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CCCCCentral Sentral Sentral Sentral Sentral StationtationtationtationtationDouble SkinDouble SkinDouble SkinDouble SkinDouble Skin
Air Handling UnitsAir Handling UnitsAir Handling UnitsAir Handling UnitsAir Handling UnitsTW/TWH SeriesTW/TWH SeriesTW/TWH SeriesTW/TWH SeriesTW/TWH Series
1400 m1400 m1400 m1400 m1400 m33333/hr thru 220/hr thru 220/hr thru 220/hr thru 220/hr thru 220,000 m,000 m,000 m,000 m,000 m33333/hr/hr/hr/hr/hr
Company BusinessZamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be established in Saudi Arabia andtoday is a leading international manufacturer of air conditioning systems and is Number One in the Middle East.
Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55countries in the Middle East, Europe, Africa and Asia.
The company’s operations are structured into four Strategic Business Units (SBUs) supporting five in-house product andservice brands as well as a number of international brands under the OEM sales.
The five in-house brands are Classic, Cooline, CoolCare, Clima Tech and Geoclima.
The four SBUs are:1. Consumer Business Unit supporting Classic, Cooline, GE and OEM brands for consumers.
2. Unitary & Applied Business Unit supporting Zamil, Cooline, GE and OEM brands for commercial and industrialcustomers.
3. Zamil CoolCare Business Unit providing industrial, electro mechanical contracting services, HVAC maintenance, retrofit& operation services and parts.
4. Geoclima srl is an independent business supporting other SBUs for their requirements of chillers & double skin AHU’s.
The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare direct their business operations fromthe corporate headquarters in Dammam, Saudi Arabia.
Geoclima has its engineering & production operations located at Monfalcone, Italy and has a design center in Austria.
All the four SBUs, while operating independently, supplement each other’s activities in a way that makes synergy work atits best and achieve the corporate goals of maximizing customer satisfaction.
Factories and ProductionsZamil Air Conditioners has two manufacturing plants in Dammam, Saudi Arabia and has one specialty production facility inItaly operated by Geoclima.
The company can produce up to 550,000 Room Air Conditioners, 300,000 Mini-Split systems and 50,000 Central AirConditioning systems per year.
Quality & Product CertificatesThe Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification.
Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabia’s Standard Organization)Certificate for Room Air Conditioners. ZAC’s products are also certified with:1. CE (Council of European Community)2. UL (Underwriters Laboratory)3. Eurovent (Certified Performance)4. ETL (Test Facilities)5. SASO (Saudi Arabian Standards Organization)6. ISO 9001:2008 (International Organization for Standardization)7. ASME (American Quality of Mechanical Engineers)
Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammedbin Fahd Al Saud Award for Factory Safety.
Our ProductsIn addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditionersmanufacturers a host of residential, commercial and industrial air conditioners. This broad range extends from the Con-cealed Units up to 5 TR, the Ducted Splits up to 30 TR, the Packaged Units up to 95 TR, the Single and Double Skin AirHandling Units up to 138,316 CFM and the Water Chillers up to 500 TR cooling capacity.
CCCCContentsontentsontentsontentsontents PPPPPageageageageage
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
INDEXINDEXINDEXINDEXINDEX
1
CCCCCONTINUING RESEONTINUING RESEONTINUING RESEONTINUING RESEONTINUING RESEARARARARARCH RESULCH RESULCH RESULCH RESULCH RESULTTTTTS IN SS IN SS IN SS IN SS IN STETETETETEADADADADADY IMPRY IMPRY IMPRY IMPRY IMPROOOOOVEMENTVEMENTVEMENTVEMENTVEMENTSSSSS.....THEREFTHEREFTHEREFTHEREFTHEREFOREOREOREOREORE, THESE SPE, THESE SPE, THESE SPE, THESE SPE, THESE SPECIFICACIFICACIFICACIFICACIFICATIONS ARE SUBJETIONS ARE SUBJETIONS ARE SUBJETIONS ARE SUBJETIONS ARE SUBJECT TCT TCT TCT TCT TO CHANGE WITHOUT NOO CHANGE WITHOUT NOO CHANGE WITHOUT NOO CHANGE WITHOUT NOO CHANGE WITHOUT NOTICETICETICETICETICE.....
CCCCContentsontentsontentsontentsontents PPPPPageageageageage
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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IntroductionIntroductionIntroductionIntroductionIntroductionThis catalogue is meant to serve as a guideline for consulting and design engineers for theselection of Zamil Air Handling Units. Please contact your local Zamil office for assistancewith any technical clarification, selection, consultancies related to the air handling unitsproduct capabilities, features or applications.
QualityQualityQualityQualityQualityThe quality and reliability of any Zamil Air Handling Unit depends on the quality of thecomponents, therefore inline with our rigorous quality management and selection of thebest suppliers, we offer you the highest quality Units.
