asw series

Company BusinessZamil 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 company’s 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 AHU’s.

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 other’s activities in a way that makes synergy work at

its best and achieve the corporate goals of maximizing customer satisfaction.

Factories and ProductionsZamil 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 Arabia’s 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 ProductsIn 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 Con-

cealed 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

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

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

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INTRODUCTIONZamil water cooled screw chillers (ASW series) offer the optimum performance and highest efficiency possible for theGulfs harsh environment and abnormal operating conditions. The ASW series chillers were designed to provide centralcooling for commercial and industrial applications with the highest reliability and least operating cost combination by theuse of high efficiency dual screw compressors in combination with a water cooled condenser for every refrigerationcircuit.

Water cooled screw chillers offer the best cooling system solution for environments with high ambient temperatures andhigh humidity by using water as a cooling medium for the condenser. Water extracts heat from the refrigerant in a muchbetter way than air, therefore it reliefs the compressor, hence lengthens the compressors life. Water cooled chillers alsohave 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 acompact 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 thechiller easy to handle and install.

ASW series chillers utilize the environmentally friendly R-134a refrigerant with the least minimum refrigerant pipe lengthsand connections to assure no refrigerant leak.

WATER OUT

WATER IN

SCREW COMPRESSOR

WATER COOLED CONDENSER

DX EVAPORATOR

LIQUID SIGHT GLASSLIQUID SOLENOID VALVE LIQUID FILTER DRIER

LIQUID SHUT-OFF VALVE

ELECTRONIC EXPANSION VALVE

PRESS. TRANS. (HP)

PRESS. TRANS. (LP)

WATER OUTWATER IN

Figure showing the ASW chiller components and its connections

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FEATURESThese ASW water cooled screw chillers offer the ultimate combination of energy saving design, superior engineeringfeatures and flexibility of application as required by today�s market.

* These chillers incorporate the newest advanced microprocessor controller. This controller monitors analog and digitalinputs to achieve precise control & protective functions of the water cooled chiller units. This microprocessor control-ler is complete with all the hardware and software necessary to control the chiller unit and insures its efficiency andreliability.

* 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 tubesbundled into a "U" shaped and expanded into a steel tubular sheet which offer efficient water flow as well as heattransfer 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 andsafety controls.

* Compressors are with part winding start.

CAPACITY CONTROLA. Standard settings:These chillers are equipped with stepless capacity control system as standard for very accurate response to loadrequirements and best part load efficiency. Each compressor is equipped with a slider controller that enables to modulatecapacity between 25% to 100%, thus giving a broad range to control total chiller capacity between 10% to 100% on anaverage. 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 monitorsthe leaving water temperature.Capacity control is achieved by cycling compressor ON/OFF and slider capacity pre-set control valve. The use of slidercontrol valve provides excellent part load capacities.On multiple compressor units, capacity is controlled by a combination of slider capacity control valve and compressorstaging.

SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORSAll compressors are compact semi-hermetic twin screw of the high capacity and efficiency due to its perfect profile formratio 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 separatorwith long-life fine filter 10 microns mesh size, robust axial bearings in tandem configuration, suction gas filter, internalpressure relief valve and manual lock-out electronic protection system for thermal motor winding temperature, phasereversal, discharge gas temperature protection controls.

STANDARD SPECIFICATIONS

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CONTROL PANELThe control panel design is equivalent to NEMA 4 (IP55) with hinged door for easy access ensuring dust and weatherproofconstruction. Internal power and control wiring is neatly routed, adequately anchored and all wires identified with cablemarkers 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 condi-tions for a long period.

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

CONDENSEREvery refrigeration circuit has a separate water cooled condenser. The condenser is a shell and tube type with a rigidexternal structure made of steel and copper tubes and baffles in the inside to provide the best performance and responseto load fluctuation. The condenser can be connected to a cooling tower or to an air cooled liquid cooler. As the evaporatorshell and tube, the condenser shell and tube has a similar design with the same features. It should be noted that onlytreated water is suitable for the water cooled condenser to prevent corrosion, scaling and biological fouling, which willsignificantly affect the total system efficiency. It might be necessary to install a fixed continuous chemical treatmentsystem to control certain properties of the cooling water used. When using a cooling tower, a makeup water tank must beused 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.

REFRIGERANT SIDE

DESIGN PRESSURE,(BAR/PSIG)

TEST PRESSURE,(BAR/PSIG)

DESIGN PRESSURE,(BAR/PSIG)

TEST PRESSURE,(BAR/PSIG)

SHELL & TUBEHEAT

EXCHANGER(COOLER)

16/235 22.8/335 29/426 41.5/610STD

10/147 11.3/165 15.5/228 23.3/342ASME (option)

WATER SIDE

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MICROPROCESSOR CONTROLLERThe microprocessor controller works on the state of art microprocessor technology. This controller monitors analog anddigital 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 historythat 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 correspondingwindows 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 throughcorresponding optional gateway interfaces.

It is also compatible with GSM protocol through GSM optional gateway that sends up to 3 mobile phone SMS messageswhenever 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 toremotely 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 waterinlet & 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 timeThe control temperature is continuously displayed on the 3 Digit 7 segments LED Display. The 3 LED lights indicate thePower 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 DEVICESMICROPROCESSOR 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 devicesare 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 whenthe 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 ACCESSORIESUNIT 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 watercooler and maintain a constant superheat and load optimization.FILTER DRIER (REPLACEABLE CORE TYPE): Refrigerant circuits are kept free of harmful moisture, sludge, acids andoil 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 mois-ture 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 accumulatingin the water cooler during the off cycle.UNDER VOLTAGE AND PHASE PROTECTION: Protects against low incoming voltage as well as single phasing, phase rever-sal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it can be set up for manualreset.COMPRESSOR CIRCUIT BREAKERS: Protects against compressor branch circuit fault. When tripped (manually orautomatically), 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 compressoron 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 unitsafety 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 toprevent 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.

