VRF Systems Presentation

VRF Systems: The
Good, The Bad and The

Ugly
Mark Hydeman, PE, Principal

Hwakong Cheng, Senior
Mechanical Designer
Taylor Engineering, LLC
http://www.taylor-engineering.com
SYSTEMS
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JUNES2LIDE
2011
1
Logistics

Safety
Restrooms
Recycling
Cell phone etiquette
Lunch
Review forms
Webinar etiquette
PG&E Resources
Rebates
Tool Lending Library
Marlene Vogelsang (mxv6@pge.com)
VRF SYSTEMS: THE GOOD, THE BAD AND THE UGLY
SLIDE 2
Agenda
Topic
Intro and Overview
Speaker(s)
M Hydeman
BREAK
VRF Manufacturer Perspective
R Wilmarth & S Khayatian
BREAK
VRF Design Perspective
H Cheng & M Hydeman
LUNCH
VRF Owner's Perspective
T Rabiah
BREAK
VRF Cx Perspective
D Sellers
BREAK
Discussion and Wrapup
All
SLIDE 3
Handouts
You can get a copy of the handouts in PDF format as
follows:
Type the following link into your web browser:
http://www.taylorengineering.com/ftp/PECClassHandouts.html
Click on the link for VRF Systems to download the

Acrobat file of the presentation.
SLIDE 4
Speakers
Mark Hydeman, PE, Principal, Taylor Engineering, LLC

mhydeman@taylor-engineering.com
Ruben Willmarth, Mitsubishi Electric HVAC
rwillmarth@HVAC.mea.com
Sherwin Khayatian, Norman S. Wright
skhayatian@norman-wright.com
Hwakong Cheng, Senior Mechanical Designer, Taylor
Engineering, LLC
hcheng@taylor-engineering.com
Tal Rabiah, PE, Sr. Mechanical Engineer, UCSC
trabiah@ucsc.edu
David Sellers, PE, Facility Dynamics
DSellers@FacilityDynamics.com
SLIDE 5
Introduction
Who are you?
Facility Operations or Engineering
Design Consultant
Contractor
Vendor
Other
What brings you here?
SLIDE 6
VRF Systems: The

Ugly
Ruben Willmarth, Regional Mgr.

Mitsubishi Electric, HVAC
http://www.mitsubishipro.com
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1
VRF Systems- The Good, The Bad & The Ugly

Two kinds of VRF
The Value of Heat Recovery

Piping
Controls
Economizers & Ventilation
SLIDE 2
Applications The Bad
SLIDE 3
Applications The Ugly
SLIDE 4
Two kinds of VRF

Heat Pump or Heat Recovery?
Who do you serve?
Would a 2-pipe Hydronic work here? Or not?
Is it a cooling only application?
Different people have different needs
Small zones?
Hotel or Assisted Living?
SLIDE 5
VRF Heat Pump Technology
HEATING
COOLING
SLIDE 6
VRF Heat Recovery Technology

Simultaneous cooling and heating
SLIDE 7

Comfort = Productivity
The lesser of Heat or Cool is essentially free
Most often occurs between 35F-65F, or with special
applications
New options to recover heat for DHW or HHW
Must always remember it is an applied benefit
SLIDE 8
VRF Systems Heat Recovery Operation
COP
SLIDE 9
What Makes Heat Recovery Different

Sample Building in Part Load: OA Temp 50oF
3000 BTU
Cubicle Area
Lobby/
Waiting Room
Conference
Room
Elect
Break Room
3000 BTU
6000 BTU
12000 BTU
3000 BTU
Janitor
6000 BTU
Open Work
Room
6000 BTU
3000 BTU
Office #1
3000 BTU
Office #2
3000 BTU
Men
Women
Simultaneous Load:
Cooling: 27000 BTU
Heating: 21000 BTU
6 Ton Heat Recovery System

SLIDE 10
Cooling Power Input PURY-P72
72,000
BTUH
6.48 KW
7.00
6.00
Power Input KW
5.00
4.00
3.00
27,000
BTUH
2.38 KW
2.00
1.00
0.00
0
12000
24000
36000
48000
60000
72000
84000
System Load BTUH
SLIDE 11

Outdoor Temperature Power Input Correction
(For a 68 Indoor WB Temperature)
2.4000
2.38 KW at
95oF
2.3000
2.2000
P owe r Input K W
2.1000
1.87 KW at
50oF
2.0000
1.9000
1.8000
1.7000
1.6000
1.5000
0
10
20
30
40
50
60
70
80
90
100
OA Temperature FDB
SLIDE 12
What does this mean

Getting 27,000 BTUH of cooling and 21,000 BTUH of
heating, while providing only 1.87 KW to the outdoor unit.
This savings cannot be realized without the ability to do
simultaneous heating and cooling.
For this scenario,

Calculated Efficiency of 25.7 EER
SLIDE 13
Value of Heat Recovery to Hot Water

72 mbh nominal cap. Estimated Incremental Installed Cost $10,000
Assumptions:
Constant Year Round Cooling, Heat Pump Boiler Always Fully Utilized
Example One - Electric Water Heater
72,000 Btu/h=21.1 KW*8760=184,836 KWH savings/year
Electric Water Heater at 100% Efficiency
184,836 KWH x $0.10/KWH x 1/1.00 = $18,484 / year cost savings
Payback is in 6.5 months.
Example Two - Gas Water Heater
72,000 Btu/h x 8760/100000 btuh/therm=6,307.2 Therm savings/year
Gas Water Heater at 80% Efficiency
6,307.2 Therm x $1.25/therm x 1/0.80 = $9,855 / year cost savings
Payback is in 12.2 months
SLIDE 14
Piping with VRF Systems

