ASY(R-134)Series Screw Chiller

5/19/2018 ASY(R-134)Series Screw Chiller

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Company Business

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

Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55

countries in the Middle East, Europe, Africa and Asia.

The companys operations are structured into four Strategic Business Units (SBUs) supporting five in-house product andservice brands as well as a number of international brands under the OEM sales.

The five in-house brands are Classic, Cooline, CoolCare, Clima Tech and Geoclima.

The four SBUs are:1. Consumer Business Unit supporting Classic, Cooline, GE and OEM brands for consumers.

2. Unitary & Applied Business Unit supporting Zamil, Cooline, GE and OEM brands for commercial and industrial customers

3. Zamil CoolCare Business Unit providing industrial, electro mechanical contracting services, HVAC maintenance, retrofit

& operation services and parts.

4. Geoclima srl is an independent business supporting other SBUs for their requirements of chillers & double skin AHUs

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

Geoclima has its engineering & production operations located at Monfalcone, Italy and has a design center in Austria.

All the four SBUs, while operating independently, supplement each others activities in a way that makes synergy work at

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

Factories and Productions

Zamil Air Conditioners has two manufacturing plants in Dammam, Saudi Arabia and has one specialty production facilityin Italy operated by Geoclima.

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

Conditioning systems per year.

Quality & Product Certificates

The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification.

Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization)

Certificate for Room Air Conditioners. ZACs products are also certified with:

1. CE (Council of European Community)

2. UL (Underwriters Laboratory)

3. Eurovent (Certified Performance)

4. ETL (Test Facilities)

5. SASO (Saudi Arabian Standards Organization)

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

7. ASME (American Quality of Mechanical Engineers)

Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammedbin Fahd Al Saud Award for Factory Safety.

Our Products

In addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditionersmanufacturers a host of residential, commercial and industrial air conditioners. This broad range extends from the ConcealedUnits up to 5 TR, the Ducted Splits up to 30 TR, the Packaged Units up to 95 TR, the Single and Double Skin Air Handling Units

up to 138,316 CFM and the Water Chillers up to 600 TR cooling capacity. In addition, centrifugal chillers - powered by MHcompressors - are available up to 5,000 TR.


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INDEX

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

Contents Page

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

Unit features, standard specifications & options .................................................................................... 3-6

Microprocessor controller .......................................................................................................................... 7

Physical data ....................................................................................................................................... 8-11

Selection procedure ............................................................................................................................12-13

Performance data................................................................................................................................14-19

Electrical data ..................................................................................................................................... 20-22

Water side pressure drop ........................................................................................................................ 23

Recommended installation for sensor & water flow switch ...................................................................... 24

Unit dimensions .................................................................................................................................25-31

Typical schematic wiring diagram .......................................................................................................32-33

Typical sequence of operation ................................................................................................................. 34

Application guidelines .........................................................................................................................35-43

Rigging instructions ................................................................................................................................. 44

Installation clearance .............................................................................................................................. 45

Mounting location .................................................................................................................................... 46

Load distribution .................................................................................................................................. 47-48

1


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2

ASY

AIRCOOLED

SCREW

WATER

CHILLERS

MO

DELDECODING

8

ELECTRICAL

SUPPLY

(V-Ph-Hz)

4,5&6

UNITSIZE

050

060

070

080

090

100

120

130

140

150

160

170

180

190

200

215

230

240

250

270

295

310

330

350

375

400

420

450

475

500

540

560

590

H:2

08/230-3-6

0

M:3

80-3-6

0

(4WIRE)

F:4

60-3-6

0

1,2&3

BASIC

(SERIES)

B:

R-1

34a

7

REFRIGER-

ANT

9

CONDENSER

COIL

A

:ALUMINUMFIN

B:

PRE-C

OATED

ALUMINUMFIN

C:

COPPERFIN

D:

ALUMINUMFIN

WITHRes

isTec

COATING

E:

COPPERFIN

WITHRes

isTec

COATING

(SEENOTE#1

BELOW)

10

CIRCU

ITBREAKER

O

PTIONS

11

COOLER

OPTIONS

A:

STANDARDWITH

VICTAULICCONN

.

B:

FLANGECONN

.

(OPTIONAL)

C:

ASMESTAMPED

WITHVICTAULIC

CONN

.

(OPTIONAL)

D:

ASMESTAMPED

WITHFLANGE

CONN

.

(OPTIONAL)

A:

STANDARD

B:CO

M

PRESSOR

CIR

CUIT

BR

EAKER

13

HGBP

OPTIONS

A:

STANDARDUNIT

WITHOUTHGBP&

WITHOUTSUCTION

SERVICEVALVE

B:

WITHHGBP&

WITHOUTSUCTION

SERVICEVALVE

(OPTIONAL)

C:

WITHOUTHGBP&

WITHSUCTION

SERVICEVALVE

(OPTIONAL)

D:

WITHHGBP&

WITHSUCTION

SERVICEVALVE

(OPTIONAL)

NOTES:

1.F

OROTHERCOATING,S

PECIFYYOUR

REQUIREMENTSINWRITING.

