Zamil Cooline CDL Series Instruction manual

PL-OM-CDL-07-1M-E
INSTALLATION,
OPERATION
&
MAINTENANCE
MANUAL
AIR COOLED CONDENSING UNITS
'CDL' SERIES
(R-22)

Contents Page
General information .................................................................................................................................. 2
Safety issues............................................................................................................................................ 2
Model decoding ....................................................................................................................................... 3
Physical data ......................................................................................................................................... 4-5
Electrical data........................................................................................................................................... 6
Dimensions.......................................................................................................................................... 7-11
Typical schematic wiring diagram...................................................................................................... 12-16
Field wiring connections ......................................................................................................................... 17
Controls & sequence of operation .......................................................................................................... 17
Rigging instructions ................................................................................................................................ 18
Installation clearance.............................................................................................................................. 19
Mounting location ................................................................................................................................... 20
Load distribution ..................................................................................................................................... 21
INSTALLATION INSTRUCTIONS
General................................................................................................................................................... 22
Location of unit ....................................................................................................................................... 22
Refrigerant piping connections ............................................................................................................... 22
Leak testing & refrigerant charging......................................................................................................... 23
Start-up inspection & check list ......................................................................................................... 23-24
Check-out & operational start-up procedure........................................................................................... 24
ELECTRICAL
Power supply.......................................................................................................................................... 25
Unbalanced voltage................................................................................................................................ 25
Motor contactor ...................................................................................................................................... 26
Fan motor............................................................................................................................................... 26
Crankcase heater ................................................................................................................................... 26
Lube oil protection control ................................................................................................................. 26-27
Voltage monitor ...................................................................................................................................... 27
REFRIGERATION
Compressor............................................................................................................................................ 28
High & low pressure protection.......................................................................................................... 29-30
Pump down control................................................................................................................................. 30
Trouble shooting chart....................................................................................................................... 31-33
Parts list ................................................................................................................................................. 34
Recommended spare parts .................................................................................................................... 35
Preventive maintenance schedule.......................................................................................................... 36
Material safety data sheet ...................................................................................................................... 37
Pressure temperature chart............................................................................................................... 38-39
INDEX
CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.
THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1

2
GENERAL STATEMENT
Cooline CDL series is designed and built for the optimum performance when matched with the right indoor unit (Refer to
indoor unit catalog). However, it is required that you become well acquainted with good practices for the proper installa-
tion, operation, and maintenance procedures in order to ensure a safe trouble free operation, year after year.
Most of the procedures described in this manual require certain skills and experience. Only highly skilled and experi-
enced technicians should perform the installation and other maintenance procedures.
SAFETY ISSUES
There are three levels of safety hazards that are identified throughout this manual as Warning (where the situation will
result in personal injury), Caution (where personal injury might occur), and Attention (where minor personal injury and/or
property damage could happen). Please understand and respect those identifications.
WARNING: These units operate on a high voltage with moving parts (at high speed) which can lead to
serious injuries and/or damage to the unit. Never attempt to service the unit unless the main electrical power
supply has been disconnected.
CAUTION: Extra care should be observed when installing, test running, adjusting, servicing, or maintaining
the unit as the hazard of explosion, fire, electrical shock, and potential personal injury and property damage
are present.
Whenperforming anytask pertainingto the installation andmaintenance of the unit, the skilled technician should observe
all the applicable safety measures (wear of safety helmet, boots, and goggles. Use of proper handling materials for
brazing and use of wet cloth for sequencing. A fire extinguisher should be easily accessible etc). He should also read all
the instructions and information in this manual prior to attempting to perform any installation or servicing of the unit.
All applicable local codes should be observed during installation and servicing.

