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

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2 Company Business Zamil Air Conditioners was founded in 1974, and is the first major business venture in manufacturing sector for the Al Zamil group of Companies. It is also the first manufacturing unit for air conditioners to be established in Saudi Arabia. Zamil Air conditioners manufactures both consumer and central range of air conditioners and has sales operations in over 55 countries in the Middle East, Europe, America, Africa, Australia and the Far East. The company s 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 AHU s. The first three SBUs - Consumer Products, Unitary & Applied Products and Zamil CoolCare direct their business operations from the corporate headquarters at Dammam, Saudi Arabia. The production facilities at Dammam are shared by Consumer Products and Unitary & Applied Products. Geoclima has its own production and functional departments located at Monfalcone, Italy. All the four SBUs, while operating independently, supplement each other s activities in a way that makes synergy work at its best and achieve the corporate goals of increased productivity and efficiently. Factories and Productions Zamil Air Conditioners has its prime manufacturing base at Dammam, Saudi Arabia and has one speciality production facility in Italy operated by Geoclima. The company can produce up to 440,000 room air conditioners, 60,000 mini-split systems and 36,500 central air-conditioning systems per year. Quality & Product Certificates The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification. Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabia s 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.DEMKO 5.ETL Other awards include the prestigious Engineering Excellence Award of General Electric, and the inaugural Prince Mohammed bin Fahd Al Saud Award for Factory Safety. Our Products In addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufacturers a host of residential and commercial air conditioners. This board range extends from the concealed units up to 5 ton, the ducted splits up to 30 tons, the packaged units up to 70 tons. The single and double skin air handling units up to 130,000 CFM and the water chillers up to 487 ton cooling capacity.

3 INDEX Contents Page Model decoding... 2 Unit features, standard specifications & options Physical data Selection procedure Ethylene glycol solution capacity correction Performance data Electrical data Water side pressure drop Unit dimensions Typical schematic wiring diagram Microprocessor controller Application guidelines Rigging instructions Installation clearance Mounting location Load distribution CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE. 1

4 MODEL DECODING 1, 2 & 3 BASIC (SERIES) 4, 5 & 6 UNIT SIZE 7 REFRIGER- ANT 8 ELECTRICAL SUPPLY ( V-Ph-Hz ) 9 CONDENSER COIL 10 CIRCUIT BREAKER 11 COOLER OPTIONS 12 HGBP OPTIONS 13 & 14 OPTIONS & ACCESSORIES ARQ COOLINE AIR COOLED RECIPROCATING CHILLERS A : R-22 L : (4 WIRE) A : ALUMINUM FIN B : PRE-COATED ALUMINUM FIN C : COPPER FIN (SEE NOTE # 1 BELOW) A : STANDARD COMPRESSOR CIRCUIT BREAKER A : STANDARD WITH VICTAULIC CONN.* B : OPTIONAL FLANGE CONNECTION* C : OPTIONAL ASME STAMPED WITH VICTAULIC CONNECTION* D : OPTIONAL ASME STAMPED WITH FLANGE CONNECTION* A : STANDARD UNIT WITHOUT HGBP B : HGBP (OPTIONAL) SEE NOTE # 2 BELOW NOTES: * NOT APPLICABLE FOR MODELS ARQ040 & ARQ050, MPT (MALE PIPE THREAD) CONNECTION ONLY. 1. FOR OTHER COATING, SPECIFY YOUR REQUIREMENTS IN WRITING. 2. COMPUTER SELECTED DIGITS (FROM 'AA' TO 'ZZ') DESCRIBING OTHER OPTIONS & ACCESSORIES OR COMBINATIONS THEREOF, SUCH AS: - CONDENSER COIL GUARD - COOLER GUARD - UNIT DISCONNECT SWITCH - SWITCH - SPRING ISOLATOR etc... 2

5 FEATURES These ARQ series, packaged air cooled water chillers are designed to provide engineering excellence in comfort air conditioning and industrial cooling with a superior combination of energy saving, performance, application flexibility, ease of service & maintenance and withstanding extremely high ambient temperatures. These chillers incorporate a wide range of features including: * * * * * * * * * * * * Microprocessor controller, which monitors analog and digital inputs to achieve precise control & protective functions of the air cooled water chiller units. The microprocessor controller is complete with all the hardware and software necessary to control the chiller unit and ensures its efficiency and reliability. Compact unit design and excellent serviceability. All packaged chillers incorporate compact water coolers with enhanced inner grooved copper tubes bundled into a U shaped 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 advanced microprocessor controller providing all the necessary operating and safety controls. Independent refrigeration circuits. Compressor connections are part winding start for all models (see electrical data). Low noise condenser fans, direct drive at 860 RPM with rolled form venturi design to eliminate airflow recycling & short circuiting. All fans are die cast aluminum propeller type with aerodynamic design, top discharge, provided with protective grille mounted on top panel within the unit casing. All condenser fan motors are totally enclosed air over type (TEAO) with class ''F'' winding insulation. STANDARD SPECIFICATIONS CAPACITY CONTROL The COOLINE packaged chillers incorporate stepped load shedding as required by most energy management systems. Modulation of capacity in response to system load requirements is affected by the microprocessor controller which monitors the leaving water temperature. Capacity control is achieved by cycling compressors ON/OFF and 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. 3

6 CAPACITY CONTROL STEPS MODEL NUMBER ARQ040A ARQ050A -ARQ070A ARQ080A -ARQ090A ARQ100A -ARQ140A ARQ150A -ARQ180A ARQ200A -ARQ220A ARQ240A -ARQ290A ARQ305A -ARQ380A % FULL LOAD CAPACITY CONTROL STANDARD OPTIONAL OFF OFF OFF OFF OFF OFF OFF OFF HGBP-OFF HGBP-OFF HGBP-OFF HGBP-OFF HGBP-OFF HGBP-OFF HGBP-OFF 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: ARQ090A 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 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. SHELL & TUBE HEAT EXCHANGER (COOLER) DESIGN PRESSURE, (BAR/PSIG) SIDE TEST PRESSURE, (BAR/PSIG) DESIGN PRESSURE, (BAR/PSIG) REFRIGERANT SIDE TEST PRESSURE, (BAR/PSIG) STD ASME (option) 16/ /335 29/ /610 10/ / / / CABINET All units are of heavy gauge (G-90) galvanized steel. Steel sheet panels are zinc coated and galvanized by hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90 followed by backed on electrostatic polyester dry powder coat. Removable access panels are provided for easy maintenance purpose. CONTROL PANEL The control panel design is equivalent to NEMA 4 (IP55) with hinged door for easy access ensuring dust and weatherproof construction. Internal power and control wiring is neatly routed, adequately anchored and all wires identified with cable markers as per NEC standards applicable to HVAC industry. The electrical controls used in the control panel are UL approved and are reliable in operation at high ambient conditions for a long period. 4

