'CAL' SERIES (R-410a)

INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
AIR COOLED CONDENSING UNITS

'CAL' SERIES
(R-134a)
PL-OM-CAL-07-1M-E
INDEX
Contents Page
General information .................................................................................................................................. 2
Safety issues ............................................................................................................................................ 2
Model decoding ....................................................................................................................................... 3
Physical data ......................................................................................................................................... 4-5
Electrical data ........................................................................................................................................... 6
Dimensions .......................................................................................................................................... 7-10
Typical schematic wiring diagram ...................................................................................................... 11-15
Field wiring connections ......................................................................................................................... 16
Controls & sequence of operation .......................................................................................................... 16
Rigging instructions ................................................................................................................................ 17
Installation clearance .............................................................................................................................. 18
Mounting location ................................................................................................................................... 19
Load distribution ..................................................................................................................................... 20
INSTALLATION INSTRUCTIONS
General ................................................................................................................................................... 21
Location of unit ....................................................................................................................................... 21
Refrigerant piping connections ............................................................................................................... 21
Leak testing & refrigerant charging ......................................................................................................... 22
Start-up inspection & check list ......................................................................................................... 22-23
Check-out & operational start-up procedure ........................................................................................... 23
ELECTRICAL
Power supply .......................................................................................................................................... 24
Unbalanced voltage ................................................................................................................................ 24
Motor contactor ...................................................................................................................................... 25
Fan motor ............................................................................................................................................... 25
Crankcase heater ................................................................................................................................... 25
Lube oil protection control ................................................................................................................. 25-26
Voltage monitor ...................................................................................................................................... 26
REFRIGERATION
Compressor ............................................................................................................................................ 27
High & low pressure protection .......................................................................................................... 28-29
Pump down control ................................................................................................................................. 29
Trouble shooting chart ....................................................................................................................... 30-32
Parts list ................................................................................................................................................. 33
Recommended spare parts .................................................................................................................... 34
Preventive maintenance schedule .......................................................................................................... 35
Material safety data sheet ...................................................................................................................... 36
Pressure temperature chart ............................................................................................................... 37-38
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1
GENERAL STATEMENT
Cooline CAL series is designed and built for the optimum performance when matched with the right indoor unit (Refer to
indoor unit catalog). However, it is required that you become well acquainted with good practices for the proper installa-
tion, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year.
Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experi-
enced technicians should perform the installation and other maintenance procedures.
These CAL series units are designed to use ozone friendly HFC R-134a refrigerant. HFC R-134a is a singular compound
form with proven highly efficient thermodynamic proprieties. The compound has no chlorine and does not contribute to
Ozone depletion. There will be no phase out and no replacement costs for the life of the equipment.
SAFETY ISSUES
There are three levels of safety hazards that are identified throughout this manual as Warning (where the situation will
result in personal injury), Caution (where personal injury might occur), and Attention (where minor personal injury and/or
property damage could happen). Please understand and respect those identifications.
WARNING: These units operate on a high voltage with moving parts (at high speed) which can lead to
serious injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical power
supply has been disconnected.
CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining
the unit as the hazard of explosion, fire, electrical shock, and potential personal injury and property damage
are present.
When performing any task pertaining to the installation and maintenance of the unit, the skilled technician should observe
all the applicable safety measures (wear of safety helmet, boots, and goggles. Use of proper handling materials for
brazing and use of wet cloth for sequencing. A fire extinguisher should be easily accessible etc). He should also read all
the instructions and information in this manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should be observed during installation and servicing.
2
MODEL DECODING
1, 2 & 3 4, 5 & 6 7 8 9 10 11
BASIC NOMINAL COOLING ELECTRICAL REFRIGERATION ELECTRICAL KITS OPTION CONDENSER COIL MECHANICAL KITS OPTIONS
CAPACITY (TONS) SUPPLY (V-Ph-Hz) CIRCUIT TYPE
CAL 018 L : 380/415-3-50 S : DUAL SCROLL * A : STANDARD OPTIONS + A : ALUMINUM FIN A : STANDARD OPTIONS +
COOLINE (4 WIRE)
K : FAN CYCLING & ADJUST- M : REPLACEABLE CORE FILTER DRIER &
CONDENSING 020 H : DUAL SEMI-HERMETIC B : COATED ALUMINUM FIN SHUT-OFF VALVE
RECIPROCATING ** ABLE HIGH & LOW
UNIT P : PRESSURE GAUGES (SUCTION &
025 PRESSURE SWITCHES C : COPPER FIN
Q : QUADRUPLE SEMI-HERMETIC DISCHARGE)
030 RECIPROCATING *** V : VOLT FREE CONTACTS **** O : PRESSURE GAUGES (SUCTION,
D : ALUMINUM FIN WITH COIL
C : COMPRESSOR CIRCUIT GUARD DISCHARGE & OIL) ++
035 L : DUAL SEMI-HERMETIC
BREAKER H : HOT GAS BYPASS VALVE
RECIPROCATING WITH
040 E : COATED ALUMINUM FIN R : CONDENSER PRESSURE RELIEF VALVE
UNLOADER ** P : PUMPDOWN SOLENOID
VALVE WITH COIL GUARD
(LEAD COMPRESSOR) J : M & P COMBO
045
M : QUADRUPLE SEMI-HERMETIC B : K & V COMBO G :COPPER FIN WITH COIL K : M & O COMBO
050 RECIPROCATING WITH GUARD
E : K & C COMBO N : M & H COMBO
UNLOADER***
060 Q : M & R COMBO
(LEAD COMPRESSOR) G : K & P COMBO
070 S : M, H & R COMBO
T : K, V & C COMBO
T : M, H & P COMBO
080 M : K, V & P COMBO
U : M, H & O COMBO
090 N : V, C & P COMBO
V : A, H & R COMBO
L : K, V, C & P COMBO
100 F : A, H & P COMBO
G : A, H & O COMBO
120
3
L : A, H, P & R COMBO
140
B : M, H, O & R COMBO
NOTES: * – Dual scroll compressors are available up to models CAL020 only.