3
1, 2 & 3
BASIC
4, 5 & 6
NOMINAL COOLING
CAPACITY (TONS)
8
REFRIGERATION
CIRCUIT TYPE
7
ELECTRICAL
SUPPLY (V-Ph-Hz)
9
ELECTRICAL KITS OPTION
CDL
COOLINE
CONDENSING
UNIT
020 025 030 035 040 050 055 065 080 100
110
135 160 195
S:DUAL SCROLL *
H:DUAL SEMI-HERMETIC
RECIPROCATING**
Q:QUADRUPLE SEMI-HERMETIC
RECIPROCATING***
L:DUAL SEMI-HERMETIC
RECIPROCATING WITH UNLOADER**
(LEAD COMPRESSOR)
M:QUADRUPLE SEMI-HERMETIC
RECIPROCATING WITH UNLOADER*** (LEAD COMPRESSOR)
A:STANDARD OPTIONS+
K:FAN CYCLING & ADJUST-
ABLE HIGH & LOW PRESSURE SWITCHES
V:VOLT FREE CONTACTS**** C:COMPRESSOR CIRCUIT
BREAKER
P:PUMPDOWN SOLENOID
VALVE
B: K & V
COMBO
E: K & C
COMBO
G: K & P
COMBO
T: K, V & C
COMBO
M: K, V & P
COMBO
N: V, C & P COMBO L: K, V, C & P COMBO
MODEL DECODING
L:380/415-3-50 (4 WIRE)
10
CONDENSER COIL
A:ALUMINUM FIN B:COATED ALUMINUM FIN C:COPPER FIN D:ALUMINUM FIN WITH COIL
GUARD
E:COATED ALUMINUM FIN
WITH COIL GUARD
G:COPPER FIN WITH COIL
GUARD
A:STANDARD OPTIONS+ M:REPLACEABLE CORE FILTER DRIER &
SHUT-OFFVALVE
P:PRESSURE GAUGES (SUCTION &
DISCHARGE)
O:PRESSURE GAUGES (SUCTION,
DISCHARGE & OIL)++
H:HOT GAS BYPASS VALVE R:
CONDENSER PRESSURE RELIEF VALVE
J: M & P
COMBO
K: M & O
COMBO
N: M & H
COMBO
Q: M & R
COMBO
S: M, H & R COMBO T: M, H & P COMBO U: M, H & O COMBO V: A, H & R COMBO F: A, H & P COMBO G: A, H & O COMBO L: A, H, P & R COMBO B: M, H, O & R COMBO
11
MECHANICAL KITS OPTIONS
NOTES:*– Dual scroll compressors are available up to models CDL055 only.
** – Dual semi-hermetic compressors are available for models CDL065 - CDL100 only.
*** – Quadruple semi-hermetic compressors are available for models CDL110 - CDL195 only. **** – A combination of volt free contact option: 1. Unit ON indication, 2. Compressor RUN/TRIP, 3. Unit trip indication.
+– Standard options (for models up to CDL065 only) contain sealed type filter drier, fixed low & high pressure switches.
Standard options (for models CDL080 - CDL195 only) contain replaceable filter drier, ball valve, sight glass, muffler and without spring isolator.
++ – Oil pressure gauge is applicable for semi-hermetic compressors only.

4
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.
MODEL NUMBER CDL020 CDL025 CDL030 CDL035 CDL040 CDL050 CDL055
NOMINAL CAPACITY , TONS*18.4 22.3 27.6 35.5 42.1 48.5 54.8
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Dual Dual Dual Dual
COMPRESSOR Type Scroll
Oil per system (liters) 3.25 3.25 4.14 4.67 5.91 6.3/5.91 6.3
Refrigerant** R-22
Charge per system (oz)*** 332 402 497 640 758 987/758 987
CONDENSERFAN Type Propeller
Qty. – Diameter (inch) 2 – 30 2 – 30 4 – 30 4 – 30 4 – 30 4 – 32 4 – 32
Nominal CFM 13000 13000 26000 26000 26000 42776 41376
Motor HP – RPM 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950 1.5 – 950 2 – 920 2 – 920
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–3–14 3/8–4–14 3/8–2–14 3/8–3–14 3/8–4–14 3/8–3–14
Total face area (Sq. ft.) 32.9 32.9 59.5 59.5 59.5 75 75
HIGHPRESSURESWITCH Open (PSIG) 450 ± 10 450 ± 10 450 ± 10 450 ± 10 450 ± 10 450 ± 10 450 ± 10
Close (PSIG) 360 ± 15 360 ± 15 360 ± 15 360 ± 15 360 ± 15 360 ± 15 360 ± 15
LOWPRESSURESWITCH Open (PSIG) 25± 5 25± 5 25± 5 25± 5 25± 5 25± 5 25± 5
Close (PSIG) 50 ± 5 50 ± 5 50 ± 5 50 ± 5 50 ± 5 50 ± 5 50 ± 5
REFRIGERANT LINES+ Suction line size (OD), inch 1-3/8 1-3/8 1-3/8 1-5/8 1-5/8 1-5/8 2-1/8
Liquid line size (OD), inch 5/8 5/8 5/8 7/8 7/8 7/8 7/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter) ++ 65.3/61.8/56.5 65.4/61.8/56.6 68.2/64.7/59.5 68.4/64.8/59.6 68.5/65/59.7 68.8/65.3/60 68.9/65.4/60.1
OPERATING WEIGHT, Kg. +++ 716 760 1050 1159 1328 1447 1480
PHYSICAL DATA
3/8–2–14
3/8–3–14

