Zamil PDS Series Installation, Operation & Maintenance Manual

Manual is about: DOUBLE SKIN PACKAGED AIR CONDITIONERS

Summary of PDS Series

  • Page 1

    Double skin packaged air conditioners 'pds' series pl-om-pds-05-1m-e installation, operation & maintenance manual.

  • Page 2: Index

    Contents page model decoding ........................................................................................................................................ 2 dimensions ............................................................................................................................

  • Page 3: Model Decoding

    2 1, 2 & 3 basic 4, 5 & 6 nominal cooling cap acity (mbh) 8 refrigera- tion cir- cuit 7 electrical suppl y ( v -ph-hz ) 10 condenser coil 13 unit configura tion pds classic double skin packaged unit 036 048 060 075 090 100 120 150 180 220 240 300 360 420 480 540 600 660 720 780 840 s :single * d :du...

  • Page 4: Unit Dimensions

    2 66 ( 1 0. 5) 302 ( 11. 9) 2 64 ( 1 0. 4) 2 55 ( 1 0. 0) 28 8 ( 11 .4) unit dimensions 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 weigh...

  • Page 5: Unit Dimensions

    336 ( 13.2) 294 (1 1.6) 372 (1 4.6) 38 9 ( 1 5. 3 ) 30 2 ( 11 .9 ) 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). 2. Service clearance should be 1200mm (4 ...

  • Page 6: Unit Dimensions

    C o nde nser a ir in r/a front view f1 r/a f2 top view r/a f3 f/a condenser air in f1' f2' f3' s/a end view s/a s/a f4 f4' 4 0 8 ( 1 6. 1) 295x1145 (11.6x45.0) 37 8 ( 1 4. 9) 47 6 ( 1 8. 8) 1330 (52.4) 1270 (50.0) 12 05 ( 47. 4) 12 5 ( 4. 9) 4412 (173.7) 30 (1.2) typ 34 6 ( 13. 6) 40 0 ( 15. 7) 465 ...

  • Page 7: Unit Dimensions

    67 7 ( 26 .7 ) 47 6 ( 18 .7 ) 45 0(1 7. 7) 312 (12.3) 476 (18.7) 677 ( 26 .7) 450(17. 7) 312 (12.3) unit dimensions standard & economizer unit model no.: 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. Servi...

  • Page 8: Unit Dimensions

    425x1645 (16.7x64.8) - r.A 634 (25.0 ) 1480 (58.3 ) 150 (5 .9) 395x1145 (15.6.6x45.0) - std. / econ. Front view top view r/a condenser air in f1 r/a r/a f2 f3 f1' condenser air in f2' f/a f3' 562 (22.2) (for economizer system, hood supplied for f4 s/a end view s/a s/a f4' Ø102 (Ø4) power entry 100% ...

  • Page 9: Unit Dimensions

    5 90 ( 23 .3) 1 32 (5.2) 642 (25.3) 745 (29.3) 24 0 ( 9. 5) 458 (18.0) 56 2 ( 22 .2 ) 75 9 ( 29. 9) unit dimensions standard & economizer unit model no.: 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. Servi...

  • Page 10: Unit Dimensions

    71 8 ( 28 .2 ) 746 ( 29 .4 ) 26 0. 6 ( 10. 3) 422 (16.6) 3 68 ( 14. 5) 378 (14.9) 6 40 ( 25. 2) 7 85 ( 30. 9) unit dimensions standard & economizer unit model no.: pds 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...

  • Page 11: Unit Dimensions

    12 8 5.1) 8 06 ( 3 1.7) 7 02 ( 2 7.6) 806 (31.7) 806 (31.7) 8 06 ( 3 1.7) 368 ( 14. 5) 640 ( 25. 2) 640 (25.2) 640 ( 25. 2) 78 5 ( 30. 9) 404 (15.9) 640 (25.2) unit dimensions standard & economizer unit model no.: pds 660/720/840 low cfm/100% fresh air unit model no.: pds 660/720/840 notes: 1. All d...

  • Page 12: Fresh Air Hood  Assembly

    11 fresh air hood assembly 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. Filter 10.Middle slide bracket 6 4 7 3 2 9 10 8 5 1 (optional) vertical damper.

  • Page 13: Rigging Instructions

    12 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. Care must be taken...

  • Page 14: Installation

    S/a s/a e' control box c o nt ro l b o x w2 w1 y2 y1 g c r r y1 g c w2 w1 y2 etb lvtb grounding field wiring earth terminal block electronic control board circuit breaker high voltage terminal block neutral terminal block neutral line n ntb hvtb cb ecb etb legend: unit control panel l3 l2 l1 ntb hvt...

  • Page 15

    Typical schematic wiring diagram (single compressor units) 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. 14 n l1 [uvm] 31a cooling 450 ± 10 290 ± 10 50 ± 5 360 ± 15 pressure switch settings nam...

