INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

AIR HANDLING UNITS

'BWY' SERIES
Part number: 800-213-73
 INDEX
Contents Page

Model decoding ........................................................................................................................................ 2

General statement .................................................................................................................................... 3

Warranty ................................................................................................................................................... 3

Safety issues ............................................................................................................................................ 3

Inspection for damage .............................................................................................................................. 3

Installation procedures ............................................................................................................................. 4

Prior to installation .................................................................................................................................... 4

Service clearance ..................................................................................................................................... 4

Site preparation ........................................................................................................................................ 5

Unit installation ......................................................................................................................................... 5

Insulation of pipes .................................................................................................................................... 6

Condensate drain connection ................................................................................................................... 6

Electrical connection ................................................................................................................................ 6

Duct connection ........................................................................................................................................ 6

Final inspection ........................................................................................................................................ 6

Sequence of operation ............................................................................................................................. 7

Unit dimensions ................................................................................................................................... 8-11

Heater box dimensions ........................................................................................................................... 12

Typical wiring diagram ............................................................................................................................ 13

Maintenance ...................................................................................................................................... 14-15

Parts list ................................................................................................................................................. 15

Troubleshooting ...................................................................................................................................... 16

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1
 MODEL DECODING
BWY03 - BWY05
1, 2 & 3 4&5 6 7 8 9 10 11 12 13 14 15
BASIC FACE AREA ARRANGEMENT ELECTRICAL COIL APPLICATION BLOWER DRIVE HEATER COIL FINS FILTER UNIT OTHER
(SQ. FT.) SUPPLY MOTOR OPTIONS OPTIONS
OPTIONS ACCESSORIES
(V-Ph-Hz) (kW/STAGE)

BWY 03 H : HORIZONTAL C : 208/230-1-60 A : STD. 3 ROW CHILLED U : 0.5 HP ODP N : DIRECT N : NO HEATER A : ALUMINUM N : NO FILTER N : STD. UNIT. N : STD. UNIT
CLASSIC WATER COIL DRIVE FIN NO ACCESORIES
V : VERTICAL H : 208/230-3-60 W : 0.75 HP ODP A : 5/1 E : 1/2" ALUMINUM
AIR HANDLING
V : VOLT FREE
UNIT B : 2 ROW CHILLED B : COATED
F : 1/2" SYNTHETIC CONTACTS*
(CHILLED WATER) 05 M : 380-3-60 WATER + 1 ROW W : 0.75 HP ODP B : 6/1 ALUMINUM
(4 WIRE) HEATING SPLIT COIL FIN
Y :1 HP ODP C : 7.5 /1** A : 1" ALUMINUM
F : 460-3-60 C : COPPER FIN
C : 1" SYNTHETIC

NOTES: * – Blower motor ON/OFF and trip indication.

** – Heater capacity will be 7kW for single phase power supply.

2
BWY07 - BWY25
1, 2 & 3 4&5 6 7 8 9 10 11 12 13 14 15
BASIC FACE AREA ARRANGEMENT ELECTRICAL COIL APPLICATION BLOWER DRIVE HEATER COIL FINS FILTER UNIT OTHER
(SQ. FT.) SUPPLY MOTOR OPTIONS OPTIONS
OPTIONS ACCESSORIES
(V-Ph-Hz) (kW/STAGE)

