Zamil PDS036, PDS048, PDS060, PDS075, PDS090 Installation, Operation & Maintenance Manual

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INSTALLATION,

OPERATION

MAINTENANCE

MANUAL

DOUBLE SKIN PACKAGED AIR CONDITIONERS

'PDS' SERIES

PL-OM-PDS-05-1M-E

INDEX

Contents Page

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

Dimensions.......................................................................................................................................... 3-10

Fresh air hood assembly ........................................................................................................................ 11

Rigging instructions ................................................................................................................................ 12

Installation .............................................................................................................................................. 13

Typical schematic wiring diagram...................................................................................................... 14-19

INSTALLATION INSTRUCTIONS

General................................................................................................................................................... 20

Location of unit ....................................................................................................................................... 20

Wiring ..................................................................................................................................................... 20

Start-up inspection & check list ......................................................................................................... 20-21

Check-out & operational start-up procedure ...................................................................................... 21-22

Belt tension testing procedure ........................................................................................................... 22-23

ELECTRICAL

Power supply .......................................................................................................................................... 24

Unbalanced voltage ................................................................................................................................ 24

Motor contactor ...................................................................................................................................... 25

Fan motor ............................................................................................................................................... 25

Crankcase heater ................................................................................................................................... 25

Lube oil protection control ................................................................................................................. 25-26

Voltage monitor ...................................................................................................................................... 26

Electronic thermostat ........................................................................................................................ 26-27

REFRIGERATION

Compressor ............................................................................................................................................ 28

High & low pressure switch .................................................................................................................... 29

Pump down control................................................................................................................................. 30

Trouble shooting chart ....................................................................................................................... 31-33

Parts list ............................................................................................................................................ 34-40

Recommended spare parts .................................................................................................................... 41

Preventive maintenance schedule.......................................................................................................... 42

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

AIR UNIT

LOW CFM & 100% FRESH

C :COPPER FIN

J :ALUMINUM FIN

K :COATED

ALUMINUM FIN

L :COPPER FIN

NOTE: The oracle system al-

lows to select 5, 6, 8, 10 or

12 rows. Please order correct

number of rows according to

the selection software.

EVAPORATOR COIL

ECONOMIZER

STANDARD UNIT &

A :ALUMINUM FIN

B :COATED

ALUMINUM FIN

****

UNIT

ECONOMIZER

CONFIGURATION

KITS

MECHANICAL OPTIONS

KITS

FRESH AIR UNIT

A : STANDARD UNIT &

B : LOW CFM & 100%

***

SENSOR

A : STD.

D : DISCHARGE GAS

VALVE

E : DRIP ELIMINATOR

H :HOT GAS BYPASS

DRIER, MUFFLER, BALL

VALVE & GAUGES

M :REPLACEABLE FILTER

B : M & H COMBO

***

PRESSURE SWITCHES AND

FAN CYCLING SWITCH

VALVE

ELECTRICAL OPTIONS

A : STD.

C :COMP. CIRCUIT BREAKER

K : ADJUSTABLE LOW & HIGH

ANTI-ICE

P : PUMP DOWN SOLENOID

V :VOLT FREE CONTACT &

B : K & V COMBO

MODEL DECODING

CONDENSER COIL

COMPRESSOR

A :ALUMINUM FIN

TYPE

S : SCROLL

FIN

B :COATED ALUMINUM

HERMETIC

(UP TO PDS600)

H :SEMI-

WITH ALUMINUM

D :HERESITE COATING

ING

FIN

HERMETIC

L : SEMI-

C :COPPER FIN

RECIPROCAT-

G : M & E COMBO

T : M & D COMBO

K : M, H & D COMBO

E : K & C COMBO

G : K & P COMBO

L : K, C & P COMBO

WITH COPPER FIN

H :HERESITE COATING

RECIPROCAT-

ING WITH

CAPACITY

CONTROL

L : M, E & D COMBO

N : H, E & D COMBO

S : M, H & E COMBO

R : M, H, D & E COMBO

M : K, V & P COMBO

N : V, C & P COMBO

T : K, V & C COMBO

R : K, V, C & P COMBO

INDOOR AIR QUALITY (IAQ)

(kW/STAGES)

HEATER OPTIONS

DRIVE OPTIONS

BLOWER MOTOR

***

MONITOR

BAG FILTER & 2" THICK ALUMINUM PRE-FILTER

2" THICK ALUMINUM FILTER

ULTRA VIOLET LAMPS

ECONOMIZER CONTROL WITH OUTSIDE AIR THERMO-

A : STD. OPTIONS

B :

D :

U :

M :

N : NO HEATER

A : 5/1

B : 6/1

A : ALT. I

B : ALT. II

C : ALT. III

A : 1 HP TEFC

B : 1.5 HP TEFC

C : 2 HP TEFC.

STAT (PSYCHROTROLL)

ECONOMIZER CONTROL WITH ENTHALPY SENSOR

D & U COMBO

D & M COMBO

D & L COMBO

D & H COMBO

B & U COMBO

L :

H :

K :

G :

R :

S :

T :

E : B & M COMBO

F : B & L COMBO

C : 7.5/1

D : 10/2

F : 15/2

G :20/2

H : 25/2

J : 30/2

D : 3 HP TEFC

E : 5 HP TEFC

F : 7.5 HP TEFC

G : 10 HP TEFC

H : 15 HP TEFC

I : 20 HP TEFC

J : B & H COMBO

N : D, M & U COMBO

P : D, L & U COMBO

V : D, H & U COMBO

I : B, M & U COMBO

L : 40/2

M : 50/2

P : 60/2

J : 25 HP TEFC

K : 30 HP TEFC

Y : B, L & U COMBO

Z : B, H & U COMBO

S : SINGLE

REFRIGERA-

TION CIR-

CUIT

D :DUAL

SUPPLY

( V-Ph-Hz )

ELECTRICAL

4, 5 & 6

NOMINAL

BASIC

1, 2 & 3

(MBH)

COOLING

CAPACITY

H :208/230-3-60

M: 380-3-60

036

048

060

075

PDS

CLASSIC

DOUBLE SKIN

(4 WIRE)

F : 460-3-60

090

100

120

UNIT

PACKAGED

150

180

220

240

300

360

420

480

540

600

660

720

780

840

SUPPLY AIRFLOW

AIRFLOW

RETURN & FRESH

T : TOP

F : FRONT

STANDARD UNIT & ECONOMIZER

T : TOP RETURN & SIDE FRESH AIR

B :BOTTOM RETURN & SIDE FRESH AIR

S : SIDE RETURN & SIDE FRESH AIR

LOW CFM & 100% FRESH AIR UNIT

(MIDDLE FAN)

R : REAR RETURN & SIDE FRESH AIR

M: TOP FRESH AIR (100% FRESH AIR)

(MIDDLE FAN)

L : SIDE FRESH AIR (100% FRESH AIR)

K : REAR FRESH AIR (100% FRESH AIR)

(MIDDLE FAN)

E : TOP RETURN & SIDE FRESH AIR

C :SIDE RETURN & SIDE FRESH AIR

N :REAR RETURN & SIDE FRESH AIR

NOTES:

– Single scroll compressors for models PDS036-PDS075 (single circuit) & single semi-hermetic compressors up to models PDS150 (single circuit). All other models are with dual compressors (dual circuit).

– Capacity control options starts from units PDS060 onwards.

– Standard options contains vibration eliminator (for semi-hermetic), fixed high/low pressure switches, fan cycling (low ambient) switches and UVM .

– To select low CFM & 100% fresh air units, follow the software selection procedure.

***

****

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 036/048/060

264 (10. 4)

302 (11.9)

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 036/048/060

266 (10. 5)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

255 (10.0)

288 (11.4)

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 075/090

372 (14.6)

336 (13.2)

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 075/090

294 (11.6)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

389 (15.3)

302 (11.9)

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 100/120/150

F/A

CONDENSER AIR IN

F1' F2' F3'

F4'

CONDENSER AIR IN

1205 (47.4)

125 (4.9)

R/A

4412 (173.7)

TOP VIEW

295x1145 (11.6x45.0)

476 (18.8)

FRONT VIEW

378 (14.9)

S/A

408 (16.1)

S/A

1270 (50.0)

1330 (52.4)

END VIEW

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 100/120/150

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

465 (18.5)

400 (15.7)

346 (13.6)

157.5 (6.2)1366 (53.8) 1365.5 (53.75)157.5 (6.2) 1366 (53.8)

30 (1.2) TYP

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 180/220

312 (12.3)

677 (26.7) 476 (18.7)

450(17.7)

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 180/220

476 (18.7)677 (26.7)

312 (12.3)

450(17.7)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

395x1145 (15.6.6x45.0) - STD. / ECON.

CONDENSER AIR IN

F1'

CONDENSER AIR IN

F/A

R/A

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 240/300

F2'

F2 F3

TOP VIEW

425x1645 (16.7x64.8) - R.A

F3'

562 (22.2)

634 (25.0)

F4'

480 (18.9)

S/A

Ø40 (1.6) DRAIN OUTLET

AUXLIARY CONTROL BOX

FRESH AIR HOOD

(For economizer s ystem, hood supplied for

S/A

100% fresh air)

MAIN CONTROL BOX

Ø102 (Ø4) POW ER ENTRY

HEATER BOX (OPTIONAL)

RIGGING HOLES Ø76.2 (2 Nos. EACH S IDE)

CONDENSER ACCE SS

S/A

1480 (58.3)

150 (5.9)

R/A

4995 (196.6)

FRONT VIEW

480 (18.9)

1770 (69.7)

1830 (72.0)

END VIEW

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 240/300

480 (18.9)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 360/420

590 (23.3)

745 (29.3)

132 (5.2)642 (25.3)

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 360/420

562 (22.2)759 (29.9)

458 (18.0)

240 (9.5)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 480/540/600

718 (28.2)746 (29.4 )

422 (16.6)

260.6 (10.3)

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 480/540/600

640 (25.2)785 (30.9)

378 (14.9)

368 (14.5)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

UNIT DIMENSIONS

STANDARD & ECONOMIZER UNIT

MODEL No.: PDS 660/720/840

806 (31.7)702 (27.6)

806 (31.7)

LOW CFM/100% FRESH AIR UNIT

MODEL No.: PDS 660/720/840

640 (25.2)785 (30.9)

640 (25.2)

404 (15.9)

128 5.1)

806 (31.7)

Notes: 1. All dimensions are in mm ( dimensions in bracket are in inches).

2. Service clearance should be 1200mm (4 feet) on all sides.

3. F1, F2.... are mounting hole locations. Please refer to page 12 for weight distribution.

368 (14.5)640 (25.2)

Legend: F/A = Fresh Air

R/A = Return Air S/A = Supply Air

640 (25.2)

FRESH AIR HOOD ASSEMBLY

VERTICAL DAMPER

(OPTIONAL)

HOOD ACCESSORIES

1. Hood panel

2. 1/4'' dia. taptite screw

3. Right hand side panel

4. Left hand side panel

5. #10 SM screw

6. Bottom panel

7. Left hand end panel

8. Right hand end panel

9. Filter

10.Middle slide bracket

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. 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.

