Air Cooled Scroll Water ChillersWith hydronic kit option

ALY Series, R-22ALY010A thru ALY190A

10 TR thru 190 TR35 kW thru 670 kW

AquaChill

Company BusinessZamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be established in Saudi Arabiaand today is a leading international manufacturer of air conditioning systems and is Number One in the Middle East.

Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55countries 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 andservice 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 Zamil, Cooline, GE and OEM brands for commercial and industrial customers.3. Zamil CoolCare Business Unit providing industrial, electro mechanical contracting services, HVAC maintenance,

retrofit & operation services and parts.4. Geoclima srl is an independent business supporting other SBUs for their requirements of chillers & double skin AHU’s.

The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare direct their business operationsfrom the corporate headquarters in Dammam, Saudi Arabia.

Geoclima has its engineering & production operations 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 atits 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 specialty production facilityin Italy operated by Geoclima.

The company can produce up to 550,000 Room Air Conditioners, 300,000 Mini-Split systems and 50,000 Central AirConditioning systems per year.

Quality & Product CertificatesThe Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 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 (Certified Performance)

4. ETL (Test Facilities)

5. SASO (Saudi Arabian Standards Organization)

6. ISO 9001:2008 (International Organization for Standardization)

7. ASME (American Quality of Mechanical Engineers)

Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammedbin 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 Condition-ers manufacturers a host of residential, commercial and industrial air conditioners. This broad range extends from theConcealed Units up to 5 TR, the Ducted Splits up to 30 TR, the Packaged Units up to 95 TR, the Single and Double SkinAir Handling Units up to 138,316 CFM and the Water Chillers up to 500 TR cooling capacity.

INDEX

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

Contents Page

Model decoding ........................................................................................................................................ 2

Introduction ........................................................................................................................................... 3-5

Unit features, standard specifications & options.................................................................................. 6-10

Physical data ..................................................................................................................................... 11-13

Selection procedure .......................................................................................................................... 14-15

Performance data .............................................................................................................................. 16-21

Electrical data .................................................................................................................................... 22-25

Water side pressure drop ....................................................................................................................... 26

Unit dimensions ................................................................................................................................ 27-30

Typical schematic wiring diagram ...................................................................................................... 31-34

Microprocessor controller ....................................................................................................................... 35

Application guidelines ........................................................................................................................ 36-40

Rigging instructions ................................................................................................................................ 41

Installation clearance .............................................................................................................................. 42

Mounting location ................................................................................................................................... 43

Load distribution ................................................................................................................................ 44-45

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INTRODUCTIONZamil Air cooled scroll chillers (ALY series) are the heart of most central Air Conditioning systems for medium sizebuildings. They consist of one or more hermetic scroll compressors, air-cooled condenser coils with condenser fan(s) andmotor(s), insulated liquid cooler, expansion device, interconnecting refrigerant piping, oil & refrigerant charge, controlpanel, wiring and other auxiliaries. As an option, integrated to these chillers are the pump, valves, expansion tank andother accessories

ALY series, The new generation of air cooled packaged liquid chillers.

ALY series air cooled scroll chillers are available in capacity range 10 TR (35 kW) to 190 TR (670 kW) at ARI conditions,in one single enclosure, utilizing refrigerant R-22 as working fluid with option of three different power supply ratings.

ALY series chillers have been designed and manufactured to meet the requirements of the Gulf’s severe climatic condi-tions and specifically for outdoor installation, on roofs or ground level. They are factory assembled, leak tested, evacu-ated, internally wired, fully charged with refrigerant. Each ALY chiller is fully factory tested before delivery and is ready forinstallation. All what required on site is to connect chilled water pipes and main power supply.

Scroll Compressor:The scroll compressor consists of two involutes or Archimedean spirals (Figure-1). One spiral is positioned inside theother to form a series of recent-shaped pockets. During compression the upper spiral remains stationary and the lowerone, being eccentrically mounted on the drive shaft, describes an orbital rather than a simple rotary motion.

3

How a Scroll Compressor works:

Compression in the scroll is created by the interaction of an orbiting spiral and a stationaryspiral. A refrigerant enters the outer openings as one of the spirals orbits.

The open passages are sealed off as gas is drawn into the spiral.

As the spiral continues to orbit, the gas is compressed into two increasingly smaller pockets.

By the time the gas arrives at the center port, discharge pressure has been reached.

Actually, during operation, all six gas passages are in various stages of compression at alltimes, resulting in nearly continuous suction and discharge.

4

FIGURE- 1

Refrigerant enters the compressor at the suction connection and flows around the motor’s housing and enters at thebottom side through the openings.

Oil droplets separate from the refrigerant and fall into the oil sump.

All suction refrigerant passes through the electrical motor, ensuring full motor cooling.

After that the refrigerant enters the scroll elements.

COOLERS1. Compact Design Shell and Tube Water Coolers (for models ALY020A - ALY190A)The DX shell and tube cooler with removable ‘U’ shaped bundled tubes are made of internally grooved copper tubesexpanded into heavy steel tubular sheets. The cooler housing and baffles are constructed of steel and brass respectively.All coolers are fitted with vent, drain connection and Victaulic type water pipe connections.

2. Coaxial Heat Exchangers: (for models ALY010A - ALY015A)The heat exchangers utilize a spirally enhanced inner tube surface to achieve greater heat transfer and optimized fluidflow. The inner tube enhancement provides greater efficiency than straight tubing and allows for higher internal burstlimits and compression strength.

Both above types of coolers are insulated with heavy closed cellular foam insulation (3/4” thick).

5

WATER SIDE REFRIGERANT SIDE

DESIGN PRESSURE,(BAR/PSIG)

TEST PRESSURE,(BAR/PSIG)

DESIGN PRESSURE,(BAR/PSIG)

TEST PRESSURE,(BAR/PSIG)

UNIT MODEL

22.8/335ALY010A - ALY190A

ALY020A - ALY190A 10/147 11.3/165 15.5/228 23.3/342

COOLER

STD

ASME (option)

16/235 29/426 41.5/610

Tandem Compressor:Models ALY055A to ALY190A use tandem scroll compressors. Tandem scroll compressors make possible great flexibil-ity in system design for a wide range of applications. Since each compressor may be operated individually, this designprovides simple, capacity reduction & maximum power savings and greatly simplifies system control. In any well de-signed system, this kind of design offers a much greater factor of redundancy than a single compressor and providesemergency protection for the product. In addition to greater reliability, one great advantage of the multiple compressordesign over other large horsepower compressors is the fact that in the event of compressor damage, replacement ofeither compressor in the tandem can be easily done.

FEATURESThese ALY series, packaged air cooled water chillers are designed to provide engineering excellence in comfort airconditioning and industrial cooling with a superior combination of energy saving, performance, application flexibility, easeof service & maintenance and withstanding extremely high ambient temperatures. These chillers incorporate a widerange of features including:

* Microprocessor controller, which monitors analog and digital inputs to achieve precise control & protective functionsof the air cooled water chiller units. The microprocessor controller is complete with all the hardware and softwarenecessary to control the chiller unit and ensures its efficiency and reliability.

* Compact unit design and open base design provides easy access and service to the major components and acces-sories.

* All units incorporate separate subcooler circuit which is integral to the condenser surface. This additional subcoolingcircuit provides superior system performance.

* High Energy Efficiency Ratio (EER) hermetic scroll compressors.

* Single point power connection to minimize job site installation cost and time.

* Completely wired control panel with the advanced microprocessor controller that provides all the necessary opera-tions and safety controls.

* Made ready connection for remote ON/OFF switch and General Alarm output.

* Compressor connections are Direct On Line (DOL) for all models (see electrical data).

* Low noise condenser fans, direct drive at 1000 RPM with rolled form venturi design to eliminate airflow recycling &short circuiting .

* Condenser fans are die-cast aluminum (for models ALY030A – ALY190A) or aluminum plates (for models ALY010A– ALY025A) type with aerodynamic design, top discharge & provided with protective grille mounted on top panelwithin the unit casing.

* All condenser fan motors are totally enclosed air over type (TEAO) with class ''F'' winding insulation.

CAPACITY CONTROLThe Zamil air cooled scroll water chillers incorporate stepped load shedding as required by most energy managementsystems. Modulation of capacity in response to system load requirements is affected by the microprocessor controllerwhich monitors the leaving water temperature.

Capacity control is achieved by cycling compressors ON/OFF and sequential operation of compressors which providesoptimal part load capacities for chillers with multiple compressors.See the following table for the standard and optional capacity control for each unit.

STANDARD SPECIFICATIONS

% FULL LOAD CAPACITY CONTROL

STANDARD OPTIONAL MODEL NUMBER

ALY010A-ALY015AALY020A - ALY045AALY055A -ALY090AALY100A - ALY140AALY160A -ALY190A

100-OFF100-50-OFF

100-75-50-25-OFF100-83-67-50-33-17-OFF

100-88-75-63-50-38-25-12-OFF

100-HGBP-OFF100-50-HGBP-OFF

100-75-50-25-HGBP-OFF100-83-67-50-33-17-HGBP-OFF

100-88-75-63-50-38-25-12-HGBP-OFF

NOTES:1. HGBP = Hot gas bypass available on lead compressor for all models (optional).2. HGBP modulates to approximately 50% of compressor step capacity. Example: ALY055 with HGBP (25% x 0.5=12.5%

minimum capacity).

6

CONDENSER COILSVertical & V-configurations condenser coils are corrugated fin and tube type, constructed of seamless 3/8" dia. & 0.011"(0.27 mm) thick copper tubes, mechanically bonded to aluminum fins for maximum heat transfer efficiency.As a standard on aluminum fins, ZAC provides Coil ResisTec Coating, which is a single component of aluminum impreg-nated coating applied on the fins of heat exchanging coils. The product has been designed for Middle East climate condi-tions. A high chemical, abrasion and UV resistance has been proven in both laboratories and on field environment. Thecoating can be applied at the Zamil Air Conditioners factory as well as in the field for maintenance or rejuvenation purposes.The fins have full self spacing collars which completely cover each tube. The staggered tube design improves thethermal efficiency. End plates support sheets are 14 gauge galvanized steel, formed to provide structural strength.Each coil is pressure tested in the factory at not less than 450 psi air pressure.

CABINETAll units are of heavy gauge (G-90) galvanized steel. Steel sheet panels are zinc coated and galvanized by hot dipprocess of lock-forming quality conforming to ASTM A 653 commercial weight G-90 followed by baked on electrostaticpolyester dry powder coat.

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

MICROPROCESSOR CONTROLLERA new compact electronic controller with a complete management for air cooled water chiller control capability. Thiscontroller manages the analog and digital inputs to achieve precise operation and safety function of the chiller unit.

A user friendly display interface allows to access the operating condition, control set point & alarm of the unit that areclearly visible on its display board.

The controller is equipped with a compressor rotation operation to allow the compressor running hours to be balanced(lead lag). The controller has feasibility to be connected to a supervisor network via RS485 serial line for RemoteMonitoring and Remote configuration of the unit parameters.

The controller consists of the following hardware:1. Control board - complete control of function and safety operation of the compressor(s) and fan(s).2. Aux. Board - Expansion Board to control 2 compressors.3. Remote Monitoring System (optional) - Remote Monitoring & Configuration of the unit.4. User interface Board/Remote Terminal (optional) - Provided with a simple to use push button to access the operating

condition, control set point and alarms of the unit.

Access of the following status on the display:1. Water inlet / outlet Temperature2. Compressor Status3. Fan Status4. Alarms5. SI or English Unit6. Pump ON/OFF status (optional)

System Protection:1. Compressor Winding High Temperature / Overloading2. Low / High Pressure3. Evaporator freeze Protection4. Sensor Error5. Time delay - Anti recycle time for compressor6. No Water Flow or Trip Pump condition7. Motor pump overloading (with optional hydronic module)

7

CONDENSER FANSCondenser fans are constructed of die cast aluminum blades/hubs with direct driven motors. All fans are statically anddynamically balanced to operate at minimum noise and vibration. Fan blades are designed with appropriate pitch anglewhich result in maximum airflow through the condenser coil.

CONDENSER FAN MOTORCondenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phasewith class ''F'' winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosedair over type (TEAO) with inherent thermal protection of automatic reset type & specially designed for outdoor applica-tions.