** – Dual semi-hermetic compressors are available for models CAL025 - CAL070 only.
*** – Quadruple semi-hermetic compressors are available for models CAL080 - CAL140 only.
**** – A combination of volt free contact option: 1. Unit ON indication, 2. Compressor RUN/TRIP, 3. Unit trip indication.
+ – Standard options (up to models CAL040) contain sealed type filter drier, low & high pressure switches, UVM and without vibration isolator for semi-hermetic compressors.
Standard options (for models CAL045 & above) contain replaceable filter drier, ball valve, sight glass, UVM and without vibration isolator for semi-hermetic compressors.
++ – Oil pressure gauge is applicable for semi-hermetic compressors only.
PHYSICAL DATA
MODEL NUMBER CAL018 CAL020 CAL025 CAL030 CAL035 CAL040 CAL045 CAL050
NOMINAL CAPACITY , TONS* 18 23 26 30 34 40 44 52
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Dual Dual Dual Dual
COMPRESSOR Type Scroll Scroll Semi-hermetic reciprocating
Oil per system (liters) 4.1 4.7 4.7 4.7 4.9 4.9 4.9 4.9
Refrigerant** R-134a
Charge per system (oz)*** 324 414 468 540 612 720 792 936
CONDENSER FAN Type Propeller
Qty. – Diameter (inch) 2 – 30 2 – 30 2 – 30 4 – 30 4 – 30 4 – 30 4 – 30 4 – 30
Nominal CFM 13000 13000 13000 26000 26000 26000 26000 26000
Motor HP – RPM 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–3–14 3/8–3–14 3/8–4–14 3/8–2–14 3/8–2–14 3/8–3–14 3/8–3–14 3/8–4–14
Total face area (Sq. ft.) 29.8 29.8 29.8 59.5 59.5 59.5 59.5 59.5
HIGH PRESSURE SWITCH Open (PSIG) 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
LOW PRESSURE SWITCH Open (PSIG) 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
REFRIGERANT LINES+ Suction line size (OD), inch 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8
Liquid line size (OD), inch 5/8 7/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 65.4/61.8/56.6 65.6/62/56.8 66.3/62.8/57.5 69.9/66.4/66.1 69.9/66.4/61.6 69.9/66.4/61.6 70.7/67.2/61.9 70.7/67.2/61.9
OPERATING WEIGHT, Kg.+++ 747 800 1024 1308 1367 1422 1450 1514
NOTE:
* Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.
** Unit is factory supplied with holding charge only.
*** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.
+ Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.
++ Based on free field area at ARI conditions. Tolerance: ±2dBA.
+++ Values indicated are for standard unit with aluminum fin condenser coils.
4
PHYSICAL DATA
MODEL NUMBER CAL060 CAL070 CAL080 CAL090 CAL100 CAL120 CAL140
NOMINAL CAPACITY , TONS* 62 72 78 90 103 121 140
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Quadruple Quadruple Quadruple Quadruple Quadruple
COMPRESSOR Type Semi-hermetic reciprocating
Oil per system (liters) 5.2 5.2 4.9 4.9 4.9 5.2 5.2
Refrigerant** R-134a
Charge per system (oz)*** 1116 1296 702 810 927 1089 1260
CONDENSER FAN Type Propeller
Qty. – Diameter (inch) 4 – 32 4 – 32 4 – 32 6 – 32 6 – 32 6 – 32 8 – 32
Nominal CFM 43408 41240 41240 63432 63432 63216 75264
Motor HP – RPM 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–3–14 3/8–4–14 3/8–4–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–4–14
Total face area (Sq. ft.) 87.5 87.5 87.5 120 120 140 140
HIGH PRESSURE SWITCH Open (PSIG) 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
LOW PRESSURE SWITCH Open (PSIG) 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
REFRIGERANT LINES+ Suction line size Dual 2-5/8 2-5/8 N.A. N.A. N.A. N.A. N.A.
(OD), inch
Quadruple N.A. N.A. 2-1/8 2-1/8 2-5/8 2-5/8 2-5/8
Liquid line size Dual 1-1/8 1-3/8 N.A. N.A. N.A. N.A. N.A.
(OD), inch
Quadruple N.A. N.A. 7/8 1-1/8 1-1/8 1-1/8 1-3/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 72/68.4/63.2 72/68.4/63.2 72/68.4/63.2 74.1/70.6/65.4 74.1/70.6/65.4 75.3/71.8/66.5 75.9/72.4/67.1
OPERATING WEIGHT, Kg.+++ 1936 2096 2486 2812 2880 3654 3862
NOTE:
* Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.
** Unit is factory supplied with holding charge only.
*** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.
+ Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.
++ Based on free field area at ARI conditions. Tolerance: ±2dBA.
+++ Values indicated are for standard unit with aluminum fin condenser coils.
5
ELECTRICAL DATA
SUPPLY VOLTAGE COMPRESSOR CONDENSER FAN MOTORS CRANKCASE HEATER
MODEL
NUMBER Nominal RLA LRA CB FLA LRA OUTPUT CB Total Total
Min. Max. MCA MOCP Qty. Qty. Volts
(V-Ph-Hz) (each) (each) Poles (each) (each) POWER (Qty.) Watts Amps
CAL018 380/415-3-50 342 457 71.0 100 2 28.8 198 3 2 3.12 19 1.5 1 380 45 0.11
CAL020 380/415-3-50 342 457 74.0 100 2 30.1 225 3 2 3.12 19 1.5 1 380 61 0.16
CAL025 380/415-3-50 342 457 59.4 80 2 23.6 193 3 2 3.12 19 1.5 1 240 140 0.58
CAL030 380/415-3-50 342 457 75.5 100 2 28.0 220 3 4 3.12 19 1.5 2 240 140 0.58
CAL035 380/415-3-50 342 457 80.0 100 2 30.0 262 3 4 3.12 19 1.5 2 240 140 0.58
CAL040 380/415-3-50 342 457 93.7 125 2 36.1 262 3 4 3.12 19 1.5 2 240 140 0.58
CAL045 380/415-3-50 342 457 111.3 150 2 43.9 323 3 4 3.12 19 1.5 2 240 140 0.58
CAL050 380/415-3-50 342 457 144.6 200 2 58.7 404 3 4 3.12 19 1.5 2 240 140 0.58
CAL060 380/415-3-50 342 457 173.9 225 2 72.5 500 3 4 2.70 13.9 1.5 2 240 140 0.58
CAL070 380/415-3-50 342 457 197.3 250 2 82.9 570 3 4 2.70 13.9 2.0 2 240 140 0.58
6
CAL080 380/415-3-50 342 457 164.2 200 4 36.1 262 3 4 2.70 13.9 2.0 2 240 140 0.58
CAL090 380/415-3-50 342 457 202.8 225 4 43.9 323 3 6 2.70 13.9 2.0 3 240 140 0.58
CAL100 380/415-3-50 342 457 265.7 300 4 58.7 404 3 6 2.70 13.9 2.0 3 240 140 0.58
CAL120 380/415-3-50 342 457 324.3 400 4 72.5 500 3 6 2.70 13.9 2.0 3 240 140 0.58
CAL140 380/415-3-50 342 457 373.9 450 4 82.9 570 3 8 2.70 13.9 2.0 4 240 140 0.58
LEGEND:
MCA - Minimum Circuit Ampacity
MOCP - Maximum Over Current Protection
RLA - Rated Load Amps
LRA - Locked Rotor Amps
FLA - Full Load Amps
CB - Circuit Breaker
DIMENSIONS
CAL 018 & CAL 020
CAL 025
NOTE: All dimensions are in mm.
7
DIMENSIONS
CAL 030, CAL 035, CAL 040, CAL 045 & CAL 050
CAL 060 & CAL 070
8
DIMENSIONS
CAL 080
CAL 090, CAL 100 & CAL 120

DIMENSIONS
MODEL L
CAL090 3823
CAL100 3823
CAL120 4343
9
DIMENSIONS
CAL 140
10
TYPICAL SCHEMATIC WIRING DIAGRAM
(Dual compressor units)
PRESSURE SWITCH SETTINGS