7 CONDENSER FANS Condenser fans are constructed of die cast aluminum blades/hubs with direct driven motors. All fans are statically and dynamically balanced to operate at minimum noise and vibration. Fan blades are designed with appropriate pitch angle which result in maximum airflow through the condenser coil. CONDENSER FAN MOTOR Condenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phase with class ''F'' winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosed air over type (TEAO) with inherent thermal protection of automatic reset type & specially designed for outdoor applications. MICROPROCESSOR CONTROLLER The microprocessor controller works on the state of art microprocessor technology. This controller monitors analog and digital 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 history that are clearly displayed on a multi-line back illuminated LCD panel. Software & programs are stored in a non-volatile memory 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 corresponding windows 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 through corresponding optional gateway interfaces. It is also compatible with GSM protocol through GSM optional gateway that sends up to 3 mobile phone SMS messages whenever alarm takes 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 operating 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 water inlet & 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 time The 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 5

8 STANDARD CONTROL & SAFETY DEVICES MICROPROCESSOR 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 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. UNIT ON-OFF SWITCH: ON-OFF switch is provided for manually switching the unit control circuit. INDICATOR LIGHTS: LED lights indicates power ON to the units, MENU adjustment and FAULT indications due to trip on safety devices. THERMAL EXPANSION VALVE: Thermal expansion valve is used to regulate the refrigerant flow to the water cooler and maintain a constant superheat. REPLACEABLE 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. 6

9 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. SWITCH: Paddle type field adjustable flow switch for water cooler circuits. Interlock into unit safety circuits so that the unit will remain off until water flow is determine. VIBRATION ELIMINATOR: To eliminate the vibration transmitted from the compressor to the pipings and unit structure. ELECTRONIC EXPANSION VALVE: Electronic expansion valve is used to regulate the refrigerant flow to the water cooler and maintain a constant superheat and allows much better stability and control over dynamic load and head changes. UNIT MOUNT SPRING ISOLATORS: These housed spring assemblies have a neoprene friction pad on the bottom to prevent vibration transmission. COMPRESSOR MOUNT SPRING ISOLATORS: Provide more isolation efficiency where noise and vibration suppression is critical. 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: Protects the condenser coil from physical damage. COMPRESSOR/COOLER GUARD: Protects the compressor and cooler 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. 7

10 PHYSICAL DATA UNIT SIZE ARQ040A ARQ050A ARQ060A ARQ070A ARQ080A ARQ090A ARQ100A ARQ110A ARQ120A COMPRESSOR PART NUMBER (2) (2) (2) (2) (2) (4) (2) (2) (4) NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters / % FULL LOAD CAPACITY CONTROL MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION ELECTRONIC PUMP TOTAL CRANKCASE HEATER WATTS REFRIGERANT R-22 EXPANSION VALVE DEVICE THERMOSTATIC CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / / / / / Total face area, Sq. ft AIR, CFM NUMBER OF FAN/FAN DIA.,mm 4/762 4/762 4/800 4/800 4/800 6/800 6/800 6/800 6/800 FAN MOTOR COOLER COOLER PART NUMBER SHELL DIAMETER, mm LENGTH, mm TOTAL HOLDING VOLUME, Liters IN/OUT PIPE DIA.mm GENERAL REFRIGERANT CHARGE PER, kg ( 1/2) /20 24 SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 72.1/68.6/ /67.6/ /68.4/ /68.4/ /70.8/ /72/ /69.7/ /70.2/ /71.4/66.1 OPERATING/SHIPPING WEIGHTS, kg 1574/ / / / / / / / /4021 NOTES: 1. All compressors with cylinder unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : ±2dBA. 8

11 PHYSICAL DATA UNIT SIZE ARQ130A ARQ140A ARQ150A ARQ160A ARQ170A ARQ180A ARQ200A ARQ210A ARQ220A COMPRESSOR (2) (2) (2) (4) (2) PART NUMBER (4) (4) (4) (6) (2) (2) (2) (2) (4) NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters / /7.4 % FULL LOAD CAPACITY CONTROL MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION ELECTRONIC PUMP TOTAL CRANKCASE HEATER WATTS REFRIGERANT R-22 EXPANSION VALVE DEVICE THERMOSTATIC CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / / / / / / Total face area, Sq. ft AIR, CFM NUMBER OF FAN/FAN DIA.,mm 8/800 8/800 10/800 10/800 12/800 12/800 14/800 14/800 14/800 FAN MOTOR COOLER COOLER PART NUMBER (2) (2) (2) SHELL DIAMETER, mm LENGTH, mm TOTAL HOLDING VOLUME, Liters IN/OUT PIPE DIA.mm GENERAL REFRIGERANT CHARGE PER, kg ( 1/2) 28/ / / / /28 SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 75.7/72.2/ /71.4/ /73.3/ /73.4/ /74.4/ /75/ /74.5/ /73.7/ /74.2/68.9 OPERATING/SHIPPING WEIGHTS, kg 4373/ / / / / / / / /7149 NOTES: 1. All compressors with cylinder unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : ±2dBA. 9

12 UNIT SIZE ARQ240A ARQ260A ARQ275A ARQ290A ARQ305A COMPRESSOR PHYSICAL DATA (2) (4) (4) PART NUMBER (6) (6) (4) (2) (4) NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters /7.4 % FULL LOAD CAPACITY CONTROL MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION ELECTRONIC PUMP TOTAL CRANKCASE HEATER WATTS REFRIGERANT R-22 EXPANSION VALVE DEVICE THERMOSTATIC CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / / / Total face area, Sq. ft AIR, CFM NUMBER OF FAN/FAN DIA.,mm 14/800 16/800 16/800 16/800 18/800 FAN MOTOR COOLER COOLER PART NUMBER (2) (2) (2) (2) (2) SHELL DIAMETER, mm LENGTH, mm TOTAL HOLDING VOLUME, Liters IN/OUT PIPE DIA.mm GENERAL REFRIGERANT CHARGE PER, kg ( 1/2) 32 36/32 36/ /28 SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 78.6/75/ /75.7/ /76.1/ /76.5/ /76.1/70.9 OPERATING/SHIPPING WEIGHTS, kg 7580/ / / / /9537 NOTES: 1. All compressors with cylinder unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : ±2dBA. 10

