Zamil Air Conditioner User Guide

PL-OM-CDL-07-1M-E
INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
AIR COOLED CONDENSING UNITS
'CDL' SERIES
(R-22)
Contents Page
General information .................................................................................................................................. 2
Safety issues ............................................................................................................................................ 2
Model decoding ....................................................................................................................................... 3
Physical data ......................................................................................................................................... 4-5
Electrical data ........................................................................................................................................... 6
Dimensions.......................................................................................................................................... 7-11
Typical schematic wiring diagram...................................................................................................... 12-16
Field wiring connections ......................................................................................................................... 17
Controls & sequence of operation .......................................................................................................... 17
Rigging instructions ................................................................................................................................ 18
Installation clearance.............................................................................................................................. 19
Mounting location ................................................................................................................................... 20
Load distribution ..................................................................................................................................... 21
INSTALLATION INSTRUCTIONS
General ................................................................................................................................................... 22
Location of unit ....................................................................................................................................... 22
Refrigerant piping connections ............................................................................................................... 22
Leak testing & refrigerant charging......................................................................................................... 23
Start-up inspection & check list ......................................................................................................... 23-24
Check-out & operational start-up procedure........................................................................................... 24
ELECTRICAL
Power supply .......................................................................................................................................... 25
Unbalanced voltage ................................................................................................................................ 25
Motor contactor ...................................................................................................................................... 26
Fan motor ............................................................................................................................................... 26
Crankcase heater ................................................................................................................................... 26
Lube oil protection control ................................................................................................................. 26-27
Voltage monitor ...................................................................................................................................... 27
REFRIGERATION
Compressor ............................................................................................................................................ 28
High & low pressure protection.......................................................................................................... 29-30
Pump down control ................................................................................................................................. 30
Trouble shooting chart ....................................................................................................................... 31-33
Parts list ................................................................................................................................................. 34
Recommended spare parts .................................................................................................................... 35
Preventive maintenance schedule.......................................................................................................... 36
Material safety data sheet ...................................................................................................................... 37
Pressure temperature chart ............................................................................................................... 38-39
INDEX
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1
2
GENERAL STATEMENT
Cooline CDL series is designed and built for the optimum performance when matched with the right indoor unit (Refer to
indoor unit catalog). However, it is required that you become well acquainted with good practices for the proper installa-
tion, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year.
Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experi-
enced technicians should perform the installation and other maintenance procedures.
SAFETY ISSUES
There are three levels of safety hazards that are identified throughout this manual as Warning (where the situation will
result in personal injury), Caution (where personal injury might occur), and Attention (where minor personal injury and/or
property damage could happen). Please understand and respect those identifications.
WARNING: These units operate on a high voltage with moving parts (at high speed) which can lead to
serious injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical power
supply has been disconnected.
CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining
the unit as the hazard of explosion, fire, electrical shock, and potential personal injury and property damage
are present.
When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observe
all the applicable safety measures (wear of safety helmet, boots, and goggles. Use of proper handling materials for
brazing and use of wet cloth for sequencing. A fire extinguisher should be easily accessible etc). He should also read all
the instructions and information in this manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should be observed during installation and servicing.
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NOTE:
* Nominal cooling capacity @ 95
0
F outdoor and 45
0
F saturated suction temperatures.
** Unit is factory supplied with holding charge only.
*** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.
+ Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.
++ Based on free field area at ARI conditions. Tolerance: 2dBA.
+++ Values indicated are for standard unit with aluminum fin condenser coils.
MODEL NUMBER CDL020 CDL025 CDL030 CDL035 CDL040 CDL050 CDL055
NOMINAL CAPACITY , TONS* 18.4 22.3 27.6 35.5 42.1 48.5 54.8
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Dual Dual Dual
COMPRESSOR Type Scroll
Oil per system (liters) 3.25 3.25 4.14 4.67 5.91 6.3/5.91 6.3
Refrigerant** R-22
Charge per system (oz)*** 332 402 497 640 758 987/758 987
CONDENSER FAN Type Propeller
Qty. Diameter (inch) 2 30 2 30 4 30 4 30 4 30 4 32 4 32
Nominal CFM 13000 13000 26000 26000 26000 42776 41376
Motor HP RPM 1.5 950 1.5 950 1.5 950 1.5 950 1.5 950 2 920 2 920
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube DiaRowsFins per inch 3/8314 3/8414 3/8214 3/8314 3/8414 3/8314
Total face area (Sq. ft.) 32.9 32.9 59.5 59.5 59.5 75 75
HIGH PRESSURE SWITCH Open (PSIG) 450 10 450 10 450 10 450 10 450 10 450 10 450 10
Close (PSIG) 360 15 360 15 360 15 360 15 360 15 360 15 360 15
LOW PRESSURE SWITCH Open (PSIG) 25 5 25 5 25 5 25 5 25 5 25 5 25 5
Close (PSIG) 50 5 50 5 50 5 50 5 50 5 50 5 50 5
REFRIGERANT LINES+ Suction line size (OD), inch 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8
Liquid line size (OD), inch 5/8 5/8 5/8 7/8 7/8 7/8 7/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 65.3/61.8/56.5 65.4/61.8/56.6 68.2/64.7/59.5 68.4/64.8/59.6 68.5/65/59.7 68.8/65.3/60 68.9/65.4/60.1
OPERATING WEIGHT, Kg.+++ 716 760 1050 1159 1328 1447 1480
PHYSICAL DATA
3/8214
3/8314
5
NOTE:
* Nominal cooling capacity @ 95
0
F outdoor and 45
0
F saturated suction temperatures.
** Unit is factory supplied with holding charge only.
*** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.
+ Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.
++ Based on free field area at ARI conditions. Tolerance: 2dBA.
+++ Values indicated are for standard unit with aluminum fin condenser coils.
MODEL NUMBER CDL065 CDL080 CDL100 CDL110 CDL135 CDL160 CDL195
NOMINAL CAPACITY , TONS* 66.7 79.2 97.5 110.9 132.9 158.7 195.1
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Quadruple Quadruple Quadruple Quadruple
COMPRESSOR Type Semi-hermetic reciprocating
Oil per system (liters) 7.4 7.4 7.7 4.0 7.4 7.4 7.7
Refrigerant** R-22
Charge per system (oz)*** 1200 1426 1755 998 1196 1428 1756
CONDENSER FAN Type Propeller
Qty. Diameter (inch) 4 32 6 32 6 32 6 32 8 32 10 32 12 32
Nominal CFM 41240 59400 59856 65736 81280 97620 119712
Motor HP RPM 2 920 2 920 2 920 2 920 2 920 2 920 2 920
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube DiaRowsFins per inch 3/8414 3/8314 3/8414 3/8414 3/8414 3/8414 3/8414
Total face area (Sq. ft.) 87.5 100 120 160 168 190 240
HIGH PRESSURE SWITCH Open (PSIG) 450 10 450 10 450 10 450 10 450 10 450 10 450 10
Close (PSIG) 360 15 360 15 360 15 360 15 360 15 360 15 360 15
LOW PRESSURE SWITCH Open (PSIG) 25 5 25 5 25 5 25 5 25 5 25 5 25 5
Close (PSIG) 50 5 50 5 50 5 50 5 50 5 50 5 50 5
REFRIGERANT LINES+ Suction line size Dual 2-1/8 2-5/8 2-5/8 N.A. N.A. N.A. N.A.
(OD), inch
Quadruple N.A. N.A. N.A. 1-5/8 2-1/8 2-1/8 2-5/8
Liquid line size Dual 7/8 1-1/8 1-1/8 N.A. N.A. N.A. N.A.
(OD), inch
Quadruple N.A. N.A. N.A. 7/8 7/8 7/8 1-1/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 68.6/65/59.8 70.5/66.9/61.7 70.6/67/61.8 70.3/66.8/61.5 71.7/68/62.7 72.8/69.2/64 73.3/69.8/64.5
OPERATING WEIGHT, Kg.+++ 1857 2145 2495 3234 3500 3956 4820
PHYSICAL DATA
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7
DIMENSIONS
NOTE: All dimensions are in mm.
CDL 020 & CDL 025
CDL 030, CDL 035 & CDL 040
8
DIMENSIONS
CDL 050 & CDL 055
CDL 065
9
DIMENSIONS
CDL 080 & CDL 100
CDL 110
MODEL H
CDL 080 1950
CDL 100 2253
DIMENSIONS
10
DIMENSIONS
CDL 135
CDL 160
11
DIMENSIONS
CDL 195
12
TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS: CDL020 - CDL100
Power supply: 380/415V-3Ph-50Hz
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.