Each unit can have designed-in flexibility to adapt to your exact requirements. This capa-bility provides you the best overall total value based upon life-expectancy, functionality,energy efficiency and serviceability. Zamil air handling unit designs incorporate manyengineering and performance features which maximized equipment up-time and theadditional benefit of reduced equipment energy and maintenance costs.
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FFFFFlexible Modular Clexible Modular Clexible Modular Clexible Modular Clexible Modular ConstructiononstructiononstructiononstructiononstructionZamil Air Handling Units are manufactured as a factory-made combined blocks of encasedindividual modules assembly based upon a wide range of standard panels (30mm, 50mmand 100mm). An air handling unit consists of a fan or fans and other necessary sectionslike 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,completely assembled or knocked down for on site-knocked down for on site-knocked down for on site-knocked down for on site-knocked down for on site-assemblyassemblyassemblyassemblyassembly.
Rigid and leak tight constructionRigid and leak tight constructionRigid and leak tight constructionRigid and leak tight constructionRigid and leak tight constructionZamil Air Handling Units are fabricated from penta post heavy gauge corrosion free alu-minium profile and PE corner connection.
Panels and frame are secured using internally bolted fixings. The Gasket liner betweenthe panels and frame ensures an excellent leak tight and also works as thermal andacoustic insulation and guarantees the tightness of the casing according to DIN EN1886DIN EN1886DIN EN1886DIN EN1886DIN EN1886.
Wide Range of SizesWide Range of SizesWide Range of SizesWide Range of SizesWide Range of SizesSeventeen Standard sizes of optimally engineered Air Handling Units can be supplied byZamil 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. Forrequirements 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-expect-ancy, functionality, energy efficiency and serviceability. Zamil custom products and sys-tem designs incorporate many engineering and performance features that maximize equip-ment up-time and the additional benefit of reduced equipment energy and maintenancecosts.
Dear valued customer, please go through this catalogue, if you need more detailed infor-mation, please don’t hesitate to contact your nearest Zamil office for assistance.
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NomenclatureNomenclatureNomenclatureNomenclatureNomenclature
5
QQQQQuickuickuickuickuick U U U U Unitnitnitnitnit S S S S SelectionelectionelectionelectionelectionRange I = Airflow volume referring to free unit cross section free unit cross section free unit cross section free unit cross section free unit cross section and airflow velocity
from 1 m/s to 3.5 m/sfrom 1 m/s to 3.5 m/sfrom 1 m/s to 3.5 m/sfrom 1 m/s to 3.5 m/sfrom 1 m/s to 3.5 m/s.Range II = Airflow volume referring to coil finned area coil finned area coil finned area coil finned area coil finned area and airflow velocity fromfromfromfromfrom
1 m/s up to 2.5 m/s.1 m/s up to 2.5 m/s.1 m/s up to 2.5 m/s.1 m/s up to 2.5 m/s.1 m/s up to 2.5 m/s.Range II
Range I
6
Air flow volume [m /h]3
UUUUUnitnitnitnitnit C C C C Crossrossrossrossross S S S S Sectionsectionsectionsectionsections
FILFILFILFILFILTER ARRANGEMENTTER ARRANGEMENTTER ARRANGEMENTTER ARRANGEMENTTER ARRANGEMENT
UNIT SIZEUNIT SIZEUNIT SIZEUNIT SIZEUNIT SIZEAIRFLAIRFLAIRFLAIRFLAIRFLOOOOOW RAW RAW RAW RAW RATETETETETEmmmmm33333/hr @ 2.5 m/s/hr @ 2.5 m/s/hr @ 2.5 m/s/hr @ 2.5 m/s/hr @ 2.5 m/s
TWP3 TWP5 ACROSSUNIT SECTION
146030
121952
ACROSSCOIL
120582
104990
TW
120
105
B (mm) H (mm) B (mm)
4450
4450
H (mm)
3830
3215
90
73
60
47
35
26
22
17
14
11
8
6
4
3
2
2565
1955
1955
1955
1650
1345
1345
1040
1040
940
735
1955
1955
1650
1345
1345
1345
1040
1040
735
735
635
3825
3520
3215
2605
2605
1995
1995
1995
1690
1385
1385
1080
1080
980
775
3215
2910
2605
2605
1995
1995
1690
1385
1385
1385
1080
1080
775
775
675
103816
85932
69723
56025
42328
31979
26805
21630
18131
14631
11131
8468
5805
5207
3382
90400
73840
59410
46890
35540
26260
21750
17350
14230
11195
8280
5975
3895
3410
2005
30 FILTER 1/1
20 FILTER 1/19 FILTER 1/2
20 FILTER 1/1
16 FILTER 1/1
12 FILTER 1/1
9 FILTER 1/1
6 FILTER 1/13 FILTER 1/2
6 FILTER 1/1
4 FILTER 1/12 FILTER 1/2
4 FILTER 1/1
2 FILTER 1/12 FILTER 1/2
1 FILTER 1/11 FILTER 1/2
1 FILTER 1/12 FILTER 1/2
1 FILTER 5/61 FILTER 1/2
1 FILTER 5/6
FILTER 1/1 = 592 x 592 mm (24" x 24") FILTER 1/2 = 287 x 592 mm (12" x 24") FILTER 5/6 = 490 x 592 mm (20" x 24")
7
42 FILTER 1/1
35 FILTER 1/1
Unit FUnit FUnit FUnit FUnit FrameramerameramerameThe Zamil TW-series air handling unit is constructed from framed modules manufactured fromextruded anodized aluminium profiles joined by means of 3D injected molded and reinforcedPE corners to form the “Penta-post” construction. This method has demonstrated superiormechanical characteristics and gives the unit its rigidity and design flexibility.
