH unit, the heating set point must be set
as high as it can be. The desired set points used
For Example: The unit is desired to be controlled
by the external water temperature controller
with a 44°F leaving chilled water set point
must not be set colder (or warmer in the case of and a 3°F dead band. Wire an external
Heat mode) than the on-board set point, or the temperature controller as shown above, set
controls will fight one another. the temperature controller to 44°F and set its
dead band to 3°F so that it turns the unit on
The wiring diagram for the External
by Enabling it at 47°F and turns it off by
Water Temperature Control looks almost
Disabling it at 44°F.
identical to the wiring of BMS control. Indeed,
the External Water Temperature Control is Set the TC set point in the WFC-S unit’s
acting like a BMS as far as the WFC-S unit is control panel to as low as it will go, 41.9°F
(5°C). Set the rocker switch on the unit control
concerned.
panel to “Remote” so that the unit will
When using this strategy, it is vitally respond to the external temperature
important that the WFC-S unit have control over controller’s demand signals.
all pumps and valves since it will be more varied Now, when the leaving chilled water
than usual in its pump and valve demands by the temperature gets above 47°F, the external
constant Enabling/Disabling that will result from temperature controller will Enable the
this control scheme. Fortunately, for the WFC-S chiller. The chiller will see a leaving chilled
unit, there is essentially no such thing as a “short water temperature through its own on-
cycle”, so it is perfectly acceptable for the WFC- board WTO sensor that is above 41.9°F (5°C),
S unit to be Enabled again within seconds after so it will immediately begin a cooling cycle.
Once the leaving chilled water temperature
being Disabled. As such, the actual desired dead
falls to 44°F, the remote temperature
band is not considered to be much of a factor.
controller will Disable the WFC-S unit, which
Using the External Water Temperature will go through a normal shut down. It will
Control strategy, the control chosen should be then remain dormant until Enabled again by
the next cycle.
P a g e | 34
CHARTS, DIAGRAMS, AND GRAPHS

Design Assistance:
For further design assistance on process, or in solar thermal applications,

integrating Yazaki water-fired chillers and/or please contact your Yazaki Sales
chiller-heaters to utilize waste heat from Representative or Yazaki Energy Systems,
engines, microturbines, fuel cells, industrial Inc., at 469-229-5443.
Cooling and/or Heating Capacities and Sound Levels:
The cooling and heating capacities are listed below:

Specifications WFC- SC5 SC10 SH10 SC20 SH20 SC30 SH30 SC50 M100
Cooling Mbtuh 60.0 120.0 240.0 360.0 600.0 1200.0
Capacity (kW) (17.6) (35.2) (70.3) (105.5) (175.8) (352)
Heating Mbtuh 166.3 332.6 498.9
--- --- --- --- ---
Capacity (kW) (48.7) (97.5) (146.2)
Sound Level dB(A) 38 49 46 51 56
When larger cooling capacities are required,

multiple Yazaki water-fired chillers and/or chiller-heaters may be installed in parallel.
Fluid Circuit Pressure Loss Characteristics:
Chilled/Hot Water Cooling Water Heat Medium

Model Flow Rate Pressure Drop Flow Rate Pressure Drop Flow Rate Pressure Drop
GPM (l/s) PSI (kPa) GPM (l/s) PSI (kPa) GPM (l/s) PSI (kPa)
12.1 7.6 40.4 11.2 19.0 11.2
SC5
(.76) (52.6) (2.6) (77.2) (1.2) (77.0)
SC10 / 24.2 8.1 80.8 12.3 38.0 13.1
SH10 (1.5) (55.8) (5.1) (84.8) (2.4) (90.3)
SC20 / 48.4 9.6 161.7 13.2 76.1 6.7
SH20 (3.1) (66.2) (10.2) (91.0) (4.8) (46.2)
SC30 / 72.6 10.1 242.5 13.4 114.1 8.8
SH30 (4.6) (69.6) (15.3) (92.4) (7.2) (60.7)
SC50 121.1 5.8 404.5 9.2 190.4 12.4

