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Zamil PDS Series, Installation, Operation & Maintenance Manual

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Contents

Page

Model decoding ........................................................................................................................................ 2

Dimensions .......................................................................................................................................... 3-10

Fresh air hood assembly ........................................................................................................................ 11

Rigging instructions ................................................................................................................................ 12

Installation .............................................................................................................................................. 13

Typical schematic wiring diagram ...................................................................................................... 14-19

INSTALLATION INSTRUCTIONS

General ................................................................................................................................................... 20

Location of unit ....................................................................................................................................... 20

Wiring ..................................................................................................................................................... 20

Start-up inspection & check list ......................................................................................................... 20-21

Check-out & operational start-up procedure ...................................................................................... 21-22

Belt tension testing procedure ........................................................................................................... 22-23

ELECTRICAL

Power supply .......................................................................................................................................... 24

Unbalanced voltage ................................................................................................................................ 24

Motor contactor ...................................................................................................................................... 25

Fan motor ............................................................................................................................................... 25

Crankcase heater ................................................................................................................................... 25

Lube oil protection control ................................................................................................................. 25-26

Voltage monitor ...................................................................................................................................... 26

Electronic thermostat ........................................................................................................................ 26-27

REFRIGERATION

Compressor ............................................................................................................................................ 28

High & low pressure switch .................................................................................................................... 29

Pump down control ................................................................................................................................. 30

Trouble shooting chart ....................................................................................................................... 31-33

Parts list ............................................................................................................................................ 34-40

Recommended spare parts .................................................................................................................... 41

Preventive maintenance schedule .......................................................................................................... 42

INDEX

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1

Summary of Contents for PDS Series

Page 1: ...DOUBLE SKIN PACKAGED AIR CONDITIONERS PDS SERIES PL OM PDS 05 1M E INSTALLATION OPERATION MAINTENANCE MANUAL ...

Page 2: ... testing procedure 22 23 ELECTRICAL Power supply 24 Unbalanced voltage 24 Motor contactor 25 Fan motor 25 Crankcase heater 25 Lube oil protection control 25 26 Voltage monitor 26 Electronic thermostat 26 27 REFRIGERATION Compressor 28 High low pressure switch 29 Pump down control 30 Trouble shooting chart 31 33 Parts list 34 40 Recommended spare parts 41 Preventive maintenance schedule 42 INDEX CO...

Page 3: ...h dual compressors dual circuit Capacity control options starts from units PDS060 onwards Standard options contains vibration eliminator for semi hermetic fixed high low pressure switches fan cycling low ambient switches and UVM To select low CFM 100 fresh air units follow the software selection procedure A ALUMINUM FIN B COATED ALUMINUM FIN C COPPER FIN D HERESITE COATING WITH ALUMINUM FIN H HERE...

Page 4: ...ket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution STANDARD ECONOMIZER UNIT MODEL No PDS 036 048 060 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 036 048 060 Legend F A Fresh Air R A Return Air S A Supply Air 3 ...

Page 5: ...OW CFM 100 FRESH AIR UNIT MODEL No PDS 075 090 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution Legend F A Fresh Air R A Return Air S A Supply Air 4 ...

Page 6: ...65 18 5 157 5 6 2 1366 53 8 1365 5 53 75 157 5 6 2 1366 53 8 UNIT DIMENSIONS STANDARD ECONOMIZER UNIT MODEL No PDS 100 120 150 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 100 120 150 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution Legend F A ...

Page 7: ... PDS 180 220 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 180 220 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution Legend F A Fresh Air R A Return Air S A Supply Air 6 ...

Page 8: ...HOOD AUXLIARY CONTROL BOX Ø40 1 6 DRAIN OUTLET HEATER BOX OPTIONAL CONDENSER ACCESS 480 18 9 1770 69 7 1830 72 0 RIGGING HOLES Ø76 2 2 Nos EACH SIDE 480 18 9 UNIT DIMENSIONS STANDARD ECONOMIZER UNIT MODEL No PDS 240 300 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 240 300 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F...

Page 9: ...PDS 360 420 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 360 420 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution Legend F A Fresh Air R A Return Air S A Supply Air 8 ...

