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Installation/Service Manual Remote Condensing Unit

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1. ened FIELD WIRING UNIT WIRING CONDENSOR r nu i sd d FAN MOTOR BLK 1 HI PSI 2 CUTOUT RELAY BEP WHT T RED 2 5 HEATER BLK SWITCH 2 BLR 55 BLK GRAY gt 54 Tee BLK O 11 L1 04 Paap OO 52 o 7012 Es l 24 WHT E RED 72 S a R YEL n L L 1 4 FAN RUN ADM SIME LINE EE me he LINE ea RD GND 29 COMPRESSOR RED A BLK BLK BLK 4990 REV A FIGURE 4 WIRING DIAGRAM 1997 2014 Cornelius Inc 10 Publication Number 301138000 TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring WARNING A Trouble Probable Cause TROUBLESHOOTING REFRIGERATION COMPRESSOR COMPRESSOR COOLS BUT IS VERY NOISY ESPECIALLY WHEN STOPPING AND STARTING COM
2. 15 LIST OF TABLES TABLE 1 DESIGN DATA SAFETY INFORMATION Recognize Safety Information This is the safety alert symbol When you see this symbol on our machine or in this manual be alert to the potentially of personal injury Follow recommended precautions and safe operating practices Understand Signal Words A signal word DANGER WARNING OR CAUTION is used with the safety alert symbol DANGER identi fies the most serious hazards Safety signs with signal word DANGER or WARNING A WA R N N G are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety mes A CAUTI O N sages in this manual Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Learn how to operate the machine and how to use the controls properly Do not let anyone operate the machine without instructions Keep your machine in proper working condition Unauthorized modifications to the machine may impair function and or safety and affect the machine life Carbon Dioxide Warning CO Displaces Oxygen Strict Attention must be observed in the prevention of carbon dioxide gas leaks in the entire system If CO gas leak is suspected particularly in a small area im mediately ventilate the contami
3. Shipping Weight approx 290 Pounds Publication Number 301138000 3 1997 2014 Cornelius Inc Table 1 Design Data cont d 2101 Ambient Operating Temperature 20 F to 120 F ZL Refrigeration Requirements D E Refrigeration Type and Charge See Unit Nameplate 2 Operating Voltage See Unit Nameplate See Unit Nameplate UNPACKING AND INSPECTION NOTE The Remote Condensing Unit was thoroughly inspected before leaving the factory and the carri er has accepted and signed for it Any damage or irregularities should be noted at time of delivery ornot later than 15 days from date of delivery and immediately reported to the delivering carrier Requesta written inspection report from Claims Inspector to substantiate any necessary claim File claim withthe delivering carrier not with Cornelius Inc 1 Unpack Remote Condensing Unit Remove all shipping tape and packing materials 2 Inspect and make sure Remote Condensing Unit is in good condition as instructed in preceding NOTE INSTALLATION SELECTING LOCATION Locate the Remote Condensing Unit so the following requirements are satisfied 1 The Remote Condensing Unit must be installed in a location which will allow shortest possible refrigeration lines route not to exceed 50 feet in length from Condensing Unit to the Evaporator Assembly The Con densing Unit must not be installed more than 10 feet below the Evaporator Assembl
4. provided inside electrical control box to connect power circuit ground wire which electrically grounds the Unit 6 Connect 208 230 60Hz or 220 240 VAC 50 Hz Single Phase electrical power circuit meeting require ments of SELECTING LOCATION to L4 and Lo N terminals on contactor inside the Unit electrical control box as shown in FIGURE NO TAG MAKE SURE POWER CIRCUIT GREEN GROUND WIRE IS INSTALLED UNDER GREEN GROUND SCREW INSIDE ELECTRICAL CONTROL BOX TO PROPERLY GROUND THE UNIT POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES 7 A24 VAC power circuit which must conform to national and local electrical codes must be routed and connected between the Evaporator Assembly Temperature Control and the Remote Condensing Unit Pur pose of the 24VAC power control circuit is to allow the Evaporator Assembly Temperature Control to con trol ON and OFF operation of the Remote Condensing Unit Route and connect 24VAC power control circuit between the Evaporator Assembly and the Remote Condensing Unit as follows A Route 24 VAC power control circuit electrical wires through hole in end panel to inside of the Remote Condensing Unit B Connect 24 VAC power control circuit electrical wires to labeled 24 V grey and red wires hanging out of the electrical control box C Install electrical control box cover and secure with screw Route 24VAC power control circuit