(7.6) (40.2) (25.5) (63.1) (12.0) (85.2)
M100 242.5 10.5 539.5 9.6 195.9 4.3

(15.3) (72.6) (34.0) (66.0) (12.4) (29.7)
For informational purposes only. Yazaki assumes no responsibility for application of this data, for WFCSUL-AM1-1C3-0516
P a g e | 35
● – Standard Rating Point
For optimum performance, the chilled/hot water flow should be within 80% to 120% of standard,
as indicated by the solid line on the chart above.
For optimum performance, the cooling water flow should be within 100% to 120% of standard,
as indicated by the solid line on the chart above.
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P a g e | 36

For optimum performance, the heat medium water flow should be within 30% to 120% of
standard, as indicated by the solid line on the chart above.
Typical Piping:
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P a g e | 37
Typical System Design:

EXAMPLE OF A SINGLE MODULE
EXAMPLE OF MULTIPLE MODULES
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P a g e | 38
Performance Characteristics at 44.6°F (7°C) for SC/SH {44.0°F (6.7°C) for M100}
WFC-SC5 WFC-SC/SH10 WFC-SC/SH20
Notes:
1. Blue lines indicate rated design conditions.
Where the blue lines cross designates the
Standard Rating Point.
2. All curves are based on water in all circuits
flowing at rated design condition flow rates.
3. Heating Efficiency = 97%.
4. Performance may be interpolated, but must
not be extrapolated from curves.
5. Expanded performance curves are provided
for reference only. Contact Yazaki Energy
Systems, Inc. to obtain certified performance
ratings from the factory or to determine
performance at other conditions outside the
scope of this publication.
6. Performance data based upon standard
fouling factor of 0.0005 ft2hr°F/Btu in all
circuits.
38
WFC-SC/SH30 WFC-SC50 WFC-M100
Allowable Flow Rates:
Chilled/Hot Water: 80 – 120%

