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MaximICE is a trademark of the Paul Mueller Company for its liquid ice system. All rights
reserved worldwide.
This software package and manual were prepared by Y.T. Li Engineering, Inc. for the Paul
Mueller Company. The software and manual are both copyright 1995-1999. All rights
reserved worldwide.
Neither the Paul Mueller Company nor Y.T. Li Engineering, Inc. assume any liability for the
use or misuse of the software. The software is made available as an analysis aid only. Any
equipment selected should be confirmed by appropriate Paul Mueller Company
representatives.
Y.T. Li Engineering, Inc. makes no express or implied warranties with regard to performance
or accuracy of the software and specifically disclaims any implied warranties of fitness for any
particular purpose. Y.T. Li Engineering, Inc. shall not be held liable for any consequential
damages that may possibly occur through the use of the software.
September 9, 1999 1
Installation
Requirements: Microsoft Excel 97 or later. It needs about 1000K memory on a hard drive. The
spreadsheet will print in color or gray-scale if your printer supports that capability.
Note: There is another version of the MAX software available for Excel 5.0 through 7.0!
Microsoft Excel 97 for Windows has minimum system requirements of a 386 or better
computer, Windows 95 or later (or Windows NT 3.51 or later). MAX recalculates fairly
quickly with any Pentium class CPU.
IBM PC
1. Create a directory named MAXIMICE & copy both template MAX.XLT and add-in
MAX.XLA into it
2. Launch Excel and open template MAX.XLT. If the feed flow label (cell B10) in the Daily
worksheet contains engineering units, then installation is complete!
If several worksheet cells contain #NAME? then continue with steps 3 through 9
3. Excel can’t find the functions in the add-in, so you need to register the add-in with the
template. Open the Tools...Add-Ins menu. Make sure that MAX is listed and that its
box is checked. If it does not appear, click the Browse... button and locate add-in
MAX.XLA in the C:\MAXIMICE directory. Click OK to register the add-in.
5. Change to Daily sheet in workbook. Click on any cell in Input section. Next, click
anywhere in the formula bar. Then hit Enter.
6. The spreadsheet should now recalculate and any cells that had contained #NAME? will
change to numbers.
7. Select the File...Save As menu. Change the Save file as Type to Template. Change the
filename to MAX.XLT then hit enter.
8. Close template MAX.XLT
9. Open template MAX.XLT (these last two steps allow support of Notes and F8 & F9
buttons)
Why a Spreadsheet?
Calculations are contained in an Excel 97 spreadsheet to
! shorten the learning curve by taking advantage of user familiarity with spreadsheets
! let the user reformat results to suit presentation requirements
! run software in foreign countries, and even present results in local language
! simplify program maintenance
! be compatible with software industry trends such as Visual Basic
! permit integration into studies or proposals through OLE 2.0
! model scenarios never contemplated by program author
September 9, 1999 2
Engineering calculations are performed by a set of functions and subroutines to maintain
calculation integrity. The user can change the inputs or presentation of results, but cannot
change the details of the calculations.
Overview
All of the engineering calculations are performed by Visual Basic subroutines & functions
contained in the MAX.XLA file. The main function PERF returns all the values contained in
the Results section of the spreadsheet. It in turn calls supporting functions for refrigerant
physical properties, compressor performance, condenser performance, MaximICE performance,
etc. These functions all appear in the User Defined category in the Insert Function menu.
The three optimize buttons try to find (respectively) the minimum size
Optimize MaximICE unit, minimum size ice storage tank, and maximum size starting ice
inventory. Each button is located near the thing it is trying to optimize. To
use them, enter your data, push the button and wait 5 to 60 seconds for the
calculations. The status bar at the bottom of the window displays messages on calculation
progress. When the optimize button is done, the window & results are updated. Normally,
you would optimize the MaximICE unit first, then choose a standard size MaximICE &
condensing unit. Next, you would optimize the tank size, then choose a standard model.
Finally, you would optimize the ice starting inventory, then print out the results.
September 9, 1999 3
You may also trigger spreadsheet calculation with the F9 key. This key calls the PERF
function using the input data and thereby updates the results section. F9 calculations are
useful if you are trying to fine-tune your MaximICE performance model.
Input Data
When first opened, MAX displays the Customer worksheet, which contains names, phone
numbers and addresses relevant to the project. Client name & company and Project name &
owner are automatically passed to cells on the Daily & Weekly worksheets. The other
information requested is merely for your inquiry records.
