Transcript
Company Business Zamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be established in Saudi Arabia and today is a leading international manufacturer of air conditioning systems and is Number One in the Middle East. Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55 countries in the Middle East, Europe, Africa and Asia. The 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 Zamil, Cooline, GE and OEM brands for commercial and industrial customers. 3. Zamil CoolCare Business Unit providing industrial, electro mechanical contracting services, HVAC maintenance, retrofit & operation services and parts. 4. Geoclima srl is an independent business supporting other SBUs for their requirements of chillers & double skin AHU’s. The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare direct their business operations from the corporate headquarters in Dammam, Saudi Arabia. Geoclima has its engineering & production operations located at Monfalcone, Italy and has a design center in Austria. All the four SBUs, while operating independently, supplement each 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 specialty 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 & Product Certificates The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification. Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi 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. ETL (Test Facilities) 4. SASO (Saudi Arabian Standards Organization) 5. ISO 9001:2008 (International Organization for Standardization) 6. ASME (American Quality of Mechanical Engineers) 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, commercial and industrial air conditioners. This broad range extends from the Concealed Units up to 5 TR, the Ducted Splits up to 30 TR, the Packaged Units up to 95 TR, the Single and Double Skin Air Handling Units up to 138,316 CFM and the Water Chillers up to 500 TR cooling capacity.
INDEX Contents
Page
Model decoding ........................................................................................................................................ 2 Introduction & features ............................................................................................................................. 3 Standard specifications ............................................................................................................................ 4 Options & accessories .............................................................................................................................. 5 Selection procedure ................................................................................................................................. 6 Performance data ..................................................................................................................................... 7 Dimensions ............................................................................................................................................ 8-9 Installation clearance .............................................................................................................................. 10 Typical schematic wiring diagram ...................................................................................................... 11-13
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1
MODEL DECODING 1, 2 & 3 BASIC
4, 5 & 6 UNIT MODEL
ZRC
010 011 012 013 014 015 019 021 023 025 027 029 034 037 039 042 046 050 053 058 068 075 078 083 092 100 108 118 129 137 147 158 168 179 188 208
AIR COOLED RADIATORS
NOTES:
* **
7 ELECTRICAL SUPPLY (V-Ph-Hz)
8 FAN & ELECTRICAL OPTIONS
H : 208/230-3-60
A : STANDARD UNIT
M : 380-3-60 (4 WIRE)
K : FAN STAGING CONTROL
F : 460-3-60 L : 380/415-3-50 (4 WIRE)
9 HEAT EXCHANGER FINS
10 MECHANICAL OPTIONS
11 GENERAL OPTIONS
A : ALUMINUM FIN
A : FLANGED WATER CONNECTION
A : STANDARD UNIT (VERTICAL DISCHARGE) B : WATER SPRAY SYSTEM
B : COPPER FIN
D : PANEL DISCONNECT SWITCH*
C : COATED ALUMINUM FIN
M : OUTER THREAD TUBE CONNECTION
V : VOLT FREE CONTACTS (STATUS INDICATION**)
D : COATED COPPER FIN
E : EXPANSION TANK
C : VIBRATION ISOLATOR D : HORIZONTAL AIR DISCHARGE
R :K + D
R:A+E
S :K + V
S:M+E
T:D+V W: K + D + V
Optional disconnect switch is non-fused and panel mount type. Fixed in unit's control panel. Status indication is provided as volt free contacts to indicate common fan run & common fault.
2
INTRODUCTION The ZRC series air cooled radiators from Zamil Air Conditioners are designed to provide engineering excellence in industrial cooling with a superior combination of energy saving, performance, application flexibility, ease of service & maintenance and the ability to withstand extreme ambient temperatures. ZRC air cooled heat exchangers utilize the ambient air to cool off the circulating fluid to the required temperature. ZRC air cooled radiators are factory assembled, suitable for horizontal or vertical mounting. Unit casing has lifting holes in a rigid construction for overhead rigging. The radiators are delivered with an integral weather resistant control panel, to be instantly connected to utilities.
