Alzamil Water Cooled - Series

Company Business
Zamil Air Conditioners was founded in 1974 as one of the first air conditioning business to be established in Saudi Arabia
and today is a leading international manufacturer of air conditioning systems and is No. 1 in the Middle East.
Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55
countries in the Middle East, Europe, Africa and Asia.
The company’s operations are structured into four Strategic Business Units (SBUs) supporting five in-house product and
service brands as well as a number of international brands under the OEM sales.
The five in-house brands are Classic, Cooline, CoolCare, Clima Tech and Geoclima.
The four SBUs are:

1. Consumer Business Unit supporting Classic, Cooline, GE and OEM brands for consumers.
2. Unitary & Applied Business Unit supporting Classic, Cooline, GE and OEM brands for commercial and industrial
customers.
3. Zamil CoolCare providing engineering & project managemen t service s, HVA C maintenance , retrofit service s and parts.
4. Geoclima srl is an independent business supporting other SBUs for their requirement of Chillers & Double skin AHU’s.
The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare Service direct their business
operations from the corporate headquarters at Dammam, Saudi Arabia.
Geoclima has its engineering & production departments located at Monfalcone, Italy and has a design center in Austria.
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 maximizing customer satisfaction.
Factories and Productions

Zamil Air Conditioners has two manufacturing plants in Dammam, Saudi Arabia and has one speciality production facility
in Italy operated by Geoclima.
The company can produce up to 550,000 Room Air Conditioners, 300,000 Mini-Split systems and 50,000 Central Air
Conditioning systems per year.
Quality and 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. ZAC's products are also certified with:
1. CE (Council of European Community)
2. UL (Underwriters Laboratory)
3. DEMKO
4. ETL
Other awa rds include the prestigious E ngineering Exc ellence Award of G ene ral E lectric and the inaugural Pr ince 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, commercial and industrial air conditioners. This broad range extends from the Con-
cealed Units up to 5 tons, the Ducted Splits up to 30 tons, the Packaged Units up to 90 tons, the Single and Double Skin
Air Handling Units up to 70,630 CFM and the Water Chillers up to 660 tons cooling capacity.
INDEX
Contents Page
Model decoding ........................................................................................................................................ 2
Introduction ............................................................................................................................................... 3
Unit features, standard specifications & options .................................................................................... 4-7
Physical data ....................................................................................................................................... 8-10
Selection procedure .......................................................................................................................... 11-12
Ethylene glycol solution capacity correction ........................................................................................... 13
Performance data .............................................................................................................................. 14-19
Electrical data .................................................................................................................................... 20-21
Water side cooler pressure drop ............................................................................................................ 22
Water side condenser pressure drop ...................................................................................................... 23
Unit dimensions ................................................................................................................................ 24-26
Typical schematic wiring diagram ...................................................................................................... 27-28
Microprocessor controller ....................................................................................................................... 29
Application guidelines ........................................................................................................................ 30-38
Rigging instructions ................................................................................................................................ 39
Installation clearance .............................................................................................................................. 40
Mounting location ................................................................................................................................... 41
Load distribution ..................................................................................................................................... 42
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1
2
INTRODUCTION
Zamil water cooled screw chillers (ASW series) offer the optimum performance and highest efficiency possible for the
Gulfs harsh environment and abnormal operating conditions. The ASW series chillers were designed to provide central
cooling for commercial and industrial applications with the highest reliability and least operating cost combination by the
use of high efficiency dual screw compressors in combination with a water cooled condenser for every refrigeration
circuit.
Water cooled screw chillers offer the best cooling system solution for environments with high ambient temperatures and
high humidity by using water as a cooling medium for the condenser. Water extracts heat from the refrigerant in a much
better way than air, therefore it reliefs the compressor, hence lengthens the compressors life. Water cooled chillers also
have a larger capacity compared to air cooled chillers and are much smaller in size.
ASW series chillers are delivered in complete package, all the chiller components are installed on a rigid steel frame in a
compact design, making the chiller suitable for indoor installation inside service rooms with the least space requirement.
The compact design makes the chiller fit through standard doors with out the need of any disassembly, which makes the
chiller easy to handle and install.
ASW series chillers utilize the environmentally friendly R-134a refrigerant with the least minimum refrigerant pipe lengths
and connections to assure no refrigerant leak.
PRESS. TRANS. (LP)
PRESS. TRANS. (HP)
SCREW COMPRESSOR
WATER OUT
WATER COOLED CONDENSER
WATER IN
WATER IN WATER OUT
ELECTRONIC EXPANSION VALVE

DX EVAPORATOR
LIQUID SHUT-OFF VALVE
LIQUID SOLENOID VALVE LIQUID SIGHT GLASS LIQUID FILTER DRIER
Figure showing the ASW chiller components and its connections
3
FEATURES
These ASW water cooled screw chillers offer the ultimate combination of energy saving design, superior engineering
features and flexibility of application as required by todays market.
* These chillers incorporate the newest advanced microprocessor controller. This controller monitors analog and digital
inputs to achieve precise control & protective functions of the water cooled chiller units. This microprocessor control-
ler is complete with all the hardware and software necessary to control the chiller unit and insures its efficiency and
reliability.
* Designed to conform to ARI standard 550/590 water chilling packages using the vapor compression cycle.
* Designed to conform to ANSI/ASHRAE 15-1994 Safety code for Mechanical Refrigeration.

Compact unit design and excellent serviceability.
*
All packaged chillers incorporate compact water coolers and condensers with enhanced inner grooved copper tubes
*
bundled into a "U" shaped and expanded into a steel tubular sheet which offer efficient water flow as well as heat
transfer design resulting in optimal unit performance.
* High Energy Efficiency Ratio (EER) semi-hermetic compact twin screw compressors provided in these units.
* 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 and
safety controls.
Compressors are with part winding start.
*
STANDARD SPECIFICATIONS
CAPACITY CONTROL
A. Standard settings:
These chillers are equipped with stepless capacity control system as standard for very accurate response to load
requirements and best part load efficiency. Each compressor is equipped with a slider controller that enables to modulate
capacity between 25% to 100%, thus giving a broad range to control total chiller capacity between 10% to 100% on an
average. This system has following advantages:
1. Infinite capacity modulation allows the compressor capacity to exactly match the cooling load.
2. Reduce compressor cycling that leads to better operational reliability.
3. Reduce operating cost.
B. Optional settings:
The ASW packaged chillers incorporate stepped load shedding as required by some energy management systems.
Modulation of capacity in response to system load requirements is affected by a microprocessor controller which monitors
the leaving water temperature.
Capacity control is achieved by cycling compressor ON/OFF and slider capacity pre-set control valve. The use of slider
control valve provides excellent part load capacities.
On multiple compressor units, capacity is controlled by a combination of slider capacity control valve and compressor
staging.
SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORS

All compressors are compact semi-hermetic twin screw of the high capacity and efficiency due to its perfect profile form
ratio 5:6. Simple and robust construction with slider control valve for capacity unloading, suction/discharge shut-off valves,
check valve in discharge gas outlet, oil sight glass, oil fill/drain service valve, directly flanged-on three stage oil separator
with long-life fine filter 10 microns mesh size, robust axial bearings in tandem configuration, suction gas filter, internal
pressure relief valve and manual lock-out electronic protection system for thermal motor winding temperature, phase
reversal, discharge gas temperature protection controls.
4
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 which are reliable in operation at high ambient condi-
tions for a long period.
EVAPORATOR (COOLER)
Direct Expansion shell and tube evaporators are used in ASW series chillers to give high capacity, easy and quick
installation and enable for easy maintenance operations. The shell is made of rigid steel with large water inlet and outlet
to handle large water flow rate and capacity. The tubes are made of copper to provide the quickest response to load
fluctuation. The evaporators have a new design that ensures a high level of mechanical strength and resistance to
vibration, the design is made of U-shaped copper coils inside the shell, sufficient space is provided between the copper
coils and the shell to allow for expansion of the tubes. This design also allows for easy cleaning of the evaporator, were
the tubes can be removed easily. The evaporators are specially designed for R-134a applications. Their new design
requires a smaller refrigerant charge and results in a lower pressure drop.
SHELL & TUBE

