INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

MODULAR CONDENSING UNITS

CTX SERIES
 INDEX
Contents Page
General information .................................................................................................................................. 2
Safety issues ............................................................................................................................................ 2
Model decoding ....................................................................................................................................... 3
Physical data ........................................................................................................................................... 4-5
Electrical data .......................................................................................................................................... 6
Dimensions .............................................................................................................................................. 7-8
Typical schematic wiring diagram ........................................................................................................... 9 -10
Field wiring connections ......................................................................................................................... 11
Controls & sequence of operation .......................................................................................................... 11
Rigging instructions ................................................................................................................................ 12
Installation clearance .............................................................................................................................. 13
Mounting location ................................................................................................................................... 14
Load distribution ..................................................................................................................................... 14
INSTALLATION INSTRUCTIONS
General ................................................................................................................................................... 15
Location of unit............................................................................................................... ........................ 15
Refrigerant piping connections ............................................................................................................... 15
Leak testing & refrigerant charging ......................................................................................................... 16
Start-up inspection & check list .............................................................................................................. 16-17
Check-out & operational start-up procedure ........................................................................................... 17
ELECTRICAL
Power supply .......................................................................................................................................... 18
Unbalanced voltage ................................................................................................................................ 18
Motor contactor ...................................................................................................................................... 18
Fan motor ............................................................................................................................................... 19
Crankcase heater ................................................................................................................................... 19
Lube oil protection control ...................................................................................................................... 19-20
Voltage monitor ...................................................................................................................................... 20
REFRIGERATION
Compressor ............................................................................................................................................ 21
High & low pressure protection ............................................................................................................... 21-22
Pump down control ................................................................................................................................. 23
Trouble shooting chart ........................................................................................................................... 24-26

Recommended spare parts .................................................................................................................... 27

Preventive maintenance schedule .......................................................................................................... 28
Material safety data sheet ...................................................................................................................... 29
Pressure temperature chart.................................................................................................................... 30

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1
 GENERAL STATEMENT
Cooline CTX series is designed and built for the optimum performance when matched with the right indoor unit (Refer to
indoor unit catalog). However, it is required that you become well acquainted with good practices for the proper installa-
tion, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year.

Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experi-
enced technicians should perform the installation and other maintenance procedures.

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

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

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

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

2
 MODEL DECODING
1, 2 & 3 4 5, 6 & 7 8 9 10 11 12 13 14 15
BASIC COMPRES- NOMINAL ELECTRICAL REFRIGERATION CONDENSER ELECTRICAL KITS OPTION MECHANICAL KITS REFRIGE- CONTROLLER GENERAL
SOR TYPE CIRCUIT TYPE RANT
COOLING SUPPLY COIL OPTIONS OPTIONS
CHARGING
CAPACITY (TONS) (V-Ph-Hz)
D : DUAL SCROLL (1) A :HOLDING A :STANDARD A : STD. OPTIONS
CTX H : HERMETIC 016 L : 380/415-3-50 A : ALUMINUM FIN A : STANDARD OPTIONS A : STANDARD OPTIONS(3)
CONDENSING SCROLL (4 WIRE) (CTX016 -CTX070)
CHARGE(4) B : DUAL STAGE
018 K : FAN CYCLING SWITCHES M : REPLACEABLE CORE FILTER C : NEMA 4X COATING
B : PRE-COATED DIGITAL
UNIT DRIER & SHUT-OFF VALVE F : FULLY FOR CONTROL
ALUMINUM FIN (5)
(R-410A) CHARGE THERMOSTAT
022 Q : QUADRUPLE V : VOLT FREE CONTACTS(2) P : PRESSURE GAUGES BOX
SCROLL (SUCTION & DISCHARGE) C : FOUR STAGE
C : COPPER FIN
025 (CTX080 - CTX100) C : COMPRESSOR CIRCUIT DIGITAL F : ADDITIONAL CORE
BREAKER H : HOT GAS BYPASS VALVE THERMOSTAT(5) FILTER DRYER
027 D : ALUMINUM FIN
WITH RESISTEC D : NON-FUSED DISCONNECT R : CONDENSER PRESSURE S : ADDITIONAL
030 COATING RELIEF VALVE SHUT-OFF VALVE
SWITCH
B : A & P COMBO
035 E : COPPER FIN P : PUMPDOWN SOLENOID I : SPRING ISOLATOR
WITH RESISTEC VALVE D : A & H COMBO UNDER THE UNIT
040 COATING E : A & R COMBO K : F & S COMBO
B : K & V COMBO
045 J : M & P COMBO
E : K & C COMBO M : C & I COMBO
050 N : M & H COMBO
G : K & P COMBO L : C, F & S COMBO
070 K : M & R COMBO
H : K & D COMBO G : C, F, S & I COMBO
080 F : A, P & H COMBO
T : K, V & C COMBO V : A, H & R COMBO
100
M : K, V & P COMBO Q : M, H & R COMBO
N : V, C & P COMBO T : M, H & P COMBO

Q : V, C & D COMBO U : M, P & R COMBO

3
L : A, H, P & R COMBO
U : V, D & P COMBO
W : M, H, P & R COMBO
L : K, V, C & P COMBO

O : K, V, C, P & D COMBO

NOTES: (1) Standard electrical options contain Under Voltage Monitor (UVM) & fixed low/high pressure switches
(2) A combination of volt free contact option: 1. Unit ON indication, 2. Compressor RUN/TRIP, 3. Unit trip indication (when all compressors have tripped)

(3) Standard options for scroll compressors contain sealed type filter drier and sight glass.
(4) As a standard, all units are supplied with holding charge only.
(5) Dual stage thermostat is applicable for CTX016 - CTX035 models & four stage thermostat is applicable for CTX040 & above models.
 PHYSICAL DATA - 50Hz
MODEL NUMBER CTX016 CTX018 CTX022

NOMINAL CAPACITY, TONS* 13 15 18.11

NUMBER OF REFRIGERATION CIRCUIT DUAL DUAL DUAL

COMPRESSOR TYPE
OIL TYPE

OIL PER SYSTEM, OZ. 60 110 110

REFRIGERANT

CHARGE PER SYSTEM (OZ)** 244 264 432

CONDENSER FAN TYPE

QTY. 2 2 2

MOTOR TYPE ION & IP54

NORMAL CFM 18804 18804 18712

MOTOR kW - RPM 1.4-890 1.4-890 1.4-890

CONDENSER COIL TYPE

ROWS - FINS PER INCH 2-14 2-14 3-14

4
TOTAL FACE AREA (SQ.FT.) 36.12 36.12 44.62

HIGH PRESSURE OPEN (PSIG) 650 ± 15 650 ± 15 650 ± 15

SWITCH
CLOSE (PSIG) 500 ± 22 500 ± 22 500 ± 22

LOW PRESSURE OPEN (PSIG) 50 ± 7 50 ± 7 50 ± 7

SWITCH
CLOSE (PSIG) 90 ± 7 90 ± 7 90 ± 7

REFRIGERANT SUCTION LINE SIZE (OD) INCH 7/8 1-1/8 1-1/8

LINES+
LIQUID LINE SIZE (OD) INCH 1/2 5/8 5/8

SOUND PRESSURE LEVEL, dBA (@ 1, 3 & 5 meters)++ 77/70.9/67.4 77.4/71.3/67.8 77.9/71.9/68.4

