TW series - Zamil Air Conditioners

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Central Station
Double Skin
Air Handling Units
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ving
Pro
uc
Li
TW/TWH Series
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1400 m 3 /hr thru 120,000 m3/hr
Certificate No.: IND.14.7268 U/Q
Company Business
Zamil Air Conditioners (ZAC), a sector business of Zamil Industrial, is the largest supplier of air conditioners in the Middle East. It manufactures
and markets a whole range of air conditioners from room air conditioners to packaged units to large capacity chillers for resid ential, commercial
and industrial applications. Zamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be es tablished in Saudi
Arabia and today is a leading international manufacturer of air conditioning systems & service solutions and is Number One in t he Middle East.
ZAC’s operations are structured into four companies supporting seven in-house brands and twelve products and service units as w
ell as a
number of international brands under the OEM Sales. The seven in-house brands are Zamil Air Conditioners, Classic, Zamil, Cooli ne, CoolCare,
Climatech and Geoclima.
The four companies are:
1. Zamil Air Conditioners & Home Appliances Co. (L.L.C.), supporting Zamil, Classic, Cooline, GE and OEM brands for consumers.
2. Zamil Central Air Conditioners Co. (L.L.C.), supporting Zamil Air Conditioners, Cooline and Climatech for commercial and indu strial customers.
3. Zamil Air Conditioning and Refrigeration Services Co. (L.L.C.), providing electromechanical engineering, construction and pro
ject management
services, HVAC Operation & Maintenance, Retrofit Services, Spare Parts, Fire Protection, Controls, Electrical Services, Coils, Ducting and Coating.
4. Geoclima srl is an independent business supporting other three companies for their requirements of Chillers and Double Skin
AHU’s.
The first three Companies- direct their business operations from the First and Second Industrial Cities in Dammam, Saudi Arabia
product design center in Austria.
GEOCLIMA has its engineering and production departments located at Monfalcone, Italy.
All the four companies, while operating independently, supplement each other’s activities in a way that makes synergy work at i
achieves ZAC’s goals of maximizing customer value and satisfaction.
and have a
ts best and
OEM Sales - Private Labeling
Zamil Air Conditioners produces branded air conditioners under OEM agreements for several leading international brands. Such relationships are
testimony to the excellence of ZAC’s engineering and production processes. Most of the units produced under the private labelin g agreements
are for window and mini-split systems. However, ZAC is expanding its OEM offerings to include residential and light commercial units. Some of
the OEM brands manufactured at Zamil Air Conditioners are: Supra, Sanyo and Blue Star.
Joint Venture
Middle East Air Conditioners - Joint Venture with General Electric.
Zamil Air Conditioners partners with GE Appliances - Europe since 1997, in a joint venture called Middle East Air Conditioners
(MEAC), for
manufacturing and marketing of GE branded air conditioners.
MEAC was awarded the license to manufacture Window, Mini Splits and Ducted Split types under the brand names GE, Hotpoint and R
CA. Today,
MEAC enjoys extensive coverage in Saudi Arabia, GCC and the African market. In an ever-changing market, MEAC continually strives to acquire
new technologies and stylish integrated design with optimum performance and reliability that bring greater value to customers.
Factories and Production
Zamil Air Conditioners has two prime manufacturing plants in Dammam, Saudi Arabia and a production facility in Italy operated b
y GEOCLIMA and
a product design center in Austria. ZAC can produce up to 900,000 room air conditioners, 300,000 mini-split systems and 65,000
central airconditioning systems per annum and supplies air conditioning products to over 55 countries across the world - the major markets
being GCC,
Middle East, North Africa, Europe and Asia.
Quality & Product Certificates
The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification.
ZAC’s products are certified with:
1. CE (Council of European Community).
2. UL (Underwriters Laboratory).
3. Eurovent (Certified Performance).
4. ISO 9001-2008 (International Organization for Standardization).
5. AHRI (Air-Conditioning, Heating and Refrigeration Institute).
Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammed bin Fah d Al Saud
Award for Factory Safety.
Our Products & Service Units
In addition to consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufactur es a host of
residential, commercial and industrial air conditioners. This broad product range extends from the concealed units up to 5 TR, the ducted splits
up to 30 TR, the packaged units up to 100 TR, the single and double skin air handling units up to 138,316 CFM, the water chillers up to 590 TR and
the centrifugal chillers up to 5,000 TR cooling capacity.
Our products and services include, in addition to Maintenance, Retrofit & Operations (MRO), complete integrate suite of solutio ns like:
• Zamil Projects: Providing EPC for electromechanical works for Industrial, Utility and Oil & Gas customers.
• Zamil Controls: Design, assembly, integration and commissioning of low current & low voltage systems.
• Zamil Fire Protection: Design, integration and commissioning of active fire protection systems.
• Zamil Electrical: Design, integration and commissioning of lv/mv (low voltage/middle voltage) systems.
• Coil & Coating: Coil replacement, anti-corrosion coating, water proofing & reflective coating and passive fire protection solutions.
• Zamil Ducting: Facilities designs and manufactures high quality duct systems and other HVAC industry related products, utilizing state of the
art automated duct lines, Plasma Cutting, CNC Turret punch press and other specific machinery through two duct factories locate
d in Saudi
Arabia western province (Yanbu) and Eastern province (Dammam).
