zamil air conditioner user guide

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ZAMIL AC USER GUIDE

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    PL-OM-CDL-07-1M

    INSTALLATION,

    OPERATION

    &

    MAINTENANCE

    MANUAL

    AIR COOLED CONDENSING UNITS

    'CDL' SERIES

    (R-22)

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    Contents Page

    General information .................................................................................................................................. 2

    Safety issues ............................................................................................................................................ 2

    Model decoding ....................................................................................................................................... 3

    Physical data ......................................................................................................................................... 4-5Electrical data ........................................................................................................................................... 6

    Dimensions .......................................................................................................................................... 7-11

    Typical schematic wiring diagram...................................................................................................... 12-16

    Field wiring connections ......................................................................................................................... 17

    Controls & sequence of operation .......................................................................................................... 17

    Rigging instructions ................................................................................................................................ 18

    Installation clearance .............................................................................................................................. 19

    Mounting location ................................................................................................................................... 20

    Load distribution ..................................................................................................................................... 21

    INSTALLATION INSTRUCTIONSGeneral ................................................................................................................................................... 22

    Location of unit ....................................................................................................................................... 22

    Refrigerant piping connections ............................................................................................................... 22

    Leak testing & refrigerant charging ......................................................................................................... 23

    Start-up inspection & check list ......................................................................................................... 23-24

    Check-out & operational start-up procedure ........................................................................................... 24

    ELECTRICAL

    Power supply .......................................................................................................................................... 25

    Unbalanced voltage ................................................................................................................................ 25

    Motor contactor ...................................................................................................................................... 26Fan motor ............................................................................................................................................... 26

    Crankcase heater ................................................................................................................................... 26

    Lube oil protection control ................................................................................................................. 26-27

    Voltage monitor ...................................................................................................................................... 27

    REFRIGERATION

    Compressor ............................................................................................................................................ 28

    High & low pressure protection .......................................................................................................... 29-30

    Pump down control ................................................................................................................................. 30

    Trouble shooting chart ....................................................................................................................... 31-33

    Parts list ................................................................................................................................................. 34

    Recommended spare parts .................................................................................................................... 35

    Preventive maintenance schedule .......................................................................................................... 36

    Material safety data sheet ...................................................................................................................... 37

    Pressure temperature chart ............................................................................................................... 38-39

    INDEX

    CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

    THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

    1

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    GENERAL STATEMENTCooline CDL series is designed and built for the optimum performance when matched with the right indoor unit (Refer

    indoor unit catalog). However, it is required that you become well acquainted with good practices for the proper install

    tion, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year.

    Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experenced technicians should perform the installation and other maintenance procedures.

    SAFETY ISSUESThere are three levels of safety hazards that are identified throughout this manual as Warning (where the situation w

    result in personal injury), Caution (where personal injury might occur), and Attention (where minor personal injury and/property damage could happen). Please understand and respect those identifications.

    WARNING: These units operate on a high voltage with moving parts (at high speed) which can lead serious injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical pow

    supply has been disconnected.

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

    are present.

    When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observ

    all the applicable safety measures (wear of safety helmet, boots, and goggles. Use of proper handling materials fobrazing and use of wet cloth for sequencing. A fire extinguisher should be easily accessible etc). He should also read a

    the instructions and information in this manual prior to attempting to perform any installation or servicing of the unit.All applicable local codes should be observed during installation and servicing.

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    1,2&3

    BASIC

    4,5&6

    NOMINALCOOLING

    CAPACITY(TON

    S)

    8

    REFRIGERATION

    CIRCUITTYPE

    7

    ELECTRICAL

    SUPPLY(V-Ph-Hz)

    9

    ELECTRICALKITSOPTION

    CDL

    COOLINE

    CONDENSING

    UNIT

    020

    025

    030

    035

    040

    050

    055

    065

    080

    100

    110

    135

    160

    195

    S:DUALSCROLL*

    H:DUALSEMI-HERMETIC

    RECIPROCATING**

    Q:QUADRUPLESEMI-HER

    METIC

    RECIPROCATING***

    L:DUALSEMI-HERMETIC

    RECIPROCATINGWITH

    UNLOADER**

    (LEADCOMPRESSOR)

    M:QUADRUPLESEMI-HER

    METIC

    RECIPROCATINGWITH

    UNLOADER***

    (LEADCOMPRESSOR)

    A:STANDARDOPTIONS+

    K:FANCYCLING&ADJUST-

    ABLEHIGH&LOW

    PRESSURESWITCHES

    V:VOLTFREECONTACTS****

    C:COMPRESSORCIRCUIT

    BREAKER

    P:PUMPDOWNSOLENOID

    VALVE

    B:K&VCOMBO

    E:K&CCOMBO

    G:K&PCOMBO

    T:K,V&CCOMBO

    M:K,V&PCOMBO

    N:V,C&PCOMBO

    L:K,V,C&PCOMBO

    MO

    DELDECODING

    L:380/415-3-50

    (4WIRE)

    10

    C

    ONDENSERCOIL

    A:ALU

    MINUMFIN

    B:COA

    TEDALUMINUMFIN

    C:COP

    PERFIN

    D:ALU

    MINUMFINWITHCOIL

    GUA

    RD

    E:COA

    TEDALUMINUMFIN

    WIT

    HCOILGUARD

    G:COP

    PERFINWITHCOIL

    GUA

    RD

    A:STANDARDOPTIONS

    +

    M

    :REPLACEABLECORE

    FILTER

    DRIER

    &

    SHUT-OFFVALVE

    P:PRESSUREGAUGES

    (SUCTION&

    DISCHARGE)

    O:PRESSUREGAUGES

    (SUCTION,

    DISCHARGE&OIL)+

    +

    H:HOTGASBYPASSVALVE

    R:CONDENSER

    PRESSU

    RE

    RELIEFVALVE

    J:M&PCOMBO

    K:M&OCOMBO

    N:M&HCOMBO

    Q:M&RCOMBO

    S:M,H&RCOMBO

    T:M,H&PCOMBO

    U:M,H&OCOMBO

    V:A,H&RCOMBO

    F:A,H&PCOMBO

    G:A,H&OCOMBO

    L:A,H,P&RCOMBO

    B:M,H,O&RCOMBO

    11

    MECHANICALKIT

    SOPTIONS

    NOTES:*DualscrollcompressorsareavailableuptomodelsCDL05

    5only.

    **Dualsemi-hermeticcompressorsareavailableformodelsCDL065-CDL100only.

    ***Quadruplesemi-hermeticcompressorsareavailableformodelsCDL110-CDL195only.

    ****Acombinationo

    fvoltfreecontactoption:1.UnitONindica

    tion,2.CompressorRUN/TRIP,3.Unittrip

    indication.

    +Standardoptions(formodelsuptoCDL065only)contains

    ealedtypefilterdrier,fixedlow&highpressureswitches.

    Standardoptions(formodelsCDL080-CDL195only)containreplaceablefilterdrier,ballvalve,sightglass,mufflerandwithoutspringisolator.

    ++Oilpressuregaugeisapplicableforsemi-hermeticcompressorsonly.

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    NOTE:

    * Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.

    ** Unit is factory supplied with holding charge only.

    *** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.

    + Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.

    ++ Based on free field area at ARI conditions. Tolerance: 2dBA.

    +++ Values indicated are for standard unit with aluminum fin condenser coils.

    MODEL NUMBER CDL020 CDL025 CDL030 CDL035 CDL040 CDL050 CDL0

    NOMINAL CAPACITY , TONS* 18.4 22.3 27.6 35.5 42.1 48.5 54.8

    NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Dual Dual Dua

    COMPRESSOR Type Scroll

    Oil per system (liters) 3.25 3.25 4.14 4.67 5.91 6.3/5.91 6.3

    Refrigerant** R-22

    Charge per system (oz)*** 332 402 497 640 758 987/758 987

    CONDENSER FAN Type Propeller

    Qty. Diameter (inch) 2 30 2 30 4 30 4 30 4 30 4 32 4 3

    Nominal CFM 13000 13000 26000 26000 26000 42776 4137

    Motor HP RPM 1.5 950 1.5 950 1.5 950 1.5 950 1.5 950 2 920 2 9

    CONDENSER COIL Type Inner grooved tubes and enhanced fins

    Tube DiaRowsFins per inch 3/8314 3/8414 3/8214 3/8314 3/8414 3/83

    Total face area (Sq. ft.) 32.9 32.9 59.5 59.5 59.5 75 75

    HIGH PRESSURE SWITCH Open (PSIG) 450 10 450 10 450 10 450 10 450 10 450 10 450

    Close (PSIG) 360 15 360 15 360 15 360 15 360 15 360 15 360

    LOW PRESSURE SWITCH Open (PSIG) 25 5 25 5 25 5 25 5 25 5 25 5 25

    Close (PSIG) 50 5 50 5 50 5 50 5 50 5 50 5 50

    REFRIGERANT LINES+ Suction line size (OD), inch 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/

    Liquid line size (OD), inch 5/8 5/8 5/8 7/8 7/8 7/8 7/8

    SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 65.3/61.8/56.5 65.4/61.8/56.6 68.2/64.7/59.5 68.4/64.8/59.6 68.5/65/59.7 68.8/65.3/60 68.9/65.4

    OPERATING WEIGHT, Kg.+++ 716 760 1050 1159 1328 1447 148

    PHYSICAL DATA

    3/82143/8314

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    NOTE:

    * Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.

    ** Unit is factory supplied with holding charge only.

    *** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.

    + Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.

    ++ Based on free field area at ARI conditions. Tolerance: 2dBA.

    +++ Values indicated are for standard unit with aluminum fin condenser coils.

    MODEL NUMBER CDL065 CDL080 CDL100 CDL110 CDL135 CDL160 CDL1

    NOMINAL CAPACITY , TONS* 66.7 79.2 97.5 110.9 132.9 158.7 195.

    NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Quadruple Quadruple Quadruple Quadru

    COMPRESSOR Type Semi-hermetic reciprocating

    Oil per system (liters) 7.4 7.4 7.7 4.0 7.4 7.4 7.7

    Refrigerant** R-22

    Charge per system (oz)*** 1200 1426 1755 998 1196 1428 175

    CONDENSER FAN Type Propeller

    Qty. Diameter (inch) 4 32 6 32 6 32 6 32 8 32 10 32 12 3

    Nominal CFM 41240 59400 59856 65736 81280 97620 1197

    Motor HP RPM 2 920 2 920 2 920 2 920 2 920 2 920 2 9

    CONDENSER COIL Type Inner grooved tubes and enhanced fins

    Tube DiaRowsFins per inch 3/8414 3/8314 3/8414 3/8414 3/8414 3/8414 3/84

    Total face area (Sq. ft.) 87.5 100 120 160 168 190 240

    HIGH PRESSURE SWITCH Open (PSIG) 450 10 450 10 450 10 450 10 450 10 450 10 450

    Close (PSIG) 360 15 360 15 360 15 360 15 360 15 360 15 360

    LOW PRESSURE SWITCH Open (PSIG) 25 5 25 5 25 5 25 5 25 5 25 5 25

    Close (PSIG) 50 5 50 5 50 5 50 5 50 5 50 5 50

    REFRIGERANT LINES+ Suction line size Dual 2-1/8 2-5/8 2-5/8 N.A. N.A. N.A. N.A

    (OD), inchQuadruple N.A. N.A. N.A. 1-5/8 2-1/8 2-1/8 2-5/

    Liquid line size Dual 7/8 1-1/8 1-1/8 N.A. N.A. N.A. N.A

    (OD), inchQuadruple N.A. N.A. N.A. 7/8 7/8 7/8 1-1/

    SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 68.6/65/59.8 70.5/66.9/61.7 70.6/67/61.8 70.3/66.8/61.5 71.7/68/62.7 72.8/69.2/64 73.3/69.8

    OPERATING WEIGHT, Kg.+++ 1857 2145 2495 3234 3500 3956 482

    PHYSICAL DATA

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    CDL020

    CDL025

    CDL030

    CDL035

    CDL040

    CDL050

    CDL055

    CDL065

    CDL080

    CDL100

    CDL110

    CDL135

    CDL160

    CDL195

    CRAN

    KCASEHEATER

    Volts

    CB

    (Qty.)

    OUTPUT

    POWER

    LRA

    (each)

    FLA

    (each)

    Qty.

    CB

    Poles

    LRA

    (each)

    RLA

    (each

    )

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    380/415-3-50

    MODEL

    NUMBER

    SUPPL

    YVOLTAGE

    COMPRESSOR

    COND

    ENSERFANMOTORS

    EL

    ECTRICALDATA

    MOCP

    MCA

    M

    ax.

    Min.

    Nominal

    (V-Ph-Hz)

    342

    342

    342

    342

    342

    342

    342

    342

    342

    342

    342

    342

    342

    342

    457

    457

    457

    457

    457

    457

    457

    457

    457

    457

    457

    457

    457

    457

    Qty.

    49.4

    70

    2

    19.2

    125

    3

    2

    3.12

    19

    1.5

    1

    380

    61

    0.16

    50.3

    70

    2

    19.6

    118

    3

    2

    3.12

    19

    1.5

    1

    380

    61

    0.16

    73.7

    100

    2

    27.2

    198

    3

    4

    3.12

    19

    1.5

    2

    380

    61

    0.16

    88.1

    120

    2

    33.6

    225

    3

    4

    3.12

    19

    1.5

    2

    380

    120

    0.32

    108.1

    150

    2

    42.5

    250

    3

    4

    3.12

    19

    1.5

    2

    380

    120

    0.32

    114.2

    150

    2

    42.5/48.7

    250/310

    3

    4

    2.70

    13.9

    2.0

    2

    380

    120

    0.32

    120.4

    150

    2

    48.7

    310

    3

    4

    2.70

    13.9

    2.0

    2

    380

    120

    0.32

    151.4

    200

    2

    60.1

    504

    3

    4

    2.70

    13.9

    2.0

    2

    240

    200

    0.83

    196.7

    250

    2

    80.2

    393

    3

    6

    2.70

    13.9

    2.0

    3

    240

    200

    0.83

    236.7

    300

    2

    98.0

    500

    3

    6

    2.70

    13.9

    2.0

    3

    240

    200

    0.83

    254.9

    300

    4

    54.9

    304

    3

    6

    2.70

    13.9

    2.0

    3

    240

    100

    0.42

    282.4

    325

    4

    60.1

    304

    3

    8

    2.70

    13.9

    2.0

    4

    240

    200

    0.83

    373.3

    450

    4

    80.2

    393

    3

    10

    2.70

    13.9

    2.0

    5

    240

    200

    0.83

    416.5

    500

    4

    98.0

    393

    3

    12

    2.70

    13.9

    2.0

    6

    240

    200

    0.83

    Total

    Watts

    Total

    Amps

    LEGEND:

    MCA

    -MinimumCircuitAmpacity

    MOCP-MaximumOverCurrentProte

    ction

    RLA

    -RatedLoadAmps

    LRA

    -LockedRotorAmps

    FLA

    -FullLoadAmps

    CB

    -CircuitBreaker

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    DIMENSIONS

    NOTE: All dimensions are in mm.

    CDL 020 & CDL 025

    CDL 030, CDL 035 & CDL 040

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    DIMENSIONS

    NOTE: All dimensions are in mm.

    CDL 050 & CDL 055

    CDL 065

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    DIMENSIONS

    NOTE: All dimensions are in mm.

    CDL 080 & CDL 100

    CDL 110

    MODEL H

    CDL 080 1950

    CDL 100 2253

    DIMENSIONS

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    DIMENSIONS

    NOTE: All dimensions are in mm.

    CDL 135

    CDL 160

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    DIMENSIONS

    NOTE: All dimensions are in mm.

    CDL 195

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    TYPICAL SCHEMATIC WIRING DIAGRAMMODELS: CDL020 - CDL100

    Power supply: 380/415V-3Ph-50Hz

    NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional item 2. Refer to unit control box (inside panel) for exact wiring diagram.

    T1A

    T1B

    COMP

    1

    T2A

    T3A

    COMP

    2

    T3B

    T2B

    DISCONNECTSWITCH OR CB

    (SEE NOTE-4)

    TO FUSED

    L2

    L1

    L3

    LUG

    HVTB

    SHEET 2OF 2FORCONDENSERFAN MOTORPOWER CONNECTIONS.

    PLEASE REFER TO

    Y2STG2COOLING

    LEDPOWER INDICATOR

    J_PROG

    FUSE

    TRANS

    12v-0-12v

    240v

    SEC

    PRI

    LIVE

    P3_##

    DIP SWITCH

    ON D IP

    LED FAULT INDICATOR

    LOCK2

    SYSTEM2

    LOCK1

    SYSTEM1

    (LP1)

    (LP2)

    LP2

    23B

    22B LPS2

    P

    (SSPS1)

    (SSPS2)

    24A21AHP1

    (HP2)

    LP1

    (HP1)

    HP2

    27B

    23A

    22A

    21B

    27A

    24B

    OLR2-1

    ON/OFF

    (ON/OFF)

    ECBSQMBO4 ( P III )

    W2

    W1

    Y2

    OLR1-1

    Y2

    JP5 26AJP3 25A

    HPS2

    LPS1

    P

    P

    (OPS2)

    JP6JP4 25B 26B

    P

    HPS1(OPS1)

    4B

    P2

    TO ATB

    NEUTRAL

    OUTFAN1

    OUTFAN2

    X2

    41B

    HEATER2

    INFAN

    HEATER1

    X1

    41A

    SEE VFCCONNECTION(ATRIGHT)

    TOFR2

    TOFR1

    1 1B1AJP1

    ATB

    JP2

    STG1COOLING

    ( NOTE 7)

    RCOMP1

    COMP2

    P1

    G

    Y1

    C

    4A

    3B

    3A

    R24Vac

    JP

    Y1

    C

    LVTB

    CC2

    CC1

    R

    C

    Y1

    ATB

    PLEASE REFER TO FAN MOTORCONTROL CONNECTION, (SHEET 2 of 2)

    G

    W1

    W2

    YellowOFF blinking slow - LPS1 ckt fault

    OrangeSet dip switch #3 according to unit's option(pump down or no pump down)

    note:

    blinking slow - LPS2 ckt fault

    blinking fast - HPS2 ckt fault

    blinking fast - HPS1 ckt fault

    system 2 fault diagnostic

    ECB DIP SWITCH SETTINGS & LED INDICATORS

    Green

    on-board programming function (always set to on)

    (Comp1&2 Auto Lead Lag)

    DIP SWITCH #

    FACTORY SETTINGS OF DIP SWITCHES

    OFF= WITHOUT PUMP DOWN

    ON

    OFF=S2

    S4

    S3

    S3S1 S2 RedS4

    LOAD BALANCE

    OFF=TEST MODE DISABLES1

    system lock-out due to system fault

    LED INDICATORS

    power on/off indicator

    system 1 fault diagnostic

    ON= COMPRESSOR 1 LEAD

    ON= WITH PUMP DOWN OPTION

    ON= TEST MODE ENABLE

    TO HVTBL1

    TO NTBN

    NTB

    NEUTRAL

    PDS1

    PDS2

    F1

    OLR2OLR1

    CC1 CC2

    DIPSWITCH S2 SHOULD ALWAYSBESET TO"ON"POSITION.COMP1SHOULD ALWAYSBE LEADCOMPRESSOR.

