AIR COOLED SCREW WATER CHILLERS

Transcription

1 GENERAL ELECTRIC AIR COOLED SCREW CHILLERS R-134a AASC Series AASC055B thru AASC445B 55 TR thru 445 TR 194 thru 1565 GE_AASC_Series.indd 1 3/26/12 5:20 PM

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3 CONTENTS Model decoding Unit features, standard specifi cations & options Physical data Selection procedure Ethylene glycol solution capacity correction Performance data Electrical data Water side pressure drop Unit dimensions Typical schematic wiring diagram Microprocessor controller Application guidelines Rigging instructions Installation clearance Mounting location Load distribution Continuing research results in steady improvements. Therefore, these specifications are subject to change without notice 1 GE_AASC_Series.indd 1 3/26/12 5:20 PM

4 MODEL DECODING & PRODUCT INFORMATION 1, 2, 3 & 4 BASIC (SERIES) 5, 6 & 7 UNIT SIZE 8 REFRIGER- ANT 9 ELECTRICAL SUPPLY ( V-Ph-Hz) 10 CONDENSER COIL 11 CIRCUIT BREAKER OPTIONS 12 COOLER OPTIONS 13 COMPRESSOR OPTIONS 14 HGBP OPTIONS AASC GE AIR COOLED SCREW CHILLERS B : R-134a L : 380/ (4 WIRE) A : ALUMINUM FIN B : PRE-COATED ALUMINUM FIN C : COPPER FIN D : COATED ALUMINUM FIN WITH THERMOGUARD E : COATED COPPER FIN WITH THERMOGUARD (SEE NOTE # 1 BELOW) A : COMPRESSOR CIRCUIT BREAKER A : S TANDARD WIT H VICTAULIC CONN. B : F LANGE CONN (OPTIONAL) C : ASME STAMPED WITH VICTAULIC CONN. (OPTIONAL) D : ASME STAMPED WITH FLANGE CONN. ( OPTIONAL) A : STANDARD UNIT WITHOUT SUCTION SERVICE VALVE B : UNIT WITH SUCTION SERVICE VALVE (OPTION) A : STANDARD UNIT WITHOUT HGBP & WITHOUT SUCTION SERVICE VALVE B : WITH HGBP & WITHOUT SUCTION SERVICE VALVE (OPTION) C : WITHOUT HGBP & WITH SUCTION SERVICE VALVE (OPTION) D : WITH HGBP & WITH SUCTION SERVICE VALVE (OPTION) NOTES: 1. FOR OTHER COATING, SPECIFY YOUR REQUIREMENTS IN WRITING. 2. COMPUTER SELECTED DIGITS (FROM AA TO ZZ') ' DESCRIBING OTHER OPTIONS & ACCESSORIES OR COMBINATIONS THEREOF, SUCH AS - CONDENSER COIL GUARD - COOLER GUARD - UNIT DISCONNECT SWICH - COMPRESSOR ENCLOSURE - SWITCH - SPRING ISOLATOR - MULTI- ResisTec PIPING - MULTI- ResisTec SHEET METAL etc & 15 OPTIONS & ACCESSORIES SEE NOTE # 2 BELOW : 2 GE_AASC_Series.indd 2 3/26/12 5:20 PM

5 UNIT FEATURES, STANDARD SPECIFICATIONS & OPTIONS FEATURES These AASC air cooled screw water chillers offer the ultimate combination of energy saving design, superior engineering features and flexibility of application as required by today s market. Wide size range for every application need. Equipped with the advanced controller from Microprocessor Control System (MCS) as standard. This controller monitors both analog and digital inputs in order to achieve precise control and full protective functions of the air cooled water chiller. It has the complete hardware and software necessary to control the chiller and to ensure the highest energy 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 Safety code for Mechanical Refrigeration. Compact unit design and excellent serviceability. All packaged chillers incorporate compact water coolers with enhanced inner grooved copper tubes expanded into a steel tubular sheets which offer efficient water flow as well as heat transfer design that results in optimal unit performance. High Energy Efficiency Ratio (EER) semi-hermetic compact twin screw compressors. Single point power connection to minimize job site installation cost and time. Complete factory wired control panel for all compressor motor starters, fan motor starters and microprocessor controller that provides all necessary operating and full safety control. Compressor motors are with part winding start or star delta start. Low noise condenser fans, direct drive at 940 RPM with rolled form venturi design to eliminate short circuiting of airflow. All fans are high quality aluminum propeller type with aerodynamic design, top discharge, provided with protective grille mounted on top panel within the unit casing. All condenser fan motors are totally enclosed air over type (TEAO) with class F winding insulation and ball bearings. Inherent thermal protection of the automatic reset type and specially designed for outdoor application.. STANDARD SPECIFICATIONS CABINET All units are of heavy gauge (G-90) galvanized steel. The steel sheet panels are zinc coated and galvanized by hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90 followed by air dry paint or backed on electrostatic polyester dry powder coat. CAPACITY CONTROL 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 that allows the compressor capacity to exactly match the cooling load. 2. Reduces compressor cycling that leads to better operational reliability. 3. Reduces operating cost. 4. For units with Hot gas bypass (optional): The unit modulates to approximately 50% of its compressor lowest unloaded capacity. 3 GE_AASC_Series.indd 3 3/26/12 5:20 PM

6 UNIT FEATURES, STANDARD SPECIFICATIONS & OPTIONS SEMI-HERMETIC COMPACT TWIN SCREW COMPRESSORS High capacity and high efficiency due to its perfect profile form ratio 5:6. Double-walled rotor housing with high strength inner ribs which is extremely stable and results in additional sound attenuation. Suction gas cooled semi-hermetic compressor with suction filter. Universal application, with or without economizer. Rain- tight terminal box. Long life bearings and high reliability. Optimized oil management. Built in directly flanged on three stage oil separator, low pressure drop demister to ensure minimal refrigerant dilution in the oil and maintain high oil viscosity. Large volume motor for part winding or direct start with integrated PTC sensor in each winding. Compressors are provided with intelligent electronics including thermal motor temperature monitoring phase sequence monitoring, manual reset lock-out and discharge temperature protection by PTCs sensors. Compressors with slider control valve for Infinite capacity control. Compressors are equipped with a discharge shut off valve, discharge check valve, suction shut of valve, suction filter, rubber mounting pads, PTC temperature sensors, economizer port, oil heater, oil filter, oil drain valve, oil sight glass, liquid injection port, oil level switch and built in safety pressure relief valve. CONDENSER COILS W-configuration condenser coils are corrugated fin and tube type, constructed of seamless 3/8 dia. & (0.27 mm) thick inner grooved copper tubes, mechanically bonded to aluminum fins for maximum heat transfer efficiency. There should advice on this feature, as a standard on aluminum fins, ZAC provides Coil ResisTec Coating, which is a single component of aluminum impregnated coating applied on the fins of heat exchanging coils. The product has been designed for Middle East climate conditions. A high chemical, abrasion and UV resistance has been proven in both laboratories and on field environment. The coating can be applied at the Zamil Air Conditioners factory as well as in the field for maintenance or rejuvenation purposes. The fins have full self spacing collars which completely cover each tube. The staggered tube design improves the thermal effiency. End plates support sheets are 14 gauge galvanized steel, formed to provide structural strenght. Each coil is pressure tested in the factory at not less than 450 psi air pressure. COMPACT DESIGN SHELL AND TUBE COOLERS The DX shell & tube is provided with tubes that are made of internally grooved copper tubes expanded into a heavy steel tubular sheets. The chiller cooler & baffles are constructed of steel and brass respectively. These coolers are insulated with heavy closed cellular foam insulation (3/4 thick). All chiller coolers are fitted with vent, drain connection and victaulic water pipe connection as standard. 4 GE_AASC_Series.indd 4 3/26/12 5:20 PM

7 UNIT FEATURES, STANDARD SPECIFICATIONS & OPTIONS SHELL & TUBE HEAT EXCHANGER (COOLER) ST D DESIGN PRESSURE, (BAR/PSIG) 16/235 SIDE TEST PRESSURE, (BAR/PSIG) 22.8/335 DESIGN PRESSURE, (BAR/PSIG) 29/426 REFRIGERANT SIDE TEST PRESSURE, (BAR/PSIG) 41.5/610 ASME (option) 10/ / / /342 CONTROL PANEL The control panel design is equivalent to NEMA 4 (IP55) with hinged door for easy access ensuring dust and weather- proof construction. Internal power and control wiring is neatly routed, adequately anchored and all wires 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 conditions for a long period. CONDENSER FANS Condenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phase with class F winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosed air over type (TEAO) with inherent thermal protection of automatic reset type. MICROPROCESSOR CONTROLLER The AASC chillers are equipped with the advanced controller from Microprocessor Control System (MCS) as standard. The MCS works as computer, decisions are made based upon the set point, timers and sensor inputs that ensure the most efficient functioning of the chiller package. This durable microprocessor controller is primary made for chiller package application. It can stand for long operation under high ambient conditions. It is fully designed to automatically protect the system that is being controlled and eliminates the needs for manual intervention. The controller provides flexibility on set points and control options that can be selected prior to commissioning on a system or when the unit is live and functioning. It is also provided with a simple to use push button that allows the user to access the unit operating conditions, control set points and alarms history. Display, alarms and other interfaces are accomplished using most common terms in a clear and simple language that can be easily understood. Characters in white on a blue background are viewed at 2.8 diagonal viewing area with 128 x 64 dot pixel STN monochrome graphics LCD. 5 GE_AASC_Series.indd 5 3/26/12 5:20 PM