WEIGHT DISTRIBUTION

RIGGING INSTRUCTIONS

STANDARD & ECONOMIZER UNIT

MODEL

NUMBER

PDS 036 PDS 048 PDS 060 PDS 075 PDS 090 PDS 100 PDS 120 PDS 150 PDS 180 PDS 220 PDS 240

PDS 300 PDS 360 PDS 420 PDS 480 PDS 540 PDS 600 PDS 660 PDS 720 PDS 780 PDS 840

LOAD DISTRIBUTION AT POINTS - KG

F1 F1' F2 F2' F3 F3' F4 F4' F5 F5' F6 F6'

155* 155* 135* 135* 170* 170* 140 140 N.A. N.A. N.A. N.A. 160* 160* 135* 135* 185* 185* 145 145 N.A. N.A. N.A. N.A. 165* 165* 140* 140* 195* 195* 150 150 N.A. N.A. N.A. N.A. 205* 205* 162* 162* 225* 225* 170 170 N.A. N.A. N.A. N.A. 220* 220* 165* 165* 240* 240* 175 175 N.A. N.A. N.A. N.A. 245* 245* 180* 180* 280* 280* 195 195 N.A. N.A. N.A. N.A. 255* 255* 182* 182* 290* 290* 198 198 N.A. N.A. N.A. N.A. 265* 265* 184* 184* 300* 300* 201 201 N.A. N.A. N.A. N.A. 305* 305* 209* 209* 360* 360* 226 226 N.A. N.A. N.A. N.A. 315* 315* 211* 211* 370* 370* 229 229 N.A. N.A. N.A. N.A. 350* 350* 216* 216* 410* 410* 234 234 N.A. N.A. N.A. N.A. 370* 370* 226* 226* 440* 440* 244 244 N.A. N.A. N.A. N.A.

250* 250* 250* 250* 240* 240* 475* 475* 160 160 N.A. N.A. 275* 275* 275* 275* 240* 240* 475* 475* 162 162 N.A. N.A. 350* 350* 350* 350* 275* 275* 550* 550* 230 230 N.A. N.A. 365* 365* 365* 365* 280* 280* 550* 550* 235 235 N.A. N.A. 375* 375* 375* 375* 280* 280* 570* 570* 240 240 N.A. N.A. 400* 400* 400* 400* 290* 290* 375* 375* 375* 375* 260 260 410* 410* 410* 410* 290* 290* 390* 390* 375* 375* 260 260 420* 420* 420* 420* 290* 290* 405* 405* 375* 375* 260 260 425* 425* 425* 425* 290* 290* 415* 415* 380* 380* 260 260

TOTAL

LOAD

(KG)

1200 1250 1300 1525 1600 1800 1850 1900 2200 2250 2420 2560

2750 2875 3510 3590 3680 4200 4270 4340 4400

LOW CFM & 100% FRESH AIR UNIT

MODEL

NUMBER

PDS 036 PDS 048 PDS 060 PDS 075 PDS 090 PDS 100 PDS 120 PDS 150 PDS 180 PDS 220 PDS 240

PDS 300 PDS 360 PDS 420 PDS 480 PDS 540 PDS 600 PDS 660 PDS 720 PDS 780 PDS 840

LOAD DISTRIBUTION AT POINTS - KG

F1 F1' F2 F2' F3 F3' F4 F4' F5 F5' F6 F6'

155* 155* 105* 105* 160* 160* 105 105 N.A. N.A. N.A. N.A. 160* 160* 105* 105* 175* 175* 110 110 N.A. N.A. N.A. N.A. 165* 165* 110* 110* 180* 180* 120 120 N.A. N.A. N.A. N.A. 205* 205* 125* 125* 215* 215* 130 130 N.A. N.A. N.A. N.A. 220* 220* 135* 135* 220* 220* 138 138 N.A. N.A. N.A. N.A. 245* 245* 146* 146* 269* 269* 165 165 N.A. N.A. N.A. N.A. 245* 245* 166* 166* 274* 274* 165 165 N.A. N.A. N.A. N.A. 255* 255* 166* 166* 294* 294* 173 173 N.A. N.A. N.A. N.A. 305* 305* 188* 188* 357* 357* 175 175 N.A. N.A. N.A. N.A. 315* 315* 211* 211* 348* 348* 204 204 N.A. N.A. N.A. N.A. 350* 350* 186* 186* 410* 410* 204 204 N.A. N.A. N.A. N.A. 370* 370* 198* 198* 440* 440* 218 218 N.A. N.A. N.A. N.A.

390* 390* 215* 215* 505* 505* 190 190 N.A. N.A. N.A. N.A. 400* 400* 231* 231* 515* 515* 216 216 N.A. N.A. N.A. N.A. 440* 440* 333* 333* 615* 615* 310 310 N.A. N.A. N.A. N.A. 465* 465* 337* 337* 625* 625* 310 310 N.A. N.A. N.A. N.A. 490* 490* 337* 337* 638* 638* 322 322 N.A. N.A. N.A. N.A. 400* 400* 400* 400* 350* 350* 575* 575* 325 325 N.A. N.A. 410* 410* 410* 410* 350* 350* 580* 580* 325 325 N.A. N.A. 420* 420* 420* 420* 350* 350* 585* 585* 335 335 N.A. N.A. 430* 430* 430* 430* 350* 350* 595* 595* 345 345 N.A. N.A.

NOTE: 1. Please refer to the dimensional drawings (page 3-10) for distance between points/mounting holes.

2. Multiply by 1.3 factor for copper fins coil and add to the total weight of the unit.

F1'

F2'

F3'

F4'

F5'

TOTAL

LOAD

(KG)

1050 1100 1175 1350 1425 1650 1700 1775 2050 2155 2300 2450

2600 2725 3400 3475 3550 4100 4150 4220 4300

F6'

MODULAR DOUBLE SKIN PACKAGED UNIT

INSTALLATION

1. Provide a concrete pad or another form of stand. Use 6-12 each rubber/cork pads 4" x 4" x 1" thick each (rubber-inshear for example) at each corner and along side rails, or use 6-12 each spring isolators.

2. Service Clearance: To avoid condenser air obstructions/recirculation, and to give adequate service space, indicated clearances must be observed. See drawing below.

3. All wiring must comply with NEC (National Electrical Code) and local electrical codes. The electric supply must comply with the unit nameplate. See the typical wiring diagram for guidance.

4. All units are pre-charged with R-22 and oil, sealed and tested for leaks. Therefore do not attempt to open the system.

5. Install a flexible connection for duct work to minimize vibration transmission. Connect drain pipe (copper or PVC) to the nearest drain pit.

Care should be taken in locating the roof curb & roof opening. The packaged unit should be adequately mounted on roof.

7. Install & secure ductwork to curb prior to mounting unit on the roof curb.

RECOMMENDED SERVICE CLEARANCE

CONTROL BOX

S/A

CONTROL BOX

– Multiply 'A' by 1.5 if nearby low walls exist. – Multiply 'A' by 2.0 if nearby high walls exist. – FOR MULTIPLE UNIT INSTALLATION, distance between adjacent unit = 2A.

NOTE: There should not be any obstacles above condenser air discharge.

TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS

APPLICABLE FOR

LEGEND:

CB ECB ETB

HVTB

NTB

POWER WIRES

CB OR FUSED

DISCONNECT SWITCH

CIRCUIT BREAKER ELECTRONIC CONTROL BOARD

EARTH TERMINAL BLOCK

HIGH VOLTAGE TERMINAL BLOCK NEUTRAL LINEN

NEUTRAL TERMINAL BLOCK

FIELD WIRING GROUNDING

380V UNITS ONLY

INDOOR THERMOSTAT

W2W1Y2Y1GCR

S/A

UNIT CONTROL PANEL

R C G

LVTB

Y2 W1 W2

NTB

HVTB

ETB

TYPICAL SCHEMATIC WIRING DIAGRAM

(Single compressor units)

REFER TO UNIT NAMEPLATE FOR POWER SUPPLY

THERMOSTAT CONTROLLER

COOLING

HEATING ST G1

HEATING ST G2

TO FUSED

DISCONNECT SWITCH OR CB

(NOTE 4)

(NEUTRAL WIRE)

(SEE NOTE -7)

[UVM]

ATB

JP1

1 1A

R R

24V

C C

LPS1

YR1-1

CR1-1

PDSR1-1

LVTB

HVTB

L1 L2 L3

NTB

LUG

T1A

COMP

[NOTE:5]

T3A

T2A

CONTROL CONNECTION

TO NTBTO HVTB

JP2

ATB

G G

(SSPS)

HPS1

31A

JP4

SEE APPLICABLE FM CONTROL CONNECTION

(ABOVE RIGHT)

TO ATB

HC1

HC2

NL1

(AI)

JP5

SR1-1

TO ATB

TRANS

TO FR (SEE OPTIONAL VFC INDICATION CONNECTION)

41A

BMC

OLR

(OPS)(DTS)

JP7JP6

2827

230V

24V

OLR-1

39A 40A

AFS

SEE APPLICABLE FM POWER CONNECTION

(AT RIGHT)

SR1

CR1

PDS

TO ATB

38A

SR1-2

ATB

RELAY SAFETIES

CONTACTOR COMPRESSOR

SOLENOID PUMP DOWN

BMC

PDSR1

YR1

WITHOUT FCS

ATB

CR1-2

ATB

CONTACTOR BLW MTR

RELAY PUMP DOWN SOLENOID

RELAY COOLING

CONTACTORS HEATER 1&2

CONDENSER FAN MOTOR CONNECTIO N - (DUAL FAN MOTOR)

L1 L2

L3 L1

FMC

37A

35A

36A

FM1

TK[FM1]

TK[FM2]

12B

(AS APPLICABL E)

36B

37B

35B

FM2

FMC

ATB

13B

[ J1 ] -- COMP. PUMP DOWN DELAY TIME

[ J2 ] -- CO MP. ANTI-RECYCLE TIMER

J1 J2

WITH FCS

ATB

TO HVTB

L2 L3 L2L1 L3

36A

35A

CR1-2

FCS

CONDENSER FAN MOTOR CONNECTION - (SINGLE F AN MOTOR)

WITHOUT FCS ATB

CR1-2

WITH FCS ATB

CR1-2

FCS

FMC1 FMC2

37A

TK[FM1]

TK[FM2]

12A

(AS APPLICABLE)

TO HVTB

L3L2L1

FMC

36A

35A

37A

TK[FM]

TO HVTBTO HVTB

37B

36B

35B

FM2FM1

FMC1

12B

FMC2

13B

FMC

12B

FMC

12B12A

PRESSURE SWITCH SETTINGS

NAME OPEN (PSIG) CLOSE (PSIG)

LPS

HPS

FCS 190 ± 15

PRESET TO 0 SEC. (STD. UNIT) / 30 SEC. (PD UNIT) PRESET TO 3 MIN.

25 ± 5

450 ± 10

TIMER SETTING ON SM

10 sec. 30 sec.0 sec.

FACTORY SETT ING OF J1 & J2

60 sec.

50 ± 5

360 ± 15

290 ± 10

90 sec.

CLOSE -- 3 min.OPEN -- 5 min.

ATB

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.

TYPICAL SCHEMATIC WIRING DIAGRAM

(Single compressor units)

SINGLE STAGE HEATING

TO HVTB TO HVTB

CB11

73A

71A

72A

HC1 HC1

T3F

T1F

T2F

HEATER1

CRANKCASE HEATER CONNECTION

SCROLL COMP.