The unique profiles with their unique cross sections designed to give extra strength and rigid-ity 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 framesare insulated with fiberglass that confirms to HH-1-545B type 1, SMACNA standard for ductliners and ASTM-C-423 and NFPA90A and 90B standards for fire resistance.
Middle webs of the same material as the profiles are used to recess the panels and stiffenthe case assembly.
The frame construction makes it possible to disassemble and reassemble the unit sectionsat site in case of access or lifting difficulties.
30mm Profile Penta-Post 50mm Profile Penta-Post
An air handling unit module
8
Unit frame Options:Unit frame Options:Unit frame Options:Unit frame Options: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).
PPPPPanels, Panels, Panels, Panels, Panels, Paint, Insulationaint, Insulationaint, Insulationaint, Insulationaint, InsulationTW-series casing panels are constructed from double wall, sandwich type panels. With thisconfiguration, the insulation is kept out of the air stream and thus assures better indoorquality, as well as the ease of cleaning. Panel thickness is 30 or 50mm based on the unitsize, as standard TW2 - TW35 comes with 30mm panel thick, while TW47 - TW120 comeswith 50mm panel thick. Upon client request, TW2 - TW35 units can be manufactured with50mm panel thickness as an option.
FFFFFor standard panel, or standard panel, or standard panel, or standard panel, or standard panel, the outer skin of the sandwich panel is zinc coated galvanized steelsheet metal of 24 gauge thickness thoroughly de-greased and then phosphated beforethe application of an average 80 micron electrostatic polyester powder paint oven bakedin 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 gaugethickness.
Stiffeners inside the panel are provided to enhance the rigidity of the casing and to securethe inside insulation.
All panels are thermally and acoustically insulated for best unit performance, and areinternally insulated with fiberglass insulation of 48 kg/m3 density, the insulation confirmsto HH-1-545B type 1, SMACNA standard for duct liners and ASTM-C-423 and NFPA 90A and90B standards for fire resistance.
50mm thermal bridge profile 100mm galvanized profile
9
Access PAccess PAccess PAccess PAccess Panels and Doorsanels and Doorsanels and Doorsanels and Doorsanels and DoorsThe access panels and doors of the air handling unit have exactly the same configurationof 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 beserved.
Five types of access panels and doors can be provided:Five types of access panels and doors can be provided:Five types of access panels and doors can be provided:Five types of access panels and doors can be provided: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.
Double Skin Panels Combination Choices. (The Standard Panel Construction is Shaded).
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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 cus-tomer request.
Unit BaseUnit BaseUnit BaseUnit BaseUnit BaseThe unit base is a fabricated, welded galvanized sheet metal base of high gauge along theperimeter of the unit. Supports extend across the length and width of the unit to supportthe internal components. The unit base construction is well painted to withstand the mostdifficult weather conditions.
For the units TW2 – TW14 the unit base height as default is 80mm, the base rail can befabricated 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 befabricated with 150 & 200mm heights.
Air handling unit base
TTTTTable (1)able (1)able (1)able (1)able (1)
SSSSStandard Access typetandard Access typetandard Access typetandard Access typetandard Access type
Unit Section
Fan Section Coil Section Filter Section
TW2 - TW11 B A B B
TW14 - TW22 C A B B
TW26 - TW120 D A D D
(if access is needed)
Unit Size Other Sections
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RRRRRoof Coof Coof Coof Coof CoveroveroveroveroverFor outdoor installations, TW-series air handling units are equipped with a standard roofcover to protect the unit from varying climates. The roof cover is made with slight pitchdown from the center line to the ends on both sides to avoid rain accumulation on theunit top. For best rainwater drainage, the roof cover is extended along the unit perimeter.
Sealant application before roof cover installation Roof Cover
Aluminum filters Synthetic filters Pleated filters
FiltersFiltersFiltersFiltersFiltersA wide variety of filter types are available to meet any filtration requirements, including flatfilters, low-velocity filters, bag filters, HEPA filters, carbon filters and many other types of filters.