8 UNIT FEATURES, STANDARD SPECIFICATIONS & OPTIONS 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: Protects the compressor by monitoring: A) Motor winding temperature in case of overload. B) Discharge gas temperature in case of overheating. C) Phase reversal for direction of rotation. STARTERS: The part winding or star delta starter is operated by the control circuit and provides power to the compressor motors. These devices are rated to safely handle 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 moisture contents and provides a mean for checking the system refrigerant charge. LIQUID LINE SOLENOID VALVE: Closes when the compressor is off to prevent any liquid refrigerant from accumulating in the water cooler during the off cycle. UNDER VOLTAGE AND PHASE PROTECTION: Protects against low incoming voltage as well as single phasing, phase reversal and phase imbalance by de-energizing the control circuit. It is an automatic reset device, but it can be set up for manual reset. 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 HOT GAS BYPASS SYSTEM: Hot gas bypass is provided on the lead circuit to permit operation of the system down to 50% of its unloaded capacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor on and off, ensuring narrow temperature swing and lengthen the life span of the compressor. SWITCH: Paddle type field adjustable flow switch for water cooler circuits. Interlock into unit safety circuits so that the unit will remain off until water flow is determine. 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. 6 GE_AASC_Series.indd 6 3/26/12 5:20 PM

9 UNIT FEATURES, STANDARD SPECIFICATIONS & OPTIONS CONDENSER COIL GUARD: Protects the condenser coil from physical damage. COMPRESSOR/COOLER GUARD: Protects the compressor and cooler from vandalism. COMPRESSOR ENCLOSURE BOX: Reduces compressor operating noise and keeps the compressor clean. FLANGED COOLER CONNECTION: Easy on-site piping connections. COOLER HEATER WRAPPED : Prevents freezing up of water on low ambient temperature. COPPER FINS/TUBES CONDENSER COILS : For seashore salty corrosive environments. COATED COPPER/ALUMINUM FINS CONDENSER COILS : For seashore or acid corrosive environments. ResisTec COATED COPPER FINS/TUBES CONDENSER COILS: For seashore or acid corrosive environments. BMS: BACNET, MODBUS, Johnson control and LON work. MULTI ResisTec : A two component coating system that withstands the extreme climate conditions. The coating can be applied to all metal parts of HVAC equipment; the piping, the compressors and grids might require a different pre- treatment and layer build up. Please check ResisTec product information sheets, the heat exchangers can not be coated using this type. The coating can be applied at the Zamil Air Conditioners factory as well as in the field for maintenance or rejuvenation purposes. 7 GE_AASC_Series.indd 7 3/26/12 5:20 PM

10 PHYSICAL DATA UNIT SIZE AASC055B AASC060B AASC070B AASC075B AASC090B AASC100B COMPRESSOR P AR T NUMBE R NUMBE R OF C OMP R E S S OR S OIL CHARGE PER COMPRESSOR, Liters C AP AC IT Y CONTR OL (S T E P LE S S ) % MOT OR OV E R LOAD P R OT E C T ION (INT E R NAL) OIL LUBRICATION REFRIGERANT E XP ANS ION V ALV E DE VICE E LE C T R ONIC INJECTION R-134a E LE C T R ONIC E XP ANS ION V ALV E CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / Total face area, Sq. ft AIR, C F M NUMBE R OF F AN/F AN DIA., mm 4/800 4/800 4/800 4/800 6/800 6/800 F AN MOT OR R P COOLER (SHELL & TUBE TYPE) COOLER PART NUMBER (1) (1) (1) (1) (1) (1) S HE LL DIAME T E R, mm LE NGTH, mm TOTAL HOLDING VOLUME, Liters WAT E R IN/OUT P IP E DIA. mm ECONOMIZER P AR T NUMBE R N.A (1) (1 ) N.A (2 ) N.A. E XP ANS ION DE V IC E N.A. T.E.V. T.E.V. N.A. T.E.V. N.A. GENERAL NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER, kg ( 1/2) SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 70.6/67/ /67/ /67.6/ /69.1/ /68.8/ /68.9/63. 6 SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 2099/ / / / / /3882 SHIPPING /OPERATING WEIGHTS (Copper coils), kg 2253/ / / / / /4265 NOTES: 1. All compressors with slider control valve unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. Sound pressure level : ±2dBA. 8 GE_AASC_Series.indd 8 3/26/12 5:20 PM

11 PHYSICAL DATA UNIT SIZE AASC110B AASC120B AASC130B AASC140B AASC150B AASC170B AASC185B COMPRESSOR P AR T NUMBE R NUMBE R OF C OMP R E S S OR S OIL CHARGE PER COMPRESSOR, Liters / C AP AC IT Y CONTR OL (S T E P LE S S ) % MOT OR OV E R LOAD P R OT E C T ION (INT E R NAL) OIL LUBRICATION REFRIGERANT E XP ANS ION V ALV E DE VICE CONTR OL V OLT AG E CONDENSER E LE C T R ONIC INJECTION R-134a E LE C T R ONIC E XP ANS ION V ALV E 220V -1P h-50hz CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / / Total face area, Sq. ft AIR, C F M NUMBE R OF F AN/F AN DIA., mm 6/800 8/800 8/800 8/800 10/800 10/800 10/800 F AN MOT OR R P COOLER (SHELL & TUBE TYPE) COOLER PART NUMBER (1) (1) (1) (1) (1) (1) (1) S HE LL DIAME T E R, mm LE NGTH, mm TOTAL HOLDING VOLUME, Liters WAT E R IN/OUT P IP E DIA. mm ECONOMIZER PART NUMBER (1) (2) (2 ) (2 ) N.A (2 ) (2 ) E XP ANS ION DE V IC E T.E.V. T.E.V. T.E.V. T.E.V. N.A. T.E.V. T.E.V. GENERAL NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER, kg ( 1/2) 39/ / SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 72.5/68.9/ /70/ /70.1/ /70.2/ /71.4/ /71.4/ /71.6/66. 4 SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 4093/ / / / / / /6035 SHIPPING /OPERATING WEIGHTS (Copper coils), kg 4539/ / / / / / / NOTES: 1. All compressors with slider control valve unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. Sound pressure level : ±2dBA. 9 GE_AASC_Series.indd 9 3/26/12 5:20 PM

12 PHYSICAL DATA UNIT SIZE AASC200B AASC215B AASC240B AASC255B AASC275B AASC300B COMPRESSOR P AR T NUMBE R NUMBE R OF C OMP R E S S OR S OIL CHARGE PER COMPRESSOR, Liters CAPACITY CONTROL (STEPLESS) % MOT OR OV E R LOAD P R OT E C T ION (INT E R NAL) OIL LUBRICATION REFRIGERANT E XP ANS ION V ALV E DE VICE E LE C T R ONIC INJECTION R-134a E LE C T R ONIC E XP ANS ION V ALV E CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / Total face area, Sq. ft AIR, C F M NUMBE R OF F AN/F AN DIA., mm 12/800 12/800 18/800 18/800 18/800 18/800 F AN MOT OR R P COOLER (SHELL & TUBE TYPE) COOLER PART NUMBER (1) (1) (1) (1) (1) (1) S HE LL DIAME T E R, mm LE NGTH, mm TOTAL HOLDING VOLUME, Liters WAT E R IN/OUT P IP E DIA. mm ECONOMIZER PART NUMBER (2) (2) N.A. N.A. N.A. N.A. E XP ANS ION DE V IC E T.E.V. T.E.V. N.A. N.A. N.A. N.A. GENERAL NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER, kg ( 1/2) SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 76/72.5/ /72.6/ /73.9/ /74.1/ /74.3/ /74.4/69.1 SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 6092/ / / / / /9748 SHIPPING /OPERATING WEIGHTS (Copper coils), kg 6587/ / / / / / NOTES: 1. All compressors with slider control valve unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. Sound pressure level : ±2dBA. 10 GE_AASC_Series.indd 10 3/26/12 5:20 PM

13 PHYSICAL DATA UNIT SIZE AASC315B AASC330B AASC350B AASC370B AASC405B AASC445B COMPRESSOR P AR T NUMBE R NUMBE R OF C OMP R E S S OR S OIL CHARGE PER COMPRESSOR, Liters CAPACITY CONTROL (STEPLESS) % MOT OR OV E R LOAD P R OT E C T ION (INT E R NAL) OIL LUBRICATION REFRIGERANT E XP ANS ION V ALV E DE VICE E LE C T R ONIC INJECTION R-134a E LE C T R ONIC E XP ANS ION V ALV E CONTROL VOLTAGE 220V-1Ph-50Hz CONDENSER CONDENSER COIL Tube Dia.- Rows - Fins per inch 3/ / / / / / Total face area, Sq. ft AIR, C F M NUMBE R OF F AN/F AN DIA., mm 18/800 18/800 20/800 20/800 24/800 24/800 F AN MOT OR R P COOLER (SHELL & TUBE TYPE) COOLER PART NUMBER (1) (1) (2) (2) (2) (2) S HE LL DIAME T E R, mm LE NGTH, mm TOTAL HOLDING VOLUME, Liters WAT E R IN/OUT P IP E DIA. mm ECONOMIZER PART NUMBER (3) (3) N.A (4) (4) (4) E XP ANS ION DE V IC E T.E.V. T.E.V. N.A. T.E.V. T.E.V. T.E.V. GENERAL NUMBER OF REFRIGERANT CIRCUITS REFRIGERANT CHARGE PER, kg ( 1/2) SOUND PRESSURE LEVEL, dba (3m./5m./10m.) 77.8/74.3/ /74.4/ /74.9/ /74.6/ /75.5/ /75.6/70.3 SHIPPING /OPERATING WEIGHTS (Aluminum coils), kg 9633/ / / / / / SHIPPING /OPERATING WEIGHTS (Copper coils), kg 10954/ / / / / /15421 NOTES: 1. All compressors with slider control valve unloading. 2. All compressors operate at Hz. 3. Cooler vent and drain size are 1/2" MPT. 4. Sound pressure level : ±2dBA. 11 GE_AASC_Series.indd 11 3/26/12 5:20 PM

