Central Station

Double Skin
Air Handling Units
TW/TWH Series
1400 m /hr thru 120,000 m /hr
Company Business
Zamil Air Conditioners (ZAC), a sector business of Zamil Industrial, is the largest supplier of air conditioners in the Middle East. It manufactures
and markets a whole range of air conditioners from room air conditioners to packaged units to large capacity chillers for residential, commercial
and industrial applications. Zamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be established in Saudi
Arabia and today is a leading international manufacturer of air conditioning systems & service solutions and is Number One in the Middle East.
ZAC’s operations are structured into four companies supporting seven in-house brands and twelve products and service units as well as a
number of international brands under the OEM Sales. The seven in-house brands are Zamil Air Conditioners, Classic, Zamil, Cooline, CoolCare,
Climatech and Geoclima.
The four companies are:
1. Zamil Air Conditioners & Home Appliances Co. (L.L.C.), supporting Zamil, Classic, Cooline, GE and OEM brands for consumers.
2. Zamil Central Air Conditioners Co. (L.L.C.), supporting Zamil Air Conditioners, Cooline and Climatech for commercial and industrial customers.
3. Zamil Air Conditioning and Refrigeration Services Co. (L.L.C.), providing electromechanical engineering, construction and project management
services, HVAC Operation & Maintenance, Retrofit Services, Spare Parts, Fire Protection, Controls, Electrical Services, Coils, Ducting and Coating.
4. Geoclima srl is an independent business supporting other three companies for their requirements of Chillers and Double Skin AHU’s.
The first three Companies- direct their business operations from the First and Second Industrial Cities in Dammam, Saudi Arabia and have a
product design center in Austria.
GEOCLIMA has its engineering and production departments located at Monfalcone, Italy.
All the four companies, while operating independently, supplement each other’s activities in a way that makes synergy work at its best and
achieves ZAC’s goals of maximizing customer value and satisfaction.

OEM Sales - Private Labeling

Zamil Air Conditioners produces branded air conditioners under OEM agreements for several leading international brands. Such relationships are
testimony to the excellence of ZAC’s engineering and production processes. Most of the units produced under the private labeling agreements
are for window and mini-split systems. However, ZAC is expanding its OEM offerings to include residential and light commercial units. Some of
the OEM brands manufactured at Zamil Air Conditioners are: Supra, Sanyo and Blue Star.

Joint Venture
Middle East Air Conditioners - Joint Venture with General Electric.
Zamil Air Conditioners partners with GE Appliances - Europe since 1997, in a joint venture called Middle East Air Conditioners (MEAC), for
manufacturing and marketing of GE branded air conditioners.
MEAC was awarded the license to manufacture Window, Mini Splits and Ducted Split types under the brand names GE, Hotpoint and RCA. Today,
MEAC enjoys extensive coverage in Saudi Arabia, GCC and the African market. In an ever-changing market, MEAC continually strives to acquire
new technologies and stylish integrated design with optimum performance and reliability that bring greater value to customers.

Factories and Production

Zamil Air Conditioners has two prime manufacturing plants in Dammam, Saudi Arabia and a production facility in Italy operated by GEOCLIMA and
a product design center in Austria. ZAC can produce up to 900,000 room air conditioners, 300,000 mini-split systems and 65,000 central air-
conditioning systems per annum and supplies air conditioning products to over 55 countries across the world - the major markets being GCC,
Middle East, North Africa, Europe and Asia.

Quality & Product Certificates

The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification.
ZAC’s products are certified with:
1. CE (Council of European Community).
2. UL (Underwriters Laboratory).
3. Eurovent (Certified Performance).
4. ISO 9001-2008 (International Organization for Standardization).
5. AHRI (Air-Conditioning, Heating and Refrigeration Institute).
Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammed bin Fahd Al Saud
Award for Factory Safety.

Our Products & Service Units

In addition to consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufactures a host of
residential, commercial and industrial air conditioners. This broad product range extends from the concealed units up to 5 TR, the ducted splits
up to 30 TR, the packaged units up to 95 TR, the single and double skin air handling units up to 138,316 CFM, the water chillers up to 500 TR and
the centrifugal chillers up to 5,000 TR cooling capacity.
Our products and services include, in addition to Maintenance, Retrofit & Operations (MRO), complete integrate suite of solutions like:
• Zamil Projects: Providing EPC for electromechanical works for Industrial, Utility and Oil & Gas customers.
• Zamil Controls: Design, assembly, integration and commissioning of low current & low voltage systems.
• Zamil Fire Protection: Design, integration and commissioning of active fire protection systems.
• Zamil Electrical: Design, integration and commissioning of lv/mv (low voltage/middle voltage) systems.
• Coil & Coating: Coil replacement, anti-corrosion coating, water proofing & reflective coating and passive fire protection solutions.
• Zamil Ducting: Facilities designs and manufactures high quality duct systems and other HVAC industry related products, utilizing state of the
art automated duct lines, Plasma Cutting, CNC Turret punch press and other specific machinery through two duct factories located in Saudi
Arabia western province (Yanbu) and Eastern province (Dammam).
 INDEX
Contents Page
Introduction .......................................................................................................................... 3
Quality................................................................................................................................... 3
Flexible Modular Construction ............................................................................................. 4
Rigid and leak tight construction ........................................................................................ 4
Wide Range of Sizes ............................................................................................................. 4
Nomenclature ....................................................................................................................... 5
Quick Unit Selection ............................................................................................................. 6
Unit Cross Sections ............................................................................................................... 7
Unit Frame ............................................................................................................................ 8
Panels, Paint, Insulation ...................................................................................................... 9
Access Panels and Doors ................................................................................................... 10
Unit Base ............................................................................................................................. 11
Roof Cover .......................................................................................................................... 12
Filters .................................................................................................................................. 12
1- Flat Filters ........................................................................................................... 12
2- Low velocity Filters (V-Filters) .......................................................................... 13
3- Bag Filters .......................................................................................................... 13
4- Hepa Filters ........................................................................................................ 13
5- Carbon Filters ..................................................................................................... 14
Coils ..................................................................................................................................... 15
Drain Pan ............................................................................................................................ 17
Fans ..................................................................................................................................... 18
1- Centrifugal Fans ................................................................................................. 18
2- Plug Fans ............................................................................................................ 21
Blower Motors .................................................................................................................... 21
Drives .................................................................................................................................. 22
Variable Frequency Drives ................................................................................................. 23

1
Contents Page
Vibration Eliminator ........................................................................................................... 24
Plenum Section .................................................................................................................. 24
Electric Heater .................................................................................................................... 24
Dampers ............................................................................................................................. 26
Energy Recovery Wheel ..................................................................................................... 28
Run Around Coils ................................................................................................................ 29
Plate Heat Exchanger ......................................................................................................... 29
Heat Pipe System ............................................................................................................... 30
Humidifiers ......................................................................................................................... 31
1- Steam Humidifiers ............................................................................................. 31
2- Air Washers ......................................................................................................... 32
3- Adiabatic Cooling / high pressure humidification ............................................ 32
Diffuser Plate ...................................................................................................................... 33
Sound Attenuators .............................................................................................................. 33
Drip Eliminators .................................................................................................................. 34
Bulk Head Light .................................................................................................................. 34
Ultra Violet Light ................................................................................................................. 35
Power Panels ...................................................................................................................... 36
Hygienic Units .................................................................................................................... 37
Air Handling Units Selection Software “ClimCalc“ ............................................................ 39
Some Air Handling Units Possible Configuration ............................................................... 46

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2
Introduction
This catalogue is meant to serve as a guideline for consulting and design engineers for the
selection of Zamil Air Handling Units. Please contact your local Zamil office for assistance
with any technical clarification, selection, consultancies related to the air handling units
product capabilities, features or applications.

Quality
The quality and reliability of any Zamil Air Handling Unit depends on the quality of the
components, therefore inline with our rigorous quality management and selection of the
best suppliers, we offer you the highest quality Units.

Each unit can have designed-in flexibility to adapt to your exact requirements. This capa-
bility provides you the best overall total value based upon life-expectancy, functionality,
energy efficiency and serviceability. Zamil air handling unit designs incorporate many
engineering and performance features which maximized equipment up-time and the
additional benefit of reduced equipment energy and maintenance costs.

3
Flexible Modular CConstruction
onstruction
Zamil Air Handling Units are manufactured as a factory-made combined blocks of encased
individual modules assembly based upon a wide range of standard panels (30mm, 50mm
and 100mm). An air handling unit consists of a fan or fans and other necessary sections
like coil, filters,…etc. to perform one or more of the functions of circulating, cleaning,
heating, cooling, humidifying, dehumidifying and mixing of air.

Zamil Air Handling Units can be delivered in sections for indoor or outdoor installation,
completely assembled or knocked down for on site- assembly
site-assembly
assembly.

Rigid and leak tight construction

Zamil 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 between
the panels and frame ensures an excellent leak tight and also works as thermal and
acoustic insulation and guarantees the tightness of the casing according to EN1886
EN1886.

Wide Range of Sizes

Seventeen Standard sizes of optimally engineered Air Handling Units can be supplied by
Zamil to handle air volumes from:
- 1,400 m3/h to 120,000 m3/h – Cooling duty.
- Up to 220,000 m3/h – Heating and Ventilation only.

Non-standard units can be produced for any application with much higher flow rates. For
requirements in excess of the above, please consult your nearest Zamil representative.

Zamil Air Handling Units provide you the best overall total value based upon life-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 maintenance
costs.

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.

4
Nomenclature

5
Quick Unit SSelection
Unit election
Range I = Airflow volume referring to free unit cross section and airflow velocity
from 1 m/s to 3.5 m/s
m/s.
W Range II = Airflow volume referring to coil finned area and airflow velocity from
W
Range II
1 m/s up to 2.5 m/s.
W Range I

Air flow volume [m3/h]

6
Unit CCross
ross SSections
ections
AIRFLOW RA
AIRFLO TE
RATE
UNIT SIZE m3/hr @ 2.5 m/s

FILTER ARRANGEMENT
FILTER TWP3 TWP5 ACROSS ACROSS
TW B (mm) H (mm) B (mm) H (mm) UNIT SECTION 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
8 1345 1040 1385 1080 11131 8280
2 FILTER 1/2

1 FILTER 1/1
6 1040 1040 1080 1080 8468 5975
2 FILTER 1/2

1 FILTER 1/1
1 FILTER 1/2 4 1040 735 1080 775 5805 3895

1 FILTER 5/6
3 940 735 980 775 5207 3410
1 FILTER 1/2

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") FILTER 5/6 = 490 x 592 mm (20" x 24")

7
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 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 frames
are insulated with fiberglass that confirms to HH-1-545B type 1, SMACNA standard for duct
liners and ASTM-C-423 and NFPA90A and 90B standards for fire resistance.

30mm Profile Penta-Post 50mm Profile Penta-Post

Middle webs of the same material as the profiles are used to recess the panels and stiffen
the case assembly.

The frame construction makes it possible to disassemble and reassemble the unit sections
at site in case of access or lifting difficulties.

An air handling unit module

8
Unit frame Options:
- 30mm, 50mm & 100mm hot dip galvanized steel profile.
- Special corrosion resistant profile, thermal contact free which provides perfect isolation
between the inside and outside airs, (only for 50mm units).

50mm thermal bridge profile 100mm galvanized profile

Panels, Paint, Insulation

Paint,
TW-series casing panels are constructed from double wall, sandwich type panels. With this
configuration, the insulation is kept out of the air stream and thus assures better indoor
quality, as well as the ease of cleaning. Panel thickness is 30 or 50mm based on the unit
size, as standard TW2 - TW35 comes with 30mm panel thick, while TW47 - TW120 comes
with 50mm panel thick. Upon client request, TW2 - TW35 units can be manufactured with
50mm panel thickness as an option.

For standard panel, the outer skin of the sandwich panel is zinc coated galvanized steel
sheet metal of 24 gauge thickness thoroughly de-greased and then phosphated before
the application of an average 80 micron electrostatic polyester powder paint oven baked
in RAL 9002 color scheme, this finishing pass 1500 hr in 5% salt path at 95oF and 100%
relative humidity. It complies to ASTM B 117 standard.

The inner skin of the panel are supplied in a zinc coated galvanized finish of 18 gauge
thickness.

Stiffeners inside the panel are provided to enhance the rigidity of the casing and to secure
the inside insulation.

All panels are thermally and acoustically insulated for best unit performance, and are
internally insulated with fiberglass insulation of 48 kg/m3 density, the insulation confirms
to HH-1-545B type 1, SMACNA standard for duct liners and ASTM-C-423 and NFPA 90A and
90B standards for fire resistance.

9
 Double Skin Panels Combination Choices. (The Standard Panel Construction is Shaded).

Access Panels and Doors

Panels
The access panels and doors of the air handling unit have exactly the same configuration
of the fixed panels described previously with same variety of choices.

The access panel type is determined based on the unit size and the section which to be
served.

Five types of access panels and doors can be provided:

A. Screwed panel is fixed with external screws for easy service access.
B. Removable access panel with latches and handle.
C. Hinged door with turn bolt.
D. Hinged door with turn-lever.
E. Hinged door with double lever lock.
F. Lockable types.

10
Table (1) shows the default selection of access panels and doors in the TW series AHU’s,
however, the type of the access can be changed among the alternatives upon the cus-
tomer request.
Table (1)
Standard Access type
Unit Section
Unit Size Other Sections
Fan Section Coil Section Filter Section (if access is needed)

TW2 - TW11 B A B B

TW14 - TW22 C A B B

TW26 - TW120 D A D D

Unit Base
The unit base is a fabricated, welded galvanized sheet metal base of high gauge along the
perimeter of the unit. Supports extend across the length and width of the unit to support
the internal components. The unit base construction is well painted to withstand the most
difficult weather conditions.

For the units TW2 – TW14 the unit base height as default is 80mm, the base rail can be
fabricated with 100, 120, 150 & 200mm heights as well.

For the units TW17 – TW120 the unit base height as default is 120mm, the base rail can be
fabricated with 150 & 200mm heights.

Air handling unit base

11
Roof CCover
over
For outdoor installations, TW-series air handling units are equipped with a standard roof
cover to protect the unit from varying climates. The roof cover is made with slight pitch
down from the center line to the ends on both sides to avoid rain accumulation on the
unit top. For best rainwater drainage, the roof cover is extended along the unit perimeter.

Sealant application before roof cover installation Roof Cover

Filters
A wide variety of filter types are available to meet any filtration requirements, including flat
filters, low-velocity filters, bag filters, HEPA filters, carbon filters and many other types of filters.

1- FFlat
lat Filters
In Zamil TW-series Air handling units, the following types of flat filters can be provided:
a. 2'' flat filters with Aluminium washable media, used as standard in Zamil TW-series air
handling units.
b. 2" flat filters with synthetic non-woven media, either disposable or cleanable,
can be provided upon request.
c. 4" flat filters with Aluminum or synthetic media, can be also provided upon request.

Aluminum filters Synthetic filters Pleated filters

12
2- LLow
ow V elocity Filters (V
Velocity -Filters)
(V-Filters)
This can be provided as an option to increase the filtration area. Filters arranged in a vee
bank, filters media options are same as flat filters.

Low velocity V-Filter section

3- B ag Filters
Bag
For a higher level of filtration than flat filters, bag filters with 95% filtration efficiency can
be used, the bag filters are made from ultra fine non-woven synthetic fibers, formed into
pockets and then attached to a rigid header.
Short bag filters with 15" deep or long bag filters with 22" deep are available.

4- HEP
HEPA A Filters
For critical air cleaning applications such as clean rooms, food factories, operation theaters
or pharmaceutical applications where a very high degree of filtration is required and the
efficiency needed to be in excess of 99.997%. HEPA filters can be provided as an option.

13
For all TW-series air handling units, a combination of three internationally common sizes from
the above types of filters are used (see page 7 for filter sizes combination for each model).
5- Carbon Filters
Activated carbon is the most common material used in HVAC systems for the removal of gaseous
contaminations by means of adsorption, absorption and chemical reaction.
Based on the application, the surrounding environment carbon filters can be carefully
selected and integrated in Zamil TW-series air handling units as an option.

Filter Frames
The pre-filters and bag filters are fixed in a specially - designed galvanized steel frames, with locks to
secure the filters in their places during operation. For TW2 - TW26 models, the filter frames are fixed
together and installed on a channel to enable sliding them out complete with the filter cells for service or
replacement, while for the models TW35-TW120 the filter frames are fixed inside the filter section and
service or replacement to be done inside the unit. The arrangement of filter frames designed to 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 the calcu-
lations for the selection of the blower motor.
Options:
- Stainless steel filter frames.
- Differential pressure switch (Loose delivery).
- Auto roll filters.
- Sand Inertia filters.
- Gas phase filters.
- Cartridge filters.
- Drum filters.
- Wide range of filters with MERV efficiency as per ASHRAE 52.2.
- For visual indication of the filter conditions, an inclined manometer for indoor applica-
tions can be provided or alternatively, a Magnehelic manometer can be provided spe-
cially for the outdoor applications (loose delivery).
14
 Inclined Manometer Magnehelic Pressure Gauge

Coils
Zamil TW Air Handling units offer a variety of chilled water coils, direct expansion coils
(R-410a, R-407c, R-134a), hot water coils and steam coils which confirms to AHRI 410
standard and comply with Eurovent standards.

All coils designed to deliver their respective duties at optimum performance at all design
conditions and to meet a wide range of applications and requirements.

As a standard, coils are manufactured from seamless copper tubes of ½” OD, mechanically
expanded into collar continuous corrugated aluminum fins to provide a continuous 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 as
an option upon the client request or to achieve the determined indoor conditions.

Extensive cleaning is done after manufacturing each coil for optimum system cleanliness
and all coils are factory tested at 300 psig air pressure under water.

Coils can be manufactured from 1 to 12 rows for both chilled water and direct expansion
coils, and up to 4 rows for heating coils.

Due to the huge variety of coil input conditions, the coils calculation and selection is
optimally done based on a fully wetted coil by selection software integrated in the unit
selection software to match the required conditions.

Direct expansion coils are equipped with a properly - sized expansion valve and distributor
to ensure equal refrigerant fed to all circuits. The number of circuits is chosen to provide
optimum heat transfer and reasonable refrigerant velocity and pressure drop so as not to
trap any oil in the coil tubing.

15
 Chilled Water Coil Direct Expansion Coil

Headers and connections for water coils and DX-coils are made of seamless copper pipes
and inlet & outlet connections are sealed against unit panels by rubber gaskets as stan-
dard wherever coil connections protrude through the casing.

Utilizing the full available unit cross section area, coils are mounted in the unit casing on
non-corrosive slide rails to allow for easy coil slide in - slide out when required. All water
coils are fitted with plugged drain and vent tapping to facilitate draining and venting.

Coil sliding rails

Options:
- 316L Stainless steel coils casing.
- On stacked coils, intermediate drain pans can be fitted to provide drainage of conden-
sate on the elevated coil block.
- Copper tube – copper fins coil.
- Pre-coated fins coil.
- 5/8’’ tube diameter - coils.
- Coated coils with coating (Please contact your local Zamil sales office for more details).
- Stainless steel coils.
- Steam coils.

16
Drain Pan
Pan
In order to remove the condensate formed during de-humidification, drain pan is supplied
as standard under the cooling coil, the drain pan is fabricated from stainless steel gauge 16
sheets which covers the whole cooling coil section not only under the coil slap.

For best drainage, drainage connection given from one side for TW2 – TW35 and from both
sides for TW47 – TW120 where the units contains big coils, the drain pan bottom sloped
properly to ensure complete and positive drainage of condensate. The drain pan outer
surface is insulated with (1/8”) closed cell foam insulation to prevent condensation.

Stainless steel drain pan The drain pan covers the whole coil section

Options:
- Double wall drain pan assembly.
- Intermediate drain pan for small units.

17
Fans
1- CCentrifugal
entrifugal FFans
ans
The standard fans used in TW-series are high performance Double Width Double Inlet (DWDI)
centrifugal fans, optimally engineered for HVAC application, with high quality, and fully tested
performance in accordance with DIN-24166 accuracy class-1, ISO 5801, BS 848 Part-1 and
AMCA-210 standards.

All fans are optimally selected for best performance and sound characteristics based on
maximum fan efficiency.

The impellers can have forward curved, backward inclined or airfoil profile blades depend-
ing 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 V5

+ + + + +

Centrifugal Fan-Motor Possible arrangements

18
 Forward Fan Reinforced Forward Fan

Backward Fan Reinforced Backward Fan

Backward Airfoil Fan Black steel Backward Airfoil Fan

19
 1-Inlet Guard 11-Belt Guard 21-Cut off
2-T-Frame 12-Belts 22-R-Frame
3-Inlet Cone 13-Outlet Flexible connection 23-Bearing Bracket
4-Inspection Door 14-Outlet guard 24-Guard Moun
5-Drain Plug 15-Outlet counter flange 25-Motor Pulley
6-Motor 16-Bearing support 26-Hub
7-Motor Rails 17-Shaft guard 27-Feet
8-Base Frame 18-Wheel 28-Bearing
9-Anti vibration mounting 19-Housing 29-Rubber interliner
10-Fan Pulley 20-Shaft 30-Outlet Flange
31-Motor Mounting Plate
18

20
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“ insula-
tion at 50oC ambient temperature and continuous duty. Motors are of IP55 and protect the
motor from dust and water. It is mounted on an adjustable base of special design so that
the belt tension can be easily adjusted.
With a voltage tolerance ±10% and frequency tolerance ±5%, motor can operate in an
ambient -16 to +50oC according to IEC60034-1 standard.
For motor sizing the mechanical losses incurred in transmitting the load from motor shaft to
the fan shaft are taken into consideration along with a reasonable safety factor.

Standard Motor Mount Standard Motor

21
Options:
- Explosion Proof motors
- Two speed motors
- Stand by motors
- IE3 motors
- Nema premium motors
Standard motors are fitted with six terminals, and a terminal connection and wiring dia-
grams are shown in the motor terminal box.

Drives
Transmission of power from the motor to the fan is provided by means of a set of pulleys and
matching V-belts. The pulleys are taper locked to the fan and motor shaft. TW-series air
handling units are equipped with the optimized pulleys and belts, which are sized and 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 Fan motors to vary the fan speed in applications where the supply CFM is not constant
and must be varied. In applications where Variable Air Volume boxes (VAV’s), for example,
are installed throughout the occupied space, the total CFM discharged by the Air Handling
Unit will depend on the demand requested by the VAV boxes. When the space is satisfied
and the VAV box closes its damper, the total required CFM will be reduced. To avoid over
pressurizing the ducting, a Variable Frequency Drive is installed to reduce the speed of the
fan and hence reduce the total CFM discharged by the unit.

A full range of Variable Frequency Drives from 0.25 kW up to 132 kW in voltage ratings of
(220V-1phase, 220V-3Phase, 380/480V-3phase) with an operating ambient temperature
rating up to 50oC are available.

The drives are easy to configure and operate with built-in Proportional, Integral, Derivative
(PID) control based on flow or temperature. Equipped with Dynamic Brake Control, Torque
Control, Dual Motor Control and Threshold Comparator. Intelligent Thermal Management
functionality to reduce tripping and motor noise. Complies with EN61800-3 and EN50082-2
for Electromagnetic Immunity as well as EN61800-3 for Electromagnetic Emissions. EMC
filters can be installed for more stringent requirements. Also equipped with protection for
under voltage, over voltage, phase loss, drive overload, over current, over temperature,
ground fault, and short circuit.

23
Vibration Eliminator
In order to reduce the transmission of noise and vibration, the complete fan motor 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 isolated
from the unit by rubber in shear while as standard in units TW47 - TW120, the frame
isolated by 1” deflection open type spring isolators.

Rubber Isolator Spring Isolator

Options:
- TW2 - TW35 equipped with the 1” deflection springs.
- 2” Deflection springs.
- Seismic springs.

Plenum section
Empty sections can be provided upon request as an access or to facilitate the function of a
component in another section or for future use. The standard length of the plenum section
is 500mm, however, custom sizes to suite any requirements can be provided.

Electric Heater
Electrical heaters with wide range of capacities and steps are available to be supplied built-in
Zamil TW-series Air handling units.

The standard electric heater is the open wire type which is provided in a stand alone section, it
consists of a heavy gauge corrosion resistant steel frame and control compartment which 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.

24
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:
- Heaters with UL control panel.
- Finned tubular heater type.
- Finned tubular heater, UL.

Finned Type Heater (Option)

25
Dampers
Zamil TW series air handling units are equipped with multiple-blade, low leakage dampers
to modulate and control the air flow.

Dampers can be provided with opposed blades or parallel blades. Dampers are prepared for
either manual or motorized operation (damper actuator can be provided as an option).
As standard, Zamil dampers are entirely made of aluminum profiles with reinforced polyamide
accessories, the blades of the damper has airfoil shape and perfectly controlled by gears that
are spaced out by special spacers located in the damper frame.
Zamil damper has an excellent anti-corrosion features as it is made of aluminum and polyamide
which make it light in weight and yet extremely strong because of its well-engineered design.
Whenever the damper width is exceeding 1220 mm, an intermediate profile is given to give
greater rigidity for larger dimensions.
The damper’s air tightness is enhanced by special gasket inserted in both, the blades and the
frame itself.
The following damper alternative can provided:
- Galvanized steel dampers with single skin blades.
- Galvanized steel dampers with airfoil blades.
- Stainless steel dampers with single skin blades.
- Stainless steel dampers with airfoil blades.
Options:
- AMCA dampers.
- Actuators.
- Back draft dampers.
- Different materials.

26
The previously mentioned dampers can be used as:
- Full-face air intake dampers.
- Bypass dampers.
- Fresh, exhaust and return air dampers for two-way or three-way mixing box.
- Economizer control.
- Multi-zone application dampers.

Some Possible Damper Positions & applications

27
In order to recover energy and conserve its consumption by exchanging the energy
between the supply and exhaust air streams, different types of heat recovery sys-
tems can be provided built-in Zamil TW
TW-- series units. This will assure the economical
running costs of the units.

Energy Recovery 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 coat-
ing condenses moisture from the air stream that has the higher humidity ratio through
absorption and releases moisture through evaporation into the air stream that has a lower
humidity ratio. The TW-series selection software optimizes the selection of the energy
wheel to achieve the needed indoor conditions.

- Heat wheels are ideal for applications that demand high percentage of fresh air intake.
- Wheels are AHRI 1060 certified as per ASHRAE standard.
- Wheels are Eurovent certified.

Energy Recovery Wheel

28
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

29
Heat Pipe SSystem
ystem
This 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 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 pre-
cool heat pipe.

Air passing through the evaporator coil is assisted to a lower temperature, resulting in
greater condensation removal. The «overcooled» air is then reheated to a comfortable
temperature by the reheat heat pipe section
section, using the heat transferred from the 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

30
For Heat R ecovery function the heat pipe also consist of two sections, each of them
Recovery
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

31
2- Air W ashers
Washers
Zamil air handling units can be equipped with air washer section which mainly serve for
adiabatic cooling, humidifying and air washing.
Air washer is a section in which the air flow is brought in contact with a large quantity of sprayed
water. Depending on the condition of the circulating water, air washers are forming a basic part
of air conditioning plants which easily combine washing, humidifying and cooling of air.
While water evaporates on the surfaces of large drops and impurities contained in the air
are washed out, extremely small droplets (Superfine aerosols) can be fully absorbed by the
air and they are designed to avoid the formation of superfine aerosols as far as possible.

Air Washer

3- Adiabatic Cooling/high pressure humidification

Zamil adiabatic cooling/high pressure humidification is a system which is ideal for the hu-
midification of medium/large industrial environments and large volumes of air.
The system atomize water into very fine water particles that evaporate easily in the air,
humidifying and cooling it. Evaporation occurs by “absorbing” sensible heat from the air
which becomes colder and more humid.
Along with this system an electronic controller is provided to manage the supply of water
and compressed air to the nozzles to maintain the humidity/temperature set point.

32
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 Attenuators
Attenuators
Sound attenuators can be used where a significant reduction to fan noise is needed.
Attenuators can be provided in the supply and/or return air side with different lengths to
provide a range of attenuator performances. Sound attenuators casings are produced with
G-90 galvanized steel sheets formed and lock formed seams with a sealant.

The acoustic infill materials are inert, non-flammable, non-hygroscopic and will not sustain
vermin or fungus and odorless, the infill has a glass tissue facing and is contained behind
galvanized perforated metal, which prevent infill material damage and fiber erosion up. To
reduce the pressure loss and regenerated noise, the splitters are radiused at both ends.

Sound Attenuators

33
Drip Eliminators
To avoid water carry-over in humid areas or when the velocity of air across the cooling
coils is high, drip eliminators are provided.
As standard, the drip eliminators are provided in two cases:
1- When the velocity across the coil is 2.64 m/s or more.
2- When the water content of the air is greater than 10.5 g/kg of dry air.

Other than in these two cases, the drip eliminator is given as an option upon the request of the
customer. Drip eliminator blades are PVC blades encased within a galvanized steel frame. The
blades are designed to completely prevent water carry-over with low pressure drop.
The drip eliminator is commonly fixed directly to the coil casing, however, separate sec-
tion for the drip eliminator can be provided upon request.

Assembled Drip Eliminator

Bulk Head Light

Zamil TW units can be equipped with bulk head lights as an option in different sections
like fan section or filter section, to provide enough lightening to watch the function of the
component or to facilitate any service or maintenance activities.

34
Ultra Violet Lights
These special lamps are provided built in the air handling unit as an option for a high level
of air purification and deodorization of an indoor unit. These lamps are used to inactivate
airborne bacterial or fungal contamination for any application, especially those that re-
quire a very high level of air cleanness like hospitals, labs or pharmaceutical applications.

Ultra Violet Lights

35
Power Panels
Panels

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 with
Overload Relays, Transformers, fuses and terminal blocks can be provided as an option.

Labeled terminal blocks allow for easy site installation and interfacing to third party con-
trol 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.

36
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 stan-
dards required by the critical applications where ultra clean air needed.

The units are custom engineered to produce the specified psychometric conditions and to
achieve the environmental design criteria for the area being served.

Taking economic issues taken into consideration, our design engineers can design hygienic air
handling units methodically and logically to suit the ultra clean application requirements.

37
Our Hygienic air handling units comply with the requirements of DIN1946, Part-4, O-Norm
H 6020, Part-1 and VDI6022 with following main product features:
- Smooth inside surface design.
- Air tight dampers.
- Light and inspection windows in desired function modules.
- Special joint sealing with silicon-free sealants.

Hygienic unit panel detail

Upon the request, the unit can be supplied with additional optional features like:
- Stainless steel panels.
- Condensate nipples in the fan casing.
- Stainless steel fabrication parts for all components.
- Anti-bacterial coating for all the inner casing and components.

Zamil hygienic air handling units are the answer when clean conditioned air is needed for today’s
hygienic applications like hospitals, pharmaceutical sectors, food factories requirements, etc.

Small size hygienic air handling unit

38
Air Handling Units Selection Software "ClimCalc"
The innovative air handling unit selection software "ClimCalc" is a powerful tool for con-
sultants, sales and application engineers. To activate this software and after the user
enters 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 in
every respect.

The program performs section by section technical verification and selection until the
whole unit is done. In each section, many options related to that particular section can be
selected to satisfy any air handling unit specifications.

Main Input Data Screen

39
 Unit Sizing Screen

Unit Construction Screen

40
Finishing Unit Construction and Units Locking Screen

Sections Parameters Input Data Screen

41
Calculation Finishing Screen

AHU Views Screen

42
By one click on “Complete” ClimCalc will work out the best solution for your application using
optimal technical design which can be checked by the output reports which consists of:
- Performance Report.
- Unit Drawing and Dimensions.
- Psychometric Chart.
- Fan operation Curve.
- Sound Curves.
- Unit weight, section by section.

Sample of Performance Report

Sample of Drawing Report

43
 Sample of Psychometric Chart

Sample of Fan operation area and operating point Chart

44
Sample of Noise Level Chart

Weight Report

45
Some Air Handling Units Possible CConfiguration
Possible onfiguration

Supply, Exhaust Simple Units

Supply, Exhaust Inline Units

46
 Stacked Unit with Energy Wheel

Stacked Unit with Plate Heat Exchanger

47
Side by side Unit

Stand by-duty Fan

48
Zamil Air Conditioners (ZAC), a wholly owned company of Zamil Industrial, is the largest supplier of air
conditioners in the Middle East. ZAC manufactures and markets a comprehensive line of air conditioners
ranging from room air conditioners to Centrifugal Chillers for residential, commercial and industrial
applications. Zamil Air Conditioners was founded in 1974 as one of the first air conditioning companies
to be established in Saudi Arabia. Today it is not only the leading international manufacturer of air
conditioning systems and service solutions, it is also number one in the Middle East.

ZAC’s head office and principal manufacturing plants are located in Dammam, Saudi Arabia as well as a
production facility in Italy. Zamil Air Conditioners produces over 900,000 air conditioners per annum and
supplies air conditioning products to over 55 countries around the world - the major markets comprising
of the GCC, the Middle East, North Africa, Europe and Asia.

Zamil Air Conditioners is an ISO 9001: 2008 certified company. It is the first Middle Eastern company to
have received the prestigious AHRI (Air-Conditioning, Heating and Refrigeration Institute, USA) and
Eurovent certifications for many of its products. As a result, ZAC is proud of its state-of-the-art testing
facility Ikhtebar which is a third party air conditioners testing facility built by Intertek Testing Services
(ITS), certified by Electrical Testing Laboratories (ETL) and accredited by the Saudi Accreditation
Committee (SASO) for compliance with international testing standards. Zamil Air Conditioners is the
only manufacturer in the region capable of guaranteeing product performance in compliance with local,
regional and international specifications and standards for operating performance, cooling capacity,
energy efficiency, airflow, noise level and durability.

Over the past few years, Zamil Air Conditioners has embarked upon an ambitious growth path. Besides
expanding its product lines through the two acquisitions made by Zamil Industrial in Europe ClimaTech
and Geoclima, Zamil Air Conditioners has been vigorously moving into newer markets, seeking strategic
alliances and investing heavily in Research & Development.

For more information, please visit our website www.zamilac.com

Zamil Central Air Conditioners

P.O. Box 41015, Dammam 31521, Kingdom of Saudi Arabia
Tel : +966 13 812 5400 Fax: +966 13 812 1977
Customer Service: 92 0000 468 www.zamilac.com