cax series

Company BusinessZamil Air Conditioners was founded in 1974, and is the first major business venture in manufacturing sector for the AlZamil group of Companies. It is also the first manufacturing unit for air conditioners to be established in Saudi Arabia.

Zamil Air conditioners manufactures both consumer and central range of air conditioners and has sales operations inover 55 countries in the Middle East, Europe, America, Africa, Australia and the Far East.

The company’s operations are structured into four Strategic Business Units (SBUs) supporting six in - house product andservice brands as well as a number of international brands under the OEM sales.

The six in-house brands are Classic, Cooline, CoolCare, Clima Tech, Geoclima and Kessler Clima Tech.

The four SBUs are:1. Consumer Business unit supporting Classic, Cooline, GE and OEM brands for consumer range of air conditioners.2. Unitary & Applied Business unit supporting Classic, Cooline, GE and OEM brands for commercial range of air

conditioners.3. Zamil CoolCare - service and maintenance provider.4. Geoclima srl - independent business and supporting other SBUs for their requirement of Chillers & Double skin

AHU’s.

The first three SBUs - Consumer Products, Unitary & Applied Products and Zamil CoolCare direct their business opera-tions from the corporate headquarters at Dammam, Saudi Arabia.

The production facilities at Dammam are shared by Consumer Products and Unitary & Applied Products. Geoclima hasits own production and functional departments located at Monfalcone, Italy.

All the four SBUs, while operating independently, supplement each other’s activities in a way that makes synergy work atits best and achieve the corporate goals of increased productivity and efficiently.

Factories and ProductionsZamil Air Conditioners has its prime manufacturing base at Dammam, Saudi Arabia and has one speciality productionfacility in Italy operated by Geoclima.The company can produce up to 440,000 room air conditioners, 60,000 mini-split systems and 36,500 central air-condi-tioning systems per year.

Quality & Product CertificatesThe Quality systems and policies at Zamil Air Conditioners comply with the required ISO 9001:2000 certification.

Zamil Air Conditioners is the first company in Saudi Arabia to receive the SASO (Saudi Arabia’s Standard Organization)certificate for room air conditioners. Its products and services are also certified with:

1. CE (Council of European Community)2. UL (Underwriters Laboratory)3. AHAM certificate (Association of Home Appliance Manufacturers)4. Eurovent5. DEMKO6. ETL

Other awards include the prestigious Engineering Excellence Award of General Electric, and the inaugural PrinceMohammed bin Fahd Al Saud Award for Factory Safety.

Our ProductsIn addition to the consumer products such as the Room Air Conditioners (RAC) and the Mini Splits, Zamil Air Condition-ers manufacturers a host of residential and commercial air conditioners. This board range extends from the concealedunits up to 5 ton, the ducted splits up to 30 tons, the packaged units up to 70 tons. The single and double skin air handlingunits up to 130,000 CFM and the water chillers up to 487 ton cooling capacity.

Contents Page

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

Unit features ............................................................................................................................................. 3

Standard specifications ......................................................................................................................... 3-5

Options & accessories ........................................................................................................................... 6-7

Physical data ......................................................................................................................................... 8-9

Selection procedure ............................................................................................................................... 10

Performance data .............................................................................................................................. 11-12

Electrical data ......................................................................................................................................... 13

Dimensions ....................................................................................................................................... 14-16

Typical schematic wiring diagram ...................................................................................................... 17-21

Rigging instructions ................................................................................................................................ 22

Installation clearance .............................................................................................................................. 23

Mounting location ................................................................................................................................... 24

Load distribution ..................................................................................................................................... 25

Installation instructions ........................................................................................................................... 26

Electrical ................................................................................................................................................. 27

System design ........................................................................................................................................ 27

INDEX

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2

UNIT FEATURESGENERALThe CAX series air cooled condensing units from Zamil Air Conditioners are designed to provide engineering excellencein comfort air conditioning and industrial cooling with a superior combination of energy saving, performance, applicationflexibility, ease of service & maintenance and ability to withstand extreme ambient temperatures. These units can becombined with a wide variety of evaporator coils and blower packages to provide quite and dependable comfort. Theseunits can be installed on a roof tops or at ground level.

These CAX series units are designed to use ozone friendly HFC R-134a refrigerant. HFC R-134a is a singular compoundform with proven highly efficient thermodynamic proprieties. The compound has no chlorine and does not contribute toOzone depletion. There will be no phase out and no replacement costs for the life of the equipment.

SALIENT FEATURES OF THE CAX SERIES:* HFC R-134a equipments are value added product and a giant leap toward addressing some of the issues relating to

climate change and environmental protection.

* Compact unit design & excellent serviceability.

* High energy efficiency ratio (EER). Scroll and semi hermetic reciprocating compressors.

* Independent refrigeration circuits.

* Integral sub cooling circuit provided to increase overall unit efficiency.

* Low noise condenser fans, direct drive with rolled form venturi design to eliminate airflow recycling.

* Condenser fan motors are totally enclosed air over type (TEAO) with class 'F' winding insulation.

* Microprocessor based controls.

* High safety standards with UL listed electrical components.

* Quality assurance according to ISO 9001: 2000. Guarantees high and constant product quality.

STANDARD SPECIFICATIONSA. UNIT CASING & CONSTRUCTIONUnit casing shall be fabricated of heavy gauge (G-90) galvanized steel. Steel sheet panels are zinc coated and galva-nized by the hot dip process of lock forming quality conforming to ASTM A 653 commercial weight G-90 followed bybacked on electrostatic polyester dry powder coat.

Condensing unit consists of dual or quadro refrigeration compressors, condenser coil, propeller fans, control wiring andinterconnecting piping completely factory assembled. The whole unit is mounted on pressed steel or 'C' channel base railwith lifting holes. The unit is provided with an integral weather resistant control panel suitable for remote thermostatcontrol, ready for field connection.

B. COMPRESSORSemi-hermetic reciprocating compressors are used as standard for models CAX030 - CAX170 except for models CAX020-CAX025 scroll compressors are used as standard. All the compressors are conforming to ARI 540 standard. The com-pressors are equipped with internal motor protection, factory installed crankcase heaters and rubber vibration isolatorsfor quiet and efficient operation. As an option, semi-hermetic compressor can be fixed on anti-vibration mounting (springtype) along with suction & discharge line vibration eliminators. Oil pressure control is provided on units with semi-her-metic compressor only. Each compressor has lock-out devices to protect it from short cycling when tripped by safetycontrols. Each compressor has separate condenser coil with safety controls. Sight glass and filter drier are standard forall models.

3

C. CONDENSER COILSV & W-configurations condenser coils are of the enhanced louvered fin-and-tube type, constructed of seamless 3/8" dia.inner grooved copper tubes, mechanically bonded to aluminum fins for maximum heat transfer efficiency. As an option,corrugated copper fins or coated aluminum fins or other coated coils may be provided. The fins have full selfspacing collars which completely cover each tube. The staggered tube design improves the thermal efficiency. Endplates support sheets are heavy gauge galvanized steel with extruded collars for better tube support, formed to providestructural strength. Each coil is pressure tested in the factory at not less than 450 psi air pressure.

D. CONDENSER FANSCondenser fans are constructed of die cast aluminum blades/hubs with direct driven motors. All fans are statically anddynamically balanced to operate at minimum noise and vibration. Fan blades are designed with appropriate pitch anglewhich result in maximum airflow through the condenser coil.

E. CONDENSER FAN MOTORCondenser fans, the impeller and motors are so constructed to form an integral unit. All fan motors shall be three phasewith class 'F' winding insulation and ball bearings for high ambient application. These fan motors are of totally enclosedair over type (TEAO) with inherent thermal protection of automatic reset type & specially designed for outdoor applica-tions.

F. SERVICE VALVESBoth suction and liquid service valves are brass, back seating type with sweat connections. Valves are externally locatedso refrigerant piping connections can be made quickly and easily.

G. CONTROL PANELThe control panel design is equivalent to NEMA-4 standard with hinged door for easy access ensuring dust and weath-erproof construction. Internal power and control wiring is neatly routed, properly anchored and all wires are identified withcable markers as per NEC standard applicable to HVAC units. The electrical controls used in the control panel are ULapproved, which are reliable in operation at high ambient conditions for a long period.

H. MICROPROCESSOR CONTROLLERThese condensing units are provided with a microprocessor control board incorporating the following features:

• BALANCE LOADING OF COMPRESSORS: The unit’s electronic control automatically operates lead/lag sequenceof compressors. This is to load the compressors evenly over long periods of operation. If required however, compres-sor 1 can also be set to always lead. In this case, compressor 1 always starts first and stops last. (Selectable throughdip switch setting on control board).

