Company Business Zamil Air Conditioners was founded in 1974 as one of the first air conditioning business to be established

in Saudi Arabia and today is a leading international manufacturer of air conditioning systems and is No. 1 in the Middle East. Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55 countries in the Middle East, Europe, Africa and Asia. The companys operations are structured into four Strategic Business Units (SBUs) supporting five in-house product and service brands as well as a number of international brands under the OEM sales. The five in-house brands are Classic, Cooline, CoolCare, Clima Tech and Geoclima. The four SBUs are: 1. Consumer Business Unit supporting Classic, Cooline, GE and OEM brands for consumers. 2. Unitary & Applied Business Unit supporting Classic, Cooline, GE and OEM brands for commercial and industrial customers. 3. Zamil CoolCare providing engineering & project management services, HVAC maintenance, retrofit services and parts. 4. Geoclima srl is an independent business supporting other SBUs for their requirement of Chillers & Double skin AHUs. The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare Service direct their business operations from the corporate headquarters at Dammam, Saudi Arabia. Geoclima has its engineering & production departments located at Monfalcone, Italy and has a design center in Austria. All the four SBUs, while operating independently, supplement each others activities in a way that makes synergy work at its best and achieve the corporate goals of maximizing customer satisfaction. Factories and Productions Zamil Air Conditioners has two manufacturing plants in Dammam, Saudi Arabia and has one speciality production facility in Italy operated by Geoclima. The company can produce up to 550,000 Room Air Conditioners, 300,000 Mini-Split systems and 50,000 Central Air Conditioning systems per year. Quality & Product The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification. Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization) Certificate for Room Air Conditioners. ZAC's products are also certified with: 1. CE (Council of European Community) 2. UL (Underwriters Laboratory) 3. Eurovent (for Fan Coil units and Air handling units, see www.eurovent-certification.com) 4. DEMKO 5. ETL Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammed bin Fahd Al Saud Award for Factory Safety. Our Products In addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufacturers a host of residential, commercial and industrial air conditioners. This broad range extends from the Concealed Units up to 5 tons, the Ducted Splits up to 30 tons, the Packaged Units up to 90 tons, the Single and Double Skin Air Handling Units up to 70,630 CFM and the Water Chillers up to 660 tons cooling capacity.

INDEX
Contents Page

Model decoding ........................................................................................................................................ 2 Introduction ............................................................................................................................................... 3 Unit features, standard specifications & options .................................................................................... 4-7 Physical data ....................................................................................................................................... 8-10 Selection procedure .......................................................................................................................... 11-12 Ethylene glycol solution capacity correction ........................................................................................... 13 Performance data .............................................................................................................................. 14-19 Electrical data .................................................................................................................................... 20-21 Water side cooler pressure drop ............................................................................................................ 22 Water side condenser pressure drop ...................................................................................................... 23 Unit dimensions ................................................................................................................................ 24-26 Typical schematic wiring diagram ...................................................................................................... 27-28 Microprocessor controller ....................................................................................................................... 29 Application guidelines ........................................................................................................................ 30-38 Rigging instructions ................................................................................................................................ 39 Installation clearance .............................................................................................................................. 40 Mounting location ................................................................................................................................... 41 Load distribution ..................................................................................................................................... 42

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

INTRODUCTION
Zamil water cooled screw chillers (ASW series) offer the optimum performance and highest efficiency possible for the Gulfs harsh environment and abnormal operating conditions. The ASW series chillers were designed to provide central cooling for commercial and industrial applications with the highest reliability and least operating cost combination by the use of high efficiency dual screw compressors in combination with a water cooled condenser for every refrigeration circuit. Water cooled screw chillers offer the best cooling system solution for environments with high ambient temperatures and high humidity by using water as a cooling medium for the condenser. Water extracts heat from the refrigerant in a much better way than air, therefore it reliefs the compressor, hence lengthens the compressors life. Water cooled chillers also have a larger capacity compared to air cooled chillers and are much smaller in size. ASW series chillers are delivered in complete package, all the chiller components are installed on a rigid steel frame in a compact design, making the chiller suitable for indoor installation inside service rooms with the least space requirement. The compact design makes the chiller fit through standard doors with out the need of any disassembly, which makes the chiller easy to handle and install. ASW series chillers utilize the environmentally friendly R-134a refrigerant with the least minimum refrigerant pipe lengths and connections to assure no refrigerant leak.
PRESS. TRANS. (LP)

PRESS. TRANS. (HP)

SCREW COMPRESSOR

WATER COOLED CONDENSER

WATER OUT WATER IN

WATER IN

WATER OUT

ELECTRONIC EXPANSION VALVE DX EVAPORATOR

LIQUID SHUT-OFF VALVE

LIQUID SOLENOID VALVE

LIQUID SIGHT GLASS

LIQUID FILTER DRIER

Figure showing the ASW chiller components and its connections

FEATURES
These ASW water cooled screw chillers offer the ultimate combination of energy saving design, superior engineering features and flexibility of application as required by todays market.

These chillers incorporate the newest advanced microprocessor controller. This controller monitors analog and digital inputs to achieve precise control & protective functions of the water cooled chiller units. This microprocessor controller is complete with all the hardware and software necessary to control the chiller unit and insures its efficiency and reliability. Designed to conform to ARI standard 550/590 water chilling packages using the vapor compression cycle. Designed to conform to ANSI/ASHRAE 15-1994 Safety code for Mechanical Refrigeration. Compact unit design and excellent serviceability. All packaged chillers incorporate compact water coolers and condensers with enhanced inner grooved copper tubes bundled into a "U" shaped and expanded into a steel tubular sheet which offer efficient water flow as well as heat transfer design resulting in optimal unit performance. High Energy Efficiency Ratio (EER) semi-hermetic compact twin screw compressors provided in these units. Single point power connection to minimize job site installation cost and time. Completely wired control panel with the advanced microprocessor controller provides all the necessary operating and safety controls. Compressors are with part winding start.

* * * * * * * *

STANDARD SPECIFICATIONS
CAPACITY CONTROL
A. Standard settings: These chillers are equipped with stepless capacity control system as standard for very accurate response to load requirements and best part load efficiency. Each compressor is equipped with a slider controller that enables to modulate capacity between 25% to 100%, thus giving a broad range to control total chiller capacity between 10% to 100% on an average. This system has following advantages: 1. Infinite capacity modulation allows the compressor capacity to exactly match the cooling load. 2. Reduce compressor cycling that leads to better operational reliability. 3. Reduce operating cost. B. Optional settings: The ASW packaged chillers incorporate stepped load shedding as required by some energy management systems. Modulation of capacity in response to system load requirements is affected by a microprocessor controller which monitors the leaving water temperature. Capacity control is achieved by cycling compressor ON/OFF and slider capacity pre-set control valve. The use of slider control valve provides excellent part load capacities. On multiple compressor units, capacity is controlled by a combination of slider capacity control valve and compressor staging.

SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORS

All compressors are compact semi-hermetic twin screw of the high capacity and efficiency due to its perfect profile form ratio 5:6. Simple and robust construction with slider control valve for capacity unloading, suction/discharge shut-off valves, check valve in discharge gas outlet, oil sight glass, oil fill/drain service valve, directly flanged-on three stage oil separator with long-life fine filter 10 microns mesh size, robust axial bearings in tandem configuration, suction gas filter, internal pressure relief valve and manual lock-out electronic protection system for thermal motor winding temperature, phase reversal, discharge gas temperature protection controls.

CONTROL PANEL
The control panel design is equivalent to NEMA 4 (IP55) with hinged door for easy access ensuring dust and weatherproof construction. Internal power and control wiring is neatly routed, adequately anchored and all wires identified with cable markers as per NEC standards applicable to HVAC industry. The electrical controls used in the control panel are UL approved which are reliable in operation at high ambient conditions for a long period.

EVAPORATOR (COOLER)
Direct Expansion shell and tube evaporators are used in ASW series chillers to give high capacity, easy and quick installation and enable for easy maintenance operations. The shell is made of rigid steel with large water inlet and outlet to handle large water flow rate and capacity. The tubes are made of copper to provide the quickest response to load fluctuation. The evaporators have a new design that ensures a high level of mechanical strength and resistance to vibration, the design is made of U-shaped copper coils inside the shell, sufficient space is provided between the copper coils and the shell to allow for expansion of the tubes. This design also allows for easy cleaning of the evaporator, were the tubes can be removed easily. The evaporators are specially designed for R-134a applications. Their new design requires a smaller refrigerant charge and results in a lower pressure drop.

SHELL & TUBE HEAT EXCHANGER (COOLER)

STD ASME (option)

WATER SIDE
DESIGN PRESSURE, (BAR/PSIG) 16/235 10/147 TEST PRESSURE, (BAR/PSIG) 22.8/335 11.3/165

REFRIGERANT SIDE
DESIGN PRESSURE, (BAR/PSIG) 29/426 15.5/228 TEST PRESSURE, (BAR/PSIG) 41.5/610 23.3/342

CONDENSER
Every refrigeration circuit has a separate water cooled condenser. The condenser is a shell and tube type with a rigid external structure made of steel and copper tubes and baffles in the inside to provide the best performance and response to load fluctuation. The condenser can be connected to a cooling tower or to an air cooled liquid cooler. As the evaporator shell and tube, the condenser shell and tube has a similar design with the same features. It should be noted that only treated water is suitable for the water cooled condenser to prevent corrosion, scaling and biological fouling, which will significantly affect the total system efficiency. It might be necessary to install a fixed continuous chemical treatment system to control certain properties of the cooling water used. When using a cooling tower, a makeup water tank must be used to supply the cooling water loop with make up water lost during cooling tower operation. Please contact the nearest Zamil representative for more information on water properties for the condenser loop.

