S.H. Reciprocating compressor ARY (R-22) series.pdf

7/29/2019 S.H. Reciprocating compressor ARY (R-22) series.pdf

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Air Cooled Reciprocating Water ChillersARY Series

ARY040A thru ARY420A40 TR thru 420 TR

141 kW thru 1479 kW


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Company Business

Zamil Air Conditioners was founded in 1974, and is the first major business venture in manufacturing sector for theAl 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 inover 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.

Factories and Productions

Zamil Air Conditioners has its prime manufacturing base at Dammam, Saudi Arabia and has one speciality production

facility in Italy operated by Geoclima.

The company can produce up to 440,000 room air conditioners, 60,000 mini-split systems and 36,500 central air-condi-tioning systems per year.

Quality & Product Certificates

The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification.

Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization)certificate for room air conditioners. Its products and services are also certified with:

1. CE (Council of European Community)2. UL (Underwriters Laboratory)

3. AHAM certificate (Association of Home Appliance Manufacturers)4. Eurovent

5. DEMKO6. ETL

Other awards include the prestigious Engineering Excellence Award of General Electric, and the inaugural PrinceMohammed 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 Conditionersmanufacturers a host of residential and commercial air conditioners. This board range extends from the concealed unitsup 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.


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CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1

INDEX

Contents Page

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

Unit features, standard specifications & options.................................................................................... 3-7

Physical data ....................................................................................................................................... 8-10

Selection procedure .......................................................................................................................... 11-12

Ethylene glycol solution capacity correction ........................................................................................... 13

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

Electrical data .................................................................................................................................... 20-21

Water side pressure drop ....................................................................................................................... 22

Unit dimensions ................................................................................................................................ 23-30

Typical schematic wiring diagram ...................................................................................................... 31-32

Microprocessor controller .................................................................................................................. 33-34

Application guidelines ........................................................................................................................ 35-44

Rigging instructions ................................................................................................................................ 45

Installation clearance .............................................................................................................................. 46

Mounting location ................................................................................................................................... 47

Load distribution ................................................................................................................................ 48-49


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MOD

ELDECODING

8

ELECTRICAL

SUPPLY

(V-Ph-Hz)

4,5&

6

UNIT

SIZE

H:208/230-3-60

M:380-3-60

(4WIRE)

F:460-3-60

1,2&

3

BASIC

(SERIES)

7

R

EFRIGER-

ANT

9

CONDENSER

COIL

A:ALUMINUM

FIN

B

:COATED

ALUMINUM

FIN

C

:COPPER

FIN

(SEENOTE#

1

BELOW)

10

CIRCUIT

BREAKER

OPTIONS

11

CO

OLER

OP

TIONS

A

:STAN

DARDWITH

VICTAULICCONN.*

B

:OPTIONALFLANGE

CONN.*

C

:OPTIONALASME

STAM

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WITH

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CONN.*

D

:OPTIONALASME

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WITH

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A:COMPRESSOR

CIRCUIT

BREAKER

12

HGBP

OPTIONS

A

:STANDARDUNIT

WITHOUTHGBP

B

:HGBP(OPTIONAL)

13&

14

OPTIONS

&

ACCESSORIES

SEENOTE#2

BELOW

NOTES:

*

NOTAPPLICABLEFORMODELSA

RY040&ARY050,MPT(MALEPIPETHREA

D)CONNECTIONONLY.

1.FOROTHERCOATING,SPECIFY

YOURREQUIREMENTSINWRITING.

2.COMPUTERSELECTEDDIGITS(FROM'AA'TO'ZZ')DESCRIBINGOTHEROPTIONS&ACCESSORIESORCOMBINATIO

NSTHEREOF,SUCHAS:-CONDENSERC

OILGUARD

-COOLERGUAR

D

-UNITDISCONNECTSWITCH

-WATERFLOWS

WITCH

-SPRINGISOLATORetc.

ARY

AIRCOOLED

RECIPROCATING

WATER

CHILLERS

A

:R-22

040

050

070

080

090

100

110

120

140

160

170

190

200

220

240

250

280

300

320

350

380

400

420

2


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FEATURESThese ARY 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 functionsof 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 packaged chillers incorporate compact water coolers with enhanced inner grooved copper tubes bundled into a Ushaped and expanded into a steel tubular sheet which offer efficient water flow and heat transfer design resulting in

optimal unit performance.

* 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) semi-hermetic reciprocating compressors.

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

* Completely wired control panel with the advanced microprocessor controller provides all the necessary operating andsafety controls.

* Independent refrigeration circuits.

* Compressor connections are part winding start 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 grillemounted on top panel within the unit casing.

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

CAPACITY CONTROLThese packaged chillers incorporate stepped load shedding as required by most energy management systems. Modula-

tion of capacity in response to system load requirements is affected by the microprocessor controller which monitors theleaving water temperature.

Capacity control is achieved by cycling compressors ON/OFF and cylinder unloading. The use of unloading provides

optimal part load capacities.

On multiple compressor units, capacity is controlled by a combination of cylinder unloading and compressor staging. See

the following table for the standard and optional capacity control for each unit.

STANDARD SPECIFICATIONS

3


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% FULL LOAD CAPACITY CONTROL

STANDARD OPTIONALMODEL NUMBER

ARY040A

ARY050A -ARY090A

ARY100A -ARY110A

ARY120A -ARY170A

ARY190A -ARY220AARY240A -ARY250A

ARY280A -ARY320A

ARY350A -ARY420A

100-66-OFF

100-83-50-33-OFF

100-75-50-25-OFF

100-92-75-67-50-42-25-17-OFF

100-87-75-62-50-37-25-12-OFF100-95-83-78-67-61-50-45-34-28-17-12-OFF

100-92-83-75-66-60-50-42-33-25-16-8-OFF

100-93-87-81-75-69-63-56-50-43-37-31-25-19-13-6-OFF

100-66-HGBP-OFF

100-83-50-33-HGBP-OFF

100-75-50-25-HGBP-OFF

100-92-75-67-50-42-25-17-HGBP-OFF

100-87-75-62-50-37-25-12-HGBP-OFF100-95-83-78-67-61-50-45-34-28-17-12-HGBP-OFF

100-92-83-75-66-60-50-42-33-25-16-8-HGBP-OFF

100-93-87-81-75-69-63-56-50-43-37-31-25-19-13-6-HGBP-OFF

NOTES:1. HGBP = Hot gas bypass available on lead compressor for all models (optional).

2. HGBP modulates to approximately 50% of compressor lowest unloaded capacity. Example: ARY 100 with HGBP (25% x 0.5=12.5%

minimum capacity).

COMPRESSORS

All compressors are semi-hermetic reciprocating type conforming to ARI 520. They are equipped with internal motor

protection and provided with vibration isolators. Each compressor has lock-out devices to protect it from short cycling

when shutdown by the safety controls. The compressor motors conform to NEMA standards MG-1 & MG-2.

CONDENSER COILS

Horizontal, V & W-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.

