Emerson KHZ506 User manual

ZSI Scroll Condensing Units
User Manual

Disclaimer
1
Icon Explanation
1
Safety Instructions
2
CDU handing
2
Nomenclature
3
CoreSense Features and Benefits
4
Scope Of supply
7
Physical Layout
7
Technical Specification
8
Installation
10
Qualified Oils & Refrigerant
10
Location and fixing
11
Installation Clearance
11
Refrigeration Piping Installation
12
Brazing Guideline
Wiring Diagram
Start Up and Operation
Leak Test
15
System Evacuation
Refrigerant charging & Charge limit
16
Maintenance & Application Tips
18
System Troubleshooting
21
System Start - Up and Operation Check Sheet
23
Contact Lists 24
Table of Content
12
13
15

Disclaimer
Thank you for purchasing the Emerson Copeland ZSI low Temperature Condensing units. We trust that you will see this
product meeting your refrigeration needs efficiently and efficaciously.
Please read through the User Manual thoroughly to familiarize yourself with the installation and commissioning process
of this product and how to use it optimally to suit your needs. Please do read the information given below before
proceeding with the rest of the manual.
The Emerson Low temperature refrigeration condensing units should only be installed by suitably qualified and
experienced refrigeration technicians. No responsibility can be accepted for damage caused by inexperienced or
inadequately trained site technicians or improper system design. All instructions and procedures described in this
manual are based on good refrigeration trade practices as applicable to this particular product. The installation
contractor may prefer to use variations to these recommendations. However, the methods described in this manual
represent the minimum requirements to avoid any subsequent warranty claims for this equipment and its components.
These instructions do not cover the fundamentals of good electrical or refrigeration practice and are therefore intended
for use only by qualified and/or experienced personnel or technicians certified by us.
These instructions are general in nature for this family of products and due to our policy of continuous improvement,
some of the details may not apply to the unit that you are installing. If in doubt, please consult your local sales office,
quoting unit model and serial number as shown on the name plate. In case of ambiguity, the wiring diagram supplied
with each unit takes precedence over the diagram in this manual.
The information contained in this manual is critical to the correct operation and maintenance of the condensing unit
and should be read by all persons responsible for the installation, commissioning and maintenance of this unit.
Important:
Icon Explanation:
WARNING
This icon indicates instructions to avoid
Personal injury and material damage.
This icon indicates operations with a danger
of electric shock.
High voltage
Danger of burning or frost burn This icon
indicates operations with a danger of
burning or frost burn.
Explosion hazard
This icon indicates operations with a danger
of explosion.
CAUTION
This icon indicates instructions to avoid
property damage and possible personal
injury.
IMPORTANT
This icon indicates instructions to avoid
malfunction of the compressor.
This word indicates a
recommendation for easier operation.
NOTE
1
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.

