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Company Business Zamil Air Conditioners (ZAC), a sector business of Zamil Industrial, is the largest supplier of air conditioners in the Middle East. It manufactures and markets a whole range of air conditioners from room air conditioners to packaged units to large capacity chillers for residential, commercial and industrial applications. Zamil Air Conditioners was founded in 1974 as one of the first air conditioning companies to be established in Saudi Arabia and today is a leading international manufacturer of air conditioning systems & service solutions and is Number One in the Middle East. ZAC’s operations are structured into four companies supporting seven in-house brands and twelve products and service units as well as a number of international brands under the OEM Sales. The seven in-house brands are Zamil Air Conditioners, Classic, Zamil, Cooline, CoolCare, Climatech and Geoclima. The four companies are: 1. Zamil Air Conditioners & Home Appliances Co. (L.L.C.), supporting Zamil, Classic, Cooline, GE and OEM brands for consumers. 2. Zamil Central Air Conditioners Co. (L.L.C.), supporting Zamil Air Conditioners, Cooline and Climatech for commercial and industrial customers. 3. Zamil Air Conditioning and Refrigeration Services Co. (L.L.C.), providing electromechanical engineering, construction and project management services, HVAC Operation & Maintenance, Retrofit Services, Spare Parts, Fire Protection, Controls, Electrical Services, Coils, Ducting and Coating. 4. Geoclima srl is an independent business supporting other three companies for their requirements of Chillers and Double Skin AHU’s. The first three Companies- direct their business operations from the First and Second Industrial Cities in Dammam, Saudi Arabia and have a product design center in Austria. GEOCLIMA has its engineering and production departments located at Monfalcone, Italy. All the four companies, while operating independently, supplement each other’s activities in a way that makes synergy work at its best and achieves ZAC’s goals of maximizing customer value and satisfaction.
OEM Sales - Private Labeling Zamil Air Conditioners produces branded air conditioners under OEM agreements for several leading international brands. Such relationships are testimony to the excellence of ZAC’s engineering and production processes. Most of the units produced under the private labeling agreements are for window and mini-split systems. However, ZAC is expanding its OEM offerings to include residential and light commercial units. Some of the OEM brands manufactured at Zamil Air Conditioners are: Supra, Sanyo and Blue Star.
Joint Venture Middle East Air Conditioners - Joint Venture with General Electric. Zamil Air Conditioners partners with GE Appliances - Europe since 1997, in a joint venture called Middle East Air Conditioners (MEAC), for manufacturing and marketing of GE branded air conditioners. MEAC was awarded the license to manufacture Window, Mini Splits and Ducted Split types under the brand names GE, Hotpoint and RCA. Today, MEAC enjoys extensive coverage in Saudi Arabia, GCC and the African market. In an ever-changing market, MEAC continually strives to acquire new technologies and stylish integrated design with optimum performance and reliability that bring greater value to customers.
Factories and Production Zamil Air Conditioners has two prime manufacturing plants in Dammam, Saudi Arabia and a production facility in Italy operated by GEOCLIMA and a product design center in Austria. ZAC can produce up to 900,000 room air conditioners, 300,000 mini-split systems and 65,000 central airconditioning systems per annum and supplies air conditioning products to over 55 countries across the world - the major markets being GCC, Middle East, North Africa, Europe and Asia.
Quality & Product Certificates The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification. ZAC’s products are certified with: 1. CE (Council of European Community). 2. UL (Underwriters Laboratory). 3. Eurovent (Certified Performance). 4. ISO 9001-2008 (International Organization for Standardization). 5. AHRI (Air-Conditioning, Heating and Refrigeration Institute). Other awards include the prestigious Engineering Excellence Award of General Electric and the inaugural Prince Mohammed bin Fahd Al Saud Award for Factory Safety.
Our Products & Service Units In addition to consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Conditioners manufactures a host of residential, commercial and industrial air conditioners. This broad product range extends from the concealed units up to 5 TR, the ducted splits up to 30 TR, the packaged units up to 100 TR, the single and double skin air handling units up to 138,316 CFM, the water chillers up to 590 TR and the centrifugal chillers up to 5,000 TR cooling capacity. Our products and services include, in addition to Maintenance, Retrofit & Operations (MRO), complete integrate suite of solutions like: • Zamil Projects: Providing EPC for electromechanical works for Industrial, Utility and Oil & Gas customers. • Zamil Controls: Design, assembly, integration and commissioning of low current & low voltage systems. • Zamil Fire Protection: Design, integration and commissioning of active fire protection systems. • Zamil Electrical: Design, integration and commissioning of lv/mv (low voltage/middle voltage) systems. • Coil & Coating: Coil replacement, anti-corrosion coating, water proofing & reflective coating and passive fire protection solutions. • Zamil Ducting: Facilities designs and manufactures high quality duct systems and other HVAC industry related products, utilizing state of the art automated duct lines, Plasma Cutting, CNC Turret punch press and other specific machinery through two duct factories located in Saudi Arabia western province (Yanbu) and Eastern province (Dammam).
