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Concealed Fan Coil Units

DY18/KY018 thru DY60/KY060 1.5 TR thru 5 TR 5 kW thru 17.5 kW Cool & Heat pump models

FEATURES
HYBRID DESIGN BETWEEN MINI SPLITS AND CENTRAL UNITS
INDOOR UNIT :

* * * * * * * * * * *

COMPACT DESIGN WITH LOW PROFILE HEIGHT RANGES FROM 9.6" TO 14.5" UNITS ARE FOR DUCTED APPLICATIONS LOW SOUND LEVELS DRAW THRU AIRFLOW CONFIGURATION 3 SPEED MOTORS REAR RETURN AIR FILTER EASY MAINTENANCE AND INSTALLATION G-90 GALVANIZED HEAVY GAUGE PANELS DIGITAL MICRO PROCESSOR CONTROL WIRED LCD DISPLAY THERMOSTAT (OPTIONAL WIRELESS REMOTE CONTROL)

INDOOR UNIT - 'DY' SERIES

OUTDOOR UNIT :

* * * * * * * * * * *

G-90 GALVANIZED HEAVY GAUGE PANELS PAINT: ELECTROSTATIC POWDER COAT COOL GRAY COLOR HIGH EFFICIENCY TROPICAL DESIGN POWERFUL COMPRESSOR 24 VOLT CONTROL OPERATES UP TO 550C AMBIENT TEMPERATURE EXTERNAL SERVICE VALVES WITH GAUGE PORTS LOW PRESSURE SWITCH OPTIONAL COPPER OR COATED ALUMINUM FINS COIL GUARD PROTECTION SIDE AIR DISCHARGE

OUTDOOR UNIT - 'KY' SERIES


(MODELS: KY042 - KY060)

INDEX
Contents Page

Model decoding ........................................................................................................................................ 2 Matching condensing units ....................................................................................................................... 2 Indoor unit features .................................................................................................................................. 3 Standard specifications ............................................................................................................................ 3 Outdoor unit features ................................................................................................................................ 4 Microprocessor controlled thermostat ...................................................................................................... 5 Physical data ............................................................................................................................................ 6 Cooling capacities .................................................................................................................................... 7 Fan performance data .............................................................................................................................. 8 Dimensions, indoor units .......................................................................................................................... 9 Dimensions, outdoor units ................................................................................................................. 10-11 Typical schematic wiring diagram ...................................................................................................... 12-13 Installation, operation & maintenance ............................................................................................... 14-15 Electrical ................................................................................................................................................. 16 System design ........................................................................................................................................ 16 Servicing instructions ............................................................................................................................. 17

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MODEL DECODING
INDOOR UNIT
1&2 3&4
ITY (x 1000 BTUH)

7
ACCESSORIES N : STANDARD

8
FIN D : ALUMINUM FINS WITH ORIFICE E : COATED FINS WITH ORIFICE F : COPPER FINS WITH ORIFICE *A : ALUMINUM FINS WITH CAPILLARY *B : COATED ALUMINUM FINS WITH CAPILLARY *C : COPPER FINS WITH CAPILLARY

9
COIL CONNECTION R : RH SIDE (FACING AIR DISCHARGE)

10
FILTER N : NONE A : ALUMINUM C : SYNTHETIC

11
OPTION N : STANDARD UNIT

BASIC (SERIES) COOLING CAPACDY : DUCTED SPLIT FAN COIL UNIT 18 24 30 36 42 48 60

ELECTRICAL REFRIGERATION SUPPLY (V-Ph-Hz) SYSTEM C : 208/230-1-60 C : COOL ONLY H : HEAT PUMP

* These options are for matching with DY18/24 heat pump units and also for matching with KXC or CX condensing units.

OUTDOOR UNIT
1&2 BASIC 3, 4 & 5 NOMINAL COOLING CAPACITY (MBH)
018 024 030 036 042 048 060 F : 460-3-60

6 ELECTRICAL SUPPLY ( V-Ph-Hz )


C : 208/230-1-60 H : 208/230-3-60 M : 380-3-60 (4 WIRE)

7 8 REFRIGERA- COMPRESSOR TION CIRCUIT TYPE

9 MODE

10 CONDENSER MOTOR

12 11 CONDENSER ACCESSORIES COIL


N : STANDARD UNIT

13 OPTIONS

KY
CONDENSING UNIT

S : SINGLE

R : HERMETIC RECIPROCATING

C : COOL ONLY H : HEAT PUMP

* *

N : STANDARD A : ALUMINUM FIN L : LOW AMBIENT B : COATED ALUMINUM FIN

N : STANDARD UNIT

F : STANDARD UNIT WITH FILTER DRIER & SIGHT GLASS C : COPPER FIN

NOTES:

Applicable for KY030 - KY060 models only.

