Zamil Air Conditioner User Guide

INSTALLATION, OPERATION & MAINTENANCE MANUAL

AIR COOLED CONDENSING UNITS 'CDL' SERIES (R-22) PL-OM-CDL-07-1M-E

Contents

INDEX

Page

General information .................................................................................................................................. 2 Safety issues ............................................................................................................................................ 2 Model decoding ....................................................................................................................................... 3 Physical data ......................................................................................................................................... 4-5 Electrical data ........................................................................................................................................... 6 Dimensions .......................................................................................................................................... 7-11 Typical schematic wiring diagram ...................................................................................................... 12-16 Field wiring connections ......................................................................................................................... 17 Controls & sequence of operation .......................................................................................................... 17 Rigging instructions ................................................................................................................................ 18 Installation clearance .............................................................................................................................. 19 Mounting location ................................................................................................................................... 20 Load distribution ..................................................................................................................................... 21 INSTALLATION INSTRUCTIONS General ................................................................................................................................................... 22 Location of unit ....................................................................................................................................... 22 Refrigerant piping connections ............................................................................................................... 22 Leak testing & refrigerant charging ......................................................................................................... 23 Start-up inspection & check list ......................................................................................................... 23-24 Check-out & operational start-up procedure ........................................................................................... 24 ELECTRICAL Power supply .......................................................................................................................................... 25 Unbalanced voltage ................................................................................................................................ 25 Motor contactor ...................................................................................................................................... 26 Fan motor ............................................................................................................................................... 26 Crankcase heater ................................................................................................................................... 26 Lube oil protection control ................................................................................................................. 26-27 Voltage monitor ...................................................................................................................................... 27 REFRIGERATION Compressor ............................................................................................................................................ 28 High & low pressure protection .......................................................................................................... 29-30 Pump down control ................................................................................................................................. 30 Trouble shooting chart ....................................................................................................................... 31-33 Parts list ................................................................................................................................................. 34 Recommended spare parts .................................................................................................................... 35 Preventive maintenance schedule .......................................................................................................... 36 Material safety data sheet ...................................................................................................................... 37 Pressure temperature chart ............................................................................................................... 38-39

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS. THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1

GENERAL STATEMENT Cooline CDL 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 installation, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year. Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experienced technicians should perform the installation and other maintenance procedures.

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

3

++

195

160

135

110

100

080

065

055

050

040

035

030

025

020

4, 5 & 6 NOMINAL COOLING CAPACITY (TONS) L : 380/415-3-50 (4 WIRE)

7 ELECTRICAL SUPPLY (V-Ph-Hz)

* **

***

(LEAD COMPRESSOR)

UNLOADER

M : QUADRUPLE SEMI-HERMETIC RECIPROCATING WITH

**

L : DUAL SEMI-HERMETIC RECIPROCATING WITH UNLOADER (LEAD COMPRESSOR)

***

Q : QUADRUPLE SEMI-HERMETIC RECIPROCATING

RECIPROCATING

H : DUAL SEMI-HERMETIC

S : DUAL SCROLL

8 REFRIGERATION CIRCUIT TYPE

****

L : K, V, C & P COMBO

N : V, C & P COMBO

M : K, V & P COMBO

T : K, V & C COMBO

G : K & P COMBO

E : K & C COMBO

B : K & V COMBO

P : PUMPDOWN SOLENOID VALVE

C : COMPRESSOR CIRCUIT BREAKER

V : VOLT FREE CONTACTS

K : FAN CYCLING & ADJUSTABLE HIGH & LOW PRESSURE SWITCHES

A : STANDARD OPTIONS

+

9 ELECTRICAL KITS OPTION

G :COPPER FIN WITH COIL GUARD

E : COATED ALUMINUM FIN WITH COIL GUARD

D : ALUMINUM FIN WITH COIL GUARD

C : COPPER FIN

B : COATED ALUMINUM FIN

A : ALUMINUM FIN

10 CONDENSER COIL

++

B : M, H, O & R COMBO

L : A, H, P & R COMBO

G : A, H & O COMBO

F : A, H & P COMBO

V : A, H & R COMBO

U : M, H & O COMBO

T : M, H & P COMBO

S : M, H & R COMBO

Q : M & R COMBO

N : M & H COMBO

K : M & O COMBO

J : M & P COMBO

R : CONDENSER PRESSURE RELIEF VALVE

H : HOT GAS BYPASS VALVE

O : PRESSURE GAUGES (SUCTION, DISCHARGE & OIL)

P : PRESSURE GAUGES (SUCTION & DISCHARGE)

M : REPLACEABLE CORE FILTER DRIER & SHUT-OFF VALVE

+

A : STANDARD OPTIONS

11 MECHANICAL KITS OPTIONS

Dual scroll compressors are available up to models CDL055 only. Dual semi-hermetic compressors are available for models CDL065 - CDL100 only. Quadruple semi-hermetic compressors are available for models CDL110 - CDL195 only. A combination of volt free contact option: 1. Unit ON indication, 2. Compressor RUN/TRIP, 3. Unit trip indication. Standard options (for models up to CDL065 only) contain sealed type filter drier, fixed low & high pressure switches. Standard options (for models CDL080 - CDL195 only) contain replaceable filter drier, ball valve, sight glass, muffler and without spring isolator. – Oil pressure gauge is applicable for semi-hermetic compressors only.

* – ** – *** – **** – + –

NOTES:

COOLINE CONDENSING UNIT

CDL

1, 2 & 3 BASIC

MODEL DECODING

PHYSICAL DATA MODEL NUMBER

CDL020

CDL025

CDL030

CDL035

CDL040

CDL050

CDL055

NOMINAL CAPACITY , TONS*

18.4

22.3

27.6

35.5

42.1

48.5

54.8

NUMBER OF REFRIGERATION CIRCUIT

Dual

Dual

Dual

Dual

Dual

Dual

Dual

5.91

6.3/5.91

6.3

758

987/758

987

COMPRESSOR

Type Oil per system (liters)

Scroll 3.25

3.25

4.14

Refrigerant** Charge per system (oz)*** CONDENSER FAN

402

497

640 Propeller

2 – 30

2 – 30

4 – 30

4 – 30

4 – 30

4 – 32

4 – 32

Nominal CFM

13000

13000

26000

26000

26000

42776

41376

1.5 – 950

1.5 – 950

1.5 – 950

1.5 – 950

1.5 – 950

2 – 920

2 – 920

Type

Inner grooved tubes and enhanced fins 3/8–3–14

3/8–4–14

3/8–2–14

3/8–3–14

3/8–4–14

3/8–2–14 3/8–3–14

3/8–3–14

32.9

32.9

59.5

59.5

59.5

75

75

Open (PSIG)

450 ± 10

450 ± 10

450 ± 10

450 ± 10

450 ± 10

450 ± 10

450 ± 10

Close (PSIG)

360 ± 15

360 ± 15

360 ± 15

360 ± 15

360 ± 15

360 ± 15

360 ± 15

Open (PSIG)

25± 5

25± 5

25± 5

25± 5

25± 5

25± 5

25± 5

Close (PSIG)

50 ± 5

50 ± 5

50 ± 5

50 ± 5

50 ± 5

50 ± 5

50 ± 5

1-3/8

1-3/8

1-3/8

1-5/8

1-5/8

1-5/8

2-1/8

5/8

5/8

5/8

7/8

7/8

7/8

7/8

Total face area (Sq. ft.)

LOW PRESSURE SWITCH

332

Qty. – Diameter (inch)

Tube Dia–Rows–Fins per inch

HIGH PRESSURE SWITCH

R-22

Type

Motor HP – RPM CONDENSER COIL

4.67

REFRIGERANT LINES+ Suction line size (OD), inch Liquid line size (OD), inch

SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 65.3/61.8/56.5 65.4/61.8/56.6 68.2/64.7/59.5 68.4/64.8/59.6 OPERATING WEIGHT, Kg.+++

716

760

1050

1159

68.5/65/59.7

68.8/65.3/60 68.9/65.4/60.1

1328

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

1447

1480

PHYSICAL DATA MODEL NUMBER

CDL065

CDL080

CDL100

CDL110

CDL135

CDL160

CDL195

NOMINAL CAPACITY , TONS*

66.7

79.2

97.5

110.9

132.9

158.7

195.1

NUMBER OF REFRIGERATION CIRCUIT

Dual

Dual

Dual

Quadruple

Quadruple

Quadruple

Quadruple

7.4

7.4

7.7

1196

1428

1756

COMPRESSOR

Type Oil per system (liters)

Semi-hermetic reciprocating 7.4

7.4

7.7

Refrigerant** Charge per system (oz)*** CONDENSER FAN

CONDENSER COIL

1200

1426

1755

998 Propeller

Qty. – Diameter (inch)

4 – 32

6 – 32

6 – 32

6 – 32

8 – 32

10 – 32

12 – 32

Nominal CFM

41240

59400

59856

65736

81280

97620

119712

Motor HP – RPM

2 – 920

2 – 920

2 – 920

2 – 920

2 – 920

2 – 920

2 – 920

Type

Inner grooved tubes and enhanced fins 3/8–4–14

3/8–3–14

3/8–4–14

3/8–4–14

3/8–4–14

3/8–4–14

3/8–4–14

87.5

100

120

160

168

190

240

Open (PSIG)

450 ± 10

450 ± 10

450 ± 10

450 ± 10

450 ± 10

450 ± 10

450 ± 10

Close (PSIG)

360 ± 15

360 ± 15

360 ± 15

360 ± 15

360 ± 15

360 ± 15

360 ± 15

Open (PSIG)

25± 5

25± 5

25± 5

25± 5

25± 5

25± 5

25± 5

Close (PSIG)

50 ± 5

50 ± 5

50 ± 5

50 ± 5

50 ± 5

50 ± 5

50 ± 5

2-1/8

2-5/8

2-5/8

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

1-5/8

2-1/8

2-1/8

2-5/8

7/8

1-1/8

1-1/8

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

N.A.