INDEX Contents
Page
Model decoding ......................................................................................................................................... 3 Indoor unit features ................................................................................................................................... 4 Standard specifications ............................................................................................................................. 4 Outdoor unit features ................................................................................................................................ 5 ECM motors .............................................................................................................................................. 6 Microprocessor controlled thermostat ........................................................................................................ 6 Physical data ............................................................................................................................................ 7 Cooling capacities ..................................................................................................................................... 8 ECM motor air flow chart ........................................................................................................................... 9 Dimensions, indoor units ......................................................................................................................... 10 Dimensions, outdoor units ...................................................................................................................11-13 Typical schematic wiring diagram ........................................................................................................... 14 Installation, operation & maintenance .................................................................................................. 15-16 Electrical ................................................................................................................................................. 17 System design ........................................................................................................................................ 17 Servicing instructions .............................................................................................................................. 18
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1
FEATURES HYBRID DESIGN BETWEEN MINI SPLITS AND CENTRAL UNITS INDOOR UNIT:
* * * * * * * * * * * *
SASO CERTIFIED COMPACT DESIGN WITH LOW PROFILE HEIGHT RANGES FROM 9.6" TO 14.5" UNITS ARE FOR DUCTED APPLICATIONS QUIET PULSE FREE OPERATION DRAW THRU AIRFLOW CONFIGURATION ELECTRONICALLY COMMUTATED MOTOR (ECM) REAR RETURN AIR FILTER EASY MAINTENANCE AND INSTALLATION G-90 GALVANIZED HEAVY GAUGE PANELS
INDOOR UNIT - 'DYA' SERIES
DIGITAL MICRO PROCESSOR CONTROL WIRED LCD DISPLAY THERMOSTAT
OUTDOOR UNIT:
* * *
SASO CERTIFIED G-90 GALVANIZED HEAVY GAUGE PANELS PAINT: ELECTROSTATIC POWDER COAT COOL GRAY COLOR
* * * * * * * *
HIGH EFFICIENCY TROPICAL DESIGN POWERFUL COMPRESSOR 230 VOLT CONTROL EXTERNAL SERVICE VALVES WITH GAUGE PORTS LOW & HIGH PRESSURE SWITCHES OPTIONAL COPPER OR COATED ALUMINUM FINS COIL GUARD PROTECTION SIDE AIR DISCHARGE
OUTDOOR UNIT - 'KYA' SERIES (MODELS: KYA018 - KYA024)
2
MODEL DECODING
INDOOR UNIT 1, 2 & 3
4&5
6
7
8
9
10
11
BASIC (SERIES)
COOLING CAPACITY (x 1000 BTUH)
MODE
ELECTRICAL SUPPLY (V-Ph-Hz)
ACCESSORIES
EVAPORATOR COIL
COIL CONNECTION
FILTER
DYA DUCTED SPLIT FAN COIL UNIT (R-410A)
18
C : COOL ONLY C : 230-1-60
N : STANDARD
24
H : HEAT PUMP M: FOR MATCHING WITH 'M' VOLTAGE OUTDOOR UNIT KYA060 ONLY. INDOOR UNIT POWER SUPPLY REMAIN 230-1-60.
S : SS DRAIN PAN E :COATED ALUMINUM FIN V : VFC F : COPPER FIN A:S & V A : ALUMINUM FIN WITH RESISTEC
30 36 48
D : ALUMINUM FIN
R : RH SIDE (FACING AIR DISCHARGE)
12
OPTION*
N : STANDARD B : R-410A
B : COPPER FIN WITH RESISTEC
60
OUTDOOR UNIT (MODELS: KYA018 & KYA024) 1, 2 & 3 BASIC (SERIES)
KYA CONDENSING UNIT (R-410A)
4, 5 & 6 NOMINAL COOLING CAPACITY (MBH)
7 MODE
8 ELECTRICAL SUPPLY (V-Ph-Hz)
018
C : COOL ONLY C : 230-1-60
024
H : HEAT PUMP
9 COMPRESSOR TYPE
10 CONDENSER MOTOR
11 CONDENSER COIL
R : RECIPROCATING
N : STANDARD
B :COATED ALUMINUM FIN
12 ACCESSORIES
N : STANDARD
13 OPTION*
B : R-410A
OUTDOOR UNIT (MODELS: KYA030 - KYA060) 1, 2 & 3 BASIC (SERIES)
KYA CONDENSING UNIT (R-410A)
4, 5 & 6 NOMINAL COOLING CAPACITY (MBH)
7 MODE
8 ELECTRICAL SUPPLY (V-Ph-Hz)
030
C : COOL ONLY C : 230-1-60
036
H : HEAT PUMP
048
9 10 COMPRESSOR TYPE CONDENSER MOTOR
S : SCROLL
N : STANDARD
**
M : 380/400-3-60 (4 WIRE)
11 CONDENSER COIL
A : ALUMINUM FIN
N : STANDARD UNIT
B :COATED ALUMINUM FIN
F : STANDARD UNIT WITH FILTER DRIER & SIGHT GLASS (LOOSE ITEMS)
C : COPPER FIN
060
12 ACCESSORIES
M: ALUMINUM FIN WITH RESISTEC N : COPPER FIN WITH RESISTEC
M: METALLIC GUARD V : VFC*** A: F & M B: F & V C: M & V D : F, M & V
* This digit is required for identification in the decoding for R-410A unit. ** Applicable for KYA060 model only. *** VFC for Run indicator only. NOTE: At 400V-3Ph-60Hz power supply, voltage variation will be -10% & +5%.