MATCHING INDOOR/OUTDOOR UNITS


INDOOR UNIT (FAN COIL UNIT)
COOL DY18CCNDRAN DY18CHNARAN DY24CCNDRAN DY24CHNARAN DY30CCNDRAN DY30CHNDRAN DY36CCNDRAN DY36CHNDRAN DY42CCNDRAN DY42CHNDRAN DY48CCNDRAN DY48CHNDRAN DY60CCNDRAN DY60CHNDRAN KY018CSRCNANN KY018CSRHNANN KY024CSRCNANN KY024CSRHNANN KY030CSRCNANN KY030CSRHNANN KY036HSRCNANN KY036HSRHNANN KY042HSRCNANN KY042HSRHNANN KY048HSRCNANN KY048HSRHNANN KY060HSRCNANN KY060HSRHNANN

MODE

INDOOR UNITS

OUTDOOR UNITS

DY18 DY24 DY30 DY36 DY42 DY48 DY60

HEAT PUMP COOL HEAT PUMP COOL HEAT PUMP COOL HEAT PUMP COOL HEAT PUMP COOL HEAT PUMP COOL HEAT PUMP

NOTE: Refer to indoor/outdoor model decoding for other available voltages.

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 and 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

Digital Thermostat

Compact Dimensions

High Cooling Capacity

Easy Installation

STANDARD SPECIFICATIONS
UNIT CONSTRUCTION These ducted indoor fan coil unit consists of a coil, motor/blower assembly, aluminum 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 lock-forming 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. 1/2" (13mm) thick washable type aluminum filter is provided. 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. Constructed of steel, they are statically and dynamically balanced for quiet and smooth performance. MOTORS Motors are permanent split capacitor type with three speed tapped windings. The bearings are of sleeve type. 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 DY18/DY24 heat pump models). This provides for ease of serviceability. Unlike capillaries there is no need for de-brazing/brazing required for site replacements of the orifice pistons. Accurately sized pistons can be easily fitted for non-standard applications (e.g. high rise buildings). Also this metering device eliminates the need for check valves in reverse cycle heat pump applications. All coils are factory tested at 350 psig. 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.
3

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 availed as standard cool only models, and also as heat pump versions as an option for added comfort during cold season.

Low Noise Level

Powerful Reciprocating 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 Compressors are fully hermetic type and are provided with all the standard controls necessary for proper and safe operation. These compressors have a self-regulating crankcase heater, 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. All copper tube return bends have 0.022" (0.56mm) wall thickness. 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 as standard (except DY18/DY24 heat pump models where capillary is provided in the indoor units). 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 25 PSIG. Also provides additional protection against evaporator freeze up due to loss of indoor airflow.

MICROPROCESSOR CONTROLLED THERMOSTAT

FEATURES
Wired remote controller with Liquid Crystal Display (LCD) (Wireless controller - optional) FAN/HEAT/AUTO/COOL/DRY mode of operation Three speed fan with AUTO mode SLEEP mode Auto Restart Real Time Clock 7 Day Programmable Timer Hot Start Cold Stop De-icing Electronic Defrost cycle Child Lock Room Temperature Display ON/OFF status LED indicator

BENEFITS
Unit operation controlled remotely with a large LCD display. 5 modes of operation with automatic shift between COOL & HEAT when on AUTO. Cover the whole range of CFM/capacity requirements. To raise/lower temperature setting by a maximum of 20F during night time for added comfort and energy. 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. Display the day and time in AM/PM format. To select up to 7 days in advance when to start and when to stop operation. No cold air blow in the room at start-up on HEAT mode. Use of the remaining thermal energy stored in evaporator coil after unit stop (HEAT mode). To avoid freezing of indoor coil during COOL cycle. Prevent freezing of outdoor coil during HEAT cycle. To restrict the number of persons tampering with the control. Both room & set point temperatures can be displayed in either 0C or 0F. To inform on the status of operation.