Page 10: ...S 480 540 600 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 480 540 600 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution Legend F A Fresh Air R A Return Air S A Supply Air 9 ...

Page 11: ...ZER UNIT MODEL No PDS 660 720 840 LOW CFM 100 FRESH AIR UNIT MODEL No PDS 660 720 840 Notes 1 All dimensions are in mm dimensions in bracket are in inches 2 Service clearance should be 1200mm 4 feet on all sides 3 F1 F2 are mounting hole locations Please refer to page 12 for weight distribution Legend F A Fresh Air R A Return Air S A Supply Air 10 ...

Page 12: ...RIES 1 Hood panel 2 1 4 dia taptite screw 3 Right hand side panel 4 Left hand side panel 5 10 SM screw 6 Bottom panel 7 Left hand end panel 8 Right hand end panel 9 Filter 10 Middle slide bracket 6 4 7 3 2 9 10 8 5 1 OPTIONAL VERTICAL DAMPER ...

Page 13: ... PDS 048 PDS 060 PDS 075 PDS 090 PDS 100 PDS 120 PDS 150 PDS 180 PDS 220 PDS 240 PDS 300 PDS 360 PDS 420 PDS 480 PDS 540 PDS 600 PDS 660 PDS 720 PDS 780 PDS 840 MODEL NUMBER LOAD DISTRIBUTION AT POINTS KG TOTAL LOAD KG 1050 1100 1175 1350 1425 1650 1700 1775 2050 2155 2300 2450 2600 2725 3400 3475 3550 4100 4150 4220 4300 F1 F1 F2 F2 F3 F3 F4 F4 F5 F5 F6 F6 155 155 105 105 160 160 105 105 N A N A ...

Page 14: ...drawing below 3 All wiring must comply with NEC National Electrical Code and local electrical codes The electric supply must comply with the unit nameplate See the typical wiring diagram for guidance 4 All units are pre charged with R 22 and oil sealed and tested for leaks Therefore do not attempt to open the system 5 Install a flexible connection for duct work to minimize vibration transmission C...

Page 15: ... min PRESET TO 0 SEC STD UNIT 30 SEC PD UNIT FACTORY SETTING OF J1 J2 PRESET TO 3 MIN J2 J1 TIMER SETTING ON SM 60 sec J1 COMP PUMP DOWN DELAY TIME 10 sec 30 sec 0 sec J2 COMP ANTI RECYCLE TIMER 90 sec FCS 190 15 LPS HPS 25 5 PUMP DOWN SOLENOID RELAY ATB 18 OLR 1 BMC 19 230V 24V CB 16 CONTACTOR BLW MTR 17 1B PDSR1 1 CR1 1 P YR1 1 LPS1 JP2 ATB 1 1A JP1 ABOVE RIGHT 1 TO ATB 2 TO ATB SEE APPLICABLE F...

Page 16: ...SW 98 LAMP OPTIONAL CCA 2B B BM ON OFF TRIP INDICATION LEGEND AI ANTI ICE THERMOSTAT AFS AIR FLOW SWITCH AR AUXILIARY RELAY ATB AUXILIARY TERMINAL BLOCK BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CC COMPRESSOR CONTACTOR CB CIRCUIT BREAKER C HTR CRANKCASE HEATER CR CONTROL RELAY COMP COMPRESSOR DTS DISCHARGE TEMPERATURE SENSOR FL FUSE LINK FCS FAN CYCLING SWITCH FM FAN MOTOR CONDENSER FMC FAN MOTOR...

Page 17: ...ATB 220VAC C POWER Y1 17 5B 5A 2 HEATING 2 STAGE nd W2 30 DDC CONTROL PANEL COOLING 2 STAGE st HEATING 1 STAGE W1 29 Y2 31B COOLING 1 STAGE nd st Y1 31A J2 BLW MTR 1 G J1 18 C 17 LLS OR THERMOSTAT BY OTHERS R 15 ATB 15 SEE COMPRESSOR PWS CONNECTION IF COMP IS STARTED IN PWS ATB 2 3A CR3 C1 CONTACTOR CC1 TO NTB N PDSR1 PDSR2 SUPPLY 24VAC C 38B 38A SUPPLY BMR 1 RB2 P 23B P TO ATB LPS2 P TO SM TO SM ...

