Flagship Marine’s extremely compact 5-ton (60,000 BTU) reverse-cycle heat pump chiller is only 16” x 23” x 28” (407mm x 584mm x 711mm)
Our new design, which has evolved over many years of experience, has resulted in the most rugged, simple, trouble free and compact unit available today. A child can follow the schematic. No expensive proprietary printed circuit boards, no add on charges for “controllers”- everything is in one modular electric control box and is “over-the-counter”.
HUGE amount of power with a TINY footprint!
This 15 ton (180,000 BTU) chiller with a bulletproof Copeland ZP154 scroll compressor (155,000BTU air cooled – we DON’T skimp!) is an incredible 19.5″ wide x 29″ long x 19.6″ high. Even so, all critical components are readily accessible and our exclusive low voltage monitor is conveniently mounted on the top of the evaporator. Electric box not shown and is on 6′ leads.
Flagship Marine Exclusive: Dry Drain Pan
No more mold and mildew starting in your drain pan! We now manufacture sloped aluminum drain pans that are dry so the condensate water doesn’t have a chance to grow mold and mildew.
All sheet metal components are laser cut with aircraft/military quality tolerances in the ten-thousandths of an inch range as depicted here with the skeleton of an air-cooled chiller. Note the PEM nut inserts and numerous stainless steel rivets that result in a very rigid, strong and exacting structure.
Flagship’s Exclusive Diagnostic Monitors Use Time Tested “Over the Counter” ICM Modules
With Flagship there are no expensive proprietary printed circuit boards. No highly trained technician needed, typically a voltmeter and a screwdriver is all that is needed to make most repairs!
All Flagship Chillers have a low voltage control module with clearly labeled LEDs advising the end user specifically what has tripped the chiller, be it high or low refrigerant pressure, freeze control protection as well as low chilled water flow.
DUAL SAFETY SWITCHES IN PARALLEL ELIMINATE NUISANCE CALLS & DOWNTIME.
Flagship Marine chillers have dual high and dual low refrigerant pressure switches which eliminate nuisance calls and out of service episodes from a faulty switch. Both switches must agree there is indeed high or low pressure to shut down the compressor.
Our 14 gauge, 316 Series stainless steel, one-piece, precision laser cut, TIG welded chassis provides superior support for all the chiller components.
All Flagship Marine condensers are hand-crafted from start to finish at our Stuart factory location to our exacting specifications.
What sets Flagship Marine apart from our competition is our belief in the KISS principle (Keep It Simple, Stupid). This has guided our component selection and design emphasis for many years. We brag that even a child can follow our schematics!
Look at this single compressor chiller electric box. All the components are “over the counter” at a fraction of typical costs in our industry. The most expensive item here is less than $53.00!
Flagship Marine’s sea water manifolds are 90/10 CuNi schedule 80 pipe, which is MUCH more durable (about 10x thicker!) than our competitors’ tubing. These, in combination with the socolets, meet mil spec requirements and will FAR outlast all others. No sinking or water damage hazard from ruptured hoses or paper thin manifolds at 3AM!
We manufacture a variety of different sized chilled water holding/storage tanks. Shown are 40 and 80 gallon tanks in 14 gauge stainless steel.
Must be on the low pressure return line, and be sure the pump sucks from the bottom of the tank so eliminating air bubbles is easy. You DON’T want the pump to suck a bubble and cavitate!
A small expansion tank open to atmospheric pressure should be placed at a high point.
The holding tank can be at any opportune location, typically in the bilge or engine room immediately before the pump, and is flooded – the expansion tank is plumbed to the top of the holding tank.
Flagship Marine Units NEVER Have Condenser Failures!
The heart of every marine air conditioner is the condenser—the heat sink to the ocean and the only component the corrosive sea water touches is the inside of the inside tube. Failure of this tube is catastrophic for the entire system. Even extremely corrosive places like the very high salinity of the Red Sea are no problem for Flagship Marine condensers because we use an unusually thick walled 90/10 CuNi (copper nickel) tube with particular annealment, hardness and other characteristics.
We don’t dramatically shorten our condensers to save money by enhancing this tub: knurling or rifling for example. Our tube is “slick walled” with no thin spots that fester these failures.
Paper thin condenser tubes dissipate heat very quickly so the condenser tube can be short and inexpensive. We don’t cut corners by doing so. We have full length condensers! The shorter the condenser, the cheaper it is and the shorter it will last!
Flagship Marine has always prioritized durability and quality over cost savings and we NEVER cut corners. We also don’t skimp on our brazing material—ALL refrigerant lines are brazed with a 15% silver alloy, not the 5% typical of other manufacturers.
As a result, Flagship Marine is very proud to have had almost ZERO condenser failures in the last two decades.
Flagship Marine takes no shortcuts with quality and design!
All condenser tube to manifold connections are made with precision machined 90/10 CuNi (Copper Nickel) socolets that are TIG welded to the schedule 80 90/10 CuNi nipple with a monel alloy and brazed to the condenser tubes to ensure many years of trouble free service.
This configuration meets all MilSpec and ABYC requirements. Naked connections aren’t nearly as durable and fail to meet those standards.
For your convenience all manifolds are fitted with reducing couplers and a 3/4″ drain plugs for winterizing.