WATER SIDE REFRIGERANT SIDE
HEAT
EXCHANGER DESIGN PRESSURE, TEST PRESSURE, DESIGN PRESSURE, TEST PRESSURE,
(COOLER) (BAR/PSIG) (BAR/PSIG) (BAR/PSIG) (BAR/PSIG)
STD 16/235 22.8/335 29/426 41.5/610
ASME (option) 10/147 11.3/165 15.5/228 23.3/342
CONDENSER
Every refrigeration circuit has a separate water cooled condenser. The condenser is a shell and tube type with a rigid
external structure made of steel and copper tubes and baffles in the inside to provide the best performance and response
to load fluctuation. The condenser can be connected to a cooling tower or to an air cooled liquid cooler. As the evaporator
shell and tube, the condenser shell and tube has a similar design with the same features. It should be noted that only
treated water is suitable for the water cooled condenser to prevent corrosion, scaling and biological fouling, which will
significantly affect the total system efficiency. It might be necessary to install a fixed continuous chemical treatment
system to control certain properties of the cooling water used. When using a cooling tower, a makeup water tank must be
used to supply the cooling water loop with make up water lost during cooling tower operation.
Please contact the nearest Zamil representative for more information on water properties for the condenser loop.
5
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.
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 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 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 and discharge temperatures
• 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 & temperature
• High discharge pressure & temperature
• Freeze protection
• Low oil pressure & high oil temperature
• Sensor error
• Time delay Anti recycle time for compressor
• Serial communication error
6
STANDARD CONTROL & SAFETY DEVICES
MICROPROCESSOR CONTROLLER: This controller monitors analog and digital inputs to achieve precise control &
safety functions of the unit.
COMPRESSOR IN-BUILT PROTECTION DEVICE: Protect the compressor by monitoring:
A) Motor winding temperature in case of overload.
B) Discharge gas temperature in case of overheating.
C) Phase reversal for direction of rotation.
STARTERS: The starter is operated by the control circuit and provides power to the compressor motors. These devices
are rated to handle safely both RLA and LRA of motors.
CRANKCASE HEATERS: Each compressor has immersion type crankcase heater. The compressor crankcase heater is always on when
the compressors are de-energized. This protect the system against refrigerant migration, oil dilution and potential compressor failure.
HIGH PRESSURE SWITCH: This switch provides an additional safety protection in the case of excessive discharge pressure.
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.
ELECTRONIC EXPANSION VALVE: Electronic expansion valve is used to regulate the refrigerant flow to the water
cooler and maintain a constant superheat and load optimization.
FILTER DRIER (REPLACEABLE CORE TYPE): Refrigerant circuits are kept free of harmful moisture, sludge, acids and
oil contaminating particles by the filter drier.
SIGHT GLASS: A moisture indicating sight glass installed in the liquid line. An easy-to-read color indicator shows mois-
ture contents and provides a mean for checking the system refrigerant charge.
LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from accumulating
in the water cooler during the off cycle.
UNDER VOLTAGE AND PHASE PROTECTION: Protects against low incoming voltage as well as single phasing, phase rever-
sal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it can be set up for manual
reset.
COMPRESSOR CIRCUIT BREAKERS: Protects against compressor branch circuit fault. When tripped (manually or
automatically), the breaker opens the power supply to the compressor and control circuit through auxiliary contacts.
OPTIONS
(All options are at extra cost. Please check with your nearest dealer/sales office)
HOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50%
of its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor
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 & condenser circuits. Interlock into unit
safety circuits so that the unit will remain off until water flow is determine.
UNIT MOUNT SPRING ISOLATORS: This 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 pressures gauges.
NON-FUSED MAIN DISCONNECT SWITCHES: De-energize power supply during servicing/repair works as well as with door interlock.
COMPRESSOR ENCLOSURE BOX: Reduce compressor operating noise and keep the compressor clean.
FLANGED COOLER CONNECTION: Easy on-site piping connections.
COOLER HEATER WRAPPED: Prevent freezing up of water on low ambient temperature.
CONDENSER: ASME code stamped water condenser.
CHILLER GUARD: Protect various parts of chiller from vandalism.
SEA WATER COOLED CONDENSER: To be used with sea water as a cooling fluid.
BMS: BACNET, MODBUS, GSM and remote monitoring.
POWER LINE ANALYZER: Perform motor current limitation. Protect against high motor current & over/under voltage.
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PHYSICAL DATA
UNIT SIZE ASW060B ASW070B ASW080B ASW095B ASW105B ASW115B ASW135B ASW150B ASW160B
COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 800-754-01 800-754-05 800-683-19 800-683-22 800-754-09 800-754-13 800-754-05 800-683-19 800-683-19
380V-3Ph-60Hz 800-754-02 800-754-06 800-683-20 800-683-23 800-754-10 800-754-14 800-754-06 800-683-20 800-683-20
460V-3Ph-60Hz 800-754-03 800-754-07 800-683-21 800-683-24 800-754-11 800-754-15 800-754-07 800-683-21 800-683-21
NUMBER OF COMPRESSORS 1 1 1 1 1 1 2 2 2
OIL CHARGE PER COMPRESSOR, Liters 15 15 22 22 19 19 15 22 22
CAPACITY CONTROL (STEPLESS) % 100-50 100-25
MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC
OIL LUBRICATION INJECTION
TOTAL CRANKCASE HEATER WATTS 200 200 300 300 300 300 200 300 300
REFRIGERANT R-134a
EXPANSION VALVE DEVICE ELECTRONIC EXPANSION VALVE
CONTROL VOLTAGE 220V-1Ph-60Hz
CONDENSER
PART NUMBER 800-895-01 800-895-02 800-895-02 800-895-03 800-895-04 800-895-05 800-895-01 800-895-02 800-895-02
NUMBER OF CONDENSERS 1 1 1 1 1 1 2 2 2
TOTAL WATER VOLUME PER CONDENSERS, Liters 28 33.2 33.2 38.3 41.8 51 28 33.2 33.2
WATER CONNECTION (DN) DN80 DN80 DN80 DN80 DN80 DN100 DN80 DN80 DN80
COOLER
PART NUMBER (QUANTITY) 800-896-01 (1) 800-896-02 (1) 800-896-02 (1) 800-896-04 (1) 800-896-06 (1) 800-896-06 (1) 800-896-08 (1) 800-896-08 (1) 800-896-09 (1)
TOTAL WATER HOLDING VOLUME, Liters 53 101 101 80.2 137 137 128 128 131
ECONOMIZER
PART NUMBER (QUANTITY) N.A. 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) 800-516-99 (1) N.A. N.A. 800-516-99 (2)
EXPANSION DEVICE PART NUMBER (QUANTITY) N.A. 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) 800-181-77 (1) N.A. N.A. 800-181-77 (2)
GENERAL
NUMBER OF REFRIGERANT CIRCUITS 1 1 1 1 1 1 2 2 2
REFRIGERANT CHARGE PER COMP., kg 30 35 40 47.5 52.5 57.5 33.75 37.5 40
SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 61.2/57.7/52.5 61.2/57.7/52.6 67/63.5/58.3 67/63.5/58.3 65.7/62.2/57 66.1/62.6/57.4 64.2/60.7/55.5 70/66.5/61.3 70/66.5/61.3
OPERATING/SHIPPING WEIGHTS, kg 1578/1525 1761/1660 2126/2025 2179/2090 2350/2213 2471/2334 3090/2962 3860/3732 3939/3808
NOTES: 1. All compressors with slider control valve unloading.