T
1
A
T
1
B
COMP
1
T
2
A
T
3
A
COMP
2
T
3
B
T
2
B
DISCONNECT
SWITCH OR CB
(SEE NOTE-4)
TO FUSED
L2
L1
L3
LUG
HVTB
SHEET 2 OF 2 FOR
CONDENSER FAN MOTOR
POWER CONNECTIONS.
PLEASE REFER TO
Y2 STG2 COOLING
LED
POWER INDICATOR
J_PROG
FUSE
TRANS
12v-0-12v
240v
S
E
C
P
R
I
L
IV
E
P3_##
DIP SWITCH
ON DIP
LED FAULT INDICATOR
LOCK2
SYSTEM2
LOCK1
SYSTEM1
(LP1)
(LP2)
LP2
23B
22B
LPS2
P
(SSPS1)
(SSPS2)
24A
21A
HP1
(HP2)
LP1
(HP1)
HP2
27B
23A
22A
21B
27A
24B
OLR2-1
ON/OFF
(ON/OFF)
ECB
SQMBO4 ( P III )
W2
W1
Y2
OLR1-1
Y2
JP5 26A JP3 25A
HPS2
LPS1
P
P
(OPS2)
JP6 JP4 25B 26B
P
HPS1 (OPS1)
4
B
P
2
TO ATB
N
E
U
T
R
A
L
O
U
T
F
A
N
1
O
U
T
F
A
N
2
X
2
4
1
B
H
E
A
T
E
R
2
IN
F
A
N
H
E
A
T
E
R
1
X
1
4
1
A
SEE VFC CONNECTION
(AT RIGHT)
TO
FR2
TO
FR1
1 1B 1A JP1
ATB
JP2
STG1 COOLING
( NOTE 7)
R
C
O
M
P
1
C
O
M
P
2
P
1
G
Y1
C
4
A
3
B
3
A
R
24Vac
JP
Y1
C
LVTB
CC2
CC1
R
C
Y1
ATB
PLEASE REFER TO FAN MOTOR
CONTROL CONNECTION, (SHEET 2 of 2)
G
W1
W2
Yellow OFF blinking slow - LPS1 ckt fault
Orange
Set dip switch #3 according to unit's option
(pump down or no pump down)
note:
blinking slow - LPS2 ckt fault
blinking fast - HPS2 ckt fault
system 2 fault diagnostic
ECB DIP SWITCH SETTINGS & LED INDICATORS
Green
on-board programming function (always set to on)
(Comp1&2 Auto Lead Lag)
DIP SWITCH #
FACTORY SETTINGS OF DIP SWITCHES
OFF= WITHOUT PUMP DOWN
ON
OFF= S2
S4
S3
S3 S1 S2 Red S4
LOAD BALANCE
OFF=TEST MODE DISABLE S1
system lock-out due to system fault
LED INDICATORS
power on/off indicator
ON= COMPRESSOR 1 LEAD
ON= WITH PUMP DOWN OPTION
ON= TEST MODE ENABLE
TO HVTB
L1
TO NTB
N
NTB
NEUTRAL
PDS1
PDS2
F1
OLR2 OLR1
CC1 CC2
DIP SWITCH S2 SHOULD ALWAYS BE SET TO "ON" POSITION.
COMP1 SHOULD ALWAYS BE LEAD COMPRESSOR.
HGS CONNECTION WITH COMP UNLOADER
AR9-1
HGS CONNECTION W/O COMP UNLOADER
AR9-1
AR9
NO
NC
5A
C
NOTE:
P
LPS5
6D
AR8-1
6E
LPS5
1 NO
P
NC
C
Y2 [LVTB]
AR8-1
6E 6D
31B
Y1 [LVTB] 31A
AR8
2 HGS
6C
HGS
6C
2
17A
17A C [LVTB]
13
LEGEND
AHU AIR HANDLING UNIT
AFS AIR FLOW SWITCH
AR AUXILIARY RELAY
ATB AUXILIARY TERMINAL BLOCK
BM BLOWER MOTOR
BMC BLOWER MOTOR CONTACTOR
CC COMPRESSOR CONTACTOR
CCA CC AUXILIARY CONTACT
CB CIRCUIT BREAKER
C. HTR CRANKCASE HEATER
COMP/C COMPRESSOR
ECB ELECTRONIC CONTROL BOARD
F FUSE
FCS FAN CYCLING SWITCH
FM FAN MOTOR (CONDENSER)
FMC FAN MOTOR CONTACTOR
FMCA FMC AUXILIARY CONTACT
FR FAULT RELAY
HC HEATER CONTACTOR
HPS HIGH PRESSURE SWITCH
HVTB HIGH VOLTAGE TERMINAL BLOCK
JP JUMPER
L1 LINE 1
L2 LINE 2
L3 LINE 3
LPS LOW PRESSURE SWITCH
LUG LUG GROUND
NTB NEUTRAL TERMINAL BLOCK
OLR OVER LOAD RELAY
OPS OIL PRESSURE SWITCH
P PRESSURE
PDS PUMP DOWN SOLENOID
S DIP SWITCH (IN ECB)
SSPS SOLID STATE PROTECTION SYSTEM
TOP FM THERMAL OVERLOAD PROTECTION
TRANS TRANSFORER
UL COMP. UNLOADER SOLENOID
UVM UNDER VOLTAGE MONITOR
FIELD WIRING
TERMINAL BLOCK OR TERMINATION POINT
SPLICE-CLOSED END
NOTES
1. ANY WIRE REPLACEMENT SHOULD BE OF 90
0
C
OR ITS EQUIVALENT.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. 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, CRANK-
CASE HEATER MUST BE ON FOR 12 HOURS BE-
FORE OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN COMPRESSOR DAMAGE.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY CONSUMER
WITH RATING AS RECOMMENDED BY COOLINE.
5. COMPRESSORS ARE PROVIDED WITH SSPS OR INTER-
NAL LINE BREAK THERMAL OVERLOAD PROTECTION.
6. IF PDS IS FACTORY INSTALLED, PLEASE READ
BROKEN LINES AS CONTINUOUS LINES.
7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.)
FOR LVTB FIELD WIRING. GROUND CONNECT
AT BOTH ENDS.
8. COOLING OUTPUT SIGNAL FROM CONTROLLER
SHOULD FOLLOW THE SEQUENCE:
ON SEQUENCE - Y1 FIRST, THEN Y2.
OFF SEQUENCE - Y2 FIRST, THEN Y1.
9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGE
ACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS 230VAC.
ALSO, COMP. LOCKOUT LIGHT (RED) OF ECB IS ON.