7/8

7/8

7/8

1-1/8

Total face area (Sq. ft.)

LOW PRESSURE SWITCH

R-22

Type

Tube Dia–Rows–Fins per inch

HIGH PRESSURE SWITCH

4.0

REFRIGERANT LINES+ Suction line size Dual (OD), inch Quadruple Liquid line size Dual (OD), inch Quadruple SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ OPERATING WEIGHT, Kg.+++

68.6/65/59.8 70.5/66.9/61.7 70.6/67/61.8 70.3/66.8/61.5 1857

2145

2495

3234

71.7/68/62.7

72.8/69.2/64 73.3/69.8/64.5

3500

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

3956

4820

6

380/415-3-50

380/415-3-50

380/415-3-50

380/415-3-50

380/415-3-50

380/415-3-50

380/415-3-50

380/415-3-50

CDL040

CDL050

CDL055

CDL065

CDL080

CDL100

CDL110

CDL135

- Minimum Circuit Ampacity

342

342

342

342

342

342

342

342

342

342

342

342

342

342

Min.

457

457

457

457

457

457

457

457

457

457

457

457

457

457

Max.

- Rated Load Amps

- Locked Rotor Amps

- Full Load Amps

- Circuit Breaker

RLA

LRA

FLA

CB

416.5

373.3

282.4

254.9

236.7

196.7

151.4

120.4

114.2

108.1

88.1

73.7

50.3

49.4

MCA

SUPPLY VOLTAGE

MOCP - Maximum Over Current Protection

MCA

LEGEND:

380/415-3-50

380/415-3-50

CDL035

CDL195

380/415-3-50

CDL030

380/415-3-50

380/415-3-50

CDL025

CDL160

380/415-3-50

Nominal (V-Ph-Hz)

CDL020

MODEL NUMBER

500

450

325

300

300

250

200

150

150

150

120

100

70

70

MOCP

4

4

4

4

2

2

2

2

2

2

2

2

2

2

Qty.

98.0

80.2

60.1

54.9

98.0

80.2

60.1

48.7

42.5/48.7

42.5

33.6

27.2

19.6

19.2

RLA (each)

393

393

304

304

500

393

504

310

250/310

250

225

198

118

125

LRA (each)

COMPRESSOR

3

3

3

3

3

3

3

3

3

3

3

3

3

3

CB Poles

12

10

8

6

6

6

4

4

4

4

4

4

2

2

Qty.

2.70

2.70

2.70

2.70

2.70

2.70

2.70

2.70

2.70

3.12

3.12

3.12

3.12

3.12

13.9

13.9

13.9

13.9

13.9

13.9

13.9

13.9

13.9

19

19

19

19

19

LRA (each)

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

2.0

1.5

1.5

1.5

1.5

1.5

OUTPUT POWER

CONDENSER FAN MOTORS FLA (each)

ELECTRICAL DATA

6

5

4

3

3

3

2

2

2

2

2

2

1

1

CB (Qty.)

240

240

240

240

240

240

240

380

380

380

380

380

380

380

Volts

200

200

200

100

200

200

200

120

120

120

120

61

61

61

Total Watts

0.83

0.83

0.83

0.42

0.83

0.83

0.83

0.32

0.32

0.32

0.32

0.16

0.16

0.16

Total Amps

CRANKCASE HEATER

DIMENSIONS CDL 020 & CDL 025

CDL 030, CDL 035 & CDL 040

NOTE: All dimensions are in mm.

7

DIMENSIONS CDL 050 & CDL 055

CDL 065

NOTE: All dimensions are in mm.

8

DIMENSIONS CDL 080 & CDL 100 DIMENSIONS

CDL 110

NOTE: All dimensions are in mm.

9

MODEL

H

CDL 080

1950

CDL 100

2253

DIMENSIONS CDL 135

CDL 160

NOTE: All dimensions are in mm.

10

DIMENSIONS CDL 195

NOTE: All dimensions are in mm.

11

TYPICAL SCHEMATIC WIRING DIAGRAM MODELS: CDL020 - CDL100 Power supply: 380/415V-3Ph-50Hz HVTB L1

TO FUSED DISCONNECT SWITCH OR CB

L2 PLEASE REFER TO SHEET 2 OF 2 FOR CONDENSER FAN MOTOR POWER CONNECTIONS.

L3

(SEE NOTE-4) NTB NEUTRAL

COMP 1

1

JP1

JP2

1A

T3B

COMP 2 TO NTB N

TO HVTB L1

ATB

T2B

CC2 OLR2

T1B

CC1 OLR1

T3A

T2A

T1A

LUG

ATB

F1 1B

PLEASE REFER TO FAN MOTOR CONTROL CONNECTION, (SHEET 2 of 2)

PDS2 PDS1

SEE VFC CONNECTION (AT RIGHT)

TO ATB

TO FR2

TO FR1

CC2

3B

3A COMP1

4A

COMP2

P1

4B P2

INFAN

HEATER1

41A X1

HEATER2

41B X2

OUTFAN1

OUTFAN2

NEUTRAL

CC1

LVTB ( NOTE 7) R

24Vac

C JP

G

LIVE

LED FAULT INDICATOR LOCK2

LOCK1

PRI

SYSTEM2

SYSTEM1

SQMBO4 ( P III )

C

C G

Y1

Y1

Y2

Y2

W1

W1

W2

W2

STG1 COOLING

Y1

STG2 COOLING

Y2

ON/OFF

FUSE

(ON/OFF)

TRANS

P3_##

240v 12v-0-12v ON

SEC

ECB

R

R

DIP

DIP SWITCH LED POWER INDICATOR

J_PROG

HP1

21A

(HP1)

27A

HP2

21B

(HP2)

27B

LP1

22A

(LP1)

23A

LP2

22B

(LP2)

23B

(SSPS1) (OPS1) JP3 25A JP5 26A

HPS1

(SSPS2) (OPS2) 24B JP4 25B JP6 26B

HPS2

OLR1-1 24A OLR2-1

P

P

LPS1 P

LPS2 P

HGS CONNECTION W/O COMP UNLOADER Y1 [LVTB] Y2 [LVTB]

1

ECB DIP SWITCH SETTINGS & LED INDICATORS ON= TEST MODE ENABLE OFF=TEST MODE DISABLE LOAD BALANCE OFF= (Comp1&2 Auto Lead Lag) ON= COMPRESSOR 1 LEAD ON= WITH PUMP DOWN OPTION S3 OFF= WITHOUT PUMP DOWN on-board programming function (always set to on) S4 LED INDICATORS FACTORY SETTINGS OF DIP SWITCHES Green power on/off indicator system lock-out due to system fault Red DIP SWITCH # S1 S2 S3 S4 system 1 fault diagnostic ON Yellow blinking slow - LPS1 ckt fault OFF blinking fast - HPS1 ckt fault note: system 2 fault diagnostic Set dip switch #3 according to unit's option Orange blinking slow - LPS2 ckt fault (pump down or no pump down) blinking fast - HPS2 ckt fault

C

6E P

AR8-1

6D

C [LVTB]

17A

AR9

31B

LPS5NO

S1

AR8

31A

17A

AR9-1

6C

HGS

2

NC

S2

HGS CONNECTION WITH COMP UNLOADER 5A

LPS5NO C

6E P

AR8-1

6D

AR9-1

6C

HGS

2

NC

NOTE: COMP1 SHOULD ALWAYS BE LEAD COMPRESSOR. DIP SWITCH S2 SHOULD ALWAYS BE SET TO "ON" POSITION.

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.

12

TYPICAL SCHEMATIC WIRING DIAGRAM MODELS: CDL020 - CDL100 Power supply: 380/415V-3Ph-50Hz

LEGEND AHU AFS AR ATB BM BMC CC CCA CB C. HTR

AIR HANDLING UNIT AIR FLOW SWITCH AUXILIARY RELAY AUXILIARY TERMINAL BLOCK BLOWER MOTOR BLOWER MOTOR CONTACTOR COMPRESSOR CONTACTOR CC AUXILIARY CONTACT CIRCUIT BREAKER CRANKCASE HEATER

COMP/C ECB F FCS FM FMC FMCA FR HC HPS HVTB JP L1 L2 L3 LPS LUG NTB OLR OPS P

COMPRESSOR ELECTRONIC CONTROL BOARD FUSE FAN CYCLING SWITCH FAN MOTOR (CONDENSER) FAN MOTOR CONTACTOR FMC AUXILIARY CONTACT FAULT RELAY HEATER CONTACTOR HIGH PRESSURE SWITCH HIGH VOLTAGE TERMINAL BLOCK JUMPER LINE 1 LINE 2 LINE 3 LOW PRESSURE SWITCH LUG GROUND NEUTRAL TERMINAL BLOCK OVER LOAD RELAY OIL PRESSURE SWITCH 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. ANY WIRE REPLACEMENT SHOULD BE OF 900C OR ITS EQUIVALENT. 2. 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, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE 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 INTERNAL 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.

13

TYPICAL SCHEMATIC WIRING DIAGRAM MODELS: CDL110 - CDL195 Power supply: 380/415V-3Ph-50Hz HVTB L1

TO FUSED DISCONNECT SWITCH OR CB

L2

COMP WITH CB OPTIONS

PLEASE REFER TO SHEET 2 & 3 OF 3 FOR CONDENSER FAN MOTOR POWER CONNECTIONS.