2.C

OMPUTERSELECTEDDIGITS(FROM

'AA'TO'ZZ')DESCRIBINGOTHEROPTIONS&A

CCESSORIESORCOMBINATIONSTHEREOF,S

UCHAS:

-CONDENSERCOILGUARD

-COMPRESSOR&COOLERGUARD

-UNITMAINNON-FUSEDDISCONNE

CTSWITCH

-COMPRESSORENCLOSURE

-WATERFLOWSWITCH

-SPRINGISOLATOR

-MULTI-ResisTecPIPING

-MULTI-ResisTecSHEET

METAL

etc...

A:

STANDARDUNIT

WITHOU

TSUCTION

SERVIC

EVALVE

B:

UNITWITH

SUCTIO

NSERVICE

VALVE

(OPTIONAL)

14&15

OPTION

S

&

ACCESSORIES

SEENOTE

#2

BELOW

16&17

UL

OPTIONS

A:

STANDARD

UNIT

WITHOUTUL

B:

STANDARD

UNITWITHUL

LISTED

1

2

COMPR

ESSOR

OPT

IONS


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FEATURESThese ASY air cooled screw water chillers offer the ultimate combination of energy saving design, superior engineering

features and flexibility of application as required by todays market.

* These chillers incorporate the newest advanced microprocessor controller. This controller monitors analog and digita

inputs to achieve precise control & protective functions of the air cooled water chiller units. This microprocessorcontroller is complete with all the hardware and software necessary to control the chiller unit and ensures its efficiency

and reliability.

* Designed to conform toARI standard 550/590water chilling packages using the vapor compression cycle.

* Designed to conform toANSI/ASHRAE 15-1994Safety code for Mechanical Refrigeration.

* Compact unit design and excellent serviceability.

* All packaged chillers incorporate compact water coolers with enhanced inner grooved copper tubes bundled into a "U"shape and expanded into a steel tubular sheets which offer efficient water flow as well as heat transfer design resulting

in optimal unit performance.

* High Energy Efficiency Ratio (EER) semi-hermetic compact twin screw compressorsare provided in these units.

* Single point power connection (for models ASY050B - ASY500B) to minimize job site installation cost and time. Duapoint power connection for models ASY540B - ASY590B.

* Completely wired control panel with the advanced microprocessor controller provides all the necessary operat-ing and safety controls.

* Compressors are with part winding start.

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

* All fans are die cast aluminum propeller type with aerodynamic design, top discharge, provided with protectivegrille mounted on top panel within the unit casing.

* All condenser fan motors are totally enclosed air over type (TEAO) with class ''F'' winding insulation and balbearings. Inherent thermal protection of the automatic reset type and specially designed for outdoor applica-

tion is included.

3

CAPACITY CONTROL

These chillers are equipped with stepless capacity control system as standard for very accurate response to load require-

ments and best part load efficiency. Each compressor is equipped with a slider controller that enables to modulate capac-ity between 25% to 100%, thus giving a broad range to control total chiller capacity between 10% to 100% on an average

This system has the following advantages:

1. Infinite capacity modulation that allows the compressor capacity to exactly match the cooling load.

2. Reduce compressor cycling which leads to better operational reliability.

3. Reduce operating cost.

4. For units with Hot gas bypass (optional): The unit modulates to approximately 50% of its compressor lowest unloaded

capacity.

STANDARD SPECIFICATIONS


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SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORSAll compressors are compact semi-hermetic twin screwof the high capacity and efficiency due to their perfect profile

form ratio 5:6. They are simple and of robust construction with slider control valve for capacity unloading, discharge shut-off valves with optional suction service valves, built-in check valve in discharge gas outlet, oil sight glass, oil fill/drain

service valve, directly flanged-on three stage oil separator with long-life fine filter 10 microns mesh size, robust axiabearings in tandem configuration, suction gas filter, internal pressure relief valve and manual lock-out electronic protection

system for thermal motor winding temperature, phase reversal, discharge gas temperature protection controls.

CONDENSER COILSW-configuration condenser coils are corrugated fin and tube type, constructed of seamless 3/8" dia. & 0.011" (0.27 mm)thick copper tubes, mechanically bonded to aluminum fins for maximum heat transfer efficiency.

As a standard on aluminum fins, ZAC provides Coil Coating, which is a single component of aluminum

impregnated coating applied on the fins of heat exchanging coils. The product has been designed for Middle Eastclimate conditions. A high chemical, abrasion and UV resistance has been proven in both laboratories and on field

environment. The coating can be applied at the Zamil Air Conditioners factory as well as in the field for maintenanceor rejuvenation purposes.

