INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

AIR COOLED CONDENSING UNITS

CX SERIES (CX150 - CX360)
Part Number: 800-213-58 (Rev.-02)

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 INDEX
Contents Page

Model decoding ........................................................................................................................................ 2

General statement .................................................................................................................................... 2

Warranty ................................................................................................................................................... 2

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

Inspection for damage .............................................................................................................................. 2

Installation procedures ............................................................................................................................. 3

Service clearance ..................................................................................................................................... 3

Dimensions ........................................................................................................................................... 4-6

Rigging & mounting .................................................................................................................................. 7

Refrigerant piping connection ................................................................................................................... 8

Leak testing & refrigerant charging ........................................................................................................... 8

Electrical connection ................................................................................................................................ 8

Typical wiring diagram ......................................................................................................................... 9-14

Operating instruction .............................................................................................................................. 15

Maintenance ........................................................................................................................................... 15

Preventive maintenance schedule .......................................................................................................... 16

Troubleshooting ................................................................................................................................. 17-18

Parts list ................................................................................................................................................. 19

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

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 MODEL DECODING
1& 2 3, 4 & 5 6 7 8 9 10 11 12 13
BASIC NOMINAL ELECTRICAL REFRIGERA- COMPRESSOR MODE CONDENSER CONDENSER PDS OPTION OTHER OPTIONS
COOLING SUPPLY TION CIRCUIT TYPE MOTOR COIL
CAPACITY ( V-Ph-Hz )
(MBH)
CX 150 H : 208/230-3-60 S : SINGLE* S : SCROLL C : COOL ONLY N : STANDARD A : ALUMINUM N : NO OPTION N : NO OPTION
FIN
H : HEAT PUMP+
CLASSIC 180 F : STD. UNIT WITH
M : 380-3-60 D : DUAL L : LOW FILTER DRYER U : UVM
CONDENSING
220 (4 WIRE) AMBIENT B : COATED & SIGHT GLASS
UNIT V : VOLT FREE
ALUMINUM K : CONDENSING CONTACTS
240
F : 460-3-60 FIN UNIT WITH
300 SYSTEMIZER** C:U&V
C : COPPER FIN P : PDS***
360
R:F&K
S : F & P***
T : K & P***
Q : F, K & P***

* Applicable for CX150 only.

** To match with double skin units only.
*** Applicable for cool only models.
+ Applicable for CX150 to CX220 only.
GENERAL STATEMENT
These units are from the Classic CX series that was designed and built for the optimum performance when matched with the
right indoor unit (Refer to indoor unit catalog). However, it is required that you become well acquainted with good practices for
the proper installation, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year.
Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experienced
technicians should perform the installation and other maintenance procedures.

WARRANTY
All of the Classic CX series are covered by the standard warranty terms against any manufacturer defect. Should you
encounter any problem that falls under the warranty terms please contact your nearest “Zamil Classic” dealer/representative.

SAFETY ISSUES
There are three levels of safety hazards that are identified throughout this manual as Warning (where the situation will
result in personal injury), Caution (where personal injury might occur), and Attention (where minor personal injury and/or
property damage could happen). Please understand and respect those identifications.

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

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

When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observe
all the applicable safety measures (wear of safety helmet, boots, and goggles. Use of proper handling materials for
brazing and use of wet cloth for sequencing. A fire extinguisher should be easily accessible etc). He should also read all
the instructions and information in this manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should be observed during installation and servicing.

INSPECTION FOR DAMAGE

The unit should be carefully inspected visually for any sign of physical damage due to mishandling or missing parts. If
such a case arises, please indicate it on the corresponding delivery note before sign it and inform your nearest “Zamil
Classic” dealer and/or sales office.

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 INSTALLATION PROCEDURES
GENERAL
These units are shipped completely assembled, charged with refrigerant (R-22) and wired. They will require external
power & thermostat wiring in the field. Selection of the condensing unit and its corresponding matching indoor unit
should be based on a heat 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 conflicts
with the instructions in this manual, installer should adhere to local standards.
LOCATION OF UNIT
When selecting the location for the unit, the following points should be kept in mind:
1. To provide a concrete pad or steel base that will allow for minimum clearance from building or structures. For
roof mounted unit, be sure that the roof should have sufficient structural strength to carry the weight of the unit.
2. To avoid installing the unit under overhangs.
3. To install the unit in an open area and away from exhaust vents or other source of contaminated air.
4. To have available electrical power.
5. To allow proper drainage away from the unit.
JOBSITE CONDITIONS
a) Check the concrete pad or steel stand for proper dimensions. Refer to attached unit dimensions sketches.
b) Check for proper clearances to allow sufficient space for service access and air circulation as per figure-1 service
clearances.

SERVICE CLEARANCE
FIGURE - 1

SINGLE UNIT MULTIPLE UNITS

Note: Allow 96” space above unit.

MODELS: CX150 - CX360

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 DIMENSIONS
CX150 - CX220

NOTE:
1. All dimensions are in mm (dimensions in brackets are in inches).

4
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 DIMENSIONS
CX 240 - CX 300

NOTE:
1. All dimensions are in mm (dimensions in brackets are in inches).

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 DIMENSIONS
CX 360
[61.0"]
1550

[8.0"]
203

2121 73 943 943

[83.50"] [2.88"] [37.13"] [37.13"]

2197 2032
[86.50"] [80.0"]

NOTE:
1. All dimensions are in mm (dimensions in brackets are in inches).

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 RIGGING & MOUNTING
These units are suitable for overhead rigging. See below rigging instructions.
Attention to Riggers:
1. Hook rigging sling through holes/insert 3" nominal pipe through holes in the base rail, as shown below.
2. Holes in base rail are centered around the unit center of gravity.
3. Use wooden pallet or 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.
For proper drainage, the condensing unit to be raised off the mounting pad. On roof top applications, locate unit at least
6" (152 mm) above roof surface. Place unit above a load-bearing wall, isolate unit and piping set from structure. Use
4"x4"x1" thick rubber/cork mounting pads.
Arrange supporting members to adequately support unit and minimize transmission of vibration to building.

RIGGING
2000mm

BUCKLE
STRAP OR SEAMLESS PIPE

DETAIL - A

CX150 - CX220

CX240 - CX300

CX360

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 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. For piping applications beyond 25 feet
(7.62 m), please follow the instructions from ZAC refrigerant pipe sizing manual.

