For Cnx220, Cnx300, Cnx360, Cnx420, Cnx240, Cnx480, Cnx540, Cnx600, Cnx720, Cnx840, Cnxm00, Cnxm10, Cnxm20, Cnxm40, Cnxm60, Cnx2m00, Cnx2m40

INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
AIR COOLED CONDENSING UNITS

'CNX' SERIES
PL-OM-CNX-07-1M-E
Downloaded from www.Manualslib.com manuals search engine

INDEX
Contents Page
Model decoding ....................................................................................................................................... 2
Physical data ......................................................................................................................................... 3-4
Electrical data ........................................................................................................................................... 5
Dimensions .......................................................................................................................................... 6-13
Microprocessor control system ............................................................................................................... 14
User sequence of operation ................................................................................................................... 15
Typical schematic wiring diagram ...................................................................................................... 16-23
Field wiring connections ......................................................................................................................... 24
Rigging instructions & weight distribution ............................................................................................... 25
Load distribution ..................................................................................................................................... 26
INSTALLATION INSTRUCTIONS
General ................................................................................................................................................... 27
Location of unit ....................................................................................................................................... 27
General ................................................................................................................................................... 27
Refrigerant piping connections ............................................................................................................... 27
Leak testing & refrigerant charging ......................................................................................................... 28
Start-up inspection & check list ......................................................................................................... 28-29
Check-out & operational start-up procedure ........................................................................................... 29
ELECTRICAL
Power supply .......................................................................................................................................... 30
Unbalanced voltage ................................................................................................................................ 30
Motor contactor ...................................................................................................................................... 31
Fan motor ............................................................................................................................................... 31
Crankcase heater ................................................................................................................................... 31
Lube oil protection control ...................................................................................................................... 31
Voltage monitor ...................................................................................................................................... 31
REFRIGERATION
Compressor ............................................................................................................................................ 32
High & low pressure protection .......................................................................................................... 33-34
Pump down control ................................................................................................................................. 34
Trouble shooting chart ....................................................................................................................... 35-37
Parts list ................................................................................................................................................. 38
Recommended spare parts .................................................................................................................... 39
Preventive maintenance schedule .......................................................................................................... 40
Material safety data sheet ...................................................................................................................... 41
Pressure temperature chart ............................................................................................................... 42-43
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

MODEL DECODING
1, 2 & 3 4, 5 & 6 7 8 9 10
BASIC NOMINAL ELECTRICAL SPECIAL OPTIONS MANUFACTURING YEAR GENERATION CODE
COOLING SUPPLY
CAPACITY* ( V-Ph-Hz )
(MBH)
150
CNX F : 460-3-60 Z :SPECIAL OPTIONS 06 00
CONDENSING 220
07 01
UNIT 240
300 08 02
360
03
420
480
540
600
720
840
**M00
**M10
**M20
**M40
**M60
***2M00
***2M40
* Capacity in MBH (MBH x 1000 = BTUH).

** M indicates for 1 Million BTUH.
*** 2M indicates for 2 Million BTUH.

PHYSICAL DATA
MODEL NUMBER CNX150 CNX220 CNX240 CNX300 CNX360 CNX420 CNX480 CNX540 CNX600
NOMINAL CAPACITY , TONS* 13 19 22 28 31 36 41 47 53
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Dual Dual Dual Dual Dual
COMPRESSOR Type Scroll Semi-hermetic reciprocating
Oil per system (liters) 4.1 4.1 4.1 4.7 4.68 4.68 4.94 4.94 4.94
Refrigerant R-134a
Charge per system (oz)** 235 330 400 504 570 650 750 850 945
CONDENSER FAN Type Propeller
Qty. – Diameter (mm) 2 – 560 2 – 630 2 – 700 2 – 700 3 – 700 3 – 700 4 – 700 4 – 700 4 – 700
Nominal CFM 8400 10000 15000 15000 22500 22500 30000 30000 30000
Motor kW – RPM 0.66–1010 0.86–1020 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–5–14
Total face area (Sq. ft.) 28 28 28 28 46.66 46.66 56 56 56
HIGH PRESSURE SWITCH Open (PSIG) 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10
Close (PSIG) 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10
LOW PRESSURE SWITCH Open (PSIG) 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5
Close (PSIG) 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5
REFRIGERANT LINES+ Suction line size (OD), inch 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8
Liquid line size (OD), inch 5/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 69/65/60 69/65/60 69.3/65.8/60.5 69.7/66.1/60.9 69.8/66.3/61 72.9/69.3/64.1 72.8/69.3/64 72.9/69.3/64.1 73.3/69.8/64.5
OPERATING WEIGHT, Kg. 800 925 980 1060 1325 1400 1525 1600 1675
NOTE:
* Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.
** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.
+ Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.
++ Based on free field area at ARI conditions. Tolerance: ±2dBA.

PHYSICAL DATA
MODEL NUMBER CNX720 CNX840 CNXM00 CNXM10 CNXM20 CNXM40 CNXM60 CNX2M00 CNX2M40
NOMINAL CAPACITY , TONS* 63 64 75 92 105 121 139 154 281
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Quadruple Quadruple Quadruple Quadruple Quadruple
COMPRESSOR Type Semi-hermetic reciprocating Screw
Oil per system (liters) 4.94 4.94 5.2 5.2 4.94 4.94 5.2 5.2 22
Refrigerant R-134a
Charge per system (oz)** 1125 1145 1350 1660 945 1090 1250 1390 2520
CONDENSER FAN Type Propeller
Qty. – Diameter (mm) 6 – 700 6 – 700 6 – 800 6 – 800 6 – 800 8 – 800 8 – 800 10 – 800 16 – 800
Nominal CFM 45000 45000 73266 73266 69000 93256 87032 108790 192048
Motor kW – RPM 1.45–1000 1.45–1000 2.15–970 2.15–970 2.15–970 2.15–970 2.15–970 2.15–970 2.15–970
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–4–14 3/8–5–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–3–14
Total face area (Sq. ft.) 70 70 120 120 120 140 140 175 304
HIGH PRESSURE SWITCH Open (PSIG) 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10
Close (PSIG) 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10
LOW PRESSURE SWITCH Open (PSIG) 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5
Close (PSIG) 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5
REFRIGERANT LINES+ Suction line size Dual 2-1/8 2-1/8 2-5/8 2-5/8 N.A. N.A. N.A. N.A. N.A.
(OD), inch
Quadruple N.A. N.A. N.A. N.A. 2-1/8 2-1/8 2-5/8 2-5/8 3-1/8
Liquid line size Dual 1-1/8 1-1/8 1-3/8 1-3/8 N.A. N.A. N.A. N.A. N.A.
(OD), inch
Quadruple N.A. N.A. N.A. N.A. 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 73.3/69.8/64.5 73.3/69.8/64.5 74.7/1.2/66 75.7/72.7/66.9 76.2/72.7/67.4 77.1/73.6/68.3 77.7/74.2/69 78.1/74.6/69.3 81.4/77.9/72.6
OPERATING WEIGHT, Kg. 2100 2600 3500 3700 4250 4700 5600 5095 8500
NOTE:
* Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.
** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.
+ Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.
++ Based on free field area at ARI conditions. Tolerance: ±2dBA.

ELECTRICAL DATA
SUPPLY VOLTAGE COMPRESSOR MOTOR CONDENSER FAN MOTORS
UNIT
SIZE Nominal RLA LRA FLA LRA
Min. Max. MCA MOCP Qty. kW Qty.
(V-Ph-Hz) (each) (each) (each) (each)
CNX 150 460-3-60 414 506 25.7 35 2 11.4 125 0.66 1.0 2.4 2
CNX 220 460-3-60 414 506 39.0 50 2 15.9 158 0.86 1.6 4.1 2
CNX 240 460-3-60 414 506 45.7 60 2 18.1 187 1.45 2.5 10.0 2
CNX 300 460-3-60 414 506 56.1 75 2 22.7 225 1.45 2.5 10.0 2
CNX 360 460-3-60 414 506 60.6 80 2 23.6 193 1.45 2.5 10.0 3
CNX 420 460-3-60 414 506 70.5 90 2 28.0 220 1.45 2.5 10.0 3
CNX 480 460-3-60 414 506 77.5 100 2 30.0 262 1.45 2.5 10.0 4
CNX 540 460-3-60 414 506 91.0 125 2 36.0 262 1.45 2.5 10.0 4
CNX 600 460-3-60 414 506 108.8 150 2 43.9 323 1.45 2.5 10.0 4
CNX 720 460-3-60 414 506 147.1 200 2 58.7 404 1.45 2.5 10.0 6
CNX 840 460-3-60 414 506 147.1 200 2 58.7 404 1.45 2.5 10.0 6
CNX M00 460-3-60 414 506 183.5 250 2 72.5 513 2.15 3.4 10.0 6
CNX M10 460-3-60 414 506 207.6 275 2 83.2 590 2.15 3.4 10.0 6
CNX M20 460-3-60 414 506 207.0 250 4 43.9 323 2.15 3.4 10.0 6
CNX M40 460-3-60 414 506 276.7 325 4 58.7 404 2.15 3.4 10.0 8
CNX M60 460-3-60 414 506 335.3 400 4 72.5 513 2.15 3.4 10.0 8
CNX 2M00 460-3-60 414 506 342.1 400 4 72.5 513 2.15 3.4 10.0 10
CNX 2M40 460-3-60 414 506 548.6 650 4 117.4 801 2.15 3.1 10.0 16
LEGEND:
MCA - Minimum Circuit Ampacity
MOCP - Maximum Over Current Protection
RLA - Rated Load Amps
LRA - Locked Rotor Amps
kW - Kilowatt
FLA - Full Load Amps

DIMENSIONS
CNX 150 - CNX 300
1
2
3
4
5
CNX 360 - CNX 420
1
2
3
4
5
7
1550 [61.0]
203 [8.0]
73 [2.875] "A" "B" "C"

2121 943 943
[83.50] [37.125] [37.125]
2197 2032
[86.50] [80.0]
NOTES: 1. All dimensions are in mm, (dimensions in brackets are in inches).

2. Allow 48" (1219 mm) clearance on all sides for proper airflow.

DIMENSIONS
CNX 480 - CNX 600
357.5 [14.07]
255.0 [10.00]
TYP
TYP
1550 [61.0]
203 [8.0]
2121
375.6 [14.80]
335.4 [13.20]
[83.50]
2197
[86.50]
CNX 720 - CNX 840
TOP VIEW
"B" "C"
73 [2.875] 965 968 968
(37.99") (38.11") (38.11")
FRONT VIEW SIDE VIEW


DIMENSIONS
CNX M00 - CNX M10

8
DIMENSIONS
CNX M20

9
DIMENSIONS
CNX M40
ELECTRIC POWER INLET

10
285.0 [11.220]
487.0 [19.173] TYP
670.5 [26.397] TYP
786.0 [30.944] TYP
917.0 [36.102] TYP

DIMENSIONS
CNX M60
ELECTRIC POWER INLET

11
285.0 [11.220]
487.0 [19.173] TYP
670.5 [26.397] TYP
786.0 [30.944] TYP
917.0 [36.102] TYP

DIMENSIONS
CNX 2M00

12
DIMENSIONS
CNX 2M40

2200 [86.614]
275 [10.826]
13
2185 [86.023]
285.0 [11.220]
487.0 [19.173] TYP
670.5 [26.397] TYP

786.0 [30.944] TYP
917.0 [36.102] TYP

MICROPROCESSOR CONTROL SYSTEM
Each condensing unit are provided with microprocessor based control board that monitors analog and digital inputs to
achieve precise control and safety functions during unit’s operation. Input signals for cooling control can be digital signals
coming from a thermostat device or analog signals from a PTC temperature sensor. The push button key board allows
accessing to the operating conditions, control set points (in case temperature control is analog signal), & alarm history
that are clearly displayed on a multi-line back illuminated LCD panel.
The unit’s controller consists of the following hardware:

1. User Interface Board – Includes push buttons to access operating conditions, change control set points, and
view alarm history. Data are clearly displayed on its LCD panel.
2. Main Board – This controls up to 2 compressor system.
3. Auxiliary Boards – Required for controlling an additional (2) or more compressors.
LCD Display Information:

In the normal operating mode, the 20 x 4 characters LCD panel displays the system status, temperature of leaving /
returning air and set point (if temperature control selected is through PTC sensors ), run time of compressor and alarm
history.
Measurement data for each circuit can be easily accessed and displayed on the LCD. Data include the following:
- Suction, Discharge, and Oil pressures
- Leaving / Returning Air temperature ( if temperature control selected is through PTC sensors )
- Compressor Motor Status
- Condenser Fan Motor Status
- Liquid Line Solenoid Status
- Supply Fan Motor Status
There are three LED lights on the user interface board to indicate “Power On” (green), “Menu Adjustment” (yellow) and
“Fault” (red).
SYSTEM PROTECTION
The unit is equipped with protective devices against motor overloads and proper system settings are factory set to ensure
safe and reliable operation of the unit. Some of these devices and settings are as follows:
- Compressor Motor External Overload Relay
- Compressor Motor Winding Over Temperature Protection
- Low suction Pressure
- High Discharge Pressure
- Low Oil Pressure
- Compressor Anti-Recycling Timer
14

USER SEQUENCE OF OPERATION
On/Off
SET Menu
CLASSIC
AIR CONDITIONERS
TOUT = 10°C TIN = 15°C
COOLING 75% Esc
Machine Starting:
- If OFF, the machine is started by pushing the ON/OFF button.
- The ON LED (green) will lit.
- On the main screen is showed the status “STARTING”.
- After 15 seconds of delay the system will be running.
Machine Shut-Down:
- The machine is halted pushing again the ON/OFF key.
- The ON LED (green) is switched off.
- On the main screen is showed the status “STOPPING”.
- All the compressors are stopped.
- Blower motor will be switched off after pre-set delay timing when all compressors are switched off.
- On the main screen is showed the status “SYSTEM OFF”.
Set Point Change:
- Press “SET”, the LCD will ask the password input.
- Using the “UP” and “DOWN” keys input the correct password.
- Press “SET”, the “MODIFY” word appears to allow the parameter to be changed. The LCD will show the actual
value.
- Using the “UP” and “DOWN” keys modify the set point value.
- Press “SET” to store it or “ESC” to exit without memorizing.
COMPRESSOR CONTROL
Control setting to switch on / off the compressors is through digital output signals from an external controller fed to the
micro-processor board. When the system is started up, the software starts to check all the necessary inputs to start the
unit. It scans the digital/analogue inputs. If any unwarranted interruption occurred the alarm signal is generated and the
compressor will be shut-off.
BLOWER MOTOR CONTROL (OPTIONAL)

Control setting to switch on / off the blower motor is through digital output signal from an external controller fed to the
micro-processor board. The system’s control will prevent the compressors to operate if this signal is not fed to the micro-
processor board.
15

SCHEMATIC WIRING DIAGRAM
POWER SUPPLY : 460-3-60 (Dual compressor units)
APPLICABLE ON MODELS: CNX150 - CNXM10
COMPRESSOR WITH CB CONNECTION
HVTB (OPTIONAL)
L1
HVTB
POWER SUPPLY L2 L1
(NOTE 4) L3 L2
L3
CB1 CB2
LUG/ETB
L1A
L2A
L3A
L1B
L2B
L3B
CC1 CC2
OLR1 OLR2 CC1 CC2
T1A
T2A
T3A
T1B
T2B
T3B
OLR1 OLR2
T1A
T2A
T3A
T1B
T2B
T3B
COMP COMP
1 2
COMP COMP
1 2
COMPRESSOR POWER & CONTROL CONNECTION IN PART WINDING STARTING (PWS) (AS APPLICABLE) COMPRESSOR IN PWS CONNECTION WITH CB (OPTIONAL)
HVTB HVTB
L1 L1
L2 L2
L3 L3
CB1 CB2
L1A
L2A
L3A
L1B
L2B
L3B
L1C
L2C
L3C
L1D
L2D
L3D
CC1 CC3 CC2 CC4 CC1 CC3 CC2 CC4
OLR1 OLR3 OLR2 OLR4 OLR1 OLR3 OLR2 OLR4

T1C
T2C
T3C
T1D
T2D
T3D
T1C
T2C
T3C
T1D
T2D
T3D
T1A
T2A
T3A
T1B
T2B
T3B
T1A
T2A
T3A
T1B
T2B
T3B
COMP COMP COMP COMP
2 2
1 2 1 2
MB MB
1O CC1 4O CC2
3A 3B
CC3 CC4
CC1A-2A 61A CC2A-2A 61B
CB1A-1A CB2A-1A
1 23A 1 23B
OLR1-1A 11A OLR3-1A OLR2-1A 11B OLR4-1A

10A 9A 10B 9B
CONDENSER FAN MOTOR POWER AND CONTROL CONNECTIONS COMP. SSPS CONNECTION(AS APPLICABLE)
CNX 360~420 COMP. 1: SSPS1
CNX 220~300 CNX 480~600
HVTB HVTB HVTB 3-FAN MOTOR LAYOUT HVTB HVTB 1 8A
L1 L2 L3 2-FAN MOTOR LAYOUT L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 4-FAN MOTOR LAYOUT M1/11 M2/14
C1 1
C1 C2 3 3 C1 1 2
1 2
CONTROL
PANEL C2 2
CONTROL
PANEL L1/MP/L L2/R/N
CONTROL 4 C2 2
PANEL
(REMOVE JP3A)
CB6 CB6 CB7 CB6 CB7 COMP. 2:
SSPS2
1 8B
M1/11 M2/14
2
104C
104C
104D
104A
104B
104A
103C
105C
104B
104A
103C
105C
104B
103D
105D
103A
105A
103B
105B
103A
105A
103B
105B
103A
105A
103B
105B
L1/MP/L L2/R/N
FMC1 FMC2 FMC1 FMC3 FMC2 FMC1 FMC3 FMC2 FMC4 (REMOVE JP4B)
(SEE NOTE 3)
35C
36C
37C
35C
36C
37C
35D
36D
37D
35B
36B
37B
35B
36B
37B
35B
36B
37B
35A
36A
37A
35A
36A
37A
35A
36A
37A
CRANKCASE HTR CONNECTION(AS APPLICABLE)

A. SEMI-HERMETIC RECIP. COMP.
FM1 FM2 FM1 FM3 FM2 FM1 FM3 FM2 FM4
1 C.HTR1 2
COMP. 1: CC1A-1B 100A
2 2 2
1 C.HTR2 2
FM1 FM1 FM1 COMP. 2: CC2A-1B 101A
TO MB T.K. TO MB T.K. TO MB T.K.
FMC1 12A FMC1 FMC1
12A 12A 13A 12A 13A
9 NO 9 NO 9 NO
FM2 FM3 FM3 B. SCROLL COMP.

T.K. FMC3 T.K. FMC3
T.K. FMC2 12C 13C 12C 13C
12B 13B 10 NO 10 NO L1 C.HTR1 L2
13 NO COMP. 1:
FM2 FM2
T.K. FMC2 T.K. FMC2
12B 13B 12B 13B
13 NO 13 NO
L2 C.HTR2 L3
COMP. 2:
FM4
T.K. FMC4
12D
14 NO
13D
OIL PRESSURE SWITCH CONN.(AS APPLICABLE)
COMP 1 3A OPS1 2
2 240
HVTB HVTB HVTB

1 64A
L1 L2 L3 L1 L2 L3 L1 L2 L3 OPS1-1
PRESSURE SETTINGS
DESC. CUT-OFF (PSIG) CUT-IN (PSIG) (REMOVE JP5A)
LOW PRESSURE -- -- COMP 2 OPS2
3B 2
CB6 CB7 CB8 2 240
HIGH PRESSURE -- --
HPS1 & 2 460 ± 10 360 ± 15 1 64B
OPS2-1
104C
104E
104A
105C
103E
105E
104F
105A
103C
104D
105F
103A
104B
105D
103F
105B
103D
HGS -- --
103B
(REMOVE JP5B)
FMC1 FMC3 FMC2 FMC4 FMC5 FMC6
JUMPER SETTINGS - MB BOARD AHU CONTROL INTER-CONNECTIONS
35C
36C
37C
35D
36D
37D
35A
36A
37A
35B
36B
37B
35E
36E
37E
35F
36F
37F
JU1 - CLOSED JU12 - CLOSED (1,2) (OPTIONAL)

FM1 FM3 FM2 FM4 FM5 FM6
JU2 - CLOSED JU13 - CLOSED (1,2) CONDENSING UNIT AIR HANDLING UNIT
CONTROL PANEL CONTROL PANEL
JU3 - CLOSED (1,2) JU15 - CLOSED (1,2)
JU4 - CLOSED (1,2) JU19 - CLOSED (1,2) LVTB
2
G
JU5 - CLOSED (1,2)
FM1 R1 (24Vac)
TO MB T.K. FMC1
ATB
12A 13A JU6 - CLOSED (1,2) TU1 - CLOSED 17
9 NO
FM5
JU7 - CLOSED (1,2) TU2 - CLOSED
T.K. FMC5
ATB R1-1
12E 13E JU8 - CLOSED (1,2) TL1 - OPEN 1
(AHU MOTOR CONTROL)
FM3 JU9 - CLOSED (1,2) TL2 - OPEN ATB
T.K. FMC3 67
12C TD1 - CLOSED
13C JU10 - CLOSED (1,2)
10 NO
JU11 - CLOSED (1,2) TD2 - CLOSED ATB
FM2 20
12B T.K.
13B
FMC2 DIP SWITCH SETTINGS - MB BOARD R2 (230Vac)
13 NO ATB
1 2 3 4
FM6
T.K. FMC6
S1 2
12F 13F ON OFF OFF OFF
R2-1
MOTOR STARTER CONTROL
FM4
T.K. FMC4 CNX 720~840 / CNXM00~20 UVM CONNECTION(OPTIONAL) AHU MOTOR ON/OFF
12D 13D SWITCHING CONTACT
14 NO 4-FAN MOTOR LAYOUT L1 L2 L3
ATB AHU MOTOR FAULT
CONTROL 5 C1 3 1 (N.C CONTACT)
PANEL
6 4 C2 2
1
(REMOVE JP7)
Ø
L1
Ø
L2
Ø
L3
ATB
UVM 52
1 UVM-1 8
Ø Ø
1A
(REMOVE JP1)
1
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
16

POWER SUPPLY : 460-3-60 (Dual compressor units)
APPLICABLE ON MODELS: CNX150 - CNXM10
TO ATB
1 LEGEND
SWITCHING CONTACTS
FROM THERMOSTAT OR DDC
2 AHU AIR HANDLING UNIT
TRANS1
(FIELD INSTALLATION)
LVTB
(75VA)
230V
ATB AUXILIARY TERMINAL BLOCK
ATB ATB
COM
R 15 24V 17 BMR BLOWER MOTOR RELAY
C
CC COMPRESSOR CONTACTOR
AHU MOTOR CONTROL
(OPTIONAL CONNECTION) CCA AUXILIARY CONTACT
G
STG1 COOLING YR1 CB CIRCUIT BREAKER
Y1
STG2 COOLING YR2
C. HTR CRANKCASE HEATER
Y2
COMP/C COMPRESSOR
F FUSE
TO HVTB TO HVTB FM FAN MOTOR (CONDENSER)
L1 L3
FMC FAN MOTOR CONTACTOR
F3 3
TRANS2
460V
4 F4 HPS HIGH PRESSURE SWITCH
230V
HVTB HIGH VOLTAGE TERMINAL BLOCK
ATB ATB
1
(UVM-1)
JP1 1A
S1
1B
F1
5 6
F2
2
JP JUMPER
TO ATB TO ATB L1 LINE 1
15 17
L2 LINE 2
L3 LINE 3
(SSPS1)
JP3A 8A A1 (SSPS-1)
24V AC PE
LUG LUG GROUND
(CB1A-1)
(OPS1-1)
JP4A 23A A2 (CB-1)
MB MOTHER BOARD
JP5A 64A A3 (OL-1)
HPS1
10A
OLR1-1A
9A A4 (HPS-1)
AO4
OLR OVER LOAD RELAY
P
(SSPS2)
A5 (FCB-1)
AO3 SSPS SOLID STATE PROTECTIVE SYSTEM
JP3B 8B A6 (SSPS-2)
(CB2A-1)
(OPS2-1)
JP4B 23B A7 (CB-2) TRANS TRANSFORMER
AO2
JP5B 64B A8 (OL-2)
HPS2
10B
OLR2-1A
9B A9 (HPS-2)
TK/TOP FAN MOTOR (PROTECTION) THERMAL CONTACT
AO1
P
A10 UL COMPRESSOR UNLOADER SOLENOID
JP6 67 A11 (FLOW SWITCH)
A12
UVM UNDER VOLTAGE MONITOR
A13 (EMERGENCY) YR COOLING RELAY
YR1-1A
YR2-1A
71A
71B
A14 (COOLING STAGE 1) ___ FIELD WIRING
A15 (COOLING STAGE 2)
A16 + DISCONNECT TAB - 1/4"