The fins have full self spacing collars which completely cover each tube. The staggered tube design improves thethermal efficiency. End plates support sheets are 14 gauge galvanized steel, formed to provide structural strength.

Each coil is pressure tested in the factory at not less than 450 psi air pressure.

COMPACT DESIGN SHELL AND TUBE WATER COOLERSThe DX shell & tube cooler with removable U shaped bundled tubes are made of internally grooved copper tubes

expanded into a heavy steel tubular sheets.

The chiller cooler & baffles are constructed of steel and brass respectively. The coolers are insulated with heavy closedcellular foam insulation (3/4" thick). All chiller barrels are fitted with vent, drain connection and victaulic water pipeconnection as standard.

WATER SIDE REFRIGERANT SIDE

DESIGN PRESSURE,

(BAR/PSIG)

TEST PRESSURE,

(BAR/PSIG)

DESIGN PRESSURE,

(BAR/PSIG)

TEST PRESSURE,

(BAR/PSIG)

16/235 22.8/335 29/426 41.5/610CE (STD)

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

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

electrostatic polyester dry powder coat.

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 are identified

with cable markers as per NEC standards applicable to HVAC industry.

The electrical controls used in the control panel are UL approved which are reliable in operation at high ambient condi-

tions for a long period.

CONDENSER FANSCondenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phasewith class ''F'' winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosed

air over type (TEAO) with inherent thermal protection of automatic reset type.

SHELL & TUBE

HEAT

EXCHANGER(COOLER)


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STANDARD CONTROL & SAFETY DEVICESMICROPROCESSOR CONTROLLER: This controller monitors analog and digital inputs to achieve precise control & safety

functions of the unit.

COMPRESSOR IN-BUILT PROTECTION DEVICE: Protects the compressor by monitoring:

A) Motor winding temperature in case of overload.

B) Discharge gas temperature in case of overheating.

C) Phase reversal for direction of rotation.

STARTERS: The starter is operated by the control circuit and provides power to the compressor motors. These devices arerated to handle safely both RLA and LRA of motors.

CRANKCASE HEATERS: Each compressor has immersion type crankcase heater. The compressor crankcase heater is

always on when the compressors are de-energized. This protects the system against refrigerant migration, oil dilution andpotential compressor failure.

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

pressure.

UNDER & OVER VOLTAGE AND PHASE PROTECTION: Protects against low & high incoming voltage as well as singlephasing, phase reversal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it canbe set up for manual reset.

COMPRESSOR CIRCUIT BREAKERS: Protects against compressor branch circuit fault. When tripped (manually or

automatically), the breaker opens the power supply to the compressor and control circuit through auxiliary contacts.

HARD WIRE TO BMS: Communicate the controller to site BMS thru hard wire:

1. Remote Unit Enable/Disable (Start/Stop) a digital input to the controller that allows the user to Start and normallyshutdown the chiller unit from remote or control room.

2. Unit General Alarm a digital output signal from the controller to indicate that alarm is existing in the chiller.

3. Compressor Circuit Enable/Disable a digital input to the controller that allows the user to Start and normally shutdown

the compressor from remote or control room.

4. Second Temperature Control Set point a digital input to the controller that allows the user to enable the second sepoint. Value for the second temperature control set point can be modified at the controller parameter.

5. Set point correction an analog input to the controller that allows the user adjust the temperature control set point viaexternal analog signal (4-20mA).

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

INDICATOR LIGHTS: LED lights indicates power ON to the units, MENU adjustment and FAULT indications due to trip onsafety devices.

ELECTRONIC EXPANSION VALVE: Electronic expansion valve is used to regulate the refrigerant flow to the water cooler

and maintain a constant superheat and load optimization.

FILTER DRIER (REPLACEABLE CORE TYPE): Refrigerant circuits are kept free of harmful moisture, sludge, acids and oicontaminating particles by the filter drier.

SIGHT GLASS: A moisture indicating sight glass is installed in the liquid line. An easy-to-read color indicator showsmoisture contents and provides a mean for checking the system refrigerant charge.

LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from accumulating in

the water cooler during the off cycle.

CONTROL CIRCUIT TRANSFORMER: On 460V-3Ph-60Hz power supply factory mounted and wired control circuit trans-former is furnished eliminating the need for running a separate 220 volt control circuit power supply.


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OPTIONS(All options are at extra cost. Please check with your nearest dealer/sales office)

HOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50% of

its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor onand off, ensuring narrow temperature swing and lengthen the life span of the compressor.

WATER FLOW SWITCH: Paddle type field adjustable flow switch for water cooler circuits. Interlock into unit safety circuits

so that the unit will remain off until water flow is determined.