14 SELECTION PROCEDURE (ENGLISH UNITS) DESIGN REQUIREMENTS The following design requirements must be known to select a package chiller. 1. Required cooling capacity in tons 2. Leaving chilled water temperature in F (LCWT) 3. Chilled water flow rate in GPM 4. Chilled water cooling range in F (water in temp. - water out temp.) 5. Design ambient temperature 6. Minimum ambient temperature 7. Altitude 8. Electrical power supply SAMPLE SELECTION EVAPORATOR FOULING FACTOR (HR-FT 2-0 F/BTU) Select an Air Cooled Packaged chiller for the following conditions: Required system capacity is 110 tons at 54 F entering chilled water and 44 F leaving water. Design ambient temperature is 95 F. Altitude is 2000 feet above sea level. Water cooler fouling factor is Power supply: 380/415V-3Ph-50Hz. STEP-1: UNIT SELECTION Entering the capacity performance data at given LCWT and ambient temperature. AASC120B chiller unit at sea level will produce tons and 123 compressor power input at 44 F leaving chilled water temperature with 10 F water temperature difference and 95 F ambient temperature. ELEVATION ABOVE SEA LEVEL (FT.) CAPACITY CORRECTION FACTOR TABLE - 2 For the conditions required, the unit actual cooling capacity when corrected for altitude (0.99) and fouling factor (1.0). Capacity = 115.7x0.99x1.0 = Tons, which then exceeds the requirements. So the selection is correct. STEP-2: CHILLED (GPM): Water GPM = Required capacity (Tons) x 24 = 110 x 24 = 264 GPM Cooling Range, ΔT 10 F CORRECTION FACTOR ( 0 F) TABLE - 1 POWER INPUT FACTOR CAPACITY CORRECTION FACTOR TABLE - 3 ARI STANDARDS ARI-550/ ARI ARI CHILLED TEMPERATURE RISE ( 0 F) Referring to pressure drop chart (page # 22), pressure drop 264 GPM = 13.3 fflof water for selected model. NOTE: The total flow rate should be divided by 2 for models AASC350B - AASC445B to find out the total pressure drop. STEP-3: ELECTRICAL Refer to electrical data at 380/415V-3Ph-50Hz, the main power wire size for AASC120B is to be sized for a minimum circuit ampacity (MCA) of 269 Amps and maximum over current protection (MOCP) of 374 Amps. STEP-4: CHILLED PUMP SELECTION For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCWT CORRECTION Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperature range is above 10 F and subtract correction from design leaving chilled water temperature (LCWT) when water temperature range is below 10 F. EXAMPLE: If LCWT rise is 12.5 F, enter correction curve at 12.5 F and read the correction factor of 0.2. The corrected LCWT is = 44.2 F. NOTE: 1. When the chilled water temperature rise is less than 5 F, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2. Please refer to water pressure drop curves. 12 GE_AASC_Series.indd 12 3/26/12 5:20 PM

15 SELECTION PROCEDURE (METRIC UNITS) DESIGN REQUIREMENTS ELEVATION ABOVE SEA LEVEL (Meter) The following design requirements must be known to select a proper package chiller Required cooling capacity in kilowatt () 2. Leaving chilled water temperature in C (LCWT) 3. Chilled water flow rate in LPS 4. Chilled water cooling range in C (water in temp. - water out temp.) 5. Design ambient temperature 6. Minimum ambient temperature 7. Altitude 8. Electrical power supply SAMPLE SELECTION EVAPORATOR FOULING FACTOR (M 2-0 C/W) Select an Air Cooled Packaged chiller for the following conditions: Required system capacity is 395 at 12 C entering chilled water and 6 C leaving water. Design ambient temperature is 35 C. Altitude is 600 meter above sea level. Water cooler fouling factor is Power supply: 380/415V-3Ph-50Hz. STEP-1: UNIT SELECTION Entering the capacity performance data at given LCWT and ambient temperature. AASC120B chiller unit at sea level will produce and compressor power input at 6 C leaving chilled water temperature with 6 C water temperature difference and 35 C ambient temperature. For the conditions required, the unit actual cooling capacity when corrected for altitude (0.99) and fouling factor (1.0). Capacity = 405.1x0.99X1.0 = 401, which then exceeds the requirements. So the selection is correct. STEP-2: CHILLED (LPS): Water LPS = Required capacity () x = 395 x = 15.7 LPS Cooling Range, ΔT 6 C CAPACITY CORRECTION FACTOR TABLE - 2 CORRECTION FACTOR ( 0 C) TABLE - 1 POWER INPUT FACTOR CAPACITY CORRECTION FACTOR TABLE - 3 ARI STANDARDS ARI-550/ ARI ARI CHILLED TEMPERATURE RISE ( 0 C) Referring to pressure drop chart (page # 22), pressure drop at 15.7 LPS = 36 kpa for selected model. NOTE: The total flow rate should be divided by 2 for models AASC350B - AASC445B to find out the total pressure drop. STEP-3: ELECTRICAL Refer to electrical data at 380/415V-3Ph-50Hz, the main power wire size for AASC120B is to be sized for a minimum circuit ampacity (MCA) of 269 Amps and maximum over current protection (MOCP) of 374 Amps. STEP-4: CHILLED PUMP SELECTION For chilled water pump selection, add all pressure drop in the closed chilled water loop piping to the pressure drop calculated in step 2. STEP-5: LCWT CORRECTION Refer to table-3: Add correction factor to design leaving chilled water temperature (LCWT) when chilled water temperature range is above 6 C and subtract correction from design leaving chilled water temperature (LCWT) when water temperature range is below 6 C. EXAMPLE: If LCWT rise is 7.4 C, enter correction curve at 7.4 C and read the correction factor of The corrected LCWT is 6 C+0.11 = 6.11 C. NOTE: 1. When the chilled water temperature rise is less than 3 C, the high water flow rate will result to excessive pressure drop. In such cases, contact factory for special selection of a cooler with wider baffle spacing. 2. Please refer to water pressure drop curves. 13 GE_AASC_Series.indd 13 3/26/12 5:20 PM

16 ETHYLENE GLYCOL SOLUTION CAPACITY CORRECTION (ANTIFREEZE) When operating in areas with temperatures below 32 F (0 C), cooler protection in the form of Ethylene glycol solution (brine solution) is required to protect cooler from low ambient freeze-up. This brine solution must be added to water loop to bring down the freezing point with a difference of 15 F (8 C) below minimum operating ambient temperature. Ethylene glycol solution causes a variation in unit performance. To obtain the effective performance, it is necessary to multiply the water performance data by correction factors corresponding to the ambient temperature or Ethylene glycol percentage indicated in the following table. ETHYLENE GLYCOL % BY WEIGHT 0% 12% 22% 30% 36% 41% 46% 50% Freezing point of Ethylene glycol solution 0 0 C (32 0 F) -5 0 C (23 0 F) C (14 0 F) C (5 0 F) C (-4 0 F) C ( F) C ( F) C ( F) Ambient temperature C (47 0 F) C (38 0 F) C (29 0 F) C (20 0 F) C (11 0 F) C (2 0 F) C (-7 0 F) C ( F) Cooling capacity correction factor Water flow correction factor Pressure drop correction factor EXAMPLE: English system - Determine Ethylene glycol percentage by weight and correction factors at 38 F ambient temperature. From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 38 F ambient temperature is 12% by weight. Find the correction factors corresponding to 38 F ambient temperature from the table. Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is Apply these correction factors for corrected system performance values. TONS (E.G. SOLUTION) = Tons (water) x Cooling capacity correction factor. BRINE (E.G. SOLUTION) (GPM) = Flow (water) x Flow correction factor. BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (Ft.) x Pressure drop correction factor. EXAMPLE: Metric system - Determine Ethylene glycol percentage by weight and correction factors where 3.3 C ambient temperature. From the above table, Ethylene glycol water solution concentration (percentage by weight) corresponding to 3.3 C ambient temperature is 12% by weight. Find the correction factors corresponding to 3.3 C ambient temperature from the table. Cooling capacity correction factor is 0.985, Flow correction factor is 1.02, Pressure drop correction factor is Apply these correction factors for corrected system performance values. KW (E.G. SOLUTION) = KW (water) x Cooling capacity correction factor. BRINE (E.G. SOLUTION) (L/S) = KW (water) x Flow correction factor. BRINE (E.G. SOLUTION) PRESSURE DROP = Water pressure drop (kpa) x Pressure drop correction factor. NOTE: Correction factors apply to published chilled water performance rating from 40 F to 50 F (4.4 C to 10 C) LCHWT. 14 GE_AASC_Series.indd 14 3/26/12 5:20 PM

17 PERFORMANCE DATA (ENGLISH UNITS) LEAVING CHILLED TEMP. (LCWT) 40 0 F 42 0 F UNIT SIZE 95 0 F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE (Tons) AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350 B AASC 370B AASC 405B AASC 445B AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B LEGEND: - C ompressor power input GP M - Gallons Per Minute EER - E nergy Efficiency Rati o EER (GPM) (Tons) EER (GPM) (Tons) NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 10 0 F water range in evaporator. 3. Ratings are based on (hr-ft 2-0 F/Btu) fouling factor for evaporator. EER (GPM) (Tons) EER (GPM) (Tons) 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. EER (GPM) 15 GE_AASC_Series.indd 15 3/26/12 5:20 PM

18 PERFORMANCE DATA (ENGLISH UNITS) LEAVING CHILLED TEMP. (LCWT) 44 0 F 46 0 F UNIT SIZE AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B LEGEND: - C ompressor power input GP M - Gallons Per Minute EER - E nergy Efficiency Rati o 95 0 F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE (Tons) EER (GPM) (Tons) EER (GPM) (Tons) NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 10 0 F water range in evaporator. 3. Ratings are based on (hr-ft 2-0 F/Btu) fouling factor for evaporator. EER (GPM) (Tons) EER (GPM) (Tons) 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. EER (GPM) 16 GE_AASC_Series.indd 16 3/26/12 5:21 PM

19 PERFORMANCE DATA (ENGLISH UNITS) LEAVING CHILLED TEMP. (LCWT) 48 0 F 50 0 F UNIT SIZE AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B LEGEND: - C ompressor power input GP M - Gallons Per Minute EER - E nergy Efficiency Rati o 95 0 F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE F AMBIENT TEMPERATURE (Tons) EER (GPM) (Tons) EER (GPM) (Tons) NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 10 0 F water range in evaporator. 3. Ratings are based on (hr-ft 2-0 F/Btu) fouling factor for evaporator. EER (GPM) (Tons) EER (GPM) (Tons) 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. EER for entire unit. Refer to electrical data for fan. EER (GPM) 17 GE_AASC_Series.indd 17 3/26/12 5:21 PM

