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Summary of Contents for Zamil PS036
- Page 1 INSTALLATION, OPERATION & MAINTENANCE MANUAL SINGLE PACKAGED ROOF TOP AIR CONDITIONERS 'PS' SERIES MODELS: PS036 - PS360 Part Number: 800-213-04...
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Page 2: Table Of Contents
INDEX Contents Page General Model decoding ..............................2 General statement ..............................3 Warranty ................................. 3 Safety issues ................................3 Inspection for damage ............................3 Installation instructions General ................................... 4 Location of unit ............................... 4 Service clearance ..............................5 Rigging instructions ..............................5 Condensate drain connection .......................... -
Page 4: General Statement
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. -
Page 5: Installation Instructions
INSTALLATION INSTRUCTIONS 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"... -
Page 6: Service Clearance
SERVICE CLEARANCE MODELS: PS036 - PS120 MODELS: PS180 - PS360 NOTE: Only two condenser fans for models PS180 - PS240. NOTE: All dimensions are in cm. MODEL DIMENSIONS MODEL DIMENSIONS NUMBER NUMBER PS036 PS180 PS048 PS215 PS240 PS060 PS075 PS300... -
Page 7: Condensate Drain Connection
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. • Wiring connection to the unit must have suitable insulation of a minimum temperature of 90 UNIT WEIGHT & WEIGHT DISTRIBUTION WEIGHT (Kg.) MODEL NUMBER PS036 PS048 PS060 PS075 PS090 PS100 PS120 PS180... -
Page 8: Unit Dimensions
[BOTH ENDS] 51 [2.00] 15 [0.59] SIDE VIEW FRONT VIEW SIDE VIEW DIMENSIONS MODEL PS036 - PS060 1460(57.48) 1025(40.35) 1430(56.3) 700(27.56) 163(6.42) 373(14.68) 250(9.84) 500(19.69) 57(2.24) 304(11.96) 343(13.49) 340(13.39) 1775(69.88) 1150(45.28) 1745(68.7) 800(31.5) 175(6.89) 480(18.9) 325(12.8) 672(26.46) 80(3.15) 280(11.02) 275(10.83) 600(23.62) - Page 9 UNIT DIMENSIONS PS090 - PS120 TOP VIEW SIDE VIEW FRONT VIEW SIDE VIEW NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides.
- Page 10 UNIT DIMENSIONS PS180 TOP VIEW SIDE VIEW FRONT VIEW SIDE VIEW NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides.
- Page 11 UNIT DIMENSIONS PS215 - PS240 TOP VIEW SIDE VIEW SIDE VIEW FRONT VIEW NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides.
- Page 12 UNIT DIMENSIONS PS300 - PS360 TOP VIEW FRONT VIEW SIDE VIEW SIDE VIEW NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides.
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Page 13: Operation Instructions
OPERATION INSTRUCTIONS START-UP, INSPECTION & CHECK LIST After the installation is completed in all respect, the following points should be covered before the system is switched on for operation. Check unit location as per installation instructions. Make sure all electrical fasteners/connections are tight and clean. All controls are set according to manufacturer's instructions (low &... -
Page 14: Electrical Data
ELECTRICAL DATA MODELS: PS036 & PS048 MODEL NUMBER DESCRIPTION PS036 PS048 COMPR- COMPR- VOLTAGE ELECTRIC ELECTRIC ESSOR ESSOR POWER RANGE HEATER HEATER (each) MOCP MOCP (each) (each) SUPPLY (V-Ph-Hz) Min. Max. RLA LRA HP FLA Nom. kW RLA LRA HP FLA Nom. kW –... - Page 15 ELECTRICAL DATA MODELS: PS090 & PS100 MODEL NUMBER DESCRIPTION PS090 PS100 COMPR- COMPR- VOLTAGE ELECTRIC ELECTRIC ESSOR ESSOR POWER RANGE HEATER HEATER (each) MOCP MOCP (each) (each) SUPPLY (V-Ph-Hz) Min. Max. RLA LRA HP FLA Nom. kW RLA LRA HP FLA Nom. kW –...
- Page 16 ELECTRICAL DATA MODELS: PS120 & PS180 MODEL NUMBER DESCRIPTION PS120 PS180 COMPR- COMPR- VOLTAGE ELECTRIC ELECTRIC ESSOR ESSOR POWER RANGE HEATER HEATER (each) MOCP MOCP (each) (each) SUPPLY (V-Ph-Hz) Min. Max. RLA LRA HP FLA Nom. kW RLA LRA HP FLA Nom. kW –...
