Air Cooled Scroll Water Chillers

ALY Series, R-407c

ALY010C thru ALY070C
10 TR thru 70 TR 35 kW thru 246 kW

Company Business Zamil Air Conditioners was founded in 1974, and is the first major business venture in manufacturing sector for the Al Zamil group of Companies. It is also the first manufacturing unit for air conditioners to be established in Saudi Arabia. Zamil Air conditioners manufactures both consumer and central range of air conditioners and has sales operations in over 55 countries in the Middle East, Europe, America, Africa, Australia and the Far East. The companys operations are structured into four Strategic Business Units (SBUs) supporting six in - house product and service brands as well as a number of international brands under the OEM sales. The six in-house brands are Classic, Cooline, CoolCare, Clima Tech, Geoclima and Kessler Clima Tech. The four SBUs are: 1. Consumer Business unit supporting Classic, Cooline, GE and OEM brands for consumer range of air conditioners. 2. Unitary & Applied Business unit supporting Classic, Cooline, GE and OEM brands for commercial range of air conditioners. 3. Zamil CoolCare - service and maintenance provider. 4. Geoclima srl - independent business and supporting other SBUs for their requirement of Chillers & Double skin AHUs. The first three SBUs - Consumer Products, Unitary & Applied Products and Zamil CoolCare direct their business operations from the corporate headquarters at Dammam, Saudi Arabia. The production facilities at Dammam are shared by Consumer Products and Unitary & Applied Products. Geoclima has its own production and functional departments located at Monfalcone, Italy. All the four SBUs, while operating independently, supplement each others activities in a way that makes synergy work at its best and achieve the corporate goals of increased productivity and efficiently. Factories and Productions Zamil Air Conditioners has its prime manufacturing base at Dammam, Saudi Arabia and has one speciality production facility in Italy operated by Geoclima. The company can produce up to 440,000 room air conditioners, 60,000 mini-split systems and 36,500 central air-conditioning systems per year. Quality & Product Certificates The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification. Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization) certificate for room air conditioners. Its products and services are also certified with: 1. 2. 3. 4. 5. 6. CE (Council of European Community) UL (Underwriters Laboratory) AHAM certificate (Association of Home Appliance Manufacturers) Eurovent DEMKO ETL

Other awards include the prestigious Engineering Excellence Award of General Electric, and the inaugural Prince Mohammed bin Fahd Al Saud Award for Factory Safety. Our Products In addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufacturers a host of residential and commercial air conditioners. This board range extends from the concealed units up to 5 ton, the ducted splits up to 30 tons, the packaged units up to 70 tons. The single and double skin air handling units up to 130,000 CFM and the water chillers up to 487 ton cooling capacity.

INDEX
Contents Page

Model decoding ........................................................................................................................................ 2 Introduction ........................................................................................................................................... 3-5 Unit features, standard specifications & options .................................................................................... 6-9 Physical data ..................................................................................................................................... 10-11 Selection procedure .......................................................................................................................... 12-13 Ethylene glycol solution capacity correction ........................................................................................... 14 Performance data .............................................................................................................................. 15-18 Electrical data ......................................................................................................................................... 19 Water side pressure drop ....................................................................................................................... 20 Unit dimensions ................................................................................................................................ 21-22 Typical schematic wiring diagram ........................................................................................................... 23 Microprocessor controller ....................................................................................................................... 24 Application guidelines ........................................................................................................................ 25-29 Rigging instructions ................................................................................................................................ 30 Installation clearance .............................................................................................................................. 31 Mounting location ................................................................................................................................... 32 Load distribution ..................................................................................................................................... 33

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

MODEL DECODING
7 REFRIGERANT C : R-407c H : 208/230-3-60 A : ALUMINUM FIN B : PRE-COATED ALUMINUM FIN C : COPPER FIN (SEE NOTE # 1 BELOW) B : OPTIONAL ASME B : HGBP (OPTIONAL) STAMPED WITH VICTAULIC CONN.** A: COMPRESSOR CIRCUIT BREAKER A : STANDARD UNIT WITHOUT HGBP A : STANDARD WITH VICTAULIC CONN.* M: 380-3-60 (4 WIRE) F : 460-3-60 8 ELECTRICAL SUPPLY ( V-Ph-Hz ) 9 CONDENSER COIL SEE NOTE # 2 BELOW 10 CIRCUIT BREAKER 11 COOLER OPTIONS 13 & 14 OPTIONS & ACCESSORIES 12 HGBP OPTIONS

1, 2 & 3 BASIC (SERIES)

4, 5 & 6 UNIT SIZE (NOMINAL CAPACITY)

ALY

010

AIR COOLED SCROLL WATER CHILLERS

015

020

025

030

035

040

045

050

055

065

070

2
- UNIT DISCONNECT SWITCH - WATER FLOW SWITCH - SPRING ISOLATOR etc...

NOTES:

* NOT APPLICABLE FOR MODELS ALY010C TO ALY055C, MPT (MALE PIPE THREAD) CONNECTION ONLY.

** ASME OPTION IS APPLICABLE FOR MODELS ALY040C TO ALY070C ONLY.

1. FOR OTHER COATING, SPECIFY YOUR REQUIREMENTS IN WRITING.

2. COMPUTER SELECTED DIGITS (FROM 'AA' TO 'ZZ') DESCRIBING OTHER OPTIONS & ACCESSORIES OR COMBINATIONS THEREOF, SUCH AS: - CHILLER GUARD

INTRODUCTION
Zamil Air cooled scroll chillers (ALY series) are the heart of most central Air Conditioning systems for medium size buildings. They consist of one or more hermetic scroll compressors, air-cooled condenser coils with condenser fan(s) and motor(s), insulated liquid cooler, expansion device, interconnecting refrigerant piping, oil & refrigerant charge, control panel, wiring and other auxiliaries. 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 70 TR (246 kW) at ARI conditions, in one single enclosure. Utilizing refrigerant R-407c 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 Gulfs severe climatic conditions and specifically for outdoor installation, on roofs or ground level. ALY series are factory assembled, leak tested, evacuated, internally wired, fully charged with refrigerant. Each ALY series chillers are fully factory tested before delivery and are ready for installation. All that is required on site is to connect chilled water pipes and main power supply. ALY series chillers are rated in accordance with ARI-550/590.

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

FIGURE- 1 How a Scroll Compressor works:

Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral. 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 all times, resulting in nearly continuous suction and discharge.

Refrigerant enters the compressor at the suction connection and flows around the motors housing and enters at the bottom 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.

COOLERS
Compact Design Shell and Tube Water Coolers: The DX shell and tube cooler with removable U shaped bundled tubes are made of internally grooved copper tubes expanded into heavy steel tubular sheets. The cooler housing and baffles are constructed steel and brass respectively. The coolers are insulated with heavy closed cellular foam insulation (3/4 thick). All coolers are fitted with vent, drain connection and Victaulic type water pipe connections as standard.
WATER SIDE UNIT MODEL COOLER
STD ASME (option) DESIGN PRESSURE, (BAR/PSIG) 16/235 10/147 TEST PRESSURE, (BAR/PSIG) 22.8/335 11.3/165

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

ALY010C - ALY070C ALY040C - ALY070C

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

* * * * * * * * * * * *

Microprocessor controller, which monitors analog and digital inputs to achieve precise control & protective functions of the air cooled water chiller units. The microprocessor controller is complete with all the hardware and software necessary to control the chiller unit and ensures its efficiency and reliability. Compact unit design and excellent serviceability. All units incorporate separate subcooler circuit which is integral to the condenser surface. This additional subcooling circuit 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 operations and safety controls. Made ready connection for remote ON/OFF switch and General Alarm output. Independent refrigeration circuits. 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 . All fans are die cast aluminum propeller type with aerodynamic design, top discharge, provided with protective grille mounted on top panel within the unit casing. All condenser fan motors are totally enclosed air over type (TEAO) with class ''F'' winding insulation.

STANDARD SPECIFICATIONS
CAPACITY CONTROL
The Zamil air cooled scroll water chillers incorporate stepped load shedding as required by most energy management systems. Modulation of capacity in response to system load requirements is affected by the microprocessor controller which monitors the leaving water temperature. Capacity control is achieved by cycling compressors ON/OFF and sequential operation of compressors which provides optimal part load capacities for chillers with multiple compressors. See the following table for the standard and optional capacity control for each unit.
MODEL NUMBER
ALY010C - ALY015C ALY020C - ALY040C ALY045C - ALY070C

% FULL LOAD CAPACITY CONTROL STANDARD

100-OFF 100-50-OFF 100-75-50-25-OFF

OPTIONAL
100-HGBP-OFF 100-50-HGBP-OFF 100-75-50-25-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: ALY045 with HGBP (25% x 0.5=12.5% minimum capacity).
6

CONDENSER COILS
Vertical & V-configurations condenser coils are corrugated fin and tube type, constructed of seamless 3/8" dia. & 0.014" (0.35 mm) thick copper tubes, mechanically bonded to aluminum fins for maximum heat transfer efficiency. As an option, copper fins or acrylic coated aluminum fins or other coated coils may be provided. The fins have full self spacing collars which completely cover each tube. The staggered tube design improves the thermal 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.