2. All compressors operate at 3500 RPM @ 60Hz.
3. Cooler vent and drain size are 1/2" MPT.
4. All coolers are single face refrigerant connection.
5. Sound pressure level : ±2dBA.
8
PHYSICAL DATA
UNIT SIZE ASW185B ASW210B ASW230B ASW245B ASW280B ASW300B ASW315B ASW345B ASW355B
COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 800-683-22 800-754-09 800-754-13 800-683-19 800-683-22 800-754-09 800-754-09 800-754-13 800-683-22
380V-3Ph-60Hz 800-683-23 800-754-10 800-754-14 800-683-20 800-683-23 800-754-10 800-754-10 800-754-14 800-683-23
460V-3Ph-60Hz 800-683-24 800-754-11 800-754-15 800-683-21 800-683-24 800-754-11 800-754-11 800-754-15 800-683-24
NUMBER OF COMPRESSORS 2 2 2 3 3 3 3 3 4
OIL CHARGE PER COMPRESSOR, Liters 22 19 19 22 22 19 19 19 22
CAPACITY CONTROL (STEPLESS) % 100-25 100-16 100-12
TOTAL CRANKCASE HEATER WATTS 300 300 300 300 300 300 300 300 300
REFRIGERANT R-134a
CONDENSER
PART NUMBER 800-895-03 800-895-04 800-895-05 800-895-02 800-895-03 800-895-04 800-895-04 800-895-05 800-895-03
NUMBER OF CONDENSERS 2 2 2 3 3 3 3 3 4
TOTAL WATER VOLUME PER CONDENSERS, Liters 38.3 41.8 51 33.2 38.3 41.8 41.8 51 38.3
COOLER
PART NUMBER (QUANTITY) 800-896-10 (1) 800-896-13 (1) 800-896-13 (1) 800-896-16 (1) 800-896-17 (1) 800-896-18 (1) 800-896-18 (1) 800-896-20 (1) 800-896-21 (1)
TOTAL WATER HOLDING VOLUME, Liters 263 229 229 285 325 353 353 401 401
ECONOMIZER
PART NUMBER (QUANTITY) 800-516-99 (2) 800-516-99 (2) 800-516-99 (2) 800-516-99 (3) 800-516-99 (3) N.A. 800-516-99 (3) 800-516-99 (3) N.A.
EXPANSION DEVICE PART NUMBER (QUANTITY) 800-181-77 (2) 800-181-77 (2) 800-181-77 (2) 800-181-77 (3) 800-181-77 (3) N.A. 800-181-77 (3) 800-181-77 (3) N.A.
GENERAL
NUMBER OF REFRIGERANT CIRCUITS 2 2 2 3 3 3 3 3 4
REFRIGERANT CHARGE PER COMP., kg 46.25 52.5 57.5 40.8 46.67 50 58.5 57.5 44.38
SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 70/66.5/61.3 68.7/65.2/60 69.1/65.6/60.4 71.8/68.3/63.1 71.8/68.3/63.1 70.5/67/61.8 70.5/67/61.8 70.9/67.4/62.2 73/69.5/64.3
OPERATING/SHIPPING WEIGHTS, kg 4290/4027 4361/4132 4601/4372 6029/5744 6242/5917 6472/6119 6479/6125 6952/6551 7922/7521

9
PHYSICAL DATA
UNIT SIZE ASW370B ASW395B ASW420B ASW445B ASW465B
COMPRESSOR
PART NUMBER 208/230V-3Ph-60Hz 800-683-22 800-754-09 800-754-09 800-754-13 800-754-13
380V-3Ph-60Hz 800-683-23 800-754-10 800-754-10 800-754-14 800-754-14
460V-3Ph-60Hz 800-683-24 800-754-11 800-754-11 800-754-15 800-754-15
NUMBER OF COMPRESSORS 4 4 4 4 4
OIL CHARGE PER COMPRESSOR, Liters 22 19 19 19 19
CAPACITY CONTROL (STEPLESS) % 100-12
TOTAL CRANKCASE HEATER WATTS 300 300 300 300 300
REFRIGERANT R-134a
CONDENSER
PART NUMBER 800-895-03 800-895-04 800-895-04 800-895-05 800-895-05
NUMBER OF CONDENSERS 4 4 4 4 4
TOTAL WATER VOLUME PER CONDENSERS, Liters 38.3 41.8 41.8 51 51
WATER CONNECTION (DN) DN80 DN80 DN80 DN100 DN100
COOLER
PART NUMBER (QUANTITY) 800-896-23 (1) 800-896-23 (1) 800-896-24 (1) 800-896-24 (1) 800-896-24 (1)
TOTAL WATER HOLDING VOLUME, Liters 487 487 574 574 574
WATER CONNECTION (DN) DN200 DN200 DN200 DN200 DN200
ECONOMIZER
PART NUMBER (QUANTITY) 800-516-99 (4) N.A. 800-516-99 (4) N.A. 800-516-99 (4)
EXPANSION DEVICE PART NUMBER (QUANTITY) 800-181-77 (4) N.A. 800-181-77 (4) N.A. 800-181-77 (4)
GENERAL
NUMBER OF REFRIGERANT CIRCUITS 4 4 4 4 4
REFRIGERANT CHARGE PER COMP., kg 46.25 49.4 52.5 55.6 58
SOUND PRESSURE LEVEL, dBA (3m./5m./10m.) 73/69.5/64.3 71.7/68.2/63 71.7/68.2/63 72.1/68.6/63.4 72.1/68.6/63.4
OPERATING/SHIPPING WEIGHTS, kg 8415/7928 8443/7956 8782/8208 9308/8734 9320/8746

10
SELECTION PROCEDURE (English units)
DESIGN REQUIREMENTS
The following design requirements must be known to select a package chiller.
1. Required cooling capacity in tons
2. Leaving chilled water temperature in 0F (LCHWT)
3. Chilled water flow rate in GPM
4. Chilled water cooling range in 0F (water in temp. _ water out temp.)
5. Design condenser leaving water temperature in 0F
6. Condenser water temperature range in 0F (water out temp. _ water in temp.)
7. Electrical power supply
EVAPORATOR FOULING CAPACITY POWER ARI
SAMPLE SELECTION 2 0
FACTOR (HR-FT - F/BTU)
CORRECTION INPUT STANDARDS
FACTOR FACTOR
Select a Water Packaged chiller for the following conditions: 0.00010 1.000 1.000 ARI-550/590-98
Required system capacity is 110 tons at 540F entering chilled water 0.00025 0.992 0.997 ARI-590-86
and 440F leaving water. Design condenser leaving water 0.00050 0.978 0.990 ARI-590-81
0.00075 0.965 0.984
temperature is 950F. Water cooler fouling factor is 0.00010. 0.00100 0.951 0.978
Power supply: 380V-3Ph-60Hz. TABLE - 1
STEP-1: UNIT SELECTION
Entering the capacity performance data at given LCHWT and ambient temperature.
ASW115B chiller unit will produce 113.89 tons and 94.3 kW compressor +0.6
power input at 440F leaving chilled water temperature & 950F condenser leaving
+0.4
water temperature with 100F water temperature difference.
+0.2
For the conditions required, the unit actual cooling capacity when corrected for
the fouling factor (1.0). 0
Capacity = 113.89 x 1.0 = 113.89 Tons, which then exceeds the requirements. -0.2
So the selection is correct.
-0.4
STEP-2: CHILLED WATER & CONDENSER WATER FLOW (GPM): 5 10 15 20
CHILLED WATER TEMPERATURE RISE (0F)
Required capacity (Tons) x 24 110 x 24 TABLE - 2

