AquaSaver
Closed-loop Clean Water Cooling System

Closed-loop systems eliminate water loss by evaporation and algae & bacteria problems.

Benefits	AquaSaver Specifications	Air-Cooled Heat Exchanger Data
AquaSaver Systems	AS Packaged Systems	Energy Saving Control Panel
Optional Features	Typical Installation	Freeze Protector
Kleen-Water Filters and Data	Pumping Stations and Data	Additional Data
Selection for Air Compressors	Sizing Example	Ten-Year Limited Warranty
	Trim Cooler Selection

Benefits

Reduce water usage by over 95% with an Aqua Saver system with Trim Cooler.
Eliminate algae and bacteria-type problems.
No water consumption.
Eliminate sewer charges.
Adaptable to heat recovery.
Eliminate scale and corrosion.
Extend equipment life.
Reduce maintenance cost.
Reduce down time.
Easy installation.
Provide cooler water with Trim Cooler.

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AquaSaver Packaged Systems (ASP series)

Aqua Saver heat exchanger
Fan cycling
Simplex or Duplex pumping station
Trim Cooler with water regulating valve
All prewired and prepiped on a single skid

Energy Saving Control Panel

Standard in ASP series and optional in AS series heat exchangers. Includes power-on/off switch, power-on indicator, fan motor starter(s), and fan cycling thermostat. Fan cycling saves energy and provides temperature control under varying load and ambient conditions.

Optional Features

Packaged Aqua Saver systems.
Freeze-Protector heat transfer fluid.
Fan cycling.
High temperature indicator and/or alarm.
Pump failure indicator and/or alarm.
Pump auto start (duplex pump only).
NEMA 4x, J.I.C., NEMA 7, NEMA 4 or NEMA 12.
TEFC motors, fan(s) and pump(s).
Trim cooler and water regulating valve.
Automatic fill.
Three-way mixing valve for temperature control.
No-flow shut down.
Expansion tank sight glass.
Low level shut down and indicator.
Larger expansion tanks.
Optional gauges.
Pressure relief valve.

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Kleen-Water Filters and Data

For longevity and dependability, we recommend Kleen-Water Filters which are 99.0% efficient down to 1 micron. For point of installation see Typical Aqua Saver installation.

MODEL	PORT SIZE	MAX.PRESS.	MAX	MAX TEMP	DIMENSIONS				APPROX. SHIPPING WT.	TYPE
	PORT SIZE	MAX.PRESS.	MAX	MAX TEMP	INCHES				APPROX. SHIPPING WT.
	NPT-IN	PSIG	GPM	Deg. F	A	B	C	D	(LBS)
KW25	1	300	25	225	161/4	41/2	-	15/16	15	T
KW50	1 1/2	300	50	225	205/8	57/16	-	1 1/4	20	T
KW100	2 1/2	300	100	225	273/4	67/8	-	1 3/4	35	T
KW150	2 1/2	300	150	225	371/2	67/8	-	1 3/4	56	T
KW200	3	300	200	225	383/8	75/8	-	2 1/8	58	T
KW250	3	300	250	225	441/4	75/8	-	2 1/8	70	T
KW300	4 FLG.	225	300	225	72	213/4	57	15	450	F
KW450	6 FLG.	225	450	225	85	207/8	68	15	500	F

NOTES:

1. Filters come with initial element(s).

2. To order spare element, add 'E' before filter Model Number.

3. Larger sizes, built to specifications.

OPTIONS:

Flange Connections, where not standard.
Pressure Differential Lights/Contacts.
Multi-Filter Assemblies with By-Pass valving.