13 PHYSICAL DATA UNIT SIZE ARQ325A ARQ340A ARQ360A ARQ370A ARQ380A COMPRESSOR PART NUMBER (8) (2) (4) (6) (6) (4) (2) (8) NUMBER OF COMPRESSORS OIL CHARGE PER COMPRESSOR, Liters % FULL LOAD CAPACITY CONTROL MOTOR OVERLOAD PROTECTION (INTERNAL) OIL LUBRICATION ELECTRONIC PUMP TOTAL CRANKCASE HEATER WATTS REFRIGERANT R-22 EXPANSION VALVE DEVICE THERMOSTATIC CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / Total face area, Sq. ft AIR, CFM NUMBER OF FAN/FAN DIA.,mm 18/800 18/800 20/800 20/800 20/800 FAN MOTOR COOLER COOLER PART NUMBER (2) (2) (2) (2) (2) SHELL DIAMETER, mm LENGTH, mm TOTAL HOLDING VOLUME, Liters IN/OUT PIPE DIA.mm GENERAL REFRIGERANT CHARGE PER, kg ( 1/2) 32 36/32 36/32 36/32 36 SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 79.7/76.2/ /76.4/ /77.3/ /77.3/ /77.6/72.4 OPERATING/SHIPPING WEIGHTS, kg 10311/ / / / /11214 NOTES: 1. All compressors with cylinder unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. All coolers are single face refrigerant connection. 5. Sound pressure level : ±2dBA. 11

14 SELECTION PROCEDURE (English units) DESIGN REQUIREMENTS The following design requirements must be known to select a package chiller. 1. Required cooling capacity in tons 2. Leaving chilled water temperature in 0 F (LCWT) 3. Chilled water flow rate in GPM 4. Chilled water cooling range in 0 F (water in temp. _ water out temp.) 5. Design ambient temperature 6. Minimum ambient temperature 7. Altitude 8. Electrical power supply SAMPLE SELECTION Select an Air Cooled Packaged chiller for the following conditions: Required system capacity is 85 tons at 54 0 F entering chilled water and 44 0 F leaving water. Design ambient temperature is 95 0 F. Altitude is 2000 feet above sea level. Water cooler fouling factor is Power supply: 380/415V-3Ph-50Hz. EVAPORATOR FOULING FACTOR (HR-FT 2-0 F/BTU) STEP-1: UNIT SELECTION Entering the capacity performance data at given LCWT and ambient temperature. ARQ090A chiller unit at sea level will produce 90.8 tons and compressor power input at 44 0 F leaving chilled water temperature with 10 0 F water temperature difference and 95 0 F ambient temperature. For the conditions required, the unit actual cooling capacity when corrected for altitude (0.99) and fouling factor (1.0). Capacity = 90.8 x0.99x1.0 = 89.8 Tons, which then exceeds the requirements. So the selection is correct. ELEVATION ABOVE SEA LEVEL (FT.) CAPACITY CORRECTION FACTOR TABLE - 2 TABLE - 1 POWER INPUT FACTOR CAPACITY CORRECTION FACTOR ARI STANDARDS ARI-550/ ARI ARI STEP-2: CHILLED (GPM): CHILLED TEMPERATURE RISE ( 0 F) Water GPM = Required capacity (Tons) x 24 = 85 x 24 TABLE - 3 = 204 GPM Cooling Range, T 10 0 F Referring to pressure drop chart (page # 22), pressure drop at 204 GPM = 12 ft. of water for selected model. NOTE: The total flow rate should be divided by 2 for models ARQ200A - ARQ380A to find out the total pressure drop. STEP-3: ELECTRICAL Refer to electrical data at 380/415V-3Ph-50Hz, the main power wire size for ARQ090A is to be sized for a minimum circuit ampacity (MCA) of 276 Amps and maximum over current protection (MOCP) of 391 Amps. STEP-4: CHILLED PUMP SELECTION For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCWT CORRECTION Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperature range is above 10 0 F and subtract correction from design leaving chilled water temperature (LCWT) when water temperature range is below 10 0 F. EXAMPLE: If LCWT rise is F, enter correction curve at F and read the correction factor of 0.2. The corrected LCWT is = F. NOTE: 1. When the chilled water temperature rise is less than 5 0 F, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2.Please refer to water pressure drop curves. CORRECTION FACTOR ( 0 F)

15 SELECTION PROCEDURE (Metric units) DESIGN REQUIREMENTS The following design requirements must be known to select a proper package chiller. 1. Required cooling capacity in kilowatt () 2. Leaving chilled water temperature in 0 C (LCWT) 3. Chilled water flow rate in LPS 4. Chilled water cooling range in 0 C (water in temp. _ water out temp.) 5. Design ambient temperature 6. Minimum ambient temperature 7. Altitude 8. Electrical power supply EVAPORATOR FOULING FACTOR (M 2-0 C/W) SAMPLE SELECTION Select an Air Cooled Packaged chiller for the following conditions: Required system capacity is 300 at 12 0 C entering chilled water and 6 0 C leaving water. Design ambient temperature is 35 0 C. Altitude is 600 meter above sea level. Water cooler fouling factor is Power supply: 380/415V-3Ph-50Hz ELEVATION ABOVE SEA LEVEL (Meter) CAPACITY CORRECTION FACTOR TABLE - 2 TABLE - 1 POWER INPUT FACTOR CAPACITY CORRECTION FACTOR ARI STANDARDS ARI-550/ ARI ARI STEP-1: UNIT SELECTION Entering the capacity performance data at given LCWT and ambient temperature. ARQ090A chiller unit at sea level will produce and compressor power input at 6 0 C leaving chilled water temperature with 6 0 C water temperature difference and 35 0 C ambient temperature. For the conditions required, the unit actual cooling capacity when corrected for altitude (0.99) and fouling factor (1.0). Capacity = 314.9x0.99x1.0 = 311.7, which then exceeds the requirements. So the selection is correct. STEP-2: CHILLED (LPS): Water LPS = Required capacity () x = 300 x = 11.9 LPS Cooling Range, T 6 0 C CORRECTION FACTOR ( 0 C) CHILLED TEMPERATURE RISE ( 0 C) TABLE Referring to pressure drop chart (page # 22), pressure drop at 11.9 LPS = 33 kpa for selected model. NOTE: The total flow rate should be divided by 2 for models ARQ200A - ARQ380A to find out the total pressure drop. STEP-3: ELECTRICAL Refer to electrical data at 380/415V-3Ph-50Hz, the main power wire size for ARQ090A is to be sized for a minimum circuit ampacity (MCA) of 276 Amps and maximum over current protection (MOCP) of 391 Amps. STEP-4: CHILLED PUMP SELECTION For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCWT CORRECTION Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperature range is above 6 0 C and subtract correction from design leaving chilled water temperature (LCWT) when water temperature range is below 6 0 C. EXAMPLE: If LCWT rise is C, enter correction curve at C and read the correction factor of The corrected LCWT is 6 0 C+0.11 = C. NOTE: 1. When the chilled water temperature rise is less than 3 0 C, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2.Please refer to water pressure drop curves. 13