3
13 OPTION*
B : R-410A
INDOOR UNIT FEATURES COMPACT DIMENSIONS Low height units are ideal to fit into tight spaces. Maximum height of unit ranges from 9.6" to 14.5" (24cm to 37cm). EASY INSTALLATION WITH FLARE NUT CONNECTIONS No need for complicated brazing for connecting the refrigerant piping. EASY MAINTENANCE / ONE SIDE ACCESS Filters can be easily removed by lifting/sliding. Piping and controls are on one side for easy access. DIGITAL & MICROPROCESSOR CONTROL WITH LCD DISPLAY THERMOSTAT Programmable wired thermostat loaded with all required functions and features for safe, energy efficient & smooth operation. QUIET, PULSE FREE AIR SUPPLY Centrifugal fans that are statically and dynamically balanced, handle upto 0.5" w.g. (125pa) external static pressure allowing you to keep the unit away from your comfort zone. MATCHED WITH RELIABLE CONDENSING UNITS For optimum performance in cooling and heat pump applications.
Quiet Operation
Dedicated Thermostat
Compact Dimensions
High Cooling Capacity
Easy Installation
STANDARD SPECIFICATIONS ENVIRONMENT FRIENDLY UNITS These units are developed as environment friendly units that use refrigerant R-410A, which has ZERO OZONE DEPLETION POTENTIAL (ODP = 0) and therefore conform to the International protocol regulations concerning refrigerant gases. Polyol Ester lubricants are used with R-410A. UNIT CONSTRUCTION These ducted indoor fan coil unit consists of a coil, motor/blower assembly, filter and a drain pan securely mounted on heavy gauge galvanized steel housing. Steel sheet panels are zinc coated and galvanized by the hot dip process of lockforming quality conforming to ASTM A 653 commercial weight G-90. This unit is designed for those concealed overhead installations which require supply ductwork. A 1.5" duct collar is provided into the front panel for supply air duct connection. Return air is from the rear side. Access to the blower assembly is provided through the removable bottom panel from where the complete fan/motor deck can be removed for servicing. The panels are insulated with 5/16" thick polyethylene acoustic and thermal insulation. BLOWER ASSEMBLY The direct drive blower motor assembly is easily accessible for complete servicing after removal of fan deck from the unit. The blower wheels are large in diameter and are of the forward curved design, statically and dynamically balanced for quiet and smooth performance. MOTORS Motors are ECM type with an ultra high efficiency programmable brush-less DC Motors. COILS All cooling coils are of corrugated fin & tube type, constructed of enhanced copper tubes and mechanically bonded to aluminum fins. As an option to aluminum fins, coated aluminum fins or corrugated copper fins may be provided. Tube support sheets are of galvanized steel, formed to provide structural strength. Coils are provided with the orifice type refrigerant metering device on all models (except DYA18/DYA24 models). This provides for ease of serviceability. DRAIN PAN The condensate drain pan is fabricated of 18 gauge galvanized steel. The drain pan is powder coat painted and the outer surface is thermally insulated. Since water never touches the metal pan, then possibility of corrosion is eliminated. FILTER Polypropylene filters are provided as standard. 4
OUTDOOR UNIT FEATURES A. GENERAL The Zamil side discharge condensing units incorporate the latest innovative technology to provide quiet, reliable performance. The wrap-around coil not only adds to the aesthetical appeal, it also gives optimum heat transfer efficiency. The access panels provide access to the compressor and to the electrical control box. Removal of top panel gives access to fan motor and coil. These condensing units can be combined with a wide variety of evaporator coils and blower packages to provide quiet and dependable comfort. These units are available as standard cool only models.