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UNIT SIZE ASW060B ASW070B ASW080B ASW095B ASW105B ASW115B ASW135B ASW150B ASW160B

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-754-01 800-754-05 800-683-19 800-683-22 800-754-09 800-754-13 800-754-05 800-683-19 800-683-19

380V-3Ph-60Hz 800-754-02 800-754-06 800-683-20 800-683-23 800-754-10 800-754-14 800-754-06 800-683-20 800-683-20

460V-3Ph-60Hz 800-754-03 800-754-07 800-683-21 800-683-24 800-754-11 800-754-15 800-754-07 800-683-21 800-683-21

NUMBER OF COMPRESSORS 1 1 1 1 1 1 2 2 2

OIL CHARGE PER COMPRESSOR, Liters 15 15 22 22 19 19 15 22 22

CAPACITY CONTROL (STEPLESS) % 100-50 100-25

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION INJECTION

TOTAL CRANKCASE HEATER WATTS 200 200 300 300 300 300 200 300 300

REFRIGERANT R-134a

EXPANSION VALVE DEVICE ELECTRONIC EXPANSION VALVE

CONTROL VOLTAGE 220V-1Ph-60Hz

CONDENSERPART NUMBER 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

NUMBER OF CONDENSERS 1 1 1 1 1 1 2 2 2

TOTAL WATER VOLUME PER CONDENSERS, Liters 28 33.2 33.2 38.3 41.8 51 28 33.2 33.2

WATER CONNECTION (DN) DN80 DN80 DN80 DN80 DN80 DN100 DN80 DN80 DN80

COOLERPART NUMBER (QUANTITY) 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)

TOTAL WATER HOLDING VOLUME, Liters 53 101 101 80.2 137 137 128 128 131


ECONOMIZERPART NUMBER (QUANTITY) N.A. 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) N.A. N.A. 800-516-99 (2)

EXPANSION DEVICE PART NUMBER (QUANTITY) N.A. 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) N.A. N.A. 800-181-77 (2)

GENERALNUMBER OF REFRIGERANT CIRCUITS 1 1 1 1 1 1 2 2 2

REFRIGERANT CHARGE PER COMP., kg 30 35 40 47.5 52.5 57.5 33.75 37.5 40

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 61.2/57.7/52.5 61.2/57.7/52.6 67/63.5/58.3 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 70/66.5/61.3

OPERATING/SHIPPING WEIGHTS, kg 1578/1525 1761/1660 2126/2025 2179/2090 2350/2213 2471/2334 3090/2962 3860/3732 3939/3808

PHYSICAL DATA

NOTES: 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.

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UNIT SIZE ASW185B ASW210B ASW230B ASW245B ASW280B ASW300B ASW315B ASW345B ASW355B

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-683-22 800-754-09 800-754-13 800-683-19 800-683-22 800-754-09 800-754-09 800-754-13 800-683-22

380V-3Ph-60Hz 800-683-23 800-754-10 800-754-14 800-683-20 800-683-23 800-754-10 800-754-10 800-754-14 800-683-23

460V-3Ph-60Hz 800-683-24 800-754-11 800-754-15 800-683-21 800-683-24 800-754-11 800-754-11 800-754-15 800-683-24

NUMBER OF COMPRESSORS 2 2 2 3 3 3 3 3 4

OIL CHARGE PER COMPRESSOR, Liters 22 19 19 22 22 19 19 19 22

CAPACITY CONTROL (STEPLESS) % 100-25 100-16 100-12



TOTAL CRANKCASE HEATER WATTS 300 300 300 300 300 300 300 300 300

REFRIGERANT R-134a



CONDENSERPART NUMBER 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

NUMBER OF CONDENSERS 2 2 2 3 3 3 3 3 4

TOTAL WATER VOLUME PER CONDENSERS, Liters 38.3 41.8 51 33.2 38.3 41.8 41.8 51 38.3


COOLERPART NUMBER (QUANTITY) 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)

TOTAL WATER HOLDING VOLUME, Liters 263 229 229 285 325 353 353 401 401


ECONOMIZERPART NUMBER (QUANTITY) 800-516-99 (2) 800-516-99 (2) 800-516-99 (2) 800-516-99 (3) 800-516-99 (3) N.A. 800-516-99 (3) 800-516-99 (3) N.A.

EXPANSION DEVICE PART NUMBER (QUANTITY) 800-181-77 (2) 800-181-77 (2) 800-181-77 (2) 800-181-77 (3) 800-181-77 (3) N.A. 800-181-77 (3) 800-181-77 (3) N.A.

GENERALNUMBER OF REFRIGERANT CIRCUITS 2 2 2 3 3 3 3 3 4

REFRIGERANT CHARGE PER COMP., kg 46.25 52.5 57.5 40.8 46.67 50 58.5 57.5 44.38

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 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

OPERATING/SHIPPING WEIGHTS, kg 4290/4027 4361/4132 4601/4372 6029/5744 6242/5917 6472/6119 6479/6125 6952/6551 7922/7521

PHYSICAL DATA






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UNIT SIZE ASW370B ASW395B ASW420B ASW445B ASW465B

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-683-22 800-754-09 800-754-09 800-754-13 800-754-13

380V-3Ph-60Hz 800-683-23 800-754-10 800-754-10 800-754-14 800-754-14

460V-3Ph-60Hz 800-683-24 800-754-11 800-754-11 800-754-15 800-754-15

NUMBER OF COMPRESSORS 4 4 4 4 4

OIL CHARGE PER COMPRESSOR, Liters 22 19 19 19 19

CAPACITY CONTROL (STEPLESS) % 100-12



TOTAL CRANKCASE HEATER WATTS 300 300 300 300 300

REFRIGERANT R-134a



CONDENSERPART NUMBER 800-895-03 800-895-04 800-895-04 800-895-05 800-895-05

NUMBER OF CONDENSERS 4 4 4 4 4

TOTAL WATER VOLUME PER CONDENSERS, Liters 38.3 41.8 41.8 51 51

WATER CONNECTION (DN) DN80 DN80 DN80 DN100 DN100

COOLERPART NUMBER (QUANTITY) 800-896-23 (1) 800-896-23 (1) 800-896-24 (1) 800-896-24 (1) 800-896-24 (1)

TOTAL WATER HOLDING VOLUME, Liters 487 487 574 574 574

WATER CONNECTION (DN) DN200 DN200 DN200 DN200 DN200

ECONOMIZERPART NUMBER (QUANTITY) 800-516-99 (4) N.A. 800-516-99 (4) N.A. 800-516-99 (4)

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

GENERALNUMBER OF REFRIGERANT CIRCUITS 4 4 4 4 4

REFRIGERANT CHARGE PER COMP., kg 46.25 49.4 52.5 55.6 58

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 73/69.5/64.3 71.7/68.2/63 71.7/68.2/63 72.1/68.6/63.4 72.1/68.6/63.4

OPERATING/SHIPPING WEIGHTS, kg 8415/7928 8443/7956 8782/8208 9308/8734 9320/8746

PHYSICAL DATA






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DESIGN REQUIREMENTSThe following design requirements must be known to select a package chiller.1. Required cooling capacity in tons2. Leaving chilled water temperature in 0F (LCHWT)3. Chilled water flow rate in GPM4. Chilled water cooling range in 0F (water in temp. _ water out temp.)5. Design condenser leaving water temperature in 0F6. Condenser water temperature range in 0F (water out temp. _ water in temp.)7. Electrical power supply

SAMPLE SELECTIONSelect a Water Packaged chiller for the following conditions:Required system capacity is 110 tons at 540F entering chilled waterand 440F leaving water. Design condenser leaving watertemperature is 950F. Water cooler fouling factor is 0.00010.Power supply: 380V-3Ph-60Hz.