JP7 52 A17 (S. FAN MOTOR FAULT)
A18
SPLICE-CLOSED END
A19 (AUX. ALARM COMP1)
TERMINAL BLOCK OR TERMINATION POINT
AC (DIGITAL COM) JUNCTION OF WIRES
CROSSING OF WIRES, NO CONNECTION
R1(DIG OUT) CC1
1C 1O
PDS1
3A COMP1 CONTACTOR EARTHING/GROUND
2C R2(DIG OUT) 2O 15A COMP1 PUMP DOWN SOLENOID
(OPTIONAL)
UL1
R3(DIG OUT) 14A COMP1 CAPACITY UNLOADER SOLENOID
3C 3O
(OPTIONAL) NOTES
R4(DIG OUT) CC2
4C 4O
3B COMP2 CONTACTOR 1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
PDS2
5C R5(DIG OUT) 5O 15B COMP2 PUMP DOWN SOLENOID OR ITS EQUIVALENT.
(OPTIONAL)
UL2
R6(DIG OUT) 14B COMP2 CAPACITY UNLOADER SOLENOID
6C 6O
(OPTIONAL) 2. USE COPPER CONDUCTOR WIRES ONLY.
HGS
7C R7(DIG OUT) 7O HOT GAS BY-PASS SOLENOID
R8(DIG OUT)
(OPTIONAL)
3. COMPRESSORS ARE PROVIDED WITH INTERNAL
8C 8NO
COMMON FAULT INDICATION
LINE BREAK OR SSPS FOR THERMAL PROTECTION.
8NC (VOLT-FREE CONTACT)
C R9(DIG OUT) 9NO

4. FUSED DISCONNECT SWITCH OR CIRCUIT
R10(DIG OUT)
REFER FAN MOTOR CONTROL BREAKER TO BE PROVIDED BY END USER WITH
10NO CONNECTION (SYSTEM 1)
RATING AS RECOMMENDED BY ZAMIL.
R11(DIG OUT) 11NO
20 AHU MOTOR ON/OFF CONTROL
R12(DIG OUT) 12NO
(230Vac)
5. USE DISCONNECT TAB + OR SPLICE ONLY
R13(DIG OUT)
WHERE- EVER REQUIRED FOR EXTENSION OF
C 13NO
REFER FAN MOTOR CONTROL ORIGINAL WIRE.
R14(DIG OUT) 14NO CONNECTION (SYSTEM 2)
R15(DIG OUT) 15NO

6. POWER MUST BE SUPPLIED TO CRANKCASE
R16(DIG OUT)
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
16NO
SYSTEM START UP.
17C R17(DIG OUT) 17NO IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
18C R18(DIG OUT) 18NO
HEATER MUST BE ON FOR 12 HOURS BEFORE
OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS MAY
28A SPT1 RESULT IN COMPRESSOR DAMAGE.
S1
- - COMP1
ST1 29A SUCTION PRESSURE TRANSDUCER
(A5-SP1) +
+
SH
SH SH
30A DPT1
T.OUT
D1 - -
(A6-DP1)
COMP1
31A DISCHARGE PRESSURE TRANSDUCER
+ +
SH SH
32A OPT1
ST2
O1 - - COMP1
(A1-ST1)
(A7-OP1) 33A OIL PRESSURE TRANSDUCER
+ + (FOR RECIP. COMP ONLY)
SH SH
SH
28B SPT2
S2 - - COMP2
TIN (A8-SP2) 29B SUCTION PRESSURE TRANSDUCER
+ +
SH
30B DPT2
D2 - - COMP2
USER INTERFACE BOARD (A9-DP2) 31B
+ + DISCHARGE PRESSURE TRANSDUCER
SH
SH
On/Off * S1 32B OPT2
ON DIP O2 - - COMP2
SERIAL CABLE (A10-OP2) 33B OIL PRESSURE TRANSDUCER
SET MENU * + + (FOR RECIP. COMP ONLY)
TOUT=15°C TIN=28°C 1 2 3 4 SH
COOLING 75%
COM1
ESC * GND
17

POWER SUPPLY : 460-3-60 (Four compressor units)
APPLICABLE ON MODELS: CNXM20 - CNXM60
COMPRESSOR POWER & CONTROL CONNECTION
HVTB / BUSBAR
L1
POWER SUPPLY L2
(NOTE 4) L3
CC1 CC2 CC3 CC4
OLR1 OLR2 OLR3 OLR4
T1C
T2C
T3C
T1D
T2D
T3D
T1A
T2A
T3A
T1B
T2B
T3B
COMP COMP COMP COMP
1 2
3 4
2 2 2 2
MB MB AB AB
1O CC1 4O CC2 1O CC3 4O CC4

3A 3B 3C 3D
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS - 6 FANS / CNXM20
FAN LAYOUT
COMP1 COMP2
CONTROL PANEL FAN1 FAN3 FAN5

FAN2 FAN4 FAN6
COMP3 COMP4
TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR

L1 L2 L3 L1 L2 L3 L1 L2 L3
CB17 CB18 CB19

104C
104D
105C
105D
104A
104E
104B
103C
103D
105A
105E
105B
104F
103A
103E
103B
105F
103F
FMC1 FMC3 FMC5 FMC2 FMC4 FMC6

35C
36C
37C
35D
36D
37D
35B
36B
37B
35A
36A
37A
35E
36E
37E
35F
36F
37F
FM1 FM3 FM5 FM2 FM4 FM6
2 2
FM3
T.K. FMC3 FM4
TO MB TO AB T.K.
12C 13C FMC4
12D 13D
9 NO 9 NO
FM1 FM2
T.K. FMC1 T.K.
12A 13A FMC2
12B 13B
10 NO 10 NO
13 NO 13 NO
FM6
T.K. FMC5 T.K. FMC6
12E 13E 12F 12F 13F
14 NO 14 NO
AHU CONTROL INTER-CONNECTIONS PRESSURE SETTINGS JUMPER SETTINGS - MB BOARD

(OPTIONAL) DESC. OPEN (PSIG) CLOSE (PSIG) JU1 - CLOSED TU1 - OPEN
CONDENSING UNIT AIR HANDLING UNIT LOW PRESSURE 10 ± 5 30 ± 5 JU2 - CLOSED TD1 - OPEN
CONTROL PANEL CONTROL PANEL
HIGH PRESSURE 300 -- TL1 - OPEN
LVTB
G
HPS1 ~4 350 ± 10 300 ± 15 DIP SWITCH SETTINGS - MB1 BOARD
BMR (24Vac) FAN MOTOR # OFF (PSIG) ON (PSIG) 1 2 3 4
ATB S1
17 125 175 ON OFF OFF OFF
FM1,2,5,6
ATB BMR-1A FM3,4 175 225 JUMPER SETTINGS - MB BOARD
1
JU1 - OPEN TU1 - OPEN
(REMOVE JP6) (AHU MOTOR CONTROL)
ATB TD1 - OPEN
JU2 - OPEN
67
TL1 - OPEN
ATB
20 DIP SWITCH SETTINGS - AB BOARD
R2 (230Vac) 1 2 3 4
ATB S1
2 OFF ON OFF OFF
R2-1
MOTOR STARTER CONTROL JUMPER SETTINGS (COMMON)
AHU MOTOR ON/OFF JU3 - CLOSED (1,2) JU11 - CLOSED (1,2)
SWITCHING CONTACT
ATB AHU MOTOR FAULT JU5 - CLOSED (1,2) JU13 - CLOSED (1,2)
(N.C CONTACT)
1
(REMOVE JP7)
ATB
52
JU9 - CLOSED (1,2) TD2 - CLOSED

JU10 - CLOSED (1,2) TL2 - OPEN
18

TO HVTB TO HVTB
L1 L3
F3 TRANS2 F4
3 4
460V
230V
ATB
S1 F1 F2
5 6
1A 1B 2
C.HTR1
CC1A-1B 100A
UVM CONNECTION (OPTIONAL)
C.HTR2
L1 L2 L3 CC2A-1B 100B
C.HTR3
CC5A-1B 100C
Ø Ø Ø CC6A-1B 100D
C.HTR4
L1 L2 L3 UVM
1 UVM-1 8
Ø Ø SSPS1
1A
(REMOVE JP1) SSPS2
1
SSPS3
ATB (UVM-1) SSPS4

1 JP1
TO ATB TO ATB
15 17
SSPS1 24V AC PE
8A A1 (SSPS-1)
(CB1A-1)
JP4A 23A A2 (CB-1)
JP5A 64A A3 (OL-1)

HPS1 OLR1-1A AO4
10A 9A A4 (HPS-1)
P
A5 (FCB-1)
SSPS2 AO3
8B A6 (SSPS-2)
(CB2A-1)
JP4B 23B A7 (CB-2)
AO2
JP5B 64B A8 (OL-2)
HPS2 OLR2-1A
10B 9B A9 (HPS-2)
P AO1
A10
A12 (EXTERNAL ENABLE)
A13 (EMERGENCY)
YR1-1A 71A
YR2-1A 71B
A16
A18

AC (DIGITAL COM)
1C R1(DIG OUT) 1O COMP1 CONTACTOR

3A (SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS1
2C R2(DIG OUT) 2O 15A COMP1 PUMP DOWN SOLENOID
UL1
3C R3(DIG OUT) 3O 14A COMP1 CAPACITY UNLOADER SOLENOID
(50% UNLOADER SOLENOID)

3B (SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS2
5C R5(DIG OUT) 5O 15B COMP2 PUMP DOWN SOLENOID
UL2
6C R6(DIG OUT) 6O 14B COMP2 CAPACITY UNLOADER SOLENOID
7C R7(DIG OUT) 7O
8C R8(DIG OUT) 8NO

C R9(DIG OUT) 9NO

REFER FAN MOTOR CONTROL
CONNECTION (SYSTEM 1)
R10(DIG OUT) 10NO (SHEET 1 OF 3)
R11(DIG OUT) 11NO

(230Vac)
R12(DIG OUT) 12NO
C R13(DIG OUT) 13NO

(SHEET 1 OF 3)
R15(DIG OUT) 15NO
R16(DIG OUT) 16NO
28A SPT1
S1
- - COMP1
(A5-SP1) + +
SH
SH SH
30A DPT1
T.OUT
D1 - -
(A6-DP1)
COMP1
31A DISCHARGE PRESSURE TRANSDUCER
+ +
SH
SH
32A OPT1
O1 - -
ST2
(A7-OP1)
COMP1
(A1-ST1) 33A OIL PRESSURE TRANSDUCER
+ +
SH SH
SH
28B SPT2
S2 - - COMP2
TIN (A8-SP2) 29B SUCTION PRESSURE TRANSDUCER
+ +
SH
30B DPT2
D2 - - COMP2
USER INTERFACE BOARD (A9-DP2) 31B
SH
SH
On/Off * S1 32B OPT2
ON DIP O2 - - COMP2
SERIAL CABLE (A10-OP2) 33B OIL PRESSURE TRANSDUCER
SET MENU * + +
TOUT=15°C TIN=28°C 1 2 3 4 SH
COOLING 75%
COM1
ESC * GND
19