RECIP. COMP.(Semi-Hermetic)

COMP. SSPS CONNECTION

OIL PRESSURE SWITCH CONN.

CR2-1A

UVM CONNECTION

TO ATB

CR2-1B

M1/11

L1/MP/L

T1G

28A

L1 L2

T2G

HEATER2

100A

(REMOVE JP4)

2 240

TO HVTB

L1 L2

T3G

C.HTR

SSPS

CR2

OPS-1

OPS

(REMOVE JP7)

UVM-1

M2/14

L2/R/N

(REMOVE JP1)

DUAL STAGE HEATING

L1 L3L2L2 L3L1

72A

71A

73A

T2F

T1F

T3F

HEATER1

(AS APPLICABLE)

(NOTE 5)

(AS APPLICABLE)

UVM

HEATER CONNECTION DETAILS

(OPTIONAL)

TO HVTB

L2 L3L1

CB12CB11

71B

73B

72B

HC2

T1G

T3G

T2G

HEATER2

UNIT STATUS INDICATION CONNECTION

(VOLT-FREE CON TACTS)

SM-4

ANTI-ICE CONNECTION

DTS CONNECTI ON

SERVICE LAMP CONNECTION

230Vac

HEATER BOX CONNECTION TY PES

T2T1 T3

TYPE-I

41A

FR-2A

FR-2B

COMP1 ON COMP1 0FF

COMP1 TRIP

FR-1

UNIT TRIP

OLR-2

BM TRIP

C. UNIT ON/OFF

AR1

AI1

(REMOVE JP5)

DTS

(REMOVE JP6)

OHT

Note: Heater 2 connection is applicable only for units with 10 to 20 kw heating.

COMP. ON/OFF/TRIP & UNIT TRIP

B. BM ON,OFF & TRIP I NDICATION

BMC-1A

AR1-1A

UNIT ON

FLFL

TYPE-II TYPE-III

HEATER DATA TA BLE

HTG.

5 K.W

1 1

6 K.W

7.5 K.W 1

10 K.W 10 K.W

1 OR 2 1 OR 2

12 KW

1 OR 2

15 KW 20 KW

1 OR 2

(OPTIONAL)

CCA-2A

CCA-2B

5756

BMC-1B

BM OFFBM ON

AR1-1B

UNIT OFF

(OPTIONAL)

LAMP

OHT

HTR1STG. HTR2 5 KW

6 KW

7.5 KW 10 KW

5 KW

7.5 KW 10 KW

T2 T3T1T1 T2

----

----1

---5 KW 6 KW6 KW

7.5 KW 10 KW

COMPRESSOR CKT. BREAKER

CONNECTION

(OPTIONAL)

TO HVTB

L2L1 L3

CB1

L1A

L2A

L3A

T2A

T1A

T3A

COMP

LEGEND

AI ANTI ICE THERMOSTAT AFS AIR FLOW SWITCH AR AUXILIARY RELAY ATB AUXILIARY TERMINAL BLOCK BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CC COMPRESSOR CONTACTOR CB CIRCUIT BREAKER C. HTR CRANKCASE HEATER CR CONTROL RELAY COMP COMPRESSOR DTS DISCHARGE TEMPERATURE SENSOR FL FUSE LINK FCS FAN CYCLING SWITCH FM FAN MOTOR (CONDENSER) FMC FAN MOTOR CONTACTOR FR FAULT RELAY HC HEATER CONTACTOR HPS HIGH PRESSURE SWITCH HVTB HIGH VOLTAGE TERMINAL BLOCK H HEATER JP JUMPER L1 LINE 1 L2 LINE 2 L3 LINE 3 LPS LOW PRESSURE SWITCH LUG LUG GROUND LLS LEAD LAG JUMPER IN SM NTB NEUTRAL TERMINAL BLOCK OLR OVER LOAD RELAY OHT OVER HEAT THERMOSTAT PDSR PUMP DOWN SOLENOID RELAY SM SYSTEMIZER SR SAFETY RELAY SSPS SOLID STATE PROTECTIVE SYSTEM TK MOTOR THERMAL CONTACT TRANS TRANSFORMER T'STAT THERMOSTAT UVM UNDER VOLTAGE MONITOR YR COOLING RELAY

_ _ _

FIELD WIRING

DISCONNECT TAB - 1/4" SPLICE-CLOSED END

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. ANY WIRE REPLACEMENT SHOULD BE OF THE 90 OR ITS EQUIVALENT. USE COPPER CONDUCTOR WIRES ONLY.

3. POWER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP.

IF POWER IS OFF 6 HOURS OR MORE, 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 END USER WITH RATING AS RECOMMENDED BY ZAMIL.

COMPRESSOR IS PROVIDED WITH INHERENT THERMAL OVERLOAD PROTECTION.

6. FOR ANY SAFETY TRIP OF COMP. (FAULT), VOLTAGE ACROSS TERMINAL 4 & 2 OF SYSTEMIZER IS 24 VAC. ALSO COMPRESSOR LOCKOUT LIGHT IS ON.

NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER SUPPLY ONLY.

TYPICAL SCHEMATIC WIRING DIAGRAM

(Dual compressor units)

REFER TO UNIT NAMEPLATE FOR POWER SUPPLY

[UVM]

ATB

JP1

K2-T1

K3-T1

K1-T1

LPS1

LPS2

TO ATB

24VAC (C) SUPPLY

YR1-1[RB2]

CR1-1[RB1]

YR2-1[RB2]

CR2-1[RB1]

PDSR1-1[RB1]

PDSR2-1[RB1]

BMR-1 [RB2]

23A

23B

TO FUSED DISCONNECT SWITCH OR CB

(SEE NOTE-4)

NEUTRAL WIRE

(SEE NOTE -12)

CONTROL CONNECTION

TO HVTB

JP2

SR1-1[RB1]

K2-T2

SR2-1[RB1]

K3-T2

18B

K1-T2

[SSPS1]

JP4

HPS1

HPS2

TO SM TO SM

38B 38A

PDSR2

ATB

24A

25A

[SSPS2]

JP7

24B

25B

TO ATB

220VAC (C)

SUPPLY

PDSR1

L1 L2 L3

[AI1] JP5

[AI2]

JP8

HVTB

NTB

LUG

TO NTB

OLR1-1

26A

OLR2-1

26B

TO ATB TO ATB

3B 3A

CR2

L2 L3

CC1 CC2

OLR1

T2A

T1A

T3A

COMP

OLR2

T3B

T2B

T1B

COMP

[NOTE:11]

ATB

SEE COMPRESSOR PWS CONNECTION IF COMP. IS STARTED IN PWS

CC1

C1-CONTACTOR

CR3

SEE COMPRESSOR PWS CONNECTION IF COMP. IS STARTED IN PWS

CC2

C2-CONTACTOR

CR4

PDS1

C1-PUMP DOWN SOLENOID

PDS2

C2-PUMP DOWN SOLENOID

BMC

BM CONTACTOR

27A

27B

SEE OPS / DTS CONNECTION

(NOTE - 8)

28C/29A

28D/29B

CR1

SR2

TRANS1

230V

24V

SR1

RB1

TO ATBTO ATB

SEE COND.FM AND

BM CONNECTION

DOL STARTING CONNECTION OF

COMPRESSOR - W/ CB [OPTIONAL]

HVTB

L1 L2 L3

L3A

L2A

L1A

L1B

CC1

OLR1

T3A

T2A

PRESSURE SW ITCH SETTINGS

NAME OPEN (PSIG)

25 ± 5LPS1 & 2

LPS3 & 4 45

HPS1 & 2 450 ± 10

190 ± 15FCS1 & 2

T1A

COMP

CLOSE(PSIG)

50 ± 5

55 6555LPS5 & 6 360 ± 15 290 ± 10

T1B

TIMER SETTINGS ON SM

PUMP DOWN DELAYJ1 ( ADJ.)

SEC'S

J2 ( ADJ.)

MIN

LLS ( ADJ.)

SELECTION

J1 - (PUMP DOWN DELAY TIME JUMPER) -- PRESET TO 30 SEC J2 - (ANTI-RECYCLE TIMER JUMPER) -- PRESET TO 3 MIN

LLS - (COMPRESSOR LEAD-LAG SEQUENCE JUMPER) -- PRESET TO M1 [FOR AUTOMATIC LEAD LAG OPTION UNITS, PR ESET TO 15D OR 30D]

ANTI-RECYCLE TIMER

COMP1

COMP2

LEADING

FACTORY SETTING OF J1,J2 & LLS

NOTE: FOR UNITS HAVING MORE THAN 2 COOLING STAGES, OR WITH HGS

LLS SHOULD ALWAYS BE IN M1 POSITION. - COMP1 AS LEAD COMP

3010 60

310

RT 15D

RUN TIME

MODE

15 DAYS

CHANGE-OVER

COMP

CB2CB1

L3B

L2B

CC2

OLR2

T3B

T2B

TST

TEST MODE

30D

30 DAYS

CHANGE-OVER

DDC CONTROL PANEL

OR THERMOSTAT

(BY OTHERS)

BLW MTR

1 STAGE

COOLING

2 STAGE COOLING

1 STAGE

HEATING

2 STAGE HEATING

LLS

POWER

Y2 4B

31A

31B

SEE OPTIONAL ECONOMIZER CONNECTIONS

AFS

5A24A

LOCKOUT-C1

LOCKOUT-C2

FROM FR1 RELAY

(SEE OPTIONAL VFC CONNECTIONS)

FROM PDSR1 (RB1)

SR1-2[RB1]

39A

SR2-2[RB1]

39B

FROM PDSR2 (RB1)

FROM FR2 RELAY

(SEE OPTIONAL VFC CONNECTIONS)

(NOTE-9)

OLR-1

18A

40A

40B

BMR

BM-CONTACT OR

YR1

STG 1 COOLING RELAY

YR2

STG 2 COOLING RELAY

RB2

HR1

STG 1 HEATER RELAY

HR2

STG 2 HEATER RELAY

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.

TYPICAL SCHEMATIC WIRING DIAGRAM

(Dual compressor units)

CRANKCASE HEATER CONNECTION

SCROLL COMP.

COMP. 1:

COMP. 2:

RECIP. COMP.(Semi-Hermetic)

M1/11

L1/MP/L

M1/11

L1/MP/L

CC1A-1B

CC2A-1B

SSPS1

(REMOVE JP4)

SSPS2

(REMOVE JP7)

COMP. 1:

COMP. 2:

COMP. SSPS CONNECTION

COMP. 1:

24A

COMP. 2:

24B

OIL PRESSURE SWITCH CONN.

COMP. 1:

27A

CR3-1

28A

COMP. 2:

27B

CR4-1

28B

COMPRESSOR UNLOADER CONNECTION

COMP 1

COMP 2

NOTES:

- COMP IS RUNNING AT FULL CAPACITY IF UNLOADER SOLENOID IS DE- ENEGIZED

- UL1 & UL2 SOLENOID CONNECTION IS APPLICABLE FOR COMPRESSORS WITH 50 % CAPACITY UNLOADER.

- UL3 & UL4 SOLENOID CONNECTION IS APPLICABLE FOR COMPRESSORS WITH

33% ~ 66% CAPACITY UNLOADER.

