Company Business

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 and is Number One in the Middle East.
Zamil Air conditioners manufactures both consumer and central air conditioners and has sales operations in over 55
countries in the Middle East, Europe, Africa and Asia.
The companys operations are structured into four Strategic Business Units (SBUs) supporting five in-house product and
service brands as well as a number of international brands under the OEM sales.
The five in-house brands are Classic, Cooline, CoolCare, Clima Tech and Geoclima.
The four SBUs are:
1. Consumer Business Unit supporting Classic, Cooline, GE and OEM brands for consumers.
2. Unitary & Applied Business Unit supporting Zamil, Cooline, GE and OEM brands for commercial and industrial customers.
3. Zamil CoolCare Business Unit providing industrial, electro mechanical contracting services, HVAC maintenance, retrofit
& operation services and parts.
4. Geoclima srl is an independent business supporting other SBUs for their requirements of chillers & double skin AHUs.
The first three SBUs - Consumer Products, Unitary & Applied Products and CoolCare direct their business operations from
the corporate headquarters in Dammam, Saudi Arabia.
Geoclima has its engineering & production operations located at Monfalcone, Italy and has a design center in Austria.
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 maximizing customer satisfaction.
Factories and Productions
Zamil Air Conditioners has two manufacturing plants in Dammam, Saudi Arabia and has one specialty production facility in
Italy operated by Geoclima.
The company can produce up to 550,000 Room Air Conditioners, 300,000 Mini-Split systems and 50,000 Central Air
Conditioning systems per year.
Quality & Product
The Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2008 certification.
Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabias Standard Organization)
Certificate for Room Air Conditioners. ZACs products are also certified with:
1. CE (Council of European Community)
2. UL (Underwriters Laboratory)
3. Eurovent (for Fan Coil units and Air handling units, see www.eurovent-certification.com)
4. ETL (Test Facilities)
5. SASO (Saudi Arabian Standards Organization)
6. ISO 9001:2008 (International Organization for Standardization)
7. ASME (American Quality of Mechanical Engineers)
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, commercial and industrial air conditioners. This broad range extends from the Concealed
Units up to 5 TR, the Ducted Splits up to 30 TR, the Packaged Units up to 95 TR, the Single and Double Skin Air Handling Units
up to 138,316 CFM and the Water Chillers up to 600 TR cooling capacity. In addition, centrifugal chillers - powered by MHI
compressors - are available up to 5,000 TR.
Contents Page
Features ................................................................................................................................................... 2
Model decoding........................................................................................................................................ 3
Matching condensing units ....................................................................................................................... 3
Indoor unit features .................................................................................................................................. 4
Standard specifications ............................................................................................................................ 4
Outdoor unit features................................................................................................................................ 5
Microprocessor controlled thermostat ...................................................................................................... 6
Physical data............................................................................................................................................ 7
Cooling capacities .................................................................................................................................... 8
Fan performance data .............................................................................................................................. 9
Dimensions, indoor units ........................................................................................................................ 10
Dimensions, outdoor units ................................................................................................................. 11-12
Typical schematic wiring diagram...................................................................................................... 13-14
Installation, operation & maintenance ............................................................................................... 15-16
Electrical ................................................................................................................................................. 17
System design........................................................................................................................................ 17
Servicing instructions ............................................................................................................................. 18
Recommended spare parts list............................................................................................................... 19
Parts list ................................................................................................................... ......................... 20
INDEX
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 :
*
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
OUTDOOR UNIT :
*
G-90 GALVANIZED HEAVY GAUGE PANELS
*
PAINT: ELECTROSTATIC POWDER COAT
COOL GRAY COLOR
*
HIGH EFFICIENCY TROPICAL DESIGN
*
POWERFUL COMPRESSOR
*
230 VOLT CONTROL
*
OPERATES UP TO 55
0
C AMBIENT TEMPERATURE
*
EXTERNAL SERVICE VALVES WITH GAUGE PORTS
*
LOW PRESSURE SWITCH
*
OPTIONAL COPPER OR COATED ALUMINUM FINS
*
COIL GUARD PROTECTION
*
SIDE AIR DISCHARGE
INDOOR UNIT - 'DY' SERIES
OUTDOOR UNIT - 'KY' SERIES
(MODELS: KY042 - KY060)
2
MODEL DECODING
1 & 2
BASIC
3, 4 & 5
NOMINAL
COOLING
CAPACITY
(MBH)
7
REFRIGERA-
TION CIRCUIT
6
ELECTRICAL
SUPPLY
( V-Ph-Hz )
9
MODE
11
CONDENSER
COI L
KY
CONDENSING
UNIT
018
024
030
036
042
048
060
S: SINGLE C : 208/230-1-60
H : 208/230-3-60*
M: 380-3-60*
(4 WIRE)
F : 460-3-60*
C: COOL ONLY
H: HEAT PUMP
A : ALUMINUM FIN
B :COATED
ALUMINUM FIN
C: COPPER FIN
8
COMPRESSOR
TYPE
R: HERMETIC
COMPRES-
SOR
13
OPTIONS
10
CONDENSER
MOTOR
N: STANDARD
L : LOW
AMBIENT**
12
ACCESSORIES
N : STANDARD
UNIT
F : STANDARD
UNIT WITH
FILTER
DRIER &
SIGHT
GLASS
N : STANDARD UNIT
B : SECOND
GENERATION
UNIT (FOR KY030
ONLY)
*
Applicable for KY030 - KY060 models only.
