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A VK PR-2007-0345-GB DENCO-C-Range BA 2007-05 150dpi
A VK PR-2007-0345-GB DENCO-C-Range BA 2007-05 150dpi
Introduction
Description
Introduction.................................................................................................................3 Scope of this Manual..................................................................................................3 "HEALTH and SAFETY at WORK ACT" (UK) ...........................................................3 Installation / Servicing Safety Instructions..............................................................4 Aircooled Condensing Units .....................................................................................5 STANDARD UNITS (Single Compressor Units) .......................................................6 V.R.F. UNITS (Twin Compressor Units)....................................................................6 R407C Refrigerant Charges.......................................................................................7 Oil Charging ................................................................................................................7 Drawing Schedule.......................................................................................................8 10311-C-146.................................................................................................................9 10311-C-147.............................................................................................................. 10 10311-D-204.............................................................................................................. 11 10311-D-201.............................................................................................................. 12 10311-D-202.............................................................................................................. 13 10311-D-203.............................................................................................................. 14 10311-D-221.............................................................................................................. 15 10311-D-223.............................................................................................................. 16 Storage and Operating Environment..................................................................... 17 Receiving the Equipment........................................................................................ 17 Condenser Location on Site................................................................................... 18 Noise Considerations.............................................................................................. 19 Cable Segregation ................................................................................................... 19 Suppression ............................................................................................................. 19 Refrigeration Pipework ........................................................................................... 20 Electrical................................................................................................................... 21 Mains Supply............................................................................................................ 21 Pre-operational Checklist ....................................................................................... 22 Control of Refrigerant Discharge........................................................................... 22 Servicing: Direct Expansion Systems ................................................................... 23
Introduction
Introduction
GEA Denco thank you for purchasing their Air Conditioning Products. This manual has been compiled to help ensure the correct installation of the equipment. Please read it fully BEFORE COMMENCING THE WORK. All installation work, including the running and connecting of services, must be carried out only by COMPETENT PERSONS. The manual does not cover the detailed commissioning, operation or servicing, which are the subject of separate Operating and Maintenance instructions and which, also, must be carried out only by COMPETENT PERSONS. The equipment has been designed and manufactured within a Quality Assurance System conforming to ISO 9001, and Quality Controlled to ensure that it reaches you in perfect condition. It is important for you to appreciate that failure to follow the instructions in this manual may result in damage, incorrect operation or danger to health and safety, and may invalidate the warranty. Any works planned that are not covered in this manual must be discussed with, and are subject to the approval of GEA Denco.
Electrical
In direct expansion systems incorporating Aircooled Condensers, the starting of these units is controlled by the associated Air Handling Units. Therefore these units should be isolated electrically BEFORE any servicing/maintenance is attempted using the isolators fitted to the units. Isolate at mains isolator BEFORE any access panels are removed for servicing or maintenance. Mains isolator should be used to stop Unit in emergency conditions. Refer to the wiring diagrams and the units rating plate for the mains electrical supply for which the unit is suitable. The units MUST NOT be used on other electrical supplies without the prior approval of the Equipment Supplier. Observe all electrical safety labels fitted to various parts of the unit / system. Observe all national / local codes of practice for electrical installation (e.g. IEE Wiring Regulations).
Mechanical
It should be noted that Aircooled Condensers are delivered with a 5 psig Nitrogen holding charge, which MUST be released before any work is carried out. Any part of a refrigeration circuit which is being serviced should be fully removed of refrigerant gas BEFORE any work is attempted on any of the refrigeration components. See Control of Refrigerant Discharge. If any heat or flame is to be used on or near to the unit and its associated installation due care should be taken to avoid contact with any combustible surfaces. Furthermore, it should be noted that some refrigerants may give off toxic fumes when heated. Whenever heat or flame is used, the working area should be thoroughly ventilated BEFORE and DURING the operation. Proper fire precautions should be observed and any necessary fire safety equipment should be on hand, typical for electrical, oil or foam fires. Observe any safety labels fitted to various parts of the unit / system.
General
Beware of the following danger areas within the unit when running: (a) Any rotating components (fans, pulleys, etc.). (b) Sharp edges (coil fins, sheet metal, etc.). (c) Hot or cold refrigeration pipework. (d) Possible live electrical components or terminals.