Cooling Water: 100 – 120%
Heat Medium: 30 – 120%
39
Heat Medium Flow Rate Correction Charts
WFC-SC5 WFC-SC/SH10, 20, & 30
WFC-SC50 WFC-M100
40
P a g e | 41
SPECIFIC APPLICATIONS
This section contains notes on specific diagrams by any means. These diagrams are
types of applications and is followed by a section intended to convey ideas only. For a more
covering select piping diagrams for these various specific diagram that may be more appropriate
applications. This is not a complete list of to your application, please contact your Yazaki
applications offering of all possible piping Rep or Yazaki Energy Systems, Inc.
Cogeneration Applications
In this context, “cogeneration” is water capacity from the WFC-S unit will reduce
considered the recovery of waste heat from fuel the temperature of the chilled water return,
cells, fuel-driven engines, or microturbines in resulting in a cooler temperature returning to
order to drive a WFC unit. This is also commonly the chill plant. The chill plant’s own logic will
known as “Combined Heating and Power” or unload the chill plant based on how effective the
“CHP”. Many sites where CHP is of practical use side-stream chiller was at pre-chilling the water
also utilize chilled and/or hot water for the for the primary chill plant. Unloading the chill
source of comfort air conditioning. Such cases plant will ideally place it into a more energy-
make for relatively simple methods of applying efficient operation, with the increase in the part-
the chilled water capacity gained from CHP. load COP magnifying the energy cost savings of
the shifted load. This method requires
The easiest method to apply this chilled
absolutely no interface to the chill plant logic or
water is in a side-stream application. This
the BMS. It simply affects the environment for
application simply takes a secondary loop off the
that chill plant and lets nature take its course.
chilled water return and routes it through the
There are other methods to apply the chilled
WFC unit where it is chilled, and then returned
water capacity from CHP, but none are as cost-
into the chilled water return piping. This is done
effective as side-stream application. An example
upstream of the primary chill plant. The chilled
of side-stream application is shown below:
TYPICAL SIDE-STREAM APPLICATION
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P a g e | 42
Another thing that should not be external heat exchanger, make certain that the
overlooked is the presence of a heat dump, most heat exchanger has a very low exhaust gas
likely in the form of a dump radiator. No matter pressure drop, usually recommended to be no
what, there WILL come a time when the more than 0.5” wc. This is to prevent abnormal
generator will need to run and the chiller will be backpressure that could reduce the gen-set’s
off for some reason. If the chiller is the sole heat efficiency. Too high of back pressure could also
dump for the gen-set, then the chiller being cause damage to the gen-set itself.
down means the gen-set itself is down too.
There are a number of reasons why the chiller
may be off. It may have satisfied the thermal Solar Applications
load demand so it has cycled off. It may be
having regular maintenance performed on itself Solar applications have many of the
or the cooling tower. It could be in alarm same design points and considerations as CHP.
condition. It could have received heat medium Like CHP, the most cost-effective method to use
above 205°F (96°C) and locked out for safety. The the chilled water capacity from a solar
point is that if the loss of ability to remove heat application is through side-stream application
from the heat medium circuit will result in the and for exactly the same reasons.
gen-set having troubles or shutting down, a heat The solar array should be sized properly,
dump is an absolute essential item in any design. of course. It is important to keep in mind that
One of the main things in any CHP almost all the data from the array manufacturers
application is to ensure the gen-set itself is base- is provided with a mindset of generating
loaded. If it is not, there will be substantially less domestic hot water. Such an application allows
recoverable heat available, particularly in for very rosy pictures of their product. However,
microturbines where the amount of heat the higher temperatures and the constant-draw
recovered falls off at even more pronounced requirements of solar cooling has shown that the
rates than with engine-driven gen-sets. data provided by the array manufacturers is, as
a rule, completely wrong and absolutely
Another thing to beware of in CHP is the inadequate for use in sizing an array for solar
on-board heat exchanger in the gen-set. Quite thermal cooling. Therefore, it is best to use only
often, the heat exchanger is intended to produce panels that have been rated by the SRCC and size
domestic hot water at 130°F (54°C) rather than the array only using the efficiency equations that
the 160-200°F (70-95°C) range of heat needed for have been tested by SRCC. This has been found
the WFC-S. This can sometimes be corrected by to be the most reliable method for proper array
slowing the flow rate through the heat sizing.
exchanger to raise the outlet temperature, but
not every gen-set can accept the lower flow As a general rule, however, 150 square
rates. Be mindful of this when designing the feet (14 square meters) of solar array will be needed
system. in order to produce one ton of chilled water. This
is an array that is significantly larger than most
In cases where bio-fuels are being used, manufacturers and designers believe to be
be mindful of the calorific value. It can vary necessary. However, the accumulated data and
significantly and can affect how much waste heat evidence from dozens of installed sites has
is available for recovery. The WFC unit can trim revealed it to be true. Almost every site that has
itself to match the amount of heat it receives, used less array area has resulted in a failed
but that heat still must arrive at usable project because an insufficient amount of heat
temperature and flow rates. could be produced for proper operation of the
In cases where heat is being recovered WFC unit. Even esteemed professors and design
from the exhaust gases of the gen-set through an firms have fallen into this trap. The purpose of
42
P a g e | 43
this document is to help the designer prevent requirements often lead concentrating arrays to
their project from falling into this and other such take up more area than other forms of arrays
traps and thus becoming another failed project. would due to the need to keep one set of panels
It cannot be stressed enough that great from shading the one behind it. None of this is
attention should be paid to the necessary size of to say that they cannot be used at all. Simply
the array. that for the cost and requirements of this array,
almost any other array choice would be simpler
It is also incredibly important to point
and less costly to apply.
out that there is no place on Planet Earth where
the WFC unit would be used that receives more Evacuated Tube arrays are often
than 1000 W of solar energy per square meter all considered to be the preferred array design.
season or all year long, no matter what any There are advantages and disadvantages to
documentation, presentation, or lecture may these. The primary advantage is that they are
say. Often, values above 1000 W per square typically more efficient than flat panel arrays. By
meter are used, knowingly or unknowingly, their nature, they perform more consistently
which inflate the performance of an array or throughout the day than a flat panel array. They
system. Do not fall for this. In most places where take up less space than the concentrating array
the WFC unit would be used, the average in most applications because they can be placed
amount of solar energy available is more closer together without one panel set shading