Safety Instruction:
The equipment has been designed and manufactured to meet international safety standards but, like any
mechanical/electrical equipment, care must be taken if you are to obtain the best results.
• Service and maintenance of this unit, that is Electrical and Mechanical in nature should be carried out by technically
trained and competent personnel. They should be familiar with Local Standards and Codes of Practice.
• When carrying out unit maintenance, ensure that the equipment is disconnected from the electrical power supply.
• Never Place the unit in flammable atmosphere. Do not bypass any Electrical and Product safety devices.
• Refrigerant used in this unit is classified under the COSHH regulations as an irritant, with set Occupational
Exposure Levels (OEL) for consideration if installed in confined or poorly ventilated areas.
• Use personal protective equipment's (PPE's) while installation and commissioning the product at site.
• Under all Circumstances, any applicable local safety regulations requirement must be fulfilled.
• Ensure the proper earthing should be connected to condensing unit before starting the Unit.
• The condensing unit must only be used for its designed purposes with approved Refrigerants & lubrication oil,
proper Electrical supply and within its scope of application.
• Do not start the unit until it is charged with refrigerant. Never charge the oxygen in the Unit/System
• Ensure that materials and wiring do not touch high temperature areas of the compressor & discharge line.
• Never install a system and leave it unattended when it has no charge, a holding charge, or with the service valves
closed without electrically locking out the system.
• Under running condition, the compressor and the tubing can reach temperatures high enough to induce burns
and in case of leak of refrigerant avoid eye contact.
• During maintenance, if Brazing or De-brazing process is required. Kindly ensure that there should not be any
refrigerant & oil inside the system pipe or the brazing area.
• Company shall not be responsible for any kind of accidents occur at sites due lack of sense of responsibility,
Mis-handling, Wrong practice of installation and not following the instructions as mentioned above.
•
• Do not pressurize the unit above 300 PSI in ideal conditions with Nitrogen, dry air,& Refrigerant. Always use pressure
regular valve while connecting to Nitrogen cylinder.
All units are shipped with a holding charge of dry nitrogen inside at a low but positive pressure. It is very important
to check that this holding pressure exists at the time you receive each unit from us or our authorized representatives.
Please inform us or our authorized representative if the holding charge is non-existent. Failure to do
so could void the claim for other related system faults at a later period.
Transit damage is essentially an insurance claim and is not covered under manufacturing defect. It is also
advisable to inspect the rest of the unit for obvious physical damage and inform us or our authorized
representative in case any is discovered.
• During transportation & storage, always keep the unit in vertical/upright position.
• Always move the CDU Boxes or pallet using shrink wrap packaging and all the boxes should be tighten
properly with strapping tape. Because it may cause transit damage.
•
• Always move the units in fully closed container/Vehicle to avoid from rain.
• Handle the unit with care. The packaging allows the use of a forklift or pallet jack for handling. Use appropriate
and safe handling equipment.
• It is recommended not to open the packaging before the unit is at final place for installation.
All the products are not released for use with caustic, poisonous or flammable substances.
Do not stack single boxes on top of each other without pallet in any case.
Receiving your unit
Condensing Unit Handling
Transport, Handling and Storage
2

CDU Family
Nomenclature:
Capacity
First two digits in
Cooling Capacity
at 60Hz (Btu/hr)
Capacity
Total no. of digits in
Cooling Capacity at
60Hz (Btu/hr)
Scope of Supply
KH
Motor Circuit
Code Description
5 3 Phase
Application
Code Description
L Low
Temperature
Voltage Range
Code Description
E 400V(380-420),50Hz, 3Ph
Compressor Family
Code Description
Z Scroll Compressor
Refrigerant
Code Description
L R404a
Code Description
R CDU with Serviceable
Chassis
3

Features & Benefits:
CoreSense™ electronics
Module
Electronic Expansion valve
ZSI Compressor
Serviceable Chassis with Door
Figure:1 KHZXXXLRL Condensing unit
Emerson Commercial and Residential Solutions is pleased to introduce the Copeland Scroll™ KHZXXXLRL condensing
units for low temp applications. These condensing units are built with the ZSI scroll compressors with liquid injection
and premium on-board CoreSense™ electronics features for diagnostics plus protection and come with a service door
for ease of access and serviceability.
Some of the key features of this line-up of condensing units is as follows:
• Provides complete line-up of scroll CDUs (below 7.5 HP) for low temperature applications.
• Built with Copeland Scroll™ ZSI compressors for a silent and enhanced reliable operation.
• On-board CoreSense™ electronics unit for diagnostics and protection to assist contractors troubleshoot in the field.
• Uses Liquid Injection technology, controlled by CoreSense™ to protect the compressor from high discharge
temperature.
• LED display alerts user of DLT sensor status and EXV operation enabling easier troubleshooting.
• Tropicalized for Indian climate to operate at higher ambient temperatures.
• Provides service door for ease of access & accessibility.
• Offering best life cycle cost solution to end users.
• Light weight and compactness, up to 20% weight reduction of equivalent semi-hermetic compressors; Leading to
Compact CDU Design.
• Optimized Condenser Design & Higher CFM for Elevated Ambient Conditions & Extreme Field Conditions.
• Hydrophilic blue fins condenser to prevent from corrosion.
• Large surface area coil ideally positioned to optimize air flow and heat transfer.
• Low Noise Fan for Quieter Fan Operation.
• Robust & Reliable components of construction.
4