NAME OPEN (PSIG) CLOSE (PSIG)
LPS1 TO 2 10 ± 5 30 ± 5
HPS1 TO 2 350 ± 10 300 ± 15
FCS1 TO 2 125 ± 10 300 ± 15
LPS 3 TO 4 30 40
LPS 5 TO 6 40 50
NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.
2. Refer to unit control box (inside panel) for exact wiring diagram.
11
(Dual compressor units)
LEGEND
AHU AIR HANDLING UNIT
AFS AIR FLOW SWITCH
CONTROL
PANEL CONTROL
PANEL
AR AUXILIARY RELAY
ATB AUXILIARY TERMINAL BLOCK
BM BLOWER MOTOR
BMC BLOWER MOTOR CONTACTOR
CC COMPRESSOR CONTACTOR
CCA CC AUXILIARY CONTACT
CB CIRCUIT BREAKER
C. HTR CRANKCASE HEATER
COMP/C COMPRESSOR
ECB ELECTRONIC CONTROL BOARD
F FUSE
FCS FAN CYCLING SWITCH
FM FAN MOTOR (CONDENSER)
FMC FAN MOTOR CONTACTOR
FMCA FMC AUXILIARY CONTACT
FR FAULT RELAY
HC HEATER CONTACTOR
HPS HIGH PRESSURE SWITCH
HVTB HIGH VOLTAGE TERMINAL BLOCK
JP JUMPER
L1 LINE 1
L2 LINE 2
L3 LINE 3
LPS LOW PRESSURE SWITCH
LUG LUG GROUND
NTB NEUTRAL TERMINAL BLOCK
OLR OVER LOAD RELAY
OPS OIL PRESSURE SWITCH
P PRESSURE
PDS PUMP DOWN SOLENOID
S DIP SWITCH (IN ECB)
SSPS SOLID STATE PROTECTION SYSTEM
TOP FM THERMAL OVERLOAD PROTECTION
TRANS TRANSFORER
UL COMP. UNLOADER SOLENOID
UVM UNDER VOLTAGE MONITOR
___ FIELD WIRING
/ TERMINAL BLOCK OR TERMINATION POINT
SPLICE-CLOSED END
NOTES
1. POWER SUPPLY, 380/415V-3PH-50Hz.
2. ANY WIRE REPLACEMENT SHOULD BE OF 900C
OR ITS EQUIVALENT. USE COPPER CONDUCTOR
WIRES ONLY.
3. POWER MUST BE SUPPLIED TO CRANKCASE
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SYSTEM START UP.
IF POWER IS OFF 6 HOURS OR MORE, CRANK-
CASE HEATER MUST BE ON FOR 12 HOURS BE-
FORE OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN COMPRESSOR DAMAGE.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
BREAKER TO BE PROVIDED BY CONSUMER
WITH RATING AS RECOMMENDED BY COOLINE.
5. COMPRESSORS ARE PROVIDED WITH SSPS OR INTER-
NAL LINE BREAK THERMAL OVERLOAD PROTECTION.
6. IF PDS IS FACTORY INSTALLED, PLEASE READ
BROKEN LINES AS CONTINUOUS LINES.
7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.)
FOR LVTB FIELD WIRING. GROUND CONNECT
AT BOTH ENDS.
8. COOLING OUTPUT SIGNAL FROM CONTROLLER
SHOULD FOLLOW THE SEQUENCE:
ON SEQUENCE - Y1 FIRST, THEN Y2.
OFF SEQUENCE - Y2 FIRST, THEN Y1.
9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGE
ACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS 230VAC.
ALSO, COMP. LOCKOUT LIGHT (RED) OF ECB IS ON.
12
(Quadruple compressor units)
HVTB
TO FUSED L1
DISCONNECT
SWITCH OR CB
L2 PLEASE REFER TO
COMP WITH CB OPTIONS
L3 SHEET 2 & 3 OF 3 FOR
(SEE NOTE-4) CONDENSER FAN MOTOR TO HVTB TO HVTB TO HVTB TO HVTB
POWER CONNECTIONS.
L1 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1 L1
NTB
NEUTRAL
CC1 CC2 CC3 CC4 CB1 CB2 CB3 CB4

LUG
OLR1 OLR2 OLR3 OLR4
L1A
L2A
L3A
L1B
L2B
L3B
L1C
L2C
L3C
L1D
L2D
L3D
T1C
T2C
T3C
T1D
T2D
T3D
T1A
T2A
T3A
T1B
T2B
T3B
UVM CONNECTION CC1 CC2 CC3 CC4
L1 L2 L3 COMP COMP COMP COMP OLR1 OLR2 OLR3 OLR4
1 2 3 4
T1A
T2A
T3A
T1B
T2B
T3B
T1C
T2C
T3C
T1D
T2D
T3D
L1 L2 L3 UVM
1 UVM-1 8 COMP COMP COMP COMP
1 2 3 4
TO ATB 1
(REMOVE JP1)
TO ATB 1A
CRANKCASE HTR CONNECTION(AS APPLICABLE)
A. SEMI-HERMETIC RECIP. COMP. (BITZER)
1 CC1A-1B C.HTR1 2
COMP. 1: 100A
TO HVTB TO NTB
L1 N
1 CC2A-1B C.HTR2 2
COMP. 2: 100B
ATB ATB
1 CC3A1B C.HTR3 2
JP1 JP2 COMP. 3: 100C
1 1A 1B
PDS2 1 CC4A-1B C.HTR4 2

COMP. 4: 100D
SEE VFC CONNECTION PDS1

TO ATB SEE FM CONNECTION
TO TO CC2 SCROLL COMP CRANKCASE HTR CONNECTION
FR2 FR1
CC1 COMP. 1:
L1 C.HTR1 L2
( NOTE 9)
SWITCHING CONTACTS
41B
41A
4B
4A
3B
3A
FROM T'STAT CONTROLLER OR DDC COMP. 2:

( NOTE 8) (by others) L2 C.HTR2 L3
LVTB
OUTFAN2
OUTFAN1
HEATER2
HEATER1
NEUTRAL
TB1
COMP1
COMP2
INFAN
15 R
X2
X1
P2
P1
R R
17 24Vac COMP. 3:
C C
JP L1 C.HTR3 L2
G G
31A STG1 COOLING Y1
Y1 Y1
31B STG2 COOLING Y2 COMP. 4:
LED FAULT INDICATOR Y2 Y2
LIVE
YR3 STG3 COOLING Y3 C.HTR4

ECB1 W1 Y3 L2 L3
31C
LOCK2 LOCK1 Y4
STG4 COOLING Y4
W2 YR4
SYSTEM2 SYSTEM1 SQMBO4 ( P III ) 31D
ON/OFF
PRI
FUSE
(ON/OFF) (SSPS1) (OPS1)
COMP. SSPS CONNECTION (NOTE 5)
OLR1-1 HPS1
21A COMP. 1: SSPS1
TRANS2 P3_## HP1 24A JP3 25A JP5 26A
P 24A 25A
230v (HP1) 27A M1/11 M2/14
OLR2-1 (SSPS2) (OPS2) HPS2
12v-0-12v 1 2
21B JP4 JP6 L1/MP/L L2/R/N
HP2 24B 25B 26B
P
(HP2) 27B
ON DIP (REMOVE JP3)
COMP. 2:
22A LPS1 SSPS2
LP1 24B 25B
SEC
DIP SWITCH M1/11 M2/14

(LP1) 23A P
LED
POWER INDICATOR 1 2
LPS2 L1/MP/L L2/R/N
J_PROG LP2 22B
(LP2) 23B P (REMOVE JP4)

COMP. 3: SSPS3
2 24C 25C
M1/11 M2/14
TO ATB PDS3
SEE VFC CONNECTION 1 2
L1/MP/L L2/R/N
SEE FM CONNECTION PDS4
TO TO
(REMOVE JP7)
FR4 FR3 COMP. 4:
CC4 SSPS4
1
24D 25D
CC3 M1/11 M2/14
1 2
L1/MP/L L2/R/N
41D
41C
4D
4C
3D
3C
(REMOVE JP8)
OUTFAN2
OUTFAN1
HEATER2
HEATER1
NEUTRAL
COMP1
COMP2
15B
INFAN
X2
X1
P2
P1
R
C
G JP
31C
YR3-1
Y1
31D YR4-1
LED FAULT INDICATOR Y2
LIVE
LOCK2 LOCK1 ECB2 W2

W1
SYSTEM2 SYSTEM1 SQMBO4 ( P III )
ON/OFF
PRI
FUSE
(ON/OFF) (SSPS3) (OPS3)
OLR3-1 HPS3
TRANS3 HP1 21C JP7 JP9
P3_## 24C 25C 26C
P
230v (HP1) 27C
OLR4-1 (SSPS4) (OPS4) HPS4
12v-0-12v 21D
HP2 24D JP8 25D JP10 26D
P
(HP2) 27D
ON DIP
22C LPS3
LP1
SEC
DIP SWITCH
(LP1) 23C P
LED
POWER INDICATOR LPS4
J_PROG LP2 22D
(LP2) 23D P
13
UNIT STATUS (VFC) INDICATION CONNECTION

UNIT ON / OFF INDIVIDUAL COMP. ON/OFF/TRIP
OIL PRESSURE SWITCH CONN.(AS APPLICABLE)
COMP 1 COMP 3 COMP 1 1 28A OPS1 2
FR1 FR3 2 CC1A-1A
2 41C 2 240
X1 41A X1
TO ECB1 TO ECB2
FR1-2A FR3-2A 25A OPS1-1 26A
1 AR1 2
(REMOVE JP5)
COMP 2
CC3A-2A
CC1A-2A
OPS2
CC2A-1A 28B 2
2 240
45 AR1-1A 46
55 56 58 65 66 68
25B 26B
OPS2-1
UNIT ON COMP1 ON COMP3 ON
(REMOVE JP6)
COMP1 TRIP COMP3 TRIP
UNIT TRIP
COMP 2 FR2 COMP 4 FR4 2
2 41D
X2
41B X2 OIL PRESSURE SWITCH CONN.(AS APPLICABLE)
TO ECB1 TO ECB2 FR4-2A
FR2-2A COMP 3 1 28C OPS3 2
CC3A-1A
2 240
43 FR1-1 44A FR2-1 44B FR3-1 44C FR4-1 44
25C OPS3-1 26D
CC4A-2A
CC2A-2A
UNIT TRIP (REMOVE JP9)
71 73 COMP 4 OPS4
60 61 63 70
CC4A-1A 28D 2
2 240
COMP2 ON COMP4 ON
COMP4 TRIP 25C 26D