UNIT STATUS (VFC) INDICATION CONNECTION

SM-4A

LPS3

CR3-2

LPS5

LPS4

CR4-2

LPS6

A. INDIVID UAL COMP. O N/OFF/TRIP & UNIT TRIP

COMP 1

FR1

41A

FR1-2A

FR1-2B

AR6-1A

COMP1 ON COMP1 0FF COMP1 TRIP

B. BM ON,OFF & TRIP INDICATION

BMC-1A B MC-1B

BM ON

OLR-2

BM TRIP

C.HTR1

C.HTR2

C.HTR1

100A

C.HTR2

101A

M2/14

L2/R/N

M2/14

L2/R/N

OPS1-1

OPS1

240

OPS2-1

OPS2

240

2 3B

AR6-1B

585756

FR1-1 FR2-1

UNIT TRIP

BM OFF

(AS APPLICABLE)

(NOTE 5)

(AS APPLICABLE)

SR1 (RB1)

28C

SR2 (RB1)

28D

(AS APPLICABLE)

UL1

UL3

UL2

UL4

SM-4B

44A

5049

52 45

L2L1

25A

25B

(NOTE-8)

COMP2 ON COMP2 0FF COMP2 TRIP

C. UNIT ON/OFF

AR1-1A

UNIT ON UNIT OFF

UVM CONNECTION

TO HVTB

L2L1

UVM-1

TO ATB

ANTI-ICE CONNECTION

COMP. 1:

COMP. 2:

25A

25B

AI1

(REMOVE JP5)

AI2

(REMOVE JP8)

SERVICE LAMP CONNECTION

230Vac

DTS CONNECTION

COMP. 1:

DTS1

28C

COMP. 2:

28D

HGS CONNECTION

Y1 [LVTB]

Y2 [LVTB]

A. FOR UNITS WIT H NO COMP. CAPACITY UNLOADERS

B. FOR UNITS WITH COMP. CAPACITY UNLOADERS

(SEE COMP. UNLOADER CONNECTIONS)

COMP 2

AR7AR6

FR2

41B

FR2-2A

FR2-2B

AR7-1A

AR7-1B

AR1

AR1-1B

DTS2

(OPTIONAL)

636261

29A

29B

AR8

31A

AR9

31B

AR8-1

AR9-1

AR8-1

UVM

(REMOVE JP1)

(OPTIONAL)

TO HVTB

(IN MAIN CONTROL PA NEL)

BLOWER MOTOR POWER CONNECTION

(OPTIONAL)

26A

26B

(OPTIONAL)

NOTE: CB5 IS APPLICABLE ONLY FOR BM WITH 7.5HP AND ABOVE

LAMP

(OPTIONAL)

TO SR1 (RB1)

TO SR2 (RB1)

(OPTIONAL)

HGS

(NOTE 8)

A. CONNECTION FOR 10 TO 30KW

HEATING.

TO HVTB1

L2L1

L2L1L3

CB11

72A

71A

73A

HC1

T2F

T1F

T3F

HEATER1 HEATER2

(Stg. 1 Heating)

(Stg. 2 Heating)

ATB

B. CONNECTION FOR 40 TO 60KW HEATING.

TO HVTB1TO HVTB1

L3L2L1 L2L1 L3 L2L1

HC2

K4-T1

K5-T1

HR1-1[RB2]

HR2-1[RB2]

71A

T1F

K4-T2

K5-T2

72A

73A

T3F

T2F

(Stg. 1 Heating)

CB11CB12

HC1

L2L3L1

72B

73B

71B

T2G

T3G

T1G

PWS STARTING CONNECTION OF COMPRESSOR - W/O CB [AS APPLICABLE]

HVTB

L1 L2 L3

CC1

OLR1

T2A

T3A

T1A

CC1A-2

26A

81A

CC3 CC2

OLR3 OLR2

T1C

T3C

T2C

COMP

CC1 CC2

CC3

27A 26B

OLR3-1OLR1-1

OLR2-1

CC2A-2

T3D

T2D

T3B

T1B

T1D

T2B

COMP

CC4

27B

OLR4-1

81B

HVTB1

L1 L2 L3

(NOTE -10)

CB5

L3E

L2E

L1E

BMC

OLR

ELECTRIC HEATER CONNECTION DETAILS

T1H

T2H

HC1

HC2

CC4

OLR4

(OPTIONAL)

TO HVTB1

CB12

73B

71B

72B

HC2

T3G

T1G

T2G

T3H

HEATER2

PWS STARTING CONNECTION OF COMPRESSOR - W/ CB [OPTIONAL]

26A

HVTB

(Stg. 2 Heating)

ATB

L1 L2 L3

CC1A-2

T2I

T1I HEATER4HEATER1 HEATER3

L2A

L1A

T2A

T1A

CC1

CC3

81A

OHT

UP TO 10 K.W

(TYPE-I)

HTG.

10 KW

COMP

T1C

T2C

15 KW 20 KW 25 KW 30 KW 15 KW 40 KW 50 KW 60 KW

NOTE: HEATER 3 & 4 IS APPLICABLE ONLY

FOR HEATING 40KW AND ABOVE

CC3CC1

OLR3

T3C

T3I

CB1

L3A

OLR1

T3A

HEATER BOX CONNECTION TYPES

OHT

10 TO 15 K.W

(TYPE-II)

HEATER DATA TABLE

STG.

I STG.

5 KW

7.5 KW

2 2

10 KW

12.5 KW 2 2

10 KW x 2

12.5 KW x 2

15 KW x 2

L2B

L1B

L3B

T2B

T1B

T3B

CC2A-2

26B27A

81B

CB2

CC2

OLR2

COMP

CC2

CC4

OHT

5 KW

7.5 KW 10 KW

12.5 KW

10 KW x 2

12.5 KW x 2 15 KW x 2

OLR4-1OLR2-1OLR1-1 OLR3-1

10 TO 15 K.W

(TYPE-III)

II STG.

15 KW

T1D

T2D

T2T1

CC4

OLR4

T3D

27B

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.

TYPICAL SCHEMATIC WIRING DIAGRAM

(Dual compressor units)

FAN LAYOUTS

[PDS100~150]

FAN2

FAN1

A. STANDARD OPTION

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS

[PDS180~300] [PDS360~600]

FAN1 FAN2

TO HVTB

L1 L2 L3

CB6

101

102

100

FMC

35A

ATB ATB

CC1A-1

12 12A 12B

CC2A-1

35B

37A

36A

FM1 FM2

TK[FM2]TK[FM1]

( 4-CONDENSER FAN MOTOR CIRCUIT )

A. STANDARD OPTION

TO HVTB

CB6

101

100

102

FMC1

36C

35C

37A

FM3

TK[FM1]

12 12B

TK[FM2]

13 13B

37C

36A

35A

FM1

ATB

CR1-2[RB1]

ATB

CR2-2[RB1]

B. WITH FAN CYCLING OPTION

TO HVTB L1 L2 L3

101

102

100

FMC1

35C

37A

35A

36A

FM1

CR1-2 [RB1]

ATB

CR2-2 [RB1]

FCS1

FCS2

TO HVTB

L1 L2 L3

104

105

103

FMC3

37C

36C

12A

13A

37B

35B

36B

FM2FM3 FM4

TK[FM1]

TK[FM3]

TK[FM2]

TK[FM4]

[PDS660~840]

FAN1 FAN3 FAN2 FAN4

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS

FAN1

FAN5

FAN3

FAN2

FAN6

FAN4

( 2-CONDENSER FAN MOTOR CIRCUIT )

B. WITH FAN CYCLING OPTION

36B

37B

ATB

FMC

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS

A. STANDARD OPTION

TO HVTB

L2 L3L1L1 L2 L3

CB7

104

105

103

FMC2

37B

35B

36B

FM2 FM4

TK[FM3]

13C

TK[FM4]

13D

36D

37D

35D

FMC1

ATB

FMC2

ATB

TO HVTB

100

35A

FM1

ATB

101

36A

102

37A

CR2-2[RB1]

B. WITH FAN CYCLING OPTION

TO HVTB

L3L2

CB7CB6

FMC2

12B

13C

13B

13D

FMC1

FMC3

FMC2

FMC4

36D

35D

37D

ATB

CB6

100

101

102

FMC1 FMC3

36A

37A

35A

35E

FM1 FM3FM5

ATB

TO HVTB

101

100

35A

36A

FM1

CC1A-1

FCS1

CC2A-1

12A

FCS2

( 6-CONDENSER FAN MOTOR CIRCUIT )

TO HVTB

CB6

103

FMC1

35B

36E

37E

35E

37C

35C

36C

FM3 FM5

CR1-2[RB1]

36E

CR1-2 [RB1]

CR2-2 [RB1]

12 12B

13 13B

37E

TK[FM3]TK[FM1]

37C

35C

36C

TK[FM1]

12B

FCS1

12A

TK[FM2]

13B

FCS2

13A

CB6

102

100

FMC1

35B

37A

TK[FM1]

12B

TK[FM2]

12C

L3L1 L2L3L2L1

CB7

105

104

FMC2

35D

37B

36B

FM2 FM4

TK[FM5]

TK[FM6]TK[FM4]TK[FM2]

TO HVTB

L3L1 L2

CB7

105

103

104

FMC2

37B

35B

36B

FM2

TK[FM5]

13E

TK[FM3]

13C

TK[FM6]

13F

TK[FM4]

13D

LEGEND

101

102

FMC2

FCS FAN CYCLING SWITCH FM FAN MOTOR (CONDENSER) FMC FAN MOTOR CONTACTOR

37B

36B

FM2

FMC1

ATB

FMC2

FR FAULT RELAY HC HEATER CONTACTOR HPS HIGH PRESSURE SWITCH HVTB HIGH VOLTAGE TERMINAL BLOCK H HEATER JP JUMPER L1 LINE 1 L2 LINE 2 L3 LINE 3 LPS LOW PRESSURE SWITCH LUG LUG GROUND LLS LEAD LAG JUMPER IN SM NTB NEUTRAL TERMINAL BLOCK OLR OVER LOAD RELAY OHT OVER HEAT THERMOSTAT PDSR PUMP DOWN SOLENOID RELAY PWS PART WIND START SM SYSTEMIZER SR SAFETY RELAY SSPS SOLID STATE PROTECTIVE SYSTEM

36F

35F

37D

36D

13E13C

13F13D

FMC1

FMC2

37F

FM6

ATB

TK MOTOR THERMAL CONTACT TRANS TRANSFORMER T'STAT THERMOSTAT UVM UNDER VOLTAGE MONITOR YR COOLING RELAY

_ _ _

FIELD WIRING

DISCONNECT TAB - 1/4" SPLICE-CLOSED END

NOTES

1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. ANY WIRE REPLACEMENT SHOULD BE OF THE 90 OR ITS EQUIVALENT. USE COPPER CONDUCTOR WIRES ONLY.

3. POWER MUST BE SUPPLIED TO CRANKCASE HEATER FOR MINIMUM OF 12 HOURS PRIOR TO SYSTEM START UP. IF POWER IS OFF 6 HOURS OR MORE, CRANKCASE HEATER MUST BE ON FOR 12 HOURS BEFORE

FMC4

37D

36D

35D

36F

35F

37F

FM4

FM6

FMC1

ATB

FMC3

FMC2

ATB

FMC4

OPERATING THE SYSTEM. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN COMPRESSOR DAMAGE.

4. FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER TO BE PROVIDED BY END USER WITH RATING AS RECOMMENDED BY ZAMIL.

