Zamil PV036, PV060 Installation, Operation & Maintenance Manual

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Page 1

INSTALLATION,

OPERATION

MAINTENANCE

MANUAL

VERTICAL PACKAGED UNITS

'PV' SERIES

MODELS: PV036 - PV060

Page 2

INDEX

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

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

Page 3

ACCESS

DIS-

AIR)

CHARGE

(SUPPLY

R :RH

F: FRONT

L :LH

OPTIONS

APPLICATIONS

UNIT

ACCESSORIES

FILTER

COIL

CONDENSER

COIL

EVAPORATOR

COND.

MOTOR

N : STD.

APPLICATION

TION

N : STANDARD

C :COMMUNICA-

N : STD. UNIT

PLEATED

FILTER

N :NO

A :ALUMINUM

FIN

B : COATED

A :ALUMINUM

FIN

B : COATED

N :STD.

SHELTER

APPLICATION

FILTER

ALUMINUM

FIN

C :COPPER

ALUMINUM

FIN

C :COPPER FIN

FIN

HEATER

MODEL DECODING

DRIVE

BLOWER

COMPRESSOR

OPTIONS

MOTOR

TYPE

N :NO

HEATER

N :DIRECT

DRIVE

MOTOR

V : STD.

HERMETIC

S : SCROLL

CATING

HERMETIC

R :RECIPRO-

RATION

CIRCUIT

REFRIGE-

S : SINGLE

SUPPLY

( V-Ph-Hz )

ELECTRICAL

3, 4 & 5

NOMINAL

COOLING

CAPACITY

1& 2

BASIC

(MBH)

(4 WIRE)

H :208/230-3-60

M: 380-3-60

036

048

060

UNIT

VERTICAL

PACKAGED

Not available for PV036.

NOTE:

Page 4

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 damage 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.

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" 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.

Page 5

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 (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.

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.

Microprocessor Based Electronic Control Board, incorporating the following features:

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 60

POWER SUPPL Y

208/230V-3Ph-60Hz

380V-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.

MODEL No. MCA

CONDUCTOR SIZE

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

AWG - MCM METRIC - MMSQ

Page 6

DIMENSIONS

TOP VIEW

SUPPLY AIR OPENING

RETURN AIR OPENING

PV036 - PV060

MOUNTING FLANGE

FILTER

CONTROL BOX

610 [24]

EVAPORATOR COIL

SUPPLY AIR

RETURN AIR

CONDENSER COIL

DIMENSIONS

BCDE

980 (38.6)

1143 (45)

920 (36.2)

1067 (42)

908 (35.8)

662 (26.1)

457 (18)

762 (30)

END VIEW

762 (30)

767 (30.2)

51 [2]

COND. AIR INLET

G I

203 (8)

251 (9.9)

762 (30)

759 (29.9)

MODEL

NUMBER

PV036

PV048

PV060

FRONT VIEW

2000 (78.7)

2134 (84)

NOTES:

1. All dimensions are in millimeters, (dimensions in brackets are in inches).

2. Service clearance should be 915 mm (3 feet) on all sides (other than the front supply & return air opening side).

350 (13.8)

403 (15.9)

Page 7

ACCESS DETAILS

PV036 - PV060

FILTER & ELE. CON T RO LS (FROM BACK SIDE)

COMPRESSOR ACCESS (FROM SIDE)

LEFT SIDE ACCESS

RIGHT SIDE ACCESS

FILTER & ELE. CONTROLS

(FROM BACK SIDE)

COMPRESSOR ACCESS

(FROM SIDE)

Page 8

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.

1. Check unit location as per installation instructions.

2. Make sure all electrical fasteners/connections are tight and clean.

3. All controls are set according to manufacturer's instructions (low & high pressure switch, fan cycling switch, etc...)

4. Follow all the instructions from the warning tags and stickers.

5. Check if condenser & blower fan are free to turn without wobbling.

6. Remove straps & wooden pieces that holds the compressor in place during transportation.

7. Compressor crankcase heater should be energized for 24 hours prior to system start-up.

8. Circuit breaker/fused disconnect switch.

9. All piping, piping insulation and piping supports are properly installed.

10. Thermostat is the right one and installed properly.

11. Connect the manifold gauge to suction & discharge line access valves. Prepare recommended instruments for checking Voltage, Amps, RPM, CFM, static pressure, etc.

12. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere.

13. Start the compressor & observe the compressor discharge and suction pressures. If not within system design limits, determine why & take corrective action.

Page 9

ELECTRICAL DATA

MODEL No.: PV036

POWER SUPPLY

(V-Ph-Hz)

208/230-3-60 187 253 11.4 77 1.9 3.6 19.7 30

VOLTAGE

RANGE

MIN. MAX. RLA LRA

COMPRESSOR

FAN

MOTOR

FLA

BLOWER

MOTOR

FLA

MCA MOCP

MODEL No.: PV048

POWER SUPPLY

(V-Ph-Hz)

208/230-3-60 187 253 16.4 91 2.1 4.6 27.2 40

380-3-60

(4 WIRE)

VOLTAGE

RANGE

MIN. MAX. RLA LRA

342 418 9.3 54 2.1 4.6 18.3 25

COMPRESSOR

FAN

MOTOR

FLA

BLOWER

MOTOR

FLA

MCA MOCP

MODEL No.: PV060

POWER SUPPLY

(V-Ph-Hz)

208/230-3-60 187 253 20.7 139 2.1 4.6 32.6 50

380-3-60 (4 WIRE)

VOLTAGE

RANGE

MIN. MAX. RLA LRA

342 418 10.7 64 2.1 4.6 20 30

COMPRESSOR

FAN

MOTOR

FLA

BLOWER

MOTOR

FLA

MCA MOCP

LEGEND:

FLA – Full Load Amps

RLA – Rated Load Amps

LRA – Locked Rotor Amps

MOCP – Maximum Over Current Protection

MCA – Minimum Circuit Amps

* Single phase motors

Page 10

MAINTENANCE INSTRUCTIONS

CRANKCASE HEATER

The function of crankcase heater is to hold the compressor oil reservoir at higher temperature than the coldest part in the system.

• Power must be supplied to crankcase heater for a minimum of 12-hours prior to system start-up. If power is off for 6-hours or more,

crankcase heater must be energized for 12-hours before operating the system. Otherwise compressor damage may result.

• Periodic checking for proper operation or crankcase heater is highly recommended as follows:

a) Check continuity of the heater using multimeter device.

b) Check grounding of the heater by Megger device (to prevent electrical hazards).

c) Observe whether the heater is warming down the compressor near the oil sump.

CLEANING OF COILS & FILTERS

• Turn off the power supply.

• Take out access panel of evaporator coil.

• Remove the filter by sliding out.

• Protect electrical components and motors from water washing.

• Clean the coil by flushing water by pressure washer followed by compressed air from supply to return direction.

• Filter shall be cleaned every month, in some hygienic application it is recommended for replacement.

• Cleaning drain pan and trap is recommended once in three months to prevent bacteria growing under the coil.

Page 11

PREVENTIVE MAINTENANCE SCHEDULE

CAUTION: Disconnect power supply and allow all rotating parts to stop before servicing the unit.

I T E M

Clean air filters & replace if required.

Clean evaporator coil, drain pan & drain line.

Clean condenser coil.

Lubricate blower motor/condenser motor.

Check/clean electrical connections, controls & control box.

Check motors, fans and blower bearings & lubricate it.

Check all electrical control components, wiring terminals etc. for spark, overheating & loose connections. Replace/correct as necessary.

Check insulation flanking. Repair/replace as required.

Check loose bolts/screws & tight as necessary.

Check for rusted/dented/damaged body parts & repair/repaint as necessary.

Check mountings/rubber pads. Repair/replace as necessary.

FREQUENCY OF MAINTENANCE, MONTHS

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 operation, calibrate/re- adjust as required.

Apply corrosion inhibitor/contact cleaner as required.

Check all pressures/temperatures as applicable and satisfy the operation & performance.

NOTE: Always observe for abnormal noise or vibration.

MAINTENANCE TOOLS/EQUIPMENT REQUIRED

STANDARD : Screw drivers (Slot & Phillips), adjustable wrenches, pliers, refrigeration wrenches & socket set wrenches, pulley

puller, etc.

SPECIAL : Manifold gauge set, R-22 charging cylinder, belt tension checker, leak detector, vacuum pump with electronic gauges,

thermometer & hook type ammeter/voltmeter/ohmmeter.