Water GPM = = = 264 GPM
0
Cooling Range, T 10 F
(Required capacity, Tons + total power input/3.516) x 24 (110 + 94.3/3.516) x 24
Total condenser GPM = = = 328 GPM.
Cooling Range, T 100F
Total condenser GPM 328
Water flow per condenser GPM = = = 328 GPM.
No. of condensers 1
Referring to pressure drop chart (page # 22 & 23), pressure drop for cooler at 264 GPM = 22 ft. of water for selected
model and pressure drop for condenser at 168 GPM = 12 ft. of water for selected model.
STEP-3: ELECTRICAL
Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ASW115B is to be sized at a minimum circuit ampacity (MCA)
of 206 Amps and the main branch protection device is to be sized at a maximum over current protection (MOCP) of 371 Amps.
STEP-4: CHILLED WATER & CONDENSER WATER PUMP SELECTION
For chilled water & condenser water pump selection, add all pressure drop in the closed chilled water loop piping to the
pressure drop calculated in step 2.
STEP-5: LCHWT CORRECTION
Refer to table-2: Add correction factor to design leaving chilled water temperature (LCHWT) when chilled water tempera-
ture range is above 100F and subtract correction from design leaving chilled water temperature (LCHWT) when water
temperature range is below 100F.
EXAMPLE:
If LCHWT rise is 12.50F, enter correction curve at 12.50F and read the correction factor of 0.2. The corrected LCHWT 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
SELECTION PROCEDURE (Metric units)
DESIGN REQUIREMENTS
The following design requirements must be known to select a package chiller.
1. Required cooling capacity in kilowatt (kW)
2. Leaving chilled water temperature in 0C (LCHWT)
3. Chilled water flow rate in LPS
4. Chilled water cooling range in 0C (water in temp. _ water out temp.)
5. Design condenser leaving water temperature in 0C
6. Condenser water temperature range in 0C (water out temp. _ water in temp.)
7. Electrical power supply
EVAPORATOR FOULING CAPACITY POWER ARI
SAMPLE SELECTION FACTOR (M2-0C/W)
CORRECTION INPUT STANDARDS
FACTOR FACTOR
Select a Water Packaged chiller for the following conditions: 0.000018 1.000 1.000 ARI-550/590-98
Required system capacity is 386 kW at 120C entering chilled water 0.000044 0.992 0.997 ARI-590-86
and 60C leaving water. Design condenser leaving water 0.000088 0.978 0.990 ARI-590-81
0.000132 0.965 0.984
temperature is 350C. Water cooler fouling factor is 0.0000176. 0.000176 0.951 0.978
Power supply: 380V-3Ph-60Hz. TABLE - 1
STEP-1: UNIT SELECTION
Entering the capacity performance data at given LCHWT and ambient temperature.
ASW115B chiller unit will produce 385.67 kW and 94.9 kW compressor +0.33
power input at 60C leaving chilled water temperature & 350C condenser leaving
+0.22
water temperature with 60C water temperature difference.
+0.11
For the conditions required, the unit actual cooling capacity when corrected for
the fouling factor (1.0). 0
Capacity = 385.67 x 1.0 = 385.67 kW, which is very close to the required capacity.
-0.11
So the selection is correct.
-0.22
STEP-2: CHILLED WATER & CONDENSER WATER FLOW (GPM): 4 5 6 7 8 9 10
CHILLED WATER TEMPERATURE RISE (0C)
Required capacity kW) x 0.239 386 x 0.239