UNIT MOUNT SPRING ISOLATORS: This housed spring assemblies have a neoprene friction pad on the bottom toprevent vibration transmission.

LIQUID COOLERS:ASME code stamped liquid cooler.

PRESSURE GAUGES: Suction & discharge pressures gauges.

SUCTION SERVICE VALVE: Compressor suction port service valves.

NON-FUSED MAIN DISCONNECT SWITCHES: De-energize power supply during servicing/repair works as well as withdoor interlock.

CONDENSER COIL GUARD:Protects the condenser coils from physical damage.

COMPRESSOR/COOLER GUARD:Protects the compressor from vandalism.

COMPRESSOR OIL LEVEL SWITCH: This monitors the oil level inside the compressor.

COMPRESSOR ENCLOSURE BOX: Reduces compressor operating noise and keeps the compressor clean.

FLANGED COOLER CONNECTION: Easy on-site piping connections.

COOLER HEATER WRAPPED: Prevents freezing up of water on low ambient temperature.

COPPER FINS/TUBES CONDENSER COILS: For seashore salty corrosive environments. Provided with 12 FPI as standard

COATED COPPER FINS/TUBES CONDENSER COILS: For seashore or acid corrosive environments.

BMS: BACNET-IP, MODBUS-RS485, GSM and stand alone remote display panel.

POWER LINE ANALYZER: Performs motor current limitation. Protects against high motor current & over/under voltage.

: A two component coating system that withstands the extreme climate conditions. The coating can be

applied to all metal parts of HVAC equipment; the piping, the compressors and grids might require a different pre- treatmentand layer build up. Please check ResisTec product informationsheets, the heat exchangers can not be coated using thistype. The coating can be applied at the Zamil Air Conditioners factory as well as in the field for maintenance or rejuvenation

purposes.

UL LISTED CHILLERS: ASY chillers in the range of ASY050B thru ASY500B can be optionally offered as UL listed. These

chillers are UL listed under UL file number SA13167.

HAND HELD CONTROLLER: Enables the chiller technician to monitor and serve the chiller by plugging this portable wiredcontroller into the chiller controller. With built-in magnets, it provides convenient access for chiller status diagnoses and

trouble shooting.

EXTERNAL COMPRESSOR MOTOR OVERLOAD RELAY:Added protection for compressor motor thermal overloadingand prolonged stalling of the motor.

DUAL MAIN POWER ENTRY: Provide flexibility of connecting the chiller to the field power supply. Applicable for chille

models ASY090B - ASY500B.

EXTENDED MAIN BUSBAR: Provide extended termination for multi cable that may require for chiller with Single poweEntry point. This is applicable only for ASY180B - ASY590B.

MAIN POWER TERMINAL LUGS: A ready to install power main terminal lugs for easy connection of main cable in thefield. The lug has wide range to accept cable sizes and designed to fix a maximum of 4 cables per lug.


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MICROPROCESSOR CONTROLLERThe microprocessor controller works on the state of art microprocessor technology. This standalone controller monitorsanalog and digital inputs to achieve precise control and safety functions of the unit.

The Software works on the Proportional Integral Derivative (PID) algorithm for precise control logic. Also it has with built-inAdaptive control logic that prevents unnecessary service call, while the controller manage to operate the chiller at safe and

designed operating limits.The simple to use push button keyboard allows accessing to the operating conditions, control set points and alarm history

that are clearly displayed on a multi-line back illuminated LCD panel.

An easy to install serial port/modem optionallows remote monitoring of the operating parameters. With correspondingwindows software, the system allows data to be viewed in tabular or graphic format as well as interact with system set up

This chiller controller is compatible with the Building Management System (BMS) BACNET/MODBUS protocols throughcorresponding optional gateway interfaces.

It is also compatible with GSM protocol through GSM optional gateway that sends up to 3 mobile phone SMS messageswhenever alarm take place, indicating the type of alarm, the corresponding compressor, the related chiller and which location

The microprocessor consists of the following hardware:

1. User Interface Board: Provided with simple to use push button keyboard and menu driven software to access operatingconditions, control set points & alarm history that are clearly displayed on the LCD panel.

2. Main Board: This controls up to two (2) compressor system.3. Auxiliary Boards: Required for controlling an additional two (2) or more compressors.

4. Remote Monitoring System [Optional]: The micro controller is complete with all hardware and software necessary to

remotely monitor and control the chiller unit.

DISPLAY INFORMATION:

In the normal operating mode the 20 x 4 characters LCD panel display the system status, the temperature of the water inlet

& outlet, the set point, run time of the compressor & the alarm history.

