Zamil CNX150 Installation, Operation & Maintenance Manual

PL-OM-CNX-07-1M-E

INSTALLATION,

OPERATION

&

MAINTENANCE

MANUAL

AIR COOLED CONDENSING UNITS

'CNX' SERIES

Contents Page

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

Physical data ......................................................................................................................................... 3-4

Electrical data ........................................................................................................................................... 5

Dimensions.......................................................................................................................................... 6-13

Microprocessor control system............................................................................................................... 14

User sequence of operation ................................................................................................................... 15

Typical schematic wiring diagram...................................................................................................... 16-23

Field wiring connections ......................................................................................................................... 24

Rigging instructions & weight distribution ............................................................................................... 25

Load distribution ..................................................................................................................................... 26

INSTALLATION INSTRUCTIONS

General................................................................................................................................................... 27

Location of unit ....................................................................................................................................... 27

General................................................................................................................................................... 27

Refrigerant piping connections ............................................................................................................... 27

Leak testing & refrigerant charging......................................................................................................... 28

Start-up inspection & check list ......................................................................................................... 28-29

Check-out & operational start-up procedure ........................................................................................... 29

ELECTRICAL

Power supply .......................................................................................................................................... 30

Unbalanced voltage ................................................................................................................................ 30

Motor contactor ...................................................................................................................................... 31

Fan motor ............................................................................................................................................... 31

Crankcase heater ................................................................................................................................... 31

Lube oil protection control ...................................................................................................................... 31

Voltage monitor ...................................................................................................................................... 31

REFRIGERATION

Compressor ............................................................................................................................................ 32

High & low pressure protection.......................................................................................................... 33-34

Pump down control................................................................................................................................. 34

Trouble shooting chart ....................................................................................................................... 35-37

Parts list ................................................................................................................................................. 38

Recommended spare parts .................................................................................................................... 39

Preventive maintenance schedule.......................................................................................................... 40

Material safety data sheet ...................................................................................................................... 41

Pressure temperature chart............................................................................................................... 42-43

INDEX

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1

2

1, 2 & 3

BASIC 4, 5 & 6

NOMINAL

COOLING

CAPACITY*

(MBH)

8

SPECIAL OPTIONS

7

ELECTRICAL

SUPPLY

( V-Ph-Hz )

10

GENERATION CODE

CNX

CONDENSING

UNIT

150

220

240

300

360

420

480

540

600

720

840

**M00

**M10

**M20

**M40

**M60

***2M00

***2M40

Z :SPECIAL OPTIONSF : 460-3-60 00

01

02

03

9

MANUFACTURING YEAR

06

07

08

MODEL DECODING

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

** M indicates for 1 Million BTUH.

*** 2M indicates for 2 Million BTUH.

MODEL NUMBER CNX150 CNX220 CNX240 CNX300 CNX360 CNX420 CNX480 CNX540 CNX600

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

NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Dual Dual Dual Dual Dual

COMPRESSOR Type Scroll Semi-hermetic reciprocating

Oil per system (liters) 4.1 4.1 4.1 4.7 4.68 4.68 4.94 4.94 4.94

Refrigerant R-134a

Charge per system (oz)** 235 330 400 504 570 650 750 850 945

CONDENSER FAN Type Propeller

Qty. – Diameter (mm) 2 – 560 2 – 630 2 – 700 2 – 700 3 – 700 3 – 700 4 – 700 4 – 700 4 – 700

Nominal CFM 8400 10000 15000 15000 22500 22500 30000 30000 30000

Motor kW – RPM

0.66–1010 0.86–1020 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000 1.45–1000

CONDENSER COIL Type Inner grooved tubes and enhanced fins

Tube Dia–Rows–Fins per inch

3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–5–14

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

HIGH PRESSURE SWITCH

Open (PSIG) 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10

Close (PSIG) 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10

LOW PRESSURE SWITCH

Open (PSIG) 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5

Close (PSIG) 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5

REFRIGERANT LINES+

Suction line size

(OD), inch 1-3/8 1-5/8 1-5/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8

Liquid line

size

(OD), inch 5/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-1/8

SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)

++

69/65/60 69/65/60 69.3/65.8/60.5 69.7/66.1/60.9 69.8/66.3/61 72.9/69.3/64.1 72.8/69.3/64 72.9/69.3/64.1 73.3/69.8/64.5

OPERATING WEIGHT, Kg. 800 925 980 1060 1325 1400 1525 1600 1675

PHYSICAL DATA

NOTE:

*Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.

** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.

+Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.

++ Based on free field area at ARI conditions. Tolerance: ±2dBA.