    HGS CONNECTION WITH COMP UNLOADER

    AR9-1

    HGS CONNECTION W/O COMP UNLOADER

    AR9-1

    AR9

    NO

    NC

    5AC

    NOTE:

    P

    LPS5

    6DAR8-1

    6E

    LPS51 NO

    PNC

    C

    Y2 [LVTB]

    AR8-16E 6D

    31B

    Y1 [LVTB] 31AAR8

    2HGS6C

    HGS6C

    2

    17A

    17A C [LVTB]

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    LEGEND

    AHU AIR HANDLING UNIT

    AFS AIR FLOW SWITCH

    AR AUXILIARY RELAY

    ATB AUXILIARY TERMINAL BLOCK

    BM BLOWER MOTOR

    BMC BLOWER MOTOR CONTACTOR

    CC COMPRESSOR C ONTACTOR

    CCA CC AUXILIARY CONTACT

    CB CIRCUIT BREAKER

    C. HTR CRANKCASE HEATER

    COMP/C COMPRESSOR

    ECB ELECTRONIC CONTROL BOARD

    F FUSE

    FCS FAN CYCLING SWITCH

    FM FAN MOTOR (CONDENSER)

    FMC FAN MOTOR CONTACTOR

    FMCA FMC AUXILIARY CONTACT

    FR FAULT RELAY

    HC HEATER CONTACTOR

    HPS HIGH PRESSURE SWITCH

    HVTB HIGH VOLTAGE TERMINAL BLOCK

    JP JUMPER

    L1 LINE 1

    L2 LINE 2

    L3 LINE 3

    LPS LOW PRESSURE SWITCH

    LUG LUG GROUND

    NTB NEUTRAL TERMINAL BLOCK

    OLR OVER LOAD RELAY

    OPS OIL PRESSURE SWITCH

    P PRESSURE

    PDS PUMP DOWN SOLENOID

    S DIP SWITCH (IN ECB)

    SSPS SOLID STATE PROTECTION SYSTEM

    TOP FM THERMAL OVERLOAD PROTECTIO

    TRANS TRANSFORER

    UL COMP. UNLOADER SOLENOIDUVM UNDER VOLTAGE MONITOR

    FIELD WIRING

    TERMINAL BLOCK OR TERMINATION POIN

    SPLICE-CLOSED END

    TYPICAL SCHEMATIC WIRING DIAGRAMMODELS: CDL020 - CDL100

    NOTES

    1. ANY WIRE REPLACEMENT SHOULD BE OF 900

    OR ITS EQUIVALENT.

    2. USE COPPER CONDUCTOR WIRES ONLY.

    3. POWER MUST BE SUPPLIED TO CRANKCAS

    HEATER FOR MINIMUM OF 12 HOURS PRIOR TSYSTEM START UP.IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM.FAILURE TO FOLLOW THESE INSTRUCTIONMAY RESULT IN COMPRESSOR DAMAGE.

    4. FUSED DISCONNECT SWITCH OR CIRCU

    BREAKER TO BE PROVIDED BY CONSUMEWITH RATING AS RECOMMENDED BY COOLINE

    5. COMPRESSORS ARE PROVIDED WITH SSPS OR INTENAL LINE BREAK THERMAL OVERLOAD PROTECTION

    6. IF PDS IS FACTORY INSTALLED, PLEASE REA

    BROKEN LINES AS CONTINUOUS LINES.

    7. USE SHIELDED TYPE CABLE, #18 AWG (MINFOR LVTB FIELD WIRING. GROUND CONNECAT BOTH ENDS.

    8. COOLING OUTPUT SIGNAL FROM CONTROLLESHOULD FOLLOW THE SEQUENCE:ON SEQUENCE - Y1 FIRST, THEN Y2.

    OFF SEQUENCE - Y2 FIRST, THEN Y1.

    9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS 230VACALSO, COMP. LOCKOUT LIGHT (RED) OF ECB IS ON.

    _ _ _

    Power supply: 380/415V-3Ph-50Hz

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    (SEE NOTE-4)

    SWITCH OR CBDISCONNECTTO FUSED L1

    L2

    L3

    LUG

    HVTB

    T2B

    T3B

    T1B

    T3A

    T2A

    T1A

    COMP

    1

    COMP

    2

    OUTFAN1

    PRI

    OUTFAN2

    NEUTRAL

    LIVE

    SEC

    LED

    COMP1

    COMP2

    INFAN

    HEATER1

    HEATER2

    ON/OFF

    (ON/OFF)

    (LP2)

    J_PROG

    P3_##

    ON DIP

    SYSTEM2

    LOCK2

    SYSTEM1

    LOCK1

    (HP2)

    (LP1)

    LP2

    LP1

    (HP1)

    HP2

    HP1

    W2

    W1

    G

    Y2

    Y1

    C

    RX2

    X1

    P2

    P1

    FUSE

    OLR1-1 HPS1

    P

    21A25A24A JP3 26AJP5

    27A

    DIP SWITCH

    26B27B

    21BOLR2-1

    25BJP424B JP6

    HPS2

    P

    LPS1

    23A

    22A

    P

    22B

    23B P

    LPS2

    TRANS2

    230v

    12v-0-12v

    R

    C

    Y1

    Y2

    LVTBR

    Y1

    Y2

    STG1 COOLING

    STG2 COOLING

    24Vac

    FROM T'STAT CONTROLLER OR DDC(by others)

    CC1

    CC2

    JP1

    ATB

    1 JP21A 1B

    ATB

    TO ATB

    41B

    41A

    4B

    4A

    3A

    3B

    UVM CONNECTION

    TO ATB

    TO ATB 1A

    1

    L2L1

    L1 L21

    (REMOVE JP1)

    L3

    L38

    UVMUVM-1

    ECB1LED FAULT INDICATOR

    POWER INDICATOR

    TOFR2 FR1

    TO

    SEE VFC CONNECTION

    SQMBO4 ( P III )

    ( NOTE 8)

    SWITCHING CONTACTS

    JP

    ( NOTE 9)

    CNEUTRAL

    SEC

    PRI

    230v

    12v-0-12v

    TRANS3

    J_PROGPOWER INDICATOR

    LED

    DIP SWITCH

    DIPON

    SYSTEM2

    FUSE

    LIVE

    SYSTEM1

    P3_##

    LED FAULT INDICATOR

    LOCK1LOCK2

    ON= WITH PUMP DOWN OPTIONOFF= WITHOUT PUMP DOWNS3

    blinking fast - HPS2 ckt fault

    blinking slow - LPS2 ckt fault

    system 2 fault diagnostic

    blinking fast - HPS1 ckt fault

    blinking slow - LPS1 ckt faultsystem 1 fault diagnostic

    system lock-out due to system fault

    power on/off indicator

    LED INDICATORS

    (pump down or no pump down)Set dip switch #3 according to unit's option

    on-board programming function (always set to on)

    FACTORY SETTINGS OF DIP SWITCHES

    ONOFF

    note:

    DIP SWITCH #

    S4

    Yellow

    Orange

    S4S2S1 S3

    Green

    Red

    ECB DIP SWITCH SETTINGS & LED INDICATORS

    ON= COMPRESSOR 1 LEAD

    ON= TEST MODE ENABLE

    (Comp1&2 Auto Lead Lag)

    OFF=TEST MODE DISABLES1

    S2 OFF=LOAD BALANCE

    25D

    25C27C

    LP1

    LP2

    (LP2)

    (LP1)

    HP2

    (HP2)

    (HP1)

    22C

    22D

    23D

    23C

    OLR4-1

    27D

    21D24D JP8

    SQMBO4 ( P III )

    HP1

    (ON/OFF)

    ON/OFF

    ECB2Y2

    W1

    W2

    Y1

    G

    OLR3-121C

    24C JP7

    JP

    P

    LPS4

    P

    P

    LPS3

    HPS4

    JP10 26DP

    HPS3

    26CJP9

    1

    SEE VFC CONNECTION

    OUTFAN2

    OUTFAN1

    HEATER2

    X2

    X1

    41D

    41C

    HEATER1

    INFAN

    FR3FR4TO TO

    P1

    P2

    COMP2

    4D

    3D

    4C

    COMP1

    R

    3C

    CC4

    CC3

    TO ATB

    TB1

    STG3 COOLING

    STG4 COOLING Y4

    Y3Y3

    Y4

    15

    17

    31A

    31B

    YR3

    YR4

    31C

    31D

    YR3-1

    YR4-1

    15B

    31C

    31D

    L2C.HTR1L1

    (REMOVE JP3)

    (REMOVE JP4)

    COMP. SSPS CONNECTION

    (REMOVE JP8)

    (REMOVE JP7)

    COMP. 2:

    1

    COMP. 4:

    24DM1/11

    L1/MP/L

    SSPS4

    1

    COMP. 3:

    24CM1/11

    L1/MP/L

    SSPS3

    1

    24B

    L1/MP/L

    M1/11

    SSPS2

    COMP. 1:

    1

    24A

    L1/MP/L

    M1/11

    SSPS1

    COMP. 3:

    COMP. 4:

    L2

    L1

    C.HTR4

    C.HTR3

    COMP. 2:

    L2 C.HTR2

    25DM2/14

    L2/R/N2

    25CM2/14

    L2/R/N2

    25B

    L2/R/N

    M2/14

    2

    25A

    L2/R/N

    M2/14

    2

    (NOTE 5)

    L3

    L2

    L3

    SCROLL COMP CRANKCASE HTR CONNECTION

    COMP. 1:

    COMP

    3 4

    COMP

    T3C

    T2C

    T1C

    T2D

    T3D

    T1D

    NEUTRAL

    NTB

    TO HVTBL1 N

    TO NTB

    PLEASEREFERTO

    POWER CONNECTIONS.CONDENSER FANMOTOR

    SHEET 2 &3 OF 3 FOR

    SEE FM CONNECTION

    SEE FM CONNECTION

    1

    COMP

    T1A

    T3A

    T2A

    2

    COMP

    T2B

    T1B

    T3B

    COMP

    3

    T3C

    T2C

    T1C

    4

    COMP

    T2D

    T3D

    T1D

    L1A

    L3A

    L2A

    CB1

    L1B

    L2B

    L3B

    CB2

    TO HVTB

    L1L1L1

    TO HVTB

    L1L1 L1

    L3C

    L1C

    L2C

    CB3

    L3D

    L2D

    L1D

    CB4

    TO HVTB

    L1L1 L1

    TO HVTB

    L1L1L1

    COMP WITH CB OPTIONS

    CRANKCASE HTR CONNECTION(AS APPLICABLE)A. SEMI-HERMETIC RECIP. COMP. (BITZER)

    C.HTR2

    C.HTR1

    COMP. 2:1

    COMP. 1:1

    100B

    100A

    2

    2

    COMP. 3: 100CC.HTR31 2

    COMP. 4: 100DC.HTR41 2

    G

    2

    PDS4

    PDS3

    OLR4

    CC4

    PDS1

    PDS2

    CC1

    OLR1 OLR2

    CC2

    OLR3

    CC3

    CC4A-1B

    CC3A1B

    OLR2

    CC2

    OLR1

    CC1

    CC1A-1B

    CC2A-1B

    OLR4

    CC4

    OLR3

    CC3

    ( SS PS 3) ( OP S3 )

    ( SS PS 4) ( OP S4 )

    ( SS PS 1) ( OP S1 )

    ( SS PS 2) ( OP S2 )

    PRESSURE SWITCH SETTINGS

    HPS1 TO 4

    LPS 9-12

    LPS 5-8

    FCS1 TO 4

    NAME

    LPS1 TO 4

    360 15450 10

    5565

    55

    190 10

    45

    290 15

    25 5

    OPEN (PSIG)

    50 5

    CLOSE (PSIG)

    14

    TYPICAL SCHEMATIC WIRING DIAGRAMMODELS: CDL110 - CDL195

    Power supply: 380/415V-3Ph-50Hz

    NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional item 2. Refer to unit control box (inside panel) for exact wiring diagram.