L3

(SEE NOTE-4)

TO HVTB L1 L1 L1

NTB

TO HVTB L1 L1 L1

TO HVTB L1 L1 L1

TO HVTB L1 L1 L1

NEUTRAL

L1 L2 L3 1 UVM-1 8 TO ATB

1

TO ATB 1A

L3D

L2D

L1D

L3C

L2C

L1C

L3B

L2B

L1B

CB4

T3D

CC4 OLR4 T2D

CC3 OLR3 T1D

CC2 OLR2 T3C

CC1 OLR1

T2C

4

T1C

COMP

3

CB3

T3B

COMP

2

T2B

COMP

1

T1B

COMP

T1A

L3

T3A

L2

T2A

UVM CONNECTION L1

CB2

L3A

L1A

L2A

CB1

T3D

T2D

T1D

T3C

T3B

T2C

CC4 OLR4

T1C

CC3 OLR3

T2B

CC2 OLR2 T1B

CC1 OLR1 T3A

T2A

T1A

LUG

UVM COMP

COMP

COMP

COMP

1

2

3

4

(REMOVE JP1)

CRANKCASE HTR CONNECTION(AS APPLICABLE) A. SEMI-HERMETIC RECIP. COMP. (BITZER) TO NTB N

TO HVTB L1

COMP. 1:

JP1

1

JP2

1A

CC1A-1B

1

CC2A-1B

1

CC3A1B

1

CC4A-1B

COMP. 2:

ATB

ATB

1

1B

COMP. 3:

100B 100C

PDS2

TO ATB SEE FM CONNECTION

TO FR2

COMP. 4:

PDS1

SEE VFC CONNECTION TO FR1

CC2

3A

TB1

COMP1

3B COMP2

4A P1

P2

INFAN

HEATER1

4B

41A X1

HEATER2

X2

OUTFAN1

NEUTRAL

OUTFAN2

41B

( NOTE 9)

LIVE

LOCK2

ECB1

LOCK1

R

G

31A

Y1

31B

Y2

YR3

W1 W2

SQMBO4 ( P III )

SYSTEM1

(by others)

C

JP

Y2

SWITCHING CONTACTS FROM T'STAT CONTROLLER OR DDC

R

24Vac

17

C Y1

SYSTEM2

( NOTE 8) LVTB

15

R G

Y3

31C

YR4

Y4

STG1 COOLING

Y1

STG2 COOLING

Y2

STG3 COOLING

Y3

(ON/OFF)

PRI TRANS2

P3_##

230v 12v-0-12v

SEC

ON

DIP

DIP SWITCH LED POWER INDICATOR

J_PROG

STG4 COOLING

Y4

HP1

21A

(HP1)

27A

HP2

21B

(HP2)

27B

LP1

22A

(LP1)

23A

LP2

22B

(LP2)

23B

(SSPS1)

OLR1-1

2

C.HTR4

2

24A

JP3

24B

JP4

JP5

25A

(SSPS2)

OLR2-1

COMP. 1: L1

C.HTR1

L2

COMP. 2: L2

C.HTR2

L3

COMP. 3: L1

C.HTR3

L2

COMP. 4: L2

C.HTR4

L3

COMP. SSPS CONNECTION

(OPS1)

HPS1 26A

(OPS2)

25B

JP6

COMP. 1: 24A

P

1

HPS2 26B

P

COMP. 2:

LPS1

24B

P

1

LPS2

(NOTE 5)

SSPS1 M1/11

M2/14

L1/MP/L

L2/R/N

25A 2

(REMOVE JP3) SSPS2 M2/14 M1/11 L1/MP/L

25B 2

L2/R/N

(REMOVE JP4)

P

COMP. 3: 24C

2

TO ATB

2

C.HTR3

31D

ON/OFF

FUSE

100D

C.HTR2

SCROLL COMP CRANKCASE HTR CONNECTION

CC1

LED FAULT INDICATOR

2

C.HTR1

100A

PDS3

1

SEE VFC CONNECTION

SSPS3 M1/11

M2/14

L1/MP/L

L2/R/N

25C 2

PDS4

SEE FM CONNECTION

TO FR4

TO FR3

COMP. 4:

CC4

1

24D CC3

3C

3D

4D

4C

1

41C

41D

(REMOVE JP7) SSPS4 M1/11

M2/14

L1/MP/L

L2/R/N

25D 2

COMP1

COMP2

P1

P2

INFAN

HEATER1

HEATER2

X1

X2

OUTFAN1

OUTFAN2

NEUTRAL

(REMOVE JP8)

S1

C JP

G

31C

Y1

LIVE

LED FAULT INDICATOR LOCK1

LOCK2

PRI

SYSTEM2

SYSTEM1

YR4-1

W2

SQMBO4 ( P III )

ON/OFF (ON/OFF)

P3_##

230v 12v-0-12v ON

DIP

DIP SWITCH LED POWER INDICATOR

J_PROG

HP1

21C

(HP1)

27C

HP2

21D

(HP2)

27D

LP1

22C

(LP1)

23C

LP2

22D

(LP2)

23D

OFF=TEST MODE DISABLE ON= TEST MODE ENABLE LOAD BALANCE OFF= (Comp1&2 Auto Lead Lag) ON= COMPRESSOR 1 LEAD ON= WITH PUMP DOWN OPTION S3 OFF= WITHOUT PUMP DOWN on-board programming function (always set to on) S4 LED INDICATORS FACTORY SETTINGS OF DIP SWITCHES Green power on/off indicator Red system lock-out due to system fault S4 DIP SWITCH # S1 S2 S3 system 1 fault diagnostic ON blinking slow - LPS1 ckt fault Yellow OFF blinking fast - HPS1 ckt fault note: system 2 fault diagnostic Set dip switch #3 according to unit's option blinking slow - LPS2 ckt fault Orange (pump down or no pump down) blinking fast - HPS2 ckt fault S2

YR3-1

W1

FUSE

TRANS3

SEC

31D

Y2

ECB2

ECB DIP SWITCH SETTINGS & LED INDICATORS

15B

R

(SSPS3)

OLR3-1 24C

JP7

25C

(SSPS4)

OLR4-1 24D

JP8

25D

(OPS3) JP9

HPS3 26C

(OPS4) JP10 26D

P

HPS4

PRESSURE SWITCH SETTINGS

P

LPS3 P

LPS4 P

NAME

OPEN (PSIG)

CLOSE (PSIG)

LPS1 TO 4

25 ± 5

50 ± 5

HPS1 TO 4

450 ± 10

360 ± 15

FCS1 TO 4 LPS 5-8

190 ± 10

290 ± 15

LPS 9-12

55

45

65

55

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.

14

TYPICAL SCHEMATIC WIRING DIAGRAM MODELS: CDL110 - CDL195 Power supply: 380/415V-3Ph-50Hz CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (6FANS) L1 L2 L3

CB6

FM1 T.O.P

L1 L2 L3

CB7

CB8

TO ECB1 OUTFAN 1

12A

TO ECB1 OUTFAN 2

12E

FM5 T.O.P

FM1

108

107

106

105

FM2

FM5

FMC1A-1 10A FCS1

FM3 T.O.P

FMC3

13C

11A

1

P

FMC5A-1 1OB FCS2

FM2 T.O.P

FM6 T.O.P

CDL110 13B

13F

FMC2A-1

12C

FM6

TO ECB2 OUTFAN 2

12F

2

FMC5

13E

12D

1

2

**

REFER OPTIONAL FCS CONNECTION BELOW.

37F

36F

35F

37E

36E

35E

FM4

12C

TO ECB2 OUTFAN 1

12B

2

FMC5A-1

**

FMC6

FMC5

37D

36D

35D

37B

36B

35B

FM3

** 1

FMC4

FMC2

37C

36C

FMC3 35C

37A

36A

35A

FMC1

104

103

102

101

100

FMC1A-1

FMC1

13A

13C

FMC6 2

FM4 T.O.P

11B

10C FCS3

12D

11B

13D

FMC4 2

REFER OPTIONAL FCS CONNECTION BELOW.

FMC3

1

2

6-FAN MOTOR LAYOUT

2

FMC6A-1

FMC2A-1

FM3 T.O.P

FMC2

CONTROL PANEL

L1 L2 L3

FMC6A-1

P

10D

FM3 T.O.P

13D

FMC4 2

11D

FCS4 P

P

CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD OPTIONS(8FANS) L1 L2 L3

L1 L2 L3

TO ECB1 OUTFAN 1 12A

TO ECB1 OUTFAN 2

111

110

109

FMC2

12E

FMC3

12B

FM2

FM5

FM4

FM7

37H

36H

35H

37F

36F

35F

37G

36G

35G

37E

36E

35E

37D

36D

35D

37B

36B

35B

37C

36C

35C

37A

36A

35A

TO ECB2 OUTFAN 2

FM3

13A

12C

13E

12G

FM3 T.O.P

8-FAN MOTOR LAYOUT

FMC1

12C

2

FM5 T.O.P

FM7 T.O.P

FMC3

12H

2

FMC4 TO ECB2 OUTFAN 1

FM1

FM1 T.O.P

CB9

108

106

FMC1

107

CB8

105

104

103

CB7

102

101

100

CB6

CDL135

L1 L2 L3

CONTROL PANEL

L1 L2 L3

12F

FM2 T.O.P

13B

FM6 T.O.P

FM4 T.O.P

12D

FM8 T.O.P

12H

13F

12D

12H

FMC2 2

FMC4 2

FM8

FM6

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : WITH FAN CYCLING OPTION (8FANS)