COMPACT DESIGN SHELL AND TUBE WATER COOLERS

The DX shell & tube coolers with removable U shaped bundled tubes are made of internally grooved copper tubes

expanded into a heavy steel tubular sheets.The cooler shell & baffles are constructed of steel and brass respectively. The coolers are insulated with heavy closed

cellular foam insulation (3/4" thick). All chiller barrels are fitted with vent, drain connection and victaulic water pipe

connection as standard.

WATER SIDE REFRIGERANT SIDE

DESIGN PRESSURE,(BAR/PSIG)

TEST PRESSURE,(BAR/PSIG)

DESIGN PRESSURE,(BAR/PSIG)

TEST PRESSURE,(BAR/PSIG)

SHELL & TUBE

HEATEXCHANGER

(COOLER)

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

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 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 PANELThe control panel design is equivalent to NEMA 4 (IP55) with hinged door for easy access ensuring dust and weather-

proof construction. Internal power and control wiring is neatly routed, adequately anchored and all wires identified withcable markers as per NEC standards applicable to HVAC industry.The electrical controls used in the control panel are UL approved and are reliable in operation at high ambient conditions

for a long period.

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

CONDENSER FAN 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. Thesefan motors are of totally enclosed air over type (TEAO) with inherent thermal protection of automatic reset type &specially designed for outdoor applications.

MICROPROCESSOR CONTROLLER

The microprocessor controller works on the state of art microprocessor technology. This controller monitors analog anddigital inputs to achieve precise control & safety functions of the unit.The Software works on the Proportional Integral Derivative (PID) algorithm for precise control logic.The simple to use push button keyboard allows accessing to the operating conditions, control set points & alarm historythat are clearly displayed on a multi-line back illuminated LCD panel. Software & programs are stored in a non-volatilememory (EPROM) to avoid chiller operating failure due to power supply interruption.

An easy to install serial port/modem option allows remote monitoring of the operating parameters. With correspondingwindows software, the system allows data to be viewed in tabular or graphic format as well as interact with system set up.This chiller controller is compatible with the Building Management System (BMS) BACNET/MODBUS protocols throughcorresponding optional gateway interfaces.

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

The microprocessor consists of the following hardware:1. User Interface Board: Provided with simple to use push button keyboard and menu driven software to access operat-

ing conditions, control set points & alarm history that are clearly displayed on the LCD panel.2. Main Board: This controls up to two (2) compressor system.3. Auxiliary Boards: Required for controlling an additional two (2) or more compressors.4. Remote Monitoring System [Optional]: The micro controller is complete with all hardware and software necessary 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 waterinlet & outlet, the set point, run time of the compressor & the alarm history.

Easily accessible measurements for each circuit include the following:

Suction temperature Suction, discharge and oil pressures Water inlet/outlet temperatures Compressor status Fan status Liquid line solenoid status Unit/Compressor run timeThe control temperature is continuously displayed on the 3 Digit 7 segments LED Display. The 3 LED lights indicate the

Power 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 pressure Sensor error Time delay Anti recycle time for compressor Serial communication error

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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 MOTOR INTERNAL OVERLOAD: The internal overload protects the compressor and senses the

motor winding temperature in case of overload.

STARTERS: The starter is operated by the control circuit and provides power to the compressor motors. These devices

are rated to handle safely both RLA and LRA of motors.

UNDER/OVER VOLTAGE AND PHASE PROTECTION: Protects against low/over incoming voltages as well as single

phasing, phase reversal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it

can be set up for manual reset.

CRANKCASE HEATERS: Each compressor has crankcase heater. The compressor crankcase heater is always on

when the compressors are de-energized. This protect the system against refrigerant migration, oil dilution and potential

compressor failure.

SAFETY VALVE: This valve protects the unit against high discharge pressure in the system due to malfunction of high

pressure switches.

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

pressure.

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 coolerand maintain a constant superheat.

REPLACEABLE CORE FILTER DRIER: Refrigerant circuits are kept free of harmful moisture, sludge, acids and oil

contaminating particles by the filter drier.

CONTROL CIRCUIT TRANSFORMER: A factory mounted and wired control circuit transformer is furnished eliminating

the need for running a separate 220 volt power supply to the unit control circuit.

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

moisture contents and provides a mean for checking the system refrigerant charge.

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

in the water cooler during the off cycle.

DISCHARGE LINE MUFFLER: Discharge line mufflers are installed to eliminate noise due to refrigerant pulsation.

CIRCUIT BREAKERS: Protects against compressor/condenser fans branch circuit fault. When tripped (manually or

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

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

VIBRATION ELIMINATOR: To eliminate the vibration transmitted from the compressor to the pipings and unit structure.

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.

PRESSURE GAUGES: Suction, discharge & oil pressures gauges.

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

door interlock.

CONDENSER COIL GUARD: Protect the condenser coil from physical damage.

COMPRESSOR/COOLER GUARD: Protect the compressor from vandalism.

FLANGED COOLER CONNECTION: Easy on-site piping connections.

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, GSM and remote display panel.

GROUND FAULT PROTECTION: Protect compressors in case ground cable has an abnormal current increase.

POWER LINE ANALYZER: Perform compressor current limitation. Protect against high motor current & over/under

voltage.

7


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UNIT SIZE ARY040A ARY050A ARY070A ARY080A ARY090A ARY100A ARY110A ARY120A ARY140

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-674-51 800-690-25 (2) 800-690-28 (2) 800-674-51 (2) 800-674-39 (2) 800-674-45 (2)

380V-3Ph-60Hz 800-690-32 800-690-26 (2) 800-690-29 (2) 800-690-32 (2) 800-674-40 (2) 800-674-46 (2)

460V-3Ph-60Hz 800-690-33 800-690-27 (2) 800-690-30 (2) 800-690-33 (2) 800-674-41 (2) 800-674-47 (2)

NUMBER OF COMPRESSORS 1 2 2 2 2 2 2 4 4

OIL CHARGE PER COMPRESSOR, Liters 7.4 4.3 7.4 7.4 7.7/7.4 7.7 7.7 7.4/4.3 7.4/7.4

% FULL LOAD CAPACITY CONTROL 100-66-0 100-83-50-33-0 100-75-50-25-0 100-92-75-67-50-42-25-17

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION PUMP

TOTAL CRANKCASE HEATER WATTS 200 200 400 400 400 400 400 600 800

REFRIGERANT R-22

EXPANSION VALVE DEVICE THERMOSTATIC

CONTROL VOLTAGE 220V-1Ph-60Hz

CONDENSER

CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/8314 3/8414 3/8414 3/8414 3/8414 3/8414 3/8414 3/841

Total face area, Sq. ft. 47.5 47.5 95 95 118.6 118.6 140 140 175

AIRFLOW, CFM 33240 31016 48948 48948 70830 68826 73014 73014 95288

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

FAN MOTOR RPM @ 230/380/460-3-60 1100/1100/1100 1100/1100/1100 900/900 /970 900/900 /970 900/900 /970 900/900 /970 900/900/970 900/900/970 900/900/97