16 ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (Antifreeze) When operating in areas with temperatures below 32 0 F (0 0 C), cooler protection in the form of Ethylene glycol solution (brine solution) is required to protect cooler from low ambient freeze-up. This brine solution must be added to water loop to bring down the freezing point with a difference of 15 0 F (8 0 C) below minimum operating ambient temperature. Ethylene glycol solution causes a variation in unit performance. To obtain the effective performance, it is necessary to multiply the water performance data by correction factors corresponding to the ambient temperature or Ethylene glycol percentage indicated in the following table. ETHYLENE GLYCOL % BY WEIGHT 0% 12% 22% 30% 36% 41% 46% 50% Freezing point of Ethylene glycol solution 0 0 C (32 0 F) -5 0 C (23 0 F) C (14 0 F) C (5 0 F) C (-4 0 F) C (-13 0 F) C (-22 0 F) C (-31 0 F) Ambient temperature C (47 0 F) C (38 0 F) C (29 0 F) C (20 0 F) C (11 0 F) C (2 0 F) C (-7 0 F) C (-16 0 F) Cooling capacity correction factor Water flow correction factor Pressure drop correction factor EXAMPLE: English system- Determine Ethylene glycol percentage by weight and correction factors at 38 0 F ambient temperature. From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 38 0 F ambient temperature is 12% by weight. Find the correction factors corresponding to 38 0 F ambient temperature from the table. Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is Apply these correction factors for corrected system performance values. TONS (E.G. SOLUTION) = Tons (water) x Cooling capacity correction factor. BRINE (E.G. SOLUTION) (GPM) = Flow (water) x Flow correction factor. BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (Ft.) x Pressure drop correction factor. EXAMPLE: Metric system- Determine Ethylene glycol percentage by weight and correction factors where C ambient temperature. From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to C ambient temperature is 12% by weight. Find the correction factors corresponding to C ambient temperature from the table. Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is Apply these correction factors for corrected system performance values. KW (E.G. SOLUTION) = KW (water) x Cooling capacity correction factor. BRINE (E.G. SOLUTION) (L/S) = KW (water) x Flow correction factor. BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (kpa) x Pressure drop correction factor. NOTE: Correction factors apply to published chilled water performance rating from 40 0 F to 50 0 F (4.4 0 C to 10 0 C) LCWT. 14

17 PERFORMANCE DATA (English units) LEAVING CHILLED TEMP. (LCWT) 40 0 F 42 0 F UNIT SIZE 95 0 F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE (Tons) LEGEND: - Compressor power input GPM - Gallons Per Minute EER - Energy Efficiency Ratio EER (GPM) (Tons) EER (GPM) (Tons) ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 10 0 F water range in evaporator. 3. Ratings are based on (hr-ft 2-0 F/Btu) fouling factor for evaporator. EER (GPM) (Tons) EER (GPM) (Tons) 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. EER (GPM) 15

18 PERFORMANCE DATA (English units) LEAVING CHILLED TEMP. (LCWT) 44 0 F 46 0 F UNIT SIZE 95 0 F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE (Tons) LEGEND: - Compressor power input GPM - Gallons Per Minute EER - Energy Efficiency Ratio EER (GPM) (Tons) EER (GPM) (Tons) ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 10 0 F water range in evaporator. 3. Ratings are based on (hr-ft 2-0 F/Btu) fouling factor for evaporator. EER (GPM) (Tons) EER (GPM) (Tons) 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. EER (GPM) 16

19 PERFORMANCE DATA (English units) LEAVING CHILLED TEMP. (LCWT) 48 0 F 50 0 F UNIT SIZE 95 0 F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE (Tons) LEGEND: - Compressor power input GPM - Gallons Per Minute EER - Energy Efficiency Ratio EER (GPM) (Tons) EER (GPM) (Tons) ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 10 0 F water range in evaporator. 3. Ratings are based on (hr-ft 2-0 F/Btu) fouling factor for evaporator. EER (GPM) (Tons) EER (GPM) (Tons) 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. EER (GPM) 17

20 PERFORMANCE DATA (Metric units) LEAVING CHILLED TEMP. (LCWT) 4 0 C 5 0 C UNIT SIZE ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A LEGEND: - Compressor power input LPS - Liters Per Second COP - Coefficient of Performance 35 0 C AMBIENT TEMPERATURE 40 0 C AMBIENT TEMPERATURE 46 0 C AMBIENT TEMPERATURE 50 0 C AMBIENT TEMPERATURE 52 0 C AMBIENT TEMPERATURE () COP (LPS) () COP (LPS) () NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 6 0 C water range in evaporator. 3. Ratings are based on (m 2-0 C/W) fouling factor for evaporator. COP (LPS) () COP (LPS) () 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. COP (LPS) 18

21 PERFORMANCE DATA (Metric units) LEAVING CHILLED TEMP. (LCWT) 6 0 C 7 0 C UNIT SIZE ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A LEGEND: - Compressor power input LPS - Liters Per Second COP - Coefficient of Performance 35 0 C AMBIENT TEMPERATURE 40 0 C AMBIENT TEMPERATURE 46 0 C AMBIENT TEMPERATURE 50 0 C AMBIENT TEMPERATURE 52 0 C AMBIENT TEMPERATURE () COP (LPS) () COP (LPS) () NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 6 0 C water range in evaporator. 3. Ratings are based on (m 2-0 C/W) fouling factor for evaporator. COP (LPS) () COP (LPS) () 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. COP (LPS) 19

22 PERFORMANCE DATA (Metric units) LEAVING CHILLED TEMP. (LCWT) 8 0 C 10 0 C UNIT SIZE ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A ARQ 040A ARQ 050A ARQ 060A ARQ 070A ARQ 080A ARQ 090A ARQ 100A ARQ 110A ARQ 120A ARQ 130A ARQ 140A ARQ 150A ARQ 160A ARQ 170A ARQ 180A ARQ 200A ARQ 210A ARQ 220A ARQ 240A ARQ 260A ARQ 275A ARQ 290A ARQ 305A ARQ 325A ARQ 340A ARQ 360A ARQ 370A ARQ 380A LEGEND: - Compressor power input LPS - Liters Per Second COP - Coefficient of Performance 35 0 C AMBIENT TEMPERATURE 40 0 C AMBIENT TEMPERATURE 46 0 C AMBIENT TEMPERATURE 50 0 C AMBIENT TEMPERATURE 52 0 C AMBIENT TEMPERATURE () COP (LPS) () COP (LPS) () NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 6 0 C water range in evaporator. 3. Ratings are based on (m 2-0 C/W) fouling factor for evaporator. COP (LPS) () COP (LPS) () 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. COP (LPS) 20