BWY 07 H : HORIZONTAL H : 208/230-3-60 A : STD. 3 ROW CHILLED FOR BWY07 N : NO HEATER A : ALUMINUM FOR BWY07 N : STD. UNIT. N : STD. UNIT
J : ALT. I
CLASSIC WATER COIL D : 2 HP ODP A : 5/1 FIN N : NO FILTER NO ACCESORIES
V : VERTICAL M : 380-3-60 B : 2 ROW CHILLED K : ALT. II B : 6/1 E : 1/2" ALUMINUM
AIR HANDLING E : 3 HP ODP
WATER + 1 ROW C : 7.5 /1 F : 1/2" SYNTHETIC V : VOLT FREE
UNIT (4 WIRE) B : COATED
D : 10 /2 CONTACTS*
(CHILLED WATER) HEATING SPLIT COIL ALUMINUM A : 1" ALUMINUM
E : 12/2
F : 460-3-60 FOR BWY10 FIN C : 1" SYNTHETIC
10 C : STD. 4 ROW CHILLED F : 15 /2
D : 2 HP ODP G : 20 /2 FOR BWY10, 14 & 18
WATER COIL
E : 3 HP ODP H : 25/2 C : COPPER FIN
N : NO FILTER
J : 30/2
D : 3 ROW CHILLED A : 1" ALUMINUM
14 WATER + 1 ROW FOR BWY14/18 FOR BWY18/25
B : 2" ALUMINUM
HEATING SPLIT COIL G : 5 HP ODP N : NO HEATER
C : 1" SYNTHETIC
18 J : 7.5 HP ODP E : 12/2
F : 15 /2 D : 2"SYNTHETIC
G : 20 /2
H : 25/2
25 FOR BWY25 J : 30/2 FOR BWY25
J : 7.5 HP ODP K : 35/2
L : 10 HP ODP N : NO FILTER
L : 40/2
B : 2" ALUMINUM
D : 2"SYNTHETIC

NOTES: * – Blower motor ON/OFF and trip indication.

 GENERAL STATEMENT
This unit is from the BWY series that was designed & built for optimum performance. However, it is required that you
become well knowledgeable about the good practices for the proper installation/operation/and maintenance procedures
in order to ensure a safe trouble free operation, year after year.
Please read through the whole manual contents before you attempt to install/operate/ and maintain the unit.
Most of the procedures described in this manual require certain skills and experience. The installation and other maintenance
procedures should be performed only by highly skilled and experienced technicians. The end user’s role should be limited
to the cleaning of the filter.
Please consult your nearest "Zamil" representative for further information.
The BWY units can be supplied, depending on the End User requirement, as the basic "Cool Only" version, the "Heat &
Cool" version (with electric heater module or with hot water coil).

WARRANTY
All of the BWY series of indoor Air Handling Units are covered by the standard warranty terms against any manufacturer
defect. Should you encounter any problem that falls under the warranty terms please fill out the attached form and send
it/contact your nearest "Zamil" representative.

SAFETY ISSUES
There are three degrees of safety hazards that are identified throughout this manual as WARNING (where the situation
will result in personal injury), CAUTION (where personal injury might occur), and ATTENTION (where minor personal
injury and/or property damage could happen). Please understand and respect those identifications.

WARNING: The BWY units operate on a high voltage with moving parts (at high speed) which can lead to
serious injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical power
supply has been disconnected.

CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining
the unit as the hazard of explosion, fire, electrical shock, and potential personal injury and property damage
are present.

When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observe
all the applicable safety measures (wear of safety helmet, boots, gloves, and goggles. Use of proper handling materials
for brazing and use of wet cloth for quenching. A fire extinguisher should be easily accessible etc.). He should also read
all the instructions and information in this Manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should also be observed.

INSPECTION FOR DAMAGE

The unit should be carefully inspected visually for any sign of physical damage due to mishandling. Whenever a damage
is detected, please indicate it on the corresponding delivery note before you sign it and inform your nearest "Zamil"
office.

3
 INSTALLATION PROCEDURES
All BWY series units can be installed horizontally (suspended or resting on pads) or vertically. They should be ordered
separately as horizontal air discharge or vertical air discharge units as per application requirements.

PRIOR TO INSTALLATION
The location of the unit to be installed should be carefully examined for space taking into consideration the physical
dimensions and the required clearances for maintenance (as indicated in Figure below).
The Contractor/ Installer should avoid installing the unit in a way to obstruct the return air and to avoid any conflict with
other utilities (electrical, plumbing, etc.). Enough space should be provided to ensure a proper connection to the supply
ducting as dictated by the ASHRAE/SMACNA recommendations.

SERVICE CLEARANCE

HORIZONTAL UNITS VERTICAL UNITS

4
SITE PREPARATION
The site for the AHU installation should be free from any obstacle that can be hazardous to the installation personnel and/
or damaging to the unit.
Properly identify all existing building utilities (such as electrical cables, plumbing pipes, sanitary hardware, etc.) before
you proceed with drilling.
Make sure that live electrical cables are not hanging or running near the AHU proposed location or obstructing in any way
the movement of the installation personnel.
Clear the floor from all debris and objects with sharp edges. Remove liquid or slippery material from the installation site
before proceeding.