_ _ _
(SEE NOTE-4)
SWITCH OR CB
DISCONNECT
TO FUSED
L1
L2
L3
LUG
HVTB
T
2
B
T
3
B
T
1
B
T
3
A
T
2
A
T
1
A
COMP
1
COMP
2
O
U
T
F
A
N
1
P
R
I
O
U
T
F
A
N
2
N
E
U
T
R
A
L
L
IV
E
S
E
C
LED
C
O
M
P
1
C
O
M
P
2
IN
F
A
N
H
E
A
T
E
R
1
H
E
A
T
E
R
2
ON/OFF
(ON/OFF)
(LP2)
J_PROG
P3_##
ON DIP
SYSTEM2
LOCK2
SYSTEM1
LOCK1
(HP2)
(LP1)
LP2
LP1
(HP1)
HP2
HP1
W2
W1
G
Y2
Y1
C
R X
2
X
1
P
2
P
1
FUSE
OLR1-1 HPS1
P
21A
25A 24A JP3 26A JP5
27A
DIP SWITCH
26B
27B
21B
OLR2-1
25B JP4 24B JP6
HPS2
P
LPS1
23A
22A
P
22B
23B P
LPS2
TRANS2
230v
12v-0-12v
R
C
Y1
Y2
LVTB
R
Y1
Y2
STG1 COOLING
STG2 COOLING
24Vac
FROM T'STAT CONTROLLER OR DDC
(by others)
CC1
CC2
JP1
ATB
1 JP2 1A 1B
ATB
TO ATB
4
1
B
4
1
A
4
B
4
A
3
A
3
B
UVM CONNECTION
TO ATB
TO ATB 1A
1
L2 L1
L1 L2
1
(REMOVE JP1)
L3
L3
8
UVM
UVM-1
ECB1
LED FAULT INDICATOR
POWER INDICATOR
TO
FR2 FR1
TO
SEE VFC CONNECTION
SQMBO4 ( P III )
( NOTE 8)
SWITCHING CONTACTS
JP
( NOTE 9)
C N
E
U
T
R
A
L
S
E
C
P
R
I
230v
12v-0-12v
TRANS3
J_PROG
POWER INDICATOR
LED
DIP SWITCH
DIP ON
SYSTEM2
FUSE
L
IV
E
SYSTEM1
P3_##
LED FAULT INDICATOR
LOCK1 LOCK2
ON= WITH PUMP DOWN OPTION OFF= WITHOUT PUMP DOWN S3
system lock-out due to system fault
power on/off indicator
LED INDICATORS
(pump down or no pump down)
Set dip switch #3 according to unit's option
on-board programming function (always set to on)
FACTORY SETTINGS OF DIP SWITCHES
ON
OFF
note:
DIP SWITCH #
S4
Yellow
Orange
S4 S2 S1 S3
Green
Red
ECB DIP SWITCH SETTINGS & LED INDICATORS
ON= COMPRESSOR 1 LEAD
ON= TEST MODE ENABLE
(Comp1&2 Auto Lead Lag)
OFF=TEST MODE DISABLE S1
S2 OFF=
LOAD BALANCE
25D
25C
27C
LP1
LP2
(LP2)
(LP1)
HP2
(HP2)
(HP1)
22C
22D
23D
23C
OLR4-1
27D
21D
24D JP8
SQMBO4 ( P III )
HP1
(ON/OFF)
ON/OFF
ECB2
Y2
W1
W2
Y1
G
OLR3-1
21C
24C JP7
JP
P
LPS4
P
P
LPS3
HPS4
JP10 26D
P
HPS3
26C JP9
1
SEE VFC CONNECTION
O
U
T
F
A
N
2
O
U
T
F
A
N
1
H
E
A
T
E
R
2
X
2
X
1
4
1
D
4
1
C
H
E
A
T
E
R
1
IN
F
A
N
FR3 FR4
TO TO
P
1
P
2
C
O
M
P
2
4
D
3
D
4
C
C
O
M
P
1
R
3
C
CC4
CC3
TO ATB
TB1
STG3 COOLING
STG4 COOLING Y4
Y3
Y3
Y4
15
17
31A
31B
YR3
YR4
31C
31D
YR3-1
YR4-1
15B
31C
31D
L2 C.HTR1 L1
(REMOVE JP3)
(REMOVE JP4)
COMP. SSPS CONNECTION
(REMOVE JP8)
(REMOVE JP7)
COMP. 2:
1
COMP. 4:
24D
M1/11
L1/MP/L
SSPS4
1
COMP. 3:
24C
M1/11
L1/MP/L
SSPS3
1
24B
L1/MP/L
M1/11
SSPS2
COMP. 1:
1
24A
L1/MP/L
M1/11
SSPS1
COMP. 3:
COMP. 4:
L2
L1
C.HTR4
C.HTR3
COMP. 2:
L2 C.HTR2
25D
M2/14
L2/R/N
2
25C
M2/14
L2/R/N
2
25B
L2/R/N
M2/14
2
25A
L2/R/N
M2/14
2
(NOTE 5)
L3
L2
L3
SCROLL COMP CRANKCASE HTR CONNECTION
COMP. 1:
COMP
3 4
COMP
T
3
C
T
2
C
T
1
C
T
2
D
T
3
D
T
1
D
NEUTRAL
NTB
TO HVTB
L1 N
TO NTB
PLEASE REFER TO
POWER CONNECTIONS.
CONDENSER FAN MOTOR
SHEET 2 & 3 OF 3 FOR
SEE FM CONNECTION
SEE FM CONNECTION
1
COMP
T
1
A
T
3
A
T
2
A
2
COMP
T
2
B
T
1
B
T
3
B
COMP
3
T
3
C
T
2
C
T
1
C
4
COMP
T
2
D
T
3
D
T
1
D
L
1
A
L
3
A
L
2
A
CB1
L
1
B
L
2
B
L
3
B
CB2
TO HVTB
L1
L1 L1
TO HVTB
L1
L1
L1
L
3
C
L
1
C
L
2
C
CB3
L
3
D
L
2
D
L
1
D
CB4
TO HVTB
L1 L1 L1
TO HVTB
L1 L1 L1
COMP WITH CB OPTIONS
CRANKCASE HTR CONNECTION(AS APPLICABLE)
A. SEMI-HERMETIC RECIP. COMP. (BITZER)
C.HTR2
C.HTR1
COMP. 2:
1
COMP. 1:
1
100B
100A
2
2
COMP. 3: 100C
C.HTR3 1 2
COMP. 4: 100D
C.HTR4 1 2
G
2
PDS4
PDS3
OLR4
CC4
PDS1
PDS2
CC1
OLR1 OLR2
CC2
OLR3
CC3
CC4A-1B
CC3A1B
OLR2
CC2
OLR1
CC1
CC1A-1B
CC2A-1B
OLR4
CC4
OLR3
CC3
(SSPS3) (OPS3)
(SSPS4) (OPS4)
(SSPS1) (OPS1)
(SSPS2) (OPS2)
PRESSURE SWITCH SETTINGS
HPS1 TO 4
LPS 9-12
LPS 5-8
FCS1 TO 4
NAME
LPS1 TO 4
360 15 450 10
55 65
55
190 10
45
290 15
25 5
OPEN (PSIG)
50 5
CLOSE (PSIG)
14
1
0
5
3
7
B
11B
FCS2
1
P
1OB
REFER OPTIONAL FCS CONNECTION BELOW.
10A FCS1
P
**
T.O.P
FM3 11A
12C 13C
FMC3
FM5
12E
12C **
1
TO ECB1
OUTFAN 2
FM3
FMC3 T.O.P
13C
2
FMC5
13E
T.O.P
2
12A TO ECB1
OUTFAN 1
FM1
FMC1
13A
T.O.P
2
3
6
C
3
7
C
3
5
C
FM1
3
7
A
3
6
A
3
5
A
FM3 FM2
3
6
B
3
5
B
FMC1
1
0
2
1
0
1
1
0
0
FMC3
1
0
3
1
0
4
CB6
L1 L2 L3 L2 L1
FCS4
1
11D
10D
P
2
10C
**
FCS3
P
11B
T.O.P
FM3
12D 13D
FMC4
2
FMC1
3
5
C
FMC4
FM6
1
TO ECB2
OUTFAN 2
FM4
T.O.P
12D 13D
13F
T.O.P
12F
FMC6
2
TO ECB2
OUTFAN 1
FM2
13B
T.O.P
12B
2
FMC2
2
12A
TO ECB1
OUTFAN 1
FM1
T.O.P
13A
3
5
F
3
5
D
3
6
D
3
7
D
FM4
FM5
3
7
E
3
6
E
3
5
E
FMC4 FMC2
1
0
7
1
0
6
1
0
8
FMC5
FM6
3
7
F
3
6
F
FM1
3
5
A
3
6
A
3
7
A
FMC6
FMC1
1
0
1
1
0
0
1
0
2
2
3
7
C
3
6
C
FM3
6-FAN MOTOR LAYOUT
CDL110
C
O
N
T
R
O
L
P
A
N
E
L CB7
CB8
L3
L1 L2 L3
CB6
L2 L1 L3
C
O
N
T
R
O
L
P
A
N
E
L
CDL135