CDL135 L1 L2 L3

CB6

L1 L2 L3

8-FAN MOTOR LAYOUT

L1 L2 L3

CB7

CB8

CONTROL PANEL

L1 L2 L3

CB9

FM1

FM3

FM2

FM4

FM5

111

FM6

FCS1

11A 12C

FM3 T.O.P

TO ECB2 OUTFAN 1

FMC1

13A

2

FM5 T.O.P

12E

13C

FM8

10C

FCS3

11C 12G

FM7 T.O.P

2 TO ECB2 OUTFAN 2 2

11B 12D

13B

FM4 T.O.P

13D

FMC2 2 FMC4 2

P

FM6 T.O.P

12F

FMC7

13G

FCS2

10B

FMC5

13E

FM2 T.O.P

12B

FMC3

P

TO ECB1 OUTFAN 2

37H

36H

FMC8 35H

37F

36F

FM7

FM1 T.O.P

12A

10A

FMC6 35F

37G

36G

35G

FMC7

37E

36E

FMC5 35E

37D

36D

35D

FMC4

110

109

108

107

106

105 37B

36B

FMC2 35B

37C

36C

FMC3 35C

37A

36A

35A

FMC1

104

103

102

101

100

TO ECB1 OUTFAN 1

FCS4

10D

2

P

11D 12H

13F

FM8 T.O.P

13H

FMC6 2 FMC8 2

P

CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (10FANS) L1 L2 L3

L1 L2 L3

L1 L2 L3

CDL160

L1 L2 L3

L1 L2 L3

10-FAN MOTOR LAYOUT CONTROL PANEL TO ECB1 OUTFAN 1

114

FMC4

113

111

110

109 FMC3

112

FMC2

FMC1

CB10

CB9

108

106

105

104

103

102

101

100

CB8 107

CB7

CB6

12A

FM2

FM3

FM4

FM7

FM9

FM8

FM5

12G

37F

36F

35F

37E

36E

35E

37J

36J

35J

37H

36H

35H

37I

36I

35I

37G

36G

35G

37D

36D

35D

37B

36B

35B

37C

36C

35C

37A

36A

35A

TO ECB1 OUTFAN 2

FM1

12C

13A

FM3 T.O.P

12C

TO ECB2 OUTFAN 1

FMC1

FM7 T.O.P

12I

13G

FMC1A-1

FM6

** 1

12E

FM5 T.O.P

FM9 T.O.P

12I

TO ECB2 OUTFAN 2

FMC3

FMC1A-1 10A FCS1

11A

P FMC7A-1 1OB FCS2

11B P

COMP 1

1

CC1A-1A

25A

OPS1 2

240

CC2A-1A

(REMOVE JP5) OPS2 28B 2

OPS2-1 (REMOVE JP6)

2

COMP 3

1

CC3A-1A

25C

2 26B

CC4A-1A

25C

28C

OPS3 2

240

12D

13H

12J

FM4 T.O.P

12D

FMC2 2

FM8 T.O.P

13E

FMC5

1

2

FM5 T.O.P

13E

FM10 T.O.P

12J

FMC4 2

FM6 12F

13F

FMC6 2

FMC8A-1

REFER OPTIONAL FCS CONNECTION BELOW. FMC2A-1

FMC5

11B

10C FCS3

12F 2

1

FMC8A-1

P

10D

FM6 T.O.P

13F

FMC6 2

11D

FCS4 P

(REMOVE JP9) OPS4 28D 2

OPS4-1

2 26D

OPS3-1

COMP 4 240

13B

OIL PRESSURE SWITCH CONN.(AS APPLICABLE)

26A

OPS1-1

COMP 2

25B

28A

FM2 T.O.P

FMC2A-1

FMC7A-1

12E

1

12H

2

REFER OPTIONAL FCS CONNECTION BELOW.

OIL PRESSURE SWITCH CONN.(AS APPLICABLE)

12B

2

FMC6

FMC6

FM10

FM1 T.O.P

240

2 26D

(REMOVE JP10)

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.

15

TYPICAL SCHEMATIC WIRING DIAGRAM MODELS: CDL110 - CDL195 Power supply: 380/415V-3Ph-50Hz

LEGEND AR ATB BM BMC CC CCA CB C. HTR COMP/C DDC ECB F FCS FM FMC FR

CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : STANDARD AND FAN CYCLING OPTION (12FANS)

CDL195 CONTROL PANEL

12-FAN MOTOR LAYOUT

L1 L2 L3

FMC5

FMC6

117

114

112

111

FMC4

CB10

CB9

116

FMC3

FMC2

FMC1

110

109

108

107

106

CB9

105

104

103

102

101

L1 L2 L3

CB7

CB6 100

L1 L2 L3

CB8

113

L1 L2 L3

115

L1 L2 L3

FMC8

FM1

FM1 T.O.P

12A

13A

12E

13B

12F

FM5 T.O.P

FM3

FM6

FM4

FM7

FM11

FM12

FM8

12E

2

1

2

1

FMC1A-1

12C

FM3 T.O.P

13C

FM2 T.O.P

12B

FM6 T.O.P

FMC2

12F

FMC2A-1

12D

**

1

FCS1

10A

FMC1A-1

12C

11A

FM3 T.O.P

13C

FM4 T.O.P

13D

FM7 T.O.P

12G

2

13G

12K

13H

12L

FM11 T.O.P

12K

FMC5 2

1

2

1

FMC5A-1

FM8 T.O.P

12H

2

2

FCS2

10C

FMC5A-1

1

12D

11B

FM4 T.O.P

13D

FMC4 2

FCS4

10D

FMC6A-1

1

FM12 T.O.P

12L

FMC6

FMC6A-1

12J

37J

36J

35J FM10 T.O.P

13J

FMC8 2

11C

12I

11D

12J

FM9 T.O.P

13I

FMC7 2

FM10 T.O.P

13J

FMC8 2

P

UNIT STATUS (VFC) INDICATION CONNECTION UNIT ON / OFF COMP 1

OPTIONAL AHU INTER-CONNECTION

(POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR)

INDIVIDUAL COMP. ON/OFF/TRIP COMP 3 FR3 2 41C X1 TO ECB2 FR3-2A

FR1

41A

X1 TO ECB1 AR1

2

REFER OPTIONAL FCS CONNECTION BELOW.

FMC3

P

1

13I

FMC7

P

FCS3

10B

FMC2A-1

12I

FM9 T.O.P

SEE FCS CONN BELOW TO ECB2 OUTFAN 2

FMC4

P

1

FM10

SEE FCS CONN BELOW TO ECB1 OUTFAN 2

FMC3

SEE FCS CONN BELOW TO ECB2 OUTFAN 1

37I

FM9

SEE FCS CONN BELOW FMC1

36I

35I

37L

36L

35L

37H

36H

35H

37K

36K

35K

37G

36G

35G

37D

36D

35D

37C

36C

35C

37F

36F

35F

FM2

FM5

TO ECB1 OUTFAN 1

37B

36B

35B

37E

36E

35E

37A

36A

35A

FMC7

FR1-2A

2

TO POWER SUPPLY L1 L2 L3

TO POWER SUPPLY L1 L2 L3

TO POWER SUPPLY L1 L2 L3

FR2-2A

60

61

COMPRESSOR UNLOADER CONNECTION (OPTIONAL) COMP 1

28A

LPS5

NO

C

P

LPS9 C

TO ATB 28B

28B

LPS6

C

COMP2 TRIP

COMP4 TRIP

Y1 [LVTB]

31A

Y2 [LVTB]

31B

UL5

UL2

2

1

NC

6B

TO ATB 28C

28C

LPS7

6C P

TO ATB 28D

28B

LPS8

C

G Y1

YR3

Y3

AR9

17A

W1

C

6E

AR8-1

6D

AR9-1

6C

HGS

2

TO ATB (in cond. unit)

NC

TO ECB (in cond. unit) INFAN

LPS5NO C

6E P

AR8-1

6D

AR9-1

6C

HGS

NC

NOTE: COMP1 SHOULD ALWAYS BE LEAD COMPRESSOR. DIP SWITCH S2 SHOULD ALWAYS BE SET TO "ON" POSITION.

UL7

UL4

6B

L3C

L2C

L1C

73B

70

69

C BM CONTROL

G

STG1 COOLING

Y1

STG2 COOLING

Y2

STG3 COOLING

COOLING RELAY FIELD WIRING

STG4 COOLING

Y4

W1

STG1 HEATER

W1

W2

STG2 HEATER

W2

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, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE OPERATING THE SYSTEM. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE.

CONTROLS 230Vac

14

BMC

HTR1 HTR2

19

2

OLR-1 AFS

29 30

HC2

NOTES

2. USE COPPER CONDUCTOR WIRES ONLY.

Y3

2 28

4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY CONSUMER WITH RATING AS RECOMMENDED BY COOLINE. 5. COMPRESSOR MOTORS ARE PROVIDED WITH SSPS OR INTERNAL LINE BREAK THERMAL OVERLOAD PROTECTION. 6. USE DISCONNECT TAB + OR SPLICE ONLY WHERE EVER REQUIRED FOR EXTENSION OF ORIGINAL WIRE. 7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR LVTB FIELD WIRING. GROUND CONNECT AT BOTH ENDS.

NC

LPS12 NO C

Y2

YR3

NC

NO

5B P

2

NC

LPS11 NO C

COMP 4

UL3

5C P

C

G Y2

HGS CONNECTION WITH COMP UNLOADER

NC

NO

C

24Vac

C

R

R

Y1

C [LVTB]

17A

VOLT FREE CONTACT

YR

1. ANY WIRE REPLACEMENT SHOULD BE OF 900C OR ITS EQUIVALENT.

LVTB ( NOTE 8)

UL6

5A COMP 3

LPS5NO P

LPS10 NO P

AR8

(by others)

W2

NO

C

R

HGS CONNECTION W/O COMP UNLOADER

NC

5B P

2

COMP2 ON

VFC

JUNCTION OF WIRES, CONNECTED SWITCHING CONTACTS FROM T'STAT CONTROLLER OR DDC

TB1 (ECB)

73

(REMOVE JUMPER JP)

COMP4 ON

SOLID STATE PROTECTION SYSTEM

SPLICE-CLOSED END

(Stg. 2 Heating)

Y4

NO

6A P

COMP 2

UL1

5A NC

71

70

63

SSPS

CROSSING OF WIRES, NO CONNECTION

CC4A-2A

UNIT TRIP

TO ATB 28A

T3H

68

FR4-2A

44 CC2A-2A

FR1-1 44A FR2-1 44B FR3-1 44C FR4-1

HIGH PRESSURE SWITCH HIGH VOLTAGE TERMINAL BLOCK JUMPER LINE 1 LINE 2 LINE 3 LOW PRESSURE SWITCH LOW VOLTAGE TERMINAL BLOCK LUG GROUND NEUTRAL TERMINAL BLOCK OVER LOAD RELAY PRESSURE PUMP DOWN SOLENOID