UNIT INSTALLATION
Horizontal application
In the horizontal type of application, the unit should be suspended to a rigid structure through “trapeze” type of hangers.
The selection of the threaded rod/ anchor bolt/ and angle bar should be as indicated in Table -1.

AHU THREADED ROD ANCHOR BOLT ‘C’ CHANNEL ANGLE IRON

MM MM MM MM

BWY 03 8 8 - 40 x 40 x 4
BWY 05 8 8 - 40 x 40 x 4
BWY 07 10 10 - 50 x 50 x 5
BWY 10 10 10 - 50 x 50 x 5
BWY14 12 12 60 x 25 x 4 x 6 -
BWY 18 12 12 60 x 25 x 4 x 6 -
BWY 25 12 12 60 x 25 x 4 x 6 -

TABLE - 1

NOTE: The location of the threaded rods should be selected in a way that they will not interfere with the maintenance
work.

ATTENTION: Always use Counter Tightening Nuts for secure tightening of the hangers.
Rubber gasket should be inserted between the unit and the ceiling, and between the unit and its angle bar/”C” Channel
support.

The unit should be properly levelled. A slight pitching (1/4 to 1/2 inch) towards the condensate pipe connection is
recommended to ensure proper drainage.

Vertical application
When the unit is installed with vertical supply air and horizontal return airflow configuration, then the unit has to rest
securely on an adequately raised concrete pad. It is always recommended to have the unit leaning against a wall or
similar heavy structure to further secure it in its position. Additional holding brackets can be used.
Rubber pads should be used to prevent the direct contact between the unit and its corresponding pad and/or any other
supporting structure.

5
INSULATION OF PIPES
The pipe insulation should cover both inlet & outlet pipes as shown below.
WATER IN
WATER OUT WATER OUT WATER OUT

INSULATION WATER IN WATER IN

INSULATION

YES NO NO

CONDENSATE DRAIN CONNECTION

- Use PVC Class 3 material for the condensate drain piping (3/4").
- Provide a "P" trap immediately at the condensate drain connection.
- Run your piping avoiding bends and elbows.
- Pitch the piping away from the unit with 2/100 slope.
- If the pipe is routed though a room (or an unconditioned space) insulate to avoid condensation on its outer walls.

ELECTRICAL CONNECTION
Power connection:
The HVTB lugs or contactor, in the control box, are clearly identified and tagged. All that one has to do is to connect the
power cables to those lugs and secure them by tightening to corresponding lug screw.
Use the dedicated Knock-Out holes near the supply side to connect the Power Cables.
Unit should be grounded properly.
CAUTION: Please ensure that the power supply is as per the unit’s name plate (Volts/Ph/Hz) requirement. Operation of
the unit on improper power supply will result in damage to the unit.
Use copper wires of proper rating for all field wiring.

Control Connection:
The 24V control wires should be run from the thermostat to the control box of the BWY unit through the corresponding
Knock-Out hole(s) near the supply side.
The control wires should be connected to the LVTB as indicated in the attached wiring diagrams (Appendix A) depending
whether it is the "Cool Only" or "Heat & Cool".
Note: Always use 16 gauge color-coded wire for the control.
Always follow the relevant applicable local codes.

DUCT CONNECTION
All of the BWY packaged Air Handling Units are provided with a 1" duct flange on the supply side. The Flexible Duct
Connection should be firmly fastened to this flange, for Cooling Only units, with proper fasteners (sheet metal screws) as
per SMACNA recommendation. Then the joint between the Flexible and the unit Duct Flange should be properly sealed.
Note: For units with Electric Heaters, the Flexible Duct Connection should be secured onto the upper lip of the Electric
Heater Module housing.

FINAL INSPECTION
After the installation is completed in all respect, the following points should be checked before the system is switched on for operation.
1. Check that the AHU is properly leveled and the retaining nuts (on the hanging brackets) are tight.
2. Check the pipe and valve connections for any signs of chilled water leaking.
3. Check the V-belt tension and deflection.
4. Check that the filter is clean and properly installed.
5. Check that all electrical fasteners/connections are tight clean.
6. Check that all panels are securely fastened.
7. Check that the thermostat is the right one and installed properly.
8. Check that the circuit breaker/fuse disconnect switch is installed properly.