MICROPROCESSOR CONTROLLER
The microprocessor controller works on the state of art microprocessor technology. This controller monitors analog and digital inputs to achieve precise control & safety functions of the unit. The Software works on the Proportional Integral Derivative (PID) algorithm for precise control logic. The simple to use push button keyboard allows accessing to the operating conditions, control set points & alarm history that are clearly displayed on a multi-line back illuminated LCD panel. An easy to install serial port/modem option allows remote monitoring of the operating parameters. With corresponding windows software, the system allows data to be viewed in tabular or graphic format as well as interact with system set up. This chiller controller is compatible with the Building Management System (BMS) BACNET/MODBUS protocols through corresponding optional gateway interfaces. It is also compatible with GSM protocol through GSM optional gateway that sends up to 3 mobile phone SMS messages whenever alarm take place, indicating the type of alarm, the corresponding compressor, the related chiller and which location. The microprocessor consists of the following hardware: 1. User Interface Board: Provided with simple to use push button keyboard and menu driven software to access operating conditions, control set points & alarm history that are clearly displayed on the LCD panel. 2. Main Board: This controls up to two (2) compressor system. 3. Auxiliary Boards: Required for controlling an additional two (2) or more compressors. 4. Remote Monitoring System [Optional]: The micro controller is complete with all hardware and software necessary to remotely monitor and control the chiller unit. Display Information: In the normal operating mode the 20 x 4 characters LCD panel display the system status, the temperature of the water inlet & outlet, the set point, run time of the compressor & the alarm history. Easily accessible measurements for each circuit include the following:

Suction and discharge temperatures Suction, discharge and oil pressures Water inlet/outlet temperatures Compressor status Fan status Liquid line solenoid status

Unit/Compressor run time The control temperature is continuously displayed on the 3 Digit 7 segments LED Display. The 3 LED lights indicate the Power ON, Menu adjustment and Fault. System Protection: The following system protection is provided to ensure system reliability:

compressor winding overheating Low suction pressure & temperature High discharge pressure & temperature Freeze protection Low oil pressure & high oil temperature Sensor error Time delay Anti recycle time for compressor Serial communication error

STANDARD CONTROL & SAFETY DEVICES

MICROPROCESSOR CONTROLLER: This controller monitors analog and digital inputs to achieve precise control & safety functions of the unit. COMPRESSOR IN-BUILT PROTECTION DEVICE: Protect the compressor by monitoring: A) Motor winding temperature in case of overload. B) Discharge gas temperature in case of overheating. C) Phase reversal for direction of rotation. STARTERS: The starter is operated by the control circuit and provides power to the compressor motors. These devices are rated to handle safely both RLA and LRA of motors. CRANKCASE HEATERS: Each compressor has immersion type crankcase heater. The compressor crankcase heater is always on when the compressors are de-energized. This protect the system against refrigerant migration, oil dilution and potential compressor failure. HIGH PRESSURE SWITCH: This switch provides an additional safety protection in the case of excessive discharge pressure.

STANDARD ACCESSORIES
UNIT ON-OFF SWITCH: ON-OFF switch is provided for manually switching the unit control circuit. INDICATOR LIGHTS: LED lights indicates power ON to the units, MENU adjustment and FAULT indications due to trip on safety devices. ELECTRONIC EXPANSION VALVE: Electronic expansion valve is used to regulate the refrigerant flow to the water cooler and maintain a constant superheat and load optimization. FILTER DRIER (REPLACEABLE CORE TYPE): Refrigerant circuits are kept free of harmful moisture, sludge, acids and oil contaminating particles by the filter drier. SIGHT GLASS: A moisture indicating sight glass installed in the liquid line. An easy-to-read color indicator shows moisture contents and provides a mean for checking the system refrigerant charge. LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from accumulating in the water cooler during the off cycle. UNDER VOLTAGE AND PHASE PROTECTION: Protects against low incoming voltage as well as single phasing, phase reversal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it can be set up for manual reset. COMPRESSOR CIRCUIT BREAKERS: Protects against compressor branch circuit fault. When tripped (manually or automatically), the breaker opens the power supply to the compressor and control circuit through auxiliary contacts.

OPTIONS
(All options are at extra cost. Please check with your nearest dealer/sales office) HOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50% of its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor on and off, ensuring narrow temperature swing and lengthen the life span of the compressor. WATER FLOW SWITCH: Paddle type field adjustable flow switch for water cooler & condenser circuits. Interlock into unit safety circuits so that the unit will remain off until water flow is determine. UNIT MOUNT SPRING ISOLATORS: This housed spring assemblies have a neoprene friction pad on the bottom to prevent vibration transmission. LIQUID COOLERS: ASME code stamped liquid cooler. PRESSURE GAUGES: Suction & discharge pressures gauges. NON-FUSED MAIN DISCONNECT SWITCHES: De-energize power supply during servicing/repair works as well as with door interlock. COMPRESSOR ENCLOSURE BOX: Reduce compressor operating noise and keep the compressor clean. FLANGED COOLER CONNECTION: Easy on-site piping connections. COOLER HEATER WRAPPED: Prevent freezing up of water on low ambient temperature. CONDENSER: ASME code stamped water condenser. CHILLER GUARD: Protect various parts of chiller from vandalism. SEA WATER COOLED CONDENSER: To be used with sea water as a cooling fluid. BMS: BACNET, MODBUS, GSM and remote monitoring. POWER LINE ANALYZER: Perform motor current limitation. Protect against high motor current & over/under voltage.
7

PHYSICAL DATA
UNIT SIZE ASW060B ASW070B ASW080B ASW095B ASW105B ASW115B ASW135B ASW150B ASW160B

COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 380V-3Ph-60Hz 460V-3Ph-60Hz NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters CAPACITY CONTROL (STEPLESS) % MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION TOTAL CRANKCASE HEATER WATTS REFRIGERANT EXPANSION VALVE DEVICE CONTROL VOLTAGE 200 200 300 300
800-754-01 800-754-05 800-754-02 800-754-06 800-754-03 800-754-07 800-683-19 800-683-22 800-754-09 800-754-13 800-754-05 800-683-19 800-683-19 800-683-20 800-683-23 800-754-10 800-754-14 800-754-06 800-683-20 800-683-20 800-683-21 800-683-24 800-754-11 800-754-15 800-754-07 800-683-21 800-683-21

1 15

1 15

1 22 100-50

1 22

1 19

1 19

2 15

2 22 100-25

2 22

ELECTRONIC INJECTION 300 R-134a ELECTRONIC EXPANSION VALVE 220V-1Ph-60Hz 300 200 300 300

CONDENSER
PART NUMBER NUMBER OF CONDENSERS TOTAL WATER VOLUME PER CONDENSERS, Liters WATER CONNECTION (DN)
800-895-01 800-895-02 800-895-02 800-895-03 800-895-04 800-895-05 800-895-01 800-895-02 800-895-02

1 28 DN80

1 33.2 DN80

1 33.2 DN80

1 38.3 DN80

1 41.8 DN80

1 51 DN100

2 28 DN80

2 33.2 DN80

2 33.2 DN80

COOLER
PART NUMBER (QUANTITY) TOTAL WATER HOLDING VOLUME, Liters WATER CONNECTION (DN)
800-896-01 (1) 800-896-02 (1) 800-896-02 (1) 800-896-04 (1) 800-896-06 (1) 800-896-06 (1) 800-896-08 (1) 800-896-08 (1) 800-896-09 (1)

53 DN80

101 DN100

101 DN100

80.2 DN100

137 DN125

137 DN125

128 DN125

128 DN125

131 DN125

ECONOMIZER
PART NUMBER (QUANTITY) EXPANSION DEVICE PART NUMBER (QUANTITY) N.A. N.A.
800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1)

N.A. N.A.

N.A. N.A.

800-516-99 (2) 800-181-77 (2)

GENERAL
NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER COMP., kg SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) OPERATING/SHIPPING WEIGHTS, kg NOTES: 1 30 1 35 1 40 1 47.5
67/63.5/58.3

1 52.5

1 57.5

2 33.75

2 37.5

2 40
70/66.5/61.3

61.2/57.7/52.5 61.2/57.7/52.6 67/63.5/58.3

65.7/62.2/57 66.1/62.6/57.4 64.2/60.7/55.5 70/66.5/61.3

1578/1525 1761/1660 2126/2025 2179/2090 2350/2213 2471/2334 3090/2962 3860/3732 3939/3808

1. All compressors with slider control valve unloading. 2. All compressors operate at 3500 RPM @ 60Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : 2dBA.