COMP2 TRIP OPS4-1
(REMOVE JP10)
COMPRESSOR UNLOADER CONNECTION (OPTIONAL) HGS CONNECTION W/O COMP UNLOADER
LPS5
ECB DIP SWITCH SETTINGS & LED INDICATORS
TO ATB NO
AR8
28A C UL1 2 Y1 [LVTB] C [LVTB] S1 OFF=TEST MODE DISABLE ON= TEST MODE ENABLE
COMP 1 28A 5A 31A 17A
NC LOAD BALANCE
P S2 OFF= (Comp1&2 Auto Lead Lag) ON= COMPRESSOR 1 LEAD
LPS9 NO AR9
C UL5 Y2 [LVTB] 31B 17A S3 OFF= WITHOUT PUMP DOWN ON= WITH PUMP DOWN OPTION
6A
S4 on-board programming function (always set to on)
NC
P FACTORY SETTINGS OF DIP SWITCHES LED INDICATORS
LPS6 NO 1 LPS5NO Green power on/off indicator
TO ATB 28B AR8-1 AR9-1 HGS 2
COMP 2 28B
C UL2 2 C
6E 6D 6C
5B DIP SWITCH # S1 S2 S3 S4 Red system lock-out due to system fault
NC
NC P system 1 fault diagnostic
P ON
LPS10 NO OFF Yellow blinking slow - LPS1 ckt fault
C UL6 blinking fast - HPS1 ckt fault
6B HGS CONNECTION WITH COMP UNLOADER
NC note: system 2 fault diagnostic
P
LPS5NO Set dip switch #3 according to unit's option Orange blinking slow - LPS2 ckt fault
5A (pump down or no pump down)
C AR8-1 AR9-1 HGS 2 blinking fast - HPS2 ckt fault
6E 6D 6C
NC
TO ATB LPS7 NO P
COMP 3 28C
28C C
5C
UL3 2 PRESSURE SWITCH SETTINGS
NOTE:
NC COMP1 SHOULD ALWAYS BE LEAD COMPRESSOR. NAME OPEN (PSIG) CLOSE (PSIG)
P
LPS11 NO DIP SWITCH S2 SHOULD ALWAYS BE SET TO "ON" POSITION.
LPS1 TO 4 10 ± 5 30 ± 5
C UL7
6C HPS1 TO 4 350 ± 10 300 ± 15
NC
P
FCS1 TO 4 125 ± 10 300 ± 15
LPS8 NO
TO ATB 28B LPS 5-8 30 40
COMP 4 28D C UL4 2
5B
NC LPS 9-12 40 50
P
LPS12 NO
C UL8
6B
P
NC OPTIONAL AHU INTER-CONNECTION
NOTE (POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR)
UL3 & UL 4 CONNECTION APPLICALBLE FOR COMP WITH 3 STEPS
CAPACITY UNLOADING. TO POWER SUPPLY TO POWER SUPPLY TO POWER SUPPLY
L1 L2 L3 L1 L2 L3 L1 L2 L3
CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : WITH STANDARD AND FAN CYCLING OPTION
CB
CB11 CB12
L1C
L2C
L3C
L1 L2 L3 L1 L2 L3
CAL080
71B
72B
73B
71A
72A
73A
BMC
6-FAN MOTOR LAYOUT
HC1 HC2 OLR
CB6 CB7
CONTROL
68
69
70
PANEL
T1H
T2H
T3H
T1F
T2F
T3F
HTR1 HTR2
(Stg. 1 Heating) (Stg. 2 Heating)

100
101
102
103
104
105
FMC1 FMC3 FMC2

SWITCHING CONTACTS
FROM T'STAT CONTROLLER OR DDC
35C
36C
37C
35D
36D
37D
35A
36A
37A
35B
36B
37B
FMC4 TB1 (ECB) (by others)

(REMOVE JUMPER JP) LVTB ( NOTE 8)
FM1 FM3 FM2 FM4 R R
R
24Vac C
C C
BM CONTROL G
G G
TO ECB1 FM1 TO ECB2 FM2 STG1 COOLING Y1
Y1 Y1
OUTFAN 1 T.O.P FMC1 OUTFAN 1 T.O.P FMC2
12A 12B STG2 COOLING Y2
13A
2
13B
2
Y2 Y2
YR3
STG3 COOLING Y3
Y3
TO ECB2 FM4 YR3
TO ECB1 FM3 OUTFAN 2
OUTFAN 2 12D T.O.P FMC4 STG4 COOLING Y4
T.O.P FMC3 13D Y4
12C 2
13C
2
STG1 HEATER W1
W1 W1
STG2 HEATER W2
W2 W2
REFER OPTIONAL FCS CONNECTION BELOW. REFER OPTIONAL FCS CONNECTION BELOW.
TO ATB CONTROLS
(in cond. unit)
230Vac
TO ECB1 FM1 TO ECB2 FM2
12A 12B
13A
2
13B
2 TO ECB
(in cond. unit) BMC OLR-1
14 19
INFAN
TO ECB2 FM4
TO ECB1 FM3 T.O.P FMC4
OUTFAN 2
OUTFAN 2 T.O.P FMC3 FCS2 11B 13D 29 AFS
FCS1 11A 13C 10B 2
10A 2 HTR1
28
P HC2
P 30
HTR2
14
LEGEND
CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : WITH STANDARD AND FAN CYCLING OPTION
AR AUXILIARY RELAY
CAL090~120
L1 L2 L3 L1 L2 L3 ATB AUXILIARY TERMINAL BLOCK
L1 L2 L3
6-FAN MOTOR LAYOUT
BM BLOWER MOTOR
CONTROL
BMC BLOWER MOTOR CONTACTOR
PANEL
CB6 CB7
CB8 CC COMPRESSOR CONTACTOR
CCA CC AUXILIARY CONTACT
CB CIRCUIT BREAKER
100
101
102
103
104
105
106
107
108
C. HTR CRANKCASE HEATER
FMC1 FMC3 FMC2 FMC4
FMC5 FMC6 COMP/C COMPRESSOR
DDC DIRECT DIGITAL CONTROLLER
35C
36C
37C
35D
36D
37D
35A
36A
37A
35B
36B
37B
35E
36E
37E
35F
36F
37F
ECB ELECTRONIC CONTROL BOARD
FM1 FM3 FM2 FM4 FM5 FM6 F FUSE
FCS FAN CYCLING SWITCH
FM1 FM2 FM FAN MOTOR (CONDENSER)
T.O.P FMC1 T.O.P FMC2
TO ECB1 12A 13A
2 TO ECB2 12B 13B
2 FMC FAN MOTOR CONTACTOR
OUTFAN 1 OUTFAN 1
FM5
T.O.P
FM6
T.O.P
FMCA FMC AUXILIARY CONTACT
FMC5 FMC6
TO ECB1 12E 13E TO ECB2 12F 13F
OUTFAN 2
2
OUTFAN 2
2 FR FAULT RELAY
FMC1A-1 FM3 FMC2A-1 FM4 HGS HOT GAS BYPASS SOLENOID
T.O.P FMC3 T.O.P
** 12C 13C 12D
FMC4
13D
1 2 1 2
FMC5A-1 FMC6A-1 HPS HIGH PRESSURE SWITCH
** ** HVTB HIGH VOLTAGE TERMINAL BLOCK
REFER OPTIONAL FCS CONNECTION BELOW. REFER OPTIONAL FCS CONNECTION BELOW.
JP JUMPER
FMC1A-1 11A FM3 FMC2A-1 11B FM3
10A FCS1 10C FCS3
12C
T.O.P
13C
FMC3
12D
T.O.P
13D
FMC4 L1 LINE 1
2 2
1 FMC5A-1 P
1 FMC6A-1
P
1OB FCS2
11B
10D FCS4 11D L2 LINE 2
P P L3 LINE 3
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : STANDARD LPS LOW PRESSURE SWITCH
LVTB LOW VOLTAGE TERMINAL BLOCK
CAL140
LUG LUG GROUND
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 8-FAN MOTOR LAYOUT
NTB NEUTRAL TERMINAL BLOCK
CONTROL
OLR OVER LOAD RELAY

PANEL
CB6 CB7 CB8 CB9 P PRESSURE

PDS PUMP DOWN SOLENOID
103
104
105
106
107
108
109
110
111
100
101
102
SSPS SOLID STATE PROTECTION SYSTEM

FMC1 FMC2 FMC3 FMC4
TOP FM THERMAL OVERLOAD PROTECTION
TRANS TRANSFORER
VFC VOLT FREE CONTACT
YR COOLING RELAY
___
35H
36H
37H
35G
36G
37G
35E
36E
37E
35F
36F
37F
35C
36C
37C
35D
36D
37D
35A
36A
37A
35B
36B
37B
FIELD WIRING
FM1 FM3 FM2 FM4 FM5 FM7 FM6 FM8 TERMINAL BLOCK OR TERMINATION POINT
SPLICE-CLOSED END
TO ECB1 TO ECB2
JUNCTION OF WIRES, CONNECTED
FM1 FM3 FM2 FM4
OUTFAN 1 T.O.P T.O.P FMC1 OUTFAN 1 T.O.P T.O.P FMC2
12A 13A 12C 12C 12B 13B 12D 12D CROSSING OF WIRES, NO CONNECTION
2 2
NOTES
OUTFAN 2
FM5
T.O.P T.O.P FMC3 OUTFAN 2
FM6
T.O.P T.O.P FMC4
1. POWER SUPPLY, 380/415V-3PH-50Hz.
12E 13E 12G 12H 12F 13F 12H 12H
2 2
2. ANY WIRE REPLACEMENT SHOULD BE OF 900C
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : WITH FAN CYCLING OPTION
OR ITS EQUIVALENT. USE COPPER CONDUCTOR
WIRES ONLY.
CAL140
L1 L2 L3 L1 L2 L3 3. POWER MUST BE SUPPLIED TO CRANKCASE
L1 L2 L3 L1 L2 L3
8-FAN MOTOR LAYOUT
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
SYSTEM START UP.
CONTROL
PANEL
IF POWER IS OFF 6 HOURS OR MORE, CRANK-

CB6 CB7 CB8 CB9
CASE HEATER MUST BE ON FOR 12 HOURS BE-
FORE OPERATING THE SYSTEM.
FAILURE TO FOLLOW THESE INSTRUCTIONS
MAY RESULT IN COMPRESSOR DAMAGE.
100
101
102
103
104
105
106
107
108
109
110
111
FMC1 FMC3 FMC2 FMC4 4. FUSED DISCONNECT SWITCH OR CIRCUIT

FMC5 FMC7 FMC6
BREAKER TO BE PROVIDED BY CONSUMER
35C
36C
37C
35D
36D
37D
35A
36A
37A
35B
36B
37B
WITH RATING AS RECOMMENDED BY COOLINE.

35G
36G
37G
35H
36H
37H
35E
36E
37E
35F
36F
37F
5. COMPRESSOR MOTORS ARE PROVIDED WITH SSPS OR IN-

FM1 FM3 FM2 FM4
FM5 FM7 FM6 FM8 TERNAL LINE BREAK THERMAL OVERLOAD PROTECTION.
6. USE DISCONNECT TAB + OR SPLICE ONLY WHERE
EVER REQUIRED FOR EXTENSION OF ORIGINAL WIRE.
12A 13A 12B 13B 7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR LVTB
2 2
FM3 FM4
FIELD WIRING. GROUND CONNECT AT BOTH ENDS.
FCS1 T.O.P FMC3 FCS2 T.O.P FMC4
10A 10B
11A 12C 13C
2
11B 12D 13D
2
8. COOLING OUTPUT SIGNAL FROM CONTROLLER
TO ECB1
P
FM5 TO ECB2
P
FM6
SHOULD FOLLOW THE SEQUENCE:
OUTFAN 2 T.O.P OUTFAN 2 T.O.P
12E 13E
FMC5 12F 13F
FMC6 ON SEQUENCE - Y1-Y2-Y3-Y4.
2 2
OFF SEQUENCE - Y4-Y3-Y2-Y1.
FM7 FM8
FCS3 T.O.P FCS4 T.O.P
10C 11C 12G 13G
FMC7 10D 11D 12H 13H
FMC8 9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGE
2 2
P P ACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS 230VAC.
ALSO, COMP. LOCKOUT LIGHT (RED) OF ECB IS ON.
15
TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS
SWITCHING CONTACTS
FROM T'STAT CONTROLLER OR DDC
CONTROLS AND SEQUENCE OF OPERATION

The unit is equipped with an electronic control board which can be linked with any commercially available 24V ac thermo-
stat or can be controlled through a DDC panel. With cooling input signals coming from a thermostat or DDC, the motors
in the equipment are started in the following sequential order: condenser fan – compressor motor. The cooling input
signals to the unit’s control board should always start first with the first stage (Y1) followed by the second stage (Y2) and
“OFF” sequence should start with the second stage (Y2) followed by the first stage (Y1).
Balance Loading of Compressors: The user can select the sequence of operation of the compressors; either com-
pressor 1 as always leading (dip switch #2 set at ON) or enabling balance loading of compressor (dip switch #2 set at
OFF). In balance loading function, the compressor with the least run time will be started first to equalize the run time of
the compressors. These functions are selectable through the dip switch on the electronic control board. Please refer to
the settings table shown in the unit’s wiring diagram.
Fault Diagnostics: In case of system fault, LED’s on the board emits a flashing signal indicating the nature or where the
fault is. This is to guide the service technician in identifying the fault. Please refer to the settings table shown in the unit’s
wiring diagram for the details of each respective fault against LED indicators.
Compressor Lock-Out Function: If any of the unit’s safety control devices trips and such condition is maintained for
approximately 3 minutes, the control will lock-out that particular system preventing a re-start. It can be re-set by shutting
off power to the thermostat or if the cooling signal to the board is turned OFF.
Compressor Anti-Recycling Timer: The unit’s electronic control board has a built-in three (3) minutes minimum off
timer for the compressor. This is for compressor protection in case of accidental manual re-set or immediate re-cycling
through the thermostat due to load demand.
16
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: CAL018 - CAL025
PROPER CLEARANCE TO BE PROVIDED
MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR

SLINGS TO AVOID BASE DAMAGE
17
INSTALLATION CLEARANCE
WALL
MODEL NUMBER A B C D E
CAL018 - CAL025 1500 1500 1500 1500 1500
FIGURE - 1
CAL030 - CAL050 1500 1500 2000 1500 1500 STRAIGHT WALL
CAL060 - CAL140 2000 2000 3000 2000 2000
FIGURE - 2
CORNER WALL
NOTE: 1. All dimensions are in mm.
2. If unit is installed in special pit, please observe the same tolerance for walls. Pit height should not exceed
the unit height.
18
MOUNTING LOCATION
MODELS: CAL018 - CAL025 MODELS: CAL030 - CAL050
MODELS: CAL080
NOTE: All dimensions are in mm. Tolerance: ±2mm.

