INSTALLATION,

OPERATION
&
MAINTENANCE
MANUAL

MODULAR PACKAGED AIR CONDITIONERS

'PTX' SERIES
 INDEX
Contents Page
Model decoding ......................................................................................................................................... 2
Unit dimensions ..................................................................................................................................... 3-10
Optional sections, dimensions ............................................................................................................ 11-20
Fresh air hood assembly ......................................................................................................................... 21
Filter dimensions ..................................................................................................................................... 52
Rigging instructions ................................................................................................................................. 27
Installation clearance .......................................................................................................................... 28-29
Installation .............................................................................................................................................. 29
Load distribution .................................................................................................................................. 30-35
Typical schematic wiring diagram ....................................................................................................... 22-26
Installation instructions
General ................................................................................................................................................... 36
Location of unit ....................................................................................................................................... 36
Wiring ..................................................................................................................................................... 36
Start-up inspection & check list .......................................................................................................... 36-37
Check-out & operational start-up procedure ......................................................................................... 37-38
Belt tension testing procedure ............................................................................................................. 38-39
Electrical
Power supply .......................................................................................................................................... 40
Unbalanced voltage ................................................................................................................................. 40
Fan motor ............................................................................................................................................... 41
Crankcase heater .................................................................................................................................... 41
Lube oil protection control ................................................................................................................... 41-42
Voltage monitor ....................................................................................................................................... 42
Refrigeration
Compressor ............................................................................................................................................ 43
High & low pressure switch ..................................................................................................................... 44
Pump down control ................................................................................................................................. 45
Trouble shooting chart ......................................................................................................................... 46-48
Recommended spare parts ..................................................................................................................... 49
Preventive maintenance schedule ........................................................................................................... 50
R-410A refrigerant pressure-temperature chart ........................................................................................51

CONTINUING RESEARCH RESULTS IN STEADY IMPROVEMENTS.

THEREFORE, THESE SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE.

1
 MODEL DECODING
1, 2 & 3 4 5, 6 & 7 8 9 10 11 12 13 14 15 16 17
BASIC COMPRES- NOMINAL ELECTRICAL REFRIGERATION CONDENSER EVAPORATOR SUPPLY AIR BLOWER BLOWER HEATER KITS KITS
SOR TYPE COOLING SUPPLY CIRCUIT TYPE COIL COIL ARRANGEMENT MOTOR ELECTRICAL MECHANICAL
OPTIONS
CAPACITY ( V-Ph-Hz ) (TEFC TYPE) (kW/STAGES) OPTIONS OPTIONS
(TONS)

PTX H : HERMETIC 003 H : 230-3-60 S : SINGLE SCROLL A :ALUMINUM A: ALUMINUM FIN H : HORIZONTAL F : FORWARD B : 0.75 kW N : NO HEATER A : STD. OPTION (4) A : STD. OPTION (6)
MODULAR SCROLL 004 COMP. (FOR FIN B: COATED SUPPLY, CURVED (2) M: REPLACEABLE CORE
C : 1.1 kW A : 5/1(3) K :FAN CYCLING
005 M : 380/400-3-60 PTX003 - PTX006) ALUMINUM FIN SINGLE SKIN FILTER DRIER &
PACKAGED B : BACKWARD SWITCH
006 (4 WIRE) B : COATED C: COPPER FIN WITH 1" THICK B : 6/1(3) SHUT-OFF VALVE
UNITS CURVED (2) D : 1.5 kW V : VOLT FREE
(R-410A) 007 (NOT D : DUAL SCROLL ALUMINUM D: ALUMINUM FG INSULATION C : 7.5/1(3) (5) P : PRESSURE GAUGES
(1) E : 2.2 kW CONTACTS
AVAILABLE COMP. (FOR FIN FIN WITH C : F + SPRING (SUCTION & DISCHARGE)
008 (3)
RESISTEC ISOLATOR D : 10/1 C : COMPRESSOR
010 FOR PTX003) PTX007 - PTX070) H : HOT GAS BYPASS
COATING F : 3 kW CIRCUIT BREAKER
C : COPPER FIN V : VERTICAL D : B + SPRING E : 12.5/1(3)
012 E: COPPER FIN R : CONDENSER
F : 460-3-60 Q : QUADRUPLE SUPPLY, ISOLATOR G : 4 kW D : NON FUSED
016 WITH F : 15/1(3) PRESSURE RELIEF
SCROLL COMP. D : ALUMINUM DISCONNECT SWITCH
RESISTEC SINGLE SKIN E : F + EXTENDED VALVE
018 L : 380/415-3-50 H : 5.5 kW G : 10/2 P : PUMPDOWN
(FOR PTX080 - FIN WITH COATING WITH 1" THICK RE-GREASING
022 SOLENOID VALVE B : A & P COMBO
(4 WIRE) PTX100) RESISTEC F: ALT. COIL (7) FG INSULATION LINE I : 7.5 kW H : 15/2
025 COATING ALUMINUM FIN (1) B : K & V COMBO D : A & H COMBO
G : B + EXTENDED I : 20/2
027 (7) J : 11 kW E : A & R COMBO
G: ALT. COIL RE-GREASING E : K & C COMBO
030 E :COPPER FIN COATED D : HORIZONTAL LINE J : 25/2 J : M & P COMBO
ALUMINUM FIN K : 15 kW G : K & P COMBO
035 WITH SUPPLY, H : F + BELT K : 30/2 N : M & H COMBO
(7) H : K & D COMBO
RESISTEC H: ALT. COIL GUARD L : 18.5 kW
040 DOUBLE SKIN
COPPER FIN L : 40/2 T : K, V & C COMBO K : M & R COMBO
045 COATING WITH 2" THICK I : B + BELT
I: ALT. COIL (7) M : 22 kW M : 50/2 F : A, H & P COMBO
050 FG INSULATION GUARD M : K, V & P COMBO
ALUMINUM
FIN WITH N : 30 kW N : V, C & P COMBO V : A, H & R COMBO
060 K : C & E COMBO O : 60/2
RESISTEC E : VERTICAL Q : M, H & R COMBO
070 L : D & G COMBO R : 50/4 Q : V, C & D COMBO
COATING SUPPLY, O : 37 kW
080 (RH) U : V, D & P COMBO T : M, H & P COMBO
J: ALT. COIL (7) DOUBLE SKIN M : C, E & H S : 60/4
080 (LH) COPPER FIN COMBO P : 45 kW U : M, P & R COMBO
WITH 2" THICK L : K, V, C & P COMBO
T : 80/4

2
100 (RH) WITH
FG INSULATION N : D, G & I O: K, V, C,P & D COMBO L : A, H, P & R COMBO
RESISTEC
100 (LH) COMBO U : 100/4 W : M, H, P & R COMBO
COATING

18 19 20 21 22 & 23
UNIT ACCESSORIES UNIT ENCLOSURE DRAIN PAN & DRIP ELIMINATOR DAMPERS SPECIAL OPTIONS
M : STD. FILTER RACK WITH 2" THICK AL. FILTER A : STANDARD A : STANDARD DRAIN PAN A : STANDARD AA : STANDARD
F : STD. FILTER RACK WITH 2" THICK PLEATED FILTER F : UNIT FULL GUARD E : STANDARD DRAIN PAN WITH DRIP B : MANUAL FRESH AIR DAMPER AB : UV LAMP
N : 4" MINI PLEATED FILTER RACK WITH 2" THICK AL. ELIMINATOR (8) C : MANUAL FRESH AIR DAMPER & AC : DUAL STAGE ELECTRONIC THERMOSTAT (9)
PRE-FILTER D : STAINLESS STEEL DRAIN PAN (304) RETURN AIR DAMPER AD : FOUR STAGE ELECTRONIC THERMOSTAT (9)
B : BAG & PRE-FILTER SECTION (SINGLE SKIN WITH 1" K : STAINLESS STEEL DRAIN PAN (316) F : ECONOMIZER CONTROL WITH AE : ANTI-ICE THERMOSTAT
THICK FG INSULATION) WITH 2" THICK ALUMINUM OUTSIDE AIR THERMOSTAT TYPE
F : STAINLESS STEEL DRAIN PAN (304) AF : DIFFERENTIAL PRESSURE SWITCH FOR PRE-FILTER
FILTERS
WITH DRIP ELIMINATOR (8) G : ECONOMIZER CONTROL WITH AG : DIFFERENTIAL PRESSURE SWITCH FOR PRE-FILTER & BAG FILTER
L : BAG & PRE-FILTER SECTION (DOUBLE SKIN WITH ENTHALPY SENSOR TYPE
H : STAINLESS STEEL DRAIN PAN (316) AH : MAGNEHELIC GAUGE WITHOUT CONTACT FOR PRE-FILTER
2" THICK FG INSULATION) WITH 2" THICK ALUMI- H : ECONOMIZER CONTROL WITH
WITH DRIP ELIMINATOR (8) AI : MAGNEHELIC GAUGE WITHOUT CONTACT FOR PRE-FILTER & BAG FILTER
NUM FILTERS ENTHALPY SENSOR TYPE & CO2
C : MIXING BOX SECTION (SINGLE SKIN WITH 1" THICK MONITOR AJ : AC & AE COMBO
FG INSULATION) WITH 2" THICK ALUMINUM FILTERS AK : AD & AE COMBO
AL : AC & AF COMBO
E : MIXING BOX SECTION (DOUBLE SKIN WITH 2" THICK
FG INSULATION) WITH 2" THICK ALUMINUM FILTERS AM : AD & AF COMBO
D : B & C COMBO AN : AC, AE, AF & AH COMBO
G : L & E COMBO AO : AD, AE, AF & AH COMBO
Q : N & C COMBO AP : AC, AE, AG & AI COMBO
R : N & E COMBO AQ : AD, AE, AG & AI COMBO