TO ATB
2
LEGEND
1
SWITCHING CONTACTS
FROM THERMOSTAT OR DDC TRANS1
AHU AIR HANDLING UNIT
(FIELD INSTALLATION) (75VA)
LVTB 230V ATB AUXILIARY TERMINAL BLOCK
ATB ATB
COM
R 15 24V 17 BMR BLOWER MOTOR RELAY
C
CC COMPRESSOR CONTACTOR
AHU MOTOR CONTROL
(OPTIONAL CONNECTION) (OPTIONAL CONNECTION)
BMR CCA AUXILIARY CONTACT
G
STG1 COOLING YR1 CB CIRCUIT BREAKER
Y1
STG2 COOLING YR2
C. HTR CRANKCASE HEATER
STG3 COOLING
Y2
COMP/C COMPRESSOR
YR3
Y3 F FUSE
STG4 COOLING YR4
Y4 FM FAN MOTOR (CONDENSER)
HPS HIGH PRESSURE SWITCH
ATB
HVTB HIGH VOLTAGE TERMINAL BLOCK
2
JP JUMPER
ATB
TO ATB TO ATB
L1 LINE 1
1
15 17 L2 LINE 2
L3 LINE 3
SSPS3 24V AC PE LUG LUG GROUND
8C A1 (SSPS-3)
(CB3A-1)
JP4C 23C A2 (CB-3) MB MOTHER BOARD
JP5C
HPS3 OLR3-1A
64C A3 (OL-3)
AO4 OLR OVER LOAD RELAY
10C 9C A4 (HPS-3)
P
SSPS4
A5
AO3
SSPS SOLID STATE PROTECTIVE SYSTEM
8D A6 (SSPS-4)
(CB4A-1)
JP4D 23D A7 (CB-4)
TRANS TRANSFORMER
HPS4
JP5D
OLR4-1A
64D A8 (OL-4)
AO2
TK/TOP FAN MOTOR (PROTECTION) THERMAL CONTACT
10D 9D A9 (HPS-4)
P
A10
AO1 UL COMPRESSOR UNLOADER SOLENOID
A11 UVM UNDER VOLTAGE MONITOR
A12
A13
YR COOLING RELAY
YR3-1A 71C
___ FIELD WIRING
YR4-1A 71D
A16
+ DISCONNECT TAB - 1/4"
A17 SPLICE-CLOSED END
A18

A20 (AUX. ALARM COMP4) JUNCTION OF WIRES
AC (DIGITAL COM)
EARTHING/GROUND
3C (SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS3
2C R2(DIG OUT) 2O 15C
COMP3 PUMP DOWN SOLENOID
3C R3(DIG OUT) 3O 14C

UL3
COMP3 CAPACITY UNLOADER SOLENOID
NOTES
R4(DIG OUT)
1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
4C 4O COMP4 CONTACTOR
3D
PDS4
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3) OR ITS EQUIVALENT.
5C R5(DIG OUT) 5O 15D COMP4 PUMP DOWN SOLENOID
R6(DIG OUT) 14D

UL4 2. USE COPPER CONDUCTOR WIRES ONLY.
6C 6O COMP4 CAPACITY UNLOADER SOLENOID
7C R7(DIG OUT) 7O 3. COMPRESSORS ARE PROVIDED WITH INTERNAL

R8(DIG OUT)
8C 8NO
8NC (VOLT-FREE CONTACT) 4. FUSED DISCONNECT SWITCH OR CIRCUIT
C R9(DIG OUT) 9NO REFER FAN MOTOR CONTROL BREAKER TO BE PROVIDED BY END USER WITH
R10(DIG OUT)
(SHEET 1 OF 3)
RATING AS RECOMMENDED BY ZAMIL.
10NO
R11(DIG OUT) 11NO 5. USE DISCONNECT TAB + OR SPLICE ONLY

R12(DIG OUT) 12NO
ORIGINAL WIRE.
C R13(DIG OUT) 13NO
R14(DIG OUT) 14NO
(SHEET 1 OF 3)
R15(DIG OUT)
15NO
SYSTEM START UP.
R16(DIG OUT) 16NO IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
17C R17(DIG OUT) 17NO HEATER MUST BE ON FOR 12 HOURS BEFORE
R18(DIG OUT)
18C 18NO
RESULT IN COMPRESSOR DAMAGE.
28C SPT3
S1
- - COMP3
ST1 29C SUCTION PRESSURE TRANSDUCER
(A5-SP1) + +
SH
SH SH
30C DPT3
T.OUT
D1 - -
(A6-DP1)
COMP3
31C
+ DISCHARGE PRESSURE TRANSDUCER
+
SH
SH
32C OPT3
O1 - -
ST2
(A7-OP1)
COMP3
(A1-ST1) 33C
+ OIL PRESSURE TRANSDUCER
+
SH SH
SH
28D SPT4
S2 - - COMP4
TIN
(A8-SP2) 29D SUCTION PRESSURE TRANSDUCER
+ +
SH
30D DPT4
D2 - - COMP4
(A9-DP2) 31D
SH
SH
S1 32D OPT4
TO MASTER BOARD MB ON DIP O2 - - COMP4
SERIAL CABLE (A10-OP2) 33D
+ OIL PRESSURE TRANSDUCER
X53 1 2 3 4 +
SH
X52
GND
20

APPLICABLE ON MODELS: CNX2M00 - CNX2M40
COMPRESSOR POWER & CONTROL CONNECTION IN PART WINDING STARTING (PWS)
HVTB / BUSBAR
L1
POWER SUPPLY L2
(NOTE 4) L3
CC1 CC3 CC2 CC4 CC5 CC7 CC6 CC8
OLR1 OLR3 OLR2 OLR4 OLR5 OLR7 OLR6 OLR8
T1G
T2G
T3G
T1C
T2C
T3C
T1D
T2D
T3D
T1H
T2H
T3H
T1A
T2A
T3A
T1B
T2B
T3B
T1E
T2E
T3E
T1F
T2F
T3F
COMP COMP COMP COMP
2 2 2 2
1 2 3 4
MB MB AB AB
1O CC1 4O CC2 1O CC5 4O CC6

3A 3B 3C 3D
CC1A-2A CC3 CC2A-2A CC4 CC5A-2A CC7 CC6A-2A CC8

61A 61B 61C 61D
OLR1-1A 11A OLR3-1A OLR2-1A 11B OLR4-1A OLR5-1A 11C OLR7-1A OLR6-1A 11D OLR8-1A
10A 9A 10B 9B 10C 9C 10D 9D
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS - 16 FANS / CNX2M40
FAN LAYOUT
COMP1 COMP3
CONTROL PANEL FAN1 FAN3 FAN5 FAN7 FAN9 FAN11 FAN13 FAN15
FAN2 FAN4 FAN6 FAN8 FAN10 FAN12 FAN14 FAN16
COMP2 COMP4
TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR TO HVTB/BUSBAR

L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3
CB17 CB18 CB19 CB20 CB21 CB22 CB23 CB24
104N
105N
104P
103N
105P
104M
103P
104L
105M
104G
104O
105L
104J
103M
105G
105O
104C
103L
105J
103G
103O
105C
104A
104E
103J
103C
104D
104H
105A
105E
103D
105D
103H
105H
103A
103E
104B
104K
103B
105B
103K
105K
104F
105F
103F
104I
105I
103I
FMC1 FMC5 FMC3 FMC7 FMC2 FMC6 FMC4 FMC8 FMC9 FMC13 FMC11 FMC15 FMC10 FMC14 FMC12 FMC16
35M
36M
37M
35G
36G
37G
35O
36O
37O
35C
36C
37C
35D
36D
37D
35H
36H
37H
35N
36N
37N
35A
36A
37A
35E
36E
37E
35B
36B
37B
35K
36K
37K
35P
36P
37P
35F
36F
37F
35L
36L
37L
35J
36J
37J
35I
36I
37I
FM1 FM5 FM3 FM7 FM2 FM6 FM4 FM8 FM9 FM13 FM11 FM15 FM10 FM14 FM12 FM16
2 2 2 2
FM1 FM2 FM9 FM10
TO MB T.K. TO MB T.K. TO AB T.K. AB T.K.
FMC1 FMC2 FMC9 FMC10
12A 12A 13A 12B 12B 13B 12I 12I 13I 12J 12J 13J
9 NO 13 NO 9 NO 13 NO
FM5 FM6 FM13 FM14
T.K. FMC5 T.K. FMC6 T.K. FMC13 T.K. FMC14
12E 13E 12F 13F 12M 13M 12N 13N
FM3 FM4 FM11 FM12

12C 12C 13C 12D 12D 13D 12K 12K 13K 12L 12L 13L
10 NO 14 NO 10 NO 14 NO
FM7 FM8 FM15 FM16
12G 13G 12H 13H 12O 13O 12P 13P
PRESSURE SETTINGS JUMPER SETTINGS - MB BOARD

AHU CONTROL INTER-CONNECTIONS
(OPTIONAL) DESC. OPEN (PSIG) CLOSE (PSIG) JU1 - CLOSED TU1 - OPEN
LOW PRESSURE 10 ± 5 30 ± 5 JU2 - CLOSED TD1 - OPEN
CONDENSING UNIT AIR HANDLING UNIT
CONTROL PANEL CONTROL PANEL HIGH PRESSURE 300 -- TL1 - OPEN
LVTB HPS1 & 2 350 ± 10 300 ± 15 DIP SWITCH SETTINGS - MB BOARD
G
FAN MOTOR # OFF (PSIG) ON (PSIG) 1 2 3 4
BMR (24Vac) S1
ATB
FM1,5,2,6,9,13,10,14 125 175 ON OFF OFF OFF
17
ATB BMR-1A FM3,7,4,8,11,15,12,16 175 225 JUMPER SETTINGS - AB BOARD

1 JU1 - OPEN TU1 - OPEN
(REMOVE JP6) (AHU MOTOR CONTROL)
ATB JU2 - OPEN TD1 - OPEN
67
TL1 - OPEN
ATB DIP SWITCH SETTINGS - AB BOARD
20
R2 (230Vac) 1 2 3 4
ATB S1
2 OFF ON OFF OFF
R2-1 JUMPER SETTINGS (COMMON)

MOTOR STARTER CONTROL
AHU MOTOR ON/OFF JU3 - CLOSED (1,2) JU11 - CLOSED (1,2)
SWITCHING CONTACT
ATB AHU MOTOR FAULT
(N.C CONTACT) JU5 - CLOSED (1,2) JU13 - CLOSED (1,2)
1
(REMOVE JP7)
ATB
52 JU7 - CLOSED (1,2) JU19 - CLOSED (1,2)
JU9 - CLOSED (1,2) TD2 - CLOSED

JU10 - CLOSED (1,2) TL2 - OPEN
21

TO HVTB TO HVTB
L1 L3
F3 TRANS2 F4
3 4
460V
230V
S1 F1 F2 ATB
5 6
1A 1B 2
C.HTR1
CC1A-1B 100A
UVM CONNECTION (OPTIONAL)
C.HTR2
L1 L2 L3 CC2A-1B 100B
CC5A-1B
C.HTR3
100C
Ø
L1
Ø
L2
Ø
L3 CC6A-1B 100D
C.HTR4
UVM
1 UVM-1 8
Ø Ø SSPS1
1A
(REMOVE JP1) SSPS2
1
SSPS3
ATB (UVM-1) SSPS4

JP1
1
TO ATB TO ATB
15 17
SSPS1 24V AC PE
8A A1 (SSPS-1)
(CB1A-1)
JP4A 23A A2 (CB-1)
JP5A 64A A3 (OL-1)

HPS1 OLR1-1A 11A OLR3-1A AO4
10A 9A A4 (HPS-1)
P
A5 (FCB-1)
SSPS2 AO3
8B A6 (SSPS-2)
(CB2A-1)
JP4B 23B A7 (CB-2)
AO2
JP5B 64B A8 (OL-2)
HPS2 OLR2-1A 11B OLR4-1A
10B 9B A9 (HPS-2)
P AO1
A10
A12 (EXTERNAL ENABLE)
A13 (EMERGENCY)
YR1-1A 71A A14 (COOLING STAGE 1)
YR2-1A 71B A15 (COOLING STAGE 2)
A16
A18

AC (DIGITAL COM)

3A (SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS1
2C R2(DIG OUT) 2O COMP1 PUMP DOWN SOLENOID
UL1-2
R3(DIG OUT) 14A

3B (SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
PDS2
UL2-2
6C R6(DIG OUT) 6O 14B COMP2 CAPACITY UNLOADER SOLENOID
UL1-4
7C R7(DIG OUT) 7O 15A CC1-1A 16A
15B CC2-1A
8C R8(DIG OUT) 8NO UL2-4
16B
C R9(DIG OUT) 9NO