23 ELECTRICAL DATA UNIT SIZE ARQ040A ARQ050A ARQ060A ARQ070A ARQ080A ARQ090A ARQ100A ARQ110A ARQ120A ARQ130A ARQ140A ARQ150A ARQ160A ARQ170A ARQ180A ARQ200A ARQ210A ARQ220A ARQ240A ARQ260A ARQ275A ARQ290A ARQ305A ARQ325A ARQ340A ARQ360A ARQ370A ARQ380A Nominal (V-Ph-Hz) SUPPLY VOLTAGE COMPRESSOR TYPE-1 COMPRESSOR TYPE-2 CONDENSER FAN MOTORS Min. Max. MCA MOCP Qty. RLA (each) LRA (each) CB Poles CB1 MTA Qty. CB2 MTA Qty. Qty. RLA (each) LRA (each) CB Poles CB1 MTA Qty. FLA (each) Total FCA CB Qty. CRANKCASE HEATER Qty. CB2 MTA Qty. Volts Total Watts Total Amps LEGEND: MCA - Minimum Circuit Ampacity per NEC MOCP - Maximum Over Current Protection RLA - Rated Load Amps LRA - Locked Rotor Amps CB - Circuit Breaker MTA - Must Trip Amps FLA - Full Load Amps FCA - Fan Circuit Amps NOTES: 1. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker. 2. The maximum incoming wire size is 500 mcm. On units having MCA greater than the ampacity of 500 mcm wire, the factory supplied power terminal block will accept two parallel field wires per pole phase. 3. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection. 4. All field wiring must be in accordance with NEC and local standards. 5. Minimum and maximum unit supply voltages are shown in the tabulated data above. 6. The ±10% voltage variation from the nominal is allowed for a short time only, not permanent. 21

24 SIDE PRESSURE DROP 2 MODEL No. ARQ040A ARQ050A ARQ060A ARQ070A ARQ080A ARQ090A ARQ100A ARQ110A ARQ120A ARQ130A ARQ140A ARQ150A ARQ160A ARQ170A CURVE No Minimum GPM Maximum GPM MODEL No. ARQ180A ARQ200A ARQ210A ARQ220A ARQ240A ARQ260A ARQ275A ARQ290A ARQ305A ARQ325A ARQ340A ARQ360A ARQ370A ARQ380A CURVE No Minimum GPM Maximum GPM CONVERSION FACTOR: GPM = Liters per second. Feet of water = 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 DIMENSIONS ARQ040A & ARQ050A DIMENSIONS MODEL A B C ARQ040A ARQ050A ARQ060A & ARQ070A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. 23

26 DIMENSIONS ARQ080A & ARQ090A ARQ100A & ARQ110A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. 24

27 DIMENSIONS ARQ120A, ARQ130A & ARQ140A ARQ150A & ARQ160A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. 25

28 DIMENSIONS ARQ170A & ARQ180A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. DIMENSIONS MODEL A B C ARQ170A ARQ180A

29 DIMENSIONS ARQ200A, ARQ210A, ARQ220A & ARQ240A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. 27

30 DIMENSIONS ARQ260A, ARQ275A & ARQ290A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. DIMENSIONS MODEL A B C ARQ260A ARQ275A ARQ290A

31 DIMENSIONS ARQ305A, ARQ325A & ARQ340A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. DIMENSIONS MODEL A B C D ARQ305A ARQ325A ARQ340A

32 DIMENSIONS ARQ360A, ARQ370A & ARQ380A NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED. 30

33 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 TYPICAL SCHEMATIC WIRING DIAGRAM UNIT EMERGENCY OPTION UVM CONNECTION OPS CONNECTION OPTION GROUND FAULT PROTECTION OPTION.(GFP) HOT GAS BYPASS OPTION LOW PRESSURE SWITCH CONNECTION WITH COMPRESSOR CB (OPTIONAL) LOW PRESSURE SWITCH CONNECTION WITHOUT COMPRESSOR CB (OPTIONAL) MAIN BOARD UNIT EXTERNAL ENABLE/DISABLE OPTION LEGEND CB CIRCUIT BREAKER COMP COMPRESSOR CC COMPRESSOR CONTACTOR CCA COMPRESSOR CONTACTOR AUXILIARY CWP CHILLED PUMP ETB EARTH TERMINAL BLOCK EEV ELECTRONIC EXPANSION VALVE EEVB ECONOMIZER EXPANSION VALVE BOARD FLS 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 BAND SB/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 OR TERMINATION POINT FIELD WIRING * FIELD SUPPLY LEGEND 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, 380/415V-3Ph-50Hz. 2. FUSES TO DUAL ELEMENT TYPE. 3. COPPER CONDUCTORS ONLY. 4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH RATING AS RECOMMENDED BY MANUFACTURER. 5. POWER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP. IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE. 6. WHENEVER THERE IS TWO UNLOADERS ON A COMPRESSOR, PLEASE READ BROKEN LINES AS CONTINUOUS LINES. 7. FOR GFP CONNECTION WITHOUT OPS, TERMINAL 64A & 64B SHALL BE CONNECTED TO ATB#1 ONLY. 32

35 MICROPROCESSOR CONTROLLER Sequence of Operation The following describes the sequence of operation for a two reciprocating compressor chiller unit. Operation is similar for 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 switch ON 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 the discharge pressure. Stage #2: After the minimum interval time elapse, if the controlled water temperature is not decreased and stays equal or greater than 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 greater than the water temperature set point, compressor #2 switch ON with the capacity unloader energized, and the unit is at 75% capacity. Stage #4: After the minimum interval time elapsed, if the controlled water temperature is still not reduced and stays equal or greater than 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 equalization is selected. As the controlled water temperature decreases below the water temperature set point and stays there, then stage #4 switch 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 switch OFF 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 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. The staging of a standard unit is shown in the following chart: Number of Compressors Stage * 1* 1* 1* 1* , 2* 1, 2* 1, 2* 1, 2* 4 5 1, 2 1, 2 1, 2, 3* 1, 2 1, 2, 3* 1, 2 1, 2, 3* 6 1, 2, 3 1, 2, 3 1, 2, 3 7 1, 2, 3, 4* 1, 2, 3, 4* 1, 2, 3, 4* 8 1, 2, 3, 4 1, 2, 3, 4 1, 2, 3, 4 9 1, 2, 3, 4, 5* 1, 2, 3, 4, 5* 10 1, 2, 3, 4, 5 1, 2, 3, 4, , 2, 3, 4, 5, 6* 1, 2, 3, 4, 5, 6* 12 1, 2, 3, 4, 5, 6 1, 2, 3, 4, 5, , 2, 3, 4, 5, 6, 7* 14 1, 2, 3, 4, 5, 6, , 2, 3, 4, 5, 6, 7, 8* 16 1, 2, 3, 4, 5, 6, 7, 8 * Indicates that compressors are unloaded. 34