Each worksheet (Daily & Weekly) contains its own (independent) Input Data. You may copy
the input data from one worksheet to the other, however. You may also copy input data from
a previous run (assuming you saved the data file).
I
Some cells affect others appearing lower in
the spreadsheet. For example, Condenser t’s important to enter data from the top to
coolant type determines whether the the bottom of the spreadsheet. Default
ambient conditions should be wet bulb or data is updated automatically, but user
dry bulb. Although the labels change overrides are not. A similar situation arises
automatically when you select a different with the Input Units. By entering data from
Condenser coolant, user specified ambient top to bottom, you avoid the problem of
conditions are not updated and you must changing the meaning of previously entered
remember to change them manually. data.
Most input data cells contain formulas or function calls to set default values. For example, the
September 9, 1999 4
Condensing unit capacity, MaximICE feed
flow and Solution volume all depend on
MaximICE capacity. You may override T o restore the formulas, type “Ctrl r”
(using the Control key). This will be
useful when you are changing an old (and
these formulas by entering fixed values or
even enter your own formulas. These fully optimized) data sheet for new
changes may be saved with the workbook. conditions. Formulas affected include those
Because MAX.XLT is a template, however, for Solution volume, Tank volume, Starting
default values and formulas are restored on inventory, Condensing unit capacity and
the next new job. Tank Height.
Customer
Project name is the building or project name; it is used to label the performance graph. Its
source is the Name field in the Project section of the Customer worksheet.
Owner is name of the owner or end-user of the project. It is printed for reference only. Its
source is the Owner field in the Project section of the Customer worksheet.
Client is the name of the contact person at the company requesting MaximICE information. It
is printed for reference only. Its source is the Name field in the Client section of the
Customer worksheet.
Company is the name of the engineer or contractor requesting MaximICE information. Its
source is the Company field in the Client section of the Customer worksheet.
Input distance affects the units for feed flow, solution volume, tank size, tank height & length
(or diameter). Choices are “feet” or “meters”. The program examines only the first
letter, and accepts either upper case or lower case. For feed flow, the units will either be
GPM or m3/hr, depending on the Input Distance code entered.
Input temperature affects the units for )P allowance to compressor suction & condenser (both
of which are pressure drops stated as losses in saturation temperature). It also affects
the condenser subcooling, suction superheat, daily high & low, and chilled water
supply to the building. Choices are “F” or “C”. The program examines only the first
letter, and accepts either upper case or lower case.
Input energy affects the units for Insulation R-factor, total load & baseload chiller capacity.
Choices are “tons” or “ton-hrs”, “BTU” or “MBTU”, “Mjoules”, “kW”, and “Mkgcal” or
“Mcal”. The program examines only the first two letters, and accepts either upper case
or lower case. Insulation R-factor units will either be hr-ft2-EF/BTU or m2-EC/watt,
September 9, 1999 5
depending on whether an English or metric Input Energy code was entered.
Output distance affects nothing in the current version of MAX.
Output temperature affects the units for feed solution temperature. Choices are “F” or “C”. The
program examines only the first letter, and accepts either upper case or lower case.
Output Energy affects MaximICE Capacity and ice slurry tank Inventory. Choices are “tons” or
“ton-hrs”, “BTU” or “MBTU”, “Mjoules”, “kW”, and “Mkgcal” or “Mcal”. The program
examines only the first two letters, and accepts either upper case or lower case.
September 9, 1999 6
Condenser subcooling refers to the reduction of refrigerant temperature below the saturation
temperature at condenser outlet. Subcooling increases refrigeration capacity by reducing
the amount of flash gas generated after the expansion valve. For program purposes,
subcooling may occur either in the condenser, an economizer or a waste heat recovery
exchanger. Do not enter subcooling which results from a suction line heat
exchanger—see below. Condenser subcooling is initialized at zero to be conservative.
Suction superheat refers to the increase in refrigerant temperature above the saturation
temperature measured at the compressor suction. Since MaximICE doesn’t produce any
superheat, the program assumes that superheat results from a suction line heat
exchanger. This would increase subcooling at the expansion valve, thereby increasing
refrigeration capacity. Suction superheat is initialized at zero to be conservative.