11111- F- F- F- F- Flat Filterslat Filterslat Filterslat Filterslat FiltersIn Zamil TW-series Air handling units, the following types of flat filters can be provided:a. 2'' flat filters with Aluminium washable media,2'' flat filters with Aluminium washable media,2'' flat filters with Aluminium washable media,2'' flat filters with Aluminium washable media,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,2" flat filters with synthetic non-woven media,2" flat filters with synthetic non-woven media,2" flat filters with synthetic non-woven media,2" flat filters with synthetic non-woven media, either disposable or cleanable,either disposable or cleanable,either disposable or cleanable,either disposable or cleanable,either disposable or cleanable,can be provided upon request.
c. 4" flat filters with Aluminum or synthetic media,4" flat filters with Aluminum or synthetic media,4" flat filters with Aluminum or synthetic media,4" flat filters with Aluminum or synthetic media,4" flat filters with Aluminum or synthetic media, can be also provided upon request.
12
22222- L- L- L- L- Low Vow Vow Vow Vow Velocity Filters (Velocity Filters (Velocity Filters (Velocity Filters (Velocity Filters (V-Filters)-Filters)-Filters)-Filters)-Filters)This can be provided as an option to increase the filtration area. Filters arranged in a veebank, filters media options are same as flat filters.
Low velocity V-Filter section
3- B3- B3- B3- B3- Bag Filtersag Filtersag Filtersag Filtersag FiltersFor a higher level of filtration than flat filters, bag filters with 95% filtration efficiency canbe used, the bag filters are made from ultra fine non-woven synthetic fibers, formed intopockets and then attached to a rigid header.Short bag filters with 15" deep or long bag filters with 22" deep are available.
4- HEP4- HEP4- HEP4- HEP4- HEPA FiltersA FiltersA FiltersA FiltersA FiltersFor critical air cleaning applications such as clean rooms, food factories, operation theatersor pharmaceutical applications where a very high degree of filtration is required and theefficiency 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 fromthe above types of filters are used (see page 7 for filter sizes combination for each model).
5- Carbon Filters5- Carbon Filters5- Carbon Filters5- Carbon Filters5- Carbon FiltersActivated carbon is the most common material used in HVAC systems for the removal of gaseouscontaminations by means of adsorption, absorption and chemical reaction.
Based on the application, the surrounding environment carbon filters can be carefullyselected and integrated in Zamil TW-series air handling units as an option.
Filter FramesFilter FramesFilter FramesFilter FramesFilter FramesThe pre-filters and bag filters are fixed in a specially - designed galvanized steel frames, with locks tosecure the filters in their places during operation. For TW2 - TW26 models, the filter frames are fixedtogether and installed on a channel to enable sliding them out complete with the filter cells for service orreplacement, while for the models TW35-TW120 the filter frames are fixed inside the filter section andservice or replacement to be done inside the unit. The arrangement of filter frames designed to mini-mize 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 thecalculations for the selection of the blower motor.
Options:Options:Options:Options:Options:- Stainless steel filter frames.- Differential pressure switch (Loose delivery).- Auto roll filters.- Sand Inertia filters.- Gas phase filters.- Cartridge filters.- For visual indication of the filter conditions, an inclined manometer for indoor applica-
tions can be provided or alternatively, a Magnehelic manometer can be provided spe-cially for the outdoor applications (loose delivery).
14
CCCCCoilsoilsoilsoilsoilsZamil 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 andcomply with Eurovent standards.
All coils designed to deliver their respective duties at optimum performance at all designconditions and to meet a wide range of applications and requirements.
As a standard, coils are manufactured from seamless copper tubes of ½” OD, mechanicallyexpanded into collar continuous corrugated aluminum fins to provide a continuous com-pression 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 asan option upon the client request or to achieve the determined indoor conditions.
Extensive cleaning is done after manufacturing each coil for optimum system cleanlinessand 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 expansioncoils, and up to 4 rows for heating coils.
Due to the huge variety of coil input conditions, the coils calculation and selection isoptimally done based on a fully wetted coil by selection software integrated in the unitselection software to match the required conditions.
Direct expansion coils are equipped with a properly - sized expansion valve and distributorto ensure equal refrigerant fed to all circuits. The number of circuits is chosen to provideoptimum heat transfer and reasonable refrigerant velocity and pressure drop so as not totrap any oil in the coil tubing.
Inclined Manometer Magnehelic Pressure Gauge
15
Headers and connections for water coils and DX-coils are made of seamless copper pipesand inlet & outlet connections are sealed against unit panels by rubber gaskets as stan-dard wherever coil connections protrude through the casing.
Utilizing the full available unit cross section area, coils are mounted in the unit casing onnon-corrosive slide rails to allow for easy coil slide in - slide out when required. All watercoils are fitted with plugged drain and vent tapping to facilitate draining and venting.
Chilled Water Coil Direct Expansion Coil
Options:Options:Options:Options:Options:- 316L Stainless steel coils casing.- On staked coils, intermediate drain pans can be fitted to provide drainage of conden-
sate on the elevated coil block.- Copper tube – copper fins coil.- Pre-coated fins coil.- 5/8’’ tube diameter - coils.- Coated coils with Resistec coating (Please contact your local Zamil sales office for more details).
- Stainless steel coils.- Steam coils.