37 APPLICATION GUIDELINES INTRODUCTION These guidelines should be considered when designing systems and their installation utilizing COOLINE ARQ series liquid chillers. Stable operation, performance and reliability of units is often dependent upon proper compliance with these recommendations. When any application varies from these guidelines, it should be referred with Cooline Air Conditioners for specific recommendations. UNIT SELECTION/SIZING Unit selection procedure and capacities are provided in this catalog for proper selection. The COOLINE electronic selection program may also be utilized for this purpose. Over sizing chillers beyond a maximum limit of 5 10 % in order to assure adequate capacity or considering future expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operation and excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operate more efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized unit is usually more costly to purchase, install and operate. 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 in applications 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 REQUIREMENT The tabulated performance data provided in this catalog are based on a fouling factor of hr-ft 2-0 F/Btu ( m 2-0 C/W). As fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other fouling factors, apply appropriate correction factor from the table provided in this catalog. These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water may result in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading to possible equipment damage. The more scale forming material and suspended solids in the system water, the greater the chances 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 scale and 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. COOLINE recommends that a water treatment specialist is consulted to provide and maintain water treatment, this is particularly critical with glycol systems. EFFECT OF ALTITUDE ON UNIT CAPACITY The tabulated performance data provided in this catalog are for use at or near sea level altitude application. At altitudes substantially above sea level, the decreased air density will reduce condenser capacity and therefore unit capacity. For unit selection at these higher altitudes, apply appropriate correction factor from the table provided in this catalog. HIGH AMBIENT CONSIDERATION These chillers are designed for year round operation over a range of ambient temperatures. As a standard, these chillers can start and operate satisfactorily up to F (52 0 C) ambient temperature at rated nominal voltage. RATES AND COOLER PRESSURE DROP The maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog. The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminar flow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessive pressure drop and severe tube erosion. During unit operation, water flow rate must not vary more than ± 5% from the design flow rate. The water flow switch should be calibrated accordingly. The piping and pumping layout should be right for the application and must assure proper water return 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 Cooline Air Conditioners for specific recommendations. 35

38 COOLER FLUID ( OR GLYCOL) TEMPERATURES RANGE Unit can start and pull down from 95 0 F (35 0 C) entering fluid temperature. The design leaving chilled fluid temperature (LCWT) range as mentioned earlier in the tabulated performance data is 40 to 50 0 F. The design entering chilled fluid temperature range is 50 to 60 0 F. The design cooler temperature drop ( T) range is 5 to 15 0 F. The tabulated performance data provided in this catalog is based on a chilled water temperature drop of 10 0 F. Units may be operated at any desired temperature drop within the range of 5 to 15 0 F as long as the temperature and flow limits are not violated and appropriate correction factors are applied on the capacity and power input. The COOLINE electronic selection program can be very handy in selecting equipment at different temperature drops. It should be noted that temperature drop outside the aforesaid range is not permitted as it is beyond the optimum range of control and could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the equipment. RATES AND/OR TEMPERATURES OUT OF RANGE Certain applications (particularly process cooling jobs) call for flow rates and/or water temperatures that are outside the above mentioned limits/range. Our chillers can be utilized for these applications by selecting the chiller based on the specific 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 45 0 F and the return water temperature is 65 0 F. A standard chiller can be used for this application as shown in the following basic schematic layout (single mixing arrangement). 45 F 500 GPM 45 F 240 GPM 200 TR Chiller 45 F 260 GPM Load 200 TR 54.6 F 500 GPM 65 F 240 GPM Example 2: An application requires 192 GPM of water at 65 0 F and the return water temperature is 80 0 F. A standard chiller can be used for this application as shown in the following basic schematic layout (dual mixing arrangement). 45 F 340 GPM 45 F 82.2 GPM 65 F 192 GPM 120 TR Chiller 45 F GPM 80 F GPM Load 120 TR 53.4 F 340 GPM 53.4 F 340 GPM 80 F 82.2 GPM 80 F 192 GPM 36

39 COOLER FREEZE PROTECTION If the unit is located in an area where ambient temperatures fall below 32 0 F (0 0 C), cooler protection in the form of Ethylene Glycol Solution is required to protect the cooler and fluid piping from low ambient freeze-up. This glycol solution must be added to the water system loop to bring down the freezing point of water to a difference of 15 0 F (8.3 0 C) below minimum operating ambient temperature. Using this glycol solution causes a variation in unit performance, flow rate and pressure drop, therefore appropriate correction factors from the aforementioned table in this catalog should be applied. MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATION A multiple chiller system has two or more chillers connected by parallel or series piping to a common distribution system. Multiple chiller arrangements offer the advantage of operational flexibility, standby capacity and less disruptive maintenance. Also, they offer some standby capacity if repair work must be done on a chiller from a set of duty chillers. Starting in-rush current is reduced, as well as power costs at partial-load conditions. A multiple chiller arrangement should be provided if the system load is greater than a single chiller capacity, standby capability is desired, large temperature drop (greater than 15 0 F) 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. COOLINE recommends the parallel arrangement for design temperature drops ( T) up to 15 0 F and the series arrangement beyond that i.e., 16 to 20 0 F. Complete design details on these parallel and series chilled water flow arrangements can be found in the ASHRAE handbooks and other design literature which should be referred by the designer in preparing his detailed designs. PIPING ARRANGEMENTS AND PLANT LAYOUT Our chillers are suitable for incorporating in Two Pipe single temperature systems or Four Pipe independent load systems. The system piping circuit (load distribution circuit) should be basically parallel piping either Direct Return or Reverse Return system with a good pumping arrangement. The method of circuiting and pumping is a judgment decision by the designer. The designer must weigh the pros and cons of cost, nature of load and configuration of building, energy economics, flexibility, installation requirements and others to determine the best arrangement for his project. In all cases, it must be ensured that the design water flow is constantly maintained through the chillers at all stages of operation. Some suggested arrangements with basic schematic layouts are as follows: 37

40 A. Single or multiple chillers with constant water flow through chillers and load system: CHWS Chiller Load Load 3-Way Valve 3-Way Valve CHWR Constant Speed Pump 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 fundamental 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 fullclosed, 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 functions they 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 installations, pumps are required to operate continuously and the sequencing of chillers is dependent on water temperatures. 38

