2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 13
2004 SERIES - CHILLER SYSTEMS - OPERATION AND INSTALLATION MANUAL - PAGE : 13
EDITION DATED 21ST AUGUST 2006
8E - CHILLED WATER PIPING
AND ACCESSORIES
Chilled water piping can be in rigid plastic
tubing and/or flexible reinforced hoses.
Internal dimensions of tubing should be in
conformity with piping drawing as sup-
plied by WEBASTO.
PAY SPECIAL ATTENTION TO :
1) ELBOWS
Only use large radius elbows and not short
radius. Short radius elbows entail a flow-
rate loss of approx. 2.5% per elbow. A suc-
cession of 8 short radius elbows will there-
fore result in total flow-rate reduction of
100% x0.975x0.975x0.975x0.975 etc =
81.66%.
Large radius elbows only result in a flow-
rate loss of approx. 0.5%.
If no large radius elbows can be found use
2 successive 45° elbows instead.
See also photo to the left.
CHILLED WATER CIRCUIT PIPING
GOLDEN RULES - INSTALLATION OF BASIC COMPONENTS
= SHUT-OFF VALVE
Secondary access with shut-
off valve 3/4” - should
always face upwards
Drain valve at lowest part of circuit. Allows full draining of the sys-
tem after initial pressure tests and also in case of doubt concerning
the exact glycol (anti-freeze) percentage of the mixture.
SHUT-OFF VALVES ON ENTRY AND EXIT
FOR EASY MAINTENANCE
If this line always goes upwards without any down-turn, it can be
used for filling the system ; if not use secondary access and attach
temporary filling hose with temporary filling tank on rooftop, up
and above highest air-handler. Diam. 5/8” or 3/4” transparent.
OPTIONAL RETURN LINE VALVE
LARGE RADIUS ELBOWS ONLY
CIRCULATION PUMP
EXPANSION TANK : If
static- should be highest
part of circuit
8.2 - ELBOWS 90° - CHILLED WATER PIPING
SHORT RADIUS ELBOW
USE LARGE RADIUS
ELBOW ONLY OR 2 X
45° ELBOWS
2) PIPE INSULATION
Only use rubber or synthetic rubber foam
insulation (Armstrong Armaflex or
Rubatex or similar) - do not use polythene
foam insulation.
Do not use split-type open insulation as
this type tends to come apart after a certain
time.
Try to use rigid foam core supports to fix
piping.
See also photo to the right.
8.3 - EXAMPLE WATER PIPING CIRCUIT - 1 CHILLER UNIT + 4 AIR-HANDLERS
FOAM THICKNESS : 9 MM FOR
BOATS UP TO 15/16 M; 13 MM
FOR BOATS OVER 16 ML.
RIGID CORE SPECIAL SUPPORT
ENABLING SOLID FIXING OF TUB-
ING WITHOUT DEFORMATION
ONLY USE RUBBER OR SYNTHETIC
RUBBER FOAM INSULATION
8.4 - TUBING INSULATION
Here-after a summary of the most basic but important guide-lines for success when installing a Chiller piping
System. These Guide-lines cover all items such as insulation, water-piping, etc
Most important pre-liminary remark :
Water-flow rates in a Chiller circulation circuit are approx. 2/3 times as high as the normal flow rates found
a central heating system at home. So pay special attention to all possible flow restrictions !