5. PLEASE ALLOW 2-3 MINUTES FOR SSPS SWITCH TO CLOSE, BEFORE STARTING THE UNIT.

6. USE DISCONNECT TAB OR SPLICE ONLY WHEREEVER REQUIRED FOR EXTENSION OF ORIGINAL WIRE.

7. FOR ANY SAFETY TRIP OF COMP. (FAULT), VOLTAGE ACROSS TERMINAL 4A/4B & 2 OF SYSTEMIZER IS 24 VAC. ALSO COMPRESSOR LOCKOUT LIGHT IS ON.

8. FOR UNIT WITH OPTIONAL OPS/DTS, FOLLOW SR COIL CONNECTION AS SHOWN IN OPS/DTS CONNECTION BLOCK.

9. IF HEATERS ARE FACTORY INSTALLED, PLEASE READ BROKEN LINES AS CONTINUOUS LINES.

10. HVTB 1 NOT REQUIRED FOR NON HEATER MODELS.

11.COMPRESSORS ARE PROVIDED WITH INTERNAL THERMAL PROTECTOR FOR OVERLOAD PROTECTION. EXTERNAL OLR IS PROVIDED FOR ADDED PROTECTION & AVAILABLE FOR PDS180 & ABOVE.

12.

NEUTRAL LINE REQUIRED ON 380V-3Ph-60Hz POWER SUPPLY ONLY.

ECONOMIZER CONNECTION

AQS

OAT

SAT

ECONOMIZER BOARD

POT2POT1LE D2LED1 POT4POT3

LED3

LED4

FCC

COUNTER

MTR3

STS

FS040

COM

24V

0-10V

AQS

RAD

MTR2

ECON BRD

OAD

MTR1

ODS

LEGEND

SAT SUPPLY AIR THERMISTOR AQS AIR QUALITY SENSOR OAT OUTDOOR AIR THERMOSTAT FCC FREE COOLING COUNTER OAD OUTDOOR AIR DAMPER MOTOR RAD RETURN AIR DAMPER MOTOR STS SUPPLY AIR TEMPERATURE SENSOR MTR DAMPER MOTOR EC ENTHALPY CONTROLLER

NOTES

1. DAMPER MOTOR IS NOT REQUIRED FOR SINGLE DAMPER MOTOR APPLICATION.

IF EC OR OAT OPTION IS FACTORY INSTALLED, PLEASE READ BROKEN LINES AS CONTINUOUS LINES.

INSTALLATION INSTRUCTIONS

GENERAL

The complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immediately to the delivery man or driver. Any damage visible at the time of delivery should be noted on the shipment invoice. These units are shipped completely assembled and wired. These units does not require any refrigerant tube installation at the field. Units require external power, thermostat wiring, condensate drain piping and ducting as applicable. Size of unit for an installation should be based on a heat gain 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 Zamil publications for the specific equipment being installed.

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.

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 24 hours (special attention should be taken to disable com-

pressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for few minutes to pumpdown the system, even the thermostat is OFF).

7. Thorough inspection on evaporator coil, condenser coil and other components for any physical damage.

8. Expansion valve bulb is strapped properly at correct location.

9. Circuit breaker/fused disconnect switch.

10. Blower fan belt is properly tightened and pulleys are properly aligned.

11. Blower fan & condenser fans are at correct rotation and their mountings are properly tightened.

12. All refrigerant service valve caps are installed.

13. All piping, piping insulation and piping supports are properly installed.

14. Thermostat is the right one and installed properly.

15. Duct work and accessories (check the following list and select whichever applicable to each jobs).

• Flexible Connection

• Air Filters Clean

• Air Filter Access Door Gasket

• Sound Attenuators (If Applicable)

• Fresh Air Intake

• Ductwork Caulking Inside/Outside Building

• Ductwork Supports Inside/Outside Building

• Duct Leakage Inside/Outside Building

• Volume Dampers

• Volume Damper Access Doors

• Fire Dampers

• Fire Damper Access Doors

• Transfer Grilles/Door Grilles

• Duct Insulation/Liner

• Diffusers/Grilles

• Duct Humidistat

• Filter flag

CHECK-OUT & OPERATIONAL START-UP PROCEDURE

After the completion of inspection and check list, the following points should be covered before system is placed in operation.

1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for check-

ing Voltage, Amps, RPM, CFM, static pressure, etc.

2. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere.

3. Start the compressor and observe the following points (on multiple compressor units, it is highly recommended to start

the compressors one by one to achieve careful observation for each compressor). (a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take

corrective action.

(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is re-

quired, leak test all connections and system components and repair any leaks before adding refrigerant.

mended oil level.

All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in order to provide some allowance for oil which will be circulating in the system during operation. Depending on the system design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may 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 tem-

peratures, supply airflow rates in occupied spaces and any other specified parameters.

BELT TENSION TESTING PROCEDURE INSTRUCTION

To determine the lbs. force required to tension a drive, you simply do the following:

1. Measure the Belt span as shown.

2. Divide belt span by 64 to get belt deflection needed to check tension.

3. Set large "0" ring on span scale at required belt deflection. This scale is in 1/16" increments.

4. Set small "0" ring at zero on the "Force Scale" (plunger).

5. Place the larger end of the tension checker squarely on one belt at the center of the belt span. Apply force on the plunger until the bottom of the large "0" ring is even with the top of the next belt or with the bottom of a straight edge laid across the sheaves.

6. Read the force scale under the small "0" ring to determine force required to give the needed deflection.

7. Compare the force scale reading with the correct value for the belt style and cross section used, as given in table on next page. The force should be between the minimum and maximum values shown.

8. If there is too little deflection force, the belts should be tightened. If there is too much defection force, the belts should be loosened.

EXAMPLE

1. Belt Span 64" (Small Sheave is 3.0 P.D. with "A" type belt.

2. 64 = 1" Deflection needed. 64

3. Set large "0" ring at 1" on span scale.

4. Set small "0" ring at zero plunger.

5. Check the force – lbs. required for a 1" deflection of the belt.

6. Press down on plunger until the bottom of the large "0" ring is even with top of the next belt in the set or with the bottom

of a straight edge.

7. 'A' type belts table shows an "A" belt with 3.0" P.D. Small sheave should have a deflection force between 1-1/2 lbs.

and 2-1/8 lbs.

8. Increase or decrease the tension on belts until the deflection force is between 1-1/2 lbs. 2-1/8 lbs.

NOTE:

Tension new drives at the maximum deflection force recommended. Check the tension at least two times during the first day's operation as there normally will be a rapid decrease in belt tension until belts have run in. Check the tension periodically after the first day's operation and keep tension in recommended area. The correct operating tension for a V-belt drive is the lowest tension at which the belts will not slip under the peak load conditions. Shafts must be adequate for the tensions required.

BELT TENSION TESTING PROCEDURE

BELT SPAN

SMALL

"0"

RING

LARGE

"0"

RING

DEFLECTION =

FORCE SCALE

SPAN SCALE

BELT TENSION CHECKER MEASURE THE BELT DEFLECTION FORCE

BELTS

BELT TYPE

–

BELT

CROSS

SECTION

3 L

4 L

5 L

PULLEY PITCH DIA. (P.D.)

SMALL

RANGE

1.25 – 1.75 2 – 2.25

2.5 – 3

2.1 – 2.8 3 – 3.5

3.7 – 5

3 – 4.2

4.5 – 5.2

DEFLECTION FORCE - LBS.

MINIMUM

1/2 5/8 3/4

1-1/8 1-1/2 1-7/8

2-3/8

MAXIMUM

5/8 7/8

1-1/8

1-5/8 2-1/8 2-5/8

2-7/8 3-3/8

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

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.

Maximum voltage deviation from average voltage

Average voltage

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

MOTOR CONTACTOR

The motor controller (contactor) is a load current carrying device which makes and breaks to start and stop the 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.

OIL PUMP

OUTLET PRESSURE

CRANKCASE

PRESSURE

NET OIL

PRESSURE

78 60 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.

• Each control reflects improved calibration stability over the control's entire pressure range.

• Controls boast truly accurate timing despite ambient temperature and voltage variations.

• All electronic components are purposely "over-sized" and computer-matched to provide the greatest safety factor and

dependable service life.

• Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibra-

tion, dirt or moisture.

• Controls reset instantaneously, thanks to the precise solid state timing circuit. No annoying wait for old-fashioned timer

heater to cool down.

• Control module is interchangeable with the old type conventional oil protection and with competitive brands of oil

protection controls. An exact replacement from a mounting, wiring and logic function standpoint.

• Control maintains timing over the full voltage range of 102 to 264 VAC. Voltage selection is not necessary.

• Unit is not position sensitive.

• Users are offered a choice of controls with or without cover, a handy mounting bracket and other options.

• "Logic" circuitry in the module monitors oil pressure pulses during marginal operation and integrates them resulting in

a longer span of time before lock-out occurs.

• Last, but not least, it has enlarged the reset button to a new "thumb-sized" dimension. The reset button is slightly

recessed to protect it from damage.

VOLTAGE MONITOR

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

LINE VOLTAGE

RANGE

190 - 480 VAC

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

UNDER VOLTAGE

TRIP

RE-SET

90%

93%

OVER VOLTAGE

TRIP

RE-SET

110%

107%

PHASE IMBALANCE

TRIP6%RE-SET

4.5%

ELECTRONIC THERMOSTATS General Informations: Single stage or two stage thermostats provide low voltage control of one or two stage heating

and/or cooling applications. The thermostat normally displays room temperature, mode of operation and which system is currently on.

You may select different heating and cooling setpoints for the systems to maintain (example 700F in heating and 750F in cooling). Raising or lowering the setpoints in heating or cooling is as simple as pushing a button.

The thermostat also allows you to select continuous fan operation, (useful when using an electronic air cleaner), or have the fan on intermittent operation with the equipment.

The thermostat is best located about 1500 mm (5 Ft.) above floor level, on a partition wall (not an outside wall), and should not be exposed to direct light from lamps, sun etc. It should be in return air stream, away from supply air registers/ diffusers.

CONTROLS & SEQUENCE OF OPERATION

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.

The operation of the air conditioning unit is controlled by a 24VAC electronic control board.

Mode:

Select the desired mode of operation by continuous pressing of the MODE button:

Controls cooling system only (the word COOL will display for 5 seconds).

Controls heating system only (the word HEAT will display for 5 seconds).

HEAT/COOL - Controls both systems automatically (the word AUTO will display for 5 seconds).

OFF - Systems will not operate

24 V (C)

24 V

L I G

G H T

Equipment Relays

2nd stage Cooling

1st stage Cooling

Fan Relay

1st stage Heating

2nd stage Heating

24VAC

Line Voltage Transformer

Cooling:

Select the temperature you want your cooling system to maintain by pressing and holding the COOLING button under the or symbols until the desired temperature is displayed. The control setpoint temperature is displayed for 5 seconds.

LED 1

LED 2

Thermostat

Field Wiring

Clogged Filter

Compressor Fault

Clogged filter switch not provided

* Clogged filter switch not provided

Heating:

Select the temperature you want your heating system to maintain by pressing and holding the HEATING button under the or symbols until the desired temperature is displayed. The control setpoint temperature is displayed for 5 seconds.

Fan:

The fan will be energized automatically when the systems are operating but no indication of this on the display. To select continuous fan operation, press the FAN button and the display will show . This is recommended for electronic air cleaners and continuous ventilation requirements.