6
 CONTROLS & SEQUENCE OF OPERATION
The operation of the air conditioning unit is controlled by a 24VAC electronic control board. All the contactors are oper-
ated by the 24V circuit, including the thermostat.

Mode:
Select the desired mode of operation by continuous press-
ing of the MODE button: 24 V
(C)
Controls cooling system only (the word COOL will 24 V
24VAC

display for 5 seconds). Equipment Line Voltage

R Relays 2nd stage Transformer
Controls heating system only (the word HEAT will Cooling
Y2
display for 5 seconds). 1st stage
Cooling
L Y1
HEAT/COOL - Controls both systems automati- I Fan Relay
G G
cally (the word AUTO will display for 5 seconds). H
T
1st stage
Heating
S W1
OFF - Systems will not operate. 2nd stage
Heating
W2

Cooling:
Select the temperature you want your cooling system to LED 1
Clogged Filter *
maintain by pressing and holding the COOLING button LED 2
Compressor Fault

under the or symbols until the desired temperature Thermostat

is displayed. The control setpoint temperature is displayed * Clogged filter switch not provided
Field Wiring
for 5 seconds.

Heating:
Select the temperature you want your heating system to maintain by pressing and holding the HEATING button under
the or symbols until the desired temperature is displayed. The control setpoint temperature is displayed for 5
seconds.

Fan:
The fan will be energized automatically when the systems are operating but no indication of this on the display. To select
continuous fan operation, press the FAN button and the display will show . This is recommended for electronic air
cleaners and continuous ventilation requirements.

Off
When the word OFF is displayed the heating and cooling systems will not operate. Avoid using the OFF mode during
extremely cold weather to prevent damage from freezing.

Auto:
Selecting this mode of operation will control both heating and cooling systems. The thermostat will automatically switch
from one to the other as determined by the selected temperatures in heating and cooling.
NOTE: The thermostat always maintains a minimum 20F (10C) difference or dead band between the heating and cooling
setpoints.

Celsius/Fahrenheit
Simultaneously press and to switch between Celsius and Fahrenheit temperature display.

7
 DIMENSIONS
BWY03 - BWY14 (HORIZONTAL DISCHARGE)

NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches).

2. Hot water coil connection is available only if hot water coils are ordered.
DIMENSIONS
MODEL
A B C D E F G H J K L M N P Q R
BWY03 1092(43) 648(25.5) 575(22.64) 483(19.02) 143(5.63) 406(15.98) 45(1.77) 542(21.34) 524(20.63) 297(11.69) 553(21.77) 171(6.73) 178(7.01) 140(5.51) 19(0.75) 19(0.75)
BWY05 1092(43) 813(32) 600(23.62) 483(19.02) 224(8.82) 406(15.98) 45(1.77) 707(27.83) 550(21.65) 297(11.69) 553(21.77) 171(6.73) 178(7.01) 140(5.51) 25(1) 25(1)
BWY07 1360(53.5) 1100(43.31) 600(23.62) 813(32) 182(7.16) 406(15.98) 66(2.6) 995(39.17) 550(21.65) 378(14.88) 721(28.38) 164(6.46) 165(6.5) 132(5.2) 32(1.25) 25(1)
BWY10 1490(58.7) 1400(55.12) 675(26.57) 813(32) 332(13.1) 406(15.98) 42(1.65) 1295(51) 625(24.61) 378(14.88) 721(28.38) 112(4.41) 206(8.11) 140(5.51) 38(1.5) 32(1.25)
BWY14 1625(64) 1600(63) 705(27.75) 1321(52) 187(7.36) 406(15.98) 55(2.16) 1495(58.86) 655(25.8) 471(18.54) 791(31.14) 127(5) 152(5.98) 140(5.51) 38(1.5) 32(1.25)

8
 DIMENSIONS
BWY03 - BWY14 (VERTICAL DISCHARGE)

NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches).