The tank size must be chosen large enough to contain the solution volume, plus allowances for
volume expansion during freezing, spray headers above the ice pack, and liquid below the (full
tank) ice level switch. The spreadsheet displays a warning if the tank won’t hold at least 130%
of the solution volume.
T
The ice slurry tank is considered full if the
his restriction to full hour operation
solution volume has over 50% ice. At this
means the ice inventory may
ice fraction, about 20 gallons of solution are
occasionally slightly exceed the “full tank”
necessary to store 1 ton-hour. If the tank is
inventory. For this same reason, it will
full at the beginning of an hourly period and
probably be impossible to find an optimized
load is less than MaximICE capacity, the
design which drives the ice inventory to
MaximICE system will not run. Once
exactly zero at some point in the cycle.
started, however, the spreadsheet assumes
the MaximICE runs all hour.
Tank volume refers to the storage capacity of an empty tank. Solution volume (above the ice
level switch) is then determined by dividing by 1.4. Tank volume is initialized to 480
gallon/ton of MaximICE capacity for the Daily worksheet, and 1250 gal/ton for
Weekly. Bigger values may be needed to minimize MaximICE capacity.
Starting ice inventory refers to the amount of energy stored in the tank at the beginning of
spreadsheet calculations. If final inventory equals starting inventory, the spreadsheet
has modeled a steady state problem (the daily or weekly cycle will repeat ad infinitum).
Normally, the user should let the Optimize buttons choose an appropriate value for
starting ice inventory.
Shape refers to the ice slurry tank shape and orientation. Choices are “cylindrical” and
September 9, 1999 7
“rectangular”. The program examines only the first letter, and accepts either upper case
or lower case. Cylindrical tanks are always vertical. Rectangular tanks always have a
square footprint. Depending on the shape chosen, a subsequent cell will ask for either
the length of a rectangular tank or the diameter of a cylindrical one.
Height refers to the nominal height of the ice slurry tank. It is used to check tank size against
solution volume and determine tank surface area for heat gain from the environment.
Length refers to the nominal length & width of the ice slurry tank footprint. It is used to
check tank size against solution volume and determine tank surface area for heat gain
from the environment. It is initialized to make the tank size 140% of solution volume.
Diameter refers to the nominal diameter of the ice slurry tank. It is used to check tank size
against solution volume and determine tank surface area for heat gain from the
environment. It is initialized to make the tank size 140% of solution volume.
Solution volume is normally calculated from tank volume by dividing by 1.4. This calculation
can be overridden if desired, with the new value affecting MAX output.
Insulation R-factor refers to the insulation applied to the ice slurry tank sides and top. It is used
to calculate heat gain from the environment.
Parasitic & accessory losses are added to the calculated heat gain from the environment. This
entry accounts for heat gain from circulating pumps, solar gain & air exchange.
Freezing point depressant refers to the additive used to promote the slush formation. It acts
through freezing point depression. Choices are salt water, propylene glycol and ethylene
glycol. The program examines only the first letter, and accepts either upper or lower
case.
Concentration (wt%) refers to the additive used to promote the formation of slush. It is
initialized at 7%, which is high enough to avoid problems with freeze-up.
Ambient temperatures are assumed to follow a roughly sinusoidal variation between a high
and low temperature. Hourly data from Atlanta, GA between July 19 and August 4, 1995
(collected in preparation for the ’96 Olympics) have been used to model this variation.
September 9, 1999 8
refers to a blend of return solution from the cooling load together with solution from
the tank. A code of 2 refers to feed taken directly from the tank.
Page 2 inputs
Cooling loads and allowable hours of operation are input in columns on left side of the Results
section.
OK to run MaximICE? refers to whether the energy management strategy allows MaximICE
operation during this hour. Choices are “yes” or “no”. The program examines only the
first letter, and accepts either upper case or lower case. To reduce the amount of data
entry on the Weekly worksheet, Tuesday through Friday are set equal to the previous
day’s data. All hours on Saturday & Sunday are assumed to be OK to run. These
defaults are easily overridden.
Total Load refers to the total cooling load (i.e. both to baseload chiller and TES system) for
the building or process. To reduce the amount of data entry on the Weekly worksheet,
Tuesday through Friday are repeats of the previous day’s data. Saturday & Sunday
loads are initially set to zero. These defaults are easily overridden.
Baseload Chiller refers to that portion of the total cooling load for the building or process
which is handled by a baseload chiller.