STANDARD CONTROL & SAFETY DEVICESMICROPROCESSOR CONTROLLER: This controller monitors the analog and digital inputs to achieve precise control& safety functions of the unit.

COMPRESSOR MOTOR INTERNAL OVERLOAD: The internal overload protects the compressor and senses themotor winding temperature in case of overload.

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.

UNDER/OVER VOLTAGE AND PHASE PROTECTION: Protects against low/over incoming voltages as well as singlephasing, phase reversal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but itcan be set up for manual reset.

CRANKCASE HEATERS: Each compressor has crankcase heater. The compressor crankcase heater is always onwhen the compressors are de-energized. This protect the system against refrigerant migration, oil dilution and potentialcompressor failure.

HIGH PRESSURE SWITCH: This switch provides an additional safety protection in the case of excessive dischargepressure.

LOW PRESSURE SWITCH: This switch provides an additional safety protection in the case of unsafe low suctionpressure.

CIRCUIT BREAKERS: Protects against compressor/condenser fans/pump branch circuit fault. When tripes, the breakeropens the power supply to the compressor/condenser fans/pump and control circuit through auxiliary contacts.

STANDARD ACCESSORIESUNIT ON-OFF SWITCH: ON-OFF switch is provided for manually switching the unit control circuit.

USER DISPLAY AND KEYPAD: Display the status of the unit, menu and setting adjustments, fault indications due totrips and reset trips and lockouts.

THERMAL EXPANSION VALVE: Thermal expansion valve is used to regulate the refrigerant flow to the water coolerand maintain a constant superheat.

REPLACEABLE FILTER DRIER: Refrigerant circuits are kept free of harmful moisture, sludge, acids and oil contami-nating particles by the filter drier.

CONTROL CIRCUIT TRANSFORMER: A factory mounted and wired control circuit transformer is furnished eliminatingthe need for running a separate 220 volt power supply to the unit control circuit.

SIGHT GLASS: A moisture indicating sight glass installed in the liquid line. An easy-to-read color indicator showsmoisture 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.

8

OPTIONSHOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50% ofits unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor onand 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 circuits. Interlock into unit safety circuitsso that the unit will remain off until water flow is determine.SUCTION AND DISCHARGE VALVES: To isolate the compressor in order to facilitate servicing or compressor replacement.UNIT MOUNT SPRING ISOLATORS: These housed spring assemblies have a neoprene friction pad on the bottom toprevent vibration transmission.LIQUID COOLERS: ASME code stamped liquid cooler (for models ALY020A - ALY190A only).PRESSURE GAUGES: Suction & discharge pressures gauges.SAFETY VALVE: This valve protects the unit against high discharge pressure in the system due to malfunction of highpressure switches.NON-FUSED MAIN DISCONNECT SWITCHES: To disconnect power supply of the unit for servicing and repair works. Thisas well equipped with door interlock device.CONDENSER COIL GUARD: Protect the condenser coil from physical damage.COMPRESSOR/COOLER GUARD: Protect the compressor from vandalism (for models ALY020A - ALY190A only).COOLER HEATER WRAPPED: Prevent freezing up of water on low ambient temperature.COPPER FINS/TUBES CONDENSER COILS: For seashore salty corrosive environments.ResisTec COATED COPPER FINS/TUBES CONDENSER COILS: For seashore or acid corrosive environments.BMS: BACNET, MODBUS, LON works and remote monitoring.MULTI ResisTec: A two component coating system that withstands the extreme climate conditions. The coating can be appliedto all metal parts of HVAC equipment; the piping, the compressors and grids might require a different pre- treatment and layerbuild up. Please check ResisTec product information sheets, the heat exchangers can not be coated using this type. Thecoating can be applied at the Zamil Air Conditioners factory as well as in the field for maintenance or rejuvenation purposes.HYDRONIC KIT: The Hydronic Module comprises of centrifugal pump, closed diaphragm type expansion tank, carbon steelpiping, piping connections with butterfly valves, calibrated balancing valve, strainer, pressure gauges, temperature gauges,additional pressure/temperature tappings, water flow switch, pressure safety valve, automatic air vents, make-up water linewith isolation valve, non-return valve and pressure reducing valve. Complete piping system within the hydronic moduleshall be provided with closed cell, rubber insulation.

The hydronic module is suitably designed for the respective chiller model(s) with various components appropriatelyselected for the design water flow rate of chiller model(s) in concern. The dynamic pump head available external to thechillers progressively increases across the chiller models and ranges between 50 - 140 Feet WG.

9

EXPANSION TANK END SUCTION WATER PUMP

10

SCHEMATIC HYDRONIC SYSTEM LAYOUT

UNIT SIZE ALY010A ALY015A ALY020A ALY025A ALY030A ALY035A ALY040A

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-674-36 800-614-83 800-674-36 (2) 800-614-83 (2) 800-674-82 (2)

380V-3Ph-60Hz 800-674-37 800-614-84 800-674-37 (2) 800-614-84 (2) 800-674-83 (2)

460V-3Ph-60Hz 800-674-38 800-614-85 800-674-38 (2) 800-614-85 (2) 800-674-84 (2)

NUMBER OF COMPRESSORS 1 1 2 2 2 2 2

NUMBER OF CIRCUITS 1 1 2 2 2 2 2

OIL CHARGE PER COMPRESSOR, Liters 3.25 3.13 3.25 3.13/3.25 3.13 4.7 6.8/4.7

% FULL LOAD CAPACITY CONTROL 100-0 100-0 100-50-0 100-50-0 100-50-0 100-50-0 100-50-0

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION CENTRIFUGAL OIL PUMP

REFRIGERANT R-22

EXPANSION VALVE DEVICE THERMOSTATIC

CONTROL VOLTAGE 220V-1Ph-60Hz

CONDENSERCONDENSER COIL Tube Dia.- Rows - Fins per inch 3/8–3–14 3/8–3–14 3/8–2–14 3/8–3–14 3/8–3–14 3/8–3–14

Total face area, Sq. ft. 13.9 27.8 44.4 44.4 44.4 44.4 53.3

AIRFLOW, CFM 7500 8200 16000 15000 25170 25170 25782

NUMBER OF FAN/FAN DIA.,mm 1/762 1/762 2/762 2/762 2/800 2/800 2/800

FAN MOTOR RPM @ 230/380/460-3-60 1100/1100/1100 1100/1100/1100 1100/1100/1100 1100/1100/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100

COOLERPART NUMBER 800-516-39 800-516-39 800-620-09 800-620-11 800-620-13 800-620-15 800-620-80

SHELL DIAMETER, mm N.A. N.A. 168 168 168 194 219

LENGTH, mm N.A. N.A. 1431 1631 1781 1815 1820

TOTAL WATER HOLDING VOLUME, Liters 6 6 17.2 19.8 21.7 30 41.8

WATER IN/OUT PIPE DIA.mm 38 38 64 64 64 76 76

GENERALREFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 6.4 12.7 6.4 9.5/7.3 9.5 12.2 15.9/12.2

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 68.9/65.4/60.1 65.6/62.1/56.8 71.9/68.4/63.1 68.6/65.1/59.8 68.6/65.1/59.8 72.6/69.1/63.8 72.7/69.2/64

SHIPPING /OPERATING WEIGHTS (Aluminum coil), kg 468/474 526/532 830/847 876/896 921/943 1145/1175 1258/1300

SHIPPING /OPERATING WEIGHTS (Copper coil), kg 500/506 588/594 893/910 972/992 1019/1041 1243/1273 1428/1470

HYDRONIC KIT (OPTIONAL)PUMP HP 2 2 2 3 3 3 5

PUMP RPM 3600 3600 3600 3500 3500 3500 3500

SHIPPING/OPERATING WT. WITH HYDRONIC KIT (Al. coil), kg 648/734 706/792 1050/1147 1096/1196 1141/1243 1365/1475 1478/1600

SHIPPING/OPERATING WT. WITH HYDRONIC KIT (CU. coil), kg 680/766 768/854 1113/1210 1192/1292 1239/1341 1463/1573 1648/1770

PHYSICAL DATA

800-614-83 800-674-17

800-614-84 800-674-18 800-614-85 800-674-19

NOTES: 1. All compressors operate at 3500 RPM @ 60Hz.2. Sound pressure level : ±2dBA.

11

800-676-89 800-674-82

800-676-90 800-674-83 800-676-91 800-674-84

3/8–4–143/8–3–14

12

UNIT SIZE ALY045A ALY055A ALY065A ALY070A ALY080A ALY090A ALY100A

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-676-89 (2) 800-614-83 (4) 800-674-82 (4) 800-676-89 (4)

380V-3Ph-60Hz 800-676-90 (2) 800-614-84 (4) 800-674-83 (4) 800-676-90 (4)

460V-3Ph-60Hz 800-676-91 (2) 800-614-85 (4) 800-674-84 (4) 800-676-91 (4)

NUMBER OF COMPRESSORS 2 4 4 4 4 4 6

NUMBER OF CIRCUITS 2 2 (TANDEM) 2 (TANDEM) 2 (TANDEM) 2 (TANDEM) 2 (TANDEM) 3 (TANDEM)

OIL CHARGE PER COMPRESSOR, Liters 6.8 3.13 4.7/3.13 4.7 6.8/4.7 6.8 4.7/3.13

% FULL LOAD CAPACITY CONTROL 100-50-0 100-75-50-25-0 100-75-50-25-0 100-75-50-25-0 100-75-50-25-0 100-75-50-25-0 100-83-67-50-33-17-0

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION CENTRIFUGAL OIL PUMP

REFRIGERANT R-22

EXPANSION VALVE DEVICE THERMOSTATIC

CONTROL VOLTAGE 220V-1Ph-60Hz

CONDENSERCONDENSER COIL Tube Dia.- Rows - Fins per inch 3/8–4–14 3/8–2–14 3/8–3–14 3/8–4–14

Total face area, Sq. ft. 53.3 88.9 88.9 88.9 106.7 106.7 133.3

AIRFLOW, CFM 25298 53076 51668 50340 51564 50596 76818

NUMBER OF FAN/FAN DIA.,mm 2/800 4/800 4/800 4/800 4/800 4/800 6/800

FAN MOTOR RPM @ 230/380/460-3-60 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100

COOLERPART NUMBER 800-620-80 800-620-84 800-620-88 800-620-88 800-620-92 800-621-01 800-621-02

SHELL DIAMETER, mm 219 273 273 273 273 324 324

LENGTH, mm 1820 1850 1850 1850 1850 2180 2180

TOTAL WATER HOLDING VOLUME, Liters 41.8 62.7 58.1 58.1 53.2 106.1 106.1

WATER IN/OUT PIPE DIA.mm 76 100 100 100 100 150 150

GENERALREFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 15.9 9.5 12.2/9.5 12.2 15.9/12.2 15.9 12.2/9.5

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 73.6/70/64.8 71.6/68.1/62.8 74/70.5/65.2 75.6/72.1/66.8 76.4/72.9/67.6 77.1/73.6/68.3 76.4/72.9/67.6

SHIPPING /OPERATING WEIGHTS (Aluminum coil), kg 1284/1326 1809/1872 1995/2053 2162/2220 2324/2377 2488/2594 3071/3177

SHIPPING /OPERATING WEIGHTS (Copper coil), kg 1454/1496 2005/2068 2190/2248 2358/2416 2613/2666 2830/2936 3332/3438

HYDRONIC KIT (OPTIONAL)PUMP HP 5 5 10 10 10 10 15

PUMP RPM 3500 3500 3500 3500 3500 3500 3500

SHIPPING/OPERATING WT. WITH HYDRONIC KIT (Al. coil), kg 1504/1626 2069/2217 2255/2398 2422/2565 2584/2722 2748/2939 3371/3545

SHIPPING/OPERATING WT. WITH HYDRONIC KIT (CU. coil), kg 1674/1796 2265/2413 2450/2593 2618/2761 2873/3011 3090/3281 3632/3806

PHYSICAL DATA

800-674-82 (2) 800-614-83 (2)

800-674-83 (2) 800-614-84 (2)800-674-84 (2) 800-614-85 (2)

NOTES: 1. All compressors operate at 3500 RPM @ 60Hz.2. Sound pressure level : ±2dBA.