STEP-1: UNIT SELECTIONEntering the capacity performance data at given LCHWT and ambient temperature.ASW115B chiller unit will produce 113.89 tons and 94.3 kW compressorpower input at 440F leaving chilled water temperature & 950F condenser leavingwater temperature with 100F water temperature difference.

For the conditions required, the unit actual cooling capacity when corrected forthe 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

= 264 GPM Cooling Range, T 100F

SELECTION PROCEDURE (English units)

TABLE - 1

EVAPORATOR FOULINGFACTOR (HR-FT2-0F/BTU)

0.000100.000250.000500.000750.00100

CAPACITYCORRECTION

FACTOR1.0000.9920.9780.9650.951

POWERINPUT

FACTOR1.0000.9970.9900.9840.978

ARISTANDARDS

ARI-550/590-98ARI-590-86ARI-590-81

Total condenser GPM = (Required capacity, Tons + total power input/3.516) x 24

= (110 + 94.3/3.516) x 24

= 328 GPM.Cooling Range, T 100F

Water flow per condenser GPM = Total condenser GPM

= 328

= 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 selectedmodel and pressure drop for condenser at 168 GPM = 12 ft. of water for selected model.

STEP-3: ELECTRICALRefer 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 SELECTIONFor chilled water & condenser water pump selection, add all pressure drop in the closed chilled water loop piping to thepressure drop calculated in step 2.

STEP-5: LCHWT CORRECTIONRefer to table-2: Add correction factor to design leaving chilled water temperature (LCHWT) when chilled water tempera-ture range is above 100F and subtract correction from design leaving chilled water temperature (LCHWT) when watertemperature 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.

TABLE - 2CHILLED WATER TEMPERATURE RISE (0F)

0

-0.2

-0.45 10

+0.4

+0.2

+0.6

15 20

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DESIGN REQUIREMENTSThe 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 LPS4. Chilled water cooling range in 0C (water in temp. _ water out temp.)5. Design condenser leaving water temperature in 0C6. Condenser water temperature range in 0C (water out temp. _ water in temp.)7. Electrical power supply

SAMPLE SELECTIONSelect a Water Packaged chiller for the following conditions:Required system capacity is 386 kW at 120C entering chilled waterand 60C leaving water. Design condenser leaving watertemperature is 350C. Water cooler fouling factor is 0.0000176.Power supply: 380V-3Ph-60Hz.

STEP-1: UNIT SELECTIONEntering the capacity performance data at given LCHWT and ambient temperature.ASW115B chiller unit will produce 385.67 kW and 94.9 kW compressorpower input at 60C leaving chilled water temperature & 350C condenser leavingwater temperature with 60C water temperature difference.

For the conditions required, the unit actual cooling capacity when corrected forthe 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

= 15.4 LPS Cooling Range, T 60C

SELECTION PROCEDURE (Metric units)

Total condenser LPS = (Required capacity, kW + total power input) x 0.239

= (386 + 94.9) x 0.239

= 19.16 LPS. Cooling Range, T 60C

Water flow per condenser LPS = Total condenser LPS

= 19.16

= 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 modeland pressure drop for condenser at 19.16 LPS = 35.85 kPa for selected model.

STEP-3: ELECTRICALRefer 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 SELECTIONFor chilled water & condenser water pump selection, add all pressure drop in the closed chilled water loop piping to thepressure drop calculated in step 2.

STEP-5: LCHWT CORRECTIONRefer to table-2: Add correction factor to design leaving chilled water temperature (LCHWT) when chilled water tempera-ture range is above 60C and subtract correction from design leaving chilled water temperature (LCHWT) when watertemperature 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.

TABLE - 1

EVAPORATOR FOULINGFACTOR (M2-0C/W)

0.0000180.0000440.0000880.0001320.000176

CAPACITYCORRECTION

FACTOR1.0000.9920.9780.9650.951

POWERINPUT

FACTOR1.0000.9970.9900.9840.978

ARISTANDARDS

ARI-550/590-98ARI-590-86ARI-590-81

TABLE - 2CHILLED WATER TEMPERATURE RISE (0C)

+0.33

+0.22

+0.11

-0.11

-0.2254 6 7 8

0

109

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 tobring 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 tomultiply the water performance data by correction factors corresponding to the ambient temperature or Ethylene glycolpercentage indicated in the following table.

EXAMPLE: English system- Determine Ethylene glycol percentage by weight and correction factors at 380F ambienttemperature.From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 380F ambi-ent 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 ambienttemperature.From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 3.30C ambi-ent 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.

ETHYLENE GLYCOL % BY WEIGHT 0% 12% 22% 30% 36% 41% 46% 50%

Freezing point of Ethylene glycol solution 00C (320F) -50C (230F) -100C (140F) -150C (50F) -200C (-40F) -250C (-130F) -300C (-220F) -350C (-310F)

Ambient temperature 8.30C (470F) 3.30C (380F) -1.70C (290F) -6.70C (200F) -11.70C (110F) -16.70C (20F) -21.70C (-70F) -26.70C (-160F)

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

13

20

CBPoles

LRA(each)

RLA(each)

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

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

ASW060B

ASW070B

ASW080B

ASW095B

ASW105B

ASW115B

ASW135B

ASW150B

ASW160B

ASW185B

ASW210B

ASW230B

UNITSIZE

SUPPLY VOLTAGE COMPRESSOR CRANKCASE HEATERS

ELECTRICAL DATA

MOCPMCAMax.Min.Nominal(V-Ph-Hz)

253418506253418506253418506253418506253418506253418506253418506253418506253418

506

253

418

506

253

418

506

253

418

506

191 343 1 152.6 732 3 122 2 230 200 0.87 PART WINDING118 212 1 94.2 442 3 75 2 230 200 0.87 PART WINDING95 172 1 76.3 350 3 61 2 230 200 0.87 PART WINDING212 381 1 169.2 885 3 135 2 230 200 0.87 PART WINDING128 230 1 102.4 534 3 82 2 230 200 0.87 PART WINDING106 190 1 84.6 423 3 68 2 230 200 0.87 PART WINDING254 457 1 203.0 1224 3 162 2 230 300 1.30 PART WINDING153 276 1 122.7 742 3 98 2 230 300 1.30 PART WINDING127 228 1 101.4 612 3 81 2 230 300 1.30 PART WINDING284 511 1 227.0 1330 3 182 2 230 300 1.30 PART WINDING172 309 1 137.5 807 3 110 2 230 300 1.30 PART WINDING142 256 1 113.6 665 3 91 2 230 300 1.30 PART WINDING306 551 1 245 1224 3 196 2 230 300 1.30 PART WINDING186 334 1 148.5 742 3 119 2 230 300 1.30 PART WINDING153 276 1 122.7 612 3 98 2 230 300 1.30 PART WINDING341 614 1 273 1330 3 218 2 230 300 1.30 PART WINDING206 371 1 165 807 3 132 2 230 300 1.30 PART WINDING170 307 1 136.3 665 3 109 2 230 300 1.30 PART WINDING369 533 2 164.1 885 3 131 4 230 400 1.74 PART WINDING223 323 2 99.3 534 3 79 4 230 400 1.74 PART WINDING185 267 2 82.1 423 3 66 4 230 400 1.74 PART WINDING435 628 2 193.2 1224 3 155 4 230 600 2.61 PART WINDING263 380 2 116.9 742 3 94 4 230 600 2.61 PART WINDING217 314 2 96.6 612 3 77 4 230 600 2.61 PART WINDING457 660 2 203.0 1224 3 162 4 230 600 2.61 PART WINDING276 399 2 122.7 742 3 98 4 230 600 2.61 PART WINDING