COOLER

COOLER PART NUMBER 800-620-14 800-620-80 800-620-92 800-620-92 800-620-36 800-620-36 800-621-05 800-621-07 800-620-5

SHELL DIAMETER, mm 194 219 273 273 273 273 324 324 324

LENGTH, mm 1815 1820 1850 1850 2654 2654 2180 2180 2693

TOTAL WATER HOLDING VOLUME, Liters 30 41.8 53.2 53.2 87.5 87.5 99.8 99.8 113.5

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

GENERAL

REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 32 21 28 32 38/32 38 42 28/25 32/28

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 71.1/67.6/62.3 71.1/67.6/62.3 71.9/68.4/63.1 71.9/68.4/63.1 75.8/72.3/67 73.2/69.7/64.4 75.9/72.4/67.1 73.7/70.2/64.9 74.9/71.4/66

SHIPPING/OPERATING WEIGHTS (Aluminum coils), kg 1477/1507 1746/1788 2204/2257 2378/2431 2761/2848 2823/2910 3067/3167 3559/3659 4295/440

SHIPPING/OPERATING WEIGHTS (Copper coils), kg 1582/1612 1897/1939 2508/2561 2682/2735 3081/3168 3201/3288 3514/3615 4005/4105 4854/496

PHYSICAL DATA

NOTES: 1. All compressors with cylinder unloading.

2. All compressors operate at 1750 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.

800-690-32 (800-690-29 (

800-690-33 (800-690-30 (

800-674-51 (800-690-28 (

800-690-29 (2)800-690-26 (2)

800-690-30 (2)800-690-27 (2)

800-690-28 (2)800-690-25 (2)

800-674-40800-690-32

800-674-41800-690-33

800-674-39800-674-51

3/84143/8314

8


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UNIT SIZE ARY160A ARY170A ARY190A ARY200A ARY220A ARY240A ARY250A ARY280A ARY300

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-674-51 (4) 800-674-39 (4) 800-674-45 (4) 800-674-51 (6) 800-674-39 (6)

380V-3Ph-60Hz 800-690-32 (4) 800-674-40 (4) 800-674-46 (4) 800-690-32 (6) 800-674-40 (6)

460V-3Ph-60Hz 800-690-33 (4) 800-674-41 (4) 800-674-47 (4) 800-690-33 (6) 800-674-41 (6)

NUMBER OF COMPRESSORS 4 4 4 4 4 6 6 6 6

OIL CHARGE PER COMPRESSOR, Liters 7.4 7.7/7.4 7.7 7.7 7.7 7.4 7.7/7.4 7.7 7.7

% FULL LOAD CAPACITY CONTROL 100-87-75-62-50-37-25-12-0



TOTAL CRANKCASE HEATER WATTS 800 800 800 800 800 1200 1200 1200 1200

REFRIGERANT R-22



CONDENSER

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

Total face area, Sq. ft. 175 175 211.9 211.9 211.9 285 285 285 387.2

AIRFLOW, CFM 95288 108790 115230 131124 131124 162442 162442 162442 199792

NUMBER OF FAN/FAN DIA.,mm 8/800 10/800 10/800 12/800 12/800 14/800 14/800 14/800 16/800

FAN MOTOR RPM @ 230/380/460-3-60 900 /900 /970 900 /900 /970 900 /900 /970 900 /900 /970 900/900 /970 900/900 /970 900/900 /970 900/900/970 900/900/97

COOLER

COOLER PART NUMBER 800-620-54 800-620-54 800-620-57 800-620-57 800-620-60 800-621-06 (2) 800-621-06 (2) 800-621-06 (2) 800-620-53 (

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

LENGTH, mm 2693 2693 2737 2737 2737 2180 2180 2180 2693

TOTAL WATER HOLDING VOLUME, Liters 113.5 113.5 221.7 221.7 206.5 199.6 199.6 199.6 227

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

GENERAL

REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 32 38/32 38 42/38 42 32 38/32 38 42/38

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 74.9/71.4/66.1 78.5/76.6/69.7 78.6/75.1/69.8 79.7/76.2/70.9 80.4/76.9/71.6 77.2/73.7/68.4 80.1/76.6/71.4 80.3/76.8/71.5 81.5/78/72.

SHIPPING/OPERATING WEIGHTS (Aluminum coils), kg 4470/4583 4601/4714 5106/5328 5214/5436 5282/5488 7450/7849 7494/7893 7582/7981 8542/899

SHIPPING/OPERATING WEIGHTS (Copper coils), kg 5028/5141 5159/5272 5782/6004 5890/6112 5957/6163 8359/8758 8403/8802 8491/8890 9648/1010

PHYSICAL DATA






100-92-75-67-50-42-25-17-0

3/84143/8314

800-674-40 (2)800-690-32 (2)

800-674-41 (2)800-690-33 (2)

800-674-39 (2)800-674-51 (2)

800-674-46 (2)800-674-40 (2)

800-674-47 (2)800-674-41 (2)

800-674-45 (2)800-674-39 (2)

800-674-40 (2)800-690-32 (4)

800-674-41 (2)800-690-33 (4)

800-674-39 (2)800-674-51 (4)

800-674-46 (800-674-40 (

800-674-47 (800-674-41 (

800-674-45 (800-674-39 (

100-95-83-78-67-61-50-45-

34-28-17-12-0

100-92-83-75-66-60-50-42

33-25-16-8-0

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UNIT SIZE ARY320A ARY350A ARY380A ARY400A ARY420A

COMPRESSOR

PART NUMBER 208/230V-3Ph-60Hz 800-674-45 (6) 800-674-39 (8) 800-674-45 (8)

380V-3Ph-60Hz 800-674-46 (6) 800-674-40 (8) 800-674-46 (8)

460V-3Ph-60Hz 800-674-47 (6) 800-674-41 (8) 800-674-47 (8)

NUMBER OF COMPRESSORS 6 8 8 8 8

OIL CHARGE PER COMPRESSOR, Liters 7.7 7.7/7.4 7.7 7.7 7.7

% FULL LOAD CAPACITY CONTROL 100-93-87-81-75-69-63-56-50-43-37-31-25-19-13-6-0



TOTAL CRANKCASE HEATER WATTS 1200 1600 1600 1600 1600

REFRIGERANT R-22



CONDENSER

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

Total face area, Sq. ft. 387.2 480 480 561.1 561.1

AIRFLOW, CFM 196912 232038 227682 256260 256260

NUMBER OF FAN/FAN DIA.,mm 16/800 18/800 18/800 20/800 20/800

FAN MOTOR RPM @ 230/380/460-3-60 900/900/970 900/900/970 900/900/970 900/900/970 900/900/970

COOLER

COOLER PART NUMBER 800-620-53 (2) 800-620-57 (2) 800-620-57 (2) 800-620-57 (2) 800-620-60 (2)