20 PERFORMANCE DATA (METRIC UNITS) LEAVING CHILLED TEMP. (LCWT) 4 0 C 5 0 C UNIT SIZE LEGEND: - C ompressor power input LP S - Liters Per Second CO P - Coefficient of Performanc e 35 0 C AMBIENT TEMPERATURE 40 0 C AMBIENT TEMPERATURE 46 0 C AMBIENT TEMPERATURE 50 0 C AMBIENT TEMPERATURE 52 0 C AMBIENT TEMPERATURE () COP (LPS) () COP (LPS) () AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300 B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 6 0 C water range in evaporator. 3. Ratings are based on (m 2-0 C/W) fouling factor for evaporator. COP (LPS) () COP (LPS) () 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. COP for entire unit. Refer to electrical data for fan. COP (LPS) 18 GE_AASC_Series.indd 18 3/26/12 5:21 PM

21 PERFORMANCE DATA (METRIC UNITS) LEAVING CHILLED TEMP. (LCWT) 6 0 C 7 0 C UNIT SIZE LEGEND: - C ompressor power input LP S - Liters Per Second CO P - Coefficient of Performanc e 35 0 C AMBIENT TEMPERATURE 40 0 C AMBIENT TEMPERATURE 46 0 C AMBIENT TEMPERATURE 50 0 C AMBIENT TEMPERATURE 52 0 C AMBIENT TEMPERATURE () COP (LPS) () COP (LPS) () AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 6 0 C water range in evaporator. 3. Ratings are based on (m 2-0 C/W) fouling factor for evaporator. COP (LPS) () COP (LPS) () 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. COP for entire unit. Refer to electrical data for fan. COP (LPS) 19 GE_AASC_Series.indd 19 3/26/12 5:21 PM

22 PERFORMANCE DATA (METRIC UNITS) LEAVING CHILLED TEMP. (LCWT) 8 0 C 10 0 C UNIT SIZE LEGEND: - C ompressor power input LP S - Liters Per Second CO P - Coefficient of Performanc e 35 0 C AMBIENT TEMPERATURE 40 0 C AMBIENT TEMPERATURE 46 0 C AMBIENT TEMPERATURE 50 0 C AMBIENT TEMPERATURE 52 0 C AMBIENT TEMPERATURE () COP (LPS) () COP (LPS) () AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B AASC 055B AASC 060B AASC 070B AASC 075B AASC 090B AASC 100B AASC 110B AASC 120B AASC 130B AASC 140B AASC 150B AASC 170B AASC 185B AASC 200B AASC 215B AASC 240B AASC 255B AASC 275B AASC 300B AASC 315B AASC 330B AASC 350B AASC 370B AASC 405B AASC 445B NOTES: 1. Packaged chillers are rated with ARI standard 550/ Performance data are based on 6 0 C water range in evaporator. 3. Ratings are based on (m 2-0 C/W) fouling factor for evaporator. COP (LPS) () COP (LPS) () 4. Direct interpolation is permissible. Do not extrapolate. 5. power input is for compressor only. 6. COP for entire unit. Refer to electrical data for fan. COP (LPS) 20 GE_AASC_Series.indd 20 3/26/12 5:21 PM

23 ELECTRICAL DATA UNIT SIZE AASC055B Nominal (V-Ph-Hz) 380/ SUPPLY VOLTAGE COMPRESSOR TYPE-1 COMPRESSOR TYPE-2 CONDENSER FAN MOTORS Min. 342 Max. 457 MCA MOCP Qty. RLA (each) LRA (each) CB Poles MTA CB Qty. Qty. RLA (each) LRA (each) CB Poles Qty. FLA (each) Total FCA CB (Qty.) CRANKCASE HEATER PW MTA CB Qty. Volts Total Watts Total Amps STAR- TER AASC060B 380/ PW AASC070B 380/ PW AASC075B 380/ SD AASC090B 380/ P W AASC100B 380/ P W AASC110B 380/ PW AASC120B 380/ P W AASC130B 380/ PW AASC140B 380/ PW AASC150B 380/ SD AASC170B 380/ SD AASC185B 380/ SD AASC200B 380/ SD AASC215B 380/ S D AASC240B 380/ SD AASC255B 380/ SD AASC275B 380/ SD AASC300B 380/ S D AASC315B 380/ SD AASC330B AASC350B AASC370B AASC405B AASC445B 380/ / / / / SD SD SD SD SD LEGEND: MCA - Minimum Circuit Ampacity per NEC MOCP - Maximum Over Current Protectio n RLA - R ated Load Amps LRA - Locked Rotor Amps CB - C ircuit Breaker MTA - Must Trip Amps FLA - F ull Load Amps FCA - Fan Circuit Amps PW - P art Winding Start Compresso r SD - S tar Delta Start Compressor (open type) - K ilo 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 MC M. 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. Under compressor type 1 are the big compressors and type 2 are the small compressors. 6. All field wiring must be in accordance with NEC and local standards. 7. Minimum and maximum unit supply voltages are shown in the tabulated data above. 8. The ±10% voltage variation from the nominal is allowed for a short time only, not permanent. 9. RLA values are based on nominal conditions. 21 GE_AASC_Series.indd 21 3/26/12 5:21 PM

24 SIDE PRESSURE DROP PRESSURE DROP (FT. OF ) RATE - GPM MODEL No. AASC055B AASC060B AASC070B AASC075B AASC090B AASC100B AASC110B AASC120B AASC130B AASC140B AASC150B AASC170B AASC185B CURVE No Minimum GPM Maximum GPM MODEL No. AASC200 B AASC215 B AASC240 B AASC255 B AASC275 B AASC300 B AASC315 B AASC330 B AASC350 B AASC370 B AASC405 B AASC445 B CURVE No Minimum GPM Maximum GPM CONVERSION FACTOR: GPM = Liters per second. F eet of water = Kilo Pascal (kpa). NOTES: 1. If an application requires certain water flow rate outside these limits, please check with your nearest dealer/sales office. 2. If the chiller has 2 evaporators, then the total water flow rate must be divided by 2 while applying the above curves. 22 GE_AASC_Series.indd 22 3/26/12 5:21 PM

25 DIMENSIONS AASC055B, AASC060B, AASC070B & AASC075B DIMENSIONS MODEL A B AASC055B - AASC070B AASC075B AASC090B, AASC100B & AASC110B 2486 NOTE: 1. Cooler dimensions are subject to chenge without notice. Final dimensions will be provided upon order placement. 2. All dimensions are in mm, unless otherwise specified. 23 GE_AASC_Series.indd 23 3/26/12 5:21 PM

26 DIMENSIONS AASC120B, AASC130B & AASC140B DIMENSIONS 2486 MODEL A B C AASC120B AASC130B - AASC140B AASC150B, AASC170B & AASC185B DIMENSIONS MODEL A B C AASC150B - AASC170B AASC185B NOTE: 1. Cooler dimensions are subject to chenge without notice. Final dimensions will be provided upon order placement. 2. All dimensions are in mm, unless otherwise specified. 24 GE_AASC_Series.indd 24 3/26/12 5:21 PM

27 DIMENSIONS AASC200B & AASC215B DIMENSIONS MODEL A AASC200 B AASC215B NOTE: 1. Cooler dimensions are subject to chenge without notice. Final dimensions will be provided upon order placement. 2. All dimensions are in mm, unless otherwise specified. 25 GE_AASC_Series.indd 25 3/26/12 5:21 PM

28 DIMENSIONS AASC240B, AASC255B, AASC275B, AASC300B, AASC315B & AASC330B DIMENSIONS MODEL A B AASC240B - AASC255B AASC275B - AASC300B AASC315B - AASC330B D A C C D NOTE: 1. Cooler dimensions are subject to chenge without notice. Final dimensions will be provided upon order placement. 2. All dimensions are in mm, unless otherwise specified. 26 GE_AASC_Series.indd 26 3/26/12 5:21 PM

29 DIMENSIONS AASC350B & AASC370B NOTE: 1. Cooler dimensions are subject to chenge without notice. Final dimensions will be provided upon order placement. 2. All dimensions are in mm, unless otherwise specified. 27 GE_AASC_Series.indd 27 3/26/12 5:21 PM

30 DIMENSIONS AASC405B & AASC445B NOTE: 1. Cooler dimensions are subject to chenge without notice. Final dimensions will be provided upon order placement. 2. All dimensions are in mm, unless otherwise specified. 28 GE_AASC_Series.indd 28 3/26/12 5:21 PM

31 RS232 TYPICAL SCHEMATIC WIRING DIAGRAM JUMPER 1 MB (MCS-MAGNUM) 230 VAC SUCT1 PRESS DISCH1 PRESS SUCT1 TEMP DISCH1 TEMP COMP1 AMP SSPS1 COMP1 PROOF COMP CB HPS1 OLR1 LWT RWT UVM SWITCH EXEN EMER STOP ** EEV DRIVER 1 (EEV SPORLAN) ** EEV DRIVER 2 (EEV SPORLAN) FLS 10 Communications to SB1 (MCS-SI16) 28A 29A 30A 31A 22A 23A C1 D1 25A 26A 27A UVR CWP * START/STOP EMER STOP MCS-1B6 EEVB1 SSPS1 MCS-1B6 EEVB2 RED BLCK/SHIELD WHITE RED BLCK/SHIELD WHITE BLACK SHIELD WHITE BLACK SHIELD WHITE 8A 8AA BLACK SHIELD WHITE BLACK SHIELD WHITE 211A 211AA 11A 11AA G 2G WA W 2A 5A 2B 5B +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI GND Vout GND Vout GND Vout GND Vout RELAY M-1 RELAY M-2 RELAY M-3 RELAY M-4 RELAY M-5 RELAY M-6 RELAY M-7 RELAY M-8 RELAY M-9 RELAY M VAC POWER IN COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC 7A 6A 16 CC1 12A LLS 1 UL4-1 15A UL3-1 14A CC2 12B LLS 2 UL4-2 15B UL3-2 14B 1 230VAC POWER SUPPLY 230Vac -1PH - 50/60Hz 2 GEN ALARM COMPRESSOR 1 1st CONTACTOR LIQ LINE 1 SOL COMPRESSOR 1 2nd CONTACTOR OR DELTA & WYE CONTACTOR POWER INCREASE COMP1 SOLENOID POWER DECREASE COMP1 SOLENOID HOT GAS BY PASS SOLENOID COMPRESSOR 2 1st CONTACTOR LIQ LINE 2 SOL COMPRESSOR 2 2nd CONTACTOR OR DELTA & WYE CONTACTOR POWER INCREASE COMP2 SOLENOID POWER DECREASE COMP2 SOLENOID ** SEE EEVB CONNECTION DETAILS WHITE BLACK + - GND + - GND Termination Termination ETHERNET + - GND USER INTERFACE BOARD (UIB) NOTE: 1. Refer to page 31 for legend, notes & wiring diagram of optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram. 29 GE_AASC_Series.indd 29 3/26/12 5:21 PM