Page 12

TROUBLE SHOOTING CHART

SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

Compressor will not start – no hum.

Compressor will not start – hums but trips on overload protector.

1. Line disconnect switch open.

2. Fuse removed or blown.

3. Overload protector tripped.

4. Control stuck in open position.

5. Control off due to cold location.

6. Wiring improper or loose.

7. Thermostat defective or improperly installed.

8. Control circuit open.

9. Burned/open circuit motor winding.

1. Improperly wired.

2. Low voltage to unit.

3. Compressor motor has a winding open or shorted.

4. Internal mechanical trouble in compressor.

5. Liquid refrigerant in compressor.

6. High discharge pressure.

1. Close start or disconnect switch.

2. Replace fuse.

3. Refer to electrical section.

4. Repair or replace control.

5. Relocate control.

6. Check wiring against diagram.

7. Replace or relocate.

Trace control circuit with wiring diagram and repair.

9. Replace the compressor with all precautions.

1. Check wiring against diagram.

2. Determine reason and correct.

3. Replace compressor.

4. Replace compressor.

5. Check crankcase heater.

6. Unequalized pressure in the system.

Compressor starts and runs, but short cycles on overload protector.

Units runs OK, but short cycles on. 1. Check the cause.

Unit operates long or continuously. 1. Shortage of refrigerant.

1. Additional current passing through overload protector.

2. Low voltage to unit (or unbalanced if three phase).

3. Overload protector defective.

4. Excessive discharge pressure.

5. Suction pressure too high.

6. Compressor too hot - return gas hot.

7. Compressor motor has a winding shorted.

1. Overload protector.

2. Thermostat.

3. High pressure cut-out due to: (a) Insufficient air. (b) Overcharge. (c) Air in system.

4. Low pressure cut-out due to: (a) Undercharge. (b) Restriction in expansion device.

2. Control contacts stuck or frozen closed.

3. Refrigerated or air conditioned space has excessive load or poor insulation.

4. System inadequate to handle load.

5. Evaporator coil iced.

6. Restriction in refrigeration system.

7. Dirty condenser.

8. Filter dirty.

1. Check wiring diagram. Check for added fan motors, pumps, etc. connected to wrong side of protector.

2. Determine the reason and correct.

3. Check current, replace protector.

4. Check airflow across the condenser coil, restrictions in refrigeration system.

5. Check for possibility of misapplication. Use stronger unit.

6. Check refrigerant charge (fix leak), add if necessary.

7. Replace compressor.

2. Differential set too close - widen.

3. (a) Check airflow to the condenser - correct. (b) Reduce refrigerant charge. (c) Purge.

4. (a) Fix leak, add refrigerant. (b) Replace device.

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.

Suction line frosted or sweating. 1. Expansion valve passing excess refrigerant or

2. Expansion valve stuck open.

3. Evaporator fan not running.

4. Overcharge of refrigerant.

is oversized.

1. Re-adjust valve or replace with smaller valve.

2. Clean valve of foreign particles, replace if necessary.

3. Determine reason and correct.

4. Correct charge.

Page 13

TROUBLE SHOOTING CHART

SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

Evaporator ices up.

1. Restricted airflow.

2. Dirty air filter.

3. Short of refrigerant.

4. Low air volume.

5. Restricted distributor tube.

6. Restricted liquid line/low liquid line pressure.

1. Check for dirt or lint on coil.

2. Clean or replace. Advice customer on periodic cleaning of filter.

3. Check system pressure. Take superheat reading. Add refrigerant.

4. Check for dirty air filter or loose belt.

5. Check for warm distributor tube.

6. Check for restriction in lines/improve liquid line pressure by proper charging or installing fan cycle switch, etc.

Head pressure too high.

Head pressure too low. 1. Low ambient temperatures (air-cooled).

High suction pressure.

Run capacitor open, shorted or blown.

Space temperature too high. 1. Control setting too high.

