zamil DY_series.pdf

8/10/2019 zamil DY_series.pdf

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Company BusinessZamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be established in Saudi Arabiaand today 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 companys 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 industrial customers.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 AHUs.

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 others 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 Air Conditioning 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 Arabias Standard Organization)Certificate for Room Air Conditioners. ZACs products are also certified with:1. CE (Council of European Community)

2. UL (Underwriters Laboratory)

3. ETL (Test Facilities)

4. SASO (Saudi Arabian Standards Organization)5. ISO 9001:2008 (International Organization for Standardization)

6. 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 ConcealedUnits 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 Unitsup to 138,316 CFM and the Water Chillers up to 600 TR cooling capacity. In addition, centrifugal chillers - powered by MHIcompressors - are available up to 5,000 TR.


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FEATURESHYBRID DESIGN BETWEEN MINI SPLITS AND CENTRAL UNITS

INDOOR UNIT :

* COMPACT DESIGN WITH LOW PROFILE

* HEIGHT RANGES FROM 9.6" TO 14.5"

* UNITS ARE FOR DUCTED APPLICATIONS

* LOW SOUND LEVELS

* DRAW THRU AIRFLOW CONFIGURATION

* 3 SPEED MOTORS

* REAR RETURN AIR FILTER

* EASY MAINTENANCE AND INSTALLATION * G-90 GALVANIZED HEAVY GAUGE PANELS

* DIGITAL MICRO PROCESSOR CONTROL

* WIRED LCD DISPLAY THERMOSTAT

OUTDOOR UNIT :

* G-90 GALVANIZED HEAVY GAUGE PANELS

* PAINT: ELECTROSTATIC POWDER COAT COOL GRAY COLOR

* HIGH EFFICIENCY TROPICAL DESIGN

* POWERFUL COMPRESSOR

* 230 VOLT CONTROL

* OPERATES UP TO 55 0C AMBIENT TEMPERATURE

* EXTERNAL SERVICE VALVES WITH GAUGE PORTS

* LOW PRESSURE SWITCH

* OPTIONAL COPPER OR COATED ALUMINUM FINS

* COIL GUARD PROTECTION

* SIDE AIR DISCHARGE

INDOOR UNIT - 'DY' SERIES

OUTDOOR UNIT - 'KY' SERIES(MODELS: KY042 - KY060)

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MODEL DECODING

1 & 2BASIC

3, 4 & 5NOMINALCOOLINGCAPACITY

(MBH)

7REFRIGERA-

TION CIRCUIT

6ELECTRICAL

SUPPLY( V-Ph-Hz )

9MODE

11CONDENSER

COIL

KYCONDENSING

UNIT

018

024

030

036

042

048

060

S : SINGLEC : 208/230-1-60

H : 208/230-3-60 *

M : 380-3-60 * (4 WIRE)

F : 460-3-60 *

C : COOL ONLY

H : HEAT PUMP

A : ALUMINUM FIN

B :COATEDALUMINUM FIN

C : COPPER FIN

8COMPRESSOR

TYPE

R : HERMETICCOMPRES-SOR

13OPTIONS

10CONDENSER

MOTOR

N : STANDARD

L :LOWAMBIENT**

12ACCESSORIES

N : STANDARDUNIT

F : STANDARDUNIT WITHFILTERDRIER &SIGHTGLASS

N : STANDARD UNIT

B : SECONDGENERATIONUNIT (FOR KY030ONLY)

* Applicable for KY030 - KY060 models only.

** Applicable for KY036 - KY060 models only.

INDOOR UNIT

OUTDOOR UNIT

1 & 2

BASIC (SERIES)

3 & 4

COOLING CAPAC-ITY (x 1000 BTUH)

5

ELECTRICALSUPPLY (V-Ph-Hz)

8

FIN

7

ACCESSORIES

11

OPTION

DYDUCTED SPLITFAN COIL UNIT

18

24

30

36

42

48

60

C : 208/230-1-60 D : ALUMINUM FINSWITH ORIFICE

E : COATED FINSWITH ORIFICE

F : COPPER FINSWITH ORIFICE

*A : ALUMINUM FINSWITH CAPILLARY

*B : COATEDALUMINUM FINSWITH CAPILLARY

*C : COPPER FINSWITH CAPILLARY

N : STANDARD N :STANDARDUNIT

6

REFRIGERATIONSYSTEM

C : COOL ONLY

H : HEAT PUMP

10

FILTER

N : NONE

A : ALUMINUM

C : SYNTHETIC

9

COILCONNECTION

R : RH SIDE(FACING AIRDISCHARGE)

* These options are for matching DY18/DY24/DY30 heat pump units with KY018/KY024/KY030 condensing units and also for matching DY36 to DY60 heat pump units withCX036 to CX060 condensing units.