228 330 2 101.4 612 3 81 4 230 600 2.61 PART WINDING

511 738 2 227.0 1,330 3 182 4 230 600 2.61 PART WINDING

309 447 2 137.5 807 3 110 4 230 600 2.61 PART WINDING

256 369 2 113.6 665 3 91 4 230 600 2.61 PART WINDING

551 796 2 245.0 1224 3 196 4 230 600 2.61 PART WINDING

334 483 2 148.5 742 3 119 4 230 600 2.61 PART WINDING

276 399 2 122.7 612 3 98 4 230 600 2.61 PART WINDING

614 887 2 273.0 1330 3 218 4 230 600 2.61 PART WINDING

371 536 2 165.0 807 3 132 4 230 600 2.61 PART WINDING

307 443 2 136.3 665 3 109 4 230 600 2.61 PART WINDING

Qty.Qty.MTA

CB

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.

LEGEND:MCA - Minimum Circuit Ampacity per NEC 430-24MOCP - Maximum Over Current ProtectionRLA - Rated Load AmpsLRA - Locked Rotor AmpsCB - Circuit BreakerMTA - Must Trip AmpsFLA - Full Load AmpsFCA - Fan Circuit AmpskW - Kilo Watt

TotalAmps

TotalWattsVolts

COMPRESSORWINDING START

187342414187342414187342414187342414187342414187342414187342414187342414187342

414

187

342

414

187

342

414

187

342

414

CBPoles

LRA(each)

RLA(each)

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

208/230-3-60380-3-60460-3-60

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

ASW245B

ASW280B

ASW300B

ASW315B

ASW345B

ASW355B

ASW370B

ASW395B

ASW420B

ASW445B

ASW465B

UNITSIZE

SUPPLY VOLTAGE COMPRESSOR CRANKCASE HEATERS

ELECTRICAL DATA

MOCPMCAMax.Min.Nominal(V-Ph-Hz)

253418506253418506253418506253418506253418506253418506253418506253418506253418

506

253

418

506

253

418

506

660 863 3 203.0 1224 3 162 6 230 900 3.91 PART WINDING399 521 3 122.7 742 3 98 6 230 900 3.91 PART WINDING330 431 3 101.4 612 3 81 6 230 900 3.91 PART WINDING738 965 3 227.0 1330 3 182 6 230 900 3.91 PART WINDING447 584 3 137.5 807 3 110 6 230 900 3.91 PART WINDING369 483 3 113.6 665 3 91 6 230 900 3.91 PART WINDING761 995 3 234.0 1224 3 187 6 230 900 3.91 PART WINDING461 603 3 141.9 742 3 114 6 230 900 3.91 PART WINDING381 498 3 117.2 612 3 94 6 230 900 3.91 PART WINDING796 1041 3 245.0 1224 3 196 6 230 900 3.91 PART WINDING483 631 3 148.5 742 3 119 6 230 900 3.91 PART WINDING399 521 3 122.7 612 3 98 6 230 900 3.91 PART WINDING887 1160 3 273.0 1330 3 218 6 230 900 3.91 PART WINDING536 701 3 165.0 807 3 132 6 230 900 3.91 PART WINDING444 580 3 136.5 665 3 109 6 230 900 3.91 PART WINDING935 1155 4 220.0 1330 3 176 8 230 1200 5.22 PART WINDING567 700 4 133.3 807 3 107 8 230 1200 5.22 PART WINDING468 578 4 110.1 665 3 88 8 230 1200 5.22 PART WINDING965 1192 4 227.0 1330 3 182 8 230 1200 5.22 PART WINDING584 722 4 137.5 807 3 110 8 230 1200 5.22 PART WINDING483 596 4 113.6 665 3 91 8 230 1200 5.22 PART WINDING995 1229 4 234.0 1224 3 187 8 230 1200 5.22 PART WINDING603 745 4 141.9 742 3 114 8 230 1200 5.22 PART WINDING498 615 4 117.2 612 3 94 8 230 1200 5.22 PART WINDING

1041 1286 4 245.0 1224 3 196 8 230 1200 5.22 PART WINDING631 780 4 148.5 742 3 119 8 230 1200 5.22 PART WINDING

521 644 4 122.7 612 3 98 8 230 1200 5.22 PART WINDING

1126 1391 4 265.0 1330 3 212 8 230 1200 5.22 PART WINDING

682 842 4 160.4 807 3 128 8 230 1200 5.22 PART WINDING

563 696 4 132.5 665 3 106 8 230 1200 5.22 PART WINDING

1160 1433 4 273.0 1330 3 218 8 230 1200 5.22 PART WINDING

701 866 4 165.0 807 3 132 8 230 1200 5.22 PART WINDING

579 716 4 136.3 665 3 109 8 230 1200 5.22 PART WINDING

Qty.Qty.MTA

CB

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 parallelfield 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.

LEGEND:MCA - Minimum Circuit Ampacity per NEC 430-24MOCP - Maximum Over Current ProtectionRLA - Rated Load AmpsLRA - Locked Rotor AmpsCB - Circuit BreakerMTA - Must Trip AmpsFLA - Full Load AmpsFCA - Fan Circuit AmpskW - Kilo Watt

TotalAmps

TotalWattsVolts

COMPRESSORWINDING START

187342414187342414187342414187342414187342414187342414187342414187342414187342

414

187

342

414

187

342

414

21

22

WATER SIDE COOLER PRESSURE DROP

CURVE No. MODEL No.12345678

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.