NOTES: (1) 1" Thick fiberglass insulation is standard for all models.
(2) All units are supplied with forward curved blower as standard, while backward curved blower is an option for all models.
(3) Single stage heater is applicable for models PTX003 - PTX006, while dual stage heater is applicable for models PTX008 - PTX070 & four stage heater for PTX080 - PTX100.
(4) Standard electrical options contain under voltage monitor (UVM) & fixed low/high pressure switches.
(5) A combination of volt free contact option: 1. Unit ON/OFF indication, 2. Compressor run & unit trip indication, 3. Blower motor run & trip indication, 4. Unit trip indication.
(6) Standard option contains sealed type filter drier & sight glass.
(7) Alternative evaporator coil is applicable for all models except for PTX035, PTX045 & PTX060.
(8) Drip eliminator is not applicable for models PTX003 - PTX010.
(9) Dual stage thermostat can be applied to PTX003 - PTX070 & Four stage thermostat for PTX080 - PTX100 .
 DIMENSIONS
PTX006, PTX007, PTX008 & PTX010 (HORIZONTAL SUPPLY)

180
975 1130

1290
180
2105

572 572

123
311
137

505

PTX006, PTX007, PTX008 & PTX010 (VERTICAL SUPPLY)

180

975 1130
1290
506

1076 311
180

2105
137

505

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

3
 DIMENSIONS
PTX012, PTX016 & PTX018 (HORIZONTAL SUPPLY)
1100 1400

Filter access

305
1" FPT drain coupling (one side)
Electric power inlet
Elecrical control box (Hinged door)
Lifting points
Blower and motor access

1590
2200
Evaporator access
Horizontal supply

305
2500

PTX012, PTX016 & PTX018 (VERTICAL SUPPLY)

2500
1100 1400
305

Filter access
1" FPT drain coupling (one side)
Electric power inlet
Elecrical control box (Hinged door)
1590

Lifting points
2200

Blower and motor access

Evaporator access
Vertical supply
305

1249 412

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

4
 DIMENSIONS
PTX022 & PTX025 (HORIZONTAL SUPPLY)
1100 1547

2200
2647

PTX022 & PTX025 (VERTICAL SUPPLY)

1100 1547
2200

2647

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

5
 DIMENSIONS
PTX027, PTX030 & PTX035 (HORIZONTAL SUPPLY)

147
2200 1547
Filter access
1-1/4" FPT drain coupling (one side)
Electric power inlet
Elecrical control box (Hinged door)
Lifting points
Blower and motor access

2200
Evaporator access

1984
Horizontal supply

69
3747
Air Discharge Air Discharge
781 638 781

81
614
2281

1206
162

156
2200 286

END VIEW FRONT VIEW END VIEW

PTX027, PTX030 & PTX035 (VERTICAL SUPPLY)
3747
147

2200 1547
781

Filter access
1-1/4" FPT drain coupling (one side)
Electric power inlet
Elecrical control box (Hinged door)
2200

1984

Lifting points
Blower and motor access
Evaporator access
Vertical supply
69

2335 614

Air Discharge Air Discharge

2281

1206
162

156

2200 286

END VIEW FRONT VIEW END VIEW

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

6
 DIMENSIONS
PTX040, PTX045 & PTX050 (HORIZONTAL SUPPLY)

147
2200 1928

1984
69
4128

73
610
2616

1663
165
307

156
PTX040, PTX045 & PTX050 (VERTICAL SUPPLY)
2200 1928 147
509
800

1984
891

69

2335 816

4128
2211

1663
165

307
156

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

7
 DIMENSIONS
PTX060 & PTX070 (HORIZONTAL SUPPLY)

3112 2835

Filter access
1-1/2" FPT drain coupling (one side)
Electric power inlet
Elecrical control box (Hinged door)
Lifting points
Blower and motor access 2200
Evaporator coil access
Horizontal supply

5947

TOP VIEW

73
610
2616

1663
165

156
END VIEW
635
FRONT VIEW

PTX060 & PTX070 (VERTICAL SUPPLY)

5947
3112 2835
398
898
2200

904

3232 898

TOP VIEW
2616

END VIEW

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

8
 DIMENSIONS
PTX080 & PTX100, LH (HORIZONTAL SUPPLY)

3924 4686

114 3696 114

8610

TOP VIEW
78

Supply Air
610

2688
Return Air
1663
194

215

329

PTX080 & PTX100, LH (VERTICAL SUPPLY)

3924 4686

1458 1007
150

1007

114 3696 114

8610

TOP VIEW
Air Discharge Air Discharge

Supply Air
2688

Return Air
1663
194

215

329

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

9
 DIMENSIONS
PTX080 & PTX100, RH (HORIZONTAL SUPPLY)

4686 3924

114 3696 114

8610

78
610
2688

1663

194
215
329

PTX080 & PTX100, RH (VERTICAL SUPPLY)

4686 3924
1007 1458
150
1007

114 3696 114

8610
2688

1663

194
215

329

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

10
 OPTIONAL SECTIONS - MIXING BOX
PTX003 - PTX005

PTX006 - PTX010

NOTES: 1. All dimensions are in mm.

2. Fresh air opening is flexible on both sides.
3. Filter access is applicable on one side only.

11
 OPTIONAL SECTIONS - MIXING BOX
PTX012 - PTX070

FRONT VIEW END VIEW

PTX080 - PTX100

NOTES: 1. All dimensions are in mm.

2. Fresh air opening is flexible on both sides.
3. Filter access is applicable on one side only.

12
 OPTIONAL SECTIONS - BAG FILTER
PTX003 - PTX005

PTX006 - PTX010

NOTES: 1. All dimensions are in mm.

2. Filter access is applicable on both sides.

13
 OPTIONAL SECTIONS - BAG FILTER
PTX012 - PTX070

PTX080 - PTX100

NOTES: 1. All dimensions are in mm.

2. Filter access is applicable on both sides.

14
 OPTIONAL SECTIONS - BAG FILTER & MIXING BOX
PTX003 - PTX005

PTX006 - PTX010

NOTES: 1. All dimensions are in mm.

2. Fresh air opening is flexible on both sides.
3. Filter access is applicable on both sides.

15
 OPTIONAL SECTIONS - BAG FILTER & MIXING BOX
PTX012 - PTX070

PTX080 - PTX100

NOTES: 1. All dimensions are in mm.

2. Fresh air opening is flexible on both sides.
3. Filter access is applicable on both sides.

16
 OPTIONAL SECTIONS - 4" MINI PLEATED FILTER
PTX003 - PTX005

PTX006 - PTX010

NOTES: 1. All dimensions are in mm.

2. Filter access is applicable on both sides.

17
 OPTIONAL SECTIONS - 4" MINI PLEATED FILTER
PTX012 - PTX070

PTX080 - PTX100

NOTES: 1. All dimensions are in mm.

2. Filter access is applicable on both sides.

18
 OPTIONAL SECTIONS - 4" MINI PLEATED FILTER & MIXING BOX
PTX003 - PTX005

PTX006 - PTX010

NOTES: 1. All dimensions are in mm.

2. Fresh air opening is flexible on both sides.
3. Filter access is applicable on both sides.

19
 OPTIONAL SECTIONS - 4" MINI PLEATED FILTER & MIXING BOX
PTX012 - PTX070

PTX080 - PTX100

NOTES: 1. All dimensions are in mm.

2. Fresh air opening is flexible on both sides.
3. Filter access is applicable on both sides.

20
 RAIN HOOD WITH FRESH AIR DAMPER

RAIN HOOD WITH ECONOMIZER DAMPER

21
 TYPICAL SCHEMATIC WIRING DIAGRAM (4 COMPRESSOR UNITS)
REFER TO UNIT
NAMEPLATE FOR HVTB
TO FUSED POWER SUPPLY L1
DISCONNECT L2
SWITCH OR CB
L3
(SEE NOTE-4) PLEASE REFER NEXT PAGE
FOR CONDENSER FAN MOTOR
LUG POWER CONNECTIONS.

CB

NTB

L1E
L2E
L3E
NEUTRAL
(SEE NOTE-9)
CC1 CC2 CC3 CC4 BMC

OLR1 OLR2 OLR3 OLR4 OLR

T1C
T2C
T3C

T1D
T2D
T3D
T1A
T2A
T3A

T1B
T2B
T3B

68
69
70
COMP COMP COMP COMP
BM
1 2 3 4

UVM CONNECTION
TO HVTB TO NTB L1 L2 L3
SMOKE DETECTOR L1 N

ATB ATB
F1
1 JP1 1A JP2 1B
L1 L2 L3 UVM
PLEASE REFER TO FAN MOTOR BMC 1 UVM-1 8
CONTROL CONNECTION, (SHEET 2 OF 2)
OPTIONAL OPTIONAL BMR
VFC CONNECTION PDS CONNECTION TO ATB 1
(SHEET 2 OF 2) (SHEET 2 OF 2)
(REMOVE JP1)
TO TO TO CC2 TO ATB 1A
TO
FR2 FR1 PDS1 PDS2
CC1

( NOTE 7)
SWITCHING CONTACTS
41B

41A

3B

3A
14

4A

4B FROM T'STAT CONTROLLER OR DDC

( NOTE 6) (by others)
LVTB
OUTFAN2

OUTFAN1

HEATER2

HEATER1

TB1

COMP1
COMP2
INFAN

15
LIVE

TO ATB R
X2

X1

P1

R R
P2

17 24Vac
C C
OLR-1
G1 19 CBA-1A G2 BM CONTROL G
G G
FUSE 31A STG1 COOLING Y1
ECB1
NEUTRAL

Y1 Y1
LED 31B STG2 COOLING Y2
POWER INDICATOR LED FAULT INDICATOR Y2 Y2
SQMBO4 ( P 4 ) YR3 STG3 COOLING Y3
W1 32C Y3
LOCK2 LOCK1 STG4 COOLING Y4
W2 YR4 Y4
SYSTEM2 SYSTEM1 32D

ON/OFF
PRI

(ON/OFF)

TRANS1 P4_## HP1

230v (HP1)
12v-0-12v
HP2

ON DIP
(HP2)

22A LPS1
LP1
SEC

DIP SWITCH
(LP1) 23A P

22B LPS2
J_PROG LP2
LVTB LOCATION 23B P
(LP2)

PLEASE REFER TO FAN MOTOR

CONTROL CONNECTION, (SHEET 2 OF 2)
TO ATB OPTIONAL OPTIONAL TO ATB
VFC CONNECTION PDS CONNECTION
1 (SHEET 2 OF 2) (SHEET 2 OF 2)
2
TO TO TO TO
TO ATB TO ATB FR4 FR3 PDS4
PDS3 CC4
2
CC3
41D

41C

4D

3D

3C
4C
OUTFAN2

OUTFAN1

HEATER2

HEATER1

TB1 BMR-1
COMP1
COMP2
INFAN

15B 15C
LIVE

X2

X1

P2
P1

R
C
G JP
FUSE 31C
YR3-1

ECB2
NEUTRAL

Y1
LED 31D YR4-1
LED FAULT INDICATOR Y2
POWER INDICATOR
SQMBO4 ( P 4 ) W1
LOCK2 LOCK1
W2
SYSTEM2 SYSTEM1
ON/OFF
PRI

(ON/OFF)
OLR3-1 HPS3
TRANS2 HP1 21C JP7 JP9
P4_## 24C 25C 26C
P
230v (HP1) 27C
OLR4-1 HPS4
12v-0-12v 21D
HP2 24D JP8 25D JP10 26D
P
(HP2) 27D
ON DIP

22C LPS3
LP1
SEC

DIP SWITCH
(LP1) 23C P

22D LPS4
J_PROG LP2
LVTB LOCATION 23D P
(LP2)

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.

