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Summary of Contents for Zamil PDS Series
- Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL DOUBLE SKIN PACKAGED AIR CONDITIONERS 'PDS' SERIES PL-OM-PDS-05-1M-E...
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Page 2: Table Of Contents
INDEX 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 &... -
Page 4: Dimensions
UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 036/048/060 LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 036/048/060 Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches). Legend: F/A = Fresh Air 2. Service clearance should be 1200mm (4 feet) on all sides. R/A = Return Air 3. -
Page 5: Unit Dimensions
UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 075/090 LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 075/090 Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches). Legend: F/A = Fresh Air 2. Service clearance should be 1200mm (4 feet) on all sides. R/A = Return Air 3. - Page 6 UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 100/120/150 CONDENSER AIR IN TOP VIEW 295x1145 (11.6x45.0) 1270 (50.0) 4412 (173.7) 1330 (52.4) FRONT VIEW END VIEW LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 100/120/150 157.5 (6.2) 1366 (53.8) 1365.5 (53.75) 1366 (53.8) 157.5 (6.2)
- Page 7 UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 180/220 312 (12.3) LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 180/220 312 (12.3) Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches). Legend: F/A = Fresh Air 2.
- Page 8 UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 240/300 395x1145 (15.6.6x45.0) - STD. / ECON. CONDENSER AIR IN Ø40 (1.6) DRAIN OUTLET AUXLIARY CONTROL BOX FRESH AIR HOOD (For economizer system, hood supplied for 100% fresh air) MAIN CONTROL BOX Ø102 (Ø4) POWER ENTRY 480 (18.9) HEATER BOX (OPTIONAL)
- Page 9 UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 360/420 LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 360/420 458 (18.0) Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches). Legend: F/A = Fresh Air 2.
- Page 10 UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 480/540/600 422 (16.6) LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 480/540/600 378 (14.9) Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches). Legend: F/A = Fresh Air 2.
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Page 11: Dimensions
UNIT DIMENSIONS STANDARD & ECONOMIZER UNIT MODEL No.: PDS 660/720/840 806 (31.7) 806 (31.7) LOW CFM/100% FRESH AIR UNIT MODEL No.: PDS 660/720/840 640 (25.2) 404 (15.9) 640 (25.2) Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches). Legend: F/A = Fresh Air 2. -
Page 12: Fresh Air Hood Assembly
FRESH AIR HOOD ASSEMBLY VERTICAL DAMPER (OPTIONAL) HOOD ACCESSORIES 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. -
Page 13: Rigging Instructions
RIGGING INSTRUCTIONS ATTENTION TO RIGGERS: Hook rigging sling thru holes in base rail, as shown below. Holes in base rail are centered around the unit center of gravity. Use spreader bar when rigging, to prevent the slings from damaging the unit. CAUTION: All panels should be in place when rigging. -
Page 14: Installation
INSTALLATION 1. Provide a concrete pad or another form of stand. Use 6-12 each rubber/cork pads 4" x 4" x 1" thick each (rubber-in- shear for example) at each corner and along side rails, or use 6-12 each spring isolators. 2. -
Page 15: Typical Schematic Wiring Diagram
TYPICAL SCHEMATIC WIRING DIAGRAM (Single compressor units) CONDENSER FAN MOTOR CONNECTION - (DUAL FAN MOTOR) HVTB (AS APPLICABLE) REFER TO UNIT NAMEPLATE FOR TO FUSED SEE APPLICABLE FM WITHOUT FCS WITH FCS TO HVTB TO HVTB TO HVTB POWER SUPPLY DISCONNECT POWER CONNECTION SWITCH OR CB... -
Page 16: Typical Schematic Wiring Diagram
(REMOVE JP6) 4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH SERVICE LAMP CONNECTION (OPTIONAL) RATING AS RECOMMENDED BY ZAMIL. 5. COMPRESSOR IS PROVIDED WITH INHERENT THERMAL OVERLOAD PROTECTION. 230Vac LAMP 6. FOR ANY SAFETY TRIP OF COMP. (FAULT), VOLTAGE ACROSS TERMINAL 4 &... - Page 17 TYPICAL SCHEMATIC WIRING DIAGRAM (Dual compressor units) HVTB TO FUSED DISCONNECT SEE COND.FM AND SWITCH OR CB BM CONNECTION DOL STARTING CONNECTION OF REFER TO UNIT (SEE NOTE-4) COMPRESSOR - W/ CB [OPTIONAL] NAMEPLATE FOR POWER SUPPLY NEUTRAL WIRE HVTB (SEE NOTE -12) OLR1 OLR2...