Outdoor unit connected to factory matched 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.
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.

ELECTRICAL CONNECTIONS
Power wiring:
Before making wiring connection, check the electric power supply.

WARNING: Power supply should match exactly with equipment nameplate ratings. Serious damage to
compressors and motors can occur, if improper voltage is applied.

Minimum circuit ampacity for each model is shown on the nameplate and product catalog. Equipment wiring diagram
should be examined and thoroughly understood before field wiring connections are made.
All wiring must comply with “National Electric Code” and local electrical standards.

Control wiring between outdoor & indoor unit:

For control wiring, use 16 gauge color-coded wire between the indoor and outdoor units.

Ground wires:
Connect ground wire to the ground lug inside the control box.

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 TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS : CX150 (SINGLE COMPRESSOR UNITS)
HVTB
POWER SUPPLY L1
PLS. REFER UNIT NAME PLATE
L2 CIRCUIT BREAKER OPTION LOW AMBIENT OPTION CONNECTION
WRG DGM SUITS
230V/3PH/60Hz L3
APPLICABLE FOR 230V - 1PH FAN MOTOR
460V/3PH/60Hz &
380V/3PH/60Hz HVTB
LUG L1 TO CC TO CC
L2 T1A/71A T2A/72A T2A/72A T3A/73A
NOTE: CC
1.NTB IS APPLICABLE FOR NTB L3
380V/3PH/60Hz
LUG FMC
2.FOR UNIT WITH ABOVE CB
VOLTAGE CONNECT 37A,37B OF
1PH FM & L2 OF TRANS TO NTB 36A 37A 36B 37B

L1A
L2A
L3A
CC CAP1 CAP2
36A 37A 36B 37B
35A 35B

71A
72A
73A
T1A
T2A
T3A
FM1 FM2

CAP1 CAP2

T1A
T2A
T3A
35A 35B
3A FCS 2
12
COMP FM1 FM2 COMP FMC

COMPRESSOR CONNECTION WITH PART WIND START ONLY

TRANS2 CONNECTION APPLICABLE FOR 460V UNIT
WITHOUT CIRCUIT BREAKER WITH CIRCUIT BREAKER
L1 460V L3 HVTB HVTB
F3 F4
3 4 L1 L1
F1 TRANS2 F2 L2 L2
5 6
230V L3 L3

ATB1 L1 L2
CB1 CB2

1 JP1 1A JP2 1B F1 F2 ATB1

230VAC

L1A
L2A
L3A

L1B
L2B
L3B
2

71A
72A
73A

71B
72B
73B
[UVM] [SD]

71A
72A
73A

71B
72B
73B
SEE HPS OPTION BELOW SEE NOTE-8
[SSPS] * [AI]
LPS 24A JP4 25A JP6 26A SR

T1C
T2C
T3C
T1A
T2A
T3A
C-SAFETY RELAY

T1C
T2C
T3C
T1A
T2A
T3A
FOR COMP.CONN.WITH PART WIND START-SEE ABOVE COMP
1 COMP
1
YR-1 SR-1 CC
2A 3A SR-1 CB1-1 CB2-1
C-CONTACTOR 3E 3F
2A 3A

CR
3A CC1 2
C-CONTROL RELAY FOR TDS OPTION
SEE CONN.BELOW
CC1A-1
3D
CC2 2

PDSR-1 4A PDS
TDS1-1SEC OLR1-1 OLR2-1 27A
C-PUMP DOWN SOLENOID CC1A-1
3C 3D
26A
81A
2
3A CC2 2 SR

TRANS1
COMP.CONN WITH OLR & W/OUT CB OPTION
HVTB
L1
L2
L3

CC
71A
72A
73A

24VAC
ATB
T1A
T2A
T3A

15 CB 16
1 COMP

17 26A OLR-1 27A SR 2

2

PDSR
38A
TO 3 C-PUMP DOWN SOLENOID RELAY SET POINTS
AHU
SR-2 YR NAME OPEN(PSIG) CLOSE(PSIG)
39A 40A
4 C-COOLING RELAY LPS 25 ± 5 50 ± 5
LPS1 45 55
5 41A USE FOR OPTION-3-B ONLY
HPS 450 ± 10 360 ± 15
FCS 190 ± 15 290 ± 10

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.

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 TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS : CX150 (SINGLE COMPRESSOR UNITS)
CONNECTION FOR COMP. WITH SSPS LEGEND

A) UNIT ON & OFF INDICATION

AHU AIR HANDLING UNIT
(SEE NOTE 6)
COMP SSPS AI ANTI ICE THERMOSTAT
15 AR1 17 AR AUXILIARY RELAY
ATB AUXILIARY TERMINAL BLOCK
1 2 CAP CAPACITOR
45 AR1-1 46 AR1-1 47
REMOVE JP4 CC COMPRESSOR CONTACTOR
CB CIRCUIT BREAKER
OPTIONS
UNIT ON UNIT OFF C. HTR CRANKCASE HEATER
1) UVM OPTION
COMP COMPRESSOR
L1 L2 L3 B) COMP ON, OFF & TRIP [&]
UNIT TRIP INDICATION OPTION CR CONTROL RELAY
FM FAN MOTOR (CONDENSER)
COMP
Ø Ø Ø ATB FMC FAN MOTOR CONTACTOR
L1 L2 L3
UVM 41A 17 FR FAULT RELAY
1 UVM-1 8
FR
Ø Ø FCS FAN CYCLING SWITCH
TO ATB 1 HPS HIGH PRESSURE SWITCH
FR-2
TO ATB 1A HVTB HIGH VOLTAGE TERMINAL BLOCK
(REMOVE JP1) FR-2 54 JP JUMPER
L1 LINE 1
2) SMOKE DETECTOR OPTION
L2 LINE 2