8-FAN MOTOR LAYOUT
FMC5
1
0
3
3
5
B
3
5
C
3
7
C
3
6
C
FM1
3
6
A
3
7
A
3
5
A
FM3
FMC1
1
0
1
1
0
2
1
0
0
FMC3
3
7
D
3
5
D
3
6
D
FM4 FM2
3
7
B
3
6
B
FM5
3
6
E
3
7
E
3
5
E
FMC2
1
0
5
1
0
4
1
0
8
1
0
7
1
0
6
FMC4
FM8
3
5
F
FM7
3
5
G
3
6
G
3
7
G
FM6
3
6
F
3
7
F
3
5
H
3
6
H
1
0
9
FMC7
1
1
0
1
1
1
FMC6
3
7
H
CB6
L2 L1 L3
CB7
L2 L3 L1
L2 L1 L3
C
O
N
T
R
O
L
P
A
N
E
L
CB8 CB9
L2 L3 L1
CDL135
8-FAN MOTOR LAYOUT
TO ECB1
OUTFAN 2
TO ECB1
OUTFAN 1
FMC6 T.O.P
12F
FMC5 T.O.P
12E
T.O.P
10C
FCS3
P
12G 11C
FM7
FMC7
13G
2
13E
2
FM8
T.O.P
10D
FCS4
12H 11D
P
FMC8
13H
2
13F
2
OUTFAN 2
TO ECB2
TO ECB2
OUTFAN 1
13A
12A
T.O.P
10A
11A 12C
P
FM5
FCS1
FM3
FMC3
13C
2
2
T.O.P
FM1
FMC1
13B
12B
FM4
T.O.P
FM6
10B
12D 11B
P
FCS2
13D
FMC4
2
2
FM2
T.O.P FMC2
L3 L1 L2
CB7
L3 L1 L2
CB8
L3 L1 L2
CB9
FM2 FM4
3
6
D
3
5
D
3
7
D
3
7
B
3
6
B
3
5
B
FMC2
1
0
5
1
0
4
1
0
3
3
7
E
3
5
E
3
6
E
FM5 FM7
3
5
G
3
7
G
3
6
G
3
7
F
3
6
F
3
5
F
FM6 FM8
3
5
H
3
7
H
3
6
H
1
1
1
1
1
0
1
0
9
1
0
6
1
0
7
1
0
8
FMC3 FMC4
CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (6FANS)
FM3
T.O.P
12C 12C
FM2 TO ECB2
T.O.P
12B
FM4
T.O.P
12D 13B 12D
FMC2
2
OUTFAN 1
FM5 TO ECB1
OUTFAN 2 T.O.P
12E
FM7
T.O.P
12G 13E 12H
FMC3
FM6
OUTFAN 2
TO ECB2
2
12F
T.O.P
FM8
T.O.P
12H 13F 12H
FMC4
2
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : WITH FAN CYCLING OPTION (8FANS)
FMC5A-1
FMC1A-1
FMC6A-1
FMC2A-1
FMC1A-1
FMC5A-1
FMC2A-1
FMC6A-1
P
A
N
E
L
C
O
N
T
R
O
L
10-FAN MOTOR LAYOUT
CDL160
FMC8
3
5
J
FM1
3
6
A
3
5
A
FM3
3
7
C
3
7
A
3
6
C
3
5
C
3
5
B
FM2
3
7
B
3
6
B
1
0
1
1
0
0
FMC1
1
0
2
CB6
1
0
3
1
0
5
1
0
4
3
7
H
3
5
H
3
6
H
3
5
I
3
7
I
3
6
I
3
5
D
FM4
3
7
D
3
6
D
FM7 FM9 FM8
1
0
8
FMC2
CB7
1
0
7
1
0
6
FMC4 FMC3
CB8
1
1
1
1
1
0
1
0
9
CB9
L1 L2 L3 L3 L2 L1 L3 L2 L1 L3 L2 L1
3
6
J
3
7
J
FM10
FM10 FM8
OUTFAN 2
13H 12H
T.O.P T.O.P
12J 12J
FMC4
2
13B
13A
13G 12G
OUTFAN 1
TO ECB2
TO ECB2
12B
T.O.P
FM2
TO ECB1
OUTFAN 1
OUTFAN 2
TO ECB1 FM7
T.O.P
12A
FM1
T.O.P
12I
FMC3
12I
12D 12D
T.O.P
FM4
FMC2
2
2
FM9
T.O.P
FM3
T.O.P
12C 12C
FMC1
2
L3 L1 L2
CB10
**
FMC8A-1 1
FMC7A-1
13E
T.O.P
12E
FMC5
2 1
FMC6
12F 13F
2
FMC2A-1
FM6 FMC1A-1
FM5
CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD OPTIONS(8FANS)
3
5
E
3
6
E
3
7
E
FM5
FMC6
FM6
FMC6
1
1
2
1
1
3
1
1
4
3
5
G
3
7
G
3
6
G
3
7
F
3
6
F
3
5
F
FCS3
FCS4
13E
T.O.P
10A
FCS2
FMC7A-1 1
1OB
12E
P
11B
FCS1
FMC1A-1
11A FM5
FMC5
1 2 FMC8A-1
10D
FMC2A-1
10C
FMC6
12F 13F
P
11D
P
2
11B FM6
T.O.P
P
(REMOVE JP9)
(REMOVE JP10)
OIL PRESSURE SWITCH CONN.(AS APPLICABLE) OIL PRESSURE SWITCH CONN.(AS APPLICABLE)
COMP 2
25B
CC2A-1A
COMP 1
25A
1 CC1A-1A
(REMOVE JP5)
(REMOVE JP6)
OPS2-1
2
28B
OPS2
26B
2
240
OPS1-1
2
28A
OPS1
26A
2
240
CC4A-1A
25C
COMP 4
OPS4-1
28D
2
CC3A-1A
25C
COMP 3 1
OPS3-1
28C
2
26D
240
OPS4
2
26D
240
OPS3
2
15
61 63 60
COMP2 ON
COMP2 TRIP
INDIVIDUAL COMP. ON/OFF/TRIP
COMP 2
TO ECB1
X2
55
COMP 1
X1
TO ECB1
COMP1 ON
COMP1 TRIP
41B
FR2
2
56
41A
FR1
58
2
UNIT ON
43
1
45
AR1
UNIT TRIP
44A
UNIT TRIP
46
44
2
UNIT ON / OFF
UNIT STATUS (VFC) INDICATION CONNECTION
AR9-1
6D 6E
AR8-1 C
NC
P
1 NO
LPS5
Y2 [LVTB]
31B
AR9
HGS CONNECTION W/O COMP UNLOADER
Y1 [LVTB] 31A
AR8
HGS 2
6C
17A
C [LVTB] 17A
X2
70
COMP4 ON
COMP4 TRIP
71
TO ECB2
COMP3 TRIP
41D
FR4
COMP3 ON
65 66
COMP 3
TO ECB2
X1
41C
FR3
73
2
68
2
COMP 4
44C 44B
7
3
B
7
2
B
7
1
B
7
3
A
7
1
A
7
2
A
CONTROLS
TO ATB
230Vac
HTR1
HTR2
INFAN
(in cond. unit)
(in cond. unit)
TO ECB
30
29
14
HC2
28
AFS
BMC
19
BM CONTROL
STG1 COOLING
STG1 HEATER
STG2 HEATER
STG2 COOLING
( NOTE 8) (REMOVE JUMPER JP)
Y1
W2
W1
Y2
R
C
G
TB1 (ECB)
Y1
W2
W1
Y2
24Vac
R
C
G
LVTB
T
3
F
T
2
F
T
1
F
(Stg. 1 Heating)
T
1
H
T
2
H
T
3
H
(Stg. 2 Heating)
(by others)
W2
W1
Y2
Y1
G
C
R
6
8
SWITCHING CONTACTS
6
9
7
0
OPTIONAL AHU INTER-CONNECTION
(POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR)
TO POWER SUPPLY
L1 L3 L2
TO POWER SUPPLY
L2 L1 L3
TO POWER SUPPLY
L
1
C
L
2
C
L
3
C
L2 L1 L3
YR3
Y4
Y3 STG3 COOLING
STG4 COOLING
YR3
Y3
Y4
LPS5
C
COMPRESSOR UNLOADER CONNECTION (OPTIONAL)
C
LPS6
COMP 2
TO ATB
28B
28B
COMP 1
TO ATB
28A
28A
P
NC
6B
NC
P
NC
NO
C
LPS10
P
5B
NO
2
P
NO LPS9
C
6A
5A
NO
NC
2
AR9-1
HGS CONNECTION WITH COMP UNLOADER
COMP1 SHOULD ALWAYS BE LEAD COMPRESSOR.
DIP SWITCH S2 SHOULD ALWAYS BE SET TO "ON" POSITION.
NC
P
NOTE:
6E
NO
LPS5
C AR8-1
6D 6C
HGS 2
5A
LPS11 NO
C
LPS12
C
NC
NO
UL3 & UL 4 CONNECTION APPLICALBLE FOR COMP WITH 3 STEPS
P
CAPACITY UNLOADING.
