INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
AIR COOLED CONDENSING UNITS
'CNX' SERIES
PL-OM-CNX-07-1M-E
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INDEX
Contents
Page
Model decoding ....................................................................................................................................... 2
Physical data ......................................................................................................................................... 3-4
Electrical data ........................................................................................................................................... 5
Dimensions .......................................................................................................................................... 6-13
Microprocessor control system ............................................................................................................... 14
User sequence of operation ................................................................................................................... 15
Typical schematic wiring diagram ...................................................................................................... 16-23
Field wiring connections ......................................................................................................................... 24
Rigging instructions & weight distribution ............................................................................................... 25
Load distribution ..................................................................................................................................... 26
INSTALLATION INSTRUCTIONS
General ................................................................................................................................................... 27
Location of unit ....................................................................................................................................... 27
General ................................................................................................................................................... 27
Refrigerant piping connections ............................................................................................................... 27
Leak testing & refrigerant charging ......................................................................................................... 28
Start-up inspection & check list ......................................................................................................... 28-29
Check-out & operational start-up procedure ........................................................................................... 29
ELECTRICAL
Power supply .......................................................................................................................................... 30
Unbalanced voltage ................................................................................................................................ 30
Motor contactor ...................................................................................................................................... 31
Fan motor ............................................................................................................................................... 31
Crankcase heater ................................................................................................................................... 31
Lube oil protection control ...................................................................................................................... 31
Voltage monitor ...................................................................................................................................... 31
REFRIGERATION
Compressor ............................................................................................................................................ 32
High & low pressure protection .......................................................................................................... 33-34
Pump down control ................................................................................................................................. 34
Trouble shooting chart ....................................................................................................................... 35-37
Parts list ................................................................................................................................................. 38
Recommended spare parts .................................................................................................................... 39
Preventive maintenance schedule .......................................................................................................... 40
Material safety data sheet ...................................................................................................................... 41
Pressure temperature chart ............................................................................................................... 42-43
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1
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MODEL DECODING
1, 2 & 3
BASIC
4, 5 & 6
NOMINAL
COOLING
CAPACITY*
(MBH)
CNX
150
CONDENSING
UNIT
220
7
ELECTRICAL
SUPPLY
( V-Ph-Hz )
F : 460-3-60
8
SPECIAL OPTIONS
9
MANUFACTURING YEAR
10
GENERATION CODE
Z :SPECIAL OPTIONS
06
00
07
01
08
02
240
300
360
03
420
480
540
600
720
840
**M00
**M10
**M20
**M40
**M60
***2M00
***2M40
* Capacity in MBH (MBH x 1000 = BTUH).
** M indicates for 1 Million BTUH.
*** 2M indicates for 2 Million BTUH.
2
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PHYSICAL DATA
MODEL NUMBER
NOMINAL CAPACITY , TONS*
NUMBER OF REFRIGERATION CIRCUIT
COMPRESSOR
CNX150
CNX220
13
19
22
28
31
36
41
47
53
Dual
Dual
Dual
Dual
Dual
Dual
Dual
Dual
Dual
Type
Oil per system (liters)
CNX240 CNX300 CNX360
Scroll
4.1
4.1
4.1
CONDENSER FAN
4.7
4.68
Nominal CFM
Motor kW – RPM
CONDENSER COIL
4.68
4.94
4.94
4.94
650
750
850
945
R-134a
235
330
400
504
Type
Qty. – Diameter (mm)
CNX540 CNX600
Semi-hermetic reciprocating
Refrigerant
Charge per system (oz)**
CNX420 CNX480
570
Propeller
2 – 560
2 – 630
2 – 700
2 – 700
3 – 700
3 – 700
4 – 700
4 – 700
4 – 700
8400
10000
15000
15000
22500
22500
30000
30000
30000
0.66–1010 0.86–1020 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000
Type
Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–5–14
Total face area (Sq. ft.)
HIGH PRESSURE SWITCH
LOW PRESSURE SWITCH
28
28
28
28
46.66
46.66
56
56
56
Open (PSIG)
350 ± 10
350 ± 10 350 ± 10 350 ± 10 350 ± 10
350 ± 10 350 ± 10
350 ± 10 350 ± 10
Close (PSIG)
300 ± 10
300 ± 10 300 ± 10 300 ± 10 300 ± 10
300 ± 10 300 ± 10
300 ± 10 300 ± 10
Open (PSIG)
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
Close (PSIG)
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
1-3/8
1-5/8
1-5/8
1-5/8
1-5/8
1-5/8
2-1/8
2-1/8
2-1/8
5/8
7/8
7/8
7/8
7/8
1-1/8
1-1/8
1-1/8
1-1/8
69/65/60
69/65/60
800
925
REFRIGERANT LINES+ Suction line size (OD), inch
Liquid line size (OD), inch
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++
OPERATING WEIGHT, Kg.
69.3/65.8/60.5 69.7/66.1/60.9 69.8/66.3/61
980
1060
1325
72.9/69.3/64.1 72.8/69.3/64
1400
1525
NOTE:
* Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.
** 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.
3
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72.9/69.3/64.1 73.3/69.8/64.5
1600
1675
PHYSICAL DATA
MODEL NUMBER
NOMINAL CAPACITY , TONS*
NUMBER OF REFRIGERATION CIRCUIT
COMPRESSOR
CNX720
CNX840
CNXM00 CNXM10 CNXM20 CNXM40 CNXM60 CNX2M00 CNX2M40
63
64
75
92
Dual
Dual
Dual
Dual
Type
105
4.94
4.94
5.2
5.2
154
281
Quadruple Quadruple Quadruple Quadruple Quadruple
4.94
Refrigerant
Screw
4.94
5.2
5.2
22
1090
1250
1390
2520
R-134a
Charge per system (oz)**
1125
1145
1350
Type
1660
945
Propeller
Qty. – Diameter (mm)
6 – 700
6 – 700
6 – 800
6 – 800
6 – 800
8 – 800
8 – 800
10 – 800 16 – 800
Nominal CFM
45000
45000
73266
73266
69000
93256
87032
108790
192048
2.15–970
2.15–970
2.15–970
2.15–970
2.15–970
2.15–970
2.15–970
Motor kW – RPM
CONDENSER COIL
139
Semi-hermetic reciprocating
Oil per system (liters)
CONDENSER FAN
121
1.45–1000 1.45–1000
Type
Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–4–14 3/8–5–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–3–14
Total face area (Sq. ft.)
HIGH PRESSURE SWITCH
LOW PRESSURE SWITCH
70
70
120
120
120
140
140
175
304
Open (PSIG)
350 ± 10
350 ± 10 350 ± 10 350 ± 10 350 ± 10
350 ± 10 350 ± 10
350 ± 10 350 ± 10
Close (PSIG)
300 ± 10
300 ± 10 300 ± 10 300 ± 10 300 ± 10
300 ± 10 300 ± 10
300 ± 10 300 ± 10
Open (PSIG)
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
10 ± 5
Close (PSIG)
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
30 ± 5
2-1/8
2-1/8
2-5/8
2-5/8
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
2-1/8
2-1/8
2-5/8
2-5/8
3-1/8
Dual
1-1/8
1-1/8
1-3/8
1-3/8
N.A.
N.A.
N.A.
N.A.
N.A.
Quadruple
N.A.
N.A.
N.A.
N.A.
1-1/8
1-1/8
1-1/8
1-1/8
1-3/8
REFRIGERANT LINES+ Suction line size Dual
(OD), inch
Quadruple
Liquid line size
(OD), inch
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 73.3/69.8/64.5 73.3/69.8/64.5
OPERATING WEIGHT, Kg.
2100
2600
74.7/1.2/66
3500
75.7/72.7/66.9 76.2/72.7/67.4 77.1/73.6/68.3 77.7/74.2/69
3700
4250
4700
5600
NOTE:
* Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.
** 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.
4
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78.1/74.6/69.3 81.4/77.9/72.6
5095
8500
ELECTRICAL DATA
SUPPLY VOLTAGE
UNIT
SIZE
COMPRESSOR MOTOR
Nominal
(V-Ph-Hz)
Min.
Max. MCA MOCP
Qty.
CNX 150
460-3-60
414
506
25.7
35
CNX 220
460-3-60
414
506
39.0
CNX 240
460-3-60
414
506
CNX 300
460-3-60
414
CNX 360
460-3-60
CNX 420
RLA
LRA
(each)
(each)
2
11.4
125
50
2
15.9
45.7
60
2
506
56.1
75
414
506
60.6
460-3-60
414
506
CNX 480
460-3-60
414
CNX 540
460-3-60
CNX 600
CONDENSER FAN MOTORS
FLA
LRA
(each)
(each)
0.66
1.0
2.4
2
158
0.86
1.6
4.1
2
18.1
187
1.45
2.5
10.0
2
2
22.7
225
1.45
2.5
10.0
2
80
2
23.6
193
1.45
2.5
10.0
3
70.5
90
2
28.0
220
1.45
2.5
10.0
3
506
77.5
100
2
30.0
262
1.45
2.5
10.0
4
414
506
91.0
125
2
36.0
262
1.45
2.5
10.0
4
460-3-60
414
506
108.8 150
2
43.9
323
1.45
2.5
10.0
4
CNX 720
460-3-60
414
506
147.1 200
2
58.7
404
1.45
2.5
10.0
6
CNX 840
460-3-60
414
506
147.1 200
2
58.7
404
1.45
2.5
10.0
6
CNX M00
460-3-60
414
506
183.5 250
2
72.5
513
2.15
3.4
10.0
6
CNX M10
460-3-60
414
506
207.6 275
2
83.2
590
2.15
3.4
10.0
6
CNX M20
460-3-60
414
506
207.0 250
4
43.9
323
2.15
3.4
10.0
6
CNX M40
460-3-60
414
506
276.7 325
4
58.7
404
2.15
3.4
10.0
8
CNX M60
460-3-60
414
506
335.3 400
4
72.5
513
2.15
3.4
10.0
8
CNX 2M00
460-3-60
414
506
342.1 400
4
72.5
513
2.15
3.4
10.0
10
CNX 2M40
460-3-60
414
506
548.6 650
4
117.4
801
2.15
3.1
10.0
16
LEGEND:
MCA
MOCP
RLA
LRA
kW
FLA
-
Minimum Circuit Ampacity
Maximum Over Current Protection
Rated Load Amps
Locked Rotor Amps
Kilowatt
Full Load Amps
5
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kW
Qty.
DIMENSIONS
CNX 150 - CNX 300
1
2
3
4
5
6
7
5
CNX 360 - CNX 420
1
2
3
4
5
6
1550 [61.0]
203 [8.0]
7
73 [2.875]
2121
[83.50]
2197
[86.50]
NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
6
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"A"
943
[37.125]
"B"
2032
[80.0]
943
[37.125]
"C"
DIMENSIONS
357.5 [14.07]
TYP
335.4 [13.20]
2121
[83.50]
2197
[86.50]
CNX 720 - CNX 840
TOP VIEW
73 [2.875]
"C"
968
(38.11")
SIDE VIEW
FRONT VIEW
NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
7
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"B"
965
(37.99")
968
(38.11")
375.6 [14.80]
1550 [61.0]
203 [8.0]
255.0 [10.00]
TYP
CNX 480 - CNX 600
8
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NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
CNX M00 - CNX M10
DIMENSIONS
9
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NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
CNX M20
DIMENSIONS
10
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NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
ELECTRIC POWER INLET
CNX M40
DIMENSIONS
917.0 [36.102] TYP
786.0 [30.944] TYP
670.5 [26.397] TYP
487.0 [19.173] TYP
285.0 [11.220]
11
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NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
ELECTRIC POWER INLET
CNX M60
DIMENSIONS
917.0 [36.102] TYP
786.0 [30.944] TYP
670.5 [26.397] TYP
487.0 [19.173] TYP
285.0 [11.220]
12
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NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
CNX 2M00
DIMENSIONS
13
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275 [10.826]
NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).
2. Allow 48" (1219 mm) clearance on all sides for proper airflow.
CNX 2M40
DIMENSIONS
2185 [86.023]
917.0 [36.102] TYP
786.0 [30.944] TYP
670.5 [26.397] TYP
487.0 [19.173] TYP
285.0 [11.220]
2200 [86.614]
MICROPROCESSOR CONTROL SYSTEM
Each condensing unit are provided with microprocessor based control board that monitors analog and digital inputs to
achieve precise control and safety functions during unit’s operation. Input signals for cooling control can be digital signals
coming from a thermostat device or analog signals from a PTC temperature sensor. The push button key board allows
accessing to the operating conditions, control set points (in case temperature control is analog signal), & alarm history
that are clearly displayed on a multi-line back illuminated LCD panel.