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 AHRI conditions. Tolerance: ±2dBA.
 PHYSICAL DATA - 50Hz
MODEL NUMBER CTX025 CTX027 CTX030 CTX035 CTX040 CTX045 CTX050 CTX060 CTX070 CTX080 CTX100

NOMINAL CAPACITY, TONS* 19.76 23.13 26.64 30.81 34.29 39 43.48 49.77 60 69.25 84.9
NUMBER OF REFRIGERATION CIRCUIT DUAL DUAL DUAL DUAL DUAL DUAL DUAL DUAL DUAL QUADRUPLE QUADRUPLE

COMPRESSOR TYPE HERMETIC SCROLL

OIL TYPE POE OIL

OIL PER SYSTEM, OZ. 110 110 110 158/110 158 230/158 230 213/230 213 158 230

REFRIGERANT R-410A

CHARGE PER SYSTEM (OZ)** 432 430 494 686/497 701 1057/835 1125 1190/803 1189 695 1140

CONDENSER FAN TYPE PROPELLER WITH DIRECT DRIVEN MOTOR

QTY. 2 4 4 4 4 4 4 6 6 8 8

MOTOR TYPE TOTALLY ENCLOSED AIR OVER TYPE (TEAO), CLASS F INSULATION & IP54

NORMAL CFM 18712 35496 37608 36288 35040 36512 35640 57360 55884 70080 73344

MOTOR kW - RPM 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890 1.4-890

CONDENSER COIL TYPE INNER GROOVED TUBES & ENHANCED FINS

ROWS - FINS PER INCH 3-14 2-14 2-14 3-14 & 2-14 3-14 4/3-14 4-14 3-14 & 2-14 3-14 3-14 4-14

5
TOTAL FACE AREA (SQ.FT.) 44.62 59.5 72.25 72.25 72.25 89.25 89.25 131.6 131.6 144.5 195.5

HIGH PRESSURE OPEN (PSIG) 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15 650 ± 15
SWITCH
CLOSE (PSIG) 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22 500 ± 22

LOW PRESSURE OPEN (PSIG) 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7 50 ± 7

SWITCH
CLOSE (PSIG) 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7 90 ± 7

REFRIGERANT SUCTION LINE SIZE (OD) INCH 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8 1-5/8 & 1-3/8 1-5/8 1-5/8 1-5/8 1-3/8 1-5/8
LINES+
LIQUID LINE SIZE (OD) INCH 5/8 7/8 7/8 7/8 7/8 7/8 7/8 1-1/8 & 7/8 1-1/8 7/8 7/8

SOUND PRESSURE LEVEL, dBA (@ 1, 3 & 5 meters)++ 78.3/72.3/68.8 80.4/74.4/70.8 80.9/74.9/71.4 82.3/76.3/72.7 83.3/77.3/73.8 84.5/78.4/74.9 85.4/79.3/75.8 85.5/79.5/76 85.2/79.2/75.7 86.3/80.3/76.8 88.4/82.478.8

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 AHRI conditions. Tolerance: ±2dBA.
 ELECTRICAL DATA

380/415V-3PH-50Hz
VOLTAGE LEAD COMPRESSOR OTHER COMPRESSOR CONDENSER FAN MTR
POWER RANGE (SEE MCA MOCP
MODEL No. SUPPLY NOTE) RLA LRA QTY RLA LRA QTY FLA LRA QTY
HP (amps) (amps)
(V-PH-Hz) (amps) (ea) (amps) (amps) (amps) (amps) (ea)
MIN. MAX. (amps) (ea)
CTX016
CTX003 380/415-3-50 342 457 14.5
6.6 101
46 1 14.5
- 101
- 1- 2.5
0.78 3.7
1.6 20
4.4 2
1 40.0
9.9 50
15
CTX018 380/415-3-50 342 457 18.6 111 1 18.6 111 1 2.5 3.7 20 2 49.3 60
CTX022 380/415-3-50 342 457 20 118 1 20 118 1 2.5 3.7 20 2 52.4 70
CTX025 380/415-3-50 342 457 20.7 118 1 20.7 118 1 2.5 3.7 20 2 54.0 70
CTX027 380/415-3-50 342 457 24.3 140 1 24.3 140 1 2.5 3.7 20 4 69.5 90
CTX030 380/415-3-50 342 457 27.9 173 1 27.9 173 1 2.5 3.7 20 4 77.6 100
CTX035 380/415-3-50 342 457 33.9 225 1 27.9 173 1 2.5 3.7 20 4 85.1 110
CTX040 380/415-3-50 342 457 33.9 225 1 33.9 225 1 2.5 3.7 20 4 91.1 110
CTX045 380/415-3-50 342 457 46.7 272 1 33.9 225 1 2.5 3.7 20 4 107.1 150
CTX050 380/415-3-50 342 457 46.7 272 1 46.7 272 1 2.5 3.7 20 4 119.9 150
CTX060 380/415-3-50 342 457 60.7 310 1 46.7 272 1 2.5 3.7 20 6 144.8 200
CTX070 380/415-3-50 342 457 60.7 310 1 60.7 310 1 2.5 3.7 20 6 158.8 200
CTX080 380/415-3-50 342 457 33.9 225 1 33.9 225 3 2.5 3.7 20 8 173.7 200
CTX100 380/415-3-50 342 457 46.7 272 1 46.7 272 3 2.5 3.7 20 8 228.1 250
NOTE: The equipment is guaranteed to operate within the voltage range mentioned in the electrical data, while further voltage tolerances can be
supported with special orders. Corrective measures should be undertaken to improve Voltages to within ±5% of nominal Voltage Supply Rating.
LEGEND:
RLA - Rated Load Amps HP - Horse power
FLA - Full Load Amps MCA - Minimum Circuit Ampacity
LRA - Locked Rotor Amps MOCP- Maximum Over Current Protection

6
 DIMENSIONS
CTX016, CTX018, CTX022 & CTX025

CTX027, CTX030, CTX035, CTX040, CTX045 & CTX050

NOTE: All dimensions are in mm.

7
 DIMENSIONS
CTX060 & CTX070

CTX080 & CTX100

NOTE: All dimensions are in mm.