TERMINAL BLOCK OR TERMINATION POINT

HTR2

(Stg. 1 Heating) 43

72B

71B

HTR1

T2H

2

2

T1H

COMP 4 X2 TO ECB2

HOT GAS BYPASS SOLENOID

HPS HVTB JP L1 L2 L3 LPS LVTB LUG NTB OLR P PDS

___

OLR

HC2

T3F

41B

X2 TO ECB1

FR2

BMC

HC1

COMP3 TRIP FR4 41D

COMP1 TRIP COMP 2

73A

COMP3 ON

COMP1 ON

UNIT TRIP

68

T2F

UNIT ON

66

65

58

72A

56

55

T1F

46

71A

CC1A-2A

AR1-1A

45

CC3A-2A

CB CB12

HGS

TOP FM THERMAL OVERLOAD PROTECTION TRANS TRANSFORER T'STAT THERMOSTAT

2 CB11

AUXILIARY RELAY AUXILIARY TERMINAL BLOCK BLOWER MOTOR BLOWER MOTOR CONTACTOR COMPRESSOR CONTACTOR CC AUXILIARY CONTACT CIRCUIT BREAKER CRANKCASE HEATER COMPRESSOR DIRECT DIGITAL CONTROLLER ELECTRONIC CONTROL BOARD FUSE FAN CYCLING SWITCH FAN MOTOR (CONDENSER) FAN MOTOR CONTACTOR FAULT RELAY

UL8

NC

8. COOLING OUTPUT SIGNAL FROM CONTROLLER SHOULD FOLLOW THE SEQUENCE: ON SEQUENCE - Y1 - Y2 - Y3 - Y4. OFF SEQUENCE - Y4 - Y3 - Y2 - Y1.

P NOTE UL3 & UL 4 CONNECTION APPLICALBLE FOR COMP WITH 3 STEPS CAPACITY UNLOADING.

9. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGE ACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS 230VAC. ALSO, COMP. LOCKOUT LIGHT (RED) IS ON.

16

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 thermostat 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 compressor 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. 17

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: CDL020 - CDL025

PROPER CLEARANCE TO BE PROVIDED

MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR

MODELS: CDL030 - CDL040 LIFT

PROPER CLEARANCE TO BE PROVIDED

MUST BE 3" NOMINAL PIPE THROUGH UNIT FOR

MODELS: CDL050 - CDL195

18

INSTALLATION CLEARANCE WALL

MODEL NUMBER

A

B

C

D

E

CDL020 - CDL025

1500 1500 1500 1500 1500

CDL030 - CDL040

1500 1500 2000 1500 1500

CDL050 - CDL195

2000 2000 3000 2000 2000

FIGURE - 1 STRAIGHT WALL

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.

19

MOUNTING LOCATION MODELS: CDL020 - CDL025

MODELS: CDL030 - CDL040

MODELS: CDL050 - CDL065

MODELS: CDL080 - CDL100

MODELS: CDL110 - CDL195 DIMENSIONS

NOTE: All dimensions are in mm. Tolerance: ±2mm. 20

MODEL

A

CDL110

1281

CDL135

1281

CDL160

1603

CDL195

1823

LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL) MODEL No.

R1

R2

R3

R4

R5

R6

R7

R8

CDL020

132

202

187

195

-

-

-

-

CDL025

142

214

198

206

-

-

-

-

CDL030

215

276

273

286

-

-

-

-

CDL035

234

308

295

322

-

-

-

-

CDL040

266

362

327

373

-

CDL050

347

352

392

356

CDL055

354

360

400

366

CDL065

445

456

495

461

CDL080

278

304

439

CDL100

336

362

CDL110

418

418

CDL135

450

CDL160

506

CDL195

610

-

-

-

-

-

-

-

-

-

-

-

-

-

-

454

332

338

-

-

497

514

390

396

-

-

410

410

445

445

344

344

450

443

443

483

483

374

374

506

488

488

539

539

445

445

610

593

593

660

660

547

547

LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL) MODEL No.

R1

R2

R3

R4

R5

R6

R7

R8

CDL020

151

221

206

214

-

-

-

-

CDL025

166

238

222

230

-

-

-

-

CDL030

237

298

295

308

-

-

-

-

CDL035

267

341

328

355

-

-

-

-

CDL040

309

405

370

416

-

-

-

-

CDL050

382

387

427

391

-

-

-

-

CDL055

396

402

442

408

-

-

-

-

CDL065

509

520

559

525

-

-

-

-

CDL080

315

341

476

491

369

375

-

-

CDL100

394

420

555

572

448

454

-

-

CDL110

476

476

468

468

503

503

402

402

CDL135

511

511

504

504

544

544

435

435

CDL160

575

575

557

557

608

608

514

514

CDL195

698

698

681

681

748

748

635

635

R1

R2

R1

R2

R1

R3

R5

R1

R3

R5

R7

R3

R4

R3

R4

R2

R4

R6

R2

R4

R6

R8

21

INSTALLATION INSTRUCTIONS

GENERAL The complete shipment should be inspected for damage. Any damage visible at the time of delivery should be noted on the shipment invoice. These units are shipped completely assembled and wired. Units require interconnecting piping (AHU), external power, thermostat wiring, condensate drain piping and ducting as applicable. Size of unit for an installation should be based on a heat load calculation made according to applicable standards. Units must also be installed in accordance with regulations of the "National Fire Protection Association" and local electrical codes. Where local regulations vary with instruction furnished, installer should adhere to local standards. Prepare your concrete pad or steel stand as applicable. Remove shipping protective covers and wooden crating and lift unit from base and place in position with necessary applicable vibration isolators. Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions and other COOLINE publications for the specific equipment being installed. These units should be charged with R-22 refrigerant. LOCATION OF UNIT When selecting the location for the unit, the following points should be kept in mind: 1. Provisions for a concrete slab which will allow for minimum clearance from building or structures 2. That the terrain allows for drainage away from the unit. 3. If the unit is to be roof mounted, inspect the roof for load bearing capacity. The roof should have sufficient structural strength to carry the weight of the unit. 4. Availability of electric power. 5. Position the unit to provide for unrestricted air circulation and to prevent any possibility of air recirculation. 6. Check minimum clearances required for your unit, with regard to walls, or other obstructions. 7. Air cooled equipment should not be installed under low structural overhangs which can cause condenser air recirculation or restriction. 8. Care should be taken to prevent air from other sources from entering condenser, if this air is at a high temperature. REFRIGERANT PIPING CONNECTIONS Piping connections: Outdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. The liquid and suction line diameters can be determined from the physical data table. 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 nameplate & 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. 22

LEAK TESTING & REFRIGERANT CHARGING Leak test: Leak can occur from joints or fittings that are improperly brazed/connected during installation of indoor and outdoor units. The installer should leak test the indoor unit & associated field supplied refrigerant piping, then the outdoor unit, each separately using electronic freon detector and/or soap bubbles. Refrigerant Charging: (To be used for system having a holding charge and to compensate for length of liquid line). 1. Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Make sure that no air & moisture enter the system. The whole system should be leak tested and evacuated before charging the refrigerant. 2. When system wired, piped and evacuated, the unit is ready for refrigerant charging. All charging lines and manifolds must be purged with refrigerant vapor prior to admitting refrigerant into the system to prevent contamination system with non-condensable. 3. It is important to first determine the amount of refrigerant required for the system, the unit nameplate normally identify the weight of the refrigerant required. 4. The refrigerant should be added in small amounts allowing sufficient time for the unit pressure to equalize each time. WIRING All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltage, frequency and phase must coincide with the unit nameplate. Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate. The unit wiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wiring. The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused disconnect switch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone wire for this purpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety & servicing purposes. Wiring connection to the unit must have insulation suitable for temperatures of a minimum of 600C. Minimum circuit ampacity for each model is shown on the name plate and product catalog. Equipment wiring diagram should be examined and thoroughly understood before field wiring connections are made. Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damage to compressors and motors can occur, if improper voltage is applied. START-UP INSPECTION & CHECK LIST After the installation is completed in all respect, the following points should be covered before the system is switched on for operation. 1. Remove or loosen shipping retainers under motor compressors. Make sure the hold down nuts on spring mounted compressors are not touching the compressor feet. 2. Make sure all electrical fasteners/connections are tight and clean. 3. All controls are set according to manufacturer's instructions (low & high pressure switch, pump down pressure switch, fan cycling switch, etc...) 4. Make sure all valves are open (compressor suction & discharge service valves, liquid line, etc.). 5. Follow all the instructions from the warning tags and stickers. 6. Compressor crankcase heater should be energized for 12 hours (special attention should be taken to disable compressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for few minutes to pumpdown the system, even the thermostat is OFF). 7. Thorough inspection on evaporator coil, condenser coil and other components for any physical damage. 8. Expansion valve bulb is strapped properly at correct location. 9. Circuit breaker/fused disconnect switch. 10. Blower fan belt is properly tightened and pulleys are properly aligned. 11. Blower fan & condenser fans are at correct rotation and their mountings are properly tightened. 12. All refrigerant service valve caps are installed. 13. All piping, piping insulation and piping supports are properly installed. 14. Thermostat is the right one and installed properly. 15. Duct work and accessories (check the following list and select whichever applicable to each jobs): • Flexible Connection • Air Filters Clean 23

• 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 checking Voltage, Amps, RPM, CFM, static pressure, etc. 2. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere. 3. Start the compressor and observe the following points (on multiple compressor units, it is highly recommended to start the compressors one by one to achieve careful observation for each compressor). (a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take corrective action. (b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is required, leak test all connections and system components and repair any leaks before adding refrigerant. (c) Observe oil level in compressor crankcase sight glass (if available) and add oil as necessary to bring to recommended oil level. All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in order to provide some allowance for oil which will be circulating in the system during operation. Depending on the system design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may be necessary either to add or remove oil from a system any time it is first placed in operation with a different compressor. An abnormally low oil level may result in a loss of lubrication; while an excessively high oil level may result in oil slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may vary considerably on initial start-up if liquid refrigerant is present in the crankcase, and the oil level should be checked with the compressor running after having reached a stabilized condition. (d) Thermostatic expansion valves must be checked for proper superheat settings. Recommended superheat is 150F to 200F. (e) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage must be within ±10% of that indicated on the compressor nameplate. If high or low voltage is indicated, notify the power company. The current normally should not exceed 110% of the nameplate rating. If amperage draw is excessive, immediately determine the cause and take corrective action. On three phase compressor motors, check to see that a balanced load is drawn by each phase. (f) Carry out any necessary tests, recording airflow rates, entering/leaving temperatures, sound levels, outdoor temperatures, supply airflow rates in occupied spaces and any other specified parameters.