5
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.
MODEL NUMBER CDL065 CDL080 CDL100 CDL110 CDL135 CDL160 CDL195
NOMINAL CAPACITY , TONS*66.7 79.2 97.5 110.9 132.9 158.7 195.1
NUMBER OF REFRIGERATION CIRCUIT Dual Dual Dual Quadruple Quadruple Quadruple Quadruple
COMPRESSOR Type Semi-hermetic reciprocating
Oil per system (liters) 7.4 7.4 7.7 4.0 7.4 7.4 7.7
Refrigerant** R-22
Charge per system (oz)*** 1200 1426 1755 998 1196 1428 1756
CONDENSERFAN Type Propeller
Qty. – Diameter (inch) 4 – 32 6 – 32 6 – 32 6 – 32 8 – 32 10 – 32 12 – 32
Nominal CFM 41240 59400 59856 65736 81280 97620 119712
Motor HP – RPM 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920 2 – 920
CONDENSER COIL Type Inner grooved tubes and enhanced fins
Tube Dia–Rows–Fins per inch 3/8–4–14 3/8–3–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–4–14 3/8–4–14
Total face area (Sq. ft.) 87.5 100 120 160 168 190 240
HIGHPRESSURESWITCH Open (PSIG) 450 ± 10 450 ± 10 450 ± 10 450 ± 10 450 ± 10 450 ± 10 450 ± 10
Close (PSIG) 360 ± 15 360 ± 15 360 ± 15 360 ± 15 360 ± 15 360 ± 15 360 ± 15
LOWPRESSURESWITCH Open (PSIG) 25± 5 25± 5 25± 5 25± 5 25± 5 25± 5 25± 5
Close (PSIG) 50 ± 5 50 ± 5 50 ± 5 50 ± 5 50 ± 5 50 ± 5 50 ± 5
REFRIGERANT LINES+ Suction line size Dual 2-1/8 2-5/8 2-5/8 N.A. N.A. N.A. N.A.
(OD), inch Quadruple N.A. N.A. N.A. 1-5/8 2-1/8 2-1/8 2-5/8
Liquid line size Dual 7/8 1-1/8 1-1/8 N.A. N.A. N.A. N.A.
(OD), inch Quadruple N.A. N.A. N.A. 7/8 7/8 7/8 1-1/8
SOUND PRESSURE LEVEL, dBA (@ 3/5/10 meter) ++ 68.6/65/59.8 70.5/66.9/61.7 70.6/67/61.8 70.3/66.8/61.5 71.7/68/62.7 72.8/69.2/64 73.3/69.8/64.5
OPERATING WEIGHT, Kg. +++ 1857 2145 2495 3234 3500 3956 4820
PHYSICAL DATA

6
CDL020 CDL025 CDL030 CDL035 CDL040 CDL050 CDL055 CDL065 CDL080 CDL100
CDL110
CDL135 CDL160 CDL195
CRANKCASE HEATER
Volts
CB
(
Qty.
)
OUTPUT
POWER
LRA
(each)
FLA
(each)
Qty.
CB
Poles
LRA
(each)
RLA
(each)
380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50 380/415-3-50
MODEL
NUMBER
SUPPLY VOLTAGE COMPRESSOR CONDENSER FAN MOTORS
ELECTRICAL DATA
MOCPMCAMax.Min.
Nominal
(V-Ph-Hz)
342 342 342 342 342 342 342 342 342 342 342 342 342 342
457 457 457 457 457 457 457 457 457 457 457 457 457 457
Qty.
49.4 70 2 19.2 125 3 2 3.12 19 1.5 1 380 61 0.16 50.3 70 2 19.6 118 3 2 3.12 19 1.5 1 380 61 0.16 73.7 100 2 27.2 198 3 4 3.12 19 1.5 2 380 61 0.16 88.1 120 2 33.6 225 3 4 3.12 19 1.5 2 380 120 0.32
108.1 150 2 42.5 250 3 4 3.12 19 1.5 2 380 120 0.32 114.2 150 2 42.5/48.7 250/310 3 4 2.70 13.9 2.0 2 380 120 0.32 120.4 150 2 48.7 310 3 4 2.70 13.9 2.0 2 380 120 0.32 151.4 200 2 60.1 504 3 4 2.70 13.9 2.0 2 240 200 0.83 196.7 250 2 80.2 393 3 6 2.70 13.9 2.0 3 240 200 0.83 236.7 300 2 98.0 500 3 6 2.70 13.9 2.0 3 240 200 0.83 254.9 300 4 54.9 304 3 6 2.70 13.9 2.0 3 240 100 0.42 282.4 325 4 60.1 304 3 8 2.70 13.9 2.0 4 240 200 0.83 373.3 450 4 80.2 393 3 10 2.70 13.9 2.0 5 240 200 0.83 416.5 500 4 98.0 393 3 12 2.70 13.9 2.0 6 240 200 0.83
Total
Watts
Total
Amps
LEGEND: MCA - Minimum Circuit Ampacity MOCP - Maximum Over Current Protection RLA - Rated Load Amps LRA - Locked Rotor Amps FLA - Full Load Amps CB - Circuit Breaker

7
DIMENSIONS
NOTE: All dimensions are in mm.
CDL 020 & CDL 025
CDL 030, CDL 035 & CDL 040

8
DIMENSIONS
NOTE: All dimensions are in mm.
CDL 050 & CDL 055
CDL 065

9
DIMENSIONS
NOTE: All dimensions are in mm.
CDL 080 & CDL 100
CDL 110
MODEL H
CDL 080 1950
CDL 100 2253
DIMENSIONS