• PUMP DOWN FUNCTION: In units equipped with pump down system, the controller provides the time delay betweensolenoid’s opening and compressor starting to equalize the pressure in the system necessary for compressor to start-up. (Selectable through dip switch setting on control board).

• COMPRESSOR ANTI-RECYCLING PROTECTION: The controller has a built-in 3 minutes minimum off timer forcompressor. This is for compressor protection in case of accidental manual re-set or immediate re-cycling of thermo-stat due to load demand.

• COMPRESSOR LOCK-OUT FUNCTION: If any of the unit’s safety control trips due to abnormal conditions, theelectronic controls locks out the compressor after a pre-determined timing preventing a re-start unless attended by aqualified service technician. The unit can be re-started through thermostat re-set after ensuring safe system condi-tions.

• FAULT DIAGNOSTICS: In case of system fault, LED’s on the board emits a flashing signal indicating where the faultis. This is to guide the service technician in identifying the fault.

• DIGITAL I/O’s: The unit’s control board is compatible to operate with a DDC controller or any standard 24V a.c.thermostat commercially available.

• SEQUENTIAL CONTROL: With input signals from the thermostat, the motors in the equipment is started in sequentialorder: supply fan – condenser fan – compressor; at a pre-determined timings.

4

I. ADJUSTABLE HIGH PRESSURE SWITCH (HPS)Field adjustable high pressure switch provides safety protection in the case of excessive discharge pressure. Typicalfactory pressure settings are shown in table below.

J. ADJUSTABLE LOW PRESSURE SWITCH (LPS)Field adjustable low pressure switch provides safety protection in the case of low suction pressure and loss of refrigerantcharge. Typical factory pressure settings are shown in table below.

OPEN CLOSE

350 ± 10 Psig 300 ± 10 Psig

OPEN CLOSE

10 ± 5 Psig 30 ± 5 Psig

K. COMPRESSOR OVER LOAD PROTECTORThe compressors has built-in thermal protector for its protection against high winding temperatures. Motor starter controlis equipped with an external overload relay as an additional protection against overload.

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

M. CRANKCASE HEATERSEach compressor has crankcase heater. The compressor crankcase heater is always on when the compressor is de-energized. This protects the system against refrigerant migration, oil dilution and potential compressor failure.

N. FILTER DRIERRefrigerant circuits are kept free of harmful moisture, sludge, acids and oil contaminating particles by the filter drier.Cartridge (sealed type) is standard for model CAX020 - CAX040 and for all other models replaceable core filter drier isprovided.

O. SIGHT GLASSMoisture indicating sight glass (supplied loose) to be installed in liquid line in the field. Easy to read color indicator showsmoisture contents and provides a mean for checking the system refrigerant charge.

LINE VOLTAGERANGE UNDER VOLTAGE

TRIP

90%190 - 480 VAC

TRIP & RE-SET VOLTAGE (% OF SET POINT)OVER VOLTAGE PHASE IMBALANCE

RE-SET

93%

TRIP

110%

RE-SET

107%

TRIP

6%

RE-SET

4.5%

5

OPTIONS & ACCESSORIESA. CAPACITY CONTROLOn semi-hermetic compressors, capacity control is achieved by cycling compressors on /off and cylinder unloading. Theuse of unloading provides good part load capacities.

Hot gas bypass is available as an option on the lead circuit to permit operation of the system down to 80 % of its unloadedcapacity. Under low ambient condition, it controls temperature by eliminating the need to cycle the compressor on andoff, ensuring narrow temperature swing and lengthen the life span of the compressor.

B. ADVANCE MICROPROCESSORAdvance microprocessor control can be offered to achieve precise control and safety functions of the condensing units.Microprocessor is simple to use, push button keyboard allows to access the operating conditions, control set points andalarm history clearly displayed on a multi-line backed illuminated LCD panel. Also it’s compatible with building manage-ment system and adoptable to LON protocol.

C. FAN CYCLE SWITCH HEAD PRESSURE CONTROL (FCS)The capacity of air-cooled condensers varies with the difference between condensing temperature and condenser enter-ing air temperate (ambient temperature). It increases as this difference increases. For a given capacity, a drop in theambient temperature will lower the condensing temperatures and if the ambient temperature drops below a given limit,head pressure control is required.

Control shall be set for a minimum of 95°F (35°C) saturated refrigerant condensing temperature, or to suit the specifiedapplication.

D. PUMP DOWN SOLENOID VALVE (PDS)A pump down solenoid valve may be installed in the liquid line. When the room thermostat is satisfied, the valve closesand the compressor continues to run until a substantial portion of the refrigerant has been pumped out from the evapo-rator. The low-pressure switch will cycle off the compressor at a predetermined evaporator pressure.

E. CIRCUIT BREAKERProtect against compressor & condenser fans branch circuit fault. When tripped (Manually or automatically), the breakeropens the power supply to the compressor and control circuit through auxiliary contacts.

F. PRESSURE GAUGESSuction, discharge and oil (semi hermetic compressor only) pressure gauges.

G. DISCHARGE LINE MUFFLERSDischarge line mufflers are installed to eliminate noise due to refrigerant pulsation.

H. SPRING ISOLATORS (for semi-hermetic compressors only)Compressors with spring isolators and vibration eliminators reduces the vibration transmitted from compressor to thepiping and unit structure.

I. CONDENSER COIL GUARDProtect the condenser coil from physical damage.

J. THERMO-GUARD COATED CONDENSERCopper/aluminum fins/ tubes condenser coils for seashore salty corrosive environment. Specify your requirement duringorder entry.

6

DESCRIPTION

STANDARD FEATURES/OPTIONS

OPTION(FACTORY INSTALLED)

Dual scroll compressor (for CAX020 - CAX025 only)Dual semi-hermetic compressor (for CAX030 - CAX080 only)Quadruple semi-hermetic compressor (for CAX090 & above)Capacity control for semi-hermetic compressor on lead compressorCompressor crankcase heatersCompressor circuit breakersCompressor overload protectionSpring isolators with vibration eliminators for semi-hermetic compressorCompressor shut-off valves for scroll compressorCondenser fan motor, totally enclosed air-over typeCondenser fan - direct drive, propeller typeCondenser fan guardUVMFilter drier (sealed type) for units upto CAX040Filter drier (replaceable type) for units CAX045 & aboveSight glass (moisture indication)Low pressure switch (adjustable type)High pressure switch (adjustable type)Fan cycling (low ambient)Pump down solenoid valvePressure relief valveSuction & discharge pressure gauges for scroll compressorSuction, discharge & oil pressure gauges for semi-hermetic compressorPIII controllerMicrosmart controllerCoil guardAluminum fins condenser coilCopper & coated fins condenser coilThermo-guard coating on aluminum/copper coilHot gas bypassLiquid line isolating valvesVolt free contact

STANDARD FEATURES

7

MODEL NUMBER CAX020 CAX025 CAX030 CAX035 CAX040 CAX045 CAX050 CAX060

NOMINAL CAPACITY , TONS* 22 28 30 35 41 46 53 60

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

COMPRESSOR Type Scroll Scroll Semi-hermetic reciprocating

Oil per system (liters) 4.1 4.7 4.7 4.7 4.9 4.9 4.9 4.9

Refrigerant** R-134a

Charge per system (oz)*** 400 500 540 630 740 830 960 1080

CONDENSER FAN Type Propeller

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

Nominal CFM 15000 15000 15000 30000 30000 30000 30000 30000

Motor HP – RPM 1.5 – 1100 1.5 – 1100 1.5 – 1100 1.5 – 1100 1.5 – 1100 1.5 – 1100 1.5 – 1100 1.5 – 1100

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 3/8–2–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–4–14

Total face area (Sq. ft.) 30 30 33.3 60 60 60 60 66.6

HIGH PRESSURE SWITCH Open (PSIG) 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10

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

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

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

REFRIGERANT LINES+ Suction line size (OD), inch 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8 2-1/8 2-1/8 2-5/8

Liquid line size (OD), inch 5/8 7/8 7/8 7/8 7/8 7/8 1-1/8 1-1/8

SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 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 73.3/69.8/64.5

OPERATING WEIGHT, Kg.+++ 754 838 1043 1315 1416 1450 1510 1551

PHYSICAL DATA

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

** Unit is factory supplied with holding charge only.

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

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

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

+++ Values indicated are for standard unit with aluminum fin condenser coils.

8

MODEL NUMBER CAX070 CAX080 CAX090 CAX100 CAX120 CAX150 CAX170

NOMINAL CAPACITY , TONS* 74 86 95 105 123 147 171

NUMBER OF REFRIGERATION CIRCUIT Dual Dual Quadruple Quadruple Quadruple Quadruple Quadruple

COMPRESSOR Type Semi-hermetic reciprocating

Oil per system (liters) 5.2 5.2 4.9 4.9 4.9 5.2 5.2

Refrigerant** R-134a

Charge per system (oz)*** 1330 1550 855 950 1110 1325 1540

CONDENSER FAN Type Propeller

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

Nominal CFM 50124 47644 73266 73266 69174 87032 95288

Motor HP – RPM 2 – 1100 2 – 1100 2 – 1100 2 – 1100 2 – 1100 2 – 1100 2 – 1100

CONDENSER COIL Type Inner grooved tubes and enhanced fins

Tube Dia–Rows–Fins per inch 3/8–3–14 3/8–4–14 3/8–3–14 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14

Total face area (Sq. ft.) 87.5 87.5 120 120 120 140 175

HIGH PRESSURE SWITCH Open (PSIG) 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10 350 ± 10

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

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

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

REFRIGERANT LINES+ Suction line size Dual 2-5/8 2-5/8 N.A. N.A. N.A. N.A. N.A.(OD), inch

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

Liquid line size Dual 1-1/8 1-3/8 N.A. N.A. N.A. N.A. N.A.(OD), inch

Quadruple N.A. N.A. 7/8 1-1/8 1-1/8 1-1/8 1-3/8

SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter)++ 74.7/71.2/66 75.1/71.6/66.3 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

OPERATING WEIGHT, Kg.+++ 1949 2112 2804 2870 2994 3738 4216

PHYSICAL DATA

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

** Unit is factory supplied with holding charge only.

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

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

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

+++ Values indicated are for standard unit with aluminum fin condenser coils.

9

ALTITUDE (FT.) 2000 4000 6000 8000 10000

Condensing Unit Cooling Capacity .99 .98 .96 .95 .94

Condensing Unit & Evaporator .98 .96 .93 .90 .88FACTOR

SELECTION PROCEDURE1. Enter performance tables at specified SST and desired ambient conditions to find gross capacity and power input.

2. HEAT REJECTION:Calculate condenser Total Heat Rejection Capacity as follows:HR = Unit cooling capacity + (3.41 x Total Unit Power Input, Watts).

3. HEAD PRESSURE:To determine head pressure (psig) use the following conversion table:

Condensing Temp. - 0F. 100 110 120 130 140 150 160

(R-134a) Head Pressure - PSIG. 124.1 146.4 171.1 198.7 229.2 262.8 299.9

4. CORRECTION FACTORS FOR ALTITUDE:

10

PER

FOR

MA

NC

E D

ATA

CA

X02

020

610

820

.319

411

822

.318

012

723

.716

313

624

.614

314

425

.0

CA

X02

526

611

126

.625

112

129

.023

012

930

.720

613

831

.817

914

632

.4

CA

X03

028

411

226

.526

512

127

.524

712

928

.322

913

829

.021

114

729

.5

CA

X03

533

010

933

.230

811

834

.228

812

735

.126

613

635

.924

714

536

.6

CA

X04

038

310

635

.135

811

536

.533

212

437

.630

813

338

.628

614

339

.5

CA

X04

543

310

940

.540

611

842

.037

712

743

.335

013

644

.332

414

545

.2

CA

X05

049

610

947

.546

311

849

.143

112

750

.540

113

651

.737

114

552

.6

CA

X06

057

111

256

.653

512

158

.349

913

059

.946

413

961

.443

014

862

.7

CA

X07

070

611

074

.065

511

976

.560

612

878

.655

613

780

.450

614

581

.9

CA

X08

082

411

186

.276

612

089

.170

712

991

.664

813

893

.658

914

695

.2

CA

X09

088

410

784

.282

711

687

.376

912

590

.071

413

492

.366

014

394

.1

CA

X10

098

611

099

.492

211

810

2.5

859

127

105.

279

813

610

7.5

738

145

109.

4

CA

X12

011

5711

111

6.5

1084

119

120.

110

1212

812

3.4

940

137

126.

487

014

612

9.2

CA

X15

014

0911

114

8.2

1309

119

153.

112

1012

815

7.3

1110

137

160.

910

1014

616

3.8

CA

X17

016

4911

117

2.4

1531

120

178.

314

1412

918

3.2

1296

138

187.

211

7814

619

0.3

CA

X02

022

711

020

.321

512

022

.420

412

925

.219

614

028

.919

015

033

.5

CA

X02

529

011

326

.627

612

329

.726

413

333

.825

414

339

.324

715

446

.1

CA

X03

031

611

428

.229

512

329

.227

613

230

.125

714

130

.923

814

931

.6

CA

X03

536

711

235

.034

312

036

.132

212

937

.229

913

838

.227

714

739

.0

CA

X04

042

710

837

.140

011

738

.637

212

639

.934

713

541

.032

214

442

.0

CA

X04

548

211

242

.945

112

144

.642

112

946

.039

213

847

.236

414

748

.2

CA

X05

055

111

150

.351

612

052

.048

112

953

.644

913

855

.041

614

756

.3

CA

X06

063

511

560

.059

512

462

.255

713

264

.151

814

165

.948

115

067

.5

CA

X07

078

111

378

.172

712

281

.067

413

083

.562

013

985

.756

614

887

.6

CA

X08

091

211

491

.184

812

394

.578

513

197

.472

114

099

.765

814

810

1.6

CA

X09

098

510

988

.892

311

892

.386

012

795

.380

013

697

.974

314

510

0.0

CA

X10

010

9711

210

4.9

1027

121

108.

395

913

011

1.5

893

139

114.

382

814

811

6.8

CA

X12

012

8411

312

3.3

1205

122

127.

711

2713

113

1.7

1050

140

135.

397

414

913

8.7

CA

X15

015

6011

315

6.3

1453

122

162.

113

4513

016

7.2

1237

139

171.

511

3014

817

5.2

CA

X17

018

2411

418

2.2

1697

123

189.

015

7013

119

4.7

1442

140

199.

513

1514

820

3.2

CA

X02

025

111

220

.823

612

222

.922

413

125

.421

114

128

.319

915

131

.7

CA

X02

532

011

527

.630

412

530

.528

813

434

.127

214

438

.225

715

443

.1

CA

X03

034

911

730

.032

812

631

.230

613

532

.228

614

333

.026

515

233

.8

CA

X03

540

711

436

.938

212

338

.235

613

239

.433

214

140

.631

014

941

.6C

AX

040

474

111

39.2

444

120

40.9

415

129

42.3

386

138

43.6

359

146

44.6

CA

X04

553

411

445

.550

212

347

.346

913

248

.943

714

150

.340

715

051

.5

CA

X05

061

011

453

.157

212

355

.153

513

256

.949

914

058

.646

414

960

.3

CA

X06

070

111

863

.965

912

666

.461

713

568

.757

614

470

.953

615

372

.8

CA

X07

086

311

582

.380

412

485

.674

613

388

.668

814

191

.262

915

093

.5

CA

X08

010

0411

696

.093

612

599

.986

813

410

3.2

798

142

106.

073

015

110

8.2

CA

X09

010

9311

193

.810

2512

097

.695

912

910

1.0

894

138

103.

983

214

710

6.5

CA

X10

012

1411

511

0.6

1139

123

114.

510

6613

211

8.1

994

141

121.

692

415

012

4.8

CA

X12

014

2111

613

0.7

1334

125

135.

812

4913

314

0.6

1168

142

145.

010

8715

114

9.1

CA

X15

017

2211

616

4.8

1606

124

171.

514

8913

317

7.4

1373

142

182.

512

5615

018

7.0

CA

X17

020

0911

619

2.1

1872

125

199.

817

3413

420

6.4

1597

142

211.

914

5915

121

6.4

35 0 F

SST

(0 F)M

OD

EL A

MB

IEN

T TE

MPE

RAT

UR

E

TC (M

BH

)

30 0 F

CT

(0 F)PI

(kW

)

40 0 F

850 F

TC (M

BH

)C

T (0 F)

PI (k

W)

950 F

TC (M

BH

)C

T (0 F)

PI (k

W)

1050 F

TC (M

BH

)C

T (0 F)

PI (k

W)

1150 F

TC (M

BH

)12

50 F

LEG

END

:S

ST

- S

atur

ated

Suc

tion

Tem

pera

ture

TC

- T

otal

Cap

acity

(10

00 B

TU

H)

Gro

ss

CT

- C

onde

nsin

g T

empe

ratu

reP

I - T

otal

uni

t pow

er in

put

CT

(0 F)PI

(kW

)

11

PER

FOR

MA

NC

E D

ATA

CA

X02

027

611

521

.626

012

423

.424

213

325

.022

314

226

.420

315

027

.7

CA

X02

535

311

828

.833

212

731

.031

013

633

.128

414

435

.025

715

336

.8

CA

X03

038

412

032

.036

112

933

.233

813

734

.331

714

635

.329

515

536

.2

CA

X03

544

811

739

.042

112

640

.539

513

441

.836

814

343

.234

315

244

.4

CA

X04

052

311

341

.649

112

243

.346

013

144

.942

814

046

.339

814

947

.4

CA

X04

558

911

748

.455

412

650

.452

013

552

.148

514

353

.745

115

255

.1

CA

X05

067

311

756

.263

212

658

.459

313

460

.555

314

362

.551

615

264

.5

CA

X06

077

212

168

.172

512

971

.068

013

873

.763

714

776

.359

415

578

.6

CA

X07

094

811

886

.688

612

790

.482

213

593

.876

014

496

.869

615

299

.3

CA

X08

011

0211

910

1.0

1027

128

105.

395

413

610

9.0

880

145

112.

280

515

311

4.9

CA

X09

012

0711

499

.311

3412

310

3.4

1063

132

107.

299

214

011

0.5

925

149

113.

4

CA

X10

013

3911

811

6.8

1259

126

121.

111

8013

512

5.4

1103

144

129.

410

2715

213

3.4

CA

X12

015

6511

913

8.9

1471

128

144.

813

8013

615

0.4

1291

145

155.

612

0615

416

0.5

CA

X15

018

9111

817

3.5

1766

127

181.

116

4013

618

7.8

1516

144

193.

713

9015

219

8.7

CA

X17

022

0311

920

1.9

2056

128

210.

619

0813

621

8.1

1759

145

224.

516

1215

322

9.7

CA

X02

030

211

722

.128

712

724

.327

113

626

.725

614

529

.224

015

432

.0

CA

X02

538

812

129

.736

713

032

.734

713

936

.032

414

939

.630

115

843

.7

CA

X03

042

212

434

.239

713

235

.537

214

036

.734

914

937

.832

515

738

.7C

AX

035

492

120

41.2

463

128

42.9

436

137

44.5

407

146

46.0

380

154

47.4

CA

X04

057

611

644

.154

112

546

.050

813

347

.747

414

249

.144

015

150

.4

CA

X04

564

812

051

.561

012

953

.757

213

755

.653

514

657

.449

915

559

.0

CA

X05

073

912

059

.569

612

862

.065

313

764

.461

214

666

.757

115

468

.8

CA

X06

084

512

472

.879

613

376

.174

814

179

.270

115

082

.265

415

884

.9

CA

X07

010

3712

191

.197

013

095

.390

213

899

.083

514

610

2.2

767

155

104.

9

CA

X08

012

0412

210

5.9

1124

131

110.

610

4513

911

4.9

965

147

118.

688

615

512

1.7

CA

X09

013

3011

710

5.3

1250

125

109.

811

7413

411

3.9

1098

143

117.

710

2415

212

1.0

CA

X10

014

7112

012

3.6

1385

129

128.

613

0013

813

3.3

1217

146

137.

711

3615

514

1.9

CA

X12

017

1612

214

8.0

1616

131

154.

715

1813

916

1.1

1422

148

167.

113

3015

717

2.8

CA

X15

020

7012

118

2.5

1936

130

190.

818

0113

819

8.2

1666

147

204.

515

3015

520

9.8

CA

X17

024

0712

221

1.7

2249

131

221.

320

8913

922

9.7

1930

147

237.

117

7115

524

3.4

50 0 F

SST

(0 F)M

OD

EL A

MB

IEN

T TE

MPE

RAT

UR

E

TC (M

BH

)

45 0 F

CT

(0 F)PI

(kW

)85

0 FTC

(MB

H)

CT

(0 F)PI

(kW

)95

0 FTC

(MB

H)

CT

(0 F)PI

(kW

)10

50 FTC

(MB

H)

CT

(0 F)PI

(kW

)11

50 FTC

(MB

H)

1250 F

CT

(0 F)PI

(kW

)

LEG

END

:S

ST

- S

atur

ated

Suc

tion

Tem

pera

ture

TC

- T

otal

Cap

acity

(10

00 B

TU

H)

Gro

ss

CT

- C

onde

nsin

g T

empe

ratu

re

PI -

Tot

al u

nit p

ower

inpu

t

12

CA

X020

CA

X025

CA

X030

CA

X035

CA

X040

CA

X045

CA

X050

CA

X060

CA

X070

CA

X080

CA

X090

CA

X100

CA

X120

CA

X150

CA

X170

CR

AN

KC

ASE

HEA

TER

Tota

lW

atts

Volts

Tota

lA

mps

CB

(Qty

.)O

UTP

UT

POW

ERLR

A(e

ach)

FLA

(eac

h)Q

ty.

CB

Pole

sLR

A(e

ach)

RLA

(eac

h)20

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

6046

0-3-

6020

8/23

0-3-

6038

0-3-

60

460-

3-60

208/

230-

3-60

380-

3-60

460-

3-60

MO

DEL

NU

MB

ER

SUPP

LY V

OLT

AG

EC

OM

PRES

SOR

CO

ND

ENSE

R F

AN

MO

TOR

S

ELEC

TRIC

AL

DAT

A

MO

CP

MC

AM

ax.

Min

.N

omin

al(V

-Ph-

Hz)

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

342

414

187

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414

187

342

414

187

342

414

187

342

414

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

253

418

506

Qty

.

91.4

125

235

.842

53

25.

430

1.50

148

070

0.15

54.7

702

21.7

239

32

2.9

181.

501

480

700.

1545

.760

217

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73

22.

713

.11.

501

480

700.

1512

2.4

150

249

.650

53

25.

430

1.50

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012

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2567

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227

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03

22.

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012

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2556

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53

22.

713

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501

480

120

0.25

117.

015

02

47.2

442

32

5.4

301.

501

220-

240

140

0.61

70.2

100

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63

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014

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6158

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22.

713

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501

220-

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0.61

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620

02

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5.4

301.

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220-

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0.61

88.0

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233

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03

42.

918

1.50

222

0-24

014

00.

6173

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02

28.0

220

34

2.7

13.1

1.50

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014

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6115

6.6

200

260

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03

45.

430

1.50

222

0-24

014

00.

6193

.412

52

36.3

333

34

2.9

181.

502

220-

240

140

0.61

78.3

100

230

.026

23

42.

713

.11.

502

220-

240

140

0.61

184.

725

02

72.5

600

34

5.4

301.

502

220-

240

140

0.61

110.

515

02

43.9

333

34

2.9

181.

502

220-

240

140

0.61

92.3

125

236

.226

23

42.

713

.11.

502

220-

240

140

0.61

218.

930

02

87.7

739

34

5.4

301.

502

220-

240

140

0.61

131.

215

02

53.1

411

34

2.9

181.

502

220-

240

140

0.61

109.

615

02

43.9

323

34

2.7

13.1

1.50

222

0-24

014

00.

6128

5.8

400

211

7.4

808

34

5.4

301.

502

220-

240

140

0.61

171.

720

02

71.1

462

34

2.9

181.

502

220-

240

140

0.61

142.

920

02

58.7

404

34

2.7

13.1

1.50

222

0-24

014

00.

6134

9.9

450

214

5.0

1230

34

5.9

172.

002

220-

240

140

0.61

211.

225

02

87.8

620

34

3.4

102.

002

220-

240

140

0.61

176.

722

52

72.5

513

34

3.4

102.

002

220-

240

140

0.61

398.

055

02

166.

412

883

45.

917

2.00

222

0-24

014

00.

6124

0.2

300

210

0.7

665

34

3.4

102.

002

220-

240

140

0.61

200.

825

02

83.2

590

34

3.4

102.

002

220-

240

140

0.61

343.

540

04

72.5

600

36

5.9

172.

003

220-

240

140

0.61

207.

025

04

43.9

333

36

3.4

102.

003

220-

240

140

0.61

174.

320

04

36.2

262

36

3.4

102.

003

220-

240

140

0.61

408.

145

04

87.7

739

36

5.9

172.

003

220-

240

140

0.61

246.

130

04

53.1

411

36

3.4

102.

003

220-

240

140

0.61

207.

025

04

43.9

323

36

3.4

102.

003

220-

240

140

0.61

546.

265

04

117.

480

83

85.

917

2.00

422

0-24

014

00.

6132

9.4

400

471

.146

23

83.

410

2.00

422

0-24

014

00.

6127

6.7

300

458

.740

43

83.

410

2.00

422

0-24

014

00.

61

663.

580

04

145.

012

303

85.

917

2.00

422

0-24

014

00.

61

400.

445

04

87.8

620

38

3.4

102.

004

220-

240

140

0.61

335.

340

04

72.5

513

38

3.4

102.

004

220-

240

140

0.61

754.

490

04

166.

412

883

85.

917

2.00

422

0-24

014

00.

61

455.

245

04

100.

766

53

83.

410

2.00

422

0-24

014

00.

6138

0.8

450

483

.259

03

83.

410

2.00

422

0-24

014

00.

61

LEG

END

:M

CA

- M

inim

um C

ircui

t Am

paci

ty

MO

CP

- M

axim

um O

ver

Cur

rent

Pro

tect

ion

R

LA -

Rat

ed L

oad

Am

ps

LR

A -

Loc

ked

Rot

or A

mps

F

LA -

Ful

l Loa

d A

mps

C

B -

Circ

uit B

reak

er

13

DIMENSIONS

NOTE: All dimensions are in mm.

CAX 020 & CAX 025

CAX 030

14

DIMENSIONS


CAX 035, CAX 040, CAX 045, CAX 050 & CAX 060

CAX 070 & CAX 080

15

DIMENSIONS


CAX 090, CAX 100 & CAX 120

CAX 150 & CAX 170MODEL LCAX150 4343

CAX170 5309

DIMENSIONS

16

UL4

UL2

UL1

UVM-1

CC2A-1A

OPS2-1

CC1A-1A

OPS1-1

OLR1

CC1

OLR2

CC2

CC1A-1B

CC2A-1B

CB1 CB2

T1A

T2A

T3A

T1B

T3B

T2B A. SEMI-HERMETIC RECIP. COMP. (BITZER)

COMP1

UVM CONNECTION (OPTIONAL)

COMPRESSOR UNLOADER CONNECTION (OPTIONAL)

COMP 1TO ATB28A

TO ATB

TO ATB

1A

1

L1

1L1

25B

(REMOVE JP1)

NO

NCP

LPS328A C

NOCLPS5

6A

5A 2

UVM

L3L2

L28

L3

(REMOVE JP6)

26B

OIL PRESSURE SWITCH CONN.(AS APPLICABLE)

COMP. 2:

25A

COMP 2

COMP 1 1

COMP2

B. SCROLL COMP.

COMP. 1:

L2

L1

COMP. 2:

COMP. 1:

1

1

(REMOVE JP5)

28B2

OPS2

28A OPS12

26A

2240

2240

C.HTR1

C.HTR2

C.HTR2

C.HTR1

100A

101A

L3

L2

2

2

L1B

COMP. WITH CB CONNECTION (OPTIONAL)

L1A

L2A

L3A

L1TO HVTB

L2 L3 M1/11

COMP. SSPS CONNECTION(AS APPLICABLE)

M1/11

L1/MP/L

CRANKCASE HTR CONNECTION(AS APPLICABLE)

L1/MP/L1

L3B

L2B 1

(SEE NOTE 3)

COMP. 2:24B

TO HVTBL2L1 L3

COMP. 1:24A

L2/R/N 2

(REMOVE JP4)

L2/R/N

(REMOVE JP3)SSPS2

M2/14

2

25B

SSPS1M2/14 25A

17A31B

COMP1 SHOULD ALWAYS BE LEAD COMPRESSOR.

AR9-1

DIP SWITCH S2 SHOULD ALWAYS BE SET TO "ON" POSITION.

NOTE:

6E5A

C

LPS5NO

PNC

6DAR8-1 2HGS6C

HGS CONNECTION W/O COMP UNLOADER (OPTIONAL)

HGS CONNECTION WITH COMP UNLOADER (OPTIONAL)

AR9-1

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

6D6E

31AY1 [LVTB]

Y2 [LVTB]

AR8

AR9

NCP

NOTE:

31B

NOLPS51C

Y2 [LVTB]

AR8-1

AR9

31AY1 [LVTB] AR8

6C

17A C [LVTB]

HGS 2

17A

C [LVTB]17A

NCP

28B

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

NOTE

COMP 2TO ATB28B

6BNC

P

NO

NCP

LPS4C

NOLPS6C

5B 2

UL3

TYPICAL SCHEMATIC WIRING DIAGRAM(Dual compressor units)

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.

17

(SEE NOTE -9)

REFER TO UNITNAMEPLATE FORPOWER SUPPLY

BMC

OLR-1

CB11 CB12

CB

HTR1

HC1

HTR2

HC2 OLR

73B

72B

71B

73A

71A

72A

70

FROM T'STAT CONTROLLER OR DDCSWITCHING CONTACTS

CONTROLSTO ATB(in cond. unit)

INFAN(in cond. unit)

HTR1

HTR2

230Vac

30

29

TO ECB

14

HC228

AFS

BMC 19

(Stg. 1 Heating)

(REMOVE JUMPER JP)

TB1 (ECB)

Y1

W2W1Y2

RCG

T2F

T1F

( NOTE 8)

Y1

W2W1Y2

24VacRCG

LVTB

STG1 COOLING

STG2 HEATERSTG1 HEATER

STG2 COOLING

W2W1

Y2

BM CONTROLY1GC

(by others)

R

T1H

T2H

T3H

T3F

(Stg. 2 Heating)

68 69

TO POWER SUPPLY

L3C

(POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR)

TO POWER SUPPLYL2L1

OPTIONAL AHU INTER-CONNECTION

TO POWER SUPPLYL3 L1 L2 L3

L1C

L2C

L1 L2 L3

LEGEND

AHU AIR HANDLING UNIT

AFS AIR FLOW SWITCH

AR AUXILIARY RELAY

ATB AUXILIARY TERMINAL BLOCK

BM BLOWER MOTOR

BMC BLOWER MOTOR CONTACTOR

CC COMPRESSOR CONTACTOR

CCA CC AUXILIARY CONTACT

CB CIRCUIT BREAKER

C. HTR CRANKCASE HEATER

COMP COMPRESSOR

ECB ELECTRONIC CONTROL BOARD

F FUSE

FCS FAN CYCLING SWITCH

FM FAN MOTOR (CONDENSER)

FMC FAN MOTOR CONTACTOR

FMCA FMC AUXILIARY CONTACT

FR FAULT RELAY

HC HEATER CONTACTOR

HPS HIGH PRESSURE SWITCH

HVTB HIGH VOLTAGE TERMINAL BLOCK

JP JUMPER

L1 LINE 1

L2 LINE 2

L3 LINE 3

LPS LOW PRESSURE SWITCH

LUG LUG GROUND

NTB NEUTRAL TERMINAL BLOCK

OLR OVER LOAD RELAY

OPS OIL PRESSURE SWITCH

P PRESSURE

PDS PUMP DOWN SOLENOID

S DIP SWITCH (IN ECB)

SSPS SOLID STATE PROTECTION SYSTEM

TOP FM THERMAL OVERLOAD PROTECTION

TRANS TRANSFORER

UL COMP. UNLOADER SOLENOID

UVM UNDER VOLTAGE MONITOR

FIELD WIRING

TERMINAL BLOCK OR TERMINATION POINT

SPLICE-CLOSED END

TYPICAL SCHEMATIC WIRING DIAGRAM(Dual compressor units)

NOTES1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. ANY WIRE REPLACEMENT SHOULD BE OF 900COR ITS EQUIVALENT. USE COPPER CONDUCTORWIRES ONLY.

3. POWER MUST BE SUPPLIED TO CRANKCASEHEATER FOR MINIMUM OF 12 HOURS PRIOR TOSYSTEM START UP.IF POWER IS OFF 6 HOURS OR MORE, CRANK-CASE HEATER MUST BE ON FOR 12 HOURS BE-FORE OPERATING THE SYSTEM.FAILURE TO FOLLOW THESE INSTRUCTIONSMAY RESULT IN COMPRESSOR DAMAGE.

4. FUSED DISCONNECT SWITCH OR CIRCUITBREAKER TO BE PROVIDED BY CONSUMERWITH RATING AS RECOMMENDED BY ZAMIL.

5. COMPRESSORS ARE PROVIDED WITH SSPS OR INTER-NAL LINE BREAK THERMAL OVERLOAD PROTECTION.

6. IF PDS IS FACTORY INSTALLED, PLEASE READBROKEN LINES AS CONTINUOUS LINES.

7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.)FOR LVTB FIELD WIRING. GROUND CONNECTAT BOTH ENDS.

8. COOLING OUTPUT SIGNAL FROM CONTROLLERSHOULD FOLLOW THE SEQUENCE:ON SEQUENCE - Y1 FIRST, THEN Y2.OFF SEQUENCE - Y2 FIRST, THEN Y1.

9. NEUTRAL LINE REQUIRED ON 380V-3Ph-60HzPOWER SUPPLY ONLY.

_ _ _

18

OUTF

AN1

PRI

OUTF

AN2

NEUT

RAL

LIVE

SEC

LED

COMP

1

COMP

2

INFA

N

HEAT

ER1

HEAT

ER2

ON/OFF

(ON/OFF)

(LP2)

J_PROG

P3_##

ON DIP

SYSTEM2

LOCK2

SYSTEM1

LOCK1

(HP2)

(LP1)

LP2

LP1

(HP1)

HP2

HP1

W2W1

G

Y2Y1

CRX2 X1 P2 P1

FUSE

OLR1-1 HPS1

P

21A 25A24A JP3 26AJP527A

DIP SWITCH

26B27B

(SEE NOTE-4)SWITCH OR CBDISCONNECT TO FUSED L1

L2L3

LUG

HVTB

T2B

T3B

T1B

T3A

T2A

T1A

COMP1

COMP2

21BOLR2-1

25BJP424B JP6HPS2

P

LPS1

23A22A

P

22B23B P

LPS2

TRANS2230v

12v-0-12v

RC

Y1Y2

LVTBR

Y1Y2

STG1 COOLINGSTG2 COOLING

24Vac

FROM T'STAT CONTROLLER OR DDC(by others)

CC1

CC2

JP1ATB 1 JP21A 1B

ATB

TO ATB

41B

41A

4B 4A 3A3B

UVM CONNECTION

TO ATB

TO ATB 1A

1

L2L1

L1 L21

(REMOVE JP1)

L3

L38

UVMUVM-1

ECB1LED FAULT INDICATOR

POWER INDICATOR

TO FR2 FR1

TO

SEE VFC CONNECTION

SQMBO4 ( P III )

( NOTE 8)

SWITCHING CONTACTS

JP

( NOTE 9)

CNEUT

RAL

SEC

PRI

230v

12v-0-12v

TRANS3

J_PROGPOWER INDICATOR

LEDDIP SWITCH

DIPON

SYSTEM2

FUSE

LIVE

SYSTEM1

P3_##

LED FAULT INDICATOR

LOCK1LOCK2

25D

25C27C

LP1

LP2(LP2)

(LP1)

HP2(HP2)

(HP1)

22C

22D23D

23C

OLR4-1

27D21D 24D JP8

SQMBO4 ( P III )

HP1

(ON/OFF)

ON/OFF

ECB2Y2W1W2

Y1G

OLR3-121C 24C JP7

JP

P

LPS4

P

P

LPS3

HPS4JP10 26D

P

HPS326CJP9

1

SEE VFC CONNECTION

OUTF

AN2

OUTF

AN1

HEAT

ER2

X2 X1

41D

41C

HEAT

ER1

INFA

N

FR3FR4TO (sheet 1 of 2)

TO

P1P2

COMP

2

4D 3D4C

COMP

1

R

3C

CC4

CC3

TO ATB(sheet 1 of 2)

TB1

STG3 COOLINGSTG4 COOLING Y4

Y3Y3Y4

1517

31A31B

YR3

YR431C

31D

YR3-1

YR4-1

15B

31C

31D

L2C.HTR1L1

(REMOVE JP3)

(REMOVE JP4)

COMP. SSPS CONNECTION

(REMOVE JP8)

(REMOVE JP7)

COMP. 2:

1

COMP. 4:24D M1/11

L1/MP/L

SSPS4

1

COMP. 3:24C M1/11

L1/MP/L

SSPS3

1

24B

L1/MP/L

M1/11SSPS2

COMP. 1:

1

24A

L1/MP/L

M1/11SSPS1

COMP. 3:

COMP. 4:L2

L1

C.HTR4

C.HTR3

COMP. 2:L2 C.HTR2

25DM2/14

L2/R/N 2

25CM2/14

L2/R/N 2

25B

L2/R/N

M2/14

2

25A

L2/R/N

M2/14

2

(NOTE 5)

L3

L2

L3

SCROLL COMP CRANKCASE HTR CONNECTION COMP. 1:

COMP3 4

COMP

T3C

T2C

T1C

T2D

T3D

T1D

NEUTRAL NTB

TO HVTBL1 N

TO NTB

PLEASE REFER TO

POWER CONNECTIONS.CONDENSER FAN MOTORSHEET 3 OF 3 FOR

SEE FM CONNECTION(sheet 1 of 2)

SEE FM CONNECTION(sheet 1 of 3)

1COMP

T1A

T3A

T2A

2COMP

T2B

T1B

T3B

COMP3

T3C

T2C

T1C

4COMP

T2D

T3D

T1D

L1A

L3A

L2A

CB1

L1B

L2B

L3B

CB2

TO HVTBL1L1L1

TO HVTBL1L1 L1

L3C

L1C

L2C

CB3

L3D

L2D

L1D

CB4

TO HVTBL1L1 L1

TO HVTBL1L1L1

COMP WITH CB OPTIONS

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

C.HTR2

C.HTR1

COMP. 2:1

COMP. 1:1

100B

100A

2

2

COMP. 3: 100CC.HTR31 2

COMP. 4: 100DC.HTR41 2

G

2

(sheet 1 of 2)

PDS4

PDS3

OLR4

CC4

PDS1

PDS2

CC1

OLR1 OLR2

CC2

OLR3

CC3

CC4A-1B

CC3A1B

OLR2

CC2

OLR1

CC1

CC1A-1B

CC2A-1B

OLR4

CC4

OLR3

CC3

(SEE NOTE -10)

REFER TO UNITNAMEPLATE FORPOWER SUPPLY

TYPICAL SCHEMATIC WIRING DIAGRAM(Quadruple compressor units)


19



20

61 6360

COMP2 ON

COMP2 TRIP

INDIVIDUAL COMP. ON/OFF/TRIP

COMP 2

TO ECB1X2

55

COMP 1

X1TO ECB1

COMP1 ON

COMP1 TRIP

41BFR2 2

56

41AFR1

58

2

UNIT ON

43

1

45

AR1

UNIT TRIP

44A

UNIT TRIP

46

44

2

UNIT ON / OFFUNIT STATUS (VFC) INDICATION CONNECTION

ON= WITH PUMP DOWN OPTIONOFF= WITHOUT PUMP DOWNS3

blinking fast - HPS2 ckt fault blinking slow - LPS2 ckt fault

system 2 fault diagnostic blinking fast - HPS1 ckt fault blinking slow - LPS1 ckt fault

system 1 fault diagnosticsystem lock-out due to system faultpower on/off indicator

LED INDICATORS

(pump down or no pump down)Set dip switch #3 according to unit's option

on-board programming function (always set to on)FACTORY SETTINGS OF DIP SWITCHES

ONOFF

note:

DIP SWITCH #

S4

Yellow

Orange

S4S2S1 S3GreenRed

ECB DIP SWITCH SETTINGS & LED INDICATORS

ON= COMPRESSOR 1 LEAD

ON= TEST MODE ENABLE

(Comp1&2 Auto Lead Lag)

OFF=TEST MODE DISABLES1

S2 OFF= LOAD BALANCE

AR9-16D6E AR8-1C

NCP

1 NOLPS5

Y2 [LVTB] 31BAR9

HGS CONNECTION W/O COMP UNLOADER

Y1 [LVTB] 31A AR8

HGS 26C

17A

C [LVTB]17A

X2

70

COMP4 ON

COMP4 TRIP

71

TO ECB2

COMP3 TRIP

41DFR4

COMP3 ON

65 66

COMP 3

TO ECB2X1

41CFR3

73

2

68

2

COMP 4

44C44B

25B

(REMOVE JP6)

26B


COMP 2

25A

COMP 1 1 OPS1

OPS2(REMOVE JP5)

28B2

28A2

2402

26A

2402

(REMOVE JP9)


(REMOVE JP10)

28D

25C

COMP 3

COMP 4

25C

1 28C

22 240

26D

OPS4

26D

2OPS3 2

240

73B

72B

71B

73A

71A

72A

CONTROLSTO ATB230Vac

HTR1

HTR2

INFAN(in cond. unit)

(in cond. unit)

TO ECB

30

29

14

HC2 28AFS

BMC 19

BM CONTROLSTG1 COOLING

STG1 HEATERSTG2 HEATER

STG2 COOLING

( NOTE 8)(REMOVE JUMPER JP)

Y1

W2W1

Y2

RCG

TB1 (ECB)

Y1

W2W1

Y2

24VacRCG

LVTB

T3F

T2F

T1F

(Stg. 1 Heating)

T1H

T2H

T3H

(Stg. 2 Heating)

FROM T'STAT CONTROLLER OR DDC(by others)

W2W1

Y2Y1GCR

68

SWITCHING CONTACTS

69 70OPTIONAL AHU INTER-CONNECTION

(POWER AND CONTROL FOR ELECTRIC HEATER &BLOWER MOTOR)TO POWER SUPPLY

L1 L3L2TO POWER SUPPLY

L2L1 L3TO POWER SUPPLY

L1C

L2C

L3C

L2L1 L3

YR3

Y4

Y3STG3 COOLING

STG4 COOLINGYR3

Y3

Y4

LPS5C

COMPRESSOR UNLOADER CONNECTION (OPTIONAL)

CLPS6

COMP 2TO ATB28B 28B

COMP 1TO ATB28A 28A

PNC

6BNC

P

NC

NOCLPS10

P

5BNO

2

PNOLPS9

C 6A

5ANO

NC

2

AR9-1

HGS CONNECTION WITH COMP UNLOADER

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

NCP

NOTE:

6ENO

LPS5C AR8-1 6D 6C HGS 25A

LPS11 NOC

LPS12C

NC

NO

UL3 & UL 4 CONNECTION APPLICALBLE FOR COMP WITH 3 STEPS

P

CAPACITY UNLOADING.

NOTE

TO ATBCOMP 4 28D C28B

LPS8

P

NO

NC6B

P

6CNC

5B 2

NO

NC

TO ATB28CCOMP 3

LPS7

P

28C C5C 2UL3

UL7

UL8

UL4

UL1

UL2

UL6

UL5

FR1-1 FR3-1FR2-1 FR4-1

CC2A

-2A

CC4A

-2A

AR1-1A

FR3-2AFR1-2A

FR2-2A

CC1A

-2A

FR4-2A

CC3A

-2A

OPS1-1

CC2A-1A

OPS2-1

CC1A-1A

OPS3-1

OPS4-1

CC4A-1A

CC3A-1A

OLR-1

HTR2HTR1

CB12

HC2HC1

CB11

BMC

OLR

CB

105

37B

11BFCS21

P

1OB

REFER OPTIONAL FCS CONNECTION BELOW.

10A FCS1

P

**

T.O.PFM311A

12C 13CFMC3

FM5

12E

12C**1

TO ECB1OUTFAN 2

FM3FMC3T.O.P

13C 2

FMC513E

T.O.P2

12ATO ECB1OUTFAN 1

FM1FMC1

13AT.O.P

2

36C

37C

35C

FM1

37A

36A

35A

FM3 FM2

36B

35B

FMC1

102

101

100

FMC3

103

104

CB6

L1 L2 L3 L2L1

REFER OPTIONAL FCS CONNECTION BELOW.

FCS41 11D10D

P

2

10C

**

FCS3

P

11BT.O.PFM3

12D 13DFMC4

2

FMC1

35C

FMC4

FM6

1

TO ECB2OUTFAN 2

FM4T.O.P

12D 13D

13FT.O.P

12FFMC6

2

TO ECB2OUTFAN 1

FM2

13BT.O.P

12B 2FMC2

2

12A

TO ECB1OUTFAN 1

FM1T.O.P

13A

35F35

D36

D

37D

FM4 FM5

37E

36E

35EFMC4

FMC2

107

106

108

FMC5

FM6

37F

36F

FM1

35A

36A

37A

FMC6

FMC1

101

100

102

2

37C

36C

FM3

6-FAN MOTOR LAYOUTCAX090-100

CONT

ROL

PANE

L

CB7 CB8

L3 L1 L2 L3

CB6

L2L1 L3

CONT

ROL

PANE

L

CAX090-1006-FAN MOTOR LAYOUT

FMC5

103

35B

35C

37C

36C

FM1

36A

37A

35A

FM3

FMC1

101

102

100

FMC3

37D

35D

36D

FM4FM2

37B

36B

FM5

36E

37E

35E

FMC2

105

104

108

107

106

FMC4

FM8

35F

FM7

35G

36G

37G

FM6

36F

37F

35H

36H

109

FMC7

110

111

FMC6

37H

CB6

L2L1 L3

CB7

L2 L3L1 L2L1 L3

CONT

ROL

PANE

L

CB8 CB9

L2 L3L1

CAX090-1006-FAN MOTOR LAYOUT

TO ECB1OUTFAN 2

TO ECB1OUTFAN 1

FMC6T.O.P12FFMC5T.O.P12E

T.O.P10CFCS3

P

12G11C

FM7FMC7

13G 2

13E 2

FM8T.O.P10D

FCS412H11D

P

FMC813H 2

13F 2

OUTFAN 2TO ECB2

TO ECB2OUTFAN 1

13A12A

T.O.P10A 11A 12C

PFM5

FCS1FM3

FMC313C 2

2T.O.PFM1

FMC113B12B

FM4T.O.P

FM6

10B 12D11B

P

FCS213D

FMC42

2

FM2T.O.P FMC2

L3L1 L2

CB7

L3L1 L2

CB8

L3L1 L2

CB9

FM2 FM4

36D

35D

37D

37B

36B

35B

FMC2

105

104

103

37E

35E

36E

FM5 FM7

35G

37G

36G

37F

36F

35F

FM6 FM8

35H

37H

36H

111

110

109

106

107

108

FMC3 FMC4

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : STANDARD

CONDENSER FAN MOTOR POWER, CONTROL CONNECTIONS : WITH STANDARD AND FAN CYCLING OPTION

FM3T.O.P

12C12C

FM2TO ECB1T.O.P

12B

FM4T.O.P

12D13B 12DFMC2

2

OUTFAN 2

FM5TO ECB2OUTFAN 1 T.O.P

12E

FM7T.O.P

12G13E 12HFMC3

FM6OUTFAN 2TO ECB2

2 12FT.O.P

FM8T.O.P

12H13F 12HFMC4

2

CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : WITH FAN CYCLING OPTION

FMC2A-1

FMC1A-1

FMC6A-1

FMC2A-1

FMC1A-1

FMC2A-1

FMC2A-1

FMC6A-1

LEGEND

AHU AIR HANDLING UNIT

AFS AIR FLOW SWITCH

AR AUXILIARY RELAY

ATB AUXILIARY TERMINAL BLOCK

BM BLOWER MOTOR

BMC BLOWER MOTOR CONTACTOR

CC COMPRESSOR CONTACTOR

CCA CC AUXILIARY CONTACT

CB CIRCUIT BREAKER

C. HTR CRANKCASE HEATER

COMP COMPRESSOR

ECB ELECTRONIC CONTROL BOARD

F FUSE

FCS FAN CYCLING SWITCH

FM FAN MOTOR (CONDENSER)

FMC FAN MOTOR CONTACTOR

FMCA FMC AUXILIARY CONTACT

FR FAULT RELAY

HC HEATER CONTACTOR

HPS HIGH PRESSURE SWITCH

HVTB HIGH VOLTAGE TERMINAL BLOCK

JP JUMPER

L1 LINE 1

L2 LINE 2

L3 LINE 3

LPS LOW PRESSURE SWITCH

LUG LUG GROUND

NTB NEUTRAL TERMINAL BLOCK

OLR OVER LOAD RELAY

OPS OIL PRESSURE SWITCH

P PRESSURE

PDS PUMP DOWN SOLENOID

S DIP SWITCH (IN ECB)

SSPS SOLID STATE PROTECTION SYSTEM

TOP FM THERMAL OVERLOAD PROTECTION

TRANS TRANSFORER

UL COMP. UNLOADER SOLENOID

UVM UNDER VOLTAGE MONITOR

FIELD WIRING

TERMINAL BLOCK OR TERMINATION POINT

SPLICE-CLOSED END


NOTES1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.

2. ANY WIRE REPLACEMENT SHOULD BE OF 900COR ITS EQUIVALENT. USE COPPER CONDUCTORWIRES ONLY.

3. POWER MUST BE SUPPLIED TO CRANKCASEHEATER FOR MINIMUM OF 12 HOURS PRIOR TOSYSTEM START UP.IF POWER IS OFF 6 HOURS OR MORE, CRANK-CASE HEATER MUST BE ON FOR 12 HOURS BE-FORE OPERATING THE SYSTEM.FAILURE TO FOLLOW THESE INSTRUCTIONSMAY RESULT IN COMPRESSOR DAMAGE.

4. FUSED DISCONNECT SWITCH OR CIRCUITBREAKER TO BE PROVIDED BY CONSUMERWITH RATING AS RECOMMENDED BY ZAMIL.

5. COMPRESSOR MOTORS ARE PROVIDED WITH SSPS OR IN-TERNAL LINE BREAK THERMAL OVERLOAD PROTECTION.

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

7. AT COMP. LOCKOUT CONDITION (FAULT), VOLTAGEACROSS TERMINAL X1, X2 OF ECB & ATB #2 IS230VAC. ALSO, COMP. LOCKOUT LIGHT (RED) IS ON.

8. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR LVTBFIELD WIRING. GROUND CONNECT AT BOTH ENDS.

9. COOLING OUTPUT SIGNAL FROM CONTROLLERSHOULD FOLLOW THE SEQUENCE:ON SEQUENCE - Y1 FIRST, THEN Y2.OFF SEQUENCE - Y2 FIRST, THEN Y1.

10.NEUTRAL LINE REQUIRED ON 380V-3Ph-60HzPOWER SUPPLY ONLY.

_ _ _

+

21

MUST BE 3" NOMINAL PIPE THROUGH UNIT FORSLINGS TO AVOID BASE DAMAGE

PROPER CLEARANCE TO BE PROVIDED

LIFT

PROPER CLEARANCE TO BE PROVIDED

MUST BE 3" NOMINAL PIPE THROUGH UNIT FORSLINGS TO AVOID BASE DAMAGE

ATTENTION TO RIGGERSHook rigging sling thru holes in base rail, as shown below.Holes in base rail are centered around the unit center of gravity.Center of gravity is not unit center line.Ensure center of gravity aligns with the main lifting point before lifting.Use spreader bar when rigging, to prevent the slings from damaging the unit.

CAUTIONAll panels should be in place when rigging.Care must be taken to avoid damage to the coils during handling.Insert packing material between coils & slings as necessary.

RIGGING INSTRUCTIONS

MODELS: CAX020 - CAX030



22

D

E

A

WALL

CB

INSTALLATION CLEARANCE

FIGURE - 2CORNER WALL

NOTE: 1. All dimensions are in mm.2. If unit is installed in special pit, please observe the same tolerance for walls. Pit height should not exceed

the unit height.

FIGURE - 1STRAIGHT WALL

MODEL NUMBER A B C D ECAX020 - CAX030 1500 1500 1500 1500 1500

CAX035 - CAX060 1500 1500 2000 1500 1500

CAX070 - CAX170 2000 2000 3000 2000 2000

23





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

MOUNTING LOCATIONMODELS: CAX020 - CAX030

MODEL ACAX150 1281

CAX170 1603

DIMENSIONS

24

LOAD DISTRIBUTION, kg. (ALUMINUM CONDENSER COIL)MODEL No. R1 R2 R3 R4 R5 R6 R7 R8

CAX020 137 217 191 209 - - - -CAX025 152 246 205 235 - - - -CAX030 194 291 255 303 - - - -CAX035 259 360 324 372 - - - -CAX040 278 392 342 404 - - - -CAX045 285 402 350 413 - - - -CAX050 299 418 363 430 - - - -CAX060 307 430 372 442 - - - -CAX070 464 488 504 493 - - - -CAX080 505 529 545 533 - - - -CAX090 495 495 507 507 400 400 - -CAX100 507 507 519 519 409 409 - -CAX120 527 527 540 540 430 430 - -CAX150 488 488 450 450 523 523 408 408CAX170 547 547 510 510 584 584 467 467

LOAD DISTRIBUTION, kg. (COPPER CONDENSER COIL)MODEL No. R1 R2 R3 R4 R5 R6 R7 R8

CAX020 154 234 208 226 - - - -CAX025 174 268 227 257 - - - -CAX030 218 315 279 327 - - - -CAX035 281 382 346 394 - - - -CAX040 313 427 377 439 - - - -CAX045 320 437 385 448 - - - -CAX050 342 461 406 473 - - - -CAX060 355 478 420 490 - - - -CAX070 513 537 553 542 - - - -CAX080 569 593 609 597 - - - -CAX090 539 539 551 551 444 444 - -CAX100 551 551 563 563 453 453 - -CAX120 585 585 598 598 488 488 - -CAX150 539 539 501 501 574 574 459 459CAX170 610 610 573 573 647 647 530 530

25

R1 R2

R4R3

R7R5R3R1

R8R6R4R2

R1 R2

R4R3 R2 R4 R6

R1 R3 R5

INSTALLATION & START-UP INSTRUCTIONSSAFETY CONSIDERATIONSImproper installation, service, maintenance or use can cause explosion, fire, electrical shock or other conditions which maycause personal injury or property damage. Check with your nearest Zamil dealer/sales office for information or assistance.Warning: Before installation or servicing the system, always turn off main power supply. Electrical shock can causepersonal injury or death.

SCROLL COMPRESSOR ROTATIONScroll compressors are designed to operate in single direction only. Hence, care has to be taken to ensure correctrotation when the system is operated. Verification of correct rotation is by observing that the suction pressure drops anddischarge pressure rises when compressor run. Reverse rotation results in abnormal sound, as well as, substantially lowcurrent draw and by interchanging power supply wire L1 & L3 will correct this problem.

INSTALLATIONSTEP-1:Check equipment and job siteUnpack unit and move to final location taking care not to damage the unit. Remove screws holding the unit to woodenpallet and after removing wooden pallet, refix the screws.

STEP- 2:Installation on a solid, level mounting padWhen installing, allow sufficient space for airflow clearance, wiring, refrigerant piping and service. Allow 48" (1219 mm)clearance all around and no obstruction above unit for proper airflow. Double the service access when multiple units areinstalled at one location.

On rooftop applications, locate unit at least 6" (152 mm) above roof surface. Place unit above a load-bearing wall, isolateunit and piping set from structure. Use 4"x4"x1" thick rubber/cork mounting pads.

Arrange supporting members to adequately support unit and minimize transmission of vibration to building.

STEP-3:Piping connectionsOutdoor units should be connected to indoor units using field-supplied piping of refrigerant grade and correct size. Theliquid and suction line diameters can be determined from the physical data table. For piping requirements beyond 50 ft(15.24 m), obtain information from your nearest Zamil dealer/sales office.

It is advisable to size piping according to recommended ASHRAE methods. Install piping according to refrigerationstandard practice. Run refrigerant pipes as directly as possible, avoiding unnecessary turns and bends. Install refrigerantpipes carefully to prevent damaging the suction pipe insulation and vibration transmission to the structure.

Compressors are already charged with the required amount of lubricant. There is no need to charge in the field. Makesure that no air & moisture enter the system as easter oil are hygroscopic in nature. The whole system should be leaktested and evacuated before charging the refrigerant.

Outdoor unit connected to factory matched indoor unitOutdoor unit contains holding charge only. The correct system refrigerant charge for operation is given in the unit nameplate & physicaldata table when connected with up to 25 ft (7.62 m) of field-supplied piping. Check refrigerant charge for maximum efficiency.

Sweat connectionUse refrigerant grade piping. Service valves are closed from factory when shipped and ready for brazing. After wrappingthe service valve with a wet cloth, the piping set can be brazed to service valve using either silver rod or silfos rod brazingmaterial. When brazing completed, refrigerant piping and indoor coil are now ready for leak testing. This check shouldalso include all field and factory brazed joints.Warning: Relieve all pressure before refrigerant system repair or final unit disposal to avoid personal injury or death. Useservice ports and open all valves.

26

ELECTRICALSTEP 1: INSTALLATIONA) Please ensure power supply to the unit is as per unit nameplate (Volts/Ph/Hz) requirements.Caution: Operation of the unit on improper power supply will result in damage to the unit.Note: Use copper wires of proper rating for all field wiring.

Warning: Before servicing or installation of the unit, always TURN OFF all power to the unit. There may be more than onedisconnect switch. Ensure all of them are turned off. Electrical shock can cause personal injury or death.

B) Ground & power wiresConnect power wires to terminal block per wiring diagram.Connect ground wire to the ground lug inside the control box.

C) Control wiring between outdoor & indoor unitUse 16 gauge color-coded wire between the indoor and outdoor units (control wiring).

STEP 2: START-UP1) Energize crankcase heater for a minimum of 12 hours prior to the system start-up. To energize crankcase heater only,

set thermostat to OFF position and close electrical disconnect switch to the outdoor unit.2) Fully open liquid/suction service valves.3) Close electrical disconnect switch to energize the system.4) Set room thermostat to desired temperature.

SYSTEM DESIGNTHESE CONDENSING UNIT SYSTEM HAS BEEN DESIGNED BASED ON THE FOLLOWING:

• Intended for outdoor installation with free air intake and discharge.

• Minimum outdoor operating air temperature during cooling with low ambient operation option is 550F.

• Maximum outdoor operating air temperature during cooling is 1300F.

TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS

27

FROM T'STAT CONTROLLER OR DDCSWITCHING CONTACTS

cax series

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