- Page 18 TYPICAL SCHEMATIC WIRING DIAGRAM (Dual compressor units) CRANKCASE HEATER CONNECTION (AS APPLICABLE) SCROLL COMP. C.HTR1 COMP. 1: C.HTR2 COMP. 2: BLOWER MOTOR POWER CONNECTION UVM CONNECTION (OPTIONAL) RECIP. COMP.(Semi-Hermetic) TO HVTB CC1A-1B C.HTR1 100A HVTB1 COMP. 1: C.HTR2 CC2A-1B 101A COMP.
- Page 19 RESULT IN COMPRESSOR DAMAGE. 4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH RATING AS RECOMMENDED BY ZAMIL. 5. PLEASE ALLOW 2-3 MINUTES FOR SSPS SWITCH TO CLOSE, BEFORE STARTING THE UNIT. 6. USE DISCONNECT TAB...
- Page 20 ECONOMIZER CONNECTION MTR3 ECONOMIZER BOARD LED1 LED2 POT1 POT2 POT3 POT4 LED3 LED4 COUNTER MTR2 0-10V ECON BRD MTR1 LEGEND SUPPLY AIR THERMISTOR AIR QUALITY SENSOR OUTDOOR AIR THERMOSTAT FREE COOLING COUNTER OUTDOOR AIR DAMPER MOTOR RETURN AIR DAMPER MOTOR SUPPLY AIR TEMPERATURE SENSOR DAMPER MOTOR ENTHALPY CONTROLLER...
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Page 21: Installation Instructions
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions and other Zamil publications for the specific equipment being installed. LOCATION OF UNIT When selecting the location for the unit, the following points should be kept in mind: 1. -
Page 22: Check-Out & Operational Start-Up Procedure
6. Compressor crankcase heater should be energized for 24 hours (special attention should be taken to disable com- pressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for few minutes to pumpdown the system, even the thermostat is OFF). 7. -
Page 23: Belt Tension Testing Procedure
All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in order to provide some allowance for oil which will be circulating in the system during operation. Depending on the system design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may be necessary either to add or remove oil from a system any time it is first placed in operation with a different compressor. -
Page 24: Belt Tension Testing Procedure
BELT TENSION TESTING PROCEDURE BELT SPAN DEFLECTION = FORCE SCALE SMALL "0" RING BELT SPAN SPAN SCALE LARGE "0" RING BELT TENSION CHECKER MEASURE THE BELT DEFLECTION FORCE BELTS BELT TYPE BELT SMALL DEFLECTION FORCE - LBS. CROSS PULLEY PITCH DIA. (P.D.) SECTION RANGE MINIMUM... -
Page 25: Electrical Power Supply
ELECTRICAL ELECTRIC POWER SUPPLY All wiring should be in accordance with National Electric Code and local standards. Before making an installation, check the electric power supply. The power supply must be of the same characteristics as that on the nameplate. Normally the wire size used establishes the circuits maximum permissible load. -
Page 26: Motor Contactor
MOTOR CONTACTOR The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compres- sor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, motor contactors are subjected to quick cycling due to various causes. -
Page 27: Voltage Monitor
OIL PUMP CRANKCASE NET OIL OUTLET PRESSURE PRESSURE PRESSURE New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type me- chanical expansion rod-resistance heater type oil protection controls. FEATURES: • An entirely new control concept. This unique design incorporates a modern pressure transducer to monitor oil pressure. •... - Page 28 CONTROLS & SEQUENCE OF OPERATION Scroll compressors are designed to operate in single direction only. Hence, care has to be taken to ensure correct rotation when the system is operated. Verification of correct rotation is by observing that the suction pressure drops and discharge pressure rises when compressor run.