INDEX
Contents
Page
Introduction .......................................................................................................................... 3
Quality................................................................................................................................... 3
Flexible Modular Construction ............................................................................................. 4
Rigid and leak tight construction ........................................................................................ 4
Wide Range of Sizes ............................................................................................................. 4
Nomenclature ....................................................................................................................... 5
Quick Unit Selection ............................................................................................................. 6
Unit Cross Sections ............................................................................................................... 7
Unit Frame ............................................................................................................................ 8
Panels, Paint, Insulation ...................................................................................................... 9
Access Panels and Doors ................................................................................................... 10
Unit Base ............................................................................................................................. 11
Roof Cover .......................................................................................................................... 12
Filters .................................................................................................................................. 12
1- Flat Filters ........................................................................................................... 12
2- Low velocity Filters (V-Filters) .......................................................................... 13
3- Bag Filters .......................................................................................................... 13
4- Hepa Filters ........................................................................................................ 13
5- Carbon Filters ..................................................................................................... 14
Coils ..................................................................................................................................... 15
Drain Pan ............................................................................................................................ 17
Fans ..................................................................................................................................... 18
1- Centrifugal Fans ................................................................................................. 18
2- Plug Fans ............................................................................................................ 21
Blower Motors .................................................................................................................... 21
Drives .................................................................................................................................. 22
Variable Frequency Drives ................................................................................................. 23
1
Contents
Page
Vibration Eliminator ........................................................................................................... 24
Plenum Section .................................................................................................................. 24
Electric Heater .................................................................................................................... 24
Dampers ............................................................................................................................. 26
Energy Recovery Wheel ..................................................................................................... 28
Run Around Coils ................................................................................................................ 29
Plate Heat Exchanger ......................................................................................................... 29
Heat Pipe System ............................................................................................................... 30
Humidifiers ......................................................................................................................... 31
1- Steam Humidifiers ............................................................................................. 31
2- Air Washers ......................................................................................................... 32
3- Adiabatic Cooling / high pressure humidification ............................................ 32
Diffuser Plate ...................................................................................................................... 33
Sound Attenuators .............................................................................................................. 33
Drip Eliminators .................................................................................................................. 34
Bulk Head Light .................................................................................................................. 34
Ultra Violet Light ................................................................................................................. 35
Power Panels ...................................................................................................................... 36
Hygienic Units .................................................................................................................... 37
Air Handling Units Selection Software “ClimCalc“ ............................................................ 39
Some Air Handling Units Possible Configuration ............................................................... 46
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2
Introduction
This catalogue is meant to serve as a guideline for consulting and design engineers for the
selection of Zamil Air Handling Units. Please contact your local Zamil office for assistance
with any technical clarification, selection, consultancies related to the air handling units
product capabilities, features or applications.
Quality
The quality and reliability of any Zamil Air Handling Unit depends on the quality of the
components, therefore inline with our rigorous quality management and selection of the
best suppliers, we offer you the highest quality Units.
Each unit can have designed-in flexibility to adapt to your exact requirements. This capability provides you the best overall total value based upon life-expectancy, functionality,
energy efficiency and serviceability. Zamil air handling unit designs incorporate many
engineering and performance features which maximized equipment up-time and the
additional benefit of reduced equipment energy and maintenance costs.
3
Flexible Modular CConstruction
onstruction
Zamil Air Handling Units are manufactured as a factory-made combined blocks of encased
individual modules assembly based upon a wide range of standard panels (30mm, 50mm
and 100mm). An air handling unit consists of a fan or fans and other necessary sections
like coil, filters,…etc. to perform one or more of the functions of circulating, cleaning,
heating, cooling, humidifying, dehumidifying and mixing of air.
Zamil Air Handling Units can be delivered in sections for indoor or outdoor installation,
assembly
completely assembled or knocked down for on sitesite-assembly
assembly.
Rigid and leak tight construction
Zamil Air Handling Units are fabricated from penta post heavy gauge corrosion free aluminium profile and PE corner connection.
Panels and frame are secured using internally bolted fixings. The Gasket liner between
the panels and frame ensures an excellent leak tight and also works as thermal and
acoustic insulation and guarantees the tightness of the casing according to EN1886
EN1886.
Wide Range of Sizes
Seventeen Standard sizes of optimally engineered Air Handling Units can be supplied by
Zamil to handle air volumes from:
- 1,400 m3/h to 120,000 m3/h – Cooling duty.
- Up to 220,000 m3/h – Heating and Ventilation only.
Non-standard units can be produced for any application with much higher flow rates. For
requirements in excess of the above, please consult your nearest Zamil representative.
Zamil Air Handling Units provide you the best overall total value based upon life-expectancy, functionality, energy efficiency and serviceability. Zamil custom products and system designs incorporate many engineering and performance features that maximize equipment up-time and the additional benefit of reduced equipment energy and maintenance
costs.
Dear valued customer, please go through this catalogue, if you need more detailed information, please don’t hesitate to contact your nearest Zamil office for assistance.
4
Nomenclature
5
Quick U
nit SSelection
election
Unit
W
Range II
W
W
Range I = Airflow volume referring to free unit cross section and airflow velocity
from 1 m/s to 3.5 m/s
m/s.
Range II = Airflow volume referring to coil finned area and airflow velocity from
1 m/s up to 2.5 m/s.