Water LPS = = = 15.4 LPS TABLE - 2
Cooling Range, T 60C
(Required capacity, kW + total power input) x 0.239 (386 + 94.9) x 0.239
Total condenser LPS = = = 19.16 LPS.
Cooling Range, T 60C
Total condenser LPS 19.16
Water flow per condenser LPS = = = 19.16 LPS.
No. of condensers 1
Referring to pressure drop chart (page 22 & 23), pressure drop for cooler at 15.4 LPS = 65.77 kPa for selected model
and pressure drop for condenser at 19.16 LPS = 35.85 kPa for selected model.
STEP-3: ELECTRICAL
Refer to electrical data at 380V-3Ph-60Hz, the main power wire size for ASW115B is to be sized at a minimum circuit ampacity (MCA)
of 206 Amps and the main branch protection device is to be sized at a maximum over current protection (MOCP) of 371 Amps.
STEP-4: CHILLED WATER & CONDENSER WATER PUMP SELECTION
For chilled water & condenser water pump selection, add all pressure drop in the closed chilled water loop piping to the
pressure drop calculated in step 2.
STEP-5: LCHWT CORRECTION
Refer to table-2: Add correction factor to design leaving chilled water temperature (LCHWT) when chilled water tempera-
ture range is above 60C and subtract correction from design leaving chilled water temperature (LCHWT) when water
temperature range is below 60C.
EXAMPLE:
If LCHWT rise is 7.40C, enter correction curve at 7.40C and read the correction factor of 0.11. The corrected LCHWT is 60C+0.11 = 6.110C.
NOTE: 1. When the chilled water temperature rise is less than 30C, the high water flow rate will result to excessive
pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing.
2.Please refer to water pressure drop curves.
12
ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (Antifreeze)
When operating in areas with temperatures below 320F (00C), cooler protection in the form of Ethylene glycol solution
(brine solution) is required to protect cooler from low ambient freeze-up. This brine solution must be added to water loop to
bring down the freezing point with a difference of 150F (80C) below minimum operating ambient temperature.
Ethylene glycol solution causes a variation in unit performance. To obtain the effective performance, it is necessary to
multiply the water performance data by correction factors corresponding to the ambient temperature or Ethylene glycol
percentage indicated in the following table.
ETHYLENE GLYCOL % BY WEIGHT 0% 12% 22% 30% 36% 41% 46% 50%
Freezing point of Ethylene glycol solution 00C (320F) -50C (23 0F) -10 0C (14 0F) -150C (5 0F) -200C (-40F) -25 0C (-130F) -300C (-220F) -350C (-310F)
Ambient temperature 8.30C (47 0F) 3.30C (38 0F) -1.7 0C (29 0F) -6.70C (20 0F) -11.70C (11 0F) -16.70C (20F) -21.70C (-70F) -26.70C (-16 0F)
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
EXAMPLE: English system- Determine Ethylene glycol percentage by weight and correction factors at 380F ambient
temperature.
From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 380F 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: Metric system- Determine Ethylene glycol percentage by weight and correction factors where 3.30C ambient
temperature.
From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 3.30C 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) LCHWT.
13
14
15
16
17
18
19
ELECTRICAL DATA
SUPPLY VOLTAGE COMPRESSOR CRANKCASE HEATERS
UNIT COMPRESSOR
SIZE Nominal RLA LRA CB CB Total Total WINDING START
Min. Max. MCA MOCP Qty. Volts
(V-Ph-Hz) (each) (each) Poles MTA Qty. Watts Amps
208/230-3-60 187 253 191 343 1 152.6 732 3 122 2 230 200 0.87 PART WINDING
ASW060B 380-3-60 342 418 118 212 1 94.2 442 3 75 2 230 200 0.87 PART WINDING
460-3-60 414 506 95 172 1 76.3 350 3 61 2 230 200 0.87 PART WINDING
208/230-3-60 187 253 212 381 1 169.2 885 3 135 2 230 200 0.87 PART WINDING
460-3-60 414 506 106 190 1 84.6 423 3 68 2 230 200 0.87 PART WINDING
208/230-3-60 187 253 254 457 1 203.0 1224 3 162 2 230 300 1.30 PART WINDING
460-3-60 414 506 127 228 1 101.4 612 3 81 2 230 300 1.30 PART WINDING
208/230-3-60 187 253 284 511 1 227.0 1330 3 182 2 230 300 1.30 PART WINDING
460-3-60 414 506 142 256 1 113.6 665 3 91 2 230 300 1.30 PART WINDING
208/230-3-60 187 253 306 551 1 245 1224 3 196 2 230 300 1.30 PART WINDING
460-3-60 414 506 153 276 1 122.7 612 3 98 2 230 300 1.30 PART WINDING
208/230-3-60 187 253 341 614 1 273 1330 3 218 2 230 300 1.30 PART WINDING
ASW115B 380-3-60 342 418 206 371 1 165 807 3 132 2 230 300 1.30 PART WINDING
460-3-60 414 506 170 307 1 136.3 665 3 109 2 230 300 1.30 PART WINDING
208/230-3-60 187 253 369 533 2 164.1 885 3 131 4 230 400 1.74 PART WINDING
460-3-60 414 506 185 267 2 82.1 423 3 66 4 230 400 1.74 PART WINDING
208/230-3-60 187 253 435 628 2 193.2 1224 3 155 4 230 600 2.61 PART WINDING
460-3-60 414 506 217 314 2 96.6 612 3 77 4 230 600 2.61 PART WINDING
208/230-3-60 187 253 457 660 2 203.0 1224 3 162 4 230 600 2.61 PART WINDING
460-3-60 414 506 228 330 2 101.4 612 3 81 4 230 600 2.61 PART WINDING
208/230-3-60 187 253 511 738 2 227.0 1,330 3 182 4 230 600 2.61 PART WINDING
460-3-60 414 506 256 369 2 113.6 665 3 91 4 230 600 2.61 PART WINDING
208/230-3-60 187 253 551 796 2 245.0 1224 3 196 4 230 600 2.61 PART WINDING
460-3-60 414 506 276 399 2 122.7 612 3 98 4 230 600 2.61 PART WINDING
208/230-3-60 187 253 614 887 2 273.0 1330 3 218 4 230 600 2.61 PART WINDING
460-3-60 414 506 307 443 2 136.3 665 3 109 4 230 600 2.61 PART WINDING
LEGEND:
MCA - Minimum Circuit Ampacity per NEC 430-24
MOCP - Maximum Over Current Protection
RLA - Rated Load Amps
LRA - Locked Rotor Amps
CB - Circuit Breaker
MTA - Must Trip Amps
FLA - Full Load Amps
FCA - Fan Circuit Amps
kW - Kilo Watt
NOTES:
1. Customer to specify the exact nominal power supply available at site so that electrical components are selected accurately; failing to do so will affect unit performance &
terms of warranty.
2. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker.
3. The maximum incoming wire size is 500 MCM. On units having MCA greater than 500 MCM wire, the factory supplied power terminal block will accept two or more parallel
field wires per pole phase.
4. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection.
5. All field wiring must be in accordance with NEC and local standards.
6. Minimum and maximum unit supply voltages are shown in the tabulated data above.
7. The ±10% voltage variation from the nominal is allowed for a short time only, not permanent.
8. Neutral line required on 380V-3Ph-60Hz power supply only.
20
ELECTRICAL DATA
SUPPLY VOLTAGE COMPRESSOR CRANKCASE HEATERS
UNIT COMPRESSOR
SIZE Nominal RLA LRA CB CB Total Total WINDING START
Min. Max. MCA MOCP Qty. Volts
(V-Ph-Hz) (each) (each) Poles MTA Qty. Watts Amps
208/230-3-60 187 253 660 863 3 203.0 1224 3 162 6 230 900 3.91 PART WINDING
460-3-60 414 506 330 431 3 101.4 612 3 81 6 230 900 3.91 PART WINDING
208/230-3-60 187 253 738 965 3 227.0 1330 3 182 6 230 900 3.91 PART WINDING
460-3-60 414 506 369 483 3 113.6 665 3 91 6 230 900 3.91 PART WINDING
208/230-3-60 187 253 761 995 3 234.0 1224 3 187 6 230 900 3.91 PART WINDING
460-3-60 414 506 381 498 3 117.2 612 3 94 6 230 900 3.91 PART WINDING
208/230-3-60 187 253 796 1041 3 245.0 1224 3 196 6 230 900 3.91 PART WINDING
460-3-60 414 506 399 521 3 122.7 612 3 98 6 230 900 3.91 PART WINDING
208/230-3-60 187 253 887 1160 3 273.0 1330 3 218 6 230 900 3.91 PART WINDING
460-3-60 414 506 444 580 3 136.5 665 3 109 6 230 900 3.91 PART WINDING
208/230-3-60 187 253 935 1155 4 220.0 1330 3 176 8 230 1200 5.22 PART WINDING
460-3-60 414 506 468 578 4 110.1 665 3 88 8 230 1200 5.22 PART WINDING
208/230-3-60 187 253 965 1192 4 227.0 1330 3 182 8 230 1200 5.22 PART WINDING
460-3-60 414 506 483 596 4 113.6 665 3 91 8 230 1200 5.22 PART WINDING
208/230-3-60 187 253 995 1229 4 234.0 1224 3 187 8 230 1200 5.22 PART WINDING
460-3-60 414 506 498 615 4 117.2 612 3 94 8 230 1200 5.22 PART WINDING
208/230-3-60 187 253 1041 1286 4 245.0 1224 3 196 8 230 1200 5.22 PART WINDING
460-3-60 414 506 521 644 4 122.7 612 3 98 8 230 1200 5.22 PART WINDING
208/230-3-60 187 253 1126 1391 4 265.0 1330 3 212 8 230 1200 5.22 PART WINDING
460-3-60 414 506 563 696 4 132.5 665 3 106 8 230 1200 5.22 PART WINDING
208/230-3-60 187 253 1160 1433 4 273.0 1330 3 218 8 230 1200 5.22 PART WINDING
460-3-60 414 506 579 716 4 136.3 665 3 109 8 230 1200 5.22 PART WINDING
LEGEND:
MCA - Minimum Circuit Ampacity per NEC 430-24
MOCP - Maximum Over Current Protection
RLA - Rated Load Amps
LRA - Locked Rotor Amps
CB - Circuit Breaker
MTA - Must Trip Amps
FLA - Full Load Amps
FCA - Fan Circuit Amps
kW - Kilo Watt
NOTES:
1. Customer to specify the exact nominal power supply available at site so that electrical components are selected accurately; failing to do so will affect unit performance &
terms of warranty.
2. Main power must be supplied from a single field supplied and mounted fused disconnects, using dual element time delay fuse or circuit breaker.
3. The maximum incoming wire size is 500 MCM. On units having MCA greater than 500 MCM wire, the factory supplied power terminal block will accept two or more parallel
field wires per pole phase.
4. The compressor crankcase heaters must be energized for 12 hours before the unit is initially started or after a prolonged power disconnection.
5. All field wiring must be in accordance with NEC and local standards.
6. Minimum and maximum unit supply voltages are shown in the tabulated data above.
7. The ±10% voltage variation from the nominal is allowed for a short time only, not permanent.
8. Neutral line required on 380V-3Ph-60Hz power supply only.
21
WATER SIDE COOLER PRESSURE DROP
2 7
12
10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 1200 1500
FLOW RATE - GPM
MODEL No. CURVE No. MODEL No. CURVE No.

ASW060 1 ASW245 9
ASW070 & 080 2 ASW280 10
ASW095 3 ASW300 & 315 11
ASW105 & 115 4 ASW345 12
ASW135 & 150 5 ASW355 13
ASW160 6 ASW370 & 395 14
ASW185 7 ASW420, 445 & 465 15
ASW210 & 230 8
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
WATER SIDE CONDENSER PRESSURE DROP
2
10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 1200 1500
FLOW RATE - GPM
MODEL No. CURVE No.