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Selection for Air Compressors

System Component Selection (Typical)							*Compressors w/Aftercooler
Aqua Saver Heat Exchanger	Pumping System	Trim Cooler	Water Reg. Valve		Mixing Valve		Max B.H.P @95°F (Max).	Max B.H.P. @105°F (Max)
Model Number	SP/DP	KFH-	in.	mm	in.	mm.	Ambient	Ambient
AS48H	33	100	3/8	10	1/2	12	20	15
AS78H	33	100	3/8	10	1/2	12	30	25
AS102H	50	100	3/8	10	1/2	12	35	30
AS156H	75	150	3/8	10	3/4	20	46	35
AS205H	75	200	1/2	12	3/4	20	58	46
AS236H	75	250	1/2	12	1	25	69	58
AS343V	100	300	3/4	20	1	25	115	87
AS449V	150	400	3/4	20	1 1/4	30	145	115
AS522V	200	500	1	25	1 1/4	30	173	144
AS674V	300	650	1	25	1 1/4	30	230	175
AS783V	300	800	1 1/4	30	1 1/2	40	250	200
AS898V	300	800	1 1/4	30	1 1/2	40	288	230
AS965V	500	1000	1 1/2	40	2	50	300	250
AS1044V	500	1000	1 1/2	40	2	50	345	288
AS1100V	500	1250	1 1/2	40	2	50	375	300
AS1347V	500	1250	2	50	2	50	460	345
AS1448V	750	1600	2 1/2	60	2 1/2	60	490	375
AS1566V	750	1600	2 1/2	60	2 1/2	60	518	400
AS1796V	750	2000	2 1/2	60	2 1/2	60	575	450
AS1931V	750	2000	2 1/2	60	2 1/2	60	650	500
AS2088V	750	2000	2 1/2	60	2 1/2	60	690	550
AS2200V	750	2500	2 1/2	60	3	75	800	650
AS2500V	750	3000	2 1/2	60	3	75	900	750
AS2846V	750	3000	2 1/2	60	3	75	950	800
AS2975V	1500	3000	2 1/2	60	3	75	1050	850

* For compressors without After Coolers multiply B.H.P. above by:
Type	Comp. W/A.C.	1-Stage	2-Stage	Rotary
BTUH/BHP	2550	900	1560	2000
Multiply BHP by	1	2.83	1.63	1.27

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AquaSaver Specifications

The packaged, single-skid, closed-loop system shall include...

Air-cooled Heat Exchanger

High-efficiency heat exchangers shall cool larger water flows with minimum pressure drop by using atmospheric air as the cooling medium. The cooling capacity to HP ration shall be maximum.

Multi-circuit design shall have minimum pressure drop.
Coil design shall allow even air distribution and therefore minimum pressure drop.
For longevity materials shall be:

Coil: aluminum fins, copper tubes

Legs: galvanized steel

Housing: aluminum

Motors shall be direct-drive, amply sized to handle designed load conditions.

Specially designed heavy-gauge aluminum blade fans shall be statically and dynamically balanced for vibration-free operation. Fans shall be protected with coated safety guards. Number of fans shall be _______, each _______ H.P. Fans shall cycle to save energy and provide temperature control. All connections shall be factory wired to the junction box on the housing exterior or to the control panel. The heat exchanger shall be Pioneer model___________

Simplex Pumping Station

Unit shall include a pump, expansion tank, starter, NEMA 1 control panel, power-on light, on/off switch, water-out pressure gauge, and water-out temperature gauge. The pumping station shall be Pioneer model__________

Trim Cooler

The Trim Cooler shall be tube and shell design. Tubes, shell and baffles shall be of rust-free materials: copper and/or brass. The trim cooler shall be Pioneer model______________

Options:

Duplex Pumping Station (in lieu of Simplex)

Unit shall include two pumps, an expansion tank, two check valves (one for each pump), starters, NEMA 1 control panel, power-on light, on/off switch, water-out pressure gauge and water-out temperature gauge. Additionally, each pump shall be piped with two isolation valves, one on the suction side and one on the discharge side, so that either of the pumps can be removed from the piping system and replaced without having to shut down the system. All components shall be prepiped, wired and mounted on a skid.