1. Refrigerant overcharge.

2. Air in system.

3. Dirty condenser.

4. Malfunction of condenser fan (air-cooled).

5. Excessive air temperature entering condenser.

6. Restriction in discharge line.

2. Refrigerant shortage.

3. Damaged valves in compressor.

1. High load on evaporator. Load in excess of design conditions.

2. Unbalanced system. Oversized air handling unit matched with under sized condensing unit.

3. Compressor discharge valve leaking.

4. Expansion valve widely open.

5. Improper bulb location or installation.

1. Improper capacitor.

2. Excessively high line voltage (110% of rated max.)

2. Expansion valve too small.

3. Cooling coils too small.

4. Inadequate air circulation.

1. Correct the refrigerant charge.

2. Recharge the system after a thorough triple evacuation.

3. Clean.

4. Check and correct or replace.

5. Check for short circuiting of condenser discharge air, correct it.

6. Correct it.

1. Install fan cycling switch, if not provided. Check the setting and operation, if provided.

2. Correct the refrigerant charge after leak testing.

3. Repair/replace the compressor.

1. Check the design.

2. Follow manufacturer's guide line and correct it.

3. Repair/replace compressor.

4. Check and adjust the superheat accordingly.

5. Check the expansion valve bulb is properly tighten at correct location.

1. Determine correct size and replace.

2. Determine reason and correct.

1. Reset control.

2. Use larger valve.

3. Add surface or replace.

4. Improve air movement.

Liquid line frosted or sweating.

Unit noisy.

1. Restriction in dehydrator or strainer.

2. Liquid shut-off valve partially closed.

1. Loose parts or mountings.

2. Tubing rattle.

3. Bent fan blade causing vibration.

4. Fan motor bearings worn.

1. Replace part.

2. Open valve fully.

1. Find and tighten.

2. Tighten the pipe support.

3. Replace blade.

4. Replace motor.

Page 14

TYPICAL SCHEMATIC WIRING DIAGRAM

(For normal air-conditioning applications)

REFER TO UNIT NAMEPLATE FOR POWER SUPPLY

NTB

(SEE NOTE -11)

HVTB

LUG

WIRING DGM SUITS 230V/3PH/60HZ [&]

380V/3PH/60HZ UNIT

NOTE:

1. NTB IS APPLICABLE FOR 380V/3PH/60Hz UNITS

2. FOR UNITS WITH ABOVE VOLTAGE CONNECT 37A OF FM, L2 OF BM & L2 OF TRANS TO NTB

LOW AMBIENT OPTION

SET POINTS

CRANKCASE HEATER CONNECTION

LEGEND

BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CAP CAPACITOR CC COMPRESSOR CONTACTOR CB CIRCUIT BREAKER C. HTR CRANKCASE HEATER COMP COMPRESSOR FM FAN MOTOR (CONDENSER) FCS FAN CYCLING SWITCH HPS HIGH PRESSURE SWITCH HVTB HIGH VOLTAGE TERMINAL BLOCK LPS LOW PRESSURE SWITCH LVTB LOW VOLTAGE TERMINAL BLOCK L1 LINE 1 L2 LINE 2 L3 LINE 3 LUG LUG GROUND NTB NEUTRAL TERMINAL BLOCK SM SYSTEMIZER TRANS TRANSFORMER

_ _ _

FIELD WIRING

DISCONNECT TAB SPLICE-CLOSED END TERMINAL BLOCK OR TERMINATION POINT

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE. THERMOSTAT CONTROL VOLTAGE - 24VAC.

2. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C OR ITS EQUIVALENT. USE COPPER CONDUCTOR WIRES ONLY.

3. POWER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP.

IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE.

4. A 3 TO 4 MINUTE (APPROX.) BUILT-IN SHORT CYCLE PROTECTION FOR COMPRESSOR IS AVAILABLE IN

ZAMIL ELECTRONIC THERMOSTAT.

5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL.

6. COMPRESSOR IS PROVIDED WITH INTERNAL OVERLOAD.

7. USE DISCONNECT TAB OR SPLICE ONLY WHERE EVER REQUIRED FOR EXTENSION OF ORIGINAL WIRE.

8. FOR ANY SAFETY TRIP OF COMP. (FAULT), VOLTAGE ACROSS TERMINAL 1 & X OF ECB (SYSTEMIZER) IS 24VAC. ALSO, COMPRESSOR LOCKOUT LIGHT IS ON.

9. FREE END OF MOTOR LEADS TO BE CAPPED WITH CRIMPABLE WIRE NUT.

10.SM HAS 3 TO 5 MINUTES PROVISION FOR COMPRESSOR ANTI-RECYCLING TIMER.