ASW060 & 135 1
ASW070, 080, 150, 160 & 245 2
ASW095, 185, 280, 355 & 370 3
ASW105, 210, 300, 315, 395 & 420 4
ASW115, 230, 345, 445 & 465 5
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.
23
DIMENSIONS
ASW060B
ASW070B, ASW080B, ASW095B, ASW105B & ASW115B
DIMENSIONS
MODEL A B D D1
ASW070B, 080B & 095B 2230 377 4" 3-1/8"
ASW105B 2150 410 5" 3-1/8"
ASW115B 2150 410 5" 4"
NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED.
24
24
DIMENSIONS
ASW135B, ASW150B, ASW160B, ASW185B, ASW210B & ASW230B
DIMENSIONS
MODEL A B D D1
ASW135B & 150B 2150 417 5" 3-1/8"
ASW160B 2400 417 5" 3-1/8"
ASW185B & 210B 2600 457 6" 3-1/8"
ASW230B 2600 457 6" 4"
ASW245B, ASW280B, ASW300B, ASW315B & ASW345B

DIMENSIONS
MODEL A B D1
ASW245B 2400 483 3-1/8"
ASW280B 2800 483 3-1/8"
ASW300B & 315B 2400 508 3-1/8"
ASW345B 2800 508 4"
NOTE: ALL DIMENSIONS ARE IN MILLIMETERS, UNLESS OTHERWISE SPECIFIED.
25
26
TYPICAL SCHEMATIC WIRING DIAGRAM
CONTROL PANEL
NTB
TO HVTB TO NTB
L1 N
ATB ATB
1B F1 3.5A CONTROL VOLTAGE 2
230VAC
SEE
CCA1-1 3A 1HTR ALSO
COMP1 OILHTR COMP
CCA2-1 3B 2HTR UNLOADER
COMP2 OILHTR TIMER
DETAILS
T1 SSPS1 T2 COMP1 SSPS
CCA3-1 1J D1
T1 SSPS2 T2
COMP2 SSPS
CCA4-1 1K D1
S1( CONTROL POWER)
SERIAL CABLE
1A UVR 1
(SEE UVM CONNECTION)
SSPS1
8A
CB1A-1 22A CB3A-1 23A
JP2A EEV X9 EEVB JUMPER & DIP SWITCH
2A
HPS1 OLR1-1 OLR3-1 TD1 CLOSED
10A 11A 5A TU1 CLOSED
TL1 OPEN
SSPS2 JU1 OPEN
8B
CB2A-1 22B CB4A-1 23B
JP3A
2B
HPS2 10B OLR2-1 11B OLR4-1 9B
5B
FLS1 10 CWP* 11
1 2G
1 2H
12A CC1
COMP1 CONTACTOR
LLS1
LIQUID LINE SOLENOID1
ECONOMIZER SOLENOID 1
14A UL2-1
POWER DECREASE CP1
12B CC2 COMP2 CONTACTOR
LLS2
LIQUID LINE SOLENOID2
ECONOMIZER SOLENOID 2
14B UL2-2
POWER DECREASE CP2
HGBS/UNIT STATUS/COOLER HTR
6A ALARM - NO CONTACT
16 ALARM - NC CONTACT
POWER LINE ANALYZER

INTERFACE
(SEE OPTION BOX)
L.I1
COM3 20A
LIQUID INJECTION 1
C
REMOTE MONITORING
INTERFACE
(SEE OPTION BOX) L.I2
COM2 20B
LIQUID INJECTION 2
17C 15A UL4-1
POWER INCREASE CP1
15B UL4-2
POWER INCREASE CP2
22A 28A
T1S 23A 29A
SUCTION TEMP SPT1 - COMP1
SENSOR COMP1 SUCTION PRESSURE
TRANSDUCER
24A 30A
T2S 25A 31A
TOUT/LWT DPT1 - COMP1
TEMP. SENSOR DISCHARGE PRESSURE JUMPER SETUP
22B TRANSDUCER ON MAIN BOARD
T3S 23B TL2 OPEN
SUCTION TEMP TD2 CLOSED
SENSOR COMP2 TU2 CLOSED
JU11 1-2 CLOSED
26A 28B
JU13 1-2 CLOSED
T4S 27A JU15 1-2 CLOSED
29B
TIN/RWT SPT2 - COMP2 JU5 1-2 CLOSED
TEMP. SENSOR SUCTION PRESSURE JU6 1-2 CLOSED
TRANSDUCER
JU7 1-2 CLOSED
30B
JU8 1-2 CLOSED
31B JU9 1-2 CLOSED
DPT2 - COMP2 JU4 1-2 CLOSED
DISCHARGE PRESSURE
TRANSDUCER JU3 1-2 CLOSED
JU19 1-2 CLOSED
JU12 1-2 CLOSED
JU10 1-2 CLOSED
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
27
TYPICAL SCHEMATIC WIRING DIAGRAM
LEGEND
AR AUXILIARY RELAY
NAME OPEN CLOSE ATB AUXILIARY TERMINAL BLOCK
1. L.V.WATER LWT° F CB CIRCUIT BREAKER
CBA MAGNETIC CIRCUIT BREAKER AUXILIARY CONTACT
3. PUMP DOWN 0 PSIG COM COMMUNICATION
4. LOW PRESSURE 15 PSIG COMP COMPRESSOR
CC COMPRESSOR CONTACTOR
5. HIGH PRESSURE 270 PSIG CCA COMPRESSOR CONTACTOR AUXILIARY
CWP CHILLED WATER PUMP
6. FREEZE 39° F
CCH CRANKCASE HEATER
CCAT TIMER AUXILIARY CONTACT
CT CURRENT TRANSFORMER
MODEL OLR SETTING
ECO ECONOMIZER SOLENOID VALVE
EEVB ELECTRONIC EXPANSION VALVE BOARD
EFR EARTH FAULT RELAY
ETB EARTH TERMINAL BLOCK
NAME CLOSE OPEN 1 FLS FLOW SWITCH
ATB FM FAN MOTOR
2
HPS (ADJUSTABLE) 270 PSIG 300 PSIG FMC FAN MOTOR CONTACTOR
ATB
F FUSE
L1 G GROUND
NOTE: GFP GROUND FAULT PROTECTION
L2 TERMINAL A,B,& C COMP HPS HIGH PRESSURE SWITCH
L3 ON UVM TO PHASE
1A UVR 1 MATCHED WITH UNIT HGBS HOT GAS BYPASS SOLENOID
CONTROLS. 70A/B HVTB HIGH VOLTAGE TERMINAL BLOCK
UVM 1 2
71A/B JP JUMPER
LI LIQUID INJECTION
GFP SET POINT LPS LOW PRESSURE SWITCH
5 AMPS @1.0 SEC T1T2 A1 A2
LWT LEAVING WATER TEMPERATURE
COMPRESSOR 1 EARTH FAULT RELAY
Current Transformer (CT) MB MASTER BOARD
32 31 34
1O(MB) wire number, 70A/71A for NTB NEUTRAL TERMINAL BLOCK
12A CC1
Comp 1 and 70B/71B for OLR OVER LOAD RELAY
2
Comp 2. PT PRESSURE TRANSDUCER
32 31
FOR TDS OPTION SEE CONN.BELOW 1 65A P PROPORTIONAL BAND
CC3 Comp 1 A3/D3 (MB) REMOVE JP2A PSIG POUNDS PER SQUARE INCH
CC1A-2 61A EFR1
1 2 PWS PART WINDING START
32 31 R CONTROLLER BUILT-IN RELAY
CC1A-2 TDS1-1SEC CC3 1 65B
1 61A 62A 2 Comp 2 A8/D8 (MB) REMOVE JP3A SLE EQUALIZER SOLENOID VALVE
EFR2 S1 CONTROL SWITCH
COMPRESSOR 2 SEC SECOND (TIME)
TRANS TRANSFORMER
4O(MB) 12B CC2
VFC FROM CUSTOMER PANEL TS PTC SENSOR/TEMPERATURE SENSOR
2 USE N/O
1 VFC 2G CONTACT TO
TDS TIME DELAY SWITCH
FOR TDS OPTION SEE CONN.BELOW ATB ATB RUN THE UNIT. VFC VOLT FREE CONTACT
CC4 UL UNLOADER SOLENOID
CC2A-2
1 61B 2 UVM UNDER VOLTAGE MONITOR
UVR UNDER VOLTAGE RELAY
CC2A-2 TDS2-1SEC CC4
61B 62B TERMINAL BLOCK
1 2 MB SET THE
----- FIELD WIRING
100B 7C R7 7O 101B CONTROLLER SEE ALSO
PARAMETER NOTE#7 * FIELD SUPPLY
# M171 = 4 LEGEND ON MASTER/SLAVE BOARD
A../D.. DIGITAL INPUT 1
C/1C COMMON
1O DIGITAL OUT 1
AC/DC DIGITAL COMMON
MB R.. SOLID STATE RELAY CONTACTS
1 7C R7 7O HGBS 2
15 SEE ALSO T1 THERMISTOR 1
NOTE#7 SH SHIELD
TIMER 11 X52/X53 SERIAL COMMUNICATION PORT
CCAT11-1 AR11 ATB EXEN EXTERNAL ENABLE
3A 4AA
2 JU/TU/TD/TL BOARD JUMPERS
AR11 3AA UL3-1
UL3-1 SEE ALSO
TIMER 21 MB NOTES
CCAT21-1 AR21 HEATER NOTE#7
4BB 1 7C R7 7O 15 2
3B 1. FUSES TO BE DUAL ELEMENT TYPE.
AR21 3BB UL3-2
UL3-2
SET POINT: 2. USE COPPER CONDUCTORS ONLY.
36 deg F
3. ALL FIELD WIRING TO COMPLY WITH LOCAL CODES.
4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER
TO BE PROVIDED BY END USER WITH RATING AS
EXTERNAL DEVICE HEATER RECOMMENDED BY MANUFACTURER.
HTR1 2
t 5. POW ER MUST BE SUPPLIED TO CRANKCASE
1B HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SET POINT = 36 degF SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
HEATER MUST BE ON FOR 12 HOURS BEFORE
GND OPERATING THE SYSTEM.
13A ECO1 -
TO MB (20) 2 ECONOMIZER 1 + FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
IS485 TO MAIN
13B ECO2 TO BOARD (COM2) RESULT IN COMPRESSOR DAMAGE.
TO MB (50) 2 ECONOMIZER 2 GATEWAY 6. FOR OIL LEVEL FAULT, PLEASE ALSO CONSIDER
THE GFP (GR OUND FAULT PROTEC TION) IF
AVAILABLE.
7. THE AUXILIARY RELAY 7O/7C AT MB CAN USE
ONLY ONE FU NCTION AT A TIME FROM THE
FOLLOWING OPTION: HGBP, COOLER HEATER &
UNIT STATUS.
8. MARK IN THE BOX FOUND AT THE UPPER RIGHT OF
THE RESPECTIVE OPTIONAL ITEM, IF THE OPTIONAL
ITEM IS INCLUDED IN THE UNIT.
28
MICROPROCESSOR CONTROLLER
Sequence of Operation
The following describes the sequence of operation for a two screw compressor chiller unit.
Operation is similar for a one or four compressor unit.
For initial start-up, the following conditions must be met:
· All power supplied to the unit shall be energized for 12 hours.
· Control power switch on for at least 5 minutes.
· All safety conditions satisfied.
· Press ESC on the microcomputer keypad.
· Chilled water pump running and chilled water flow switch contact closed.
· Customer interlock contact closed, if any.
· Condenser water pump running and condenser water flow switch contact closed.
STAGE - ON SEQUENCE
Staging ON & OFF sequence, shall be accomplished by the Leaving water temperature control selection.
Stage #1:
If the Leaving Water Temperature is greater than the Stage 1- ON water temperature set point value, the Compressor #1
liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloaded
capacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.
Stage #2:
If the Leaving Water Temperature is greater than the Stage 2- ON water temperature set point value, the Compressor #2
liquid line solenoid & slider control valves shall be switched ON. Now the compressor is in the minimum or unloaded
capacity. The compressor capacity is varied to achieve the full/part load capacity as per the load demand.
STAGE - OFF SEQUENCE

