Cooline PT036 Installation, Operation & Maintenance Manual
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Cooline PT036, TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PT300 - PT360 (Dual compressor units) LEGEND AR AUXILIARY RELAY AFS AIRFLOW SWITCH ATB AUXILIARY TERMINAL BLOCK BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CC COMPRESSOR CONTACTOR CCA AUXILIARY CONTACT CB CIRCUIT BREAKER C. HTR CRANKCASE HEATER COMP COMPRESSOR ECB ELECTRONIC CONTROL BOARD FCS FAN CYCLING SWITCH F FUSE FL FUSE LINK FM FAN MOTOR (CONDENSER) FMC FAN MOTOR CONTACTOR FR FAULT RELAY HC HEATER CONTACTOR HPS HIGH PRESSURE SWITCH HVTB HIGH VOLTAGE TERMINAL BLOC
Cooline PT036, UNIT DIMENSIONS PT036 - PT075 ABCDEFGHJKLM PT036 - PT060 1460(57.48) 1025(40.35) 1430(56.3) 700(27.56) 163(6.42) 373(14.68) 250(9.84) 500(19.69) 57(2.24) 304(11.96) 343(13.49) 340(13.39) PT075 1775(69.88) 1150(45.28) 1745(68.7) 800(31.5) 175(6.89) 480(18.9) 325(12.8) 672(26.46) 80(3.15) 280(11.02) 275(10.83) 600(23.62) MODEL DIMENSIONS NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides. 7 CONDENSATE DRAIN OUTLET [BOTH ENDS] MOUNTING HOLES Ø 13 [0.5] [ 4 EACH] K J 286 [11.27] 90 [3.53] 51 [2.00] 15 [0.59] 61 [2.41] 850 [33.46] FRESH AIR OPENING POWE
Cooline PT036, Contents Page General Model decoding ...................................................................................................................................................... 2 General statement .................................................................................................................................................. 3 Warranty ................................................................................................................................................................. 3 Safety issues ............................................................
JUMPER SETTING ON ECB DIP SWITCH SETTINGS HEATER DATA TABLE (SEE HEATER DATA TABLE) HEATER CONNECTION DETAILS TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PT036 - PT075 (Single compressor units) NOTE: 1. Refer to next page for legend, notes & wiring diagram for optional items. 2. Refer to unit control box (inside panel) for exact wiring diagram. 22
Cooline PT036, MIN. MAX. FLA RLA LRA HP FLA kW FLA – – 15.2 20 5/6 7.6/9.1 16.4/18.3 20/20 380/415-3-50 342 457 2.3 5.9 42 0.75 5.5 7.5/10* 11.4/15.2 21.1/25.9 25/30 12* 18.2 29.6 30 – – 20.8 30 5/6 7.6/9.1 20.8/20.8 30/30 380/415-3-50 342 457 2.3 10.4 55 0.75 5.5 7.5/10* 11.4/15.2 21.1/25.9 35/30 12* 18.2 29.6 30 – – 22.1 30 5/6 7.6/9.1 22.1/22.1 30/30 380/415-3-50 342 457 2.3 9.6 65 1 7.8 7.5/10* 11.4/15.2 24/28.8 30/30 12* 18.2 32.5 35 POWER SUPPLY (V-Ph-Hz) VOLTAGE RANGE BLOWER MOTOR ELECTRIC HEATER ELECTRICAL DATA (4 WIRE) FM COMPRES- SOR (4 WIRE) (4 WIRE) MODEL NUMBER PT036 PT048 PT060 342 457
Cooline PT036, 7. LEAD/LAG OPERATION: Whenever a compressor needs to be on, the controller will turn on the compressor with the shorter accumulated run time provided its 3 minutes minimum off time has lapsed. Otherwise the other compressor will on first. Similarly, the compressor with the longer accumulated run time will be the first one to be cut off. This is to load the compressors evenly over long run period. Balance loading is enabled when compressor #1 lead option is disabled. 8. AUTO MODE: In Auto mode, operating mode will be selected automatically between Heat and Cool mode, dep