4
CoreSense™ Electronics Module:
CoreSense™ electronics Module
Function Descriptions:
Dipswitch
Factory Setting
SW1 bit1 OFF
SW1 bit2 OFF
SW2 and SW3 Not used
UP
Reserved
RESET
Dry Contact - Alarm
Output Terminal
Compressor
Contactor
Board Power Supply
Input Terminals (From
12VAC Transformer)
DLT Sensor
EXV Driver
Board Operation - EXV Testing
Button
Function
Up
To operate EXV manually
Down
Reset Resets the board
The KHZXXXLRL use the proven ZSI compressor range which features Liquid Injection Technology controlled by an
intelligent electronics platform—the CoreSense™ Control Board. CoreSense™ regulates liquid injection by sensing the
Discharge Line Temperature (DLT) to widen the operating envelope and enhance the product reliability. It also features
LED display that alerts the user of sensor status and Electronic Expansion Valve (EEV) operation.
The board will be used to turn the compressor on/off based on
the demand signal from low pressure switch and thermostat.
The board will control Liquid Injection through an EXV based
on a temperature sensor placed on the discharge line.
Dipswitch Setting
• SW1 is used to control the liquid injection
setpoint and cut out. Do not change settings and
ensure that a replacement board is set correctly.
 • SW2 and SW3 are not functional in ZSI CDU units
5

LED Display Description
1
(Yellow Green)
LED Blinking Pattern Indicates DLT Sensor Status
2
(Yellow Green)
LED2 and LED3 Combination and Blinking Patterns Indicate EXV Opening or Closing
3
(Yellow Green)
LED2 and LED3 Blink Once When Entering or Exiting EXV Manual Operation
4
(Red)
LED4 Turns on as an Alarm when Triggered by any of the following:
1) DLT overheat protection
2) DLT sensor open circuit
3) DLT sensor short circuit
Operation: Shift Between Auto Mode and Test Mode
• Push “Up” and “Down” together for 5 seconds to shift between Control Mode and Auto Mode
• LED2 and LED3 flashing together once means the shift is successful
Operate EXV Manually
• Short Push (< 2s) “Up” or “Down” to open or close EXV by one step
• Long Push “Up” and “Down” to open and close EXV rapidly
• LED2 will flash when EXV is opening and will remain on when EXV is fully open
• LED3 will flash when EXV is closing and will remain on when EXV reaches minimum opening
• Push “Up” and “Down” together for 5 seconds to revert to Auto Mode
• Board will automatically revert to Auto operation after 10 minutes from last manual button push
Diagnostic Function of the Board
LED1: Status Indicator of Discharge Line Temperature Sensor
LED4: Warning Signal
• Overheat Protection
• Sensor Failure, Circuit Open/Short
Opening Fully Open Closing Minimum Opening
LED 2 LED 3 LED 2 LED 3 LED 2 LED 3 LED 2 LED 3
Flash OFF ON OFF OFF Flash OFF ON
ON OFF
Warning Normal
6
Circuit Open/Short
Flash
Flash
Repeat
5 Seconds
3 Times 3 Times

5
Figure 2 : KHZXXXLRL Physical layout
Physical Layout
ZSI Scroll
Compressor
Receiver
LP/HP
Oil Separator
Filter Drier
CoreSense Module
Service Valve
The following components are included in the KHZXXXLRL - E5EC6C condensing unit scope of supply:
Table 1: Scope of Supply Details of KHZXXXLRL CDU models
Model KHZ506 KHZ508 KHZ509 KHZ511 KHZ514 KHZ515 KHZ518 KHZ521
Compressor with oil Sight glass ✓
✓ ✓ ✓ ✓ ✓ ✓ ✓
CoreSense along with EXV
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Fan motor
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Serviceable chassis
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Blue fin coated condenser
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Receiver with valve
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Accumulator
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Oil separator
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Adjustable LP/HP switch
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Liquid Line filter drier
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Moisture Indicator
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
CDU service valves
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Electrical Terminals
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Crank Case Heater
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Important Note - Above given Scope of supply comes with our Standard designed Models. For any customized
requirement of additional accessories/system component, please contact our Authorized WHS/Dealer or our
Regional Sales Manager
Hydrophilic Blue
fin Condenser
Serviceable chassis
Accumulator
Standard Scope of Supply:
7