22
 TYPICAL SCHEMATIC WIRING DIAGRAM (4 COMPRESSOR UNITS)
CONDENSER FAN MOTOR POWER & CONTROL CONNECTIONS : WITH FAN CYCLING OPTION (8FANS)

STANDARD CONNECTION (NO FAN CYCLING SWITCH)

ECB1 FM1 ECB2 FM2
T.O.P FMC1 ATB T.O.P FMC2 ATB
12A 12A 13A 12B 12B 13B
OUTFAN 1 2 OUTFAN 1 2
FM3 FM4
T.O.P FMC3 T.O.P FMC4
12C 13C 12D 13D

FM5 FM6
T.O.P FMC5 T.O.P FMC6
12E 12E 13E 12F 12F 13F
OUTFAN 2 OUTFAN 2
FM7 FM8
T.O.P FMC7 T.O.P FMC8
12G 13G 12H 13H

L1 L2 L3 L1 L2 L3 8-FAN MOTOR LAYOUT

L1 L2 L3 L1 L2 L3

CONTROL
PANEL
CB6 CB7 OPTIONAL CONNECTION (WITH FAN CYCLING SWITCH)
CB8 CB9

TO ECB1 FM1 TO ECB2 FM2

OUTFAN 1 T.O.P FMC1 OUTFAN 1 T.O.P FMC2
12A 13A 12B 13B
2 2
100
101
102

103
104
105

FM3 FM4
106
107
108

109
110
111
FCS1 T.O.P FMC3 FCS2 T.O.P FMC4
10A 11A 12C 13C 10B 11B 12D 13D
FMC1 FMC3 FMC2 FMC4 2 2
FMC5 FMC7 FMC6 FMC8 P P
TO ECB1 FM5 TO ECB2 FM6
OUTFAN 2 T.O.P OUTFAN 2 T.O.P
FMC5 FMC6
35C
36C
37C

35D
36D
37D
35A
36A
37A

35B
36B
37B

12E 12F
35G
36G
37G

35H
36H
37H
35E
36E
37E

35F
36F
37F
13E 13F
2 2

FM7 FM8
FM1 FM3 FM2 FM4 FM5 FM7 FM6 FM8 FCS3 T.O.P FMC7 FCS4 T.O.P FMC8
10C 11C 12G 13G 10D 11D 12H 13H
2 2
P P

SCHEMATIC DIAGRAM S1
ECB DIP SWITCH SETTINGS & LED INDICATORS
OFF=TEST MODE DISABLE ON= TEST MODE ENABLE

ELECTRIC HEATER POWER AND CONTROL CONNECTION

LOAD BALANCE
S2 OFF= (Comp1&2 Auto Lead Lag) ON= COMPRESSOR 1 LEAD
S3 OFF= WITHOUT PUMP DOWN ON= WITH PUMP DOWN OPTION
HEATER CONNECTIONS DETAILS (OPTIONAL) S4 OFF= SINGLE COMPRESSOR ON= DUAL COMPRESSOR
FACTORY SETTINGS OF DIP SWITCHES LED INDICATORS
HEATER DATA TABLE Green power on/off indicator
STAGE 1 HTR (KW) STAGE 2 HTR (KW) DIP SWITCH # S1 S2 S3 S4
TTL KW CONN. HTR 1 HTR 3 HTR 5 HTR 7 HTR 2 HTR 4 HTR 6 HTR 8 Red system lock-out due to system fault
POWER CONNECTION CONTROL CONNECTION ON system 1 fault diagnostic
10 A 5 -- -- -- 5 -- -- -- OFF
Yellow blinking slow - LPS1 ckt fault
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 15 A 7.5 -- -- -- 7.5 -- -- -- notes: blinking fast - HPS1 ckt fault
20 A 10 -- -- -- 10 -- -- -- * Set dip switch #3 according to unit's option
(pump down or no pump down) system 2 fault diagnostic
30 A 15 -- -- -- 15 -- -- -- * Ensure dip switch #1 is in OFF position Orange blinking slow - LPS2 ckt fault
ECB 40 B 10 10 -- -- 10 10 -- -- before operating the unit. blinking fast - HPS2 ckt fault
HC1
29 28 50 B
CB12 CB14 CB16 CB18 HEATER 1 12.5 12.5 -- -- 12.5 12.5 -- --
60 B
HOT GAS BY PASS CONNECTION
15 15 -- -- 15 15 -- --
LVTB
71G
72G
73G

75 C
71E
72E
73E
71C
72C
73C

15 15 7.5 -- 15 15 7.5 --
71A
72A
73A

HC2 17
30 C
HEATER 2 100 C 12.5 12.5 12.5 12.5 12.5 12.5 12.5 12.5 AR8
31A
HC1 HC3 HC5 HC7 Y1
HEATER BOX CONNECTION SCHEMES AR9
(380V AND 460V HEATERS) 31B
Y2
ATB L1 L2 L3 L1 L2 L3
1 HC1A-1A 28A HC3
T1G
T2G
T3G

T1H
T2H
T3H
T1F
T2F
T3F

T1I
T2I
T3I

1 LPS NO
HC5 C
7E AR8-1 7F AR9-1 7G
HGS 2
HEATER1 HEATER3 HEATER5 HEATER7 NC
OHT OHT
P
NOTE
HC7 FL FL OHT OHT
(Stage 1 Heaters) FOR UNITS WITH HGS CONNECTION, COMP 1 SHALL BE LEAD COMPRESSOR.
DIP SWITCH S2 IN ECB SHOULD ALWAYS BE IN "ON" POSITION.
MOHT MOHT
HC2A-1A 28B HC4 ANTI ICE CONNECTION (OPTIONAL)
( 5 TO 12.5KW ) ( 15KW )
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 ECB1
HC6
HEATER BOX CONNECTION SCHEMES 22A LPS1
(230V HEATERS) LP1
HC8 29A AI-1 23A P
OHT FL (LP1)
L1
22B LPS2
CB13 CB15 CB17 CB19 LP2
29B AI-2 23B P
AFS (LP2)
71H
72H
73H
71D
72D
73D

71F
72F
73F
71B
72B
73B

ATB NC
2 C
ECB2
NO L2
HC2 HC4 HC6 HC8 22C LPS3
OHT FL LP3
L3
29C AI-3 23C P
( 5 TO 7.5KW ) (LP3)
L1 22D LPS4
LP4
T1G
T2G
T3G

T1H
T2H
T3H
T1F
T2F
T3F

T1I
T2I
T3I

OHT FL
29D AI-4 23D P
(LP4)
HEATER2 HEATER4 HEATER5 HEATER6
FL OHT
(Stage 2 Heaters)
NOTE: L2
OHT FL
PRESSURE SWITCH SETTINGS (R410a)
FOLLOW APPLICABLE POWER AND CONTROL CONNECTION AS PER L3 NAME OPEN (PSIG) CLOSE (PSIG)
REQUIRED HEATER KW OF UNIT. REFER HEATER TABLE FOR
( 10 TO 15KW )
CORRESPONDING NOS. OF HEATERS AND CONTACTORS. LPS1 ~ 4
LPS(HGS) 125 105
NON-FUSED DISCONNECT SWITCH CONNECTION LPS5 & 6(UL) 140 130
SW HPS1 ~ 4
HVTB
L1 L1 FCS1 ~ 4
TO EQUIPMENT L2 L2
CKT BREAKER
(SEE NOTE-4) L3 L3

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.

23
TYPICAL SCHEMATIC WIRING DIAGRAM (4 COMPRESSOR UNITS)
LEGEND
OPTIONAL CONNECTIONS
AHU AIR HANDLING UNIT
UNIT STATUS (VFC) INDICATION CONNECTION
AFS AIR FLOW SWITCH
PUMP DOWN SOLENOID CONNECTION
PDS2 ATB UNIT ON/OFF AR AUXILIARY RELAY
2 AR1
PDS1
1 2
ATB AUXILIARY TERMINAL BLOCK
BM BLOWER MOTOR
4B

4A
45 AR1-1A 46

BMC BLOWER MOTOR CONTACTOR

P2

P1

ECB1 UNIT ON
PDS4 ATB
UNIT TRIP CC COMPRESSOR CONTACTOR
2
PDS3 43 FR1-1A 44A FR2-1A 44B FR3-1A 44C FR4-1A 44 CCA CC AUXILIARY CONTACT
4D