INDOOR UNIT MODE

DY18COOL DY18CCNDRAN KY018CSRCNANN

HEAT PUMP DY18CHNARAN KY018CSRHNANN

DY24COOL DY24CCNDRAN KY024CSRCNANN

HEAT PUMP DY24CHNARAN KY024CSRHNANN

DY30COOL DY30CCNDRAN KY030CSRCNANB

HEAT PUMP DY30CHNARAN KY030CSRHNANB

DY36COOL DY36CCNDRAN KY036HSRCNANN

HEAT PUMP DY36CHNDRAN KY036HSRHNANN







MATCHING INDOOR/OUTDOOR UNITS

(FAN COIL UNIT)

NOTE: Refer to indoor/outdoor model decoding for other available voltages.

OUTDOOR UNITSINDOOR UNITS

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OUTDOOR UNIT FEATURESA. GENERALThe Zamil side discharge condensing units incorporate the latest innovative technology to provide quiet, reliable perfor-mance. The wrap-around coil not only adds to the aesthetical appeal, it also gives optimum heat transfer efficiency.The access panels provide access to the compressor and to the electrical control box. Removal of top panel gives accessto fan motor and coil.These condensing units can be combined with a wide variety of evaporator coils and blower packages to provide quietand dependable comfort.These units are availed as standard cool only models, and also as heat pump versions as an option for added comfortduring cold season.

B. UNIT ENCLOSUREAll panels are of heavy gauge (G-90) galvanized steel sheet and completely weatherized for outdoor installation. Steelsheet panels are zinc coated and galvanized by the hot dip process of lock-forming quality conforming to ASTM A 653commercial weight G-90, followed by baked on electrostatic polyester dry powder coat.

C. COMPRESSORCompressors are fully hermetic type and are provided with all the standard controls necessary for proper and safe opera-tion. These compressors have improved internal pressure relief valve which provides high pressure protection to therefrigerant system and rubber vibration isolators for quiet and efficient operation.

D. AIR COOLED CONDENSER1. The condenser coils are of the enhanced fin & tube type, constructed of enhanced copper tubes and mechanically

bonded to aluminum fins. All copper tube return bends have 0.022" (0.56mm) wall thickness. As an option to aluminumfins, coated aluminum fins or corrugated copper fins may be provided. Tube support sheets are of galvanized steel,formed to provide structural strength. Tubes are circuited to ensure minimum pressure drop and maximum heattransfer. Each coil is completely dehydrated, charged and sealed at the factory upon completion of pressure tests.

2. The fans are propeller type and direct-driven, front discharge & provided with fan guards.

3. Units are equipped with totally enclosed fan motors for greater reliability and dependable performance for many years.Inherent thermal protection is automatic reset type.

4. For heat pump version units, fixed orifice expansion device is inherent within the condensing units on KY036 - KY060(except KY018, KY024 & KY030 heat pump models where capillary is provided in the indoor units).

E. SERVICE VALVESBoth suction and liquid service valves are brass, back seating type with flare connections. Valves are externally located sorefrigerant tube connections can be made quickly and easily. Each valve has a gauge pressure port for ease of checkingrefrigerant operating pressures.

F. LOW PRESSURE SWITCHAuto reset SPST switch activated by refrigerant pressure - locks out the compressor, if the refrigerant pressure falls below25 PSIG. Also provides additional protection against evaporator freeze up due to loss of indoor airflow.

G. HIGH PRESSURE SWITCH

Auto reset SPST switch activated by refrigerant pressure - locks out the compressor, if the refrigerant pressure rises above450 PSIG. Also provides additional protection against compressor damage due to loss of outdoor airflow.

Low Noise Level Powerful Hermetic Compressor High Energy Efficiency Ratio

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FEATURES BENEFITS

Wired remote controller with Liquid Crystal Display (LCD) Unit operation controlled remotely with a large LCD display.

FAN/HEAT/AUTO/COOL/DRY mode of operation 5 modes of operation with automatic shift between COOL & HEAT when on AUTO.

Three speed fan with AUTO mode Cover the whole range of CFM/capacity requirements.

SLEEP mode To raise/lower temperature setting by a maximum of 2 0F during night time foradded comfort and energy.

Auto Restart Thermostat settings are preserved in the memory in case of power interruptionand will be retrieved to operate the unit accordingly when power is restored.