Page 18: ...26A OPTIONAL REMOVE JP1 L2 L1 AS APPLICABLE C HTR2 101A 2 L2 L1 8 1 UVM 1 C HTR1 100A 2 Stg 1 Heating 33 66 CAPACITY UNLOADER COMP IS RUNNING AT FULL CAPACITY IF UNLOADER SOLENOID IS DE ENEGIZED UL3 UL4 SOLENOID CONNECTION IS APPLICABLE FOR COMPRESSORS WITH UL1 UL2 SOLENOID CONNECTION IS APPLICABLE FOR COMPRESSORS WITH OPTIONAL 63 62 61 60 58 57 56 55 C HTR2 L3 UVM CONNECTION TO HVTB L3 UVM L3 OPT...

Page 19: ...EMIZER SR SAFETY RELAY SSPS SOLID STATE PROTECTIVE SYSTEM TK MOTOR THERMAL CONTACT TRANS TRANSFORMER T STAT THERMOSTAT UVM UNDER VOLTAGE MONITOR YR COOLING RELAY FIELD WIRING DISCONNECT TAB 1 4 SPLICE CLOSED END _ _ _ 18 FMC1 ATB TK FM3 13C 2 FM3 36C 35C 37A 37C FM2 FM4 37B 35B 36B 36D 37D 35D TK FM6 TK FM4 TK FM2 CR2 2 RB1 FMC2 CB6 L1 TO HVTB L3 L2 B WITH FAN CYCLING OPTION 1 ATB 13 13B CB7 TO HV...

Page 20: ...SUPPLY AIR THERMISTOR AQS AIR QUALITY SENSOR OAT OUTDOOR AIR THERMOSTAT FCC FREE COOLING COUNTER OAD OUTDOOR AIR DAMPER MOTOR RAD RETURN AIR DAMPER MOTOR STS SUPPLY AIR TEMPERATURE SENSOR MTR DAMPER MOTOR EC ENTHALPY CONTROLLER NOTES 1 DAMPER MOTOR IS NOT REQUIRED FOR SINGLE DAMPER MOTOR APPLICATION 2 IF EC OR OAT OPTION IS FACTORY INSTALLED PLEASE READ BROKEN LINES AS CONTINUOUS LINES 19 ...

Page 21: ...ich can cause condenser air recircu lation or restriction 8 Care should be taken to prevent air from other sources from entering condenser if this air is at a high temperature WIRING All wiring must comply with the National Electric Code and local electrical standards The power supply voltage frequency and phase must coincide with the unit nameplate Power wiring to the equipment must be adequately...

Page 22: ...side Outside Building Duct Leakage Inside Outside Building Volume Dampers Volume Damper Access Doors Fire Dampers Fire Damper Access Doors Transfer Grilles Door Grilles Duct Insulation Liner Diffusers Grilles Duct Humidistat Filter flag CHECK OUT OPERATIONAL START UP PROCEDURE After the completion of inspection and check list the following points should be covered before system is placed in operat...

Page 23: ... shown 2 Divide belt span by 64 to get belt deflection needed to check tension 3 Set large 0 ring on span scale at required belt deflection This scale is in 1 16 increments 4 Set small 0 ring at zero on the Force Scale plunger 5 Place the larger end of the tension checker squarely on one belt at the center of the belt span Apply force on the plunger until the bottom of the large 0 ring is even wit...

Page 24: ...ECTION 3 L 4 L 5 L SMALL PULLEY PITCH DIA P D RANGE 1 25 1 75 2 2 25 2 5 3 2 1 2 8 3 3 5 3 7 5 3 4 2 4 5 5 2 MINIMUM 1 2 5 8 3 4 1 1 8 1 1 2 1 7 8 2 2 3 8 MAXIMUM 5 8 7 8 1 1 8 1 5 8 2 1 8 2 5 8 2 7 8 3 3 8 BELTS DEFLECTION FORCE LBS FORCE SCALE SPAN SCALE RING 0 LARGE 0 RING SMALL BELT SPAN DEFLECTION 64 BELT SPAN ...