4C

CB CIRCUIT BREAKER
P2

P1

UNIT TRIP
ECB2 INDIVIDUAL COMP. RUN/TRIP
C. HTR CRANKCASE HEATER
FR1 2
COMP COMPRESSOR
HOT GAS BY PASS CONNECTION COMP 1 TO ECB1 41A
LVTB
X1 ECB ELECTRONIC CONTROL BOARD
17 FR1-2A
C F FUSE
AR8 CC1A-2A
Y1
31A FCS FAN CYCLING SWITCH
AR9 FM FAN MOTOR (CONDENSER)
31B
Y2 56 58
55
FMC FAN MOTOR CONTACTOR
1 LPS
C
NO
AR8-1 HGS 2
COMP1 ON FMCA FMC AUXILIARY CONTACT
7E 7F AR9-1 7G COMP1 TRIP
P
NC
FR FAULT RELAY
NOTE FR2 2
FOR UNITS WITH HGS CONNECTION, COMP 1 SHALL BE LEAD COMPRESSOR.
COMP 2 TO ECB1
X2
41B HC HEATER CONTACTOR
DIP SWITCH S2 IN ECB SHOULD ALWAYS BE IN "ON" POSITION.
FR2-2A HPS HIGH PRESSURE SWITCH
COMP. SSPS CONNECTION (AS APPLICABLE)
(SEE NOTE 5)
CC2A-2A HVTB HIGH VOLTAGE TERMINAL BLOCK
COMP. 1: SSPS1
24A
M1/11 M2/14
25A JP JUMPER
1
L1/MP/L L2/R/N
2 60 61 63 L1 LINE 1
(REMOVE JP3)
COMP2 ON L2 LINE 2
COMP. 2:
SSPS2 COMP2 TRIP
L3 LINE 3
24B 25B
M1/11 M2/14
TO ECB2 41C
FR3 2 LPS LOW PRESSURE SWITCH
1 2 COMP 3
L1/MP/L L2/R/N X1
LUG LUG GROUND
FR3-2A
(REMOVE JP4)
COMP. 3: SSPS3
NTB NEUTRAL TERMINAL BLOCK
24C 25C CC3A-2A
M1/11 M2/14 OLR OVER LOAD RELAY
1
L1/MP/L L2/R/N
2
OPS OIL PRESSURE SWITCH
65 66 68
(REMOVE JP7) P PRESSURE
COMP. 4:
SSPS4 COMP3 ON
24D
M1/11 M2/14
25D PDS PUMP DOWN SOLENOID
COMP3 TRIP
1
L1/MP/L L2/R/N
2 FR4 S DIP SWITCH (IN ECB)
TO ECB2 2
COMP 4 41D
(REMOVE JP8)
X2 SSPS SOLID STATE PROTECTION SYSTEM
FR4-2A
TOP FM THERMAL OVERLOAD PROTECTION
CC4A-2A
TRANS TRANSFORER
COMP. CRANKCASE 230V HTR CONNECTION UL COMP. UNLOADER SOLENOID
70 71 73
COMP. 1:
1B CC1A-1B
100A
C.HTR1 2
UVM UNDER VOLTAGE MONITOR
1B CC2A-1B
100B
C.HTR2 2
COMP4 ON
COMP4 TRIP
___ FIELD WIRING
COMP. 2:

COMP. 3:
1B CC3A-1B
100C
C.HTR1 2
BM RUN/TRIP TERMINAL BLOCK OR TERMINATION POINT
COMP. 4:
1B CC4A-1B
100D
C.HTR2 2 ATB
CBA-1B AR2
ATB SPLICE-CLOSED END
1 20 2

TB1(ECB1) OLR-1 AR2-1B LVTB

NOTES
COMP. CRANKCASE 380V HTR CONNECTION G1 19 G2
L1 CC1A-1B C.HTR1 L2
G G
1. POWER SUPPLY, REFER TO UNIT NAMEPLATE.
COMP. 1: 100A NOTE
FOLLOW ABOVE CONNECTION FOR UNITS WITH VFC CONNECTION . 2. ANY WIRE REPLACEMENT SHOULD BE OF 900C OR
L2 C.HTR2 L3
COMP. 2:
CC2A-1B
100B 48 BMCA-1A 49 ITS EQUIVALENT. USE COPPER CONDUCTOR
COMP. 3:
L1 CC3A-1B
100C
C.HTR1 L2
WIRES ONLY.
BM RUN
L2 CC4A-1B C.HTR2 L3 51 OLR-2 52
3. POWER MUST BE SUPPLIED TO CRANKCASE
COMP. 4: 100D
HEATER FOR MINIMUM OF 12 HOURS PRIOR TO
AR2-2A
SYSTEM START UP.
BM TRIP
IF POWER IS OFF 6 HOURS OR MORE, CRANK-
CASE HEATER MUST BE ON FOR 12 HOURS BE-
FORE OPERATING THE SYSTEM.
COMP. WITH CB CONNECTION (OPTIONAL)
FAILURE TO FOLLOW THESE INSTRUCTIONS
TO HVTB TO HVTB TO HVTB TO HVTB
L1 L2 L3 L1 L2 L3 L1 L2 L3 L1 L2 L3 MAY RESULT IN COMPRESSOR DAMAGE.
4. FUSED DISCONNECT SWITCH OR CIRCUIT
CB1 CB2 CB3 CB4
BREAKER TO BE PROVIDED BY CONSUMER
WITH RATING AS RECOMMENDED BY ZAMIL.
L1C
L2C
L3C

L1D
L2D
L3D
L1A
L2A
L3A

L1B
L2B
L3B

5. COMPRESSORS ARE EITHER PROVIDED WITH

CC1 CC2 CC3 CC4
SSPS OR INTERNAL LINE BREAK THERMAL OVER-
OLR1 OLR2 OLR3 OLR4
LOAD PROTECTION.
6. IN 460 VOLT UNITS, A STEP DOWN CONTROL
T1C
T2C
T3C

T1D
T2D
T3D
T1A
T2A
T3A

T1B
T2B
T3B

TRANSFORMER IS PROVIDED FOR THE 230 VOLT

CONTROL VOLTAGE.
COMP COMP COMP COMP
1 2 3 4 7. USE SHIELDED TYPE CABLE, #18 AWG (MIN.) FOR
LVTB FIELD WIRING. GROUND CONNECT AT
COMP CB AUXILIARY CONTACT CONNECTION BOTH ENDS.
ECB ECB
8. COOLING OUTPUT SIGNAL FROM CONTROLLER
21A 21C SHOULD FOLLOW THE SEQUENCE:
HP1 CB1A-1A HP3 CB3A-1A
27A 27C
(HP1) 8A
HPS1 (HP3) 8C
HPS3 ON SEQUENCE - Y1 - Y2 - Y3 - Y4.
HP2 21B HP4 21D OFF SEQUENCE - Y4 - Y3 - Y2 - Y1.
CB2A-1A 27B CB4A-1A 27D
(HP2) 8B
HPS2 (HP4) 8D
HPS4 9. NEUTRAL LINE REQUIRED ON 380/400V-3Ph-60Hz
& 380/415V-3Ph-50Hz POWER SUPPLY ONLY.

24
 ECONOMIZER CONNECTION
(APPLICABLE FOR DUAL COMPRESSOR UNITS)
TO ATB
1 2

TRANS2
SWITCHING CONTACTS
FROM T'STAT CONTROLLER OR DDC 230V
(by others)
24V
( NOTE 8) ( NOTE 7)
LVTB F5 ATB
R R 15C
R 17
C C
C
G BM CONTROL G 18A BMR 18B OLR-1
19 CBA-1A
G
Y1 STG1 COOLING Y1 31A YR1
Y1
Y2 STG2 COOLING Y2 31B YR2
Y2
W1 STG1 HEATING W1 HR1
W1
W2 STG2 HEATING W2 HR2
W2

ECONOMIZER BOARD SETTINGS

POTENTIOMETER # SETTING FUNCTION
POT 1 (OPTIONAL) AIR QUALITY SENSOR SETTING

POT 2 75% OAD POSITION TO ENERGIZE RELIEF FAN RELAY

POT 3 25% MINIMUM OAD POSITION

POT 4 52 F SUPPLY AIR TEMPERATURE SETTING- TO ACTIVATE ECON CYCLE

R
C

R
C
R C G Y1 Y2 W1 W2 R C B C1 C2 H1 H2 RETURN AIR
DAMPER ACTUATOR
SUPPLY AIR TEMP. SENSOR P3 B1 (S3) P3
165 FEEDBACK
(SAT) ECONOMIZER CONTROL BOARD P2 B2 (S2) P2 POTENTIOMETER
ET 858
STS

166 B3 (S1)
P1 P1
1-
RAD B3 (black)
1

2+ B4 (red) MOTOR
2
3+ B5 (white)
COM 3
INDOOR AIR
24V
QUALITY SENSOR
AQS

(OPTIONAL) 0~10V DC

(OAT)
ET858
L
167
C
ODS

168
H OUTDOOR AIR
DAMPER ACTUATOR
P3 A1 (S3)
P3 FEEDBACK
(EC) A2 (S2) POTENTIOMETER
TO ECB2 P2 P2
167 A3 (S1)
ENTHALPHY CONTROLLER 2 ODS P1 P1
1
168
OAD

OPTIONAL - IN PLACE OF OAT 3 1-

(USE NO CONTACT) TR TR1 A3 (black)
1
POTENTIOMETERS REF A4 (red)
2+ 2 MOTOR
POT 1 POT 2 POT 3 POT 4
C NO NC
3+ A5 (white)
24V ac 3

RELAY OUTPUT
FOR RELIEF FAN
(OPTIONAL)

INPUT SIGNAL CONNECTION TO ECB (P3) BOARD BLOWER MOTOR RUN & TRIP INDICATION (VFC)

ATB ATB
ECB 1 CBA-1B 20
AR2 2

OLR-1 AR2-1B ATB

TB1 BMR 18B 19
(COIL) 17
15A
R NOTE
C FOLLOW ABOVE CONNECTION FOR UNITS WITH VFC CONNECTION .
18A BMR-1A
G
32A YR1-1A BMCA-1A 49
Y1 48
32B YR2-1A
Y2
34A HR1-1A
W1 BM RUN
34B HR2-1A
W2
51 OLR-2 52

AR2-2A

BM TRIP

LEGEND
SAT SUPPLY AIR THERMISTOR NOTES
AQS AIR QUALITY SENSOR
1. DAMPER MOTOR IS NOT REQUIRED FOR SINGLE
OAT OUTDOOR AIR THERMOSTAT
DAMPER MOTOR APPLICATION.
FCC FREE COOLING COUNTER
OAD OUTDOOR AIR DAMPER MOTOR 2. IF EC OR OAT OPTION IS FACTORY
RAD RETURN AIR DAMPER MOTOR INSTALLED, PLEASE READ BROKEN LINES
STS SUPPLY AIR TEMPERATURE SENSOR AS CONTINUOUS LINES.
MTR DAMPER MOTOR
EC ENTHALPY CONTROLLER

25
TYPICAL HIGH AND LOW VOLTAGE FIELD WIRING CONNECTIONS

PACKAGED UNIT CONTROL PANEL (2 COMP.