reasonably 600-800 W per square meter. The another. But they are typically about twice the
average amount of solar energy falling on the cost per panel of a flat panel and deliver about
array during the time of intended use should be the same amount of heat at about the same
used when determining the contribution from a temperatures as the flat panel arrays. Their
solar array. Peak values for solar energy are only primary advantage is that they minimize re-
available for a few days a year, assuming the radiation, which is to say that they do not turn
weather cooperates. into heat radiators when the sun goes down like
the flat panels have been known to do. Also,
When selecting the type of array, there
failure of a single tube does not disable the
tend to be three distinct types: Concentrators,
entire panel. In snow-prone climates, however,
Evacuated Tubes, and Flat Panels. There are also
care must be taken to prevent snow
some hybrid versions available, but this
accumulation on the evacuated tube array,
document will stick with the main three.
which would render the array useless.
Concentrator arrays use reflective
Finally, flat panel arrays are the cheapest
surfaces to concentrate a larger area of sunlight
arrays available, but they are also the least
onto a pipe that has fluid running through it. A
efficient, typically. They are better at capturing
concentrating array’s only advantage over any
diffuse solar radiation than any other panel, so
other type is the fluid temperature it can attain.
they may actually be advantageous to use over
No other form of array can generate higher
the more efficient arrays in climates where a
temperatures, and other arrays are hard-pressed
high portion of the solar radiation is scattered by
to deliver temperature as quickly. However, the
high humidity or high particulate counts. Flat
WFC unit has absolutely no need for the higher
panels will turn into heat radiators when the sun
temperatures that the concentrators can
goes down if particular care isn’t taken to
provide. Couple that with a requirement for
prevent flow through the array at such times.
complex logic to keep the reflectors in proper
However, this can be an advantage in snow-
position every second of the day and it has been
prone climates. Flat panel arrays can be set to
found that concentrating arrays are actually
purposely allow some flow in order to melt the
some of the poorest choices for use in solar
snow that might otherwise accumulate on the
powered cooling. Also, their installation
array.
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P a g e | 44
As can be seen, each array type has its source of heat feeding the WFC unit at any one
advantages and disadvantages. None is time. For example, if the unit is drawing off of
considered to be a poor choice when it comes to the solar array, then the boiler must not be
providing heat from the sun. Even the operating. If the boiler is operating, it should not
concentrator arrays work well so long as they be feeding into the buffer tank. In short, every
feed a buffer tank and are not directed straight heat source must be able to be isolated from the
into the WFC unit. heat medium circuit and no more than one heat
source should ever be allowed to feed into the
Another consideration for a solar
heat medium circuit at any one time. All others
application is the absolute need for a heat dump.
must be looped back on themselves. Piping the
Just as with CHP, there will always be some point
auxiliary boiler in series with the heat medium
in time at which the chiller will not be drawing
piping is highly discouraged since actual
heat from the buffer tank. Once that buffer tank
installations have proven this to cause numerous
reaches its temperature limit, any excess heat
problems with array and heat medium
will have to be dumped in order to protect the
temperature control.
solar array, usually done through a dump
radiator. It is also important that there be a
temperature and pressure relief valve at the
outlet of the solar array for its protection as well Buffer Tanks
as the protection of the entire heat medium
A Buffer Tank is a vital part in the design
circuit.
of any solar design and can also be useful in CHP
Finally, it should be noted that there is designs as well. Actual applications have proven
absolutely no economic case for solar thermal that any site without one will likely fail. Nothing
cooling without some sort of subsidies. Even else can react quickly enough to stop a slug of
with subsidies, it is still very difficult to cost- water heated above 205°F (96°C) from reaching
justify. This is primarily due to the cost of the the chiller. No bypass valve, no mixing valve, no
solar array needed to drive the chiller, not the “off-sun” logic routines – nothing reacts quickly
cost of the chiller itself. Further, there is enough. All have been tried and all have failed.
absolutely no economic case to justify solar The only way to ensure that such temperatures
cooling being applied to residence. It is far do not reach the chiller and lock it out due to
cheaper to operate a 5 or 10 ton conventional air over-temperature conditions is to have the array
conditioning system than to apply a 5 or 10 ton feed a buffer tank and the heat medium loop pull
chiller to a residence. And the typical air from that buffer tank. In cases where the
conditioning system comes without any sort of volume of the loop itself was considered to be
cooling tower maintenance requirement. ROI on the storage tank, the lack of temperature mixing
such solar installations typically runs in the 25+ is a serious problem. Further, radiant heat losses
year range. Even with subsidies and incentives, of the loop cause almost every bit of stored heat
there simply is no reasonable case for residential to be lost overnight so that the array has to start
solar thermal cooling. from ambient temperature nearly every day.
There simply is no adequate substitute for
having a buffer tank incorporated into the
Auxiliary Boilers design.
In instances where the WFC unit must be In instances where the solar array will be
able to run even when the sun is not out or the isolated from the heat medium circuit in an
gen-set is not running, it is recommended that an “indirect” application, the simplest method is to
auxiliary boiler be installed as well. However, it simply use a buffer tank that incorporates a heat
is vitally important that there only ever be one exchanger in its design. Such a tank could also
44
P a g e | 45
be used in place of a regular heat exchanger on unit. The result will be about 1.5 hours
gen-sets that use “indirect” piping. Other of actual run time with constantly
methods are also available, but the embedded diminishing chilled water capacity before
heat exchanger design is one of the most cost- the chiller ultimately shuts down. This
effective options when both a heat exchanger result is derived from the assumption
and a buffer tank are to be used in the design. that the tank starts at 190.4°F (88°C). The
chart showing the rate of depletion at
A key consideration of the buffer tank is
this temperature is displayed below.
its capacity. Logic might dictate that the larger it
is, the better, but that is not the case. Unless the
tank is intended to store enough heat to run the
chiller in the nighttime hours, there is no need
for the buffer tank to be any larger than what
would be needed for about 15 minutes of heat
medium flow. This results in a buffer tank
capacity of approximately 50 gallons (190 liters)
per ton of chilled water capacity. Anything larger
will require an abnormally large solar array to
charge the tank.
For example: A 10-ton WFC-S unit has a flow rate
of 38 GPM (2.4 l/s), so the buffer tank
should be (15 x 38 = 570 gallon capacity)
so that 38 GPM can be provided for 15
minute at rated temperature. Therefore,
a 500 gallon (1900 liter) tank would be an
appropriate choice for a 10-ton WFC-S Buffer Tank Depletion Chart
EXAMPLE PIPING DIAGRAMS

