Vertical Packaged Units

PV Series
PV036 thru PV060
3 TR thru 5 TR
10 kW thru 17.5 kW
Company Business
Zamil Air Conditioners was founded in 1974, and is the first major business venture in manufacturing sector for the Al Zamil
group of Companies. It is also the first manufacturing unit for air conditioners to be established in Saudi Arabia.
Zamil Air conditioners manufactures both consumer and central range of air conditioners and has sales operations in over
55 countries in the Middle East, Europe, America, Africa, Australia and the Far East.
The companys operations are structured into four Strategic Business Units (SBUs) supporting six in - house product and
service brands as well as a number of international brands under the OEM sales.
The six in-house brands are Classic, Cooline, CoolCare, Clima Tech, Geoclima and Kessler Clima Tech.
The four SBUs are:
1. Consumer Business unit supporting Classic, Cooline, GE and OEM brands for consumer range of air conditioners.
2. Unitary & Applied Business unit supporting Classic, Cooline, GE and OEM brands for commercial range of air
conditioners.
3. Zamil CoolCare - service and maintenance provider.
4. Geoclima srl - independent business and supporting other SBUs for their requirement of Chillers & Double skin AHUs.
The first three SBUs - Consumer Products, Unitary & Applied Products and Zamil CoolCare direct their business operations
from the corporate headquarters at Dammam, Saudi Arabia.
The production facilities at Dammam are shared by Consumer Products and Unitary & Applied Products. Geoclima has its
own production and functional departments located at Monfalcone, Italy.
All the four SBUs, while operating independently, supplement each others activities in a way that makes synergy work at
its best and achieve the corporate goals of increased productivity and efficiently.
Factories and Productions
Zamil Air Conditioners has its prime manufacturing base at Dammam, Saudi Arabia and has one speciality production
facility in Italy operated by Geoclima.
The company can produce up to 440,000 room air conditioners, 60,000 mini-split systems and 36,500 central air-condition-
ing systems per year.
Quality & Product Certificates
The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification.
Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization)
certificate for room air conditioners. Its products and services are also certified with:
1. CE (Council of European Community)
2. UL (Underwriters Laboratory)
3. AHAM certificate (Association of Home Appliance Manufacturers)
4. Eurovent
5. DEMKO
6. ETL
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
In addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air
Conditioners manufacturers a host of residential and commercial air conditioners. This board range extends from the
concealed units up to 5 ton, the ducted splits up to 30 tons, the packaged units up to 70 tons. The single and double skin
air handling units up to 130,000 CFM and the water chillers up to 487 ton cooling capacity.
Contents Page
Model decoding ......................................................................................................................................... 2
Unit features .......................................................................................................................................... 3-4
Physical data ............................................................................................................................................ 5
Cooling capacities ..................................................................................................................................... 6
Electrical data ........................................................................................................................................... 6
Dimensions ............................................................................................................................................... 7
Access details .......................................................................................................................................... 8
Typical schematic wiring diagram ........................................................................................................ 9-10
Parts list ................................................................................................................................................. 11
INDEX
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
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2
UNIT FEATURES
A. GENERAL
The wall mounted vertical packaged units from "Zamil Air Conditioners" are designed for optimum cooling, convenience and
dependability, which make them suitable for most demanding applications such as telecom industry, beside general air-
conditioning applications. These self contained units have the sheet metal panels designed to provide service access for
compressors and electrical controls even when two units are mounted side by side with minimal space in between. Filters
and controls are accessible from the back of the unit.
B. UNIT ENCLOSURE
Panels are of heavy gauge, G-90 galvanized steel sheet with removable access panels, completely weatherized for outdoor
installation and properly reinforced & brazed. Panels and access doors will provide easy inspection and access to all
internal parts. Enclosures are provided with adequately reinforced points of support for wall mounting application. 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, followed by baked-on electrostatic polyester dry powder coat, and capable of withstanding 1500
hours in salt spray test.
C. COMPRESSOR
Compressors are fully hermetic type, provided with all standard controls necessary for safe operation. These are equipped
with internal motor protector, factory-installed crankcase heater and rubber vibration isolators for quiet and efficient opera-
tion. Scroll compressors are installed as standard on these units. Reciprocating hermetic compressors can be available
as an option.