CURVE No. MODEL No.ASW245ASW280

ASW300 & 315ASW345ASW355

ASW370 & 395ASW420, 445 & 465

9101112131415

ASW060ASW070 & 080

ASW095ASW105 & 115ASW135 & 150

ASW160ASW185

ASW210 & 230

10 2010 4020 30

FLOW RATE - GPM6050 70 80 10090 400200 300 500 700600 800 12001000900 1500

12

72

FLOW RATE - GPM604030 50 9070 80 100 300200 400 500 600 15001000800700 900 1200

23

10 4020 30

FLOW RATE - GPM6050 70 80 10090 400200 300 500 700600 800 12001000900 1500

FLOW RATE - GPM604030 50 9070 80 100 300200 400 500 600 15001000800700 900 1200

2

10 20

WATER SIDE CONDENSER PRESSURE DROP

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

CURVE No.12345

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.

24

ASW060B

ASW070B, ASW080B, ASW095B, ASW105B & ASW115B

DIMENSIONS

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

MODEL A B D D1ASW070B, 080B & 095B 2230 377 4" 3-1/8"

ASW105B 2150 410 5" 3-1/8"

ASW115B 2150 410 5" 4"

DIMENSIONS

24

25

DIMENSIONS

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

ASW135B, ASW150B, ASW160B, ASW185B, ASW210B & ASW230B

ASW245B, ASW280B, ASW300B, ASW315B & ASW345B

MODEL A B D1ASW245B 2400 483 3-1/8"

ASW280B 2800 483 3-1/8"

ASW300B & 315B 2400 508 3-1/8"

ASW345B 2800 508 4"

DIMENSIONS

MODEL A B D D1ASW135B & 150B 2150 417 5" 3-1/8"

ASW160B 2400 417 5" 3-1/8"

ASW185B & 210B 2600 457 6" 3-1/8"

ASW230B 2600 457 6" 4"

DIMENSIONS

CC112A

1-2 CLOSEDJU1329B27A

1-2 CLOSED1-2 CLOSED

1-2 CLOSED1-2 CLOSED

1-2 CLOSED

1-2 CLOSED

1-2 CLOSED1-2 CLOSED1-2 CLOSED

1-2 CLOSED

1-2 CLOSEDJU10

TIN/RWTTEMP. SENSOR

JU8

JU3

JU12JU19

DISCHARGE PRESSUREDPT2 - COMP2

TRANSDUCER

JU4JU9

30B

31B

JU6JU7

SUCTION PRESSURETRANSDUCER

SPT2 - COMP2 JU5JU15

LIQUID LINE SOLENOID1

POWER DECREASE CP1

HGBS/UNIT STATUS/COOLER HTR

POWER DECREASE CP2

LIQUID LINE SOLENOID2COMP2 CONTACTOR

ALARM - NC CONTACT

LIQUID INJECTION 1

ALARM - NO CONTACT

LIQUID INJECTION 2

POWER INCREASE CP1

POWER INCREASE CP2

JUMPER SETUP

OPENCLOSED

1-2 CLOSEDCLOSED

ON MAIN BOARD

COMP1 CONTACTOR

REMOTE MONITORING

TRANSDUCER

T3S

SENSOR COMP2SUCTION TEMP

T4S

26A

23B

TEMP. SENSORTOUT/LWT

22B

T2S 25A

24A

28B

TD2TU2JU11

TL2

31A

30A

DISCHARGE PRESSUREDPT1 - COMP1

TRANSDUCER

COM2

SENSOR COMP1SUCTION TEMP

23AT1S

22A

(SEE OPTION BOX)INTERFACE

15B

29A

28A

SUCTION PRESSURESPT1 - COMP1

L.I2

17C 15A

20B

UL4-2

UL4-1

6A

COM3

INTERFACE(SEE OPTION BOX)

POWER LINE ANALYZER

L.I1

C

20A

16

LLS2

14B UL2-2

14A

12B CC2

UL2-1

LLS1

CLOSED

OPENOPENCLOSED

EEVB JUMPER & DIP SWITCH

1A UVR 1

1 2H

2G1

OLR2-1HPS2 10B

FLS1

JP3A22BCB2A-1

9BOLR4-111B

11CWP*10

23BCB4A-1

5B2B

CB3A-122ACB1A-1 23A

OLR1-110A

SSPS2 8B

HPS1JP2A

11A OLR3-1

(SEE UVM CONNECTION)

SSPS1 8A

X9

5A2AEEV

TU1TL1JU1

TD1

CONTROL VOLTAGE 22F1 3.5A1B1B

S1( CONTROL POWER)

230VAC

COMP1 SSPST2 T1 SSPS1CCA3-1

CCA4-1

SERIAL CABLE

COMP2 SSPS1K D1

T2SSPS2D11J

T1

3A

CCA2-1 3B

CCA1-1COMP1 OILHTR

2HTRCOMP2 OILHTR

1HTR

ATB

TO HVTBL1

TO NTBN

ATB

DETAILS

COMPUNLOADERTIMER

SEEALSO

NTB

CONTROL PANEL

ECONOMIZER SOLENOID 1

ECONOMIZER SOLENOID 2

TYPICAL SCHEMATIC WIRING DIAGRAM

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

SET POINT:15

70A/B

REMOVE JP3AEFR2

EXTERNAL DEVICE

Comp 1 and 70B/71B for

EFR1

Comp 231

132

Comp 2.

Comp 131

132

65BA8/D8 (MB)

REMOVE JP2A65A

A3/D3 (MB)

wire number, 70A/71A for Current Transformer (CT)

5 AMPS @1.0 SECGFP SET POINT

71A/B

A2T1T2 A1EARTH FAULT RELAY

3132

t

34

21

SET POINT = 36 degF

HEATER

1B

HTR1 2

36 deg F

R7MB

UVMUVR

COMP

1 7C

11AL3L2 TERMINAL A,B,& C

MATCHED WITH UNIT ON UVM TO PHASE

CONTROLS.

NOTE:

27O HEATER NOTE#7SEE ALSO

# M171 = 4

+IS485 TO MAIN

TO GATEWAY

100B 7C

BOARD (COM2)

-GND

SET THE

PARAMETER101B7O

MBR7

TDS2-1SEC CC4

CC1A-2 TDS1-1SEC CC31 61A 62A 2

1CC2A-2 61B 62B 2

12B4O(MB)