Real Time Clock Display the day and time in AM/PM format.

7 Day Programmable Timer To select up to 7 days in advance when to start and when to stop operation.

Hot Start No cold air blow in the room at start-up on HEAT mode.

Cold Stop Use of the remaining thermal energy stored in evaporator coil after unit stop (HEAT mode).

De-icing To avoid freezing of indoor coil during COOL cycle.

Electronic Defrost cycle Prevent freezing of outdoor coil during HEAT cycle.

Child Lock To restrict the number of persons tampering with the control.

Room Temperature Display Both room & set point temperatures can be displayed in either 0C or 0F.

ON/OFF status LED indicator To inform on the status of operation.

MICROPROCESSOR CONTROLLED THERMOSTAT

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MODEL INDOOR UNIT DY 18 DY 24 DY 30 DY 36 DY 42 DY 48 DY 60

OUTDOOR UNIT KY 018 KY 024 KY 030 KY 036 KY 042 KY 048 KY 060PERFORMANCECooling capacity at high fan speed, BTUH/kW 18000/5.27 23000/6.74 30000/8.8 36200/10.6 44100/12.9 50000/14.6 58000/16.9

Total unit power input, kW/EER 2.2/8.0 2.8/7.9 3.6/7.9 4.1/8.4 5.0/8.4 5.7/8.4 7.3/7.5

Heating capacity at high speed, BTUH/kW 19000/5.56 23750/6.96 31000/9.09 36000/10.55 42300/12.38 46000/13.46 59000/17.27

Total unit power input, kW/COP 2.1/2.7 2.7/2.6 3.3/2.8 3.8/2.8 4.4/2.8 4.4/3.1 6.1/2.8

Evaporator airflow, CFM (high/medium/low) 650/550/450 750/650/550 1050/850/650 1250/1050/850 1400/1250/1000 1600/1350/1100 1950/1600/1350

Sound pressure level, dBA (high/medium/low) 36/34/33 42/36/35 44/41/37 44/41/37 46/44/40 37/34/31 41/37/34

INDOOR UNITPower supply (V-Ph-Hz) 208/230-1-60

Blower quantity 2 2 2 2 2 2 2

Watts - RPM 180 - 1270 220 - 1490 458 - 1400 480 - 1400 564 - 1500 695 - 1240 819 - 1400Blower motor FLA 1.2 1.2 2.6 2.6 2.6 3.6 3.6

Face area, ft 2 2.2 2.2 3 3 3 4.4 4.4

Evaporator coil Tube dia, inch 3/8 3/8 3/8 3/8 3/8 3/8 3/8

No. of rows/FPI 3/14 3/14 3/14 3/14 4/14 4/14 4/14

Suction - Liquid line, inch 5/8 - 3/8 5/8 - 3/8 3/4 - 3/8 3/4 - 3/8 3/4 - 3/8 7/8 -1/2 7/8 -1/2

Return air filter (1/2" thick) size, inch & quantity 8x16.5 (2) 8x16.5 (2) 9.5x18.5 (2) 9 .5x18.5 (2) 9 .5x18.5 (2) 11x22.75 (2) 11x22.75 (2)

Weight, Kg. 40 40 52 52 55 65 65

Minimum circuit ampacity, Amps 1.5 1.5 3.25 3.25 3.25 4.5 4.5

Maximum fuse size, Amps 15 15 15 15 15 15 15

OUTDOOR UNIT 208/230-1-60 9.7/60 13/73 13.2/85 18.4/95 20.4/109 22.1/137 30.1/144

Compressor 208/230-3-60 N.A. N.A. 11.8/67 11.4/77 13.9/88 16.4/91 20.7/128RLA/LRA 380-3-60 N.A. N.A. 5.6/39 9.3/54 9.3/54 9.3/54 10.7/64

460-3-60 N.A. N.A. 5.4/29.2 5.7/40 7.1/44 7.9/50 8.4/65

208/230-1-60 12.8/20 16.9/25 17.5/30 24.6/40 28.7/45 30.8/50 40.8/70

MCA/MOCP

208/230-3-60 N.A. N.A. 15.7/25 15.9/25 20.6/30 23.7/40 29.1/45(Outdoor unit)