Range I
Air flow volume [m3/h]
6
Unit CCross
ross SSections
ections
AIRFL
OW RA
TE
AIRFLO
RATE
UNIT SIZE
m3/hr @ 2.5 m/s
TWP3
FIL
TER ARRANGEMENT
FILTER
TW
B (mm)
TWP5
H (mm)
B (mm)
H (mm)
ACROSS
UNIT SECTION
ACROSS
COIL
42 FILTER 1/1
120
4450
3830
146030
120582
35 FILTER 1/1
105
4450
3215
121952
104990
30 FILTER 1/1
90
3825
3215
103816
90400
20 FILTER 1/1
9 FILTER 1/2
73
3520
2910
85932
73840
20 FILTER 1/1
60
3215
2605
69723
59410
16 FILTER 1/1
47
2605
2605
56025
46890
12 FILTER 1/1
35
2565
1955
2605
1995
42328
35540
9 FILTER 1/1
26
1955
1955
1995
1995
31979
26260
6 FILTER 1/1
3 FILTER 1/2
22
1955
1650
1995
1690
26805
21750
6 FILTER 1/1
17
1955
1345
1995
1385
21630
17350
4 FILTER 1/1
2 FILTER 1/2
14
1650
1345
1690
1385
18131
14230
4 FILTER 1/1
11
1345
1345
1385
1385
14631
11195
2 FILTER 1/1
2 FILTER 1/2
8
1345
1040
1385
1080
11131
8280
1 FILTER 1/1
2 FILTER 1/2
6
1040
1040
1080
1080
8468
5975
1 FILTER 1/1
1 FILTER 1/2
4
1040
735
1080
775
5805
3895
1 FILTER 5/6
1 FILTER 1/2
3
940
735
980
775
5207
3410
1 FILTER 5/6
2
735
635
775
675
3382
2005
FILTER 1/1 = 592 x 592 mm (24" x 24")
FILTER 1/2 = 287 x 592 mm (12" x 24")
7
FILTER 5/6 = 490 x 592 mm (20" x 24")
Unit FFrame
rame
The Zamil TW-series air handling unit is constructed from framed modules manufactured from
extruded anodized aluminium profiles joined by means of 3D injected molded and reinforced
PE corners to form the “Penta-post” construction. This method has demonstrated superior
mechanical characteristics and gives the unit its rigidity and design flexibility.
The unique profiles with their unique cross sections designed to give extra strength and rigidity to the unit frame and to prevent any buckling or deformation.
For the best thermal and acoustical performance, the internal cavities of the Penta-Post frames
are insulated with fiberglass that confirms to HH-1-545B type 1, SMACNA standard for duct
liners and ASTM-C-423 and NFPA90A and 90B standards for fire resistance.
30mm Profile Penta-Post
50mm Profile Penta-Post
Middle webs of the same material as the profiles are used to recess the panels and stiffen
the case assembly.
The frame construction makes it possible to disassemble and reassemble the unit sections
at site in case of access or lifting difficulties.
An air handling unit module
8
Unit frame Options:
- 30mm, 50mm & 100mm hot dip galvanized steel profile.
- Special corrosion resistant profile, thermal contact free which provides perfect isolation
between the inside and outside airs, (only for 50mm units).
50mm thermal bridge profile
100mm galvanized profile
Panels, P
aint, Insulation
Paint,
TW-series casing panels are constructed from double wall, sandwich type panels. With this
configuration, the insulation is kept out of the air stream and thus assures better indoor
quality, as well as the ease of cleaning. Panel thickness is 30 or 50mm based on the unit
size, as standard TW2 - TW35 comes with 30mm panel thick, while TW47 - TW120 comes
with 50mm panel thick. Upon client request, TW2 - TW35 units can be manufactured with
50mm panel thickness as an option.
For standard panel, the outer skin of the sandwich panel is zinc coated galvanized steel
sheet metal of 24 gauge thickness thoroughly de-greased and then phosphated before
the application of an average 80 micron electrostatic polyester powder paint oven baked
in RAL 9002 color scheme, this finishing pass 1500 hr in 5% salt path at 95oF and 100%
relative humidity. It complies to ASTM B 117 standard.
The inner skin of the panel are supplied in a zinc coated galvanized finish of 18 gauge
thickness.
Stiffeners inside the panel are provided to enhance the rigidity of the casing and to secure
the inside insulation.
All panels are thermally and acoustically insulated for best unit performance, and are
internally insulated with fiberglass insulation of 48 kg/m3 density, the insulation confirms
to HH-1-545B type 1, SMACNA standard for duct liners and ASTM-C-423 and NFPA 90A and
90B standards for fire resistance.
9
Double Skin Panels Combination Choices. (The Standard Panel Construction is Shaded).
Access P
anels and Doors
Panels
The access panels and doors of the air handling unit have exactly the same configuration
of the fixed panels described previously with same variety of choices.
The access panel type is determined based on the unit size and the section which to be
served.
Five types of access panels and doors can be provided:
A. Screwed panel is fixed with external screws for easy service access.
B. Removable access panel with latches and handle.
C. Hinged door with turn bolt.
D. Hinged door with turn-lever.
E. Hinged door with double lever lock.
F. Lockable types.
10
Table (1) shows the default selection of access panels and doors in the TW series AHU’s,
however, the type of the access can be changed among the alternatives upon the customer request.
Table (1)
Standard Access type
Unit Size
Unit Section
Other Sections
Fan Section
Coil Section
Filter Section
(if access is needed)
TW2 - TW11
B
A
B
B
TW14 - TW22
C
A
B
B
TW26 - TW120
D
A
D
D
Unit Base
The unit base is a fabricated, welded galvanized sheet metal base of high gauge along the
perimeter of the unit. Supports extend across the length and width of the unit to support
the internal components. The unit base construction is well painted to withstand the most
difficult weather conditions.