(SHEET 1 OF 3)
R11(DIG OUT) 11NO
(230Vac)
R12(DIG OUT) 12NO
C R13(DIG OUT) 13NO

(SHEET 1 OF 3)
R15(DIG OUT) 15NO
R16(DIG OUT) 16NO
28A SPT1
S1
- - COMP1
(A5-SP1) +
+
SH
SH SH
(OPTIONAL) 24 30A DPT1
D1 - -
LEAVING AIR TEMP. SENSOR T.OUT COMP1
25 (A6-DP1) 31A
(PTC : -10 ~ +50 C) + DISCHARGE PRESSURE TRANSDUCER
+
SH SH
SH
ST2
O1 -
(A7-OP1)
(A1-ST1) +
SH
(OPTIONAL) SH
26 28B SPT2
RETURNING AIR TEMP. SENSOR S2 - - COMP2
27 TIN
(PTC : -10 ~ +50 C) (A8-SP2) 29B SUCTION PRESSURE TRANSDUCER
SH
+ +
SH
30B DPT2
D2 - - COMP2
(A9-DP2)
USER INTERFACE BOARD +
31B
SH
SH
On/Off * S1
ON DIP O2 -
SERIAL CABLE (A10-OP2)
SET MENU * +
TOUT=15°C TIN=28°C 1 2 3 4
COOLING 75%
COM1
ESC * GND
22

TO ATB
2
LEGEND
SWITCHING CONTACTS 1
FROM THERMOSTAT OR DDC
(FIELD INSTALLATION)
TRANS1
(75VA)
AHU AIR HANDLING UNIT
LVTB
ATB
230V
ATB ATB AUXILIARY TERMINAL BLOCK
COM
R 15 24V 17
BMR BLOWER MOTOR RELAY
C CC COMPRESSOR CONTACTOR
AHU MOTOR CONTROL BMR
(OPTIONAL CONNECTION)
G
(OPTIONAL CONNECTION)
CCA AUXILIARY CONTACT
STG1 COOLING YR1
Y1
CB CIRCUIT BREAKER
STG2 COOLING YR2 C. HTR CRANKCASE HEATER
Y2
STG3 COOLING YR3 COMP/C COMPRESSOR
Y3
STG4 COOLING YR4 F FUSE
Y4
FM FAN MOTOR (CONDENSER)
ATB
HPS HIGH PRESSURE SWITCH
2 HVTB HIGH VOLTAGE TERMINAL BLOCK
JP JUMPER
ATB
1
TO ATB TO ATB
L1 LINE 1
15 17
L2 LINE 2
L3 LINE 3
SSPS3 24V AC PE
8C
(CB3A-1)
A1 (SSPS-3) LUG LUG GROUND
JP4C 23C A2 (CB-3)
JP5C 64C A3 (OL-3) MB MOTHER BOARD

HPS3 OLR5-1A OLR7-1A AO4
P
10C 9C A4 (HPS-3)
OLR OVER LOAD RELAY
A5
SSPS4
8D
(CB4A-1)
A6 (SSPS-4)
AO3
SSPS SOLID STATE PROTECTIVE SYSTEM
JP4D 23D A7 (CB-4)
AO2 TRANS TRANSFORMER
JP5D 64D A8 (OL-4)
HPS4
10D
OLR6-1A OLR8-1A
9D A9 (HPS-4) TK/TOP FAN MOTOR (PROTECTION) THERMAL CONTACT
P AO1
A10
A11
UL COMPRESSOR UNLOADER SOLENOID
A12 UVM UNDER VOLTAGE MONITOR
A13
YR3-1A 71C
YR COOLING RELAY
YR4-1A 71D

___ FIELD WIRING
A16
A17
+ DISCONNECT TAB - 1/4"
A18 SPLICE-CLOSED END

AC (DIGITAL COM)
JUNCTION OF WIRES
3C
PDS3
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)
EARTHING/GROUND
UL3-2
R3(DIG OUT) 14C
(50% UNLOADER SOLENOID) NOTES
3D
PDS4
(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3) 1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C
5C R5(DIG OUT) 5O COMP4 PUMP DOWN SOLENOID OR ITS EQUIVALENT.
UL4-2
6C R6(DIG OUT) 6O 14D COMP4 CAPACITY UNLOADER SOLENOID
UL3-4
(50% UNLOADER SOLENOID) 2. USE COPPER CONDUCTOR WIRES ONLY.
7C R7(DIG OUT) 7O 15C CC5-1A 16C
8C R8(DIG OUT) 8NO

15D CC6-1A
UL4-4
3. COMPRESSORS ARE PROVIDED WITH INTERNAL
16D
8NC COMMON FAULT INDICATION
(VOLT-FREE CONTACT)
C R9(DIG OUT) 9NO 4. FUSED DISCONNECT SWITCH OR CIRCUIT
R10(DIG OUT)
BREAKER TO BE PROVIDED BY END USER WITH
10NO
(SHEET 1 OF 3) RATING AS RECOMMENDED BY ZAMIL.
R11(DIG OUT) 11NO
R12(DIG OUT) 12NO 5. USE DISCONNECT TAB + OR SPLICE ONLY

R13(DIG OUT)
C 13NO
REFER FAN MOTOR CONTROL ORIGINAL WIRE.
(SHEET 1 OF 3)
R15(DIG OUT) 15NO
R16(DIG OUT)
16NO
SYSTEM START UP.
17C R17(DIG OUT) 17NO IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE
18C R18(DIG OUT) 18NO HEATER MUST BE ON FOR 12 HOURS BEFORE
28C SPT3 RESULT IN COMPRESSOR DAMAGE.
S1
- - COMP3
ST1 29C SUCTION PRESSURE TRANSDUCER
(A5-SP1) +
+
SH
SH SH
30C DPT3
D1 - -
T.OUT COMP3
(A6-DP1) 31C
+
SH SH
O1 -
ST2
(A7-OP1)
(A1-ST1) +
SH
SH
28D SPT4
S2 - - COMP4
TIN
(A8-SP2) 29D SUCTION PRESSURE TRANSDUCER
+ +
SH
30D DPT4
D2 - - COMP4
(A9-DP2) 31D
SH
SH
S1
ON DIP O2 -
TO MASTER BOARD MB
SERIAL CABLE (A10-OP2)
X53 +
1 2 3 4
X52
GND
23

TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS
17
1
(REMOVE JP6)
67
20
1
(REMOVE JP7) (REMOVE JP7)
52
24

RIGGING INSTRUCTIONS
ATTENTION TO RIGGERS
Hook rigging sling thru holes in base rail, as shown below.
Holes in base rail are centered around the unit center of gravity.
Center of gravity is not unit center line.
Ensure center of gravity aligns with the main lifting point before lifting.
Use spreader bar when rigging, to prevent the slings from damaging the unit.
CAUTION
All panels should be in place when rigging.
Care must be taken to avoid damage to the coils during handling.
Insert packing material between coils & slings as necessary.
MODELS: CNX150 - CNX840
MODELS: CNXM00 - CNX2M00
MODELS: CNX2M40
25

LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)
MODEL No. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
CNX150 200 200 200 200 - - - - - -
CNX220 231 231 231 231 - - - - - -
CNX240 245 245 245 245 - - - - - -
CNX300 265 265 265 265 - -
CNX360 228 228 232 232 204 204 - - - -
CNX420 240 240 244 244 216 216 - - - -
CNX480 233 233 273 273 258 258 - - - -
CNX540 245 245 285 285 270 270 - -
CNX600 258 258 298 298 282 282 - - - -
CNX720 272 272 303 303 276 276 199 199 - -
CNX840 272 272 303 303 276 276 199 199 - -
CNXM00 655 486 540 600 - - - - - -
CNXM10 675 508 560 620 - - - - - -
CNXM20 807 641 692 752 - - - - - -
CNXM40 558 558 533 533 523 523
CNXM60 674 674 649 649 639 639
CNX2M00 591 591 536 536 531 531 526 526
CNX2M40 822 822 742 742 737 737 732 732 727 727
LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)

MODEL No. R1 R2 R3 R4 R5 R6 R7 R8 R9 R10
CNX150 225 225 225 225 - - - - - -
CNX220 256 256 256 256 - - - - - -
CNX240 270 270 270 270 - - - - - -
CNX300 290 290 290 290 - -
CNX360 253 253 257 257 229 229 - - - -
CNX420 268 268 272 272 244 244 - - - -
CNX480 266 266 306 306 291 291 - - - -
CNX540 278 278 318 318 303 303 - -
CNX600 295 295 335 335 319 319 - - - -
CNX720 304 304 335 335 308 308 232 232 - -
CNX840 304 304 335 335 308 308 232 232 - -
CNXM00 721 552 606 666 - - - - - -
CNXM10 741 574 626 686 - - - - - -
CNXM20 903 737 788 848 - - - - - -
CNXM40 609 609 584 584 574 574
CNXM60 749 749 724 724 714 714
CNX2M00 661 661 606 606 601 601 596 596
CNX2M40 888 888 808 808 803 803 798 798 793 793
R1 R2 R1 R3 R5 R1 R3 R5 R7 R1 R3 R5 R7 R9
R3 R4 R2 R4 R6 R2 R4 R6 R8 R2 R4 R6 R8 R10
26

INSTALLATION INSTRUCTIONS
GENERAL
The complete shipment should be inspected for damage. Any damage visible at the time of delivery should be noted on
the shipment invoice.
These units are shipped completely assembled and wired. Units require interconnecting piping (AHU), external power,
thermostat wiring, condensate drain piping and ducting as applicable.
Size of unit for an installation should be based on a heat load calculation made according to applicable standards. Units
must also be installed in accordance with regulations of the "National Fire Protection Association" and local electrical
codes. Where local regulations vary with instruction furnished, installer should adhere to local standards.
Prepare your concrete pad or steel stand as applicable. Remove shipping protective covers and wooden crating and lift
unit from base and place in position with necessary applicable vibration isolators.
Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Make
sure that no air & moisture enter the system as easter oil are hygroscopic in nature.
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions
and other Zamil publications for the specific equipment being installed.
These units are charged with ozone friendly R-134a refrigerant.
LOCATION OF UNIT
When selecting the location for the unit, the following points should be kept in mind:
1. Provisions for a concrete slab which will allow for minimum clearance from building or structures
2. That the terrain allows for drainage away from the unit.
3. If the unit is to be roof mounted, inspect the roof for load bearing capacity. The roof should have sufficient structural
strength to carry the weight of the unit.
4. Availability of electric power.
5. Position the unit to provide for unrestricted air circulation and to prevent any possibility of air recirculation.
6. Check minimum clearances required for your unit, with regard to walls, or other obstructions.
7. Air cooled equipment should not be installed under low structural overhangs which can cause condenser air 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.
Outdoor unit connected to matching Zamil indoor unit:

Outdoor unit contain adequate system refrigerant charge for operating with matched indoor unit (as per corresponding
cooling capacity table) and when connected with up to 25 feet (7.62 m) of field-supplied piping.
Sweat connection:
Units are provided with service valves and are ready for brazing. After wrapping the service valve with a wet cloth, the
piping set can be brazed to service valve using either silver rod or silfos rod brazing materials.
LEAK TESTING & REFRIGERANT CHARGING

Leak test:
Leak can occur from joints or fittings that are improperly brazed/connected during installation of indoor and outdoor units.
The installer should leak test the indoor unit & associated field supplied refrigerant piping, then the outdoor unit, each
separately using electronic freon detector and/or soap bubbles.
Refrigerant Charging:
(To be used for system having a holding charge and to compensate for length of liquid line).
1. When system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging lines and manifolds
must be purged with refrigerant vapor prior to admitting refrigerant into the system to prevent contamination system
with non-condensable.
27

2. It is important to first determine the amount of refrigerant required for the system, the unit nameplate normally identify
the weight of the refrigerant required.
3. The refrigerant should be added in small amounts allowing sufficient time for the unit pressure to equalize each time.
WIRING
All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltage,
frequency and phase must coincide with the unit nameplate.
Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate. The unit
wiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wiring.
The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused disconnect
switch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone wire for this
purpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety & servicing purposes.
Wiring connection to the unit must have insulation suitable for temperatures of a minimum of 600C.
Minimum circuit ampacity for each model is shown on the name plate and product catalog. Equipment wiring diagram
should be examined and thoroughly understood before field wiring connections are made.
Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damage to
compressors and motors can occur, if improper voltage is applied.
START-UP INSPECTION & CHECK LIST

