Central SStation tation Double Skin Air Handling Units TW/TWH Series 1400 m3/hr thru 220 ,000 m3/hr 220,000
Company Business Zamil Air Conditioners was founded in 1974, and is the first major business venture in manufacturing sector for the Al Zamil group of Companies. It is also the first manufacturing unit for air conditioners to be established in Saudi Arabia. Zamil Air conditioners manufactures both consumer and central range of air conditioners and has sales operations in over 55 countries in the Middle East, Europe, America, Africa, Australia and the Far East. The company’s operations are structured into four Strategic Business Units (SBUs) supporting six in - house product and service brands as well as a number of international brands under the OEM sales. The six in-house brands are Classic, Cooline, CoolCare, Clima Tech, Geoclima and Kessler Clima Tech. The four SBUs are: 1. Consumer Business unit supporting Classic, Cooline, GE and OEM brands for consumer range of air conditioners. 2. Unitary & Applied Business unit supporting Classic, Cooline, GE and OEM brands for commercial range of air conditioners. 3. Zamil CoolCare - service and maintenance provider. 4. Geoclima srl - independent business and supporting other SBUs for their requirement of Chillers & Double skin AHU’s. The first three SBUs - Consumer Products, Unitary & Applied Products and Zamil CoolCare direct their business operations from the corporate headquarters at Dammam, Saudi Arabia. The production facilities at Dammam are shared by Consumer Products and Unitary & Applied Products. Geoclima has its own production and functional departments located at Monfalcone, Italy. All the four SBUs, while operating independently, supplement each other’s activities in a way that makes synergy work at its best and achieve the corporate goals of increased productivity and efficiently. Factories and Productions Zamil Air Conditioners has its prime manufacturing base at Dammam, Saudi Arabia and has one speciality production facility in Italy operated by Geoclima. The company can produce up to 440,000 room air conditioners, 60,000 mini-split systems and 36,500 central air-conditioning systems per year. Quality & Product Certificates The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification. Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabia’s Standard Organization) certificate for room air conditioners. Its products and services are also certified with: 1. 2. 3. 4. 5. 6.
CE (Council of European Community) UL (Underwriters Laboratory) AHAM certificate (Association of Home Appliance Manufacturers) Eurovent DEMKO ETL
Other awards include the prestigious Engineering Excellence Award of General Electric, and the inaugural Prince Mohammed bin Fahd Al Saud Award for Factory Safety. Our Products In addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufacturers a host of residential and commercial air conditioners. This board range extends from the concealed units up to 5 ton, the ducted splits up to 30 tons, the packaged units up to 70 tons. The single and double skin air handling units up to 130,000 CFM and the water chillers up to 487 ton cooling capacity.
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
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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 Diffuser Plate ...................................................................................................................... 33 Sound Attenuators.............................................................................................................. 33 Drip Eliminators .................................................................................................................. 34 Bulk Head Light .................................................................................................................. 34 Ultra Violet Light ................................................................................................................. 35 Power Panels ...................................................................................................................... 36 Corrosion Resistance and Micro-organism Adhesion Coating ......................................... 37 Hygienic Units ..................................................................................................................... 39 Air Handling Units Selection Software “ClimCalc“ ........................................................... 41 Some Air Handling Units Possible Configuration .............................................................. 48
CONTINUING RESE AR CH RESUL TE AD OVEMENT RESEAR ARCH RESULTTS IN SSTE TEAD ADY IMPRO VEMENTSS. Y IMPR THEREF ORE CIFICA TIONS ARE SUBJE CT TTO O CHANGE WITHOUT NO TICE THEREFORE ORE,, THESE SPE SPECIFICA CIFICATIONS SUBJECT NOTICE TICE..
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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.
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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 DIN 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.
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Nomenclature
5
Quick U nit SSelection election Unit !
Range II
!
!
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]
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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")
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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
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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 with galvanized profile).
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.
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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.
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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 B ase 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. Due to the penta-post construction of the double skin air handling unit, which is rigid and stable by itself, the unit base is given as an option for all TW series models. In case no base rail is required, wooden pallets are provided to facilitate shipping and handling.
Air handling unit base
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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 other types. 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. woven media, either disposable or washable, can b. 2" flat filters with synthetic nonnon-woven be provided upon the request of the client. c. 4" flat filters with Aluminum or synthetic media, can be also provided upon the request.
Aluminum filters
Synthetic filters
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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 can be provided as an option.