Unit Specification
Components are mounted on a rigid aluzink steel base and enclosed by plastic coated metal side sections and top lid. The base has plastic coated steel channel feet to assist in transporting and sitting the unit. The feet have holes for securing the unit in position when installed. The coil and fan(s) are mounted vertically so that air is drawn through the coil and discharged horizontally through a plastic-coated wire fan guard. The fan(s) and guard(s) are mounted on an aluzink steel diaphragm. The compressor and electrical components are mounted in a sealed compartment at the end of the unit. Access to this compartment is by a removable panel fitted with a door interlocked mains isolator. If required, additional access to this area and to the fan(s), can be provided by removing the lid and side panels, which are held in place by self-tapping screws. The refrigerant pipework between the compressor and condenser is fitted with a vibration eliminating connector. The compressor suction pipework is looped to prevent vibration damage. Condenser liquid and compressor suction pipes terminate as stub connections protruding through a recessed, aluzink service panel. The compressor is protected by HP/LP switches, and condenser pressure is controlled by a fan switch (fan speed controller may be fitted as an option). HP/LP service tappings are on the compressor valves. The Condensing Units are normally delivered with a 5 p.s.i.g. holding charge of nitrogen. The Condensing Units are normally wired for direct starting from the Air Handling Unit's controls. A four (4) core 3 phase and neutral cable is required for the power supply, which is normally supplied from the MCBs within the Air Handling Unit. For Standard (single compressor) units, a four (4) core cable is required between the Air Handling Unit and Condensing Unit for control signal and alarms, whilst for V.R.F. (twin compressor) units a seven (7) core cable is required. The HP/LP switches have normally open contacts for use when alarm signals are required. These alarms are connected into the microprocessor controls using the additional cores in the signal cable. Signal cables must be segregated from cables carrying mains potential (refer to "Cable Segregation" later in this Manual). The compressors are robust, hermetic scroll type running on refrigerant R407C, and are complete with isolation valves, crankcase heater and oil level sight glass. The compressor is provided with an electrical contactor. For details of compressor size fitted to each Condensing Unit see tables overleaf.
0.450
0.91
0.700
1.19
0.876
1.83
1.410
3.40
IMPORTANT: The figures shown above are for the Aircooled Condensing Units ONLY and do not include the Air Handling Unit or for any interconnecting pipework. Refer to Air Handling Unit Range Installation Manuals for the actual Air Handling Unit R407C refrigerant charges.
Oil Charging
Recommended Refrigeration Oils within GEA Denco Equipment Unit fitted with Copeland Compressors Refrigerant R407C R134a In Compressor or Recharging Oil RL32-CF RL32-CF To Top Up Oil RL32-S RL32-S
The refrigerant compressor is filled with sufficient oil for standard installations where the liquid line run is under thirty (30) metres. Where runs are longer than this, additional oil as indicated above is required. As a guide, 5 g of oil should be added for each additional 1.0 kg of refrigerant charge. Additional oil should be added to ensure correct operation of oil traps (where fitted). Refrigerants R407C and R134a can ONLY be used with ester oils, however refrigerant R22 should be used with mineral oils. Mineral and ester oils MUST NEVER be mixed. Ester oils are very hygroscopic and therefore must not be exposed to the air for any length of time.
Drawing Schedule
Drawing Schedule
The following drawings are included: Condensing Unit CT18 to CP90 and CPV48 CL90 to CL19 CLV48 to CLV90 Drawing Number 10311-C-146 10311-C-147
The following Schematic Wiring Diagrams using 24 Volt controls are included: Condensing Unit CT18 to CT28 (1 phase) CT22 to CP81 CP90 CL90 to CL19 CPV48 CLV48 to CLV90 Drawing Number 10358-C-204 10358-C-201 10311-C-202 10311-C-203 10311-C-221 10311-C-223
10311-C-146
10311-C-146
10311-C-147
10311-C-147
10
10311-D-204
10311-D-204
11
10311-D-201
10311-D-201
12
10311-D-202
10311-D-202
13
10311-D-203
10311-D-203
14
10311-D-221
10311-D-221
15
10311-D-223
10311-D-223
16
For Operating Ambients below 5oC the following is recommended: For Ambients down to 25oC: it is recommended that a "Winter Start Kit" be fitted. This consists of separate HP and LP switches and an LP timer. This is sometimes fitted to the Air Handling Unit as standard. For Ambients down to -40oC: it is recommended that a "Extra Low Ambient Temperature Kit (ELATE)" be fitted. This consists of a horizontal liquid receiver with trace heating and pressure relief valve situated in a special section under the main unit, and includes separate HP and LP switches and an LP timer. This Kit increases the overall height of the Condensing Unit by approximately 400mm.