  • Page 16

    27 (optional) 26 (optional) 47 17 44 52 50 58 (as applicable) (as applicable) (as applicable) cb12 cb11 cc m2/14 m1/11 cb11 t1 g 71 b heater1 heater2 heater1 t3 f t1 f t2 f t3 g t1 g t2 g t2 f t1 f t3 f 73 a 71 a 72 a hc1 hc1 72 a 71 a 73 a 1 or 2 28a 2 240 1 6 kw 6 kw 12 kw note: heater 2 connectio...

  • Page 17

    Typical schematic wiring diagram (dual compressor units) 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. 16 see cond.Fm and wire neutral switch or cb (see note-4) l3 to fused disconnect l1 l2 cc1...

  • Page 18

    Typical schematic wiring diagram (dual compressor units) 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. 17 ar1 50 49 48 bmc-1a bmc-1b bm off bm trip bm on 51 olr-2 unit on unit off ar1-1a 52 45 ...

  • Page 19

    Typical schematic wiring diagram (dual compressor units) notes 1. Power supply, refer to unit nameplate. 2. Any wire replacement should be of the 90 0 c 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....

  • Page 20: Economizer Connection

    Sat ec oat 8 1 2 aqs mtr1 ra d mtr2 mtr3 led3 pot2 pot1 led2 led1 pot4 pot3 economizer board counter led4 fc c 24v com fs 04 0 oa d st s od s aq s econ brd 0-10v j1 economizer connection legend sat supply air thermistor aqs air quality sensor oat outdoor air thermostat fcc free cooling counter oad o...

  • Page 21: Installation Instructions

    General the complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immedi- ately to the delivery man or driver. Any damage visible at the time of delivery should be noted on the shipment invoice. These units are shipped completely assembled and wired. ...

  • Page 22

    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. Thoro...

  • Page 23

    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 compresso...

  • Page 24

    23 belt tension testing procedure belt tension checker measure the belt deflection force belt type – a b belt cross section 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 ...

  • Page 25: Electrical

    24 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 circ...

  • Page 26

    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 d...

  • Page 27

    26 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 t...

  • Page 28

    27 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. Reverse rotat...

  • Page 29: Refrigeration

    28 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 (du...

  • Page 30

    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 ...

  • Page 31

    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 meterin...

  • Page 32: Trouble Shooting Chart

    31 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. 8. Trace control circuit with wiring dia- gram and repair. 9. Replace the compressor with all pre- caut...

  • Page 33: Trouble Shooting Chart

    Trouble shooting chart symptom causes check & corrective measure units runs ok, but short cycles on. 1. Check the cause. 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 devic...

  • Page 34: Trouble Shooting Chart

    33 trouble shooting chart symptom causes check & corrective measure 1. High load on evaporator. Load in ex- cess of design conditions. 2. Unbalanced system. Oversized air han- dling unit matched with under sized condensing unit. 3. Compressor discharge valve leaking. 4. Expansion valve widely open. ...

  • Page 35: Parts List (Single Circuit)

    Parts list (single circuit) model number compressor (scroll) contactor (scroll) compressor (semi-hermatic recip.) compressor (semi-herm. W/-unloader) contactor (semi-hermatic recip.) cond. Fan ass’y (fan, motor with grille) contactor filter dryer sight glass expansion valve distributor blower wheel ...

  • Page 36: Parts List (Single Circuit)

    Parts list (single circuit) 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 bl...

  • Page 37: Parts List (Dual Circuit)

    Parts list (dual circuit) 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 blow...

  • Page 38: Parts List (Dual Circuit)

    Parts list (dual circuit) 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 blow...

  • Page 39: Parts List (Dual Circuit)

    Parts list (dual circuit) model number 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 whe...

  • Page 40

    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 1 380-3-60 800-879-63(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) 800-09...

  • Page 41: Parts List: Heater Group

    Parts list: heater group kilowatts voltage (v-ph-hz) contactor heater 208/230-3-60 800-098-51/800-098-50* 80032030 5 460-3-60 800-098-51/800-098-50* 80032042 380-3-60 800-098-51/800-098-50* 80032036 208/230-3-60 800-098-51/800-098-50* 80032031 6 460-3-60 800-098-51/800-098-50* 80032043 380-3-60 800-...

  • Page 42: Recommended Spare Parts

    Percentage of spare parts one year supply two year supply 100 units 1000 units 100 units 1000 units compressor 2% 1% 3% 2% capacitor 3 2 5 4 condenser fan motor 2 1 3 2 evaporator blower motor 1 0.5 2 1 belt 2 1 4 3 contactor compressor 2 1 3 2 contactor heater 2 1 3 2 contactor fan motors 2 1 3 2 h...

  • Page 43

    1 x x x x x x x 3 x x x x x x x 6 x x 12 x x x x 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. Lu...