PHYSICAL DATA
UNIT SIZE ASW185B ASW210B ASW230B ASW245B ASW280B ASW300B ASW315B ASW345B ASW355B

COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 380V-3Ph-60Hz 460V-3Ph-60Hz NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters CAPACITY CONTROL (STEPLESS) % MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION TOTAL CRANKCASE HEATER WATTS REFRIGERANT EXPANSION VALVE DEVICE CONTROL VOLTAGE 300 300 300 300
800-683-22 800-754-09 800-683-23 800-754-10 800-683-24 800-754-11 800-754-13 800-683-19 800-683-22 800-754-09 800-754-09 800-754-13 800-683-22 800-754-14 800-683-20 800-683-23 800-754-10 800-754-10 800-754-14 800-683-23 800-754-15 800-683-21 800-683-24 800-754-11 800-754-11 800-754-15 800-683-24

2 22

2 19 100-25

2 19

3 22

3 22

3 19 100-16

3 19

3 19

4 22 100-12

ELECTRONIC INJECTION 300 R-134a ELECTRONIC EXPANSION VALVE 220V-1Ph-60Hz 300 300 300 300

CONDENSER
PART NUMBER NUMBER OF CONDENSERS TOTAL WATER VOLUME PER CONDENSERS, Liters WATER CONNECTION (DN)
800-895-03 800-895-04 800-895-05 800-895-02 800-895-03 800-895-04 800-895-04 800-895-05 800-895-03

2 38.3 DN80

2 41.8 DN80

2 51 DN100

3 33.2 DN80

3 38.3 DN80

3 41.8 DN80

3 41.8 DN80

3 51 DN100

4 38.3 DN80

COOLER
PART NUMBER (QUANTITY) TOTAL WATER HOLDING VOLUME, Liters WATER CONNECTION (DN)
800-896-10 (1) 800-896-13 (1) 800-896-13 (1) 800-896-16 (1) 800-896-17 (1) 800-896-18 (1) 800-896-18 (1) 800-896-20 (1) 800-896-21 (1)

263 DN150

229 DN150

229 DN150

285 DN200

325 DN200

353 DN200

353 DN200

401 DN200

401 DN200

ECONOMIZER
PART NUMBER (QUANTITY) EXPANSION DEVICE PART NUMBER (QUANTITY)
800-516-99 (2) 800-516-99 (2) 800-516-99 (2) 800-516-99 (3) 800-516-99 (3) 800-181-77 (2) 800-181-77 (2) 800-181-77 (2) 800-181-77 (3) 800-181-77 (3)

N.A. N.A.

800-516-99 (3) 800-516-99 (3) 800-181-77 (3) 800-181-77 (3)

N.A. N.A.

GENERAL
NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER COMP., kg SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) OPERATING/SHIPPING WEIGHTS, kg NOTES: 2 46.25 2 52.5 2 57.5 3 40.8 3 46.67 3 50 3 58.5 3 57.5 4 44.38

70/66.5/61.3 68.7/65.2/60 69.1/65.6/60.4 71.8/68.3/63.1 71.8/68.3/63.1 70.5/67/61.8

70.5/67/61.8 70.9/67.4/62.2 73/69.5/64.3

4290/4027 4361/4132 4601/4372 6029/5744 6242/5917 6472/6119 6479/6125 6952/6551 7922/7521

1. All compressors with slider control valve unloading. 2. All compressors operate at 3500 RPM @ 60Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : 2dBA.

PHYSICAL DATA
UNIT SIZE ASW370B ASW395B ASW420B ASW445B ASW465B

COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 380V-3Ph-60Hz 460V-3Ph-60Hz NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters CAPACITY CONTROL (STEPLESS) % MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION TOTAL CRANKCASE HEATER WATTS REFRIGERANT EXPANSION VALVE DEVICE CONTROL VOLTAGE 300 300 800-683-22 800-683-23 800-683-24 4 22 800-754-09 800-754-10 800-754-11 4 19 800-754-09 800-754-10 800-754-11 4 19 100-12 ELECTRONIC INJECTION 300 R-134a ELECTRONIC EXPANSION VALVE 220V-1Ph-60Hz 300 300 800-754-13 800-754-14 800-754-15 4 19 800-754-13 800-754-14 800-754-15 4 19

CONDENSER
PART NUMBER NUMBER OF CONDENSERS TOTAL WATER VOLUME PER CONDENSERS, Liters WATER CONNECTION (DN) 800-895-03 4 38.3 DN80 800-895-04 4 41.8 DN80 800-895-04 4 41.8 DN80 800-895-05 4 51 DN100 800-895-05 4 51 DN100

COOLER
PART NUMBER (QUANTITY) TOTAL WATER HOLDING VOLUME, Liters WATER CONNECTION (DN) 800-896-23 (1) 487 DN200 800-896-23 (1) 487 DN200 800-896-24 (1) 574 DN200 800-896-24 (1) 574 DN200 800-896-24 (1) 574 DN200

ECONOMIZER
PART NUMBER (QUANTITY) EXPANSION DEVICE PART NUMBER (QUANTITY) 800-516-99 (4) 800-181-77 (4) N.A. N.A. 800-516-99 (4) 800-181-77 (4) N.A. N.A. 800-516-99 (4) 800-181-77 (4)

GENERAL
NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER COMP., kg SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) OPERATING/SHIPPING WEIGHTS, kg NOTES: 4 46.25 73/69.5/64.3 8415/7928 4 49.4 71.7/68.2/63 8443/7956 4 52.5 71.7/68.2/63 8782/8208 4 55.6 72.1/68.6/63.4 9308/8734 4 58 72.1/68.6/63.4 9320/8746

1. All compressors with slider control valve unloading. 2. All compressors operate at 3500 RPM @ 60Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : 2dBA.

10

SELECTION PROCEDURE (English units)

DESIGN REQUIREMENTS The following design requirements must be known to select a package chiller. 1. Required cooling capacity in tons 2. Leaving chilled water temperature in 0F (LCHWT) 3. Chilled water flow rate in GPM 4. Chilled water cooling range in 0F (water in temp. _ water out temp.) 5. Design condenser leaving water temperature in 0F 6. Condenser water temperature range in 0F (water out temp. _ water in temp.) 7. Electrical power supply SAMPLE SELECTION Select a Water Packaged chiller for the following conditions: Required system capacity is 110 tons at 540F entering chilled water and 440F leaving water. Design condenser leaving water temperature is 950F. Water cooler fouling factor is 0.00010. Power supply: 380V-3Ph-60Hz.
POWER ARI EVAPORATOR FOULING CAPACITY CORRECTION INPUT STANDARDS 2 0 FACTOR (HR-FT - F/BTU) FACTOR FACTOR
0.00010 0.00025 0.00050 0.00075 0.00100 1.000 0.992 0.978 0.965 0.951 1.000 0.997 0.990 0.984 0.978 ARI-550/590-98 ARI-590-86 ARI-590-81

TABLE - 1

STEP-1: UNIT SELECTION Entering the capacity performance data at given LCHWT and ambient temperature. ASW115B chiller unit will produce 113.89 tons and 94.3 kW compressor power input at 440F leaving chilled water temperature & 950F condenser leaving water temperature with 100F water temperature difference. For the conditions required, the unit actual cooling capacity when corrected for the fouling factor (1.0). Capacity = 113.89 x 1.0 = 113.89 Tons, which then exceeds the requirements. So the selection is correct. STEP-2: CHILLED WATER & CONDENSER WATER FLOW (GPM): Water GPM = Required capacity (Tons) x 24 = 110 x 24
0

+0.6 +0.4 +0.2 0 -0.2 -0.4 5 10 15 20

CHILLED WATER TEMPERATURE RISE (0F)

Cooling Range, T 10 F (Required capacity, Tons + total power input/3.516) x 24 (110 + 94.3/3.516) x 24 Total condenser GPM = = = 328 GPM. Cooling Range, T 100F Total condenser GPM 328 Water flow per condenser GPM = = = 328 GPM. No. of condensers 1 Referring to pressure drop chart (page # 22 & 23), pressure drop for cooler at 264 GPM = 22 ft. of water for selected model and pressure drop for condenser at 168 GPM = 12 ft. of water for selected model. STEP-3: ELECTRICAL Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ASW115B is to be sized at a minimum circuit ampacity (MCA) of 206 Amps and the main branch protection device is to be sized at a maximum over current protection (MOCP) of 371 Amps. STEP-4: CHILLED WATER & CONDENSER WATER PUMP SELECTION For chilled water & condenser water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCHWT CORRECTION Refer to table-2: Add correction factor to design leaving chilled water temperature (LCHWT) when chilled water temperature range is above 100F and subtract correction from design leaving chilled water temperature (LCHWT) when water temperature range is below 100F. EXAMPLE: If LCHWT rise is 12.50F, enter correction curve at 12.50F and read the correction factor of 0.2. The corrected LCHWT is 44+0.2 = 44.20F. NOTE: 1. When the chilled water temperature rise is less than 50F, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2.Please refer to water pressure drop curves.
11

= 264 GPM

TABLE - 2

SELECTION PROCEDURE (Metric units)

DESIGN REQUIREMENTS The following design requirements must be known to select a package chiller. 1. Required cooling capacity in kilowatt (kW) 2. Leaving chilled water temperature in 0C (LCHWT) 3. Chilled water flow rate in LPS 4. Chilled water cooling range in 0C (water in temp. _ water out temp.) 5. Design condenser leaving water temperature in 0C 6. Condenser water temperature range in 0C (water out temp. _ water in temp.) 7. Electrical power supply SAMPLE SELECTION Select a Water Packaged chiller for the following conditions: Required system capacity is 386 kW at 120C entering chilled water and 60C leaving water. Design condenser leaving water temperature is 350C. Water cooler fouling factor is 0.0000176. Power supply: 380V-3Ph-60Hz.
POWER ARI EVAPORATOR FOULING CAPACITY CORRECTION INPUT STANDARDS FACTOR (M2-0C/W) FACTOR FACTOR
0.000018 0.000044 0.000088 0.000132 0.000176 1.000 0.992 0.978 0.965 0.951 1.000 0.997 0.990 0.984 0.978 ARI-550/590-98 ARI-590-86 ARI-590-81

