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INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

AIR COOLED CONDENSING UNITS


'CNX' SERIES
PL-OM-CNX-07-1M-E

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.

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.

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

0.661010 0.861020 1.451000 1.451000 1.451000 1.451000 1.451000 1.451000 1.451000

Type

Inner grooved tubes and enhanced fins

Tube DiaRowsFins per inch 3/8314 3/8414 3/8414 3/8414 3/8314 3/8414 3/8414 3/8414 3/8514
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.

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

2.15970

2.15970

2.15970

2.15970

2.15970

2.15970

2.15970

Motor kW RPM
CONDENSER COIL

139

Semi-hermetic reciprocating

Oil per system (liters)

CONDENSER FAN

121

1.451000 1.451000

Type

Inner grooved tubes and enhanced fins

Tube DiaRowsFins per inch 3/8414 3/8514 3/8314 3/8314 3/8414 3/8314 3/8314 3/8414 3/8314
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.

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)

11.4

125

50

15.9

45.7

60

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

158

0.86

1.6

4.1

18.1

187

1.45

2.5

10.0

22.7

225

1.45

2.5

10.0

80

23.6

193

1.45

2.5

10.0

70.5

90

28.0

220

1.45

2.5

10.0

506

77.5

100

30.0

262

1.45

2.5

10.0

414

506

91.0

125

36.0

262

1.45

2.5

10.0

460-3-60

414

506

108.8 150

43.9

323

1.45

2.5

10.0

CNX 720

460-3-60

414

506

147.1 200

58.7

404

1.45

2.5

10.0

CNX 840

460-3-60

414

506

147.1 200

58.7

404

1.45

2.5

10.0

CNX M00

460-3-60

414

506

183.5 250

72.5

513

2.15

3.4

10.0

CNX M10

460-3-60

414

506

207.6 275

83.2

590

2.15

3.4

10.0

CNX M20

460-3-60

414

506

207.0 250

43.9

323

2.15

3.4

10.0

CNX M40

460-3-60

414

506

276.7 325

58.7

404

2.15

3.4

10.0

CNX M60

460-3-60

414

506

335.3 400

72.5

513

2.15

3.4

10.0

CNX 2M00

460-3-60

414

506

342.1 400

72.5

513

2.15

3.4

10.0

10

CNX 2M40

460-3-60

414

506

548.6 650

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

kW

Qty.

DIMENSIONS
CNX 150 - CNX 300
1
2
3
4
5
6
7

CNX 360 - CNX 420


1
2
3
4
5
6

1550 [61.0]

203 [8.0]

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.

"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]

"B"

965
(37.99")

"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.

968
(38.11")

375.6 [14.80]

1550 [61.0]

203 [8.0]

255.0 [10.00]
TYP

CNX 480 - CNX 600

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

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

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

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

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

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.

275 [10.826]

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 units 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 units 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

USER SEQUENCE OF OPERATION


On/Off

SET

Menu

CLASSIC
AIR CONDITIONERS
TOUT = 10C TIN = 15C
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 systems control will prevent the compressors to operate if this signal is not fed to the microprocessor board.

15

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

COMPRESSOR POWER & CONTROL CONNECTION IN PART WINDING STARTING (PWS)

COMP

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

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

L3

OPS1

3A

240

64A

OPS1-1

OPS2

3B

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

ATB

(AHU MOTOR CONTROL)

67

ATB

ON

OFF

OFF

OFF

L1

4-FAN MOTOR LAYOUT


5 C1 3

L2

C.HTR2

20

ATB

R2 (230Vac)

R2-1

UVM CONNECTION(OPTIONAL)

CNX 720~840 / CNXM00~20


CONTROL
PANEL

C.HTR1

L2

17

DIP SWITCH SETTINGS - MB BOARD

FMC2

FMC4

L1

ATB

TD2 - CLOSED

JU11 - CLOSED (1,2)


13B

(REMOVE JP5A)
COMP 2

JUMPER SETTINGS - MB BOARD

9 NO

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

C.HTR2

101A

CC2A-1B

CUT-OFF (PSIG) CUT-IN (PSIG)

LOW PRESSURE

8B

100A

CC1A-1B

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

COMP. 1:

FMC2

M1/11
L1/MP/L

(REMOVE JP4B)

COMP. 2:

FMC1

13A

FM3
T.K.