Easily accessible measurements for each circuit include the following:

Suction and discharge temperatures

Suction and discharge pressures

Water inlet/outlet temperatures

Compressor status

Fan status

Liquid line solenoid status

Unit/Compressor run time

Compressor amps (optional)

Unit amps (optional)

Unit 3 phase voltage (optional)The control temperature is continuously displayed on the 3 Digit 7 segments LED Display. The 3 LED lights indicate thePower ON, Menu adjustment and Fault.

SYSTEM PROTECTION:

The following system protection is provided to ensure system reliability:

Compressor winding overheating

Low suction pressure

High discharge pressure

Freeze protection

Low oil level (optional)

Sensor error/Thermistor malfunction

Time delay Anti recycle time for compressor

Serial communication error

Compressor/fan motor overload

Compressor/fan motor circuit breaker

Compressor reverse rotation

Under/over voltage

Low/high superheat


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UNIT SIZE ASY050B ASY060B ASY070B ASY080B ASY090B ASY100B ASY120B ASY130B ASY140B ASY15

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-683-13 800-683-16 800-683-19 800-683-22 800-683-13 (2) 800-683-13 (2) 800-683-16 (2) 800-683-19 (2) 800-683-19 (2) 800-683-1

380V-3Ph-60Hz 800-683-14 800-683-17 800-683-20 800-683-23 800-683-14 (2) 800-683-14 (2) 800-683-17 (2) 800-683-20 (2) 800-683-20 (2) 800-683-2

460V-3Ph-60Hz 800-683-15 800-683-18 800-683-21 800-683-24 800-683-15 (2) 800-683-15 (2) 800-683-18 (2) 800-683-21 (2) 800-683-21 (2) 800-683-2

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

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

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

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION INJECTION

TOTAL CRANKCASE HEATER WATTS 200 300 300 300 400 400 600 600 600 600

REFRIGERANT R-134a

EXPANSION DEVICE ELECTRONIC EXPANSION VALVE

CONTROL VOLTAGE 220V-1Ph-60Hz

AIRCOOLED CONDENSER

CONDENSER Tube Dia.-Rows-Fins per inch* 3/8214 3/8314 3/8414 3/8414 3/8414 3/8414 3/8314 3/8414 3/8414 3/83

COILTotal face area, Sq. ft. 87.5 87.5 87.5 87.5 100.1 100.1 140 140 140 175

AIRFLOW, CFM 45264 43920 47644 47644 63798 63798 93256 87032 87032 11657

NUMBER OF FAN/FAN DIA.,mm 4/762 4/762 4/800 4/800 6/800 6/800 8/800 8/800 8/800 10/80

FAN MOTOR RPM @ 230/380/460-3-60 1100/1100/1100 1100/1100/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/11001080/1080

COOLER

COOLER PART NUMBER 800-893-00 800-893-01 800-893-01 800-893-01 800-893-02 800-893-02 800-893-03 800-893-04 800-893-04 800-893

SHELL DIAMETER, mm 219 273 273 273 324 324 324 324 324 406

TOTAL LENGTH, mm 2314 2152 2152 2152 2496 2496 2696 2677 2677 2739

WATER HOLDING VOLUME, Liters 49 76.5 76.5 76.5 120 120 128 117 117 206

WATER IN/OUT PIPE DIA.mm 75 100 100 100 125 125 125 125 125 150

ECONOMIZER

PART NUMBER N.A. N.A. N.A. N.A. N.A. 800-516-68(2) N.A. N.A. 800-516-69(2) 800-516-6

EXPANSION DEVICE N.A. N.A. N.A. N.A. N.A. T.E.V. N.A. N.A. T.E.V. T.E.V

GENERAL

NUMBER OF REFRIGERANT CIRCUITS 1 1 1 1 2 2 2 2 2 2

REFRIGERANT CHARGE PER COMP., kg 33 39 45 50 33 33 39 45 47 48

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.)72.2/68.7/63.4 72.6/69.1/63.8 75.4/71.9/66.6 75.6/72.1/66.8 74.4/71/65.7 74.5/71/65.7 75.3/71.8/66.5 78.4/74.9/69.6 78.4/74.9/69.6 78.7/75.2/

SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 1865/1914 2336/2412 2455/2531 2472/2548 3220/3340 3233/3353 4319/4447 4468/4585 4494/4611 4998/52

SHIPPING /OPERATING WEIGHTS (Copper coils), kg 1990/2039 2529/2605 2735/2811 2751/2827 3540/3660 3553/3673 4627/4755 4914/5031 4941/5058 5383/55

PHYSICAL DATA

NOTES: 1. All compressors with slider control valve unloading.2. All compressors operate at 3500 RPM @ 60Hz.3. Cooler vent and drain size are 1/2" MPT.4. All coolers are single face refrigerant connection.5. Sound pressure level : 2dBA.* CU/CU option has 12FPI.