For the units TW2 – TW14 the unit base height as default is 80mm, the base rail can be
fabricated with 100, 120, 150 & 200mm heights as well.
For the units TW17 – TW120 the unit base height as default is 120mm, the base rail can be
fabricated with 150 & 200mm heights.
Air handling unit base
11
Roof CCover
over
For outdoor installations, TW-series air handling units are equipped with a standard roof
cover to protect the unit from varying climates. The roof cover is made with slight pitch
down from the center line to the ends on both sides to avoid rain accumulation on the
unit top. For best rainwater drainage, the roof cover is extended along the unit perimeter.
Sealant application before roof cover installation
Roof Cover
Filters
A wide variety of filter types are available to meet any filtration requirements, including flat
filters, low-velocity filters, bag filters, HEPA filters, carbon filters and many other types of filters.
1- FFlat
lat Filters
In Zamil TW-series Air handling units, the following types of flat filters can be provided:
a. 2'' flat filters with Aluminium washable media, used as standard in Zamil TW-series air
handling units.
b. 2" flat filters with synthetic non-woven media, either disposable or cleanable,
can be provided upon request.
c. 4" flat filters with Aluminum or synthetic media, can be also provided upon request.
Aluminum filters
Synthetic filters
12
Pleated filters
2- LLow
ow V
elocity Filters (V
-Filters)
Velocity
(V-Filters)
This can be provided as an option to increase the filtration area. Filters arranged in a vee
bank, filters media options are same as flat filters.
Low velocity V-Filter section
3- B
ag Filters
Bag
For a higher level of filtration than flat filters, bag filters with 95% filtration efficiency can
be used, the bag filters are made from ultra fine non-woven synthetic fibers, formed into
pockets and then attached to a rigid header.
Short bag filters with 15" deep or long bag filters with 22" deep are available.
4- HEP
A Filters
HEPA
For critical air cleaning applications such as clean rooms, food factories, operation theaters
or pharmaceutical applications where a very high degree of filtration is required and the
efficiency needed to be in excess of 99.997%. HEPA filters can be provided as an option.
13
For all TW-series air handling units, a combination of three internationally common sizes from
the above types of filters are used (see page 7 for filter sizes combination for each model).
5- Carbon Filters
Activated carbon is the most common material used in HVAC systems for the removal of gaseous
contaminations by means of adsorption, absorption and chemical reaction.
Based on the application, the surrounding environment carbon filters can be carefully
selected and integrated in Zamil TW-series air handling units as an option.
Filter Frames
The pre-filters and bag filters are fixed in a specially - designed galvanized steel frames, with locks to
secure the filters in their places during operation. For TW2 - TW26 models, the filter frames are fixed
together and installed on a channel to enable sliding them out complete with the filter cells for service or
replacement, while for the models TW35-TW120 the filter frames are fixed inside the filter section and
service or replacement to be done inside the unit. The arrangement of filter frames designed to minimize air bypass and allow for filter access and replacement from the access side of the air handling unit.
Withdrawable Filter Frame for TW2 - TW26.
Fixed Filter Frame for TW35 - TW120
For the calculation of internal pressure drop ’’Mid-life’’ resistance is considered in the calculations for the selection of the blower motor.
Options:
- Stainless steel filter frames.
- Differential pressure switch (Loose delivery).
- Auto roll filters.
- Sand Inertia filters.
- Gas phase filters.
- Cartridge filters.
- Drum filters.
- Wide range of filters with MERV efficiency as per ASHRAE 52.2.
- For visual indication of the filter conditions, an inclined manometer for indoor applications can be provided or alternatively, a Magnehelic manometer can be provided specially for the outdoor applications (loose delivery).
14
Inclined Manometer
Magnehelic Pressure Gauge
Coils
Zamil TW Air Handling units offer a variety of chilled water coils, direct expansion coils
(R-410a, R-407c, R-134a), hot water coils and steam coils which confirms to AHRI 410
standard and comply with Eurovent standards.
All coils designed to deliver their respective duties at optimum performance at all design
conditions and to meet a wide range of applications and requirements.
As a standard, coils are manufactured from seamless copper tubes of ½” OD, mechanically
expanded into collar continuous corrugated aluminum fins to provide a continuous compression bond over the entire finned length for maximum heat transfer rates.
The standard number of fins per inch is 12 FPI; however 10 and 14 FPI coils are available as
an option upon the client request or to achieve the determined indoor conditions.
Extensive cleaning is done after manufacturing each coil for optimum system cleanliness
and all coils are factory tested at 300 psig air pressure under water.
Coils can be manufactured from 1 to 12 rows for both chilled water and direct expansion
coils, and up to 4 rows for heating coils.
Due to the huge variety of coil input conditions, the coils calculation and selection is
optimally done based on a fully wetted coil by selection software integrated in the unit
selection software to match the required conditions.
Direct expansion coils are equipped with a properly - sized expansion valve and distributor
to ensure equal refrigerant fed to all circuits. The number of circuits is chosen to provide
optimum heat transfer and reasonable refrigerant velocity and pressure drop so as not to
trap any oil in the coil tubing.