During the staging OFF, the first-in last-out sequence is adopted, if equalization of compressor timing is not selected.
Else the more used is switched off.
As the applied load decreases and when the leaving water temperature falls below the stage 2 -OFF water temperature
set point value, stage 2 is turned off.
If the leaving water temperature falls below the stage 1-OFF water temperature set point value, the stage 1 is turned off.
29
APPLICATION GUIDELINES
INTRODUCTION
These guidelines should be considered when designing systems and their installation utilizing Zamil ASW series liquid
chillers. Stable operation, performance and reliability of units is often dependent upon proper compliance with these
recommendations. When any application varies from these guidelines, it should be referred with Zamil Air Conditioners
for specific recommendations.
UNIT SELECTION/SIZING
Unit selection procedure and capacities are provided in this catalog for proper selection. The Zamil electronic selection
program may also be utilized for this purpose.
Over sizing chillers beyond a maximum limit of 5 10 % in order to assure adequate capacity or considering future
expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operation
and excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operate
more efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized
unit is usually more costly to purchase, install and operate.
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 WATER REQUIREMENT

The tabulated performance data provided in this catalog are based on a fouling factor of 0.00010 hr-ft2-0F/Btu (0.000018 m2-0C/W)
for the cooler and 0.000244 hr-ft2-0F/Btu (0.004392 m2-0C/W) for the condenser. As the 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. Zamil recommends that a water treatment specialist is consulted to provide and maintain
water treatment, this is particularly critical with glycol systems.
WATER FLOW RATES AND COOLER PRESSURE DROP

The maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog.
The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminar flow
causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessive
pressure drop and severe tube erosion.
During unit operation, water flow rate must not vary more than ± 5% from the design flow rate. The water flow switch
should be calibrated accordingly. 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 Zamil Air Conditioners for specific
recommendations.
30
COOLER/CONDENSER FLUID TEMPERATURES RANGE
Unit can start and pull down from 950F (350C) entering fluid temperature. The design leaving chilled fluid temperature
(LCHWT) range as mentioned earlier in the tabulated performance data is 40 to 500F. The design entering chilled fluid
temperature range is 50 to 600F. The design cooler temperature drop ( T) range is 5 to 150F.
The tabulated performance data provided in this catalog is based on a chilled water temperature drop and a condenser
water temperature rise of 100F. Units may be operated at any desired temperature drop within the range of 5 to 150F as
long as the temperature and flow limits are not violated and appropriate correction factors are applied on the capacity and
power input. The Zamil electronic selection program can be very handy in selecting equipment at different temperature
drops.
It should be noted that temperature drop/rise 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 detri-
mental for the equipment.
FLOW RATES AND/OR WATER 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 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).
45°F 45°F
500 GPM 240 GPM
200 TR CHILLER
Chiller 45°F Load

260 GPM 200 TR
54.6°F
500 GPM
65°F
240 GPM
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).
45°F 45°F 65°F

340 GPM 82.2 GPM 192 GPM
120 TR CHILLER
Chiller 80°F Load

45°F
257.8 GPM 109.8 GPM 120 TR
53.4°F
340 GPM
53.4°F 80°F 80°F

340 GPM 82.2 GPM 192 GPM
31
COOLER FREEZE PROTECTION
If the unit is located in an area where ambient temperatures fall below 320F (00C), cooler protection in the form of Ethylene
Glycol Solution is required to protect the cooler and fluid piping from low ambient freeze-up. This glycol solution must be
added to the water system loop to bring down the freezing point of water to a difference of 150F (8.30C) below minimum
operating ambient temperature.
Using this glycol solution causes a variation in unit performance, flow rate and pressure drop, therefore appropriate
correction factors from the aforementioned table in this catalog should be applied.
MULTIPLE CHILLER ARRANGEMENT OR PLANT CONFIGURATION