800-674-82 (4)800-614-83 (2)

800-674-83 (4)800-614-84 (2) 800-674-84 (4)800-614-85 (2)

3/8–3–143/8–2–14

800-676-89 (2) 800-674-82 (2)

800-676-90 (2) 800-674-83 (2) 800-676-91 (2) 800-674-84 (2)

3/8–3–143/8–2–14

3/8–4–143/8–3–14

13

UNIT SIZE ALY110A ALY120A ALY130A ALY140A ALY160A ALY170A ALY180A ALY190A

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-674-82 (6) 800-676-89 (6) 800-676-89 (8)

380V-3Ph-60Hz 800-674-83 (6) 800-676-90 (6) 800-676-90 (8)

460V-3Ph-60Hz 800-674-84 (6) 800-676-91 (6) 800-676-91 (8)

NUMBER OF COMPRESSORS 6 6 6 6 8 8 8 8

NUMBER OF CIRCUITS 3 (TANDEM) 3 (TANDEM) 3 (TANDEM) 3 (TANDEM) 4 (TANDEM) 4 (TANDEM) 4 (TANDEM) 4 (TANDEM)

OIL CHARGE PER COMPRESSOR, Liters 4.7 6.8/4.7 6.8/4.7 6.8 6.8/4.7 6.8/4.7 6.8/4.7 6.8

% FULL LOAD CAPACITY CONTROL 100-83-67-50-33-17-0 100-88-75-63-50-38-25-12-0

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION CENTRIFUGAL OIL PUMP

REFRIGERANT R-22

EXPANSION VALVE DEVICE THERMOSTATIC

CONTROL VOLTAGE 220V-1Ph-60Hz

CONDENSERCONDENSER COIL Tube Dia.- Rows - Fins per inch 3/8–3–14 3/8–4–14 3/8–4–14

Total face area, Sq. ft. 133.3 160 160 160 133.3 133.3 160 160

AIRFLOW, CFM 75510 77838 76854 75894 104120 103128 102152 101192

NUMBER OF FAN/FAN DIA.,mm 6/800 6/800 6/800 6/800 8/800 8/800 8/800 8/800

FAN MOTOR RPM @ 230/380/460-3-60 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100

COOLERPART NUMBER 800-621-02 800-621-06 800-621-10 800-621-10 800-620-54 800-620-54 800-620-57 800-620-60

SHELL DIAMETER, mm 324 324 324 324 324 324 406 406

LENGTH, mm 2180 2180 2180 2180 2693 2693 2737 2737

TOTAL WATER HOLDING VOLUME, Liters 106.1 99.8 89.8 89.8 113.5 113.5 221.7 206.5

WATER IN/OUT PIPE DIA.mm 150 150 150 150 150 150 200 200

GENERALREFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 12.2 15.9/12.2 15.9/12.2 15.9 15.9/12.2 15.9/12.2 15.9/12.2 15.9

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 77.4/73.9/68.6 77.9/74.4/69.1 78.4/74.9/69.7 78.9/75.4/70.1 79/75.5/70.2 79.4/75.9/70.6 79.8/76.3/71 80.1/76.6/71.3

SHIPPING /OPERATING WEIGHTS (Aluminum coil), kg 3265/3371 3461/3561 3569/3659 3657/3747 4495/4608 4196/4309 4851/5073 4970/5176

SHIPPING /OPERATING WEIGHTS (Copper coil), kg 3559/3665 3866/3966 4028/4118 4167/4257 5017/5130 4483/4596 5480/5702 5650/5856

HYDRONIC KIT (OPTIONAL)PUMP HP 15 15 15 15 20 20 20 20

PUMP RPM 3500 3500 3500 3500 3500 3500 3500 3500

SHIPPING/OPERATING WT. WITH HYDRONIC KIT (Al. coil), kg 3565/3739 3761/3929 3869/4027 3957/4115 4845/5058 4546/4759 5201/5523 5320/5626

SHIPPING/OPERATING WT. WITH HYDRONIC KIT (CU. coil), kg 3859/4033 4166/4334 4328/4486 4467/4625 5367/5580 4833/5046 5830/6152 6000/6306

PHYSICAL DATA

NOTES: 1. All compressors operate at 3500 RPM @ 60Hz.2. Sound pressure level : ±2dBA.

3/8–4–143/8–3–14

3/8–4–143/8–3–14

3/8–4–143/8–3–14

800-676-89 (2) 800-674-82 (4)

800-676-90 (2) 800-674-83 (4) 800-676-91 (2) 800-674-84 (4)

3/8–4–143/8–3–14

3/8–4–143/8–3–14

800-676-89 (4) 800-674-82 (2)

800-676-90 (4) 800-674-83 (2) 800-676-91 (4) 800-674-84 (2)

800-676-89 (2) 800-674-82 (6)

800-676-90 (2) 800-674-83 (6) 800-676-91 (2) 800-674-84 (6)

800-676-89 (4) 800-674-82 (4)

800-676-90 (4) 800-674-83 (4) 800-676-91 (4) 800-674-84 (4)

800-676-89 (6) 800-674-82 (2)

800-676-90 (6) 800-674-83 (2) 800-676-91 (6) 800-674-84 (2)

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 (LCWT)3. Chilled water flow rate in GPM4. Chilled water cooling range in 0F (water in temp. _ water out temp.)5. Design ambient temperature6. Minimum ambient temperature7. Altitude8. Electrical power supply

SAMPLE SELECTIONSelect an Air Cooled Packaged chiller for the following conditions:Required system capacity is 33 tons at 540F entering chilled waterand 440F leaving water. Design ambient temperature is 950F.Altitude is 2000 feet above sea level.Water cooler fouling factor is 0.00010. Power supply: 380V-3Ph-60Hz.

STEP-1: UNIT SELECTIONEntering the capacity performance data at given LCWT and ambient temperature.ALY035 chiller unit at sea level will produce 36.5 tons and 39.8 kW compressorpower input at 440F leaving chilled water temperature with 100F water temperaturedifference and 950F ambient temperature.

For the conditions required, the unit actual cooling capacity when corrected foraltitude (0.99) and fouling factor (1.0).Capacity = 36.5x0.99x1.0 = 36.1 Tons, which then exceeds the requirements.So the selection is correct.

STEP-2: CHILLED WATER FLOW (GPM):

Water GPM = Required capacity (Tons) x 24

= 33 x 24

= 79.2 GPM Cooling Range, ∆T 100F

SELECTION PROCEDURE (English units)

ELEVATION ABOVESEA LEVEL (FT.)

CAPACITYCORRECTION

FACTOR0

200040006000

1.000.990.980.97

TABLE - 1

TABLE - 2

Referring to pressure drop chart (page # 26), pressure drop at 79.2 GPM = 8.65 ft. of water for selected model.

STEP-3: ELECTRICALRefer to electrical data at 380V-3Ph-60Hz, the main power wire size for ALY035 is to be sized at a minimum circuitampacity (MCA) of 101 Amps and the main branch protection device is to be sized at a maximum over current protection(MOCP) of 143 Amps.

STEP-4: CHILLED WATER PUMP SELECTIONFor chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure dropcalculated in step 2.

STEP-5: LCWT CORRECTIONRefer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water tempera-ture range is above 100F and subtract correction from design leaving chilled water temperature (LCWT) when watertemperature range is below 100F.EXAMPLE:If LCWT rise is 12.50F, enter correction curve at 12.50F and read the correction factor of 0.2. The corrected LCWT is44+0.2 = 44.20F.

NOTE: 1. When the chilled water temperature rise is less than 50F, the high water flow rate will result to excessivepressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.

2.Please refer to water pressure drop curves.

14

TABLE - 3CHILLED WATER TEMPERATURE RISE (0F)

CO

RR

ECTI

ON

FA

CTO

R (0 F)

0

-0.2

-0.45 10

+0.4

+0.2

+0.6

15 20

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

SELECTION PROCEDURE (Metric units)

ELEVATION ABOVESEA LEVEL (Meter)

CAPACITYCORRECTION

FACTOR0

60012001800

1.000.990.980.97

TABLE - 1

Referring to pressure drop chart (page # 26), pressure drop 4.85 LPS = 25.85 kPa for selected model.

STEP-3: ELECTRICALRefer to electrical data at 380V-3Ph-60Hz, the main power wire size for ALY035 is to be sized at a minimum circuitampacity (MCA) of 101 Amps and the main branch protection device is to be sized at a maximum over current protection(MOCP) of 143 Amps.

STEP-4: CHILLED WATER PUMP SELECTIONFor chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure dropcalculated in step 2.

STEP-5: LCWT CORRECTIONRefer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water tempera-ture range is above 60C and subtract correction from design leaving chilled water temperature (LCWT) when watertemperature range is below 60C.EXAMPLE:If LCWT rise is 7.40C, enter correction curve at 7.40C and read the correction factor of 0.11. The corrected LCWT is60C+0.11 = 6.110C.

NOTE: 1. When the chilled water temperature rise is less than 30C, the high water flow rate will result to excessivepressure 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 - 2

DESIGN REQUIREMENTSThe following design requirements must be known to select a proper package chiller.1. Required cooling capacity in kilowatt (kW)2. Leaving chilled water temperature in 0C (LCWT)3. Chilled water flow rate in LPS4. Chilled water cooling range in 0C (water in temp. _ water out temp.)5. Design ambient temperature6. Minimum ambient temperature7. Altitude8. Electrical power supply

SAMPLE SELECTIONSelect an Air Cooled Packaged chiller for the following conditions:Required system capacity is 122 kW at 120C entering chilled waterand 60C leaving water. Design ambient temperature is 350C.Altitude is 600 meter above sea level.Water cooler fouling factor is 0.000018. Power supply: 380V-3Ph-60Hz.

STEP-1: UNIT SELECTIONEntering the capacity performance data at given LCWT and ambient temperature.ALY035 chiller unit at sea level will produce 126.7 kW and 39.6 kW compressorpower input at 60C leaving chilled water temperature with 60C water temperaturedifference and 350C ambient temperature.

For the conditions required, the unit actual cooling capacity when corrected foraltitude (0.99) and fouling factor (1.0).Capacity = 126.7x0.99X1.0 = 125.4 kW, which then exceeds the requirements.So the selection is correct.

STEP-2: CHILLED WATER FLOW (LPS):

Water LPS = Required capacity (kW) x 0.239

= 122 x 0.239

= 4.85 LPS Cooling Range, ∆T 60C

15

TABLE - 3CHILLED WATER TEMPERATURE RISE (0C)

CO

RR

ECTI

ON

FA

CTO

R (0 C

)

+0.33

+0.22

+0.11

-0.11

-0.2254 6 7 8

0

109

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

42 0 F

40 0 F

ALY

010

A8.

69.

69.

6620

.68.

110

.78.

2919

.67.

711

.97.

0818

.47.

312

.96.

3217

.6A

LY 0

15A

1314

.79.

8931

.212

.416

.58.

4429

.611

.618

.47.

1527

.911

.119

.96.

3526

.7A

LY 0

20A

17.9

19.4

9.92

42.9

16.9

21.7

8.5

40.6

15.9

24.2

7.25

38.3

15.2

26.1

6.46

36.5

ALY

025

A24

.427

.59.

8758

.623

.130

.78.

4155

.321

.634

.27.

151

.820

.536

.96.

2849

.2A

LY 0

30A

27.2

27.9

10.5

765

.425

.931

.39.

0662

.224

.535

.17.

7258

.923

.538

6.87

56.3

ALY

035

A34

.238

.99.

7982

.132

.243

.68.

2877

.229

.948

.96.

9271

.828

.253

6.05

67.7

ALY

040

A40

.444

.310

.26

97.1

38.1

49.3

8.73

91.4

35.6

54.9

7.38

85.4

33.7

59.1

6.52

81A

LY 0

45A

46.1

50.8

10.2

711

0.6

43.4

56.3

8.79

104.

240

.762

.27.

4997

.738

.866

.66.

6993

ALY

055

A55

.456

10.7

113

2.9

52.6

62.9

9.16

126.

249

.670

.47.

7911

9.1

47.4

76.2

6.92

113.

8A

LY 0

65A

62.5

66.8

10.3

150

59.1

74.8

8.77

141.