SALIENT FEATURES OF THE ZRC SERIES *
Flexible design and components for various specifications.
*
Easy installation & excellent serviceability.
*
Available in horizontal and vertical unit configurations.
*
High safety standards with UL listed electrical components.
*
Quality assurance according to ISO 9001: 2008. All deliveries meet performance specifications.
*
Low noise condenser fans, direct drive with rolled form venture design to eliminate airflow recycling.
*
Condenser fan motors are totally enclosed air over type (TEAO) with class 'F' winding insulation.
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Side panels are provided with openings for coil maintenance.
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One component metallic impregnated poly urethane coating, factory applied corrosion resistant coil coating available.
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Flexible warranty and performance contract available.
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STANDARD SPECIFICATIONS A. UNIT ENCLOSURE Steel sheet panels are zinc-coated and galvanized by the hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90, followed by baked on electrostatic polyester dry powder coat.
B. UNIT CONSTRUCTION 1. FINNED COIL SLAB Coils are corrugated fin and tube type; constructed of 1/2" or 3/8" dia. & 0.017" (0.43 mm) thick seamless copper tubes, mechanically bonded to enhanced corrugated aluminum fins for maximum heat transfer efficiency. 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 made of heavy gauge galvanized steel; formed to provide structural strength. Each coil is factory tested at no less than 450 psi air pressure. Water connections are available in flange type or with outer threaded tube, they are welded to copper distribution headers, headers are equipped with air-vent and drain as standard. 2. FANS 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 coil.
3. MOTORS The impeller and motors are 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. Motors are wired using PVC 6 core flexible cord type #16 AWG 90° thermoplastic insulation 600V and entered to the electrical panel using straight liquid tight fittings. 4. ELECTRICAL PANEL The control panel design is equivalent to NEMA-4 standards ensuring dust and weatherproof construction with hinged door for easy access. It is properly anchored and internal wirings are identified with cable markers and wiring design follows guidelines as per NEC standard. The panel includes motor controllers which are UL approved and are reliable in operation at high ambient conditions for a long period. Power and Control Components Magnetic contactors are provided on individual motors. Circuit breakers are provided individually on motors with fan arrangement of up to 1x3 fan arrangement. For higher fan arrangement, a single circuit breaker is provided on each pair of motors. A power distribution block is provided in the panel for single point power supply cable connection. Control power is 230Vac. Control wiring is designed with removable jumper provisions connected on terminal blocks for the purpose of connecting volt-free contact signal to start/stop individual fan or group of fans. These signals may come from customer’s control devices or may be requested to be built-in the equipment. 4
OPTIONS & ACCESSORIES A. FAN STAGING CONTROLLER Single to 4-stage temperature controller can be provided on request to stage the fans ON/OFF based on temperature of leaving water. This results to energy savings most specially during low ambient conditions.
B. DISCONNECT SWITCH Optional disconnect switch can be provided to shut-off power to the equipment. The switch is non-fused and panel mounted type. Operating handle of the switch is IP55 protection and mechanically interlocked with the door of control panel for safety purposes.
C. STATUS INDICATOR (VOLT FREE CONTACT) Two volt-free contact signals are provided to indicate “common run” status and “common fault” status. In multiple fan units, the trip signal may not indicate that the entire unit has tripped. It indicates that at least one fan has tripped. Other fans will still be operating continuously. Note: The above mentioned status indication signal can be changed on customer’s request. Volt free contact signals for status indication can be provided based on customer defined requirements.
D. WATER SPRAY SYSTEM During high load peaks water spray system will lower the entering air temperate by intermittently and efficiently evaporating water on the heat rejection surface of the radiator, this will increase the cooling capacity and reduce the operation cost.