12A1O(MB) CC1

FOR TDS OPTION SEE CONN.BELOW

1CC1A-2 CC3

61A 2

1

2

CC2

FOR TDS OPTION SEE CONN.BELOWCC2A-2 61B

CC4

2

2

TIMER 11

UL3-23BB

3AATIMER 21

3BCCAT21-1

AR21

3ACCAT11-1

AR11UL3-1

UL3-2

AR214BB

UL3-1

AR114AA

ATB2

ATB

1

ATB2

HGBSR7 27O 151 7C

MB

NOTE#7SEE ALSO

NOTE#7SEE ALSO

ATBATB

VFC FROM CUSTOMER PANEL1 VFC 2G

USE N/O

RUN THE UNIT.CONTACT TO

COMPRESSOR 1

COMPRESSOR 2

ECONOMIZER 2

ECONOMIZER 1

TO MB (50)13B

2

ECO1

ECO2

13ATO MB (20) 2

L1

PSIG2705. HIGH PRESSURE

6. FREEZE 39° F

1. L.V.WATER LWT° F

4. LOW PRESSURE

3. PUMP DOWN 0 PSIG

15 PSIG

NAME OPEN CLOSE

MODEL OLR SETTING

NAME CLOSE OPEN

270 PSIG 300 PSIGHPS (ADJUSTABLE)

CONTROLLER

TYPICAL SCHEMATIC WIRING DIAGRAMLEGEND

AR AUXILIARY RELAYATB AUXILIARY TERMINAL BLOCKCB CIRCUIT BREAKERCBA MAGNETIC CIRCUIT BREAKER AUXILIARY CONTACTCOM COMMUNICATIONCOMP COMPRESSORCC COMPRESSOR CONTACTORCCA COMPRESSOR CONTACTOR AUXILIARYCWP CHILLED WATER PUMPCCH CRANKCASE HEATERCCAT TIMER AUXILIARY CONTACTCT CURRENT TRANSFORMERECO ECONOMIZER SOLENOID VALVEEEVB ELECTRONIC EXPANSION VALVE BOARDEFR EARTH FAULT RELAYETB EARTH TERMINAL BLOCKFLS FLOW SWITCHFM FAN MOTORFMC FAN MOTOR CONTACTORF FUSEG GROUNDGFP GROUND FAULT PROTECTIONHPS HIGH PRESSURE SWITCHHGBS HOT GAS BYPASS SOLENOIDHVTB HIGH VOLTAGE TERMINAL BLOCK JP JUMPERLI LIQUID INJECTIONLPS LOW PRESSURE SWITCHLWT LEAVING WATER TEMPERATUREMB MASTER BOARDNTB NEUTRAL TERMINAL BLOCKOLR OVER LOAD RELAYPT PRESSURE TRANSDUCERP PROPORTIONAL BANDPSIG POUNDS PER SQUARE INCHPWS PART WINDING STARTR CONTROLLER BUILT-IN RELAYSLE EQUALIZER SOLENOID VALVES1 CONTROL SWITCHSEC SECOND (TIME)TRANS TRANSFORMERTS PTC SENSOR/TEMPERATURE SENSORTDS TIME DELAY SWITCHVFC VOLT FREE CONTACTUL UNLOADER SOLENOIDUVM UNDER VOLTAGE MONITORUVR UNDER VOLTAGE RELAY

TERMINAL BLOCK - - - - - FIELD WIRING

* FIELD SUPPLY LEGEND ON MASTER/SLAVE BOARD

A../D.. DIGITAL INPUT 1C/1C COMMON1O DIGITAL OUT 1AC/DC DIGITAL COMMONR.. SOLID STATE RELAY CONTACTST1 THERMISTOR 1SH SHIELDX52/X53 SERIAL COMMUNICATION PORTEXEN EXTERNAL ENABLEJU/TU/TD/TL BOARD JUMPERS

NOTES1. 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 BREAKERTO BE PROVIDED BY END USER WITH RATING ASRECOMMENDED BY MANUFACTURER.

5. POWER MUST BE SUPPLIED TO CRANKCASEHEATER FOR MINIMUM OF 12 HOURS PRIOR TOSYSTEM START UP.

IF POWER IS OFF 6 HOURS OR MORE, CRANKCASEHEATER MUST BE ON FOR 12 HOURS BEFOREOPERATING THE SYSTEM.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAYRESULT IN COMPRESSOR DAMAGE.

6. FOR OIL LEVEL FAULT, PLEASE ALSO CONSIDERTHE GFP (GROUND FAULT PROTECTION) IFAVAILABLE.

7. THE AUXILIARY RELAY 7O/7C AT MB CAN USEONLY ONE FUNCTION AT A TIME FROM THEFOLLOWING OPTION: HGBP, COOLER HEATER &UNIT STATUS.

8. MARK IN THE BOX FOUND AT THE UPPER RIGHT OFTHE RESPECTIVE OPTIONAL ITEM, IF THE OPTIONALITEM IS INCLUDED IN THE UNIT.

28

MICROPROCESSOR CONTROLLERSequence of OperationThe 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 SEQUENCEStaging 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 #1liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloadedcapacity. 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 #2liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloadedcapacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.

STAGE - OFF SEQUENCEDuring 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 temperatureset 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

30

APPLICATION GUIDELINESINTRODUCTIONThese guidelines should be considered when designing systems and their installation utilizing Zamil ASW series liquidchillers. Stable operation, performance and reliability of units is often dependent upon proper compliance with theserecommendations. When any application varies from these guidelines, it should be referred with Zamil Air Conditionersfor specific recommendations.

UNIT SELECTION/SIZINGUnit selection procedure and capacities are provided in this catalog for proper selection. The Zamil electronic selectionprogram 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 futureexpansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operationand excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operatemore efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversizedunit 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 demanddue to expansion. Further, it is also recommended that installing two chillers instead of a single chiller be considered inapplications 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 possiblecapacity.

FOULING FACTOR AND WATER REQUIREMENTThe 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 capacitydecreases and power input increases. For unit selection at other fouling factors, apply appropriate correction factor from the tableprovided in this catalog.

These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water mayresult in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading topossible equipment damage. The more scale forming material and suspended solids in the system water, the greater thechances of scale and deposit formation and fouling. These include calcium, magnesium, biological growth (algae, fungiand bacteria), dirt, silt, clays, organic contaminants (oils), silica, etc. which should be kept to the minimum to retard scaleand deposit formation. In order to prevent corrosion and pitting, the pH value of the water flowing through the cooler mustbe kept between 7 and 8.5. Zamil recommends that a water treatment specialist is consulted to provide and maintainwater treatment, this is particularly critical with glycol systems.

WATER FLOW RATES AND COOLER PRESSURE DROPThe 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 flowcausing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessivepressure 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 switchshould be calibrated accordingly. The piping and pumping layout should be right for the application and must assureproper 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 specificrecommendations.

Load200 TR

200 TRChiller

54.6°F500 GPM

45°F500 GPM

45°F240 GPM

65°F240 GPM

45°F260 GPM

CHILLER

COOLER/CONDENSER FLUID TEMPERATURES RANGEUnit 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 fluidtemperature 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 condenserwater temperature rise of 100F. Units may be operated at any desired temperature drop within the range of 5 to 150F aslong as the temperature and flow limits are not violated and appropriate correction factors are applied on the capacity andpower input. The Zamil electronic selection program can be very handy in selecting equipment at different temperaturedrops.

It should be noted that temperature drop/rise outside the aforesaid range is not permitted as it is beyond the optimumrange of control and could adversely affect the functioning of microprocessor controller and may also prove to be detri-mental for the equipment.