Low Noise Level
Powerful R-410A Compressor
High Energy Efficiency Ratio
B. UNIT ENCLOSURE All panels are of heavy gauge (G-90) galvanized steel sheet and completely weatherized for outdoor installation. Steel sheet panels are zinc coated and galvanized by the hot dip process of lock-forming quality conforming to ASTM A 653 commercial weight G-90, followed by baked on electrostatic polyester dry powder coat. C. COMPRESSOR R-410A compressors are fully hermetic type and are provided with all the standard controls necessary for proper and safe operation. These compressors have improved internal pressure relief valve which provides high pressure protection to the refrigerant system and rubber vibration isolators for quiet and efficient operation. D. AIR COOLED CONDENSER 1. The condenser coils are of the enhanced fin & tube type, constructed of enhanced copper tubes and mechanically bonded to aluminum fins. As an option to aluminum fins, coated aluminum fins or corrugated copper fins may be provided. Tube support sheets are of galvanized steel, formed to provide structural strength. Tubes are circuited to ensure minimum pressure drop and maximum heat transfer. Each coil is completely dehydrated, charged and sealed at the factory upon completion of pressure tests. 2. The fans are propeller type and direct-driven, front discharge & provided with fan guards. 3. Units are equipped with totally enclosed fan motors for greater reliability and dependable performance for many years. Inherent thermal protection is automatic reset type. 4. For heat pump version units, fixed orifice expansion device is inherent within the condensing units on KYA030 - KYA060 (except KYA018 & KYA024 models where capillary is provided). E. SERVICE VALVES Both suction and liquid service valves are brass, back seating type with flare connections. Valves are externally located so refrigerant tube connections can be made quickly and easily. Each valve has a gauge pressure port for ease of checking refrigerant operating pressures. F. LOW PRESSURE SWITCH Auto reset SPST switch activated by refrigerant pressure - locks out the compressor, if the refrigerant pressure falls below 50 PSIG. Also provides additional protection against evaporator freeze up due to loss of indoor airflow. G. HIGH PRESSURE SWITCH Auto reset SPST switch activated by refrigerant pressure - locks out the compressor, if the refrigerant pressure rises above 650 PSIG. Also provides additional protection against compressor damage due to loss of outdoor airflow. 5
ELECTRONICALLY COMMUTATED MOTOR (ECM) The ECM (Electronically Commutated Motor) is an ultra high efficiency programmable brush-less DC motor utilizing a permanent magnet motor and a built-in inverter. DC motors are significantly more energy efficient than AC motors and much easier to control. 1. Significant energy savings (67% average compared to PSC motors). 2. Unique factory preset air volume capability (+/- 5%). 3. Pressure independent fan operation. 4. Field adjustable fan air volume controller.
MICROPROCESSOR CONTROLLED THERMOSTAT FEATURES
BENEFITS
Wired remote controller with Liquid Crystal Display (LCD) with Touch screen
Unit operation controlled remotely with a large LCD display.
FAN/HEAT/AUTO/COOL/DRY mode of operation
5 modes of operation with automatic shift between COOL & HEAT when on AUTO.
Modulating fan speed with 10 steps along with AUTO mode
Cover the whole range of CFM/capacity requirements.
SLEEP mode
To raise/lower temperature setting by a maximum of 20F during night time for added comfort and energy.
Auto Restart
Thermostat settings are preserved in the memory in case of power interruption and will be retrieved to operate the unit accordingly when power is restored.
Real Time Clock
Display the day and time in AM/PM format.
7 Day Programmable Timer
To select up to 7 days in advance when to start and when to stop operation.
De-icing
To avoid freezing of indoor coil during COOL cycle.
Electronic Defrost cycle
Prevent freezing of outdoor coil during HEAT cycle.
Child Lock
To restrict the number of persons tampering with the control.
Room Temperature Display
Both room & set point temperatures can be displayed in either 0C or 0F.
ON/OFF status LED indicator
To inform on the status of operation.
6
PHYSICAL DATA INDOOR UNIT OUTDOOR UNIT PERFORMANCE MODEL
DYA 18 KYA 018
DYA 24 KYA 024
DYA 30 KYA 030
DYA 36 KYA 036
DYA 48 KYA 048
DYA 60 KYA 060
Gross cooling capacity, BTUh/kW
19381/5.678
23913/7.06
28835/8.44
34600/10.08
48130/14.02
55720/16.23
Rated cooling capacity, BTUh/kW
19000/5.56
23700/6.94
28200/8.26
33000/9.66
46000/13.47
53000/15.52
Actual total unit power input, Kw
1.6
1.94
2.276
2.797
3.711
4.52
Rated total unit power input, Kw
1.62
2.008
2.4
2.82
3.767
4.57
Actual EER
12.06
12.3
12.51
12.114
12.7
12.01
Rated EER
11.67
11.8
12.15
11.7
12.2
11.6
15893/4.65
19893/5.80
25298/7.36
27250/7.95
43060/12.54
49360/14.37
Total unit power input, Kw
1.56
2.06
2.16
3.0
3.5
4.0
Evaporator airflow, CFM
700
800
970
1200
1590
1800
36/34/33
42/36/35
44/41/37
45/42/37
45/43/38
46/44/38
2.2
2.67
4.37
4.37
4.37
Heating capacity, BTUH/Kw
Sound pressure level, dBA (high/medium/low)
INDOOR UNIT Power supply (V-Ph-Hz) Face area, ft2 Evaporator coil
230-1-60 4.37
Tube dia, inch
3/8
3/8
3/8
3/8
3/8
3/8
No. of rows/FPI
3/14
4/14
4/14
4/14
4/14
5/14
5/8 - 3/8
5/8 - 3/8
3/4 - 3/8
7/8 -1/2
7/8 -1/2
7/8 -1/2
Weight, Kg.
Suction - Liquid line, inch
40
40
65
65
65
73
Minimum circuit ampacity, Amps
1.5
1.5
3.3
3.3
4.5
4.5
Maximum fuse size, Amps
15
15
15
15
15
15
230-1-60
6/43
9.4/54
13.8/80
15.7/77
24.3/137
30.1/144
380/400-3-60
N.A.