After the installation is completed in all respect, the following points should be covered before the system is switched on for operation.
1. Remove or loosen shipping retainers under motor compressors. Make sure the hold down nuts on spring mounted
compressors are not touching the compressor feet.
2. Make sure all electrical fasteners/connections are tight and clean.
3. All controls are set according to manufacturer's instructions (low & high pressure switch, pump down pressure switch,
fan cycling switch, etc...)
4. Make sure all valves are open (compressor suction & discharge service valves, liquid line, etc.).
5. Follow all the instructions from the warning tags and stickers.
6. Compressor crankcase heater should be energized for 12 hours (special attention should be taken to disable 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
• Air Filter Access Door Gasket
• Sound Attenuators (If Applicable)
• Fresh Air Intake
• Ductwork Caulking Inside/Outside Building
• Ductwork Supports Inside/Outside Building
28

• Duct Leakage Inside/Outside Building
• Volume Dampers
• Volume Damper Access Doors
• Fire Dampers
• Fire Damper Access Doors
• Transfer Grilles/Door Grilles
• Duct Insulation/Liner
• Diffusers/Grilles
• Duct Humidistat
• Filter flag
CHECK-OUT & OPERATIONAL START-UP PROCEDURE

After the completion of inspection and check list, the following points should be covered before system is placed in operation.
1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for 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.
29

ELECTRICAL
ELECTRIC POWER SUPPLY
All wiring should be in accordance with National Electric Code and local standards.
Before making an installation, check the electric power supply. The power supply must be of the same characteristics as
that on the nameplate.
Normally the wire size used establishes the circuits maximum permissible load. For example a number 12 wire circuit is
considered to be a 20 ampere circuit and is protected by a 20 ampere fuse. The unit amperage nameplate rating should
not exceed 80% of the circuit rating, 16 amperes.
When identifying electrical trouble in any unit, check the power supply at the main disconnect switch and the unit. A high
or low voltage condition may prevent the unit from starting, or if the unit is running, compressor can cut-off automatically
on the motor overload. On some installations, the voltage may be entirely adequate when tested, but may drop or surge
some time later due to increase or decrease of load on the power line. This condition may be repeated daily at the same
hour. When this condition is suspected, make arrangements with the local power supplier to place a recording voltmeter
on the line to check and correct the erratic voltage conditions.
The voltage drop should not be more or less than 10% of the units rated voltage. If the voltage at the meter is correct, but
the voltage at the unit fluctuates 10% or more, the branch circuit is not adequate.
UNBALANCED VOLTAGE
Unbalanced voltage on a three phase circuit may be the source of electrical trouble. If balanced supply voltages are not
always maintained, so with the three line currents will not be equal. Unbalanced voltage on a three phase compressor
motor may overheat and trip the motor on external or internal current sensing motor protector, whichever one is provided.
To determine that an unbalanced voltage condition exists, the supply voltage at the main disconnect switch and at the
unit disconnect switch should be measured. Voltage unbalance is calculated as follows.
The percentage of voltage unbalance equals one hundred times the ratio of the Maximum Voltage Deviation from the
Average Voltage, and the Average Voltage.
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.
30

MOTOR CONTACTOR
The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compres-
sor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, motor
contactors are subjected to quick cycling due to various causes. This may cause burned and/or sticking contacts and can
cause a compressor motor failure, even though the motor overload protectors trip and open the control circuit.
FAN MOTOR
The condenser fan motor is a single speed electrical motor with ball bearings, protected with an automatic reset internal overload.
CRANKCASE HEATERS
The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest part
of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize when
the compressor is operating.
Power must be supplied to crankcase heater for minimum of 12 hours prior to system start up. If power is off 6 hours or
more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions may
result in compressor damage.
Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are not
a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper piping
practice, over feeding to the evaporator, leaking solenoid valve, etc.
In some cases where migration of refrigerant to the crankcase occurred due to long storage time, shutdown period,
defective components, etc. The crankcase heater may be ineffective. Such cases may be easily observed by high oil
level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharge
service valves of the compressor and release all liquid refrigerant from the compressor.
The liquid refrigerant dilutes the oil in the crankcase and the refrigerant rich oil will be pumped to the rods and the
bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at the
bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor to
drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinders
during the suction stroke causing them to wear during the compression stroke.
When the crankcase is filled with liquid refrigerant and the compressor starts severe agitation, oil foaming etc. will cause
major damage to the compressor.
Periodic checking for proper operation of crankcase heater is highly recommended.
LUBE OIL PROTECTION CONTROL

Pressure lubricated refrigeration compressors require a pressure protector in the event of an oil pressure failure. The
lube oil pressure protection control is factory set conforming to compressor manufacturer’s specification.
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 net oil pump pressure is sensed through a pressure transducer sending analogue signals to the unit’s microproces-
sor board. The control is set to trip or stop the compressor when oil differential pressure goes down at a pre-set level and
time delay setting. Trip settings for low oil pressure and time delay can be changed in the unit’s controller. Factory set
values for low oil pressure trip is at 30 psi after a time delay of 180 seconds.
VOLTAGE MONITOR
This device protects the motors in the unit from faults such as; under or over voltage, unbalance & phase reversal of the
power supply. When the device sensed such faults, it will cut-off the supply in the control circuit thereby cutting off power
to the motors. The voltage monitor will re-set automatically when power is brought back to it’s normal conditions.
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%
31

REFRIGERATION
COMPRESSOR
Scroll compressors are used as standard for models CNX150 - CNX300 and semi-hermetic reciprocating compressors
are standard for models CNX360 - CNX2M00 except for model CNX2M40 available with semi-hermetic compact screw
compressors. All compressors are conforming to ARI 540. The compressors are equipped with internal motor protection;
factory installed crankcase heater and rubber vibration isolators for quiet and efficient operation. As an option, semi-
hermetic compressor can be fixed on anti vibration mounting (spring type) along with suction & discharge line vibration
eliminators. Oil pressure control is provided on units with semi-hermetic compressor only. Each compressor has lock-out
devices to protect it from short cycling when tripped by safety controls. Each compressor has separate condenser coil
with safety controls. Sight glass and filter dryer are standard for all models.
Semi-hermetic Compressor:
These Semi hermetic reciprocating compressors are accessible –hermetic type. Compressor and motor are enclosed in
a hermetically sealed housing, with out shaft seal. The compressors are equipped with an oil sight glass through which
the oil quantity and its conditions in the crankcase can be observed. These compressors can be disassembled in the field
for service.
Refrigerant-cooled motor –compressors have an oil pressure lubrication system. This system is supplied by a positive
displacement oil pump, working in either direction. It is protected by a screen and is made accessible for quick oil
pressure checking by a Schrader check valve. The use of oil pressure control safeguards the lubrication system. These
compressors can be provided with capacity control (optional). The use of unloading provides optimal part load capacities.
Semi-hermetic compact twin screw Compressor:

All compressors are compact semi-hermetic twin screw of the high capacity and efficiency due to its perfect profile form
ratio 5:6. Simple and robust construction with slider control valve for capacity unloading, suction/discharge shut-off
valves, check valve in discharge gas outlet, oil sight glass, oil fill/drain service valve, directly flanged-on three stage oil
separator with long-life fine filter 10 microns mesh size, robust axial bearings in tandem configuration, suction gas filter,
internal pressure relief valve and manual lock-out electronic protection system for thermal motor winding temperature,
phase reversal, discharge gas temperature protection controls.
Scroll Compressors:
Scroll Compressors are used in some of these units. The major benefits being:
1. Low Sound Level: Quieter operation because of no dynamic suction and discharge valves action.
2. Low vibration and discharge pulses.
3. High Energy Efficiency: Because of high volumetric efficiency it minimize pressure and heat transfer losses.
4. High Capacity: Due to its high mass flow and high compression ratios.
5. High Durability: With its robust design, few moving parts, low motor strains, large internal volume for liquid handling
makes this compressor highly reliable.
6. High Charge Limit: Therefore, lower applied costs as no suction accumulator required, no need for pump down
system and check valve in discharge line.
Low capacity can be caused by inefficient compressor, that is, the compressor does not pump sufficient quantity of
refrigerant, even though a full charge is available in the system.
Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is found
to be all right but the electrical components are defective, remove and replace the defective electrical components only.
Below are some tests that should be performed on the compressor to determine, if the compressor is defective.
1. Test compressor motor winding for ground.
2. Test compressor motor windings for continuity.
3. Test that compressor motor will run both without a load and under a load.
4. Test the current or ampere drawn.
5. Observe sound level of compressor.
To establish that the compressor suction and discharge valves are operating and holding properly, attach gauges to the
liquid and suction service valves. "Front seat" the liquid service valve.
32

Start the compressor, allowing it to operate long enough to pump down to approximately 1 PSIG. Shut the compressor off
and observe the compound gauge. The gauge pressure may build rapidly. Repeat the pump down process several times
observing the gauge pressure each time after the compressor stops. If the gauge pressure builds rapidly each time after
the compressor stops, it indicates that the compressor discharge valves are not holding and refrigerant is leaking from
the high side to the low side of the compressor.
To check the suction valves, assuming that the discharge valves are holding, allow the compressor to operate long
enough to pump down the system to approximately 10 inches of vacuum. If the compressor required longer time to
accomplish this, then the suction valves are not holding and the compressor should be changed out as it is defective.
MOTOR COMPRESSOR BURN OUT PROCEDURE

The extent of the contamination in a system will indicate the amount of clean-up necessary. If a compressor had burned
out, the following method of clean-up is recommended:
1. Discharge the refrigerant from the system.
2. Replace the inoperative compressor.
3. Clean up the system thoroughly and remove all the contaminations.
4. Install a system cleaner or filter drier in the suction line and replace the liquid line filter drier.
5. Connect a vacuum pump to both the low and the high side of the system to remove air and other non-condensables
from the system.
6. Allow the vacuum pump to operate until a pressure of 500 microns is achieved.
7. Recharge the system and allow it to operate 8 to 12 hours.
8. Take an oil sample and test for acidity.
If the first acidity test shows that the acid content is below the safe level, as indicated in the test kit instructions, and the
oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the system
provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. For a badly
contaminated system that indicates acid in the oil after 8 to 12 hours of operation, change the suction and liquid line filter-
driers and check the system after 24 hours of operation.
There are instances where contaminants are discovered in a refrigeration system with the compressor still operational.
The same procedure applies, when cleaning these systems, as on a compressor burn-out.
SOURCE OF CONTAMINATION
There are many ways in which a refrigerant system can become contaminated. The most common of these are as
follows:
1. Improper or inadequate dehydration.
2. Wet refrigerant.
3. Wet oil (caution: It is best to purchase oil in small containers and use as needed. Open containers will absorb mois-
ture).
4. Refrigerant leaks (allowing system to operate in a vacuum).
5. Failure to remove oil and moisture after having opened the system for repair.
6. Higher than normal operating temperatures and pressures will cause a breakdown of the oil and refrigerant.
7. Improper use of soldering or brazing flux.
HIGH PRESSURE SWITCH

A high pressure switch is located in the discharge line and senses the discharge pressure. Should the discharge pressure
exceed 350 psig, the control will open turning off the compressor. The control is designed to protect against excessive
discharge temperatures and pressures which can cause compressor overheating and damage to the motor windings or
valves.
33

Should the control open, it will remain open until the pressure in the system is lowered to 300 psig. Tripping of the high
pressure control is normally due to:
1. Restricted condenser coil.
2. Overcharge of refrigerant.
3. Defective fan motor or fan capacitor.
4. Incorrect fan blade.
5. Fan motor internal overload tripping due to lack of lubrication or defective bearings.
To test the high pressure control: Install a high pressure gauge to the access valve or the liquid line valve. Disconnect the
condenser fan motor. Turn on the unit and observe the pressure on the gauge when the compressor trip off. The pressure
should be 350 ± 10 psig. Allow the system to remain off, until the gauge pressure drop to approximately 300 ± 10 psig and
reconnect the condenser fan motor. Reset the unit by putting off the thermostat and if the high pressure control has
closed, the compressor will restart.
LOW PRESSURE PROTECTION

To provide protection for the compressor in the event of refrigerant loss, a low pressure sensor is installed in the suction
line.
The control is preset to open when the suction pressure is 10 ± 5 psig. The contacts of the control will close when the
suction pressure rises to 30 ± 5 psig. To test the control for the correct pressure setting, install a compound gauge to the
gauge port on the suction service valve. "Front seat" the liquid valve and start the unit. Note the gauge pressure, when
the compressor stops.
To determine the cut-in pressure, allow the suction pressure to build slowly and observe the gauge pressure at the time
when contact closes. A good functional low pressure switch must have both cut-out and cut-in pressure within ± 2 psig.
PUMP DOWN CONTROL