A. SEMI-HERMETIC RECIP. COMP.

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

FMC1

23B

COMP. SSPS CONNECTION(AS APPLICABLE)

CNX 360~420
HVTB
L1 L2 L3

HVTB
L1 L2 L3

CB2A-1A

9B

CONDENSER FAN MOTOR POWER AND CONTROL CONNECTIONS


CNX 220~300
2-FAN MOTOR LAYOUT

T2B

T1B

T3C

T2C

T1C

T3A

CC4
1

OLR3-1A

COMP

CC2

CC3

61A

OLR1-1A

COMP
2

MB
CC1

HVTB
L1 L2 L3

L2B

L1B

L3C

L2C

L1C

L3A

L2A

L1A

T2A

COMP
2

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

4 C2 2

L1
1

L2

UVM-1

L3
8

ATB
UVM

MOTOR STARTER CONTROL


AHU MOTOR ON/OFF
SWITCHING CONTACT

AHU MOTOR FAULT


(N.C CONTACT)
(REMOVE JP7)

52

(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

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

ATB
17

24V

C
AHU MOTOR CONTROL

(OPTIONAL CONNECTION)

STG1 COOLING

YR1
Y1

STG2 COOLING

YR2
Y2

TO HVTB
L1

TO HVTB
L3

F3

TRANS2

F4

460V
230V

ATB

HPS1

F1

S1

(UVM-1)
JP1

1A

1B

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)

AO1

A10

JP6

A1 (SSPS-1)

23A

(OPS2-1)
JP5B

TO ATB

15

24V AC

(SSPS1)
JP3A

(SSPS2)
JP3B

TO ATB

ATB

F2

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)

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

ESC *

ON

S1

O2 (A10-OP2)

DIP

1 2 3 4
COM1

COMP2 CAPACITY UNLOADER SOLENOID


(OPTIONAL)
HOT GAS BY-PASS SOLENOID
(OPTIONAL)

REFER FAN MOTOR CONTROL


CONNECTION (SYSTEM 1)
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

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

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=15C TIN=28C
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

OPT2

32B
33B

SH

GND

17

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

4O

CC2

3B

T3D

COMP

AB

MB
CC1

T2D

T1D

COMP

MB
3A

T3C

T3B

COMP
2

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

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

FMC3

13 NO

(REMOVE JP6)

FM4

9 NO

12A

FMC6

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

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

R2-1

ATB
1

ATB

MOTOR STARTER CONTROL


AHU MOTOR ON/OFF
SWITCHING CONTACT

AHU MOTOR FAULT


(N.C CONTACT)
(REMOVE JP7)

52

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

SCHEMATIC WIRING DIAGRAM


POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNXM20 - CNXM60
TO HVTB
L1

TO HVTB
L3

F3

TRANS2

460V

F4

230V
F1

S1

1A

1B

CC1A-1B

100A

L1
1

L3

L2

CC2A-1B

100B

CC5A-1B

100C

L2

UVM-1

L3
8

UVM

CC6A-1B

100D

C.HTR2
C.HTR3
C.HTR4

(REMOVE JP1)

2
C.HTR1

UVM CONNECTION (OPTIONAL)


L1

ATB

F2

SSPS1
1A

SSPS2

1
SSPS3
ATB

SSPS4

(UVM-1)
JP1

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)

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)

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

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

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=15C TIN=28C
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

SCHEMATIC WIRING DIAGRAM


POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNXM20 - CNXM60
TO ATB
2

LEGEND

SWITCHING CONTACTS
FROM THERMOSTAT OR DDC
(FIELD INSTALLATION)

TRANS1
(75VA)

LVTB
COM

230V

ATB

ATB

24V

15

17

C
AHU MOTOR CONTROL

(OPTIONAL CONNECTION)

BMR

(OPTIONAL CONNECTION)