6
Technical Specifications:
• Refer Table 2 below for the dimension, weight & other mechanical details of the product.
Table 2: Mechanical Details of KHZXXXLRL CDU models
CDU Model*
No of
Fans
Fan
W/V/P
Receiver Dimensions Mounting
Dimensions
Suction
Line
Liquid Line Net
Weight
Sound
W/V/P Liters L1 D1 Connection Connection Kg dBA.
KHZ506LRL
1
160
Watts
230V/
1Ph/50Hz
4.6
1043 x 440
x
805
656 402 5/8” 3/8” 96.5 60
KHZ508LRL
656 402 5/8” 3/8” 96.5 62
KHZ509LRL
656 402 5/8” 3/8” 96.5 63
KHZ511LRL
656 402 7/8" 1/2" 111 68
KHZ514LRL
656 402 7/8" 1/2" 140 71
KHZ515LRL
656 402 7/8" 1/2"
140 71
KHZ518LRL
2
5.7
1043 x 440
x
1140
656 402 7/8" 1/2" 169 73
KHZ521LRL
656 402 7/8" 1/2"
190 74
*Power Input is 400V/3Ph/50Hz
Figure 3: KHZXXXLRL CDU Top View, Side View & Dimensions
W
D
H
H
Mounting dimensions as per above table:
W X D
mm
X H
8

7
•Refer Table 3, for the Electrical details of the KHZXXXLRL CDU models as under
Table 3: Electrical data for the KHZXXXLRL CDUs
Model Compressor Rated Voltage
CDU MCC
(A)
Contactor
Rating
Cu. Cable Size
ZSI06KQE-TFM
380-420V/50 Hz/3Ph
7.9
9A
2.5 Sq. mm
ZSI08KQE-TFM
380-420V/50 Hz/3Ph
7.9
9A
2.5 Sq. mm
ZSI09KQE-TFM
380-420V/50 Hz/3Ph
7.8
9A
2.5 Sq. mm
ZSI11KQE-TFM
380-420V/50 Hz/3Ph
11.2
12A
2.5 Sq. mm
ZSI14KQE-TFM
380-420V/50 Hz/3Ph
12.1
12A
2.5 Sq. mm
ZSI15KQE-TFM
380-420V/50 Hz/3Ph
12.7 18A
2.5 Sq. mm
ZSI18KQE-TFM
380-420V/50 Hz/3Ph
15
22A
4.0 Sq. mm
ZSI21KQE-TFM
380-420V/50 Hz/3Ph
19.3
22A
4.0 Sq. mm
•
Always use AC-3 Category Contactor with above mentioned rating in table
.
•Refer below the operating envelope of the KHZXXXLRL CDU models
Figure 4 : Operating Envelope f or KHZXXXLRL Models
Refrigerant R404A; Suction return gas temperature: 5° C
KHZ506LRL-E5EC6C
KHZ508LRL-E5EC6C
KHZ509LRL-E5EC6C
KHZ511LRL-E5EC6C
KHZ514LRL-E5EC6C
KHZ515LRL-E5EC6C
KHZ518LRL-E5EC6C
KHZ521LRL-E5EC6C
9