19
LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)
MODEL No. R1 R2 R3 R4 R5 R6 R7 R8
CAL018 136 215 189 207 - - - -
CAL020 143 236 197 224 - - - -
CAL025 189 286 249 300 - - - -
CAL030 258 357 322 371 - - - -
CAL035 267 379 330 391 - - - -
CAL040 278 395 343 406 - - - -
CAL045 284 403 348 415 - - - -
CAL050 298 421 362 433 - - - -
CAL060 462 483 500 491 - - - -
CAL070 501 524 541 530 - - - -
CAL080 638 605 638 605 - - - -
CAL090 494 494 508 508 404 404 - -
CAL100 505 505 520 520 415 415 - -
CAL120 469 469 457 457 503 503 398 398
CAL140 497 497 488 488 533 533 413 413
LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)

MODEL No. R1 R2 R3 R4 R5 R6 R7 R8
CAL018 153 232 206 224 - - - -
CAL020 160 253 214 241 - - - -
CAL025 211 308 271 322 - - - -
CAL030 280 379 344 393 - - - -
CAL035 289 401 352 413 - - - -
CAL040 313 430 378 441 - - - -
CAL045 319 438 383 450 - - - -
CAL050 341 464 405 476 - - - -
CAL060 511 532 549 540 - - - -
CAL070 565 588 605 594 - - - -
CAL080 702 669 702 669 - - - -
CAL090 538 538 552 552 448 448 - -
CAL100 549 549 564 564 459 459 - -
CAL120 520 520 508 508 554 554 449 449
CAL140 548 548 539 539 584 584 464 464
R1 R2 R1 R2 R1 R2 R1 R3 R5
R3 R4 R3 R4 R3 R4 R2 R4 R6
R1 R3 R5 R7
R2 R4 R6 R8
20
INSTALLATION INSTRUCTIONS
GENERAL
The complete shipment should be inspected for damage. Any damage visible at the time of delivery should be noted on
the shipment invoice.
These units are shipped completely assembled and wired. Units require interconnecting piping (AHU), external power,
thermostat wiring, condensate drain piping and ducting as applicable.
Size of unit for an installation should be based on a heat load calculation made according to applicable standards. Units
must also be installed in accordance with regulations of the "National Fire Protection Association" and local electrical
codes. Where local regulations vary with instruction furnished, installer should adhere to local standards.
Prepare your concrete pad or steel stand as applicable. Remove shipping protective covers and wooden crating and lift
unit from base and place in position with necessary applicable vibration isolators.
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions
and other COOLINE publications for the specific equipment being installed.
These units 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.
It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigeration
standard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigerant
pipes carefully to prevent damaging the suction pipe insulation and vibration transmission to the structure.
Outdoor unit connected to factory matched indoor unit

Outdoor unit contains holding charge only. The correct system refrigerant charge for operation is given in the unit name-
plate & physical data table when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge for
maximum efficiency.
Sweat connection:
Use refrigerant grade piping. Service valves are closed from factory when shipped and ready for brazing. After wrapping
the service valve with a wet cloth, the piping set can be brazed to service valve using either silver rod or silfos rod brazing
material. When brazing completed, refrigerant piping and indoor coil are now ready for leak testing. This check should
also include all field and factory brazed joints.
Warning: Relieve all pressure before refrigerant system repair or final unit disposal to avoid personal injury or
death. Use service ports and open all valves.
21
LEAK TESTING & REFRIGERANT CHARGING
Leak test:
Leak can occur from joints or fittings that are improperly brazed/connected during installation of indoor and outdoor units.
The installer should leak test the indoor unit & associated field supplied refrigerant piping, then the outdoor unit, each
separately using electronic freon detector and/or soap bubbles.
Refrigerant Charging:
(To be used for system having a holding charge and to compensate for length of liquid line).
1. Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Make
sure that no air & moisture enter the system as easter oil are hygroscopic in nature. The whole system should be leak
tested and evacuated before charging the refrigerant.
2. When system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging lines and manifolds must be
purged with refrigerant vapor prior to admitting refrigerant into the system to prevent contamination system with non-condensable.
3. It is important to first determine the amount of refrigerant required for the system, the unit nameplate normally identify
the weight of the refrigerant required.
4. The refrigerant should be added in small amounts allowing sufficient time for the unit pressure to equalize each time.
WIRING
All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltage,
frequency and phase must coincide with the unit nameplate.
Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate. The unit
wiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wiring.
The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused disconnect
switch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone wire for this
purpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety & servicing purposes.
Wiring connection to the unit must have insulation suitable for temperatures of a minimum of 600C.
Minimum circuit ampacity for each model is shown on the name plate and product catalog. Equipment wiring diagram
should be examined and thoroughly understood before field wiring connections are made.
Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damage to
compressors and motors can occur, if improper voltage is applied.
START-UP INSPECTION & CHECK LIST

After the installation is completed in all respect, the following points should be covered before the system is switched on for operation.
1. Remove or loosen shipping retainers under motor compressors. Make sure the hold down nuts on spring mounted
compressors are not touching the compressor feet.
2. Make sure all electrical fasteners/connections are tight and clean.
3. All controls are set according to manufacturer's instructions (low & high pressure switch, pump down pressure
switch, fan cycling switch, etc...)
4. Make sure all valves are open (compressor suction & discharge service valves, liquid line, etc.).
5. Follow all the instructions from the warning tags and stickers.
6. Compressor crankcase heater should be energized for 12 hours (special attention should be taken to disable com-
pressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for few
minutes to pumpdown the system, even the thermostat is OFF).
7. Thorough inspection on evaporator coil, condenser coil and other components for any physical damage.
8. Expansion valve bulb is strapped properly at correct location.
9. Circuit breaker/fused disconnect switch.
10. Blower fan belt is properly tightened and pulleys are properly aligned.
11. Blower fan & condenser fans are at correct rotation and their mountings are properly tightened.
12. All refrigerant service valve caps are installed.
13. All piping, piping insulation and piping supports are properly installed.
14. Thermostat is the right one and installed properly.
15. Duct work and accessories (check the following list and select whichever applicable to each jobs):
• Flexible Connection
• Air Filters Clean
22
• Air Filter Access Door Gasket
• Sound Attenuators (If Applicable)
• Fresh Air Intake
• Ductwork Caulking Inside/Outside Building
• Ductwork Supports Inside/Outside Building
• Duct Leakage Inside/Outside Building
• Volume Dampers
• Volume Damper Access Doors
• Fire Dampers
• Fire Damper Access Doors
• Transfer Grilles/Door Grilles
• Duct Insulation/Liner
• Diffusers/Grilles
• Duct Humidistat
• Filter flag
CHECK-OUT & OPERATIONAL START-UP PROCEDURE
After the completion of inspection and check list, the following points should be covered before system is placed in operation.
1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for check-
ing Voltage, Amps, RPM, CFM, static pressure, etc.
2. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere.
3. Start the compressor and observe the following points (on multiple compressor units, it is highly recommended to start
the compressors one by one to achieve careful observation for each compressor).
(a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take
corrective action.
(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required,
leak test all connections and system components and repair any leaks before adding refrigerant.
(c) Observe oil level in compressor crankcase sight glass (if available) and add oil as necessary to bring to recom-
mended oil level.
All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in order
to provide some allowance for oil which will be circulating in the system during operation. Depending on the system
design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may be
necessary either to add or remove oil from a system any time it is first placed in operation with a different compressor.
An abnormally low oil level may result in a loss of lubrication; while an excessively high oil level may result in oil
slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may vary consider-
ably on initial start-up if liquid refrigerant is present in the crankcase, and the oil level should be checked with the
compressor running after having reached a stabilized condition.
(d) Thermostatic expansion valves must be checked for proper superheat settings. Recommended superheat is 150F
to 200F.
(e) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage must
be within ±10% of that indicated on the compressor nameplate. If high or low voltage is indicated, notify the power
company. The current normally should not exceed 110% of the nameplate rating. If amperage draw is excessive,
immediately determine the cause and take corrective action. On three phase compressor motors, check to see
that a balanced load is drawn by each phase.
(f) Carry out any necessary tests, recording airflow rates, entering/leaving temperatures, sound levels, outdoor tem-
peratures, supply airflow rates in occupied spaces and any other specified parameters.
23
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.
24
MOTOR CONTACTOR
The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compres-
sor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, motor
contactors are subjected to quick cycling due to various causes. This may cause burned and/or sticking contacts and can
cause a compressor motor failure, even though the motor overload protectors trip and open the control circuit.
FAN MOTOR
The condenser fan motor is a single speed electrical motor with ball bearings, protected with an automatic reset internal
overload.
CRANKCASE HEATERS
The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest part
of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize when
the compressor is operating.
Power must be supplied to crankcase heater for minimum of 12 hours prior to system start up. If power is off 6 hours or
more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions may
result in compressor damage.
Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are not
a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper piping
practice, over feeding to the evaporator, leaking solenoid valve, etc.
In some cases where migration of refrigerant to the crankcase occurred due to long storage time, shutdown period,
defective components, etc. The crankcase heater may be ineffective. Such cases may be easily observed by high oil
level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharge
service valves of the compressor and release all liquid refrigerant from the compressor.
The liquid refrigerant dilutes the oil in the crankcase and the refrigerant rich oil will be pumped to the rods and the
bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at the
bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor to
drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinders
during the suction stroke causing them to wear during the compression stroke.
When the crankcase is filled with liquid refrigerant and the compressor starts severe agitation, oil foaming etc. will cause
major damage to the compressor.
Periodic checking for proper operation of crankcase heater is highly recommended.
LUBE OIL PROTECTION CONTROL