32 WHITE BLACK TYPICAL SCHEMATIC WIRING DIAGRAM SB1 (MCS-SI16-230) SUCT2 PRESS DISCH2 PRESS SUCT2 TEMP DISCH2 TEMP COMP2 AMP SSPS2 COMP2 PROOF COMP CB 28B RED BLCK/SHIELD 29B WHITE 30B RED BLCK/SHIELD 31B WHITE 22B BLACK SHIELD 23B WHITE CB BLACK SHIELD DB WHITE SSPS2 8B 8BB +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI +5 GND SI HPS2 OLR2 +5 GND SI +5 GND SI Communications to MB (MCS-MAGNUM) Communications to SB2 (MCS-RO8) WHITE BLACK + - GND Termination 230 VAC POWER IN 1 230VAC 2 POWER SUPPLY 230Vac -1PH - 50/60Hz SB2 (MCS-RO8-230) LIQUID INJECTION 1 SOLENOID LI 1 20A COM NO NC RELAY 1-1 RELAY 1-5 COM NO NC 20B LI 2 LIQUID INJECTION 2 SOLENOID FAN 5 FAN 3 FAN 7 FAN 9 FAN 1 FMC1 FMC2 FMC3 FMC4 FMC TK5 TK3 TK7 118 TK9 18A 19A 110 TK1 21A COM NO NC COM NO NC COM NO NC RELAY 1-2 RELAY 1-3 RELAY 1-4 RELAY 1-6 RELAY 1-7 RELAY 1-8 COM NO NC COM NO NC COM NO NC 19B 21B 18B TK6 TK4 TK8 TK10 TK FMC6 FMC7 FMC8 FMC9 FMC10 FAN 6 FAN 4 FAN 8 FAN 10 FAN 2 Communications to SB1 (MCS-SI16) + - GND Termination 230 VAC POWER IN 1 230VAC 2 POWER SUPPLY 230Vac -1PH - 50/60Hz MB (MCS-MAGNUM) RELAY M-6 COM NO NC 230 VAC HGBP 15 HOT GAS BY PASS MB (MCS-MAGNUM) SOLENOID COMP AMP1 102A CT1 103A +5 GND SI EXTERNAL DEVICE HTR1 HEATER TAPE SB1(MCS-SI13-230) SETTING TEMP = 36degF 230 VAC COMP AMP2 CT2 102B 103B +5 GND SI NOTE: 1. Refer to next page for legend, notes & wiring diagram of optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram. 30 GE_AASC_Series.indd 30 3/26/12 5:21 PM

33 TYPICAL SCHEMATIC WIRING DIAGRAM COMP1 COMP2 CONTROL PANEL LEGEND CONTROL PANEL FAN1 FAN2 FAN3 FAN4 COMP1 FM FAN5 FAN7 FAN6 FAN8 COMP2 FM MB (MCS-MAGNUM) RELAY M-3 RELAY M-8 HPS1 OLR1 12B CB2A-1 CB4A-1 CCA4-1A 22B 23B 110B COMP2 PROOF COMP CB 110BB HPS2 OLR2 RELAY M-3 RELAY M-8 COMP1 PROOF COMP CB HPS1 OLR1 HPS1 HPS2 MB (MCS-MAGNUM) COM NO NC COM NO NC CB1A-1 HPS1 12A OLR2A-1 OLR4A-1 10B 11B 9B 9BB 12A 12B CC1A-1 CC2A-1 CB1A-1 CB3A-1 CCA3-1A 22A 23A 110A COMP1 PROOF COMP CB 110AA OLR1A-1 OLR3A-1 10A 11A 9A COM NO NC COM NO NC CC5A-2 CC3A VAC CC6A-2 CC4 61B CC4A-2 22A 10A 230 VAC 61A 230 VAC 61B 230 VAC 61A 62A 62B CCA3-1A OLR1A-1 CC3 CC4 9AA CC3 CC5 CC6 MB (MCS-MAGNUM) SB1(MCS-SI13-230) 110A 110AA 11A 9AA 2 +5 GND SI +5 GND SI +5 GND SI +5 GND SI 2 2nd CC FOR COMP #1 2nd CC FOR COMP #2 +5 GND SI +5 GND SI DELTA CC FOR COMP #1 WYE CC FOR COMP #1 DELTA CC FOR COMP #2 WYE CC FOR COMP #2 MB (MCS-MAGNUM) SB1(MCS-SI13-230) CB CIRCUIT BREAKER COM P C OMPRESSOR CC COMPRESSOR CONTACTO R CC A C OMPRESSOR CONTACTOR AUXILIARY CWP CHILLED PUMP DISC H DISCHARG E ETB EARTH TERMINAL BLOCK EE V E LECTRONIC EXPANSIOV VALV E EEVB ELECTRONIC EXPANSIOV VALVE BOAR D EXEN REMOTE ENABLE/DISABLE F F US E FL S F LOW SWITCH FM FAN MOTOR FMC FAN MOTOR CONTACTO R GND ELECTRICAL GROUNDING HPS HIGH PRESSURE SWITCH HGBS HOT GAS BYPASS SOLENOID HTR COMPRESSOR CRANKCASE HEATER HVTB HIGH VOLTAGE TERMINAL BLOCK HZ HERTZ (ELECTRICAL FREQUENCY) L... LINE (ELECTRICAL POWER LINE/PHASE ) LI LIQUID INJECTION SOLENOID LLS LIQUID LINE SOLENOID LWT L EAVING TEMPERATURE MB MASTER BOARD MC S MICROPROCESSOR CONTROL SYSTE M NTB NEUTRAL TERMINAL BLOC K OLR OVER LOAD RELAY PT PRESSURE TRANSDUCER PH PHASE (ELECTRICAL PHASE) RWT RETURN TEMPERATUR E SB SLAVE BOAR D S1 CONTROL SWITCH SSP S S OLID STATE PROTECTION SYSTEM SUCT SUCTIO N TK FAN MOTOR THERMAL CONTAC T TRANS TRANSFORMER TS TEMPERATURE SENSOR UL UNLOADER UVM UNDER VOLTAGE MONITO R UVR UNDER VOLTAGE RELA Y TERMINAL BLOCK OR TERMINATION POIN T FIELD WIRING * FIELD SUPPL Y TERMINATION JUMPER IS CLOSED TERMINATION JUMPER IS OPEN NOTES 1. POWER SUPPLY, 380/415V-3Ph-50Hz. ALL FIELD WIRING TO COMPLY WITH LOCAL CODES. 2. FUSES TO DUAL ELEMENT TYPE. 3. USE COPPER CONDUCTORS ONLY. 4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH RATING AS RECOMMENDED BY MANUFACTURER. 5. POWER MUST BE SUPPLIED TO CRANKCAS E HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP. IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFOR E OPERATING THE SYSTEM. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE. 6. MARK THE BOX AT THE UPPER RIGHT CORNER OF THE RESPECTIVE OPTIONAL ITEM, IF THE OPTIONA L ITEM IS INCLUDED IN THE UNIT. COMP2 PROOF COMP CB HPS2 OLR2 CB2A-1 HPS2 CCA4-1A 22B OLR2A-1 10B 110B 110BB 11B 9BB +5 GND SI +5 GND SI 31 GE_AASC_Series.indd 31 3/26/12 5:21 PM

34 MICROPROCESSOR CONTROLLER SEQUENCE OF OPERATION For Initial start up of the unit, the following conditions must be met: 1. Power to the unit shall be continuously energized for 12 hours minimum. 2. Control power has been accomplished and the display shows no alarm. 3. All safety conditions are satisfied. 4. Chilled water pump is running normal and chilled water flow switch contact is closed. 5. Customer control or remote on/off is switched to run mode, if any. Staging ON and OFF sequence is accomplished based on the controlled water temperature. Using the stepless compressor capacity control (called slider), the controller will drive the slider to maintain the required demand as constant as possible. COMPRESSOR STAGE ON SEQUENCE Stage-1: If the controlled water temperature is above the water temperature set point the first compressor or the compressor with less running hours will start by unloading for certain second. A erwards, slider will move then to part load or to full capacity of the compressor depends upon the required load demand of the unit. As the discharge pressure of the running compressor rises, the corresponding fan will turn ON accordingly to its fan stage ON set point. If the discharge falls below the fan stage OFF set point value, the corresponding fan then will turn OFF. Stage-2: nd A er such time delay. If the controlled water temperature is still above from the water temperature set point. The 2 compressor or the next less running hours compressor will start by unloading for certain time. Then the slider will move to part load or to full capacity of the compressor depends upon on the load demand of the unit. As the discharge pressure of the 2 nd compressor rises, the corresponding fan at the nd 2circuit will turn ON accordingly to its fan stage ON set point. If the discharge falls below the fan stage OFF set point value, the corresponding fan then will turn OFF. For the unit with more than two refrigerant circuits, all compressor staging will be the same as illustrated above. For the unit with one circuit, the staging will based from the part load to the full capacity of the compressor. COMPRESSOR STAGE OFF SEQUENCE During the staging OFF, the FIFO (First-In First-Out) sequence is adopted as standard. If the compressor equalization is not activated the LIFO (Last-In First-Out) then will be adopted. As the demand load decreases and when the water temperature falls below the water temperature set point. The first compressor or the compressor with most running hours will then start unloading. If the water temperature continuously falls below the set point the first compressor then will turn OFF. If the water temperature still below the set point the next compressor with most running hours will start unloading, then OFF. 32 GE_AASC_Series.indd 32 3/26/12 5:21 PM