The Duplex Pumping Station shall be Pioneer model _________________

Freeze Protector heat transfer fluid, _________ gallons.
NEMA 4 electrical
TEFC motors, fan(s)
TEFC motors, pump(s)
Water filter, Pioneer model _____________.

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AquaSaver Packaged Systems

Model	Components
ASP48H	AS48H, KFH100, SP033
ASP78H	AS78H, KFH100, SP033
ASP102H	AS102H, KFH100, SP050
ASP156H	AS156H, KFH150, SP075
ASP205H	AS205H, KFH200, SP075
ASP236H	AS236H, KFH250, SP075
ASP343V	AS343V, KFH300, SP100
ASP449V	AS449V, KFH400, SP150
ASP522V	AS522V, KFH500, SP200
ASP674V	AS674V, KFH650, SP300
ASP783V	AS783V, KFH800, SP300
ASP898V	AS898V, KFH800, SP300
ASP965V	AS965V, KFH1000, SP500

Model	Components
ASP1044V	AS1044V, KFH1000, SP500
ASP1100V	AS1100V, KFH1000, SP500
ASP1347V	AS1347V, KFH1250, SP500
ASP1448V	AS1448V, KFH1600, SP750
ASP1566V	AS1566V, KFH1600, SP750
ASP1796V	AS1796V, KFH2000, SP750
ASP1931V	AS1931V, KFH2000, SP750
ASP2088V	AS2088V, KFH2000, SP750
ASP2200V	AS2200V, KFH2500, SP750
ASP2500V	AS2500V, KFH3000, SP750
ASP2846V	AS2846V, KFH3000, SP750
ASP2975V	AS2975V, KFH3000, SP1500

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Typical AquaSaver Installation

Pumping Stations and Data

Simplex	Duplex... greater reliability
Includes - Pump Starter NEMA 1 control panel Power-on light ON/OFF switch Water-out pressure gauge Prepiped, prewired and mounted on a heavy skid.	Includes - Two pumps Two check valves (one for each pump) Starters, NEMA 1 control panel, power-on light, on/off switch, water-out pressure gauge and water-out temperature gauge. Additionally, each pump is piped with two isolation valves. Either of the pumps can be replaced without disturbing the other. All components are prepiped, prewired and mounted on a heavy skid.

The following figure shows the typical pump curves.

Simplex and Duplex Pumping Stations Data

Model SP- DP-	HP	Dimensions				Expans. Tank		Water	Approx. Shipping Wt.
		Simplex (SP)		Duplex (DP)				Water	Approx. Shipping Wt.
		Width x Depth x Height		Width x Depth x Height				IN/OUT	Simplex		Duplex
		IN	MM	IN	MM	Gal	Lit.	NPT IN	LBS	KGS	LBS	KGS
33	1/3	34 x 27 x 48	864 x 686 x 1219	57 x 30 x 48	1448 x 762 x 1219	6	23	1 1/4	300	136	590	268
50	1/2	34 x 27 x 48	864 x 686 x 1219	57 x 30 x 48	1448 x 762 x 1219	6	23	1 1/4	350	159	690	313
75	3/4	34 x 27 x 48	864 x 686 x 1219	57 x 30 x 48	1448 x 762 x 1219	6	23	1 1/4	385	175	750	340
100	1	34 x 27 x 83	864 x 686 x 2108	57 x 30 x 83	1448 x 762 x 2108	10	38	1 1/2	495	225	895	406
150	1 1/2	34 x 27 x 83	864 x 686 x 2108	57 x 30 x 83	1448 x 762 x 2108	10	38	2	535	283	990	449
200	2	34 x 27 x 83	864 x 686 x 2108	57 x 30 x 83	1448 x 762 x 2108	10	38	2	595	270	1090	494
300	3	39 x 31 x 47	991 x 787 x 1194	63 x 35 x 48	1600 x 889 x 1219	15	57	2	695	315	1290	585
500	5	39 x 31 x 47	991 x 787 x 1194	63 x 35 x 48	1600 x 889 x 1219	15	57	21/2	795	360	1390	631
750	7 1/2	39 x 31 x 47	991 x 787 x 1194	63 x 35 x 48	1600 x 889 x 1219	21	79	3	890	403	1490	676
1000	10	45 x 34 x 47	1143 x 864 x 1194	78 x 44 x 48	1981 x 1118 x 1219	21	79	4 FLG.	990	449	1790	812
1500	15	45 x 34 x 47	1143 x 864 x 1194	78 x 44 x 48	1981 x 1118 x 1219	21	79	4 FLG.	1095	497	1990	903
2000	20	48 x 36 x 56	1219 x 914 x 1422	84 x 48 x 56	2134 x 1219 x 1422	42	159	6 FLG.	1295	587	2290	1039
2500	25	48 x 36 x 56	1219 x 914 x 1422	84 x 48 x 56	2134 x 1219 x 1422	42	159	6 FLG.	1395	633	2490	1129
3000	30	48 x 36 x 56	1219 x 914 x 1422	84 x 48 x 56	2134 x 1219 x 1422	42	159	6 FLG.	1495	678	2690	1220
4000	40	52 x 40 x 60	1320 x 1016 x 1524	90 x 70 x 60	2286 x 1778 x 1524	80	303	6 FLG.	1695	769	2950	1356
5000	50	52 x 40 x 60	1320 x 1016 x 1524	90 x 70 x 60	2286 x 1778 x 1524	80	303	8 FLG.	1795	814	3250	1492