A multiple chiller system has two or more chillers connected by parallel or series piping to a common distribution system.
Multiple chiller arrangements offer the advantage of operational flexibility, standby capacity and less disruptive 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 capac-
ity for better part load operation.
In designing a multiple chiller plant, units of same size should be preferred over different sizes to facilitate balanced water
flow. It is mandatory that cooler flow rates must be balanced to ensure proper flow to each chiller based on its respective
capacity. As mentioned above, two basic multiple chiller systems are used: parallel and series chilled water flow.
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 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:
32
A. Single or multiple chillers with constant water flow through chillers and load system:
CHWS
CHILLER Load Load
3-Way 3-Way
Valve 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 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.
33
B. Single or multiple chillers with constant water flow through chillers and variable water flow through load system:
FM-1
CHWS
Bypass
Line
CHILLER CHILLER CHILLER

Bypass Load Load
Control
Valve
P
2-Way 2-Way
Valve 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 ( 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 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 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 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.
34
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 CHILLER CHILLER Load Load
Flow Sensor
P
2-Way 2-Way
Valve 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 ( P) 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.
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 either side of the flow switch.
• 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.
• 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.
35
• The cooler must be protected by a strainer, preferably of 20 mesh, fitted as close as possible to the liquid inlet connec-
tion, and provided with a means of local isolation.
• Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler.
Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if any
variations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop
across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstream
from any connection (flange etc.) but as near to the cooler as possible.
• Drain and air vent connections should be provided at all low and high points in the piping system to permit complete
drainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for use
in all lines to facilitate servicing.
• The system water piping must be flushed thoroughly before connecting to the unit cooler. The cooler must not be
exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and
valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance to
isolate the cooler without disrupting flow to other units.
CONDENSER PIPING CONNECTION

The same points should be followed for the condenser piping as the cooler piping, plus the following:
• A make-up water tank should be provided in the condenser loop to supply make-up water to the condenser when using
an open type cooling tower.
• A water treatment and cleaning system should be connected to the condenser loop to treat and clean the water when
using an open type cooling tower.
The following is a suggested water piping arrangement for the condenser and the cooler at the chiller for single unit
installations. For multiple chiller installations, each unit should be piped as shown:
OUT
IN
Isolating Valve - Normally Open Pressure tapping
Isolating Valve - Normally Closed Flow Switch
Balancing Valve Connection (flanged / Victaulic)
Flow meter Pipe work
Strainer Flexible connection
36
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 ASW105B operating with a design water flow rate of 239 GPM for a standard air conditioning
application would require 102.8 (Nom. Cap.) x 3 = 308.4 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 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 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.
37
• 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 designers 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 oper-
ating 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 con-
straints 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.
38
RIGGING INSTRUCTIONS
ATTENTION TO RIGGERS
Hook rigging sling thru holes on the lifting plates, as shown below.
Lifting plates or holes in base rail are centered around the unit center of gravity.
Center of gravity is not unit center line.
Ensure center of gravity aligns with the main lifting point before lifting.
Use spreader bar when rigging, to prevent the slings from damaging the unit.
CAUTION
All panels should be in place when rigging.
Care must be taken to avoid damage to the coils during handling.
Insert packing material between coils & slings as necessary.
MODELS: ASW060B - ASW115B

LIFT
LIFT
SPREADER BAR
PROPER CLEARANCE
TO BE PROVIDED
LIFT
LIFT
SPREADER BAR
PROPER CLEARANCE
TO BE PROVIDED
39
INSTALLATION CLEARANCE
WALL
FIGURE - 1
STRAIGHT WALL
FIGURE - 2
CORNER WALL
NOTE: All dimensions are in mm.
40
MOUNTING LOCATION
MODEL: ASW060B
NOTE: All dimensions are in mm. Tolerance: ±2mm.
41
LOAD DISTRIBUTION, kg
MODEL No. R1 R2 R3 R4 R5 R6
ASW060 299 283 275 253 238 230
ASW070 323 308 300 290 274 266
ASW080 404 389 381 330 315 307
ASW095 414 398 390 339 323 315
ASW105 433 417 409 377 361 353
ASW115 454 438 430 396 380 373
ASW135 582 551 535 500 469 453
ASW150 751 719 704 588 557 541
ASW160 760 729 713 605 574 558
ASW185 806 774 758 677 645 630
ASW210 814 783 767 692 660 645
ASW230 856 824 809 730 699 683
ASW245 1133 1094 1074 942 903 883
ASW280 1166 1127 1107 980 941 921
ASW300 1192 1152 1133 1031 992 972
ASW315 1193 1154 1134 1032 993 973
ASW345 1269 1229 1210 1114 1075 1055
ASW355 1490 1443 1420 1229 1182 1158
ASW370 1546 1499 1475 1338 1290 1267
ASW395 1549 1502 1478 1344 1297 1273
ASW420 1588 1541 1517 1418 1371 1347
ASW445 1679 1632 1608 1502 1455 1432
ASW465 1682 1634 1611 1504 1456 1433
MODELS: ASW060B - ASW115B MODELS: ASW135B - ASW465B
42

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The four SBUs are:

Factories and Productions

Quality and Product Certificates

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

Unit features, standard specifications & options .................................................................................... 4-7

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

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

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

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

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

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

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

Unit dimensions ................................................................................................................................ 24-26

Typical schematic wiring diagram ...................................................................................................... 27-28

Microprocessor controller ....................................................................................................................... 29

Application guidelines ........................................................................................................................ 30-38

Rigging instructions ................................................................................................................................ 39

Installation clearance .............................................................................................................................. 40

Mounting location ................................................................................................................................... 41

Load distribution ..................................................................................................................................... 42

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

PRESS. TRANS. (LP)

PRESS. TRANS. (HP)

WATER IN WATER OUT

ELECTRONIC EXPANSION VALVE

LIQUID SHUT-OFF VALVE

LIQUID SOLENOID VALVE LIQUID SIGHT GLASS LIQUID FILTER DRIER

Figure showing the ASW chiller components and its connections

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

SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORS

SHELL & TUBE

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

Easily accessible measurements for each circuit include the following:

OIL CHARGE PER COMPRESSOR, Liters 15 15 22 22 19 19 15 22 22

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

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION INJECTION

EXPANSION VALVE DEVICE ELECTRONIC EXPANSION VALVE

CONTROL VOLTAGE 220V-1Ph-60Hz

REFRIGERANT CHARGE PER COMP., kg 30 35 40 47.5 52.5 57.5 33.75 37.5 40

NOTES: 1. All compressors with slider control valve unloading.

OIL CHARGE PER COMPRESSOR, Liters 22 19 19 22 22 19 19 19 22

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

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION INJECTION

EXPANSION VALVE DEVICE ELECTRONIC EXPANSION VALVE

CONTROL VOLTAGE 220V-1Ph-60Hz

NOTES: 1. All compressors with slider control valve unloading.

380V-3Ph-60Hz 800-683-23 800-754-10 800-754-10 800-754-14 800-754-14

460V-3Ph-60Hz 800-683-24 800-754-11 800-754-11 800-754-15 800-754-15

OIL CHARGE PER COMPRESSOR, Liters 22 19 19 19 19

CAPACITY CONTROL (STEPLESS) % 100-12

MOTOR OVERLOAD PROTECTION (INTERNAL) ELECTRONIC

OIL LUBRICATION INJECTION

TOTAL CRANKCASE HEATER WATTS 300 300 300 300 300

EXPANSION VALVE DEVICE ELECTRONIC EXPANSION VALVE

CONTROL VOLTAGE 220V-1Ph-60Hz

TOTAL WATER VOLUME PER CONDENSERS, Liters 38.3 41.8 41.8 51 51

WATER CONNECTION (DN) DN80 DN80 DN80 DN100 DN100

WATER CONNECTION (DN) DN200 DN200 DN200 DN200 DN200

REFRIGERANT CHARGE PER COMP., kg 46.25 49.4 52.5 55.6 58

OPERATING/SHIPPING WEIGHTS, kg 8415/7928 8443/7956 8782/8208 9308/8734 9320/8746