N.A.
N.A.
N.A.
N.A.
10.7/64
8.96/20
16.9/25
18.08/30
21.28/35
33.5/55
40.2/70
N.A.
N.A.
N.A.
N.A.
N.A.
16.57/45
OUTDOOR UNIT Compressor RLA/LRA Outdoor unit MCA/MOCP
230-1-60 380/400-3-60
Condenser airflow, CFM Condenser Fan HP - RPM (Qty.) motor FLA (each) Condenser coil
2200
2200
2200
4600
4800
4800
1/8 - 900
1/8 - 900
1/8 - 900
1/8 - 900(2)
1/8 - 900(2)
1/8 - 900(2)
0.83
0.83
0.83
0.83
0.83
0.83
Tube dia, inch
7mm
7mm
3/8
3/8
3/8
3/8
No. of rows/FPI
3/16
4/14
3/14
2/14
2/14
2/14
96
101
201
353
260
310
Refrigerant (R-410A) charge, oz. - Cool Refrigerant (R-410A) charge, oz. - Heat pump Suction - Liquid line, inch
92
115
188
364
265
292
5/8 - 3/8
5/8 - 3/8
3/4 - 3/8
7/8 -1/2
7/8 - 1/2
7/8 - 1/2
Dimensions, mm (width x depth x height) 1005x402x830 1005x402x830
967x392x829 1177x516x1282 1297x516x1282 1297x516x1282
Weight, Kg. (cool models)
70
74
85
132
145
145
Weight, Kg. (heat pump models)
73
78
90
138
150
150
NOTE: 1. Cooling capacities & power input data @ 80.60F (270C) DB/66.20F (190C) WB indoor & 950F (350C) ambient temperatures (SASO std.). 2. Heating capacities & power input data @ 680F (200C) DB/590F (150C) WB indoor & 44.60F (70C) outdoor temperatures. At outdoor temperature less than -20C, other source of heating must be used. 3. Sound pressure level @ 9 feet distance and 0.15 ESP. 4. Pipe sizes are for runs up to 25 feet (7.6 meters) to indoor unit.
7
COOLING CAPACITIES MODEL NUMBER (INDOOR UNIT/OUTDOOR UNIT) DYA18/ KYA018 CONDENSER ENTERING AIR TEMP. (0F)
95
105
115
8 125
DYA30/ KYA030
DYA36/ KYA036
DYA48/ KYA048
DYA60/ KYA060
1600/0.086
1800/0.080
EVAPORATOR AIRFLOW, CFM/DR 710/0.128 62
85
DYA24/ KYA024 800/0.128
66.2
72
62
950/0.135
66.2
72
1200/0.095
EVAPORATOR ENTERING AIR, WBE (0F) 72 66.2 72 62 66.2 62
62
66.2
72
62
66.2
72
TC
19.35
21.50
24.73
23.25
25.83
28.16
29.18
31.71
34.25
34.38
37.37
39.98
48.26
52.46
56.66
55.11
59.90
63.49
SC
18.86
17.46
15.71
20.97
19.78
18.59
24.96
23.54
22.13
30.62
28.89
26.87
42.96
40.53
37.29
48.83
45.64
41.98
kW
1.43
1.48
1.57
1.78
1.87
1.97
2.03
2.13
2.24
2.38
2.51
2.66
3.14
3.34
3.57
3.90
4.15
4.44
TC
17.64
19.38
22.29
21.77
23.92
26.31
26.24
28.83
31.42
31.83
34.60
37.37
43.80
48.13
52.94
50.71
55.72
60.01
SC
17.47
16.48
14.83
19.78
18.66
17.35
23.54
22.21
20.88
29.45
27.78
25.28
40.16
37.53
34.15
45.59
42.61
39.20
kW
1.52
1.60
1.70
1.85
1.95
2.07
2.16
2.27
2.38
2.65
2.79
2.96
3.52
3.71
3.97
4.31
4.51
4.83
TC
16.21
17.25
19.83
20.03
22.01
24.21
24.40
26.52
28.65
29.29
31.83
33.42
41.18
44.28
48.71
48.19
51.82
55.29
SC
15.80
15.49
13.94
18.40
17.35
16.31
21.19
19.99
18.79
26.80
25.28
22.75
37.00
34.90
32.11
42.86
40.05
37.25
kW
1.64
1.71
1.81
2.00
2.09
2.21
2.26
2.38
2.50
2.94
3.12
3.31
4.02
4.23
4.53
4.75
5.05
5.38
TC
14.44
15.20
17.48
17.11
18.80
20.30
23.31
25.06
26.81
26.36
28.65
30.37
36.67
40.29
43.92
43.86
47.67
51.01
SC
14.85
14.56
13.10
17.84
16.83
15.65
19.92
18.79
17.29
24.12
22.75
20.25
34.73
32.46
30.19
40.71
38.05
35.77
kW
1.70
1.79
1.90
2.09
2.20
2.33
2.65
2.76
2.90
3.29
3.50
3.74
4.63
4.82
5.16
5.41
5.76
6.16
TC
13.11
13.38
15.38
14.82
15.60
16.85
19.60
21.30
23.01
24.19
25.73
27.02
33.28
36.98
39.57
40.08
44.04
46.24