1. Always use type ACR copper piping
2. Always specify brazing with dry Nitrogen
3. Always specify pressure test with dry Nitrogen(550psi)
4. Always specify triple evacuation to <500 microns, and
hold for 1 hour.
5. Always accommodate thermal expansion into your
piping design
SLIDE 15

A Good installation
SLIDE 16

A Good installation
SLIDE 17
Piping The Bad

Poor brazing - oil stains indicate a leak

18
SLIDE 18
Piping The Bad

Pipe has shifted to the right due to thermal expansion

19
SLIDE 19
Piping The Ugly

No accommodation
for thermal expansion

20
SLIDE 20
VRF Controls
Controls are an integral part of all VRF Systems
SLIDE 21
VRF Controls- Which to Use?

All VRF Companies use Pre-Integrated
controls. Reduces cost & commissioning
time
Can be very simple or expanded to
include most normal HVAC features.
Local Zone Controllers

Simplified
Programmable/ Full-Featured
SLIDE 22

Central Controllers
PC w/GUI
TG-2000
LAN
Touch Screen
Hub
Power Supply
Up to 40
Central Controllers
PC-Based
Power Supply
Consider when 5-10 Zones or more for easier scheduling

Use for remote access, alerts, IPhone, etc.
SLIDE 23

BMS Interfaces
SLIDE 24

BMS Interfaces
1. Many can interface with BacNet,
LON, Crestron, and others
2. A Controls integrator is a must with a BMS, but
optional with pre-integrated controllers
3. Never specify a system with BMS interface only.
Must have local zone or Central controller as well
SLIDE 25
Economizers with VRF

They are available, but are they a benefit?
Offsets Heat
Recovery energy
Can increase
fan energy
Can Model in
Energy Pro
SLIDE 26
Economizers with VRF economizers? Night Setback?
SLIDE 27
Ventilation with VRF Systems

1.
2.
Combined Conditioning/Ventilation
Separate Conditioning/Ventilation (DOAS)
15% Distributed OSA
Pair of 12 Dia. Ducts
Air
30 Diameter
Ductwork
15% Central OSA

Single 16Dia Duct
1200 CFM
Space required to deliver 20 tons of cooling

SLIDE 28

And you dont have to do this to your attic.
SLIDE 29

Or this to your lovely old church (now thats Ugly!)
SLIDE 30
Questions
SLIDE 31
VRF Systems: The

Ugly
Sherwin Khayatian, MBA

Norman S. Wright MEC
http://www.norman-wright.com
JUNE 2 2011
VRF Design Pitfalls

1. Over Zoning the Floor Plan
One Fan Coil, Separate Point of Changeover per Room
2. Heat Pump versus Heat Recovery Applications
Picking the Right # of Changeover Points
Grouping Fan Coils on a Common Point of Changeover
3. Heat Recovery: Establishing Cooling Only Zones
Comfort Cooling and Process Cooling
4. Zone Controller Application and Misconceptions
5. Centralized Controller. The Best Money you ever spent.
Is a Separate BAS even required?
If so, what functions should a 3rd party BAS provide?
VRF Design Pitfalls - Over Zoning the Floor Plan

One Fan Coil, Separate Point of Changeover per Room

This is the Most Expensive Configuration possible
This is usually a requirement for Hotel Guest Rooms
Multiple Fan Coils on a Common Point of Changeover

This can shave some costs and in some cases is an appropriate
solution for Office Spaces A.
o
This can be done so long as the Capacity of the Changeover

Device is not exceeded (i.e. No more than 8 Tons of Fan Coils per
Point of Changeover; Heat Pumps Points can be even bigger)
This is good design practice when you have multiple fan coils
serving a common zone (i.e. Fan Coils should change over from
Heat to Cool and vice versa together as a group)
Can also be considered for fan coils serving partitioned spaces that
share a common load profile (i.e. Individual offices on same
exposure). This will reduce equipment costs.
Single Floor Office Example

10,000 ft office space

4 open plan office spaces, 8 single offices & a server room
Office Space has a peak load of 26 tons & block load of 20 tons
Server room has a 2 ton load
Engineer assumes that customer needs individual temperature control in each room
North
Zone
3 Ton
Server
Room
4 Ton
1 Ton
2 Ton
Open Plan Office

6 Ton
South Zone
1.5
Ton
1.5
Ton
1.5
Ton
1.5
Ton
1.5
Ton
1.5
Ton
1.5
Ton
1.5
Ton
*Nominal conditions with no correction factors have been used for example purposes only
Typical Office Example

As the customer is looking for temperature control per zone this would mean
a fan coil & branch selector box per indoor unit
This is an effective, efficient solution but can increase first cost
Approximate VRV installed cost 110%

North Zone
FXMQ36
FXMQ48
BSVQ
36
BSVQ
60
Open Plan Office
FXMQ12
BSVQ
36
BSVQ
36
FXMQ36
BSVQ
36
BSVQ
36
BSVQ
36
FXMQ18
FXMQ18
BSVQ
36
FXMQ18
FXMQ18
BSVQ
36
FXMQ18
BSVQ
36
FXMQ18
BSVQ
36
FXMQ18
BSVQ
36
FXMQ18
FXMQ36
BSVQ
36
South Zone
20 Ton System

Combining indoor units in the same heat/cool changeover zone onto a common branch selector box
provides the most cost effective solution and meet the customers needs
This reduces overall equipment and installation costs
Approximate VRV installed cost 78%
North Zone
FXMQ36
FXMQ48
FXMQ12
BSVQ
96
Open Plan Office
20 Ton System
FXMQ36
FXMQ36
BSVQ
96
BS
South Zone
FXMQ72
FXMQ18
BSVQ
96
FXMQ18
FXMQ18
FXMQ18
FXMQ18
FXMQ18
BSVQ
96
FXMQ18