Unpacking Units
Remove the wooden crate (if applicable) using appropriate tools and taking care not to damage the cardboard protection and unit beneath. The cardboard case should then be lifted from the unit. Beneath the cardboard case is a protective polythene cover. NOTE: A door interlocked type isolator is fitted, its handle and fascia are packed within the control panel.
Levelling Units
The unit should be set in an upright position - level in both directions. Failure to carry out levelling correctly may cause operational problems. Pack as required below to bring into alignment.
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Important:
NOTE: All Condensers are supplied with a 5 psig NITROGEN holding charge.
Access
Access is gained by means of a removable panel secured by two screws. The panel also contains the interlocked door isolator, which will have to be turned to the `OFF' position, before the panel can be removed. This panel is situated on the left-hand side of the unit (looking at the fan). For major service work such as replacing the compressor, the top and side panels may be removed. The compressor is of the fully hermetic type and, apart from the usual service checks, no other maintenance is necessary.
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Noise Considerations
Noise Considerations
It is important that the problems of noise are considered at all points in the installation of equipment. In order to reduce these problems, the following measures are suggested, dependent upon site conditions: Abrupt bends in pipework should be avoided by fitting long turn elbows or forming long radius bends. All pipes should be rigidly supported to a solid structure. Where pipes pass through walls or partitions, provide an oversize sleeve and pack with fibreglass or similar insulation material. Insulate pipes, and box in with sound-deadening material to solid structures.
Noise Levels
The airborne noise emission does not exceed 70 dB(A) at three (3) metres under load conditions measured using a Precision Impulse Sound Level Meter (BS 5969 Type 1) in freefield conditions.
Cable Segregation
Ensure that segregation is maintained between control wiring (24V AC or DC) and mains potential wiring (415V/240V AC) throughout the entire installation. The ramifications are: Control signals to condensing units must be run in a separate cable to the mains power cabling. - Where it is unavoidable that power and signal/control cables run in close proximity, ensure that there is a gap of AT LEAST 30 mm between each category. - Ideally power and signal/control cables should never cross, but if unavoidable, ensure that they cross at 90o (right angles) to each other. IMPORTANT: Any additional equipment installed in the control section, or supplied from it, will render the warranty invalid, unless it is verified and approved by the GEA Denco Technical Department. -
Suppression
All relay and contactor coils within the condensing units are fitted with CR network type suppressors (120 OHM + 0.1 microfarad). These are mounted either directly across the coil connections, or mounted on PCB's to which the relay or contactor is connected. If additional relays or contactors (240V or 24V AC) or any other inductive load capable of generating electromagnetic interference (EMI's) is to be installed within the equipment (or directly supplied from it). Ensure that these components are suppressed as close to the source of EMI generation as possible. NOTE: Remember! Any additional equipment installed in the Unit must be verified and approved by the GEA Denco Limited Technical Department, and must comply with EMC Standards in force.