SC
13.38
13.12
11.81
16.84
16.51
15.52
17.93
16.91
15.22
22.86
21.57
18.98
32.81
31.25
29.06
38.67
35.81
32.23
kW
1.86
1.93
2.07
2.23
2.38
2.52
2.78
2.93
3.10
3.94
4.15
4.38
5.14
5.47
5.83
6.09
6.41
6.89
LEGEND: TC
– Total Capacity (1000 Btuh) Gross
SC
– Sensible Heat Capacity (1000 Btuh)
kW
– Total unit power input
DR
– Wet Bulb depression ratio
DBE – Dry Bulb Temp. (0F) of Air Entering Coil WBE – Wet Bulb Temp. (0F) of Air Entering Coil DBL – Dry Bulb Temp. (0F) of Air Leaving Coil WBL – Wet Bulb Temp. (0F) of Air Leaving Coil NOTES: 1. Capacities above are based on DBE = 80.60F. For higher or lower DBE, add following Correction Factor = 1.08 x CFM (1 – DR) (DBE – 80.6). 2. To calculate leaving conditions, follow this procedure: DBL = DBE – (Sensible Capacity (Btuh) / 1.08 x CFM);
WBL = DBL – [DR (DBE – WBE)].
MULTIPLIERS FOR LOWER CFM % of rated airflow
100%
95%
90%
85%
80%
75%
70%
60%
TC
1
0.98
0.96
0.93
0.91
0.89
0.87
0.83
SC
1
0.965
0.93
0.90
0.87
0.845
0.82
0.78
kW
1
0.992
0.985
0.97
0.965
0.96
0.94
0.93
ECM AIR FLOW CHART Model No.
CFM Range
Factory Set
Minimum
Maximum
DYA18
700
400
750
DYA24
800
510
850
DYA30
1000
650
1100
DYA36
1200
900
1250
DYA48
1600
1275
1600
DYA60
1800
1550
1900
NOTE: Values include losses for dry coil and filters.
DYA24 WITH 1/4 HP ECM 0.30
0.25
0.25
ESP (IN.W.G)
ESP (IN.W.G)
DYA18 WITH 1/4 HP ECM 0.30
0.20
0.15
0.10
0.05
0.20
0.15
0.10
0.05
0.00 400
460
525
590
655
705
0.00 510
750
575
640
700
CFM
0.40
0.40
0.30
0.20
0.10
0.20
0.10
700
750
800
850
880
920
960
1005
1055
0.00 900
1100
935
970
1000
1050
1080
1125
1160
1200
1225
1250
CFM
DYA48 WITH 1/2 HP ECM
DYA60 WITH 1/2 HP ECM
0.50
0.50
0.40
0.40
ESP (IN.W.G)
ESP (IN.W.G)
850
0.30
CFM
0.30
0.20
0.10
0.00 1275
805
DYA36 WITH 1/3 HP ECM 0.50
ESP (IN.W.G)
ESP (IN.W.G)
DYA30 WITH 1/3 HP ECM 0.50
0.00 650
765
CFM
0.30
0.20
0.10
1305
1340
1375
1400
1445
1470
1500
1540
1570
0.00 1550
1600
CFM
1590
1625
1665
1695
1730
CFM
9
1755
1785
1825
1865
1900
DIMENSIONS - INDOOR UNITS DYA18 - DYA60 D A
4 5
I
3/4" NPT(14TPI) DRAIN TUBE
H
B
E
2
25 (1.00")
1
7
END VIEW
TOP VIEW
6
END VIEW
89 (3.50")
3
G
C
F
FRONT VIEW 1. Blower & motor assembly 2. Evaporator coil 3. Control box 4. Filter rack 5. Unit mounting brackets (4 Nos.) 6. Duct connection 7. Power entry hole (1-1/8" dia.)
NOTE: All dimensions are in mm (dimensions in brackets are in inches). DIMENSIONS MODEL
A
B
C
D
E
F
G
H
I
DYA 18
904 (35.6)
610 (24)
244 (9.6)
960 (37.8)
521 (20.5)
769 (30.3)
183 (7.2)
841 (33.1)
206 (8.1)
DYA 24 DYA 30 DYA 36 DYA 48 DYA 60
904 (35.6) 1194 (47) 1194 (47) 1194 (47) 1194 (47)
610 (24) 762 (30) 762 (30) 762 (30) 762 (30)
305 (12) 368 (14.5) 368 (14.5) 368 (14.5) 368 (14.5)
960 (37.8) 1245 (49) 1245 (49) 1245 (49) 1245 (49)
521 (20.5) 625 (24.6) 625 (24.6) 625 (24.6) 625 (24.6)
769 (30.3) 851 (33.5) 851 (33.5) 894 (35.2) 894 (35.2)
183 (7.2) 234 (9.2) 234 (9.2) 266 (10.5) 266 (10.5)
841 (33.1) 1155 (45.5) 1155 (45.5) 1155 (45.5) 1155 (45.5)
206 (8.1) 292 (11.5) 292 (11.5) 292 (11.5) 292 (11.5)
10
DIMENSIONS - OUTDOOR UNITS KYA018 & KYA024
AIR IN
C
D
Model KYA018 KYA024
A (mm) 1005 1005
B (mm) 830 830
19 mm x 14mm MOUNTING SLOT 4 NOS.
AIR OUT
E
TOP VIEW
A
FRONT VIEW
END VIEW
NOTE: All dimensions are in mm (dimensions in brackets are in inches).
11
C (mm) 402 402
D (mm) 436 436
E (mm) 628 628
DIMENSIONS - OUTDOOR UNITS KYA030
15(0.59)
AIR IN
435(17.16)
AIR IN
392 (15.43)
20 (0.79)
70(2.76) DETAIL- A SEE DETAIL -A
AIR OUT
133 (5.25)
(TYPICAL AT FOUR PLACES)
698(27.5)
TOP VIEW
967 (38.1)
POWER & CONTROL WIRE ENTRY
152 (6.0)
16(0.63)
63(2.5) 533(21)
9.5 (3 8") FLARE TYPE CONN.
82 (3.25)
829 (32.62)
ACCESS PANEL
19(0.75)
FRONT VIEW
19 (3 4") FLARE TYPE CONN.
END VIEW
NOTE: All dimensions are in mm (dimensions in brackets are in inches).
12
89 (3.5)
DIMENSIONS - OUTDOOR UNITS KYA036, KYA048 & KYA060
D
E
C
AIR IN
AIR IN
AIR IN
AIR OUT
A TOP VIEW TOP VIEW
B
CONTROL BOX ACCESS PANEL
ACCESS PANEL
38 [1.5"]
7
8"
CONTROL WIRE ENTRY
5
POWER WIRE ENTRY
1
8"
2"
F
LIQUID CONN.)
G 7
8" SUCTION CONN.)
FRONT VIEW
END VIEW
FRONT VIEW
END VIEW
MODEL NUMBER
A
B
C
D
E
F
G
KYA036
1177 (46.32)
1244 (48.97)
516 (20.32)
713 (28.07)
549 (21.6)
282 (11.11)
102 (4)
KYA048 - KYA060 1297 (51.04)
1244 (48.97)
516 (20.32)
783 (30.83)
549 (21.6)
299 (11.78)
102 (4)
NOTE: All dimensions are in mm (dimensions in brackets are in inches).
13
TYPICAL SCHEMATIC WIRING DIAGRAM LEGEND ATB AUXILIARY TERMINAL BLOCK COM COMMON ECB ELECTRONIC CONTROL BOARD ECM ELECTRONICALLY COMMUTATED MOTOR GND LUG GROUND L1
LINE 1
L2 LINE 2 OR NEUTRAL _ _ _ FIELD WIRING FACTORY WIRING NOTES 1. POWER SUPPLY, REFER TO UNIT NAMEPLATE. 2. MOTORS ARE THERMALLY PROTECTED. 3. USE COPPER CONDUCTOR WIRES ONLY. 4. REFER TO INTERCONNECTING WIRING DIAGRAM BEFORE INSTALLATION
INTERCONNECTING DETAILS BETWEEN INDOOR & OUTDOOR UNIT NOTE: Route wires according to diagram below & ignore all other terminal connection on outdoor unit. Also route outdoor coil sensor wire from indoor to outdoor sensor holder for heat pump units. ATB
1
6
T3A/N 37A
8
INDOOR UNIT DYA SERIES
ATB 6
1
INDOOR UNIT DYA SERIES
ATB
1
5
6
OUTDOOR UNIT KYA SERIES
8
T3A
OUTDOOR UNIT KYA SERIES
37A 36A CAP
1
5
6
COMP
ATB
35A FM
NOTE: T3A IS T1 ON 1PH CONDENSER UNITS
COOL MODELS
HEAT PUMP MODELS
14
INSTALLATION - INDOOR UNIT The complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immediately to the delivery man or driver and noted on the shipping invoice. Place unit in position and make sure that unit is level. This is important to assure proper drainage and operation. Slots provided in the mounting brackets should be used for installing the units. Be sure that foreign material is not allowed to fall into or collect in the drain pan. Special care must be taken to prevent paint, plaster, insulation or other foreign material from being deposited on the motor or blower wheels.
MAINTENANCE COIL: Coil may be cleaned by removing case and brushing between fins with a stiff wire brush. Brushing should be followed by cleaning with vacuum cleaner. The coil may also be cleaned by using a high pressure air, if compressed air source is available. It should be pointed out that if air filters are used and periodically cleaned, the coils will not be clogged up prematurely. DRAIN PIPE: Drain pipe should be checked before summer operation of unit is begun. If it is clogged, steps should be taken to clear the debris so that condensate will flow out easily. A standard pipe cleaner for 1/2" ID pipe may be used. Periodic checks of the drain pipe should be taken during summer operation, as there is a possibility of it becoming clogged with dirt. FILTER CLEANING: Remove access panel, slide filter out of filter rack, and clean as follows: Tap filter on solid surface to dislodge heavy particles. Wash under stream of water. Set filter on end with slots in frame down, which allows it to drain. Filters should dry thoroughly before reuse. REPLACEMENT PARTS: When writing for replacement parts, refer to model number and serial number on the name plate of the unit.