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COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-683-22 (2) 800-683-22 (2) 800-683-16 (3) 800-683-16 (3) 800-683-16 (3) 800-683-22 (3) 800-683-22 (3) 800-683-16 (4) 800-683-1

380V-3Ph-60Hz 800-683-23 (2) 800-683-23 (2) 800-683-17 (3) 800-683-17 (3) 800-683-17 (3) 800-683-23 (3) 800-683-23 (3) 800-683-17 (4) 800-683-2

460V-3Ph-60Hz 800-683-24 (2) 800-683-24 (2) 800-683-18 (3) 800-683-18 (3) 800-683-18 (3) 800-683-24 (3) 800-683-24 (3) 800-683-18 (4) 800-683-2


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

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




REFRIGERANT R-134a



AIRCOOLED CONDENSER

CONDENSER Tube Dia.-Rows-Fins per inch* 3/8314 3/8414 3/8314 3/8414 3/8414 3/8414 3/8314 3/83

COILTotal face area, Sq. ft. 175 175 210 210 210 240 240 240 304 304

AIRFLOW, CFM 116570 108790 139884 133524 130548 140892 138276 138276 192048 19204


FAN MOTOR RPM @ 230/380/460-3-60 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/1100 1080/1080/11001080/1080

COOLER

COOLER PART NUMBER 800-893-05 800-893-05 800-893-06 800-893-06 800-893-06 800-893-07 800-893-08 800-893-08 800-893-04(2) 800-893-0


TOTAL LENGTH, mm 2739 2739 2749 2749 2749 3241 3741 3741 2677 2739

WATER HOLDING VOLUME, Liters 206 206 190 190 190 225 260 260 234 412


ECONOMIZER

PART NUMBER N.A. 800-516-69(2) N.A. 800-516-69(2) 800-516-69(3) N.A. 800-516-69 800-516-69(3) N.A. N.A

EXPANSION DEVICE N.A. T.E.V. N.A. T.E.V. T.E.V. N.A. T.E.V. T.E.V. N.A. N.A

GENERAL


REFRIGERANT CHARGE PER COMP., kg 50 54 39 42/39 42 50/45 54/50 54 39 45

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.)78.9/75.4/70.1 78.9/75.4/70.1 77.1/73.6/68.3 77.1/73.6/68.3 77.1/73.6/68.3 80.3/76.8/71.5 80.4/76.9/71.6 80.4/76.9/71.6 81.4/77.9/72.6 81.4/77.9/



PHYSICAL DATA


3/84143/8314

3/84143/8314

800-683-22 (2)800-683-19 (1)

800-683-23 (2)800-683-20 (1)

800-683-24 (2)800-683-21 (1)


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10


COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-683-22 (4) 800-683-16 (6) 800-683-19 (6) 800-683-19 (6) 800-683-22 (6) 800-683-

380V-3Ph-60Hz 800-683-23 (4) 800-683-17 (6) 800-683-20 (6) 800-683-20 (6) 800-683-23 (6) 800-683-

460V-3Ph-60Hz 800-683-24 (4) 800-683-18 (6) 800-683-21 (6) 800-683-21 (6) 800-683-24 (6) 800-683-


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

CAPACITY CONTROL (STEPLESS) % 100 - 12 100 - 8




REFRIGERANT R-134a



AIRCOOLED CONDENSER

CONDENSER Tube Dia.-Rows-Fins per inch* 3/8414 3/8414 3/8414 3/8414 3/8314 3/8414 3/8414 3/84

COILTotal face area, Sq. ft. 304 304 430.7 430.7 430.7 521.3 521.3 521.3 521.3 521.

AIRFLOW, CFM 180560 180560 224046 220770 220770 281490 275110 269038 269038 2690


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

COOLER

COOLER PART NUMBER 800-893-05(2) 800-893-05(2) 800-893-09(2) 800-893-09(2) 800-893-06(2) 800-893-06(2) 800-893-06(2) 800-893-10(2) 800-893-10(2) 800-893-


TOTAL LENGTH, mm 2739 2739 2741 2741 2749 2749 2749 2754 2754 275

WATER HOLDING VOLUME, Liters 412 412 412 412 380 380 380 488 488 488


ECONOMIZER

PART NUMBER N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. 800-516-69(3) 800-516-

EXPANSION DEVICE N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. T.E.V. T.E.V

GENERAL


REFRIGERANT CHARGE PER COMP., kg 50/45 50 39/33 39 45 47 50/45 50/45 54/50 54

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 81.5/78/72.7 81.6/78.1/72.8 79.4/75.8/70.6 79.4/75.9/70.6 82.9/79.3/74.1 83.1/79.5/74.3 83.2/79.7/74.4 83.2/79.7/74.4 83.3/79.8/74.5 83.3/79.8