PHYSICAL DATA
MODEL INDOOR UNIT OUTDOOR UNIT DY 18 KY 018
18000/5.27 2.2/8.0 19000/5.56 2.1/2.7 650/550/450 36/34/33 1.6/12.8 15/20

DY 24 KY 024
23000/6.74 2.8/7.9 23750/6.96 2.7/2.6 750/650/550 42/36/35 1.6/16.9 15/25

DY 30 KY 030
31000/9.0 3.7/7.9 32000/9.37 3.4/2.8 1050/850/650 44/41/37 4.5/21.1 15/35

DY 36 KY 036
36200/10.6 4.1/8.4

DY 42 KY 042
44100/12.9 5.0/8.4

DY 48 KY 048
50000/14.6 5.7/8.4

DY 60 KY 060
58000/16.9 7.3/7.5

PERFORMANCE
Cooling capacity at high fan speed, BTUH/kW Total unit power input, kW/EER Heating capacity at high speed, BTUH/kW Total unit power input, kW/COP Evaporator airflow, CFM (high/medium/low) Sound pressure level, dBA (high/medium/low) Minimum circuit ampacity, Amps (Indoor/Outdoor unit) Maximum fuse size, Amps (Indoor/Outdoor)

36000/10.55 42300/12.38 46000/13.46 59000/17.27 3.8/2.8 4.4/2.8 4.4/3.1 6.1/2.8

1250/1050/850 1400/1250/1000 1600/1350/1100 1950/1600/1350 44/41/37 4.5/16.4 15/25 46/44/40 4.5/19.6 15/30 37/34/31 6/23.2 15/35 41/37/34 6/27.7 15/45

INDOOR UNIT
Power supply (V-Ph-Hz) Blower quantity Blower motor Watts - RPM FLA Face area, ft Evaporator coil
2

208/230-1-60 2 180 - 1270 1.3 2.2 3/8 3/14 5/8 - 3/8 8 x 16.5 (2) 40 2 220 - 1490 1.3 2.2 3/8 3/14 5/8 - 3/8 8 x 16.5 (2) 40 2 458 - 1400 3.6 3 3/8 3/14 3/4 - 3/8 9.5 x18.5 (2) 52 2 480 - 1400 3.6 3 3/8 3/14 3/4 - 3/8 2 564 - 1500 3.6 3 3/8 4/14 3/4 - 3/8 2 695 - 1240 4.8 4.4 3/8 4/14 3/4 -1/2 2 819 - 1400 4.8 4.4 3/8 4/14 3/4 -1/2

Tube dia, inch No. of rows/FPI

Suction - Liquid line, inch Return air filter (1/2" thick) size, inch & quantity Weight, Kg.

9.5 x 18.5 (2) 9.5 x 18.5 (2) 11 x 22.75 (2) 11 x 22.75 (2) 52 55 65 65

OUTDOOR UNIT
Power supply (V-Ph-Hz) Compressor (hermetic type), RLA/LRA Condenser airflow, CFM Condenser Fan HP - RPM motor FLA Face area, ft2 Condenser coil Tube dia, inch No. of rows/FPI Refrigerant (R-22) charge, oz. Suction - Liquid line, inch Dimensions, mm (depth x width x height) Weight, Kg. 9.7/52 1400 1/10 - 875 0.6 5.6 3/8 2/16 62 5/8 - 3/8 208/230-1-60 13/73 1400 1/10 - 875 0.6 5.6 3/8 2/16 76 5/8 - 3/8 15.6/90 2200 1/4 - 1000 1.6 6.5 5/16 3/16 133 3/4 - 3/8 11.8/67 2200 1/4 - 1000 1.6 6.5 3/8 3/16 130 3/4 - 3/8 208/230-3-60 13.1/80 4200 16/97 4200 19.6/105 4200

1/4 - 1000 (2) 1/4 - 1000 (2) 1/4 - 1000 (2) 1.6 10.5 3/8 2/16 141 7/8 - 3/8 1.6 10.5 3/8 2/16 135 7/8 - 3/8 1.6 10.5 3/8 2/16 127 7/8 - 3/8

800 x 325 x 685 800 x 325 x 685 965 x 390 x 726 965 x 390 x 726 965 x 390 x 1158 965 x 390 x 1158 965 x 390 x 1158 65 66 96 101 115 120 130

NOTE: 1. Cooling capacities & power input data @ 800F (26.70C) DB/670F (19.40C) WB indoor & 950F (350C) ambient temperatures. 2. Heating capacities & power input data @ 700F (21.10C) DB/600F (15.60C) WB indoor & 470F (8.30C) outdoor temperatures. 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.