755

.383

.87.

3813

2.7

52.4

90.7

6.51

125.

8A

LY 0

70A

68.6

77.9

9.8

164.

664

.487

.38.

2915

4.6

59.8

97.8

6.92

143.

656

.410

5.9

6.04

135.

2A

LY 0

80A

80.9

88.6

10.2

619

4.2

76.2

98.7

8.74

182.

971

.210

9.8

7.38

171

67.6

118.

26.

5316

2.2

ALY

090

A93

.510

2.3

10.3

622

4.5

88.2

113.

38.

8821

1.7

82.8

125.

17.

5819

8.8

7913

3.9

6.77

189.

5A

LY 1

00A

9610

8.1

9.83

230.

390

.412

1.1

8.34

217

84.3

135.

67

202.

479

.714

6.7

6.15

191.

4A

LY 1

10A

102.

911

6.9

9.81

247

96.8

131

8.3

232.

289

.914

6.8

6.93

215.

984

.815

96.

0620

3.5

ALY

120

A11

5.3

126.

310

.22

276.

810

8.6

141

8.69

260.

710

1.4

157.

27.

3224

3.4

96.1

169.

66.

4623

0.6

ALY

130

A12

613

9.1

10.2

130

2.4

118.

815

4.6

8.71

285

111.

117

1.6

7.38

266.

710

5.6

184.

46.

5525

3.3

ALY

140

A13

7.3

152.

210

.23

329.

612

9.5

168.

68.

7531

0.8

121.

518

6.2

7.47

291.

511

5.7

199.

36.

6627

7.7

ALY

160

A15

4.5

165.

810

.43

370.

814

6.2

185.

28.

8935

0.8

137.

220

77.

5132

9.2

130.

522

3.7

6.64

313.

1A

LY 1

70A

164.

617

8.3

10.3

839

4.9

155.

519

8.7

8.86

373.

314

622

1.2

7.51

350.

413

923

8.2

6.67

333.

7A

LY 1

80A

176.

219

1.6

10.3

942

2.9

166.

221

2.7

8.88

398.

915

5.9

235.

77.

5537

4.1

148.

425

36.

7235

6.2

ALY

190

A18

5.6

204

10.3

144

5.5

175

225.

98.

8342

016

4.1

249.

47.

5339

3.8

156.

326

76.

7337

5.2

ALY

010

A9

9.7

10.0

621

.78.

610

.88.

6420

.68.

112

.17.

3919

.57.

813

6.6

18.6

ALY

015

A13

.714

.910

.27

32.9

1316

.78.

7631

.212

.218

.77.

4329

.411

.720

.26.

628

.1A

LY 0

20A

18.8

19.7

10.3

445

.217

.822

8.86

42.8

16.8

24.5

7.56

40.3

1626

.46.

7438

.5A

LY 0

25A

24.8

27.6

9.99

59.6

23.5

30.9

8.52

56.3

2234

.47.

2152

.820

.937

.16.

3850

.2A

LY 0

30A

28.6

28.2

1168

.827

.331

.79.

4365

.425

.835

.58.

0361

.924

.738

.47.

1559

.2A

LY 0

35A

35.6

39.4

10.0

685

.433

.544

.28.

5280

.431

.249

.57.

1374

.829

.553

.66.

2570

.7A

LY 0

40A

41.4

44.7

10.4

299

.339

49.7

8.88

93.7

36.5

55.3

7.52

87.6

34.7

59.5

6.66

83.2

ALY

045

A46

.751

.110

.36

112.

144

56.6

8.87

105.

741

.362

.57.

5799

.239

.466

.96.

7694

.5A

LY 0

55A

57.1

56.4

10.9

713

754

.363

.39.

3913

0.2

51.2

70.9

7.99

122.

949

76.7

7.11

117.

6A

LY 0

65A

64.2

67.3

10.5

115

4.2

60.8

75.4

8.96

145.

857

84.5

7.56

136.

754

.191

.46.

6712

9.9

ALY

070

A70

.478

.69.

9816

8.9

66.2

888.

4515

961

.798

.77.

0714

858

.310

6.8

6.2

139.

8A

LY 0

80A

8389

.410

.44

199.

378

.399

.58.

918

7.9

73.2

110.

77.

5317

5.8

69.6

119.

16.

6716

6.9

ALY

090

A94

.510

2.7

10.4

322

6.8

89.2

113.

88.

9421

4.1

83.8

125.

77.

6420

1.1

8013

4.5

6.83

191.

9A

LY 1

00A

99.4

109.

310

.08

238.

693

.812

2.4

8.56

225

87.6

137.

17.

221

0.2

8314

8.3

6.33

199.

2A

LY 1

10A

106.

611

8.3

10.0

525

5.9

100.

413

2.5

8.52

241

93.6

148.

57.

1322

4.5

88.4

160.

76.

2521

2.2

ALY

120

A11

8.5

127.

510

.42

284.

511

1.8

142.

28.

8726

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104.

515

8.6

7.49

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16.

6123

8.1

ALY

130

A12

8.7

140.

110

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812

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155.

78.

8429

1.3

113.

817

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7.51

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8.3

185.

76.

6725

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ALY

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110

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169.

58.

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123.

418

7.3

7.55

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311

7.7

200.

56.

7428

2.5

ALY

160

A15

7.6

166.

810

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186.

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7.62

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9.4

ALY

170

A16

7.4

179.

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6.5

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6.75

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5A

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80A

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168.

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8.96

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515

8.2

236.

97.

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ALY

190

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205.

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7.7

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28.

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6.5

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6.76

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ALY

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61.7

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31.2

8.75

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22.8

34.8

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21.7

37.5

6.57

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ALY

030

A29

.628

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LY 0

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2.9

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3.6

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66.

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2.8

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8A

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ALY

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6.8

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LEAV

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ALY

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11.2

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536

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5435

13.8

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8.11

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20.9

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ALY

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8.31

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3.5

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8.4

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7.3

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1.6

ALY

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7.9

156.

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9.6

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319

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7.03

301

ALY

160

A17

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171.

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412.

216

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639

1.7

154.

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369.

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7.4

231.

67.

2635

3.7

ALY

170

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4.1

11.0

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116

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8A

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193.

219

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68.

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6.6

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9A

LY 1

90A

199.

120

9.8

10.7

747

7.8

188.

123

2.2

9.25

451.

617

725

6.4

7.92

424.

916

9.2

274.

57.

0940

6A

LY 0

10A

11.4

10.3

12.0

427

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2610

.212

.88.

8624

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813

.77.

9223

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LY 0

15A

16.8

15.8

11.9

140

.416

.117

.810

.21

38.5

15.2

19.9

8.71

36.5

14.6

21.5

7.76

35.1

ALY

020

A24

.921

.212

.74

59.7

2423

.711

.08

57.5

2326

.59.

655

.122

.228

.68.

6653

.4A

LY 0

25A

29.9

29.2

11.4

271

.828

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7868

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.836

.58.

3264

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.639

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4161

.5A

LY 0

30A

35.8

29.9

13.0

786

34.3

33.5

11.2

782

.432

.737

.69.

6678

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6475

.5A

LY 0

35A

40.4

41.3

10.9

597

38.2

46.1

9.32

91.6

35.8

51.6

7.86

85.8

3455

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9381

.5A

LY 0

40A

46.2

46.5

11.2

111

0.9

43.7

51.7

9.59

104.

941

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1698

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.261

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2694

ALY

045

A50

.652

.810

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121.

547

.958

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3511

4.8

4564

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108.

143

.169

.17.

1710

3.3

ALY

055

A66

.658

.612

.38

159.

963

.465

.710

.61

152.

159

.973

.59.

0414

3.7

57.3

79.5

8.04

137.

6A

LY 0

65A

75.5

70.7

11.8

118

1.2

71.6

79.1

10.1

171.

967

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5716

264

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.77.

615

4.6

ALY

070

A82

.583

.211

.119

878

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9.46

187.

473

.310

4.1

7.99

175.

969

.711

2.6

7.06

167.

4A

LY 0

80A

91.9

92.8

11.1

622

0.5

86.9

103.

29.

5620

8.6

81.8

114.

78.

1319

6.3

78.1

123.

47.

2418

7.3

ALY

090

A10

3.6

106.

611

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248.

598

.411

8.1

9.51

236.

293

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0.7

8.18

223.

689

.414

0.3

7.34

214.

6A

LY 1

00A

110.

411

3.3

10.8

326

4.9

104.

312

6.7

9.23

250.

497

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1.7

7.79

234.

793

153.

26.

8822

3.1

ALY

110

A11

8.4

122.

810

.79

284.

311

1.9

137.

39.

1726

8.4

104.

715

3.7

7.73

251.

399

.416

6.2

6.81

238.

6A

LY 1

20A

129.

213

1.4

11.0

531

0.1

122.

214

6.4

9.44

293.

211

4.7

163.

18

275.

410

9.3

175.

87.

126

2.3

ALY

130

A14

3.2

145.

811

.134

3.7

135.

416

1.9

9.51

325.

112

7.4

179.

58.

1130

5.8

121.

619

2.8

7.23

292

ALY

140

A15

1.9

158.

510

.89

364.

714

3.7

175.

49.

3534

4.9

135.

319

3.7

8.01

324.

812

9.4

207.

47.

1731

0.5

ALY

160

A17

717

3.8

11.4

342

4.8

168.

319

49.

8140

415

9.1

216.

68.

3538

1.8

152.

323

47.

4336

5.5

ALY

170

A18

518

611

.21

444.

117

5.9

207.

29.

6342

2.1

166.

323

0.6

8.23

399.

215

9.4

248.

47.

3438

2.5

ALY

180

A19

8.6

200.

611

.21

476.

718

8.9

222.

89.

6645

3.4

178.

924

7.3

8.28

429.

417

1.7

265.

97.

4141

2.1

ALY

190

A20

4.2

212

10.9

449

0.2

193.

223

4.6

9.4

463.

718

225

9.1

8.06

436.

817

427

7.5

7.21

417.

6

LEAV

ING

CHIL

LED

WAT

ER T

EMP.

(LCW

T)

PER

FOR

MA

NC

E D

ATA

(Eng

lish

units

)

UN

ITSI

ZE

950 F

AM

BIE

NT

TEM

PER

ATU

RE

1050 F

AM

BIE

NT

TEM

PER

ATU

RE

1150 F

AM

BIE

NT

TEM

PER

ATU

RE

1220 F

AM

BIE

NT

TEM

PER

ATU

RE

CAP.

(Ton

s)C

OM

P.kW

EER

WAT

ERFL

OW

(GPM

)CA

P.(T

ons)

CO

MP.

kWEE

RW

ATER

FLO

W(G

PM)

CAP.

(Ton

s)C

OM

P.kW

EER

WAT

ERFL

OW

(GPM

)CA

P.(T

ons)

CO

MP.

kWEE

RW

ATER

FLO

W(G

PM)

18

LEG

END

:kW

-C

ompr

esso

r pow

er in

put

GPM

-G

allo

ns P

er M

inut

e

EER

-E

nerg

y E

ffici

ency

Rat

io

NO

TES:

1.P

acka

ged

chill

ers

are

rate

d w

ith A

RI s

tand

ard

550/

590.

2.P

erfo

rman

ce d

ata

are

base

d on

100 F

wat

er ra

nge

in e

vapo

rato

r.3.

Rat

ings

are

bas

ed o

n 0.

0001

0 (h

r-ft2 -

0 F/B

tu) f

oulin

g fa

ctor

for e

vapo

rato

r.4.

Dire

ct in

terp

olat

ion

is p

erm

issi

ble.

Do

not e

xtra

pola

te.

5.kW

pow

er in

put i

s fo

r com

pres

sor o

nly.

6.E

ER

for

ent

ire u

nit.

Ref

er to

ele

ctric

al d

ata

for f

an k

W.

5 0 C

4 0 C

ALY

010

A29

.89.

52.

81.

228

.410

.52.

41.

126

.611

.92.

01.

125

.412

.81.

81.

0A

LY 0

15A

44.5

14.6

2.8

1.8

42.4

16.2

2.5

1.7

39.8

18.2

2.1

1.6

37.9

19.8

1.8

1.5

ALY

020

A61

.619

.32.