Coil sliding rails
16
Drain PDrain PDrain PDrain PDrain PanananananIn order to remove the condensate formed during de-humidification, drain pan is suppliedas standard under the cooling coil, the drain pan is fabricated from stainless steel gauge 16sheets 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 bothsides for TW47 – TW120 where the units contains big coils, the drain pan bottom slopedproperly to ensure complete and positive drainage of condensate. The drain pan outersurface 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:Options:Options:Options:Options:- Double wall drain pan assembly.- Intermediate drain pan for small units.
17
FFFFFansansansansans11111- C- C- C- C- Centrifugal Fentrifugal Fentrifugal Fentrifugal Fentrifugal FansansansansansThe 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 testedperformance in accordance with DIN-24166 accuracy class-1, ISO 5801, BS 848 Part-1 andAMCA-210 standards.
All fans are optimally selected for best performance and sound characteristics based onmaximum fan efficiency.
The impellers can have forward curved, backward inclined or airfoil profile blades depend-ing on the customer requirements and the system static pressure.
The impeller is galvanized finished for forward curve blade, glass reinforced polymid orwelded heavy gauge steel painted with epoxy for backward and airfoil blade. All fans arestatically and dynamically balanced for stable non-surging operation.
Fans are securely fixed to hardened steel shafts with high safety factor and preciselyground and polished, shafts are coated with protective paint for added protection, theshaft ends are grooved and keyed.
Depends on fan class and size, TW-series fans equipped with self-aligned ball bearingsthat are greased for life or pillow block bearings with re-greasing nipples.
The complete fan-motor assembly mounted on a common base frame entirely isolatedfrom 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 connectionwhich will minimize the vibration and accordingly the sound level.
Centrifugal Fan-Motor Possible arrangements
18
++
V5V4V3
+
V2
+
V1
+
Backward Airfoil Fan Black steel Backward Airfoil Fan
Backward Fan Reinforced Backward Fan
Forward Fan Reinforced Forward Fan
19
20
18
11-Belt Guard12-Belts13-Outlet Flexible connection14-Outlet guard15-Outlet counter flange16-Bearing support17-Shaft guard18-Wheel19-Housing20-Shaft
21-Cut off22-R-Frame23-Bearing Bracket24-Guard Moun25-Motor Pulley26-Hub 27-Feet28-Bearing29-Rubber interliner30-Outlet Flange31-Motor Mounting Plate
1-Inlet Guard2-T-Frame3-Inlet Cone4-Inspection Door5-Drain Plug6-Motor7-Motor Rails8-Base Frame9-Anti vibration mounting10-Fan Pulley
18
11-Belt Guard12-Belts13-Outlet Flexible connection14-Outlet guard15-Outlet counter flange16-Bearing support17-Shaft guard18-Wheel19-Housing20-Shaft
21-Cut off22-R-Frame23-Bearing Bracket24-Guard Moun25-Motor Pulley26-Hub 27-Feet28-Bearing29-Rubber interliner30-Outlet Flange31-Motor Mounting Plate
1-Inlet Guard2-T-Frame3-Inlet Cone4-Inspection Door5-Drain Plug6-Motor7-Motor Rails8-Base Frame9-Anti vibration mounting10-Fan Pulley
22222- Plug F- Plug F- Plug F- Plug F- Plug Fansansansansans
Most of the energy consumed by an air handling unit is the electricity used to run the fanmotor, whilst only a small percentage of the energy goes to heat generation, so high fanefficiency means power saving, this is why the plug fans which are high fan efficiencysignificantly 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 environmentalfactors which we fine tuned our product to reduce it, the choice of using plug fan will beideal to achieve this goal. Plug fans are extremely quiet efficiency and quiet operationmake an exceptional combination for your air handling unit.
Plug Fan
Blower MotorsBlower MotorsBlower MotorsBlower MotorsBlower MotorsFan motors are Totally Enclosed Fan Cooled (TEFC) squirrel cage type with class “F“ insula-tion at 50oC ambient temperature and continuous duty. Motors are of IP55 and protect themotor from dust and water. It is mounted on an adjustable base of special design so thatthe belt tension can be easily adjusted.
With a voltage tolerance ±10% and frequency tolerance ±5%, motor can operate in anambient -16 to +50oC according to IEC60034-1 standard.
For motor sizing the mechanical losses incurred in transmitting the load from motor shaftto the fan shaft are taken into consideration along with a reasonable safety factor.
Standard Motor Mount
21
Standard Motor
Options:Options:Options:Options:Options:- Explosion Proof motors- Two speed motors- Stand by motors
Standard motors are fitted with six terminals, and a terminal connection and wiring dia-grams are shown in the motor terminal box.Sample wiring connections are shown in the below diagram.
DrivesDrivesDrivesDrivesDrivesTransmission of power from the motor to the fan is provided by means of a set of pulleysand matching V-belts. The pulleys are taper locked to the fan and motor shaft. TW-seriesair handling units are equipped with the optimized pulleys and belts, which are sized andpre-installed by factory. Optimal selection of drives and proper installation will ensurethat the fan re-stats at the required designed speed and at same time help to optimizefan and motor bearing life.