Results
The Results section tabulates MaximICE performance hour by hour over a daily or weekly
cycle, depending on the worksheet. All values are determined from the input data by compiled
functions.
September 9, 1999 9
slightly exceed the “maximum” inventory if the tank wasn’t quite full at the beginning
of a period and the MaximICE ran all hour. Negative values have no physical
significance and represent an error condition which must be corrected. For this reason,
all negative inventories are displayed in red. To get rid of a negative inventory, you
might increase starting ice inventory, solution volume or MaximICE capacity.
Totals refer to the TES Load, Baseload Chiller, Total Load, MaximICE capacity and High
Side Power for the entire worksheet.
StandardICE
The green StandardICE button at the top of each worksheet tries to simplify user interaction
with the program by selecting standard size components which satisfy the given conditions.
Pressing the StandardICE button is
U
equivalent to the following steps:
se the StandardICE button for “plain
Optimize MaximICE capacity, then
vanilla” applications under 1000 tons
select the closest standard
capacity. First, enter your data, then hit
MaximICE & condensing
the StandardICE button. The spreadsheet
units
then solves your problem automatically,
Optimize Tank Size, then select the
choosing appropriate size MaximICE &
closest standard size tank
condensing units, then selecting a suitable
Optimize Starting Ice Inventory
tank.
Display the results in a graphical
presentation
Because these steps involve many iterative calculations, the complete process for a weekly cycle
takes two minutes on a 486-66. The status bar at the bottom of the window will show
progress.
If the optimum component size is larger than the standard sizes built into the program, a
warning message displays alerting the user to that fact. If that occurs, you must consult Paul
Mueller representatives for advice on component sizing. Once you have their input, you can
use that value to complete the optimization manually.
Optimizing
There are three Optimize buttons on each worksheet. Each one is located adjacent to the
particular input being optimized: MaximICE capacity, Tank Size or Starting Ice Inventory.
After an Optimize button is clicked, a Visual Basic subroutine goes through iterative
calculations to determine the optimum steady state value of that parameter. Steady state here
means a solution that can repeat indefinitely if the input conditions should continue
occurring. After completing the optimization, the subroutine updates the results section. For
this reason, you must manually trigger recalculation (using another button or F9) if you
change the input data after an optimization.
Optimize MaximICE capacity finds the smallest MaximICE system that gives a steady state
September 9, 1999 10
solution using the given solution volume (and other input data). To reach steady state, the
starting ice inventory is adjusted to equal the final ice inventory. The optimum MaximICE
capacity occurs when the minimum ice inventory is close to zero. The bisection algorithm is
used with ten iterations for good accuracy (0.1%). In the bisection algorithm, there is both a
MaximICE capacity too small to reach steady state, as well as one larger than necessary to
reach steady state. The average of the high and low values is tested, and then becomes the
new value for either the high or low limit. The status bar (at the bottom of the window)
describes progress of optimization.
Optimize Tank Size finds the smallest tank (and hence solution volume) that gives a steady
state solution using the given MaximICE system (and other input data). To reach steady state,
the starting ice inventory is adjusted to equal the final ice inventory. The bisection algorithm
is used, with ten iterations.
Optimize Starting Ice Inventory finds the solution with the largest reserve capacity. Reserve
capacity is the minimum ice inventory at any point during the period being studied. This
situation (which happens to be steady state) occurs when the starting inventory is adjusted to
equal the final ice inventory. The bisection algorithm is used, with ten iterations.
O
Sequential optimization
ptimizing in sequence is a good
1. Input customer conditions. Try to guess a
strategy for designing a
reasonable size MaximICE capacity.
MaximICE system. The overall goal
2. Optimize MaximICE capacity
is to select the smallest MaximICE
3. Select a standard increment of MaximICE and
and ice slurry tank. Because tanks
condensing unit capacity that is equal or
and MaximICE units only come in
larger than the minimum capacity identified
certain sizes, the resulting system will
in the preceding step
always have reserve capacity. It’s
4. Optimize Tank Size
these last results (showing the reserve
5. Select a standard increment of ice slurry tank
capacity) that the customer wants.
6. Optimize Starting Ice Inventory
7. Print the results
F
Graphical results
or a quick peek at the
For a quick peek at graphical results, double-click on
graphical results, double click
any cell which does not contain a small red triangle in
any cell which doesn’t contain
its upper right corner. The chart will then display for
notes.