Page 25: ...Unbalanced voltage on a three phase compressor motor may overheat and trip the motor on external or internal current sensing motor protector whichever one is provided To determine that an unbalanced voltage condition exists the supply voltage at the main disconnect switch and at the unit disconnect switch should be measured Voltage unbalance is calculated as follows The percentage of voltage unbal...

Page 26: ...t boils off there will not be enough oil for sufficient lubrication at the bearings furthest from the oil pump The center and rear bearings may seize or may wear enough to allow the rotor to drop and drag on the stator causing it to short Also the liquid refrigerant washes the oil off the pistons and cylinders during the suction stroke causing them to wear during the compression stroke When the cr...

Page 27: ...nger span of time before lock out occurs Last but not least it has enlarged the reset button to a new thumb sized dimension The reset button is slightly recessed to protect it from damage VOLTAGE MONITOR This device protects the motors in the unit from faults such as under or over voltage unbalance phase reversal of the power supply When the device sensed such faults it will cut off the supply in ...

Page 28: ...t the temperature you want your heating system to maintain by pressing and holding the HEATING button under the or symbols until the desired temperature is displayed The control setpoint temperature is displayed for 5 seconds Fan The fan will be energized automatically when the systems are operating but no indication of this on the display To select continuous fan operation press the FAN button an...

Page 29: ...ctive 1 Test compressor motor winding for ground 2 Test compressor motor windings for continuity 3 Test that compressor motor will run both without a load and under a load 4 Test the current or ampere drawn 5 Observe sound level of compressor To establish that the compressor suction and discharge valves are operating and holding properly attach gauges to the liquid and suction service valves Front...

Page 30: ...ressor The control is designed to protect against excessive discharge temperatures and pressures which can cause compressor overheating and damage to the motor windings or valves Should the control open it will remain open until the pressure in the system is lowered to 360 psig Tripping of the high pressure control is normally due to 1 Restricted condenser coil 2 Overcharge of refrigerant 3 Defect...

Page 31: ...and the compressor to start When the thermostat is satisfied the solenoid valve closes and the compressor continues to run until a substantial portion of the refrigerant has been pumped out from the evaporator When the pump down pressure switch cut out setting is achieved power to the control circuit is interrupted and the compressor stops A pump down control may be necessary on an installation wh...

Page 32: ...refrigeration system 5 Check for possibility of misapplica tion Use stronger unit 6 Check refrigerant charge fix leak add if necessary 1 Check wiring against diagram 2 Determine reason and correct 3 Replace compressor 4 Replace compressor 5 Check crankcase heater 6 Unequilized pressure in the system 1 Improperly wired 2 Low voltage to unit 3 Compressor motor has a winding open or shorted 4 Interna...

Page 33: ...eratures air cooled 2 Refrigerant shortage 3 Damaged valves in compressor 1 Fix leak add charge 2 Clean contacts or replace control 3 Determine the fault and correct 4 Replace with larger system 5 Defrost 6 Determine location and remove 7 Clean condenser 8 Clean or replace 1 Check for dirt or lint on coil 2 Clean or replace Advice customer on periodic cleaning of filter 3 Check system pressure Tak...

Page 34: ...ounting 1 Check the design 2 Follow manufacturer s guide line and correct it 3 Repair replace compressor 4 Check and adjust the superheat ac cordingly 5 Check the expansion valve bulb is properly tighten at correct location High suction pressure 1 a Correct the system piping b Trace out the wiring defective con trols components etc and correct it c Add oil d Check the superheat of expansion valve ...

Page 35: ...0 705 38 800 705 38 800 705 38 800 705 38 800 207 08 800 207 08 800 207 08 800 207 08 800 207 08 800 207 08 800 207 08 800 207 08 800 207 08 800 706 30 800 706 30 800 706 30 800 706 30 800 706 30 800 706 30 800 706 30 800 706 30 800 706 30 800 706 31 800 706 31 800 706 31 800 706 31 800 706 31 800 706 31 800 706 31 800 706 31 800 706 31 800 557 29 800 557 29 800 557 29 800 557 29 800 557 29 800 55...