Off

When the word OFF is displayed the heating and cooling systems will not operate. Avoid using the OFF mode during extremely cold weather to prevent damage from freezing.

Auto:

Selecting this mode of operation will control both heating and cooling systems. The thermostat will automatically switch from one to the other as determined by the selected temperatures in heating and cooling. NOTE: The thermostat always maintains a minimum 20F (10C) difference or dead band between the heating and cooling setpoints.

Celsius / Fahrenheit

Simultaneously press and to switch between Celsius and Fahrenheit temperature display.

REFRIGERATION

COMPRESSOR

Single scroll compressor for models PDS036 to PDS075 and dual scroll compressors for model PDS090 to PDS600 are used as standard. Optional single semi-hermetic compressor for models PDS036 to PDS150 (single circuit). All other models are dual semi-hermetic compressors (dual circuit). The compressors are equipped with internal motor protection and also provided with vibration isolators. Oil pressure control is provided on units with semi-hermetic compressor only. Each compressor has lockout devices to protect it from short cycling when tripped by safety controls. The compressor motors conform to NEMA MG-1 & MG-2. Scroll Compressors are used in some of these units. The major benefits being:

1. Low Sound Level: Quieter operation because of no dynamic suction and discharge valves action.

2. Low vibration and discharge pulses.

3. High Energy Efficiency: Because of high volumetric efficiency it minimize pressure and heat transfer losses.

4. High Capacity: Due to its high mass flow and high compression ratios.

5. High Durability: With its robust design, few moving parts, low motor strains, large internal volume for liquid handling makes this compressor highly reliable.

6. High Charge Limit: Therefore, lower applied costs as no suction accumulator required, no need for pump down system and check valve in discharge line.

Low capacity can be caused by inefficient compressor, that is, the compressor does not pump sufficient quantity of refrigerant, even though a full charge is available in the system. Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is found to be all right but the electrical components are defective, remove and replace the defective electrical components only. Below are some tests that should be performed on the compressor to determine, if the compressor is defective.

1. Test compressor motor winding for ground.

2. Test compressor motor windings for continuity.

3. Test that compressor motor will run both without a load and under a load.

4. Test the current or ampere drawn.

5. Observe sound level of compressor.

To establish that the compressor suction and discharge valves are operating and holding properly, attach gauges to the liquid and suction service valves. "Front seat" the liquid service valve.

Start the compressor, allowing it to operate long enough to pump down to approximately 1 PSIG. Shut the compressor off and observe the compound gauge. The gauge pressure may build rapidly. Repeat the pump down process several times observing the gauge pressure each time after the compressor stops. If the gauge pressure builds rapidly each time after the compressor stops, it indicates that the compressor discharge valves are not holding and refrigerant is leaking from the high side to the low side of the compressor.

To check the suction valves, assuming that the discharge valves are holding, allow the compressor to operate long enough to pump down the system to approximately 10 inches of vacuum. If the compressor required longer time to accomplish this, then the suction valves are not holding and the compressor should be changed out as it is defective.

MOTOR COMPRESSOR BURN OUT PROCEDURE

The extent of the contamination in a system will indicate the amount of clean-up necessary. If a compressor had burned out, the following method of clean-up is recommended:

1. Discharge the refrigerant from the system.

2. Replace the inoperative compressor.

3. Clean up the system thoroughly and remove all the contaminations.

4. Install a system cleaner or filter drier in the suction line and replace the liquid line filter drier.

5. Connect a vacuum pump to both the low and the high side of the system to remove air and other non-condensables from the system.

6. Allow the vacuum pump to operate until a pressure of 500 microns is achieved.

7. Recharge the system and allow it to operate 8 to 12 hours.

8. Take an oil sample and test for acidity.

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. Using oil other than specified (Sunoco 3G is recommended).

8. Improper use of soldering or brazing flux.

HIGH PRESSURE SWITCH

A high pressure switch is located in the discharge line and senses the discharge pressure. Should the discharge pressure exceed 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.

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 control is installed in the suction line.

The control is preset to open when the suction pressure is 25 psig. The contacts of the control will close when the suction pressure rises to 50 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.

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

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

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

A pump down control may be necessary on an installation where additional protection for the compressor is required to prevent slugging of oil or liquid refrigerant.

Below are some conditions which may exist in an installation where additional protection is required:

1. Migration of refrigerant to the compressor during the off cycle.

2. Flooding, at start-up, due to improperly trapped lines or coil.

3. Suction line in slab or beneath ground forming a large trap.

4. Suction line in cool area causing refrigerant to condense during off cycle.

5. Where condensing unit is installed using existing coils and copper lines, or on a new installation where the above said

conditions exist that cannot be avoided, which could result in compressor damage.

TROUBLE SHOOTING CHART

SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

Compressor will not start – no hum.

Compressor will not start – hums but trips on overload protector.

Compressor starts and runs, but short cycles on overload protector.

1. Line disconnect switch open.

2. Fuse removed or blown.

3. Overload protector tripped.

4. Control stuck in open position.

5. Control off due to cold location.

6. Wiring improper or loose.

7. Thermostat defective or improperly installed.

8. Control circuit open.

9. Burned/open circuit motor winding.

1. Improperly wired.

2. Low voltage to unit.

3. Compressor motor has a winding open or shorted.

4. Internal mechanical trouble in compressor.

5. Liquid refrigerant in compressor.

6. High discharge pressure.

1. Additional current passing through overload protector.

2. Low voltage to unit (or unbalanced if three phase).

3. Overload protector defective.

4. Excessive discharge pressure.

5. Suction pressure too high.

6. Compressor too hot - return gas hot.

1. Close start or disconnect switch.

2. Replace fuse.

3. Refer to electrical section.

4. Repair or replace control.

5. Relocate control.

6. Check wiring against diagram.

7. Replace or relocate.

8. Trace control circuit with wiring diagram and repair.

9. Replace the compressor with all precautions.

1. Check wiring against diagram.

2. Determine reason and correct.

3. Replace compressor.

4. Replace compressor.

5. Check crankcase heater.

6. 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.

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

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

Space temperature too high. 1. Control setting too high.

2. Expansion valve too small.

3. Cooling coils too small.

4. Inadequate air circulation.

Suction line frosted or sweating.

Liquid line frosted or sweating.

1. Expansion valve passing excess re-

2. Expansion valve stuck open.

3. Evaporator fan not running.

4. Overcharge of refrigerant.

1. Restriction in dehydrator or strainer.

2. Liquid shut-off valve partially closed.

frigerant or is oversized.

1. Reset control.

2. Use larger valve.

3. Add surface or replace.

4. Improve air movement.

1. Re-adjust valve or replace with smaller valve.

2. Clean valve of foreign particles, replace if necessary.

3. Determine reason and correct.

4. Correct charge.

1. Replace part.

2. Open valve fully.

TROUBLE SHOOTING CHART

SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

Units runs OK, but short cycles on.

Unit operates long or continuously.

Evaporator ices up.

1. Overload protector.

2. Thermostat.

3. High pressure cut-out due to: (a) Insufficient air. (b) Overcharge. (c) Air in system.

4. Low pressure cut-out due to: (a) Undercharge. (b) Restriction in expansion device.

1. Shortage of refrigerant.

2. Control contacts stuck or frozen closed.

3. Refrigerated or air conditioned space has excessive load or poor insulation.

4. System inadequate to handle load.

5. Evaporator coil iced.

6. Restriction in refrigeration system.

7. Dirty condenser.

8. Filter dirty.

1. Restricted airflow.

2. Dirty air filter.

3. Short of refrigerant.

4. Low air volume.

5. Restricted distributor tube.

6. Restricted liquid line/low liquid line pressure.

1. Check the cause.

2. Differential set too close - widen.

3. (a) Check airflow to the condenser correct.

(b) Reduce refrigerant charge. (c) Purge.

4. (a) Fix leak, add refrigerant.

(b) Replace device.

1. Fix leak, add charge.

2. Clean contacts or replace control.

3. Determine the fault and correct.

4. Replace with larger system.

5. Defrost.

6. Determine location and remove.

7. Clean condenser.

8. Clean or replace.

1. Check for dirt or lint on coil.

2. Clean or replace. Advice customer

on periodic cleaning of filter.

3. Check system pressure. Take super-

heat reading. Add refrigerant.

4. Check for dirty air filter or loose belt.

5. Check for warm distributor tube.

6. Check for restriction in lines/improve

liquid line pressure by proper charging or installing fan cycle switch, etc.

Head pressure too high.

Head pressure too low.

1. Refrigerant overcharge.

2. Air in system.

3. Dirty condenser.

4. Malfunction of condenser fan (air-

5. Excessive air temperature entering

6. Restriction in discharge line.

1.Low ambient temperatures (air-

2. Refrigerant shortage.

3. Damaged valves in compressor.

cooled).

condenser.

cooled).

1. Correct the refrigerant charge.

2. Recharge the system after a thorough

triple evacuation.

3. Clean.

4. Check and correct or replace.

5. Check for short circuiting of con-

denser discharge air, correct it.

6. Correct it.

1. Install fan cycling switch, if not pro-

vided. Check the setting and operation, if provided.

2. Correct the refrigerant charge after

leak testing.

3. Repair/replace the compressor.

TROUBLE SHOOTING CHART

SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE

High suction pressure.

Loss of oil 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. 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. 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.

1. (a) Correct the system piping. (b) Trace out the wiring/defective con-

trols/components, etc. and correct it. (c) Add oil. (d) Check the superheat of expansion

valve and other possible causes

like clogged filter, low CFM, iced

evaporator etc. & correct it.

2. Check the system for correct superheat & other possible causes like clogged filter, low CFM, iced evaporator, etc. and correct it.

3. Repair or replace it.

4. Clean/replace it (oil change recommended).

Relay defective or burned out.

Unit noisy. 1. Loose parts or mountings.

1. Incorrect relay.

2. Incorrect mounting angle.

3. Line voltage too high or too low.

4. Excessive short cycling.

Relay being influenced by loose mounting.

2. Tubing rattle.

3. Bent fan blade causing vibration.

4. Fan motor bearings worn.

1. Check and replace.

2. Remount relay in correct position.

3. Determine reason and correct.

4. Determine reason and correct.

5. Remount rigidly.

1. Find and tighten.

2. Tighten the pipe support.

3. Replace blade.

4. Replace motor.

PARTS LIST (SINGLE CIRCUIT)

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

DISTRIBUTOR

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS036H PDS036M PDS036F PDS048H PDS048M PDS048F PDS060H PDS060M PDS060F

800-674-26 N.A. 800-674-28 800-674-20 800-674-21 800-674-22 800-674-13 800-674-14 800-674-15

800-098-55 N.A. 800-098-55 800-098-57 800-098-55 800-098-55 800-098-59 800-098-55 800-098-55

800-688-03 800-688-03 800-688-02 800-688-05 800-688-05 800-688-06 800-688-07 800-688-07 800-688-08

800-098-57 800-098-55 800-098-55 800-098-59 800-098-55 800-098-55 800-098-59 800-098-57 800-098-55

800-227-05 800-227-05 800-227-06 800-227-10 800-227-10 800-227-11 800-577-00 800-227-14 800-227-15

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

800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08

800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00

800-187-01 800-187-01 800-187-01 800-187-02 800-187-02 800-187-02 800-187-03 800-187-03 800-187-03

800-198-00 800-198-00 800-198-00 800-198-00 800-198-00 800-198-00 800-198-00 800-198-00 800-198-00

800-077-16 800-077-16 800-077-16 800-077-16 800-077-16 800-077-16 800-077-16 800-077-16 800-077-16

800-077-16 800-077-11 800-077-11 800-077-11 800-077-11 800-077-11 800-077-11 800-077-11 800-077-11

800-705-88 800-705-88 800-705-88 800-705-88 800-705-88 800-705-88 800-705-88 800-705-88 800-705-88

800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31

N.A. N.A. N.A. N.A. N.A. N.A. 800-688-16 800-688-16 800-688-17

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

DISTRIBUTOR

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS075H PDS075M PDS075F PDS090H PDS090M PDS090F PDS100H PDS100M PDS100F

800-674-23 800-674-24 800-674-25 N.A. N.A. N.A. N.A. N.A. N.A.