8
 TYPICAL WIRING DIAGRAM
Standard units (Quadruple Compressor)
HVTB
L1
REFER TO UNIT
NAMEPLATE FOR
L2
POWER SUPPLY L3
PLEASE REFER
NEXT PAGE FOR
NTB CONDENSER FAN MOTOR
POWER CONNECTIONS
NEUTRAL
(SEE NOTE-9)
LUG
CC1 CC2 CC3 CC4

OLR1 OLR2 OLR3 OLR4

27T1A

T1C
T2C
T3C

T1D
T2D
T3D
T2A
T3A

T1B
T2B
T3B
COMP COMP COMP COMP
1 2 3 4

TO HVTB TO NTB
SMOKE DETECTOR L1 N
ATB
F1 230VAC
ATB 1 1A JP2 1B
BMR
PLEASE REFER TO FAN MOTOR
CONTROL CONNECTION, (SHEET 2 OF 2)
OPTIONAL OPTIONAL
VFC CONNECTION PDS CONNECTION
(SHEET 2 OF 2) (SHEET 2 OF 2)
TO TO TO TO CC2
FR2 FR1 PDS1 PDS2
CC1
41B

41A

14

3B

3A
4A

4B

( NOTE 6)
LVTB
OUTFAN2

OUTFAN1

HEATER2

HEATER1

COMP1
INFAN

COMP2

TB1
LIVE

TO ATB
X2

X1

P1

P2

R
C
G
FUSE
ECB1
NEUTRAL

Y1
LED
POWER INDICATOR LED FAULT INDICATOR Y2
SQMBO4 ( P 4 ) W1
LOCK2 LOCK1
W2
SYSTEM2 SYSTEM1
ON/OFF
PRI

(ON/OFF)

TRANS1 P4_## HP1

230v (HP1)
12v-0-12v
HP2

ON DIP
(HP2)

22A LPS1
LP1
SEC

DIP SWITCH
(LP1) 23A P

22B LPS2
J_PROG LP2
LVTB LOCATION 23B P
(LP2)

PLEASE REFER TO FAN MOTOR

CONTROL CONNECTION, (SHEET 2 OF 2)
TO ATB OPTIONAL OPTIONAL TO ATB
VFC CONNECTION PDS CONNECTION
1 (SHEET 2 OF 2) (SHEET 2 OF 2)
2
TO TO TO TO
TO ATB TO ATB FR4 FR3 PDS3 PDS4 CC4
2
CC3
41D

41C

4D

3D

3C
4C
OUTFAN2

OUTFAN1

HEATER2

HEATER1

BMR-1
COMP1
COMP2

TB1
INFAN
LIVE

15B 15C
X2

X1

P2
P1

R
C
G JP
FUSE 31C
YR3-1

ECB2
NEUTRAL

Y1
LED 31D YR4-1
LED FAULT INDICATOR Y2
POWER INDICATOR
SQMBO4 ( P 4 ) W1
LOCK2 LOCK1
W2
SYSTEM2 SYSTEM1
ON/OFF
PRI

(ON/OFF)
OLR3-1 HPS3
TRANS2 HP1 21C JP7 JP9
P4_## 24C 25C 26C
P
230v (HP1) 27C
OLR4-1 HPS4
12v-0-12v 21D
HP2 24D JP8 25D JP10 26D
P
(HP2) 27D
ON DIP

22C LPS3
LP1
SEC

DIP SWITCH
(LP1) 23C P

22D LPS4
J_PROG LP2
LVTB LOCATION 23D P
(LP2)

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.

9
 TYPICAL WIRING DIAGRAM
Standard units (Quadruple Compressor)
OPTIONAL CONNECTIONS LEGEND
AR AUXILIARY RELAY
COMPRESSOR WITH CB CONNECTION ATB AUXILIARY TERMINAL BLOCK
TO HVTB TO HVTB TO HVTB TO HVTB BM BLOWER MOTOR
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 COMP CB AUXILIARY CONTACT CONNECTION
BMC BLOWER MOTOR CONTACTOR
ECB1
CC COMPRESSOR CONTACTOR
HP1 21A CCA CC AUXILIARY CONTACT
CB1 CB2 CB3 CB4 CB1A-1A 27A
(HP1) 8A CB CIRCUIT BREAKER
HPS1

HP2 21B C. HTR CRANKCASE HEATER

L1C
L2C
L3C

L1D
L2D
L3D
CB2A-1A
L1A
L2A
L3A

L1B
L2B
L3B

27B
8B
(HP2) HPS2 COMP/C COMPRESSOR
CC1 CC2 CC3 CC4 DDC DIRECT DIGITAL CONTROLLER
OLR1 OLR2 OLR3 OLR4
ECB2
ECB ELECTRONIC CONTROL BOARD
F FUSE
T1C
T2C
T3C

T1D
T2D
T3D
T1A
T2A
T3A

T1B
T2B
T3B

21C
HP1 CB3A-1A 27C FCS FAN CYCLING SWITCH
(HP1) 8C
COMP COMP COMP COMP HPS3
FM FAN MOTOR (CONDENSER)
1 2 3 4 21D
HP2 CB4A-1A 27D FMC FAN MOTOR CONTACTOR
(HP2) 8D
HPS4
FMCA FMC AUXILIARY CONTACT
FR FAULT RELAY
COMP. SSPS CONNECTION (AS APPLICABLE) HOT GAS BY PASS CONNECTION UNIT STATUS (VFC) INDICATION CONNECTION
UNIT ON/OFF
HGS HOT GAS BYPASS SOLENOID
COMP. 1: (SEE NOTE 5) LVTB
SSPS1
24A 25A C
17 1 AR1 2 HPS HIGH PRESSURE SWITCH
M1/11 M2/14
1 2 31A
AR8 HVTB HIGH VOLTAGE TERMINAL BLOCK
L1/MP/L L2/R/N Y1 45 AR1-1A 46
JP JUMPER
AR9
(REMOVE JP3)
COMP. 2: Y2
31B UNIT ON L1 LINE 1
SSPS2
24B 25B UNIT TRIP L2 LINE 2
M1/11 M2/14
1 LPS NO 43 FR1-1 44A FR2-1 44B FR3-1 44C FR4-1 44
1
L1/MP/L L2/R/N
2 C
7E AR8-1 7F AR9-1 7G
HGS 2 L3 LINE 3
NC