E. COIL BUNDLE OPTIONS a. Aluminum fins pre-coated b. Aluminum fins with anti-corrosive coating c. Copper fins d. Copper fins with anti-corrosive coating e. Copper fins with electro-tin coating
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SELECTION PROCEDURE Design Criteria: If the required capacity is already known at nominal condition as stated on performance data on next page, then the suitable radiator can be selected directly, if not; then the below data is required to make the proper design selection: 1. Required heat load to be rejected (kW) 2. The design ambient temperature (°C) 3. Water (Fluid) Inlet temperature (°C) 4. Water (Fluid) Outlet temperature (°C) 5. Fluid flow rate (LPS) 6. Power supply Design Capacity (kW) = (Fluid Flow (L/sec) x ∆T°C) / fluid constant ∆T = Fluid temperature IN – Fluid temperature OUT
% Glycol 0 10 20 30 40 50
Fluid Constant 0.239 0.242 0.247 0.254 0.264 0.275
% Glycol 0 10 20 30 40 50
Fluid Constant 500 493 484 470 453 435
Example: Water inlet temperature : 49°C Water outlet temperature : 44°C Water flow rate : 99 m³/h = 27.4815 L/S TABLE - A Using table A the fluid constant for water = 0.239 Using the above formula: Capacity = (27.48 x 5)/0.239 Capacity = 574.8 kW Upon completing the calculated capacity, provide complete set of data to Sales office to provide a submittal that includes radiator details and dimensional drawings. For British units, use the below formula: Capacity (BTU) = ∆T°F x Fluid constant x GPM Fluid constant: See table - B ∆T: Fluid temperature IN – Fluid temperature OUT GPM: Fluid flow (Gallon per minute) Example: Water inlet temperature : 120°F Water outlet temperature : 111°F Water flow rate = 436 GPM Using table B fluid constant = 500 Using the above formula : Capacity = (120°F – 111°F) x 500 x 435 Capacity = 1,957,500 BTU
TABLE - B
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PERFORMANCE DATA Unit Model Capacity (kW) Fan arrangement
Air flow, m³/h
Internal Vol. (liter) Fluid flow, m³/h Connection Size, Liquid ∆P (Kp) Surface Exchange S.P. (dB(A) @ 10m Inch Area, m²
ZRC010
34
1x1
17000
9.90
26.0
1-3/8
47.35
53.6
49.4
ZRC011
38
1x1
16900
9.90
29.1
1-5/8
50.28
62.9
49.4
ZRC012
41
1x1
16100
14.60
31.7
1-3/8
28.54
90.9
49.4
ZRC013
45
1x1
15500
19.50
34.3
1-3/8
38.12
102.9
49.4
ZRC014
48
1x1
15100
19.50
36.5
1-3/8
43.22
121.3
49.4
ZRC015
52
1x1
17000
19.50
40.1
1-5/8
36.98
121.2
58.4
ZRC019
66
1x2
33000
19.70
51.1
2-1/8
37.10
107.2
52.4
ZRC021
75
1x2
33000
19.70
57.2
2-5/8
42.00
125.8
52.4
ZRC023
81
1x2
32000
26.30
62.1
2-5/8
64.00
142.9
52.4
ZRC025
89
1x2
31600
26.30