CCA-1A

CCA-1B
VFC-FROM CUSTOMER'S
SMOKE DETECTOR L3 LINE 3
1A 1B LPS LOW PRESSURE SWITCH
55 56 57 58 LUG LUG GROUND
REMOVE JP2
C-ON NTB NEUTRAL TERMINAL BLOCK
C-OFF OPS OIL PRESSURE SWITCH
CONN.FOR OIL PRESSURE SWITCH OPTION C-TRIP OLR OVER LOAD RELAY
PDS PUMP DOWN SOLENOID
FOR PWS CCA-1A IS CC1A-2A & PDSR PUMP DOWN SOLENOID RELAY
26A/27A OPS 28C SR 2 CCA-1B IS CC1A-2B
RR RESET RELAY
43 FR-1 44 SD SMOKE DETECTOR
SSPS SOLID STATE PROTECTION SYSTEM
OPS
1 CR-1 2 UNIT-TRIP TDS TIME DELAY SWITCH
28A 2 240 TRANS TRANSFORMER
T'STAT THERMOSTAT
4. HPS OPTION UL UNLOADER SOLENOID
UVM UNDER VOLTAGE MONITOR
TO 23A HPS 24A VFC VOLT FREE CONTACT
LPS YR COOLING RELAY
___ FIELD WIRING
+ DISCONNECT TAB - 1/4"
CRANKCASE HTR CONNECTION UNLOADER CIRCUIT CONNECTION FOR COMP WITH SPLICE-CLOSED END

ONE UNLOADER NOTES

CRANKCASE HTR CONNECTION FOR SEMI HERMETIC
COMPRESSOR ONLY
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
3A LPS1 2 1 AR8-1 2 2. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
5A 6A
AR8 UL OR ITS EQUIVALENT.
USE COPPER CONDUCTOR WIRES ONLY.
3. POWER MUST BE SUPPLIED TO CRANKCASE
NOTE: HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
BITZER COMP: FULLY LOADED WHEN UL IS DE-ENERGIZED SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
COPELAND COMP:-FULLY LOADED WHEN UL IS ENERGIZED
HEATER MUST BE ON FOR 12 HOURS BEFORE
(PLS. CONNECT LPS ACCORDINGLY) OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
RESULT IN COMPRESSOR DAMAGE.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY END USER WITH
RATING AS RECOMMENDED BY ZAMIL.
5. IF PDS IS FACTORY INSTALLED, PLEASE READ
BROKEN LINES AS CONTINUOUS LINES.
6. ALLOW 2-3 MINUTES FOR SSPS SWITCH TO CLOSE,
BEFORE STARTING THE UNIT.
7. USE DISCONNECT TAB OR SPLICE ONLY WHERE
EVER REQUIRED FOR EXTENSION OF ORIGINAL
WIRE.
8. REMOVE JUMPER FOR AI OPTION. ROUTE AI
WIRES FROM AHU.
9. FOR UNITS HAVING COMP. OLR, FM WIRES 36A &
36B TO BE CONNECTED TO 71A & 72A AND 37A &
37B TO BE CONNECTED TO 72A & 73A RESPEC-
TIVELY.

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 TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS : CX180 - CX220 (DUAL COMPRESSOR UNITS)
HVTB
POWER SUPPLY L1
PLS. REFER UNIT NAME PLATE L2
WRG DGM SUITS
230V/3PH/60Hz L3
460V/3PH/60Hz
380V/3PH/60Hz
LUG

NOTE: NTB
1.NTB IS APPLICABLE FOR
380V/3PH/60Hz

2.FOR UNIT WITH ABOVE

VOLTAGE CONNECT 37A,37B OF
1PH FM & L2 OF TRANS TO NTB

CC1 FMC1 CC2 FMC2

T1B
T2B
T3B
T2A

35A
36A
37A
T1A

T3A

35B
36B
37B
COMP COMP
1 FM1 2 FM2

TRANS2 CONNECTION APPLICABLE FOR 460V UNIT

L1 460V L3
F3 F4
3 4

F1 TRANS2 F2
5 6
230V

[UVM] [SD] ATB1 L1 L2

1 JP1 1A JP2 1B F1 F2 ATB1
230VAC 2
SEE HPS OPTION BELOW SEE NOTE-8
[SSPS1]
LPS1 JP4 25A
* [AI1]
26A SR1
24A JP6
C1-SAFETY RELAY

CC1
YR1-1 SR1-1 3A
2A
C1-CONTACTOR

CR1-1 CR1
C1-CONTROL RELAY

PDSR1-2 4A PDS1
C1-PUMP DOWN SOLENOID

SEE HPS OPTION BELOW

[SSPS2] * [AI2]
LPS2 24B JP7 25B JP8 26B SR2
C2-SAFETY RELAY

YR2-1 SR2-1 CC2

2B 3B
C2-CONTACTOR

CR2-1 CR2
C2-CONTROL RELAY

PDSR2-1 4B PDS2
C2-PUMP DOWN SOLENOID
CCA1-1 FMC1
12A
FAN MTR1-CONTACTOR
CCA2-1 FMC2
12B
FAN MTR2-CONTACTOR

(FOR FCS CONNECTION SEE LOW AMBIEMT OPTION)

TRANS1
24VAC 17
ATB

15 CB 16
1

38A PDSR1
3 C1-PUMP DN SOLENOID RELAY

SR1-2 YR1
39A 40A
4 C1-COOLING RELAY
PDSR2
TO AHU 38B
5 C2-PUMP DN SOLENOID RELAY

SR2-2 YR2
39B 40B
6 C2-COOLING RELAY

7 41A
USE FOR OPTION-3-B ONLY

8 41B

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.

11
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 TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS : CX180 - CX220 (DUAL COMPRESSOR UNITS)
LEGEND
CONNECTION APPLICABLE FOR 1PH FAN MOTOR ONLY 4. LOW AMBIENTOPTION APPLICABLE
FOR 3PH FAN MOTOR ONLY AHU AIR HANDLING UNIT
L1/L1A L2/L2A L2/L2B L3/L3B
AI ANTI ICE THERMOSTAT
TO HVTB
AR AUXILIARY RELAY
FMC1 FMC2
ATB AUXILIARY TERMINAL BLOCK
36A 37A 36B 37B CAP CAPACITOR
36A 36B CC COMPRESSOR CONTACTOR
CAP1 CAP2 CB CIRCUIT BREAKER

L1

L2

L3
35A 35B C. HTR CRANKCASE HEATER
FM1 FM2
COMP COMPRESSOR
CR CONTROL RELAY
CIRCUIT BREAKER OPTION FM FAN MOTOR (CONDENSER)
FMC1 FMC2
HVTB
L1
FMC FAN MOTOR CONTACTOR

35A

36A

37A

35B
36B
37B
L2 FR FAULT RELAY
L3 FCS FAN CYCLING SWITCH
LUG FM1 FM2 HPS HIGH PRESSURE SWITCH
CB1 CB2
HVTB HIGH VOLTAGE TERMINAL BLOCK
JP JUMPER
L1A
L2A
L3A