15
INSTALLATION & START-UP INSTRUCTIONS - OUTDOOR UNIT SAFETY CONSIDERATIONS Improper installation, service, maintenance or use can cause explosion, fire, electrical shock or other conditions which may cause personal injury or property damage. Check with your nearest Zamil dealer/sales office for information or assistance. Warning: Before installation or servicing the system, always turn off main power supply. Electrical shock can cause personal injury or death.
INSTALLATION STEP-1: Check equipment and job site Unpack unit and move to final location taking care not to damage the unit. Remove screws holding the unit to wooden pallet and remove wooden pallet.
STEP- 2: Location of unit Place the unit with minimum clearance as shown in figure below to enable space for installation, service and optimum performance of the unit. Be sure that the discharge air from the condenser is not restricted. Double the clearance when multiple units are installed at one location. Units may be installed using mounting pads on the floor, concrete slabs, steel frames with adequate strength.
203mm (8") FOR KYA018, 024 & 030 254mm (10") FOR KYA036 AND ABOVE
AIR IN
254mm (10") FOR KYA036 AND ABOVE
203mm (8") FOR KYA018, 024 & 030
AIR IN
610mm (24") CLEARANCE MINIMUM
AIR OUT 914mm (36") CLEARANCE MINIMUM
STEP-3: Piping connections Outdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. The liquid and suction line diameters can be determined from the physical data table. For piping requirements beyond 25 ft (7.62 m), obtain information from your nearest Zamil dealer/sales office. If either refrigerant piping or indoor coil is exposed to atmospheric conditions, it must be dehydrated to 500 microns to eliminate moisture contamination in the system. It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigeration standard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigerant pipes carefully to prevent damaging the suction pipe insulation and vibration transmission to the structure.
Outdoor unit connected to factory matched indoor unit Outdoor unit contains correct system refrigerant charge for operation with matched indoor unit as given on cooling capacity table and when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge for maximum efficiency. 16
ELECTRICAL STEP 1: INSTALLATION A) Please ensure regular power supply to the unit is as per unit nameplate (Volts/Ph/Hz) requirements. Caution: Operation of the unit on improper power supply like generators will result in damage to the unit. Note: Use copper wires of proper rating for all field wiring. Warning: Before servicing or installation of the unit, always TURN OFF all power to the unit. There may be more than one disconnect switch. Ensure all of them are turned off. Electrical shock can cause personal injury or death. B) Ground & power wires Connect power wires to terminal block per wiring diagram. Connect ground wire to the ground lug inside the control box. C) Wiring 1. All wiring must comply with the "National Electric Code" and local electrical standards. 2. The power supply, voltage, frequency and phase must coincide with the unit nameplate. 3. Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate; but not less than 14 gauge (2.5 mm2) for lower amps. 4. For control wiring, use approved thermostat wire [minimum 18 gauge (0.75 mm2)], color coded wires. Never use telephone wire for this purpose. 5. Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damage to compressors and motors can occur, if improper voltage is applied. 6. Install adequate branch disconnect switch as per NEC size requirements to handle unit starting current. Locate disconnect switch within sight and readily accessible from the unit.
STEP 2: START-UP 1. Energize crankcase heater for a minimum of 12 hours prior to the system start-up. To energize crankcase heater only, set thermostat to "off" position and close electrical disconnect switch to the outdoor unit. 2. Fully open liquid/suction service valves. 3. Close electrical disconnect switch to energize the system. 4. Set room thermostat to desired temperature.
SYSTEM DESIGN THE CONDENSING UNIT SYSTEM HAS BEEN DESIGNED BASED ON THE FOLLOWING:
• Intended for outdoor installation with free air intake and discharge. • Minimum outdoor operating air temperature during cooling without low ambient operation option is 55 F (12.7 C). • For reliable operation, unit should be level on horizontal plane. • For interconnecting refrigerant pipe lengths greater than 25 feet (7.6 meters), check with your local Zamil sales office. • Use only copper wire for electric connection at unit. Aluminum and clad aluminum are not acceptable for the type of 0
connector provided.
17
0
SERVICING INSTRUCTIONS
ss ce c A
ers low b for CM
r oto m &
95
30
CM
Blower deck holding bolt 50
50
Blower deck
CM
CM
Bottom panel
NOTES: 1. Required indoor unit access clearances are shown as hatched area. 2. Free sevice access should be available from the bottom of the unit for removing & servicing the blower/motor deck. 3. Servicing instructions: a) Remove the bottom panel. b) Support the blower deck while unscrewing the 4 blower deck holding bolts and bring down the blower deck.
18