67.8
2-5/8
75.20
167.8
52.4
ZRC027
94
1x2
33500
38.90
72.2
3-1/8
22.00
205.8
61.4
ZRC029
102
1x2
33000
38.90
77.9
3-1/8
25.30
242.5
61.4
ZRC034
120
1x3
48000
39.40
91.1
4-1/8
26.10
214.4
54.2
ZRC037
129
1x3
46500
39.40
98.6
4-1/8
29.92
251.7
54.2
ZRC039
137
1x3
46500
58.40
105.2
3-1/8
61.00
308.8
54.2
ZRC042
147
1x3
45200
58.40
112.3
3-1/8
68.75
363.8
54.2
ZRC046
162
2x2
64000
52.60
123.7
4-1/8
62.09
285.9
55.4
ZRC050
177
2x2
63000
52.60
135.2
4-1/8
72.63
335.6
55.4
ZRC053
186
2x2
58000
77.90
141.8
4-1/8
21.83
485
55.4
ZRC058
204
2x2
66000
77.90
155.9
4-1/8
25.80
485
64.4
ZRC068
239
2x3
96000
78.80
182.7
4-1/8
28.9
428.9
57.2
ZRC075
262
2x3
94800
78.80
200.3
4-1/8
34
503.3
57.2
ZRC078
274
2x3
92400
116.80
209.1
4-1/8
61.31
617.6
57.2
ZRC083
293
2x3
90000
116.80
224.1
4-1/8
69.23
727.3
57.2
ZRC092
324
2x4
128000
105.10
247.4
4-1/8
63.43
571.9
58.4
ZRC100
353
2x4
125600
105.10
269.9
4-1/8
73.99
671.1
58.4
ZRC108
381
2x4
120000
155.70
290.6
4-1/8
28.25
970
58.4
ZRC118
416
2x4
136000
155.70
318.3
4-1/8
33.29
970
67.4
ZRC129
454
2x5
155000
194.60
346.5
4-1/8
45.23
1029
59.4
ZRC137
483
2x5
150000
194.60
369.4
4-1/8
50.76
1212
59.4
ZRC147
518
2x5
165000
194.60
395.8
4-1/8
57.54
1212
68.4
ZRC158
555
2x6
188400
233.60
424.0
4-1/8
74.35
1235
60.2
ZRC168
589
2x6
181000
233.60
449.5
4-1/8
82.64
1455
60.2
ZRC179
628
2x6
198000
233.60
479.9
4-1/8
93.00
1455
69.2
ZRC188
662
2x7
203000
259.50
505.9
4-1/8
110.58
1616
60.9
ZRC208
732
2x8
256000
279.00
559.2
4-1/8
139.79
1475
70.4
N O T E S : Capacities are given according to following conditions: 1. Inlet Air (Ambient) temperature = 25°C 2. Water IN temperature = 40°C 3. Water OUT temperature = 35°C
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DIMENSIONS ZRC010, 011, 012, 013, 014 & 015
ZRC019, 021, 023, 025, 027 & 029
NOTE: All dimensions are in mm.
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DIMENSIONS ZRC034, 037, 039 & 042
ZRC046 - ZRC208
DIMENSIONS MODEL ZRC046 ZRC050 ZRC053 ZRC058 ZRC068 ZRC075 ZRC078 ZRC083 ZRC092 ZRC100 ZRC108 ZRC118 ZRC129 ZRC137 ZRC147 ZRC158 ZRC168 ZRC179 ZRC188 ZRC208
NOTE: All dimensions are in mm.
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L 2450 2450 2450 2450 3650 3650 3650 3650 4850 4850 4850 4850 6050 6050 6050 7250 7250 7250 8050 8690
A 2370 2370 2370 2370 3570 3570 3570 3570 2345 2345 2345 2345 2345 2345 2345 2345 2345 2345 2273 3219
B 2345 2345 2345 2345 3545 3545 3545 2400 2400 2400 3424 2172
C 2345 2345 2345 2273 3219
INSTALLATION CLEARANCE
DIMENSIONS MODEL NUMBER
A
ZRC010 - ZRC042 1130 ZRC046 - ZRC208 2200
NOTE: All dimensions are in mm.