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    105

    37B

    11BFCS21

    P

    1OB

    REFER OPTIONAL FCS CONNECTION BELOW.

    10A FCS1

    P

    **

    T.O.PFM311A

    12C 13CFMC3

    FM5

    12E

    12C**1

    TOECB1OUTFAN2

    FM3FMC3T.O.P

    13C2

    FMC513E

    T.O.P

    2

    12ATOECB1OUTFAN1

    FM1

    FMC1

    13A

    T.O.P

    2

    36C

    37C

    35C

    FM1

    37A

    36A

    35A

    FM3 FM2

    36B

    35B

    FMC1

    102

    101

    100

    FMC3

    103

    104

    CB6

    L1 L2 L3 L2L1

    REFER OPTIONAL FCS CONNECTION BELOW.

    FCS41 11D

    10D

    P

    2

    10C

    **

    FCS3

    P

    11BT.O.PFM3

    12D 13DFMC4

    2

    FMC1

    35C

    FMC4

    FM6

    1

    TO ECB2OUTFAN2

    FM4T.O.P

    12D 13D

    13FT.O.P

    12FFMC6

    2

    TO ECB2OUTFAN1

    FM2

    13BT.O.P

    12B2

    FMC2

    2

    12A

    TO ECB1OUTFAN 1

    FM1T.O.P

    13A

    35F

    35D

    36D

    37D

    FM4FM5

    37E

    36E

    35E

    FMC4FMC2

    107

    106

    108

    FMC5

    FM6

    37F

    36F

    FM1

    35A

    36A

    37A

    FMC6

    FMC1

    101

    100

    102

    2

    37C

    36C

    FM3

    6-FAN MOTOR LAYOUT

    CDL110

    CONTROL

    PANELCB7

    CB8

    L3L1 L2 L3

    CB6

    L2L1 L3

    CONTROL

    PANEL

    CDL135

    8-FAN MOTOR LAYOUT

    FMC5

    103

    35B

    35C

    37C

    36C

    FM1

    36A

    37A

    35A

    FM3

    FMC1

    101

    102

    100

    FMC3

    37D

    35D

    36D

    FM4FM2

    37B

    36B

    FM5

    36E

    37E

    35E

    FMC2

    105

    104

    108

    107

    106

    FMC4

    FM8

    35F

    FM7

    35G

    36G

    37G

    FM6

    36F

    37F

    35H

    36H

    109

    FMC7

    110

    111

    FMC6

    37H

    CB6

    L2L1 L3

    CB7

    L2 L3L1L2L1 L3

    CONTROL

    PANEL

    CB8 CB9

    L 2 L 3L1

    CDL135

    8-FAN MOTOR LAYOUT

    TOECB1OUTFAN 2

    TOECB1OUTFAN 1

    FMC6T.O.P12FFMC5T.O.P

    12E

    T.O.P10C

    FCS3

    P

    12G11C

    FM7

    FMC713G2

    13E2

    FM8T.O.P

    10D

    FCS4

    12H11D

    P

    FMC813H2

    13F2

    OUTFAN 2TOECB2

    TOECB2OUTFAN 1

    13A12A

    T.O.P10A 11A 12C

    P

    FM5

    FCS1FM3

    FMC313C

    2

    2

    T.O.PFM1

    FMC113B12B

    FM4T.O.P

    FM6

    10B12D11B

    P

    FCS2

    13DFMC4

    2

    2

    FM2T.O.P FMC2

    L3L1 L2

    CB7

    L3L 1 L2

    CB8

    L3L1 L2

    CB9

    FM2 FM4

    36D

    35D

    37D

    37B

    36B

    35B

    FMC2

    105

    104

    103

    37E

    35E

    36E

    FM5 FM7

    35G

    37G

    36G

    37F

    36F

    35F

    FM6 FM8

    35H

    37H

    36H

    111

    110

    109

    106

    107

    108

    FMC3 FMC4

    CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (6FANS)

    FM3T.O.P

    12C12C

    FM2TO ECB2

    T.O.P12B

    FM4T.O.P

    12D13B 12DFMC2

    2

    OUTFAN1

    FM5TO ECB1OUTFAN 2 T.O.P

    12E

    FM7T.O.P

    12G13E 12HFMC3

    FM6OUTFAN2TO ECB2

    2

    12FT.O.P

    FM8T.O.P

    12H13F 12HFMC4

    2

    CONDENSER FAN MOTOR POWER & C ONTROL CONNECTIONS : WITH FAN CYCLING OPTION (8FANS)

    FMC5A-1

    FMC1A-1

    FMC6A-1

    FMC2A-1

    FMC1A-1

    FMC5A-1

    FMC2A-1

    FMC6A-1

    PANEL

    CONTROL

    10-FAN MOTOR LAYOUT

    CDL160

    FMC8

    35J

    FM1

    36A

    35A

    FM3

    37C

    37A

    36C

    35C

    35B

    FM2

    37B

    36B

    101

    100

    FMC1

    102

    CB6

    103

    105

    104

    37H

    35H

    36H

    35I

    37I

    36I

    35D

    FM4

    37D

    36D

    FM7 FM9 FM8

    108

    FMC2

    CB7

    107

    106

    FMC4FMC3

    CB8

    111

    110

    109

    CB9

    L1 L2 L3 L3L2L1 L3L2L1 L3L2L1

    36J

    37J

    FM10

    FM10FM8OUTFAN2

    13H12HT.O.P T.O.P

    12J 12JFMC4

    2

    13B13A

    13G12G

    OUTFAN1TOECB2

    TOECB2

    12BT.O.PFM2

    TOECB1OUTFAN 1

    OUTFAN 2TOECB1 FM7

    T.O.P

    12A

    FM1T.O.P

    12IFMC3

    12I

    12D12DT.O.PFM4

    FMC2

    2

    2

    FM9T.O.P

    FM3T.O.P

    12C 12CFMC1

    2

    L3L1 L2

    CB10

    **FMC8A-11 FMC7A-1

    13ET.O.P

    12EFMC5

    2 1

    FMC612F 13F

    2

    FMC2A-1 FM6FMC1A-1 FM5

    CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD OPTIONS(8FANS)

    35E

    36E

    37E

    FM5

    FMC6

    FM6

    FMC6

    112

    113

    114

    35G

    37G

    36G

    37F

    36F

    35F

    REFER OPTIONAL FCS CONNECTION BELOW. REFER OPTIONAL FCS CONNECTION BELOW.

    FCS3

    FCS4

    13ET.O.P10A

    FCS2FMC7A-11

    1OB

    12E

    P11B

    FCS1FMC1A-1 11A FM5

    FMC5

    12 FMC8A-110D

    FMC2A-110C

    FMC612F 13F

    P11D

    P

    2

    11B FM6T.O.P

    P

    (REMOVE JP9)

    (REMOVE JP10)

    OIL PRESSURE SWITCH CO NN.(AS APPLICABLE)OIL PRESSURE SWITCH CONN.(AS APPLICABLE)

    COMP 2

    25B

    CC2A-1A

    COMP 1

    25A

    1 CC1A-1A

    (REMOVE JP5)

    (REMOVE JP6)

    OPS2-1

    228B

    OPS2

    26B

    2240

    OPS1-1

    228A OPS1

    26A

    2240

    CC4A-1A

    25C

    COMP 4

    OPS4-1

    28D2

    CC3A-1A

    25C

    COMP 3 1

    OPS3-1

    28C2

    26D

    240

    OPS42

    26D

    240

    OPS32

    CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (10FANS)

    15

    TYPICAL SCHEMATIC WIRING DIAGRAMMODELS: CDL110 - CDL195

    Power supply: 380/415V-3Ph-50Hz

    NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional item 2. Refer to unit control box (inside panel) for exact wiring diagram.

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    61 6360

    COMP2 ON

    COMP2 TRIP

    INDIVIDUAL COMP. ON/OFF/TRIP

    COMP 2

    TO ECB1X2

    55

    COMP 1

    X1TO ECB1

    COMP1 ON

    COMP1 TRIP

    41BFR2 2

    56

    41AFR1

    58

    2

    UNIT ON

    43

    1

    45

    AR1

    UNIT TRIP

    44A

    UNIT TRIP

    46

    44

    2

    UNIT ON / OFF

    UNIT STATUS (VFC) IND ICATION CONNECTION

    AR9-16D6E

    AR8-1C

    NCP

    1 NOLPS5

    Y2 [LVTB] 31BAR9

    HGS CONNECTION W/O COMP UNLOADER

    Y1 [LVTB] 31AAR8

    HGS 26C

    17A

    C [LVTB]17A

    X2

    70

    COMP4 ON

    COMP4 TRIP

    71

    TO ECB2

    COMP3 TRIP

    41DFR4

    COMP3 ON

    65 66

    COMP 3

    TO ECB2X1

    41CFR3

    73

    2

    68

    2

    COMP 4

    44C44B

    73B

    72B

    71B

    73A

    71A

    72A

    CONTROLSTO ATB

    230Vac

    HTR1

    HTR2

    INFAN

    (in cond. unit)

    (in cond. unit)

    TO ECB

    30

    29

    14

    HC228

    AFS

    BMC19

    BM CONTROL

    STG1 COOLING

    STG1HEATER

    STG2HEATER

    STG2 COOLING

    ( NOTE 8)(REMOVEJUMPERJP)

    Y1

    W2

    W1

    Y2

    R

    C

    G

    TB1 (ECB)

    Y1

    W2

    W1

    Y2

    24VacR

    C

    G

    LVTB

    T3F

    T2F

    T1F

    (Stg. 1 Heating)

    T1H

    T2H

    T3H

    (Stg. 2 Heating)

    FROM T'STAT CONTROLLER OR DDC(by others)

    W2

    W1

    Y2

    Y1

    G

    C

    R

    68

    SWITCHING CONTACTS

    69

    70

    OPTIONAL AHU INTER-CONNECTION(POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR)

    TO POWER SUPPLYL1 L3L2

    TO POWER SUPPLYL2L1 L3

    TO POWER SUPPLY

    L1C

    L2C

    L3C

    L2L1 L3

    YR3

    Y4

    Y3STG3 COOLING

    STG4 COOLINGYR3

    Y3

    Y4

    LPS5C

    COMPRESSOR UNLOADER CONNECTION (OPTIONAL)

    C

    LPS6

    COMP 2TO ATB28B

    28B

    COMP 1TO ATB28A

    28A

    PNC

    6BNC

    P

    NC

    NOCLPS10

    P

    5B

    NO

    2

    PNOLPS9

    C6A

    5A

    NO

    NC

    2

    AR9-1

    HGS CONNECTION WITH COMP UNLOADER

    COMP1 SHOULDALWAYS BELEADCOMPRESSOR.DIPSW ITCH S2 SHOULDALWAYS BE SET TO "ON" POSITION.