800-098-59 800-098-55 800-098-55 N.A. N.A. N.A. N.A. N.A. N.A.

800-688-09 800-688-09 800-688-10 800-688-11 800-688-11 800-688-12 800-688-13 800-688-14 800-688-15

800-688-18 800-688-18 800-688-19 800-688-20 800-688-20 800-688-21 800-688-22 800-688-23 800-688-24

800-098-61 800-098-57 800-098-55 800-098-61 800-098-57 800-098-57 800-098-61 800-098-57 800-098-57

800-227-14 800-227-14 800-227-15 800-226-33 800-226-33 800-226-34 800-227-14 800-227-14 800-227-15

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

800-531-08 800-531-08 800-531-08 800-531-05 800-531-05 800-531-05 800-531-05 800-531-05 800-531-05

800-201-00 800-201-00 800-201-00 800-200-00 800-200-00 800-200-00 800-200-01 800-200-01 800-200-01

800-187-03 800-187-03 800-187-03 800-182-00 800-182-00 800-182-00 800-182-00 800-182-00 800-182-00

800-191-00 800-191-00 800-191-00 800-198-41 800-198-41 800-198-41 800-198-45 800-198-45 800-182-00

800-077-20 800-077-20 800-077-20 800-077-20 800-077-20 800-077-20 800-077-16 800-077-23 800-077-23

800-077-16 800-077-16 800-077-16 800-077-16 800-077-16 800-077-16 800-077-22 800-077-22 800-077-22

800-705-89 800-705-89 800-705-89 800-705-91 800-705-91 800-705-91 800-705-94 800-705-94 800-705-94

800-705-38 800-705-38 800-705-38 800-705-40 800-705-40 800-705-40 800-705-41 800-705-41 800-705-41

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31

PARTS LIST (SINGLE CIRCUIT)

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS120H PDS120M PDS120F PDS150H PDS150M PDS150F

N.A. N.A. N.A. N.A. N.A. N.A.

800-690-01 800-690-02 800-690-03 800-677-04 800-677-05 800-677-06

800-690-01 800-690-02 800-690-03 800-677-44 800-677-45 800-677-46

800-098-65 800-098-59 800-098-59 800-098-65 800-098-59 800-098-59

800-577-02 800-577-02 800-577-02 800-577-00 800-577-00 800-577-00

800-227-14 800-227-14 800-227-15 800-227-14 800-227-14 800-227-15

800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51

800-531-05 800-531-05 800-531-05 800-531-05 800-531-05 800-531-05

800-200-00 800-200-00 800-200-00 800-200-00 800-200-00 800-200-00

800-185-00 800-185-00 800-185-00 800-186-00 800-186-00 800-186-00

800-077-23 800-077-23 800-077-23 800-077-23 800-077-23 800-077-23

800-077-22 800-077-22 800-077-22 800-077-22 800-077-22 800-077-22

800-705-94 800-705-94 800-705-94 800-705-20 800-705-20 800-705-20

800-705-40 800-705-40 800-705-40 800-705-40 800-705-40 800-705-40

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29

800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS090H PDS090M PDS090F PDS100H PDS100M PDS100F PDS120H PDS120M PDS120F

800-674-73 N.A. 800-674-75 800-674-20 800-674-21 800-674-22 800-674-13 800-674-14 800-674-15

800-098-57 N/A 800-098-55 800-098-57 800-098-55 800-098-55 800-098-59 800-098-55 800-098-55

800-226-33 800-226-33 800-226-34 800-227-14 800-227-14 800-227-15 800-227-14 800-227-14 800-227-15

800-093-11 800-093-11 800-093-11 800-093-11 800-093-11 800-093-11 800-093-11 800-093-11 800-093-11

800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08 800-531-08

800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00 800-201-00

800-187-02 800-187-02 800-187-02 800-187-02 800-187-02 800-187-02 800-187-03 800-187-03 800-187-03

800-077-16 800-077-20 800-077-20 800-077-23 800-077-23 800-077-23 800-077-23 800-077-23 800-077-23

800-077-16 800-077-16 800-077-16 800-077-22 800-077-22 800-077-22 800-077-22 800-077-22 800-077-22

800-705-89 800-705-89 800-705-89 800-705-91 800-705-91 800-705-91 800-705-91 800-705-91 800-705-91

800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38 800-705-38

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31

DUAL CIRCUIT

N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A.

N.A. N.A. N.A. N.A. N.A. N.A. 800-577-00 N.A. N.A.

PARTS LIST (DUAL CIRCUIT)

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS150H PDS150M PDS150F PDS180H PDS180M PDS180F PDS220H PDS220M PDS220F

800-674-23 800-674-24 800-674-25 800-674-79 800-674-80 800-674-81 800-674-01 800-674-02 800-674-03

800-098-59 800-098-55 800-098-55 800-098-63 800-098-57 800-098-57 800-098-61 800-098-57 800-098-57

800-227-14 800-227-14 800-227-15 800-226-33 800-226-33 800-226-34 800-226-33 800-226-33 800-226-34

800-093-11 800-093-11 800-093-11 800-093-12 800-093-12 800-093-12 800-098-51 800-098-51 800-098-51

800-531-08 800-531-08 800-531-08 800-531-05 800-531-05 800-531-05 800-531-05 800-531-05 800-531-05

800-201-00 800-201-00 800-201-00 800-200-00 800-200-00 800-200-00 800-200-00 800-200-00 800-200-00

800-186-00 800-186-00 800-186-00 800-182-00 800-182-00 800-182-00 800-182-00 800-182-00 800-182-00

800-077-23 800-077-23 800-077-23 800-077-24 800-077-24 800-077-24 800-077-16 800-077-24 800-077-24

800-077-22 800-077-22 800-077-22 800-077-24 800-077-24 800-077-24 800-077-24 800-077-24 800-077-24

800-705-91 800-705-91 800-705-91 800-705-94 800-705-94 800-705-94 800-705-94 800-705-94 800-705-94

800-705-38 800-705-38 800-705-38 800-705-40 800-705-40 800-705-40 800-705-40 800-705-40 800-705-40

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31

N.A. N.A. N.A. 800-688-11 800-688-11 800-688-12 800-688-13 800-688-14 800-688-15

N.A. N.A. N.A. 800-688-20 800-688-20 800-688-21 800-688-22 800-688-23 800-688-24

N.A. N.A. N.A. 800-098-61 800-098-57 800-098-57 800-098-61 800-098-57 800-098-57

N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A.

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS240H PDS240M PDS240F PDS300H PDS300M PDS300F PDS360H PDS360M PDS360F

800-674-36 800-674-37 800-674-38 800-674-17 800-674-18 800-674-19 800-674-70 800-674-71 800-674-72

800-098-65 800-098-61 800-098-59 800-098-65 800-098-61 800-098-61 800-098-65 800-098-63 800-098-61

800-690-01 800-690-02 800-690-03 800-690-04 800-690-05 800-690-06 800-690-07 800-690-08 800-690-09

800-098-65 800-098-59 800-098-59 800-098-67 800-098-63 800-098-61 800-098-68 800-098-63 800-098-61

800-577-02 800-577-02 800-577-02 800-577-00 800-577-02 800-577-02 800-577-02 800-577-02 800-577-02

800-226-03 800-226-04 800-226-01 800-226-03 800-226-04 800-226-01 800-226-33 800-226-33 800-226-34

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

800-531-41 800-531-41 800-531-41 800-531-41 800-531-41 800-531-41 800-531-42 800-531-42 800-531-42

800-200-00 800-200-00 800-200-00 800-200-00 800-200-00 800-200-00 800-200-01 800-200-01 800-200-01

800-184-70 800-184-70 800-184-70 800-184-71 800-184-71 800-184-71 800-184-71 800-184-71 800-184-71

800-077-26 800-077-26 800-077-26 800-077-26 800-077-26 800-077-26 800-077-28 800-077-28 800-077-28

800-077-26 800-077-26 800-077-26 800-077-26 800-077-26 800-077-26 800-077-26 800-077-26 800-077-26

800-705-20 800-705-20 800-705-20 800-705-20 800-705-20 800-705-20 800-705-21 800-705-21 800-705-21

800-705-40 800-705-40 800-705-40 800-705-40 800-705-40 800-705-40 800-705-41 800-705-41 800-705-41

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-30 800-557-30 800-557-30

PARTS LIST (DUAL CIRCUIT)

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS420H PDS420M PDS420F PDS480H PDS480M PDS480F PDS540H PDS540M PDS540F

800-674-82 & 70 800-674-83 & 71 800-674-84 & 72 800-674-82 800-674-83 800-674-84 800-674-85 & 82 800-674-86 & 83 800-674-87 & 84

800-677-13 800-677-14 800-677-15 800-690-10 800-690-11 800-690-12 800-690-22 &10 800-690-23 & 11 800-690-24 & 12

800-677-53 800-677-54 800-677-55 800-690-10 800-690-11 800-690-12 800-690-22&10 800-690-23&11 800-690-24&12

800-098-67 800-098-63 800-098-61 800-098-68 800-098-65 800-098-63 800-098-65 & 65 800-098-65 & 63

800-577-00 800-577-00 800-577-00 800-577-02 800-577-02 800-577-02 800-577-02 800-577-02 800-577-02

800-226-33 800-226-33 800-226-34 800-226-03 800-226-04 800-226-01 800-226-03 800-226-04 800-226-01

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

800-531-42 800-531-42 800-531-42 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17

800-200-01 800-200-01 800-200-01 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04

800-184-72 800-184-72 800-184-72 800-184-73 800-184-73 800-184-73 800-184-73 800-184-73 800-184-73

800-077-28 800-077-28 800-077-28 800-077-16 800-077-32 800-077-32 800-077-32 800-077-32 800-077-32

800-077-26 800-077-26 800-077-26 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29

800-705-21 800-705-21 800-705-21 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08

800-705-41 800-705-41 800-705-41 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-30 800-557-30 800-557-30

800-093-41 800-098-65

800-098-65 & 63 800-098-63 & 61

800-093-41 800-098-65 800-098-63 800-098-67 & 65 800-098-65 & 63

800-097-54 800-093-41

800-098-63/61 800-098-67/61

MODEL NUMBER

COMPRESSOR (SCROLL)

CONTACTOR (SCROLL)

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS600H PDS600M PDS600F PDS660H PDS660M PDS660F PDS720H PDS720M PDS720F

800-674-85 800-674-86 800-674-87 N.A. N.A. N.A. N.A. N.A. N.A.