FLOW RATES AND/OR WATER TEMPERATURES OUT OF RANGECertain applications (particularly process cooling jobs) call for flow rates and/or water temperatures that are outside theabove mentioned limits/range. Our chillers can be utilized for these applications by selecting the chiller based on thespecific process load and making a suitable piping and mixing arrangement in order to bring the flow rates and/or watertemperatures 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).

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).

31

Load120 TR

120 TRChiller

45°F340 GPM

80°F109.8 GPM

45°F257.8 GPM

80°F82.2 GPM

53.4°F340 GPM

80°F192 GPM

65°F192 GPM

53.4°F340 GPM

45°F82.2 GPM

CHILLER

COOLER FREEZE PROTECTIONIf the unit is located in an area where ambient temperatures fall below 320F (00C), cooler protection in the form of EthyleneGlycol Solution is required to protect the cooler and fluid piping from low ambient freeze-up. This glycol solution must beadded to the water system loop to bring down the freezing point of water to a difference of 150F (8.30C) below minimumoperating ambient temperature.

Using this glycol solution causes a variation in unit performance, flow rate and pressure drop, therefore appropriatecorrection factors from the aforementioned table in this catalog should be applied.

MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATIONA 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 mainte-nance. Also, they offer some standby capacity if repair work must be done on a chiller from a set of duty chillers. Startingin-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, standbycapability is desired, large temperature drop (greater than 150F) is desired or application calls for splitting the total capac-ity for better part load operation.

In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced waterflow. It is mandatory that cooler flow rates must be balanced to ensure proper flow to each chiller based on its respectivecapacity. 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 arecombined again in a common line after chilling. Water temperatures (EWT or LWT) can be used to cycle units On and Offbased on the cooling demand. Parallel arrangements permit adding chillers in the future for plant expansion with theappropriate considerations beforehand.

In the series arrangement, the chilled liquid pressure drop may be higher unless coolers with fewer liquid-side passes orbaffles are used. No over chilling by either unit is required, and compressor power consumption is lower than it is for theparallel 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 resultinginstallation and operational cost savings. Series chiller arrangements can be controlled in several ways based on thewater 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 forservice without a complete shutdown.

Zamil recommends the parallel arrangement for design temperature drops ( T) up to 150F and the series arrangementbeyond that i.e., 16 to 200F. Complete design details on these parallel and series chilled water flow arrangements can befound in the ASHRAE handbooks and other design literature which should be referred by the designer in preparing hisdetailed designs.

PIPING ARRANGEMENTS AND PLANT LAYOUTOur chillers are suitable for incorporating in �Two Pipe� single temperature systems or �Four Pipe� independent loadsystems. The system piping circuit (load distribution circuit) should be basically parallel piping either Direct Return orReverse 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 andcons of cost, nature of load and configuration of building, energy economics, flexibility, installation requirements andothers to determine the best arrangement for his project. In all cases, it must be ensured that the design water flow isconstantly maintained through the chillers at all stages of operation. Some suggested arrangements with basic schematiclayouts are as follows:

32

CHWS

CHWR

Load Load

3-WayValve

3-WayValve

Constant Speed Pump

CHILLER

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

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 funda-mental 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 controlloads. 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 tovary the amount of water flowing through the load device. With a two-way valve, as the valve strokes from full-open to full-closed, the quantity of water flowing through the load gradually decreases from design flow to no flow. The three-waymixing valve has the same effect on the load as the two way valve - as the load reduces, the quantity of water flowingthrough 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 functions�they both vary the flowthrough the load as the load changes. The fundamental difference between the two-way valve and the three-way valve isthat as the source or distribution system sees the load, the two-way valve provides a variable flow load response and thethree-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-wayvalve systems especially on the pumping side due to constant water circulation in the system. On multiple chiller instal-lations, pumps are required to operate continuously and the sequencing of chillers is dependent on water temperatures.

33

CHWR

Load

2-Way Valve

CHWS

Bypass ControlValve

P

Bypass Line

SystemController

FM-1

Load

2-Way Valve

Variable Speed Pump

CHILLER CHILLER CHILLER

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

In this type of arrangement, constant water flow through the chillers is maintained, however the quantity of water flowingthrough the load distribution piping system decreases in proportion to the load and the difference amount is directedthrough 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 FM1measures 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 bypassvalve to maintain the desired flow in the bypass based on the set points in the system controller (the valve is positioned bysum of flow meters FM1 and FM2).

The speed of the chiller pumps is controlled by the differential pressure sensor/transmitter, maintaining the desireddifferential pressure ( P) across the cooling coils, their control valves and the branch piping. The pump speed is modu-lated within a certain range in order to reduce the pumping head and not to alter the water flow rate (the duty flow rate ofthe pumps remains constant). Each chiller-pump combination operates independently from the remaining chillers andeach pump is shutdown when the respective chiller is stopped. Instead of using water temperature as an indicator ofdemand, the sequencing of chillers is dependent on water flow. The chillers are rated in gallons per minute; the actual flowto 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 anddue to cycling of pumps.

Note: Some designers may consider installing constant speed pumps and utilize pressure relief bypass control valvescontrolled by a differential pressure sensor/controller to maintain a fixed differential pressure between the supply andreturn mains of the chilled water system in order to accommodate for the required chiller flow and to achieve some formof variable volume system. This method is not recommended as it�s a wasteful practice because a considerable amountof energy is lost, an almost constant volume system results and the pumping energy remains substantially that requiredat full system flow and head.

Also, the problem with this system is improper control of the bypass valve which does not guarantee proper flow throughthe chillers and high differential pressures in the control valves on the cooling coils when the system friction subsides atlow loads which can cause lifting of the valve stems or wire cutting of the valve seats. Further, as all the water must bepumped at a head equal to or greater than the design head, the pump or pumps are forced to run up the pump headcapacity curve, which increases the overpressure on the system and also increases the wear on the pumps, since theyare forced to operate with high radial thrusts.

34

Flow Sensor

CHWR

P

2-Way Valve

Load

CHWSA

B

Variable Speed Secondary Pump

SystemController

Load

2-Way Valve

Constant SpeedPrimary Pump

CHILLER CHILLER CHILLER

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

This system is called a Primary � Secondary System and in this arrangement, the generation zone is separated from thetransportation 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 theload and the difference amount is directed through a bypass pipe that connects the supply and return headers. Thisbypass pipe forms a �Hydraulic Coupling� between the points A � B and is also called as Common Bridge or DecouplingLine. 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 desireddifferential pressure ( P) across the cooling coils, their control valves and the branch piping. This pump speed is modulatedwithin 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 chiller-pump combination operates independently from the remaining chillers and each pump is shutdown when the respective chilleris stopped. The sequencing of chillers is dependent on water flow. If greater flow is demanded than that supplied by the chiller-pumps, return water is forced through the bypass into the supply header. This flow indicates a need for additional chillercapacity and another chiller-pump starts. Excess bypass flow with reference to the set points in the system controller in theopposite 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 partialcooling loads on the system and due to cycling of Primary Pumps.