15
Chilled Water Coil
Direct Expansion Coil
Headers and connections for water coils and DX-coils are made of seamless copper pipes
and inlet & outlet connections are sealed against unit panels by rubber gaskets as standard wherever coil connections protrude through the casing.
Utilizing the full available unit cross section area, coils are mounted in the unit casing on
non-corrosive slide rails to allow for easy coil slide in - slide out when required. All water
coils are fitted with plugged drain and vent tapping to facilitate draining and venting.
Coil sliding rails
Options:
- 316L Stainless steel coils casing.
- On stacked coils, intermediate drain pans can be fitted to provide drainage of condensate on the elevated coil block.
- Copper tube – copper fins coil.
- Pre-coated fins coil.
- 5/8’’ tube diameter - coils.
- Coated coils with
coating (Please contact your local Zamil sales office for more details).
- Stainless steel coils.
- Steam coils.
16
Drain P
an
Pan
In order to remove the condensate formed during de-humidification, drain pan is supplied
as standard under the cooling coil, the drain pan is fabricated from stainless steel gauge 16
sheets which covers the whole cooling coil section not only under the coil slap.
For best drainage, drainage connection given from one side for TW2 – TW35 and from both
sides for TW47 – TW120 where the units contains big coils, the drain pan bottom sloped
properly to ensure complete and positive drainage of condensate. The drain pan outer
surface is insulated with (1/8”) closed cell foam insulation to prevent condensation.
Stainless steel drain pan
The drain pan covers the whole coil section
Options:
- Double wall drain pan assembly.
- Intermediate drain pan for small units.
17
Fans
1- CCentrifugal
entrifugal FFans
ans
The standard fans used in TW-series are high performance Double Width Double Inlet (DWDI)
centrifugal fans, optimally engineered for HVAC application, with high quality, and fully tested
performance in accordance with DIN-24166 accuracy class-1, ISO 5801, BS 848 Part-1 and
AMCA-210 standards.
All fans are optimally selected for best performance and sound characteristics based on
maximum fan efficiency.
The impellers can have forward curved, backward inclined or airfoil profile blades depending on the customer requirements and the system static pressure.
The impeller is galvanized finished for forward curve blade, glass reinforced polymid or
welded heavy gauge steel painted with epoxy for backward and airfoil blade. All fans are
statically and dynamically balanced for stable non-surging operation.
Fans are securely fixed to hardened steel shafts with high safety factor and precisely
ground and polished, shafts are coated with protective paint for added protection, the
shaft ends are grooved and keyed.
Depends on fan class and size, TW-series fans equipped with self-aligned ball bearings
that are greased for life or pillow block bearings with re-greasing nipples.
The complete fan-motor assembly mounted on a common base frame entirely isolated
from the unit by rubber vibration eliminators or open type anti-vibration spring isolators.
As standard the fan discharge also isolated from the casing by use a flexible connection
which will minimize the vibration and accordingly the sound level.
V1
V2
+
V4
V3
+
+
Centrifugal Fan-Motor Possible arrangements
18
V5
+
+
Forward Fan
Reinforced Forward Fan
Backward Fan
Reinforced Backward Fan
Backward Airfoil Fan
Black steel Backward Airfoil Fan
19
1-Inlet Guard
2-T-Frame
3-Inlet Cone
4-Inspection Door
5-Drain Plug
6-Motor
7-Motor Rails
8-Base Frame
9-Anti vibration mounting
10-Fan Pulley
11-Belt Guard
12-Belts
13-Outlet Flexible connection
14-Outlet guard
15-Outlet counter flange
16-Bearing support
17-Shaft guard
18-Wheel
19-Housing
20-Shaft
18
20
21-Cut off
22-R-Frame
23-Bearing Bracket
24-Guard Moun
25-Motor Pulley
26-Hub
27-Feet
28-Bearing
29-Rubber interliner
30-Outlet Flange
31-Motor Mounting Plate
2- Plug FFans
ans
Most of the energy consumed by an air handling unit is the electricity used to run the fan
motor, whilst only a small percentage of the energy goes to heat generation, so high fan
efficiency means power saving, this is why the plug fans which are high fan efficiency
significantly reduces the consumption of electricity, and therefore the operation cost.
Direct Drive simplicity converts to less operating expenses also as there are no fan shafts,
bearing, belts or guards to maintain.
Noise emission level of air handling units is also one of the most important environmental
factors which we fine tuned our product to reduce it, the choice of using plug fan will be
ideal to achieve this goal. Plug fans are extremely quiet efficiency and quiet operation
make an exceptional combination for your air handling unit.
Blower Motors
Plug Fan
Fan motors are Totally Enclosed Fan Cooled (TEFC) squirrel cage type with class “F“ insulation at 50oC ambient temperature and continuous duty. Motors are of IP55 and protect the
motor from dust and water. It is mounted on an adjustable base of special design so that
the belt tension can be easily adjusted.
With a voltage tolerance ±10% and frequency tolerance ±5%, motor can operate in an
ambient -16 to +50oC according to IEC60034-1 standard.
For motor sizing the mechanical losses incurred in transmitting the load from motor shaft to
the fan shaft are taken into consideration along with a reasonable safety factor.
Standard Motor Mount
Standard Motor
21
Options:
- Explosion Proof motors
- Two speed motors
- Stand by motors
- IE3 motors
- Nema premium motors
Standard motors are fitted with six terminals, and a terminal connection and wiring diagrams are shown in the motor terminal box.