)

START/STOP COMMANDS
FROM T'STAT CONTROLLER OR DDC

NOTE: OPTIONAL CONNECTION :

IF REMOTE TEMPERATURE SENSING
FUNCTION IS REQUIRED.
SENSOR
REMOTE
SENSOR

NOTE: --- FIELD WIRING FOR SINGLE / DUAL COMPRESSOR UNITS

WITH 2-COOLING + 2 HEATING EXTERNAL CONTROLLER
PACKAGED UNIT CONTROL PANEL (4 COMP.
)
START/STOP COMMANDS
FROM T'STAT CONTROLLER OR DDC

CABLE ENTRY DETAILS

PTX003 - PTX006 PTX007 - PTX070 PTX080 - PTX100

26
 RIGGING INSTRUCTIONS
ATTENTION TO RIGGERS
Hook rigging sling thru holes in base rail, as shown below.
Holes in base rail are centered around the unit center of gravity.
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.
CAUTION
All 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.
MODELS: PTX003 - PTX010 MODELS: PTX012 - PTX050

MODELS: PTX060 - PTX070

MODELS: PTX080 - PTX100

27
 INSTALLATION CLEARANCE
(SINGLE UNIT)

NOTES: 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 heigh t.
3. No obstruction above condenser fan.

28
 INSTALLATION CLEARANCE (MULTIPLE UNITS)

NOTES: 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 heigh t.
3. No obstruction above condenser fan.

INSTALLATION
1. Provide a concrete pad or another form of stand. Use 4-12 each rubber/cork pads 4" x 4" x 1" thick each (rubber-in-shear for
example) at each corner and along side rails, or use 4-12 each spring isolators.
2. Service Clearance: To avoid condenser air obstructions/recirculation, and to give adequate service space, indicated clearance s
must be observed. See drawings above.
3. All wiring must comply with NEC (National Electrical Code) and local electrical codes. The electric supply must comply with t he
unit nameplate. See the typical wiring diagram for guidance.
4. All units are pre-charged with R-410A and oil, sealed and tested for leaks. Therefore do not attempt to open the system.
5. Install a flexible connection for duct work to minimize vibration transmission. Connect drain pipe (copper or PVC) to the ne arest drain pit.

29
LOAD DISTRIBUTION (kg) & MOUNTING POINTS (STANDARD UNIT)

NOTE: All dimensions are in mm.

30
LOAD DISTRIBUTION (kg) & MOUNTING POINTS (STANDARD UNIT
WITH BAG FILTER)

NOTE: All dimensions are in mm.

31
LOAD DISTRIBUTION (kg) & MOUNTING POINTS (STANDARD UNIT
WITH MIXING BOX)

250 A A A

NOTE: All dimensions are in mm.

32
LOAD DISTRIBUTION (kg) & MOUNTING POINTS (STANDARD UNIT
WITH MIXING BOX & BAG FILTER)

B
250 A A

NOTE: All dimensions are in mm.

33
LOAD DISTRIBUTION (kg) & MOUNTING POINTS (STANDARD UNIT
WITH 4" MINI PLEATED FILTER)

NOTE: All dimensions are in mm.

34
LOAD DISTRIBUTION (kg) & MOUNTING POINTS (STANDARD UNIT
WITH 4" MINI PLEATED FILTER & MIXING BOX)

250

NOTE: All dimensions are in mm.

35
 INSTALLATION INSTRUCTIONS
GENERAL
The complete shipment should be inspected for damage. Any damage, visible or concealed, should be reported immedi-
ately to the delivery man or driver. Any damage visible at the time of delivery should be noted on the shipment invoice.
These units are shipped completely assembled and wired. These units does not require any refrigerant tube installation
at the field. Units require external power, thermostat wiring, condensate drain piping and ducting as applicable.
Size of unit for an installation should be based on a heat gain calculation made according to applicable standards. Units
must also be installed in accordance with regulations of the "National Fire Protection Association" and local electrical
codes. Where local regulations vary with instruction furnished, installer should adhere to local standards.
Prepare your concrete pad or steel stand as applicable. Remove shipping protective covers and wooden crating and lift
unit from base and place in position with necessary applicable vibration isolators.
Equipment must be installed so as to allow for service access and air circulation in accordance with these instructions
and other ZAMIL publications for the specific equipment being installed.

LOCATION OF UNIT
When selecting the location for the unit, the following points should be kept in mind:
1. Provisions for a concrete slab which will allow for minimum clearance from building or structures
2. That the terrain allows for drainage away from the unit.
3. If the unit is to be roof mounted, inspect the roof for load bearing capacity. The roof should have sufficient structural
strength to carry the weight of the unit.
4. Availability of electric power.
5. Position the unit to provide for unrestricted air circulation and to prevent any possibility of air recirculation.
6. Check minimum clearances required for your unit, with regard to walls, or other obstructions.
7. Air cooled equipment should not be installed under low structural overhangs which can cause condenser air recircu-
lation or restriction.
8. Care should be taken to prevent air from other sources from entering condenser, if this air is at a high temperature.

WIRING
All wiring must comply with the "National Electric Code" and local electrical standards. The power supply, voltage,
frequency and phase must coincide with the unit nameplate.
Power wiring to the equipment must be adequately sized for maximum ampacity as shown on unit name plate. The unit
wiring diagram, completely illustrates the internal wiring and field connection needed for power supply and control wiring.
The power supply should be run through the sized shielded cable or rigid conduit and through a separate fused discon-
nect switch/circuit breaker. For control wiring, use approved thermostat wire (minimum 18 gauge). Never use telephone
wire for this purpose. A sized circuit breaker/fused disconnect switch should be located adjacent to the unit for safety &
servicing purposes.
Wiring connection to the unit must have insulation suitable for temperatures of a minimum of 600C.
Minimum circuit ampacity for each model is shown on the name plate and product catalog. Equipment wiring diagram
should be examined and thoroughly understood before field wiring connections are made.
Power supply should be checked to be certain that supply voltage agrees with equipment nameplate. Serious damage to
compressors and motors can occur, if improper voltage is applied.

START-UP INSPECTION & CHECK LIST

After the installation is completed in all respect, the following points should be covered before the system is switched on
for operation.
1. Remove or loosen shipping retainers under motor compressors. Make sure the hold down nuts on spring mounted
compressors are not touching the compressor feet.
2. Make sure all electrical fasteners/connections are tight and clean.
3. All controls are set according to manufacturer's instructions (low & high pressure switch, pump down pressure switch,
fan cycling switch, etc...)
4. Make sure all valves are open (compressor suction & discharge service valves, liquid line, etc.).
5. Follow all the instructions from the warning tags and stickers.

36
6. Compressor crankcase heater should be energized for 24 hours (special attention should be taken to disable com-
pressor contactor before energizing the unit fitted with pump down controls. If not, compressor may operate for few
minutes to pumpdown the system, even the thermostat is OFF).
7. Thorough inspection on evaporator coil, condenser coil and other components for any physical damage.
8. Expansion valve bulb is strapped properly at correct location.
9. Circuit breaker/fused disconnect switch.
10. Blower fan belt is properly tightened and pulleys are properly aligned.
11. Blower fan & condenser fans are at correct rotation and their mountings are properly tightened.
12. All refrigerant service valve caps are installed.
13. All piping, piping insulation and piping supports are properly installed.
14. Thermostat is the right one and installed properly.
15. Duct work and accessories (check the following list and select whichever applicable to each jobs).
• Flexible Connection
• Air Filters Clean
• Air Filter Access Door Gasket
• Sound Attenuators (If Applicable)
• Fresh Air Intake
• Ductwork Caulking Inside/Outside Building
• Ductwork Supports Inside/Outside Building
• Duct Leakage Inside/Outside Building
• Volume Dampers
• Volume Damper Access Doors
• Fire Dampers
• Fire Damper Access Doors
• Transfer Grilles/Door Grilles
• Duct Insulation/Liner
• Diffusers/Grilles
• Duct Humidistat
• Filter flag
CHECK-OUT & OPERATIONAL START-UP PROCEDURE
After the completion of inspection and check list, the following points should be covered before system is placed in operation.

1. Connect the manifold gauge to suction & discharge line service valves. Prepare recommended instruments for check-
ing Voltage, Amps, RPM, CFM, static pressure, etc.
2. Start the blower fan and condenser fan. Check the amperage against the nameplate ampere.
3. Start the compressor and observe the following points (on multiple compressor units, it is highly recommended to start
the compressors one by one to achieve careful observation for each compressor).
(a) Check compressor discharge and suction pressures. If not within system design limits, determine why and take
corrective action.
(b) Check liquid line sight glass and expansion valve operation. If there are indications that more refrigerant is re-
quired, leak test all connections and system components and repair any leaks before adding refrigerant.
(c) Observe oil level in compressor crankcase sight glass (if available) and add oil as necessary to bring to recom-
mended oil level.

37
 All compressors are charged with somewhat greater than the normal oil level required for adequate lubrication, in order
to provide some allowance for oil which will be circulating in the system during operation. Depending on the system
design, the amount of oil in the system at the time of compressor installation, oil lost due to leakage, etc., it may be
necessary either to add or remove oil from a system any time it is first placed in operation with a different compressor.

An abnormally low oil level may result in a loss of lubrication; while an excessively high oil level may result in oil
slugging and possible damage to the compressor valves or excessive oil circulation. The oil level may vary consider-
ably on initial start-up if liquid refrigerant is present in the crankcase, and the oil level should be checked with the
compressor running after having reached a stabilized condition.

(d) Thermostatic expansion valves must be checked for proper superheat settings. Recommended superheat is 150F
to 200F.
(e) Using suitable instruments, carefully check line voltage and amperage at the compressor terminals. Voltage must
be within ±10% of that indicated on the compressor nameplate. If high or low voltage is indicated, notify the power
company. The current normally should not exceed 110% of the nameplate rating. If amperage draw is excessive,
immediately determine the cause and take corrective action. On three phase compressor motors, check to see
that a balanced load is drawn by each phase.
(f) Carry out any necessary tests, recording airflow rates, entering/leaving temperatures, sound levels, outdoor tem-
peratures, supply airflow rates in occupied spaces and any other specified parameters.