92.

558

.621

.42.

52.

354

.924

.02.

12.

252

.325

.91.

92.

1A

LY 0

25A

86.1

27.5

2.9

3.4

81.7

30.4

2.5

3.3

76.1

34.2

2.1

3.0

72.1

36.9

1.8

2.9

ALY

030

A93

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03.

789

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63.

684

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.82.

23.

380

.337

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03.

2A

LY 0

35A

116.

138

.52.

84.

610

9.9

42.7

2.4

4.4

101.

648

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04.

195

.652

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73.

8A

LY 0

40A

141.

844

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05.

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4.3

48.8

2.6

5.4

124.

854

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25.

011

8.1

59.0

1.9

4.7

ALY

045

A16

1.7

50.8

3.0

6.4

153.

355

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66.

114

3.0

62.0

2.2

5.7

135.

966

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05.

4A

LY 0

55A

193.

556

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17.

718

4.8

62.1

2.7

7.4

173.

570

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36.

916

5.5

76.1

2.0

6.6

ALY

065

A21

9.1

66.7

3.0

8.7

208.

173

.92.

68.

319

3.7

83.5

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7.7

183.

490

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97.

3A

LY 0

70A

240.

677

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99.

622

7.4

86.2

2.5

9.1

209.

897

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419

7.2

105.

71.

87.

9A

LY 0

80A

280.

188

.23.

011

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5.5

97.2

2.6

10.6

246.

810

9.0

2.1

9.8

233.

611

7.6

1.9

9.3

ALY

090

A32

7.8

102.

23.

013

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1.1

112.

02.

612

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0.6

124.

72.

211

.627

6.6

133.

82.

011

.0A

LY 1

00A

334.

310

7.8

2.9

13.3

316.

911

9.3

2.5

12.6

293.

813

4.9

2.0

11.7

277.

314

6.3

1.8

11.1

ALY

110

A35

8.6

116.

62.

914

.333

9.2

129.

12.

513

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3.4

146.

02.

012

.529

4.7

158.

51.

811

.8A

LY 1

20A

402.

812

6.1

3.0

16.1

381.

713

9.1

2.6

15.2

354.

415

6.6

2.1

14.1

335.

016

9.2

1.9

13.4

ALY

130

A44

4.5

139.

23.

017

.742

1.3

153.

12.

616

.839

2.0

171.

42.

215

.637

1.7

184.

51.

914

.8A

LY 1

40A

484.

415

2.4

3.0

19.3

459.

316

7.0

2.6

18.3

428.

518

6.0

2.2

17.1

407.

519

9.5

2.0

16.2

ALY

160

A54

0.7

165.

53.

021

.651

4.8

183.

02.

620

.548

1.1

206.

42.

219

.245

7.3

223.

51.

918

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LY 1

70A

575.

917

8.0

3.0

23.0

547.

919

6.3

2.6

21.8

512.

222

0.5

2.2

20.4

487.

223

8.0

2.0

19.4

ALY

180

A61

7.8

191.

43.

024

.658

6.3

210.

32.

623

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7.0

235.

02.

221

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9.9

252.

82.

020

.7A

LY 1

90A

650.

020

3.7

3.0

25.9

616.

522

3.2

2.6

24.6

575.

124

8.5

2.2

22.9

547.

026

6.5

2.0

21.8

ALY

010

A31

.19.

62.

91.

229

.710

.62.

51.

227

.912

.02.

11.

126

.712

.91.

91.

1A

LY 0

15A

47.3

14.8

3.0

1.9

45.1

16.4

2.6

1.8

42.3

18.5

2.2

1.7

40.4

20.1

1.9

1.6

ALY

020

A64

.919

.63.

02.

661

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62.

557

.924

.32.

22.

355

.226

.21.

92.

2A

LY 0

25A

86.5

27.6

2.9

3.4

82.2

30.4

2.5

3.3

76.6

34.3

2.1

3.1

72.7

37.0

1.9

2.9

ALY

030

A99

.028

.13.

23.

994

.731

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83.

889

.135

.32.

33.

685

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13.

4A

LY 0

35A

123.

539

.32.

94.

911

7.0

43.5

2.5

4.7

108.

449

.22.

14.

310

2.1

53.4

1.8

4.1

ALY

040

A14

4.0

44.5

3.0

5.7

136.

549

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65.

412

7.0

55.0

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120.

459

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94.

8A

LY 0

45A

163.

251

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06.

515

4.8

55.9

2.6

6.2

144.

462

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25.

813

7.4

66.7

2.0

5.5

ALY

055

A19

7.9

56.3

3.2

7.9

189.

162

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87.

517

7.7

70.5

2.3

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169.

776

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16.

8A

LY 0

65A

223.

067

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08.

921

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74.3

2.6

8.5

197.

784

.02.

27.

918

7.4

91.1

1.9

7.5

ALY

070

A24

4.4

78.3

2.9

9.7

231.

486

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59.

221

4.1

98.0

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8.5

201.

610

6.4

1.8

8.0

ALY

080

A28

9.4

89.2

3.0

11.5

274.

498

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610

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5.3

110.

12.

210

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2.0

118.

81.

99.

7A

LY 0

90A

331.

210

2.6

3.0

13.2

314.

411

2.5

2.7

12.5

293.

812

5.2

2.2

11.7

279.

913

4.3

2.0

11.2

ALY

100

A34

4.2

108.

82.

913

.732

6.5

120.

42.

513

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3.3

136.

12.

112

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6.6

147.

61.

811

.4A

LY 1

10A

369.

211

7.7

2.9

14.7

349.

713

0.3

2.5

13.9

323.

814

7.4

2.1

12.9

305.

215

9.9

1.8

12.2

ALY

120

A41

2.0

127.

03.

016

.439

0.7

140.

12.

615

.636

3.3

157.

72.

214

.534

4.0

170.

41.

913

.7A

LY 1

30A

447.

313

9.5

3.0

17.8

424.

415

3.5

2.6

16.9

395.

517

1.8

2.2

15.8

375.

618

5.0

1.9

15.0

ALY

140

A48

6.1

152.

63.

019

.446

1.3

167.

32.

618

.443

0.8

186.

32.

217

.241

0.0

199.

92.

016

.3A

LY 1

60A

551.

116

6.5

3.1

22.0

524.

318

4.0

2.7

20.9

489.

720

7.4

2.2

19.5

465.

222

4.5

2.0

18.5

ALY

170

A58

5.9

179.

13.

123

.455

7.0

197.

32.

722

.252

0.4

221.

52.

220

.849

4.9

239.

02.

019

.7A

LY 1

80A

624.

919

2.2

3.1

24.9

593.

321

1.2

2.7

23.7

554.

023

6.0

2.2

22.1

527.

025

3.8

2.0

21.0

ALY

190

A65

8.5

204.

73.

026

.362

4.7

224.

42.

624

.958

3.2

249.

82.

223

.355

5.1

267.

82.

022

.1

19

LEG

END

:kW

-C

ompr

esso

r pow

er in

put

LPS

-Li

ters

Per

Sec

ond

CO

P-

Coe

ffici

ent o

f Per

form

ance

NO

TES:

1.P

acka

ged

chill

ers

are

rate

d w

ith A

RI s

tand

ard

550/

590.

2.P

erfo

rman

ce d

ata

are

base

d on

60 C

wat

er ra

nge

in e

vapo

rato

r.3.

Rat

ings

are

bas

ed o

n 0.

0000

18 (m

2 -0 C

/W) f

oulin

g fa

ctor

for e

vapo

rato

r.4.

Dire

ct in

terp

olat

ion

is p

erm

issi

ble.

Do

not e

xtra

pola

te.

5.kW

pow

er in

put i

s fo

r com

pres

sor o

nly.

6.C

OP

for e

ntire

uni

t. R

efer

to e

lect

rical

dat

a fo

r fan

kW

.

PER

FOR

MA

NC

E D

ATA

(Met

ric u

nits

)LE

AVIN

GCH

ILLE

DW

ATER

TEM

P.(L

CWT)

UN

ITSI

ZE

350 C

AM

BIE

NT

TEM

PER

ATU

RE

400 C

AM

BIE

NT

TEM

PER

ATU

RE

460 C

AM

BIE

NT

TEM

PER

ATU

RE

500 C

AM

BIE

NT

TEM

PER

ATU

RE

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

7 0 C

6 0 C

ALY

010

A32

.69.

73.

01.

331

.110

.82.

61.

229

.212

.12.

21.

227

.913

.12.

01.

1A

LY 0

15A

49.0

15.0

3.0

2.0

46.8

16.6

2.6

1.9

43.9

18.7

2.2

1.8

41.9

20.3

2.0

1.7

ALY

020

A67

.619

.83.

12.

764

.421

.82.

72.

660

.124

.52.

32.

457

.626

.52.

02.

3A

LY 0

25A

88.7

27.8

3.0

3.5

84.4

30.7

2.6

3.4

78.8

34.5

2.2

3.1

74.9

37.3

1.9

3.0

ALY

030

A10

2.6

28.4

3.3

4.1

98.1

31.5

2.8

3.9

92.4

35.6

2.4

3.7

88.4

38.6

2.1

3.5

ALY

035

A12

6.7

39.6

3.0

5.1

120.

143

.92.

64.

811

1.4

49.6

2.1

4.4

105.

153

.81.

94.

2A

LY 0

40A

147.

544

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642.

225

8.8

2.4

25.6

613.

327

7.8

2.1

24.5

21

LEG

END

:kW

-C

ompr

esso

r pow

er in

put

LPS

-Li

ters

Per

Sec

ond

CO

P-

Coe

ffici

ent o

f Per

form

ance

NO

TES:

1.P

acka

ged

chill

ers

are

rate

d w

ith A

RI s

tand

ard

550/

590.

2.P

erfo

rman

ce d

ata

are

base

d on

60 C

wat

er ra

nge

in e

vapo

rato

r.3.

Rat

ings

are

bas

ed o

n 0.

0000

18 (m

2 -0 C

/W) f

oulin

g fa

ctor

for e

vapo

rato

r.4.

Dire

ct in

terp

olat

ion

is p

erm

issi

ble.

Do

not e

xtra

pola

te.

5.kW

pow

er in

put i

s fo

r com

pres

sor o

nly.

6.C

OP

for e

ntire

uni

t. R

efer

to e

lect

rical

dat

a fo

r fan

kW

.

PER

FOR

MA

NC

E D

ATA

(Met

ric u

nits

)LE

AVIN

GCH

ILLE

DW

ATER

TEM

P.(L

CWT)

UN

ITSI

ZE

350 C

AM

BIE

NT

TEM

PER

ATU

RE

400 C

AM

BIE

NT

TEM

PER

ATU

RE

460 C

AM

BIE

NT

TEM

PER

ATU

RE

500 C

AM

BIE

NT

TEM

PER

ATU

RE

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

CAP.

(kW

)C

OM

P.kW

CO

PW

ATER

FLO

W(L

PS)

NO

TES:

1.M

ain

pow

er m

ust b

e su

pplie

d fro

m a

sin

gle

field

sup

plie

d an

d m

ount

ed fu

sed

disc

onne

cts,

usi

ng d

ual e

lem

ent t

ime

dela

y fu

se o

r circ

uit b

reak

er.

2.Th

e m

axim

um in

com

ing

wire

siz

e is

500

mcm

. O

n un

its h

avin

g M

CA

gre

ater

than

the

ampa

city

of 5

00 m

cm w

ire, t

he fa

ctor

y su

pplie

d po

wer

term

inal

blo

ck w

ill a

ccep

t tw

o pa

ralle

l fie

ld w

ires

per p

hase

.

3.Th

e co

mpr

esso

r cra

nkca

se h

eate

rs m

ust b

e en

ergi

zed

for 1

2 ho

urs

befo

re th

e un

it is

initi

ally

sta

rted

or a

fter a

pro

long

ed p

ower

dis

conn

ectio

n.

4.A

ll fie

ld w

iring

mus

t be

in a

ccor

danc

e w

ith N

EC

and

loca

l sta

ndar

ds.

5.M

inim

um a

nd m

axim

um u

nit s

uppl

y vo

ltage

s ar

e sh

own

in th

e ta

bula

ted

data

abo

ve (s

ee a

lso

note

# 7

).