COOLER PIPING CONNECTIONSThe following pertinent guidelines are served to ensure satisfactory operation of the units. Failure to follow these recommenda-tions 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 andleave 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 controlpanel 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) maybe controlled external to the unit - but an interlock must be wired to the unit control panel (as shown in the wiringdiagram) 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 tominimize transmission of vibrations to the piping / building as some movement of the unit can be expected duringnormal operation. The piping and fittings must be separately supported to prevent any loading on the cooler.

35

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

• The cooler must be protected by a strainer, preferably of 20 mesh, fitted as close as possible to the liquid inlet connec-tion, 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 anyvariations occur in the cooler and system. When installing pressure taps to measure the amount of pressure dropacross the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstreamfrom 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 completedrainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for usein all lines to facilitate servicing.

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

CONDENSER PIPING CONNECTIONThe 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 usingan open type cooling tower.

• A water treatment and cleaning system should be connected to the condenser loop to treat and clean the water whenusing an open type cooling tower.

The following is a suggested water piping arrangement for the condenser and the cooler at the chiller for single unitinstallations. For multiple chiller installations, each unit should be piped as shown:

36

CHILLED FLUID VOLUME REQUIREMENTThe volume of water in a piping system loop is critical to the smooth and proper operation of a chilled water system. Ifsufficient volume of water is not there in the system, the temperature control can be lost resulting in erratic systemoperation and excessive compressor cycling. Therefore, to prevent this effect of a �Short Water Loop� ensure that totalvolume of water in the piping system loop equals or exceeds 3 Gallons per Nominal Ton of cooling capacity for standardair conditioning applications and 6 Gallons per Nominal Ton of cooling capacity for process cooling jobs where accuracyis 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 conditioningapplication 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 toincrease the volume of water in the system and therefore, reduce the rate of change of return water temperature. This tankshould be provided on the return water side to the chiller and the tank should be baffled to ensure that there is no stratificationand the entering stream thoroughly mixes with the tank water. See recommended tank design schematics below:

SUGGESTIONS ON SYSTEM DESIGN AND PIPING PRACTICESThe prospective chilled water system should be designed to the specific requirements of the owner and to achieve themost 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 onetemperature difference for all chilled water systems. The actual temperature difference that is selected for a specificinstallation is determined by the cost of the cooling coils for various temperature differences and the effect that higherdifferences may have on the operating cost of the chillers. A careful balance between energy savings and first costshould be made by the designer. These are the decisions that must be made by the designer for each application andonly experienced designers should entertain water temperature differences in excess of 120F on chilled water sys-tems. 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 meantemperature difference.

c) Higher temperature differentials increase the possibilities of loss of temperature difference in coils due to dirt on theair 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 systemdesigner. The possibility of laminar flow is greater with higher temperature differences. Laminar flow reduces theheat-transfer rate and should not occur in a coil at any point in its load range. Many systems operate inefficientlybecause of coils that were selected at too low a friction loss through them at design load; therefore, at reducedloads and flows, they operate with laminar flow.

37

TANK SCHEMATIC

• Control of Return Water Temperature: Return water temperature is one of the most important operating values for achilled water system. It tells the operator just how good a job the control system and coils are doing in convertingenergy from the chillers to the air or water systems that are cooling the building. This is such a basic criterion that itshould be addressed early in the design of a chilled water system. The proper method of controlling return temperatureis through the correct selection of control valves and cooling coils. In conclusion, one of the designer�s most importanttasks is the selection of a sound temperature differential that will provide maximum possible system efficiency. Thesecond 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-wastingdevices. 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 branchof 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 thenormal 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 systemwithout lifting the valve head off the valve seat.

• Expansion tank should be provided to so that water volume changes can be accommodated. Expansion tanks aregenerally 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 parallelpumps are operated at different speeds, but only experienced designers should make evaluations for such a proposedoperation. Also, it is better to use pumps of the same size when operating them in parallel. Variable speed pumpsshould be controlled so that pumps operating in parallel never have more than one percent difference in actual oper-ating speed. Mixing of constant and variable speed pumps in parallel operation is wrong and leads to disastrousresults.

• Distribution pumps should be selected for maximum efficiency at the design condition and within the economic con-straints of the project. Distribution pumps should be added and subtracted to avoid operation of pumps at points ofhigh 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 checkvalves should be center guided, spring loaded, disc type check valves and should be sized so that the check valve isfull open at design flow rate. Generally this will require the check valve to be one pipe size smaller than the connectingpiping.

• Circuiting Chilled water to Multiple Chillers : There are fundamentals for the circuiting of chillers that should not beviolated 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

ATTENTION TO RIGGERSHook 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.

CAUTIONAll 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.

RIGGING INSTRUCTIONS

39

LIFTSPREADER BAR

PROPER CLEARANCETO BE PROVIDED

LIFT

LIFT

SPREADER BAR

PROPER CLEARANCETO BE PROVIDED

LIFT

MODELS: ASW135B - ASW465B


40

WALL

INSTALLATION CLEARANCE

FIGURE - 1STRAIGHT WALL

FIGURE - 2CORNER WALL

NOTE: All dimensions are in mm.

41



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

MOUNTING LOCATIONMODEL: ASW060B


42

LOAD DISTRIBUTION, kgMODEL No. R1 R2 R3 R4 R5 R6

ASW060 299 283 275 253 238 230

ASW070 323 308 300 290 274 266

ASW080 404 389 381 330 315 307

ASW095 414 398 390 339 323 315

ASW105 433 417 409 377 361 353

ASW115 454 438 430 396 380 373

ASW135 582 551 535 500 469 453

ASW150 751 719 704 588 557 541

ASW160 760 729 713 605 574 558

ASW185 806 774 758 677 645 630

ASW210 814 783 767 692 660 645

ASW230 856 824 809 730 699 683

ASW245 1133 1094 1074 942 903 883

ASW280 1166 1127 1107 980 941 921

ASW300 1192 1152 1133 1031 992 972

ASW315 1193 1154 1134 1032 993 973

ASW345 1269 1229 1210 1114 1075 1055

ASW355 1490 1443 1420 1229 1182 1158

ASW370 1546 1499 1475 1338 1290 1267

ASW395 1549 1502 1478 1344 1297 1273

ASW420 1588 1541 1517 1418 1371 1347

ASW445 1679 1632 1608 1502 1455 1432

ASW465 1682 1634 1611 1504 1456 1433

MODELS: ASW060B - ASW115B MODELS: ASW135B - ASW465B

asw series

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