380-3-60 N.A. N.A. 8/15 13.2/20 14.8/20 14.8/20 16.6/25

460-3-60 N.A. N.A. 7.7/15 8.73/15 12.1/15 13.1/20 13.7/20

Condenser airflow, CFM 1400 1400 1800 2200 4200 4200 4200

Condenser Fan HP - RPM 1/10 - 875 1/10 - 875 1/8 - 1000 1/4 - 1000 1/4 - 1000 (2) 1/4 - 1000 (2) 1/4 - 1000 (2)motor FLA 0.6 0.6 0.94 1.6 1.6 1.6 1.6

Face area, ft 2 5.6 5.6 5.6 8 10.5 10.5 10.5

Condenser coil Tube dia, inch 5/16 5/16 5/16 3/8 3/8 3/8 3/8

No. of rows/FPI 2/16 2/16 3/16 2/14 2/14 2/14 2/14

Refrigerant (R-22) charge, oz. 62 76 83 128 141 135 127

Suction - Liquid line, inch 5/8 - 3/8 5/8 - 3/8 5/8 - 3/8 3/4 - 3/8 7/8 - 3/8 7/8 - 1/2 7/8 - 1/2

Dimensions, mm (depth x width x height) 800x325x685 800x325x685 800x325x685 965x390x727 965x390x1158 965x390x1158 965x390x1158

Weight, Kg. 65 66 72 101 115 120 130

PHYSICAL DATA

NOTE: 1. Cooling capacities & power input data @ 80 0F (26.7 0C) DB/67 0F (19.4 0C) WB indoor & 95 0F (35 0C) ambient temperatures.2. Heating capacities & power input data @ 70 0F (21.1 0C) DB/60 0F (15.6 0C) WB indoor & 47 0F (8.3 0C) outdoor temperatures.3. Sound pressure level @ 9 feet distance and 0.15 ESP.4. Pipe sizes are for runs up to 25 feet (7.6 meters) to indoor unit.5. Motor FLA values are based on standard motors.


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DIMENSIONS - INDOOR UNITSDY18 - DY60

MODELA B C D E F G H I

DY 18 904 (35.6) 610 (24) 244 (9.6) 960 (37.8) 521 (20.5) 769 (30.3) 183 (7.2) 841 (33.1) 206 (8.1)DY 24 904 (35.6) 610 (24) 244 (9.6) 960 (37.8) 521 (20.5) 769 (30.3) 183 (7.2) 841 (33.1) 206 (8.1)DY 30 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)DY 36 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)DY 42 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)DY 48 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)

DY 60 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)

DIMENSIONS

NOTE: All dimensions are in mm (dimensions in brackets are in inches).

1. Blower & motor assembly

2. Evaporator coil 3. Control box 4. Filter rack 5. Unit mounting brackets (4 Nos.) 6. Duct connection

10

F R ON T V I E W

T O P V I E W E N D V I E W E N D V I E W

3/4" NPT(14TPI)DRAIN TUBE.

1 3 ( 0

. 5 0 " )

2

5

D

H

A4I

3

3 8 ( 1

. 5 0 " )

89 (3.50")

1

6

C G

F

E B


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800(31.5)

3 6 6 ( 1 4

. 4 )

E N D V I E W

TYPE CONN.9.5 ( 38") FLARE

48(1.890)

1 4 ( 0

. 5 5 1 )

8 3 ( 3

. 2 6 8 )

49 (1.929)

TYPE CONN.16 ( 58") FLARE

F R O N T V I E W

6 8 5 ( 2 7 )

AIR OUT

AIRI N

A I R I N

D E TA I L - A

SEEDETAIL -A

20 (0.788)

( T Y P I C A L AT F O U R P L A C E S )

70(2.755)

1 5 ( 0

. 5 9 0 )

POWER & CONTROLWIRE ENTRY

LIQUID VALVE

SUCTION VALVE

T O P V I E W

3 2 5 ( 1 2

. 7 9 5 )

4 0 6 ( 1 5

. 9 8 4 )

442 (17.402)

DIMENSIONS - OUTDOOR UNITS

11

KY018, KY024 & KY030

A I R I N

AIR OUT

AIR IN


SEE DETAIL -A( T Y P I C A L AT F O U R P L A C E S )

D E TA I L - A

19 ( 34") FLARE

9.5 ( 38") FLARETYPE CONN.

E N D V I E W

TYPE CONN.