6.N

eutr

al li

ne re

quire

d on

380

V-3

Ph-

60H

z po

wer

sup

ply

only

.

7.Th

e ±1

0% v

olta

ge v

aria

tion

from

the

nom

inal

is a

llow

ed fo

r a s

hort

time

only

, not

per

man

ent.

LEG

END

:

MC

A-

Min

imum

Circ

uit A

mpa

city

per

NE

C 4

30-2

4

MO

CP

-M

axim

um O

ver C

urre

nt P

rote

ctio

n

RLA

-R

ated

Loa

d A

mps

LRA

-Lo

cked

Rot

or A

mps

CB-

Circ

uit B

reak

er

MTA

-M

ust T

rip A

mps

FLA

-Fu

ll Lo

ad A

mps

FCA

-To

tal F

an C

ircui

t Am

ps

CR

AN

KC

ASE

HEA

TER

Tota

lW

atts

Volts

Tota

lAm

psCB (Qty

.)FC

ATo

tal

kWFL

A(e

ach)

Qty

.CB Po

les

LRA

(eac

h)RL

A(e

ach)

Qty

.CB Po

les

LRA

(eac

h)RL

A(e

ach)

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

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

ALY0

10A

ALY0

15A

ALY0

20A

ALY0

25A

ALY0

30A

ALY0

35A

ALY0

40A

ALY0

45A

ALY0

55A

ALY0

65A

ALY0

70A

UN

ITSI

ZE

SUPP

LY V

OLT

AG

EC

OM

PRES

SOR

TYP

E-1

CO

MPR

ESSO

R T

YPE-

2C

ON

DEN

SER

FA

N M

OTO

RS

ELEC

TRIC

AL

DAT

A (W

ithou

t hyd

roni

c ki

t opt

ion)

MO

CP

MC

AM

ax.

Min

.N

omin

al(V

-Ph-

Hz)

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

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

Qty

.Q

ty.

MTA

CBQ

ty.

MTA

CB

5810

01

42.0

239

367

10

00

00

01

5.1

1.10

5.1

123

090

0.39

3255

123

.014

53

371

00

00

00

12.

91.

102.

91

380

900.

2427

461

19.0

125

330

10

00

00

01

2.8

1.10

2.8

146

090

0.20

7813

71

58.6

340

394

10

00

00

01

5.1

1.10

5.1

123

090

0.39

4883

135

.719

63

571

00

00

00

12.

91.

102.

91

380

900.

2439

671

28.6

173

346

10

00

00

01

2.8

1.10

2.8

146

090

0.20

105

147

242

.023

93

672

00

00

00

25.

12.

2010

.21

230

180

0.78

5881

223

.014

53

372

00

00

00

22.

92.

205.

81

380

180

0.47

4867

219

.012

53

302

00

00

00

22.

82.

205.

61

460

180

0.39

131

189

158

.634

03

941

147

.124

53

751

25.

12.

2010

.21

230

180

0.78

7511

11

35.7

196

357

11

24.4

145

339

12

2.9

2.20

5.8

138

018

00.

4762

911

28.6

173

346

11

20.7

125

333

12

2.8

2.20

5.6

146

018

00.

3914

220

02

58.6

340

394

20

00

00

02

5.0

3.00

101

230

180

0.78

8612

22

35.7

196

357

20

00

00

02

3.0

3.00

61

380

180

0.47

7199

228

.617

33

462

00

00

00

23.

23.

806.

41

460

180

0.39

193

275

281

.450

53

130

20

00

00

02

5.0

3.00

101

230

240

1.04

101

143

242

.128

03

672

00

00

00

23.

03.

006

138

024

00.

6382

116

233

.622

53

542

00

00

00

23.

23.

806.

41

460

240

0.52

208

302

193

.660

53

150

11

81.4

505

313

01

25.

03.

0010

123

027

01.

1711

817

31

55.7

353

389

11

42.1

280

367

12

3.0

3.00

61

380

240

0.63

9213

31

41.4

272

366

11

33.6

225

354

12

3.2

3.80

6.4

146

027

00.

5922

131

42

93.6

605

315

02

00

00

00

25.

03.

0010

123

030

01.

3013

118

72

55.7

353

389

20

00

00

02

3.0

3.00

61

380

240

0.63

100

141

241

.427

23

662

00

00

00

23.

23.

806.

41

460

300

0.65

269

328

458

.634

03

944

00

00

00

45.

06.

0020

223

036

01.

5716

419

94

35.7

196

357

40

00

00

04

3.0

6.00

122

380

360

0.95

134

163

428

.617

33

464

00

00

00

43.

27.

6012

.82

460

360

0.78

320

402

281

.450

53

130

22

58.6

340

394

24

5.0

6.00

202

230

420

1.83

178

220

242

.128

03

672

235

.719

63

572

43.

06.

0012

238

042

01.

1114

617

92

33.6

225

354

22

28.6

173

346

24

3.2

7.60

12.8

246

042

00.

9136

644

74

81.4

505

313

04

00

00

00

45.

06.

0020

223

048

02.

0919

123

34

42.1

280

367

40

00

00

04

3.0

6.00

122

380

480

1.26

156

189

433

.622

53

544

00

00

00

43.

27.

6012

.82

460

480

1.04

22

NO

TES:

1.M

ain

pow

er m

ust b

e su

pplie

d fro

m a

sin

gle

field

sup

plie

d an

d m

ount

ed fu

sed

disc

onne

cts,

usi

ng d

ual e

lem

ent t

ime

dela

y fu

se o

r circ

uit b

reak

er.

2.Th

e m

axim

um in

com

ing

wire

siz

e is

500

mcm

. O

n un

its h

avin

g M

CA

gre

ater

than

the

ampa

city

of 5

00 m

cm w

ire, t

he fa

ctor

y su

pplie

d po

wer

term

inal

blo

ck w

ill a

ccep

t tw

o pa

ralle

l fie

ld w

ires

per p

hase

.

3.Th

e co

mpr

esso

r cra

nkca

se h

eate

rs m

ust b

e en

ergi

zed

for 1

2 ho

urs

befo

re th

e un

it is

initi

ally

sta

rted

or a

fter a

pro

long

ed p

ower

dis

conn

ectio

n.

4.A

ll fie

ld w

iring

mus

t be

in a

ccor

danc

e w

ith N

EC

and

loca

l sta

ndar

ds.

5.M

inim

um a

nd m

axim

um u

nit s

uppl

y vo

ltage

s ar

e sh

own

in th

e ta

bula

ted

data

abo

ve (s

ee a

lso

note

# 7

).

6.N

eutr

al li

ne re

quire

d on

380

V-3

Ph-

60H

z po

wer

sup

ply

only

.

7.Th

e ±1

0% v

olta

ge v

aria

tion

from

the

nom

inal

is a

llow

ed fo

r a s

hort

time

only

, not

per

man

ent.

LEG

END

:

MC

A-

Min

imum

Circ

uit A

mpa

city

per

NE

C 4

30-2

4

MO

CP

-M

axim

um O

ver C

urre

nt P

rote

ctio

n

RLA

-R

ated

Loa

d A

mps

LRA

-Lo

cked

Rot

or A

mps

CB-

Circ

uit B

reak

er

MTA

-M

ust T

rip A

mps

FLA

-Fu

ll Lo

ad A

mps

FCA

-To

tal F

an C

ircui

t Am

ps

CR

AN

KC

ASE

HEA

TER

Tota

lW

atts

Volts

Tota

lAm

psCB (Qty

.)FC

ATo

tal

kWFL

A(e

ach)

Qty

.CB Po

les

LRA

(eac

h)RL

A(e

ach)

Qty

.CB Po

les

LRA

(eac

h)RL

A(e

ach)

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

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

ALY0

80A

ALY0

90A

ALY1

00A

ALY1

10A

ALY1

20A

ALY1

30A

ALY1

40A

ALY1

60A

ALY1

70A

ALY1

80A

ALY1

90A

UN

ITSI

ZE

SUPP

LY V

OLT

AG

EC

OM

PRES

SOR

TYP

E-1

CO

MPR

ESSO

R T

YPE-

2C

ON

DEN

SER

FA

N M

OTO

RS

ELEC

TRIC

AL

DAT

A (W

ithou

t hyd

roni

c ki

t opt

ion)

MO

CP

MC

AM

ax.

Min

.N

omin

al(V

-Ph-

Hz)

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

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

Qty

.Q

ty.

MTA

CBQ

ty.

MTA

CB

393

487

293

.660

53

150

22

81.4

505

313

02

45.

06.

0020

223

054

02.

3522

227

72

55.7

353

389

22

42.1

280

367

24

3.0

6.00

122

380

480

1.26

173

215

241

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23

662

233

.622

53

542

43.

27.

6012

.82

460

540

1.17

418

511

493

.660

53

150

40

00

00

04

5.0

6.00

202

230

600

2.61

249

304

455

.735

33

894

00

00

00

43.

06.

0012

238

048

01.

2618

923

04

41.4

272

366

40

00

00

04

3.2

7.60

12.8

246

060

01.

3049

357

54

81.4

505

313

04

258

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03

942

65.

09.

0030

323

066

02.

8726

831

04

42.1

280

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42

35.7

196

357

26

3.0

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183

380

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1.74

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253

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53

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33

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211

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346

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01.

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962

06

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313

06

00

00

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65.

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323

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03.

1328

132

36

42.1

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60

00

00

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1.89

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53

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00

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211

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01.

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02

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02

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53

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33

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03

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63.

09.

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338

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01.

8924

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82

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24

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1.70

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493

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53

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02

65.

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323

084

03.

6533

939

54

55.7

353

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42

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23

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211

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010

204.

4340

245

82

55.7

353

389

26

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438

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22

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gle

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plie

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ount

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sed

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cts,

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ng d

ual e

lem

ent t

ime

dela

y fu

se o

r circ

uit b

reak

er.

2.Th

e m

axim

um in

com

ing

wire

siz

e is

500

mcm

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n un

its h

avin

g M

CA

gre

ater

than

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ampa

city

of 5

00 m

cm w

ire, t

he fa

ctor

y su

pplie

d po

wer

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inal

blo

ck w

ill a

ccep

t tw

o pa

ralle

l fie

ld w

ires

per p

hase

.

3.Th

e co

mpr

esso

r cra

nkca

se h

eate

rs m

ust b

e en

ergi

zed

for 1

2 ho

urs

befo

re th

e un

it is

initi

ally

sta

rted

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fter a

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long

ed p

ower

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conn

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n.

4.A

ll fie

ld w

iring

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t be

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ccor

danc

e w

ith N

EC

and

loca

l sta

ndar

ds.

5.M

inim

um a

nd m

axim

um u

nit s

uppl

y vo

ltage

s ar

e sh

own

in th

e ta

bula

ted

data

abo

ve (s

ee a

lso

note

# 7

).

6.N

eutr

al li

ne re

quire

d on

380

V-3

Ph-

60H

z po

wer

sup

ply

only

.

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e ±1

0% v

olta

ge v

aria

tion

from

the

nom

inal

is a

llow

ed fo

r a s

hort

time

only

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per

man

ent.

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END

:

MC

A-

Min

imum

Circ

uit A

mpa

city

per

NE

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NO

TES:

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ain

pow

er m

ust b

e su

pplie

d fro

m a

sin

gle

field

sup

plie

d an

d m

ount

ed fu

sed

disc

onne

cts,

usi

ng d

ual e

lem

ent t

ime

dela

y fu

se o

r circ

uit b

reak

er.

2.Th

e m

axim

um in

com

ing

wire

siz

e is

500

mcm

. O

n un

its h

avin

g M

CA

gre

ater

than

the

ampa

city

of 5

00 m

cm w

ire, t

he fa

ctor

y su

pplie

d po

wer

term

inal

blo

ck w

ill a

ccep

t tw

o pa

ralle

l fie

ld w

ires

per p

hase

.

3.Th

e co

mpr

esso

r cra

nkca

se h

eate

rs m

ust b

e en

ergi

zed

for 1

2 ho

urs

befo

re th

e un

it is

initi

ally

sta

rted

or a

fter a

pro

long

ed p

ower

dis

conn

ectio

n.