41 B. Single or multiple chillers with constant water flow through chillers and variable water flow through load system: FM-1 CHWS Bypass Line Chiller Bypass Control Valve Load P Load FM-2 2-Way Valve 2-Way Valve Variable Speed Pump CHWR System Controller 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 directed through 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 positioned by sum of flow meters FM1 and FM2). The speed of the chiller pumps is controlled by the differential pressure sensor/transmitter, maintaining the desired differential pressure ( T) across the cooling coils, their control valves and the branch piping. The pump speed is modulated within a certain range in order to reduce the pumping head and not to alter the water flow rate (the duty flow rate of the 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 of demand, 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 and due 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 form of variable volume system. This method is not recommended as it s a wasteful practice because a considerable amount of energy is lost, an almost constant volume system results and the pumping energy remains substantially that required at 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 at low 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 head capacity curve, which increases the overpressure on the system and also increases the wear on the pumps, since they are forced to operate with high radial thrusts. 39

42 C. Single or multiple chillers with constant water flow through chillers and variable water flow through load system (primary/secondary pumping arrangement): A CHWS Variable Speed Secondary Pump Chiller Load Load Flow Sensor P 2-Way Valve 2-Way Valve Constant Speed Primary Pump B CHWR System Controller 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 maintained, however the quantity of water flowing through the load distribution pump/piping system decreases in proportion to the 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 Decoupling Line. 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 the desired differential pressure ( T) across the cooling coils, their control valves and the branch piping. This pump speed is modulated 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. Each chiller-pump combination operates independently from the remaining chillers and each pump is shutdown when the respective chiller is stopped. The sequencing of chillers is dependent on water flow. If greater flow is demanded than that supplied 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 in the 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 INSTALLATION These chillers are designed for outdoor installation and can be installed at ground level or on a suitable rooftop location. In order to achieve good operation, performance and trouble-free service, it is essential that the proposed installation location and subsequent installing procedures meet the following requirements: The most important consideration while deciding upon the location of air cooled chillers is the provision for supply of adequate ambient air to the condenser and removal of heated discharge air from the condenser. This is accomplished by maintaining sufficient clearances which have been specified in this Catalog around the units and avoiding obstructions in the condenser air discharge area to prevent the possibility of warm air circulation. Further, the condenser fans are propeller type and are not recommended for use with ductwork or other hindrances in the condenser air stream. Where these requirements are not complied, the supply or discharge airflow restrictions or warm air recirculation will cause higher condensing temperatures resulting in poor unit operation, higher power consumption and possible eventual failure of equipment. 40

43 The unit s longitudinal axis should be parallel to the prevailing wind direction in order to ensure a balanced air flow through the condenser coils. Consideration should also be given to the possibility of down-drafts caused by adjacent buildings, which may cause recirculation or uneven unit airflow. For locations where significant cross winds are expected, an enclosure of solid or louver type is recommended to prevent wind turbulence interfering with the unit airflow. When units are installed in an enclosure, the enclosure height should not exceed the height of the unit. The location should be selected for minimum sun exposure and away from hot air sources, steam, exhaust vents and sources of airborne chemicals that could attack the condenser coils and steel parts of the unit. Avoid locations where the sound output and air discharge from the units may be objectionable. If the location is an area which is accessible to unauthorized persons, steps must be taken to prevent access to the unit by means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage or possible harm caused by unauthorized removal of panels or protective guards exposing rotating or high voltage components. The clearance requirements prescribed above are necessary to maintain good airflow and provide access for unit operation and maintenance. However, it is also necessary to consider access requirements based on practical considerations 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 of handling complete operating weight of the unit as given in the Physical Data tables in this Catalog. For ground level installations, it must be ensured that the concrete base is stable and does not settle or dislocate upon installation of the unit which can strain the refrigerant lines resulting in leaks and may also cause compressor oil return problems. It is recommended that the concrete slab is provided with appropriate footings. The slab should not be connected to the main building foundation to avoid noise and vibration transmission. For rooftop installations, choose a place with adequate structural strength to safely support the entire operating weight of the unit. The unit shall be mounted on a concrete slab similar to ground installations. The roof must be reinforced for supporting the individual point loads at the mounting isolator locations. It must be checked and ensured that the concrete base is perfectly horizontal and levelled, especially if the roof has been pitched to aid in water removal. It should be determined prior to installation if any special treatment is required to assure a levelled installation else it could lead to the above mentioned problems. Vibration isolators are necessary for installing these chillers in order to minimize the transmission of vibrations. The two types of vibration isolators generally utilized for mounting these units are Neoprene Pads and Spring Isolators. Neoprene Pads are recommended for ground level normal installations jobs where vibration isolation is not critical and job costs must be kept to a minimum. Spring Isolators are recommended for ground level installations which are noisesensitive areas or exposed to wind loads and all roof top installations. For critical installations (extremely noise and vibration sensitive areas), follow the recommendations of structural and acoustical consultants. Based on the specific project requirements, choose the type of vibration isolators best suited for the application. Carefully select the vibration isolators models / configuration based on the respective point loads and place each mount in its correct position following the Load Distribution Data and Mounting Drawings provided in this Catalog. Refer to the Schematic Mounting Layout drawings provided in the IOM manual of these chillers for further details in this regard. COOLER PIPING CONNECTIONS The following pertinent guidelines are served to ensure satisfactory operation of the units. Failure to follow these recommendations may cause improper operation and loss of performance, damage to the unit and difficulty in servicing and maintenance: Water piping must be connected correctly to the unit i.e., water must enter from the inlet connection on the cooler and leave from the outlet connection. A flow switch must be installed in the field piping at the outlet of the cooler (in horizontal piping) and wired back to the unit control panel using shielded cable. There should be a straight run of piping of at least five pipe diameters on either side of the flow switch. Paddle type flow switches can be obtained from COOLINE which are supplied as optional items. The chilled water pump(s) installed in the piping system should discharge directly into the unit cooler. The pump(s) may be controlled external to the unit - but an interlock must be wired to the unit control panel (as shown in the wiring diagram) so that the unit can start only upon proof of pump operation. 41

44 Flexible connections suitably selected for the fluid and pressure involved should be provided as mandatory in order to minimize transmission of vibrations to the piping / building as some movement of the unit can be expected during normal operation. The piping and fittings must be separately supported to prevent any loading on the cooler. The cooler must be protected by a strainer, preferably of 20 mesh, fitted as close as possible to the liquid inlet connection, and provided with a means of local isolation. Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler. Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if any variations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstream from any connection (flange etc.) but as near to the cooler as possible. Drain and air vent connections should be provided at all low and high points in the piping system to permit complete drainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for use in all lines to facilitate servicing. The system water piping must be flushed thoroughly before connecting to the unit cooler. The cooler must not be exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance to isolate the cooler without disrupting flow to other units. The following is a suggested piping arrangement at the chiller for single unit installations. For multiple chiller installations, each unit should be piped as shown: OUT IN Isolating Valve - Normally Open Isolating Valve - Normally Closed Pressure tapping Flow Switch Balancing Valve Connection (flanged / Victaulic) Flow meter Pipe work Strainer Flexible connection Note: For chillers with two coolers, the connecting pipes for entering and leaving water on one cooler must be joined to the corresponding pipes on the other cooler before connecting to the main headers in the system piping. 42