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.
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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. 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. - 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-22, R-407c, R-134a), hot water coils and steam coils which confirms to ARI 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 8, 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.
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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 staked 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 thermo guard protection. (see page 37).
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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: - For 50mm units, double wall drain pan assembly. - Intermediate drain pan for small units.
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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
+
V3
+
V4
+ 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
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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 ange 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.
Plug Fan
Blower Motors 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
21
Options: - Explosion Proof motors - Two speed motors - Stand by motors Standard motors are fitted with six terminals, and a terminal connection and wiring diagrams are shown in the motor terminal box. Sample wiring connections are shown in the below diagram.
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 pre-installed 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 backward inclined or backward air foil 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 90 KW in voltage ratings from 200 VAC Single Phase to 480 VAC Three Phase with an operating temperature rating of 40oC – 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.
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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 for better efficiency in eliminating the vibration.
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 Type Heater (Option)
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Dampers Zamil TW series air Handling units are equipped with heavy duty, multi-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 (motor can be provided as an option). As standard, the damper frame is constructed from 1.5mm galvanized steel, non-welded oppose single skin galvanized steel blades fitted to the case with close gap, shafts made from chrome pleated steel, self-lubricating hard nylon shaft bushes and galvanized steel linkage and brackets. To ensure low leakage, the dampers are equipped with side-edge seals.
The following damper alternatives can be provided: - Galvanized steel dampers with airfoil blades. - Stainless steel dampers with single skin blades. - Stainless steel dampers with airfoil blades. - Gear type dampers with Aluminum airfoil blades. For easy installation, the damper frame is designed and fabricated to serve as a flange for ductwork connection.
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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
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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 like in hospitals, labs, universities and pharmaceutical applications.
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 ÂŤovercooledÂť 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
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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
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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
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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.
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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
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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. 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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Corrosion resistance and microorganism adhesion coating micro-organism
The air drawn into air conditioning systems always contains contaminants. This can consist of a variety of pollutants, organic and dirt particles and spores of micro-organisms. Because of the enormous quantity of air passing through the system, a substantial part will deposit onto the heat transfer surfaces. Temperature, humidity, draught, oxygen, dust and pollution are all key factors that will affect the growth of a biofilm on these surfaces. Circumstances in air condition systems are perfect for a rapid growth of micro-organisms, creating biological corrosion. Nutrients combined with the condensation water cause spores to germinate and grow rapidly. Contaminated central air handling systems distribute these contaminants throughout the indoor area, with unhealthy air and unpleasant odors as a result. To overcome such a situation, one can provide corrective actions such as cleaning, which are relative cheap but are short-term solutions and have to be repeated on a regular basis. In addition, cleaning agents can corrode a metal surface as well, leaving a rough surface. This rough surface will even increase adhesion of dirt and organic particles, thus creating a culture medium for rapid multiplication. Uniquely, Zamil TW-Series air handling units can be coated with specially developed coating medium for rapid multiplication.
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Uniquely Zamil TW-Series air handling units can be coated with special developed coatings which prevent corrosion and adhesion of potential nutrients, thus avoiding micro-organism multiplication for extended periods of time. Micro-organisms that nevertheless have been able to adhere will not be able to because of the anti-microbial.
Characteristics: - The coating creates a smooth surface to stop dirt and microbiological adhesion. - The structure of the coating is infused with a micro biocide... It stops the growth of micro-organism that have been able to adhere to the surface. - Contains an Environmental Protection Agency (EPA) registered anti microbial, fit for use in coatings of HVAC and Refrigeration systems. - Anti Microbial originates from crop disinfection. - Prevents build up of nutrients, taking away the culture medium for the growth of microorganism. - Minimizes leaching for long lasting performance.
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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.
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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
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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
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Unit Sizing Screen
Unit Construction Screen
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Finishing Unit Construction and Units Locking Screen
Sections Parameters Input Data Screen
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Calculation Finishing Screen
AHU Views Screen
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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
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Sample of Psychometric Chart
Sample of Fan operation area and operating point Chart
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Sample of Noise Level Chart
Weight Report
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Some Air Handling Units P ossible CConfiguration onfiguration Possible
Supply, Exhaust Simple Units
Supply, Exhaust Inline Units
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Stacked Unit with Energy Wheel
Stacked Unit with Plate Heat Exchanger
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Side by side Unit
L - Shape Unit
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Stand by-duty Fan
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PL-AP-TWS-08-2M-E