4.A

ll fie

ld w

iring

mus

t be

in a

ccor

danc

e w

ith N

EC

and

loca

l sta

ndar

ds.

5.M

inim

um a

nd m

axim

um u

nit s

uppl

y vo

ltage

s ar

e sh

own

in th

e ta

bula

ted

data

abo

ve (s

ee a

lso

note

# 7

).

6.N

eutr

al li

ne re

quire

d on

380

V-3

Ph-

60H

z po

wer

sup

ply

only

.

7.Th

e ±1

0% v

olta

ge v

aria

tion

from

the

nom

inal

is a

llow

ed fo

r a s

hort

time

only

, not

per

man

ent.

LEG

END

:

MC

A-

Min

imum

Circ

uit A

mpa

city

per

NE

C 4

30-2

4

MO

CP

-M

axim

um O

ver C

urre

nt P

rote

ctio

n

RLA

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ated

Loa

d A

mps

LRA

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cked

Rot

or A

mps

CB-

Circ

uit B

reak

er

MTA

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ust T

rip A

mps

FLA

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ll Lo

ad A

mps

FCA

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tal F

an C

ircui

t Am

ps

HP

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orse

Pow

er

CR

AN

KC

ASE

HEAT

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tal

Wat

tsVo

ltsTo

tal

Amps

CB (Qty

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tal

kWFL

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ach)

Qty

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les

LRA

(eac

h)RL

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ach)

Qty

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les

LRA

(eac

h)RL

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ach)

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230-

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380-

3-60

460-

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380-

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230-

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3-60

380-

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460-

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230-

3-60

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460-

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208/

230-

3-60

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460-

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208/

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380-

3-60

460-

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208/

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3-60

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460-

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80A

ALY0

90A

ALY1

00A

ALY1

10A

ALY1

20A

ALY1

30A

ALY1

40A

ALY1

60A

ALY1

70A

ALY1

80A

ALY1

90A

UN

ITSI

ZE

SUPP

LY V

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EC

OM

PRES

SOR

TYP

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MPR

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SER

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N M

OTO

RS

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AL

DAT

A (W

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nic

kit o

ptio

n)

MO

CP

MC

AM

ax.

Min

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omin

al(V

-Ph-

Hz)

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

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

Qty

.Q

ty.

MTA

CBQ

ty.

MTA

CB

25

HYD

RO

NIC

PUM

P

HP

Qty

.

WATER SIDE PRESSURE DROP

CURVE No. Maximum GPM MODEL No.ALY010AALY015AALY020AALY025AALY030AALY035AALY040AALY045AALY055AALY065AALY070A

11223455677

28.642.156.975.386.9

101.9116.7128.0167.3189.8207.8

Minimum GPM17.226.135.848.055.265.979.190.9

111.5122.9131.6

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.

26

PRES

SUR

E D

RO

P (F

T. O

F W

ATE

R)

1

10 20

23

48

65

79

1060

3020

5040

7010

090

8020

0

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

1 2 3 4 5 6 78 9

10

11 1213

CURVE No. Maximum GPM MODEL No.ALY080AALY090AALY100AALY110AALY120AALY130AALY140AALY160AALY170AALY180AALY190A

89997

101011111213

231.7260.6278.4298.8326.0361.7384.2444.4465.0499.3516.3

Minimum GPM158.3185.5186.5198.0224.9247.5271.6306.1326.3348.4367.2

339338

171

1523

1825

1243

227

100

339338

171

1523

1700

1243

227

100

ALY010A

ALY015A

DIMENSIONS

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

27

2286BA

C

D

1600

275

390

590

790

2286185A

246

2075

1600390

590

790

100

ALY020A & ALY025A

ALY030A, ALY035A, ALY040A & ALY045A

DIMENSIONS

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

28

TOP VIEWTOP VIEWTOP VIEWTOP VIEWTOP VIEW

TOP VIEWTOP VIEWTOP VIEWTOP VIEWTOP VIEW

600

3900

275

D

C

A B2230

2600BA

C

2230

D

275

355

ALY055A, ALY065A, ALY070A, ALY080A & ALY090A

ALY100A, ALY110A, ALY120A, ALY130A & ALY140A

DIMENSIONS

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

29

TOP VIEWTOP VIEWTOP VIEWTOP VIEWTOP VIEW

2230

2325

275

B

C

A5208

1000

ALY160A, ALY170A, ALY180A & ALY190ADIMENSIONS

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

30

TYPICAL SCHEMATIC WIRING DIAGRAM(1 Compressor & 1 fan)

31

COMP 1

COMPRESSOR LAYOUT

CONTROL BOX

FAN1

FAN LAYOUT

cooler

CONTROL BOX

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.

REFER TO UNITNAMEPLATE FORPOWER SUPPLY

LEGEND

B1/B2 ANALOG INPUTC1/C2 COMMONCB CIRCUIT BREAKERCOMP COMPRESSORCC COMPRESSOR CONTACTORCCA COMPRESSOR CONTACTOR AUXILIARYCWP CHILLED WATER PUMPD1/ID.. DIGITAL INPUT 1ETB EARTH TERMINAL BLOCKFLS FLOW SWITCHFM FAN MOTORFMC FAN MOTOR CONTACTORF FUSEG/GO POWER INPUTHPS HIGH PRESSURE SWITCHHVTB HIGH VOLTAGE TERMINAL BLOCKMB MASTER BOARDNO1/1O DIGITAL OUT 1S1 CONTROL SWITCHSB SLAVE BOARDSSPS SOLID STATE PROTECTION SYSTEMSH SHIELDTK CONDENSER FAN THERMAL CONTACTtLAN LOCAL NETWORK PORTTRANS TRANSFORMERUVM UNDER VOLTAGE MONITOR

TERMINAL BLOCK - - - FIELD WIRING

* FIELD SUPPLY

TYPICAL SCHEMATIC WIRING DIAGRAM(1 Compressor & 1 fan)

NOTES1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. FUSES TO BE DUAL ELEMENT TYPE.

3. USE COPPER CONDUCTORS ONLY.

4. ALL FIELD WIRING TO COMPLY WITH LOCAL CODES.

5. FUSED DISCONNECT SWITCH OR CIRCUITBREAKER TO BE PROVIDED BY END USER WITHRATING AS RECOMMENDED BY MANUFACTURER.

6. 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.

7. IF SSPS IS NOT AVAILABLE, A JUMPER SHOULD BEUSED TO CONNECT DIRECTLY TO NEXT TERMINALAND SSPS SUPPLY SHOULD BE REMOVED & NOTNECESSARY TO CONNECT FROM ATB1B TO ATB2.

8. REFER TO INSTALLATION MANUAL FOR THE MAINFIELD WIRING CONNECTION.

9. JUMPER 20 MUST BE INSTALLED ONLY IF THEOPTIONAL 3 POSITION SWITCH IS NOT INSTALLEDOR REQUIRED IN THE UNIT.

10. NEUTRAL LINE REQUIRED ON 380V-3Ph-60HzPOWER SUPPLY ONLY.

32

FLOW SWITCH

EXEN (RUN/STOP)

10FLS CWP *

RWT

LWT

RELAY M-8

RELAY M-10

230 VAC

PO

WE

R IN

230VAC

RELAY M-9

RELAY M-7

RELAY M-6

RELAY M-4

RELAY M-5

RELAY M-2

RELAY M-3

RELAY M-1

MB

230VAC

GND DIRECT TO MTG PLATE

HPS2

THERMAL1

THERMAL3

FAN1

FAN2

FAN LAYOUT

CONTROL BOX

HPS1

FMC1

FMC2

FMC4

FMC3

THERMAL2

THERMAL4

FAN3

FAN4

SEE PUMP SAFETY CONNECTION (OPTIONAL)

SEE PUMP CONTACTOR COILCONNECTION (OPTIONAL)

EEV DRIVER 2

EEV DRIVER 1

EEVB2

EEVB1

TYPICAL SCHEMATIC WIRING DIAGRAM(2 Tandem compressors & 4 fans)

33

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.

RE

FE

R T

O U

NIT

NA

ME

PLA

TE F

OR

PO

WE

R S

UP

PLY

RELAY M-10

GND

2

1

SUPRESSOR

AR1A-2A

TRANS2

EEVB162A

63A

2A

5A

GND DIRECT TO MTG PLATE

2B

63B

62B

AR2A-2A

EEVB2

5B

GND DIRECT TO MTG PLATEGND SUPRESSOR

EEVB1

EEVB2

LEGEND

B1/B2 ANALOG INPUTC1/C2 COMMONCB CIRCUIT BREAKERCOMP COMPRESSORCC COMPRESSOR CONTACTORCCA COMPRESSOR CONTACTOR AUXILIARYCWP CHILLED WATER PUMPD1/ID.. DIGITAL INPUT 1ETB EARTH TERMINAL BLOCKFLS FLOW SWITCHFM FAN MOTORFMC FAN MOTOR CONTACTORF FUSEG/GO POWER INPUTHPS HIGH PRESSURE SWITCHHVTB HIGH VOLTAGE TERMINAL BLOCKMB MASTER BOARDNO1/1O DIGITAL OUT 1S1 CONTROL SWITCHSB SLAVE BOARDSSPS SOLID STATE PROTECTION SYSTEMSH SHIELDTK CONDENSER FAN THERMAL CONTACTtLAN LOCAL NETWORK PORTTRANS TRANSFORMERUVM UNDER VOLTAGE MONITOR

TERMINAL BLOCK - - - FIELD WIRING

* FIELD SUPPLY

TYPICAL SCHEMATIC WIRING DIAGRAM(2 Tandem compressors & 4 fans)

NOTES1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. FUSES TO BE DUAL ELEMENT TYPE.

3. USE COPPER CONDUCTORS ONLY.

4. ALL FIELD WIRING TO COMPLY WITH LOCAL CODES.

5. FUSED DISCONNECT SWITCH OR CIRCUITBREAKER TO BE PROVIDED BY END USER WITHRATING AS RECOMMENDED BY MANUFACTURER.

6. 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.

7. IF SSPS IS NOT AVAILABLE, A JUMPER SHOULD BEUSED TO CONNECT DIRECTLY TO NEXT TERMINALAND SSPS SUPPLY SHOULD BE REMOVED & NOTNECESSARY TO CONNECT FROM ATB1B TO ATB2.

8. REFER TO INSTALLATION MANUAL FOR THE MAINFIELD WIRING CONNECTION.

9. JUMPER 20 MUST BE INSTALLED ONLY IF THEOPTIONAL 3 POSITION SWITCH IS NOT INSTALLEDOR REQUIRED IN THE UNIT.

10. NEUTRAL LINE REQUIRED ON 380V-3Ph-60HzPOWER SUPPLY ONLY.

34

MICROPROCESSOR CONTROLLERCONTROLLER SEQUENCE OF OPERATIONFor initial start-up, the following condition must be met:

· All power supplied to the unit shall be continuously energized for 12 hours.

· All safety conditions are satisfied.

· Chilled water pump is running normal and chilled water flow switch contact is closed.

· Customer control or remote ON/OFF is switch to run mode, if any.

Staging ON and OFF sequence is accomplished based on controlled water temperature. The controller works to maintainthe required demand as constant as possible.

Below sequence of operation belongs to chiller unit with 2 scroll compressors. For 4, 6 & 8 scroll compressors chiller unitthe operation will be the same. Only that the capacity changes depend on the quantity of the compressor. For single scrollcompressor unit the capacity change to 100%.

COMPRESSOR STAGE - ON SEQUENCEIf the water temperature is above the temperature set point: The compressor with less running hours will start, and theunit is now at the 50% capacity. After such interval of time, and if the water temperature is still high compared to thetemperature set point, the second compressor will start. The unit now is at 100% capacity.

COMPRESSOR STAGE - OFF SEQUENCEAssume that the 2 compressors are running (capacity is at 100%). After such interval of time, if the water temperature isdecreases or below the temperature set point the compressor with more running hours will off. Now the unit is at 50%capacity. After such interval of time, if water temperature still below the set point temperature, then second compressorwill off.

FAN - ON/OFFThe fan will switch ON & OFF together with the compressor ON and OFF operation respectively.

35

APPLICATION GUIDELINESINTRODUCTIONThese guidelines should be considered when designing systems and their installation utilizing Zamil ALY 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.