The unit’s controller consists of the following hardware:
1. User Interface Board – Includes push buttons to access operating conditions, change control set points, and
view alarm history. Data are clearly displayed on its LCD panel.
2. Main Board – This controls up to 2 compressor system.
3. Auxiliary Boards – Required for controlling an additional (2) or more compressors.
LCD Display Information:
In the normal operating mode, the 20 x 4 characters LCD panel displays the system status, temperature of leaving /
returning air and set point (if temperature control selected is through PTC sensors ), run time of compressor and alarm
history.
Measurement data for each circuit can be easily accessed and displayed on the LCD. Data include the following:
-
Suction, Discharge, and Oil pressures
-
Leaving / Returning Air temperature ( if temperature control selected is through PTC sensors )
-
Compressor Motor Status
-
Condenser Fan Motor Status
-
Liquid Line Solenoid Status
-
Supply Fan Motor Status
There are three LED lights on the user interface board to indicate “Power On” (green), “Menu Adjustment” (yellow) and
“Fault” (red).
SYSTEM PROTECTION
The unit is equipped with protective devices against motor overloads and proper system settings are factory set to ensure
safe and reliable operation of the unit. Some of these devices and settings are as follows:
-
Compressor Motor External Overload Relay
-
Compressor Motor Winding Over Temperature Protection
-
Low suction Pressure
-
High Discharge Pressure
-
Low Oil Pressure
-
Compressor Anti-Recycling Timer
14
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USER SEQUENCE OF OPERATION
On/Off
SET
Menu
CLASSIC
AIR CONDITIONERS
TOUT = 10°C TIN = 15°C
COOLING 75%
Esc
Machine Starting:
- If OFF, the machine is started by pushing the ON/OFF button.
-
The ON LED (green) will lit.
-
On the main screen is showed the status “STARTING”.
-
After 15 seconds of delay the system will be running.
Machine Shut-Down:
- The machine is halted pushing again the ON/OFF key.
-
The ON LED (green) is switched off.
-
On the main screen is showed the status “STOPPING”.
-
All the compressors are stopped.
-
Blower motor will be switched off after pre-set delay timing when all compressors are switched off.
-
On the main screen is showed the status “SYSTEM OFF”.
Set Point Change:
- Press “SET”, the LCD will ask the password input.
-
Using the “UP” and “DOWN” keys input the correct password.
-
Press “SET”, the “MODIFY” word appears to allow the parameter to be changed. The LCD will show the actual
value.
-
Using the “UP” and “DOWN” keys modify the set point value.
-
Press “SET” to store it or “ESC” to exit without memorizing.
COMPRESSOR CONTROL
Control setting to switch on / off the compressors is through digital output signals from an external controller fed to the
micro-processor board. When the system is started up, the software starts to check all the necessary inputs to start the
unit. It scans the digital/analogue inputs. If any unwarranted interruption occurred the alarm signal is generated and the
compressor will be shut-off.
BLOWER MOTOR CONTROL (OPTIONAL)
Control setting to switch on / off the blower motor is through digital output signal from an external controller fed to the
micro-processor board. The system’s control will prevent the compressors to operate if this signal is not fed to the microprocessor board.
15
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SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Dual compressor units)
APPLICABLE ON MODELS: CNX150 - CNXM10
COMPRESSOR WITH CB CONNECTION
HVTB
(OPTIONAL)
L1
HVTB
L2
POWER SUPPLY
L1
L3
(NOTE 4)
L2
L3
COMP
1
2
COMPRESSOR POWER & CONTROL CONNECTION IN PART WINDING STARTING (PWS)
COMP
1
2
3A
4O
3B
CC2A-2A
61B
11A
9A
OLR2-1A
10B
11B
OLR4-1A
CB1A-1A
23A
C1
1
C2
3-FAN MOTOR LAYOUT
3
CONTROL
PANEL
2
CONTROL
PANEL
CB6
CB6
HVTB
L1 L2 L3
4-FAN MOTOR LAYOUT
C1 1
CONTROL
PANEL
C2 2
CB7
L3B
CB6
FM1
4 C2 2
FM2
FM1
T.K.
TO MB
12A
9 NO
FM2
T.K.
12B
13 NO
12A
13B
2
TO MB
FMC1
9 NO
FMC2
FM1
T.K.
12A
FM3
T.K.
12C
10 NO
13C
FM2
T.K.
12B
13 NO
13A
13B
FM1
T.K.
TO MB
12A
9 NO
FMC3
12C
13C
10 NO
FM2
T.K.
12B
13 NO
104D
FMC3
COMP. 2:
13D
FMC4
HVTB
L1 L2 L3
CB6
CB8
CB7
--
--
HIGH PRESSURE
--
--
460 ± 10
360 ± 15
--
--
FM1
FM3
FM2
105F
104F
103F
104E
105E
103E
105D
HGS
FM4
FM5
FM1
T.K.
TO MB
12A
12E
FM5
T.K.
FM3
T.K.
12C
10 NO
13 NO
FM2
T.K.
12B
12F
14 NO
12D
FM6
T.K.
FM4
T.K.
13A
13E
13C
37F
FM6
JU1 - CLOSED
JU12 - CLOSED (1,2)
JU2 - CLOSED
JU13 - CLOSED (1,2)
JU3 - CLOSED (1,2)
JU15 - CLOSED (1,2)
JU4 - CLOSED (1,2)
JU19 - CLOSED (1,2)
JU5 - CLOSED (1,2)
FMC1
FMC5
FMC3
JU6 - CLOSED (1,2)
TU1 - CLOSED
JU7 - CLOSED (1,2)
TU2 - CLOSED
JU8 - CLOSED (1,2)
TL1 - OPEN
JU9 - CLOSED (1,2)
TL2 - OPEN
JU10 - CLOSED (1,2)
TD1 - CLOSED
13F
13D
S1
FMC6
6
L3
OPS1
3A
2
2
240
64A
OPS1-1
OPS2
3B
2
2
240
OPS2-1
64B
AHU CONTROL INTER-CONNECTIONS
(OPTIONAL)
AIR HANDLING UNIT
CONTROL PANEL
CONDENSING UNIT
CONTROL PANEL
LVTB
G
ATB
R1 (24Vac)
R1-1
1
ATB
(AHU MOTOR CONTROL)
67
ATB
1
2
3
4
ON
OFF
OFF
OFF
L1
4-FAN MOTOR LAYOUT
5 C1 3
L2
C.HTR2
20
ATB
R2 (230Vac)
2
R2-1
UVM CONNECTION(OPTIONAL)
CNX 720~840 / CNXM00~20
CONTROL
PANEL
C.HTR1
L2
17
DIP SWITCH SETTINGS - MB BOARD
FMC2
FMC4
L1
1
ATB
TD2 - CLOSED
JU11 - CLOSED (1,2)
13B
2
(REMOVE JP5A)
COMP 2
JUMPER SETTINGS - MB BOARD
2
9 NO
2
C.HTR1
(REMOVE JP5B)
FMC6
36F
37E
36E
35E
37D
FMC5
35F
104D
36D
FMC4
35D
37B
36B
35B
37C
36C
103D
104B
105B
FMC2
FMC3
35C
37A
36A
FMC1
103B
104C
105C
103C
104A
105A
HPS1 & 2
2
C.HTR2
101A
CC2A-1B
CUT-OFF (PSIG) CUT-IN (PSIG)
LOW PRESSURE
8B
100A
CC1A-1B
1
PRESSURE SETTINGS
DESC.
L2/R/N
OIL PRESSURE SWITCH CONN.(AS APPLICABLE)
COMP 1
HVTB
L1 L2 L3
M2/14
B. SCROLL COMP.
FMC2
13B
FM4
T.K.
12D
14 NO
HVTB
L1 L2 L3
1
COMP. 1:
FMC2
M1/11
L1/MP/L
(REMOVE JP4B)
1
COMP. 2:
FMC1
13A
FM3
T.K.
2
A. SEMI-HERMETIC RECIP. COMP.
2
FMC1
8A
CRANKCASE HTR CONNECTION(AS APPLICABLE)
FM4
COMP. 1:
2
L2/R/N
(SEE NOTE 3)
37D
36D
FMC4
35D
37B
36B
35B
37C
35C
36C
FM3
M2/14
(REMOVE JP3A)
SSPS2
105D
103D
104B
103B
105B
104C
105C
103C
104A
103A
FM1
M1/11
L1/MP/L
COMP. 2:
FMC2
FMC3
37A
35A
FM2
36A
FMC1
37B
36B
35B
FMC2
FM3
T3D
SSPS1
3 C1 1
CB7
105A
104B
105B
103B
103C
104C
36C
35C
FMC3
37C
37A
35A
FM2
36A
FMC1
37B
36B
35B
FM1
105C
105A
104A
103A
104B
105B
103B
104A
103A
105A
37A
36A
FMC2
T2D
T1D
T3B
COMP. 1:
1
CNX 480~600
HVTB
L1 L2 L3
1
FMC1
23B
COMP. SSPS CONNECTION(AS APPLICABLE)
CNX 360~420
HVTB
L1 L2 L3
HVTB
L1 L2 L3
CB2A-1A
1
9B
CONDENSER FAN MOTOR POWER AND CONTROL CONNECTIONS
CNX 220~300
2-FAN MOTOR LAYOUT
T2B
T1B
T3C
T2C
T1C
T3A
2
CC4
1
OLR3-1A
COMP
1
CC2
CC3
61A
OLR1-1A
COMP
2
2
MB
CC1
HVTB
L1 L2 L3
L2B
L1B
L3C
L2C
L1C
L3A
L2A
L1A
T2A
COMP
2
1
CC1A-2A
T1A
T3B
T1B
COMP
T3D
CC4
OLR4
T2D
CC2
OLR2
T1D
CC3
OLR3
T2B
CC1
OLR1
T3C
CC4
OLR4
T2C
CC2
OLR2
T1C
CC3
OLR3
T3A
T2A
T1A
CC1
OLR1
MB
10A
CB2
L1D
L3
L3D
L2
L3
L2D
L2
1O
35A
(OPTIONAL)
L1
CB1
103A
T3B
COMP
HVTB
L1
35A
T2B
T1B
CC2
OLR2
T3A
CC1
OLR1
COMPRESSOR IN PWS CONNECTION WITH CB
(AS APPLICABLE)
HVTB
L3B
L1B
L3A
L2A
L1A
COMP
T2A
T1A
T3B
T2B
T1B
CC2
OLR2
T3A
T2A
T1A
CC1
OLR1
CB2
L2B
CB1
LUG/ETB
L2
L3
ATB
1
1
4 C2 2
Ø
L1
1
Ø
L2
Ø
UVM-1
Ø
L3
8
ATB
UVM
MOTOR STARTER CONTROL
AHU MOTOR ON/OFF
SWITCHING CONTACT