2. Hot water coil connection is available only if hot water coils are ordered.
DIMENSIONS
MODEL
A B C D E F G H J K L M N P Q R
BWY03 1092(43) 648(25.5) 575(22.64) 483(19.02) 134(5.28) 406(15.98) 35(1.38) 543(21.38) 502(19.76) 285(11.22) 553(21.77) 171(6.73) 178(7.01) 140(5.51) 19(0.75) 19(0.75)
BWY05 1092(43) 813(32) 600(23.62) 483(19.02) 229(9.02) 406(15.98) 32(1.26) 712(28.03) 502(19.76) 300(11.81) 553(21.77) 171(6.73) 178(7.01) 140(5.51) 25(1) 25(1)
BWY07 1360(53.5) 1100(43.31) 600(23.62) 813(32) 213(8.4) 406(15.98) 85(3.34) 991(39) 504(19.83) 302(11.87) 697(27.53) 164(6.46) 165(6.5) 132(5.2) 32(1.25) 25(1)
BWY10 1490(58.7) 1400(55.12) 675(26.57) 813(32) 365(14.38) 406(15.98) 35(1.38) 1299(51.15) 607(23.91) 338(13.29) 732(28.81) 101(3.98) 194(7.64) 159(6.26) 38(1.5) 32(1.25)
BWY14 1625(64) 1600(63) 705(27.75) 1321(52) 224(8.82) 406(15.98) 49(1.92) 1497(58.95) 607(23.91) 370(14.59) 929(36.56) 127(5) 152(5.98) 140(5.51) 38(1.5) 32(1.25)

9
 DIMENSIONS
BWY18 - BWY25 (HORIZONTAL DISCHARGE)

NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches).

2. Hot water coil connection is available only if hot water coils are ordered.
DIMENSIONS
MODEL
A B C D E F G H J K L M N P Q R
BWY18 1625(64) 2070(81.5) 705(27.75) 1575(62) 382(15.04) 483(19.02) 35(1.38) 1965(77.36) 655(25.79) 471(18.54) 791(31.14) 127(5) 152(5.98) 140(5.51) 38(1.5) 32(1.25)
BWY25 1825(71.85) 2362(93) 840(33.1) 1575(62) 590(23.23) 483(19.02) 50(1.97) 2257(88.86) 790(31.1) 503(19.8) 913(35.94) 127(5) 152(5.98) 140(5.51) 38(1.5) 32(1.25)

10
 DIMENSIONS
BWY18 - BWY25 (VERTICAL DISCHARGE)

NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches).

2. Hot water coil connection is available only if hot water coils are ordered.
DIMENSIONS
MODEL
A B C D E F G H J K L M N P Q R
BWY18 1625(64) 2070(81.5) 705(27.75) 1575(62) 422(16.61) 483(19.02) 46(1.81) 1969(77.52) 596(23.46) 354(13.94) 878(34.57) 127(5) 152(5.98) 140(5.51) 38(1.5) 32(1.25)
BWY25 1825(71.85) 2362(93) 840(33.1) 1575(62) 625(24.61) 483(19.02) 74(2.91) 2217(87.28) 596(23.46) 704(27.72) 878(34.57) 127(5) 152(5.98) 140(5.51) 38(1.5) 32(1.25)

11
 DIMENSIONS - HEATER BOX
BWY03 - BWY05
.3")
(16
415

(1")
25.4 YP
T

205 (8.1")

490
(19.3
")

HEATER CONTROLS MTG HEATER CONTROLS MTG

PLATE
COVER

BWY07 - BWY14
.2")
(16
412

P
) TY
4 (1 "
25.
205 (8.1")

DIMENSIONS
MODEL
A HEATER ACCESS COVER
BWY07 818 (32.2) HEATER CONTROLS MTG
BWY10 818 (32.2)
COVER
HEATER CONTROLS MTG
BWY14 1326(52.2) PLATE

BWY18 - BWY25
.4")
(19
492

T YP
( 1")
25.4
205 (8.1")

1581 (6
2.3")

HEATER ACCESS COVER

(BOTH SIDES) HEATER CONTROLS MTG
COVER
HEATER CONTROLS MTG
PLATE

NOTES: 1. All dimensions are in mm (dimensions in brackets are in inches).