5. DO NOT BLOCK AIR CIRCULATION THROUGH THE UNIT 1997 2014 Cornelius Inc 4 Publication Number 301138000 4 If the Remote Condensing Unit is installed on the rooftop the Unit must be installed in a level position and must be anchored with adequate fastening devices INSTALLING REMOTE CONDENSING UNIT see Figures 2 3 and 4 1 Install Remote Condensing Unit meeting requirements of SELECTING LOCATION The Unit must be installed in a level position and must be anchored with adequate fastening devices NOTE The following Refrigeration Lines Kits are recommended to connect the Remote Condensing Unit to the Evaporator Assembly Contact Cornelius if refrigeration lines exceed 50 feet in length 308900025 Refrigeration Lines Kit 25 ft long 90 insulated 3 8 O D Liquid and 5 8 O D Discharge 308900050 Refrigeration Lines Kit 50 ft long 90 insulated 3 8 O D Liquid and 5 8 O D Discharge 2 Route refrigeration lines from Remote Condensing Unit to the Evaporator Assembly 3 Connect ends of refrigeration lines to Remote Condensing Unit refrigeration connectors 4 Remove four screws securing Remote Condensing Unit top cover then remove cover for access to electri cal control box 5 Remove one screw securing electrical control box cover then remove cover WARNING The Remote Condensing Unit must be electrically grounded to avoided possible fatal electrical shock or serious injury to the operator A green ground wire is
6. will automatically reset to restart the refrigeration system OPERATING IN THIS MANNER FOR PROLONGED PERIODS OF TIME COULD RESULT IN COMPRESSOR FAILURE The Remote Condensing Unit condenser coil must be cleaned every 30 days Circulating air required to cool the coil is drawn in through the coil and is exhausted out through grilles on end and back of the Unit Clean condenser coil as follows 1 Disconnect electrical power from Evaporator Assembly 24VAC Temperature Control Disconnect electrical power to Remote Condensing Unit at disconnect switch 2 3 Remove four screws securing top cover on Remote Condensing Unit then remove cover 4 Clean condenser coil using vacuum cleaner whisk broom or a soft bristle brush to remove any debris from coil e Make sure fan blade is not out of balance is not bent and is not striking any surface during rotation 6 If the Remote Condensing Unit has been installed on the rooftop check and make sure roof area immediately surrounding the Remote Condensing Unit is free and clear of any debris that may have collected such as leaves paper trash etc 7 Install top cover on Remote Condensing Unit and secure with four screws 8 Restore electrical power to Remote Condensing Unit at disconnect switch 9 Restore electrical power to Evaporator Assembly 24VAC Temperature Control Publication Number 301138000 7 1997 2014 Cornelius Inc TOP COVER TOP COVER RETAINING SCREVV 4 CO
7. 0001 FIGURE 5 REMOTE CONDENSER ASS Y Publication Number 301 138000 15 1997 2014 Cornelius Inc REMOTE CONDENSER ASS Y CON T Part No Description 4161170001 Remote Condenser Ass y 230V 60HZ 4961170001 Remote Condenser Ass y 230V 50HZ ju 819941000 Thread Rolling Screw SL Hex Washer HD No 8 32 By 3 8 in Long 3 E 5 7 1 f 3726 Compressor 230V 60HZ 3725 Compressor 230V 50HZ 2893 Motor 1 6 H P 230V 60HZ 2115 Motor 1 6 H P 230V 50HZ 324143000 Capacitor Start Fan 325956000 Strap Capacitor H 1 1 17 8 8 19 20 21 22 23 24 25 26 27 28 1997 2014 Cornelius Inc 16 Publication Number 301138000 REMOTE CONDENSER ASS Y CON T 325518000 Capacitor Run 230V 60HZ 3617 Capacitor Run 230V 50HZ 3 3 1 0 2 5 6 7 8 1 2 3 4 9 0 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 Publication Number 301138000 17 1997 2014 Cornelius Inc THIS PAGE LEFT BLANR INTENTIONALLY 1997 2014 Cornelius Inc 18 Publication Number 301138000 CORNELIUS INC ES CORPORATE HEADQUARTERS One Cornelius Place Anoka Minnesota 55303 6234 612 421 6120 800 238 3600