15 seconds before returning to the spreadsheet.
September 9, 1999 11
Performance Map Worksheet
This worksheet calculates the performance of a MaximICE system at solution inlet
temperatures from 24~50°F (or equivalent °C range). This range covers common chilling and
ice-making regimes possible for a standard system.
Inputs are basically the same as for the Daily & Weekly worksheets, except for the condensing
unit, whose performance model can be fine-tuned. See the section on Standard sizes of
MaximICE, condensing units and tanks for further details (including formula for
calculating compressor performance).
D
Standard capacity refers to the refrigeration
on’t override the default unless you
duty of the condensing unit at
know how to calculate compressor
standard conditions (20°F saturated
performance at standard conditions!
compressor suction, 100°F saturated
Vendor catalogs usually tabulate
compressor discharge, no superheat
performance with superheat & subcooling
and no subcooling). Default data is
to make capacity seem larger and efficiency
taken from the StandardICE
better.
worksheet, but may be overridden to
model a specific condensing unit.
Standard approach refers to the difference between saturated compressor discharge temperature
and ambient (or cooling water return) temperature, measured at standard conditions.
Default data is taken from the StandardICE worksheet, but may be overridden.
Standard compressor power refers to the electric power (kW) consumed by the compressor at
standard conditions
Standard fan power refers to the electric power (kW) consumed by the fans on the condensing
unit at standard conditions.
H
Function PerfMap calculates the Performance Map it F9 to recalculate the results in
(results) section when you hit F9. You can change the Performance Map. This
more than one input before recalculating. avoids the aggravation of waiting for
the spreadsheet to recalculate each
Sol’n In refers to the solution temperature time you change an input.
entering the MaximICE
Sol’n Out refers to the solution temperature
leaving the MaximICE. This temperature
won’t be any lower than freezing temperature.
Freezing Temp refers to the freezing temperature of the ice slurry. In chilling regimes, it is
calculated using the input concentration of freeze point depressant. In ice-making
regimes, it is the taken as the solution inlet temperature.
Capacity refers to the refrigeration duty of the condensing unit
Power refers to the kW energy consumption of the condensing unit (compressor & fan). It does
not include energy consumption of the MaximICE orbital drive, feed pump & ice
slurry pump
September 9, 1999 12
Efficiency refers to the energy efficiency, COP or EER of the condensing unit using the above
Power & Capacity
THR refers to the total heat of rejection to the condenser, including both compressor power
and refrigeration duty
Evap refers to the saturated refrigerant temperature leaving the MaximICE. It does not include
the suction line temperature loss (from the input data).
Cond refers to the saturated refrigerant temperature leaving the compressor discharge. It does
not include the discharge line saturation temperature loss (from the input data).
Although the user has no control over which data is calculated in the Performance Map, you
can control the appearance of the printed output. For example, suppose you don’t want to
publish the freezing temperature. Merely select that column and hide it using the
Format...Column...Hide menu.
Help
D
Detailed descriptions of each input and output escriptions of each input & output
are provided by Comments which display appear when you double-click any
automatically whenever the cursor moves over cell containing a Note marker (small red
a cell. Cells containing notes have a small red triangle ).
triangle in their upper right corner. If this
proves disconcerting, turn the feature off using
the Tools…Options…View…Comments menu. To view a Comment, double-click on the cell.
It will display for 15 seconds, then return to the spreadsheet.
You can change the Comments display duration by going to Visual Basic Module1. In sub
MaximICEinfo (the second one in Module1) the variable DisplaySeconds controls duration of
Comments display.
For technical support, contact Brad Yundt of Paul Mueller Company at (417) 831-3000 X336.
His FAX number is (417) 831-4175.
September 9, 1999 13
to a standard location (such as cell A7—MaximICE capacity)
4. Select the Daily worksheet and F9. Move the cursor to the standard location.
5. Select the Splash worksheet
6. Select the File...Save As menu. Change the Save file as Type to Template. Change the
filename to MAX.XLT then hit enter.
7. Close the workbook
Add-in preparation:
1. Launch Excel
2. Open MAX.XLW and make the desired changes
3. Make sure to save MAX.XLW workbook! Subsequent steps destroy the copy in memory.
4. Using the Tools...Add-Ins... menu, uncheck MAX
5.Select the Weekly worksheet (by clicking on that tab)
6. Using the Edit...Delete Sheet menu, delete the Weekly worksheet
7. Repeat the procedure to delete Daily, Performance Map, Compressor Map, Splash and
Customer worksheets
8. Switch to Visual Basic editing by hitting Alt F11.
9. Using the Tools...References... menu, uncheck MAX
10. Using the project explorer window, look for Module1. If it does not appear, then double-
click Modules.