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).As fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other foulingfactors, 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 mayresult in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading topossible equipment damage.

EFFECT OF ALTITUDE ON UNIT CAPACITYThe tabulated performance data provided in this catalog are for use at or near sea level altitude application. At altitudessubstantially above sea level, the decreased air density will reduce condenser capacity and therefore unit capacity. For unitselection at these higher altitudes, apply appropriate correction factor from the table provided in this catalog.

HIGH AMBIENT CONSIDERATIONThese chillers are designed for year round operation over a range of ambient temperatures. As a standard, these chillerscan start and operate satisfactorily up to 1220F (500C) ambient temperature at rated nominal voltage.

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 laminarflow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause exces-sive 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 becalibrated accordingly.

COOLER FLUID (WATER OR GLYCOL) TEMPERATURES RANGEUnit can start and pull down from 950F (350C) entering fluid temperature. The design leaving chilled fluid temperature(LCWT) 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 of 100F. Units maybe operated at any desired temperature drop within the range of 5 to 150F as long as the temperature and flow limits arenot violated and appropriate correction factors are applied on the capacity and power input. The Zamil electronic selec-tion program can be very handy in selecting equipment at different temperature drops.

It should be noted that temperature drop outside the aforesaid range is not permitted as it is beyond the optimum range of controland could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the equipment.

36

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 totalcapacity 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.

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.

UNIT LOCATION AND INSTALLATIONThese chillers are designed for outdoor installation and can be installed at ground level or on a suitable rooftop location.In order to achieve good operation, performance and trouble-free service, it is essential that the proposed installationlocation and subsequent installing procedures meet the following requirements:

• The most important consideration while deciding upon the location of air cooled chillers is the provision for supply ofadequate ambient air to the condenser and removal of heated discharge air from the condenser. This is accomplishedby maintaining sufficient clearances which have been specified in this Catalog around the units and avoiding obstruc-tions in the condenser air discharge area to prevent the possibility of warm air circulation. Further, the condenser fansare propeller type and are not recommended for use with ductwork or other hindrances in the condenser air stream.Where these requirements are not complied, the supply or discharge airflow restrictions or warm air recirculation willcause higher condensing temperatures resulting in poor unit operation, higher power consumption and possible even-tual failure of equipment.

37

• The unit’s longitudinal axis should be parallel to the prevailing wind direction in order to ensure a balanced air flowthrough the condenser coils. Consideration should also be given to the possibility of down-drafts caused by adjacentbuildings, which may cause recirculation or uneven unit airflow. For locations where significant cross winds are ex-pected, an enclosure of solid or louver type is recommended to prevent wind turbulence interfering with the unit airflow.When units are installed in an enclosure, the enclosure height should not exceed the height of the unit.

• The location should be selected for minimum sun exposure and away from hot air sources, steam, exhaust vents andsources of airborne chemicals that could attack the condenser coils and steel parts of the unit. Avoid locations wherethe sound output and air discharge from the units may be objectionable.

• If the location is an area which is accessible to unauthorized persons, steps must be taken to prevent access to the unitby means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage or possibleharm caused by unauthorized removal of panels or protective guards exposing rotating or high voltage components.

• The unit must be installed on a ONE-PIECE, FLAT and LEVELLED {within 1/2'' (13 mm) over its length and width} /CONCRETE BASE that extends fully to support the unit. The carrying or supporting structure should be capable ofhandling complete operating weight of the unit as given in the Physical Data tables in this Catalog.

• For ground level installations, it must be ensured that the concrete base is stable and does not settle or dislocate uponinstallation of the unit which can strain the refrigerant lines resulting in leaks and may also cause compressor oil returnproblems. It is recommended that the concrete slab is provided with appropriate footings. The slab should not beconnected to the main building foundation to avoid noise and vibration transmission.

• For rooftop installations, choose a place with adequate structural strength to safely support the entire operating weightof the unit. The unit shall be mounted on a concrete slab similar to ground installations. The roof must be reinforced forsupporting the individual point loads at the mounting isolator locations. It must be checked and ensured that theconcrete base is perfectly horizontal and levelled, especially if the roof has been pitched to aid in water removal. Itshould be determined prior to installation if any special treatment is required to assure a levelled installation else itcould lead to the above mentioned problems.

• Vibration isolators are necessary for installing these chillers in order to minimize the transmission of vibrations. Thetwo types of vibration isolators generally utilized for mounting these units are Neoprene Pads and Spring Isolators.Neoprene Pads are recommended for ground level normal installations jobs where vibration isolation is not critical andjob costs must be kept to a minimum. Spring Isolators are recommended for ground level installations which are noise-sensitive areas or exposed to wind loads and all roof top installations. For critical installations (extremely noise andvibration sensitive areas), follow the recommendations of structural and acoustical consultants.

• Based on the specific project requirements, choose the type of vibration isolators best suited for the application.Carefully select the vibration isolators’ models / configuration based on the respective point loads and place eachmount in its correct position following the Load Distribution Data and Mounting Drawings provided in this Catalog.Refer to the Schematic Mounting Layout drawings provided in the IOM manual of these chillers for further details in thisregard.

COOLER PIPING CONNECTIONSThe following pertinent guidelines are served to ensure satisfactory operation of the units. Failure to follow these recom-mendations may cause improper operation and loss of performance, damage to the unit and difficulty in servicing andmaintenance:

• 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 theunit control panel using shielded cable. There should be a straight run of piping of at least five pipe diameters on eitherside of the flow switch. Paddle type flow switches can be obtained from Zamil which are supplied as optional items.

• 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 wiringdiagram) so that the unit can start only upon proof of pump operation.

38

• 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.

• 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.

• The following is a suggested piping arrangement at the chiller for single unit installations. For multiple chiller installa-tions, each unit should be piped as shown:

39

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

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 ALY080 operating with a design water flow rate of 180 GPM for a standard air conditioningapplication would require 80 (Nom. Cap.) x 3 = 240 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 loopto increase the volume of water in the system and therefore, reduce the rate of change of return water temperature. Thistank should be provided on the return water side to the chiller and the tank should be baffled to ensure that there is nostratification and the entering stream thoroughly mixes with the tank water. See recommended tank design schematicsbelow:

40

TANK SCHEMATIC

LIFT

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

MODELS: ALY010A - ALY015A

MODELS: ALY160A - ALY190A

41

MODELS: ALY020A - ALY045A

MODELS: ALY055A - ALY090A MODELS: ALY100A - ALY140A

1500

1500

2000

WALL

1500

1500

INSTALLATION CLEARANCE

FIGURE - 2CORNER WALL

NOTE: 1. All dimensions are in mm.2. Pit installations are not recommended. Re-circulation of hot condenser air in combination with surface air

turbulence can not be predicted, hot air re-circulation will severely affect unit efficiency (EER) and can causehigh pressure or fan motor temperature trips.

FIGURE - 1STRAIGHT WALL

42

MODELS: ALY160A - ALY190A

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

MOUNTING LOCATIONMODELS: ALY010A - ALY015A

43

MODELS: ALY020A - ALY045A

MODELS: ALY055A - ALY090A MODELS: ALY100A - ALY140A

LOAD DISTRIBUTION (kg.), ALUMINUM CONDENSER COIL(Without hydronic kit option)

44

MODEL No. R1 R2 R3 R4 R5 R6 R7 R8ALY010A 111 128 111 128 - - - -ALY015A 121 147 121 147 - - - -ALY020A 240 235 189 183 - - - -ALY025A 254 249 199 194 - -ALY030A 261 256 203 198 - - - -ALY035A 359 355 232 229 - - - -ALY040A 398 378 272 252 - - - -ALY045A 409 389 274 254 - - - -ALY055A 517 510 401 394 - - - -ALY065A 597 591 422 416 - - - -ALY070A 675 669 441 435 - - - -ALY080A 723 718 471 465 - - - -ALY090A 784 784 513 513 - - - -ALY100A 642 628 611 447 433 416 - -ALY110A 694 680 663 460 445 429 - -ALY120A 731 718 701 485 471 455 - -ALY130A 753 740 724 495 482 465 - -ALY140A 774 761 745 503 490 474 - -ALY160A 741 692 692 666 497 449 448 423ALY170A 708 660 659 633 455 407 406 381ALY180A 801 761 763 735 539 499 502 473ALY190A 818 779 781 752 547 508 510 481

LOAD DISTRIBUTION (kg.), COPPER CONDENSER COIL (Without hydronic kit option)MODEL No. R1 R2 R3 R4 R5 R6 R7 R8ALY010A 143 138 117 112 - - - -ALY015A 167 162 137 132 - - - -ALY020A 256 251 204 199 - - - -ALY025A 278 273 223 218 - -ALY030A 277 272 219 214 - - - -ALY035A 383 380 257 253 - - - -ALY040A 431 430 305 304 - - - -ALY045A 442 441 307 306 - - - -ALY055A 549 542 433 426 - - - -ALY065A 638 632 462 456 - - - -ALY070A 724 718 490 484 - - - -ALY080A 796 790 543 537 - - - -ALY090A 870 869 599 598 - - - -ALY100A 686 671 655 491 476 459 - -ALY110A 743 729 712 509 494 478 - -ALY120A 799 785 769 552 539 522 - -ALY130A 830 817 800 571 558 542 - -ALY140A 859 846 830 588 575 559 - -ALY160A 806 752 763 731 563 508 519 488ALY170A 744 690 701 669 491 437 448 416ALY180A 879 831 851 813 618 569 589 552ALY190A 903 855 875 837 632 584 604 566

R6

R2

R5

R1

R7 R8

R3 R4

R5R4 R6

R2R1 R3

R3

R1

R4

R2

LOAD DISTRIBUTION (kg.), ALUMINUM CONDENSER COIL(With hydronic kit option)

45

MODEL No. R1 R2 R3 R4 R5 R6 R7 R8ALY010A 137 154 215 232 - - - -ALY015A 147 173 225 251 - - - -ALY020A 270 265 309 303 - - - -ALY025A 284 279 319 314 - -ALY030A 297 292 329 324 - - - -ALY035A 389 385 352 349 - - - -ALY040A 428 408 392 372 - - - -ALY045A 439 419 394 374 - - - -ALY055A 564 558 551 545 - - - -ALY065A 639 633 566 560 - - - -ALY070A 710 704 579 573 - - - -ALY080A 758 753 609 603 - - - -ALY090A 819 819 651 651 - - - -ALY100A 660 646 629 576 543 490 - -ALY110A 712 698 681 589 555 503 - -ALY120A 749 736 719 614 581 529 - -ALY130A 771 758 742 624 592 539 - -ALY140A 792 779 763 632 600 548 - -ALY160A 759 710 710 684 632 557 516 491ALY170A 726 678 677 651 590 515 474 449ALY180A 819 779 781 753 674 607 570 541ALY190A 836 797 799 770 682 616 578 549

LOAD DISTRIBUTION (kg.), COPPER CONDENSER COIL (With hydronic kit option)MODEL No. R1 R2 R3 R4 R5 R6 R7 R8ALY010A 168 163 220 215 - - - -ALY015A 192 187 240 235 - - - -ALY020A 286 281 324 319 - - - -ALY025A 308 303 343 338 - -ALY030A 322 317 353 349 - - - -ALY035A 413 410 377 373 - - - -ALY040A 461 460 425 424 - - - -ALY045A 472 471 427 426 - - - -ALY055A 613 607 600 594 - - - -ALY065A 688 682 615 609 - - - -ALY070A 759 753 628 622 - - - -ALY080A 831 825 681 675 - - - -ALY090A 905 904 737 736 - - - -ALY100A 704 689 673 620 586 533 - -ALY110A 761 747 730 638 604 552 - -ALY120A 817 803 787 681 649 596 - -ALY130A 848 835 818 700 668 616 - -ALY140A 877 864 848 717 685 633 - -ALY160A 824 770 781 749 698 616 587 556ALY170A 762 708 719 687 626 545 516 484ALY180A 897 849 869 831 753 677 657 620ALY190A 921 873 893 855 767 692 672 634

R6

R2

R5

R1

R7 R8

R3 R4

R5R4 R6

R2R1 R3

R3

R1

R4

R2

PL-AP-ALY-11-2M-E