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Refrigeration Pipework
Refrigeration Pipework
Pipes must be properly sized, and the pipework system designed, having regard to ensuring oil return to compressors and avoidance of excessive pressure drops. All refrigeration pipework should be installed to national and local standards as detailed in GEA Denco Code of Practice CP 12. All soldering / brazing should be done in accordance with the requirements of the European Pressure Equipment Directive (P.E.D.), which includes soldering / brazing certification. Extreme care should be taken to keep refrigeration tubing clean and dry before installation and the following procedures will help to adhere to good practice: 1. Only refrigeration grade copper tubing correctly sealed against contamination should be used. 2. Do not carry out installation outside whilst it is raining. 3. Always cap the free end of tubing whilst carrying out installation. 4. Do not leave dehydrated compressors or filter/driers open to the atmosphere. 5. Use only copper eutectic or specialist soft solders containing at least 3.5% silver on suction and liquid lines and high temperature copper eutectic rods or silver solder on discharge lines. It is suggested that one of the following are used: (a) Copper to copper - Eutectic 1805 (2% silver) - no flux. (b) Copper to brass - Eutectic 1805 - flux 1802. (c) Copper to steel - Eutectic 1810 (2% silver) - flux 1820. NB: STANDARD SOFT SOLDER MUST NOT BE USED. 6. With any high temperature rod where oxidisation is liable to take place use an inert gas such as dry nitrogen or carbon dioxide to avoid scale formation inside the tubing. Dry nitrogen is preferred. 7. When using soldering paste or flux use the minimum required to prevent contamination of the filter and joint. Flux only the male part of the connection - never the female. After making the joint remove the surplus flux with a damp cloth. 8. Where vibration eliminators are used the ends should be wrapped with a damp cloth and rods with a melting temperature of no greater than 650oC (1200oF) should be used to avoid damage to the internal joints.
Leak Testing
After all lines are connected, but before they are insulated, the system must be leak tested. The use of an electronic leak detector or halide torch is recommended. For a satisfactory installation, the system MUST be leak tight. Leak testing should be carried out before initial charging and after any service work has been carried out, and before evacuation. This is done by charging refrigerant gas until system pressure is approximately 1.4 bar and then pressurising with dry nitrogen to a maximum pressure of 24 bar. Refer to Control of Refrigerant Discharge.
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Electrical
Electrical
WARNING: DANGEROUS VOLTAGE LEVELS EXIST WITHIN THIS EQUIPMENT. USUAL ELECTRICAL SAFETY PRECAUTIONS MUST BE OBSERVED. THIS EQUIPMENT MUST BE EARTHED. All installation wiring associated with this equipment must comply with the latest edition of the IEE Regulations to national and local codes of practice, and any relevant British Standards. A set of relevant electrical schematic drawings for the unit are secured inside the electrical hinged door for your reference.
Mains Supply
This equipment in its standard form, is designed to operate with an electrical supply of 400-415 V/3 phase/4 wire/50 Hz or 380 V/3 phase/4 wire/50 Hz . The phase sequence to the isolator is shown on the schematic wiring diagrams. The classification of this equipment is Class 1, as defined in the IEE Regulations and BS 2754 (1976) as: "Equipment in which protection against electric shock does not rely on basic insulation only, but which includes an additional safety precaution in such a way that means are provided for the connection of accessible conductive parts to the protective [earthing] conductor in the fixed wiring of the installation in such a way that accessible conductive parts cannot become live in the event of a failure of the basic insulation". Always use the appropriate holes provided in the gland plate for terminating incoming and outgoing cables. Do not remove any blanking plugs from redundant holes as these protect against particle ingress. Use the correct gland for the type/size of cable being installed. IMPORTANT: As a matter of common sense NEVER cut additional entry holes into the top of the electrical enclosure as this will deposit swarf, etc onto the delicate printed circuit boards directly underneath. Terminate all site earth cable conductors to gland plate earth bolt(s) provided. Ensure that the mains electrical supply is of the correct voltage, frequency, phase and rating. Ensure that the cable sizes are of adequate size for the maximum load of the equipment under normal automatic running conditions [see relevant data sheets dependant upon unit configuration]. NOTE: Supply cable sizes must not be determined from maximum FLA figures only other criteria must be considered, e.g. length of run (and associated volt-drop), installation methods and grouping factors, disconnect times etc. All of these have a de-rating influence on the current-carrying capacity of cables, and are detailed in Appendix 9 of the IEE Regulations. Before connection to the equipment, check each installed cable for continuity and short circuit (phase/phase, phase/neutral, phase/earth and neutral/earth). Check the tightness of all electrical connections before switching on supply. Check all site connected items before switching on supply. IMPORTANT NOTE: The Condensing Units incorporate scroll compressors that will only compress in one rotational direction. The rotational direction is dependent upon the phasing of the power to motor terminal connections (L1, L2 and L3). Verification of correct rotational direction is made by observing that the suction pressure drops and discharge pressure rises when the compressor is energised. Reverse rotation results in a sound level above that with correct rotation, as well as substantially reduced current drawn compared to tabulated values. There is no negative impact on durability caused by operating the scroll compressors in the reverse direction, however, after several minutes the compressor internal protection will trip. THIS PROTECTIVE DEVICE SHOULD NEVER BE BY-PASSED FOR ANY REASON.