NOTE
TO ATB
COMP 4 28D
C 28B
LPS8
P
NO
NC
6B
P
6C
NC
5B
2
NO
NC
TO ATB
28C COMP 3
LPS7
P
28C C
5C
2 UL3
UL7
UL8
UL4
UL1
UL2
UL6
UL5
FR1-1 FR3-1 FR2-1 FR4-1
C
C
2
A
-2
A
C
C
4
A
-2
A
AR1-1A
FR3-2A FR1-2A
FR2-2A
C
C
1
A
-2
A
FR4-2A
C
C
3
A
-2
A
OLR-1
HTR2 HTR1
CB12
HC2 HC1
CB11
BMC
OLR
CB
3
5
I
1
1
2
FM1
3
6
A
3
5
A
3
7
E
FM5
3
6
E
3
5
E
3
7
A
3
7
B
3
5
B
3
6
B
FM2 FM11
3
6
K
3
5
G
3
5
F
3
6
F
3
7
F
FM6
3
5
K
3
7
G
3
6
G
FM7
3
7
H
3
6
H
3
7
K
3
5
H
FM8 FM12
3
6
L
3
5
L
3
7
L
FMC2
1
0
1
1
0
0
L1
CB7 CB6
FMC1
1
0
2
1
0
4
1
0
3
1
0
5
L3 L2 L3 L2 L1
CB9
1
0
7
1
0
6
FMC5
1
0
8
L1 L3 L2
CB9
1
1
0
1
0
9
1
1
1
FMC6
L3 L1 L2
3
6
J
3
5
J
3
7
I
3
6
I
FM9
3
7
J
FM10
CB10
FMC7
1
1
3
1
1
4
FMC8
13A
13G 12G
TO ECB1
OUTFAN 1
OUTFAN 2
TO ECB1 FM7
T.O.P
12A
FM1
T.O.P
12K
FMC5
12K
2
FM11
T.O.P
FM5
T.O.P
12E 12E
FMC1
2
12-FAN MOTOR LAYOUT
CDL195
C
O
N
T
R
O
L
P
A
N
E
L
FM9
T.O.P
1
12I FMC5A-1
13I
FMC7
2
FMC1A-1
1
FMC3 T.O.P
12C 13C
2
FM3
3
5
C
3
6
C
3
7
C
FM3
FMC3
CB8
L3 L2 L1
FMC4
FM4
3
7
D
3
6
D
3
5
D
FM2 TO ECB2
12B
OUTFAN 1 T.O.P
12F 13B 12D
FM6
FMC2
12F
T.O.P
2
FMC2A-1
1
TO ECB2 FM4
FMC4
13D
T.O.P
2
OUTFAN 2
12H
T.O.P
FM12
13H
T.O.P
FM8
12L 12L
FMC6
2
12J FMC6A-1
1
13J
T.O.P
FM10
FMC8
2
1
1
5
1
1
6
1
1
7
**
FMC1A-1
1
FM3
FMC3
13C
T.O.P
2
SEE FCS CONN BELOW
SEE FCS CONN BELOW
SEE FCS CONN BELOW
SEE FCS CONN BELOW
10A
11A
FCS1
P
12C
1
FMC2A-1
P
12D
FCS3
10B
11B
13D
T.O.P FMC4
2
FM4
10C
10D
1
1
FMC6A-1
FMC5A-1
12J
FCS4
11D
P
P
FMC8
13J
FM10
T.O.P
12I
FCS2
11C
13I
T.O.P
FM9
FMC7
2
2
16
NOTES
1. ANY WIRE REPLACEMENT SHOULD BE OF 90
0
C
OR ITS EQUIVALENT.
2. USE COPPER CONDUCTOR WIRES ONLY.
3. 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, CRANK-
CASE HEATER MUST BE ON FOR 12 HOURS BE-
FORE OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN COMPRESSOR DAMAGE.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY CONSUMER
WITH RATING AS RECOMMENDED BY COOLINE.
5. COMPRESSOR MOTORS ARE PROVIDED WITH SSPS OR IN-
TERNAL LINE BREAK THERMAL OVERLOAD PROTECTION.
6. USE DISCONNECT TAB OR SPLICE ONLY WHERE
EVER REQUIRED FOR EXTENSION OF ORIGINAL WIRE.
7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR LVTB
FIELD WIRING. GROUND CONNECT AT BOTH ENDS.
8. COOLING OUTPUT SIGNAL FROM CONTROLLER
SHOULD FOLLOW THE SEQUENCE:
ON SEQUENCE - Y1 - Y2 - Y3 - Y4.
OFF SEQUENCE - Y4 - Y3 - Y2 - Y1.
9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGE
ACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS
230VAC. ALSO, COMP. LOCKOUT LIGHT (RED) IS ON.
+
LEGEND
AR AUXILIARY RELAY
ATB AUXILIARY TERMINAL BLOCK
BM BLOWER MOTOR
BMC BLOWER MOTOR CONTACTOR
CC COMPRESSOR CONTACTOR
CCA CC AUXILIARY CONTACT
CB CIRCUIT BREAKER
C. HTR CRANKCASE HEATER
COMP/C COMPRESSOR
DDC DIRECT DIGITAL CONTROLLER
ECB ELECTRONIC CONTROL BOARD
F FUSE
FCS FAN CYCLING SWITCH
FM FAN MOTOR (CONDENSER)
FMC FAN MOTOR CONTACTOR
FR FAULT RELAY
HGS HOT GAS BYPASS SOLENOID
HPS HIGH PRESSURE SWITCH
HVTB HIGH VOLTAGE TERMINAL BLOCK
JP JUMPER
L1 LINE 1
L2 LINE 2
L3 LINE 3
LPS LOW PRESSURE SWITCH
LVTB LOW VOLTAGE TERMINAL BLOCK
LUG LUG GROUND
NTB NEUTRAL TERMINAL BLOCK
OLR OVER LOAD RELAY
P PRESSURE
PDS PUMP DOWN SOLENOID
SSPS SOLID STATE PROTECTION SYSTEM
TOP FM THERMAL OVERLOAD PROTECTION
TRANS TRANSFORER
T'STAT THERMOSTAT
VFC VOLT FREE CONTACT
YR COOLING RELAY
FIELD WIRING
TERMINAL BLOCK OR TERMINATION POINT
SPLICE-CLOSED END
JUNCTION OF WIRES, CONNECTED
CROSSING OF WIRES, NO CONNECTION
_ _ _
TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS
17
CONTROLS AND SEQUENCE OF OPERATION
The unit is equipped with an electronic control board which can be linked with any commercially available 24V ac thermo-
stat or can be controlled through a DDC panel. With cooling input signals coming from a thermostat or DDC, the motors
in the equipment are started in the following sequential order: condenser fan compressor motor. The cooling input
signals to the units control board should always start first with the first stage (Y1) followed by the second stage (Y2) and
OFF sequence should start with the second stage (Y2) followed by the first stage (Y1).
Balance Loading of Compressors: The user can select the sequence of operation of the compressors; either com-
pressor 1 as always leading (dip switch #2 set at ON) or enabling balance loading of compressor (dip switch #2 set at
OFF). In balance loading function, the compressor with the least run time will be started first to equalize the run time of
the compressors. These functions are selectable through the dip switch on the electronic control board. Please refer to
the settings table shown in the units wiring diagram.
Fault Diagnostics: In case of system fault, LEDs on the board emits a flashing signal indicating the nature or where the
fault is. This is to guide the service technician in identifying the fault. Please refer to the settings table shown in the units
wiring diagram for the details of each respective fault against LED indicators.
Compressor Lock-Out Function: If any of the units safety control devices trips and such condition is maintained for
approximately 3 minutes, the control will lock-out that particular system preventing a re-start. It can be re-set by shutting
off power to the thermostat or if the cooling signal to the board is turned OFF.
Compressor Anti-Recycling Timer: The units electronic control board has a built-in three (3) minutes minimum off
timer for the compressor. This is for compressor protection in case of accidental manual re-set or immediate re-cycling
through the thermostat due to load demand.
SWITCHING CONTACTS
18
PROPER CLEARANCE TO BE PROVIDED
MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR
MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR
PROPER CLEARANCE TO BE PROVIDED
LIFT
ATTENTION TO RIGGERS
Hook rigging sling thru holes in base rail, as shown below.
Holes in base rail are centered around the unit center of gravity.
Center of gravity is not unit center line.
Ensure center of gravity aligns with the main lifting point before lifting.
Use spreader bar when rigging, to prevent the slings from damaging the unit.
CAUTION
All panels should be in place when rigging.
Care must be taken to avoid damage to the coils during handling.
Insert packing material between coils & slings as necessary.
RIGGING INSTRUCTIONS
19
WALL
INSTALLATION CLEARANCE
FIGURE - 2
CORNER WALL
NOTE: 1. All dimensions are in mm.
2. If unit is installed in special pit, please observe the same tolerance for walls. Pit height should not exceed
the unit height.
FIGURE - 1
STRAIGHT WALL
MODEL NUMBER A B C D E
CDL020 - CDL025 1500 1500 1500 1500 1500
CDL030 - CDL040 1500 1500 2000 1500 1500
CDL050 - CDL195 2000 2000 3000 2000 2000
20
NOTE: All dimensions are in mm. Tolerance: 2mm.
MOUNTING LOCATION
MODEL A
CDL110 1281
CDL135 1281
CDL160 1603
CDL195 1823
DIMENSIONS
21
LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)
MODEL No. R1 R2 R3 R4 R5 R6 R7 R8
CDL020 132 202 187 195 - - - -
CDL025 142 214 198 206 - - - -
CDL030 215 276 273 286 - - - -
CDL035 234 308 295 322 - - - -
CDL040 266 362 327 373 - - - -
CDL050 347 352 392 356 - - -
CDL055 354 360 400 366 - - - -
CDL065 445 456 495 461 - - - -
CDL080 278 304 439 454 332 338 - -
CDL100 336 362 497 514 390 396 - -
CDL110 418 418 410 410 445 445 344 344
CDL135 450 450 443 443 483 483 374 374
CDL160 506 506 488 488 539 539 445 445
CDL195 610 610 593 593 660 660 547 547
LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)
MODEL No. R1 R2 R3 R4 R5 R6 R7 R8
CDL020 151 221 206 214 - - - -
CDL025 166 238 222 230 - - - -
CDL030 237 298 295 308 - - - -
CDL035 267 341 328 355 - - - -
CDL040 309 405 370 416 - - - -
CDL050 382 387 427 391 - - - -
CDL055 396 402 442 408 - - - -
CDL065 509 520 559 525 - - - -
CDL080 315 341 476 491 369 375 - -
CDL100 394 420 555 572 448 454 - -
CDL110 476 476 468 468 503 503 402 402
CDL135 511 511 504 504 544 544 435 435
CDL160 575 575 557 557 608 608 514 514
CDL195 698 698 681 681 748 748 635 635
R1 R2
R4 R3
R1 R2
R4 R3
R2 R4 R6
R1 R3 R5
R7 R5 R3 R1
R8 R6 R4 R2
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.
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions
and other COOLINE publications for the specific equipment being installed.
These units should be charged with R-22 refrigerant.
LOCATION OF UNIT
When selecting the location for the unit, the following points should be kept in mind:
1. Provisions for a concrete slab which will allow for minimum clearance from building or structures
2. That the terrain allows for drainage away from the unit.
3. If the unit is to be roof mounted, inspect the roof for load bearing capacity. The roof should have sufficient 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 recircu-
lation 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.
It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigeration
standard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigerant
pipes carefully to prevent damaging the suction pipe insulation and vibration transmission to the structure.
Outdoor unit connected to factory matched indoor unit
Outdoor unit contains holding charge only. The correct system refrigerant charge for operation is given in the unit name-
plate & physical data table when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge for
maximum efficiency.
Sweat connection:
Use refrigerant grade piping. Service valves are closed from factory when shipped and 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
material. When brazing completed, refrigerant piping and indoor coil are now ready for leak testing. This check should
also include all field and factory brazed joints.
Warning: Relieve all pressure before refrigerant system repair or final unit disposal to avoid personal injury or death. Use
service ports and open all valves.
INSTALLATION INSTRUCTIONS
22
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. 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. The whole system should be leak tested and evacuated before charging
the refrigerant.
2. 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.
3. 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.
4. 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 60
0
C.
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 com-
pressor 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
23
Air Filter Access Door Gasket
Sound Attenuators (If Applicable)
Fresh Air Intake
Ductwork Caulking Inside/Outside Building
Ductwork Supports Inside/Outside Building
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 check-
ing 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 recom-
mended 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 consider-
ably 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 15
0
F
to 20
0
F.
(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 tem-
peratures, supply airflow rates in occupied spaces and any other specified parameters.
24
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.
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 com-
pressor 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.
ELECTRICAL
Voltage unbalance, % = 100 x
Average voltage
Maximum voltage deviation from average voltage
25
MOTOR CONTACTOR
The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compres-
sor 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 to conform with compressor manufacturers specifications and should
not be changed.
The control measures the net oil pressure available to circulate oil through the lubrication system. The positive displace-
ment 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 control contains a built-in time delay switch that is a trip-free expansion rod device actuated by a resistance heater.
The control is factory set to cut-in at 18 PSIG and cut out at 9 PSIG. When the compressor starts the resistance heater
of the time delay becomes energized. If the net oil pressure does not build to 18 PSIG or above within 120 seconds, the
time delay trips to stop the compressor. If the net oil pressure drops below 18 PSIG, but not below 9 PSIG during a
running cycle, the time delay resistance heater becomes energized and unless the net oil pressure returns to 18 PSIG or
above during the 120 seconds safety time period, the compressor will shut down. The compressor will shut down when-
ever the net oil pressure drops below 9 PSIG, and will never run for more than the predetermined 120 seconds on
abnormal oil pressure.
26
27
New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type me-
chanical expansion rod-resistance heater type oil protection controls.
FEATURES:
An entirely new control concept. This unique design incorporates a modern pressure transducer to monitor oil pressure.
Each control reflects improved calibration stability over the control's entire pressure range.
Controls boast truly accurate timing despite ambient temperature and voltage variations.
All electronic components are purposely "over-sized" and computer-matched to provide the greatest safety factor and
dependable service life.
Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibra-
tion, dirt or moisture.
Controls reset instantaneously, thanks to the precise solid state timing circuit. No annoying wait for old-fashioned timer
heater to cool down.
Control module is interchangeable with the old type conventional oil protection and with competitive brands of oil
protection controls. An exact replacement from a mounting, wiring and logic function standpoint.
Control maintains timing over the full voltage range of 102 to 264 VAC. Voltage selection is not necessary.
Unit is not position sensitive.
Users are offered a choice of controls with or without cover, a handy mounting bracket and other options.
"Logic" circuitry in the module monitors oil pressure pulses during marginal operation and integrates them resulting in
a longer span of time before lock-out occurs.
Last, but not least, it has enlarged the reset button to a new "thumb-sized" dimension. The reset button is slightly
recessed to protect it from damage.
VOLTAGE MONITOR
This device protects the motors in the unit from faults such as; under or over voltage, unbalance & phase reversal of 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 its normal conditions.
LINE VOLTAGE
RANGE
UNDER VOLTAGE
TRIP
90% 190 - 480 VAC
TRIP & RE-SET VOLTAGE (% OF SET POINT)
OVER VOLTAGE PHASE IMBALANCE
RE-SET
93%
TRIP
110%
RE-SET
107%
TRIP
6%
RE-SET
4.5%
78 60 18
_
=
OIL PUMP
OUTLET PRESSURE
CRANKCASE
PRESSURE
NET OIL
PRESSURE
REFRIGERATION
COMPRESSOR
Scroll compressors are used as standard for models CDL020-CDL055 and semi-hermetic reciprocating compressors are
standard for models CDL065 - CDL195. All the compressors are conforming to ARI 540 standard. The compressors are
equipped with internal motor protection, factory installed crankcase heaters and rubber vibration isolators for quiet and
efficient operation. As an option, semi-hermetic 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 compres-
sor 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 drier 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.
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.
Scroll Compressor Rotation:
Scroll compressors are designed to operate in single direction only. Hence, care has to be taken to ensure correct
rotation when the system is operated. Verification of correct rotation is by observing that the suction pressure drops and
discharge pressure rises when compressor run. Reverse rotation results in abnormal sound, as well as, substantially low
current draw and by interchanging power supply wire L1 & L3 will correct this problem.
Compressor Maintenance:
Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is 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.
28
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 filter-
driers and check the system after 24 hours of operation.
There are instances where contaminants are discovered in a refrigeration system with the compressor still 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 mois-
ture).
4. Refrigerant leaks (allowing system to operate in a vacuum).
5. Failure to remove oil and moisture after having opened the system for repair.
6. Higher than normal operating temperatures and pressures will cause a breakdown of the oil and refrigerant.
7. Improper use of soldering or brazing flux.
HIGH PRESSURE SWITCH
A high pressure switch is located in the discharge line and senses the discharge pressure. Should the discharge pressure
exceed 450 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.