TABLE - 1

STEP-1: UNIT SELECTION Entering the capacity performance data at given LCHWT and ambient temperature. ASW115B chiller unit will produce 385.67 kW and 94.9 kW compressor power input at 60C leaving chilled water temperature & 350C condenser leaving water temperature with 60C water temperature difference. For the conditions required, the unit actual cooling capacity when corrected for the fouling factor (1.0). Capacity = 385.67 x 1.0 = 385.67 kW, which is very close to the required capacity. So the selection is correct. STEP-2: CHILLED WATER & CONDENSER WATER FLOW (GPM): Water LPS = Required capacity kW) x 0.239 = 386 x 0.239

+0.33 +0.22 +0.11 0 -0.11 -0.22

10

CHILLED WATER TEMPERATURE RISE (0C)

TABLE - 2 = 15.4 LPS Cooling Range, T 60C (Required capacity, kW + total power input) x 0.239 (386 + 94.9) x 0.239 Total condenser LPS = = = 19.16 LPS. Cooling Range, T 60C Total condenser LPS 19.16 Water flow per condenser LPS = = = 19.16 LPS. No. of condensers 1 Referring to pressure drop chart (page 22 & 23), pressure drop for cooler at 15.4 LPS = 65.77 kPa for selected model and pressure drop for condenser at 19.16 LPS = 35.85 kPa for selected model. STEP-3: ELECTRICAL Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ASW115B is to be sized at a minimum circuit ampacity (MCA) of 206 Amps and the main branch protection device is to be sized at a maximum over current protection (MOCP) of 371 Amps. STEP-4: CHILLED WATER & CONDENSER WATER PUMP SELECTION For chilled water & condenser water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCHWT CORRECTION Refer to table-2: Add correction factor to design leaving chilled water temperature (LCHWT) when chilled water temperature range is above 60C and subtract correction from design leaving chilled water temperature (LCHWT) when water temperature range is below 60C. EXAMPLE: If LCHWT rise is 7.40C, enter correction curve at 7.40C and read the correction factor of 0.11. The corrected LCHWT is 60C+0.11 = 6.110C. NOTE: 1. When the chilled water temperature rise is less than 30C, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2.Please refer to water pressure drop curves.
12

ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (Antifreeze)

When operating in areas with temperatures below 320F (00C), cooler protection in the form of Ethylene glycol solution (brine solution) is required to protect cooler from low ambient freeze-up. This brine solution must be added to water loop to bring down the freezing point with a difference of 150F (80C) below minimum operating ambient temperature. Ethylene glycol solution causes a variation in unit performance. To obtain the effective performance, it is necessary to multiply the water performance data by correction factors corresponding to the ambient temperature or Ethylene glycol percentage indicated in the following table.

ETHYLENE GLYCOL % BY WEIGHT

0%
00C (320F)

12%
-50C (23 0F)

22%
-10 0C (14 0F)

30%
-150C (5 0F)

36%
-200C (-40F)

41%

46%

50%

Freezing point of Ethylene glycol solution

-25 0C (-130F) -300C (-220F) -350C (-310F)

Ambient temperature

8.30C (47 0F) 3.30C (38 0F) -1.7 0C (29 0F) -6.70C (20 0F) -11.70C (11 0F) -16.70C (20F) -21.70C (-70F) -26.70C (-16 0F)

Cooling capacity correction factor

1.0

0.985

0.980

0.974

0.970

0.965

0.964

0.960

Water flow correction factor

1.0

1.02

1.04

1.075

1.11

1.14

1.17

1.20

Pressure drop correction factor

1.0

1.07

1.11

1.18

1.22

1.24

1.27

1.30

EXAMPLE: English system- Determine Ethylene glycol percentage by weight and correction factors at 380F ambient temperature. From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 380F ambient temperature is 12% by weight. Find the correction factors corresponding to 380F ambient temperature from the table. Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is 1.07. Apply these correction factors for corrected system performance values. TONS (E.G. SOLUTION) = Tons (water) x Cooling capacity correction factor. BRINE (E.G. SOLUTION) FLOW (GPM) = Flow (water) x Flow correction factor. BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (Ft.) x Pressure drop correction factor. EXAMPLE: Metric system- Determine Ethylene glycol percentage by weight and correction factors where 3.30C ambient temperature. From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 3.30C ambient temperature is 12% by weight. Find the correction factors corresponding to 3.30C ambient temperature from the table. Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is 1.07. Apply these correction factors for corrected system performance values. KW (E.G. SOLUTION) = KW (water) x Cooling capacity correction factor. BRINE (E.G. SOLUTION) FLOW (L/S) = KW (water) x Flow correction factor. BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (kPa) x Pressure drop correction factor. Note: Correction factors apply to published chilled water performance rating from 400F to 500F (4.40C to 100C) LCHWT.

13

14

15

16

17

18

19

ELECTRICAL DATA
UNIT SIZE SUPPLY VOLTAGE Nominal (V-Ph-Hz) 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 ASW160B 380-3-60 460-3-60 208/230-3-60 ASW185B 380-3-60 460-3-60 208/230-3-60 ASW210B 380-3-60 460-3-60 208/230-3-60 ASW230B 380-3-60 460-3-60 LEGEND: MCA MOCP RLA LRA CB MTA FLA FCA kW - Minimum Circuit Ampacity per NEC 430-24 - Maximum Over Current Protection - Rated Load Amps - Locked Rotor Amps - Circuit Breaker - Must Trip Amps - Full Load Amps - Fan Circuit Amps - Kilo Watt Min. 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 Max. 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 COMPRESSOR CRANKCASE HEATERS Volts 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 Total Watts 200 200 200 200 200 200 300 300 300 300 300 300 300 300 300 300 300 300 400 400 400 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 Total Amps 0.87 0.87 0.87 0.87 0.87 0.87 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.74 1.74 1.74 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 2.61 RLA LRA CB CB MCA MOCP Qty. (each) (each) Poles MTA Qty. 191 343 1 152.6 732 3 122 2 118 212 1 94.2 442 3 75 2 95 172 1 76.3 350 3 61 2 212 128 106 254 153 127 284 172 142 306 186 153 341 206 170 369 223 185 435 263 217 457 276 228 511 309 256 551 334 276 614 371 307 381 230 190 457 276 228 511 309 256 551 334 276 614 371 307 533 323 267 628 380 314 660 399 330 738 447 369 796 483 399 887 536 443 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 169.2 102.4 84.6 885 534 423 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 135 82 68 162 98 81 182 110 91 196 119 98 218 132 109 131 79 66 155 94 77 162 98 81 182 110 91 196 119 98 218 132 109 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 COMPRESSOR WINDING START PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING

ASW060B

ASW070B

ASW080B

ASW095B

203.0 1224 122.7 742 101.4 612 227.0 1330 137.5 807 113.6 665 245 1224 148.5 742 122.7 612 273 1330 165 136.3 164.1 807 665 885

ASW105B

ASW115B

ASW135B

99.3 534 82.1 423 193.2 1224 116.9 742 96.6 612 203.0 1224 122.7 101.4 137.5 113.6 148.5 122.7 165.0 136.3 742 612 807 665 742 612 807 665

ASW150B

227.0 1,330

245.0 1224

273.0 1330

NOTES: 1. Customer to specify the exact nominal power supply available at site so that electrical components are selected accurately; failing to do so will affect unit performance & terms of warranty. 2. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker. 3. The maximum incoming wire size is 500 MCM. On units having MCA greater than 500 MCM wire, the factory supplied power terminal block will accept two or more parallel field wires per pole phase. 4. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection. 5. All field wiring must be in accordance with NEC and local standards. 6. Minimum and maximum unit supply voltages are shown in the tabulated data above. 7. The 10% voltage variation from the nominal is allowed for a short time only, not permanent. 8. Neutral line required on 380V-3Ph-60Hz power supply only.

20

ELECTRICAL DATA
UNIT SIZE SUPPLY VOLTAGE Nominal (V-Ph-Hz) 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 ASW420B 380-3-60 460-3-60 208/230-3-60 ASW445B 380-3-60 460-3-60 208/230-3-60 ASW465B 380-3-60 460-3-60 LEGEND: MCA MOCP RLA LRA CB MTA FLA FCA kW NOTES: 1. Customer to specify the exact nominal power supply available at site so that electrical components are selected accurately; failing to do so will affect unit performance & terms of warranty. 2. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker. 3. The maximum incoming wire size is 500 MCM. On units having MCA greater than 500 MCM wire, the factory supplied power terminal block will accept two or more parallel field wires per pole phase. 4. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection. 5. All field wiring must be in accordance with NEC and local standards. 6. Minimum and maximum unit supply voltages are shown in the tabulated data above. 7. The 10% voltage variation from the nominal is allowed for a short time only, not permanent. 8. Neutral line required on 380V-3Ph-60Hz power supply only. - Minimum Circuit Ampacity per NEC 430-24 - Maximum Over Current Protection - Rated Load Amps - Locked Rotor Amps - Circuit Breaker - Must Trip Amps - Full Load Amps - Fan Circuit Amps - Kilo Watt Min. 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 Max. 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 MCA 660 399 330 738 447 369 761 461 381 796 483 399 887 536 444 935 567 468 965 584 483 995 603 498 1041 631 521 1126 682 563 1160 701 579 COMPRESSOR RLA LRA CB CB MOCP Qty. (each) (each) Poles MTA Qty. 863 3 203.0 1224 3 162 6 521 3 122.7 742 3 98 6 431 3 101.4 612 3 81 6 965 584 483 995 603 498 1041 631 521 1160 701 580 1155 700 578 1192 722 596 1229 745 615 1286 780 644 1391 842 696 1433 866 716 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 227.0 1330 137.5 807 113.6 665 234.0 141.9 117.2 245.0 148.5 122.7 273.0 165.0 136.5 220.0 133.3 110.1 1224 742 612 1224 742 612 1330 807 665 1330 807 665 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 182 110 91 187 114 94 196 119 98 218 132 109 176 107 88 182 110 91 187 114 94 196 119 98 212 128 106 218 132 109 6 6 6 6 6 6 6 6 6 6 6 6 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 CRANKCASE HEATERS Volts 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 Total Watts 900 900 900 900 900 900 900 900 900 900 900 900 900 900 900 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 Total Amps 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 3.91 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 5.22 COMPRESSOR WINDING START PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING PART WINDING