11. Using the File…Remove menu, delete Module1.
12. Switch back to the Excel worksheets by hitting Alt F11.
13. Using the File...Save As... menu, change the Save as type to Microsoft Excel Add-In
(*.XLA) and the File name to MAX.XLA. Then hit enter to save the remaining
modules and worksheet into the MaximICE directory.
14. Close workbook MAX.XLW. Ignore the prompt reminding you to save the changes! Ignore
prompts about cannot find MaximICE_FKey or macro ...
Template preparation:
1. Open workbook MAX.XLW
2. Select the Weekly worksheet and F9 (this will speed up template loading). Move the cursor
to a standard location (such as cell A7--MaximICE capacity)
3. Select the Daily worksheet and F9. Move the cursor to the standard location.
September 9, 1999 14
4. Select the Performance Map worksheet and F9. Move the cursor to the standard location.
5. Select the Compressor Map worksheet and F9. Move the cursor to the standard location.
6. Using the Tools...Add-Ins... menu, check MAX. If it does not appear, click the Browse...
button and locate add-in MAX.XLA in the C:\MAXIMICE directory. Click OK to
register the add-in.
7. Select the StandardICE worksheet (by clicking on that tab)
8. Using the Edit...Delete Sheet menu, delete the StandardICE worksheet
9. Switch to Visual Basic editing by hitting Alt F11
10. Right-click MAX.xla in the project explorer window
11. Change Project Name to MAX
12. Change Project Description to “MaximICE sizing & performance calculations. For Excel 97
only!”
13. Click the Protection tab, lock the project for viewing and enter a password
14. Using the File save menu, save the changes to the MAX Add-In properties
15. On the Tools...References... menu, move cursor to MAX. Make sure box refers to
C:\MAXIMICE\MAX.XLA. If MAX not in list, click the Browse... button and
locate add-in MAX.XLA in the C:\MAXIMICE directory. Click OK to register the
add-in.
16. Using the project explorer window, double-click the Compressor module
17. Using the File…Remove menu, delete the Compressor module. Do not export it!
18. Repeat the procedure to delete Tank, Bohn & ORE, Feed Code, Properties, Maps,
Optimization and Misc modules
19. Switch back to the worksheets by hitting Alt F11
20. Select the Splash worksheet (by clicking on that tab)
21. Select the File...Save As menu. Change the Save file as type to Template (*.XLT). Change
the File name to MAX.XLT. Then hit enter to save the remaining module and
worksheets into the MaximICE directory.
22. Close the workbook
September 9, 1999 15
change to numbers.
9. Select the Splash worksheet (by clicking on its tab)
10. Select the File...Save As menu. Change the Save file as Type to Template. Change the
filename to MAX.XLT then hit enter.
11. Close template MAX.XLT
12. Open template MAX.XLT (the last two steps initialize Comments and F9 buttons)
If you have a copy of Excel valid for a locale other than USA, then the spreadsheet
automatically uses the appropriate local format for dates, times and numbers (separators and
decimal points). Even if you have a copy of Excel valid for USA, you can reformat the output
to reflect local standards.
Units of measure are appended to the Input Data and Results section labels by compiled
functions. Although you can choose the desired units (by specifying Input & Output units),
you will not be able to correct their spelling (unless you write your own functions).
Some input entries contain text information. The program examines only the first one or two
letters, and accepts either upper case or lower case. If the English word has the same initial
characters as the non-English equivalent, then no changes are necessary. Otherwise, you must
treat that input item as a code. The program will also accept numbers instead of letters if that
seems more appropriate.
Note that MaximICE mode is output as English text. You will not be able to convert it to
another language without changing the compiled functions.
September 9, 1999 16
The names of the worksheet tabs (Daily and Weekly) are not used by the program, so you
may choose any other names desired. Although not apparent to the casual user, the
worksheets contain defined Names that refer to specific cell ranges. Do not change these
Names, because the compiled functions refer to them specifically.
Once you have completed all the changes to the spreadsheet, save it as a template by following
the directions in How to Modify the Template.