3

MODEL NUMBER CNX720 CNX840 CNXM00 CNXM10 CNXM20 CNXM40 CNXM60 CNX2M00

CNX2M40

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

NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual

Quadruple Quadruple Quadruple Quadruple Quadruple

COMPRESSOR Type Semi-hermetic reciprocating Screw

Oil per system (liters) 4.94 4.94 5.2 5.2 4.94 4.94 5.2 5.2 22

Refrigerant R-134a

Charge per system (oz)** 1125 1145 1350 1660 945 1090 1250 1390 2520

CONDENSER FAN Type Propeller

Qty. – Diameter (mm) 6 – 700 6 – 700 6 – 800 6 – 800 6 – 800 8 – 800 8 – 800 10 – 800 16 – 800

Nominal CFM 45000 45000 73266 73266 69000 93256 87032 108790 192048

Motor kW – RPM

1.45–1000 1.45–1000 2.15–970 2.15–970 2.15–970 2.15–970 2.15–970 2.15–970 2.15–970

CONDENSER COIL Type Inner grooved tubes and enhanced fins

Tube Dia–Rows–Fins per inch

3/8–4–14 3/8–5–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–3–14

Total face area (Sq. ft.) 70 70 120 120 120 140 140 175 304

HIGH PRESSURE SWITCH

Open (PSIG) 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10

Close (PSIG) 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10 300 ± 10

LOW PRESSURE SWITCH

Open (PSIG) 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5 10 ± 5

Close (PSIG) 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5 30 ± 5

REFRIGERANT LINES+

Suction line size

Dual 2-1/8 2-1/8 2-5/8 2-5/8 N.A. N.A. N.A. N.A. N.A.

(OD), inch Quadruple N.A. N.A. N.A. N.A. 2-1/8 2-1/8 2-5/8 2-5/8 3-1/8

Liquid line size Dual 1-1/8 1-1/8 1-3/8 1-3/8 N.A. N.A. N.A. N.A. N.A.

(OD), inch Quadruple N.A. N.A. N.A. N.A. 1-1/8 1-1/8 1-1/8 1-1/8 1-3/8

SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)

++

73.3/69.8/64.5 73.3/69.8/64.5 74.7/1.2/66 75.7/72.7/66.9 76.2/72.7/67.4 77.1/73.6/68.3 77.7/74.2/69 78.1/74.6/69.3 81.4/77.9/72.6

OPERATING WEIGHT, Kg. 2100 2600 3500 3700 4250 4700 5600 5095 8500

PHYSICAL DATA

NOTE:

*Nominal cooling capacity @ 950F outdoor and 450F saturated suction temperatures.

** Operating system charge is applicable when matched with air handling units & connected by 25 feet of refrigerant piping.

+Pipe sizes are for runs up to 50 feet to indoor unit. For refrigerant lines longer than 50 feet, use next larger size.

++ Based on free field area at ARI conditions. Tolerance: ±2dBA.

4

LRA

(each)

RLA

(each)

460-3-60

CNX 150

CNX 220

CNX 240

CNX 300

CNX 360

CNX 420

CNX 480

CNX 540

CNX 600

CNX 720

CNX 840

CNX M00

CNX M10

CNX M20

CNX M40

CNX M60

CNX 2M00

CNX 2M40

UNIT

SIZE

SUPPLY VOLTAGE COMPRESSOR MOTOR CONDENSER FAN MOTORS

MOCP

MCAMax.Min.

Nominal

(V-Ph-Hz)

414

506

25.7 35 2 11.4 125 0.66 1.0 2.4 2

39.0 50 2 15.9 158 0.86 1.6 4.1 2

45.7 60 2 18.1 187 1.45 2.5 10.0 2

56.1 75 2 22.7 225 1.45 2.5 10.0 2

60.6 80 2 23.6 193 1.45 2.5 10.0 3

70.5 90 2 28.0 220 1.45 2.5 10.0 3

77.5 100 2 30.0 262 1.45 2.5 10.0 4

91.0 125 2 36.0 262 1.45 2.5 10.0 4

108.8 150 2 43.9 323 1.45 2.5 10.0 4

147.1 200 2 58.7 404 1.45 2.5 10.0 6

183.5 250 2 72.5 513 2.15 3.4 10.0 6

207.6 275 2 83.2 590 2.15 3.4 10.0 6

207.0 250 4 43.9 323 2.15 3.4 10.0 6

276.7 325 4 58.7 404 2.15 3.4 10.0 8

335.3 400 4 72.5 513 2.15 3.4 10.0 8

342.1 400 4 72.5 513 2.15 3.4 10.0 10

548.6 650 4 117.4 801 2.15 3.1 10.0 16

Qty.

ELECTRICAL DATA

FLA

(each)

Qty.

LRA

(each)

kW

LEGEND:

MCA - Minimum Circuit Ampacity

MOCP - Maximum Over Current Protection

RLA - Rated Load Amps

LRA - Locked Rotor Amps

kW - Kilowatt

FLA - Full Load Amps

5

2121

[86.50]

[83.50]

2197

203 [8.0]

1550 [61.0]

943 943

73 [2.875] [37.125]

[80.0]

[37.125]

2032

"A" "B" "C"

1

2

3

5

4

6

7

5

7

6

4

5

3

2

1

DIMENSIONS

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

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

CNX 150 - CNX 300

CNX 360 - CNX 420

6

255.0 [10.00]

TYP

357.5 [14.07]

TYP

335.4 [13.20]

375.6 [14.80]

2121

[86.50]

2197

[83.50]

1550 [61.0]

203 [8.0]

DIMENSIONS

CNX 480 - CNX 600

CNX 720 - CNX 840

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

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

7

73 [2.875] 968

(38.11")

968

(38.11")

965

(37.99")

"B" "C"

SIDE VIEW

FRONT VIEW

TOP VIEW

DIMENSIONS

CNX M00 - CNX M10

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

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

8

DIMENSIONS

CNX M20

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

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

9

ELECTRIC POWER INLET

285.0 [11.220]

917.0 [36.102] TYP

786.0 [30.944] TYP

670.5 [26.397] TYP

487.0 [19.173] TYP

DIMENSIONS

CNX M40

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

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

10

285.0 [11.220]

917.0 [36.102] TYP

786.0 [30.944] TYP

670.5 [26.397] TYP

487.0 [19.173] TYP

ELECTRIC POWER INLET

DIMENSIONS

CNX M60

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

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

11

DIMENSIONS

CNX 2M00

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

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

12

DIMENSIONS

CNX 2M40

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

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

13

2185 [86.023]

275 [10.826]

2200 [86.614]

917.0 [36.102] TYP

786.0 [30.944] TYP

670.5 [26.397] TYP

487.0 [19.173] TYP

285.0 [11.220]

14

MICROPROCESSOR CONTROL SYSTEM

Each condensing unit are provided with microprocessor based control board that monitors analog and digital inputs to

achieve precise control and safety functions during unit’s operation. Input signals for cooling control can be digital signals

coming from a thermostat device or analog signals from a PTC temperature sensor. The push button key board allows

accessing to the operating conditions, control set points (in case temperature control is analog signal), & alarm history

that are clearly displayed on a multi-line back illuminated LCD panel.

The unit’s controller consists of the following hardware:

1. User Interface Board – Includes push buttons to access operating conditions, change control set points, and

view alarm history. Data are clearly displayed on its LCD panel.

2. Main Board – This controls up to 2 compressor system.

3. Auxiliary Boards – Required for controlling an additional (2) or more compressors.

LCD Display Information:

In the normal operating mode, the 20 x 4 characters LCD panel displays the system status, temperature of leaving /

returning air and set point (if temperature control selected is through PTC sensors ), run time of compressor and alarm

history.

Measurement data for each circuit can be easily accessed and displayed on the LCD. Data include the following:

- Suction, Discharge, and Oil pressures

- Leaving / Returning Air temperature ( if temperature control selected is through PTC sensors )

- Compressor Motor Status

- Condenser Fan Motor Status

- Liquid Line Solenoid Status

- Supply Fan Motor Status

There are three LED lights on the user interface board to indicate “Power On” (green), “Menu Adjustment” (yellow) and

“Fault” (red).

SYSTEM PROTECTION

The unit is equipped with protective devices against motor overloads and proper system settings are factory set to ensure

safe and reliable operation of the unit. Some of these devices and settings are as follows:

-Compressor Motor External Overload Relay

-Compressor Motor Winding Over Temperature Protection

-Low suction Pressure

-High Discharge Pressure

-Low Oil Pressure

-Compressor Anti-Recycling Timer

15

USER SEQUENCE OF OPERATION

Machine Starting:

- If OFF, the machine is started by pushing the ON/OFF button.

- The ON LED (green) will lit.

- On the main screen is showed the status “STARTING”.

- After 15 seconds of delay the system will be running.

Machine Shut-Down:

- The machine is halted pushing again the ON/OFF key.

- The ON LED (green) is switched off.

- On the main screen is showed the status “STOPPING”.

- All the compressors are stopped.

- Blower motor will be switched off after pre-set delay timing when all compressors are switched off.

- On the main screen is showed the status “SYSTEM OFF”.

Set Point Change:

- Press “SET”, the LCD will ask the password input.

- Using the “UP” and “DOWN” keys input the correct password.

- Press “SET”, the “MODIFY” word appears to allow the parameter to be changed. The LCD will show the actual

value.

- Using the “UP” and “DOWN” keys modify the set point value.

- Press “SET” to store it or “ESC” to exit without memorizing.

COMPRESSOR CONTROL

Control setting to switch on / off the compressors is through digital output signals from an external controller fed to the

micro-processor board. When the system is started up, the software starts to check all the necessary inputs to start the

unit. It scans the digital/analogue inputs. If any unwarranted interruption occurred the alarm signal is generated and the

compressor will be shut-off.

BLOWER MOTOR CONTROL (OPTIONAL)

Control setting to switch on / off the blower motor is through digital output signal from an external controller fed to the

micro-processor board. The system’s control will prevent the compressors to operate if this signal is not fed to the micro-

processor board.

CLASSIC

AIR CONDITIONERS

TOUT = 10°C TIN = 15°C

COOLING 75%

SET

Menu

Esc

On/Off

OLR2 CC1 CC2

OLR1

OLR2

CC2

CB6 CB7CB6 CB6

UVM-1

CC1

OLR1

CC3

OLR3

CB7

FMC1

CB6 CB8

FMC5FMC4FMC2

CB7

FMC6

FMC2FMC1 FMC2FMC1 FMC3 FMC1

OPS1-1

OPS2-1

FMC4FMC2

CC2A-1B

CC1A-1B

DIP SWITCH SETTINGS - MB BOARD

JU11 - CLOSED (1,2)

OFF

TD2 - CLOSED

S1 ON

12

OFF

3

OFF

4

OLR2

CC2

OLR4

CC4

OLR3

CC3

OLR1

CC1

ATB

JU9 - CLOSED (1,2)

JU8 - CLOSED (1,2)

JU7 - CLOSED (1,2)

JU6 - CLOSED (1,2)

JU5 - CLOSED (1,2)

JU4 - CLOSED (1,2)

JU3 - CLOSED (1,2)

JU2 - CLOSED

JU1 - CLOSED

HPS1 & 2

HIGH PRESSURE

HGS

LOW PRESSURE

TL2 - OPEN

TL1 - OPEN

TU2 - CLOSED

TU1 - CLOSED

JU19 - CLOSED (1,2)

JU15 - CLOSED (1,2)

JU13 - CLOSED (1,2)

JU12 - CLOSED (1,2)

JUMPER SETTINGS - MB BOARD

PRESSURE SETTINGS

460 ± 10

CUT-OFF (PSIG)

--

DESC.

--

360 ± 15

--

CUT-IN (PSIG)

--

2

20

ATB

MOTOR STARTER CONTROL

SWITCHING CONTACT

AHU MOTOR ON/OFF

R2-1

R2 (230Vac)

(OPTIONAL)

AHU CONTROL INTER-CONNECTIONS

CONDENSING UNIT

CONTROL PANEL

LVTB

17

67

ATB

1

ATB

G

CONTROL PANEL

AIR HANDLING UNIT

(AHU MOTOR CONTROL)

R1-1

R1 (24Vac)

(REMOVE JP7)

52

ATB

(N.C CONTACT)

AHU MOTOR FAULT

1

ATB

FMC3

OLR2

CC1 CC2

OLR1

OLR4

CC4

8B1

3

4

4-FAN MOTOR LAYOUT

CNX 720~840 / CNXM00~20

FM2

14 NO

13 NO

12D

12F

12B

13D

T.K.

FM4

13F

FM6

T.K. 13B

FMC6

FMC4

FMC2

CONTROL 6

PANEL 5C1

L3L2L1L1 L2 L3L2L1 L3

FM2FM3FM1

TO MB

10 NO

9 NO

12C

12E

12A

103C

35C

104A

36A

35A 103A

37A 105A

37C

36C 105C

104C

35B

36B

37B

103B

104B

105B

3B

MB

T2B

T1B

T3B

9B

4-FAN MOTOR LAYOUT

CNX 480~600

L3L2

HVTB

PANEL 4

CONTROL 3

C2 2

C1 1

1

11B

61B

OLR4-1A

CC2

CC4

T2D

COMP

2

T1D

T3D

1

2

T1B

1

T3A

(AS APPLICABLE)

COMP

2

T2B

T3B

HVTB

T2B

(REMOVE JP3A)

SSPS1

M1/11

L1/MP/L

SSPS2

L2/R/N

M2/14 8A

2

T1C

CB1A-1A

T3A

T1A

T2A

COMP

1

23A 1

T3C

T2C

T1B

CB2A-1A

COMP

2

T3B

T2D

T1D

T3D

23B

L2B

COMPRESSOR IN PWS CONNECTION WITH CB

L1C

L3A

L1A

L2A

CB1

L3C

L2C

L1B

1

T3A

T1A

T2A

COMP

L3D

L3B

L1D

L2D

CB2

(OPTIONAL)

2

T2B

T3B

T1B

COMP

(OPTIONAL)

COMPRESSOR WITH CB CONNECTION

HVTB

L2A

L1A

L3A

L3

L1

L2

CB1

L2B

L1B

L3B

CB2

TD1 - CLOSED

JU10 - CLOSED (1,2)

2

M2/14

L2/R/N 2

OLR3-1A

3-FAN MOTOR LAYOUT

CNX 360~420

COMPRESSOR POWER & CONTROL CONNECTION IN PART WINDING STARTING (PWS)

CONDENSER FAN MOTOR POWER AND CONTROL CONNECTIONS

T3C

T2A

COMP

L1 L3L2

HVTB CNX 220~300

2-FAN MOTOR LAYOUT

C1

PANEL

CONTROL 1 2C2

10A

L1 L3L2

HVTB L1

PANEL

HVTB

L2 L3

CONTROL

3A

1O

MB

T1A

OLR1-1A

CC1A-2A

11A

61A CC3

CC1

COMP

T3A

T2A

1

T1C

T2C

Ø

L2

(REMOVE JP1)

Ø

1

Ø

L1

1A

1

UVM

Ø

8

Ø

L3

UVM CONNECTION(OPTIONAL)

L2L1 L3

L1

L3

L2

HVTB

T1A

POWER SUPPLY

(NOTE 4)

HVTB

LUG/ETB

L2

L3

L1

L3

L2

COMP. 1:

COMP. SSPS CONNECTION(AS APPLICABLE)

COMP. 2:

OLR2-1A

CC2A-2A

L1

10B9A

HVTB

L3

2

C2

3C1 1L1 L2

4O

2

COMP 2

103B

35B

12A

12D

14 NO

FM4

T.K.

12B

12C

10 NO

13 NO

9 NO

T.K.

FM2

FM3

T.K.

105A

37A

2

FM1

35A

36A

103A

104A

FM3

TO MB T.K.

FM1

104C

36C

35C 103C

37C 105C

13A

13D FMC4

13B FMC2

13C FMC3

COMP 1

FMC1

FM2

2

FM4

37B

36B 105B

104B

36D

35D

37D

104D

103D

105D

64B

OPS2

(REMOVE JP5A)

(REMOVE JP5B)

1

3B 2240 2

64A

C.HTR2

C.HTR1

OPS1

3A

1

2

L1

L2

240 2

L2

L3

(REMOVE JP4B)

100A

101A

1

M1/11

L1/MP/L

C.HTR1

C.HTR2

FM6FM5FM4

FM3

T.K. 13C

FM5

T.K. 13E

FMC3

FMC5

T.K.

FM1

13A

2

FMC1

103E

35D

36D 104D

103D

37D 105D

37E

36E

35E

105E

104E

35F

36F

37F

104F

103F

105F

12A 12A

HVTB

13 NO

9 NO

12B

HVTB

13B

FM2

T.K. FMC2

103B

35B

TO MB

FM1

104A

36A

35A 103A

37A 105A

FM1

T.K.

FM2

FMC1

2

37B

36B 105B

104B

12A 13A

12B

12C

10 NO

9 NO

13 NO

HVTB

T.K.

FM2

FM3

T.K.

FMC2

13B

FMC3

13C

105C

FM3FM1

TO MB

35A

36A

37A

103A

105A

104A

36C

35C 103C

104C

T.K.

FM1 FMC1

FM2

104B36B

37C

35B 103B

37B 105B

C2 2

1

(SEE NOTE 3)

CRANKCASE HTR CONNECTION(AS APPLICABLE)

COMP. 1:

COMP. 2:

COMP. 1:

B. SCROLL COMP.

OIL PRESSURE SWITCH CONN.(AS APPLICABLE)

COMP. 2:

A. SEMI-HERMETIC RECIP. COMP.

NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items.

2. Refer to unit control box (inside panel) for exact wiring diagram.

16

SCHEMATIC WIRING DIAGRAM

POWER SUPPLY : 460-3-60 (Dual compressor units)

APPLICABLE ON MODELS: CNX150 - CNXM10

17

SCHEMATIC WIRING DIAGRAM

POWER SUPPLY : 460-3-60 (Dual compressor units)

APPLICABLE ON MODELS: CNX150 - CNXM10

NOTES

1. ANY WIRE REPLACEMENT SHOULD BE OF THE 900C

OR ITS EQUIVALENT.

2. USE COPPER CONDUCTOR WIRES ONLY.

3. COMPRESSORS ARE PROVIDED WITH INTERNAL

LINE BREAK OR SSPS FOR THERMAL PROTECTION.

4. FUSED DISCONNECT SWITCH OR CIRCUIT

BREAKER TO BE PROVIDED BY END USER WITH

RATING AS RECOMMENDED BY ZAMIL.

5. USE DISCONNECT TAB OR SPLICE ONLY

WHERE- EVER REQUIRED FOR EXTENSION OF

ORIGINAL WIRE.

6. 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.

+

LEGEND

AHU AIR HANDLING UNIT

ATB AUXILIARY TERMINAL BLOCK

BMR BLOWER MOTOR RELAY

CC COMPRESSOR CONTACTOR

CCA AUXILIARY CONTACT

CB CIRCUIT BREAKER

C. HTR CRANKCASE HEATER

COMP/C

COMPRESSOR

F FUSE

FM FAN MOTOR (CONDENSER)

FMC FAN MOTOR CONTACTOR

HPS HIGH PRESSURE SWITCH

HVTB HIGH VOLTAGE TERMINAL BLOCK

JP JUMPER

L1 LINE 1

L2 LINE 2

L3 LINE 3

LUG LUG GROUND

MB MOTHER BOARD

OLR OVER LOAD RELAY

SSPS SOLID STATE PROTECTIVE SYSTEM

TRANS TRANSFORMER

TK/TOP

FAN MOTOR (PROTECTION) THERMAL CONTACT

UL COMPRESSOR UNLOADER SOLENOID

UVM UNDER VOLTAGE MONITOR

YR COOLING RELAY

FIELD WIRING

DISCONNECT TAB - 1/4"

SPLICE-CLOSED END

TERMINAL BLOCK OR TERMINATION POINT

JUNCTION OF WIRES

CROSSING OF WIRES, NO CONNECTION

EARTHING/GROUND

_ _ _

+

COMP2 PUMP DOWN SOLENOID

COMP2 CAPACITY UNLOADER SOLENOID

COMP1 PUMP DOWN SOLENOID

COMP1 CAPACITY UNLOADER SOLENOID

HOT GAS BY-PASS SOLENOID

(OPTIONAL)

COMP2 CONTACTOR

(OPTIONAL)

ATB

STG2 COOLING

OLR2-1A

OLR1-1A

TO HVTB

10A

YR2-1A

(OPS2-1)

(SSPS2)

YR1-1A

P

HPS2 JP5B

P

JP3B

10B

64B

8B

JP4B

(CB2A-1)

ATB

(OPS1-1)

(SSPS1)

HPS1 JP5A

JP3A

(UVM-1)

1JP1 1A

64A

8A

JP4A

(CB1A-1)

S1 1B

9A A4 (HPS-1)

A17 ( S. FAN MOTOR FAULT)

A15 (COOLING STAGE 2)

AC (DIGITAL COM)

A20 (AUX. ALARM COMP2)

A19 (AUX. ALARM COMP1)

1C

52

71B

A18

A16

1O

A11 (FLOW SWITCH)

A9 (HPS-2)

A6 (SSPS-2)

A7 (CB-2)

A8 (OL-2)

A5 (FCB-1)

A12

A13 (EMERGENCY)

A14 ( COOLING STAGE 1)

71A

67

A10

23B

9B AO1

AO2

AO3

3A CC1

4

6

15

TO ATB

A2 (CB-1)

A3 (OL-1)

A1 (SSPS-1)

23A

5

24V AC

AO4

PE

TO ATB

17

L1

3

Y2

460V

230V

TRANS2

R1(DIG OUT)

R2(DIG OUT)

R3(DIG OUT)

R4(DIG OUT)

R5(DIG OUT)

R6(DIG OUT)

R7(DIG OUT)

R8(DIG OUT)

R9(DIG OUT)

R10(DIG OUT)

R11(DIG OUT)

R12(DIG OUT)

R13(DIG OUT)

R14(DIG OUT)

R15(DIG OUT)

R16(DIG OUT)

R17(DIG OUT)

R18(DIG OUT)

+

-

O1

-

SH

D1

ST1

18C

17C

18NO

(A5-SP1) -

+

S1

17NO

16NO

15NO

SH

OPT1

DPT1

SPT2

DPT2

33A

29B

30B

SH

28B

SH

32A

SH

30A

31A

COMP2

+

-

COMP1

+

-

SPT1

28A

29A COMP1

-

+

C

11NO

13NO

14NO

12NO

9NO

10NO

8NC

5C

8C

7C

6C

4C

3C

2C

5O

8NO

7O

6O

4O

3O

2O

COMMON FAULT INDICATION

CONNECTION (SYSTEM 2)

REFER FAN MOTOR CONTROL

CONNECTION (SYSTEM 1)

REFER FAN MOTOR CONTROL

(VOLT-FREE CONTACT)

20 (230Vac)

15B

14B

HGS

15A

14A

PDS2 3B

UL2

CC2

UL1

2

L3

YR2

TO HVTB

(FIELD INSTALLATION)

FROM THERMOSTAT OR DDC

SWITCHING CONTACTS

AHU MOTOR CONTROL

STG1 COOLING

COM

(OPTIONAL CONNECTION)

TRANS1

ATB

15

G

Y1

C

LVTB

R

230V

24V

(75VA)

ATB

17

YR1

2

TO ATB

1

COMP1 CONTACTOR

JP6

JP7

F4

F2F1

F3

SET

*

*SERIAL CABLE 3

COM1

S1

ON

12

GND

DIP

4+

(A10-OP2)

-

O2

+

(A9-DP2)

SH OPT2

32B

33B

SH

31B

SH

COMP2

-

+

SH

ST2

T.OUT

(A1-ST1)

TIN

SH

+

(A7-OP1)

(A8-SP2)+

SH

-

S2

(A6-DP1)

PDS1

AHU MOTOR ON/OFF CONTROL

(FOR RECIP. COMP ONLY)

OIL PRESSURE TRANSDUCER

DISCHARGE PRESSURE TRANSDUCER

SUCTION PRESSURE TRANSDUCER

COMP2

-

D2 -

USER INTERFACE BOARD

COOLING 75%

TOUT=15°C TIN=28°C

ESC *

On/Off

MENU

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.

18

SCHEMATIC WIRING DIAGRAM

POWER SUPPLY : 460-3-60 (Four compressor units)

APPLICABLE ON MODELS: CNXM20 - CNXM60

TO HVTB/BUSBAR

L2L1 L3

COMP3 COMP4

FAN2

CONTROL PANEL FAN1 FAN4 FAN6

FAN3 FAN5

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS - 6 FANS / CNXM20

FAN LAYOUT

COMP1 COMP2

TO HVTB/BUSBAR

L3L2L1

ATB

52

ATB

1

ATB

2

20

ATB

MOTOR STARTER CONTROL

SWITCHING CONTACT

AHU MOTOR ON/OFF

AHU MOTOR FAULT

(REMOVE JP7)

(N.C CONTACT)

R2-1

R2 (230Vac)

AHU CONTROL INTER-CONNECTIONS

17

1

(REMOVE JP6) ATB

67

ATB

LVTB

G

ATB

CONTROL PANEL

CONDENSING UNIT

(AHU MOTOR CONTROL)

BMR-1A

BMR (24Vac)

AIR HANDLING UNIT

CONTROL PANEL

(OPTIONAL)

FMC1 FMC3

CB17

FMC4FMC5 FMC2

FM6

T.K.

2

FMC1

FMC3

12E

14 NO FMC5

13E

T.K.

13 NO

12A

10 NO

FM1

13A

T.K.

12C

9 NO

TO MB FM3

13C

T.K.

14 NO 12F

12F

13 NO

10 NO 12B

TO AB

9 NO 12D

FM3FM1

36C

35C

36A

37A

35A

37C 104C

103C

104A

105A

103A

105C

FM5

37E

35E

36E

FM2

37B

36B

35B

103E

104E

105E

105B

104B

103B

2

13F FMC6

T.K.

FM2 FMC2

13B

FMC4

T.K. 13D

FM4

36F

FM6FM4

37D

36D

35D

35F

37F 104F

105D

104D

103D

103F

105F

TO HVTB/BUSBAR

L2L1 L3

COMPRESSOR POWER & CONTROL CONNECTION

HVTB / BUSBAR

POWER SUPPLY

(NOTE 4) L3

L1

L2

ON (PSIG)

CLOSE (PSIG)

300 ± 15

3B

MB

2

1O 3C

2AB

COMP

1

T2A

T1A

T3A

COMP

2COMP

3

T3B

T1B

T2B

T1C

T3C

T2C

4O

CC3 3D

2AB

CC4

2

COMP

4

T3D

T2D

T1D

FM3,4

FM1,2,5,6 175125

225175

OFF (PSIG)FAN MOTOR #

HPS1 ~4 350 ± 10

LOW PRESSURE

HIGH PRESSURE

30 ± 510 ± 5

--300

OPEN (PSIG)

PRESSURE SETTINGS

DESC.

TL1 - OPEN

JU13 - CLOSED (1,2)

JU15 - CLOSED (1,2)

JU12 - CLOSED (1,2)

JU11 - CLOSED (1,2)

JU5 - CLOSED (1,2)

JU6 - CLOSED (1,2)

JU3 - CLOSED (1,2)

JU4 - CLOSED (1,2)

DIP SWITCH SETTINGS - AB BOARD

JUMPER SETTINGS (COMMON)

S1 OFF ON

21

OFF OFF

34

OFFOFF

OFFON

TD1 - OPEN

TU1 - OPEN

JUMPER SETTINGS - MB BOARD

JU1 - OPEN

JU2 - OPEN

DIP SWITCH SETTINGS - MB1 BOARD

TL1 - OPEN

TD1 - OPEN

S1 12

JU2 - CLOSED

43

JUMPER SETTINGS - MB BOARD

TU1 - OPEN

JU1 - CLOSED

FMC6

CB19

CB18

OLR2

CC2CC1

OLR1 OLR3

CC3 CC4

OLR4

TU2 - CLOSED

TL2 - OPEN

TD2 - CLOSED

JU9 - CLOSED (1,2)

JU10 - CLOSED (1,2)

JU8 - CLOSED (1,2)

CC1

1O 3A

MB

CC2

4O

JU19 - CLOSED (1,2)

JU7 - CLOSED (1,2)

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.