Installation
Before Installation
During Installation and Subsequent Maintenance
Oil & Refrigerant:
Qualified Refrigerant R404A
Copeland® Brand
Products Standard Oils
Emkarate RL 32 3MAF
Servicing Oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22 CC
The condensing unit should be located in such a place to prevent any dirt, plastic bag, leaves or papers from
covering the condenser and its fins. The unit must be installed without restricting the airflow. A clogged condenser
will increase the condensing temperature, thus reduce the cooling capacity, and lead to a high-pressure switch
tripping. Clean the condenser fins on a regular basis.
• Check all the LOTO tags, Working Space, operative should have correct tools etc.
• Ensure the units received are the correct models for the intended application.
• Ensure the refrigerant, voltage and gauges are all suitable for the proposed application & unit.
• Check there is no damage to the units.
• Check that the proposed equipment locations are suitable and provide adequate support for the weight
of the units.
• Installation and maintenance are to be performed only by qualified personnel who are familiar with
local codes and regulations and experienced with this type of equipment.
• As lifting equipment is required, ensure that it is suitable for purpose, certified and that the operators
are qualified to use it
• Safe working methods are identified, and operator have suitable PPE's.
• Ensure the working area has adequate ventilation during brazing procedures.
• Disconnect and shut off power before installation or service of the equipment
• Refrigerant release into the atmosphere is illegal. Proper evacuation, recovery, handling and leak
testing procedures must always be observed.
• Units must be earthed, and no maintenance work should be attempted prior to disconnecting the
electrical supply
• The electrical box/terminal covers, and fan guards must always remain fitted.
Note: All Compressors are delivered with sufficient oil for normal operation. The optimum oil level or oil
return should be checked by operating the compressor until the system is stable. It is not recommended
to top up Oil unnecessary. If required additional charge of oil for top-up or oil change during
maintenance or in case of leakage. kindly use our qualified oil as per below table recommended for
these Condensing units. Oil Level should not exceed 1/3rd of the Compressor sight glass.
10

•
• All Dimensions are in mm
Above instructions are recommended for Dual Fan CDU Units Also.
500
500
500
Location and Fixing
500
Installation Clearance:
• The unit should always be installed in a location that ensures clean air flow. Both service access and
airflow have been considered in making these recommendations.
• Where multiple units are to be installed in the same location, the contractor needs to
consider each individual case carefully.
• Ideally, the unit should be mounted on a solid concrete slab with anti-vibration pads between unit
feet and concrete.
• Ensure that there is no obstruction to air flow into or out of the unit. Remove obstacles which
block air intake or discharge
• The location must be well ventilated, so the air can pass properly through condenser by
maintaining the proper condensation in the system.
It is recommended to have a clearance of 500 mm between the condenser face and adjacent wall or
unit, while a clearance of 500mm on remaining 3 sides and top for service and free circulation.
11

Tube Size Max distance between
2 clamp support
12.7mm (1/2 inch) 1.20 m
16.0mm (5/8 inch) 1.50 m
22.0mm (7/8 inch) 1.85 m
28.5mm (1 1/8 inch) 2.20 m
OUTSIDE INSIDE UNIT
End of Tube
During brazing
protecthousing
withdampcloth
During brazing
pull back fire
insulation
All interconnecting pipes should be of refrigeration grade, clean, dehydrated and must remain capped at
both ends until installation. Even during installation, if the system is left for any reasonable period (say
two hours), pipes should be re- capped to prevent moisture and contaminants from entering the system.
Do not assume that the service connection sizes on the unit (at the service valves) are the correct size to
run your interconnecting refrigeration pipes. The service valve sizes have been selected for convenience
of installation and in some cases (larger units) these may be considered too small. However, for the very
short pipe run within our units, these service connection sizes are adequate.
The pipe should be sized to ensure optimum performance and good oil return. The sizing must also take
into account the full capacity range through which this particular unit will need to operate.
Pipe runs should be kept as short as possible, using the minimum number of directional changes. Use
large radius bends and avoid trapping of oil and refrigerant. This is particularly important for the suction
line. The suction line should ideally slope gently towards the unit. Recommendation slope is
1/200~1/250. P traps, double risers and reduced pipe diameters may be required for suction lines where
long vertical risers cannot be avoided. All pipes should be adequately supported to prevent sagging
which can create oil traps.
The recommended pipe clamp support distance is shown in the table.
Refrigeration Piping Installation
Brazing Recommendations
Maintain a flow of oxygen-free nitrogen through the system at a very low-pressure during brazing.
Nitrogen displaces the air and prevents the formation of copper oxides in the system. If copper
oxidization is allowed to form, the copper oxide material can later be swept through the system and
block screens such as those protecting capillary tubes, thermal expansion valves, and accumulator oil
return holes. This minimizes any entry of contaminants and moisture.
• Remove the liquid line connection cap.
• Then remove the suction connection cap.
• Open both valves midway. Care should be taken to
avoid the holding charge from releasing too quickly.
• Be sure tube fitting inner diameter and tube outer
diameter are clean prior to assembly.
• Since both tubes are extended from the condensing
unit housing, we recommend insulating the housing by
using a wet cloth on the copper tubing.
• Recommended brazing materials: a copper /
phosphorous or copper/ phosphorous / silver alloy rod
should be used for joining copper to copper whereas to
join dissimilar or ferric metals, use a silver alloy rod,
either flux coated or with a separate.
• Use a double tip torch.
12