AHU MOTOR FAULT
(N.C CONTACT)
(REMOVE JP7)
52
Ø
(REMOVE JP1)
1A
1
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
16
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SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Dual compressor units)
APPLICABLE ON MODELS: CNX150 - CNXM10
TO ATB
LEGEND
1
2
SWITCHING CONTACTS
FROM THERMOSTAT OR DDC
(FIELD INSTALLATION)
TRANS1
(75VA)
LVTB
COM
230V
ATB
15
R
ATB
17
24V
C
AHU MOTOR CONTROL
(OPTIONAL CONNECTION)
G
STG1 COOLING
YR1
Y1
STG2 COOLING
YR2
Y2
TO HVTB
L1
TO HVTB
L3
F3
TRANS2
3
F4
4
460V
230V
ATB
HPS1
F1
S1
(UVM-1)
JP1
1
1A
1B
5
8A
(OPS1-1)
JP5A
64A
(CB1A-1)
JP4A
10A
HPS2
17
OLR1-1A
PE
A2 (CB-1)
A3 (OL-1)
9A
AO4
A4 (HPS-1)
A5 (FCB-1)
8B
(CB2A-1)
JP4B
64B
10B
OLR2-1A
AO3
A6 (SSPS-2)
23B
A7 (CB-2)
9B
A9 (HPS-2)
AO2
A8 (OL-2)
P
AO1
A10
JP6
2
A1 (SSPS-1)
23A
P
(OPS2-1)
JP5B
TO ATB
15
24V AC
(SSPS1)
JP3A
(SSPS2)
JP3B
TO ATB
ATB
F2
6
67
A11 (FLOW SWITCH)
A12
A13 (EMERGENCY)
YR1-1A
71A
YR2-1A
71B
A20 (AUX. ALARM COMP2)
AC (DIGITAL COM)
1C
R1(DIG OUT)
1O
2C
R2(DIG OUT)
2O
15A
3C
R3(DIG OUT)
3O
14A
4C
R4(DIG OUT)
4O
PDS1
R5(DIG OUT)
5O
15B
6C
R6(DIG OUT)
6O
14B
7C
R7(DIG OUT)
7O
8C
R8(DIG OUT)
C
R9(DIG OUT)
9NO
R10(DIG OUT)
10NO
R11(DIG OUT)
11NO
R12(DIG OUT)
12NO
R13(DIG OUT)
13NO
14NO
15NO
R16(DIG OUT)
16NO
17C
R17(DIG OUT)
17NO
18C
R18(DIG OUT)
18NO
-
S1
(A5-SP1) +
SH
D1
(A6-DP1)
T.OUT
O1
(A7-OP1)
ST2
(A1-ST1)
+
+
SH
S2 (A8-SP2)
TIN
+
D2 (A9-DP2)
USER INTERFACE BOARD
+
ON
S1
O2 (A10-OP2)
DIP
ESC *
+
1 2 3 4
COM1
HOT GAS BY-PASS SOLENOID
(OPTIONAL)
20
AHU MOTOR ON/OFF CONTROL
(230Vac)
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 2)
SPT1
28A
-
29A
+
SH
DPT1
30A
-
31A
+
SH
OPT1
32A
-
33A
+
SH
SPT2
28B
29B
+
SH
DPT2
30B
31B
+
SH
OPT2
32B
33B
+
SH
GND
17
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COMP2 CAPACITY UNLOADER SOLENOID
(OPTIONAL)
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 1)
SH
SERIAL CABLE
COMP2 PUMP DOWN SOLENOID
(OPTIONAL)
UL2
COMMON FAULT INDICATION
(VOLT-FREE CONTACT)
SH
SH
COMP2 CONTACTOR
PDS2
8NO
R15(DIG OUT)
ST1
COMP1 CAPACITY UNLOADER SOLENOID
(OPTIONAL)
HGS
R14(DIG OUT)
SH
COMP1 CONTACTOR
COMP1 PUMP DOWN SOLENOID
(OPTIONAL)
CC2
3B
5C
C
CC1
3A
UL1
8NC
On/Off *
COMPRESSOR
FUSE
FAN MOTOR (CONDENSER)
FAN MOTOR CONTACTOR
HIGH PRESSURE SWITCH
HIGH VOLTAGE TERMINAL BLOCK
JUMPER
LINE 1
LINE 2
LINE 3
LUG GROUND
MOTHER BOARD
OVER LOAD RELAY
SOLID STATE PROTECTIVE SYSTEM
TRANSFORMER
FAN MOTOR (PROTECTION) THERMAL CONTACT
COMPRESSOR UNLOADER SOLENOID
UNDER VOLTAGE MONITOR
COOLING RELAY
FIELD WIRING
DISCONNECT TAB - 1/4"
SPLICE-CLOSED END
TERMINAL BLOCK OR TERMINATION POINT
JUNCTION OF WIRES
CROSSING OF WIRES, NO CONNECTION
EARTHING/GROUND
+
A17 (S. FAN MOTOR FAULT)
52
A19 (AUX. ALARM COMP1)
SET MENU *
COMP/C
F
FM
FMC
HPS
HVTB
JP
L1
L2
L3
LUG
MB
OLR
SSPS
TRANS
TK/TOP
UL
UVM
YR
A15 (COOLING STAGE 2)
A18
TOUT=15°C TIN=28°C
COOLING 75%
AIR HANDLING UNIT
AUXILIARY TERMINAL BLOCK
BLOWER MOTOR RELAY
COMPRESSOR CONTACTOR
AUXILIARY CONTACT
CIRCUIT BREAKER
CRANKCASE HEATER
___
A14 (COOLING STAGE 1)
A16
JP7
AHU
ATB
BMR
CC
CCA
CB
C. HTR
NOTES
1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
OR ITS EQUIVALENT.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. COMPRESSORS ARE PROVIDED WITH INTERNAL
LINE BREAK OR SSPS FOR THERMAL PROTECTION.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY END USER WITH
RATING AS RECOMMENDED BY ZAMIL.
+
5. USE DISCONNECT TAB
OR SPLICE ONLY
WHERE- EVER REQUIRED FOR EXTENSION OF
ORIGINAL WIRE.
6. POWER MUST BE SUPPLIED TO CRANKCASE
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
HEATER MUST BE ON FOR 12 HOURS BEFORE
OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN COMPRESSOR DAMAGE.
COMP1
SUCTION PRESSURE TRANSDUCER
COMP1
DISCHARGE PRESSURE TRANSDUCER
COMP1
OIL PRESSURE TRANSDUCER
(FOR RECIP. COMP ONLY)
COMP2
SUCTION PRESSURE TRANSDUCER
COMP2
DISCHARGE PRESSURE TRANSDUCER
COMP2
OIL PRESSURE TRANSDUCER
(FOR RECIP. COMP ONLY)
SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNXM20 - CNXM60
COMPRESSOR POWER & CONTROL CONNECTION
HVTB / BUSBAR
L1
L2
POWER SUPPLY
COMP
2
4O
4
2
CC2
3B
T3D
COMP
3
2
AB
MB
CC1
T2D
T1D
COMP
2
MB
3A
T3C
T3B
COMP
2
1
1O
T2C
CC4
OLR4
T1C
CC3
OLR3
T2B
CC2
OLR2
T1B
CC1
OLR1
T3A
T1A
T2A
L3
(NOTE 4)
AB
1O
CC3
3C
4O
CC4
3D
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS - 6 FANS / CNXM20
FAN LAYOUT
COMP1
FAN1
FAN2
FAN3
FAN4
FAN5
FAN6
COMP3
TO HVTB/BUSBAR
L1 L2 L3
FM5
13C
FM1
T.K.
13A
104F
105F
103F
104D
105D
37F
37D
36D
12D
FM2
T.K.
FMC1
12B
10 NO
13D
13B
FMC4
FMC2
13 NO
12E
T.K.
13E
CONDENSING UNIT
CONTROL PANEL
FMC5
12F
12F
14 NO
FM6
T.K.
AIR HANDLING UNIT
CONTROL PANEL
G
BMR (24Vac)
BMR-1A
1
(AHU MOTOR CONTROL)
67
CLOSE (PSIG)
LOW PRESSURE
10 ± 5
HIGH PRESSURE
300
HPS1 ~4
350 ± 10
300 ± 15
OFF (PSIG)
ON (PSIG)
FAN MOTOR #
17
OPEN (PSIG)
13F
FMC6
JUMPER SETTINGS - MB BOARD
PRESSURE SETTINGS
DESC.
LVTB
ATB
FM4
T.K.
TO AB
AHU CONTROL INTER-CONNECTIONS
(OPTIONAL)
ATB
FM6
2
FMC3
13 NO
(REMOVE JP6)
FM4
9 NO
12A
FMC6
2
FM3
T.K.
10 NO
ATB
35D
FM2
9 NO
14 NO
FMC4
37B
36B
FMC2
35B
37E
36E
35E
FM3
103D
104B
105B
103B
104E
103E
105E
104C
105C
105A
FM1
FMC5
37C
36C
FMC3
35C
37A
36A
35A
FMC1
12C
CB19
CB18
103C
104A
103A
CB17
TO HVTB/BUSBAR
L1 L2 L3
36F
TO HVTB/BUSBAR
L1 L2 L3
TO MB
COMP4
35F
CONTROL PANEL
COMP2
30 ± 5
JU1 - CLOSED
TU1 - OPEN
JU2 - CLOSED
TD1 - OPEN
TL1 - OPEN
--
FM1,2,5,6
125
175
FM3,4
175
225
DIP SWITCH SETTINGS - MB1 BOARD
S1
1
2
3
4
ON
OFF
OFF
OFF
JUMPER SETTINGS - MB BOARD
JU1 - OPEN
TU1 - OPEN
JU2 - OPEN
TD1 - OPEN
TL1 - OPEN
ATB
DIP SWITCH SETTINGS - AB BOARD
20
ATB
R2 (230Vac)
S1
2
R2-1
ATB
1
ATB
MOTOR STARTER CONTROL
AHU MOTOR ON/OFF
SWITCHING CONTACT
AHU MOTOR FAULT
(N.C CONTACT)
(REMOVE JP7)
52
1
2
3
4
OFF
ON
OFF
OFF
JUMPER SETTINGS (COMMON)
JU3 - CLOSED (1,2)
JU11 - CLOSED (1,2)
JU4 - CLOSED (1,2)
JU12 - CLOSED (1,2)
JU5 - CLOSED (1,2)
JU13 - CLOSED (1,2)
JU6 - CLOSED (1,2)
JU15 - CLOSED (1,2)
JU7 - CLOSED (1,2)
JU19 - CLOSED (1,2)
JU8 - CLOSED (1,2)
TU2 - CLOSED
JU9 - CLOSED (1,2)
TD2 - CLOSED
JU10 - CLOSED (1,2)
TL2 - OPEN
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
18
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SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNXM20 - CNXM60
TO HVTB
L1
TO HVTB
L3
F3
TRANS2
3
4
460V
F4
230V
F1
S1
1A
5
1B
6
CC1A-1B
100A
Ø
L1
1
L3
L2
CC2A-1B
100B
CC5A-1B
100C
Ø
L2
Ø
UVM-1
Ø
L3
8
UVM
CC6A-1B
100D
C.HTR2
C.HTR3
C.HTR4
Ø
(REMOVE JP1)
2
C.HTR1
UVM CONNECTION (OPTIONAL)
L1
ATB
F2
SSPS1
1A
SSPS2
1
SSPS3
ATB
SSPS4
(UVM-1)
JP1
1
8A
JP5A
(CB1A-1)
JP4A
17
OLR1-1A
10A
PE
A1 (SSPS-1)
23A
A2 (CB-1)
64A
A3 (OL-1)
9A
AO4
A4 (HPS-1)
P
A5 (FCB-1)
SSPS2
8B
JP5B
HPS2
TO ATB
15
24V AC
SSPS1
HPS1
TO ATB
10B
(CB2A-1)
JP4B
OLR2-1A
AO3
A6 (SSPS-2)
23B
A7 (CB-2)
64B
A8 (OL-2)
9B
A9 (HPS-2)
P
AO2
AO1
A10
JP6
67
A11 (FLOW SWITCH)
A12 (EXTERNAL ENABLE)
A13 (EMERGENCY)
YR1-1A
71A
YR2-1A
71B
A14 (COOLING STAGE 1)
A15 (COOLING STAGE 2)
A16
JP7
52
A17 (S. FAN MOTOR FAULT)
A18
A19 (AUX. ALARM COMP1)
A20 (AUX. ALARM COMP2)
AC (DIGITAL COM)
1C
R1(DIG OUT)
1O
2C
R2(DIG OUT)
2O
3C
R3(DIG OUT)
3O
4C
R4(DIG OUT)
4O
5C
R5(DIG OUT)
3A
15A
COMP1 CONTACTOR
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS1
COMP1 PUMP DOWN SOLENOID
UL1
14A