(REMOVE JP4) NOTE

P
UNIT TRIP LPS LOW PRESSURE SWITCH
COMP. 3: SSPS3 FOR UNITS WITH HGS CONNECTION, COMP 1 SHALL BE LEAD COMPRESSOR. INDIVIDUAL COMP. RUN/TRIP LVTB LOW VOLTAGE TERMINAL BLOCK
DIP SWITCH S2 IN ECB SHOULD ALWAYS BE IN "ON" POSITION.
24C 25C
M1/11 M2/14 FR1
COMP 1 TO ECB1 41A
2 LUG LUG GROUND
1 2 X1
L1/MP/L L2/R/N NTB NEUTRAL TERMINAL BLOCK
UVM CONNECTION FR1-2A
(REMOVE JP7) L1 L2 L3 OLR OVER LOAD RELAY
COMP. 4: CC1A-2A
SSPS4
24D 25D P PRESSURE
M1/11 M2/14
1 2
PDS PUMP DOWN SOLENOID
L1/MP/L L2/R/N
55 56 58 SSPS SOLID STATE PROTECTION SYSTEM
(REMOVE JP8) L1 L2 L3 UVM
1 UVM-1 8 COMP1 ON TOP FM THERMAL OVERLOAD PROTECTION
COMP1 TRIP
OPTIONAL AHU INTER-CONNECTION
TRANS TRANSFORER
(POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR) FR2 2
TO ATB 1 COMP 2 TO ECB1 41B VFC VOLT FREE CONTACT
X2
TO POWER SUPPLY TO POWER SUPPLY TO POWER SUPPLY (REMOVE JP1)
L1 L2 L3 L1 L2 L3 L1 L2 L3 TO ATB 1A FR2-2A YR COOLING RELAY
_ _ _ FIELD WIRING
CC2A-2A
PUMP DOWN SOLENOID CONNECTION
CB PDS2 ATB TERMINAL BLOCK OR TERMINATION POINT
2
CB11 CB12 PDS1 60 61 63 SPLICE-CLOSED END
L1C
L2C
L3C

4B

4A

JUNCTION OF WIRES, CONNECTED

71B
72B
73B
71A
72A
73A

COMP2 ON
BMC
P2

P1

COMP2 TRIP CROSSING OF WIRES, NO CONNECTION

HC1 HC2 OLR ECB1
PDS4 ATB
2 FR3 2 NOTES
68
69
70

COMP 3 TO ECB2 41C

PDS3 X1 1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
T1H
T2H
T3H
T1F
T2F
T3F

4D

4C

HEATER1 HEATER2
FR3-2A
2. ANY WIRE REPLACEMENT SHOULD BE OF 900C OR ITS
EQUIVALENT. USE COPPER CONDUCTOR WIRES ONLY.
P2

P1

(Stg. 1 Heating) (Stg. 2 Heating) CC3A-2A

ECB2 ( NOTE 6)
TB1 (ECB1) SWITCHING CONTACTS
3. POWER MUST BE SUPPLIED TO CRANKCASE HEATER
(REMOVE JUMPER JP) LVTB ( NOTE 8)
FROM T'STAT CONTROLLER OR DDC 65 66 68 FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM
R
24Vac
R
R
COMP3 ON
START UP.
C
C C
BM CONTROL G COMP3 TRIP
FR4 IF POWER IS OFF 6 HOURS OR MORE, CRANK-
G G 2
Y1 Y1
STG1 COOLINGY1 COMP 4 TO ECB2
X2
41D CASE HEATER MUST BE ON FOR 12 HOURS BE-
Y2 Y2
STG2 COOLINGY2
FR4-2A FORE OPERATING THE SYSTEM.
STG3 COOLINGY3
W1 Y3
STG4 COOLINGY4
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
W2 Y4
STG1 HEATER W1
CC4A-2A
RESULT IN COMPRESSOR DAMAGE.
W1
W2 STG2 HEATER W2
70 71 73 4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY CONSUMER WITH
TO ATB COMP4 ON
(in cond. unit)
CONTROLS RATING AS RECOMMENDED BY ZAMIL.
230Vac COMP4 TRIP
5 . COMPRESSORS ARE EITHER PROVIDED WITH
TO ECB
(in cond. unit) BMC
SSPS OR INTERNAL LINE BREAK FOR THERMAL
OLR-1
INFAN
14 19 OVERLOAD PROTECTION.
HC1 ECB1 & 2 DIP SWITCH SETTINGS & LED INDICATORS 6. IF PDS IS FACTORY INSTALLED, PLEASE READ
29 AFS
HTR1 S1 OFF=TEST MODE DISABLE ON= TEST MODE ENABLE
HC2
28
LOAD BALANCE
DASHED LINES AS CONTINUOUS LINES.
30 S2 OFF= (Comp1&2 Auto Lead Lag) ON= COMPRESSOR 1 LEAD
HTR2 7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR LVTB
S3 OFF= WITHOUT PUMP DOWN ON= WITH PUMP DOWN OPTION
S4 OFF= SINGLE STAGE ON= DUAL STAGE FIELD WIRING. GROUND CONNECT AT BOTH ENDS.
PRESSURE SWITCH SETTINGS (R410a) FACTORY SETTINGS OF DIP SWITCHES LED INDICATORS 8. COOLING OUTPUT SIGNAL FROM CONTROLLER
Green power on/off indicator
NAME OPEN (PSIG) CLOSE (PSIG) DIP SWITCH # S1 S2 S3 S4
Red system lock-out due to system fault SHOULD FOLLOW THE SEQUENCE:
LPS1 & 2
ON system 1 / 3 fault diagnostic ON SEQUENCE: Y1-Y2-Y3-Y4.
OFF
Yellow blinking slow - LPS1 ckt fault OFF SEQUENCE: Y4-Y3-Y2-Y1.
LPS 108 95 note: blinking fast - HPS1 ckt fault
- Set dip switch #S3 according to unit's option
HPS1 & 2 (pump down or no pump down) system 2 / 4 fault diagnostic 9. NEUTRAL LINE REQUIRED ON 380/400V-3Ph-60Hz
FCS1 & 2 - Dip switch #S1 should always be OFF Orange blinking slow - LPS2 ckt fault & 380/415V-3Ph-50Hz POWER SUPPLY ONLY.
during operation. blinking fast - HPS2 ckt fault

10
 TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS

SWITCHING CONTACTS
FROM T'STAT CONTROLLER OR DDC

CONTROLS AND SEQUENCE OF OPERATION

The unit is equipped with an electronic control board which can be linked with any commercially available 24V ac thermo-
stat or can be controlled through a DDC panel. With cooling input signals coming from a thermostat or DDC, the motors
in the equipment are started in the following sequential order: condenser fan – compressor motor. The cooling input
signals to the unit’s control board should always start first with the first stage (Y1) followed by the second stage (Y2) and
“OFF” sequence should start with the second stage (Y2) followed by the first stage (Y1).

Balance Loading of Compressors: The user can select the sequence of operation of the compressors; either com-
pressor 1 as always leading (dip switch #2 set at ON) or enabling balance loading of compressor (dip switch #2 set at
OFF). In balance loading function, the compressor with the least run time will be started first to equalize the run time of
the compressors. These functions are selectable through the dip switch on the electronic control board. Please refer to
the settings table shown in the unit’s wiring diagram.