L1B
L2B
L3B

CC1A-1 FMC1
L1 LINE 1
12A
FAN1 CONTACTOR L2 LINE 2
FMC1 CC2 FMC2 12B FCS1 13
FMC2 L3 LINE 3
CC1
ATB2 1 2 FAN2 CONTACTOR
CC2A-1
LPS LOW PRESSURE SWITCH
FCS2 ATB2
T1A

T3A
T2A

T1B
T2B
T3B

LUG LUG GROUND

35A
36A
37A

35B
36B
37B

PDS PUMP DOWN SOLENOID

COMP COMP
1 FM1 2 FM2 PDSR PUMP DOWN SOLENOID RELAY
RR RESET RELAY
CRANKCASE HTR CONNECTION SET POINTS 3. VOLT FREE CONTACT OPTIONS SSPS SOLID STATE PROTECTION SYSTEM
NAME
OPEN CLOSE A) UNIT ON & OFF INDICATION SD SMOKE DETECTOR
(PSIG) (PSIG)
TRANS TRANSFORMER
LPS1&2 25 ± 5 50 ± 5 AR1
15 17
T'STAT THERMOSTAT
HPS1&2 450 ± 10 360 ± 15
45 AR1-1 46 AR1-1 47 UVM UNDER VOLTAGE MONITOR
VFC VOLT FREE CONTACT
1. UVM OPTION
CONNECTION FOR COMP. WITH SSPS UNIT ON UNIT OFF YR COOLING RELAY
(SEE NOTE 6) L1 L2 L3 ___ FIELD WIRING
SSPS1 B) COMP ON, OFF & TRIP [&]
COMP1:
M1/11 M2/14 UNIT TRIP INDICATION OPTION + DISCONNECT TAB - 1/4"
1
L1/MP L2/R
2 Ø Ø Ø COMP1 SPLICE-CLOSED END
ATB(7)
REMOVE JP4 UVM
1 UVM-1 8 41A 17 NOTES
Ø Ø FR1
COMP2:
SSPS2
TO ATB 1
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
M1/11 M2/14
FR1-2
TO ATB 1A 2. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
FR1-2
1
L1/MP L2/R
2 (REMOVE JP1) 54 OR ITS EQUIVALENT.
USE COPPER CONDUCTOR WIRES ONLY.
REMOVE JP7 2. SMOKE DETECTOR OPTION
3. POWER MUST BE SUPPLIED TO CRANKCASE
CC1A-2A

CC1A-2B

VFC-FROM CUSTOMER'S HEATER FOR MINIMUM OF 12 HOURS PRIOR TO

SMOKE DETECTOR SYSTEM START UP.
1A 1B 55 56 57 58
IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
C1-ON HEATER MUST BE ON FOR 12 HOURS BEFORE
REMOVE JP2
C1-OFF OPERATING THE SYSTEM.
C1-TRIP FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
COMP2 RESULT IN COMPRESSOR DAMAGE.
ATB(8) 4. FUSED DISCONNECT SWITCH OR CIRCUIT
41B 17 BREAKER TO BE PROVIDED BY END USER WITH
FR2 RATING AS RECOMMENDED BY ZAMIL.
5. ATB (3) & (5) IS APPLICABLE FOR PDS OPTION UNITS
FR2-2
ONLY.
FR2-2 59 6. ALLOW 2-3 MINUTES FOR SSPS SWITCH TO CLOSE,
BEFORE STARTING THE UNIT.
7. USE DISCONNECT TAB OR SPLICE ONLY WHERE
CC2A-2A

CC2A-2B

EVER REQUIRED FOR EXTENSION OF ORIGINAL

WIRE.
60 61 62 63
C2-ON 8. REMOVE JUMPER FOR AI OPTION. ROUTE AI
WIRES FROM AHU.
C2-OFF
C2-TRIP

43 FR1-1 FR2-1 44
44A

UNIT-TRIP

5. HPS OPTION

TO 23A HPS1 24A

LPS1

TO 23A HPS2 24A

LPS2

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 TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS : CX240 - CX360 (DUAL COMPRESSOR UNITS)
HVTB
POWER SUPPLY L1
PLS. REFER UNIT NAME PLATE L2
WRG DGM SUITS L3
230V/3PH/60Hz FOR FAN MOTOR
460V/3PH/60Hz CONNECTIONS SEE BELOW COMPRESSOR CONN. WITH PART WIND START
380V/3PH/60Hz LUG CC1 CC2
HVTB

86A
87A
88A

86B
87B
88B
NOTE: NTB L1
1.NTB IS APPLICABLE FOR L2
380V/3PH/60Hz OLR1 OLR2
L3

T1A
T2A
T3A

T1B
T2B
T3B
2.FOR UNIT WITH ABOVE
VOLTAGE CONNECT L2 OF

86B
87B
88B

86D
87D
88D
TRANS TO NTB

86A
87A
88A

86C
87C
88C
COMP COMP
1 2

T2D
T3D
T1B
T2B
T3B
T2C
T3C

T1D
T1A
T2A
T3A

T1C
TRANS2 CONNECTION APPLICABLE FOR 460V UNIT

L1 460V L3
F3 F4 COMP COMP
3 4
1 2
F1 TRANS2 F2
5 6
230V

CC1 CC2

CONTROL CONNECTION 3A

CC1A-2
FOR TDS OPTION
SEE CONN.BELOW
CC3
2 3B

CC2A-2
FOR TDS OPTION
SEE CONN.BELOW
CC4
2

3D 3E
2 2
L1 L2 CC1A-2 TDS1-1SEC CC3 CC2A-2 TDS2-1SEC CC4
ATB1 3C 3D 3F 3E
1 JP1 1A JP2 1B F1 F2 ATB1 3A 2 3B 2
2
[UVM] [SD]
SEE HPS OPTION BELOW SEE NOTE-8
OLR1-1 OLR3-1 SR1 26B OLR2-1 OLR4-1 SR2
[SSPS1] * [AI1] 26A 27A 2 27B 2
81A 81B
LPS1 24A JP4 25A JP6 26A OLR1-1 27A SR1
C1-SAFETY RELAY
FOR OPS & DTS CONNECTION
SEE OPTION 4 & 6
FOR COMPRESSOR CONNECTIONS FOR OPS&DTS CONNECTION
WITH PART WIND START-SEE ABOVE SEE OPTION-4 & 6
YR1-1 SR1-1 3A CC1
2A
C1-CONTACTOR