29
30
Should the control open, it will remain open until the pressure in the system is lowered to 360 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 450 10 psig. Allow the system to remain off, until the gauge pressure drop to approximately 360 15 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 SWITCH
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 25 5 psig. The contacts of the control will close when the
suction pressure rises to 50 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 evapo-
rator 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 systems 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.
31
1. Close start or disconnect switch.
2. Refer to electrical section.
3. Repair or replace control.
4. Relocate control.
5. Check wiring against diagram.
6. Replace or relocate.
7. Trace control circuit with wiring dia-
gram and repair.
8. Replace the compressor with all pre-
cautions.
1. Line disconnect switch open.
2. Overload protector tripped.
3. Control stuck in open position.
4. Control off due to cold location.
5. Wiring improper or loose.
6. Thermostat defective or improperly
installed.
7. Control circuit open.
8. Burned/open circuit motor winding.
Compressor will not start no
hum.
TROUBLE SHOOTING CHART
SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE
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.
6. Compressor too hot - return gas hot.
7.Compressor motor has a winding
shorted.
1.Check wiring diagram. Check for
added fan motors, pumps, etc. con-
nected to wrong side of protector.
2. Determine the reason and correct.
3. Check current, replace protector.
4. Check airflow across the condenser
coil, restrictions in refrigeration sys-
tem.
5. Check for possibility of misapplica-
tion. Use stronger unit.
6. Check refrigerant charge (fix leak),
add if necessary.
7. Replace compressor.
1. Check wiring against diagram.
2. Determine reason and correct.
3. Determine reason and correct, re-
place if necessary.
6. Check crankcase heater.
7. Unequilized pressure in the system.
1. Improperly wired.
2. Low voltage to unit.
3. Relay failing to close.
4.Compressor motor has a winding
open or shorted.
5. Internal mechanical trouble in com-
pressor.
6. Liquid refrigerant in compressor.
7. High discharge pressure.
Compressor starts and runs,
but short cycles on overload
protector.
Compressor will not start
hums but trips on overload
protector.
Suction line frosted or
sweating.
Liquid line frosted or
sweating.
1. Expansion valve passing excess re-
frigerant or is oversized.
2. Expansion valve stuck open.
3. Evaporator fan not running.
4. Overcharge of refrigerant.
1. Restriction in dehydrator or strainer.
2. Liquid shut-off valve partially closed.
1.Re-adjust valve or replace with
smaller valve.
2. Clean valve of foreign particles, re-
place if necessary.
3. Determine reason and correct.
4. Correct charge.
1. Replace part.
2. Open valve fully.
Units runs OK, but short
cycles on.
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.
Head pressure too high.
Head pressure too low.
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. Refrigerant overcharge.
2. Air in system.
3. Dirty condenser.
4. Malfunction of condenser fan (air-
cooled).
5. Excessive air temperature entering
condenser.
6. Restriction in discharge line.
1.Low ambient temperatures (air-
cooled).
2. Refrigerant shortage.
3. Damaged valves in compressor.
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.
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 con-
denser discharge air, correct it.
6. Correct it.
1. Install fan cycling switch, if not pro-
vided. Check the setting and opera-
tion, if provided.
2. Correct the refrigerant charge after
leak testing.
3. Repair/replace the compressor.
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.
32
1. High load on evaporator. Load in ex-
cess 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 ac-
cordingly.
5. Check the expansion valve bulb is
properly tighten at correct location.
High suction pressure.
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 evapo-
rator, etc. and correct it.
3. Repair or replace it.
4.Clean/replace it (oil change recommended).
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.
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.
33
MODEL NUMBER CDL020L CDL025L CDL030L CDL035L CDL040L CDL050L CDL055L CDL065L CDL080L
COMPRESSOR 800-674-38 800-674-19 800-674-72 800-674-84 800-674-87 800-676-82 800-690-30 800-690-33
CONTACTOR 800-098-59 800-098-59 800-098-61 800-098-63 800-098-65 800-098-65 800-098-65 800-098-68 800-097-51
CAPACITY UNLOADER KITS NIL NIL NIL NIL NIL NIL NIL 800-577-02 800-577-02
COND. FAN MOTOR 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06 800-237-00 800-237-00 800-237-00 800-237-00
CONTACTOR 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51
FILTER DRYER 800-531-05 800-531-05 800-531-05 800-531-00 800-531-00 800-531-00 800-531-01 800-531-01 800-531-17
FILTER DRYER CORE NIL NIL NIL NIL NIL NIL NIL NIL 800-027-65
SIGHT GLASS 800-200-00 800-200-00 800-200-00 800-200-01 800-200-01 800-200-01 800-200-01 800-200-01 800-200-04
MECHANICAL SHUT OFF VALVE 800-705-40 800-705-40 800-705-40 800-705-41 800-705-41 800-705-41 800-705-41 800-705-41 800-705-42
PUMP DOWN SOLENOID VALVE 800-705-20 800-705-20 800-705-20 800-705-21 800-705-21 800-705-21 800-705-21 800-705-21 800-70660
PRESSURE GAUGE - SUCTION 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
PRESSURE GAUGE - DISCHARGE 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31
PRESSURE GAUGE - OIL NIL NIL NIL NIL NIL NIL NIL 800-600-30 800-600-30
FIXED LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
FIXED HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00
ADJ. LOW PRESSURE SWITCH 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29
ADJ. HIGH PRESSURE SWITCH 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30
P3 CONTROLLER 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51
MICROSMART CONTROLLER 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45
USER INTERFACE CARD 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50
PTC TEMP. SENSOR 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55
RELATIVE PRESSURE TRANSDUCER -DP 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56
RELATIVE PRESSURE TRANSDUCER -OIL NIL NIL NIL NIL NIL NIL NIL 800-646-57 800-646-57
RELATIVE PRESS. TRANSDUCER -SUCTION 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58
PARTS LIST
34
800-676-82
800-674-87
MODEL NUMBER CDL100L CDL110L CDL135L CDL160L CDL195L
COMPRESSOR 800-674-41 800-690-27 800-690-30 800-690-33 800-674-41
CONTACTOR 800-097-54 800-098-67 800-098-68 800-097-51 800-097-54
CAPACITY UNLOADER KITS 800-577-02 800-577-02 800-577-00 800-577-02 800-577-02
COND. FAN MOTOR 800-237-00 800-237-00 800-237-00 800-237-00 800-237-00
CONTACTOR 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51
FILTER DRYER 800-531-17 800-531-42 800-531-42 800-531-42 800-531-17
FILTER DRYER CORE 800-027-65 800-027-65 800-027-65 800-027-65 800-027-65
SIGHT GLASS 800-200-04 800-200-01 800-200-01 800-200-01 800-200-04
MECHANICAL SHUT OFF VALVE 800-705-42 800-705-41 800-705-41 800-705-41 800-705-42
PUMP DOWN SOLENOID VALVE 800-70660 800-705-21 800-705-21 800-705-21 800-70660
PRESSURE GAUGE - SUCTION 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
PRESSURE GAUGE - DISCHARGE 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31
PRESSURE GAUGE - OIL 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
FIXED LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
FIXED HIGH PRESSURE SWITCH 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00
ADJ. LOW PRESSURE SWITCH 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29
ADJ. HIGH PRESSURE SWITCH 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30
P3 CONTROLLER 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51
MICROSMART CONTROLLER 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45
USER INTERFACE CARD 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50
PTC TEMP. SENSOR 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55
RELATIVE PRESSURE TRANSDUCER -DP 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56
RELATIVE PRESSURE TRANSDUCER -OIL 800-646-57 800-646-57 800-646-57 800-646-57 800-646-57
RELATIVE PRESS. TRANSDUCER -SUCTION 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58
PERCENTAGE OF SPARE PARTS
ONE YEAR SUPPLY TWO YEAR SUPPLY
100 UNITS 1000 UNITS 100 UNITS 1000 UNITS
Compressor 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 (control) 1 0.5 2 1
Propeller fan 1 0.5 2 1
Heater-crankcase 3 1 4 2
RECOMMENDED SPARE PARTS
NOTE : When ordering spare parts, please quote the complete model number on the unit nameplate.
ITEM
35
1
X
X
X
X
X
X
X
3
X
X
X
X
X
X
X
6
X
X
12
X
X
X
X
PREVENTIVE MAINTENANCE SCHEDULE
FREQUENCY OF MAINTENANCE, MONTHS
I T E M
Clean air filters & replace if required.