35 MICROPROCESSOR CONTROLLER The controller consists of the following hardware: 1. User Interface Board (UIB): the display board LCD with user friendly control push buttons. 2. Main Board Controller: Equipped with advanced logic to safely operate the chiller and run at its most efficiency. 3. Auxiliary Board Controller: Only when applicable, this serves as an extension of analog and digital I/O s. 4. Electronic Expansion Valve Board: Communicate with the Main Board to control the electronic expansion valve at its high efficient and performance. 5. Sensors: The devices that feeding inputs to the controller. Display Information: Easily accessible measurements for unit and each circuit include the following: 1. Circuit suction and discharge pressure 2. Circuit suction and discharge temperature 3. Leaving and return water temperature 4. Compressor amps percentage 5. Compressor status 6. Compressor drawn Ampere 7. Fan status 8. Solenoid status 9. Expansion Valve status 10. Circuit Suction and Discharge Superheat value 11. Current Unit Cooling Capacity Status 12. Current Circuit Cooling Capacity Status 13. Ambient Temperature (optional) 14. Lockouts and 60 History of Alarms 15. Target temperature set point 16. Sensor input/output set up 17. Real Time Graphical Display 18. Analog and Digital Input/output Status 19. Circuit Suction and Discharge Saturated Value 20. Unit Cooling and Expansion Valve Rate of Change System Protection: The following system protection is provided to insure system reliability: Chiller Unit Standard Lockouts: 1. Freeze Protection 2. No Water Flow Protection 3. Phase Loss Protection 4. Over and Under Voltage Protection 5. Serial Communication Error Compressor Circuit Safeties and Lockouts: 1. Compressor Motor Winding Overheating 2. Low Suction Pressure 3. High and Low Discharge Pressure 4. High Discharge Temperature 5. High and Low Motor amps 6. Sensors Error 7. Anti recycle time delay for compressor 33 GE_AASC_Series.indd 33 3/26/12 5:21 PM

36 MICROPROCESSOR CONTROLLER Microprocessor Control System (MCS) Main Feature provides the following: 1. A special software was been developed for air cooled chiller application with screw compressors. 2. Compressor Lead / Lag operation. This is to balance the run hours operation of every compressor in the chiller unit. 3. The user interface board is having 9 user friendly push buttons with simple identification for easy accessing the data and information from the display. 4. The controller is equipped with self diagnostic functions. That in case of any errors, it will give an alarm and shut off only the affected circuit or the whole unit if necessary. The full description of the alarm/error is visible in the display. 5. A special control zone based on the Leaving or Return Water Temperature that leads the compressor function to maintain the unit capacity at its target set point. 6. A flexible authorization levels is available. This is to maximize the security on the control system. 7. Thru Volt free contact, the chiller unit can be remotely enable/disabled. 8. Energy efficient compressor staging for multi screw compressor chiller unit. This provides the user with additional capabilities in fine tuning the efficiency of the screw compressor. 9. Adaptive capacity control where the controller takes the necessary corrective action when reached at critical status of temperature or pressure in the circuit prior to a safety being tripped. 10. Compressor ampere is monitored continuously by the controller, for safety operation and its properly locates the position of the compressor slider. 11. BMS protocol like Bacnet, Modbus, Johnson Control and Lonworks are available, it can configure from the controller set up menu and can be connected thru its available port in the controller board. 12. A windows based program (MCS-Connect) was installed to monitor and access all data at the microprocessor using a windows based computer for easy servicing. 13. In an occurrence of lockouts/alarm, the last reading of every sensors are logged in the microprocessor and it can be viewed using the UIB or a PC. 14. Seven days operating schedule plus holidays can be encoded or programmed to the controller to ON and OFF the chiller unit accordingly. 15. Components are UL approved as standard. 16. The controller automatically performs a 144 data logging of all I/Os signal and saved it into the microprocessor; this logged data can be presented using its built in graphing function. 34 BMS Interfacing (optional): A standard on board RS-485 port is provided for interfacing with building management system as well as to communicate both locally and remotely. For more interfacing connectivity also a RS-232 and Ethernet port was provided as standard. The controller can be interfaced to different protocol like Bacnet, Modbus, Johnson Control and Lonworks. Controller network can support 20 Main Boards and its associated inputs/outputs using the RS-232 or RS-485 connection. Note that RS-232 transmissions should not exceed 50 feet in length and for RS-485 transmission should not exceed 1 mile. Part of the BMS features. Is the MCS-Connect, this is a PC- support so ware that was available at the controller. With this features, all the points of each individual refrigerant circuits and unit status, alarms, set points, analog and digital inputs / outputs can be viewed. Also the controller configuration on the chiller unit can be easily done using a local or remote PC. PC minimum system requirements to run the program: Windows 2000; Pentium 1.0 MHz or Faster; 40 GB Hard drive; 256 RAM; 56k Modem & VGA display capable for 256 color. MCS also provides the Volt free contact connection for BMS: 1. Remote Unit Run and Stop Enable remotely enable/disable the chiller unit thru volt free contact from the field. 2. General Alarm a volt free contact from the controller that closes when a chiller unit indicates a problem. 3. Emergency Stop a volt free contact when closes from remote it enable the chiller unit to immediately shut down in case of emergency situation. 4. Compressor Run Status This is a relay output closure from the controller board to the BMS indicating the compressor is running. 5. Chiller Water Reset An analog input (0 to 5 V) supplied to the board from the BMS. A reading of 2.5V will result in a zero adjustment. A reading of less than 2.5V will result for a negative adjustment, and a greater then 2.5V will result in a positive adjustment. GE_AASC_Series.indd 34 3/26/12 5:21 PM

37 APPLICATION GUIDELINES INTRODUCTION These guidelines should be considered when designing systems and their installation utilizing GE AASC series liquid chillers. Stable operation, performance and reliability of units is offen dependent upon proper compliance with these recommendations. When any application varies from these guidelines, it should be referred with GE Air Conditioners for specific recommendations. UNIT SELECTION/SIZING Unit selection procedure and capacities are provided in this catalog for proper selection. The GE electronic selection program may also be utilized for this purpose. Over sizing chillers beyond a maximum limit of 5 10 % in order to assure adequate capacity or considering future expansions is not recommended. Over sizing adversely affects the operating efficiency due to erratic system operation and excessive compressor cycling which also results in reduced compressor life. It should be noted that, units operate more efficiently when fully loaded rather than larger equipment operating at partial capacities. In addition, an oversized unit is usually more costly to purchase, install and operate. When over sizing is desired due to anticipation of future plant expansion, consider using multiple units. For example, install a single chiller for the present load requirement and install a second chiller for the foreseen additional load demand due to expansion. Further, it is also recommended that installing two chillers instead of a single chiller be considered in applications where partial load operation at low capacities is necessary. Operation of two chillers at higher loading is preferred to operating a single chiller at or near its minimum possible capacity. FOULING FACTOR AND REQUIREMENT The tabulated performance data provided in this catalog are based on a fouling factor of hr-ft 2 - F/Btu ( m 2 - C/W). As fouling factor is increased, unit capacity decreases and power input increases. For unit selection at other fouling factors, apply appropriate correction factor from the table provided in this catalog. These chillers are suitable for operation with well maintained water systems. Using unclean and untreated water may result in scale and deposit formation causing reduced cooler efficiency or heat transfer and corrosion or pitting leading to possible equipment damage. The more scale forming material and suspended solids in the system water, the greater the chances of scale and deposit formation and fouling. These include calcium, magnesium, biological growth (algae, fungi and bacteria), dirt, silt, clays, organic contaminants (oils), silica, etc. which should be kept to the minimum to retard scale and deposit formation. In order to prevent corrosion and pitting, the ph value of the water flowing through the cooler must be kept between 7 and 8.5. GE recommends that a water treatment specialist is consulted to provide and maintain water treatment, this is particularly critical with glycol systems. EFFECT OF ALTITUDE ON UNIT CAPACITY The tabulated performance data provided in this catalog are for use at or near sea level altitude application. At altitudes substantially above sea level, the decreased air density will reduce condenser capacity and therefore unit capacity. For unit selection at these higher altitudes, apply appropriate correction factor from the table provided in this catalog. HIGH AMBIENT CONSIDERATION These chillers are designed for year round operation over a range of ambient temperatures. As a standard, these chillers can start and operate satisfactorily up to 125 F (52 C) ambient temperature at rated nominal voltage. RATES AND COOLER PRESSURE DROP The maximum and minimum water flow rates for all unit models and the pressure drop chart are provided in this catalog. The design water flow rate must be within this range. Design flow rates below the minimum limits will result in laminar flow causing freeze-up problems, stratification and poor control and flow rates beyond the maximum limits cause excessive pressure drop and severe tube erosion. During unit operation, water flow rate must not vary more than ± 5% from the design flow rate. The water flow switch should be calibrated accordingly. The piping and pumping layout should be right for the application and must assure proper water return and circulation. When using glycol solution, flow rate and pressure drop are higher than with water, therefore care must be taken not to exceed the limits. In such applications, consult GE Air Conditioners for specific recommendations. 35 GE_AASC_Series.indd 35 3/26/12 5:22 PM