CR1-1 CR1
C1-CONTROL RELAY
COMPRESSOR CONN. WITH PART WIND START&CIRCUIT BREAKER OPTION
PDSR1-1 4A PDS1
HVTB
SEE HPS OPTION BELOW SEE NOTE-8
[SSPS2] * [AI2]
LPS2 24B JP7 25B JP8 26B OLR2-1 27B SR2
C2-SAFETY RELAY

FOR OPS&DTS CONNECTION

FOR COMPRESSOR CONNECTIONS SEE OPTION-4 & 6
WITH PART WIND START-SEE ABOVE

L1C
L2C
L3C
L1A
L2A
L3A

L1D
L2D
L3D
L1B
L2B
L3B
YR2-1 2B SR2-1 CC2
3B
C2-CONTACTOR

86D
87D
88D
86A
87A
88A

86C
87C
88C

86B
87B
88B
CR2-1 CR2
C2-CONTROL RELAY

T2C
T3C

T2D
T3D
T1B
T2B
T3B
T1C

T1D
T1A
T2A
T3A
PDSR2-1 4B PDS2

COMP COMP
1 2
FOR FAN MOTORS CONNECTIONS
SEE FAN MOTOR CONNECTION DIAGRAM
CC1 CB2-1 CB4-1 CC2
230V CB1-1 CB3-1 3H
3F 3B 3I 2
3A 3G 2 FOR TDS OPTION
FOR TDS OPTION SEE CONN.BELOW
SEE CONN.BELOW
CC3 CC2A-2 CC4
ATB CC1A-2 3E
3D
CB TRANS1 2 2
1 15 16 24V 17
TDS1-1SEC CC3 CC2A-2 TDS2-1SEC CC4
CC1A-2
3C 3D 3F 3E
3G 2 3I 2
2
PDSR1 OLR3-1 SR1 SR2
38A 26A OLR1-1 27A 2 26B OLR2-1 OLR4-1 27B 2
3 81A 81B

SR1-2 YR1
39A 40A FOR OPS & DTS CONNECTION
4 C1-COOLING RELAY SEE OPTION 4 & 6
TO PDSR2
38B
AHU 5

SR2-2 YR2
39B 40B
6 C2-COOLING RELAY

7 41A
USE FOR OPTION-3-B ONLY
8 41B

FAN MOTOR CONNECTIONS - STANDARD

1. 2FM CONNECTION: [CX240/300] 2. 3FM CONNECTION: [CX360]

L1 L2 L3 L1 L2 L3

CB6 CB6
100

101

103

104

100

101

103

104

106

107
102

105

102

105

108

FMC1 FMC2 FMC1 FMC2 FMC3

35C

36C

37C
35A

36A

37A

35B

36B

37B

35A

36A

37A

35B

36B

37B

FM1 FM2 FM1 FM2 FM3

CR1-2 FMC1 CR2-2 FMC2 CR1-2 FMC1 CR2-2 FMC2 FMC1A-1 FMC3
12 13 12 13 13A
1 2 1 2 1 2 1 2 1 2
FMC2A-1

FAN MOTOR CONNECTIONS - LOW AMBIENT OPTION

1. 2FM CONNECTION: [CX240/300] 2. 3FM CONNECTION: [CX360]

L1 L2 L3 L1 L2 L3

CB6 CB6
100

101

102

103

105
104

100

103

106
101

104

107
102

105

108

FMC1 FMC2 FMC1 FMC2 FMC3

35A

36A

37A

35B
36B
37B

35C

36C

37C
35A

36A

37A

35B

36B

37B

FM1 FM2

FM1 FM2 FM3

CR1-2 12 FMC1
FAN1
FCS1 13 FMC2 CONTACTOR FMC1
ATB2 CR1-2 FMC3
1 2 FAN2 1 12 2 FMC1A-1 12A FCS1 13A
CONTACTOR 1 2
CR2-2 12A FCS2 ATB2
CR2-2 FMC2 FMC2A-1 FCS2
1 13 2

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.

13
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 TYPICAL SCHEMATIC WIRING DIAGRAM
MODELS : CX240 - CX360 (DUAL COMPRESSOR UNITS)
LEGEND
CRANKCASE HTR CONNECTION. APPLICABLEFOR BITZER COMP-230V TYPE COMPRESSOR CONN. APPLICABLE
FOR CIRCUIT BRAKER OPTION AHU AIR HANDLING UNIT
TO HVTB TO HVTB AI ANTI ICE THERMOSTAT
COMP1 1 CC1A-1 C.HTR1 2 COMP2 1 CC2A-1 C.HTR2 2
100A 101A
AR AUXILIARY RELAY
CRANKCASE HTR CONNECTION - SCROLL COMP CB1 CB2 ATB AUXILIARY TERMINAL BLOCK
COMP1 COMP2
CAP CAPACITOR

L1A
L2A
L3A

L1B
L2B
L3B
L1 C.HTR1 L2 L2 C.HTR2 L3
CC1 CC2 CC COMPRESSOR CONTACTOR
CRANKCASE HTR CONN. APPLICABLE FOR SEMI-HERMETIC COMPRESSOR CB CIRCUIT BREAKER

