Company 8uslness

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 opera-
tions 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.
Pactorles and Productlons
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-condi-
tioning systems per year.
Quallty & Product
The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification.
Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization)
certificate for room air conditioners. Its products and services are also certified with:
1. CE (Council of European Community)
2. UL (Underwriters Laboratory)
3. AHAM certificate (Association of Home Appliance Manufacturers)
4. Eurovent (for Fan Coil units and Air handling units, see www.eurovent-certification.com)
5. DEMKO
6. 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
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJ ECT TO CHANGE WITHOUT NOTICE.
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
1
2
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 condi-
tions 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.
3
4
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.
FIGURE- 1
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 REFRIGERANT SIDE
DESIGN PRESSURE,
(BAR/PSIG)
TEST PRESSURE,
(BAR/PSIG)
DESIGN PRESSURE,
(BAR/PSIG)
TEST PRESSURE,
(BAR/PSIG)
UNIT MODEL
22.8/335
ALY010C - ALY070C
ALY040C - ALY070C
10/147 11.3/165 15.5/228 23.3/342
COOLER
STD
ASME (option)
16/235 29/426 41.5/610
5
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 opera-
tions 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
% FULL LOAD CAPACITY CONTROL
STANDARD OPTIONAL
MODEL NUMBER
ALY010C - ALY015C
ALY020C - ALY040C
ALY045C - ALY070C
100-OFF
100-50-OFF
100-75-50-25-OFF
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).
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.
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 weather-
proof 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
7
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 applica-
tions.
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 mo-
tor 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 contaminat-
ing 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 mois-
ture contents and provides a mean for checking the system refrigerant charge.
LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from 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 replace-
ment.
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.
9
UNIT SIZE ALY010C ALY015C ALY020C ALY025C ALY030C ALY035C
COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 800-692-00 800-692-06 800-692-00 (2) 800-692-06 (2) 800-692-09 (2)
380V-3Ph-60Hz 800-692-01 800-692-07 800-692-01 (2) 800-692-07 (2) 800-692-10 (2)
460V-3Ph-60Hz 800-692-02 800-692-08 800-692-02 (2) 800-692-08 (2) 800-692-11 (2)
NUMBER OF COMPRESSORS 1 1 2 2 2 2
OIL CHARGE PER COMPRESSOR, Liters 3.125 3.977 3.125 3.977/3.125 3.977 4.489
% FULL LOAD CAPACITY CONTROL 100-0 100-0 100-50-0 100-50-0 100-50-0 100-50-0
MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC
OIL LUBRICATION CENTRIFUGAL ACTION
REFRIGERANT R-407c
EXPANSION VALVE DEVICE THERMOSTATIC
CONTROL VOLTAGE 220V-1Ph-60Hz
CONDENSER
CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/8314 3/8314 3/8214 3/8314 3/8314 3/8414
Total face area, Sq. ft. 13.9 27.8 44.4 44.4 44.4 44.4
AIRFLOW, CFM 10529 13251 26538 25170 25170 23950
NUMBER OF FAN/FAN DIA.,mm 1/800 1/800 2/800 2/800 2/800 2/800
FAN MOTOR RPM @ 230/380/460-3-60 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070
COOLER
COOLER PART NUMBER 800-516-39 800-516-39 800-620-07 800-620-09 800-620-11 800-620-13
SHELL DIAMETER, mm N.A. N.A. 168 168 168 168
LENGTH, mm N.A. N.A. 1281 1431 1631 1781
TOTAL WATER HOLDING VOLUME, Liters N.A. N.A. 15.3 17.2 19.8 21.7
WATER IN/OUT PIPE DIA.mm 38 38 64 64 64 64
GENERAL
REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 8 12 8 12/10 12 14
SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 68.9/65.4/60.1 66.7/63.2/57.9 71.9/68.4/63.1 69.2/65.7/60.4 69.7/66.2/60.9 72.6/69.1/63.8
SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 416/426 506/516 795/810 889/906 949/969 1049/1071
SHIPPING /OPERATING WEIGHTS (Copper coils), kg 447/457 568/578 858/873 986/1003 1047/1067 1191/1213
PHYSICAL DATA
NOTES: 1. All compressors operate at 3500 RPM @ 60Hz.