SHELL DIAMETER, mm 324 406 406 406 406

LENGTH, mm 2693 2737 2737 2737 2737

TOTAL WATER HOLDING VOLUME, Liters 227 443.4 443.4 443.4 413

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

GENERAL

REFRIGERANT CHARGE PER COMP., kg (COMP. 1/2) 42 38/32 38 42/38 42

SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 82/78.5/73.2 81.4/77.9/72.6 81.4/77.9/72.7 82.5/78.9/73.7 83.2/79.7/74.4

SHIPPING/OPERATING WEIGHTS (Aluminum coils), kg 8646/9100 9633/10076 9886/10329 10488/10931 10620/11034

SHIPPING/OPERATING WEIGHTS (Copper coils), kg 9882/10336 10981/11424 11481/11924 12277/12720 12410/12824

PHYSICAL DATA






100-92-83-75-66-60-50-42-33-25-16-8-0

800-674-40 (4)800-690-32 (4)

800-674-41 (4)800-690-33 (4)

800-674-39 (4)800-674-51 (4)

800-674-46 (4)800-674-40 (4)

800-674-47 (4)800-674-41 (4)

800-674-45 (4)800-674-39 (4)

3/84143/8314

10


13/52

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 90 tons at 540F entering chilled waterand 440F leaving water. Design ambient temperature is 950F.

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

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

ARY100 chiller unit at sea level will produce 94.8 tons and 111.5 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 = 94.8x0.99x1.0 = 93.8 Tons, which then exceeds the requirements.

So the selection is correct.

STEP-2: CHILLED WATER FLOW (GPM):

Water GPM =

Required capacity (Tons) x 24

=

90 x 24

= 216 GPM Cooling Range, T 10

0F

SELECTION PROCEDURE (English units)

TABLE - 3

CHILLED WATER TEMPERATURE RISE (0F)

CORRECTIONFACTOR(0F)

TABLE - 2

EVAPORATOR FOULING

FACTOR (HR-FT2-0F/BTU)

0.00010

0.00025

0.00050

0.00075

0.00100

CAPACITYCORRECTION

FACTOR1.000

0.992

0.978

0.965

0.951

POWERINPUT

FACTOR1.000

0.997

0.990

0.984

0.978

ARISTANDARDS

ARI-550/590-98

ARI-590-86

ARI-590-81

Referring to pressure drop chart (page # 22), pressure drop at 216 GPM = 11.4 ft. of water for selected model.

NOTE: The total flow rate should be divided by 2 for models ARY240A - ARY420A to find out the total pressure drop.

STEP-3: ELECTRICAL

Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ARY100 is to be sized for a minimum circuitampacity (MCA) of 283 Amps and maximum over current protection (MOCP) of 400 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 CORRECTIONRefer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water tempera-

ture range is above 100F and subtract correction from design leaving chilled water temperature (LCWT) when watertemperature range is below 100F.

EXAMPLE:If LCWT rise is 12.50F, enter correction curve at 12.50F and read the correction factor of 0.2. The corrected LCWT 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.

11

0

-0.2

-0.45 10

+0.4

+0.2

+0.6

15 20

ELEVATION ABOVESEA LEVEL (FT.)

CAPACITYCORRECTION

FACTOR0

2000

4000

6000

8000

10000

1.00

0.99

0.98

0.97

0.96

0.95

TABLE - 1


14/52

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 320 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.

ARY100 chiller unit at sea level will produce 330.8 kW and 111 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 = 330.8x0.99X1.0 = 327.5 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

=

320 x 0.239

= 12.7 LPS Cooling Range, T 6

0C

SELECTION PROCEDURE (Metric units)

Referring to pressure drop chart (page # 22), pressure drop at 12.7 LPS = 27.4 kPa for selected model.

NOTE: The total flow rate should be divided by 2 for models ARY240A - ARY420A to find out the total pressure drop.

STEP-3: ELECTRICAL

Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ARY100 is to be sized for a minimum circuitampacity (MCA) of 283 Amps and maximum over current protection (MOCP) of 400 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 excessivepressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.

2.Please refer to water pressure drop curves.

TABLE - 2

EVAPORATOR FOULING

FACTOR (M2-0C/W)

0.000018

0.000044

0.000088

0.000132

0.000176

CAPACITYCORRECTION

FACTOR1.000

0.992

0.978

0.965

0.951

POWERINPUT

FACTOR1.000

0.997

0.990

0.984

0.978

ARISTANDARDS

ARI-550/590-98

ARI-590-86

ARI-590-81

TABLE - 3

CHILLED WATER TEMPERATURE RISE (0C)

CORRECTIONFACTOR(0C)

12

+0.33

+0.22

+0.11

-0.11

-0.2254 6 7 8

0

109

ELEVATION ABOVESEA LEVEL (Meter)

CAPACITYCORRECTION

FACTOR0

600

1200

18002400

3000

1.00

0.99

0.98

0.970.96

0.95

TABLE - 1


15/52

ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (Antifreeze)When operating in areas with temperatures below 320F (00C), cooler protection in the form of Ethylene glycol solution(brine solution) is required to protect cooler from low ambient freeze-up. This brine solution must be added to water loop to

bring down the freezing point with a difference of 150F (80C) below minimum operating ambient temperature.

Ethylene glycol solution causes a variation in unit performance. To obtain the effective performance, it is necessary to

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

EXAMPLE:English system- Determine Ethylene glycol percentage by weight and correction factors at 380F ambienttemperature.

From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 380F ambi-ent temperature is 12% by weight.

Find the correction factors corresponding to 380F ambient temperature from the table.Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is 1.07.

Apply these correction factors for corrected system performance values.

TONS (E.G. SOLUTION) = Tons (water) x Cooling capacity correction factor.BRINE (E.G. SOLUTION) FLOW (GPM) = Flow (water) x Flow correction factor.

BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (Ft.) x Pressure drop correction factor.

EXAMPLE: Metricsystem- Determine Ethylene glycol percentage by weight and correction factors where 3.30C ambi-

ent temperature.From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 3.30C ambi-

ent temperature is 12% by weight.

Find the correction factors corresponding to 3.30C ambient temperature from the table.Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is 1.07.Apply these correction factors for corrected system performance values.

KW (E.G. SOLUTION) = KW (water) x Cooling capacity correction factor.

BRINE (E.G. SOLUTION) FLOW (L/S) = KW (water) x Flow correction factor.BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (kPa) x Pressure drop correction factor.

NOTE: Correction factors apply to published chilled water performance rating from 400F to 500F (4.40C to 100C) LCWT.

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

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

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

Cooling capacity correction factor 1.0 0.985 0.980 0.974 0.970 0.965 0.964 0.960

Water flow correction factor 1.0 1.02 1.04 1.075 1.11 1.14 1.17 1.20

Pressure drop correction factor 1.0 1.07 1.11 1.18 1.22 1.24 1.27 1.30

13


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18/52


19/52


20/52


21/52


22/52


23/52


24/52

WATER SIDE PRESSURE DROP

CURVE No. Maximum GPMMODEL No.