8. Guli CORNELIUS INC 28 One Cornelius Place 38 Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3246 Installation Service Manual REMOTE CONDENSING UNIT UNIT PART NUMBERS 416117 0001 R 404A Refrigerant 496117 0001 R 404A Refrigerant Publication Number 301138000 Revision Date May 06 2014 Revision B THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment 1997 2014 CORNELIUS INC PRINTED IN U S A TABLE OF CONTENTS SAFETY INFORMATION iik asa ais a k a ia ai RECOGNIZE SAFETY INFORMATION UNDERSTAND SIGNAL WORDS FOLLOW SAFETY INSTRUCTIONS CARBON DIOXIDE WARNING INSTALLATION ea ee emma ean TO THE USER OF THIS MANUAL DESCRIPTION Atia pots necu dot negat ated LES UNPACKING AND INSPECTION ti acom RA INSTALLATION ete cia Sea Mon ca tat SELECTING LOCATION erba et are INSTALLING REMOTE CONDENSING UNIT SERVICE AND MAINTENANCE PERIODIC INSPECTION DRI RIGATION C ES CLEANING CONDENSER COIL tea GC L
9. changed The noise will not affect the performance or shorten compressor life Compressor must be changed Clean condenser coil with vacuum cleaner low pressure compressed air or soft brush then allow compressor to cool and restart Voltage cannot be less than 198 V to start compressor Correct the loose or disconnected wires Contactor must pull in If no current is drawn or very little capacitor is open and must be replaced If capacitor is blown look for inoperable start relay or low voltage Note If all above checks have been made and compressor will not start increase start capacitor value by about 15 and try to start This can be done two ways The substitute capacitor must have voliage rating equal to or greater than the existing start capacitor a Remove existing capacitor and replace with one having a 15 greater MFD rating or step b b Wire capacitor that has 15 of the MFD rating in parallel with the existing capacitor c Try to start compressor If all the previous steps a and b will not make compressor operate label compressor stuck and replace Publication Number 301138000 11 1997 2014 Cornelius Inc Trouble Probable Cause Remedy COMPRESSOR STARTS BUT Inoperable Start Relay A Replace start relay WILL NOT OPERATE FOR MORE THAN A FEW Note To check relay remove SECONDS wire from No 1 terminal on start relay and touch to No 2 termi nal Start compressor and im me
10. from Remote Condensing Unit to the Evaporator Assembly loca tion E Refer to manual provided with the Evaporator Assembly for instructions to connect 24VAC power cir cuit to Evaporator Assembly Temperature Control Publication Number 301138000 5 1997 2014 Cornelius Inc THIS PAGE LEFT BLANR INTENTIONALLY 1997 2014 Cornelius Inc 6 Publication Number 301138000 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the Unit WARNING Disconnect electrical power to Remote Condensing Unit to prevent personal injury before attempting any internal maintenance Only qualified personnel should service internal components or electrical wiring PERIODIC INSPECTION Make sure Remote Condensing Unit Condenser Coil is free from debris Restricting air through the condenser coil will decrease the refrigeration systems cooling efficiency LUBRICATION The Remote Condensing Unit condenser fan motor must be lubricated once every six months with S A E 20W oil DO NOT OVER OIL CLEANING CONDENSER COIL CAUTION Remote Condensing Unit is equipped with a condenser coil that must be cleaned every 30 days Allowing condenser coil to become clogged will cause refrigeration system to overheat which will automatically shut refrigeration system down After condenser coil has been cleaned high pressure cutout sensing switch located inside the Remote Condensing Unit electrical control box
11. MPRESSOR CONDENSER COIL ELECTRICAL CONTROL BOX CONDENSER FAN MOTOR RECEIVER TANR REFRIGERATION LINES CONNECTORS FIGURE 2 PARTS IDENTIFICATION 1997 2014 Cornelius Inc 8 Publication Number 301138000 REMOTE ROOFTOP CONDENSING UNIT STRAINER DRYER EE HIGH PRESSURE CUTOUT SWITCH SERVICE VALVE 2 27 CONDENSER COIL hi i NG CE 1 3 A B i 4 Le EP LE FUMER neu 1 7 COMPRESSOR RECEIVER CONDENSER TANK BONDEGSER MOTOR FAN FAN HEATER HEAD PRESSURE SWITCH CONTROL NS REFRIGERATION EVAPORATOR ASSEMBLY LINES MUST NOT BE INSTALLED MORE THAN NOT TO EXCEED 10 FEET ABOVE REMOTE CONDENSING UNIT 50 FEET IN LENGTH FIGURE 3 REFRIGERATION FLOW DIAGRAM Publication Number 301138000 9 1997 2014 Cornelius Inc RECEIVER HEATER LEGEND