COOLING CAPACITIES
MODEL NUMBER (INDOOR UNIT/OUTDOOR UNIT)
DY24/KY024 DY30/KY030 DY36/KY036 DY42/KY042 DY48/KY048 DY60/KY060 1950/0.085 72 62 57.35 56.56 6.48 53.02 52.95 6.05 54.76 38.02 5.37 41.97 41.38 5.62 42.48 31.01 5.38 5.71 23.97 6.07 5.55 39.46 38.89 5.82 5.7 46.68 37.09 5.9 43.98 36.06 6.21 29.85 6.06 51.86 28.94 6.29 48.90 27.92 6.63 6.93 51.92 51.18 7.02 49.20 48.52 7.2 45.97 45.33 7.56 59.79 31.65 5.51 55.38 30.56 67 62.73 47.04 6.8 57.99 45.80 7.31 56.89 44.80 7.41 53.93 43.72 7.6 50.47 42.39 8.01 72 68.33 36.79 7.11 63.12 35.43 7.66 61.95 34.57 7.78 58.75 33.51 8.01 55.05 32.26 8.45 1600/0.070 72 62 67 54.10 39.90 5.2 50.01 38.89 5.7 49.39 48.80 47.99 4.92 45.04 45.02 5.37 44.41 43.65 51.96 27.10 4.74 48.64 26.34 5.27 47.49 25.67 5.4 45.08 24.78 1400/0.090 67 47.22 34.21 4.51 44.12 33.51 5.01 43.03 32.73 5.11 40.79 31.79 5.31 38.42 EVAPORATOR AIRFLOW, CFM/DR 750/0.120 1050/0.127 1250/0.145 EVAPORATOR ENTERING AIR, WBE (0F) 72 62 67 72 62 37.52 35.46 39.07 42.94 42.76 41.15 4.28 39.90 39.56 4.74 38.86 38.12 4.84 36.78 36.00 5.01 34.59 33.94 22.56 3.9 39.87 21.92 4.32 39.12 21.24 4.32 36.96 20.55 4.66 34.75 19.82 4.89 28.48 3.72 36.25 27.94 4.11 35.49 27.10 4.1 33.49 26.40 4.41 31.48 25.67 4.61 34.31 3.52 32.84 32.19 3.89 32.14 31.97 3.87 30.28 30.20 4.16 28.43 28.38 4.33 19.71 3.55 34.08 19.05 3.86 33.94 18.62 3.97 32.09 18.00 4.19 30.05 17.26 4.41 72 62 67 34.09 24.80 3.4 31.00 24.30 3.7 30.82 23.72 3.79 29.09 23.09 3.98 27.22 22.33 4.19 30.93 29.81 3.25 28.09 27.53 3.53 27.91 27.35 3.6 26.31 25.78 3.78 24.52 24.03 3.96 26.67 13.85 2.88 25.15 13.35 2.98 23.53 12.46 3.2 20.85 11.89 3.3 18.33 11.32 3.5 72 62 67 24.42 17.52 2.7 23.02 17.02 2.8 21.52 16.02 3.0 19.02 15.50 3.1 16.71 15.00 3.3 22.19 21.07 2.53 20.88 20.56 2.61 19.51 18.74 2.81 17.22 16.96 2.9 15.10 14.80 3.1

DY18/KY018

CONDENSER ENTERING AIR TEMP. (0F)

650/0.112

62

67

TC

17.98

19.78

21.71

85 2.1

SC

17.83

14.88

11.68

kW

1.9

TC

16.31

18.01

19.78

95

SC

15.99

14.50

11.24

kW

2.09

2.2

2.31

TC

16.12

17.81

19.61

105

SC

16.05

14.20

11.02

kW

2.18

2.3

2.43

TC

13.99

15.50

17.12

115

SC

13.79

13.20

10.07

kW

2.26

2.4

2.54

TC

12.04

13.39

14.82

125

SC

11.81

12.38

9.29

kW

2.36

2.5

2.65

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: WBL = DBL [DR (DBE WBE)].

1. Capacities above are based on DBE = 800F. For higher or lower DBE, add following Correction Factor = 1.08 x CFM (1 DR) (DBE 80).