ARY040A

ARY050A

ARY070A

ARY080A

ARY090A

ARY100A

ARY110A

ARY120A

ARY140A

ARY160A

ARY170A

ARY190A

1

2

3

3

4

4

5

5

6

6

6

7

112

141.3

197.2

226

244

267.1

318

349.3

408.7

441.5

475.6

532.2

Minimum GPM

75.7

93.5

130.5

152.6

174.6

184.2

218.5

242

286.6

310.9

333.7

369.1

CURVE No. Maximum GPMMODEL No.

ARY200A

ARY220A

ARY240A

ARY250A

ARY280A

ARY300A

ARY320A

ARY350A

ARY380A

ARY400A

ARY420A

7

8

5

5

5

6

6

7

7

7

8

554.7

598.1

679.3

710.6

764.2

858.5

884.7

983.6

1048.1

1105.5

1181.9

Minimum GPM

382.9

389.4

472.6

491.1

532.4

590.3

605.6

677.1

726.8

763.4

734.2

CONVERSION FACTOR: GPM = 0.063 Liters per second.

Feet of water = 2.989 Kilo Pascal (kpa).

NOTE: If an application requires certain water flow rate outside these limits, please check with your nearest dealer/sales office.

22


25/52

ARY040A & ARY050A

ARY070A & ARY080A

DIMENSIONS

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

23

DIMENSIONS

MODEL A B C

ARY040A 1530 250 310

ARY050A 1500 250 342


26/52

ARY090A & ARY100A

ARY110A & ARY120A

DIMENSIONS


24


27/52

DIMENSIONS


25

ARY140A & ARY160A

ARY170A


28/52

ARY190A

ARY200A & ARY220A

DIMENSIONS


26


29/52

NOTE:ALLDIMENSIONSAREIN

MILLIMETERS,

UNLESSOTHERWISES

PECIFIED.

DIMENSIONS

ARY24

0A,ARY250A&ARY280A

27


30/52


MILLIMETERS,

UNLESSOTHERWISES

PECIFIED.

DIMENSIONS

ARY300A

&ARY320A

28


31/52


MILLIMETERS,

UNLESSOTHERWISES

PECIFIED.

DIMENSIONS

ARY350A

&ARY380A

29


32/52


MILLIMETERS,

UNLESSOTHERWISES

PECIFIED.

DIMENSIONS

ARY400A

&ARY420A

30


33/52

FAN4

FAN3

COMP1

FAN8

FAN7

FAN6

FAN5

COMP2

CONTROL PANEL

CONTROL PANEL

FAN2

FAN1

TYPICAL SCHEMATIC WIRING DIAGRAM

NOTE: 1. Refer to next page for legend, notes & wiring diagram of optional items.2. Refer to unit control box (inside panel) for exact wiring diagram.

31


34/52

TYPICAL SCHEMATIC WIRING DIAGRAM

LEGEND

CB CIRCUIT BREAKER

COMP COMPRESSOR

CC COMPRESSOR CONTACTOR

CCA COMPRESSOR CONTACTOR AUXILIARY

CWP CHILLED WATER PUMPETB EARTH TERMINAL BLOCK

EEV ELECTRONIC EXPANSION VALVE

EEVB ECONOMIZER EXPANSION VALVE BOARD

FLS FLOW SWITCH

FM FAN MOTOR

FMC FAN MOTOR CONTACTOR

F FUSE

HGBS HOT GAS BYPASS SOLENOID

HPS HIGH PRESSURE SWITCH

HVTB HIGH VOLTAGE TERMINAL BLOCK

I/O INPUT/OUTPUT

LPS LOW PRESSURE SWITCH

LLSV LIQUID LINE SOLENOID VALVE

MB MAIN BOARD

OPS OIL PRESSURE SWITCH

PT PRESSURE TRANSDUCER

P PROPORTIONAL BANDSB/AB SLAVE/AUXILIARY BOARD

S1 CONTROL SWITCH

SSPS SOLID STATE PROTECTION SYSTEM

TRANS TRANSFORMER

TS TEMPERATURE SENSOR

UL UNLOADER

UVM UNDER VOLTAGE MONITOR

UVR UNDER VOLTAGE RELAY

TERMINAL BLOCK

- - - FIELD WIRING

* FIELD WIRINGLEGEND ON MAIN BOARD

A../D.. DIGITAL INPUT 1

AC/DC DIGITAL COMMON

C/1C.. COMMON

1O DIGITAL OUT 1

JU/TU/TD/TL DIGITAL OUT 1

T1 THERMISTOR Q

SH SHIELD

X52/X53 SERIAL COMMUNICATION PORT

X39 SERIAL COMMUNICATION PORT

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. FUSES TO DUAL ELEMENT TYPE.

3. COPPER CONDUCTORS ONLY.

4. FUSED DISCONNECT SWITCH OR CIRCUITBREAKER TO BE PROVIDED BY END USER WITH

RATING AS RECOMMENDED BY MANUFACTURER.

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

SYSTEM START UP.

IF POWER IS OFF 6 HOURS OR MORE, CRANKCASEHEATER MUST BE ON FOR 12 HOURS BEFORE

OPERATING THE SYSTEM.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY

RESULT IN COMPRESSOR DAMAGE.6. WHENEVER THERE IS TWO UNLOADERS ON A

COMPRESSOR, PLEASE READ BROKEN LINES AS

CONTINUOUS LINES.

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

8. FOR GFP CONNECTION WITHOUT OPS,

TERMINAL 64A & 64B SHALL BE CONNECTED TO

ATB#1 ONLY.

32

LOW PRESSURE SWITCH CONNECTION WITH COMPRESSOR CB (OPTIONAL)

UNIT EXTERNAL ENABLE/DISABLE OPTION

HOT GAS BYPASS OPTION

GROUND FAULT PROTECTION OPTION.(GFP)

UVM CONNECTION

UNIT EMERGENCY OPTION

OPS CONNECTION OPTION

LOW PRESSURE SWITCH CONNECTION WITHOUT COMPRESSOR CB (OPTIONAL)

MAIN BOARD


35/52

MICROPROCESSOR CONTROLLERSequence of Operation

The following describes the sequence of operation for a two reciprocating compressor chiller unit. Operation is similarfor a one or eight reciprocating compressor unit.

For initial start-up, the following condition must be met:

All power supplied to the unit shall be continuously energized for 12 hours. Control power is switch on for at least 5 minutes. All safety conditions are satisfied. Press ESC on the microcomputer keypad. Chilled water pump is running and chilled water flow switch contact is closed. Customer control is switch to run mode, if any.

STAGE - ON SEQUENCE

Staging ON & OFF sequence is accomplished based on controlled water Temperature PID algorithm.

Stage #1:If the controlled water temperature is greater than or equal to the water temperature set point, then compressor #1 switchON with the capacity unloader energized and the unit is at 25% capacity.

The condenser fans will switch ON with the increase of discharge pressure and switch OFF with the decrease of thedischarge pressure.

Stage #2:

After the minimum interval time elapse, if the controlled water temperature is not decreased and stays equal or greaterthan the water temperature set point, compressor #1 capacity unloader will be de-energized and the unit is at 50%

capacity.