Cooline PT036, TROUBLE SHOOTING CHART SYMPTOM CAUSES CHECK & CORRECTIVE MEASURE 1. Low suction pressure 2. High discharge pressure 3. Less air quantity 4. Cooling coil ices up 5. Second stage (If exists) not working 6. Serving large area 1. Low ambient condition 2. Safety low pressure switch open due to low suction pressure 3. Fan cycling (whenever applicable) setting low 4. Thermostat setting too low 5. Cooling coil ices-up 6. Less air quantity 1. High discharge pressure 2. High thermostat setting 3. Serving large area 4. Less air quantity 5. High ambient condition 6. Dirty condenser 1. Less freon 2. Less air quantity 3. Dirty filter 4. D
Cooline PT036, HEATER DATA TABLE CONNECTION FOR MANUEROP COMP. WITH SSPS CONNECTION FOR COMPRESSOR WITH MOTOR OVERLOAD 230V (SEE HEATER DATA TABLE) HEATER CONNECTION DETAILS CONNECTION FOR SCROLL COMP. WITH SSPS TO HVTB TYPICAL SCHEMATIC WIRING DIAGRAM 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. MODELS : PT180 - PT240 (Dual compressor units) 26
Cooline PT036, FORCE SCALE SPAN SCALE RING "0" LARGE "0" RING SMALL BELT SPAN DEFLECTION = 64 BELT SPAN B G - GROUND FIELD WIRING N - NEUTRAL TERMINAL BLOCK L3 - LINE3 L2 - LINE2 LI - LINE1 LEGEND CONTROL WIRES-INTERCONNECTING A B +5V A +5V GND FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER L1 G L3 N L2 PACKAGED UNIT CONTROL PANEL L1 L3L2 N GND ( USE 16 TO 22 AWG WIRE) INDOOR THERMOSTAT ECB HVTBNTB HVTB - HIGH VOLTAGE TERMINAL BLOCK ECB - ELECTRONIC CONTROL BOARD BELT TENSION TESTING PROCEDURE BELT TENSION CHECKER MEASURE THE BELT DEFLECTION FORCE BELT TYPE – A B BELT CROSS SECTION 3 L 4 L 5 L SMALL PULLEY PITCH DIA. (P.D.
Cooline PT036, ELECTRICAL DATA 342 457 1.9 – – 51 60 7.5/10 11.4/15.2 51/51 60/60 10*/12* 15.2/18.2 51/51 60/60 15*/20* 22.8/30.4 51/51 60/60 25*/30* 38/45.6 59/68.5 60/70 – – 54.8 70 7.5/10 11.4/15.2 54.8/54.8 70/70 10*/12* 15.2/18.2 54.8/54.8 70/70 15*/20* 22.8/30.4 54.8/54.8 70/70 25*/30* 38/45.6 63.8/73.3 70/80 MOCPMCA ELECTRIC HEATER BM COMPR- ESSOR (each) RLA LRA HP FLA Nom. kW FLA MOCPMCA ELECTRIC HEATER BM COMPR- ESSOR (each) RLA LRA HP FLA Nom. kW FLA VOLTAGE RANGE FLAMax.M
Cooline PT036, Performex-1 TM CONTROLLER : OPERATION & FUNCTIONS The COOLINE Packaged units are provided with technologically advanced new Performex TM Controller Microprocessor Based Electronic Control Board, incorporating the following benefits and features: - COMPLETE UNIT CONTROL: Provides complete unit control for heating and cooling application whether single stage or two stage utilizing the input from sensor that measure temperatures during unit operation. - COMPRESSOR LOCKOUT: If any of the unit’s safety controls trip due to abnormal conditions the Electronic Control locks out the compressor, preventing restart, unless attended by