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Page 29: Refrigeration
REFRIGERATION COMPRESSOR Single scroll compressor for models PDS036 to PDS075 and dual scroll compressors for model PDS090 to PDS600 are used as standard. Optional single semi-hermetic compressor for models PDS036 to PDS150 (single circuit). All other models are dual semi-hermetic compressors (dual circuit). The compressors are equipped with internal motor protection and also provided with vibration isolators. -
Page 30: High & Low Pressure Switch
If the first acidity test shows that the acid content is below the safe level, as indicated in the test kit instructions, and the oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the system provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. -
Page 31: Pump Down Control
PUMP DOWN CONTROL A pump down control is a solenoid type valve installed in the liquid line to prevent the flow of refrigerant into the evapo- rator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liquid line, but ahead of metering device. -
Page 32: Trouble Shooting Chart
TROUBLE SHOOTING CHART SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE Compressor will not start – no 1. Close start or disconnect switch. 1. Line disconnect switch open. hum. 2. Replace fuse. 2. Fuse removed or blown. 3. Refer to electrical section. 3. - Page 33 TROUBLE SHOOTING CHART SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE Units runs OK, but short 1. Overload protector. 1. Check the cause. cycles on. 2. Thermostat. 2. Differential set too close - widen. 3. High pressure cut-out due to: 3. (a) Check airflow to the condenser correct.
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Page 34: Trouble Shooting Chart
TROUBLE SHOOTING CHART SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE High suction pressure. 1. High load on evaporator. Load in ex- 1. Check the design. cess of design conditions. 2. Follow manufacturer's guide line and 2. Unbalanced system. Oversized air han- correct it. -
Page 35: Parts List
PARTS LIST (SINGLE CIRCUIT) MODEL NUMBER PDS036H PDS036M PDS036F PDS048H PDS048M PDS048F PDS060H PDS060M PDS060F COMPRESSOR (SCROLL) 800-674-26 N.A. 800-674-28 800-674-20 800-674-21 800-674-22 800-674-13 800-674-14 800-674-15 CONTACTOR (SCROLL) 800-098-55 N.A. 800-098-55 800-098-57 800-098-55 800-098-55 800-098-59 800-098-55 800-098-55 COMPRESSOR (SEMI-HERMATIC RECIP.) 800-688-03 800-688-03 800-688-02 800-688-05 800-688-05 800-688-06 800-688-07 800-688-07 800-688-08 COMPRESSOR (SEMI-HERM. - Page 36 PARTS LIST (SINGLE CIRCUIT) MODEL NUMBER PDS120H PDS120M PDS120F PDS150H PDS150M PDS150F COMPRESSOR (SCROLL) N.A. N.A. N.A. N.A. N.A. N.A. CONTACTOR (SCROLL) N.A. N.A. N.A. N.A. N.A. N.A. COMPRESSOR (SEMI-HERMATIC RECIP.) 800-690-01 800-690-02 800-690-03 800-677-04 800-677-05 800-677-06 COMPRESSOR (SEMI-HERM. W/-UNLOADER) 800-690-01 800-690-02 800-690-03...
- Page 37 PARTS LIST (DUAL CIRCUIT) MODEL NUMBER PDS150H PDS150M PDS150F PDS180H PDS180M PDS180F PDS220H PDS220M PDS220F COMPRESSOR (SCROLL) 800-674-23 800-674-24 800-674-25 800-674-79 800-674-80 800-674-81 800-674-01 800-674-02 800-674-03 CONTACTOR (SCROLL) 800-098-59 800-098-55 800-098-55 800-098-63 800-098-57 800-098-57 800-098-61 800-098-57 800-098-57 COMPRESSOR (SEMI-HERMATIC RECIP.) N.A.