2. Heater box is an optional feature.

12
 TYPICAL SCHEMATIC WIRING DIAGRAM
WIRING DIAGRAM SUITS FOR
208/230V-3PH-60HZ LEGEND
460V-3PH-60HZ [&]
380V-3PH-60HZ & NTRL. UNITS TO POWER AFS AIRFLOW SWITCH
LUG SUPPLY/ HVTB
L1 L2 L3
AR AUXILIARY RELAY
L1

L2/N
L1/L
TO POWER BF BUSMAN FUSE
L2

* SEE NOTE-7
SUPPLY/ HVTB
L3 BM BLOWER MOTOR
BMC
BMC
BMC BLOWER MOTOR CONTACTOR

T1E
T2E
T3E
FL FUSE LINK

CAP
BMC HC HEATER CONTACTOR
OLR
NOTE:
HVTB HIGH VOLTAGE TERMINAL BLOCK

70
69
68
1. NTB IS APPLICABLE FOR
68 69 70

68
69
70
380V/3PH/60Hz HTR HEATER
2. FOR UNITS WITH ABOVE BM
VOLTAGE CONNECT L3 OF
BM
L1 LINE 1
TRANS TO NTB
BM
L3 L1
L2 LINE 2
L3 LINE 3
THS'T LVTB TRANS ATB
24V 24V
LVTB
G
18 OLR 19 BMC
17
LVTB LOW VOLTAGE TERMINAL BLOCK
BF 15
LUG LUG GROUND
R R 12 17
MOHT MANUAL RESET OHT
24V(C) C
17 NTB NEUTRAL TERMINAL BLOCK
BMC OHT OVERHEAT THERMOSTAT
18
G G
OLR OVER LOAD RELAY
(SEE CONNECTION APPLICABLE FOR
TRANS TRANSFORMER
YR
Y
31 BM WITH EXTERNAL OLR) VFC VOLT FREE CONTACT
Y
YR COOLING RELAY
HEATER OPTION SEE NOTE-4 ___ FIELD WIRING
HTR CONTROL
CONNECTION
AFS + DISCONNECT TAB - 1/4"
29 29 28 C NC 17
W1 W1 NO
STG1 SEE HTR
OPTION NOTES
30 30 28 28
W2 W2
SEE HTR
STG2 OPTION
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

TO 13
1
ELECTRIC
THERMOSTAT CONTROL VOLTAGE - 24VAC.
YR-1
VALVE 14
2
2. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
OR ITS EQUIVALENT.
TO HVTB TO HVTB USE COPPER CONDUCTOR WIRES ONLY.
L1 L2 L3 L1 L2 L3
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
OHT OHT 3. A 3 TO 4 MINUTE (APPROX.) BUILT-IN SHORT CYCLE
PROTECTION FOR COMPRESSOR IS AVAILABLE IN
FL FL
H1

ZAMIL ELECTRONIC THERMOSTAT.

4. IF HEATERS ARE FACTORY INSTALLED, PLEASE
HC1 HC3
OHT OHT
READ BROKEN LINES AS CONTINUOUS LINES.
HC1 HC2 HC3 HC4
H2
T1F
T2F
T3F
T1G
T2G
T3G

T1H
T2H
T3H
T1F
T2F
T3F

T1I
T2I
T3I

5. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER

TO BE PROVIDED BY CONSUMER WITH RATING AS
OHT
RECOMMENDED BY MANUFACTURER.
(#1)
FL

HEATER OPTION-1 (SEE TABLE) HEATER OPTION-2 (SEE TABLE) H3 FL

6. * HVTB IS REQUIRED ONLY FOR HEATER MODELS.
HEATER DATA TABLE
7. BMC-OLR CONNECTING WIRE NOT REQUIRED FOR
OHT FL
TO HVTB TO HVTB HTR OPT# STG I STG II STG
(#2)

L1 L2 L3 L1 L2 L3 5 K.W 2 1 5 K.W --- OLR. FIXED DIRECTLY BENEATH CONTACTOR.