10
Wiring Diagram:
2 Fans Unit
13

Wiring Diagram:
Single Fan Unit
14

Leak Check
Start Up and Operation
The unit has been leaktested and QA approved from the factory. However, due to handling and shipping
the entire refrigeration systemmust be tested for leaks. Failure to carry out leak test can result to
undesirable system performance.
Step-by-step:
1. Open both the liquid and suction service valves.
2. Ensure the solenoid valve is energized and open, if available.
3. Pressurize the system to300 psig/21 Bar maximum with dry nitrogen.
4. Allow dry nitrogen to reach all parts of the system.
5. Check all joints and components using soap/bubble test or with an electronic leak detector.
6. Wait for atleast an hour to ensure the system is holding the pressure and is found to beleaked proof,
if the system loses any pressure over the course of 30 minutes to1 hour, then it is a sure indication
that the system is leaking
System Evacuation
If leak has been detected somewhere on the system, relief the pressure and repair the leak. For an
effective installation, the system must be leak tight.
Evacuating a refrigeration system serves two primary objectives: (1) remove non-condensable and
(2) remove water vapor or dehydrate the system.
Air and moisture are detrimental to system operation. The successful long-term operation of the system
depends on thoroughly conditioning them before charging with refrigerant and the losses associated
with improper evacuation erodes system efficiency as well as costly for the installers.
A 2-stage vacuum pump along with a micron gauge is recommended in performing evacuation. The
quality of vacuum is not determined by time – a micron gauge must be used since it is the only device
that accurately reads the vacuum pressure during the evacuation process.
Do not use the system compressor as a vacuum pump and never operate the compressor
while the system is in vacuum. Emerson Climate Technologies recommends Triple Evacuation Process
(best practice) to be implemented on all our installations.
REMINDER:
Note that the following procedure is based upon achieving an actual system vacuum
standard and it is NOT TIMEDEPENDENT!
Step-by-step:
1. Open both the liquid and suction service valves.
2. Ensure the solenoid valve is energized and open, if available.
3. Connect vacuum pump to the liquid and suction service valves.
4. Start the vacuum pump and then open the service valves.
5. Perform triple evacuation process as follows:
i. Vacuum until a pressure of 500 microns is reached — at which time the vacuum
should be broken with the refrigerant to be used in the system through a drier
until the system pressure rises to 20 psig
ii. Repeat this vacuuming process again.
iii. Evacuate the entire system to 500 microns (minimum recommended). Evacuate
the system below 500 microns may enhance the reliability of system.
15