Stage #3:

After the minimum interval time elapsed, if the controlled water temperature is not decreased and stays equal or greaterthan the water temperature set point, compressor #2 switch ON with the capacity unloader energized, and the unit is at75% capacity.

Stage #4:

After the minimum interval time elapsed, if the controlled water temperature is still not reduced and stays equal or greaterthan the water temperature set point, compressor #2 unloader will be de-energized and the unit is at 100% capacity.

STAGE - OFF SEQUENCE

During the staging OFF, the more running hour compressor is switched OFF if the compressor running time equalizationis selected.

As the controlled water temperature decreases below the water temperature set point and stays there, then stage #4switch OFF by energizing compressor #2 capacity unloader.

If the controlled water temperature stays below the water temperature set point or decreased more, then stage #3

switches OFF by switching OFF compressor #2.

If the controlled water temperature stays below the water temperature set point or decreased more, then stage #2 switchOFF by energizing compressor #1 capacity unloader.

If the controlled water temperature stays below the water temperature set point or decreased more, then stage #1 switch

OFF by switching OFF compressor #1.

33


36/52

Compressor and Unloader Staging

A one compressor unit has 2 stages, two compressor unit has 4 stages and a four compressor unit has 8 stages. Thestaging of a standard unit is shown in the following chart:

Number of Compressors

Stage

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1

1*

1

2

1*

1

1, 2*

1, 2

4

1*

1

1, 2*

1, 2

1, 2, 3*

1, 2, 3

1, 2, 3, 4*

1, 2, 3, 4

6

1*

1

1, 2*

1, 2

1, 2, 3*

1, 2, 3

1, 2, 3, 4*

1, 2, 3, 4

1, 2, 3, 4, 5*

1, 2, 3, 4, 5

1, 2, 3, 4, 5, 6*

1, 2, 3, 4, 5, 6

8

1*

1

1, 2*

1, 2

1, 2, 3*

1, 2, 3

1, 2, 3, 4*

1, 2, 3, 4

1, 2, 3, 4, 5*

1, 2, 3, 4, 5

1, 2, 3, 4, 5, 6*

1, 2, 3, 4, 5, 6

1, 2, 3, 4, 5, 6, 7*

1, 2, 3, 4, 5, 6, 7

1, 2, 3, 4, 5, 6, 7, 8*

1, 2, 3, 4, 5, 6, 7, 8

* Indicates that compressors are unloaded.

34


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35

APPLICATION GUIDELINESINTRODUCTIONThese guidelines should be considered when designing systems and their installation utilizing Zamil ARY series liquidchillers. 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 Conditionersfor specific recommendations.

UNIT SELECTION/SIZINGUnit selection procedure and capacities are provided in this catalog for proper selection. The Zamil electronic selectionprogram may also be utilized for this purpose.

Over sizing chillers beyond a maximum limit of 5 10 % in order to assure adequate capacity or considering future

expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operationand excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operatemore efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized

unit is usually more costly to purchase, install and operate.

When over sizing is desired due to anticipation of future plant expansion, consider using multiple units. For example,

install a single chiller for the present load requirement and install a second chiller for the foreseen additional load demand

due to expansion. Further, it is also recommended that installing two chillers instead of a single chiller be considered inapplications where partial load operation at low capacities is necessary.

Operation of two chillers at higher loading is preferred to operating a single chiller at or near its minimum possible capacity.

FOULING FACTOR AND WATER REQUIREMENTThe tabulated performance data provided in this catalog are based on a fouling factor of 0.00010 hr-ft2-0F/Btu (0.000018 m2-0C/W).

As fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other foulingfactors, apply appropriate correction factor from the table provided in this catalog.

These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water mayresult in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading to

possible equipment damage. The more scale forming material and suspended solids in the system water, the greater thechances of scale and deposit formation and fouling. These include calcium, magnesium, biological growth (algae, fungi

and bacteria), dirt, silt, clays, organic contaminants (oils), silica, etc. which should be kept to the minimum to retard scaleand deposit formation. In order to prevent corrosion and pitting, the pH value of the water flowing through the cooler must

be kept between 7 and 8.5. Zamil recommends that a water treatment specialist is consulted to provide and maintainwater treatment, this is particularly critical with glycol systems.

EFFECT OF ALTITUDE ON UNIT CAPACITYThe tabulated performance data provided in this catalog are for use at or near sea level altitude applications. At altitudessubstantially 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 CONSIDERATIONThese 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 1250F (520C) ambient temperature at rated nominal voltage.

WATER FLOW RATES AND COOLER PRESSURE DROPThe maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog.

The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminarflow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause exces-sive pressure drop and severe tube erosion.

During unit operation, water flow rate must not vary more than 5% from the design flow rate. The water flow switch should

be calibrated accordingly. The piping and pumping layout should be right for the application and must assure proper waterreturn and circulation. When using glycol solution, flow rate and pressure drop are higher than with water, therefore care

must be taken not to exceed the limits. In such applications, consult Zamil Air Conditioners for specific recommendations.


38/52

36

COOLER FLUID (WATER OR GLYCOL) TEMPERATURES RANGEUnit can start and pull down from 950F (350C) entering fluid temperature. The design leaving chilled fluid temperature

(LCWT) range as mentioned earlier in the tabulated performance data is 40 to 500F. The design entering chilled fluidtemperature range is 50 to 600F. The design cooler temperature drop (T) range is 5 to 150F.

The tabulated performance data provided in this catalog is based on a chilled water temperature drop of 100F. Units maybe operated at any desired temperature drop within the range of 5 to 150F as long as the temperature and flow limits are

not violated and appropriate correction factors are applied on the capacity and power input. The Zamil electronic selec-tion program can be very handy in selecting equipment at different temperature drops.

It should be noted that temperature drop outside the aforesaid range is not permitted as it is beyond the optimum range of

control and could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the

equipment.

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

temperatures relevant to the chiller within acceptable limits.

Example 1:An application requires 240 GPM of water at 450F and the return water temperature is 650F.A standard chiller can be used for this application as shown in the following basic schematic layout (single mixing arrangement).

Example 2:

An application requires 192 GPM of water at 650F and the return water temperature is 800F.A standard chiller can be used for this application as shown in the following basic schematic layout (dual mixing arrangement).

Load

200 TR

200 TR

Chiller

54.6F

500 GPM

45F

500 GPM

45F

240 GPM

65F

240 GPM

45F

260 GPM

Load

120 TR

120 TR

Chiller

45F

340 GPM

80F

109.8 GPM45F

257.8 GPM

80F

82.2 GPM

53.4F

340 GPM

80F

192 GPM

65F

192 GPM

53.4F

340 GPM

45F

82.2 GPM


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COOLER FREEZE PROTECTIONIf the unit is located in an area where ambient temperatures fall below 320F (00C), cooler protection in the form of Ethylene

Glycol Solution is required to protect the cooler and fluid piping from low ambient freeze-up. This glycol solution must be

added to the water system loop to bring down the freezing point of water to a difference of 150F (8.30C) below minimum

operating ambient temperature.