Fault Diagnostics: In case of system fault, LED’s on the board emits a flashing signal indicating the nature or where the
fault is. This is to guide the service technician in identifying the fault. Please refer to the settings table shown in the unit’s
wiring diagram for the details of each respective fault against LED indicators.

Compressor Lock-Out Function: If any of the unit’s safety control devices trips and such condition is maintained for
approximately 3 minutes, the control will lock-out that particular system preventing a re-start. It can be re-set by shutting
off power to the thermostat or if the cooling signal to the board is turned OFF.

Compressor Anti-Recycling Timer: The unit’s electronic control board has a built-in three (3) minutes minimum off
timer for the compressor. This is for compressor protection in case of accidental manual re-set or immediate re-cycling
through the thermostat due to load demand.

11
 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: CTX016 - CTX025

MODELS: CTX027 - CTX050 MODELS: CTX060 - CTX070

LIFT
LIFT
SPREADER BAR

PROPER CLEARANCE
TO BE PROVIDED

MODELS: CTX080 - CTX100 LIFT

12
 INSTALLATION CLEARANCE
WALL

MODEL NUMBER A B C D E
CTX006 - CTX050 1500 1500 2000 1500 1500
CTX060 - CTX100 2000 2000 3000 2000 2000

FIGURE - 1
STRAIGHT WALL

FIGURE - 2
CORNER WALL

NOTE: 1. All dimensions are in mm.

2. PIT Installation: If unit is installed in special pit, please observe the same tolerance for walls. Pit height
should not exceed the unit height.

13
 LOAD DISTRIBUTION (kg.)

CTX012 - CTX025 CTX027 - CTX050

CTX060 - CTX070 CTX080 - CTX100

14
 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.
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions
and other COOLINE publications for the specific equipment being installed.
These units should be charged with R-410a refrigerant.

LOCATION OF UNIT
When selecting the location for the unit, the following points should be kept in mind:
1. Provide a concrete pad or another form of stand. Use 4-6 each rubber/cork pads 4" x 4" x 1" thick each (rubber-in-
shear for example) at each corner and along side rails, or use 4-6 each spring isolators.
2. That the terrain allows for drainage away from the unit.
3. If the unit is to be roof mounted, inspect the roof for load bearing capacity. The roof should have sufficient structural
strength to carry the weight of the unit.
4. Availability of electric power.
5. Position the unit to provide for unrestricted air circulation and to prevent any possibility of air recirculation.
6. Check minimum clearances required for your unit, with regard to walls, or other obstructions.
7. Air cooled equipment should not be installed under low structural overhangs which can cause condenser air recircu-
lation or restriction.
8. Care should be taken to prevent air from other sources from entering condenser, if this air is at a high temperature.

REFRIGERANT PIPING CONNECTIONS

Piping connections:
Outdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. The
liquid and suction line diameters can be determined from the physical data table.

It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigeration
standard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigerant
pipes carefully to prevent damaging the suction pipe insulation and vibration transmission to the structure.

Outdoor unit connected to factory matched indoor unit

Outdoor unit contains holding charge only. The correct system refrigerant charge for operation is given in the unit name-
plate & physical data table when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge for
maximum efficiency.

Sweat connection:
Use refrigerant grade piping. Service valves are closed from factory when shipped and ready for brazing. After wrapping
the service valve with a wet cloth, the piping set can be brazed to service valve using either silver rod or silfos rod brazing
material. When brazing completed, refrigerant piping and indoor coil are now ready for leak testing. This check should
also include all field and factory brazed joints.
Warning: Relieve all pressure before refrigerant system repair or final unit disposal to avoid personal injury or death. Use
service ports and open all valves.

15
LEAK TESTING & REFRIGERANT CHARGING
Leak test:
Leak can occur from joints or fittings that are improperly brazed/connected during installation of indoor and outdoor units.
The installer should leak test the indoor unit & associated field supplied refrigerant piping, then the outdoor unit, each
separately using electronic freon detector and/or soap bubbles.

Refrigerant Charging:
(To be used for system having a holding charge and to compensate for length of liquid line).
1. Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Make
sure that no air & moisture enter the system. The whole system should be leak tested and evacuated before charging
the refrigerant.
2. When system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging lines and manifolds must be
purged with refrigerant vapor prior to admitting refrigerant into the system to prevent contamination system with non-condensable.
3. It is important to first determine the amount of refrigerant required for the system, the unit nameplate normally identify
the weight of the refrigerant required.
4. The refrigerant should be added in small amounts allowing sufficient time for the unit pressure to equalize each time.

WIRING
All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltage,
frequency and phase must coincide with the unit nameplate.
Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate. The unit
wiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wiring.
The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused disconnect
switch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone wire for this
purpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety & servicing purposes.
Wiring connection to the unit must have insulation suitable for temperatures of a minimum of 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 com-
pressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for few
minutes to pumpdown the system, even the thermostat is OFF).
7. Thorough inspection on evaporator coil, condenser coil and other components for any physical damage.
8. Expansion valve bulb is strapped properly at correct location.
9. Circuit breaker/fused disconnect switch.
10. Blower fan belt is properly tightened and pulleys are properly aligned.
11. Blower fan & condenser fans are at correct rotation and their mountings are properly tightened.
12. All refrigerant service valve caps are installed.
13. All piping, piping insulation and piping supports are properly installed.
14. Thermostat is the right one and installed properly.
15. Duct work and accessories (check the following list and select whichever applicable to each jobs):
• Flexible Connection
• Air Filters Clean
16
 • Air Filter Access Door Gasket
• Sound Attenuators (If Applicable)
• Fresh Air Intake
• Ductwork Caulking Inside/Outside Building
• Ductwork Supports Inside/Outside Building
• Duct Leakage Inside/Outside Building
• Volume Dampers
• Volume Damper Access Doors
• Fire Dampers
• Fire Damper Access Doors
• Transfer Grilles/Door Grilles
• Duct Insulation/Liner
• Diffusers/Grilles
• Duct Humidistat
• Filter flag
CHECK-OUT & OPERATIONAL START-UP PROCEDURE
After the completion of inspection and check list, the following points should be covered before system is placed in operation.

1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for check-
ing Voltage, Amps, RPM, CFM, static pressure, etc.
2. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere.
3. Start the compressor and observe the following points (on multiple compressor units, it is highly recommended to start
the compressors one by one to achieve careful observation for each compressor).
(a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take
corrective action.
(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required,
leak test all connections and system components and repair any leaks before adding refrigerant.
(c) Observe oil level in compressor crankcase sight glass (if available) and add oil as necessary to bring to recom-
mended oil level.
All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in order
to provide some allowance for oil which will be circulating in the system during operation. Depending on the system
design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may be
necessary either to add or remove oil from a system any time it is first placed in operation with a different compressor.