Transmission AssemblyFan Pulley – Motor Pulley – Belt and Bushes
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VVVVVariable Fariable Fariable Fariable Fariable Frequency Drivesrequency Drivesrequency Drivesrequency Drivesrequency Drives
Variable Frequency Drives or Frequency Inverters as they are sometimes called are installedon Fan motors to vary the fan speed in applications where the supply CFM is not constantand 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 HandlingUnit will depend on the demand requested by the VAV boxes. When the space is satisfiedand the VAV box closes its damper, the total required CFM will be reduced. To avoid overpressurizing the ducting, a Variable Frequency Drive is installed to reduce the speed of thefan 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 temperaturerating 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, TorqueControl, Dual Motor Control and Threshold Comparator. Intelligent Thermal Managementfunctionality to reduce tripping and motor noise. Complies with EN61800-3 and EN50082-2for Electromagnetic Immunity as well as EN61800-3 for Electromagnetic Emissions. EMCfilters can be installed for more stringent requirements. Also equipped with protection forunder voltage, over voltage, phase loss, drive overload, over current, over temperature,ground fault, and short circuit.
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Variable Frequency
Vibration EliminatorVibration EliminatorVibration EliminatorVibration EliminatorVibration EliminatorIn order to reduce the transmission of noise and vibration, the complete fan motor sub-base assembly is mounted on set of anti-vibration mounts.
As standard for TW2 - TW35, the fan assembly is a common base frame entirely isolatedfrom the unit by rubber in shear while as standard in units TW47 - TW120, the frameisolated by 1” deflection open type spring isolators.
Rubber Isolator Spring Isolator
Options:Options:Options:Options:Options:- TW2 - TW35 equipped with the 1” deflection springs.- 2” Deflection springs.- Seismic springs.
Plenum sectionPlenum sectionPlenum sectionPlenum sectionPlenum sectionEmpty sections can be provided upon request as an access or to facilitate the function of acomponent in another section or for future use. The standard length of the plenum sectionis 500mm, however, custom sizes to suite any requirements can be provided.
Electric HeaterElectric HeaterElectric HeaterElectric HeaterElectric HeaterElectrical heaters with wide range of capacities and steps are available to be supplied built-inZamil TW-series Air handling units.
The standard electric heater is the open wire type which is provided in a stand alone section, itconsists of a heavy gauge corrosion resistant steel frame and control compartment which con-tains 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 construc-tion designed to allow for free flow of air with lowest possible pressure drop.
Open Type Heater
Options:Options:Options:Options:Options:- Heaters with UL control panel.- Finned tubular heater type.
Finned Type Heater (Option)
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DampersDampersDampersDampersDampers
Dampers can be provided with opposed blades or parallel blades. Dampers are prepared foreither manual or motorized operation (damper actuator can be provided as an option).
As standard, Zamil dampers are entirely made of aluminum profiles with reinforced polya-mide accessories, the blades of the damper has airfoil shape and perfectly controlled bygears 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 polya-mide which make it light in weight and yet extremely strong because of its well-engi-neered design.
Whenever the damper width is exceeding 1220 mm, an intermediate profile is given to givegreater rigidity for larger dimensions.
The damper’s air tightness is enhanced by special gasket inserted in both, the blades andthe 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.
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Zamil TW series air handling units are equipped with multiple-blade, low leakage dampersto modulate and control the air flow.
The previously mentioned dampers can be used as:The previously mentioned dampers can be used as:The previously mentioned dampers can be used as:The previously mentioned dampers can be used as: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 energyIn order to recover energy and conserve its consumption by exchanging the energyIn order to recover energy and conserve its consumption by exchanging the energyIn order to recover energy and conserve its consumption by exchanging the energyIn order to recover energy and conserve its consumption by exchanging the energybetween the supply and exhaust air streams, different types of heat recovery sys-between the supply and exhaust air streams, different types of heat recovery sys-between the supply and exhaust air streams, different types of heat recovery sys-between the supply and exhaust air streams, different types of heat recovery sys-between the supply and exhaust air streams, different types of heat recovery sys-tems can be provided built-in Zamil TWtems can be provided built-in Zamil TWtems can be provided built-in Zamil TWtems can be provided built-in Zamil TWtems can be provided built-in Zamil TW-----series units. This will assure the economicalseries units. This will assure the economicalseries units. This will assure the economicalseries units. This will assure the economicalseries units. This will assure the economicalrunning costs of the units.running costs of the units.running costs of the units.running costs of the units.running costs of the units.
Energy REnergy REnergy REnergy REnergy Recovery Wheelecovery Wheelecovery Wheelecovery Wheelecovery WheelThe heat wheel is a rotating wheel consisting of an air permeable aluminum matrix witha large interior surface, the wheel consists of two half moon sections, and it should beinstalled in a double deck or side by side units where the supply air flows through one halfof the rotary wheel while the exhaust air flows in counter flow through the other half, thewheel is rotating with low speed simultaneously.