11.NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER SUPPLY ONLY.

MODEL PV036 PV048 PV060

FACTORY INSTALLED

BM SPEED (WIRE COLOR)

BLK BLU BLK

Page 15

TYPICAL SCHEMATIC WIRING DIAGRAM

(For communication shelter applications)

NTB

POWER SUPPLY

PLS. REFER UNIT NAME PLATE

WIRING DG M SUITS

230V/3PH/60Hz 380V/3PH/60Hz

NOTE:

1. NTB IS APPLIC A BL E FOR 380V/3PH/60Hz UNITS

2. FOR UNITS WITH ABOVE VOLTAGE CONNECT 37A OF FM & L2 OF BM TO NTB

SET POINTS

LEGEND

ATB AUXILIARY TERMINAL BLOCK BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CC COMPRESSOR CONTACTOR CAP CAPACITOR C. HTR CRANKCASE HEATER COMP COMPRESSOR FM FAN MOTOR (CONDENSER) FCS FAN CYCLING SWITCH HPS HIGH PRESSURE SWITCH HVTB HIGH VOLTAGE TERMINAL BLOCK L1 LINE 1 L2 LINE 2 L3 LINE 3 LPS LOW PRESSURE SWITCH LUG LUG GROUND NTB NEUTRAL TERMINAL BLOCK

_ _ _

FIELD WIRING

DISCONNECT TAB SPLICE-CLOSED END TERMINAL BLOCK OR TERMINATION POINT

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE. THERMOSTAT CONTROL VOLTAGE - 24VAC.

2. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C OR ITS EQUIVALENT. USE COPPER CONDUCTOR WIRES ONLY.

3. POWER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP.

IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM.

FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE.

4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY ZAMIL.

5. COMPRESSOR IS PROVIDED WITH INTERNAL OVERLOAD.

6. USE DISCONNECT TAB OR SPLICE ONLY WHERE EVER REQUIRED FOR EXTENSION OF ORIGINAL WIRE.

7. FREE END OF MOTOR LEADS TO BE CAPPED WITH CRIMPABLE WIRE NUT.

8. NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER SUPPLY ONLY.

MODEL PV036 PV048 PV060

FACTORY INSTALLED

BM SPEED (WIRE COLOR)

BLK BLU BLK

* CONTROLLER SETUP IS FOR 2 UNITS.

Page 16

PARTS LIST

MODEL NUMBER PV036H PV048H PV048M PV060H PV060M

COMPRESSOR 800-674-26 800-674-20 800-674-21 800-674-13 800-674-14

CONDENSER FAN MOTOR 800-545-97 800-547-40 800-547-40 800-547-40 800-547-40

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

BLOWER MOTOR 800-547-52 800-555-29 800-555-29 800-555-29 800-555-29 BLOWER (SCROLL+WHEEL) 800-711-52* 800-089-63 800-089-63 800-089-63 800-089-63

CONDENSER FAN (PROPELLER) 800-941-41 800-225-01 800-225-01 800-225-01 800-225-01

CONDENSER FAN CYCLING SWITCH

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

CONTACTOR BLOWER MOTOR 800-736-01 800-736-01 800-736-01 800-736-01 800-736-01

TRANSFORMER (24V.) 800-012-30 800-012-30 800-012-30 800-012-30 800-012-30

EXPANSION VALVE 800-184-01 800-183-01 800-183-01 800-181-00 800-181-00

DISTRIBUTOR 800-198-01 800-198-02 800-198-02 800-198-02 800-198-02

LOW PRESSURE CONTROL 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00

HIGH PRESSURE CONTROL 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00

CONDENSER MOTOR MOUNT N.A. 800-154-15 800-154-15 800-154-15 800-154-15

FILTER DRIER 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08

RETURN AIR PLEATED FILTER 800-240-58 800-240-51 800-240-51 800-240-51 800-240-51

SUPPLY AIR GRILLE 800-622-60 800-622-55 800-622-55 800-622-55 800-622-55

RETURN AIR GRILLE 800-622-87 800-622-83 800-622-83 800-622-83 800-622-83

N.A. 800-557-31 800-557-31 800-557-31 800-557-31

* BLOWER WHEEL ONLY