Zamil DY-KY series.pdf

Concealed Fan Coil UnitsDY18/KY018 thru DY60/KY060

1.5 TR thru 5 TR5 kW thru 17.5 kW

Cool & Heat pump models

Company BusinessZamil Air Conditioners was founded in 1974 as one of the first air conditioning business to be established in Saudi Arabiaand today is a leading international manufacturer of air conditioning systems and is No. 1 in the Middle East.

Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55countries in the Middle East, Europe, Africa and Asia.

The company’s operations are structured into four Strategic Business Units (SBUs) supporting five in-house product andservice brands as well as a number of international brands under the OEM sales.

The five in-house brands are Classic, Cooline, CoolCare, Clima Tech and Geoclima.

The four SBUs are:1. Consumer Business Unit supporting Classic, Cooline, GE and OEM brands for consumers.2. Unitary & Applied Business Unit supporting Classic, Cooline, GE and OEM brands for commercial and industrial

customers.3. Zamil CoolCare providing engineering & project management services, HVAC maintenance, retrofit services and parts.4. Geoclima srl is an independent business supporting other SBUs for their requirement of Chillers & Double skin AHU’s.

The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare Service direct their businessoperations from the corporate headquarters at Dammam, Saudi Arabia.

Geoclima has its engineering & production departments located at Monfalcone, Italy and has a design center in Austria.

All the four SBUs, while operating independently, supplement each other’s activities in a way that makes synergy work atits best and achieve the corporate goals of maximizing customer satisfaction.

Factories and ProductionsZamil Air Conditioners has two manufacturing plants in Dammam, Saudi Arabia and has one speciality production facilityin Italy operated by Geoclima.

The company can produce up to 550,000 Room Air Conditioners, 300,000 Mini-Split systems and 50,000 Central AirConditioning systems per year.

Quality & Product CertificatesThe Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification.

Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabia’s Standard Organization)Certificate for Room Air Conditioners. ZAC's products are also certified with:1. CE (Council of European Community)2. UL (Underwriters Laboratory)3. Eurovent4. ASME5. ETL

Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammedbin Fahd Al Saud Award for Factory Safety.

Our ProductsIn addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditionersmanufacturers a host of residential, commercial and industrial air conditioners. This broad range extends from the Con-cealed Units up to 5 tons, the Ducted Splits up to 30 tons, the Packaged Units up to 90 tons, the Single and Double SkinAir Handling Units up to 70,630 CFM and the Water Chillers up to 660 tons cooling capacity.

Contents Page

Features ................................................................................................................................................... 2

Model decoding ........................................................................................................................................ 3

Matching condensing units ....................................................................................................................... 3

Indoor unit features .................................................................................................................................. 4

Standard specifications ............................................................................................................................ 4

Outdoor unit features ................................................................................................................................ 5

Microprocessor controlled thermostat ...................................................................................................... 6

Physical data ............................................................................................................................................ 7

Cooling capacities .................................................................................................................................... 8

Fan performance data .............................................................................................................................. 9

Dimensions, indoor units ........................................................................................................................ 10

Dimensions, outdoor units ................................................................................................................. 11-12

Typical schematic wiring diagram ...................................................................................................... 13-14

Installation, operation & maintenance ............................................................................................... 15-16

Electrical ................................................................................................................................................. 17

System design ........................................................................................................................................ 17

Servicing instructions ............................................................................................................................. 18

Recommended spare parts list ............................................................................................................... 19

Parts list ................................................................................................................... ......................... 20

INDEX

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1

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

* 24 VOLT CONTROL

* OPERATES UP TO 550C 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)

2

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 :COATEDALUMINUMFIN

C : COPPER FIN

8COMPRESSOR

TYPE

R : HERMETICRECIPRO-CATING

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.

INDOOR UNIT

OUTDOOR UNIT

1 & 2BASIC (SERIES)

3 & 4COOLING CAPAC-ITY (x 1000 BTUH)

5ELECTRICAL

SUPPLY (V-Ph-Hz)

8FIN

7ACCESSORIES

11OPTION

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

6REFRIGERATION

SYSTEM

C : COOL ONLY

H : HEAT PUMP

10FILTER

N : NONE

A : ALUMINUM

C : SYNTHETIC

9COIL

CONNECTION

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

3

INDOOR UNIT FEATURESCOMPACT DIMENSIONSLow height units are ideal to fit into tight spaces. Maximum height of unit ranges from 9.6" to 14.5" (24cm to 37cm).

EASY INSTALLATION WITH FLARE NUT CONNECTIONSNo need for complicated brazing for connecting the refrigerant piping.

EASY MAINTENANCE / ONE SIDE ACCESSFilters can be easily removed by lifting/sliding. Piping and controls are on one side for easy access.

DIGITAL & MICROPROCESSOR CONTROL WITH LCD DISPLAY THERMOSTATProgrammable wired thermostat loaded with all required functions and features for safe and smooth operation.

QUIET, PULSE FREE AIR SUPPLYCentrifugal fans that are statically and dynamically balanced, handle upto 0.5" w.g. (125pa) external static pressureallowing you to keep the unit away from your comfort zone.

MATCHED WITH RELIABLE CONDENSING UNITSFor optimum performance in cooling and heat pump applications.

STANDARD SPECIFICATIONSUNIT CONSTRUCTIONThese ducted indoor fan coil unit consists of a coil, motor/blower assembly, aluminum filter and a drain pan securelymounted on heavy gauge galvanized steel housing. Steel sheet panels are zinc coated and galvanized by the hot dipprocess of lock-forming quality conforming to ASTM A 653 commercial weight G-90.This unit is designed for those concealed overhead installations which require supply ductwork. A 1.5" duct collar isprovided into the front panel for supply air duct connection. Return air is from the rear side.Access to the blower assembly is provided through the removable bottom panel from where the complete fan/motor deckcan be removed for servicing. The panels are insulated with 5/16" thick polyethylene acoustic and thermal insulation.1/2" (13mm) thick washable type aluminum filter is provided.

BLOWER ASSEMBLYThe direct drive blower motor assembly is easily accessible for complete servicing after removal of fan deck from the unit.The blower wheels are large in diameter and are of the forward curved design. Constructed of steel, they are staticallyand dynamically balanced for quiet and smooth performance.

MOTORSMotors are permanent split capacitor type with three speed tapped windings. The bearings are of sleeve type.

COILSAll cooling coils are of corrugated fin & tube type, constructed of enhanced copper tubes and mechanically bonded toaluminum fins. As an option to aluminum fins, coated aluminum fins or corrugated copper fins may be provided. Tubesupport sheets are of galvanized steel, formed to provide structural strength. Coils are provided with the orifice type refrig-erant metering device on all models (except DY18/DY24/DY30 heat pump models). This provides for ease of serviceability.Unlike capillaries there is no need for de-brazing/brazing required for site replacements of the orifice pistons. Accuratelysized pistons can be easily fitted for non-standard applications (e.g. high rise buildings). Also this metering device elimi-nates the need for check valves in reverse cycle heat pump applications. All coils are factory tested at 350 psig.

DRAIN PANThe condensate drain pan is fabricated of 18 gauge galvanized steel. The drain pan is powder coat painted and the outersurface is thermally insulated. Since water never touches the metal pan, then possibility of corrosion is eliminated.

Quiet Operation Digital Thermostat Compact Dimensions High Cooling Capacity Easy Installation

4

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 safeoperation. These compressors have improved internal pressure relief valve which provides high pressure protection tothe refrigerant 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 locatedso refrigerant tube connections can be made quickly and easily. Each valve has a gauge pressure port for ease ofchecking refrigerant operating pressures.

F. LOW PRESSURE SWITCHAuto reset SPST switch activated by refrigerant pressure - locks out the compressor, if the refrigerant pressure fallsbelow 25 PSIG. Also provides additional protection against evaporator freeze up due to loss of indoor airflow.

Low Noise Level Powerful Reciprocating Compressor High Energy Efficiency Ratio

5

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 20F 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

6

7

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 1.3 1.3 3.6 3.6 3.6 4.8 4.8

Face area, ft2 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 3/4 -1/2 3/4 -1/2

Return air filter (1/2" thick) size, inch & quantity 8 x 16.5 (2) 8 x 16.5 (2) 9.5 x18.5 (2) 9.5 x 18.5 (2) 9.5 x 18.5 (2) 11 x 22.75 (2) 11 x 22.75 (2)

Weight, Kg. 40 40 52 52 55 65 65

Minimum circuit ampacity, Amps 1.6 1.6 4.5 4.5 4.5 6 6

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 16.7/84 19.4/109 24.6/132 30.7/135

Compressor 208/230-3-60 N.A. N.A. 11.8/67 11.8/67 13.1/80 16/97 19.6/105

RLA/LRA 380-3-60 N.A. N.A. 5.6/39 5.6/39 8.2/50 8.2/50 10.4/55

460-3-60 N.A. N.A. 5.4/29.2 5.4/29.2 5.9/42 8.2/50 10.4/55

208/230-1-60 12.8/20 25.2/35 17.4/30 22.5/40 27.5/45 33.9/60 41.5/70

MCA/MOCP 208/230-3-60 N.A. N.A. 15.7/25 16.4/25 19.6/30 23.2/40 27.7/45

(Outdoor unit)380-3-60 N.A. N.A. 8/15 8.5/15 13.4/20 13.4/20 16.2/25

460-3-60 N.A. N.A. 7.7/15 8.3/15 10.6/15 13.4/20 13.4/20

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, ft2 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 3/4 - 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) 800 x 325 x 685 800 x 325 x 685 800 x 325 x 685 965 x 390 x 726 965 x 390 x 1158 965 x 390 x 1158 965 x 390 x 1158

Weight, Kg. 65 66 72 101 115 120 130

PHYSICAL DATA

NOTE: 1. Cooling capacities & power input data @ 800F (26.70C) DB/670F (19.40C) WB indoor & 950F (350C) ambient temperatures.2. Heating capacities & power input data @ 700F (21.10C) DB/600F (15.60C) WB indoor & 470F (8.30C) 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.

TC

85SC kW TC

95SC kW TC

105

SC kW TC

115

SC kW TC

125

SC kW

CO

OLI

NG

CA

PAC

ITIE

S

CO

ND

ENSE

REN

TER

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AIR

TEM

P. (0 F

)

MO

DEL

NU

MB

ER (I

ND

OO

R U

NIT

/OU

TDO

OR

UN

IT)

DY1

8/K

Y018

DY2

4/K

Y024

DY3

0/K

Y030

DY3

6/K

Y036

DY4

2/K

Y042

DY4

8/K

Y048

DY6

0/K

Y060

EVA

POR

ATO

R A

IRFL

OW

, CFM

/DR

650/

0.11

275

0/0.

120

1050

/0.1

2712

50/0

.145

1400

/0.0

9016

00/0

.070

1950

/0.0

85EV

APO

RAT

OR

EN

TER

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AIR

, WB

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apac

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apac

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abo

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DB

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BE

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DB

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s, fo

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this

pro

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re: D

BL

= D

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ble

Cap

acity

(Btu

h) /

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x C

FM);

WB

L =

DB

L –

[DR

(DB

E –

WB

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ties

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of r

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100%

95%

90%

85%

80%

75%

70%

60%

TC1

0.98

0.96

0.93

0.91

0.89

0.87

0.83

SC

10.

965

0.93

0.90

0.87

0.84

50.

820.

78

kW1

0.99

20.

985

0.97

0.96

50.

960.

940.

93

6267

7262

6772

6267

7262

6772

6267

7262

6772

6267

72

17.9

819

.78

21.7

122

.19

24.4

226

.67

30.3

033

.40

36.8

035

.46

39.0

742

.94

42.7

647

.22

51.9

648

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54.1

059

.79

57.3

562

.73

68.3

3

17.8

314

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11.6

821

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17.5

213

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29.2

024

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19.3

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28.4

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41.1

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16.3

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19.7

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23.0

225

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27.5

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33.4

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36.2

539

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39.9

044

.12

48.6

445

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50.0

155

.38

53.0

257

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63.1

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15.9

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11.2

420

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17.0

213

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27.0

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18.7

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27.9

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39.5

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26.3

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52.9

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35.4

3

2.09

2.2

2.31

2.61

2.8

2.98

3.53

3.7

3.86

3.89

4.11

4.32

4.74

5.01

5.27

5.37

5.7

6.05

6.93

7.31

7.66

16.1

217

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19.6

119

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21.5

223

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27.3

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33.3

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35.4

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61.9

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16.0

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11.0

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16.0

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38.1

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25.6

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51.1

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34.5

7

2.18

2.3

2.43

2.81

3.0

3.2

3.6

3.79

3.97

3.87

4.1

4.32

4.84

5.11

5.4

5.37

5.7

6.06

7.02

7.41

7.78

13.9

915

.50

17.1

217

.22

19.0

220

.85

25.8

028

.50

31.4

030

.28

33.4

936

.96

36.7

840

.79

45.0

841

.97

46.6

851

.86

49.2

053

.93

58.7

5

13.7

913

.20

10.0

716

.96

15.5

011

.89

25.3

022

.60

17.6

030

.20

26.4

020

.55

36.0

031

.79

24.7

841

.38

37.0

928

.94

48.5

243

.72

33.5

1

2.26

2.4

2.54

2.9

3.1

3.3

3.78

3.98

4.19

4.16

4.41

4.66

5.01

5.31

5.62

5.55

5.9

6.29

7.2

7.6

8.01

12.0

413

.39

14.8

215

.10

16.7

118

.33

24.0

026

.70

29.5

028

.43

31.4

834

.75

34.5

938

.42

42.4

839

.46

43.9

848

.90

45.9

750

.47

55.0

5

11.8

112

.38

9.29

14.8

015

.00

11.3

223

.50

21.9

016

.90

28.3

825

.67

19.8

233

.94

31.0

123

.97

38.8

936

.06

27.9

245

.33

42.3

932

.26

2.36

2.5

2.65

3.1

3.3

3.5

3.96

4.19

4.41

4.33

4.61

4.89

5.38

5.71

6.07

5.82

6.21

6.63

7.56

8.01

8.45

8

0.0 0.05 0.1 0.15 0.2 0.25 0.3 0.4 0.5

HIGH 650 640 591 566 542 508 475 406 334

DY18 MEDIUM 552 528 514 478 452 421 390 333 255

LOW 470 445 420 395 375 345 - - -

HIGH 750 729 698 670 643 613 584 510 427

DY24 MEDIUM 660 642 591 566 542 508 475 406 334

LOW 552 528 504 478 452 421 - - -

HIGH 1050 987 960 934 908 886 864 804 741

DY30 MEDIUM 852 827 802 775 748 727 706 650 594

LOW 637 614 592 575 559 533 - - -

HIGH 1250 1209 1184 1153 1122 1083 1044 966 894

DY36 MEDIUM 1050 987 960 934 908 886 864 804 741

LOW 852 827 802 775 748 727 - - -

HIGH 1400 1362 1324 1291 1258 1218 1178 1102 1009

DY42 MEDIUM 1225 1192 1160 1130 1100 1064 1028 958 877

LOW 995 975 955 928 902 876 - - -

HIGH 1600 1590 1571 1538 1505 1466 1426 1331 1245

DY48 MEDIUM 1366 1338 1310 1277 1244 1199 1153 1070 970

LOW 1100 1065 1030 992 954 912 - - -

HIGH 1950 1900 1840 1780 1728 1690 1651 1558 1463

DY60 MEDIUM 1631 1601 1571 1538 1505 1466 1426 1331 1245

LOW 1366 1338 1310 1277 1244 1199 - - -

FAN PERFORMANCE DATACFM @ EXTERNAL STATIC PRESSURE (Inches of water)BLOWER

MOTORSPEED

MODELNUMBER

NOTE: Values include losses for dry coil and filters.

9

DIMENSIONS - INDOOR UNITS

DY18 - 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

FRONT VIEW

TOP VIEW END VIEWEND VIEW

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

13 (0

.50")

2

5

D

H

A4I

3

38 (1

.50")

89 (3.50")

1

6

C G

F

EB

800(31.5)

366(

14.4)

END VIEW

TYPE CONN. 9.5 (3

8") FLARE

48(1.890)

14 (0

.551)

83 (3

.268

)

49 (1.929)

TYPE CONN. 16 (58") FLARE

FRONT VIEW

685(

27)

AIR OUT

AIR IN

AIR

IN

DETAIL - A

SEE DETAIL -A

20 (0.788)

(TYPICAL AT FOUR PLACES)

70(2.755)

15(0

.590)

POWER & CONTROL WIRE ENTRY

LIQUID VALVE

SUCTION VALVE

TOP VIEW

325 (

12.79

5)

406

(15.9

84)

442 (17.402)

DIMENSIONS - OUTDOOR UNITS

11

KY018, KY024 & KY030AI

R IN

AIR OUT

AIR IN

POWER & CONTROL WIRE ENTRY

SEE DETAIL -A (TYPICAL AT FOUR PLACES)DETAIL - A

19 (34") FLARE

9.5 (38") FLARE TYPE CONN.

END VIEW

TYPE CONN.

ACCESS PANEL

TOP VIEW

FRONT VIEW

965(38)

435(

17.16

)

16(0.63)

19(0.75)

727(

28.63

)

133 (5.25) 698(27.5)

390(

15.38

)

82 (3

.25)

152 (

6.0)

89 (3.5)

431(

17)

70(2.76)15

(0.59

)

20 (0.79)

KY036


DIMENSIONS - OUTDOOR UNITS

KY042, KY048 & KY060


12

AIR

IN

AIR IN

WIRE ENTRYPOWER & CONTROL

SEE DETAIL-A (TYPICAL AT FOUR PLACES)DETAIL - A

TOP VIEW

ACCESS PANEL

AIR OUT

9.5 (38") FLARE

22 (78") FLARE

TYPE CONN.

TYPE CONN.

END VIEWFRONT VIEW

1158

(45.

63)

863(

34)

79(3.13)

16(0.63)

27(1.06)

965(38)

435(

17.1

6)

133 (5.25)

390(

15.38

)

698(27.5)

15(0

.6)

70(2.76)

20 (0.79)

82.(3

.25)

146 (

5.75)

60** * * * *DY 36

DY 60

DY 48

DY 42 * ** * ** ** * *

* * *

** *

**

IN HERTZ

FREQUENCY

APPLICABLE

ATB

COM

* *

SPEED

WIRE COLOR

DY 18

DY 30

DY 24

MODEL

ORN

FM SPEED CONNECTIONSMED-LOWMED-HI MEDHI

VIO

* ** * *

* ** * ** * *

BLK

*

* **

BLU

COMLOW LOWEST

*

RED GRY YEL

ID

LOWN2

N1

HIG

H

LIVE

MED

CN4

COMPCOM

Refer to table below forSpeed 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

CAPBRN

BRN

60

60

60

60

60

4) YEL TX RCV

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

NOTES1. 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

LEGEND

ATB 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 4/61NATB L

CAP

ATB

NOTE:

OUTDOOR DE-ICE SENSOR

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

FIX THE OUTDOOR DE-ICE SENSOR

15

DY 18

WIRE COLOR

SPEED

MODEL

DY 30

DY 36

DY 42

DY 48

DY 60

DY 24

FM SPEED CONNECTIONSMED

* ** *

* * ** * *

* * *

* * *

** *

* ** * *

** *

* * ** * *

BLK

* * *

HI

VIO BLU

* * *

MED-HI

*

**

ORN

MED-LOW

RED GRY

LOWESTLOW

MED

N1

N2

LOW

HIG

HLIVE

4WV

CN4ECB

OF/OOF/I

ID

COMPCOM

OD

21B

21A

21

39A

TO FUSE DISCONNECT SWITCH

230VACL2/N GNDL1

COM

Speed Connections.Refer to table below for

* **

* * *

CABLE CONNECTIONS AT LCD

60

60

IN HERTZ

APPLICABLE

FREQUENCYYEL

COM

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

60

60

60

60

60

4) YEL TX RCV

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

LEGEND

ATB 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

NOTES1. 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

PN

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

BLK

T3A

FM

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.

ELECTRICALPlease ensure power supply (V-Ph-Hz) to the unit is as per unit nameplate requirements.

Caution: Operation of the unit on improper power supply will result in damage to the unit.

Warning: Before installation or servicing, always TURN OFF all power to the unit. There may be more than one discon-nect switch. Ensure all of them are turned off.

Ground & Power wiresConnect power wires as per wiring diagram. Connect ground wire to the ground lug inside the control box.

Control wiring between outdoor & indoor unitsUse 16 gauge color-coded wire between the indoor and outdoor units (control wiring). Then match the auxiliary terminalblock (ATB) numbers (indoor and outdoor units) to interconnect the two units.

Note: 1. Field wiring to comply with local Safety and Fire codes.

2. Use copper wires of proper rating for all field wiring.

3. Install adequate branch disconnect switch as per NEC size requirements to handle unit starting current. Locate disconnect switch within sight and readily accessible from the unit.

MAINTENANCE

COIL: 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 becomingclogged with 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 excep-tional service, a mild solution of Sal-Soda, Tri-Sodium Phosphate or any other commercial solvent can be used. Set filteron 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 nameplate of the unit.

15

AIR

IN

AIR OUT

AIR IN

610mm (24") CLEARANCE MINIMUM

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

254mm (10") FOR KY036 AND ABOVE

914mm (36") CLEARANCE MINIMUM

254m

m (1

0") F

OR

KY0

36 A

ND

AB

OV

E

203m

m (8

") F

OR

KY0

18, 0

24 &

030

INSTALLATION & START-UP INSTRUCTIONS - OUTDOOR UNITSAFETY CONSIDERATIONSImproper 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.

16

17

ELECTRICALSTEP 1: INSTALLATIONA) Please ensure power supply to the unit is as per unit nameplate (Volts/Ph/Hz) requirements.Caution: Operation of the unit on improper power supply 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 thanone disconnect 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) Control wiring between outdoor & indoor unitUse 16 gauge color-coded wire between the indoor and outdoor units (control wiring).

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 550F (12.70C).

• Maximum outdoor operating air temperature during cooling mode is 1300F (550C).

• 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 ofconnector provided.

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.

18

50 CM

50 CM

30 CM

Bottom panel

95 CM

Blower deck holding bolt

Blower deck

Access for blowers & motor

19

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 2

HPS/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.

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 800-684-01 800-684-04 800-684-14 800-684-07 800-684-02 800-684-05

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

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

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

COMPRESSOR CONTACTOR 800-097-00 800-095-00 800-095-00 800-095-00 800-097-00 800-095-00

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

MODEL NUMBER KY042M KY042F KY048C KY048H KY048M KY048F

COMPRESSOR 800-684-09 800-684-08 800-684-03 800-684-06 800-684-09 800-684-09

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



MODEL NUMBER KY060C KY060H KY060M KY060F

COMPRESSOR 800-672-59 800-672-51 800-672-52 800-672-52

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 800-736-23 800-097-00 800-095-00 800-095-00

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

MODEL NUMBER KY018C KY024C KY030C KY030H KY030M KY030F

COMPRESSOR, COOL ONLY 800-675-79 800-675-80 800-675-89 800-684-04 800-684-14 800-684-07

COMPRESSOR, HEAT PUMP 800-675-86 800-675-87 800-675-90 800-684-04 800-684-14 800-684-07

FAN MOTOR 800-555-32 800-555-32 800-555-37 800-545-97 800-545-97 800-545-96

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

CONDENSER FAN 800-224-19 800-224-19 800-224-55 800-941-41 800-941-41 800-941-41



20

PL-AP-DYS-10-2M-E

Zamil DY-KY series.pdf

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Transcript of Zamil DY-KY series.pdf