45 CHILLED FLUID VOLUME REQUIREMENT The volume of water in a piping system loop is critical to the smooth and proper operation of a chilled water system. If sufficient volume of water is not there in the system, the temperature control can be lost resulting in erratic system operation and excessive compressor cycling. Therefore, to prevent this effect of a Short Water Loop ensure that total volume of water in the piping system loop equals or exceeds 3 Gallons per Nominal Ton of cooling capacity for standard air conditioning applications and 6 Gallons per Nominal Ton of cooling capacity for process cooling jobs where accuracy is vital and applications requiring operation at very low ambient temperatures and low loading conditions. For example, chiller model ARQ100 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 system loop to increase the volume of water in the system and therefore, reduce the rate of change of return water temperature. This tank should be provided on the return water side to the chiller and the tank should be baffled to ensure that there is no stratification and the entering stream thoroughly mixes with the tank water. See recommended tank design schematics below: TANK SCHEMATIC SUGGESTIONS ON SYSTEM DESIGN AND PIPING PRACTICES The 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 one temperature 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 higher differences 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 and only experienced designers should entertain water temperature differences in excess of 12 0 F on chilled water systems. 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 the air 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 the heat-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 reduced loads and flows, they operate with laminar flow. 43

46 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 converting energy from the chillers to the air or water systems that are cooling the building. This is such a basic criterion that it should 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 designer s most important tasks 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.g., two streams connected to the run connections of a tee with the discharge on the branch of the tee). The friction for the piping should be calculated for all pipe runs, fittings and valves. Cooling coils should be selected with a high enough water velocity in the tubes to avoid laminar flow throughout the normal load range imposed on the coils. Coil control valves and their actuators should be sized to ensure that they can operate at all loads on the system without lifting the valve head off the valve seat. Expansion tank should be provided to so that water volume changes can be accommodated. Expansion tanks are generally connected to the suction side of the pump - lowest pressure point. Pumps in parallel must always operate at the same speed. There may be some exceptional cases where parallel pumps are operated at different speeds, but only experienced designers should make evaluations for such a proposed operation. Also, it is better to use pumps of the same size when operating them in parallel. Variable speed pumps should be controlled so that pumps operating in parallel never have more than one percent difference in actual operating speed. Mixing of constant and variable speed pumps in parallel operation is wrong and leads to disastrous results. Distribution pumps should be selected for maximum efficiency at the design condition and within the economic constraints of the project. Distribution pumps should be added and subtracted to avoid operation of pumps at points of high thrust and poor efficiency. Pump sequencing should achieve maximum possible system efficiency. Differential pressure control (bypass) valves should never be installed at the pump discharges. Check valves should be provided in pump discharges when pumps are operating in parallel. Pump discharge check valves should be center guided, spring loaded, disc type check valves and should be sized so that the check valve is full open at design flow rate. Generally this will require the check valve to be one pipe size smaller than the connecting piping. Circuiting Chilled water to Multiple Chillers : There are fundamentals for the circuiting of chillers that should not be violated in order to achieve maximum efficiency. Some of these are: a) Design the piping arrangement so that energy consumption of chillers is not increased. b) Arrange the piping so that all chillers receive the same return water temperature. c) Ensure that the required design water flow through the coolers is always maintained. 44

47 RIGGING INSTRUCTIONS ATTENTION TO RIGGERS Hook rigging sling thru holes in base rail, as shown below. Holes in base rail are centered around the unit center of gravity. Center of gravity is not unit center line. Ensure center of gravity aligns with the main lifting point before lifting. Use spreader bar when rigging, to prevent the slings from damaging the unit. CAUTION All panels should be in place when rigging. Care must be taken to avoid damage to the coils during handling. Insert packing material between coils & slings as necessary. MODELS: ARQ040A - ARQ180A MODELS: ARQ200A - ARQ290A MODELS: ARQ305A - ARQ380A 45

48 INSTALLATION CLEARANCE WALL MODEL NUMBER A B ARQ040A - ARQ050A ARQ060A - ARQ180A ARQ200A - ARQ380A FIGURE - 1 STRAIGHT WALL FIGURE - 2 CORNER WALL NOTES:1. All dimensions are in mm. 2. Pit installations are not recommended. Re-circulation of hot condenser air in combination with surface air turbulence can not be predicted, hot air re-circulation will severely affect unit efficiency (EER) and can cause high pressure or fan motor temperature trips. 46

49 MOUNTING LOCATION MODELS: ARQ040A - ARQ070A MODEL A B ARQ040A ARQ050A ARQ060A ARQ070A MODELS: ARQ080A - ARQ110A MODEL A ARQ080A 1662 ARQ090A 1662 ARQ100A 1922 ARQ110A 1922 MODELS: ARQ120A - ARQ180A MODEL A ARQ120A 1603 ARQ130A 1603 ARQ140A 1603 ARQ150A 1603 ARQ160A 1603 ARQ170A 2052 ARQ180A 2052 MODELS: ARQ200A - ARQ290A MODEL A ARQ200A 1850 ARQ210A 1850 ARQ220A 1850 ARQ240A 1850 ARQ260A 2060 ARQ275A 2060 ARQ290A 2060 MODELS: ARQ305A - ARQ340A MODELS: ARQ360A - ARQ380A NOTE: All dimensions are in mm. Tolerance: ±2mm. 47

50 LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL) MODEL No. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 ARQ040A ARQ050A ARQ060A ARQ070A ARQ080A ARQ090A ARQ100A ARQ110A ARQ120A ARQ130A ARQ140A ARQ150A ARQ160A ARQ170A ARQ180A ARQ200A ARQ210A ARQ220A ARQ240A ARQ260A ARQ275A ARQ290A ARQ305A ARQ325A ARQ340A ARQ360A ARQ370A ARQ380A R1 R2 R1 R3 R5 R3 R4 R6 48

51 LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL) MODEL No. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 ARQ040A ARQ050A ARQ060A ARQ070A ARQ080A ARQ090A ARQ100A ARQ110A ARQ120A ARQ130A ARQ140A ARQ150A ARQ160A ARQ170A ARQ180A ARQ200A ARQ210A ARQ220A ARQ240A ARQ260A ARQ275A ARQ290A ARQ305A ARQ325A ARQ340A ARQ360A ARQ370A ARQ380A R1 R2 R1 R3 R5 R3 R4 R6 49

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