What follows are a series of piping This is by no means a complete list of
diagrams meant to illustrate methods of possibilities, but instead is intended to display a
application that have generally been known to broad range of possibilities in a few diagrams.
result in successful applications. For assistance with your particular application,
contact your Yazaki representative, or contact
Yazaki Energy Systems, Inc., at 469-229-5443.
45
P a g e | 46
Cogeneration Applications
46
P a g e | 47
47
P a g e | 48
48
P a g e | 49
49
P a g e | 50
Microturbine Applications
50
P a g e | 51
51
P a g e | 52
Solar Applications
52
P a g e | 53
53
P a g e | 54
54
P a g e | 55
ABBREVIATION DEFINITIONS
AL Alarm HIF Heat Input Factor
ASP Authorize Service Provider HMBV Heat Medium Bypass Valve
BMS Building Management System HMV Heat Medium Bypass Valve
CCF Cooling Capacity Factor HWT Heat Medium Temperature
CHP Combined Heat and Power IF Freeze Protection
CHSTN Chiller Disabled JB Junction Box
CM# Common Terminal L1 Power Leg 1
CN# Connector/Molex L2 Power Leg 2, High Leg, Wild Leg
CP Cooling Water Pump L3 Power Leg 3
CTF Cooling Tower Fan P Chilled/Hot Water Pump
CTI Cooling Water Inlet P1 Chilled/Hot Water Pump
CTO Cooling Water Outlet P2 Cooling Water Pump
CTS Cooling Tower Sump P3 Heat Medium Pump
CVR Changeover Valve P3A Heat Medium Demand
CWTS Cooling Water Sump Thermostat P3B Heat Medium Bypass
CWV Cooling Water Diverting Valve PG Propylene Glycol
DCP Digital Communication Port SRCC Solar Rating and Certification Corporation
DP Dip Switch ST2 Safety Shutdown
DS Dial Switch SV Solenoid Valve
EG Ethylene Glycol TB# Terminal Block
EMS Energy Management System TC Cooling Temperature Set Point
ESC External Signal Mode Relay TH Heating Temperature Set Point
ESON External Signal Enable Relay VFD Variable Frequency Drive
FS Flow Switch WTI Chilled/Hot Water Inlet
G Ground, Earth Ground WTO Chilled/Hot Water Outlet
HCF Heating Capacity Factor YESI Yazaki Energy Systems, Inc.
INDEX
Cooling Tower Fan Control --------------------- 9-11, 26
Access ----------------------------------------------------- 3, 4 Cooling Water Crossover -------------------------------- 8
Adiabatic Coolers ------------------------------------ 12, 13 Control Wiring --------------------------------------- 24-31
Anti-Freeze Strategies ------ 5, 6, 8, 10, 12, 13, 15, 30 Crossover Piping ------------------------------------------- 8
ASP (Authorized Service Provider) --------------------- 2
Auxiliary Boilers ------------------------------------------- 44
Dimensions -------------------------------------------------- 4
Dump Radiators -------------------------------------- 42, 44
Building Management System ------- 24-26, 28-30, 33
Buffer Tanks ------------------------------------------ 44, 45
Electrical Requirements -------------------------------- 24
Emergency Shutdown Contacts (ST2) ---------- 29, 30
Changing Set Point --------------------------------------- 32 Equipment Dimensions ----------------------------------- 4
Clearances ----------------------------------------------- 3, 4 Evacuation --------------------------------------------------- 2
Cogeneration Applications ------------------------ 41, 42 Evaporative Dry Coolers -------------------------------- 13
Coil Selection ------------------------------------------- 7, 23 Expansion Tank ---------------------------------- 5, 6, 9, 15
Cooling Capacity ------------------------------------------ 34 External Water Temperature Control --------------- 33
Cooling Towers ---------------------------------------- 8-13
55
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Pressure Drops --------------------------------------- 34-36