NOTES:

Standard voltages: 115-1-60 or 230-1-60 for SP/DP033 through SP/DP075; 230-3-60 or 460-3-60 for SP/DP100 and up.
Nonstandard voltages available.
The Aqua Saver heat exchanger shall be oversized by 10-20%, and the pumping system shall be oversized by 25-50%.

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Sizing Example

Size an Aqua Saver and Trim Cooler to cool a 100 HP rotary screw compressor with an aftercooler for the following conditions:

Maximum ambient temperature: 95 Deg. F/35 Deg. C

Minimum ambient temperature: 0 Deg. F/-18 Deg. C

Water temperature required: 95 Deg. F/35 Deg. C or lower

City water available @ 70 Deg. F/21 Deg. C

Heat load (Q) = 100 x 2550 = 255,000 BTUH

A screw compressor may run into motor service factor at peak loads, therefore we shall plan a cooling system with a capacity of 1.15 x 255,000 = 293,250 BTUH.

The Aqua Saver alone will not cool water to 95 Deg.F when the ambient temperature reaches 95 Deg. F, so we shall include a Trim Cooler to provide partial cooling at peak temperatures.

Let us assume the system is adjusted to 20 GPM flow at 95 Deg. F to compressor. At peak ambient temperature, the Aqua Saver may cool water from 125 Deg. F to 102 Deg. F and the Trim Cooler further cools it to 95 Deg. F. At these conditions, the Aqua Saver will remove 20 x 500 x 23 = 230,000 BTUH and the Trim Cooler will remove 63,250 BTUH. Since the objective is to minimize cooling water usage by the Trim Cooler, we will size the Aqua Saver for 10-15 Deg. F approach temperature (0.7 correction factor-see correction factors table).

The Aqua Saver shall have a minimum capacity of 230,000 / 0.7 = 328,571 BTUH.

We recommend AS343V.

Now, we will size the Trim Cooler to handle 63,250 BTUH:

Small DeltaT (S) / Large DeltaT (L) = 5 / 25 = 0.2
From 'P' Factors table, P = 0.5
LMTD = P x Large DeltaT = 0.5 x 25 = 12.5
Required surface area (A) = Q / (U x LMTD), where (U) is the heat transfer coefficient (Heat Transfer Coefficients table). For water to water, (U) = 400. Therefore, (A) = 63,250 / (400 x 12.5) = 12.65 sq. ft.

Pioneer Model KFH300 is recommended (see Trim Cooler selection table).