ACCESS PANEL

T O P V I E W

F R O N T V I E W

965(38)

4 3 5 ( 1 7 . 1 6 )

16(0.63)

19(0.75)

7 2 7 ( 2 8

. 6 3 )

133 (5.25) 698(27.5)

3 9 0 ( 1 5 . 3 8 )

8 2 ( 3

. 2 5 )

1 5 2 ( 6

. 0 )

89 (3.5)

4 3 1 ( 1 7 )

70(2.76)

1 5 ( 0

. 5 9 )

20 (0.79)

KY036



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DIMENSIONS - OUTDOOR UNITSKY042, KY048 & KY060


12

1 1 5 8 ( 4 5

. 6 3 )

8 6 3 ( 3 4 )

F R O N T V I E W 79(3.13)

E N D V I E W

16(0.63)

27(1.06)

TYPE CONN.

FLARE TYPE CONN.

22 (7 8") FLARE

965(38)

ACCESS PANEL

4 3 5 ( 1 7

. 1 6 )

133 (5.25)

3 9 0 ( 1 5

. 3 8 )

A I R

I N

698(27.5)

T O P V I E W

AIR OUT

AIR IN

1 5 ( 0

. 6 )

D E TA I L - A

( T Y P I C A L AT F O U R P L A C E S)

70(2.76)

20 (0.79)

SEE DETAIL-A


8 2

. ( 3

. 2 5 )

1 4 6 ( 5

. 7 5 )

9.5 (3 8") (FOR KY042)& 12.7 (12") (FOR KY048/060)


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60DY 36

DY 60

DY 48

DY 42

IN HERTZ

FREQUENCY

APPLICABLE

ATB

COM

* *

SPEED

WIRE COLOR

DY 18

DY 30

DY 24

MODEL

YEL

FM SPEED CONNECTIONSMEDHI MED-HIS-HI

BLUBLK RED

COMLOW

ORG WHT

ID

LOW

N2

N1

HI GH

L I V E

ME D

CN4

COMPCOM

Refer to table below for Speed Connections.

15

39A

*

L2/N L1 GND

230VAC

TO FUSE DISCONNECT SWITCH

* * *

60

INDOOR DE-ICE SENSOR

3) WHT TX

2) BLK GND

CABLE CONNECTIONS AT LCD

1) RED 5V

CONTROL PANEL TB

LCD CONTROL PANEL

COND.UNIT6

1TO

CAP

BRN

BRN

60

60

60

60

60

4) YEL TX RCV

LOWEST

GREY

* * *

* * *

* * ** * *

* * ** * *

* ** *

* ** *

* ** *

* *

**

**

**

*

* * *

TYPICAL SCHEMATIC WIRING DIAGRAMCOOL MODELS

INTERCONNECTING DETAILS BETWEEN INDOOR & OUTDOOR UNITNOTE: Route wires according to diagram below & ignore all other terminal connection on outdoor unit.

13

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. USE COPPER CONDUCTOR WIRES ONLY.

3. MOTORS ARE THERMALLY PROTECTED.

4. REFER TO INTERCONNECTING WIRING DIA-GRAM BEFORE INSTALLATION

5. DO NOT ROUTE ATB1(5) FROM CONDENSINGUNIT

LEGENDATB AUXILIARY TERMINAL BLOCK

CAP CAPACITOR

COMP COMPRESSOR

COM COMMON

ECB ELECTRONIC CONTROL BOARD

FL FUSE LINK

FM FAN MOTOR

GND LUG GROUND

HF HIGH FAN

L1 LINE 1

L2 LINE 2 OR NEUTRAL

LF LOW FAN

MF MEDIUM FAN_ _ _ FIELD WIRING

FACTORY WIRING

DY SERIESINDOOR UNIT INDOOR UNIT

DY SERIES

KY SERIESOUTDOOR UNITOUTDOOR UNIT

KY SERIES

6

ATB

ATB5 6

161

ATB

15 4/61N ATB L


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CAP

ATB

NOTE:

OUTDOOR DE-ICE SENSOR

TO THE TUBE PROVIDED ON THERETURN BEND OF THE OUTDOOR COIL.