Field Wiring Diagram -------------------------- 24, 28, 31 Pressure Limits ----------------------------- 5, 6, 9, 13, 15
Flow Switch --------------------------------------------- 3, 29 Pump Controls ------------------------------ 24-26, 20, 30
Freeze Protection ----------- 5, 6, 8, 10, 12, 13, 15, 30
Fusible Plug -------------------------------------------------- 4
Remote Temperature Control ------------------------- 33
Glycol --------------------------- 5, 6, 8, 12, 13, 16, 18-23

Ground Loops ---------------------------------------- 10, 12 Safety Interlocks -------------------------------- 24, 25, 27
Service Access ------------------------------------------- 3, 4
Side-Stream Application --------------------------- 41, 42
Heat Dump -------------------------------------------- 42, 44 Solar Applications ------------------------------------ 42-44
Heat Medium Bypass/Proportional Valve -------------- Sound Data ------------------------------------------------ 34
6, 13-15, 17, 25, 29 ST2 ------------------------------------------------------ 29, 30
Heat Mode Applications ------------------------ 7, 16, 24 Start Up ------------------------------------------------------- 2
High Voltage ----------------------------------------------- 24 Strainer --------------------------------------------- 6, 10, 15
Hydronic Heating ---------------------------------- 6, 7, 16
Test Ports -------------------------------------------- 5, 9, 15