19

SCHEMATIC WIRING DIAGRAM

POWER SUPPLY : 460-3-60 (Four compressor units)

APPLICABLE ON MODELS: CNXM20 - CNXM60

JP7

AHU MOTOR ON/OFF CONTROL

(230Vac)

20

R15(DIG OUT)

R16(DIG OUT)

R17(DIG OUT)

R18(DIG OUT)

SSPS4

1

1A

UVM

SSPS2

SSPS3

SSPS1

100C

C.HTR4

100D

C.HTR3

100B

TO HVTB

1B

S1

1A 5

3

L1

230V

C.HTR1

100A

6ATB

2

L3

TRANS2

460V 4

OLR1-1A AO4

HPS1

71A

A17 ( S. FAN MOTOR FAULT)

A15 (COOLING STAGE 2)

A14 (COOLING STAGE 1)

AC (DIGITAL COM)

A20 (AUX. ALARM COMP2)

A19 (AUX. ALARM COMP1)

YR2-1A

YR1-1A

A16

52

A18

71B

A12 ( EXTERNAL ENABLE)

A11 (FLOW SWITCH)

A13 (EMERGENCY )

OLR2-1A

HPS2

P10B

67

JP6

9B A9 (HPS-2)

A10

8B

JP5B

SSPS2

P10A

A6 (SSPS-2)

64B

23B

(CB2A-1)

JP4B A7 (CB-2)

A8 (OL-2)

9A

A5 (FCB-1)

A4 (HPS-1)

AO1

AO2

AO3

Ø

L3

(REMOVE JP1)

L3

81 ØØ

Ø

L2

Ø

L1

L1 L2

ATB

24V AC

8A

JP5A

SSPS1 A1 (SSPS-1)

JP4A

(CB1A-1)

64A

23A A2 (CB-1)

A3 (OL-1)

JP1

(UVM-1)

1

15

TO ATB

PE

17

TO ATB

F3

F1

UVM-1

F4

F2

CC6A-1B

CC5A-1B

CC2A-1B

CC1A-1B

R1(DIG OUT)

R2(DIG OUT)

R3(DIG OUT)

R4(DIG OUT)

R5(DIG OUT)

R6(DIG OUT)

R7(DIG OUT)

R8(DIG OUT)

R9(DIG OUT)

R10(DIG OUT)

R11(DIG OUT)

R12(DIG OUT)

R13(DIG OUT)

R14(DIG OUT)

C.HTR2

UVM CONNECTION (OPTIONAL)

SH

29A

S1

SH

+

(A5-SP1) SH

DISCHARGE PRESSURE TRANSDUCER

-COMP1

+

SUCTION PRESSURE TRANSDUCER

+

17C

18C

17NO

SPT1

28A

18NO

(SHEET 1 OF 3)

CONNECTION (SYSTEM 2)

16NO

15NO

14NO

C

8C

(SHEET 1 OF 3)

10NO

13NO

12NO

11NO

CONNECTION (SYSTEM 1)

REFER FAN MOTOR CONTROL

COMMON FAULT INDICATION

(VOLT-FREE CONTACT)

8NC

9NO

8NO

4C

7C

6C

5C

3C

2C

COMP1 CONTACTOR

3B

4O

14B

7O

6O

15B

5O PDS2

UL2

14A

3O

15A

2O

3A PDS1

UL1

12 43

On/Off S1 -

O2 -33B

+

(A10-OP2)

SH OIL PRESSURE TRANSDUCER

COMP2

+

OPT2

DPT2

31B

(A9-DP2)

32B

+

SH SH

30B

D2 -

SH

DISCHARGE PRESSURE TRANSDUCER

+COMP2

-

REFER FAN MOTOR CONTROL

COMP1

--

SH

TIN

ST2

(A1-ST1)

T.OUT

SH

ST1

OPT1

SPT2

SH

28B

29B

SH

S2 -

(A8-SP2)

33A

32A

O1 -

+

(A7-OP1) +

SUCTION PRESSURE TRANSDUCER

COMP2

-

OIL PRESSURE TRANSDUCER

COMP1

-

DPT1

30A

31A

D1 -

(A6-DP1) +

COMP1 CONTACTOR

1O1C

(SEE COMP. POWER & CONTROL CONNECTION, SHEET 1 0F 3)

(50% UNLOADER SOLENOID)

COMP2 PUMP DOWN SOLENOID

COMP2 CAPACITY UNLOADER SOLENOID

COMP1 PUMP DOWN SOLENOID

COMP1 CAPACITY UNLOADER SOLENOID

++

USER INTERFACE BOARD

COOLING 75%

TOUT=15°C TIN=28°C

GND

DIPON

*

SERIAL CABLE

*

ESC

SET *

MENU

COM1

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Zamil CNX150 Installation, Operation & Maintenance Manual

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