Conclusion: Recommended Aqua Saver Packaged system ASP343V

The system includes AS343V heat exchanger, KFH300 Trim Cooler and SP100 pumping system.

Notes:

The actual temperatures and flows may vary.
The city water usage is for a very short time when the ambient temperature may be over 85 Deg.F.
A typical Aqua Saver system with Trim Cooler reduces water usage by over 95%.

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Air-Cooled Heat Exchanger Data

MODEL	CAPACITY x 1000		FANS	WATER	DIMENSIONS-(INS ,MM)						FLUID CAPACITY		APPROX. SHPG./OPER.
MODEL	BTU/HR	K.CAL/HR	(HP)	IN/OUT	OAW		OAD		OAH		GALS	LITERS	LBS.	KGS
AS48H	48	12.1	1(1/2)	1"MPT	33	839	36	915	41	1,042	22	83	165	75
AS78H	78	19.7	1(1/2)	1"MPT	38	966	36	915	46	1,169	23	87	188	86
AS102H	102	25.7	1(1/2)	1"MPT	38	966	36	915	46	1,169	25	95	204	93
AS156H	156	39.3	2(1/2)	11/4"MPT	71	1,804	36	915	46	1,169	28	106	303	138
AS205H	205	51.7	2(1/2)	11/4"MPT	71	1,804	36	915	46	1,169	30	114	328	149
AS236H	236	59.5	2(1/2)	11/4"MPT	71	1,804	36	915	46	1,169	32	121	352	160
AS343V	343	86.4	2(1)	11/2"MPT	88	2,236	64	1,626	46	1,169	41	155	649	295
AS449V	449	113.1	2(1)	2"MPT	88	2,236	64	1,626	46	1,169	53	201	709	322
AS522V	522	131.5	2(1)	2"MPT	88	2,236	64	1,626	46	1,169	55	208	791	359
AS674V	674	169.5	3(1)	21/2"MPT	112	2,845	64	1,626	46	1,169	70	265	972	441
AS783V	783	197.3	3(1)	21/2"MPT	112	2,845	64	1,626	46	1,169	74	280	1,062	482
AS898V	898	226.3	4(1)	21/2"MPT	118	2,998	89	2,261	46	1,169	78	295	1,243	564
AS965V	965	243.2	4(1)	21/2"MPT	118	2,998	89	2,261	46	1,169	80	303	1,284	583
AS1044V	1,044	263.1	4(1)	21/2"MPT	118	2,998	89	2,261	46	1,169	85	322	1,365	620
AS1100V	1,100	277.2	4(1)	21/2"MPT	118	2,998	89	2,261	46	1,169	90	341	1,420	645
AS1347V	1,347	339.4	6(1)	3"MPT	169	4,293	89	2,261	46	1,169	100	379	1,746	792
AS1448V	1,448	364.9	6(1)	3"MPT	169	4,293	89	2,261	46	1,169	105	398	1,809	821
AS1566V	1,566	394.6	6(1)	3"MPT	169	4,293	89	2,261	46	1,169	110	416	1,929	875
AS1796V	1,796	452.6	8(1)	4"FLG	220	5,588	89	2,261	46	1,169	125	473	2,266	1,028
AS1931V	1,931	486.6	8(1)	4"FLG	220	5,588	89	2,261	46	1,169	130	492	2,349	1,066
AS2088V	2,088	526.2	8(1)	4"FLG	220	5,588	89	2,261	46	1,169	140	530	2,510	1,139
AS2200V	2,200	554.4	8(1)	4"FLG	220	5,588	89	2,261	46	1,169	145	549	2,620	1,189
AS2500V	2,500	630	10(1)	4"FLG	220	5,588	89	2,261	46	1,169	150	568	2,751	1,248
AS2846V	2,846	717.2	12(1)	4"FLG	261	6,630	89	2,261	46	1,169	155	587	3,124	1,418
AS2975V	2,975	749.7	12(1)	4"FLG	261	6,630	89	2,261	46	1,169	160	606	3,256	1,477