CABINET
All units are of heavy gauge (G-90) galvanized steel. Steel sheet panels are zinc coated and galvanized by hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90 followed by backed on electrostatic polyester dry powder coat. Removable access panels are provided for easy maintenance purpose.

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

MICROPROCESSOR CONTROLLER
A new compact electronic controller with a complete management for air cooled water chiller control capability. This controller 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 are clearly visible on its 3 digits display board. The controller is equipped with a compressor rotation operation to allow the compressor running hours to be balanced. The controller has feasibility to be connected to a supervisor network via RS485 serial line for Remote Monitoring 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 one compressor. 2. Aux. Board - Expansion Board to control 2 or more compressor. 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 alarm of the unit. Access of the following status on the display: 1. Water inlet / Outlet Temperature 2. Compressor Status 3. Fan Status 4. Alarms 5. SI or English Unit System protection: 1. Compressor Winding High Temperature / Overloading 2. Low / High Pressure 3. Freeze Protection 4. Sensor Error 5. Time Delay - Anti recycle time for compressor 6. No Water Flow or Trip Pump condition

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

CONDENSER FAN MOTOR

Condenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phase with class ''F'' winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosed air over type (TEAO) with inherent thermal protection of automatic reset type & specially designed for outdoor applications.

STANDARD CONTROL & SAFETY DEVICES

MICROPROCESSOR 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 the motor winding temperature in case of overload. STARTERS: The starter is operated by the control circuit and provides power to the compressor motors. These devices are rated to handle safely both RLA and LRA of motors. UNDER/OVER VOLTAGE AND PHASE PROTECTION: Protects against low/over incoming voltages as well as single phasing, phase reversal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it can be set up for manual reset. CRANKCASE HEATERS: Each compressor has crankcase heater. The compressor crankcase heater is always on when the compressors are de-energized. This protect the system against refrigerant migration, oil dilution and potential compressor failure. HIGH PRESSURE SWITCH: This switch provides an additional safety protection in the case of excessive discharge pressure. LOW PRESSURE SWITCH: This switch provides an additional safety protection in the case of unsafe low suction pressure. CIRCUIT BREAKERS: Protects against compressor/condenser fans branch circuit fault. When tripes, the breaker opens the power supply to the compressor and control circuit through auxiliary contacts.

STANDARD ACCESSORIES
UNIT ON-OFF SWITCH: ON-OFF switch is provided for manually switching the unit control circuit. INDICATOR LIGHTS: LED lights indicates power ON to the units, MENU adjustment and FAULT indications due to trip on safety devices. THERMAL EXPANSION VALVE: Thermal expansion valve is used to regulate the refrigerant flow to the water cooler and maintain a constant superheat. REPLACEABLE FILTER DRIER: Refrigerant circuits are kept free of harmful moisture, sludge, acids and oil contaminating particles by the filter drier. CONTROL CIRCUIT TRANSFORMER: A factory mounted and wired control circuit transformer is furnished eliminating the 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 shows moisture contents and provides a mean for checking the system refrigerant charge. LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from accumulating in the water cooler during the off cycle.
8

OPTIONS
HOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50% of its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor on and off, ensuring narrow temperature swing and lengthen the life span of the compressor. WATER FLOW SWITCH: Paddle type field adjustable flow switch for water cooler circuits. Interlock into unit safety circuits so 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 to prevent vibration transmission. LIQUID COOLERS: ASME code stamped liquid cooler (for models ALY040C to ALY070C 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 high pressure switches. NON-FUSED MAIN DISCONNECT SWITCHES: To disconnect power supply of the unit for servicing and repair works. This as well equipped with door interlock device. CHILLER GUARD: Protect the condenser, cooler & compressor from vandalism. COOLER HEATER WRAPPED: Prevent freezing up of water on low ambient temperature. COPPER FINS/TUBES CONDENSER COILS: For seashore salty corrosive environments. COATED COPPER OR ALUMINUM FINS/TUBES CONDENSER COILS: For seashore salty corrosive environments. BMS: BACNET, MODBUS, LON works and remote monitoring display.

PHYSICAL DATA
UNIT SIZE ALY010C ALY015C ALY020C ALY025C ALY030C ALY035C

COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 380V-3Ph-60Hz 460V-3Ph-60Hz NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters % FULL LOAD CAPACITY CONTROL MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION REFRIGERANT EXPANSION VALVE DEVICE CONTROL VOLTAGE
800-692-00 800-692-01 800-692-02 800-692-06 800-692-07 800-692-08 800-692-00 (2) 800-692-01 (2) 800-692-02 (2) 800-692-06 800-692-03 800-692-07 800-692-04 800-692-08 800-692-05 800-692-06 (2) 800-692-07 (2) 800-692-08 (2) 800-692-09 (2) 800-692-10 (2) 800-692-11 (2)

1 3.125 100-0

1 3.977 100-0

2 3.125 100-50-0

2 3.977/3.125 100-50-0

2 3.977 100-50-0

2 4.489 100-50-0

ELECTRONIC CENTRIFUGAL ACTION R-407c THERMOSTATIC 220V-1Ph-60Hz

CONDENSER
CONDENSER COIL Tube Dia.- Rows - Fins per inch Total face area, Sq. ft. AIRFLOW, CFM NUMBER OF FAN/FAN DIA.,mm FAN MOTOR RPM @ 230/380/460-3-60 3/8314 13.9 10529 1/800 3/8314 27.8 13251 1/800 3/8214 44.4 26538 2/800 3/8314 44.4 25170 2/800 3/8314 44.4 25170 2/800 3/8414 44.4 23950 2/800

1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070

COOLER
COOLER PART NUMBER SHELL DIAMETER, mm LENGTH, mm TOTAL WATER HOLDING VOLUME, Liters WATER IN/OUT PIPE DIA.mm 800-516-39 N.A. N.A. N.A. 38 800-516-39 N.A. N.A. N.A. 38 800-620-07 168 1281 15.3 64 800-620-09 168 1431 17.2 64 800-620-11 168 1631 19.8 64 800-620-13 168 1781 21.7 64

GENERAL
REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg SHIPPING /OPERATING WEIGHTS (Copper coils), kg NOTES: 8 68.9/65.4/60.1 416/426 447/457 12 66.7/63.2/57.9 506/516 568/578 8 71.9/68.4/63.1 795/810 858/873 12/10 69.2/65.7/60.4 889/906 986/1003 12 69.7/66.2/60.9 949/969 1047/1067 14 72.6/69.1/63.8 1049/1071 1191/1213

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

10

PHYSICAL DATA
UNIT SIZE ALY040C ALY045C ALY050C ALY055C ALY065C ALY070C

COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 380V-3Ph-60Hz 460V-3Ph-60Hz NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters % FULL LOAD CAPACITY CONTROL MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION REFRIGERANT EXPANSION VALVE DEVICE CONTROL VOLTAGE
800-692-12 (2) 800-692-13 (2) 800-692-14 (2) 800-692-03 (4) 800-692-04 (4) 800-692-05 (4) 800-692-06 (2) 800-692-03 (2) 800-692-07 (2) 800-692-04 (2) 800-692-08 (2) 800-692-05 (2) 800-692-06 (4) 800-692-07 (4) 800-692-08 (4) 800-692-09 (2) 800-692-06 (2) 800-692-10 (2) 800-692-07 (2) 800-692-11 (2) 800-692-08 (2) 800-692-09 (4) 800-692-10 (4) 800-692-11 (4)

2 5.682 100-50-0

4 3.125

4 3.977/3.125

4 3.977

4 4.489/3.977

4 4.489

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 ELECTRONIC CENTRIFUGAL ACTION R-407c THERMOSTATIC 220V-1Ph-60Hz

CONDENSER
CONDENSER COIL Tube Dia.- Rows - Fins per inch Total face area, Sq. ft. AIRFLOW, CFM NUMBER OF FAN/FAN DIA.,mm FAN MOTOR RPM @ 230/380/460-3-60 3/8314 88.9 26000 4/762 3/8314 88.9 50340 4/800 3/8314 88.9 50340 4/800 3/8314 88.9 50340 4/800
3/8414 3/8314

3/8414 88.9 47900 4/800

88.9 49092 4/800

1100/1100/1100 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070

COOLER
COOLER PART NUMBER SHELL DIAMETER, mm LENGTH, mm TOTAL WATER HOLDING VOLUME, Liters WATER IN/OUT PIPE DIA.mm 800-620-15 194 1815 30 75 800-695-06 194 1815 30 75 800-620-82 219 1820 41.8 75 800-620-82 219 1820 41.8 75 800-620-86 273 1850 62.7 100 800-620-86 273 1850 62.7 100

GENERAL
REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg SHIPPING /OPERATING WEIGHTS (Copper coils), kg NOTES: 17 74.9/71.4/66.1 1541/1571 1737/1767 10 71.6/68.1/62.8 1571/1601 1766/1796 12/10 72.2/68.7/63.4 1728/1770 1924/1966 12 72.7/69.2/63.9 1845/1887 2040/2082 14/12 74.4/70.9/65.6 2013/2076 2253/2316 14 75.6/72.1/66.8 2108/2171 2392/2455

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

11

SELECTION PROCEDURE (English units)

DESIGN REQUIREMENTS The following design requirements must be known to select a package chiller. 1. Required cooling capacity in tons 2. Leaving chilled water temperature in 0F (LCWT) 3. Chilled water flow rate in GPM 4. Chilled water cooling range in 0F (water in temp. _ water out temp.) 5. Design ambient temperature 6. Minimum ambient temperature 7. Altitude 8. Electrical power supply EVAPORATOR SAMPLE SELECTION Select an Air Cooled Packaged chiller for the following conditions: Required system capacity is 33 tons at 540F entering chilled water and 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.
ELEVATION ABOVE SEA LEVEL (FT.)
0 2000 4000 6000

CAPACITY CORRECTION FACTOR

1.00 0.99 0.98 0.97

TABLE - 1

POWER ARI FOULING CAPACITY CORRECTION INPUT STANDARDS 2 0 FACTOR (HR-FT - F/BTU) FACTOR FACTOR
0.00010 0.00025 0.00050 0.00075 0.00100 1.000 0.992 0.978 0.965 0.951 1.000 0.997 0.990 0.984 0.978 ARI-550/590-98 ARI-590-86 ARI-590-81

TABLE - 2

CORRECTION FACTOR (0F)

STEP-1: UNIT SELECTION Entering the capacity performance data at given LCWT and ambient temperature. ALY035 chiller unit at sea level will produce 35.1 tons and 36.9 kW compressor power input at 440F leaving chilled water temperature with 100F water temperature difference and 950F ambient temperature. For the conditions required, the unit actual cooling capacity when corrected for altitude (0.99) and fouling factor (1.0). Capacity = 35.1x0.99x1.0 = 34.7 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

+0.6 +0.4 +0.2 0 -0.2 -0.4

10

15

20

CHILLED WATER TEMPERATURE RISE (0F)

TABLE - 3

Cooling Range, T 100F Referring to pressure drop chart (page # 20), pressure drop at 79.2 GPM = 18.9 ft. of water for selected model. STEP-3: ELECTRICAL Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ALY035 is to be sized at a minimum circuit ampacity (MCA) of 92 Amps and the main branch protection device is to be sized at a maximum over current protection (MOCP) of 129 Amps. STEP-4: CHILLED WATER PUMP SELECTION For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCWT CORRECTION Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperature range is above 100F and subtract correction from design leaving chilled water temperature (LCWT) when water temperature 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 is 44+0.2 = 44.20F. NOTE: 1. When the chilled water temperature rise is less than 50F, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2.Please refer to water pressure drop curves.

12

SELECTION PROCEDURE (Metric units)

DESIGN REQUIREMENTS The 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 LPS 4. Chilled water cooling range in 0C (water in temp. _ water out temp.) 5. Design ambient temperature 6. Minimum ambient temperature 7. Altitude 8. Electrical power supply EVAPORATOR SAMPLE SELECTION Select an Air Cooled Packaged chiller for the following conditions: Required system capacity is 118 kW at 120C entering chilled water and 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.
ELEVATION ABOVE SEA LEVEL (Meter)
0 600 1200 1800

CAPACITY CORRECTION FACTOR

1.00 0.99 0.98 0.97

TABLE - 1

POWER ARI FOULING CAPACITY CORRECTION INPUT STANDARDS FACTOR (M2-0C/W) FACTOR FACTOR
0.000018 0.000044 0.000088 0.000132 0.000176 1.000 0.992 0.978 0.965 0.951 1.000 0.997 0.990 0.984 0.978 ARI-550/590-98 ARI-590-86 ARI-590-81

TABLE - 2

CORRECTION FACTOR (0C)

STEP-1: UNIT SELECTION Entering the capacity performance data at given LCWT and ambient temperature. ALY035 chiller unit at sea level will produce 121 kW and 36.7 kW compressor power input at 60C leaving chilled water temperature with 60C water temperature difference and 350C ambient temperature. For the conditions required, the unit actual cooling capacity when corrected for altitude (0.99) and fouling factor (1.0). Capacity = 121x0.99x1.0 = 119.8 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 Cooling Range, T = 118 x 0.239 60C = 4.7 LPS

+0.33 +0.22 +0.11 0 -0.11 -0.22

10

CHILLED WATER TEMPERATURE RISE (0C)

TABLE - 3

Referring to pressure drop chart (page # 20), pressure drop 4.7 LPS = 52 kPa for selected model. STEP-3: ELECTRICAL Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ALY035 is to be sized at a minimum circuit ampacity (MCA) of 92 Amps and the main branch protection device is to be sized at a maximum over current protection (MOCP) of 129 Amps. STEP-4: CHILLED WATER PUMP SELECTION For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCWT CORRECTION Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperature range is above 60C and subtract correction from design leaving chilled water temperature (LCWT) when water temperature 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 is 60C+0.11 = 6.110C. NOTE: 1. When the chilled water temperature rise is less than 30C, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2.Please refer to water pressure drop curves.
13

ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (Antifreeze)

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

ETHYLENE GLYCOL % BY WEIGHT

Freezing point of Ethylene glycol solution Ambient temperature Cooling capacity correction factor Water flow correction factor Pressure drop correction factor

0%
00C (320F) 8.30C (470F) 1.0 1.0 1.0

12%
-50C (230F) 3.30C (380F) 0.985 1.02 1.07

22%
-100C (140F) -1.70C (290F) 0.980 1.04 1.11

30%
-150C (50F) -6.70C (200F) 0.974 1.075 1.18

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

14

PERFORMANCE DATA (English units)

950F AMBIENT TEMPERATURE COMP. kW EER
9.6 10.2 9.7 10.0 9.9 9.7 9.8 10.0 9.6 9.5 10.0 9.8 10.0 10.6 10.1 10.4 10.2 10.0 10.1 10.3 9.9 9.7 10.4 10.2 10.4 10.9 10.4 10.6 34.2 47.1 61.8 13.5 18.0 24.3 15.5 21.0 28.6 9.3 8.7 9.0 32.3 43.3 58.2 12.7 16.8 22.7 150.7 164.9 23.9 59.0 64.3 9.2 73.7 83.5 10.7 8.7 8.5 8.7 141.7 154.3 22.0 55.0 59.4 8.6 83.8 95.4 12.1 17.6 23.7 32.1 113.7 121.8 44.8 48.0 56.1 62.5 8.4 8.2 107.4 115.3 42.1 45.4 63.2 70.8 97.9 108.2 38.3 42.4 49.5 50.3 8.5 8.8 92.0 101.8 35.6 39.7 55.8 56.3 7.1 7.4 7.1 6.9 7.2 6.9 7.4 7.8 7.3 7.6 80.9 31.5 41.5 8.3 75.5 28.9 47.4 6.8 65.2 25.6 31.7 8.6 61.4 24.0 35.9 7.3 45.5 60.1 17.5 23.5 20.9 28.4 8.5 8.8 42.1 56.5 16.4 22.1 23.6 31.9 7.2 7.4 39.3 52.9 57.7 69.4 85.5 95.3 101.1 108.8 132.0 142.4 20.6 30.4 40.4 54.6 32.8 12.9 15.4 8.9 31.0 12.2 17.4 7.6 29.2 22.9 8.8 10.7 8.4 21.2 8.2 12.0 7.1 19.8 157.1 61.2 82.3 8.2 146.8 56.3 94.2 6.6 135.1 143.4 56.1 72.7 8.4 134.6 52.2 82.7 6.9 125.2 49.3 52.6 8.0 11.6 15.7 21.0 23.0 27.0 33.6 37.7 40.3 43.5 52.0 55.6 8.3 12.1 16.2 21.7 110.0 118.1 43.2 46.5 55.7 62.0 8.2 8.0 103.7 111.5 40.5 43.7 62.7 70.2 6.9 6.7 97.2 105.0 38.6 41.8 103.6 40.6 49.8 8.5 97.4 38.0 55.8 7.2 91.1 36.1 94.0 36.8 48.9 8.3 88.2 34.1 55.2 6.9 81.9 32.1 60.0 60.2 68.0 76.6 90.6 103.5 13.0 19.0 25.6 34.6 39.1 52.0 60.6 60.8 68.6 77.2 91.7 104.7 13.1 19.1 25.7 34.9 77.2 30.0 40.9 8.0 72.0 27.5 46.8 6.5 66.1 25.6 51.5 62.9 24.7 31.4 8.4 59.2 23.2 35.5 7.1 55.6 22.1 38.7 43.0 57.4 16.8 22.5 20.8 28.1 8.2 8.5 40.4 54.1 15.8 21.1 23.4 31.6 7.0 7.2 37.9 50.7 15.2 20.1 25.4 34.3 6.2 6.3 6.2 5.6 6.0 6.4 6.1 6.0 6.0 5.7 6.4 6.7 6.4 6.6 6.4 5.8 6.2 6.6 6.3 6.2 6.3 5.9 6.6 6.9 6.6 6.7 31.5 12.4 15.3 8.7 29.7 11.7 17.3 7.3 28.0 11.2 18.8 6.4 21.8 8.5 10.6 8.1 20.3 7.9 11.9 6.9 19.0 7.6 12.9 6.2 18.3 26.8 36.4 48.3 53.1 61.5 77.1 86.6 92.7 100.4 118.2 126.1 19.1 27.9 37.8 50.4 55.1 64.7 80.7 90.6 96.6 104.4 124.8 133.4 19.9 29.1 38.9 52.0

1050F AMBIENT TEMPERATURE CAP. (Tons) EER EER EER COMP. kW WATER FLOW (GPM) CAP. (Tons) COMP. kW CAP. (Tons) COMP. kW WATER FLOW (GPM) WATER FLOW (GPM)

1150F AMBIENT TEMPERATURE

1220F AMBIENT TEMPERATURE

LEAVING CHILLED WATER TEMP. (LCWT) WATER FLOW (GPM)

9.4 13.5 18.5 24.9 27.8 35.9 43.4 44.4 49.4 54.8 64.1 72.3 9.5 13.6 18.6 25.2 28.0 36.5 44.0 44.8 49.7 55.2 65.0 73.4 9.6 13.7 18.8 25.4

UNIT SIZE

CAP. (Tons)

ALY 010C

9.1

ALY 015C

13.1

ALY 020C ALY 025C

17.9 23.9

ALY 030C

26.2

40 F

ALY 035C

32.2

ALY 040C

39.2

ALY 045C

43.2

ALY 050C ALY 055C

45.8 49.2

ALY 065C

59.7

ALY 070C

65.5

ALY 010C

9.5

ALY 015C

13.7

ALY 020C ALY 025C

19.0 25.0

ALY 030C

27.2

42 F

ALY 035C

33.7

ALY 040C ALY 045C

40.8 45.1

ALY 050C ALY 055C

47.4 50.7

15
28.3 36.9 44.5 45.2 50.8 56.4 65.8 74.4 10.5 171.9 67.0 84.6 8.7 10.6 10.4 10.7 124.3 133.7 157.0 48.8 52.6 61.5 57.2 63.8 74.5 9.0 8.8 9.0 117.2 126.3 147.6 160.9 10.6 10.3 10.4 10.6 67.8 84.1 101.3 112.1 26.6 32.7 39.7 44.0 32.0 42.0 50.0 50.7 8.9 8.6 8.8 9.0 63.9 78.5 95.2 105.5 25.0 30.1 36.9 41.2 45.8 49.5 57.3 61.9

ALY 065C ALY 070C ALY 010C

62.8 68.7 9.9

ALY 015C ALY 020C ALY 025C

14.2 19.6 25.8

44 0F

ALY 030C ALY 035C ALY 040C ALY 045C

28.3 35.1 42.2 46.7

36.2 47.9 56.3 56.8 64.4 72.2 84.6 96.4

7.5 7.0 7.3 7.7 7.6 7.4 7.4 7.1

60.0 72.3 88.6 98.8 110.0 118.9 137.4 148.6

23.9 28.1 34.9 39.2 43.7 47.3 54.1 58.0

39.4 52.5 61.1 61.3 69.9 78.6 92.5 105.7

6.6 6.0 6.4 6.8 6.8 6.6 6.5 6.1

57.3 67.5 83.7 94.0 105.0 113.6 129.9 139.2

ALY 050C ALY 055C ALY 065C

51.8 55.7 65.4

ALY 070C

71.6

LEGEND:

NOTES: 1. Packaged chillers are rated with ARI standard 550/590. 2. Performance data are based on 100F water range in evaporator. 3. Ratings are based on 0.00010 (hr-ft2-0F/Btu) fouling factor for evaporator. 4. Direct interpolation is permissible. Do not extrapolate. 5. kW power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan kW.

kW

- Compressor power input

GPM

- Gallons Per Minute

EER

- Energy Efficiency Ratio

PERFORMANCE DATA (English units)

950F AMBIENT TEMPERATURE COMP. kW EER EER EER
7.6 8.0 7.6 7.8 7.7 7.2 7.5 7.9 7.9 7.7 7.6 7.3 7.8 8.2 8.0 8.1 8.0 7.4 7.8 8.2 8.1 7.9 7.7 7.4 8.0 17.9 24.3 33.0 8.3 8.2 8.3 44.9 59.4 64.7 78.1 95.9 107.3 118.0 127.8 143.6 155.7 22.7 33.0 46.1 61.1 32.4 22.1 152.7 141.0 55.5 59.6 8.8 12.9 17.9 23.6 25.7 30.5 37.8 42.6 46.8 50.7 56.4 60.7 8.9 13.1 18.2 24.2 114.7 124.2 45.5 49.3 102.8 40.8 92.1 36.3 61.6 61.9 70.5 79.4 93.0 106.3 13.3 19.4 26.2 35.6 40.0 53.5 62.2 62.6 71.0 79.9 93.4 106.8 13.4 19.5 26.3 35.8 75.2 29.3 53.0 62.3 24.7 39.7 42.2 56.7 16.9 22.5 25.9 35.2 6.8 6.9 6.8 6.2 6.6 7.0 7.0 6.8 6.6 6.3 6.9 7.3 7.1 7.2 7.0 6.4 6.8 7.3 7.1 6.9 6.7 6.4 7.0 7.4 7.3 7.3 31.5 12.5 19.3 7.1 21.4 8.6 13.2 6.8 20.6 30.1 40.6 54.0 59.4 70.3 87.1 97.9 109.2 118.4 133.1 143.0 21.1 30.9 42.9 56.5 61.6 73.1 90.8 102.2 112.3 121.6 135.5 145.7 21.5 31.5 43.7 58.1

1050F AMBIENT TEMPERATURE CAP. (Tons) CAP. (Tons) CAP. (Tons) EER COMP. kW
8.9 13.1 17.6 23.6 25.9 31.3 38.4 42.8 47.8 51.7 58.8 63.6 9.2 13.5 18.7 24.7 27.0 32.6 40.0 44.7 49.2 53.2 59.8 64.9 9.4 13.8 19.2 25.5 85.6 97.6 12.3 65.5 73.4 57.5 57.9 48.9 36.8 24.2 32.8 17.8 12.3 97.1 85.2 65.0 72.9 57.3 56.8 48.4 36.5 23.9 32.4 17.7 12.2

1150F AMBIENT TEMPERATURE COMP. kW WATER FLOW (GPM) WATER FLOW (GPM)

1220F AMBIENT TEMPERATURE

LEAVING CHILLED WATER TEMP. (LCWT) WATER FLOW (GPM) COMP. kW

10.8 15.7 21.2 28.8 32.3 42.5 50.6 51.2 57.8 64.6 75.1 85.3 10.9 15.8 21.4 29.2 32.6 43.0 51.3 51.7 58.3 65.0 75.5 85.9 10.9 15.8 21.5 29.4 9.9 9.6 9.8 35.1 48.7 65.3 9.3 9.0 9.3 154.5 168.9 24.0 9.6 9.4 126.1 136.4 9.2 9.6 102.9 114.4 9.1 84.8 9.5 69.0 9.4 9.6 47.6 63.3 9.7 34.4 9.2 23.5 8.9 165.5 9.2 151.6 9.4 9.2 122.5 132.3 9.3 109.7 9.0 98.8 8.8 81.7 9.2 66.4 9.0 9.3 45.1 60.4 9.5 33.5 8.9 22.8

UNIT SIZE WATER FLOW (GPM)

9.6 13.8 18.9 25.6 28.6 37.4 45.1 45.6 51.4 57.1 66.3 75.1 9.7 13.9 19.0 25.9 28.9 37.9 45.8 46.1 51.8 57.6 66.7 75.7 9.7 14.0 19.0 26.1 11.7 11.1 11.6 37.2 50.8 69.4 14.6 20.3 27.2 11.1 10.9 10.9 164.7 180.8 25.2 64.4 70.4 10.0 11.3 11.1 134.1 144.9 52.6 56.8 10.9 11.3 109.4 121.4 42.9 47.7 10.9 90.8 35.3 11.2 73.3 28.8 11.1 11.3 50.5 67.2 19.8 26.4 11.5 36.4 14.3 10.8 25.0 9.8 10.7 177.0 69.0 10.9 161.4 63.2 11.0 10.8 130.2 140.5 51.0 55.1 10.9 116.4 45.7 10.6 105.1 41.2 10.6 87.4 34.0 10.9 70.4 27.7 10.8 10.9 48.9 64.1 18.8 25.2 11.3 35.4 13.9 10.6 24.6 9.5

CAP. (Tons)

ALY 010C

10.2

ALY 015C

14.8

ALY 020C ALY 025C

20.4 26.7

ALY 030C

29.3

46 F

ALY 035C

36.4

ALY 040C

43.8

ALY 045C

48.5

ALY 050C ALY 055C

54.2 58.5

ALY 065C

67.3

ALY 070C

73.7

ALY 010C

10.4

ALY 015C

15.2

ALY 020C ALY 025C

21.1 28.0

ALY 030C

30.5

48 F

ALY 035C

37.8

ALY 040C ALY 045C

45.6 50.6

ALY 050C ALY 055C

55.9 60.4

16
29.3 38.3 46.3 46.5 52.4 58.3 67.1 76.2 11.0 184.4 71.8 86.4 9.2 11.7 11.5 11.2 140.6 151.6 167.9 55.2 59.5 65.6 59.0 65.8 75.9 9.9 9.7 9.4 132.4 142.9 157.5 172.3 11.6 11.1 11.1 11.6 77.2 93.6 113.2 126.0 30.3 36.4 44.3 49.4 33.1 43.4 51.8 52.2 9.9 9.3 9.5 9.9 72.8 87.4 106.4 118.7 28.4 33.5 41.3 46.3 51.7 55.8 60.9 66.2

ALY 065C ALY 070C ALY 010C

68.6 75.3 10.5

ALY 015C ALY 020C ALY 025C

15.5 21.2 28.9

50 0F

ALY 030C ALY 035C ALY 040C ALY 045C

32.2 39.0 47.2 52.5

37.3 49.3 58.0 58.4 66.3 74.3 86.0 98.2

8.3 7.6 7.9 8.4 8.4 8.2 7.8 7.5

68.1 80.5 99.2 111.2 124.0 133.8 146.3 158.8

27.0 31.3 39.1 44.1 49.1 53.1 57.5 61.9

40.5 53.8 62.6 63.2 71.9 80.7 93.8 107.3

7.3 6.5 7.0 7.5 7.4 7.2 6.8 6.5

64.8 75.2 93.8 105.8 117.9 127.3 137.9 148.5

ALY 050C ALY 055C ALY 065C

58.6 63.2 70.0

ALY 070C

76.8

LEGEND:

NOTES: 1. Packaged chillers are rated with ARI standard 550/590. 2. Performance data are based on 100F water range in evaporator. 3. Ratings are based on 0.00010 (hr-ft2-0F/Btu) fouling factor for evaporator. 4. Direct interpolation is permissible. Do not extrapolate. 5. kW power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan kW.

kW

- Compressor power input

GPM

- Gallons Per Minute

EER

- Energy Efficiency Ratio

PERFORMANCE DATA (Metric units)

350C AMBIENT TEMPERATURE COMP. kW COP
2.8 3.0 2.7 2.8 2.9 2.8 2.8 2.9 2.9 2.8 2.9 2.9 2.9 3.1 2.9 3.0 3.0 2.9 2.9 3.0 2.8 2.8 3.0 2.9 3.0 3.2 3.0 3.1 2.0 2.7 3.6 46.7 63.0 84.6 15.3 20.8 28.1 2.7 2.6 2.7 1.9 2.5 3.4 43.7 58.4 78.8 8.6 9.5 1.4 204.7 223.3 31.8 72.4 82.0 10.6 2.6 2.5 2.5 8.2 8.9 1.3 189.7 204.8 29.6 83.2 94.7 12.0 17.5 23.5 31.9 6.4 6.9 153.4 164.7 55.0 61.3 2.5 2.4 6.1 6.6 143.6 154.6 62.6 70.1 5.6 6.2 133.6 147.8 48.7 49.6 2.5 2.6 5.3 5.9 123.5 137.5 55.4 56.0 2.1 2.2 2.0 2.0 2.1 2.0 2.1 2.3 2.1 2.2 4.6 109.5 40.8 2.5 4.4 100.0 47.1 2.0 3.7 89.1 31.2 2.5 3.6 83.3 35.6 2.1 2.6 3.5 61.4 82.2 20.7 27.9 2.5 2.6 2.4 3.3 57.0 76.6 23.4 31.7 2.1 2.2 2.3 3.1 3.3 4.0 4.9 5.5 5.7 6.2 7.6 8.2 1.2 1.7 2.3 3.1 1.9 44.9 15.1 2.6 1.8 42.1 17.3 2.2 1.7 1.3 30.7 10.5 2.5 1.2 28.5 11.9 2.1 1.1 9.1 213.9 81.0 2.4 8.5 195.3 93.6 1.9 7.8 8.3 195.8 71.5 2.5 7.8 180.9 82.2 2.0 7.2 170.3 181.7 27.5 40.2 54.7 72.9 79.4 93.1 116.2 130.5 136.9 147.9 179.0 191.2 28.6 41.8 56.1 75.0 6.6 7.1 157.0 169.5 55.3 61.6 2.5 2.5 6.3 6.8 146.4 158.5 62.8 70.5 2.1 2.0 5.8 6.3 139.2 151.2 5.9 140.6 49.1 2.5 5.6 130.7 55.4 2.1 5.2 124.0 5.4 127.5 48.0 2.4 5.1 117.6 54.7 2.0 4.7 110.5 59.8 59.9 68.3 77.1 90.3 103.1 13.0 18.9 25.5 34.5 38.9 51.8 60.4 60.6 68.1 76.7 91.2 104.2 13.1 19.1 25.6 34.7 4.4 104.0 40.2 2.4 4.1 94.8 46.5 1.9 3.8 88.1 51.2 3.6 86.5 31.0 2.5 3.4 80.7 35.4 2.1 3.2 77.0 38.7 2.3 3.2 56.5 76.8 20.4 27.5 2.3 2.5 2.3 3.1 53.2 71.7 23.2 31.3 2.0 2.0 2.1 2.9 50.8 68.3 25.2 34.0 1.8 1.8 1.8 1.6 1.7 1.8 1.8 1.8 1.7 1.6 1.8 1.9 1.9 1.9 1.9 1.7 1.8 1.9 1.8 1.8 1.8 1.7 1.9 2.0 1.9 2.0 1.8 43.4 15.0 2.6 1.7 40.6 17.2 2.1 1.6 38.8 18.8 1.9 1.3 29.6 10.4 2.4 1.2 27.6 11.9 2.0 1.1 26.5 12.9 1.8 1.1 1.5 2.0 2.7 3.1 3.5 4.4 4.9 5.6 6.0 6.8 7.2 1.1 1.6 2.2 2.9 3.2 3.7 4.6 5.2 5.5 5.9 7.1 7.6 1.1 1.7 2.2 3.0

400C AMBIENT TEMPERATURE CAP. (kW) COP COP COP COMP. kW WATER FLOW (LPS) CAP. (kW) COMP. kW CAP. (kW) COMP. kW WATER FLOW (LPS) WATER FLOW (LPS)

460C AMBIENT TEMPERATURE

500C AMBIENT TEMPERATURE

LEAVING CHILLED WATER TEMP. (LCWT) WATER FLOW (LPS)

9.4 13.5 18.2 24.7 27.7 35.7 43.1 44.2 49.7 55.2 63.8 72.0 9.5 13.6 18.6 25.1 27.9 36.3 43.8 44.7 49.4 54.8 64.6 73.0 9.5 13.7 18.7 25.3

UNIT SIZE

CAP. (kW)

ALY 010C

31.4

ALY 015C

45.7

ALY 020C ALY 025C

58.4 80.9

ALY 030C

91.3

4 C

ALY 035C

110.7

ALY 040C

134.9

ALY 045C

148.6

ALY 050C ALY 055C

165.9 178.7

ALY 065C

207.3

ALY 070C

227.5

ALY 010C

32.8

ALY 015C

47.3

ALY 020C ALY 025C

65.6 86.8

ALY 030C

94.0

5 0C

ALY 035C

116.6

ALY 040C ALY 045C

141.4 156.2

ALY 050C ALY 055C

161.5 173.1

17
28.2 36.7 44.2 45.0 50.3 55.8 65.4 74.0 3.0 9.9 233.2 83.0 2.6 3.0 3.0 3.1 7.0 7.5 9.0 165.6 178.1 213.8 56.0 62.4 73.2 2.6 2.5 2.6 6.6 7.1 8.5 9.3 3.0 3.0 3.0 3.1 3.9 4.8 5.8 6.4 92.4 113.7 138.0 152.9 31.5 41.2 49.2 50.0 2.6 2.5 2.6 2.7 3.7 4.5 5.5 6.1 86.3 104.0 127.7 142.4 155.1 167.2 198.2 214.1

ALY 065C ALY 070C ALY 010C

216.5 237.1 34.2

ALY 015C ALY 020C ALY 025C

49.1 67.8 89.3

6 0C

ALY 030C ALY 035C ALY 040C ALY 045C

97.4 121.0 146.0 161.5

35.9 47.5 55.9 56.4 63.7 71.3 84.1 95.7

2.2 2.0 2.1 2.2 2.2 2.1 2.2 2.1

3.4 4.1 5.1 5.7 6.2 6.7 7.9 8.5

82.3 96.9 120.3 135.2 147.9 159.9 187.0 200.2

39.2 52.3 60.8 61.1 69.3 78.0 92.1 105.3

1.9 1.7 1.8 2.0 1.9 1.9 1.9 1.8

3.3 3.9 4.8 5.4 5.9 6.4 7.5 8.0

ALY 050C ALY 055C ALY 065C

174.4 187.2 226.0

ALY 070C

247.4

LEGEND:

NOTES: 1. Packaged chillers are rated with ARI standard 550/590. 2. Performance data are based on 60C water range in evaporator. 3. Ratings are based on 0.000018 (m2 -0C/W) fouling factor for evaporator. 4. Direct interpolation is permissible. Do not extrapolate. 5. kW power input is for compressor only. 6. COP for entire unit. Refer to electrical data for fan kW.

kW

- Compressor power input

LPS

- Liters Per Second

COP

- Coefficient of Performance

PERFORMANCE DATA (Metric units)

350C AMBIENT TEMPERATURE COMP. kW COP
3.1 3.2 3.1 3.1 3.1 3.1 3.1 3.2 3.2 3.1 3.2 3.1 3.1 3.3 3.2 3.2 3.2 3.1 3.1 3.2 3.3 3.2 3.2 3.2 3.2 3.4 3.3 3.4 2.2 3.0 4.1 52.0 71.9 96.6 15.7 21.3 29.1 3.0 2.9 2.9 2.1 2.9 3.9 48.6 67.9 89.9 9.5 10.4 1.5 225.5 246.4 35.5 74.4 84.5 10.8 2.8 2.7 2.8 9.0 9.8 1.4 208.5 226.0 33.4 85.2 97.1 12.3 17.9 24.2 33.0 7.7 8.3 182.2 196.9 57.3 63.9 2.8 2.8 7.3 7.9 169.7 183.8 65.0 72.9 6.2 6.9 147.5 163.7 50.2 50.8 2.7 2.8 5.9 6.5 136.8 152.7 56.9 57.4 2.2 2.3 2.3 2.3 2.3 2.2 2.3 2.5 2.4 2.4 5.2 122.0 42.1 2.7 4.9 111.7 48.4 2.1 4.2 98.9 32.0 2.8 3.9 92.3 36.5 2.3 2.9 3.8 67.5 90.2 21.0 28.6 2.7 2.8 2.7 3.6 62.8 84.2 23.9 32.4 2.3 2.3 2.5 3.4 3.7 4.5 5.5 6.1 6.8 7.3 8.3 9.0 1.3 1.9 2.7 3.6 2.1 49.8 15.5 2.9 2.0 46.6 17.7 2.4 1.9 1.4 34.0 10.7 2.7 1.4 31.7 12.2 2.3 1.3 10.2 240.9 83.9 2.6 9.6 221.2 96.5 2.1 8.8 9.3 220.7 73.9 2.7 8.8 204.4 84.7 2.2 8.1 192.7 206.7 30.4 44.5 60.3 80.1 87.8 104.3 129.1 145.2 161.3 174.9 196.5 211.2 31.5 46.3 64.3 85.4 7.4 8.0 176.4 190.3 56.8 63.4 2.7 2.7 7.0 7.6 164.6 177.9 64.5 72.3 2.3 2.2 6.6 7.1 156.6 169.7 6.6 157.9 50.3 2.7 6.3 147.2 56.9 2.3 5.9 139.9 6.0 142.5 49.7 2.6 5.7 132.0 56.4 2.2 5.3 124.5 61.3 61.6 70.2 79.0 92.8 106.0 13.3 19.3 26.0 35.3 39.8 53.1 61.8 62.1 70.7 79.5 93.2 106.6 13.4 19.5 26.4 35.8 5.0 117.8 41.6 2.6 4.7 107.8 48.0 2.1 4.3 100.5 52.7 4.0 95.6 31.7 2.7 3.8 89.3 36.2 2.2 3.6 85.1 39.5 2.8 3.7 64.8 87.0 20.9 28.3 2.6 2.7 2.6 3.5 60.0 81.1 23.7 32.2 2.2 2.3 2.4 3.2 57.8 77.2 25.8 35.0 2.0 2.0 2.0 1.8 1.9 2.0 2.0 2.0 1.9 1.8 2.0 2.1 2.0 2.0 2.0 1.8 2.0 2.1 2.1 2.0 2.0 1.9 2.1 2.2 2.1 2.2 2.0 48.4 15.4 2.8 1.9 45.3 17.6 2.3 1.8 43.2 19.2 2.0 1.4 33.0 10.7 2.6 1.3 30.7 12.1 2.2 1.2 29.6 13.2 2.0 1.2 1.7 2.3 3.1 3.4 4.0 5.0 5.6 6.2 6.8 7.7 8.2 1.2 1.8 2.4 3.2 3.5 4.2 5.1 5.8 6.4 7.0 7.8 8.4 1.3 1.8 2.6 3.4

400C AMBIENT TEMPERATURE CAP. (kW) COP COP COP COMP. kW WATER FLOW (LPS) CAP. (kW) COMP. kW CAP. (kW) COMP. kW WATER FLOW (LPS) WATER FLOW (LPS)

460C AMBIENT TEMPERATURE

500C AMBIENT TEMPERATURE

LEAVING CHILLED WATER TEMP. (LCWT) WATER FLOW (LPS)

9.6 13.8 18.8 25.4 28.4 37.1 44.7 45.4 51.1 56.8 66.1 74.8 9.6 13.9 18.9 25.7 28.7 37.6 45.3 45.7 51.5 57.3 66.5 75.4 9.7 14.0 19.0 26.1

UNIT SIZE

CAP. (kW)

ALY 010C

35.4

ALY 015C

50.9

ALY 020C ALY 025C

69.9 91.8

ALY 030C

100.9

7 C

ALY 035C

125.2

ALY 040C

150.6

ALY 045C

166.7

ALY 050C ALY 055C

186.1 200.5

ALY 065C

233.4

ALY 070C

255.7

ALY 010C

36.2

ALY 015C

52.5

ALY 020C ALY 025C

72.4 95.2

ALY 030C

104.3

8 0C

ALY 035C

129.6

ALY 040C ALY 045C

155.8 172.7

ALY 050C ALY 055C

192.5 207.8

18
29.3 38.3 46.4 46.6 52.5 58.4 67.2 76.3 3.2 10.8 255.2 85.4 2.7 3.4 3.4 3.3 8.2 8.9 9.8 195.9 211.3 233.1 58.3 65.1 75.1 3.0 2.9 2.8 7.8 8.4 9.3 10.2 3.4 3.3 3.3 3.4 4.5 5.5 6.6 7.4 107.6 129.4 157.4 175.6 32.7 42.9 51.3 51.6 3.0 2.8 2.8 3.0 4.3 5.2 6.3 7.0 100.3 118.5 145.9 163.7 182.4 197.0 215.3 233.8

ALY 065C ALY 070C ALY 010C

238.5 261.7 37.0

ALY 015C ALY 020C ALY 025C

54.8 74.5 102.0

10 0C

ALY 030C ALY 035C ALY 040C ALY 045C

113.6 137.6 166.4 185.3

37.3 49.2 57.9 58.4 66.2 74.2 85.9 98.0

2.4 2.2 2.3 2.5 2.5 2.4 2.3 2.2

4.0 4.7 5.8 6.5 7.3 7.9 8.6 9.3

95.2 110.6 137.8 155.6 173.3 187.1 202.7 218.3

40.6 53.9 62.7 63.3 71.9 80.8 93.8 107.4

2.2 1.9 2.0 2.2 2.2 2.1 2.0 1.9

3.8 4.4 5.5 6.2 6.9 7.5 8.1 8.7

ALY 050C ALY 055C ALY 065C

206.8 222.9 246.9

ALY 070C

271.2

LEGEND:

NOTES: 1. Packaged chillers are rated with ARI standard 550/590. 2. Performance data are based on 60C water range in evaporator. 3. Ratings are based on 0.000018 (m2 -0C/W) fouling factor for evaporator. 4. Direct interpolation is permissible. Do not extrapolate. 5. kW power input is for compressor only. 6. COP for entire unit. Refer to electrical data for fan kW.

kW

- Compressor power input

LPS

- Liters Per Second

COP

- Coefficient of Performance

ELECTRICAL DATA
COMPRESSOR TYPE-1 CRANKCASE HEATER Volts Qty. FCA COMPRESSOR TYPE-2 CONDENSER FAN MOTORS Max.

UNIT SIZE

SUPPLY VOLTAGE

Min.

ALY010C

ALY015C

ALY020C

ALY025C

ALY030C

ALY035C

ALY040C

19
NOTES: 4. All field wiring must be in accordance with NEC and local standards. 6. Neutral line required on 380V-3Ph-60Hz power supply only.

ALY045C

ALY050C

ALY055C

ALY065C

ALY070C

Nominal (V-Ph-Hz) 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 208/230-3-60 380-3-60 460-3-60 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 253 418 506 CB CB RLA LRA MCA MOCP Qty. (each) (each) Poles MTA Qty. 48 81 1 33.3 239 3 53 1 29 49 1 20.1 145 3 32 1 24 41 1 16.6 125 3 27 1 66 115 1 48.3 425 3 77 1 40 69 1 29.2 239 3 47 1 34 58 1 24.1 187 3 39 1 87 120 2 33.3 239 3 53 2 52 72 2 20.1 145 3 32 2 44 61 2 16.6 125 3 27 2 73 121 1 48.3 425 3 77 1 44 73 1 29.2 239 3 47 1 37 61 1 24.1 187 3 39 1 121 169 2 48.3 425 3 77 2 73 102 2 29.2 239 3 47 2 61 85 2 24.1 187 3 39 2 165 233 2 67.8 505 3 108 2 92 129 2 37.6 280 3 60 2 77 108 2 31.1 225 3 50 2 188 262 2 74.4 500 3 119 2 113 158 2 45.0 305 3 72 2 95 132 2 37.2 250 3 60 2 179 216 4 36.4 245 3 58 4 108 130 4 22.0 145 3 35 4 91 110 4 18.2 125 3 29 4 206 254 2 48.3 425 3 77 2 124 153 2 29.2 239 3 47 2 105 129 2 24.1 187 3 39 2 230 278 4 48.3 425 3 77 4 138 167 4 29.2 239 3 47 4 116 141 4 24.1 187 3 39 4 274 341 2 67.8 505 3 108 2 157 195 2 37.6 280 3 60 2 132 163 2 31.1 225 3 50 2 313 380 4 67.8 505 3 108 4 174 211 4 37.6 280 3 60 4 146 177 4 31.1 225 3 50 4 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 FLA (each) 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 5.1 2.9 2.8 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.5 3.5 6.1 3.52 3.5 6.1 3.52 3.5 12.2 7.04 7 12.2 7.04 7 12.2 7.04 7 12.2 7.04 7 20.2 11.72 11.12 24.4 14.08 14 24.4 14.08 14 24.4 14.08 14 24.4 14.08 14 24.4 14.08 14 CB (Qty.) 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 230 380 460 Total Watts 90 61 90 70 45 70 180 122 180 160 135 160 140 90 140 240 240 240 300 300 300 360 360 360 320 270 320 280 180 280 380 330 380 480 480 480 Total Amps 0.39 0.16 0.20 0.30 0.12 0.15 0.78 0.32 0.39 0.70 0.36 0.35 0.61 0.24 0.30 1.04 0.63 0.52 1.30 0.79 0.65 1.57 0.95 0.78 1.39 0.71 0.70 1.22 0.47 0.61 1.65 0.87 0.83 2.09 1.26 1.04 Total kW 1.91 1.91 2.10 1.91 1.91 2.10 3.82 3.82 4.20 3.82 3.82 4.20 3.82 3.82 4.20 3.82 3.82 4.20 4.40 4.40 4.40 7.64 7.64 8.40 7.64 7.64 8.40 7.64 7.64 8.40 7.64 7.64 8.40 7.64 7.64 8.40 CB CB RLA LRA Qty. (each) (each) Poles MTA Qty. 1 36.4 245 3 58 1 1 22.0 145 3 35 1 1 18.2 125 3 29 1 2 36.4 245 3 58 2 2 22.0 145 3 35 2 2 18.2 125 3 29 2 2 48.3 425 3 77 2 2 29.2 239 3 47 2 2 24.1 187 3 39 2 -

187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414 187 342 414

1. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker. 2. The maximum incoming wire size is 500 mcm. On units having MCA greater than the ampacity of 500 mcm wire, the factory supplied power terminal block will accept two parallel field wires per phase. 3. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection. 5. Minimum and maximum unit supply voltages are shown in the tabulated data above (see also note # 7). 7. The 10% voltage variation from the nominal is allowed for a short time only, not permanent.

LEGEND: MCA - Minimum Circuit Ampacity per NEC 430-24 MOCP - Maximum Over Current Protection RLA - Rated Load Amps LRA - Locked Rotor Amps CB - Circuit Breaker MTA - Must Trip Amps FLA - Full Load Amps FCA - Total Fan Circuit Amps

WATER SIDE PRESSURE DROP

200

1
60 70 80 90 100

234

6 7

PRESSURE DROP (FT. OF WATER)

8 9 10

20

30

40

50

10

20

30

40

50

60

70

80

90 100

200

300

400

500

600 700 800 900 1000 1200

1500

FLOW RATE - GPM

MODEL No.
ALY010C ALY015C ALY020C ALY025C ALY030C ALY035C ALY040C ALY045C ALY050C ALY055C ALY065C ALY070C

CURVE No. Minimum GPM Maximum GPM

1 1 2 3 4 5 6 6 7 7 8 8 18.3 26.8 36.3 48.3 53.0 61.5 77.2 86.5 92.7 100.4 117.8 126.1 26.5 39.3 52.9 73.4 81.6 99.1 119.5 133.1 148.7 160.1 177.6 195.2

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.

20

DIMENSIONS
ALY010C & ALY015C
DIMENSIONS
MODEL ALY010C A 466 393 B 144 217 C 318 206

275

1245

1025

ALY015C

1640

ALY020C, ALY025C, ALY030C & ALY035C

DIMENSIONS
MODEL ALY020C ALY025C
1335

A 1030 1180 1380 1530

B 570 420 245 220

ALY030C ALY035C

275

235

A 2287

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

21

246

2000

DIMENSIONS
ALY040C

100

2675

1530 2287

220

ALY045C, ALY050C, ALY055C, ALY065C & ALY070C

260

DIMENSIONS
MODEL ALY045C ALY050C ALY055C ALY065C ALY070C
2675

A 1530 1500 1500 1500 1500

B 260 292 292 338 338

275

260

A 2287

220

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

22

2000

2000

TYPICAL SCHEMATIC WIRING DIAGRAM

LEGEND
REFER TO UNIT NAMEPLATE FOR POWER SUPPLY
CONTROL PANEL COOLER

COMP 1

CONTROL PANEL

FAN1

B1/B2 C1/C2 CB COMP CC CCA CWP D1/ID.. ETB FLS FM FMC F G/GO HPS HVTB MB NO1/1O S1 SB SSPS SH TK tLAN TRANS UVM ---

ANALOG INPUT COMMON CIRCUIT BREAKER COMPRESSOR COMPRESSOR CONTACTOR COMPRESSOR CONTACTOR AUXILIARY CHILLED WATER PUMP DIGITAL INPUT 1 EARTH TERMINAL BLOCK FLOW SWITCH FAN MOTOR FAN MOTOR CONTACTOR FUSE POWER INPUT HIGH PRESSURE SWITCH HIGH VOLTAGE TERMINAL BLOCK MASTER BOARD DIGITAL OUT 1 CONTROL SWITCH SLAVE BOARD SOLID STATE PROTECTION SYSTEM SHIELD CONDENSER FAN THERMAL CONTACT LOCAL NETWORK PORT TRANSFORMER UNDER VOLTAGE MONITOR TERMINAL BLOCK FIELD WIRING FIELD SUPPLY

NOTES
1. 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 CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH RATING AS RECOMMENDED BY MANUFACTURER. 6. POWER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP. IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE. 7. NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER SUPPLY ONLY.

23

MICROPROCESSOR CONTROLLER
CONTROLLER SEQUENCE OF OPERATION
For 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 maintain the required demand as constant as possible. Below sequence of operation belongs to chiller unit with 2 scroll compressors. For 4 scroll compressors chiller unit the operation will be the same. Only that the capacity change to 25% per compressor. For single scroll compressor unit the capacity change to 100%.

COMPRESSOR STAGE - ON SEQUENCE

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

COMPRESSOR STAGE - OFF SEQUENCE

Assume that the 2 compressors are running (capacity is at 100%). After such interval of time, if the water temperature is decreases 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 compressor will off.

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

24

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

UNIT SELECTION/SIZING
Unit selection procedure and capacities are provided in this catalog for proper selection. The Zamil electronic selection program may also be utilized for this purpose. Over sizing chillers beyond a maximum limit of 5 10 % in order to assure adequate capacity or considering future expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operation and excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operate more efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized unit is usually more costly to purchase, install and operate.

FOULING FACTOR AND WATER REQUIREMENT

The tabulated performance data provided in this catalog are based on a fouling factor of 0.00010 hr-ft2-0F/Btu (0.000018 m2-0C/W). As fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other fouling factors, apply appropriate correction factor from the table provided in this catalog. These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water may result in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading to possible equipment damage.

EFFECT OF ALTITUDE ON UNIT CAPACITY

The tabulated performance data provided in this catalog are for use at or near sea level altitude application. At altitudes substantially above sea level, the decreased air density will reduce condenser capacity and therefore unit capacity. For unit selection at these higher altitudes, apply appropriate correction factor from the table provided in this catalog.

HIGH AMBIENT CONSIDERATION

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

WATER FLOW RATES AND COOLER PRESSURE DROP

The maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog. The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminar flow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessive pressure drop and severe tube erosion. During unit operation, water flow rate must not vary more than 5% from the design flow rate. The water flow switch should be calibrated accordingly.

COOLER FLUID (WATER OR GLYCOL) TEMPERATURES RANGE

Unit 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 fluid temperature range is 50 to 600F. The design cooler temperature drop (T) range is 5 to 150F. The tabulated performance data provided in this catalog is based on a chilled water temperature drop of 100F. Units may be operated at any desired temperature drop within the range of 5 to 150F as long as the temperature and flow limits are not violated and appropriate correction factors are applied on the capacity and power input. The Zamil electronic selection program can be very handy in selecting equipment at different temperature drops. It should be noted that temperature drop outside the aforesaid range is not permitted as it is beyond the optimum range of control and could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the equipment.
25

COOLER FREEZE PROTECTION

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

MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATION

A multiple chiller system has two or more chillers connected by parallel or series piping to a common distribution system. Multiple chiller arrangements offer the advantage of operational flexibility, standby capacity and less disruptive maintenance. Also, they offer some standby capacity if repair work must be done on a chiller from a set of duty chillers. Starting in-rush current is reduced, as well as power costs at partial-load conditions. A multiple chiller arrangement should be provided if the system load is greater than a single chiller capacity, standby capability is desired, large temperature drop (greater than 150F) is desired or application calls for splitting the total capacity for better part load operation. In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced water flow. It is mandatory that cooler flow rates must be balanced to ensure proper flow to each chiller based on its respective capacity. As mentioned above, two basic multiple chiller systems are used: parallel and series chilled water flow. Zamil recommends the parallel arrangement for design temperature drops (T) up to 150F and the series arrangement beyond that i.e., 16 to 200F. Complete design details on these parallel and series chilled water flow arrangements can be found in the ASHRAE handbooks and other design literature which should be referred by the designer in preparing his detailed designs.

PIPING ARRANGEMENTS AND PLANT LAYOUT

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

UNIT LOCATION AND INSTALLATION

These 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 installation location 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 of adequate ambient air to the condenser and removal of heated discharge air from the condenser. This is accomplished by maintaining sufficient clearances which have been specified in this Catalog around the units and avoiding obstructions in the condenser air discharge area to prevent the possibility of warm air circulation. Further, the condenser fans are 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 will cause higher condensing temperatures resulting in poor unit operation, higher power consumption and possible eventual failure of equipment.

26

 The units longitudinal axis should be parallel to the prevailing wind direction in order to ensure a balanced air flow
through the condenser coils. Consideration should also be given to the possibility of down-drafts caused by adjacent buildings, which may cause recirculation or uneven unit airflow. For locations where significant cross winds are expected, 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 and
sources of airborne chemicals that could attack the condenser coils and steel parts of the unit. Avoid locations where the 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 unit
by means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage or possible harm 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 of handling 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 upon
installation of the unit which can strain the refrigerant lines resulting in leaks and may also cause compressor oil return problems. It is recommended that the concrete slab is provided with appropriate footings. The slab should not be connected 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 weight
of the unit. The unit shall be mounted on a concrete slab similar to ground installations. The roof must be reinforced for supporting the individual point loads at the mounting isolator locations. It must be checked and ensured that the concrete base is perfectly horizontal and levelled, especially if the roof has been pitched to aid in water removal. It should be determined prior to installation if any special treatment is required to assure a levelled installation else it could lead to the above mentioned problems.

Vibration isolators are necessary for installing these chillers in order to minimize the transmission of vibrations. The
two 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 and job costs must be kept to a minimum. Spring Isolators are recommended for ground level installations which are noisesensitive areas or exposed to wind loads and all roof top installations. For critical installations (extremely noise and vibration 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 each mount 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 this regard.

COOLER PIPING CONNECTIONS

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

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

A flow switch must be installed in the field piping at the outlet of the cooler (in horizontal piping) and wired back to the
unit control panel using shielded cable. There should be a straight run of piping of at least five pipe diameters on either side of the flow switch. 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 wiring diagram) so that the unit can start only upon proof of pump operation.
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 Flexible connections suitably selected for the fluid and pressure involved should be provided as mandatory in order to
minimize transmission of vibrations to the piping / building as some movement of the unit can be expected during normal operation. The piping and fittings must be separately supported to prevent any loading on the cooler.

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

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

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

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

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

OUT IN

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

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

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CHILLED FLUID VOLUME REQUIREMENT

The volume of water in a piping system loop is critical to the smooth and proper operation of a chilled water system. If sufficient volume of water is not there in the system, the temperature control can be lost resulting in erratic system operation and excessive compressor cycling. Therefore, to prevent this effect of a Short Water Loop ensure that total volume of water in the piping system loop equals or exceeds 3 Gallons per Nominal Ton of cooling capacity for standard air conditioning applications and 6 Gallons per Nominal Ton of cooling capacity for process cooling jobs where accuracy is vital and applications requiring operation at very low ambient temperatures and low loading conditions. For example, chiller model ALY070 operating with a design water flow rate of 170 GPM for a standard air conditioning application would require 70 (Nom. Cap.) x 3 = 210 Gallons of water in the piping system loop. To achieve the aforementioned water volume requirements, it may be necessary to install a tank in the piping system loop to increase the volume of water in the system and therefore, reduce the rate of change of return water temperature. This tank should be provided on the return water side to the chiller and the tank should be baffled to ensure that there is no stratification and the entering stream thoroughly mixes with the tank water. See recommended tank design schematics below:

TANK SCHEMATIC

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RIGGING INSTRUCTIONS
ATTENTION TO RIGGERS Hook rigging sling thru holes on the lifting plates, as shown below. Lifting plates or holes in base rail are centered around the unit center of gravity. Center of gravity is not unit center line. Ensure center of gravity aligns with the main lifting point before lifting. Use spreader bar when rigging, to prevent the slings from damaging the unit. CAUTION All panels should be in place when rigging. Care must be taken to avoid damage to the coils during handling. Insert packing material between coils & slings as necessary. MODELS: ALY010C - ALY015C

MODELS: ALY020C - ALY035C

MODELS: ALY040C - ALY070C

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INSTALLATION CLEARANCE
WALL

FIGURE - 1 STRAIGHT WALL

FIGURE - 2 CORNER 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 cause high pressure or fan motor temperature trips.

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MOUNTING LOCATION
MODELS: ALY010C - ALY015C

MODELS: ALY020C - ALY035C

MODELS: ALY040C - ALY070C

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

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LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)

MODEL No. ALY010C ALY015C ALY020C ALY025C ALY030C ALY035C ALY040C ALY045C ALY050C ALY055C ALY065C ALY070C R1 121 127 227 258 280 313 447 466 514 558 607 640 R2 121 128 227 258 280 313 447 446 495 538 584 617 R3 85 123 169 190 203 226 343 362 404 426 473 495 R4 97 136 182 197 205 221 330 326 357 365 407 422

LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)

MODEL No. ALY010C ALY015C ALY020C ALY025C ALY030C ALY035C ALY040C ALY045C ALY050C ALY055C ALY065C ALY070C R1 129 142 243 282 304 349 496 515 563 607 661 704 R2 129 143 243 282 304 349 496 495 544 587 641 685 R3 93 139 185 214 228 261 392 411 449 475 529 562 R4 104 151 198 221 229 256 379 375 400 414 461 487

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PL-AP-ALC-07-2M-E