2. To calculate leaving conditions, follow this procedure: DBL = DBE (Sensible Capacity (Btuh) / 1.08 x CFM);

3. Multiply cooling capacities by 0.95 for heat pump units.

MULTIPLIERS FOR LOWER CFM


% of rated airflow TC SC kW 100% 1 1 1 95% 0.98 0.965 0.992 90% 0.96 0.93 0.985 85% 0.93 0.90 0.97 80% 0.91 0.87 0.965 75% 0.89 0.845 0.96 70% 0.87 0.82 0.94 60% 0.83 0.78 0.93

FAN PERFORMANCE DATA


MODEL NUMBER BLOWER MOTOR SPEED HIGH DY18 MEDIUM LOW HIGH DY24 MEDIUM LOW HIGH DY30 MEDIUM LOW HIGH DY36 MEDIUM LOW HIGH DY42 MEDIUM LOW HIGH DY48 MEDIUM LOW HIGH DY60 MEDIUM LOW CFM @ EXTERNAL STATIC PRESSURE (Inches of water) 0.0 650 552 470 750 660 552 1050 852 637 1250 1050 852 1400 1225 995 1600 1366 1100 1950 1631 1366 0.05 640 528 445 729 642 528 987 827 614 1209 987 827 1362 1192 975 1590 1338 1065 1900 1601 1338 0.1 591 514 420 698 591 504 960 802 592 1184 960 802 1324 1160 955 1571 1310 1030 1840 1571 1310 0.15 566 478 395 670 566 478 934 775 575 1153 934 775 1291 1130 928 1538 1277 992 1780 1538 1277 0.2 542 452 375 643 542 452 908 748 559 1122 908 748 1258 1100 902 1505 1244 954 1728 1505 1244 0.25 508 421 345 613 508 421 886 727 533 1083 886 727 1218 1064 876 1466 1199 912 1690 1466 1199 0.3 475 390 584 475 864 706 1044 864 1178 1028 1426 1153 1651 1426 0.4 406 333 510 406 804 650 966 804 1102 958 1331 1070 1558 1331 0.5 334 255 427 334 741 594 894 741 1009 877 1245 970 1463 1245 -

NOTE: Values include losses for dry coil and filters.

DIMENSIONS - INDOOR UNITS


DY18 - DY60

4
I

D A

3/4" NPT(14TPI) DRAIN TUBE.

1
38 (1.50")

END VIEW

TOP VIEW

END VIEW

89 (3.50") F

FRONT VIEW

NOTE: All dimensions are in mm (dimensions in brackets are in inches). DIMENSIONS MODEL DY 18 DY 24 DY 30 DY 36 DY 42 DY 48 DY 60 A 904 (35.6) 904 (35.6) 1011 (39.8) 1011 (39.8) 1011 (39.8) 1194 (47) 1194 (47) B 610 (24) 610 (24) 762 (30) 762 (30) 762 (30) 762 (30) 762 (30) C 244 (9.6) 244 (9.6) 318 (12.5) 318 (12.5) 318 (12.5) 368 (14.5) 368 (14.5) D 960 (37.8) 960 (37.8) 1067 (42) 1067 (42) 1067 (42) 1245 (49) 1245 (49) E 521 (20.5) 521 (20.5) 640 (25.2) 640 (25.2) 640 (25.2) 625 (24.6) 625 (24.6) F 769 (30.3) 769 (30.3) 858 (33.8) 858 (33.8) 858 (33.8) 894 (35.2) 894 (35.2) G 183 (7.2) 183 (7.2) 241 (9.5) 241 (9.5) 241 (9.5) 266 (10.5) 266 (10.5) H 841 (33.1) 841 (33.1) 945 (37.2) 945 (37.2) 945 (37.2) 1155 (45.5) 1155 (45.5) I 206 (8.1) 206 (8.1) 259 (10.2) 259 (10.2) 259 (10.2) 292 (11.5) 292 (11.5) 1. Blower & motor assembly 2. Evaporator coil 3. Control box 4. Filter rack 5. Unit mounting brackets (4 Nos.) 6. Duct connection

13 (0.50")

DIMENSIONS - OUTDOOR UNITS


AIR IN

KY018 & KY024


366(14.4)

325 (12.795)

406 (15.984)

SUCTION VALVE AIR IN LIQUID VALVE

70(2.755) DETAIL - A (TYPICAL AT FOUR PLACES)

AIR OUT

SEE DETAIL -A

442 (17.402)

TOP VIEW

800(31.5)

POWER & CONTROL WIRE ENTRY

685(27)

49 (1.929) 14 (0.551)
9.5 (3") FLARE 8 TYPE CONN.