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

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)

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

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

DPT3

30C
31C

OPT3

33C

SPT4

29D

DPT4

31D

O2 (A10-OP2)

DIP

1 2 3 4

OPT4

33D
SH

SH
32D

SH
30D

SH
28D

SH
32C

SH

SH

SERIAL CABLE
X52

SPT3

28C
29C

SH

SH

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)

AHU
ATB
BMR
CC
CCA
CB
C. HTR

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

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

61A

OLR1-1A 11A

10A

4O

CC2A-2A

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

AB
CC5

CC4

61B

COMP
2

AB
CC2

3B

CC3

OLR3-1A

COMP
2

MB
CC1

CC1A-2A

T3E

COMP
2

1
3A

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

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

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

R2-1

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

ATB

12I

FMC6

DESC.

CB24

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

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

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

SCHEMATIC WIRING DIAGRAM


POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNX2M00 - CNX2M40
TO HVTB
L1

TO HVTB
L3

F3

TRANS2

460V

F4

230V
F1

S1

1A

1B

CC1A-1B

100A

L2

L1
1

L3

CC2A-1B

100B

CC5A-1B

100C

L2

UVM-1

L3
8

UVM

CC6A-1B

100D

2
C.HTR1

UVM CONNECTION (OPTIONAL)


L1

ATB

F2

C.HTR2
C.HTR3
C.HTR4

SSPS1

(REMOVE JP1)

1A

SSPS2

1
SSPS3
ATB

SSPS4

(UVM-1)
JP1

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)

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)

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)

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=15C TIN=28C
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

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

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

15

ATB

24V

17

C
AHU MOTOR CONTROL

(OPTIONAL CONNECTION)

BMR

(OPTIONAL CONNECTION)

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

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)

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)

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)

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

COMP4 CAPACITY UNLOADER SOLENOID


16C

UL3-4

(50% UNLOADER SOLENOID)

CC6-1A
16D

UL4-4

COMMON FAULT INDICATION


(VOLT-FREE CONTACT)
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

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

(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)

PDS4

5C

COMP4 CONTACTOR

3D

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

GND

23

TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS

17
1
(REMOVE JP6)
67
20
2

1
(REMOVE JP7)

(REMOVE JP7)
52

24

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

25

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

26

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.
27

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
28

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.

29

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.
30

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 manufacturers 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 units 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 units 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 its normal conditions.
LINE VOLTAGE
RANGE
190 - 480 VAC

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


UNDER VOLTAGE

OVER VOLTAGE

PHASE IMBALANCE

TRIP

RE-SET

TRIP

RE-SET

TRIP

RE-SET

90%

93%

110%

107%

6%

4.5%

31

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.
32

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.
33

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 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.

34

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

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

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

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

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

Contactor compressor

Contactor fan motors

HPS/Sensor/Transducer

Expansion valve

0.5

Filter drier

Transformer (24V secondary)

0.5

Propeller fan

0.5

Heater-crankcase

Compressor

NOTE : When ordering spare parts, please quote the complete model number on the unit nameplate.

39

PREVENTIVE MAINTENANCE SCHEDULE


FREQUENCY OF MAINTENANCE, MONTHS

ITEM

1
Clean air filters & replace if required.

12

Clean evaporator coil, drain pan & drain line.

Clean condenser coil.

Check blower belt/tension/wear/crack and replace it, if required.

X
X

Lubricate blower motor/condenser motor (if applicable).


Check alignment of pulleys.

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.

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.

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.

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-134a charging cylinder, belt tension checker, leak detector, vacuum pump with
electronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.

40

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 113F (45C). 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

PRESSURE TEMPERATURE CHART, R-134a


TEMPERATURE (0F)

TEMPERATURE (0C)

PRESSURE

PRESSURE

PSIA

PSIG

Kpa (Absolute)

Kpa (Gauge)

21.2

6.5

-17.78

146.2

44.9

22.2

7.5

-16.67

153.2

51.8

23.3

8.6

-15.56

160.4

59.1

24.3

9.6

-14.44

167.9

66.6

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

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