A pump down control is a solenoid type valve installed in the liquid line to prevent the flow of refrigerant into the evapo-
rator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liquid
line, but ahead of metering device.
Pump down operation takes place as soon as the signal for cooling is switched off. The system’s control closes the liquid
line solenoid valve while the compressor is continuously running to pump out a substantial portion of refrigerant in the
evaporator. The compressor will shut off when either the suction pressure goes down at a pre-set pressure of 25 psi or
at a pre-set timing of 10 seconds whichever is satisfied first. On call for the next cooling cycle, the solenoid valve will get
energized ahead of the compressor at a pre-set timing. This is to allow refrigerant to flow in the evaporator and thereby
increasing the suction pressure above the low pressure trip setting before the compressor starts.
A pump down control may be necessary on an installation where additional protection for the compressor is required to
prevent slugging of oil or liquid refrigerant.
Below are some conditions which may exist in an installation where additional protection is required:
1. Migration of refrigerant to the compressor during the off cycle.
2. Flooding, at start-up, due to improperly trapped lines or coil.
3. Suction line in slab or beneath ground forming a large trap.
4. Suction line in cool area causing refrigerant to condense during off cycle.
5. Where condensing unit is installed using existing coils and copper lines, or on a new installation where the above said
conditions exist that cannot be avoided, which could result in compressor damage.
34

TROUBLE SHOOTING CHART
SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE
Compressor will not start – no 1. Line disconnect switch open. 1. Close start or disconnect switch.
hum.
2. Overload protector tripped. 2. Refer to electrical section.
3. Control stuck in open position. 3. Repair or replace control.
4. Control off due to cold location. 4. Relocate control.
5. Wiring improper or loose. 5. Check wiring against diagram.
6. Thermostat defective or improperly 6. Replace or relocate.
installed.
7. Trace control circuit with wiring dia-
7. Control circuit open. gram and repair.
8. Burned/open circuit motor winding. 8. Replace the compressor with all pre-
cautions.
Compressor will not start – 1. Improperly wired. 1. Check wiring against diagram.
hums but trips on overload
protector. 2. Low voltage to unit. 2. Determine reason and correct.
3. Relay failing to close. 3. Determine reason and correct, re-
place if necessary.
4.Compressor motor has a winding
open or shorted. 4. Replace compressor.
5. Internal mechanical trouble in com- 5. Replace compressor.
pressor.
6. Check crankcase heater.
6. Liquid refrigerant in compressor.
7. High discharge pressure. 7. Unequilized pressure in the system.
Compressor starts and runs, 1. Additional current passing through 1.Check wiring diagram. Check for
but short cycles on overload overload protector. added fan motors, pumps, etc. con-
protector. nected to wrong side of protector.
2. Low voltage to unit (or unbalanced if
three phase). 2. Determine the reason and correct.
3. Check current, replace protector.
3. Overload protector defective.
4. Check airflow across the condenser
4. Excessive discharge pressure. coil, restrictions in refrigeration sys-
tem.
5. Suction pressure too high.
5. Check for possibility of misapplica-
6. Compressor too hot - return gas hot. tion. Use stronger unit.
7.Compressor motor has a winding 6. Check refrigerant charge (fix leak),

shorted. add if necessary.
7. Replace compressor.
Suction line frosted or 1. Expansion valve passing excess re- 1.Re-adjust valve or replace with
sweating. frigerant or is oversized. smaller valve.
2. Expansion valve stuck open. 2. Clean valve of foreign particles, re-
3. Evaporator fan not running. place if necessary.
4. Overcharge of refrigerant. 3. Determine reason and correct.
4. Correct charge.
Liquid line frosted or 1. Restriction in dehydrator or strainer. 1. Replace part.

sweating. 2. Liquid shut-off valve partially closed. 2. Open valve fully.
35

Units runs OK, but short 1. Overload protector. 1. Check the cause.
cycles on. 2. Thermostat. 2. Differential set too close - widen.
3. High pressure cut-out due to: 3. (a) Check airflow to the condenser
(a) Insufficient air. correct.
(b) Overcharge. (b) Reduce refrigerant charge.
(c) Air in system. (c) Purge.
4. Low pressure cut-out due to: 4. (a) Fix leak, add refrigerant.
(a) Undercharge. (b) Replace device.
(b) Restriction in expansion device.
Unit operates long or 1. Shortage of refrigerant. 1. Fix leak, add charge.
continuously. 2. Control contacts stuck or frozen 2. Clean contacts or replace control.
closed. 3. Determine the fault and correct.
3. Refrigerated or air conditioned space 4. Replace with larger system.
has excessive load or poor insulation.
5. Defrost.
4. System inadequate to handle load.
6. Determine location and remove.
5. Evaporator coil iced.
7. Clean condenser.
6. Restriction in refrigeration system.
8. Clean or replace.
7. Dirty condenser.
8. Filter dirty.
Head pressure too high. 1. Refrigerant overcharge. 1. Correct the refrigerant charge.
2. Air in system. 2. Recharge the system after a thorough
3. Dirty condenser. triple evacuation.
4. Malfunction of condenser fan (air- 3. Clean.
cooled). 4. Check and correct or replace.
5. Excessive air temperature entering 5. Check for short circuiting of con-
condenser. denser discharge air, correct it.
6. Restriction in discharge line. 6. Correct it.
Head pressure too low. 1.Low ambient temperatures (air- 1. Install fan cycling switch, if not pro-
cooled). vided. Check the setting and opera-
2. Refrigerant shortage. tion, if provided.
3. Damaged valves in compressor. 2. Correct the refrigerant charge after
leak testing.
3. Repair/replace the compressor.
High suction pressure. 1. High load on evaporator. Load in ex- 1. Check the design.
cess of design conditions. 2. Follow manufacturer's guide line and
2. Unbalanced system. Oversized air correct it.
handling unit matched with under 3. Repair/replace compressor.
sized condensing unit.
4. Check and adjust the superheat ac-
3. Compressor discharge valve leaking. cordingly.
4. Expansion valve widely open. 5. Check the expansion valve bulb is
5. Improper bulb location or installation. properly tighten at correct location.
36

Loss of oil pressure. 1. Loss of oil from compressor due to: 1. (a) Correct the system piping.
(a) Oil trapping in system. (b) Trace out the wiring/defective controls/
(b) Compressor short cycling. components, etc. and correct it.
(c) Insufficient oil in system. (c) Add oil.
(d) Operation at excessively low (d) Check the superheat of expansion
suction pressure. valve and other possible causes
like clogged filter, low CFM, iced
2. Excessive liquid refrigerant returning
evaporator etc. and correct it.
to compressor.
2. Check the system for correct super
3. Malfunctioning oil pump.
heat and other possible causes like
4. Restriction in oil pump inlet screen. clogged filter, low CFM, iced evapo-
rator, etc. and correct it.
3. Repair or replace it.
4.Clean/replace it (oil change recommended).
Space temperature too high. 1. Control setting too high. 1. Reset control.
2. Expansion valve too small. 2. Use larger valve.
3. Cooling coils too small. 3. Add surface or replace.
4. Inadequate air circulation. 4. Improve air movement.
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.
37

PARTS LIST
MODEL NUMBER CNX150F CNX220F CNX240F CNX300F CNX360F CNX420F CNX480F CNX540F CNX600F
COMPRESSOR 80061402 80061408 80061411 80061414 80069717 80069720 80069723 80069726 80069729
COMPRESSOR CONTACTOR 80009857 80009861 80009861 80009863 80009863 80009865 80009865 80009865 80009867
CAPACITY UNLOADER KITS NIL NIL NIL NIL 80057700 80057700 80057700 80057700 80057700
COND. FAN MOTOR 80022715 80023704 80023703 80023703 80023703 80023703 80023703 80023703 80023703
COND. FAN MOTOR CONTACTOR 80009851 80009851 80009851 80009851 80009851 80009851 80009851 80009851 80009851
FILTER DRYER 80053141 80053142 80053142 80053142 80053142 80053142 80053117 80053117 80053117
FILTER DRYER CORE 80002765 80002765 80002765 80002765 80002765 80002765 80002765 80002765 80002765
SIGHT GLASS 80020000 80020001 80020001 80020001 80020001 80020001 80020004 80020004 80020004
MECHANICAL SHUT OFF VALVE 80070540 80070541 80070541 80070541 80070541 80070541 80070542 80070542 80070542
PUMP DOWN SOLENOID VALVE 80070520 80070521 80070521 80070521 80070521 80070521 80070660 80070660 80070660
PRESSURE GAUGE - SUCTION 80060030 80060030 80060030 80060030 80060030 80060030 80060030 80060030 80060030
PRESSURE GAUGE - DISCHARGE 80060031 80060031 80060031 80060031 80060031 80060031 80060031 80060031 80060031
PRESSURE GAUGE - OIL NIL NIL NIL NIL 80060030 80060030 80060030 80060030 80060030
ADJ. HIGH PRESSURE SWITCH 80055730 80055730 80055730 80055730 80055730 80055730 80055730 80055730 80055730
MICROSMART CONTROLLER 80064645 80064645 80064645 80064645 80064645 80064645 80064645 80064645 80064645
USER INTERFACE CARD 80064650 80064650 80064650 80064650 80064650 80064650 80064650 80064650 80064650
PTC TEMP. SENSOR 80064655 80064655 80064655 80064655 80064655 80064655 80064655 80064655 80064655
RELATIVE PRES. TRANSDUCER -DP 80064656 80064656 80064656 80064656 80064656 80064656 80064656 80064656 80064656
RELATIVE PRES. TRANSDUCER -OIL NIL NIL NIL NIL 80064657 80064657 80064657 80064657 80064657
RELATIVE PRES. TRANSDUCER -SUCTION 80064658 80064658 80064658 80064658 80064658 80064658 80064658 80064658 80064658
MODEL NUMBER CNX720F CNX840F CNXM00F CNXM10F CNXM20F CNXM40F CNXM60F CNX2M00F CNX2M40F
COMPRESSOR 80069732 80069732 80069735 80069738 80069729 80069732 80069735 80069735 80068318
COMPRESSOR CONTACTOR 80009868 80009868 80009865 80009865 80009867 80009868 80009865 80009865 80009851
CAPACITY UNLOADER KITS 80057700 80057700 80057700 80057700 80057700 80057700 80057700 80057700 NIL
COND. FAN MOTOR 80023703 80023703 80023700 80023700 80023700 80023700 80023700 80023700 80023700
COND. FAN MOTOR CONTACTOR 80009851 80009851 80009851 80009851 80009851 80009851 80009851 80009851 80009851
FILTER DRYER 80053117 80053117 80053113 80053113 80053117 80053117 80053117 80053117 80053113
FILTER DRYER CORE 80002765 80002765 80002765 80002765 80002765 80002765 80002765 80002765 80002765
SIGHT GLASS 80020004 80020004 80020005 80020005 80020004 80020004 80020004 80020004 80020005
MECHANICAL SHUT OFF VALVE 80070542 80070542 80070543 80070543 80070542 80070542 80070542 80070542 80070543
PUMP DOWN SOLENOID VALVE 80070660 80070660 80070509 80070509 80070660 80070660 80070660 80070660 80070509
PRESSURE GAUGE - SUCTION 80060030 80060030 80060030 80060030 80060030 80060030 80060030 80060030 80060030
PRESSURE GAUGE - DISCHARGE 80060031 80060031 80060031 80060031 80060031 80060031 80060031 80060031 80060031
PRESSURE GAUGE - OIL 80060030 80060030 80060030 80060030 80060030 80060030 80060030 80060030 NIL
ADJ. HIGH PRESSURE SWITCH 80055730 80055730 80055730 80055730 80055730 80055730 80055730 80055730 80055730
MICROSMART CONTROLLER 80064645 80064645 80064645 80064645 80064645 80064645 80064645 80064645 80064645
USER INTERFACE CARD 80064650 80064650 80064650 80064650 80064650 80064650 80064650 80064650 80064650
PTC TEMP. SENSOR 80064655 80064655 80064655 80064655 80064655 80064655 80064655 80064655 80064655
RELATIVE PRES. TRANSDUCER -DP 80064656 80064656 80064656 80064656 80064656 80064656 80064656 80064656 80064656
RELATIVE PRES. TRANSDUCER -OIL 80064657 80064657 80064657 80064657 80064657 80064657 80064657 80064657 NIL
RELATIVE PRES. TRANSDUCER -SUCTION 80064658 80064658 80064658 80064658 80064658 80064658 80064658 80064658 80064658
38