24

ELECTRICAL ELECTRIC POWER SUPPLY All wiring should be in accordance with National Electric Code and local standards. Before making an installation, check the electric power supply. The power supply must be of the same characteristics as that on the nameplate. Normally the wire size used establishes the circuits maximum permissible load. For example a number 12 wire circuit is considered to be a 20 ampere circuit and is protected by a 20 ampere fuse. The unit amperage nameplate rating should not exceed 80% of the circuit rating, 16 amperes. When identifying electrical trouble in any unit, check the power supply at the main disconnect switch and the unit. A high or low voltage condition may prevent the unit from starting, or if the unit is running, compressor can cut-off automatically on the motor overload. On some installations, the voltage may be entirely adequate when tested, but may drop or surge some time later due to increase or decrease of load on the power line. This condition may be repeated daily at the same hour. When this condition is suspected, make arrangements with the local power supplier to place a recording voltmeter on the line to check and correct the erratic voltage conditions. The voltage drop should not be more or less than 10% of the units rated voltage. If the voltage at the meter is correct, but the voltage at the unit fluctuates 10% or more, the branch circuit is not adequate. UNBALANCED VOLTAGE Unbalanced voltage on a three phase circuit may be the source of electrical trouble. If balanced supply voltages are not always maintained, so with the three line currents will not be equal. Unbalanced voltage on a three phase compressor motor may overheat and trip the motor on external or internal current sensing motor protector, whichever one is provided. To determine that an unbalanced voltage condition exists, the supply voltage at the main disconnect switch and at the unit disconnect switch should be measured. Voltage unbalance is calculated as follows. The percentage of voltage unbalance equals one hundred times the ratio of the Maximum Voltage Deviation from the Average Voltage, and the Average Voltage. Voltage unbalance, % = 100 x

Maximum voltage deviation from average voltage Average voltage

The percentage increase in temperature rise in a phase winding resulting from voltage unbalance will be approximately two times the square of the voltage unbalance. Because of the unbalanced voltage condition in a three phase circuit, it is possible that one phase winding in the compressor motor may be over-heated while the other have a temperature within normal limits. Where unbalanced voltage on a three phase circuit exists, the power company should be notified of such unbalance to determine, if the situation can be corrected. A common source of unbalanced voltage on a three phase circuit is a single phase load between two of the three phases. A large lighting or heating circuit connection to one phase of a three phase circuit can easily cause sufficient variations in motor currents to endanger the motor. Interchange the single phase loads to equally divide the entire loads among the three phases. Balance the supply voltage as evenly as possible. Unless the unbalanced voltage condition can be corrected, the only way to insure motor safety is to be sure that the protectors are in the high current phase when using two leg protection, or to use protectors in all three legs.

25

MOTOR CONTACTOR The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the compressor motor. The magnetic coil of the controller is energized to make and break the contactor contacts. Frequently, motor contactors are subjected to quick cycling due to various causes. This may cause burned and/or sticking contacts and can cause a compressor motor failure, even though the motor overload protectors trip and open the control circuit. FAN MOTOR The condenser fan motor is a single speed electrical motor with ball bearings, protected with an automatic reset internal overload. CRANKCASE HEATERS The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest part of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize when the compressor is operating. Power must be supplied to crankcase heater for minimum of 12 hours prior to system start up. If power is off 6 hours or more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions may result in compressor damage. Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are not a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper piping practice, over feeding to the evaporator, leaking solenoid valve, etc. In some cases where migration of refrigerant to the crankcase occurred due to long storage time, shutdown period, defective components, etc. The crankcase heater may be ineffective. Such cases may be easily observed by high oil level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharge service valves of the compressor and release all liquid refrigerant from the compressor. The liquid refrigerant dilutes the oil in the crankcase and the refrigerant rich oil will be pumped to the rods and the bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at the bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor to drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinders during the suction stroke causing them to wear during the compression stroke. When the crankcase is filled with liquid refrigerant and the compressor starts severe agitation, oil foaming etc. will cause major damage to the compressor. Periodic checking for proper operation of crankcase heater is highly recommended. LUBE OIL PROTECTION CONTROL Pressure lubricated refrigeration compressors require a pressure protector in the event of an oil pressure failure. The lube oil pressure protection control is factory set 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 displacement oil pump circulates the refrigerant oil through the lubrication system. Since the oil pump is connected directly to the compressor crankcase, the inlet pressure to the oil pump will always be the crankcase pressure. The oil pump outlet pressure will be the crankcase pressure plus the oil pump pressure. Therefore, net oil pump pressure will always be the pump outlet pressure minus the crankcase pressure. The 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 whenever the net oil pressure drops below 9 PSIG, and will never run for more than the predetermined 120 seconds on abnormal oil pressure. 26

OIL PUMP OUTLET PRESSURE

CRANKCASE PRESSURE

_

78

60

NET OIL PRESSURE

=

18

New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type mechanical 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.

•

Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibration, 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.

•

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.

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.

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.

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. LINE VOLTAGE RANGE 190 - 480 VAC

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

OVER VOLTAGE

PHASE IMBALANCE

TRIP

RE-SET

TRIP

RE-SET

TRIP

RE-SET

90%

93%

110%

107%

6%

4.5%

27

REFRIGERATION COMPRESSOR Scroll compressors are used as standard for models CDL020-CDL055 and semi-hermetic reciprocating compressors are standard for models CDL065 - CDL195. 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.

28

Start the compressor, allowing it to operate long enough to pump down to approximately 1 PSIG. Shut the compressor off and observe the compound gauge. The gauge pressure may build rapidly. Repeat the pump down process several times observing the gauge pressure each time after the compressor stops. If the gauge pressure builds rapidly each time after the compressor stops, it indicates that the compressor discharge valves are not holding and refrigerant is leaking from the high side to the low side of the compressor. To check the suction valves, assuming that the discharge valves are holding, allow the compressor to operate long enough to pump down the system to approximately 10 inches of vacuum. If the compressor required longer time to accomplish this, then the suction valves are not holding and the compressor should be changed out as it is defective. MOTOR COMPRESSOR BURN OUT PROCEDURE The extent of the contamination in a system will indicate the amount of clean-up necessary. If a compressor had burned out, the following method of clean-up is recommended: 1. Discharge the refrigerant from the system. 2. Replace the inoperative compressor. 3. Clean up the system thoroughly and remove all the contaminations. 4. Install a system cleaner or filter drier in the suction line and replace the liquid line filter drier. 5. Connect a vacuum pump to both the low and the high side of the system to remove air and other non-condensables from the system. 6. Allow the vacuum pump to operate until a pressure of 500 microns is achieved. 7. Recharge the system and allow it to operate 8 to 12 hours. 8. Take an oil sample and test for acidity. If the first acidity test shows that the acid content is below the safe level, as indicated in the test kit instructions, and the oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the system provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. For a badly contaminated system that indicates acid in the oil after 8 to 12 hours of operation, change the suction and liquid line filterdriers and check the system after 24 hours of operation. There are instances where contaminants are discovered in a refrigeration system with the compressor still operational. The same procedure applies, when cleaning these systems, as on a compressor burn-out. SOURCE OF CONTAMINATION There are many ways in which a refrigerant system can become contaminated. The most common of these are as follows: 1. Improper or inadequate dehydration. 2. Wet refrigerant. 3. Wet oil (caution: It is best to purchase oil in small containers and use as needed. Open containers will absorb moisture). 4. Refrigerant leaks (allowing system to operate in a vacuum). 5. Failure to remove oil and moisture after having opened the system for repair. 6. Higher than normal operating temperatures and pressures will cause a breakdown of the oil and refrigerant. 7. Improper use of soldering or brazing flux. HIGH PRESSURE SWITCH A high pressure switch is located in the discharge line and senses the discharge pressure. Should the discharge pressure exceed 450 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.

29

Should the control open, it will remain open until the pressure in the system is lowered to 360 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 450 ± 10 psig. Allow the system to remain off, until the gauge pressure drop to approximately 360 ± 15 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 25 ± 5 psig. The contacts of the control will close when the suction pressure rises to 50 ± 5 psig. To test the control for the correct pressure setting, install a compound gauge to the gauge port on the suction service valve. "Front seat" the liquid valve and start the unit. Note the gauge pressure, when the compressor stops. To determine the cut-in pressure, allow the suction pressure to build slowly and observe the gauge pressure at the time when contact closes. A good functional low pressure switch must have both cut-out and cut-in pressure within ± 2 psig. PUMP DOWN CONTROL A pump down control is a solenoid type valve installed in the liquid line to prevent the flow of refrigerant into the evaporator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liquid line, but ahead of metering device. Pump down operation takes place as soon as the signal for cooling is switched off. The 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.

30

TROUBLE SHOOTING CHART SYMPTOM

CAUSES

CHECK & CORRECTIVE MEASURE

Compressor will not start – no hum.