38 APPLICATION GUIDELINES COOLER FLUID ( OR GLYCOL) TEMPERATURES RANGE Unit can start and pull down from 95 F (35 C) entering fluid temperature. The design leaving chilled fluid temperature (LCWT) range as mentioned earlier in the tabulated performance data is 40 to 50 F. The design entering chilled fluid temperature range is 50 to 60 F. The design cooler temperature drop (ΔT) range is 5 to 15 F. The tabulated performance data provided in this catalog is based on a chilled water temperature drop of 10 F. Units may be operated at any desired temperature drop within the range of 5 to 15 F as long as the temperature and flow limits are not violated and appropriate correction factors are applied on the capacity and power input. The GE electronic selection program can be very handy in selecting equipment at different temperature drops. It should be noted that temperature drop outside the aforesaid range is not permitted as it is beyond the optimum range of control and could adversely affect the functioning of microprocessor controller and may also prove to be detrimental for the equipment. RATES AND/OR TEMPERATURES OUT OF RANGE Certain applications (particularly process cooling jobs) call for flow rates and/or water temperatures that are outside the above mentioned limits/range. Our chillers can be utilized for these applications by selecting the chiller based on the specific process load and making a suitable piping and mixing arrangement in order to bring the flow rates and/or water temperatures relevant to the chiller within acceptable limits. Example 1: An application requires 240 GPM of water at 45 F and the return water temperature is 65 F. A standard chiller can be used for this application as shown in the following basic schematic layout (single mixing arrangement). 45 F 500 GPM 45 F 240 GPM 200 TR Chiller 45 F 260 GPM Load 200 TR 54.6 F 500 GPM Example 2: 65 F 240 GPM An application requires 192 GPM of water at 65 F and the return water temperature is 80 F. A standard chiller can be used for this application as shown in the following basic schematic layout (dual mixing arrangement). 45 F 340 GPM 45 F 82.2 GPM 65 F 192 GPM 120 TR Chiller 45 F GPM 80 F GPM Load 120 TR 53.4 F 340 GPM 53.4 F 340 GPM 80 F 82.2 GPM 80 F 192 GPM 36 GE_AASC_Series.indd 36 3/26/12 5:22 PM

39 APPLICATION GUIDELINES COOLER FREEZE PROTECTION If the unit is located in an area where ambient temperatures fall below 32 F (0 C), cooler protection in the form of Ethylene Glycol Solution is required to protect the cooler and fl uid 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 diff erence of 15 F (8.3 C) below minimum operating ambient temperature. Using this glycol solution causes a variation in unit performance, fl ow 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 off er the advantage of operational fl exibility, standby capacity and less disruptive maintenance. Also, they off er some standby capacity if repair work must be done on a chiller from a set of duty chillers. Starting in-rush current is reduced, as well as power costs at partial-load conditions. A multiple chiller arrangement should be provided if the system load is greater than a single chiller capacity, standby capability is desired, large temperature drop (greater than 15 F) is desired or application calls for splitting the total capacity for better part load operation. In designing a multiple chiller plant, units of same size should be preferred over diff erent sizes to facilitate balanced water fl ow. It is mandatory that cooler fl ow rates must be balanced to ensure proper fl ow to each chiller based on its respective capacity. As mentioned above, two basic multiple chiller systems are used: parallel and series chilled water fl ow. 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 baffl es 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 fl ow 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. GE recommends the parallel arrangement for design temperature drops (ΔT) up to 15 F and the series arrangement beyond that i.e., 16 to 20 F. Complete design details on these parallel and series chilled water fl ow 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 confi guration of building, energy economics, fl exibility, installation requirements and others to determine the best arrangement for his project. In all cases, it must be ensured that the design water fl ow is constantly maintained through the chillers at all stages of operation. Some suggested arrangements with basic schematic layouts are as follows: 37 GE_AASC_Series.indd 37 3/26/12 5:22 PM

40 APPLICATION GUIDELINES A. Single or multiple chillers with constant water fl ow through chillers and load system: CHWS Chiller Load Load 3-Way Valve 3-Way Valve CHWR Constant Speed Pump In this type of arrangement, constant water fl ow through the chillers and load distribution piping circuit is maintained. Before proceeding further, a brief explanation on the operation of a typical chilled water system / valves which is fundamental to the design or analysis of a system. Where multiple zones of control are required, the various load devices are controlled fi rst; 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 fl ow through the load device. Control valves for these applications are two-way (straight-through) and three-way valves. The eff ect of either valve is to vary the amount of water fl owing through the load device. With a two-way valve, as the valve strokes from full-open to full-closed, the quantity of water fl owing through the load gradually decreases from design fl ow to no fl ow. The three-way mixing valve has the same eff ect on the load as the two way valve as the load reduces, the quantity of water fl owing through the load decreases in proportion to the load and the diff erence amount is directed through a bypass. In terms of load control, a two-way valve and a three-way valve perform identical functions they both vary the fl ow through the load as the load changes. The fundamental diff erence 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 fl ow load response and the three-way valve provides a constant fl ow load response. Referring to the foregoing schematic layout, this is a conventional system and is not as energy effi cient as the two-way valve systems especially on the pumping side due to constant water circulation in the system. On multiple chiller installations, pumps are required to operate continuously and the sequencing of chillers is dependent on water temperatures. 38 GE_AASC_Series.indd 38 3/26/12 5:22 PM

41 APPLICATION GUIDELINES B. Single or multiple chillers with constant water flow through chillers and variable water flow through load system (primary/secondary pumping arrangement): A CHWS Variable Speed Secondary Pump Chiller Load Load Flow Sensor P 2-Way Valve 2-Way Valve Constant Speed Primary Pump B CHWR System Controller This system is called a Primary Secondary System and in this arrangement, the generation zone is separated from the transportation or distribution zone. In this type of arrangement also, constant water flow through the chillers is maintained, however the quantity of water flowing through the load distribution pump/piping system decreases in proportion to the load and the difference amount is directed through a bypass pipe that connects the supply and return headers. This bypass pipe forms a Hydraulic Coupling between the points A B and is also called as Common Bridge or Decoupling Line. The sequence of operation is similar as the foregoing system with the following explanation: The speed of the secondary chiller pump is controlled by the differential pressure sensor/transmitter, maintaining the desired differential pressure (ΔT) 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 chillerpump 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 chillerpumps, return water is forced through the bypass into the supply header. This flow indicates a need for additional chiller capacity and another chiller-pump starts. Excess bypass flow with reference to the set points in the system controller in the opposite direction i.e., into the return header indicates overcapacity and the chiller-pumps are turned off. Energy is saved because the system head and water flow rate are reduced on the Secondary Pump when there are partial cooling loads on the system and due to cycling of Primary Pumps. UNIT LOCATION AND INSTALLATION These chillers are designed for outdoor installation and can be installed at ground level or on a suitable roo op location. In order to achieve good operation, performance and trouble-free service, it is essential that the proposed installation location and subsequent installing procedures meet the following requirements: The most important consideration while deciding upon the location of air cooled chillers is the provision for supply of adequate ambient air to the condenser and removal of heated discharge air from the condenser. This is accomplished by maintaining sufficient clearances which have been specified in this Catalog around the units and avoiding obstructions in the condenser air discharge area to prevent the possibility of warm air circulation. Further, the condenser fans are propeller type and are not recommended for use with ductwork or other hindrances in the condenser air stream. Where these requirements are not complied, the supply or discharge airflow restrictions or warm air recirculation will cause higher condensing temperatures resulting in poor unit operation, higher power consumption and possible eventual failure of equipment. 39 GE_AASC_Series.indd 40 3/26/12 5:22 PM

42 APPLICATION GUIDELINES The unit s longitudinal axis should be parallel to the prevailing wind direction in order to ensure a balanced air flow through the condenser coils. Consideration should also be given to the possibility of down-drafts caused by adjacent buildings, which may cause recirculation or uneven unit airflow. For locations where significant cross winds are expected, an enclosure of solid or louver type is recommended to prevent wind turbulence interfering with the unit airflow. When units are installed in an enclosure, the enclosure height should not exceed the height of the unit. The location should be selected for minimum sun exposure and away from hot air sources, steam, exhaust vents and sources of airborne chemicals that could attack the condenser coils and steel parts of the unit. Avoid locations where the sound output and air discharge from the units may be objectionable. If the location is an area which is accessible to unauthorized persons, steps must be taken to prevent access to the unit by means of a protective fence. This will help to prevent the possibility of vandalism, accidental damage or possible harm caused by unauthorized removal of panels or protective guards exposing rotating or high voltage components. The clearance requirements prescribed above are necessary to maintain good airflow and provide access for unit operation and maintenance. However, it is also necessary to consider access requirements based on practical considerations for servicing, cleaning and replacing large components. The unit must be installed on a ONE-PIECE, FLAT and LEVELLED {within 1/2 (13 mm) over its length and width} / CONCRETE BASE that extends fully to support the unit. The carrying or supporting structure should be capable of handling complete operating weight of the unit as given in the Physical Data tables in this Catalog. For ground level installations, it must be ensured that the concrete base is stable and does not settle or dislocate upon installation of the unit which can strain the refrigerant lines resulting in leaks and may also cause compressor oil return problems. It is recommended that the concrete slab is provided with appropriate footings. The slab should not be connected to the main building foundation to avoid noise and vibration transmission. For rooftop installations, choose a place with adequate structural strength to safely support the entire operating weight of the unit. The unit shall be mounted on a concrete slab similar to ground installations. The roof must be reinforced for supporting the individual point loads at the mounting isolator locations. It must be checked and ensured that the concrete base is perfectly horizontal and levelled, especially if the roof has been pitched to aid in water removal. It should be determined prior to installation if any special treatment is required to assure a levelled installation else it could lead to the above mentioned problems. Vibration isolators are necessary for installing these chillers in order to minimize the transmission of vibrations. The two types of vibration isolators generally utilized for mounting these units are Neoprene Pads and Spring Isolators. Neoprene Pads are recommended for ground level normal installations jobs where vibration isolation is not critical and job costs must be kept to a minimum. Spring Isolators are recommended for ground level installations which are noise- sensitive areas or exposed to wind loads and all roof top installations. For critical installations (extremely noise and vibration sensitive areas), follow the recommendations of structural and acoustical consultants. Based on the specific project requirements, choose the type of vibration isolators best suited for the application. Carefully select the vibration isolators models / configuration based on the respective point loads and place each mount in its correct position following the Load Distribution Data and Mounting Drawings provided in this Catalog. Refer to the Schematic Mounting Layout drawings provided in the IOM manual of these chillers for further details in this regard. COOLER PIPING CONNECTIONS The following pertinent guidelines are served to ensure satisfactory operation of the units. Failure to follow these recommendations may cause improper operation and loss of performance, damage to the unit and difficulty in servicing and maintenance: Water piping must be connected correctly to the unit i.e., water must enter from the inlet connection on the cooler and leave from the outlet connection. A flow switch must be installed in the field piping at the outlet of the cooler (in horizontal piping) and wired back to the unit control panel using shielded cable. There should be a straight run of piping of at least five pipe diameters on either side of the flow switch. Paddle type flow switches can be obtained from GE which are supplied as optional items. The chilled water pump(s) installed in the piping system should discharge directly into the unit cooler. The pump(s) may be controlled external to the unit - but an interlock must be wired to the unit control panel (as shown in the wiring diagram) so that the unit can start only upon proof of pump operation. 40 GE_AASC_Series.indd 41 3/26/12 5:22 PM