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TYPICAL SCHEMATIC WIRING DIAGRAM POWER & CONTROL CONNECTIONS (1 FAN, 2 FAN & 3 FAN MODELS)
CB1
CB2
TO HVTB
CB3
L1
1
1
TK (FM1)
TK (FM2)
TK (FM3)
108 37C
36C
35C
37B
36B
35B
37A
36A
35A
L3
L2
L1
TRANS
FMC1
FMC2
7
6
F1
F2
5
FMC3
3
FMC2
4
FMC1
107
106
105
104
103
102
101
100
L2
FMC3
460V 230V ( Note 2 )
FM1 HVTB
FM2
FM3 ATB
ETB
2
J1
21
J2
22
J3
23
FAN MOTOR LAYOUT
(common)
1 - FAN
S1
S2
S3
2 - FAN POWER SUPPLY 460V-3PH-60HZ 3 - FAN
STEP CONTROLLER OR FAN CYCLING CONTROLLER ( OPTIONAL CONNECTION BY OTHERS ) NOTE: REMOVE JUMPERS J1, J2, J3
NOTE: Refer to unit control box (inside panel) for exact wiring diagram.
11
12
L1
L1
L2
L2
L3
L3
ETB
101 36A
FM1
104 36B
FM2
105 37B
103 35B
102 37A
100
35A
FMC2
NOTE: 1. Refer to next page for legend & notes. 2. Refer to unit control box (inside panel) for exact wiring diagram.
POWER SUPPLY 460V-3PH-60HZ
HVTB
FMC1
107 36C
FM3
109 3
4
2
35D 1
FMC3
110 36D
111 37D
FAN MOTOR LAYOUT
FM4
FMC4
14
13
136 35M 16
15
137 36M
138 37M
HEADER SIDE
FM13
FMC13
140 36N
FM14
FMC14
142 35O
141 37N
139 35N
108 37C
106 35C
CB7
143
FM15
36O
CB2
144 37O
CB1
FMC15
CB8
145 35P
POWER & CONTROL CONNECTIONS (4 FAN TO 16 FAN MODELS)
146
FM16
36P
TYPICAL SCHEMATIC WIRING DIAGRAM
147 37P
TYPICAL SCHEMATIC WIRING DIAGRAM POWER & CONTROL CONNECTIONS (4 FAN TO 16 FAN MODELS)
TO HVTB L1
1
1
1
1
TK (FM1)
TK (FM2)
TK (FM3)
TK (FM4)
1
1
TK (FM13)
1
TK (FM14)
TK (FM15)
TK (FM16)
L2
TRANS
FMC1
FMC3
FMC2
FMC4
20
19
18
17
8
7
6
4
3
5
F1
F2
FMC13
FMC14
FMC15
FMC16
J13
J14
J15
J16
460V 230V ( Note 2 )
ATB 2
J1
21
J2
22
J3
23
J4
24
33
34
35
36
(common)
NOTES
S1
S2
S3
1.
ANY WIRE REPLACEMENT SHOULD BE OF 90 DEG. C TYPE OR ITS EQUIVALENT.
2.
CONTROL TRANSFORMER IS REQUIRED ONLY IN UNIT MODELS WITH : a) 460V-3PH-60HZ POWER SUPPLY b) 380V-3PH-50/60HZ (if power supply at site does not have a neutral wire).
S4
S13
S14
STEP CONTROLLER OR FAN CYCLING CONTROLLER ( OPTIONAL CONNECTION BY OTHERS ) SYMBOLS AND LEGEND ATB
NOTE: Remove corresponding jumpers J1, J2, . . . as per specific fan/s or nos. of fans required to be controlled.
AUXILIARY TERMINAL BLOCK
CB
CIRCUIT BREAKER
ETB
EARTHING TERMINAL BLOCK
HVTB
HIGH VOLTAGE TERMINAL BLOCK
F
FUSE
FM
FAN MOTOR
FMC
FAN MOTOR CONTACTOR
S
SWITCH
TRANS
TRANSFORMER (CONTROLS)
TK
FM THERMAL OVERLOAD PROTECTION CONTINUOUS CIRCUIT SEQUENCE SAME AS PREVIOUS FIELD WIRING GROUNDING / EARTHING
13
S15
S16