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

MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATIONA multiple chiller system has two or more chillers connected by parallel or series piping to a common distribution system.

Multiple chiller arrangements offer the advantage of operational flexibility, standby capacity and less disruptive mainte-

nance. Also, they offer some standby capacity if repair work must be done on a chiller from a set of duty chillers. Starting

in-rush current is reduced, as well as power costs at partial-load conditions.

A multiple chiller arrangement should be provided if the system load is greater than a single chiller capacity, standby

capability is desired, large temperature drop (greater than 150F) is desired or application calls for splitting the total

capacity for better part load operation.

In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced water

flow. It is mandatory that cooler flow rates must be balanced to ensure proper flow to each chiller based on its respective

capacity. As mentioned above, two basic multiple chiller systems are used: parallel and series chilled water flow.

In the parallel arrangement, liquid to be chilled is divided among the liquid chillers; the multiple chilled streams are

combined again in a common line after chilling. Water temperatures (EWT or LWT) can be used to cycle units On and Off

based on the cooling demand. Parallel arrangements permit adding chillers in the future for plant expansion with the

appropriate considerations beforehand.

In the series arrangement, the chilled liquid pressure drop may be higher unless coolers with fewer liquid-side passes or

baffles are used. No over chilling by either unit is required, and compressor power consumption is lower than it is for the

parallel arrangement at partial loads. It is also possible to achieve higher overall entering to leaving temperature drops,

which may in turn provide the opportunity for lower chilled water design temperature, lower design flow and resulting

installation and operational cost savings. Series chiller arrangements can be controlled in several ways based on the

water temperatures depending on cooling demand.

A valved piping bypass is suggested around each chiller to facilitate future servicing as it gives the personnel an option

for service without a complete shutdown.

Zamil recommends the parallel arrangement for design temperature drops (T) up to 150F and the series arrangement

beyond that i.e., 16 to 200F. Complete design details on these parallel and series chilled water flow arrangements can be

found in the ASHRAE handbooks and other design literature which should be referred by the designer in preparing his

detailed designs.

PIPING ARRANGEMENTS AND PLANT LAYOUTOur 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. Some suggested arrangements with basic sche-

matic layouts are as follows:


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

In this type of arrangement, constant water flow through the chillers and load distribution piping circuit is maintained.

Before proceeding further, a brief explanation on the operation of a typical chilled water system / valves which is funda-

mental to the design or analysis of a system.

Where multiple zones of control are required, the various load devices are controlled first; then the source (chillers)

system capacity is controlled to follow the capacity requirement of the loads. Control valves are commonly used to

control loads. These valves control the capacity of each load by varying the amount of water flow through the load device.

Control valves for these applications are two-way (straight-through) and three-way valves. The effect of either valve is to

vary the amount of water flowing through the load device. With a two-way valve, as the valve strokes from full-open to full-

closed, the quantity of water flowing through the load gradually decreases from design flow to no flow. The three-way

mixing valve has the same effect on the load as the two way valve - as the load reduces, the quantity of water flowing

through the load decreases in proportion to the load and the difference amount is directed through a bypass.

In terms of load control, a two-way valve and a three-way valve perform identical functionsthey both vary the flow

through the load as the load changes. The fundamental difference between the two-way valve and the three-way valve is

that as the source or distribution system sees the load, the two-way valve provides a variable flow load response and the

three-way valve provides a constant flow load response.

Referring to the foregoing schematic layout, this is a conventional system and is not as energy efficient as the two-way

valve systems especially on the pumping side due to constant water circulation in the system. On multiple chiller instal-

lations, pumps are required to operate continuously and the sequencing of chillers is dependent on water temperatures.

CHWS

CHWR

Load Load

3-WayValve

3-Way

Valve

Constant Speed Pump

Chiller


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39

2-WayValve

CHWS

Bypass

ControlValve

P

BypassLine

SystemController

FM-1

FM-2

Load

2-WayValve

Chiller

Variable Speed Pump

CHWR

Load

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

In this type of arrangement, constant water flow through the chillers is maintained, however the quantity of water flowing

through the load distribution piping system decreases in proportion to the load and the difference amount is directedthrough a bypass pipe that connects the supply and return headers. Brief sequence of operation is as follows:

The bypass with its control valve and flow meter provides the design flow required through the chillers. Flow meter FM1

measures the actual flow to the chilled water system. The system flow is compared with the required flow for the chillers.The difference is made up through the bypass and is monitored by flow meter FM2. This flow meter controls the bypass

valve to maintain the desired flow in the bypass based on the set points in the system controller (the valve is positionedby sum of flow meters FM1 and FM2).

The speed of the chiller pumps is controlled by the differential pressure sensor/transmitter, maintaining the desireddifferential pressure (P) across the cooling coils, their control valves and the branch piping. The pump speed is modu-

lated within a certain range in order to reduce the pumping head and not to alter the water flow rate (the duty flow rate ofthe pumps remains constant). Each chiller-pump combination operates independently from the remaining chillers and

each pump is shutdown when the respective chiller is stopped. Instead of using water temperature as an indicator ofdemand, the sequencing of chillers is dependent on water flow. The chillers are rated in gallons per minute; the actual

flow to the system determines the number of chillers that should be in operation.

Energy is saved because the system head is reduced appreciably when there are light cooling loads on the system anddue to cycling of pumps.

Note: Some designers may consider installing constant speed pumps and utilize pressure relief bypass control valves

controlled by a differential pressure sensor/controller to maintain a fixed differential pressure between the supply and

return mains of the chilled water system in order to accommodate for the required chiller flow and to achieve some formof variable volume system. This method is not recommended as its a wasteful practice because a considerable amount

of energy is lost, an almost constant volume system results and the pumping energy remains substantially that requiredat full system flow and head.

Also, the problem with this system is improper control of the bypass valve which does not guarantee proper flow through

the chillers and high differential pressures in the control valves on the cooling coils when the system friction subsides atlow loads which can cause lifting of the valve stems or wire cutting of the valve seats. Further, as all the water must be

pumped at a head equal to or greater than the design head, the pump or pumps are forced to run up the pump headcapacity curve, which increases the overpressure on the system and also increases the wear on the pumps, since theyare forced to operate with high radial thrusts.


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

This system is called a Primary Secondary System and in this arrangement, the generation zone is separated from the

transportation or distribution zone. In this type of arrangement also, constant water flow through the chillers is main-tained, however the quantity of water flowing through the load distribution pump/piping system decreases in proportion tothe load and the difference amount is directed through a bypass pipe that connects the supply and return headers. This

bypass pipe forms a Hydraulic Coupling between the points A B and is also called as Common Bridge or DecouplingLine. The sequence of operation is similar as the foregoing system with the following explanation:

The speed of the secondary chiller pump is controlled by the differential pressure sensor/transmitter, maintaining thedesired differential pressure (P) across the cooling coils, their control valves and the branch piping. This pump speed ismodulated within a broad range in order to reduce the pumping head and alter the water flow rate based on the changing

load conditions.