September 9, 1999 17
equivalent. Total kWh and tons will still be correct, however.
Paul Mueller Company engineers may defeat this heat flux error checking by changing Visual
Basic code in either the .XLA add-in or the uncompiled workbook MAX.XLW. This code is
found in module Bohn & ORE near the end of function ORE. The heat flux limits are
specified in the Select Case block (i.e. Case Is <2500 or Case Is > 7000). Change either or
both limits, then rerun the data.
You may add, delete or modify data contained in the tables using normal Excel spreadsheet
techniques. Enter data either as discrete numbers or as formulas. By convention, fully
accepted data is entered in a roman (plain) font; other data is entered in an italic font.
The compiled functions refer to data by name, such as AirCndsrxl & AirCndsrDataxl, which
point to specific ranges of cells on the StandardICE worksheet. Each name starts with the
prefix StandardICE! so they don’t appear in the name menu for other worksheets. The range
definitions may be viewed (and changed) from the Insert...Name...Define menu. Each table
(surrounded by double-line border) contains two named ranges: one for the nominal size ( e.g.
MaximICExl) and the other for the supporting data (e.g. MaximICEDataxl).
September 9, 1999 18
After changing data in the StandardICE
tables, the program must be recompiled for
distribution. That way, casual users are
prevented from changing the database.
C ondensing unit manufacturers never
tabulate performance at the program’s
“standard” conditions of 20°F saturated
suction, 100°F saturated discharge, no
Condensing units superheat and no subcooling. You’ll need
Condensing unit tables (AirCndsr, to do some math to derate the published
EvapCndsr & WaterCndsr) describe the capacity for the superheat and subcooling
standard increments and performance of air that they invariably included.
cooled, evap cooled and water cooled
condensing units. The nominal size of each
condensing unit should match the nominal size of the associated MaximICE modules. Actual
capacity, approach, compressor power and fan power are then entered for “standard” rating
conditions: 20EF saturated compressor suction temperature, 100EF saturated compressor
discharge temperature, no condenser subcooling & no suction superheat. If the compressor
manufacturer doesn’t tabulate data with zero subcooling & superheat, you can correct the
tabulated capacity by doing a heat & mass balance.
Using the manufacturers’ tabulated capacity, solve for the unknown mass flow. Increase the
mass flow by the ratio of absolute temperatures (SST+superheat)/SST. Then use the corrected
mass flow in the above equation without the superheat and subcooling terms to determine the
refrigeration capacity at “standard” rating conditions.
The approach temperature refers to the difference between compressor saturated discharge and
coolant inlet temperatures. Coolant inlet temperature means ambient dry bulb for an air
cooled condensing unit, wet bulb for evap cooled and cooling water return temperature for a
water cooled unit. If the condensing unit manufacturer doesn’t publish approach data, you
must either demand data from the manufacturer, measure the performance of an actual system
or back-calculate from published compressor & condensing unit data.
For open compressors, the required data must be slightly adjusted. The approach and
compressor power are interpreted as though for a semi-hermetic or hermetic compressor.
Because the motor inefficiency in open compressors does not get rejected in the condenser, you
need to adjust the input data so MAX.XLT calculates the correct condensing temperature and
total energy consumption. The easiest way is to calculate the motor inefficiency and add it to
the actual fan power; approach and compressor power are then input as measured. For better
accuracy over a range of ambient conditions, enter the actual fan power, expected motor kW
for the compressor power, and a slightly reduced approach (by ratio of actual compressor kW
to expected motor kW).
September 9, 1999 19
MaximICE modules
MaximICE modules are presently available
in 3, 25, 50 and 100 ton nominal sizes.
They may be combined in any proportion to
I t’s OK to run a MaximICE module at
more than nominal capacity. A 100 ton
MaximICE mates nicely to a 130 ton
get larger or in-between capacities. The most condensing unit.
economical system often has a larger or
smaller MaximICE nominal capacity than
condensing unit nominal capacity. For most economical system cost, avoid using 3 ton
modules if required capacity exceeds 10 tons. Also, never use more than one 25 or 50 ton
module in a system. The table incorporates these guidelines and lists standard combinations of
MaximICE modules under 1000 ton nominal size. The associated data field lists total surface
area (based on the average of tube ID and OD) for each combination.