- Page 38 PARTS LIST (DUAL CIRCUIT) MODEL NUMBER PDS420H PDS420M PDS420F PDS480H PDS480M PDS480F PDS540H PDS540M PDS540F COMPRESSOR (SCROLL) 800-674-82 800-674-83 800-674-84 800-674-82 & 70 800-674-83 & 71 800-674-84 & 72 800-674-85 & 82 800-674-86 & 83 800-674-87 & 84 800-093-41 800-097-54 CONTACTOR (SCROLL) 800-093-41 800-098-65 800-098-63 800-098-65 &...
- Page 39 PARTS LIST (DUAL CIRCUIT) MODEL NUMBER PDS780H PDS780M PDS780F PDS840H PDS840M PDS840F COMPRESSOR (SEMI-HERMATIC RECIP.) 800-690-28&25 800-690-29&26 800-690-30&27 800-690-28 800-690-29 800-690-30 COMPRESSOR (SEMI-HERM. W/-UNLOADER) 800-690-28&25 800-690-29&26 800-690-30&27 800-690-28 800-690-29 800-690-30 800-097-54/098-65 CONTACTOR (SEMI-HERMATIC RECIP.) 800-098-68&67 800-097-54/098-65 800-098-65/61 800-098-68 800-098-65/61 & 65/59 &...
- Page 40 PARTS LIST: BLOWER MOTOR GROUP HP (TEFC) VOLTAGE (V-Ph-Hz) MOTOR (RPM) CONTACTOR OVER LOAD RELAY 208/230-3-60 800-879-43(3600) 800-098-50 800-098-85 460-3-60 800-879-43(3600) 800-098-50 800-098-84 380-3-60 800-879-63(3600) 800-098-50 800-098-84 208/230-3-60 800-879-19(1800) 800-098-50 800-098-85 460-3-60 800-879-19(1800) 800-098-50 800-098-84 380-3-60 800-879-55(1800) 800-098-50 800-098-84 208/230-3-60 800-882-43(3600) 800-098-50 800-098-87...
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Page 41: Parts List
PARTS LIST: HEATER GROUP KILOWATTS VOLTAGE (V-Ph-Hz) CONTACTOR HEATER 208/230-3-60 800-098-51/800-098-50* 80032030 460-3-60 800-098-51/800-098-50* 80032042 380-3-60 800-098-51/800-098-50* 80032036 208/230-3-60 800-098-51/800-098-50* 80032031 460-3-60 800-098-51/800-098-50* 80032043 380-3-60 800-098-51/800-098-50* 80032037 208/230-3-60 800-098-51 80032003 460-3-60 800-098-51 80032023 380-3-60 800-098-51 80032013 208/230-3-60 800-098-51 80032004 460-3-60 800-098-51 80032024 380-3-60... -
Page 42: Recommended Spare Parts
RECOMMENDED SPARE PARTS PERCENTAGE OF SPARE PARTS ITEM ONE YEAR SUPPLY TWO YEAR SUPPLY 100 UNITS 1000 UNITS 100 UNITS 1000 UNITS Compressor Capacitor Condenser fan motor Evaporator blower motor Belt Contactor compressor Contactor heater Contactor fan motors HPS/LPS/other controls Expansion valve Filter drier Electric heater... -
Page 43: Preventive Maintenance Schedule
PREVENTIVE MAINTENANCE SCHEDULE FREQUENCY OF MAINTENANCE, MONTHS I T E M Clean air filters & replace if required. Clean evaporator coil, drain pan & drain line. Clean condenser coil. Check blower belt/tension/wear/crack and replace it, if required. Lubricate blower motor/condenser motor. Check alignment of pulleys.
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