Energy wheels designed to recover either sensible heat only or both sensible and latent tomeet the requirements of the indoor air quality. The recovery of sensible heat achieved whenthe sensible heat is transferred as the metallic substrate gain and stores heat from the warmerair 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 coat-ing condenses moisture from the air stream that has the higher humidity ratio throughabsorption and releases moisture through evaporation into the air stream that has a lowerhumidity ratio. The TW-series selection software optimizes the selection of the energywheel to achieve the needed indoor conditions.
Heat wheels are ideal for applications that demand high percentage of fresh air intakelike in hospitals, labs, universities and pharmaceutical applications.
Energy Recovery Wheel
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RRRRRun Around Cun Around Cun Around Cun Around Cun Around CoilsoilsoilsoilsoilsIt is an air to water heat exchanger system, it is used to recover sensible heat only, it consistsof two coils, one located in the exhaust air stream and the other in the supply air stream, bothof them are connected with a pump in a closed circuit (pump and piping by others), the heattransfer medium is water.
When the cold air passes through the first coil of the run around system which is located in thecold air stream, it cools down the water inside the coil, after the water looses heat, the pumppasses this cold water to the coil in the hot air stream, heat exchange happened thus coolingthe air and warming the water, warm water returns to the coil in the cold stream and the cycleis repeated.
Plate Heat Exchanger
Run Around Coils
Plate Heat EPlate Heat EPlate Heat EPlate Heat EPlate Heat ExchangerxchangerxchangerxchangerxchangerThis type of heat recovery systems depends on the thermal conduction propriety to recoversensible heat only.
The plate heat exchanger is specially thermoformed plates, connected together via foldededges permanently bonded and sealed. The supply and exhaust airflows pass crossways throughthe heat exchanger alternate aluminum layers of the plate heat exchanger. The two air streamsare totally separated by the nature of the heat exchanger construction, so to use this type ofheat exchangers, the unit shall be a double deck unit.
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Heat Pipe SHeat Pipe SHeat Pipe SHeat Pipe SHeat Pipe SystemystemystemystemystemThis type of heat recovery system utilizes the refrigerant phase change property. It con-sists of two coils connected to each other circuit by circuit independently; each circuit isfilled with a refrigerant.
Two main functions can be done using this system; it can be used for dehumidification orfor heat recovery, according to the arrangement of the heat pipe coils with respect toother components.
Heat pipes for dehumidification function Heat pipes for dehumidification function Heat pipes for dehumidification function Heat pipes for dehumidification function 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 airpasses over the heat pipes, the refrigerant vaporizes, carrying heat to the second sectionof heat pipes, placed downstream. Because some heat has been removed from the airbefore encountering the evaporator coil, the incoming air stream section is called the pre-pre-pre-pre-pre-cool heat pipe.cool heat pipe.cool heat pipe.cool heat pipe.cool heat pipe.
Air passing through the evaporator coil is assisted to a lower temperature, resulting ingreater condensation removal. The «overcooled» air is then reheated to a comfortabletemperature by the reheat heat pipe sectionreheat heat pipe sectionreheat heat pipe sectionreheat heat pipe sectionreheat heat pipe section, using the heat transferred from the pre-cool heat pipe.
This entire process of pre-cooling and reheating is accomplished with no additional en-ergy use. The result is an air conditioning system with superior ability to remove moisture.
Heat Pipe For Dehumidification
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For Heat RHeat RHeat RHeat RHeat Recovery function ecovery function ecovery function ecovery function ecovery function the heat pipe also consist of two sections, each of theminstalled 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 thesecond section and the warm air will be cooled down while the relatively cold air in thecold air stream will condense the refrigerant which will return back to the first part bygravity, then this cycle repeated.
Steam Humidifier
HumidifiersHumidifiersHumidifiersHumidifiersHumidifiers11111- S- S- S- S- Steam humidifiersteam humidifiersteam humidifiersteam humidifiersteam humidifiers
Zamil TW-series Air handling units can be equipped with a self-contained humidifier, whichis electronically controlled to sense and control the humidity.
The steam is generated in a polypropylene cylinder mounted onto the outside of thehumidifier section within a special enclosure. A stainless steel distributor suitable in lengthpasses through the unit casing to inject steam in the air stream to reach the neededhumidity conditions.
Heat Pipe For Heat Recovery
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Steam Distributor
Air Washer
22222- Air W- Air W- Air W- Air W- Air WashersashersashersashersashersZamil air handling units can be equipped with air washer section which mainly serve foradiabatic cooling, humidifying and air washing.
Air washer is a section in which the air flow is brought in contact with a large quantity of sprayedwater. Depending on the condition of the circulating water, air washers are forming a basic partof 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 airare washed out, extremely small droplets (Superfine aerosols) can be fully absorbed by theair and they are designed to avoid the formation of superfine aerosols as far as possible.
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3- Adiabatic Cooling / high pressure humidification3- Adiabatic Cooling / high pressure humidification3- Adiabatic Cooling / high pressure humidification3- Adiabatic Cooling / high pressure humidification3- Adiabatic Cooling / high pressure humidification
Zamil adiabatic cooling / high pressure humidification is a system which is ideal for thehumidification of medium/large industrial environments and large volumes of air.