6 K.W 2 1 6 K.W ---
OHT
7.5 K.W 2 1 7.5 K.W --- 8. NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER
10 K.W 2 2 5 K.W 5 K.W
SUPPLY ONLY.
FL FL
H4
FL
12 K.W 2 2 6 K.W 6 K.W

15 K.W 2 2 7.5 K.W 7.5 K.W OHT

HC1 HC2 10 K.W 10 K.W

20 K.W 2 2

25 K.W 2 2 12.5 K.W 12.5 K.W

T1G
T2G
T3G

T1H
T2H
T3H

30 K.W 2 2 15 K.W 15 K.W

T1F
T2F
T3F

T1I
T2I
T3I

35 K.W * 2
40 K.W * 2 2 x 10 K.W 2 x 10 K.W
29 HC1 28 30 HC2 28 NOTES: HTR-35 & 40KW IS APPLICABLE FOR
BWY 18 & 25 MODEL ONLY.
HEATER OPTION-3 (SEE TABLE) *USE OPTION 1 FOR 230V/3PH UNIT MODEL
*USE OPTION 3 FOR 380/460V/3PH UNIT MODEL

VFC OPTION FOR BM ON,OFF &TRIP INDICATION

WITH FURNAS/SIEMENS CONTACTOR AND OLR BMC-1A BMC-1B
AR4-2A AR4-2B 48 49 50
BM ON BM OFF
48 49 50
OLR-2
BM ON BM OFF 51 52
AR5-1 AR4-1
51A
BM TRIP
51 52
BM TRIP/FAIL
AR4 AR5
18 17 * *
* FOR UNITS WITH HEATER,CONNECT AR5 ACROSS
TERMINAL # 18 & 28
* FOR UNITS WITHOUT HEATER & BM WITH OLR
CONNECT AR5 ACROSS TERMINAL # 19 & 17
* FOR UNITS WITHOUT HEATER & BM WITHOUT OLR
FOLLOW AR5 CONNECTION BELOW:
AFS AR5
NC 28B
C 17
18
NO

NOTE: Refer to unit control box (inside panel) for exact wiring diagram.

13
 MAINTENANCE
Periodic Maintenance:
A systematic Periodic Maintenance will reduce the possibility of unsuspected breakdowns and will definitely minimize the
outage process. The following is a list of recommended checks and actions to be conducted at regular intervals for
smooth, reliable operation.

Weekly:
a) Listen to abnormal sounds. Stop the unit and rectify immediately
b) Check the condition of the filters. Clean or replace as necessary.
c) Check the general operating parameters (Temperature In & Out, CFM, Amps, etc.).

Monthly:
a) Check the condition of Fan belt. Replace if frayed or worn.
b) Check the Fan belt for proper tension.
c) Ensure the alignment of the pulleys. Secure them in position.
d) Inspect the motor and fan shaft bearing for signs of wear and/or lubricant leaks. Repair accordingly.
e) Check the condensate drain system for clogging. Clear and clean .
f) Check the condition of electrical contacts of all contactors, relays, starters, and control. Clean or replace as necessary.

MAINTENANCE PROCEDURES
Filter Cleaning/Replacement:
If the filter is of the throw-away type (synthetic media), then it is recommended to replace it every month (depending on
the operating conditions and the return air cleanliness).
If it is of the Aluminum, permanent type, then it is recommended to take it out and rinse it with clean water then leave to
completely dry in the sun before installing it again.

Belt Tensioning:
Once the variable pulley has been set to the desired speed (check CFM Adjustment), then the belt tension has to be
checked and adjusted if necessary.
Basically the belt should not be over tightened as it can damage the motor, nor to be loose as it can reduce the performance
of the blower.
To check for proper tension, push the belt from the center distance between the two pulleys with the thumb. It should not
sag for more than 1 cm.
To adjust the tension, you have to tighten or loosen the Quick Arm Adjustment screw to move the whole blower motor
assembly back or forth at will.

Caution: make sure to securely tighten the retaining nuts of the Quick Arm Adjustment shaft once you are
done with the adjustment of the belt tension.

Note: This is not applicable for units with Direct Drive type of Blower Fans (BWY 03/05).

Motor Replacement:
All the motors supplied with BWY series are equipped with self-lubricated bearings intended for lifetime continuous
operation.
However, and if it is required to change the motor (different selection, different requirement, etc.), then the special
arrangement for the Blower Motor Assembly will make the motor replacement a straightforward job following those
simple steps:
a) Disconnect the power supply to the unit.