48(1.890) 83 (3.268)

16 (5") FLARE 8 TYPE CONN.

FRONT VIEW

END VIEW

AIR IN

KY030 & KY036


20 (0.79) 15(0.59) 70(2.76)
SEE DETAIL -A

390(15.38)

435(17.16)

AIR IN

DETAIL - A (TYPICAL AT FOUR PLACES)

AIR OUT

133 (5.25)

698(27.5)

TOP VIEW
965(38)

15(0.590)

20 (0.788)

POWER & CONTROL WIRE ENTRY

ACCESS PANEL

727(28.63)

82 (3.25)

9.5 (3") FLARE 8 TYPE CONN.

16(0.63)

19(0.75)

19 (3") FLARE 4 TYPE CONN.

89 (3.5)

FRONT VIEW

END VIEW

NOTE: All dimensions are in mm (dimensions in brackets are in inches).


10

152 (6.0)

431(17)

DIMENSIONS - OUTDOOR UNITS


KY042, KY048 & KY060

AIR IN 20 (0.79) 15(0.6) 390(15.38) AIR IN 435(17.16) 70(2.76) AIR OUT 133 (5.25) 698(27.5) SEE DETAIL-A

DETAIL - A (TYPICAL AT FOUR PLACES)

TOP VIEW
965(38)

POWER & CONTROL WIRE ENTRY

ACCESS PANEL

1158(45.63)

9.5 (3") FLARE 8 TYPE CONN. 16(0.63) 82.(3.25) 22 (7") FLARE 8 TYPE CONN.

FRONT VIEW

27(1.06)

79(3.13)

END VIEW

NOTE: All dimensions are in mm (dimensions in brackets are in inches).

11

146 (5.75)

863(34)

TYPICAL SCHEMATIC WIRING DIAGRAM


COOL MODELS
LEGEND
TO FUSE DISCONNECT SWITCH L2/N L1 GND

ATB CAP COMP


COM

AUXILIARY TERMINAL BLOCK CAPACITOR COMPRESSOR COMMON ELECTRONIC CONTROL BOARD FUSE LINK FAN MOTOR LUG GROUND HIGH FAN LINE 1 LINE 2 OR NEUTRAL LOW FAN MEDIUM FAN FIELD WIRING FACTORY WIRING

230VAC

COM ECB FL
BRN CAP BRN

*** ** *
Refer to table below for Speed Connections. 15 39A ATB 1

FM GND HF

TO 6 COND.UNIT

L1 L2 LF
LCD CONTROL PANEL

N1 N2

LOW LIVE HI BLK HIGH MED MED-HI VIO MED BLU COM COMP

MF ___

CN4

ID

INDOOR DE-ICE SENSOR

NOTES
CABLE CONNECTIONS AT LCD CONTROL PANEL TB

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE. 2. USE COPPER CONDUCTOR WIRES ONLY. 3. MOTORS ARE THERMALLY PROTECTED. 4. REFER TO INTERCONNECTING WIRING DIAGRAM BEFORE INSTALLATION 5. DO NOT ROUTE ATB1(5) FROM CONDENSING UNIT

FM SPEED CONNECTIONS
SPEED WIRE COLOR MODEL DY 18 DY 24 DY 30 DY 36 DY 42 DY 48 DY 60 MED-LOW ORN LOW RED LOWEST GRY COM YEL APPLICABLE FREQUENCY IN HERTZ

1) RED 2) BLK 3) WHT

5V GND TX RCV

** ** *** *** *** ** *** *** **

*** ***

* * ** ** * ** *

60 60

* * *

60 60 60 60 60

INTERCONNECTING DETAILS BETWEEN INDOOR & OUTDOOR UNIT


NOTE: Route wires according to diagram below & ignore all other terminal connection on outdoor unit.

ATB 1 INDOOR UNIT DY SERIES 6 1 6

ATB INDOOR UNIT DY SERIES

OUTDOOR UNIT KY SERIES

OUTDOOR UNIT KY SERIES

ATB

4/6

ATB

12

TYPICAL SCHEMATIC WIRING DIAGRAM


HEAT PUMP MODELS
LEGEND
TO FUSE DISCONNECT SWITCH L1 GND L2/N 230VAC COM

ATB CAP COMP COM ECB FL FM GND HF


TO COND.UNIT

AUXILIARY TERMINAL BLOCK CAPACITOR COMPRESSOR COMMON ELECTRONIC CONTROL BOARD FUSE LINK FAN MOTOR LUG GROUND HIGH FAN LINE 1 LINE 2 OR NEUTRAL LOW FAN MEDIUM FAN OUTDOOR FAN

*** ** * Refer to table below for


Speed Connections.

