zamil air conditioner user guide
DESCRIPTION
ZAMIL AC USER GUIDETRANSCRIPT
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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.
-
5/25/2018 Zamil Air Conditioner User Guide
16/40
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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19/4018
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
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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-