87A
86A

88A

88B
86B
87B
L1 CC1A-1
100A
C.HTR1 L2 L2 CC2A-1
101A
C.HTR2 L3 C. HTR CRANKCASE HEATER
OLR1 OLR2
COMP COMPRESSOR

T1B
T2B
T3B
T1A
T2A
T3A
CONNECTION FOR COMP. WITH SSPS
CR CONTROL RELAY
(SEE NOTE 6)
COMP. 2:
COMP COMP FM FAN MOTOR (CONDENSER)
COMP. 1: 1 2
24A
SSPS1
25A 24B
SSPS2
25B FMC FAN MOTOR CONTACTOR
M1/11 M2/14 M1/11 M2/14
FR FAULT RELAY
1 2 1 2
L1/MP/L L2/R/N L1/MP/L L2/R/N FCS FAN CYCLING SWITCH
ATB2 REMOVE JP4 ATB2 ATB2 REMOVE JP7 ATB2 HPS HIGH PRESSURE SWITCH
CONNECTION FOR MANUEROP COMP. WITH SSPS HVTB HIGH VOLTAGE TERMINAL BLOCK
JP JUMPER
L1 SSPS1-CT L2 24A SSPS1-CC 25A
L1 LINE 1
L2 LINE 2
L2 SSPS2-CT L3 24B SSPS2-CC 25B
L3 LINE 3
LPS LOW PRESSURE SWITCH
SSPS-CT PRI TO BE FACTORY WIRED AS SHOWN IN SCHEMATIC
DIAGRAM. SECONDARY ALREADY WIRED BY COMP. SUPPLIER. LUG LUG GROUND
SEE DETAILS WIRING INSIDE COMP. TERMINAL COVER. SSPS-CC
CONTROL CIRCUIT WIRES TO BE CONNECTED TO CONTROL CIRCUIT NTB NEUTRAL TERMINAL BLOCK
TERMINALS IN SPPS MODULE INSIDE COMPRESSOR TERMINAL BOX.
OPS OIL PRESSURE SWITCH
4. OIL PRESSURE SWITCH OPTION
OLR OVER LOAD RELAY
27A OPS1 SR1 2 27B OPS2 SR2 2
28C 28D
PDS PUMP DOWN SOLENOID
3A CR3 2 3B CR4 2 PDSR PUMP DOWN SOLENOID RELAY
OPS1 OPS2
RR RESET RELAY
1 CR3-1 28A 2 2 1 CR4-1 28B 2 2
240 240
SD SMOKE DETECTOR
SSPS SOLID STATE PROTECTION SYSTEM
5. HOUR RUN METER OPTION
COMP1: COMP2:
TDS TIME DELAY SWITCH
3A HRM1 2 3B HRM2 2 TRANS TRANSFORMER
PRESSURE SWITCH SETTINGS T'STAT THERMOSTAT
6. DISCHARGE TEMPERATURE SENSOR OPTION NAME OPEN (PSIG) CLOSE(PSIG) UL UNLOADER SOLENOID
27A/28C * DTS1 29A
SR1 2 27B/28D * DTS2 29B
SR2 2
LPS1 & 2 25 ± 5 50 ± 5
UVM UNDER VOLTAGE MONITOR
HPS1 & 2 450 ± 10 360 ± 15
FCS1 & 2
VFC VOLT FREE CONTACT
* 28C/28D IS APPLICATION FOR UNITS WITH OPS OPTION 190 ± 15 290 ± 10
YR COOLING RELAY
___ FIELD WIRING
7.CONNECTIONS APPLICABLE FOR COMPRESSORS WITH UNLOADER
1. UVM OPTION + DISCONNECT TAB - 1/4"
1.UNLOADER CIRCUIT
LPS3 AR8
L1 L2 L3 SPLICE-CLOSED END
3A 2 1 AR8-1 UL1 2
5A 6A

Ø Ø Ø NOTES
3B LPS4 AR9 2 1 AR9-1 UL2 L1 L2 L3
5B 6B 2
UVM
1 UVM-1 8 1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
Ø Ø
2. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
LPS SETTING FOR UNLOADING TO ATB 1
OR ITS EQUIVALENT.
OPEN CLOSE TO ATB 1A
LPS3 & 4
45 PSIG 55 PSIG USE COPPER CONDUCTOR WIRES ONLY.
(REMOVE JP1)
NOTE: 3. POWER MUST BE SUPPLIED TO CRANKCASE
2. SMOKE DETECTOR OPTION
BITZER:-COMPRESSOR WILL BE FULLY LOADED WHEN UNLOADING SOLENOID VFC-FROM CUSTOMER'S SMOKE DETECTOR
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
IS DE-ENERGIZED. SYSTEM START UP.
1A 1B
COPELAND:-COMPRESSOR WILL BE FULLY LOADED WHEN UNLOADING SOLENOID
IS ENERGIZED. IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
PLS CONNECT LPS ACCORDINGLY.
REMOVE JP2 HEATER MUST BE ON FOR 12 HOURS BEFORE
3. VOLT FREE CONTACT OPTIONS OPERATING THE SYSTEM.
8. HOT GAS BY-PASS OPTION
A) UNIT ON & OFF INDICATION FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
A. FOR UNITS WITHOUT UNLOADER 15 AR1 17 45 AR1-1 46 AR1-1 47 RESULT IN COMPRESSOR DAMAGE.

3A AR12 2 AR13 2 1 AR12-1 AR13-1 HGS 2 UNIT ON UNIT OFF

4. FUSED DISCONNECT SWITCH OR CIRCUIT
3B
9A 10A BREAKER TO BE PROVIDED BY END USER WITH
B. COMP ON,OFF&TRIP[&]UNIT TRIP INDICATION OPTION RATING AS RECOMMENDED BY ZAMIL.
B. FOR UNITS WITH 1 UNLOADER COMP 1: COMP 2:
FR1-2A FR2-2A
5. IF PDS IS FACTORY INSTALLED, PLEASE READ
3A AR12 2 BROKEN LINES AS CONTINUOUS LINES.
FR1-2B 54 FR2-2B
1 AR12 AR13-1 AR8-2 AR9-2 HGS 2 59
AR13
9A 1OA 11A 14A 6. ALLOW 2-3 MINUTES FOR SSPS SWITCH TO CLOSE,
AR7-1A

AR7-1B

3B 2
BEFORE STARTING THE UNIT.
AR6-1A

AR6-1B

7. USE DISCONNECT TAB OR SPLICE ONLY WHERE

NOTE: 55 56 57 58 60 61 62 63
EVER REQUIRED FOR EXTENSION OF ORIGINAL
WITH HGS OPTION, LLS POSITION IN AHU SHALL BE WITH COMP1 IN THE
COMP1 ON COMP2 ON WIRE.
LEAD & COMP2 IN THE LAG SEQUENCE ONLY. COMP1 OFF COMP2 OFF
COMP1 TRIP COMP2 TRIP 8. REMOVE JUMPER FOR AI OPTION. ROUTE AI
3A 2 3B 2
9. HPS OPTION AR6 AR7
WIRES FROM AHU.
ATB ATB ATB ATB 9. REQUIRED FOR PARTWIND START MODELS ONLY.
41A 17 41B 17
FR2
FR1 10. ATB (3) & (5) IS APPLICABLE FOR PDS OPTION UNITS
TO 23A HPS1 24A TO 23A HPS2 24B
43 FR1-1 FR2-1 44 ONLY.
LPS1 LPS2 44A
11. CC-OLR CONNECTING WIRE NOT REQUIRED FOR
UNIT-TRIP OLR. FIXED DIRECTLY BENEATH CONTACTORS.