An abnormally low oil level may result in a loss of lubrication; while an excessively high oil level may result in oil
slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may vary consider-
ably on initial start-up if liquid refrigerant is present in the crankcase, and the oil level should be checked with the
compressor running after having reached a stabilized condition.

(d) Thermostatic expansion valves must be checked for proper superheat settings. Recommended superheat is 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 tem-
peratures, supply airflow rates in occupied spaces and any other specified parameters.

17
 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.

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.

Maximum voltage deviation from average voltage

Voltage unbalance, % = 100 x
Average voltage
The percentage increase in temperature rise in a phase winding resulting from voltage unbalance will be approximately
two times the square of the voltage unbalance.

Because of the unbalanced voltage condition in a three phase circuit, it is possible that one phase winding in the com-
pressor motor may be over-heated while the other have a temperature within normal limits. Where unbalanced voltage on
a three phase circuit exists, the power company should be notified of such unbalance to determine, if the situation can be
corrected.

A common source of unbalanced voltage on a three phase circuit is a single phase load between two of the three phases.
A large lighting or heating circuit connection to one phase of a three phase circuit can easily cause sufficient variations in
motor currents to endanger the motor. Interchange the single phase loads to equally divide the entire loads among the
three phases. Balance the supply voltage as evenly as possible.

Unless the unbalanced voltage condition can be corrected, the only way to insure motor safety is to be sure that the
protectors are in the high current phase when using two leg protection, or to use protectors in all three legs.

MOTOR CONTACTOR
The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compres-
sor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, motor
contactors are subjected to quick cycling due to various causes. This may cause burned and/or sticking contacts and can
cause a compressor motor failure, even though the motor overload protectors trip and open the control circuit.

18
FAN MOTOR
The condenser fan motor is a single speed electrical motor with ball bearings, protected with an automatic reset internal
overload.

CRANKCASE HEATERS
The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest part
of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize when
the compressor is operating.

Power must be supplied to crankcase heater for minimum of 12 hours prior to system start up. If power is off 6 hours or
more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions may
result in compressor damage.

Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are not
a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper piping
practice, over feeding to the evaporator, leaking solenoid valve, etc.

In some cases where migration of refrigerant to the crankcase occurred due to long storage time, shutdown period,
defective components, etc. The crankcase heater may be ineffective. Such cases may be easily observed by high oil
level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharge
service valves of the compressor and release all liquid refrigerant from the compressor.

The liquid refrigerant dilutes the oil in the crankcase and the refrigerant rich oil will be pumped to the rods and the
bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at the
bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor to
drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinders
during the suction stroke causing them to wear during the compression stroke.

When the crankcase is filled with liquid refrigerant and the compressor starts severe agitation, oil foaming etc. will cause
major damage to the compressor.

Periodic checking for proper operation of crankcase heater is highly recommended.

LUBE OIL PROTECTION CONTROL

Pressure lubricated refrigeration compressors require a pressure protector in the event of an oil pressure failure. The
lube oil pressure protection control is factory set to conform with compressor manufacturers specifications and should
not be changed.

The control measures the net oil pressure available to circulate oil through the lubrication system. The positive displace-
ment oil pump circulates the refrigerant oil through the lubrication system. Since the oil pump is connected directly to the
compressor crankcase, the inlet pressure to the oil pump will always be the crankcase pressure. The oil pump outlet
pressure will be the crankcase pressure plus the oil pump pressure. Therefore, net oil pump pressure will always be the
pump outlet pressure minus the crankcase pressure.

The control contains a built-in time delay switch that is a trip-free expansion rod device actuated by a resistance heater.

The control is factory set to cut-in at 18 PSIG and cut out at 9 PSIG. When the compressor starts the resistance heater
of the time delay becomes energized. If the net oil pressure does not build to 18 PSIG or above within 120 seconds, the
time delay trips to stop the compressor. If the net oil pressure drops below 18 PSIG, but not below 9 PSIG during a
running cycle, the time delay resistance heater becomes energized and unless the net oil pressure returns to 18 PSIG or
above during the 120 seconds safety time period, the compressor will shut down. The compressor will shut down when-
ever the net oil pressure drops below 9 PSIG, and will never run for more than the predetermined 120 seconds on
abnormal oil pressure.

19
 OIL PUMP CRANKCASE NET OIL
OUTLET PRESSURE PRESSURE PRESSURE

78 _ 60 = 18

New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type me-
chanical expansion rod-resistance heater type oil protection controls.

FEATURES:
• An entirely new control concept. This unique design incorporates a modern pressure transducer to monitor oil pressure.
• Each control reflects improved calibration stability over the control's entire pressure range.
• Controls boast truly accurate timing despite ambient temperature and voltage variations.
• All electronic components are purposely "over-sized" and computer-matched to provide the greatest safety factor and
dependable service life.
• Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibra-
tion, dirt or moisture.
• Controls reset instantaneously, thanks to the precise solid state timing circuit. No annoying wait for old-fashioned timer
heater to cool down.
• Control module is interchangeable with the old type conventional oil protection and with competitive brands of oil
protection controls. An exact replacement from a mounting, wiring and logic function standpoint.
• Control maintains timing over the full voltage range of 102 to 264 VAC. Voltage selection is not necessary.
• Unit is not position sensitive.
• Users are offered a choice of controls with or without cover, a handy mounting bracket and other options.
• "Logic" circuitry in the module monitors oil pressure pulses during marginal operation and integrates them resulting in
a longer span of time before lock-out occurs.
• Last, but not least, it has enlarged the reset button to a new "thumb-sized" dimension. The reset button is slightly
recessed to protect it from damage.

VOLTAGE MONITOR
This device protects the motors in the unit from faults such as; under or over voltage, unbalance & phase reversal of the
power supply. When the device sensed such faults, it will cut-off the supply in the control circuit thereby cutting off power
to the motors. The voltage monitor will re-set automatically when power is brought back to it’s normal conditions.

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

LINE VOLTAGE
UNDER VOLTAGE OVER VOLTAGE PHASE IMBALANCE
RANGE
TRIP RE-SET TRIP RE-SET TRIP RE-SET
190 - 480 VAC 90% 93% 110% 107% 6% 4.5%

20
 REFRIGERATION
COMPRESSOR
Single scroll compressors are used as standard for models PTH006, dual scroll compressors for CTX012 - CTX070 and
quadruple scroll compressors for CTX080 - CTX100. All compressors are conforming to AHRI 540. The compressors are
equipped with internal motor protection; factory installed crankcase heater and rubber vibration isolators for quiet and
efficient operation. Each compressor has lock-out devices to protect it from short cycling when tripped by safety controls.
The compressor motors conform to NEMA MG-1 & MG-2.
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.
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.

21
If the first acidity test shows that the acid content is below the safe level, as indicated in the test kit instructions, and the
oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the system
provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. For a badly
contaminated system that indicates acid in the oil after 8 to 12 hours of operation, change the suction and liquid line filter-
driers and check the system after 24 hours of operation.