BRN CAP BRN ATB 15 1 39A 6 21 21A 8 T3A/N 37A


NOTE:

L1 L2 LF MF
LCD CONTROL PANEL

21B

N1 LOW N2 OF/I OF/O 4WV COM COMP OD CN4 ECB ID LIVE HIGH MED

FIX THE OUTDOOR DE-ICE SENSOR TO THE TUBE PROVIDED ON THE

OF

RETURN BEND OF THE OUTDOOR COIL. OUTDOOR DE-ICE SENSOR

4WV/RV FOUR WAY/REVERSING VALVE ___ FIELD WIRING FACTORY WIRING

INDOOR DE-ICE SENSOR CABLE CONNECTIONS AT LCD CONTROL PANEL TB 1) RED COM YEL APPLICABLE FREQUENCY IN HERTZ 2) BLK 3) WHT GND TX RCV 5V

NOTES 1. POWER SUPPLY, REFER TO UNIT NAMEPLATE. 2. USE COPPER CONDUCTOR WIRES ONLY. 3. MOTORS ARE THERMALLY PROTECTED. 4. REFER TO INTERCONNECTING WIRING DIAGRAM BEFORE INSTALLATION 5. DO NOT ROUTE ATB1(5) FROM CONDENSING UNIT 6. T3A/N & 37A ARE TERMINAL MARKINGS FOR JP4 ON CONDENSER FAN MOTOR CONNECTION. T3A/N IS T1 ON SINGLE PHASE CONDENSER UNITS.

FM SPEED CONNECTIONS
SPEED WIRE COLOR MODEL DY 18 DY 24 DY 30 DY 36 DY 42 DY 48 DY 60 HI BLK MED-HI VIO MED BLU MED-LOW ORN LOW RED LOWEST GRY

*** ***

** ** *** *** *** ** *** *** **

* * ** ** * ** *

60 60

* * *

60 60 60 60 60

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
ATB 1 6 8 T3A/N 37A ATB 1 6 8 T3A/N 37A

INDOOR UNIT DY SERIES OUTDOOR UNIT KY SERIES ATB ATB 1 5 6 8

INDOOR UNIT DY SERIES

OUTDOOR UNIT KY SERIES

4/6

T3A T3A PNK BLK 37A CAP COMP 35A

37A 36A

FM
O/L R

COMP

FM

NOTE: T3A IS T1 ON 1PH CONDENSER UNITS

13

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.

ELECTRICAL
Please ensure power supply (V-Ph-Hz) to the unit is as per unit nameplate requirements. Caution: Operation of the unit on improper power supply will result in damage to the unit. Warning: Before installation or servicing, always TURN OFF all power to the unit. There may be more than one disconnect switch. Ensure all of them are turned off.

Ground & Power wires


Connect power wires as per wiring diagram. Connect ground wire to the ground lug inside the control box.

Control wiring between outdoor & indoor units


Use 16 gauge color-coded wire between the indoor and outdoor units (control wiring). Then match the auxiliary terminal block (ATB) numbers (indoor and outdoor units) to interconnect the two units. Note: 1. Field wiring to comply with local Safety and Fire codes. 2. Use copper wires of proper rating for all field wiring. 3. 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.

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 hot water. If filter has been put to exceptional service, a mild solution of Sal-Soda, Tri-Sodium Phosphate or any other commercial solvent can be used. 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.

14

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 KY018, 024 & 030

AIR IN

254mm (10") FOR KY036 AND ABOVE

254mm (10") FOR KY036 AND ABOVE

203mm (8") FOR KY018, 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.
15

ELECTRICAL
STEP 1: INSTALLATION
A) Please ensure power supply to the unit is as per unit nameplate (Volts/Ph/Hz) requirements. Caution: Operation of the unit on improper power supply 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) Control wiring between outdoor & indoor unit Use 16 gauge color-coded wire between the indoor and outdoor units (control wiring).

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 550F (12.70C). Maximum outdoor operating air temperature during cooling mode is 1300F (550C). 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 connector provided.