Clean evaporator coil, drain pan & drain line.
Clean condenser coil.
Check blower belt/tension/wear/crack and replace it, if required.
Lubricate blower motor/condenser motor (if applicable).
Check alignment of pulleys.
Check/clean electrical connections, controls & control box.
Check motors, blower bearings & lubricate it.
Check all electrical control components, wiring terminals etc. for spark,
overheating & loose connections. Replace/correct as necessary.
Check all damper operation. Repair/replace as required.
Check insulation flanking. Repair/replace as required.
Check loose bolts/screws & tight as necessary.
Check for rusted/dented/damaged body parts & repair/repaint as necessary.
Check mountings (spring isolator/rubber pads). Repair/replace as necessary.
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.
Apply corrosion inhibitor/contact cleaner as required.
Check all pressures/temperatures as applicable and satisfy the operation &
performance.
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-22 charging cylinder, belt tension checker, leak detector, vacuum pump with elec-
tronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.
36
CAUTION: Disconnect power supply and allow all rotating parts to stop before servicing the unit.
SAFETY DATA REFRIGERANT R-22
Toxicity Low
In Contact With Skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorp-
tion. R-22 may be slightly irritant and liquid has a de-greasing effect. 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 blis-
tering), obtain medical attention.
In Contact With Eyes Vapor has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate
with eyewash solution or clean water for at least 10 minutes. Obtain immediate medical
attention.
Inhalation High levels of vapor concentration initially produce stimulation and then depression of the
central nervous system, causing headaches and giddiness and may lead to unconscious-
ness. Can prove suddenly fatal if the exposure has been severe.
At higher concentration, there is a danger from asphyxiation due to reduced oxygen content
of atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if
necessary. Apply artificial respiration if breathing has ceased or shows signs of failing. In
event of cardiac arrest, apply external cardiac massage. Obtain immediate medical atten-
tion.
Stability Unstable.
Conditions to Avoid Use in presence of naked flames, red hot surfaces and high moisture levels.
Hazardous Reactions May react violently with sodium, potassium, barium and all other alkali and alkaline earth met-
als. Incompatible materials: Magnesium and alloys containing more than 2% magnesium.
Hazardous Halogen acids formed by thermal decomposition.
Decomposition Products
General Precautions 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 Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources
of heat such as radiators. Keep at temperatures not exceeding 45C (113F).
Protective Clothing Wear overalls, impervious gloves and goggles/face protection.
Spill / leak Procedure Ensure suitable personal protective clothing and respiratory protection is worn. Provided it
is safe to do so, isolate the source of the leak. Allow small spillages to evaporate provided
there is suitable ventilation. Large spillages: ventilate area. Contain spillages with sand,
earth or any suitable absorbent material. Prevent liquid from entering drains, sewers, base-
ments and work pits since vapor may create a suffocating atmosphere.
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
MATERIAL SAFETY DATA SHEET
37
38
PRESSURE TEMPERATURE CHART, R-22
TEMPERATURE (
0
F) PRESSURE TEMPERATURE (
0
C) PRESSURE
PSIA PSIG Kpa (Absolute) Kpa (Gauge)
0 38.66 23.96 -17.78 266.54 165.21
2 40.31 25.61 -16.67 277.93 176.60
4 42.01 27.32 -15.56 289.69 188.36
5 42.89 28.19 -15.00 295.71 194.38
6 43.78 29.08 -14.44 301.83 200.50
8 45.59 30.90 -13.33 314.35 213.02
10 47.46 32.77 -12.22 327.26 225.94
12 49.40 34.70 -11.11 340.59 239.26
14 51.39 36.69 -10.00 354.31 252.98
16 53.44 38.74 -8.89 368.46 267.13
18 55.55 40.86 -7.78 383.02 281.70
20 57.73 43.03 -6.67 398.03 296.70
22 59.97 45.27 -5.56 413.47 312.14
24 62.27 47.58 -4.44 429.37 328.04
26 64.64 49.95 -3.33 445.72 344.39
28 67.08 52.39 -2.22 462.54 361.21
30 69.59 54.90 -1.11 479.83 378.50
32 72.17 57.47 0.00 497.61 396.28
34 74.82 60.12 1.11 515.87 414.54
36 77.54 62.84 2.22 534.64 433.31
38 80.34 65.64 3.33 553.92 452.59
40 83.21 68.51 4.44 573.71 472.38
42 86.15 71.46 5.56 594.02 492.70
44 89.18 74.48 6.67 614.88 513.55
46 92.28 77.58 7.78 636.27 534.94
48 95.46 80.77 8.89 658.22 556.89
50 98.73 84.03 10.00 680.72 579.39
52 102.07 87.38 11.11 703.77 602.49
54 105.50 90.81 12.22 727.42 626.13
56 109.02 94.32 13.33 751.69 650.34
58 112.62 97.93 14.44 776.51 675.23
60 116.31 101.62 15.56 801.96 700.67
62 120.09 105.39 16.67 828.02 726.66
64 123.96 109.26 17.78 854.70 753.35
66 127.92 113.22 18.89 882.01 780.65
68 131.97 117.28 20.00 909.93 808.65
70 136.12 121.43 21.11 938.55 837.26
72 140.37 125.67 22.22 967.85 866.49
74 144.71 130.01 23.33 997.78 896.42
76 149.15 134.45 24.44 1028.39 927.03
78 153.69 138.99 25.56 1059.69 958.34
80 158.33 143.63 26.67 1091.69 990.33
82 163.07 148.37 27.78 1124.37 1023.01
84 167.92 153.22 28.89 1157.81 1056.45
86 172.87 158.17 30.00 1191.94 1090.58
88 177.93 163.23 31.11 1226.83 1125.47
90 183.09 168.40 32.22 1262.41 1161.12
92 188.37 173.67 33.33 1298.81 1197.45
39
PRESSURE TEMPERATURE CHART, R-22
TEMPERATURE (
0
F) PRESSURE TEMPERATURE (
0
C) PRESSURE
PSIA PSIG Kpa (Absolute) Kpa (Gauge)
94 193.76 179.06 34.44 1335.98 1234.62
96 199.26 184.56 35.56 1373.90 1272.54
98 204.87 190.18 36.67 1412.58 1311.29
100 210.60 195.91 37.78 1452.09 1350.80
102 216.45 201.76 38.89 1492.42 1391.14
104 222.42 207.72 40.00 1533.59 1432.23
106 228.50 213.81 41.11 1575.51 1474.22
108 234.71 220.02 42.22 1618.33 1517.04
110 241.04 226.35 43.33 1661.97 1560.68
112 247.50 232.80 44.44 1706.51 1605.16
114 254.08 239.38 45.56 1751.88 1650.53
116 260.79 246.10 46.67 1798.15 1696.86
118 267.63 252.94 47.78 1845.31 1744.02
120 274.60 259.91 48.89 1893.37 1792.08
122 281.71 267.01 50.00 1942.39 1841.03
124 288.95 274.25 51.11 1992.31 1890.95
126 296.33 281.63 52.22 2043.20 1941.84
128 303.84 289.14 53.33 2094.98 1993.62
130 311.50 296.80 54.44 2147.79 2046.44
132 319.29 304.60 55.56 2201.50 2100.22
134 327.23 312.54 56.67 2256.25 2154.96
136 335.32 320.63 57.78 2312.03 2210.74
138 343.56 328.86 58.89 2368.85 2267.49
140 351.94 337.25 60.00 2426.63 2325.34
142 360.48 345.79 61.11 2485.51 2384.22
144 369.17 354.48 62.22 2545.43 2444.14
146 378.02 363.32 63.33 2606.45 2505.09
148 387.03 372.33 64.44 2668.57 2567.22
150 369.19 381.50 65.56 2545.57 2630.44
152 405.52 390.83 66.67 2796.06 2694.77
154 415.02 400.32 67.78 2861.56 2760.21
156 424.68 409.99 68.89 2928.17 2826.88
158 434.52 419.82 70.00 2996.02 2894.66
160 444.53 429.83 71.11 3065.03 2963.68
162 454.71 440.01 72.22 3135.23 3033.87
164 465.07 450.37 73.33 3206.66 3105.30
166 475.61 460.92 74.44 3279.33 3178.04
168 486.34 471.65 75.56 3353.31 3252.03
170 497.26 482.56 76.67 3428.61 3327.25

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