The most cost effective solution for this would be to zone the system as you would a VAV system
This reduces overall equipment and installation costs
Approximate Installed Cost 73%
This does not meet the customers requirements of temperature control per zone
North Zone
FXMQ36
FXMQ48
BSVQ
36
BSVQ
60
FXMQ12
BSVQ
36
FXMQ72
Open Plan Office
South Zone
BSVQ
96
FXMQ72
BSVQ
96
FXMQ72

20 Ton System
BSVQ
96
VRF Design Pitfalls

Heat Pump versus Heat Recovery Applications

Picking the Right # of Changeover Points
Grouping Fan Coils on a Common Point of Changeover
For Grouping, similar concept as Fan Coils on a Common
BSVQ for a Heat Recovery System
Heat Pump Systems can be up to 30% lower cost than Heat
Recovery Systems
Be careful not to cross zones; Think of it as a VVT or 2 Pipe
o
o
o
Do not serve both Interior and Perimeter on the Same System A

Each System is a Point of Changeover; Changeover Routine
should be discussed before hand to insure customer buy-in
Smaller Systems allow for more points of changeover and easier
retrofits
Heat Pumps are typically used for Cool Only Applications

Heating Operation Mode can be locked using Dip Switch Settings
or with Controls
VRF Design Pitfalls Cool Only Zones

Heat Recovery: Establishing Cooling Only Zones
Process Cooling
Do you really want your 2 Ton Server Room on your 20 Ton
Heat Recovery System? Think about your House VAV, CW

o
o
Benefit: Can Potentially Recover Heat Absorbed in Process Area

Benefit: Less Equipment
For Colder Ambient Climates, add BSVQ as PRD
Not a given; Each Design and System is Unique
What if majority of Comfort Zones are Interior? After Hours?
Cons: Significant Additional Run Hours on Expensive House
System
Would a separate Split System, VRF, or RTU with Economizer
be a better option with VRF Fan Coil as backup only?
VRF Design Pitfalls Cool Only Zones

Heat Recovery: Establishing Cooling Only Zones

Comfort Cooling
Is the Makeup Air Tempered or does the Design incorporate
Heat Reclaim Ventilation? If so, ventilation loads are fully or
partially handled elsewhere and only internal loads are
present for certain occupied zones.
Potential for Design without Point of Heat/Cool Changeover

o
Design can eliminate BSVQ Box and save costs, reduce units
With VRF technology, the Expansion Valve can shut in Cooling

so that there is no Coil Capacity when satisfied
This is quite different from the typical Single Duct VAV

installation
Single Floor Office Example

The most cost effective way is to design around heat pumps, right?
This project consists of 4 main heat cool changeover zones
This would mean 3 VRV heat pump outdoor units & a Split System
Approximate VRV Installed Cost = 100% (this will be used as the baseline cost)
A heat recovery system best suits this project as one outdoor unit can be utilized to match the loads
Does this mean we can now connect the server room to the VRV system?
No, this should be connected to a single split system (this is true of all VRV/VRF systems!)
o
A VRV indoor unit can however be used as a back up
North Zone
3FXMQ36
Ton
12
FXMQ12
Ton
48
FXMQ48
Ton
Server
Room
FXAQ24
2 Ton
Open Plan Office

FXMQ36
6 Ton
FXMQ36
South Zone
FXMQ12
FXMQ12
FXMQ12
FXMQ12
FXMQ12
FXMQ12
FXMQ12
FXMQ12
*Nominal conditions with no correction factors have been used for example purposes only

Eliminating Unnecessary BSVQs reduces costs and equipment
Just Branch off Liquid and Suction Main Only
North Zone
FXMQ36
FXMQ48
BSVQ
36
BSVQ
60
FXMQ12
BSVQ
36
FXMQ72
Open Plan Office
South Zone
BSVQ
96
FXMQ72
BSVQ
96
FXMQ72

20 Ton System
VRF Design Pitfalls - Controls

Zone Controller Application and Misconceptions

Zone Controller is Not Necessary
o
o
Yes, Control can be strictly centralized

However, it is Better to use a Zone Controller (Service Functions)
Functionality can be restricted from the Centralized Device

BAD Idea: Trying to use 3rd Party Zone Controls
This is possible and has been done successfully

o
Most Instances required additional coordination
Unnecessary Costs; Requires Skilled Programmer
Zone Controller is Point of Temperature Sensing

o
Not Always the Case; This is Configurable on Some models
Grouping Fan Coils onto a Common Point of Zone Control

o
o
Simplifies Control and Eliminates Unnecessary Costs

Considerations: How to View at Central Level, How to Sense and
Report Zone Temperature for Control and Monitoring Purposes
VRF Design Pitfalls - Controls

Centralized Controller. The Best Money you ever spent.

Is a Separate BAS even required? It really depends.
3rd Party BAS is very costly especially if full control integration is
required
Can a Central Controller provide enough functionality?
3rd Party Equipment Start/Stop Scheduling, Status, Interlocks
Central Controller is designed by Equipment Manufacturer so
you get all the controllable points and some basic routines
If a requirement, what functions should 3rd party BAS provide?