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Pre-operational Checklist
Pre-operational Checklist
After all necessary installation work has been completed and before the mains supply is applied to the unit, ensure you have read all the previous sections of this manual, and that the relevant parts have been fully complied with. If the unit has been stored in a colder environment than its final permanent site, allow an adequate period for acclimatisation and evaporation of any condensation that may have occurred before the mains power supply is connected to the unit. - Keep access panels/doors closed as much as possible to prevent the unnecessary ingress of dust or other particles. - Ensure that all exterior access panels have been replaced to provide correct airflow when switched on. - When the unit is running, if switched off do not switch back on for a period of at least 20 seconds. ALWAYS REPLACE THIS MANUAL IN THE SERVICES SECTION OF THE UNIT. WARNING: DANGEROUS VOLTAGE LEVELS EXIST WITHIN THIS EQUIPMENT. USUAL ELECTRICAL SAFETY PRECAUTIONS MUST BE OBSERVED. -
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E B
GEA Happel Belgium N.V. B-1130 Brussels Tel. +32 / 2 / 2406161 EVISS Ltd. BG-7000 Rousse Tel. +359 / 82 / 81000 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatec Schweiz AG CH-3065 Bolligen-Station Tel. +41 / 31 / 9171919 GEA LVZ, a.s. CZ-46312 Liberec Tel. +420 / 48 / 5225-111 GEA Klimatizace spol. s r.o. CZ-46312 Liberec Tel. +420 / 48 / 5225-303 GEA Happel Klimatechnik GmbH D-44625 Herne Tel. +49 / 2325 / 468-00
EST
GEA Air Treatment Marketing Services Int. GmbH - oficina Espaa E-28036 Madrid Tel. +34 / 91 / 3837701 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Happel France sarl F-59436 Roncq Cedex Tel. +33 / 3 / 20689020 OY TEKNOCALOR AB FIN-01300 Vantaa Tel. + 358 / 9 / 82546020 Denco Ltd. UK-HR4 8DS Hereford Tel. +44 / 1432 / 277 277 GEA Klimatechnika Kft H-1037 Budapest Tel. +36 / 1 / 4393200 GEA Klima-rashladna tehnika d.o.o. HR-10000 Zagreb Tel. +385 / 1 / 6064900
GEA Happel Luxembourg L-4940 Bascharage Tel. +352 / 26 / 502970 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatechnik UAB LT-01141 Vilnius Tel. +370 / 5 / 2106060 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 GEA Klimaprodukter AS N-0484 Oslo Tel. +47 / 220 / 27990 GEA Happel Nederland B.V. NL-2909 LL Capelle a/d Ijssel Tel. +31 / 10 / 2350606 Nnio, Lda. P-1269-090 Lisboa Tel. +351 / 21 / 3826160 GEA Klimatyzacja Sp. z o.o. PL-54610 Wroclaw Tel. +48 / 71 / 3737952
RUS
GEA Kondicioner Moskva RU-105094 Moskva Tel. +7 / 495 / 9566674 GEA EXOS Ventilation AB S -74528 Enkping Tel. +46 / 171 / 85530 GEA Klimatizcia s.r.o. SK-83104 Bratislava Tel. +421 / 7 / 44457917 GEA Klimatizacijska Tehnika d.o.o. SI-1000 Ljubljana Tel. +386 / 1 / 2573850 GEA Klimatehnika RS-11070 Novi Beograd Tel. +381 / 11 / 3193955 ISISAN TR-80700 Balmumcu Istanbul Tel. +90 / 212 / 2757171 GEA Ukraina t.o.v. UA-01135 Kyiv Tel. +38 / 044 / 4619356
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