There are instances where contaminants are discovered in a refrigeration system with the compressor still operational.
The same procedure applies, when cleaning these systems, as on a compressor burn-out.

SOURCE OF CONTAMINATION
There are many ways in which a refrigerant system can become contaminated. The most common of these are as
follows:
1. Improper or inadequate dehydration.
2. Wet refrigerant.
3. Wet oil (caution: It is best to purchase oil in small containers and use as needed. Open containers will absorb mois-
ture).
4. Refrigerant leaks (allowing system to operate in a vacuum).
5. Failure to remove oil and moisture after having opened the system for repair.
6. Higher than normal operating temperatures and pressures will cause a breakdown of the oil and refrigerant.
7. Using oil other than specified (Sunoco 3G is recommended).
8. 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 650 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.

Should the control open, it will remain open until the pressure in the system is lowered to 500 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 650 ± 15 psig. Allow the system to remain off, until the gauge pressure drop to approximately 500 ± 22 psig and
reconnect the condenser fan motor. Reset the unit by putting off the thermostat and if the high pressure control has
closed, the compressor will restart.

LOW PRESSURE SWITCH

To provide protection for the compressor in the event of refrigerant loss, a low pressure control is installed in the suction
line.

The control is preset to open when the suction pressure is 50 psig. The contacts of the control will close when the suction
pressure rises to 90 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.

22
PUMP DOWN CONTROL
A pump down control is a solenoid type valve installed in the liquid line to prevent the flow of refrigerant into the evapo-
rator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liquid
line, but ahead of metering device.

The thermostat and other controls are used in conjunction with the solenoid valve to control the operation. A pump down
pressure switch is used to stop the compressor at pre-determine evaporator pressure.

The thermostat is wired through the controls to energize the liquid line solenoid valve when the room temperature calls for
cooling, its contacts closes and through the controls it energize the solenoid valve. The opened solenoid valve allows
refrigerant to flow to the evaporator coil - causing the evaporator pressure to rise, the low pressure control contacts to
close and the compressor to start.

When the thermostat is satisfied, the solenoid valve closes and the compressor continues to run until a substantial
portion of the refrigerant has been pumped out from the evaporator. When the pump down pressure switch cut-out
setting is achieved, power to the control circuit is interrupted and the compressor stops.

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.

23

SYMPTOM
Compressor will not start – no
hum.
Compressor will not start –
hums but trips on overload
protector.
Compressor starts and runs,
but short cycles on overload
protector.
Space temperature too high.
Suction line frosted or sweating.
Liquid line frosted or sweating.
TROUBLE SHOOTING CHART
CAUSES
1. Line disconnect switch open.
2. Fuse removed or blown.
3. Overload protector tripped.
4. Control stuck in open position.
5. Control off due to cold location.
6. Wiring improper or loose.
7. Thermostat defective or improperly
installed.
8. Control circuit open.
9. Burned/open circuit motor winding.
1. Improperly wired.
2. Low voltage to unit.
3. Compressor motor has a winding
open or shorted.
4. Internal mechanical trouble in com-
pressor.
5. Liquid refrigerant in compressor.
6. High discharge pressure.
1. Additional current passing through
overload protector.
2. Low voltage to unit (or unbalanced if
three phase).
3. Overload protector defective.
4. Excessive discharge pressure.
5. Suction pressure too high.
6. Compressor too hot - return gas hot.
1. Control setting too high.
2. Expansion valve too small.
3. Cooling coils too small.
4. Inadequate air circulation.
1. Expansion valve passing excess re-
frigerant or is oversized.
2. Expansion valve stuck open.
3. Evaporator fan not running.
4. Overcharge of refrigerant.
1. Restriction in dehydrator or strainer.
2. Liquid shut-off valve partially closed.
24
CHECK & CORRECTIVE MEASURE
1. Close start or disconnect switch.
2. Replace fuse.
3. Refer to electrical section.
4. Repair or replace control.
5. Relocate control.
6. Check wiring against diagram.
7. Replace or relocate.
8. Trace control circuit with wiring dia-
gram and repair.
9. Replace the compressor with all pre-
cautions.
1. Check wiring against diagram.
2. Determine reason and correct.
3. Replace compressor.
4. Replace compressor.
5. Check crankcase heater.
6. Unequalized pressure in the system.
1. Check wiring diagram. Check for
added fan motors, pumps, etc. con-
nected to wrong side of protector.
2. Determine the reason and correct.
3. Check current, replace protector.
4. Check airflow across the condenser
coil, restrictions in refrigeration system.
5. Check for possibility of misapplica-
tion. Use stronger unit.
6. Check refrigerant charge (fix leak),
add if necessary.
1. Reset control.
2. Use larger valve.
3. Add surface or replace.
4. Improve air movement.
1. Re-adjust valve or replace with smaller valve.
2. Clean valve of foreign particles, re-
place if necessary.
3. Determine reason and correct.
4. Correct charge.
1. Replace part.
2. Open valve fully.

SYMPTOM
Units runs OK, but short
cycles on.
Unit operates long or continu-
ously.
Evaporator ices up.
Head pressure too high.
Head pressure too low.
TROUBLE SHOOTING CHART
CAUSES
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. 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. Restricted airflow.
2. Dirty air filter.
3. Short of refrigerant.
4. Low air volume.
5. Restricted distributor tube.
6. Restricted liquid line/low liquid line
pressure.
1. Refrigerant overcharge.
2. Air in system.
3. Dirty condenser.
4. Malfunction of condenser fan (air-
cooled).
5. Excessive air temperature entering
condenser.
6. Restriction in discharge line.
1.Low ambient temperatures (air-
cooled).
2. Refrigerant shortage.
3. Damaged valves in compressor.
25
CHECK & CORRECTIVE MEASURE
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.
1. Fix leak, add charge.
2. Clean contacts or replace control.
3. Determine the fault and correct.
4. Replace with larger system.
5. Defrost.
6. Determine location and remove.
7. Clean condenser.
8. Clean or replace.
1. Check for dirt or lint on coil.
2. Clean or replace. Advice customer
on periodic cleaning of filter.
3. Check system pressure. Take super-
heat reading. Add refrigerant.
4. Check for dirty air filter or loose belt.
5. Check for warm distributor tube.
6. Check for restriction in lines/improve
liquid line pressure by proper charg-
ing or installing fan cycle switch, etc.
1. Correct the refrigerant charge.
2. Recharge the system after a thorough
triple evacuation.
3. Clean.
4. Check and correct or replace.
5. Check for short circuiting of con-
denser discharge air, correct it.
6. Correct it.
1. Install fan cycling switch, if not pro-
vided. Check the setting and opera-
tion, if provided.
2. Correct the refrigerant charge after
leak testing.
3. Repair/replace the compressor.