800-097-54 800-098-67 800-098-65 N.A. N.A. N.A. N.A. N.A. N.A.

800-690-22 800-690-23 800-690-24 800-677-25 800-677-26 800-677-27 800-690-25 800-690-26 800-690-27

800-690-22 800-690-23 800-690-24 800-677-65 800-677-66 800-677-67 800-690-25 800-690-26 800-690-27

800-098-68/63 800-098-65 800-098-65 800-098-65/65 800-098-67 800-098-65 800-098-68 800-098-67

800-577-00 800-577-02 800-577-02 800-577-00 800-577-00 800-577-00 800-577-02 800-577-02 800-577-02

800-226-03 800-226-04 800-226-01 800-226-03 800-226-04 800-226-01 800-226-03 800-226-04 800-226-01

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

800-531-17 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17

800-200-04 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04

800-184-74 800-184-74 800-184-74 800-184-75 800-184-75 800-184-75 800-184-75 800-184-75 800-184-75

800-077-32 800-077-32 800-077-32 800-077-35 800-077-35 800-077-35 800-077-35 800-077-35 800-077-35

800-077-29 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29

800-705-08 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08

800-705-42 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

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

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

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-30 800-557-30 800-557-30

800-097-51 800-098-65

PARTS LIST (DUAL CIRCUIT)

MODEL NUMBER

COMPRESSOR (SEMI-HERMATIC RECIP.)

COMPRESSOR (SEMI-HERM. W/-UNLOADER)

CONTACTOR (SEMI-HERMATIC RECIP.)

CAPACITY UNLOADER KITS

COND. FAN ASS’Y (FAN, MOTOR WITH GRILLE)

CONTACTOR

FILTER DRYER

SIGHT GLASS

EXPANSION VALVE

BLOWER WHEEL (STD. & ECONOMIZER)

BLOWER WHEEL (100% FRESH AIR)

PUMP DOWN SOLENOID VALVE

MECHANICAL SHUT OFF VALVE

ACCESS VALVE

LOW PRESSURE GAUGE (LIQUID FILLED)

HIGH PRESSURE GAUGE (LIQUID FILLED)

ADJUSTABLE

FAN CYCLING SWITCH

HIGH PRESSURE SWITCH LOW PRESSURE SWITCH

PDS780H PDS780M PDS780F PDS840H PDS840M PDS840F

800-690-28&25 800-690-29&26 800-690-30&27 800-690-28 800-690-29 800-690-30

800-097-54/098-65

& 097-51/098-65

800-577-02 800-577-02 800-577-02 800-577-02 800-577-02 800-577-02

800-226-03 800-226-04 800-226-01 800-226-03 800-226-04 800-226-01

800-098-51 800-098-51 800-098-51 800-098-51 800-098-51 800-098-51

800-531-17 800-531-17 800-531-17 800-531-17 800-531-17 800-531-17

800-200-04 800-200-04 800-200-04 800-200-04 800-200-04 800-200-04

800-184-75 800-184-75 800-184-75 800-184-76 800-184-76 800-184-76

800-077-35 800-077-35 800-077-35 800-077-35 800-077-35 800-077-35

800-077-29 800-077-29 800-077-29 800-077-29 800-077-29 800-077-29

800-077-16 800-705-08 800-705-08 800-705-08 800-705-08 800-705-08

800-705-42 800-705-42 800-705-42 800-705-42 800-705-42 800-705-42

800-207-08 800-207-08 800-207-08 800-207-08 800-207-08 800-207-08

800-706-30 800-706-30 800-706-30 800-706-30 800-706-30 800-706-30

800-706-31 800-706-31 800-706-31 800-706-31 800-706-31 800-706-31

800-557-29 800-557-29 800-557-29 800-557-29 800-557-29 800-557-29

800-557-30 800-557-30 800-557-30 800-557-30 800-557-30 800-557-30

800-557-31 800-557-31 800-557-31 800-557-31 800-557-31 800-557-31

800-098-65/61 & 65/59

800-098-68&67 800-097-54/098-65 800-098-65/61 800-098-68

PARTS LIST: BLOWER MOTOR GROUP

HP (TEFC) VOLTAGE (V-Ph-Hz) MOTOR (RPM) CONTACTOR OVER LOAD RELAY

208/230-3-60 800-879-43(3600) 800-098-50 800-098-85

460-3-60 800-879-43(3600) 800-098-50 800-098-84

1 380-3-60 800-879-63(3600) 800-098-50 800-098-84

208/230-3-60 800-879-19(1800) 800-098-50 800-098-85

460-3-60 800-879-19(1800) 800-098-50 800-098-84 380-3-60 800-879-55(1800) 800-098-50 800-098-84

208/230-3-60 800-882-43(3600) 800-098-50 800-098-87

460-3-60 800-882-43(3600) 800-098-50 800-098-84

1.5 380-3-60 800-882-63(3600) 800-098-50 800-098-85 208/230-3-60 800-882-19(1800) 800-098-50 800-098-87

460-3-60 800-882-19(1800) 800-098-50 800-098-84 380-3-60 800-882-55(1800) 800-098-50 800-098-85

208/230-3-60 800-828-43(3600) 800-098-50 800-098-87

460-3-60 800-828-43(3600) 800-098-50 800-098-85

2 380-3-60 800-828-63(3600) 800-098-50 800-098-85

208/230-3-60 800-828-19(1800) 800-098-50 800-098-87

460-3-60 800-828-19(1800) 800-098-50 800-098-85 380-3-60 800-828-54(1800) 800-098-50 800-098-85

208/230-3-60 800-770-43(3600) 800-098-54 800-098-88

460-3-60 800-770-43(3600) 800-098-50 800-098-85

3 380-3-60 800-770-61(3600) 800-098-50 800-098-87

208/230-3-60 800-770-19(1800) 800-098-54 800-098-88

460-3-60 800-770-19(1800) 800-098-50 800-098-85 380-3-60 800-770-63(1800) 800-098-50 800-098-87

208/230-3-60 800-771-19(1800) 800-098-57 800-098-89

5 460-3-60 800-771-19(1800) 800-098-50 800-098-87

380-3-60 800-876-05(1450) 800-098-55 800-098-88

208/230-3-60 800-772-19(1800) 800-098-57 800-098-91

7.5 460-3-60 800-772-19(1800) 800-098-55 800-098-88

380-3-60 800-876-09(1800) 800-098-55 800-098-89

208/230-3-60 800-773-19(1800) 800-098-59 800-098-91

10 460-3-60 800-773-19(1800) 800-098-55 800-098-89

380-3-60 800-876-13(1800) 800-098-57 800-098-89

208/230-3-60 800-774-19(1800) 800-098-63 800-098-93

15 460-3-60 800-774-19(1800) 800-098-57 800-098-89

380-3-60 800-876-17(1800) 800-098-59 800-098-91

208/230-3-60 800-775-19(1800) 800-098-65 800-098-94

20 460-3-60 800-775-19(1800) 800-098-59 800-098-91

380-3-60 800-876-21(1800) 800-098-61 800-098-91

208/230-3-60 800-776-19(1800) 800-098-67 800-098-95

25 460-3-60 800-776-19(1800) 800-098-61 800-098-91

380-3-60 800-876-25(1800) 800-098-63 800-098-93

208/230-3-60 800-777-19(1800) 800-098-68 800-098-95

30 460-3-60 800-777-19(1800) 800-098-63 800-098-93

380-3-60 800-876-29(1800) 800-098-65 800-098-94

PARTS LIST: HEATER GROUP

KILOWATTS VOLTAGE (V-Ph-Hz) CONTACTOR HEATER

208/230-3-60 800-098-51/800-098-50* 80032030

5 460-3-60 800-098-51/800-098-50* 80032042

380-3-60 800-098-51/800-098-50* 80032036

208/230-3-60 800-098-51/800-098-50* 80032031

6 460-3-60 800-098-51/800-098-50* 80032043

380-3-60 800-098-51/800-098-50* 80032037

208/230-3-60 800-098-51 80032003

7.5 460-3-60 800-098-51 80032023

380-3-60 800-098-51 80032013

208/230-3-60 800-098-51 80032004

10 460-3-60 800-098-51 80032024

380-3-60 800-098-51 80032014

208/230-3-60 800-098-51 80032006

15 460-3-60 800-098-51 80032026

380-3-60 800-098-51 80032016

208/230-3-60 800-098-55/800-098-54*

20 460-3-60 800-098-51

380-3-60 800-098-51

208/230-3-60 800-098-57/800-098-54* 80032005 (12.5 kW)

25 460-3-60 800-098-51 80032025 (12.5 kW)

380-3-60 800-098-51 80032015 (12.5 kW)

208/230-3-60 800-098-57/800-098-56*

30 460-3-60 800-098-51/800-098-50*

380-3-60 800-098-55/800-098-54*

208/230-3-60 800-098-55

40 460-3-60 800-098-55

380-3-60 800-098-57

208/230-3-60 800-098-57

50 460-3-60 800-098-57

380-3-60 800-098-57

208/230-3-60 800-098-57

60 460-3-60 800-098-59

380-3-60 800-098-57

NOTE: Heater contactor part number with 230 & 24V control volts, please refer to units diagram for the specific contactor control voltage. Contactor part number with * mark is 24V.

RECOMMENDED SPARE PARTS

PERCENTAGE OF SPARE PARTS

ITEM

Compressor 2% 1% 3% 2%

Capacitor 3 2 5 4

Condenser fan motor 2 1 3 2

Evaporator blower motor 1 0.5 2 1

Belt 2 1 4 3

Contactor compressor 2 1 3 2

Contactor heater 2 1 3 2

Contactor fan motors 2 1 3 2

HPS/LPS/other controls 2 1 3 2

Expansion valve 1 0.5 2 1

Filter drier 2 1 3 2

Electric heater 1 0.5 2 1

Fuse link, heater 3 1 4 3

ONE YEAR SUPPLY TWO YEAR SUPPLY

100 UNITS 1000 UNITS 100 UNITS 1000 UNITS

Transformer (24V secondary) 1 0.5 2 1

Propeller fan 1 0.5 2 1

Blower Wheel 0.5 0.25 1 0.5

Bearing-blower 2 1 4 2

Thermostat (Wall) 1 1 2 1

Heater-crankcase 3 1 4 2

Filter 2 1 4 4

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

PREVENTIVE MAINTENANCE SCHEDULE

I T E M

Clean air filters & replace if required.

Clean evaporator coil, drain pan & drain line.

Clean condenser coil.

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

Lubricate blower motor/condenser motor.

Check alignment of pulleys.

Check/clean electrical connections, controls & control box.

Check motors, blower bearings & lubricate it.

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

Check all damper operation. Repair/replace as required.

Check insulation flanking. Repair/replace as required.

FREQUENCY OF MAINTENANCE, MONTHS

Check loose bolts/screws & tight as necessary.

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

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

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. Apply corrosion inhibitor/contact cleaner as required.

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

NOTE: Always observe for abnormal noise or vibration.

MAINTENANCE TOOLS/EQUIPMENT REQUIRED

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

pulley puller, etc.

SPECIAL : Manifold gauge set, R-22 charging cylinder, belt tension checker, leak detector, vacuum pump with elec-

tronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.

Zamil PDS036, PDS048, PDS060, PDS075, PDS090 Installation, Operation & Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual