Zamil PV036 Instruction manual

INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
VERTICAL PACKAGED UNITS
'PV' SERIES
MODELS: PV036 - PV060

Contents Page
General
Model decoding ...................................................................................................................................................... 2
General statement .................................................................................................................................................. 3
Warranty ................................................................................................................................................................. 3
Safety issues .......................................................................................................................................................... 3
Inspection for damage ............................................................................................................................................ 3
Installation instructions
General................................................................................................................................................................... 3
Location of unit ....................................................................................................................................................... 3
Condensate drain connection................................................................................................................................. 4
Duct connection...................................................................................................................................................... 4
Electrical controls ................................................................................................................................................... 4
Cable size............................................................................................................................................................... 4
Unit dimensions ...................................................................................................................................................... 5
Access details ........................................................................................................................................................ 6
Operation instructions
Start-up inspection & check list .............................................................................................................................. 7
Electrical data ......................................................................................................................................................... 8
Maintenance instructions
Crankcase heater ................................................................................................................................................... 9
Cleaning of coils & filters ........................................................................................................................................ 9
Preventive maintenance schedule ....................................................................................................................... 10
Trouble shooting chart ..................................................................................................................................... 11-12
Typical schematic wiring diagram.................................................................................................................... 13-14
Parts list ................................................................................................................................................................ 15
INDEX
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1

1& 2
BASIC 3, 4 & 5
NOMINAL COOLING
CAPACITY
(MBH)
6
ELECTRICAL
SUPPLY
( V-Ph-Hz )
9
BLOWER
MOTOR
13
EVAPORATOR
COIL
14
CONDENSER
COIL
15
FILTER
11
HEATER 16
UNIT
ACCESSORIES
PV
VERTICAL
PACKAGED
UNIT
036 048 060
H: 208/230-3-60 M: 380-3-60*
(4 WIRE)
V: STD.
MOTOR A:ALUMINUM
FIN B:COATED
ALUMINUM FIN
C:COPPER FIN
N:NO HEATER
N: STD. UNIT
MODEL DECODING
8
COMPRESSOR
TYPE
S: SCROLL
HERMETIC
R: RECIPRO-
CATING HERMETIC
N:DIRECT DRIVE
10
DRIVE
OPTIONS
19
DIS-
CHARGE
(SUPPLY
AIR)
18
OPTIONS
12
COND.
MOTOR
N: STD. A:ALUMINUM
FIN B: COATED
ALUMINUM FIN
C:COPPER
FIN
17
APPLICATIONS
N: STANDARD
APPLICATION
C:COMMUNICA-
TION SHELTER APPLICATION
20
ACCESS
F: FRONT
NOTE:*Not available for PV036.
7
REFRIGE-
RATION
CIRCUIT
S: SINGLE N:NO
FILTER
G:
2" PLEATED FILTER
N: STD. R:RH
L:LH
2

GENERAL
GENERAL STATEMENT
This unit is from the PV series that was designed & built for the optimum performance. However, it is required that you become well
acquainted with good practices for the proper installation/operation/and maintenance procedures in order to ensure a safe trouble free
operation, year after year.
Please read through the whole manual contents before you attempt to install/operate/ and maintain the unit.
Most of the procedures described in this manual require certain skills and experience. The installation and other maintenance procedures
should be performed only by highly skilled and experienced technicians. The end user’s role should be limited to the cleaning of the
filter. Please consult your nearest "Zamil"representative for further information.
WARRANTY
All of the PV series of Vertical Packaged Units are covered by the standard warranty terms against any manufacturer defect. Should
you encounter any problem that falls under the warranty terms please contact your nearest "Zamil"representative.
SAFETY ISSUES
There are three degrees of safety hazards that are identified throughout this manual as WARNING (where the situation will result in
personal injury), CAUTION (where personal injury might occur), and ATTENTION (where minor personal injury and/or property dam-
age could happen). Please understand and respect those identifications.
WARNING: The PV units operate on a high voltage with moving parts (at high speed) which can lead to serious injuries and/
or damage to the unit. Never attempt to service the unit unless the main electrical power supply has been disconnected.
CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining the unit as the
hazard of explosion, fire, electrical shock, and potential personal injury and property damage are present.
When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observe all the
applicable safety measures (wear of safety helmet, boots, gloves, and goggles. Use of proper handling materials for brazing and use
of wet cloth for quenching. A fire extinguisher should be easily accessible etc.). He should also read all the instructions and information
in this Manual prior to attempting to perform any installation or servicing of the unit. All applicable local codes should also be observed.
INSPECTION FOR DAMAGE
The unit should be carefully inspected visually for any sign of physical damage due to mishandling. Whenever a damage is detected,
please indicate it on the corresponding delivery note before you sign it and inform your nearest "Zamil"office.
GENERAL
These units are shipped completely assembled, charged and wired. They do not require any field installation of refrigerant tubing.
Units require external power, thermostat wiring, condensate drain piping and ducting as applicable.
Size of unit for an installation should be based on a heat gain calculation made according to applicable standards. Units must also be
installed in accordance with regulations of the "National Fire Protection Association" and local electrical codes. Where local regulations
conflicts with the instructions in this manual, installer should adhere to local standards.
These units are wall mounted outside the building and proper openings in the wall should be given for return & supply air flows. Unit
should be installed and erected properly to prevent it from falling down.
LOCATION OF UNIT
When selecting the location for the unit, the following points should be kept in mind:
1. Provisions to fix the unit on walls.
2. That the terrain allows for drainage away from the unit.
3. Availability of electric power.
4. To position the unit for unrestricted air circulation of the condenser air inlet on the free side.
5. Check minimum clearances required for your unit, with regard to walls, or other obstructions.
6. Care should be taken to prevent air from other sources from entering condenser, if this air is at a high temperature.
7. Level the unit on its final location and be sure that the levelling tolerance is ±5 mm per linear meter in any direction.
CAUTION: Do not install the unit as indoor unit, install it in an open area, and unit air inlets must not be located near exhaust
vents or other source of contaminated air.
INSTALLATION INSTRUCTIONS
3