Scheduling, Monitoring Only? Custom Routines? Interlocks?
Centralized Controllers can provide many beneficial features

Zone Controller Restrictions, More Custom Changeover
Routines, Remote Monitoring/Control and Alarm Reporting
Other Things to Watch Out For When Designing A

VRV Solution
Things that can lead to Poor Comfort
Poor zoning
Over connecting capacity to an outdoor unit
o
Is there diversity in the building?
Wrong type of indoor units

Over sizing units (poor temperature control)
Return air sensor position
o
Is outside air integrated to the indoor unit?
Things that can lead to a Project going Over Budget

Too many, or wrong indoor unit type.
Too many zones on heat recovery unit
Oversized units
Questions
VRF Systems: The

Ugly
Hwakong Cheng
Senior Mechanical Designer
Taylor Engineering, LLC
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1
Designer Perspective
Agenda
System Selection
Zoning and system layout
Pipe Sizing and Layout
Refrigerant Management
Coordination with other trades
Code Compliance
Controls Integration
Limitations
Photos
SLIDE 2
System Selection
Ducted vs Ductless
(but still need ventilation)
Heat Pump vs Heat

Recovery Systems
Air vs Water-cooled
condensing units
SLIDE 3
Heat Pump System Type
System serves interior zones

zones typically in cooling
SLIDE 4
Simultaneous Heating & Cooling

Cool Morning
Extract heat from east zones

and transfer to west zones
SLIDE 5
Simultaneous Heating & Cooling

Cool Afternoon
Extract heat from west zones

and transfer to east zones
SLIDE 6

Pipe length, effective pipe
length, vertical height, and
overall system pipe length
limitations
Reduced capacity with longer
pipe lengths
Prescriptive pipe sizing from
manufacturer (selection
software)
SLIDE 7

Hard pipe
Soft tubing
Brazed joints
Higher PD
Higher installation
cost
Tidy installation
with straight runs
and 90s
Not available for
small diameters
Flared fittings
Lower PD
Lower installation
cost
Consistent
insulation from
linesets
SLIDE 8

Pressure testing
SLIDE 9
VRF lots of refrigerant
ASHRAE Stds 15/34, CMC Ch 11
R-410A: Safety group A1
25 lb / 1000 cubic feet
R-410A
SLIDE 10
Example:
Ductless fan coils operable
windows
System charge: 48.3 lb R410A
Normal room: 16x15x10 = 2400 cf
Smallest room: 16x10x10 = 1600 cf
Catastrophic discharge into
smallest room:
48.3 lb / 1600 cf = 30.1 lb / 1000 cf
Above limit of 25 lb / 1000 cf!
Smallest volume
SLIDE 11
Possible solutions:
Permanent openings
Door louver/undercuts
Transfer air grilles
Transfer fan
Connected duct systems
SLIDE 12
LEED EAc4 Enhanced Refrigerant Management
R-410 high global warming potential GWP =1890
(GWP of CO2 = 1)
Look at: Lbs/ton, GWP, leakage rate, lifespan

LEED Credit EAc4 difficult to achieve
Refrigerant in rated corridors
SLIDE 13
Coordination with other trades

Electrical power to each:
fan coil
branch controller / branch selector
condensing unit
Plumbing:
condensate from each
fan coil, branch
controller
may be over sensitive
ceilings, electrical
equipment
piping may need to be
sloped
SLIDE 14
Code Compliance
Title 24 (Part 6)
Prescriptive Path
Performance Path
No testing standard yet for VRF
EnergyPro
(AHRI 1230 in development)
DOE/CEC waivers
SLIDE 15
Controls Integration
Stand-alone controls
Scheduling
Setpoint control
Monitoring / Feedback
Web access
BMS system integration
BACnet/LonWorks
SLIDE 16
Limitations
Humidity control
Fan pressure
Limited control of airside pressure drop
Watch PD for ducted systems
Standard filters ~ MERV 4
Sound
SLIDE 17
Limitations
Airside Economizer
45
45
40
40
Weather Hours
Weather
0 to 1 Hours
0 to117
1 to 105
0 to104
1 to 92
0 to911 to 79
0 to781 to 66
0 to651 to 53
0 to521 to 40
0 to391 to 27
0 to261 to 14
13 to 1
NO
YES
San Francisco
Weather
30
30
25
25
Return Air
Return Air
10
10
00
55
70
70
60
60
20
20
15
15
80
80
50
50
Supply Air
Humidity Ratio, grains/lb of dry air

Humidity Ratio, grains/lb of dry air
35
35
170
170
160
160
150
150
140
140
130
130
120
120
110
110
100
100
90
90
40
40
30
30
YES
NO
20
20
10
10
-10
-5-5 00 55 10
-10
10 15
15 20
20 25
25 30
30 35
35 40
40 45
45 50
50 55
55 60
60 65
65 70
70 75
75 80
80 85
85 90
90 95
95 100
100 105
105 110
110
Chart by: HANDS
DOWN SOFTWARE, www.handsdownsoftware.com
Chart by: HANDS DOWN SOFTWARE, www.handsdownsoftware.com
Dry-Bulb Temperature, F
Dry-Bulb Temperature, F
SLIDE 18
Limitations
Airside Economizer
aftermarket option for
ducted systemsL
SLIDE 19
Photos
SLIDE 20
Photos
SLIDE 21
Questions
SLIDE 22
VRF Systems: The

Ugly
Tal Rabiah, PE
Physical Planning & Construction
UC Santa Cruz
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1
Overview
1. Existing Installations
2. Pros and Cons
3. Outdoor
4. Indoor
5. Recommendations
Plumbing
HVAC
Maintenance
Design
SLIDE 2
1. Existing Installations (past 7 years)

University of Michigan (Ann Arbor, MI)
N. Campus Recreational Sports Building
o
2-story building; 32 tons
Central Campus Printing Building

o
Central Campus Recreational Building

o
SLIDE 3
1. Existing Installations (past 7 years)

University of California-Santa Cruz
Communication Building
o
Cell phone areas; 16 tons
Communication Building
o
Computer areas; 16 tons
UC Santa Cruz Extension

o
Santa Clara Computer Labs; 8 tons
SLIDE 4
2. Pros and Cons of VRF Systems

Pros:
A VRF system is possibly more suitable for cooling
upgrades in existing buildings than chilled water system
since the VRF has less than 1/4th the pipe size. The VRF
system may even be a preferable alternative to the
extension of an existing chilled water system to a new
building or building addition.
VRF is possibly the best option for systems with fewer than
100 tons of cooling capacity.
SLIDE 5