1. Line disconnect switch open.

1. Close start or disconnect switch.

2. Overload protector tripped.

2. Refer to electrical section.

3. Control stuck in open position.

3. Repair or replace control.

4. Control off due to cold location.

4. Relocate control.

5. Wiring improper or loose. 6. Thermostat defective or improperly installed.

5. Check wiring against diagram.

7. Control circuit open. 8. Burned/open circuit motor winding. Compressor will not start – hums but trips on overload protector.

1. Improperly wired.

1. Check wiring against diagram.

2. Low voltage to unit.

2. Determine reason and correct.

3. Relay failing to close.

3. Determine reason and correct, replace if necessary.

4.Compressor motor has a winding open or shorted. 5. Internal mechanical trouble in compressor. 6. Liquid refrigerant in compressor. 7. High discharge pressure. Compressor starts and runs, but short cycles on overload protector.

6. Replace or relocate. 7. Trace control circuit with wiring diagram and repair. 8. Replace the compressor with all precautions.

1. Additional current passing through overload protector. 2. Low voltage to unit (or unbalanced if three phase). 3. Overload protector defective. 4. Excessive discharge pressure. 5. Suction pressure too high.

4. Replace compressor. 5. Replace compressor. 6. Check crankcase heater. 7. Unequilized pressure in the system. 1.Check wiring diagram. Check for added fan motors, pumps, etc. connected to wrong side of protector. 2. Determine the reason and correct. 3. Check current, replace protector. 4. Check airflow across the condenser coil, restrictions in refrigeration system.

6. Compressor too hot - return gas hot.

5. Check for possibility of misapplication. Use stronger unit.

7.Compressor motor has a winding shorted.

6. Check refrigerant charge (fix leak), add if necessary. 7. Replace compressor.

Suction line frosted or sweating.

1. Expansion valve passing excess refrigerant or is oversized. 2. Expansion valve stuck open. 3. Evaporator fan not running. 4. Overcharge of refrigerant.

1.Re-adjust valve or replace with smaller valve. 2. Clean valve of foreign particles, replace if necessary. 3. Determine reason and correct. 4. Correct charge.

Liquid line frosted or sweating.

1. Restriction in dehydrator or strainer. 2. Liquid shut-off valve partially closed.

1. Replace part. 2. Open valve fully.

31

TROUBLE SHOOTING CHART SYMPTOM

CAUSES

CHECK & CORRECTIVE MEASURE

Units runs OK, but short cycles on.

1. Overload protector. 2. Thermostat. 3. High pressure cut-out due to: (a) Insufficient air. (b) Overcharge. (c) Air in system. 4. Low pressure cut-out due to: (a) Undercharge. (b) Restriction in expansion device.

1. Check the cause. 2. Differential set too close - widen. 3. (a) Check airflow to the condenser correct. (b) Reduce refrigerant charge. (c) Purge. 4. (a) Fix leak, add refrigerant. (b) Replace device.

Unit operates long or continuously.

1. Shortage of refrigerant. 2. Control contacts stuck or frozen closed. 3. Refrigerated or air conditioned space has excessive load or poor insulation. 4. System inadequate to handle load. 5. Evaporator coil iced. 6. Restriction in refrigeration system. 7. Dirty condenser. 8. Filter dirty.

1. Fix leak, add charge. 2. Clean contacts or replace control. 3. Determine the fault and correct. 4. Replace with larger system. 5. Defrost. 6. Determine location and remove. 7. Clean condenser. 8. Clean or replace.

Head pressure too high.

1. Refrigerant overcharge. 2. Air in system. 3. Dirty condenser. 4. Malfunction of condenser fan (aircooled). 5. Excessive air temperature entering condenser. 6. Restriction in discharge line.

1. Correct the refrigerant charge. 2. Recharge the system after a thorough triple evacuation. 3. Clean. 4. Check and correct or replace. 5. Check for short circuiting of condenser discharge air, correct it. 6. Correct it.

Head pressure too low.

1.Low ambient temperatures (aircooled). 2. Refrigerant shortage. 3. Damaged valves in compressor.

1. Install fan cycling switch, if not provided. Check the setting and operation, if provided. 2. Correct the refrigerant charge after leak testing. 3. Repair/replace the compressor.

High suction pressure.

1. High load on evaporator. Load in excess of design conditions. 2. Unbalanced system. Oversized air handling unit matched with under sized condensing unit. 3. Compressor discharge valve leaking. 4. Expansion valve widely open. 5. Improper bulb location or installation.

1. Check the design. 2. Follow manufacturer's guide line and correct it. 3. Repair/replace compressor. 4. Check and adjust the superheat accordingly. 5. Check the expansion valve bulb is properly tighten at correct location.

32

TROUBLE SHOOTING CHART SYMPTOM

CAUSES

CHECK & CORRECTIVE MEASURE

Loss of oil pressure.

1. Loss of oil from compressor due to: (a) Oil trapping in system. (b) Compressor short cycling. (c) Insufficient oil in system. (d) Operation at excessively low suction pressure. 2. Excessive liquid refrigerant returning to compressor. 3. Malfunctioning oil pump. 4. Restriction in oil pump inlet screen.

1. (a) Correct the system piping. (b) Trace out the wiring/defective controls/ components, etc. and correct it. (c) Add oil. (d) Check the superheat of expansion valve and other possible causes like clogged filter, low CFM, iced evaporator etc. and correct it. 2. Check the system for correct super heat and other possible causes like clogged filter, low CFM, iced evaporator, etc. and correct it. 3. Repair or replace it. 4.Clean/replace it (oil change recommended).

Space temperature too high.

1. Control setting too high. 2. Expansion valve too small. 3. Cooling coils too small. 4. Inadequate air circulation.

1. Reset control. 2. Use larger valve. 3. Add surface or replace. 4. Improve air movement.

Unit noisy.

1. Loose parts or mountings. 2. Tubing rattle. 3. Bent fan blade causing vibration. 4. Fan motor bearings worn.

1. Find and tighten. 2. Tighten the pipe support. 3. Replace blade. 4. Replace motor.

33

PARTS LIST MODEL NUMBER

CDL020L

CDL025L

CDL030L

CDL035L

CDL040L

CDL050L

CDL055L

CDL065L

CDL080L

COMPRESSOR

800-674-38

800-674-19

800-674-72

800-674-84

800-674-87

800-676-82 800-674-87

800-676-82

800-690-30

800-690-33

CONTACTOR

800-098-59

800-098-59

800-098-61

800-098-63

800-098-65

800-098-65

800-098-65

800-098-68

800-097-51

CAPACITY UNLOADER KITS COND. FAN MOTOR

NIL

NIL

NIL

NIL

NIL

NIL

NIL

800-577-02

800-577-02

800-555-06

800-555-06

800-555-06

800-555-06

800-555-06

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

800-098-51

800-098-51

800-098-51

FILTER DRYER

800-531-05

800-531-05

800-531-05

800-531-00

800-531-00

800-531-00

800-531-01

800-531-01

800-531-17

FILTER DRYER CORE SIGHT GLASS

NIL

NIL

NIL

NIL

NIL

NIL

NIL

NIL

800-027-65

800-200-00

800-200-00

800-200-00

800-200-01

800-200-01

800-200-01

800-200-01

800-200-01

800-200-04

MECHANICAL SHUT OFF VALVE

800-705-40

800-705-40

800-705-40

800-705-41

800-705-41

800-705-41

800-705-41

800-705-41

800-705-42

PUMP DOWN SOLENOID VALVE

800-705-20

800-705-20

800-705-20

800-705-21

800-705-21

800-705-21

800-705-21

800-705-21

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

NIL

NIL

NIL

NIL

NIL

NIL

NIL

800-600-30

800-600-30

800-557-00

800-557-00

800-557-00

800-557-00

800-557-00

800-557-00

800-557-00

800-557-00

800-557-00

FIXED HIGH PRESSURE SWITCH 800-558-00

800-558-00

800-558-00

800-558-00

800-558-00

800-558-00

800-558-00

800-558-00

800-558-00

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

NIL

NIL

NIL

NIL

NIL

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

CDL110L

CDL135L

CDL160L

CDL195L

PRESSURE GAUGE - OIL FIXED LOW PRESSURE SWITCH

CDL100L

COMPRESSOR

800-674-41

800-690-27

800-690-30

800-690-33

800-674-41

CONTACTOR

800-097-54

800-098-67

800-098-68

800-097-51

800-097-54

CAPACITY UNLOADER KITS

800-577-02

800-577-02

800-577-00

800-577-02

800-577-02

COND. FAN MOTOR

800-237-00

800-237-00

800-237-00

800-237-00

800-237-00 800-098-51

CONTACTOR

800-098-51

800-098-51

800-098-51

800-098-51

FILTER DRYER

800-531-17

800-531-42

800-531-42

800-531-42

800-531-17

FILTER DRYER CORE

800-027-65

800-027-65

800-027-65

800-027-65

800-027-65

SIGHT GLASS

800-200-04

800-200-01

800-200-01

800-200-01

800-200-04

MECHANICAL SHUT OFF VALVE

800-705-42

800-705-41

800-705-41

800-705-41

800-705-42

PUMP DOWN SOLENOID VALVE

800-70660

800-705-21

800-705-21

800-705-21

800-70660

PRESSURE GAUGE - SUCTION

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

PRESSURE GAUGE - OIL

800-600-30

800-600-30

800-600-30

800-600-30

800-600-30

FIXED LOW PRESSURE SWITCH

800-557-00

800-557-00

800-557-00

800-557-00

800-557-00

FIXED HIGH PRESSURE SWITCH 800-558-00

800-558-00

800-558-00

800-558-00

800-558-00

ADJ. LOW PRESSURE SWITCH

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

P3 CONTROLLER

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

USER INTERFACE CARD

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

RELATIVE PRESSURE TRANSDUCER -DP 800-646-56

800-646-56

800-646-56

800-646-56

800-646-56

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

RELATIVE PRESSURE TRANSDUCER -OIL

34

RECOMMENDED SPARE PARTS PERCENTAGE OF SPARE PARTS ITEM

ONE YEAR SUPPLY

TWO YEAR SUPPLY

100 UNITS

1000 UNITS

100 UNITS

1000 UNITS

2%

1%

3%

2%

Condenser fan motor

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 (control)

1

0.5

2

1

Propeller fan

1

0.5

2

1

Heater-crankcase

3

1

4

2

Compressor

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

35

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

FREQUENCY OF MAINTENANCE, MONTHS

ITEM

1 Clean air filters & replace if required.

3

6

12

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 X

Lubricate blower motor/condenser motor (if applicable). Check alignment of pulleys.