43 APPLICATION GUIDELINES Flexible connections suitably selected for the fluid and pressure involved should be provided as mandatory in order to minimize transmission of vibrations to the piping / building as some movement of the unit can be expected during normal operation. The piping and fittings must be separately supported to prevent any loading on the cooler. The cooler must be protected by a strainer, preferably of 20 mesh, fitted as close as possible to the liquid inlet connection, and provided with a means of local isolation. Thermometer and pressure gauge connections should be provided on the inlet and outlet connections of each cooler. Pressure gauges are recommended to check the water pressure before and after the cooler and to determine if any variations occur in the cooler and system. When installing pressure taps to measure the amount of pressure drop across the water side of the cooler, the taps should be located in the water piping a minimum of 24 inches downstream from any connection (flange etc.) but as near to the cooler as possible. Drain and air vent connections should be provided at all low and high points in the piping system to permit complete drainage of the cooler and piping as well as to vent any air in the pipes. Hand shut-off valves are recommended for use in all lines to facilitate servicing. The system water piping must be flushed thoroughly before connecting to the unit cooler. The cooler must not be exposed to flushing velocities or debris released during flushing. It is recommended that a suitably sized bypass and valve arrangement is installed to allow flushing of the piping system. The bypass can be used during maintenance to isolate the cooler without disrupting flow to other units. The following is a suggested piping arrangement at the chiller for single unit installations. For multiple chiller installations, each unit should be piped as shown: OUT IN Isolating Valve - Normally Open Isolating Valve - Normally Closed Pressure tapping Flow Switch Balancing Valve Connection ( anged / Victaulic) Flow meter Pipe work Strainer Flexible connection Note: For chillers with two coolers, the connecting pipes for entering and leaving water on one cooler must be joined to the corresponding pipes on the other cooler before connecting to the main headers in the system piping. 41 GE_AASC_Series.indd 42 3/26/12 5:22 PM

44 APPLICATION GUIDELINES 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 AASC100B operating with a design water flow rate of 205 GPM for a standard air conditioning application would require 100 (Nom. Cap.) x 3 = 300 Gallons of water in the piping system loop. To achieve the aforementioned water volume requirements, it may be necessary to install a tank in the piping system loop to increase the volume of water in the system and therefore, reduce the rate of change of return water temperature. This tank should be provided on the return water side to the chiller and the tank should be baffled to ensure that there is no stratification and the entering stream thoroughly mixes with the tank water. See recommended tank design schematics below: TANK SCHEMATIC SUGGESTIONS ON SYSTEM DESIGN AND PIPING PRACTICES The prospective chilled water system should be designed to the specific requirements of the owner and to achieve the most efficient system possible. Following are some recommendations: The first decision a designer of a chilled water system must make is the selection of the temperature differential. Temperature differential is the difference between the supply water and the return water temperatures. There is no one temperature difference for all chilled water systems. The actual temperature difference that is selected for a specific installation is determined by the cost of the cooling coils for various temperature differences and the effect that higher differences may have on the operating cost of the chillers. A careful balance between energy savings and first cost should be made by the designer. These are the decisions that must be made by the designer for each application and only experienced designers should entertain water temperature differences in excess of 12 F on chilled water systems. A number of conditions must be recognized before making the final selection of temperature differential: a) An increase in temperature differential decreases water flow and therefore saves pumping energy. b) An increase in temperature differential may increase the cost of cooling coils that must operate with a higher mean temperature difference. c) Higher temperature differentials increase the possibilities of loss of temperature difference in coils due to dirt on the air side and chemical deposits on the water side of them. d) Laminar flow on the water side due to lower velocities at low loads on a coilisal ways 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. 42 GE_AASC_Series.indd 43 3/26/12 5:22 PM

45 APPLICATION GUIDELINES Control of Return Water Temperature: Return water temperature is one of the most important operating values for a chilled water system. It tells the operator just how good a job the control system and coils are doing in converting energy from the chillers to the air or water systems that are cooling the building. This is such a basic criterion that it should be addressed early in the design of a chilled water system. The proper method of controlling return temperature is through the correct selection of control valves and cooling coils. In conclusion, one of the designer s most important tasks is the selection of a sound temperature differential that will provide maximum possible system efficiency. The second step in this process is to ensure that the differential is maintained after the system is commissioned. The water system should be configured to distribute the water efficiently with a minimum use of energy-wasting devices. These devices are listed here: a) Three-way temperature control valves. b) Balancing valves, manual or automatic. c) Pressure-reducing or pressure-regulating valves. The piping should be designed without: a) Reducing flanges or threaded reducing couplings. b) Bullhead connections (e.g., two streams connected to the run connections of a tee with the discharge on the branch of the tee). The friction for the piping should be calculated for all pipe runs, fittings and valves. Cooling coils should be selected with a high enough water velocity in the tubes to avoid laminar flow throughout the normal load range imposed on the coils. Coil control valves and their actuators should be sized to ensure that they can operate at all loads on the system without lifting the valve head off the valve seat. Expansion tank should be provided to so that water volume changes can be accommodated. Expansion tanks are generally connected to the suction side of the pump - lowest pressure point. Pumps in parallel must always operate at the same speed. There may be some exceptional cases where parallel pumps are operated at different speeds, but only experienced designers should make evaluations for such a proposed operation. Also, it is better to use pumps of the same size when operating them in parallel. Variable speed pumps should be controlled so that pumps operating in parallel never have more than one percent difference in actual operating speed. Mixing of constant and variable speed pumps in parallel operation is wrong and leads to disastrous results. Distribution pumps should be selected for maximum efficiency at the design condition and within the economic constraints of the project. Distribution pumps should be added and subtracted to avoid operation of pumps at points of high thrust and poor efficiency. Pump sequencing should achieve maximum possible system efficiency. Differential pressure control (bypass) valves should never be installed at the pump discharges. Check valves should be provided in pump discharges when pumps are operating in parallel. Pump discharge check valves should be center guided, spring loaded, disc type check valves and should be sized so that the check valve is full open at design flow rate. Generally this will require the check valve to be one pipe size smaller than the connecting piping. Circuiting Chilled water to Multiple Chillers : There are fundamentals for the circuiting of chillers that should not be violated in order to achieve maximum efficiency. Some of these are: a) Design the piping arrangement so that energy consumption of chillers is not increased. b) Arrange the piping so that all chillers receive the same return water temperature. c) Ensure that the required design water flow through the coolers is always maintained. 43 GE_AASC_Series.indd 44 3/26/12 5:22 PM

46 RIGGING INSTRUCTIONS ATTENTION TO RIGGERS Hook rigging sling thru holes in base rail, as shown below. Holes in base rail are centered around the unit center of gravity. Center of gravity is not unit center line. Ensure center of gravity aligns with the main li ing point before li ing. 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. LIFT MODELS: AASC055B - AASC215B SPREADER BAR LIFT PROPER CLEARANCE TO BE PROVIDED LIFT MODELS: AASC240B - AASC330B SPREADER BAR LIFT PROPER CLEARANCE TO BE PROVIDED MODELS: AASC350B - AASC445B SPREADER BAR PROPER CLEARANCE TO BE PROVIDED 44 GE_AASC_Series.indd 45 3/26/12 5:22 PM

47 INSTALLATION CLEARANCE WALL MODEL NUMBER A B AASC055B - AASC110B AASC120B - AASC215B AASC240B - AASC445B FIGURE - 1 STRAIGHT WALL FIGURE - 2 CORNER WALL NOTE: 1. All dimensions are in mm. 2. Pit installations are not recommended. Re-circulation of hot condenser air in combination with surface air turbulence can not be predicted, hot air re-circulation will severely affect unit efficiency (EER) and can cause high pressure or fan motor temperature trips. 45 GE_AASC_Series.indd 46 3/26/12 5:22 PM

48 MOUNTING LOCATION MODELS: AASC055B - AASC070B MODELS: AASC075B - AASC140B MODEL A AASC075B 1312 AASC090B 1922 AASC100B 1922 AASC110B 1922 AASC120B 1922 AASC130B 1922 AASC140B 1922 MODELS: AASC150B - AASC215B MODELS: AASC240B - AASC330B MODELS: AASC350B - AASC445B NOTE: All dimensions are in mm. 46 GE_AASC_Series.indd 47 3/26/12 5:22 PM

49 LOAD DISTRIBUTION, KG. (ALUMINUM CONDENSER COIL) MODEL No. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC ` AASC AASC R1 R2 R1 R3 R4 R6 47 GE_AASC_Series.indd 48 3/26/12 5:22 PM

50 LOAD DISTRIBUTION, KG. (COPPER CONDENSER COIL) MODEL No. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC AASC R1 R2 R1 R3 R4 R6 48 GE_AASC_Series.indd 49 3/26/12 5:22 PM

51 Middle East Air Conditioners Co. Ltd. Middle East Air Conditioners Co. Ltd. P.O. Box Dammam KSA Kingdom of Saudi Arabia Tel: Fax: GE_AASC_Series.indd 50 3/26/12 5:22 PM