Inhibitor ------------------------------------------------------ 2
Valve(s)
Junction Box ----------------------------------------- 3, 4, 25 Diverting Valves -------------------------- 10, 11
Heat Medium Bypass/Proportional -----------
6, 13-15, 17, 25, 29
Laying Unit Sideways -------------------------------------- 2 Mixing Valves ----------------------------- 14, 17
Lead/Lag ---------------------------------------------------- 29 Types of -------------------------- 5, 6, 9, 10, 15
Leveling ------------------------------------------------------- 2
Varying Flow Rates --------------------- 7, 12, 14, 16, 17
LON Adapter ------------------------------------------ 27, 30
VFD Pumps --------------------------------- 7, 9, 12, 16, 17
Vibration ----------------------------------------------------- 2
Maintenance ------------------------------------------------ 2
Modular Configuration ------------------------------ 4, 37
Warranty Conditions -------------------------------------- 2
Multiple Units ------------------------------------------ 4, 37
Water
Chemistry ---------------------- 5, 8, 12, 13, 23
Noise Criteria ---------------------------------------------- 34 Conservation ------------------------------ 12, 13
Flow Rates --------- 5, 7, 8, 13, 14, 17, 34-36
Pressure Drops ---------------------------- 34-36
Performance Characteristics ---------------------- 38-40
Wiring Diagram ------------------------ 24, 26, 28, 29, 31
Piping
Chilled/Hot Water --------------------------- 5-7
Cooling Water ------------------------------ 8-13 Yazaki (YESI) Contact Information --------------------- 2
Diagrams
Cogeneration ------------------ 46-49
Microturbine ------------------ 50, 51
Solar ----------------------------- 52-54
Typical --------------- 5, 9, 15, 36, 37
Heat Medium ----------------------------- 13-17
Power Requirements ----------------------------------- 24

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Page |1

APPLICATIONS MANUAL FOR WFC SERIES

Multiple Unit Arrangement

CHILLED/HOT WATER CIRCUIT

TYPICAL CHILLED/HOT WATER PIPING

SPECIFIC CHILLED/HOT WATER CIRCUIT OBJECTIVES

Varying the Flow Rate by Use of VFDs

COOLING WATER CIRCUIT

TYPICAL COOLING WATER PIPING

A balance valve/circuit setter is If used, Pressure and Temperature test

SPECIFIC COOLING WATER CIRCUIT OBJECTIVES

HEAT MEDIUM CIRCUIT

TYPICAL HEAT MEDIUM PIPING

SPECIFIC HEAT MEDIUM CIRCUIT OBJECTIVES

Varying the Heat Medium Temperature by

ETHYLENE GLYCOL CHARTS

Exercises: The presence of 30% EG in the cooling water

PROPYLENE GLYCOL CHARTS

COOLING AND HEATING COIL SELECTION

WFC-SC/SH Control Wiring Options

TYPICAL WFC-SC/SH JUNCTION BOX

Heat Medium Control in Extraordinary Other Control Wiring Options

REMOTE LEAVING WATER TEMPERATURE CONTROL

CHARTS, DIAGRAMS, AND GRAPHS

For further design assistance on process, or in solar thermal applications,

Cooling and/or Heating Capacities and Sound Levels:

The cooling and heating capacities are listed below:

When larger cooling capacities are required,

Fluid Circuit Pressure Loss Characteristics:

Chilled/Hot Water Cooling Water Heat Medium

SC50 121.1 5.8 404.5 9.2 190.4 12.4

M100 242.5 10.5 539.5 9.6 195.9 4.3

● – Standard Rating Point

● – Standard Rating Point

● – Standard Rating Point

Typical System Design:

EXAMPLE OF MULTIPLE MODULES

WFC-SC5 WFC-SC/SH10 WFC-SC/SH20

Allowable Flow Rates:

Chilled/Hot Water: 80 – 120%

TYPICAL SIDE-STREAM APPLICATION

EXAMPLE PIPING DIAGRAMS

Pressure Drops --------------------------------------- 34-36

Glycol --------------------------- 5, 6, 8, 12, 13, 16, 18-23

Test Ports -------------------------------------------- 5, 9, 15

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