Cooline PT036, TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PT180 - PT240 (Dual compressor units) LEGEND AR AUXILIARY RELAY AFS AIRFLOW SWITCH ATB AUXILIARY TERMINAL BLOCK BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CC COMPRESSOR CONTACTOR CCA AUXILIARY CONTACT CB CIRCUIT BREAKER C. HTR CRANKCASE HEATER COMP COMPRESSOR ECB ELECTRONIC CONTROL BOARD FCS FAN CYCLING SWITCH F FUSE FL FUSE LINK FM FAN MOTOR (CONDENSER) FMC FAN MOTOR CONTACTOR FR FAULT RELAY HC HEATER CONTACTOR HPS HIGH PRESSURE SWITCH HVTB HIGH VOLTAGE TERMINAL BLOCK HTR HEATER JP JUMPER L1 LINE 1 L2 LINE 2 L3 LINE 3 LPS LOW PRESSURE SWITCH LUG LUG GROUND NTB NEUTR
Cooline PT036, MAINTENANCE INSTRUCTIONS AIRFLOW ADJUSTMENT (Applicable for PT075 - PT360 only) The airflow could be adjusted by adjusting pulleys of blower motor or belt tension with proper mounting and alignment of the pulleys: • Refer to fan performance tables in the catalog for selecting applicable airflow, RPM and brake horse power at specified static pressure. • Select the appropriate drive as per motor and blower characteristic in the catalog. • The set screw shall be loosened to make the pulley moving. • Adjust pulley’s diameter, opening counter clockwise to reduce RPM and further reduce airflow, while closing clockwise increases RPM and airflow. • Tighten the set screw and then
CONDENSATE DRAIN CONNECTION • Use standard PVC pipe with NPT connection for the condensate drain. Provide a 'P' trap immediately at the condensate drain connection. • Piping has to be sloped away from the unit. • Remember to remove the drain hole plug before operating the unit. Avoid bends & elbows. DUCT CONNECTION The units can be connected to the duc
2. SMOKE DETECTOR OPTION CRANKCASE HEATER CONNECTION 4. HPS CONNECTION OPTION STANDARD OPTIONS 1. UVM OPTION 3. VOLT FREE CONTACT OPTIONS A. UNIT ON & OFF INDICATION OPTION C. BM ON,OFF & TRIP INDICATION OPTION PRESSURE SWITCH SETTINGS TO HVTB TO NTB * TO HVTB * TO NTB FACTORY INSTALLED B.M SPEED * * * TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PT036 - PT075 (Single compressor units) L
UNIT DIMENSIONS PT215 - PT240 NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides. 10 SIDE VIEW SIDE VIEW FRONT VIEW TOP VIEW
Cooline PT036, 1. Check the power. Switch ON the circuit breaker. Replace fuse if it blown. 2. Check wiring against diagram. 3. Check and correct it. 4. Replace it. 1. Replace battery 1. Correct belt. Check tension and alignment. 2. Check wiring against diagram. 3. Check and correct it. 4. Replace if. 5. Replace it. 1. Check the rotation of blower, interchange phase of blower motor from blower motor contactor. 1. Adjust it & check belt tension. 2. Adjust the pitch of the pulley. 3. Check and remove the obstructions. 4. Verify static pressure and fan performance data. 5. Change pulley (i
Cooline PT036, HPS OPTION FAN MOTOR CONTROL CONNECTION (APPLICABLE FOR FM WITH T.O.P) N TO NTB L2 TO HVTB BM WITH EXTERNAL OLR CONNECTION APPLICABLE FOR 1PH FM ONLY CRANKCASE HEATER CONNECTION A. UNIT ON & OFF INDICATION OPTION 3. VOLT FREE CONTACT OPTIONS 1. UVM OPTION 2. SMOKE DETECTOR OPTION STANDARD OPTIONS C. BM ON,OFF & TRIP INDICATION OPTION TYPICAL SCHEMATIC WIRING DIAGRAM MODELS : PT090 - PT120 (Dual compressor units) LEGEND AR AUXILIARY RELAY AFS AIRFLOW SWITCH ATB AUXILIARY TERMINAL BLOCK BM BLOWER MOTOR BMC BLOWER MOTOR CONTACTOR CC COMPRESSOR CONTACTOR CCA AUXILIARY CONTACT CB CIRCUIT BREAKER C. HTR CRANKCASE HEATER COMP COMPRESSOR ECB ELECTRONIC CONTROL BOARD FCS FAN CYCLING