BELT TENSION TESTING PROCEDURE INSTRUCTION

To determine the lbs. force required to tension a drive, you simply do the following:
1. Measure the Belt span as shown.
2. Divide belt span by 64 to get belt deflection needed to check tension.
3. Set large "0" ring on span scale at required belt deflection. This scale is in 1/16" increments.
4. Set small "0" ring at zero on the "Force Scale" (plunger).
5. Place the larger end of the tension checker squarely on one belt at the center of the belt span. Apply force on the
plunger until the bottom of the large "0" ring is even with the top of the next belt or with the bottom of a straight edge
laid across the sheaves.
6. Read the force scale under the small "0" ring to determine force required to give the needed deflection.
7. Compare the force scale reading with the correct value for the belt style and cross section used, as given in table on
next page. The force should be between the minimum and maximum values shown.
8. If there is too little deflection force, the belts should be tightened. If there is too much defection force, the belts
should be loosened.
EXAMPLE
1. Belt Span 64" (Small Sheave is 3.0 P.D. with "A" type belt.
2. 64 = 1" Deflection needed.
64
3. Set large "0" ring at 1" on span scale.
4. Set small "0" ring at zero plunger.
5. Check the force – lbs. required for a 1" deflection of the belt.
6. Press down on plunger until the bottom of the large "0" ring is even with top of the next belt in the set or with the bottom
of a straight edge.
7. 'A' type belts table shows an "A" belt with 3.0" P.D. Small sheave should have a deflection force between 1-1/2 lbs.
and 2-1/8 lbs.
8. Increase or decrease the tension on belts until the deflection force is between 1-1/2 lbs. 2-1/8 lbs.
NOTE:
Tension new drives at the maximum deflection force recommended. Check the tension at least two times during the first
day's operation as there normally will be a rapid decrease in belt tension until belts have run in. Check the tension
periodically after the first day's operation and keep tension in recommended area. The correct operating tension for a
V-belt drive is the lowest tension at which the belts will not slip under the peak load conditions. Shafts must be adequate
for the tensions required.

38
 BELT TENSION TESTING PROCEDURE

BELT SPAN
DEFLECTION =
64
FORCE SCALE
SMALL
"0"
RING
BELT SPAN

SPAN SCALE
LARGE
"0"
RING

BELT TENSION CHECKER MEASURE THE BELT DEFLECTION FORCE

BELTS
BELT DEFLECTION FORCE - LBS.
BELT SMALLEST
CROSS SHEAVE DIA. RPM SUPER GRIPBELTS & GRIPNOTCH BELTS &
SECTION RANGE RANGE UNNOTCHED GRIPBANDS NOTCHED GRIPBANDS (X)
USED BELT NEW BELT USED BELT NEW BELT

A, AX 3.0 – 3.6 1000 – 2500 3.7 5.5 4.1 6.1

2501 – 4000 2.8 4.2 3.4 5.0
1000 – 2500 4.5 6.8 5.0 7.4
3.8 – 4.8
2501 – 4000 3.8 5.7 4.3 6.4
1000 – 2500 5.4 8.0 5.7 9.4
5.0 – 7.0 2501 – 4000 4.7 7.0 5.1 7.6
B, BX 860 – 2500 – – 4.9 7.2
3.4 – 4.2 2501 – 4000 – – 4.2 6.2
860 – 2500 5.3 7.9 7.1 10.5
4.4 – 5.6
2501 – 4000 4.5 6.7 7.1 9.1
860 – 2500 6.3 9.4 8.5 12.6
5.8 – 8.6
2501 – 4000 6.0 8.9 7.3 10.9
500 – 1749 – – 10.2 15.2
5V, 5VX
4.4 – 6.7 1750 – 3000 – – 8.8 13.2
3001 – 4000 – – 5.6 8.5
7.1 – 10.9 500 – 1740 12.7 18.9 14.8 22.1
1741 – 3000 11.2 16.7 13.7 20.1
500 – 1740 15.5 23.4 17.1 25.5
11.8 – 16.0
1741 – 3000 14.6 21.8 16.8 25.0

39
 ELECTRICAL
ELECTRIC POWER SUPPLY
All wiring should be in accordance with National Electric Code and local standards.

Before making an installation, check the electric power supply. The power supply must be of the same characteristics as
that on the nameplate.

Normally the wire size used establishes the circuits maximum permissible load. For example a number 12 wire circuit is
considered to be a 20 ampere circuit and is protected by a 20 ampere fuse. The unit amperage nameplate rating should
not exceed 80% of the circuit rating, 16 amperes.

When identifying electrical trouble in any unit, check the power supply at the main disconnect switch and the unit. A high
or low voltage condition may prevent the unit from starting, or if the unit is running, compressor can cut-off automatically
on the motor overload. On some installations, the voltage may be entirely adequate when tested, but may drop or surge
some time later due to increase or decrease of load on the power line. This condition may be repeated daily at the same
hour. When this condition is suspected, make arrangements with the local power supplier to place a recording voltmeter
on the line to check and correct the erratic voltage conditions.

The voltage drop should not be more or less than 10% of the units rated voltage. If the voltage at the meter is correct, but
the voltage at the unit fluctuates 10% or more, the branch circuit is not adequate.

UNBALANCED VOLTAGE
Unbalanced voltage on a three phase circuit may be the source of electrical trouble. If balanced supply voltages are not
always maintained, so with the three line currents will not be equal. Unbalanced voltage on a three phase compressor
motor may overheat and trip the motor on external or internal current sensing motor protector, whichever one is provided.

To determine that an unbalanced voltage condition exists, the supply voltage at the main disconnect switch and at the
unit disconnect switch should be measured. Voltage unbalance is calculated as follows.
The percentage of voltage unbalance equals one hundred times the ratio of the Maximum Voltage Deviation from the
Average Voltage, and the Average Voltage.

Maximum voltage deviation from average voltage

Voltage unbalance, % = 100 x
Average voltage

The percentage increase in temperature rise in a phase winding resulting from voltage unbalance will be approximately
two times the square of the voltage unbalance.

Because of the unbalanced voltage condition in a three phase circuit, it is possible that one phase winding in the com-
pressor motor may be over-heated while the other have a temperature within normal limits. Where unbalanced voltage on
a three phase circuit exists, the power company should be notified of such unbalance to determine, if the situation can be
corrected.

A common source of unbalanced voltage on a three phase circuit is a single phase load between two of the three phases.
A large lighting or heating circuit connection to one phase of a three phase circuit can easily cause sufficient variations in
motor currents to endanger the motor. Interchange the single phase loads to equally divide the entire loads among the
three phases. Balance the supply voltage as evenly as possible.

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

40
FAN MOTOR
The condenser fan motor is a single speed 3 phase electrical motor with ball bearings, protected with an automatic reset
internal overload. The motor is totally enclosed and permanently lubricated.

CRANKCASE HEATERS
The function of the crankcase heater is to hold the compressor oil reservoir at a temperature higher than the coldest part
of the system. The low wattage heaters are energize continuously and it is not necessary to have them de-energize when
the compressor is operating.

Power must be supplied to crankcase heater for minimum of 12 hours prior to system start up. If power is off 6 hours or
more, crankcase heater must be on for 12 hours before operating the system. Failure to follow these instructions may
result in compressor damage.

Crankcase heaters are effective to retard migration of liquid refrigerant to the crankcase during off cycle. But they are not
a remedy for slugging or flood back due to liquid refrigerant accumulating in a trapped suction line, improper piping
practice, over feeding to the evaporator, leaking solenoid valve, etc.

In some cases where migration of refrigerant to the crankcase occurred due to long storage time, shutdown period,
defective components, etc. The crankcase heater may be ineffective. Such cases may be easily observed by high oil
level and cold crankcase. In these cases, it is highly recommended to front seat or close both suction and discharge
service valves of the compressor and release all liquid refrigerant from the compressor.

The liquid refrigerant dilutes the oil in the crankcase and the refrigerant rich oil will be pumped to the rods and the
bearings through the crankshaft. As the refrigerant boils off, there will not be enough oil for sufficient lubrication at the
bearings furthest from the oil pump. The center and rear bearings may seize or may wear enough to allow the rotor to
drop and drag on the stator causing it to short. Also the liquid refrigerant washes the oil off the pistons and cylinders
during the suction stroke causing them to wear during the compression stroke.

When the crankcase is filled with liquid refrigerant and the compressor starts severe agitation, oil foaming etc. will cause
major damage to the compressor.

Periodic checking for proper operation of crankcase heater is highly recommended.

LUBE OIL PROTECTION CONTROL

Pressure lubricated refrigeration compressors require a pressure protector in the event of an oil pressure failure. The
lube oil pressure protection control is factory set to conform with compressor manufacturers specifications and should
not be changed.

The control measures the net oil pressure available to circulate oil through the lubrication system. The positive displace-
ment oil pump circulates the refrigerant oil through the lubrication system. Since the oil pump is connected directly to the
compressor crankcase, the inlet pressure to the oil pump will always be the crankcase pressure. The oil pump outlet
pressure will be the crankcase pressure plus the oil pump pressure. Therefore, net oil pump pressure will always be the
pump outlet pressure minus the crankcase pressure.

The control contains a built-in time delay switch that is a trip-free expansion rod device actuated by a resistance heater.

The control is factory set to cut-in at 18 PSIG and cut out at 9 PSIG. When the compressor starts the resistance heater
of the time delay becomes energized. If the net oil pressure does not build to 18 PSIG or above within 120 seconds, the
time delay trips to stop the compressor. If the net oil pressure drops below 18 PSIG, but not below 9 PSIG during a
running cycle, the time delay resistance heater becomes energized and unless the net oil pressure returns to 18 PSIG or
above during the 120 seconds safety time period, the compressor will shut down. The compressor will shut down when-
ever the net oil pressure drops below 9 PSIG, and will never run for more than the predetermined 120 seconds on
abnormal oil pressure.

41
 OIL PUMP CRANKCASE NET OIL
OUTLET PRESSURE PRESSURE PRESSURE

78 _ 60 = 18

New series of solid state lube oil protection controls with modern pressure transducers are replacing the old type me-
chanical expansion rod-resistance heater type oil protection controls.