FIX THE OUTDOOR DE-ICE SENSOR

15

ME D

N1

N2

LOW

HI GH

L I V E

4WV

CN4ECB

OF/OOF/I

ID

COMPCOM

OD

21B

21A

21

39A

TO FUSE DISCONNECT SWITCH

230VAC

L2/N GNDL1

COM

Speed Connections.Refer to table below for

* **

* * *

CABLE CONNECTIONS AT LCD

3) WHT TX

CONTROL PANEL TB

2) BLK GND

1) RED 5V

LCD CONTROL PANEL

INDOOR DE-ICE SENSOR

COND.UNIT

37A

T3A/N

6

8

1

TO

BRNBRN

4) YEL TX RCV

60DY 36

DY 60

DY 48

DY 42

IN HERTZ

FREQUENCY

APPLICABLESPEED

WIRE COLOR

DY 18

DY 30

DY 24

MODEL

YEL

FM SPEED CONNECTIONSMEDHI MED-HIS-HI

BLUBLK RED

COMLOW

ORG WHT

60

60

60

60

60

60

LOWEST

GREY

* * *

* * *

* * ** * *

* * ** * *

* ** *

* ** *

* * * ** *

**

**

* **

* * *

TYPICAL SCHEMATIC WIRING DIAGRAMHEAT PUMP MODELS

INTERCONNECTING DETAILS BETWEEN INDOOR & OUTDOOR UNITNOTE: Route wires according to diagram below & ignore all other terminal connection on outdoor unit. Also routeoutdoor coil sensor wire from indoor to outdoor sensor holder

LEGENDATB AUXILIARY TERMINAL BLOCK

CAP CAPACITOR

COMP COMPRESSOR

COM COMMON

ECB ELECTRONIC CONTROL BOARD

FL FUSE LINK

FM FAN MOTOR

GND LUG GROUND

HF HIGH FAN

L1 LINE 1

L2 LINE 2 OR NEUTRAL

LF LOW FAN

MF MEDIUM FAN

OF OUTDOOR FAN

4WV/RV FOUR WAY/REVERSING VALVE_ _ _ FIELD WIRING

FACTORY WIRING

14

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. USE COPPER CONDUCTOR WIRES ONLY.

3. MOTORS ARE THERMALLY PROTECTED.

4. REFER TO INTERCONNECTING WIRING DIA-GRAM BEFORE INSTALLATION

5. DO NOT ROUTE ATB1(5) FROM CONDENSINGUNIT

6. T3A/N & 37A ARE TERMINAL MARKINGS FORJP4 ON CONDENSER FAN MOTOR CONNEC-TION. T3A/N IS T1 ON SINGLE PHASE CON-DENSER UNITS.

T3A IS T1 ON 1PH CONDENSER UNITS

COMP

5

S R

C

O/L

P N K

OUTDOOR UNIT

ATB L

KY SERIES

N 1

DY SERIESINDOOR UNIT

ATB 61 8

INDOOR UNITDY SERIES

KY SERIESOUTDOOR UNIT

5

37A

NOTE:

4/6 8

ATB 1

COMP35A

FM

CAP

36A

6 8

T3A 37A

T3A /N 37A ATB 1 T3A/N86 37A

B L K

T3A

FM


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INSTALLATION - INDOOR UNITThe complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immedi-

ately to the delivery man or driver and noted on the shipping invoice.

Place unit in position and make sure that unit is level. This is important to assure proper drainage and operation. Slotsprovided in the mounting brackets should be used for installing the units.

Be sure that foreign material is not allowed to fall into or collect in the drain pan. Special care must be taken to preventpaint, plaster, insulation or other foreign material from being deposited on the motor or blower wheels.

MAINTENANCECOIL : Coil may be cleaned by removing case and brushing between fins with a stiff wire brush. Brushing should befollowed by cleaning with vacuum cleaner. The coil may also be cleaned by using a high pressure air, if compressed airsource is available. It should be pointed out that if air filters are used and periodically cleaned, the coils will not be cloggedup prematurely.

DRAIN PIPE : Drain pipe should be checked before summer operation of unit is begun. If it is clogged, steps should betaken to clear the debris so that condensate will flow out easily. A standard pipe cleaner for 1/2" ID pipe may be used.Periodic checks of the drain pipe should be taken during summer operation, as there is a possibility of it becoming cloggedwith dirt.

FILTER CLEANING: Remove access panel, slide filter out of filter rack, and clean as follows:Tap filter on solid surface to dislodge heavy particles. Wash under stream of hot water. If filter has been put to exceptionalservice, a mild solution of Sal-Soda, Tri-Sodium Phosphate or any other commercial solvent can be used. Set filter on end

with slots in frame down, which allows it to drain. Filters should dry thoroughly before reuse.

REPLACEMENT PARTS : When writing for replacement parts, refer to model number and serial number on the name plateof the unit.

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A I R I N

AIR OUT

AIR IN

610mm (24") CLEARANCE MINIMUM

203mm (8") FOR KY018, 024 & 030

254mm (10") FOR KY036 AND ABOVE

914mm (36") CLEARANCE MINIMUM

2 5 4 m m

( 1 0 " ) F O R K Y 0 3 6 A N D A B O V E

2 0 3 m m

( 8 " ) F O R K Y 0 1 8

, 0 2 4 & 0 3 0

INSTALLATION & START-UP INSTRUCTIONS - OUTDOOR UNITSAFETY CONSIDERATIONS

Improper installation, service, maintenance or use can cause explosion, fire, electrical shock or other conditions which maycause personal injury or property damage. Check with your nearest Zamil dealer/sales office for information or assistance.

Warning: Before installation or servicing the system, always turn off main power supply. Electrical shock can causepersonal injury or death.

INSTALLATIONSTEP-1:Check equipment and job siteUnpack unit and move to final location taking care not to damage the unit. Remove screws holding the unit to woodenpallet and remove wooden pallet.

STEP- 2:Location of unitPlace the unit with minimum clearance as shown in figure below to enable space for installation, service and optimumperformance of the unit. Be sure that the discharge air from the condenser is not restricted. Double the clearance whenmultiple units are installed at one location. Units may be installed using mounting pads on the floor, concrete slabs, steelframes with adequate strength.

STEP-3:Piping connectionsOutdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. Theliquid and suction line diameters can be determined from the physical data table. For piping requirements beyond 25 ft(7.62 m), obtain information from your nearest Zamil dealer/sales office.If either refrigerant piping or indoor coil is exposed to atmospheric conditions, it must be dehydrated to 500 microns toeliminate moisture contamination in the system.It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigerationstandard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigerantpipes carefully to prevent damaging the suction pipe insulation and vibration transmission to the structure.

Outdoor unit connected to factory matched indoor unitOutdoor unit contains correct system refrigerant charge for operation with matched indoor unit as given on cooling capacitytable and when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge for maximum efficiency.

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ELECTRICALSTEP 1: INSTALLATION

A) Please ensure regular power supply to the unit is as per unit nameplate (Volts/Ph/Hz) requirements.Caution: Operation of the unit on improper power supply like generators will result in damage to the unit.Note: Use copper wires of proper rating for all field wiring.

Warning: Before servicing or installation of the unit, always TURN OFF all power to the unit. There may be more than onedisconnect switch. Ensure all of them are turned off. Electrical shock can cause personal injury or death.

B) Ground & power wiresConnect power wires to terminal block per wiring diagram.Connect ground wire to the ground lug inside the control box.

C) Wiring

1. All wiring must comply with the "National Electric Code" and local electrical standards.2. The power supply, voltage, frequency and phase must coincide with the unit nameplate.

3. Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate; but notless than 14 gauge (2.5 mm 2) for lower amps.

4. For control wiring, use approved thermostat wire [minimum 18 gauge (0.75 mm 2)], color coded wires. Then match theauxiliary terminal block (ATB) numbers (indoor and outdoor units) to interconnect the two units. Never use telephonewire for this purpose.

5. Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damageto compressors and motors can occur, if improper voltage is applied.

6. Install adequate branch disconnect switch as per NEC size requirements to handle unit starting current. Locate discon-

nect switch within sight and readily accessible from the unit.

STEP 2: START-UP1. Energize crankcase heater for a minimum of 12 hours prior to the system start-up. To energize crankcase heater only,

set thermostat to "off" position and close electrical disconnect switch to the outdoor unit.

2. Fully open liquid/suction service valves.

3. Close electrical disconnect switch to energize the system.

4. Set room thermostat to desired temperature.

SYSTEM DESIGNTHE CONDENSING UNIT SYSTEM HAS BEEN DESIGNED BASED ON THE FOLLOWING:

Intended for outdoor installation with free air intake and discharge. Minimum outdoor operating air temperature during cooling without low ambient operation option is 55 0F (12.7 0C). Maximum outdoor operating air temperature during cooling mode is 130 0F (55 0C). For reliable operation, unit should be level on horizontal plane. For interconnecting refrigerant pipe lengths greater than 25 feet (7.6 meters), check with your local Zamil sales office. Use only copper wire for electric connection at unit. Aluminum and clad aluminum are not acceptable for the type of

connector provided.


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SERVICING INSTRUCTIONS

NOTES:1. Required indoor unit access clearances are shown as hatched area.2. Free sevice access should be available from the bottom of the unit for removing & servicing the blower/motor deck.3. Servicing instructions:

a) Remove the bottom panel.b) Support the blower deck while unscrewing the 4 blower deck holding bolts and bring down the blower deck.