RECOMMENDED SPARE PARTS
PERCENTAGE OF SPARE PARTS
ITEM ONE YEAR SUPPLY TWO YEAR SUPPLY
100 UNITS 1000 UNITS 100 UNITS 1000 UNITS
Compressor 2% 1% 3% 2%
Condenser fan motor 2 1 3 2

Contactor compressor 2 1 3 2
Contactor fan motors 2 1 3 2
HPS/Sensor/Transducer 2 1 3 2
Expansion valve 1 0.5 2 1
Filter drier 2 1 3 2
Transformer (24V secondary) 1 0.5 2 1

Propeller fan 1 0.5 2 1
Heater-crankcase 3 1 4 2
NOTE : When ordering spare parts, please quote the complete model number on the unit nameplate.
39

PREVENTIVE MAINTENANCE SCHEDULE
FREQUENCY OF MAINTENANCE, MONTHS
ITEM
1 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 (if applicable). 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-134a charging cylinder, belt tension checker, leak detector, vacuum pump with
electronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.
40

MATERIAL SAFETY DATA SHEET
SAFETY DATA REFRIGERANT R134a
Toxicity NIL
In Contact With Skin Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorp-
tion. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere
to skin in case of freeze burns. Wash affected areas with plenty of warm water. If symptoms
occur (irritation or blistering), obtain medical attention.
In Contact With Eyes Contact with liquid or cold vapor can cause freezing of tissue. Immediately flush with plenty
of clean water for at least 15 minutes. Obtain immediate medical attention.
Inhalation High concentration of HFC 134a vapor is harmful. It can act as an asphyxiant by limiting
available oxygen. Human health effects of overexposure to HFC- 134a vapors by inhalation
may include temporary nervous system depression with anaesthetic effects such as dizzi-
ness, headache, confusion, incoordination and loss of consciousness. At very high doses,
cardiac sensitization to circulating epinephrine-like compounds can result in fatal cardiac
arrhythmias.
If large concentrations are inhaled, immediately remove to fresh air. Keep person calm. If
not breathing, give artificial respiration, perferably mouth to mouth. If breathing is labored,
give oxygen. In the event of cardiac arrest, apply external cardiac massage. Do not admininster
adreneline or similar sympathominectic drugs as cardiac arrhythmias may result. Get imme-
diate medical attention.
Stability Stable under normal conditions.
Conditions to Avoid Any source of ignition, such as lighted cigarettes, flames, hot spots, welding.
Materials to Avoid Finely divided metals, magnesium and alloys conatining more than 2% magnesium. Can
react violently if in contact with alkali earth metals such as sodium, potassium, calcium,
barium, powdered aluminium, magnesium and Zinc.
Hazardous Halogens, halogen acids and possibly carbonyl halides such as phosgene. These are toxic
Decomposition Products and corrosive.
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 Store in a cool, well-ventilated area of low fire risk. Keep cylinders dry. Cylinders should be
stored upright with valve protection cap in place and firmly secured to prevent falling or being
knocked over. Protect cylinders from physical damage; do not drag, roll, slide or drop. Do
not allow storage area temperature to exceed 113ºF (45ºC). Keep away from direct sunlight,
heat and sources of ignition. Full and empty cylinders should be segregated. Use a first-in,
first-out inventory system to prevent full containers from being stored for long periods of
time.
Protective Clothing Wear overalls, impervious gloves and goggles/face protection.
Spill / leak Procedure Ensure suitable personal protective clothing and respiratory protection is worn. Evacuate all
personnel from the affected area. Shut off source of leak, if possible without risk. Ventilate
spill area, especially low places where heavy vapors might collect. If possible dike and con-
tain spillage. Prevent liquid from entering sewers, sumps or pit areas, since vapor can create
suffocating atmosphere. Allow spilled liquid to evaporate.
Disposal Best to recover and recycle. If this is not possible, destruction is to be in an approved facility
which is equipped to absorb and neutralize acids and other toxic processing products.
Fire Extinguishing Data Non-flammable.
Containers Fire exposed containers should be kept cool with water sprays. Containers may burst if
overheated.
Fire Fighting Protective Self-contained breathing apparatus and protective clothing must be worn in fire conditions.
Equipment
41

PRESSURE TEMPERATURE CHART, R-134a
TEMPERATURE (0F) PRESSURE TEMPERATURE (0C) PRESSURE
PSIA PSIG Kpa (Absolute) Kpa (Gauge)
0 21.2 6.5 -17.78 146.2 44.9
2 22.2 7.5 -16.67 153.2 51.8
4 23.3 8.6 -15.56 160.4 59.1
6 24.3 9.6 -14.44 167.9 66.6
8 25.5 10.8 -13.33 175.7 74.3
10 26.6 11.9 -12.22 183.7 82.4
12 27.8 13.2 -11.11 192.0 90.7
14 29.1 14.4 -10.00 200.7 99.3
16 30.4 15.7 -8.89 209.6 108.3
18 31.7 17.0 -7.78 218.8 117.5
20 33.1 18.4 -6.67 228.4 127.0
22 34.5 19.8 -5.56 238.2 136.9
24 36.0 21.3 -4.44 248.4 147.1
26 37.5 22.9 -3.33 258.9 157.6
28 39.1 24.4 -2.22 269.8 168.5
30 40.7 26.1 -1.11 281.0 179.7
32 42.4 27.7 0.00 292.6 191.3
34 44.2 29.5 1.11 304.6 203.2
36 45.9 31.3 2.22 316.9 215.5
38 47.8 33.1 3.33 329.6 228.2
40 49.7 35.0 4.44 342.6 241.3
42 51.6 36.9 5.56 356.1 254.8
44 53.7 39.0 6.67 370.0 268.7
46 55.7 41.0 7.78 384.3 283.0
48 57.9 43.2 8.89 399.0 297.7
50 60.0 45.4 10.00 414.1 312.8
52 62.3 47.6 11.11 429.7 328.4
54 64.6 49.9 12.22 445.7 344.4
56 67.0 52.3 13.33 462.2 360.9
58 69.5 54.8 14.44 479.1 377.8
60 72.0 57.3 15.56 496.5 395.2
62 74.6 59.9 16.67 514.4 413.0
64 77.2 62.6 17.78 532.7 431.4
66 80.0 65.3 18.89 551.6 450.2
68 82.8 68.1 20.00 570.9 469.6
70 85.7 71.0 21.11 590.8 489.4
72 88.6 73.9 22.22 611.1 509.8
74 91.6 77.0 23.33 632.0 530.7
76 94.8 80.1 24.44 653.5 552.1
78 97.9 83.2 25.56 675.4 574.1
80 101.2 86.5 26.67 698.0 596.6
82 104.6 89.9 27.78 721.1 619.7
84 108.0 93.3 28.89 744.7 643.4
86 111.5 96.8 29.95 769.0 667.6
88 115.1 100.4 31.11 793.8 692.5
90 118.8 104.1 32.22 819.2 717.9
92 122.6 107.9 33.33 845.3 743.9
94 126.4 111.7 34.44 871.9 770.6
42

PRESSURE TEMPERATURE CHART, R-134a
TEMPERATURE (0F) PRESSURE TEMPERATURE (0C) PRESSURE
PSIA PSIG Kpa (Absolute) Kpa (Gauge)
96 130.4 115.7 35.56 899.2 797.9
98 134.4 119.7 36.67 927.1 825.8
100 138.6 123.9 37.78 955.7 854.3
102 142.8 128.1 38.89 984.9 883.6
104 147.1 132.4 40.00 1014.8 913.4
106 151.6 136.9 41.11 1045.3 944.0
108 156.1 141.4 42.22 1076.6 975.2
110 160.7 146.0 43.33 1108.5 1007.2
112 165.5 150.8 44.44 1141.2 1039.8
114 170.3 155.6 45.56 1174.5 1073.2
116 175.2 160.6 46.67 1208.6 1107.3
118 180.3 165.6 47.78 1243.4 1142.1
120 185.5 170.8 48.89 1279.0 1177.7
122 190.7 176.0 50.00 1315.3 1214.0
124 196.1 181.4 51.11 1352.4 1251.1
126 201.6 186.9 52.22 1390.3 1288.9
128 207.2 192.5 53.33 1428.9 1327.6
130 212.9 198.2 54.44 1468.4 1367.1
132 218.8 204.1 55.56 1508.7 1407.4
134 224.7 210.0 56.67 1549.8 1448.5
136 230.8 216.1 57.78 1591.7 1490.4
138 237.0 222.3 58.89 1634.5 1533.2
140 243.3 228.6 60.00 1678.2 1576.8
142 249.8 235.1 61.11 1722.7 1621.4
144 256.4 241.7 62.22 1768.1 1666.8
146 263.1 248.4 63.33 1814.4 1713.1
148 269.9 255.2 64.44 1861.6 1760.3
150 276.9 262.2 65.56 1909.8 1808.5
152 284.0 269.3 66.67 1958.9 1857.6
154 291.3 276.6 67.78 2008.9 1907.6
156 298.7 284.0 68.89 2059.9 1958.6
158 306.2 291.5 70.00 2111.9 2010.6
160 313.9 299.2 71.11 2164.9 2063.6
162 321.7 307.1 72.22 2218.9 2117.6
164 329.7 315.0 73.33 2274.0 2172.7
166 337.9 323.2 74.44 2330.1 2228.7
168 346.1 331.5 75.56 2387.2 2285.9
170 354.6 339.9 76.67 2445.4 2344.1
43

For Cnx220, Cnx300, Cnx360, Cnx420, Cnx240, Cnx480, Cnx540, Cnx600, Cnx720, Cnx840, Cnxm00, Cnxm10, Cnxm20, Cnxm40, Cnxm60, Cnx2m00, Cnx2m40

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For Cnx220, Cnx300, Cnx360, Cnx420, Cnx240, Cnx480, Cnx540, Cnx600, Cnx720, Cnx840, Cnxm00, Cnxm10, Cnxm20, Cnxm40, Cnxm60, Cnx2m00, Cnx2m40

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INSTALLATION,

AIR COOLED CONDENSING UNITS

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CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

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* Capacity in MBH (MBH x 1000 = BTUH).

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NOMINAL CAPACITY , TONS* 13 19 22 28 31 36 41 47 53

COMPRESSOR Type Scroll Semi-hermetic reciprocating

CONDENSER FAN Type Propeller

CONDENSER COIL Type Inner grooved tubes and enhanced fins

Total face area (Sq. ft.) 28 28 28 28 46.66 46.66 56 56 56

LOW PRESSURE SWITCH Open (PSIG) 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5

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NOMINAL CAPACITY , TONS* 63 64 75 92 105 121 139 154 281

COMPRESSOR Type Semi-hermetic reciprocating Screw

CONDENSER FAN Type Propeller

CONDENSER COIL Type Inner grooved tubes and enhanced fins

LOW PRESSURE SWITCH Open (PSIG) 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5

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CNX 360 - CNX 420

73 [2.875] "A" "B" "C"

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

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CNX 720 - CNX 840

FRONT VIEW SIDE VIEW

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ELECTRIC POWER INLET

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487.0 [19.173] TYP

670.5 [26.397] TYP

786.0 [30.944] TYP

917.0 [36.102] TYP

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

ELECTRIC POWER INLET

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487.0 [19.173] TYP

670.5 [26.397] TYP

786.0 [30.944] TYP

917.0 [36.102] TYP

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

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487.0 [19.173] TYP

670.5 [26.397] TYP

917.0 [36.102] TYP

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

The unit’s controller consists of the following hardware:

LCD Display Information:

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BLOWER MOTOR CONTROL (OPTIONAL)

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OLR1 OLR2 CC1 CC2

OLR1 OLR3 OLR2 OLR4 OLR1 OLR3 OLR2 OLR4

OLR1-1A 11A OLR3-1A OLR2-1A 11B OLR4-1A

CRANKCASE HTR CONNECTION(AS APPLICABLE)

FM2 FM3 FM3 B. SCROLL COMP.

HVTB HVTB HVTB

JU1 - CLOSED JU12 - CLOSED (1,2) (OPTIONAL)

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