12. PRESSOR COOLS BUT IS MODERATELY NOISY LOUD ENOUGH TO BE NOTICED BUT NO SHARP BANGS OR CLATTERING COMPRESSOR OPERATES BUT REFRIGERATION SYSTEM DOES NOT COOL COMPRESSOR STARTS AND OPERATES FORA FEW SECONDS THEN STOPS COMPRESSOR WILL NOT START A Compressor cools but is very noisy especially when stopping and starting This is either a broken suspension spring or loose crank shaft extension Compressor cools but is moderately noisy loud enough to be somewhat annoying but no sharp bangs or clattering Look for a refrigerant leak or oil at tubing joints If compressor is moderately noisy and no leaks are evident it is probably a broken valve inside compressor Compressor running too hot due to condenser coils plugged with dust lint and grease restricting cooling air flow through the condenser coil Check line voltage across terminals on contactor loose or disconnected wires Check control circuit Examine start capacitor for signs of excessive heat blown up Check for open by connecting test cord and checking amp draw If repairs will be made to Remote Condensing Unit turn off electrical power to Evaporator Assembly then disconnect power to Remote Condensing Unit at disconnect switch before proceeding Remedy Compressor must be changed This is probably a discharge or suction tube rattling inside the compressor If noise level can be tolerated compressor need not be
13. R TROUBLESHOOTING 6010 0 ie Pate es TROUBLESHOOTING REFRIGERATION COMPRESSOR COMPRESSOR COOLS BUT IS VERY NOISY ESPECIALLY WHEN STOPPING AND STARTING COMPRESSOR COOLS BUT IS MODERATELY NOISY LOUD ENOUGH TO BE NOTICED BUT NO SHARP BANGS CLATTERING COMPRESSOR OPERATES BUT REFRIGERATION SYSTEM DOES NOTCOOL sz deien matei een ss e Pee rei e ed oo COMPRESSOR STARTS AND OPERATES FORA FEW SECONDS THEN STOPS ree ere tte t rec tee teg edt Dr tg COMPRESSOR WILL NOT START COMPRESSOR STARTS BUT WILL NOT OPERATE FOR MORE THAN FEW SECONDS cintes tao sasas UL k Yard Weeds TROUBLESHOOTING REMOTE CONDENSING UNIT COMPRESSOR DOES NOT OPERATE COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT COOL SUFFIGIENTEY tree Rex EU RM tel CONDENSER FAN MOTOR NOT OPERATING PARTS LIST a ea e uL n ene hata 11 11 11 TABLE OF CONTENTS cont Page LIST OF FIGURES FIGURE 1 REMOTE CONDENSING UNIT 3 FIGURE 2 PARTS IDENTIFICATION 8 FIGURE REFRIGERATION FLOW DIAGRAM 9 FIGURE 4 WIRING DIAGRAM 10 FIGURE 5 REMOTE CONDENSER ASS Y
14. diately remove wire from No 2 terminal If compressor starts and operates problem is in the start relay B Low Voltage B If less than 198 V is present upgrade Unit power source Note Remove compressor termi nals cover and connect voltme ter test leads between C top terminal and R lower right terminal Start compressor A minimum of 198 VAC nominal must be present to operate com pressor Unit run capacitor must be discharged by momentarily touching both capacitor terminals at the same time using an insulated handled screwdriver WARNING To avoid electrical shock even after electrical power has been disconnected from C Inoperative Run Capacitor C Inspect capacitor for bulges cracks or any external deformation If found assume capacitor is inoperable and replace If none of the above conditions are evident disconnect wires from capacitor Connect test cord to capacitor terminals Connect ammeter to one wire of test cord Plug test cord into electrical outlet and record amp reading See formula on next page at end of this trouble topic 1997 2014 Cornelius Inc 12 Publication Number 301138000 Trouble Probable Cause Remedy COMPRESSOR STARTS BUT D Grounded or Shorted Motor D Disconnect all electrical wires WILL NOT OPERATE FOR Windings from compressor terminals Set MORE THAN A FEW ohmmeter on 100 000 ohm scale SECONDS CONT D touch one lead to copper line or bare metal of compr
15. essor Touch other lead to each of the compressor terminals in succession Continuity must not be indicated If an ohmmeter reading is obtained then compressor is grounded and must be replaced To check for shorted windings set ohmmeter on 10 ohm scale Attach one lead to C top terminal The reading should be approximately 1 to 1 1 2 ohms Leave one lead on C terminal and touch other lead to S lower left terminal The reading should be 3 1 2 to 5 Ohms Leave one lead on S terminal and touch other lead to R terminal This reading should be exactly the sum of the first two readings obtained If the resistance readings do not fall within these limits the compressor is shorted or has an open winding and must be replaced Replace compressor 2650xAmp Use amps reading in formula vors eonz M F D to determine actual value of capacitor If calculated actual val ue is 10 more or less than rated value replace capacitor Publication Number 301138000 13 1997 2014 Cornelius Inc Trouble Probable Cause TROUBLESHOOTING REMOTE CONDENSING UNIT COMPRESSOR DOES NOT OPERATE COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT COOL SUFFICIENTLY CONDENSER FAN MOTOR NOT OPERATING 1997 2014 Cornelius Inc A Evaporator Assembly not calling for refrigeration Electrical power to Remote Condensing Unit turned off Electrical power to Evaporator Assembly turned off No Remote Condensing Unit power so
16. nated area before attempting to repair the leak Personnel exposed to high concentration of gas will experience tremors which are followed rapidly by loss of con sciousness and suffocation Publication Number 301138000 1 1997 2014 Cornelius Inc THIS PAGE LEFT BLANR INTENTIONALLY 1997 2014 Cornelius Inc 2 Publication Number 301138000 INSTALLATION TO THE USER OF THIS MANUAL This manual is a guide for installing and maintaining this equipment Refer to Table of Contents for page location of detailed information pertaining to questions that may arise during installation service and maintenance or troubleshooting this equipment This Unit must be installed and serviced by a qualified Service Person This Unit contains no user serviceable parts DESCRIPTION The Remote Condensing Unit consists basically of a refrigeration compressor a receiver tank a fan cooled condenser coil a head pressure control and a strainer dryer mounted on an enclosed platform The Remote Condensing Coil Unit see Figure 1 is designed to be used with any Evaporator Assembly with a rated temperature range of 10 F to 32 F The Evaporator Assembly is connected by refrigeration lines and is refrigerated by the Remote Condensing Unit FIGURE 1 REMOTE CONDENSING UNIT 230V 50 HZ Unit R 404A Refrigerant 4961170001 pU Overall Dimensions Height 22 1 4 inches Width 28 1 2 inches Depth 25 3 4 inches
17. urce Blown fuse or tripped circuit breaker Loose disconnected or broken wiring High pressure cutout switch tripped Low voltage Inoperable run capacitor or start relay Inoperable compressor Refrigeration capacity is exceeded by product overdrawing Air circulation through Remote Condensing Unit condenser coil is restricted Insufficient refrigerant charge Fan blade obstructed Inoperative condenser fan motor Compressor contactor inoperable Disconnected or broken electrical wire Remedy Refrigeration not called for Turn on electrical power to Remote Condensing Unit Turn on electrical power to Evaporator Assembly Replace fuse or reset circuit breaker Tighten connections or replace broken wiring High pressure cutout switch will automatically reset after refrigeration system pressure has lowered see CAUTION note under CLEANING CONDENSER COIL Voltage must be at least 198 V at compressor terminals when compressor is trying to start Replace inoperable part Replace compressor Reduce amount of product drawn per given time Check and if necessary clean condenser coil as instructed Find and repair refrigeration leak then replenish refrigerant charge Remove obstruction Replace condenser fan motor Replace compressor contactor Connect or repair broken electrical wire Publication Number 301138000 PARTS LIST UNIT PART NUMBERS 416117 0001 496117
18. y Dispenser DANGER To avoid possible fatal electrical shock or serious injury to the operator it is highly recommended that a GFI ground fault circuit interrupt be installed in the electrical circuit for the 60 Hz Units It is required that an ELCB earth leakage circuit breaker be installed in the electrical circuit for the 50 Hz Units 2 Close to a properly grounded 208 230 VAC 60HZ or 220 240 VAC 50Hz single phase electrical circuit with a 30 amp minimum rated disconnect switch not provided fused at 25 amps slow blow or power circuit connected through an equivalent HACR circuit breaker must be available to the Unit Use No 8 AWG cop per wire or larger depending upon line length in suitable conduit or BX sheath POWER CIRCUIT MUST BE MADE UP OF COPPER CONDUCTORS AND ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES MAKE SURE UNIT IS PROPERLY GROUNDED 3 An extreme warm climate installation may require extra caution in Remote Condensing Unit location Avoid hot sunny locations and seek shaded area if possible If Remote Condensing Unit is to be installed on the rooftop the use of a structure to shade the Unit from direct sun exposure and or a platform extending Unit an additional 18 inches above the roof is highly recommended and will improve performance Ample space 24 inches on all sides and 48 inches above Unit must be provided for proper air circulation through the Unit and also access for service and maintenance

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