Cooline PT036, UNIT DIMENSIONS PT090 - PT120 NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides. 8 SIDE VIEW SIDE VIEWFRONT VIEW TOP VIEW
Cooline PT036, GENERAL GENERAL STATEMENT This unit is from the PT series that was designed & built for the optimum performance. However, it is required that you become well acquainted with good practices for the proper installation/operation/and maintenance procedures in order to ensure a safe trouble free operation, year after year. Please read through the whole manual contents before you attempt to install/operate/ and maintain the unit. Most of the procedures described in this manual require certain skills and experience. The installation and other maintenanc
Cooline PT036, B C A E D B C D A ATTENTION TO RIGGERS • Insert 2" nominal pipe through holes in the base rail as shown in the figure below for slings. • Holes in base rail are centered around the unit center of gravity. • Use wooden pallet or spreader bar when rigging, to prevent the slings from damaging the unit. • Rollers may be used to move the unit on the roof or ground. CAUTION: All panels should be in place when rigging. RIGGING INSTRUCTIONS MODELS: PT036 - PT360 5 SERVICE CLEARANCE MODEL DIMENSIONS NUMBER A B C D PT036 85 105 85 150 PT048 85 105 85 150 PT060 85 105 85 150 PT075 90 105 90 200 PT090 90 105 90 200 PT100 90 1
Cooline PT036, C : 1.5 HP ODP D : 2 HP ODP D : 2 HP ODP E : 3 HP ODP F : 3 HP TEFC G : 5 HP ODP H : 5 HP TEFC J : 7.5 HP ODP K : 7.5 HP TEFC J : 7.5 HP ODP K : 7.5 HP TEFC L : 10 HP ODP M : 10 HP TEFC L : 10 HP ODP M : 10 HP TEFC N : 15 HP ODP P : 15 HP TEFC MODELS: PT075 - PT360 (BELT DRIVEN MOTOR) 1& 2 BASIC 3, 4 & 5 NOMINAL COOLING CAPACITY (MBH) 8 BLOWER MOTOR 6 ELECTRICAL SUPPLY ( V-Ph-Hz ) 10 HEATER OPTIONS (kW/STAGE) 12 CONDENSER COIL PT COOLINE PACKAGED UNIT 036 048 060 W : 0.75 HP ODP W : 0.75 HP ODP Y : 1 HP ODP L : 380/415-3-50 (4 WIRE) N : NO HEATER
Cooline PT036, UNIT DIMENSIONS PT300 - PT360 NOTE: 1. All dimensions are in mm (dimensions in brackets are in inches). 2. Service clearance should be 1200mm (4 feet) on all sides. 11 SIDE VIEW SIDE VIEW FRONT VIEW TOP VIEW
Cooline PT036, PREVENTIVE MAINTENANCE SCHEDULE 12 X X X X X X X X X X X X X FREQUENCY OF MAINTENANCE, MONTHS (FIRST 4 YEARS) I T E M CAUTION: Disconnect power supply and allow all rotating parts to stop before servicing the unit. 6 X X Clean air filter (Aluminum)* Pressure wash condenser & cooling coil as required Check blower belt, tension, wear tear/replace if required Check alignment of pulleys Clean drain pan, drain pipe Clean blower wheel Check for loose bolts/screws & tighten as necessary Check all electrical controls, components, wiring terminals, etc..., for
Cooline PT036, TYPICAL SCHEMATIC WIRING DIAGRAM 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. MODELS : PT090 - PT120 (Dual compressor units) 24
Cooline PT036, POWER SUPPLY 380/415-3-50 (4 wire) OPERATION INSTRUCTIONS 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. Check unit location as per installation instructions. 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 solenoid, etc...) 4. Make sure all valves are open (compressor suction & discharge service val
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