- Page 17 ELECTRICAL DATA MODELS: PS215 & PS240 MODEL NUMBER DESCRIPTION PS215 PS240 COMPR- COMPR- VOLTAGE ELECTRIC ELECTRIC ESSOR ESSOR POWER RANGE HEATER HEATER (each) MOCP MOCP (each) (each) SUPPLY (V-Ph-Hz) Min. Max. RLA LRA HP FLA Nom. kW RLA LRA HP FLA Nom. kW –...
- Page 18 ELECTRICAL DATA MODELS: PS300 & PS360 MODEL NUMBER DESCRIPTION PS300 PS360 COMPR- COMPR- VOLTAGE ELECTRIC ELECTRIC ESSOR ESSOR POWER RANGE HEATER HEATER (each) MOCP MOCP (each) (each) SUPPLY (V-Ph-Hz) Min. Max. RLA LRA HP FLA Nom. kW RLA LRA HP FLA Nom. kW –...
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Page 19: Performex Controller, Operation & Functions
Performex-1 CONTROLLER : OPERATION & FUNCTIONS The Zamil Packaged units are provided with technologically advanced new Performex Controller Microprocessor Based Electronic Control Board, incorporating the following benefits and features: - COMPLETE UNIT CONTROL: Provides complete unit control for heating and cooling application whether single stage or two stage utilizing the input from sensor that measure temperatures during unit operation. -
Page 20: Crankcase Heater
7. LEAD/LAG OPERATION: Whenever a compressor needs to be on, the controller will turn on the compressor with the shorter accumulated run time provided its 3 minutes minimum off time has lapsed. Otherwise the other compressor will on first. Similarly, the compressor with the longer accumulated run time will be the first one to be cut off. This is to load the compressors evenly over long run period. -
Page 21: Maintenance Instructions
MAINTENANCE INSTRUCTIONS AIRFLOW ADJUSTMENT (Applicable for PS075 - PS360 only) The airflow could be adjusted by adjusting pulleys of blower motor or belt tension with proper mounting and alignment of the pulleys: • Refer to fan performance tables in the catalog for selecting applicable airflow, RPM and brake horse power at specified static pressure. -
Page 22: Belt Tension Testing Procedure
BELT TENSION TESTING PROCEDURE BELT SPAN D EFLEC TI O N = FO R C E SC ALE SM ALL " 0" R I N G BELT SPAN SPAN SC ALE LAR G E " 0" R I N G BELT TENSION CHECKER MEASURE THE BELT DEFLECTION FORCE BELTS... -
Page 23: Preventive Maintenance Schedule
PREVENTIVE MAINTENANCE SCHEDULE CAUTION: Disconnect power supply and allow all rotating parts to stop before servicing the unit. FREQUENCY OF MAINTENANCE, MONTHS (FIRST 4 YEARS) I T E M Clean air filter (Aluminum)* Pressure wash condenser & cooling coil as required Check blower belt, tension, wear tear/replace if required Check alignment of pulleys Clean drain pan, drain pipe... -
Page 24: Trouble Shooting Chart
TROUBLE SHOOTING CHART SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE Thermostat shows no display 1. Power off/Blown fuse 1. Check the power. Switch ON the circuit breaker. Replace fuse if it blown. 2. Faulty field wiring 2. Check wiring against diagram. 3. - Page 25 TROUBLE SHOOTING CHART SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE 1. Low suction pressure 1. Verify the reason & correct it (refer to symptom Unit works continuously, no sufficient for "low suction pressure"). cooling 2. High discharge pressure 2. Verify the reason and adjust the freon, if required.(refer to symptom for "high discharge pressure").
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Page 26: Typical Schematic Wiring Diagram
TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS036 - PS075 (Single compressor units) (POWER SUPPLY: 208/230V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram. - Page 27 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS036 - PS075 (Single compressor units) (POWER SUPPLY: 208/230V - 3Ph - 60Hz) LEGEND AUXILIARY RELAY AIRFLOW SWITCH AUXILIARY TERMINAL BLOCK BLOWER MOTOR BLOWER MOTOR CONTACTOR COMPRESSOR CONTACTOR AUXILIARY CONTACT CIRCUIT BREAKER C. HTR CRANKCASE HEATER...