Pressure lubricated refrigeration compressors require a pressure protector in the event of an oil pressure failure. The
lube oil pressure protection control is factory set to conform with compressor manufacturers specifications and should
not be changed.
The control measures the net oil pressure available to circulate oil through the lubrication system. The positive displace-
ment oil pump circulates the refrigerant oil through the lubrication system. Since the oil pump is connected directly to the
compressor crankcase, the inlet pressure to the oil pump will always be the crankcase pressure. The oil pump outlet
pressure will be the crankcase pressure plus the oil pump pressure. Therefore, net oil pump pressure will always be the
pump outlet pressure minus the crankcase pressure.
The control contains a built-in time delay switch that is a trip-free expansion rod device actuated by a resistance heater.
The control is factory set to cut-in at 18 PSIG and cut out at 9 PSIG. When the compressor starts the resistance heater
of the time delay becomes energized. If the net oil pressure does not build to 18 PSIG or above within 120 seconds, the
time delay trips to stop the compressor. If the net oil pressure drops below 18 PSIG, but not below 9 PSIG during a
running cycle, the time delay resistance heater becomes energized and unless the net oil pressure returns to 18 PSIG or
above during the 120 seconds safety time period, the compressor will shut down. The compressor will shut down when-
ever the net oil pressure drops below 9 PSIG, and will never run for more than the predetermined 120 seconds on
abnormal oil pressure.
25
OIL PUMP CRANKCASE NET OIL
OUTLET PRESSURE PRESSURE PRESSURE
78 _ 60 = 18
New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type me-
chanical expansion rod-resistance heater type oil protection controls.
FEATURES:
• An entirely new control concept. This unique design incorporates a modern pressure transducer to monitor oil pressure.
• Each control reflects improved calibration stability over the control's entire pressure range.
• Controls boast truly accurate timing despite ambient temperature and voltage variations.
• All electronic components are purposely "over-sized" and computer-matched to provide the greatest safety factor and
dependable service life.
• Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibra-
tion, dirt or moisture.
• Controls reset instantaneously, thanks to the precise solid state timing circuit. No annoying wait for old-fashioned timer
heater to cool down.
• Control module is interchangeable with the old type conventional oil protection and with competitive brands of oil
protection controls. An exact replacement from a mounting, wiring and logic function standpoint.
• Control maintains timing over the full voltage range of 102 to 264 VAC. Voltage selection is not necessary.
• Unit is not position sensitive.
• Users are offered a choice of controls with or without cover, a handy mounting bracket and other options.
• "Logic" circuitry in the module monitors oil pressure pulses during marginal operation and integrates them resulting in
a longer span of time before lock-out occurs.
• Last, but not least, it has enlarged the reset button to a new "thumb-sized" dimension. The reset button is slightly
recessed to protect it from damage.
VOLTAGE MONITOR
This device protects the motors in the unit from faults such as; under or over voltage, unbalance & phase reversal of the
power supply. When the device sensed such faults, it will cut-off the supply in the control circuit thereby cutting off power
to the motors. The voltage monitor will re-set automatically when power is brought back to it’s normal conditions.
TRIP & RE-SET VOLTAGE (% OF SET POINT)

LINE VOLTAGE
UNDER VOLTAGE OVER VOLTAGE PHASE IMBALANCE
RANGE
TRIP RE-SET TRIP RE-SET TRIP RE-SET
190 - 480 VAC 90% 93% 110% 107% 6% 4.5%
26
REFRIGERATION
COMPRESSOR
Semi-hermetic reciprocating compressors are used as standard for models CAL025 - CAL140 except for models
CAL018 - CAL020 scroll compressors are used as standard. All the compressors are conforming to ARI 540 standard.
The compressors are equipped with internal motor protection, factory installed crankcase heaters and rubber vibration
isolators for quiet and efficient operation. As an option, semi-hermetic compressor can be fixed on anti-vibration
mounting (spring type) along with suction & discharge line vibration eliminators. Oil pressure control is provided on
units with semi-hermetic 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
drier are standard for all models.
Semi-hermetic Compressor:
These Semi hermetic reciprocating compressors are accessible –hermetic type. Compressor and motor are enclosed in
a hermetically sealed housing, with out shaft seal. The compressors are equipped with an oil sight glass through which
the oil quantity and its conditions in the crankcase can be observed. These compressors can be disassembled in the field
for service.
Refrigerant-cooled motor –compressors have an oil pressure lubrication system. This system is supplied by a positive
displacement oil pump, working in either direction. It is protected by a screen and is made accessible for quick oil
pressure checking by a Schrader check valve. The use of oil pressure control safeguards the lubrication system. These
compressors can be provided with capacity control (optional). The use of unloading provides optimal part load capacities.
Scroll Compressors:
Scroll Compressors are used in some of these units. The major benefits being:
1. Low Sound Level: Quieter operation because of no dynamic suction and discharge valves action.
2. Low vibration and discharge pulses.
3. High Energy Efficiency: Because of high volumetric efficiency it minimize pressure and heat transfer losses.
4. High Capacity: Due to its high mass flow and high compression ratios.
5. High Durability: With its robust design, few moving parts, low motor strains, large internal volume for liquid handling
makes this compressor highly reliable.
6. High Charge Limit: Therefore, lower applied costs as no suction accumulator required, no need for pump down
system and check valve in discharge line.
Low capacity can be caused by inefficient compressor, that is, the compressor does not pump sufficient quantity of
refrigerant, even though a full charge is available in the system.
Scroll Compressor Rotation:

Scroll compressors are designed to operate in single direction only. Hence, care has to be taken to ensure correct
rotation when the system is operated. Verification of correct rotation is by observing that the suction pressure drops and
discharge pressure rises when compressor run. Reverse rotation results in abnormal sound, as well as, substantially low
current draw and by interchanging power supply wire L1 & L3 will correct this problem.
Compressor Maintenance:
Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is found
to be all right but the electrical components are defective, remove and replace the defective electrical components only.
Below are some tests that should be performed on the compressor to determine, if the compressor is defective.
1. Test compressor motor winding for ground.
2. Test compressor motor windings for continuity.
3. Test that compressor motor will run both without a load and under a load.
4. Test the current or ampere drawn.
5. Observe sound level of compressor.
To establish that the compressor suction and discharge valves are operating and holding properly, attach gauges to the
liquid and suction service valves. "Front seat" the liquid service valve.
27
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.
28
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 SWITCH