Pros (con't) :
The new 100% outside air fan coil unit for VRFs is a
significant advancement in the application of VRF system
in make-up air and laboratory HVAC applications where
100% outside air is required.
VRF when compared to central chilled water system is

simpler to design, operate and maintain by eliminating
cooling tower, boiler, pumps and chemical treatment.
SLIDE 6

Pros (con't) :
VRF offers simultaneous cooling and heating on the same
piping network through the use of heat pump and heat
recovery systems with automatic changeover.
All brazed cooper piping system for more corrosion and

leak resistance compared to steel piping.
Long refrigerant piping lengths to accommodate many

types of applications.
SLIDE 7

Pros (con't) :
Low operating sound levels-58 dB at full load for outdoor
unit and 25dB for indoor unit.
Water balancing is eliminated and air balancing is

simplified.
Suitable for LEED credits on energy efficiency and Title 24

compliant.
Capacities are AHRI certified.
SLIDE 8

Cons:
VRF is a proprietary system. Mixing of parts from different
VRF manufacturers is not possible.
Operates at 530 psig which is considered very high

pressure piping system inside a building, which makes leak
protection essential.
Is suitable for certain heights and sizes of buildings.
SLIDE 9

Cons (con't) :
Occupancy sensors are not provided as part of the
system.
Maintenance accessibility for Branch Selectors and

Branch Controllers is required.
Can only be installed and maintained by VRF trained

personnel.
Few manufacturers are available which leads to lesser

competition.
SLIDE 10

Cons (con't) :
System lifetime is not yet as predictable as the hydronic
systems.
Is not widely known by U.S. HVAC designers.
SLIDE 11
3. Outdoor Installation
For roof installation provide spring-type vibration isolators
with lateral restraints. Bolt isolators onto a 4 thick
concrete pad and onto bottom of condensing unit.
Do not use wooden or sheet metal roof curbs under
units.
On grade, install unit on a 4 concrete curb with
neoprene or cork isolators bolted to bottom of unit and to
concrete curb.
SLIDE 12
Outdoor Installation cont

- Use vibration isolators
Roof: spring-type
Grade: neoprene
Bolt to concrete pad

NO wood curbs
NO sheet metal curbs
SLIDE 13
Units shall be braced so that they will not

laterally tilt due to high winds.
SLIDE 14
Piping through roof should be run

through a pipe roof curb with flashing
around it.
SLIDE 15
Flexible Connection
When vibration isolators are provided,

provide 6 long flexible braided copper
connector on refrigerant piping that connects
to the unit. Do not bend flexible connectors
excessively.
SLIDE 16
Provide a services ball-type shut-off valve

with a charging port at the connection to the
unit.
SLIDE 17
Insulation refrigeration lines with

thick closed-cell foam insulation.
SLIDE 18
Piping should be supported every 6 feet or

less without pinching insulation.
SLIDE 19
H. Follow manufacturers instructions regarding the amount of

required open space around the units to allow for adequate air
movement.
SLIDE 20
Do not allow suspension rods, ducts, or conduits

to touch the piping (to avoid electrolysis).
SLIDE 21
Weather coat the outdoor insulation of piping with a

weather-resistant PVC coating. Valves should have
removable and re-installable covers.
SLIDE 22
Labeling
Label piping on roof with weather-resistant

pipe labels including directional arrows. Also
label condensing units with the equipment
numbers of the indoor evaporator units that
they serve. Follow ANSI A13.1 standards.
SLIDE 23
Clean condenser fins where there is vegetation

buildup on the condenser tubing fins.
SLIDE 24
Indoor Installation
SLIDE 25
Connect the ceiling supported unit to duct through a 4

long flexible connection. Do not allow kinks in the flexible
connection.
SLIDE 26
Seismic Supports
See manufacturer instructions
See local codes
SLIDE 27
Condensate Waste
Prefer gravity flow
Use a trap
Provide secondary
drainpipe
Or: heavy-duty with

redundant pump
SLIDE 28
Connect the ceiling supported unit to duct through a 4

long flexible connection. Do not allow kinks in the flexible
connection.
SLIDE 29
Condensate Drain Pan

Provide drain pan
under unit separate
from the evaporator
unit drain pipe.
If condensate pumps
are used put in drain
pan.
SLIDE 30
Example of unit discharge ductwork from a

plenum box.
SLIDE 31
Assure that filters, unit control panel, and fan

motor are all easily accessible for periodic
maintenance or replacement.
SLIDE 32
Recommendations
Plumbing
HVAC
Maintenance
Design
SLIDE 33
Plumbing Recommendations
Read the fine print with regard to limitations of piping
length. The length specified is the total equivalent pipe
length.
Confirm pressure testing of pipes at 600 psig for 24
hours.
3. The VRF system typically operates in the 300-400 psig
range, making leak protection essential.
SLIDE 34
HVAC Recommendations
A BacNet or Lonworks device is required to connect the
VRF controls to the rest of your building or campus
control system. This device will allow you to monitor the
VRF system, but not control it.
If there are many confined spaces served by the VRF
system, there is a possibility that refrigerant detection
alarms may be required in order to meet ASHRAE
standards 15 and 34.
SLIDE 35
Maintenance Recommendations
The VRF system is a complete proprietary packaged
system, including its own related controls, except for the
refrigerant piping.
You cannot intermix parts from the different
manufacturers of the VRF system.
System maintenance requires an experienced refrigerant
technician who is familiar with applicable codes related to
refrigerants, leak detection, and ventilation requirements.
SLIDE 36
When selecting a VRF system for your building, select
contractors that are trained and qualified to install this
system. Select a contractor who has experience
pressure testing refrigerant piping which has been
pressurized up to 600 psig.
Keep in mind that the VRF system is all site-connected,
therefore quality of brazing, evacuating, and pressure
testing can affect the VRF system performance
SLIDE 37
Provide easy access to units on roof (not through an
access hatch or a catwalk).
For the maintenance program, allow inspection of units
every three (3) months.
SLIDE 38
Design Recommendations
When comparing a VRF system to other air conditioning
systems, compare it to the 4-pipe fan coil system, or to a
water source heat pump system. Keep in mind the
systems lifetime and maintenance costs.
If outdoor installation is within a mile of the ocean, or if
the air is otherwise salty, specify salt air resistant
coatings on unit exterior finish and on condenser copper
tubing and fans.
Coordinate unit color selection with the architect.
Aesthetics can be especially important at some
installations.
SLIDE 39
Questions
SLIDE 40
VRF Systems: The