CONDENSATE DRAIN CONNECTION
•Use standard PVC pipe with NPT connection for the condensate drain. The plastic drain pan has an internal built-in trap. Accord-
ingly there will be no need for external 'P' trap.
•Piping has to be sloped away from the unit.
•Remember to remove the drain hole plug before operating the unit. Avoid bends & elbows.
DUCT CONNECTION
The units can be connected to the ducting in either vertical or horizontal configuration. Just remove the dummy panels and connect
using flexible duct connection. The duct should be properly designed and the drive package should match the required CFM &
corresponding external static pressure.
ELECTRICAL CONTROLS
1. For normal air-conditioning applications
This packaged unit control consists of Systemizer
TM
Microprocessor Based Electronic Control Board, incorporating the following features:
(a) Compressor Lockout. If any of the unit’s safety controls trips due to abnormal conditions the Electronic Controls lockout the
compressor, preventing restart, unless attended by service personnel. The unit can be re-started only by reset of thermostat after
ensuring safe system conditions.
(b) Anti recycle timer for compressor safety in case of accidental manual reset or immediate recycling of thermostat due to load
demand.
(c) Indicator LED lights:
Green – Power ON.
Red – Fault indication.
(d) Typical single stage thermostats to be ordered (part number 800-645-31).
2. For communication shelter applications (To be ordered separately)
The set of two PV units (when used for communication shelter applications) is provided with a dedicated control with the following features:
(a) Auto-reset High Pressure Switch: Built in lockout circuit with auto reset. Provides protection to the compressor.
(b) Auto reset Low Pressure Switch: Built in lockout circuit and low-pressure timed bypass circuit.
(c) Microprocessor based electronic board provides the compressor lockout, if any of the unit safety controls trip due to abnormal conditions.
(d) Auto lead/lag controller: The Auto lead/lag controller is a complete control package designed to operate a fully or partially
redundant air conditioning system having two units paired together. It consists of a thermostat and solid state timer with selectable
change-over intervals (typical 7 days). This control unit is factory-wired, tested and mounted in separate enclosure for quick
installation inside the air-conditioned space.
(e) Low ambient control: By using automatic condenser fan speed controls.
CABLE SIZE
•All wiring should be in accordance with local standards.
•Before making any connection, check the electric power supply, it must have the same characteristics as what is displayed in the nameplate.
•For selecting cable size, refer to wire ampacity table at different MCA (Minimum Circuit Amps) provided in unit electrical data, which
is listed as a guideline (see table below).
•Wiring connection to the unit must have suitable insulation of a minimum temperature of 600C.
MODEL No. MCA CONDUCTOR SIZE
AWG - MCM METRIC - MMSQ
PV036 19.7 14 2.5
PV048 27.2 10 6.0
PV060 32.6 10 6.0
PV048 18.3 14 2.5
PV060 20.0 14 2.5
POWER SUPPLY
208/230V-3Ph-60Hz
LEGEND: MCA - Minimum Circuit Amps
NOTES: 1. Customer is to select cable size also with cross reference as per cable manufacturer data for voltage reduction per unit
length. The above cable ampacity table is for guidance only.
2. The selected cables for specified units is as per following characteristics:
a. Unit without electric heaters.
b. Any extra electrical accessories shall add to MCA rate, for more information, refer to unit electrical tables in the catalog.
380V-3Ph-60Hz
4