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5 0 C M

5 0 C M

3 0 C M

Bottom panel

9 5 C M

Blower deck holding bolt

Blower deck

A c c e s s

f o r b l o

w e r s &

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PERCENTAGE OF SPARE PARTS

ONE YEAR SUPPLY TWO YEAR SUPPLY

100 UNITS 1000 UNITS 100 UNITS 1000 UNITS

ITEM

Compressor 2% 1% 3% 2%

Capacitor 3 2 5 4

Condenser Fan Motor 2 1 3 2

Evaporator Blower Motor 1 0.5 2 1

Contactor Compressor 2 1 3 2

Contactor Fan Motors 2 1 3 2HPS/LPS/Other controls 2 1 3 2

Filter Drier 2 1 3 2

Transformer (24V. Secondary) 1 0.5 2 1

Propeller Fan 1 0.5 2 1

Blower Wheel 0.5 0.25 1 0.5

Thermostat (Wall) 1 1 2 1

Heater-Crankcase 3 1 4 2

Filter 2 1 4 4

RECOMMENDED SPARE PARTS

NOTE: When ordering spare parts, please quote the complete model number on the unit nameplate.


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PARTS LISTMODEL NUMBER DY18 DY24 DY30 DY36 DY42 DY48 DY60

FAN DECK ASSEMBLY 700-384-88 700-384-88 700-384-89 700-384-89 700-384-89 700-384-90 700-384-90

BLOWER MOTOR 800-547-65 800-547-65 800-547-66 800-547-66 800-547-66 800-547-67 800-547-67

FILTER 800-249-39 800-249-39 800-249-38 800-249-38 800-249-38 800-249-36 800-249-36

ORIFICE DISTRIBUTOR 800-194-10 800-194-10 800-194-14 800-194-14 800-194-14 800-194-16 800-194-16

ORIFICE PISTON 800-195-13 800-195-13 800-195-15 800-195-16 800-195-17 800-195-20 800-195-22

THERMOSTAT, COOL 800-654-01 800-654-01 800-654-01 800-654-01 800-654-01 800-654-01 800-654-01

THERMOSTAT, HEAT PUMP 800-654-03 800-654-03 800-654-03 800-654-03 800-654-03 800-654-03 800-654-03

INDOOR UNITS

OUTDOOR UNITS

MODEL NUMBER KY036C KY036H KY036M KY036F KY042C KY042H

COMPRESSOR 800-674-27 800-674-26 800-674-21 800-674-28 800-674-74 800-674-73

FAN MOTOR 800-545-12 800-545-12 800-545-12 800-545-96 800-545-12 800-545-12

FAN MOTOR CAPACITOR 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15CONDENSER FAN 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41

COMPRESSOR CONTACTOR 800-736-22 800-095-01 800-095-01 800-095-01 800-736-22 800-095-01

LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00

HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00

MODEL NUMBER KY042M KY042F KY048C KY048H KY048M KY048F

COMPRESSOR 800-674-21 800-674-75 800-674-29 800-674-20 800-674-21 800-674-22

FAN MOTOR 800-545-12 800-545-96 800-545-12 800-545-12 800-545-12 800-545-96

FAN MOTOR CAPACITOR 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15

CONDENSER FAN 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41

COMPRESSOR CONTACTOR 800-095-01 800-095-01 800-736-22 800-095-01 800-095-01 800-095-01LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00


MODEL NUMBER KY060C KY060H KY060M KY060F

COMPRESSOR 800-674-16 800-674-13 800-674-14 800-674-15

FAN MOTOR 800-545-12 800-545-12 800-545-12 800-545-96

FAN MOTOR CAPACITOR 800-353-15 800-353-15 800-353-15 800-353-15

CONDENSER FAN 800-941-41 800-941-41 800-941-41 800-941-41

COMPRESSOR CONTACTOR 800-297-37 800-736-22 800-095-01 800-095-01

LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00

HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00

MODEL NUMBER KY018C KY024C KY030C KY030H KY030M KY030F

COMPRESSOR, COOL ONLY 800-675-79 800-675-80 800-675-89 800-674-26 800-684-14 800-674-28

COMPRESSOR, HEAT PUMP 800-675-86 800-675-87 800-675-90 800-674-26 800-684-14 800-674-28

FAN MOTOR 800-555-32 800-555-32 800-555-98 800-555-98 800-555-98 800-555-89

FAN MOTOR CAPACITOR - - 800-353-15 800-353-15 800-353-15 800-353-15

CONDENSER FAN 800-224-19 800-224-19 800-224-55 800-224-55 800-224-55 800-224-55

COMPRESSOR CONTACTOR 800-736-27 800-736-27 800-736-22 800-095-01 800-095-01 800-095-01

LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00


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zamil DY_series.pdf

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