Ugly
David Sellers, PE, Senior

Engineer
Facility Dynamics Engineering
NW Satellite Office
www.FacilityDynamics.com
The Commissioning
Perspective
JUNE 2 2011
The Commissioning Providers Perspective

Corporate Perspective
Limited VRF Exposure
Some Daikin and some Mitsubishi
No tests developed in our
commissioning database
One system designed by a senior
engineer in a past life (about 15
years ago in the Air Force)
Several people can hardly wait to
get inside a branch controller/point
of change-over
On person about to take factory
training
Early Commissioning Providers

VRF SYSTEMS: THE GOOD, THE BAD AND THE UGLY; THE COMMISSIONING PERSPECTIVE
The Commissioning Providers Perspective

Personal Perspective
One new construction and one
retrocommissioning project with
Mitsubishi VRF equipment (both
current projects)
Exposure to built up direct
expansion systems since 1976
o
Dual mode system serving an

ice rink in winter and building
loads in the summer (See
Mentoring Field Technicians; A
Learning Experience for
Everyone Involved;
Proceedings - NCBC 2009)
Various commercial and

process projects

Commissioning Process Goals

New Construction
s
Retrocommissioning* (MBCx
program context)
Verify:
Develop facility baselines
Installed performance
Design intent achieved
Enable persistence
o
Documentation
Commissioning record
System Manual
Train the staff
Identify and assess energy

efficiency opportunities
Coordinate with the Owner to
implement improvements
Verify goals are achieved
Enable persistence
Documentation
Try not to go crazy
Pre and post baseline reports
Have fun
Train the staff
Have Fun
A.K.A. Existing Building Commissioning, EBCx, RCx,
Recommissioning, Monitoring Based Commissioning,
Building Tune-up, and, when I first started, operating the
building properly
Typical Issues
Cx/EBCx
VRF Experience to Date
Access/Serviceability
Access/Serviceability
Occupant satisfaction
Occupant satisfaction
Installation does not comply with

Manufacturer or industry standards
Installation does not comply with

Manufacturer or industry standards
Implementation of complex
technology difficult to achieve in
real world environments
Implementation of complex
technology difficult to achieve in
real world environments
Installation does not reflect design

intent
Installation does not reflect design

intent
Integration
Integration
Optional/2nd party equipment
Optional/2nd party equipment
Other HVAC processes
Other HVAC processes
Control systems
Control systems
Persistence
Persistence
Access and Serviceability

During Construction
Access and Serviceability

After Construction
Simple Constant Volume AHU System Diagram
VRF System Diagram
Electronic expansion valve, variable speed

fan, filters, economizer dampers and related
controls above a 10 foot semi-hard ceiling
Ceiling plenum, shafts, and other

building structure provide relief
path
The Actual VRF System Diagram
To existing constant
volume reheat
zones
10
Filter Access
Filter Access Door:

Typical access interval
Open once every
6 to 12 months to
change filters
11
Filter Access
DDC Panel:
Typical rewire and/or
recommission interval
Once every 6 to
12 months if
mounted on filter
access door
Once every 6 to
12 years if
mounted
somewhere else
12
Branch Controller Technology

http://www.mylinkdrive.com/CityMulti/Software/CM_Refrigerant_Flow/
Image courtesy Mitsubishi Refrigerant Flow

Demonstrator; Used with Permission
13

http://www.mylinkdrive.com
Image courtesy Mitsubishi PRUY Service

Instruction; Used with Permission
14

http://www.mylinkdrive.com
Recommended
access opening
nominally 18 x
18
Small to medium
technical person - 20
Image courtesy
Mitsubishi
PRUY Service
Instruction;
Used with
Permission
15
Branch Controller Installed Location
16
17
18
Branch Controller Service Procedures
Image courtesy Mitsubishi PRUY Service Instruction; Used with Permission
19
20
21
Image courtesy Mitsubishi PRUY Service Instruction;

Used with Permission
22

Typical service welding equipment

23

24
Image
courtesy
Mitsubishi
PRUY
Service
Instruction;
Used with
Permission
25
Image
courtesy
Mitsubishi
PRUY
Service
Instruction;
Used with
Permission
26
Installation Practices
Refrigerant piping installation practice critical to short and
long term system integrity
General requirements no different from those employed
with any built up refrigeration system
Details associated with R410 systems may vary from

standard practice in the field at this point in time
27
Cleanliness Is Essential
Cleaned and Capped
Used to be Cleaned
and Capped
Cleaned to an ASTM
established limit for residue
Purged with dry nitrogen
Sealed with rubber plugs with
positive nitrogen pressure
inside the tuber
Continuous nitrogen purge

necessary during installation
Maintains factory cleaned
and capped integrity
Prevents contamination by
the oxides and residuals
produce by brazing
Mitsubishi recommends
brazing temporary caps on
pipes that are not connected at
the end of the day
28
Cleaned and Capped

Used to be Cleaned
and Capped
Moisture and refrigerant dont work well

together
Corrosion
Ice
Refrigerant oil problems
Motor problems
29
Cleaned and Capped