SYMPTOM
High suction pressure.
Loss of oil pressure.
Relay defective or burned out.
Unit noisy.
TROUBLE SHOOTING CHART
CAUSES
1. High load on evaporator. Load in ex-
cess of design conditions.
2. Unbalanced system. Oversized air han-
dling 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 suction
pressure.
2. Excessive liquid refrigerant returning to
compressor.
3. Malfunctioning oil pump.
4. Restriction in oil pump inlet screen.
1. Incorrect relay.
2. Incorrect mounting angle.
3. Line voltage too high or too low.
4. Excessive short cycling.
5. Relay being influenced by loose mounting.
1. Loose parts or mountings.
2. Tubing rattle.
3. Bent fan blade causing vibration.
4. Fan motor bearings worn.
26
CHECK & CORRECTIVE MEASURE
1. Check the design.
2. Follow manufacturer's guide line and
correct it.
3. Repair/replace compressor.
4. Check and adjust the superheat ac-
cordingly.
5. Check the expansion valve bulb is
properly tighten at correct location.
1. (a) Correct the system piping.
(b) Trace out the wiring/defective con-
trols/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. & correct it.
2. Check the system for correct super-
heat & other possible causes like
clogged filter, low CFM, iced evapo-
rator, etc. and correct it.
3. Repair or replace it.
4. Clean/replace it (oil change recommended).
1. Check and replace.
2. Remount relay in correct position.
3. Determine reason and correct.
4. Determine reason and correct.
5. Remount rigidly.
1. Find and tighten.
2. Tighten the pipe support.
3. Replace blade.
4. Replace motor.
 RECOMMENDED SPARE PARTS
PERCENTAGE OF SPARE PARTS
ITEM ONE YEAR SUPPLY TWO YEAR SUPPLY
100 UNITS 1000 UNITS 100 UNITS 1000 UNITS

Compressor 2% 1% 3% 2%

Capacitor 3 2 5 4
Condenser fan motor 2 1 3 2
Evaporator blower motor 1 0.5 2 1

Belt 2 1 4 3
Contactor compressor 2 1 3 2
Contactor heater 2 1 3 2

Contactor fan motors 2 1 3 2

HPS/LPS/other controls 2 1 3 2
Expansion valve 1 0.5 2 1

Filter drier 2 1 3 2
Electric heater 1 0.5 2 1
Fuse link, heater 3 1 4 3
Transformer (24V secondary) 1 0.5 2 1

Propeller fan 1 0.5 2 1

Blower Wheel 0.5 0.25 1 0.5
Bearing-blower 2 1 4 2

Thermostat (Wall) 1 1 2 1
Heater-crankcase 3 1 4 2
Filter 2 1 4 4
NOTE : When ordering spare parts, please quote the complete model number on the unit nameplate.

27
 PREVENTIVE MAINTENANCE SCHEDULE
FREQUENCY OF MAINTENANCE, MONTHS
ITEM
1 3 6 12

Clean air filters & replace if required. X

Clean evaporator coil, drain pan & drain line. X

Clean condenser coil. X

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

Lubricate blower motor/condenser motor. X

Check alignment of pulleys. X

Check/clean electrical connections, controls & control box. X

Check motors, blower bearings & lubricate it. X

Check all electrical control components, wiring terminals etc. for spark, X
overheating & loose connections. Replace/correct as necessary.
Check all damper operation. Repair/replace as required. X

Check insulation flanking. Repair/replace as required. X

Check loose bolts/screws & tight as necessary. X

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

Check mountings (spring isolator/rubber pads). Repair/replace as necessary. X

Check flexible canvas connections & duct work. Repair/replace as required. X

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

Apply corrosion inhibitor/contact cleaner as required. X

Check all pressures/temperatures as applicable and satisfy the operation &
performance. X

NOTE: Always observe for abnormal noise or vibration.

MAINTENANCE TOOLS/EQUIPMENT REQUIRED

STANDARD : Screw drivers (Slot & Phillips), adjustable wrenches, pliers, refrigeration wrenches & socket set wrenches,
pulley puller, etc.

SPECIAL : Manifold gauge set, R-410A charging cylinder, belt tension checker, leak detector, vacuum pump with
electronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.

28
 MATERIAL SAFETY DATA SHEET
SAFETY DATA REFRIGERANT R-410a
Toxicity Low
In Contact With Skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorp-
tion. R-410A may be slightly irritant and liquid has a de-greasing effect. Thaw affected areas
with water. Remove contaminated clothing carefully - may adhere to skin in case of freeze
burns. Wash affected areas with plenty of warm water. If symptoms occur (irritation or blis-
tering), obtain medical attention.
In Contact With Eyes Vapor has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate
with eyewash solution or clean water for at least 10 minutes. Obtain immediate medical
attention.
Inhalation High levels of vapor concentration initially produce stimulation and then depression of the
central nervous system, causing headaches and giddiness and may lead to unconscious-
ness. Can prove suddenly fatal if the exposure has been severe.
At higher concentration, there is a danger from asphyxiation due to reduced oxygen content
of atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if
necessary. Apply artificial respiration if breathing has ceased or shows signs of failing. In
event of cardiac arrest, apply external cardiac massage. Obtain immediate medical atten-
tion.
Stability Unstable.
Conditions to Avoid Use in presence of naked flames, red hot surfaces and high moisture levels.
Hazardous Reactions May react violently with sodium, potassium, barium and all other alkali and alkaline earth met-
als. Incompatible materials: Magnesium and alloys containing more than 2% magnesium.
Hazardous Halogen acids formed by thermal decomposition.
Decomposition Products
General Precautions Avoid inhalation of high concentrations of vapors. Atmospheric concentrations should be
minimized and kept as low as possible. The vapor is heavier than air and collects at low
level and in confined areas. Ventilate by extraction at lowest levels.
Respiratory Protection Where doubt exists on atmospheric concentration, suitable breathing apparatus should be
worn. This should be self-contained or of the long breather type.
Storage Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources
of heat such as radiators. Keep at temperatures not exceeding 45ºC (113ºF).
Protective Clothing Wear overalls, impervious gloves and goggles/face protection.
Spill / leak Procedure Ensure suitable personal protective clothing and respiratory protection is worn. Provided it
is safe to do so, isolate the source of the leak. Allow small spillages to evaporate provided
there is suitable ventilation. Large spillages: ventilate area. Contain spillages with sand,
earth or any suitable absorbent material. Prevent liquid from entering drains, sewers, base-
ments and work pits since vapor may create a suffocating atmosphere.
Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility
which is equipped to absorb and neutralize acids and other toxic processing products.
Fire Extinguishing Data Non-flammable.
Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if
overheated.
Fire Fighting Protective Self-contained breathing apparatus and protective clothing must be worn in fire conditions.
Equipment

29
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