    NCP

    NOTE:

    6ENOLPS5

    C AR8-16D 6C

    HGS 25A

    LPS11 NOC

    LPS12C

    NC

    NO

    UL3 & UL 4 CONNECTION APPLICALBLE FOR COMP WITH 3 STEPS

    P

    CAPACITY UNLOADING.

    NOTE

    TO ATBCOMP 4 28D

    C28BLPS8

    P

    NO

    NC

    6B

    P

    6CNC

    5B2

    NO

    NC

    TO ATB28CCOMP 3

    LPS7

    P

    28C C5C

    2UL3

    UL7

    UL8

    UL4

    UL1

    UL2

    UL6

    UL5

    FR1-1 FR3-1FR2-1 FR4-1

    CC2A-2A

    CC4A-2A

    AR1-1A

    FR3-2AFR1-2A

    FR2-2A

    CC1A-2A

    FR4-2A

    CC3A-2A

    OLR-1

    HTR2HTR1

    CB12

    HC2HC1

    CB11

    BMC

    OLR

    CB

    CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (12FANS)

    35I

    112

    FM1

    36A

    35A

    37E

    FM5

    36E

    35E

    37A

    37B

    35B

    36B

    FM2 FM11

    36K

    35G

    35F

    36F

    37F

    FM6

    35K

    37G

    36G

    FM7

    37H

    36H

    37K

    35H

    FM8 FM12

    36L

    35L

    37L

    FMC2

    101

    100

    L1

    CB7CB6

    FMC1

    102

    104

    103

    105

    L3L2 L3L2L1

    CB9

    107

    106

    FMC5

    108

    L1 L3L2

    CB9

    110

    109

    111

    FMC6

    L3L 1 L2

    36J

    35J

    37I

    36I

    FM9

    37J

    FM10

    CB10

    FMC7

    113

    114

    FMC8

    13A 13G12G

    TOECB1OUTFAN1

    OUTFAN 2TO ECB1 FM7

    T.O.P12A

    FM1T.O.P

    12KFMC5

    12K2

    FM11T.O.P

    FM5T.O.P

    12E 12EFMC1

    2

    12-FAN MOTOR LAYOUT

    CDL195

    CONTROL

    PANEL

    FM9T.O.P

    112IFMC5A-1 13I

    FMC7

    2

    FMC1A-1

    1

    FMC3T.O.P12C 13C

    2

    FM3

    35C

    36C

    37C

    FM3

    FMC3

    CB8

    L3L2L1

    FMC4

    FM4

    37D

    36D

    35D

    FM2TOECB2

    12BOUTFAN1 T.O.P

    12F13B 12D

    FM6FMC2

    12FT.O.P

    2FMC2A-1

    1

    TO ECB2FM4FMC4

    13DT.O.P

    2

    OUTFAN 212H

    T.O.PFM12

    13HT.O.PFM8

    12L 12LFMC6

    212JFMC6A-1

    113J

    T.O.PFM10

    FMC8

    2

    115

    116

    117

    REFER OPTIONAL FCS CONNECTION BELOW.**

    FMC1A-1

    1

    FM3FMC3

    13CT.O.P

    2

    SEE FCS CONN BELOW

    SEE FCS CONN BELOW

    SEE FCS CONN BELOW

    SEE FCS CONN BELOW

    10A 11AFCS1

    P

    12C

    1FMC2A-1

    P

    12DFCS310B 11B 13DT.O.P FMC4

    2

    FM4

    10C

    10D

    1

    1FMC6A-1

    FMC5A-1

    12JFCS4 11D

    P

    P

    FMC813J

    FM10T.O.P

    12IFCS2 11C 13IT.O.PFM9

    FMC7

    2

    2

    16

    TYPICAL SCHEMATIC WIRING DIAGRAMMODELS: CDL110 - CDL195

    Power supply: 380/415V-3Ph-50Hz

    NOTES1. ANY WIRE REPLACEMENT SHOULD BE OF 900

    OR ITS EQUIVALENT.

    2. USE COPPER CONDUCTOR WIRES ONLY.

    3. POWER MUST BE SUPPLIED TO CRANKCASHEATER FOR MINIMUM OF 12 HOURS PRIOR TSYSTEM START UP.IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM.FAILURE TO FOLLOW THESE INSTRUCTIONMAY RESULT IN COMPRESSOR DAMAGE.

    4. FUSED DISCONNECT SWITCH OR CIRCU

    BREAKER TO BE PROVIDED BY CONSUMEWITH RATING AS RECOMMENDED BY COOLINE

    5. COMPRESSOR MOTORS ARE PROVIDED WITH SSPS OR ITERNAL LINE BREAK THERMAL OVERLOAD PROTECTION

    6. USE DISCONNECT TAB OR SPLICE ONLY WHEREVER REQUIRED FOR EXTENSION OF ORIGINAL WIR

    7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR LVTFIELD WIRING. GROUND CONNECT AT BOTH ENDS.

    8. COOLING OUTPUT SIGNAL FROM CONTROLLESHOULD FOLLOW THE SEQUENCE:ON SEQUENCE - Y1 - Y2 - Y3 - Y4.OFF SEQUENCE - Y4 - Y3 - Y2 - Y1.

    9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGACROSS TERMINAL X1, X2 OF ECB & ATB #2 I230VAC. ALSO, COMP. LOCKOUT LIGHT (RED) IS ON

    +

    LEGEND

    AR AUXILIARY RELAY

    ATB AUXILIARY TERMINAL BLOCK

    BM BLOWER MOTOR

    BMC BLOWER MOTOR CONTACTOR

    CC COMPRESSOR C ONTACTOR

    CCA CC AUXILIARY CONTACT

    CB CIRCUIT BREAKER

    C. HTR CRANKCASE HEATER

    COMP/C COMPRESSOR

    DDC DIRECT DIGITAL CONTROLLER

    ECB ELECTRONIC CONTROL BOARD

    F FUSE

    FCS FAN CYCLING SWITCH

    FM FAN MOTOR (CONDENSER)

    FMC FAN MOTOR CONTACTOR

    FR FAULT RELAY

    HGS HOT GAS BYPASS SOLENOID

    HPS HIGH PRESSURE SWITCH

    HVTB HIGH VOLTAGE TERMINAL BLOCK

    JP JUMPER

    L1 LINE 1

    L2 LINE 2

    L3 LINE 3

    LPS LOW PRESSURE SWITCH

    LVTB LOW VOLTAGE TERMINAL BLOCK

    LUG LUG GROUND

    NTB NEUTRAL TERMINAL BLOCK

    OLR OVER LOAD RELAY

    P PRESSURE

    PDS PUMP DOWN SOLENOID

    SSPS SOLID STATE PROTECTION SYSTEM

    TOP FM THERMAL OVERLOAD PROTECTIO

    TRANS TRANSFORER

    T'STAT THERMOSTAT

    VFC VOLT FREE CONTACT

    YR COOLING RELAY

    FIELD WIRINGTERMINAL BLOCK OR TERMINATION POIN

    SPLICE-CLOSED END

    JUNCTION OF WIRES, CONNECTED

    CROSSING OF WIRES, NO CONNECTION

    _ _ _

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    TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS

    17

    CONTROLS AND SEQUENCE OF OPERATIONThe unit is equipped with an electronic control board which can be linked with any commercially available 24V ac thermstat or can be controlled through a DDC panel. With cooling input signals coming from a thermostat or DDC, the moto

    in the equipment are started in the following sequential order: condenser fan compressor motor. The cooling inpusignals to the units control board should always start first with the first stage (Y1) followed by the second stage (Y2) an

    OFF sequence should start with the second stage (Y2) followed by the first stage (Y1).

    Balance Loading of Compressors:The user can select the sequence of operation of the compressors; either com

    pressor 1 as always leading (dip switch #2 set at ON) or enabling balance loading of compressor (dip switch #2 set OFF). In balance loading function, the compressor with the least run time will be started first to equalize the run time

    the compressors. These functions are selectable through the dip switch on the electronic control board. Please refer the settings table shown in the units wiring diagram.

    Fault Diagnostics:In case of system fault, LEDs on the board emits a flashing signal indicating the nature or where th

    fault is. This is to guide the service technician in identifying the fault. Please refer to the settings table shown in the unitwiring diagram for the details of each respective fault against LED indicators.

    Compressor Lock-Out Function:If any of the units safety control devices trips and such condition is maintained foapproximately 3 minutes, the control will lock-out that particular system preventing a re-start. It can be re-set by shuttin

    off power to the thermostat or if the cooling signal to the board is turned OFF.

    Compressor Anti-Recycling Timer: The units electronic control board has a built-in three (3) minutes minimum otimer for the compressor. This is for compressor protection in case of accidental manual re-set or immediate re-cyclinthrough the thermostat due to load demand.

    FROM T'STAT CONTROLLER OR DDCSWITCHING CONTACTS

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    PROPER CLEARANCE TO BE PROVIDED

    MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR

    MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR

    PROPER CLEARANCE TO BE PROVIDED

    LIFT

    ATTENTION TO RIGGERS

    Hook rigging sling thru holes in base rail, as shown below.