COMP1 CAPACITY UNLOADER SOLENOID
(50% UNLOADER SOLENOID)
5O
6C
R6(DIG OUT)
6O
7C
R7(DIG OUT)
7O
8C
R8(DIG OUT)
8NO
C
R9(DIG OUT)
9NO
R10(DIG OUT)
10NO
R11(DIG OUT)
11NO
R12(DIG OUT)
12NO
COMP1 CONTACTOR
3B
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS2
15B
COMP2 PUMP DOWN SOLENOID
UL2
14B
COMP2 CAPACITY UNLOADER SOLENOID
(50% UNLOADER SOLENOID)
COMMON FAULT INDICATION
(VOLT-FREE CONTACT)
8NC
C
R13(DIG OUT)
13NO
R14(DIG OUT)
14NO
R15(DIG OUT)
15NO
R16(DIG OUT)
16NO
17C
R17(DIG OUT)
17NO
18C
R18(DIG OUT)
18NO
S1
(A5-SP1)
ST1
SH
+
SH
D1
(A6-DP1)
T.OUT
+
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 1)
(SHEET 1 OF 3)
20
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 2)
(SHEET 1 OF 3)
O1
(A7-OP1)
ST2
(A1-ST1)
+
SH
S2 (A8-SP2)
TIN
+
D2 (A9-DP2)
USER INTERFACE BOARD
+
On/Off *
TOUT=15°C TIN=28°C
COOLING 75%
SET MENU *
ESC *
ON
S1
DPT1
30A
31A
OPT1
33A
SPT2
29B
DPT2
31B
O2 (A10-OP2)
DIP
+
1 2 3 4
OPT2
33B
SH
+
SH
32B
+
SH
30B
+
SH
28B
+
SH
32A
+
SH
SH
SERIAL CABLE
COM1
SPT1
28A
29A
SH
SH
AHU MOTOR ON/OFF CONTROL
(230Vac)
+
COMP1
SUCTION PRESSURE TRANSDUCER
COMP1
DISCHARGE PRESSURE TRANSDUCER
COMP1
OIL PRESSURE TRANSDUCER
COMP2
SUCTION PRESSURE TRANSDUCER
COMP2
DISCHARGE PRESSURE TRANSDUCER
COMP2
OIL PRESSURE TRANSDUCER
GND
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
19
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SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNXM20 - CNXM60
TO ATB
2
LEGEND
1
SWITCHING CONTACTS
FROM THERMOSTAT OR DDC
(FIELD INSTALLATION)
TRANS1
(75VA)
LVTB
COM
230V
ATB
ATB
24V
15
R
17
C
AHU MOTOR CONTROL
(OPTIONAL CONNECTION)
BMR
(OPTIONAL CONNECTION)
G
STG1 COOLING
YR1
Y1
STG2 COOLING
YR2
Y2
STG3 COOLING
YR3
Y3
STG4 COOLING
YR4
Y4
ATB
2
ATB
1
8C
JP5C
(CB3A-1)
JP4C
17
OLR3-1A
10C
PE
A1 (SSPS-3)
A2 (CB-3)
23C
64C
A3 (OL-3)
AO4
A4 (HPS-3)
9C
P
A5
SSPS4
8D
JP5D
HPS4
TO ATB
15
24V AC
SSPS3
HPS3
TO ATB
10D
(CB4A-1)
JP4D
OLR4-1A
AO3
A6 (SSPS-4)
A7 (CB-4)
23D
64D
A8 (OL-4)
9D
A9 (HPS-4)
P
AO2
AO1
A10
A11
A12
A13
YR3-1A
71C
YR4-1A
71D
A15 (COOLING STAGE 4)
A17
A18
A19 (AUX. ALARM COMP3)
A20 (AUX. ALARM COMP4)
AC (DIGITAL COM)
1C
R1(DIG OUT)
1O
2C
R2(DIG OUT)
2O
3C
R3(DIG OUT)
3O
4C
R4(DIG OUT)
4O
5C
R5(DIG OUT)
5O
3C
15C
COMP3 CONTACTOR
6C
R6(DIG OUT)
6O
7C
R7(DIG OUT)
7O
COMP3 PUMP DOWN SOLENOID
UL3
14C
COMP3 CAPACITY UNLOADER SOLENOID
8C
R8(DIG OUT)
8NO
C
R9(DIG OUT)
COMP4 CONTACTOR
3D
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS4
15D
COMP4 PUMP DOWN SOLENOID
UL4
14D
COMP4 CAPACITY UNLOADER SOLENOID
(50% UNLOADER SOLENOID)
COMMON FAULT INDICATION
(VOLT-FREE CONTACT)
8NC
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 3)
9NO
R10(DIG OUT)
10NO
R11(DIG OUT)
11NO
R12(DIG OUT)
12NO
R13(DIG OUT)
13NO
R14(DIG OUT)
14NO
R15(DIG OUT)
15NO
R16(DIG OUT)
16NO
17C
R17(DIG OUT)
17NO
18C
R18(DIG OUT)
18NO
S1
(A5-SP1)
+
SH
D1
(A6-DP1)
T.OUT
+
(SHEET 1 OF 3)
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 4)
(SHEET 1 OF 3)
O1
(A7-OP1)
ST2
(A1-ST1)
+
SH
S2 (A8-SP2)
TIN
+
D2 (A9-DP2)
+
TO MASTER BOARD MB
X53
ON
S1
SPT3
28C
29C
DPT3
30C
31C
OPT3
33C
SPT4
29D
DPT4
31D
O2 (A10-OP2)
DIP
SERIAL CABLE
+
1 2 3 4
X52
OPT4
32D
33D
SH
+
SH
SH
+
SH
30D
+
SH
28D
+
SH
32C
+
SH
SH
SH
+
COMP3
SUCTION PRESSURE TRANSDUCER
COMP3
DISCHARGE PRESSURE TRANSDUCER
COMP3
OIL PRESSURE TRANSDUCER
COMP4
SUCTION PRESSURE TRANSDUCER
COMP4
DISCHARGE PRESSURE TRANSDUCER
COMP4
OIL PRESSURE TRANSDUCER
GND
20
Downloaded from www.Manualslib.com manuals search engine
COMPRESSOR
FUSE
FAN MOTOR (CONDENSER)
FAN MOTOR CONTACTOR
HIGH PRESSURE SWITCH
HIGH VOLTAGE TERMINAL BLOCK
JUMPER
LINE 1
LINE 2
LINE 3
LUG GROUND
MOTHER BOARD
OVER LOAD RELAY
SOLID STATE PROTECTIVE SYSTEM
TRANSFORMER
FAN MOTOR (PROTECTION) THERMAL CONTACT
COMPRESSOR UNLOADER SOLENOID
UNDER VOLTAGE MONITOR
COOLING RELAY
FIELD WIRING
DISCONNECT TAB - 1/4"
SPLICE-CLOSED END
TERMINAL BLOCK OR TERMINATION POINT
JUNCTION OF WIRES
CROSSING OF WIRES, NO CONNECTION
EARTHING/GROUND
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS3
(50% UNLOADER SOLENOID)
SH
COMP/C
F
FM
FMC
HPS
HVTB
JP
L1
L2
L3
LUG
MB
OLR
SSPS
TRANS
TK/TOP
UL
UVM
YR
+
A16
ST1
AIR HANDLING UNIT
AUXILIARY TERMINAL BLOCK
BLOWER MOTOR RELAY
COMPRESSOR CONTACTOR
AUXILIARY CONTACT
CIRCUIT BREAKER
CRANKCASE HEATER
___
A14 (COOLING STAGE 3)
C
AHU
ATB
BMR
CC
CCA
CB
C. HTR
NOTES
1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
OR ITS EQUIVALENT.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. COMPRESSORS ARE PROVIDED WITH INTERNAL
LINE BREAK OR SSPS FOR THERMAL PROTECTION.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY END USER WITH
RATING AS RECOMMENDED BY ZAMIL.
+
5. USE DISCONNECT TAB
OR SPLICE ONLY
WHERE- EVER REQUIRED FOR EXTENSION OF
ORIGINAL WIRE.
6. POWER MUST BE SUPPLIED TO CRANKCASE
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
HEATER MUST BE ON FOR 12 HOURS BEFORE
OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN COMPRESSOR DAMAGE.
SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNX2M00 - CNX2M40
COMPRESSOR POWER & CONTROL CONNECTION IN PART WINDING STARTING (PWS)
HVTB / BUSBAR
L1
L2
POWER SUPPLY
4O
OLR1-1A 11A
CC2A-2A
OLR3-1A
9A
OLR2-1A 11B
10B
1O
CC5A-2A
OLR4-1A
9B
4O
T3H
CC6
3D
CC7
61C
OLR5-1A 11C
10C
T2H
T1H
T3F
T2F
T1F
T3G
T2G
T1G
3C
CC6A-2A
OLR7-1A
2
4
AB
CC5
CC4
61B
COMP
2
3
AB
CC2
3B
CC3
61A
COMP
2
2
MB
CC1
3A
10A
T3E
COMP
2
1
CC1A-2A
T1E
T3B
T1B
COMP
MB
1O
T2E
CC8
OLR8
T3D
CC6
OLR6
T2D
CC7
OLR7
T1D
CC5
OLR5
T2B
CC4
OLR4
T3C
CC2
OLR2
T2C
CC3
OLR3
T1C
CC1
OLR1
T3A
T1A
T2A
L3
(NOTE 4)
9C
CC8
61D
OLR6-1A 11D
10D
OLR8-1A
9D
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS - 16 FANS / CNX2M40
FAN LAYOUT
COMP3
COMP1
FAN7
FAN8
FAN9
FAN10
FAN11
FAN12
FAN13
FAN14
FM1
FM5
FM3
FM4
12A
12A
12E
10 NO
12C
FM5
T.K.
FM3
T.K.
12C
12G
FM7
T.K.
13 NO
12B
FMC5
13E
14 NO
FMC7
13G
12D
AIR HANDLING UNIT
CONTROL PANEL
LVTB
FM6
T.K.
13B
13F
FM4
T.K.
12D
12H
AHU CONTROL INTER-CONNECTIONS
(OPTIONAL)
CONDENSING UNIT
CONTROL PANEL
12B
12F
FMC3
13C
FM8
T.K.
13D
13H
ATB
BMR-1A
FMC4
10 NO
12K
12O
PRESSURE SETTINGS
OPEN (PSIG)
10 ± 5
30 ± 5
HIGH PRESSURE
300
HPS1 & 2
350 ± 10
300 ± 15
FM15
FM10
13K
FM15
T.K.
13O
37P
104P
FM16
FM12
2
13 NO
12J
FMC13
FM10
T.K.
12J
12N
FMC11
14 NO
FMC15
36P
FMC16
35P
37L
36L
35L
FMC12
FM14
AB
FMC9
105P
103P
104L
105L
103L
104N
105N
37N
FMC14
36N
37J
36J
35J
37O
36O
103N
104J
105J
103J
104O
105O
105K
104K
13M
FM11
T.K.
OFF (PSIG)
ON (PSIG)
JU1 - CLOSED
TU1 - OPEN
JU2 - CLOSED
TD1 - OPEN
12L
FM14
T.K.
12P
13N
FM12
T.K.
12L
FM16
T.K.
13J
13L
13P
FMC10
FMC14
FMC12
FMC16
TL1 - OPEN
--
FM1,5,2,6,9,13,10,14
125
175
FM3,7,4,8,11,15,12,16
175
225
(AHU MOTOR CONTROL)
DIP SWITCH SETTINGS - MB BOARD
S1
1
2
3
4
ON
OFF
OFF
OFF
JUMPER SETTINGS - AB BOARD
JU1 - OPEN
TU1 - OPEN
JU2 - OPEN
TD1 - OPEN
TL1 - OPEN
DIP SWITCH SETTINGS - AB BOARD
R2 (230Vac)
S1
2
R2-1
1
FMC10
JUMPER SETTINGS - MB BOARD
CLOSE (PSIG)
20
ATB
13I
FM13
T.K.
12K
FMC8
ATB
ATB
37K
36M
35M
37I
36I
35I
103K
104M
105M
103M
104I
105I
103I
105H
37H
37M
FM9
T.K.
12I
67
ATB
FMC15
FM11
12M
1
ATB
12I
FMC6
DESC.
CB24
2
9 NO
LOW PRESSURE
TO HVTB/BUSBAR
L1 L2 L3
CB23
FMC11
FM13
TO AB
FMC2
FAN MOTOR #
BMR (24Vac)
17
(REMOVE JP6)
FMC13
FM9
G
ATB
CB22
FMC9
FM8
TO HVTB/BUSBAR
L1 L2 L3
2
FM2
T.K.
TO MB
FMC1
13A
36H
FMC8
2
FM1
T.K.