Used to be Cleaned
and Capped
Dirt and precision machinery dont work

well together
Moving parts in compressors
Small orifices in metering and control
valves and lubrication system
Chemical reactions with oil and
refrigerant
30
Field Joints
Field joints are made using a frustum of right circular
cone
Image
courtesy
Mitsubishi
PRUY
Service
Instruction;
Used with
Permission
31
Field Joints
Field joints are made using a 45SAE Flare joint
Operating Pressures
Refrigerant
Low Side
R22
55-70 psig
R410
95 - 135 psig
High Side
180 - 260 psig
305 - 410 psig
Image
courtesy
Mitsubishi
PRUY
Service
Instruction;
Used with
Permission
32
Field Joints
33
Field Joints
34
Flaring Tools; Theyre Not All Created Equal
Conventional flaring tools

press the flare onto the end of
the tube
Recommended flaring tool rolls

the flare onto the end of the
tube
Either way:
Metal to metal sealing mechanism
Lubricate flare before tightening
Images courtesy www.ridgid.com/; Used with Permission
35
Tightening the Connection
Lubricate with a refrigerant compatible oil

Use two wrenches
Use specified torque values
36
Torque Wrenches, Flare Nut Wrench and Crows

Foot
37
Tightening the Connection
Easier accomplished on the bench than in the air

Factory line sets minimize field flares
38
Vibration and Stress Relief

Branch controller support per
Mitsubishi requirements
Flare
Flare
Rigid support nominally with-in

20 per Mitsubishi requirements
39
Vibration and Stress Relief
Relative motion still possible

with out sway bracing
40
Refrigerant Oil
R22 systems use mineral oil as a lubricant
R410A systems use an ester oil, either ether oil or
alkylbenzene
Using the wrong oil can cause sludge and other problems
leading to failure
Tools use on R22 systems can be contaminated with

mineral oil and should not be used on R410A systems
Contamination can lead to sludge and other problems

R410 oil is an order of magnitude more hygroscopic than
R22 oil
41
Connecting to Existing Branch Controllers

Concern on the part of the new project contractor
regarding unknown quality of the previous contractors
work
Pipe installation practice
System evacuation and charging practice
Low charge in existing system due to leakage
Near Azeotropic refrigerant compounds the problem
42
Azeotrope
A mixture made up of two or more refrigerants with
similar boiling points that act as a single fluid. The
components of azeotropic mixtures will not separate
under normal operating conditions and can be charged
as a vapor or liquid
Definitions from the National Refrigerants web site; http://www.refrigerants.com/frame.htm
43
Near Azeotrope
different boiling points that, when in a totally liquid or
vapor state, act as one component. However, when
changing from vapor to liquid or liquid to vapor, the
individual refrigerants evaporate or condense at different
temperatures. Near-azeotropic mixtures have a
temperature glide of less than 10 F and should be
charged in the liquid state to assure proper mixture (nonazeotropic) composition
44
Zeotrope
different boiling points. Zeotropic mixtures are similar to
near-azeotropic mixtures with the exception of having a
temperature glide greater than 10 F. Zeotropic mixtures
should be charged in the liquid state
45
Control Sensor Installation
Damper face velocity = 800 fpm

Mixing plenum depth = 39
Do you think the mixed air

Sensor is really measuring
The mixed temperature?
Outdoor
Air
VRF Fan Coil

Single Point Mixed Air
Sensor Location
Dampers
Return
Air
46
Economizer Outdoor Air Enthalpy Changeover Sensor
47
48
49

Are there any issues with this enthalpy
sensor installation given:
The duct is the outdoor air duct

The sensor is lying
on the bottom of
the duct,
unsecured
50
The Improved installation

Image courtesy Brian Nixon
51

52

53
VRF Unit Economizer Design Intent

Provide an economizer cycle
No mechanical cooling until the
economizer is on 100% outdoor air
(Code requirement; integrated
economizer)
Supplement the outdoor air cooling
as required (Code requirement;
integrated economizer)
Continue to use outdoor air until the
outdoor air is not suitable for cooling
economizer)
Use minimum outdoor air if the
outdoor air enthalpy is not suitable
for cooling (Code requirement;
Do not heat until the economizer is
on minimum outdoor air (i.e. no
simultaneous heating and cooling)
Position to full return air if the VRF

system is off (critical given the OA
source)
Use no outdoor air in warm-up mode
if the space is not occupied
Use outdoor air in the cool-down
mode only if outdoor air is suitable
for cooling
Minimum outdoor air flow matches
contract document requirements for
minimum occupancy and maximum
occupancy
The demand controlled ventilation
system can over-ride the
temperature based control of the
economizer cycle if necessary to
maintain adequate ventilation.
54
Design Intent Documentation

Required accessory on the VRF unit schedule
Code compliance required
Economizer supplier uses Honeywell W7212 which:
Can perform integrated economizer cycle (but also can do
a non-integrated economizer cycle
Can do warm-up/cool down if configured properly

Can close the dampers when the system is off if configured
properly
Can do either/or demand controlled ventilation cycle

o
Minimum occupancy air flow if CO2 below threshold
Maximum occupancy air flow if CO2 above threshold
55
Design Intent Documentation vs. Intent

Covered
by Documents
Provide
an economizer
cycle
No mechanical cooling until the
economizer
is on 100%
outdoor air
Covered
by Code
economizer)
Supplement the outdoor air cooling
as required
(Codeby
requirement;
Covered
Code
Continue to use outdoor air until the
outdoor air is not suitable for cooling
Covered by integrated
Code
(Code requirement;
economizer)
Use minimum outdoor air if the
outdoor air enthalpy is not suitable
Covered
Code
for cooling
(Code by
requirement;
Do not heat until the economizer is
on minimum outdoor air (i.e. no
simultaneous heating and cooling)
Position to full return air if the VRF