Drives
Transmission of power from the motor to the fan is provided by means of a set of pulleys and
matching V-belts. The pulleys are taper locked to the fan and motor shaft. TW-series air
handling units are equipped with the optimized pulleys and belts, which are sized and preinstalled by factory. Optimal selection of drives and proper installation will ensure that the
fan re-stats at the required designed speed and at same time help to optimize fan and
motor bearing life.
Transmission Assembly
Fan Pulley – Motor Pulley – Belt and Bushes
22
Variable FFrequency
requency Drives
Variable Frequency
Variable Frequency Drives or Frequency Inverters as they are sometimes called are installed
on Fan motors to vary the fan speed in applications where the supply CFM is not constant
and must be varied. In applications where Variable Air Volume boxes (VAV’s), for example,
are installed throughout the occupied space, the total CFM discharged by the Air Handling
Unit will depend on the demand requested by the VAV boxes. When the space is satisfied
and the VAV box closes its damper, the total required CFM will be reduced. To avoid over
pressurizing the ducting, a Variable Frequency Drive is installed to reduce the speed of the
fan and hence reduce the total CFM discharged by the unit.
A full range of Variable Frequency Drives from 0.25 kW up to 132 kW in voltage ratings of
(220V-1phase, 220V-3Phase, 380/480V-3phase) with an operating ambient temperature
rating up to 50oC are available.
The drives are easy to configure and operate with built-in Proportional, Integral, Derivative
(PID) control based on flow or temperature. Equipped with Dynamic Brake Control, Torque
Control, Dual Motor Control and Threshold Comparator. Intelligent Thermal Management
functionality to reduce tripping and motor noise. Complies with EN61800-3 and EN50082-2
for Electromagnetic Immunity as well as EN61800-3 for Electromagnetic Emissions. EMC
filters can be installed for more stringent requirements. Also equipped with protection for
under voltage, over voltage, phase loss, drive overload, over current, over temperature,
ground fault, and short circuit.
23
Vibration Eliminator
In order to reduce the transmission of noise and vibration, the complete fan motor subbase assembly is mounted on set of anti-vibration mounts.
As standard for TW2 - TW35, the fan assembly is a common base frame entirely isolated
from the unit by rubber in shear while as standard in units TW47 - TW120, the frame
isolated by 1” deflection open type spring isolators.
Rubber Isolator
Spring Isolator
Options:
- TW2 - TW35 equipped with the 1” deflection springs.
- 2” Deflection springs.
- Seismic springs.
Plenum section
Empty sections can be provided upon request as an access or to facilitate the function of a
component in another section or for future use. The standard length of the plenum section
is 500mm, however, custom sizes to suite any requirements can be provided.
Electric Heater
Electrical heaters with wide range of capacities and steps are available to be supplied built-in
Zamil TW-series Air handling units.
The standard electric heater is the open wire type which is provided in a stand alone section, it
consists of a heavy gauge corrosion resistant steel frame and control compartment which contains the basic electrical components. The heating wire is a composition of 80% Nickel and 20%
Chrome, via anti-thermal shock, moisture resistant steatite free floating holding ceramics.
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All heating elements are supported by corrosion resistant heavy gauge wire rack construction designed to allow for free flow of air with lowest possible pressure drop.
Open Type Heater
Options:
- Heaters with UL control panel.
- Finned tubular heater type.
- Finned tubular heater, UL.
Finned Type Heater (Option)
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Dampers
Zamil TW series air handling units are equipped with multiple-blade, low leakage dampers
to modulate and control the air flow.
Dampers can be provided with opposed blades or parallel blades. Dampers are prepared for
either manual or motorized operation (damper actuator can be provided as an option).
As standard, Zamil dampers are entirely made of aluminum profiles with reinforced polyamide
accessories, the blades of the damper has airfoil shape and perfectly controlled by gears that
are spaced out by special spacers located in the damper frame.
Zamil damper has an excellent anti-corrosion features as it is made of aluminum and polyamide
which make it light in weight and yet extremely strong because of its well-engineered design.
Whenever the damper width is exceeding 1220 mm, an intermediate profile is given to give
greater rigidity for larger dimensions.
The damper’s air tightness is enhanced by special gasket inserted in both, the blades and the
frame itself.
The following damper alternative can provided:
- Galvanized steel dampers with single skin blades.
- Galvanized steel dampers with airfoil blades.
- Stainless steel dampers with single skin blades.
- Stainless steel dampers with airfoil blades.
Options:
- AMCA dampers.
- Actuators.
- Back draft dampers.
- Different materials.
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The previously mentioned dampers can be used as:
- Full-face air intake dampers.
- Bypass dampers.
- Fresh, exhaust and return air dampers for two-way or three-way mixing box.
- Economizer control.
- Multi-zone application dampers.
Some Possible Damper Positions & applications
27
In order to recover energy and conserve its consumption by exchanging the energy
between the supply and exhaust air streams, different types of heat recovery systems can be provided built-in Zamil TW
TW-- series units. This will assure the economical
running costs of the units.
Energy R
ecovery Wheel
Recovery
The heat wheel is a rotating wheel consisting of an air permeable aluminum matrix with
a large interior surface, the wheel consists of two half moon sections, and it should be
installed in a double deck or side by side units where the supply air flows through one half
of the rotary wheel while the exhaust air flows in counter flow through the other half, the
wheel is rotating with low speed simultaneously.