ASW245B

ASW280B

ASW300B

ASW315B

ASW345B

ASW355B

ASW370B

227.0 1330 137.5 807 113.6 665 234.0 1224 141.9 742 117.2 612 245.0 1224 148.5 742 122.7 160.4 132.5 165.0 136.3 612 807 665 807 665 265.0 1330

ASW395B

273.0 1330

21

WATER SIDE COOLER PRESSURE DROP

2 7

12

10

20

30

40

50

60

70

80

90 100

200

300

400

500

600 700 800 900 1000 1200

1500

FLOW RATE - GPM

MODEL No.
ASW060 ASW070 & 080 ASW095 ASW105 & 115 ASW135 & 150 ASW160 ASW185 ASW210 & 230

CURVE No.
1 2 3 4 5 6 7 8

MODEL No.
ASW245 ASW280 ASW300 & 315 ASW345 ASW355 ASW370 & 395 ASW420, 445 & 465

CURVE No.
9 10 11 12 13 14 15

CONVERSION FACTOR: GPM = 0.063 Liters per second. Feet of water = 2.989 Kilo Pascal (kpa). NOTE: If an application requires certain water flow rate outside these limits, please check with your nearest dealer/sales office.

22

WATER SIDE CONDENSER PRESSURE DROP

2

10

20

30

40

50

60

70

80 90 100

200

300

400

500

600 700 800 900 1000 1200

1500

FLOW RATE - GPM

MODEL No.
ASW060 & 135 ASW070, 080, 150, 160 & 245 ASW095, 185, 280, 355 & 370 ASW105, 210, 300, 315, 395 & 420 ASW115, 230, 345, 445 & 465

CURVE No.
1 2 3 4 5

CONVERSION FACTOR: GPM = 0.063 Liters per second. Feet of water = 2.989 Kilo Pascal (kpa). NOTE: If an application requires certain water flow rate outside these limits, please check with your nearest dealer/sales office.

23

DIMENSIONS
ASW060B

ASW070B, ASW080B, ASW095B, ASW105B & ASW115B

DIMENSIONS
MODEL ASW105B ASW115B A B D 4" 5" 5" D1 3-1/8" 3-1/8" 4" ASW070B, 080B & 095B 2230 377 2150 410 2150 410

NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED.

24 24

DIMENSIONS
ASW135B, ASW150B, ASW160B, ASW185B, ASW210B & ASW230B
DIMENSIONS
MODEL ASW135B & 150B ASW160B ASW185B & 210B ASW230B A 2150 2400 2600 2600 B 417 417 457 457 D 5" 5" 6" 6" D1 3-1/8" 3-1/8" 3-1/8" 4"

ASW245B, ASW280B, ASW300B, ASW315B & ASW345B

DIMENSIONS
MODEL ASW245B ASW280B ASW300B & 315B ASW345B A 2400 2800 2400 2800 B 483 483 508 508 D1 3-1/8" 3-1/8" 3-1/8" 4"

NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED.

25

26

TYPICAL SCHEMATIC WIRING DIAGRAM

CONTROL PANEL

NTB

TO HVTB L1 ATB 1B F1 3.5A

TO NTB N ATB 2 CCA1-1 CCA2-1 3A 3B 1HTR 2HTR T1 SSPS1 T2 CCA3-1 1J 1K D1 T1 SSPS2 T2 D1 COMP1 OILHTR COMP2 OILHTR COMP1 SSPS COMP2 SSPS SEE ALSO COMP UNLOADER TIMER DETAILS

CONTROL VOLTAGE 230VAC

S1( CONTROL POWER) 1A UVR (SEE UVM CONNECTION) SERIAL CABLE 1

CCA4-1

SSPS1

8A CB1A-1

HPS1

22A CB3A-1 JP2A OLR1-1 10A 11A

23A
EEV

OLR3-1

2A 5A

X9

SSPS2

8B CB2A-1

EEVB JUMPER & DIP SWITCH TD1 CLOSED TU1 CLOSED TL1 OPEN JU1 OPEN

HPS2

22B CB4A-1 23B JP3A 10B OLR2-1 11B OLR4-1 10 1 1 CWP* 2G 2H 11

9B

2B 5B

FLS1

12A

CC1 LLS1

COMP1 CONTACTOR LIQUID LINE SOLENOID1 ECONOMIZER SOLENOID 1 POWER DECREASE CP1

14A 12B

UL2-1 CC2 LLS2

14B

UL2-2

COMP2 CONTACTOR LIQUID LINE SOLENOID2 ECONOMIZER SOLENOID 2 POWER DECREASE CP2 HGBS/UNIT STATUS/COOLER HTR

6A 16

ALARM - NO CONTACT ALARM - NC CONTACT

POWER LINE ANALYZER INTERFACE (SEE OPTION BOX) COM3 C REMOTE MONITORING INTERFACE (SEE OPTION BOX) COM2 17C 20B 15A 15B 22A T1S SUCTION TEMP SENSOR COMP1 24A T2S TOUT/LWT TEMP. SENSOR 22B T3S SUCTION TEMP SENSOR COMP2 26A T4S TIN/RWT TEMP. SENSOR 30B 31B 27A 28B 29B 23B 25A 30A 31A 23A 28A 29A 20A

L.I1 LIQUID INJECTION 1

L.I2 LIQUID INJECTION 2 UL4-1 UL4-2 POWER INCREASE CP1 POWER INCREASE CP2

SPT1 - COMP1 SUCTION PRESSURE TRANSDUCER

DPT1 - COMP1 DISCHARGE PRESSURE TRANSDUCER

JUMPER SETUP ON MAIN BOARD TL2 TD2 TU2 JU11 JU13 JU15 JU5 JU6 JU7 JU8 JU9 JU4 JU3 JU19 JU12 JU10 OPEN CLOSED CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED 1-2 CLOSED

SPT2 - COMP2 SUCTION PRESSURE TRANSDUCER

DPT2 - COMP2 DISCHARGE PRESSURE TRANSDUCER

NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.

27

TYPICAL SCHEMATIC WIRING DIAGRAM

LEGEND
NAME 1. L.V.WATER 3. PUMP DOWN 4. LOW PRESSURE 5. HIGH PRESSURE 6. FREEZE OPEN LWT F 0 PSIG 15 PSIG CLOSE
AR ATB CB CBA COM COMP CC CCA CWP CCH CCAT CT ECO EEVB EFR ETB FLS FM FMC F G GFP HPS HGBS HVTB JP LI LPS LWT MB NTB OLR PT P PSIG PWS R SLE S1 SEC TRANS TS TDS VFC UL UVM UVR ----* A../D.. C/1C 1O AC/DC R.. T1 SH X52/X53 EXEN JU/TU/TD/TL AUXILIARY RELAY AUXILIARY TERMINAL BLOCK CIRCUIT BREAKER MAGNETIC CIRCUIT BREAKER AUXILIARY CONTACT COMMUNICATION COMPRESSOR COMPRESSOR CONTACTOR COMPRESSOR CONTACTOR AUXILIARY CHILLED WATER PUMP CRANKCASE HEATER TIMER AUXILIARY CONTACT CURRENT TRANSFORMER ECONOMIZER SOLENOID VALVE ELECTRONIC EXPANSION VALVE BOARD EARTH FAULT RELAY EARTH TERMINAL BLOCK FLOW SWITCH FAN MOTOR FAN MOTOR CONTACTOR FUSE GROUND GROUND FAULT PROTECTION HIGH PRESSURE SWITCH HOT GAS BYPASS SOLENOID HIGH VOLTAGE TERMINAL BLOCK JUMPER LIQUID INJECTION LOW PRESSURE SWITCH LEAVING WATER TEMPERATURE MASTER BOARD NEUTRAL TERMINAL BLOCK OVER LOAD RELAY PRESSURE TRANSDUCER PROPORTIONAL BAND POUNDS PER SQUARE INCH PART WINDING START CONTROLLER BUILT-IN RELAY EQUALIZER SOLENOID VALVE CONTROL SWITCH SECOND (TIME) TRANSFORMER PTC SENSOR/TEMPERATURE SENSOR TIME DELAY SWITCH VOLT FREE CONTACT UNLOADER SOLENOID UNDER VOLTAGE MONITOR UNDER VOLTAGE RELAY TERMINAL BLOCK FIELD WIRING FIELD SUPPLY LEGEND ON MASTER/SLAVE BOARD DIGITAL INPUT 1 COMMON DIGITAL OUT 1 DIGITAL COMMON SOLID STATE RELAY CONTACTS THERMISTOR 1 SHIELD SERIAL COMMUNICATION PORT EXTERNAL ENABLE BOARD JUMPERS

270 PSIG 39 F

MODEL

OLR SETTING

NAME HPS (ADJUSTABLE) L1 L2 L3 1A UVM

CLOSE 270 PSIG

OPEN 300 PSIG

1 ATB 2 ATB

UVR

NOTE: TERMINAL A,B,& C ON UVM TO PHASE MATCHED WITH UNIT CONTROLS.