Covered
W7212
Implemented
system by
is off
(criticalif given
the OA
source)
Use no outdoor air in warm-up mode
Covered
by W7212
if Implemented
if the space
is not occupied
Use outdoor air in the cool-down
mode only
if outdoor
is suitable
Covered
by W7212
if air
Implemented
for cooling
Minimum outdoor air flow matches
Covered
Documents;
Probably
contract by
document
requirements
for
minimum
occupancy
maximum
requires
TAB RFI and
to clarify
occupancy
The demand controlled ventilation
system can over-ride the
temperature
based ifcontrol
of the
Covered
by W7212
Implemented
economizer cycle if necessary to
maintain adequate ventilation.
56
Economizer Procurement
VRF Fan coil unit provided by
1st party
Includes wiring harness for
economizer interface
Economizer mixing box

installed by a 4th party
Economizer controls installed
by a 5th party
Includes generic wiring

diagram
Economizer must interface to a

building wide automation
system by a 6th party to do
demand controlled ventilation
Capable of a number of
change over strategies
Verification of design intent by

a independent 7th party
Economizer package provided

by 2nd party
Economizer mixing box and

controls provided by a 3rd party
Includes multiple product
specific data sheets with a
wide range of capability
57
The Result: The Economizer Doesnt Work

Confusion regarding the pre-functional testing
requirements
Must reference:
Contract documents (contractor charged with developing
and executing start-up and functional tests with spot
checks by the Cx provider after completion)
Economizer package documents (generic in nature)

Economizer controller documents (product specific in
nature but no project specific details)
Control system submittals (retransmits demand controlled

ventilation signal and BACnet interface)
California energy code (very thick book)

58
Generic Economizer Package Documents
No wiring or check out information in one set of instructions

but a lot of product specific information
Generic wiring and a cut and paste check out procedure in a
different set of instructions but no product specific information
Both use a clicks on economizer change over switch as a
basis of design
59

In the normal Berkeley
climate, it would be
possible for a clicks-on
with the tolerances
shown to disable the
economizer in the
afternoon of the first day
of August and not reenable it until September
some time
60

There are many days in
many other months were
the same thing could
happen (the light green
band on the graphs is
the normal range)
61
Product vs. Project Specific Wiring Information
Honeywell documentation includes wiring diagrams for 9

applications
None are Mitsubishi systems
None are VRF systems
2010 Honeywell International Inc.; Used with permission
62
Outdoor air provided by an economizer

equipped constant volume reheat system
VRF zones are variable volume and require
system control strategy change
VRF zones potentially interactive with each
other and constant volume zones
Must balance economizer benefits with
reheat penalty
VRF dampers currently not interlocked to
close with VRF shut down
volume reheat
zones
63
Conflicting Sensor Location Information

Discharge air vs. mixed air
Either will work but discharge air
location will cause the
economizer to generally
function like a non-integrated
economizer
Bad for maximizing energy

savings
Good for compressor

replacement costs in
packaged equipment with
limited or no turn-down
capability
2010 Honeywell International Inc.; Used with permission
64
Economizer Controller to VRF Control Integration

W7212 designed
to interlock with
the mechanical
cooling and keep
it off until the
economizer has
a chance to work
Economizer
package wiring
diagram shows
no interlocks
Field wiring for
intelock is there,
but wheres it
going?
65
Economizer Controller to VRF Control Integration

W7212 is
capable of a
warm-up and
cool-down cycle
(design intent)
but currently is
not wired for it
66
Main AHU schedules are provided by the

building wide control system
VRF schedules are provided by the VRF
control system
Currently no communication of schedules
between the two systems
volume reheat
zones
67
Occupant Satisfaction
Space temperature
drifts up 2F in about 1
hour and 30 minutes
then is
driven
back down
2F below
set point
in about
20
minutes
Three out of four

zones sampled at
random so far are
doing this
68
Throttling Range
Meanwhile the pneumatic and chilled

water technology that is being replaced
by the VRF systems floated around within the throttling range of the controller
during the same time period
Two out of two

pneumatic zones
sampled at
random were
working this way
69
Technology Can Have its Limitations

VRF systems have turndown capability but not below
about 20-25% of capacity
Subject to issues related to over-sizing just like any
other approach
If the peak load potential in a zone is unknown, then
you know what you dont know
o Consider the minimum load potential
Seasonal load profile
Daily load profile
o Address the current reality with provisions for the
future potential
o Make sure you understand the details of the
technology you are about to embrace
70
Comfort aside, this could

be costing energy in the
form of unnecessary
dehumidification
Note room dew point

dropping below
outdoor air dew point
71
The Machinery Can Be Made to Work
72
But it Requires Attention to Detail
73
And Taking the Time to Integrate Things
74
Integration; The Commissioning Perspective

Integrate the equipment into a
working system
Verify design intent in the short
term
Ensure its persistence in the
long term
Integrate all the players into a
team to identify and solve
problems
Bring new technology into the
mainstream
Understand how it should work
Address prototypical issues
Ensure it things keep working

for the life of the system
75
National Refrigerants
www.refrigerants.com
76
Principles of Refrigeration by Roy Dossat

Complex principles in understandable terms
77
Other Resources
Trane Refrigeration Manual
http://www.trane.com/Commercial/Dna/View.aspx?i=492
Copeland Refrigeration Manual

http://www.emersonclimate.com/en-us/brands/pages/copeland.aspx
http://lvhvac.com/cope_bulletins/aeIndex.pdf
Sporlan Valve
http://www.sporlanonline.com/literature.shtml
Mueller Brass
http://www.muellerindustries.com/
ASHRAE Journal
Variable Refrigerant Flow Systems by William Goetzler, April 2007;
www.ashrae.org
78
Questions
79

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VRF Systems: The

Good, The Bad and The

Mark Hydeman, PE, Principal

VRF SYSTEMS: THE GOOD, THE BAD AND THE UGLY

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