PHYSICAL DATA


3/84143/8314

3/84143/8314

800-683-22 (2)800-683-19 (2)

800-683-23 (2)800-683-20 (2)

800-683-24 (2)800-683-21 (2)

800-683-16 (4)800-683-13 (2)

800-683-17 (4)800-683-14 (2)

800-683-18 (4)800-683-15 (2)

800-683-22 (3)800-683-19 (3)

800-683-23 (3)800-683-20 (3)

800-683-24 (3)800-683-21 (3)

800-683-22 (4)800-683-19 (2)

800-683-23 (4)800-683-20 (2)

800-683-24 (4)800-683-21 (2)


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11

UNIT SIZE ASY540B ASY560B ASY590B

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-683-19 (8)

380V-3Ph-60Hz 800-683-20 (8)

460V-3Ph-60Hz 800-683-21 (8)

NUMBER OF COMPRESSORS 8 8 8

OIL CHARGE PER COMPRESSOR, Liters 22 22 22

CAPACITY CONTROL (STEPLESS) % 100 - 6



TOTAL CRANKCASE HEATER WATTS 1800 1800 1800

REFRIGERANT R-134a



AIRCOOLED CONDENSER

CONDENSER Tube Dia.-Rows-Fins per inch* 3/8414 3/8414 3/8414

COILTotal face area, Sq. ft. 608 608 608

AIRFLOW, CFM 361120 361120 361120

NUMBER OF FAN/FAN DIA.,mm 32/800 32/800 32/800

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

COOLER

COOLER PART NUMBER 800-893-41(2) 800-893-41(2) 800-893-41(2)

SHELL DIAMETER, mm 508 508 508

TOTAL LENGTH, mm 3326 3326 3326

WATER HOLDING VOLUME, Liters 802 802 802

WATER IN/OUT PIPE DIA.mm 200 200 200

ECONOMIZER

PART NUMBER N.A. N.A. N.A.

EXPANSION DEVICE N.A. N.A. N.A.

GENERAL

NUMBER OF REFRIGERANT CIRCUITS 8 8 8

REFRIGERANT CHARGE PER COMP., kg 45/39 45 50/45

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 83.6/80.1/74.8 84.4/80.9/75.6 84.6/81/75.8

SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 2 x 9355/2 x 9756 2 x 9390/2 x 9791 2 x 9423/2 x 9824

SHIPPING /OPERATING WEIGHTS (Copper coils), kg 2 x 10325/2 x 10726 2 x 10360/2 x 10761 2 x 10393/2 x 10794

PHYSICAL DATA


800-683-19 (4)800-683-16 (4)

800-683-22 (4)800-683-19 (4)

800-683-20 (4)800-683-17 (4)

800-683-21 (4)800-683-18 (4)

800-683-23 (4)800-683-20 (4)

800-683-24 (4)800-683-21 (4)


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12

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 temperature6. Minimum ambient temperature

7. Altitude8. Electrical power supply

SAMPLE SELECTION

Select an Air Cooled Packaged chiller for the following conditions:

Required system capacity is 115 tons at 540F entering chilled waterand 440F leaving water. Design ambient temperature is 95 0F.

Altitude is 2000 feet above sea level.Water cooler fouling factor is 0.00010. Power supply: 380V-3Ph-60Hz.

STEP-1:UNIT SELECTIONEntering the capacity performance data at given LCWT and ambient temperature.

ASY120B chiller unit at sea level will produce 116.5 tons and 129.3 kW compressorpower 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 = 116.5x0.99x1.0 = 115.3 Tons, which then exceeds the requirements.

So the selection is correct.

STEP-2: CHILLED WATER FLOW (GPM):

Water GPM =

Required capacity (Tons) x 24

=

115 x 24

= 276 GPM Cooling Range, T 10

0F

SELECTION PROCEDURE (English units)

ELEVATION ABOVE

SEA LEVEL (FT.)

CAPACITY

CORRECTION

FACTOR

0

2000

4000

6000

8000

10000

1.00

0.99

0.98

0.97

0.96

0.95

TABLE - 2

EVAPORATOR FOULING

FACTOR (HR-FT2-0F/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

Referring to pressure drop chart (page # 23), pressure drop at 276 GPM = 13.5 ft. of water for selected model.

NOTE:The total flow rate should be divided by 2 for models ASY250B - ASY590B to find out the total pressure drop.

STEP-3:ELECTRICAL

Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ASY120B is to be sized for a minimum circuit

ampacity (MCA) of 311 Amps and maximum over current protection (MOCP) of 437 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 calcu-lated in step 2.

STEP-5: LCWT CORRECTION

Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperaturerange 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.