    Holes in base rail are centered around the unit center of gravity.Center of gravity is not unit center line.Ensure center of gravity aligns with the main lifting point before lifting.

    Use spreader bar when rigging, to prevent the slings from damaging the unit.

    CAUTION

    All panels should be in place when rigging.Care must be taken to avoid damage to the coils during handling.

    Insert packing material between coils & slings as necessary.

    RIGGING INSTRUCTIONS

    MODELS: CDL020 - CDL025

    MODELS: CDL030 - CDL040

    MODELS: CDL050 - CDL195

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    WALL

    INSTALLATION CLEARANCE

    FIGURE - 2

    CORNER WALL

    NOTE: 1. All dimensions are in mm.

    2. If unit is installed in special pit, please observe the same tolerance for walls. Pit height should not exceedthe unit height.

    FIGURE - 1

    STRAIGHT WALL

    MODEL NUMBER A B C D E

    CDL020 - CDL025 1500 1500 1500 1500 1500

    CDL030 - CDL040 1500 1500 2000 1500 1500

    CDL050 - CDL195 2000 2000 3000 2000 2000

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    MODELS: CDL030 - CDL040

    MODELS: CDL050 - CDL065

    MODELS: CDL080 - CDL100

    MODELS: CDL110 - CDL195

    NOTE: All dimensions are in mm. Tolerance: 2mm.

    MOUNTING LOCATIONMODELS: CDL020 - CDL025

    MODEL A

    CDL110 1281

    CDL135 1281

    CDL160 1603

    CDL195 1823

    DIMENSIONS

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    LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)

    MODEL No. R1 R2 R3 R4 R5 R6 R7 R8

    CDL020 132 202 187 195 - - - -

    CDL025 142 214 198 206 - - - -

    CDL030 215 276 273 286 - - - -

    CDL035 234 308 295 322 - - - -

    CDL040 266 362 327 373 - - - -

    CDL050 347 352 392 356 - - -

    CDL055 354 360 400 366 - - - -

    CDL065 445 456 495 461 - - - -

    CDL080 278 304 439 454 332 338 - -

    CDL100 336 362 497 514 390 396 - -

    CDL110 418 418 410 410 445 445 344 344

    CDL135 450 450 443 443 483 483 374 374

    CDL160 506 506 488 488 539 539 445 445

    CDL195 610 610 593 593 660 660 547 547

    LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)

    MODEL No. R1 R2 R3 R4 R5 R6 R7 R8

    CDL020 151 221 206 214 - - - -

    CDL025 166 238 222 230 - - - -

    CDL030 237 298 295 308 - - - -

    CDL035 267 341 328 355 - - - -

    CDL040 309 405 370 416 - - - -

    CDL050 382 387 427 391 - - - -

    CDL055 396 402 442 408 - - - -

    CDL065 509 520 559 525 - - - -

    CDL080 315 341 476 491 369 375 - -

    CDL100 394 420 555 572 448 454 - -

    CDL110 476 476 468 468 503 503 402 402

    CDL135 511 511 504 504 544 544 435 435

    CDL160 575 575 557 557 608 608 514 514

    CDL195 698 698 681 681 748 748 635 635

    R1 R2

    R4R3

    R1 R2

    R4R3 R2 R4 R6

    R1 R3 R5 R7R5R3R1

    R8R6R4R2

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    GENERAL

    The complete shipment should be inspected for damage. Any damage visible at the time of delivery should be noted othe shipment invoice.

    These units are shipped completely assembled and wired. Units require interconnecting piping (AHU), external powe

    thermostat wiring, condensate drain piping and ducting as applicable.

    Size of unit for an installation should be based on a heat load calculation made according to applicable standards. Unimust also be installed in accordance with regulations of the "National Fire Protection Association" and local electric

    codes. Where local regulations vary with instruction furnished, installer should adhere to local standards.

    Prepare your concrete pad or steel stand as applicable. Remove shipping protective covers and wooden crating and lunit from base and place in position with necessary applicable vibration isolators.

    Equipment must be installed so as to allow for service access and air circulation in accordance with these instructionand other COOLINE publications for the specific equipment being installed.

    These units should be charged with R-22 refrigerant.

    LOCATION OF UNIT

    When selecting the location for the unit, the following points should be kept in mind:

    1. Provisions for a concrete slab which will allow for minimum clearance from building or structures

    2. That the terrain allows for drainage away from the unit.

    3. If the unit is to be roof mounted, inspect the roof for load bearing capacity. The roof should have sufficient structurstrength to carry the weight of the unit.

    4. Availability of electric power.

    5. Position the unit to provide for unrestricted air circulation and to prevent any possibility of air recirculation.

    6. Check minimum clearances required for your unit, with regard to walls, or other obstructions.

    7. Air cooled equipment should not be installed under low structural overhangs which can cause condenser air recirc

    lation or restriction.

    8. Care should be taken to prevent air from other sources from entering condenser, if this air is at a high temperatur

    REFRIGERANT PIPING CONNECTIONS

    Piping connections:

    Outdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. Th

    liquid and suction line diameters can be determined from the physical data table.

    It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigeratio

    standard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigera

    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 holding charge only. The correct system refrigerant charge for operation is given in the unit nam

    plate & physical data table when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge f

    maximum efficiency.

    Sweat connection:

    Use refrigerant grade piping. Service valves are closed from factory when shipped and ready for brazing. After wrappin

    the service valve with a wet cloth, the piping set can be brazed to service valve using either silver rod or silfos rod brazin

    material. When brazing completed, refrigerant piping and indoor coil are now ready for leak testing. This check shou

    also include all field and factory brazed joints.

    Warning: Relieve all pressure before refrigerant system repair or final unit disposal to avoid personal injury or death. Us

    service ports and open all valves.

    INSTALLATION INSTRUCTIONS

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    LEAK TESTING & REFRIGERANT CHARGING

    Leak test:

    Leak can occur from joints or fittings that are improperly brazed/connected during installation of indoor and outdoor unitThe installer should leak test the indoor unit & associated field supplied refrigerant piping, then the outdoor unit, eacseparately using electronic freon detector and/or soap bubbles.

    Refrigerant Charging:(To be used for system having a holding charge and to compensate for length of liquid line).

    1. Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Mak

    sure that no air & moisture enter the system. The whole system should be leak tested and evacuated before charginthe refrigerant.

    2. When system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging lines and manifolds must b

    purged with refrigerant vapor prior to admitting refrigerant into the system to prevent contamination system with non-condensab

    3. It is important to first determine the amount of refrigerant required for the system, the unit nameplate normally identthe weight of the refrigerant required.

    4. The refrigerant should be added in small amounts allowing sufficient time for the unit pressure to equalize each tim

    WIRING

    All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltag

    frequency and phase must coincide with the unit nameplate.

    Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate. The unwiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wirin

    The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused disconneswitch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone wire for thpurpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety & servicing purpose

    Wiring connection to the unit must have insulation suitable for temperatures of a minimum of 600C.

    Minimum circuit ampacity for each model is shown on the name plate and product catalog. Equipment wiring diagramshould be examined and thoroughly understood before field wiring connections are made.

    Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damage compressors and motors can occur, if improper voltage is applied.

    START-UP INSPECTION & CHECK LIST

    After the installation is completed in all respect, the following points should be covered before the system is switched on for operatio

    1. Remove or loosen shipping retainers under motor compressors. Make sure the hold down nuts on spring mounte

    compressors are not touching the compressor feet.

    2. Make sure all electrical fasteners/connections are tight and clean.

    3. All controls are set according to manufacturer's instructions (low & high pressure switch, pump down pressuswitch, fan cycling switch, etc...)

    4. Make sure all valves are open (compressor suction & discharge service valves, liquid line, etc.).

    5. Follow all the instructions from the warning tags and stickers.

    6. Compressor crankcase heater should be energized for 12 hours (special attention should be taken to disable compressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for fe

    minutes to pumpdown the system, even the thermostat is OFF).

    7. Thorough inspection on evaporator coil, condenser coil and other components for any physical damage.

    8. Expansion valve bulb is strapped properly at correct location.

    9. Circuit breaker/fused disconnect switch.

    10. Blower fan belt is properly tightened and pulleys are properly aligned.

    11. Blower fan & condenser fans are at correct rotation and their mountings are properly tightened.

    12. All refrigerant service valve caps are installed.

    13. All piping, piping insulation and piping supports are properly installed.

    14. Thermostat is the right one and installed properly.

    15. Duct work and accessories (check the following list and select whichever applicable to each jobs):

    Flexible ConnectionAir Filters Clean

    23

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    Air Filter Access Door GasketSound Attenuators (If Applicable)Fresh Air IntakeDuctwork Caulking Inside/Outside BuildingDuctwork Supports Inside/Outside BuildingDuct Leakage Inside/Outside BuildingVolume DampersVolume Damper Access DoorsFire DampersFire Damper Access DoorsTransfer Grilles/Door GrillesDuct Insulation/LinerDiffusers/GrillesDuct HumidistatFilter flag

    CHECK-OUT & OPERATIONAL START-UP PROCEDURE

    After the completion of inspection and check list, the following points should be covered before system is placed in operatio

    1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for checing Voltage, Amps, RPM, CFM, static pressure, etc.

    2. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere.

    3. Start the compressor and observe the following points (on multiple compressor units, it is highly recommended to stathe compressors one by one to achieve careful observation for each compressor).

    (a) Check compressor discharge and suction pressures. If not within system design limits, determine why and takcorrective action.

    (b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is requireleak test all connections and system components and repair any leaks before adding refrigerant.

    (c) Observe oil level in compressor crankcase sight glass (if available) and add oil as necessary to bring to recommended oil level.

    All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in ord

    to provide some allowance for oil which will be circulating in the system during operation. Depending on the syste

    design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may b

    necessary either to add or remove oil from a system any time it is first placed in operation with a different compressor

    An abnormally low oil level may result in a loss of lubrication; while an excessively high oil level may result in o

    slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may vary conside

    ably on initial start-up if liquid refrigerant is present in the crankcase, and the oil level should be checked with th

    compressor running after having reached a stabilized condition.