- Page 28 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS036 - PS075 (Single compressor units) (POWER SUPPLY: 380V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 29 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS036 - PS075 (Single compressor units) (POWER SUPPLY: 380V - 3Ph - 60Hz) LEGEND AUXILIARY RELAY AIRFLOW SWITCH AUXILIARY TERMINAL BLOCK BLOWER MOTOR BLOWER MOTOR CONTACTOR COMPRESSOR CONTACTOR AUXILIARY CONTACT CIRCUIT BREAKER C. HTR CRANKCASE HEATER...
- Page 30 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS036 - PS075 (Single compressor units) (POWER SUPPLY: 460V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 31 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS036 - PS075 (Single compressor units) (POWER SUPPLY: 460V - 3Ph - 60Hz) LEGEND AUXILIARY RELAY AIRFLOW SWITCH AUXILIARY TERMINAL BLOCK BLOWER MOTOR BLOWER MOTOR CONTACTOR COMPRESSOR CONTACTOR AUXILIARY CONTACT CIRCUIT BREAKER C. HTR CRANKCASE HEATER...
- Page 32 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS090 - PS120 (Dual compressor units) (POWER SUPPLY: 208/230V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 33 SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF ANY CHANGE IN DIP SWITCH SETTING IS REQUIRED,...
- Page 34 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS090 - PS120 (Dual compressor units) (POWER SUPPLY: 380V - 3Ph - 60Hz) TO HVTB TO NTB NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 35 SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF ANY CHANGE IN DIP SWITCH SETTING IS REQUIRED,...
- Page 36 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS090 - PS120 (Dual compressor units) (POWER SUPPLY: 460V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 37 SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF ANY CHANGE IN DIP SWITCH SETTING IS REQUIRED,...
- Page 38 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS180 - PS240 (Dual compressor units) (POWER SUPPLY: 208/230V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 39 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE- SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF COMPRESSOR IS SUPPLIED WITH SSPS, CONNECT AS SHOWN.
- Page 40 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS180 - PS240 (Dual compressor units) (POWER SUPPLY: 380V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 41 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE- SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF COMPRESSOR IS SUPPLIED WITH SSPS, CONNECT AS SHOWN.
- Page 42 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS180 - PS240 (Dual compressor units) (POWER SUPPLY: 460V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 43 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE- SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF COMPRESSOR IS SUPPLIED WITH SSPS, CONNECT AS SHOWN.
- Page 44 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS300 - PS360 (Dual compressor units) (POWER SUPPLY: 208/230V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 45 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE- SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF COMPRESSOR IS SUPPLIED WITH SSPS, CONNECT AS SHOWN.
- Page 46 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS300 - PS360 (Dual compressor units) (POWER SUPPLY: 380V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 47 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE- SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF COMPRESSOR IS SUPPLIED WITH SSPS, CONNECT AS SHOWN.
- Page 48 TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PS300 - PS360 (Dual compressor units) (POWER SUPPLY: 460V - 3Ph - 60Hz) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram.
- Page 49 FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE- SULT IN COMPRESSOR DAMAGE. 5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL. 6. COMPRESSORS ARE PROVIDED WITH INTERNAL OVER- LOAD. 7. IF COMPRESSOR IS SUPPLIED WITH SSPS, CONNECT AS SHOWN.
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Page 50: Parts List
RETURN AIR FILTERS Aluminum filter (1” Thick) : 80025410 (2 Each) for PS036 - PS060, 80025411 (2 Each) for PS075 & 80025412 (2 Each) for PS090 - PS100. Aluminum filter (2” Thick) : 80025416 (2 Each) for PS036 - PS060, 80025417 (2 Each) for PS075 & 80025418 (2 Each) for PS090 - PS100. - Page 51 PARTS LIST MODEL NUMBER PS120H PS120M PS120F PS180H PS180M PS180F PS215H PS215M PS215F COMPRESSOR 80067251 80067252 80067252 80067476/7980067477/8080067478/8180067465 80067466 80067467 FAN MOTOR 80054568 80054568 80054568 80054568 80054568 80054568 80054568 80054568 80054568 BLOWER MOTOR (STANDARD) 80054417 80054417 80054417 80054472 80054464 80054472 80054472 80054464 80054472 BLOWER WHEEL 80070702 80070702 80070702 80070702 80070702 80070702 80070723 80070723 80070723 COND.
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