TABLE - 1

TABLE - 3

CHILLED WATER TEMPERATURE RISE (0F)

CORRECTIONFACTOR(0F)

0

-0.2

-0.45 10

+0.4

+0.2

+0.6

15 2


15/51

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 temperature6. Minimum ambient temperature

7. Altitude8. Electrical power supply

SAMPLE SELECTION

Select an Air Cooled Packaged chiller for the following conditions:

Required system capacity is 390 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.

STEP-1:UNIT SELECTIONEntering the capacity performance data at given LCWT and ambient temperature.

ASY120B chiller unit at sea level will produce 408.1 kW and 129.1 kW compressorpower 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 = 408.1x0.99X1.0 = 404 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

=

390 x 0.239

= 15.5 LPS Cooling Range, T 6

0C

SELECTION PROCEDURE (Metric units)

ELEVATION ABOVE

SEA LEVEL (Meter)

CAPACITY

CORRECTION

FACTOR

0

600

1200

1800

2400

3000

1.00

0.99

0.98

0.97

0.96

0.95

Referring to pressure drop chart (page # 23), pressure drop at 15.5 LPS = 34.4 kPa for selected model.

NOTE:The total flow rate should be divided by 2 for models ASY250B - ASY590B to find out the total pressure drop.

STEP-3:ELECTRICAL

Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ASY120B is to be sized for a minimum circuitampacity (MCA) of 311 Amps and maximum over current protection (MOCP) of 437 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 dropcalculated 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 60C and subtract correction from design leaving chilled water temperature (LCWT) when watertemperature range is below 60C.

EXAMPLE:If LCWT rise is 7.40C, enter correction curve at 7.40C and read the correction factor of 0.11. The corrected LCWT is 60C+0.11 = 6.110C

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

drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.2. Please refer to water pressure drop curves.

TABLE - 2

EVAPORATOR FOULING

FACTOR (M2-0C/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

TABLE - 1

TABLE - 3

CHILLED WATER TEMPERATURE RISE (0C)

CORRECTIONFACTOR(0C)

+0.33

+0.22

+0.11

-0.11

-0.2254 6 7 8

0

109

13


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23

WATER SIDE PRESSURE DROP

CURVE No. Maximum GPMMODEL No.

ASY050B

ASY060B

ASY070B

ASY080B

ASY090B

ASY100B

ASY120B

ASY130B

ASY140B

ASY150B

ASY160B

ASY170B

ASY180B

ASY190B

ASY200B

ASY215B

1

2

2

2

3

3

4

5

5

6

6

6

7

7

7

8

138

170

192

214

265

271

325

356

372

411

437

455

498

522

534

593

Minimum GPM

82

98

108

124

164

184

203

222

251

267

272

315

301

343

365

375

CONVERSION FACTOR: GPM = 0.063 Liters per second.

Feet of water = 2.989 Kilo Pascal (kpa).

NOTE: 1. If an application requires certain water flow rate outside these limits, please check with your nearest dealer/sales office.2. If the chiller has 2 evaporators, then the total water flow must be divided by 2 while applying the above curves (applicable for models

ASY250B - ASY590B.

CURVE No. Maximum GPMMODEL No.

ASY230B

ASY240B

ASY250B

ASY270B

ASY295B

ASY310B

ASY330B

ASY350B

ASY375B

ASY400B

ASY420B

ASY450B

ASY475B

ASY500B

ASY540B

ASY560B

ASY590B

8

8

5

6

6

6

6

6

77

7

9

9

9

10

10

10

620

633

708

768

826

866

925

971

1048

1095

1164

1242

1297

1332

1514

1577

1662

Minimum GPM

412

447

425

450

502

537

572

601

634

650

710

779

866

886

896

924

995

PRESSUREDROP(F

T.OFWATER)

110 20

2

3

4

8

6

5

7

910

60

30

20

50

40

70

100

9

0

80

200

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

1 2 3 4 5 6

7

9

8

10


26/51

RECOMMENDED INSTALLATIONLEAVING/RETURN WATER TEMPERATURE SENSOR & WATER FLOW SWITCH

24

NOTE: 1. For chiller with 2 coolers, leaving water temperature sensor and return water temperature sensor should be installed in the water pipingmain header of every chiller.

2. Water flow switch should be installed vertically on the horizontal pipe line closed to the leaving water port of every cooler.

OUTININ OUT

CHILLER # 1

CONTROL PANEL

COOLER 1 COOLER 2

CHILLER # 2

CHILLER # n

LEAVINGWATER

RETURNWATER

LWTLEAVING WATER SENSOR

(FIELD INSTALLATION]

FLS2


FLS1


RWT

RETURN WATER SENSOR(FIELD INSTALLATION]

FS

FS

LWT

RWT

> or

Date post:	09-Oct-2015
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ASY(R-134)Series Screw Chiller

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