    (d) Thermostatic expansion valves must be checked for proper superheat settings. Recommended superheat is 15to 200F.

    (e) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage mu

    be within 10% of that indicated on the compressor nameplate. If high or low voltage is indicated, notify the pow

    company. The current normally should not exceed 110% of the nameplate rating. If amperage draw is excessiv

    immediately determine the cause and take corrective action. On three phase compressor motors, check to se

    that a balanced load is drawn by each phase.

    (f) Carry out any necessary tests, recording airflow rates, entering/leaving temperatures, sound levels, outdoor tem

    peratures, supply airflow rates in occupied spaces and any other specified parameters.

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    ELECTRIC POWER SUPPLY

    All wiring should be in accordance with National Electric Code and local standards.

    Before making an installation, check the electric power supply. The power supply must be of the same characteristics a

    that on the nameplate.

    Normally the wire size used establishes the circuits maximum permissible load. For example a number 12 wire circuit

    considered to be a 20 ampere circuit and is protected by a 20 ampere fuse. The unit amperage nameplate rating shou

    not exceed 80% of the circuit rating, 16 amperes.

    When identifying electrical trouble in any unit, check the power supply at the main disconnect switch and the unit. A hig

    or low voltage condition may prevent the unit from starting, or if the unit is running, compressor can cut-off automatica

    on the motor overload. On some installations, the voltage may be entirely adequate when tested, but may drop or surg

    some time later due to increase or decrease of load on the power line. This condition may be repeated daily at the sam

    hour. When this condition is suspected, make arrangements with the local power supplier to place a recording voltmet

    on the line to check and correct the erratic voltage conditions.

    The voltage drop should not be more or less than 10% of the units rated voltage. If the voltage at the meter is correct, b

    the voltage at the unit fluctuates 10% or more, the branch circuit is not adequate.

    UNBALANCED VOLTAGE

    Unbalanced voltage on a three phase circuit may be the source of electrical trouble. If balanced supply voltages are n

    always maintained, so with the three line currents will not be equal. Unbalanced voltage on a three phase compresso

    motor may overheat and trip the motor on external or internal current sensing motor protector, whichever one is provide

    To determine that an unbalanced voltage condition exists, the supply voltage at the main disconnect switch and at th

    unit disconnect switch should be measured. Voltage unbalance is calculated as follows.The percentage of voltage unbalance equals one hundred times the ratio of the Maximum Voltage Deviation from th

    Average Voltage, and the Average Voltage.

    The percentage increase in temperature rise in a phase winding resulting from voltage unbalance will be approximate

    two times the square of the voltage unbalance.

    Because of the unbalanced voltage condition in a three phase circuit, it is possible that one phase winding in the com

    pressor motor may be over-heated while the other have a temperature within normal l imits. Where unbalanced voltage o

    a three phase circuit exists, the power company should be notified of such unbalance to determine, if the situation can b

    corrected.

    A common source of unbalanced voltage on a three phase circuit is a single phase load between two of the three phase

    A large lighting or heating circuit connection to one phase of a three phase circuit can easily cause sufficient variations

    motor currents to endanger the motor. Interchange the single phase loads to equally divide the entire loads among th

    three phases. Balance the supply voltage as evenly as possible.

    Unless the unbalanced voltage condition can be corrected, the only way to insure motor safety is to be sure that th

    protectors are in the high current phase when using two leg protection, or to use protectors in all three legs.

    ELECTRICAL

    Voltage unbalance, % = 100 xAverage voltage

    Maximum voltage deviation from average voltage

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    MOTOR CONTACTOR

    The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compre

    sor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, mot

    contactors are subjected to quick cycling due to various causes. This may cause burned and/or sticking contacts and ca

    cause a compressor motor failure, even though the motor overload protectors trip and open the control circuit.

    FAN MOTORThe condenser fan motor is a single speed electrical motor with ball bearings, protected with an automatic reset internoverload.

    CRANKCASE HEATERS

    The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest pa

    of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize whe

    the compressor is operating.

    Power must be supplied to crankcase heater for minimum of 12 hours prior to system start up. If power is off 6 hours

    more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions ma

    result in compressor damage.

    Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are n

    a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper pipinpractice, over feeding to the evaporator, leaking solenoid valve, etc.

    In some cases where migration of refrigerant to the crankcase occurred due to long storage time, shutdown period

    defective components, etc. The crankcase heater may be ineffective. Such cases may be easily observed by high o

    level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharg

    service valves of the compressor and release all liquid refrigerant from the compressor.

    The liquid refrigerant dilutes the oil in the crankcase and the refrigerant rich oil will be pumped to the rods and th

    bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at th

    bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor t

    drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinder

    during the suction stroke causing them to wear during the compression stroke.

    When the crankcase is filled with liquid refrigerant and the compressor starts severe agitation, oil foaming etc. will causmajor damage to the compressor.

    Periodic checking for proper operation of crankcase heater is highly recommended.

    LUBE OIL PROTECTION CONTROL

    Pressure lubricated refrigeration compressors require a pressure protector in the event of an oil pressure failure. Th

    lube oil pressure protection control is factory set to conform with compressor manufacturers specifications and shou

    not be changed.

    The control measures the net oil pressure available to circulate oil through the lubrication system. The positive displac

    ment oil pump circulates the refrigerant oil through the lubrication system. Since the oil pump is connected directly to th

    compressor crankcase, the inlet pressure to the oil pump will always be the crankcase pressure. The oil pump outle

    pressure will be the crankcase pressure plus the oil pump pressure. Therefore, net oil pump pressure will always be thpump outlet pressure minus the crankcase pressure.

    The control contains a built-in time delay switch that is a trip-free expansion rod device actuated by a resistance heate

    The control is factory set to cut-in at 18 PSIG and cut out at 9 PSIG. When the compressor starts the resistance heat

    of the time delay becomes energized. If the net oil pressure does not build to 18 PSIG or above within 120 seconds, th

    time delay trips to stop the compressor. If the net oil pressure drops below 18 PSIG, but not below 9 PSIG during

    running cycle, the time delay resistance heater becomes energized and unless the net oil pressure returns to 18 PSIG

    above during the 120 seconds safety time period, the compressor will shut down. The compressor will shut down whe

    ever the net oil pressure drops below 9 PSIG, and will never run for more than the predetermined 120 seconds o

    abnormal oil pressure.

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    New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type m

    chanical expansion rod-resistance heater type oil protection controls.

    FEATURES:

    An entirely new control concept. This unique design incorporates a modern pressure transducer to monitor oil pressur

    Each control reflects improved calibration stability over the control's entire pressure range.

    Controls boast truly accurate timing despite ambient temperature and voltage variations.

    All electronic components are purposely "over-sized" and computer-matched to provide the greatest safety factor andependable service life.

    Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibrtion, dirt or moisture.

    Controls reset instantaneously, thanks to the precise solid state timing circuit. No annoying wait for old-fashioned timheater to cool down.

    Control module is interchangeable with the old type conventional oil protection and with competitive brands of oprotection controls. An exact replacement from a mounting, wiring and logic function standpoint.

    Control maintains timing over the full voltage range of 102 to 264 VAC. Voltage selection is not necessary.

    Unit is not position sensitive.

    Users are offered a choice of controls with or without cover, a handy mounting bracket and other options.

    "Logic" circuitry in the module monitors oil pressure pulses during marginal operation and integrates them resulting a longer span of time before lock-out occurs.

    Last, but not least, it has enlarged the reset button to a new "thumb-sized" dimension. The reset button is slightrecessed to protect it from damage.

    VOLTAGE MONITOR

    This device protects the motors in the unit from faults such as; under or over voltage, unbalance & phase reversal of th

    power supply. When the device sensed such faults, it will cut-off the supply in the control circuit thereby cutting off pow

    to the motors. The voltage monitor will re-set automatically when power is brought back to its normal conditions.

    LINE VOLTAGE

    RANGEUNDER VOLTAGE

    TRIP

    90%190 - 480 VAC

    TRIP & RE-SET VOLTAGE (% OF SET POINT)

    OVER VOLTAGE PHASE IMBALANCE

    RE-SET

    93%

    TRIP

    110%

    RE-SET

    107%

    TRIP

    6%

    RE-SET

    4.5%

    78 60 18_ =

    OIL PUMPOUTLET PRESSURE

    CRANKCASEPRESSURE

    NET OILPRESSURE

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    REFRIGERATIONCOMPRESSOR

    Scroll compressors are used as standard for models CDL020-CDL055 and semi-hermetic reciprocating compressors a

    standard for models CDL065 - CDL195. All the compressors are conforming to ARI 540 standard. The compressors a

    equipped with internal motor protection, factory installed crankcase heaters and rubber vibration isolators for quiet an

    efficient operation. As an option, semi-hermetic compressor can be fixed on anti-vibration mounting (spring type) alon

    with suction & discharge line vibration eliminators. Oil pressure control is provided on units with semi-hermetic compre

    sor only. Each compressor has lock-out devices to protect it from short cycling when tripped by safety controls. Eac

    compressor has separate condenser coil with safety controls. Sight glass and filter drier are standard for all models.

    Semi-hermetic Compressor:

    These Semi hermetic reciprocating compressors are accessible hermetic type. Compressor and motor are enclosed a hermetically sealed housing, with out shaft seal. The compressors are equipped with an oil sight glass through whic

    the oil quantity and its conditions in the crankcase can be observed. These compressors can be disassembled in the fiefor service.

    Refrigerant-cooled motor compressors have an oil pressure lubrication system. This system is supplied by a positivdisplacement oil pump, working in either direction. It is protected by a screen and is made accessible for quick o

    pressure checking by a Schrader check valve. The use of oil pressure control safeguards the lubrication system. Thes

    compressors can be provided with capacity control (optional). The use of unloading provides optimal part load capacitie

    Scroll Compressors:

    Scroll Compressors are used in some of these units. The major benefits being:

    1. Low Sound Level: Quieter operation because of no dynamic suction and discharge valves action.

    2. Low vibration and discharge pulses.

    3. High Energy Efficiency: Because of high volumetric efficiency it minimize pressure and heat transfer losses.

    4. High Capacity: Due to its high mass flow and high compression ratios.

    5. High Durability: With its robust design, few moving parts, low motor strains, large internal volume for liquid handlinmakes this compressor highly reliable.