Refrigerant
Maximum
Condensing
Temp.
LP Minimum
Evaporating
Temp.
HP
Cut Out Cut In Cut Out Cut In
R404A 60°C 1.0 bar 2.7 bar -30°C 29.6 bar 24.1 bar
Refrigerant Charging
After ensuring the system is vacuumed properly and all valves are opened, only then start the refrigerant
charging process
1. Ensure that there is no power supply to the CDU unit. The Liquid Line solenoid needs to be kept open for the
charging process, if available and this may require a temporary power feed to it.
2. Connect the refrigerant cylinder to main service hose and purge line at the manifold end.
3. Ensure correct orientation of the refrigerant cylinder.
4. Follow cylinder labeling/instructions so that liquid refrigerant can be charged into the high side of the system
using high-pressure side of the manifold.
5. The refrigerant cylinder should be weighed at this point to be able to record the final refrigerant charge.
6. Now open the liquid service valve (off the back seat). With a good vacuum in the system, system will in-take 60-
70 of the refrigerant required in the system without running the compressor.
7. The compressor can then be started, and the unit continued to be charged (with liquid refrigerant through the
suction service valve).
The quantity of charge should always be measured. See note.
8. The system needs to be operated down to its design evaporating temperature before you can be sure the charge
is correct. Check the liquid line sight glass for violent bubbles and the operating pressures.
In the event that the system is still short of refrigerant, repeat from step #7 onwards.
Pressure Cut Out Settings
Please ensure following setting for the cut outs for the safe operation of the unit:
16
Refrigerant charging is said to be complete when the operating temperature of the system has been stable
for some time and the liquid line sight glass is clear ensuring Suction & Discharge pressure, Superheat
and subcooling.
Do not Charge the refrigerant by measuring the current drawn by compressor. Note:

Model
Refrigerant Charge
(R404a) kg
Refer to the table below for the approximate Refrigerant holding capacity of Condensing Unit :
Refrigerant Charge
KHZ506LRL-EX 4.10
KHZ508LRL-EX 4.10
KHZ509LRL-EX 4.10
KHZ511LRL-EX 4.10
KHZ514LRL-EX 4.10
KHZ515LRL-EX 4.10
KHZ518LRL-EX
KHZ521LRL-EX
4.54
4.54
17

Maintenance
Condenser Fins
• Condenser fins become dirty over time as ambient air is induced to the condenser. Dirty coil surfaces
result in high condensing temperatures and poor unit performance. Regular cleaning is recommended
with frequency depending on the installation and the surrounding environment. As a general guide,
it is advisable to do this at least once every two months.
• Fins should be cleaned with proper cleaning agent. Before washing, a light brush downward (in the
direction of the fins) should be brushed to remove heavy deposits.
Electrical Connections
• Check tightness of electrical connections occasionally.
• Always ensure the below mentioned Electrical tips before starting the unit.
Compressor
• Check the oil level if sight glass is available.
• No corrosion is deposited at compressor body over the period of time.
• Ensure compressor superheat and all system parameters as per designed conditions.
Routine Leak Test
• All joints should be checked for leaks during site visits. All joints should be leak tested once-a-year.
Condenser Fan(s) and Motor(s)
An annual inspection of these items is recommended. Fastenings may loosen, bearings may wear, and fans
may require cleaning of solid deposits which can cause imbalance.
WARNING: TURN OFF OR DISCONNECT THE ELECTRICAL POWER SOURCE BEFORE CLEANING THE CONDENSER
Application Tips for Scroll Compressors/ Do's & Don'ts:
General Tips:
• Please do Vacuum break with pure liquid refrigerant charge on high side and top-up by liquid bleed
in suction
• Always ensure the LP/HP Setting before starting the compressor.
• Don't use refrigeration compressor for self-evacuation.
• Never use the compressor to suck oil into the system.
• Do not test compressor by closing suction valve.
• Do not set low pressure switch below 1 bar.
• Do not pump down below 1 bar.
• To avoid the refrigerant flood back a Solenoid valve should be used in liquid line.
• Don't start the compressor when it is in vacuum.
• Don't operate the compressor in open air.
• Don't allow short- cycling of compressor.
• Ensure the oil return in sight glass during running cycle.
18