NOTES :

"H" = Horizontal air discharge-standard; vertical-optional.
"V" = Vertical air discharge-standard; horizontal-optional.
Approximate capacity @ 90-95 Deg. F ambient, 115 Deg. F outlet temperature and 140 Deg. F inlet temperature.
Includes simplex pump, expansion tank and 100 ft. length of in/out size piping. Add 6% for duplex pump.
Due to fluid weight, operating weight approximately equals shipping weight.
Standard voltages: 115-1-60 or 230-1-60 for models in AS48H through AS205H. 230-3-60, 208-3-60 or 460-3-60 for models AS236H and up. Nonstandard voltages available.

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Freeze-Protector

The chemically inhibited fluid is designed to provide freeze, burst and corrosion protection as well as efficient heat transfer. The fluid is fluorescent pink providing easy leak detection.

The special corrosion inhibitor in the fluid coats the metal surfaces to prevent acid formation from normal oxidation. This reduces maintenance costs and extends the life of process equipment. Freeze-Protector is available in 55-gallon and 5-gallon drums.

Installation

1. Clean system properly.

2. Mix with good quality water. Distilled water is recommended.

The Selection For Air Compressors table lists the configurations for the different models of Air Compressors.

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Data Tables For AquaSavers

Maximum recommended flow
Pipe Size	GPM @20 -50 PSIG
0.5"	8
0.75"	14
1.0"	23
1.25"	36
1.5"	50
2.0"	78
2.5"	120
3.0"	180
4.0"	300
5.0"	450
6.0"	600
8.0"	1200

Freezing & Boiling Points Aqueous Solutions
Freezing Temp. F	% Freeze Protector (Wt)	Boiling Temp. F
26	10	14
18	20	216
7	30	220
-8	40	220
-29	50	225
-55	60	230
<-60	70	242

Typical heat transfer coefficients (U)
Tube side fluid	water	oil	50% freeze
Water	400	100	350
Oil	50
50% Freeze Protector		90	300

Conversion data
1 PSI =	2.036 in. of mercury = 2.31 ft. of water
	0.069 bar = 0.070 KG/cm2 = 6895 Pascal
1 Cu. Ft=	7.48 U.S. gallons = 0.0283 cu. meter = 28.32 liter
	29.92 quarts = 59.84 pints = 6.233 imp. gallons
1 Lb. =	0.4536 KG
1 HP =	746 watts = 2547 BTUH = 33,000 ft. lbs./min. = 10.68 k. calories/min.
°F =	32 + (1.8 x °C)
1 BTU raises 1 lb. of water 1°F.
1 BTU raises 54 cu. ft. of air 1°F (std. press. & temp.)
1 lb. of steam raises 1 gal. of water approx. 100°F.

Heat load (Q)
Fluid	Formula
Water	Q = 500 x GPM x deltaT x specific heat
Oil	Q = 210 x GPM x deltaT x specific heat
50% Freeze Protector	Q = 450 x GPM x deltaT x specific heat

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Ten-Year Limited Warranty

Ten-year prorated heat exchanger and pump warranty is standard in ASP series.
For one year from the date of purchase, Pioneer Air Systems, Inc. will replace or repair, or provide free of charge any part or parts found to be defective in material or workmanship. One-year mechanical parts only warranty applies to equipment outside the mainland USA, Canada and Mexico.
The customer shall contact the factory to obtain warranty service authorization prior to performing any service.
Manufacturer is not responsible for incidental, consequential, shipping and handling charges.
Extended warranty available.

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÷Pioneer Air Systems, Inc.÷

÷210 Flatfork Rd. ÷Wartburg, TN 37887÷Tel: 800-264-1AIR÷Fax: 423-346-3865 ÷ sales@pioneerair.com ÷

AquaSaver Closed-loop Clean Water Cooling System

AquaSaver
Closed-loop Clean Water Cooling System