Page 36: ... 800 674 15 800 098 57 N A 800 098 55 800 098 57 800 098 55 800 098 55 800 098 59 800 098 55 800 098 55 N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A 800 577 00 N A N A 800 226 33 800 226 33 800 226 34 800 227 14 800 227 14 800 227 15 800 227 14 800 227 14 800 227 15 800 093 11 800 093 11 800 093 11 800 093 11 80...

Page 37: ...00 557 30 800 557 30 800 557 30 800 557 30 800 557 30 800 557 30 800 557 30 800 557 31 800 557 31 800 557 31 800 557 31 800 557 31 800 557 31 800 557 30 800 557 30 800 557 30 MODEL NUMBER COMPRESSOR SCROLL CONTACTOR SCROLL COMPRESSOR SEMI HERMATIC RECIP COMPRESSOR SEMI HERM W UNLOADER CONTACTOR SEMI HERMATIC RECIP CAPACITY UNLOADER KITS COND FAN ASS Y FAN MOTOR WITH GRILLE CONTACTOR FILTER DRYER S...

Page 38: ...00 557 30 MODEL NUMBER COMPRESSOR SCROLL CONTACTOR SCROLL COMPRESSOR SEMI HERMATIC RECIP COMPRESSOR SEMI HERM W UNLOADER CONTACTOR SEMI HERMATIC RECIP CAPACITY UNLOADER KITS COND FAN ASS Y FAN MOTOR WITH GRILLE CONTACTOR FILTER DRYER SIGHT GLASS EXPANSION VALVE BLOWER WHEEL STD ECONOMIZER BLOWER WHEEL 100 FRESH AIR PUMP DOWN SOLENOID VALVE MECHANICAL SHUT OFF VALVE ACCESS VALVE LOW PRESSURE GAUGE ...

Page 39: ...6 03 800 226 04 800 226 01 800 226 03 800 226 04 800 226 01 800 098 51 800 098 51 800 098 51 800 098 51 800 098 51 800 098 51 800 531 17 800 531 17 800 531 17 800 531 17 800 531 17 800 531 17 800 200 04 800 200 04 800 200 04 800 200 04 800 200 04 800 200 04 800 184 75 800 184 75 800 184 75 800 184 76 800 184 76 800 184 76 800 077 35 800 077 35 800 077 35 800 077 35 800 077 35 800 077 35 800 077 29...

Page 40: ...00 770 61 3600 800 098 50 800 098 87 208 230 3 60 800 770 19 1800 800 098 54 800 098 88 460 3 60 800 770 19 1800 800 098 50 800 098 85 380 3 60 800 770 63 1800 800 098 50 800 098 87 208 230 3 60 800 771 19 1800 800 098 57 800 098 89 5 460 3 60 800 771 19 1800 800 098 50 800 098 87 380 3 60 800 876 05 1450 800 098 55 800 098 88 208 230 3 60 800 772 19 1800 800 098 57 800 098 91 7 5 460 3 60 800 772...

Page 41: ...5 460 3 60 800 098 51 80032026 380 3 60 800 098 51 80032016 208 230 3 60 800 098 55 800 098 54 20 460 3 60 800 098 51 380 3 60 800 098 51 208 230 3 60 800 098 57 800 098 54 80032005 12 5 kW 25 460 3 60 800 098 51 80032025 12 5 kW 380 3 60 800 098 51 80032015 12 5 kW 208 230 3 60 800 098 57 800 098 56 30 460 3 60 800 098 51 800 098 50 380 3 60 800 098 55 800 098 54 208 230 3 60 800 098 55 40 460 3 ...

Page 42: ...1 3 2 Contactor fan motors 2 1 3 2 HPS LPS other controls 2 1 3 2 Expansion valve 1 0 5 2 1 Filter drier 2 1 3 2 Electric heater 1 0 5 2 1 Fuse link heater 3 1 4 3 Transformer 24V secondary 1 0 5 2 1 Propeller fan 1 0 5 2 1 Blower Wheel 0 5 0 25 1 0 5 Bearing blower 2 1 4 2 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...

Page 43: ...ed body parts repair repaint as necessary Check mountings spring isolator rubber pads Repair replace as necessary Check flexible canvas connections duct work Repair replace as required Run test all motors and check the amperage abnormality etc Run test compressors and check the amperage noise oil level pressure etc and correct them accordingly Check the thermostat control devices for correct opera...

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