COMP 70A/B 71A/B GFP SET POINT 5 AMPS @1.0 SEC 1 2

COMPRESSOR 1 1O(MB) 12A CC1 2

1 1

FOR TDS OPTION SEE CONN.BELOW CC3 CC1A-2 61A CC1A-2 TDS1-1SEC 61A 62A CC3

2 2

Current Transformer (CT) wire number, 70A/71A for Comp 1 and 70B/71B for Comp 2. 32 31 1 Comp 1 EFR1 Comp 2 1 32 31 EFR2

T1T2 A1 A2 EARTH FAULT RELAY 32 31 34

65A A3/D3 (MB) REMOVE JP2A 65B A8/D8 (MB) REMOVE JP3A

COMPRESSOR 2 4O(MB) 12B CC2 2 FOR TDS OPTION SEE CONN.BELOW CC4 CC2A-2 61B 2 CC2A-2 TDS2-1SEC 61B 62B CC4 2 MB 100B 7C R7 7O 101B SET THE CONTROLLER PARAMETER # M171 = 4 SEE ALSO NOTE#7 VFC FROM CUSTOMER PANEL VFC 2G 1 ATB ATB USE N/O CONTACT TO RUN THE UNIT.

1 1

1
TIMER 11 CCAT11-1 3A TIMER 21 CCAT21-1 3B

MB 7C R7 7O

15

HGBS 2

SEE ALSO NOTE#7

4AA AR11 3AA 4BB AR21 3BB UL3-2 UL3-1

AR11

ATB 2 UL3-1

AR21 UL3-2

MB HEATER 7C R7 7O 15

SEE ALSO NOTE#7 SET POINT: 36 deg F

NOTES
1. FUSES TO BE DUAL ELEMENT TYPE. 2. USE COPPER CONDUCTORS ONLY. 3. ALL FIELD WIRING TO COMPLY WITH LOCAL CODES. 4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH RATING AS RECOMMENDED BY MANUFACTURER.

EXTERNAL DEVICE HEATER HTR1 t 1B

2 SET POINT = 36 degF

5. POW ER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP. IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM.

TO MB (20) TO MB (50)

13A

ECO1

2 ECONOMIZER 1 2 ECONOMIZER 2 TO GATEWAY

13B ECO2

GND + IS485

TO MAIN BOARD (COM2)

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE. 6. FOR OIL LEVEL FAULT, PLEASE ALSO CONSIDER THE GFP (GR OUND FAULT PROTEC TION) IF AVAILABLE. 7. THE AUXILIARY RELAY 7O/7C AT MB CAN USE ONLY ONE FU NCTION AT A TIME FROM THE FOLLOWING OPTION: HGBP, COOLER HEATER & UNIT STATUS. 8. MARK IN THE BOX FOUND AT THE UPPER RIGHT OF THE RESPECTIVE OPTIONAL ITEM, IF THE OPTIONAL ITEM IS INCLUDED IN THE UNIT.

28

MICROPROCESSOR CONTROLLER
Sequence of Operation
The following describes the sequence of operation for a two screw compressor chiller unit. Operation is similar for a one or four compressor unit. For initial start-up, the following conditions must be met: All power supplied to the unit shall be energized for 12 hours. Control power switch on for at least 5 minutes. All safety conditions satisfied. Press ESC on the microcomputer keypad. Chilled water pump running and chilled water flow switch contact closed. Customer interlock contact closed, if any. Condenser water pump running and condenser water flow switch contact closed.

STAGE - ON SEQUENCE
Staging ON & OFF sequence, shall be accomplished by the Leaving water temperature control selection. Stage #1: If the Leaving Water Temperature is greater than the Stage 1- ON water temperature set point value, the Compressor #1 liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloaded capacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.

Stage #2: If the Leaving Water Temperature is greater than the Stage 2- ON water temperature set point value, the Compressor #2 liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloaded capacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.

STAGE - OFF SEQUENCE

During the staging OFF, the first-in last-out sequence is adopted, if equalization of compressor timing is not selected. Else the more used is switched off. As the applied load decreases and when the leaving water temperature falls below the stage 2 -OFF water temperature set point value, stage 2 is turned off. If the leaving water temperature falls below the stage 1-OFF water temperature set point value, the stage 1 is turned off.

29

APPLICATION GUIDELINES
INTRODUCTION
These guidelines should be considered when designing systems and their installation utilizing Zamil ASW series liquid chillers. Stable operation, performance and reliability of units is often dependent upon proper compliance with these recommendations. When any application varies from these guidelines, it should be referred with Zamil Air Conditioners for specific recommendations.

UNIT SELECTION/SIZING
Unit selection procedure and capacities are provided in this catalog for proper selection. The Zamil electronic selection program may also be utilized for this purpose. Over sizing chillers beyond a maximum limit of 5 10 % in order to assure adequate capacity or considering future expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operation and excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operate more efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized unit is usually more costly to purchase, install and operate. When over sizing is desired due to anticipation of future plant expansion, consider using multiple units. For example, install a single chiller for the present load requirement and install a second chiller for the foreseen additional load demand due to expansion. Further, it is also recommended that installing two chillers instead of a single chiller be considered in applications where partial load operation at low capacities is necessary. Operation of two chillers at higher loading is preferred to operating a single chiller at or near its minimum possible capacity.

FOULING FACTOR AND WATER REQUIREMENT

The tabulated performance data provided in this catalog are based on a fouling factor of 0.00010 hr-ft2-0F/Btu (0.000018 m2-0C/W) for the cooler and 0.000244 hr-ft2-0F/Btu (0.004392 m2-0C/W) for the condenser. As the fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other fouling factors, apply appropriate correction factor from the table provided in this catalog. These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water may result in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading to possible equipment damage. The more scale forming material and suspended solids in the system water, the greater the chances of scale and deposit formation and fouling. These include calcium, magnesium, biological growth (algae, fungi and bacteria), dirt, silt, clays, organic contaminants (oils), silica, etc. which should be kept to the minimum to retard scale and deposit formation. In order to prevent corrosion and pitting, the pH value of the water flowing through the cooler must be kept between 7 and 8.5. Zamil recommends that a water treatment specialist is consulted to provide and maintain water treatment, this is particularly critical with glycol systems.

WATER FLOW RATES AND COOLER PRESSURE DROP

The maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog. The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminar flow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessive pressure drop and severe tube erosion. During unit operation, water flow rate must not vary more than 5% from the design flow rate. The water flow switch should be calibrated accordingly. The piping and pumping layout should be right for the application and must assure proper water return and circulation. When using glycol solution, flow rate and pressure drop are higher than with water, therefore care must be taken not to exceed the limits. In such applications, consult Zamil Air Conditioners for specific recommendations.
30

COOLER/CONDENSER FLUID TEMPERATURES RANGE

Unit can start and pull down from 950F (350C) entering fluid temperature. The design leaving chilled fluid temperature (LCHWT) range as mentioned earlier in the tabulated performance data is 40 to 500F. The design entering chilled fluid temperature range is 50 to 600F. The design cooler temperature drop ( T) range is 5 to 150F. The tabulated performance data provided in this catalog is based on a chilled water temperature drop and a condenser water temperature rise of 100F. Units may be operated at any desired temperature drop within the range of 5 to 150F as long as the temperature and flow limits are not violated and appropriate correction factors are applied on the capacity and power input. The Zamil electronic selection program can be very handy in selecting equipment at different temperature drops. It should be noted that temperature drop/rise outside the aforesaid range is not permitted as it is beyond the optimum range of control and could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the equipment.

FLOW RATES AND/OR WATER TEMPERATURES OUT OF RANGE

Certain applications (particularly process cooling jobs) call for flow rates and/or water temperatures that are outside the above mentioned limits/range. Our chillers can be utilized for these applications by selecting the chiller based on the specific process load and making a suitable piping and mixing arrangement in order to bring the flow rates and/or water temperatures relevant to the chiller within acceptable limits. Example 1: An application requires 240 GPM of water at 450F and the return water temperature is 650F. A standard chiller can be used for this application as shown in the following basic schematic layout (single mixing arrangement).
45F 500 GPM 45F 240 GPM

200 TR Chiller

CHILLER

45F 260 GPM

Load 200 TR

54.6F 500 GPM

Example 2: An application requires 192 GPM of water at 650F and the return water temperature is 800F. A standard chiller can be used for this application as shown in the following basic schematic layout (dual mixing arrangement).
45F 340 GPM 45F 82.2 GPM 65F 192 GPM

65F 240 GPM

120 TR Chiller

CHILLER

45F 257.8 GPM

80F 109.8 GPM

Load 120 TR

53.4F 340 GPM

53.4F 340 GPM

80F 82.2 GPM

80F 192 GPM

31

COOLER FREEZE PROTECTION

If the unit is located in an area where ambient temperatures fall below 320F (00C), cooler protection in the form of Ethylene Glycol Solution is required to protect the cooler and fluid piping from low ambient freeze-up. This glycol solution must be added to the water system loop to bring down the freezing point of water to a difference of 150F (8.30C) below minimum operating ambient temperature. Using this glycol solution causes a variation in unit performance, flow rate and pressure drop, therefore appropriate correction factors from the aforementioned table in this catalog should be applied.

MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATION

A multiple chiller system has two or more chillers connected by parallel or series piping to a common distribution system. Multiple chiller arrangements offer the advantage of operational flexibility, standby capacity and less disruptive maintenance. Also, they offer some standby capacity if repair work must be done on a chiller from a set of duty chillers. Starting in-rush current is reduced, as well as power costs at partial-load conditions. A multiple chiller arrangement should be provided if the system load is greater than a single chiller capacity, standby capability is desired, large temperature drop (greater than 150F) is desired or application calls for splitting the total capacity for better part load operation. In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced water flow. It is mandatory that cooler flow rates must be balanced to ensure proper flow to each chiller based on its respective capacity. As mentioned above, two basic multiple chiller systems are used: parallel and series chilled water flow. In the parallel arrangement, liquid to be chilled is divided among the liquid chillers; the multiple chilled streams are combined again in a common line after chilling. Water temperatures (EWT or LWT) can be used to cycle units On and Off based on the cooling demand. Parallel arrangements permit adding chillers in the future for plant expansion with the appropriate considerations beforehand. In the series arrangement, the chilled liquid pressure drop may be higher unless coolers with fewer liquid-side passes or baffles are used. No over chilling by either unit is required, and compressor power consumption is lower than it is for the parallel arrangement at partial loads. It is also possible to achieve higher overall entering to leaving temperature drops, which may in turn provide the opportunity for lower chilled water design temperature, lower design flow and resulting installation and operational cost savings. Series chiller arrangements can be controlled in several ways based on the water temperatures depending on cooling demand. A valved piping bypass is suggested around each chiller to facilitate future servicing as it gives the personnel an option for service without a complete shutdown. Zamil recommends the parallel arrangement for design temperature drops ( T) up to 150F and the series arrangement beyond that i.e., 16 to 200F. Complete design details on these parallel and series chilled water flow arrangements can be found in the ASHRAE handbooks and other design literature which should be referred by the designer in preparing his detailed designs.

PIPING ARRANGEMENTS AND PLANT LAYOUT

Our chillers are suitable for incorporating in Two Pipe single temperature systems or Four Pipe independent load systems. The system piping circuit (load distribution circuit) should be basically parallel piping either Direct Return or Reverse Return system with a good pumping arrangement. The method of circuiting and pumping is a judgment decision by the designer. The designer must weigh the pros and cons of cost, nature of load and configuration of building, energy economics, flexibility, installation requirements and others to determine the best arrangement for his project. In all cases, it must be ensured that the design water flow is constantly maintained through the chillers at all stages of operation. Some suggested arrangements with basic schematic layouts are as follows:

32

A. Single or multiple chillers with constant water flow through chillers and load system:

CHWS

CHILLER

Load

Load

3-Way Valve

3-Way Valve

CHWR
Constant Speed Pump

In this type of arrangement, constant water flow through the chillers and load distribution piping circuit is maintained. Before proceeding further, a brief explanation on the operation of a typical chilled water system / valves which is fundamental to the design or analysis of a system. Where multiple zones of control are required, the various load devices are controlled first; then the source (chillers) system capacity is controlled to follow the capacity requirement of the loads. Control valves are commonly used to control loads. These valves control the capacity of each load by varying the amount of water flow through the load device. Control valves for these applications are two-way (straight-through) and three-way valves. The effect of either valve is to vary the amount of water flowing through the load device. With a two-way valve, as the valve strokes from full-open to fullclosed, the quantity of water flowing through the load gradually decreases from design flow to no flow. The three-way mixing valve has the same effect on the load as the two way valve - as the load reduces, the quantity of water flowing through the load decreases in proportion to the load and the difference amount is directed through a bypass. In terms of load control, a two-way valve and a three-way valve perform identical functionsthey both vary the flow through the load as the load changes. The fundamental difference between the two-way valve and the three-way valve is that as the source or distribution system sees the load, the two-way valve provides a variable flow load response and the three-way valve provides a constant flow load response. Referring to the foregoing schematic layout, this is a conventional system and is not as energy efficient as the two-way valve systems especially on the pumping side due to constant water circulation in the system. On multiple chiller installations, pumps are required to operate continuously and the sequencing of chillers is dependent on water temperatures.

33

B. Single or multiple chillers with constant water flow through chillers and variable water flow through load system:
FM-1

CHWS

Bypass Line

CHILLER

CHILLER

CHILLER

Bypass Control Valve

Load

Load

2-Way Valve

2-Way Valve

Variable Speed Pump

CHWR System Controller

In this type of arrangement, constant water flow through the chillers is maintained, however the quantity of water flowing through the load distribution piping system decreases in proportion to the load and the difference amount is directed through a bypass pipe that connects the supply and return headers. Brief sequence of operation is as follows: The bypass with its control valve and flow meter provides the design flow required through the chillers. Flow meter FM1 measures the actual flow to the chilled water system. The system flow is compared with the required flow for the chillers. The difference is made up through the bypass and is monitored by flow meter FM2. This flow meter controls the bypass valve to maintain the desired flow in the bypass based on the set points in the system controller (the valve is positioned by sum of flow meters FM1 and FM2). The speed of the chiller pumps is controlled by the differential pressure sensor/transmitter, maintaining the desired differential pressure ( P) across the cooling coils, their control valves and the branch piping. The pump speed is modulated within a certain range in order to reduce the pumping head and not to alter the water flow rate (the duty flow rate of the pumps remains constant). Each chiller-pump combination operates independently from the remaining chillers and each pump is shutdown when the respective chiller is stopped. Instead of using water temperature as an indicator of demand, the sequencing of chillers is dependent on water flow. The chillers are rated in gallons per minute; the actual flow to the system determines the number of chillers that should be in operation. Energy is saved because the system head is reduced appreciably when there are light cooling loads on the system and due to cycling of pumps. Note: Some designers may consider installing constant speed pumps and utilize pressure relief bypass control valves controlled by a differential pressure sensor/controller to maintain a fixed differential pressure between the supply and return mains of the chilled water system in order to accommodate for the required chiller flow and to achieve some form of variable volume system. This method is not recommended as its a wasteful practice because a considerable amount of energy is lost, an almost constant volume system results and the pumping energy remains substantially that required at full system flow and head. Also, the problem with this system is improper control of the bypass valve which does not guarantee proper flow through the chillers and high differential pressures in the control valves on the cooling coils when the system friction subsides at low loads which can cause lifting of the valve stems or wire cutting of the valve seats. Further, as all the water must be pumped at a head equal to or greater than the design head, the pump or pumps are forced to run up the pump head capacity curve, which increases the overpressure on the system and also increases the wear on the pumps, since they are forced to operate with high radial thrusts.
34

C. Single or multiple chillers with constant water flow through chillers and variable water flow through load system (primary/secondary pumping arrangement):
A CHWS

Variable Speed Secondary Pump

CHILLER

CHILLER

CHILLER

Load Flow Sensor

Load

2-Way Valve

2-Way Valve

Constant Speed Primary Pump

CHWR

System Controller

This system is called a Primary Secondary System and in this arrangement, the generation zone is separated from the transportation or distribution zone. In this type of arrangement also, constant water flow through the chillers is maintained, however the quantity of water flowing through the load distribution pump/piping system decreases in proportion to the load and the difference amount is directed through a bypass pipe that connects the supply and return headers. This bypass pipe forms a Hydraulic Coupling between the points A B and is also called as Common Bridge or Decoupling Line. The sequence of operation is similar as the foregoing system with the following explanation: The speed of the secondary chiller pump is controlled by the differential pressure sensor/transmitter, maintaining the desired differential pressure ( P) across the cooling coils, their control valves and the branch piping. This pump speed is modulated within a broad range in order to reduce the pumping head and alter the water flow rate based on the changing load conditions. The primary pumps are constant speed pumps and the design flow rate through the chillers remains constant. Each chillerpump combination operates independently from the remaining chillers and each pump is shutdown when the respective chiller is stopped. The sequencing of chillers is dependent on water flow. If greater flow is demanded than that supplied by the chillerpumps, return water is forced through the bypass into the supply header. This flow indicates a need for additional chiller capacity and another chiller-pump starts. Excess bypass flow with reference to the set points in the system controller in the opposite direction i.e., into the return header indicates overcapacity and the chiller-pumps are turned off. Energy is saved because the system head and water flow rate are reduced on the Secondary Pump when there are partial cooling loads on the system and due to cycling of Primary Pumps.

COOLER PIPING CONNECTIONS

The following pertinent guidelines are served to ensure satisfactory operation of the units. Failure to follow these recommendations may cause improper operation and loss of performance, damage to the unit and difficulty in servicing and maintenance:

Water piping must be connected correctly to the unit i.e., water must enter from the inlet connection on the cooler and
leave from the outlet connection.

A flow switch must be installed in the field piping at the outlet of the cooler (in horizontal piping) and wired back to the unit control
panel using shielded cable. There should be a straight run of piping of at least five pipe diameters on either side of the flow switch.