X

Check/clean electrical connections, controls & control box.

X X

Check motors, blower bearings & lubricate it. Check all electrical control components, wiring terminals etc. for spark, overheating & loose connections. Replace/correct as necessary.

X

Check all damper operation. Repair/replace as required.

X X

Check insulation flanking. Repair/replace as required. 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 X

Check flexible canvas connections & duct work. Repair/replace as required. Run test all motors and check the amperage, abnormality etc. Run test compressors and check the amperage, noise, oil level, pressure etc. and correct them accordingly. Check the thermostat/control devices for correct operation, calibrate/ re-adjust as required.

X X X

Apply corrosion inhibitor/contact cleaner as required.

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-22 charging cylinder, belt tension checker, leak detector, vacuum pump with electronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter. 36

MATERIAL SAFETY DATA SHEET SAFETY DATA Toxicity

REFRIGERANT R-22 Low

In Contact With Skin

Liquid splashes or spray may cause freeze burns. Unlikely to be hazardous by skin absorption. R-22 may be slightly irritant and liquid has a de-greasing effect. Thaw affected areas with water. Remove contaminated clothing carefully - may adhere to skin in case of freeze burns. Wash affected areas with plenty of warm water. If symptoms occur (irritation or blistering), obtain medical attention.

In Contact With Eyes

Vapor has no effect. Liquid splashes or spray may cause freeze burns. Immediately irrigate with eyewash solution or clean water for at least 10 minutes. Obtain immediate medical attention. High levels of vapor concentration initially produce stimulation and then depression of the central nervous system, causing headaches and giddiness and may lead to unconsciousness. Can prove suddenly fatal if the exposure has been severe. At higher concentration, there is a danger from asphyxiation due to reduced oxygen content of atmosphere. Remove patient to fresh air, keep warm and at rest. Administer oxygen if necessary. Apply artificial respiration if breathing has ceased or shows signs of failing. In event of cardiac arrest, apply external cardiac massage. Obtain immediate medical attention. Unstable. Use in presence of naked flames, red hot surfaces and high moisture levels. May react violently with sodium, potassium, barium and all other alkali and alkaline earth metals. Incompatible materials: Magnesium and alloys containing more than 2% magnesium.

Inhalation

Stability Conditions to Avoid Hazardous Reactions

Hazardous Halogen acids formed by thermal decomposition. Decomposition Products General Precautions

Avoid inhalation of high concentrations of vapors. Atmospheric concentrations should be minimized and kept as low as possible. The vapor is heavier than air and collects at low level and in confined areas. Ventilate by extraction at lowest levels.

Respiratory Protection Where doubt exists on atmospheric concentration, suitable breathing apparatus should be worn. This should be self-contained or of the long breather type. Storage

Keep containers dry and in a cool place away from fire risk, direct sunlight, and all sources of heat such as radiators. Keep at temperatures not exceeding 45ºC (113ºF).

Protective Clothing Spill / leak Procedure

Wear overalls, impervious gloves and goggles/face protection. Ensure suitable personal protective clothing and respiratory protection is worn. Provided it is safe to do so, isolate the source of the leak. Allow small spillages to evaporate provided there is suitable ventilation. Large spillages: ventilate area. Contain spillages with sand, earth or any suitable absorbent material. Prevent liquid from entering drains, sewers, basements and work pits since vapor may create a suffocating atmosphere.

Disposal

Best to recover and recycle. If this is not possible, destruction is to be in an approved facility which is equipped to absorb and neutralize acids and other toxic processing products.

Fire Extinguishing Data

Non-flammable.

Containers

Fire exposed containers should be kept cool with water sprays. Containers may burst if overheated. Self-contained breathing apparatus and protective clothing must be worn in fire conditions.

Fire Fighting Protective Equipment

37

PRESSURE TEMPERATURE CHART, R-22 TEMPERATURE (0F)

PRESSURE

TEMPERATURE (0C)

PRESSURE

PSIA

PSIG

Kpa (Absolute)

Kpa (Gauge)

0

38.66

23.96

-17.78

266.54

165.21

2

40.31

25.61

-16.67

277.93

176.60

4

42.01

27.32

-15.56

289.69

188.36

5

42.89

28.19

-15.00

295.71

194.38

6

43.78

29.08

-14.44

301.83

200.50

8

45.59

30.90

-13.33

314.35

213.02

10

47.46

32.77

-12.22

327.26

225.94

12

49.40

34.70

-11.11

340.59

239.26

14

51.39

36.69

-10.00

354.31

252.98

16

53.44

38.74

-8.89

368.46

267.13

18

55.55

40.86

-7.78

383.02

281.70

20

57.73

43.03

-6.67

398.03

296.70

22

59.97

45.27

-5.56

413.47

312.14

24

62.27

47.58

-4.44

429.37

328.04

26

64.64

49.95

-3.33

445.72

344.39

28

67.08

52.39

-2.22

462.54

361.21

30

69.59

54.90

-1.11

479.83

378.50

32

72.17

57.47

0.00

497.61

396.28

34

74.82

60.12

1.11

515.87

414.54

36

77.54

62.84

2.22

534.64

433.31

38

80.34

65.64

3.33

553.92

452.59

40

83.21

68.51

4.44

573.71

472.38

42

86.15

71.46

5.56

594.02

492.70

44

89.18

74.48

6.67

614.88

513.55

46

92.28

77.58

7.78

636.27

534.94

48

95.46

80.77

8.89

658.22

556.89

50

98.73

84.03

10.00

680.72

579.39

52

102.07

87.38

11.11

703.77

602.49

54

105.50

90.81

12.22

727.42

626.13

56

109.02

94.32

13.33

751.69

650.34

58

112.62

97.93

14.44

776.51

675.23

60

116.31

101.62

15.56

801.96

700.67

62

120.09

105.39

16.67

828.02

726.66

64

123.96

109.26

17.78

854.70

753.35

66

127.92

113.22

18.89

882.01

780.65

68

131.97

117.28

20.00

909.93

808.65

70

136.12

121.43

21.11

938.55

837.26

72

140.37

125.67

22.22

967.85

866.49

74

144.71

130.01

23.33

997.78

896.42

76

149.15

134.45

24.44

1028.39

927.03

78

153.69

138.99

25.56

1059.69

958.34

80

158.33

143.63

26.67

1091.69

990.33

82

163.07

148.37

27.78

1124.37

1023.01

84

167.92

153.22

28.89

1157.81

1056.45

86

172.87

158.17

30.00

1191.94

1090.58

88

177.93

163.23

31.11

1226.83

1125.47

90

183.09

168.40

32.22

1262.41

1161.12

92

188.37

173.67

33.33

1298.81

1197.45

38

PRESSURE TEMPERATURE CHART, R-22 TEMPERATURE (0F)

PRESSURE

TEMPERATURE (0C)

PRESSURE

PSIA

PSIG

Kpa (Absolute)

Kpa (Gauge)

94

193.76

179.06

34.44

1335.98

1234.62

96

199.26

184.56

35.56

1373.90

1272.54

98

204.87

190.18

36.67

1412.58

1311.29

100

210.60

195.91

37.78

1452.09

1350.80

102

216.45

201.76

38.89

1492.42

1391.14

104

222.42

207.72

40.00

1533.59

1432.23

106

228.50

213.81

41.11

1575.51

1474.22

108

234.71

220.02

42.22

1618.33

1517.04

110

241.04

226.35

43.33

1661.97

1560.68

112

247.50

232.80

44.44

1706.51

1605.16

114

254.08

239.38

45.56

1751.88

1650.53

116

260.79

246.10

46.67

1798.15

1696.86

118

267.63

252.94

47.78

1845.31

1744.02

120

274.60

259.91

48.89

1893.37

1792.08

122

281.71

267.01

50.00

1942.39

1841.03

124

288.95

274.25

51.11

1992.31

1890.95

126

296.33

281.63

52.22

2043.20

1941.84

128

303.84

289.14

53.33

2094.98

1993.62

130

311.50

296.80

54.44

2147.79

2046.44

132

319.29

304.60

55.56

2201.50

2100.22

134

327.23

312.54

56.67

2256.25

2154.96

136

335.32

320.63

57.78

2312.03

2210.74

138

343.56

328.86

58.89

2368.85

2267.49

140

351.94

337.25

60.00

2426.63

2325.34

142

360.48

345.79

61.11

2485.51

2384.22

144

369.17

354.48

62.22

2545.43

2444.14

146

378.02

363.32

63.33

2606.45

2505.09

148

387.03

372.33

64.44

2668.57

2567.22

150

369.19

381.50

65.56

2545.57

2630.44

152

405.52

390.83

66.67

2796.06

2694.77

154

415.02

400.32

67.78

2861.56

2760.21

156

424.68

409.99

68.89

2928.17

2826.88

158

434.52

419.82

70.00

2996.02

2894.66

160

444.53

429.83

71.11

3065.03

2963.68

162

454.71

440.01

72.22

3135.23

3033.87

164

465.07

450.37

73.33

3206.66

3105.30

166

475.61

460.92

74.44

3279.33

3178.04

168

486.34

471.65

75.56

3353.31

3252.03

170

497.26

482.56

76.67

3428.61

3327.25

39