TO MB
9 NO
104H
103H
104D
105D
37D
36D
37F
FM6
TO HVTB/BUSBAR
L1 L2 L3
CB21
FMC4
35D
FMC6
36F
37B
36B
FM2
103D
104F
105F
103F
104B
103B
FM7
TO HVTB/BUSBAR
L1 L2 L3
CB20
FMC2
35B
37G
36G
FMC7
35G
37C
36C
35C
FMC3
105B
104G
105G
103G
104C
105C
103C
104E
105E
37E
36E
FMC5
35E
37A
36A
35A
FMC1
TO HVTB/BUSBAR
L1 L2 L3
CB19
CB18
103E
104A
105A
103A
CB17
TO HVTB/BUSBAR
L1 L2 L3
35H
TO HVTB/BUSBAR
L1 L2 L3
35F
TO HVTB/BUSBAR
L1 L2 L3
COMP4
35N
COMP2
FAN15
FAN16
35O
FAN5
FAN6
103O
FAN3
FAN4
36K
FAN1
FAN2
35K
CONTROL PANEL
1
2
3
4
OFF
ON
OFF
OFF
JUMPER SETTINGS (COMMON)
MOTOR STARTER CONTROL
AHU MOTOR ON/OFF
SWITCHING CONTACT
AHU MOTOR FAULT
(N.C CONTACT)
(REMOVE JP7)
52
JU3 - CLOSED (1,2)
JU11 - CLOSED (1,2)
JU4 - CLOSED (1,2)
JU12 - CLOSED (1,2)
JU5 - CLOSED (1,2)
JU13 - CLOSED (1,2)
JU6 - CLOSED (1,2)
JU15 - CLOSED (1,2)
JU7 - CLOSED (1,2)
JU19 - CLOSED (1,2)
JU8 - CLOSED (1,2)
TU2 - CLOSED
JU9 - CLOSED (1,2)
TD2 - CLOSED
JU10 - CLOSED (1,2)
TL2 - OPEN
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
21
Downloaded from www.Manualslib.com manuals search engine
SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNX2M00 - CNX2M40
TO HVTB
L1
TO HVTB
L3
F3
TRANS2
3
4
460V
F4
230V
F1
S1
1A
5
1B
6
CC1A-1B
100A
L2
Ø
L1
1
L3
CC2A-1B
100B
CC5A-1B
100C
Ø
L2
Ø
UVM-1
Ø
L3
8
UVM
CC6A-1B
100D
2
C.HTR1
UVM CONNECTION (OPTIONAL)
L1
ATB
F2
C.HTR2
C.HTR3
C.HTR4
Ø
SSPS1
(REMOVE JP1)
1A
SSPS2
1
SSPS3
ATB
SSPS4
(UVM-1)
JP1
1
TO ATB
15
24V AC
SSPS1
8A
JP5A
HPS1
10A
(CB1A-1)
JP4A
OLR3-1A
OLR1-1A 11A
PE
A1 (SSPS-1)
23A
A2 (CB-1)
64A
A3 (OL-1)
9A
AO4
A4 (HPS-1)
P
A5 (FCB-1)
SSPS2
8B
JP5B
HPS2
TO ATB
17
10B
(CB2A-1)
JP4B
OLR2-1A 11B
OLR4-1A
AO3
A6 (SSPS-2)
A7 (CB-2)
23B
64B
A8 (OL-2)
9B
A9 (HPS-2)
P
AO2
AO1
A10
JP6
67
A11 (FLOW SWITCH)
A12 (EXTERNAL ENABLE)
A13 (EMERGENCY)
YR1-1A
71A
YR2-1A
A14 (COOLING STAGE 1)
71B
A15 (COOLING STAGE 2)
A16
JP7
52
A17 (S. FAN MOTOR FAULT)
A18
A19 (AUX. ALARM COMP1)
A20 (AUX. ALARM COMP2)
AC (DIGITAL COM)
1C
R1(DIG OUT)
1O
2C
R2(DIG OUT)
2O
3C
R3(DIG OUT)
3O
4C
R4(DIG OUT)
4O
COMP1 CONTACTOR
3A
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS1
COMP1 PUMP DOWN SOLENOID
UL1-2
14A
COMP1 CAPACITY UNLOADER SOLENOID
(50% UNLOADER SOLENOID)
5O
COMP2 PUMP DOWN SOLENOID
6C
R6(DIG OUT)
6O
14B
7C
R7(DIG OUT)
7O
15A
8C
R8(DIG OUT)
C
R9(DIG OUT)
9NO
R10(DIG OUT)
10NO
R11(DIG OUT)
11NO
R12(DIG OUT)
12NO
R13(DIG OUT)
13NO
R14(DIG OUT)
14NO
R15(DIG OUT)
15NO
R16(DIG OUT)
16NO
R17(DIG OUT)
17NO
18C
R18(DIG OUT)
18NO
-
S1
(A5-SP1) +
SH
(OPTIONAL)
SH
24
LEAVING AIR TEMP. SENSOR
(PTC : -10 ~ +50 C)
D1
(A6-DP1)
T.OUT
25
SH
O1
(A7-OP1)
ST2
(A1-ST1)
+
SH
D2 (A9-DP2)
USER INTERFACE BOARD
+
On/Off *
TOUT=15°C TIN=28°C
COOLING 75%
SET MENU *
ESC *
ON
S1
16B
UL2-4
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 1)
(SHEET 1 OF 3)
AHU MOTOR ON/OFF CONTROL
(230Vac)
20
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 2)
(SHEET 1 OF 3)
SPT1
28A
29A
DPT1
30A
+
SH
31A
+
SH
COMP1
SUCTION PRESSURE TRANSDUCER
COMP1
DISCHARGE PRESSURE TRANSDUCER
SPT2
28B
29B
DPT2
30B
31B
SH
+
SH
+
COMP2
SUCTION PRESSURE TRANSDUCER
COMP2
DISCHARGE PRESSURE TRANSDUCER
SH
O2 (A10-OP2)
DIP
SERIAL CABLE
+
1 2 3 4
COM1
(50% UNLOADER SOLENOID)
CC2-1A
+
S2 (A8-SP2)
TIN
27
UL1-4
-
SH
26
RETURNING AIR TEMP. SENSOR
(PTC : -10 ~ +50 C)
+
16A
COMMON FAULT INDICATION
(VOLT-FREE CONTACT)
SH
SH
(OPTIONAL)
COMP2 CAPACITY UNLOADER SOLENOID
CC1-1A
8NO
17C
ST1
UL2-2
15B
8NC
C
COMP1 CONTACTOR
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS2
R5(DIG OUT)
5C
3B
GND
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
22
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SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNX2M00 - CNX2M40
TO ATB
2
LEGEND
1
SWITCHING CONTACTS
FROM THERMOSTAT OR DDC
(FIELD INSTALLATION)
TRANS1
(75VA)
LVTB
COM
230V
ATB
R
15
ATB
24V
17
C
AHU MOTOR CONTROL
(OPTIONAL CONNECTION)
BMR
(OPTIONAL CONNECTION)
G
STG1 COOLING
YR1
Y1
STG2 COOLING
YR2
Y2
STG3 COOLING
YR3
Y3
STG4 COOLING
YR4
Y4
ATB
2
ATB
TO ATB
17
TO ATB
15
1
24V AC
SSPS3
8C
JP5C
HPS3
10C
(CB3A-1)
JP4C
OLR5-1A
OLR7-1A
A2 (CB-3)
A3 (OL-3)
64C
9C
AO4
A4 (HPS-3)
P
A5
SSPS4
8D
JP5D
HPS4
PE
A1 (SSPS-3)
23C
10D
(CB4A-1)
JP4D
OLR6-1A
OLR8-1A
AO3
A6 (SSPS-4)
A7 (CB-4)
23D
64D
A8 (OL-4)
9D
A9 (HPS-4)
P
AO2
AO1
A10
A11
A12
A13
YR3-1A
71C
YR4-1A
71D
A15 (COOLING STAGE 4)
A18
A19 (AUX. ALARM COMP3)
A20 (AUX. ALARM COMP4)
AC (DIGITAL COM)
1C
R1(DIG OUT)
1O
2C
R2(DIG OUT)
2O
3C
R3(DIG OUT)
3O
4C
R4(DIG OUT)
4O
COMP3 CONTACTOR
3C
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS3
14C
COMP3 CAPACITY UNLOADER SOLENOID
R5(DIG OUT)
5O
6C
R6(DIG OUT)
6O
7C
R7(DIG OUT)
8C
R8(DIG OUT)
C
R9(DIG OUT)
9NO
R10(DIG OUT)
10NO
7O
COMP4 PUMP DOWN SOLENOID
UL4-2
14D
CC5-1A
15C
15D
8NO
R11(DIG OUT)
11NO
R12(DIG OUT)
12NO
R13(DIG OUT)
13NO
R14(DIG OUT)
14NO
R15(DIG OUT)
15NO
R16(DIG OUT)
16NO
17C
R17(DIG OUT)
17NO
18C
R18(DIG OUT)
18NO
-
S1
(A5-SP1) +
ST1
SH
SH
D1
(A6-DP1)
T.OUT
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS4
5C
C
COMP4 CONTACTOR
3D
+
COMP4 CAPACITY UNLOADER SOLENOID
16C
UL3-4
16D
UL4-4
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 3)
(SHEET 1 OF 3)
REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 4)
(SHEET 1 OF 3)
SPT3
28C
29C
DPT3
30C
+
SH
31C
+
SH
SH
COMP3
SUCTION PRESSURE TRANSDUCER
COMP3
DISCHARGE PRESSURE TRANSDUCER
+
SH
S2 (A8-SP2)
TIN
+
D2 (A9-DP2)
+
SPT4
28D
29D
DPT4
30D
31D
SH
+
SH
+
COMP4
SUCTION PRESSURE TRANSDUCER
COMP4
DISCHARGE PRESSURE TRANSDUCER
SH
O2 (A10-OP2)
DIP
SERIAL CABLE
+
1 2 3 4
GND
23
Downloaded from www.Manualslib.com manuals search engine
NOTES
1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
OR ITS EQUIVALENT.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. COMPRESSORS ARE PROVIDED WITH INTERNAL
LINE BREAK OR SSPS FOR THERMAL PROTECTION.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY END USER WITH
RATING AS RECOMMENDED BY ZAMIL.
+
5. USE DISCONNECT TAB
OR SPLICE ONLY
WHERE- EVER REQUIRED FOR EXTENSION OF
ORIGINAL WIRE.
6. POWER MUST BE SUPPLIED TO CRANKCASE
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
HEATER MUST BE ON FOR 12 HOURS BEFORE
OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN COMPRESSOR DAMAGE.
O1 (A7-OP1)
ST2
(A1-ST1)
SH
X52
(50% UNLOADER SOLENOID)
CC6-1A
COMMON FAULT INDICATION
(VOLT-FREE CONTACT)
8NC
ON
COMPRESSOR
FUSE
FAN MOTOR (CONDENSER)
FAN MOTOR CONTACTOR
HIGH PRESSURE SWITCH
HIGH VOLTAGE TERMINAL BLOCK
JUMPER
LINE 1
LINE 2
LINE 3
LUG GROUND
MOTHER BOARD
OVER LOAD RELAY
SOLID STATE PROTECTIVE SYSTEM
TRANSFORMER
FAN MOTOR (PROTECTION) THERMAL CONTACT
COMPRESSOR UNLOADER SOLENOID
UNDER VOLTAGE MONITOR
COOLING RELAY
FIELD WIRING
DISCONNECT TAB - 1/4"
SPLICE-CLOSED END
TERMINAL BLOCK OR TERMINATION POINT
JUNCTION OF WIRES
CROSSING OF WIRES, NO CONNECTION
EARTHING/GROUND
COMP3 PUMP DOWN SOLENOID
UL3-2
(50% UNLOADER SOLENOID)
X53
COMP/C
F
FM
FMC
HPS
HVTB
JP
L1
L2
L3
LUG
MB
OLR
SSPS
TRANS
TK/TOP
UL
UVM
YR
+
A17
TO MASTER BOARD MB
AIR HANDLING UNIT
AUXILIARY TERMINAL BLOCK
BLOWER MOTOR RELAY
COMPRESSOR CONTACTOR
AUXILIARY CONTACT
CIRCUIT BREAKER
CRANKCASE HEATER
___
A14 (COOLING STAGE 3)
A16
S1
AHU
ATB
BMR
CC
CCA
CB
C. HTR
TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS
17
1
(REMOVE JP6)
67
20
2
1
(REMOVE JP7)
(REMOVE JP7)
52
24
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RIGGING INSTRUCTIONS
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.
MODELS: CNX150 - CNX840
MODELS: CNXM00 - CNX2M00
MODELS: CNX2M40
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LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)
MODEL No.