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 OPERATION INSTRUCTIONS
PRE-STARTUP INSPECTION AND 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 straps & wooden pieces that hold the compressor in place during transportation.
2. Make sure all electrical fasteners/connections are tight and secure.
3. Make sure circuit breakers/fused disconnect switches are properly installed.
4. Make sure all controls are set according to instructions (low & high pressure switch, pump down pressure switch, fan
cycling switch, etc.).
5. Make sure all valves are open (compressor suction and discharge service valves, liquid line valve, etc.).
6. Make sure expansion valve bulb is strapped properly at correct location.
7. Make sure thermostat is installed properly.
8. Follow all the instructions from the warning tags and stickers.
9. Energize compressor crankcase heater for a minimum of 12 hours prior to the system start-up. To energize crankcase
heater only, set thermostat to OFF position and close electrical disconnect switch of the outdoor unit.
10. Inspect condenser coil and other components for any physical damage.
11. Make sure condenser fans are free to turn without wobbling and their mountings are properly tightened.
12. Make sure all refrigerant service valve caps are installed.
13. Make sure all piping, piping insulation and piping supports are properly installed.
14. Connect the manifold gauge to suction and discharge line service valves.
15. Prepare instruments required for checking voltage, Amps, fan RPM etc.
16. Start the unit and observe compressor discharge and suction pressures.

CONTROLS AND SEQUENCE OF OPERATION

The details of the controls and sequence of operation can be found in the corresponding indoor unit catalog.

MAINTENANCE
GENERAL
As with all mechanical equipment, a program of regular inspection, cleaning and preventing maintenance by trained
personnel will contribute greatly to the long satisfactory service life of this product.

Electric shock warning: Before servicing the unit, make sure that electric power supply is OFF and all
remote disconnects are open. Turning the unit OFF does not mean it is disconnected. Failure to do so might
result in severe injury/death.

MONTHLY INSPECTION
Shut unit down and open main disconnect, wipe down external surfaces of unit, inspect control panel, checking for loose
wires, burned contacts, signs of overheated wires, etc. Restart unit and check performance of controls. Check sight
glasses for proper refrigerant charge.

COIL CLEANING
Dirty coils can be cleaned using a soft brush or by flushing with cool water or commercially available coil cleaners. DO
NOT USE HOT WATER OR STEAM in cleaning the coil.

COMPRESSOR MAINTENANCE
Maintenance is limited to visual checking for oil leakage and electrical connections. In case of failure contact Zamil sales/
dealer office.

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 PREVENTIVE MAINTENANCE SCHEDULE

CAUTION: Disconnect power supply and allow all rotating parts to stop before servicing the unit.

FREQUENCY OF MAINTENANCE, MONTHS

ITEM (FIRST 4 YEARS)

6 12
Check all electrical controls, components, wiring terminals, etc..., for sparks,
over heat, loose connections & repair or correct it X

Clean condenser coil X

Check motors, blower bearings & lubricate it X

Check for loose bolts/screws & tighten as necessary X

Check for rusted/dented/damaged body parts & repair/repaint as necessary X

Run test all motors and check the amperage, abnormality etc.. X

Check mountings (spring isolators/rubber pads) & repair/replace as necessary X

Run test compressors and check the amperage, noise, oil level, pressure,
X
etc..., and correct them accordingly
Check the thermostat/control devices for correct operation. Calibrate/re-adjust
X
as required

Apply corrosion inhibitor/contact cleaner as required X

Check all temperature, pressure readings as applicable and satisfy the
X
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, etc.

SPECIAL : Manifold gauge set, R-22 charging cylinder, leak detector, vacuum pump with electronic gauges, thermometer &
hook type ammeter/voltmeter/ohmmeter etc.

16
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SYMPTOM
Compressor will not start, no hum.
Compressor will not start, hums but
trips on overload protector
Compressor starts, but does not switch
off the start winding
Compressor starts and runs, but short
cycles on overload protector
Unit runs OK, but short cycles
frequently
Unit operates Continuously
Evaporator ices up
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TROUBLE SHOOTING CHART
CAUSES CHECK & CORRECTIVE MEASURE
1. Line disconnect switch open 1. Close start or disconnect switch
2. Fuse removed or blown 2. Replace fuse
3. Overload protector tripped 3. Refer to electrical section
4. Control stuck in open position 4. Repair or replace control
5. Control off due to cold location 5. Relocate control
6. Wiring improper or loose 6. Check wiring against diagram
7. Thermostat defective or improperly installed 7. Replace or relocate
8. Control circuit open 8. Trace control circuit with wiring diagram & repair
9. Burned/open circuit motor winding 9. Replace the compressor with all precautions
1. Improperly wired 1. Check wiring against diagram
2. Low voltage to unit 2. Determine reason and correct
3. Starting capacitor defective 3. Determine reason and replace
4. Relay failing to close 4. Determine reason and correct, replace if necessary
5. Compressor motor has a winding open or shorted 5. Replace compressor
6. Internal mechanical trouble in compressor 6. Replace compressor
7. Liquid refrigerant in compressor 7. Check crank case heater
8. High discharge pressure 8. Unequilized pressure in the system
1. Improperly wired 1. Check wiring against diagram
2. Low voltage to unit 2. Determine reason and correct
3. Relay failing to open 3. Determine reason and correct, replace if necessary
4. Run capacitor defective 4. Determine reason and replace
5. Excessively high discharge pressure 5. Check discharge shut off valve, possible
overcharge, or insufficient cooling on condenser
6. Compressor motor has a winding open or shorted 6. Replace compressor
7. Internal mechanical trouble in compressor stuck up or frozen 7. Replace compressor
1. Additional current passing through overload protector 1. Check wiring diagram. Check for added fan motors,
pumps, etc.connected to wrong side of protector
2. Low voltage to unit (or unbalanced if three phase) 2. Determine the reason and correct
3. Overload protector defective 3. Check current, replace protector
4. Run capacitor defective 4. Determine reason and replace
5. Excessive discharge pressure 5. Check airflow across the condenser coil,
restrictions in refrigeration system
6. Suction pressure too high 6. Check for possibility of misapplication. Use stronger unit
7. Compressor too hot, return gas hot 7. Check refrigerant charge (fix leak), add if necessary
8. Compressor motor has a winding shorted 8. Replace compressor
1. Overload protector 1. Check the cause
2. Thermostat 2. Differential set too close - widen
3. High pressure cut-out due to: 3. a. Check airflow to the condenser correct
a. Insufficient air b. Reduce refrigerant charge
b. Overcharge c. Purge
c. Air in system
4. Low pressure cut-out due to: 4. a. Fix leak, add refrigerant
a. Undercharge b. Replace device
b. Restriction in expansion device
1. Shortage of refrigerant 1. Fix leak, add charge
2. Control contacts stuck or frozen closed 2. Clean contacts or replace control
3. Refrigerated or air conditioned space has exc- 3. Determine the fault and correct
essive load or poor insulation
4. System inadequate to handle 4. Replace with larger system
5. Evaporator coil iced 5. Defrost
6. Restriction in refrigeration system 6. Determine location and remove
7. Dirty condenser 7. Clean condenser
8. Filter dirty 8. Clean or replace
1. Restricted airflow 1. Check for dirt or lint on coil
2. Dirty air filter 2. Clean or replace. Clean filter periodically
3. Short of refrigerant 3. Check system pressure. Take superheat
reading. Add refrigerant
4. Low air volume 4. Check for dirty air filter or loose belt
5. Restricted distributor tube 5. Check for warm distributor tube
6. Restricted liquid line/low liquid line pressure 6. Check for restriction in lines/improve liquid line
pressure by proper charging or installing fan
cycling switch,etc.
17