D. AIR COOLED CONDENSING SECTION
1. The air-cooled condensing section is enclosed within the unit housing and consists of condenser coil, fan, electric motor
and inherently protected compressor. All condenser coils are of the corrugated fin-and-tube type constructed of seam-
less copper tubes with wall thickness of 0.014 inches (0.356 mm), mechanically bonded to aluminum fins. Return bends
have 0.022 inch thickness (0.56 mm). As an option, corrugated copper fins or coated aluminum fins may be
provided. Tube support sheets are galvanized steel, formed to provide structural strength.
2. Fans are propeller type, direct drive, with side air discharge through the condenser coil.
3. Motors are totally enclosed air-over type. Inherent thermal protection is automatic reset type.
E. EVAPORATOR COIL SECTION
1. All cooling coils are of the corrugated fin-and-tube type constructed of seamless copper tubes with wall thickness of
0.014 inches (0.356 mm), mechanically bonded to aluminum fins. Return bends have 0.022 inch thickness (0.56 mm).
As an option, corrugated copper fins or coated aluminum fins may be provided. Tube support sheets are
galvanized steel, formed to provide structural strength. The refrigerant metering device is a thermostatic expansion
valve. A coated galvanized steel condensate drain pan is provided.
2. Insulation: Insulation is supplied in adequate thickness (1/2) and density to prevent condensation from forming on the
unit casing. Insulation meets the requirements of NFPA 90A and is protected against deterioration and erosion from air
panels.
F. EVAPORATOR BLOWER ASSEMBLY.
The direct drive evaporator blowers are of the centrifugal forward curved design. The twin blower wheels are constructed of
steel, and they are statically and dynamically balanced for quiet and smooth performance. Motors are permanent split
capacitor type with tapped speed windings to suit various air delivery requirements corresponding to each model. The
bearings are of sleeve type.
G. FILTERS
Two inch Pleated high efficiency filters are provided as standard.
3
H. ELECTRICAL CONTROLS
1. For normal air-conditioning applications
This packaged unit control consists of Systemizer
TM
Microprocessor Based Electronic Control Board, incorporating the
following features:
(a) Compressor Lockout. If any of the units 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.
(c) Indicator LED lights:
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 changeover 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.
I. OUTSIDE AIR OPTIONS
Fresh air Inlet with manual damper can be provided as an option for adding upto 25% fresh air as required.
4
MODEL NUMBER PV036 PV048 PV060
NOMINAL CAPACITY (TONS) 3 4 5
COOLING CAPACITIES Total capacity (BTUH) 38200 48200 59000
(@ 80
0
F DB/62
0
F WB indoor, 95
0
F outdoor)
Sensible capacity (BTUH) 28200 36600 43200
COOLING CAPACITIES Total capacity (BTUH) 30400 39600 49000
(@ 74
0
F DB/62
0
F WB indoor, 115
0
F outdoor)
Sensible capacity (BTUH) 24800 33200 38000
COMPRESSOR Type Scroll
Quantity 1 1 1
Oil (oz) 42 46 66
Refrigerant R-22
Operating Charge (oz) 115 147 198
CONDENSER FAN Type Propeller
Quantity Diameter (inch) 1 18 1 24 1 24
Nominal CFM 3000 3000 2700
Motor HP RPM 1/4 1075 1/3 1075 1/3 1075
CONDENSER COIL Type Corrugated Fin and Tube
Tube dia. - Rows - Fins per inch 3/8-3-16 3/8-3-16 3/8-4-16
Total face area (Sq. ft.) 6.4 8 8
EVAPORATOR BLOWER Type Centrifugal
Size (inch) 7 x 9.5 (2 Nos.) 8 x 8.5 (2 Nos.) 8 x 8.5 (2 Nos.)
Drive type Direct drive
Nominal airflow, CFM 1200 1600 1800
Motor watts 700 870 940
EVAPORATOR COIL Type Corrugated Fin and Tube
Tube dia. - Rows - Fins per inch 3/8-4-14 3/8-4-14 3/8-4-14
Total face area (Sq. ft.) 3.4 5 5
RETURN AIR FILTERS Quantity 1 1 1
Size (inch) 30 x 22 x 2 36 x 22 x 2 36 x 22 x 2
WEIGHT Kgs. 190 255 265
PHYSICAL DATA
5
CONDENSER
ENTERING AIR
TEMP. (
0
F)
Model No.: PV036, PV048 & PV060
62 67 72 62 67 72 62 67 72
36.4 39.7 42.9 46.0 50.1 54.2 56.1 61.4 66.7
34.0 29.5 22.8 44.0 37.9 29.2 53.8 45.2 34.3
3.45 3.50 3.60 4.90 5.00 5.10 6.00 6.20 6.30
35.1 38.2 41.4 44.4 48.2 52.3 54.1 59.0 63.5
33.0 28.2 22.3 43.0 36.6 28.6 52.0 44.2 33.6
3.82 3.88 3.95 5.40 5.50 5.60 6.50 6.70 6.80
32.1 35.8 38.9 42.7 46.0 50.3 52.1 56.6 61.2
30.2 27.5 21.8 41.0 35.6 27.9 50.1 43.6 32.8
4.13 4.21 4.24 5.90 6.00 6.10 7.27 7.37 7.50
30.4 33.6 36.8 39.6 43.5 47.3 49.0 54.1 58.9
29.6 26.2 21.3 39.1 34.5 27.3 48.3 42.8 32.0
4.54 4.60 4.67 6.40 6.50 6.55 7.90 8.10 8.20
28.9 31.9 34.7 38.2 42.1 46.2 47.9 52.2 56.5
28.1 25.4 20.8 37.4 33.6 26.6 46.9 41.0 31.3
4.80 4.90 4.98 6.80 6.90 7.00 8.50 8.60 8.70
TC
85 SC
kW
TC
95 SC
kW
TC
105 SC
kW
TC
115 SC
kW
TC
125 SC
kW
EVAPORATOR AIRFLOW, CFM/DR
1200/0.042 1600/0.059 1800/0.067
EVAPORATOR ENTERING AIR, WBE (
0
F)
COOLING CAPACITIES
NOTES: 1. Direct interpolation is permissible Do not extrapolate.
2. Capacities above are based on DBE = 80
0
F. For higher or lower DBE, add following correction factor to sensible capacity = 1.08 x CFM (1 DR) (DBE 80).
3. To calculate leaving conditions, follow this procedure: DBL = DBE (Sensible Capacity (Btuh) / 1.08 x CFM); WBL = DBL [DR (DBE WBE)].
TC Total Capacity (1000 Btuh) Gross
SC Sensible Heat Capacity (1000 Btuh) Gross
DBE Dry Bulb Temp. (
0
F) of Air Entering Coil
WBE Wet Bulb Temp. (
0
F) of Air Entering Coil
DBL Dry Bulb Temp. (
0
F) of Air Leaving Coil
WBL Wet Bulb Temp. (
0
F) of Air Leaving Coil
kW Total unit power input
DR Wet Bulb depression ratio
PV036 PV048 PV060
6
ELECTRICAL DATA
COMPRESSOR *
FAN
MOTOR
FLA
VOLTAGE
RANGE
POWER
SUPPLY
(V-Ph-Hz)
MODEL No.: PV036
MIN. MAX. RLA LRA
208/230-3-60 187 253 11.4 77 1.9 3.6 19.7 30
MCA MOCP
*
BLOWER
MOTOR
FLA
COMPRESSOR *
FAN
MOTOR
FLA
VOLTAGE
RANGE
POWER
SUPPLY
(V-Ph-Hz)
MODEL No.: PV048
MIN. MAX. RLA LRA
208/230-3-60 187 253 16.4 91 2.1 4.6 27.2 40
342 418 9.3 54 2.1 4.6 18.3 25
MCA MOCP
*
BLOWER
MOTOR
FLA
380-3-60
(4 WIRE)
COMPRESSOR *
FAN
MOTOR
FLA
VOLTAGE
RANGE
POWER
SUPPLY
(V-Ph-Hz)
MODEL No.: PV060
MIN. MAX. RLA LRA
208/230-3-60 187 253 20.7 139 2.1 4.6 32.6 50
342 418 10.7 64 2.1 4.6 20 30
MCA MOCP
*
BLOWER
MOTOR
FLA
380-3-60
(4 WIRE)
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
DIMENSIONS
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).
MODEL
NUMBER
DIMENSIONS
B C D E
PV036
PV048
PV060
2000 (78.7)
2134 (84)
2134 (84)
980 (38.6)
1143 (45)
1143 (45)
920 (36.2)
1067 (42)
1067 (42)
908 (35.8)
662 (26.1)
662 (26.1)
457 (18)
762 (30)
762 (30)
A F H
762 (30)
767 (30.2)
767 (30.2)
762 (30)
759 (29.9)
759 (29.9)
203 (8)
251 (9.9)
251 (9.9)
G I
350 (13.8)
403 (15.9)
403 (15.9)
FRONT VIEW
TOP VIEW
END VIEW
CONDENSER COIL
COND. AIR INLET
CONTROL BOX
EVAPORATOR COIL
SUPPLY AIR
RETURN AIR
SUPPLY AIR OPENING
RETURN AIR OPENING
F
610 [24]
H
!
G
MOUNTING FLANGE
FILTER
D
5
1

[
2
]
E
A
C
B
PV036 - PV060
7
ACCESS DETAILS
PV036 - PV060
8
(FROM SIDE)
COMPRESSOR ACCESS
LEFT SIDE ACCESS
(FROM SIDE)
COMPRESSOR ACCESS
RIGHT SIDE ACCESS
FILTER & ELE. CONTROLS
(FROM BACK SIDE)
FILTER & ELE. CONTROLS
(FROM BACK SIDE)
TYPICAL SCHEMATIC WIRING DIAGRAM
LEGEND
ATB AUXILIARY TERMINAL BLOCK
BM BLOWER MOTOR
BMC BLOWER MOTOR CONTACTOR
CC COMPRESSOR CONTACTOR
CB CIRCUIT BREAKER
C. HTR CRANKCASE HEATER
COMP COMPRESSOR
FL FUSE LINK
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
N NEUTRAL
NTB NEUTRAL TERMINAL BLOCK
SM SYSTEMIZER
FIELD WIRING
DISCONNECT TAB - 1/4"
SPLICE-CLOSED END
_ _ _
+
(For normal air-conditioning applications)
MODEL PV036 PV048 PV060
BLK BLU BLK
FACTORY INSTALLED
BM SPEED (WIRE COLOR)
NOTES
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
THERMOSTAT CONTROL VOLTAGE - 24VAC.
2. 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 OPERAT-
ING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE-
SULT 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 REC-
OMMENDED 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 COMPRES-
SOR ANTI-RECYCLING TIMER.
11. NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER
SUPPLY ONLY.
+
9
NTB
REFER TO UNIT
NAMEPLATE FOR
POWER SUPPLY
N (SEE NOTE -11)
TYPICAL SCHEMATIC WIRING DIAGRAM
(For communication shelter applications)
10
(SEE NOTE -8)
L2 OF BM TO NTB
1. FOR UNITS WITH ABOVE VOLTAGE CONNECT 37A OF FM &
NOTE:
NTB
SET POINTS
NOTES
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
2. 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 OPERAT-
ING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RE-
SULT IN COMPRESSOR DAMAGE.
4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER
TO BE PROVIDED BY CONSUMER WITH RATING AS REC-
OMMENDED BY ZAMIL.
5. COMPRESSOR IS PROVIDED WITH INTERNAL OVERLOAD.
6. USE DISCONNECT TAB OR SPLICE ONLY WHEREEVER
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
BLK BLU BLK
FACTORY INSTALLED
BM SPEED (WIRE COLOR)
* CONTROLLER SETUP IS FOR 2 UNITS.
LEGEND
ATB AUXILIARY TERMINAL BLOCK
BM BLOWER MOTOR
BMC BLOWER MOTOR CONTACTOR
CC COMPRESSOR CONTACTOR
CB CIRCUIT BREAKER
C. HTR CRANKCASE HEATER
COMP COMPRESSOR
FL FUSE LINK
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
N NEUTRAL
NTB NEUTRAL TERMINAL BLOCK
FIELD WIRING
DISCONNECT TAB - 1/4"
SPLICE-CLOSED END
_ _ _
+
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11
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 N.A. 800-557-31 800-557-31 800-557-31 800-557-31
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
PARTS LIST
* BLOWER WHEEL ONLY
PL-AP-PVS-08-2M-E