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
CNX150
200
200
200
200
-
-
-
-
-
-
CNX220
231
231
231
231
-
-
-
-
-
-
CNX240
245
245
245
245
-
-
-
-
-
-
CNX300
265
265
265
265
-
-
CNX360
228
228
232
232
204
204
-
-
-
-
CNX420
240
240
244
244
216
216
-
-
-
-
CNX480
233
233
273
273
258
258
-
-
-
-
CNX540
245
245
285
285
270
270
-
-
CNX600
258
258
298
298
282
282
-
-
-
-
CNX720
272
272
303
303
276
276
199
199
-
-
CNX840
272
272
303
303
276
276
199
199
-
-
CNXM00
655
486
540
600
-
-
-
-
-
-
CNXM10
675
508
560
620
-
-
-
-
-
-
CNXM20
807
641
692
752
-
-
-
-
-
-
CNXM40
558
558
533
533
523
523
727
727
CNXM60
674
674
649
649
639
639
CNX2M00
591
591
536
536
531
531
526
526
CNX2M40
822
822
742
742
737
737
732
732
LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)
MODEL No.
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
CNX150
225
225
225
225
-
-
-
-
-
-
CNX220
256
256
256
256
-
-
-
-
-
-
CNX240
270
270
270
270
-
-
-
-
-
-
CNX300
290
290
290
290
-
-
CNX360
253
253
257
257
229
229
-
-
-
-
CNX420
268
268
272
272
244
244
-
-
-
-
CNX480
266
266
306
306
291
291
-
-
-
-
CNX540
278
278
318
318
303
303
-
-
CNX600
295
295
335
335
319
319
-
-
-
-
CNX720
304
304
335
335
308
308
232
232
-
-
CNX840
304
304
335
335
308
308
232
232
-
-
CNXM00
721
552
606
666
-
-
-
-
-
-
CNXM10
741
574
626
686
-
-
-
-
-
-
CNXM20
903
737
788
848
-
-
-
-
-
-
CNXM40
609
609
584
584
574
574
CNXM60
749
749
724
724
714
714
CNX2M00
661
661
606
606
601
601
596
596
CNX2M40
888
888
808
808
803
803
798
798
793
793
R1
R2
R1
R3
R5
R1
R3
R5
R7
R1
R3
R5
R7
R9
R3
R4
R2
R4
R6
R2
R4
R6
R8
R2
R4
R6
R8
R10
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INSTALLATION INSTRUCTIONS
GENERAL
The complete shipment should be inspected for damage. Any damage visible at the time of delivery should be noted on
the shipment invoice.
These units are shipped completely assembled and wired. Units require interconnecting piping (AHU), external power,
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. Units
must also be installed in accordance with regulations of the "National Fire Protection Association" and local electrical
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 lift
unit from base and place in position with necessary applicable vibration isolators.
Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Make
sure that no air & moisture enter the system as easter oil are hygroscopic in nature.
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions
and other Zamil publications for the specific equipment being installed.
These units are charged with ozone friendly R-134a 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 structural
strength 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 recirculation or restriction.
8. Care should be taken to prevent air from other sources from entering condenser, if this air is at a high temperature.
REFRIGERANT PIPING CONNECTIONS
Piping connections:
Outdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. The
liquid and suction line diameters can be determined from the physical data table.
Outdoor unit connected to matching Zamil indoor unit:
Outdoor unit contain adequate system refrigerant charge for operating with matched indoor unit (as per corresponding
cooling capacity table) and when connected with up to 25 feet (7.62 m) of field-supplied piping.
Sweat connection:
Units are provided with service valves and are ready for brazing. After wrapping the service valve with a wet cloth, the
piping set can be brazed to service valve using either silver rod or silfos rod brazing materials.
LEAK TESTING & REFRIGERANT CHARGING
Leak test:
Leak can occur from joints or fittings that are improperly brazed/connected during installation of indoor and outdoor units.
The installer should leak test the indoor unit & associated field supplied refrigerant piping, then the outdoor unit, each
separately 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. When system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging lines and manifolds
must be purged with refrigerant vapor prior to admitting refrigerant into the system to prevent contamination system
with non-condensable.
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2. It is important to first determine the amount of refrigerant required for the system, the unit nameplate normally identify
the weight of the refrigerant required.
3. The refrigerant should be added in small amounts allowing sufficient time for the unit pressure to equalize each time.
WIRING
All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltage,
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 unit
wiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wiring.
The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused disconnect
switch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone wire for this
purpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety & servicing purposes.
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 diagram
should 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 to
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 operation.
1. Remove or loosen shipping retainers under motor compressors. Make sure the hold down nuts on spring mounted
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 pressure switch,
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 few
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 Connection
• Air Filters Clean
• Air Filter Access Door Gasket
• Sound Attenuators (If Applicable)
• Fresh Air Intake
• Ductwork Caulking Inside/Outside Building
• Ductwork Supports Inside/Outside Building
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• Duct Leakage Inside/Outside Building
• Volume Dampers
• Volume Damper Access Doors
• Fire Dampers
• Fire Damper Access Doors
• Transfer Grilles/Door Grilles
• Duct Insulation/Liner
• Diffusers/Grilles
• Duct Humidistat
• Filter 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 operation.
1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for checking 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 start
the 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 take
corrective action.
(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required,
leak 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 order
to provide some allowance for oil which will be circulating in the system during operation. Depending on the system
design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may be
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 oil
slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may vary considerably on initial start-up if liquid refrigerant is present in the crankcase, and the oil level should be checked with the
compressor running after having reached a stabilized condition.
(d) Thermostatic expansion valves must be checked for proper superheat settings. Recommended superheat is 150F
to 200F.
(e) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage must
be within ±10% of that indicated on the compressor nameplate. If high or low voltage is indicated, notify the power
company. The current normally should not exceed 110% of the nameplate rating. If amperage draw is excessive,
immediately determine the cause and take corrective action. On three phase compressor motors, check to see
that a balanced load is drawn by each phase.
(f) Carry out any necessary tests, recording airflow rates, entering/leaving temperatures, sound levels, outdoor temperatures, supply airflow rates in occupied spaces and any other specified parameters.
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ELECTRICAL
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 as
that on the nameplate.
Normally the wire size used establishes the circuits maximum permissible load. For example a number 12 wire circuit is
considered to be a 20 ampere circuit and is protected by a 20 ampere fuse. The unit amperage nameplate rating should
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 high
or low voltage condition may prevent the unit from starting, or if the unit is running, compressor can cut-off automatically
on the motor overload. On some installations, the voltage may be entirely adequate when tested, but may drop or surge
some time later due to increase or decrease of load on the power line. This condition may be repeated daily at the same
hour. When this condition is suspected, make arrangements with the local power supplier to place a recording voltmeter
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, but
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 not
always maintained, so with the three line currents will not be equal. Unbalanced voltage on a three phase compressor
motor may overheat and trip the motor on external or internal current sensing motor protector, whichever one is provided.
To determine that an unbalanced voltage condition exists, the supply voltage at the main disconnect switch and at the
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 the
Average Voltage, and the Average Voltage.
Voltage unbalance, % = 100 x
Maximum voltage deviation from average voltage
Average voltage
The percentage increase in temperature rise in a phase winding resulting from voltage unbalance will be approximately
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 compressor motor may be over-heated while the other have a temperature within normal limits. Where unbalanced voltage on
a three phase circuit exists, the power company should be notified of such unbalance to determine, if the situation can be
corrected.
A common source of unbalanced voltage on a three phase circuit is a single phase load between two of the three phases.
A large lighting or heating circuit connection to one phase of a three phase circuit can easily cause sufficient variations in
motor currents to endanger the motor. Interchange the single phase loads to equally divide the entire loads among the
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 the
protectors are in the high current phase when using two leg protection, or to use protectors in all three legs.
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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 compressor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, motor
contactors are subjected to quick cycling due to various causes. This may cause burned and/or sticking contacts and can
cause a compressor motor failure, even though the motor overload protectors trip and open the control circuit.
FAN MOTOR
The condenser fan motor is a single speed electrical motor with ball bearings, protected with an automatic reset internal overload.
CRANKCASE HEATERS
The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest part
of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize when
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 or
more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions may
result in compressor damage.
Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are not
a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper piping
practice, 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 oil
level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharge
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 the
bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at the
bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor to
drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinders
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 cause
major 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. The
lube oil pressure protection control is factory set conforming to compressor manufacturer’s specification.
The control measures the net oil pressure available to circulate oil through the lubrication system. The positive displacement oil pump circulates the refrigerant oil through the lubrication system. Since the oil pump is connected directly to the
compressor crankcase, the inlet pressure to the oil pump will always be the crankcase pressure. The oil pump outlet
pressure will be the crankcase pressure plus the oil pump pressure. Therefore, net oil pump pressure will always be the
pump outlet pressure minus the crankcase pressure.
The net oil pump pressure is sensed through a pressure transducer sending analogue signals to the unit’s microprocessor board. The control is set to trip or stop the compressor when oil differential pressure goes down at a pre-set level and
time delay setting. Trip settings for low oil pressure and time delay can be changed in the unit’s controller. Factory set
values for low oil pressure trip is at 30 psi after a time delay of 180 seconds.
VOLTAGE MONITOR
This device protects the motors in the unit from faults such as; under or over voltage, unbalance & phase reversal of the
power supply. When the device sensed such faults, it will cut-off the supply in the control circuit thereby cutting off power
to the motors. The voltage monitor will re-set automatically when power is brought back to it’s normal conditions.
LINE VOLTAGE
RANGE
190 - 480 VAC
TRIP & RE-SET VOLTAGE (% OF SET POINT)
UNDER VOLTAGE
PHASE IMBALANCE
RE-SET
TRIP
RE-SET
TRIP
RE-SET
90%
93%
110%
107%
6%
4.5%
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OVER VOLTAGE
TRIP
REFRIGERATION
COMPRESSOR
Scroll compressors are used as standard for models CNX150 - CNX300 and semi-hermetic reciprocating compressors
are standard for models CNX360 - CNX2M00 except for model CNX2M40 available with semi-hermetic compact screw
compressors. All compressors are conforming to ARI 540. The compressors are equipped with internal motor protection;
factory installed crankcase heater and rubber vibration isolators for quiet and efficient operation. As an option, semihermetic compressor can be fixed on anti vibration mounting (spring type) along with suction & discharge line vibration
eliminators. Oil pressure control is provided on units with semi-hermetic compressor only. Each compressor has lock-out
devices to protect it from short cycling when tripped by safety controls. Each compressor has separate condenser coil
with safety controls. Sight glass and filter dryer are standard for all models.
Semi-hermetic Compressor:
These Semi hermetic reciprocating compressors are accessible –hermetic type. Compressor and motor are enclosed in
a hermetically sealed housing, with out shaft seal. The compressors are equipped with an oil sight glass through which
the oil quantity and its conditions in the crankcase can be observed. These compressors can be disassembled in the field
for service.
Refrigerant-cooled motor –compressors have an oil pressure lubrication system. This system is supplied by a positive
displacement oil pump, working in either direction. It is protected by a screen and is made accessible for quick oil
pressure checking by a Schrader check valve. The use of oil pressure control safeguards the lubrication system. These
compressors can be provided with capacity control (optional). The use of unloading provides optimal part load capacities.
Semi-hermetic compact twin screw Compressor:
All compressors are compact semi-hermetic twin screw of the high capacity and efficiency due to its perfect profile form
ratio 5:6. Simple and robust construction with slider control valve for capacity unloading, suction/discharge shut-off
valves, check valve in discharge gas outlet, oil sight glass, oil fill/drain service valve, directly flanged-on three stage oil
separator with long-life fine filter 10 microns mesh size, robust axial bearings in tandem configuration, suction gas filter,
internal pressure relief valve and manual lock-out electronic protection system for thermal motor winding temperature,
phase reversal, discharge gas temperature protection controls.
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 handling
makes this compressor highly reliable.
6. High Charge Limit: Therefore, lower applied costs as no suction accumulator required, no need for pump down
system and check valve in discharge line.
Low capacity can be caused by inefficient compressor, that is, the compressor does not pump sufficient quantity of
refrigerant, even though a full charge is available in the system.
Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is found
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 the
liquid 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 off
and observe the compound gauge. The gauge pressure may build rapidly. Repeat the pump down process several times
observing the gauge pressure each time after the compressor stops. If the gauge pressure builds rapidly each time after
the compressor stops, it indicates that the compressor discharge valves are not holding and refrigerant is leaking from
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 long
enough to pump down the system to approximately 10 inches of vacuum. If the compressor required longer time to
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 burned
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-condensables
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 the
oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the system
provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. For a badly
contaminated system that indicates acid in the oil after 8 to 12 hours of operation, change the suction and liquid line filterdriers and check the system after 24 hours of operation.