    6. High Charge Limit: Therefore, lower applied costs as no suction accumulator required, no need for pump dow

    system and check valve in discharge line.Low capacity can be caused by inefficient compressor, that is, the compressor does not pump sufficient quantity orefrigerant, even though a full charge is available in the system.

    Scroll Compressor Rotation:

    Scroll compressors are designed to operate in single direction only. Hence, care has to be taken to ensure correrotation when the system is operated. Verification of correct rotation is by observing that the suction pressure drops an

    discharge pressure rises when compressor run. Reverse rotation results in abnormal sound, as well as, substantially locurrent draw and by interchanging power supply wire L1 & L3 will correct this problem.

    Compressor Maintenance:

    Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is foun

    to be all right but the electrical components are defective, remove and replace the defective electrical components only.Below are some tests that should be performed on the compressor to determine, if the compressor is defective.

    1. Test compressor motor winding for ground.

    2. Test compressor motor windings for continuity.

    3. Test that compressor motor will run both without a load and under a load.

    4. Test the current or ampere drawn.

    5. Observe sound level of compressor.

    To establish that the compressor suction and discharge valves are operating and holding properly, attach gauges to thliquid and suction service valves. "Front seat" the liquid service valve.

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    Start the compressor, allowing it to operate long enough to pump down to approximately 1 PSIG. Shut the compressor o

    and observe the compound gauge. The gauge pressure may build rapidly. Repeat the pump down process several time

    observing the gauge pressure each time after the compressor stops. If the gauge pressure builds rapidly each time aft

    the compressor stops, it indicates that the compressor discharge valves are not holding and refrigerant is leaking fro

    the high side to the low side of the compressor.

    To check the suction valves, assuming that the discharge valves are holding, allow the compressor to operate lon

    enough to pump down the system to approximately 10 inches of vacuum. If the compressor required longer time accomplish this, then the suction valves are not holding and the compressor should be changed out as it is defective.

    MOTOR COMPRESSOR BURN OUT PROCEDURE

    The extent of the contamination in a system will indicate the amount of clean-up necessary. If a compressor had burne

    out, the following method of clean-up is recommended:

    1. Discharge the refrigerant from the system.

    2. Replace the inoperative compressor.

    3. Clean up the system thoroughly and remove all the contaminations.

    4. Install a system cleaner or filter drier in the suction line and replace the liquid line filter drier.

    5. Connect a vacuum pump to both the low and the high side of the system to remove air and other non-condensable

    from the system.

    6. Allow the vacuum pump to operate until a pressure of 500 microns is achieved.

    7. Recharge the system and allow it to operate 8 to 12 hours.

    8. Take an oil sample and test for acidity.

    If the first acidity test shows that the acid content is below the safe level, as indicated in the test kit instructions, and th

    oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the syste

    provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. For a bad

    contaminated system that indicates acid in the oil after 8 to 12 hours of operation, change the suction and liquid line filte

    driers and check the system after 24 hours of operation.

    There are instances where contaminants are discovered in a refrigeration system with the compressor still operationa

    The same procedure applies, when cleaning these systems, as on a compressor burn-out.

    SOURCE OF CONTAMINATION

    There are many ways in which a refrigerant system can become contaminated. The most common of these are a

    follows:

    1. Improper or inadequate dehydration.

    2. Wet refrigerant.

    3. Wet oil (caution: It is best to purchase oil in small containers and use as needed. Open containers will absorb moi

    ture).

    4. Refrigerant leaks (allowing system to operate in a vacuum).

    5. Failure to remove oil and moisture after having opened the system for repair.

    6. Higher than normal operating temperatures and pressures will cause a breakdown of the oil and refrigerant.

    7. Improper use of soldering or brazing flux.

    HIGH PRESSURE SWITCH

    A high pressure switch is located in the discharge line and senses the discharge pressure. Should the discharge pressu

    exceed 450 psig, the control will open turning off the compressor. The control is designed to protect against excessiv

    discharge temperatures and pressures which can cause compressor overheating and damage to the motor windings

    valves.

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    Should the control open, it will remain open until the pressure in the system is lowered to 360 psig. Tripping of the hig

    pressure control is normally due to:

    1. Restricted condenser coil.

    2. Overcharge of refrigerant.

    3. Defective fan motor or fan capacitor.

    4. Incorrect fan blade.5. Fan motor internal overload tripping due to lack of lubrication or defective bearings.

    To test the high pressure control: Install a high pressure gauge to the access valve or the liquid line valve. Disconnect th

    condenser fan motor. Turn on the unit and observe the pressure on the gauge when the compressor trip off. The pressu

    should be 450 10 psig. Allow the system to remain off, until the gauge pressure drop to approximately 360 15 psig an

    reconnect the condenser fan motor. Reset the unit by putting off the thermostat and if the high pressure control ha

    closed, the compressor will restart.

    LOW PRESSURE SWITCH

    To provide protection for the compressor in the event of refrigerant loss, a low pressure sensor is installed in the suctio

    line.

    The control is preset to open when the suction pressure is 25 5 psig. The contacts of the control will close when thsuction pressure rises to 50 5 psig. To test the control for the correct pressure setting, install a compound gauge to th

    gauge port on the suction service valve. "Front seat" the liquid valve and start the unit. Note the gauge pressure, whe

    the compressor stops.

    To determine the cut-in pressure, allow the suction pressure to build slowly and observe the gauge pressure at the tim

    when contact closes. A good functional low pressure switch must have both cut-out and cut-in pressure within 2 psi

    PUMP DOWN CONTROL

    A pump down control is a solenoid type valve installed in the liquid line to prevent the flow of refrigerant into the evap

    rator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liqu

    line, but ahead of metering device.

    Pump down operation takes place as soon as the signal for cooling is switched off. The systems control closes the liquline solenoid valve while the compressor is continuously running to pump out a substantial portion of refrigerant in thevaporator. The compressor will shut off when either the suction pressure goes down at a pre-set pressure of 25 psi

    at a pre-set timing of 10 seconds whichever is satisfied first. On call for the next cooling cycle, the solenoid valve will genergized ahead of the compressor at a pre-set timing. This is to allow refrigerant to flow in the evaporator and thereb

    increasing the suction pressure above the low pressure trip setting before the compressor starts.

    A pump down control may be necessary on an installation where additional protection for the compressor is required

    prevent slugging of oil or l iquid refrigerant.

    Below are some conditions which may exist in an installation where additional protection is required:

    1. Migration of refrigerant to the compressor during the off cycle.

    2. Flooding, at start-up, due to improperly trapped lines or coil.

    3. Suction line in slab or beneath ground forming a large trap.

    4. Suction line in cool area causing refrigerant to condense during off cycle.

    5. Where condensing unit is installed using existing coils and copper lines, or on a new installation where the above sa

    conditions exist that cannot be avoided, which could result in compressor damage.

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    1. Close start or disconnect switch.

    2. Refer to electrical section.

    3. Repair or replace control.

    4. Relocate control.

    5. Check wiring against diagram.

    6. Replace or relocate.

    7. Trace control circuit with wiring dia-gram and repair.

    8. Replace the compressor with all pre-cautions.

    1. Line disconnect switch open.

    2. Overload protector tripped.

    3. Control stuck in open position.

    4. Control off due to cold location.

    5. Wiring improper or loose.

    6. Thermostat defective or improperlyinstalled.

    7. Control circuit open.

    8. Burned/open circuit motor winding.

    Compressor will not start nohum.

    TROUBLE SHOOTING CHART

    SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

    1. Additional current passing through

    overload protector.

    2. Low voltage to unit (or unbalanced ifthree phase).

    3. Overload protector defective.

    4. Excessive discharge pressure.

    5. Suction pressure too high.

    6. Compressor too hot - return gas hot.

    7.Compressor motor has a winding

    shorted.

    1.Check wiring diagram. Check for

    added fan motors, pumps, etc. con-nected to wrong side of protector.

    2. Determine the reason and correct.

    3. Check current, replace protector.

    4. Check airflow across the condenser

    coil, restrictions in refrigeration sys-tem.

    5. Check for possibility of misapplica-

    tion. Use stronger unit.

    6. Check refrigerant charge (fix leak)add if necessary.

    7. Replace compressor.

    1. Check wiring against diagram.

    2. Determine reason and correct.

    3. Determine reason and correct, re-place if necessary.

    4. Replace compressor.

    5. Replace compressor.

    6. Check crankcase heater.

    7. Unequilized pressure in the system

    1. Improperly wired.

    2. Low voltage to unit.

    3. Relay failing to close.

    4.Compressor motor has a windingopen or shorted.

    5. Internal mechanical trouble in com-

    pressor.

    6. Liquid refrigerant in compressor.

    7. High discharge pressure.

    Compressor starts and runs,

    but short cycles on overloadprotector.

    Compressor will not start

    hums but trips on overloadprotector.

    Suction line frosted orsweating.

    Liquid line frosted orsweating.

    1. Expansion valve passing excess re-frigerant or is oversized.

    2. Expansion valve stuck open.

    3. Evaporator fan not running.

    4. Overcharge of refrigerant.

    1. Restriction in dehydrator or strainer.

    2. Liquid shut-off valve partially closed.

    1.Re-adjust valve or replace withsmaller valve.

    2. Clean valve of foreign particles, re-

    place if necessary.

    3. Determine reason and correct.

    4. Correct charge.

    1. Replace part.

    2. Open valve fully.

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    TROUBLE SHOOTING CHART

    SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

    Units runs OK, but shortcycles on.

    1. Check the cause.

    2. Differential set too close - widen.

    3. (a) Check airflow to the condensercorrect.

    (b) Reduce refrigerant charge.

    (c) Purge.

    4. (a) Fix leak, add refrigerant.

    (b) Replace device.

    Unit operates long or

    continuously.

    Head pressure too high.

    Head pressure too low.

    1. Shortage of refrigerant.

    2. Control contacts stuck or frozenclosed.

    3. Refrigerated or air conditioned spacehas excessive load or poor insulation.

    4. System inadequate to handle load.

    5. Evaporator coil iced.

    6. Restriction in refrigeration system.

    7. Dirty condenser.

    8. Filter dirty.

    1. Refrigerant overcharge.

    2. Air in system.

    3. Dirty condenser.

    4. Malfunction of condenser fan (air-