EXPANSION VALVES VS. CAPILLARY TUBES
All Flagship Marine equipment incorporates expansion valves which adjust the modulation of the refrigerant to match the conditions of sea water, humidity and ambient temperature. This maximizes performance by preventing excessive or inadequate refrigerant head pressures, resulting in more cooling and extended component life!
This is why all new HVAC equipment must now use expansion valves instead of the capillary tubes you may still have in your home air conditioner. We don’t “cut corners” – these cost us about $75-175 each vs a $3.00 cap tube, and on the larger units we use “balanced port” rather than the standard expansion valves which automatically adjust to the amount of refrigerant flowing rather than being a fixed flow and out of balance.
Capillary tubes cannot adjust the refrigerant modulation which is fixed by the physical length of the tube. Like a broken clock that is right only twice a day, capillary tubes either over-modulate or under-modulate the refrigerant as the sea water temperatures vary. As an extreme example, if you are in upper Mississippi when the water is 40° and the air is 95° the modulation will be excessive and the head pressure much too low. Expansion valves adjust the modulation according to the conditions.
The optional heat can be one of our legendary incoloy clad electric elements in the fan coil (shown), an in line oil fired boiler, an electric element in the chiller, or reverse cycle.
We prefer the electric elements in the fan coils because the entire system is shut down when in the heating season – the only moving part is the blower motor when heat is called for. We have had tens of thousands of these elements in service for many years – they are extremely safe and basically indestructible.
Considering a Mini Split System?
This fairly new innovation has one variable speed condensing unit supplying refrigerant to up to eight small remote evaporators. This can result in a very significant savings to the end user in certain situations, such as a home, by cooling only the rooms that are occupied.
In a marine application it’s not typical for air conditioned areas to not be occupied, so these savings are not realized in the marine industry. However, the many detriments of these systems remain and they can be acute in a marine application. It’s no wonder why no marine HVAC manufacturer makes mini split systems. If you do decide to install a residential system on your vessel, you should expect to be replacing the outdoor components quite frequently! Due to the adverse marine environment you might get a couple years out of the condensing unit!
In operation when one of the remote evaporators calls for cooling, the slave board in the remote evaporator sends a signal to the mother board in the condensing unit. This triggers the compressor to ramp up and open the solenoid going to that evaporator to provide refrigerant thus cooling the room.
Every remote evaporator requires its own refrigerant lines connecting it to the condenser. On a typical vessel you will have hundreds of feet of refrigerant lines, half of which are cold return lines that must be insulated. Each evaporator requires separate piping and wiring of the power cable, the refrigerant tubing, the suction tubing, and a condensate drain between itself and the condensing unit. Now imagine all of this buried behind panels, deck heads and cabinetry. This is reminiscent of the split systems of the past which have fallen out of favor in the marine industry over the years because of the ongoing maintenance and down time due to relentless refrigerant leaks caused by rotted copper lines and leaking brazed joints that are so hard to locate.
Imagine the difficulty a technician will have trying to sniff out a leak that could be anywhere along these hundreds of feet of refrigerant lines. At least every 50′ (the length of a roll of copper tubing) you have a brazed joint, and these lines are buried in the structure of the moving/flexing vessel. With a SINGLE leak the ENTIRE system is down!
As proven time and time again there is “no free lunch” with thermodynamics, so the tonnage is the same resulting in no weight or current savings. The only way to save weight is to use thin sheet metal and other inferior components. If the load is 12 tons you will need twelve tons of cooling regardless of the type of system – you will NOT be running a mini split system at 25% capacity at high noon with a hundred people on board! It will be 100%! A chiller system works the same way so at 10PM your Flagship Marine chiller might be running ten minutes/hour, so the total current consumption will be basically the same with any system.
The condensate is oftentimes problematic because it can be difficult finding a sensible means of running a condensate drain from every remote wet evaporator. Sometimes it’s easier to run dry ducting rather than install wet evaporators.
In conclusion, we believe a chiller system in these applications is much more desirable, and especially with Flagship Marine equipment you will have ZERO expensive/proprietary printed boards that can cost you a small fortune over the years. Mini splits are the MOST complicated/complex systems electronically. Printed circuit boards and naked copper tubing don’t do well on a moving, flexing vessel in a marine environment!
VARIABLE FREQUENCY DRIVES AND DIGITAL SCROLL COMPRESSORS?
If your vessel is wired single phase or you have marginally sized generators, or if you want to almost completely eliminate voltage fluctuation when compressors start, we can install Variable Frequency Drives (VFDs) in our equipment.
The VFD reduces the start up inrush and will greatly reduce any brown out, generator lag or flickering in your TV when the compressors start. The typical inrush (millisecond start up amperage) is about 5-7 times the running amps, however with a VFD the compressor frequency slowly ramps up to the 60 HZ speed so the inrush is typically about 1.3 times the running amps. You can also manually program in lower or higher frequencies as well to accomplish running on lower amps or more output at higher amps if you need to, but of course you will lose or gain proportional performance by doing so.
Flagship Marine strives to provide the most simple, trouble free and durable equipment available, and frequency drives are not in keeping with the KISS principal that guides our component selection and design, however there are applications that warrant these excellent products.
Approximate Specifications for Chiller Units - Water Cooled
|Month||BTUs of Cooling||Length in inches/mm||Width in inches/mm||Height in inches/mm||Amps (cool) 230v||Weight lbs/kg|