There are instances where contaminants are discovered in a refrigeration system with the compressor still operational.
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 as
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 moisture).
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 pressure
exceed 350 psig, the control will open turning off the compressor. The control is designed to protect against excessive
discharge temperatures and pressures which can cause compressor overheating and damage to the motor windings or
valves.
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Should the control open, it will remain open until the pressure in the system is lowered to 300 psig. Tripping of the high
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 the
condenser fan motor. Turn on the unit and observe the pressure on the gauge when the compressor trip off. The pressure
should be 350 ± 10 psig. Allow the system to remain off, until the gauge pressure drop to approximately 300 ± 10 psig and
reconnect the condenser fan motor. Reset the unit by putting off the thermostat and if the high pressure control has
closed, the compressor will restart.
LOW PRESSURE PROTECTION
To provide protection for the compressor in the event of refrigerant loss, a low pressure sensor is installed in the suction
line.
The control is preset to open when the suction pressure is 10 ± 5 psig. The contacts of the control will close when the
suction pressure rises to 30 ± 5 psig. To test the control for the correct pressure setting, install a compound gauge to the
gauge port on the suction service valve. "Front seat" the liquid valve and start the unit. Note the gauge pressure, when
the compressor stops.
To determine the cut-in pressure, allow the suction pressure to build slowly and observe the gauge pressure at the time
when contact closes. A good functional low pressure switch must have both cut-out and cut-in pressure within ± 2 psig.
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 evaporator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liquid
line, but ahead of metering device.
Pump down operation takes place as soon as the signal for cooling is switched off. The system’s control closes the liquid
line solenoid valve while the compressor is continuously running to pump out a substantial portion of refrigerant in the
evaporator. The compressor will shut off when either the suction pressure goes down at a pre-set pressure of 25 psi or
at a pre-set timing of 10 seconds whichever is satisfied first. On call for the next cooling cycle, the solenoid valve will get
energized ahead of the compressor at a pre-set timing. This is to allow refrigerant to flow in the evaporator and thereby
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 to
prevent slugging of oil or liquid 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 said
conditions exist that cannot be avoided, which could result in compressor damage.
34
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TROUBLE SHOOTING CHART
SYMPTOM
CAUSES
CHECK & CORRECTIVE MEASURE
Compressor will not start – no
hum.
1. Line disconnect switch open.
1. Close start or disconnect switch.
2. Overload protector tripped.
2. Refer to electrical section.
3. Control stuck in open position.
3. Repair or replace control.
4. Control off due to cold location.
4. Relocate control.
5. Wiring improper or loose.
6. Thermostat defective or improperly
installed.
5. Check wiring against diagram.
7. Control circuit open.
8. Burned/open circuit motor winding.
Compressor will not start –
hums but trips on overload
protector.
1. Improperly wired.
1. Check wiring against diagram.
2. Low voltage to unit.
2. Determine reason and correct.
3. Relay failing to close.
3. Determine reason and correct, replace if necessary.
4.Compressor motor has a winding
open or shorted.
5. Internal mechanical trouble in compressor.
6. Liquid refrigerant in compressor.
7. High discharge pressure.
Compressor starts and runs,
but short cycles on overload
protector.
6. Replace or relocate.
7. Trace control circuit with wiring diagram and repair.
8. Replace the compressor with all precautions.
1. Additional current passing through
overload protector.
2. Low voltage to unit (or unbalanced if
three phase).
3. Overload protector defective.
4. Excessive discharge pressure.
5. Suction pressure too high.
4. Replace compressor.
5. Replace compressor.
6. Check crankcase heater.
7. Unequilized pressure in the system.
1.Check wiring diagram. Check for
added fan motors, pumps, etc. connected 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 system.
6. Compressor too hot - return gas hot.
5. Check for possibility of misapplication. Use stronger unit.
7.Compressor motor has a winding
shorted.
6. Check refrigerant charge (fix leak),
add if necessary.
7. Replace compressor.
Suction line frosted or
sweating.
1. Expansion valve passing excess refrigerant or is oversized.
2. Expansion valve stuck open.
3. Evaporator fan not running.
4. Overcharge of refrigerant.
1.Re-adjust valve or replace with
smaller valve.
2. Clean valve of foreign particles, replace if necessary.
3. Determine reason and correct.
4. Correct charge.
Liquid line frosted or
sweating.
1. Restriction in dehydrator or strainer.
2. Liquid shut-off valve partially closed.
1. Replace part.
2. Open valve fully.
35
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TROUBLE SHOOTING CHART
SYMPTOM
CAUSES
CHECK & CORRECTIVE MEASURE
Units runs OK, but short
cycles on.
1. Overload protector.
2. Thermostat.
3. High pressure cut-out due to:
(a) Insufficient air.
(b) Overcharge.
(c) Air in system.
4. Low pressure cut-out due to:
(a) Undercharge.
(b) Restriction in expansion device.
1. Check the cause.
2. Differential set too close - widen.
3. (a) Check airflow to the condenser
correct.
(b) Reduce refrigerant charge.
(c) Purge.
4. (a) Fix leak, add refrigerant.
(b) Replace device.
Unit operates long or
continuously.
1. Shortage of refrigerant.
2. Control contacts stuck or frozen
closed.
3. Refrigerated or air conditioned space
has 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. Fix leak, add charge.
2. Clean contacts or replace control.
3. Determine the fault and correct.
4. Replace with larger system.
5. Defrost.
6. Determine location and remove.
7. Clean condenser.
8. Clean or replace.
Head pressure too high.
1. Refrigerant overcharge.
2. Air in system.
3. Dirty condenser.
4. Malfunction of condenser fan (aircooled).
5. Excessive air temperature entering
condenser.
6. Restriction in discharge line.
1. Correct the refrigerant charge.
2. Recharge the system after a thorough
triple evacuation.
3. Clean.
4. Check and correct or replace.
5. Check for short circuiting of condenser discharge air, correct it.
6. Correct it.
Head pressure too low.
1.Low ambient temperatures (aircooled).
2. Refrigerant shortage.
3. Damaged valves in compressor.
1. Install fan cycling switch, if not provided. Check the setting and operation, if provided.
2. Correct the refrigerant charge after
leak testing.
3. Repair/replace the compressor.
High suction pressure.
1. High load on evaporator. Load in excess of design conditions.
2. Unbalanced system. Oversized air
handling unit matched with under
sized condensing unit.
3. Compressor discharge valve leaking.
4. Expansion valve widely open.
5. Improper bulb location or installation.
1. Check the design.
2. Follow manufacturer's guide line and
correct it.
3. Repair/replace compressor.
4. Check and adjust the superheat accordingly.
5. Check the expansion valve bulb is
properly tighten at correct location.
36
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TROUBLE SHOOTING CHART
SYMPTOM
CAUSES
CHECK & CORRECTIVE MEASURE
Loss of oil pressure.
1. Loss of oil from compressor due to:
(a) Oil trapping in system.
(b) Compressor short cycling.
(c) Insufficient oil in system.
(d) Operation at excessively low
suction pressure.
2. Excessive liquid refrigerant returning
to compressor.
3. Malfunctioning oil pump.
4. Restriction in oil pump inlet screen.
1. (a) Correct the system piping.
(b) Trace out the wiring/defective controls/
components, etc. and correct it.
(c) Add oil.
(d) Check the superheat of expansion
valve and other possible causes
like clogged filter, low CFM, iced
evaporator etc. and correct it.
2. Check the system for correct super
heat and other possible causes like
clogged filter, low CFM, iced evaporator, etc. and correct it.
3. Repair or replace it.
4.Clean/replace it (oil change recommended).
Space temperature too high.
1. Control setting too high.
2. Expansion valve too small.
3. Cooling coils too small.
4. Inadequate air circulation.
1. Reset control.
2. Use larger valve.
3. Add surface or replace.
4. Improve air movement.
Unit noisy.
1. Loose parts or mountings.
2. Tubing rattle.
3. Bent fan blade causing vibration.
4. Fan motor bearings worn.
1. Find and tighten.
2. Tighten the pipe support.
3. Replace blade.
4. Replace motor.
37
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PARTS LIST
MODEL NUMBER
CNX150F
CNX220F
CNX240F
CNX300F
CNX360F
CNX420F
CNX480F
CNX540F
CNX600F
COMPRESSOR
80061402
80061408
80061411
80061414
80069717
80069720
80069723
80069726
80069729
COMPRESSOR CONTACTOR
80009857
80009861
80009861
80009863
80009863
80009865
80009865
80009865
80009867
NIL
NIL
NIL
NIL
80057700
80057700
80057700
80057700
80057700
CAPACITY UNLOADER KITS
COND. FAN MOTOR
80022715
80023704
80023703
80023703
80023703
80023703
80023703
80023703
80023703
COND. FAN MOTOR CONTACTOR
80009851
80009851
80009851
80009851
80009851
80009851
80009851
80009851
80009851
FILTER DRYER
80053141
80053142
80053142
80053142
80053142
80053142
80053117
80053117
80053117
FILTER DRYER CORE
80002765
80002765
80002765
80002765
80002765
80002765
80002765
80002765
80002765
SIGHT GLASS
80020000
80020001
80020001
80020001
80020001
80020001
80020004
80020004
80020004
MECHANICAL SHUT OFF VALVE
80070540
80070541
80070541
80070541
80070541
80070541
80070542
80070542
80070542
PUMP DOWN SOLENOID VALVE
80070520
80070521
80070521
80070521
80070521
80070521
80070660
80070660
80070660
PRESSURE GAUGE - SUCTION
80060030
80060030
80060030
80060030
80060030
80060030
80060030
80060030
80060030
PRESSURE GAUGE - DISCHARGE
80060031
80060031
80060031
80060031
80060031
80060031
80060031
80060031
80060031
PRESSURE GAUGE - OIL
NIL
NIL
NIL
NIL
80060030
80060030
80060030
80060030
80060030
ADJ. HIGH PRESSURE SWITCH
80055730
80055730
80055730
80055730
80055730
80055730
80055730
80055730
80055730
MICROSMART CONTROLLER
80064645
80064645
80064645
80064645
80064645
80064645
80064645
80064645
80064645
USER INTERFACE CARD
80064650
80064650
80064650
80064650
80064650
80064650
80064650
80064650
80064650
PTC TEMP. SENSOR
80064655
80064655
80064655
80064655
80064655
80064655
80064655
80064655
80064655
RELATIVE PRES. TRANSDUCER -DP
80064656
80064656
80064656
80064656
80064656
80064656
80064656
80064656
80064656
RELATIVE PRES. TRANSDUCER -OIL
NIL
NIL
NIL
NIL
80064657
80064657
80064657
80064657
80064657
RELATIVE PRES. TRANSDUCER -SUCTION
80064658
80064658
80064658
80064658
80064658
80064658
80064658
80064658
80064658
MODEL NUMBER
CNX720F
CNX840F
CNXM00F
CNXM10F
CNXM20F
CNXM40F
CNXM60F
CNX2M00F
CNX2M40F
COMPRESSOR
80069732
80069732
80069735
80069738
80069729
80069732
80069735
80069735
80068318
COMPRESSOR CONTACTOR
80009868
80009868
80009865
80009865
80009867
80009868
80009865
80009865
80009851
CAPACITY UNLOADER KITS
80057700
80057700
80057700
80057700
80057700
80057700
80057700
80057700
NIL
COND. FAN MOTOR
80023703
80023703
80023700
80023700
80023700
80023700
80023700
80023700
80023700
COND. FAN MOTOR CONTACTOR
80009851
80009851
80009851
80009851
80009851
80009851
80009851
80009851
80009851
FILTER DRYER
80053117
80053117
80053113
80053113
80053117
80053117
80053117
80053117
80053113
FILTER DRYER CORE
80002765
80002765
80002765
80002765
80002765
80002765
80002765
80002765
80002765
SIGHT GLASS
80020004
80020004
80020005
80020005
80020004
80020004
80020004
80020004
80020005
MECHANICAL SHUT OFF VALVE
80070542
80070542
80070543
80070543
80070542
80070542
80070542
80070542
80070543
PUMP DOWN SOLENOID VALVE
80070660
80070660
80070509
80070509
80070660
80070660
80070660
80070660
80070509
PRESSURE GAUGE - SUCTION
80060030
80060030
80060030
80060030
80060030
80060030
80060030
80060030
80060030
PRESSURE GAUGE - DISCHARGE
80060031
80060031
80060031
80060031
80060031
80060031
80060031
80060031
80060031
PRESSURE GAUGE - OIL
80060030
80060030
80060030
80060030
80060030
80060030
80060030
80060030
NIL
ADJ. HIGH PRESSURE SWITCH
80055730
80055730
80055730
80055730
80055730
80055730
80055730
80055730
80055730
MICROSMART CONTROLLER
80064645
80064645
80064645
80064645
80064645
80064645
80064645
80064645
80064645
USER INTERFACE CARD
80064650
80064650
80064650
80064650
80064650
80064650
80064650
80064650
80064650
PTC TEMP. SENSOR
80064655
80064655
80064655
80064655
80064655
80064655
80064655
80064655
80064655
RELATIVE PRES. TRANSDUCER -DP
80064656
80064656
80064656
80064656
80064656
80064656
80064656
80064656
80064656
RELATIVE PRES. TRANSDUCER -OIL
80064657
80064657
80064657
80064657
80064657
80064657
80064657
80064657
NIL
RELATIVE PRES. TRANSDUCER -SUCTION
80064658
80064658
80064658
80064658
80064658
80064658
80064658
80064658
80064658
38
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RECOMMENDED SPARE PARTS
PERCENTAGE OF SPARE PARTS
ITEM
ONE YEAR SUPPLY
TWO YEAR SUPPLY
100 UNITS
1000 UNITS
100 UNITS
1000 UNITS
2%
1%
3%
2%
Condenser fan motor
2
1
3
2
Contactor compressor
2
1
3
2
Contactor fan motors
2
1
3
2
HPS/Sensor/Transducer
2
1
3
2
Expansion valve
1
0.5
2
1
Filter drier
2
1
3
2
Transformer (24V secondary)
1
0.5
2
1
Propeller fan
1
0.5
2
1
Heater-crankcase
3
1
4
2
Compressor
NOTE : When ordering spare parts, please quote the complete model number on the unit nameplate.