Energy wheels designed to recover either sensible heat only or both sensible and latent to
meet the requirements of the indoor air quality. The recovery of sensible heat achieved when
the sensible heat is transferred as the metallic substrate gain and stores heat from the warmer
air stream and gives it up to the cooler stream while the rotation of the wheel.
Latent heat is transferred as the metallic substrate which is coated by a hygroscopic coating condenses moisture from the air stream that has the higher humidity ratio through
absorption and releases moisture through evaporation into the air stream that has a lower
humidity ratio. The TW-series selection software optimizes the selection of the energy
wheel to achieve the needed indoor conditions.
- Heat wheels are ideal for applications that demand high percentage of fresh air intake.
- Wheels are AHRI 1060 certified as per ASHRAE standard.
- Wheels are Eurovent certified.
Energy Recovery Wheel
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Run Around CCoils
oils
It is an air to water heat exchanger system, it is used to recover sensible heat only, it consists
of two coils, one located in the exhaust air stream and the other in the supply air stream, both
of them are connected with a pump in a closed circuit (pump and piping by others), the heat
transfer medium is water.
When the cold air passes through the first coil of the run around system which is located in the
cold air stream, it cools down the water inside the coil, after the water looses heat, the pump
passes this cold water to the coil in the hot air stream, heat exchange happened thus cooling
the air and warming the water, warm water returns to the coil in the cold stream and the cycle
is repeated.
Run Around Coils
Plate Heat EExchanger
xchanger
This type of heat recovery systems depends on the thermal conduction propriety to recover
sensible heat only.
The plate heat exchanger is specially thermoformed plates, connected together via folded
edges permanently bonded and sealed. The supply and exhaust airflows pass crossways through
the heat exchanger alternate aluminum layers of the plate heat exchanger. The two air streams
are totally separated by the nature of the heat exchanger construction, so to use this type of
heat exchangers, the unit shall be a double deck unit.
Plate Heat Exchanger
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Heat Pipe SSystem
ystem
This type of heat recovery system utilizes the refrigerant phase change property. It consists of two coils connected to each other circuit by circuit independently; each circuit is
filled with a refrigerant.
Two main functions can be done using this system; it can be used for dehumidification or
for heat recovery, according to the arrangement of the heat pipe coils with respect to
other components.
Heat pipes for dehumidification function may be described as having two sections:
Pre-cool and reheat. The first section is located in the incoming air stream. When warm air
passes over the heat pipes, the refrigerant vaporizes, carrying heat to the second section
of heat pipes, placed downstream. Because some heat has been removed from the air
before encountering the evaporator coil, the incoming air stream section is called the precool heat pipe.
Air passing through the evaporator coil is assisted to a lower temperature, resulting in
greater condensation removal. The «overcooled» air is then reheated to a comfortable
temperature by the reheat heat pipe section
section, using the heat transferred from the precool heat pipe.
This entire process of pre-cooling and reheating is accomplished with no additional energy use. The result is an air conditioning system with superior ability to remove moisture.
Heat Pipe For Dehumidification
30
For Heat R
Recovery
ecovery function the heat pipe also consist of two sections, each of them
installed in an air steams, side by side or staked depending on the unit arrangement.
When warm air passes over the heat pipes, the refrigerant vaporizes; carrying heat to the
second section and the warm air will be cooled down while the relatively cold air in the
cold air stream will condense the refrigerant which will return back to the first part by
gravity, then this cycle repeated.
Heat Pipe For Heat Recovery
Humidifiers
1- SSteam
team humidifiers
Zamil TW-series Air handling units can be equipped with a self-contained humidifier, which
is electronically controlled to sense and control the humidity.
The steam is generated in a polypropylene cylinder mounted onto the outside of the
humidifier section within a special enclosure. A stainless steel distributor suitable in length
passes through the unit casing to inject steam in the air stream to reach the needed
humidity conditions.
Steam Humidifier
Steam Distributor
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2- Air W
ashers
Washers
Zamil air handling units can be equipped with air washer section which mainly serve for
adiabatic cooling, humidifying and air washing.
Air washer is a section in which the air flow is brought in contact with a large quantity of sprayed
water. Depending on the condition of the circulating water, air washers are forming a basic part
of air conditioning plants which easily combine washing, humidifying and cooling of air.
While water evaporates on the surfaces of large drops and impurities contained in the air
are washed out, extremely small droplets (Superfine aerosols) can be fully absorbed by the
air and they are designed to avoid the formation of superfine aerosols as far as possible.
Air Washer
3- Adiabatic Cooling/high pressure humidification
Zamil adiabatic cooling/high pressure humidification is a system which is ideal for the humidification of medium/large industrial environments and large volumes of air.
The system atomize water into very fine water particles that evaporate easily in the air,
humidifying and cooling it. Evaporation occurs by “absorbing” sensible heat from the air
which becomes colder and more humid.
Along with this system an electronic controller is provided to manage the supply of water
and compressed air to the nozzles to maintain the humidity/temperature set point.
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Diffuser Plate
The diffuser plate is a perforated, heavy gauge galvanized steel plate provided to shutter
the air and distribute it uniformly across the section.
The use of diffuser plate becomes essential when a functionally sensitive section - like
HEPA filters or an energy wheel, is facing high face velocities.
Diffuser plate
Sound A
ttenuators
Attenuators
Sound attenuators can be used where a significant reduction to fan noise is needed.