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b) Open the side access panel.
c) Remove the motor cables from the contactor’s terminals.
d) Loosen the belt tension (Refer to “Belt Tensioning” above).
e) Free the belt(s) from the adjustable drive pulley.
f) Loosen the four (4) bolt/nut securing the legs of the motor to the Mounting Plate and slide the motor out.

For mounting the new motor, proceed in the reverse order.

For units with Direct Drive Blower Fan, steps “c” through “e” will be simply read as “ loosen the three nuts of the motor
holding arms and slide out the motor”.

Caution: Every time you change the motor, you have to verify the motor for right direction of rotation (proper
sequence of electrical phases) to secure the cable connection, the motor mounting nuts and the Quick Arm
Adjustment retaining nuts. The belt tensioning and pulleys alignment have to be observed.
CFM Adjustment:
Every Motor/Drive can operate in a 20% plus or minus bracket of the rated CFM through the adjustment of the adjustable
drive pulley and/or the selection of different Motor/Drive arrangement.
The drive pulley pitch diameter can be adjusted by:
a) Using an Allen Key, loosen the corresponding screw.
b) Rotate the outer sheave (disc) of the pulley clockwise to increase the speed, and counter clockwise to reduce the speed as desired.
c) Adjust the belt tension and secure the Allen Key screw in position.

For the Direct Drive type fans (BWY 03/05) the speed can modified by simply connecting the motor terminal to different
sockets as per the corresponding Wiring Diagram.

PARTS LIST
MODEL NUMBER BWY03C BWY03H BWY03M BWY03F BWY05C BWY05H BWY05M BWY05F

BLOWER MOTOR 800-547-72 800-547-72 800-547-72 800-547-73 800-546-88 800-546-88 800-546-88 800-546-90

BLOWER WHEEL 800-707-10 800-707-10 800-707-10 800-707-10 800-707-10 800-707-10 800-707-10 800-707-10

BLOWER MOTOR CONTACTOR 800-736-01 800-736-01 800-736-01 800-736-01 800-736-01 800-736-01 800-736-01 800-736-01

AIRFLOW SWITCH 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02

MODEL NUMBER BWY07H BWY07M BWY07F BWY10H BWY10M BWY10F BWY14H BWY14M BWY14F

BLOWER MOTOR 800-544-16 800-546-29 800-544-16 800-544-16 800-546-29 800-544-16 800-544-72 800-544-64 800-544-72

BLOWER WHEEL 800-707-46 800-707-46 800-707-46 800-707-02 800-707-02 800-707-02 800-707-02 800-707-02 800-707-02

BLOWER MOTOR CONTACTOR 800-095-00 800-095-00 800-095-00 800-095-00 800-095-00 800-095-00 800-098-56 800-098-54 800-098-54

AIRFLOW SWITCH 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02

MODEL NUMBER BWY18H BWY18M BWY18F BWY25H BWY25M BWY25F

BLOWER MOTOR 800-544-72 800-544-64 800-544-72 800-544-73 800-544-65 800-544-73

BLOWER WHEEL 800-707-00 800-707-00 800-707-00 800-707-22 800-707-22 800-707-22

BLOWER MOTOR CONTACTOR 800-098-56 800-098-54 800-098-54 800-098-58 800-098-56 800-098-54

AIRFLOW SWITCH 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02 800-005-02

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 TROUBLE SHOOTING
This table will provide the service people with basic outline and guidance about the most common problems they might face, their corresponding
symptoms, and the recommended action(s). If the problem persists, please call the nearest Zamil Dealer.

CAUTION OF SAFETY:
Disconnect all the mains supply to the unit. Check for proper power supply connections. Check for proper grounding of the unit. Make sure there is no
short circuit of the power supplies. With these basic checks, you can proceed to trouble shoot the unit. Switch ON the power to the Unit.

PROBLEM SYMPTOMS POSSIBLE CAUSES RECOMMENDATION

Unit not running No air delivery Electrical power not connected Check the power supply

Airflow switch open or defective Repair or replace

Broken belt/Defective motor Replace

Low cooling capacit Normal operating parameters Undersized unit Check the load calculation

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Reduced airflow Dirty coil Clean coil

Dirty or clogged filters Clean or replace

Loose belt Adjust the tension

Faulty drive selection Check and reselect