The system uses compressed air to atomize the water into very fine water particles thatevaporate 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 waterand compressed air to the nozzles to maintain the humidity/temperature set point.
Diffuser plate
Diffuser PlateDiffuser PlateDiffuser PlateDiffuser PlateDiffuser PlateThe diffuser plate is a perforated, heavy gauge galvanized steel plate provided to shutterthe air and distribute it uniformly across the section.
The use of diffuser plate becomes essential when a functionally sensitive section - likeHEPA filters or an energy wheel, is facing high face velocities.
Sound Attenuators
Sound ASound ASound ASound ASound AttenuatorsttenuatorsttenuatorsttenuatorsttenuatorsSound 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 toprovide a range of attenuator performances. Sound attenuators casings are produced withG-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 sus-tain vermin or fungus and odorless, the infill has a glass tissue facing and is containedbehind galvanized perforated metal, which prevent infill material damage and fiber ero-sion up. To reduce the pressure loss and regenerated noise, the splitters are radiused atboth ends.
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Assembled Drip Eliminator
Drip EliminatorsDrip EliminatorsDrip EliminatorsDrip EliminatorsDrip EliminatorsTo avoid water carry-over in humid areas or when the velocity of air across the coolingcoils 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 thecustomer. Drip eliminator blades are PVC blades encased within a galvanized steel frame. Theblades 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 sec-tion for the drip eliminator can be provided upon request.
Bulk Head LightBulk Head LightBulk Head LightBulk Head LightBulk Head LightZamil TW units can be equipped with bulk head lights as an option in different sectionslike fan section or filter section, to provide enough lightening to watch the function of thecomponent or to facilitate any service or maintenance activities.
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Ultra Violet Lights
Ultra Violet LightsUltra Violet LightsUltra Violet LightsUltra Violet LightsUltra Violet LightsThese special lamps are provided built in the air handling unit as an option for a high levelof air purification and deodorization of an indoor unit. These lamps are used to inactivateairborne bacterial or fungal contamination for any application, especially those that re-quire a very high level of air cleanness like hospitals, labs or pharmaceutical applications.
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PPPPPower Power Power Power Power Panelsanelsanelsanelsanels
Self contained power panels including all necessary accessories for a fully functional sys-tem. Panels are built-in to the AHU body and include MCCBs, Blower Contactors withOverload Relays, Transformers, fuses and terminal blocks.
Labeled terminal blocks allow for easy site installation and interfacing to third party con-trol networks. Terminal Blocks can be customized as per customer requirements and caninclude Motor Run Status, Motor Trip Status, Start/Stop Commands, Pre-Filter Alarms, BagFilter Alarms, Airflow Alarms, Damper Control and indication and others.
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Hygienic UnitsHygienic UnitsHygienic UnitsHygienic UnitsHygienic Units
Zamil hygienic air-handling units incorporate the state-of-the-art technology to providerefrigeration and meet filtration, pressurization, condensation control and sanitization stan-dards required by the critical applications where ultra clean air needed.
The units are custom engineered to produce the specified psychometric conditions and toachieve the environmental design criteria for the area being served.
Taking economic issues taken into consideration, our design engineers can design hygienic airhandling units methodically and logically to suit the ultra clean application requirements.
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Hygienic unit panel detail
Our Hygienic air handling units comply with the requirements of DIN1946, Part-4, O-NormH 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.
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’shygienic applications like hospitals, pharmaceutical sectors, food factories requirements, etc.
Small size hygienic air handling unit
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Air Handling Units Selection Software Air Handling Units Selection Software Air Handling Units Selection Software Air Handling Units Selection Software Air Handling Units Selection Software "ClimCalc""ClimCalc""ClimCalc""ClimCalc""ClimCalc"The innovative air handling unit selection software "ClimCalc" is a powerful tool for con-sultants, sales and application engineers. To activate this software and after the userenters the design parameters that reflect the customer requirements or consultants guide-lines "ClimCalc" will then configure and calculate within a very short period the air han-dling unit equipment. If any data entered doesn’t correspond with the various certifica-tion 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 inevery respect.
The program performs section by section technical verification and selection until thewhole unit is done. In each section, many options related to that particular section can beselected 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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Sample of Performance Report
Sample of Drawing Report
By one click on “Complete” ClimCalc will work out the best solution for your application usingoptimal 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.
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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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Supply, Exhaust Simple Units
Supply, Exhaust Inline Units
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Some Air Handling Units PSome Air Handling Units PSome Air Handling Units PSome Air Handling Units PSome Air Handling Units Possible Cossible Cossible Cossible Cossible Configurationonfigurationonfigurationonfigurationonfiguration
Stacked Unit with Energy Wheel
Stacked Unit with Plate Heat Exchanger
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Side by side Unit
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Stand by-duty Fan
PL-AP-TWH-11-2M-E