Tanks
Data is presented for both cylindrical and rectangular tanks. Cylindrical tanks shown are
molded plastic and can be shipped completely assembled. Rectangular tanks will probably be
field-assembled. The program uses tank data only when the StandardICE button is clicked.
For cylindrical tanks, the required data includes the overall height, diameter and solution
volume. The program expects outside dimensions (to calculate heat gain). The nominal size is
the catalog value for tank volume.
For rectangular tanks, the required data includes the overall height, length, width and
solution volume. The program expects outside dimensions (to calculate heat gain). The current
version of the program assumes that length and width are the same, and so ignores the second
column. The nominal size is the catalog value for tank volume.
Troubleshooting
Installation problems
#NAME? appears in Input Data cells
! MAX can’t find the MAX.XLA add-in. You need to register the add-in with the template.
Repeat instructions 3 through 9 in the Installation section.
! You tried to install the add-in without first quitting Excel. Because the add-in is loaded
every time you launch Excel, you cannot change it without first quitting Excel. Repeat
instructions 2 through 9 in the Installation section.
Printing problems
Print-out too slow
! Color or gray-scale printing takes too long. Use a faster printer (such as laser or Hewlett-
Packard professional series ink-jet).
! Color or gray-scale printing takes too long and I’m not changing printers. If the appearance
is less important than speed, make a special copy of template MAX.XLT that
eliminates color. As a minimum, you must change the blue color used for input data,
September 9, 1999 20
the special colors used in the schematic diagram (created using the Excel drawing
toolbar), and the line colors used in the graphical results presentation. You may also
wish to change the red color used to signal negative ice inventory in the Results and for
warning messages on page 1. The Excel User’s Guide gives detailed instructions.
Warning messages
September 9, 1999 21
Negative ice (displayed in red)
! Tank too small. In the graphical results, does the ice inventory reach and maintain a peak
value early in the off-peak hours? In the tabular results, MaximICE mode will
frequently be “Tank full”. If so, then the tank is too small to hold all the production
possible by the MaximICE system.
! MaximICE too small. Total MaximICE capacity must exceed the total cooling load plus
losses. Increase it and try again.
! Starting ice inventory too small. You probably also got a warning message about initial and
final ice inventories not agreeing. Optimize starting ice inventory.
MaximICE or condensing unit too large to standardize. Use your own judgement.
! The MAX.XLA add-in contains a table of standard size components. If the required
MaximICE or condensing unit exceeds the biggest value in the table, consult Paul
Mueller representatives for more information on larger capacities. In the meantime, stay
with the optimized size (shown in the Input Data) until additional data is forthcoming.
Tank size doesn’t match tank dimensions (too large or too small)
! The volume calculated from tank dimensions doesn’t match the specified tank size. This may
occur in rectangular tanks if the footprint is not square (as the spreadsheet assumes).
The spreadsheet calculates heat gain from the environment, and so needs to know the
exposed surface area. If you are satisfied that this calculation is sufficiently conservative
(such as by adjusting the tank ambient temperature), then you can delete the warning
message.
September 9, 1999 22
Energy consumption seems too high
! Manufacturer’s data sheets are normally based on suction superheat and inlet subcooling,
both of which increase compressor capacity and decrease kW/ton. Because MAX
defaults to zero superheat and zero subcooling, its projected energy consumption may
seem too high. Override the default input values for superheat and subcooling and
MAX should come much closer.
!MAX includes fan power in its energy consumption, whereas compressor manufacturers do
not for their kW/ton projections. MAX assumes that air-cooled condensers use 0.12
kW/ton for the fans and that evap-cooled condensers use 0.06 kW/ton. Water-cooled
condensers are not penalized by fan power.
!MAX bases its calculations on data from a 35 HP Copeland reciprocating compressor. Large
screw compressors may be more efficient. This problem can be corrected in the
Performance Map and Compressor Map worksheets, but not in the Daily and Weekly.
!You are trying to model an energy-efficient condenser (with close approach). MAX assumes a
24°F approach for air-cooled condensers and 18°F for water-cooled and evap-cooled.
These assumptions can be overridden in the Performance Map and Compressor Map
worksheets. They can be compensated for in the Daily and Weekly worksheets by
reducing the ambient temperature range to artificially lower values. Column K
(normally hidden) shows the condenser saturation temperature. Select columns H
through L, then use the Format…Column…Unhide menu to expose column K. Adjust
the ambient temperature range until the condenser temperature matches expectations.
September 9, 1999 23