16

SERVICING INSTRUCTIONS

es cc

sf

lo rb

rs we
CM

to mo &

95

30

CM

Blower deck holding bolt


50 CM

Blower deck

50

CM

Bottom panel

NOTE: 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.

17

PARTS LIST
INDOOR UNITS
MODEL NUMBER FAN DECK ASSEMBLY BLOWER MOTOR FILTER ORIFICE DISTRIBUTOR ORIFICE PISTON THERMOSTAT, COOL THERMOSTAT, HEAT PUMP DY18 800-089-71 800-547-51 800-249-39 800-194-10 800-195-13 800-645-95 800-645-97 DY24 800-089-71 800-547-51 800-249-39 800-194-10 800-195-13 800-645-95 800-645-97 DY30 800-089-72 800-547-52 800-249-38 800-194-14 800-195-15 800-645-95 800-645-97 DY36 800-089-72 800-547-52 800-249-38 800-194-14 800-195-16 800-645-95 800-645-97 DY42 800-089-72 800-547-52 800-249-38 800-194-14 800-195-17 800-645-95 800-645-97 DY48 800-089-73 800-547-53 800-249-36 800-194-16 800-195-20 800-645-95 800-645-97 DY60 800-089-73 800-547-53 800-249-36 800-194-16 800-195-22 800-645-95 800-645-97

OUTDOOR UNITS
MODEL NUMBER COMPRESSOR, COOL ONLY COMPRESSOR, HEAT PUMP FAN MOTOR FAN MOTOR CAPACITOR CONDENSER FAN COMPRESSOR CONTACTOR TRANSFORMER (24V) LOW PRESSURE SWITCH MODEL NUMBER COMPRESSOR FAN MOTOR FAN MOTOR CAPACITOR CONDENSER FAN COMPRESSOR CONTACTOR TRANSFORMER (24V) LOW PRESSURE SWITCH KY018C 800-675-79 800-675-86 800-555-32 800-224-19 800-736-01 800-012-30 800-557-00 KY036C 800-684-01 800-545-97 800-353-15 800-941-41 800-097-00 800-012-30 800-557-00 KY024C 800-675-80 800-675-87 800-555-32 800-224-19 800-736-01 800-012-30 800-557-00 KY036H 800-684-04 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00 KY030C 800-675-89 800-675-90 800-545-97 800-353-15 800-941-41 800-097-00 800-012-30 800-557-00 KY036M 800-684-14 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00 KY030H 800-684-04 800-684-04 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00 KY036F 800-684-07 800-545-96 800-353-15 800-941-41 800-095-00 800-012-31 800-557-00 KY030M 800-684-14 800-684-14 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00 KY042C 800-684-02 800-545-97 800-353-15 800-941-41 800-097-00 800-012-30 800-557-00 KY030F 800-684-07 800-684-07 800-545-96 800-353-15 800-941-41 800-095-00 800-012-31 800-557-00 KY042H 800-684-05 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00

MODEL NUMBER COMPRESSOR FAN MOTOR FAN MOTOR CAPACITOR CONDENSER FAN COMPRESSOR CONTACTOR TRANSFORMER (24V) LOW PRESSURE SWITCH

KY042M 800-684-09 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00

KY042F 800-684-08 800-545-96 800-353-15 800-941-41 800-095-00 800-012-31 800-557-00

KY048C 800-684-03 800-545-97 800-353-15 800-941-41 800-097-00 800-012-30 800-557-00

KY048H 800-684-06 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00

KY048M 800-684-09 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00

KY048F 800-684-09 800-545-96 800-353-15 800-941-41 800-095-00 800-012-31 800-557-00

MODEL NUMBER COMPRESSOR FAN MOTOR FAN MOTOR CAPACITOR CONDENSER FAN COMPRESSOR CONTACTOR TRANSFORMER (24V) LOW PRESSURE SWITCH

KY060C 800-672-59 800-545-97 800-353-15 800-941-41 800-736-23 800-012-30 800-557-00

KY060H 800-672-51 800-545-97 800-353-15 800-941-41 800-097-00 800-012-30 800-557-00

KY060M 800-672-52 800-545-97 800-353-15 800-941-41 800-095-00 800-012-30 800-557-00

KY060F 800-672-52 800-545-96 800-353-15 800-941-41 800-095-00 800-012-31 800-557-00

PL-AP-DYS-06-2M-E