Attenuators can be provided in the supply and/or return air side with different lengths to
provide a range of attenuator performances. Sound attenuators casings are produced with
G-90 galvanized steel sheets formed and lock formed seams with a sealant.
The acoustic infill materials are inert, non-flammable, non-hygroscopic and will not sustain
vermin or fungus and odorless, the infill has a glass tissue facing and is contained behind
galvanized perforated metal, which prevent infill material damage and fiber erosion up. To
reduce the pressure loss and regenerated noise, the splitters are radiused at both ends.
Sound Attenuators
33
Drip Eliminators
To avoid water carry-over in humid areas or when the velocity of air across the cooling
coils is high, drip eliminators are provided.
As standard, the drip eliminators are provided in two cases:
1- When the velocity across the coil is 2.64 m/s or more.
2- When the water content of the air is greater than 10.5 g/kg of dry air.
Other than in these two cases, the drip eliminator is given as an option upon the request of the
customer. Drip eliminator blades are PVC blades encased within a galvanized steel frame. The
blades are designed to completely prevent water carry-over with low pressure drop.
The drip eliminator is commonly fixed directly to the coil casing, however, separate section for the drip eliminator can be provided upon request.
Assembled Drip Eliminator
Bulk Head Light
Zamil TW units can be equipped with bulk head lights as an option in different sections
like fan section or filter section, to provide enough lightening to watch the function of the
component or to facilitate any service or maintenance activities.
34
Ultra Violet Lights
These special lamps are provided built in the air handling unit as an option for a high level
of air purification and deodorization of an indoor unit. These lamps are used to inactivate
airborne bacterial or fungal contamination for any application, especially those that require a very high level of air cleanness like hospitals, labs or pharmaceutical applications.
Ultra Violet Lights
35
Power P
anels
Panels
Self contained power panels including all necessary accessories for a fully functional system. Panels are built-in to the AHU body and include MCCBs, Blower Contactors with
Overload Relays, Transformers, fuses and terminal blocks can be provided as an option.
Labeled terminal blocks allow for easy site installation and interfacing to third party control networks. Terminal Blocks can be customized as per customer requirements and can
include Motor Run Status, Motor Trip Status, Start/Stop Commands, Pre-Filter Alarms, Bag
Filter Alarms, Airflow Alarms, Damper Control and indication and others.
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Hygienic Units
Zamil hygienic air-handling units incorporate the state-of-the-art technology to provide
refrigeration and meet filtration, pressurization, condensation control and sanitization standards required by the critical applications where ultra clean air needed.
The units are custom engineered to produce the specified psychometric conditions and to
achieve the environmental design criteria for the area being served.
Taking economic issues taken into consideration, our design engineers can design hygienic air
handling units methodically and logically to suit the ultra clean application requirements.
37
Our Hygienic air handling units comply with the requirements of DIN1946, Part-4, O-Norm
H 6020, Part-1 and VDI6022 with following main product features:
- Smooth inside surface design.
- Air tight dampers.
- Light and inspection windows in desired function modules.
- Special joint sealing with silicon-free sealants.
Hygienic unit panel detail
Upon the request, the unit can be supplied with additional optional features like:
- Stainless steel panels.
- Condensate nipples in the fan casing.
- Stainless steel fabrication parts for all components.
- Anti-bacterial coating for all the inner casing and components.
Zamil hygienic air handling units are the answer when clean conditioned air is needed for today’s
hygienic applications like hospitals, pharmaceutical sectors, food factories requirements, etc.
Small size hygienic air handling unit
38
Air Handling Units Selection Software "ClimCalc"
The innovative air handling unit selection software "ClimCalc" is a powerful tool for consultants, sales and application engineers. To activate this software and after the user
enters the design parameters that reflect the customer requirements or consultants guidelines "ClimCalc" will then configure and calculate within a very short period the air handling unit equipment. If any data entered doesn’t correspond with the various certification standards and norms, "ClimCalc" will reject it via an error message.
"ClimCalc" is thus able to provide the security of a planning procedure that is correct in
every respect.
The program performs section by section technical verification and selection until the
whole unit is done. In each section, many options related to that particular section can be
selected to satisfy any air handling unit specifications.
Main Input Data Screen
39
Unit Sizing Screen
Unit Construction Screen
40
Finishing Unit Construction and Units Locking Screen
Sections Parameters Input Data Screen
41
Calculation Finishing Screen
AHU Views Screen
42
By one click on “Complete” ClimCalc will work out the best solution for your application using
optimal technical design which can be checked by the output reports which consists of:
- Performance Report.
- Unit Drawing and Dimensions.
- Psychometric Chart.
- Fan operation Curve.
- Sound Curves.
- Unit weight, section by section.
Sample of Performance Report
Sample of Drawing Report
43
Sample of Psychometric Chart
Sample of Fan operation area and operating point Chart
44
Sample of Noise Level Chart
Weight Report
45
Some Air Handling Units P
ossible CConfiguration
onfiguration
Possible
Supply, Exhaust Simple Units
Supply, Exhaust Inline Units
46
Stacked Unit with Energy Wheel
Stacked Unit with Plate Heat Exchanger
47
Side by side Unit
Stand by-duty Fan
48
Zamil Central Air Conditioners
P.O. Box 41015, Dammam 31521, Kingdom of Saudi Arabia
Tel : +966 13 812 5400
Fax: +966 13 812 1977
Customer Service: 92 0000 468
www.zamilac.com
PL-AP-TWH-16-2M-E