FEATURES:
• An entirely new control concept. This unique design incorporates a modern pressure transducer to monitor oil pressure.
• Each control reflects improved calibration stability over the control's entire pressure range.
• Controls boast truly accurate timing despite ambient temperature and voltage variations.
• All electronic components are purposely "over-sized" and computer-matched to provide the greatest safety factor and
dependable service life.
• Control's solid state circuitry is completely encapsulated to protect the components from the harmful effects of vibra-
tion, dirt or moisture.
• Controls reset instantaneously, thanks to the precise solid state timing circuit. No annoying wait for old-fashioned timer
heater to cool down.
• Control module is interchangeable with the old type conventional oil protection and with competitive brands of oil
protection controls. An exact replacement from a mounting, wiring and logic function standpoint.
• Control maintains timing over the full voltage range of 102 to 264 VAC. Voltage selection is not necessary.
• Unit is not position sensitive.
• Users are offered a choice of controls with or without cover, a handy mounting bracket and other options.
• "Logic" circuitry in the module monitors oil pressure pulses during marginal operation and integrates them resulting in
a longer span of time before lock-out occurs.
• Last, but not least, it has enlarged the reset button to a new "thumb-sized" dimension. The reset button is slightly
recessed to protect it from damage.

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

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

LINE VOLTAGE
UNDER VOLTAGE OVER VOLTAGE PHASE IMBALANCE
RANGE
TRIP RE-SET TRIP RE-SET TRIP RE-SET
190 - 480 VAC 90% 93% 110% 107% 6% 4.5%

42
 REFRIGERATION
COMPRESSOR
Single scroll compressors are used as standard for models PTH006, dual scroll compressors for PTH007 - PTH035 and
quadruple scroll compressors for PTH040 - PTH060. All compressors are conforming to AHRI 540. The compressors are
equipped with internal motor protection; factory installed crankcase heater and rubber vibration isolators for quiet and
efficient operation. Each compressor has lock-out devices to protect it from short cycling when tripped by safety controls.
The compressor motors conform to NEMA MG-1 & MG-2.
Scroll Compressors are used in some of these units. The major benefits being:
1. Low Sound Level: Quieter operation because of no dynamic suction and discharge valves action.
2. Low vibration and discharge pulses.
3. High Energy Efficiency: Because of high volumetric efficiency it minimize pressure and heat transfer losses.
4. High Capacity: Due to its high mass flow and high compression ratios.
5. High Durability: With its robust design, few moving parts, low motor strains, large internal volume for liquid handling
makes this compressor highly reliable.
6. High Charge Limit: Therefore, lower applied costs as no suction accumulator required, no need for pump down system
and check valve in discharge line.
Low capacity can be caused by inefficient compressor, that is, the compressor does not pump sufficient quantity of
refrigerant, even though a full charge is available in the system.
Electrical and mechanical tests should be performed to determine if the compressor is defective. If the compressor is found
to be all right but the electrical components are defective, remove and replace the defective electrical components only.
Below are some tests that should be performed on the compressor to determine, if the compressor is defective.
1. Test compressor motor winding for ground.
2. Test compressor motor windings for continuity.
3. Test that compressor motor will run both without a load and under a load.
4. Test the current or ampere drawn.
5. Observe sound level of compressor.
To establish that the compressor suction and discharge valves are operating and holding properly, attach gauges to the
liquid and suction service valves. "Front seat" the liquid service valve.
Start the compressor, allowing it to operate long enough to pump down to approximately 1 PSIG. Shut the compressor off
and observe the compound gauge. The gauge pressure may build rapidly. Repeat the pump down process several times
observing the gauge pressure each time after the compressor stops. If the gauge pressure builds rapidly each time after
the compressor stops, it indicates that the compressor discharge valves are not holding and refrigerant is leaking from
the high side to the low side of the compressor.
To check the suction valves, assuming that the discharge valves are holding, allow the compressor to operate long
enough to pump down the system to approximately 10 inches of vacuum. If the compressor required longer time to
accomplish this, then the suction valves are not holding and the compressor should be changed out as it is defective.
MOTOR COMPRESSOR BURN OUT PROCEDURE
The extent of the contamination in a system will indicate the amount of clean-up necessary. If a compressor had burned
out, the following method of clean-up is recommended:
1. Discharge the refrigerant from the system.
2. Replace the inoperative compressor.
3. Clean up the system thoroughly and remove all the contaminations.
4. Install a system cleaner or filter drier in the suction line and replace the liquid line filter drier.
5. Connect a vacuum pump to both the low and the high side of the system to remove air and other non-condensables from
the system.
6. Allow the vacuum pump to operate until a pressure of 500 microns is achieved.
7. Recharge the system and allow it to operate 8 to 12 hours.
8. Take an oil sample and test for acidity.

43
If the first acidity test shows that the acid content is below the safe level, as indicated in the test kit instructions, and the
oil is clean, the clean-out system can be removed. If an in-line suction filter drier was used, it can remain in the system
provided the pressure drop through the filter does not exceed the manufacturers listed pressure drop. For a badly
contaminated system that indicates acid in the oil after 8 to 12 hours of operation, change the suction and liquid line filter-
driers and check the system after 24 hours of operation.

There are instances where contaminants are discovered in a refrigeration system with the compressor still operational.
The same procedure applies, when cleaning these systems, as on a compressor burn-out.

SOURCE OF CONTAMINATION
There are many ways in which a refrigerant system can become contaminated. The most common of these are as
follows:
1. Improper or inadequate dehydration.
2. Wet refrigerant.
3. Wet oil (caution: It is best to purchase oil in small containers and use as needed. Open containers will absorb mois-
ture).
4. Refrigerant leaks (allowing system to operate in a vacuum).
5. Failure to remove oil and moisture after having opened the system for repair.
6. Higher than normal operating temperatures and pressures will cause a breakdown of the oil and refrigerant.
7. Using oil other than specified (Sunoco 3G is recommended).
8. Improper use of soldering or brazing flux.

HIGH PRESSURE SWITCH

A high pressure switch is located in the discharge line and senses the discharge pressure. Should the discharge pressure
exceed 650 psig, the control will open turning off the compressor. The control is designed to protect against excessive
discharge temperatures and pressures which can cause compressor overheating and damage to the motor windings or
valves.

Should the control open, it will remain open until the pressure in the system is lowered to 500 psig. Tripping of the high
pressure control is normally due to:
1. Restricted condenser coil.
2. Overcharge of refrigerant.
3. Defective fan motor or fan capacitor.
4. Incorrect fan blade.
5. Fan motor internal overload tripping due to lack of lubrication or defective bearings.
To test the high pressure control: Install a high pressure gauge to the access valve or the liquid line valve. Disconnect the
condenser fan motor. Turn on the unit and observe the pressure on the gauge when the compressor trip off. The pressure
should be 650 ± 15 psig. Allow the system to remain off, until the gauge pressure drop to approximately 500 ± 22 psig and
reconnect the condenser fan motor. Reset the unit by putting off the thermostat and if the high pressure control has
closed, the compressor will restart.

LOW PRESSURE SWITCH

To provide protection for the compressor in the event of refrigerant loss, a low pressure control is installed in the suction
line.

The control is preset to open when the suction pressure is 50 psig. The contacts of the control will close when the suction
pressure rises to 90 psig. To test the control for the correct pressure setting, install a compound gauge to the gauge port on
the suction service valve. "Front seat" the liquid valve and start the unit. Note the gauge pressure, when the compressor
stops.

To determine the cut-in pressure, allow the suction pressure to build slowly and observe the gauge pressure at the time
when contact closes. A good functional low pressure switch must have both cut-out and cut-in pressure within ± 2 psig.

44
PUMP DOWN CONTROL
A pump down control is a solenoid type valve installed in the liquid line to prevent the flow of refrigerant into the evapo-
rator during the off cycle. The valve is mounted in the liquid line refrigerant stream or at other suitable location in the liquid
line, but ahead of metering device.

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

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

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

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

Below are some conditions which may exist in an installation where additional protection is required:
1. Migration of refrigerant to the compressor during the off cycle.
2. Flooding, at start-up, due to improperly trapped lines or coil.
3. Suction line in slab or beneath ground forming a large trap.
4. Suction line in cool area causing refrigerant to condense during off cycle.
5. Where condensing unit is installed using existing coils and copper lines, or on a new installation where the above said
conditions exist that cannot be avoided, which could result in compressor damage.

45
 TROUBLE SHOOTING CHART
SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE
Compressor will not start – no 1. Line disconnect switch open. 1. Close start or disconnect switch.
hum. 2. Replace fuse.
2. Fuse removed or blown.
3. Overload protector tripped. 3. Refer to electrical section.
4. Control stuck in open position. 4. Repair or replace control.
5. Relocate control.
5. Control off due to cold location.
6. Check wiring against diagram.
6. Wiring improper or loose. 7. Replace or relocate.
7. Thermostat defective or improperly 8. Trace control circuit with wiring dia-
installed. gram and repair.
8. Control circuit open. 9. Replace the compressor with all pre-
9. Burned/open circuit motor winding. cautions.

mkmpressor will not start – 1. Improperly wired. 1. Check wiring against diagram.
hums but trips on overload 2. Low voltage to unit. 2. Determine reason and correct.
protector.
3. Compressor motor has a winding 3. Replace compressor.
open or shorted. 4. Replace compressor.
4. Internal mechanical trouble in com- 5. Check crankcase heater.
pressor.
6. Unequilized pressure in the system.
5. Liquid refrigerant in compressor.
6. High discharge pressure.

Compressor starts and runs, 1. Additional current passing through 1. Check wiring diagram. Check for
but short cycles on overload overload protector. added fan motors, pumps, etc. con-
protector. 2. Low voltage to unit (or unbalanced if nected to wrong side of protector.
three phase). 2. Determine the reason and correct.
3. Overload protector defective. 3. Check current, replace protector.
4. Excessive discharge pressure. 4. Check airflow across the condenser
5. Suction pressure too high. coil, restrictions in refrigeration system.
6. Compressor too hot - return gas hot. 5. Check for possibility of misapplica-
tion. Use stronger unit.
6. Check refrigerant charge (fix leak),
add if necessary.