39
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PREVENTIVE MAINTENANCE SCHEDULE
FREQUENCY OF MAINTENANCE, MONTHS
ITEM
1
Clean air filters & replace if required.
3
6
12
X
Clean evaporator coil, drain pan & drain line.
X
Clean condenser coil.
X
Check blower belt/tension/wear/crack and replace it, if required.
X
X
Lubricate blower motor/condenser motor (if applicable).
Check alignment of pulleys.
X
Check/clean electrical connections, controls & control box.
X
X
Check motors, blower bearings & lubricate it.
Check all electrical control components, wiring terminals etc. for spark,
overheating & loose connections. Replace/correct as necessary.
X
X
Check all damper operation. Repair/replace as required.
X
Check insulation flanking. Repair/replace as required.
Check loose bolts/screws & tight as necessary.
X
Check for rusted/dented/damaged body parts & repair/repaint as necessary.
X
Check mountings (spring isolator/rubber pads). Repair/replace as necessary.
X
X
Check flexible canvas connections & duct work. Repair/replace as required.
Run test all motors and check the amperage, abnormality etc.
Run test compressors and check the amperage, noise, oil level, pressure
etc. and correct them accordingly.
Check the thermostat/control devices for correct operation, calibrate/
re-adjust as required.
X
X
X
Apply corrosion inhibitor/contact cleaner as required.
X
Check all pressures/temperatures as applicable and satisfy the operation &
performance.
X
NOTE: Always observe for abnormal noise or vibration.
MAINTENANCE TOOLS/EQUIPMENT REQUIRED
STANDARD : Screw drivers (Slot & Phillips), adjustable wrenches, pliers, refrigeration wrenches & socket set wrenches,
pulley puller, etc.
SPECIAL
: Manifold gauge set, R-134a charging cylinder, belt tension checker, leak detector, vacuum pump with
electronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.
40
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MATERIAL SAFETY DATA SHEET
SAFETY DATA
Toxicity
In Contact With Skin
REFRIGERANT R134a
NIL
Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere
to skin in case of freeze burns. Wash affected areas with plenty of warm water. If symptoms
occur (irritation or blistering), obtain medical attention.
In Contact With Eyes
Contact with liquid or cold vapor can cause freezing of tissue. Immediately flush with plenty
of clean water for at least 15 minutes. Obtain immediate medical attention.
Inhalation
High concentration of HFC 134a vapor is harmful. It can act as an asphyxiant by limiting
available oxygen. Human health effects of overexposure to HFC- 134a vapors by inhalation
may include temporary nervous system depression with anaesthetic effects such as dizziness, headache, confusion, incoordination and loss of consciousness. At very high doses,
cardiac sensitization to circulating epinephrine-like compounds can result in fatal cardiac
arrhythmias.
If large concentrations are inhaled, immediately remove to fresh air. Keep person calm. If
not breathing, give artificial respiration, perferably mouth to mouth. If breathing is labored,
give oxygen. In the event of cardiac arrest, apply external cardiac massage. Do not admininster
adreneline or similar sympathominectic drugs as cardiac arrhythmias may result. Get immediate medical attention.
Stability
Stable under normal conditions.
Conditions to Avoid
Any source of ignition, such as lighted cigarettes, flames, hot spots, welding.
Materials to Avoid
Finely divided metals, magnesium and alloys conatining more than 2% magnesium. Can
react violently if in contact with alkali earth metals such as sodium, potassium, calcium,
barium, powdered aluminium, magnesium and Zinc.
Hazardous
Halogens, halogen acids and possibly carbonyl halides such as phosgene. These are toxic
Decomposition Products and corrosive.
Avoid inhalation of high concentrations of vapors. Atmospheric concentrations should be
minimized and kept as low as possible. The vapor is heavier than air and collects at low level
and in confined areas. Ventilate by extraction at lowest levels.
Respiratory Protection Where doubt exists on atmospheric concentration, suitable breathing apparatus should be
worn. This should be self-contained or of the long breather type.
Storage
Store in a cool, well-ventilated area of low fire risk. Keep cylinders dry. Cylinders should be
stored upright with valve protection cap in place and firmly secured to prevent falling or being
knocked over. Protect cylinders from physical damage; do not drag, roll, slide or drop. Do
not allow storage area temperature to exceed 113ºF (45ºC). Keep away from direct sunlight,
heat and sources of ignition. Full and empty cylinders should be segregated. Use a first-in,
first-out inventory system to prevent full containers from being stored for long periods of
time.
Protective Clothing
Wear overalls, impervious gloves and goggles/face protection.
Spill / leak Procedure Ensure suitable personal protective clothing and respiratory protection is worn. Evacuate all
personnel from the affected area. Shut off source of leak, if possible without risk. Ventilate
spill area, especially low places where heavy vapors might collect. If possible dike and contain spillage. Prevent liquid from entering sewers, sumps or pit areas, since vapor can create
suffocating atmosphere. Allow spilled liquid to evaporate.
Disposal
Best to recover and recycle. If this is not possible, destruction is to be in an approved facility
which is equipped to absorb and neutralize acids and other toxic processing products.
Fire Extinguishing Data Non-flammable.
Containers
Fire exposed containers should be kept cool with water sprays. Containers may burst if
overheated.
Fire Fighting Protective Self-contained breathing apparatus and protective clothing must be worn in fire conditions.
Equipment
General Precautions
41
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PRESSURE TEMPERATURE CHART, R-134a
TEMPERATURE (0F)
TEMPERATURE (0C)
PRESSURE
PRESSURE
PSIA
PSIG
Kpa (Absolute)
Kpa (Gauge)
0
21.2
6.5
-17.78
146.2
44.9
2
22.2
7.5
-16.67
153.2
51.8
4
23.3
8.6
-15.56
160.4
59.1
6
24.3
9.6
-14.44
167.9
66.6
8
25.5
10.8
-13.33
175.7
74.3
10
26.6
11.9
-12.22
183.7
82.4
12
27.8
13.2
-11.11
192.0
90.7
14
29.1
14.4
-10.00
200.7
99.3
16
30.4
15.7
-8.89
209.6
108.3
18
31.7
17.0
-7.78
218.8
117.5
20
33.1
18.4
-6.67
228.4
127.0
22
34.5
19.8
-5.56
238.2
136.9
24
36.0
21.3
-4.44
248.4
147.1
26
37.5
22.9
-3.33
258.9
157.6
28
39.1
24.4
-2.22
269.8
168.5
30
40.7
26.1
-1.11
281.0
179.7
32
42.4
27.7
0.00
292.6
191.3
34
44.2
29.5
1.11
304.6
203.2
36
45.9
31.3
2.22
316.9
215.5
38
47.8
33.1
3.33
329.6
228.2
40
49.7
35.0
4.44
342.6
241.3
42
51.6
36.9
5.56
356.1
254.8
44
53.7
39.0
6.67
370.0
268.7
46
55.7
41.0
7.78
384.3
283.0
48
57.9
43.2
8.89
399.0
297.7
50
60.0
45.4
10.00
414.1
312.8
52
62.3
47.6
11.11
429.7
328.4
54
64.6
49.9
12.22
445.7
344.4
56
67.0
52.3
13.33
462.2
360.9
58
69.5
54.8
14.44
479.1
377.8
60
72.0
57.3
15.56
496.5
395.2
62
74.6
59.9
16.67
514.4
413.0
64
77.2
62.6
17.78
532.7
431.4
66
80.0
65.3
18.89
551.6
450.2
68
82.8
68.1
20.00
570.9
469.6
70
85.7
71.0
21.11
590.8
489.4
72
88.6
73.9
22.22
611.1
509.8
74
91.6
77.0
23.33
632.0
530.7
76
94.8
80.1
24.44
653.5
552.1
78
97.9
83.2
25.56
675.4
574.1
80
101.2
86.5
26.67
698.0
596.6
82
104.6
89.9
27.78
721.1
619.7
84
108.0
93.3
28.89
744.7
643.4
86
111.5
96.8
29.95
769.0
667.6
88
115.1
100.4
31.11
793.8
692.5
90
118.8
104.1
32.22
819.2
717.9
92
122.6
107.9
33.33
845.3
743.9
94
126.4
111.7
34.44
871.9
770.6
42
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PRESSURE TEMPERATURE CHART, R-134a
TEMPERATURE (0F)
TEMPERATURE (0C)
PRESSURE
PRESSURE
PSIA
PSIG
Kpa (Absolute)
Kpa (Gauge)
96
130.4
115.7
35.56
899.2
797.9
98
134.4
119.7
36.67
927.1
825.8
100
138.6
123.9
37.78
955.7
854.3
102
142.8
128.1
38.89
984.9
883.6
104
147.1
132.4
40.00
1014.8
913.4
106
151.6
136.9
41.11
1045.3
944.0
108
156.1
141.4
42.22
1076.6
975.2
110
160.7
146.0
43.33
1108.5
1007.2
112
165.5
150.8
44.44
1141.2
1039.8
114
170.3
155.6
45.56
1174.5
1073.2
116
175.2
160.6
46.67
1208.6
1107.3
118
180.3
165.6
47.78
1243.4
1142.1
120
185.5
170.8
48.89
1279.0
1177.7
122
190.7
176.0
50.00
1315.3
1214.0
124
196.1
181.4
51.11
1352.4
1251.1
126
201.6
186.9
52.22
1390.3
1288.9
128
207.2
192.5
53.33
1428.9
1327.6
130
212.9
198.2
54.44
1468.4
1367.1
132
218.8
204.1
55.56
1508.7
1407.4
134
224.7
210.0
56.67
1549.8
1448.5
136
230.8
216.1
57.78
1591.7
1490.4
138
237.0
222.3
58.89
1634.5
1533.2
140
243.3
228.6
60.00
1678.2
1576.8
142
249.8
235.1
61.11
1722.7
1621.4
144
256.4
241.7
62.22
1768.1
1666.8
146
263.1
248.4
63.33
1814.4
1713.1
148
269.9
255.2
64.44
1861.6
1760.3
150
276.9
262.2
65.56
1909.8
1808.5
152
284.0
269.3
66.67
1958.9
1857.6
154
291.3
276.6
67.78
2008.9
1907.6
156
298.7
284.0
68.89
2059.9
1958.6
158
306.2
291.5
70.00
2111.9
2010.6
160
313.9
299.2
71.11
2164.9
2063.6
162
321.7
307.1
72.22
2218.9
2117.6
164
329.7
315.0
73.33
2274.0
2172.7
166
337.9
323.2
74.44
2330.1
2228.7
168
346.1
331.5
75.56
2387.2
2285.9
170
354.6
339.9
76.67
2445.4
2344.1
43
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