The chilled water pump(s) installed in the piping system should discharge directly into the unit cooler. The pump(s) may
be controlled external to the unit - but an interlock must be wired to the unit control panel (as shown in the wiring diagram) so that the unit can start only upon proof of pump operation.

Flexible connections suitably selected for the fluid and pressure involved should be provided as mandatory in order to
minimize transmission of vibrations to the piping / building as some movement of the unit can be expected during normal operation. The piping and fittings must be separately supported to prevent any loading on the cooler.

35

 The cooler must be protected by a strainer, preferably of 20 mesh, fitted as close as possible to the liquid inlet connection, and provided with a means of local isolation.

Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler.
Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if any variations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstream from any connection (flange etc.) but as near to the cooler as possible.

Drain and air vent connections should be provided at all low and high points in the piping system to permit complete
drainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for use in all lines to facilitate servicing.

The system water piping must be flushed thoroughly before connecting to the unit cooler. The cooler must not be
exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance to isolate the cooler without disrupting flow to other units.

CONDENSER PIPING CONNECTION

The same points should be followed for the condenser piping as the cooler piping, plus the following:

A make-up water tank should be provided in the condenser loop to supply make-up water to the condenser when using
an open type cooling tower.

A water treatment and cleaning system should be connected to the condenser loop to treat and clean the water when
using an open type cooling tower. The following is a suggested water piping arrangement for the condenser and the cooler at the chiller for single unit installations. For multiple chiller installations, each unit should be piped as shown:

OUT IN

Isolating Valve - Normally Open Isolating Valve - Normally Closed Balancing Valve Flow meter Strainer

Pressure tapping Flow Switch Connection (flanged / Victaulic) Pipe work Flexible connection

36

CHILLED FLUID VOLUME REQUIREMENT

The volume of water in a piping system loop is critical to the smooth and proper operation of a chilled water system. If sufficient volume of water is not there in the system, the temperature control can be lost resulting in erratic system operation and excessive compressor cycling. Therefore, to prevent this effect of a Short Water Loop ensure that total volume of water in the piping system loop equals or exceeds 3 Gallons per Nominal Ton of cooling capacity for standard air conditioning applications and 6 Gallons per Nominal Ton of cooling capacity for process cooling jobs where accuracy is vital and applications requiring operation at very low ambient temperatures and low loading conditions. For example, chiller model ASW105B operating with a design water flow rate of 239 GPM for a standard air conditioning application would require 102.8 (Nom. Cap.) x 3 = 308.4 Gallons of water in the piping system loop. To achieve the aforementioned water volume requirements, it may be necessary to install a tank in the piping system loop to increase the volume of water in the system and therefore, reduce the rate of change of return water temperature. This tank should be provided on the return water side to the chiller and the tank should be baffled to ensure that there is no stratification and the entering stream thoroughly mixes with the tank water. See recommended tank design schematics below:

TANK SCHEMATIC

SUGGESTIONS ON SYSTEM DESIGN AND PIPING PRACTICES

The prospective chilled water system should be designed to the specific requirements of the owner and to achieve the most efficient system possible. Following are some recommendations:

The first decision a designer of a chilled water system must make is the selection of the temperature differential.
Temperature differential is the difference between the supply water and the return water temperatures. There is no one temperature difference for all chilled water systems. The actual temperature difference that is selected for a specific installation is determined by the cost of the cooling coils for various temperature differences and the effect that higher differences may have on the operating cost of the chillers. A careful balance between energy savings and first cost should be made by the designer. These are the decisions that must be made by the designer for each application and only experienced designers should entertain water temperature differences in excess of 120F on chilled water systems. A number of conditions must be recognized before making the final selection of temperature differential: a) An increase in temperature differential decreases water flow and therefore saves pumping energy. b) An increase in temperature differential may increase the cost of cooling coils that must operate with a higher mean temperature difference. c) Higher temperature differentials increase the possibilities of loss of temperature difference in coils due to dirt on the air side and chemical deposits on the water side of them. d) Laminar flow on the water side due to lower velocities at low loads on a coil is always a concern of the water system designer. The possibility of laminar flow is greater with higher temperature differences. Laminar flow reduces the heat-transfer rate and should not occur in a coil at any point in its load range. Many systems operate inefficiently because of coils that were selected at too low a friction loss through them at design load; therefore, at reduced loads and flows, they operate with laminar flow.
37

 Control of Return Water Temperature: Return water temperature is one of the most important operating values for a
chilled water system. It tells the operator just how good a job the control system and coils are doing in converting energy from the chillers to the air or water systems that are cooling the building. This is such a basic criterion that it should be addressed early in the design of a chilled water system. The proper method of controlling return temperature is through the correct selection of control valves and cooling coils. In conclusion, one of the designers most important tasks is the selection of a sound temperature differential that will provide maximum possible system efficiency. The second step in this process is to ensure that the differential is maintained after the system is commissioned.

The water system should be configured to distribute the water efficiently with a minimum use of energy-wasting
devices. These devices are listed here: a) Three-way temperature control valves b) Balancing valves, manual or automatic c) Pressure-reducing or pressure-regulating valves

The piping should be designed without

a) Reducing flanges or threaded reducing couplings b) Bullhead connections (e.g., two streams connected to the run connections of a tee with the discharge on the branch of the tee)

The friction for the piping should be calculated for all pipe runs, fittings and valves. Cooling coils should be selected with a high enough water velocity in the tubes to avoid laminar flow throughout the
normal load range imposed on the coils.

Coil control valves and their actuators should be sized to ensure that they can operate at all loads on the system
without lifting the valve head off the valve seat.

Expansion tank should be provided to so that water volume changes can be accommodated. Expansion tanks are
generally connected to the suction side of the pump - lowest pressure point.

Pumps in parallel must always operate at the same speed. There may be some exceptional cases where parallel
pumps are operated at different speeds, but only experienced designers should make evaluations for such a proposed operation. Also, it is better to use pumps of the same size when operating them in parallel. Variable speed pumps should be controlled so that pumps operating in parallel never have more than one percent difference in actual operating speed. Mixing of constant and variable speed pumps in parallel operation is wrong and leads to disastrous results.

Distribution pumps should be selected for maximum efficiency at the design condition and within the economic constraints of the project. Distribution pumps should be added and subtracted to avoid operation of pumps at points of high thrust and poor efficiency. Pump sequencing should achieve maximum possible system efficiency.

Differential pressure control (bypass) valves should never be installed at the pump discharges. Check valves should be provided in pump discharges when pumps are operating in parallel. Pump discharge check
valves should be center guided, spring loaded, disc type check valves and should be sized so that the check valve is full open at design flow rate. Generally this will require the check valve to be one pipe size smaller than the connecting piping.

Circuiting Chilled water to Multiple Chillers : There are fundamentals for the circuiting of chillers that should not be
violated in order to achieve maximum efficiency. Some of these are: a) Design the piping arrangement so that energy consumption of chillers is not increased. b) Arrange the piping so that all chillers receive the same return water temperature. c) Ensure that the required design water flow through the coolers is always maintained.

38

RIGGING INSTRUCTIONS
ATTENTION TO RIGGERS Hook rigging sling thru holes on the lifting plates, as shown below. Lifting plates or holes in base rail are centered around the unit center of gravity. Center of gravity is not unit center line. Ensure center of gravity aligns with the main lifting point before lifting. Use spreader bar when rigging, to prevent the slings from damaging the unit. CAUTION All panels should be in place when rigging. Care must be taken to avoid damage to the coils during handling. Insert packing material between coils & slings as necessary. MODELS: ASW060B - ASW115B
LIFT SPREADER BAR LIFT

PROPER CLEARANCE TO BE PROVIDED

MODELS: ASW135B - ASW465B

LIFT SPREADER BAR LIFT

PROPER CLEARANCE TO BE PROVIDED

39

INSTALLATION CLEARANCE
WALL

FIGURE - 1 STRAIGHT WALL

FIGURE - 2 CORNER WALL

NOTE: All dimensions are in mm.

40

MOUNTING LOCATION
MODEL: ASW060B

MODELS: ASW070B - ASW115B

MODELS: ASW135B - ASW230B

MODELS: ASW245B - ASW465B

NOTE: All dimensions are in mm. Tolerance: 2mm.

41

LOAD DISTRIBUTION, kg
MODEL No.
ASW060 ASW070 ASW080 ASW095 ASW105 ASW115 ASW135 ASW150 ASW160 ASW185 ASW210 ASW230 ASW245 ASW280 ASW300 ASW315 ASW345 ASW355 ASW370 ASW395 ASW420 ASW445 ASW465

R1
299 323 404 414 433 454 582 751 760 806 814 856 1133 1166 1192 1193 1269 1490 1546 1549 1588 1679 1682

R2
283 308 389 398 417 438 551 719 729 774 783 824 1094 1127 1152 1154 1229 1443 1499 1502 1541 1632 1634

R3
275 300 381 390 409 430 535 704 713 758 767 809 1074 1107 1133 1134 1210 1420 1475 1478 1517 1608 1611

R4
253 290 330 339 377 396 500 588 605 677 692 730 942 980 1031 1032 1114 1229 1338 1344 1418 1502 1504

R5
238 274 315 323 361 380 469 557 574 645 660 699 903 941 992 993 1075 1182 1290 1297 1371 1455 1456

R6
230 266 307 315 353 373 453 541 558 630 645 683 883 921 972 973 1055 1158 1267 1273 1347 1432 1433

MODELS: ASW060B - ASW115B

MODELS: ASW135B - ASW465B

42