SYMPTOM
Head pressure too high
Head pressure too low
High suction pressure
Loss of oil pressure
TROUBLE SHOOTING CHART
CAUSES
1. Refrigerant overcharge
2. Air in system
3. Dirty condenser
4. Malfuction of condenser fan (air-cooled)
5. Excessive air temperature entering condenser
6. Restriction in discharge line
1. Low ambient temperatures (air-cooled)
2. Refrigerant shortage
3. Damaged valves in compressor
1. 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. 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 pressure
2. Excessive liquid refrigerant returning to
compressor
3. Malfunctioning oil pump
4. Restriction in oil pump inlet screen
CHECK & CORRECTIVE MEASURE
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
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
1. Check the design
2. Follow manufacture’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
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 superheat 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)

Relay defective or burned out 1. Incorrect relay 1. Check and replace

2. Incorrect mounting angle 2. Remount relay in correct position
3. Line voltage too high or too low 3. Determine reason and correct
4. Excessive short cycling 4. Determine reason and correct
5. Relay being influenced by loose mounting 5. Remount rigidly
Space temperature too high 1. Control setting too high 1. Reset control
2. Expansion valve too small 2. Use larger valve
3. Cooling coil too small 3. Add surface or replace
4. Inadequate air circulation 4. Improve air movement
Suction line frosted or sweating 1. Expansion valve passing excess refrigerant or 1. Re-adjust valve or replace with smaller valve
is oversized
2. Expansion valve stuck open 2. Clean valve from foreign particles, replace if necessary
3. Evaporator fan not running 3. Determine reason and correct
4. Overcharge of refrigerant 4. Correct charges
Liquid line frosted or sweating 1. Restriction in dehydrator or strainer 1. Replace it
2. Liquid shut-off valve partially closed 2. Open valve fully
Unit noisy 1. Loose parts or mountings 1. Find and tighten
2. Tubing rattle 2. Tighten the pipe support
3. Bent fan blade causing vibration 3. Replace blade
4. Fan motor bearings worn 4. Replace motor

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 PARTS LIST
MODEL NUMBER CX150H CX150M CX150F CX180H CX180M CX180F
COMPRESSOR (Single),Scroll 800-674-17 800-674-18 800-674-19 N.A. N.A. N.A. .
COMPRESSOR (Dual), Scroll 800-674-23 800-674-24 800-674-25 800-674-79 800-674-80 800-674-81
FAN MOTOR 800-545-58 800-545-58 800-545-63 800-545-68 800-545-68 800-545-68
FAN MOTOR CAPACITOR 800-572-20 800-572-20 800-572-20 N.A. N.A. N.A.
CONDENSER FAN 800-224-23 800-224-23 800-224-23 800-224-23 800-224-23 800-224-23
COMP. CONTACTOR (Single),Scroll 800-098-65 800-736-22 800-736-22 N.A. N.A. N.A.
COMP. CONTACTOR (Dual), Scroll 800-097-00 800-095-00 800-095-00 800-736-48 800-095-01 800-095-01
TRANSFORMER (24V) 800-012-14 800-012-14 800-012-14 800-012-14 800-012-14 800-012-14
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH (OPTIONAL) 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00

MODEL NUMBER CX220H CX220M CX220F CX240H CX240M CX240F

COMPRESSOR, Scroll 800-674-65 800-674-66 800-674-67 800-674-36 800-674-37 800-674-38
COMP. CONTACTOR, Scroll 800-736-48 800-736-22 800-095-01 800-098-65 800-098-61 800-098-61
FAN MOTOR 800-545-68 800-545-68 800-545-68 800-555-06 800-555-06 800-555-06
CONDENSER FAN 800-224-23 800-224-23 800-224-23 800-224-28 800-224-28 800-224-28
TRANSFORMER (24V) 800-012-14 800-012-14 800-012-14 800-012-30 800-012-30 800-012-30
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH (OPTIONAL) 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00

MODEL NUMBER CX300H CX300M CX300F CX360H CX360M CX360F

COMPRESSOR, Scroll 800-674-17 800-674-18 800-674-19 800-674-70 800-674-71 800-674-72
COMP. CONTACTOR, Scroll 800-098-65 800-098-61 800-098-61 800-098-67 800-098-63 800-098-61
FAN MOTOR 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06
FAN MOTOR CONTACTOR 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51
CONDENSER FAN 800-224-28 800-224-28 800-224-28 800-224-28 800-224-28 800-224-28
TRANSFORMER (24V) 800-012-30 800-012-30 800-012-30 800-012-30 800-012-30 800-012-30
LOW PRESSURE SWITCH 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00 800-557-00
HIGH PRESSURE SWITCH (OPTIONAL) 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00 800-558-00

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