To provide protection for the compressor in the event of refrigerant loss, a low pressure sensor is installed in the suction
line.
The control is preset to open when the suction pressure is 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.
29
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.
30
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.
31
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.
32
PARTS LIST
MODEL NUMBER CAL018L CAL020L CAL025L CAL030L CAL035L CAL040L CAL045L CAL050L CAL060L
COMPRESSOR 800-614-11 800-614-14 800-697-17 800-697-20 800-697-23 800-697-26 800-697-29 800-697-32 800-697-35
CONTACTOR 800-098-63 800-098-63 800-098-63 800-098-65 800-098-65 800-098-65 800-098-67 800-098-68 800-098-65
800-098-63
CAPACITY UNLOADER KITS NIL NIL 800-577-00 800-577-00 800-577-00 800-577-00 800-577-00 800-577-00 800-577-00
COND. FAN MOTOR 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06 800-555-06 800-237-00
CONTACTOR 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51
FILTER DRYER 800-531-05 80053100 80053100 80053100 80053100 80053100 800-531-17 800-531-17 800-531-17
FILTER DRYER CORE NIL NIL NIL NIL NIL NIL 800-027-65 800-027-65 800-027-65
SIGHT GLASS 800-200-00 800-200-01 800-200-01 800-200-01 800-200-01 800-200-01 800-200-04 800-200-04 800-200-04
MECHANICAL SHUT OFF VALVE 800-705-40 800-705-41 800-705-41 800-705-41 800-705-41 800-705-41 800-705-42 800-705-42 800-705-42
PUMP DOWN SOLENOID VALVE 800-705-20 800-705-21 800-705-21 800-705-21 800-705-21 800-705-21 800-70660 800-70660 800-70660
PRESSURE GAUGE - SUCTION 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
PRESSURE GAUGE - DISCHARGE 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31
PRESSURE GAUGE - OIL NIL NIL 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
ADJ. LOW PRESSURE SWITCH 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29
ADJ. HIGH PRESSURE SWITCH 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30
P3 CONTROLLER 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51
MICROSMART CONTROLLER 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45
USER INTERFACE CARD 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50
PTC TEMP. SENSOR 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55
RELATIVE PRESSURE TRANSDUCER -DP 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56
RELATIVE PRESSURE TRANSDUCER -OIL NIL NIL 800-646-57 800-646-57 800-646-57 800-646-57 800-646-57 800-646-57 800-646-57
RELATIVE PRESS. TRANSDUCER -SUCTION 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58
MODEL NUMBER CAL070L CAL080L CAL090L CAL100L CAL120L CAL140L

COMPRESSOR 800-697-38 800-697-26 800-697-29 800-697-32 800-697-35 800-697-38
800-098-68 800-098-65 800-098-68
CONTACTOR 800-098-65 800-098-65 800-098-67 800-098-68 800-098-63 800-098-65
CAPACITY UNLOADER KITS 800-577-00 800-577-00 800-577-00 800-577-00 800-577-00 800-577-00
COND. FAN MOTOR 800-237-00 800-237-00 800-237-00 800-237-00 800-237-00 800-237-00
CONTACTOR 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51
FILTER DRYER 800-531-13 800-531-42 800-531-17 800-531-17 800-531-17 800-531-13
FILTER DRYER CORE 800-027—65 800-027—65 800-027—65 800-027—65 800-027—65 800-027—65
SIGHT GLASS 800-200-05 800-200-01 800-200-04 800-200-04 800-200-04 800-200-05
MECHANICAL SHUT OFF VALVE 800-705-43 800-705-41 800-705-42 800-705-42 800-705-42 800-705-43
PUMP DOWN SOLENOID VALVE 800-705-09 800-705-21 800-70660 800-70660 800-70660 800-705-09
PRESSURE GAUGE - SUCTION 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
PRESSURE GAUGE - DISCHARGE 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31 800-600-31
PRESSURE GAUGE - OIL 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30 800-600-30
ADJ. LOW PRESSURE SWITCH 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29
ADJ. HIGH PRESSURE SWITCH 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30
P3 CONTROLLER 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51 800-652-51
MICROSMART CONTROLLER 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45 800-646-45
USER INTERFACE CARD 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50 800-646-50
PTC TEMP. SENSOR 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55 800-646-55
RELATIVE PRESSURE TRANSDUCER -DP 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56 800-646-56
RELATIVE PRESSURE TRANSDUCER -OIL 800-646-57 800-646-57 800-646-57 800-646-57 800-646-57 800-646-57
RELATIVE PRESS. TRANSDUCER -SUCTION 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58 800-646-58
33
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.
34
PREVENTIVE MAINTENANCE SCHEDULE
CAUTION: Disconnect power supply and allow all rotating parts to stop before servicing the unit.
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.
35
MATERIAL SAFETY DATA SHEET
SAFETY DATA REFRIGERANT R-134a
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
36
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
37
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
38

&#39;CAL&#39; SERIES (R-410a)

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INSTALLATION,

AIR COOLED CONDENSING UNITS

NOTES: * – Dual scroll compressors are available up to models CAL020 only.

NOMINAL CAPACITY , TONS* 18 23 26 30 34 40 44 52

COMPRESSOR Type Scroll Scroll Semi-hermetic reciprocating

CONDENSER FAN Type Propeller

Qty. – Diameter (inch) 2 – 30 2 – 30 2 – 30 4 – 30 4 – 30 4 – 30 4 – 30 4 – 30

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

NOMINAL CAPACITY , TONS* 62 72 78 90 103 121 140

COMPRESSOR Type Semi-hermetic reciprocating

CONDENSER FAN Type Propeller

Qty. – Diameter (inch) 4 – 32 4 – 32 4 – 32 6 – 32 6 – 32 6 – 32 8 – 32

Nominal CFM 43408 41240 41240 63432 63432 63216 75264

Motor HP – RPM 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920

CONDENSER COIL Type Inner grooved tubes and enhanced fins

Close (PSIG) 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

NOTE: All dimensions are in mm.

CAL 060 & CAL 070

NOTE: All dimensions are in mm.

CAL 090, CAL 100 & CAL 120

NOTE: All dimensions are in mm.

NOTE: All dimensions are in mm.

PRESSURE SWITCH SETTINGS

CC1 CC2 CC3 CC4 CB1 CB2 CB3 CB4

PDS2 1 CC4A-1B C.HTR4 2

SEE VFC CONNECTION PDS1

FROM T'STAT CONTROLLER OR DDC COMP. 2:

YR3 STG3 COOLING Y3 C.HTR4

DIP SWITCH M1/11 M2/14

(LP2) 23B P (REMOVE JP4)

LOCK2 LOCK1 ECB2 W2

SYSTEM2 SYSTEM1 SQMBO4 ( P III )

UNIT STATUS (VFC) INDICATION CONNECTION

COMP4 TRIP 25C 26D

(Stg. 1 Heating) (Stg. 2 Heating)

FMC1 FMC3 FMC2

FMC4 TB1 (ECB) (by others)

OLR OVER LOAD RELAY

CB6 CB7 CB8 CB9 P PRESSURE

SSPS SOLID STATE PROTECTION SYSTEM

IF POWER IS OFF 6 HOURS OR MORE, CRANK-

FMC1 FMC3 FMC2 FMC4 4. FUSED DISCONNECT SWITCH OR CIRCUIT

WITH RATING AS RECOMMENDED BY COOLINE.

5. COMPRESSOR MOTORS ARE PROVIDED WITH SSPS OR IN-

CONTROLS AND SEQUENCE OF OPERATION

PROPER CLEARANCE TO BE PROVIDED

MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR

MODELS: CAL030 - CAL050

MODELS: CAL060 - CAL140

MODELS: CAL060 - CAL070

MODELS: CAL090 - CAL100

MODELS: CAL120 - CAL140

NOTE: All dimensions are in mm. Tolerance: ±2mm.

LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)

REFRIGERANT PIPING CONNECTIONS

Outdoor unit connected to factory matched indoor unit

START-UP INSPECTION & CHECK LIST

Maximum voltage deviation from average voltage

LUBE OIL PROTECTION CONTROL

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

Scroll Compressor Rotation:

MOTOR COMPRESSOR BURN OUT PROCEDURE

'CAL' SERIES (R-410a)

'CAL' SERIES (R-410a)