The primary pumps are constant speed pumps and the design flow rate through the chillers remains constant. Eachchiller-pump combination operates independently from the remaining chillers and each pump is shutdown when therespective chiller is stopped. The sequencing of chillers is dependent on water flow. If greater flow is demanded than thatsupplied by the chiller-pumps, return water is forced through the bypass into the supply header. This flow indicates a

need for additional chiller capacity and another chiller-pump starts. Excess bypass flow with reference to the set points inthe system controller in the opposite direction i.e., into the return header indicates overcapacity and the chiller-pumps are

turned off.

Energy is saved because the system head and water flow rate are reduced on the Secondary Pump when there are

partial cooling loads on the system and due to cycling of Primary Pumps.

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

The most important consideration while deciding upon the location of air cooled chillers is the provision for supply ofadequate ambient air to the condenser and removal of heated discharge air from the condenser. This is 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 fansare propeller type and are not recommended for use with ductwork or other hindrances in the condenser air stream.

Where these requirements are not complied, the supply or discharge airflow restrictions or warm air recirculation willcause higher condensing temperatures resulting in poor unit operation, higher power consumption and possible even-

tual failure of equipment.

Flow Sensor

CHWR

P

2-WayValve

Load

CHWSA

B

VariableSpeed Secondary Pump

SystemController

Load

2-WayValve

Constant SpeedPrimary Pump

Chiller


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41

The units longitudinal axis should be parallel to the prevailing wind direction in order to ensure a balanced air flowthrough the condenser coils. Consideration should also be given to the possibility of down-drafts caused by 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 wherethe sound output and air discharge from the units may be objectionable.

If the location is an area which is accessible to unauthorized persons, steps must be taken to prevent access to the

unit by means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage orpossible harm caused by unauthorized removal of panels or protective guards exposing rotating or high voltage

components.

The clearance requirements prescribed above are necessary to maintain good airflow and provide access for unitoperation and maintenance. However, it is also necessary to consider access requirements based on practical consid-

erations for servicing, cleaning and replacing large components.

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

For ground level installations, it must be ensured that the concrete base is stable and does not settle or dislocate upon

installation of the unit which can strain the refrigerant lines resulting in leaks and may also cause compressor oil returnproblems. It is recommended that the concrete slab is provided with appropriate footings. The slab should not 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 weightof 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 theconcrete base is perfectly horizontal and levelled, especially if the roof has been pitched to aid in water removal. Itshould be determined prior to installation if any special treatment is required to assure a levelled installation else 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 andvibration sensitive areas), follow the recommendations of structural and acoustical consultants.

Based on the specific project requirements, choose the type of vibration isolators best suited for the application.Carefully select the vibration isolators models / configuration based on the respective point loads and place 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 recommenda-tions may cause improper operation and loss of performance, damage to the unit and difficulty in servicing and maintenance:

Water piping must be connected correctly to the unit i.e., water must enter from the inlet connection on the cooler 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 eitherside of the flow switch. Paddle type flow switches can be obtained from Zamil which are supplied as optional items.

The chilled water pump(s) installed in the piping system should discharge directly into the unit cooler. The pump(s)

may be controlled external to the unit - but an interlock must be wired to the unit control panel (as shown in the wiringdiagram) so that the unit can start only upon proof of pump operation.


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Flexible connections suitably selected for the fluid and pressure involved should be provided as mandatory in order to

minimize transmission of vibrations to the piping / building as some movement of the unit can be expected duringnormal operation. The piping and fittings must be separately supported to prevent any loading on the cooler.

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

Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler.

Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if anyvariations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop

across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstreamfrom any connection (flange etc.) but as near to the cooler as possible.

Drain and air vent connections should be provided at all low and high points in the piping system to permit complete

drainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for usein all lines to facilitate servicing.

The system water piping must be flushed thoroughly before connecting to the unit cooler. The cooler must not beexposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and

valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance toisolate the cooler without disrupting flow to other units.

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

Note: For chillers with two coolers, the connecting pipes for entering and leaving water on one cooler must be joined tothe corresponding pipes on the other cooler before connecting to the main headers in the system piping.

OUT

IN

Isolating Valve - Normally Open

Isolating Valve - Normally Closed

Balancing Valve

Flow meter

Strainer

Pressure tapping

Flow Switch

Connection (flanged / Victaulic)

Pipe work

Flexible connection


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CHILLED FLUID VOLUME REQUIREMENTThe 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 systemoperation 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 standardair 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 ARY100 operating with a design water flow rate of 205 GPM for a standard air conditioning

application would require 100 (Nom. Cap.) x 3 = 300 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 systemloop 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 schemat-ics below:

SUGGESTIONS ON SYSTEM DESIGN AND PIPING PRACTICESThe prospective chilled water system should be designed to the specific requirements of the owner and to achieve the

most efficient system possible. Following are some recommendations:

The first decision a designer of a chilled water system must make is the selection of the temperature differential.Temperature differential is the difference between the supply water and the return water temperatures. There is no onetemperature difference for all chilled water systems. The actual temperature difference that is selected for a specific

installation is determined by the cost of the cooling coils for various temperature differences and the effect that higherdifferences may have on the operating cost of the chillers. A careful balance between energy savings and first cost

should be made by the designer. These are the decisions that must be made by the designer for each application andonly experienced designers should entertain water temperature differences in excess of 120F on chilled water sys-

tems. A number of conditions must be recognized before making the final selection of temperature differential:

a) An increase in temperature differential decreases water flow and therefore saves pumping energy.b) An increase in temperature differential may increase the cost of cooling coils that must operate with a higher mean

temperature difference.

c) Higher temperature differentials increase the possibilities of loss of temperature difference in coils due to dirt on theair side and chemical deposits on the water side of them.

d) Laminar flow on the water side due to lower velocities at low loads on a coil is always a concern of the water system

designer. The possibility of laminar flow is greater with higher temperature differences. Laminar flow reduces theheat-transfer rate and should not occur in a coil at any point in its load range. Many systems operate inefficiently

because of coils that were selected at too low a friction loss through them at design load; therefore, at reducedloads and flows, they operate with laminar flow.

TANK SCHEMATIC


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Control of Return Water Temperature: Return water temperature is one of the most important operating values for a

chilled water system. It tells the operator just how good a job the control system and coils are doing in convertingenergy from the chillers to the air or water systems that are cooling the building. This is such a basic criterion that itshould be addressed early in the design of a chilled water system. The proper method of controlling return temperature

is through the correct selection of control valves and cooling coils. In conclusion, one of the designers most importanttasks is the selection of a sound temperature differential that will provide maximum possible system efficiency. The

second step in this process is to ensure that the differential is maintained after the system is commissioned. The water system should be configured to distribute the water efficiently with a minimum use of energy-wasting

devices. These devices are listed here:

a) Three-way temperature control valves

b) Balancing valves, manual or automatic

c) Pressure-reducing or pressure-regulating valves

The piping should be designed without

a) Reducing flanges or threaded reducing couplings

b) Bullhead connections (e

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