**
Applicable for KY036 - KY060 models only.
INDOOR UNIT
OUTDOOR UNIT
1 & 2
BASIC (SERIES)
3 & 4
COOLING CAPAC-
ITY (x 1000 BTUH)
5
ELECTRICAL
SUPPLY (V-Ph-Hz)
8
FIN
7
ACCESSORIES
11
OPTION
DY
DUCTED SPLIT
FAN COIL UNIT
18
24
30
36
42
48
60
C : 208/230-1-60 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
N : STANDARD N : STANDARD
UNIT
6
REFRIGERATION
SYSTEM
C: COOL ONLY
H: HEAT PUMP
10
FILTER
N : NONE
A : ALUMINUM
C : SYNTHETIC
9
COIL
CONNECTION
R : RH SIDE
(FACING AIR
DISCHARGE)
*
These options are for matching DY18/DY24/DY30 heat pump units with KY018/KY024/KY030 condensing units and also for matching DY36 to DY60 heat pump units with
CX036 to CX060 condensing units.
INDOOR UNIT MODE
DY18
COOL DY18CCNDRAN KY018CSRCNANN
HEAT PUMP DY18CHNARAN KY018CSRHNANN
DY24
COOL DY24CCNDRAN KY024CSRCNANN
HEAT PUMP DY24CHNARAN KY024CSRHNANN
DY30
COOL DY30CCNDRAN KY030CSRCNANB
HEAT PUMP DY30CHNARAN KY030CSRHNANB
DY36
COOL DY36CCNDRAN KY036HSRCNANN
HEAT PUMP DY36CHNDRAN KY036HSRHNANN
DY42
COOL DY42CCNDRAN KY042HSRCNANN
HEAT PUMP DY42CHNDRAN KY042HSRHNANN
DY48
COOL DY48CCNDRAN KY048HSRCNANN
HEAT PUMP DY48CHNDRAN KY048HSRHNANN
DY60
COOL DY60CCNDRAN KY060HSRCNANN
HEAT PUMP DY60CHNDRAN KY060HSRHNANN
MATCHING INDOOR/OUTDOOR UNITS
(FAN COIL UNIT)
NOTE: Refer to indoor/outdoor model decoding for other available voltages.
OUTDOOR UNITS INDOOR UNITS
3
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.
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 refrig-
erant metering device on all models (except DY18/DY24/DY30 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 elimi-
nates 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.
Quiet Operation Digital Thermostat Compact Dimensions High Cooling Capacity Easy Installation
4
OUTDOOR UNIT FEATURES
A. GENERAL
The Zamil side discharge condensing units incorporate the latest innovative technology to provide quiet, reliable perfor-
mance. 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.
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 opera-
tion. 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. 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 on KY036 - KY060
(except KY018, KY024 & KY030 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.
G. HIGH PRESSURE SWITCH
Auto reset SPST switch activated by refrigerant pressure - locks out the compressor, if the refrigerant pressure rises above
450 PSIG. Also provides additional protection against compressor damage due to loss of outdoor airflow.
Low Noise Level Powerful Hermetic Compressor High Energy Efficiency Ratio
5
FEATURES BENEFITS
Wired remote controller with Liquid Crystal Display (LCD) 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.
Three speed fan with AUTO mode Cover the whole range of CFM/capacity requirements.
SLEEP mode To raise/lower temperature setting by a maximum of 2
0
F 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.
Hot Start No cold air blow in the room at start-up on HEAT mode.
Cold Stop Use of the remaining thermal energy stored in evaporator coil after unit stop (HEAT mode).
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
0
C or
0
F.
ON/OFF status LED indicator To inform on the status of operation.
MICROPROCESSOR CONTROLLED THERMOSTAT
6
7
MODEL
INDOOR UNIT DY 18 DY 24 DY 30 DY 36 DY 42 DY 48 DY 60
OUTDOOR UNIT KY 018 KY 024 KY 030 KY 036 KY 042 KY 048 KY 060
PERFORMANCE
Cooling capacity at high fan speed, BTUH/kW 18000/5.27 23000/6.74 30000/8.8 36200/10.6 44100/12.9 50000/14.6 58000/16.9
Total unit power input, kW/EER 2.2/8.0 2.8/7.9 3.6/7.9 4.1/8.4 5.0/8.4 5.7/8.4 7.3/7.5
Heating capacity at high speed, BTUH/kW 19000/5.56 23750/6.96 31000/9.09 36000/10.55 42300/12.38 46000/13.46 59000/17.27
Total unit power input, kW/COP 2.1/2.7 2.7/2.6 3.3/2.8 3.8/2.8 4.4/2.8 4.4/3.1 6.1/2.8
Evaporator airflow, CFM (high/medium/low) 650/550/450 750/650/550 1050/850/650 1250/1050/850 1400/1250/10001600/1350/11001950/1600/1350
Sound pressure level, dBA (high/medium/low) 36/34/33 42/36/35 44/41/37 44/41/37 46/44/40 37/34/31 41/37/34
INDOOR UNIT
Power supply (V-Ph-Hz) 208/230-1-60
Blower quantity 2 2 2 2 2 2 2
Watts - RPM 180 - 1270 220 - 1490 458 - 1400 480 - 1400 564 - 1500 695 - 1240 819 - 1400
Blower motor
FLA 1.2 1.2 2.6 2.6 2.6 3.6 3.6
Face area, ft
2
2.2 2.2 3 3 3 4.4 4.4
Evaporator coil Tube dia, inch 3/8 3/8 3/8 3/8 3/8 3/8 3/8
No. of rows/FPI 3/14 3/14 3/14 3/14 4/14 4/14 4/14
Suction - Liquid line, inch 5/8 - 3/8 5/8 - 3/8 3/4 - 3/8 3/4 - 3/8 3/4 - 3/8 7/8 -1/2 7/8 -1/2
Return air filter (1/2" thick) size, inch & quantity 8x16.5 (2) 8x16.5 (2) 9.5x18.5 (2) 9.5x18.5 (2) 9.5x18.5 (2) 11x22.75 (2) 11x22.75 (2)
Weight, Kg. 40 40 52 52 55 65 65
Minimum circuit ampacity, Amps 1.5 1.5 3.25 3.25 3.25 4.5 4.5
Maximum fuse size, Amps 15 15 15 15 15 15 15
OUTDOOR UNIT
208/230-1-60 9.7/60 13/73 13.2/85 18.4/95 20.4/109 22.1/137 30.1/144
Compressor

208/230-3-60 N.A. N.A. 11.8/67 11.4/77 13.9/88 16.4/91 20.7/128
RLA/LRA
380-3-60 N.A. N.A. 5.6/39 9.3/54 9.3/54 9.3/54 10.7/64
460-3-60 N.A. N.A. 5.4/29.2 5.7/40 7.1/44 7.9/50 8.4/65
208/230-1-60 12.8/20 16.9/25 17.5/30 24.6/40 28.7/45 30.8/50 40.8/70
MCA/MOCP

208/230-3-60 N.A. N.A. 15.7/25 15.9/25 20.6/30 23.7/40 29.1/45
(Outdoor unit)
380-3-60 N.A. N.A. 8/15 13.2/20 14.8/20 14.8/20 16.6/25
460-3-60 N.A. N.A. 7.7/15 8.73/15 12.1/15 13.1/20 13.7/20
Condenser airflow, CFM 1400 1400 1800 2200 4200 4200 4200
Condenser Fan
HP - RPM 1/10 - 875 1/10 - 875 1/8 - 1000 1/4 - 1000 1/4 - 1000 (2) 1/4 - 1000 (2) 1/4 - 1000 (2)
motor
FLA 0.6 0.6 0.94 1.6 1.6 1.6 1.6
Face area, ft
2
5.6 5.6 5.6 8 10.5 10.5 10.5
Condenser coil Tube dia, inch 5/16 5/16 5/16 3/8 3/8 3/8 3/8
No. of rows/FPI 2/16 2/16 3/16 2/14 2/14 2/14 2/14
Refrigerant (R-22) charge, oz. 62 76 83 128 141 135 127
Suction - Liquid line, inch 5/8 - 3/8 5/8 - 3/8 5/8 - 3/8 3/4 - 3/8 7/8 - 3/8 7/8 - 1/2 7/8 - 1/2
Dimensions, mm (depth x width x height) 800x325x685800x325x685800x325x685965x390x727 965x390x1158 965x390x1158 965x390x1158
Weight, Kg. 65 66 72 101 115 120 130
PHYSICAL DATA
NOTE: 1. Cooling capacities & power input data @ 80
0
F (26.7
0
C) DB/67
0
F (19.4
0
C) WB indoor & 95
0
F (35
0
C) ambient temperatures.
2. Heating capacities & power input data @ 70
0
F (21.1
0
C) DB/60
0
F (15.6
0
C) WB indoor & 47
0
F (8.3
0
C) 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.
5. Motor FLA values are based on standard motors.
8
0.0 0.05 0.1 0.15 0.2 0.25 0.3 0.4 0.5
HIGH 650 640 591 566 542 508 475 406 334
DY18 MEDIUM 552 528 514 478 452 421 390 333 255
LOW 470 445 420 395 375 345 - - -
HIGH 750 729 698 670 643 613 584 510 427
DY24 MEDIUM 660 642 591 566 542 508 475 406 334
LOW 552 528 504 478 452 421 - - -
HIGH 1050 987 960 934 908 886 864 804 741
DY30 MEDIUM 852 827 802 775 748 727 706 650 594
LOW 637 614 592 575 559 533 - - -
HIGH 1250 1209 1184 1153 1122 1083 1044 966 894
DY36 MEDIUM 1050 987 960 934 908 886 864 804 741
LOW 852 827 802 775 748 727 - - -
HIGH 1400 1362 1324 1291 1258 1218 1178 1102 1009
DY42 MEDIUM 1225 1192 1160 1130 1100 1064 1028 958 877
LOW 995 975 955 928 902 876 - - -
HIGH 1600 1590 1571 1538 1505 1466 1426 1331 1245
DY48 MEDIUM 1366 1338 1310 1277 1244 1199 1153 1070 970
LOW 1100 1065 1030 992 954 912 - - -
HIGH 1950 1900 1840 1780 1728 1690 1651 1558 1463
DY60 MEDIUM 1631 1601 1571 1538 1505 1466 1426 1331 1245
LOW 1366 1338 1310 1277 1244 1199 - - -
FAN PERFORMANCE DATA
CFM @ EXTERNAL STATIC PRESSURE (Inches of water)
BLOWER
MOTOR
SPEED
MODEL
NUMBER
NOTE: Values include losses for dry coil and filters.
9
DIMENSIONS - INDOOR UNITS
DY18 - DY60
MODEL
A B C D E F G H I
DY 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)
DY 24 904 (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)
DY 30 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)
DY 36 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)
DY 42 1011 (39.8) 762 (30) 318 (12.5) 1067 (42) 640 (25.2) 858 (33.8) 241 (9.5) 945 (37.2) 259 (10.2)
DY 48 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)
DY 60 1194 (47) 762 (30) 368 (14.5) 1245 (49) 625 (24.6) 894 (35.2) 266 (10.5) 1155 (45.5) 292 (11.5)
DIMENSIONS
NOTE: All dimensions are in mm (dimensions in brackets are in inches).
1. Blower & motor assembly
2. Evaporator coil
3. Control box
4. Filter rack
5. Unit mounting brackets (4 Nos.)
6. Duct connection
10
FROAT UIEW
TOP UIEW EAD UIEW EAD UIEW
3/ 4" NPT(14TPI)
DRAINTUBE.
2
5
D
H
A 4
I
3
89(3.50")
1
6
F
800(31.5)
EAD UIEW
TYPE CONN.
9.5 (
3
8") FLARE
48(1.890)
49(1.929)
TYPE CONN.
16 (
5
8") FLARE
FROAT UIEW
AIROUT
AIRIN
DETAIL - A
SEEDETAIL-A
20(0.788)
{TYPICAL AT FOOR PLACES)
70(2.755)
POWER &CONTROL
WIRE ENTRY
LIQUID VALVE
SUCTION VALVE
TOP UIEW
442(17.402)
DIMENSIONS - OUTDOOR UNITS
11
KY018, KY024 & KY030
AIROUT
AIRIN
POWER&CONTROL
WIREENTRY
SEEDETAIL-A
{TYPICAL AT FOOR PLACES)
DETAIL - A
19 (
3
4") FLARE
9.5 (
3
8") FLARE
TYPE CONN.
EAD UIEW
TYPE CONN.
ACCESS PANEL
TOP UIEW
FROAT UIEW
965(38)
16(0.63)
19(0.75)
133 (5.25) 698(27.5)
89 (3.5)
70(2.76)
20 (0.79)
KY036
NOTE: All dimensions are in mm (dimensions in brackets are in inches).
DIMENSIONS - OUTDOOR UNITS
KY042, KY048 & KY060
NOTE: All dimensions are in mm (dimensions in brackets are in inches).
12
FROAT UIEW
79(3.13)
EAD UIEW
16(0.63)
27(1.06)
TYPECONN.
FLARETYPECONN.
22 (
7
8") FLARE
965(38)
ACCESS PANEL
133 (5.25) 698(27.5)
TOP UIEW
AIR OUT
AIR IN
DETAIL - A
{TYPICAL AT FOOR PLACES)
70(2.76)
20 (0.79)
SEE DETAIL-A
POWER & CONTROL
WIREENTRY
9.5 (
3
8") (FOR KY042)
&12.7 (
1
2") (FOR KY048/060)
60 DY 36
DY 60
DY 48
DY 42
IN HERTZ
FREQUENCY
APPLICABLE
ATB
COM
* *
SPEED
WIRE COLOR
DY 18
DY 30
DY 24
MODEL
YEL
FM SPEED CONNECTIONS
MED HI MED-HI S-HI
BLU BLK RED
COM LOW
ORG WHT
ID
LOW
N2
N1
CN4
COMP COM
Refer to table below for
Speed Connections.
15
39A
*
L2/N L1 GND
230VAC
TO FUSE DISCONNECT SWITCH
* * *
60
INDOOR DE-ICE SENSOR
3) WHT TX
2) BLK GND
CABLE CONNECTIONS AT LCD
1) RED 5V
CONTROL PANEL TB
LCD CONTROL PANEL
COND.UNIT
6
1
TO
CAP
BRN
BRN
60
60
60
60
60
4) YEL TX RCV
LOWEST
GREY
* * *
* * *
* * *
* * *
* * *
* * *
* *
* *
* *
* *
* *
* *
* *
*
*
*
*
*
*
*
* * *
TYPICAL SCHEMATIC WIRING DIAGRAM
COOL MODELS
INTERCONNECTING DETAILS BETWEEN INDOOR & OUTDOOR UNIT
NOTE: Route wires according to diagram below & ignore all other terminal connection on outdoor unit.
13
NOTES
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. MOTORS ARE THERMALLY PROTECTED.
4. REFER TO INTERCONNECTING WIRING DIA-
GRAM BEFORE INSTALLATION
5. DO NOT ROUTE ATB1(5) FROM CONDENSING
UNIT
LEGEND
ATB AUXILIARY TERMINAL BLOCK
CAP CAPACITOR
COMP COMPRESSOR
COM COMMON
ECB ELECTRONIC CONTROL BOARD
FL FUSE LINK
FM FAN MOTOR
GND LUG GROUND
HF HIGH FAN
L1 LINE 1
L2 LINE 2 OR NEUTRAL
LF LOW FAN
MF MEDIUM FAN
_ _ _
FIELD WIRING
FACTORY WIRING
DY SERIES
INDOOR UNIT INDOOR UNIT
DY SERIES
KY SERIES
OUTDOOR UNIT OUTDOOR UNIT
KY SERIES
6
ATB
ATB 5 6
1 6 1
ATB
1 5 4/6 1 N ATB L
CAP
ATB
NOTE:
OUTDOOR DE-ICE SENSOR
TO THE TUBE PROVIDEDONTHE
RETURN BEND OF THE OUTDOOR COIL.
FIX THE OUTDOOR DE-ICE SENSOR
15
N1
N2
LOW
4WV
CN4
ECB
OF/O OF/I
ID
COMP COM
OD
21B
21A
21
39A
TO FUSE DISCONNECT SWITCH
230VAC
L2/N GND L1
COM
Speed Connections.
Refer to table below for
* *
*
* * *
CABLE CONNECTIONS AT LCD
3) WHT TX
CONTROL PANEL TB
2) BLK GND
1) RED 5V
LCD CONTROL PANEL
INDOOR DE-ICE SENSOR
COND.UNIT
37A
T3A/N
6
8
1
TO
BRN
BRN
4) YEL TX RCV
60 DY 36
DY 60
DY 48
DY 42
IN HERTZ
FREQUENCY
APPLICABLE SPEED
WIRE COLOR
DY 18
DY 30
DY 24
MODEL
YEL
FM SPEED CONNECTIONS
MED HI MED-HI S-HI
BLU BLK RED
COM LOW
ORG WHT
60
60
60
60
60
60
LOWEST
GREY
* * *
* * *
* * *
* * *
* * *
* * *
* *
* *
* *
* *
* *
* *
* *
*
*
*
*
*
*
*
* * *
TYPICAL SCHEMATIC WIRING DIAGRAM
HEAT PUMP MODELS
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
LEGEND
ATB AUXILIARY TERMINAL BLOCK
CAP CAPACITOR
COMP COMPRESSOR
COM COMMON
ECB ELECTRONIC CONTROL BOARD
FL FUSE LINK
FM FAN MOTOR
GND LUG GROUND
HF HIGH FAN
L1 LINE 1
L2 LINE 2 OR NEUTRAL
LF LOW FAN
MF MEDIUM FAN
OF OUTDOOR FAN
4WV/RV FOUR WAY/REVERSING VALVE
_ _ _
FIELD WIRING
FACTORY WIRING
14
NOTES
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. MOTORS ARE THERMALLY PROTECTED.
4. REFER TO INTERCONNECTING WIRING DIA-
GRAM BEFORE INSTALLATION
5. DO NOT ROUTE ATB1(5) FROM CONDENSING
UNIT
6. T3A/N & 37A ARE TERMINAL MARKINGS FOR
J P4 ON CONDENSER FAN MOTOR CONNEC-
TION. T3A/N IS T1 ON SINGLE PHASE CON-
DENSER UNITS.
T3A IS T1 ON 1PH CONDENSER UNITS
COMP
5
S R
C
O/L
OUTDOOR UNIT
ATB L
KY SERIES
N 1
DY SERIES
INDOOR UNIT
ATB 6 1 8
INDOOR UNIT
DY SERIES
KY SERIES
OUTDOOR UNIT
5
37A
NOTE:
4/6 8
ATB 1
COMP
35A
FM
CAP
36A
6 8
T3A 37A
T3A/N 37A ATB 1 T3A/N 8 6 37A
T3A
FM
INSTALLATION - INDOOR UNIT
The complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immedi-
ately 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 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.
15
AIR OUT
AIR IN
610mm (24") CLEARANCE MINIMUM
203mm (8") FOR KY018, 024 & 030
254mm (10") FOR KY036 AND ABOVE
914mm (36") CLEARANCE MINIMUM
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.
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
17
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 mm
2
) for lower amps.
4. For control wiring, use approved thermostat wire [minimum 18 gauge (0.75 mm
2
)], color coded wires. Then match the
auxiliary terminal block (ATB) numbers (indoor and outdoor units) to interconnect the two units. 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 discon-
nect 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
0
F (12.7
0
C).

Maximum outdoor operating air temperature during cooling mode is 130

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.
SERVICING INSTRUCTIONS
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
Bottom panel
Blower deck holding bolt
Blower deck
19
PERCENTAGE OF SPARE PARTS
ONE YEAR SUPPLY TWO YEAR SUPPLY
100 UNITS 1000 UNITS 100 UNITS 1000 UNITS
ITEM
Compressor 2% 1% 3% 2%
Capacitor 3 2 5 4
Condenser Fan Motor 2 1 3 2
Evaporator Blower Motor 1 0.5 2 1
Contactor Compressor 2 1 3 2
Contactor Fan Motors 2 1 3 2
HPS/LPS/Other controls 2 1 3 2
Filter Drier 2 1 3 2
Transformer (24V. Secondary) 1 0.5 2 1
Propeller Fan 1 0.5 2 1
Blower Wheel 0.5 0.25 1 0.5
Thermostat (Wall) 1 1 2 1
Heater-Crankcase 3 1 4 2
Filter 2 1 4 4
RECOMMENDED SPARE PARTS
NOTE: When ordering spare parts, please quote the complete model number on the unit nameplate.
PARTS LIST
MODEL NUMBER DY18 DY24 DY30 DY36 DY42 DY48 DY60
FAN DECK ASSEMBLY 700-384-88 700-384-88 700-384-89 700-384-89 700-384-89 700-384-90 700-384-90
BLOWER MOTOR 800-547-65 800-547-65 800-547-66 800-547-66 800-547-66 800-547-67 800-547-67
FILTER 800-249-39 800-249-39 800-249-38 800-249-38 800-249-38 800-249-36 800-249-36
ORIFICE DISTRIBUTOR 800-194-10 800-194-10 800-194-14 800-194-14 800-194-14 800-194-16 800-194-16
ORIFICE PISTON 800-195-13 800-195-13 800-195-15 800-195-16 800-195-17 800-195-20 800-195-22
THERMOSTAT, COOL 800-654-01 800-654-01 800-654-01 800-654-01 800-654-01 800-654-01 800-654-01
THERMOSTAT, HEAT PUMP 800-654-03 800-654-03 800-654-03 800-654-03 800-654-03 800-654-03 800-654-03
INDOOR UNITS
OUTDOOR UNITS
MODEL NUMBER KY036C KY036H KY036M KY036F KY042C KY042H
COMPRESSOR 800-674-27 800-674-26 800-674-21 800-674-28 800-674-74 800-674-73
FAN MOTOR 800-545-12 800-545-12 800-545-12 800-545-96 800-545-12 800-545-12
FAN MOTOR CAPACITOR 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15
CONDENSER FAN 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41
COMPRESSOR CONTACTOR 800-736-22 800-095-01 800-095-01 800-095-01 800-736-22 800-095-01
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00
MODEL NUMBER KY042M KY042F KY048C KY048H KY048M KY048F
COMPRESSOR 800-674-21 800-674-75 800-674-29 800-674-20 800-674-21 800-674-22
FAN MOTOR 800-545-12 800-545-96 800-545-12 800-545-12 800-545-12 800-545-96
FAN MOTOR CAPACITOR 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15 800-353-15
CONDENSER FAN 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41 800-941-41
COMPRESSOR CONTACTOR 800-095-01 800-095-01 800-736-22 800-095-01 800-095-01 800-095-01
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00
MODEL NUMBER KY060C KY060H KY060M KY060F
COMPRESSOR 800-674-16 800-674-13 800-674-14 800-674-15
FAN MOTOR 800-545-12 800-545-12 800-545-12 800-545-96
FAN MOTOR CAPACITOR 800-353-15 800-353-15 800-353-15 800-353-15
CONDENSER FAN 800-941-41 800-941-41 800-941-41 800-941-41
COMPRESSOR CONTACTOR 800-297-37 800-736-22 800-095-01 800-095-01
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00
MODEL NUMBER KY018C KY024C KY030C KY030H KY030M KY030F
COMPRESSOR, COOL ONLY 800-675-79 800-675-80 800-675-89 800-674-26 800-684-14 800-674-28
COMPRESSOR, HEAT PUMP 800-675-86 800-675-87 800-675-90 800-674-26 800-684-14 800-674-28
FAN MOTOR 800-555-32 800-555-32 800-555-98 800-555-98 800-555-98 800-555-89
FAN MOTOR CAPACITOR - - 800-353-15 800-353-15 800-353-15 800-353-15
CONDENSER FAN 800-224-19 800-224-19 800-224-55 800-224-55 800-224-55 800-224-55
COMPRESSOR CONTACTOR 800-736-27 800-736-27 800-736-22 800-095-01 800-095-01 800-095-01
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00
20