Space temperature too high. 1. Control setting too high. 1. Reset control.
2. Expansion valve too small. 2. Use larger valve.
3. Cooling coils too small. 3. Add surface or replace.
4. Inadequate air circulation. 4. Improve air movement.
Suction line frosted or sweating. 1. Expansion valve passing excess re- 1. Re-adjust valve or replace with smaller valve.
frigerant or is oversized. 2. Clean valve of foreign particles, re-
2. Expansion valve stuck open. place if necessary.
3. Evaporator fan not running. 3. Determine reason and correct.
4. Overcharge of refrigerant. 4. Correct charge.
Liquid line frosted or sweating. 1. Restriction in dehydrator or strainer. 1. Replace part.
2. Liquid shut-off valve partially closed. 2. Open valve fully.

46
 TROUBLE SHOOTING CHART
SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE
Units runs OK, but short 1. Overload protector. 1. Check the cause.
cycles on. 2. Thermostat. 2. Differential set too close - widen.
3. High pressure cut-out due to: 3. (a) Check airflow to the condenser
(a) Insufficient air. correct.
(b) Overcharge. (b) Reduce refrigerant charge.
(c) Air in system. (c) Purge.
4. Low pressure cut-out due to: 4. (a) Fix leak, add refrigerant.
(a) Undercharge. (b) Replace device.
(b) Restriction in expansion device.
Unit operates long or continu- 1. Shortage of refrigerant. 1. Fix leak, add charge.
ously. 2. Control contacts stuck or frozen 2. Clean contacts or replace control.
closed. 3. Determine the fault and correct.
3. Refrigerated or air conditioned space 4. Replace with larger system.
has excessive load or poor insulation.
5. Defrost.
4. System inadequate to handle load.
6. Determine location and remove.
5. Evaporator coil iced.
7. Clean condenser.
6. Restriction in refrigeration system.
8. Clean or replace.
7. Dirty condenser.
8. Filter dirty.
Evaporator ices up. 1. Restricted airflow. 1. Check for dirt or lint on coil.
2. Dirty air filter. 2. Clean or replace. Advice customer
3. Short of refrigerant. on periodic cleaning of filter.
4. Low air volume. 3. Check system pressure. Take super-
heat reading. Add refrigerant.
5. Restricted distributor tube.
4. Check for dirty air filter or loose belt.
6. Restricted liquid line/low liquid line
pressure. 5. Check for warm distributor tube.
6. Check for restriction in lines/improve
liquid line pressure by proper charg-
ing or installing fan cycle switch, etc.
Head pressure too high. 1. Refrigerant overcharge. 1. Correct the refrigerant charge.
2. Air in system. 2. Recharge the system after a thorough
3. Dirty condenser. triple evacuation.
4. Malfunction of condenser fan (air- 3. Clean.
cooled). 4. Check and correct or replace.
5. Excessive air temperature entering 5. Check for short circuiting of con-
condenser. denser discharge air, correct it.
6. Restriction in discharge line. 6. Correct it.
Head pressure too low. 1.Low ambient temperatures (air- 1. Install fan cycling switch, if not pro-
cooled). vided. Check the setting and opera-
2. Refrigerant shortage. tion, if provided.
3. Damaged valves in compressor. 2. Correct the refrigerant charge after
leak testing.
3. Repair/replace the compressor.

47
 TROUBLE SHOOTING CHART
SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE
High suction pressure. 1. High load on evaporator. Load in ex- 1. Check the design.
cess of design conditions. 2. Follow manufacturer's guide line and
2. Unbalanced system. Oversized air han- correct it.
dling unit matched with under sized 3. Repair/replace compressor.
condensing unit.
4. Check and adjust the superheat ac-
3. Compressor discharge valve leaking. cordingly.
4. Expansion valve widely open. 5. Check the expansion valve bulb is
5. Improper bulb location or installation. properly tighten at correct location.

Loss of oil pressure. 1. Loss of oil from compressor due to: 1. (a) Correct the system piping.
(a) Oil trapping in system. (b) Trace out the wiring/defective con-
(b) Compressor short cycling. trols/components, etc. and correct it.
(c) Insufficient oil in system. (c) Add oil.
(d) Operation at excessively low suction (d) Check the superheat of expansion
pressure. valve and other possible causes
like clogged filter, low CFM, iced
2. Excessive liquid refrigerant returning to
evaporator etc. & correct it.
compressor.
2. Check the system for correct super-
3. Malfunctioning oil pump.
heat & other possible causes like
4. Restriction in oil pump inlet screen. clogged filter, low CFM, iced evapo-
rator, etc. and correct it.
3. Repair or replace it.
4. Clean/replace it (oil change recommended).
Relay defective or burned out. 1. Incorrect relay. 1. Check and replace.
2. Incorrect mounting angle. 2. Remount relay in correct position.
3. Line voltage too high or too low. 3. Determine reason and correct.
4. Excessive short cycling. 4. Determine reason and correct.
5. Relay being influenced by loose mounting. 5. Remount rigidly.

Unit noisy. 1. Loose parts or mountings. 1. Find and tighten.

2. Tubing rattle. 2. Tighten the pipe support.
3. Bent fan blade causing vibration. 3. Replace blade.
4. Fan motor bearings worn. 4. Replace motor.

48
 RECOMMENDED SPARE PARTS
PERCENTAGE OF SPARE PARTS
ITEM ONE YEAR SUPPLY TWO YEAR SUPPLY
100 UNITS 1000 UNITS 100 UNITS 1000 UNITS

Compressor 2% 1% 3% 2%

Capacitor 3 2 5 4
Condenser fan motor 2 1 3 2
Evaporator blower motor 1 0.5 2 1

Belt 2 1 4 3
Contactor compressor 2 1 3 2
Contactor heater 2 1 3 2

Contactor fan motors 2 1 3 2

HPS/LPS/other controls 2 1 3 2
Expansion valve 1 0.5 2 1

Filter drier 2 1 3 2
Electric heater 1 0.5 2 1
Fuse link, heater 3 1 4 3
Transformer (24V secondary) 1 0.5 2 1

Propeller fan 1 0.5 2 1

Blower Wheel 0.5 0.25 1 0.5
Bearing-blower 2 1 4 2

Thermostat (Wall) 1 1 2 1
Heater-crankcase 3 1 4 2
Filter 2 1 4 4
NOTE : When ordering spare parts, please quote the complete model number on the unit nameplate.

49
 PREVENTIVE MAINTENANCE SCHEDULE
FREQUENCY OF MAINTENANCE, MONTHS
ITEM
1 3 6 12

Clean air filters & replace if required. X

Clean evaporator coil, drain pan & drain line. X

Clean condenser coil. X

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

Lubricate blower motor/condenser motor. X

Check alignment of pulleys. X

Check/clean electrical connections, controls & control box. X

Check motors, blower bearings & lubricate it. X

Check all electrical control components, wiring terminals etc. for spark, X
overheating & loose connections. Replace/correct as necessary.
Check all damper operation. Repair/replace as required. X

Check insulation flanking. Repair/replace as required. X

Check loose bolts/screws & tight as necessary. X

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

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

Check flexible canvas connections & duct work. Repair/replace as required. X

Run test all motors and check the amperage, abnormality etc. X
Run test compressors and check the amperage, noise, oil level, pressure
etc. and correct them accordingly. X
Check the thermostat/control devices for correct operation, calibrate/
re-adjust as required. X

Apply corrosion inhibitor/contact cleaner as required. X

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

NOTE: Always observe for abnormal noise or vibration.

MAINTENANCE TOOLS/EQUIPMENT REQUIRED

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

SPECIAL : Manifold gauge set, R-410A charging cylinder, belt tension checker, leak detector, vacuum pump with
electronic gauges, thermometer & hook type ammeter/voltmeter/ohmmeter.

50
51
 FILTER DIMENSIONS

2" ALUMINUM FILTER 2" PLEATED FILTER 4" MINI PLEATED FILTER 15" BAG FILTER
MODEL
DIMENSION QTY. DIMENSION QTY. DIMENSION QTY. DIMENSION QTY.
12x20 1 12x20 1 12x20 1 12x20 1
PTX003
20x20 1 20x20 1 20x20 1 20x20 1
12x20 1 12x20 1 12x20 1 12x20 1
PTX004
20x20 1 20x20 1 20x20 1 20x20 1
12x20 1 12x20 1 12x20 1 12x20 1
PTX005 1 1 1 1
20x20 20x20 20x20 20x20
12x20 1 12x20 1 12x20 1 12x20 1
PTX006 2 2 2 2
20x20 20x20 20x20 20x20
12x20 1 12x20 1 12x20 1 12x20 1
PTX007 2 2 2 2
20x20 20x20 20x20 20x20
12x20 1 12x20 1 12x20 1 12x20 1
PTX008 20x20 2 20x20 2 20x20 2 20x20 2
12x20 1 12x20 1 12x20 1 12x20 1
PTX010
20x20 2 20x20 2 20x20 2 20x20 2
24x20 2 24x20 2 24x20 2 24x20 2
PTX012 4 4 4 4
20x20 20x20 20x20 20x20
24x20 2 24x20 2 24x20 2 24x20 2
PTX016 20x20 20x20 20x20 20x20
4 4 4 4
24x20 2 24x20 2 24x20 2 24x20 2
PTX018 20x20 4 20x20 4 20x20 4 20x20 4

PTX022 20x20 8 20x20 8 20x20 8 20x20 8

PTX025 20x20 8 20x20 8 20x20 8 20x20 8

PTX027 24x20 8 24x20 8 24x20 8 24x20 8

PTX030 24x20 8 24x20 8 24x20 8 24x20 8

PTX035 24x20 8 24x20 8 24x20 8 24x20 8

20x24 4 20x24 4 20x24 4 20x24 4

PTX040 20x20 8 20x20 8 20x20 8 20x20 8
20x24 4 20x24 4 20x24 4 20x24 4
PTX045 20x20 8 20x20 8 20x20 8 20x20 8
20x24 4 20x24 4 20x24 4 20x24 4
PTX050 20x20 8 20x20 8 20x20 8 20x20 8
24x20 6 24x20 6 24x20 6 24x20 6
PTX060 24x24 3 24x24 3 24x24 3 24x24 3
24x20 6 24x20 6 24x20 6 24x20 6
PTX070 24x24 3 24x24 3 24x24 3 24x24 3
24x20 12 24x20 12 24x20 12 24x20 12
PTX080 24x24 6 24x24 6 24x24 6 24x24 6
24x20 12 24x20 12 24x20 12 24x20 12
PTX100 24x24 6 24x24 6 24x24 6 24x24 6

52