2. Sound pressure level : 2dBA.
800-692-06
800-692-03
800-692-07
800-692-04
800-692-08
800-692-05
10
UNIT SIZE ALY040C ALY045C ALY050C ALY055C ALY065C ALY070C
COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 800-692-12 (2) 800-692-03 (4) 800-692-06 (4) 800-692-09 (4)
380V-3Ph-60Hz 800-692-13 (2) 800-692-04 (4) 800-692-07 (4) 800-692-10 (4)
460V-3Ph-60Hz 800-692-14 (2) 800-692-05 (4) 800-692-08 (4) 800-692-11 (4)
NUMBER OF COMPRESSORS 2 4 4 4 4 4
OIL CHARGE PER COMPRESSOR, Liters 5.682 3.125 3.977/3.125 3.977 4.489/3.977 4.489
% 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
MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC
OIL LUBRICATION CENTRIFUGAL ACTION
REFRIGERANT R-407c
EXPANSION VALVE DEVICE THERMOSTATIC
CONTROL VOLTAGE 220V-1Ph-60Hz
CONDENSER
CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/8314 3/8314 3/8314 3/8314 3/8414
Total face area, Sq. ft. 88.9 88.9 88.9 88.9 88.9 88.9
AIRFLOW, CFM 26000 50340 50340 50340 49092 47900
NUMBER OF FAN/FAN DIA.,mm 4/762 4/800 4/800 4/800 4/800 4/800
FAN MOTOR RPM @ 230/380/460-3-60 1100/1100/1100 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070 1026/1025/1070
COOLER
COOLER PART NUMBER 800-620-15 800-695-06 800-620-82 800-620-82 800-620-86 800-620-86
SHELL DIAMETER, mm 194 194 219 219 273 273
LENGTH, mm 1815 1815 1820 1820 1850 1850
TOTAL WATER HOLDING VOLUME, Liters 30 30 41.8 41.8 62.7 62.7
WATER IN/OUT PIPE DIA.mm 75 75 75 75 100 100
GENERAL
REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 17 10 12/10 12 14/12 14
SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 74.9/71.4/66.1 71.6/68.1/62.8 72.2/68.7/63.4 72.7/69.2/63.9 74.4/70.9/65.6 75.6/72.1/66.8
SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 1541/1571 1571/1601 1728/1770 1845/1887 2013/2076 2108/2171
SHIPPING /OPERATING WEIGHTS (Copper coils), kg 1737/1767 1766/1796 1924/1966 2040/2082 2253/2316 2392/2455
PHYSICAL DATA
NOTES: 1. All compressors operate at 3500 RPM @ 60Hz.
2. Sound pressure level : 2dBA.
800-692-06 (2)
800-692-03 (2)
800-692-07 (2)
800-692-04 (2)
800-692-08 (2)
800-692-05 (2)
800-692-09 (2)
800-692-06 (2)
800-692-10 (2)
800-692-07 (2)
800-692-11 (2)
800-692-08 (2)
3/8414
3/8314
11
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
0
F (LCWT)
3. Chilled water flow rate in GPM
4. Chilled water cooling range in
0
F (water in temp.
_
water out temp.)
5. Design ambient temperature
6. Minimum ambient temperature
7. Altitude
8. Electrical power supply
SAMPLE SELECTION
Select an Air Cooled Packaged chiller for the following conditions:
Required system capacity is 33 tons at 54
0
F entering chilled water
and 44
0
F leaving water. Design ambient temperature is 95
0
F.
Altitude is 2000 feet above sea level.
Water cooler fouling factor is 0.00010. Power supply: 380V-3Ph-60Hz.
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 44
0
F leaving chilled water temperature with 10
0
F water temperature
difference and 95
0
F 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
Cooling Range, T 10
0
F
SELECTION PROCEDURE (English units)
ELEVATION ABOVE
SEA LEVEL (FT.)
CAPACITY
CORRECTION
FACTOR
0
2000
4000
6000
1.00
0.99
0.98
0.97
TABLE - 1
TABLE - 2
EVAPORATOR FOULING
FACTOR (HR-FT
2
-
0
F/BTU)
0.00010
0.00025
0.00050
0.00075
0.00100
CAPACITY
CORRECTION
FACTOR
1.000
0.992
0.978
0.965
0.951
POWER
INPUT
FACTOR
1.000
0.997
0.990
0.984
0.978
ARI
STANDARDS
ARI-550/590-98
ARI-590-86
ARI-590-81
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 tempera-
ture range is above 10
0
F and subtract correction from design leaving chilled water temperature (LCWT) when water
temperature range is below 10
0
F.
EXAMPLE:
If LCWT rise is 12.5
0
F, enter correction curve at 12.5
0
F and read the correction factor of 0.2. The corrected LCWT is
44+0.2 =44.2
0
F.
NOTE: 1. When the chilled water temperature rise is less than 5
0
F, 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
TABLE - 3
CHILLED WATER TEMPERATURE RISE (
0
F)
0
-0.2
-0.4
5 10
+0.4
+0.2
+0.6
15 20
SELECTION PROCEDURE (Metric units)
ELEVATION ABOVE
SEA LEVEL (Meter)
CAPACITY
CORRECTION
FACTOR
0
600
1200
1800
1.00
0.99
0.98
0.97
TABLE - 1
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 tempera-
ture range is above 6
0
C and subtract correction from design leaving chilled water temperature (LCWT) when water
temperature range is below 6
0
C.
EXAMPLE:
If LCWT rise is 7.4
0
C, enter correction curve at 7.4
0
C and read the correction factor of 0.11. The corrected LCWT is
6
0
C+0.11 =6.11
0
C.
NOTE: 1. When the chilled water temperature rise is less than 3
0
C, the high water flow rate will result to excessive
pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.
2.Please refer to water pressure drop curves.
TABLE - 2
EVAPORATOR FOULING
FACTOR (M
2
-
0
C/W)
0.000018
0.000044
0.000088
0.000132
0.000176
CAPACITY
CORRECTION
FACTOR
1.000
0.992
0.978
0.965
0.951
POWER
INPUT
FACTOR
1.000
0.997
0.990
0.984
0.978
ARI
STANDARDS
ARI-550/590-98
ARI-590-86
ARI-590-81
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
0
C (LCWT)
3. Chilled water flow rate in LPS
4. Chilled water cooling range in
0
C (water in temp.
_
water out temp.)
5. Design ambient temperature
6. Minimum ambient temperature
7. Altitude
8. Electrical power supply
SAMPLE SELECTION
Select an Air Cooled Packaged chiller for the following conditions:
Required system capacity is 118 kW at 12
0
C entering chilled water
and 6
0
C leaving water. Design ambient temperature is 35
0
C.
Altitude is 600 meter above sea level.
Water cooler fouling factor is 0.000018. Power supply: 380V-3Ph-60Hz.
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 6
0
C leaving chilled water temperature with 6
0
C water temperature
difference and 35
0
C 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
=
118 x 0.239
=4.7 LPS
Cooling Range, T 6
0
C
13
TABLE - 3
CHILLED WATER TEMPERATURE RISE (
0
C)
+0.33
+0.22
+0.11
-0.11
-0.22
5 4 6 7 8
0
10 9
ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (Antifreeze)
When operating in areas with temperatures below 32
0
F (0
0
C), 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 15
0
F (8
0
C) 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.
EXAMPLE: English system- Determine Ethylene glycol percentage by weight and correction factors at 38
0
F ambient
temperature.
From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 38
0
F ambi-
ent temperature is 12% by weight.
Find the correction factors corresponding to 38
0
F 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 3.3
0
C ambient
temperature.
From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 3.3
0
C ambi-
ent temperature is 12% by weight.
Find the correction factors corresponding to 3.3
0
C 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 40
0
F to 50
0
F (4.4
0
C to 10
0
C) LCWT.
ETHYLENE GLYCOL % BY WEIGHT 0% 12% 22% 30%
Freezing point of Ethylene glycol solution 0
0
C (32
0
F) -5
0
C (23
0
F) -10
0
C (14
0
F) -15
0
C (5
0
F)
Ambient temperature 8.3
0
C (47
0
F) 3.3
0
C (38
0
F) -1.7
0
C (29
0
F) -6.7
0
C (20
0
F)
Cooling capacity correction factor 1.0 0.985 0.980 0.974
Water flow correction factor 1.0 1.02 1.04 1.075
Pressure drop correction factor 1.0 1.07 1.11 1.18
14
15
16
17
18
19
WATER SIDE PRESSURE DROP
CURVE No. Maximum GPM MODEL No.
ALY010C
ALY015C
ALY020C
ALY025C
ALY030C
ALY035C
ALY040C
ALY045C
ALY050C
ALY055C
ALY065C
ALY070C
1
1
2
3
4
5
6
6
7
7
8
8
26.5
39.3
52.9
73.4
81.6
99.1
119.5
133.1
148.7
160.1
177.6
195.2
Minimum GPM
18.3
26.8
36.3
48.3
53.0
61.5
77.2
86.5
92.7
100.4
117.8
126.1
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
10 20
FLOW RATE - GPM
60 40 30 50 90 70 80 100
8 7 1 3 2 4 6 5
300 200 400 500 600 1500 1000 800 700 900 1200
2287
A B
235
C 1640
ALY010C & ALY015C
ALY020C, ALY025C, ALY030C & ALY035C
DIMENSIONS
NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED.
DIMENSIONS
MODEL A B
ALY020C 1030 570
ALY025C 1180 420
ALY030C 1380 245
ALY035C 1530 220
DIMENSIONS
MODEL A B C
ALY010C 466 144 318
ALY015C 393 217 206
21
2287
A
260
220
2287
1530
100
220
ALY040C
DIMENSIONS
DIMENSIONS
MODEL A B
ALY045C 1530 260
ALY050C 1500 292
ALY055C 1500 292
ALY065C 1500 338
ALY070C 1500 338
ALY045C, ALY050C, ALY055C, ALY065C & ALY070C
NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED.
22
COOLER
FAN1
CONTROL PANEL
COMP 1
CONTROL PANEL
LEGEND
B1/B2 ANALOG INPUT
C1/C2 COMMON
CB CIRCUIT BREAKER
COMP COMPRESSOR
CC COMPRESSOR CONTACTOR
CCA COMPRESSOR CONTACTOR AUXILIARY
CWP CHILLED WATER PUMP
D1/ID.. DIGITAL INPUT 1
ETB EARTH TERMINAL BLOCK
FLS FLOW SWITCH
FM FAN MOTOR
FMC FAN MOTOR CONTACTOR
F FUSE
G/GO POWER INPUT
HPS HIGH PRESSURE SWITCH
HVTB HIGH VOLTAGE TERMINAL BLOCK
MB MASTER BOARD
NO1/1O DIGITAL OUT 1
S1 CONTROL SWITCH
SB SLAVE BOARD
SSPS SOLID STATE PROTECTION SYSTEM
SH SHIELD
TK CONDENSER FAN THERMAL CONTACT
tLAN LOCAL NETWORK PORT
TRANS TRANSFORMER
UVM UNDER VOLTAGE MONITOR
TERMINAL BLOCK
- - - FIELD WIRING
*
FIELD SUPPLY
TYPICAL SCHEMATIC WIRING DIAGRAM
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.
REFER TO UNIT
NAMEPLATE FOR
POWER SUPPLY
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-ft
2
-
0
F/Btu (0.000018 m
2
-
0
C/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 122
0
F (50
0
C) 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 95
0
F (35
0
C) entering fluid temperature. The design leaving chilled fluid temperature
(LCWT) range as mentioned earlier in the tabulated performance data is 40 to 50
0
F. The design entering chilled fluid
temperature range is 50 to 60
0
F. The design cooler temperature drop (T) range is 5 to 15
0
F.
The tabulated performance data provided in this catalog is based on a chilled water temperature drop of 10
0
F. Units may
be operated at any desired temperature drop within the range of 5 to 15
0
F 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 32
0
F (0
0
C), 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 15
0
F (8.3
0
C) 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 mainte-
nance. 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 15
0
F) is desired or application calls for splitting the total capac-
ity for better part load operation.
In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced 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 15
0
F and the series arrangement
beyond that i.e., 16 to 20
0
F. 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 obstruc-
tions 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 even-
tual 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 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 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 noise-
sensitive 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 recom-
mendations 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.
27
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 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 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 installa-
tions, each unit should be piped as shown:
28
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 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:
29
TANK SCHEMATIC
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.
RIGGING INSTRUCTIONS
MODELS: ALY010C - ALY015C
MODELS: ALY020C - ALY035C
MODELS: ALY040C - ALY070C
30
WALL
INSTALLATION CLEARANCE
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.
31
MODELS: ALY020C - ALY035C
MODELS: ALY040C - ALY070C
NOTE: All dimensions are in mm. Tolerance: 2mm.
MOUNTING LOCATION
MODELS: ALY010C - ALY015C
32
LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)
MODEL No. R1 R2 R3 R4
ALY010C 121 121 85 97
ALY015C 127 128 123 136
ALY020C 227 227 169 182
ALY025C 258 258 190 197
ALY030C 280 280 203 205
ALY035C 313 313 226 221
ALY040C 447 447 343 330
ALY045C 466 446 362 326
ALY050C 514 495 404 357
ALY055C 558 538 426 365
ALY065C 607 584 473 407
ALY070C 640 617 495 422
LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)
MODEL No. R1 R2 R3 R4
ALY010C 129 129 93 104
ALY015C 142 143 139 151
ALY020C 243 243 185 198
ALY025C 282 282 214 221
ALY030C 304 304 228 229
ALY035C 349 349 261 256
ALY040C 496 496 392 379
ALY045C 515 495 411 375
ALY050C 563 544 449 400
ALY055C 607 587 475 414
ALY065C 661 641 529 461
ALY070C 704 685 562 487
33